fanuc R-30iB Mate, R-30iB Mate Plus CONTROLLER Maintenance Manual

< > series

R-30+B Mate/R-30+B Mate Plus CONTROLLER

MAINTENANCE MANUAL

© FANUC CORPORATION, 2012

B-83525EN/08

•

Original Instructions

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

oreign Exchange and

Trade Law". The export from Japan may be subject to an export license by the

Should you wish to export or re-export these products, please contact FANUC for advice.

a failure of the product, install a safety device.

and if the manual

that any operations that are not explicitly described as being possible are "not possible".

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 products in this manual are controlled based on Japan's “F
Foreign
government of Japan. Further, re-export to another country may be s ubject 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.

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

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,
contained them all, it would be enormous in volume. It is, therefore, requested to assume

B-83525EN/08 SAFETY PRECAUTIONS

SAFETY PRECAUTIONS

This chapter must be read before using the robot.

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.
For safe use of FANUC robots, you must read and follow the instructions in “FANUC Robot SAFETY
HANDBOOK (B-80687EN)”.

1 DEFINITION 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 or Teaching operator:

• Operates the robot

• Teaches the robot inside the safety fence

Trained maintenance worker:

• Operates the robot

• Teaches the robot inside the safety fence

• Performs maintenance (repair, adjustment, replacement)

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

- Programmer/Teaching operator and trained maintenance worker 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.

s-1

SAFETY PRECAUTIONS B-83525EN/08

worker

Turn power ON/OFF to Robot controller

  

Select operating mode (AUTO, T1, T2)





Select remote/local mode





Select robot program with teach pendant





Select robot program with external device





Start robot program with operator’s panel

  

Start robot program with teach pendant





Reset alarm with operator’s panel





Reset alarm with teach pendant





Set data on teach pendant





Teaching with teach pendant





Emergency stop with operator’s panel

  

Emergency stop with teach pendant

 

Maintain for operator’s panel





Maintain for teach pendant



Symbol

Definitions

occur if he or she fails to follow the approved procedure.

procedure.

is to be indicated.

Table 1(a) lists the work outside the safety fence. In this table, the symbol “” means the work allowed
to be carried out by the worker.

Table 1 (a) List of work outside the fence

Trained

maintenance

Operator



Programmer or

Teaching operator

In the robot operating, programming and maintenance, the operator, programmer/teaching operator and
trained maintenance worker take care of their safety using at least the following safety protectors.

• Use clothes, uniform, overall adequate for the work

• Safety shoes

• 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.

WARNING

CAUTION

Used if hazard resulting in the death or serious injury of the user will be expected to

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

NOTE

Used if a supplementary explanation not related to any of WARNING and CAUTION

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

s-2

B-83525EN/08 SAFETY PRECAUTIONS

3 WARNING & CAUTION LABEL

(1) Step-on prohibitive label

Fig.3 (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.3 (b) High-Temperature warning label

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

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

s-3

SAFETY PRECAUTIONS B-83525EN/08

(3) 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

(4) Caution label

Description
See related contents of this manual.

Fig.3 (c) High-voltage warning label

Fig.3 (d) Caution label

s-4

B-83525EN/08 SAFETY PRECAUTIONS

WARNING

connecting power supply to the controller.

Key

Locked state

4 WARNING & CAUTION REGARDING USE

OF CONTROLLER

1 The R-30iB Mate/R-30iB Mate Plus controller has a sealed structure, it is

designed so that dust, oil mist, conductive foreign particulate, etc. around the
controller do not enter the interior of the controller.
Whether or not the controller is in operation, if the door is not locked with the
key, the original sealing capacity of the controller cannot be secured. In this
case, failure may occur due to internal contamination, and there is the risk of
electric shock, electric leakage, and fire due to insulation deterioration.

2 Be sure to lock the controller securely with the key to prohibit that the person

except the trained maintenance worker opens the door of the controller.
3 To prevent electric shock, do not energize the controller while the door is open.
4 After connecting input power cable, in order to avoid turning on the main

breaker, padlocking can be installed to the breaker handle.
5 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.
6 Be sure to connect the ground wire according to Section 3.3.3.1 when

s-5

B-83525EN/08 PREFACE

Model

Abbreviation

FANUC Robot LR Mate 200iD

LR Mate 200iD

FANUC Robot LR Mate 200iD/4S

LR Mate 200iD/4S

FANUC Robot LR Mate 200iD/4SC

LR Mate 200iD/4SC

FANUC Robot LR Mate 200iD/4SH

LR Mate 200iD/4SH

FANUC Robot LR Mate 200iD/7C

LR Mate 200iD/7C

FANUC Robot LR Mate 200iD/7H

LR Mate 200iD/7H

FANUC Robot LR Mate 200iD/7L

LR Mate 200iD/7L

FANUC Robot LR Mate 200iD/7LC

LR Mate 200iD/7LC

FANUC Robot LR Mate 200iD/7WP

LR Mate 200iD/7WP

FANUC Robot LR Mate 200iD/14L

LR Mate 200iD/14L

FANUC Robot LR Mate 200iC/5WP *

LR Mate 200iC/5WP

LR Mate 200iC

FANUC Robot ER-4iA **

ER-4iA

ER-4iA

FANUC Robot M-1iA/0.5A

M-1iA/0.5A

FANUC Robot M-1iA/0.5AL

M-1iA/0.5AL

FANUC Robot M-1iA/0.5S

M-1iA/0.5S

FANUC Robot M-1iA/0.5SL

M-1iA/0.5SL

FANUC Robot M-1iA/1H

M-1iA/1H

FANUC Robot M-1iA/1HL

M-1iA/1HL

FANUC Robot M-2iA/3A

M-2iA/3A

FANUC Robot M-2iA/3AL

M-2iA/3AL

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-3iA/6A

M-3iA/6A

FANUC Robot M-3iA/6S

M-3iA/6S

FANUC Robot M-3iA/12H

M-3iA/12H

FANUC Robot DR-3iB/8L **

DR-3iB/8L

DR-3iB

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-10iD/8L **

M-10iD/8L

FANUC Robot M-10iD/10L **

M-10iD/10L

FANUC Robot M-10iD/12 **

M-10iD/12

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

PREFACE

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

LR Mate 200iD

M-1iA

M-2iA

M-3iA

M-10iA

M-10iD

M-20iA

p-1

PREFACE B-83525EN/08

Model

Abbreviation

FANUC Robot M-20iB/25

M-20iB/25

FANUC Robot M-20iB/25C

M-20iB/25C

FANUC Robot M-20iB/35S **

M-20iB/35S

FANUC Robot M-20iD/12L **

M-20iD/12L

FANUC Robot M-20iD/25 **

M-20iD/25

FANUC Robot ARC Mate 50iD

ARC Mate 50iD

FANUC Robot ARC Mate 50iD/7L

ARC Mate 50iD/7L

FANUC ROBOWELD 100iC *

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 100iD **

ARC Mate 100iD

FANUC Robot ARC Mate 100iD/8L **

ARC Mate 100iD/8L

FANUC Robot ARC Mate 100iD/10L **

ARC Mate 100iD/10L

FANUC Robot ARC Mate 120iC
FANUC ROBOWELD 120iC *

FANUC ROBOWELD 120iC/10L *

FANUC Robot ARC Mate 120iC/12L

ARC Mate 120iC/12L

FANUC Robot ARC Mate 120iD **

ARC Mate 120iD

FANUC Robot ARC Mate 120iD/12L **

ARC Mate 120iD/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-2000iD/100FH

R-2000iD/100FH

FANUC Robot R-2000iD/165FH

R-2000iD/165FH

FANUC Robot R-2000iD/210FH

R-2000iD/210FH

FANUC Robot R-1000iA/80F

R-1000iA/80F

FANUC Robot R-1000iA/100F

R-1000iA/100F

FANUC Robot M-710iC/12L

M-710iC/12L

FANUC Robot M-710iC/20L

M-710iC/20L

FANUC Robot M-710iC/20M

M-710iC/20M

FANUC Robot M-710iC/45M

M-710iC/45M

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/70

M-710iC/70

FANUC Robot M-710iC/70T

M-710iC/70T

FANUC Robot CR-4iA

CR-4iA

CR-4iA

FANUC Robot CR-7iA

CR-7iA

FANUC Robot CR-7iA/L

CR-7iA/L

FANUC Robot CR-14iA/L **

CR-14iA/L

CR-14iA

M-20iB

M-20iD

ARC Mate 50iD

FANUC Robot ARC Mate 100iC *

FANUC Robot ARC Mate 100iC/6L *

ARC Mate 100iC

ARC Mate 100iC/6L

ARC Mate 120iC

ARC Mate 120iC/10L

ARC Mate 100iC

ARC Mate 100iD

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

ARC Mate 120iD

R-2000iC

R-2000iD

R-1000iA

M-710iC

CR-7iA

p-2

B-83525EN/08 PREFACE

Model

Abbreviation

FANUC Robot CR-15iA **

CR-15iA

CR-15iA

Hazardous substances

(PBDE)

unit main body

Motor × ○ ○ ○ ○ ○

Cables × ○ ○ ○ ○ ○

Teach pendant

× ○ ○ ○ ○

○

Control unit
main body

unit main body

part is above the limit requirement of GB/T 26572.

* Models do not correspond to R-30iB Mate Plus controller.
** Models do not correspond to R-30iB Mate controller.

Name and content of hazardous substances in products based on the “Restriction of the
Use of Certain Hazardous Substances in Electrical and Electronic Equipment (Chinese
RoHS2)”

The hazardous substances contained in th e R-30iB Mate/R-30iB Mate Plus controller as listed in the
table below.

The names and contents of hazardous substances in the product

Part name

Mechanical
Mechanical
unit

Control unit
Mechanical
unit

This table is prepared in accordance with the provisions of SJ/T 11364.

