R-G2 Controller Connecting and Maintenance Manual

This publication contains proprietary information of the GMFanuc Robotics Corporation furnished for customer use only. No other uses are authorized without the express written permission of the GMFanuc Robotics Corporation.

GMFanuc Robotics Corporation 2000 South Adams Road Auburn Hills, Michigan 48326-2800

The clescriptions and specifications contained in this manual were in effect at the time this manual was approved for. printing. GMFanuc Robotics Corporation, hereinafter referred to as GMFanuc Robotics or. GMFanuc, xesexves the right to discontinue models at any time or to change specifications or design without notice and without incurring obligations. This manual presents information and procedures regarding troubleshooting, maintenance, and connections of the robot. GMFanuc recommends that only persons who have been trained in the troubleshooting and maintenance of the robot in an approved GMFanuc Training Course perform these procedures.

GMFanuc TRAINING

GMFanuc Robotics conducts training courses on GMFanuc products on a regularly scheduled basis at our facilities in Auburn Hills, Michigan. For additional information contact: GMFanuc Robotics Training and Llocumentation 1,Iepartment 2000 South Adams Road Auburn Hills, Michigan 48326-2800 (313) 377-7000

1990 by GMFanuc Robotics Corporation All Rights Reserved

TABLE OF CONTENTS

................................................... 3 2.. PERIPHERAL DEVICE SAFETY .......................................... 4 3 . PRECAUTIONS FOR WORK ............................................... 6 3.1 Safety Speed Control ........................................... 8 4 . SAFETY FOR MAINTENANCE ............................................ 9 I1 MAINTENANCE ...................................................... 11
1.

I .

SAFETY

1 ~

OPERATOR SAFETY

.
a

......................................... 25 2 TROUBLESHOOTING ......... 25 2.1 Power Cannot be Turned .............e........................ 25 2.2 Troubleshooting by LEDs (41-44) on the Nain CPU PCB ............ 27 2.2.1 AT turning on the power switch ............................. 27 The teach pendant cannot display after all of LEDs (41-44) 2.2.2 are lit .............e...................................... 31 2.3 Troubleshooting Using Error Codes .............................. 32
e ~ ~ ~ 0 a . e . . . e e . e . 0 e . ~ . . ~ 4 ~ 0 . e 0 0 e 0 ~ 0 e ~ . 0

GENERAL .........we.... 1.1 Configuration 1.2 Component Functions 1.3 Preventive Maintenance

.......... 13 .................................................. ....................e....................... 213 3

.............e.................

On

2.4

............................... ............................... ........... 3 . DETAILS OF PCB .................................................... 67 3.1 Main CPU PCB ......0........................................0... 67 3.2 Serial Port PCB ................................................ 68 3.3 1/0 PCB ...0.................................................... 70 3.4 Axis Control PCB .......................O....................... 74 3.5 Axislwelding Control PCB ...................................... 75 3.6 Servo Amplifier PCB ...................O........................77

2.5 2.6 2.7 2.8

Position is Displayed in Reference Point Return (Calibration) Robot Vibrates Manual Operation Is Not Possible Problems of the Servo Amplifiers Checking Status Using Diagnostic Function (DIAGNOSE)

.................................................. .................................................

47 48 48 49 51

3.7 3.8 3-9 3. 10 3.11 3.12

Back Panel PCB Input Unit PCB Peripheral PCB Pulse Coder Detection PCB (A-600) Additional 1/0 PCB Laser interface PCB

................................................. 87 86 a................................................ ................e................................ 90 ....e......................... 92 ............................................. 93 ............................................ 94

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

99 ............................................ 100 ....................................... 104 5 . REPLACI.NG COMPONENTS .............................................. 105 5.1 Replacing PCBs ........................................... 105 5.2 Replacing Input Unit ........................................... 110
5.3 5.4

SETTlNG AND ADJUSTING POWER SYSTEM 4.1 Power System Block Diagram . e . e . a . 4 e ~ o . . e e * . e . m . . . e o a Q ~ e ~ e ~ ~ 4.2 Selecting Transformer Taps 4.3 Checking Input Unit 4.4 Checking Power Unit 4.5 Checking Servo Amplifier

.....................................

................................

95 95 96

5 . 5
5.6 5.7

Replacing Replacing Replacing Replacing Replacing

Power Unit Servo Amplifier Teach Pendant Battery Fuses

................................................

........................................... ...................................... ........................................ ..............................................

110 111 111 111 112

............................................... ........................... I11. CONNECTIONS ....................................................... 1. GENERAL ........................................................... 2 . BLOCK DIAGRAM ..................................................... 30 CONNECTION DIAGRAMS e.............................................. 3.1 Electrical Interface ........................................... 3.1.1 Connecting the input power supply ....................e..... 3.1.2 Connecting the external on-off and external
5.8 .5.9

Replacing Relays Replacing Key Sheet of Teach Pendant

emergency stop switches Control unit and peripheral device connections Mechanical unit and end effector connections Control unit and welding machine connection 3.2 Interface Signal Details Types of signal Robot control signals Robot status signals 3 . 2 - 4 Peripheral device control signals End effector control signals Arc welding machine signals (arc welding interfaces) (ARC Mate. ARC Mate S r . . S-600) 7 Control unit and spot welding machine connections (spot welding interface) (S-300. S . 4 2 0 . S-700)

3.1.4 3.1.5 3.2.1 3.2.2 3.2.3 3.2.5 3.2.6 3.2.

3.1.3

.................................... ............. ............... ................ ....................................... ............................................ ...................................... ....................................... .......................... ...............................
............................

4.

TRANSPORTATION INSTALLATION Transportation 4 . 2 Installation

4.1

APPENDIX . . e e e . e e e e e e . . e . . o . . e e o o e e e * * m o * e * e o o o o e o e o e * * * * * e o * * * e * o o e e o o * * APPENDIX 1 INPUT/OUTPUT (DI/DO) 1.1 Peripheral Device Control Interface Signal End Effector Control Interface Signal 1.3 Arc Welding Interface Signal 1 . 4 Selecting Input Signal Common Line (24VlOV Common) 1.5 Noise Suppressors

1 . 2

........................... .................................... APPENDIX 3 SPARE PARTS LIST ...O................................O..... 3 . 1 Fuse Specification ............................................. 3 . 2 Spare Parts of Controller ...................................... 3 . 3 Location of Driver and Signals ................................. APPENDIX 4 SERVO AMPLIFIER ........................................... APPENDIX 5 TOTAL CONNECTION DIAGRAM .................................. 5 . 1 Total Connection Diagram ....................................... 5 . 2 Emergency Stop Signal Diagram .................................. 5 . 3 Overtravel Signal Circuit .................................O.... 5 . 4 Pulse Coder Signal Connection Diagram .......................... 5 . 5 Overload Alarm Detection Signal Diagram ........................ 5.6 Error Code 003 (Hand Broken) ....................O.O....e....... 5 . 7 Fuse Alarm for Brake Control ................................... 5 . 8 Error Code 300 (Servo Not Ready) ............................... 5 . 9 Cable List .....................................................

APPENDIX 2 PERIPHERAL DEVICE CABLE SPECIFICATIONS 2.1 Peripheral Device Control Interface A . B. Cable End Effector Control Interface Cable 2. 3 Arc Welding Interface Cable

2 . 2

............. AND ................................... ................................................. ................................................... DIGITAL SIGNAL TABLE ................. ..................... .......................... ................................... ............. O............................................. .................... .............. C

I.

SAFETY

SAFETY PRECAUTIONS Follow a l l s a f e t y p r e c a u t i o n s devices.

when

operating

robot

and

its

peripheral

1. OPERATOR SAFETY Operator s a f e t y i s t h e primary s a f e t y c o n s i d e r a t i o n . Because i t i s v e r y d a n g e r o u s f o r anyope t o e n t e r t h e o p e r a t i n g s p a c e of t h e r o b o t d u r i n g a u t o m a t i c o p e r a t i o n , a d e q u a t e s a f e t y p r e c a u t i o n s must be o b s e r v e d . The f o l l o w i n g p r e c a u t i o n s can h e l p e n s u r e o p e r a t o r s a f e t y . 1) P r e c a u t i o n f o r i n s p e c t i o n a ) Turn o f f t h e power of t h e c o n t r o l l e r . b ) Turn o f f t h e c o ~ p r e s s e da i r s o u r c e and r e l i e v e t h e a i r p r e s s u r e . c ) Check t o mske s u r e t h e r o b o t immediately s t o p s a f t e r p r e s s i n g t h e ENERGENCY STOP b u t t o n f o r i n i t i a l i n s p e c t i o n of d a i l y o p e r a t i o n . d ) I f t h e r o b o t motion i s n o t needed f o r i n s p e c t i n g t h e e l e c t r i c a l c i r c u i t s , p r e s s t h e EMERGENCY STOP b u t t o n on t h e o p e r a t o r p a n e l . e ) I f power i s needed t o c h e c k t h e r o b o t motion o r e l e c t r i c a l c i r c u i t s , be s u r e t o p r e s s t h e EMERGENCY STOP b u t t o n Immediately when n e c e s s a r y . 2) Precaution for setup a ) I f r o b o t motion o r o p e r a t i o n i s n o t needed, t u r n o f f t h e power a t t h e controller. b ) B e f o r e i n d i c a t i n g program, d i a g n o s t i c d a t a , o r o t h e r d a t a on t h e t e a c h p e n d a n t , p r e s s t h e EMERGENCY STOP b u t t o n o r t u r n o f f t h e ENBL s i g n a l o f t h e p e r i p h e r a l d e v i c e c o n t r o l . i n t e r f a c e t o p r e v e n t t h e r o b o t motion. 3) P r e c a u t i o n for. e n t e r i n g t h e r o b o t motion a r e a a ) I n s t a l l a p r o t e c t i v e fence t h a t completely surrounds t h e operating space of t h e r o b o t s y s t e m . b ) P r o v i d e a door w i t h a n i n t e r l o c k i n t h e p r o t e c t i v e f e n c e t o p r e v e n t I n s t a l l a door e n t r y i n t o t h e work a r e a u n l e s s t h e door i s opened. i n t e r l o c k t h a t sends a s i g n a l t o a c t i v a t e t h e s a f e t y speed s i g n a l (*SFSD) i n t h e p e r i p h e r a l d e v i c e c o n t r o l i n t e r f a c e t o p r e v e n t r o b o t o p e r a t i o n whenever anyone e n t e r s t h e work a r e a . c ) A l t e r n a t i v e l y , c o v e r t h e f l o o r o f t h e o p e r a t i n g s p a c e w i t h a mat h a v i n g a b u i l t - i n s w i t c h , o r mount a p h o t o e l e c t r i c s w i t c h i n t h e r o b o t work area. The s w i t c h s h o u l d be s e t up t o send an a u d i b l e o r v i s u a l a l a r m w h e ~ anyone e n t e r s t h e o p e r a t i n g s p a c e and s t o p r o b o t motion i f required. d ) I n s t a l l a w i r e s p r i n g l i m i t s w i t c h on t h e r o b o t t o s t o p i t when i t s e n s e s t h e e n t r y of anyone i n t h e work a r e a . e ) I n s t a l l a n EMERGENCY STOP b u t t o n f o r t h e r o b o t w i t h i n t h e o p e r a t o r ' s r e a c h i n t h e r o b o t ' s operatLng space. I n a d d i t i o n t o t h e p r e c a u t i o n s above, always f o 1 l . o ~a l l r e g u l a t i o n s f o r t h e f a c i l i t y i n which t h e r o b o t i s i n s t a l l e d .

Provide a limit switch which operates when the gate is opened. (To be connected in series with the *SFSD signal)

Fig. 1 Protective fence

2. PERIPHERAL DEVICE SAFETY

When d e s i g n i n g t h e c o n f i g u r a t i o n of t h e r o b o t system, t a k e adequate p r e c a u t i o n s t o avoid damage t o t h e r o b o t and p e r i p h e r a l d e v i c e s . I ) I r s t a l l a s a f e t y j o i n t between t h e end e f f e c t o r and t h e w r i s t of t h e r o b o t . To Design t h e j o i n t s o t h a t i f i t i s broken, t h e r o b o t st.ops immediately. e f f e c t t h e s t o p motion ~ i g n a l ,u s e t h e breakage d e t e c t i o n s i g n a l (*HRP) of t h e end e f f e c t o r c o n t r o l i n t e r f a c e . 2 ) I n s t a l l a l i m i t s w i t c h or s e n s o r a t t h e machine end p o s i t i o n , machine save p o s i t i o n , e t c . , on t h e machine t o o l o r p e r i p h e r a l d e v i c e . These s e n s o r s o u t p u t s i g n a l s t o inform t h e r o b o t t h a t i t h a s e r t e r e d t h e work a r e a of t h e machine. The r o b o t can be programmed a f u n c t i o n to s t o p i t s motion when these s i g n a l s a r e received. 3) I f any a x i s of t h e r o b o t moves beyond t h e s p e c i f i e d l i m i t ( o v e r t r a v e l ) , t h e r o b o t immediately goes i n t o an emergency s t o p c o n d i t i o n . 4 ) The r o b o t can be stopped by t h e EMERGENCY STOP b u t t o n on e i t h e r t h e I t can a l s o be stopped by an e x t e r n a l o p e r a t o r panel or t e a c h pendant. emergency s t o p s i g n a l through t h e p e r i p h e r a l d e v i c e c o n t r o l i n t e r f a c e . 5) The r o b o t s t o p s o p e r a t i n g , i f ( a ) t h e r o b o t s e r v o u n i t m a l f u n c t i o n s , (b) t h e c o n t r o l u n i t or. motor i s o v e r h e a t e d , ( c ) an a x i s o v e r t r a v e l s , o r (d) t h e d a t a memory i s abnormal. 6 ) When t e a c h i n g t h e r o b o t t o g r a s p a workpiece o r t o o l , always make s u r e t h a t t h e r o b o t g r i p p e r i s f u l l y c l o s e d o r f u l l y open s o t h a t t h e r o b o t can s t o p t o grasp the object. if it f ~ i l s 7) S e t t i n g of r o b o t motion range I f t h e system s e r v i c e r a r g e i s narrower t h a n t h e r o b o t motion range, t h e r o b o t motion range can be s e t by a parameter s o t h a t t h e r o b o t motion range does n o t exceed t h e s e r v i c e range. 8) Use r o b o t i n t e r l o c k s i g n a l The r o b o t h a s s e v e r a l k i n d s of t e r m i n a l s f o r r e c e i v i n g e x t e r n a l i n t e r l o c k s i g n a l s . The r o b o t can be h e l d or stopped by t h e s e s i g n a l s . To u s e them, s e t up c o n t r o l c i r c u i t s on t h e p e r i p h e r a l d e v i c e s t h a t w i l l be a c t i v a t e d when t h e r e i s a p o s s i b i l i t y of damage t o t h e equipment.

9) Use a limit switch with a tactile bar

a)

In order to prevent injury to a worker or damage to the robot, a limit switch with a tactile bar can be used. A typical tactile switch circuit is shown in Fig. 2 (a)

13.2

Circuit composition

Limit switch CODE:

@ = Diameter

Fig. 2 (a) Limit switch with tactile bar

YAIIATAKE HONEYWELL limit switch: 8LS-1-J IOA-125, 250 or 480VAC 0.8A-115VDC; 0.4A-230VDC, 0.1A-550VDC
b To connect a tactile switch to the robot: Mount the tactile switch on the robot or machine tool. Connect a close b ) . contact on the limit switch to the *ESP signal as shown in Fig. 2 (

Limit switch with tactile b a ~

)I
I

Contlol unit

---i
i

. _ . -

PCB

Fig. 2 (b) Example of a circuit using a limit switch with tactile bar mounted on a robot

If two or more limit switches with tactile bars are mbunted on the robot, connect them in series as shown in Fig. 2 ( c ) .

Fig. 2 (c) When two or more limit switches are used

3. PRECAUTIONS FOR WORK 1 ) The r o b o t h a s t h e f o l l o w i n g s a f e t y f u n c t i o n s : a ) S t a r t and s t o p s i g n a l s The s t a r t s i g n a l s t h a t e f f e c t t h e r o b o t motion a r e provided i n t h e t e a c h pendant, o p e r a t o r p a n e l and p e r i p h e r a l d e v i c e c o n t r o l i n t e r f a c e A . More t h a n one s i g n a l i s n o t e f f e c t i v e a t a time. E n a b l e l d i s a b l e s t a t e of t h e s e s i g n a l s i s c o n t r o l l e d by t h e ON/OFF s w i t c h on t h e t e a c h pendant and t h e R E M O T E s w i t c h on t h e o p e r a t o r p a n e l a s shown i n Table 3 . The o p e r a t o r s t a n d i n g n e a r t h e r o b o t mechanical u n i t can i n h i b i t an o t h e r o p e r a t o r ' s control device. S i g n a l s t o s t o p t h e r o b o t motion (emergency s t o p , h o l d , r e s e t , e t c . ) a r e always e f f e c t i v e . The o p e r a t o r can s t o p t h e r o b o t motion u s i n g t h e s e s i g n a l s immediately a f t e r d e t e c t i n g danger. b) Safety s t a r t When s t a r t i n g t h e program u s i n g t h e t e a c h pendant, t h e r o b o t moves when t h e s t a r t key o r S h i f t key on t h e t e a c h pendant a r e p r e s s e d . R e l e a s i n g any of t h e s e keys c a u s e s t h e r o b o t t o s t o p ( s a f e t y s t a r t ) . The o p e r a t o r can s t o p t h e r o b o t motion o n l y by r e l e a s i n g t h e s e keys on t h e t e a c h pendant. c ) Override clamp Override i n manual o p e r a t i o n i s clamped l e s s t h a n t h e v a l u e s e t i n parameter No. 101. S e t t h e a p p r o p r i a t e v a l u e t o t h e parameter a c c o r d i n g t o the operator's s k i l l . The p r o t e c t i v e f e n c e open/close s i g n a l (*SFSD) i n t h e p e r i p h e r a l d e v i c e c o n t r o l i n t e r f a c e i s monitored i n repeat operation. When t h i s s i g n a l t u r n s o f f , t h e r o b o t motion i s stopped and o v e r r i d e i s clamped l e s s t h a n t h e v a l u e s e t t o parameter No. 100. The *SFSD s i g n a l i s connected t o t h e door of t h e p r o t e c t i v e f e n c e o r t h e s a f e t y mat so t h a t t h e s i g n a l t u r n s o f f when t h e o p e r a t o r e n t e r s t h e r o b o t motion a r e a .
Table 3 Conditions affecting the start signal

Source Teach pendant Condition Operator p a n e l Peripheral device control interface

Signal ON/OFF R E M O T E
ENBL

~ * 0 *
N
N

~ 1 1 1 1 1 0

1 0 1 1

1 0 1 0

1 1 1 1 .

1 1 1 0
N
N

0 0 1 1
N

0 0 1 0
N

*SFSD

Teach pendant Start Operator p a n e l Peripheral device control interface

START (BWD) START START

SSSSSSSSN
N N N N N

*
N: Y:

shows e i . t h e r 0 o r I . Ineffective Effective

Note 1 ) In addition to the above table, start signal is not received under the hold, reset, alarm or move condition. Note 2) SS shows the safety start. The motion is effective while the key is pressed. If *SFSD signal is zero, override is clamped less than the value of safety speed set by parameter No. 100. Note 3) When *SFSD signal turns off, the robot is held and override is clamped to the value of safety speed set by parameter No. 101. Use the teach pendant to reset the override. 1: Start is ineffective 0: Start is effective

2) An operator using the teach pendant must have priority over other people working on the system. When more than one worker is involved in a task, the worker carrying the teach pendant should be regarded as the operator; all other workers should follow his or her instruction. Never operate the robot controller or. any connected interface control panel without the operator's permission. 3) To avoid accident, no worker other than the operator should enter the robot motion range. Only the operator knows when the robot will move. Other workers in the area may not be aware of robot motion, which can cause serious injury. 4) Use the safety speed control to sufficiently decrease motion speed when anyone is in the robot's work area. To avoid injury, pay attention to the following:. a) The operator should always have a predetermined escape path. b) Never block the operator's escape route as shown in Fig. 3 (iii). c) Never enter the work area without an escape route as shown in Fig. 3 ( j ) , (ii).

Fig. 3 Dangerous work arrangement

d ) If any sign of danger is noticed, prese the EMERGENCY STOP button on the

teach pendant. When a program is being checked in repeat mode, a worker other than the operator should always be at the operator panel to press the EMERGFNCY STOP button. Use the HOLD key or HOLD signal to stop the robot motjon normally. 5) An external emergency stop signal can be input to the controller via the peripheral device control interface A. The emergency stop buttons should be provided in the vicinity of the protective fence and other locations around the work area as required. 6) The robot should not have a high-speed runaway because the robot's servo system provides a double safeguard function against this type of failure. However, if a rupaway does occur, the robot is immediately set to an alarm condition and stops operating. Always take care to use the proper operating mode. 7) Whenever entering the robot work area with the power turned on, turn off the ENBL signal in the peripheral device control interface A so that the axis motion, service code output or manual data input is ineffective.

3.1 Safety Speed Control The robot provides a safety speed control function during manual, repeat, and automatic operation. 1 ) Safe speed during repeat and automatic operation In repeat and automatic operation, robot motion is temporarily held by a falling digital input signal, called *SFSD, from the peripheral device control interface. When the robot is started at *SFSD=O the override is clamped less than the value set in parameter No. 100. *SFSD=l: The robot moves at the feedrate override set by the teach pendant. The speed can be set up to the maximum depending on the override setting. *SFSD=O: A moving robot is temporarily stopped at the time that the *SFSD signal falls. Subsequent motion speed is clamped to the lower override value set in parameter No. 100 when the robot is restarted. 2 ) Safe speed during manual operation The maximum override value that can be set during manual operation in TEACH mode is clamped less than the value set in parameter No. 101. 3) Motion speed holding when modes are selected The override value automatically changes according to the following rules so that a vastly different motion speed changeover does not occur when going back and forth from REPEAT mode and TEACH mode. a) From REPEAT to TEACH The override value in REPEAT mode is kept and the speed is decelerated by 50% as a result. If the override exceeds the preset value in parameter No. 101, it is clamped even further. b) From TEACH to REPEAT The override in REPEAT mode is automatically selected to the reduced speed closest in value to the speed selected in TEACH mode. Because of the preset parameter values, however, this speed may be lower than the corresponding value set in TEACH mode. Fig. 3.1 (a) shows an example of this transition function.

Override

A c t u a l
speed

Override
7

p a r a m e t e r No 1 0 1
5
20 X

REPEAT

TEACH

Fig. 3.1 (a) Transition of override to mode selection

@ The robot is operated at override 7 in REPEAT mode. @ When REPEAT mode is switched to TEACH mode, the override value is
usually kept to 7 . However, since parameter No. 101 is set to 6, the . override is clamped to 6 @ When TEACH mode is switched to REPEAT mode again, the override 4 is selected to retain the actual speed. @ The mode is switched from REPEAT to TEACH, and override 4 is maintained. 4 ) Example of using the safe speed control during repeat operation and aut0mati.c operation In this example, the motion speed is automatically decelerated to be lower than 40% of the maximum speed when the safety fence around the robot has been opened during automatic operation. This deceleration can be accomplished with an interface connection and parameter setting. a) Interface connection
Safety fence

Parametel No. 100 is ineffective

Do01 check limit switch (closed)

@
\

Cont~ol

* q--.Li-cg" A 9' "

,-

-J-

-.

SFSD

hametel

NO

100 is effective

Do01 check limit switch (open)

Fig. 3.1 (b) Safety speed interface connection

b) Parameter setting Parameter No. 1 0 0 : Set value 4 By setting parameter No. 100 to a value of 4, the robot is temporarily held and override is automatically clamped to 4 or less when the robot is restarted so that the motion speed is no more than 30% of the maximum speed.
4. SAFETY FOR MAINTENANCE

1) Never enter the robot's motion area while the robot is operating. Turn off the power before entering the robot's motion area for inspection and maintenance. 2 ) If it is necessary to enter the robot's motion area with the power turned on, first press the EMERGENCY STOP button on the operator panel. 3) When replacing or reinstalling components, take care to prevent entry of foreign matter into the system. When replacing the parts in the pneumatic presstrre system, be sure to decrease the pressure in the piping to zero by operating the pressure setting handle on the air regulator. 4 ) Press the power off switch on the control unit and turn off the auto breaker before handling the control unit components or entering the interior of the control unit. 5) When replacing parts, be sure to use only specified parts. To avoid damage to parts in the control unit or fire, never use fuses, etc. of nonspecified ratings. 6) Before restarting the robot, be sure to check that no one is in the robot motion area. Also check that the robot and the peripheral devices are in a normal operating condition.

I I.

MA1NTENANCE

1. GENERAL
This manual describes the maintenance and connection of the R-G2 controller for a robot. Maintenance Part: Troubleshooting, and installation, adjustment and replacement of the unit. Connection Part : Connection of R-G2 controll-er to the robot mechanical unit and peripheral devices, and installation of R-C2 controller. Note) Before going into the robot working area, be sure to turr, off the control unit power switch or press the errergency stop button on the operator panel or the teach pendant.
1.I Configuration Fig. l.l(e) shows the external view of the R-G2 controller.

To the peripher a1 device interface

To the pexiphexal device intex face S-500, S-700, M-400 ARC Mate (with additional axis) ARC Mate SI (with additional axis) L- 1000

S-5, S-10, S-600, ARC Mate, ARC Mate Sr., M-100, A-200, A-5 10, A-600, C-100

I [/Operat01 panel

To the peripheral device interface

Fig. 1.1 (a) The external view of the R-G2 controller

The robot control unit (hereinafter called a control unit) consists of the following units. For the mounting positions of each unit, refer to Fig. 1 . 1 (b) - g For the specifications of each unit, refer to the APPENDIX 3 SPARE PARTS.

Main CPU PCB Serial port PCB I/O PCB Axis control PCB Axis/welding control PCB Back panel PCB (g) Input unit (h) Power unit (i) Teach pendant ( j ) Servo amplifier (k) Operator panel ( 1 ) Transformer, AC line filter (m) Fan unit (11) Breaker, Breaker handle ( 0 ) Battery unit (p) Regenerative discharge unit (q) Laser I/F PCB (L-1000 alone) (r) Laser operator panel (L-1000 alone) ( s ) Peripheral.PCB (option) (t) Additional 110 PCB (option) ( u ) Floppy cassetteladspter (option) The control unit controls 3 - 6 sets of AC motors for controlling the interface signal with the hand and peripheral units.

(a) (b) (c) (d) (e) (f)

Floppy cassette adapter

Teach pendant Input unit

--

Breaker Power unit Serial port PCB Regenerative discharge unif (M-100) Additional I/O PCB 1 1 0 PCB Main CPU PCB Axis control PCB2, Axislwelding control PCB l 1 Axis c o n t ~ oPCB

Fan 2

Servo amp. 1
Fig. 1.1

(b) Control unit interior 6-5, S-10, S.600, ARC Mate,

ARC Mate Sr., M-100, A-200, A-510, A-600, C-100)

Regenerative discharge unit Servo amplifier 3

Servo amplifier 2

Servo amplifier 1

Fan 6

Servo ampiifier 4 Battery unit (Main Cabinet)

Servo I transformer (TF I ) or AC line filter Note) For S-420 traverse umt (Auxiliary Cabmet)

Input unit

C o n t ~ ot~ansfor l me1

Fan

Main CPU PCB Axis control PCB 2 Axis control PCB 1 Additional I/O PCB or periphe~al PCB

Input transformer (TF3)

I

Servo amplifier 2 Servo amplifier 1

Battery unit

Servo transformer (TFI) or AC line filter

Fig. 1.1 (d) Control unit interior (S-500, S-700, ARC Mate with additional axis, ARC Mate Sr. with additional axis, L-1000)

Table I .I (a) Relationship between servo amplifiers and axes

Robot

Servo amplifier 415 (Additiona1 &-axis M-axis L-axis N-axis M-axis L-axis M-axis L-axis axis)

Servo amplifier 1

Servo amplifier 2

Servo amplifier 3

S-5 ARC Mate S-600 S-10 ARC Mate Sr. 5-axis M-100 4-axis A-200 3-axis
,

w
h '

u
8

a a

Specified separately

u
U

Y
a a

B
B
Q

Specified separately

z
z z

R
R R

8
8 8 8

A-510 A-600 L-1000 5-axis 4-axis C-100 3-axis 2-axis

a
U

u
z
Y

w
x
X
X
X

R Y
Y

z
Z
Z

B
a

Y
Y

--

Robot

Servo Servo amplifier 1 amplifier 2

Setvo amplifier 3

Servo amplifier 4

M-axis L-axis N-axis M-axis L-axis S-300 S-420 S-500, S-700 5-axis M-400 4-axis
8

Servo amplifier 5 Traverse unit

W
W

8 8 U U U

f3

a a

( Y )

U
W
Z

Y
a
~1

--

Y
f3

B -

cc

Teach pendant

Control unlt Back panel

*
Robot mechanical unlt

ROBOT DIlDO

cassette
(Optlon)

Brake drive slgnal

Servomotor power

Data transfer control interface

Input power source

Welding Interface

Peripheral dev~ce control Interface

-*.- -^.- -.

uxi.la,rx id.'"

. i * a . , . * e -

-.- -,-.-.- %.".

I ^

3 . . r ., . * < . , . . * .

, ~ = - ~ . i ~ ' "

-..-.-..

.-

*- , . .

,--. . .-...---,

' -..---,--l"--r^t---.*--

'

"

'

, , ~ --

Fig. 1.1 (g) Block diagram of control unit (S-300, S-420, S-500, S-700, M-400)

Fig. 1.1 (h) Block diagram of control unit (L-1000)

Axis number and axis name The correspondence between numbers and names of robot axis set by parameters, etc. is shown below. (the order may different from that to be connected to the axis control PCB,)
Table 1.I (b) Numbers and names of axes
r

Axis number Robot 1 2 3 4 5 6 7 S-5, S-10, S-300, S-420, S-500, S-600, S-700 0 W U ARC Mate, ARC Mate Sr.
y

Remarks
-

B a Y *1
*1 S-420F Traverse unit

M-100, M-400 A-200 A-510 A-600 L-1000 C-100

Component Functions

0 W R y B - Y X Z a B - -

Main CPU PCB This has the RON containing a microprocessor (MPU), its peripheral circuit and a control program, and controls the robot. Serial port PCB This has the data memory to store the robot command data, parameters, etc. It controls the DT/DO signals for the serial data transfer interface for the teach pendant, floppy cassette, sensors, etc. and the switches and LEDs on the operator panel.. I/O PCB This controls the D U D 0 signals, such as the robot status signals, hand control signals and peripheral unit interface signals, Axis control PCB This controls the servo system position and the voltage for the servo amplifier. The 4-axis control PCB c a i l control up to four axes. Axislwelding control PCB This is used in the robot for welding, It controls the position of the servo system for two axes, the voltage for the servo amplifier, the analog signal for welding, and DI/DO signals. Back panel PCB PCBs used for control are mounted on this PCB. Tt relays the signals of control PCBs. Input unit (Input unit PCB) This controls the on/off sequence of the R-G2 controller. It also controls the connection/disconnection of the 100 VAC for driving the servo system depending on the presence of an error such as emergency stop or overtravel. It is provided with a driver for controlling the robot motor brake.

Power unit This converts AC input power to various DC power. It is mounted on the back panel PCB. Teach pendant This is used for programming a robot, The robot status and other various data are displayed by LCD. The display and key input are controlled by the serial PCB in the serial communication mode. Servo amplifier This controls the power amplification of the servomotor. Operator's panel This has the LEDs for indicating the robot state, the switch for starting the robot, etc, and is used in conjunction with the teach pendant. Two ports for the serial communication interfaces with the external units are connected to this panel. Transformer, AC line filter These are used for converting the voltage or eliminating a noise (AC line filter) from the power to be supplied to the control unit and servo amplifier. When the input power voltage of 200 VAC or 220 VAC, a noise of the input power for the servo amplifier is eliminated by the AC line filter. When the input power voltage is greater than 220 VAC, the voltage is converted by the transformer to meet the control unit and servo amplifier. The transformer differs according to the power supply capacity of robot. Fan unit This is used to cool the control unit interior. Breaker, Breaker handle The input power is connected to the breaker. With the breaker turned off, the power supply of a robot is shut off and a robot is stopped. The breaker ON/OFF can be controlled by the breaker handle from the outside of the control unit. The breaker can also be fixed to the OFF state by the breaker handle. Battery unit This is used for the back up of the data memory of the serial port PCB, etc. Regenerative discharge unit This is used for discharging the counterelectromotive force of the motor, and connected to the servo amplifier, Laser interface PCB Controls signal for laser oscillator. Laser operator panel This has switch to control laser oscillator and iluminescent diode for status display. Peripheral PCB (option) This controls the line tracking signal, analog output signal and laser oscillator (be sure to be used in case of L-1000). Additiorial 110 PCB (option) This is the same interface as that for connecting the peripheral unit of 110 PCB. It is used when the number of signals of 110 PCB is insufficient Floppy cassetteladapter (Option) This is an external storage to save the robot command data and the set data.

