fanuc R30iB User Manual

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R-30+B Mate CONTROLLER

MAINTENANCE MANUAL

B-83525EN/06

• Original Instructions

Thank you very much for purchasing FANUC Robot. Before using the Robot, be sure to read the "FANUC Robot SAFETY HANDBOOK (B-80687EN)" and understand the content.

• No part of this manual may be reproduced in any form.

• The appearance and specifications of this product are subject to change without notice.

The products in this manual are controlled based on Japan's “Foreign Exchange and Foreign Trade Law". The export from Japan may be subject to an export license by the government of Japan. Further, re-export to another country may be subject to the license of the government of the country from where the product is re-exported. Furthermore, the product may also be controlled by re-export regulations of the United States government. Should you wish to export or re-export these products, please contact FANUC for advice.

The products in this manual are manufactured under strict quality control. However, when using any of the products in a facility in which a serious accident or loss is predicted due to a failure of the product, install a safety device.

In this manual, we endeavor to include all pertinent matters. There are, however, a very large number of operations that must not or cannot be performed, and if the manual contained them all, it would be enormous in volume. It is, therefore, requested to assume that any operations that are not explicitly described as being possible are "not possible".

B-83525EN/06 SAFETY PRECAUTIONS

SAFETY PRECAUTIONS

This chapter describes the precautions which must be followed to ensure the safe use of the robot. Before using the robot, be sure to read this chapter thoroughly.

For detailed functions of the robot operation, read the relevant operator's manual to understand fully its specification. For the safety of the operator and the system, follow all safety precautions when operating a robot and its peripheral equipment installed in a work cell. In addition, refer to the “FANUC Robot SAFETY HANDBOOK (B-80687EN)”.

1 DEFINITON OF USER

The personnel can be classified as follows.

Operator

Turns the robot controller power on/off

•

Starts the robot program from operator panel

•

Programmer

Operates the robot

•

Teaches the robot inside the safety fence

•

Maintenance engineer

Operates the robot

•

Teaches the robot inside the safety fence

•

Maintenance (repair, adjustment, replacement)

•

- Operator is not allowed to work in the safety fence.

- Programmer and maintenance engineer is allowed to work in the safety fence. Works carried out in the safety fence include transportation, installation, teaching, adjustment, and maintenance.

- To work inside the safety fence, the person must be trained on proper robot operation.

During the operation, programming, and maintenance of your robotic system, the programmer, operator, and maintenance engineer should take additional care of their safety by wearing the following safety items.

- Adequate clothes for the operation

- Safety shoes

- A helmet

2 DEFINITION OF SAFETY NOTATIONS

To ensure the safety of users and prevent damage to the machine, this manual indicates each precaution on safety with "WARNING" or "CAUTION" according to its severity. Supplementary information is indicated by "NOTE". Read the contents of each "WARNING", "CAUTION" and "NOTE" before using the robot.

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SAFETY PRECAUTIONS B-83525EN/06

Symbol Definitions

WARNING

CAUTION

NOTE

• Check this manual thoroughly, and keep it handy for the future reference.

Used if hazard resulting in the death or serious injury of the user will be expected to occur if he or she fails to follow the approved procedure. Used if a hazard resulting in the minor or moderate injury of the user, or equipment damage may be expected to occur if he or she fails to follow the approved procedure. Used if a supplementary explanation not related to any of WARNING and CAUTION is to be indicated.

3 USER SAFETY

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

(1) Have the robot system users attend the training courses held by FANUC.

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

(2) Even when the robot is stationary, it is possible that the robot is still in a ready to move state, and is

waiting for a signal. In this state, the robot is regarded as still in motion. To ensure user safety, provide the system with an alarm to indicate visually or aurally that the robot is in motion.

(3) Install a safety fence with a gate so that no user can enter the work area without passing through the

gate. Install an interlocking device, a safety plug, and so forth in the safety gate so that the robot is stopped as the safety gate is opened.

The controller is designed to receive this interlocking signal of the door switch. When the gate is opened and this signal received, the controller stops the robot (Please refer to "STOP TYPE OF ROBOT" in "SAFETY PRECAUTIONS" for detail of stop type). For connection, see Fig. 3 (b).

(4) Provide the peripheral equipment with appropriate earth (Class A, Class B, Class C, and Class D). (5) Try to install the peripheral equipment outside the robot operating space. (6) Draw an outline on the floor, clearly indicating the range of the robot operating space, including the

tools such as a hand.

(7) Install a mat switch or photoelectric switch on the floor with an interlock to a visual or aural alarm

that stops the robot when a user enters the work area.

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

the robot.

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

(9) When adjusting each peripheral equipment independently, be sure to turn off the power of the robot. (10) Operators should be ungloved while manipulating the operator panel or teach pendant. Operation

with gloved fingers could cause an operation error.

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B-83525EN/06 SAFETY PRECAUTIONS

(11) Programs, system variables, and other information can be saved on memory card or USB memories.

Be sure to save the data periodically in case the data is lost in an accident. (refer to Controller OPERATOR’S MANUAL.)

(12) The robot should be transported and installed by accurately following the procedures recommended

by FANUC. Wrong transportation or installation may cause the robot to fall, resulting in severe injury to workers.

(13) In the first operation of the robot after installation, the operation should be restricted to low speeds.

Then, the speed should be gradually increased to check the operation of the robot.

(14) Before the robot is started, it should be checked that no one is inside the safety fence. At the same

time, a check must be made to ensure that there is no risk of hazardous situations. If detected, such a situation should be eliminated before the operation.

(15) When the robot is used, the following precautions should be taken. Otherwise, the robot and

peripheral equipment can be adversely affected, or workers can be severely injured.

- Avoid using the robot in a flammable environment.

- Avoid using the robot in an explosive environment.

- Avoid using the robot in an environment full of radiation.

- Avoid using the robot under water or at high humidity.

- Avoid using the robot to carry a person or animal.

- Avoid using the robot as a stepladder. (Never climb up on or hang from the robot.)

- Outdoor

(16) When connecting the peripheral equipment related to stop (safety fence etc.) and each signal

(external emergency, fence etc.) of robot, be sure to confirm the stop movement and do not take the

wrong connection. (17) When preparing footstep, please consider security for installation and maintenance work in high place

according to Fig. 3 (c). Please consider footstep and safety belt mounting position.

RP1 Pulsecoder RI/RO,XHBK,XROT

RM1 Motor power/brake

EARTH

Interlocking device and safety plug that are activated if the gate is opened.

扉が開いたときに作動するインタロック装置および安全プラグ

Fig. 3 (a) Safety fence and safety gate

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Safety fence

安全柵

SAFETY PRECAUTIONS B-83525EN/06

Emergency stop board

EAS1

EAS11

EAS2

EAS21

Fig.3 (b) Limit switch circuit diagram of the safety fence

Hook for safety belt

Fence

Steps

(Note) Connect EAS1 and EAS11, EAS2 and EAS21. T erminals EAS1,EA11,EAS2,EAS21 are on the emergency sto board.

Pedestal for maintenance

Trestle

Fig. 3 (c) Pedestal for maintenance

3.1 SAFETY OF THE OPERATOR

An operator refers to a person who turns on and off the robot system and starts a robot program from, for example, the operator panel during daily operation. Operators cannot work inside of the safety fence.

(1) If the robot does not need to be operated, turn off the robot controller power or press the

EMERGENCY STOP button during working. (2) Operate the robot system outside the operating space of the robot. (3) Install a safety fence or safety door to avoid the accidental entry of a person other than an operator in

charge or keep operator out from the hazardous place.

(4) Install one or more necessary quantity of EMERGENCY STOP button(s) within the operator’ s reach

in appropriate location(s) based on the system layout.

The robot controller is designed to be connected to an external EMERGENCY STOP button. With this connection, the controller stops the robot operation (Please refer to "STOP TYPE OF ROBOT" in "SAFETY PRECAUTIONS" for detail of stop type) when the external EMERGENCY STOP button is pressed. See the diagram below for connection.

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B-83525EN/06 SAFETY PRECAUTIONS

External EMERGENCY

STOP button

Emergency stop board

EES1

EES11

EES2

EES21

Fig. 3.1 Connection diagram for external emergency stop button

(No te ) Connect EES1 and EES11, EES2 and EES21. Terminals EES1,EES11,EES2,EES21 are on the emergenc stop board.

3.2 SAFETY OF THE PROGRAMMER

While teaching the robot, the operator must enter the robot operation area. The programmer must ensure the safety especially.

(1) Unless it is specifically necessary to enter the robot operating space, carry out all tasks outside the

operating space.

(2) Before teaching the robot, check that the robot and its peripheral equipment are all in the normal

operating condition.

(3) If it is inevitable to enter the robot operating space to teach the robot, check the locations, settings,

and other conditions of the safety devices (such as the EMERGENCY STOP button, the DEADMAN switch on the teach pendant) before entering the area.

(4) The programmer must be extremely careful not to let anyone else enter the robot operating space. (5) Programming should be done outside the area of the safety fence as far as possible. If programming

needs to be done inside the safety fence, the programmer should take the following precautions:

– Before entering the area of the safety fence, ensure that there is no risk of dangerous situations

in the area.

– Be prepared to press the emergency stop button whenever necessary. – Robot motions should be made at low speeds. – Before starting programming, check the whole robot system status to ensure that no remote

instruction to the peripheral equipment or motion would be dangerous to the user.

Our operator panel is provided with an emergency stop button and a key switch (mode switch) for selecting the automatic operation (AUTO) and the teach modes (T1 and T2). Before entering the inside of the safety fence for the purpose of teaching, set the switch to a teach mode, remove the key from the mode switch to prevent other people from changing the operation mode carelessly, then open the safety gate. If the safety gate is opened with the automatic operation set, the robot stops (Please refer to "STOP TYPE OF ROBOT" in "SAFETY PRECAUTIONS" for detail of stop type). After the switch is set to a teach mode, the safety gate is disabled. The programmer should understand that the safety gate is disabled and is responsible for keeping other people from entering the inside of the safety fence.

Our teach pendant is provided with a DEADMAN switch as well as an emergency stop button. These button and switch function as follows: (1) Emergency stop button: Causes the stop of the robot (Please refer to "STOP TYPE OF ROBOT" in

"SAFETY PRECAUTIONS" for detail of stop type) when pressed.

(2) DEADMAN switch: Functions differently depending on the teach pendant enable/disable switch setting

status. (a) Enable: Servo power is turned off when the operator releases the DEADMAN switch or when the

operator presses the switch strongly. (b) Disable: The DEADMAN switch is disabled. (Note) The DEADMAN switch is provided to stop the robot when the operator releases the teach pendant or

presses the pendant strongly in case of emergency. The R-30iB/R-30iB Mate employs a 3-position

DEADMAN switch, which allows the robot to operate when the 3-position DEADMAN switch is pressed

to its intermediate point. When the operator releases the DEADMAN switch or presses the switch

strongly, the robot stops immediately.

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SAFETY PRECAUTIONS B-83525EN/06

The operator’s intention of starting teaching is determined by the controller through the dual operation of setting the teach pendant enable/disable switch to the enable position and pressing the DEADMAN switch. The operator should make sure that the robot could operate in such conditions and be responsible in carrying out tasks safely.

Based on the risk assessment by FANUC, number of operation of DEADMAN SW should not exceed about 10000 times per year.

The teach pendant, operator panel, and peripheral equipment interface send each robot start signal. However the validity of each signal changes as follows depending on the mode switch and the DEADMAN switch of the operator panel, the teach pendant enable switch and the remote condition on the software.

Mode

AUTO

mode

T1, T2

mode

T1,T2 mode: DEADMAN switch is effective.

Teach pendant

enable switch

Off

Software

remote

condition

Local Not allowed Not allowed Not allowed

Remote Not allowed Not allowed Not allowed

Local Not allowed Allowed to start Not allowed

Remote Not allowed Not allowed Allowed to start

Local Allowed to start Not allowed Not allowed

Remote Allowed to start Not allowed Not allowed

Local Not allowed Not allowed Not allowed

Remote Not allowed Not allowed Not allowed

Teach pendant Operator panel

(6) To start the system using the operator box or operator panel, make certain that nobody is the robot

operating space area and that there are no abnormalities in the robot operating space.

(7) When a program is completed, be sure to carry out a test operation according to the following

procedure. (a) Run the program for at least one operation cycle in the single step mode at low speed. (b) Run the program for at least one operation cycle in continuous operation at low speed. (c) Run the program for one operation cycle in continuous operation at the intermediate speed and

check that no abnormalities occur due to a delay in timing.

(d) Run the program for one operation cycle in continuous operation at the normal operating speed

and check that the system operates automatically without trouble.

(e) After checking the completeness of the program through the test operation above, execute it in

the automatic operation.

(8) While operating the system in the automatic operation, the programmer should leave the safety

fence.

Peripheral

equipment

3.3 SAFETY OF THE MAINTENANCE ENGINEER

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

(1) During operation, never enter the robot operating space. (2) A hazardous situation may arise when the robot or the system, are kept with their power-on during

maintenance operations. Therefore, for any maintenance operation, the robot and the system should be put into the power-off state. If necessary, a lock should be in place in order to prevent any other person from turning on the robot and/or the system. In case maintenance needs to be executed in the power-on state, the emergency stop button must be pressed.

(3) If it becomes necessary to enter the robot operating space while the power is on, press the emergency

stop button on the operator box or operator panel, or the teach pendant before entering the range. The maintenance worker must indicate that maintenance work is in progress and be careful not to allow other people to operate the robot carelessly.

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(4) When entering the area enclosed by the safety fence, the worker must check the whole robot system

in order to make sure no dangerous situations exist. In case the worker needs to enter the safety area whilst a dangerous situation exists, extreme care must be taken, and whole robot system status must be carefully monitored.

(5) Before the maintenance of the pneumatic system is started, the supply pressure should be shut off

and the pressure in the piping should be reduced to zero.

(6) Before the start of maintenance work, check that the robot and its peripheral equipment are all in the

normal operating condition.

(7) Do not operate the robot in the automatic operation while anybody is in the robot operating space. (8) When you maintain the robot alongside a wall or instrument, or when multiple users are working

nearby, make certain that their escape path is not obstructed.

(9) When a tool is mounted on the robot, or when any movable device other than the robot is installed,

such as belt conveyor, pay careful attention to its motion.

(10) If necessary, have a user who is familiar with the robot system stand beside the operator panel and

observe the work being performed. If any danger arises, the user should be ready to press the EMERGENCY STOP button at any time.

(11) When replacing a part, please contact your local FANUC representative. If a wrong procedure is

followed, an accident may occur, causing damage to the robot and injury to the user.

(12) When replacing or reinstalling components, take care to prevent foreign material from entering the

system.

(13) When handling each unit or printed circuit board in the controller during inspection, turn off the

circuit breaker to protect against electric shock. If there are two cabinets, turn off the both circuit breaker. (14) A part should be replaced with a part recommended by FANUC. If other parts are used, malfunction

or damage would occur. Especially, a fuse that is not recommended by FANUC should not be used.

Such a fuse may cause a fire. (15) When restarting the robot system after completing maintenance work, make sure in advance that

there is no person in the operating space and that the robot and the peripheral equipment are not

abnormal. (16) When a motor or brake is removed, the robot arm should be supported with a crane or other

equipment beforehand so that the arm would not fall during the removal. (17) Whenever grease is spilled on the floor, it should be removed as quickly as possible to prevent

dangerous falls. (18) The following parts are heated. If a maintenance user needs to touch such a part in the heated state,

the user should wear heat-resistant gloves or use other protective tools.

－ Servo motor － Inside the controller － Reducer － Gearbox － Wrist unit

(19) Maintenance should be done under suitable light. Care must be taken that the light would not cause

any danger. (20) When a motor, reducer, or other heavy load is handled, a crane or other equipment should be used to

protect maintenance workers from excessive load. Otherwise, the maintenance workers would be

severely injured. (21) The robot should not be stepped on or climbed up during maintenance. If it is attempted, the robot

would be adversely affected. In addition, a misstep can cause injury to the worker. (22) When performing maintenance work in high place, secure a footstep and wear safety belt. (23) After the maintenance is completed, spilled oil or water and metal chips should be removed from

the floor around the robot and within the safety fence. (24) When a part is replaced, all bolts and other related components should put back into their original

places. A careful check must be given to ensure that no components are missing or left not mounted. (25) In case robot motion is required during maintenance, the following precautions should be taken :

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SAFETY PRECAUTIONS B-83525EN/06

- Foresee an escape route. And during the maintenance motion itself, monitor continuously the whole robot system so that your escape route will not become blocked by the robot, or by peripheral equipment.

- Always pay attention to potentially dangerous situations, and be prepared to press the emergency

stop button whenever necessary. (26) The robot should be periodically inspected. (Refer to the robot mechanical manual and controller

maintenance manual.) A failure to do the periodical inspection can adversely affect the performance

or service life of the robot and may cause an accident (27) After a part is replaced, a test execution should be given for the robot according to a predetermined

method. (See TESTING section of “Controller operator’s manual”.) During the test execution, the

maintenance worker should work outside the safety fence.

4 SAFETY OF THE TOOLS AND

PERIPHERAL DEVICES

4.1 PRECAUTIONS IN PROGRAMMING

(1) Use a limit switch or other sensor to detect a dangerous condition and, if necessary, design the

program to stop the robot when the sensor signal is received. (2) Design the program to stop the robot when an abnormality occurs in any other robots or peripheral

equipment, even though the robot itself is normal. (3) For a system in which the robot and its peripheral equipment are in synchronous motion, particular

care must be taken in programming so that they do not interfere with each other. (4) Provide a suitable interface between the robot and its peripheral equipment so that the robot can

detect the states of all devices in the system and can be stopped according to the states.

4.2 PRECAUTIONS FOR MECHANISM

(1) Keep the component cells of the robot system clean, operate the robot where insulated from the

influence of oil, water, and dust. (2) Don’t use unconfirmed liquid for cutting fluid and cleaning fluid. (3) Adopt limit switches or mechanical stoppers to limit the robot motion, and avoid the robot from

collisions against peripheral equipment or tools. (4) Observe the following precautions about the mechanical unit cables. Failure to follow precautions

may cause problems.

• Use mechanical unit cable that have required user interface.

• Do not add user cable or hose to inside of the mechanical unit.

• Please do not obstruct the movement of the mechanical unit when cables are added to outside

of mechanical unit.

• In the case of the model that a cable is exposed, please do not perform remodeling (Adding a protective cover and fix an outside cable more) obstructing the behavior of the outcrop of the cable.

• When installing user peripheral equipment on the robot mechanical unit, please pay attention that the device does not interfere with the robot itself.

(5) The frequent power-off stop for the robot during operation causes the trouble of the robot. Please

avoid the system construction that power-off stop would be operated routinely. (Refer to bad case example.) Please perform power-off stop after reducing the speed of the robot and stopping it by hold stop or cycle stop when it is not urgent. (Please refer to "STOP TYPE OF ROBOT" in "SAFETY PRECAUTIONS" for detail of stop type.)

(Bad case example)

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• Whenever poor product is generated, a line stops by emergency stop and power-off of the robot is incurred.

• When alteration is necessary, safety switch is operated by opening safety fence and power-off stop is incurred for the robot during operation.

• An operator pushes the emergency stop button frequently, and a line stops.

• An area sensor or a mat switch connected to safety signal operates routinely and power-off stop

is incurred for the robot.

• Power-off stop is regularly incurred due to an inappropriate setting for Dual Check Safety (DCS).

(6) Power-off stop of Robot is executed when collision detection alarm (SRVO-050) etc. occurs. Please

try to avoid unnecessary power-off stops. It may cause the trouble of the robot, too. So remove the causes of the alarm.

5 SAFETY OF THE ROBOT MECHANISM

5.1 PRECAUTIONS IN OPERATION

(1) When operating the robot in the jog mode, set it at an appropriate speed so that the operator can

manage the robot in any eventuality.

