FANUC Robotics SYSTEM R-J2 Controller P–10, P–15 and P–200 Electrical Maintenance Manual MARO2P10203704E REV B This publication contains proprietary information of FANUC Robotics North America, Inc. furnished for customer use only. No other uses are authorized without the express written permission of FANUC Robotics North America, Inc. FANUC Robotics North America, Inc. 3900 W. Hamlin Road Rochester Hills, Michigan 48309-3253
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FANUC RoboticsSYSTEM R-J2 ControllerP–10, P–15 and P–200 ElectricalMaintenance Manual
MARO2P10203704E REV B
This publication contains proprietary information of FANUC RoboticsNorth America, Inc. furnished for customer use only. No other uses areauthorized without the express written permission of FANUC RoboticsNorth America, Inc.
FANUC Robotics North America, Inc.3900 W. Hamlin RoadRochester Hills, Michigan 48309-3253
MARO2P10203704E REV B2
The descriptions and specifications contained in this manual were in effectat the time this manual was approved for printing. FANUC RoboticsNorth America, Inc, hereinafter referred to as FANUC Robotics, reservesthe right to discontinue models at any time or to change specifications ordesign without notice and without incurring obligations.
FANUC Robotics manuals present descriptions, specifications, drawings,schematics, bills of material, parts, connections and/or procedures forinstalling, disassembling, connecting, operating and programming FANUCRobotics’ products and/or systems. Such systems consist of robots,extended axes, robot controllers, application software, the KAREL
programming language, INSIGHT vision equipment, and special tools.
FANUC Robotics recommends that only persons who have been trained inone or more approved FANUC Robotics Training Course(s) be permittedto install, operate, use, perform procedures on, repair, and/or maintainFANUC Robotics’ products and/or systems and their respectivecomponents. Approved training necessitates that the courses selected berelevant to the type of system installed and application performed at thecustomer site.
WARNINGThis equipment generates, uses, and can radiate radiofrequency energy and if not installed and used inaccordance with the instruction manual, may causeinterference to radio communications. As temporarilypermitted by regulation, it has not been tested forcompliance with the limits for Class A computing devicespursuant to subpart J of Part 15 of FCC Rules, which aredesigned to provide reasonable protection against suchinterference. Operation of the equipment in a residentialarea is likely to cause interference, in which case the user,at his own expense, will be required to take whatevermeasure may be required to correct the interference.
FANUC Robotics conducts courses on its systems and products on aregularly scheduled basis at its headquarters in Rochester Hills, Michigan.For additional information contact
FANUC Robotics North America, Inc.Training Department3900 W. Hamlin RoadRochester Hills, Michigan 48309-3253Tel: (248)377-7234FAX: (248)377-7367 or (248)377-7362web site: www.fanucrobotics.com
Send your comments and suggestions about this manual to:[email protected]
3MARO2P10203704E REV B
Copyright 2000 by FANUC Robotics North America, Inc.All Rights Reserved
The information illustrated or contained herein is not to be reproduced,copied, translated into another language, or transmitted in whole or in partin any way without the prior written consent of FANUC Robotics NorthAmerica, Inc.
AccuStat, ArcTool, DispenseTool, FANUC LASER DRILL ,KAREL , INSIGHT, INSIGHT II , PaintTool, PaintWorks,PalletTool, SOCKETS, SOFT PARTS SpotTool,TorchMate, and YagTool are Registered Trademarks of FANUCRobotics.
FANUC Robotics reserves all proprietary rights, including but not limitedto trademark and trade name rights, in the following names:
This manual includes information essential to the safety of personnel,equipment, software, and data. This information is indicated by headingsand boxes in the text.
WARNINGInformation appearing under WARNING concerns theprotection of personnel. It is boxed and in bold type to setit apart from other text.
CAUTIONInformation appearing under CAUTION concerns the protectionof equipment, software, and data. It is boxed to set it apartfrom other text.
NOTE Information appearing next to NOTE concerns related informationor useful hints.
Conventions Used inthis Manual
Issued United States Patents iv
One or more of the following U.S. patents might be related to the FANUC Robotics products described in thismanual.
Tel: 248–377–7278 / Fax: 248–377–78328:00 am to 8:00 pm / Mon – Fri
TRAININGPRESS 3
Tel: 248–377–7234 / Fax: 248–377–73678:00 am to 5:00 pm / Mon – Fri
MARKETING & SALESPRESS 4
Tel: 248–377–7000 / Fax: 248–377–73668:00 am to 5:00 pm / Mon – Fri
Parts for down robots
Replenishment part order
Warranty part replacement
Robot software and PACs
Training class registration
Consultation for special training or on–site requests
________________________
For best call results have:
Customer number (if known)
Company name
Your name
Your phone & fax numbers
Robot & controller type
“F#” or serial number of robot
Hour meter reading (if available)
Software type and edition
Any error messages and LED displays (if applicable)
Your P.O., Credit Card, or Receiving # for warranty or down robot or preventive
________________________
For best call results have:
Customer number (if known)
Company name
Your name
Your phone & fax numbers
Part name & number (if known)
“F#” or serial number of robot,
P.O., Credit Card, or Receiving # for warranty, down units, or software
Shipping & billing addresses
Reason for repair (any symptoms,
________________________
For best call results have:
Customer number (if known)
Company name
Your name
Your phone & fax numbers
Your shipping or billing address
Types of courses needed
Robot and controller type
Number of people attending
Method of payment (P.O., credit
________________________
For best call results have:
Company name
Your name
Your phone & fax numbers
Description of your need
1–800–47–ROBOT(1–800–477–6268)
(International: 011–1–248–377–7159)
*NOTE: A RETURN AUTHORIZATION (“RA”) FROM “PARTS” IS REQUIRED BEFORE SHIPPING ANY MATERIAL BACK
CUSTOMER FOCUS CENTER
maintenance service orders
if available (req’d for warranty)
error codes, or diagnostic LEDsthat were identified)
Special Requirements
Proposed Schedules
card, etc.)
Company address
TO FANUC ROBOTICS FOR PROPER RECEIVING & TRACKING. F# IS LOCATED ON THE ROBOT BASE OR OP. PANEL.
3MXXXXXXXXXXXXXE REV X
Page 4
UPDATES
UPDATESMARO2P10203704E Updates–1
This section lists the update that has been made to the FANUC RoboticsSYSTEM R–J2 Controller P–10, P–15 and P–200 Electrical MaintenanceManual in the following area:
The controller is transported by a crane. Attach a lifting strap to the eyebolts at the top of the controller, as shown in Figure A–1.
Figure A–1. Transportation
Î
ÎÎÎÎÎÎÎÎÎ
ÎÎÎÎ
ÏÏ
ÏÏ
1.1TRANSPORTATION
UPDATES
MARO2P10203704E Updates–5
Figure 2. P-200 Brake Release Option Package
BATTERYPACK
ISBUNIT
TO PURGE BRAKE BOARD
MOUNT SWITCHES AND RC’S ONALTERED COVER PLATE
MOUNT TERMINALS AND RELAYON HEAT EXCHANGER
BK
P1
BK
M1
EE–3287–122–XXX
EE–3287–121–XXX
EE–3287–120–XXXAXES 1 & 2
AXES 4,5,6
AXES 3 & 7
BK
P2
BK
P1
BK
M1
BK
P3
BK
M2
BK
M3
BK
P3
BK
M3
BK
P2
BK
M2
OPENER CONNECTIONS
INSTALLATION IN C SIZE CONTROLLER
ROBOT CABLE CONNECTION
PURGEUNIT
1 2 3 4 5 6 7 8 9 10 11 12 13 14
BK
P4
BK
M4
1 1 2 2 3 3 4 4 5 6 7 8 9 10
EE–3287–110–XXX
EE–3287–111–XXX
EE–3287–112–XXX
NOTE: AXIS 6 WIRES CONNECTEDEVEN IN UNITS WHEREAXIS 6 DOES NOT HAVE BRAKES
INSIDE
VIEW
TO TERMINAL STRIP
2’’
6’’ 2 3/4 ’’
AXES
1 & 7
AXES
4 & 5
AXIS 6 AXIS 2 AXIS 3
BLUE–17BLUE–18
BLUE 19BLUE–20
BLUE 19BLUE–20
BLUE–17BLUE–18
BLACK–5BLACK–6
BLACK–11BLACK–12
BLACK–17BLACK–18
P–200 BRAKE RELEASE
OPTION PACKAGE
EE–3287–516
TERMINAL STRIP
MOUNTED ON CONTROLLER DOOR HEAT EXCHANGER
Page 4
UPDATES
UPDATES
MARO2P10203704E UPDATES –3
Figure 1. P-200 Brake Release Option Package
BATTERYPACK
ISBUNIT
TO PURGE BRAKE BOARD
MOUNT SWITCHES AND RC’S ONALTERED COVER PLATE
MOUNT TERMINALS AND RELAYON HEAT EXCHANGER
BK
P1
BK
M1
EE–3287–122–XXX
EE–3287–121–XXX
EE–3287–120–XXXAXES 1 & 2
AXES 4,5,6
AXES 3 & 7
BK
P2
BK
P1
BK
M1
BK
P3
BK
M2
BK
M3
BK
P3
BK
M3
BK
P2
BK
M2
OPENER CONNECTIONS
INSTALLATION IN C SIZE CONTROLLER
ROBOT CABLE CONNECTION
PURGEUNIT
1 2 3 4 5 6 7 8 9 10 11 12 13 14
BK
P4
BK
M4
1 1 2 2 3 3 4 4 5 6 7 8 9 10
EE–3287–110–XXX
EE–3287–111–XXX
EE–3287–112–XXX
NOTE: AXIS 6 WIRES CONNECTEDEVEN IN UNITS WHEREAXIS 6 DOES NOT HAVE BRAKES
INSIDE
VIEW
TO TERMINAL STRIP
2’’
6’’ 2 3/4 ’’
AXES
1 & 7
AXES
4 & 5
AXIS 6 AXIS 2 AXIS 3
BLUE–17BLUE–18
BLUE 19BLUE–20
BLUE 19BLUE–20
BLUE–17BLUE–18
BLACK–5BLACK–6
BLACK–11BLACK–12
BLACK–17BLACK–18
P–200 BRAKE RELEASE
OPTION PACKAGE
EE–3287–516
TERMINAL STRIP
MOUNTED ON CONTROLLER DOOR HEAT EXCHANGER
UPDATESMARO2P10203704E Updates–1
This section lists the update that has been made to the FANUC RoboticsSYSTEM R–J2 Controller P–10, P–15 and P–200 Electrical MaintenanceManual in the following area:
Page
Figure 14–40 P–200 Brake Release OptionPackage
14–81
P–200 Brake Release Option Package, Figure 14–40
The correct terminations for the Axis 4 and 5 wires are as follows:
Wire Terminal LocationBKP3(Blk–5) and BKP3(Blk–11) BKP(Terminal 3)BKM3(Blk–6) and BKM3(Blk–12) BKM(Terminal 4)
MARO2P10203704EUpdates–2
UPDATES
Page 2
UPDATES
UPDATES
MARO2P10203704E UPDATES –1
Figure 1–1. P-200 R-J2 Robot Control Drawing Purge and Intrinsic Wiring sheet 1 NOTE: This page replaces page 12–43.
ALTERNATE I.S. BATTERY PACKS:A05B–2072–C181A05B–2047–C182SHALL BE USED PEREG–00127–SECTION VI
SOLENOID CABLE
IBRC6062R
(FMRC APPROVED)
FRAME GND.
TO CRS1
(MAIN CPU)
F1 F2 F3 F4 F5
I/S TEACH PENDANT
I/SGROUND
A05B–2308–C300
ISB UNITA05B–2308–C370
MODEL P–200–7+3–J2
24VDCPOWERSUPPLY
120VACFROM
CONVEYOR
OVPUNIT
EE–3112–600
24V 24V
789101112
ISB3
ISB4
46
KHD2–SR–EX1.2S.P+24
12
7824V KFD2–SD–EX1.36
12
91078
+24
+
+
+
24V
I/PSIG ISB5
KHD2–CD–1.P32
78
34
1ISB6
56
2+
+
24V
SIGZ787
127
8 +ISB7 Z728
127
8 +Z728ISB8
+
+
ISB3–4ISB3–6
ISB4–1ISB4–2ISB5–1
ISB6–1
ISB7–1
ISB8–1
ISB5–2
ISB6–2ISB6–4
ISB7–2
ISB8–2
TO ACCUFLOW
FROM I/O
FROM I/O
FROM I/O
P&F
P&F
P&F
P&F
P&F
EE–3287–328–001 CBLBYPASSSWITCH
I/P
UNIT
FLOWMETER
TRIGGER 1
TRIGGER 2
DELTRONW112A
EE–3287–324–001
M1
EE–3185–356–001N1 N4
M4
P1 P4
HAND BRKNO1 O4
PRES. SW CABLE
FLOW SW CABLE
M1
M1
S1 S4
M4
M4
SOL SOL
PS1 PS1
FS1 FS1
BATT
OPTIONAL DOOR OPENER DEVICE
OPENERSOLENOID
CABLEEE–3066–115–00XOPTIONAL CATRAC CABLE
EE–3066–215–00XAK1
AJ1
AH1
X2
AE1
AK2 AK3 AK4
AJ2 AJ3 AJ4
AH2 AH3 AH4
AE2EE–3066–316–001
EE–3066–321–001
EE–3066–322–001
EE–3066–323–001
I.S. GND
I.S. GND
MODEL Q–DRQ
IDEC
AE3 AE4
EE-3287-550-001
BATT
PrefaceMARO2P10203703E vii
The SYSTEM R-J2 Controller P-10, P-15 and P-200 ElectricalMaintenance Manual provides specific information regarding FANUCRobotics electrical hardware. The information contained within themanual has been arranged so that it can answer specific questions quicklyand accurately.
Use this table to locate specific information in the manual.
If you want to Refer to
Find information about a specific topic Table of Contents
Identify the components of the SYSTEMR-J2 controller
Chapter 1 , Overview
Use diagnostic and controller initializationutilities
Chapter 2 , DiagnosticScreens
View status information on teach pendantscreens and using other indicators
Chapter 3 , Lights, Indicators,and LEDs
Perform troubleshooting procedures andidentify specific errors
Chapter 4 , Troubleshooting
Look at fuse information or replace a fuse Chapter 5 , Replacing Fuses
Release the brakes Chapter 6 , Brakes
Turn outputs on or off and simulate inputs Chapter 7 , Controlling I/O
Find complete schematics of the controllercircuitry
Chapter 12, Schematics
Find wiring diagrams of the P-200 cables. Chapter 13, Cables
Find wiring diagrams and schematics forthe P-10 and P-15 openers, Integral PumpControl, and the Brake Release Option
Chapter 14, Openers andOptions
Use controller transportation and installationinformation
Appendix A , Transportationand Installation
Purpose of this Manual
How to Use thisManual
PREFACE MARO2P10203703Eviii
This manual includes information essential to the safety of personnel,equipment, software, and data. This information is indicated by headingsand boxes in the text.
WARNINGInformation appearing under WARNING concerns theprotection of personnel. It is boxed and in bold type to setit apart from other text.
CAUTIONInformation appearing under CAUTION concerns the protectionof equipment, software, and data. It is boxed to set it apartfrom other text.
NOTE Information appearing next to NOTE concerns related informationor useful hints.
FANUC Robotics is not and does not represent itself as an expert in safetysystems, safety equipment, or the specific safety aspects of your companyand/or its work force. It is the responsibility of the owner, employer, oruser to take all necessary steps to guarantee the safety of all personnel inthe workplace.
The appropriate level of safety for your application and installation canbest be determined by safety system professionals. FANUC Roboticstherefore, recommends that each customer consult with such professionalsin order to provide a workplace that allows for the safe application, use,and operation of FANUC Robotic systems.
According to the industry standard ANSI/RIA R15–06, the owner or useris advised to consult the standards to ensure compliance with its requestsfor Robotics System design, usability, operation, maintenance, and service.Additionally, as the owner, employer, or user of a robotic system, it is yourresponsibility to arrange for the training of the operator of a robot systemto recognize and respond to known hazards associated with your roboticsystem and to be aware of the recommended operating procedures for yourparticular application and robot installation.
FANUC Robotics therefore, recommends that all personnel who intend tooperate, program, repair, or otherwise use the robotics system be trained inan approved FANUC Robotics training course and become familiar withthe proper operation of the system. Persons responsible for programmingthe system-including the design, implementation, and debugging ofapplication programs-must be familiar with the recommendedprogramming procedures for your application and robot installation.
The following guidelines are provided to emphasize the importance ofsafety in the workplace.
SAFETY MARO2P10203703Exxvi
Safety is essential whenever robots are used. Keep in mind the followingfactors with regard to safety:
The safety of people and equipmentUse of safety enhancing devicesTechniques for safe teaching and manual operation of the robot(s)Techniques for safe automatic operation of the robot(s)Regular scheduled inspection of the robot and workcellProper maintenance of the robot
The safety of people is always of primary importance in any situation. However, equipment must be kept safe, too. When prioritizing how to apply safety to your robotic system, consider thefollowing:
PeopleExternal devicesRobot(s)ToolingWorkpiece
Always give appropriate attention to the work area that surrounds therobot. The safety of the work area can be enhanced by the installation ofsome or all of the following devices:
A safe workcell is essential to protect people and equipment. Observe thefollowing guidelines to ensure that the workcell is set up safely. Thesesuggestions are intended to supplement and not replace existing federal,state, and local laws, regulations, and guidelines that pertain to safety.
Sponsor your personnel for training in approved FANUC Roboticstraining course(s) related to your application. Never permit untrainedpersonnel to operate the robots.
Install a lockout device that uses an access code to preventunauthorized persons from operating the robot.
Use anti-tie-down logic to prevent the operator from bypassing safetymeasures.
Arrange the workcell so the operator faces the workcell and can seewhat is going on inside the cell.
CONSIDERINGSAFETY FOR YOURROBOTINSTALLATION
Keeping People andEquipment Safe
Using SafetyEnhancing Devices
Setting Up a SafeWorkcell
SAFETYMARO2P10203703E xxvii
Clearly identify the work envelope of each robot in the system withfloor markings, signs, and special barriers. The work envelope is thearea defined by the maximum motion range of the robot, including anytooling attached to the wrist flange that extend this range.
Position all controllers outside the robot work envelope.
Never rely on software as the primary safety element.
Mount an adequate number of EMERGENCY STOP buttons orswitches within easy reach of the operator and at critical points insideand around the outside of the workcell.
Install flashing lights and/or audible warning devices that activatewhenever the robot is operating, that is, whenever power is applied tothe servo drive system.
Wherever possible, install safety fences to protect against unauthorizedentry by personnel into the work envelope.
Install special guarding that prevents the operator from reaching intorestricted areas of the work envelope.
Use interlocks.
Use presence or proximity sensing devices such as light curtains, mats,and capacitance and vision systems to enhance safety.
Periodically check the safety joints or safety clutches that can beoptionally installed between the robot wrist flange and tooling. If thetooling strikes an object, these devices dislodge, remove power fromthe system, and help to minimize damage to the tooling and robot.
Make sure all external devices are properly filtered, grounded,shielded, and suppressed to prevent hazardous motion due to theeffects of electro-magnetic interference (EMI), radio frequencyinterference (RFI), and electro-static discharge (ESD).
Make provisions for power lockout/tagout at the controller.
Eliminate pinch points. Pinch points are areas where personnel couldget trapped between a moving robot and other equipment.
Provide enough room inside the workcell to permit personnel to teachthe robot and perform maintenance safely.
Program the robot to load and unload material safely.
If high voltage electrostatics are present, be sure to provide appropriateinterlocks, warning, and beacons.
If materials are being applied at dangerously high pressure, provideelectrical interlocks for lockout of material flow and pressure.
SAFETY MARO2P10203703Exxviii
Advise all personnel who must teach the robot or otherwise manuallyoperate the robot to observe the following rules:
Never wear watches, rings, neckties, scarves, or loose clothing thatcould get caught in moving machinery.
Know whether or not you are using an intrinsically safe teach pendantif you are working in a hazardous environment.
Before teaching, visually inspect the robot and work envelope to makesure that no potentially hazardous conditions exist. The workenvelope is the area defined by the maximum motion range of therobot. These include tooling attached to the wrist flange that extendsthis range.
The area near the robot must be clean and free of oil, water, or debris.Immediately report unsafe working conditions to the supervisor orsafety department.
FANUC Robotics recommends that no one enter the work envelope ofa robot that is on, except for robot teaching operations. However, ifyou must enter the work envelope, be sure all safeguards are in place,check the teach pendant DEADMAN switch for proper operation, andplace the robot in teach mode. Take the teach pendant with you, turn iton, and be prepared to release the DEADMAN switch. Only theperson with the teach pendant should be in the work envelope.
WARNINGNever bypass, strap, or otherwise deactivate a safety device,such as a limit switch, for any operational convenience.Deactivating a safety device is known to have resulted inserious injury and death.
Know the path that can be used to escape from a moving robot; makesure the escape path is never blocked.
Isolate the robot from all remote control signals that can cause motionwhile data is being taught.
Test any program being run for the first time in the following manner:
WARNINGStay outside the robot work envelope whenever a programis being run. Failure to do so can result in injury.
– Using a low motion speed, single step the program for at least onefull cycle.
– Using a low motion speed, test run the program continuously forat least one full cycle.
– Using the programmed speed, test run the program continuouslyfor at least one full cycle.
Make sure all personnel are outside the work envelope before runningproduction.
Staying Safe WhileTeaching or ManuallyOperating the Robot
SAFETYMARO2P10203703E xxix
Advise all personnel who operate the robot during production to observethe following rules:
Make sure all safety provisions are present and active.
Know the entire workcell area. The workcell includes the robot and itswork envelope, plus the area occupied by all external devices andother equipment with which the robot interacts.
Understand the complete task the robot is programmed to performbefore initiating automatic operation.
Make sure all personnel are outside the work envelope beforeoperating the robot.
Never enter or allow others to enter the work envelope duringautomatic operation of the robot.
Know the location and status of all switches, sensors, and controlsignals that could cause the robot to move.
Know where the EMERGENCY STOP buttons are located on both therobot control and external control devices. Be prepared to press thesebuttons in an emergency.
Never assume that a program is complete if the robot is not moving.The robot could be waiting for an input signal that will permit it tocontinue activity.
If the robot is running in a pattern, do not assume it will continue torun in the same pattern.
Never try to stop the robot, or break its motion, with your body. Theonly way to stop robot motion immediately is to press anEMERGENCY STOP button located on the controller panel, teachpendant, or emergency stop stations around the workcell.
When inspecting the robot, be sure to
Turn off power at the controller.
Lock out and tag out the power source at the controller according tothe policies of your plant.
Turn off the compressed air source and relieve the air pressure.
If robot motion is not needed for inspecting the electrical circuits,press the EMERGENCY STOP button on the operator panel.
Never wear watches, rings, neckties, scarves, or loose clothing thatcould get caught in moving machinery.
Staying Safe DuringAutomatic Operation
Staying Safe DuringInspection
SAFETY MARO2P10203703Exxx
If power is needed to check the robot motion or electrical circuits, beprepared to press the EMERGENCY STOP button, in an emergency.
Be aware that when you remove a servomotor or brake, the associatedrobot arm will fall if it is not supported or resting on a hard stop. Support the arm on a solid support before you release the brake.
When performing maintenance on your robot system, observe the following rules:
Never enter the work envelope while the robot or a program is inoperation.
Before entering the work envelope, visually inspect the workcell tomake sure no potentially hazardous conditions exist.
Never wear watches, rings, neckties, scarves, or loose clothing thatcould get caught in moving machinery.
Consider all or any overlapping work envelopes of adjoining robotswhen standing in a work envelope.
Test the teach pendant for proper operation before entering the workenvelope.
If it is necessary for you to enter the robot work envelope while poweris turned on, you must be sure that you are in control of the robot. Besure to take the teach pendant with you, press the DEADMAN switch,and turn the teach pendant on. Be prepared to release the DEADMANswitch to turn off servo power to the robot immediately.
Whenever possible, perform maintenance with the power turned off.Before you open the controller front panel or enter the work envelope,turn off and lock out the 3-phase power source at the controller.
Be aware that when you remove a servomotor or brake, the associatedrobot arm will fall if it is not supported or resting on a hard stop. Support the arm on a solid support before you release the brake.
WARNINGLethal voltage is present in the controller WHENEVER IT ISCONNECTED to a power source. Be extremely careful toavoid electrical shock.
HIGH VOLTAGE IS PRESENT at the input side wheneverthe controller is connected to a power source. Turning thedisconnect or circuit breaker to the OFF position removespower from the output side of the device only.
Release or block all stored energy. Before working on the pneumaticsystem, shut off the system air supply and purge the air lines.
Staying Safe DuringMaintenance
SAFETYMARO2P10203703E xxxi
Isolate the robot from all remote control signals. If maintenance mustbe done when the power is on, make sure the person inside the workenvelope has sole control of the robot. The teach pendant must beheld by this person.
Make sure personnel cannot get trapped between the moving robot andother equipment. Know the path that can be used to escape from amoving robot. Make sure the escape route is never blocked.
Use blocks, mechanical stops, and pins to prevent hazardousmovement by the robot. Make sure that such devices do not createpinch points that could trap personnel.
WARNINGDo not try to remove any mechanical component from therobot before thoroughly reading and understanding theprocedures in the appropriate manual. Doing so can resultin serious personal injury and component destruction.
Be aware that when you remove a servomotor or brake, the associatedrobot arm will fall if it is not supported or resting on a hard stop. Support the arm on a solid support before you release the brake.
When replacing or installing components, make sure dirt and debris donot enter the system.
Use only specified parts for replacement. To avoid fires and damageto parts in the controller, never use nonspecified fuses.
Before restarting a robot, make sure no one is inside the workenvelope; be sure that the robot and all external devices are operatingnormally.
SAFETY MARO2P10203703Exxxii
Certain programming and mechanical measures are useful in keeping themachine tools and other external devices safe. Some of these measures areoutlined below. Make sure you know all associated measures for safe useof such devices.
Implement the following programming safety measures to prevent damageto machine tools and other external devices.
Back-check limit switches in the workcell to make sure they do notfail.
Implement ‘‘failure routines” in programs that will provide appropriaterobot actions if an external device or another robot in the workcellfails.
Use handshaking protocol to synchronize robot and external deviceoperations.
Program the robot to check the condition of all external devices duringan operating cycle.
Implement the following mechanical safety measures to prevent damage tomachine tools and other external devices.
Make sure the workcell is clean and free of oil, water, and debris.
Use software limits, limit switches, and mechanical hardstops toprevent undesired movement of the robot into the work area ofmachine tools and external devices.
KEEPING MACHINETOOLS ANDEXTERNALDEVICES SAFE
Programming SafetyPrecautions
Mechanical SafetyPrecautions
SAFETYMARO2P10203703E xxxiii
Observe the following operating and programming guidelines to preventdamage to the robot.
The following measures are designed to prevent damage to the robotduring operation.
Use a low override speed to increase your control over the robot whenjogging the robot.
Visualize the movement the robot will make before you press the jogkeys on the teach pendant.
Make sure the work envelope is clean and free of oil, water, or debris.
Use circuit breakers to guard against electrical overload.
The following safety measures are designed to prevent damage to the robotduring programming:
Establish interference zones to prevent collisions when two or morerobots share a work area.
Make sure that the program ends with the robot near or at the homeposition.
Be aware of signals or other operations that could trigger operation oftooling resulting in personal injury or equipment damage.
In dispensing applications, be aware of all safety guidelines withrespect to the dispensing materials.
NOTE Any deviation from the methods and safety practices described inthis manual must conform to the approved standards of your company. Ifyou have questions, see your supervisor.
KEEPING THEROBOT SAFE
Operating SafetyPrecautions
Programming SafetyPrecautions
SAFETY MARO2P10203703Exxxiv
Process technicians are sometimes required to enter the paint booth, forexample, during daily or routine calibration or while teaching new paths toa robot. Maintenance personnel also must work inside the paint boothperiodically.
Whenever personnel are working inside the paint booth, ventilationequipment must be used. Instruction on the proper use of ventilatingequipment usually is provided by the paint shop supervisor.
Although paint booth hazards have been minimized, potential dangers stillexist. Therefore, today’s highly automated paint booth requires thatprocess and maintenance personnel have full awareness of the system andits capabilities. They must understand the interaction that occurs betweenthe vehicle moving along the conveyor and the robot(s), hood/deck anddoor opening devices, and high-voltage electrostatic tools.
Paint robots are operated in three modes:
Teach or manual modeAutomatic mode, including automatic and exercise operationDiagnostic mode
During both teach and automatic modes, the robots in the paint booth willfollow a predetermined pattern of movements. In teach mode, the processtechnician teaches (programs) paint paths using the teach pendant.
In automatic mode, robot operation is initiated at the System OperatorConsole (SOC) or Manual Control Panel (MCP), if available, and can bemonitored from outside the paint booth. All personnel must remainoutside of the booth or in a designated safe area within the booth wheneverautomatic mode is initiated at the SOC or MCP.
In automatic mode, the robots will execute the path movements they weretaught during teach mode, but generally at production speeds.
When process and maintenance personnel run diagnostic routines thatrequire them to remain in the paint booth, they must stay in a designatedsafe area.
Process technicians and maintenance personnel must become totallyfamiliar with the equipment and its capabilities. To minimize the risk ofinjury when working near robots and related equipment, personnel mustcomply strictly with the procedures in the manuals.
This section provides information about the safety features that areincluded in the paint system and also explains the way the robot interactswith other equipment in the system.
The paint system includes the following safety features:
Most paint booths have red warning beacons that illuminate when therobots are armed and ready to paint. Your booth might have otherkinds of indicators. Learn what these are.
Some paint booths have a blue beacon that, when illuminated,indicates that the electrostatic devices are enabled. Your booth mighthave other kinds of indicators. Learn what these are.
EMERGENCY STOP buttons are located on the robot controller andteach pendant. Become familiar with the locations of all E-STOPbuttons.
An intrinsically safe teach pendant is used when teaching in hazardouspaint atmospheres.
A DEADMAN switch is located on each teach pendant. When thisswitch is held in, and the teach pendant is on, power is applied to therobot servo system. If the engaged DEADMAN switch is releasedduring robot operation, power is removed from the servo system, allaxis brakes are applied, and the robot comes to an EMERGENCYSTOP. Safety interlocks within the system might also E-STOP otherrobots.
WARNINGAn EMERGENCY STOP will occur if the DEADMAN switchis released on a bypassed robot.
Overtravel by robot axes is prevented by software limits. All of themajor and minor axes are governed by software limits. Limit switchesand hardstops also limit travel by the major axes.
Paint System SafetyFeatures
SAFETY MARO2P10203703Exxxvi
EMERGENCY STOP limit switches and photoelectric eyes might bepart of your system. Limit switches, located on the entrance/exit doorsof each booth, will EMERGENCY STOP all equipment in the booth ifa door is opened while the system is operating in automatic or manualmode. For some systems, signals to these switches are inactive whenthe switch on the SCC is in teach mode.
When present, photoelectric eyes are sometimes used to monitorunauthorized intrusion through the entrance/exit silhouette openings.
System status is monitored by computer. Severe conditions result inautomatic system shutdown.
When you work in or near the paint booth, observe the following rules, inaddition to all rules for safe operation that apply to all robot systems.
WARNINGObserve all safety rules and guidelines to avoid injury.
WARNINGNever bypass, strap, or otherwise deactivate a safety device,such as a limit switch, for any operational convenience.Deactivating a safety device is known to have resulted inserious injury and death.
Know the work area of the entire paint station (workcell).
Know the work envelope of the robot and hood/deck and door openingdevices.
Be aware of overlapping work envelopes of adjacent robots.
Know where all red, mushroom-shaped EMERGENCY STOP buttonsare located.
Know the location and status of all switches, sensors, and/or controlsignals that might cause the robot, conveyor, and opening devices tomove.
Make sure that the work area near the robot is clean and free of water,oil, and debris. Report unsafe conditions to your supervisor.
Become familiar with the complete task the robot will performBEFORE starting automatic mode.
Make sure all personnel are outside the paint booth before you turn onpower to the robot servo system.
Staying Safe WhileOperating the PaintRobot
SAFETYMARO2P10203703E xxxvii
Never enter the work envelope or paint booth before you turn offpower to the robot servo system.
Never enter the work envelope during automatic operation unless asafe area has been designated.
Never wear watches, rings, neckties, scarves, or loose clothing thatcould get caught in moving machinery.
Remove all metallic objects, such as rings, watches, and belts, beforeentering a booth when the electrostatic devices are enabled.
Stay out of areas where you might get trapped between a movingrobot, conveyor, or opening device and another object.
Be aware of signals and/or operations that could result in the triggeringof guns or bells.
Be aware of all safety precautions when dispensing of paint isrequired.
Follow the procedures described in this manual.
When you perform maintenance on the painter system, observe thefollowing rules, and all other maintenance safety rules that apply to allrobot installations. Only qualified, trained service or maintenancepersonnel should perform repair work on a robot.
Paint robots operate in a potentially explosive environment. Usecaution when working with electric tools.
When a maintenance technician is repairing or adjusting a robot, thework area is under the control of that technician. All personnel notparticipating in the maintenance must stay out of the area.
For some maintenance procedures, station a second person at thecontrol panel within reach of the EMERGENCY STOP button. Thisperson must understand the robot and associated potential hazards.
Be sure all covers and inspection plates are in good repair and in place.
Always return the robot to the ‘‘home’’ position before you disarm it.
Never use machine power to aid in removing any component from therobot.
During robot operations, be aware of the robot’s movements. Excessvibration, unusual sounds, and so forth, can alert you to potentialproblems.
Whenever possible, turn off the main electrical disconnect before youclean the robot.
Staying Safe DuringMaintenance
SAFETY MARO2P10203703Exxxviii
When using vinyl resin observe the following:
– Wear eye protection and protective gloves during application andremoval
– Adequate ventilation is required. Overexposure could causedrowsiness or skin and eye irritation.
– If there is contact with the skin, wash with water.
When using paint remover observe the following:
– Eye protection, protective rubber gloves, boots, and apron arerequired during booth cleaning.
– Adequate ventilation is required. Overexposure could causedrowsiness.
– If there is contact with the skin or eyes, rinse with water for atleast 15 minutes.
Page 1
1 OVERVIEW
1 OVERVIEW
1–1MARO2P10203703E
Topics In This Chapter Page
Overview This manual describes the SYSTEM R-J2 controller which is used in conjunction with the P-200 robot, P-10 door opener, P-15 hood and deck opener and the Systems PaintTool software. This chapter describes the major components used in the controller. 1–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
The main CPU PC board contains the central processing units,integrated circuit, and all the memory used by the controller. 1–10. . . . . . . . . . . . . . . .
Sub-CPU Printed CircuitBoard
The sub CPU performs all calculations required by the controller. 1–13. . . . . . . . . . . .
Aux Axis Printed CircuitBoard
The aux axis printed circuit board contains up to five servo control modules that provide servo control to the available auxiliary axes. 1–16. . . . . . . . . . .
Power Supply UnitPrinted Circuit Board
The power supply unit printed circuit board is supplied with 210 VAC nominal.from the multi-tap transformer and produces DC voltages. 1–17. . . . . . . . . . . . . . . . . .
Emergency Stop ControlPrinted Circuit Board
Supplies 24 VDC to the (Magnetic Control Contactor), turns off 24 VDC to the (Magnetic Control Contactor) during fault conditions, supplies power to the motor brakes and to the serial pulse coders. 1–18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Multi-Tap Transformer The multi-tap transformer is supplied 3 phase VAC from the main disconnect or circuit breaker. This supply voltage can range from 220 - 575 volts. To accommodate the various levels of supply, tap selections are provided on the primary side of the transformer. 1–27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ethernet remote PCB’s are an R-J2 option that use communication protocols to back up and restore all the information on a controller to and from an external device, or host computer. 1–34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operator Panel Pushbuttons and LEDs on the operator panel of the R-J2 are used to start and shut down the robot and indicate status. 1–38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Teach Pendant The teach pendant is a hand held device used to operate and program the robot and controller. 1–39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Heat Exchange and Fans The temperature in the controller is kept within operating range through the use of an air-to-airheat exchange system. 1–40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Purge Control Unit The purge control unit consists of an purge intrinsically safe barrier unit module, contact signal transducer, purge control PCB, and 24VDC power supply. 1–41. . . . . .
Purge System IBRC The IBRC is an intrinsically safe barrier unit that is used as part of the purge system. 1–42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Purge Unit Power Supply The purge unit power supply is a 24VDC auxiliary power supply used exclusively for the purge system. 1–44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1–2
1. OVERVIEW
MARO2P10203703E
Topics In This Chapter Page
Purge Intrinsically SafeBarriers
The Purge Intrinsically Safety Barriers are used in the purge system in that they restrict power that may cause a spark. 1–45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brake Release (Option) The brake release option adds (4) optional brake switches to selectively release the gravity and non-gravity axes of the P-200 robot. 1–55. . . . . . . . . . . . . . . . . . . . . . . .
P-10 Door Opener andP-15 Hood and DeckOpener (Option)
The P-10 opener is a three axis, electrically-driven door opener and the P-15 opener is a three axis, electrically-driven hood and deck opener. 1–56. . . . . . . .