1.3 Preventive Maintenance

Daily maintenance and periodical maintenance/inspection is necessary to enable satisfactory robot performance a long period of time. 1) Daily maintenance Before starting the system operation every day, clean each part of the system, check each part for any damage or cracks, and check the following items. a) Before the service operation Verify that the cable connected to the teach pendant is not unnaturally twisted. Verify that the cannot be operated by the command from the peripheral unit. b) After the service operation (At the end of the service operation, return the robot to the zero point (optional) and turn off the power.) Check for a crack and damage as well as cleaning each part. Eliminate the dust if the ventilation port of the control unit is dusty. c) 6-month periodical inspection Check the following items every 6 months. Verify that +5V, +15V, +24V and -15V of the power supply unit and t5V, t15V, +.20V, +24V and -15V power supply of the servo amplifier are normal. 2) Maintenance tools The following tools and instruments are required for the maintenance procedures contained in this manual. a) Measuring instruments AC voltmeter Capable of measuring AC supply voltage. Tolerance: Max. +2% voltmeter Max. scale: 10V, 30V Tolerance: Max. rt2% (A digital voltmeter is required in some cases.) Oscilloscope Frequency band: 5 MHz min. 2 channels b) Tools Cross-pit (+) screwdrivers : Large, medium, and small sizes Flat-tip (-) screwdrivers: Large, medium, and small sizes Pliers Cutting pliers Cutting nippers

DC

2. TROUBLESHOOTING

This sectiori describes solutions to problems due to the hardware classified by error code. Refer to the Operator's manual concerning the probl.ems due to program.
2.1 Power Cannot be Turned On

(Check 1) Verify that the breaker is on, or the breaker has not been tripped. (Corrective action) Turn on the breaker. (Check 2 ) If door interlock function is provided, the door is opened. (Corrective action) Close the door, or turn off the door interlock switch.

(Check 3) Check if the fuses F11 or F12 of the power supply unit are blown. (Corrective action) If a fuse is blown, replace the fuse according to 4.4 ( 3 ) , and look for the cause.

) When the input transformer (TF2) is used, verify that the fuse (Fl) (Check 4 on the transformer is not blown,
(Corrective action) If the fuse is blown, replace it. (Check 5) Verify that the LED (PIL : Yellow) is lit on the input unit PCB. (Corrective action) If the LED is not lit, the input unit is not powered. Look for the cause. Tf the LED is lit but the primary side of the servo transformer is not powered, fuse F7, F8, or F9 of the input unit may be blown. Replace the blown fuse. (Check 6) Verify the LED (ALM : Red) on the input unit PCB. (Corrective action) When the LED is not lit or 20 - 24VAC is not generated between 24VS and OVS of the test pins of the input unit, replace the inyut unit PCB. When the LED is lit, turn off the power switch and turn it on again. If the LED is still lit, check the output voltage of the power unit and if it is defective, replace the power unit. When alarm input is connected from a peripheral device, check if an alarm occurs in the peripheral device. (Check 7) Verify that the circuit between OFF and COM is shorted at the terminal TP1 of the input unit PCB, (Corrective action) When the circu3.t between OFF and COM is open, short it, When the cable is connected between OFF and COM, check the contact or the cable itse1.f. (Check 8 ) Check the contact of the power ON/OFF button on the operator panel. (The ON button is of the "a" contact, and the OFF button is of the "b" contact,) (Corrective action) If the contact is defective, replace the contact. If the power cannot be turned on even sfter the above checks 1 the service representative.

8, contact

2.2 Troubleshooting by LEDs (Q1-Q4) on the Main CPU PCB

When an error occurs before the teach pendant display is enabled after power up, or when the teach pendant cannot display, check the cause using LEDs Q1 44 on the main CPU PCB. When the robot works normally, all of the four LEDs are lit.
2.2.1
A t turning on the power switch

e: Lit
STEP 0

0:Not l.it After. power up all of LEDs Q1 to 44 remain light. (Cause 1) Defective the main CPU PCB. (Corrective action 1 ) Replace the main CPU PCB. (Cause 2) Abnormal system clear signal ("SYSCLR). (Corrective action 2) Replace the serial port PCB. Remount the serial port PCB in thirty minutes after replacement because CMOS RAM losts the taught data and parameter backupped using battery.

STEP 1 (Cause) Defective RAM of the main CPU PCB. (Corrective action) Replace the main CPU PCB. STEP 2 (Cause 1 ) Missetting (0, V) of the back panel PCB. (Corrective action 1) Set correctly. (Note 1) (Cause 2) Defective system clock (ASYSCLK). (Corrective action 2 ) Replace the serial port PCB. STEP 3 (Cause 1) The axis control PCB is defective or not mounted. (Corrective action 1 ) Replace or mount the axis control PCB. (Cause 2 ) Missetting (Tl) of the main CPU PCB. (Corrective action 2) Set correctly. (Note 1)

STEP 4 (Cause) Defective RAM of serial port PCB. (Corrective action) Replace the serial port PCB. STEP 5 (Cause) Defective serial port PCB. (Corrective action) Replace the serial port PCB. STEP 6 (Cause 1) The teach pendant is defective or not connected. (Corrective action 1) Replace or connect the teach pendant. (Cause 2,) Defective serial port PCB. (Corrective action 2 ) Replace the serial port PCB.

On and after STEP 7, the error display on the teach pendant is possible. STEP 7 (Cause 1) Missetting (0, V) of the back panel PCB. (Corrective action 1 ) Set correctly. (Note 1 )
) (Cause 2 Co-processor is not mounted on the main CPU PCB.

(Corrective action 2) Mount the co-processor on the main CPU PCB. (Cause 3) Defective 1/0 PCB, (Corrective action 3) Replace the 1/0 PCB. (Cause 4) Defective ROM of the main CPU PCB. (Corrective action 4) Replace the main CPU PCB. (Cause 5) Missetting of the axis control PCB, or defective PCB. (Corrective action 5) Set S1 to the B position. Replace the axis PCB. STEP 8 (Cause) Defective axis ccntroi PCB. (Corrective action) Replace the axis control PCB. STEP 9 (Cause 1 ) Peripheral PCB or laser I/F PCB is not mounted in the case of L-.1000. (Corrective action 1) Mount the peripheral PCB or laser I/F PCB. (Cause 2) Defective main CPU PCB. (Corrective action 2) Replace the main CPU PCB.

STEP 10

(Cause) ~ eective f main CPU PCB, (Corrective action) Replace the main CPU PCB.

STEP 11 (Cause) Abnormal J:lTP, SYSTMR signals. (Corrective action) Replace the serial port PCB. STEP 12, STEP 13, STEP 14 (Cause) Defective main CPU PCB. (Corrective action) Replace the main CPU PCB. Replace ROM of the main CPU PCB,

STEP 15 The robot works normal1.y.

(Note 1 ) For the setting of each PCB, refer to the details of PCB.

2.2.2 The teach pendant cannot display after all of LEDs (QI-Q4) are lit

Teach pendant defect 1 (Cause) Parity error of communication data (hardware) (Corrective action) Replace the serial port PCB or the teach pendant. Check the teach pendant cable. Teach pendant defect 2 (Cause) Communication overrun error (hardware) (Corrective action) Replace the serial port PCB or the teach pendant, Check the teach pendant cable. Teach pendant defect 3 (Cause) Communication framing error (Corrective action) Replace the serial port PCB or the teach pendant. Check the teach pendant cable. Teach pendant defect 4 (Cause) The character not defined by the software is received. (Software communication error) (Corrective action) Replace the serial port PCB or the teach pendant. Teach pendant defect 5 (Cause) Parity error of communication data (software) (Corrective action) Replace the serial port PCB or the teach pendant. Teach pendant defect 6 (Cause) No response to the sent data (software) (Corrective action) Replace the serial port PCB or the teach pendant. Check the teach pendant cable. Teach pendant defect 7 (Cause) Defective data in transmission (software) (Corrective action) Replace the serial port PCB or the teach pendant. Check the teach pendant cable.

2.3 Troubleshooting Using Error Codes

1 )

Error code 001 (emergency stop) When error code 001 cannot be reset even by resetting all the emergency 9. stop buttons, check and take corrective action according to checks 1

(Check 1) Bit 7 (*ESP) of diagnostic data No. 030 is "0". Measure the *ESP voltage of the test pin on the 110 PCB. (Corrective action) When the *ESP voltage is +24 V, replace the 1/0 PCB. When the voltage of *ESP is 0 V, the cable connected to CN1 of the 110 PCB is defective or the peripheral device is in the emergency stop state. Check the peripheral device, and take a corrective action. (Check 2) Bit 0 (*ESP) of diagnostic data No. 031 is "0". (Corrective action) The cable connected to CN1 of the 110 PCB is defective or the receiver of the 110 PCB is defective. Replace the cable or the 110 PCB. (Check 3 ) Bit 7 (EMG SWITCH) of diagnostic data KO. 025 is "1". Verify the functions of each switch on the teach pendant according to the APPENDIX 5.2. (Corrective action) When the switch is defective, replace it. (Check 4 ) Verily the circuit between FN1 and FN2 of the terminal board TP1 on the input unit PCB. When the contact of the safety fence is connected, check the contact. (Corrective action) Short the circuit between FN1 and FN2. Replace the contact. (Check 5 ) Check the conduction of the cables R40 and K14 referring to APPENDIX 5.2. (Corrective action) When the cable is defective, replace it. (Check 6) Bit 7 (EMG SWITCH) of diagnostic data No. 025 is "1" even though all of are ncrva.1. (Corrective actiou) Replace the serial port PCB. (Check 7) Bit 6 (*ESP) of diagnostic data No. 019 is "0". Check the contact cf the emergency stop switch on the operator's pane1. (Corrective action) When the switch is defective, replace it. When the switch is normal, replace the serial port PCB.

BKR l
0 24VS
0 OVS

BKR2

OVB

BKR3

Fig. 2.3 (a)

Input unit PCB

(Check 8) Check t h e i n p u t uni.t PCB r e f e r r i n g t o APPENDIX 5.2 and Fig. 2 . 3 . (Corrective action) Replace t h e i n p u t u n i t r e l a y o r t h e i n p u t u n i t PCB. (Check 9) Check t h e connection of emergency s t o p s i g n a l r e f e r r i n g t o APPENDIX

5.2.
(Corrective action) Find t h e d e f e c t i v e p a r t , and connect t h e s i g n a l c o r r e c t l y .

1 1 0 PCB

RVE I

RI'J 2

Fig. 2.3 (b) Locations of receivers (RVEI, RVJ2) and test pin (*ESP)

Serial port PCB

RVS B

0
CYPT CNPI Clop CD 1

1
Fig. 2.3 (c) Location of receiver RV5B

2)

Error code 002 (overtravel) Limit switches are provided for each robot axis in both directions of movement. When these limits are exceeded, an error code 002 is displayed, the robot stops suddenly and the servo amplifier power is turned off. Usually, by the parameters (software limit) for controlling the operation range, the robot motion is controlled not to exceed the limit switch positions. However, when this alarm occurs, check the cause in the following procedure.

(Check 1) The robot is in the state of delivery.

' $

(Corrective action) When a robot is delivered from the factory, it is in the overtravel state. Jog the robot into the motion range. (Check 2) Error code 002 occurs though the robot is in the motion range (the limit switches do not function). At this time, +24V is applied to the test pin *ROT of the 110 PCB. (Corrective action) 4-24 V is applied to the test pin *ROT of the 110 PCB. If the error. code 002 is not reset even by executing the reset operation, replace the 110 PCB. The voltage at the test pin *ROT of the 110 PCB is not +24 V. Check the connection of the overtravel circuit referring to APPENDIX 5.3.

Feed rate

' 7
!----A Deceleration distance

--

Position

Software limit value

Fig. 2.3 (dl Overtravel limit switch position

Fig. 2.3 (e) Location of receiver (RVF4) and test pin *ROT on the I/O PCB

3) E r r o r code 003 (End E f f e c t o r Breakage Detection) When t h e s a f e t y j o i n t connectirlg t h e robot w r i s t and an end e f f e c t o r i s broken o r when t h e end e f f e c t o r s a f e t y j o i n t breakage d e t e c t i o n switch o p e r a t e s improperly, an e r r o r code 003 i s displayed. (Check 1) Check i f t h e s a f e t y j o i n t i s broken. (Corrective action) Replace t h e s a f e t y j o i n t . (Check 2) Measure t h e v o l t a g e a t t h e t e s t p i n *HBK on t h e 110 PCB, and check (Note t h e s t a t e of t h e j o i n t breakage d e t e c t i o n s w i t c h of t h e hand. 11 (Corrective action) Replace t h e j o i n t breakage d e t e c t i o n s w i t c h of t h e hand. (Check 3) Check t h e c a b l e K34. (Corrective action) I f t h e c a b l e K34 i s broken, r e p l a c e i t . Note 1) This e r r o r code can be checked by a d i a g n o s t i c d a t a No. 027 b i t 6 (*HBK). This b i t i s 0 when t h i s alarm occurs. Refer t o t h e f o l l o w i n g Check t h e hand breakage c i r c u i t f i g u r e t o check using t h e 110 PCB. r e f e r r i n g t o Appendix 5.6.

, The test pin *HBK is OV

OV 0v
0
' ,,,

i ' /

/"
*HBK/
CN 4
/ '

0 i

when an end effector breakage alarm occurs. (When 20 V - 24 V, it is not broken )

CK 3

+ 24 E
Q

Q CN2

CN 1

I I

I I

Fig. 2.3 (f) Location of test pin *HBK on the I/O PCB

( 4 ) Error code 098 (Parameter parity error)

Error code 099 (Program parity error) If a data error occurs in the data memory, which stores parameters and robot command data, error code 098 or 099 will be displayed. To remove the problems, reset the parameter or reteach the robot command data. If the error is still present follow the flow chart below. Error code 098 Error code 099

I
Clear all parameters.

--No occur after

Yes

Yes

v Operate robot as it is. If an alarm occurs again, replace serial port PCB.
No

connected to the

' r '
PCB to the back panel

Replace the serial port PCB.

5) Error Code 120 (APC Pulse Missing) This alarm is generated when the pulse coder cannot catch up with the motor, perform a mastering operation again. 6) Error Code 121 (APC Power Off) . This alarm indicates that battery voltage for the pulse coder reaches 0 V Check that the battery cable is not disconnected or the battery is correctly mounted. 7 ) Warning "voltage drop (APC)" Replace batteries in the battery unit for pulse codes. Replace batteries after pressing the emergency stop button when turning on the power of the controller and supplying +5V power to the pulse coder.

8) Error Code 124 (APC follow up error) This alarm is generated when the pulse coder cannot follow the motor rotation during data reading from the pulse coder. Turn the power OFF and then ON, making sure that the motor does not fall due to its weight. 9) Error Code 125 (APC Data Transfer Error) This is an alarm indicating a data transfer error between the pulse coder and the axis control PCB or axis/welding control PCB. Replace the pulse coder or the axis control PCB. 10) Error Code 129 (APC Error History) A history of errors on APC is displayed on parameter No. 82. . Since axes in overtravel during Reset the parameter No. 82 to 0 shipment, error code 126 or 129 is generated at the time of installation. Move the concerned axes within the stroke and set parameter No. 82 to 0 . 11) Error code 201 (blown fuse for brake control) The error code 201 occurs in the following cases. The fuse F4 for controlling the brake of the input unit is blown. The brake coil is shorted. The brake connection wire is shorted. If the fuse F4 is still blown even after it is replaced, replace the brake coil or the brake connection wire. Refer to APPENDIX 5.7 for Fuse Alarm circuit. 12) Error Code 300 (Servo Not-Ready) When the DRDY signal generated by the magnetic contactor on the servo amplifier is not sent to the main CPU PCB, an error code 300 is displayed. (Check 1 ) The red diode (error indicator) is lit on the servo amplifier PCB. (Corrective action) Refer to 2.3 (18) - (22). (Check 2 ) 100 VAC is applied between 3 and 4 of the terminal board T1 of the servo amplifier. (Corrective action) When 100 VAC is not applied: Emergency stop state Overtravel state Broken hand Defective relay of the input unit Reset the above state, or replace the relay of the input unit or replace the input unit PCB. (Check 3) When the reset operation is executed, the electromagnetic contactor (MCC) of the servo amplifier turns on and then turns off immediately. (A click noise is generated when MCC is turned on/off.) (Corrective action) Check the servo amplifier in which MCC is not turned on, and replace the servo amplifier PCB or the servo amplifier. Refer to DRDY Circuit in APPENDIX 5.8. (Check 4) Error code 300 occurs even after the above checks 1 - 3. (Corrective action) Replace the axis control PCB or the cable connecting the axis control PCB and the servo amplifier. Refer to DRDY Circuit in APPENDIX 5.8.

13) Error Code 303 (Control Unit Overheat) When the control unit overheats, error code 303 is indicated. (Check 1) Check if the fan of the fan unit rotates. (Corrective action) Replace the defective fan. ) The radiation duct is heavily smudged. (Check 2 (Corrective action) Clean the radiation duct. (Check 3) The servo transformer is extremely warm. If so, check the load condition of the motor. (Corrective action) Lower the motor load. If the motor is defective, replace it. (Check 4) Check the serial port PCB according to Notes 1 and 2. (Corrective action) If the serial port PCB is defective, replace it. Modify the mounting of the PCB, and improve the circulation of air. (Check 5) The ambient temperature is over 45OC. (Corrective action) Lower the ambient temperature below 45OC.

Thermal switch

CNPI

CYOP

-HI+l-J---I
When the diagnostic data No 018, bit 4 (OHC) is 1 even though the lead wires of the thermal switch is open, the serial port PCB is malfunctioning.
Fig. 2 . 3 (g) Serial port PCB

Note 1) If a peripheral PCB is mounted before a serial PCB, the temperature rise of the thermal switch unit will be higher than usual. If there is space between the slot and the mounted PCB, it is more effective to move this PCB to other slot. When it is required to change the slot, it is necessary to change the setting on the backpanel.

14) Error Code 310, 311, 330, 331, 350, 351, 370, 371, 410, 411, 430, 431 (Excessive Error Stoppage during Stop, Excessive Error during Movement) When the error between the present position of the robot and the command position of the position control circuit becomes excessive, an error is displayed corresponding to each axis. This alarm may be generated whether the robot is stopped or movirg. The error value indicates whether the robot was stopped or moving. Error code during stop 310 330 350 370 410 430 Error code during movement 311 331 351 371 411 Axis
1

2
3 4

431

(Check 1 ) Setting of the parameter of excessive error, position gain, maximum speed acceleration/deceleration, etc. is wrong. (Corrective action) Set the parameters correctly. (Check 2 ) Check the wiring and the input supply voltage of the primary side of the servo transformer referring to 4.2. (Corrective action) Correct the wiring of the servo transformer. (Check 3) Check if the pulse coder signals C1, C 2 , C4 and C8 are interrupted due to a wire breakage. (Corrective action) Replace the pulse coder or the cable. (Check 4) The brake function is abnormal. (Corrective action) Adjust the gap, or replace the brake. (Check 5) Fuses (F7, F8, F9) on the power input unit for servo are blown. (Corrective action) Remove the cause of problem and replace the fuse. (Check 6 ) The error still occurs after the above checks 1 - 5. (Corrective action) Replace the axis control PCB and the axislwelding control PCB.

15) Error Code 312, 332, 352, 372, 412, 432 (Excessive Output Pulses) When the number of pulses exceeds 1.5 times the max. speed set by the mechanical unit, this error code is indicated.
9

Error code 312 332 352 372 412 432

Axis 1 2 3 4 5

(Check 1) An excessive value is set in the parameter of the maximum speed. (Corrective action) Set the parameters correctly. 16) Error Code 320, 340, 360, 380, 420, 440 (Pulse Coder Alarm DAL) Disconnection of A and B phase signals of pulse coder are checked by hardware to determine if the relationship between A and A signal or B and B signal is correct. This error code is displayed with faulty pulse coder, disconnection of pulse coder signal cable, faulty axis control PCB, or axis/welding control PCB. Yike the following checks, referring to APPENDIX 5.4, Pulse coder signal connection diagram.

---Axis 1 2 3 4
5

Error code 320 340 360 380 420 440

(Check 1 ) Check the continuity of the pulse coder connecting cable. (Corrective action) Repair or replace the cable. (Check 2) Check 1 is normal. (Corrective action) Replace the pulse coder. Replace the axis control PCB and the axislwelding control PCB.

17)

Error Code 321, 341, 361, 381, 421, 441 (Pulse Coder Alarm TGAL) The A, B and Z phases of pulse coder and status of C1, C2, C4 and C8 signals are checked by software to determine whether operation of A and B phases is equivalent to that of gray codes C1 to C8. This error code is displayed with faulty pulse coder, disconnection of pulse coder signal cable, faulty axis control PCB, or axis/welding control PCB. Make the following check referring to APPENDIX 5.4, Pulse coder signal connection diagram. Error code 321 341 361 381 421 441 Axis

1 2 3 4 5 6

(Check 1) Check the continuity of the pulse coder connecting cable. (Corrective action) Repair or replace the cable. (Check 2 ) Check 1 is normal. (Corrective action) Replace the pulse coder. Replace the axis control PCB and the axislwelding control PCB. 18) Error Code 322, 342, 362, 382, 422, 442 (Excessive Regenerative Current) If an excessive current flows into the regenerative discharge circuit of the servo amplifier, this error code is indicated. When this alarm occurs, the LED (DC) on the servo amplifier is lit. Refer to APPENDIX 5.4, Pulse coder signal connection diagram. In some robot, this alarm may be generated when 200 VAC power supplied to a servo unit has open phase or unbalance of phases. Error code 322 342 362 382 422
-

Axis
1

2 3

4
5
6

442

(Check 1) The positioning frequency at high speed exceeds 0.5 - 1 timelsec. (Corrective action) Modify the program by setting a pause time, for example. (Check 2) This error occurs immediately after the power is turned on. (Corrective action) Replace the servo amplifier or the servo amplifier PCB.

19) Error Code 3 2 3 , 3 4 3 , 3 6 3 , 3 8 3 , 4 2 3 , 4 4 3 (Excessive Servo Voltage) When this alarm occurs, the LED (HV) on the servo amplifier PCB is lit. Refer to APPENDIX 5 . 4 , Pulse coder signal connection diagram. Error code
323 343 363 383 423 443

Axis
I

2 3 4 5

--

1 0 % or more. (Check 1) The supply voltage fluctuation is ' (Corrective action) Set the supply voltage fluctuation within the rated value. (Check 2) Check the wiring and the input supply voltage of the primary side of the servo transformer referring to 4 . 2 . (Corrective action) Correct the wiring by cha~gingthe wiring of the servo transformer. (Check 3 ) Check the insulation of the motor winding (power line) and the motor body. (Corrective ection) If the insulation is defective, replace the motor. (Check 4 ) The motor power l i ~ e is shorted. (Corrective action) Repair the shorted part, or replace the cable. (Check 5) Checks 1 - 4 are normal. (Corrective action) Replace the servo amplifier PCB or the servo amplifier.

20) Error Code 3 2 4 , 3 4 4 , 3 6 4 , 384, 4 2 4 , 444 (Excessive Servo Current) When this alarm occurs, the LED (HC) on the servo amplifier PCB is lit. Refer to the APPENDIX 5 . 4 , Pulse coder signal connection diagram.
Error code
324 344 364 384 424 444

Axis 1

2
3 4 5

(Check 1) The HC error occurs when the power is turned on with the motor power line disconnected. Note) Make the brake effective or support the arm to prevent from falling (Corrective action) When the HC error occurs, replace the servo amplifier. When the HC error does not occur (another error occurs), replace the motor power cable. (Check 2) Check the insulation of the motor winding (power line) and the motor body. (Corrective action) If the insulation is defective, replace the motor.

21) Error Code 325, 345, 365, 385, 425, 445 (Excessive Motor Current) When this alarm occurs, the LED (HC) on the servo amplifier is lit. Refer to the circuit diagram of the pulse coder signal in APPENDIX 5.4. Error code 325 345 365 385 425 445 Axis 1
2

3 4

5
6

(Check 1) The motor power line is disconnected. (Corrective action) Connect the motor power line. (Check 2 ) Excessive payload is applied to the motor. (Corrective action) Reduce the payload; lengthen the dwell period, etc. Check to see if the mechanical unit malfunctions. (Check 3) Checks 1 - 2 are normal. (Corrective action) Replace the servo 'amplifier PCB or the servo amplifier.

22) Error Code 326, 346, 366, 386, 426, 446 (Lower Servo Voltage) When this alarm occurs, the LED (LV) on the servo amplifier PCB is lit. Refer to the circuit diagram of the pulse coder signal in APPENDIX 5.4. Error code 326 346 366
-

Axis 1 2 3 4
5

386 426 446

,

(Check 1 ) The fluctuation of power voltage is out of -10%. (Corrective action) Adjust the power voltage within the specified range, (Check 2) Check the primary side wiring of the servo transformer and the input power voltage referring to section 4 . 2 . (Corrective action) Wire the power circuitry properly. (Check 3) Checks 1 2 are normal. (Corrective action) Replace the servo amplifier PCB or the servo amplifier.

23)

Error Code 327, 347, 367, 387, 427, 447 (Motor Overload) This alarm occurs at the overheat of motor, the servo amplifier, or servo transformer, or regenerative discharge unit. The LED "OH" on the servo amplifier PCB is lit. Refer to APPENDIX 5.4, Overload alarm detection circuit.
t

Error code 327 347 367 387 427 447

Axis

1
2

4
5
6

(Check 1 ) Check if the jumper S 1 of the servo amplifier PCB is correCtly set. (Corrective action) Set the jumper S 1 correctly. (Check 2) Check if an extremely large load is applied to the motor. (Corrective action) Decrease the load by setting a pause time, etc. Check the mechanical section for any defect. (Check 3) The radiator fin of the servo amplifier or the servo amplifier is overheated. Check if the fan of the control urlit rotates normally. (Corrective action) Replace the fan. Decrease the motor load. If this error still occurs even after decreasing the motor load, replace the servo amplifier.

24) Error Code 328, 348, 368, 388, 428, 448 (motor overheat).
This alarm is generated when a thermostat in a motor works. Error code 328 348 368 388 428 448 Axis 1 2 3

4
5

(Check 1 ) check if an extremely large load is applied to the motor. (Corrective action) Decrease the load by setting a pause time, etc. Check the mechanical unit for any defect.

25) Error Code 921 (Axis Control PCB or axislwelding control PCB is not mounted) The axis control PCB may not be mounted or not be connected properly. Mount the PCB properly. 26) Error Code 922 (110 PCB is not mounted) The I/O PCB may not be mounted or not be connected properly. Mount the PCB properly. 27) Error Code 931 (Axis Control PCB or axis/welding control PCB program verification error) Replace the axis control PCB. 28) Error Code 940 (Power failure) Replace the input unit or the power unit.
Note) It is a normal condition that this error code is displayed temporarily when the power is turned off.

29) Error Code 970 (Main CPU PCB watch dog) Replace the CPU (80286) on the main CPU PCB or the main CPU PCB.

E r r o r Code 980 t o 986 (CPU e r r o r ) P U PCB o r t h e main C P U PCB i n c l u d i n g Replace t h e C P U (80286) on t h e main C ROMs E r r o r Code 990, 991 ( R A M parity) P U PCB. P U PCB m a l f u n c t i o n s . Replace t h e main C The RAM on t h e main C E r r o r Code 998 ( R O M parity) Replace ROMs on t h e main C P U PCB o r t h e main C P U PCB. E r r o r Code 7960 ( S e r i a l p o r t e r r o r ) Replace t h e s e r i a l p o r t PCB. E r r o r Code 7970 ( S e r i a l p o r t PCB watch dog) Replace t h e s e r i a l p o r t PCB. E r r o r Code 7990 ( S e r i a l p o r t PCB RAM p a r i t y ) Replace t h e RAX on t h e s e r i a l p o r t PCB o r t h e s e r i a l p o r t PCB. E r r o r Code 7998 ( S e r i a l p o r t PCB S U M parity) Replace t h e s e r i a l p o r t PCB. E r r o r Code 8970 (Axis c o n t r o l PCB 1 watch dog) Replace t h e a x i s c o n t r o l PCB 1 (01P2D). E r r o r Code 8990 (Axis c o n t r o l PCB 1 RAM p a r i t y ) Replace t h e a x i s c o n t r o l PCB 1 (01P2D). E r r o r Code 8996 (Axis c o n t r o l PCB 1 bus e r r o r ) Replace t h e a x i s c o n t r o l PCB 1 (01P2D). E r r o r Code 8970 (Axis control. PCB 2 o r a x i s l w e l d i n g c o n t r o l PCB watch dog) Replace t h e a x i s c o n t r o l PCB 2 (02P2D) o r t h e a x i s c o n t r o l PCB (OlPlC). E r r o r Code 8990 (Axis c o n t r o l PCB 2 o r t h e a x i s l w e l d i n g c o n t r o l PCB RAM parity) Replace t h e a x i s c o n t r o l PCB 2 (02P2D) o r t h e a x i s l w e l d i n g c o n t r o l PCB (01PlC) E r r o r Code 8996 (Axis c o n t r o l PCB 2 o r t h e a x i s l w e l d i n g c o n t r o l PCB bus error) Replace t h e a x i s c o n t r o l PCB 2 (02P2D) or t h e a x i s l w e l d i n g c o n t r o l PCB (OlPlC). Alarms (27) (40) may o c c u r a c c o r d i n g t o t h e s o f t w a r e e r r o r . 43) Other E r r o r Codes Refer t o t h e O p e r a t o r ' s manual, "Error code l i s t " f o r o t h e r e r r o r codes.

Note)

Alarms d e s c r i b e d i n i t e m s (27) t o (40) may occur due t o n o t hardware m a l f u n c t i o n b u t a l s o s o f t w a r e e r r o r .

only

2.4 Position is Displayed in Reference Point Return (Calibration)

(Check 1) Check t h e p o s i t i o n d e v i a t i o n a t t h e s t o p by t h e 95). 90 (Corrective action) S e t c o r r e c t l y t h e parameters of c a l i b r a t i o n . (Check 2) Check i f t h e p o s i t i o n i n g i s normal i n t h e motor (Corrective action) I f t h e p o s i t i o n i n g i s normal, check t h e mechanical (Check 3) Check t h e mechanical u n i t f o r p l a y . (Corrective action) Replace a d e f e c t i v e p a r t , such a s a key. 3 a r e normal. (Check 4) Checks 1 (Corrective action) Replace t h e p u l s e c o d e r , t h e a x i s c o n t r o l PCB c o n t r o l PCB.

d i a g n o s t i c d a t a (No.

axis. unit.

or

the axislwelding

2.5 Robot Vibrates

(Check 1) Check t h e s e t t i n g of parameters of p o s i t i o n l o o p g a i n , e t c . (Corrective action) S e t t h e parameters c o r r e c t l y . (Check 2) Check t h e mechanical u n i t f o r p l a y . (Corrective action) Replace a d e f e c t i v e p a r t , such a s a key.

2.6 Manual Operation Is Not Possible

When t h e manual o p e r a t i o n of t h e r o b o t f a i l s a f t e r t h e c o n t r o l u n i t i s turned on, check and c o r r e c t u s i n g t h e f o l l o w i n g procedure.

1) F a i l u r e i n manual o p e r a t i o n (Check 1) Check i f "TEACH1' i s d i s p l a y e d on t h e t e a c h pendant. (Corrective action) S e l e c t t h e t e a c h mode. (Check 2) The ON/OFF s w i t c h of t h e t e a c h pendant i s s e t t o "OFF1'. (Corrective action) S e t t h e s w i t c h t o "ON". (Check 3) The t e a c h pendant i s o p e r a t e d i n c o r r e c t l y . (Corrective action) To move a n a x i s manually, s i m u l t a n e o u s l y p r e s s t h e a x i s s e l e c t key and t h e S h i f t key. S e t t h e manual f e e d o v e r r i d e t o a p o s i t i o n o t h e r t h a n "INCREMENTAL FEED". (Check 4) Check i f ENBL s i g n a l of t h e p e r i p h e r a l d e v i c e c o n t r o l i n t e r f a c e i s "1". (Corrective action) S e t t h e p e r i p h e r a l d e v i c e c o n t r o l i n t e r f a c e t o t h e ENBL s t a t e . O L D s i g n a l of t h e p e r i p h e r a l d e v i c e c o n t r o l i n t e r f a c e (Check 5) Check i f t h e H o r the H O L D s w i t c h of t h e o p e r a t o r ' s p a n e l i s t u r n e d on (HOLD state). (Check i f t h e H O L D lamp i s l i t on t h e t e a c h pendant.) (Corrective action) O L D switch. Turn o f f t h e H O L D signal or the H (Check 6) Check i f t h e RESET s i g n a l of t h e p e r i p h e r a l d e v i c e c o n t r o l i n t e r f a c e o r t h e RESET s w i t c h of t h e o p e r a t o r ' s p a n e l i s t u r n e d on (RESET state). (Corrective action) Turn o f f t h e RESET s i g n a l o r t h e RESET s w i t c h . (Check 7) Check i f t h e p r e v i o u s manual o p e r a t i o n i s completed. (Corrective action) I f t h e p r e v i o u s o p e r a t i o n h a s n o t ended because of f a i l i n g t o g e t i n p o s i t i o n due t o t h e o f f s e t of speed command v o l t a g e , check t h e p o s i t i o n d e v i a t i o n by t h e d i a g n o s t i c f u n c t i o n and change t h e s e t t i n g , e t c . (Check 8) The c o n t r o l u n i t i s i n a n a l a r m s t a t e . (Corrective action) Reset the alarm s t a t e .
2) Repeat o p e r a t i o n cannot be done (Check 1) Check i f "REPEAT" i s d i s p l a y e d on t h e t e a c h pendant. (Corrective p c t i c r ) S e l e c t t h e r e p e a t mode. (Check 2 ) The o v e r r i d e i s s e t t o "I~JCREMENTAI. FEED". (Corrective. a c t i o n ) S e t t h e o v e r r i d e t o a p o s i t i o n o t h e r t h a n "INCREMENTAL FEED".

