• Original Instructions

Thank you very much for purchasing FANUC Robot.

Before using the Robot, be sure to read the "FANUC Robot series SAFETY HANDBOOK
(B-80687EN)" and understand the content.

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

• All specifications and designs are subject to change without notice.

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

In this manual, we endeavor to include all pertinent matters. There are, however, a very
large number of operations that must not or cannot be performed, and if the manual
contained them all, it would be enormous in volume. It is, therefore, requested to assume
that any operations that are not explicitly described as being possible are "not possible".
B–80945EN/02 PREFACE

PREFACE

This manual describes the following models (R–J3 controller).

Model Abbreviation
FANUC Robot S–430iF S–430iF
FANUC Robot S–430iW, iW/200 S–430iW
FANUC Robot S–430iR/130, iR/165, S–430iR
iR/Press HT/Press HS S–430i
FANUC Robot S–430iL/80, iL/125 S–430iL
FANUC Robot S–430iU S–430iU
FANUC Robot S–430iCF, iCI S–430iC
FANUC Robot S–500i S–500i
FANUC Robot S–900iW, iH, iL S–900i
FANUC Robot M–6i, 6iT M–6i
FANUC Robot M–16i/ iL, 16iT/ iLT M–16i
FANUC Robot M–410iHS, iHW, iWW M–410i
FANUC Robot M–500i M–500i
FANUC Robot M–710i, iW, iT M–710i
FANUC Robot ARC Mate 50i ARC Mate 50i
FANUC Robot ARC Mate 100i/ iT ARC Mate 100i
FANUC Robot ARC Mate 120i/ iL/ iT/ iLT ARC Mate 120i
FANUC Robot LR Mate 200i/ iL LR Mate 200i
FANUC Robot SR Mate 200i SR Mate 200i
FANUC Robot A–520i A–520i
FANUC Robot F–200i F–200i

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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 Teach 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

2. CONFIGURATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.1 EXTERNAL VIEW OF THE CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.2 COMPONENT FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
2.3 PREVENTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

3. TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.1 POWER CANNOT BE TURNED ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3.2 ALARM OCCURRENCE SCREEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.3 SAFETY SIGNALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3.4 MASTERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
3.5 TROUBLESHOOTING USING THE ERROR CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
3.6 TROUBLESHOOTING BASED ON FUSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
3.7 TROUBLESHOOTING BASED ON LED INDICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
3.8 POSITION DEVIATION FOUND IN RETURN TO THE REFERENCE POSITION
(POSITIONING) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
3.9 VIBRATION OBSERVED DURING MOVEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
3.10 MANUAL OPERATION IMPOSSIBLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

4. PRINTED CIRCUIT BOARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

4.1 MAIN BOARD (A16B–3200–0330, –0331) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
4.2 EMERGENCY STOP CONTROL PC BOARD (A20B–1007–0440) . . . . . . . . . . . . . . . . . . . . . . . . 104
4.3 BACKPLANE PC BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

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4.4 PANEL BOARD (A20B–2100–0420, 0421, 0423) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

4.5 PROCESS I/O BOARD EA (A16B–3200–0230) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
4.6 PROCESS I/O BOARD EB (A16B–3200–0231) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
4.7 PROCESS I/O BOARD FA (A16B–2203–0420) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
4.8 PROCESS I/O BOARD CA (A16B–2201–0470) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
4.9 PROCESS I/O BOARD CB (A16B–2201–0472) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
4.10 PROCESS I/O BOARD DA (A16B–2201–0480) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
4.11 PROCESS I/O BOARD GA (A16B–2203–0520) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
4.12 PANEL SWITCH BOARD (A20B–9002–0310) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

5. SERVO AMPLIFIERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

5.1 LED OF SERVO AMPLIFIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
5.2 SETTING OF SERVO AMPLIFIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

6. SETTING AND ADJUSTING THE POWER SUPPLY . . . . . . . . . . . . . . . . . . . . . . . . 129

6.1 BLOCK DIAGRAM OF THE MAIN POWER INCLUDING POWER SUPPLY . . . . . . . . . . . . . . 130
6.2 SELECTING TRANSFORMER TAPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
6.3 CHECKING THE POWER SUPPLY UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

7. REPLACING A UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

7.1 A–CABINET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
7.1.1 Replacing the A–Cabinet Top Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
7.1.2 Replacing the A–Cabinet Rear Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
7.1.3 Replacing the A–Cabinet Louver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
7.1.4 Replacing the A–Cabinet Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
7.2 REPLACING THE PRINTED–CIRCUIT BOARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
7.2.1 Replacing the Backplane Board (Unit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
7.2.2 Replacing the Power Unit and Printed–Circuit Boards on the Backplane Unit . . . . . . . . . . . . . . . . . . . 141
7.2.3 Replacing Process I/O Boards EA, EB, FA, and GA (A–Cabinet) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
7.2.4 Replacing the Panel Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
7.3 REPLACING CARDS AND MODULES ON THE MAIN BOARD . . . . . . . . . . . . . . . . . . . . . . . . 144
7.4 REPLACING THE TRANSFORMER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
7.5 REPLACING THE REGENERATIVE RESISTANCE UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
7.6 REPLACING THE EMERGENCY STOP UNIT (A–CABINET) . . . . . . . . . . . . . . . . . . . . . . . . . . 157
7.7 REPLACING THE MAGNETIC CONTACTOR (MCC) (A–CABINET) . . . . . . . . . . . . . . . . . . . . 158
7.8 REPLACING SERVO AMPLIFIERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
7.9 REPLACING THE MODEL A I/O UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
7.9.1 Replacing the Base Unit of the Model A I/O Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
7.9.2 Replacing a Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
7.10 REPLACING THE MODEL B I/O UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
7.11 REPLACING THE TEACH PENDANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
7.12 REPLACING THE CONTROL SECTION FAN MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
7.13 REPLACING THE AC FAN MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
7.13.1 Replacing the Heat Exchanger and Door Fan Unit (A–Cabinet) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
7.13.2 Replacing the Rear Fan Unit (A–Cabinet) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
7.13.3 Replacing Top Fan Unit and Door Fan Unit (B–Cabinet) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
7.13.4 Replacing Side Panel Fan Unit (B–Cabinet) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171

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7.14 REPLACING THE OPERATOR PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173

7.15 REPLACING THE PANEL SWITCH BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
7.16 REPLACING THE MCC UNIT (B–CABINET) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
7.17 REPLACING FUSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
7.17.1 Replacing Fuses in the Servo Amplifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
7.17.2 Replacing Fuses in the Power Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
7.17.3 Replacing the Fuse on the Process I/O Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
7.17.4 MCC unit fuse replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
7.18 REPLACING RELAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
7.18.1 Replacing Emergency Stop Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
7.19 BATTERY REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
7.19.1 Battery for Memory Backup (3 VDC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183

III CONNECTIONS
1. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187

2. BLOCK DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188

3. ELECTRICAL CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190

3.1 CONNECTION DIAGRAM BETWEEN MECHANICAL UNITS . . . . . . . . . . . . . . . . . . . . . . . . . 191
3.2 EXTERNAL CABLE WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
3.2.1 Robot Connection Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
3.2.2 Teach Pendant Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
3.2.3 Connecting the Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
3.2.4 Connecting the External Power Supply ON/OFF Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
3.2.5 Connecting the External Emergency Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226

4. PERIPHERAL DEVICE, ARC WELDING, AND

END EFFECTOR INTERFACES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
4.1 PERIPHERAL DEVICE INTERFACE BLOCK DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
4.1.1 When Process I/O Board EA or EB or GA is used (A–Cabinet) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
4.1.2 When Process I/O Board FA is Used (A–cabinet) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
4.1.3 When Process I/O Board CA or CB is Used (B–cabinet) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
4.1.4 When Process I/O Board DA is Used (B–cabinet) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
4.1.5 When I/O Unit–MODEL A is Used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
4.1.5.1 In case of A–cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
4.1.5.2 In case of B–cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
4.1.6 When I/O Unit–MODEL B is Used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
4.1.6.1 In case of A–cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
4.1.6.2 In case of B–cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
4.1.7 When Two or more Process I/O Printed Circuit Boards and
I/O Unit (Model A or Model B) are Used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
4.2 PERIPHERAL DEVICE INTERFACE COMBINATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
4.2.1 In Case of A–Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
4.2.2 In Case of B–Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
4.3 PROCESS I/O BOARD SIGNALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
4.4 INTERFACE FOR PERIPHERAL DEVICES, END EFFECTORS, AND WELDERS . . . . . . . . . . 248
4.4.1 Peripheral Device and Control Unit Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
4.4.2 Connection Between the Mechanical Unit and End Effector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
4.4.3 Connection Between the Control Unit and Welder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263

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4.5 DIGITAL I/O SIGNAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269

4.5.1 Peripheral Device Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
4.5.2 End Effector Control Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
4.5.3 I/O Signal Specifications for ARC–Welding Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
4.6 SPECIFICATIONS OF THE CABLES USED
FOR PERIPHERAL DEVICES AND WELDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
4.6.1 Peripheral Device Interface A Cable (CRM2: Honda Tsushin, 50 pins) . . . . . . . . . . . . . . . . . . . . . . . . 277
4.6.2 Peripheral Device Interface B Cable (CRM4: Honda Tsushin, 20 pins) . . . . . . . . . . . . . . . . . . . . . . . . 277
4.6.3 ARC Weld Connection Cable (CRW1, CRW7: Honda Tsushin, 34 pins) . . . . . . . . . . . . . . . . . . . . . . 278
4.7 CABLE CONNECTION FOR THE PERIPHERAL DEVICES,
END EFFECTORS, AND ARC WELDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279
4.7.1 Peripheral Device Connection Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279
4.7.2 Peripheral Device Cable Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
4.7.3 End Effector Cable Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
4.7.4 Recommended Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283
4.8 CONNECTING THE COMMUNICATION UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284
4.8.1 RS–232C Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284
4.8.1.1 Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284
4.8.1.2 RS–232–C Interface Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
4.8.1.3 Connection between RS–232–C Interface and External Device . . . . . . . . . . . . . . . . . . . . . . . . 286
4.8.2 Ethernet Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288
4.8.2.1 Connection to Ethernet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289
4.8.2.2 10BASE–T Connector (CD38) Pin Assignments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290
4.8.2.3 Cable Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290
4.8.2.4 Lead Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
4.8.2.5 Connector Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
4.8.2.6 Cable Clamp and Shielding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
4.8.2.7 Grounding the Network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293

5. TRANSPORTATION AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295

5.1 TRANSPORTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296
5.2 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297
5.2.1 Installation Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297
5.2.2 Assemble at Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300
5.3 INSTALLATION CONDITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
5.4 ADJUSTMENT AND CHECKS AT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
5.5 RESETTING OVERTRAVEL AND EMERGENCY STOP AT INSTALLATION . . . . . . . . . . . . . . 304
5.5.1 Peripheral Device Interface Processing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304
5.5.2 Resetting Overtravel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304

APPENDIX
A. TOTAL CONNECTION DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307

B. SPECIFICATIONS OF PERIPHERAL DEVICE INTERFACE . . . . . . . . . . . . . . . . . 352

B.1 SIGNALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 353
B.2 SETTING COMMON VOLTAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 355
B.3 I/O SIGNALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 356
B.3.1 Input Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 356
B.3.2 Output Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 361
B.4 SPECIFICATIONS OF DIGITAL AND ANALOG INPUT/OUTPUT . . . . . . . . . . . . . . . . . . . . . . . 365
B.4.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 365

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B.4.2 Input/Output Hardware Usable in the R-J3 Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 365

B.4.3 Software Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 365

C. POWER DISTRIBUTION CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 366

D. OPTICAL FIBER CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 380

E. CARD INTERFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 383

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B–80945EN/02 SAFETY PRECAUTIONS 1. SAFETY PRECAUTIONS

1 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.

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1. SAFETY PRECAUTIONS SAFETY PRECAUTIONS B–80945EN/02

1.1 Operator safety is the primary safety consideration. Because it is very

dangerous to enter the operating space of the robot during automatic
OPERATOR SAFETY 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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(9) When adjusting each peripheral device independently, be sure to turn

off the power of the robot.

Limit switch which operates

when the gate is opened.

Limit switch for

the safety gate
Printed circuit board for
operator’s box

Note) Terminals FENCE1 and FENCE2 are

on the PC board in the operator’s box.

Fig.1.1 Safety Fence and Safety Gate

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1. SAFETY PRECAUTIONS SAFETY PRECAUTIONS B–80945EN/02

1.1.1 The operator is a person who operates the robot system. In this sense, a
Operator Safety 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

Panel board

EMGIN1
EMGIN2

Note) Connect to EMGIN1 and EMGIN2.

Terminals EMGIN1 and EMGIN2 are on the PC board in the
operator’s box.

Fig.1.1.1 Connection Diagram for External Emergency Stop Switch

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B–80945EN/02 SAFETY PRECAUTIONS 1. SAFETY PRECAUTIONS

1.1.2 While teaching the robot, it is necessary for the operator to enter the work
Safety of the Teach area of the robot. It is particularly necessary to ensure the safety of the
teach pendant operator.
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’s switch on the teach
pendant).
The teach pendant supplied by FANUC is provided with a teach pendant en-
able switch and a deadman’s switch in addition to the EMERGENCY STOP
button. The functions of each switch are as follows.
EMERGENCY STOP button : Pressing this button stops the robot in an
emergency, irrespective to the condition of
the teach pendant enable switch.
Deadman’s switch : The function depends on the state of the
teach pendant enable switch.
When the enable switch is on – Releasing the finger from the dead man’s
switch stops the robot in an emergency.
When the enable switch is off – The deadman’s switch is ineffective.

NOTE
The deadman’s switch is provided so that the robot operation can
be stopped simply by releasing finger from the teach pendant in
case of 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’s switch also have the following function.
By pressing the deadman’s switch while the enable switch is on,
the emergency stop factor (normally the safety gate) connected
to FENCE1 and FENCE2 of the controller is invalidated. In this
case, it is possible for an operator to enter the fence during teach
operation without pressing the EMERGENCY STOP button. In
other words, the system understands that the combined
operations of pressing the teach pendant enable switch and
pressing the deadman’s switch indicates the start of teaching. The
teach pendant operator should be well aware that the safety gate
is not functional under this condition and bear full responsibility to
ensure that no one enters the fence during teaching.

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1. SAFETY PRECAUTIONS SAFETY PRECAUTIONS B–80945EN/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’s
panel other than the teach pendant.

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

Teach pen-
dant enable Remote Teach Operator’s Peripheral
switch switch pendant panel devices

On Independent Allowed to Not allowed Not allowed

start
Off Remote OFF Not allowed Allowed to Not allowed
start
Off Remote ON Not allowed Not allowed Allowed to
start
(6) To start the system using the operator’s box, make certain that nobody
is in the robot work area and that there are no abnormal conditions in
the robot work area.
(7) 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.
(8) While operating the system in the automatic operation mode, the
teach pendant operator should leave the robot work area.

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B–80945EN/02 SAFETY PRECAUTIONS 1. SAFETY PRECAUTIONS

1.1.3 For the safety of maintenance personnel, pay utmost attention to the
Safety During following.
Maintenance (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’s 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.

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1. SAFETY PRECAUTIONS SAFETY PRECAUTIONS B–80945EN/02

1.2
SAFETY OF THE
TOOLS AND
PERIPHERAL
DEVICES

1.2.1 (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
Precautions in signal is received.
Programming (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.

1.2.2 (1) Keep the component cells of the robot system clean, and operate the
robot in an environment free of grease, water, and dust.
Precautions for
(2) Employ a limit switch or mechanical stopper to limit the robot motion
Mechanism so that the robot does not come into contact with its peripheral devices
or tools.

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1.3
SAFETY OF THE
ROBOT MECHANISM

1.3.1 (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.
Precautions in
(2) Before pressing the jog key, be sure you know in advance what
Operation motion the robot will perform in the jog mode.

1.3.2 (1) When the work areas of robots overlap, make certain that the motions
of the robots do not interfere with each other.
Precautions in
(2) Be sure to specify the predetermined work origin in a motion program
Programming 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.

1.3.3 (1) Keep the work area of the robot clean, and operate the robot in an
environment free of grease, water, and dust.
Precautions for
Mechanisms

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1. SAFETY PRECAUTIONS SAFETY PRECAUTIONS B–80945EN/02

1.4
SAFETY OF THE END
EFFECTOR

1.4.1 (1) To control the pneumatic, hydraulic and electric actuators, carefully
consider the necessary time delay after issuing each control command
Precautions in up to actual motion and ensure safe control.
Programming (2) Provide the end effector with a limit switch, and control the robot
system by monitoring the state of the end effector.

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1.5
(1) Never enter the robot work area while the robot is operating. Turn off
SAFETY IN the power before entering the robot work area for inspection and
MAINTENANCE 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’s box.
(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.

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1. SAFETY PRECAUTIONS SAFETY PRECAUTIONS B–80945EN/02

1.6
WARNING LABEL (1) Step–on prohibitive label

Step–on Prohibitive Label

Description Do not step on or climb the robot or controller as it may adversely affect
the robot or controller and you may get hurt if you lose your footing as
well.

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II MAINTENANCE
B–80945EN/02 MAINTENANCE 1. OVERVIEW

1 OVERVIEW

This manual describes the maintenance and connection of the R-J3 robot
controller (called the R-J3).
Maintenance Part : Troubleshooting, and the setting, adjustment,
and replacement of units
Connection Part : Connection of the R-J3 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.

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2. CONFIGURATION MAINTENANCE B–80945EN/02

2 CONFIGURATION

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B–80945EN/02 MAINTENANCE 2. CONFIGURATION

2.1 The appearance and components might slightly differ depending on the
controlled robot, application, and options used.
EXTERNAL VIEW OF Fig.2.1 (a) and (b) show the view of R–J3.
THE CONTROLLER Fig.2.1 (c), (d), (e) and (f) show the major components of the R–J3 controller.

Operator box

Teach pendant

R–J3 Controller

Fig.2.1 (a) External View of the R–J3 Controller (A–cabinet)

NOTE
The term i–cabinet used as the name of the controller was
changed to the term A–cabinet. When referencing the
manual, read “i–cabinet” as referring to “A–cabinet.”