○: Indicates that said hazardous substance contained in all of the homogeneous mat erials for this part is below

the limit requirement of GB/T 26572.
×: Indicates that said hazardous substance contained in at leas t one of the homogeneous materials used for this

Mechanical

Lead

(Pb)

Mercury

(Hg)

○ ○ ○ ○ ○ ○

× ○ ○ ○ ○ ○

× ○ ○ ○ ○ ○

Cadmium

(Cd)

Hexavalent

Chromium

(Cr (VI))

Polybromin-

ated

biphenyls

(PBB)

Polybromin-

ated

diphenyl

ethers

p-3

PREFACE B-83525EN/08

Environmental Protection Use Period

In the following proper use environmental conditions, Environmental Protection Use Period
is 20 years after manufacture.

protection use period, is attached as shown in the figure below.

Installation location : Indoor
Ambient temperature : 0°C to 45°C
Ambient humidity : 75%RH or less
Vibration : 4.9m/s
Atmosphere : It corrosive gas is not

The pollution prevention label, which indicates the environmental

2

(0.5G) or less

p-4

B-83525EN/08 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 ........................................................................ 10

2.3 CHECKS AND MAINTENANCE .................................................................. 11

3 TROUBLESHOOTING .......................................................................... 13

3.1 POWER CANNOT BE TURNED ON ........................................................... 13

3.1.1 When the Teach Pendant Cannot be Powered on ................................................... 14

3.1.2 When the Teach Pendant does not Change from the Initial Screen ....................... 15

3.2 ALARM OCCURRENCE SCREEN .............................................................. 17

3.3 STOP SIGNALS .......................................................................................... 19

3.4 MASTERING ............................................................................................... 20

3.5 TROUBLESHOOTING USING THE ALARM CODE .................................... 22

3.6 FUSE-BASED TROUBLESHOOTING ......................................................... 76

3.7 TROUBLESHOOTING BASED ON LED INDICATIONS ............................. 84

3.7.1 Troubleshooting Using the LEDS on the Main Board ........................................... 85

3.7.2 Troubleshooting by LEDs on the 6-Axis Servo Amplifier .................................... 89

3.7.3 Troubleshooting by LED on the Emergency Stop Board ....................................... 90

3.7.4 Troubleshooting by Alarm LEDs on the Process I/O Board .................................. 92

3.7.5 Troubleshooting by LEDs on the Sensor I/F Unit for Collaborative Robot ........... 93

3.7.5.1 Status indication of the I/O Link i ..................................................................... 93

3.7.5.2 Status indications of the distributed Link .......................................................... 94

3.8 MANUAL OPERATION IMPOSSIBLE ......................................................... 95

3.9 LEDS ON UNITS SUPPORTING I/O LINK i ...................................................... 96

3.9.1 Meanings of LEDs on Units Supporting I/O Link i ............................................... 96

4 PRINTED CIRCUIT BOARDS ............................................................... 98

4.1 MAIN BOARD .............................................................................................. 98

4.2 EMERGENCY STOP BOARD (A20B-2005-0150, A20B-2103-0170) ........ 103

4.3 BACKPLANE ............................................................................................. 104

4.4 PROCESS I/O BOARD MA (A20B-2004-0381) ......................................... 104

4.5 PROCESS I/O BOARD MB (A20B-2101-0731) ......................................... 105

4.6 CONNECTOR CONVERTER BOARD (A20B-2004-0411) ........................ 106

4.7 TERMINAL CONVERTER BOARD (A20B-1009-0690) ............................. 107

5 6-AXIS SERVO AMPLIFIERS ............................................................. 108

c - 1

TABLE OF CONTENTS B-83525EN/08

5.1 LEDS OF 6-AXIS SERVO AMPLIFIER ...................................................... 109

5.2 SETTING OF 6-AXIS SERVO AMPLIFIER ............................................... 110

5.3 6-AXIS SERVO AMPLIFIER SPECIFICATIONS ....................................... 111

6 SENSOR I/F UNIT FOR COLLABORATIVE ROBOT ......................... 112

7 POWER SUPPLY ................................................................................ 113

7.1 BLOCK DIAGRAM OF THE POWER SUPPLY ......................................... 113

8 REPLACING UNITS ............................................................................ 115

8.1 REPLACING THE PRINTED-CIRCUIT BOARDS ..................................... 115

8.1.1 Replacing the Backplane Board (Unit) ................................................................. 116

8.1.2 Replacing the Main Board .................................................................................... 117

8.2 REPLACING CARDS AND MODULES ON THE MAIN BOARD ............... 117

8.3 REPLACING THE EMERGENCY STOP UNIT .......................................... 122

8.4 REPLACING THE EMERGENCY STOP BOARD ..................................... 122

8.5 REPLACING THE POWER SUPPLY UNIT ............................................... 123

8.6 REPLACING THE DISCHARGE RESISTOR UNIT ................................... 124

8.7 REPLACING THE 6-AXIS SERVO AMPLIFIER ........................................ 125

8.8 REPLACING THE TEACH PENDANT ....................................................... 127

8.9 REPLACING THE CONTROL SECTION FAN MOTOR ............................ 128

8.10 REPLACING THE AC FAN MOTOR ......................................................... 129

8.10.1 Replacing the Heat Exchanger and Door Fan Unit .............................................. 129

8.11 REPLACING THE BATTERY .................................................................... 130

8.11.1 Battery for Memory Backup (3 VDC) .................................................................. 130

II. CONNECTIONS

1 OVERVIEW ......................................................................................... 135

2 BLOCK DIAGRAM .............................................................................. 136

3 ELECTRICAL CONNECTIONS ........................................................... 137

3.1 CONNECTION DIAGRAM BETWEEN MECHANICAL UNITS .................. 137

3.2 CONNECTION TO FANUC I/O Link and FANUC I/O Link i .......................... 139

3.2.1 Connection of I/O Link and I/O Link i by Using JRS26 Connector .................... 139

3.2.1.1 Connection of the I/O Link cable by using JRS26 connector .......................... 140

3.2.1.2 Cable connection diagram of the I/O Link cable by using JRS26 connector .. 141

3.2.2 Connection of JD44A Connector(Option) ............................................................ 142

3.2.2.1 Connection of the I/O Link cable by using JD44A connector ......................... 142

3.2.2.2 Cable connection diagram of the I/O Link cable by using JD44A connector . 143

3.3 EXTERNAL CABLE WIRING DIAGRAM ................................................... 144

3.3.1 Robot Connection Cables ..................................................................................... 144

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

3.3.3 Connecting the Input Power ................................................................................. 147

3.3.3.1 Connecting the input power cable ................................................................... 147

3.3.3.2 Isolated transformer ......................................................................................... 148

3.3.3.3 Leakage breaker ............................................................................................... 149

3.3.4 Connecting the External Emergency Stop ............................................................ 150

3.3.5 Connecting the Auxiliary Axis Brake (CRR65 A/B) ........................................... 158

3.3.6 Connecting the Auxiliary Axis Over Travel (CRM68) ........................................ 159

147

c - 2

B-83525EN/08 TABLE OF CONTENTS

4 PERIPHERAL DEVICE, ARC WELDING, AND EE INTERFACES .... 160

4.1 PERIPHERAL DEVICE INTERFACE BLOCK DIAGRAM .......................... 163

4.1.1 In Case of Main Board (CRMA15, CRMA16) .................................................... 163

4.1.2 In the Case of the Process I/O Board MA ............................................................ 163

4.1.3 In the Case of the Process I/O Board MB ............................................................ 164

4.1.4 In the Case of the Connector Conversion Board .................................................. 164

4.1.5 In the Case of the Terminal Converter Board ....................................................... 165

4.2 I/O SIGNALS O F MAIN BOARD ................................................................ 166

4.3 INTERFACE FOR PERIPHERAL DEVICES .............................................. 168

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

Peripheral Devices ................................................................................................ 168

4.3.2 Connection between the Connector Converter Board and Peripheral Devices .... 174

4.3.3 Connection between the Terminal Converter Board and Peripheral Devices ...... 175

4.3.4 Connecting Additional Safety I/O Terminal Conversion Board .......................... 176

4.3.5 Connection between the Process I/O Board MA and Peripheral Devices ............ 178

4.4 INTERFACE FOR WELDING MACHINES ................................................ 182

4.4.1 Connection between the Process I/O Board MB and Welding Machines ............ 182

4.5 EE INTERFACE ......................................................................................... 184

4.5.1 Connection between the Robot and End Effector ................................................ 184

4.6 DIGITAL I/O SIGNAL SPECIFICATIONS .................................................. 187

4.6.1 Peripheral Device Interface A .............................................................................. 187

4.6.2 EE Interface .......................................................................................................... 189

4.6.3 I/O Signal Specifications for ARC-Welding Interface

(A-cabinet/Process I/O Board MB) ...................................................................... 190

4.7 SPECIFICATIONS OF THE CABLES USED FOR PERIPHERAL

DEVICES AND WELDERS ........................................................................ 193

4.7.1 Peripheral Device Interface A1 Cable

(CRMA15: Tyco Electronics AMP, 40 pins) ....................................................... 193

4.7.2 Peripheral Device Interface A2 Cable

(CRMA16: Tyco Electronics AMP, 40 pins) ....................................................... 193

4.7.3 Peripheral Device Interface B1 and B2 Cables

(CRMA52; Tyco Electronics AMP, 30 pin)......................................................... 194

4.7.4 ARC Weld Connection Cables

(CRW11; Tyco Electronics AMP, 20 pin) ........................................................... 194

4.8 CABLE CONNECTION FOR THE PERIPHERAL DEVICES, END

EFFECTORS, AND ARC WELDERS ........................................................ 195

4.8.1 Peripheral Device Connection Cable .................................................................... 195

4.8.2 Peripheral Device Cable Connector ..................................................................... 196

4.8.3 Recommended Cables .......................................................................................... 198

4.9 CONNECTION OF HDI ............................................................................. 199

4.9.1 Connecting HDI ................................................................................................... 199