(Check 3 ) Check i f t h e ENBL s i g n a l of t h e p e r i p h e r a l d e v i c e c o n t r o l i n t e r f a c e i s s e t t o "1". (Corrective action) S e t t h e p e r i p h e r a l d e v i c e c o n t r o l i n t e r f a c e t o t h e ENBL s t a t e . (Check 4 ) Check i f t h e HOLD s i g n a l of t h e p e r i p h e r a l d e v i c e c o n t r o l i n t e r f a c e o r t h e HOLD s w i t c h of t h e o p e r a t c r panel i s t u r n e d on (HOLD s t a t e ) . (Check i f t h e HOLD lamp i s l i t on t h e t e a c h pendant.) (Corrective action) Turn o f f t h e H O L D s i g n a l o r t h e HOI,D s w i t c h . (Check 5) Check i f t h e RESET s i g n a l of t h e p e r i p h e r a l d e v i c e c o n t r o l i n t e r f a c e o r t h e RESET s w i t c h of t h e o p e r a t o r p a n e l i s t u r n e d on (RESET state). (Corrective action) Turn o f f t h e RESET s i g n a l o r t h e RESET s w i t c h . (Check 6 ) Check i f t h e p r e v i o u s manual ope ratio^ i s completed. (Corrective action) I f t h e p r e v i o u s o p e r a t i o n h a s n o t ended because of f a i l i n g t o g e t i n p o s i t i o n due t o t h e o f f s e t of speed command v o l t a g e , check t h e p o s i t i o n d e v i a t i o n by t h e d i a g n o s t i c f u n c t i o n and change t h e s e t t i n g , etc. (Check 7) The c o n t r o l u n i t i s i n an a l a r m s t a t e . (Corrective action) Reset t h e alarm s t a t e .

3) LED on t h e PCB i s l i t When an a l a r m i s g e ~ ? e r a t e d ,a corresponding e r r o r code i s displayed. on t h e L C D of t h e t e a c h pendant. Rut i f a problem on t h e L C D i s g e n e r a t e d , no alarm can be d i s p l a y e d on t h e LCD. I n t h i s c a s e , t h e a l a r m i s i n d i c a t e d by t h e LEDs on each PCB. a ) Main CPU PCB: Refer t o 7.2 and 3.1. b) S e r i a l p o r t PCB: Refer t o 3 . 2
2.7
Problems of the Servo Amplifiers

For t h e p o s i t i o n s of each LED, r e f e r t o t h e d e t a i l s of t h e s e r v o a m p l i f i e r PCB. (Check 1) The c i r c u i t b r e a k e r of t h e s e r v o a m p l i f i e r i s o f f or t r i p p e d s t a t e . I f i t i s t r i p p e d , check t h e mechanical u n i t f o r abnormal l o a d , e t c . (Corrective action) Turn on t h e c i r c u i t b r e a k e r ( p r e s s t h e b u t t o n ) . The b u t t o n p r o j e c t s In such a c a s e , w a i t f o r about 10 when t h e breaker is t r i p p e d . minutes. I f t h e c i r c u i t b r e a k e r i s s t i l l t r i p p e d a f t e r t h e power s w i t c h i s t u r n e d on a f t e r r e s e t t i n g once, r e p l a c e t h e s e r v o a m p l i f i e r .
Circuit breaker

(Check 2 ) Check if the HV LED is lit. If the HV LED is lit, check the connection of the tap of the servo transformer. (Corrective action) If the tap of the servo transformer is correctly connected, replace the servo motor, servo amplifier PCB, etc. (Check 3) Check if the HC LED is lit. If the HC LED is lit, check the connection of the tap of the motor power cable. (Corrective action) If the motor power cable is correctly connected, replace the servo motor, servo amplifier PCB, etc. ) Check if the LV LED is lit. (Check 4 If the LV LED is lit, check the connection of the tap of the servo transformer and the connectio~ibetween the transformer and the servo amplifier PCB CN2. (Corrective action) If the connection is correctly connected, replace the servo amplifier PCB. (Check 5) Check if the DC LED is lit. If the DC LED is lit, check if the robot acceleration/deceleration is too frequent. (Corrective action) When the robot is operating with frequent acceleration/deceleration, lower the frequency of acceleration/deceleration by adding a timer, etc. to the program. If the DC LED is lit simply by turning on the power switch, replace the servo amplifier. (Check 6) Check if the OH LED is lit. I f the OH LED is lit, check the robot load, defects in the mechanical unit etc. Check if the jumper S1 of the servo amplifier PCB is set correctly. (Corrective action) Decrease the robot load. Set the jumper S1 correctly.

Circuit

Note) The above figure shows the view when the PCB is removed.
Fig. 2.7 (b) Circuit breaker of servo amplifier

2.8 Checking Status Using Diagnostic Function (DIAGNOSE)

The input/output signal conditions of the robot interface can be checked by the self-,diagnosticfunction. Pressing the softkey DIAGNOSE on the teach pendant displays the status of input/output signals.
DIAGNOSE

01/20

TEACH

NO00
N O 0 1

00000000
00000000

00000000 00000000
00000000 00000000

NO02 NO03 NO04

00000000 00000000 00000000

00000000

Fig. 2.8 (a) An example of diagnostic data display

A zero ( 0 ) displayed at a bit position indicates that the contact of the signal displayed at that position is open, while one (1) indicates that the contact of the signal is closed. Press page keys " I . " , "J." to show a required diagnostic data. S codes that are turning on external signals or receiving external signals will be executed while the DIAGNOSE screen is displayed. This allows you to view the status of the signals.
1

>

Teach pendant The diagnostic data of the teach pendant is classified into 3 types as follows: 1 ) LED 2) Key 3) Others (teach pendant ON/OFF switch, EMERGENCY STOP button or DEADMAN switch)

LCD display

----------

LED displays

' \
\

Teach pendant ON/OFF switch

EMERGENCY STOP button

Fig. 2.8 (b) Diagnostic of teach pendant

DEADMAN switc

,EDs
Table 2.8 (a) Diagnostic data of LED

Bit No.

.
7
6 TOOL

3
2

Remarks

5
CARTESIAN

4
JOINT

0
ALARM
LED lights

ARC ENABLE or BEAM OUTPUT ENABLE ARC ENABLE or BEAM OUTPUT ENABLE BUSY STEP HOLD

006

007

TOOL

CARTESIAN

JOINT

BUSY

STEP HOLD

ALARM

LED flickers

If any bit of diagnostic No. 006 is 1, it shows that the corresponding LED lights. If any bit of diagnostic No. 007 is 1, it shows that a corresponding LED flickers. The same bit cannot be 1 between diagnostic No. 006 and 007 at the same time.

b) Keys
Table 2.8 (b) Diagnostic data of key input

Bit No. 7 020 6

.f

Remarks 5 F1 4 F2 3 F3 2 F4

1
F5

+
Next menu Sof t k e y row

Previous menu 021 %+ %+ INS ENTER

So2 t k e y s FUNCTI O N 6 A L A R M RESET

+
Shift 1 HOLD

1st l i n e
2nd l i n e

022

BS

3
2

POS DISP
BWD

023

+
Cursor

+
Page

F W D

3rd l i n e

024

-+
Cursor E M G SWITCH

+
Page ONIOFF DEAD

7 M O D E

PRGRM

DATA

4th l i n e

025

MAN
SWITCH

Coordi5th l i n e Shift 2 nate

i

2) P e r i p h e r a l d e v i c e c o n t r o l i n t e r f a c e A, B The s t a t u s o f i n p u t and o u t p u t s i g n a l s from t h e p e r i p h e r a l d e v i c e c o n t r o l i n t e r f a c e A, B c a n be d i s p l a y e d . R e f e r t o t h e d i s p l a y e d c o n t e n t s a n d - c h e c k a program and t h e s t a t u s o f t h e p e r i p h e r a l d e v i c e c o n t r o l i n t e r f a c e . a ) Output s i g n a l

No. . 7 002 6 5 4
Bit

Remarks 3 2

SD04 SD02 SDOl SD07 SD08 SD05 SD06 SD03 CNl(40) CNl(39) CNl(38) CNl(37) CNl(36) CNl(35) CNl(34) CNl(33)

003

004

SD016 SD015 SD013 SD012 SDOll SDOlO SD09 SD014 CNl(48) CNl(4.7) CNl(46) CNl(45) CNl(44) CNl(43) CNl(42) CNl(41) ACK4 REF1 ACK3 ACK2 ACKl REF3 REF2 HELDE CN4(20) CN4(19) CN4(12) CN4(18) CN4(17) CN4(16) CN4(15) CN4(14) BUSYE A L M REMOTE CNl(22) CNl(23) CNl(21) CNl(20)

b) Input signal

Bit 1 0

- Remarks
SDI2 SDIl CNl(10) CNl(9)

/ I 1
030 *ESP CNl(7)

1029

SDIlO SDI9 SDIl6 SDIl5 SDIl4 SD113 50112 SDIll CNl(31) CNl(30) CNl(29) CNl(28) CNl(27) CNl(26) CNl(25) CNl(24) *HOLD CNl(8) *SFSD CNl(6) ENBL CNl(5) RSETE START RSR2 CNl(4) CNl(3) CNl(2) RSRl CNl(1) *ESP
I

1 031 (

INPTY3 I INPTY2 1 INPTY1 ( *PPABN

I I

*FALM

RLWD e

Refer to 6) y INTPY1: Display The bit TNTPY2: Display The bit

r to 8)

of common voltage of SDIl to SDI16. state is 1 when +24 V is connected; 0 when 0 V is connected. of common voltage of RSR1, RSR2, ENBL, *SFSD, *HOLD and *ESP. state is 1 when +24 V is connected; 0 when 0 V is connected. Bit

. - .
No. 7 032 6 PNS7 CN4(8)
5

Remarks 4 PNS5 CN4(5) PNS8 CN4 (9) PNS6 CN4(6) 2 3 PNS3 PNS4 ~ CN4(4) C N (3) INPTY4
1

1 PNS2 CN4(2)

PNSl C N (1) ~

RSR4 RSR3 CN4(11) CN4(10)

Program select signal

L. Display of common voltage

of PNSl to 8, RSR3, 4. The bit state is 1 when +24 V is connected; 0 when 0 V is connected.

3) Peripheral device control interface C There are 48 additional 110 signals as a peripheral device control interface C . The states of them are displayed. a) Output signal Bit No. 7 014 AD08 CNAl (40) AD016 CNAl (48) AD024 CNA2 (36) AD032 CNA2 (44) AD040 CNA2 (30) AD048 CNA3 (11) 6 AD07 CNAl (39) AD015 CNAl ( 4 7) AD023 CNA2 (35) AD031 CNA2 (43) AD039 CNA2 (29) AD047 CNA3 (20)
5

Remarks 4 AD05 CNA 1 (37) AD013 CNA 1 (45) AD021 CNA2 (33) AD029 CNA2 (41) AD037 CNA2 (27) AD045 CNA3 (18) 3 AD04 CNAl (36) AD012 CNAl (44) AD020 CNA2 (30) AD028 CNA2 (40) AD036 CNA2 (48) AD044 CNA3 (17) 2 AD03 CNAl (35) ADO11 CNAl (43) AD019 CNAl (29) AD027 CNA2 (39) AD035 CNA2 (47) AD043 CNA3 (16) 1 AD02 CNAl (34) ADO10 CNA 1 (42) AD018 CNAl (28) AD026 CNA2 (38) AD034 CNA2 (46) AD042 CNA3 (15) 0 ADOl CNAl (33) AD09 CNAl (41) Additional DO Addit ional DO AD06 CNAl (38) AD014 CNAl (46) AD022 CNA2
(34)

015

077

AD017 AddiCNAl tional (2'7) DO AD025 AddiCNA2 tional DO (37) AD033 AddiCNA2 tional DO (45) AD041 AddiCNA3 tional DO (14)

078

AD030 CNA2 (42) AD038 CNA2 (28) AD046 CNA3 (19)

016

076

L
ADOl

-. AD048: When this signal is "l", the output transistor is on.

b ) Input signal

Bit No. 7 038 AD18 CNAl ( 8 ) AD116 CNAl (16) AD124 CNA2 6 AD17 CNAl (7) AD115 CNAl (15) AD123 CNA2 (3) AD131 CNA2 (11) AD139 CNA2 (21) AD147 CNA3 (8) 5 AD16 CNA 1 (6) AD114 CNAl (14) AD122 CNA2 (2) AD130 CNA2 (10) AD138 CNA2 (20) AD146 CNA3 (6) 4 AD15 CNA 1 (5) AD113 CNAl (13) AD121 CNA2 (1) AD129 CNA2 (9) AD137 CNA2 (19) AD145 CNA3 (5) 3 AD14 CNAl (4) AD112 CNAl ( 12 ) AD120 CNAl (22) AD128 CNA2 (8) AD136 CNA2 (16) AD144 CNA3 (4) 2 AD13 CNAl (3) AD111 CNAl (11) AD119 CNAl (21) AD127 CNA2 (7) AD135 CNA2 (15) AD143 CNA3
(3)

Remarks 1 AD12 CNAl (2) AD110 CNAl (10) AD118 CNAl (20) AD126 CNA2 (6) AD134 CNA2 (14) AD142 CNA3 (2) 0 AD11 CNAl (1) AD19 CNAl (9) Additional DI Additional DI

039

080

( 4 )
081 AD132 CNA2 (12) AD140 CNA2 (22) AD148 CNA3 (9)

AD117 Additional CNAl DI (19) AD125 AddiCNA2 tional DI (5) AD133 AddiCNA2 tional DI (13) AD141 AddiCNA3 tional DI: (1)

037

079

AD11

- ADI48:

When this signal is "1" , the input signal is on (contact closed).

4) Welding interface The status of output/input signals for welding interface is displayed. a) Output signals Bit No. 7 010 WST 6
5

Remarks 4 3 ADSL4 2 ADSL3 1 ADSL2 0 ADSLl PCB internal

Analog command CH 1

no

011

CHI DA7 CH2 DA7

CH 1 DA6 CH2 DA6 m07 CNl(29)

CH 1 DA5 CH2 DA5

CH 1 PA4 CH2 DA4

CH 1 DA3 CH2 DA3

CH 1 DA2 CH2 DA2

CH 1 DA1 CH2 DAI

CHI DAO CH2 DAO

012

Analog command CH2

013 WD08 CNl(30)

Welding WD05 WD02 WDOl WD06 WD03 WD04 CNl(28) C N (27) ~ CNl(26) CNl(25) CNl(24) CNl(23) DO

--

WST: Wire stick detection signal, when this signal is 1 wire stick detection is performed. ADSLl

4: These signals select the signals connected to the A/D converter tnput

ADSL4 0

ADSL3 0

ADSL2 0

ADSLl 1

Selected signals Analog input CH1

p p p p

I
CHI DAO (LSB) CH2 DAO

Standard voltage 10 V

DA7 (MSB): Command value to channel 1 of D/A converter. This signal is specified as a binary code and value of LSB is about 50.2 mV. DA7: Command value to channel 2 of D/A converter.

b) I n p u t s i g n a l s

Bit No. Remarks

7
034 035 AD7 * W S T K (WSTK)

6 AD6 C E N D (*CEND)

5
AD5 AD13

4 AD4 AD12

3 AD3 AD11

2
AD 2

1
AD 1

0
ADO
AD8

AD10

AD9

036

WDI8 WDI7 WDI6 WDI5 CNl(1.2) CNI(11) CNI(10) CNl(9)

WDI4 CNl(8)

WDI3 CNl(7)

WDI2 CNl(6)

WDIl CNl(5)

Welding DI

ADO

- AD13:

AID c o n v e r t e r o u t p u t s i g n a l s a r e i n d i c a t e d i n complementary o f f s e t binary.

CEND, ("CEND): When AID c o n v e r t e r f i n i s h e s c o n v e r t i n g , t h e s i g n a l i s 1. (Robot u s i n g t h e a x i s / w e l d i n g c o n t r o l PCB), t h e s i g n a l i s 0 a t completion. *WSTK, (WSTK): Wire s t i c k d e t e c t i o n s i g n a l . When d e t e c t e d , t h e s i g n a l i s 0. (Robot u s i n g t h e a x i s l w e l d i n g c o n t r o l PCB), t h e s i g n a l i s 1 when d e t e c t e d .

5) Operator p a n e l
The s t a t u s of i n p u t and o u t p u t s i g n a l s of t h e o p e r a t o r p a n e l mounted on t h e f r o n t of t h e c a b i n e t i s d i s p l a y e d .

PORT 1

PORT 2

BATTERY AURM

HOLD

REMOTE

BUSY

REMOTE

RESET

START

!= !I
OYERTRAYEL RELEASE
WAIT RELEASE now

EYEROENCY STOP

Fig. 2.8 (c) Operator panel

Bit

No. 7 008 6 B T A L M L 5 A L M L 4 H O L D L 3 BUSYL 2 R E M O T L

Remarks

BTALML: ALML : HOLDL : BUSYL : REMOTL:

BATTERY A L A R M A L A R M H O L D B U S Y R E M O T E

b) I n p u t s i g n a l s

No. 7 019 *OTREL 6 *ESP 5

Bit

Remarks

4
W T R E L

3
*HOLD

2 R E M O T E

1
RESET

0 START

*OTREL: *ESP : W T R E L : *HOLD : REMOTE: RESET : START :

OVERTRAVEL RELEASE EMERGENCY STOP WAIT RELEASE H O L D R E M O T E RESET START

6) Robot The s t a t u s of i n p u t s i g n a l s and o u t p u t s i g n a l s i n t e r f a c i n g w i t h t h e r o b o t mechanical u n i t i s d i s p l a y e d . Refer t o t h e d i s p l a y e d c o n t e n t s and check t h e L i m i t s w i t c h e s and t h e end e f f e c t o r 011 t h e m e c h a ~ i i c a lu n i t . a ) Output s i g n a l s

Bit

No. 7 000 6 5

- Remarks
2

RDOl RD08 RD07 RD02 RD04 RD06 RD03 RD05 CN2(30) CN2(29) CN2(28) CN2(27) CN2(26) CN2(25) CN2(24) CN2(23)
-

001
I

BKRl

BKR2

BKR3

BKRE

HBREL

'

A L M L OPRL CN2(21) CN2(31)

1
robot

L These

signals are i n t e r f a c e . See 8 ) .

not

related

to

the

b) Input signals Bit No. Remarks

7
026 027 RD18 CN2 (8) -

5 RD16 CN2(6)

4 RD15 CN2(5)

1 RDI2 CN2(2)

0
RDIl CN2(1)

RD17 CN2(7)

RD14 RD13 CN2(4) CN2(3)

*HBK I *ROT CN2(14) CN2(13) *FALM

-1

031 INPTY3 INPTY2 INPTYl *PPABN 1 CN2 (9) L r I

RLWD

*ESP
I

Refer to item 8 ) . LThese signals are not related to the robot interface, See 2 ) . INPTY3: Display of common voltage of RDIl to 8, *PPABN. The bit state is 1 when +24 V is connected; 0 when 0 V is connected7 ) Servo control system The diagnostic data for the servo control system is classified into three following groups: a) Interface signals sent from the main CPU PCB to the axis control PCB and axislwelding control PCB. b ) Interface signals sent from the ax3.s control PCB and axislwelding coiitrol PCB to the main CPU PCB. c) Information on position control. The correspondence between axis numbers and axis names is as follows. Axes of robot
S-5, S-10 S-600 ARC Mate, ARC Mate Sr. S-300, S-420, S-500, S-700

M-100, M-400, A-200

A-510

A-600

L-1000

C-100

1st axis 2nd axis

3rd axis
4th. axis 5 t h axis 6th axis

w
. . . -

w
u
8

z
8
R

e
z

e
u
z
a

u
8

w
R

x
z
a
f3

u
a

Y
B

a
B

a
13

Y
Y (Note)

7th axis

Note) S-420F Traverse unit

a) Interface signals sent from the main CPU PCB to the axis control PCB and axislwelding control PCB.

PRDY: Control unit ready signal (Common to all axes) A signal corresponding to the conventional position ready signal. The MCC (magnetic contactor) of the servo amplifier actuates with PRDY on. "1" is displayed when the signal is ON. Normally, this signal stays on. ENB 1 to 8: Enable signal When the enable signal turns on and the MCC in the servo amplifier operates, an excitation current flows to the motor. The bit is 1 when the enable signal is on. b) Interface signals sent from the axis control PCB and axislwelding control PCB to the main CPU PCB.
-.

Bit No. Remarks

7
040 PRDY

6 VRDY

5 *VmY VRDY6

0 ---

041
~ e f e rto a)

VRDY5

VRDY4

VRDY3

VRDY2

VRDYl

VRDY : Servo amplifier ready signal. The bit turns to 1 when all axes become ready to operate. *VRDY: Servo amplifier not ready. The bit turns to 0 when all axes do not become ready. VRDY 1 to 6: Each axis servo amplifier ready s-lgnal. The MCC operates when the PRDY signal ON state is received by the servo amplifier. The VRDY signal turns on to inform that MCC has actuated. The bit becomes 1 when this signal turns on. Error code 300 (Servo not ready) This alarm is generated when VRDY has not turned on within a specified time after the signal PRDY has turned on. Refer to . 8 . APPENDIX 5

1
I

Bit No. 7 044 046 048 050 052 054 045 047 049 051 053 055
t

- Remarks

3 SSTB1 SSTB2 SSTB3 SSTB4 SSTB5 SSTB6

1 SRDY1 SRDY2 SRDY3 SRDY4 SRDY5 SRDY6

OVLl OVL2 OVL3 OVL4 OVL5 OVL6

OVCl OVC2 OVC3 OVC4 OVC5 OVC6

HCALl HCAL2 HCAL3 HCAL4 HCAL5 HCAL6

HVALl HVAL2 HVAL3 HVAL4 HVAL5 HVAL6

DCALl DCAL2 DCAL3 DCAL4 DCAL5 DCAL6

FBALl FBAL2 FBAL3 FBAL4 FBAL5 FBAL6

SRDY: Servo display signal This signal corresponds to the conventional V-Ready signal. This signal becomes "1" after the axis control PCB receives the servo amplifier ready signal. This signal becomes "0" when the servo amplifier ready signal is turned OFF. SSTB: Servo stand-by signal This signal becomes "1" when the CPU of the axis control PCB and axislwelding control PCB have become ready after the power is supplied. FBAL: Feedback pulse signal alarm The bit turns to 1 when the feedback pulse signal from the pulse coder is abnormal. (Including cable disconnection). DCAL: Discharge alarm The regenerative current of the motor POWER energy is discharged. If the current exceeds a specified value, this signal turns to 1. HVAL: High voltage alarm If the motor drive voltage exceeds a specified value, this signal turns to 1 . HCAL: High current alarm If the motor drive current exceeds a specified value momentarily, this signal turns to 1 . OVC : Overcurrent alarm If the motor drive current exceeds a specified value in a specified time, this signal turns to 1 . OVL : Overload If a motor is overloaded and a thermostat in a motor operates, this signal turns to 1 . c) Information of position control
,

Bit No. 7 043 6 5 INP6 4 INP5 3 INP4 2 INP3 1 INP2 0 INPl Each axis in-position Remarks

In-position signal This signal turns to 1 when the robot reaches at the comnanded position due to the servomotor rotation. When in-position signals of all axes turn to 1, one motion command of the robot is completed. However, if a G code, CNT (positioning neglect) is programmed, the text position command starts even if the in-position signal is not 1. No. 100 101
-

Decimal value

Remarks 1-axis error register 2-axis error register 3-axis error register 4-axis error register register

102

105

6-axis error I register 1

Error register The amount of error between the move command value and the present position value is displayed as a signed decimal number. This is the error register value used for generating the PWM command value. The register is also used for checking the following items: 1. In-position condition check 2. Excessive error check during stop 3. Excessive error check during movement Refer to parameters No. 152 to 175 for these values. Error code for excessive error during stop Error code for excessive error during movement

Axis name

I I

310 330 350 370 410 430

I I

311 331 351 371 411 431

I /

1st axis 2nd axis 3rd axis 4th axis 5th axis 6th axis

I I

8) Other D I / D O s i g n a l s a ) DO
>

No.

7
6 BKR2 5 BKR3 4 BKRE

Bit

Remarks

2 HBREL

1
A L M L
I

0 OPRA

001

BKRl

See 6)
B K R l t o 3: Brake r e l e a s e s i g n a l . When BKRE i s 1 and t h i s s i g n a l i s 1 , t h e brake i s r e l e a s e d . The correspondence between t h e brake r e l e a s e s i g n a l s and a x i s names i s a s follows:

Robot

Brake-release s i g n a l name BKR 1

BKR 2

BKR 3

ARC Mate

U
WY

S-5, S-10, S-600 ARC Mate, ARC Mate Sr. S-300, S-700 S-420, S-500,

u
8

YY

B y

W, U
Z ZY u

Y Y 69 a

M-100, A-200, M-400

A-510

8 Z
W, R

a, B

--

A-600 L-1000 C-100

8
8

YY B
a, B

Y, X

BKRE :

HBREL :

Brake r e l e a s e e n a b l e s i g n a l T h i s s i g n a l t u r n s on and o f f t h e power of t h e brake d r i v e c i r c u i t . When t h i s s i g n a l i s 1 and any of BKRl t o 3 i s 1 , t h e corresponding brake i s r e l e a s e d . Hand breakage r e l e a s e s i g n a l When a hand of t h e r o b o t i s broken, t h e i n p u t u n i t r e c e i v e s t h e hand breakage d e t e c t i o n s i g n a l (*HBK) and c u t s o f f 100 VAC s u p p l y i n g t o t h e MCC of t h e s e r v o a m p l i f i e r . Then, t h e r o b o t stops. To r e s t a r t t h e r o b o t , p r e s s t h e RESET key on t h e t e a c h pendant o r p r e s s t h e RESET b u t t o n on t h e o p e r a t o r p a n e l . This o p e r a t i o n makes HBREL 1 and s u p p l i e s 100 VAC and t h e r o b o t becomes r e a d y t o o p e r a t e . When s i g n a l *HBK t u r n s t o 1, HBREL a u t o m a t i c a l l y t u r n s t o 0.

No. 7 018
6

Bit

Remarks

4
OHC

3 B T A L M

0
DI in serial port PCB
L

: Overheat d e t e c t i o n s i g n a l When t h e t h e r m o s t a t on t h e s e r i a l p o r t PCB o p e r a t e s , t h i s s i g n a l t u r n s t o 1. BTALM: B a t t e r y a l a r m s i g n a l When v o l t a g e of t h e b a t t e r y connected t o t h e back p a n e l i s lower t h a n a s p e c i f i e d l e v e l , t h i s s i g n a l t u r n s t o I. Replace t h e b a t t e r y w h i l e t h e power i s on.

OHC

Bit

No. 7 031
4

m
. Remarks
3
2
*FALM

6
INPTY2
I

5
INPTYl ,

4
*PPABN
I

1
R L W D

0 *ESP

INPTY3
I

L Refer t o 6 )
Refer t o 2)

*FALM: Fuse a l a r m s i g n a l When any of t h e f u s e s used i n t h e t h r e e brake on/off s i g n a l c i r c u i t s (about 90 VDC) i s m e l t e d , t h i s s i g n a l t u r n s t o 0. R L W D : Relay m e l t s i g n a l When t h e r e l a y , which c u t s o f f 100 VAC s u p p l i e d from t h e i n p u t u n i t t o t h e s e r v o a m p l i f i e r , m e l t s due t o an a l a r m , t h i s s i g n a l t u r n s t o 1. *ESP : Emergency s t o p s i g n a l When t h e emergency s t o p b u t t o n on t h e t e a c h pendant i s p r e s s e d or when t h e s a f e t y f e n c e i s open, t h i s s i g n a l t u r n s t o 0.

c ) Other i n p u t
Table 2.8 (c) ONIOFF switch, EMERGENCY STOP button and deadman switch on teach pendant
9

Bit

No.

Remarks

7
025

6
ON/OFF

5 D E A D M A SWITCH

EMG SWITCH

: Emergency s t o p b u t t o n on t h e t e a c h pendant B i t s t a t e i s 1 w i t h emergency s t o p s t a t e . ON/OFF : ON/OFF s w i t c h on t h e t e a c h pendant B i t s t a t e i s 1 w i t h ON. B i t s t a t e i s 0 w i t h OFF. DEADMA SWITCH : Deadman s w i t c h B i t s t a t e i s 0 with the switch pressed; released.

EMG SWITCH

1 with t h e switch

3.

DETAILS OF PCB

Since the PCBs are set and adjusted at the factory before shipment, it is usually not necessary for the customer to set and adjust them. This section describes the standard settings and the adjustments required when replacing a faulty PCB, and also describes the meanings of test pins and LEDs.
3.1
Main CPU PCB

1 ) Setting Name Standard setting ROM system Meaning Selection of ROM used 1M: 1 mega bytes ROM ROM system (76A0, 76B0, 76CO) 2M: 2 mega bytes ROM ROM system (76A1)

T1

2 ) Neaning of test pins

Name
+.5v
GND

Meaning For measuring the DC power voltage For testing PCB

Others

3 ) Meaning of LEDs
Name PAL WDA SYSF Q1 Color Red Red Red Blue Meaning Parity error of RAM on the main CPU PCB. Main CPU PCB malfunctions, The system does not operate due to a system error, Refer to error code list. Indicates the operation status of the system. (Refer to section 2 . 2 "Troubleshooting" for details.)

44

Fig. 3.1 (a)

Main CPU PCB

3.2

Serial Port PCB

1) Setting
-

Name BAT2 SC2

Standard setting Short between BAT1 and BAT2. Short between SC1 and SC2.

Meaning For testing PCB (Note 1 ) For testing PCB (Note 2)

Note 1 ) When this jumper is disconnected, the RAM on the serial port PCB is separated from the battery unit and the data may be lost by the interruption of power supply. So, be sure to set it shorted. Note 2) When the serial port PCB is removed from the back panel with this jumper disconnected, the data is immediately lost. So be sure to set it shorted. 2) Meaning of test pins Name BAT C 7M C16M *TMR *ITP +5V +12v -12v
+24E GND

Meaning For measuring a battery voltage

7 MHz clock pulse 16 MHz clock pulse

2 msec clock pulse (Note 2) 16 msec clock pulse (Note 2) For measuring the DC power voltage

Others

For testing the PCB

Note 2) Wave forms of *TMR and *ITP are shown below.

* ITP

L--

16msec

J 195,sec C

3) Meaning of L D s
Name Color Meaning

B T A L M

Red

The b a t t e r y power v o l t a g e i s low. batteries. The s e r i a l p o r t PCB m a l f u n c t i o n s .

Replace t h e

W D A L M RSTIN

Red Red

The s e r i a l p o r t P C B i s u n d e r t h e r e s e t condition. P a r i t y e r r o r of RAM on t h e s e r i a l p o r t PCB occurs.

P A L M

Red

4) Holding d a t a s t o r e d on RAM
The d a t a s t o r e d on RAM can be h o l d f o r a t l e a s t one hour even i f t h e PCB s e r i a l p o r t i s removed from t h e PCB back p a n e l . 5) PCB p r e s e r v a t i o n d u r i n g d a t a s t o r a g e P r e s e r v e d a t a a v o i d i n g s h o r t c i r c u i t i n t h e l e a d w i r e s on t h e PCB. Because a s h o r t c i r c u i t can cause d a t a t o be d e l e t e d o r problems w i t h parts.

CNA
*TMR B *ITP 8 GND 8

C16M

z ! z E?:
@ BAT

a e

C7M

GND @

'f,

+
m I
N N 0

o I
0 N
c . '

Fig. 3.2 Serial port PCB

3.3

1 1 0 PCB 1) S e t t i n g
Table 3.3 (a) In case of PCB version 02 and before

Name DIP 1

Standard s e t t i n g
A side

Meaning S e l e c t i o n of common v o l t a g e of t h e r e c e i v e r c i r c u i t f o r SDIOl t o SDI16 s i g n a l s . A s i d e : +24 V common B s i d e : 0 V common S e l e c t i o n of common v o l t a g e of t h e r e c e i v e r c i r c u i t f o r RSR1, RSR2, START, RSETE, AUTO, *SFSD, *HOLD and *ESP s i g n a l s . A s i d e : +24 V common B s i d e : 0 V common S e l e c t i o n of common v o l t a g e of t h e r e c e i v e r c i r c u i t f o r R D I O l t o RDI08, N Z 1 t o NZ5 and *PPABN s i g n a l s . A s i d e : +24 V common B s i d e : 0 V common S e l e c t i o n of common v o l t a g e of t h e r e c e i v e r c i r c u i t f o r PNSl t o PNS8, RSR3 and RSR4 s i g n a l s . A s i d e : +24 V common B s i d e : 0 V common

DIP 2

A side

DIP 3

A side

DIP 4

A side

--

-.

