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.
扉が開いきに作動するンタロック装置および安全プ
Fig. 3 (a) Safety fence and safety gate
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Safety fence
安全
SAFETY PRECAUTIONS B-83525EN/06
p
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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y
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
On
Off
On
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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- 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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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
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 this option is loaded.

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
Small
Large
Large
Medium
Medium
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 Medium
Large
Large
Large
Single phase/Three phase
p-2
B-83525EN/06 TABLE OF CONTENTS

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
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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 -
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