Teach pendant Operator panel

R–J3 controller

Fig.2.1 (b) External View of the R–J3 Controller (B–cabinet)

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2. CONFIGURATION MAINTENANCE B–80945EN/02

Fig.2.1 (c) R–J3 controller interior (A–cabinet)

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B–80945EN/02 MAINTENANCE 2. CONFIGURATION

 Operator box type A

 Operator box type B

Fig.2.1 (d) R–J3 operator box interior

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2. CONFIGURATION MAINTENANCE B–80945EN/02

FANUC handy file Teach pendant

Option board Main board

Fan unit 1
Power supply unit

I/O unit model A

Operator panel or
I/O unit model B

Breaker
Fan unit 2
Fan unit 3 Servo amplifier
MCC unit

Fig.2.1 (e) R–J3 B–cabinet interior (Front)

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B–80945EN/02 MAINTENANCE 2. CONFIGURATION

Dischange resister
Transformer
or
Line filter

Fig.2.1 (f) R–J3 B–cabinet overview (Back)

Table 2.1 Servo amplifier specifications

Robot models Servo amplifier Discharge resistor

S–430iF, S–430iR/130, A05B–2400–C201 (A–cabinet)
A06B–6100–H002
S–430iC, M–710i A05B–2401–C201 (B–cabinet)
S–430iW, S–430iL, S–430iR/165,
A05B–2400–C200 (A–cabinet)
S–430iR/Press HT/Press HS, A06B–6100–H001
A05B–2401–C200 (B–cabinet)
S–430iU, S–900i
A05B–2400–C200 (A–cabinet)
M–410i, M–500i A06B–6100–H001 (Note)
A05B–2401–C200 (B–cabinet)
ARC Mate 100i, M–6i, A05B–2400–C202 (A–cabinet)
A06B–6100–H004
SR Mate 200i A05B–2401–C202 (B–cabinet)
ARC Mate 120i, M–16i, A05B–2400–C201 (A–cabinet)
A06B–6100–H003
S–500i A05B–2401–C201 (B–cabinet)
A05B–2400–C201 (A–cabinet)
A–520i A06B–6100–H003 (Note)
A05B–2401–C201 (B–cabinet)
A05B–2400–C202 (A–cabinet)
F–200i A06B–6100–H006
A05B–2401–C202 (B–cabinet)
ARC Mate 50i, A05B–2400–C202 (A–cabinet)
A06B–6100–H005
LR Mate 200i A05B–2401–C202 (B–cabinet)

NOTE
Robot M–410iH, M–500i and A–520i are 4–axis robot.

23
 Operator box
Backplane printed circuit board
Process I/O
Panel board or I/O unit
model A
model B
2. CONFIGURATION

Power supply unit Main board Memory

card
Battery (PCMIA)

Periphe-
ral
device

(FSSB)
signal

Servo signal
Fan Serial communication signal

Teach
pendant

DC power supply/interlock
Transformer
or Transformer over heat signal Periphe-
Line filter unit ral
device

24
Printed Sensor
circuit board computer
Servo amplifier for emergency
precharge stop control Handy
MAINTENANCE

File
CRT/KB
Printer

External
emergency
Stop External
Breaker 210VAC on/off
(Servo power
supply) Robot RDI/RDO signal

Fig.2.1 (g) Block diagram of the R–J3 (A–cabinet)

Servo amplifier Pulse coder signal
(6–axis amplifier)

over heat signal

Motor power supply Robot

Dischange resister
Brake power supply

AC input
200–575 VAC
3φ Dischange
resister
B–80945EN/02
B–80945EN/02 MAINTENANCE 2. CONFIGURATION

pendant
Teach
Operator panel

HSSB Brake power encoder

Motor power encoder
Backplane printed circuit board

Serial
Encoder signal

communication
Main board

signal

DC power supply
Interlock signal

Servo signal
Line filter unit
Transformer
or

Fig.2.1 (h) Block diagram of the R–J3 (B–cabinet)

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2. CONFIGURATION MAINTENANCE B–80945EN/02

2.2 – Main board

COMPONENT The main board contains a microprocessor, its peripheral circuits,
memory, and operator’s box control circuit. The main CPU controls
FUNCTIONS servo mechanism positioning and servo amplifier voltages.
- I/O printed circuit board, FANUC I/O Unit MODEL–A and MODEL B
Various types of printed circuit boards are provided for applications
including process I/O. The FANUC I/O unit MODEL-A or MODEL
B can also be installed. When it is used, various I/O types can be
selected. These are connected with FANUC I/O Link.
- Printed circuit board for emergency stop control, MCC Unit
This printed circuit board controls the emergency stop system, both
of the magnetic contactor and the precharge of servo amplifier.
- Power supply unit
The power supply unit converts the AC power to various levels of DC
power.
- Backplane printed circuit board
The various control printed circuit boards are mounted on the
backplane printed circuit board.
- Teach pendant
All operations including robot programming are performed with this
unit. The controller status and data are indicated on the liquid-crystal
display (LCD) on the pendant.
- Servo amplifier
The servo amplifier controls servomotor power, pulse coder, brake
control, overtravel and hand broken.
- Operator box/panel
Buttons and LEDs on the operator box/panel are used to start the robot
and to indicate the robot status. The box/panel has a port for the serial
interface to an external device and an interface to connect the memory
card for data backup. It also controls the emergency stop control
circuit.
- Transformer
The supply voltage is converted to an AC voltage required for the
controller by the transformer. Three kinds of transformer accepts a
line voltage from 200 to 575 VAC according to the tap setting.
- Fan unit, heat exchanger
These components cool the inside of the control unit.
- Circuit Breaker
Large current might flow in the control unit due to an error in electric
circuits in it or an input power supply error.
To protect the facility in such a case, connect the input power supply
to the circuit breaker.
- Regenerative resistor
To discharge the counter electromotive force from the servomotor,
connect a regenerative resistor to the servo amplifier.

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B–80945EN/02 MAINTENANCE 2. CONFIGURATION

2.3 Daily maintenance and periodic maintenance/inspection ensure reliable

robot performance for extended periods of time.
PREVENTIVE
MAINTENANCE (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

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3. TROUBLESHOOTING MAINTENANCE B–80945EN/02

3 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.

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B–80945EN/02 MAINTENANCE 3. TROUBLESHOOTING

3.1
POWER CANNOT BE
TURNED ON
Check and Corrective action Figure
(Check 1) Check that the circuit breaker is on and has not tripped. Breaker Operator box
(Corrective Turn on the circuit breaker.
action)

Breaker

(Check 2) Check whether the LED (PIL: green) on the power supply unit
is on.
(Corrective If the LED is not on, 200 VAC is not supplied to the power supply
action) unit. It is likely that fuse F1 in the power supply unit has blown. Diode stack F1 8.0A
DB1 Fuse for AC input
– If 200 VAC is not supplied:
Find the cause by referencing the general schematic diagram
presented in the appendix.
– If 200 VAC is supplied:
Find the cause of the blown fuse. Fuse F1 is in the power sup- CP1 connector
ply unit. Before you start troubleshooting, turn off the circuit
breaker.
a) If fuse F1 has blown:
Surge absorber
– See Corrective action (1). VS1 F3 7.5A
b) If fuse F1 has not blown: Spare power Fuse for +24E
– Replace the power supply unit. supply module
F4 7.5A
H1
Fuse for +24V
(Corrective Causes of blown fuses F1 and corrective action PIL
action(1)) a) Check whether the unit and printed–circuit board connected LED (green)
for AC power
to the connectors CP2 and CP3 in the power supply unit are supply display
abnormal, by referencing the general schematic diagram CP6 connector
presented in the appendix. CP5 connector
b) Short-circuit in the surge absorber VS1
LED (red) for
VS1 is inserted to absorb surge voltage between input lines. alarm display
If the surge voltage is excessive or sustained, excessively
high voltage is applied to VS1 and a failure occurs in the
short-circuit mode, causing F1 to blow. If a short-circuit oc-
curs in VS1, and there is not a spare part, the system is per-
mitted to operate without VS1. In this case, however, obtain
and install a new VS1 as soon as possible.
VS1 ordering number: A50L-2001-0122#G431k
c) Short-circuit of diode stack DB1
d) The secondary power supply module is faulty :
If one of the causes (b) to (c) above is detected, replace the
power supply unit with a spare unit.
The spec. for F1 is : A60L-0001-0396#8.0A

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3. TROUBLESHOOTING MAINTENANCE B–80945EN/02

Check and Corrective action Figure

(Check 3) Check whether the OFF1 and OFF2 signals are connected on
the terminal block on the panel board. Short connection board : between 3(OFF1) and 4(OFF2)

(Corrective If the external ON/OFF function is not used, connect the external
action) ON and OFF lines. If the external ON and OFF lines are already
connected, check the mating contacts and the cable.

Panel board

(Check 4) Check 1 to 3 above confirm that 200 VAC power is supplied to

Diode stack F1 8.0A
connector CP1 of the power supply unit and that the ON/OFF DB1 Fuse for AC input
switch functions normally. Therefore check the power supply
unit using the following procedure:
If the LED (ALM: red) on the power supply unit is on
Check if the +24 V external connection cable is connected to 0
V or ground. CP1 connector
a) Fuse F4 blown :
See corrective action (2).
b) None of the above fuses blown [d) is also probable] :
A printed circuit board or unit that uses a DC supply volt- Surge absorber
VS1
age (+3.3V, +5V, +24V, or ±15V) is faulty. Spare power
F3 7.5A
Fuse for +24E
c) None of the above fuses blown : supply module
Check that 200 VAC is supplied to connector CP1. If it H1 F4 7.5A
Fuse for +24V
is supplied replace the power supply unit. PIL
LED (green)
for AC power
(Corrective If the power supply unit is not faulty, replace the panel board or supply display
action) operator panel.
CP6 connector
CP5 connector
(Corrective Causes of blown fuse F4 and corrective action
action(2)) The device connected to connector CP5 of the power supply unit LED (red) for
may be faulty. If no device is connected to CP5 or the connected alarm display
device is normal, the +24 V power used in a printed circuit board
connected to the backplane is faulty.
The code of F4 is A60L–0001–0046#7.5 :

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B–80945EN/02 MAINTENANCE 3. TROUBLESHOOTING

3.2 The alarm occurrence screen displays only the alarm conditions that are
currently active. If an alarm reset signal is input to reset the alarm
ALARM conditions, the alarm occurrence screen displays the message “PAUSE or
OCCURRENCE more serious alarm has not occurred.”
SCREEN 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 Automatic alarm display
[4 ALARM]. Press the alarm key. 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 MAINTENANCE B–80945EN/02

Displaying the alarm history/alarm detail information

Step (1) Press the MENUS key to display the screen menu.
(2) Select [ALARM].
You will see a screen similar to the following
3
4 ALARM INTP–224 (SAMPLE1, 7) Jump label is fail
5 I/O MEMO–027 Specified line does not exist
Alarm JOINT 30 %
1/25
MENUS 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].

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

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

F5 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

[ 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].

CLEAR HELP NOTE

When system variable $ER_NOHIS = 1, NONE alarms or
F4 WARN alarms are not recorded. When $ER_NOHIS=2,
SHIFT
resets are not recorded in the alarm history. When
$ER_NOHIS=3, resets, WARN alarms, and NONE alarms
are not recorded.

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B–80945EN/02 MAINTENANCE 3. TROUBLESHOOTING

The following map indicates teach pendant operations used to check an

alarm.
4 ALARM
F1 [TYPE]
Alarm : Active
F1 [TYPE]
F3 HIST
Alarm : HIST
F1 [TYPE]
F3 [ACTIVE]
F4 CLEAR
F5 HELP
DETAIL Alarm
F1 [TYPE]
F3 [ACTIVE]
F4 CLEAR
F5 HELP

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3. TROUBLESHOOTING MAINTENANCE B–80945EN/02

3.3 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.
SAFETY SIGNALS On this screen, it is impossible to change the state of any safety signal.
Table 3.3 Safety Signals
Safety signal Description
Operator panel emergency stop This item indicates the state of the emergency stop button on the operator panel. If the
EMERGENCY STOP board is pressed, the state is indicated as “TRUE”.
Teach pendant emergency stop This item indicates the state of the emergency stop button on the teach pendant. If the
EMERGENCY STOP board is pressed, the state is indicated as “TRUE”.
External emergency stop This item indicates the state of the external emergency stop signal. If the EMERGENCY
STOP signal is input, the state is indicated as “TRUE”.
Fence open This item indicates the state of the safety fence. If the safety fence is open, the state is
indicated as “TRUE”.
Deadman switch This item indicates whether the DEADMAN switch on the teach pendant is grasped. If
the teach pendant is operable, and the DEADMAN switch is grasped, the state is indi-
cated as “TRUE”. If the deadman switch is released when the teach pendant is enabled,
an alarm occurs, causing the servo power to be switched off.
Teach pendant enable This item indicates whether the teach pendant is enable. If the teach pendant is enable,
the state is indicated as “TRUE”.
Hand broken This item indicates the state of the hand safety joint. If the hand interferes with a work-
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.
Robot overtravel This item indicates whether the current position of the robot tripped an overtravel switch.
If any robot articulation goes out of the operation range beyond the overtravel switch, the
state is indicated as “TRUE”. In this case, an alarm occurs, causing the servo power to be
switched off.
Abnormal air pressure This item indicates the state of the air pressure. The abnormal air pressure signal is con-
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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B–80945EN/02 MAINTENANCE 3. TROUBLESHOOTING

3.4 Mastering is needed if:

MASTERING (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.

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

SYSTEM Variables JOINT 10%

57/136
57 $MASTER_ENB 1

Example of fixture position mastering procedure.

Step (1) Press <MENUS>.
(2) Select SYSTEM.
(3) Press F1, TYPE.
(4) Select Master/Cal you will see a screen similar to the following.
9 USER
0 –– NEXT –– SYSTEM Master/Cal JOINT 30%

1 FIXTURE POSITION MASTER

MENUS
2 ZERO POSITION MASTER
3 QUICK MASTER
5 POSITION 4 SINGLE AXIS MASTER
6 SYSTEM 5 SET QUICK MASTER REF
7 6 CALIBRATE

Master/Cal Press ’ENTER’ or number key to select.

TYPE
[TYPE] LOAD RES_PCA DONE

F1

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

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3. TROUBLESHOOTING MAINTENANCE B–80945EN/02

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

(yes). Mastering data is set.

SYSTEM Master/Cal SYSTEM Master/Cal JOINT 30 %

ENTER
1 FIXTURE POSITION MASTER 1 FIXTURE POSITION MASTER
2 ZERO POSITION MASTER 2 ZERO POSITION MASTER
Master at master position? [NO] 3 QUICK MASTER
4 SINGLE AXIS MASTER
Master at master position? [NO] 5 SET QUICK MASTER REF
[ TYPE ] YES NO 6 CALIBRATE
Robot Mastered! Mastering Data:
<0> <11808249> <38767856>
<9873638> <122000309> <2000319>
F4
[ TYPE ] LOAD RES_PCA DONE

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

performed.
Alternatively, to perform positioning, turn the power off, then turn it
on again. Calibration is performed whenever the power is turned on.
5 SET QUICK MASTER REF
SYSTEM Master/Cal JOINT 30 %
6 CALIBRATE
Calibrate? [NO] ENTER
1 FIXTURE POSITION MASTER
2 ZERO POSITION MASTER
Calibrate? [NO] 3 QUICK MASTER
[ TYPE ] YES NO 4 SINGLE AXIS MASTER
5 SET QUICK MASTER REF
6 CALIBRATE
F4 Robot Calibrated! Cur Jnt Ang(deg):
<10.000> <–25.000> <40.000>
<5.000> <–15.000> <0.000>
[ TYPE ] LOAD RES_PCA DONE

(8) Press F5 “DONE”, after mastering.

DONE

F5

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B–80945EN/02 MAINTENANCE 3. TROUBLESHOOTING

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

(Explanation) The emergency stop button on the operation box or
TROUBLESHOOTING operator’s panel or is pressed. If the SYST–067
USING THE ERROR (Panel HSSB disconnect) alarm is also generated, or
CODES if the LED (green) on the panel board is turned off,
communication between the main board (CRJ2A)
and the panel board (CRJ2B) is abnormal. The
connectors of the optical fiber cable between the main
board and the panel board may be loose. Or, the
optical fiber cable, panel board, or main board may be
faulty. (Note)
(Action 1) Release the emergency stop button pressed on the
operator’s box.
(Action 2) Check the wires connecting the emergency stop
switch connector CRT8 for continuity. If an open wire
is found replace the entire harness.
(Action 3) With the emergency stop in the released position,
check for continuity across the terminals of the
switch. If continuity is not found, replace the switch.
If continuity is found replace the operator panel PCB.
Before executing the (Action 4), perform a complete
controller back–up to save all your programs and
settings.
(Action 4) Replace the Main Board.
NOTE
If the LED is turned off, the SRVO–001 (Operator panel
E–stop), SRVO–004 (Fence open), SRVO–007 (External
emergency stops), SRVO–019 (SVON input), or SRVO–200
(Control box fan abnormal) alarm is also generated. Check
the alarm history display on the teach pendant.

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3. TROUBLESHOOTING MAINTENANCE B–80945EN/02

Emergency stop button

Emergency
stop button

Panel board

Connector (CRJ2B) LED (Green)

Connector (CRJ2A)
Main board

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B–80945EN/02 MAINTENANCE 3. TROUBLESHOOTING

(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

(3) SRVO–003 SVAL1 Deadman switch released

(Explanation) The teach pendant is enabled, but the deadman’s
switch is not pressed.
(Action 1) Press the deadman switch to run the robot.
(Action 2) Replace the teach pendant.

Deadman switch

(4) SRVO–004 SVAL1 Fence open

(Explanation) On the terminal block TBOP1of the panel board, no
connection is made between 3 (FENCE1) and 4
(FENCE2). If a safety fence is connected between 3
(FENCE1) and 4 (FENCE2), the door of the safety
fence is open. If the SYST–067 (Panel HSSB
disconnect) alarm is also generated, or if the LED
(green) on the panel board is turned off,
communication between the main board (CRJ2A)

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3. TROUBLESHOOTING MAINTENANCE B–80945EN/02

and the panel board (CRJ2B) is abnormal. The

connectors of the optical fiber cable between the main
board and the panel board may be loose. Or, the
optical fiber cable, panel board, or main board may be
faulty. (Note)
(Action 1) If a safety fence is connected, close the door.
(Action 2) Check the switch and cable connected to 3 (FENCE1)
and 4 (FENCE2).
(Action 3) When this signal is not used, make a connection
between 3 (FENCE1) and 4 (FENCE2).
(Action 4) Replace the panel PC board.

WARNING
Do NOT short–circuit, or disable, this signal in a system in
which the Fence 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.

NOTE
If the LED is turned off, the SRVO–001 (Operator panel
E–stop), SRVO–004 (Fence open), SRVO–007 (External
emergency stops), SRVO–019 (SVON input), or SRVO–200
(Control box fan abnormal) alarm is also generated. Check
the alarm history display on the teach pendant.