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

jog mode.

5.2 PRECAUTIONS IN PROGRAMMING

(1) When the operating spaces of robots overlap, make certain that the motions of the robots do not

interfere with each other.

(2) Be sure to specify the predetermined work origin in a motion program for the robot and program the

motion so that it starts from the origin and terminates at the origin. Make it possible for the operator to easily distinguish at a glance that the robot motion has terminated.

5.3 PRECAUTIONS FOR MECHANISMS

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

5.4 PROCEDURE TO MOVE ARM WITHOUT DRIVE POWER

IN EMERGENCY OR ABNORMAL SITUATIONS

For emergency or abnormal situations (e.g. persons trapped in or pinched by the robot), brake release unit

can be used to move the robot axes without drive power. Please refer to controller maintenance manual and mechanical unit operator’s manual for using method of brake release unit and method of supporting robot.

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SAFETY PRECAUTIONS B-83525EN/06

6 SAFETY OF THE END EFFECTOR

6.1 PRECAUTIONS IN PROGRAMMING

(1) To control the pneumatic, hydraulic and electric actuators, carefully consider the necessary time

delay after issuing each control command up to actual motion and ensure safe control.

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

the end effector.

7 STOP TYPE OF ROBOT

The following three robot stop types exist:

Power-Off Stop (Category 0 following IEC 60204-1)

Servo power is turned off and the robot stops immediately. Servo power is turned off when the robot is

moving, and the path of the deceleration is uncontrolled.

The following processing is performed at Power-Off stop.

- An alarm is generated and servo power is turned off.

- The robot operation is stopped immediately. Execution of the program is paused.

Frequent Power-Off stop of the robot during operation can cause failures of the robot.

Avoid system designs that require routine or frequent Power-Off stop conditions.

Controlled stop (Category 1 following IEC 60204-1)

The robot is decelerated until it stops, and servo power is turned off.

The following processing is performed at Controlled stop.

- The alarm "SRVO-199 Controlled stop" occurs along with a decelerated stop. Execution of the program is paused.

- An alarm is generated and servo power is turned off.

Hold (Category 2 following IEC 60204-1)

The robot is decelerated until it stops, and servo power remains on. The following processing is performed at Hold.

- The robot operation is decelerated until it stops. Execution of the program is paused.

WARNING

The stopping distance and stopping time of Controlled stop are longer than the

stopping distance and stopping time of Power-Off stop. A risk assessment for the whole robot system, which takes into consideration the increased stopping distance and stopping time, is necessary when Controlled stop is used.

When the emergency stop button is pressed or the FENCE is open, the stop type of robot is Power-Off stop or Controlled stop. The configuration of stop type for each situation is called stop pattern. The stop pattern is different according to the controller type or option configuration.

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There are the following 3 Stop patterns.

Stop

pattern

AUTO P-Stop P-Stop C-Stop C-Stop P-Stop

A T1 P-Stop P-Stop - C-Stop P-Stop

T2 P-Stop P-Stop - C-Stop P-Stop AUTO P-Stop P-Stop P-Stop P-Stop P-Stop

B T1 P-Stop P-Stop - P-Stop P-Stop

T2 P-Stop P-Stop - P-Stop P-Stop AUTO C-Stop C-Stop C-Stop C-Stop C-Stop

C T1 P-Stop P-Stop - C-Stop P-Stop

T2 P-Stop P-Stop - C-Stop P-Stop

Mode

Emergency

stop

button

External

Emergency

stop

FENCE open SVOFF input

Servo

disconnect

P-Stop: Power-Off stop C-Stop: Controlled stop

-: Disable

The following table indicates the Stop pattern according to the controller type or option configuration.

Option

Standard A (*) Controlled stop by E-Stop (A05B-2600-J570) C (*)

R-30iB/ R-30iB Mate

(*) R-30iB / R-30iB Mate does not have servo disconnect. / R-30iB Mate does not have SVOFF input.

The stop pattern of the controller is displayed in "Stop pattern" line in software version screen. Please refer to "Software version" in operator's manual of controller for the detail of software version screen.

"Controlled stop by E-Stop" option

When "Controlled stop by E-Stop" (A05B-2600-J570) option is specified, the stop type of the following alarms becomes Controlled stop but only in AUTO mode. In T1 or T2 mode, the stop type is Power-Off stop which is the normal operation of the system.

Alarm Condition

SRVO-001 Operator panel E-stop Operator panel emergency stop is pressed. SRVO-002 Teach pendant E-stop Teach pendant emergency stop is pressed. SRVO-007 External emergency stops External emergency stop input (EES1-EES11, EES2-EES21) is

open. SRVO-408 DCS SSO Ext Emergency Stop In DCS Safe I/O connect function, SSO[3] is OFF. SRVO-409 DCS SSO Servo Disconnect In DCS Safe I/O connect function, SSO[4] is OFF.

Controlled stop is different from Power-Off stop as follows:

- In Controlled stop, the robot is stopped on the program path. This function is effective for a system where the robot can interfere with other devices if it deviates from the program path.

- In Controlled stop, physical impact is less than Power-Off stop. This function is effective for systems where the physical impact to the mechanical unit or EOAT (End Of Arm Tool) should be minimized.

- The stopping distance and stopping time of Controlled stop is longer than the stopping distance and stopping time of Power-Off stop, depending on the robot model and axis. Please refer to the operator's manual of a particular robot model for the data of stopping distance and stopping time.

When this option is loaded, this function cannot be disabled.

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SAFETY PRECAUTIONS B-83525EN/06

The stop type of DCS Position and Speed Check functions is not affected by the loading of this option.

WARNING

The stopping distance and stopping time of Controlled stop are longer than the

8 WARNING & CAUTION LABEL

(1) Step-on prohibitive label

Fig.8 (a) Step-on prohibitive label

Description Do not step on or climb the robot or controller as it may adversely affect the robot or controller

and you may get hurt if you lose your footing.

(2) High-temperature warning label

Fig.8 (b) High-Temperature warning label

Description Be cautious about a section where this label is affixed, as the section generates heat. If y ou

must touch such a section when it is hot, use a protective provision such as heat-resistant gloves.

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(3) High-voltage warning label

Fig.8 (c) High-voltage warning label

Description A high voltage is applied to the places where this label is attached. Before starting maintenance, turn the power to the controller off, and turn the circuit breaker

off to avoid electric shock hazards. Take additional precautions with the servo amplifier and other equipment, because high-voltage remains in these units for a certain amounts of time

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B-83525EN/06 PREFACE

PREFACE

This manual describes the following models (R-30iB Mate controller).

Model Abbreviation Controller Size

FANUC Robot LR Mate 200iD LR Mate 200iD FANUC Robot LR Mate 200iD/4S LR Mate 200iD/4S FANUC Robot LR Mate 200iD/7L LR Mate 200iD/7L FANUC Robot LR Mate 200iD/7C LR Mate 200iD/7C FANUC Robot LR Mate 200iD/4SC LR Mate 200iD/4SC FANUC Robot LR Mate 200iD/7LC LR Mate 200iD/7LC FANUC Robot LR Mate 200iD/7H LR Mate 200iD/7H FANUC Robot LR Mate 200iD/4SH LR Mate 200iD/4SH FANUC Robot LR Mate 200iD/7WP LR Mate 200iD/7WP FANUC Robot M-1iA/0.5A M-1iA/0.5A FANUC Robot M-1iA/0.5S M-1iA/0.5S FANUC Robot M-1iA/1H M-1iA/1H FANUC Robot M-1iA/0.5AL M-1iA/0.5AL FANUC Robot M-1iA/0.5SL M-1iA/0.5SL FANUC Robot M-1iA/1HL M-1iA/1HL FANUC Robot M-2iA/3S M-2iA/3S FANUC Robot M-2iA/3SL M-2iA/3SL FANUC Robot M-2iA/6H M-2iA/6H FANUC Robot M-2iA/6HL M-2iA/6HL FANUC Robot M-2iA/3A M-2iA/3A FANUC Robot M-2iA/3AL M-2iA/3AL FANUC Robot M-3iA/6A M-3iA/6A FANUC Robot M-3iA/6S M-3iA/6S FANUC Robot M-3iA/12H M-3iA/12H FANUC Robot M-10iA M-10iA FANUC Robot M-10iA/6L M-10iA/6L FANUC Robot M-10iA/7L M-10iA/7L FANUC Robot M-10iA/8L M-10iA/8L FANUC Robot M-10iA/10S M-10iA/10S FANUC Robot M-10iA/10M M-10iA/10M FANUC Robot M-10iA/10MS M-10iA/10MS FANUC Robot M-10iA/12 M-10iA/12 FANUC Robot M-10iA/12S M-10iA/12S FANUC Robot M-20iA M-20iA FANUC Robot M-20iA/10L M-20iA/10L FANUC Robot M-20iA/12L M-20iA/12L FANUC Robot M-20iA/20M M-20iA/20M FANUC Robot M-20iA/35M M-20iA/35M FANUC Robot M-20iB/25 M-20iB/25 M-20iB FANUC Robot ARC Mate 50iD ARC Mate 50iD FANUC Robot ARC Mate 50iD/7L ARC Mate 50iD/7L

LR Mate 200iD

M-1iA

M-2iA

M-3iA

M-10iA

M-20iA

ARC Mate 50iD

Small

Large

Medium

Medium or Small

p-1

PREFACE B-83525EN/06

Model Abbreviation Controller Size

FANUC Robot ARC Mate 100iC FANUC ROBOWELD 100iC

FANUC Robot ARC Mate 100iC/6L FANUC ROBOWELD 100iC/6L

FANUC Robot ARC Mate 100iC/7L ARC Mate 100iC/7L FANUC Robot ARC Mate 100iC/8L ARC Mate 100iC/8L FANUC Robot ARC Mate 100iC/10S ARC Mate 100iC/10S FANUC Robot ARC Mate 100iC/12 ARC Mate 100iC/12 FANUC Robot ARC Mate 100iC/12S ARC Mate 100iC/12S FANUC Robot ARC Mate 120iC

FANUC ROBOWELD 120iC FANUC Robot ARC Mate 120iC/10L

FANUC ROBOWELD 120iC/10L FANUC Robot ARC Mate 120iC/12L ARC Mate 120iC/12L FANUC Robot ARC Mate 0iB ARC Mate 0iB ARC Mate 0iB FANUC Robot R-0iB R-0iB R-0iB FANUC Robot R-2000iC/125L R-2000iC/125L FANUC Robot R-2000iC/165F R-2000iC/165F FANUC Robot R-2000iC/165R R-2000iC/165R FANUC Robot R-2000iC/210F R-2000iC/210F FANUC Robot R-2000iC/210R R-2000iC/210R FANUC Robot R-1000iA/80F R-1000iA/80F FANUC Robot R-1000iA/100F R-1000iA/100F FANUC Robot M-710iC/70 M-710iC/70 FANUC Robot M-710iC/70T M-710iC/70T FANUC Robot M-710iC/50 M-710iC/50 FANUC Robot M-710iC/50S M-710iC/50S FANUC Robot M-710iC/50T M-710iC/50T FANUC Robot M-710iC/50E M-710iC/50E FANUC Robot M-710iC/45M M-710iC/45M FANUC Robot M-710iC/20L M-710iC/20L FANUC Robot M-710iC/20M M-710iC/20M FANUC Robot M-710iC/12L M-710iC/12L

Explanation of Controller size

Controller size

Small 400X470X322 Small 10A Single phase/Three phase

Medium 400X470X402 Large 20A Three phase

Large 400X470X402 Large 30A Three phase

Dimension

(Height X Width X Depth)

ARC Mate 100iC

ARC Mate 100iC/6L

ARC Mate 120iC

ARC Mate 120iC/10L

Discharge

resistor

ARC Mate 100iC

ARC Mate 120iC

R-2000iC

R-1000iA

M-710iC

Breaker

capacity

Medium

Medium Medium

Large

Single phase/Three phase

p-2

B-83525EN/06 TABLE OF CONTENTS

SAFETY PRECAUTIONS............................................................................s-1

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

I. MAINTENANCE

1 OVERVIEW .............................................................................................3

2 CONFIGURATION .................................................................................. 4

2.1 EXTERNAL VIEW OF THE CONTROLLER .................................................. 4

2.2 COMPONENT FUNCTIONS.......................................................................... 8

2.3 CHECKS AND MAINTENANCE .................................................................... 9

3 TROUBLESHOOTING .......................................................................... 11

3.1 POWER CANNOT BE TURNED ON ........................................................... 11

3.1.1 When the Teach Pendant Cannot be Powered on...................................................11

3.1.2 When the Teach Pendant does not Change from the Initial Screen .......................12

3.2 ALARM OCCURRENCE SCREEN.............................................................. 13

3.3 STOP SIGNALS ..........................................................................................15

3.4 MASTERING ...............................................................................................16

3.5 TROUBLESHOOTING USING THE ALARM CODE.................................... 18

3.6 FUSE-BASED TROUBLESHOOTING......................................................... 63

3.7 TROUBLESHOOTING BASED ON LED INDICATIONS ............................. 67

3.7.1 Troubleshooting Using the LEDS On the Main Board ..........................................67

3.7.2 Troubleshooting by LEDs on the 6-Axis Servo Amplifier ....................................71

3.7.3 Troubleshooting by LED on the Emergency Stop Board.......................................72

3.7.4 Troubleshooting by Alarm LEDs on the Process I/O Board ..................................74

3.8 MANUAL OPERATION IMPOSSIBLE ......................................................... 74

3.9 LEDS ON UNITS SUPPORTING I/O LINK i ................................................ 75

3.9.1 Meanings of LEDs on Units Supporting I/O Link i ...............................................75

4 PRINTED CIRCUIT BOARDS...............................................................77

4.1 MAIN BOARD.............................................................................................. 77

4.2 EMERGENCY STOP BOARD (A20B-2005-0150)....................................... 80

4.3 BACKPLANE ............................................................................................... 80

4.4 PROCESS I/O BOARD MA (A20B-2004-0381)........................................... 81

4.5 PROCESS I/O BOARD MB (A20B-2101-0731)........................................... 82

4.6 CONNECTOR CONVERTER BOARD (A20B-2004-0411) .......................... 83

4.7 TERMINAL CONVERTER BOARD (A20B-1009-0690) ............................... 83

5 6-AXIS SERVO AMPLIFIERS............................................................... 84

5.1 LEDS OF 6-AXIS SERVO AMPLIFIER........................................................ 85

5.2 SETTING OF 6-AXIS SERVO AMPLIFIER ................................................. 86

5.3 6-AXIS SERVO AMPLIFIER SPECIFICATIONS ......................................... 87

6 POWER SUPPLY ..................................................................................88

6.1 BLOCK DIAGRAM OF THE POWER SUPPLY ........................................... 88

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TABLE OF CONTENTS B-83525EN/06

7 REPLACING UNITS.............................................................................. 89

7.1 REPLACING THE PRINTED-CIRCUIT BOARDS ....................................... 89

7.1.1 Replacing the Backplane Board (Unit)...................................................................90

7.1.2 Replacing the Main Board......................................................................................91

7.2 REPLACING CARDS AND MODULES ON THE MAIN BOARD ................. 91

7.3 REPLACING THE EMERGENCY STOP UNIT............................................ 96

7.4 REPLACING THE EMERGENCY STOP BOARD ....................................... 96

7.5 REPLACING THE POWER SUPPLY UNIT................................................. 97

7.6 REPLACING THE REGENERATIVE RESISTOR UNIT .............................. 98

7.7 REPLACING THE 6-AXIS SERVO AMPLIFIER .......................................... 99

7.8 REPLACING THE TEACH PENDANT....................................................... 101

7.9 REPLACING THE CONTROL SECTION FAN MOTOR............................ 102

7.10 REPLACING THE AC FAN MOTOR ......................................................... 103

7.10.1 Replacing the Heat Exchanger and Door Fan Unit ..............................................103

7.11 REPLACING THE BATTERY .................................................................... 104

7.11.1 Battery for Memory Backup (3 VDC)..................................................................104

II. CONNECTIONS

1 OVERVIEW .........................................................................................109

2 BLOCK DIAGRAM ..............................................................................110

3 ELECTRICAL CONNECTIONS...........................................................111

3.1 CONNECTION DIAGRAM BETWEEN MECHANICAL UNITS .................. 111

3.2 CONNECTION TO FANUC I/O Link and FANUC I/O Link i ...................... 113

3.2.1 Connection of I/O Link and I/O Link i by Using JRS26 Connector ....................113

3.2.1.1 Connection of the I/O Link cable by using JRS26 connector.......................... 114

3.2.1.2 Cable connection diagram of the I/O Link cable by using JRS26 connector .. 115

3.2.2 Connection of JD44A Connector(Option)............................................................116

3.2.2.1 Connection of the I/O Link cable by using JD44A connector......................... 116

3.2.2.2 Cable connection diagram of the I/O Link cable by using JD44A connector . 117

3.3 EXTERNAL CABLE WIRING DIAGRAM................................................... 117

3.3.1 Robot Connection Cables .....................................................................................117

3.3.2 Teach Pendant Cable ............................................................................................120

3.3.3 Connecting the Input Power .................................................................................120

3.3.3.1 Connecting the input power cable ................................................................... 120

3.3.3.2 Isolated transformer......................................................................................... 121

3.3.3.3 Leakage breaker............................................................................................... 122

3.3.4 Connecting the External Emergency Stop............................................................123

3.3.5 Connecting the Auxiliary Axis Brake (CRR65 A/B) ...........................................129

3.3.6 Connecting the Auxiliary Axis Over Travel (CRM68) ........................................130

4 PERIPHERAL DEVICE, ARC WELDING, AND EE INTERFACES ....131

4.1 PERIPHERAL DEVICE INTERFACE BLOCK DIAGRAM.......................... 133

4.1.1 In Case of Main Board (CRMA15, CRMA16) ....................................................133

4.1.2 In the Case of the Process I/O Board MA ............................................................133

4.1.3 In the Case of the Process I/O Board MB ............................................................134

4.1.4 In the Case of the Connector Conversion Board ..................................................134

4.1.5 In the Case of the Terminal Converter Board.......................................................135

4.2 I/O SIGNALS OF MAIN BOARD................................................................ 136

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B-83525EN/06 TABLE OF CONTENTS

4.3 INTERFACE FOR PERIPHERAL DEVICES.............................................. 138

4.3.1 Connection between the Main Board (CRMA15, CRMA16) and

Peripheral Devices................................................................................................138

4.3.2 Connection between the Connector Converter Board and Peripheral Devices ....144

4.3.3 Connection between the Terminal Converter Board and Peripheral Devices ......145

4.3.4 Connection between the Process I/O Board MA and Peripheral Devices ............146

4.4 INTERFACE FOR WELDING MACHINES ................................................ 150

4.4.1 Connection between the Process I/O Board MB and Welding Machines ............150

4.5 EE INTERFACE......................................................................................... 152

4.5.1 Connection between the Robot and End Effector ................................................152

4.6 DIGITAL I/O SIGNAL SPECIFICATIONS.................................................. 155

4.6.1 Peripheral Device Interface A ..............................................................................155

4.6.2 EE Interface ..........................................................................................................157

4.6.3 I/O Signal Specifications for ARC-Welding Interface

(A-cabinet/Process I/O Board MB) ......................................................................158

4.7 SPECIFICATIONS OF THE CABLES USED FOR

PERIPHERAL DEVICES AND WELDERS ................................................ 161

4.7.1 Peripheral Device Interface A1 Cable

(CRMA15: Tyco Electronics AMP, 40 pins) .......................................................161

4.7.2 Peripheral Device Interface A2 Cable

(CRMA16: Tyco Electronics AMP, 40 pins) .......................................................161