4.9.2 Input Signal Rules for the High-speed Skip (HDI) .............................................. 200

4.10 CONNECTING THE COMMUNICATION UNIT ......................................... 201

4.10.1 RS232C Interface ................................................................................................. 201

4.10.1.1 Interface ........................................................................................................... 201

4.10.1.2 RS232C interface signa ls ................................................................................. 202

4.10.1.3 Connection between RS232C interface and I/O device ................................... 202

4.10.2 Ethernet Interface ................................................................................................. 204

4.10.2.1 Connection to Ethernet .................................................................................... 204

4.10.2.2 Routing of the Ethernet cable .......................................................................... 205

4.10.2.3 100BASE-TX connector (CD38A, CD38B) / 1000BASE-T Connector

(CD38C) pin assignments ................................................................................ 206

4.10.2.4 Twisted-pair cable specification ...................................................................... 206

c - 3

TABLE OF CONTENTS B-83525EN/08

4.10.2.5 Electrical noise countermeasures ..................................................................... 209

4.10.2.6 Check items at installation ............................................................................... 213

5 TRANSPORTATION AND INSTALLATION ....................................... 214

5.1 TRANSPORTATION .................................................................................. 214

5.2 PACKAGE ................................................................................................. 215

5.3 INSTALLATION ......................................................................................... 216

5.3.1 Installation Method ............................................................................................... 216

5.3.2 Assembly at Installation ....................................................................................... 220

5.4 INSTALLATION OF TEACH PENDANT HOOK (OPTION) ....................... 221

5.5 INSTALLATION CONDITIONS .................................................................. 222

5.6 CAUTION ON EMC (ELECTROMAGNETIC COMPATIBILITY) ................ 225

5.7 ADJUSTMENT AND CHECKS AT INSTALLATION .................................. 226

5.8 RESETTING OVERTRAVEL AND EMERGENCY STOP

AT INSTALLATION .................................................................................... 226

5.8.1 Peripheral Device Interface Processing ................................................................ 226

5.8.2 Resetting Overtravel ............................................................................................. 227

5.8.3 How to Disable/Enable HBK ............................................................................... 227

5.8.4 How to Disable/Enable Pneumatic Pressure Alarm (PPABN) ............................. 227

APPENDIX

A SPECIFICATION LIST ........................................................................ 231

B TOTAL CONNECTION DIAGRAM ...................................................... 253

C SPECIFICATIONS OF PERIPHERAL DEVICE INTERFACE ............. 289

C.1 SIGNAL ..................................................................................................... 289

C.2 SETTING COMMON VOLTAGE ................................................................ 291

C.3 I/O SIGNALS ............................................................................................. 291

C.3.1 Input Signals ......................................................................................................... 291

C.3.2 Output Signals ...................................................................................................... 294

C.4 SPECIF ICATIONS OF DIGITAL INPUT/OUTPUT ..................................... 297

C.4.1 Overview .............................................................................................................. 297

C.4.2 Input/Output Hardware Usable in the R-30iB Mate Controller ........................... 297

C.4.3 Software Specifications ........................................................................................ 298

D OPTICAL FIBER CABLE .................................................................... 299

E BRAKE RELEASE UNIT ..................................................................... 302

E.1 SAFETY PRECAUTIONS .......................................................................... 302

E.2 CONFIRMATIONS BEFORE OPERATION ............................................... 302

E.3 OPERATION.............................................................................................. 303

E.3.1 In Case of Operating to the Robot ........................................................................ 303

E.3.2 In Case of Operating to the Auxiliary Axis .......................................................... 305

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

(IN CASE OF NO POWER PLUG) ............................................................ 306

E.5 DIMENSION .............................................................................................. 307

E.6 FUSE ......................................................................................................... 308

E.7 SPECIFICATIONS ..................................................................................... 309

c - 4

B-83525EN/08 TABLE OF CONTENTS

F TEACH PENDANT DISCONNECT FUNCTION (OPTION) ................. 310

F.1 CONFIGURATION ..................................................................................... 310

F.2 PROCEDURE OF TEACH PENDANT DISCONNECT .............................. 310

F.2.1 Teach Pendant Disconnect ................................................................................... 310

F.2.2 Teach Pendant Co nnect ........................................................................................ 311

G INSTRUCTION FOR TERMINAL BLOCK .......................................... 312

G.1 EXTERNAL EMERGENCY STOP SIGNAL INPUT/OUTPUT TERMINAL

BLOCK ...................................................................................................... 312

G.2 TERMINAL CONVERTER BOARD TERMINAL BLOCK ........................... 314

H REPLACING THE PROTECTION SHEET .......................................... 315

I SEALING OF THE CABLE ENTRANCE OF THE CABINET ............. 316

I.1 CABLE ENTRANCE FOR Mate-CABINET ................................................ 316

I.2 HOLES OF CABLE SEAL BLOCK FOR CABLE ENTRANCE ................... 317

I.3 SUITABLE CABLE DIAMETER ................................................................. 318

I.4 ADJUST THE CABLE DIAMETER ............................................................ 319

J FLEX CABLE CONDITION ................................................................. 320

J.1 MINIMUM BEND RADIUS OF CABLE ...................................................... 320

J.2 FLEX CABLE ............................................................................................. 320

J.3 CABLE CARRIER ...................................................................................... 320

J.4 CABLE DURABILITY TEST ....................................................................... 320

J.5 EXPERIMENTAL RESULT ........................................................................ 320

J.6 WRING IN THE CABLE CARRIER ............................................................ 321

K INSTRUCTION FOR STACKING CABINETS ..................................... 325

L BRAKE RELEASE UNIT FOR DR-3iB ............................................... 328

L.1 CONFIGURATION ..................................................................................... 328

L.2 BRAKE RELEASE OPERATION ............................................................... 328

L.3 BRAKE RELEASE UNIT ............................................................................ 329

L.4 REPLACING THE FUSE ........................................................................... 329

L.5 ROBOT CONNECTION CABLE ................................................................ 330

L.6 TOTAL CONNECTION DIAGRAM ............................................................ 331

c - 5

I. MAINTENANCE

B-83525EN/08 MAINTENANCE 1. OVERVIEW

safety

Standard

Electrical Standard

controller

Canada

•Shielded cable

supported.

WARNING

Otherwise, you could injure personnel or damage equipment.

1 OVERVIEW

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

R-30iB Mate/R-30iB Mate Plus has different controller depending on the required standards.

NRTL controller: To meet UL/CSA standard.
CE controller: To meet Machinery Directive, Low v oltage Directive, EMC Directive to cover

the requirement of CE standard.

CE/NRTL controller: To meet both CE standard and UL/CSA standard.

This manual covers these controllers of the R-30iB Mate/R-30iB Mate Plus.
The difference of NRTL, CE and CE/NRTL controller from the Basic controller is small as shown in
Table 1 (a) (ex. EMC parts, Breakers).
And the specific descriptions of the CE and NRTL controllers are noted in this manual.

Table 1 (a) Applied standards

Functional

EMC

Robot Standard

Requirement Difference

Basic

NRTL
controller

CE
controller

CE/NRTL
controller

ISO 13849-1
IEC 61508

- - - -

UL standard
CSA standard

•USA and Canada

CE standard

•Europe

CE standard

•Europe
UL standard
CSA standard

•USA and Canada

-

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

UL1740
CAN/CSA Z434
NFPA79

EN/ISO 10218-1
EN 60204-1

UL1740
CAN/CSA Z434
NFPA79
EN/ISO 10218-1
EN 60204-1

•UL listed main breaker

•E-stop unit with UL

listed breaker

•600V input circuit for

•Noise filter

•EMC Cabinet

•Noise filter

•EMC Cabinet

•Shielded cable

•UL listed main breaker

•E-stop unit with UL

listed breaker

•600V input circuit for
Canada can not be

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

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

peripheral devices, and installation of the controller

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

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

- 3 -

2. CONFIGURATION MAINTENANCE B-83525EN/08

Dimension

(Height X Width X Depth)

Discharge

resistor

Breaker

capacity

supply

phase

phase

α

β

,

M-1iA

LR Mate 200iD

LR Mate 200iC/5WP, ER-4iA

M-2iA, M-3iA, DR-3iB

Large O 2 O

M-10iA, ARC Mate 100iC

Medium

O 1 O O

O** 1 O O 1 O

O

M-20iA, M-20iB, ARC Mate 120iC,
M-20iD, ARC Mate 120iD

Small O 0 O Medium

O 0 O O

ARC Mate 0iB, R-0iB

Medium

O 1 O O

R-2000iC, R-2000iD, R-1000iA,
M-710iC

Small O 0 O Medium

O* 0 O

O

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) to (b) show the view of R-30iB Mate/ R-30iB Mate Plus.
Fig.2.1 (c) to (g) show the construction of the R-30iB Mate/ R-30iB Mate Plus controller.
Fig.2.1 (h) to (k) show the external view of the operator’s panel and teach pendant.

Explanation of Controller size

Controller size

Small 400X470X322 Small 10A Single phase/Three phase

Medium 400X470X402 Large 20A Single phase/Three phase

Large 400X470X402 Large 30A Three phase

Single phase/Three phase

Abbreviation

LR Mate 200iD/7C/4SC/7LC/7H/4SH

(except /7C/4SC/7LC/7H/4SH),

M-10iD, ARC Mate 100iD, CR-15iA

ARC Mate 50iD

Controller Power

Controller

Size

Small O O* 0 O
Small O O* 0 O

Medium O 0 O O

Medium
Medium

Single

O

Three

Rear fan

Q’ty

2

Aux.axis Amp

iSV

O O

iSV

CR-4iA, CR-7iA, CR-14iA

* The 3phase controller which marked with “*” is corresponded to basic type only.
** The single phase controller which marked with “**” of CR-15iA does not correspond to CE controller.