Refer t o t h e Appendix of OPERATOR'S MANUAL f o r d e t a i l s .

Table 3.3 (b)

In case of PCB version 03

Name DIP I

Standard setting

Me aning Selection for SDIOl A side: B side: of common voltage of the receiver circuit to SDI16 signals. +24 V common 0 V common

A side

DIP 2

A side

DIP 3 A side

Selection of common voltage of the receiver circuit for RSR1, RSR2, START, RSETE, AUTO, *SFSDy *HOLD and *ESP signals. A side: +24 V common B side: 0 V common Selection for RDIOl A side: B side: of common voltage of the receiver circuit to RDI08 signals. +24 V common 0 V common

DIP 4

A side

Selection of common voltage of the receiver circuit for PNSl to PNS8, RSR3 and RSR4 signals. A side: C24 V common B side: 0 V common Always set to A side. Short circuit if the end effector breakage detection is not required.
7

DIP 5 *HBK

A side
Open

Table 3.3(c) In case of PCB version 05 and after

Name DIP 1

Standard s e t t i n g A side

Meaning S e l e c t i o n of common v o l t a g e of t h e r e c e i v e r c i r c u i t f o r SDIOl t o SDI16 s i g n a l s . A s i d e : +24 V common B s i d e : 0 V common S e l e c t i o n of common v o l t a g e of t h e r e c e i v e r c i r c u i t f o r RSR1, RSR2, START, RSETE, AUTO, "SFSD, and *HOLD s i g n a l s . A s i d e : +24 V common B s i d e : 0 V common Same s e t t i n g a s DIP 2 S e l e c t i o n of common v o l t a g e of t h e r e c e i v e r c i r c u i t f o r RDIO1 t o RDI08 s i g n a l s . A s i d e : +24 V common B s i d e : 0 V common S e l e c t i o n of common v o l t a g e of t h e r e c e i v e r c i r c u i t f o r PNSl t o PNS8, RSR3 and RSR4 s i g n a l s . A s i d e : +24 V common B s i d e : 0 V common Always s e t t o A s i d e .
---

DIP 2

A side

DIP 2S DIP 3

A side A side

DIP 4

A side

DIP 5
*HBK

A side

Open Open Open Open Open

S h o r t i f t h e end e f f e c t o r breakage d e t e c t i o n i s not required. Short i f robot o v e r t r a v e l d e t e c t i o n i s not required.

-

*ROT *HOLD *SFSD ENBL

S h o r t when t h e hold s i g n a l i s n o t used i n t h e p e r i p h e r a l d e v i c e i n t e r f a c e A. (Note)

--

S h o r t when t h e s a f e t y speed s i g n a l i s n o t used i n t h e p e r i p h e r a l d e v i c e i n t e r f a c e A. (Note) S h o r t when ENABLE s i g n a l i s n o t used i n t h e p e r i p h e r a l d e v i c e i n t e r f a c e A. (Note)

Note) When t h i s s i g n a l i s n o t used, s h o r t t o t h e common s i g n a l . connector s i d e o r u s i n g s e t t i n g p i n .

Perform a t

2) Meaning of test pins

Name
I

Meaning

*ESP

Input sigrial of the emergency stop switch on the peripheral device. 0 V indicates emergency stop status. Input signal of the end effector breakage detection switch.
0 V indicates end effector breakage status.

-Input signal of the overtravel switch. 0 V indicates that the robot is in overtravel. -.---.

i 4

r--I
CNA

--

For measuring the DC power voltage

1
a
DIP l

-_----.-

DIP3
Fig. 3.3 (a)

I
DIP 2

PCB version

I10 PCB (PCB version 02)

DIP 1

I
DIP 2
Fig. 3.3 (b)

PC~Bversion

I/O PCB (PCB version 03)

i
3 . 4 Axis Control PCB 1) S e t t i n g
Name Standard s e t t i n g

OV DIP2

e
CN 2
CN 1

( ENBL ) ( *HOT ) ( .+HBK)

-PCB ve~sion

(*HOLD) ($sFSD)

Fig. 3.3 (c) I10 PCB (PCB version 05,06 and after)

Meaning

S1

B side

System s e l e c t i o n Always s e t t o B s i d e

1
-----servo error occurs.

2 ) Meaning of LED

----Name SALM Color Red This

LED

Meaning

is

lit

when

+
CL

CNA

m
I
P5 N

rn

S 1

0 0

I
0 N
Cn

CF94

CF92

CF93

CF91

CV24

CV32

CV23

CV21

SALM

8
A
i

3.5

Axislwelding Control PCB

I) Setting
Name S1 S2 Standard setting Meaning Selection of system Always set to B side. Setting of polarity of D/A converter output (channel 1 ) Short: Output voltage is negative (-). Open: Output voltage is positive (+). Setting of polarity of D/A converter output (channel 2) Short: Output voltage is negative (-). Open: Output voltage is positive (+). Switching of output voltage gain of D/A converter (channel 1 ) Open: Max. output voltage +10V Short: Max. output voltage over t12V Switching of output voltage gain of D/A converter (channel 2 ) Open: Max. output voltage t10V Short: Max. output voltage over f12V

B side
Short

S4

Short

S3

Open

S5

Open

Standard setting of analog output is negative polarity setting at the shipment.

2) Adjustment Adjust the reference voltage and gain of the D/A converter in the procedure shown below.
(Procedure 1 ) Adjusting the reference voltage of D/A converter Observe 10V of the test pin with a digital voltmeter, and adjust it to 9.94V t O.lV with the variable resistor VR1. (Procedure 2) Adjusting the gain of channel 1 Execute S49 1, 255 using the teach pendant, observe the voltage at the test pin DAOl with a digital voltmeter, and adjust it to 10.OV with the variable resistor VR2. At this time, connect the "-" side of the digital voltmeter to the test pin OVF (different from ordinary O V ) . (Procedure 3) Adjusting the gain of channel 2 Execute S49 2, 255 using the teach pendant, observe the voltage at the test pin DA02, and adjust it to 10.OV with the variable resistor VR3. At this time, connect the "-" side of the digital voltmeter to the test pin OVF (different from ordinary O V ) .

3) Meaning of test pins Name 1OV OVF DAO1 DA02 A1 1 A12 WDIP WDIM Meaning For adjusting the standard voltage of the D/A converter. OV terminal of analog output voltage. (GND of floating power supply) Analog output voltage (channel 1 ) Perform voltage measurement between DAOl and OVF. Analog output voltage (channel 1 ) Perform voltage measurement between DA02 and OVF. Analog input voltage (channel 1 ) Analog input voltage (channel 2) Wire stick detection voltage (+ side) Wire stick detection voltage (- side)

4 ) Meaning of LED
pame SALM

color Red

Meaning This LED is lit when an error of servo occurs.

+
w

CNA
0

m
I
N

G3

N 0
0

ov

'
0 W 0

CF92

CF91

CVZZ

CVZl

m A11

CA

CA

A12 DAOI DA02

9 0 0 .OVF
I

I
Fig. 3.5 Axislwelding control PCB

WDIP

3 . 6 Servo Amplifier PCB There are three types of the servo amplifier PCBs; for 3 axes, 2 axes and 1 axis. 1 ) Setting Setting depends upon each axis.
Standard setting Name Servo Servo amp. 1 amp. 2 (Note 1 ) L
H

Servo amp. 3

Servo amp. 4

Servo amp. 5

Meaning

S-5 S-600 ARC Mate S-10 ARC Mate Sr, M-100 A-200 A-510 A-600 C-100 S-300 S-420 S-500 S-700 M-400 L-1000

TGH setting (Note 2 )

H (L)

H (L)

H (Traverse unit)
-.

Standard setting Name Servo amp. 1 (Note 1) Servo amp. 2 Servo amp. 3 Servo amp. 4 Servo amp. 5 Meaning

S-5 S.1600 ARC Mate C-100 S-10 ARC Mate Sr. A-200 A-5 10 S2 A-600 M-100 S-300 S-420 S-500 S-700 M-400 L- 1000

DC alarm setting (Note 3)

H H

L
H

L
(running axis)

L L (HI ) (Note 6) (Note 4 H

Note 2) When the servo transformer is used and an overheat signal is connected I ) , (2) or the terminal between the thermostat and the connector CN2 ( board T4 ( I ) , (2) for S series servo amplifier, the jumper S1 is set to L side. When an overheat signal is not used, S1 is set to H side. Set to H side when the servo amplifier mounted in additional cabinet with one side door is cooled by the outside air. Note 3) When a separate regenerated discharge unit is not used, the jumper S2 is set to L side. When it is used, the jumper S2 is set to H side. Note 4) Set S2 to H side when the fan unit with regenerated resistor is specified. Note 5) There is no S2 in the PCBs of servo amplifier 2 (1 axis control) of M-100, A-200 and servo amplifier 4 of M-400. Note 6) For servo amplifier 2 for S-500, S-700, and M-400, setting depends on the payload condition. Set the jumper to the previous setting when replacement.

Servo amp. 1 S-5, S-10, S-600, ARC Mate, ARC Mate Sr., M-100, A-200, A-5 10, A-600, C-100

Se~vo amp. 3 Servo amp 2 Servo amp 1

(Additional cabinet)

(Main cabinet)

Note)

Use f o r S-420F Traverse unit

Fig. 3.6 (a) Locations of the servo amp.

Servo amp 1

/I

- Servo amp. 4

S-500, S-700, ARC Mate with additional axis, ARC Mate SI. with additional axis, M-400, GlOOO
Fig. 3.6 (b) Locations of the servo amp.

2) Meaning of t e s t p i n s a ) 3-axis PCB, 2-axis PCB The 2-axis PCB does n o t have N a x i s . Name CIIlL (*PWMAL)
CH l M
M

Axis L

Meaning

A phase P W M signal

(*PwMAM)
CHlN

(*PwMAN>
CH7L (IRL) C H 7 M (IW) CH7N URN) CH8L (ISL) C H 8 M (ISM) CH8N (ISN) CH9L (0 V) C H 9 M (0 V)
'

R phase c u r r e n t feedback

N
1 ,

S phase c u r r e n t feedback

These a r e used t o check s i g n a l s CHI, CH7 and CH8 f o r L, M and N a x e s respective1.y.

CH9N (0 V) CH9 (0 V)
CHlO

0 V

+5 V power

(+5 V)
CHl 1

+15 V power

(+I5 V) CH12 (-15 V) CH13 (+20 V) Others -15 V power

+24 V power (+20 V f o r S s e r i e s )

For t e s t i n g t h e PCB

~ ~ t For e ) S s e r i e s s e r v o a m p l i f i e r s , s i g n a l name i s e x p l a i n e d i n p a r e n t h e s e s .

b ) 1-axis PCB Name CH7 (IR) Cli8 ( I S ) CH9 (OV) C H l O (+5 V) CHI1 (+I5 V) CH12 (-15 V) CH13 (+20 V) Meaning R phase c u r r e n t feedback S phase c u r r e n t feedback 0 V
+5 V power

+15 V power -15 V power ,+24 V o r +20 V power (Note 1) For t e s t i n g t h e PCB

Others

Note) For S s e r i e s s e r v o a m p l i f i e r s , s i g n a l name i s e x p l a i n e d i n p a r e n t h e s e s .

3) Meaning of LEDs

Name
DRDY
HV

Color Green Red Red Red Red Red Green

Meaning

Positioning c o n t r o l ready s i g n a l Overvoltage alarm (Note 1) Overcurrent alarm (Note 1) Low power v o l t a g e alarm (Note 1) Discharge c i r c u i t alarm (Note 1)

HC

LV
DC

OH

Overheat alarm (Note 1)

-t,5 V power

+5 V

Note 1) Refer t o s e c t i o n s 2.3(18) t o (23) f o r d e t a i l s .

A16B- 1100-0280/ I

A16B-1100-0330

CHlAL CH2AL

CH2CL CHlCL

CH2EL

CHlAM

CHlVS CH2VS
0 CH13(+20V)

CH2AN CHlAN

1
CNlL

sl t o
s2

:o
0 0 0 0 0

e
0

OCN9M oCN8M

OCN9N oCNSN

IRL ISL IRM ISM IRN ISN

OV

CNlM

CNlN

3-axis PCB S-10, S-420, ARC Mate SI., M-100, A-200, S-300, L- 1000, C-100
Fig. 3 . 6 (c) Servo amplifier PCB

A16B- 1200-0800,'

I
OCHlL

CH~ALOO CH2AL CHI C L o o CHZCL CHI E L 0 0 CHZEL CHI AM00 CH2AM CHI CMoo CH2CM C H l E OOCH2E oCHlVS oCH2VS

r
0
t ,

0 CH2L

OCH3L
0CHl E 0 CH2E 0 CH3E

m
w
7-

OCHlC OCH2C 0 I OCH3C OCHlA hl OCH2A OCH3A

oCHlO(+5V) H L 0 CH9 (OV) 0 CH8M o CH7M o CH8 L o CH7L o CHlM

o CHI 3 (+24V) o CH12(-15V)

oCH11(+15V) 0 CHlO(+5V) OCHS(0V) 0 CH8 0 CH7 0 CH6 0 CH5 0 CH4 0 CH3 0 CH2 0 CHl CN 1

jc
m y
@
@ HV

2-axis PCB M-100, A-600, A-5 10, A-200, M-400, S-700, S-5, S-500, S-600, ARC Mate, L-1000, C-100

HC

I
1-axis PCB (S-420)
Fig. 3.6 (d) Servo amplifier PCB

CN2

~ ;:o:

e LV

S1 S2

I I

CHlA 0 CH2A 0 CHlVS 0 CH2VS 0 CHlE 0 CH2E 0 CHlC CH2C

A2OB-1003-0090/-

CHPA CHlA CH3A

0 0 0

CH2C CHlC CH3C

0
0 0

CH2E CHlE CH3E

0 CH8 @ +5 0 CH7 0
0 0

0 0 0 -15 f20 $15

\ 0
I

HV @ HC @ LV @ DC 8 OH
@

CH2COM CHlCOM CH3COM

0
0 0

o o
m
0

0 w

m
0

0 +5

2
0

CHI8
8 DRDY

INCLO
0 DOF 0 CH6 0 CH5 0 CH4 0 CH3

DRDY F1 F2 F3

o CHI4 s HV o s HC 0 s LV

yt,:: @,E$? H OC
0 w D L OH oCH8 s2 @ +5v o CH7 H oCHl CHI5 CHI6 CHI7 O o O S1 CN 1

[IL
T4

1 a x i sPCB (M-100, M-400, A-200, C-100)

1 a x i sPCB (S-300, S-420, S-500, S-700, M-400, C-100)

Fig. 3 . 6 (e) Servo amplifier PCB

3.7

Back Panel PCB 1) Setting

Name

Meaning Selection of usage of connectors CNAl to CNA5. PCB is mounted. V side: PCB is not mounted.
0 side:

P1 P4 P5

PI, P4 and P5 are corresponding with CNA1, CNA4 and CNA5, respectively.

2) Meaning of test pins

Name Meaning For measuring the power of the back panel PCB. VBAT is for battery voltage of the battery unit.

ov

+5V +15V -15V

+24V VBAT
Others For testing the PCB

a
+ 5v
-0v
U

CA27

A16B- 1 2 1 2 - 0 3 6 0

P5
VBAT
0

P4
0

P1 u

ov

ov

ov

Fig. 3 . 7

Back panel PCB

3.8 Input Unit PCB 1) Setting

I I

Name

SDIL

1 I

Model Common to all models ARC Mate Sr. Other than the above (Note) all models (Note) S-420 ARC Mate Sr. Other than the above (Note)

Standard setting Short Short

Meaning Open when using the door interlock.

For controlling the brake

Short

Open

For controlling the brake

SBK2B Common to all models (Note) SFG Common to all models

Open

Short

For PCB test

Note) When the PCB is replaced, make the same setting as that before the replacement. 2) Setting of the terminal block (TP1) Name EMGIN1 EMGIN2 FN1 Standard setting Remarks When using these signals, refer to the CONNECTING 3.1.2 "Connection for ON/OFF of external power supply and external emergency stop".

EMGINC EMGINC Short

FN2

3) Meaning of jumpers Name Meaning Measures the DC supply voltage.

+24V

ov

24VS OVS OVB

Tests the PCB.

4) Meaning of LEDs Name SVON Color Yellow Meaning Lights up to indicate that 100 VAC is supplied to the servo amplifier. Lights up to Indicate that the brake is released. Lights up to indicate that the input unit is powered. Lights up to indicate that the power unit does not operate normally. When an alarm signal is applied from an external device (laser controller) like L-1000, an alarm occurs outside of the control unit. Lights up to indicate that the fuse F4 on the input unit PCB is blown or the brake coil or the wire connected to the brake is shorted.

BKR 1 BKR2 . Yellow BKR3 PIL ALM Yellow Red

FALM

Red

Fig. 3.8 (a)

Input unit PCB

3.9 Peripheral PCB

1 ) Setting Name S1 Standard setting Short Meaning Selection of output polarity of channel 3 on D/A converter

S2

A side Positive
Nega tive

S1 Open Short

S2 B side

A side

S3

Short

Selection of output polarity of channel 4 on D/A converter

S4

A side

S3 Positive Negative Open Short

S4 B side A side

S5 S6 S7 S8 DIP 1 (Note 2)

Refer to (2)

For adjusting duty of position LSI clock (16 MHz) Selection of common voltage of welding DI (WDI 9-16) connected to the peripherals A side: f24 V common B side: 0 V common Selection of common voltage of optional DI (ADI1-16) connected to the peripherals A side: +24 V common B side: 0 V common

B side

DIP2 (Note 1) (Note 2 )

B side

Note 1) Jumper DIP2 is mounted only on optional peripheral PCB (A16B-12110501). Analog signal cannot be used in some models. Note 2) If this setting is changed to A side, parameter No. 48 also should be changed.

2 ) Adjusting a) Adjusting duty of position LSI clock (16 MHz) This adjustment has been done before shipment. Adjust one of jumpers S5 - S8 according to the condition shown below if necessary.
(Measuring point) 17th pin of position LSI (B8; MB87103)

1 5v

yie,aiei than

y z t e r than/ I st pin

~~87103

/
17th pin

I
2lthpin

Fig. 3.9(a)

Waveform of position LSI clock

b ) Adjusting reference voltage This adjustment has been done before shipment. Adjust the test pin lOVREF to +10.00 V by turning the variable resistor VR1.

3) Meaning of test pins

Name *CLK 16M *CLK8M CLKlM 1OVREF Meaning 16 MHz clock pulse

8 MHz clock pulse

1 MHz clock pulse For adjusting +10 V reference voltage Analog output voltage (channel 1 ) Analog output voltage (channel 2 )
I

CH IDAO
CH2DAO CHlAI CH2AI
I

Analog input voltage (channel 1) Analog input voltage (channel 2) Wire stick detection voltage (+ side) Wire stick detection voltage (- side)

W D I (-1

A16B-1211-050e/~
f CLK8M

CLKlM JCLKI6M S5678

@

~MB811-q
WDI

rrm

0V

O 0 V

DIP2

CN2

VR I
Fig. 3.9(b)

CN I

Peripheral PCB

3.10 Pulse Coder Detection PCB (A-600)

1) S e t t i n g Standard setting

Name
U24 U54 U66

Meaning

Open

For t e s t i n g t h e PCB

2) Meaning of check p i n
Name Meaning For checking a p u l s e coder s i g n a l

CH2 CHll

CH9 CH18

+5 v / 1 +5 V/2 GNDl G N D 6

For measuring DC power v o l t a g e

Others

For t e s t i n g t h e PCB

3 ) Meaning of LED
Name ALM (Red) Lit Lit Lit Lit Lit Lit A L O (Red) A L1 (Red) Meaning

Watch dog alarm of t h e p u l s e coder d e t e c t i o n PCB Level alarm of p u l s e coder

7

Poor accuracy alarm of p u l s e coder

I

I
1

CNA
0

U6 6

GND2
0

GND3

C\1

03

GND4
u54

3 0 ; <
ALO

1 000000000
CH2-9

GND 1
0

0+5/1

u2 4

I ;
CF121
i
7

00000000

+5/2

CH11-CHI8 ALO

ALM/AL~_GND~ 0000 CFl22

CF112

CFlll

000

Fig. 3.10 Pulse coder detection PCB

3,11 Additional I10 PCB

I) Setting

Name

Standard setting A side

Meaning Selection of common voltage of the ADO01 receiver circuit. A side +24V common B side OV common

- AD048

signal

...

...

2) Meaning of test pin Name CLK16M CLK8M Meaning 16MHz clock pulse 8MHz clock pulse Measures DC supply voltage

+24E GND 1
GND2

3) Meaning of LED
Name LED 1 Color Red Meaning Lights up to indicate that the fuse F1 is blown.

PCB version
a
I

m
N
C-L

CLK8M

CLKl6M

N
0
C-'

GND2

~1

0GNDl

CN.3+24E
@

CNA3

DIP1

CNA 2

LED1

I
Fig. 3.1 1 Additional 1 1 0

3.12 Laser interface PCB 1) Setting This PCB has no s e t t i n g part. 2) Meaning of check pin
Name Meaning

+24 V +15 V -15 V + 5 v 0v

For DC supply voltage measurement

CNA

A16B-1212-0420

Fig. 3.12 Laser interface PCB

4. SETTING AND ADJUSTING POWER SYSTEM Since the power system is set and adjusted before shipment, it is usually not necessary for the customer to set or adjust it. This section describes how to set and adjust a replacement power system.

4.1 Power System Block Diagram The power system block diagram of the control unit is shown is Fig. 4.1.

Operator panel

1 transf ormer TF2

Servo transformer E

transformex D Input power voltage of Sewo transformer E: 2201230-550 VAC Input power voltage of AC line filter 01 servo transformer D: 200-220 VAC

Fig. 4.1 Power system block diagram

4.2 Selecting Transformer Taps 1) Tap selection of servo transformer TF1 Perform tap connection so as the power supply voltage becomes within +I0 to -15% against the tap voltage.

Input voltage

Primary tap
Jumper

Connection type

Note) 575V tap is not used.

Fig. 4.2 (a) Selecting servo transformer tap T F I 6-5, S-10, S-600 ARC Mate, ARC Mate Sr., M-100, A-200, A-510, A-600, C-100)

Input Voltage
200
-

Primary tap V
7-24 6-24 15-8 14-8 13-8 14 13 12 11 10 9

W
23-16 22-16 21-16 22 21 20 19 18 17

Jumper

Connection type

220 240 380 415 460 480

6 5 4 3 2 1

5-24

8- 16-24

500 550

Fig. 4.2 (b) Selecting servo transformer tap TFI (S-300, S-420, S-500, S-700, M-400, L-1000)

2) Selecting input transformer taps TF2, TF3 When the input power voltage is other than 200 VAC 50160 Hz or 220 VAC 60 Hz, it is necessary to use the input transformer. Select proper taps so that the power voltage is within +lo% to 15% of the tap voltage. Fig. 4.2 (f) shows tap selection for 380 VAC of input power voltage.

Fig. 4.2 (c) Selecting input transformer taps TF2, TF3

4.3

Checking Input Unit

1 ) Checking fuses F7, F8, and F9 Check capacity of fuses F7, F8, and F9. (Refer to APPENDIX 3. "Spare Parts List. " 2) Checking voltage When replacing the input unit (or the input unit PCB) follow the procedures 1 to 4 described below to check voltage of each unit.) (Since high voltage is applied to the input unit, take care not to touch any part of it when checking,)

A14B-0076-B357: S-5, S-10, S-600, ARC Mate, ARC Mate Sr., M-100, A-200, A-5 10, A-600, C-100

Fig. 4.3 Checking voltage of input unit

@ Input power voltage (200-550 VAC)

Verify that the voltage between the phases of the input supply voltage is normally applied. A14B-0076-B357 Check between 11-12, 11-13 and 12-13 A14B-0076-B355/A14B-0076-B355 Check between 1-3, 1-5 and 3-5. @ Input voltage of the control transformer (200 VAC) Verify that 200VAC is applied between 200 and COM of the control transformer. @ Output voltage of the control transformer (200 VAC) Verify that lOOVAC is applied between lOOA and lOOB of the control transformer.

@ Power voltage for servo (200-550 VAC)

Verify that the voltage between the phases of fuses F7, F8 and F9 is normal. The voltage between the phases is the same as the input power voltage.

3 ) When the input unit malfunctions a) When the LED (ALM) on the PCB is not lit, the cable may not be connected properly, a fuse may be blown or the input unit may be faulty. b) When the LED (ALM) is lit, the power unit is faulty or alarm occurs outside controller (in case of L-1000)
Note) When the LED (ALM) i.s lit, the power cannot be turned on again. Turn off the power by cutting off the input power, pressing the power off button or external off switch.
4.4 Checking Power Unit 1) Rated output

Output Rated Allowable variation range Rated current name voltage (Max. )

Remarks Without voltage - adjustment

+5
+15 -15 +24

+5 V +15V -15 V +24 V

+5 % +5 %
+5 % +lo%

24 A 0.3 A 0.3 A 1.5 A / 2.3 A

Without output voltage. adjustment is not provided. With output fuse

F13.

+24E

+24 V

-+lo%

4.0 A / 3.0 A

Without output voltage. adjustment is not provided. With output fuse

F14.

VBT

+4.5 V

Lowering to 3.6 V will cause battery alarm

24 A

Battery voltage.

Back panel PCB

0 0 - 15V 0 ov 0 + 24V 0
VBT

+ 5V + 15V

Fig. 4.4 (a)

Voltage check terminal on bask panel PCB

2) Adjustment and setting The power unit is not necessary to set or adjust. Since the reference voltage A10 (10.00 V ) is adjusted before shipment, check the voltage between test pins A10 and A0 on the connector CP16 and be careful not to adjust it unnecessarily. When the voltage of test pin A10 differs, adjust it to 10.00 V by VRll using the digital voltmeter. Turning VRll clockwise increases the voltage. When replacing the power unit, always check the reference voltage A10. 3) Cause and remedy of blown fuse The power unit provides fuses, F11 and F12 for input, F13 for +24 output and F14 for +24E output. (For fuse replacement, refer to APPENDIX 3. "Spare Parts List" and make sure to replace the fuse with the specified part.) a) Fuses F11 and F12 i) Surge absorber VSll absorbs a surge voltage between input lines. When an excessive energy surge voltage is applied or an excessive voltage is constantly applied, the VSll is broken by shorting and fuses F11 and F12 are blown. If the replacement VSll is not available, it is possible to operate without VS11. However, be sure to repair the VSll as soon as possible especially where the controller is used in a condition where the surge voltage generates frequently. VSll specification: A50L-8001-0067#431U ii) Piode stack DSll is shorted. iii) Pins between C and E of switching transistors 414 and 415 are shorted. iv) Diodes D33 and D34 are shorted. v) Pins between C and E of the transistor on the sub power circuit Qll are shorted. When any of parts in itens (i) to (v) are shorted, replace the power unit. b) Fuse F13 After removing The f24 circuit may be shorted on varius PCBs. connectors CPll and CP13 to 15, remove the power unit from the back panel PCB and check whether the power supply of each PCB is short-circuited.
c ) Fuse F14 i) Check whether the power line of the teach pendant, operator panel or their cables is not grounded. ii) Check whether the +24 power live to the peripheral device is not grounded or shorted to other power line after removing the connector CP14. When Fuse F14 is blown, check the F7 on the input unit, too.

+24E C I R C U I T

+ 2 4 ~

+24E

+24V

+15V

-15V

+5V

ov

EN

w
I

For unit test

\

A l OADJ VRI I

F l l - 12 5A AC input

F13 3.2AS +24 fuse F14 7.5A +24E fuse

6 5 4

For AC inuut (black) For connection unit (brown) For CRTIMDI (brown)

2) S e r i a l p o r t PCB T h i s PCB i s provided w i t h t h e b a t t e r y backed up r o b o t parameter and t e a c h I f t h e PCB i s data. The b a t t e r y i s s u p p l i e d from t h e back p a n e l . removed from t h e back p a n e l , t h e s t o r e d d a t a may d i s a p p e a r . (Refer t o 3.2.) Remove c a b l e s K14, K16 and K40, and t h e n two screws; t h e n p u l l o u t t h e PCB
Screw

R e m o d direction

Back panel PCB

Fig. 5.1 (b) Serial port PCB

3) PCBs on t h e back p a n e l
For t h e PCBs mounted on t h e back p a n e l e x c l u d i n g s e r i a l p o r t PCB, remove c a b l e s , and t h e n 2 screws; t h e n p u l l o u t t h e PCB slowly. 4) Teach pendant c o n t r o l PCB, keyboard PCB, L C D module PCB and L C D module Remove c a b l e s K40, f i v e screws, and t h e n t h e r e a r panel. Remove c a b l e s from PCBs, and t h e n t h e PCBs.

Fig. 5.1 (c) Teach pendant

a ) Control PCB Remove t h e c a b l e from t h e PCB, and t h e n f o u r b o l t s and f o u r screws Remove f o u r screws mounting t h e mounting t h e LCD module c o n t r o l PCB. c o n t r o l PCB.

6-M3 snews and washers

4-M2 3 scIews and foul screws the LCD module control PCB

---

-----

Control PCB A20B-1002-0980

\
Fig. 5.1 (d) Control PCB (teach pendant)

b ) LCD module c o n t r o l PCB Remove t h e c a b l e from t h e PCB, and t h e n f o u r screws, t h e n p u l l o u t t h e PCB slowly.

Fig. 5.1 (e) LCD module control PCB (teach pendant)

c ) Keyboard PCB Remove t h e c o n t r o l PCB r e f e r r i n g t o s t e p ( a ) . Remove t h e c a b l e from t h e keyboard PCB, and t h e n f o u r s e t s of n u t s , s p r i n g washers, and washers.
Keyboard PCB A 2 0 B - 1002 - 0.-9 7 0

Four screws

Fig. 5.1 (f) Keyboard PCB (teach pendant)

d) LCD module Remove the cable from the Remove the control PCB referring to step ( a ) . LCD module, and then four sets of nuts, spring washers, and washers.

4-M3 screws and washers

Fig. 5.1 (g) LCD module (teach pendant)

5) Servo amplifier PCB

) a) PCB for 1-axis (M-100/A-200 servo amplifier 2, M-400 servo amplifier 4

Disconnect the cable from the servo amplifier PCB, and remove the screws (4) fastening the PCB.

b) Other PCBs
Disconnect the cable from the servo amplifier PCB, loosen the stoppers mounting the PCB in the arrow direction shown in the drawing, and pull out the PCB. The PCB comes off from the servo amplifier.

Fig. 5.1 (h) Servo amplifier PCB

6) I n p u t u n i t PCB Remove t h e c a b l e c o n n e c t i n g t h e i n p u t u n i t PCB w i t h o t h e r u n i t s , t h e n t a k e o f f t h e a c r y l i c c o v e r , and f i n a l l y remove t h e 4 screws mounting t h e PCB.

2-acrylic cover stoppe1 (Turn in one of the indicated directions)

Sc~ew mounting the PCB

Fig. 5.1 (i) Input unit PCB

7) O p e r a t o r ' s p a n e l PCB
Remove c a b l e s from t h e PCB, and t h e n four n u t s from t h e p l a t e ; t h e n p u l l o u t t h e PCB t o g e t h e r w i t h t h e p l a t e slowly.

Metal plate

Fig. 5.1 (j) Operator's panel PCB

5.2 Replacing lnput Unit Procedure a) Turn two holders mounting the acrylic resin cover, and then the cover. b ) Remove cables connecting the input unit with other units. c ) Loosen two lower screws. d) Remove two upper screws, and then remove the input unit.

Note)

Before replacing the input unit, always turn off the power source using the breaker.

4-M5 Input unit

mew

4-acrylic cover stoppers (Turn in one of the indicated diIections)

Fig. 5.2 lnput unit

5.3 Replacing Power Unit Procedure a) Turn off the power., and remove cables K 1 0 and K 1 2 from the power unit. b ) Remove four screws and then pull out the power unit slowly.

'

, Powel

supply unit

@ 4powe1 supply unit

mounting screws

Fig. 5.3 Power unit

5.4 Replacing Servo Amplifier Procedure a) Remove the cables. Be sure to correctly reconnect cables with the terminal board T1 referring to the cable marks and the terminal names. b) Remove four screws mounting the servo amplifier to the cabinet, and then replace the servo amplifier.

4-M5mounting screws

T1 terminal board

Fig. 5.4 Servo amplifier

5.5 Replacing Teach Pendant Remove the cable K40 from the teach pendant, and then replace the teach pendant.

Fig. 5.5 Teach pendant

5.6 Replacing Battery Remove two screws from the cover, and batteries of D size.

then replace three alkaline dry

Note 1) Replace batteries while the power is on. Note 2,) Be sure to place the battery in the correct position. Note 3) Replace batteries annually.

mounting

SCIBWS

Fig. 5.6 Battery

5.7 Replacing Fuses When a fuse inside the control unit is blown out, locate the cause and take suitable corrective action. Then, replace the fuse. The following fuses are mounted on each unit. See APPENDIX.3 Spare Parts List for fuse specification. 1) Input unit F1, F2 : Input fuse for 200 VAC F3 : Fuse for power on/off control circuit : Power fuse for driving brake F4 F7, F8, F9: Input fuses for power unit

Fig. 5.7 (a) Fuses of input unit

Note 1 ) After confirming the PIL lamp on the input unit is off, replace the fuse.