Integral Pump Control(Option)
The Integral Pump Control option is the FANUC Robotics integrated two component fluid delivery system which features metering pumps directly coupled to FANUC servomotors that are controlled by the FANUC R-J2 controller. 1–57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1–3
1. OVERVIEW
MARO2P10203703E
The R-J2 controller, hereafter referred to as the controller, contains thecomputer that operates the robots. It executes a user-defined program toperform the following functions:
Supply drive power to the servomotors of the P-10, P-15, and P-200,robots to move it through a series of program motions.
Send control signals to process devices and other peripheralequipment.
The controller consists of modular circuit boards, components, controlsand indicators that are housed in a C-size cabinet with or without a sidecabinet depending if a door or hood and deck opener are included.
Figure 1–1 illustrates an external view of the controller. Figure 1–2illustrates the internal view of the controller. Figure 1–3 illustrates a R-J2C-size controller with side cabinet.
Figure 1–1. External View of the P-200 R-J2 Controller
Teachpendant
ÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎ
ÎÎÎÎÎÎÎ
ÎÎÎÎÎÎÎÎÎÎ
ÎÎÎÎÎ
ÎÎÎÎÎÎÎÎÎÎ
ÎÎÎÎÎÎÎ
ÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎ
ÎÎÎÎÎÎÎ
ÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎ
1.1OVERVIEW
1–4
1. OVERVIEW
MARO2P10203703E
Figure 1–2. Internal View of the P-200 R-J2 Controller
Operator panel
Main CPU
Power supply unit
Multi-tap transformer
Modular I/O rack
Main power disconnect
ÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎ
ÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎ
ÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎ
Servo amplifiers #1–3Fuses FL1–3
ÎÎ
ÎÎÎÎÎÎÎÎÎÎÎÎÏÏ
User transformer
ISB unit
SPC battery case
SERVO ON Light
Emergency stop controlprinted circuit board
Servo amplifier #4
Front Door
Aux axis board
Teach pendant
Flowmeter interface module
ISBUIBRC
Purge Control Power Supply
Purge Control PCB
1–5
1. OVERVIEW
MARO2P10203703E
Figure 1–3. R-J2 C-Size Controller with Side Cabinet
OFF
ON
OFF
ON
DISCONNECT
USERTRANS.
FANUCAC SERVOAMPLIFIERC series
FANUCAC SERVOAMPLIFIERC series
OPT
PURGE CONTROL UNIT
CONTACT SIGNAL
TRANSDUCER
1 1/2 ”W X 4”H DUCT
1”W X 4”H DUCT
AMP 1 AMP 2
EMGBOARD
I/O RACK
OFF
ON
FANUCAC SERVOAMPLIFIERC series
AMP 3
MAINPSUCPU
FANUCAC SERVOAMPLIFIER
STATUS
8
0
1
AMP 4
OFF
ON
FANUCAC SERVOAMPLIFIER
AMP 5 AMP 6
DELTRONW112A24V @ 1.2A
OVP
ISB3ISB4ISB5ISB6ISB7ISB8ISB9
OFF
ON
FANUCAC SERVOAMPLIFIER
R-J2-C Size cabinet with door removedSide cabinet
1–6
1. OVERVIEW
MARO2P10203703E
Three styles of backplane are available:
2-Slot3-Slot5-Slot
These three printed circuit boards are interchangeable. The backplaneconsists of a printed circuit board and two, three, or five board racksattached to it.
The controller printed circuit boards are mounted on the backplane printedcircuit board. See Figure 1–4, Figure 1–5, and Figure 1–6. It provides thebus structure for communication between the controller printed circuitboards.
A thermostat switch is mounted on the backplane printed circuit board. Itsenses the temperature within the controller. If the internal temperatureexceeds 65 degrees centigrade (149 degrees Fahrenheit), the thermostatwill open, generating a system overheat alarm.
The board racks support the printed circuit boards and guides them intotheir electrical connectors on the backplane printed circuit board.
A 24 VDC cooling fan is mounted in the top of each backplane board rack.
Total version2 slot back plane printed circuit boardA20B-2001-0860
PCMCIA Memory Card
1–8
1. OVERVIEW
MARO2P10203703E
Figure 1–5. 3-Slot Backplane (A05B-2316-C105)
FanFans
Backplane PrintedCircuit Board
Total version3 slot back plane printed circuit boardA20B-2001-0670
Main CPUPower Supply
PCMCIA Memory Card
1–9
1. OVERVIEW
MARO2P10203703E
Figure 1–6. 5-Slot Backplane (A05B-2316-C111)
Fan
Fan
Backplane Printed Circuit Board
Total version5 slot back plane printed circuit boardA20B-2001-0990
Main CPUPower Supply
PCMCIA Memory Card
1–10
1. OVERVIEW
MARO2P10203703E
The main Central Processor Unit printed circuit board is mounted in theslot marked “1” at the far left end of the backplane. It contains the centralprocessing units, integrated circuit, and all the memory used by thecontroller.
The main CPU performs all calculations required by the controller. Itgenerates axis drive signals on the basis of programmed requirements andfeedback signals from encoders driven by each axis.
The main CPU also acts as the interface between the controller and theoperator and attached devices, through connections to:
The I/O unit(s)The teach pendantOne or more general purpose serial communication portsThe operator panel lights and push buttons
A storage capacitor on the main CPU printed circuit board maintainspower to the CMOS RAM for short periods of time (up to 30 minutes) ifthe main CPU is removed from the backplane. The BAT-VBAT connectorcan be used to connect the battery from the power supply unit to the mainCPU when either of the two printed circuit boards is removed from thebackplane for an extended period of time.
The main CPU consists of a main mother board with several modulesinstalled perpendicular to it. The modules are small printed circuit boardswith components surface-mounted on both sides. The modules areinstalled in sockets, allowing them to be changed quickly and easily.
The following kinds of memory exist in the controller:
Controller memoryFlash ROM (F-ROM or FROM)C-MOS RAMD-RAM (or DRAM)
Controller memory consists of Flash Read Only Memory (Flash ROM),Complementary Metal Oxide Semiconductor Random Access Memory(C-MOS RAM), and Dynamic Random Access Memory (D-RAM).C-MOS RAM memory stores some robot system software, someapplication software, and some user programs. Flash ROM stores themajority of the robot system software such as core, and applicationsoftware.
Most of the SYSTEM R-J2 system software executes from D-RAM.When the controller is turned on, the system software is loaded from FlashROM to D-RAM and then is executed. Teach pendant programs are storedand are executed from C-MOS RAM.
1.3MAIN CPU PRINTEDCIRCUIT BOARDA16B–3200–0040
NOTE: This part numberspecifies a Main CPU withoutdaughter boards.
1.3.1 Identifying Kinds ofMemory
Controller Memory
1–11
1. OVERVIEW
MARO2P10203703E
Flash ROM Module contains System and Application Software. FlashROM (F-ROM or FROM disk) is not battery-backed but is non-volatile.Non-volatile means that all data in Flash ROM is saved even after you turnoff and turn on the controller. Flash ROM has three parts: a systemmemory section, an image memory section, and a flash file section.
The system memory section contains the software that executes all systemsoftware. Image memory contains software options. The flash file systemsection contains space for backing up user programs and robotconfiguration information. It also holds hidden files required for Re-INITstart (CMOSINIT).
CMOS RAM Module stores user programs, system variables, I/Oconfiguration files, and mastering data. C-MOS RAM is battery-backed.C-MOS RAM is non-volatile only while the batteries are working. If thebatteries are faulty or removed, C-MOS RAM is lost. C-MOS RAM hastwo parts: the TPP memory pool, and the permanent (PERM) memorypool.
The TPP memory pool contains the teach pendant programs. ThePERM memory pool contains system variables.
PERM can also contain system software and options.
DRAM (Dynamic) Module loads information from Flash ROM, eliminatesfragmentation and must reload after a cold start. D-RAM is volatile, but itis loaded from flash ROM when the controller is turned on. D-RAM alsohas three parts: a SYSTEM memory pool, an IMAGE memory pool, and aTEMP memory pool. The SYSTEM memory pool contains the softwarethat executes all system software. The IMAGE memory pool containsKAREL programs and software options. The TEMP memory poolcontains the read/write scratch space for system and KAREL software andKAREL programs.
CAUTIONData in C-MOS RAM can be lost if the battery is removed orloses its charge, or if new core software is loaded on thecontroller. The C-MOS RAM memory will last for 30 minuteswithout the battery when power is off. To prevent loss of data,back up or copy all files for permanent storage.
CAUTIONTo transport or store the contents of the MAIN CPU, you canplug the battery into the VBAT connector in the MAIN CPU.However, do not plug it into the RESET connector; otherwiseyou could damage equipment.
Figure 1–7 shows the board layout.
Table 1–1 lists the modules available for installation on the board.
Flash ROM
C-MOS RAM
D-RAM
1–12
1. OVERVIEW
MARO2P10203703E
Figure 1–7. Main CPU Printed Circuit Board
CMOS module
DRAM module
Axis module (J1,-J2)
Axis module (J3, J4)
Axis module (J5, J6)
Flash ROM module
Table 1–1. Main CPU Modules
Name Part Number Remarks
Flash ROM Module A20B-2902-0370 2.0 Mbyte
Flash ROM Module A20B-2902-0371 4.0 Mbyte
Flash ROM Module A20B-2902-0372 6.0 Mbyte
Flash ROM Module A20B-2902-0373 8.0 Mbyte
CMOS RAM Module A20B-2902-0211 0.5 Mbyte
CMOS RAM Module A20B-2902-0210 1.0 Mbyte
CMOS RAM Module A20B-2902-0380 2.0 Mbyte
DRAM Module A20B-2902-0021 3.0 Mbyte
DRAM Module A20B-2902-0531 4.0 Mbyte
DRAM Module A20B-2902-0530 8.0 Mbyte
Axis Control Module A20B-2902-0070 Three required
Robot Output Driver DV1 and DV2 A76L-0151-0062 Two required
1–13
1. OVERVIEW
MARO2P10203703E
The sub Central Processor Unit printed circuit board is mounted in the slotmarked “1” at the far left end of the backplane. It contains the centralprocessing units, integrated circuit, and all the memory used by thecontroller.
The sub CPU performs all calculations required by the controller. Itgenerates axis drive signals on the basis of programmed requirements andfeedback signals from encoders driven by each axis.
The Sub CPU also acts as the interface between the controller and theoperator and attached devices, through connections to:
The I/O unit(s)The teach pendantOne or more general purpose serial communication portsThe operator panel lights and push buttons
The sub CPU consists of a main mother board with one module installedperpendicular to it. The module is a small printed circuit board withcomponents surface-mounted on both sides. The module is installed in asocket, allowing it to be changed quickly and easily.
1.4SUB CPU PRINTEDCIRCUIT BOARDA16B–3200–015
NOTE: This part numberspecifies a Sub CPU withoutdaughter boards.
1–14
1. OVERVIEW
MARO2P10203703E
Figure 1–8. Sub-CPU Printed Circuit Board
A16B-3200-015FANUC
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ÎÎÎÎÎÎÎÎ
ÎÎÎÎÎÎÎÎ
LV ALM
F21 5A
RISC-B
STATUSALARM
VD1
PC
3
PC
5
PC
13
PR
1
EP
RO
M M
OD
ULE
JNA
BAT
1
5.0A
D16
Table 1–2. Sub CPU Modules
Name Part Number Remarks
ROM Module Memory for the sub-CPU
1–15
1. OVERVIEW
MARO2P10203703E
Figure 1–9. Block Diagram
SUB-CPU
BUS I/F
FANUC BUS
BUS I/F
DRAM
SHARED RAM
SUB-CPUSystem ROM
1–16
1. OVERVIEW
MARO2P10203703E
The auxiliary axis control printed circuit board is mounted in the slotmarked “3” at the right end of the backplane. It contains up to five servocontrol modules that provided servo control of the available auxiliary axes(7 through 16). It is required whenever more than six axes are used, suchas for a rail-mounted P-200 robot. See Figure 1–10.
Figure 1–10. Aux Axis Printed Circuit Board
Servo control module (for axis15 and 16)
Servo control module (for axis 13 and 14)
JRY2
JNA
Servo control module (for axis 9 and 10)
Servo control module (for axis 7 and 8)
Servo control module (for axis 11 and 12)
AM
P15
JV15
AM
P16
JV16
AM
P14
JV14
AM
P13
JV13
AM
P12
JV12
AM
P11
JV11
AM
P9
JV9
AM
P10
PV
10
AM
P8
JV8
AM
P7
JV7
AU
X.A
XIS
CO
NT.
PC
B
EN
C16
JRF
1B
EN
C15
JRF
1A
EN
C14
JF14
EN
C13
JF13
EN
C12
JF12
EN
C11
JF11
EN
C10
JF10
EN
C9
JF9
EN
C8
JF8
EN
C7
JF7
LINE
2JF
22R
S232C
/RS
422JD
29
A20B–2902–0070
A20B–2902–0070
A20B–2902–0070
A20B–2902–0070
A20B–2902–0070
1.5AUX AXIS PRINTEDCIRCUIT BOARD
A16B–2202–0820
MARO2P10203703E 1–17
1. OVERVIEW
The power supply unit printed circuit board is mounted on the backplanein the slot marked PSU. See Figure 1–11.
The power supply unit printed circuit board is supplied with 210 VACnominal from the multi-tap transformer and produces the following DCvoltages:+24V used:
– For inputs, outputs receivers, drivers, and relays– As the power source for the teach pendant power supply circuitry
+15V, –15V, and +5V used:– For logic power within the controller
The power supply unit printed circuit board also contains the ON/OFFlogic circuits used by the controller.
CAUTIONThe CMOS RAM backup battery is mounted on the powersupply unit printed circuit board. Do not remove the board forlonger than 30 minutes; otherwise, all controller software will belost and will need to be reloaded.
Figure 1–11. Power Supply Unit
Battery cover
Battery
F1:7.5A fuse forAC input
PIL:Green LED forindicating the ACpower supplystatus
ALM:Red LED forindicating analarm
F4:5A fuse for +24E
F3:5A Slow-Blow
(With the batterycover removed)
fuse for +24V
JNPO
PCMCIA receptacle
1.6POWER SUPPLY UNITPRINTED CIRCUITBOARD
A16B-1212-0870
MARO2P10203703E1–18
1. OVERVIEW
The emergency stop control printed circuit board is mounted on the side ofthe board rack adjacent to the CPU. See Figure 1–2, for location. Itcontains the circuits that:
Supply 24VDC to the servo amplifiers magnetic control contactors(MCCs) during normal operation.
Turn off 24VDC for the MCC during fault conditions such as:
– Emergency stop– Axis overtravel– Safety fence open– Teach pendant DEADMAN switch– Hand breakage detection
Supply power to the motor brakes to release them during normaloperation. Brake power is turned off (applying motor brakes) duringmajor alarm conditions, or when regulated by the software. There is asecond brake circuit that is manually operated by a front panel keyswitch. See Section 6. This key switch operated circuit provides amethod to move the robot manually should servo power fail, or whenmastering is required.
Supply 24VDC required for serial pulse code (SPC) encoder operationthrough the 24 to 5VDC converter unit located within the robot baseand switched on through the purge complete relay contacts forprotection from explosive gases.
Figure 1–12 shows the emergency stop control printed circuit boardlayout.
1.7EMERGENCY STOPCONTROL PRINTEDCIRCUIT BOARD
A16B-1212-0931
1–19
1. OVERVIEW
MARO2P10203703E
Figure 1–12. Emergency Stop Control Printed Circuit Board
Door interlock jumper/connector
COM
HBK
AB
B A
COMMON JUMPERA=0VDC commonB=24VDC common
HAND BROKEN JUMPERA= USING SWITCHB= BY-PASSING SWITCH
RLY4 RLY5 RLY6
RLY2 RLY3RLY1
1–20
1. OVERVIEW
MARO2P10203703E
The servo amplifiers are mounted on the back wall of the controller.See Figure 1–2 for component location.
The servo amplifier drives the motor(s) in response to signals from theaxis control circuitry.
Servo amplifiers are supplied in single, double or triple-axisconfigurations.
CAUTIONWhile two servo amplifiers might look identical, they might havedifferent output power capabilities. If you replace a servoamplifier, make sure that the new unit has the same partnumber as the old one. Otherwise, the servo amplifier orservomotor might be damaged or destroyed.
See Figure 1–13 for a typical servo amplifier.
The P-200 controller uses α-series SVU type amplifiers. The features ofthe servo amplifier units are as follows:
Compact – The servo amplifier unit is integrated with a powersupply. It enables implementation of a compact system with one ortwo feed axes.
Satisfies safety standards – The servo amplifier unit is designed tocomply with the VDE 0160 (Europe), UL (USA), and CSA (Canada)safety standards.
New interfacing capability – The servo amplifier unit provides anew interface (type B) as well as the conventional interface (type A)for the CNC.
Up-to-date power device – The servo amplifier unit uses anup-to-date power device, IPM (intelligent power module), to reducepower loss and enhance alarm detection, thereby increasing itsreliability.
1.8SERVO AMPLIFIERS
Refer to Table 1–3 forpart numbers.
1–21
1. OVERVIEW
MARO2P10203703E
Figure 1–13. Servo Amplifier
LED
Terminal board T1
Circuit breaker
IRLISL
0V
IRMISM
+5VFuse
PE (G)L1 (R)
L2 (S)
L3 (T)
100A100B
MC1MC2
UV
W
G
L1CL2C
TH1TH2
RC
RIRE
FAN1FAN2
12
3
4
5
6
78
910
11
12
1314
1516
17
1819
20
21
1–22
1. OVERVIEW
MARO2P10203703E
Figure 1–14. Servo Amplifier Specifications
Item Specifications
Three-phase inputfor power
Single-phase inputfor control power
Voltage : 200/220/230 VAC +10 %. –15 %Frequency : 50/60 Hz +/- 2HzVoltage deviation due to load (at maximum output) shall be 79% or less).
Control of main circuit Sine-wave PWM control by transistor bridge (IPM)
Alarm and protection functions Over-voltage alarmLow control power voltage alarmLow DC link voltage alarmRegenerative discharge control circuit failure alarmOver-regenerative discharge alarmDynamic brake circuit failure alarmOver-current alarmIPM alarmCircuit breaker
Power Supply
Figure 1–15 through Figure 1–19 show the mounting location ofamplifiers for various robot locations.
Figure 1–15. Mounting Locations of Servo Amplifiers for the P-200 6 Axis Robot
Amp 4
J2
Amp1 Amp2 Amp 3
J1-J4 J3-J5 J6
1–23
1. OVERVIEW
MARO2P10203703E
Figure 1–16. Mounting Locations of Servo Amplifiers for the P-200 7 Axis Robot
Amp 1 Amp 2
J1-J4
Amp 3
J6-J7J3-J5
Amp 4
J2
Figure 1–17. Mounting Locations of Servo Amplifiers for the P-200 6+2 Robot
Amp 1
J1-J4
Amp 2 Amp 3
J3-J5 J6
J2
Amp 4 Amp 5
J7–J8
1–24
1. OVERVIEW
MARO2P10203703E
Figure 1–18. Mounting Locations of Servo Amplifiers for the P-200 7+2 Robot
Amp 3
Amp 5
Amp 1 Amp 2
Amp 4
J2
J1-J4 J3-J5 J6–J7
J8-J9
Figure 1–19. Mounting Locations of Servo Amplifiers for the P-200 7+3 Robot
The multi-tap transformer is located on the floor of the controller on theright side of the rear cabinet. See Figure 1–2 for component location.
The multi-tap transformer is supplied 3-phase VAC from the maindisconnect or circuit breaker. This supply voltage can range from 220 – 575 volts. To accommodate the various levels of supply, tapselections are provided on the primary side of the transformer.
The transformer output supplies the following voltages:
3–phase 210 VAC nominal for the servo amplifiers1–phase 210 VAC nominal for the backplane–mounted components1–phase 210 VAC nominal for the IBRC module1–phase 210 VAC nominal for the 24VDC Purge Power Supply1–phase 100VAC nominal for the brakes and servo amplifier
A06B–6066–Hxxx MCC
Two series-connected thermostats are mounted on the transformer. Theyare connected to fault detection circuitry in one servo amplifier. If thetransformer overheats, the controller will signal a SRVO–0043 DCALalarm.
Figure 1–20 shows the transformer. Table 1–5 and Table 1–6 list theinformation necessary for selecting a proper primary tap.
Table 1–5. Multi-Tap Transformer Part Numbers
Transformer Type Part Number
7.5kVA A80L–0026–0010#A
5kVA A80L–0024–0010#A
1.9MULTI-TAPTRANSFORMER
Refer to TABLE 1–5 for partnumbers.
MARO2P10203703E1–28
1. OVERVIEW
Figure 1–20. Multi-Tap Transformer
575V550V500V480V460V
240/415V220V/380V
1
234
5
6
7
0V575V550V500V480V460V
240/415V220V/380V
8
91011
12
13
14
0V575V550V500V480V460V
240/415V220V/380V
0V
16
171819
20
21
22
15
23
24
F1 F2 F3
1 3 5
2 4 6
13
31
32
14
23
41
42
24
A1 A2
F4 7.5
F5 7.5
Table 1–6. Selecting Transformer Taps
S pply VoltagePrimary Tap
Connection TypeSupp ly VoltageL1 L2 L3 Jumper
Connect ion Type
220 7 15 23 8–15/16–23/24–7
240 6 14 22 8–14/16–22/24–6
DELTA
380 7 15 23
415 6 14 22
460 5 13 21Y480 4 12 20
8–16 16–24Y
STAR500 3 11 19
8–16 16–24 STAR
550 2 10 18
575 1 9 17
1–29
1. OVERVIEW
MARO2P10203703E
The interface between the controller and peripheral devices is provided byinput and output signals from one or more of the following:
Modular I/O (Model A) Unit
Distributed I/O (Model B) UnitProcess I/O printed circuit board
A printed circuit board specializing in communicating with a logiccontroller, which includes
– ABRIO for communication to an Allen-Bradley PLC– Genius I/O for communication to a GE Fanuc programmable
controller
Digital I/O to and from the robot through the axis control board.
External E-Stop peripheral device connections.
The modular I/O unit provides communication between the controller andvarious peripheral devices. See Figure 1–21.
Figure 1–21. Modular I/O
Modular I/O Rack(Backplane)
I/O ModuleSlot I/F
Slot 1Slot 2
Interface Module
I/O ModuleInterface Module
F
1.10INTERFACE DEVICES
1.10.1 Modular I/O Unit
MARO2P10203703E1–30
1. OVERVIEW
The modular I/O unit uses the following communication modes:
Discrete (On or Off) input and output signal lines at 24VDC or120VAC. Outputs can be sink or source outputs.
Analog signal lines, which can vary from –10VDC to +10VDC
The modular I/O unit consists of the following:
The base unitThe interface moduleVarious discrete input and output (I/O) modules
The control can use as many as 64 modular I/O modules concatenated(daisy-chained) together on multiple racks.
A single modular I/O unit is referred to as rack 1. The I/O modules arelocated in slots 1 to 5 or 1 - 10, depending on the model used.
The base unit is the backplane for the modular I/O unit. The interfacemodule and the I/O modules plug into it.
The base unit has no LEDs, fuses, or electrical connections, except for themodule sockets.
The first slot to the left (I/F) always contains the interface module. Theother slots are used for the I/O modules.
The interface module transfers data between the main CPU and the I/Omodules.
The interface module is connected to the JD4 connector on the main CPUprinted circuit board through connector JD1B. The interface module isalways mounted in the I/F (first) slot.
Discrete input modules receive 24VDC or 120VAC signals on theirterminals and relay the data to the interface module.
Discrete output modules transmit 24VDC or 120VAC signals on theirterminals under command of the interface module.
Base Unit5 I/O Module SlotA03B-0807-C002
10 I/O Module SlotA03B-0807-C001
Interface ModuleWith 1 RackA03B-0807-C011
Additional RacksA03B-0807-C012
Discrete Input ModulesRefer to Table 1–7 andTable 1–9 for specificationsand part numbers.
Discrete Output ModulesRefer to Table 1–8 andTable 1–9 for specificationsand part numbers.
1–31
1. OVERVIEW
MARO2P10203703E
Table 1–7. Digital Input Module Specifications
Input Type ModuleName
RatedVoltage
RatedCurrent Polarity* Response
Time Points ExternalConnection LED Display
Non-isolatedDC input
AID32A 24VDC 7.5 mA Both Maximum20 ms
32 Connector Not provided
AID32B 24VDC 7.5 mA Both Maximum2 ms
32 Connector Not provided
OpticallyisolatedDC inp t
AID16C 24 VDC 7.5 mA NEG Maximum20 ms
16 Terminal block Provided
DC input AID16D 24VDC 7.5 mA POS Maximum20 ms
16 Terminal block Provided
AID32E 24VDC 7.5 mA Both Maximum20 ms
32 Connector Not provided
AID32F 24VDC 7.5 mA Both Maximum2 ms
32 Connector Not provided
AC input AIA16G 100~120VAC
10.5 mA(120VAC)
ON Max 35 msOFF Max 45 ms
16 Terminal block Provided
* Polarity is defined as follows: Negative : 0 V common (current source type); ON when input is at low level.Positive : 24 V common (current sink type); ON when input is at high level.
* Polarity is defined as follows: Negative : 0 V common (current sink type); output is at low level when ON.Positive : 24 V common (current source type); output is at high level when ON.
MARO2P10203703E1–32
1. OVERVIEW
Table 1–9. I/O Module Part Numbers
Name Part Number
DC inputmodule
Non-isolated 32 points20 ms
AID32A A03B-0807-C101
32 points2 ms
AID32B A03B-0807-C102
Opticallyisolated
16 pointsNEG
AID16C A03B-0807-C103
16 pointsPOS
AID16D A03B-0807-C104
32 points20 ms
AID32E A03B-0807-C105
32 points2 ms
AID32F A03B-0807-C106
AC input module16 points
AIA16G A03B-0807-C107
DC outputmodule
Not fused 32 pointsNEG
A0D32A A03B-0807-C162
Fused 8 pointsNEG
AOD08C A03B-0807-C151
8 pointsPOS
AOD08D A03B-0807-C152
Not fused 16 pointsNEG
AOD16C A03B-0807-C153
16 pointsPOS
AOD16D A03B-0807-C154
32 pointsNEG
AOD32C A03B-0807-C155
32 pointsPOS
AOD32D AO3B-0807-C156
AC outputmodule
Fused 5 points, 2 A AOA05E A03B-0807-C157module 8 points
1 AAOA08E A03B-0807-C158
12 points0.5 A
AOA12F A03B-0807-C159
Relay output module 8 points4 A
AOR08G A03B-0807-C160
16 points2 A
AOR16G A03B-0807-C161
Analog input module AAD04A A03B-0807-C051
Analog output module ADA02A A03B-0807-C052
1–33
1. OVERVIEW
MARO2P10203703E
The ABRIO and Genius I/O printed circuit boards use serialcommunication to interface to a programmable controller. These printedcircuit boards are used for communicating control information between theR-J2 controller and the programmable controller.
Refer to the following manuals for information on these boards.
A User’s Guide to the FANUC Robotics Genius Network Interface forGEFanuc
A User’s Guide to the FANUC Robotics Genius Network Interface forGEFanuc (R-H Style Board in R-J2 Controller)
A User’s Guide to the FANUC Robotics Remote I/O Interface for anAllen-Bradley PLC (R-H Style Board in R-J2 Controller)
A User’s Guide to the FANUC Robotics SYSTEM R-J2 ControllerRemote I/O Interface for an Allen Bradley PLC.
The ER-1 style consists of a full-size motherboard printed circuit boardwith an optionally attached daughter printed circuit board. The five kindsof ER-1 printed circuit boards that support Ethernet are listed inTable 1–10. See Figure 1–22 for the ER-1 Printed Circuit Boards.
The ER-2 style consists of a single printed circuit board in a half-slot formfactor that allows it to be installed in the half slot available in the powersupply unit. The three kinds of ER-2 that support Ethernet are listed inTable 1–10. See Figure 1–23 for the ER-2 Printed Circuit Boards.
The controller can contain an optional user transformer. It supplies120VAC single-phase power to a National Electrical ManufacturersAssociation (NEMA) outlet receptacle and is located on the lower left sideof the controller. See Figure 1–24.
Figure 1–24. User Transformer
Multi-tap transformer
1.12USER TRANSFORMER
A80L-0001-0520
MARO2P10203703E1–38
1. OVERVIEW
Pushbuttons and LEDs on the operator panel of the R-J2 are used to startthe robot and indicate status. The panel has a port for serial interface to anexternal device. The operator panel can be equipped with one or both ofthe following
Disconnectable teach pendant port with a switch for operation withoutserial interface to an external device.
DB–25 connector for serial interface (External disk drive, forexample.)
An emergency stop button on the operator panel places the system into theemergency stop condition when pressed.
Figure 1–25. Operator Panel without Teach Panel Disconnect
ÎÎÎÎÎÎÎÎÎ
ÎÎÎÎÎÎ
ÎÎÎÎÎÎÎÎ
ÎÎ
ÎÎÎÎÎ
ÎÎÎÎ
ÎÎ
BATTERY
ALARM CYCLE STARTON
OFF
REMOTE
REMOTE
LOCAL
HOLD
PURGECOMPLETE
PURGE ENABLE
PURGEFAULT
EMERGENCY STOP
ENABLED
FAULT RESET
FAULT
ÏÏÏÏ
ÏÏÏÏ
ON
OFF HOUR METERPORT
BRAKE ENABLE
1.13OPERATOR PANEL
A05B-2363-C001A05B-2363-C002
1–39
1. OVERVIEW
MARO2P10203703E
The teach pendant is a hand held device used to operate and program therobot and controller. See Figure 1–26. Keys on the teach pendant are used to enter data, jog the robot, and to display menus.
The pendant has a liquid crystal display 16 lines long by 40 characterswide. The teach pendant also has an emergency stop button that, whenpressed, places the robot into an emergency stop condition.
A DEADMAN switch mounted on the back of the teach pendant enablesservo drive power if held with the teach pendant on/off switch turned toON. When the teach pendant switch is turned to OFF, pressing theDEADMAN switch is not required to keep servo drive power enabled.
WARNINGThe robot will become fully functional and capable of beingstarted at the operator panel if the teach pendant is turnedoff and the fence circuit is not installed or closed. Whenworking in the robot envelope, ALWAYS CARRY THETEACH PENDANT and HAVE THE TEACH PENDANTENABLED. Otherwise, you could injure personnel ordamage equipment.
Seven of the keys on the teach pendant provide different functionsdepending on the software in the controller. Eleven indicators, located onthe left side of the LCD display, indicate status of the system. Theindicator labels are different based on software operating in the controller.
Refer to Chapter 3, “Lights, Indicators, and LEDs,” for an explanation ofthe indicators.
Figure 1–26. Teach Pendant
Software-Dependent Keys
LCD Display
IndicatorLabels
DEADMANSwitches
Emergency Stop Button
Indicators
Enable/disableswitch
1.14TEACH PENDANTA05B–2308–C300
MARO2P10203703E1–40
1. OVERVIEW
The temperature in the controller is kept within operating range throughthe use of an air-to-air heat exchange system. The controller is sealed toprohibit outside air from entering the controller cabinet. Internal controllerair is circulated by fans around the inside of the controller and downwardthrough the internal side of the heat exchange unit. Outside air iscirculated upward through the external side of the heat exchange unit alsoby using a fan. This process cools the inside air.
Fans are provided on the printed circuit board racks mounted on thebackplane to circulate air over the printed circuit boards.
Cooling fins connected to the servo amplifiers are within the heatexchange unit to keep the heat generated by the servo power circuits out ofthe controller.
Figure 1–27 shows the heat exchange system for the controller.
Figure 1–27. Heat Exchange System
Outside air in
Internal air
Outsideair
Backplane fan(s)
Air flow
Fan 3
Fan 1
Fan 2
A05B–2301–C901 Fan AssyA90L–0001–0213 Fan
A05B–2051–C902 Fan AssyA90L–0001–219#A Fan
A02B–0056–C904 Fan AssyA90L–0001–0219#A Fan
A90L–0001–0378A90L–0001–0385#A
1.15HEAT EXCHANGE ANDFANSRefer to Figure 1–27 forFan Part Numbers
1–41
1. OVERVIEW
MARO2P10203703E
The purge control unit consists of an Intrinsically Safe Barrier Unit (ISBU)module, an IDEC model IBRC contact signal transducer (IBRC), purgecontrol PCB, and 24VDC power supply. There are no authorizedadjustments on the purge control unit. Refer to Figure 1–28 foridentification of components and Figure 1–2 for component locations.
WARNINGThe purge control timer is set at five minutes to conform toFactory Mutual Specifications. Do not adjust the purgecontrol timer; otherwise, an explosion or fire could occur.
Figure 1–28. Purge Control Unit
Power supplyIBRCISBU
Purge control PCB
CH1 CH2 CH3 CH4 CH5 CH6
A1 C1 A2 C2 A3 C3 A4 C4 A5 A6C5 C6 0V 220V200V
P1 N1 P2 N2 P3 P4N3 N4 P5 P6 N6N5 G G FG
1
1
2 3 4 5 6 7 8 9
2 3 4 5 6 7 8 9
1011 12 1314 1516 171819 20 21 222324
1011 12 13 14 15 16 1718 19 20 21 22 2324
1.16PURGE CONTROLUNITA05B–2363–C020
1–42
1. OVERVIEW
MARO2P10203703E
The IDEC model IBRC contact signal transducer is an intrinsically safeisolation unit that is used as part of the purge system. It has sixphoto-isolated relays and provides an intrinsically safe barrier for thefollowing signals. See Figure 1–29.
Channel 1 (P1-N1) Pressure switch from robot or pressure switchesfrom robot and opener in series.
Channel 2 (P2-N2) Flow switch from robot or flow switches fromrobot and opener in series.
Channel 3 (P3-N3) Robot overtravel switches, If used.Channel 4 (P4-N4) Hand broken signal, If used.Channel 5 (P5-N5) Teach pendant disconnected, If used.Channel (P6-N6) End of arm tooling input, Not used.
The IBRC operates on 220 (max. 250)VAC from a secondary winding ofTF1.
There are six red LEDs, one for each device used in the field. There are apair of terminals, labeled Px and Nx, for each hazardous signal, while thecorresponding safe side terminals have Ax and Cx. Ax and Cx are thenormally open contact output located on the safe side. When thehazardous location switches are closed, the IBRC LED will be illuminatedfor that particular contact. Should a jumper be installed across the P and Nterminals, the LED for those terminals will be illuminated.
When plant air is supplied to the robot, and power is available to the IBRCwhen the disconnect switch is in the ON position, the PS-1 LED will beilluminated.
1.17PURGE SYSTEMIBRC
A15L–0001–0048
1–43
1. OVERVIEW
MARO2P10203703E
Figure 1–29. Contact Signal Transducer (IBRC)
A1 C1 A2 C2 A3 C3 A4 C4
CH1
A5 C5
CH2 CH3 CH4 CH5 CH6
A6 C6 0V 200V 220V
P1 N1 P2 N2 P3 N3 P4 N4 P5 N5 P6 N6 G G FG
idec IZBARLRelay Barrier
Type IBRC6062RIntrinsically Sake Circuit
DC16V 14mA
Relay AC/DC 250VSafety Rating of Out Put
1–44
1. OVERVIEW
MARO2P10203703E
The Purge Unit Power Supply is a 24VDC auxiliary power supply usedexclusively for the purge system. It is mounted alongside the IBRC unit.It provides voltage necessary to energize the purge solenoid valve withinthe robot and opening devices when applicable. It also provides 24VDC tothe relay coils mounted on the piggy-back Purge Control PCB in the EMGmodule.
It requires 210VAC supplied by TF1 and is internally fused by two fusesmounted on the power supply PCB itself, F-11 and F-12. See Figure 1–30.
Figure 1–30. Purge Power Supply
Cover
F12F11
Purge Power Supply
Contact Signal Transducer IBRC
1.18PURGE UNIT POWERSUPPLYA20B–1000–0472
1–45
1. OVERVIEW
MARO2P10203703E
The P-200 R-J2 controller contains a number of Intrinsically SafetyBarriers (ISB) units and signal repeaters. They are used for the robot oropener purge circuits. The number of barriers and repeaters installed isdependant on the options ordered for that particular installation. ThePurge Intrinsically Safety Barriers and repeaters are mounted to the left ofthe IBRC unit. These devices limit the energy in their respective circuitsto eliminate the possibility of an explosion in the hazardous environmentof the paint booth. The internal atmosphere of the robot must beconsidered hazardous prior to operation, therefore a Purge IntrinsicallySafe Barrier or repeater device is used to safely control the purge process.
Purge Intrinsically Safe Barriers and repeaters are similar to a fuse. If oneshould be found defective, it must be replaced by a known good PurgeIntrinsically Safe Barrier or repeater, and you must discard the defectiveone. Refer to Table 1–11 for part number used for specific ISB functions.
For detailed illustrations of the Purge Intrinsically Safe Barriers and Signalrepeaters see Figure 1–31 through Figure 1–36. To troubleshoot faults youmight encounter with the Purge Intrinsically Safe Barriers and Signalrepeaters refer to Table 1–12.
The barriers ISB1 and ISB2 are used to energize the purge air solenoidvalves in the base of the robot or opener.
ISB3 and ISB10 are Intrinsically Safe repeater relays which are used toisolate the signals from the robot/opener bypass switches, used to detectthat powered down units are out of the way and it is safe for the conveyorto run.