Large O

- 4 -

2

O

B-83525EN/08 MAINTENANCE 2. CONFIGURATION

Teach pendant

(iPendant)

Operator’s panel

Breaker

Teach pendant hook
(Option)

USB port (Option)

Key

WARNING

“SAFETY PRECAUTIONS” and Section 2.3 in MAINTENANCE.

Rear fan unit

Fig.2.1 (a) External view of the R-30iB Mate/ R-30iB Mate Plus controller

Lock the door with the key before using the controller.
Refer to “WARNING&CAUTION REGARDING USE OF CONTROLLER” in

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

- 5 -

2. CONFIGURATION MAINTENANCE B-83525EN/08

mode switch

Heat exchanger

6-Axis Servo amplifier

Emergency stop button

Main board

E-stop unit

Breaker
Battery

Back plane unit

Power supply unit

Noise Filter
(EMC

Option)

Process I/O board
(Option)

Fig.2.1 (c) R-30iB Mate/ R-30iB Mate Plus cabinet interior (Front-1)

Fig.2.1 (d) R-30iB Mate/ R-30iB Mate Plus cabinet interior (Front-2)

- 6 -

B-83525EN/08 MAINTENANCE 2. CONFIGURATION

Sensor I/F unit

Aux. axis cabinet(Integrated)

Discharge resistor

6-Axis Servo amplifier (Rear side)

Line filter

6-Axis Servo amplifier (Rear side)
6-Axis Servo amplifier (Rear side)

Line filter

(Small size)

(Middle size)

(Large size)

Fig.2.1 (e) R-30iB Mate/ R-30iB Mate Plus cabinet interior (Front-3) (Collaborative Robot)

Fig.2.1 (f) R-30iB Mate/ R-30iB Mate Plus cabinet interior (Rear)

- 7 -

2. CONFIGURATION MAINTENANCE B-83525EN/08

Discharge resistor

Rear fan unit

NOTE

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

Emergency Stop but to n

CYCLE START button with LED(Green)

Mode switch
(In case of 3-mode switch)

Emergency Stop but to n

CYCLE START button with LED(Green)

Mode switch
(In case of 3-mode switch)

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

Fig.2.1 (h) R-30iB Mate/ R-30iB Mate Plus operator’s panel

Fig.2.1 (i) R-30iB Mate/ R-30iB Mate Plus symbol operator’s panel

- 8 -

B-83525EN/08 MAINTENANCE 2. CONFIGURATION

Emergency Stop b ut t on

Teach Pendant ON/OFF switch
(Teach Pendant enable switch)

USB port

Enabling device

(Deadman switch)

Symbol

Description

Enables the user to select operation mode suitable to the robot operation conditions or the

Teach mode

Fig.2.1 (j) Mode switch

Fig.2.1 (k) Teach pendant (iPendant)

status of its use.
Automatic operation mode（ ）

（ ）

Starts the currently selected program. Lit while the program is being started.

- 9 -

2. CONFIGURATION MAINTENANCE B-83525EN/08

2.2 COMPONENT FUNCTIONS

Fig.2.2 (a) Block diagram of the R-30iB Mate/ R-30iB Mate Plus

- 10 -

B-83525EN/08 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 types 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 o n/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.

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

the servo amplifier.

2.3 CHECKS AND MAINTENANCE

Daily maintenance and periodic maintenance/insp ection 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 th e system parts for

any damage or cracks. Also, check t he following:
(a) Before operation
Check the cable connected to the teach pendan t 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.
(c) Make sure that the controller is closed securely with a key.

(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
(a) Remove any dirt and dust from the inside of the cabinet. Wipe off dirt and dust from the fan

and transformer.

- 11 -

2. CONFIGURATION MAINTENANCE B-83525EN/08

CAUTION

twice or more in a year.

WARNING

breaker, padlocking can be installed to the breaker handle.

(b) To confirm that the safety function can work correctly, please check the alarm detection by

inputting emergency stop, or please check the system operation b y cycling power (refer to the

following CAUTION).
(c) ・Open the door and check the door gasket for damage or crushing.

・Check the controller for abnormal contamination.

If there is any dirt, investigate the cause and take necessary measures, then clean the dirt.

・Check that there is no gap around the door gasket in the door locked state.

・According to Appendix I, check that there is no gap in the cable entrance of the cabinet.

(4) Battery daily check
Replace the battery on the front panel of the main board every 4 years. Please refer to the Section

8.11.

(5) Maintenance tools
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
Cutting pliers
Diagonal cutting pliers

(6) Automatic backup
When the au tomatic backup area (FRA:) of F-ROM in the controller is specified as a backup copy

destination and automatic backup is performed frequently, F-ROM may be damaged. If the
automatic backup is performed frequently, use the external storage device.

R-30iB Mate/R-30iB Mate Plus is evaluated as a system with the high demand

1 The R-30iB Mate/R-30iB Mate Plus controller has a sealed structure, it is

2 Be sure to lock the controller securely with the key to prohibit that the person
3 To prevent electric shock, do not energize the controller while the door is open.

4 After connecting input power cable, in order to avoid turning on the main

mode of operation defined in IEC61508. To confirm that the safety funct ion can
work correctly, please check the alarm detection by inputting emergency stop
twice or more in a year, or please check the system operation by cycling power

designed so that dust, oil mist, conductive foreign particulate, etc. around the
controller do not enter the interior of the controller.
Whether or not the controller is in operation, if the door is not locked with the
key, the original sealing capacity of the controller cannot be secured. In this
case, failure may occur due to internal contamination, and there is the risk of
electric shock, electric leakage, and fire due to insulation deterioration.

except the maintenance engineer opens the door of the controller.

- 12 -

B-83525EN/08 MAINTENANCE 3. TROUBLESHOOTING

Inspection and action

Figure

(Inspection 1)

Check the circuit breaker.

presented in the appendix.

3 TROUBLESHOOTING

This chapter describes the checking methods and corrective actions for alarms due to hardware rel ated
trouble by alarm code. Refer to the OPERATOR’S MANUAL (ALARM CODE LIST) (B-83284EN-1) to
release alarms.

3.1 POWER CANNOT BE TURNED ON

(Action) a) If circuit breaker is OFF,

turn on the circuit breaker.

b) If the c i r cuit breaker has

tripped (the circuit breaker
trip state is identical to
OFF state), find the cause
by referencing the total
connection diagram

Circuit Breaker

- 13 -

3. TROUBLESHOOTING MAINTENANCE B-83525EN/08

Inspection and action

Illustration

3.1.1 When the Teach Pendant Cannot be Powered on

(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

(R-30iB Mate)

(R-30iB Mate Plus)

- 14 -

B-83525EN/08 MAINTENANCE 3. TROUBLESHOOTING

Inspection and action

Illustration

7 Segment LED

LEDG1
LEDG

2
LEDG3
LEDG4

RLED1

(Red)

(Green)

LEDG1
LEDG2
LEDG3
LEDG4

7-segment LED

RLED1

(Red)

(Green)

3.1.2 When the Teach Pendant does not Change f rom the Initial

Screen

(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".

(R-30iB Mate)

(R-30iB Mate Plus)

- 15 -

3. TROUBLESHOOTING MAINTENANCE B-83525EN/08

Inspection and action

Illustration

Back plane

Mini slot (2slot)

FUSE1

FUSE1

(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.

(R-30iB Mate)

(R-30iB Mate Plus)

- 16 -

B-83525EN/08 MAINTENANCE 3. TROUBLESHOOTING

Alarm history screen display

Press F3 [HIST].

Press F3 [ACTIVE].

Alarm occurrence screen display

Automatic alarm display
upon occurrence

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

Alarm : 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 failed

MEMO-027 Specified line does not exis JOINT

30%

Alarm detail code

3.2 ALARM OCCURRENCE SCREEN

The alarm occurrence screen displays only t he alar m that occu rs currently. If an alarm reset signal is input
to reset the alarm conditions, the alarm occurrence screen displays the message "PAUSE or more serio us
alarm has not occurred."
The alarm occurrence screen displays only t he alarms (if an y) that occur after the most recently entered
alarm reset signal. To erase all alarm displays fro m th e alarm occu rrence screen. Press the CLEAR
key (+ shift) on the alarm history screen.
The alarm occurrence screen is intended to display only alarms with severity is equal or higher than
PAUSE. It will not display WARN, NONE, or a reset. It is possible to d isable PAUSE and some of more
serious alarms from being displayed by setti ng the $ER_NOHIS system variable appropriately .
If two or more alarms have occurred at the same time, 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.

Fig.3.2 (a) Alarm occurrence screen and alarm history screen display procedure

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 .

- 17 -

3. TROUBLESHOOTING MAINTENANCE B-83525EN/08

Alarm : Hist

[ TYPE ]

[ VIEW ]

ACTIVE

CLEAR

DETAIL

NOTE

on the screen, press the F5, HELP, and then press the right arrow key.

Alarm : Hist

[ TYPE ]

[ VIEW ]

ACTIVE

CLEAR

DETAIL

NOTE

recorded.

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

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

The latest alarm is assigned number 1. To view messages that are currently not

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

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

(5) To return to the alarm history screen, p r ess the [PREV] key.

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

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

- 18 -

B-83525EN/08 MAINTENANCE 3. TROUBLESHOOTING

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

Stop signal

Description

emergency stop

the EMERGENCY STOP button is pressed, the state is indicated as “TRUE”.

emergency stop

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”.

is operable, an alarm occurs, causing the servo power to be switched off.

operable, the state is indicated as “TRUE”.

“TRUE”. In this case, an alarm occurs, causing the servo power to be switched off.