Short connection board

Panel board

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B–80945EN/02 MAINTENANCE 3. TROUBLESHOOTING

(5) SRVO–005 SVAL1 Robot overtravel

(Explanation) The robot has moved beyond a hardware limit switch
on the axes. It is factory–placed in the overtravel state
for packing purposes.
If the Overtravel signal is not in use, it may have been
disabled by short–circuiting CRM37B on the servo
amplifier.
(Action 1) 1) Select [System OT release] on the overtravel
release screen to release each robot axis from the
overtravel state.
2) Hold down the shift key, and press the alarm
release button to reset the alarm condition.
3) Still hold down the shift key, and jog to bring all
axes into the movable range.
(Action 2) Check the FU1 fuse on the servo amplifier.
If the SRVO–043 DCAL alarm is also generated, FU1
fuse have been blown.
(Action 3) Verify the following for connector RP1 at the base of
the robot :
1) There are no bent or dislocated pins in the mail or
femail connectors.
2) The connector is securely connected.
Then verify that connector CRM37B on the servo
amplifier is securely connected. Also verify that the
RP1 cable is in good condition, and there are no cuts
or kinks visible. If no limit switch is in use, a jumper
connector must be attached to the CRM37B
connector of the servo amplifier. Check for the
jumper connector.
(Action 4) Replace the servo amplifier.

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3. TROUBLESHOOTING MAINTENANCE B–80945EN/02

Servo amplifier
Main board

CRM37B
Connector
Fuse FU1

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B–80945EN/02 MAINTENANCE 3. TROUBLESHOOTING

(6) SRVO–006 SVAL1 Hand broken

(Explanation) The safety joint (if in use) might have been broken.
Alternatively, the HBK signal on the robot
connection cable might be a ground fault or a cable
disconnection.
If the Hand broken signal is not in use, it may have
been disabled by short–circuiting CRM37A on the
servo amplifier.
(Action 1) Hold down the shift key, and press the alarm release
button to reset the alarm condition. Still hold down
the shift key, and jog the tool to the work area.
1) Replace the safety joint.
2) Check the safety joint cable.
(Action 2) Check the FU1 fuse on the servo amplifier. If the
SRVO–043 DCAL alarm is also generated, FU1 fuse
have been blown.
(Action 3) Verify the following for connector RP1 at the base of
the robot :
1) There are no bent or dislocated pins in the mail or
femail connectors.
2) The connector is securely connected.
Then verify that connector CRM37A on the servo
amplifier is securely connected. Also verify that the
RP1 cable is in good condition, and there are no cuts
or kinks visible. Check the robot connection cable
(RP1) for a ground fault or a cable disconnection.
(Action 4) Replace the servo amplifier.

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Servo amplifier
Main board

CRM37A
Connector

Fuse FU1

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(7) SRVO–007 SVAL1 External E–stop

(Explanation) On the terminal block TBOP1 of the panel board, no
connection is made between 1 (EMGIN1) and 2
(EMGIN2). If an external emergency stop switch is
connected between 1 (EMGIN1) and 2 (EMGIN2),
the switch is pressed. If the SYST–067 (Panel HSSB
disconnect) alarm is also generated, or if the LED
(green) on the panel board is turned off,
communication between the main board (CRJ2A)
and the panel board (CRJ2B) is abnormal. The
connectors of the optical fiber cable between the main
board and the panel board may be loose. Or, the
optical fiber cable, panel board, or main board may be
faulty. (Note)
(Action 1) If an external emergency stop switch is connected,
releases the switch.
(Action 2) Check the switch and cable connected to 1(EMGIN1)
and 2 (EMGIN2).
(Action 3) When this signal is not used, make a connection
between 1 (EMGIN1) and 2 (EMGIN2).
(Action 4) Replace the PC board.

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.

NOTE
If the LED is turned off, the SRVO–001 (Operator panel
E–stop), SRVO–004 (Fence open), SRVO–007 (External
emergency stops), SRVO–019 (SVON input), or SRVO–200
(Control box fan abnormal) alarm is also generated. Check
the alarm history display on the teach pendant.

Short connection board

Panel board

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(8) SRVO–009 SVAL1 Pneumatic pressure alarm

(Explanation) An abnormal air pressure was detected.
(Action 1) If an abnormal air pressure is detected, check the
cause.
If the peripheral device are normal, check the robot
cable and if the peripheral device are abnormal,
replace the device.
(Action 2) Replace the servo amplifier.

Servo amplifier
Main board

(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

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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 using the air
conditioning unit.
(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 main board is defective,
replace the backplane unit.
Main board Fan motor

Fan motor

A–cabinet (Openning the door) A–cabinet (Front)

Main board
Heat exchanger
Fan unit1

Fan unit3 B–cabinet Fan unit2

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(11)SRVO–018 SVAL1 Brake abnormal

(Explanation) An excessive brake current is detected. The
seven–segment LED on the servo amplifier indicates 1.
(Action 1) Check the robot connection cable (RM1) and cables
internal to the mechanical section for a short–circuit
and connection to the ground.
(Action 2) Replace the servo amplifier.

Servo amplifier Main board

(12)SRVO–019 SVAL1 SVON input

(Explanation) On the terminal block TBOP1 of the panel board, no
connection is made between 5 (SVOFF1) and 6
(SVOFF2). If a switch is connected between 5
(SVOFF1) and 6 (SVOFF2), the switch is pressed.
(Action 1) If a switch is connected, release the switch. If the
SYST–067 (Panel HSSB disconnect) alarm is also
generated, or if the LED (green) on the panel board is
turned off, communication between the main board
(CRJ2A) and the panel board (CRJ2B) is abnormal.
The connectors of the optical fiber cable between the
main board and the panel board may be loose. Or, the
optical fiber cable, panel board, or main board may be
faulty. (Note)
(Action 2) Check the switch and cable connected to 5 (SVOFF1)
and 6 (SVOFF2).
(Action 3) When this signal is not used, make a connection
between 5 (SVOFF1) and 6 (SVOFF2).
(Action 4) Replace the panel board. Before executing (Action 5),
perform a complete controller back–up to save all
your programs and settings.
(Action 5) Replace the main board.

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WARNING
Do NOT short–circuit, or disable, this signal in a system in
which the Servo off emergency stop signal input 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.

NOTE
If the LED is turned off, the SRVO–001 (Operator panel
E–stop), SRVO–004 (Fence open), SRVO–007 (External
emergency stops), SRVO–019 (SVON input), or SRVO–200
(Control box fan abnormal) alarm is also generated. Check
the alarm history display on the teach pendant.

Short connection board

Panel board

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

(Explanation) The HRDY signal is on and the SRDY signal is off,
although there is no other cause of an alarm. (HRDY
is a signal with which the host directs the servo
system whether to turn on or off the servo amplifier
magnetic contactor. SRDY is a signal with which the
servo system informs the host whether the magnetic
contactor is turned on.)
If the servo amplifier magnetic contactor cannot be
turned on when so directed, 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) Check whether a break has occurred on an emergency
stop line (teach pendant emergency stop, teach
pendant enable/disable switch, teach pendant
deadman switch, operator box emergency stop,
external emergency stop input, fence input, servo–off
input, or door switch). This alarm occurs if the alarm
cause cannot be detected by software because of a
short break of emergency stop line.
(Action 2) Replace the servo amplifier.
(Action 3) Check the magnetic contactor for continuity. If it is bad
replace it. In case of B–cabinet, replace the MCC unit.
(Action 4 and 5 are not necessary.)
(Action 4) Replace the cable between the emergency stop board
and the magnetic contactor.
(Action 5) Replace the emergency stop control PCB.
(Action 6) Replace axis control card on the main board.
Servo amplifier Main board

Axis control card

Magnetic Emergency MCC unit
contactor stop board

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

(Explanation) When the HRDY signal is about to go on, the SRDY
signal is already on. (HRDY is a signal with which the
host directs the servo system whether to turn on or off
the servo amplifier magnetic contactor. SRDY is a
signal with which the servo system informs the host
whether the magnetic contactor is turned on.
(Action 1) Replace the axis control board on the main board.
(Action 2) Replace the servo amplifier.
Servo amplifier Main board

Axis control card

(15)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) 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 higher than the capacity of the
motor. As a result, the motor becomes unable to
follow the command, and an alarm is issued.)
(Action 3) Check each phase voltage of the CRR38A or CRR38B
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 4) If the line voltage is 170 VAC or higher, replace the
servo amplifier.
(Action 5) Check disconnection of motor power cable (RM1,
RM2, RM3).

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(Action 6) Replace the motor.

Servo amplifier Main board

(16)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. $TRKERRLIM).
It is likely that the robot cannot follow the speed
specified by program.
(Action 1) Check the robot for a binding axis.
(Action 2) Take the same actions as described for the SRVO–023
alarm.
(17)SRVO–025 SVAL1 Motn dt overflow (Group : i Axis : j)
(Explanation) The specified value is too great.
(18)SRVO–026 WARN2 Motor speed limit (Group : i Axis : j)
(Explanation) A value higher than the maximum motor speed
($PARAM_GROUP.$MOT_SPD_LIM) was
specified. The actual motor speed is clamped to the
maximum speed.
(19)SRVO–027 WARN Robot not mastered (Group : i)
(Explanation) An attempt was made to calibrate the robot, but the
mastering procedure was not completed.
(Action) Master the robot.
(20)SRVO–030 SVAL1 Brake on hold (Group : i)
(Explanation) This alarm occurs when the robot pauses, if the brake
on hold function has been enabled ($SCR.
$BRKHOLD _ ENB = 1). Disable the function if it
is not necessary.
(Action) Disable [Servo–off during pause] on the general
setting menu (Select Setting general).
(21)SRVO–031 SVAL1 User servo alarm (Group : i)
(Explanation) An user servo alarm occurred.
(22)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.

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

(Explanation) An attempt was made to perform quick master the
robot, but the reference point had not been set up.
(Action) Set up a quick master reference point on the positioning
menu.
(24)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.
(25)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 SRVO–23 (stop error
excess).
(26)SRVO–037 SVAL1 Imstp input (Group : i)
(Explanation) The *IMSTP signal for a peripheral device interface
was input.
(Action) Turn on the *IMSTP signal.
(27)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 Main Board.
(Action) Perform APC 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.
6. 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.
(28)SRVO–041 SVAL2 MOFAL alarm (Group : i Axis : j)
(Explanation) The servo value was too high.
(Action) Cold start the controller.
(29)SRVO–042 MCAL alarm (Group : i Axis : j)
(Explanation) This alarm means that the contacts of the magnetic
contactor have stuck to each other. The alarm condition
occurs if the magnetic contactor turns out to be already
on when an attempt is made to turn it on. The alarm
condition is detected between the time contact sticking
occurs and the time an attempt is made to turn on the
magnetic contactor. This alarm is represented by “2” on
the 7–segment LED indicator of the servo amplifier.
(Action 1) Check the magnetic contactor, and replace it if
necessary.
If the contacts of the magnetic contactor have stuck
to each other, turn off the circuit breaker. If the power
is switched off without turning off the circuit breaker,
the servo amplifier may get damaged, because the
stuck contacts keep three–phase 200 V applied to the
servo amplifier.
(Action 2) Replace the emergency stop board.

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(Action 3) Replace the servo amplifier.

Servo amplifier Magnetic contactor

Emergency stop board Emergency stop board

(in the MCC unit)

(30)SRVO–043 SVAL1 DCAL alarm (Group : i Axis : j)

(Explanation) The regenerative discharge energy was too high to be
dissipated as heat. (To run the robot, the servo
amplifier supplies energy to the robot. When going
down the vertical axis, the robot operates from the
potential energy. If a reduction in the potential energy
is higher than the energy needed for acceleration, the
servo amplifier receives energy from the motor. A
similar phenomenon occurs even when no gravity is
applied, for example, at deceleration on a horizontal
axis. The energy that the servo amplifier receives
from the motor is called the regenerative energy. The
servo amplifier dissipates this energy as heat. If the
regenerative energy is higher than the energy
dissipated as heat, the difference is stored in the servo
amplifier, causing an alarm.) “8” is display on the
servo segment LED of the servo amplifier.
(Action 1) This alarm may occur if the axis is subjected to frequent
acceleration/deceleration or if the axis is vertical and
generates a large amount of regenerative energy. If this
alarm has occurred, relax the service conditions.
(Action 2) Check fuse FU1 in the servo amplifier. If it has blown,
remove the cause, and replace the fuse. One of the
probable causes of a blown fuse is a ground fault in
the end effecter (RDI/RDO), ROT, or HBK signal.
(Action 3) Detach the cable from CRR43A on the emergency stop
board, and check for continuity between pins 1 and 2 of
the cable–end connector. If there is no continuity
between the pins, replace the regenerative resistance.
(Action 4) Detach the cables from CRR45A, CRR45B, and
CRR45C on the servo amplifier, and check the
resistance between pins 1 and 2 of each cable–end
connector. If the resistance is not 9Ω, replace the
regenerative resistance.

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(Action 5) Replace the servo amplifier.

Regenerative resistor
Servo amplifier

A–cabinet (Front)

A–cabinet (Back)

Servo amplifier Regenerative

resistor

B–cabinet (Front) B–cabinet (Back)

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(31)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 servo amplifier
LED indicates 7.
(Action 1) Check the three–phase input voltage at the servo
amplifier. 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 servo amplifier.
Servo amplifier Main board

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

(Explanation) Abnormally high current flowed in the main circuit of
the servo amplifier. The servo amplifier 7–segment
LED indicates –. At the same time, a red LED (HC1
to HC6) corresponding to the HCAL alarm on the side
of 7–segment LED.
(Action 1) Disconnect the Robot connection cable (Motor power)
from the servo amplifier connector (CNJ**), and then
see if the alarm occurs again. If the alarm occurs,
replace the servo amplifier.
(Action 2) Disconnect the Robot connection cable (Motor power)
from the servo amplifier connector (CNJ**), 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 them
and replace them if necessary.
(Action 3) Disconnect the Robot connection cable (Motor power)
from the servo amplifier connector (CNJ**), 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 and replace it if
necessary.
Servo amplifier Main board

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(33)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 servo amplifier. If it is 170
VAC or lower, check the line voltage.
(Action 3) Replace the servo amplifier.
(Action 4) Check the robot connection cable (RM1, RM2, RM3).
If any problems are found in the cables, replace the
cables.
(Action 5) Replace the motor.
Servo amplifier Main board

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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 Overcurrent alarm Servo software
OVL Overload alarm Thermal relay in the motor OHAL2
Thermal relay in the servo amplifier OHAL1
Thermal relay in the separate regenerative dis-
charge unit DCAL
HC High current alarm Servo amplifier

Purpose of each alarm

1) HC alarm (high current alarm)
If high current flow in a power transistor momentarily due to
abnormality or noise in the control circuit, the power transistor and
rectifier diodes might be damaged, or the magnet of the motor might
be degaussed. The HC alarm is intended to prevent such failures.
2) OVC and 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 Stop Start Stop Start

Temperature at Thermal time constant of

the motor is high.
which the winding
starts to burn
Thermal time constant of
the thermal relay is low.

Time

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

To prevent the above defects, software is used to monitor the current

in the motor constantly in order to estimate the temperature of the
motor. The OVC alarm is issued based on this estimated temperature.
This method estimates the motor temperature with substantial
accuracy, so it can prevent the failures described above.

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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.
Current
Protection area for
the motor and
servo amplifier
Protection by the OVL
Limit current

Protection by
the OVC

Rated continuous current

Time

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.

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

(Explanation) The control power supply voltage (+5 V, etc.) is
abnormally low.
The servo amplifier seven segment LED indicates “6”.
(Action 1) Replace the servo amplifier.
(Action 2) Replace the power supply unit.
Servo amplifier Power supply unit

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

(Explanation) The thermostat in the transformer worked.
Alternatively, fuse F1 or F2 in the servo amplifier has
blown. The servo amplifier LED indicates “3”.
(Action 1) Check the operating conditions for the robot and relax
the service conditions.
(Action 2) If fuses F1 and F2 have blown, replace the servo
amplifier.
(Action 3) If the fan motor is not running, check it and its cables.
Replace them if necessary.
(Action 4) Replace the transformer.

A–cabinet (Front)
Transformer
A–cabinet (Back)

Transformer
Servo amplifier

B–cabinet (Back)
B–cabinet (Front)

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(36)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) 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 3) Check the phase voltage of the three–phase input
power (200 VAC) to the servo amplifier. If it is 170
VAC or lower, check the line voltage.
(Action 4) Replace the servo amplifier.
Servo amplifier Main board

(37)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.
Servo amplifier Main board

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(38)SRVO–054 DSM Memory Error

(Explanation) An access to the servo module memory fails.
(Action) Replace the axis control card on the main board.
Main board

Axis control card

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

(Explanation) A communication error has occurred between the
main board and servo amplifier.
(Action 1) Check the communication cable (optical fiber)
between the main board and servo amplifier. Replace
it if it is faulty.
(Action 2) Replace the axis control card on the main board.
(Action 3) Replace the servo amplifier.
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 main board.
Servo amplifier Main board

Axis control card

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

(Explanation) A communication error has occurred between the
main board and servo amplifier.
(Action 1) Check the communication cable (optical fiber)
between the main board and servo amplifier. Replace
it if it is faulty.
(Action 2) Replace the axis control card on the main board.
(Action 3) Replace the servo amplifier.
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 main board.
Servo amplifier Main board

Axis control card

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

(Explanation) Communication was interrupted between the main
board and servo amplifier.
(Action 1) Check whether fuse F3 in the power supply unit has
blown. If it has, take a measure according to the
explanation in Section 3.5.
(Action 2) Check the communication cable (optical fiber)
between the main board and servo amplifier. Replace
it if it is faulty.
(Action 3) Replace the axis control card on the main board.
(Action 4) Replace the servo amplifier.
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 5) Replace the main board.
(Action 6) Check the RP1 cable of robot connection cable.
(+5V ground fault)
Servo amplifier Main board

Axis control card

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

(Explanation) Communication was interrupted between the main
board and servo amplifier.
(Action 1) Check whether fuse F3 in the power supply unit has
blown. If it has, take a measure according to the
explanation in Section 3.5.
(Action 2) Check the communication cable (optical fiber)
between the main board and servo amplifier. Replace
it if it is faulty.
(Action 3) Replace the axis control card on the main board.
(Action 4) Replace the servo amplifier.
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 5) Replace the main board.
Servo amplifier Main board

Axis control card

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(43)SRVO–059 SVAL2 Servo amp init error (Group : i Axis : j)

(Explanation) The servo amplifier was not initialized.
(Action) Replace the servo amplifier.

Servo amplifier

(44)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
This alarm might accompany the DTERR, CRCERR, or
STBERR alarm. In this case, however, there is no actual
condition for this alarm.