4.7.3 Peripheral Device Interface B1 and B2 Cables

(CRMA52; Tyco Electronics AMP, 30 pin).........................................................162

4.7.4 ARC Weld Connection Cables

(CRW11; Tyco Electronics AMP, 20 pin) ...........................................................162

4.8 CABLE CONNECTION FOR THE PERIPHERAL DEVICES, END

EFFECTORS, AND ARC WELDERS ........................................................ 163

4.8.1 Peripheral Device Connection Cable....................................................................163

4.8.2 Peripheral Device Cable Connector .....................................................................164

4.8.3 Recommended Cables ..........................................................................................166

4.9 CONNECTION OF HDI ............................................................................. 167

4.9.1 Connecting HDI ...................................................................................................167

4.9.2 Input Signal Rules for the High-speed Skip (HDI) ..............................................168

4.10 CONNECTING THE COMMUNICATION UNIT ......................................... 169

4.10.1 RS232C Interface .................................................................................................169

4.10.1.1 Interface ........................................................................................................... 169

4.10.1.2 RS232C interface signals................................................................................. 170

4.10.1.3 Connection between RS232C interface and I/O device................................... 170

4.10.2 Ethernet Interface .................................................................................................172

4.10.2.1 Connection to Ethernet ....................................................................................172

4.10.2.2 Routing of the Ethernet cable ..........................................................................173

4.10.2.3 100BASE-TX connector (CD38A, CD38B) pin assignments......................... 173

4.10.2.4 Twisted-pair cable specification...................................................................... 174

4.10.2.5 Electrical noise countermeasures..................................................................... 177

4.10.2.6 Check items at installation............................................................................... 180

5 TRANSPORTATION AND INSTALLATION ....................................... 181

5.1 TRANSPORTATION.................................................................................. 181

5.2 INSTALLATION ......................................................................................... 182

5.2.1 Installation Method...............................................................................................182

5.2.2 Assemble at Installation .......................................................................................184

5.3 INSTALLATION OF TEACH PENDANT HOOK (OPTION) ....................... 185

5.4 INSTALLATION CONDITION .................................................................... 186

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TABLE OF CONTENTS B-83525EN/06

5.5 ADJUSTMENT AND CHECKS AT INSTALLATION .................................. 189

5.6 RESETTING OVERTRAVEL AND EMERGENCY STOP

AT INSTALLATION.................................................................................... 189

5.6.1 Peripheral Device Interface Processing ................................................................189

5.6.2 Resetting Overtravel .............................................................................................190

5.6.3 How to Disable/Enable HBK ...............................................................................190

5.6.4 How to Disable/Enable Pneumatic Pressure Alarm (PPABN).............................190

APPENDIX

A SPECIFICATION LIST ........................................................................ 193

B TOTAL CONNECTION DIAGRAM......................................................196

C SPECIFICATIONS OF PERIPHERAL DEVICE INTERFACE............. 220

C.1 SIGNAL .....................................................................................................220

C.2 SETTING COMMON VOLTAGE................................................................ 222

C.3 I/O SIGNALS ............................................................................................. 222

C.3.1 Input Signals.........................................................................................................222

C.3.2 Output Signals ......................................................................................................225

C.4 SPECIFICATIONS OF DIGITAL INPUT/OUTPUT.....................................228

C.4.1 Overview ..............................................................................................................228

C.4.2 Input/Output Hardware Usable in the R-30iB Mate Controller ...........................228

C.4.3 Software Specifications ........................................................................................229

D OPTICAL FIBER CABLE....................................................................230

E BRAKE RELEASE UNIT.....................................................................233

E.1 SAFETY PRECAUTIONS..........................................................................233

E.2 CONFIRMATIONS BEFORE OPERATION............................................... 233

E.3 OPERATION.............................................................................................. 234

E.3.1 In Case of Operating to the Robot........................................................................234

E.3.2 In Case of Operating to the Auxiliary Axis..........................................................236

E.4 HOW TO CONNECT THE PLUG TO THE POWER CABLE

(IN CASE OF NO POWER PLUG) ............................................................237

E.5 DIMENSION .............................................................................................. 238

E.6 FUSE ......................................................................................................... 239

E.7 SPECIFICATIONS..................................................................................... 240

F TEACH PENDANT DISCONNECT FUNCTION (OPTION).................241

F.1 CONFIGURATION..................................................................................... 241

F.2 PROCEDURE OF TEACH PENDANT DISCONNECT .............................. 241

F.2.1 Teach Pendant Disconnect ...................................................................................241

F.2.2 Teach Pendant Connect ........................................................................................242

G INSTRUCTION FOR TERMINAL BLOCK .......................................... 243

G.1 EXTERNAL EMERGENCY STOP SIGNAL INPUT/OUTPUT

TERMINAL BLOCK ...................................................................................243

G.2 TERMINAL CONVERTER BOARD TERMINAL BLOCK ........................... 245

H REPLACING THE PROTECTION SHEET .......................................... 246

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B-83525EN/06 TABLE OF CONTENTS

I SEALING OF THE CABLE ENTRANCE OF THE CABINET .............247

I.1 CABLE ENTRANCE FOR Mate-CABINET ................................................ 247

I.2 HOLES OF CABLE SEAL BLOCK FOR CABLE ENTRANCE................... 248

I.3 SUITABLE CABLE DIAMETER ................................................................. 249

I.4 ADJUST THE CABLE DIAMETER ............................................................ 250

c - 5

I. MAINTENANCE

B-83525EN/06 MAINTENANCE 1. OVERVIEW

1 OVERVIEW

This manual is applied to R-30iB Mate controller (called R-30iB Mate).

R-30iB Mate has three variations depending on the required standards.

Basic controller : To meet Safety Standard and General electrical requirement CE controller : To meet Machinery Directive, Low voltage Directive, EMC Directive to cover the requirement of CE mark NRTL controller : To meet UL/CSA standard

This manual covers these three variations of R-30iB Mate. The difference of NRTL and CE controller from Basic controller is small as shown in Table 1 (ex. EMC parts, Breakers). And the specific descriptions of CE and NRTL controller have notifications in this manual.

Table 1. Applied standards

Basic controller

CE controller

NRTL controller

Common Standard

ISO 10218-1 ISO 13849-1 IEC 60204-1 IEC 61508

This manual describes the maintenance and connection of R-30iB Mate.

･Maintenance Part: Troubleshooting, and the setting, adjustment, and replacement of units ･Connection Part: Connection of R-30iB Mate to the robot mechanical unit and peripheral devices,

and installation of the controller

WARNING

Before you enter the robot working area, be sure to turn off the power to the

controller or press the EMERGENCY STOP button on the operator's panel or teach pendant.

Otherwise, you could injure personnel or damage equipment.

EMC

Standard

- -

EN 55011 EN 61000-6-2 EN 61000-6-4

UL/CSA

Standard

UL1740 CAN/CSA Z434 NFPA79

Requirement Difference

Safety Standard General electrical requirement

CE Marking

•Europe UL standard

CSA standard

•USA and Canada

•Noise filter

•EMC Cabinet

•Shielded cable

•UL listed main breaker

- 3 -

2. CONFIGURATION MAINTENANCE B-83525EN/06

2 CONFIGURATION

2.1 EXTERNAL VIEW OF THE CONTROLLER

The appearance and components might slightly differ depending on the controlled robot, application, and options used. Fig.2.1 (a) shows the view of R-30iB Mate. Fig.2.1 (b) to (d) show the construction of the R-30iB Mate controller. Fig.2.1 (e) to (g) show the external view of the operator’s panel and teach pendant.

Teach pendant hook (Option)

Operator’s panel

Breaker

Key

Teach pendant

(iPendant)

Fig.2.1 (aa) External view of the R-30iB Mate controller

NOTE

Be sure to lock the key.

USB port (Option)

Rear fan unit

Fig.2.1 (ab) External view of the R-30iB Mate controller (Middle/Large size) (Rear)

- 4 -

B-83525EN/06 MAINTENANCE 2. CONFIGURATION

Emergency stop button

Main board

Battery

Back plane unit

mode switch

Heat exchanger 6-Axis Servo amplifier

Fig.2.1 (b) R-30iB Mate cabinet interior (Front-1)

Noise Filter (EMC Option)

Breaker

E-stop unit

Fig.2.1 (c) R-30iB Mate cabinet interior (Front-2)

Power supply unit

Process I/O board (Option)

- 5 -

2. CONFIGURATION MAINTENANCE B-83525EN/06

Line filter

Regenerative resistor

(Small size)

6-Axis Servo amplifier (Rear side)

Line filter

6-Axis Servo amplifier (Rear side)

(Middle size) (Large size)

Fig.2.1 (da) R-30iB Mate cabinet interior (Rear)

Regenerative resistor

6-Axis Servo amplifier (Rear side)

Rear fan unit

Fig.2.1 (db) R-30iB Mate cabinet interior (Middle/Large size) (Rear)

- 6 -

B-83525EN/06 MAINTENANCE 2. CONFIGURATION

NOTE

The number of fans on the fan unit (0,1,2) will vary depending on the robot type.

Mode switch (In case of 3-mode switch)

Emergency Stop button

Enable/disable switch

CYCLE START button with LED(Green)

Fig.2.1 (e) R-30iB Mate operator’s panel

2 mo de sw itch 3 mode swit ch

Fig.2.1 (f) Mode switch

Emergency Stop button

USB port

Fig.2.1 (g) Teach pendant (iPendant)

- 7 -

Deadman sw it ch

2. CONFIGURATION MAINTENANCE B-83525EN/06

2.2 COMPONENT FUNCTIONS

Fig.2.2 Block diagram of the R-30iB Mate

- 8 -

B-83525EN/06 MAINTENANCE 2. CONFIGURATION

- Main board The main board contains a microprocessor, its peripheral circuits, memory, and operator's panel

control circuit. The main CPU controls servo mechanism positioning.

- I/O printed circuit board Various ty pes of printed circuit boards are provided for applications including process I/O board.

These are connected with FANUC I/O Link.

- E-stop unit This unit controls the emergency stop system of the robot controller. It also has user interface

terminals of safety relevant signals, external on/off signals etc.

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

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

- Teach pendant All operations including robot programming are performed with this unit. The controller status and

data are indicated on the liquid-crystal display (LCD) on the pendant.

- 6-Axis Servo amplifier The servo amplifier controls servomotor, Pulsecoder signal, brake control, overtravel and hand

broken.

- Operator's panel Buttons and LEDs on the operator's panel are used to start the robot and to indicate the robot status.

- Fan unit, heat exchanger These components cool the inside of the controller.

- Circuit breaker If the electric system in the controller malfunctions, or if abnormal input power causes high current

in the system, the input power is connected to the circuit breaker to protect the equipment.

- Regenerative resistor To discharge the counter electromotive force from the servomotor, connect a regenerative resistor to

the servo amplifier.

2.3 CHECKS AND MAINTENANCE

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

(1) Daily maintenance Before operating the system each day, clean each part of the system and check the system parts for

any damage or cracks. Also, check the following: (a) Before operation Check the cable connected to the teach pendant for excessive twisting. Check the controller

and peripheral devices for abnormalities. (b) After operation At the end of operation, return the robot to the specified position, and then turn off the

controller. Clean each part, and check for any damage or cracks. If the ventilation port of

the controller is dusty, clean it.

(2) Check after one month Check that the fan is rotating normally. If the fan has dirt and dust built up, clean the fan according

to step (3) described below for inspection to be performed every 6 months. (3) Periodic inspection performed every six months Remove any dirt and dust from the inside of the cabinet. Wipe off dirt and dust from the fan. (4) Battery daily check Replace the battery on the front panel of the main board every 4 years. Please refer to the Section

7.11.

(5) Maintenance tools

- 9 -

2. CONFIGURATION MAINTENANCE B-83525EN/06

The following maintenance tools are recommended:

(a) Measuring instruments AC/DC voltmeter (A digital voltmeter is sometimes required.) Oscilloscope with a frequency range of 5 MHz or higher, two channels (b) Tools Cross-head screwdrivers: Large, medium, and small Straight-head screwdrivers: Large, medium, and small Nut driver set (Metric) Pliers Needle-nose pliers Diagonal cutting pliers

- 10 -

B-83525EN/06 MAINTENANCE 3. TROUBLESHOOTING

3 TROUBLESHOOTING

This chapter describes the checking method and corrective action for each alarm code indicated if a hardware alarm occurs. Refer to the R-30iB/R-30iB Mate OPERATOR’S MANUAL (ALARM CODE LIST) (B-83284EN-1) to release program alarms.

3.1 POWER CANNOT BE TURNED ON

Check and Corrective action Figure

(Check 1) Check that the circuit

breaker is on and has not

tripped. (Corrective action)

a) If circuit breaker is OFF.

Turn on the circuit breaker.

b) If the circuit breaker has

tripped, find the cause by referencing the total connection diagram presented in the appendix.

Circuit Breaker

3.1.1 When the Teach Pendant Cannot be Powered on

Inspection and action Illustration

(Inspection 1) Confirm that fuse (FUSE3) on the

emergency stop board is not blown. When it is blown, the LED on the emergency stop board lights in red. When fuse (FUSE3) is blown, carry out action 1 and replace the fuse.

(Inspection 2) When fuse (FUSE3) is not blown,

carry out action 2.

(Action 1) (a) Check the cable of the teach

pendant for failure and replace it as necessary. (b) Check the teach pendant for failure and replace it as necessary. (c) Replace the emergency stop board.

(Action 2) When the LED on the main board

does not light, replace the emergency stop unit. When the LED on the main board lights, carry out action 1.

Teach pendant

FUSE3

LED (Red)

- 11 -

3. TROUBLESHOOTING MAINTENANCE B-83525EN/06

3.1.2 When the Teach Pendant does not Change from the Initial

Screen

Inspection and action Illustration

(Inspection 1)

Check that the status display LED and 7-segment LED on the main board operate normally.

(Action) Carry out an action according to the

LED status. For details, see "TROUBLESHOOTING USING THE LEDS ON THE MAIN BOARD".

7 Segment LED

(Inspection 2) When the LED on the main board

does not light in inspection 1, check if fuse (FUSE1) on the main board is blown. (a) When fuse (FUSE1) is blown See action 1. (b) When fuse (FUSE1) is not blown See action 2.

(Action 1) (a) Replace the backplane board.

(b) Replace the main board. (c) When an option board is installed in the mini slot, replace the option board.

(Action 2) (a) Replace the emergency stop

unit. (b) Replace the cable between the main board and the emergency stop unit. (c) Replace the boards indicated in action 1.

Back plane

RLED1

LEDG1 LEDG2 LEDG3 LEDG4

(Red)

(Green)

FUSE1

Mini slot (2slot)

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B-83525EN/06 MAINTENANCE 3. TROUBLESHOOTING

3.2 ALARM OCCURRENCE SCREEN

The alarm occurrence screen displays only the alarm conditions that are currently active. If an alarm reset signal is input to reset the alarm conditions, the alarm occurrence screen displays the message "PAUSE or more serious alarm has not occurred." The alarm occurrence screen displays only the alarm conditions (if any) that occur after the most recently entered alarm reset signal. To erase all alarm displays from the alarm occurrence screen. Press the CLEAR key (+ shift) on the alarm history screen. The alarm occurrence screen is intended to display PAUSE or alarms that are more serious. It will not display WARN, NONE, or a reset. It is possible to disable PAUSE and some of more serious alarms from being displayed by setting the $ER_NOHIS system variable appropriately. If two or more alarms have occurred, the display begins with the most recent alarm. Up to 100 lines can be displayed. If an alarm has a cause code, it is displayed below the line indicating the alarm.

Press the screen selection key to select [4 ALARM].

larm occurrence screen display

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

larm history screen display

Fig.3.2 Alarm occurrence screen and alarm history screen display procedure

utomatic alarm display

upon occurrence

Displaying the alarm active/ alarm history/alarm detail information

Step

(1) Press the [MENU] key to display the screen menu. (2) Select [ALARM]. You will see a screen similar to the following. If an alarm has occurred, however, the alarm screen appears automatically.

larm : Active 1/2 1 INTP-224 (TEST1, 6) Jump label faile MEMO-027 Specified line does not exi

[ TYPE ] [ VIEW ] HIST RES_1CH

INTP-224 (TEST1, 6)Jump label faile

EMO-027 Specified line does not exis JOINT

- 13 -

30%

larm detail code

3. TROUBLESHOOTING MAINTENANCE B-83525EN/06

(3) To display the alarm history screen, press F3, [HIST]. Press F3 [ACTIVE] again, the alarm screen appears.

Alarm : Hist 1/25 1 INTP-224 (TEST1, 6) Jump label faile 2 R E S E T 3 SRVO-007 External emergency stop 4 SRVO-001 Operator panel E-stop 5 R E S E T 6 SRVO-001 Operator panel E-stop 7 SRVO-012 Power failure recovery 8 INTP-127 Power fail detected 9 SRVO-047 LVAL alarm (Group:1 Axis:5) 10 SRVO-047 LVAL alarm (Group:1 Axis:4) 11 SRVO-002 Teach pendant E-stop

[ TYPE ] [ VIEW ] ACTIVE CLEAR DETAIL

NOTE

The latest alarm is assigned number 1. To view messages that are currently

not on the screen, press the F5, HELP, and then press the right arrow key.

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

Alarm : Hist DETAIL Alarm INTP-224 (TEST1, 6) Jump label failed MEMO-027 Specified line does not exist

STOP.L 21-NOV-11 12:16 Alarm : Hist 1 INTP-224 (TEST1, 6) Jump label faile 2 R E S E T

3 SRVO-007 External emergency stop 4 SRVO-001 Operator panel E-stop 5 R E S E T 6 SRVO-001 Operator panel E-stop 7 SRVO-012 Power failure recovery

[ TYPE ] [ VIEW ] ACTIVE CLEAR DETAIL

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

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

NOTE

When system variable $ER_NOHIS = 1, NONE alarms or WARN alarms are not

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

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B-83525EN/06 MAINTENANCE 3. TROUBLESHOOTING

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

4 ALARM

F1 [TYPE]

Alarm : Active

F1 [TYPE] F3 HIST

Alarm : HIST

F1 [TYPE] F3 [ACTIVE] F4 CLEAR F5 HELP

DETAIL Alarm

F1 [TYPE] F3 [ACTIVE] F4 CLEAR F5 HELP

3.3 STOP SIGNALS

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

Table 3.3 Stop signals

Stop signal Description

Operator’s panel emergency stop Teach pendant emergency stop External emergency stop This item indicates the state of the external emergency stop signal. If the

Fence open This item indicates the state of the safety fence. If the safety fence is open, the state is

DEADMAN switch This item indicates whether the DEADMAN switch on the teach pendant is grasped. If

Teach pendant operable This item indicates whether the teach pendant is operable. If the teach pendant is

Hand broken This item indicates the state of the hand safety joint. If the hand interferes with a

This item indicates the state of the emergency stop button on the operator’s panel. If the EMERGENCY STOP button is pressed, the state is indicated as “TRUE”. This item indicates the state of the emergency stop button on the teach pendant. If the EMERGENCY STOP button is pressed, the state is indicated as “TRUE”.

EMERGENCY STOP signal is asserted, the state is indicated as “TRUE”.

indicated as “TRUE”.

the teach pendant is operable, and the DEADMAN switch is grasped correctly, the state is indicated as “TRUE”. If the DEADMAN switch is released or is grasped tightly when the teach pendant is operable, an alarm occurs, causing the servo power to be switched off.

operable, the state is indicated as “TRUE”.

workpiece or anything like this, and the safety joint is opened, the state is indicated as “TRUE”. In this case, an alarm occurs, causing the servo power to be switched off.

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3. TROUBLESHOOTING MAINTENANCE B-83525EN/06

Stop signal Description

Robot overtravel This item indicates whether the current position of the robot is out of the operation

range. If any robot articulation goes out of the operation range beyond the overtravel switch, the state is indicated as “TRUE”. In this case, an alarm occurs, causing the servo power to be switched off.