ISB4, 5, 6, 7, and 8 are used to provide power and control to the variouscircuits which control paint flow.
ISB9 is use specifically for the P-10 and P-15 openers. ISB9 detects thestatus of the proximity switch in the openers arm. Refer to Table 1–11 foradditional information regarding intrinsically safety barriers and signalrepeaters.
Table 1–11. Purge Intrinsically Safety Barriers and Signal Repeaters
Part Number ISB# Terminals Figure Description
9001/01-252-100-14
1
InputTerminals 1 and 2
24VOutput
Terminals 3 and 4 topurge solenoid
Figure 1–31Refer to
Figure 12–13Figure 12–21Figure 12–22Figure 12–23
P-200 Purge Solenoid
For P-200+2 versionsthis barrier is Stahl9001/01-280-165-10For openers thebarrier is Stahl9001/01-252-100-14
2
InputTerminals 1 and 2
24VOutput
Terminals 3 and 4 toopener purge
solenoid
Figure 1–31Refer to
Figure 12–13Figure 12–21Figure 12–22Figure 12–23
Opener Purge SolenoidFor P-200-+2 versions ISB2 use
Stahl 9001-01/-280-165-10For P-200-+3 (P10) ISB2 use Stahl
Table 1–11. (Cont’d) Purge Intrinsically Safety Barriers and Signal Repeaters
Part Number DescriptionFigureTerminalsISB#
KHD2-SR-Ex1.PKFD2-SR2-Ex1.W
SWITCH POSITIONSS1 = IS2 = IIS3 = I
9
InputTerminals 1+,3≈DC8V/≈8mA
Output Terminals Notintrinsically safe
7,8,9Terminals
14(L+).-.15(L-)DC 20V 30V
Figure 1–36Refer to
Figure 12–13Figure 12–23
Single ChannelDC 24 V Nominal Power SupplySelectable Mode of Operation1 Signal Output with 1 Form “C”
RelayLead Breakage (LB) Monitoring
KHD2-SR-Ex1.PKFD2-SR2-Ex1.W
SWITCH POSITIONSS1 = IS2 = IS3 = II
10
InputTerminals 1+,3≈DC8V/≈8mA
Output Terminals Notintrinsically safe
7,8,9Terminals
14(L+).-.15(L-)DC 20V 30V
Figure 1–36Refer to
Figure 12–13
From P-10 Bypass SwitchSingle ChannelDC 24 V Nominal Power SupplySelectable Mode of Operation1 Signal Output with 1 Form “C”
RelayLead Breakage (LB) Monitoring
WARNINGWhen you replace this Purge Intrinsically Safe Barrierdevice, pay careful attention to the exact model or partnumber. Many models appear physically identical, buthave different power ratings and entity ratings.Also, careful observance of which end of the device isconsidered to be the “SAFE” side, or the “HAZARDOUS”side is critical. Typically the end with the “Blue” coloredcap should be connected to the device located in theHAZARDOUS zone for STAHL barriers. Otherwise, youcould injure personnel or damage equipment.
1 Stahl Symptom: Incomplete purge cycle.See Figure 1–31 and Refer to Table 1–11 for additional information.
1. Check for 24 VDC on terminals 1 and 2 during controller purge cycle. If24VDC is not present troubleshoot controller. If 24VDC is present go toStep 2.
2. Check for 18 VDC on terminals 3 and 4 during controller purge cycle. If18V is not present barrier is defective. If 18V is present troubleshoot flowswitch or robot.
2 Stahl Symptom: Incomplete purge cycle.See Figure 1–31 and Refer to Table 1–11 for additional information.
1. Check for 24 VDC on terminals 1 and 2 during controller purge cycle. If24VDC is not present troubleshoot controller. If 24VDC is present go toStep 2.
2. Check for 18 VDC on terminals 3 and 4 during controller purge cycle. If18V is not present barrier is defective. If 18V is present troubleshoot theopener.
1–52
1. OVERVIEW
MARO2P10203703E
Table 1–12. (Cont’d) Troubleshooting
ISB TroubleshootingManufacturer
3 Pepperl+Fuchs Symptom:No bypass signal in “parked” position.Robot and or opener are safely parked out of the path of the conveyer.Provides signal to conveyer system.Bypass circuitsSee Figure 1–32 or Figure 1–36 and Refer to Table 1–11 for additionaltroubleshooting information.Yellow LED OFF : Problem in the hazard area (ex. proximity switch wires) go
to Step 7.Green LED power indicator
1. Check for green power ON LED. If LED is not ON go to Step 2. If LED isON go to Step 7.
2. Check input 120VAC to Deltron 24V power supply. If voltage is present goto Step 3. If voltage is not present troubleshoot 120 VAC from theconveyer.
3. Check output 24V from Deltron to OVP (EE-3112-600). If 24 VDC ispresent go to Step 4. If 24VDC is not present replace the power supply.
4. Check input 24V to OVP. If 24VDC is present go to Step 5. If 24VDC is notpresent replace wiring between the power supply and the OVP.
5. Check the output voltage from the OVP. If 24 VDC is present go to Step 6.If 24VDC is not present replace the OVP.
6. Check for 24 VDC between terminals 14 and 15 on the ISB. If 24 VDC ispresent the ISB is defective . If 24VDC is not present replace the wiringbetween the OVP and the ISB.
7. Check for signal on terminals 1 and 3 .If signal is present barrier isdefective. If signal is not present robot proximity switch may be out ofadjustment or defective.
4 Pepperl+Fuchs Symptom:Problem controlling atomizing pressure.Supplies power to the current to pressure solenoid.See Figure 1–33 and Refer to Table 1–11 for additional troubleshootinginformation.
1. Check for 24VDC input signal on terminals 7 and 8. If 24V is not presenttroubleshoot the P-200 I/O. If 24VDC is present go to Step 2.
2. Check for 18VDC output signal on terminals 1 and 2. If 18V is not presentthe barrier is defective . If the 18 VDC output signal is present troubleshoot the current to pressure solenoid
5 Pepperl+Fuchs Symptom:Problem controlling atomizing pressure.Relays signal to the current to pressure transducer.See Figure 1–34 and Refer to Table 1–11 for additional troubleshootinginformation.
1. Check for 24VDC input signal on terminals 9 and 10. If 24VDC is notpresent troubleshoot the P-200 I/O. If 24VDC is present go to Step 3.
2. Check for 24VDC output signal on terminals 7 and 8. If 24V is not present check connection to purge control printed circuit board(A16B-1310-0601). If 24VDC is present go to Step 3.
3. Check for 18VDC output signal on terminals 1 and 2. If 18V is not presentdefective barrier. If 18 VDC signal is present transducer is defective.
1–53
1. OVERVIEW
MARO2P10203703E
Table 1–12. (Cont’d) Troubleshooting
ISB TroubleshootingManufacturer
6 Pepperl+Fuchs Symptom:No flowmeter data, accuflow errors.See Figure 1–35 and Refer to Table 1–11 for additional troubleshootinginformation.
1. Check for 24VDC input signal on terminals 7 and 8. If 24VDC is notpresent troubleshoot controller. If 24VDC is present go to Step 2.
2. Check for 24VDC output signal on terminals 1 and 2. If 24VDC is notpresent the barrier is defective. If 24VDC is present go to Step 3.
3. Check for input signal on terminals 2 and 4. If input signal from the P-200flow meter is not present troubleshoot the flow meter. If the input signal ispresent go to Step 4.
4. Check for output signal on terminals 7 and 8. If the signal is not presentthe barrier is defective. If the signal is present troubleshoot the P-200 I/O.
7 Pepperl+Fuchs Symptom:Paint gun will not trigger.Paint process trigger one signal.See Figure 1–35 and Refer to Table 1–11 for additional troubleshootinginformation.
1. Check for 24VDC input signal on terminals 7 and 8. If 24V is not presenttroubleshoot the P-200 I/O. If the 24VDC is present go to Step 2.
2. Check for output signal on terminals 1 and 2. If the output signal is notpresent defective barrier. If the output signal is present trouble shoot thenumber one trigger.
8 Pepperl+Fuchs Symptom:Paint gun #2 will not trigger.Paint process trigger two signal.See Figure 1–35 and Refer to Table 1–11 for additional troubleshootinginformation.
1. Check for 24VDC input signal on terminals 7 and 8. If 24V is not presenttroubleshoot the P-200 I/O. If the 24VDC is present go to Step 2.
2. Check for output signal on terminals 1 and 2. If the output signal is notpresent defective barrier. If the output signal is present trouble shoot thenumber two trigger.
1–54
1. OVERVIEW
MARO2P10203703E
Table 1–12. (Cont’d) Troubleshooting
ISB TroubleshootingManufacturer
9 Pepperl+Fuchs Symptom: Opener “acquire” signal inoperative.See Figure 1–36 and Refer to Table 1–11 for additional information.Yellow LED magnet on opener acquired the door or hood.Red LED lead breakage indicatorGreen LED power is ON.
1. Check for green power ON LED. If LED is not ON go to Step 2. If LED isON go to Step 3.
2. Check for 24VDC input between terminals 8 and 15, 11 and 15, 14 and 15.If 24VDC is not present at any one of the tested terminals troubleshoot thecontroller. If 24VDC is present go to Step 3.
3. Check for signal on terminals 1 and 3 .If signal is present barrier isdefective. If signal is not present opener lead break switch may be out ofadjustment or defective.
10 Pepperl+Fuchs Symptom: No opener “bypass” signal in parked position.Robot and or opener are safely parked out of the path of the conveyor.Provides signal to conveyor system.Bypass circuitsSee Figure 1–36 and Refer to Table 1–11 for additional troubleshootinginformation.Yellow LED OFF : Problem in the hazard area (ex. proximity switch wires) go
to Step 7.Green LED power indicator
1. Check for green power ON LED. If LED is not ON go to Step 2. If LED isON go to Step 7.
2. Check input 120VAC to Deltron 24V power supply. If voltage is present goto Step 3. If voltage is not present troubleshoot 120 VAC from theconveyer.
3. Check output 24V from Deltron to OVP (EE-3112-600). If 24 VDC ispresent go to Step 4. If 24VDC is not present replace the power supply.
4. Check input 24V to OVP. If 24VDC is present go to Step 5. If 24VDC is notpresent replace wiring between the power supply and the OVP.
5. Check the output voltage from the OVP. If 24 VDC is present go to Step 6.If 24VDC is not present replace the OVP.
6. Check for 24 VDC between terminals 14 and 15 on the ISB. If 24 VDC ispresent the ISB is defective . If 24VDC is not present replace the wiringbetween the OVP and the ISB.
7. Check for signal on terminals 1 and 3 .If signal is present barrier isdefective. If signal is not present opener proximity switch might be out ofadjustment or defective.
1–55
1. OVERVIEW
The brake release option adds (4) optional brake switches to selectivelyrelease the gravity and non-gravity axes of the P-200 robot. Refer toProcedure 6–1 . For circuit schematics and cable diagrams refer toChapter 14 Openers and Options.
WARNINGReleasing the brakes could cause the robot to move.Provide support for the arm of the robot before releasingthe brakes; otherwise, you could injure personnel ordamage equipment.
Figure 1–37. C Size R-J2 Controller With Optional Brake Release Switches
SYSTEM R–J2
AXESAXIS
2 3
OPENERALL
P-200AXES1,4,5,7
P-200AXIS
P-200
P-200 BRAKE SELECT SWITCHES
AXESAXIS
2 3
OPENERALL
P-200AXES1,4,5,7
P-200AXIS
P-200
P-200 BRAKE SELECT SWITCHES
1.20BRAKE RELEASE(OPTION)
1–56
1. OVERVIEW
MARO2P10203703E
The P-10 opener is a three axis, electrically-driven door opener and theP-15 opener is a three axis, electrically-driven hood and deck opener.Refer to Chapter 14, “Openers and Options,” for schematics and diagrams.
Figure 1–38. P-10 Door opener and P-15 Hood and Deck Opener
Axis 2
Axis 3
Outer Arm
Axis 1
Base
Link
Carriage
Rail
Inner Arm
Riser (P-15 only)
P-15 End of Arm Tool
P-10 End of Arm Tool
1.21P-10 DOOR OPENERP-15 HOOD AND DECKOPENER (OPTIONS)
1–57
1. OVERVIEW
MARO2P10203703E
The Integral Pump Control option is the FANUC Robotics integrated twocomponent fluid delivery system which features metering pumps directlycoupled to FANUC servomotors that are controlled by the FANUC R-J2controller.
This is a high performance fluid delivery system that accurately controlsvariable ratios and flow rates of two component materials. The P-200robot and the R-J2 controller provide control for the color changesequence, fluid metering and fluid flow control operations.
The paint process control enclosure provides the electro-pneumaticinterface between the R-J2 controller and the spray applicator. Theoperator interface is provided via the R-J2 teach pendant. See Figure 1–39.For circuit schematics and cable diagrams refer to Chapter 14 Openers andOptions.
Two different styles of the Integral Pump Control are available. The Tophat model which is mounted atop the outer arm and the Side Saddle modelwhich is mounted on the rail next to the robot. See Figure 1–40.
The integrated two component fluid delivery system offers the followingfeatures and benefits:
Enhanced trigger response time
Common fluid control and robot motion control architecture
Gear pump and servo motor integral to P-200 robot mechanical unit
Reduced color change time and paint waste compared to conventionalwall mounted two component systems
Accurate flow and ratio control through precise pump control
The integrated two component fluid delivery system consists of thefollowing major components:
Two mechanical coupled gear pump assemblies
Two FANUC servo controlled motors
One FANUC servo amplifier
Four pressure transducers
One mixing block assembly
One trigger assembly
One purged enclosure
One by-pass manifold
One Sames Moduflow valve stack assembly
1.22INTEGRAL PUMPCONTROL (OPTION)
1–58
1. OVERVIEW
MARO2P10203703E
Figure 1–39. Integral Pump Control Component Locator Diagram
OUT
IN
Axis 3
OUT#2
IN
OUT
OUT
IN
OUT
IN
IN
OUT
REG. 1BP 1
BP 2
REG. 2
0–100 P.S.I.
0–500 P.S.I.
0–500 P.S.I.
0–100 P.S.I.
#1IN
FAR SIDE
FAR SIDE
PR2
PR1
View From Front of Arm
Mix Tube
Motor and Gear Reducer Assy.
To Gun
Trigger Valve Ass’y
Mix Valves
By-Pass Block
Gear Pump #1
Gear Pump #2Pump Inlet Transducers
Pump Outlet TransducersInlet Regulators
Purge Enclosure
1–59
1. OVERVIEW
MARO2P10203703E
Figure 1–40. Top Hat and Side Saddle Mounted Models
Side Saddle Mounted
Top Hat Mounted
Page 2
2 DIAGNOSTIC SCREENS
2 DIAGNOSTIC SCREENS
2–1MARO2P10203703E
Topics In This Chapter Page
Safety Signals The safety signal screen displays the status of safety-related control signals coming into the controller. 2–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Version ID Status The STATUS Version ID screen displays information specific to your controller. 2–5
Memory Status The STATUS Memory screen displays information about controller memory. 2–8. . .
Position Status The POSITION screen displays positional information in joint angles or Cartesian coordinates. 2–10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Axis Status The axis status screen displays information for each axis. 2–12. . . . . . . . . . . . . . . . . .
Alarm Log The Alarm Log displays a list of the 100 most recent alarms. 2–16. . . . . . . . . . . . . . . .
I/O Status You can view the status of an I/O signal by displaying a status screen. 2–18. . . . . . . .
Various built-in diagnostic screens reveal important information regardingthe status of the controller. This section describes each of these screens indetail. The diagnostic screen section provides coverage of the P-200.Figure 2–1 displays the teach pendant that displays the Status Screens.
2–2
2. DIAGNOSTIC SCREENS
MARO2P10203703E
Figure 2–1. Teach Pendant
OFF ON
POSN
MANFCTNS
MOVEMENU
QUEUE
APPLINST
STATUSALARMS
FAULT
HOLDSTEPBUSY
RUNNING
MAN ENBL
TOOL
XYZ
JOINT
PROD MODE
2–3
2. DIAGNOSTIC SCREENS
MARO2P10203703E
The safety signal screen displays the status of safety-related control signalscoming into the controller.
The safety signal screen displays the current state (TRUE or FALSE) ofeach safety signal. You cannot change the condition of the safety signalusing this screen. Table 2–1 lists and describes each safety signal. UseProcedure 2–1 to display safety signal status.
Table 2–1. Safety Signals
SAFETYSIGNAL DESCRIPTION
SOP E-Stop Indicates whether the EMERGENCY STOP button on the operator panel has been pressed. Thestatus is TRUE if the operator panel EMERGENCY STOP button has been pressed.
TP E-Stop Indicates whether the EMERGENCY STOP button on the teach pendant has been pressed. Thestatus is TRUE if the teach pendant EMERGENCY STOP button has been pressed.
Ext E-Stop Indicates whether an external emergency exists. The status is TRUE if the external emergency stopcontacts are open on the emergency control (EMG) printed circuit board and the following conditionsexist:SOP E-STOP is FALSETP E-Stop is FALSEHand Broken is FALSEOvertrave l is FALSE
If any one of these conditions is TRUE, Ext E-Stop is displayed as FALSE even though thesecontacts could be open.
Fence Open Indicates whether the safety fence switch is open. The status is TRUE if the safety fence contactsare open on the emergency control (EMG) printed circuit board.
TP Deadman Indicates when either the left or right teach pendant DEADMAN switch is pressed. The status isTRUE if either DEADMAN switch is pressed. When released with teach pendant enabled, thisalarm shuts off servo power.
TP Enable Indicates whether the teach pendant ON/OFF switch is ON. The status is TRUE when the teachpendant ON/OFF switch is ON.
Hand Broken Indicates whether the safety joint switch in the robot hand has been tripped and the hand might bedamaged. The status is TRUE when the safety joint switch has been tripped. This turns off the handbroken signal (*HBK) to the axis control printed circuit board. This alarm shuts off servo power.
Overtravel Indicates whether the robot has moved beyond its overtravel limits. The status is TRUE when therobot has moved beyond its overtravel limits tripping the overtravel switch. This turns off (*ROT) tothe axis control printed circuit board. This alarm shuts off servo power.
Low Air Alarm Indicates whether the air pressure has decreased below the acceptable limit. Low Air Alarm isusually connected to an air pressure sensing device. The status is TRUE when the air pressure isbelow the acceptable limit. This opens the pressure switch which turns off (*PPABN) to the axiscontrol printed circuit board. You must set the $PPABN_ENBL system variable to TRUE to use thissignal. This alarm shuts off servo power.
2.1 SAFETY SIGNALSTATUS
2–4
2. DIAGNOSTIC SCREENS
MARO2P10203703E
Procedure 2–1 Displaying Safety Signal Status
1 Press MENUS.
2 Select STATUS.
3 Press F1, [TYPE].
4 Select Safety Signal. You will see a screen similar to the following.
SIGNAL NAME STATUS 1/10 1 SOP E–Stop: TRUE 2 TP E–Stop: FALSE 3 Ext E–Stop: FALSE 4 Fence Open: FALSE 5 TP Deadman: FALSE 6 TP Enable: FALSE 7 Hand Broken: FALSE 8 Overtravel: FALSE 9 Low Air Alarm FALSE
[ TYPE ]
STATUS Safety JOINT 10 %
SOP E–Stop
Step
2–5
2. DIAGNOSTIC SCREENS
MARO2P10203703E
The STATUS Version ID screen displays information specific to yourcontroller. Use this information when you call the FANUC RoboticsHotline if a problem occurs with your controller. You cannot change theinformation displayed on this screen. Table 2–2 lists and describes theversion identification status information.
Table 2–2. Version Identification Status Items
ITEM DESCRIPTION
SOFTWARE Lists the software item loaded.
ID Lists the version number of the software item loaded.
Use Procedure 2–2 to display version identification status.
Procedure 2–2 Displaying the Version Identification Status
1 Press STATUS.
2 Press F1, [TYPE].
3 Select Version ID. You will see a screen similar to the following.
The STATUS Memory screen displays information about controllermemory. Table 2–3 lists and describes each memory status item.
Use Procedure 2–3 to display memory status.
Table 2–3. Memory Status
MEMORY STATUS DESCRIPTION
Pools Indicates the amount of memory forTPP contains teach pendant programsPERM contains system variables and some KAREL variablesSYSTEM contains the operating systemIMAGE contains KAREL programs and optionsTEMP contains temporary memory used for system operations
Hardware Indicates the total amount of memory forFROM Flash ROMDRAM D-RAMCMOS CMOS RAM
Procedure 2–3 Displaying Memory Status
1 Press STATUS.
2 Press F1, [TYPE].
3 Select Memory. You will see a screen similar to the following.
The POSITION screen displays positional information in joint angles orCartesian coordinates. The positional information on this screen isupdated continuously when the robot moves. You cannot change thedisplayed information using this screen.
NOTE E1, E2, and E3 indicate extended axis positional information ifextended axes are installed in your system.
The joint screen displays positional information in degrees for each robotaxis. Tool indicates the number of the active tool frame.
The user screen displays positional information in Cartesian coordinatesbased on the user frame. Tool indicates the number of the active toolframe. Frame indicates the number of the active user frame.
The world screen displays positional information in Cartesian coordinatesbased on the world frame. Tool indicates the number of the active toolframe.
Use Procedure 2–4 to display position status.
Procedure 2–4 Displaying Position Status
1 Press POSN.
2 Select the appropriate coordinate system.
For joint , press F2, JNT. You will see a screen similar to thefollowing.
The axis status screen displays information for each axis. Thisinformation is continually updated. Use this information when you callthe FANUC Robotics Hotline if a problem occurs with your robot.
This screen displays:
Status 1Status 2PulseMonitorTrackingDisturbance Torque
The Axis Status Pulse screen displays information about axis motion.Table 2–4 lists and describes each kind of information displayed on thisscreen.
Use Procedure 2–5 to display the axis status pulse screen.
Table 2–4. Axis Status Pulse Screen Items
ITEM DESCRIPTION
MotionCommand
Displays the desired value of the Serial Pulse Coder (SPC) when the robot gets to the positioncommanded by the controller.
Machine Pulse Shows the actual SPC count as read by the controller.
Position Error Displays the difference between the commanded SPC count versus the actual SPC count.
You cannot change any information on this screen except for the groupnumber. Group number only applies if you have multiple groups;otherwise, it remains as 1.
2.5AXIS STATUS
2–13
2. DIAGNOSTIC SCREENS
MARO2P10203703E
Procedure 2–5 Displaying the Axis Status Pulse Screen
The Alarm Log displays a list of the 100 most recent alarms. Figure 2–2shows an example of the Alarm Log.
Figure 2–2. Alarm Log
1/1001 SRVO–049 OHAL 1 alarm (Group:1 Axis:6)2 SRVO–042 MCAL 1 Alarm (Group:1 Axis:6)3 R E S E T
[ TYPE ] CLEAR HELP
Alarm JOINT 10%
SRVO–049 OHAL 1 alarm (Group=1 Axis=6)PROGRAM LINE 4
14
2
3
1
The areas of the Alarm Log are as follows:
1. This is the most recent alarm message. This message will bedisplayed in this line regardless of the screen you choose.
2. Indicates the program name and line number of program last havingbeen acted upon.
3. Lists all of the alarm messages, up to 100, with the most recent alarmon the top of the list. When the RESET key is pressed, a RESET islogged on the alarm message screen.
4. Indicates the line number the cursor is on in proportion to how manylines numbers available.
Use Procedure 2–6 to display the Alarm Log.
2.6ALARM LOG
2–17
2. DIAGNOSTIC SCREENS
MARO2P10203703E
Procedure 2–6 Displaying the Alarm Log
An error has occurred.
1 Press ALARMS.
2 Press F1, [TYPE].
3 Select Alarm Log. The alarm log will be displayed. This lists allerrors. See the following screen for an example.
1/1001 SRVO–002 Teach pendant emergency sto2 SRVO–001 Operator panel emergency st3 R E S E T4 SRVO–029 Robot calibrated (Group:1)5 SRVO–001 Operator panel emergency st6 SRVO–012 Power fail recovery7 INTP–127 Power fail detected8 SRVO–047 LVAL alarm (Group:1 Axis:5)9 SRVO–047 LVAL alarm (Group:1 Axis:4)
10 SRVO–002 Teach pendant emergency sto
[ TYPE ] CLEAR HELP
Alarm WORLD 100 %
SRVO–002 Teach pendant emergency stopTEST1 LINE 15 ABORTED
1
The most recent error is number 1.To display the complete message for a message that does not fit on thescreen, press and hold the SHIFT key and press the right arrow key.
4 To display the motion log, which lists only motion-related errors,press F1, [TYPE], and select Motion Log.
5 To display the system log, which displays only system errors, pressF1, [TYPE], and select System Log.
6 To display the application log, which displays onlyapplication-specific errors, press F1, [TYPE], and select Appl Log.
7 To display more information about an error, move the cursor to theerror and press F5, HELP. The error help screen displays informationspecific to the error you selected. When you are finished viewing theinformation, press PREV.
8 To remove all of the error messages displayed on the screen, pressF4, CLEAR.
Condition
Step
2–18
2. DIAGNOSTIC SCREENS
MARO2P10203703E
You can view the status of an I/O signal by displaying a status screen. UseProcedure 2–7 to display I/O status.
Procedure 2–7 Displaying I/O Status
1 Press MENUS.
2 Select I/O.
3 Press F1, [TYPE].
4 Select the kind of I/O for which you want to display status: spotwelding, digital, analog, group, robot, UOP, or SOP.
For digital outputs for example, you will see a screen similar to thefollowing.
# SIM STATUSDO[ 1] U OFF [ ]DO[ 2] U ON [ ]DO[ 3] U OFF [ ]DO[ 4] U OFF [ ]DO[ 5] U OFF [ ]DO[ 6] U ON [ ]DO[ 7] U OFF [ ]DO[ 8] U OFF [ ]DO[ 9] U OFF [ ]DO[ 10] U OFF [ ]
[ TYPE ] CONFIG IN/OUT SIMULATE UNSIM
I/O Digital Out WORLD 10%
U
5 To change the display between inputs and outputs, press F3,IN/OUT.
6 To view the I/O configuration of the signal, press F2, CONFIG.
2.7I/O STATUS
Step
Inde
x
3 LIGHTS, INDICATORS,AND LEDS
3 LIGHTS, INDICATORS, AND LEDS
3–1MARO2P10203703E
Topics In This Chapter Page
Teach PendantDiagnostic Indicators
The teach pendant has several indicators to assist you in determining controller status. 3–2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operator Panel andCabinet Lights
The operator panel has several LEDs to assist you in determining the status of the controller. 3–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Servo On Lights The controller cabinet has a single Servo On light on the right-hand side of the cabinet. 3–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
This chapter describes the lights, indicators and LEDs you can use fordiagnostics.
3–2
3. LIGHTS, INDICATORS, AND LEDS
MARO2P10203703E
The teach pendant has several indicators to assist you in determiningcontroller status. Figure 3–1 shows the teach pendant indicators andTable 3–1 lists and describes the teach pendant indicators. The indicatorswhose labels are blank vary depending on the application.
Refer to the Systems PaintTool Setup and Operations Manual forinformation on indicators.
Figure 3–1. Teach Pendant Indicators
ÎÎÎÎ
FAULT
ÎÎÎÎ
HOLD
ÎÎSTEP
ÎÎBUSY
ÎÎÎÎ
RUNNING
ÎÎÎÎÎÎÎÎÎÎ
JOINT
ÎÎXYZTOOL
OFF ON
Indicators
MAN ENBLMODEPROD
Table 3–1. Teach Pendant Status Indicators
INDICATOR DESCRIPTION
FAULT Indicates that a fault condition has occurred.
HOLD Indicates that the robot is in a hold condition. HOLD is not on continuously during a hold condition.
STEP Indicates that the robot is in step mode.
BUSY Indicates that the controller is processing information.
RUNNING Indicates that a program is being executed.
MAN ENBL Indicates that the robot is in MANUAL MODE.
PROD MODE Indicates that the robot is in PRODUCTION MODE.
JOINT Indicates that the current jog coordinate system is JOINT.
XYZ Indicates that the current jog coordinate system is CARTESIAN (JOG FRAME OR WORLD).
TOOL Indicates that the current jog coordinate system is TOOL.
3.1TEACH PENDANTDIAGNOSTICINDICATORS
3–3
3. LIGHTS, INDICATORS, AND LEDS
MARO2P10203703E
The operator panel has several LEDs to assist you in determining thestatus of the controller. Figure 3–2 shows the operator panel LEDs for theP-200 robot. Table 3–2 describes the indicator functions.
Figure 3–2. Operator Panel LEDS
ÎÎÎÎ
ÎÎÎÎ ÎÎ
ÎÎÎÎÎÎ
ÎÎÎÎÎÎÎÎ
ÎÎÎÎÎÎÎÎ
ÎÎÎÎÎÎÎÎ
BATTERY
ALARM CYCLE STARTON
OFF
REMOTE
REMOTE
LOCAL
PURGECOMPLETE
PURGE ENABLE
PURGEFAULT
EMERGENCY STOP
TEACH PENDANT
ENABLED
FAULT RESET
FAULT
ÏÏÏÏ
ÏÏÏÏ
ON
OFFPORT
BRAKE ENABLE
HOUR METER
H
H
h
m
h
h
HOUR METER
HOLD
Table 3–2. Standard Operator Panel Status Indicators
INDICATOR DESCRIPTION
BATTERY ALARM Indicates that the backup battery voltage is low. Replace the battery.Refer to Procedure 9–1 .
TEACH PENDANT ENABLED Indicates that the teach pendant is enabled and has motion control.
FAULT Indicates a fault condition has occurred.
REMOTE Indicates that robot motion can only be started by a remote device (PLC or otherremote device). The operator panel cycle start pushbutton cannot cause robotmotion. This is determined by the position of the REMOTE/LOCAL keyswitch.
PURGE COMPLETE Identifies that the robot cavities for the P-200 motor cavity containment cases havebeen purged and are presently at the prescribed pressure as outlined in the FANUCRobotics SYSTEM R-J2 Controller P-200 and In Booth Rail Mechanical Unit Parts andService Manuals .
This LED must be illuminated in order to turn power on to the R-J2 controller.
PURGE FAULT Indicates a fault exists with the purge system.
PURGE ENABLE PUSHBUTTON Indicates that the purge cycle has started. You can now release the pushbutton if youare holding it.
POWER ON PUSHBUTTON LED Indicates that the robot is powered on.
CYCLE START PUSHBUTTON LED Indicates that the robot is currently running a program
HOLD Indicates that the robot is in a software hold condition.
3.2OPERATOR PANELAND CABINET LIGHTS
3–4
3. LIGHTS, INDICATORS, AND LEDS
MARO2P10203703E
The controller cabinet has a single Servo On light on the right-hand side ofthe cabinet. See Figure 3–3 for light location. Refer to Table 3–3 for adescription of the Servo On light.
Figure 3–3. Servo Amp Light
ÎÎÎÎÎÎÎÎÎÎÎ
ÎÎÎÎÎÎÎÎÎÎÎ
ÎÎÎÎÎÎÎÎÎÎÎÎ
ÎÎÎÎÎÎ
ÎÎ
ÎÎÎÎÎÎÎÎÎÎÎÎ
ÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎ
ÎÎÎÎÎÎÎÎÎÎ
ÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎ
SERVO ON Light
Table 3–3. Servo Amp On Description
INDICATOR DESCRIPTION
SERVO ON Indicates that power is available to the servo amplifiers.
3.3SERVO ON LIGHT
3–5
3. LIGHTS, INDICATORS, AND LEDS
MARO2P10203703E
The R-J2 controller contains several diagnostic LEDs within the controller.They are on the circuit boards that plug into the backplane, on the servoamplifiers, and on the Modular I/O (Model A) and Distributed I/O(Model B) units as well as the Intrinsic Barrier Relay Control (IBRC)Purge Control Unit. Figure 3–4 shows an overview of the circuit boarddiagnostic LEDs. Refer to the following sections for descriptions of eachcircuit board diagnostic LED:
Power supply unit (PSU)Main CPU boardSub CPU boardModular I/O (Model A)Servo amplifierEmergency Stop Control Printed Circuit BoardModule Assembly #EE-3044-401Contact Signal Transducer (IBRC)ABRIO PCB (optional)
3.4CIRCUIT BOARDDIAGNOSTIC LEDS
3–6
3. LIGHTS, INDICATORS, AND LEDS
MARO2P10203703E
Figure 3–4. Diagnostic LEDs
Main CPU
Main CPU LEDsSection 3.4.2
PSU LEDsSection 3.4.1
Servo Amplifier
SERVO AMPLIFIERLEDSection 3.4.4
PSU
12345671234567
AB
InterfaceModule
I/O Module
MODEL A
INTERFACEMODULESection3.4.3
I/O MODULESection 3.4.3
EMG StopControl PCBSection 3.4.5
CH1 CH2 CH3 CH4 CH5 CH6
IBRC
IBRC Section3.4.6
3–7
3. LIGHTS, INDICATORS, AND LEDS
MARO2P10203703E
Figure 3–5 shows each power supply unit (PSU) diagnostic LED.
Figure 3–5. Power Supply Unit (PSU) Diagnostic LEDs
PIL LED
ALM LED
The PIL LED lights if 210 VAC nominal isbeing supplied to the PSU from the Transformer(circuit breaker is on), if Fuse F1 is notblown, if 24VDC Aux is supplied, and thepower supply internal circuitry is in goodcondition.
The ALM LED will light if one of thefollowing conditions exist:– Bad DC Power Supply– Alarm received from the remotedevice– Fuse F3 on the Power Supply unitis blown
3.4.1 Power Supply Unit(PSU) Diagnostic LEDs
3–8
3. LIGHTS, INDICATORS, AND LEDS
MARO2P10203703E
The Main CPU printed circuit board alarm LEDs are shown in Figure 3–6.Table 3–4 provides information for troubleshooting problems.
Figure 3–6. Main CPU Board Diagnostic LEDs
3.4.2 Main CPU BoardDiagnostic LEDs
3–9
3. LIGHTS, INDICATORS, AND LEDS
MARO2P10203703E
Table 3–4. Troubleshooting Main CPU Board Diagnostic LEDs
LEDs Remarks Procedure
1 2 3 4STATUSALARM
Parity alarm onRAM in the MainCPU.
1. Restart the controller.
2. Reload Software.
3. Replace the Main CPU.
1 2 3 4STATUSALARM
The battery voltagethat backs up theMain CPU CMOSRAM memory islow.
1. Get a replacement battery.
2. Turn off controller power and lock out the controller.
3. Replace the battery.
The controller will retain memory for at least a half hour between the timethe controller is turned off and the new battery is installed.
WARNING: Lethal voltage is present in the controller WHENEVER ITIS CONNECTED to a power source. Be extremely careful to avoidelectrical shock.
1 2 3 4STATUSALARM
Non-maskableinterrupt occurred inthe ABC chip on theMain CPU Board.
1. Restart the controller.
2. Reload software.
3. Replace the Main CPU.
1 2 3 4STATUSALARM
Servo alarmoccurred on theMain CPU Board.
1. Restart the controller.
2. Reload software.
3. Replace the Main CPU.
1 2 3 4STATUSALARM
Non-maskableinterrupt occurred inthe SLC2 chip onthe Main CPUBoard
1. Restart the controller.
2. Reload software.
3. Replace the Main CPU.
1 2 3 4STATUSALARM
SYS FAIL Signaloccurred
1. Restart the controller.
2. Reload software.
3. Replace the Main CPU.
1 2 3 4STATUSALARM
Normal Status Controller should be operational.
= OFF = ON
NOTE To save time during board replacement, preload software on aspare main CPU board first. Refer to the appropriate software installationmanual specific to your software for software loading information.
CAUTIONTo prevent software loss in the CMOS RAM module of theremoved board, be sure a battery backup is attached to themain CPU before the board is removed from the controller.
3–10
3. LIGHTS, INDICATORS, AND LEDS
MARO2P10203703E
The Sub CPU printed circuit board alarm LEDs are shown in Figure 3–7.Table 3–5 provides information for troubleshooting problems.
Figure 3–7. Sub CPU Board Diagnostic LEDs
LV ALM
F21 5A
RISC-B
STATUSALARM
5.0A
3.4.3 Sub CPU BoardDiagnostic LEDs
3–11
3. LIGHTS, INDICATORS, AND LEDS
MARO2P10203703E
Table 3–5. Troubleshooting Sub CPU Board STATUS LEDs (Green)
LEDs DESCRIPTION
1 2 3 4STATUSALARM
Power-off
1 2 3 4STATUSALARM
Power on
1 2 3 4STATUSALARM
SUBCPU start up
1 2 3 4STATUSALARM
DRAM test OK
1 2 3 4STATUSALARM
Software loading complete. Operating system start.
Software internal checking. ((INIT task initialization process complete)
= OFF = ON
Table 3–6. Troubleshooting Sub CPU Board ALARM LEDs (Red)
LEDs Procedure
1 2 3 4STATUSALARM
The Sub-CPU is not started.
1 2 3 4STATUSALARM
A parity alarm occured in the SRAM.
1 2 3 4STATUSALARM
A parity alarm occured in the DRAM on the Sub-CPU board
= OFF = ON
Table 3–7. Troubleshooting Sub CPU Board ALARM LEDs (Red)
LEDs Procedure
LV ALM (Red)
The output voltage of the 3.3V power supply exceeded the specified range.