(45)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) Check the battery and battery cable, and replace the
new battery.
Then set the system variable $MCR.$SPC_RESET
to TRUE, then supply power again. After this,
mastering is required.
(46)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
This alarm might accompany the DTERR, CRCERR, or
STBERR alarm. In this case, however, there is no actual
condition for this alarm.

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(47)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.

(48)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.
(49)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.

(50)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.
(51)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
(52)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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(53)SRVO–070 SVAL2 STBERR alarm (Group : i Axis : j)

(Explanation) The start and stop bits of the serial data are abnormal.
(Action 1) 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 2) Check that each unit is grounded securely.
(Action 3) Replace the servo amplifier.
(Action 4) Replace the pulse coder.
(Action 5) Replace the robot interconnection cable (for the pulse
coder).
Servo amplifier Main board

(54)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.
(55)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.
(56)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) Make a simplified adjustment and enhance the
shielding.
(57)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.
(58)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)
(59)SRVO–081 WARN EROFL alarm (Track enc : i)
(Explanation) The pulse counter for line tracking has overflowed.
(Action) Contact the FANUC service center.

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(60)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.
(61)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.
(62)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).
(63)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.
(64)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).
(65)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. See
the description about the BLAL alarm (SRVO–065).
(66)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.
(67)SRVO–089 WARN OHAL2 alarm (Track enc : i)
(Explanation) The motor has overheated. See the description about
the OHAL2 alarm (SRVO–067).
(68)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).
(69)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).
(70)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).
(71)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).
(72)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).

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(73)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).
(74)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).
(75)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.
(76)SRVO–105 SVAL1 Door open or E. Stop
(Explanation) The door of the A–cabinet is open.
(Action 1) Close the door if open.
(Action 2) Check the door switch and door switch contact cable.
Replace any abnormal component.
(Action 3) This alarm occurs also if the emergency stop line was
broken, but the software failed to identify the cause.
Check whether the emergency stop line is abnormal,
by referencing the general connection diagram in the
appendix.
(Action 4) Replace the servo amplifier.
Servo amplifier

Door switch

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(77)SRVO–136 SVAL1 DCLVAL alarm (Group : i Axis : j)

(Explanation) The servo the DC current of amplifier (DC link
voltage) of the main power supply is abnormally low.
the servo amplifier LED indicates “4”.
–This alarm occured in the robot operation.
(Action 1) Check the phase voltage of the three–phase input
power (200 VAC) to the servo amplifier. If it is 170
VAC or lower, check the line voltage.
(Action 2) Replace the servo amplifier.
–If this alarm occurs before the magnetic contactor is turned on:
(Action 1) Check each phase–to–phase voltage of the
three–phase input (200 VAC) on the primary side of
the magnetic contactor. If the input is not higher than
170 VAC, check the input power supply voltage.
(Action 2) Replace the emergency stop board.
(Action 3) Replace the servo amplifier.

Servo amplifier

Emergency stop board (In the MCC unit)

(78)SRVO–156 SVAL1 IPMAL alarm (Group : i Axis : j)

(Explanation) Abnormally high current flowed through the main
circuit of the servo amplifier.
The hyphen “–” appears in the servo amplifier
7–segment LED indicator. At the same time, the LED
(red) corresponding to the axis (IPM1 to IPM6) for
which the IPMAL alarm has occurred lights. This
LED is beside the 7–segment LED indicator.
(Action 1) Detach the motor power lines from the respective
terminals on the servo amplifier, and switch on the
power, then check to see if the alarm occurs again. If
the alarm occurs, replace the servo amplifier.
(Action 2) Detach the motor power lines from the respective
terminals on the servo amplifier, and check for isolation
between each motor power line (U, V, or W) and a
ground potential (GND). If a motor power line is
short–circuited to a ground, the motor, robot connection
cable, or robot internal cable is likely to be defective.
Check each of them, and replace it if necessary.

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(Action 3) Detach the motor power lines from the respective

terminals on the servo amplifier, and check the
resistance between each motor power line pair (U and
V, V and W, or W and U) using a meter that is capable
of measuring a very low resistance. If the measured
three resistances are different, the motor, robot
connection cable, or robot internal cable is likely be
defective. Check each of them, and replace it if
necessary.
Servo amplifier Main board

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(79)SRVO–200 WARN Control box fan abnormal

(Explanation) The fan motor (option) in the operation box is
abnormal.
If the SYST–067 (Panel HSSB disconnect) alarm is
also generated, or if the LED (green) on the panel
board is turned off, communication between the main
board (CRJ2A) and the panel board (CRJ2B) is
abnormal. The connectors of the optical fiber cable
between the main board and the panel board may be
loose. Or, the optical fiber cable, panel board, or main
board may be faulty. (Note)
(Action) Check the fan motor and fan motor connection cable.
If they turn out to be defective, replace them.
NOTE
If the LED is turned off, the SRVO–001 (Operator panel
E–stop), SRVO–004 (Fence open), SRVO–007 (External
emergency stops), SRVO–019 (SVON input), or SRVO–200
(Control box fan abnormal) alarm is also generated. Check
the alarm history display on the teach pendant.

Fan motor (option)

Panel board

Connector (CRJ2B) LED (Green)

Main board
Connector (CRJ2A)

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(80)SRVO–201 SVAL1 Panel E–stop or SVEMG abnormal

(Explanation) The EMERGENCY STOP button on the operation
panel was pressed, but the EMERGENCY STOP line
was not disconnected.
(Action 1) Check the EMERGENCY STOP button on the
operation panel, and replace it if necessary.
(Action 2) Replace the panel board.
(Action 3) Replace the servo amplifier.

NOTE
This alarm might occur if the EMERGENCY STOP button
is pressed slowly.

Servo amplifier Emergency stop botton

Main board
Panel board
Emergency
stop button

Main board

Emergency stop button Servo amplifier

Panel board

Emergency stop board

MCC unit

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(81)SRVO–202 SVAL1 TP E–stop or SVEMG abnormal

(Explanation) The EMERGENCY STOP button on the teach
pendant was pressed, but the EMERGENCY STOP
line was not disconnected.
(Action 1) Check the teach pendant connection cable, and
replace it if necessary.
(Action 2) Replace the teach pendant.
(Action 3) Replace the panel board.
(Action 4) Replace the servo amplifier.

NOTE
This alarm might occur if the EMERGENCY STOP button
is pressed slowly.

Servo amplifier
Main board

Panel board
EMERGENCY
STOP board

Main board

Emergency stop button Servo amplifier

Panel board

Emergency stop board

MCC unit

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(82)SRVO–203 SVAL1 SVON input (SVEMG abnormal)

(Explanation) The switch connected across SVOFF1 and SVOFF2
on the TBOP1 terminal board on the panel board was
pressed, but the emergency stop line was not
disconnected.
(Action 1) Replace the panel board.
(Action 2) Replace the servo amplifier.
Servo amplifier
Main board

EMERGENCY
STOP board
Panel board

Main board

Emergency stop button Servo amplifier

Panel board

Emergency stop board

MCC unit

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(83)SRVO–204 SVAL1 External (SVEMG abnormal) E–stop

(Explanation) The switch connected across EMGIN1 and EMGIN2
on the TBOP1 terminal board on the panel board was
pressed, but the EMERGENCY STOP line was not
disconnected.
(Action 1) Replace the panel board.
(Action 2) Replace the servo amplifier.

Servo amplifier
Main board

Panel board
EMERGENCY
STOP board

Main board

Emergency stop button Servo amplifier

Panel board

Emergency stop board

MCC unit

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(84)SRVO–205 SVAL1 Fence open (SVEMG abnormal)

(Explanation) The switch connected across FENCE1 and FENCE2
on the TBOP1 terminal board on the panel board was
pressed, but the EMERGENCY STOP line was not
disconnected.
(Action 1) Replace the panel board.
(Action 2) Replace the servo amplifier.
Servo amplifier
Main board
Panel board

EMERGENCY
STOP board

Main board

Emergency stop button Servo amplifier

Panel board

Emergency stop board

MCC unit

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(85)SRVO–206 SVAL1 Deadman switch (SVEMG abnormal)

(Explanation) The DEADMAN switch was released when the teach
pendant was enabled, but the EMERGENCY STOP
line was not disconnected.
(Action 1) Check the teach pendant connection cable. Replace it
if necessary.
(Action 2) Replace the teach pendant.
(Action 3) Replace the panel board.
(Action 4) Replace the servo amplifier.

Servo amplifier
Main board
Panel board
EMERGENCY
STOP board

Main board

Emergency stop button Servo amplifier

Panel board

Emergency stop board

MCC unit

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(86)SRVO–207 SVAL1 TP switch abnormal or door open

(Explanation) The teach pendant is enabled, and the deadman switch
has been grasped, but the EMERGENCY STOP line
is kept disconnected. Alternatively, the control unit
door is open. (In case of A–cabinet)
(Action 1) Close the control unit door, if open. (In case of
A–cabinet)
(Action 2) Check the door switch, and replace it if necessary. (In
case of A–cabinet)
(Action 3) Check the teach pendant connection cable, and
replace it if necessary.
(Action 4) Replace the teach pendant.
(Action 5) Replace the panel board.
(Action 6) Replace the servo amplifier.
Servo amplifier
Main board
Panel board
EMERGENCY
STOP board

Door switch
Main board

Emergency stop button Servo amplifier

Panel board

Emergency stop board

MCC unit

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(87)SRVO–208 SVAL2 Extended axis brake abnormal

(Group : i Axis : j)
(Explanation) An alarm has occured in the brake circuit of extended
axis.
(Action) Replace the servo amplifier.
Servo amplifier

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3.6
(1) When the fuses of the power supply unit have blown
TROUBLESHOOTING F1: Fuse for AC input
BASED ON FUSE F3: Fuse for +24 E
F4: Fuse for +24 V
Name Symptom observed when fuse has blown Action
F1 The LED (PIL: Green) of the power supply unit does not light, and 1 Check the units (fans) and cables connected to the CP2 and
the power cannot be turned on. CP3 connectors of the power supply unit to see if there is any
short circuit.
2 Replace the power supply unit.
F3 If the fuse blows when the power supply is turned on, an alarm 1 Check the printed circuit boards, units, and cables using +24
such as for overtravel, hand breakage, FSSB breakage LVAL is E according to the power supply system diagram. Replace a
output on the teach pendant. faulty printed circuit board, unit, servo amplifier or cable if any.
Seven segment LED of servo amplifier indicates “8”. 2 Replace the power supply unit.
If the fuse turns out to have already blown when the power supply
is turned on, the FSSB initialization alarm is displayed on the
teach pendant.
F4 The power, when turned on, is immediately turned off. At this 1 Check the printed circuit boards, units, and cables using +24
time, the LED (ALM: Red) lights. V according to the power supply system diagram. Replace a
faulty printed circuit board, unit, or cable if any. The LED of
ALM is turned off by pressing the OFF button once.
2 Replace the power supply unit.

Power supply unit

F1 8.0A F3 7.5A
Fuse for AC input Fuse for +24E

F4 7.5A
Fuse for +24V
PIL
LED (green) for AC power
supply display

ALM
LED (red) for alarm display

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(2) Servo amplifier fuse

FU1 : For transformer regenerative resistance thermostat detection,
end effector and protecting +24E.
F1, F2 : Fuses for detection of the circuit failure in the servo amplifier.
Name Symptom observed when fuse has blown Action
FU1 The DCAL, Robot over travel, Hand broken alarm is 1 Check +24E used by the end effecter for a ground fault.
output on the teach pendant. 2 Replace the regenerative resistance.
3 Replace the transformer.
4 Replace the servo amplifier.
F1 The OHAL1 alarm is output on the teach pendant, and 1 Check if the cables connected to three phase input of servo amplifier is
F2 the seven–segment LED on the servo amplifier indi- defective.
cate 3. 2 Replace the servo amplifier.

Fuse FU1

Fuse F2

Fuse F1

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(3) Fuse on the process I/O printed circuit board

FUSE1: Fuse for +24 E
Name Symptom observed when fuse has blown Action
FUSE1 The LED (ALM–2 or FALM) on the process I/O printed circuit 1 Check if the cables and peripheral equipment connected to
board lights, and an alarm such as IMSTP input is output on the the process I/O printed circuit board are normal.
teach pendant. (The display data depends on state of peripheral 2 Replace the process I/O printed circuit board.
equipmentconnection.)

Process I/O board EA, EB

Fuse location position is common to EA and EB. The following is figure of EA.

Total version

Process I/O board FA

Total version

Fig.3.6 (a) Troubleshooting Based on Fuse

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Process I/O board GA

Total version

FUSE1 LED : FALM

Fig.3.6 (b) Troubleshooting Based on Fuse

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Process I/O board CA,CB

FUSE1

Process I/O board DA

FUSE1

Fig.3.6 (c) Troubleshooting Based on Fuse

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3.7 The printed circuit boards and servo amplifier are provided with alarm
LEDs and status LEDs. The LED status and corresponding
TROUBLESHOOTING troubleshooting procedures are described below.
BASED ON LED
INDICATIONS
Main board
Process I/O board
Power supply unit
Servo amplifier

Panel board

Main board
Process I/O board Power supply unit

Servo amplifier
Panel board

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(1) TROUBLESHOOTING USING THE LEDS ON THE MAIN

BOARD
To troubleshoot an alarm that arises before the teach pendant is ready
to display, check the status LEDs (green) on the main board at
power–on. If the robot’s status is normal, all the status LEDs will be
lit.
After power–on, the LEDs light as described in steps 1 to 17, in the
order described. If an alarm is detected, the step in which the alarm
occurred can be determined from which LEDs are lit.
Step LED Action to be taken
1: After power–on, all LEDs are [Action1] Replace the CPU card
lit. * [Action2] Replace the main board.

2: Software operation start–up. [Action1] Replace the CPU card

* [Action2] Replace the main board.

3: The initialization of dram on [Action1] Replace the CPU card

the CPU card is completed. * [Action2] Replace the main board.

4: The initialization of SRAM [Action1] Replace the CPU card

and DPRAM is completed. * [Action2] Replace the main board.
* [Action3] Replace the flash ROM module.

5: The initialization of the com- * [Action1] Replace the main board.

munication IC is completed. * [Action2] Replace the flash ROM module.

6: The loading of the basic soft- * [Action1] Replace the main board.
ware is completed. * [Action2] Replace the flash ROM module.

7: Basic software start–up. * [Action1] Replace the main board.

* [Action2] Replace the flash ROM module.

8: Start–up of communication * [Action1] Replace the main board.

with the teach pendant. * [Action2] Replace the flash ROM module.

9: The loading of optional soft- * [Action1] Replace the main board.

ware is completed. [Action2] Replace the process I/O board.

10:DI/DO initialization * [Action1] Replace SRAM module.

* [Action2] Replace the main board.

* If the main board or SRAM module is replaced, the contents of memory (parameters, specified data, etc.) will
be lost. Before you replace the unit, therefore, make a backup copy of the data. Similarly, make a backup
copy of the current data when you replace the Flash ROM module with one of a later software edition.

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Step LED Action to be taken

11:The preparation of the SRAM [Action1] Replace the axis control card.
module is completed. * [Action2] Replace the main board.
[Action3] Replace the servo amplifier.

12:Axis control card initialization [Action1] Replace the axis control card.
* [Action2] Replace the main board.
[Action3] Replace the servo amplifier.

13:Calibration is completed. [Action1] Replace the axis control card.

* [Action2] Replace the main board.
[Action3] Replace the servo amplifier.

14:Start–up of power application * [Action1] Replace the main board.

for the servo system

15:Program execution * [Action1] Replace the main board.

[Action2] Replace the process I/O board.

16:DI/DO output start–up. * [Action1] Replace the main board.

17: Initialization is terminated. Initialization has ended normally.

18:Troubleshooting is Status LEDs 1 and 2 blink when the system is operating normally.
completed. ll

* If the main board or SRAM module is replaced, the contents of memory (parameters, specified data, etc.) will
be lost. Before you replace the unit, therefore, make a backup copy of the data. Similarly, make a backup
copy of the current data when you replace the Flash ROM module with one of a later software edition.

CPU card

SRAM module

Axis control card Flash ROM module

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(2) TROUBLESHOOTING BY 7–SEGMENT LED INDICATOR

7–segment LED
Description
indicator
[Description] A parity alarm condition has occurred in RAM on the CPU card installed on the main
board.
[Action1] Replace the CPU card.
[Action2] Replace the main board.

[Description] A parity alarm condition has occurred in RAM on the SRAM module installed on the
main board.
[Action1] Replace the SRAM module.
[Action2] Replace the main board.

[Description] A bus error has occurred in the communication controller.

[Action] Replace the main board.

[Description] A parity alarm condition has occurred in DRAM controlled by the communication con-
troller.
[Action] Replace the main board.

[Description] A communication error has occurred during communication with the panel board.
[Action1] Check the communication cable (optical cable) between the main and panel boards,
and replace it if necessary.
[Action2] Replace the main board.
[Action3] Replace the panel board.
[Description] A servo alarm condition has occurred on the main board.
[Action1] Replace the axis control card.
[Action2] Replace the main board.

[Description] The SYSEMG alarm has occurred.

[Action1] Replace the axis control card.
[Action2] Replace the CPU card.
[Action3] Replace the main board.

[Description] The SYSFAIL alarm has occurred.

[Action1] Replace the axis control card.
[Action2] Replace the CPU card.
[Action3] Replace the main board.

* If the main board or SRAM module is replaced, the contents of memory (parameters, specified data, etc.) will
be lost. Before you replace the unit, therefore, make a backup copy of the data. Similarly, make a backup
copy of the current data when you replace the Flash ROM module with one of a later software edition.

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Troubleshooting by LEDs on power supply unit

LED indication Failure description and required measure

[Description] When ALM LED (red) turned on, power supply alarm has occurred.
[Action1] Check fuse F4 (+24V) on the power supply unit, and replace it if it has blown.
[Action2] Check the printed–circuit boards powered by the DC power supplies (+5V, 15V,
and +24V), the relevant units, and cables, and replace them if defective.
[Action3] Replace the power supply unit.

[Description] If the PIL LED (Green) does not light, the power supply unit has not been sup-
plied with 200 VAC.
[Action1] Check fuse F1 on the power supply unit, and replace it if it has blown.
For detailed causes of fuse blown out, please refer to section 3.1.
[Action2] Replace the power supply unit.

F1 8.0A F3 7.5A
Fuse for AC input Fuse for +24E

F4 7.5A
Fuse for +24V

PIL
LED (green) for AC power
supply display

ALM
LED (red) for alarm display

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3. TROUBLESHOOTING MAINTENANCE B–80945EN/02

Troubleshooting by LED on the panel board

LED indication Failure description and required measure
[Description] When the LED (green) cloes not light. Communication with the main board
does not execute.
[Action1] Check the communication cable (optical cable) between the main and panel
boards, and replace it if necessary.
[Action2] Replace the main board.
[Action3] Replace the panel board.