2) Power unit F11, F12: 2001220 VAC input fuse of power unit 3'13 : +24 V fuse F14 : +24 VE fuse

Fll-12 5A \ AC input fuse

F13 3.2A t 2 4 V fuse F14 7..5A +24E fuse

Fig. 5.7 (b) Fuses of power unit

3) Servo amp. PCB (S-420, M-100, M-400, A-200) F1 : +5 V fuse F1, F2, F3: 2001220 VAC fuse

A20B-1003-0030/

FFF

Fig. 5.7 (c) Fuse of servo amp. PCB

4) Additional I10 PCB F1: Fuse for f24V

Fig. 5.7(d) Fuse of additional I/O PCB

5) Input transformer (TF2) F1: Fuse for 200 VAC

Fuse f 1

Fig. 5.7 (el Fuse of input transformer (TF2)

5 . 8 Replacing Relays
After relays have been used for a long period of time they may develop defective contacts and cause erratic voltages. Replace them as shown below. Relays are mounted on the input unit PCB. (See APPENDIX.3 Spare Parts List for Specification of relays.)

Fig. 5.8 Relay positions of input unit

5.9 Replacing Key Sheet of Teach Pendant If the key sheet is damaged, replace it as follows: Remove the key sheet attached to the panel board. (At this time, remove the adhesive agent from the panel hoard completely.) (See APPENDIX.3 Spare Parts List for specifications of key sheet)

Teach pendant

Fig. 5.9 Replacing teach pendant key sheet

I I I CONNECTIONS

1.

GENERAL

This section describes the electrical interfaces connections in the robot control units. It also includes information for installing the robot.

2 . BLOCK DIAGRAM A block diagram of connections to the robot is shown in Fig. 2 .

Pneumatic pressure source

-Mechanical
.
Teach pendant

....-..-... End eflector

Ope~ato panel ~

i y~;---;
Input power source

-f~lo~p~

cassette

Note 1 )

- - -

: Mechanical connection : Electrical connection

Note 2) For connections indicated with *1 refer to separate manuals.

Fig. 2 Block diagram of the robot connections

The control unit interfaces electrically with the following devices: a) Robot mechanical unit b) Teach pendant c) Operator panel d) Peripheral devices e) Welder f) Floppy cassette g) External device h) Sensor i) AC power source

3. CONNECTION DIAGRAMS Fig. 3 (a) to (j) show the connection diagram and Fig. 3 (k) to (P) show the interface diagram for the external cabling to the control unit.
control unit

I Mechanical unit

02p2D ~ ~ 9 1 . 9 2 01P32 Servo amp.. T 1

Input unit BK1, 2, 3

(Brake)
OlPOE CN2

P -u

]filaa P--

End effector

01P32 CNl

(ARC Mate)

Note)

* marked
-

cables are to be provided by the customer.

Fig. 3 (a) Connection diagram (S-5, ARC Mate)

Control unit
01P2D CF91,92,93 01P2D CF94
K35

Mechanical unit
P1

02P2D} CF91,92 01P32

]0 +
3
3--

K36

[ P2

Servo amp. T1 Input unit BK2, 3 (Brake) Servo amp. T1

Input unit BK2,3

a [ MI

K32

QC M2
D1

(B~ake)

OlPOE CN2

I ff

K34

K43

01P32 CN1

Welder

Note)

* marked

cables are to be provided by the customer.

Fig. 3 (b) Connection diagram (S-10, ARC Mate Sr.)

Control unit

Servo amp. T 1 (W-axis) Input unit BK1 (Brake)

Servo amp T1 (U-axis) Input unit BK1 (Brake)

Servo amp T1 (8-axis) Input unit BK2 (Brake) Servo amp T 1 (a, 0, T-axis) Input unit BK3 (Brake) Servo amp. T1 (Y-axis)

OlPOE CN2

Note 1)

* marked cables are t o be provided by the customer

Note 2) usable for *S-420 (standard) with the traverse unit

Fig. 3 (c) Connection diagram (S-300, S-420)

Servo amp. T1 Input unit BK 2 (Brake) Servo amp. T1 Input unit BK 1, 3 (Brake)

r IM1
K32

OlPOE CN2

bo

K34

Ill

lmd

~ n effector d

Note)

marked cables are to be provided by the customer.

Fig. 3 (dl Connection diagram (S-500, S-700)

Control unit

I Mechanical ynjt I

Servo amp. T1 Input unit BK1,2 (Brake) Servo amp. T1 Input unit BK3 (Brake)

OlPOE CN2

Note)

marked cables are to be provided by the customer.

Fig. 3 (e) Connection diagram (S-600)

Control unit 01P2D CF91,92

Mechanical unit
P1

P2

Se~vo amp.. T 1

l f*k

I
End effector

Input unit BK1, 2, 3 (Blake)

Note)

marked cables are to be provided by the customer.

Fig. 3 (f) Connection diagram (M-100, A-200, C-100)

Control unit

Mechanical unit

Servo amp. T1 Input unit BK1,2 (Brake) Servo amp. T1

Input unit BK 2 , 3

w qM1
b+fl
fl
M2

(Brake)

Note)

* marked

cables are to be provided by the customer.

Fig. 3 (g) Connection diagram (M-400)

I
End effector

Note)

marked cables are to be provided by the customer.

Fig. 3 (h) Connection diagram (A-600)

Control unit

Se~vo amp T1
(a, Z, U-axis)

Input unit BK1 (Brake)

OlPOE C N 2

4 3
End effector
Fig. 3 (i) Connection diagram (A-510)

Note)

marked cables are to be provided by the customer.

End effector

Note)

marked cables are to be provided by the customer.

Fig. 3 (j) Connection between mechanical units (1-1000)

OlPOD
OlPOE OlPOE

CNTP CN1 CN4

Peripheral device C

OlPOD

CD4

EON

External power ONIOFF switch

EMGIN 1 EMGIN2

Note) *I marked cables are to be provided by the customer. *2 marked cable is attached to the Floppy cassette.
Fig. 3 (k) Connection diagram (Common)

S-5 00,S-700, L- 1000 ARC Mate additional axis M-400, ARC Mate S x additional axis
Fig. 3 (1) Control unit external interface cabling

S-5, S-10, S-600, ARC Mate, ARC Mate SI , M-100, A-200, A-5 10, A-600, C- 100

A-600 (PULSE DETECTOR)

Fig. 3 (m) Control unit external interface cabling

input terminal unit

AMP 1 (2.axis AMP)

ARC M a t e

AMP 2

AMP 3

(2-axis AMP) (2-axis AMP)

S - 5

Input unit b~ake

Mechanical unit

K31

M1

(2-axis AMP)
S

(2-axis AMP)
K-31 M I K32 -M2

600

Fig. 3 (n)

Control unit external interface cabling

Input unit

Input unit terminal

AMP1 (3-axis AMP)

ARC M a t e SI. S-10
1

AMP2 (3-axis AMP)

L 6L7L 5M6M7M5N6N

Input unit

brake

Mechanical unit

M1

(2-axis AMP)
5L6L 7L 5M6M7M

(2-axis AMP)

5L 6L7L5M6M7M

t-7
BK1 BK2BK3

M2

I
t

(3-axis AMP)
5L6L7L5M6M7M 5N 6N7N

(2-axis AMP)
5L 6L 7L 5M 6M 7M

I
(2-axis AMP)

Fig. 3 (0) Control unit external interface cabling

unit

K33

AMPle-3
(S-300,s-420)

AMP 4

Fig. 3 (p) Control unit external interface cabling

Input terminal unit

(ARC Mate additional axis) Input terminal unit

1 are Note) Ground terminals (.=) provided between 7L and 5M, and between 7M and 5N in T1 for 3-axis amplifier A06B-6058-H33*. "..

K31,K32

AMP1,2 (ARC Mate Sr . additional axis)

K32

AMP1 (L-1000)

AMP2 (L- 1000)

Fig. 3 (p) Control unit external interface cabling

3.1
3.1.7

Electrical Interface
Connecting the input power supply

Considering the robot power capacity and the circuit breaker capacity, connect the power supply of the voltage specified in the robot installation conditions to the terminal located above the circuit breaker. Use a grounding better than class 3. Be sure to ground the work table or jig used by an arc welding robot to handle a large current. Use a thick wire to withstand 'the maximum current to be used. Selection of input transformer tap is necessary depending on the input voltage. The tap is set at the time of shipment; however, make sure to set and check it referring to section 4.2 in "Maintenance" when changing the input voltage, and before supplying the power (before the breaker's switch is turned ON). Because the motor is driven by P W M inverter method, use the following breaker for servo amplifier with no transformer. Fuji Electric Co. Hitachi Co. Matsushita Co. EG-A series SG-A series ES 1OOC ES225C Leakage breaker C type Leakage breaker KC type

n
Input unit

S-5, S-10, S-600, ARC Mate, ARC Mate Sr., M-100, A-200, A-510, A-600, C-100

\
-Input power cable

Note: Always mount the breaker cover after routing S-300, S-420 S-500, S-700, M-400, L-1000 ARC Mate additional axis ARC Mate SI. additional axis
Fig. 3.1.I input power supply connection

3.1.2

Connecting the external on-off and external emergency stop switches

The external ONIOFF signal which turns on/off the power outside of the control unit is connected as shown below.

supply from the

/-

Input unit

' I

(S-5, S-10, S-600, ARC Mate, ARC Mate SI , ' M-100, A-200, A-5 10, A-600, C-100)

Input unit terminal

7
__CO

-L

Remove this jumper when the external power supply ON/OFF switch is used

PORTER ON

POWER OFF

External power supply ON/OFF switch S-300, S-420 S-500, S-700, M-400, L-1000 ARC Mate additional axis ARC Mate Sr additional axis

Fig. 3.1.2 External power supply ONIOFF connection

The timing is as follows.

EON-COM EOF-COM

-TON 2 500ms TOFF 2 500ms

----> 6s TOFF-ON-

Power ON

The contacts used for remote power on/off must conform to the following: 50 VDC or more (between contacts) Voltage rating Current 100 mA or more Following emergency stop signals are provided on the input unit.
Table 3.1.2 Emergency stop signals on the input unit

Terminal name

Description

Current, voltage Open/close of 100 VAC, 5A

ENGIN11 Connect one of 2-circuit contacts of external emergency switch in peripheral device interface EMGINC to these terminals. When the external emergency EMGIN21 stop switch is pressed, 100 VAC current, which controls the motor power, is cut directly. EMGINC If this switch is linked to EMGOUT1, 2, connect to EMGIN1, axid EMGINC and short between EMGIN2 and ENGINC. If not, connect to EPlG2, EMGINC and short between ENGIN1 and EMGINC.

FN1 FN2

These signals are used to stop the robot when the door on the safety fence is open. While the DEADMAN switch on the teach pendant is being pressed, these signals are ignored and an emergency stop does not occur. If these signals are not used, short these terminals.

Open/close of 24 VDC, 0.1A

EMGOUTl ENGOUTC7

These terminals are used to output the emergency Rated contact specification: stop signal. The contact is open when 1 ) an 250 VAC, 5A emergency stop occurs or 2) the power is turned for resistor off. load It is closed in normal operation state.

EMGOUT2 These terminals are used to output the emergency Rated contact specification: ENGOUTC1 stop signal. The contact is closed when 1 ) an 250 VAC, 5A emergency stop occurs or 2) the power is turned for resistor off. load It is closed in normal operation state.

M3 screws are provided on the terminal. in width can be used.

Crimp-style terminals less than 7 mrn

Terminal on input unit

~ Relay f o emeIgency stop output

-I

-.I
I

0 EMGOUTI 0 EMGOUTC 0 EMGOUT2

Output signal from input unit

External emergency stop switch

/7\

EMGIN l EMGINC
(> EMGIN2
Shorted at shipment

1Connect to emergency stop input of lperipheral

device interface Door switch on safety fence
Shorted at shipment

Note: Connect t o EMGINl or EMGIN2.

To connect the external emergency stop signal provide a 2-circuit emergency stop switch and connect to both the input unit and peripheral device interface. Use the contact on the input unit rated 250V, 10A or more.

3.1.3 Control unit and peripheral device connections

Peripheral device A

Petipheral device B

Note 1) Cables K 4 1 and K 4 2 a r e o p t i o n a l .

Control unit

CNA l

Peripheral

Peripheral device C

Peripheral device C

Periphex a1 device interface C

OlP28

Note) Cable K44

K46 a r e o p t i o n a l .

Diaguostic data number

Note 1) Refer t o s e c t i o n 3.2.2(4) f o r t h e emergency s t o p . Connect t h e emergency s t o p c o n t a c t t o t h e i n p u t u n i t . Note 2) Refer t o t h e Table 1.4 on Appendix 1.4 f o r s e l e c t i n g i n p u t s i g n a l common l i n e .

Note) Refer t o t h e Table 1.4 on Appendix 1.4 f o r s e l e c t i n g i n p u t s i g n a l common line.

Control unit (Peripheral device control interface A) Diagnostic data number

0 lPOE
Connector pin No.

Peripheraldevice

Control unit (Peripheral device control interface B) Diagnostic data number Receiver circuit
+24

OlPOE
Connector pin No.

Peripheral device

Program number select signal

Robot service request signal

Note) Refer t o t h e Table 1.4 on Appendix 1.4 f o r s e l e c t i n g i n p u t s i g n a l common line.

Control unit (Peripheral device control interface B) Diagnostic data number

OlPOE
Connector pin No.

Peripheral device

Hold signal

HELDE

Reference

CN4 (13)

)-@
0

.power supply

+24V Stabilizing

@
4-2 4 v
4

C o n t ~ ounit l (Peripheral device c o n t ~ ointe~face l C Ex of OV common)

Connector pin No.

P e ~ i p h e ~device al

0 Q

2
Q

a m c3EI
2

3 8 1 1 * 1 1 AD17 AD18 AD19 381*1 1 I I I l l l 391 I I I I I I I*I RV

RV

CNA l ( 0 7 I,,
\I

, , r l , ,

2 td

2
0

w 2

CNA 1 ( 08 I,,

I
1

a o

10

39 39 13 9

* *
.xim

C N AV I ( 10) CNA I ( I I

AD1 l I

I,,

I'

, , "
, ,
b I

AD1 I 2
A D 1 13 AD1 I 4

RV

CNA1(12),,
.I

I
I

;39l I I I* I I I l l 39 m
391 I*l I I I I l

RV RV

CNA 1 ( 1 3 I,,

, ,

A D 1 15

CNA 1 ( 1 5 I,,

\.

.,
I

Common selection
+24V common (standard) "1" at contact close

CNA1(17.49,50)

I "0"

0 V common

at contact close

Ex of OV common)

Common selection
+24V common (standard) "1" at contact close
0 V common

"O" at contact close

---Common selection

0 V common (standard)

Control unit (Peripheral device control interface C ) Signal name Diagnostic No

Connector pin No

Per ipher a1 device

AD033

16) I I I I

01 P28

*1

AD034 AD035 AD036 AD037 ADO38

8

I 61 I

I. I I * T l

-3 6

5%

AD039 AD040 AD04 1 AD042 AD043 AD044 AD045 AD046 AD04-7 \AD048

22

53 2z
&lo

1 I -6

3.1.4

Mechanical unit and end effector connections

Mechanical unit

EE

Note) C o n n e c t i o n c a b l e s a r e customer p r o v i d e d .
r
Mechanical unit Diagnostic data number Receiver circuit breakage

*
Connection pin No.
+24

End eflecector

*HBK

3.1.5

Control unit and welding machine connection

1) ARC Mate, ARC Mate S r . ,

S-300,

S-420,

S-500,

S-600,

S-700

Welder

Note: Cable K43 is optional Control unit Welding voltage command signal

Wire speed designation signal

Welding voltage detection signal Welding current detection signal

CNl(31)
Wire stick detection signal WDI -t WDI -

N
,.P

"

, " " R:
R
*I

Greater than 100fi

CN1(32)..

a 3
b

Welding power supply

+

Connector pin No.

FG (Cabinet ground) -.--

2) ARC Mate, ARC Nate Sr., S-600

Control unit

CN 1

ClP12-CNl

Note:Cable K 4 3 is optional.

Control unit Welding voltage command signal Greater than 2 kG? of

Wire speed designation signal

Welding voltage detection signal Welding current detection signal

Wire stick detection signal

WDI

<; +

CNl(31)

:$

CN l ( 3 2 ) .

fl
6 3

It: Grkater than lOOS2

WDI -

Welding power supply

d

Control unit Diagnostic data No..

I 1

01P12 Connector pin No.

Wire inching

*
Cannon connector pin No. Welder Relay

037 Arc WDIlO generating detection signal ..., Gas shortage detection signal Wire cut detection signal Cooling water shortage detection signd Welding power supply abnormality signal

3.3 k

FG (Cabinet ground)

Shield

3.2 l nterface Signal Details

3.2.1 Types of signal Table 3.2.1 Signals table (113)

Symbols Classification Names Reference items Peripher a1 device control interface A (CN1OlPOE) ENBL Periphera1 device control interface B (CN4OlPOE) Peripheral device control interface C (CNA1, 2-41P28) End effector control interface (CN2OlPOE) Welding interface (CN101P12)

Robo t control signal

Motion enabling signal Start signal Hold signal

3.2.2(1)

3.2.2(2) 3.2.2(3)

START

*HOLD *ESP

Emergency 3.2.2(4) stop s igna 1 Robot service request Program number select signal External reset signal Safety speed s igna.1 3.2.2(5)

RSR1, 2

RSR3, 4

3.2.2 (6)

PNSl

3.2.2(7)

RSETE

3.2.2 (8)

*SFSD

Table 3.2.1 Signals table (313)

I
Classification Names Referenc items Peripheral device control interface A Peripheral devzce control interface B

Symbols Peripheral device control. interface C Welding End effector intercontrol face interface

End effector status signal

Wrist breakage detection signal Air pressure abnormal signal

Welder control s i.gnal

3.2.6(1)

WDO1-8, 9- 16 DACH1,3 DACH2,4

W D I 1-8, 10-16 ADCH 1 , 3 ADCH2,4

Welder status signal

3.2.6(2)

3.2.2 Robot control signals

WDI + WD1-

I ) Motion e n a b l i n g s i g n a l s ( i n p u t ) ENBL When t h e E N B L c i r c u i t i s c l o s e d , t h e robot i s ready f o r o p e r a t i o n

Control unit

Peripherai device

Fig. 3.2.2 (a)

Motion enabling signal connection

2) S t a r t s i g n a l s ( i n p u t ) START When t h e START c i r c u i t i s opened a f t e r having been c l o s e d , t h e r o b o t w i l l b e g i n one of t h e f o l l o w i n g o p e r a t i o n s : a ) Zero p o i n t r e t u r n i n TEACH mode o r p o s i t i o n matching f o r APC motors. b) Repeat o p e r a t i o n by t h e e x e c u t i o n of a program i n REPEAT mode These o p e r a t i o n s w i l l n o t occur i f one of t h e followi.ng c o n d i t i o n s e x i s t s : (See item 3.2.2(1)) a ) It i s n o t i n t h e motion enabled s t a t u s . b ) The h o l d s i g n a l i s e f f e c t i v e . (See 3.2.2(3)) C ) It i s i n t h e emergency s t o p s t a t u s . (See 3.2.2(4)) d ) When t h e KEFIOTE s w i t c h i s OFF.

Fig. 3.2.2 (b)

Start circuit diagram

3) Hold s i g n a l s , *HOLD ( i n p u t ) If When t h e *HOLD c i r c u i t i s open, t h e moving a x i s slows down and s t o p s . an S code i s b e i n g executed, t h e r o b o t s t o p s o p e r a t i n g a f t e r t h e S code h a s been s e n t , Refer t o Fig. 3 . 2 . 2 ( ~ ) .

Fig. 3.2.2 (c)

Remote hold circuit

The r e l a t i o n s h i p between t h e c y c l e - s t a r t shown below.

s ignal. and t h e hold s i g n a l

Startsignal START

Hold

Fig. 3.2.2 (d)

Time chart showing the relationship between the HOLD and START signals

To r e s e t t h e hold c o n d i t i o n , t u r n on t h e s t a r t s i g n a l a f t e r c l o s i n g t h e *HOLD.

4) Emergency s t o p s i g n a l ( i n p u t ) *ESP When *ESP i s opened, t h e moving a x i s s t o p s momentarily. Robot motion s t o p s w i t h o u t t e r m i n a t i n g t h e sending of t h e S code, i f an S code i s b e i n g s e n t . The emergency s t o p c o n d i t i o n can t h e n be r e s e t by p r e s s i n g t h e RESET b u t t o n a f t e r c l o s i n g t h e open c i r c u i t . The c i r c u i t diagram i s shown i n Fig. 3.2.2(e).
Control unit Peripheral "ESP device interface +24E Input unit E M G I N C
EMGINI or

E M G I N 2

Fig. 3.2.2 (e)

Emergency stop circuit

5) Robot s e r v i c e r e q u e s t s i g n a l s ( i n p u t ) when RSR1, RSR2, RSR3, RSR4 A p r e s e t program w i l l be executed when RSRl - RSR4 a r e t u r n e d on.
RSR's, r e f e r t o t h e O p e r a t o r ' s manual. The c i r c u i t diagram i s shown below.

To u s e

Control unit

Peripheral device

RSRl o
RSRZi} RSR3
)

RSR4o
t.2 4 E o

Fig. 3.2.2 (f)

Robot service request signals circuit

6) Program number s e l e c t s i g n a l s ( i n p u t ) PNSl t o PNS8 T h i s s i g n a l i s e f f e c t i v e when t h e s o f t w a r e o p t i o n AG ( E x t e r n a l program s e l e c t function) i s specified. RSR2, 3, 4 (Robot s e r v i c e r e q u e s t s i g n a l ) axe i n e f f e c t i v e when a u t o m a t i c o p e r a t i o n i s done i n parameter No. 030 (EXTP=l). During RSRl ( a s a s t r o b e p u l s e ) b e i n g s e n t t o a r o b o t , s i g n a l s t a t u s of PNSl t o PNS8 a r e r e a d i n ; corresponding program number i s s e l e c t e d and stored. During program e x e c u t i n g , a maximum of t h r e e program numbers and t h e i r acceptance sequence a r e s t o r e d . A f t e r completion of programs, r e p e a t o p e r a t i o n i s done i n t h e s p e c i f i e d o r d e r . S i g n a l s of PNSl t o PNS8 a r e r e a d i n a s b i n a r y d a t a , and a maximum of 256 (0 t o 255) d i f f e r e n t programs a r e c a l l e d e x t e r n a l l y . This f u n c t i o n i s e f f e c t i v e when parameter No. 030 EXTP i s s e t t o 1 and t h e E M O T E a u t o m a t i c o p e r a t i o n s t a t u s ( p e r i p h e r a l d e v i c e s c o n t r o l i n t e r f a c e A, R s i g n a l = 1). a ) Timechart
REMOTE

PNSl - 8
RSRl stlobe
Binary code reading Binary code setting ACKl output External:program select i s effective ACKl output time setting (setting data No. 64) Unit 0.1 sec.; 0 to 9.9 sac. (0 to 99)

b) S e t t i n g Parameter No. 030, b i t 3 , E x t e r n a l program s e l e c t EXTP = 1 S e t t i n g d a t a No. 00, b i t 0. Robot s e r v i c e r e q u e s t f l a g RSR1=1 S e t t i n g d a t a No. 63. Added v a l u e t o PNS decode v a l u e (0 t o 9734) c ) S p e c i f y i n g method of program number A c t u a l program number s e l e c t e d e x t e r n a l l y i s one which adds r e g i s t e r e d v a l u e t o s e t t i n g d a t a No. 63 t o s p e c i f i e d v a l u e by PNSl t o 8. Program number = (Decode v a l u e of PNSl t o 8 b i n a r y d a t a ) (Value of s e t t i n g d a t a No. 63) 6 5 = (PNS8) x z7 + (PNS7) x 2 + (PNS6) x 2

.+
2

+
-t

(PNS5) x Z 4 (PNS2) x 2'

+ +

(PNS4) x

z3 +
0

(PNS3) x 2

(PNS1) x 2

(Value of s e t t i n g d a t a No.

63)

Note) (PNSi) (i = 1 t o 8) i s 1 o r 0.

S e t t i n g d a t a No. 63

9,000

Program number

7 6 5 4 1 x 2* + 1 x 2 1 - t 0 x 2 + 0 x 2 0 1 x 2 + O x 2 + 1 x 2 +9000 = 9197
=

0 x 2

Accordingly, a program number 09197 i s s e l e c t e d i n t h i s c a s e . By Program number i s o n l y s e l e c t e d from 0 t o 255 i n PNSl t o 8 s i g n a l s . s e t t i n g v a r i o u s v a l u e s t o s e t t i n g d a t a No. 63, a d d i t i o n a l program numbers from 00000 t o 09989 can be s e l e c t e d .

7) E x t e r n a l r e s e t s i g n a l ( i n p u t ) RSETE T h i s s i g n a l i s used t o r e s e t a r o b o t a l a r m e x t e r n a l l y . However, o v e r t r a v e l alarms cannot be r e s e t by o n l y t h i s s i g n a l . Refer t o t h e O p e r a t o r ' s Manual f o r t h e procedure f o r c o r r e c t i n g o v e r t r a v e l . T h i s c i r c u i t i s shown below.
Control unit Remote control panel

RS ETE o

+ 24E

Fig. 3.2.2 (g)

External reset signal circuit

8) S a f e t y speed s i g n a l ( i n p u t ) *SFSD When t h e *SFSD c i r c u i t i s opened d u r i n g r e p e a t o p e r a t i o n of t h e r o b o t , t h e moving a x i s i s d e c e l e r a t e d . When t h e c i r c u i t i s c l o s e d a g a i n , t h e o v e r r i d e speed does n o t r e t u r n s t o i t s o r i g i n a l v a l u e , b u t s t a y s a t t h e v a l u e s e t i n parameter No. 100 u n t i l i t i s changed by t h e o p e r a t o r .

Control unit
f24E
0

Peripheral device

*SFSDO

Use thiscircuit for the door switch on the safety fence around the robot and for other safety devices.
Fig. 3.2.2 (h) Safety speed signal circuit

3.2.3

Robot status signals

1 ) Ready s i g n a l ( o u t p u t ) RDY P e r i p h e r a l d e v i c e c o n t r o l i n t e r f a c e s i g n a l RDY i s s e n t when t h e c o n t r o l u n i t i s ready f o r normal o p e r a t i o n a f t e r t h e power supply h a s been turned on. For d e t a i l s , r e f e r t o ( 8 ) .
f

Control unit

Peripheral device

RDY ,,
0v

Fig. 3.2.3 (a) Ready signal circuit

Stabilizing power supply

2 ) Automatic o p e r a t i o n s i g n a l ( o u t p u t ) REMOTE s i g n a l i s s e n t on t h e p e r i p h e r a l d e v i c e c o n t r o l i n t e r f a c e under t h e following conditions. a ) Completion of a z e r o p o i n t r e t u r n or. p o s i t i o n matching f o r APC motors. b) ENBL s i g n a l of a p e r i p h e r a l d e v i c e s c o n t r o l i n t e r f a c e A was i n p u t . c ) REPEAT mode i s s e l e c t e d . d ) *SFSD s i g n a l of a p e r i p h e r a l d e v i c e c o n t r o l i n t e r f a c e A i s s e t t o "1". e ) ON/OFF s w i t c h on a t e a c h i n g pendant i s s e t t o OFF. f ) The s e r v i c e r e g i s t e r i s s e t t o "1". g) REMOTE s w i t c h on t h e o p e r a t o r ' s p a n e l i s t u r n e d on.

Fig. 3.2.3 (b)

Automatic operation signal (output) REMOTE

Robot s e r v i c e r e q u e s t s i g n a l and e x t e r n a l program s e l e c t f u n c t i o n a r e e f f e c t i v e and a u t o m a t i c o p e r a t i o n can be done when t h i s s i g n a l i s s e n t .

3 ) Alarm s i g n a l ( o u t p u t ) A L M
The p e r i p h e r a l d e v i c e c o n t r o l i n t e r f a c e s i g n a l A L M i s s e n t when t h e r o b o t i s placed under a n alarm c o n d i t i o n . For. d e t a i l s , r e f e r t o ( 1 0 ) .
Peripheral device or remote control panel

Control unit

ALM
0

v
Stabilizing power supply Alarm signal circuit

Fig. 3.2.3 (c)

4) Hold s t a t u s s i g n a l ( o u t p u t ) HELDE When t h e r o b o t i s i n t h e h o l d mode, a s i g n a l i s p r e s e n t a t t h e p e r i p h e r a l

device control i n t e r f a c e B output.

controlunit

r Peripheral device
Stabilizing power supply

HELDE

Fig. 3.2.3 (d)

Hold signal

5) O p e r a t i n g s i g n a l ( o u t p u t ) BUSYE When t h e r o b o t i s i n t h e z e r o p o i n t r e t u r n , i n t h e REPEAT mode o r i s p r o c e s s i n g d a t a i n t h e c o n t r o l u n i t , t h e BUSYE s i g n a l w i l l be p r e s e n t a t peripheral device control i n t e r f a c e A output.

Control unit

Peripherai device

BUSYE

Stabilizing'power supply

Fig. 3.2.3 (e)

Operating signal

The BUSYE s i g n a l w i l l r!ot be o u t p u t f n c a s e o f az emergency s t o p o r s i n g l e b l o c k s t o p even i f t h e r o b o t i s i n t h e o p e r a t i o n repeat: mode.

6) REPEAT s i g n a l ( o u t p u t ) STRTE A s i g n a l (STRTE) i n REPEAT mode w i l l be p r e s e t a t t h e p e r i p h e r a l d e v i c e control i n t e r f a c e A output.

Control unit

STRTE 1
0v

Peripheral device

Fig. 3.2.3 (f) Repeat signal

Stabilizing power

STRTE s i g n a l i s s e n t i n t h e hold mode and s i n g l e b l o c k s t o p mode.

7) RSR acknowledge s i g n a l ( o u t p u t ) ACK 1

RSRl i s used a s s t r o b e p u l s e f o r d a t a r e a d i n g when e x t e r n a l program s e l e c t i o n (EXTP) of parameter No. 030 i s s e t t o 1. When Robot s e r v i c e r e q u e s t s i g n a l P.SR1 i s acknowledged i n a u t o m a t i c o p e r a t i o n , t h e RSR acknowledge s i g n a l ACKl of a p e r i p h e r a l d e v i c e i n t e r f a c e B w i l l be c l o s e d . The P u l s e width of ACKl can be s e t from 0 t o 9.9 s e c . by s e t t i n g d a t a No. 64. ACK2 t o 4 cannot be used. ACKl t o ACK4 a r e n o t t o be used when parameter No. 030, EXTP i s 0.

pzxZ-1

Peripheral device

Fig. 3.2.3 (g)

Circuit of RSR acknowledge signal

8 ) Reference point signal (Output) REF1 to 3 When a robot is in the allowable range of a reference point specified by setting data No. 24 the corresponding reference point signal (REF1 to 3) is sent. This signal is used to start a robot automatically from a special position, to inform the peripheral devices that a robot is in special position.

Setting data No. Allowable range 1st reference point 2nd reference point 3rd reference point 135 145 Reference point setting 136 to 143 146 to 153
-

-Reference point return sequence

144 154 164

----

155

156 to 163

Fig. 3.2.3 (h)

Reference point signal circuit

9) Changes i n t h e r o b o t ' s s t a t u s s i g n a l s w h i l e performing normal o p e r a t i o n s

There a r e t h r e e k i n d s of r o b o t s t a t u s s i g n a l s t h a t b e s t i n d i c a t e t h e r o b o t ' s o p e r a t i n g c o n d i t i o n s . They a r e : t h e r o b o t ready s i g n a l (RDY), t h e r o b o t automatic o p e r a t i o n s i g n a l (REMOTE) and t h e r o b o t alarm s i g n a l (ALM). The f o l l o w i n g flow c h a r t shows t h e changes i n t h e r o b o t ' s s t a t u s s i g n a l s when o p e r a t i n g c o n d i t i o n s a r e changed.

( F )
L = l
Power cn

RENOTE RDY ALM

[OlO,*

Zero point return

I
/
Alarms requiring

(010)~
@
change operation to in manual REPEAT

Automatic opmtion in prognsr

( 1 1 0 ) .

mode

1'

( 0 1 0 ) .