= ON
NOTE To save time during board replacement, preload software on aspare sub CPU board first. Refer to the appropriate software installationmanual specific to your software for software loading information.
3–13
3. LIGHTS, INDICATORS, AND LEDS
MARO2P10203703E
The LEDs associated with module I/O are on the interface module printedcircuit board and on each I/O module. Figure 3–8 shows the modular I/OLEDs. Table 3–8 describes the I/O LEDs.
Figure 3–8. Modular I/O LEDs
1 2 3 4 5 6 7
1 2 3 4 5 6 7
A
B
JD1B JD1A
CP32 JD2
PWR LINK
BAO
BAI
AIF0IA
LEDS
LEDS
INTERFACE MODULE I/O MODULE
0
0
Table 3–8. Modular I/O LEDs
LED Location Description
PWR Interfacemodule
ON: The interface module is supplied with24 VDC power.
Link Interfacemodule
ON: The I/O Link is operating properly.Normally, this LED lights several secondsafter the power is turned on.
BA1 Interfacemodule
These LEDs indicate that a fault hasoccurred in the modular I/O system.
BA0 Interfacemodule
A 0 1 2 3 4 5 6 7 B 0 1 2 3 4 5 6 7
I/O Module Indicates if the input or output is on.
3.4.4 Modular (Model A) I/OLEDs
3–14
3. LIGHTS, INDICATORS, AND LEDS
MARO2P10203703E
Figure 3–9 shows the servo amplifier seven-segment LED and Table 3–9shows and describes the LED displays.
This alarm occurs if:–The short-time regenerative discharge energy is too high–The regenerative discharge circuit is abnormal.
Over-regenerativedischarge alarm (DCOH)
This alarm occurs if:–The average regenerative discharge energy is too high (too frequentacceleration/deceleration).–The transformer overheats.
Dynamic brake circuitfailure alarm (DBRLY)
This alarm occurs if the relay contacts of the dynamic brake welds together.
L-axis over-currentalarm (HCL)
This alarm occurs if an abnormally high current flows in the L-axis motor.
M-axis over-currentalarm (HCM)
This alarm occurs if an abnormally high current flows in the M-axis motor.
L- and M- axis overcurrent alarm (HCLM)
This alarm occurs if an abnormally high current flows in the L- and M axis-motors
L-Axis IPM alarm (IPML) This alarm is detected by the IPM (intelligent power module) of the L-axis.*
M-Axis IPM alarm(IPMM)
This alarm is detected by the IPM (intelligent power module) of the M-axis.*
L- and M- axis IPM alarm(IPMLM)
The MCC contactor in the servo amplifier is turned on. The amplifier is armed andcan drive the motor.
Circuit breakerTrips
The circuit breaker trips if an abnormally high current (exceeding the working currentof the circuit breaker) flows through it. **
Amplifier not ready Indicates that the servo amplifier is not ready to drive the motor.
Amplifier ready Indicates that the servo amplifier is ready to drive the motor
*NOTE The IPM can detect the following alarms.
Over-currentOver-heatDrop in IPM control power voltage
** NOTE When the control power is separated from the main power, if the circuit breaker for the servoamplifier is off, low DC link voltage alarm (LVDC) is detected.
3–16
3. LIGHTS, INDICATORS, AND LEDS
MARO2P10203703E
The LEDs associated with the Emergency Stop Control Printed CircuitBoards are shown in Figure 3–10 and described in Table 3–10.
Figure 3–10. Emergency Stop Control Printed Circuit Board
Brake fuse blown alarm LED
1 4
2 3
3.4.6 Emergency StopControl Printed CircuitBoard
3–17
3. LIGHTS, INDICATORS, AND LEDS
MARO2P10203703E
Table 3–10. Emergency Stop Control Printed Circuit Board LEDFunctions
LED Function
BRAKE FUSE ALARM Brake fuse blown.
1 LED SVON
2 LED Q1 and Q2 ON (Brakes 1, 2, and 3)
3 LED Q4 ON (Brake 4)
4 LED Q3 ON (Brakes 6 and 7)
3–18
3. LIGHTS, INDICATORS, AND LEDS
MARO2P10203703E
The Module Assembly # EE–3044–401 is located in the robot purgecavity. Before you enter to the purge cavity, be sure to perform theprocedures and warnings in Section 4.6.43 shall be performed. The LEDindicators are described in Table 3–11 and are shown in Figure 3–11.
Figure 3–11. Intrinsic Barrier Relay Control Indicators
DC/DC MODULE
CR1
24V 6.5V
24V LED
6.5V LED
MODULE ASSY # EE–3044–401
‘
Table 3–11. Modular I/O LEDs
Channel Function
24V Indicates 24VDC input from 24VDC power supply in controller
6.5V Indicates output of 6.5 VDC through relay CR1
3.4.7 Module Assembly # EE–3044–401
3–19
3. LIGHTS, INDICATORS, AND LEDS
MARO2P10203703E
The Intrinsic Barrier Relay Control (IBRC) LED indicators are describedin Table 3–12 and are shown in Figure 3–12.
Figure 3–12. Intrinsic Barrier Relay Control Indicators
CH1 CH2 CH3 CH4 CH5 CH6
Table 3–12. Modular I/O LEDs
Channel Function Description
CH1 Air pressureswitch
Monitors internal air pressure. The switch is closed when the robot is in a safeoperating state.
CH2 Flow switch Monitors air flow during purge sequence.
CH3 *ROT switch Robot overtravel closed when robot is not in an overtravel condition.
CH4 *HBK switch Hand broken switch. Robot wrist is broken. Normally this is a closed input.
CH5 TPDSC switch Teach pendant disconnect switch.
CH6 EOAT switch End of arm tooling switch triggers RDI2.
3.4.8 Contact SignalTransducer (IBRC)
3–20
3. LIGHTS, INDICATORS, AND LEDS
MARO2P10203703E
Figure 3–13 and Figure 3–14 show ER-1 and ER-2 R-J2 Ethernet printedcircuit boards. Refer to A User’s Guide to the FANUC Robotics SYSTEMR-J2 Controller Remote I/O Interface for an Allen-Bradley PLC for LEDdescriptions.
Figure 3–13. ER-1 and ER-2 Printed Circuit Board LEDs
Table 3–13 lists and describes the ER-1 alarm LEDs.
Table 3–13. ER-1 Alarm LEDs
ALARM DESCRIPTION
1 2 3 4
Fuse Alarm
DRAM Parity ErrorSoft Alarm LED
STATUSALARM
Soft Alarm LED Turned on and off by system software.
DRAM Parity Error Turns on when a DRAM parity error occurs.
Fuse Alarm Turns on when a fuse has blown (for 10BASE5 PCBs only).
Table 3–14 lists and describes the ER-2 alarm LEDs.
Table 3–14. ER-2 Alarm LEDs
ALARM DESCRIPTION
Not used
Not usedDRAM Parity Error
Soft Alarm LED
ALARM
A1
A2
A4
A3
Soft Alarm LED Turned on and off by system software.
DRAM Parity Error Turns on when a DRAM parity error occurs.
ER-1 Alarm LEDs
ER-2 Alarm LEDs
Page 23
4 TROUBLESHOOTING
4 TROUBLESHOOTING
4–1MARO2P10203703E
Topics In This Chapter Page
Power ON Sequence The following procedures are applicable to all P-200 robot systems including those on a pedestal, rail or with an opener. 4–3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Controller shutdown Use this procedure for complete controller shutdown including purge circuitry. 4–4.
A Class 1 Fault is a malfunction that prevents the controller from operating. The main contactor might or might not be energized. No text is displayed on the teach pendant. Refer to Section 4.1. 4–5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Class 2 FaultTroubleshooting
A Class 2 Fault is a malfunction that prevents the Boot ROM operating system from turning the system over to the application software. Text will be displayed on the the teach pendant, but the teach pendant display will be frozen and will not respond to keypad entries. Refer to Section 4.5. 4–21. . . . . . . . . . . . . . . . . . . . . . .
A Class 4 Fault is a malfunction that prevents the robot paint system components in the outer arm of the P-200 from operating normally, even though the application software is running. No numbered alarm messages will be displayed as in the case of a class 3 fault. Process defects will be noticed on each job as a result. 4–63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Trigger Valve 4–64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Shut Off 4–65. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Trigger (Electrical) 4–66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Process Fault Transducer 4–73. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Flow Meter 4–76. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
This chapter describes the steps you must follow to repair electrical faultsin the R-J2 controller.
WARNINGThe procedures described in this section require you towork with high voltage circuits. Carelessness orinattention can kill you. Do not attempt any of theseprocedures unless you are trained and experienced inelectrical repair.
4–3
4. TROUBLESHOOTING
MARO2P10203703E
The following procedures are applicable to all P-200 robot systemsincluding those on a pedestal, rail or with an opener. In the case of aP-200 robot and opener, both units must be properly purged before thecontroller can be turned on.
Procedure 4–1 Troubleshooting Purge Problems
1 With the main disconnect ON, you should observe:
Purge complete LED is off.Purge enable pushbutton (purging) lamp is off.ON pushbutton lamp is off.Purge fault LED is on
2 Push and hold the PURGE ENABLE pushbutton. You should observe
Purge solenoid engages when minimum pressure requirements aremet.
4 At the end of the 5 minute purge, the pushbutton purging lamp willturn off and the purge complete LED will turn on. Also, the purgesolenoid will shut off.
5 If this procedure does not work, go to troubleshooting Table 4–1. Ifthe purge cycle works correctly but the robot will not power up, go toProcedure 4–4 .
4.1POWER ONSEQUENCE
Step
4–4
4. TROUBLESHOOTING
MARO2P10203703E
Use this procedure for complete controller shutdown including purgecircuitry.
Procedure 4–2 Controller Shutdown Procedure
1 Push the E-stop push button.
2 Push the controller “OFF” pushbutton.
3 Pull the Main Disconnect switch.
For servo lockout use the following procedure:
Procedure 4–3 Servo Lockout Procedure
1 Push the E-stop push button.
2 Open the servo lockout disconnect switch.
3 Lockout switch
4.2CONTROLLERSHUTDOWN
Step
4.3SERVO LOCKOUT
Step
4–5
4. TROUBLESHOOTING
MARO2P10203703E
This section contains troubleshooting information for Class 1 Faults. A Class 1 fault prevents the controller from operating. The main A.C. linecontractor (ALC) might be energized. The Purge Complete light might beon. No text is displayed on the teach pendant.
This section contains several tables. Each table provides procedures tocorrect the fault. To troubleshoot a Class 1 fault, always start atProcedure 4–1 . Perform the procedures in order. You will either correctthe fault using Table 4–1 or it will refer you to another table in thissection.
Use the other tables only when Table 4–1 refers you to them.
If the following conditions are true, follow the steps in Table 4–1.
The main disconnect is ON.The ON button has been pressed.The power on sequence (Procedure 4–1 ) has been attempted.The controller does not operate.
Without turning off the main disconnect, open the controller door.Release the disconnect latch by turning the screw to the lower right of thedisconnect handle.
3. Press and hold the Purge Enable pushbutton on theStandard Operator Panel until it lights (1 - 5 seconds) andthen release.
If the Purge Complete light comes on test thecontroller for proper operation. Go to Table 4–4.
If the Purge Enable or Purge Complete light does notcome on and/or the Purge Fault light comes on
continue troubleshooting.
Purgeenable
ÎÎÎÎÎÎÎÎÎ
ÎÎÎÎÎ
ÎÎÎÎ
PURGECOMPLETE
PURGEFAULT
ÏÏÏÏ
ÏÏ
Purgefault
PURGE ENABLE
HOUR METER
FAULT RESET
REMOTE
ON
OFF
LOCAL
EMERGENCY STOP
PORT
BRAKE ENABLE
4. Turn off the main disconnect handle.
5. On the Intrinsically Safe Terminal Board (ISTB) unit,connect test jumper wires between terminals 1 and 4, andbetween terminals 5 and 8 on the ISTB.These terminals are the inputs from the
robot-mounted air pressure and air flow switches. Goto Step 6.
Refer to Figure 12–13.
ISTBTest Jumpers
NOTE: Jumper 1-2 simulates the pressure switch from the robot. Jumper 3-4 simulates the pressure switch from the opener, If applicable (If there is no opener all ready jumpered). Jumper 5-6 simulates the flow switch from the robot. Jumper 7-8 simulates the flow switch from the opener, if applicable (If there is no opener all ready jumpered).
7. Press and hold the Purge Enable pushbutton on theStandard Operator Panel until it lights (1 - 5 seconds) andthen release it.If the purge circuit is cycling, the purge enable
pushbutton will stay lit until the 5 minute purge iscomplete. The Purge Fault light will be out.
If the robot does not purge with jumpers inserted goto step 8.
If the purge is successful with jumpers the problemcould be:
– The wiring connected to the pressure switch(s) or
the flow switch(s)
– The pressure switch in robot (or opener if
applicable)
– The flow switch in robot (or opener if applicable)
– Possibly a casting leak in robot (or opener if
applicable)Locate the problem and replace faulty component.If problem still exists check any Auxiliary device
pressure and flow switches. If not used checkjumpers across terminals 3 and 4, and terminals 5and 6.
Locate the problem and replace faulty component.Refer to Figure 12–13.Remove jumpers from step 5 and retest purge
system.If the purge is successful without jumpers Go to
Table 4–4.
PurgeEnable
ÎÎÎÎÎÎ
ÎÎÎÎÎÎÎÎ
ÏÏ
ÏÏÏÏ
PurgeFault
PORT
REMOTE
OFF HOUR METER
ON
EMERGENCY STOP
LOCAL
BRAKE ENABLE
PURGE FAULT
PURGE ENABLE
8. Replace purge control PCB.Retest purge control without jumpers.If purge control is still not working go to Table 4–2.
WARNINGThe purge control timer is adjusted to five minutes toconform to Factory Mutual Specifications. Do not adjustthe purge control timer; otherwise, an explosion or firecould occur.
If one or more of the lights are on go to Table 4–3. Lights CH1 CH2 CH3 CH4 CH5 CH6
2. Measure the AC voltage coming into the IDEC IBRC unit atterminals 220 VAC and 0V.
If the voltage is 200 to 240 VAC replace the IDEC IBRCUnit.
If there is no voltage continue troubleshooting.
Refer to Figure 12–1, Figure 12–12, Figure 12–13 andFigure 12–15.
MultiTap TransformerTF1
43 44
3. Measure the AC Voltage at terminals R and S on the purgecontrol PCB
If the voltage is 200 to 240 VAC replace the wires betweenIDEC IBRC and CP1 on the purge control PCB.
If there is no voltage check for continuity between terminalsFRA1 and FRA2 on purge control PCB.
If there is no continuity replace jumper between FRA1 andFRA2.
If there is continuity continue troubleshooting.
Refer to Figure 12–1, Figure 12–7 and Figure 12–13.
1 2FRA
SR
G
200A 200B
FRA
Purge Control PCB
. .4. Measure the AC voltage coming into the purge control PCB at
terminals 200A and 200B.
If there is 200 to 240 VAC replace purge control PCB.
If there is no voltage turn off main power disconnect andcheck for continuity between terminals 200A and 200B onpurge control PCB and terminals 43 and 44 on the multi-taptransformer. Continue troubleshooting.
Refer to Figure 12–1, Figure 12–7 and Figure 12–13.
G
15ma MAX.24VDC PSU
IDEC IBRC
220VAC 0VAC IN
5. If there is no continuity replace the wires betweenterminals 200A and 200B on the purge control PCB andterminals 43 and 44 on the multi-tap transformer.
1. Turn off the power disconnect handle.Continue troubleshooting.
2. Reseat the following connectors: Contact signal transducer(IDEC IBRC) connector CNCA. Purge control printed circuitboard (mounted with EMG control PCB) connector CNIN.Continue troubleshooting.Refer to Figure 12–1, Figure 12–12, Figure 12–13 and
Figure 12–14.
3. Turn off the power disconnect handle.
ÎÎÎ ÎÎ
ÎÎÎÎÎÎ
REMOTE
REMOTE
LOCAL
PURGECOMPLETE
BRAKE ENABLE
PURGE ENABLE
PURGEFAULT
FAULT RESET
ÏÏÏÏ
ÏÏÏÏ
ON
OFF
PurgeFault
4. Observe on the Standard Operator Panel that the purge faultlight is lit.
8. If CH 2 light is out, test jumper ISTB terminals 5 to 8 andobserve if the light comes on.
If the CH 2 light does not come on go to step 9.
If the light comes on replace the auxiliary flow switch orwiring or replace the jumper, when auxiliary flow switch is notused.
NOTE Remove test jumpers at the end of each step.
Lights
CH1 CH2 CH3 CH4 CH5 CH6
IDEC IBRC
9. Replace the following in the order shown:
Purge enable switchPurge control PCBIBRC unit
Procedure 4–4 Troubleshooting Turn-on Problems
You have performed Procedure 4–1 and the system is purged.
The following conditions exist:
Purge complete LED onPurge enable pushbutton (purging) lamp is off.ON pushbutton lamp is off.Purge fault LED off.
1 Attempt normal power by pressing the ON pushbutton.
The ON pushbutton will light.Main CPU and axis control PCBs also execute internal diagnostics.
When the diagnostics are all complete the MCC on all servo amplifierswill energize and “click”. When this occurs, the teach pendant is on andthe controller is ready to operate.
If unit powered up correctly go to Section 4.5.
If the unit did not turn ON normally, go to Table 4–4.
Condition
Step
4–13
4. TROUBLESHOOTING
MARO2P10203703E
Table 4–4. Troubleshooting Procedure 4(General Power Supply Troubleshooting)
Troubleshooting Procedure Illustration
1. Check and see if the green PIL light in the center of thePower Supply Unit module is ON.
If the light is on go to Table 4–6.
If the light is off continue troubleshooting.
CP1G
S
R1
2
3
2. Check fuse F1 in the top center of the Power Supply Unitmodule.
A white flag in the center of the fuse indicates it isbad.
If the fuse is bad, replace it and attempt the power upProcedure 4–4 .
If the fuse is good go to step 3.
If the fuse continues to blow go to step 5.
Battery
F1: 7.5A fusefor AC input
CP2
G1
S1
R1
CP3
S2
R2
G2
11
2 2
3 3
3. If the white flag does not appears in the center fuse windowand the green PIL light still does not come on, check fusewith an ohmeter
If the fuse is blown replace the fuse.
If the fuse blows again replace the Power Supply Unit.
If the fuse is OK and the green PIL light does not come on continue troubleshooting.
Battery
PIL: Green LEDfor indicatingthe AC powersupply status
ALM: RedLED f4. Disconnect CP1 at the top of the Power Supply Unit module.
Measure the voltage coming into the PSU on the two redwires in the harness connector (S and R).
Check to see if the voltage is 220 to 240 VAC.If the voltage is ok go to step 5.
If their is no voltage go to Table 4–5.
F4:
LED forindicating analarm
5. Turn off the main disconnect switch and, using an ohmmeter,to test for a short in the wiring harnesses at CP2 and CP3.
If no short is evident go to step 6.
If there is a short replace the shorted wiring harness andattempt power up sequence.
F4:5A fuse for +24E
F3:5A Slow-Blowfuse for +24V
4–14
4. TROUBLESHOOTING
MARO2P10203703E
Table 4–4. (Cont’d) Troubleshooting Procedure 4(General Power Supply Troubleshooting)
Troubleshooting Procedure Illustration
6. Reconnect harnesses CP2 and CP3 and turn the maindisconnect switch to on. Press the ON pushbutton and checkfor proper operation.
If the fuse continues to blow Continue troubleshooting.
Power Supply Unit Module
PIL: Green LEDAC Power Supply Status
7. If fuse F1 has blown again it is due to a short in one of thefollowing. Replace components one at a time the untilproblem is solved.
Wiring harness to servo power control coilServo power control coilWiring harness to fans (check in particular where cable and
1. Measure the AC voltage between Multi-Tap Transformerterminals 43 and 44 of TF1.
You should see 200 to 240 VAC.If 200 to 240 VAC is present replace the harness betweenthe Power Supply Unit and the Multi-Tap Transformer.
If voltage is not present or incorrect continuetroubleshooting.
Refer to Figure 12–1 and Figure 12–3.
CAPACITY SPECIFICATION F1,F2,F3 F4,F5
7.5KVA A80L–0026–0010#A 30A 7.5A
SPECIFICATION OF TF1
575550500480460415/240380/220
OV575550500480460415/240380/220
OV575550
480460415/240380/220
500
OV24
L1
L2
L343
44
51
52
F4
F5
SERVO POWER CONTROL
SERVO POWER
100 VAC
THERMOSTAT
FOR OVERHEAT
F2
F1
220 VAC
(210 VAC)
(220VAC)
30A
3 4
1 2
5 6
13 14
23 24ST1
ST2
A1
A2
MULTI–TAP TRANSFORMER TF1
EE–0989–550
7.5A
F3
2. Check Multi-Tap Transformer tap settings. As shown inSection 1.9.
If the tap settings are set incorrectly Set to correct values.
If the tap settings are correct continue troubleshooting.
Refer to Figure 12–1 and Figure 12–3.
F1BREAKER
L1L2
IN CASE OF CIRCUIT BREAKER
3. Check AC voltage between transformer primary terminals.
Check between terminals L1 and L2.Check between terminals L2 and L3.Check between terminals L1 and L3.All voltage readings should be the be the same depending on
plant supplied 3 phase voltage.If proper voltage is present replace Multi-Tap Transformer.
If incorrect or no input voltage is present continuetroubleshooting.
4. Check the terminal block TBOP1 on the operator panel forjumpers between terminals (EX COM) and (EX OFF).
If you use an external OFF button, there will be a wire on eachterminal.
If the terminals are connected with a jumper wire check forloose screws and good contact.
If an external OFF button is used test for continuity of theexternal OFF, and DIL circuits replace it if necessary. Continue troubleshooting.
Refer to Figure 12–16 and Figure 12–17.
CNHM
PORT 2CRS1
CNOP
KA1
KA2
EXON
EXCOM
EXOFF
SVON1
SVON2
E STOP1
5. On the operator panel, momentarily connect (Ex ON) to (ExCOM).
Controller should turn on.If the controller turns on there is a break in the on/offswitch circuit replace any damaged wire or the on/off switchcircuit.
If the controller does not turn on replace the Power SupplyUnit module.
1. Check fuse F3 at the bottom of the Power Supply Unit.
A white flag in the center of the fuse indicates it is bad and that24V power is missing.
If the fuse is blown there might be a short circuit in one of thefollowing:
-Backplane (See Figure 4–1 and Figure 4–2)-24VDC Cooling Fans for module card cage-Process I/O 24 VDC supply-Main CPU Module-Modular I/O 24 VDC supply-Option #1 Card-Option #2 Card-Option #3 Card
Isolate the short and replace the defective component.If the fuse is good replace the Power Supply Unit.
Refer to Figure 12–6, Figure 12–7 and Figure 12–8.
Power Supply Unit Module
F3: 5-AS slow blowfuse for +24V
ALM: Red LEDfor indicating analarm
F4: 5-A fuse for +24E
Figure 4–1. 24 Volt (24V) Power Distribution Chart
CA44
JRM
10
JRM
3
CNOP (FOR PAINT ONLY)
JD1A
For 5 slot backplane only
JNA
3
3
4–20
4. TROUBLESHOOTING
MARO2P10203703E
Figure 4–2. 24 Volt (24E) Power Distribution ChartJR
A5
JRA
5
CR
M10
ISB
CNOP
JNA
3
For 5 slot backplaneonly
#3
4–21
4. TROUBLESHOOTING
MARO2P10203703E
A Class 2 Fault occurs when frozen text (letters or numbers) are displayedon the teach pendant. This indicates a problem with the main CPU printedcircuit board caused by either the memory, processor, the board itself, or abad teach pendant cable. Use Table 4–8 to troubleshoot a class 2 fault.
Table 4–8. Class 2 Faults Troubleshooting Procedure
Troubleshooting Procedure
1. Is the Battery light on the main CPU module on?
If the Battery light is on replace the battery. Refer to Procedure 9–1 . Continue troubleshooting.
2. Perform a cold start of the controller following the procedures in the Systems PaintTool Setup and Operations Manual.Go to Step 3.
3. Are all four green LEDs on the main CPU board turned on?
If all four green LEDs are on continue troubleshooting.
If all four green LEDs are not on troubleshoot the controller using Table 3–4 .
4. Turn the controller off. Hold down the NEXT and PREV keys on the teach pendant and press the ON button.
Check the teach pendant cable by swapping it with a known working cable or by doing a continuity test. Does the “BMON>” prompt appear on the teach pendant? If it does not appear, replace the main CPU printed circuit
board and reload the software. Otherwise, continue troubleshooting.
5. Perform the following steps on the teach pendant to check the CMOS memory:
a. Press the NEXT key twice.
b. Press F1, DIAG.
c. Press ENTER.The prompt changes to DIAG> (diagnostic monitor).
d. Press the NEXT key three times.
e Press F5, TEST.
f. Press F1, CMOS.
g. Press ENTER.
The teach pendant will display a message that gives you an opportunity to exit without destroying the contents of CMOSmemory.
CAUTIONDo not continue unless your controller actually has a Class 2 fault. Continuing beyond thispoint will erase all software stored in the controller including all taught positions in yourapplication. Otherwise, a complete software reload will be required.
h. Press 1, and then press ENTER if you want to continue with the test.
The CMOS memory test will take a few minutes to run. If an error is encountered, replace the CMOS module and reload thesoftware. Refer to the Paint Tool SYSTEM R-J2 Controller Software installation manual for more information.
If the CMOS memory test passes, continue troubleshooting.
4.5CLASS 2 FAULTSTROUBLESHOOTING
4–22
4. TROUBLESHOOTING
MARO2P10203703E
Table 4–8. (Cont’d) Class 2 Faults Troubleshooting Procedure
Troubleshooting Procedure
6. Perform the following steps on the teach pendant to check the FROM:
a. Press the NEXT key three times.
b. Press F5, TEST.
c. Press F3, FROM.
d. Press ENTER.
The teach pendant will display a message that gives you an opportunity to exit without destroying thecontents of Flash ROM memory.
e. Press 1, and then ENTER if you want to continue with the test.
The Flash ROM memory test will take a few minutes to run. If an error is encountered, replace the FlashROM module and reload the software. Otherwise, continue troubleshooting.
7. Perform the following steps on the teach pendant to check the DRAM:
a. Press the NEXT key three times.
b. Press F2, DRAM.
c. Press ENTER.
The teach pendant will display a message that gives you an opportunity to exit without destroying the contents of the DRAM memory.
d. Press 1 and then ENTER if you want to continue with the test.
The DRAM memory test will take a few minutes to run. If an error is encountered, replace the DRAM module. The software does not have to be reloaded. Otherwise, go to Step 8.
8. The hardware in your controller is OK. Reload your application software. Refer to the Paint Tool SYSTEM R-J2Controller Software installation manual for more information.
4–23
4. TROUBLESHOOTING
MARO2P10203703E
A class 3 fault occurs when the teach pendant displays a fault message.This section contains troubleshooting procedures for each class 3 faultmessage. To determine which procedure to use, perform the followingsteps:
1. Press the MENUS key on the teach pendant.
2. Select ALARM.
3. Refer to the appropriate section and follow the correspondingtroubleshooting procedure. The subsections that follow are arrangedin numerical error code order.
4.6CLASS 3 FAULTTROUBLESHOOTING
4–24
4. TROUBLESHOOTING
MARO2P10203703E
The operator panel emergency stop pushbutton is pressed.
If the problem still exists, it is caused by an error in the emergency stopcircuit or a bad main CPU. Perform the following troubleshootingprocedure:
Table 4–9. SRVO-001 Troubleshooting Procedure
Troubleshooting Procedure Illustration
1. Make sure that the teach pendant E-stop button is notpressed and that the external emergency stop inputs andfence switch inputs are jumpered or closed.
2. Reseat the CNOP connector on the operator panel. Reseatthe JRM10 connector on the main CPU.
3. Turn on the controller and check for proper operation. If theproblem is still present, continue troubleshooting.
4. Open the door of the controller. Press and release the E-stopbutton several times. Listen for relay KA4 to click. Does therelay KA4 on the standard operator panel click?
If yes replace the cable between the operator panel CNOPand main CPU JRM10.
If no continue troubleshooting.
5. Connect jumper wires across terminals 1 and 2 of eachswitch section of the E-stop switch and then press reset onteach pendant. Does the fault reset?
If yes replace the E-stop switch assembly
If no replace the operator panel.
Refer to Figure 12–9, Figure 12–15 and Figure 12–16.
CNHM
PORT 2CRS1
CNOP
KA1
KA2
KA3
KA4
EXON
EXCOM
EXOFF
EMGIN1
EMGIN2
FENCE 1
FENCE 2
SVON1
SVON2
E STOP1
E STOP2
EMGOUT2
EMGOUTC
EMGOUT1
TBOP2 TBOP1
NCNC
1
1
2
2
E-Stop Switch
E-Stopbutton
4.6.1 SRVO-001 ER_SVAL1Operator Panel E-Stop
4–25
4. TROUBLESHOOTING
MARO2P10203703E
The teach pendant emergency stop (E-Stop) pushbutton has been pressed.
Remedy: Twist the teach pendant emergency stop pushbutton clockwiseto release and press RESET.
If the problem still exists, it is caused by the loss of 24VDC to the teachpendant relay RLY2 or the 5VDC signal to the matrix decoding from thenormally closed contact of the teach pendant relay RLY2.
Any of the following can cause this problem:
A defective teach pendant emergency stop switch.A defective component on the teach pendant printed circuit board.Loss of 24VDC to the E-STOP switch (not part of the teach pendant
power).
This loss of power can be caused by a bad teach pendant emergencystop switch, a broken wire in the teach pendant cable, a bad operatorpanel, or a bad cable between the operator panel CNOP and the mainCPU JRM10. You can fix it by replacing the teach pendant.
If you want to troubleshoot the problem further, perform the followingtroubleshooting procedure:
Table 4–10. SRVO-002 Troubleshooting Procedure
Troubleshooting Procedure
1. Turn off the controller.
2. Reseat CNOP at the operator panel interface and connector JRM10 at the main CPU.
3. Turn on the controller and check for proper operation. If the problem is still present,continue troubleshooting.
4. One of the following components is bad.
Replace the teach pendant.Replace the operator panel.Replace cable between CNOP on the operator panel and JRM10 on the main CPU.Replace main CPU.
Determine the bad component by substituting it with a new component.
Refer to Figure 12–8 and Figure 12–16.
4.6.2 SRVO-002 ER_SVAL1Teach Pendant E-stop
4–26
4. TROUBLESHOOTING
MARO2P10203703E
The teach pendant DEADMAN switch is released while the teach pendantis enabled.
Remedy: Press and hold the teach pendant DEADMAN switch. PressRESET.
If the problem still exists, perform the following steps:
Table 4–11. SRVO-003 Troubleshooting Procedure
Troubleshooting Procedure
1. Turn off the controller.
2. Reseat the teach pendant cable at both ends, connector JRM10 at the operator panel printed circuit board, andconnector JRM10 at the main CPU.
3. Turn on the controller and check for proper operation. If the problem is still present, continue troubleshooting.
4. Open the controller door. Turn on the controller. Make sure the teach pendant E-Stop pushbutton is not pressed.
5. Press and release a DEADMAN switch several times. You should be able to hear relay KA1 click on the operator panelinterface.
If the relay clicks replace cable between the operator panel interface and the main CPU.
After replacing the cable check the DEADMAN switch for proper operation, if problem still exists continue troubleshooting.Go to step 6.
If the relay does not click one of the following components is bad:
The teach pendant The teach pendant cable The operator panel interface.
Determine the bad component by substitution. Problem solved.
6. If your teach pendant is bad, and you want to troubleshooting the teach pendant continue troubleshooting.
7. Turn off the controller.
8. Remove the seven screws on the teach pendant back.8. Remove the seven screws on the teach endant back.
9. Remove the teach pendant back but leave all electrical connectors in place.
10. Press each DEADMAN switch bar while you watch the switch body inside the teach pendant.
11. Make sure that the copper strip presses the switch actuator all the way into the switch body.You should be able to hear and feel it click into place.
12. If the actuator is frozen or will not click sharply, replace the switch.
13. Slide the wiring connector half way off the circuit board connector.
14. Measure the resistance between:
Pins 1 and 2Pins 3 and 4.
NOTE When the DEADMAN switch is not pressed, there is continuity between pins 1 and 2 and nocontinuity between pins 3 and 4.
NOTE When the DEADMAN switch is pressed, there is no continuity between pins 1 and 2 andcontinuity between pins 3 and 4.
If one or more measurements are bad replace the DEADMAN switch assembly.
If the measurements are good the teach pendant is defective replace the teach pendant.
4.6.3 SRVO-003 ER_SVAL1Deadman switchreleased
4–27
4. TROUBLESHOOTING
MARO2P10203703E
The safety fence gate is open.
Remedy: Close the gate. Several gates in the workcell might beinvolved.
If the problem still exists, perform the following troubleshootingprocedure:
Table 4–12. SRVO-004 Troubleshooting Procedure
Troubleshooting Procedure Illustration
1. Look at terminals Fence 1 and Fence 2 on TBOP1 on theoperator panel interface. Check for a jumper connecting theterminals or a wire on each terminal. There should becontinuity between the two terminals.
If there is no continuity install a jumper or repair theexternal fence circuit.
If there is continuity continue troubleshooting.
PORT 2
EXONSVON1
CRS1
CNOP
CNHM
2. Turn off the controller.EXCOM
KA1
3. Reseat CNOP at the operator panel interface and connectorJRM10 at the main CPU.
EXCOMSVON2
4. Make sure that no EMERGENCY STOP buttons are pressed. EXOFFE STOP1 KA2
5. Open the controller door.EMGIN1E STOP2
6. Disconnect one end of the fence jumper or external fencecircuit.
EMGOUT1
EMGIN1
EMGIN2
E STOP2
KA3
7. Briefly short the two fence terminals on the operator panelinterface together. You should be able to hear and see relayKA4 click on the operator panel interface.
If the relay clicks replace the cable between the operatorpanel interface CNOP and the main CPU connector JRM10.
If the relay does not click replace the operator panel.
Refer to Figure 12–8 and Figure 12–16.
EMGOUT2
EMGOUTC
EMGOUT1 EMGIN2
FENCE 1
FENCE 2
TBOP1TBOP2
KA4
4.6.4 SRVO-004 ER_SVAL1Fence open
4–28
4. TROUBLESHOOTING
MARO2P10203703E
An overtravel error occurs when the robot moves beyond the softwaremotion limits, tripping the overtravel limit switch.
If more than one axis is moving when the switch is tripped, the controllerwill report an overtravel error on several axes.
Table 4–13. SRVO-005 Troubleshooting Procedure
Troubleshooting Procedure Illustration
1. If you have not already done so, continuously press and holdthe DEADMAN switch and turn the teach pendant ON/OFFswitch to ON.
2. Hold down the SHIFT key and press RESET.
3. Press COORD until you select the JOINT coordinate system.
4. Jog the axis in overtravel off of the overtravel switch.
5. If you cannot jog the robot off of the overtravel switch thewrong motion inhibit flag has been set; therefore, continue toStep 6. Otherwise, the axis (or axes) are no longer inovertravel and you can end the procedure now.
6. Cold start the controller and go to Step 1. If the overtravel stillcannot be cleared, continue troubleshooting.
NOTE In some instances, the teach pendant screen willindicate a FALSE for a given axis when a TRUE should beset because of the way overtravel is read in the software. It isbest to perform the following procedure on all of the axes.
7. Press MENUS.
8. Select MANUAL FCTNS.
9. Press F1, [TYPE].
10. Select OT Release.
11. Move the cursor to the OT PLUS or OT MINUS value of theaxis in overtravel. The status of OT PLUS or OT MINUS forthat axis is TRUE.
12. Press and hold SHIFT and press F2, RELEASE.
13. Press and hold SHIFT and press RESET.
14. Press COORD until you select the JOINT coordinate system.
15. Continuously press and hold the DEADMAN switch and turnthe teach pendant ON/OFF switch to ON.
17. Turn the teach pendant ON/OFF switch OFF and release theDEADMAN switch.
If the error cannot be reset continue troubleshooting.
18. Check fuse F4 on the power supply unit.
If the fuse is blown replace it and check for a short circuit inthe external 24V circuit (I/O and/or end effector power.)
If fuse is not blown continue troubleshooting.
19. Reseat connector JRF2 at the main CPU and connectorsCRM11 and JRF2 on the emergency stop control board.
20. Turn on the controller and check for proper operation. If theproblem is still present, continue troubleshooting.
21. Using an ohmmeter and the wiring diagrams, check theCRM11 (Emergency Stop Control Board) cable for continuity.If a break is found, replace the cable on CRM11 emergencystop control board.
22. If error still exist, one of the following is bad:
Determine the bad component by substitution.
The ribbon connector between the main CPU connectorJRF2 and Emergency Stop Control Board connector JRF2.
The Emergency Stop Control Board. The main CPU.Refer to Figure 12–8 and Figure 12–9.
JRF2
Central Processing Unit
F4: 5-A fuse for +24E
Power Supply Unit
4–30
4. TROUBLESHOOTING
MARO2P10203703E
A hand breakage error occurs when the hand (wrist) breakage detectionswitch or aux hand breakage detection switch is tripped.