Abnormal air pressure This item indicates the state of the air pressure. The abnormal air pressure signal is

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

Step

(1) Press [MENU] key to display the screen menu. (2) Select STATUS on the next page. (3) Press F1, [TYPE] to display the screen switching menu. (4) Select Stop Signal. You will see a screen similar to the following.

STATUS Stop Signal SIGNAL NAME STATUS 1/12

1 SOP E-Stop: FALSE 2 TP E-STOP: FALSE 3 EXT E-STOP: FALSE 4 Fence Open: FALSE 5 TP Deadman: TRUE 6 TP Enable: TRUE 7 Hand Broken: FALSE 8 Overtravel: FALSE 9 Low Air Alarm: FALSE 10 Belt Broken: FALSE 11 SVOFF Input: FALSE 12 Non Teacher Enb. Dev.: FALSE

[ TYPE ]

3.4 MASTERING

Mastering is needed if: (1) The SRVO-062 BZAL or SRVO-038 pulse mismatch alarm occurs, or (2) The Pulsecoder is replaced. Item (1) requires quick mastering, while item (2) requires single axis or fixture position mastering. The mastering procedure is described below. For details, refer to an applicable maintenance manual of mechanical unit or Mastering chapter of the Appendix B of the R-30iB/R-30iB Mate OPERATOR’S MANUAL (BASIC OPERATION) (B-83284EN) .

Condition

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

SYSTEM Variables

272 $MASTER_ENB 1

Step

(1) Press the [MENU] key to display the screen menu. (2) Select SYSTEM on the next page. (3) Press F1, [TYPE] to display the screen switching menu. (4) Select Master/Cal you will see a screen similar to the following.

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B-83525EN/06 MAINTENANCE 3. TROUBLESHOOTING

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

screen if necessary.

SYSTEM Master/Cal TORQUE = [ON ] 1 FIXTURE POSITION MASTER 2 ZERO POSITION MASTER 3 QUICK MASTER 4 QUICK MASTER FOR SINGLE AXIS 5 SINGLE AXIS MASTER 6 SET QUICK MASTER REF 7 CALIBRATE

Press ‘ENTER’ or number key to select.

[ TYPE ] LOAD RES_PCA DONE

NOTE

Mastering cannot be performed until axis is rotated enough to establish a pulse.

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

SYSTEM Master/Cal TORQUE = [ON ] 1 FIXTURE POSITION MASTER 2 ZERO POSITION MASTER 3 QUICK MASTER 4 QUICK MASTER FOR SINGLE AXIS

5 SINGLE AXIS MASTER 6 SET QUICK MASTER REF 7 CALIBRATE Robot Mastered! Mastering Data: <-3105333> <-13216881> <22995280> <-1354153> <0> <0>

[ TYPE ] LOAD RES_PCA DONE

(7) Select "7 CALIBRATE" and press the F4 key (yes). Calibration is performed. Alternatively, to perform positioning, turn the power off, and then turn it on again. Calibration is

performed whenever the power is turned on.

SYSTEM Master/Cal TORQUE = [ON ] 1 FIXTURE POSITION MASTER 2 ZERO POSITION MASTER 3 QUICK MASTER 4 QUICK MASTER FOR SINGLE AXIS

5 SINGLE AXIS MASTER 6 SET QUICK MASTER REF 7 CALIBRATE Robot Calibrated! Cur Jnt Ang(deg): < 0.0000> < 24.6528> < -94.2241> < 0.0000> < -85.7759> < 0.0000>

[ TYPE ] LOAD RES_PCA DONE

(8) Press F5 "DONE", after mastering. (9) Restore the brake condition to its original condition.

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3. TROUBLESHOOTING MAINTENANCE B-83525EN/06

3.5 TROUBLESHOOTING USING THE ALARM CODE

SRVO-001 Operator panel E-stop

(Explanation) The emergency stop button on the operator's panel is pressed. (Action 1) Release the emergency stop button pressed on the operator's panel. (Action 2) Check the wires connecting between the emergency stop button and the emergency

stop board (CRT30) for continuity. If an open wire is found, replace the entire harness.

(Action 3) Check the wires connecting between the teach pendant and the emergency stop board

(CRS36) for continuity. If an open wire is found, replace the entire harness.

(Action 4) With the emergency stop in the released position, check for continuity across the

terminals of the switch. If continuity is not found, the emergency stop button is

broken. Replace the emergency stop button or the operator's panel. (Action 5) Replace the teach pendant. (Action 6) Replace the emergency stop board.

Before executing the (Action 7), perform a complete controller back-up to save all your programs

and settings.

(Action 7) Replace the main board.

NOTE

If SRVO-001 is issued together with SRVO-213, a fuse may have blown. Take

the same actions as for SRVO-213.

Emergency stop button

CRT30

CRS36

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

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B-83525EN/06 MAINTENANCE 3. TROUBLESHOOTING

SRVO-002 Teach pendant E-stop

(Explanation) The emergency stop button on the teach pendant was pressed. (Action 1) Release the emergency stop button on the teach pendant. (Action 2) Replace the teach pendant.

SRVO-003 Deadman switch released

(Explanation) The teach pendant is enabled, but the deadman switch is not pressed. Alternatively,

the deadman switch is pressed strongly. (Action 1) Check the intermediate position of the deadman switch on the teach pendant. (Action 2) Check that the mode switch on the operator's panel and the enable/disable switch on

the teach pendant are at the correct positions. (Action 3) Replace the teach pendant. (Action 4) Check the mode switch connection and operation. If trouble is found, replace the

mode switch. (Action 5) Replace the emergency stop board.

Enable/disable

Emergency stop button

(Teach pendant)

2 mode switch

(Mode switch)

Emergency stop board

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

SRVO-003 Deadman switch released

Deadman switch

3 mode switch

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3. TROUBLESHOOTING MAINTENANCE B-83525EN/06

SRVO-004 Fence open

(Explanation) In the automatic operation mode, the safety fence contact connected to EAS1-EAS11

or EAS2-EAS21 of TBOP20 is open. (Action 1) When a safety fence is connected, close the safety fence. (Action 2) Check the cables and switches connected between EAS1 and EAS11 and between

EAS2 and EAS21 of the terminal block TBOP20 on the emergency stop board. (Action 3) If the safety fence signal is not used, make a connection between EAS1 and EAS11

and between EAS2 and EAS21 of the terminal block TBOP20 on the emergency stop

board. (Action 4) Check the mode switch. If trouble is found, replace the mode switch. (Action 5) Replace the emergency stop board.

NOTE

If SRVO-004 is issued together with SRVO-213, a fuse may have blown. Take

the same actions as for SRVO-213.

2 mode switch

(Mode switch)

3 mode switch

TBOP20

No. Name 12 21

E-STOP

(ESPB)

11 2 10 11 9 8 21

FENCE

(EAS)

7 2 6 11 5 4 21

EMGIN

(EES)

3 2 2 11 1

Fig.3.5 (c) SRVO-004 Fence open

WARNING

In a system using the safety fence signal, it is very dangerous to disable the

signal when a connection is made between EAS1 and EAS11 and between EAS2 and EAS21. Never make such an attempt. If a temporary connection is needed for operation, separate safety measures must be taken.

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B-83525EN/06 MAINTENANCE 3. TROUBLESHOOTING

SRVO-005 Robot overtravel

(Explanation) The robot has moved beyond a hardware limit switch on the axes. (Action 1) 1) Select [System OT release] on the overtravel release screen to release each robot

axis from the overtravel state.

2) Hold down the shift key, and press the alarm release button to reset the alarm

condition.

3) Still hold down the shift key, and jog to bring all axes into the movable range. (Action 2) Replace the limit switch. (Action 3) Check the FS2 fuse on the servo amplifier. If the SRVO-214 6ch amplifier fuse

blown alarm is also generated, the FS2 fuse has blown. (Action 4) Check the EE connector. (Action 5) Replace the 6-Axis servo amplifier. (Action 6) Verify the following for connector RMP1, RP1 at the base of the robot:

1) There are no bent or dislocated pins in the male or female connectors.

2) The connector is securely connected. Then verify that connectors CRF8 and CRM68 on the servo amplifier are securely

connected. Also, verify that the robot connection cable (RMP1, RP1) is in good

condition, and there are no cuts or kinks visible. Check the internal cable of the robot

for a short circuit or connection to ground.

NOTE

It is factory-placed in the overtravel state for packing purposes. If the Overtravel signal is not in use, it may have been disabled by

short-circuiting in the mechanical unit.

SRVO-006 Hand broken

(Explanation) The safety joint (if in use) might have been broken. Alternatively, the HBK signal on

the robot connection cable might be a ground fault or a cable disconnection. (Action 1) Hold down the shift key, and press the alarm release button to reset the alarm

condition. Still hold down the shift key, and jog the tool to the work area.

1) Replace the safety joint.

2) Check the safety joint cable. (Action 2) Replace the 6-Axis servo amplifier. (Action 3) Verify the following for connector RMP1, RP1 at the base of the robot:

1) There are no bent or dislocated pins in the male or female connectors.

2) The connector is securely connected. Then verify that connectors CRF8 and CRM68 on the servo amplifier are securely

connected. Also, verify that the robot connection cable (RMP1, RP1) is in good

condition, and there are no cuts or kinks visible. Check the internal cable of the robot

for a short circuit or connection to ground.

NOTE

If the Hand broken signal is not in use, it can be disabled by software setting. Refer to Subsection 5.6.3 in CONNECTIONS to disable the Hand broken signal.

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3. TROUBLESHOOTING MAINTENANCE B-83525EN/06

6-Axis servo amplifier

Connector(CRM68)

Con nector(CRF8)

FS2 (3.2A)

(6-Axis servo amplifier)

Fig.3.5 (d) SRVO-005 Robot overtravel

SRVO-006 Hand broken

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B-83525EN/06 MAINTENANCE 3. TROUBLESHOOTING

SRVO-007 External emergency stops

(Explanation) On the terminal block TBOP20 of the emergency stop board, no connection of

external emergency stop is made between EES1 and EES11, EES2 and EES21. (Action 1) If an external emergency stop switch is connected, release the switch. (Action 2) Check the switch and cable connected to EES1-EES11 and EES2-EES21 on

TBOP20 of the emergency stop board. (Action 3) When this signal is not used, make a connection between EES1 and EES11, EES2

and EES21. (Action 4) Replace the emergency stop board.

NOTE

If SRVO-007 is issued together with SRVO-213, a fuse may have blown. Take

the same actions as for SRVO-213.

TBOP20

No. Name 12 21

E-STOP

(ESPB)

11 2 10 11 9 8 21

FENCE

(EAS)

7 2 6 11 5 4 21

EMGIN

(EES)

3 2 2 11 1

Fig.3.5 (e) SRVO-007 External emergency stops

WARNING

In a system using the external emergency stop signal, it is very dangerous to

disable the signal when a connection is made between EES1 and EES11 and between EES2 and EES21. Never make such an attempt. If a temporary connection is needed for operation, separate safety measures must be taken.

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3. TROUBLESHOOTING MAINTENANCE B-83525EN/06

SRVO-009 Pneumatic pressure alarm

(Explanation) An abnormal air pressure was detected. The input signal is located on the end EE

interface of the robot. Refer to the manual of your robot. (Action 1) If an abnormal air pressure is detected, check the cause. (Action 2) Check the EE connector. (Action 3) Check the robot connection cable (RMP1, RP1) and the internal cable of the robot

for a ground fault or a cable disconnection. If a fault or a disconnection is detected,

replace the cable. (Action 4) Replace the 6-Axis servo amplifier. (Action 5) Replace the internal cables of the robot.

NOTE

Pneumatic pressure alarm input is on the EE interface. Please refer to the

manual of your robot.

6-Axis servo amplifier

Fig.3.5 (f) SRVO-009 Pneumatic pressure alarm

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B-83525EN/06 MAINTENANCE 3. TROUBLESHOOTING

SRVO-014 Fan motor abnormal (n), CPU STOP

(Explanation) When a fan motor stops on backplane unit, Teach pendant shows the following

message. In one minutes from occurring of alarm, robot stops and cannot be operated

from TP. The robot can be recovered by replacing a fan motor. Number in the

bracket indicates which fan is abnormal. (1): FAN0 (2): FAN1 (3): both fans (Action 1) Check the fan motor and its cables. Replace them if necessary. (Action 2) Replace the fan board. Before executing the (Action 3), perform a complete controller back up to save all your programs and settings. (Action 3) Replace the main board.

NOTE

The controller will stop operation after 1 minutes of this alarm.

Fan motor (FAN0)

Fan motor (FAN1)

Main board

Fig.3.5 (g) SRVO-014 Fan motor abnormal

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3. TROUBLESHOOTING MAINTENANCE B-83525EN/06

SRVO-015 System over heat

(Explanation) The temperature in the controller exceeds the specified value. In one minutes from

occurring of alarm, robot stops and cannot be operated from TP. (Action 1) If the ambient temperature is higher than specified (45°C), cool down the ambient

temperature. (Action 2) If the fan motor is not running, check it, its cables and related fuses. Replace them if

necessary.

Before executing the (Action 3), perform a complete controller backup to save all your programs and

settings.

(Action 3) Replace the main board. (The thermostat on the main board may be faulty.)

NOTE

The controller will stop operation after 1 minutes of this alarm.

Door fan

Fan motor

Main board

Fig.3.5 (h) SRVO-015 System over heat

Heat exchanger

Rear fan

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B-83525EN/06 MAINTENANCE 3. TROUBLESHOOTING

SRVO-018 Brake abnormal (G:i A:j)

(Explanation) An excessive brake current is detected. The ALM LED (SVALM) on the 6-Axis

servo amplifier is lit. (Action 1) Check the robot connection cable (RMP1, RP1) and the internal cable of the robot

and motor brakes connected to CRR88 connector on the 6-Axis servo amplifier.

If a short-circuit or grounding fault is found, replace the failed part. (Action 2) Check the cables and motor brakes connected to CRR65A, CRR65B connector on

the 6-Axis servo amplifier. If a short-circuit or grounding fault is found, replace the

failed part. (Action 3) Replace the 6-Axis servo amplifier.

CAUTION

This error can be caused by the optional brake release unit if the on/off switch is

left in on position while the operator attempts to jog the robot. To recover, turn the brake release unit off and cycle the controller power.

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

(Explanation) The HRDY is on and the SRDY is off, although there is no other cause of an alarm.

(HRDY is a signal with which the host detects the servo system whether to turn on or

off the servo amplifier magnetic contactor. SRDY is a signal with which the servo

system informs the host whether the magnetic contactor is turned on.) If the servo amplifier magnetic contactor cannot be turned on when directed so, it is

most likely that a servo amplifier alarm has occurred. If a servo amplifier alarm has

been detected, the host will not issue this alarm (SRDY off). Therefore, this alarm

indicates that the magnetic contactor cannot be turned on for an unknown reason. (Action 1) Make sure that the emergency stop board connectors CP5A, CRMA92, CRMB22,

and 6-Axis servo amplifier CRMA91 are securely attached to the servo amplifier. In case of using aux. axis amplifier, make sure that the connectors CXA2A (6-axis

amplifier) or CXA2B (aux. axis amplifier) are securely attached to the servo

amplifier. (Action 2) It is possible that an instant disconnection of power source causes this alarm. Check

whether an instant disconnection occurred. (Action 3) Replace the E-stop unit. (Action 4) Replace the servo amplifier.

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

(Explanation) When the HRDY is about to go on, the SRDY is already on. (HRDY is a signal

with which the host directs the servo system whether to turn on or off the servo

amplifier magnetic contactor. SRDY is a signal with which the servo system

informs the host whether the magnetic contactor is turned on.) (Action 1) Replace the servo amplifier as the alarm message.

SRVO-023 Stop error excess (G:i A:j)

(Explanation) When the servo is at stop, the position error is abnormally large. Check whether the brake is released through the clack sound of the brake or

vibration.

In case that the brake is not released.

(Action 1) If the brake is not released, check the continuity of the brake line in the robot

connection cable and the mechanical unit cable. (Action 2) If the disconnection is not found, replace the 6-Axis servo amplifier or the servo

motor.

In case that the brake is released.

(Action 1) Check whether the obstacle disturbs the robot motion.

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3. TROUBLESHOOTING MAINTENANCE B-83525EN/06

(Action 2) Make sure that connectors CNJ1A-CNJ6 are securely attached to the 6-Axis servo

amplifier. (Action 3) Check the continuity of the robot connection cable and the internal robot power

cable. (Action 4) Check to see if the load is greater than the rating. If greater, reduce it to within the

rating. (If the load is too great, the torque required for acceleration / deceleration

becomes higher than the capacity of the motor. As a result, the motor becomes unable to follow the command, and an alarm is

issued.) (Action 5) Check the input voltage to the controller is within the rated voltage and no phase is

lack. Check each phase voltage of the CRR38A or CRR38B connector of the three-phase

power (200 VAC) input to the 6-Axis servo amplifier. If it is 210 VAC or lower,

check the line voltage. (If the voltage input to the 6-Axis servo amplifier becomes

low, the torque output also becomes low. As a result, the motor may become unable

to follow the command, hence possibly causing an alarm.). (Action 6) Replace the servo amplifier. (Action 7) Replace the motor of the alarm axis.

NOTE

Incorrect setting of the brake number causes this alarm.

6-Axis servo amplifier

Fig.3.5 (i) SRVO-018 Brake abnormal

SRVO-021 SRDY off SRVO-022 SRDY on SRVO-023 Stop error excess

SRVO-024 Move error excess (G:i A:j)

(Explanation) When the robot is running, its position error is greater than a specified value

($PARAM _ GROUP. $MOVER _ OFFST). It is likely that the robot cannot

follow the speed specified by program. (Action 1) Take the same actions as SRVO-023.

SRVO-027 Robot not mastered (Group:i)

(Explanation) An attempt was made to calibrate the robot, but the necessary adjustment had not

been completed. (Action) Check whether the mastering is valid. If the mastering is invalid, master the robot.

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B-83525EN/06 MAINTENANCE 3. TROUBLESHOOTING

WARNING

If the position data is incorrect, the robot or additional axis can operate

abnormally, set the position data correctly. Otherwise, you could injure personnel or damage equipment.

SRVO-030 Brake on hold (Group:i)

(Explanation) If the temporary halt alarm function is enabled ($SCR.$BRKHOLD ENB=1),

SRVO-030 is issued when a temporary halt occurs. When this function is not used,

disable the setting. (Action) Disable [Servo-off in temporary halt] on the general item setting screen [6 General

Setting Items].

SRVO-033 Robot not calibrated (Group:i)

(Explanation) An attempt was made to set up a reference point for quick mastering, but the robot

had not been calibrated. (Action) Calibrate the robot.

1. Supply power.

2. Set up a quick mastering reference point using [Positioning] on the positioning menu.

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

(Explanation) An attempt was made to perform quick mastering, but the reference point had not

been set up. (Action) Set up a quick mastering reference point on the positioning menu.

SRVO-036 Inpos time over (G:i A:j)

(Explanation) The robot did not get to the effective area ($PARAM _ GROUP.$ STOPTOL) even

after the position check monitoring time ($PARAM _ GROUP. $INPOS _ TIME)

elapsed. (Action) Take the same actions as for SRVO-023 (large position error at a stop).

SRVO-037 IMSTP input (Group:i)

(Explanation) The *IMSTP signal for a peripheral device interface was input. (Action) Turn on the *IMSTP signal.

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

(Explanation) The pulse count obtained when power is turned off does not match the pulse count

obtained when power is applied. This alarm is asserted after exchange the

Pulsecoder or battery for back up of the Pulsecoder data or loading back up data to

the Main Board.

Check the alarm history.

