Fanuc R-J3iBMate Controller Control

FANUC Robotics
R-J3iBMate Controller
(RIA R15.06 – 1999 Compliant)
Maintenance Manual

MARMIBRIA01021E REV. B

B-81535EN/02

This publication contains proprietary information of FANUC Robotics
North America, Inc. furnished for customer use only. No other uses
are authorized without the express written permission of FANUC
Robotics North America, Inc.

FANUC Robotics North America, Inc.
3900 W. Hamlin Road
Rochester Hills, Michigan 48309–3253

The descriptions and specifications contained in this manual were in
effect at the time this manual was approved for printing. FANUC
Robotics North America, Inc, hereinafter referred to as FANUC
Robotics, reserves the right to discontinue models at any time or to
change specifications or design without notice and without incurring
obligations.

FANUC Robotics manuals present descriptions, specifications,
drawings, schematics, bills of material, parts, connections and/or
procedures for installing, disassembling, connecting, operating and
programming FANUC Robotics’ products and/or systems. Such
systems consist of robots, extended axes, robot controllers,
application software, the KAREL programming language,
INSIGHT vision equipment, and special tools.

FANUC Robotics recommends that only persons who have been
trained in one or more approved FANUC Robotics Training
Course(s) be permitted to install, operate, use, perform procedures
on, repair, and/or maintain FANUC Robotics’ products and/or
systems and their respective components. Approved training
necessitates that the courses selected be relevant to the type of
system installed and application performed at the customer site.

WARNING
This equipment generates, uses, and can radiate radio
frequency energy and if not installed and used in accordance
with the instruction manual, may cause interference to radio
communications. As temporarily permitted by regulation, it
has not been tested for compliance with the limits for Class A
computing devices pursuant to subpart J of Part 15 of FCC
Rules, which are designed to provide reasonable protection
against such interference. Operation of the equipment in a
residential area is likely to cause interference, in which case
the user, at his own expense, will be required to take
whatever measure may be required to correct the
interference.

FANUC Robotics conducts courses on its systems and products on
a regularly scheduled basis at its headquarters in Rochester Hills,
Michigan. For additional information contact

FANUC Robotics North America, Inc.
Training Department
3900 W. Hamlin Road

Rochester Hills, Michigan 48309-3253

www.fanucrobotics.com

Send your comments and suggestions about this manual to:

[e-mail]

Conventions

Copyright 2002 by FANUC Robotics North America, Inc.
All Rights Reserved

The information illustrated or contained herein is not to be
reproduced, copied, translated into another language, or transmitted
in whole or in part in any way without the prior written consent of
FANUC Robotics North America, Inc.

AccuStat, ArcTool, DispenseTool, FANUC LASER DRILL,
KAREL, INSIGHT, INSIGHT II, PaintTool, PaintWorks,
PalletTool, SOCKETS, SOFT PARTS SpotTool,
TorchMate, and YagTool are Registered Trademarks of FANUC
Robotics.

FANUC Robotics reserves all proprietary rights, including but not
limited to trademark and trade name rights, in the following names:

AccuAir AccuCal AccuChop AccuFlow AccuPath
AccuSeal ARC Mate ARC Mate Sr.  ARC Mate System 1
ARC Mate System 2 ARC Mate System 3 ARC Mate System
4 ARC Mate System 5 ARCWorks Pro AssistTool
AutoNormal AutoTCP BellTool BODYWorks Cal Mate Cell
Finder Center Finder Clean Wall CollisionGuard
DispenseTool F-100 F-200i FabTool FANUC LASER
DRILL Flexibell FlexTool HandlingTool HandlingWorks
INSIGHT INSIGHT II IntelliTrak Integrated Process Solution
Intelligent Assist Device IPC -Integrated Pump Control IPD
Integral Pneumatic Dispenser ISA Integral Servo Applicator ISD
Integral Servo Dispenser Laser Mate System 3 Laser Mate
System 4 LaserPro LaserTool LR Tool MIG Eye
MotionParts NoBots Paint Stick PaintPro PaintTool 100
PAINTWorks PAINTWorks II PAINTWorks III PalletMate
PalletMate PC PalletTool PC PayloadID RecipTool
RemovalTool Robo Chop Robo Spray S-420i S-430i
ShapeGen SoftFloat SOF PARTS SpotTool+ SR Mate
SR ShotTool SureWeld SYSTEM R-J2 Controller SYSTEM R­J3 Controller SYSTEM R-J3iB Controller TCP Mate
TurboMove TorchMate visLOC visPRO-3D visTRAC
WebServer WebTP YagTool

This manual includes information essential to the safety of
personnel, equipment, software, and data. This information is
indicated by headings and boxes in the text.

WARNING

Information appearing under WARNING concerns the
protection of personnel. It is boxed and in bold type to set it
apart from other text.

CAUTION

Information appearing under CAUTION concerns the protection of
equipment, software, and data. It is boxed to set it apart from
other text.

NOTE Information appearing next to NOTE concerns related information
or useful hints.

Safety

Safety-1

FANUC Robotics is not and does not represent itself as an expert in
safety systems, safety equipment, or the specific safety aspects of
your company and/or its work force. It is the responsibility of the
owner, employer, or user to take all necessary steps to guarantee
the safety of all personnel in the workplace.

The appropriate level of safety for your application and installation
can best be determined by safety system professionals. FANUC
Robotics therefore, recommends that each customer consult with
such professionals in order to provide a workplace that allows for
the safe application, use, and operation of FANUC Robotic systems.

According to the industry standard ANSI/RIA R15.06, the owner or
user is advised to consult the standards to ensure compliance with
its requests for Robotics System design, usability, operation,
maintenance, and service. Additionally, as the owner, employer, or
user of a robotic system, it is your responsibility to arrange for the
training of the operator of a robot system to recognize and respond
to known hazards associated with your robotic system and to be
aware of the recommended operating procedures for your particular
application and robot installation.

FANUC Robotics therefore, recommends that all personnel who
intend to operate, program, repair, or otherwise use the robotics
system be trained in an approved FANUC Robotics training course
and become familiar with the proper operation of the system.
Persons responsible for programming the system–including the
design, implementation, and debugging of application programs–
must be familiar with the recommended programming procedures
for your application and robot installation.

The following guidelines are provided to emphasize the importance
of safety in the workplace.

Safety-2

y

CONSIDERING
SAFETY FOR YOUR
ROBOT
INSTALLATION

Keeping People and
Equipment Safe

Using Safet
Enhancing Devices

Safety is essential whenever robots are used. Keep in mind the
following factors with regard to safety:

• The safety of people and equipment

• Use of safety enhancing devices

• Techniques for safe teaching and manual operation of the

robot(s)

• Techniques for safe automatic operation of the robot(s)

• Regular scheduled inspection of the robot and workcell

• Proper maintenance of the robot

The safety of people is always of primary importance in any
situation. However, equipment must be kept safe, too. When
prioritizing how to apply safety to your robotic system, consider the
following:

• People

• External devices

• Robot(s)

• Tooling

• Workpiece

Always give appropriate attention to the work area that surrounds
the robot. The safety of the work area can be enhanced by the
installation of some or all of the following devices:

• Safety fences, barriers, or chains

• Light curtains

• Interlocks

• Pressure mats

• Floor markings

• Warning lights

• Mechanical stops

• EMERGENCY STOP buttons

• DEADMAN switches

Setting Up a Safe
Workcell

A safe workcell is essential to protect people and equipment.
Observe the following guidelines to ensure that the workcell is set
up safely. These suggestions are intended to supplement and not
replace existing federal, state, and local laws, regulations, and
guidelines that pertain to safety.

• Sponsor your personnel for training in approved FANUC

Robotics training course(s) related to your application. Never
permit untrained personnel to operate the robots.

Safety-3

• Install a lockout device that uses an access code to prevent

unauthorized persons from operating the robot.

• Use anti–tie–down logic to prevent the operator from bypassing

safety measures.

• Arrange the workcell so the operator faces the workcell and can

see what is going on inside the cell.

• Clearly identify the work envelope of each robot in the system

with floor markings, signs, and special barriers. The work
envelope is the area defined by the maximum motion range of
the robot, including any tooling attached to the wrist flange that
extend this range.

• Position all controllers outside the robot work envelope.

• Never rely on software as the primary safety element.

• Mount an adequate number of EMERGENCY STOP buttons or

switches within easy reach of the operator and at critical points
inside and around the outside of the workcell.

• Install flashing lights and/or audible warning devices that

activate whenever the robot is operating, that is, whenever
power is applied to the servo drive system. Audible warning
devices shall exceed the ambient noise level at the end–use
application.

• Wherever possible, install safety fences to protect against

unauthorized entry by personnel into the work envelope.

• Install special guarding that prevents the operator from reaching

into restricted areas of the work envelope.

• Use interlocks.

• Use presence or proximity sensing devices such as light

curtains, mats, and capacitance and vision systems to enhance
safety.

• Periodically check the safety joints or safety clutches that can be

optionally installed between the robot wrist flange and tooling. If
the tooling strikes an object, these devices dislodge, remove
power from the system, and help to minimize damage to the
tooling and robot.

Safety-4

• Make sure all external devices are properly filtered, grounded,

shielded, and suppressed to prevent hazardous motion due to
the effects of electro–magnetic interference (EMI), radio
frequency interference (RFI), and electro–static discharge
(ESD).

• Make provisions for power lockout/tagout at the controller.

• Eliminate pinch points. Pinch points are areas where personnel

could get trapped between a moving robot and other equipment.

• Provide enough room inside the workcell to permit personnel to

teach the robot and perform maintenance safely.

• Program the robot to load and unload material safely.

• If high voltage electrostatics are present, be sure to provide

appropriate interlocks, warning, and beacons.

• If materials are being applied at dangerously high pressure,

provide electrical interlocks for lockout of material flow and
pressure.

Staying Safe While
Teaching or Manually
Operating the Robot

Advise all personnel who must teach the robot or otherwise
manually operate the robot to observe the following rules:

• Never wear watches, rings, neckties, scarves, or loose clothing

that could get caught in moving machinery.

• Know whether or not you are using an intrinsically safe teach

pendant if you are working in a hazardous environment.

• Before teaching, visually inspect the robot and work envelope to

make sure that no potentially hazardous conditions exist. The
work envelope is the area defined by the maximum motion
range of the robot. These include tooling attached to the wrist
flange that extends this range.

• The area near the robot must be clean and free of oil, water, or

debris. Immediately report unsafe working conditions to the
supervisor or safety department.

• FANUC Robotics recommends that no one enter the work

envelope of a robot that is on, except for robot teaching
operations. However, if you must enter the work envelope, be
sure all safeguards are in place, check the teach pendant
DEADMAN switch for proper operation, and place the robot in
teach mode. Take the teach pendant with you, turn it on, and be
prepared to release the DEADMAN switch. Only the person
with the teach pendant should be in the work envelope.

Safety-5

WARNING

Never bypass, strap, or otherwise deactivate a safety device,
such as a limit switch, for any operational convenience.
Deactivating a safety device is known to have resulted in
serious injury and death.

• Know the path that can be used to escape from a moving robot;

make sure the escape path is never blocked.

• Isolate the robot from all remote control signals that can cause

motion while data is being taught.

• Test any program being run for the first time in the following

manner:

WARNING

Stay outside the robot work envelope whenever a program is
being run. Failure to do so can result in injury.

Staying Safe During
Automatic Operation

- Using a low motion speed, single step the program for at

least one full cycle.

- Using a low motion speed, test run the program continuously

for at least one full cycle.

- Using the programmed speed, test run the program

continuously for at least one full cycle.

• Make sure all personnel are outside the work envelope before

running production.

Advise all personnel who operate the robot during production to
observe the following rules:

• Make sure all safety provisions are present and active.

• Know the entire workcell area. The workcell includes the robot

and its work envelope, plus the area occupied by all external
devices and other equipment with which the robot interacts.

• Understand the complete task the robot is programmed to

perform before initiating automatic operation.

• Make sure all personnel are outside the work envelope before

operating the robot.

Safety-6

• Never enter or allow others to enter the work envelope during

automatic operation of the robot.

• Know the location and status of all switches, sensors, and

control signals that could cause the robot to move.