Remedy:
If you are not using the hand broken function, ensure that the HBKjumper on the Emergency Stop Control Printed Circuit Board is set to theA side.
If you are using the hand broken function, perform the following steps:
1. If you have not already done so, continuously press and hold theDEADMAN switch and turn the teach pendant ON/OFF switch to ON.
2. Hold down the SHIFT key and press RESET. The robot can now bemoved.
3. Jog the robot to a safe position off of the limit switch.
4. Turn the teach pendant ON/OFF switch to OFF and release theDEADMAN switch.
4.6.6 SRVO-006 ER_SVAL1Hand Broken
4–31
4. TROUBLESHOOTING
MARO2P10203703E
If the problem still exists, perform the following troubleshootingprocedure:
Table 4–14. SRVO-006 Troubleshooting Procedure
Troubleshooting Procedure Illustration
1. Turn off the controller and check fuse F4 on thepower supply unit.
If the fuse is blown replace it and check for a shortcircuit in the external 24V circuit (I/O and/or endeffector power.)
If fuse is not blown continue troubleshooting.
F4: 5-A fuse for +24E
Power Supply Unit
2. Reseat the CRM10 and JRF2 connectors on themain CPU and the CRM11 and JRF2 connectors onthe emergency stop control board.
3. Turn on the controller and check for proper operation. If the problem still exists, continuetroubleshooting.
4. Test the end effector switch and its wires at the robotfor continuity.
If there is no continuity replace the switch or itswires.
If there is continuity continue troubleshooting. HBK
EmergencyStopControlBoard
HAND BROKEN5. Set the HBK jumper on the Emergency Stop Control
Board to the A side and test the robot for properoperation.
If the fault is fixed replace the cable between themain CPU connector CRM10 and the robot. Be sure toreset the jumper on the emergency stop control boardto the B side.
If the fault is not fixed one of the followingcomponents is bad.
Determine the bad component by substitution.The Emergency Stop control board.The ribbon cable between the Emergency Stop
Control Board and the main CPU.Main CPU.
Power Supply Unit
HAND BROKENJUMPER
CRM 10
4–32
4. TROUBLESHOOTING
MARO2P10203703E
An external emergency stop button somewhere in the workcell has beenpressed.
Remedy: Locate and release the external emergency stop button. Pressreset on the operator panel or teach pendant.
If the problem still exists, perform the following troubleshootingprocedure:
Table 4–15. SRVO-006 Troubleshooting Procedure
Troubleshooting Procedure Illustration
1. Look at terminals EMGIN1 and EMGIN2 on the operatorpanel interface. Check for a jumper connecting the terminalsor a wire on each terminal. There should be continuitybetween the two terminals.
If there is no continuity install a jumper or repair theexternal fence circuit.
If there is continuity continue troubleshooting.
CNHM
PORT 2CRS1
CNOP
KA1
KA2
KA3
KA4
EXON
EXCOM
EXOFF
EMGIN1
EMGIN2
FENCE 1
FENCE 2
SVON1
SVON2
E STOP1
E STOP2
EMGOUT2
EMGOUTC
EMGOUT1
TBOP2 TBOP12. Turn off the controller.
3. Reseat the JRM10 connector at the operator panel interfaceand the JRM10 connector at the main CPU.
4. Turn off the controller and check for proper operation. If theproblem still exists continue troubleshooting.
PORT 2CRS1
CNOP
5. Make sure that no EMERGENCY STOP push buttons arepressed. Check the operator panel, teach pendant and anyother external EMERGENCY STOP buttons that wereadded.
CNHM
PORT 2CRS1
KA1
EXON
EXCOM
SVON1
6. Open the controller door.
KA2
EXCOM
EXOFF
SVON2
E STOP17. Disconnect one end of the EMGIN1 and 2 jumper or external
emergency stop circuit.
KA2
KA3
EXOFF
EMGIN1
E STOP1
E STOP2
8. Briefly short the EMGIN1 and EMGIN2 terminals on theoperator panel interface TBOP1 together. You should beable to hear relay KA4 click on the operator panel interface.
If the relay clicks replace cable between the operatorpanel CNOP and the main CPU
If not replace the operator panel.
Refer to Figure 12–8, Figure 12–9 and Figure 12–16.
KA3
KA4
EMGIN2
FENCE 1
FENCE 2EMGOUT2
EMGOUTC
EMGOUT1
TBOP2 TBOP1
4–34
4. TROUBLESHOOTING
MARO2P10203703E
Teach pendant DEADMAN switch was released while enabled.
Remedy: Press the DEADMAN switch, then press RESET.
Normal power is on (hot start).
Remedy: This message is normal and does not indicate a problem. Noaction is required by the operator.
One or all of the 24VDC cooling fans in the backplane cage are notrunning.
Each double-board board cage in the backplane has a cooling fan mountedin its top. Each fan contains a centrifugal switch that opens when the fanis not running.
Table 4–16. SRVO-014 Troubleshooting Procedure
Troubleshooting Procedure Illustration
1. With power on, test whether each fan is turning by passing a strip of paperover the top of each board cage.
If all fans are turning go to Step 3.
If one or more fans are motionless continue troubleshooting.
2. Remove the circuit boards from the board cage with the motionless fan.Reconnect the four-wire connector on the backplane behind the boardcage. Re-install the boards and turn on the controller.
If the fault is not fixed replace the fan. Fanmotor
Cable
3. One of the fans or the board is probably defective. Determine which part isbad by temporarily replacing it with a known-good part.
If the fault is not fixed continue troubleshooting.Connector
Backplane4. Replace the backplane.
Back lane
4.6.8 SRVO-011ER_SVAL1TP Released WhileEnabled
4.6.9 SRVO-012ER_SVAL1Power FailureRecovery
4.6.10 SRVO-014 Fan Motor Abnormal(Group:i Axis:j)
4–35
4. TROUBLESHOOTING
MARO2P10203703E
The temperature in the controller is too high, or the overheat sensorlocated on the backplane has opened.
Table 4–17. SRVO-015 Troubleshooting Procedure
Troubleshooting Procedure Print Reference
1. Check the heat exchanger fans for operation.
If the fans are operating replace the backplane.
If one or more fans do not work continue troubleshooting.
Figure 12–1.
2. Check the AC voltage at the terminals of the non-working fan(s).
If the voltage is 200 to 240 VAC replace the non operational fan(s).
If the voltage is out of tolerance replace the fan motor wiring harness.
4.6.11 SRVO-015 ER_SVAL1System Over Heat(Group:i Axis:j)
4–36
4. TROUBLESHOOTING
MARO2P10203703E
The SVON (servo ON/OFF) input is asserted.
Perform the following troubleshooting steps.
Table 4–18. SRVO-019 Troubleshooting Procedure
Troubleshooting Procedure Print Reference
1. Check for continuity between SVON1 and SVON2 on the operator panel interface terminal stripTBOP2.
If no continuity jumper terminals together or replace application wiring.
If there is continuity replace the operator panel.
If the alarms still exist replace the cable between the operator panel (CNOP) and the Main CPU(JRM10).
If alarm still exists replace the main CPU.
Figure 12–16.
The teach pendant cable is disconnected or a momentary break occurred inany of the teach pendant emergency stop circuits; DEADMAN switch orteach pendant EMERGENCY STOP button.
Perform the following troubleshooting steps.
Table 4–19. SRVO-020 Troubleshooting Procedure
Troubleshooting Procedure Print Reference
1. Replace the teach pendant cable or teach pendant as necessary.
If alarm still exists replace the cable between the operator panel (CNOP) and the main CPU
If alarm still exists replace the main CPU.
Figure 12–8 andFigure 12–16.
4.6.12 SRVO-019 ER_SVAL1SVON input
4.6.13 SRVO-020 ER_SVAL1SRDY off (TP)
4–37
4. TROUBLESHOOTING
MARO2P10203703E
The Magnetic Control Contactor on the servo amplifier cannot turn on andno obvious emergency stop conditions exist.
Perform the following troubleshooting steps. Refer to Table 4–20.
NOTE The paint robot is normally set up for Group 1, Axes 1-6 or Group 1, Axes 1-7.
The opener, if present is usually set up as Group 2.
The alarms will indicate which group is having problems.
Table 4–20. SRVO-021 Troubleshooting Procedure
Troubleshooting Procedure Print Reference
1. Check the continuity of the plunger switch that detects an open controller door. The switch shouldshow continuity when the actuator is pressed.
Figure 12–1Figure 12 –15.show continuity when the actuator is ressed.
If the plunger switch does not show continuity replace the plunger switch.
Figure 12–15.
p g y g
If the plunger switch shows continuity continue troubleshooting.
2. Remove connector from CRM15 on the Emergency Stop Control Board and check switchcontinuity thru CRM15 socket.
3. Check the servo amplifier connections between the Emergency Stop Control Board.
4. Check servo amplifier switch settings. See Figure 4–3.
5. Check for proper cable connections between Emergency Stop Control Board and servo amplifier.See Figure 4–4.
6. Turn on the controller and check for proper operation. If the problem is still exists continuetroubleshooting.
7. Check the Magnetic Control Contactor coil for continuity:
If the Magnetic Control Contactor (MCC) coil is bad replace the MCC.
If the MCC coil is good continue troubleshooting.
8. One of the following components is bad.
Determine the bad component by substituting it with a new component. Replace the followingcomponents one at a time until problem the is solved. The Emergency Stop Control Board Cable between the Emergency Stop Control Board (CRR15) and the MCC. The cable between the MCC (CRR20) and the servo amplifiers. The ribbon connector between the main CPU and the Emergency Stop Control Board (JRV1). Cable from Emergency Stop Control board JS1 thru JS6 and servo amplifier. The servo amplifier.
4.6.14 SRVO-021 ER_SVAL1SRDY off(Group:i Axis:j)
4–38
4. TROUBLESHOOTING
MARO2P10203703E
Figure 4–3. Servo Amplifier Switch Settings
OFF ON
123
4
LED
There are four channel switches above the 7-segment LEDbehind the terminal board cover on the front of the servo amplifier. These switches should be set as described belowbefore you use the servo amplifier.
ON
OFF
Type B Interface
Type A Interface
Set switch 2 to OFF. If the setting is incorrect, SRVO-021 SRDY OFF alarm might occur.
Switch 1
The switches are sequentially numbered 1, 2, 3, and 4with the one at the bottom as switch 1. The OFFposition is on the left and the ON position is on theright.
Switch 1 determines the interface type.Paint controllers use the Type Binterface for Robot Axes 1–6
Normal settings for switches 3 and 4 are in the ON position.Refer to Figure 4–6.
4–39
4. TROUBLESHOOTING
MARO2P10203703E
Figure 4–4. Connector and Terminal (T1) Identification
AO6B-6089-H101-H106 AO6B-6089-H201-H210
1
357
89
34567
12
89
NAME INDICATION REMARK
1
2
3
4
5
6
7
8
9
TYPE A InterfaceJV1B
Connector for M-Axis (minor channel)type A interface
Connector for L-Axis (major channel)type B interface
Connector for L-Axis (minor channel)type B interface
TYPE A Interface
TYPE B Interface
TYPE B Interface
TYPE B Interface
TYPE B Interface
TYPE B Interface
N/A
N/A
N/A
Connector for main powersupply (Y key)
Connector for expo signal(X key)
CX4
CX3
JA4
JF2
JF1
JS2B
JS1B
JV2B
3 pin1 pin
2 pin: ESP (at open)3 pin: 24V
Connector for L-Axis (major channel) type Ainterface
4–40
4. TROUBLESHOOTING
MARO2P10203703E
The Magnetic Control Contactor on the servo amplifier is on before it isexpected to be on.
Perform the following troubleshooting steps.
Table 4–21. SRVO-022 Troubleshooting Procedure
Troubleshooting Procedure Print Reference
1. Check the Magnetic Control Contactor (MCC) for stuck contacts.
If the contacts are stuck replace the MCC.
If the MCC is OK continue troubleshooting.
2. Refer to the Section 4.6.14.
The axis position is too far from its commanded position when the robot isstopping, or the robot is stopped and it will not move. The torquenecessary to decelerate an overloaded motor could cause this alarm tooccur.
Perform the following troubleshooting steps.
Table 4–22. SRVO-023 Troubleshooting Procedure
Troubleshooting Procedure Print Reference
1. Make sure that the load on the robot is not excessive.
2. Check that the affected axis is not binding and rotates freely. Especially, make sure that the brakeis not stuck.
3. Check that the motor power cables do not have any open wires and that the cables are notmisconnected.
4. Either the motor or the servo amplifier is bad. Determine the bad component by substituting it witha new component.
The servo error is too big when the robot is moving, or the robot moveswhen it is supposed to be stopped.
The motor cannot rotate as fast as the calculated speed required for thecurrent motion.
Remedy: Even though this is just a warning, every attempt should bemade to eliminate this error by modifying the programmed speed ormotion.
The robot is not mastered.
Remedy: Master the robot. Refer to Chapter 8.
The robot is not calibrated.Remedy: Calibrate the robot. Refer to Chapter 8.
Joint cannot rotate as fast as the calculated speed required for the currentmotion.
Remedy: Even though this is just a warning, every attempt should bemade to eliminate this error by modifying the programmed or motionspeed.
The robot is not in position for the specified period, or the servo error is inexcess of the specified position when the robot is stopping, or the robot isstopped and it will not move. The torque necessary to decelerate anoverloaded motor could cause this alarm to occur.
When the controller was powered up, one or more of its axes was at adifferent position from when it was powered off. This might occur when amotor is replaced or when a CPU from one controller is installed inanother.
Remedy: Perform the following procedure:
Table 4–23. SRVO-038 Alarm Reset Procedure
Reset Procedure Print Reference
1. Press MENUS.
2. Select SYSTEM.
3. Press F1, [TYPE].
4. Select MASTER/CAL
If MASTER/CAL is not displayed, perform the following:a. Select VARIABLES.b. Select $MASTER_ENB.c. Set $MASTER_ENB to 1.d. Press F1 [TYPE] and select MASTER/CAL.
5. Press F3, RES_PCA.
6. Press F4, YES.
7. Press RESET to clear the alarm without turning off the controller. If the fault does not reset, coldstart the controller. Refer to Procedure 10–3 .
4.6.24 SRVO-038PULSE MISMATCH(Group:i Axis:j)
4–43
4. TROUBLESHOOTING
MARO2P10203703E
The servo amplifier magnetic control contactor (MCC) is welded closed.If the contact of the MCC is already closed when the contactor is turnedon, this alarm circuit regards the contact as welded closed and the MCCalarm occurs. This error code can also be caused by improper controllershut down sequence (see Procedure 10–5 ) or improper servo lockoutprocedure (see Procedure 10–6 ).
Perform the following troubleshooting procedure:
Table 4–24. SRVO-042 Troubleshooting Procedure
Troubleshooting Procedure Print Reference
1. Does this alarm occur with SRVO-049?
If SRVO-049 occurs check for the absence of input three-phase voltage. Connect as necessary.Check (reseat) the cable between the servo amplifier and the Emergency Stop Control Board.
Figure 12–8Figure 12–9.
2. Turn the controller power off for fifteen second and then turn it on again. See Procedure 4–1 . If thealarm is still present, continue troubleshooting.
3. Replace the servo amplifier.
If error still exists replace the cable between the Emergency Stop Control Board and the servoIf error still exists re lace the cable between the Emergency Sto Control Board and the servoamplifier.
If error still exists replace the cable between the Emergency Stop Control Board (JRV1) and theIf error still exists re lace the cable between the Emergency Sto Control Board (JRV1) and themain CPU.
If error still exists replace the Emergency Stop Control BoardIf error s till exists replace the Emergency Stop Control Board.
If error still exists replace the main CPU.
4.6.25 SRVO-042ER_SVAL2MCAL Alarm(Group:i Axis:j)
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4. TROUBLESHOOTING
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The regenerative energy produced by the motor exceeded thespecifications.
NOTE The amplifier supplies the energy (velocity energy) to the motorwhen the axis (without gravity) moves at the acceleration and constantspeed. When the axis moves at the deceleration and constant speed andwith gravity (gravity energy), the motor supplies this energy (velocityenergy plus gravity energy) to the amplifier.
This energy from the motor to the amplifier is the regenerative energy.The amplifier discharges this energy by converting this energy to heatenergy through the discharge resistor. If the charged energy exceeds thedischarged energy, this alarm occurs.
Remedy: Check the LED on the amplifier, then perform the followingtroubleshooting procedure.
Table 4–25. SRVO-043 Troubleshooting Procedure
Troubleshooting Procedure Print Reference
1. Is “4” or “5” indicated on the servo amplifier 7-segment display?
If 4 is indicated go to Step 2.
Figure 12–1Figure 12–3
If 4 is indicated go to Ste 2.
If 5 is indicated go to Step 3.
If no number is indicated check the cables between the servo amplifier and Emergency StopControl Board Verify the correct switch 3 and 4 setting (see Figure 4 5)Control Board. Verify the correct switch 3 and 4 setting (see Figure 4–5).
If the error still exists replace the servo amplifier.
If the error still exists replace the cable between the servo amplifier and the Emergency StopIf the error still exists re lace the cable between the servo am lifier and the Emergency StoControl Board.
If the error still exists replace the ribbon cable (JRV1) between the main CPU and EmergencyStop Control Board.Sto Control Board.
If the error still exists replace the Emergency Stop Control Board.
If the error still exists replace the main CPU.
2. A “4” is indicated (DCSW alarm) when the regenerative transistor is on continuously for one secondor longer. See Figure 4–6. Reduce the load of the robot.If error still exists replace the servo amplifier.
3. A “5” is indicated (DCOH alarm). See Figure 4–6. The DCOH alarm is caused when theregenerative resistor overheats and is sensed by the thermostat or the thermostat in transformerTF1 opensTF1 opens.
If the average regenerative energy is excessive This alarm occurs when theacceleration/deceleration frequency is high or gravity energy at the axis is large. Relax the operatingacceleration/deceleration frequency is high or gravity energy at the axis is large. Relax the o eratingconditions.
For robots with extended axes or if the thermostat is incorrectl y wired or is defective When aFor robots with extended axes or if the thermostat is incorrectly wired or is defective When aseparate regenerative discharge unit or power transformer for the servo controller is used, check thewiring for the thermostat according to the connection diagrams for proper wiring.
4.6.26 SRVO-043ER_SVAL2DCAL Alarm(Group:i Axis:j)
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4. TROUBLESHOOTING
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Figure 4–5. Switch 3 and 4 Settings
SWITCH 3 AND 4 SETTINGS The setting varies depending on the regenerative discharge resistance used. If the setting is incorrect, theregenerative discharge control circuit failure alarm (DCSW) cannot be detected. Normal setting for switches 3 and 4 are ON.
3 4
3 4
3 4
Regenerative Discharge Resistor
Regenerative Discharge Resistor
Regenerative Discharge Resistor
SVU1 (12, 20)
SVU1 (130)
ON ON
ON OFF
OFF OFF
Built-in
Separate A06B-6089-H510
Separate A06B-6089-H500
SVU1 (40, 80), SVU2 /
ON ON
OFF OFF
ON OFF
ON ON
OFF OFF
ON OFF
Built-in
Built-in
Separate A06B–6089-H500
Separate A06B-6089 H713(800W), A06B-6089-H714(1200W)
The short-time regenerative discharge energy is too high.
The regenerative discharge circuit is abnormal.
The average regenerative discharge energy is too high (too frequent acceleration/deceleration).
The transformer overheats.
4
5
This alarm occurs if:
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4. TROUBLESHOOTING
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The DC voltage on the main power circuit of the servo amplifier exceededspecification. HVAL (High Voltage Alarm)
Remedy: Check the three-phase voltage to the servo amplifier input. Itshould not exceed 253 VAC phase-to-phase.
If the problem still exists, perform the following troubleshootingprocedure:
Table 4–26. SRVO-044 Troubleshooting Procedure
Troubleshooting Procedure Print Reference
1. Is the voltage of the three-phase input servo to the amplifier higher than 253 VAC?
If the voltage than 253 VAC check multi-tap transformer TF1 taps.
If it is within limits 200 to 240 VAC continue troubleshooting.
Figure 12–3
2. Is the load of the robot within the specification? This alarm can be caused by the charge of theregenerative energy when the load exceeds the specification.
If it exceeds the specification reduce the load of the robot.
If the specification is not exceeded continue troubleshooting.
3. Replace the servo amplifier.
If the error still exists replace the cable between the Emergency Stop Control Board andIf the error st ill exists replace the cable between the Emergency Stop Control Board andthe servo amplifier.
If error still exists replace the cable (JRV1) between the Emergency Stop Control Boardand the main CPUand the main CPU.
If error still exists replace the Emergency Stop Control Board.If error still exists re lace the Emergency Sto Control Board.
The current in the main power circuit of the servo amplifier exceededspecification. The servo amplifier LED should display “8”, “9”, “6”, “8.”,“9.”, or “6.”.
Remedy: If no alarm is indicated on the servo amplifier 7-segmentdisplay, check the cabling between the servo amplifier (JS1B or JS2B) andthe Emergency Stop Control Printed Circuit Board (JS1-6).
If the problem still exists, perform the following troubleshootingprocedure:
Table 4–27. SRVO-045 Troubleshooting Procedure
Troubleshooting Procedure Print Reference
1. Disconnect the motor power lines from the amplifier terminals and turn on the power. This alarmwill re-occur if the servo amplifier is defective.
If an HCAL (High Current Alarm) alarm occurs replace the servo amplifier.
If an HCAL alarm does not occur continue troubleshooting.
2. Remove the motor power lines from the amplifier terminals and check the continuity between GNDand each of the lines U, V, and W that go to the motor.
If any are short-circuited go to Step 3.
If all are not shorted go to Step 4.
3. Remove the power lines from the motor connectors (J1-6) and re-check the continuity betweenGND and each of the lines U, V, and W to the robot motor.
If any lines are shorted, the motor is defective replace the motor.
If all lines are open the power lines to the motor are defective replace the line that wasshorted to GND.
4. Remove the motor power lines from the amplifier terminals and measure the resistancebetween U-V, V-W, and W-U on the servo amplifier using a measuring instrument sensitiveenough to detect small resistances.
If the three measured values are the same go to Step 5.
If the three measured values are different go to Step 6.
5. Remove the power lines from the motor connectors and remeasure the resistance between U-V, V-W, and W-U using a measuring instrument sensitive enough to detect small resistances.
If the three measured values are the same the power lines are defective. Replace thepower lines.
If the three measured values are different the motor is defective replace the motor. Goto Step 7.
6. Replace the servo amplifier. Continue troubleshooting.
7. Check whether you are using the robot under conditions that exceed the specification. Forexample, load, duty, and so forth. If there is no mechanical reason (binding and so forth) to causethis alarm this alarm might occur under conditions that exceed the specification If you are usingthis alarm, this alarm might occur under conditions that exceed the specification. If you are usingthe robot over the specification, relax the operating conditions.
If the error still exists replace the cable between the servo amplifier and the EmergencyIf the error s till exists replace the cable between the servo amplifier and the EmergencyStop Control Board.
If the error still exists replace the cable between the Emergency Stop Control Board (JRV1)If the error still exists replace the cable between the Emergency Stop Control Board (JRV1)and the main CPU.
If the error still exists replace the Emergency Stop Control BoardIf the error still exists replace the Emergency Stop Control Board.
The average current calculated by the servo software exceededspecification. OVC (Over Current Alarm).
This is caused by excessive load or by a collision with an axis hard stop oran object in the robot work envelope.
The DC voltage on the main power circuit of the servo amplifier is lowerthan specification. LVAL (Low Voltage Alarm)
Remedy: If no alarm is indicated on the servo amplifier LED, check thecabling between the servo amplifier and the Emergency Stop ControlBoard.
If the problem still exists, perform the following troubleshootingprocedure:
Table 4–28. SRVO-047 Troubleshooting Procedure
Troubleshooting Procedure Print Reference
1. Does the LED of the amplifier indicate “2” ? Check the three-phase input voltage to the amplifier.
If the LED indicates a “2” the voltage is lower than the recommended specification. Thephase-to-phase input voltage at the servo amplifier terminals should measure at least 170VACbetween each phase
Check for 200 to 240 VAC input power to terminals 13 and 14 of the servo amplifier. If it is low ormissing, check multi-tap transformer TF1 taps, fuses, and Magnetic Control Contactor (MCC).
If the alarm occurs again replace the servo amplifier. Go to Step 4.
Figure 12–1Figure 12–3
2. Does the LED of the amplifier indicate “3” ? This indicates the DC current in the main power circuit is too low.
Check the three-phase 200 to 240 VAC input voltage to the amplifier.
If the voltage is lower than 170VAC the three-phase input voltage needs to be adjusted to withinthe FANUC specifications. Check the multi-tap transformer TF1 taps and fuses.
3. Did the circuit breaker on the servo amplifier trip? (If a circuit breaker trips, this alarm will occurincidentally.)
If a circuit breaker trips turn on the breaker. If it trips again, replace the servo amplifier.Continue troubleshooting.
4. Does the LED of the amplifier indicate a “7”? This alarm could occur when the contact of the magnetic contactor (MCC) is melted (welded together).
Refer to the SRVO-042 MCAL alarm. See Section 4.6.25.
5. If the servo amplifier has been replaced and the error still exists; replace the cable between theservo amplifier and the Emergency Stop Control Board.servo am lifier and the Emergency Sto Control Board.
If error still exists replace the cable between the Emergency Stop Control Board (JRV1) and themain CPUmain CPU.
If error still exists replace the Emergency Stop Control Board.If error still exists re lace the Emergency Sto Control Board.
If error still exists replace the main CPU.
4.6.29 SRVO-046ER_SVAL2OVC Alarm(Group:i Axis:j)
4.6.30 SRVO-047ER_SVAL2LVAL Alarm(Group:i Axis:j)
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The servo amplifier or transformer is overheated. OHAL1 (Over HeatAlarm 1)
Remedy: Check the fans and the heat exchange unit for proper operation.
If the problem still exists, perform the following troubleshootingprocedure:
Table 4–29. SRVO-049 Troubleshooting Procedure
Troubleshooting Procedure Print Reference
1. Relax the operating condition (duty cycle).
If the alarm no longer occurs the operating condition of the robot exceeded the specification.
Figure 12–8Figure 12–15g g
If the alarm still occurs replace the servo amplifier
If no alarm is indicated on the servo am plifier 7-se gment dis play check the cabling betweenIf no alarm is indicated on the servo amplifier 7-segment display check the cabling betweenthe servo amplifier and the Emergency Stop Control Board. If the cabling is not bad, continuetroubleshooting.
2. Replace the cable between the Emergency Stop Control Board (JRV1) and the main CPU.
If the alarm still occurs replace the Emergency Stop Control Board.
If the alarm still occurs replace the main CPU.
The servo software detected a disturbance torque that was too high or acollision occurred and tripped a collision detection alarm. CLALM(Collision Alarm)
Remedy: Reset the robot by using the teach pendant reset and jog therobot away from obstructions.
If the problem still exists, perform the following troubleshootingprocedure:
Table 4–30. SRVO-050 Troubleshooting Procedure
Troubleshooting Procedure Print Reference
1. Does the load exceed the specifications? (When the robot moves over the specifications, theestimated disturbance torque might become larger and this alarm could occur.)
If the load exceeds the specifications lower the load to within the specifications.
If the load does not exceed the specifications continue troubleshooting.
Figure 12–1Figure 12–3
2. Is the three-phase AC input voltage to the servo amplifier lower than 170VAC phase-to-phase(O-V, V-W, U-W).
If the voltage is lower than 170VAC increase the input voltage to within the specifications.Check multi-tap transformer TF1 taps and fuses.
If the voltage is not lower than 170VAC continue troubleshooting.
3. Check the continuity of the motor power wires (from the servo amplifier to the motor).
If the motor power wires are defective replace as required.
If after the motor power wires have been replaced and the problem still exists replace themain CPU.
The battery voltage for the serial pulse coders is zero volts. BZAL(Battery Zero Alarm).
Table 4–33. SRVO-062 Troubleshooting Procedure
Troubleshooting Procedure Print Reference
1. Did a SRVO-068 DTERR, or SRVO-069 CRCERR, or a SRVO-070 STBERR occur with thisalarm?
If YES disregard the BZAL alarm and refer to the procedure for the other alarm(SRVO-68 - SRVO-70).
If NO continue troubleshooting.
2. Did this alarm message list only one axis?
If YES check the battery cable for the serial pulse coder of the axis listed in the alarm message.Reconnect, or replace as necessary. Go to Step 4.
If NO continue troubleshooting.
3. Press the teach pendant emergency stop button. Turn the controller on. Check the pulse coderbatteries for 6 VDC at the battery terminals on the battery box in the door of the controller.
Do the batteries read 6 VDC ?Do the batteries read 6 VDC ?If YES replace the battery compartment cable. Go to Step 4.
If NO replace the batteries. Continue troubleshooting.
4. Perform serial pulse coder reset procedure under SRVO-038 alarm.
5. Turn the controller off and then back on.
6. It might be necessary to perform the SRVO-038 procedure again.If alarm still exists on only one axis Replace the serial pulse coder (after verifying batterycable is good) .
4.6.37 SRVO-062ER_SVAL2BZAL Alarm(Group:i Axis:j)
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4. TROUBLESHOOTING
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The built-in rotation counter on the serial pulse coder is abnormal.RCAL (Revolution Clock Alarm).
Table 4–34. SRVO-063 Troubleshooting Procedure
Troubleshooting Procedure Print Reference
1. Did a SRVO-068 DTERR, or SRVO-069 CRCERR, or a SRVO-070 STBERR occur with thisalarm?
If YES disregard SRVO_063 and refer to the remedy of any of the other three alarms.
If NO replace the serial pulse coder on the specified axis and master the robot. See Chapter 8.
The relationship between the analog signals on the serial pulse coder areabnormal. PHAL (Phase Alarm).
Table 4–35. SRVO-064 Troubleshooting Procedure
Troubleshooting Procedure Print Reference
1. Did a SRVO-068 DTERR, or SRVO-069 CRCERR, or a SRVO-070 STBERR occur with thisalarm?
If YES disregard SRVO_064 and refer to the remedy of any of the other three alarms.
If NO replace the serial pulse coder on the specified axis and master the robot. See Chapter 8.
The serial pulse coder batteries are low. BLAL (Battery Low Alarm).
Table 4–36. SRVO-065 Troubleshooting Procedure
Troubleshooting Procedure Print Reference
1. Did a SRVO-068 DTERR, or SRVO-069 CRCERR, or a SRVO-070 STBERR occur with thisalarm?
If YES disregard SPC_065 and refer to the remedy of any of the other three alarms.
If NO replace the SPC backup batteries with controller power on.
NOTE: Replace the battery as soon as possible when this alarm occurs, otherwise, if the batteryvoltage goes to zero volts, the robot will require remastering.
4.6.38 SRVO-063ER_SVAL2RCAL Alarm(Group:i Axis:j)
4.6.39 SRVO-064ER_SVAL2PHAL Alarm(Group:i Axis:j)
4.6.40 SRVO-065ER_WARN BLAL Alarm(Group:i Axis:j)
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4. TROUBLESHOOTING
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The serial pulse coder ROM checksum data are abnormal. CSAL (CheckSum Alarm).
Table 4–37. SRVO-066 Troubleshooting Procedure
Troubleshooting Procedure Print Reference
1. Did a SRVO-068 DTERR, or SRVO-069 CRCERR, or a SRVO-070 STBERR occur with thisalarm?
If YES disregard SRVO_066 and refer to the remedy of any of the other three alarms.
If No alarms occur replace the serial pulse coder on the specified axis and master the robot.See Chapter 8.
The serial pulse coder overheated. OHAL2 (Over Heat Alarm).
Table 4–38. SRVO-067 Troubleshooting Procedure
Troubleshooting Procedure Print Reference
1. Did a SRVO-068 DTERR, or SRVO-069 CRCERR, or a SRVO-070 STBERR occur with thisalarm?
If YES disregard SRVO-067 and refer to the remedy of any of the other three alarms.
If NO continue troubleshooting.
2. Does the operating condition (load, duty) exceed the specifications?
If the operating condition exceeds the specifications relax the operating condition within thespecification. (Reduce the load, change the program).
If it operating conditions does not exceed the specifications continue troubleshooting.
3. Turn off the controller and when the temperature of the motor returns to normal, turn it back on.
If the alarm immediately occurs again the built-in thermostat in the serial pulse coder isdefective. Replace the serial pulse coder.
If the alarm occurs again, but not immediately the motor is generating too much heat. Replacethe motor.
The main CPU sent the serial data request signal to the serial pulse coder,but did not receive serial data from the serial pulse coder.
In order to troubleshoot the 24V to 5V converter, it will be necessary tooperate the power supply with the covers removed from the robot. Thefollowing procedure is necessary to insure the proper pre-test conditionsare met.
WARNINGThe robot is designed to operate in a hazardous location.The covers are an integral part of the protection thereforeall of the steps listed below must be followed EXACTLYAND IN THE ORDER PRESENTED. These steps must betaken IN ADDITION TO NORMAL SAFETY PRECAUTIONS.Failure to follow these procedures could result in anexplosion.
1 Consult your plant procedures to insure the area around the robot isKNOWN to be NON HAZARDOUS. Typically this will include thebooth in which the robot is located.
2 Take steps to insure the area around the robot will REMAIN NONHAZARDOUS for the duration of the test procedure and until thecovers are replaced on the robot.
3 Install a TEMPORARY jumper between terminals ISTB 1 and ISTB 4.
4 Install a TEMPORARY jumper from terminals ISTB 5 to ISTB 8.
5 Shut off the air supply to the robot.
6 If the above procedure causes a loss of controller power, press thepurge enable pushbutton and wait 5 minutes. When the PURGECOMPLETE light comes on, the controller can be turned on.
7 After you complete Steps 1-6 remove the covers on the robot and withthe controller powered ON, perform the required troubleshooting.
8 After the troubleshooting is complete, replace the covers tightly.
9 Turn on the air supply to the robot.
10 Turn off the controller and open the disconnect switch.
11 Remove both temporary jumpers and insure the connections to theISTB are correct.
WARNINGDO NOT TAMPER WITH THE SETTING of the purge timer;otherwise, you could cause an explosion.
WARNINGFor continued safety, the temporary jumpers must beremoved; otherwise, you could cause an explosion.
12 Close the main disconnect to the controller.
13 Press the PURGE ENABLE pushbutton. Hold the pushbutton until itlights (approximately 10 seconds). This indicates adequate purge airflow. If the pushbutton does not light, purge air flow is not adequateand the robot should be checked for leaks.
14 After the PURGE COMPLETE light comes on, the controller can beturned back on. The controller can not be turned on before the purgecomplete light comes on.
Table 4–39. SRVO-068 Troubleshooting Procedure
Troubleshooting Procedure Print Reference
1. If an individual axes has failed, check for connection and continuity of the serial pulse coder cable.Replace if necessary.
If all axes indicate failure or if the alarm occurs again continue troubleshooting.
2. Check the 24V and 6.5 V LEDs on Module Assembly EE-3044-401 located in the purge cavity.See Steps 1 through 14 and Warnings of SRVO-068 and Figure 4-7.
If the 24V LED is not illuminated check the wiring between the Module Assembly EE-3044-401and the 24V power supply in the controller.
If the 24V LED is illuminated and 6.5V LED is not illuminated disconnect CONN1 throughCONN7 on Module Assy EE-3044-401. If 6.5V LED illuminates, check for shorted Cable. If 6.5Vdoes not illuminate, replace the Module Assembly EE-3044-401.
If the 24V LED is illuminated and 6.5 LED is illuminated continue troubleshooting.
3. Replace the main CPU.
If the alarm occurs again continue troubleshooting.
4. Replace the serial pulse coder.
Figure 4–7. Module Assembly # EE-3044-401
DC/DC MODULECR1
MODULE ASSY #EE-3044-401
24V 6.5V
LEDs
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4. TROUBLESHOOTING
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The serial data from the serial pulse coder changed during communicationto the main Central Processor Unit. CRCERR (Cyclical RedundancyCheck Error).
This fault is frequently caused by electrical noise induced on the serialpulse coder cable. Make sure that the cable does not lie parallel or close topower cables. Make sure that the robot-mounted relays and solenoids havespark suppression diodes. Check all pulsecoder cable shield groundspoints.
Make sure that all cable connections are properly connected.
Only as a last resort should the cable or a serial pulse coder be replaced.
The communication stop and start bits are abnormal. STBERR (Stop BitError).
Refer to the SRVO-068 remedy.
The feedback velocity exceeds the specifications. SPHAL (SoftwarePhase Alarm).
If the problem still exists, perform the following troubleshootingprocedure:
Table 4–40. SRVO-071 Troubleshooting Procedure
Troubleshooting Procedure Print Reference
1. Does this alarm occur with any other alarm?
If another alarm occurs this alarm is caused by the previous alarm of the serial serial pulsed R f t th th l f d t il
ycoder. Refer to the other alarm for details.
If another alarm does not occur replace the serial pulse coder.
If this alarm occurs along with a SRVO-068 DTERR, SRVO-069 CRCERR, or SRVO-070STBERR disregard this alarm and refer to the other three alarm remedies.
If this alarm does not occur along with a SRVO-068 DTERR, SRVO-069 CRCERR, orSRVO-070 STBERR continue troubleshooting.