(Action 1) If the brake number is set to the non-brake motors, this alarm may occur. Check the

software setting of the brake number. (Action 2) In case the robot has been moved by using the brake release unit while the power is

off or when restoring the back-up data to the main board, this alarm may occur.

Remaster the robot. (Action 3) If the robot has been moved because the brake failed, this alarm may occur. Check

the cause of the brake trouble. Then remaster the robot. (Action 4) Replace the Pulsecoder and master the robot.

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

(Explanation) The regenerative discharge energy was too high to be dissipated as heat. (To run

the robot, the servo amplifier supplies energy to the robot. When going down the

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3. TROUBLESHOOTING MAINTENANCE B-83525EN/06

vertical axis, the robot operates from the potential energy. If a reduction in the

potential energy is higher than the energy needed for acceleration, the servo amplifier

receives energy from the motor. A similar phenomenon occurs even when no

gravity is applied, for example, at deceleration on a horizontal axis. The energy that

the servo amplifier receives from the motor is called the regenerative energy. The

servo amplifier dissipates this energy as heat. If the regenerative energy is higher

than the energy dissipated as heat, the difference is stored in the servo amplifier,

causing an alarm.) (Action 1) This alarm may occur if the axis is subjected to frequent acceleration/deceleration or

if the axis is vertical and generates a large amount of regenerative energy. If this alarm has occurred, relax the service conditions. (Action 2) Check fuse (FS3) in the 6-Axis servo amplifier. If it has blown, remove the cause,

and replace the fuse. (Action 3) The ambient temperature is excessively high. Or the regenerative resistor can't be

cooled effectively. Check the external fan unit and related fuses. Clean up the fun

unit, the regenerative resistor and the louver if they are dirty. (Action 4) Make sure that the 6-Axis servo amplifier CRR63A and CRR63B connectors are

connected tightly. Then detach the cable from CRR63A and CRR63B connectors on

the 6-Axis servo amplifier, and check for continuity between pins 1 and 2 of the

cable-end connector. If there is no continuity between the pins, replace the

regenerative resistor. (Action 5) Make sure that the 6-Axis servo amplifier CRRA11A and CRRA11B are connected

tightly, then detach the cables from CRRA11A and CRRA11B on the 6-Axis servo

amplifier and check the resistance between pins 1 and 3 of each cable end connector.

If the resistance is not 6.5Ω, replace the regenerative resistor. CRRA11B may not

be used depending on the robot model. (Action 6) Replace the 6-Axis servo amplifier.

Regenerative resistor

(Small size) (Middle/Large size)

Fig.3.5 (ja) SRVO-043 DCAL alarm

6-Axis servo amplifier E-stop unit

Fig.3.5 (jb) SRVO-043 DCAL alarm

Regenerative resistor

- 30 -

B-83525EN/06 MAINTENANCE 3. TROUBLESHOOTING

SRVO-044 DCHVAL%s alarm (G:i A:j)

(Explanation) The DC voltage (DC link voltage) of the main circuit power supply is abnormally

high. (Action 1) Check the input voltage to the controller is within the rated voltage. And check the

setting of the transformer is correct. (Action 2) Check the three-phase input voltage at the 6-Axis servo amplifier. If it is 240 VAC

or higher, check the line voltage. (If the three-phase input voltage is higher than

240 VAC, high acceleration/deceleration can cause in this alarm.) (Action 3) Check that the load weight is within the rating. If it is higher than the rating, reduce

it to within the rating. (If the machine load is higher than the rating, the

accumulation of regenerative energy might result in the HVAL alarm even when the

three-phase input voltage is within the rating.) (Action 4) Check that the CRRA11A and CRRA11B connectors of the 6-Axis servo amplifier

are attached firmly. Next, detach the cables then check the continuity between pins.

If the resistance is not 6.5Ω, replace the regenerative resistor. CRRA11B may not be

used depending on the robot model. (Action 5) Replace the 6-Axis servo amplifier.

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

(Explanation) Abnormally high current flowed in the main circuit of the servo amplifier. (Action 1) Turn off the power, and disconnect the power cable from the servo amplifier

indicated by the alarm message. (And disconnect the brake cable (CRR88 on the

6-Axis servo amplifier) to avoid the axis falling unexpectedly.) Supply power and

see if the alarm occurs again. If the alarm occurs again, replace the servo amplifier. (Action 2) Turn off the power and disconnect the power cable from the servo amplifier

indicated by the alarm message, and check the insulation of their U, V, W and the

GND lines each other. If there is a short-circuit, replace the power cable. (Action 3) Turn off the power and disconnect the power cable from the servo amplifier by the

alarm message, and measure the resistance between their U and V, V and W and W

and U with an ohmmeter that has a very low resistance range. If the resistances at the

three places are different from each other, the motor, the power cable is defective.

Check each item in detail and replace it if necessary.

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

(Explanation) This alarm is issued to prevent the motor from thermal damage that might occur

when the root meant square current calculated within the servo system is out of the

allowable range. (Action 1) Check the operating condition for the robot and relax the service condition if possible.

If the load or operating condition has exceeded the rating, reduce the load or relax

the operating condition to meet the rating. (Action 2) Check whether the voltage input to the controller is within the rated voltage. (Action 3) Check whether the brake of the corresponding axis is released. (Action 4) Check whether there is a factor that has increased the mechanical load on the

corresponding axis. (Action 5) Replace the servo amplifier. (Action 6) Replace the motor of the corresponding axis. (Action 7) Replace the E-stop unit (Action 8) Replace the motor power line (robot connection cable) of the corresponding axis. (Action 9) Replace the motor power line and brake line (internal cable of the robot) of the

corresponding axis.

- 31 -

3. TROUBLESHOOTING MAINTENANCE B-83525EN/06

6-Axis servo amplifier

Fig.3.5(k) SRVO-044 HVAL alarm

SRVO-045 HCAL alarm SRVO-046 OVC alarm

Reference

Relationships among the OVC, OHAL, and HC alarms

- Overview

This section points out the differences among the OVC, OHAL, and HC alarms and describes the purpose of each alarm.

- Alarm detection section

Abbreviation Designation Detection section

OVC Overcurrent alarm Servo software OHAL Overheat alarm Thermal relay in the motor

Thermal relay in the servo amplifier Thermal relay in the separate regenerative resister

HC High current alarm Servo amplifier

- Purpose of each alarm

1) HC alarm (high current alarm) If high current flow in a power transistor momentarily due to abnormality or noise in the control

circuit, the power transistor and rectifier diodes might be damaged, or the magnet of the motor might be degaussed. The HC alarm is intended to prevent such failures.

2) OVC and OHAL alarms (overcurrent and overload alarms) The OVC and OHAL alarms are intended to prevent overheat that may lead to the burnout of the

motor winding, the breakdown of the servo amplifier transistor, and the separate regenerative resistor.

The OHAL alarm occurs when each built-in thermal relay detects a temperature higher than the rated

value. However, this method is not necessarily perfect to prevent these failures. For example, if the motor frequently repeats to start and stop, the thermal time constant of the motor, which has a large mass, becomes higher than the time constant of the thermal relay, because these two components are different in material, structure, and dimension. Therefore, if the motor continues to start and stop within a short time as shown in Fig. 3.5 (l), the temperature rise in the motor is steeper than that in the thermal relay, thus causing the motor to burn before the thermal relay detects an abnormally high temperature.

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B-83525EN/06 MAINTENANCE 3. TROUBLESHOOTING

Temperature

Start StartStartStop Stop

Thermal time constant of the

Temperature at which the winding starts to burn

motor is high.

Thermal time constant of the thermal relay is low.

Time

Fig.3.5 (l) Relationship between the temperatures of the motor and thermal relay on start/stop cycles

To prevent the above defects, software is used to monitor the current in the motor constantly in order to estimate the temperature of the motor. The OVC alarm is issued based on this estimated temperature. This method estimates the motor temperature with substantial accuracy, so it can prevent the failures described above. To sum up, a double protection method is used; the OVC alarm is used for protection from a short-time overcurrent, and the OHAL alarm is used for protection from long-term overload. The relationship between the OVC and OHAL alarms is shown in Fig.3.5 (m).

Current

Protection area for the motor and ser vo

amplifier

Protecti on by the OHAL

Lim it c urrent

Protection by the OVC

Rated continuous cur r ent

ime

Fig.3.5 (m) Relationship between the OVC and OHAL alarms

NOTE

The relationship shown in Fig.3.5 (m) is taken into consideration for the OVC

alarm. The motor might not be hot even if the OVC alarm has occurred. In this case, do not change the parameters to relax protection.

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3. TROUBLESHOOTING MAINTENANCE B-83525EN/06

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

(Explanation) The control power supply voltage (+5 V, etc.) supplied from the power supply circuit

in the servo amplifier is abnormally low. (Action 1) Replace the servo amplifier. (Action 2) Replace the power supply unit.

6-Axis servo amplifier

Fig.3.5 (n) SRVO-047 LVAL alarm

Power supply unit

SRVO-049 OHAL1 alarm (Grp:i Ax:j)

(Explanation) The 6-Axis servo amplifier detects transformer overheat signal. (Action 1) Check that a connection is made between the 6-Axis servo amplifier CRMA91. (Action 2) Check whether no phase occurs. (Action 3) Replace the E-stop unit. (Action 4) Replace the 6-Axis servo amplifier.

SRVO-050 Collision Detect alarm (G:i A:j)

(Explanation) The disturbance torque estimated by the servo software is abnormally high. (A

collision has been detected.) (Action 1) Check whether the robot has collided and also check whether there is a factor that

has increased the mechanical load on the corresponding axis. (Action 2) Check whether the load settings are valid. (Action 3) Check whether the brake of the corresponding axis is released. (Action 4) If the load weight exceeds the rated range, decrease it to within the limit. (Action 5) Check whether the voltage input to the controller is within the rated voltage. (Action 6) Replace the servo amplifier. (Action 7) Replace the motor of the corresponding axis. (Action 8) Replace the E-stop unit. (Action 9) Replace the motor power line (robot connection cable) of the corresponding axis. (Action 10) Replace the motor power line and brake line (internal cable of the robot) of the

corresponding axis.

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B-83525EN/06 MAINTENANCE 3. TROUBLESHOOTING

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

(Explanation) The offset of the current feedback value is abnormally high. (Action) Replace the servo amplifier.

6-Axis servo amplifier E-stop unit

Fig.3.5 (o) SRVO-049 OHAL1 alarm

SRVO-050 CLALM alarm SRVO-051 CUER alarm

SRVO-055 FSSB com error 1 (G:i A:j)

(Explanation) A communication error has occurred between the main board and servo amplifier. (Action 1) Check the optical fiber cable between the axis control card and servo amplifier.

Replace it if it is faulty. (Action 2) Replace the axis control card on the main board. (Action 3) Replace the servo amplifier.

SRVO-056 FSSB com error 2 (G:i A:j)

(Explanation) A communication error has occurred between the main board and servo amplifier. (Action 1) Check the optical fiber cable between the axis control card and servo amplifier.

Replace it if it is faulty. (Action 2) Replace the axis control card on the main board. (Action 3) Replace the servo amplifier.

SRVO-057 FSSB disconnect (G:i A:j)

(Explanation) Communication was interrupted between the main board and servo amplifier. (Action 1) Check whether fuse (FS1) on the 6-Axis servo amplifier has blown. If the fuse has

blown, replace the 6-Axis servo amplifier including the fuse. (Action 2) Check the optical fiber cable between the axis control card and servo amplifier.

Replace it if it is faulty. (Action 3) Replace the axis control card on the main board. (Action 4) Replace the servo amplifier. (Action 5) Check for a point where the robot connection cable (RMP1, RP1) or an internal cable

running to each Pulsecoder through the robot mechanical section is grounded.

Before continuing to the next step, perform a complete controller back up to save all your programs

and settings.

(Action 6) Replace the main board.

SRVO-058 FSSB xx init error (yy)

(Explanation) Communication was interrupted between the main board and servo amplifier. (Action 1) Check whether fuse (FS1) on the 6-Axis servo amplifier has blown. If the fuse has

blown, replace the 6-Axis servo amplifier including the fuse.

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3. TROUBLESHOOTING MAINTENANCE B-83525EN/06

(Action 2) Turn off the power and disconnect the CRF8 connector on the 6-Axis servo amplifier.

Then check whether this alarm occurs again. (Ignore the alarm SRVO-068 because of

disconnecting the CRF8 connector.) If this alarm does not occur, the robot connection cable (RMP1, RP1) or the internal

cable of the robot may be short-circuited to the ground. Check the cables and replace

it if necessary. (Action 3) Check whether the LED (P5V and P3.3V) on the 6-Axis servo amplifier is lit. If they

are not lit, the DC power is not supplied to the 6-Axis servo amplifier. Make sure the connector CP5 on the power supply unit and the connector CXA2B on

the 6-Axis servo amplifier are connected tightly. If they are connected tightly,

replace the 6-Axis servo amplifier. (Action 4) Check the optical fiber cable between the axis control card and servo amplifier.

Replace it if it is faulty. (Action 5) Replace the axis control card on the main board. (Action 6) Replace the 6-Axis servo amplifier. (Action 7) If the other units (the servo amplifier for the auxiliary axis and the line tracking

interface) are connected in the FSSB optical communication, disconnect these units

and connect only 6-Axis servo amplifier for the robot. Then turn on the power. If this

alarm does not occur, search the failed unit and replace it.

Before executing the (Action 8), perform a complete controller back up to save all your programs

and settings.

(Action 8) Replace the main board.

6-Axis servo amplifierMain board

xis control card

(Main board)

Fig.3.5 (p) SRVO-055 FSSB com error 1

SRVO-056 FSSB com error 2 SRVO-057 FSSB disconnect SRVO-058 FSSB init error

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B-83525EN/06 MAINTENANCE 3. TROUBLESHOOTING

SRVO-059 Servo amp init error (G:i A:j)

(Explanation) Servo amplifier initialization is failed. (Action 1) Check the optical fiber cable between the axis control card on the main board servo

amplifier. Replace it if it is faulty. (Action 2) Turn off the power and disconnect the CRF8 connector on the 6-Axis servo amplifier.

Then check whether this alarm occurs again. (Ignore the alarm SRVO-068 because of

disconnecting the CRF8 connector.) If this alarm does not occur, the robot connection cable (RMP1, RP1) or the internal

cable of the robot (Pulsecoder cable) may be short-circuited to the ground. Check the

cables and replace it if necessary. (Action 3) Check whether the LED (P5V and P3.3V) on the 6-Axis servo amplifier is lit. If they

are not lit, the DC power is not supplied to the servo amplifier. Make sure the connector CP5 on the power supply unit and the connector CXA2B on

the 6-Axis servo amplifier are connected tightly. If they are connected tightly,

replace the 6-Axis servo amplifier. (Action 4) Replace the servo amplifier. (Action 5) Replace the line tracking board (If installed). (Action 6) Replace the Pulsecoder

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

(Explanation) This alarm occurs if battery for Pulsecoder absolute-position backup is empty.

A probable cause is a broken battery cable or no batteries in the robot. (Action 1) Replace the battery in the battery box of the robot base. (Action 2) Replace the Pulsecoder with which an alarm has been issued. (Action 3) Check whether the mechanical unit cable for feeding power from the battery to the

Pulsecoder is not disconnected and grounded. If an abnormality is found, replace

the cable.

CAUTION

After correcting the cause of this alarm, set the system variable

($MCR.$SPC_RESET) to TRUE then turn on the power again. Mastering is needed.

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

(Explanation) This alarm occurs if the phase of the pulses generated in the Pulsecoder is abnormal. (Action) Replace the Pulsecoder with which an alarm has been issued.

NOTE

This alarm might accompany the DTERR, CRCERR, or STBERR alarm. In this

case, however, there may be no actual condition for this alarm.

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

(Explanation) The battery voltage for the Pulsecoder is lower than the rating. (Action) Replace the battery. (If this alarm occurs, turn on the power and replace the battery as soon as possible. A

delay in battery replacement may result in the BZAL alarm being detected. In this

case, the position data will be lost. Once the position data is lost, mastering will

become necessary.

SRVO-067 OHAL2 alarm (Grp:i Ax:j)

(Explanation) The temperature inside the Pulsecoder or motor is abnormally high, and the built-in

thermostat has operated.

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3. TROUBLESHOOTING MAINTENANCE B-83525EN/06

(Action 1) Check the robot operating conditions. If a condition such as the duty cycle and load

weight has exceeded the rating, relax the robot load condition to meet the allowable

range. (Action 2) When power is supplied to the motor after it has become sufficiently cool, if the

alarm still occurs, replace the motor.

SRVO-068 DTERR alarm (Grp:i Ax:j)

(Explanation) The serial Pulsecoder does not return serial data in response to a request signal. (Action 1) Make sure that the robot connection cable (RMP1, RP1) connector (CRF8) of 6-Axis

servo amplifier and the connector (motor side) are connected tightly. (Action 2) Check that the shielding of the robot connection cable (RMP1, RP1) is grounded

securely in the cabinet. (Action 3) Replace the Pulsecoder. (Action 4) Replace the servo amplifier. (Action 5) Replace the robot connection cable (RMP1, RP1, RM1). (Action 6) Replace the internal cable of the robot (for the Pulsecoder, For the Motor).

SRVO-069 CRCERR alarm (Grp:i Ax:j)

(Explanation) The serial data has disturbed during communication. (Action) See actions on SRVO-068

SRVO-070 STBERR alarm (Grp:i Ax:j)

(Explanation) The start and stop bits of the serial data are abnormal. (Action) See actions on SRVO-068

6-Axis servo amplifier

Fig.3.5 (q) SRVO-059 Servo amp init error

SRVO-070 STBERR alarm

SRVO-071 SPHAL alarm (Grp:i Ax:j)

(Explanation) The feedback speed is abnormally high. (Action) Action as same as the SRVO-068.

NOTE

If this alarm occurs together with the PHAL alarm (SRVO-064), this alarm does

not correspond to the major cause of the failure.

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

(Explanation) It is likely that the Pulsecoder is abnormal. (Action) Replace the Pulsecoder and remaster the robot.

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B-83525EN/06 MAINTENANCE 3. TROUBLESHOOTING

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

(Explanation) It is likely that the Pulsecoder is abnormal or the Pulsecoder has malfunctioned due

to noise. (Action 1) Check whether the connection of the controller earth is good. Check the earth cable

connection between controller and robot connection cables are connected securely to

the grounding plate. (Action 2) Reinforce the earth of the motor flange. (In case of Auxiliary axis) (Action 3) Reset the Pulse count. (Action 4) Replace the Pulsecoder. (Action 5) Replace the robot connection cable (RMP1, RM1, RP1). (Action 6) Replace the internal cable of the robot (for the Pulsecoder, For the Motor).

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

(Explanation) The LED in the Pulsecoder is broken. (Action) Replace the Pulsecoder, and remaster the robot.

SRVO-075 Pulse not established (G:i A:j)

(Explanation) The absolute position of the Pulsecoder cannot be established. (Action) Reset the alarm, and jog the axis on which the alarm has occurred until the same

alarm will not occur again.

SRVO-076 Tip Stick Detection (G:i A:j)

(Explanation) An excessive disturbance was assumed in servo software at the start of operation.

(An abnormal load was detected. The cause may be welding.) (Action 1) Check whether the robot has collided. Or check whether the machinery load of the

corresponding axis is increased. (Action 2) Check whether the load settings are valid. (Action 3) Check whether the brake of the corresponding axis is released. (Action 4) Check whether the load weight is within the rated range. If the weight exceeds the

upper limit, decrease it to the limit. (Action 5) Check whether the voltage input to the controller is within the rated voltage. (Action 6) Replace the servo amplifier. (Action 7) Replace the corresponding servo motor. (Action 8) Replace the E-stop unit. (Action 9) Replace the power cable of the robot connection cable in which the corresponding

axis is connected. (Action 10) Replace the internal cable of the robot (power/brake) in which the corresponding axis

is connected.