Reset operation 1

B
Rtset operation 2

Fig. 3.2.3 (i)

Robot status changes

*Note) The number shown i n p a r e n t h e s e s i n d i c a t e s t h e s t a t u s of t h e t h r e e s i g n a l s (REMOTE, RDY, ALM). A number "1" means t h a t a s t a t u s s i g n a l i.s ON, and "0" means i t i s OFF. (010) means RDY i s ON; REMOTE; A L M a r e OFF. Example: Status Signals The f o l l o w i n g sequence d e s c r i b e s t h e changes i n t h e s t a t u s s i g n a l s REMOTE, RDY, A L M ) which occur w h i l e t h e r o b o t c o n t r o l l e r i s performing t h e o p e r a t i n g sequence shown i n t h e flow c h a r t (Pig. 3 . 2 . 3 ( i ) ) . The sequence i s a s f o l l o w s : @ Apply power u s i n g t h e power ON-OFF switch. The s t a t u s s i g n a l s which were (000) b e f o r e a p p l y i n g power, change t o (010) a f t e r i t i s a p p l i e d . T h i s means t h e RDY s i g n a l i s p r e s e n t a t an o u t p u t c o n n e c t i o n on t h e interface.

@ If no alarm occurs, the status signals remain at (OlO), but if an alarm

does occur, they will change to (001). If an alarm occurs, remove Dower and repeat the start procedure. To perform a zero point return for incremental robots or position matching for APC robots, press the START button on the operator panel or close the external start signal (START) in the interface. Note) For incremental robots if the STNG bit of parameter No. 016 is set to 1 1 1 " , the robot will automatically perform a zero point return. If the REMOTE switch in the operator panel is ON, and the automatic mode change signal SSFS bit in setting data 000 is set to "l", the control unit will be placed in the REPEAT mode automatically, and the status signals become (110).

@ In the following cases, the robot status signal will change from (110)
to (010) during automatic operation. a) The ENBL signal of peripheral device control interface A is open. b) The *SFSD signal is open. c) The REMOTE switch on the operator panel is turned OFF. d) The ON/OFF switch on the teach pendant is in the OFF mode. @ If an alarm is generated during automatic operation, the alarm status will become (001) or (311) and the robot will reduce its speed until it comes to a complete stop. x i d recovery operation 2 for the status Perform recovery operation 1 a signal (001) and (Ill), respectively, to resume normal operation. a) Verify that the fault that caused the alarm has been corrected. b) Close the external reset circuit (RSETE). c) For incremental robots, repeat zero point return as performed in . The status signals will return to (110). step 2 Reset operatton No. 2 a) Verify the end effector is gripping the workpiece properly. b) Verify the robot is working properly. c) Close the external reset signal (RSETE) in the remote control interface. d) Close the start (START) circuit. The status signals will return to (110).
3.2.4 Peripheral device control signals

1 ) Peripheral device control signals (output) SDOl - SD016 a) Connection diagram The SDO i signals (i = 1 - 16) are used to control peripheral devices.
Control unit Peripheral device

SDOi

-I-:-++Stabilizing power supply Fig. 3.2.4 (a) Peripheral device control signal circuit

4 * + G 1 * -

b) Uses and output types SDOs have 5 types of outputs: pulse, continuous, complementary, timer pulse, and external data. The type needed is determined according to the output needed, and the circuit required is selected by setting parameters and S codes. . 2 . 4 ( a ) shows the uses the types of outputs for peripheral device Table 3 control signals.

Table 3.2.4 (a)

Peripheral device control signal use and output types

xternal data output 1st

. -

External data output 2nd

External data output 5th

c) Output types Output types depend on S codes as follows Refer to the Operator's manual for setting parameters.
Table 3.2.4 (b) Type of outputs

Type of output Pulse output

Command type Processing S code Operand SON a

SON command

Remarks

@ To set the pulse

SDO (a)

j 1 T
T

width T, set parameter No. 034 and 035 (SPW) as shown below. SPW
=

SPW

200 t 8 msec

400 +8 msec

@ The digital output

signals from SDOl to 16, which have been set to have pulse outputs by setting parameter No. 034 and 035 (SH1-8)to 0 will have this type output.

Continuous signa1 output

SON SOF

a a
SON command SOF command

SDO (a)

k--i-

@ The digital output

signals from SDOl to 16, which have been set to have continuous signal outputs by setting parameter No. 034 and 035 (SH1 - 8) to 1 will have this type output.

Complementary cont inuous signal output

SON SOF

a a

(a=2n-1)
SON command SOF command

SDO(a) SDO(a + 1) 7

x ,
-1
I

I
fl

@ When parameter ho.

034 and 035 (SHT) is set to 1, a pair of signals from the group set to have continuous signal output by setting parameter No. 034 and 035 (SH1 - 8 ) out of SDOl to 16 (SH1 - 8) groups will be turned on and off as complementary signals.

Type of output Timer pulse output

Command type Processing S code Operand S82 a,t

t x 0.1 sec

Remarks

S82 co~t~mand

F I lbbot motion

SDO (a)

The width of the pulse for the outputs of SDOl 16, can be set from 0.1 to 9.9 seconds by setting 2 the ~ 8 command operand t. The operand t is set in units of 0.1 seconds. To set the SDOs set SH1 - 8 in parameter No. 034 and 035 to 0.

@ Robot motion and

the next S code can be executed concurrently with this

(1) Parameter No. 030 (CTP)=O; pulse signal output

T = 200 msoc +8 maec

or 400 msec

+8 mssc

(2) Parameter No. 030 (CTP)=l; continuous signal output

can be fed out a pulse signal in a binary coded 3-digit or 5-digit word by setting parameter No. 030 (CDO) and using an S83 code. Information is detected using the leading edge of the strobe pulse SDO11. When the CDO and NCDO bits are "0" the

Type of output Externa 1 data output

Command t y p e Processing S code Operand S83 Remarks

When b i t CDO = 1 and NCDO = 0 i n parameter No. 030, r e g i s t e r x can have a 5 b i t o u t p u t , making u s e of SD015 (EDW8) f o r t h e 4 t h b i t and SD016 (EDW16) f o r t h e 5 t h b i t . The maximum decimal o u t p u t w i l l be 31. When used f o r t h e 5 t h b i t SD016 w i l l n o t be a v a i l a b l e a s an output f o r the ZPOS s i g n a l . When CDO and NCDO b o t h = 1 i n parameter No. 030, r e g i s t e r x can have an 8 b i t output. I n t h i s case, a t y p i c a l o u t p u t map i s a s shown i n Fig. 3.2.4 ( b ) .

SDOll Strobe Pulse

SD012 2*7 128

SD013 2*6 64

SD014 2*5 32

SD015 2*4 16

SD016 2*3 8

SD06 2*2

SD07 2*1 2

SD08 2*0 1

+dout + b i n weight +dec v a l u e

Note: S t r o b e o u t p u t p u l s e s a u t o m a t i c a l l y , and t u r n s on 60 msec a f t e r t h e group o u t p u t i s commanded t o v e r i f y t h a t t h e d i g i t a l o u t p u t s on t h e o t h e r lines are valid.

Fig. 3.2.4 (b) Typical group output map

SDI16 2) P e r i p h e r a l d e v i c e s t a t u s s i g n a l s ( i n p u t ) SDI1 a ) Connection diagram 16) a r e used t o inform t h e r o b o t of The SDI i s i g n a l s ( i = 1 p e r i p h e r a l device s t a t u s . , +

the

Control unit

Peripheral device
J \

SDI i
+

+24E

*A

1
-

Fig. 3.2.4 (c) Peripheral device status signals circuit

174

b) uses T a b l e 3 . 2 . 4 ( c ) shows t h e u s e s of p e r i p h e r a l d e v i c e Some of them a r e a l s o used a s d a t a i n p u t c i r c u i t s .

Table 3 . 2 , 4 (c) Use of peripheral device status signals

status circuits.

SDIs SDI 1 SDI2 SD13 SD14 SDI5 SDI6 SD17 SD18 SDI9 SDIlO

Uses

E x t e r n a l code i n p u t 1 s t b i n a r y d i g i t (EDR1) SDI12 (Any E x t e r n a l code i n p u t 2nd b i n a r y d i g i t (EDR2) SDI13 (Any) E x t e r n a l code i n p u t 3 r d b i n a r y d i g i t (EDR4) SDI14 (Any E x t e r n a l code i n p u t 4 t h b i n a r y d i g i t (EDR8) *Note 1 SDI15 (Any E x t e r n a l code i n p u t 5 t h b i n a r y d i g i t (EDR16) *Note 1

Note 1) SDIl4 and 15 can be u s e d f o r e x t r a i n p u t s i g n a l s (EDR8 and EDR16) when p a r a m e t e r No. 030 CDI = 1.

SDIs Peripheral SDIl SDI16 device status (S84 b, x) signal (S85 b, n) (S86 b, n) (S87 b, n)

Functions These peripheral device status status signals are used to inform the robot of the peripheral device status. Sixteen input signals SDIl SD116 are used. These input signal status are judged, used as signals for branching, waited for, and checked by robot command data according to S codes S84 - S87.
Execution SD' of S(h' codes
( S84--S87

Remarks For S84, S85, S86 and S87 refer to ( 3 ) .

x i n
L .
Processing

External data input signal

SDIll SDI15 (S88, x)

Binary input values are decoded Closed contacts are signals in SDI11 - SDI13 read as "I", and (parameter No. 030 (CDI) = 0 ) or open contacts are or. SDIll -- SDI15 (parameter read as 0 for No. 030 (CDI) - I), and are set SDIl - SDI15 when to register x by S88, x command. S88 is commanded. For S88 refer to Para( 3 ) . meter External Register When parameter No.030 Weight x input No. 030 (CDI) = 0, data CDI SDT14 and 15 can input value setting be used as normal peripheral device SDIl 1 2O status signals. (EDRI)
0

SDI12 (EDR2) SDI13 (EDR4)

0 - 7

2* 23
24

SDI14 (EDR8) SDI15 (EDRIG)

31

3) S codes used w i t h p e r i p h e r a l d e v i c e c o n t r o l s i g n a l s The purpose of S codes and t h e i r operands i s t o i d e n t i f y c o n t r o l s i g n a l s . shows t h e S codes which c o n t r o l t h e p e r i p h e r a l d e v i c e Table 3.2.4(e) control signals.
Table 3.2.4 (e) S codes for peripheral device control signals

S code S O N SOF

Operand a a
-

Description Turns on and o u t p u t s t h e S D O (a) s i g n a l . Turns o f f and o u t p u t s t h e S D O (a) signal. (Note 1)

S82

a, t

T u r ~ i s o n a n d o u t p u t st h e S D O (a) s i g n a l for ( t ) sec. The r o b o t can move d u r i n g t h e s p e c i f i e d time.

--

S83

Outputs d a t a from r e g i s t e r (x) v i a t h e p e r i p h e r a l c o n t r o l i n t e r f a c e a s code s i g n a l s . I n p u t s s t a t u s of SDI (b) s i g n a l t o r e g i s t e r (x). Branches t o sequence number ( n ) , i f SDI (b) s i g n a l t u r n s on. Waits f o r t h e s p e c i f i e d time u n t i l SDI (b) s i g n a l t u r n s on, and branches t o sequence number ( n ) , i f SDI (b) s i g n a l does n o t t u r n on w i t h i n t h e s p e c i f i e d time. Waits f o r t h e s p e c i f i e d time u n t i l SDI (b) s i g n a l t u r n s o f f , and t h e n branches t o sequence number ( n ) , i f SDI (b) s i g n a l does n o t t u r n o f f w i t h i n t h e s p e c i f i e d time. I n p u t s e x t e r n a l d a t a t o r e g i s t e r (x) w i t h encoded v a l u e .

S84 S85

by x

by n
b, n

S86

S87

by n

S88

Note 1) The a and b of S D O ( a ) and SDI (b) i n d i c a t e t h e number of t h e c i r c u i t b e i n g used. For example, i f a = 10 S D O ( a ) becomes SDO10.
3.2.5 End effector control signals

1) End e f f e c t o r c o n t r o l s i g n a l s ( o u t p u t ) R D O l

RD08

a ) Connection diagram

--Control unit End eflector

+24V

- - - t *

Solenoid valve

fO'
a*

,--

Fig. 3.2.5 (a)

End effector control signal circuit

-. 1 7 7 -

b) Types of outputs . 2 . 5 ( b ) . Three types of output are available as shown in Table 3 Refer to OPERATOR'S MANUAL for setting parameters.

Table 3.2.5 (a)

Types of outputs

Output type Pulse output

Connection type
'

Processing

Remarks

Command Operand RON a

RON
command

@ Set parameter

n '

RDO(a)

lrlT

No. 032 (RPW) to specify the output pulse width

Z p q f

RPW

RPW

msec

msec

@ The digital output

Continuous output

RON ROF

a a

,c

command

command

RDO (a)

r L

signals from RDOl - 8, which have been set to have pulse outputs by setting parameter No. 032 (RH1 - 4) to 0 will have this type output. signals from RDOl - 8, which have been set to have continuous signal outputs by setting parameter No. 032 (RH1 - 4) to 1 will have this type output. (RHT) is set to "l", a pair of signals from the group set to have continuous signal output by setting parameter No. 032 (RH1 - 4) out of RDOl - 8 (RH1 - 4 groups) will be turned on as complementary signals.

@ The digital output

Complementary continuous signal output

RON ROF

a a

(a=2n-1) RON
command command

RD 0 (a) "OF( a + l ) RDO

k ? E

,.,

@ When parameter No. 032

2) End e f f e c t o r s t a t u s s i g n a l s ( i n p u t ) R D I l a ) Connection diagram ,

Control unit +24V -

RDI4, and RDI8

End effector

Fig. 3.2.5 (b)

End effector status signals circuit

b) S i g n a l d e s c r i p t i o n S i g n a l d e s c r i p t i o n s of end e f f e c t o r s t a t u s s i g n a l s a r e shown i n Table 3.2.5(b).

Table 3.2.5 (b) Signal description
+

Output type

Name of s i g n a l

Functions End e f f e c t o r s t a t u s s i g n a l s a r e used t o inform t h e r o b o t of t h e end e f f e c t o r s t a t u s . F i v e i n p u t i n p u t s i g n a l s RDI 1 4 , 8 a r e used. The s t a t u s of t h e s e i n p u t s i g n a l s i s checked by S codes S74-S77; comparing, branching, and w a i t i n g a r e p o s s i b l e .

Remarks

R D I 1 4, 8 (S74 b , x) (S75 b , n ) (S76b,n) (~77 b, n )

End effector status signal

Refer t o (5) f o r S74, S75, S76, and S77.

RDI (b)
Execution of S c d e s 674- S77)

r ; Processing
-1

3 ) W r i s t b r e a k d e t e c t i o n s i g n a l ( i n p u t ) *HBK a ) Connect i o n diagram S i g n a l "HBK i s connected t o t h e end e f f e c t o r c o n t r o l i n t e r f a c e a s shown i n Fig. 3.2.5(c).

End cffector Control unit

24 7 - +24V

Fig. 3.2.5 (c)

Circuit for the wrist break detection signal

b ) Signal description The break detection signal is explained in Table 3.2.5(c).

Table 3.2.5 (c) Signal description

Symbol
*HBK Wrist break detection signal

Description

Remarks Error code 0003 is displayed during emergency stop of the robot.

The wrist break detection signal is an input signal that detects a wrist break by the opening of the *HBK circuit, causing an emergency stop of the robot.

Robot motion Robot motion in progress

4) Pneumatic pressure abnormal signal (input) *PPABN

a) Connection diagram Signal *PPABN is connected to the end effector control interface as shown in Fig. 3.2.5(d).

Control unit +24V

*PPABN

Fig. 3.2.5 (d)

Circuit for the pneumatic pressure abnormal signal

b) Signal description The pneumatic pressure abnormal signal is explained in Table 3.2.5(d).
Table 3.2.5 (d) Signal description

Symbo1

Description

--

Remarks

Pneumatic *PPABN The pneumatic pressure abnormal signal is an input signal that detects a pneumatic pressure abnormal pressure abnormal state by the opening the *PPABN circuit, causing an emergency signal stop of the robot.

The robot slows down and stops and error code 0004 is displayed when an abnormal status is detected.

Stop of robot

Robot motion in progress

5) End effector control S codes The codes and their operands are used to control the end effector circuits. shows the S codes to control the end effector control Table 3.2.5(e) interface.
Table 3.2.5 (e) End effector control command and S codes

Cornmandl Operand S code

Description Turns on RDO (a) signal output. Turns off RDO (a) signal output.

RON ROF

a a b, x

S74
S75
S76

----

Inputs status of RDI (b) signal to register x. Branches to sequence number n when R D I (b) signal turns on.

b, n b, n

--

Waits for the specified time until RDI (b) signal turns on. It then branches to sequence number ( n ) , if RDI (b) slgnal does not turn on within the specified time. Waits for the specified time until RDI (b) signal turns n ) , if R D I (b) off. It then branches to sequence number ( signal does not turn off within the specified time.

3.2.6

Arc welding machine signals (arc welding interfaces) (ARC Mate, ARC Mate Sr., S-600)

1) Welding machine c o n t r o l s i g n a l s ( o u t p u t ) a ) Digital signals WD014) (WDO1 - WD06, WD09 i) Connection diagram

Control unit
L

WDOi

,.

Welding machine

OV

,,

O V
0

+24V~

t
Stabilizing power supply

Fig. 3.2.6 (a)

Welding machine control signal

ii)

Uses Table 3.2.6(a)

shows u s e s of welding machine c o n t r o l s i g n a l s .

Uses of welding machine control signals

Table 3.2.6 (a)

Signals

.WDOl /WD09 WD02/~~010 WD03 /mO 11 WD04/WD012 ( P o s i t i v e ) WD05 /hQ013 (Negative) WD06/WD014

Uses

Welding s t a r t command s i g n a l Gas d i s c h a r g e command s i g n a l Wire s t i c k r e s e t command s i g n a l Both w i r e i n c h i n g p o s i t i v e s i g n a l and w i r e i n c h i n g n e g a t i v e s i g n a l a r e output Wire d e p o s i t i o n alarm s i g n a l i s o u t p u t

b) Welding machine c o n t r o l analog s i g n a l s ( o u t p u t ) (DACH1, DACH2, DACH3, DACH4) i) Connection diagram

Control unit Welding command DACH 1 voltage Welding machine

..

Wire speed command

DACH2 COMDA2

,,

I\

Greater than 3 3 kf?. of input impedance with ladiefrequency filter

B a s i c two c h a n n e l s a r e provided on t h e Axis/Weld PCB. The a n a l o g o u t p u t c i r c u i t and t h e c o n t r o l c i r c u i t a r e i s o l a t e d because of f l o a t i n g o u t p u t c i r c u i t .

Fig. 3.2.6 (b) Welding macine control analog signal (Basic two channels)

F l o a t i n g a n a l o g o u t p u t b l o c k diagram i s shown below.

Axis/Weld PCB A16B-2200-0300

Isolated amp. Channel 1 Command voltage

OP amp
C~l(1) DACHl COMDAl
A

Welder

CNl(2)

Channel 2 Command voltage

0

CNl(3)

DACH2 MD.2

lA\

'

Note1

I'

+24V

DC-DC converter (Separate tlans )

f15V

ov

Note 1) I n p u t impedance: g r e a t e r t h a n 3 . 3 kQ. Radio frequency f i l t e r A d d i t i o n a l two c h a n n e l s a r e provided on t h e p e r i p h e r a l PCB (A16B-1211-,0500 o r -0501) ( o p t i o n ) and a r e n o t f l o a t e d .
Welder
+:
A

Controller Weld command DACH3 COMDA3 voltage Wire speed command

DACH4 COMDA.1,)

\
D

/\

Input impedance: greater than 2 kn Radio frequency filter

Fig. 3.2.6 (c) Welder co"tro1 analog signal (~dditional two channels)

ii)

Uses Table 3.2.6(b) signals.

shows uses

of welding machine

control analog

Table 3.2.6 (b)

Welding machine control analog signals

Signals DACHl DACH3 DACH2 DACH4

Signal names Welding voltage comband signal

Explanation

* 0 - -10 V output voltage controls 0 50 V of welding voltage.

Wire feed speed command signal

* 0 - -10 V output voltage 50 m/min of wire controls 0 feed speed.

Note) There is a relationship between command value and output voltage in standard welding parameter No. 022. This relationship can be set by (See setting the welding conversion constants (ANOCI or ANOC3). OPERATOR'S MANUAL) iii) Analog output voltage conversion method The actual analog output voltage is calculated by the following method, for welding voltage command value and wire feed speed command value input from the teach pendant.

ANOC x VCM = X, -V = 0.05 X ANOC: Analog output conversion constant of welding parameter No. 022. VCM : Command voltage X : DA converter command value : Output voltage V (ANOC selection method) @ Welding command voltage Assume that the specifications of a welding machine are to output 50 V of maximum actual welding voltage at V = -10 V. V = -10 V (X = 200) should be output, for the value (VCM) of command 50.0 from the teach pendant using the V upldown softkeys. Therefore, ANOCl =

x =200 VCM 50
machine are to at V = -10 V, value (VCM) of the A upldown

ANOCl = 4 is obtained. Wire feed speed command voltage Assume that the specifications of a welding output 50 m/min of maximum wire feed speed V = -10 V (X = 200) should be output for the command 50.0 from the teach pendant using softkeys. Therefore, ANOC3 = ANOC3
=

X = -200 VCM

50

4 is obtained.

2 ) Welding machine status signals (input) a) Digital signals (WDI2 - WDI6, WDIlO - WDI14) i) Connection diagram
Control unit

f24V

Welding machine

Fig. 3.2.6 (d)

Welding machine status signal

ii)

Uses Table 3.2.6(c)

shows uses of welding machine analog status signals.

Uses of welding machine analog status signals

Table 3.2.6 (c)

Signals WDI2, WDIlO WDI3, WDIll WDI4, WDI12

WDI5, WDI13

Uses Arc generation detection signal Gas shortage detection signal Wire shortage detection Cooling water shortage detection signal Welding power supply failure detection signal

F7DI6, WDI14

b) Welding machine analog status signals (input) (ADCHI, ADCH2, ADCH3, ADCH4) i) Connection diagram
Control unit ADCH 1/ 3 Welding machine

Welding voltage . COMADl/? ADCH2/4 Welding current .

.. / \ I\
1
A

To send signals without ripples

Table 3.2.6 (e)

Welding machine analog status signal

ii)

Uses Table 3.2.6(d)

shows u s e s of welding machine a n a l o g s t a t u s s i g n a l s .

Welding machine analog status signals uses

Table 3.2.6 (d)

Signals ADCH 1 ADCH3

Functions Welding v o l t a g e

Explanat i o n

*
0

+10 V of i n p u t v o l t a g e contro1.s 50 V of welding v o l t a g e -10 V of o u t p u t v o l t a g e contro1.s 500 A of welding c u r r e n t

AnCH2 ADCH4

Welding c u r r e n t

*
0

Note) There i s a r e l a t i o n s h i p between i n p u t v a l u e and i n p u t v o l t a g e i n t h e s t a n d a r d welding parameter No. 024 and 025. T h i s r e l a t i o n s h i p can be (See OPERATOR'S s e t by s e t t i n g t h e welding c o n s t a n t s (ANIC1 o r ANIC2). MANUAL) i i i ) Analog o u t p u t v o l t a g e c o n v e r s i o n method The a c t u a l v o l t a g e and t h e a c t u a l c u r r e n t a r e c a l c u l a t e d and d i s p l a y e d i n t h e f o l l o w i n g method, f o r welding v o l t a g e , feedback v o l t a g e and welding c u r r e n t feedback v o l t a g e i n p u t t o t h e c o n t r o l u n i t AD c o n v e r t e r from t h e welding machine.

ANIC x

X -10

= Vdp

Vdp : D i s p l a y v a l u e V : Input voltage X : An convertev o u t p u t v a l u e ANIC: Analog i n p u t conversion c o n s t a n t s of welding parameter No. 024 (ANIC1) and 025 (ANIC3). Vdp : The v a l u e of Vdp i s t h e i n t e g e r omittirig t h e decimal p o i n t from t h e d i s p 1 . a ~v a l u e . For example, i.n t h e c a s e of 50.0 V of d i s p l a y v a l u e , Vdp = 500 i s o b t a i n e d . (ANIC s e l e c t i o n method) 1 Actual welding v o l t a g e 50.0 V) a t V = 10(V), When Vdp = 500 ( d i s p l a y e d v a l u e : X = 128; therefore ANICl i ; - 39 i s o b t a i n e d . 2 A c t u a l welding c u r r e n t 39 When Vdp = 500 A a t V = 10(V), X = 128; t h e r e f o r e ANIC3 i s obtained.

c) Wire stick detection signal WDI+, WDIi) Connection diagram

Cbntroi unit Power source for stick detection Approx. lSV, 70mA Welding machine

Wire stick
L/1

WD+
WD

, , detection

aI

R: Greater than loon

Circuit will withstand voltage up to lOOVDC (Between electrodes and between grounds)

Welding voltage m a . 8OVDC

Fig. 3.2.6 (el

Wire stick detection signal (1/ 2 )

ii)

Uses Table 3.2.6(e)

shows wire stick.

Fig. 3.2.6 (f)

Wire stick signal uses

Name of signal Wire stick detection signal WDI+, -

Function It detects the stick between the wire and the weldment. To select the wire stick detection circuit in the robot, use the WST, (*WST) signal. After selecting the WST, (*WST) si.gna1 and the time set in welding parameter No. 015 WSTDL has passed, the wire stick detection will be done at 16 msec intervals in the time designated by welding parameter No. 013 WSM.

(Note 1) WST signal for the machine with axislwelding control PCB. (Note 2 ) For parameters for welding, refer to the OPERATOR'S MANUAL. If the welding current is an alternating current, or a direct current exceeding 80 VDC, the stick detection is done at the welding machine, and transmitted back to the control unit.

Power source for WDt stick detection Approx. +lSV, 70mA

*
--Wire stick detection signal (212)

Fig. 3.2.6 (g)

3 ) S code f o r welding machine s i g n a l s

Welding machine s i g n a l s a r e o u t p u t by S code AS. The welding machine s i g n a l i s o u t p u t by welding c o n d i t i o n (wire f e e d r a t e , welding v o l t a g e ) which a r e loaded i n t o t h e welding c o n d i t i o n number s e l e c t e d by operand. Fig. 3.2.6(h) shows t h e welding motion sequence.
3

Signal name

Signal code

Sequence

AS
AE

l l -----

Welding start command Gas signal Voltage command

WD02 AD OUTCH1

PI^-flow time (PRFTM)

---

Weld palam N o 017

Wire feedrate

AD OUTCH3

7 -

Arc generation signal Wire stick detection circuit selection Wire stick detection

WDI2

---

WST

WDI+,

--Weld palam No. 0 14

I I SD
Weld palam N o 012

Robot motion

QFD= 0
Fig. 3.2.6 (h) Welding motion sequence

3.2.7

Control unit and spot welding machine connections (spot welding interface) (S-300, S-420, S-700)

1 ) Welding machine control signal (output) a) Digital signal i) Connection

r

Control unit Welder

OV

.
7

-.ii)

-I24V Stabilizing ,power supply

' OV

' )

Uses The welding machine control signels are selected from SDO, RDO, WDO and additional DO (ADO), and their functions are designated by parameter. (See OPERATOR'S YiNUAL)

2) Welding machine status signal (input) Weldi.ng machine status signals are used for weld end, weld alarm detection, full open detection, full close detection half open detection signals. Which RDI, SDI, WDI or additional DI (ADI) to be used is selected by parameter. (See OPERATOR'S MANUAL)
(Robot side)

Level conversion circuit

+24V at robot side is applied

Receiver contact input.

3 ) Welding S codes
Welding signal is collectively commanded by S code SPY a or SPW, al, a2. The welding conditions for the welding control signal are set by operand a, al, a2.

Welding motion sequence is shown below.

Move Robot motion In-position Welding S code process Press command condition Weld command Weld stop signal Stop Move Stop Move

I I

+-

In-position width pulse

I I t In-position width pulse

I
1
Motion delay 1 -+

r
1 1 I + Welding command delay 1

1
I 1 + Welding command delay 2 Motion delay 2 I 1
+

1 l Full open

t
Half open Half open

t
Half open

Half open

Stroke switch signal (type A) Stroke switch signal (type B)

1
I I
+

Stroke delay timer 1

Robot motion

Stop \ -

Move

Move

Stop

Move

I /
In-position Welding S code process Press command condition Weld command Weld stop signal Sto~oke switch signal (type A) Stroke switch signal (type B) Half open

In-position width pulse

A
1

I I

&-

In-position width pulse

1
1 I--1

1-1
I I +. Welding command delay 1 Motion delay 1 I I
8
8

I I + Welding command delay 2 Motion delay 2 I I

+

A
Half open Half' open

I I I

Half open
+

t
Fuii open
Stroke delay timer 2

R"NspT ~"~T,o ,

d~ INSTALLATION
A t t a c h a rope t o eye b o l t s a t

mansportation ntrol X r a n s p o r t e d u s i n g a crane. , , ! h e control unit.

j-10, S-600, ARC Mate, ARC Mate SI., 0, A-5 10, A-600, M-100, C-100

S-300, S-420

S-500, S-700, M-400, L-1000 ARC Mate additional axis, ARC Mate SI additional axis
Fig. 4.1 Transportation by crane

Fig. 4.2 la)

Maintenance area (112)

If more than one control unit is installed

S-700, M-400, L-1000, ARC Mate additional axis, ARC Mate Sr , additional axis
Fig. 4.2 (a) Maintenance area (212)

1) Assembly during installation

Teach pendant

E If 4P
,,

Robot mechanical unit connection cable

11 K41. K42.

K 01

"

Input power cable

11 ~ 4 4~; 4 5 K46 : L - - - Peripheral device connection cable 11- - K43= = 4 (= == Welding inte~face cable

-a

a) Welding interface cable ARC Mate/ARC Mate Sr./S-600: Connect K43 to the welder. Other models: Prepare by the customer, and connect to the welder. b ) Robot connection cables Connect each cable to the robot referring to the markings on each cable. For the details of connections see the connection diagrams in section 3.

2) Installation condition Item Model Common to all models

'. Specification/ condition

200 VAC/50 HZ, 2001220 VACI6O HZ +lo%, -15% 50/60 Hz+lHz 3-phase 220/240/380/41.5/460/ 48015001550 VAC +lo%, -15% 50160 Hz 3-phase 2 . 5 KVA

I Input power supply (

1 Input power
supply

Common to all models

Input power supply capacity

ARC Mate Sr., S-10, S-600, A-200, 3 KVA 10 KVA 12 KVA 6.5 KVA
4 KVA

7 KVA
Average power consumption

ARC Mate, ARC Mate Sr., S-5, S-10 1 . 0 KW

Allowable ambient temperature Allowable ambient temperature Atmosphere Vibration Weight of control unit

Common to allmodels Common to all models Common to all models Common to all models ARC Mate Sr., M-100, A-200, A-510, A-600, C-100 75% RH max. No dewing (Note 1) No corresive gas (Note 2) 0.5 G max.

Note 1) 95W RE maximum in a short period (1 month pax.) Note 2) Consult us when operating where there is heavy vibration, dust, and high density of cutting oil. 3) Adjustments and checks during installation Adjust the robot in the sequence given below. Item 1 2 3 Description Visually inspect the interior and exterior appearances of the control unit. Verify that screws on terminals are tight. Verify that the connectors are properly connected. Check the transformer tap setting. Connect cables to the control and mechanical units. Verify the breaker is off. Check the input voltage. Press the EKERGENCY STOP button on the operator panel, turn on the power supply, and check the power supply voltages.
-

4
5
6

Connect the power input cable.

7
8

Check the interface signals from the control and mechanical units. Check parameters. Change if necessary.

1 0 11
12

Turn on the power supply after releasing the EMERGENCY STOP button. Check the movement of each axis in the manual jog mode. Check the interface signals to the end effector. Check peripheral device control interface signals. -

13
14

4) Resetting overtravel and emergency stop The robot is delivered with the W and U axes pressed against the hard stops. Accordingly, an overtravel occurs when the power is turned on after installation. To operate the robot it is necessary to reset overtravel and emergency stop after installing the robot and connecting the cables to the robot mechanical and control units. It will also be necessary to reset emergency stop again because the robot is set to the emergency stop condition before the peripheral device control interface is connected.

a) Peripheral device control interface connection Connect the peripheral device control interface (CN1 of OlPOE) as shown below if the EhBL signal, *HOLD signal and *ESP signal are not used.

* SFSD

Fig. 4.2 (b)

Peripheral device control interface connection

b) Resetting ordinary overtravel After pressing the overtravel release switch on the operator panel, press the RESET key while pressing the Shift key on the teach pendant. The press the manual jog key to move the overtraveled axis in the direction opposite to the overtravel direction. The overtraveled axis will then move away from the overtravel limit switch, and normal operation can be done.