2. Replace the serial pulse coder and master the robot. See Chapter 8 Mastering.
Incorrect position data detected in the serial pulse coder, or abnormal serialpulse coder data caused by noise.
Table 4–42. SRVO-071 Troubleshooting Procedure
Troubleshooting Procedure Print Reference
1. If this alarm occurs along with a SRVO-068 DTERR, SRVO-069 CRCERR, or SRVO-070 STBERR, disregard this alarm and refer to the other three alarm remedies. If theSRVO-068 DTERR, SRVO-069 CRCERR, or SRVO-070 STBERR, does not occur with this alarm,continue troubleshooting.
2. Master the robot. See Chapter 8 then continue troubleshooting.
3. Check the grounding of the serial pulse coder cable shield.
If the serial pulse coder cable shield is grounded go to step 4.
If the serial pulse coder cable shield is not grounded ground the shield or replace the cable.
4. Replace the serial pulse coder and master the robot. See Chapter 8, “Mastering”.
The Serial pulse coder failure.
Table 4–43. SRVO-071 Troubleshooting Procedure
Troubleshooting Procedure Print Reference
1. If this alarm occurs along with a SRVO-068 DTERR, SRVO-069 CRCERR, or SRVO-070 STBERR, disregard this alarm and refer to the other three alarm remedies. Otherwise,continue troubleshooting.
2. Replace the serial pulse code and master the robot. See Chapter 8, “Mastering”.
The feedback velocity exceeds the specification for line tracking axis.
Remedy: Refer to SRVO-071 remedy.
The back-up charge circuit for the amplifier has an abnormal voltage. Thiserror code can also be caused by improper controller shut down sequence(See Procedure 10–5 ) or improper servo lockout procedure (SeeProcedure 10–6 ).
Remedy: Check the cables and connections between amplifier (CN1) andMCC. Check the fuse (F1,F2) in transformer. Replace the amplifier.
The DSM (Digital Servo Module) hardware does not all match.
Remedy: Remove the main Central Processor Unit from the controllerand check the part numbers on the DSM boards mounted in the axismodule slots. The part numbers should be the same. If the robot has morethan six axes, also check the multifunction board DSM hardware. AllDSM hardware must have the same part number to prevent this alarm.(See Figure 1–7 and Table 1–1).
The current servo parameters do not match the DSM hardware installed.
Remedy: Replace all DSP-IV DSM modules with DSP-V type. (See Figure 1–7 and Table 1–1).
The panel emergency stop button is pressed and the controller detected awiring error on SVON or EMGIN terminals.
Remedy: Turn off the controller and check EMGIN and SVON wiring tooperator panel interface terminals. Correct external wiring as necessary.
The teach pendant emergency stop button is pressed and the controllerdetected a wiring error on SVON or EMGIN terminals.
Remedy: Turn of the controller and check EMGIN and SVON wiring tooperator panel interface terminals. Correct external wiring as necessary.
The teach pendant DEADMAN was released and the controller detected awiring error on SVON or EMGIN.
Remedy: Turn off the controller and check EMGIN and SVON wiring tooperator panel interface terminals. Correct external wiring as necessary.
The external emergency stop or external SVON switch is pressed and thecontroller detected a wiring error on the SVON or EMGIN terminals.
Remedy: This error is applicable is the redundant external emergencystop or SVON wiring is used. If so, turn off the controller and check theEMGIN and SVON wiring to the operator panel interface terminals.Correct external wiring as necessary.
A Class 4 Fault occurs when the process equipment within the outer armof the P-200 robot fails to perform correctly. This section containstroubleshooting procedures for each kind of malfunction.
Trigger Valve Malfunctions and Troubleshooting
Gun(s) that do not turn on (Trigger) or work intermittently. Refer toProcedure 4–5 .
Gun(s) that do not shut off Refer to Procedure 4–6
Current to Pressure Transducer Troubleshooting Refer to Section 4.7.4
Poor Film Build (Too heavy or light)
Repeated “Adapted Out Of Range” messages
Need for continual Preset corrections
Transducer Troubleshooting Procedure. Refer to Procedure 4–8 .
Flow Meter Troubleshooting Procedure. Refer to Procedure 4–9 .
P-200 end of arm troubleshooting error descriptions
Error #178, Cal. Timeout at maximum flow
Error #179, Cal. Timeout at low flow
Error #183, Min. output has flow > setpoint
Error # 189, Failed to reach setpoint
Display reads 0 cc/min when paint is actually flowing from the gun.
Display reads the exact same cc/min value whether paint is flowing ornot.
Depending on the manufacturer, style and/or type of gun assembly used,these malfunctions could be attributed to a single gun assembly when twoguns are mounted on a common manifold having a common supply pilotsignal. In this case, the problem would be in the individual gun assembly;the gun assembly would be suspected first and replaced before lookinginto the supply.
4.7CLASS 4 FAULTS
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4. TROUBLESHOOTING
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Remedy: There is no clear cut remedy for this type of malfunction.
Considerations: This function is electrical and pneumatic in operation.Procedure 4–5 first considers the most common causes which may bepneumatic in nature, then , if the problem still exists, will continuetroubleshooting the electrical components.
Procedure 4–5 Both Guns Do Not Trigger or Work Intermittently
Perform the following troubleshooting steps.
1 Shut off the plant supplied air to the pilot trigger valve.
2 Remove the output pilot line from the pilot trigger valve.
3 Apply plant supplied air to the pilot trigger valve.
4 Push the mechanical override button on the valve body. Refer to theTrigger Valve/ Regulator Assembly in Figure 12–32.
5 Determine whether pilot air is coming out of the pilot trigger valve.
If NO > Remove and replace pilot trigger valve.If YES > Go to step 6.
WARNINGThis valve is intrinsically safe. Repair of the solenoid andpilot section is prohibited. If the solenoid portion is faulty,you must replace the solenoid and pilot section as oneassembly. They are assembled as a matched set andshould not be exchanged with other components.
6 Is pilot air sufficient and constant with plant supplied air pressure?Refer to gun manufacture’s specification.
If NO > Go to step 7.If YES > Troubleshoot pilot trigger line to gun assembly. Refer to the Trigger Valve/ Regulator Assembly in Figure 12–32.
If problem still exists , Go to step 8.
7 Is the air supply to the system sufficient and consistent with plantsupplied air pressure?
If NO > Troubleshoot air supply.If YES > Remove and replace pilot trigger valve. Is problem solved.If NO > Go to step 9.
4.7.1 Process Fault - BothGuns Do Not Trigger orWork Intermittently
Step
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4. TROUBLESHOOTING
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WARNINGThis valve is intrinsically safe. Repair of the solenoid andpilot section is prohibited. If the solenoid portion is faulty,you must replace the solenoid and pilot section as oneassembly. They are assembled as a matched set andshould not be exchanged with other components.
8 Troubleshoot the paint spray gun assembly. Determine whether theproblem is solved.If NO > go to step 9.
9 Continue troubleshooting with Procedure 4–7 .
Remedy: There is no clear cut remedy for this type of malfunction.
Considerations: This function is electrical and pneumatic in operation.Procedure 4–6 first considers the most common causes which may bepneumatic in nature, then , if the problem still exists will continuetroubleshooting the electrical components.
Procedure 4–6 Both Guns Will Not Shut Off
Perform the following troubleshooting steps.
1 Shut off the air supply to the pilot trigger valve. Refer to the Trigger Valve/ Regulator Assembly in Figure 12–32.
2 Remove the output pilot line from the pilot trigger valve.
3 Apply air supply to the pilot trigger valve.
4 Is air leaking from valve output port? Refer to the Trigger Valve/Regulator Assembly in Figure 12–32.
If NO > troubleshoot trigger (s) in gun assembly.If YES > Go to step 5.
5 Check for 12Vdc on solenoid/pilot trigger valve. Refer to the TriggerValve/ Regulator Assembly in Figure 12–32.
WARNINGThis valve is intrinsically safe. Repair of the solenoid andpilot section is prohibited. If the solenoid portion is faulty,you must replace the solenoid and pilot section as oneassembly. They are assembled as a matched set andshould not be exchanged with other components.
If NO > Remove and replace pilot trigger valve. If YES > Go to Procedure 4–7 .
4.7.2 Both Guns Will NotShut Off
Step
4–66
4. TROUBLESHOOTING
MARO2P10203703E
Use Procedure 4–7 to troubleshoot the electrical paint gun triggercomponents.
# SIM STATUS 145/256DO[ 140] U OFF [ Reserved ]DO[ 141] U OFF [ Reserved ]DO[ 142] U OFF [ Reserved ]DO[ 143] U OFF [ Reserved ]DO[ 144] U OFF [ Reserved ]DO[ 145] U OFF [ Gun 1 pilot ]DO[ 146] U OFF [ ]DO[ 147] U OFF [ ]DO[ 148] U OFF [ ]DO[ 149] U OFF [ ]
[ TYPE ] CONFIG IN/OUT ON OFF
I/O Digital Out G2 JOINT 100%
OFF
2 Reconfigure using Site I/O program, then go to step 3.
3 Is DOUT [145] (PT) ON ?
If NO > Go to step 4.If YES > Go to step 5.
4 Set DOUT [145] (PT) to ON. Refer to Procedure 7–1 .Is output led (AO) on the output module ON? Refer to Figure 4–8.
5 Is DOUT [145] (PT) simulated. Refer to Procedure 7–2 .
If YES > Go to step 6If NO > Go to step 7.
6 Unsimulate DOUT [145] (PT).Go to step 3.
4–68
4. TROUBLESHOOTING
MARO2P10203703E
7 Determine whether the interface module power LED (PWR) is on?Refer to Figure 4–9.
If NO > Go to step 8.If YES > Go to step 10.
Figure 4–9. Interface Module PWR LED
JD1B JD1A
CP32 JD2
PWR LINK
BAO
BAI
AIF0IA
INTERFACE MODULE
PWR LED
LINK LED
4–69
4. TROUBLESHOOTING
MARO2P10203703E
8 Determine whether the 24V input fuse is good? Refer to Figure 4–10.
If NO > Replace 24VDC input fuses.If YES > Go to step 9.
Figure 4–10. Interface Module
InterfacemoduleAIFO1A
Fuse
3.2A
3.2AInput
Fuse5.0AOutput
5.0AF2
F1
4–70
4. TROUBLESHOOTING
MARO2P10203703E
9 Determine whether 24E at input connector (CP32) to I/F (InterfaceModule)? Refer to Figure 4–11.
If NO > Troubleshoot the 24E circuit and wiring.If YES > Replace I/F module.
Figure 4–11. Pin Out and Locator for Connector CP32
MODULAR I/O5–SLOT BASE UNIT A03B–0807–J002
MODULAR I/OINTERFACE
MODULEA03B–0807–J011
CP32
JD1B
JD1A
JD2
MODULAR I/O
POWER SUPPLYA16B–1212–0870
MAIN CPUA16B–3200–0040
CP6
JD1A
123
+24V0V
CP32
I/O UNIT MODEL A
10–SLOT BASE UNIT A03B–0807–J001
10 Determine whether the interface module Link LED is ON? Refer to Figure 4–12.
If NO > Go to step 11.If YES > Replace output module, AOD16D.
Figure 4–12. Interface Module PWR LED
JD1B JD1A
CP32 JD2
PWR LINK
BAO
BAI
AIF0IA
INTERFACE MODULE
LINK LED
4–71
4. TROUBLESHOOTING
MARO2P10203703E
11 Is output fuse good? Refer to Figure 4–10.
If No > Replace output fuse.If YES > Replace interface module.
12 Replace output module, AOD16D.
13 Is there 24Vdc at ISB7 input terminals 7 and 8? Refer to Figure 4–13
If NO > Go to step 14.If YES > Go to step 15.
Figure 4–13. Intrinsic Safety Barrier
8
7
1
2
ISB7
ISB7-1
ISB7-2
P1
I.S. GROUND
EE-3287-328-001
INTRINSIC CABLEEE-3287-117-XXX
LOCATED IN P-200 ROBOT ARM
8663SOL
GRNWHT
DC OUTPUT MODULE
8336F.5 AMP
2
14 Is wiring from the output module to ISB7 okay? Refer to Figure 4–13.
If NO > Repair wiring.If YES > Go to step 16.
15 Is fuse 8336F/0.5A blown? Refer to Figure 4–13.
If NO > Replace output module, AOD16D.If YES > Replace 8336F 0.5A Fuse.
4–72
4. TROUBLESHOOTING
MARO2P10203703E
16 Is 12Vdc at ISB7 output terminals 1 and 2 correct. Refer toFigure 4–14.
WARNINGNever apply test leads to output terminals during paintbooth operations. To do so could injure personnel ordamage equipment. Remove ISB7 output terminals 1 and 2before any voltage measurements are taken.
If NO > Replace Intrinsic Safety BarrierIf YES > Go to step 17.
Figure 4–14. Intrinsic Safety Barrier
8
7
1
2
ISB7
ISB7-1
ISB7-2
P1
I.S. GROUND
EE-3287-328-001
INTRINSIC CABLEEE-3287-117-XXX
LOCATED IN P-200 ROBOT ARM
8663SOL
GRNWHT
DC OUTPUT MODULE
8336F.5 AMP
2
17 Is 12Vdc at pilot trigger valve connector? Refer to Trigger Valve/Regulator Assembly Figure 12–32.
If NO > Check the cables and connector.If YES > Replace the 8336SOL valve assembly.
WARNINGThe 8336SOL valve is intrinsically safe. Repair of thesolenoid and pilot section is prohibited. If the solenoidportion is faulty, you must replace the solenoid and pilotsection as one assembly. They are assembled as amatched set and should not be exchanged with othercomponents.
4–73
4. TROUBLESHOOTING
MARO2P10203703E
Use Procedure 4–8 to cover:
Poor Film Build (Too heavy or light)
Repeated “Adapted Out Of Range” Messages
Need for Continual Preset Corrections
Remedy: There is no clear remedy for these types of symptoms. It mightbe caused by a faulty current to pressure transducer (I/P) or a faulty flowmeter.
Considerations: The current to pressure transducer is an electrical andpneumatic device that is intrinsically safe. The only troubleshooting thatcan be done to the transducer is covered in Procedure 4.7.4.
Procedure 4–8 Transducer Troubleshooting
1 Is AOUT[1] set to a count of 200?
If NO > Go to step 2.If YES > Go to step 3.
# SIM VALUE 1/25AO[ 1] U 200 [ Fluid Flow 1 ]AO[ 2] U 200 [ Atom. Air 1 ]AO[ 3] U 200 [ Fan Air 1 ]AO[ 4] U 200 [ Estats 1 ]DO[ 5] U 0 [ Flw setpoint ]DO[ 6] U 0 [ Flw diag out ]DO[ 7] * * [ ]DO[ 8] * * [ ]DO[ 9] * * [ ]DO[ 10] * * [ ]
[ TYPE ] CONFIG IN/OUT SIMULATE UNSIM
I/O Analog Out G1 JOINT 10%
U
2 Set AOUT[1] to a count of 200. Refer to Procedure 7.1.
3 Attach an analog 0 to 60 psi gauge to the gage port on the current topressure transducer. Refer to Trigger Valve/Regulator AssemblyFigure 12–32.
4 Set AOUT[1] to a count of 1000. Refer to Procedure 7.1.
5 Is there any output pressure?
If NO > Go to step 6.If YES > Go to step 12.
4.7.4 Process Fault -TransducerTroubleshootingProcedure
Step
4–74
4. TROUBLESHOOTING
MARO2P10203703E
6 Is the plant air supply ON?
If NO > Turn ON air supply.If YES > Go to step 7.
7 Is your paint system in the proper mode of operation? (Proper modeof operation will depend upon the unique characteristics of yoursystem).
If NO > Set paint mode to proper mode of operation.If YES > Go to step 8.
8 Is there 14.5 VDC at the current to pressure transducer I/P connectorP1 pins 1 and 6. Refer to Trigger Valve/ Regulator AssemblyFigure 12–32.
If NO > Go to step 9.If YES > Go to step 12.
WARNINGNever apply test leads to output terminals during paintbooth operations. Otherwise, you could injure personaland damage equipment.
9 Is there 14.5 Vdc at ISB4 terminals 1 and 2? Refer to Single StagePurge Process Control Figure 12–41.
If NO > Go to step 10.If YES > Go to step 11.
10 Is there 24Vdc at ISB4 input terminals 7 and 8? Refer to Single StagePurge Process Control Figure 12–41.
If NO > Check power supply and wiring.If YES > Replace ISB4.
11 Check the cable and connector wiring from ISB4 to I/P transducer P1.
12 Check for pressure leaks at pneumatic connections. This can beaccomplished using a soapy liquid solution.
If No > Tighten pneumatic connections.If YES. Go to step 13.
4–75
4. TROUBLESHOOTING
MARO2P10203703E
13 Perform calibration on the Current to Pressure Transducer I/P. Refer to Procedure 10.1.
Consider the following while doing the calibration procedure:
– Non-Linearity
– Hunting
– Poor Response
– No Reaction at Output
– Poor Hysteresis
– Poor Accuracy
– Poor Repeatability
– Inaccurate Span
14 Did the Current to Pressure Transducer (I/P) pass the calibration?
If NO > Go to step 15.If YES > Troubleshoot other process equipment.
15 Connect a mA meter in series with terminal 8 of the D/A module(ADA02A) in slot 3 of the I/O rack. Refer to Single Stage PurgeProcess Control Figure 12–41.
16 Set the AOUT[1] on the teach pendant to 600 counts
# SIM VALUE 1/25AO[ 1] U 600 [ Fluid Flow 1 ]AO[ 2] U 200 [ Atom. Air 1 ]AO[ 3] U 200 [ Fan Air 1 ]AO[ 4] U 200 [ Estats 1 ]DO[ 5] U 0 [ Flw setpoint ]DO[ 6] U 0 [ Flw diag out ]DO[ 7] * * [ ]DO[ 8] * * [ ]DO[ 9] * * [ ]DO[ 10] * * [ ]
[ TYPE ] CONFIG IN/OUT SIMULATE UNSIM
I/O Analog Out G1 JOINT 10%
U
17 Is there 12.00mA on the meter?
If NO > Go to step 18.If YES > Go to step 19
18 Is there 24 Vdc at ISB5 terminals 7 & 8? Refer to Single Stage PurgeProcess Control Figure 12–41.
If NO > Check source of 24 Vdc power.If YES > Go to step 22.
4–76
4. TROUBLESHOOTING
MARO2P10203703E
19 Connect mA meter in series with terminal 1 of ISB5.
20 Is there 12.00 mA on the meter?
If NO > Go to step 21.If YES > Replace I/P transducer.
21 Check the cable and wiring from the ISB5 to the I/P transducer. Is thewiring defective?
If NO > Replace the ISB5.If YES. Replace the wiring or cable.
22 Is AOUT[1] configured correctly?
If NO use Site I/O program. Refer to PaintTool Manual SetupChapter.IF YES > Go to step 23.
23 Is AOUT[1] Simulated? Refer to Procedure 7.2
If NO > Check cable/wiring from D/A module to IBS5, terminals 9 and 10.If YES > Unsimulate.
Remedy: There is no clear remedy for these types of symptoms. It may becaused by a faulty flow meter.
Considerations:The Flow Meter is a mechanical to electrical feedbacktransducer. The only troubleshooting that can be done to the transducer iscovered in Procedure 4–9 .
Procedure 4–9 Flow Meter Troubleshooting
1 Remove MODUFLOW/Flow Meter assembly from the P-200 robotarm. Refer to Figure 12–33.
2 Remove the Flow Meter from the MODUFLOW assembly.
3 Remove the electrical connector from the Flow Meter.
4 Blow air into the Flow Meter input port. Do the gears spin?
If NO > Disassemble, clean, and then reassemble the Flow Meter.Return to step 4.If gears do not spin after Flow Meter has been cleaned replace FlowMeter.If YES > Go to step 5.
4.7.5 Process Fault - FlowMeter TroubleshootingProcedure
Step
4–77
4. TROUBLESHOOTING
MARO2P10203703E
5 Reconnect the sensor cable.
6 Monitor GIN[8] and GIN[9] at the teach pendant from the I/O menu.
# SIM VALUE 1/25GI[ 1] S 0 [ Init data ]GI[ 2] S 0 [ Init type ]GI[ 3] U 0 [ CC cycsel ]GI[ 4] U 0 [ CC shared ]GI[ 5] U 0 [ CC group ]GI[ 6] U 0 [ Flw/tpar ]GI[ 7] U 0 [ Parm/indc ]GI[ 8] U 59147 [ Totl cnt ]GI[ 9] U 32767 [ Rate cnt ]GI[ 10] U 0 [ Job type ]
[ TYPE ] CONFIG IN/OUT SIMULATE UNSIM
I/O Group In JOINT 100%
U
7 Blow air into the Flow Meter input port. Did you see a change inGIN[8] and GIN[9]?
If NO > Go to step 8If YES > Go to step
8 Is GIN[8] & GIN[9] configured correctly?
If NO > Run Site I/O program Refer to PaintTool Setup Chapter.then > Go back to step 6.If YES > Go to step 9.
9 Is there 24 Vdc at the terminal block of the Flow Meter Interfacemodule, wires 82091 and 82092? Refer to schematics 47 A sheet 082and 087
If NO > Check wiring and CPU power supplyIf YES > Go to step 10.
10 Is there +5 Vdc at the terminal block of the Flow Meter Interfacemodule, wires 82142 and 82092? Refer to Figure 12–39 andFigure 12–42.
If NO > Go to step 11If YES > Go to step
11 Is fuse 8214F blown? Refer to Figure 12–43.
If NO > Go to step 12If YES > Replace fuse
4–78
4. TROUBLESHOOTING
MARO2P10203703E
12 Check connector and wiring at JD1A port of the I/F module. Refer toFigure 4–11.
If the wiring is damaged replace wiringIf the connector is damaged replace I/F moduleVerify for proper operation. If the problem still exists > Go to step 13.
13 Is there 24 Vdc at the terminal block of the Flow Meter Interfacemodule, wires 87091 and 87101? Refer to Figure 12–39 andFigure 12–42.
If No > Replace Flow Meter Interface module.If YES > Go to step 14.
14 Is there 24 Vdc at ISB6, terminals 7 and 8. Refer to Figure 12–42.
If NO > Replace wiringIf YES > Go to step 15.
15 Is there zero ohms at the terminal block of the Flow Meter Interfacemodule, -Sig. and wire 87101? Refer to Figure 12–42.
If NO > Tighten jumper connections or Replace jumper.If YES > Go to step 16.
16 Is there 24 Vdc at ISB6, terminals 1 and 2. Refer Figure 12–42.
If NO > Replace ISB6If YES > Go to step 17.
WARNINGNever apply test leads to these pins during paint boothoperations. Otherwise, you could injure personnel anddamage equipment.
17 Is there 24 Vdc at the Flow Meter connector P1, pins A and B. Referto Figure 12–42.
If NO > Replace wiringIf YES > Replace Flow Meter
18 Perform a Flow Test (Beakering Test). Refer to Procedure 10–2 .
4–79
4. TROUBLESHOOTING
MARO2P10203703E
19 Does the amount in the beaker equal the Total (cc) and Flow Ratecalled for?
If NO > Go to step 20.If YES > Troubleshooting completed.
STATUS AccuFlow JOINT 100 % AccuFlow Status Display Selected Operating Mode: Adaptive Current Operating Mode: Open Loop Color Valve Number: 1 Calibration Status: Complete Actual yield ((cc/min)/cnt): .78 Total (cc): 216 Set Point/Actual (cc/min): 600/594 Applicator Trigger: ON Set point reached: ON[ TYPE ] RES TOT HELP
20 Calculate new KFT factor and enter into the Equipment Characteristicsparameter section on the teach pendant.
cc in beakertotalizer
X * old KFT new KFT
4–80
4. TROUBLESHOOTING
MARO2P10203703E
AccuFlow Global Parameters 1/25
1 Mode selection source: Pendant2 Selected operating mode: Adaptive3 Percent Tolerance Band: 1.84 Min. tolerance band: 55 Sample amount: 36 Normal gain modifier (%): 95.07 Pulsing pump gain mod. (%): 70.0
10 Trigger delay (ms): 5011 Flow delay (ms): 3212 Time up (ms/1000 cnts): 72
Calibration parameters14 Hysteresis checks: YES15 Leveling trys: 216 Cal time out (sec): 1517 Cal step delay (ms): 80018 Table point no. 2 (cc/min): 200
Table adjustment parameters19 Flow in-tol trys: 220 Indep point shift band (%): 30.0
Alarm parameters21 Adaptive tolerance (%): 10.022 Max. error from setpoint (%): 6.023 Max. control out (ms): 20024 Min. set point reached (ms): 300025 Grace period (ms): 4000
[ TYPE ] CHAN KFT_CAL [CHOICE] HELP
SETUP AccuFlow JOINT 100 %
21 Preform a Flow Test (Beakering Test). Refer to Procedure 10–2
22 Does the amount in the beaker equal the Total (cc) and Flow Ratecalled for?
If NO > Replace Flow Meter Interface module. Verify problem issolved by rerunning the Flow Test if problem still exists ReplaceDigital 32 bit Input module (AID32B) in the I/O rack.If YES > Troubleshooting completed.
Page 81
5 REPLACING FUSES
5 REPLACING FUSES
5–1MARO2P10203703E
Topics In This Chapter Page
Fused Flange MountedDisconnect Fuses
The fused flange-mounted disconnect provides overcurrent protection supply through three fuses; one for each leg of the 3-phase supply. 5–2. . . . . . . . . . . . . . . .
Multi-Tap TransformerFuses
Five fuses reside on the multi-tap transformer with fuses F1, F2, and F3 for thethree-phase 200 VAC servo power and F4 and F5 for 100 VAC. 5–4. . . . . . . . . . . . .
Power Supply Unit Fuses Three fuses are located in the power supply unit F1 AC input, F3 and F4 +24V. 5–5
Servo Amplifier Fuses The servo amplifiers for the P-200 contain one fuse (F1), except for ModelA06B–6089–H106 which includes a second fuse (F2). 5–6. . . . . . . . . . . . . . . . . . . . .
Emergency Stop ControlPCB Fuses
Two fuses reside on the Emergency Stop Control printed circuit board. 5–7. . . . . . .
Purge Power SupplyFuses
Two fuses reside on the Purge Power Supply F11 and F12. 5–8. . . . . . . . . . . . . . . . .
One fuse resides on the Sub-CPU printed circuit board. 5–12. . . . . . . . . . . . . . . . . . . .
If a fuse blows in the controller, determine the cause, repair or replace thedefective part or unit and replace the fuse with the same type and rating.Fuse replacement procedures are provided for the following fuses in thecontroller
WARNINGBefore replacing a fuse, turn the power off and lock out thecontroller; otherwise, you could injure personnel ordamage equipment.
5–2
5. REPLACING FUSES
MARO2P10203703E
The controller is supplied with a fused flange-mounted disconnect.
The fused flange-mounted disconnect provides overcurrent protectionsupply through three fuses; one for each leg of the 3-phase supply. SeeFigure 5–1 for fused flange-mounted disconnect location and Table 5–1for description of the fuse flange-mounted disconnect and fuses.
The fused flange-flange disconnect provides a means for shutting offpower to the controller and locking the power out.
WARNINGLethal voltage is present in the controller WHENEVER IT ISCONNECTED to a power source. Be extremely careful toavoid electrical shock.
Turning the disconnect to the OFF position removes powerfrom the output side of the device only. High voltage isalways present at the input side whenever the controller isconnected to a power source.
Five fuses reside on the multi-tap transformer with fuses F1, F2, and F3for the three-phase 200 VAC servo power and F4 and F5 for 100 VAC.The fuses are described in Table 5–2 and are located in Figure 5–2.
Table 5–2. Multi-Tap Transformer Fuses
Fuse Number Robot RatedCurrent Part Number
F1, F2, F3 P-200 30A A60L–0001–0042#JG1–30
F4, F5 P-200 7.5A A60L–0001–0101#P475H
Figure 5–2. Replacing Transformer Fuses
FuseFuse
WARNINGBefore you replace a fuse, turn the power off and lock outthe controller. Otherwise, you could injure personnel ordamage equipment.
5.2MULTI-TAPTRANSFORMERFUSES
5–5
5. REPLACING FUSES
MARO2P10203703E
Refer to Figure 5–3 for fuse locations on the PSU and Table 5–3 for fuseratings.
Table 5–3. PSU Fuse Ratings
Fuse No. Rated current Part number
F1(AC Input)
7.5A A60L00010245#GP75
F3 (+24V)
5A A60L00010075#5.0
F4(+24E)
5A A60L00010046#5.0
Figure 5–3. Replacing a Fuse of the Power Supply Unit
F1 : 7.5Afuse for AC input
F3 : 5AS (slow-blow)fuse for +24V
F4 : 5Afuse for +24E
5.3POWER SUPPLY UNITFUSES
5–6
5. REPLACING FUSES
MARO2P10203703E
The servo amplifiers for the P-200 contain one fuse (F1), except for ModelA06B–6089–H106 which includes a second fuse (F2). The fuse(s) arelocated behind the servo front cover as located in Figure 5–4 and aredescribed in Table 5–4.
Table 5–4. Servo Fuse Ratings
Fuse Number Rating Part Number
F1 5A– 250V A60L–0001–0359
F2 5A – 250V A60L–0001–0359
Figure 5–4. Replacing Fuses of Servo Amplifier
F1
Circuit breaker
F2 (In servo A06B–6089–H106 only)
5.4SERVO AMPLIFIERFUSES
5–7
5. REPLACING FUSES
MARO2P10203703E
Two fuses reside on the Emergency Stop Control printed circuit board.The location of these fuses are shown in Figure 5–5 and the specificationsare listed in Table 5–5.
Table 5–5. Emergency Stop Control Printed Circuit Board Fuses
Fuse Number Rated Current Part Number Purpose
F1 5A XGMF-00762 Fuse for brake power supply.
F2 0 32 A60L–0001–0046#0 32 Fuse for +24EF2 0.32 A60L–0001–0046#0.32 Fuse for +24E.
Figure 5–5. Replacing Emergency Stop Control Board Fuses
Fuse2
Fuse1
F1
F2
5.5EMERGENCY STOPCONTROL PCB FUSES
5–8
5. REPLACING FUSES
MARO2P10203703E
The two fuses that reside on the Purge Power Supply are described inTable 5–6 and are shown in Figure 5–6.
Table 5–6. Emergency Stop Control PCB Fuses
Fuse Number RatedCurrent Part Number
F11 3.2A A60L–0001–0175#3.2
F12 3.2A A60L–0001–0175#3.2
Figure 5–6. Purge Power Supply Location
Purge Power Supply
F11 F12
5.6PURGE POWERSUPPLY FUSES
5–9
5. REPLACING FUSES
MARO2P10203703E
The modular I/O (Model A) modules that contain fuses are described inTable 5–7 and are shown in Figure 5–7, Figure 5–8, and Figure 5–9.
Figure 5–9. Modular I/O Fuse Locations – AOS08C and AOD08D
AOD08C AOD08D
FUSES FUSES
5–12
5. REPLACING FUSES
MARO2P10203703E
One fuse resides on the Sub-CPU printed circuit board. The location ofthis fuse is shown in Figure 5–10 and the specifications are listed inTable 5–8.
Figure 5–10. Main CPU Printed Circuit Board
A16B-3200-015FANUC
ÎÎÎÎÎ
ÎÎÎÎÎÎÎÎÎÎÎÎ
ÎÎÎÎÎÎ
ÎÎÎÎÎÎ
LV ALM
F21 5A
RISC-B
STATUSALARM
D16
VD1
PC
3
PC
5
PC
13
PR
1
EP
RO
M M
OD
ULE
JNA
BAT
1
5.0A
FUSE
Table 5–8. Emergency Stop Control PCB Fuses
Fuse Number Rated Current Part Number
F21 5.0A XGMF-00762
5.8SUB CPU PRINTEDCIRCUIT BOARD FUSE
Page 13
6 BRAKE RELEASE
6 BRAKE RELEASE
6–1MARO2P10203703E
Topics In This Chapter Page
Brake Release You can release the axes brakes using the operator panel switch. 6–2. . . . . . . . . . .
When you troubleshoot and perform some error recovery procedures onthe P-200 robot you might need to release the brakes. Refer toProcedure 6–1 for the brake release procedure.
6–2
6. BRAKE RELEASE
MARO2P10203703E
Use Procedure 6–1 to release the brakes using the operator key.
Procedure 6–1 Brake Release Using the Operator Panel Switch
Insure that the following conditions exist:
Controller main power disconnect is ON.
Purge complete.
Controller power on
Insure that area around robot is clear and that all personnel are clear ofthe area.
1 Press the EMERGENCY STOP push button on the operator panel.
WARNINGReleasing the brakes could cause the robot to move.Provide support for the arm of the robot before releasingthe brakes; otherwise, you could injure personnel ordamage equipment.
2 Insert the key into BRAKE ENABLE key switch on the operator paneland turn to the ON position. See Figure 6–1.
3 If you have the optional brake release switches for individual axescontinue to step 4.
Figure 6–1. Operator Panel
ÎÎÎÎÎÎ
ÎÎÎÎ
ÎÎÎÎÎÎÎÎ
ÎÎÎÎ
ÎÎ
ÎÎÎÎ
BATTERY
ALARM
OFF
LOCAL
PURGECOMPLETE
PURGE ENABLE
PURGEFAULT
EMERGENCY STOP
TEACH PENDANTENABLED
FAULT RESET
FAULT
ÏÏÏÏ
ÏÏÏÏ
ON
OFF HOUR METERPORT
HOLD
CYCLE START
REMOTE
REMOTE
BRAKE ENABLE
ON
6.1BRAKE RELEASE
Condition
Step
MARO2P10203703E 6–3
6. BRAKE RELEASE
4 Activate the enable switch for axis:
SW1 – P-200 axes 1, 4, 5 and 7
SW2 - P-200 axes 2 *
SW3 – P-200 axes 3 *
SW4 – Opener all axes *
NOTE * P-200 axes 2, 3 and opener axes 2 and 3 will drop due to gravity.They do not have balancers.
NOTE * Enable switches must be held, they are momentary switches.
Figure 6–2. C Size R-J2 Controller With Optional Brake Release Switches
Simulating inputs and outputs is forcing inputs and outputs without signals entering or leaving the controller. 7–4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SOP I/O Status The I/O SOP screen indicates the status of the standard operator panel signals. 7–5
Controlling I/O allows you to test the I/O in your system for properfunction.
MARO2P10203703E7–2
7. CONTROLLING I/O
Forcing outputs is turning output signals on or off. Outputs can also beforced within a program using I/O instructions. Use Procedure 7–1 toforce outputs outside of a program.
NOTE RO[1] and RO[2] control HAND 1, and RO[3] and RO[4] controlHAND 2.
Procedure 7–1 Forcing Outputs
The outputs you are forcing have been configured.
1 Press MENUS.
2 Select I/O.
3 Press F1, [TYPE].
4 Select the type of output you want to force: digital, analog, group,robot, UOP, or SOP.
WARNINGForcing digital outputs causes connected devices tofunction. Make certain you know what the digital output isconnected to and how it will function before forcing it;otherwise, you could injure personnel or damageequipment.
7.1FORCING OUTPUTS
Condition
Step
MARO2P10203703E 7–3
7. CONTROLLING I/O
For digital outputs for example, you will see a screen similar to thefollowing.
# SIM STATUS DO[ 1] OFF [ ] DO[ 2] U ON [ ] DO[ 3] U OFF [ ] DO[ 4] U OFF [ ] DO[ 5] U OFF [ ] DO[ 6] U ON [ ] DO[ 7] U OFF [ ] DO[ 8] U OFF [ ] DO[ 9] U OFF [ ] DO[ 10] U OFF [ ]
[ TYPE ] CONFIG IN/OUT SIMULATE UNSIM
I/O Digital Out WORLD 10%
U
E1
5 Move the cursor to the STATUS of the output you want to force.
6 Press the function key that corresponds to the value you want.
For digital, robot, UOP, and SOP outputs, press :
F4 for ON
F5 for OFF
For analog and group outputs, move the cursor to value, and use thenumeric keys to type the value. Value entry is always in decimalformat. To change the displayed value from decimal to hexadecimal,press F4, FORMAT. Hexadecimal numbers are followed by an ‘‘H’’on the screen.
DO[ 4] U OFF
AO[ 4] U 12H
MARO2P10203703E7–4
7. CONTROLLING I/O
Simulating inputs and outputs is forcing inputs and outputs without signalsentering or leaving the controller. Simulate I/O to test program logic andmotion when I/O devices and signals are not set up. You can simulatedigital, analog, and group I/O only; you cannot simulate robot, UOP, orSOP I/O. When you are finished simulating a signal, you can reset, orunsimulate it. Use Procedure 7–2 to simulate and unsimulate I/O.
Procedure 7–2 Simulating and Unsimulating Inputs and Outputs
The input or output has been configured.
1 Press MENUS.
2 Select I/O.
3 Press F1, [TYPE].
4 Select the type of input or output you want to simulate: digital, analog,or group.
For digital inputs for example, you will see a screen similar to thefollowing.