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

3.3 STOP SIGNALS

The stop signal screen indicates the state of signals related to safety.
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

Operator’s panel

Teach pendant

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 s tate is

Enabling device
(Deadman switch)

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

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

This item indicates the state of the emergenc y stop button on the operator’s panel. If

This item indicates the state of the emergenc y stop button on the teach pendant. If the

This item indicates whether the enabling device (the deadman switch) on the t each
pendant is grasped. If the teach pendant is operable, and the enabling device (the
deadman switch) is grasped correctly, the state is indicated as “TRUE”. If the enabling
device (the deadman switch) is released or is grasped tightly when the teach pendant

workpiece or anything like this, and the safety joint is opened, the state is indicated as

- 19 -

3. TROUBLESHOOTING MAINTENANCE B-83525EN/08

Stop signal

Description

servo power to be switched off.

specified value, the state is indicated as “TRU E ”.

STATUS Stop Signal

[ TYPE ]

SYSTEM Variables

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

range. If any of robot axes goes out of the operation range beyond the overtravel
switch, the state is indicated as “TRUE”. In this case, an alarm occurs, causing the

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 pr essure is not higher than the

Steps to display stop signal screen

(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.

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

3.4 MASTERING

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

Condition

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

272 $MASTER_ENB 1

Step

As an example, the following describes the procedure for fixture position mastering.
(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 [CALIBRATE] and you will see a screen similar to the following.

- 20 -

B-83525EN/08 MAINTENANCE 3. TROUBLESHOOTING

SYSTEM Master/Cal

4

[ TYPE ]

LOAD

RES_PCA

DONE

NOTE

Mastering cannot be performed until position of the Pulsecoder is established.

SYSTEM Master/Cal

4

[ TYPE ]

LOAD

RES_PCA

DONE

SYSTEM Master/Cal

4

[ TYPE ]

LOAD

RES_PCA

DONE

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

brake release if necessary.

TORQUE = [ON ]
1 FIXTURE POSITION MASTER
2 ZERO POSITION MASTER
3 QUICK MASTER

5 SINGLE AXIS MASTER
6 SET QUICK MASTER REF
7 CALIBRATE

Press ‘ENTER’ or number key to select.

QUICK MASTER FOR SINGLE AXIS

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

TORQUE = [ON ]
1 FIXTURE POSITION MASTER
2 ZERO POSITION MASTER
3 QUICK MASTER

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

QUICK MASTER FOR SINGLE AXIS

5 SINGLE AXIS MASTER

(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.

TORQUE = [ON ]
1 FIXTURE POSITION MASTER
2 ZERO POSITION MASTER
3 QUICK 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>

QUICK MASTER FOR SINGLE AXIS

5 SINGLE AXIS MASTER

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

- 21 -

3. TROUBLESHOOTING MAINTENANCE B-83525EN/08

NOTE

the same actions as for SRVO-213.

Emergency stop
button

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 whether the wires connecting between the emergency stop button and the

emergency stop board (CRT30) not disconnected. If a disconnection is found, replace
the entire wires.

(Action 3) Check whether the wires conn ecting between the teach pendant and the emergency

stop board (CRS36) are not disconnected. If a disconnection is found, replace the
entire wires.

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

terminals of the switch. If there is a shor t-circuit on the contact points, 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.

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

(R-30iB Mate) (R-30iB Mate Plus)

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

- 22 -

B-83525EN/08 MAINTENANCE 3. TROUBLESHOOTING

Teach Pendant ON/OFF switch
(Teach Pendant enable switch

)

Enabling device
(Deadman switch)

Emergency stop button

SRVO-002 Teach pendant E-stop

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

SRVO-003 Enabling device (Deadman switch) released

(Explanation) Th e teach pendant is enabled, but t he enabling device (the deadman switch) is not

pressed. Alternatively, the enabling device (the deadman switch) is pressed strongly.
(Action 1) Check the in termediate position of the enabling device (the deadman switch) on the

teach pendant.
(Action 2) Check that the mode switch on the operator's panel and the teach pendant ON/OFF

switch (the teach pendant enable 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.

(Teach pendant)

(Mode switch)

- 23 -

3. TROUBLESHOOTING MAINTENANCE B-83525EN/08

Emergency stop board

NOTE

the same actions as for SRVO-213.

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

SRVO-003 Enabling device (Deadman switch) released

SRVO-004 Fence open

(Explanation) In the automatic operat ion mode, th e safety fence co ntact connected to EAS1-EAS11

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

between EAS2-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.

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

(Mode switch)

- 24 -

B-83525EN/08 MAINTENANCE 3. TROUBLESHOOTING

WARNING

safety measures must be taken.

(R-30iB Mate)

(R-30iB Mate Plus)

Fig.3.5 (c) SRVO-004 Fence open

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

signal using a short-circuit when a connection is made between EAS1 and
EAS11 and between EAS2 and EAS21. Do not make such an attempt. If a
temporary connection with a short-circuit is needed for operation, separate

- 25 -

3. TROUBLESHOOTING MAINTENANCE B-83525EN/08

NOTE

short-circuiting in the mechanical unit.

NOTE

Refer to Subsection 5.6.3 in CONNECTIONS to disable the Hand broken signal.

SRVO-005 Robot overtravel

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

robot axis from the overtravel state.

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

condition.

3) While holding down the shift key, and jog the overtravel axes to 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 bl own. Eliminate the cause of fuse

melting, and replace the fuse.
(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 an d 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.

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

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 key to reset the alarm condition.

While 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 an d 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.

If the Hand broken signal is not in use, it can be disabled by software setting.

- 26 -

B-83525EN/08 MAINTENANCE 3. TROUBLESHOOTING

6-Axis servo amplifier

(6-Axis servo amplifier)

Fig.3.5 (d) SRVO-005 Robot overtravel

SRVO-006 Hand broken

- 27 -

3. TROUBLESHOOTING MAINTENANCE B-83525EN/08

NOTE

the same actions as for SRVO-213.

SRVO-007 External emer gency stops

(Explanation) The contact of external emergency stop connected between EES1-EES11,

EES2-EES21 of the terminal block TBOP20 on the emergency stop board is open.
(Action 1) If an external emergency stop switch is connected, release the switch.
(Action 2) Check the switch and cable connected between EES1-EES11, EES2-EES21 of the

terminal block TBOP20 on the emergency stop board.
(Action 3) When this signal is not used, make a short-circuit between EES1-EES11,

EES2-EES21.
(Action 4) Replace the emergency stop board.

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

(R-30iB Mate)

(R-30iB Mate Plus)

(Emergency stop board)

Fig.3.5 (e) SRVO-007 External emergen cy sto ps

- 28 -

B-83525EN/08 MAINTENANCE 3. TROUBLESHOOTING

WARNING

safety measures must be taken.

NOTE

the manual of your robot.

6-Axis servo amplifier

In a system using the external emergency stop signal using a short-circuit, 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 with a short-circuit is needed for operation, separate

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 disconn ection is detected,

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

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

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

- 29 -

3. TROUBLESHOOTING MAINTENANCE B-83525EN/08

NOTE

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

Fan motor (FAN0)

Main board

Fan motor (FAN1)

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 of backplane. 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.

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

- 30 -

B-83525EN/08 MAINTENANCE 3. TROUBLESHOOTING

NOTE

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

Door fan

Heat exchanger

Fan motor

Main board

Rear fan

SRVO-015 System over heat

(Explanation) The temperature in the controller exceeds the specified value. In o ne 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 by air conditioner and so on.
(Action 2) If the fan motor is not running, check the fan, the fan unit, and the 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.)

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

- 31 -

3. TROUBLESHOOTING MAINTENANCE B-83525EN/08

CAUTION

the brake release unit off and cycle the controller power.

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

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

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

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

In case that the brake is not released.

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

amplifier is lit.
(Action 1) Check the robot connection cables (RMP1, RP1), 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 and 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.

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. For recovery, turn

(Explanation) Th e HRDY is on and the SRDY is off, althou gh there is no other cause of an alarm.

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

off the servo amplifier magnetic contactor. SRDY is a signal with wh ich 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 ampli fier alarm has

been detected, the host will not i ssue 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 or 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 connector CXA2A (6-axis

amplifier) or CXA2B (aux. axis amplifier) is 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.

(Explanation) Wh en the HRDY is about to be turned 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 ser vo system

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

(Explanation) The position error is abnormally large when the servo stops.
Check whether the brake is released through the clack sound of the brake or

vibration.

(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.
(Action 3) Check whether an abnormal noise occurs from inside the balancer.
If abnormal noise occurs, the balancer spring may be broken. Please replace the

balancer unit or contact the FANUC service representative to report a detailed

situation when it occurs.

- 32 -

B-83525EN/08 MAINTENANCE 3. TROUBLESHOOTING

NOTE

Incorrect setting of the brake number causes this alarm.

6-Axis servo amplifier

In case that the brake is released.

(Action 1) Check whether the obstacle disturbs the robot or the corresponding auxiliary axis

motion.
(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 the rated

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

becomes higher than the capacity of the motor.
As a result, when the overloaded motion is performed, the motor becomes unable to

follow the command, and an alarm may be 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 resu lt, the motor may become unab le

to follow the command, hence possibly causing this alarm.)
(Action 6) Replace the servo amplifier.
(Action 7) Replace the motor of the alarm axis.
(Action 8) Check whether an abnormal noise occurs from inside the balancer.
If abnormal noise occurs, the balancer spring may be broken. Please replace the

balancer unit or contact the FANUC service representative to report a detailed

situation when it occurs.

Fig.3.5 (i) SRVO-018 Brake abnormal

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

- 33 -

3. TROUBLESHOOTING MAINTENANCE B-83525EN/08

WARNING

or damage equipment.

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 has not

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

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

abnormally, set the position data correctly. Otherwise, you could injure pers onnel

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 calibr at ed (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 (G r oup:i)

(Explanation) An attempt was made to perform quick mastering, but the reference point has 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 motor 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 th e

software setting of the brake number.

- 34 -

B-83525EN/08 MAINTENANCE 3. TROUBLESHOOTING

Discharge resistor

Discharge resistor

(Action 2) In case the robot has been moved by using the brake rel ease 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, th is alarm may occur. Confirm

the setup or brake type setting and correct setting.
(Action 4) Replace the motor and master the robot.