6-Axis servo amplifier

Fig.3.5 (r) SRVO-076 Tip stick detection

E-stop unit

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3. TROUBLESHOOTING MAINTENANCE B-83525EN/06

SRVO-081 EROFL alarm (Track enc:i)

(Explanation) The pulse counter for line tracking has overflowed. (Action 1) Check whether the condition of the line tracking exceeds the limitation. (Action 2) Replace the Pulsecoder. (Action 3) Replace the line tracking board.

SRVO-082 DAL alarm (Track encoder:i)

(Explanation) The line tracking Pulsecoder has not been connected. (Action 1) Check the connection cable at each end (the line tracking board and the motor side) (Action 2) Check whether the shielding of the connection cable is connected securely to the

grounding plate. (Action 3) Replace the line tracking cable. (Action 4) Replace the Pulsecoder. (Action 5) Replace the line tracking board.

SRVO-084 BZAL alarm (Track enc:i)

(Explanation) This alarm occurs if the backup battery for the absolute position of the Pulsecoder

has not been connected. See the description about the BZAL alarm (SRVO-062).

SRVO-087 BLAL alarm (Track enc:i)

(Explanation) This alarm occurs if the voltage of the backup battery for the absolute position of the

Pulsecoder is low. See the description about the BLAL alarm (SRVO-065).

SRVO-089 OHAL2 alarm (Track enc:i)

(Explanation) The motor has overheated. When power is supplied to the Pulsecoder after it has

become sufficiently cool, if the alarm still occurs. See the description about the

OHAL2 alarm (SRVO-067).

SRVO-090 DTERR alarm (Track enc:i)

(Explanation) Communication between the Pulsecoder and line tracking board is abnormal. See

the SRVO-068 DTERR alarm. (Action 1) Check the connection cable at each end (the line tracking board and the Pulsecoder) (Action 2) Check whether the shielding of the connection cable is connected securely to the

grounding plate. (Action 3) Replace the Pulsecoder. (Action 4) Replace the line tracking cable. (Action 5) Replace the line tracking board.

SRVO-091 CRCERR alarm (Track enc:i)

(Explanation) Communication between the Pulsecoder and line tracking board is abnormal. (Action) Action as same as the SRVO-090.

SRVO-092 STBERR alarm (Track enc:i)

(Explanation) Communication between the Pulsecoder and line tracking board is abnormal. (Action) Action as same as the SRVO-090.

SRVO-093 SPHAL alarm (Track enc:i)

(Explanation) This alarm occurs if the current position data from the Pulsecoder is higher than the

previous position data. (Action) Action as same as the SRVO-090.

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B-83525EN/06 MAINTENANCE 3. TROUBLESHOOTING

SRVO-094 PMAL alarm (Track enc:i)

(Explanation) It is likely that the Pulsecoder is abnormal. See the description about the PMAL

alarm (SRVO-072). (Action) Replace the Pulsecoder.

SRVO-095 CMAL alarm (Track enc:i)

(Explanation) It is likely that the Pulsecoder is abnormal or the Pulsecoder has malfunctioned due

to noise. See the description about the CMAL alarm (SRVO-073). (Action 1) Reinforce the earth of the flange of the Pulsecoder. (Action 2) Reset the Pulse count. (Action 3) Replace the Pulsecoder.

SRVO-096 LDAL alarm (Track enc:i)

(Explanation) The LED in the Pulsecoder is broken. See the description about the LDAL alarm

(SRVO-074).

SRVO-097 Pulse not established (Enc:i)

(Explanation) The absolute position of the Pulsecoder cannot be established. See the description

about (SRVO-075). Pulse not established. (Action 1) Reset the alarm, and jog the axis on which the alarm has occurred until the same

alarm does not occur again. (Jog one motor revolution)

SRVO-105 Door open or E.Stop

(Explanation) The cabinet door is open.

- When the door switch is not mounted skip Action 1 and 2 and start from Action 3 (Action 1) If the auxiliary cabinet (option) is installed, check whether the door of the auxiliary

cabinet is open. When the door is open, close it (Action 2) If the auxiliary cabinet (option) is installed, check the door switch and its wiring. If

the switch or wiring is faulty, replace it. (Action 3) Check that the CRMA92, CRMB8 connectors on the E-STOP unit and CRMA91 on

the 6-Axis servo amplifier are connected securely. (Action 4) Replace the emergency stop board. (Action 5) Replace the 6- Axis servo amplifier.

6-Axis servo amplifier

Fig.3.5 (s) SRVO-105 Door open or E-stop

- 41 -

E-stop unit

(Emergency stop board)

3. TROUBLESHOOTING MAINTENANCE B-83525EN/06

SRVO-123 Fan motor rev slow down(i)

(Explanation) The rotation speed of fan motor is slow down.

(Action 1) Check the fan motor and its cables. Replace them if necessary. (Action 2) Replace the backplane unit. Before executing the (Action 3), perform a complete controller back up to save all your programs and settings. (Action 3) Replace the main board.

Fan motor

Main board

Fig.3.5 (t) SRVO-123 Fan motor rev slow down(i)

SRVO-134 DCLVAL alarm (G:i A:j)

(Explanation) The DC voltage (DC link voltage) of the main circuit power supply for the servo

amplifier is abnormally low. (Action 1) It is possible that an instant disconnection of power source causes this alarm. Check

whether an instant disconnection occurred. (Action 2) Check the input voltage to the controller is within the rated voltage. (Action 3) Modify the program in order that robot and the auxiliary axis do not accelerate

simultaneously in the system with the auxiliary axis. (Action 4) Replace the E-stop unit. (Action 5) Replace the servo amplifier.

SRVO-156 IPMAL alarm (G:i A:j)

(Explanation) Abnormally high current flowed through the main circuit of the servo amplifier. (Action 1) Turn off the power, and disconnect the power cable from the servo amplifier

indicated by the alarm message. (And disconnect the brake cable (CRR88 on the

servo amplifier) to avoid the axis falling unexpectedly.) Turn on the power, and if the

alarm occurs again, replace the servo amplifier. (Action 2) Turn off the power and disconnect the power cable from the servo amplifier

indicated by the alarm message, and check the insulation of their U, V, W and the

GND lines each other. If there is a short-circuit, replace the power cable. (Action 3) Turn off the power and disconnect the power cable from the servo amplifier by the

alarm message, and measure the resistance between their U and V, V and W and W

and U with an ohmmeter that has a very low resistance range. If the resistances at the

three places are different from each other, the motor, the power cable is defective.

Check each item in detail and replace it if necessary.

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B-83525EN/06 MAINTENANCE 3. TROUBLESHOOTING

SRVO-157 CHGAL alarm (G:i A:j)

(Explanation) The capacitor on the servo amplifier was not charged properly within the specified

time when the servo power is on. (Action 1) Check the input voltage to the controller is within the rated voltage. (Action 2) Make sure that the 6-axis servo amplifier CRRA12 and emergency stop board

CRRA12 connector are connected tightly. In case of single phase, make sure that the connectors CRRB14 is securely attached

to the servo amplifier. (Action 3) Replace the 6-axis servo amplifier. (Action 4) Replace the E-stop unit.

6-Axis servo amplifier

Fig.3.5 (u) SRVO-156 IPMAL alarm

SRVO-157 CHGAL alarm

E-stop unit (Emergency stop board)

- 43 -

3. TROUBLESHOOTING MAINTENANCE B-83525EN/06

SRVO-204 External (SVEMG abnormal) E-stop

(Explanation) The switch connected across EES1 – EES11 and EES2 – EES21 on the TBOP20 on

the emergency stop board was pressed, but the EMERGENCY STOP line was not

disconnected. (Action 1) Check the switch and cable connected to EES1 – EES11 and EES2 – EES21 on the

TBOP20. If the cable is abnormal, replace it.

Before executing the (Action 2), perform a complete controller back up to save all your programs

and settings. (Action 2) Replace the main board. (Action 3) Replace the emergency stop board. (Action 4) Replace the 6-Axis servo amplifier.

6-Axis servo amplifier

E-stop unit (Emergency stop board)

TBOP20

No. Name 12 21

E-STOP

(ESPB)

11 2 10 11 9 8 21

FENCE

(EAS)

7 2 6 11 5 4 21

EMGIN

(EES)

3 2 2 11 1

(Emergency stop board)

Fig.3.5 (v) SRVO-204 External (SVEMG abnormal) E-stop

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B-83525EN/06 MAINTENANCE 3. TROUBLESHOOTING

SRVO-205 Fence open (SVEMG abnormal)

(Explanation) The switch connected across EAS1 – EAS11 and EAS2 – EAS21 on the TBOP20 on

the emergency stop board was opened, but the EMERGENCY STOP line was not

disconnected. (Action 1) Check the switch and cable connected to EAS1 – EAS11 and EAS2 – EAS21 on the

TBOP20. If the cable is abnormal, replace it.

Before executing the (Action 2), perform a complete controller back up to save all your programs

and settings. (Action 2) Replace the main board. (Action 3) Replace the emergency stop board. (Action 4) Replace the 6-Axis servo amplifier.

6-Axis servo amplifier

TBOP20

No. Name 12 21

E-STOP

(ESPB)

11 2 10 11 9 8 21

FENCE

(EAS)

7 2 6 11 5 4 21

EMGIN

(EES)

3 2 2 11 1

(Emergency stop board)

Fig.3.5 (w) SRVO-205 Fence open (SVEMG abnormal)

E-stop unit (Emergency stop board)

- 45 -

3. TROUBLESHOOTING MAINTENANCE B-83525EN/06

SRVO-206 Deadman switch (SVEMG abnormal)

(Explanation) When the teach pendant was enabled, the DEADMAN switch was released or

pressed strongly, but the emergency stop line was not disconnected. (Action 1) Replace the teach pendant. (Action 2) Check the teach pendant cable. If it is inferior, replace the cable.

Before executing the (Action 3), perform a complete controller back up to save all your programs

and settings. (Action 3) Replace the main board. (Action 4) Replace the emergency stop board. (Action 5) Replace the 6-Axis servo amplifier.

SRVO-213 E-STOP Board FUSE2 blown

(Explanation) A fuse (FUSE2) on the emergency stop board has blown, or no voltage is supplied to

EXT24V. (Action 1) Check whether the fuse (FUSE2) on the emergency stop board has blown. If the

fuse has blown, 24EXT may be short-circuited to 0EXT. Take Action 2. If FUSE2

has not blown, take Action 3 and up. (Action 2) Disconnect the connection destinations of 24EXT that can cause grounding then

check that the fuse (FUSE2) does not blow. Disconnect the following on the

emergency stop board then turn on the power:

- CRS36

- CRT30

- TBOP20: EES1, EES11, EAS1, EAS11 If the fuse (FUSE2) does not blow in this state, 24EXT and 0EXT may be

short-circuited at any of the connection destinations above. Isolate the faulty

location then take action.

If the fuse (FUSE2) blows even when the connection destinations above are detached,

replace the emergency stop board. (Action 3) Check whether 24 V is applied to between EXT24V and EXT0V of TBOP19. If

not, check the external power supply circuit.

If no external power supply is used, check whether the terminals above are connected

to the INT24V and INT0V terminals, respectively. (Action 4) Replace the emergency stop board. (Action 5) Replace the teach pendant cable. (Action 6) Replace the teach pendant. (Action 7) Replace the operator’s panel cable (CRT30).

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B-83525EN/06 MAINTENANCE 3. TROUBLESHOOTING

TBOP19

No. Name 4 EXT0V 3 INT0V 2 INT24V 1 EXT24V

TBOP20

No. Name 12 21

E-STOP

(ESPB)

11 2 10 11 9 8 21

FENCE

(EAS)

7 2 6 11 5 4 21

EMGIN

(EES)

3 2 2 11 1

(Emergency stop board)

FUSE2

CRT30

CRS36

6-Axis servo amplifier

E-stop unit (Emergency stop board)

Fig.3.5 (x) SRVO-206 DEADMAN switch (SVEMG abnormal)

SRVO-213 E-STOP Board FUSE2 blown

SRVO-214 6ch amplifier fuse blown (Robot:i)

(Explanation) A fuse (FS2 or FS3) in the 6-Axis servo amplifier has blown. (Action 1) A fuse (FS2 or FS3) is blown, eliminate the cause, and then replace the fuse. (See

Section 3.6) (Action 2) Replace the 6-Axis servo amplifier.

SRVO-216 OVC (total) (Robot:i)

(Explanation) The current (total current for six axes) flowing through the motor is too large. (Action 1) Slow the motion of the robot where possible. Check the robot operation conditions. If

the robot is used with a condition exceeding the duty or load weight robot rating,

reduce the load condition value to the specification range. (Action 2) Check the input voltage to the controller is within the rated voltage. (Action 3) Replace the 6-Axis servo amplifier.

- 47 -

3. TROUBLESHOOTING MAINTENANCE B-83525EN/06

SRVO-221 Lack of DSP (G:i A:j)

(Explanation) A controlled axis card corresponding to the set number of axes is not mounted. (Action 1) Check whether the set number of axes is valid. If the number is invalid, set the

correct number. (Action 2) Replace the axis control card with a card corresponding to the set number of axes.

SRVO-223 DSP dry run (a,b)

(Explanation) A servo DSP initialization failure occurred due to hardware failure or wrong software

setting. Then, the software entered DSP dry run mode. The first number indicates the

cause of the failure. The second number is extra information. (Action) Perform an action according to the first number that is displayed in the alarm

message. 1: This is a warning due to $scr.$startup_cnd=12. 2,3,4,7: Replace a servo card. 5: Invalid ATR setting. Software axis config (FSSB line number, hardware start axis

number, amplifier number, and amplifier type) might be wrong. 6: SRVO-180 occurs simultaneously. Controllable axis does not exist on any group.

Execute aux axis setting to add axis at controlled start. 8,10: SRVO-058 (FSSB init error) occurs simultaneously. Follow the remedy of

SRVO-058. 9: There is no amplifier that is connected to the servo card.

•Check the hardware connection.

•Check the optical fiber cable.

•In case of using aux. axis amplifier, make sure that the connectors CXA2A (6-axis amplifier) or CXA2B (aux. axis amplifier) are securely attached to the servo amplifier.

•Check whether the servo amplifier power is supplied.

•Check whether the fuse on the servo amplifier has blown.

•Replace the optical fiber cable.

•Replace the servo amplifier 11: Invalid axisorder setting. Non-existing axis number is specified. Software axis

config (FSSB line number) might be wrong or auxiliary axis board is necessary.

12: SRVO-059 (Servo amp init error) occurs simultaneously. Follow the remedy of

SRVO-059.

13,14,15: Document the events that led to the error, and contact your FANUC

technical representative.

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B-83525EN/06 MAINTENANCE 3. TROUBLESHOOTING

Main board

Axis control card

(Main board)

Fig.3.5 (y) SRVO-214 6ch amplifier fuse blown (Panel PCB) SRVO-216 OVC (total) SRVO-221 Lack of DSP SRVO-223 DSP dry run (a,b)

6-Axis servo amplifier

- 49 -

3. TROUBLESHOOTING MAINTENANCE B-83525EN/06

SRVO-230 Chain 1 abnormal a, b SRVO-231 Chain 2 abnormal a, b

(Explanation) A mismatch occurred between duplicate safety signals.

SRVO-230 is issued if such a mismatch that a contact connected on the chain 1 side (between EES1 and EES11, between EAS1 and EAS11, and so forth) is closed, and a contact on the chain 2 side (between EES2 and EES21, between EAS2 and EAS21, and so forth) is open occurs. SRVO-231 is issued if such a mismatch that a contact on the chain 1 side is open, and a contact on the chain 2 side is closed occurs. If a chain error is detected, correct the cause of the alarm then reset the alarm according to the method described later.

(Action) Check the alarms issued at the same time in order to identify with which signal the

mismatch occurred. SRVO-266 through SRVO-275 and SRVO-370 through SRVO-385 are issued at the same time. Take the action(s) described for each item.

WARNING

If this alarm is issued, do not reset the chain error alarm until the failure is

identified and repaired. If robot use is continued with one of the duplicate circuits being faulty, safety may not be guaranteed when the other circuit fails.

CAUTION

1 The state of this alarm is preserved by software. After correcting the cause of the

alarm, reset the chain error alarm according to the chain error reset procedure described later.

2 Until a chain error is reset, no ordinary reset operation must be performed. If

an ordinary reset operation is performed before chain error resetting, the message "SRVO-237 Chain error cannot be reset" is displayed on the teach pendant.

6-Axis servo amplifier

Fig.3.5 (z) SRVO-230 Chain 1 (+24V) abnormal a, b

SRVO-231 Chain 2 (0V) abnormal a, b

E-stop unit (Emergency stop board)

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B-83525EN/06 MAINTENANCE 3. TROUBLESHOOTING

Alarm history display method

1. Press the screen selection key on the teach pendant.

2. Select [4 ALARM] on the teach pendant.

3. Press F3 [HIST] on the teach pendant.

Chain error reset procedure

CAUTION

Do not perform this operation until the cause of the alarm is corrected.

1. Press the emergency stop button.

2. Press the screen selection key on the teach pendant.

3. Select [0 NEXT PAGE] on the teach pendant.

4. Press [6 SYSTEM] on the teach pendant.

5. Press [7 SYSTEM SETTING] on the teach pendant.

6. Find "28" Chain Error Reset Execution.

7. Press F3 on the teach pendant to reset "Chain Error".

1. Press the screen selection key on the teach pendant.

2. Select [4 ALARM] on the teach pendant.

3. Press F4 [CHAIN RESET] on the teach pendant.

SRVO-233 TP OFF in T1/ T2

(Explanation) Teach pendant is disabled when the mode switch is T1 or T2. Or controller door is opened. (Action 1) Enable the teach pendant in teaching operation. In other case the mode switch should

be AUTO mode. (Action 2) Close the controller door, if open. (Action 3) Replace the teach pendant. (Action 4) Replace the teach pendant cable. (Action 5) Replace the mode switch. (Action 6) Replace the emergency stop board. (Action 7) Replace the 6-Axis servo amplifier.

SRVO-235 Short term Chain abnormal

(Explanation) Short term single chain failure condition is detected.

• Cause of this alarm is;

- Half release of DEADMAN switch

- Half operation of emergency stop switch. (Action 1) Cause the same error to occur again, and then perform resetting. (Action 2) Replace the emergency stop board. (Action 3) Replace the 6-Axis servo amplifier.

SRVO-251 DB relay abnormal (G:i A:j)

(Explanation) An abnormality was detected in the internal relay (DB relay) of the servo amplifier. (Action 1) Replace the servo amplifier. (Action 2) Replace the E-stop unit.

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3. TROUBLESHOOTING MAINTENANCE B-83525EN/06

SRVO-252 Current detect abnl (G:i A:j)

(Explanation) An abnormality was detected in the current detection circuit inside the servo

amplifier.

(Action) Replace the servo amplifier.

SRVO-253 Amp internal over heat (G:i A:j)

(Explanation) An overheat was detected inside the servo amplifier. (Action) Replace the servo amplifier.

6-Axis servo amplifier

2 mode switch

(Mode switch)

Fig.3.5 (aa) SRVO-233 TP OFF in T1, T2

SRVO-235 Short term Chain abnormal SRVO-251 DB relay abnormal SRVO-252 Current detect abnl SRVO-253 Amp internal over heat

E-stop unit (Emergency stop board)

3 mode switch

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B-83525EN/06 MAINTENANCE 3. TROUBLESHOOTING

SRVO-266 FENCE1 status abnormal SRVO-267 FENCE2 status abnormal

(Explanation) A chain alarm was detected with the EAS (FENCE) signal. (Action 1) Check whether the circuitry connected to the dual input signal (EAS) is faulty. (Action 2) Check whether the timing of the dual input signal (EAS) satisfies the timing

specification (See Subsection 3.2.5, Table 3.2.5 in CONNECTIONS).