• Know where the EMERGENCY STOP buttons are located on

both the robot control and external control devices. Be prepared
to press these buttons in an emergency.

• Never assume that a program is complete if the robot is not

moving. The robot could be waiting for an input signal that will
permit it to continue activity.

• If the robot is running in a pattern, do not assume it will continue

to run in the same pattern.

• Never try to stop the robot, or break its motion, with your body.

The only way to stop robot motion immediately is to press an
EMERGENCY STOP button located on the controller panel,
teach pendant, or emergency stop stations around the workcell.

Staying Safe During
Inspection

When inspecting the robot, be sure to

• Turn off power at the controller.

• Lock out and tag out the power source at the controller

according to the policies of your plant.

• Turn off the compressed air source and relieve the air pressure.

• If robot motion is not needed for inspecting the electrical circuits,

press the EMERGENCY STOP button on the operator panel.

• Never wear watches, rings, neckties, scarves, or loose clothing

that could get caught in moving machinery.

• If power is needed to check the robot motion or electrical

circuits, be prepared to press the EMERGENCY STOP button,
in an emergency.

• Be aware that when you remove a servomotor or brake, the

associated robot arm will fall if it is not supported or resting on a
hard stop. Support the arm on a solid support before you
release the brake.

Staying Safe During
Maintenance

When performing maintenance on your robot system, observe the
following rules:

Safety-7

• Never enter the work envelope while the robot or a program is in

operation.

• Before entering the work envelope, visually inspect the workcell

to make sure no potentially hazardous conditions exist.

• Never wear watches, rings, neckties, scarves, or loose clothing

that could get caught in moving machinery.

• Consider all or any overlapping work envelopes of adjoining

robots when standing in a work envelope.

• Test the teach pendant for proper operation before entering the

work envelope.

• If it is necessary for you to enter the robot work envelope while

power is turned on, you must be sure that you are in control of
the robot. Be sure to take the teach pendant with you, press the
DEADMAN switch, and turn the teach pendant on. Be prepared
to release the DEADMAN switch to turn off servo power to the
robot immediately.

• Whenever possible, perform maintenance with the power turned

off. Before you open the controller front panel or enter the work
envelope, turn off and lock out the 3–phase power source at the
controller.

• Be aware that when you remove a servomotor or brake, the

associated robot arm will fall if it is not supported or resting on a
hard stop. Support the arm on a solid support before you
release the brake.

WARNING

Lethal voltage is present in the controller WHENEVER IT IS
CONNECTED to a power source. Be extremely careful to
avoid electrical shock.

HIGH VOLTAGE IS PRESENT at the input side whenever the
controller is connected to a power source. Turning the
disconnect or circuit breaker to the OFF position removes
power from the output side of the device only.

• Release or block all stored energy. Before working on the

pneumatic system, shut off the system air supply and purge the
air lines.

Safety-8

• Isolate the robot from all remote control signals. If maintenance

must be done when the power is on, make sure the person
inside the work envelope has sole control of the robot. The
teach pendant must be held by this person.

• Make sure personnel cannot get trapped between the moving

robot and other equipment. Know the path that can be used to
escape from a moving robot. Make sure the escape route is
never blocked.

• Use blocks, mechanical stops, and pins to prevent hazardous

movement by the robot. Make sure that such devices do not
create pinch points that could trap personnel.

WARNING
Do not try to remove any mechanical component from the

robot before thoroughly reading and understanding the
procedures in the appropriate manual. Doing so can result in
serious personal injury and component destruction.

KEEPING MACHINE
TOOLS AND
EXTERNAL
DEVICES SAFE

• Be aware that when you remove a servomotor or brake, the

associated robot arm will fall if it is not supported or resting on a
hard stop. Support the arm on a solid support before you
release the brake.

• When replacing or installing components, make sure dirt and

debris do not enter the system.

• Use only specified parts for replacement. To avoid fires and

damage to parts in the controller, never use nonspecified fuses.

• Before restarting a robot, make sure no one is inside the work

envelope; be sure that the robot and all external devices are
operating normally.

Certain programming and mechanical measures are useful in
keeping the machine tools and other external devices safe. Some
of these measures are outlined below. Make sure you know all
associated measures for safe use of such devices.

Programming Safety
Precautions

Implement the following programming safety measures to prevent
damage to machine tools and other external devices.

Mechanical Safety
Precautions

Safety-9

• Back–check limit switches in the workcell to make sure they do

not fail.

• Implement ‘‘failure routines” in programs that will provide

appropriate robot actions if an external device or another robot
in the workcell fails.

• Use handshaking protocol to synchronize robot and external

device operations.

• Program the robot to check the condition of all external devices

during an operating cycle.

Implement the following mechanical safety measures to prevent
damage to machine tools and other external devices.

• Make sure the workcell is clean and free of oil, water, and

debris.

• Use software limits, limit switches, and mechanical hardstops to

prevent undesired movement of the robot into the work area of
machine tools and external devices.

KEEPING THE
ROBOT SAFE

Operating Safety
Precautions

Programming Safety
Precautions

Observe the following operating and programming guidelines to
prevent damage to the robot.

The following measures are designed to prevent damage to the
robot during operation.

• Use a low override speed to increase your control over the robot

when jogging the robot.

• Visualize the movement the robot will make before you press

the jog keys on the teach pendant.

• Make sure the work envelope is clean and free of oil, water, or

debris.

• Use circuit breakers to guard against electrical overload.

The following safety measures are designed to prevent damage to
the robot during programming:

• Establish interference zones to prevent collisions when two or

more robots share a work area.

Safety-10

• Make sure that the program ends with the robot near or at the

home position.

• Be aware of signals or other operations that could trigger

operation of tooling resulting in personal injury or equipment
damage.

• In dispensing applications, be aware of all safety guidelines with

respect to the dispensing materials.

NOTE Any deviation from the methods and safety practices

described in this manual must conform to the approved standards of
your company. If you have questions, see your supervisor.

ADDITIONAL
SAFETY
CONSIDERATIONS
FOR PAINT ROBOT
INSTALLATIONS

Process technicians are sometimes required to enter the paint
booth, for example, during daily or routine calibration or while
teaching new paths to a robot. Maintenance personal also must
work inside the paint booth periodically.

Whenever personnel are working inside the paint booth, ventilation
equipment must be used. Instruction on the proper use of
ventilating equipment usually is provided by the paint shop
supervisor.

Although paint booth hazards have been minimized, potential
dangers still exist. Therefore, today’s highly automated paint booth
requires that process and maintenance personnel have full
awareness of the system and its capabilities. They must
understand the interaction that occurs between the vehicle moving
along the conveyor and the robot(s), hood/deck and door opening
devices, and high–voltage electrostatic tools.

Paint robots are operated in three modes:

• Teach or manual mode

• Automatic mode, including automatic and exercise operation

• Diagnostic mode

During both teach and automatic modes, the robots in the paint
booth will follow a predetermined pattern of movements. In teach
mode, the process technician teaches (programs) paint paths using
the teach pendant.

In automatic mode, robot operation is initiated at the System
Operator Console (SOC) or Manual Control Panel (MCP), if
available, and can be monitored from outside the paint booth. All
personnel must remain outside of the booth or in a designated safe

Safety-11

area within the booth whenever automatic mode is initiated at the
SOC or MCP.

In automatic mode, the robots will execute the path movements they
were taught during teach mode, but generally at production speeds.

When process and maintenance personnel run diagnostic routines
that require them to remain in the paint booth, they must stay in a
designated safe area.

Paint System Safety
Features

Process technicians and maintenance personnel must become
totally familiar with the equipment and its capabilities. To minimize
the risk of injury when working near robots and related equipment,
personnel must comply strictly with the procedures in the manuals.

This section provides information about the safety features that are
included in the paint system and also explains the way the robot
interacts with other equipment in the system.

The paint system includes the following safety features:

• Most paint booths have red warning beacons that illuminate

when the robots are armed and ready to paint. Your booth
might have other kinds of indicators. Learn what these are.

• Some paint booths have a blue beacon that, when illuminated,

indicates that the electrostatic devices are enabled. Your booth
might have other kinds of indicators. Learn what these are.

• EMERGENCY STOP buttons are located on the robot controller

and teach pendant. Become familiar with the locations of all E–
STOP buttons.

• An intrinsically safe teach pendant is used when teaching in

hazardous paint atmospheres.

• A DEADMAN switch is located on each teach pendant. When this

switch is held in, and the teach pendant is on, power is applied to the
robot servo system. If the engaged DEADMAN switch is released
during robot operation, power is removed from the servo system, all
axis brakes are applied, and the robot comes to an EMERGENCY
STOP. Safety interlocks within the system might also E–STOP other
robots.

WARNING

An EMERGENCY STOP will occur if the DEADMAN switch is
released on a bypassed robot.

Safety-12

• Overtravel by robot axes is prevented by software limits. All of

the major and minor axes are governed by software limits. Limit
switches and hardstops also limit travel by the major axes.

• EMERGENCY STOP limit switches and photoelectric eyes

might be part of your system. Limit switches, located on the
entrance/exit doors of each booth, will EMERGENCY STOP all
equipment in the booth if a door is opened while the system is
operating in automatic or manual mode. For some systems,
signals to these switches are inactive when the switch on the
SCC is in teach mode.

When present, photoelectric eyes are sometimes used to
monitor unauthorized intrusion through the entrance/exit
silhouette openings.

• System status is monitored by computer. Severe conditions

result in automatic system shutdown.

Staying Safe While
Operating the Paint
Robot

When you work in or near the paint booth, observe the following
rules, in addition to all rules for safe operation that apply to all robot
systems.

WARNING

Observe all safety rules and guidelines to avoid injury.

WARNING

Never bypass, strap, or otherwise deactivate a safety device,
such as a limit switch, for any operational convenience.
Deactivating a safety device is known to have resulted in
serious injury and death.

• Know the work area of the entire paint station (workcell).

• Know the work envelope of the robot and hood/deck and door

opening devices.

• Be aware of overlapping work envelopes of adjacent robots.

• Know where all red, mushroom–shaped EMERGENCY STOP

buttons are located.

Safety-13

• Know the location and status of all switches, sensors, and/or

control signals that might cause the robot, conveyor, and
opening devices to move.

• Make sure that the work area near the robot is clean and free of

water, oil, and debris. Report unsafe conditions to your
supervisor.

• Become familiar with the complete task the robot will perform

BEFORE starting automatic mode.

• Make sure all personnel are outside the paint booth before you

turn on power to the robot servo system.

• Never enter the work envelope or paint booth before you turn off

power to the robot servo system.

• Never enter the work envelope during automatic operation

unless a safe area has been designated.

• Never wear watches, rings, neckties, scarves, or loose clothing

that could get caught in moving machinery.

Staying Safe While
Operating Paint
Application Equipment

• Remove all metallic objects, such as rings, watches, and belts,

before entering a booth when the electrostatic devices are
enabled.

• Stay out of areas where you might get trapped between a

moving robot, conveyor, or opening device and another object.

• Be aware of signals and/or operations that could result in the

triggering of guns or bells.

• Be aware of all safety precautions when dispensing of paint is

required.

• Follow the procedures described in this manual.

When you work with paint application equipment, observe the
following rules, in addition to all rules for safe operation that apply to
all robot systems.

WARNING

When working with electrostatic paint equipment, follow all
national and local codes as well as all safety guidelines
within your organization. Also reference the following
standards: NFPA 33 Standards for Spray Application Using
Flammable or Combustible Materials, and NFPA 70 National
Electrical Code.

Safety-14

• Grounding: All electrically conductive objects in the spray area

must be grounded. This includes the spray booth, robots,
conveyors, workstations, part carriers, hooks, paint pressure
pots, as well as solvent containers. Grounding is defined as the
object or objects shall be electrically connected to ground with a
resistance of not more than 1 megohms.

• High Voltage: High voltage should only be on during actual

spray operations. Voltage should be off when the painting
process is completed. Never leave high voltage on during a cap
cleaning process.

• Avoid any accumulation of combustible vapors or coating

matter.

• Follow all manufacturer recommended cleaning procedures.

• Make sure all interlocks are operational.

• No smoking.

Staying Safe During
Maintenance

• Post all warning signs regarding the electrostatic equipment and

operation of electrostatic equipment according to NFPA 33
Standard for Spray Application Using Flammable or
Combustible Material.