Panel board (A20B–2100–0420)

Total version LED

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B–80945EN/02 MAINTENANCE 3. TROUBLESHOOTING

Troubleshooting by alarm LEDs on the process I/O printed circuit board

LED Description and action to be taken
Process I/O CA/CB/DA Process I/O EA/EB/FA/GA [Description] A communication alarm occurred between the main CPU
PC board and process I/O PC board.
[Action1] Replace the process I/O PC board.
* [Action2] Replace the main CPU PC board.
[Action3] Replace the I/O link connection cable.
ALMO

FALM
Process I/O CA/CB/DA Process I/O EA/EB/FA/GA [Description] A fuse on the process I/O PC board is blown.
[Action1] Replace the blown fuse on the process I/O PC board.
[Action2] Examine the cables and peripheral devices connected to the
process I/O PC board.
Replace any failed components.
ALMO
[Action3] Replace the process I/O PC board.

FALM

Fuse

Fuse

For process I/O printed circuit board CA/CB/DA Process I/O PC board EA/EB/FA/GA
Specificalion : A60l–0001–0046#2.0 Fuse Specification : A60L–0001–0046#2.0

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3. TROUBLESHOOTING MAINTENANCE B–80945EN/02

Troubleshooting by The servo amplifier has alarm LEDs and a seven–segment LED.
LEDs on servo amplifier Troubleshoot the alarm indicated by the LEDs, referring also to the alarm
indication on the teach pendant.

Name LED Description

Brake failure The brake control circuit in the servo amplifier is defective.

Corresponding alarm
Servo–018 Brake failure
Electromagnetic con- This alarm is issued when a contact of the electromagnetic contactor melts.
tactor melt alarm
The corresponding alarm is:
Servo–042 MCAL Alarm
Servo amplifier over- The servo amplifier blow or the thermostat in the transformer tripped.
heat
Corresponding alarm
Servo–049 OHAL1 Alarm
Insufficient DC link The DC voltage being supplied to the main circuit is too low.
voltage
Corresponding alarm
Servo–136 DCLVAL Alarm
Insufficient control The voltage being supplied to the control circuit (+5V, +24E, +15V, –15V) is too low.
supply voltage
Corresponding alarm
Servo–047 LVAL Alarm
Excessive voltage The DC voltage being supplied to the main circuit is too high.

Corresponding alarm
Servo–044 HVAL Alarm
Excessive regenera- This alarm occurs, if the amount of regenerative discharge energy is abnormally large,
tive discharge the regenerative resistance is defective, or fuse FU1 in the servo amplifier has blown.
Corresponding alarm
Servo–043 DCAL Alarm
FSSB Broken–wire A broken wire was detected during communication between the main board and servo amplifier.
alarm
Corresponding alarm
SERVO – 057 FSSB Broken–wire alarm
FSSB Broken–wire A broken wire was detected during communication between the servo amplifier and the additional–
alarm axis servo amplifier.

Corresponding alarm
SERVO – 057 FSSB Broken–wire alarm
Servo amplifier not The electromagnetic contactor for the main power supply is open. The amplifier is not ready to drive
ready the motor.

Servo amplifier ready The electromagnetic contactor for the main power supply is closed. The amplifier is ready to drive
the motor. (Normal operating status.)

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B–80945EN/02 MAINTENANCE 3. TROUBLESHOOTING

HC1 to HC6
[Description] An excessive current was detected in the main circuit
of the servo amplifier.
The 7–segment LED on the servo amplifier displays
a hyphen (–). Of LEDs HC1 to HC6, above the
7–segment LED, the LED corresponding to the axis
on which HCAL occurred lights (red).
Corresponding alarm
SERVO–045 HCAL alarm
IPM1 to IPM6
[Description] An excessive current was detected in the main circuit
of the servo amplifier.
The 7–segment LED on the servo amplifier displays
a hyphen (–). Of LEDs IPM1 to IPM6, above the
7–segment LED, the LED corresponding to the axis
on which HCAL occurred lights (red).
Corresponding alarm
SERVO–156 IPMAL alarm
WD
[Description] A watch–dog alarm occurred on the servo amplifier
control PC board.
The WD LED (red) on the servo amplifier is lit.
Corresponding alarm
SERVO–021 SRDY off
LINK
[Description] This LED (green) lights, when communication
between the main board and servo amplifier is
normal. It is turned off if a communication error
occurs.
This LED goes off if the 7–segment LED on the main
board indicates a number from 0 to 6.

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3. TROUBLESHOOTING MAINTENANCE B–80945EN/02

3.8
(Check 1) On the status screen, check the position deviation in the
POSITION DEVIATION stopped state. To display the position deviation, press the
FOUND IN RETURN screen selection key, and select STATUS from the menu.
TO THE REFERENCE Press F1, [TYPE], select AXIS from the menu, then press
the F4, PULSE.
POSITION (Corrective action)
(POSITIONING) Correct the parameters related to return to the reference
position (positioning).
(Check 2) Check whether the motor axis can be positioned normally.
(Corrective action)
If the motor axis can be positioned normally, check the
mechanical unit.
(Check 3) Check the mechanical unit for backlash.
(Corrective action)
Replace a faulty key of motor shaft or other faulty parts.
(Check 4) If checks 1 to 3 show normal results
(Corrective action)
Replace the pulse coder and main board.

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3.9
(Check 1) Check the settings of parameters such as the position loop
VIBRATION gain parameter.
OBSERVED DURING (Corrective action)
MOVEMENT Correct parameters.
(Check 2) Check the mechanical unit for backlash.
(Corrective action)
Replace a faulty key of motor shaft or other faulty parts.

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3. TROUBLESHOOTING MAINTENANCE B–80945EN/02

3.10 The following explains checking and corrective action required if the
robot cannot be operated manually after the controller is turned on:
MANUAL (1) Check and corrective action to be made if manual operation is
OPERATION impossible
IMPOSSIBLE (Check 1) Check whether the teach pendant is on.
(Corrective action)
Turn on the teach pendant.
(Check 2) Check whether the teach pendant is handled correctly.
(Corrective action)
To move an axis by manual operation, press the axis
selection key and case shift key at the same time.
Set the override for manual feed to a position other than the
FINE and VFINE positions.
(Check 3) Check whether the ENBL signal of the peripheral device
control interface is set to 1.
(Corrective action)
Place the peripheral device control interface in the ENBL
status.
(Check 4) Check whether the HOLD signal of the peripheral device
control interface or the HOLD switch on the operator’s panel
is on (hold status). (Check whether the hold lamp on the
teach pendant is on.)
(Corrective action)
Turn off the HOLD signal of the peripheral device control
interface or the HOLD switch on the operator’s panel.
(Check 5) Check whether the previous manual operation has been
completed.
(Corrective action)
If the robot cannot be placed in the effective area because of
the offset of the speed command voltage preventing the
previous operation from being completed, check the position
deviation on the status screen, and change the setting.
(Check 6) Check whether the controller is in the alarm status.
(Corrective action)
Release the alarm.
(2) Check and corrective action to be taken if the program cannot be
executed
(Check 1) Check whether the ENBL signal for the peripheral-device
control interface is on.
(Corrective action)
Put the peripheral-device control interface in the ENBL state.
(Check 2) Check whether the HOLD signal for the peripheral-device
control interface is on. Also check whether the HOLD
switch on the operator’s panel is on. (Check whether the
HOLD lamp on the teach pendant is on.)
(Corrective action)
If the HOLD signal is on, turn it off. If the HOLD switch
is on, turn it off.
(Check 3) Check whether the previous manual operation has been
completed.
(Corrective action)
If the robot cannot be placed in the effective area because of
the offset of the speed command voltage, which prevents the
previous operation from being completed, check the position
deviation on the status screen, then change the setting.
(Check 4) Check whether the controller is in the alarm status.
(Corrective action)
Release the alarm.

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4 PRINTED CIRCUIT BOARDS

The printed circuit boards are factory-set for operation. Usually, you do
not need to set or adjust them. This chapter describes the standard settings
and adjustment required if a defective printed circuit board is replaced.
It also describes the test pins and the LED indications.
The standard printed circuit board includes the main unit printed circuit
board and one or more cards or modules installed horizontally to the
main–unit printed–circuit board.
These PC boards have interface connectors, LED indicators, and a plastic
panel at the front. At the rear, there is a backplane connector.

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4. PRINTED CIRCUIT BOARDS MAINTENANCE B–80945EN/02

4.1
MAIN BOARD
(A16B–3200–0330,
–0331)
SRAM module
Axis control card
Flash ROM module CPU card Total version

Axis control card SRAM module

Flash ROM module CPU card
Total version

(Note)

(Note) These are not prepared for A16B–3200–0330

Fig.4.1 Main board

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B–80945EN/02 MAINTENANCE 4. PRINTED CIRCUIT BOARDS

(1) Test pins

Name Use
GND1
GND2
GND3
For testing the printed circuit board
CACHOFF
LOAD
MCBOOT

(2) LEDs
Seven segment LED Description

A parity alarm occurred in a RAM of the main CPU

card on the main board.

A parity alarm occurred in a RAM of the SRAM mod-

ule on the main board.

Bus error occurred on the communication controller.

A parity alarm occurred in DRAM controlled by com-

munication controller.

A communication error occurred between panel

boards and main board.

A servo alarm occurred on the main board.

SYSEMG occurred.

SYSFAIL occurred.
This number appears temporarily after the power is
switched on, but it is not abnormal.

Status LED Description

STATUS Operating status of the system.

LED

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4.2
EMERGENCY STOP
CONTROL PC
BOARD
(A20B–1007–0440) Total
version

Fig.4.2 Emergency stop control PC board

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B–80945EN/02 MAINTENANCE 4. PRINTED CIRCUIT BOARDS

4.3
(A20B–2002–0771)
BACKPLANE PC
BOARD

Total version

Fig.4.3 (a) Backplane PC Board

(1) Test pins
Name Use
HI1
TEST1 For testing the printed circuit board
LOW1

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4. PRINTED CIRCUIT BOARDS MAINTENANCE B–80945EN/02

(A20B–2002–0761)

Total
version

Test pins

Fig.4.3 (b) Backplane PC Board

(1) Test pins
Name Use
HI1
TEST1 For testing the printed circuit board
LOW1

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B–80945EN/02 MAINTENANCE 4. PRINTED CIRCUIT BOARDS

(A20B–2002–0751)

Total version

Fig.4.3 (c) Backplane PC Board

(1) Test pins

Name Use
HI1
TEST1 For testing the printed circuit board
LOW1

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4. PRINTED CIRCUIT BOARDS MAINTENANCE B–80945EN/02

4.4
PANEL BOARD
(A20B–2100–0420,
0421, 0423)

A20B–2100–0420: For operation box type A Total version LED

A20B–2100–0421 : For B–cabinet
A20B–2100–0423 : For operation box type B

Fig.4.4 Panel Board

(1) LED
Name Use
Communication status with main board
LED1 ON Normal
OFF Communication error

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4.5
PROCESS I/O
BOARD EA
(A16B–3200–0230)

Fig.4.5 Process I/O Board EA

(1) Test pins

Name Use
P24V +24V
P5V +5V
P15VC +15V
For measuring the DC supply voltage
M15VC –15V
GND1 GND
GND2 GND

P10V +10V For measuring the reference voltage of the digital/

analog converter
P15VF +15V
M15VF –15V Power for the digital/analog converter
GNDF GND
AI1 Channel 1
AI2 Channel 2
AI3 Channel 3 For measuring the voltage of the analog input signal
AI4 Channel 4 (analog/digital)
AI5 Channel 5
AI6 Channel 6
AOUT1 Channel 1 For measuring the voltage of the analog output sig-
AOUT2 Channel 2 nal (digital/analog)
(2) Settings
Name Standard Description
setting

ICOM1 UDI1 to UDI20

(Connector CRM2A)
The common voltage is
ICOM2 UDI21 to UDI40 Side A adjusted to:
(Connector CRM2B) Side A : +24 V common
Side B : 0 V common
ICOM3 WDI01 to WDI08
(Connector CRW1)
SP1 Channel 1 The polarity of the output voltage
Open is switched to:
Strapped : Negative (–)
SP2 Channel 2 Open : Positive (+)

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4. PRINTED CIRCUIT BOARDS MAINTENANCE B–80945EN/02

(3) Adjustment
VR1: Adjusts the gain of channel 1.
Execute a robot program and set AOUT[1] to 4095 on the teach
pendant. Connect a digital voltmeter to test pin AOUT1 and
rotate VR1 until the meter reads 12.0 V.
Connect the negative (–) lead of the digital voltmeter to test pin
GNDF.
VR2: Adjusts the gain of channel 2.
Execute a robot program and set AOUT[2] to 4095 on the teach
pendant. Connect the digital voltmeter to test pin AOUT2 and
rotate VR2 until the meter reads 12.0 V.
Connect the negative (–) lead of the digital voltmeter to test pin
GNDF. (The 0VF test pin is different from the common 0V test
pin.)
VR3: Adjusts the reference supply voltage of the digital/analog
converter.
Connect the digital voltmeter to test pin P10V and rotate VR3
until the meter reads 10.0"0.1 V.
VR4, VR5: Internal power supply adjustment
These VRs are used to adjust the internal supply voltage for the
printed circuit board. They are set at the factory and need not
be adjusted.
(4) LEDs
Color Description

ALMO A communication alarm occurred between

Red the main CPU and process I/O board.

FALM

ALMO A fuse (FUSE 1) in the process I/O board

Red blew.

FALM

(5) Correspondence between driver chips and DO signals

Ordering code for the driver chips: A76L-0151-0062
Driver chip DO signal
DV1 CMDENBL, SYSRDY, PROGRUN, PAUSED
DV2 HELD, FALT, ATPERCH, TPENBL
DV3 BATALM, BUSY, ACK1/SNO1, ACK2/SNO2
DV4 ACK3/SNO3, ACK4/SNO4, ACK5/SNO5, ACK6/SNO6
DV5 ACK7/SNO7, ACK8/SNO8, SNACK, RESERVED
DV6 SDO01, SDO02, SDO03, SDO04
DV7 SDO05, SDO06, SDO07, SDO08
DV8 SDO09, SDO10, SDO11, SDO12
DV9 SDO13, SDO14, SDO15, SDO16
DV10 SDO17, SDO18, SDO19, SDO20
DV11 WDO01, WDO02, WDO03, WDO04
DV12 WDO05, WDO06, WDO07, WDO08

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4.6
PROCESS I/O
BOARD EB
(A16B–3200–0231)

Total version

Fig.4.6 Process I/O Board EB

(1) Test pins

Name Use
P24V +24V
P5V +5V
For measuring the DC supply voltage
GND1 GND
GND2 GND

(2) Settings
Name Standard Description
setting
UDI1 to UDI20 The common voltage is
ICOM1
(Connector CRM2A) adjusted to:
Side A Side A : +24 V common
UDI21 to UDI40
ICOM2 Side B : 0 V common
(Connector CRM2B)

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4. PRINTED CIRCUIT BOARDS MAINTENANCE B–80945EN/02

(3) LEDs
Color Description

A communication alarm occurred between

Red the main CPU and process I/O board.

A fuse (FUSE 1) in the process I/O board

Red blew.

(4) Correspondence between driver IC and DO signals

Ordering code for the driver IC: A76L-0151-0062
Driver IC DO signal
DV1 CMDENBL, SYSRDY, PROGRUN, PAUSED
DV2 HELD, FALT, ATPERCH, TPENBL
DV3 BATALM, BUSY, ACK1/SNO1, ACK2/SNO2
DV4 ACK3/SNO3, ACK4/SNO4, ACK5/SNO5, ACK6/SNO6
DV5 ACK7/SNO7, ACK8/SNO8, SNACK, RESERVED
DV6 SDO01, SDO02, SDO03, SDO04
DV7 SDO05, SDO06, SDO07, SDO08
DV8 SDO09, SDO10, SDO11, SDO12
DV9 SDO13, SDO14, SDO15, SDO16
DV10 SDO17, SDO18, SDO19, SDO20

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4.7
PROCESS I/O
BOARD FA
(A16B–2203–0420)

Total version

Fig.4.7 Process I/O Board FA

(1) Test pins

Name Use
P24V +24V
P5V +5V
For measuring the DC supply voltage
GND1 GND
GND2 GND

(2) Settings
Name Standard Description
setting
UDI1 to UDI20
ICOM1
(Connector CRM2A)
UDI21 to UDI40
ICOM2
(Connector CRM2B)
UDI41 to UDI60 The common voltage is
ICOM3
(Connector CRM2C) adjusted to:
Side A Side A : +24 V common
UDI61 to UDI80
ICOM4 Side B : 0 V common
(Connector CRM2D)
UDI81 to UDI88
ICOM5
(Connector CRM4A)
UDI89 to UDI96
ICOM6
(Connector CRM4B)

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4. PRINTED CIRCUIT BOARDS MAINTENANCE B–80945EN/02

(3) LEDs
Color Description

A communication alarm occurred between

Red the main CPU and process I/O board.

A fuse (FUSE 1) in the process I/O board

Red blew.