Before executing the (Action 3), perform a complete controller back up to save all your programs and settings. (Action 3) Replace the main board. (Action 4) Replace the emergency stop board.

WARNING

If this alarm is issued, do not reset the chain error alarm until the failure is

identified and repaired. If robot use is continued with one of the duplicate circuits being faulty, safety may not be guaranteed when the other circuit fails.

NOTE

For the procedure of recovery from this alarm, see the descriptions of SRVO-230

and SRVO-231.

TBOP20

No. Name 12 21

E-STOP

(ESPB)

11 2 10 11 9

FENCE

8 21

(EAS)

7 2 6 11 5 4 21

EMGIN

(EES)

3 2 2 11 1

Fig.3.5 (ab) SRVO-266 FENCE1 status abnormal

(Emergency stop board)

SRVO-267 FENCE2 status abnormal

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3. TROUBLESHOOTING MAINTENANCE B-83525EN/06

SRVO-270 EXEMG1 status abnormal SRVO-271 EXEMG2 status abnormal

(Explanation) A chain alarm was detected with the EES (EXEMG) signal. (Action 1) Check whether the circuitry connected to the dual input signal (EES) is faulty. (Action 2) Check whether the timing of the dual input signal (EES) satisfies the timing

specification (See Subsection 3.2.5, Fig 3.2.5(c) in CONNECTIONS). (Action 3) Replace the teach pendant cable. (Action 4) Replace the teach pendant. (Action 5) Replace the emergency stop board. (Action 6) Replace the emergency stop switch on the operator's panel (or replace entire

operator’s panel).

Before executing the (Action 7), perform a complete controller back up to save all your programs and settings. (Action 7) Replace the main board.

WARNING

If this alarm is issued, do not reset the chain error alarm until the failure is

identified and repaired. If robot use is continued with one of the duplicate circuits being faulty, safety may not be guaranteed when the other circuit fails.

NOTE

For the procedure of recovery from this alarm, see the descriptions of SRVO-230

and SRVO-231.

TBOP20

No. Name 12 21

E-STOP

(ESPB)

11 2 10 11 9 8 21

FENCE

(EAS)

7 2 6 11 5

EMGIN

4 21

(EES)

3 2 2 11 1

Fig.3.5 (ac) SRVO-270 EXEMG1 status abnormal

(Emergency stop board)

SRVO-271 EXEMG2 status abnormal

- 54 -

B-83525EN/06 MAINTENANCE 3. TROUBLESHOOTING

SRVO-274 NTED1 status abnormal SRVO-275 NTED2 status abnormal

(Explanation) A chain alarm was detected with the NTED signal. (Action 1) This alarm may be issued when the DEADMAN switch is pressed to a proper

position or is operated very slowly. In such a case, release the DEADMAN switch

once completely then press the DEADMAN switch again. (Action 2) Check whether the circuitry connected to the dual input signal (NTED) is faulty. (Action 3) Check whether the timing of the dual input signal (NTED) satisfies the timing

specification (See Subsection 3.2.5, Fig 3.2.5(c) in CONNECTIONS). (Action 4) Replace the teach pendant cable. (Action 5) Replace the teach pendant. (Action 6) Replace the emergency stop board. (Action 7) Replace the mode switch on the operator's panel.

Before executing the (Action 8), perform a complete controller back up to save all your programs and settings. (Action 8) Replace the main board.

WARNING

If this alarm is issued, do not reset the chain error alarm until the failure is

identified and repaired. If robot use is continued with one of the duplicate circuits being faulty, safety may not be guaranteed when the other circuit fails.

NOTE

For the procedure of recovery from this alarm, see the descriptions of SRVO-230

and SRVO-231.

SRVO-277 Panel E-stop (SVEMG abnormal)

(Explanation) The emergency stop line was not disconnected although the emergency stop button

on the operator's panel was pressed.

Before executing the (Action 1), perform a complete controller back up to save all your programs and settings. (Action 1) Replace the main board. (Action 2) Replace the emergency stop board. (Action 3) Replace the 6-Axis servo amplifier.

- 55 -

3. TROUBLESHOOTING MAINTENANCE B-83525EN/06

SRVO-278 TP E-stop (SVEMG abnormal)

(Explanation) The emergency stop line was not disconnected although the emergency stop button

on the teach pendant was pressed. (Action 1) Replace the teach pendant. (Action 2) Replace the teach pendant cable.

Before executing the (Action 3), perform a complete controller back up to save all your programs and settings. (Action 3) Replace the main board. (Action 4) Replace the emergency stop board. (Action 5) Replace the 6-Axis servo amplifier.

NOTE

This alarm may be issued if the emergency stop button is pressed very slowly.

6-Axis servo amplifier

2 mode switch

(Mode switch)

Fig.3.5 (ad) SRVO-274 NTED1 status abnormal

SRVO-275 NTED2 status abnormal SRVO-277 Panel E-stop (SVEMG abnormal) SRVO-278 TP E-stop (SVEMG abnormal)

E-stop unit

(Emergency stop board)

3 mode switch

- 56 -

B-83525EN/06 MAINTENANCE 3. TROUBLESHOOTING

SRVO-291 IPM over heat (G:i A:j)

(Explanation) IPM on the servo amplifier is overheated. (Action 1) Check whether the vent hole is clogged. If necessary, clean them. (Action 2) If SRVO-291 is issued when the robot operating condition is severe, check the robot

operating condition then relax the condition when possible. (Action 3) If SRVO-291 is issued frequently, replace the servo amplifier.

SRVO- 295 Amp com error(G:i A:j)

(Explanation) A communication error occurred in the 6-axis servo amplifier. (Action 1) Replace the 6-axis servo amplifier.

SRVO- 297 Improper input power (G:i A:j)

(Explanation) The 6-axis servo amplifier has detected the input voltage phase lack. (Action 1) Check the input voltage of the controller whether phase is not lack. (Action 2) Measure the secondary voltage between each phase at the main breaker, if phase lack

is detected, replace the main breaker. (Action 3) Replace the E-stop unit. (Action 4) Replace the 6-axis servo amplifier.

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

(Explanation) Although HBK was disabled, the HBK signal was input. (Action 1) Press RESET on the teach pendant to release the alarm. (Action 2) Check whether the hand broken signal is connected to the robot. When the hand

broken signal circuit is connected, enable hand broken. (See Subsection 5.6.3 in CONNECTIONS)

SRVO-335 DCS OFFCHK alarm a, b

(Explanation) A failure was detected in the safety signal input circuit.

Before executing the (Action 1), perform a complete controller back up to save all your programs and settings. (Action 1) Replace the main board.

SRVO-348 DCS MCC OFF alarm a, b

(Explanation) A command was issued to turn off the magnetic contactor, but the magnetic contactor

was not turned off. (Action 1) If a signal is connected to the E-stop unit CRMB8, check whether there is a problem

in the connection destination. Make sure that the connector CRMB16 (6-axis

amplifier) is securely attached to the servo amplifier. (Action 2) Replace the E-stop unit.

Before executing the (Action 3), perform a complete controller back up to save all your programs and settings. (Action 3) Replace the main board. (Action 4) Replace the 6-Axis servo amplifier.

SRVO-349 DCS MCC ON alarm a, b

(Explanation) A command was issued to turn on the magnetic contactor, but the magnetic contactor

was not turned on. (Action 1) Replace the E-stop unit.

Before executing the (Action 2), perform a complete controller back up to save all your programs and settings.

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3. TROUBLESHOOTING MAINTENANCE B-83525EN/06

(Action 2) Replace the main board. (Action 3) Replace the 6-Axis servo amplifier.

SRVO-370 SVON1 status abnormal SRVO-371 SVON2 status abnormal

(Explanation) A chain alarm was detected with the main board internal signal (SVON).

Before executing the (Action 1), perform a complete controller back up to save all your programs and settings. (Action 1) Replace the main board. (Action 2) Replace the 6-Axis servo amplifier. (Action 3) Replace the emergency stop board.

WARNING

If this alarm is issued, do not reset the chain error alarm until the failure is

identified and repaired. If robot use is continued with one of the duplicate circuits being faulty, safety may not be guaranteed when the other circuit fails.

NOTE

For the procedure of recovery from this alarm, see the descriptions of SRVO-230

and SRVO-231.

6-Axis servo amplifir

Main board

Fig.3.5 (ae) SRVO-291 IPM over heat SRVO-295 Amp com error

SRVO-297 Improper input power SRVO-335 DCS OFFCHK alarm a, b SRVO-348 DCS MCC OFF alarm a, b SRVO-349 DCS MCC ON alarm a, b SRVO-370 SVON1 status abnormal SRVO-371 SVON2 status abnormal

E-stop unit (Emergency stop board)

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B-83525EN/06 MAINTENANCE 3. TROUBLESHOOTING

SRVO-372 OPEMG1 status abnormal SRVO-373 OPEMG2 status abnormal

(Explanation) A chain alarm was detected with the emergency stop button on the operator's panel. (Action 1) Replace the emergency stop board. (Action 2) Replace the teach pendant cable. (Action 3) Replace the teach pendant. (Action 4) Replace the emergency stop button on the operator's panel.

Before executing the (Action 5), perform a complete controller back up to save all your programs and settings. (Action 5) Replace the main board.

WARNING

If this alarm is issued, do not reset the chain error alarm until the failure is

identified and repaired. If robot use is continued with one of the duplicate circuits being faulty, safety may not be guaranteed when the other circuit fails.

NOTE

For the procedure of recovery from this alarm, see the descriptions of SRVO-230

and SRVO-231.

SRVO-374 MODE11 status abnormal SRVO-375 MODE12 status abnormal SRVO-376 MODE21 status abnormal SRVO-377 MODE22 status abnormal

(Explanation) A chain alarm was detected with the mode switch signal. (Action 1) Check the mode switch and its cable. Replace them if a defect is found. (Action 2) Replace the emergency stop board. Before executing the (Action 3), perform a complete controller back up to save all your programs and settings. (Action 3) Replace the main board.

WARNING

If this alarm is issued, do not reset the chain error alarm until the failure is

identified and repaired. If robot use is continued with one of the duplicate circuits being faulty, safety may not be guaranteed when the other circuit fails.

NOTE

For the procedure of recovery from this alarm, see the descriptions of SRVO-230

and SRVO-231.

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3. TROUBLESHOOTING MAINTENANCE B-83525EN/06

E-stop unit (Emergency stop board)

2 mode switch

3 mode switch

(Mode switch)

(Yellow)

(Red)

(Emergency stop button)

Fig.3.5 (af) SRVO-372 OPEMG1 status abnormal

SRVO-373 OPEMG2 status abnormal SRVO-374 MODE11 status abnormal SRVO-375 MODE12 status abnormal SRVO-376 MODE21 status abnormal SRVO-377 MODE22 status abnormal

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B-83525EN/06 MAINTENANCE 3. TROUBLESHOOTING

SRVO-378 SFDIxx status abnormal

(Explanation) A chain alarm was detected with the SFDI signal. xx shows signal name. (Action 1) Check whether the circuitry connected to the dual input signal (SFDI) is faulty. (Action 2) Check whether the timing of the dual input signal (SFDI) satisfies the timing

specification. (See Subsection 3.3.4, Fig 3.3.4(c) in CONNECTIONS).

WARNING

If this alarm is issued, do not reset the chain error alarm until the failure is

identified and repaired. If robot use is continued with one of the duplicate circuits being faulty, safety may not be guaranteed when the other circuit fails.

NOTE

For the procedure of recovery from this alarm, see the descriptions of SRVO-230

and SRVO-231.

E-stop unit (Emergency stop board)

Fig.3.5 (ag) SRVO-378 SFDIxx status abnormal

SRVO-450 Drvoff circuit fail(G:i A:j)

(Explanation) The two drive off inputs are not in the same status.

(Action 1) Check the line of the two drive off inputs. (Action 2) Make sure that the connector CRMB16 (6-axis amplifier) is securely attached to the

servo amplifier. (Action 3) Replace the servo amplifier.

SRVO-451 Internal S-BUS fail(G:i A:j)

(Explanation) An error is found in the serial bus communication in the servo amplifier.

(Action 1) Replace the servo amplifier.

SRVO-452 ROM data failure (G:i A:j)

(Explanation) An error is found in the ROM data in the servo amplifier. (Action 1) Replace the servo amplifier.

SRVO-453 Low volt driver (G:i A:j)

(Explanation) Driver supply voltage in the servo amplifier is low. (Action 1) Replace the servo amplifier.

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3. TROUBLESHOOTING MAINTENANCE B-83525EN/06

SRVO-454 CPU BUS failure (G:i A:j)

(Explanation) An error was found in CPU bus data in the amplifier. (Action 1) Replace the servo amplifier.

SRVO-455 CPU watch dog (G:i A:j)

(Explanation) An error occurred in CPU operation in the amplifier. (Action 1) Replace the servo amplifier.

SRVO-456 Ground fault (G:i A:j)

(Explanation) An error is found in the motor current detection data in the servo amplifier. (Action 1) Replace the servo amplifier.

SRVO-459 Excess regeneration2%s (G:i A:j)

(Explanation) An error is found in the discharge circuit in the servo amplifier. (Action 1) Replace the servo amplifier.

SRVO-460 Illegal parameter%s (G:i A:j)

(Explanation) An error is found in the setting of the parameters in the servo amplifier. (Action 1) Replace the servo amplifier.

SRVO-461 Hardware error%s (G:i A:j)

(Explanation) An error is found in the circuit in the servo amplifier. (Action 1) Replace the servo amplifier.

PRIO-095 Overload <Connector>

(Explanation) The DO of the specified connector might be grounded. (Action 1) Check the connection of the DO of the specified connector.

Before executing the (Action 2), perform a complete controller back-up to save all your programs

and settings.

(Action 2) Replace the main board.

Main board

Fig.3.5 (ah) PRIO-095 Overload

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B-83525EN/06 MAINTENANCE 3. TROUBLESHOOTING

3.6 FUSE-BASED TROUBLESHOOTING

This section describes the alarms and symptoms generated and actions required when the fuses installed on the printed circuit boards and units have blown.

(1) Fuses on the main board FUSE1: For protecting the +24 V output of the peripheral device interface

(A60L-0001-0290#LM10C)

Name Symptom observed when fuse has blown Action

FUSE1 An alarm (SRVO-220) is displayed on the teach

pendant.

1. 24SDI and 0 V may be short-circuited. Check the peripheral device cable for any abnormality, and replace it if necessary.

2. Disconnect CRS40. If fuse (FUSE3) still blows, replace the main board.

3. Replace the cable between the emergency stop unit and the servo amplifier.

4. Replace the cable between the main board and the emergency stop unit.

5. Replace the emergency stop unit.

6. Replace the servo amplifier.

CRS40 FUS E1 (1.0A)

Fig.3.6(a) Fuse on the main board

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3. TROUBLESHOOTING MAINTENANCE B-83525EN/06

(2) Servo amplifier fuse

FS1: For generation of the power to the amplifier control circuit (A60L-0001-0290#LM32C) FS2: For protection of the 24V output to the end effector, XROT, XHBK, and the fan motor inside the robot (M-3iA, option). (A60L-0001-0290#LM32C) FS3: For protection of the 24V output to the regenerative resister (A60L-0001-0290#LM32C)

Name Symptom observed when fuse has

blown

FS1 All LEDs on the servo amplifier go out.

The FSSB disconnection alarm (SRVO-057) or FSSB initialization alarm (SRVO-058) is displayed on the teach pendant.

FS2 The 6-Axis servo amplifier fuse blown

(SRVO-214), Hand broken (SRVO-006), and Robot overtravel (SRVO-005) are displayed on the teach pendant.

FS3 The 6-Axis servo amplifier fuse blown

(SRVO-214), DCAL alarm (SRVO-043) are displayed on the teach pendant.

Replace the 6-Axis servo amplifier.

1 Check +24VF used by the end effector for a ground fault. 2 Check the robot connection cable and the robot’s internal

cable. 3 Replace the 6-Axis servo amplifier. 4 In case of M-3iA, check the fan motor inside the robot

(option). 1 Check the regenerative resister, and replace it if

required. 2 Replace the 6-Axis servo amplifier.

Action

Fig.3.6(b) Fuse on the servo amplifier

FS1 (3.2A)

FS3 (3.2A)

FS2 (3.2A)

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B-83525EN/06 MAINTENANCE 3. TROUBLESHOOTING

(3) Emergency stop board fuses

FUSE2: For emergency stop circuit (A60L-0001-0290#LM10C) FUSE3: For teach pendant power supply circuit (A60L-0001-0290#LM10C) FUSE4: For +24V protection (A60L-0001-0290#LM20C) FUSE5: For +24V of mainboard protection (A60L-0001-0290#LM50C) FUSE6,FUSE7: For AC200V of fans protection (door/rear) (A60L-0001-0175#3.2A)

Name Symptom observed when fuse has blown Action

FUSE2 Alarm (SRVO-007) is displayed on the teach

pendant, and the red LED (24EXT) on the emergency stop board lights.

FUSE3 The display on the teach pendant disappears,

and the red LED (24T) on the emergency stop board lights.

FUSE4 An alarm relating to an input signal that

causes an emergency stop is issued, and the red LED (24V2) on the emergency stop board lights.

FUSE5 The teach pendant can not be operated and

the red LED (24V3) on the emergency stop board lights.

FUSE6 FUSE7

The fan stops.

1. Check the voltage between EXT24V and EXT0V (TBOP19). If no external power supply is used, check the jumper pin between EXT24V and INT24V or between EXT0V and INT0V.

2. Check the 24EXT (emergency stop line) for a short circuit or connection to ground.

3. Replace the emergency stop board.

4. Check the teach pendant and replace it if necessary.

1. Check the teach pendant cable and replace it if

necessary.

2. Check the cable between the emergency stop

board (CRS40) and the main board (CRS40) , and replace it if necessary.

3. Check the teach pendant and replace it if

necessary.

4. Replace the emergency stop board.

5. Replace the main board. (*)

1. Check the connection on TROP20.

2. Check the cable between the emergency stop

board (CRS40) and the main board (CRS40), and replace it if necessary.

3. Check the cable between the emergency stop

board (CRMA92) and the 6-Axis servo amplifier (CRMA91), and replace it if necessary.

4. If the cable between the emergency stop board

(CRMB22) and the 6-Axis servo amplifier (CRMB16) exist. Check this cable and replace it if necessary.

5. Replace the emergency stop board.

6. Replace the E-stop unit.

7. Replace the main board. (*)

8. Replace the 6-Axis servo amplifier.

1. Check the cable between the emergency stop

board (CRS40) and the main board (CRS40), and replace it if necessary.

2. Check the cable between the emergency stop

board (CRMA92) and the 6-Axis servo amplifier (CRMA91), and replace it if necessary.

3. Replace the back plane board.

4. Replace the main board. (*)

5. Replace the emergency stop board.

6. Replace the 6-Axis servo amplifier.

1. Check the fan cable and replace it if necessary.

2. Replace the fan unit.

3. Replace the emergency stop board.

* If the main board or FROM/SRAM module is replaced, the contents of memory (parameters,

specified data, etc.) will be lost. Before you replace the unit, therefore, make a backup copy of the data.

If an alarm is issued, data backup may be disabled. So, back up the contents of memory routinely.

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3. TROUBLESHOOTING MAINTENANCE B-83525EN/06

LED:24EXT(Red)

LED:24T（Red）

FUSE4 (2A) FUSE5 (5A) FUSE2 (1A)

TBOP19

TBO P20

FUSE3 (1A)

LED:24V2(Red)

LED:24V3(Red)

LED:SVON2(Green)

FUSE6 (3.2A)

FUSE7 (3.2A)

LED:SVON1(Green)

Fig.3.6 (c) Fuse on the emergency stop board

(4) Fuse on the process I/O MA,MB

FUSE1: Fuse for +24E (A60L-0001-0046#1.0)

Name

Symptom observed when fuse has

blown

FUSE1 The LED (ALM1 or FALM) the process I/O

board lights.