• Disable all air and paint pressure to bell.

• Verify that the lines are not under pressure.

When you perform maintenance on the painter system, observe the
following rules, and all other maintenance safety rules that apply to
all robot installations. Only qualified, trained service or maintenance
personnel should perform repair work on a robot.

• Paint robots operate in a potentially explosive environment. Use

caution when working with electric tools.

• When a maintenance technician is repairing or adjusting a robot,

the work area is under the control of that technician. All
personnel not participating in the maintenance must stay out of
the area.

• For some maintenance procedures, station a second person at

the control panel within reach of the EMERGENCY STOP
button. This person must understand the robot and associated
potential hazards.

Safety-15

• Be sure all covers and inspection plates are in good repair and

in place.

• Always return the robot to the ‘‘home’’ position before you

disarm it.

• Never use machine power to aid in removing any component

from the robot.

• During robot operations, be aware of the robot’s movements.

Excess vibration, unusual sounds, and so forth, can alert you to
potential problems.

• Whenever possible, turn off the main electrical disconnect

before you clean the robot.

• When using vinyl resin observe the following:

- Wear eye protection and protective gloves during application

and removal

- Adequate ventilation is required. Overexposure could cause

drowsiness or skin and eye irritation.

- If there is contact with the skin, wash with water.

• When using paint remover observe the following:

- Eye protection, protective rubber gloves, boots, and apron

are required during booth cleaning.

- Adequate ventilation is required. Overexposure could cause

drowsiness.

- If there is contact with the skin or eyes, rinse with water for

at least 15 minutes.

Update Section

Single Phase Power Option

B–81535EN/02

Table of Contents

PREFACE p–1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

I SAFETY PRECAUTIONS

1. SAFETY PRECAUTIONS 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.1 OPERATOR SAFETY 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.1.1 Operator Safety 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.1.2 Safety of the T each Pendant Operator 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.1.3 Safety During Maintenance 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.2 SAFETY OF THE TOOLS AND PERIPHERAL DEVICES 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.2.1 Precautions in Programming 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.2.2 Precautions for Mechanism 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.3 SAFETY OF THE ROBOT MECHANISM 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.3.1 Precautions in Operation 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.3.2 Precautions in Programming 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.3.3 Precautions for Mechanisms 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.4 SAFETY OF THE END EFFECTOR 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.4.1 Precautions in Programming 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.5 SAFETY IN MAINTENANCE 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.6 WARNING LABEL 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

II MAINTENANCE

1. OVERVIEW 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2. CONFIGURATION 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1 EXTERNAL VIEW OF THE CONTROLLER 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.2 COMPONENT FUNCTIONS 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3 PREVENTIVE MAINTENANCE 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3. TROUBLESHOOTING 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.1 POWER CANNOT BE TURNED ON 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.1.1 T each Pendant Cannot be Turned On 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.1.2 Initial Screen Remains on the T each Pendant 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2 ALARM OCCURRENCE SCREEN 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3 SAFETY SIGNALS 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.4 MASTERING 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.5 TROUBLESHOOTING USING THE ERROR CODE 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.6 TROUBLESHOOTING USING FUSES 92. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.7 TROUBLESHOOTING BASED ON LED INDICATIONS 97. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.8 POSITION DEVIATION FOUND IN RETURN TO THE REFERENCE POSITION

(POSITIONING) 107. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.9 VIBRATION OBSERVED DURING MOVEMENT 108. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.10 MANUAL OPERATION IMPOSSIBLE 109. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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4. PRINTED CIRCUIT BOARDS 1 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1 ROBOT CONTROL BOARD (A16B–3200–0450) 112. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.2 EMERGENCY STOP BOARD (A20B–1008–0010, –0011) 116. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3 BACKPLANE BOARD (A20B–2003–0330) 117. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.4 PROCESS I/O BOARD HE (A16B–2203–0764), HF (A16B–2203–0765) 118. . . . . . . . . . . . . . . . . . .

5. SERVO AMPLIFIERS 120. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.1 OUTLINE DRAWINGS 121. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.1.1 Power Supply Module PSM (A06B–6115–H001) 121. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.1.2 Servo Amplifier Module (A06B–6114–H205, A06B–6114–H302) 122. . . . . . . . . . . . . . . . . . . . . . . . . . .

5.2 LED OF SERVO AMPLIFIER 123. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.2.1 LED of Power Supply Module 123. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.2.2 LED of Servo Amplifier Module 124. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6. SETTING THE POWER SUPPLY 125. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.1 BLOCK DIAGRAMS OF THE POWER SUPPLY 126. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.2 CHECKING THE POWER SUPPLY UNIT 127. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.3 CHECKING THE POWER SUPPLY MODULE 127. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7. REPLACING A UNIT 128. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.1 REPLACING THE PRINTED–CIRCUIT BOARDS 129. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.1.1 Replacing the Backplane Board (Unit) 130. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.1.2 Replacing the Robot Control Board and Printed–Circuit Boards on the Backplane Unit 131. . . . . . . . . . .

7.1.3 Replacing the Emergency Stop Board 132. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.2 REPLACING CARDS AND MODULES ON THE ROBOT CONTROL BOARD 133. . . . . . . . . . . . .

7.3 REPLACING THE TRANSFORMER 137. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.3.1 Replacing the Brake Power Transformer 137. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.4 REPLACING THE EMERGENCY STOP UNIT 138. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.5 REPLACING THE MAGNETIC CONTACTOR 139. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.6 REPLACING SERVO AMPLIFIERS 140. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.7 REPLACING THE TEACH PENDANT 141. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.8 REPLACING THE CONTROL SECTION FAN MOTOR 142. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.9 REPLACING THE FAN MOTOR OF THE SERVO AMPLIFIER CONTROL UNIT 143. . . . . . . . . .

7.10 REPLACING THE DOOR FAN UNIT AND HEAT EXCHANGER 144. . . . . . . . . . . . . . . . . . . . . . . .

7.11 REPLACING THE OPERATOR PANEL 145. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.12 REPLACING THE POWER SUPPLY UNIT 146. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.13 REPLACING A FUSE 147. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.13.1 Replacing a Fuse on the Robot Control Board 147. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.13.2 Replacing a Fuse on the Emergency Stop Board 148. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.13.3 Replacing the Fuse on the Door 149. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.13.4 Replacing the Fuse on the Power Supply Module 150. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.13.5 Replacing the Fuse on the Servo Amplifier Module 151. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.13.6 Replacing the Fuse on the Process I/O Boards 152. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.14 REPLACING A RELAY 153. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.14.1 Replacing a Relay on the Emergency Stop Board 153. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.15 REPLACING BATTERY 154. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.15.1 Battery for Memory Backup (3 VDC) 154. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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III CONNECTION

1. GENERAL 159. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2. BLOCK DIAGRAM 160. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3. CONNECTION DETAILS 161. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.1 CONNECTION OF POWER SUPPLY CABLE 162. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2 FANUC I/O LINK 163. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3 CONNECTION OF I/O LINK CABLE 165. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.4 EMERGENCY STOP CIRCUIT 167. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.4.1 Circuit Diagram of Emergency Stop 167. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.4.2 External Emergency Stop Input 168. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.4.3 External Emergency Stop Output 169. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.4.4 External 24 V Input 170. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.5 COONECTION OF SERVO AMPLIFIER 171. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.6 CONNECTION OF ROBOT 172. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.7 CONNECTION OF TEACH PENDANT CABLE 173. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.8 CONNECTION OF CABLE FOR RS–232–C/RS–422 174. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.9 CONNECTING A CABLE TO A PERIPHERAL DEVICE 175. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.9.1 Peripheral Device Interfaces CRM79 and CRM81 175. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.9.2 When the Robot is Connected to the CNC by a Peripheral Device Cable 176. . . . . . . . . . . . . . . . . . . . . . .

3.9.3 Digital I/O Signal Specifications 193. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.9.3.1 Peripheral device interface CRM 79 and CRM 81 193. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.9.4 Peripheral Device Cable Connector 195. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.9.5 Recommended Cables 196. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.10 END EFFECTOR INTERFACE 197. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.10.1 Connecting the Mechanical Unit and End Effector 197. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.10.2 Digital I/O Signal Specifications of End Effector Control Interface 199. . . . . . . . . . . . . . . . . . . . . . . . . . .

3.11 TREATMENT FOR THE SHIELDED CABLE 200. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.12 PERIPHERAL DEVICE, ARC WELDING, INTERFACES 201. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.12.1 Peripheral Device Interface Types 201. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.12.2 Peripheral Device Interface Block Diagram and Specifications 202. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.12.3 Peripheral Device and Control Unit Connection 203. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.12.4 Connection Between the Control Unit and Welder 208. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.12.5 Digital I/O Signal Specifications of Peripheral Device Interface A 214. . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.12.6 I/O Signal Specifications for ARC–W elding Interface 216. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.12.7 Specifications of the Cables used for Peripheral Devices A (CRM2: Honda T sushin, 50 pins) 219. . . . . .

3.12.8 ARC Weld Connection Cable (CRW1: Honda Tsushin, 34 pins) 219. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.12.9 Peripheral Device Cable Connector 220. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.12.10 Recommended Cables 221. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4. TRANSPORTATION AND INSTALLATION 222. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1 TRANSPORTATION 223. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.2 INSTALLATION 223. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.3 EXTERNAL CONTROLLER DIMENSIONS 224. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.4 INSTALLATION CONDITION 225. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.5 ADJUSTMENT AND CHECKS AT INSTALLATION 225. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.6 NOTE AT INSTALLATION 226. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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4.7 DISABLING HAND BREAK 226. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

APPENDIX

A. TOTAL CONNECTION DIAGRAM 229. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

B. PERIPHERAL INTERFACE 238. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

B.1 SIGNAL TYPES 239. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

B.2 I/O SIGNALS 240. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

B.2.1 Input Signals 240. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

B.2.2 Output Signals 241. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

B.3 SPECIFICATIONS OF DIGITAL INPUT/OUTPUT 242. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

B.3.1 Overview 242. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

B.3.2 Input/Output Hardware Usable in the R-J3iB Mate Controller 242. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

B.3.3 Software Specifications 243. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

C. OPTICAL FIBER CABLE 244. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

B–81535EN/02

c–4

B–81535EN/02

PREFACE

PREFACE

This manual describes the following models.

Model Abbreviation

FANUC Robot LR Mate 100iB LR Mate 100iB
FANUC Robot LR Mate 200iB LR Mate 200iB
FANUC Robot ARC Mate 50iB ARC Mate 50iB

p–1

I SAFETY PRECAUTIONS

B–81535EN/02

1

SAFETY PRECAUTIONS

SAFETY PRECAUTIONS

For the safety of the operator and the system, follow all safety precautions
when operating a robot and its peripheral devices installed in a work cell.

1. SAFETY PRECAUTIONS

3

1. SAFETY PRECAUTIONS

SAFETY PRECAUTIONS

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1.1

OPERATOR SAFETY

Operator safety is the primary safety consideration. Because it is very
dangerous to enter the operating space of the robot during automatic
operation, adequate safety precautions must be observed.

The following lists the general safety precautions. Careful consideration
must be made to ensure operator safety.

(1) Have the robot system operators attend the training courses held by

FANUC.

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

(2) Even when the robot is stationary, it is possible that the robot is still

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

(3) Install a safety fence with a gate so that no operator can enter the work

area without passing through the gate. Equip the gate with an
interlock that stops the robot when the gate is opened.

The controller is designed to receive this interlock signal. When the gate is
opened and this signal received, the controller stops the robot in an emergency .
For connection, see Fig.1.1.

(4) Provide the peripheral devices with appropriate grounding (Class 1,

Class 2, or Class 3).
(5) Try to install the peripheral devices outside the work area.
(6) Draw an outline on the floor, clearly indicating the range of the robot

motion, including the tools such as a hand.
(7) Install a mat switch or photoelectric switch on the floor with an

interlock to a visual or aural alarm that stops the robot when an

operator enters the work area.
(8) If necessary, install a safety lock so that no one except the operator

in charge can turn on the power of the robot.