APPENDIX

APPENDIX 1

DIGITAL INPUT/OUTPUT (DIIDO) SIGNAL TABLE

1.1

Peripheral Device Control Interface Signal

Table 1.1 DIIDO signal standards table

DI/DO

Type

Connection type
Spark suppression diode

Signal standards

Digital Open collector output signal output (DO)

Rated voltage:24 VDC

[Robot side]

+gFYv
-t 24V
--.-Protective

>$
+.24~
,-JV

Maximum applied voltage: 30 VDC Maximum load current: 0.2 A Transistor type: NPN Output pulse width: 200 msec +8 msec (Note 1) Saturation voltage at turn-on time: About 1.OV

1 Signal
SDO 1 iD0 16

RDY REMOTE 1 ALM STRTE BUSYE HELDE REF^ REF3 ACKl ACK4

Do not use the internal +24 V power supply from the robot

Spark suppression diode Rated peak inverse voltage: Greater than 100 V Rated effective forward current: Greater than 1 A If a relay or solenoid is directly connected as a load, connect a spark suppression diode in parallel to the load. Protective resistor When a lamp or similar device is to be used, connect a protective resistor of a value such that the lamp will be in a half-lighted condition so as to prevent a surge current when it is turned on.
i

Note 1) The output pulse widths of all digital output signals can be set to f 8 msec by setting parameter No. 034 and 035, SPW, to I . 400 msec -

DI/DO

Type

Connection tvpe

Signal standards standards Type : Grounding type voltage receiver Rated input voltage: 20-28 VDC (logic "1"

Signal

Digital Receiver input contact signal input (DI)

(Robot side)

@ Digital input signal SDI 1

+733kQ
I

,T-Ly+

SDT 16 RSR 1 RSR 2 PSR 3 RSR 4 *ESP *HOLD START RSETE *SFSD ENBL PNSl PNS8

Level convexsion circuit

+4 V (logic closed) "0" open) Maximum input voltage: +28 V

Input impedance: Approx. 3.3 kQ Response time: 5-20 msec Use +24 V from the robot side as the input circuit voltage.

@ Peripheral device contact standards

Rated contact capacity: 30 VDC, 50 mA or over Input signal width: Less than 5 msec (ON and OFF) Chattering time: Shorter than 5 msec Closed circuit resistance: Less than 100 Q Open circuit resistance: Greater than 100 kQ
(Signal) (Signal) End effector signal Robot receiver output sign (Chattering: Less than 5 msec)

Apply +24V of input voltage at robot side. The input voltage is needed to satisfy the rated input voltage described above. Note) Refer to section 1.4 "Selecting input signal common line. "

1.2

End Effector Control Interface Signal

Table 1.2
DI/DO signals standards

DI/DO

Type

Connection type

Signal standards Rated voltage: 24 VDC

Signal RDO 1 RDO 6

Digital Open collector output signal output (DO)

V? f I

Spark suppression diode

(Robot side) Lower than 0 2A

Maximum applied voltage: 30 VDC Maximum current: load 0.2 A Transistor type: NPN Output pulse 200width: msec

v: e-$ ,7

x Protective resistor

+8 -

msec (Note 1)

Saturation voltage at turn-on time: About 1.OV the robot When using a .t24 VDC output sig~al, side 4-24 V power source can be used within +24 VDC 4-7%, 0.7 A. This power source is for driv?ng the small solenoid valves in the end effector or other devices. Spark suppression diode Rated peak inverse voltage Greater than 100 VDC Rated effective forward current Greater than 1 A If a relay or solenoid is directly connected as a load, connect a spark suppression diode parallel with the load.

.....

....

Protective resistor When a lamp is used, connect a protective resistor of a value such that the lamp will be in a half-lighted conditions so as to prevent a surge current when it is turned on. Note 1) The output pulse widths of all digital output signals can be set to - msec by setting parameter No. 032, RPW, to 1. 400 msec +8

DI/DO

Type

Connection type

Signal standards standards Type : Grounding type voltage receiver

Signal RDI 4 RDI 8 *HBK *PPABN

Digital Receiver contact input input signal (DI)

@ Digital input signal RDI 1 -

(Robot side)

&g
33kQ

Rated input voltage: +20-28 VDC (logic "1" closed) 0 - +4 V (logic "0" Maximum input open) voltage: +28 VDC Input impedance: Approx. 3.3 kQ Response time: 5-20 msec

Level conversion circuit

Use +24V from the robot side as the input circuit voltage.

@ End effector side contact standards

Rated contact capacity: 30 VDC, 50 mA or over Chattering time: Shorter than 5 msec Closed circuit resistance: Less than 100 Q Open circuit resistance: Greater than 100 kQ
(Signal) (Signal) End effector signal Robot receiver output si (Chattering: Less than 5 mse

Note) Refer to section 1.4 "Selecting input signal common line."

1.3

Arc Welding Interface Signal

Table 1.3 (a)
DIIDO signals standards

Digital output signal Open collector output

Connection t y p e
(Robot side) Spaik suppression diode

Signal standards Rated v o l t a g e : 24 VDC Maximum a p p l i e d v o l t a g e : 30 VDC Maximum l o a d c u r r e n t : 0.2 A T r a n s i s t o r type: KPN Saturation voltage a t turn-on t i m e : About 1. OV

---

For +24 VDC common f o r o u t p u t s i g n a l , t h e r o b o t s i d e +24 VDC +7%, 0 . 4 A t o g e t h e r w i t h end e f f e c t o r c o n t r o l i n t e r f a c e . U t i l i z e t h i s power source f o r driving the small r e l a y i n the welder, e t c . w i t h i n t h e c a p a c i t y range. Spark s u p p r e s s i o n d i o d e Rated peak i n v e r s e v o l t a g e : G r e a t e r t h a n 100 VDC Rated e f f e c t i v e f o r w a r d c u r r e n t : Greater than 1 A I f a r e l a y o r s o l e n o i d i s d i r e c t l y c o n n e c t e d as a load, connect a spark suppression diode i n p a r a l l e l t o the load. Protective resistor When a lamp i s u s e d , c o n n e c t a p r o t e c t i v e r e s i s t o r of a v a l u e s u c h t h a t i t w i l l be i n a half-lighted condition so a s t o prevent a surge c u r r e n t when i t i s t u r n e d on.

DI/DO

Type

Connection type
[Robot side]

Signal standards

Signal

Digital Receiver input contact input (DI)

@ Digital input

WDI2 signal standards WDI6

&
3

kR

Type : Grounding type voltage receiver Rated voltage: 0 - +4 input VDC (logic "1" closed) +20 - +24 VDC (logic "0" open) Input impedance: Approx. 3.3 k C 2 Response time: 5 - 20 msec

circuit Level conversion

@ Welder side contact standards

Rated contact capacity: 30 VDC, 10 A or over Chattering time: Shorter than 5 msec Closed circuit resistance: Less than 100 C2 Open circuit resistance: Greater than 300 k C 2

(Signal)

(Signal)

Welder contact signal

Robot receiver output signal (Chattering : Less than 5 msec)

--

Table 1.3 (b)

Analog input/output signal specifications

1
Analog output signal

Name of s i g n a l Welding v o l t a g e corcmand signal Wire f e e d r a t e command signa 1 .

Signal specifications

Welder side

0 -. -lov

ov.
I
I

Input impedance: Greate~ than 3.3 k a

' Connect a high-frequency filter

-Analog input signals Welding c u r r e n t d e t e c t i o n

Robot side

0 - +1ov--4--

Eliminate ripples by filter before feeding to the robot

Wire s t i c k d e t e c t i o n signal

--.

-Electric pole of welder

~ o b o side t

1 I

Welder side

R e s i s t a n c e between and - t e r m i n a l s of w e l d e r s h o u l d be g r e a t e r t h a n 100 a. T h i s c i r c u i t s h o u l d be i s o l a t e d from TI w e l d i n g (high-frequency) ci.r c u i t Maximum v o l t a g e of t h i s c i r c u i t i s 80

1.4 Selecting Input Signal Common Line (24 VIO V Common) 1) Setting on 1/0 PCB For peripheral device control interfaces A and B and the end effector input signal, the signal common line shown in the table below can be changed. In this case, the polarity attendant on common setting change is corrected automatical.ly, thus eliminating the need for ON/OFF or logical change of contact opening/closing. Setting is performed using the DIP1 to DIP4 setting pins on the 110 PCB.
Table 1.4 (a) Selecting input signal common line (110 PCB)

Shortcircuit setting Setting 24 V common 0 V common pin DIP 1 DIP2

A
A

Signal whose setting is changed SDIl

Remarks

B B

SDI16

RSR1,Z START, RESET, ENBL, *SFSD *HOLD RDIl (NZ1 PNSl

0V for PCB No.

common is valid the models of (Note 1 ) edition 03C or later.

DIP3 DIP4

A
A

B B

RDI8, NZ6, *PPABN) PNS8, RSR3,4

) (Note 2

Note 1 ) 0 V common setting is possible from I / O PCB edition 03C and subsequent editions. For previous editions, since the *ESP signal is added, no O V common setting is possible. Note 2) For the 1/0 PCB, 02B edition or earlier, NZ1 to NZ6 and the *PPABN signal are set with the end effector signals. m e n 24 V common is used for connection at the robot mechanical unit side, no 0 V common setting is possible. 2) Setting on the peripheral PCB The common line shown i~ the table 1.4(b) can be changed for the input signals of the peripheral device interface C and welding machine control signal. The polarity to be changed as a result of the change in common setting is compensated by setting parameter No. 048, but the parameter may not be available in some models and software editions. In such a case, change the logic of on/off input signal or open/close contact. The common line setting is made by DIP1 and DIP2 on the peripheral PCB.

Table 1.4 (b)

Selection of input signal common line (Peripheral PCB)

Standard setting Setting pin

24 V 0 V

Signal to be changed

Remarks

common common DIP1 DIP2 A A B B WDI9

WnIl6

Standard setti.ng is B. Standard setting is A.

AD11 -.. AD116

Note) When using other than the standard setting, it is necessary to change parameter No. 048. If the parameter is not available, it is necessary to change the input signal 1ogi.c.

3 ) Setting on additional 110 PCE Related to the input signals for peripheral device interface, it is possible to change COMMON line for signal described in the table below. In that case, compensate the polarity in accordance with the change on COMMON setting by setting parameter No. 048. However, there are cases that parameters are not provided depending on type of machine or version of software. When parameters are not provided, change the theory for ON/OFF input signal or open/close contact. Set the COMMON line using jumper DIP1 on the additional 1/0 PCB.

Standard setting Jumper

0V common common
24 V

Signal to be changed

Remarks

DIP 1

ADTI

AD148

Standard setting is A.

Note) When using other than the standard setting, it is necessary to change If the parameter is not prepared, it i.s the parameter No. 048. necessary to change the input signal logic.

1.5 Noise Suppressors All relays, solenoids, and motors to be used in a nachine or on peripheral devices connected to the control unit must be provided with noise suppressors. These suppressors are also used to protect the relay contacts. Fig. 1.5 (a) shows examples of noise suppressors; Fig. 1.5 (b) and (c) show noise suppressors in a circuit.
DC relay +24 VDC DC relay
I

AC relay 100 VAC AC relay, solenoid or motor

I

Diode V06C (HITACHI)

Noise suppressor Sl-B (FUJITSU)

3 phase motor
3 phase mot01

.
L--.

220 VAC 3 phase

Noise suppressor S2-A (FUJITSU)

Fig. 1.5 (a) Noise suppressor examples

Fig. 1.5 (b)

Noise suppressor S1-Bdiagram

Fig. 1.5 (c)

Noise suppressor S2-A diagram

208

Note) I f l i n e v o l t a g e exceeds 220 VAC, u s e t h e f o l l o w i n g n o i s e s u p p r e s s o r s . a ) DCR2-50D100B (up t o 2-phase 1000 VDC) b) DCR4-60A55 (up t o 3-phase 550 VAC) Both a r e manufactured by MARCON e l e c t r i c . a ) Dimensions and s p e c i f i c a t i o n s f o r DCR2-50D100B Rated tance Resistor

Plastic case (black)

1.25 mm2 Heat resisting vinyl wire

b) Dimensions and s p e c i f i c a t i o n s f o r DCR4-60A55 Capacitance Tolerance Rated voltage Resistor

0.75 mm2 Vinyl wire .-

Tin plate case Coating: Gray lacquer

56f 1

APPENDIX 2 PERIPHERAL DEVICE CABLE SPEC1FlCATlONS

2.1

Peripheral Device Control Interface A, B, C Cable

Fig. 2.1 (a)

PCB mounting position (01POE)

(Note)

Clamp
I
-'

--l

unit

Peripheral device connection cable A , B

Peripheral device connection cable installation

Additional I/O PCB PCB mounting position (01P28)

--

To mechanical unit

Fig. 2.1 (b)

Peripheral device connection cable installation

Note) Peel out the cable sheath partially for noise suppression and expose the shield. Clamp by the cable clamp at that part.

1) Specifications of the cable connector

@ Connector for interface

OlPOE-CN1

Controlle~

Connector

(MRSORMA)
Fig. 2.1 (c)

T
\-.

IJse MRPSOLWFOI or MRSOLFH

(HONDA TSUSHIN KOGYO)

Cable connector (for interface A)

Cable connector MR50LFH can be supplied as an optional equipment. specification: A02B-0029-K891)

(Our

@ Connector for interface B

\
Connector (MR2ORFA)

Use MRP2OLWMOI or MRZOLMH

Fig. 2.1 (d)

Cable connector (for interface B)

Cable connector MR20LMH can be supplied as an optional equipment. specification A02B-0029-K898)

(Our

@) Connector for interface CA, CR

Connector (MRSORFA)
Fig. 2.l(e)

\ Use MRPSOLWMOI or MRSOLMH

(HONDA TSUSHIN FOGYO)

Cable connector (for CA, CB)

Cable connector MR50LMH can be supplied as an optional equipment. specification A02B-0029-K899)

(Our

@ Connector for interface CC

~ont~olle~ Connect01 (MR20RFA)

\ Use MRP20LWMOl 01 MR20LMH

(HONDA TSUSHIN KOGYO)

Fig. 2.l(f) Cable connector (for CC)

Cable connector MR20LMH can be svpplied as an optional equipment. (Our specification A02B-0029-K891)

Interface A C B

Specification MR50LFH

A
67.9

(B)
73.5

C 44.8 39.8

(D) 18
17

Pin 50 20

MR5OLMH NR20LMH
39.3

44.9

Symbol

Name Outer diameter of cable Connector cover Cable clamp Clamp spring Clamp screw Connector (male) (MR20MH) Connector (male) (MR50MH) Connector (female) (MR50FH) MR-20L 410 mm max. MR-50L 416 mm max.

0
0 0
@

Fig. 2.1 (g) Connector

212

2) Recommended c a b l e Use a completely s h i e l d e d c a b l e conforming t o t h e s p e c i f i c a t i o n s shown i n Table 2.1. The c a b l e l e n g t h should be long enough t o r e a c h i n s i d e t h e c o n t r o l u n i t , and i t s t o t a l l e n g t h should be l e s s t h a n 30 m i n c l u d i n g 1.5 m f o r connecting i n s i d e t h e cabinet.
Table 2.1 Meterial of cable

Interface

No.of cores

Electrical characteristics Outer Thickness Composi- of s h e a t h diameter Conductor Allowable Diameter resistance current tion Conduct o r 41.05 mm d1.05 mm 710.18 710.18 1.5 mm 1.5 mm Q12.5 mm 410.0 mm 106 Qlkm 106 Qlkm 1.6 A 1.6 A

A, CAY CB 50 c o r e s
B, CC 20 c o r e s

The f o l l o w i n g c a b l e i s recommended. Braided, s h i e l d e d and m u l t i p a i r e d v i n y l c a b l e : 2 50-core, 0.2mm ( i n t e r f a c e s A, CAY CB) 2 20-core, 0.2mm ( i n t e r f a c e s B y CC) Our s p e c i f i c a t i o n A66L-0001-0042 ( f o r i n t e r f a c e A, CAY CB) A661,-0001-0041 ( f o r i n t e r f a c e B y CC)

3) Standard i n t e r f a c e c a b l e @ The s t a n d a r d i n t e r f a c e c a b l e i s (K41) s u p p l i e d a s an o p t i o n . one-to-one c a b l e ) (See APPENDIX 5.6 f o r s p e c i f i c a t i o n s )

(50 c o r e

Standard cable (K4 1) OlPOE.CN1

Peripheral device side

The cable is supplied with this connector attached.

Fig. 2.l(h) Standard interface cable (for interface A)

@ The s t a n d a r d cab1.e f o r i n t e r f a c e B i s (K42) s u p p l i e d a s an o p t i o n .

(20-cores, one t o one c a b l e ) (See APPENDIX 5.6 f o r s p e c i f i c a t i o n s )

I
0 IPOE-CN4

Standard cable (K42)

I
Perivheral device side

LMR~ORFH
The cable is supplied with this connect01 attached.
Fig. 2.l(i) Standard interface cable (for interface B)

@ The s t a n d a r d c a b l e f o r i n t e r f a c e CA i s (K44) when s u p p l i e d a s an

option. (50-cores, specifications) one to one cable) (See APPENDIX 5.6 for

MRPSOLWMO 1 .--

MRSOLFOI

/
Fig. 2.1 (j) Standard interface cable (for interface CA)

device side

MRSORMH

The cable is supplied with this connector attached.

@ The s t a n d a r d c a b l e f o r i n t e r f a c e
option. (50--cores, specifications) one to one

CB i s ( K 4 5 ) when s u p p l i e d a s an cable) (See APPENDIX 5.6 for

MRP5 OLWMO 1

'

device side

MRIORMH ,The cable is supplied with this connector attached..

Fig. 2.1 (k) Standard interface cable (for interface CB)

@ The standard cable for interface CC is ( K 4 6 ) when supplied as an for option. (50-cores, one to one cable) (See APPENDIX 5.6
specifications)
MRPZOLWMOl
Standard cable (K46) Controller 0 1P28-CNA3 Per ipher a1 device side

MRZOLMOl
I

MRZORFH The cable is supplied with this connector attached..

Fig. 2.1(1) Standard interface cable (for interface CC)

(i) MR20RFH, MR50RFH

2-M2

Fig. 2.1 (rn) Outer view of attached connector (112)

(ii) MR50RMH

a
Cable

- Lamp metal

0-

Sc~ew (42 6 x 8)

@ - Connector (MR-20150 RFH)

@ - Connector (MR-50 RMH)

Specification

Pin 20 50

K42, K46 K41 K44, K45

MR-20RHF

32.8

27.8

MR-5 ORHF 61.4 MR- 5 ORMH

Fig. 2.1 (rn) Outer view of attached connector (212)

56.4

2.2 End Effector Control Interface Cable

1 )

Cable connector specifications (S-5, S-10, S-300, S-420, S-600, ARC Mate, ARC Mate Sr., A-200, C-100) . 2 ( a ) , The wrist connector shown in Fig. 2 end effector interface.

M-100, M-400,

( b ) is used to connect to the

833 11.2 24.7 C : 54.5 D : 9.6 - 15.0 (inner diameter) Denshi Kogyo Co.) JMLP2524M (made by Daiichi
E : F : G :
Fig. 2.2 (a) Specifications of wrist connector

A : M30x1 B : 63.0

C : 37.5 G : 24.7 D : 9.6 - 15.0 (inner diameter) JMSP2524M (made by Daiichi Denshi Kogyo Co.)
Fig. 2.2 (b) Specifications of wrist connector 6-200, S-300, S-420, S-600, ARC Mate)

2)

Specification of connectiong connector (A-510, L-1000) In A-510 and L-1000, wrist connector shown in Fig. 2 . 2 ( c ) the end effector control interface.

is provided for

A : M22 x 1 B : 48.8 G : 16.6 C : 30.5 D : 3.0 - 9.0 (Inside diameter) JMCR1610 (made by Daiichi Denshi Kogyo Co.)
Fig. 2.2(c) Connector specification

217

3)

Specification of crimp type terminal (A-600) In A-600, crimp type terminal shown in Fig. 2.2(d) effector control interface.

provided for the end

Made by Japan Crimp Terminal nonagonal crimp type terminals

Fig. 2.2(d) Crimp type terminal

(Insulated flat

I
1

4)

Wire specification for the recommended cable Table 2.2 shows an example of recommended wires unshielded cabtyre cable using ETFE (ethylene-tetrafluoroethylene) as an insulator, conforming to the specifications shown in this table. The cable should be long enough to allow the wrist to operate over its full rapge without interfering with the end effector.
Table 2.2 Recommended wires

Specifications No. of cores Diameter' Conductors No. and types Thickness of sheath Outer diameter Conductor resistance Allowable current

A66L-0001-0143 6 cores

A66L-0001-0144 20 cores 41.1 mm 4010.08

1 mm

dl.l mm
4010.08 1 mm d5.3 mm 91 Q/km 3.7 A

48.6 mm 91 Q/km 2.3 A

2.3

Arc Welding Interface Cable

Fig. 2.3 (a)

Arc welding connection cable

1) Welding c a b l e s p e c i f i c a t i o n F i g . 2 . 3 ( b ) shows t h e w e l d i n g c a b l e s p e c i f i c a t i o n .

Welding machine

I
Controller MR34RFA

Cannon connector

MS3102A28-21 S Guide key position

MS.3 108B28-21P MS3057-16 (Nihon Koku Denshi)

Fig. 2.3 (b)

Welding cable specification

Welding cable specifications.)

specified

should

be

used.

(See

APPENDIX

5.6

for

APPENDIX 3 SPARE PARTS LIST 3.1 Fuse Specification

a ) Input u n i t fuse F1, F2: A60L-0001-0101#P4100H 10A D a i t o T s u s h i n P r o d u c t P4100H F3 : A60L-0001-0172//D~03 0.3A D a i t o T s u s h i n P r o d u c t DM03 A60L-0001-0046jI5.0 F4 : 5A D a i t o T s u s h i n P r o d u c t MP50 The s p e c i f i c a t i o n i s d i f f e r e n t depending on t y p e of r o b o t and i n p u t power s u p p l y v o l t a g e . R e f e r t o t h e t a b l e below. A60L-0001-0042#JG1-30 30A Utsunomiya Denki P r o d u c t JG1-30 A60L-0001-0042iIJGl-20 20A Utsunomiya Denki P r o d u c t JG1-20 A60L-0001-0042iIJGl-15 15A Utusnomiya Denki P r o d u c t JG1-15 A60L-0001-0042/IJG1-10 10A Utusnomiya Denki P r o d u c t JG1-10

Robot
ARC Mate S-5 A-510, A-600

I n p u t power s u p p l y v o l t a g e 200/220/240V 380-550V 200/220/24OV 380-550V

Fuse s p e c i f i c a t i o n A60L-000 1-0042# JG1-20 A60L-0001-0042#JG1-10 A60L-0001-0042#JG1-20 A60L-0001-0042#JG1-15

ARC Mate S r . S-10, S-500, S-600, S-700, M-100, M-400, A-200, C-100

S-300

20@/220/240V

A60L-0001-~0042PJG1-~30 A 6 0 L 0 1 -

--

b) Power u n i t f u s e F11, F12: A60L-0001-019485.0 5A D a i t o T s u s h i n P r o d u c t HP50 F13: A60L-0001-0075#3.2 3.2A D a i t o T s u s h i n P r o d u c t SMP3.2AS F14: A60L-0001-0046jI7.5 7.5A D a i t o T s u s h i n P r o d u c t MP75
c ) Input transformer fuse

I n p u t t r a n s f o r m e r i s u s e d when i n p u t power s u p p l y v o l t a g e i.s between 380 VAC and 550 VAC. F1: A60L-0001-0042~/3~1-10 10A Utsunomiya Denki P r o d u c t JG1-10 d ) Fuse of a d d i t i o c a l I / O PCB F1: A60L-0001-0046#2.0 2A D a i t o T s u s h i n P r o d u c t MP20

3.2 Spare Parts of Controller

The number of spares are different according to type of machine, configuration of options or the number of units. 1) Controller PCB Type of model/ application Common to all types of robots Common to all types of Data memory 1500 points robots Select according to Data memory data memory capacity 6800 points Common to all types of robots Common to all types of robots Common to all types of robots
-

Item Main CPU Serial port

Specification A16B-2200-0200 A16B-2200-0210 A16B-2200-0211

Remarks

I/O Back panel Power unit Axis control

A16B-1211-0170 A16B-1212-0360 A16B-1212-0110 A16B-2200-0250 A16B-2200-0251 A16B-2200-0252 A16B-2200-0253

Select according to type of robot and required number of axis

4-axis control 3-axis control Z-axis control 1-axis control

-

Axis/welding

A16B-2200-0300

ARC Mate, ARC Mate Sr. S-300, S-420, S-600, S-700

For welding

Peripheral Additional 1/0

-

A16B-1211-0501 A16B-1212-0120 A06B-6061-H001 A16B-1212-0420

--Pulse detection circuit Laser I/F

Used for line tracking Option and laser control Option

A-600 L-1000

Note) PCBs included in each unit are excluded.

2) Teach pendant
Teach pendant (Unit, key sheet) Unit specification English version Key sheet specification

Item For arc welding

Remarks

A05B-2115-COO1

A290-7202-X822 A290-7202-X821
S series Also used for handling

Japanese A05B-2115-COO2 version For spot welding English version

A05B-2115-COO3 A290-7202-X824 A290-7202-X823

Japanese A05B-2115-COO4 version

A-510, A-600 for handling

English version

A05B-2115-COO5 A290-7202-X826 A290-7202-X825

Japanese A05B-2115-COO6 version

A-200, M-100 for handling

English version

A05B-2115-COO7 A290-7202-X828 A290-7202-X827

Japanese A05B-2115-COO8 version

M-400 for handling

English version

A05B-2115-COO9 A290-7202-X832 A290-7202-X831 A290-7202-X834 A290-7202-X833 A290-7202-X838 A290-7202-X837

Japanese A05B-2115-C010 version For C-100 English version

A05B-2115-COll

Japanese A05B-2115-C012 version For L-1000 English version

A05B-2115-C013

Japanese A05B-2115-C014 version

Teach pendant (Main c0nfigurati.m parts) Item Control PCB Keyboard PCB LCD module Specification A20B-1002-0980 A20B-1002-0970 A61L-0001-0109 with backlight Remarks

LCD module control PCB A61L-0001-0100/~CB1053RP ROM p se 3) Input unit Input unit Robot S-5, S-10, S-600, ARC Mate, ARC Mate Sr., M-100, A-200, A-510, A-600, C-100 S-300, S-,420,S-500, S-700, M-400, L-1000, ARC mate and ARC Mate Sr. with additional axes A14B.-0076-B355 A14B-0076-I3356 For large-type cabinet B356 : UL, CSA standard use of an electromagnetic contactor A05B-2104-J55 1

1 A290-7202-T801

Specification

Remarks

Input unit (Main configuration parts)

I I

Item

II

specification A16B-1310-0660 A80L.-0001-0342 A58L-0001-0223

Remarks Common to all models TF3 for A14B-0076-B357 LC3

PCB Control transformer'

Electromagnetic contactor

A581~-0001-0094#200V2A for A14B-,0076-B355 A58L-0001-0283 for A14B-0076-B356

~58~-0001-1092//1192D RL1 Relay A58~-0001-0192//1172M RL2, RL3 A58~-0001-0192//1786H LC1, LC2

4) Operator panel Robot Display Specification Remarks for small-type cabinet for large-type cabinet

S-5, S-10, S-600, ARC Mate, English version A05B-2104-C020 ARC Mate Sr., M-100, A-200 A-510, A-600, C-100 Japanese version A05B-2104-C021 S-300, S-420, S-500, S-700 English version A05B-2111-C020 M-400, L-1000, ARC Mate and ARC Mate Sr. with Japanese version A05B-2111-C021 additional axis

5) Fan The fan unit differs depending on the model; however, the specification of a single fan motor is the same for all models. Item Fan motor Specification A90L-0001-0213#A Remarks Common to all models

6) Breaker, leakage breaker Breaker and leakage breaker differ depending on models, input power supply voltage, and so forth. Breaker Robot

200-550~AC/30A A6GL-0001-0188#P S-300, S-420 , S-500, S-700 M-400, L-1000 380-46OVAC/2OA A60L-0001--0265 #FHA3020L Other than the above

1 1
Input voltage/ cutoff current

Specification

Remarks Fuji Electric Co.Ltd. EA53 Fuji Electric Co.Ltd. BU-FHA

200-550VAC/30A A60~-0001-0098#3/30A Fuji Electric Co.Ltd. SA33 380-55OVAC/15A A60~-0001-.0093#3/15A Fuji. Electric Co.Ltd. SA33

Leakage breaker
Robot Input voltage/ cutoff c u r r e n t / leakage detection current 200-550VAC/30A/30mA
A l l robots

Specification

Remarks

A60L-0001-0116WBA

F u j i E l e c t r i c Co.,Ltd. SGH6 3 F u j i E l e c t r i c Co.,Ltd. SGH63

380-550VAC/20A/ 3 0 m A

A60L-0001-0016iAA

7) Transformer Three types of transformers are available for use with various type robots and purposes. Input transformer Converts the input voltage (200 to 575 VAC) into 200VAC.

ARC Mate, ARC Yite Sr., S-5, S-10 S-600, A-200, A-510, A-600, M-100, C-100 S-420, S-300, S-500, S-700, M-400, L-1000 100 VAC transformer. Converts 200VAC into lO0VAC Robot S-420F, S-500, S-700 M-400, L-1000 S-420R/A/S Other robots

A80L-0012-0010

Input voltage 200-550 VAC

~8G~-0012-0010//D Input voltage 220-575 VAC

Specification A80L-0010-0018 A80L.-0001-0456 A80L-0001-0342

Remarks

with 18VAC output Built-in the input unit

Transformer for servo For power supply for servo amplifier Robot ARC Mate, S-5, A-510, A-600 ARC Mate Sr., S-10, S-600, A-200, M-100, C-100 S-300, S-420 S-500, S-700, M-400, L-1000 Specification A80L-0022-0003 A80L-0024.-0002 ~80~-~~0026-0002//A ~80~-0024-0005/!A -Remarks

8) Line filter Used when input power supply voltage is 200 and 220VAC. (For input power supply voltage of 220VAC or more, refer. to the item on tracsformer.)

Robot Common to all models

Specification ~80~-0001-0083#3

Remarks

9) Regenerative discharge resistance

Robot S-300, S-420 M-100 Specification A05B-,2114-C030 A05B-2104-C030 Remarks Regenerative discharge registor 16R

Regenerative discharge registor 32R

10) Short circuit connector. For short circuit of ENBL, *ESP, *HOLD and *SFSD of peripheral device inputloutput A. Robot Common to all models (11) Servo amplifier Robot S-5 ARC Mate Servo amplifier
1

Specification A05B-2121-J300

Remarks

Axis
WY
U13

Specification A06B-6058-HZ25 A06B-6058-H225 A06B-6058-HZ28 A06B-6058-H327 A06B-6058-H333 A06B-6058-H325 A06B-6058-H331 A06B-6058-,8006 A06B-6058-H006 A06B-6058-HOll A06B-6058-H321 A06B-6058-H006 A06B-6058-H334 A06B-6058-H006 A06B~-6058-HOll A06B-6058-H324 A06B-6058-H334

Remarks

2 3 S-10 ARC Mate Sr. 1 2 S-300

1

0a
WU0

Y @a

W
U
8

2 3 4 S-420F 1
2

~ Y B
W

U
0

3 4 5 S-420s S-420R
1
2

A06B-6058-H0C6 A06B-6057-H007 A06B-6057-H007 A06B-6057-H007 A06B-6058-H324 A06B-6058-H334

Only with Y axis

W
U
8

3
4

Robot S-420A
. -

Servo amplifier 1 2 3 4

Axis W
U

Specification A06B-6057-H007 A06B-6057-H006 A06B-6057-HO07 A06B-6058-H324 A06B-6058-H334 A06B-6058-H011 A06B-60 58-H006 A06B-6058-H227 A06B-6058-H221 A06B-6058-H224 A06B-6058-HZ22 A06B-6058-H225 A06B-6058-H012 A06B-6058-H006 A06B-6058-HZ22 A06B-6058-HZ21 A06B-6058-H334 A06B--6058-H323 A06B-60 58-.HZ2 1 A06B-6058-H003 A06B-6058-HOll A06B-6058-H006 A06B-6058-H222 A06B--6058-H003 ~06~-6058-H322/ JOll A06B-6058-H335 A06B-6058-H221 A06B-6058-H003
-

Remarks

8
~ Y B
0

S-500

1 2 3 4

U,a
B,Y
WU

S-600

1 2 3

8Y
Ba

S-700

1 2 3 4

8 W
UCX

BY

M-100

1 2 2
-

ZOR

a6
a

5-axis control 4-,axiscontrol

M-400

8
Z

2 3 4 A-200 1

Ua ,
6

5-axis control

Z8R

a6 a

5-axis control 4-axis control

Robot A-510

Servo amplifier 1
2

Axis
0a
ZU

Specification A06B-6058-H226 A06B-6058-H222 A06B-6058-HZ21 A06B-6058-H221 A06B-6058-H333 A06B-6058-HZ21 A06B-6058-H334 A06B-6058-H223

Remarks

A-600

1
2

0U
Za

L-1000

8 W R
YB

1
1 C-100
2

YXZ

5, 4 and 3-axis control Z-axis control 5-axis control 4-axis control

YX
aB
a

A06B-6058-H221 A06B-6058-H231
A06B-6058-H003 A06B-6058-H004

Note)
2

Note) Robot C-100 is used for linear traverse, so axis combination depend on the application of the machines (1 to 5-axis). This table shows already developed ones.