(4) Correspondence between driver IC and DO signals

Ordering code for the driver IC: A76L-0151-0062
Driver IC DO signal
DV1 CMDENBL, SYSRDY, PROGRUN, PAUSED
DV2 HELD, FALT, ATPERCH, TPENBL
DV3 BATALM, BUSY, ACK1/SNO1, ACK2/SNO
DV4 ACK3/SNO3, ACK4/SNO4, ACK5/SNO5, ACK6/SNO6
DV5 ACK7/SNO7, ACK8/SNO8, SNACK, RESERVED
DV6 SDO01, SDO02, SDO03, SDO04
DV7 SDO05, SDO06, SDO07, SDO08
DV8 SDO09, SDO10, SDO11, SDO12
DV9 SDO13, SDO14, SDO15, SDO16
DV10 SDO17, SDO18, SDO19, SDO20
DV11 SDO21, SDO22, SDO23, SDO24
DV12 SDO25, SDO26, SDO27, SDO28
DV13 SDO29, SDO30, SDO31, SDO32
DV14 SDO33, SDO34, SDO35, SDO36
DV15 SDO37, SDO38, SDO39, SDO40
DV16 SDO41, SDO42, SDO43, SDO44
DV17 SDO45, SDO46, SDO47, SDO48
DV18 SDO49, SDO50, SDO51, SDO52
DV19 SDO53, SDO54, SDO55, SDO56
DV20 SDO57, SDO58, SDO59, SDO60
DV21 SDO61, SDO62, SDO63, SDO64
DV22 SDO65, SDO66, SDO67, SDO68
DV23 SDO69, SDO70, SDO71, SDO72
DV24 SDO73, SDO74, SDO75, SDO76

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4.8
PROCESS I/O
BOARD CA
(A16B–2201–0470)

Fig.4.8 Process I/O Board CA

(1) Test pins

Name Use
P24V +24V
P5V +5V
P15VC +15V
For measuring the DC supply voltage
M15VC –15V
GND1 GND
GND2 GND
For measuring the reference voltage of the
P10V +10V
digital/analog converter
P15VF +15V
M15VF –15V Power for the digital/analog converter
GNDF GND
AI1 Channel 1
AI2 Channel 2
AI3 Channel 3 For measuring the voltage of the analog input sig-
AI4 Channel 4 nal (analog/digital)
AI5 Channel 5
AI6 Channel 6
AOUT1 Channel 1 For measuring the voltage of the analog output
AOUT2 Channel 2 signal (digital/analog)

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4. PRINTED CIRCUIT BOARDS MAINTENANCE B–80945EN/02

(2) Settings
Name Standard Description
setting
UDI1 to UDI20
ICOM1
(Connector CRM2A) The common voltage is
UDI21 to UDI40 adjusted to:
ICOM2 Side A
(Connector CRM2B) Side A : +24 V common
WDI01 to WDI08 Side B : 0 V common
ICOM3
(Connector CRW1)

SP1 Channel 1 The polarity of the output voltage

is switched to:
Open
Strapped : Negative (–)
SP2 Channel 2
Open : Positive (+)

(3) Adjustment
VR1: Adjusts the gain of channel 1.
Execute a robot program and set AOUT[1] to 4095 on the teach
pendant. Connect a digital voltmeter to test pin AOUT1 and
rotate VR1 until the meter reads 12.0 V.
Connect the negative (–) lead of the digital voltmeter to test pin
GNDF.
VR2: Adjusts the gain of channel 2.
Execute a robot program and set AOUT[2] to 4095 on the teach
pendant. Connect the digital voltmeter to test pin AOUT2 and
rotate VR2 until the meter reads 12.0 V.
Connect the negative (–) lead of the digital voltmeter to test pin
GNDF. (The 0VF test pin is different from the common 0V test
pin.)
VR3: Adjusts the reference supply voltage of the digital/analog
converter.
Connect the digital voltmeter to test pin P10V and rotate VR3
until the meter reads 10.0 "0.1 V.
(4) LEDs
Color Description

A communication alarm occurred between

Red
the main CPU and process I/O board.

A fuse (FUSE 1) in the process I/O board

Red
blew.

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(5) Correspondence between driver chips and DO signals

Ordering code for the driver chips: A76L-0151-0062
Driver chip DO signal
DV1 CMDENBL, SYSRDY, PROGRUN, PAUSED
DV2 HELD, FALT, ATPERCH, TPENBL
DV3 BATALM, BUSY, ACK1/SNO1, ACK2/SNO2
DV4 ACK3/SNO3, ACK4/SNO4, ACK5/SNO5, ACK6/SNO6
DV5 ACK7/SNO7, ACK8/SNO8, SNACK, RESERVED
DV6 SDO01, SDO02, SDO03, SDO04
DV7 SDO05, SDO06, SDO07, SDO08
DV8 SDO09, SDO10, SDO11, SDO12
DV9 SDO13, SDO14, SDO15, SDO16
DV10 SDO17, SDO18, SDO19, SDO20
DV11 WDO01, WDO02, WDO03, WDO04
DV12 WDO05, WDO06, WDO07, WDO08
RESERVED For replacement

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4.9
PROCESS I/O
BOARD CB
(A16B–2201–0472)

Test pins

Fig.4.9 Process I/O Board CB

(1) Test pins

Name Use
P24V +24V
P5V +5V
P15VC +15V
For measuring the DC supply voltage
M15VC –15V
GND1 GND
GND2 GND

(2) Settings
Name Standard Description
setting
UDI1 to UDI20 The common voltage is
ICOM1
(Connector CRM2A) adjusted to:
Side A
UDI21 to UDI40 Side A : +24 V common
ICOM2 Side B : 0 V common
(Connector CRM2B)

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(3) LEDs
Color Description

A communication alarm occurred between

Red
the main CPU and process I/O board.

A fuse (FUSE 1) in the process I/O board

Red
blew.

(4) Correspondence between driver chips and DO signals

Ordering code for the driver chips: A76L-0151-0062
Driver chip DO signal
DV1 CMDENBL, SYSRDY, PROGRUN, PAUSED
DV2 HELD, FALT, ATPERCH, TPENBL
DV3 2BATALM, BUSY, ACK1/SNO1, ACK2/SNO
DV4 ACK3/SNO3, ACK4/SNO4, ACK5/SNO5, ACK6/SNO6
DV5 ACK7/SNO7, ACK8/SNO8, SNACK, RESERVED
DV6 SDO01, SDO02, SDO03, SDO04
DV7 SDO05, SDO06, SDO07, SDO08
DV8 SDO09, SDO10, SDO11, SDO12
DV9 SDO13, SDO14, SDO15, SDO16
DV10 SDO17, SDO18, SDO19, SDO20
RESERVED For replacement

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4. PRINTED CIRCUIT BOARDS MAINTENANCE B–80945EN/02

4.10
PROCESS I/O
BOARD DA
(A16B–2201–0480)

Total version

Test pins

Fig.4.10 Process I/O Board DA

(1) Test pins

Name Description
P24V +24V
P5V +5V
For measuring the DC supply voltage
GND1 GND
GND2 GND

(2) Settings
Name Standard Description
setting
UDI01 to 20
ICOM1
(Connector CRM2A)
UDI21 to 40
ICOM2
(Connector CRM2B)
UDI41 to 60 The common voltage is
ICOM3
(Connector CRM2C) adjusted to:
Side A
UDI61 to 80 Side A : +24 V common
ICOM4 Side B : 0 V common
(Connector CRM2D)
UDI81 to 88
ICOM5
(Connector CRM4A)
UDI89 to 96
ICOM6
(Connector CRM4B)

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B–80945EN/02 MAINTENANCE 4. PRINTED CIRCUIT BOARDS

(3) LEDs
Color Description

A communication alarm occurred between

Red
the main CPU and process I/O board.

A fuse (FUSE 1) in the process I/O board

Red
below.

(4) Correspondence between driver chips and DO signals

Ordering code for the driver chips: A76L-0151-0062
Driver chip DO signal
DV1 CMDENBL, SYSRDY, PROGRUN, PAUSED
DV2 HELD, FALT, ATPERCH, TPENBL
DV3 BATALM, BUSY, ACK1/SNO1, ACK2/SNO2
DV4 ACK3/SNO3, ACK4/SNO4, ACK5/SNO5, ACK6/SNO6
DV5 ACK7/SNO7, ACK8/SNO8, SNACK, RESERVED
DV6 SDO01, SDO02, SDO03, SDO04
DV7 SDO05, SDO06, SDO07, SDO08
DV8 SDO09, SDO10, SDO11, SDO12
DV9 SDO13, SDO14, SDO15, SDO16
DV10 SDO17, SDO18, SDO19, SDO20
DV11 ADO21, SDO22, SDO23, SDO24
DV12 SDO25, SDO26, SDO27, SDO28
DV13 SDO29, SDO30, SDO31, SDO32
DV14 SDO33, SDO34, SDO35, SDO36
DV15 SDO37, SDO38, SDO39, SDO40
DV16 SDO41, SDO42, SDO43, SDO44
DV17 SDO45, SDO46, SDO47, SDO48
DV18 SDO49, SDO50, SDO51, SDO52
DV19 SDO53, SDO54, SDO55, SDO56
DV20 SDO57, SDO58, SDO59, SDO60
DV21 SDO61, SDO62, SDO63, SDO64
DV22 SDO65, SDO66, SDO67, SDO68
DV23 SDO69, SDO70, SDO71, SDO72
DV24 SDO73, SDO74, SDO75, SDO76
RESERVED For replacement

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4. PRINTED CIRCUIT BOARDS MAINTENANCE B–80945EN/02

4.11
PROCESS I/O
BOARD GA
(A16B–2203–0520)
Total version

Fig.4.11 Process I/O Board GA

(1) Test pins

Name Use
P24V +24V
P5V +5V
GND1 GND For measuring the DC supply voltage
GND2 GND
GND3 GND
P24VF +24V
P5VF +5V Power for the digital/analog converter
GNDF GND
AOUT1 Channel 1 For measuring the voltage of the analog output sig-
AOUT2 Channel 2 nal (digital/analog)

(2) Settings
Name Standard Description
setting

ICOM1 UDI1 to UDI20

(Connector CRM2A)
The common voltage is
ICOM2 UDI21 to UDI40 Side A adjusted to:
(Connector CRM2B) Side A : +24 V common
Side B : 0 V common
ICOM3 WDI01 to WDI08
(Connector CRW7)

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B–80945EN/02 MAINTENANCE 4. PRINTED CIRCUIT BOARDS

(3) Adjustment
VR1/VR2: Adjusts the gain and the offset of channel 1.
Execute a robot program and set AOUT[1] to 3413 on the teach
pendant. Connect a digital voltmeter to test pin AOUT1 and
rotate VR1 or VR2 until the meter reads 15.0 V.
Connect the negative (–) lead of the digital voltmeter to test pin
GNDF.
VR3/VR4: Adjusts the gain and the offset of channel 2.
Execute a robot program and set AOUT[2] to 3413 on the teach
pendant. Connect the digital voltmeter to test pin AOUT2 and
rotate VR3 or VR4 until the meter reads 15.0 V.
Connect the negative (–) lead of the digital voltmeter to test pin
GNDF. (The 0VF test pin is different from the common 0V test
pin.)
(4) LEDs
Color Description

ALMO A communication alarm occurred between

Red the main CPU and process I/O board.

FALM

ALMO A fuse (FUSE 1) in the process I/O board

Red blew.

FALM

(5) Correspondence between driver chips and DO signals

Ordering code for the driver chips: A76L-0151-0062
Driver chip DO signal
DV1 CMDENBL, SYSRDY, PROGRUN, PAUSED
DV2 HELD, FALT, ATPERCH, TPENBL
DV3 BATALM, BUSY, ACK1/SNO1, ACK2/SNO2
DV4 ACK3/SNO3, ACK4/SNO4, ACK5/SNO5, ACK6/SNO6
DV5 ACK7/SNO7, ACK8/SNO8, SNACK, RESERVED
DV6 SDO01, SDO02, SDO03, SDO04
DV7 SDO05, SDO06, SDO07, SDO08
DV8 SDO09, SDO10, SDO11, SDO12
DV9 SDO13, SDO14, SDO15, SDO16
DV10 SDO17, SDO18, SDO19, SDO20

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4. PRINTED CIRCUIT BOARDS MAINTENANCE B–80945EN/02

4.12
PANEL SWITCH
BOARD
(A20B–9002–0310)

Total version

Fig.4.12 Panel Switch Board

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B–80945EN/02 MAINTENANCE 5. SERVO AMPLIFIERS

5 SERVO AMPLIFIERS

The servo amplifiers are factory-set for operation. Usually, you do not
need to set or adjust them.
This chapter describes the standard settings and adjustment required if a
defective servo amplifier is replaced. It also describes the use of test pins
and meanings of the LED indications.
Table 5 Servo amplifier specifications

Robot models Servo amplifier Discharge resistor

S–430iF, S–430iR/130, A05B–2400–C201 (A–cabinet)
A06B–6100–H002
S–430iC, M–710i A05B–2401–C201 (B–cabinet)
S–430iW, S–430iL, S–430iR/165,
A05B–2400–C200 (A–cabinet)
S–430iR/Press HT/Press HS, A06B–6100–H001
A05B–2401–C200 (B–cabinet)
S–430iU, S–900i
A05B–2400–C200 (A–cabinet)
M–410i, M–500i A06B–6100–H001 (Note)
A05B–2401–C200 (B–cabinet)
ARC Mate 100i, M–6i, A05B–2400–C202 (A–cabinet)
A06B–6100–H004
SR Mate 200i A05B–2401–C202 (B–cabinet)
ARC Mate 120i, M–16i, A05B–2400–C201 (A–cabinet)
A06B–6100–H003
S–500i A05B–2401–C201 (B–cabinet)
A05B–2400–C201 (A–cabinet)
A–520i A06B–6100–H003 (Note)
A05B–2401–C201 (B–cabinet)
A05B–2400–C202 (A–cabinet)
F–200i A06B–6100–H006
A05B–2401–C202 (B–cabinet)
ARC Mate 50i, A05B–2400–C202 (A–cabinet)
A06B–6100–H005
LR Mate 200i A05B–2401–C202 (B–cabinet)

NOTE
Robot M410i, M–500i and A–520i are 4–axis robot.

Fuse FU1

Fuse F2

Fuse F1

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5. SERVO AMPLIFIERS MAINTENANCE B–80945EN/02

5.1 The servo amplifier has alarm LEDs and a seven–segment LED.
Troubleshoot the alarm indicated by the LEDs, referring also to the alarm
LED OF SERVO indication on the teach pendant.
AMPLIFIER

Name LED Description

Brake failure The brake control circuit in the servo amplifier is defective.

Corresponding alarm
Servo–018 brake fuse blown?
Electromagnetic contactor This alarm is issued when a contact of the electromagnetic contactor
weld alarm melts.

The corresponding alarm is: Servo 042 – MCAL alarm

Servo amplifier overheat The thermostat in the servo amplifier or transformer tripped or the fuses
F1, F2 in the servo amplifier are blown.

Corresponding alarm
Servo–049 OHAL1 Alarm
Insufficient DC link voltage The DC voltage being supplied to the main circuit is too low.

Corresponding alarm
Servo–047 LVAL Alarm
Insufficient control supply The voltage being supplied to the control circuit (+5V, +24V, +15V, –15V)
voltage is too low.

Corresponding alarm
Servo–047 LVAL Alarm
Excessive voltage The DC voltage being supplied to the main circuit is too high.
(HV)
Corresponding alarm
Servo–044 HVAL Alarm
Excessive regenerative dis- The regenerative discharge energy is too high.
charge An alarm is issued if the regenerative resistance is defective, or the fuse
FU1 in the servo amplifier has blown.

Corresponding alarm
Servo–043 DCAL Alarm

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B–80945EN/02 MAINTENANCE 5. SERVO AMPLIFIERS

Name LED Description

FSSB Broken–wire alarm A broken wire was detected during communication between the main board and
servo amplifier.

Corresponding alarm
SERVO – 057 FSSB Broken–wire alarm
FSSB Broken–wire alarm A broken wire was detected during communication between the servo amplifier and
the additional–axis servo amplifier.

Corresponding alarm
SERVO – 057 FSSB Broken–wire alarm
Servo amplifier not ready The electromagnetic contactor for the main power supply is off. The am-
plifier is not ready to drive the motor.
Servo amplifier ready The electromagnetic contactor for the main power supply is on. The am-
plifier is ready to drive the motor. (Normal operating status.)

HC1 to HC6
[Description] An excessive current was detected in the main circuit
of the servo amplifier.
The 7–segment LED on the servo amplifier displays
a hyphen (–). Of LEDs HC1 to HC6, above the
7–segment LED, the LED corresponding to the axis
on which HCAL occurred lights (red).
Corresponding alarm
SERVO–045 HCAL alarm
IPM1 to IPM6
[Description] An excessive current was detected in the main circuit
of the servo amplifier.
The 7–segment LED on the servo amplifier displays
a hyphen (–). Of LEDs IPM1 to IPM6, above the
7–segment LED, the LED corresponding to the axis
on which IPMAL occurred lights (red).
Corresponding alarm
SERVO–156 IPMAL alarm
WD
[Description] A watch–dog alarm occurred on the servo amplifier
control PC board.
The WD on the servo amplifier occurred lights (red).
Corresponding alarm
SERVO–021 SRDY off
LINK
[Description] The LED (green) lights when communication
between the main board and servo amplifier is
normal. It goes off if a communication error occurs.

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5. SERVO AMPLIFIERS MAINTENANCE B–80945EN/02

5.2 Settings
SETTING OF SERVO Name Standard Description
setting
AMPLIFIER COM1 Side A This jumper sets the common voltage for the
Robot digital Inputs (RDI) to:
Side A : +24V common
Side B : 0V common

Set jumper

BA
Fuse FU1

Fuse F2

Fuse F1

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 6. SETTING AND ADJUSTING
B–80945EN/02 MAINTENANCE THE POWER SUPPLY

6 SETTING AND ADJUSTING THE POWER SUPPLY

The power supply is factory-set for operation. Usually, you do not need
to set or adjust it.
This chapter describes settings and adjustment required if a defective
power supply unit is replaced.

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6. SETTING AND ADJUSTING
THE POWER SUPPLY MAINTENANCE B–80945EN/02

6.1
BLOCK DIAGRAM OF
THE MAIN POWER
INCLUDING POWER
SUPPLY

Transformer Servo amplifier

Amplifier
Power input of Circuit
200 to 575VAC breaker

Supply voltage to the transformer:

Power supply unit

Back plane

Fan

Robot

Motor

Emergency stop control

Brake
PC board
Pulse
coder

End
effector

Main CPU PC board

Operator
box
Teach
pendant

Battery
Process I/O Peripheral
device

Handy File
etc.

Fig.6.1 (a) Block Diagram Main Power, Including Power Supply (A–cabinet)

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 6. SETTING AND ADJUSTING
B–80945EN/02 MAINTENANCE THE POWER SUPPLY

Transformer Servo amplifier

amplifier
Power input of Circuit
200 to 575VAC breaker

Supply voltage to the

transformer:

Power supply unit

Back plane

Fan
Robot

Motor

Brake
Emergency stop board
Pulse
coder

End
effector
I/O

Main board

Operator
panel
Battery
Teach pendant

Process I/O Handy File etc

board

Peripheral
device

Fig.6.1 (b) Block diagram of the power supply (B–cabinet)

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6. SETTING AND ADJUSTING
THE POWER SUPPLY MAINTENANCE B–80945EN/02

6.2 Select a transformer and tap according to the supply voltage. Select a
transformer tap such that the supply voltage is +10% to –15% of the
SELECTING induced voltage.
TRANSFORMER
TAPS

Transformer specification
Power supply voltage For A–cabinet For B–cabinet

A80L–0026–0024(7.5KVA) A80L–0026–0027(7.5KVA)
A80L–0028–0007(10.5KVA) A80L–0028–0010(10.5KVA)

A80L–0026–0022(7.5KVA) A80L–0026–0025(7.5KVA)
A80L–0028–0005(10.5KVA) A80L–0028–0008(10.5KVA)

A80L–0026–0023(7.5KVA) A80L–0026–0026(7.5KVA)
A80L–0028–0006(10.5KVA) A80L–0028–0009(10.5KVA)

Transformer

Transformer mounting locations Transformer structure

Structure of transformer

Transformer

Transformer mounting location

Fig.6.2 (a) Transformer mounting locations and structure

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 6. SETTING AND ADJUSTING
B–80945EN/02 MAINTENANCE THE POWER SUPPLY

Connect the tap according to the supply voltage.