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

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SAFETY PRECAUTIONS

1. SAFETY PRECAUTIONS

(9) When adjusting each peripheral device independently, be sure to turn

off the power of the robot.

Safety gate which executes with opening the door.

Fig.1.1 Safety Fence and Safety Gate

5

1. SAFETY PRECAUTIONS

SAFETY PRECAUTIONS

B–81535EN/02

1.1.1

Operator Safety

The operator is a person who operates the robot system. In this sense, a
worker who operates the teach pendant is also an operator. However, this
section does not apply to teach pendant operators.

(1) If it is not necessary for the robot to operate, turn off the power of the

robot controller or press the EMERGENCY STOP button, and then

proceed with necessary work.
(2) Operate the robot system at a location outside the work area.
(3) Install a safety fence with a safety gate to prevent any worker other

than the operator from entering the work area unexpectedly and also

to prevent the worker from entering a dangerous area.
(4) Install an EMERGENCY STOP button within the operator’s reach.

The robot controller is designed to be connected to an external EMERGENCY
STOP button. With this connection, the controller stops the robot operation
when the external EMERGENCY STOP button is pressed. See the diagram
below for connection.

External EMERGENCY STOP button

Emergency stop board

EMGIN11
EMGIN12
EMGIN21
EMGIN22

Note) Connect between EMGIN1 and EMGIN2 and between EMGIN21 and EMGIN22.

EMGIN11, EMGIN12, EMGIN21 and EMGIN22 are on the emergency stop
board.

Fig.1.1.1 Connection Diagram for External Emergency Stop Switch

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SAFETY PRECAUTIONS

1. SAFETY PRECAUTIONS

1.1.2

Safety of the Teach
Pendant Operator

While teaching the robot, it is necessary for the operator to enter the work
area of the robot. It is particularly necessary to ensure the safety of the
teach pendant operator.

(1) Unless it is specifically necessary to enter the robot work area, carry

out all tasks outside the area.
(2) Before teaching the robot, check that the robot and its peripheral

devices are all in the normal operating condition.
(3) When entering the robot work area and teaching the robot, be sure to

check the location and condition of the safety devices (such as the

EMERGENCY STOP button and the deadman switch on the teach

pendant).

FANUC’s teach pendant has a switch for enabling or disabling the robot opera-
tion from the teach pendant and a deadman switch in addition to the EMER­GENCY STOP button. The switches function as follows.

EMERGENCY STOP button : Pressing this button always brings the robot

to an emergency stop, irrespective of the
state of the enable/disable switch and the
mode switch of operator panel.

Deadman switch : The function of this switch depends on the

state of the enable/disable switch and the
mode switch of operator panel.

When the mode switch is in the AUTO position

– The enable/disable switch and deadman

switch are disabled.

When the mode switch is in the TI position and the enable/disable switch is
in the enable position

– Releasing the deadman switch brings the

robot to an emergency stop.

When the mode switch is in the TI position and the enable/disable switch is
in the disable position

– The robot is brought to an emergency stop

regardless of the operation of the deadman
switch.

Note)The deadman switch is provided to bring the robot to an emergency

stop when the operator releases the teach pendant in an emergency.

(4) The teach pendant operator should pay careful attention so that no

other workers enter the robot work area.

NOTE

In addition to the above, the teach pendant enable switch and the
deadman switch also have the following function.

By pressing the deadman switch while the enable switch is on, the
emergency stop factor (normally the safety gate) connected to
FENCE11 and FENCE12 of the controller is invalidated. In this
case, it is possible for an operator to enter the fence during teach
operation without making the robot in the emergency stop
condition. In other words, the system understands that the
combined operations of pressing the teach pendant enable switch
and pressing the deadman switch indicates the start of teaching.
The teach pendant o perator s hould b e w ell a ware t hat the s afety gate
is not functional under this condition and bear full res ponsibility to
ensure that no one enters the fence during teaching.

7

1. SAFETY PRECAUTIONS

SAFETY PRECAUTIONS

B–81535EN/02

(5) When entering the robot work area, the teach pendant operator should

enable the teach pendant whenever he or she enters the robot work

area. In particular, while the teach pendant enable switch is off, make

certain that no start command is sent to the robot from any operator

panel other than the teach pendant.

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

Operator panel

mode switch

T1 On Independent Allowed to start Not allowed Not allowed
AUTO Off Local Not allowed Allowed to start Not allowed
AUTO Off Remote Not allowed Not allowed Allowed to start

Teach pendant

enable switch

Remote

condition

Teach

pendant

Operator panel

Peripheral

devices

(6) When a program is completed, be sure to carry out a test run according

to the procedure below.
(a) Run the program for at least one operation cycle in the single step

mode at low speed.

(b) Run the program for at least one operation cycle in the continuous

operation mode at low speed.

(c) Run the program for one operation cycle in the continuous

operation mode at the intermediate speed and check that no
abnormalities occur due to a delay in timing.

(d) Run the program for one operation cycle in the continuous

operation mode at the normal operating speed and check that the
system operates automatically without trouble.

(e) After checking the completeness of the program through the test

run above, execute it in the automatic operation mode.

(7) While operating the system in the automatic operation mode, the

teach pendant operator should leave the robot work area.

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SAFETY PRECAUTIONS

1. SAFETY PRECAUTIONS

1.1.3

Safety During
Maintenance

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

(1) Except when specifically necessary, turn off the power of the

controller while carrying out maintenance. Lock the power switch,
if necessary, so that no other person can turn it on.

(2) When disconnecting the pneumatic system, be sure to reduce the

supply pressure.

(3) Before the start of teaching, check that the robot and its peripheral

devices are all in the normal operating condition.

(4) If it is necessary to enter the robot work area for maintenance when

the power is turned on, the worker should indicate that the machine
is being serviced and make certain that no one starts the robot
unexpectedly.

(5) Do not operate the robot in the automatic mode while anybody is in

the robot work area.

(6) When it is necessary to maintain the robot alongside a wall or

instrument, or when multiple workers are working nearby, make
certain that their escape path is not obstructed.

(7) When a tool is mounted on the robot, or when any moving device

other than the robot is installed, such as belt conveyor, pay careful
attention to its motion.

(8) If necessary, have a worker who is familiar with the robot system

stand beside the operator panel and observe the work being
performed. If any danger arises, the worker should be ready to press
the EMERGENCY STOP button at any time.

(9) When replacing or reinstalling components, take care to prevent

foreign matter from entering the system.

(10) When handling each unit or printed circuit board in the controller

during inspection, turn off the power of the controller and also turn
off the circuit breaker to protect against electric shock.

(11)When replacing parts, be sure to use those specified by FANUC.

In particular, never use fuses or other parts of non-specified ratings.
They may cause a fire or result in damage to the components in the
controller.

9

1. SAFETY PRECAUTIONS

1.2

SAFETY OF THE
TOOLS AND
PERIPHERAL
DEVICES

SAFETY PRECAUTIONS

B–81535EN/02

1.2.1

Precautions in
Programming

1.2.2

Precautions for
Mechanism

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

if necessary, design the program to stop the robot when the sensor
signal is received.

(2) Design the program to stop the robot when an abnormal condition

occurs in any other robots or peripheral devices, even though the
robot itself is normal.

(3) For a system in which the robot and its peripheral devices are in

synchronous motion, particular care must be taken in programming
so that they do not interfere with each other.

(4) Provide a suitable interface between the robot and its peripheral

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

(1) Keep the component cells of the robot system clean, and operate the

robot in an environment free of grease, water, and dust.

(2) Employ a limit switch or mechanical stopper to limit the robot motion

so that the robot does not come into contact with its peripheral devices
or tools.

10

B–81535EN/02

1.3

SAFETY OF THE
ROBOT MECHANISM

SAFETY PRECAUTIONS

1. SAFETY PRECAUTIONS

1.3.1

Precautions in
Operation

1.3.2

Precautions in
Programming

1.3.3

Precautions for
Mechanisms

(1) When operating the robot in the jog mode, set it at an appropriate

speed so that the operator can manage the robot in any eventuality.

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

motion the robot will perform in the jog mode.

(1) When the wor k a r e a s o f r o b o ts overlap, make certain that the motions

of the robots do not interfere with each other.

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

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

(1) Keep the work area of the robot clean, and operate the robot in an

environment free of grease, water, and dust.

11

1. SAFETY PRECAUTIONS

1.4

SAFETY OF THE END
EFFECTOR

SAFETY PRECAUTIONS

B–81535EN/02

1.4.1
Precautions in
Programming

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

consider the necessary time delay after issuing each control command
up to actual motion and ensure safe control.

(2) Provide the end effector with a limit switch, and control the robot

system by monitoring the state of the end effector.

12

B–81535EN/02

1.5

SAFETY IN
MAINTENANCE

SAFETY PRECAUTIONS

(1) Never enter the robot work area while the robot is operating. T urn of f

the power before entering the robot work area for inspection and
maintenance.

(2) If it is necessary to enter the robot work area with the power turned

on, first press the EMERGENCY STOP button on the operator panel.

(3) When replacing or reinstalling components, take care to prevent

foreign matter from entering the system.
When replacing the parts in the pneumatic system, be sure to reduce
the pressure in the piping to zero by turning the pressure control on
the air regulator.

(4) When handling each unit or printed circuit board in the controller

during inspection, turn off the power of the controller and turn off the
circuit breaker to protect against electric shock.

(5) When replacing parts, be sure to use those specified by FANUC.

In particular, never use fuses or other parts of non-specified ratings.
They may cause a fire or result in damage to the components in the
controller.

(6) Before restarting the robot, be sure to check that no one is in the robot

work area and that the robot and its peripheral devices are all in the
normal operating state.

1. SAFETY PRECAUTIONS

13

1. SAFETY PRECAUTIONS

1.6

W ARNING LABEL

Description

SAFETY PRECAUTIONS

B–81535EN/02

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 as
well.

(1) Step–on prohibitive label

Description

Description

Fig.1.6 (a) Step–on Prohibitive Label

Be cautious about a section where this label is affixed, as the section
generates heat. If you have to inevitably touch such a section when it is
hot, use a protective provision such as heat–resistant gloves.

(2) High–temperature warning label

Fig.1.6 (b) High–Temperature Warning Label

A high voltage is applied to the places where this label is attached.
Before starting maintenance, turn the power to the control unit off, then
turn the circuit breaker off to avoid electric shock hazards. Be careful with
servo amplifier and other units because high–voltage places in these units
may remain in the high–voltage state for a fixed time.

14

B–81535EN/02

SAFETY PRECAUTIONS

(3) High–voltage warning label

Fig.1.6 (c) High–Voltage Warning Label

1. SAFETY PRECAUTIONS

Description

There may be a high voltage in a place with this label. Before working
on such a portion, turn off the power to the controller and set its circuit
breaker to the off position to avoid shock hazards.
In addition, be careful about servo amplifiers and other electric circuits
because a high voltage may remain in them for a certain period of time
after the power is turned off.

15

II MAINTENANCE

B–81535EN/02

1

1. OVERVIEWMAINTENANCE

OVERVIEW

This manual describes the maintenance and connection of the R–J3iB
Mate robot controller (called the R–J3iB Mate).

Maintenance Part : Troubleshooting, and the setting, adjustment,

and replacement of units

Connection Part : Connection of the R–J3iB Mate controller to the

robot mechanical unit and peripheral devices,
and installation of the controller

WARNING

Before you enter the robot working area, be sure to turn off
the power to the controller or press the EMERGENCY
STOP button on the operator panel or teach pendant.
Otherwise, you could injure personnel or damage
equipment.

TERM

The R–J3iB Mate robot controller uses the FANUC servo
amplifier α i series (called the servo amplifier (i).
The servo amplifier α i comprises a power supply module
(PSM) and a servo amplifier module (SVM).
In this manual, the terms “power supply module” and “servo
amplifier module” refer to the individual modules. The term
“servo amplifier” refers to the combination of the power
supply module and servo amplifier module.

19

2. CONFIGURATION

CONFIGURATION

2

MAINTENANCE

B–81535EN/02

20

B–81535EN/02

2. CONFIGURATIONMAINTENANCE

2.1

EXTERNAL VIEW OF
THE CONTROLLER

The appearance and components might slightly differ depending on the
controlled robot, application, and options used.