# SIM STATUS DI[ 1] U OFF [ ] DI[ 2] ON [ ] DI[ 3] U OFF [ ] DI[ 4] U OFF [ ] DI[ 5] U OFF [ ] DI[ 6] U ON [ ] DI[ 7] U OFF [ ] DI[ 8] S OFF [ ] DI[ 9] U OFF [ ] DI[ 10] U OFF [ ]
[ TYPE ] CONFIG IN/OUT SIMULATE UNSIM
I/O Digital Input WORLD 10%
S
E1
5 If you simulate a signal, you can force the status by setting it to avalue. When the signal is unsimulated, its actual status is displayed.
6 Move the cursor to the SIM column of the signal you want to simulate.
U means the signal is not simulated or unsimulated.
S means the signal is simulated.
7 Simulate or unsimulate the signal.
To simulate, press F4, SIMULATE.
To unsimulate, press F5, UNSIM.
8 To unsimulate all simulated signals, press FCTN and then selectUNSIM ALL I/O.
7.2SIMULATING INPUTS AND OUTPUTS
Condition
Step
DO[ 4] OFF
MARO2P10203703E 7–5
7. CONTROLLING I/O
The I/O SOP screen indicates the status of the standard operator panelsignals. SOP input signals (SI) and SOP output signals (SO) correspondto internal controller software Panel Digital Input signals (PDI) and PanelDigital Output signals (PDO). Refer to Table 7–1 and Table 7–2.
Table 7–1. Standard Operator Panel Input Signals
SI PDI Function Description
0 1 EMERGENCYSTOP
Input signal is normally turned ON, indicating that the EMERGENCY STOP button isnot being pressed.
1 2 FAULT RESET Input signal is normally turned OFF, indicating that the FAULT RESET button is notbeing pressed.
2 3 REMOTE Input signal is normally turned OFF, indicating that the controller is not set to remote.
3 4 HOLD Input signal is normally turned ON, indicating that the HOLD push button is not beingpressed.
4 5 PURGE ENABLE Input signal is normally turned OFF, indicating that the PURGE ENABLE push buttonis not being pressed.
6 7 CYCLE START Input signal is normally turned OFF, indicating that the CYCLE START push button isnot being pressed.
7-15 8-16 NOT USED Open for additional PDI.
Table 7–2. Standard Operator Panel Output Signals
SO PDO Function Description
0 1 REMOTE LED Output signal indicates the controller is set to remote.
1 2 CYCLE START Output signal indicates the CYCLE START button has been pressed or a program isrunning.
2 3 HOLD Output signal indicates the HOLD button has been pressed or a hold condition exists.
3 4 FAULT LED Output signal indicates a fault has occurred.
4 5 BATTERY ALARM Output signal indicates the voltage in the battery is low.
5 6 PURGECOMPLETE
Output signal indicates the purge cycle is complete.
6 7 PURGE FAULT Output signal indicates a purge fault condition exists.
7 8 TEACH PENDANTENABLED
Output signal indicates the teach pendant is enabled.
8-15 9-16 NOT USED Open for additional PDO.
Use Procedure 7–3 to display and force SOP I/O.
7.3SOP I/O STATUS
MARO2P10203703E7–6
7. CONTROLLING I/O
Procedure 7–3 Displaying and Forcing SOP I/O
1 Press MENUS.
2 Select I/O.
3 Press F1, [TYPE].
4 Select SOP. You will see a screen similar to the following.
# STATUS SO[ 1] OFF [ ] SO[ 2] OFF [ ] SO[ 3] OFF [ ] SO[ 4] OFF [ ] SO[ 5] OFF [ ] SO[ 6] OFF [ ] SO[ 7] OFF [ ] SO[ 8] OFF [ ] SO[ 9] OFF [ ] SO[ 10] OFF [ ]
[ TYPE ] IN/OUT ON OFF
I/O SOP Out JOINT 10 %
OFF
E1
To change between the display of the input and output screens, pressF3, IN/OUT.
To move quickly through the information, press and hold the SHIFTkey and press the down or up arrow keys.
NOTE You can only view the status of input signals. Input signals cannotbe forced.
5 To force an output signal, move the cursor to the output you want tochange:
To turn on an output signal, press F4, ON.
To turn off an output signal, press F5, OFF.
Step
Inde
x
8 MASTERING
8 MASTERING
MARO2P10203703E 8–1
Topics In This Chapter Page
Resetting Alarms and Preparing for Mastering
Before mastering the robot or opener you must reset the alarm 8–2. . . . . . . . . . . . .
Use when mastering was lost due to a single axis going bad, and that axis is the only axis affected.. 8–16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Standard Mastering forthe P-10 Door Opener andP-15 Hood and DeckOpener
Method of choice for the P-10 and P-15 openers. 8–19. . . . . . . . . . . . . . . . . . . . . . . . . . When mastery was lost due to mechanical disassembly or repair.When a quick master reference position was not previously set.
When you master a robot or an opener you electronically calibrate theserial pulse coders of the servomotor on the robot or opener against amechanical zero position. When a robot or opener is mastered, theposition data from the encoders are stored while the robot or opener is at aknown mechanical position. Mastering is required to ensure that the unitaxes motion is limited to the designed travel range.
Robot and openers must be mastered to operate properly. Robots andopeners are usually mastered before they leave FANUC Robotics.However, it is possible that they might lose their mastering data and needremastering. This chapter provides mastering methods for the P-200 robotand P-10 and P-15 openers.
Before you master the robot or openers, you must clear any faults thatprevent servo power from being restored or that prevent masteringcompletion.
CAUTIONRecord the quick master reference position after the robot oropener is installed to preserve the factory mastering settingsfor future remastering.
8–2
8. MASTERING
MARO2P10203703E
When you turn on the robot or opener after disconnecting the pulsecoderbackup batteries you might see a SRVO–062 BZAL or SRVO–038 Pulsemismatch alarm. Before mastering the robot or opener you must reset thealarm and rotate the motor of each axis that lost battery power to preparethe robot or opener for mastering.
Use Procedure 8–1 to reset these alarms and prepare the robot or openerfor mastering.
NOTE These SRVO errors will also appear after you have installed allnew application software on a robot or opener.
Procedure 8–1 Preparing the Robot or Opener for Mastering
You see a SRVO–062 BZAL or SRVO–038 Servo mismatch alarm.
1 Replace the robot and opener batteries with four new 1.5 volt alkalinebatteries, size D. Observe the direction arrows in the battery box forproper orientation of the batteries. Refer to Procedure 9–2 .
2 Press MENUS.
3 Select SYSTEM.
4 Press F1, [TYPE].
5 Select Master/Cal.
If Master/Cal is not listed on the [TYPE] menu, do the following;otherwise, continue to Step 6.
a Select VARIABLE from the [TYPE] menu.
b Move the cursor to $MASTER_ENB.
c Press the numeric key “1” and then press ENTER on the teachpendant.
d Press F1, [TYPE].
e Select Master/Cal. You will see a screen similar to the following.
SYSTEM Master/Cal JOINT 10%
[ TYPE ] LOAD RES_PCA
1 FIXTURE POSITION MASTER2 ZERO POSITION MASTER3 QUICK MASTER4 SINGLE AXIS MASTER5 SET QUICK MASTER REF6 CALIBRATE
Press ’ENTER’ or number key to select.
DONE
8.1 RESETTING ALARMSAND PREPARING FORMASTERING
Condition
Step
8–3
8 MASTERING
MARO2P10203703E
6 Press F3, RES_PCA. You will see a screen similar to the following.
‘
SYSTEM Master/Cal JOINT 10%
[ TYPE ] YES NO
1 FIXTURE POSITION MASTER2 ZERO POSITION MASTER3 QUICK MASTER4 SINGLE AXIS MASTER5 SET QUICK MASTER REF6 CALIBRATE
Press ’ENTER’ or number key to select.
Reset pulse coder alarm? [NO]
E1
7 Press F4, YES.
8 Cold start the controller.
a Turn off the robot or the opener.
b Press and continue pressing the FAULT RESET button on theoperator panel.
c While still pressing FAULT RESET, press the ON button on theoperator panel.
9 If the SRVO–062 alarm is still present, there is a battery, cable or pulsecoder problem. Refer to the FANUC Robotics SYSTEM R-J2Controller Series Electrical Connection and Maintenance Manual forfurther information.
10 If a SRVO–038 alarm is present at this time, repeat Step 6 to reset it.It is not necessary to cold start the robot or opener after resetting toclear this alarm.
11 Rotate each axis that lost battery power by at least one motorrevolution in either direction to clear SRVO–075 Pulse NotEstablished.
a Jog each rotary axis at least twenty degrees.
b Jog each linear axis at least thirty millimeters.
12 Perform any of the mastering procedures from the MASTER/CALmenu.
8–4
8. MASTERING
MARO2P10203703E
Standard mastering is the preferred method used to master the P-200 robot.
Use Procedure 8–2 to perform standard mastering.
Procedure 8–2 Standard Mastering
NOTE You do not need a fixture to master the P-200 robot. To performStandard Mastering, select Fixture Position Master.
You have cleared any servo faults that prevent you from jogging therobot.
You have jogged each axis that has lost mastery at least one motorturn.
You have reset all “Pulse not established (SRVO-075)” errors .
1 Jog the robot to the approximate mastering position shown inFigure 8–1.
Figure 8–1. Zero Degree Position of the P-200 Robot
8.2STANDARDMASTERING FOR THEP-200 ROBOT
Condition
Step
8–5
8 MASTERING
MARO2P10203703E
NOTE Align surfaces using a 1 - 2 - 3 block or other straight edge device.
NOTE Always rotate each axis into the mastered position from the samedirection to insure backlash errors are not added to the mastering data.
Figure 8–2. Axes 4, 5, and 6 100° Wrist Assembly
Axis 5 Bearing Surface
Axis 6 Bearing Surface
Inner Knuckle
Outer Knuckle
Axis 4 Bearing Surface
8–6
8. MASTERING
MARO2P10203703E
2 Rotate the inner knuckle counter-clockwise. Align the edge of thenotch on the inner knuckle and the pin in the bearing retainer (axis 4)See Figure 8–2. See Figure 8–3 if the wrist is 100°, or Figure 8–4 ifthe wrist is 140.
3 Rotate the outer knuckle counter-clockwise aligning the edge of thenotch on the outer knuckle and the pin in the bearing retainer (axis 5)See Figure 8–2. See Figure 8–3 if the wrist is 100°, or Figure 8–4 ifthe wrist is 140.
4 Rotate the wrist faceplate counter-clockwise aligning the edge of thenotch on the faceplate and the pin in the bearing retainer (axis 6). SeeFigure 8–2. See Figure 8–3 if the wrist is 100°, or Figure 8–4 if thewrist is 140.
8–8
8. MASTERING
MARO2P10203703E
5 Align the witness marks on the turret and pedestal (axis 1). SeeFigure 8–5.
NOTE If you are mastering a 100 wrist robot, go to step 7. If your robothas a 140° wrist, go to step 8.
7 Lower the outer arm aligning the notches on the inner and outer arm(axis 3). See Figure 8–7. Go to step 14.
Figure 8–7. Axis 3 100° Mastered Position
MASTERED POSITION:AXIS 3 = –65°
Inner ArmOuter Arm
Inner Arm
Outer Arm
Witness Mark
Witness Mark
8–11
8 MASTERING
MARO2P10203703E
8 Lower the outer arm aligning the mastering pin on the 140° wrist tothe mastering surface located on the inner arm (axis 3). SeeFigure 8–8.
NOTE If your robot is not mounted on a rail, go to to step 16.
Figure 8–8. Axis 3 Mastering Position (140° Wrist)
MASTERED POSITION:AXIS 3
Mastering Surface
ARM LENGTH
1200 MM
1400 MM
94.366°
97.0°
Inner Arm
Outer Arm
140° Wrist
Mastering Pin
Left and Right SideMastering Pins
8–12
8. MASTERING
MARO2P10203703E
NOTE If your robot is using a P-200 Clean Wall Retrofit (P-150 Retrofit)rail, go to to step 9. If not continue to step 14.
9 Attach the mastering block to the side of the saddle. See Figure 8–9.
Figure 8–9. Mastering Block
10 Release the brakes for the rail axis.
11 Manually push the saddle until the mastering block comes in contactwith the rail axis master stop. See Figure 8–9.
8–13
8 MASTERING
MARO2P10203703E
12 Engage the brakes for the rail axis and reset all faults.
13 Go to Step 16.
14 Jog the robot to the approximate mastering position shown inFigure 8–10.
Figure 8–10. Axis 7 Mastering Position
Mastering Surface
Witness MarkRail
AXIS 7Side View
15 Align the mastering surface on the pedestal to the witness mark on therail using a 1-2-3 block or other straight edge device.
16 Press MENUS.
17 Select SYSTEM.
18 Press F1, [TYPE].
19 Select Master/Cal.
8–14
8. MASTERING
MARO2P10203703E
NOTE You do not need a fixture to master the P-200 robot. To performStandard Mastering, select Fixture Position Master. See the followingscreen for an example.
SYSTEM Master/Cal G1 JOINT 10 %
TORQUE =[ON]
1 FIXTURE POSITION MASTER 2 ZERO POSITION MASTER 3 QUICK MASTER 4 SINGLE AXIS MASTER 5 SET QUICK MASTER REF 6 CALIBRATE
Press ‘Enter’ or number key to select.
[ TYPE ] LOAD RES_PCA
20 Select FIXTURE POSITION MASTER. You will see a screen similarto the following.
SYSTEM Master/Cal G1 JOINT 10 %
TORQUE =[ON]
1 FIXTURE POSITION MASTER 2 ZERO POSITION MASTER 3 QUICK MASTER 4 SINGLE AXIS MASTER 5 SET QUICK MASTER REF 6 CALIBRATE
Press ‘Enter’ or number key to select.
Master at master position? [NO][ TYPE ] YES NO
8–15
8 MASTERING
MARO2P10203703E
21 Press F4, YES. You will see a screen similar to the following.
TORQUE = [ON]
1 FIXTURE POSITION MASTER 2 ZERO POSITION MASTER 3 QUICK MASTER 4 SINGLE AXIS MASTER 5 SET QUICK MASTER REF 6 CALIBRATE
6 Jog all unaffected axes to their respective mastering positions so thatthe actual position matches that of the master position column.
7 Using a 1-2-3 block, or other straight edge device, align theunmastered axis (axes) to their witness mark(s) as described inProcedure 8–2 .
8 Move the cursor to the SEL column for each unmastered axis (axes)and press the numeric key “1”, then press ENTER.
8–18
8. MASTERING
MARO2P10203703E
WARNINGDo not modify the values in the column labeled (MSTRPOS). Otherwise, unexpected motion could occur whichcould injure personnel or damage equipment.
9 Press F5, EXEC. Mastering will be performed automatically.
10 Press PREV.
11 Select Calibrate.
12 Press F4, YES.
Single axis mastering is now complete.
8–19
8 MASTERING
MARO2P10203703E
Use Procedure 8–4 to master the P-10 Door Opener and the P-15 Hoodand Deck opener.
NOTE You do not need a fixture to master the P-10 or P-15 openers. Toperform Standard Mastering, select Fixture Position Master on the teachpendant.
Procedure 8–4 Standard Mastering for the P-10 Door Opener and the P-15Hood and Deck Opener
You have cleared any servo faults that prevent you from jogging theopener.
You have reset all “Pulse not established (SRVO-075)” errors.
1 Select Motion Group 2.
a Press FCTN.
b Select CHANGE GROUP. G2 should be displayed in the title lineof the teach pendant screen.
2 Jog the opener to the approximate mastering position shown inFigure 8–12.
NOTE Align surfaces using a 1 - 2 - 3 block or other straight edge device.
8.4STANDARDMASTERING FOR THEP-10 DOOR OPENERAND THE P-15 HOODAND DECK OPENER
Condition
Step
8–20
8. MASTERING
MARO2P10203703E
Figure 8–12. P-10 and P-15 Opener Mastering Position
45°
45°
BO
OT
H W
ALL AXIS 2
AXIS 3
AXIS 1
8–21
8 MASTERING
MARO2P10203703E
3 Align the mastering surfaces on the x-drive housing and the rail. See Figure 8–13.
Figure 8–13. P-10 and P-15 Axis One Mastering Position
25T700T A
RAIL – REF.
Mastering Surfaces Line Up Machine Edge On RailWith Cover As Shown
View A
8–22
8. MASTERING
MARO2P10203703E
4 Align the mastering surfaces on the base and the inner arm. SeeFigure 8–14.
Figure 8–14. P-10 and P-15 Axis Two Mastering Position
FrontOf Opener
Line Up TheseSurfaces
Mastering Surfaces(Inner Arm To Base)
View A
A
View B (rear view) B
B
Inner Arm
Base
Inner Arm
Base
8–23
8 MASTERING
MARO2P10203703E
5 Align the mastering surfaces on the crank and base. See Figure 8–15.
Figure 8–15. P-10 and P-15 Axis Three Mastered Position
FrontOf Opener
BASE
Line Up These
Surfaces
(Crank To Base)s
45°REF
A
B
View A
View BB
Mastering Surfaces (Crank To base)
6 Press MENUS.
7 Select SYSTEM.
8 Press F1, [TYPE].
8–24
8. MASTERING
MARO2P10203703E
9 Select Master/Cal.
NOTE You do not need a fixture to master the P-10 opener. To performStandard Mastering, select Fixture Position Master on the teach pendant.You will see a screen similar to the following.
SYSTEM Master/Cal G2 JOINT 10 %
TORQUE =[ON]
1 FIXTURE POSITION MASTER 2 ZERO POSITION MASTER 3 QUICK MASTER 4 SINGLE AXIS MASTER 5 SET QUICK MASTER REF 6 CALIBRATE
Press ‘Enter’ or number key to select.
[ TYPE ] LOAD RES_PCA
10 Select FIXTURE POSITION MASTER. You will see a screensimilar to the following.
TORQUE =[ON]
1 FIXTURE POSITION MASTER 2 ZERO POSITION MASTER 3 QUICK MASTER 4 SINGLE AXIS MASTER 5 SET QUICK MASTER REF 6 CALIBRATE
Press ‘Enter’ or number key to select.
Master at master position? [NO][ TYPE ] YES NO
SYSTEM Master/Cal G2 JOINT 10 %
11 Press F4, [YES]. You will see a screen similar to the following.
NOTE If there is an encoder fault that was not reset, the teach pendantwill not confirm mastering and the mastering position will not be entered.
8–25
8 MASTERING
MARO2P10203703E
12 Select CALIBRATE. You will see a screen similar to the following.
TORQUE =[ON]
1 FIXTURE POSITION MASTER 2 ZERO POSITION MASTER 3 QUICK MASTER 4 SINGLE AXIS MASTER 5 SET QUICK MASTER REF 6 CALIBRATE
Press ‘Enter’ or number key to select.
Calibrate [NO][ TYPE ] YES NO
SYSTEM Master/Cal G2 JOINT 10 %
13 Press F4, YES. The robot is now calibrated and can be jogged incoordinate frames.
TORQUE = [ON]
1 FIXTURE POSITION MASTER 2 ZERO POSITION MASTER 3 QUICK MASTER 4 SINGLE AXIS MASTER 5 SET QUICK MASTER REF 6 CALIBRATE
FANUC Robotics recommends that all batteries be changed immediatelyprior to production start up. Change the batteries annually to assurereliable robot performance for extended periods of time. Use Procedure 9–1 to replace the PSU battery, Procedure 9–2 to replacethe SPC battery, and Procedure 9–3 to replace the PCMCIA memory cardbattery.
Procedure 9–1 Replacing the PSU Battery
1 Get the new battery. (number: A98L-0031-0012)
2 Turn off and lock out the controller.
CAUTIONThe battery must be replaced within 30 minutes. If the power isturned off and the battery is removed for 30 minutes or more,the contents of the memory on the main CPU printed circuitboard may be lost.
WARNINGDo not short circuit or incinerate a discarded battery.Follow your company’s procedures for disposing of lithiumbatteries. Otherwise, you could injure personnel ordamage equipment.
WARNINGLethal voltage is present in the controller WHENEVER IT ISCONNECTED to a power source. Be extremely careful toavoid electrical shock.
3 Remove the battery case from the front panel of the power supply unit.See Figure 9–1. The case can be removed easily by squeezing the topand bottom of it and pulling.
2 Remove the PCMCIA (memory) card from the Memory Card Interfaceboard (PN A 20B-2000-0600).
3 Insert a small diameter pointed object into the hole on the upper sideof the 2 MG SRAM PC card (PN DISKMF32M1LCDA7).
4 Release the battery holder by pressing the small diameter objectagainst the battery holder catch and pull the battery holder straight outfrom the card. See Figure 9–3 for the location of the battery.
5 Replace the old battery with the new battery. Insure that the (+)symbol on the battery is located as shown on the battery holder.
Step
9–5
9. REPLACING COMPONENTS
MARO2P10203703E
WARNINGDO NOT Install the Memory Card Interface board with thepower on. This will damage the Interface board.
6 With the new battery in the holder, install the battery holder into thememory card and reinstall the card into the controller. See Figure 9–4.
Figure 9–3. Replacing Memory Card Battery
Figure 9–4. 3-Slot Backplane (A05B-2316-C105)
FanFans
Backplane PrintedCircuit Board
Total version3 slot back plane printed circuit boardA20B-2001-0670
Main CPUPower Supply
PCMCIA Memory Card
9–6
9. REPLACING COMPONENTS
MARO2P10203703E
This section includes relays located on the back of the operator controlpanel and the EMG printed circuit boards relay replacement procedures.
See Figure 9–5 for relay locations and Table 9–1 for operator controlpanel relay identification.
When replacing a printed circuit board, insure that the followingprecautions are followed:
The controller is locked out and tagged out.Remove the battery from the power supply unit and plug it into the
battery connector (BAT. VBAT) on the front panel of the main CPU, ifthe power supply unit or the main CPU are to be removed from thebackplane. See Figure 9–8.
Figure 9–8. Battery Transfer to Maintain CMOS RAM Memory
BatteryAuxConnection
Main CPU Printed Circuit BoardPower Supply Unit
(BAT. VBAT)
Battery
9.3REPLACING APRINTED CIRCUITBOARD
9–10
9. REPLACING COMPONENTS
MARO2P10203703E
Removal and replacement of a printed circuit board from the backplaneprinted circuit board is provided in Procedure 9–4 and is shown inFigure 9–9.
Procedure 9–4 Printed Circuit Board Removal and Replacement
1 Turn the power off and remove the cable(s) from the power supply unitor printed circuit board to be replaced. If the cable markings aremissing or difficult to read, write them down before removing thecables.
CAUTIONBe sure to back up all program and setup data on a floppy diskbefore you replace a printed circuit board otherwise, you couldlose data.
CAUTIONWhen either the power supply or main CPU printed circuitboards are removed from the controller, the data storagebattery is disconnected. All boards must be reinstalled properlywithin half an hour to avoid data loss.
NOTE When removing the printed circuit board, do not touchsemiconductor components on it and do not let the components touchother components.
9.3.1 Removal andReplacement of aPrinted Circuit Boardfrom the BackplanePrinted Circuit Board
9–11
9. REPLACING COMPONENTS
MARO2P10203703E
2 Squeeze the removal tabs at the top and bottom of the front panel ofthe power supply unit or printed circuit board. The latches of thecontrol unit rack are released. Holding the tabs in this state, pull outthe unit or printed circuit board. See Figure 9–9.
Figure 9–9. Replacing the Components on the Backplane Printed Circuit Board
Main CPU printed circuit board
Power supply unit
Optional boards
Removal tab
Removal tab
NOTE If you are removing the printed circuit boards in preparation toremove the backplane go to Procedure 9–5 .
3 Insert a new power supply unit or printed circuit board into the slot ofthe control unit rack. Carefully push it into the slot until the frontpanel is latched at the top and bottom.
4 Check that the printed circuit board to be installed is correctly set andadjusted.
5 Connect the cables removed for replacement to the original positions.
9–12
9. REPLACING COMPONENTS
MARO2P10203703E
Procedure 9–5 provides instructions for replacement of the backplaneprinted circuit boards and Figure 9–10 shows an example of boardreplacement.
1 When you replace the backplane printed circuit board, remove theentire rack. Remove the power supply unit printed circuit board, mainCPU printed circuit board, and any optional printed circuit boardsusing Procedure 9–4 .
2 Remove the ground cable from the backplane printed circuit board.
3 Loosen the screws fastening the rack at the top. Then remove thescrews fastening the rack at the bottom. See Figure 9–10.
4 Lift up on backplane until slots have cleared the mounting screws andcarefully move it forward until the backplane is clear of the controller.
5 Install the new backplane in reverse order.
Figure 9–10. Replacing the Backplane Printed Circuit Board
Backplaneprinted circuit board
Loosen screws
Remove screws
9.3.2 Replacing theBackplane PrintedCircuit Board
9–13
9. REPLACING COMPONENTS
MARO2P10203703E
Use Procedure 9–6 to replace a module.
CAUTIONFollowing electrostatic discharge procedures when handling allcircuit boards.
Procedure 9–6 Replacing a Module on the Main CPU or Aux Axis ControlPrinted Circuit Board
1 Move the latches at both ends of the module socket toward the outside.The spring of the contact tilts the module. See Figure 9–11.
Figure 9–11. Moving the Latches on the End of the Module Socket
2 If the tilted module touches the next module, it might be difficult toremove it. In this case, release the latches of the next module asdescribed in step 1 above.
3 Now the module is free in the socket. Pull out the module carefully ina straight line. Do not pull it out in an arc. The contacts of the socketor module might be damaged.
4 Install a new module in the socket at an angle. Push it into the socketuntil the bottom of the module reaches the bottom of the socketgroove. Be sure you have the module facing in the proper direction.align the groove in the module with the tab as shown in Figure 9–12.
9.4REPLACING AMODULE ON THEMAIN CPU OR AUXAXIS CONTROLPRINTED CIRCUITBOARDRefer to Chapter 1 for part numbers.
Step
9–14
9. REPLACING COMPONENTS
MARO2P10203703E
Figure 9–12. Installing a New Module at an Angle
Short Long
Fit the recess onthe module overthe tab in themodule socket.
5 Push the module in the top edge so that the module stands upright.See Figure 9–13.
Figure 9–13. Pushing in the Module
6 Check that the module is latched properly at both ends of the socket.If it is insufficiently latched, the electrical contact might be improperand a malfunction could occur.
9–15
9. REPLACING COMPONENTS
MARO2P10203703E
Figure 9–14. Mounting Locations of the Modules
Flash ROM module DRAM module
Axis module (J1, J2)
Axis module (J3, J4)
Axis module (J5, J6)
CMOS module
Servo control module (for axis 1 and 2)
Servo control module (for axis 3 and 4)
Servo control module (for axis 5 and 6)
JNA
JRY2
Servo control module (for axis 9 and 10)
Servo control module (for axis 7 and 8)
MAIN CPU
AUX AXIS CONTROL PCB
9–16
9. REPLACING COMPONENTS
MARO2P10203703E
Use Procedure 9–8 and Procedure 9–9 to replace an Interface Module andI/O Module (Model A). Replacement of the Interface Module is providedin Procedure 9–8 and replacement of the I/O Module is provided inProcedure 9–9 and shown in Figure 9–16. Use Procedure 9–7 to replacethe base unit if needed after you remove the I/O Interface Module.
Procedure 9–7 Replacing the Base Unit
1 Remove the I/O modules from the base unit.
2 Loosen the upper two mounting screws.
3 Remove the lower two mounting screws and replace the base unit.
Figure 9–15. Replacing the Base Unit of the Model A I/O
M4 screw
9.5REPLACING AN I/OMODULE (MODEL A)
Step
9–17
9. REPLACING COMPONENTS
MARO2P10203703E
Use Procedure 9–8 to replace a Model A Interface Module.
Procedure 9–8 Replacing a Model A Interface Module
1 Turn off and lock out the controller.
2 Disconnect the signal and power cables from the interface module.
3 Press the latch on the bottom of the module and rotate the moduletoward you and up.
4 Engage the hook at the top rear of the module with the bar above thebase unit socket.
5 Rotate the module downward until the latch engages.
6 Reconnect the signal and power cables to the interface module.
Use Procedure 9–9 to replace a Model A I/O Module.
Procedure 9–9 Replacing a Model A I/O Module
1 Turn off and lock out the controller.
2 Remove the wiring harness block.
a Lift the latch at the lower left corner of the module window.
b Rotate the block toward you and down.
3 Press the latch on the bottom of the module and rotate the moduletoward you and up. See Figure 9–16.
4 Engage the hook at the top read of the module with the bar above thebase unit socket.
5 Rotate the module downward until the latch engages.
9.5.1 Replacing a Model AInterface Module
Step
9.5.2 Replacing a Model AI/O Module
Step
9–18
9. REPLACING COMPONENTS
MARO2P10203703E
Figure 9–16. Replacing a Model A I/O Module
6 Install the wiring harness block.
a Engage the hook at the bottom rear of the block with the bar at the bottom of the module.
b Rotate the block upward until the latch engages.
9–19
9. REPLACING COMPONENTS
MARO2P10203703E
Use Procedure 9–10 to replace the multi-tap transformer.
Procedure 9–10 Replacing the Multi-Tap Transformer
1 Turn off and lock out the controller.
2 Remove the acrylic covers from the transformer and ALC relay.
3 Disconnect the wiring harnesses and ground wire from the transformer.
4 Disconnect the three wires from the bottom of the ALC relay.
5 After removing the eight screws fastening the transformer, remove thetransformer. See Figure 9–17. Put a new transformer on the rail in thecontroller and push it into the controller along the rail. Then reinstallthe screws.
6 Reconnect the wires and harnesses.
7 Reinstall the acrylic covers.
Figure 9–17. Replacing the Multi-Tap Transformer
M5 screws
9.6REPLACING THEMULTI-TAPTRANSFORMERRefer to Chapter 1 for partnumbers.
Step
9–20
9. REPLACING COMPONENTS
MARO2P10203703E
Use Procedure 9–11 to replace a servo amplifier. See Figure 9–18.
Procedure 9–11 Replacing a Servo Amplifier
1 Turn off and lock out the controller.
2 Remove the five bus bars from the servo amplifier bank.
3 Disconnect the wires from the servo amplifier terminal strip. Removethe two screws fastening the servo amplifier and remove the amplifier.
4 Set the terminal strip jumpers on the new servo amplifier to matchthose of the one you removed.
5 Install the new servo amplifier by following these steps in reverseorder.
Figure 9–18. Replacing a Servo Amplifier
Screw
9.7REPLACING A SERVOAMPLIFIERRefer to Chapter 1 for partnumbers.
Step
9–21
9. REPLACING COMPONENTS
MARO2P10203703E
Use Procedure 9–12 to replace the operator panel. See Figure 9–19.
Procedure 9–12 Replacing the Operator Panel
1 Power down and lock out the controller.
2 Remove all connectors and wires from the rear of the rear operatorpanel and all connectors from the front panel. Identify all wires andconnectors for installation of new operator panel.
3 Remove the six nuts fastening the operator panel and remove theoperator panel.
4 Install new operator panel using 6 nuts removed during removal of oldoperator panel.
5 Reconnect all wires and connectors removed during Step 2.
Figure 9–19. Replacing the Operator Panel
Î
ÎÎÎÎÎÎÎÎÎÎÎÎÎÎÏÏÏ ON
Nuts (Qyt 6)
9.8REPLACING THEOPERATOR PANELRefer to Chapter 1 for partnumbers.
Step
9–22
9. REPLACING COMPONENTS
MARO2P10203703E
Replace a defective fan motor using Procedure 9–13 and as shown inFigure 9–20.
Procedure 9–13 Fan Motor Replacement
1 Identify the defective fan motor and remove any printed circuit boarddirectly below the fan to be replaced.
2 The cable connected to the fan motor is connected to the backplaneprinted circuit board in the slot. Holding the connector, remove thecable from the backplane printed circuit board.
3 Open the lid at the top of the backplane rack by placing the tip of aflat-blade screwdriver into the center hole at the front of the lid andmoving the screwdriver like a lever in the direction in Figure 9–20.this will release the latch.
4 Replace the fan motor.
5 Close the lid until it is latched.
6 Connect the cable of the fan motor to the connector on the backplaneprinted circuit board. Suspend the center of the cable on the hook inthe back of the rack.
7 Reinstall the removed printed circuit board.
9.9REPLACING THE FANMOTOR IN THEBACKPLANE
Step
9–23
9. REPLACING COMPONENTS
MARO2P10203703E
Figure 9–20. Replacing the Fan Motor
Fan motor
Cable
Connector
9–24
9. REPLACING COMPONENTS
MARO2P10203703E
Replace a defective teach pendant using Table 9–4 for ordering and asshown in Figure 9–21.
Figure 9–21. Replacing the Teach Pendant
Table 9–4. Teach Pendant Part Numbers
Part Number(s) Use Remarks
A05B-2301-C305 General use English
A05B-2308-C300Intrinsically Safe Teach
PendantR-J2
Paint
9.10REPLACING THETEACH PENDANT
9–25
9. REPLACING COMPONENTS
MARO2P10203703E
Use Procedure 9–14 to replace an externally or internally mounted serialpulse coder.
Procedure 9–14 Replacing Internal Mounted Serial Pulse Coder
NOTE The robot will have to be remastered after this procedure.
1 Turn off and lock out the robot.
2 At the end of the motor, remove both cables from the serial pulsecoder cover.
3 Remove the four bolts that secure the serial pulse coder cover to themotor housing.
4 Remove the four screws holding the large serial pulse coder cableconnector to the serial pulse coder cover.
5 Retract the rubber boot on the inside of the serial pulse coder cableconnector.
6 Remove the snap ring on the inside of the serial pulse coder cableconnector.
7 Separate the two-wire connector on the inside of the internalconnector.
8 Detach the serial pulse coder cable from the serial pulse coder housing.
CAUTIONIn the next step, be sure to remove the correct bolts, as shownin Figure 9–22. Removing the wrong bolts can destroy theserial pulse coder.
9 Remove the four bolts attaching the serial pulse coder to the motor.See Figure 9–22.
10 Remove the serial pulse coder and the black plastic coupling and retainthe black plastic coupling to be installed with the new serial pulsecoder. See Figure 9–23.
11 Position the new serial pulse coder, with black plastic coupling, ontothe motor so that the coupling engages both motor and pulse coder. Ifthere are witness marks on the serial pulse coder case and the motorcase, make sure that they line up.
12 Install the new serial pulse coder to the motor housing using fourbolts.
13 Attach the serial pulse coder cable to the serial pulse coder housing.
9.11REPLACING A SERIALPULSE CODER
Step
9–26
9. REPLACING COMPONENTS
MARO2P10203703E
14 Install the snap ring on the inside of the serial pulse coder cableconnector.
15 Reposition the rubber boot on the inside of the serial pulse coder cableconnector.
16 Install the screws holding the serial pulse coder cable connector to theserial pulse coder housing.
17 Connect the two-wire cable connectors together.
18 Install the serial pulse coder housing to the motor, using four bolts
19 Attach both outside cables to the serial pulse coder housing.
Figure 9–22. Removing the Internally Mounted serial pulse coder
FANUC
REAR VIEW
DO NOT REMOVE THESCREWS FROM THESE FOURRIBBED HOLES. THE SERIALPULSE CODER WILLSEPARATE AND BEDESTROYED.
CAUTION:
M4 MountingHoles
9–27
9. REPLACING COMPONENTS
MARO2P10203703E
Figure 9–23. Removing the Black Plastic Coupling
CouplingBlack Plastic
Serial Pulse Coder
Procedure 9–15 Replacing an Externally Mounted Serial Pulse Coder
NOTE The robot will have to be remastered after this procedure.
1 Turn off and lock out the robot.
2 At the end of the motor, remove the two screws securing the serialpulse coder connector cover.
3 Remove the two screws securing the cable connector to the serial pulsecoder receptacle.
CAUTIONIn the next step, be sure to remove the correct bolts, as shownin Figure 9–22. Removing the wrong bolts can destroy theserial pulse coder.
4 Remove the four screws holding the serial pulse coder to the motorhousing and carefully remove the serial pulse coder. See Figure 9–22.Remove the coupling from the motor and serial pulse coder. SeeFigure 9–23.
Step
9–28
9. REPLACING COMPONENTS
MARO2P10203703E
5 Position the new serial pulse coder, with coupling, onto the motor sothat the coupling engages both the shaft of the serial pulse coder andthe motor. See If there are witness marks on the serial pulse codercase and the motor case, make sure that they line up.
6 Install four new screws and secure the serial pulse coder housing to themotor.
7 Attach the serial pulse coder connector to the serial pulse coderhousing using two screws.
8 Attach the connector cover to the serial pulse coder housing using twoscrews.
Page 29
10 BOARD ADJUSTMENTS AND CALIBRATIONS
10MARO2P10203703E 10–1
BOARD ADJUSTMENTS ANDCALIBRATIONS
Topics In This Chapter Page
I/P transducer/RegulatorPerformance Check
On a periodic basis, and whenever a transducer/regulator is replaced, this procedure should be preformed (Procedure 10–1 ). 10–2. . . . . . . . . . . . . . . . . . . . . . . .
Cold Start Standard Method For Turning On Power To The Robot And Controller.(Procedure 10–3 ) 10–7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Powering on the RobotSystems
The following procedures are applicable to all P-200 robot systems including those on a pedestal, rail or with an opener. 10–10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Controller ShutdownProcedure
Use this procedure for complete controller shutdown including purge circuitry. 10–11.