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

(Explanation) Th e 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

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

potential energy is higher than t he 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 energ y t hat

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

servo amplifier dissipates this energy as heat. If the regenerative energy i s 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 discharge resistor can't be

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

unit, the discharge 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 cables 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 discharge

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

tightly, then detach the cables fro m 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 discharge resistor. CRRA11B may not be

used depending on the robot model.
(Action 6) Replace the 6-Axis servo amplifier.
(Action 7) This alarm may occur because of an incorrect actual input voltage. Measure the input

voltage between each phase at the main breaker and make sure that each voltage

satisfies the input voltage rating. If each voltage do es not satisfy the input voltage

rating, check the power supply faci lity.

(Small size) (Middle/Large size)

Fig.3.5 (ja) SRVO-043 DCAL alarm

- 35 -

3. TROUBLESHOOTING MAINTENANCE B-83525EN/08

6-Axis servo amplifier

E-stop unit

Fig.3.5 (jb) SRVO-043 DCAL alarm

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 the rated level. (If the machine load is higher than the rating, the accumulation of

regenerative energy might result in the HVAL alarm even wh en th e th ree-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 discharge 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 insul ation 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.

- 36 -

B-83525EN/08 MAINTENANCE 3. TROUBLESHOOTING

6-Axis servo amplifier

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 ex ceeded 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.

Fig.3.5(k) SRVO-044 HVAL alarm

SRVO-045 HCAL alarm
SRVO-046 OVC alarm

- 37 -

3. TROUBLESHOOTING MAINTENANCE B-83525EN/08

Abbreviation

Designation

Detection section

OVC

Overcurrent alarm

Servo software

Thermal relay in the separate regenerative resister

HC

High current alarm

Servo amplifier

Temperature
Start

Start

Start

Stop

Stop

Temperature at
which the winding
starts to burn

Thermal time constant of the
motor is high.

Thermal time constant of the
thermal relay is low.
Time

Reference

Relationships among the OVC, OHAL, and HC alarms

- Overview

This section points out the differences among the OVC , OHAL, and HC alarms and descr ibes the p urp ose
of each alarm.

- Alarm detection section

OHAL Overheat alarm Thermal relay in the motor

Thermal relay in the 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 d iod es 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 overheat alarms)
The OVC and OHAL alarms are intended to prevent overheat that may lead to the burn out of the

motor winding, the breakdown of the servo amplifier transistor, and the separate discharge resistor
for PS.

The OHAL alarm occurs when each built-in thermal relay detects a temperature hig her than th e rated

value. However, this method is not necessarily p erfect to p rev ent t hese fai lur es. Fo r example, if t he
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 t hese two components are
different in material, structure, and dimension. Therefore, if the motor continues to start and stop in 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 even though the thermal relay is not in operation mode.

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

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.

cycles

- 38 -

B-83525EN/08 MAINTENANCE 3. TROUBLESHOOTING

NOTE

case, do not change the parameters to relax protection.

6-Axis servo amplifier

Power supply unit

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).

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

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

SRVO-047 LVAL alarm (Gr oup: 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.

Fig.3.5 (n) SRVO-047 LVAL alarm

- 39 -

3. TROUBLESHOOTING MAINTENANCE B-83525EN/08

6-Axis servo amplifier

E-stop unit

SRVO-049 OHAL1 alarm (G rp: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 whether there is a factor that has in creased

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 the limit rated l evel.
(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.
(Action 11) There might be a failure with the following parts. Replace it or contact your local

FANUC representative.
・Reducer
・Balance

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

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

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

Fig.3.5 (o) SRVO-049 OHAL1 alarm

SRVO-050 CLALM alarm
SRVO-051 CUER alarm

(Explanation) A co mmunication error has occurred between the main board and servo ampli f ier.
(Action 1) Check the optical fiber cable b etween the servo card and servo amplifier. Replace it

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

- 40 -

B-83525EN/08 MAINTENANCE 3. TROUBLESHOOTING

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

(Explanation) A co mmunication error has occurred between the main board and servo ampli f ier.
(Action 1) Check the optical fiber cable between the servo card and servo amplifier. Replace it

if it is faulty.
(Action 2) Replace the servo 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.

A servo card corresponding to the set number of axes is not mounted. Check whether

the set number of axes is valid. If the number is invalid, set the correct number.

(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 b etween the servo card and servo amplifier. Replace it

if it is faulty.
(Action 3) Replace the servo 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 er r or (yy)

(Explanation) Communication was interrupted between the main board and servo amplifier.
(Action 1) Turn off the power and disconnect the CRF8 connector on the 6-axis servo amplifier.

Turn on the power supply and 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 2) 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 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 ampli f ier.
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 co nnected tightly , rep lace

the 6-axis servo amplifier.
(Action 4) Check the optical fiber cable between the servo card and servo amplifier. Replace it

if it is faulty.
(Action 5) Replace the servo 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 co mmunication, 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.

- 41 -

3. TROUBLESHOOTING MAINTENANCE B-83525EN/08

6-Axis servo amplifier

Main board

Servo card

Servo card

(R-30iB Mate)

(R-30iB Mate Plus)

(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

- 42 -

B-83525EN/08 MAINTENANCE 3. TROUBLESHOOTING

CAUTION

needed.

NOTE

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

SRVO-059 Servo amp init er r or (G:i A:j)

(Explanation) Servo amplifier initialization is fail ed.
(Action 1) Check the optical fiber cable between the servo 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.

Turn on the power supply and 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 co nnected tightly , rep lace

the 6-axis servo amplifier.
(Action 4) Replace the servo amplifier.
(Action 5) Replace the line tracking board (if installed).
(Action 6) Replace the motor.

SRVO-062 BZAL alarm (Gr oup: i Axis:j)

(Explanation) Th is alarm occurs if battery voltage for Pulsecoder backup has declined, and backup

cannot be performed.

A probable cause is a broken battery cab l e or no batteries in the robot.
(Action 1) Replace the battery in the battery box of the robot base.
(Action 2) Replace the motor of axis 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.

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

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

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

SRVO-065 BLAL alarm (Gr oup: 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 p ossible. A

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

case, the position data will be lost. Once the position data are 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.
(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.

- 43 -

3. TROUBLESHOOTING MAINTENANCE B-83525EN/08

6-Axis servo amplifier

(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 Pulsecoder connector of servo motor 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 motor of axis with which an alarm has been issued .
(Action 4) Replace the servo amplifier of axis with which an alarm has been issued.
(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 have 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

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.

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

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

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

(Explanation) It is likely that the Pulsecoder is abnormal or the Pulseco der 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 the robot connection cables are connected

securely to the grounding plate.

- 44 -

B-83525EN/08 MAINTENANCE 3. TROUBLESHOOTING

E-stop unit

6-Axis servo amplifier

(Action 2) Reinforce the earth of the motor flange. (In case of Auxiliary axis)
(Action 3) Reset the Pulse count.
(Action 4) Replace the motor.
(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 (Gr oup: i Axis:j)

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

SRVO-075 Pulse not establi shed (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 th e 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 rel eased.
(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 axis servo motor.
(Action 8) Replace the E-stop unit.
(Action 9) Replace the power cable of the robot connection cable in wh ich the corresponding

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

is connected.

SRVO-081 EROFL alarm (Tr ack enc: i)

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

(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 motor.
(Action 3) Replace the line tracking board.

- 45 -

3. TROUBLESHOOTING MAINTENANCE B-83525EN/08

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 motor.
(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 descripti on 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 has declined. See the descriptio n about the BLAL alarm (SRVO-065).

SRVO-089 OHAL2 alarm (Tr ack enc: i)

(Explanation) The temperature inside the Pulsecoder is abnormally high, and 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 (Tr ack enc:i)

(Explanation) Communication between the Pulsecoder and line tracking board is abnormal. See the

SRVO-068 DTERR alarm.
(Action 1) Check the connection of line tracking cable at each end (the line tracking board and

the Pulsecoder)
(Action 2) Check whether the shielding of the of line tracking cab le is connected secu rely to th e

grounding plate.
(Action 3) Replace the motor.
(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) Th is alarm occurs if the current posi tion data from the Pulsecoder are higher than the

previous position data.
(Action) Action as same as the SRVO-090.

SRVO-094 PMAL alarm (Tr ack enc: i)

(Explanation) It is likely that the Pulsecoder is abnormal. See the description about the PMAL

alarm (SRVO-072).
(Action) Replace the motor.

- 46 -

B-83525EN/08 MAINTENANCE 3. TROUBLESHOOTING

6-Axis servo amplifier

E-stop unit

(Emergency stop board)

SRVO-095 CMAL alarm (Tr ack enc: i)

(Explanation) It is likely that the Pulsecoder is abnormal or the Pulseco der 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 motor.

SRVO-096 LDAL alarm (Track enc: i )

(Explanation) Th e LED in the Pulsecoder is broken. See the description about th e LDAL alarm

(SRVO-074).

SRVO-097 Pulse not establi shed (Enc:i)

(Explanation) The absolute position of the Pulsecoder cannot be established. See the description

about Pulse not established alarm (SRVO-075).
(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.

Fig.3.5 (s) SRVO-105 Door open or E-stop

- 47 -

3. TROUBLESHOOTING MAINTENANCE B-83525EN/08

Fan motor

Main board

SRVO-123 Fan motor rev slow down(i)

(Explanation) The rotation speed of fan motor slows 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.

Fig.3.5 (t) SRVO-123 Fan motor rev slow down(i)

SRVO-134 DCLVAL alarm (G:i A:j)

(Explanation) This alarm occurs during the robot operation. 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 disco nnection 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 of the corresponding axis 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 of the corresponding axis from

the servo amplifier indicated by the alarm message, and check that there is no

conduction between U, V, W and GND. If there is conduction, it indicates the po wer

cable is faulted, replace the power cable of the corresponding axis.
(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 one of the

resistances at the three places is much smaller than other two, there is likely to be a

- 48 -

B-83525EN/08 MAINTENANCE 3. TROUBLESHOOTING

6-Axis servo amplifier

E-stop unit
(Emergency stop board)

short-circuit between phases, the motor, the power cable is defective. Check each

item in detail and replace it if necessary.