Fig.2.1 (a) shows the view of R–J3iB Mate.
Fig.2.1 (b) shows the R–J3iB Mate consists of the R–J3iB Mate controller.

Teach pendant

R–J3iB Mate controller

Operator
panel

Fan unit

Fig.2.1 (a) External View of the R–J3iB Mate Controller

Teach pendant cable

21

2. CONFIGURATION

MAINTENANCE

B–81535EN/02

Circuit protector

Emergency stop
button

Mode
switch

Emergency stop unit

Emergency stop board

Heat exchange

Fuse

MCC

Power supply unit

Power supply transformer
for brake

Servo amplifier module2 (AMP2)

Servo amplifier module1 (AMP1)

Power supply module (PSM)

Enable/disable switch Emergency stop

Option slot (Process I/O board)

Robot control board

Teach pendan t

button

Back plane board

Robot

LR Mate 100iB

LR Mate 200iB

LR Mate 200iB
ARC Mate 50iB

ARC Mate 50iB

Fig.2.1 (b) R–J3iB Mate interior (Front)

Table 2.1 Servo amplifier specifications

Power supply module Servo amplifier module1 Servo amplifier module2

A06B–6115–H001

(αPSMR–1i)

A06B–6114–H205

(αSVM–20/20i)

A06B–6114–H302
(αSVM–10/10/10i)

L M L M N

J1 J2 J3 J4 J5

A06B–6115–H001

(αPSMR–1i)

A06B–6114–H302
(αSVM–10/10/10i)

A06B–6114–H302
(αSVM–10/10/10i)

L M N L M N

J1 J2 J3 J4 J5 J6

22

B–81535EN/02

2. CONFIGURATIONMAINTENANCE

2.2

COMPONENT
FUNCTIONS

– Robot control printed circuit board

This board is equipped with a microprocessor and its peripheral
circuitry , memory, and operator panel control circuit. A servo control
circuit is also included.

– Emergency stop unit, emergency stop printed circuit board

This unit controls the emergency stop system, magnetic contactor
(MCC) of the servo amplifier, and brake. The unit contains the power
supply unit for converting the AC power to the DC power.

– Backplane board

Various control boards are mounted on the backplane board.

– Teach pendant

This unit is used to carry out all operations including robot
programming. The liquid crystal display (LCD) of this unit displays
the status of the control unit, data, and the like.

– Servo amplifier

The servo amplifier amplifies the power of the servo amplifier and
controls the pulse coder.

– MCC

The MCC controls the main power of the servo amplifier.

– Operator panel

The operator panel has a port for the serial interface to an external
device. The panel also has an EMERGENCY STOP button.

– Fan unit, heat exchanger

These components are used to cool the inside of the control unit.

– Circuit protector

This component turns on or off the power.
The input power is connected to the circuit protector in order to

protect the equipment from a large current that could result from a
problem in the electric system of the control unit or an abnormal input
power.

23

2. CONFIGURATION

MAINTENANCE

B–81535EN/02

2.3

PREVENTIVE
MAINTENANCE

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

(1) Daily maintenance

Before operating the system each day, clean each part of the system
and check the system parts for any damage or cracks. Also check the
following:

(a) Before service operation

Check the cable connected to the teach pendant for excessive
twisting. Check the controller and peripheral devices for
abnormalities.

(b) After service operation

At the end of service operation, return the robot to the specified
position, 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) 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 (d) described below for
inspection to be performed every 6 months.

(d) Periodic inspection performed every six months

Remove the top cover, louver, and back panel (if possible), then
remove any dirt and dust from the inside of the transformer
compartment. Wipe off dirt and dust from the fan and
transformer.

(2) 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

Phillips screwdrivers : Large, medium, and small
Standard screwdrivers: Large, medium, and small
Nut driver set (Metric)
Pliers
Needle-nose pliers
Diagonal cutting pliers

24

B–81535EN/02

3

3. TROUBLESHOOTINGMAINTENANCE

TROUBLESHOOTING

This chapter describes the checking method and corrective action for each
error code indicated if a hardware alarm occurs. Refer to the operator’s
manual to release program alarms.

25

3. TROUBLESHOOTING

3.1

POWER CANNOT BE
TURNED ON

Check and Corrective action Figure

(Check 1) Check that the circuit protector is on and

(Corrective
action)

has not tripped.
Turn on the circuit protector.

MAINTENANCE

Circuit protector
(on/off switch)

B–81535EN/02

(Check 2) Check that the door fan unit and the fan

(Corrective
action)

motor o f the heat exchanger are rotating
and that the LED indication on the power
supply module is “–”.

If the fan motor is not rotating or if the
LED of the power supply module is not
glowing, the fuse on the back of the door
may have been blown.

– Check the fuse on the back of the

door.
If the fuse on the back of the door has
been blown, replace the fuse.

Circuit protector

Heat exchange for
fan unit (door face)

fan unit (door face)

Fuse

LED of the power supply module

Secondary side of the circuit protector

26

B–81535EN/02

3.1.1

Teach Pendant Cannot
be Turned On

Check and Corrective action Figure

(Check 1) Check the LCD display and LED indica-

(Corrective
action)

tion on the teach pendant.
Check the LCD display and LED indica-

tion on the teach pendant to see whether
the emergency stop unit is faulty.

– Check whether the fuse FUS4 on the

emergency stop board is blown. If the
fuse is blown, the FALM LED glows.
Replace th e b l o w n f u s e .

– If the fuse FUS4 on the emergency

stop board is not blown, the emergen­cy stop unit may be faulty. Replace
the emergency stop unit.

3. TROUBLESHOOTINGMAINTENANCE

Teach pendant

Emergency stop board

FALM LED

Fuse FUS4

Emergency stop unit

27

3. TROUBLESHOOTING

3.1.2

Initial Screen Remains
on the Teach Pendant

Check and Corrective action Figure

(Check 1) Check that the “.” portion of the seven–

(Corrective
action)

(Corrective
action(1))

(Corrective
action(2)) a) Problem in the DC/DC converter

segment LED glows on the robot control
board.

If the “.” portion is not glowing, the fuse
FUS1 on the robot control board may be
blown. Alternatively, the DC/DC con­verter module may be damaged.
If the FUSE ALARM LED is glowing, the
fuse FUS1 may be blown.
The fuse FUS1 is provided on the robot
control board. Before checking the fuse,
turn off the circuit protector.
a) If the fuse FUS1 has been blown

– See Corrective action (1).
b) If the fuse FUS1 is not blown

– See Corrective action (2).
Cause of the blowing of the fuse FUS1

and corrective action
a) Check whether the device which is

connected to the RS–232–C/
RS–422 port and requires the power
supply of +24 V is sound.

b) Problem in the DC/DC converter

module
If the DC/DC converter module gets
faulty in the short–circuit mode,
FUS1 is blown.
Replace the DC/DC converter mod­ule.

module
Replace the DC/DC converter mod­ule.

b) Problem in the robot control board

Replace the robot control board.
(For the LED indications, see Section

3.7, “TROUBLESHOOTING USING
LEDS.”)

MAINTENANCE

B–81535EN/02

+24V input
connector
CP5

DC/DC converter
module

dot part of seven
segment L E D

FUS1 7.5A
DC24V input fuse

28

B–81535EN/02

3. TROUBLESHOOTINGMAINTENANCE

3.2

ALARM
OCCURRENCE
SCREEN

The alarm occurrence screen displays only the alarm conditions that are
currently active. If an alarm reset signal is input to reset the alarm
conditions, the alarm occurrence screen displays the message “PAUSE or
more serious alarm has not occurred.”

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

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

Press the alarm key.

Automatic alarm display
upon occurrence

Alarm occurrence screen display

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

Alarm history screen display

Fig.3.2 Alarm Occurrence Screen and Alarm History Screen Display

Procedure

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3. TROUBLESHOOTING

Displaying the alarm history/alarm detail information

MAINTENANCE

B–81535EN/02

Step

3
4 ALARM
5 I/O

MENUS

CLEAR HELP

F5

(1) Press the MENUS key to display the screen menu.
(2) Select [ALARM].

You will see a screen similar to the following

INTP–224 (SAMPLE1, 7) Jump label is fail
MEMO–027 Specified line does not exist
Alarm JOINT 30 %
1/25
1 INTP–224 (SAMPLE1, 7) Jump label is
2 SRVO–002 Teach pendant E–stop
3 R E S E T
4 SRVO–027 Robot not mastered(Group:1)
5 SYST–026 System normal power up

[ TYPE ] CLEAR HELP

NOTE

The latest alarm is assigned number 1. To view messages
that are currently not on the screen, press the F5, HELP,
then press the right arrow key.

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

INTP–224 (SAMPLE1, 7) Jump label is fail

INTP–224 (SAMPLE1, 7) Jump label is fail
MEMO–027 Specified line does not exist
30–MAY–44 07:15
STOP.L 00000110
Alarm
1/25
1 INTP–224 (SAMPLE1, 7) Jump label is
2 SRVO–002 Teach pendant E–stop

CLEAR HELP

SHIFT

F4

[ TYPE ] CLEAR HELP

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

PREV

(5) To delete all the alarm histories, press and hold down the SHIFT key,

then press F4, [CLEAR].

NOTE

When system variable $ER_NOHIS = 1, NONE alarms or
WARN alarms are not recorded. When $ER_NOHIS=2,
resets are not recorded in the alarm history. When
$ER_NOHIS=3, resets, WARN alarms, and NONE alarms
are not recorded.

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3. TROUBLESHOOTINGMAINTENANCE

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

4 ALARM

F1 [TYPE]

Alarm : Active

F1 [TYPE]
F3 HIST

Alarm : HIST

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

DETAIL Alarm

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

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3.3

SAFETY SIGNALS

Safety signal

Operator panel emergency stop This item indicates the state of the emergency stop button on the operator panel. If the

Teach pendant emergency stop This item indicates the state of the emergency stop button on the teach pendant. If the

External emergency stop This item indicates the state of the external emergency stop signal. If the EMERGENCY

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

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

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

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

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

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

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

T able 3.3 Safety Signals

Description

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

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

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

indicated as “TRUE”.

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

able, the state is indicated as “TRUE”.

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

If any robot articulation goes out of the operation range beyond the overtravel switch, the
state is indicated as “TRUE”. I n this case, an alarm o ccur s, causi ng t he ser vo p ower t o b e
switched off.

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

Step

(1) Press the MENUS 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 Safety Signal. You will see a screen similar to the following.

SYSTEM Safety JOINT 30%
SIGNAL NAME STATUS 1/11

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 Over Travel: FALSE
9 Low Air Alarm: FALSE

[TYPE]

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3.4

MASTERING

Condition

Step

9 USER
0 –– NEXT ––

MENUS

5 POSITION
6 SYSTEM
7

Mastering is needed if:
(1) The SRVO 062 BZAL or SRVO 038 pulse mismatch alarm occurs,

or

(2) The pulse coder is replaced.
Item (1) requires simplified mastering, while item (2) requires

zero–degree or jig position mastering. (Zero–degree position mastering
is just for quick–fix purposes. After zero–degree position mastering is
used, jig position mastering should be performed later.)
The mastering procedure is described below. For details, refer to an
applicable maintenance manual of mechanical unit or operator’s manual
of control unit.

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

SYSTEM Variables JOINT 10%
57/136
57 $MASTER_ENB 1

(1) Press <MENUS>.
(2) Select SYSTEM.
(3) Press F1, TYPE.
(4) Select Master/Cal you will see a screen similar to the following.

SYSTEM Master/Cal JOINT 30%

1 FIXTURE POSITION MASTER

2 ZERO POSITION MASTER
3 QUICK MASTER
4 SINGLE AXIS MASTER
5 SET QUICK MASTER REF
6 CALIBRATE

Master/Cal

TYPE

F1

Press ’ENTER’ or number key to select.

[TYPE] LOAD RES_PCA DONE

(5) Move the robot by jog feed to the mastering position. Release the

brake on the manual brake control screen if necessary.

NOTE

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

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3. TROUBLESHOOTING

MAINTENANCE

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(6) Select “1 FIXTURE POSITION MASTER” and press the F4 key

(yes). Mastering data is set.