(1) A80L–0026–0022, A80L–0028–0005

A80L–0026–0025, A80L–0028–0008

Input voltage 220 to 240 (∆ connector)

G1–L2, G2–L3, G3–L1
Input voltage 380 to 415 (Y connector)
G1–G2–G3

(2) A80L–0026–0023, A80L–0028–0006

A80L–0026–0026, A80L–0028–0009

Input voltage 200 to 220 (∆ connector)

G1–L2, G2–L3, G3–L1
Input voltage 380 to 400 (Y connector)
G1–G2–G3

(3) A80L–0026–0024, A80L–0028–0007

A80L–0026–0027, A80L–0028–0010

Input voltage: 500 to 575V

Connect the cable from the circuit breaker to side A.
Input voltage: 440 to 480V
Connect the cable from the circuit breaker to side B.

Fig.6.2 (b) Setting a tap

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6. SETTING AND ADJUSTING
THE POWER SUPPLY MAINTENANCE B–80945EN/02

6.3 The power supply unit need not be set or adjusted.

CHECKING THE Table 6.3 Rating of the Power supply unit
POWER SUPPLY Output Rated voltage Tolerance
UNIT +5V +5.1V "3%
+3.3V +3.3V "3%
+24V +24V "5%
+24E +24E "5%
+15V +15V "10%
–15V –15V "10%

LED for indicating the

LED for indicating

AC power supply

the alarm (Red)

status (Green)
fuse for +24V
fuse for +24E

F4 7.5A
F3 7.5A

ALM
PIL
AC input
F1 8.0A
Fuse for

Fig.6.3 (a) Interface of the power supply unit

134
 R2

R1
AC
B–80945EN/02

S2 OUTPUT
S1

G2
G1
P280
+5.1
F1 8A
R +5.1V
AC INPUT NF
S +5.1VDC REGULATOR 0V
P0 0V
G +3.3
+3.3VDC +3.3V
REGULATOR
0V
A24 0V
A12 F3 7.5A
P22 +24E

135
A5
+24
F4 7.5A
AUX P.S. +24V
MAINTENANCE

0V
P0 +24VDC REGULATOR 0V
P280 P22 A24 A5
+15
+15V
+5.1
ON +3.3 15VDC
–15

Fig.6.3 (b) Block diagram of the power supply unit

COM +24
REGULATOR –15V
OFF +15
–15
0V
ALM CONTROL
CIRCUIT ENA

EN5
A24
HI FA
LO FB

P0 0V
THE POWER SUPPLY
6. SETTING AND ADJUSTING
7. REPLACING A UNIT MAINTENANCE B–80945EN/02

7 REPLACING A UNIT

This section explains how to replace each unit in the control section.

WARNING
Before you start to replace a unit, turn off the control unit
main power. Also keep all machines in the area of the control
unit switched off for safety’s sake.

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B–80945EN/02 MAINTENANCE 7. REPLACING A UNIT

7.1 The following components of the A–cabinet can be removed.

A–CABINET D Top panel
D Rear panel
D Louver
D Door

7.1.1 Remove three M4 screws from the upper edge of the rear surface. Pull the
Replacing the top panel slightly backward, then lift it off.
A–Cabinet Top Panel

Top panel

M4 screws
(3 places)

Fig.7.1.1 Replacing the Top Panel

7.1.2 Remove seven retaining M4 screws and four M10 bolts from the rear
panel.
Replacing the
A–Cabinet Rear Panel
Rear panel

M4 screws
(7 places)

M10 bolts (4 places)

Fig.7.1.2 Replacing the Rear Panel

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7. REPLACING A UNIT MAINTENANCE B–80945EN/02

7.1.3 Loosen four retaining M4 screws from the louver, then dismount the
Replacing the louver.
A–Cabinet Louver Louver

Fig.7.1.3 Replacing the Louver

7.1.4 Detach the cables from each unit (such as the fan unit) installed on the
door. Lift the door off its hinges to dismount it.
Replacing the
A–Cabinet Door

Lift up the door to

dismount it.

Fig.7.1.4 Replacing the Door

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B–80945EN/02 MAINTENANCE 7. REPLACING A UNIT

7.2
REPLACING THE CAUTIONS
When you replace printed–circuit boards, observe the
PRINTED–CIRCUIT following cautions:
BOARDS 1 Keep the control unit power switched off.
2 When you remove a printed–circuit board, do not touch the
semiconductor devices on the board with your hand or
make them touch other components.
3 Make sure that the replacement printed–circuit board has
been set up appropriately. (Jumpers etc.)
4 If the backplane board, power supply unit, or main board
(including cards and modules) is replaced, it is possible that
robot parameters and taught data are lost. Before you start
to replace these components, save a backup copy of the
robot parameters and taught data to a memory card, floppy
disk, or any other external memory device.
5 If a cable is detached for replacement, reconnect it exactly
as before. Before you disconnect a cable, note its location.

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7. REPLACING A UNIT MAINTENANCE B–80945EN/02

7.2.1 When replacing the backplane board, do so together with the plastic rack.
Replacing the (1) Detach the cables from the power unit and boards on the backplane
board.
Backplane Board (Unit)
CAUTION
When you remove the main PC Board, be sure that the
battery is good (3.1–3.3VDC) and it is installed correctly.
USE STATIC PROTECTION.

(2) Remove the power unit and boards from the rack. (See Section 7.2.2.)
(3) Detach the grounding cable from the backplane unit.
(4) Loosen the retaining screws in the upper section of the rack. Remove
the retaining screws from the lower section of the rack.
(5) Side rack up and out.
(6) To replace the backplane and rack, reverse steps (1) – (6).

CAUTION
There is a possibility of data loss when a
backplane–mounted printed circuit board is replaced. Be
sure to back up all program and setup data on a floppy disk
or memory card before proceeding.

Fig.7.2.1 Replacing the Backplane Board

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B–80945EN/02 MAINTENANCE 7. REPLACING A UNIT

7.2.2 The backplane unit incorporates the power unit, main board, and option
Replacing the Power boards. There are two types of option boards: Full–size board and
mini–size board. A full–size board occupies one slot. A mini–size board
Unit and uses part of a full–size board.
Printed–Circuit Boards
on the Backplane Unit CAUTION
Before starting replacement, turn off the control unit main
power. The main board is equipped with battery–backed
memory devices for holding robot parameters and taught
data, for example. When the main board is replaced, the
data in the memory devices is lost.

(1) Detach the cable from the power supply unit or the printed–circuit
board, whichever is to be replaced.
(2) Pinch the barbed handles on the upper and lower sections of the board
to unlatch it, then pull it toward you.
(3) Place the replacement board on the rail in the appropriate slot of the
rack, then push it in gently by the handles until it is latched.
(4) There are two rails in the main board SLOT (slot 1). When inserting
the main board, align it to the right–side rail.
(5) There are two rails in slots 3 and 5 (slots for a full–size option board).
When you insert a full–size option board, align it to the left–side rail.
SLOT 1
PSU
SLOT 2 (Power supply
SLOT 3 SLOT)

Handles

SLOT 1

SLOT 10

Handles

SLOT 9 SLOT 8

Fig.7.2.2 Replacing the Power Unit and Printed–Circuit Boards

on the Backplane Unit

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7. REPLACING A UNIT MAINTENANCE B–80945EN/02

7.2.3 Process I/O boards EA, EB, FA, and GA are in the operator box.
Replacing Process I/O (1) Open the door of the operator box.
Boards EA, EB, FA, (2) Detach the cables from the process I/O boards.
and GA (A–Cabinet) (3) Remove two retaining screws (left side) from the process I/O boards,
and dismount them. Hooking nuts are used on the right side of the
printed–circuit board.
Operator box Type A

2–M4 screws

Process I/O board

Operator box Type B

2–M4 screws

Process I/O board

Fig.7.2.3 Replacing Process I/O Boards

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B–80945EN/02 MAINTENANCE 7. REPLACING A UNIT

7.2.4 The panel board is at the back of the operator panel.

Replacing the Panel (1) Detach all cables from the panel board. The terminal boards (TBOP1
Board and TBOP2) are of a connector type. Pull out the upper terminal board
sections.
(2) Remove four retaining screws from the panel board, and replace the
panel board.
Operator box Type B
(Common to TypeA)

4–M4 screw

4–M4 screw

B–cabinet

Fig.7.2.4 Panel board replacement

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7. REPLACING A UNIT MAINTENANCE B–80945EN/02

7.3
REPLACING CARDS CAUTION
AND MODULES ON Before you start to replace a card or module, make a backup
copy of robot parameters and taught data. If the SRAM
THE MAIN BOARD module is replaced, memory contents are lost.

Demounting a Card
(1) Pull outward the clip of each of the four spacers used to secure the card
PCB, then release each latch.
(2) Extract the card upward.

Card Card

Card

Spacer
Connector

Card

Spacer
Connector

Fig.7.3(a) Demounting a card

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B–80945EN/02 MAINTENANCE 7. REPLACING A UNIT

Mounting a Card
(1) Check that the clip of each of the four spacers is latched outward, then
insert the card into the connector.
(2) Push the clip of each spacer downward to secure the card PCB.

Card

Spacer
Connector

Card Card

Card

Spacer
Connector

Fig.7.3(b) Mounting a card

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7. REPLACING A UNIT MAINTENANCE B–80945EN/02

Demounting a module

CAUTION
When replacing the module, be careful not to touch the
module contact. If you touch the contact inadvertently, wipe
out dirt on the contact with a clean cloth.

(1) Move the clip of the socket outward. (a)

(2) Extract the module by raising it at a 30 degree slant and pulling
outward.
Mounting a module
(1) Insert the module at a 30 degree slant into the module socket, with
side B facing upward. (b)
(2) Push the module inward and downward until it is locked. (c)
(a)

(b)

(c)

Fig.7.3(c) Demounting/Mounting a module

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B–80945EN/02 MAINTENANCE 7. REPLACING A UNIT

Figure 7.3 (d) shows the locations of the cards and modules.
CPU card

Axis control card Flash ROM module SRAM module

(below the CPU card)

Fig.7.3(d) Locations of Cards and Modules

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7. REPLACING A UNIT MAINTENANCE B–80945EN/02

7.4
REPLACING THE WARNING
TRANSFORMER Before you start replacement procedure, turn off the main
power to the control unit. The transformer is quite heavy; it
weighs 45 to 60 kg.

If the A–cabinet is connected to the robot, it will need to be separated.

Following (1) to (3) are not need for the remote type A–cabinet.
For the remote type A–cabinet, start from (4).
Cabinet separation
(1) Disconnect the cable connectors and ground clamps coming from the
robot. These cables are generally at the following connectors on the
Servo amplifier: CRF1, CRM30, CRM37, CNJ1–6, and CNJGA to
CNJGC, and the ground cables.

Grounding cable
Motor power cable Remove the cable clamps.
Pulse coder and end effecter signal cable

(2) Remove the four M10 robot retaining bolts that hold the cabinet to a
robot.

Rear view of the A–cabinet

Robot retaining bolts (M10, 4 places)

(3) Being careful not to strain or break any cables, gently separate the
cabinet from the robot and it’s cables.

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B–80945EN/02 MAINTENANCE 7. REPLACING A UNIT

(4) At the transformer input terminal board disconnect the power cable
coming from the operator box.

Power line from the

operator box

To the breaker (box)

(5) Disconnect the transformer output cables as follows:

At the MCC contactor – terminal 1 (L1), terminal 3 (L2), and terminal
5 (L3).

At the power supply unit (PSU) – connector CPI.

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7. REPLACING A UNIT MAINTENANCE B–80945EN/02

At the emergency stop board – connector CRR43B.

CRR43B

Remove the three M4 screws from the upper portion of the rear of the
cabinet, then remove the top plate (see Fig. 7.1.1).
(6) Unscrew and remove the control cabinet back cover.
Unscrew and remove the transformer terminal board plate.
Transformer terminal
board plate

(7) Unscrew and remove the regenerative resistor from top the
transformer.
Screw
Washer
The type of the regenerative resistor
varies with the model of the robot.

Regenerative resistor
cable

Shape of the transformer

Transformer Screw (2–M6)

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B–80945EN/02 MAINTENANCE 7. REPLACING A UNIT

(8) Remove the 2 M6 bolts holding the transformer in place and remove
the transformer.

Shape of the transformer

Screw (2–M6)

(9) Install a replacement transformer by reversing steps 1 through 9.

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In case of B–cabinet
(1) Remove the six M4 screws and detach the back panel.

(2) Detach the cables from the transformer input terminal board (on the
MCC unit).
(3) Remove transformer input terminal board XT1 from the MCC unit.

Input
terminal
Cable board XT1
Screw (M4x2)

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(4) Detach the lead–out cables from the transformer as following order.
* The terminal R, S and T (Terminal XT2) of a MCC unit.
* The connector CP1 of a power supply unit (PSU).
* The connector CRR43B of the emergency stop board on a MCC
unit.
If a cable is fastened with nylon ties, cut them with a diagonal cutter
to release the cable. Be careful not to damage the cable.

(5) Remove the retaining screws from the transformer terminal board and
remove metal plate.

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(6) Remove the four retaining screws and detach the regenerative
resistance unit from the transformer top plate.

Regenerative
resistance unit is
different and it is
depended on each
robot.
Screw
washer

(7) Remove the two retaining M6 screws from the transformer, then
remove the transformer.

Shape of the transformer

Screw (2–M6)

(8) Install a replacement transformer by reversing procedure (1) to (7).

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7.5
REPLACING THE WARNING
REGENERATIVE Before you start, turn off the control unit main power.
RESISTANCE UNIT In case of A–cabinet
(1) Remove the top acess panel from the A–cabinet. Remove the Louver
plate.
Remove the lower right plate on the right side of the cabinet.
(2) Unplug connector CRR45A at the Servo amplifier and connector
CRR43A at the emergency stop unit.
(3) Unscrew the cord grip nut inside the transformer compartment and
pull the cables through being careful not to damage the connectors or
cables.
(4) Unscrew the four retaining screws on the regenerative feedback
resistance unit remove it.
(5) Install the replacement unit by reversing this procedure.

CRR45A

CRR43A

Regenerative resistance unit cable

Screw
Washer
The type of the regenerative resistance
varies with the model of the robot.

Regenerative resistance
unit cable

Transformer
The cable is retained using a cord grip. Remove the cord grip,
and pull out the cable. The cord grip is retained with nuts on the
rear side. Remove the lower right plate beforehand.

Fig.7.5 (a) Replacing the Regenerative Resistance Unit

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In case of B–cabinet
(1) Remove the four retaining M4 screws from the rear panel, then detach
the panel. (See Section 7.4.)
(2) Detach the connector CRR45 of the servo amplifier and the connector
CRR43A of the emergency stop unit. If a cable is fastened with nylon
ties, cut them with a diagonal cutter to release the cable. Be careful
not to damage the cable.

Cable

Fig.7.5 (b) Cable of B–cabinet

(3) Remove the two retaining M4 screws and detach the housing that
fastens the lead–out cables.
(4) Remove the four retaining screws and lift away the regenerative
resistance unit.

Regenerative
resistance unit
is different and it
is depended on
each robot.
Screw
washer

Screw (2–M4)

Fig.7.5 (c) Regenerative Resistance Unit

(5) Install a replacement regenerative resistance unit by reversing the

procedure (1) to (4).

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7.6
REPLACING THE WARNING
EMERGENCY STOP Before you start replacement, turn off the control unit main
power.
UNIT (A–cabinet)
A–cabinet
(1) Detach the cables from the emergency stop unit.
(2) Remove retaining screws (M4, 4 places) from the emergency stop
unit, and replace the emergency stop unit.
(3) Reconnect the cables.

Emergency stop unit

Screws (M4, 4 places)

Fig.7.6 Replacing the Emergency Stop Unit

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7.7
REPLACING THE WARNING
MAGNETIC Before you start replacement, turn off the control unit main
power.
CONTACTOR (MCC)
(A–cabinet) A–cabinet
(1) Detach the cables from the magnetic contactor (MCC). Be sure that
each cable is properly marked.
(2) Remove retaining screws (M4, 2 places) from the MCC, then replace
it.
(3) Reconnect the cables.

Magnetic contactor (MCC)

Screw (M4, 2 places)

Fig.7.7 Replacing the Magnetic Contactor (MCC)

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7.8
REPLACING SERVO WARNING
AMPLIFIERS Before you start replacement, turn off the control unit main
power.

In case of A–cabinet
A servo amplifier can be dismounted by pulling it out from the side, using
its rail. Only a flat–head screwdriver is required, provided that servo
amplifier SHIPPING screws have been removed. These screws are
intended to prevent damage to the servo amplifier during shipment.
(1) Make sure that servo amplifier shipping screws (2 phillips head) have
been removed. Retain screws for shipping purposes.
(2) Open the door. Detach the cables from the servo amplifier. Pull out
the detached cables away from the amplifier toward you so that they
will not be caught when it slides along the rail.
(3) Unlock the servo amplifier by rotating the quarter–turn screws on the
outside surface of the plate using a coin.
(4) Hold the upper and lower handles, and pull out the servo amplifier
slowly. Be sure that all cables are unplugged from the servo amp
before you try to remove the servo amplifier. After pulling the servo
amplifier a little, check again that it is all right to continue to pull the
servo amplifier. Be careful not to let the servo amplifier slide off the
rail.
(5) Place a replacement servo amplifier on the rail, slide it in gently until
it is hooked on the guide pins.
(6) Rotate the quarter–turn screws on the outside surface of the plate to
lock the servo amplifier.
(7) Reconnect the cables.

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Servo amplifier
Quarter–turn screws
(4 places)

Unlock Lock

Detach the cables from the servo

amplifier, and pull them out toward
Servo amplifier shipping screws you.
(M5, 2 places)

Guide pins

Rail
Handles

Fig.7.8 (a) Replacing the Servo Amplifier (A–cabinet)

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In case of B–cabinet
The servo amplifier is fixed by inserting its right side into the metal
fastening plate and using the fasteners (hinges) attached to its left side.
No tools are required to replace the servo amplifier.
(1) Detach the cable from the servo amplifier.
(2) Remove the two fasteners from the left side of the servo amplifier,
then pull out the servo amplifier by swinging it to the right around the
portion inserted into the metal fastening plate at the right side. Be
careful not to touch any components, such as capacitors, on the lower
part of the servo amplifier printed–circuit board. Also, be careful not
to damage the cables that are routed under the servo amplifier when
pulling it out.
Insert Fig.7.8(a)

Fastener

Fig.7.8 (b) Replacing the servo Amplifier (B–cabinet)

(3) Install a replacement servo amplifier by reversing step (b).