LED:ALM1（Red）

1. Check if the cables and peripheral devices connected to the process I/O board are normal.

2. Replace the process I/O board.

Action

LED:FALM（Red）

FUSE1 (1A)

Fig.3.6 (d) Fuse on the process I/O board MA

LED:FALM (Red)

LE D:A LM1 (Red)

FUSE1 (1A)

Fig.3.6 (e) Fuse on the process I/O board MB

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B-83525EN/06 MAINTENANCE 3. TROUBLESHOOTING

3.7 TROUBLESHOOTING BASED ON LED INDICATIONS

The printed circuit boards and servo amplifier are provided with alarm LEDs and status LEDs. The LED status and corresponding troubleshooting procedures are described below.

Main board

6-Axis servo amplifier

Fig.3.7 Troubleshooting based on LED indication

Emergency stop board

3.7.1 Troubleshooting Using the LEDS on the Main Board

(1) Troubleshooting using the status display LED To troubleshoot an alarm that arises before the teach pendant is ready to display, check the status

LEDs (green) on the main board at power-on. After power-on, the LEDs light as described in steps 1 to end, in the order described. If an alarm is detected, the step in which the alarm occurred can be determined from which LEDs are lit.

7-segment LED

RLED1

LEDG1 LEDG2 LEDG3 LEDG4

Fig. 3.7.1 Troubleshooting Using the LEDS On the Main Board

(Red)

(Green)

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3. TROUBLESHOOTING MAINTENANCE B-83525EN/06

Step LED Action to be taken

LEDG1

1: After power-on, all

LEDs are lit.

2: Software operation

start-up.

3: The initialization of

dram on the CPU card is completed.

LEDG2 LEDG3 LEDG4

LEDG1 LEDG2 LEDG3 LEDG4

[Action 1] Replace the CPU card. * [Action 2] Replace the main board.

4: The initialization of

DPRAM on the communication IC is completed.

5: The initialization of

the communication IC is completed.

6: The loading of the

basic software is completed.

7: Basic software

start-up.

8: Start-up of

communication with the teach pendant.

LEDG1 LEDG2 LEDG3 LEDG4

[Action 1] Replace the CPU card. * [Action 2] Replace the main board. * [Action 3] Replace the FROM/SRAM module.

* [Action 1] Replace the main board. * [Action 2] Replace the FROM/SRAM module.

* [Action 1] Replace the main board. * [Action 2] Replace the FROM/SRAM module. * [Action3] Replace the power supply unit.

* [Action 1] Replace the main board.

[Action 2] Replace the FROM/SRAM module.

9: The loading of optional

software is completed.

10: DI/DO initialization

LEDG1 LEDG2 LEDG3 LEDG4

* [Action 1] Replace the main board. [Action 2] Replace the process I/O board.

[Action 1] Replace the FROM/SRAM module. [Action 2] Replace the main board.

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B-83525EN/06 MAINTENANCE 3. TROUBLESHOOTING

Step LED Action to be taken

LEDG1

11: The preparation of the

SRAM module is completed.

LEDG2 LEDG3 LEDG4

[Action 1] Replace the axis control card. * [Action 2] Replace the main board.

[Action 3] Replace the servo amplifier.

LEDG1

12: Axis control card

initialization

LEDG2 LEDG3 LEDG4

[Action 1] Replace the axis control card. * [Action 2] Replace the main board.

[Action 3] Replace the servo amplifier.

LEDG1

13: Calibration is

completed.

LEDG2 LEDG3 LEDG4

[Action 1] Replace the axis control card. * [Action 2] Replace the main board.

[Action 3] Replace the servo amplifier.

LEDG1

14: Start-up of power

application for the servo system

LEDG2 LEDG3 LEDG4

* [Action 1] Replace the main board.

LEDG1

15: Program execution

LEDG2 LEDG3 LEDG4

* [Action 1] Replace the main board. [Action 2] Replace the process I/O board.

LEDG1 LEDG2

16: DI/DO output start-up.

LEDG3 LEDG4

* [Action 1] Replace the main board.

LEDG1

17: Initialization is

terminated.

LEDG2 LEDG3 LEDG4

Initialization has ended normally.

LEDG1

18: Normal status

LEDG2 LEDG3 LEDG4

Status LEDs 1 and 2 blink when the system is operating normally.

* If the main board or FROM/SRAM module is replaced, the contents of memory (parameters,

specified data, etc.) will be lost. Before you replace the unit, therefore, make a backup copy of the data.

If an alarm is issued, data backup may be disabled. So, back up the contents of memory routinely.

LED indication Description

RLED1

(Red)

[Description] CPU card is not working. [Action 1] Replace the CPU card.

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3. TROUBLESHOOTING MAINTENANCE B-83525EN/06

(2) TROUBLESHOOTING BY 7-SEGMENT LED INDICATOR

7-segment LED

indicator

[Description] A parity alarm condition has occurred in DRAM on the CPU card installed on

[Action1] Replace the CPU card.3.7

* [Action2] Replace the main board.

[Description] A parity alarm condition has occurred in SRAM on the FROM/SRAM module

[Action1] Replace the FROM/SRAM module.

* [Action2] Replace the main board.

[Description] A bus error has occurred in the communication controller.

* [Action] Replace the main board.

[Description] A parity alarm condition has occurred in DRAM controlled by the

* [Action] Replace the main board.

[Description] A servo alarm condition has occurred on the main board. [Action1] Replace the axis control card.

* [Action2] Replace the main board.

[Action3] If an option board is installed, replace the option board. [Description] The SYSEMG alarm has occurred. [Action1] Replace the axis control card. [Action2] Replace the CPU card.

* [Action3] Replace the main board.

[Description] The SYSFAIL alarm has occurred. [Action1] Replace the axis control card. [Action2] Replace the CPU card.

* [Action3] Replace the main board.

[Action4] If an option board is installed, replace the option board. [Description] 5V is supplied to Main board. Above alarms do not occur.

the main board.

installed on the main board.

communication controller.

* If the main board or FROM/SRAM module is replaced, the contents of memory (parameters,

specified data, etc.) will be lost. Before you replace the unit, therefore, make a backup copy of the data.

If an alarm is issued, data backup may be disabled. So, back up the contents of memory routinely.

Description

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B-83525EN/06 MAINTENANCE 3. TROUBLESHOOTING

3.7.2 Troubleshooting by LEDs on the 6-Axis Servo Amplifier

The 6-Axis servo amplifier has alarm LEDs. Troubleshoot the alarm indicated by the LEDs, referring also to the alarm indication on the teach pendant.

Check that the voltage is not higher than 50V.

LED: V4 (R)

LED:

SVALM (R) SVEMG (R) DRDY (G) OPEN (G) P5V (G) P3.3V(G)

Fig.3.7.2 LEDs on the 6-Axis servo amplifier

WARNING

Before touching the 6-Axis servo amplifier, check the DC link voltage with the

screws located above the LED "V4". By using a DC voltage tester, check that the voltage is 50 V or less.

LED Color Description

V4 Red Lights when the DCLINK circuit inside the servo amplifier is charged to reach the specified

voltage. If the LED does not light after pre-charge is finished: [Action 1] The DC Link may be short-circuited. Check for connection. [Action 2] The charge current control resistor may be defective. Replace the

emergency stop unit.

[Action 3] Replace the servo amplifier.

SVALM Red Lights when the servo amplifier detects an alarm.

If the LED lights when there is no alarm condition in the machine: [Action] Replace the servo amplifier. If the LED does not light when there is an alarm condition in the machine: [Action] Replace the servo amplifier.

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3. TROUBLESHOOTING MAINTENANCE B-83525EN/06

LED Color Description

SVEMG Red Lights when an emergency stop signal is input to the servo amplifier.

If the LED lights when the machine is not at an emergency stop: [Action] Replace the servo amplifier. If the LED does light when the machine is at an emergency stop: [Action] Replace the servo amplifier.

DRDY Green Lights when the servo amplifier is ready to drive the servo motor.

If the LED does not light when the motor is activated: [Action] Replace the servo amplifier.

OPEN Green Lights when the communication between the servo amplifier and the main board is normal.

If the LED does not light: [Action 1] Check for the connection of the FSSB optical cable. [Action 2] Replace the servo card. [Action 3] Replace the servo amplifier.

P5V Green Lights when the power supply circuit inside the servo amplifier outputs a voltage of +5 V

normally. If the LED does not light: [Action 1] Check the robot connection cable (RP1/RMP1) to see if there is a ground

fault in the +5V wire.

[Action 2] Replace the servo amplifier.

P3.3V Green Lights when the power supply circuit inside the servo amplifier outputs a voltage of +3.3 V

normally. If the LED does not light: [Action] Replace the servo amplifier.

3.7.3 Troubleshooting by LED on the Emergency Stop Board

LED indication Failure description and required measure

[Description] When the LED (red) turned on, the fuse (FUSE2) is brown. 24EXT for

the emergency stop circuit is not supplied.

[Action 1] If the fuse (FUSE2) has not brown in this state, check the voltage

between EXT24V and EXT0V (TBOP19). If no external power supply

24EXT

(Red)

24T

(Red)

[Action 2] Check the 24EXT (emergency stop line) for a short circuit or

[Action 3] Replace the emergency stop board. [Action 4] Check the teach pendant, and replace it if required. [Description] When the LED (red) turned on, the fuse (FUSE3) is brown. 24T for the

[Action 1] Check the teach pendant cable (CRS36), and replace it if required. [Action 2] Check the cable between the emergency stop board (CRS40) and the

[Action 3] Check the teach pendant, and replace it if required. [Action 4] Replace the emergency stop board. *[Action 5] Replace the main board.

is used, check the jumper pin between EXT24V and INT24V or between EXT0V and INT0V.

connection to ground.

teach pendant is not supplied.

main board (CRS40), and replace it if necessary.

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B-83525EN/06 MAINTENANCE 3. TROUBLESHOOTING

LED indication Failure description and required measure

[Description] When the LED (red) turned on, the fuse (FUSE4) is brown. 24V-2 for

the emergency stop input signal is not supplied. [Action 1] Check the connection of TBOP20. [Action 2] Check the cable between the emergency stop board (CRS40) and the

main board (CRS40), and replace it if necessary. [Action 3] Check the cable between the emergency stop board (CRMA92) and

24V2 (Red)

[Action 4] If the cable between the emergency stop board (CRMB22) and the

the 6-Axis servo amplifier (CRMA91), and replace it if necessary.

6-Axis servo amplifier (CRMB16) exist. Check this cable and replace it

if necessary. [Action 5] Replace the emergency stop board. [Action 6] Replace the E-stop unit. *[Action 7] Replace the main board. [Action 8] Replace the 6-Axis servo amplifier. [Description] When the LED (red) turned on, the fuse (FUSE5) is brown. 24V-3 for

the main board is not supplied. [Action 1] Check the cable between the emergency stop board (CRS40) and the

main board (CRS40), and replace it if necessary.

24V3 (Red)

[Action 2] Check the cable between the emergency stop board (CRMA92) and

the 6-Axis servo amplifier (CRMA91), and replace it if necessary. [Action 3] Replace the backplane board. *[Action 4] Replace the main board. [Action 5] Replace the emergency stop board. [Action 6] Replace the 6-Axis servo amplifier. [Description] These LEDs (green) indicate the status of SVON1/SVON2 signals

SVON1/SVON2

(Green)

from the emergency stop board to the servo amplifier. When the

SVON1 and SVON2 (green) turned on, the servo amplifier is ready to

energize.

* If the main board or FROM/SRAM module is replaced, the contents of memory (parameters,

specified data, etc.) will be lost. Before you replace the unit, therefore, make a backup copy of the data.

If an alarm is issued, data backup may be disabled. So, back up the contents of memory routinely.

LED:24EXT(Red)

FUSE4 (2A) FUSE5 (5A) FUSE2 (1A)

LED:24V2(Red)

LED:24V3(Red)

TBOP19

LED:24T（Red）

TBO P20

FUSE3 (1A)

LED:SVON2(Green)

FUSE6 (3.2A)

FUSE7 (3.2A)

LED:SVON1(Green)

Fig.3.7.3 LEDs on the emergency stop board

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3. TROUBLESHOOTING MAINTENANCE B-83525EN/06

3.7.4 Troubleshooting by Alarm LEDs on the Process I/O Board

Process I/O MA,MB

LED Color Description

[Description] An alarm was issued during communication between the main board and

the process I/O board.

ALM1 Red

FALM Red

LED:ALM1（Red）

[Action 1] Replace the process I/O board. [Action 2] Replace the I/O link connection cable. [Action 3] Replace the main board. [Description] The fuse on the process I/O board was blown. [Action1] Replace the fuse on the process I/O board. [Action2] Check the cables and peripheral units connected to the process I/O board

and replace the defective units.

[Action3] Replace the process I/O board.

LED:FALM（Red）

LED:FALM (Red)

LED:ALM1 (Red)

FUSE1 (1A)

Fig.3.7.4 (a) LEDs on the process I/O board MA

FUSE1 (1A)

Fig.3.7.4 (b) LEDs on the process I/O board MB

3.8 MANUAL OPERATION IMPOSSIBLE

The following explains checking and corrective action required if the robot cannot be operated manually after the controller is turned on:

(1) Check and corrective action to be made if manual operation is impossible

(Check 1) Check whether the teach pendant is enabled. (Corrective action) Turn on the teach pendant "enable". (Check 2) Check whether the teach pendant is handled correctly. (Corrective action) To move an axis by manual operation, press the axis selection key and shift key at

the same time.

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B-83525EN/06 MAINTENANCE 3. TROUBLESHOOTING

Set the override for manual feed to a position other than the FINE and VFINE

positions.

(Check 3) Check whether the ENBL signal of the peripheral device control interface is set to

on. (Corrective action) Place the peripheral device control interface in the ENBL status. (Check 4) Check whether the HOLD signal of the peripheral device control interface (hold

status). (Check whether the hold lamp on the teach pendant is on.) (Corrective action) Turn off the HOLD signal of the peripheral device control interface. (Check 5) Check whether the previous manual operation has been completed. (Corrective action) If the robot cannot be placed in the effective area because of the offset of the speed

command voltage preventing the previous operation from being completed, check the

position deviation on the status screen, and change the setting. (Check 6) Check whether the controller is in the alarm status. (Corrective action) Release the alarm.

(2) Check and corrective action to be taken if the program cannot be executed

(Check 1) Check whether the ENBL signal for the peripheral-device control interface is on. (Corrective action) Put the peripheral-device control interface in the ENBL state. (Check 2) Check whether the HOLD signal for the peripheral-device control interface is on.

Also check whether the HOLD lamp on the teach pendant is on. (Corrective action) If the HOLD signal of the peripheral device control interface is on, turn it off. (Check 3) Check whether the previous manual operation has been completed. (Corrective action) If the robot cannot be placed in the effective area because of the offset of the speed

command voltage, which prevents the previous operation from being completed,

check the position deviation on the status screen, then change the setting. (Check 4) Check whether the controller is in the alarm status. (Corrective action) Release the alarm.

3.9 LEDS ON UNITS SUPPORTING I/O LINK i

3.9.1 Meanings of LEDs on Units Supporting I/O Link i

The standard I/O Link i incorporates three LEDs, “LINK” (green), “ALM” (red), and “FUSE” (red) for each unit separately. These LEDs indicate the states of the units. The following table lists the ON/OFF states of the LEDs and their meanings.

LED ON/OFF state ON and OFF duration

Steadily OFF Steadily ON Blink (1:1) ON = approx. 0.5 sec, OFF = approx. 0.5 sec Blink (3:1) ON = approx. 1.5 sec, OFF = approx. 0.5 sec Blink (1:3) ON = approx. 0.5 sec, OFF = approx. 1.5 sec Blink (1:1 at high speed) ON = approx. 0.25 sec, OFF = approx. 0.25 sec

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3. TROUBLESHOOTING MAINTENANCE B-83525EN/06

LED「LINK」(green)

The “LINK” (green) LED indicates the state of communication. The following table lists the meanings of LED states.

Operation

mode

Common

I/O Link Blink (1:3) Communication in progress

I/O Link i

LED state Meaning Fault location and action

OFF Power OFF ON

Blink (1:1 at high speed)

Blink (1:1) Communication in progress Blink (3:1)

Power ON (before communication start)

Communication at halt

Communication in progress (Dual check safety in use)

Communication is at halt because of an alarm. Identify the cause according to the states of the red LED stated below or information displayed on the CNC screen.

LED「ALM」(red)

The “ALM” (red) LED indicates an alarm in the unit of interest or a unit subsequent to it. The following table lists the meanings of LED states.

Operation

mode

Common OFF Normal state or power OFF I/O Link ON Alarm

I/O Link i

LED state Meaning Fault location and action

It is likely that the hardware may be defective. Replace the unit.

ON Alarm

Broken wire between the unit

Blink (1:1)

Blink (3:1)

Blink (1:3) Status alarm

of interest and a unit subsequent to it

Power failure (including instantaneous power failure) in a unit subsequent to the unit of interest

It is likely that the hardware may be defective. Replace the unit. Check for a defective cable or a poor cable connection between JD1A on the unit of interest and JD1B on a unit subsequent to that unit. Alternatively, it is likely that there may be noise. Check to see if there is noise around the cable.

Identify and remove the cause of a power failure in a unit subsequent to the unit of interest.

A status alarm, such as a DO ground fault, has occurred. Identify and remove the cause of the alarm.

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fanuc R30iB User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

B-83525EN/06

SAFETY PRECAUTIONS

1 DEFINITON OF USER

2 DEFINITION OF SAFETY NOTATIONS

3 USER SAFETY

3.1 SAFETY OF THE OPERATOR

3.2 SAFETY OF THE PROGRAMMER

3.3 SAFETY OF THE MAINTENANCE ENGINEER

4.1 PRECAUTIONS IN PROGRAMMING

4.2 PRECAUTIONS FOR MECHANISM

5 SAFETY OF THE ROBOT MECHANISM

5.1 PRECAUTIONS IN OPERATION

5.2 PRECAUTIONS IN PROGRAMMING

5.3 PRECAUTIONS FOR MECHANISMS

6 SAFETY OF THE END EFFECTOR

6.1 PRECAUTIONS IN PROGRAMMING

7 STOP TYPE OF ROBOT

8 WARNING & CAUTION LABEL

PREFACE

TABLE OF CONTENTS

I. MAINTENANCE

1 OVERVIEW

2 CONFIGURATION

2.1 EXTERNAL VIEW OF THE CONTROLLER

2.2 COMPONENT FUNCTIONS

2.3 CHECKS AND MAINTENANCE

3 TROUBLESHOOTING

3.1 POWER CANNOT BE TURNED ON

3.1.1 When the Teach Pendant Cannot be Powered on

3.2 ALARM OCCURRENCE SCREEN

3.3 STOP SIGNALS

3.4 MASTERING

3.5 TROUBLESHOOTING USING THE ALARM CODE

3.6 FUSE-BASED TROUBLESHOOTING

3.7 TROUBLESHOOTING BASED ON LED INDICATIONS

3.7.1 Troubleshooting Using the LEDS on the Main Board

3.7.2 Troubleshooting by LEDs on the 6-Axis Servo Amplifier

3.7.3 Troubleshooting by LED on the Emergency Stop Board

3.7.4 Troubleshooting by Alarm LEDs on the Process I/O Board

3.8 MANUAL OPERATION IMPOSSIBLE

3.9 LEDS ON UNITS SUPPORTING I/O LINK i

3.9.1 Meanings of LEDs on Units Supporting I/O Link i