SYSTEM Master/Cal

1 FIXTURE POSITION MASTER
2 ZERO POSITION MASTER
Master at master position? [NO]

Master at master position? [NO]
[ TYPE ] YES NO

ENTER

F4

(7) Select “6 CALIBRATE” and press the F4 key (yes). Calibration is

5 SET QUICK MASTER REF
6 CALIBRATE
Calibrate? [NO]

Calibrate? [NO]
[ TYPE ] YES NO

ENTER

F4

SYSTEM Master/Cal JOINT 30 %

1 FIXTURE POSITION MASTER
2 ZERO POSITION MASTER
3 QUICK MASTER
4 SINGLE AXIS MASTER
5 SET QUICK MASTER REF
6 CALIBRATE
Robot Mastered! Mastering Data:
<0> <11808249> <38767856>
<9873638> <122000309> <2000319>

[ TYPE ] LOAD RES_PCA DONE

performed.
Alternatively, to perform positioning, turn the power off, then turn it
on again. Calibration is performed whenever the power is turned on.

SYSTEM Master/Cal JOINT 30 %

1 FIXTURE POSITION MASTER
2 ZERO POSITION MASTER
3 QUICK MASTER
4 SINGLE AXIS MASTER
5 SET QUICK MASTER REF
6 CALIBRATE
Robot Calibrated! Cur Jnt Ang(deg):
<10.000> <–25.000> <40.000>
<5.000> <–15.000> <0.000>
[ TYPE ] LOAD RES_PCA DONE

DONE

F5

(8) Press F5 “DONE”, after mastering.

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3. TROUBLESHOOTINGMAINTENANCE

3.5

TROUBLESHOOTING
USING THE ERROR
CODE

Emergency stop button

(1) SRVO–001 SVAL1 Operator panel E–stop

(Explanation) The EMERGENCY STOP button on the operator

panel is pressed.

(Action 1) Release the emergency stop button pressed on the

operator panel.

(Action 2) Release the EMERGENCY STOP button on the

operator panel.

(Action 3) Replace the emergency stop unit.

Before taking (Action 4), make a backup copy of all
the programs and settings of the control unit.

(Action 4) Replace the robot control board.

Operator
panel

Fig.3.5 (1) (a) SRVO–001 SVAL1 Operator panel E–stop

Robot control board

Emergency stop unit

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3. TROUBLESHOOTING

MAINTENANCE

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(2) SRVO–002 SVAL1 Teach pendant E–stop

(Explanation) The emergency stop button on the operator’s Teach

Pendant was pressed.

(Action 1) Release the emergency stop button on the teach

pendant.

(Action 2) Replace Teach Pendant.

Emergency stop button

Fig.3.5 (2) SRVO–002 SVAL1 Teach pendant E–stop

(3) SRVO–003 SVAL1 Deadman switch released

(Explanation) The teach pendant is enabled, but the deadman switch

is not pressed.

(Action 1) Press the deadman switch to run the robot.
(Action 2) Replace the teach pendant.

Deadman switch

Fig.3.5 (3) SRVO–001 SVAL1 Deadman switch released

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3. TROUBLESHOOTINGMAINTENANCE

(4) SRVO–004 SVAL1 Fence open

(Explanation) In AUTO mode, there is no short circuit between

FENCE11 and FENCE12 and between FENCE21
and FENCE22 on the terminal block TBEB5 of the
emergency stop board.
If the safety fence is connected between FENCE11
and FENCE12 and between FENCE21 and
FENCE22, the door of the safety fence is open.

(Action 1) When the safety fence is connected, close the door.
(Action 2) Check the cables and switches connected to

FENCE11, FENCE12, FENCE21 and FENCE22.

(Action 3) When this signal is not used, short–circuit between

FENCE11 and FENCE12 and between FENCE21
and FENCE22.

NOTE

In the system that uses the fence signal, do not short–circuit
this signal to disable it because the operation is dangerous.
When this signal must be temporarily short–circuited, make
safety provisions separately.

(Action 4) When AUTO mode is not entered even though the

mode switch is set to AUTO, the mode switch may be
faulty. Replace the operator panel.

(Action 5) Replace the emergency stop unit.

Before taking (Action 6), make a backup copy of all
the programs and settings of the control unit.

(Action 6) Replace the robot control board.

Short connection boards:
two positions (terminal blocks
located on the right when
viewing from the front)

Emergency stop unit

Fig.3.5 (4) SRVO–004 SVAL1 Fence open

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(5) SRVO–005 SVAL1 Robot overtravel

(Explanation) This alarm should not occur because no overtravel

input signal is provided. However, this alarm can be
caused by an abnormal overtravel input signal across
the robot interconnection cable and robot control
board.

(Action 1) Check the robot interconnection cable (RMP) for the

following.

1) The male and female connection pins are not
twisted or are not loose.

2) The connector is securely connected.

3) The cable is free from a break and ground fault.

Next, check that the connector CRM82 of the robot
control board is securely connected. In addition,
check that the RMP cable is sound and free from a
break or visible twist.
Before taking (Action 2), make a backup copy of all
the programs and settings of the control unit.

(Action 2) Replace the robot control board.

Robot control board

Fig.3.5 (5) SRVO–005 SVAL1 Robot overtravel

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3. TROUBLESHOOTINGMAINTENANCE

(6) SRVO–006 SVAL1 Hand broken

(Explanation) The safety joint, if any, is broken. If no joint is

broken, the HBK signal line of the robot
interconnection cable has a break or ground fault.

(Action 1) Holding down the shift key, press the alarm release

button. This releases the alarm. Keeping on holding
down the shift key, carry out jog feed to move the tool
to the work area.

1) Replace the safety joint.

2) Examine the cable.

(Action 2) Check the robot interconnection cable (RMP) for the

following.

1) The male and female connection pins are not
twisted or are not loose.

2) The connector is securely connected.

3) The cable is free from a break and ground fault.

Next, check that the connector CRM82 of the robot
control board is securely connected. In addition,
check that the RMP cable is sound and free from a
break or visible twist.
Before taking (Action 3), make a backup copy of all
the programs and settings of the control unit.

(Action 3) Replace the robot control board.

Robot control board

Fig.3.5 (6) SRVO–006 SVAL1 Hand broken

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MAINTENANCE

B–81535EN/02

(7) SRVO–007 SVAL1 External E–stop

(Explanation) EMGIN11 and EMGIN12/EMGIN21 and EMGIN22

on the terminal block TB EB5 of the emergency stop
board are not short–circuited. If an external e mer ge nc y
stop switch is connected across EMGIN11 and
EMGIN12/EMGIN21 and EMGIN22, the switch has
been pres sed .

(Action 1) If an external emergency stop switch is connected,

releases the switch.

(Action 2) Check the switch and cable connected to EMGIN11

and EMGIN12 and to EMGIN21 and EMGIN22.

(Action 3) When this signal is not used, make a connection

between EMGIN11 and EMGIN12 and a connection
between EMGIN21 and EMGIN22. (WARNING)

(Action 4) Replace the emergency stop unit.

WARNING

Do NOT short–circuit, or disable, this signal in a system in
which the External emergency stop input signal is in use, as
it is very dangerous. If it is necessary to run the robot by
short–circuiting the signal even temporarily, an additional
safety provision must be provided.

Emergency stop unit

Short connection boards:
two positions (terminal blocks
located on the left when
viewing from the front)

Fig.3.5 (7) SRVO–007 SVAL1 External E–stop

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(8) SRVO–009 SVAL1 Pneumatic pressure alarm

(Explanation) An abnormal air pressure was detected. The input

signal is located on the end effector of the robot.
Refer to the manual of your robot.

(Action 1) If an a bnorma l a ir p r essur e i s d e tec ted , c hec k t he cause.

If the peripheral device are normal, check the robot
connection cable.
Before taking (Action 2), make a backup copy of all
the programs and settings of the control unit.

(Action 2) Replace the robot control board.

Robot control board

Fig.3.5 (8) SRVO–009 SVAL1 Pneumatic pressure alarm

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(9) SRVO–014 WARN Fan motor abnormal

(Explanation) A fan motor in the backplane unit is abnormal.
(Action) Check the fan motor and its cables. Replace them if

necessary.

Fan motor

Fig.3.5 (9) SRVO–014 WARN Fan motor abnormal

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(10)SRVO–015 SVAL1 SYSTEM OVER HEAT (Group : i Axis : j)

(Explanation) The temperature in the control unit exceeds the

specified value.

(Action 1) If the ambient temperature is higher than specified

(45°C), cool down ambient temperature.

(Action 2) If the fan motor is not running, check it and its cables.

Replace them if necessary.

(Action 3) If the thermostat on the robot control board is

defective, replace the robot control board.

Fan motor
(on the heat exchange)

Fan motor (door face) Robot control board

Fig.3.5 (10) SRVO–015 SVAL1 SYSTEM OVER HEAT

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(11)SRVO–021 SVAL1 SRDY off (Group : i Axis : j)

(Explanation) The HRDY is on and the SRDY is off, although there

is no other cause of an alarm. (HRDY is a signal with
which the host detects the servo system whether to
turn on or off the servo amplifier magnetic contactor.
SRDY is a signal with which the servo system
informs the host whether the magnetic contactor is
turned on.)
If the servo amplifier magnetic contactor cannot be
turned on when directed so, it is most likely that a
servo amplifier alarm has occurred. If a servo
amplifier alarm has been detected, the host will not
issue this alarm (SRDY off). Therefore, this alarm
indicates that the magnetic contactor cannot be turned
on for an unknown reason.

(Action 1) Measure the voltage of the 200–VAC input to the

power supply module. If the voltage is 170 VAC or
lower, adjust the input voltage.

(Action 2) Check that CRR78 of the emergency stop board and

CX3 and CX4 of the power supply module are
securely connected. Check the cables of the
emergency stop board and power supply module for
a break.

(Action 3) Check the EMERGENCY STOP line (teach pendant

emergency stop, teach pendant enable/disable switch,
teach pendant deadman switch, operator panel
emergency stop, external emergency stop input, fence
input) for a possibility of an instantaneous
interruption. If the software cannot judge the cause
of the alarm at an instantaneous interruption of the
EMERGENCY STOP line, this alarm occurs.

(Action 4) Replace the emergency stop unit.
(Action 5) If an alarm occurs on all axes, the power supply

module may be faulty. Replace the power supply
module.

(Action 6) If an alarm occurs on a particular axis, the servo

amplifier module may be faulty. Replace the servo
amplifier module controlling the axis.

(Action 7) Replace the axis control card on the robot control

board.

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Emergency stop unit

Power supply module

Axis control card

Robot control board

Servo amplifier module

Fig.3.5 (11) SRVO–021 SVAL1 SRDY off

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(12)SRVO–022 SVAL1 SRDY on (Group : i Axis : j)

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

on. (HR DY is a signal with which the host di rects the
servo system whether to turn on or off the servo
amplifier magnetic contactor. SRDY is a signal with
which the servo system informs the host whether the
magnetic contactor is turned on.

(Action 1) Replace the axis control card on the robot control

board.

(Action 2) If an alarm occurs on all axes, the power supply

module may be faulty. Replace the power supply
module.

(Action 3) If an alarm occurs on a particular axis, the servo

amplifier module may be faulty. Replace the servo
amplifier module controlling the axis.

Robot control board

Servo amplifier module

Power supply module

Axis control card

Fig.3.5 (12) SRVO–022 SVAL1 SRDY on

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(13)SRVO–023 SVAL1 Stop error excess (Group : i Axis : j)

(Explanation) When the servo is at stop, the position error is

abnormally large.

(Action 1) Check whether the motor brake has been released.
(Action 2) Make sure that the servo amplifier CZ2L to N are

connected tightly.

(Action 3) Check to see if the load is greater than the rating. If

greater, reduce it to within the rating. (If the load is
too greater, the torque required for acceleration /
deceleration becomes h igher than the capaci ty of the
motor. As a result, the motor becomes unable to
follow the command, and an alarm is issued.)

(Action 4) Check each phase voltage of the CZ1 connector of the

three–phase power (200 VAC) input to the servo
amplifier. If it is 170 VAC or lower, check the line
voltage. (If the voltage input to the servo amplifier
becomes low, the torque output also becomes low. As
a result the motor may become unable to follow the
command, hence possibly an alarm.)