SRVO-157 CHGAL alarm (G:i A:j)

(Explanation) Th e capacitor on the servo amplifier was not charged properly within the specified

time when the servo power is on.
(Action 1) Check the three-phase 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 E-stop unit.
(Action 4) Replace the 6 axis servo amplifier.

Fig.3.5 (u) SRVO-156 IPMAL alarm

SRVO-157 CHGAL alarm

- 49 -

3. TROUBLESHOOTING MAINTENANCE B-83525EN/08

6-Axis servo amplifier

E-stop unit
(Emergency stop board)

SRVO-204 External (SVEMG abnor m al ) E-stop

(Explanation) Th e switch connected across EES1 – EES11 or 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 i s 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.

- 50 -

B-83525EN/08 MAINTENANCE 3. TROUBLESHOOTING

(R-30iB Mate)

(R-30iB Mate Plus)

(Emergency stop board)

Fig.3.5 (v) SRVO-204 External (SVEMG abnormal) E-stop

- 51 -

3. TROUBLESHOOTING MAINTENANCE B-83525EN/08

6-Axis servo amplifier

E-stop unit
(Emergency stop board)

SRVO-205 Fence open (SVEMG abnormal)

(Explanation) Th e switch connected across EAS1 – EAS11 or 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.

- 52 -

B-83525EN/08 MAINTENANCE 3. TROUBLESHOOTING

(R-30iB Mate)

(R-30iB Mate Plus)

(Emergency stop board)

Fig.3.5 (w) SRVO-205 Fence open (SVEMG abnormal)

- 53 -

3. TROUBLESHOOTING MAINTENANCE B-83525EN/08

SRVO-206 Enabling device (Deadman switch) (SVEMG abnormal)

(Explanation) When the teach pend ant was enabled, the enabling device (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.

In systems where multiple safety I/O devices are connect ed, the number of the saf ety

I/O device that the alarm occurs is displayed in the end of t he message such as (1).

The safety I/O device number corresponds to t he sequence of the safety I/O devices

connected by the I/O link i is displayed in DCS Safety I/O device menu.
(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 followings.
(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 det ached,

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).

- 54 -

B-83525EN/08 MAINTENANCE 3. TROUBLESHOOTING

TBOP20

No.

Name

12

21
11

2
10

11
9

E-STOP

(ESPB)

1
8

21
7

2
6

11
5

FENCE

(EAS)

1
4

21
3

2
2

11
1

EMGIN

(EES)

1

TBOP19

No.

Name

4

EXT0V
3

INT0V
2

INT24V
1

EXT24V

CRT30

CRS36

FUSE2

(R-30iB Mate)

(R-30iB Mate Plus)

(Emergency stop board)

- 55 -

3. TROUBLESHOOTING MAINTENANCE B-83525EN/08

6-Axis servo amplifier

E-stop unit
(Emergency stop board)

Fig.3.5 (x) SRVO-206 Enabling device (Deadman switch) (SVEMG abnormal)

SRVO-213 E-STOP Board FUSE2 blown

SRVO-214 6ch amplifi er 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 cau se, 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.

SRVO-219 Safety I/O board fuse1 blown %s

Safety I/O board fuse2 blown %s

(Explanation) A fuse on the additional Safety I/O board has blown.

The number of the safety I/O device that the al arm occurs is displayed in the end of

the message such as (1). The safety I/O device number is displ ayed in DCS Safety

I/O device menu.
(Action 1) Check whether the fuse (FU1 or FU2) on the additional Safety I/O board has blown.

If the fuse has blown, check whether there is ground-fault occurring at the

connection destination of CRMA90. Remove the cause of the ground-fault and

replace the fuse.

(Action 2) Replace the additional Safety I/O board.

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 servo card with a card corresponding to the set number of axes.

- 56 -

B-83525EN/08 MAINTENANCE 3. TROUBLESHOOTING

SRVO-223 DSP dry run (a,b)

(Explanation) A servo DSP initialization failure occurred due to h ardware failure or wrong software

setting. Then, the software entered DSP dry run mode. The first number ind icates 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 starting with $scr.$startup_cnd=12.
2,3,4,7: Replace a servo card.
5: Invalid ATR setting. Check whether software axis config (FSSB line number,

hardware start axis number, amplifier number, and amplifier type) is correct.
6: SRVO-180 occurs simultaneously. Controllable axis does not exist in 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: No amplifier can be identified. Perform the following actions.

•Check the hardware connection whether servo amplifier is connected properly.

•Check the optical fiber cable whether the optical fiber i s connected properly.

•In case of using aux. axis amplifier, make sure that the connectors CXA2A
(6-axis amplifier) or CXA2B (aux. axis amplifier) are securely at tached 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 connecting to servo amplifier.

•Replace the servo amplifier
11: Specified axis number is on the non-existing servo card. Check whether software

axis config (FSSB line number) is correct or auxiliary axis board may be 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.

- 57 -

3. TROUBLESHOOTING MAINTENANCE B-83525EN/08

6-Axis servo amplifier

Main board

Servo 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)

- 58 -

B-83525EN/08 MAINTENANCE 3. TROUBLESHOOTING

WARNING

circuits being faulty, safety may not be guaranteed when the other circuit fails.

CAUTION

pendant.

6-Axis servo amplifier

E-stop unit
(Emergency stop board)

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 ident ify 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.

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

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, ordinary reset operation must not 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

Fig.3.5 (z) SRVO-230 Chain 1 (+ 24V) abnormal a, b

SRVO-231 Chain 2 (0V) abnormal a, b

- 59 -

3. TROUBLESHOOTING MAINTENANCE B-83525EN/08

CAUTION

Do not perform this operation until the cause of the alarm is corr ec t ed.

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

<Method 1>

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".

<Method 2>

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 if in teaching operation. In other case the mode switch

should be changed to 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 Chai n abnor m al

(Explanation) Sho rt term single chain failure condition is detected.

• Possible cause of this alarm are;

- Half release of Enabling device (Deadman switch)

- Half press 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.

- 60 -

B-83525EN/08 MAINTENANCE 3. TROUBLESHOOTING

6-Axis servo amplifier

E-stop unit
(Emergency stop board)

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.

(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

- 61 -

3. TROUBLESHOOTING MAINTENANCE B-83525EN/08

WARNING

circuits being faulty, safety may not be guaranteed when the other circuit fails.

NOTE

and SRVO-231.

SRVO-266 FENCE1 status abnormal
SRVO-267 FENCE2 status abnormal

(Explanation) A ch ain 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 3.3.4, Fig.3.3.4(c) 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.

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

For the procedure of recovery from this alarm, see the descriptions of SRVO-230

- 62 -

B-83525EN/08 MAINTENANCE 3. TROUBLESHOOTING

(R-30iB Mate)

(R-30iB Mate Plus)

(Emergency stop board)

Fig.3.5 (ab) SRVO-266 FENCE1 st atus abnormal

SRVO-267 FENCE2 status abnormal

- 63 -

3. TROUBLESHOOTING MAINTENANCE B-83525EN/08

WARNING

circuits being faulty, safety may not be guaranteed when the other circuit fails.

NOTE

and SRVO-231.

SRVO-270 EXEMG1 status abnorm al
SRVO-271 EXEMG2 status abnorm al

(Explanation) A ch ain 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 3.3.4, Fig 3.3.4(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 con troller back up t o save all your programs
and settings.
(Action 7) Replace the main board.

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

For the procedure of recovery from this alarm, see the descriptions of SRVO-230

- 64 -

B-83525EN/08 MAINTENANCE 3. TROUBLESHOOTING

(R-30iB Mate)

(R-30iB Mate Plus)

(Emergency stop board)

Fig.3.5 (ac) SRVO-270 EXEMG1 status abnormal

SRVO-271 EXEMG2 status abnormal

- 65 -

3. TROUBLESHOOTING MAINTENANCE B-83525EN/08

WARNING

circuits being faulty, safety may not be guaranteed when the other circuit fails.

NOTE

and SRVO-231.

SRVO-274 NTED1 status abnormal
SRVO-275 NTED2 status abnormal

(Explanation) A ch ain alarm was detected with the NTED signal.
(Action 1) This alarm may be issued wh en the Enabling device (the Deadman switch) is pressed

to a proper position or is operated very slowly . In such a case, release the Enabling

device (the Deadman switch) once completely then press the Enabling device (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 emergency stop board.
(Action 5) Replace the teach pendant cable.
(Action 6) Replace the teach pendant.
(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.

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

For the procedure of recovery from this alarm, see the descriptions of SRVO-230

SRVO-277 Panel E-stop (SVEMG abnor m al )

(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.

- 66 -

B-83525EN/08 MAINTENANCE 3. TROUBLESHOOTING

NOTE

This alarm may be issued if the emergency stop button is pressed very slowly.

6-Axis servo amplifier

E-stop unit

(Emergency stop board)

SRVO-278 TP E-stop (SVEMG abnorm al )

(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.

(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)

- 67 -

3. TROUBLESHOOTING MAINTENANCE B-83525EN/08

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) Alt hough 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 fai l ure 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 th e magn etic 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 (including the magnetic contactor).

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.

- 68 -

B-83525EN/08 MAINTENANCE 3. TROUBLESHOOTING

WARNING

circuits being faulty, safety may not be guaranteed when the other circuit fails.

NOTE

and SRVO-231.

Main board

E-stop unit
(Emergency stop board)

6-Axis servo amplifir

SRVO-349 DCS MCC ON al arm 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 (included the magnetic contactor).

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 6-Axis servo amplifier.

SRVO-370 SVON1 status abnormal
SRVO-371 SVON2 status abnormal

(Explanation) A ch ain 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.