3.3 Location of Driver and Signals

The d r i v e r i s mounted on t h e I C s o c k e t f o r almost of PCBs e x c e p t e a r l y v e r s i o n of them. D r i v e r : T r a n s i s t o r a r r a y TD63107P made by Toshiba. (Order s p e c i f i c a t i o n : A76L-0151-0062) 1) 110 PCB (A16B-1211-0170) Locat i o n A v a i l a b l e f o r v e r s i o n 06D ( J u l y 1987) Signal
RDOOl RD002

G8

OPRL

A L M L

STRTE

HELDE REF1 B10 K5

ACKl

REF2 ACK3 ACK4

ACK2

BUSYE R D Y

R E M O T E A L M

KI

I Spare

I
A v a i l a b l e f o r v e r s i o n 04A ( J u l y 1987) A v a i l a b l e f o r v e r s i o n 03A ( J u l y 1987) Signal

2) P e r i p h e r a l PCB (A16B-1211-0500) (A16B-1211-0501) Location

G9

WDOOl WD002 WOO3 WD004

GI0
G8

WD005 WD006 WD007 WD008 ADO01 AD002 AD003 AD004 AD005 AD006 AD007 AD008 AD009 ADO10 A D O l l AD012 AD013 AD014 AD015 AD016

F8 F9 F10

3) Axis/weld PCB (A16B-1211-0780) Available for all version Location HI1 H12 Signal WDOOl WD002 WD003 WD004 WD005 WD006 WD007 WD008

4) Additional 1/0 PCB (A16B-1211-0120) Available for all version Location K10 K9 K8 K7 G10 G9
G8

Signal ADO01 AD002 AD003 AD004 AD005 AD006 AD007 AD008 AD009 ADO10 ADO11 AD012 AD013 AD014 AD015 AD016 AD017 AD018 AD019 AD020 AD021 AD022 AD023 AD024 AD025 AD026 AD027 AD028 AD029 AD030 AD031 AD032 AD033 AD034 AD035 AD036 AD037 AD038 AD039 AD040 AD041 AD042 AD043 AD044

G7 G6

APPENDIX 4

SERVO AMPLIFIER

The relationship between the robot and servo amplifiers is shown in APPENDIX 3 - ( 1 ) Refer to the Digital AC Servomotor Maintenance Manual (B-65015E) for additional information on the servo amplifiers.

APPENDIX 5 TOTAL CONNECTION DIAGRAM

5.1 Total Connection Diagram

Fig. 5.1 (a) Internal connection diagram 6-51

232

CIRCUIT BREAKER

01

ROBOT S-

10

I I

I
I

I I

I I

C ~ - X 4 h - AOI/O - ~

C - - - ~ _ K I - - AD ~ I , O

(..a
WELD CONT
, ---I

, . . a
I

ADDITIONAL MOTOR PULSE CODER ;gE:iIONAL MOTOR

I I I

I I

Cp~4a--aA

~ 41-50 ~ /

I_---

p 5s --a

A ~ ~ / 21 O -40

---------

i
I

i i i i

'LLl-I---K6%--C L 1- - -K46- - - -

MI

ROBOT S-420

Fig. 5.1 (i) Internal connection diagram (S-500)

Fig. 5.1 (j) Internal connection diagram (S-600)

241

I W Z ~

30--

Fig. 5.1 (k) Internal connection diagram (S-700)

CIRCUIT BREAKER 30A 2M)-5MV

Fig. 5.1 (n) Internal connection diagram (A-600)

CIRCUIT BREAKER 30A 200-55OV 20A 380-55OV

P O W E R IW"T W I T

20A 200.240" ; 7 5 A 380-550V

LINE FILTER KO5

K2 1 SERVO TRANSFORMER TF I

i 1

--

II

1 : )

W2 CNlL CNlH

SERVO TRAPISFORMER

200/220

0 -

EXTEQNAL LASE9 CONTRDL

ClOOO C2OOO.C3000

C O N T R h PCB

CPI

ROBOT L-1000

CNI (OPERATOR'S PANEL1

PORT 2 INTERFACE

PORT I INTERFACE

------i ri
CONTROL PCB
PORT 2

OPERATOR'S PANEL

, a +

CN2 ( S E R I A L PORT1

POWER INPUT U N I T

I
FLOPPY CASSETTE ADAPTER

CONTROL PCB

TP I CN3
I

I 1 1

21
3 4

TP3 TP4 ALA ALE

EMGOUT l EMGOUTC EMGOUT2

PERIPHERAL EMERGENCY STOP

I I

7 CN3

1 CNIT

I RELAY CONTACT ETC. I I FOR EMERGENCY STOP I

L

- - - - - - - - - - -2

1CNIO
a
0
CNIO

BKP 1 TO BRAKE OF ROBOT

3 CPI
7 CP2

r-----------7

I I

EXTERNAL OIN OFF

I I

I
I I

CP3

-----------

THEY SHOULD B E SHORTED.

BATTETY

I BACK PANEL

o IPat
CNA3

0 l POE CNA2

0 l POD CNAO

CD1 W

C W I a*TP

CPI I

INTERFACE OF SERVO A M P L I F I E R PCB

CNI* SERVO AMP

t*=L.M.N) PCB

CNOP

T"
SERVO AMP PCB CNPI CNTP

OIP2D CNA6

0 I P32 02P2D CNA)

BACK PANEL 01P14 CNA4 0 I P28 CNAl

N >
0

P , N < - P , N * N N N m Q Q Q > > > L L Y L L L 0 0 0 0 0 0 0

CFIII.CFI12

CNA l

LAYOUT OF CONNECTOR ON AXES CONTROL PCB I

LAYOUT OF CONNECTOR ON AXES CONTROL PCB 2

LAYOUT OF CONNECTOR ON AXES & WELD CONTROL

d------n
TEACH PENDANT

Note) Connector specifications show cable side.

PI

ROBOT INTERFACE

P2

PI(MS31068 32AIOS)

PZLMS31068 3 2 A I O S - 2 1

DI

M2

+24V

TP2

TPI

10 SGIOVI S G ~ O V I o v

14 FG

13
SGIOVI

Note) Connector specifications show cable side.

WM

ROBOT INTERFACE
WMlMS3106B 24-10s) UM(MS3106B 24-1032) BM(MS31068 24-IOSWI

UM

m
TEACH PENDANT
C l P I Y

PZ YI.PZ

YICI Y

Note) Connector specifications show cable side.

is.420

i : ~

ROBOT INTERFACE

OI(MS3106B 22-1451

Note) Connector specifications show cable side.

I T ,

TEACH PENDANT

0
I

K3 1

MI

ROBOT INTERFACE

K32 F J M2

Note) Connector specifications show cable side.

K 31

77,
7
3
Dl
MI(MS31060 28-21s)

1 MI 1 M2
PI

ROBOT INTERFACE

M2(MS31060 28-21SX)

K36

p2

Note) Connector specifications show cable side.

-!-El
TEACH PENDANT

P 2 ( M S 3 1 0 6 B 32AlOS-23

ii
:
i

i
I

PI

ROBOT INTERFACE

0 1 C 1 8 1 A .PA2 I PA2 I .PZZ PZZ J I H I G I F I E t 5 V I OH2A I OHlA I .PBZ I P8Z

n
TEACH PENDANT

1
Note) Connector specifications show cable s~de.

B P

ROBOT INTERFACE

PI

8PlMS3106B 22-14s)

PIlMS31068 32A10S-2)

DI

MI

aM(MS3106B 18-115)

MI(MS3106B 22-14SWl

/Jfi#,
83

02

MI 23

H
63 u3

G2 U2 UI

Note) Connector specifications show cable side.

Fig. 5.1 (ad)

External connection diagram (A-600)

261

MI

ROBOT INTERFACE

Note) Connector specifications show cable side.

!-TI

TEACH PENDANT

ROBOT INTERFACE

Note) Connector specifications show cable side.

TEACH PENDANT

PI

ROBOT INTERFACE

Note) Connector specifications show cable side.

-tl

TEACH PENDANT

5.3

Overtravel Signal Circuit

7

Mechmcal u n ~ t (S-300)

0/W AXIS connector panel

S )

b 8 axu :c:d) connectot pnnci

j
Input unit

Fig. 5.3 (a) Overtravel signal circuit (S-300)

Mechanical unit (S.420)

WULS

wuor

1I

\
9-axs connector panel

Klll

Y
Control unit
K13

--

--

RVF4

Input umt -

1 1 0 PCB

Fig. 5.3 (b) Overtravel signal circuit (S-420)

RV"

'

Fig. 5.3 (c) Overtravel signal circuit IS-600)

I_ - _ _ _ - _ _ _ /K105
..cham&

-.

unn

~ a t d

1
1

( T , ~ ) 8 alxs connector panel

_ . _ _ _ _ _ _ _ _ _ _ _ _ .

Fig. 5.3 (d) Overtravel signal circuit 6 - 5 , ARC Mate)

Mechanical unit (ARC Mate S r , S-10)

I(

O-aeaxis connector panel

Control unit

LI
1
I

1 1 0 PCB

Fig. 5.3 (e) Overtravel signal circuit (S-10, ARC Mate Sr.)

K169

' O T
1

~ioxirnity switch

ov
(V)
L

(T,U)
J

Fig. 5.3 (f) Overtravel signal circuit (S-500)

Control unit
cN2

*m
Input unit

110 PCB

Fig. 5.3 (g) Overtravel signal circuit (S-700)

Mechanical unit (M- 100)

Z-axis connector panel

Raxis connector panel

Wrist connector panel

LSW

Z-OT R-OT

-------7 --__
K112

1
Control unit

K105
( ) I

a b )-axis connector ~ : d ) panel l

I

' 3 "'

*ROT

110 PCB

Fig. 5.3 (h) Overtravel signal circuit diagram (M-100)

Mechanical unit (M-300)

ZOT
K105

0 OT

UOT

s
I

6 : ! 3
I

&axis connector panel

K34

Control unit
I I

'CN2

(13)

*lcROT
:

(32-34) (22) +24 E

f+*m
RVF4

CN3 -(2) --

K13

I 1 0 PCB

Fig. 5.3 (i) Overtravel signal circuit diagram (M-400)

Mechanical unit

(A-200)

R-axis connector panel

Z-OT

8-OT

Dl1 (21)

Wrist connector panel

R-OT

- LSW

\\
-C-

(7,14,15,16 17,25) K103

K109

(a ,b

(s)

c ,d)

&axis connector panel

Fig. 5.3 (j) Overtravel signal circuit diagram (A-200)

Fig. 5.3 (k) Overtravel signal circuit diagram (A-510)

Mechanical unit (A-600)

r e kiK34
(C, M, R, V) Control unit
110 PCB

Fig. 5.3 (I) Overtravel signal circuit (A-600)

Mechanical unit (L- 1000)

K105

~:&
0 OT

(Belt b~eakage detection switch)

0')
(a,b,c,d) (R) 6)
1

WOT

ROT

(s)

;Dl

Control unit

(22) (32--34) +24E

CN2 (10) (7) (13)

(1

Input unit

RDI7
1 1 0 PCB

Note: An over.travel signal will also be sent when a belt is broken

Fig. 5.3 (m) Overtravel signal circuit (L-1000)

Mechanical unit

((2-100)

Y-OT
r

Y+OT

X-OT

X+OT

Z-OT

Z+OT

(V)
I

(T, U) 8-axis connect01 panel

I 1D l

K34

Control unit

C I CN2 (13) (32-34) (22) +24E

I

--T
K13

~ b r l
Input unit

I/O PCB

Fig. 5.3 (n) Overtravel signal circuit (C-100)

5.4 Pulse Coder Signal Connection Diagram

AXIS control PCB

Motor

CF92 CF94 CF91 CF92

U-axe y-axa

baxa
a-axs

Fig. 5.4 (a) Pulse coder signal connection diagram (S-300)

Fig. 5.4 (b) Pulse coder signal connection diagram (S-420)

2,78

Fig. 5.4 (c) Pulse coder signal connection diagram (S-600)

Fig. 5.4 (dl Pulse coder signal connection diagram 6 5 , ARC Mate)

279

Axislueldine. control PCB

Motor

--

C P I~ CF92

-B a -

Fig. 5.4 (e) Pulse coder signal connection (S-10, ARC Mate Sr.)

PCB

control

MOh

*1 *2

S-500 K102 K104

S-700 KlOl K102

Fig. 5.4 (f) Pulse coder signal connection (S-500, S-700)

Axis control Control unit PCB 1

K35

Gc.
UL

Ie-axis connector panel

KlOl

Mechanical unit (M-100)

Z-axis connector
CF94 K36 K106

(02P2D)

Axis control PCB 2

Fig. 5 . 4 (g) Pulse coder signal connection diagram (M-100)

Axis control

Control unit
CF9 1 CF93 CF94 K36 CF9 1 K35

0-axis connector panel

KlOl

Mechanical unit (M-400) motor motor

K102

motor

Fig. 5 . 4 (h) Pulse coder signal connection diagram (M-400)

Axis control PCB 1

Control unit
K35

Main connector panel

Mechanical unit

t'P

K102

R-axisconnector panel

K109

Axis control PCB2

Wrist connector panel

Fig. 5.4(i) Pulse coder signal connection diagram (A-200)

Fig. 5.4 (j)

Pulse coder signal connection diagram (A-510)

Axis Control unit control

Pulse detection PCB

Axis control PCB

CF9 2 CF9 3 C E ' 9 4
Q

Pulse Pulse detection PCB coder

CFl 1 1 CF121

CF112 CF122

Fig. 5.4(k) Pulse coder signal connection diagram (A-600)

Fig. 5.4 (1) Pulse coder signal connection diagram (L-1000)

Fig. 5.4 (m) Pulse coder signal connection diagram (C-100)

5.5 Overload Alarm Detection Signal Diagram

Fig. 5.5 (a) Overload alarm detection circuit 6-5, S-600, ARC Mate)

Axis control PC11 1

Il~i,ol
I
I

2. i ; c -.
r+

( I )

9 Y 0
R

cn

( I )

ID

! 0

Fig. 5.5(c) Overload alarm detection circuit (S-300, S-420)

287

Axis control PCB 1

Axis control PCB2

Robot

L------l

I
I
I

L - - - - - - - - -1

Fig. 5.5 (e) Overload alarm detection circuit (S-700)

Fig. 5.5 (f)

Overload alarm detection circuit (M-100 5-axis)

Note: When the servo transformer and generative discharge unit are not used, short the set pm S 1 on the servo amplifier PCB.

Discharge unit

Servo transformer

Regeneratwe discharge! unit,, etc.

Axis control PCB 1

Note)

Short the jumper "S1"on the servo amplifier PCB when the servo transformer or regeneratlve discharge unlt 1s not used.

a axis

Servo transformer Axis control PCB 1

I
-- --- ----J

Regenerative discharge

etc.

-ID-=--

CNl M

iZ axls)

CN? L

Note)
1

Short the jumper "S1" on the servo amplifier PCB when the servo transformer or regeneratwe discharge unlt 1s not used.

CF91

Error detection
I

(Error display) Overload alarm

CF94

Fig. 5.5 (j) Overload alarm detection circuit (A-600)

Servo transformer

Note: When the servo transformer and generative discharge umt are not used, short the set pm S 1 on the servo amplifier PCB.

I I I I

I I I
I

Discharge unit

Fig. 5.5 (I) Overload alarm detection circuit (C-100)

296

5.6
Error Code003 (Hand Broken)

5.7

Fuse Alarm for Brake Control

Fig. 5.7 (b) Error code 201 (fuse alarm for brake control) (ARC Mate, S-5, B211, B212)

M e c h a n ~ c a lU n ~ t F ~ x e dI/O

BKP2 BKM2

00)

BKP2 BKM2

I
U2),U31 K13

BKP3 BKM3

ov

BKP3 BKM3

Fig. 5.7 (dl Error code 201 (fuse alarm for brake control) (ARC Mate, S-5, B261, B262)

hote)

This differs from B211, B212 in that BKM 3 is connected to pin 3 an yBK and OBK.

Power
Fixed 1 / 0

Input U n ~ t

BKP 1 BKMl

BKP 2 BKM2

Fig. 5.7 (f) Error code 201 (fuse alarm for brake control) (ARC Mate Sr, S-10)

Power Input U n ~ t
F i x e d I/O

M e c h a n ~ c a lU n l t

ov

Fig. 5.7 (g) Error code 201 (fuse alarm for brake control) (S-300)

Fig. 5.7 (j) Error code 201 (fuse alarm for brake control) (S-500)

Fig. 5.7 (I) Error code 201 (fuse alarm for brake control) (S-700)

Power Input Un I t

Mechan~calU n ~ t

F ~ x e dI/O

CN3 U6)

--

K13

ov
K13 K13 K13 K13 K13 K13

+24E
(4)

CFALM K13

UZ),U3)

K13

ov

Fig. 5.7 (q) Error code 201 (fuse alarm for brake control) (M-400)

Fig. 5.7 (s) Error code 201 (fuse alarm for brake control) (C-100)

Error Code 300 (Servo Not Ready)

5.9 Cable List

Table 5 . 9 (a) Robot connecting cable list (ARC Mate, S-5)

No,

Cablespecification A660-8006-T7448L7R403

Length 7 m

Robot connecti n g end

M1

Application

Cable maximum outside diameter 818.0 mm

K3 1 A660-8006-T744#L14R43 A660-2003-T308#L8R003AA K34 A660-2003-T308#L15RO3AA A660-4002-T803!iL7R603A K35 A660-4002-T803/iL14R63A A660-4002-T804iiL7R603A K36 A660-4002-T804iiL14R63A 14 m A660-8002-T688#L7R203 A660-8002-T68//L14R23 14 m 14 m 7 m 14 m 7 m 14 m 7 m

Motor power

D1

Robot D I / D O
W, U,

410.5 mm

P1

8-axis Pulse coder signal

816.0 mm

a , 8 , y-axis

P2

Pulse coder signal Ground c a b l e

816.0 mm

Ground terminal

63.5 mm

Table 5 . 9 (b) Robot connecting cable list (ARC Mate S r . ,S-10)

No.

Cable s p e c i f i c a t i o n A660-8007-TO4 7//L7R403

Length 7 m 14 m 7 m

Robot connecti n g end

Application

8, W-axis motor power

Cable maximum outside diameter 813.5 mrn

K3 1 A660-8007-T047//L14R43 K32 A660-8007-T048!/L7R403 A660-8007-T048fL14R43

-

M2

14 m 7 m
D1

U , a , 6, y-axis motor power

-

816.0 mm
--

A660-2003-T308#L8R003AA K34

Robot D I / D O

,810.5 mm

~ 6 6 0 - 2 0 0 3 - ~ 3 0 8 / / ~ 1 5 ~ 014 3 ~m ~

W, U,

A660-4002-T803//L7R603A K35 A660-4002-T803#L14R63A A660-4002-T804iiL7R603A K36 A660-4002-T804~1,14R63A

7 m P1 14 m

8-axis P u l s e coder signal

816.0 mm

7 m
P2 14 m Ground terminal

a , 8 , y-axis Pulse coder signal

816.0 mm

A660-8002-T688#L7R203 A660-8002-T688i/L14R23 14 m

Ground c a b l e

Q3.5 mm

Table 5.9 (c) Robot connecting cable list (S-300, S-420)

No.

Cable specification A660-8007-~068//1~7R803

Robot Length connecting end 7m

Application

Cable maximum outside diameter 416.5 mm

K31 . A660-8007-T06B#L14R83 A660-8007-T069#L7R803 K32 A660-8007-TO69iiL14R83 A660-8007-T0'70//L7R803 K33 A660-8007-T070//L14R83

A660-2002-T946iiL8R003BA

WM
14 m 7m
UM

W-axis motor power U-axis motor power 8-axis motor power

416.5 mm

14 m 7m
8M

416.5 mm

14 m

7m D1
Robot D I / D O W, U, 8-axis Pulse coder signal a, 6 , y-axis Pulse coder signal a, 8 , y-axis motor power Ground Ground cable terminal 413.0 mm

K34
~ 6 6 0 - 2 0 0 2 - ~ 9 4 6 / / L 1 5 ~ 0 3 B A 14 m

A660-4002-T803#L 7R803 K35 A660-4002--T803//L14R83 A660-4002-T804i/L7R803 K36 A660-4002-T804//L14R83 A660-8007-TO7 1 #Id7R803 K37 A660-8007-TO71~~L14R83

7 m
P1 14 m 7m P2 14 m 7m 14 m 7m 14 m

416.0 mm

416.0 mm

416.0 mm

A660-8006-T910#L7R203 A660--8006-T91O#L14R23
A660--8004--T859//L8R503

44.7 mm

7m

YM

A660-2003-T371//L8R503C

7m

YP
-

Y-axis S-420F motor 415.5 mm cable power for Y-axis traverse pulse unit 412.5 mm coder signal

Table 5.9 (dl Fiabot connecting caale list (S-500)

No.

Cable specification

Robot Length connecting end 7m M1

Application

Cable maximum outside diameter 815.2 mm

A660-8007-T350!/L7R803 K31

A660-800'7-T350//L14R83 14 m ~660-8007-~35 1!/~7R803 K32 A660-8007-T351#L14R83

A660-2003-T308//L8R003AA

W, U-axis motor power

0 , a,
B y

7m

M2
14 m 7m
D1

y-axis

818.0 mm

K34
A660-2003-T308i/L15RO3AA

Robot DI/DO W, U, @-axis pulse coder signal

a , By y-axis pulse coder signal

810.5 mm

14 m 7m

A660-4002-T894fL7R803 K35
-

P1
14 m

816.0 mm

A660-4002-T894#L14R83 A660-4002-T895i/L7R803 K36 A660-4002-T895fL14R83

7 m
P2 14 m 7m 14 m terminal -

816.0 mm

A660-8006-T909i/L7R203 A660-8006-T909#L14R23

Ground cable

84.7 mm

Table 5.9 (e) Robot connecting cable list (S-600)

No.

Cable specification A660-8007-T169//L7R403

Rob0t Length connecting end 7m M1 14 m 7m

Application

Cable maximum outside diameter 418.0 mm

K31 A660-8007-T169I';L14R43 A660-8007-T170#~7R403 K32 A660-8007-T170//L14R43

A660-2002-.T946fL8RO03BA K34 -

W, U, 8-axis motor power a, B y y-axis motor power

M2
14 m 7m
-

d15.2 mm

D1

Robot D I / D O
W, U, 8-axis

413.0 mm

~ 6 6 0 - 2 0 0 2 - T 9 4 6 / / ~ 1 5 R O 3 ~ A 14 m

A660-4002-T803#L7R603A K35 A660-4002-T803#~14R63A ~660-4002-T804//~7R603 K36 A660-4002-T804iiL14R63

7m P1 14 m 7m P2 14 m

Pulse coder si.gnal y-axis Pulse coder signal

a,
B y

d16.0 mm

416.0 mm

A660-8002-T688#L 7R203 A660-8002-T688#L14R23

7m
14 m

Ground Ground cable terminal

Q3.5 mm

Table 5.9 (f) Robot connecting cable list (S-700)

No.

Cable specification A660-8007-T073#L7R803

Length 7m 14 m

Robot connecting end

Application

Cable maximum outside diameter $13.5 mm

K31 ~660-8007-~073//L14R83 K32 14 m

,

8, U-axis motor power

~660-8007-~0748~7~803 7 m

M2
~660-2003-T308i/L8R003AA

U, a, B y y-axis motor power

d16.0 mm

7m

K34
A660-2003-T308//L15RO3AA

D1
14 m A660-4002-T803iiL7R803

Robot D I / D O

410.5 mm

7m
P1 14 m 7m P2 14 m

K35 ~660-4002-T803i/L14R83 A660-4002-T804i/L7R803 K36 A660-4002-T804i/L14R83 ~660-8006-~910#L7R203 A660-8006-T9 10!/L14R23

W, U, 0-axis Pulse coder signal

a, B y y-axis Pulse coder signal

416.0 mm

$16.0 mm

7m
14 m

Ground terminal

Ground cable

$4.7 mm

Table 5.9 (g) Robot connecting cable list (A-200, M-100)

Cable s p e c i f i c a t i o n

Length

Rob0 t connect! i n g end1

Application

Cable maximum outside diameter

A660-8006-T753iIL7R403 A660-8006-T753i/L14R43

7 m
14 m

Z , 8, R, a , b-axis motor power I n c a s e of 5-axis control

d16.0 mm

Z , 8, R, a , b-axis motor power I n c a s e of 4-axis control Z , 8, R, a , b - a x i s motor power I n c a s e of 3-axis control

d16.0 mm

616.0 mm

Robot DIIDO

d13.0 mm

R, a , B-axis P u l s e coder s i g n a l I n c a s e of 5-axis control

416.0 mm

R, a , B-axis I n c a s e of 4-axis control A660-2003-T288i/L8R003 A660-2003-T288i/L15R03

7 m
14 m

R, a , B-axis P u l s e coder s i g n a l I n c a s e of 3-axis control

d16.0 mm

A660-8004-T537i/L7R203 A660-8004-T537//14R23

7 m 14 m Ground cable 84.7

mm

Table 5.9 (h) Robot connecting cable list (A-510)

No.

Cable specification A660-8006-T596/iL9~003A

Length 7m

Robot connecting end

OM

Application

Cable maximum outside diameter d12.0 mm

-

K31

A660-8006-T596#Ll6RO3A ~660-8006-T729#L7R503 K32 A660-8006-~729#L14R53 ~660-2003-T161#L8R003A K34 A660-2003-T161i!L15RO3A

--

14 m 7m

8-axis motor power Z, U, a-axis motor power

Mi
14 m 7m D1 14 m 7m 8P 14 m

d13.5 mm

Robot DI/DO 8-axis Pulse coder signal

d10.5 mm

A660-2003-T284iiL8R503 K35 A660-2003-T2848L15R53 A660-4002-T801/~L8R003A K36

d12.5 mm

7m P1
14 m

7 No. K32 K34 K35

A660-4002-T801/!L18RO3A ~660-8004-T537#L7R503 A660-8004-T537#L15R53

Z, U, a-axis Pulse coder signal

d16.0 mm
-

14 m

Ground Ground cable terminal

d4.7 mm

Table 5.9 (i)

Robot connecting cable list (A-600)

Cable specification A660-8007-TOlO~~L7R503 A660-8007--TOlO#L14R53 A660-2003-T343#L8RO03A A660-2003-T343#L15RO3A A660-4002-T8688L8R503 ~660-4002-T868#L8R53

Robot Length connecting end

Application 8-axis motor power

Cab1.e maximum outside diameter d16.0 mm

7m M1
14 m
--

7m 14 m

Z, U, a-axis motor power

810.5 mm

7m P1
14 m Ground Ground cable terminal 44.7 mm Robot DI/DO d19.5 mm

A660-8006-T909#L7R503 A660-8006-T909#Ll4R53 14 m

Table 5.9 (j) Robot connecting cable list (M-400)

No.

Cable specification A660-8007-,T25 1IIL7R803

Robot Length connecting end 7m 14 m

Application

Cable maximum outside diameter d15.2 nnn

K31

A660-8007-T25 lIiL14R83 A660-8007-T252#L7R803 K32 A660-8007-T252#L14R83

A660-2002-T946i,L8R003BA

Z , 0-axis motox power

7m

M2
14 m 7m

Z , a , B-axis motor power

415.2 mm

K34
A660-2002-T946iiL15RO3BA

D1
14 m A660-4002-T894liL7R803

Robot DI/DO
Z , 8-axis Pulse coder signal

413.0 mm

7m
P1 14 m 7m P2 14 m 7m 14 m

K35

d16.0 mm

A660-4002-T894#~14R83 A660-4002-T896iIL7R803 K36 A660-4002-T896#L14R83 A660-8006-T910I/~7~203

-

Z , a , 6-axis Pulse coder signal

d16.0 nnn

A660-8006-T910iIL14R23

Ground Ground cable terminal

44.7 mm

Table 5.9 (k) Robot connecting cable list (L-1000)

No.

Cable specification A660-8007-T658iIL7R803

Rob0t Length connecting end

Application

Cable maximum outside diameter 615.2 mm

7m
14 m 7m M2 14 m

F31 A660-8007-T658fL14R83 A660-8007-T659fL7R803

K3 2

8, W-axis motor power

A660-8007-T659iIL14R83 K34 . A660-2002-T946fL8R003BA A660-2002-T946iIL15RO3BA A660-4002-T894fL7R803 K35

R, y, B-axis motor power

815.2 mm

7m D1
14 m 7m P1 14 m 7m P2
0 , W, R-axis Pulse coder signal
y, B-axis Pulse coder signal

Robot DI/DO

813.0 mm

816.0 mm
-

K36

A660-4002-T894fL14R83 A660-4002-T896fL7R803 A660-4002-T896/'L14R83

616.0 mm

A660-8006-T909fL7R203

A660-8006-T909fL14R23

14 m

Ground Ground cable terminal

84.7 mm

Table 5.9 (t) Robot connecting cable list (C-100)

No.

Cable specification

Robot Length connecting end 7m 14 m 7m

P

Application

Cable maximum outside diameter 818.0 mm

A660-8007-T620fL7R803 A660-8007-T620fL14R83 A660-8007-T551i/L7R803 A660-8007-T551i/L14R83 K3 1 A660-8007-T550fL7~803 A660-8007-T550fL14R83 A660-8007-T618i/L7R803A A660-8007-T618i/L14R83A A660-2003-T308fL8R003AA K34 A660-2003-T308fL15RO3AA A660-4002-T894fL7R603A

YY X Y Z Y a9 6-axis motor power In case of 5-axis control Y, X, Z, a-axis motor power In case of 4-axis control M1 Y, X, Z-axis motor power In case of 3-axis control

818.0 mm

14 m 7m
-

d18.0 mm

14 m 7m 14 m 7m

Y, X-axis motorpower In case of 2-axis control D1

Robot DI/DO
-Y, X, Z-axis Pulse coder signal In case of 5, 4, 3-axis control

815.2mm

(610.5 mm

14 m 7m

816.0 mrn

~660-4002-~894!/~14~63~14 m K35 A660-4002-T921fL7R603A A660-4002-T921i/L14R63A A660-4002-T896i/L7R803 A660-4002-T896f~14~83 K36 A660-2003-T502//~7~803 A660-2003-T502fL14R83 A660-8002-T688fL7R203 A660-8002-T688//L14R23 14 m 7m 14 m 7m 14 m 7m 14 m P2 P1

Y, X-axis Pulse coder d16.0 mm signal In case of 2-axis control a, 6-axis Pulse coder 816.0 mm signal In case of 4, 3-axis control a-axis Pulse coder 816.0 mm signal In case of 2-axis control Ground Ground cable terminal 83.5 mm

Table 5.9 (m) Teach pendant connecting cable

No.

Cable specification

Length Appl icationlconnectinp end

Cable maximum outside diameter 611.0 mm

A660-2002-T902#LlORO3A K40 A660-2002-T902#L2ORO3A

10 m 20 m

Teach pendant connection Serial port PCB CNTPTeach pendant

Table 5.9 (n) Peripheral device connecting cable list

No.

Cable specification

Length Applicationlconnecting end

Cable maximum outside diameter

A660-2003-T214#L7R003C

7m 14 m 7m 14 m

K41

A660-2003-T214l/L14RO3C
. -

Peripheral device connecting cable AA, AB For SDO/SDI 110 PCB CN1 Peripheral device connecting cable BAY BB For SDOISDI 110 PCB CN4 Peripheral device connecting cable CAI, CA2 For AD001-20 AD10 1-20 Additional 110 PCB CNAl Peripheral device connecting cable CB1, CB2 For AD021-40 ADI21-40 Additional I/O PCB CNA2 Peripheral device connecting cable CC1, CC2 For AD041-48 ADI41-48 Additional 110 PCB CNA3

Q13.0 mm

- ----. - --

A660-2003-T2~72l/L7R003

K42

A660-2003-T272llL 14RO3
A660-2003-TO348L7R003B
-

610.5 mm

7m
14 m 7m 14 m 7m 14 m

K44

A660-2003-TO348L14RO3B
A660-2003-T034i'/L7R003C

Q13.0 mm

K45

A660-2003-T034//L1 4RO3C A660-2003-T423ilL7R003

Q13.0 mm

K46

A660-2003-T423i/L14R03

Q10.5 mm

--

Table 5.9 (0) Welding machine connecting cable

No.

Cable specification
A660-2003-T280#L4R003A

Length Applicationlconnecting end

3 m 6 m 13 m

Cable maximum outside diameter

Welding machine connecting cables A, B, C AxisIWelding control PCB CN1-Welding machine

d13.0 mm

K43

A660-2003-T280iiL 7R003A A660-2003-~280#L14RO3A

Table 5.9 (p) Power supply connecting cable

No.

Cable specification
A660-8002-T896#146R003A

Length Application/connecting end

4 m
7 m

Cable maximum outside diameter

412.0 mm d16.5 mm

For small--typecabinet For large-type cabinet

KO 1

A660-8006-,T896#9R003A

Table 5.9 (q) Laser oscillator connection cable list (L-1000)

Cable No.

Cable specification

length Application/connecting end

Max outside diameter $12.5 mm

A660-2001-T450fL7R803

7 mm 14 mm 7 mm 14 mm

For laser oscillator control. For laser oscillator control, For laser osclillator power supply,

A660-2001-T450fiL14R83 A660-2003-T366#1,7R803A A660-2003-T366#L14R83A A660-8007-T807fIL9R003 A660-8007-T808/IL16RO3 A660-8007-T808iiL9R003 A660-8007-T808~/L16RO3

410.7 mm

7 mm
14 mm 7 mm 14 mm

(913.0 mm

For alarm/door interlock

connection.
$10.0 mm