(Action 5) If the line voltage is 170 VAC or higher, replace the

power supply module or servo amplifier module.

(Action 6) Check disconnection of robot connection cable

(RMP).

(Action 7) Replace the motor.

Servo amplifier module

Power supply module

Fig.3.5 (13) SRVO–023 SVAL1 Stop error excess

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(14)SRVO–024 SVAL1 Move error excess (Group : i Axis : j)

(Explanation) When the robot is running, its position error is greater

than a specified value ($PARAM _ GROUP.
$MOVER _ OFFST or $PARAM _ GROUP.
$TRKERRLIM). It is likely that the robot cannot
follow the speed specified by program.

(Action 1) Check the robot for binding axis.
(Action 2) Take the same actions as described for the above

alarm.

(15)SRVO–025 SVAL1 Motn dt overflow (Group : i Axis : j)

(Explanation) The specified value is too great.

(16)SRVO–026 WARN2 Motor speed limit (Group : i Axis : j)

(Explanation) A value higher than the maximum motor speed

($PARAM_GROUP.$MOT_SPD_LIM) was
specified. The actual motor speed is clamped to the
maximum speed.

(17)SRVO–027 WARN Robot not mastered (Group : i)

(Explanation) An attempt was made to calibrate the robot, but the

necessary adjustment had not been completed.

(Action) Master the robot.

(18)SRVO–030 SVAL1 Brake on hold (Group : i)

(Explanation) This alarm occurs when the robot pauses, if the brake

on hold function has been enabled ($SCR.
$BRKHOLD _ ENB = 1). Di sable the function if it is
not necessary.

(Action) Disable [Servo–off during pause] on the general

setting menu (Select Setting general).

(19)SRVO–031 SVAL1 User servo alarm (Group : i)

(Explanation) An user servo alarm occurred.

(20)SRVO–033 WARN Robot not calibrated (Group : i)

(Explanation) An attempt was made to set up a reference point for

simplified adjustment, but the robot had not been
calibrated.

(Action) Calibrate the robot.

1.Supply power.

2.Set up a simplified adjustment reference point

using [Positioning] on the positioning menu.

(21)SRVO–034 WARN Ref pos not set (Group : i)

(Explanation) An a ttempt w as m ade t o perform simplifie d adjustment,

but the reference point had not been set up.

(Action) Set up a simplified adjustment reference point on the

positioning menu.

(22)SRVO–035 WARN2 Joint speed limit (Group : i Axis : j)

(Explanation) A value higher than the maximum axis speed

($PARAM_GROUP.$JNTVELLIM) was specified.
Each actual axis speed is clamped to the maximum
speed.

(23)SRVO–036 SVAL1 Inpos time over (Group : i Axis : 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 SR VO–23 (lar ge position

error at a stop).

(24)SRVO–037 SVAL1 Imstp input (Group : i)

(Explanation) The *IMSTP signal for a peripheral device interface

was input.

(Action) Turn on the *IMSTP signal.

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(25)SRVO–038 SVAL2 Pulse mismatch (Group : i Axis : j)

(Explanation) The pulse count obtained when power is turned off

does not match the pulse count obtained when power
is applied. This alarm is asserted after exchange the
pulsecoder or battery for back up of the pulsecoder
data or loading back up data to the Robot control
board.

(Action) Perform Absolute Pulse Coder reset and remaster

robot (RES–PCA)

1. Press MENUS.

2. Select SYSTEM.

3. Press F1 [TYPE].

4. Select MASTER/CAL.

5. Press F3, PES–PCA and YES.

6. Execute mastering.

7. Press RESET.
The fault condition should reset. If the controller
is still faulted with additional servo–related errors,
cold start the controller.
It might be necessary to remaster the robot.

(26)SRVO–041 SVAL2 MOFAL alarm (Group : i Axis : j)

(Explanation) The servo value was too high.
(Action) Cold start the controller.

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(27)SRVO–044 SVAL1 HVAL alarm (Group : i Axis : j)

(Explanation) The DC voltage (DC link voltage) of the main circuit

power supply is abnormally high.
The LED indication on the power supply module is
“7” (HVAL).

(Action 1) Check the three–phase input voltage at the power

supply module. If it is 253 VAC or higher, check the
line voltage. (If the three–phase input voltage is
higher than 253 VAC, high acceleration/deceleration
can result in this alarm.)

(Action 2) Check that the load weight is within the rating. If it

is higher than the rating, reduce it to within the rating.
(If the machine load is higher than the rating, the
accumulation of regenerative energy might result in
the HVAL alarm even when the three–phase input
voltage is within the rating.

(Action 3) Replace the power supply module.

Power supply module

Fig.3.5 (27) SRVO–044 SVAL1 HVAL alarm

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(28)SRVO–045 SVAL1 HCAL alarm (Group : i Axis : j)

(Explanation) Abnormally high current flowed in the main circuit of

the servo amplifier module.
The LED indications on the servo amplifier modules
are “b”, “C”, and “d”.

(Action 1) Disconnect the Robot connection cable (Motor power)

from the connector CZ2 of the servo amplifier
module. If error occurs, replace the servo amplifier.

(Action 2) Disconnect the Robot connection cable (Motor power)

from the servo amplifier module connector (CZ2),
and check the insulation of each Robot connection
cable (Motor power) (U, V, or W) and the GND line.
If there is a short–circuit, the motor, robot
interconnection cable, or intra–robot cable is
defective. Check t hem and repl ace them i f necessary.

(Action 3) Disconnect the Robot connection cable (Motor power)

from the servo amplifier module connector (CZ2),
and measure the resistance between the U and V, V
and W , and W and U with a ohmmeter with a very low
resistance range. If the resistances at these three
places are different from each other, the motor, robot
interconnection cable, or intra–robot cable is
defective. Check each item in detail.
Before taking (Action 4), make a backup copy of all
the programs and settings of the control unit.

(Action 4) Replace the robot control board.

Robot control board

Servo amplifier module

Fig.3.5 (28) SRVO–045 SVAL1 HCAL alarm

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(29)SRVO–046 SVAL2 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 conditions for the robot and relax

the service conditions.

(Action 2) Check each phase voltage of the three–phase input

power (200 VAC for the power supply module. If it
is 170 VAC or lower, check the line voltage.

(Action 3) Replace the power supply module and servo

amplifier module.

(Action 4) Check the robot connection cable (RMP).
(Action 5) Replace the motor.

Servo amplifier module

Power supply module

Fig.3.5 (29) SRVO–046 SVAL2 OVC alarm

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Reference

Relationships among the OVC, OVL, and HC alarms

Overview

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

Alarm detection section

Abbreviation Designation Detection section

OVC

OVL

HC

Overcurrent alarm Servo software
Overload alarm Thermal relay in the motor OHAL2

Thermal relay in the servo amplifier OHAL1
Thermal relay in the separate regenerative dis­charge unit DCAL

High current alarm Servo amplifier

Purpose of each alarm

1) HC alarm (high current alarm)
If high current flow in a power transistor momentarily due to

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

2) OVC and OVL alarms (overcurrent and overload alarms)
The OVC and OVL alarms are intended to prevent overheat that may

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

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

Temperature

Start StartStartStop Stop

Thermal time constant

Temperature at
which the winding
starts to burn

Fig.1 Relationship between the temperatures of the motor and thermal relay on start/stop cycles

of the motor is high.

Thermal time constant
of the thermal relay is
low.

Time

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.

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To sum up, a double protection method is used; the OVC alarm is used
for protection from a short–time overcurrent, and the OVL alarm is
used for protection from long–term overload. The relationship
between the OVC and OVL alarms is shown in Fig 2.

Limit current

Rated continuous current

Current

Protection area for
the motor and
servo amplifier

Protection by the OVL

Protection b y
the OVC

Fig.2 Relationship between the OVC and OVL alarms

NOTE

The relationship shown in Fig. 2 is taken into consideration
for the OVC alarm. The motor might not be hot even if the
OVC alarm has occurred. In this case, do not change the
parameters to relax protection.

Time

(30)SRVO–047 SVAL1 LVAL alarm (Group : i Axis : j)

(Explanation) The control power voltage (+5 V, etc.) on the servo

amplifier module is too low. The LED indication on
the servo amplifier module is “2” (LVAL).

(Action 1) Replace the servo amplifier module.

Servo amplifier module

Fig.3.5 (30) SRVO–047 SVAL1 LVAL alarm

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(31)SRVO–049 SVAL1 OHAL1 alarm (Group : i Axis : j)

(Explanation) This alarm does not occur when the power supply

module and serve amplifier modules used with the
R–J3iB Mate are under normal conditions.
This alarm indicates that any of the power supply
module and servo amplifier modules is faulty.

(Action 1) If this alarm occurs in relation to all axes, replace the

power supply module.

(Action 2) If this alarm occurs in relation to a specific axis,

replace the servo amplifier module that controls the
axis.

Servo amplifier module

Power supply module

Fig.3.5 (31) SRVO–049 SVAL1 OHAL1 alarm

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(32)SRVO–050 SVAL1 CLALM alarm (Group : i Axis : j)

(Explanation) The disturbance torque estimated by the servo software

is abnormally high. (A collision has been detected.)

(Action 1) Check that the robot has collided with anything. If it

has, reset the robot and jog–feed it to recover from the
collision.

(Action 2) Make sure that the load setting is correct.
(Action 3) Check that the load weight is within the rating. If it

is higher than the rating, reduce it to within the rating.
(If the robot is used out of its usable range, the
estimated disturbance torque becomes abnormally
high, possibly resulting in this alarm being detected.)

(Action 4) Check the phase voltage of the three–phase input

power (200 VAC) to the power supply module. If it
is 170 VAC or lower, check the line voltage.

(Action 5) Replace the power supply module and the servo

amplifier module.

Servo amplifier module

Power supply module

Fig.3.5 (32) SRVO–050 SVAL1 CLALM alarm

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(33)SRVO–051 SVAL2 CUER alarm (Group : i Axis : j)

(Explanation) The offset of the current feedback value is abnormally

high.

(Action) Replace the servo amplifier module.

Servo amplifier module

Fig.3.5 (33) SRVO–051 SVAL2 CUER alarm

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(34)SRVO–054 DSM Memory Error

(Explanation) An access to the axis control card on the robot control

board memory fails.

(Action) Replace the axis control card.

Robot control board

Servo amplifier module

Axis control card

Fig.3.5 (34) SRVO–054 DSM Memory Error

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(35)SRVO–055 SVAL2 FSSB com error 1 (Group : i Axis : j)

(Explanation) A communication error has occurred between the

robot control board and servo amplifier.

(Action 1) Check the communication cable (optical fiber)

between the robot control board and servo amplifier.
Replace it if it is faulty.

(Action 2) Replace the axis control card on the robot control

board.

(Action 3) Replace the servo amplifier module.

Before continuing to the next step, perform a
complete controller back–up to save all your
programs and settings. Failure to perform this could
result in damage to equipment or lost data.

(Action 4) Replace the robot control board.

Robot control board

Servo amplifier module

Axis control card

Fig.3.5 (35) SRVO–055 SVAL2 FSSB com error 1

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(36)SRVO–056 SVAL2 FSSB com error 2 (Group : i Axis : j)

(Explanation) A communication error has occurred between the

robot control board and servo amplifier.

(Action 1) Check the communication cable (optical fiber)

between the robot control board and servo amplifier.
Replace it if it is faulty.

(Action 2) Replace the axis control card on the robot control

board.

(Action 3) Replace the servo amplifier module.

Before continuing to the next step, perform a
complete controller back–up to save all your
programs and settings. Failure to perform this could
result in damage to equipment or lost data.

(Action 4) Replace the robot control board.

Robot control board

Servo amplifier module

Axis control card

Fig.3.5 (36) SRVO–056 SVAL2 FSSB com error 2

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(37)SRVO–057 SVAL2 FSSB disconnect (Group : i Axis : j)

(Explanation) Communication was interrupted between the robot

control board and servo amplifier.

(Action 1) Check whether fuse FU1 in the power supply module

unit has blown.

(Action 2) Check whether fuse FU1 in the servo amplifier

module has blown.

(Action 3) Check the communication cable (optical fiber)

between the robot control board and servo amplifier.
Replace it if it is faulty.