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

For the procedure of recovery from this alarm, see the descriptions of SRVO-230

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

- 69 -

3. TROUBLESHOOTING MAINTENANCE B-83525EN/08

WARNING

circuits being faulty, safety may not be guaranteed when the other circuit fails.

NOTE

and SRVO-231.

WARNING

circuits being faulty, safety may not be guaranteed when the other circuit fails.

NOTE

and SRVO-231.

SRVO-372 OPEMG1 stat us abnor m al
SRVO-373 OPEMG2 status abnormal

(Explanation) A ch ain 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.

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

For the procedure of recovery from this alarm, see the descriptions of SRVO-230

SRVO-374 MODE11 status abnorm al
SRVO-375 MODE12 status abnorm al
SRVO-376 MODE21 status abnorm al
SRVO-377 MODE22 status abnorm al

(Explanation) A ch ain 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.

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

For the procedure of recovery from this alarm, see the descriptions of SRVO-230

- 70 -

B-83525EN/08 MAINTENANCE 3. TROUBLESHOOTING

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

- 71 -

3. TROUBLESHOOTING MAINTENANCE B-83525EN/08

WARNING

circuits being faulty, safety may not be guaranteed when the other circuit fails.

NOTE

and SRVO-231.

E-stop unit
(Emergency stop board)

SRVO-378 SFDIxx stat us abnor m al

(Explanation) A ch ain 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).

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

For the procedure of recovery from this alarm, see the descriptions of SRVO-230

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 whether the two drive off inputs are correct.
(Action 2) Make sure that the connector CRMB16 (6-axis amplifier) is securely attached to th e

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 vol t driver (G:i A:j)

(Explanation) Driver supply voltage in the servo amplifier has declined.
(Action 1) Replace the servo amplifier.

- 72 -

B-83525EN/08 MAINTENANCE 3. TROUBLESHOOTING

SRVO-454 CPU BUS fail ure (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 wat ch 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 par am eter%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 Hardw ar e er r or %s (G:i A:j)

(Explanation) An error is found in the circuit in the servo amplifier.
(Action 1) Replace the servo amplifier.

SRVO-473 DCS CLLB CC_EXTF alarm

(Explanation) The result is different in 2 CPU for Collaborative Robot.
(Action) Check the other alarms for more information.
Note: You need to cycle power to release th is alarm.

SRVO-476 CLLB alarm %x,%x

(Explanation) Internal error of the collaborative robot function.
(Action) Restart the controller. If the error is not cleared, execute Diagnostic log function

[FNCT menu / Diagnostic log] before you do other operation such as power off or

jogging, and get the image backup. And contact your FANUC technical

representative. If you cannot execute Diagnostic log function, document the events

that led to the error and get the image backup. And contact your FANUC

representative.

SRVO-477 Calibration data error

(Explanation) The sensor calibration data of the collaborative robot are wrong.
(Action 1) Copy "CLLB.CM" file from the CD-R which is appendix of the collaborative robot

to a memory card or USB memory. Perform the same file with a teach pendant, set

the sensor calibration parameter. After this change, perform “APPLY TO DCS

PARAMETER”. Refer to “1.3 Apply to DCS parameter” in ”Dual Check Safety

Function Operator’s manual” (B-83184EN) for detail.

As this file is unique to each collaborative robot, do not use other robot’s file. Check

that the serial number which is printed on CD-R is same as the number which is

written on collaborative robot sensor.

- 73 -

3. TROUBLESHOOTING MAINTENANCE B-83525EN/08

SRVO-478 Temperature difference too large

(Explanation) The force sensor temperature difference is too large.
(Action) Please make sure that the environment temperature does not change greatly, and then

restart the controller. If the error is n ot cleared, document the events that led to the

error and contact your local FANUC repr esentative.

SRVO-479 Temperature changes too fast

(Explanation) The force sensor temperature changes too fast.
(Action) Please make sure that the environment temperature does not change greatly, and
then restart the controller.
If the error is not cleared, document the events that led to the error and contact your
FANUC technical representative.

SRVO-480 FORCE alarm %x,%x

(Explanation) For ce sensor error.
(Action1) Restart the controll er .
(Action2) Replace the sensor cable.
If the error is not cleared, document the events that led to the error and contact your
FANUC technical representative.

SRVO-486 Hand Guidance E-stop

(Explanation) The EMERGENCY STOP button on the Hand Guidance device was pressed.
(Action1) Release EMERGENCY STOP on the Hand Guidance device, then press the

[RESET] key.
(Action2) Check setting and connection to Safety I/O board.

SRVO-487 Hand Guidance Enabling device (Deadman switch)

(Explanation) The enabling device (deadman switch) on the Hand Guidance device was released.
(Action1) Grip the enabling device (deadman switch), then press the [RESET] key.
(Action2) Enable Contact stop, when Collaborative robot is used.
(Action3) Set Hand Guidance disable I/O to ON if you do not use Hand Guidance function.

SRVO-489 Force sensor type error %x, %x

(Explanation) For ce sensor type error.
(Action1) Restart the controll er .
If the error is not cleared, document the events that led to the error and contact your

local FANUC representative.

SRVO-490 FORCE alarm 2 %x, %x

(Explanation) For ce sensor error.
(Action1) Restart the controll er .
(Action2) Replace the force sensor cable.
If the error is not cleared, document the events th at led to the error and contact your

local FANUC representative.

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.

- 74 -

B-83525EN/08 MAINTENANCE 3. TROUBLESHOOTING

Main board

Fig.3.5 (ah) PRIO-095 Overload

- 75 -

3. TROUBLESHOOTING MAINTENANCE B-83525EN/08

Name

Symptom observed when fuse has blown

Action

6. Replace the servo amplifier.

3. Replace the main board.

3.6 FUSE-BASED TROUBLESHOOTING

This section describes the alarms and symptoms generated and action s 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#LM10)

(R-30iB Mate Plus)
FUSE9:For protecting the +24E output for vision
(This fuse is installed on the R-30iB Mate Plus main board.)

(A60L-0001-0290#LM10)

FUSE1 An alarm (SRVO-220) is displayed on the teach

pendant.

FUSE9

(R-30iB

Mate
Plus)

+24E used for vision is not output. 1. Check +24E used by the vision for a ground

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.

fault.

2. Check the cables connecting to the vision

camera and the related parts for an abnormally.

- 76 -

B-83525EN/08 MAINTENANCE 3. TROUBLESHOOTING

CRS40

FUSE1 (1.0A)

CRS40

FUSE1 (1.0A)

FUSE9 (1.0A)

(R-30iB Mate)

(R-30iB Mate Plus)

Fig.3.6 (a) Fuse on the main board

- 77 -

3. TROUBLESHOOTING MAINTENANCE B-83525EN/08

blown

FS1

All LEDs on the servo amplifier go out.

pendant.

Replace the 6-Axis servo amplifier.

(option).

displayed on the teach pendant.

(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 discharge resister (A60L-0001-0290#LM32C)

Name Symptom observed when fuse has

The FSSB disconnection alarm
(SRVO-057) or FSSB initialization alarm
(SRVO-058) is displayed on the teach

Action

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

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

1 Check the discharge resister, and replace it if required.
2 Replace the 6-Axis servo amplifier.

Fig.3.6 (b) Fuse on the servo amplifier

- 78 -

B-83525EN/08 MAINTENANCE 3. TROUBLESHOOTING

Name

Symptom observed when fuse has blown

Action

4. Check the teach pendant and replace it if necessary.

5. Replace the main board. (*)

8. Replace the 6-Axis servo amplifier.

6. Replace the 6-Axis servo amplifier.

3. Replace the emergency stop board.

(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)
(R-30iB Mate Plus)
FUSE8: For 200V power monitor circuit (A60L-0001-0175#0.3A)

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.

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) f or a short
circuit or connection to ground.

3. Replace the emergency stop board.

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.

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. (*)

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 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.

1. Check the fan cable and replace it if necessary.

2. Replace the fan unit.

- 79 -

3. TROUBLESHOOTING MAINTENANCE B-83525EN/08

Name

Symptom observed when fuse has blown

Action

The system does not work correctly.

FUSE8
(R-30iB

Mate
Plus)

The teach pendant can not be operated and
the seven segment LED located on the main
board displays “7”.
If this fuse blows when power-on, the green
LEDs “LEDG2” and “LEDG4” of the status
LEDs on the main board light.

1. 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.

(R-30iB Mate)

(R-30iB Mate Plus)

Fig.3.6 (c) Fuse on the emergency stop board

- 80 -

B-83525EN/08 MAINTENANCE 3. TROUBLESHOOTING

blown

2. Replace the process I/O 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

Action

FUSE1 The LED (ALM1 or FALM) the process I/O

board lights.

Fig.3.6 (d) Fuse on the process I/O board MA

1. Check if the cables and peripheral devices connected
to the process I/O board are normal.

Fig.3.6 (e) Fuse on the process I/O board MB

- 81 -

3. TROUBLESHOOTING MAINTENANCE B-83525EN/08

Name

Symptom observed when fuse has blown

Action

2. Replace the additional Safety I/O board.

2. Replace the additional Safety I/O board.

FU2 (3.2A)

FU1 (1A)

(5) Safety I/O board fuses

FU1: For protecting +24V to the safety signal input (SFDI) (A60L-0001-0290#LM10C)
FU2: For protecting +24V to the safety signal output (SFDO) (A60L-0001-0290#LM32C)

FU1 An alarm “SRVO-219 S afety I/O board fuse1

blown” is displayed on the teach pendant.

FU2 An alarm “SRVO-219 Safety I/O board fuse2

blown” is displayed on the teach pendant.

1. Check whether there is ground-fault occurring at
the connection cable of CRMA90, and replace it
if necessary.

1. Check whether there is ground-fault occurring at
the connection cable of CRMA90, and replace it
if necessary.

Fig.3.6 (f) Fuse on the safety I/O board

- 82 -