Servo Lockout Procedure For servo lockout use the following procedure. 10–11. . . . . . . . . . . . . . . . . . . . . . . . . . . .
No board adjustments are required on the controller. However, EmergencyStop Control Board jumper settings are included for reference. SeeFigure 10–1. These jumpers are set at installation and are not to bechanged. To set servo amplifier dip switches, refer to Chapter 1.
MARO2P10203703E10–2
10. BOARD ADJUSTMENTS AND CALIBRATIONS
On a periodic basis, and whenever a transducer/regulator is replaced, thisprocedure should be preformed to check out the Paint Regulator (PR) andthe Proportion Air transducer/regulator assembly in the P-200 outer arm.
Tools Required:
0–60 psi precision pressure gauge with ±0.5 psi accuracy
The robot/controller has been reset, and the system is in the MANUALor PRODUCTION mode.
1 Remove the air supply to the panel.
2 Remove output line from the regulator.
NOTE If a gauge port is available, connect the gauge here.
3 Connect a precision 0-60 psi pressure gauge at the output port on thePR I/P regulator section. This will register a pneumatic output signalwhile testing the transducer/regulator.
NOTE When testing the I/P transducer for acceptable performance,connect at least a volume of approximately one cubic foot to the output ofthe regulator. Ensure that the inlet pressure is at least 5% higher than thedesired output pressure but no more than +10% of the I/P transducersystem range being used (maximum of 300 psi).
4 Turn on the air supply to the panel.
5 Ensure all connections are “bubble tight”.
NOTE The signal to the transducer/regulator can be varied by selectingthe desired transducer count at the analog output (AOUT[1]) menu screenon the teach pendant.
6 Full scale response check: at the teach pendant select I/O, then PressF1 [TYPE].
7 Select AO (Analog Out) menu.
8 Enter a value of 1000 transducer counts, and press [ENTER] Thegauge should climb swiftly and smoothly to a maximum value (it isnot important what this value is).
9 Set the AO equal to 200. The gauge will fall steadily (usually slowerthan climbing) back to zero. Any observable irregular responseindicates a problem.
10.1I/P TRANSDUCER/REGULATORPERFORMANCECHECK
Condition
Step
MARO2P10203703E 10–3
10. BOARD ADJUSTMENTS AND CALIBRATIONS
10 Supply 4 mA to the transducer.
11 Starting at 0% (4mA) electrical signal, supply electrical signals in thefollowing incremental and decremental order and observe thecorresponding pneumatic output signals: (Refer to Table 10–1)
– Incremental (mA) 4, 8, 12, 16, 20.
– Decremental (mA) 20, 16, 12, 8, 4.
12 Verify that the pressure output falls within the tolerance range as listedin Table 10–1 (including the hysteresis between the up and downsetpoints).
13 If a unit is found to be defective - Replace the unit.
WARNINGThis I/P transducer/regulator is intrinsically safe and anyrepair is prohibited. Replacement must be done byProportionAir. If you attempt any repair yourself, you willviolate the warranty and could injure personnel or damageequipment.
SBK1−1 Adds Surge Suppression Across Brake Outputs BKP&M1. SBK1−2Adds A Diode Across TheBrake Coil At BKP&M1.SBK2−1 Adds Surge Suppression Across Brake Outputs BKP&M4. SBK2−2Adds A Diode Across TheBrake Coil At BKP&M4.
Aux. brake control input plugCRM16−P1=*BRKON3CRM16−P2=*BRKON4
control
MARO2P10203703E 10–5
10. BOARD ADJUSTMENTS AND CALIBRATIONS
Use Procedure 10–2 to perform a beaker test.
Procedure 10–2 Manual Flow Test (Beakering Test)
All personnel and unnecessary equipment are out of the workcell.
The applicator is functioning properly.
The controller is in manual mode. This is performed either by the cellcontroller or by turning on the manual enable input.
Turn off the servo disconnect.
Place a graduated beaker under gun assembly.
1 Press MAN FCTNS.
2 Press F1, [TYPE].
3 Select Gun Control. You will see a screen similar to the following.
Manual/Appl./Con/ JOINT 10 %
** Entries Affect Outputs Immediately **Pulse time (sec.): 0.0
Gun Gun Select Color
Paint Fluid Atomizing Ai Fan Air
Electrostatic
OFF 1 1
0.0 30.0 0.0
0.0
Press a function key[ TYPE ] ON PULSE ALLOFF [GROUP] >
[ TYPE ] HELP >
CAUTIONThe following steps will actually turn on and off the outputs. Besure your workcell is set up properly.
10.2MANUAL FLOW TEST(BEAKERING TEST)
Condition
Step
MARO2P10203703E10–6
10. BOARD ADJUSTMENTS AND CALIBRATIONS
4 Move the cursor to each item you want to set, and set the itemappropriately.
Set pulse time.
Set gun select
Set color number
Set paint fluid (Flow rate in cc/min)
Set Atomizing Ai, Fam Air and Electrostatic to 0.
5 To pulse the selected output, select the item to be pulsed and pressF3, PULSE. The output will pulse on then off automatically. Thesystem will dispense selected color for 30 seconds then turn off.
6 Measure paint in graduated beaker for proper results.
7 To turn off or set all outputs to 0, press NEXT, >, then press F4,ALLOFF.
NOTE Any outputs turned on will remain until they are turned off or untilall outputs are set to off.
MARO2P10203703E 10–7
10. BOARD ADJUSTMENTS AND CALIBRATIONS
A cold start (START COLD) is the standard method for turning on powerto the robot and controller. A cold start does the following:
Initializes changes to system variablesInitializes changes to I/O setupDisplays the UTILITIES Hints screen
A cold start will be complete in approximately 30 seconds.
Use Procedure 10–3 to perform a cold start.
Procedure 10–3 Performing a Cold Start
All personnel and unnecessary equipment are out of the workcell.
WARNINGDO NOT turn on the robot if you discover any problems orpotential hazards. Report them immediately. Turning on arobot that does not pass inspection could result in seriousinjury.
1 Visually inspect the robot, controller, workcell, and the surroundingarea. During the inspection make sure all safeguards are in place andthe work envelope is clear of personnel.
2 Turn the power disconnect circuit breaker on the operator box oroperator panel to ON.
3 On the teach pendant, press and hold the PREV and NEXT keys. SeeFigure 10–2.
4 While still pressing PREV and NEXT on the teach pendant, press theON button on the operator panel. See Figure 10–2.
10.3COLD START(START COLD)
Condition
Step
ON
OFF
POWER DISCONNECTC-SIZE CONTROLLER
MARO2P10203703E10–8
10. BOARD ADJUSTMENTS AND CALIBRATIONS
Figure 10–2. Teach Pendant and Operator Panel
ÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎÎ
ÎÎÎÎÎÎÎÎ
ÎÎÎ
ÎÎÎÎÎÎ
ÎÎÎÎÎÎÎÎ
ÎÎ
ÎÎÎ
ÎÎÎÎÎ
ÎÎÎÎÎÎ
PORT
BATTERYALARM
CYCLE START ON
OFF
REMOTE
REMOTE
HOLD
PURGECOMPLETE
PURGEFAULT
EMERGCY STOP
TEACH PENDANTENABLED
FAULT RESET
FAULT
ÏÏÏÏ
ÏÏÏÏ
ON
OFFHOUR METER
Î
BRAKE ENABLE
PURGE ENABLE
LOCAL
ON BUTTON
PREVIOUSKEY
NEXT KEY
(FAULT)RESET KEY
FAULT
HOLD
STEP
BUSY
RUNNING
MAN ENBL
PROD MODE
JOINT
XYZ
TOOL
OFF ON
5 After the BMON> prompt appears on the teach pendant screen, releasethe PREV and NEXT keys.
BMON>
MARO2P10203703E 10–9
10. BOARD ADJUSTMENTS AND CALIBRATIONS
6 Turn on the controller. You will see a screen similar to the following.
COLD CTRL INIT START >
*** BOOT MONITOR for R-J2 CONTROLLER ***Version 4.22P(OIE) 01-JAN-199x
F-ROM/D-RAM/C-MOS : 8.0/8.0/2 MBTP Version : ICurrent TIME : 01-JAN-199x 22:52:53
Slot ID FC OP0 9B 1 0 R-J2 Main CPU1 AF 1 0 R4600 Sub-CPU V4.20D 6A 0 0 MCARD I/FE 8A 0 0 AB/Ether I/F
BMON>
NOLOAD
optionaloptionaloptional
7 Press F1, COLD, and press ENTER.
8 Press F5, START, and press ENTER.
On the operator panel or operator box, the ON button will beilluminated, indicating robot power is on.
On the teach pendant screen, you will see a screen similar to thefollowing.
UTILITIES Hints JOINT 10 %
PaintTool (TM)
V4.30-x
Copyright 1997, FANUC Robotics
North America, Inc.
All Rights Reserved
[TYPE ] HELP
BMON> COLD
BMON> START
MARO2P10203703E10–10
10. BOARD ADJUSTMENTS AND CALIBRATIONS
The following procedures are applicable to all P-200 robot systemsincluding those on a pedestal, rail or with an opener. In the case of aP-200 robot and opener, both units must be properly purged before thecontroller can be turned on.
Procedure 10–4 Powering on the Robot Systems
1 With the main disconnect ON, you should observe:
Purge complete LED is off.Purge enable pushbutton (purging) lamp is off.ON pushbutton lamp is off.Purge fault LED is on
2 Push and hold the PURGE ENABLE pushbutton. You should observe
Purge solenoid engages when minimum pressure requirements aremet.
At this point you can release the purge enable pushbutton, no changeshould occur.
3 At the end of the 5 minute purge, the pushbutton purging lamp willturn off and the purge complete LED will turn on. Also, the purgesolenoid will shut off.
4 If this procedure does not work, go to Chapter 4 Troubleshooting.
10.4POWER ONSEQUENCE
Step
MARO2P10203703E 10–11
10. BOARD ADJUSTMENTS AND CALIBRATIONS
Use this procedure for complete controller shutdown including purgecircuitry.
Procedure 10–5 Controller Shutdown Procedure
1 Push the E-stop push button.
2 Push the controller “OFF” pushbutton.
3 Pull the Main Disconnect switch.
For servo lockout use the following procedure:
Procedure 10–6 Servo Lockout Procedure
1 Push the E-stop push button.
2 Open the servo lockout disconnect switch.
3 Lockout switch
10.5CONTROLLERSHUTDOWN
Step
10.6SERVO LOCKOUT
Step
Page 2
11 CONNECTIONS
CONNECTIONS
11–1MARO2P10203703E 11This section includes the connections and specifications for modular I/Ounits. It also contains diagrams for the cables connecting the R-J2 to theP-200 robot and noise reduction guidelines.
Excessive noise might cause errors in the controller. Wiring guidelines foreliminating these conditions include routing I/O wiring well away fromany conductors connected to the pulse coder and other internal controlwiring.
I/O wiring must not occupy the same wireways as the internal controlwiring. Where possible avoid parallel runs of I/O and internal controlwiring. Cross internal control wiring with I/O wiring at right angles. A minimum separation of 100 mm is recommended.
Provide all I/O wiring with a separate power supply. Do not use controllerinternal voltages such as +5VDC or 24VDC for I/O. Insure that commonconductors for power supplies are not shared. Use separate commons foreach power supply used for I/O.
Insure that all coils for electromechanical devices such as relays,contactors, pneumatic solenoids, etc. are equipped with suppressiondevices. For DC circuits, diode suppressors are recommended and for ACcircuits the suppressors should be a combination of a MOV with aresistor/capacitor network.
11.1NOISE REDUCTIONGUIDELINES
MARO2P10203703E11–2
11. CONNECTIONS
This section describes the connections and specifications for modular I/Ooutputs.
OFF ON Max. 2 ms This is the value from input to output in the module. The actual value isdetermined by adding it to the scanning time depending on each systemTime
ON OFF Max. 2 msdetermined by adding it to the scanning time depending on each system.
Fuse 3.2A, 1 piece for each output A0 ~ A5 andB0 ~ B5
Terminal connection andcircuitry
A1
A3
A5
B1
B3
B5
O
O
O
O
O
O
O
L
L
L
L
L
A0L
A2L
A4L
B0L
B2L
B4L
OO
O
O
O
O
O
O
: output circuitO
O
LED
Fuse
Fuse
12
3
45
67
89
1011
1213
1415
1617
20
1819
L
9 19
: loadL
NOTE:Each output signal group (A0–A5 andB0–B5) contains six output signals.However, each group must have an entiregroup of eight signals assigned to it.For example, A0–A5 might be occupiedby digital outputs 1 through 6 and B0–B5might be occupied by digital outputs9 through 14. Digital outputs 7 and 8 anddigital outputs 15 and 16 are unusuable.
MARO2P10203703E 11–9
11. CONNECTIONS
Table 11–8. Output Modules AOR08G and AOR16G
Item AOR08G AOR16G
Points/module 8 points 8 points
Points/common 1 point/common 4 points/common
Maximum load 30VDC/250VAC, 4A (resistance load) 30VDC/250VAC, 2A (resistance load)
Minimum load 5VDC, 10mA 1A (however 2A/common)
Maximum current — 4A/common
Limit of load Refer to load derating curve Refer to load derating curve
Response Time
OFF ON Max. 15ms
This is the valuefrom input tooutput in themodule. Theactual value is
Max. 15ms
This is the valuefrom input tooutput in themodule. Theactual value is
ON OFF Max. 15ms
actual value isdetermined byadding it to thescanning timedepending oneach system.
Max. 15ms
actual value isdetermined byadding it to thescanning timedepending oneach system.
Relay life Mechanical Min. 20,000,000 times Min. 20,000,000 times
Electrical Min. 100,000 times (resistance load) Min. 100,000 times (resistance load)
Terminal connection andcircuitry
v
v
v
v
A4
A5
A7
A6
L
L
L
L
1
23
45
67
89
1011
1213
1415
1617
20
1819
v
v
v
v
A0
A1
A3
A2
L
L
L
L
: Direct current power or alternating current power
v
A7
1
23
45
67
89
10
v
v
A0
A1
A3A2
L
L
L
L
L
L
L
A4
A5A6
L
B3
v
L
LL
BO
B1B2
L
11
1213
1415
B7
L
LL
B4
B5B6
L
17
1819
20
16v
: Direct current power or alternating current powerv
MARO2P10203703E11–10
11. CONNECTIONS
Table 11–9. Output Module ADA02A
Item ADA02A
Number of outputchannels
2 channels/module
Digital input 12-bit binary (2’s complement representation)
Analog output –10VDC ~ +10VDC (external load resistance: 10K or more) selectable0mADC ~ + 20mADC (external load resistance: 400 or less) usable
Input/outputcorrespondence
Digital Input Analog Output
+2000 +10V+1000 +5V or +20mA 0 0V or 0mA–1000 –5V–2000 –10V
Resolution 5mV or 20 A
Comprehensive accuracy Voltage output 0.5% (for the full scale)Current output 1% (for the full scale)
Converting time 1ms or less. The converting time is the one only inside the module. The actual response timeis added a scan time that is determined by the system.
Isolation Photocopier isolation (between output signal and base). However, non-isolation betweenoutput channels.
(Note 1) Use a 2–core twisted shielded cable as the connection cable.(Note 2) Ground the cable shield on the load side
ADA02A
Channel 0
D/Aconverter
V0+
Voltageamp.
V0–
Currentamp.
10+
10–
Channel 1
D/Aconverter
Voltageamp.
Currentamp.
V1+
V1–
10+
10–
Current outputLoad
400 ohms or less
Voltage outputLoad
10K ohms or more2
4
6
8
10
12
14
16
18
20
MARO2P10203703E 11–11
11. CONNECTIONS
Figure 11–1 shows both the ER-1 and ER-2 R-J2 Allen-Bradley RemoteI/O (ABRIO) printed circuit boards. For more detailed information on thetypes and styles of the Ethernet Remote Printed Circuit Board, seeSection 1.11, Table 3–13, and Table 3–14 which list the functions of thealarm LEDs.
Figure 11–1. ER-1 and ER-2 Printed Circuit Board LEDs
This section describes the connections and specifications for modular I/Ounits.
Table 11–10. Input Module AID32B, Non-isolated
Item AID32B
Points/module 32 points
Points/common 16 points/common
Sink/source cur-rent
Both directions
Input voltage 24 VDC +10% –20%
Input current 7.5mA (average)
ON voltage cur-rent
Min. 18 VDC min. 6 mA
OFF voltage cur-rent
Max. 6VDC max. 1.5 mA
Response
OFF ON Max. 2 ms This is the value from input to output in the module. The actual value is determined byadding it to the scanning time depending on each systemnse
Time ON OFF Max. 2 msadding it to the scanning time depending on each system.
Input display Not provided
External connec-tion
Connector (HONDA TSUSIN MR-50RMA)
Terminalconnection andcircuitry
A0A1A2A3A4A5A6A7B0B1B2B3B4B5B6B7
16324815314730461228441127431042
29,4549,50CMA
13,17 ––+24V
14,18 ––GND
C0C1C2C3C4C5C6D7D0D1D2D3D4D5D6D7
07243906233822370320350219340133
21,3640,41CMC
04,08 ––+24V
05,09 ––GND
: input circuit CMInternalCircuit
+24V or GND can be selected for input common as above figure.Note: Make sure to connect all common (CMA, CMC) pins.
11.4MODULAR I/O INPUTS
MARO2P10203703E 11–13
11. CONNECTIONS
Table 11–11. Input Modules AID16C and AID16D
Item AID16C AID16D
Points/module 16 points 16 points
Points/common 16 points/common 16 points/common
Sink/source current Source current type Sink current type
Input voltage 24VDC +10% –20% 24 VDC +10% –20%
Input current 7.5 mA (average) 7.5 mA (average)
ON voltage current Min. 15VDC min. 4 mA Min. 15 VDC min. 4 mA
OFF voltage current Max. 5VDC max. 1.5 mA Max. 5VDC max. 1.5 mA
ResponseTime OFF ON Max. 20ms
This is the value from input tooutput in the module. Theactual value is determined by
Max. 20msThis is the value from input tooutput in the module. Theactual value is determined by
ON OFF Max. 20ms
actual value is determined byadding it to the scanning timedepending on each system.
Max. 20ms
actual value is determined byadding it to the scanning timedepending on each system.
(Note 1) Though the example above shows the connection of channels 0 and 2, it is just thesame with the channel 1 (I1+, V1+, V1–, COM1 and FG1) and the channel 3 (I3+, V3+,V3–, COM3 and FG3).(Note 2) Either voltage input or current input can be specified for each channel. When current input is specified,make sure to short–circuit in + and Vn+.
(Note 3) Use shielded cables of twisted pair for connecting.
Voltage input
Voltage
supply
Current input
Current
supply
2
4
6
8
10+
11+V0+
V0–
V1+
V1–
COM0
COM1
FG0
1
3
5
7
11
13
15
17
16
14
12
10
9
FG1
12+
13+ 250
V2+
V3+
V2–
V3–
COM2
18
19
20
COM3
FG2
FG3
MULTIPROCESSOR
11.5ANALOG INPUTMODULE
Page 15
12 SCHEMATICS
SCHEMATICS
MARO2P10203703E 12–112Topics In This Chapter Page
Schematics The following section includes separate print sets for the P-200 robot. Each print set includes the R-J2 controller schematic with R-J2 internal cable connector pinouts and an overview of the C-size cabinet with component locations. 12–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MARO2P10203703E12–2
12. SCHEMATICS
NOTES
MARO2P10203703E
12. SCHEMATICS
12–3
Figure 12–1. R-J2 P-200 Controller Total Circuit Diagram
TERMINATE AT24 COLOR – EO–3150–123–00012 COLOR – EO–3150–124–0008 COLOR – EO–3150–125–0004 COLOR – EO–3150–126–000
TERMINATE ATEO–3150–127–000
MOUNT TO CABLE CARRIER
AREA FOR PLACEMENTOF INLINE UNION
CLAMP
PR – [5/16 OD.]PT – [5/16 OD.]
FM – [5/16 OD.]WW – [5/16 OD.]
NOTE:MARK BOTH ENDS OF TUBINGWITH LABLE SHOWN.
EO–3150–223–001MOUNT OPPOSITE OFCABLE CARRIER
TERMINATE ATSOLVENTRECOVERY
ESTAT – [5/16 OD.]GROUND – [1/4 OD.]
RP – [1/2 OD.]
FAS – [1/2 OD.]
AAS – [1/2 OD.]
FAS – [3/8 OD.]
AAS – [3/8 OD.]
FAP – [1/4 OD.]
AAP – [1/4 OD.]
PD – [1/4 OD.]
DUMP – [1/2 OD.]
PTS – [3/8 OD.]PTS – [3/8 OD.]
LOWER GUN CONTROL LINES RAIL
EO3150–223–000A000B
AIR VALVE TO SHUTOFF
1:1 Ratio Boosters
12–76
12. SCHEMATICS
MARO2P10203703E
NOTES
MARO2P10203703E
12. SCHEMATICS
12–77
Figure 12–38. Color Changer Rail 4 Color Lines
CP3 – [5/32 OD.]CP1 – [5/32 OD.]
CP2 – [5/32 OD.]CP4 – [5/32 OD.]
PSP – [5/32 OD.]CCSS – [3/8 OD.]
CCAS – [3/8 OD.]PAP – [5/32 OD.]
PS3 – [3/8 OD.]PS1 – [3/8 OD.]
PR3 – [5/16 OD.]PR1 – [5/16 OD.]
TERMINATE INSIDE OFPAINT DROP BOX
TERMINATE INSIDE OFPAINT DROP BOXBO
OT
H W
ALL
PR2 – [5/16 OD.]PR4 – [5/16 OD.]
PS2 – [3/8 OD.]PS4 – [3/8 OD.]
TERMINATE INSIDE OFPAINT DROP BOX
P–200
P–200
PLACE IN CABLECARRIER BEFORECLAMP
PR2PR4
PS2PS4
CP2CP4
CCASPAP
CP3CP1
PSPCCSS
PS3PS1
PR3PR1
PS1PAINT SUPPLY 1
PS2PAINT SUPPLY 2
COLOR CHANGER ASM.4 COLOR
CP4COLOR PILOT 4
PR2PAINT RETURN 2
PR1PAINT RETURN 1
CP3COLOR PILOT 3
AREA FOR PLACEMENTOF INLINE UNIONSSTAGER UNIONS THRU BRACKET
TO PPCE
4.0 METERS[13.0 FT]
SEE NOTE 1
COLOR CHANGER LINES4 COLOR RAIL
EO3150–227–000A000B
12–78
12. SCHEMATICS
MARO2P10203703E
NOTES
MARO2P10203703E
12. SCHEMATICS
12–79
Figure 12–39. FANUC R-J2 P-200 Single Stage Purge Paint Process Control With Connector Option
0VDC
CP32–2CP32–1
+5VDC
RACK INTERFACEMODULE 0VDC
0VDC
13 14A1 A2
INSERT INTO FANUC I/O RACK
(14 AWG YELLOW) (14 AWG YELLOW)
0VDC
INTERNAL DC WIRE TO BE16 AWG BLUE–TYPICAL
FLOWMETERINTERFACEMODULE
LEGEND
1.
NOTES:
BLUE–TYPICAL.
8200
8201
8202
8203
8204
8205
8206
8207
8208
8209
I/O POWERENABLE8204CR
8210
8211
8212
8213
8214
8215
8216
8217
8218
8219
8221
8222
8226
8227
8220
RC RC
16 AWG BLUE16 AWG BLUE
CP6–1 CP6–2ON CPU POWER SUPPLY
XGMF–09989
+5VDC JD1A PORTON INTERFACE MODULE CUT END OF CABLE AND TIE
THE FOLLOWING TOGETHERAT FUSE TERMINAL:PINK/2 BLACK DOTSYELLOW/2 BLACK DOTSPINK/1 BLACK DOT
TO LINE 8300 TO LINE 8300
DC WIRES TO BE 16 AWG
RC TERMINAL IN ROBOT CONTROLLER
TERMINAL IN REMOTE EQUIPMENTDEVICE OUTSIDE THIS ENCLOSURE
120VAC FROMCELL CONTROL PANEL
NEUTRAL FROMCELL CONTROL PANEL
8228
8229
8230
8231
8232
8233
8234
8235
8236
8237
8238
0VDC
ROBOT MAIN AIRSUPPLY VALVE(FIRE VALVE)
8239
8240
8241
8242
8243
8244
8245
8246
8247
8248
8249
8250
8251
8252
8253
8254
8255
RC RC
RC
TERMINAL IN PAINT PROCESSVALVE PANEL
PP
PP1 AMP
.5 AMP
82091 82092
82092
820118204CR/SUPPRESSOR
14132
82091 82092
821428214F
82321
82231
82231
I/O POWERENABLE(8222,SP,SP,SP)
82291
82292822928232SOL8232F
8223
8224
8225
+24VDC
+24VDC
+24VDC
+24VDC
14132[3][47]
82011
82091 82092[07][04]
[11][11]
(5)
(9)
[15] [15][14]
2. NUMBERS IN BRACKETS [ ] ARETERMINALS ON TERMINAL STRIPT1, UNLESS OTHERWISE NOTED.
(TERMINAL STRIP T2)
FROM SPADE CONNECTORS
ON POWER INPUT UNIT (PIU)(REF. NE–2000–411)
+24F
IPCBL–21 (REF) IPCBL–6 (REF)
PPCBL–1 PPCBL–2
82141
NE–2200–47A
PURGE PAINT PROCESS CONTROL
WITH CONNECTOR OPTION
FROM CP6 CONNECTOR
PP
SHT. 82
FANUC R-J2 P-200 SINGLE STAGE
12–80
12. SCHEMATICS
MARO2P10203703E
NOTES
MARO2P10203703E
12. SCHEMATICS
12–81
Figure 12–40. FANUC R-J2 P-200 Single Stage Purge Paint Process Control With Connector Option
+24VDC 0VDC+24VDC 0VDC
1
11
2
3
5
6
7
8
9
12
13
15
16
17
18
19
10
20
AOD16DSLOT 1
4
BLACKSOLENOID
PIGTAIL–TYP.
REDSOLENOID
PIGTAIL–TYP.
14
DC OUTPUT MODULE
SPARE
SPARE
SPARE
SPARE
SPARE
SPARE
SPARE
SPARE
SPARE
1
11
2
3
5
6
7
8
9
12
13
15
16
17
18
19
10
20
AOD16DSLOT 2
4
14
DC OUTPUT MODULE
SPARE
SPARE
SPARE
SPARE
SPARE
SPARE
SPARE
SPARE
SPARE
SPARE
SPARE
SPARE
SPARE
PILOT DUMP
(PT)8
7
1
2
(PD)
SPARE
ALL FUSES.5 AMP
SPARE
SPARE
8300
8301
8302
8303
8304
8305
8306
8307
8308
8309
8310
8311
8312
8313
8314
8315
8316
8317
8318
8319
8321
8322
8325
8326
8327
8323
8324
8320
8353
8352
8351
8350
8349
8348
8347
8346
8345
8344
8343
8342
8341
8340
8339
8338
8337
8336
8333
8332
8331
8330
8329
8328
8354
8355
TO LINE 8328 TO LINE 8328
FROM LINE 8327 FROM LINE 8327FROM LINE 8227 FROM LINE 8227
(PSP)
(PAP)
APPLICATOR CLEANERSOLVENT PILOT
APPLICATOR CLEANERAIR PILOT
PURGE SOLVENT PILOT
PURGE AIR PILOT
EE–3287–117–XXX
LOCATEDIN P–200
ROBOT ARM
GRNWHT PILOT TRIGGER
TO LINE 8400 TO LINE 8400
LEGEND RC TERMINAL IN ROBOT CONTROLLER
TERMINAL IN REMOTE EQUIPMENTDEVICE OUTSIDE THIS ENCLOSURE
TERMINAL IN PAINT PROCESSVALVE PANEL
PP
SPARE
PP
PP
PP
PP
PP
PP
TO LINE8411
8308SOL83081
83082
8309SOL83091
83092
8308F
8309F
83101
83111
83121
83131
83141
83112
83122
8310SOL
8311SOL
8312SOL
82231
83102
82231
82231
82231
8310F
8311F
8312F
8313F
8314F
8336SOL83361
8336F
82092
82092
82092
82092
8334
I.S. GROUND
8335
P1
ISB7
EE–3287–328–001
SUPPLIED AS PART OF ROBOT PRODUCT
REF. EE–3287–550
ISB7–1
ISB7–2
[16][16]
[17]
[18]
[19]
[20]
[21]
[22] [22]
[21]
[20]
[19]
[18]
[17]
.5 AMP
[23] [23]
NOTES:1. NUMBERS IN BRACKETS [ ] ARE
TERMINALS ON TERMINAL STRIP T1.
(ACSP)
(ACAP)
INTRINSIC CABLE
82092
PPCBL–3
PPCBL–4
PPCBL–5
PPCBL–6
PPCBL–7
PP
83132
PPCBL–8
PP
83142
PPCBL–9
PPCBL–10
NE–2200–47A
PURGE PAINT PROCESS CONTROLWITH CONNECTOR OPTIONSHT. 83
FANUC R-J2 P-200 SINGLE STAGE
12–82
12. SCHEMATICS
MARO2P10203703E
NOTES
MARO2P10203703E
12. SCHEMATICS
12–83
Figure 12–41. FANUC R-J2 P-200 Single Stage Purge Paint Process Control With Connector Option
4–20 maI/P PAINT
PRESSURETRANSDUCER
0VDC
(+)
(+)
(–)
(–)
SHIELD CLEAR
BLACK
1.
CABLE C1INTERNAL TOTHIS PANEL
2.
NOTES:
+24VDC
ANALOG OUTPUT MODULE
FLOWCOMMAND
ATOMIZINGAIR
8
10
18
20
6(FG)
3.
16(FG)
SLOT 3ADA02A
NOTE THAT CARD OUTPUTS ARE NOT
4.
5.
ALL WIRING NOT ACCOMPLISHED BYBELDEN CABLE #8761 OR TRANSDUCERPIGTAIL TO BE 16 AWG BLUE WIRE.
JUM
PE
R
TERMINATE THE SHIELD DRAIN WIRESAT TERMINALS 6 AND 16 ON THEANALOG OUTPUT MODULE. AT THETRANSDUCER END OF THE CABLE CUTTHE DRAIN WIRE SHORT AND TAPEOR SHRINK WRAP.
ISOLATED, THEY SHARE A COMMON
(OF THE 24VDC SUPPLY).RETURN LINE THAT IS TIED TO 0VDCBELDEN CABLE
#8761–TYPICAL LOCATED IN P–200ROBOT ARM
9 1
210
7
8
1
82
7
8400
8401
8402
8403
8404
8405
8406
8407
8408
8409
8410
8411
8412
8413
8414
8415
8416
8417
8418
8419
8421
8422
8425
8426
8427
8423
8424
8420
8403XDUCER
FROM LINE 8355
LEGEND RC TERMINAL IN ROBOT CONTROLLER
TERMINAL IN REMOTE EQUIPMENT
DEVICE OUTSIDE THIS ENCLOSURE
INTRINSIC CABLE#EE–3287–117–XXX
82092 82231
84061
84071
TRANSDUCERS ARE SUPPLIED WITH 72”LONG PIGTAIL (RED/WHT, RED, GREEN,RED/YEL, AND RED/BLU CONDUCTORS).I.S. GROUND
I.S. GROUND
P1
P1
P1
P1
EE–3287–328–001
ISB5
ISB4
REF. EE–3287–550SUPPLIED AS PART OF ROBOT PRODUCT
ISB4–1
ISB4–2
ISB5–1
ISB5–2
6.NUMBERS IN BRACKETS [ ] ARETERMINALS ON TERMINAL STRIPT1, UNLESS OTHERWISE NOTED.
RC
RC
84071
84061[25]
[26]
[27]
(FG) TERMINALS 6 AND 16 ARE TIEDTOGETHER INTERNALLY AT THEMODULE AND ARE BROUGHT TO”FRAME GROUND” USING THEGROUND WIRE TERMINATED ATTHE GROUND BAR.
SHEILD 1
NE–2200–47A
PURGE PAINT PROCESS CONTROLWITH CONNECTOR OPTION
SHT.84
RC
TO LINE 8500
82092 82231
FANUC R-J2 P-200 SINGLE STAGE
12–84
12. SCHEMATICS
MARO2P10203703E
NOTES
MARO2P10203703E
12. SCHEMATICS
12–85
Figure 12–42. Flow Meter Interface Circuitry FANUC R-J2 P-200 Single Stage Purge Paint Process Control With Connector Option
12345678
1011
1314
222324252627282930
323334
9
CONTACT
FLOWMETERINTERFACE
353637
394041424344454647484950
DC INPUT MODULECONTACT–INPUT
NUMBER1–D62–D33–D0
6–C37–C0
10–B611–B3
22–C623–C424–C1
27–B428–B1
30–A6
32–A133–D734–D535–D2
37–C7
39–C2
42–B743–B544–B2
46–A747–A548–A2
3131–A4
1212–B0
15161718192021
15–A316–A0
19–D420–D1
NEW DATA AVAILABLE
PULSE PERIOD BIT 0
PULSE PERIOD BIT 1
PULSE PERIOD BIT 2
PULSE PERIOD BIT 3
PULSE PERIOD BIT 4
PULSE PERIOD BIT 5
PULSE PERIOD BIT 6
PULSE PERIOD BIT 7
PULSE PERIOD BIT 8
PULSE PERIOD BIT 9
PULSE PERIOD BIT 10
PULSE PERIOD BIT 11
PULSE PERIOD BIT 12
PULSE PERIOD BIT 13
PULSE PERIOD BIT 14
PULSE COUNTER BIT 0PULSE COUNTER BIT 3
PULSE COUNTER BIT 1PULSE COUNTER BIT 4PULSE COUNTER BIT 6
1. SIGNAL NAMES IN THE PRODUCT CABLEEE–3287–323–001 WILL NOT MATCH SIGNALNAMES ON THE INTRINSIC CABLENE–2000–977–XXX OR THE PROCESSCABLE NE–2000–977–003.
C
SEE NOTE 1. NE–2000–896–005THRU –055
IDEC IBRC 6062RFMRELAY BARRIER
14–70
14. OPENERS AND OPTIONS
MARO2P10203703E
NOTES
MARO2P10203703E
14. OPENERS AND OPTIONS
14–71
Figure 14–35. Side Saddle Option Intrinsic Connections
The controller is transported by a crane. Attach a rope to the eye bolts atthe top of the controller, as shown in Figure A–1.
Figure A–1. Transportation
Î
ÎÎÎÎÎÎÎÎÎ
ÎÎÎÎ
ÏÏ
ÏÏ
A.1TRANSPORTATION
MARO2P10203703E A–3
A. TRANSPORTATION AND INSTALLATION
When you install the controller, allow the space for maintenance as shownin Figure A–2.
Figure A–2. Installation Area
Controller Controller Controller
A.2INSTALLATION
A.2.1 Installation Area
MARO2P10203703EA–4
A. TRANSPORTATION AND INSTALLATION
Figure A–3. Assembly During Installation
ÎÎÎÎ
ÎÎÎÎÎÎ
ÎÎ
ÎÎÎÎÎÎ
ÏÏÏ
Mechanical unitconnectioncables (5)
Peripheral deviceconnection cable
Input power cable
ISB
Intrinsically safeteach pendant
A.2.2 Assembly DuringInstallation
MARO2P10203703E A–5
A. TRANSPORTATION AND INSTALLATION
Procedure A–1 Adjustment and Checks at InstallationSTEP ACTION ITEM # Q’TY SERVICE NOTES
1 Visually check the inside and outside of the controller.
2 Verify that the screwed terminal is connected properly.
3 Check that the connectors and printed circuit boards areinserted correctly.
4 Check transformer tap setting.
5 Connect the controller unit and mechanical unit cables.
6 Turn the breaker or disconnect off and connect the input powercable.
7 Check the input power voltage.
8 Press the EMERGENCY STOP button on the operator paneland turn the power on. Check the output voltage.
9 Check the interface signals between the control unit andmechanical unit.
10 Check the parameters. If necessary, set them.
11 Release the EMERGENCY STOP button on the operator panel.Turn on the controller.
12 Check the movement along each axis in the manual jog mode.
13 Check the end effector interface signals.
14 Check the peripheral device control interface signals.
A.2.3 Adjustment andChecks at Installation
MARO2P10203703EA–6
A. TRANSPORTATION AND INSTALLATION
The physical characteristic of the C-Size R-J2 controller are provided inTable A–1.
Table A–1. Physical Characteristics
ItemModel
Specifications/Condition
Transformer All models Three-phase 220, 240, 380, 415, 460, 480, 500, 550, or 575 V +10% –15%, 50/60+/–1 Hz
Input powersource capacity
All models 7.5 kVA + 1.1 kVA for optional user transformer
Average powerconsumption
All models 3.5KW nominal – path dependent (During rapid acceleration, the unit will temporarilyrequire two times the continuous rated power value.)
Permissibleambienttemperature
All models 0 degrees C to 45 degrees C
Permissibleambienthumidity
All models 75% RH or less, non-condensing, up to 95% RH for a limited period(within one month)
Surroundinggas
All models No corrosive gas. When you use the robot in an environment with a highconcentration of dust or coolant, consult with your FANUC Robotics salesrepresentative.
Vibration All models 0.5 G or less. When you use the robot in a location subject to serious vibration,consult with your FANUC Robotics sales representative.