(Action 4) Replace the axis control card on the robot control

board.

(Action 5) Replace the power supply module and the servo

amplifier module.
Before continuing to the next step, perform a
complete controller back–up to save all your
programs and settings. Failure to perform this could
result in damage to equipment or lost data.

(Action 6) Replace the robot control board.
(Action 7) Check the RMP cable of robot connection cable.

(+5V ground fault)

Robot control board

Servo amplifier module

Power supply module

Axis control card

Fig.3.5 (37) SRVO–057 SVAL2 FSSB disconnect

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(38)SRVO–058 SVAL2 FSSB init error (Group : i Axis : j)

(Explanation) Communication was interrupted between the robot

control board and servo amplifier module.

(Action 1) Check whether fuse FU1 in the power supply module

have blown.
If they have blown, see Section 3.6, “Troubleshooting
for Blown Fuse.”

(Action 2) Check whether seven segment LEDs on the servo

amplifier module are on.
If they are on, perform “Action 4” and all actions that
follow it. If they are not on, perform “Action 3” and
all actions that follow it.

(Action 3) Check whether connector CX1 on the power supply

module is securely connected.

(Action 4) Check the communication cable (optical fiber)

between the robot control board and servo amplifier
module. Replace it if it is faulty.

(Action 5) Replace the axis control card on the robot control

board.

(Action 6) If the seven–segment LED on the servo amplifier

module is glowing, replace the servo amplifier
module. If the seven–segment LED on the servo
amplifier module is not glowing, replace the power
supply module.
Before continuing to the next step, perform a
complete controller back–up to save all your
programs and settings. Failure to perform this could
result in damage to equipment or lost data.

(Action 7) Replace the robot control board.

Robot controll board

Servo amplifier module

Power supply module

Axis control card

Fig.3.5 (38) SRVO–058 SVAL2 FSSB init error

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(39)SRVO–059 SVAL2 Servo amp init error

(Explanation) Servo amplifier initialzation is failed.
(Action 1) Check all connectors on the PSM and SVM. Make

sure they are installed correctly.

(Action 2) Replace the power supply module and the servo

amplifier module.

Servo amplifier module

Power supply module

Fig.3.5 (39) SRVO–059 SVAL2 Servo amp init error

(40)SRVO–061 SVAL2 CKAL alarm (Group : i Axis : j)

(Explanation) This alarm occurs if the rotation speed count in the

pulse coder is abnormal (abnormal count clock).

(Action) Replace the pulse coder.

NOTE

In this case, perform actions associated with DTERR,
CRCERR, or STBERR first.

(41)SRVO–062 SVAL2 BZAL alarm (Group : i Axis : j)

(Explanation) This alarm occurs if battery for pulse coder

absolute-position backup is empty.
A probable cause is a broken battery cable or no
batteries in the robot.

(Action) Remove the cause of the alarm, set the system

variable ($MCR.$SPC RESET) to TRUE, then turn
the power off and on again. Mastering is required.

(42)SRVO–063 SVAL2 RCAL alarm (Group : i Axis : j)

(Explanation) This alarm occurs if the rotation speed count in the

pulse coder is abnormal (abnormal counter).

(Action) Replace the pulse coder.

NOTE

In this case, perform actions associated with DTERR,
CRCERR, or STBERR first.

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(43)SRVO–064 SVAL2 PHAL alarm (Group : i Axis : j)

(Explanation) This alarm occurs if the phase of the pulses generated

in the pulse coder is abnormal.

(Action) Replace the pulse coder.

NOTE

This alarm might accompany the DTERR, CRCERR, or
STBERR alarm. In this case, however, there is no actual
condition for this alarm.

(44)SRVO–065 WARN BLAL alarm (Group : i Axis : j)

(Explanation) The battery voltage for the pulse coder is lower than

the rating.

(Action) Replace the battery.

(If this alarm occurs, turn on the AC power and
replace the battery as soon as possible. A delay in
battery replacement may result in the BZAL alarm
being detected. In this case, the position data will be
lost. Once the position data is lost, mastering will
become necessary.

(45)SRVO–066 SVAL2 CSAL alarm (Group : i Axis : j)

(Explanation) The ROM in the pulse coder is abnormal.
(Action) Replace the pulse coder.

NOTE

This alarm might accompany the DTERR, CRCERR, or
STBERR alarm. In this case, however, there is no actual
condition for this alarm.

(46)SRVO–067 SVAL2 OHAL2 alarm (Group : i Axis : j)

(Explanation) The temperature inside the pulse coder or motor is

abnormally high, and the built–in thermostat has
operated.

(Action 1) Check the operating conditions for the robot and relax

the service conditions.

(Action 2) When power is supplied to the motor after it has

become sufficiently cool, if the alarm still occurs,
replace the motor.

(47)SRVO–068 SVAL2 DTERR alarm (Group : i Axis : j)

(Explanation) The serial pulse coder does not return serial data in

response to a request signal.
–See actions on SRVO–070

(48)SRVO–069 SVAL2 CRCERR alarm (Group : i Axis : j)

(Explanation) The serial data has disturbed during communication.

–See actions on SRVO–070

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(49)SRVO–070 SVAL2 STBERR alarm (Group : i Axis : j)

(Explanation) The start and stop bits of the serial data are abnormal.
(Action 1) Make sure that the JF1 to JF3 connector of servo

amplifire module is connected tightly.

(Action 2) Check that the shielding of the robot interconnection

cable (for the pulse coder) and the peripheral equipment
cable is connected securely to the grounding plate.

(Action 3) Check that each unit is grounded securely.
(Action 4) Replace the servo amplifier module.
(Action 5) Replace the pulse coder.
(Action 6) Replace the robot interconnection cable (RMP).

Servo amplifier module

Fig.3.5 (49) SRVO–070 SVAL2 STBERR alarm

(50)SRVO–071 SVAL2 SPHAL alarm (Group : i Axis : j)

(Explanation) The feedback speed is abnormally high.
(Action 1) If this alarm occurs together with the PHAL alarm

(No. 064), this alarm does not correspond to the major
cause of the failure.

(Action 2) Replace the pulse coder.

(51)SRVO–072 SVAL2 PMAL alarm (Group : i Axis : j)

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

(52)SRVO–073 SVAL2 CMAL alarm (Group : i Axis : j)

(Explanation) It is likely that the pulse coder is abnormal or the pulse

coder has malfunctioned due to noise.

(Action) Master the robot and enhance the shielding.

(53)SRVO–074 SVAL2 LDAL alarm (Group : i Axis : j)

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

(54)SRVO–075 WARN Pulse not established (Group : i Axis : j)

(Explanation) The absolute position of the pulse coder 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. (Jog one motor revolution)

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(55)SRVO–076 SVAL1 Tip Stick Detection (Group : i Axis : 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 comes into collision with

foreign matter . If a collision occurs, reset the system,
then switch it to the jog feed mode to avoid the
collision.

(Action 2) Check whether the load settings are valid.
(Action 3) Check whether the load weight is within the rated

range. If the weight exceeds the upper limit, decrease
it to the limit.
(Use of the robot with a load exceeding the limit
applied may abnormally increase the assumed
disturbance, resulting in this alarm.)

(Action 4) Check each inter–phase voltage of the three–phase

input (200 VAC) to the power supply module. If the
voltage is 170 VAC or lower, check the input power
supply voltage.

(Action 5) Replace the power supply module and the servo

amplifier module.

Servo amplifier module

Power supply module

Fig.3.5 (60) SRVO–076 SVAL1 Tip Stick Detection

(56)SRVO–081 WARN EROFL alarm (Track enc : i)

(Explanation) The pulse counter for line tracking has overflowed.

(57)SRVO–082 WARN DAL alarm (Track ebc : i)

(Explanation) The line tracking pulse coder has not been connected.
(Action 1) Check the pulse coder connection cable, and replace

it if necessary.

(Action 2) Replace the pulse coder.

(58)SRVO–083 WARN CKAL alarm (Track ebc : i)

(Explanation) This alarm occurs if the rotation speed count in the

pulse coder is abnormal (abnormal count clock).

(Action) See the description about the SRVO–061 CKAL

alarm.

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(59)SRVO–084 WARN BZAL alarm (Track enc : i)

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

position of the pulse coder has not been connected. See
the description about the BZAL alarm (SRVO–062).

(60)SRVO–085 WARN RCAL alarm (Track ebc : i)

(Explanation) This alarm occurs if the rotation speed count in the

pulse coder is abnormal (abnormal counter).

(Action) See the description about the SRVO–063 RCAL

alarm.

(61)SRVO–086 WARN PHAL alarm (Track enc : i)

(Explanation) This alarm occurs if the phase of pulses generated in

the pulse coder is abnormal. See the description
about the PHAL alarm (SRVO–064).

(62)SRVO–087 WARN BLAL alarm (Track enc : i)

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

for the absolute position of the pulse coder is low. S e e
the description about the BLAL alarm (SRVO–065).

(63)SRVO–088 WARN CSAL alarm (Track ebc : i)

(Explanation) The ROM in the pulse coder is abnormal.
(Action) See the description about the SRVO–066 CSAL

alarm.

(64)SRVO–089 WARN OHAL2 alarm (Track enc : i)

(Explanation) The motor has overheated. See the description about

the OHAL2 alarm (SRVO–067).

(65)SRVO–090 WARN DTERR alarm (Track enc : i)

(Explanation) Communication between the pulse coder and line

tracking interface board is abnormal. See the
description about the DTERR alarm (SRVO–068).

(66)SRVO–091 WARN CRCERR alarm (Track enc : i)

(Explanation) Communication between the pulse coder and line

tracking interface board is abnormal. See the
description about the CRCERR alarm (SRVO–069).

(67)SRVO–092 WARN STBERR alarm (Track enc : i)

(Explanation) Communication between the pulse coder and line

tracking interface board is abnormal. See the
description about the STBERR alarm (SRVO–070).

(68)SRVO–093 WARN SPMAL alarm (Track enc : i)

(Explanation) This alarm occurs if the current position data from the

pulse coder is higher than the previous position data.
See the description about the SPHAL alarm
(SRVO–071).

(69)SRVO–094 WARN PMAL alarm (Track enc : i)

(Explanation) It is likely that the pulse coder is abnormal. See the

description about the PMAL alarm (SRVO–072).

(70)SRVO–095 WARN CMAL alarm (Track enc : i)

(Explanation) It is likely that the pulse coder is abnormal or the pulse

coder has malfunctioned due to noise. See the
description about the CMAL alarm (SRVO–073).

(71)SRVO–096 WARN LDAL alarm (Track enc : i)

(Explanation) The LED in the pulse coder is broken. See the

description about the LDAL alarm (SRVO–074).

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(72)SRVO–097 WARN Pulse not established (enc : i)

(Explanation) The absolute position of the pulse coder cannot be

established. See the description about (SRVO–075).
Pulse not established.

(73)SRVO–131 SVAL1 LVAL (PSM) alarm (Group : i Axis : j)

(Explanation) The control power supply voltage (for example, +5

V) on the power supply module is abnormally low.
The LED indication on the power supply module is
“6” (LVAL).

(Action 1) Replace the power supply module.

Power supply module

Fig.3.5 (73) SRVO–131 SVAL1 LVAL(PSM) alarm

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(74)SRVO–134 SVAL1 DCLVAL (PSM) alarm (Group : i Axis : j)

(Explanation) The DC voltage (DC link voltage) of the main circuit

power supply on the power supply module is
abnormally low. The LED indication on the power
supply module is “4.”

–If this alarm occurs during robot operation:
(Action 1) Check the phase voltage of the three–phase input (200

VAC) to the power supply module. If it is 170 VAC
or lower, check the input power supply voltage.

(Action 2) Replace the power supply module.
–If this alarm occurs before the magnetic contactor (MCC) is turned

on:
(Action 1) Check the emergency stop board and the wiring

between the power supply module and magnetic
contactor (MCC) for an abnormal condition.

(Action 2) Replace the magnetic contactor (MCC).
(Action 3) Replace the emergency stop unit.
(Action 4) Replace the power supply module.

Magnetic contactor

Emergency stop unit

Fig.3.5 (74) SRVO–134 SVAL1 DCLVAL (PSM) alarm

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Servo amplifier module

Power supply module