(4) Re–attach the cables.

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7.9
REPLACING THE WARNING
MODEL A I/O UNIT Before you start replacement, turn off the control unit main
power.

7.9.1 First dismount the modules from the base unit of I/O unit model A. The
base unit is retained with 4 (Operator box) or 2 (B–cabinet) screws. Of
Replacing the Base
these screws, loosen the upper 2 (Operator box) or 1 (B–cabinet) screw
Unit of the Model A I/O and remove the lower 2 (Operator box) or 1 (B–cabinet) screw, then
Unit replace the base unit.

Operator box M4 screw (4 pieces)

Screw (2–M4)

B–cabinet

Fig.7.9.1 Replacing the Base Unit of the Model A I/O Unit

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7.9.2 An interface module and input/output module can be easily installed in

Replacing a Module and removed from the base unit, as described below.

Installing a module (a) Put the upper hook of the module into the upper hole of the base unit.
(b) Fit the connectors of the module and the base unit each other.
(c) Push the module until the lower stopper of the module is caught in the
lower hole of the base unit.

Removing a module (a) Press the lever at the bottom of the module to release the stopper.
(b) Lift the module up.

Fig.7.9.2 Replacing the module

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7.10 A–cabinet
The interface unit of the model B I/O unit is on the A–cabinet door.
REPLACING THE
Interface unit
MODEL B I/O UNIT (1) Detach the cables from the unit. Be sure that they are properly
labeled.
(2) Remove the unit retaining nuts (M4, 4 places). Replace the unit.
Base and expansion units
(1) Detach the cables from the unit. Be sure that they are properly
labeled.
(2) Remove the unit retaining screw (M4, 2 places). Replace the unit.
B–cabinet
Interface unit
(1) Detach the cables from the unit. Be sure that they are properly labeled.
(2) Remove the unit retaining screws (M4, 4 places). Replace the unit.
Base and expansion units
(1) Detach the cables from the unit. Be sure that they are properly labeled.
(2) Remove the unit retaining screws (M4, 2 places). Replace the unit.
Base unit Expansion unit

Operator box type A

I/O unit model B interface unit

Expansion unit
Basic unit

Screw (2–M4)
Screw (2–M4)

Interface unit

Fig.7.10 Replacing I/O Unit Model B

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7.11 The specifications of the teach pendant vary with its use. When you
replace the teach pendant, check its specifications carefully.
REPLACING THE
TEACH PENDANT (1) Be sure that the power of the robot controller is off.
(2) Detach the cable from the teach pendant.
(3) Replace the teach pendant.

Detach or attach the cable by rotating

the connector retaining ring.

Fig.7.11 Replacing the Teach Pendant

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7.12 The control section fan motor can be replaced without using a tool. The
fan motor is mounted on the fan unit rack.
REPLACING THE
CONTROL SECTION (1) Be sure that the power of the robot controller is off.
FAN MOTOR (2) Put your finger in the dent in the upper section of the fan unit, and pull
the fan unit until it is unlatched.
(3) Lift the fan unit slightly, and dismount it from the rack.
(4) Place a replacement fan on the upper section of the rack, and slide it
gently until it is latched.

Fan motor connector

Fan motor

Pull the fan motor unit

toward you to unlatch it.

Fig.7.12 Replacing the Control Section Fan Motor

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7.13
REPLACING THE AC WARNING
Before you start replacement, turn off the control unit main
FAN MOTOR power. Do not touch the fan motor when it is rotating. You
could be injured.

7.13.1 The heat exchanger of the A–cabinet is inside its door. To replace the heat
exchanger, it is necessary to remove the door fan unit in advance.
Replacing the Heat
Exchanger and Door Door fan unit
(1) Remove retaining screws (M4, 4 places).
Fan Unit (A–Cabinet) (2) Detach the cable from the heat exchanger.
(3) Mount the replacement fan unit by reversing the removal procedure.
Be careful not to let the cable get caught in the fan.
Heat exchanger
(1) Dismount the fan unit from the door. (See the above procedure.)
(2) Open the A–cabinet door, and detach cables.
(3) Remove retaining nuts (M5, 4 places), and dismount the unit.
(4) Mount the replacement heat exchanger by reversing the dismounting
procedure.

Screws (M4, 4 places)

Door fan unit.

Heat exchanger

Nuts (M5, 4 places)

Fig.7.13.1 Replacing the Heat Exchanger and Door Fan Unit

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7.13.2 A fan unit for cooling air is at the right rear of the A–cabinet. This rear
Replacing the Rear Fan fan unit has two fans mutually connected with a cable. When the rear fan
unit is replaced, the cable is replaced together with the fan unit.
Unit (A–Cabinet)
NOTE
There are two fan unit types. When replacing a fan unit, be
aware of its specification.

For fan unit A05B–2400–C901

(1) Remove the louver and top panel. (See Section 7.1.)
(2) Remove the screws (M5, 5 places) used to fasten the fans to the
cabinet from the outside.
(3) Remove the plate from the lower right side plate. Also remove the
nuts from the cord grip where the fan cable is led in.
(4) Open the door, and detach the fan cable. The fan cable is connected
to CP3 in the power supply unit.
(5) Dismount the fans together with the cable.
(6) Mount spare fans, and reconnect the cable.

Rear fan unit Screws (M5, 4 places)

to be removed together
with the finger guard

Fan unit cable

Fig.7.13.2 (a) Replacing the Rear Fan Unit (A05B–2400–C901)

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For fan unit A05B–2400–C903

(1) Loosen the retaining screws of the louver, then remove it. (See
Section 7.1.)
(2) Detach the fan unit. (The fan unit is fastened together with the louver.)
(3) Detach the fan unit lead–out cable and grounding wire. (The cable is
terminated with a connector. The grounding wire is fastened with a
screw.)
(4) Replace the fan unit with a new one.

Fan unit
Screws (M5, four places)
Used to fasten both the fan
unit and louver.

The grounding wire is fastened

with an M4 screw.

The fan cable is attached using

an in–line connector.

Fig.7.13.2 (b) Replacing the Rear Fan Unit (A05B–2400–C903)

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7.13.3 Door fan unit

Replacing Top Fan Unit (1) Detach the cable from the fan unit.
and Door Fan Unit (2) Remove the four retaining M4 screws from the fan unit, then
(B–Cabinet) dismount it.
(3) Install a new fan unit by reversing the dismounting procedure.

Top fan unit

(1) Detach the cable from the CP2A connector on the MCC unit.
(2) Remove the two retaining M5 screws from the fan unit, then dismount
it together with the cable.
(3) Install a new fan unit by reversing the dismounting procedure.

Nut (2–M5)
Screw (4–M4)

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7.13.4 The fresh–air fan unit is located on the right–side panel of the B–cabinet.
Replacing Side Panel The fan unit has two fans connected with a cable. The fan unit and cable
must be replaced together as a unit.
Fan Unit (B–Cabinet)
(1) Dismount the right–side panel (fastened with four M4 screws) and the
rear panel. (See Section 7.1.)
(2) Detach the fan cable from the CP3A connector on the MCC unit.

Screw
washer

Screw (4–M4)

CP3A

(3) Dismount the housing (fastened with two M4 screws) that fastens the
fan cable.
(4) Working from the outside, remove the four retaining M4 screws that
fasten the fan unit to the cabinet.

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7. REPLACING A UNIT MAINTENANCE B–80945EN/02

(5) Dismount the fans together with the cable.

Screw (4–M4)

Screw (2–M4)

(6) Install new fans and attach the cable.

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7.14
(1) Detach the cable (CRT8) from the panel board.
REPLACING THE
(2) Remove 8 retaining screws from the operator panel, then replace the
OPERATOR PANEL operator panel.
Operator panel

8–M3 screw

Screw (8–M3)

Fig.7.14 Replacing the operator panel

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7.15
REPLACING THE (1) Disconnect the cables (CRTB and CRM51) from the panel switch
board.
PANEL SWITCH
(2) Unlock the latches of the switches and LEDs. Replace the panel
BOARD switch board.

Latch

Unlocked

Locked

Panel switch board

Fig.7.15 Replacing the Panel Switch Board

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7.16
REPLACING THE WARNING
MCC UNIT Before attempting to replace the emergency stop unit,
switch off the main power supply.
(B–CABINET)

(1) Detach the cables from the MCC unit, and dismount transformer
input terminal board XT1.
(2) Remove the four retaining M5 screws from the MCC unit, then
replace the MCC unit.
(3) Re–attach the cables.

MCC unit Input terminal

Screw (4–M5) board XT1

Fig.7.16 Replacing the MCC Unit (B–cabinet)

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7. REPLACING A UNIT MAINTENANCE B–80945EN/02

7.17 If a fuse in the control unit has blown, find the cause and take an
appropriate measure before replacing the fuse.
REPLACING FUSES

7.17.1 The following fuses are in the servo amplifier.

Replacing Fuses in the F1, F2:
Servo Amplifier Fuses for detection of the circuit failure in the servo amplifier,
A60L–0001–0245#GP20
If either of these fuses has blown, it is likely that the servo amplifier
is defective. Replace the servo amplifier.
FU1: Fuse for protecting the +24V output, A60L–0001–0290#LM32C

Fuse FU1

Fuse F2

Fuse F1

Fig.7.17.1 Replacing Fuses in the Servo Amplifier

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B–80945EN/02 MAINTENANCE 7. REPLACING A UNIT

7.17.2 The following fuses are in the power unit.

Replacing Fuses in the F1: Fuse for the AC input, A60L–0001–0396#8.0A
Power Unit F3: Fuse for protecting the +24E output, A60L–0001–0046#7.5
F4: Fuse for protecting the +24V output, A60L–0001–0046#7.5

F1 8.0A
AC input fuse

F3 7.5A
+24E fuse

F4 7.5A
+24V fuse

Fig.7.17.2 Replacing Fuses in the Power Unit

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7.17.3 The following fuse is on each process I/O board.

Replacing the Fuse on FUSE1:Fuse for protecting the +24V output for peripheral equipment
the Process I/O Boards interfaces.
A60L–0001–0046#2.0

Process I/O boards EA and EB

FUSE1

Total version

Process I/O board FA

FUSE1

Total version

Fig.7.17.3 (a) Replacing the Fuse on the Process I/O Boards

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Process I/O boards GA

Total version

FUSE1

Fig.7.17.3 (b) Replacing the Fuse on the Process I/O Boards

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Process I/O board CA,CB

FUSE1

Total version

Process I/O board DA

FUSE1

Total version

Fig.7.17.3 (c) Replacing the Fuse on the Process I/O Boards

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7.17.4 The MCC unit incorporates the following fuses:

MCC unit fuse F1 and F2: For 100 VAC output; A60L–0001–0245#GP32
replacement

F1

F2

Fig.7.17.4 MCC unit fuse replacement

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7.18 Prolonged use of a relay might result in its contacts failing to make a
secure connection or sticking to each other permanently. If such a failure
REPLACING RELAYS occurs, replace the relay.

7.18.1 RL1: Relay for servo amplifier pre–charge circuit,

Replacing Emergency A58L–0001–0422#3232K
Stop Relays RL2: Relay to energize the magnetic contactor (MCC),
A58L–0001–0192#1509A

Relay RL1

Relay RL2

Fig.7.18.1 Replacing Emergency Stop Unit Relays

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7.19
BATTERY
REPLACEMENT

7.19.1 The programs and system variables are stored in the SRAM in the main
Battery for Memory board. The power to the SRAM memory is backed up by a lithium battery
mounted on the front panel of the main board. A new battery can maintain
Backup (3 VDC) the contents of memory for about a year (Note).
When the voltage of the battery becomes low, the battery alarm LED on
the operator box (panel) is lit, and the low–voltage battery alarm
(system–035) is displayed on the teach pendant. When this alarm is
displayed, replace the battery immediately.
If the battery voltage gets lower, it becomes impossible to back up the
content of the SRAM. Turning on the power to the controller in this state
causes system not to start and the LED on the main board will display “1”
because the contents of memory are lost. Reload data after replacing the
battery. Important data should be saved to the memory card or floppy disk
beforehand in case of emergency.
When replacing the memory backup battery, do so while the robot
controller is turned off.

NOTE
In a newly introduced robot, the battery is factory–installed.
Battery replacement may, therefore, be needed within a
year after the introduction of the robot.

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7. REPLACING A UNIT MAINTENANCE B–80945EN/02

Replacing the lithium (1) Prepare a new lithium battery (ordering drawing number:
battery A02B–0200–K102).
(2) Turn the robot controller on for about 30 seconds.
(3) Turn the robot controller off.
(4) Remove the old battery from the top of the main board.
First unlatch the battery, remove it from the battery holder, and detach
its connector.

Battery latch

Lithium battery
Battery
connector

(5) Remove the old battery, insert a new one into the battery holder, and
attach the connector. Confirm that the battery is latched firmly.
WARNING
Using other than the recommended battery may result in the
battery exploding.
Replace the battery only with the specified battery
(A02B–0200–K102).

CAUTION
Complete the steps (3) to (5) within 30 minutes.
If the battery is left disconnected for a long time, the
contents of memory will be lost.
To prevent possible data loss, it is recommended that the
robot data such as programs and system variables be
backed up before battery replacement.

Dispose of the replaced battery as an industrial waste, according to the

laws and other rules in the country where the controller is installed and
those established by the municipality and other organizations that have
jurisdiction over the area where the controller is installed.

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III CONNECTIONS
B–80945EN/02 CONNECTIONS 1. GENERAL

1 GENERAL

This section describes the electrical interface connections in the R-J3. It

also includes information about installation of the R-J3.

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2. BLOCK DIAGRAM CONNECTIONS B–80945EN/02

2 BLOCK DIAGRAM

Fig. 2 is a block diagram of electrical interface connections with the R-J3.

R-J3 Pneumatic pressure source

(A–cabinet)

Mechanical unit End effector

Memory card
(PCMCIA)

Teach pendant

Operator box RS-232-C (note2)

Peripheral device

Welding machine

Ethernet

AC power supply

Fig.2 (a) Block Diagram of Electrical Interface Connection (A–cabinet)

NOTE
1 : Indicates electrical connection.
: Indicates mechanical connection.
2 For more information, contanct our service section.

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B–80945EN/02 CONNECTIONS 2. BLOCK DIAGRAM

Pneumatic
R–J3
pressure source
(B–cabinet)

Mechanical unit End effector

Memory card
(PCMCIA)

Teach pendant

RS–232–C (Note2)

Peripheral device

Welding machine

Ethernet

AC power supply

Fig.2 (b) Block Diagram of Electrical Interface Connection (In case of B–cabinet)

NOTE
1 : Indicates electrical connection.
: Indicates mechanical connection.
2 For more information, contanct our service section.

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3 ELECTRICAL CONNECTIONS

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3.1 Fig. 3.1 (a) to 3.1 (d) show mechanical connection diagrams.
CONNECTION
DIAGRAM BETWEEN
MECHANICAL UNITS
R-J3 Robot

CRF1 Pulse coder

(Pulse coder signal) J1/J2/J3

Pulse coder
J4/J5/J6

CRM30 EE
End effector
(RDI/RDO signal)
(Note 2)
CRM37A
(HBK signal)

CRM37B
ROT signal
(ROT signal)

CNJ1A Motor power

(J1 motor power) J1

(Note 1) CNJ1B
(J1 motor power)

CNJ2A Motor power

(J2 motor power) J2

(Note 1) CNJ2B
(J2 motor power)

CNJ3A Motor power

(J3 motor power) J3

(Note 1) CNJ3B
(J3 motor power)
Motor power
CNJ4
J4/J5/J6
(J4 motor power)
Motor brake
CNJ5
(J5 motor power)

CNJ6
(J6 motor power)

CNGA
(J1–J3 ground)

(Note 1) CNGB
(J1–J3 ground)

CNGC
(J4–J6 ground)

CN6
(Brake control)

Fig.3.1 (a) Mechanical Connection Diagram (S–430i, M–710i/A–cabinet integrated type)

NOTE
1 CNJ1B, CNJ2B, CNJ3B, and GNGB are used in the S–430iW, S–430iL, S–430iR/165,
S–430iR/Press HT/Press HS, S–430iU, S–900i. They are not used in the S–430iF, S–430iR/130,
S–430iC or M–710i.
2 This cable is not included. It must be supplied by the customer.

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3. ELECTRICAL CONNECTIONS CONNECTIONS B–80945EN/02

R-J3 Robot

CRF1
(Pulse coder signal)
RP1
Pulse coder EE
J1–J6 End effector
RDI/RDO
HBK/ROT (Note 2)
CRM30
(RDI/RDO signal)

CRM37A
(HBK signal)

CRM37B
(ROT signal)

CNJ1A RM2
(J1 motor power) Motor power
J1/J2/J3
(Note 1) CNJ1B RM3 (S–430iW only)
(J1 motor power) Motor power
J1/J2/J3
CNJ2A
(J2 motor power)

(Note 1) CNJ2B
(J2 motor power)

CNJ3A
(J3 motor power)

(Note 1) CNJ3B
(J3 motor power)
Motor power
CNJ4
J4/J5/J6
(J4 motor power)
Motor brake
CNJ5
(J5 motor power)

CNJ6
(J6 motor power)

CNGA
(J1–J3 ground)

(Note 1) CNGB
(J1–J3 ground)

CNGC
(J4–J6 ground)

CN6
(Brake control)

Fig.3.1 (b) Mechanical Connection Diagram (S–430i, M–710i/A–cabinet remote type, B–cabinet)

NOTE
1 CNJ1B, CNJ2B, CNJ3B, and GNGB are used in the S–430iW, S–430iL, S–430iR/165,
S–430iR/Press HT/Press HS, S–430iU, S–900i. They are not used in the S–430iF, S–430iR/130,
S–430iC or M–710i
2 This cable is not included. It must be supplied by the customer.

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R-J3 Robot

CRF1 Pulse coder

(Pulse coder signal) J1/J2/J3

Pulse coder
J4/J5/J6

CRM30 EE
End effector
(RDI/RDO signal)
(Note)
CRM37A
(HBK signal)

CRM37B
ROT signal
(ROT signal)

CNJ1A Motor power

(J1 motor power) J1

CNJ1B
(J1 motor power)

CNJ2A Motor power

(J2 motor power) J2

CNJ2B
(J2 motor power)

CNJ3A Motor power

(J3 motor power) J3

CNJ3B
(J3 motor power)
Motor power
CNJ4
J4
(J4 motor power)
Motor brake

CNGA
(J1–J3 ground)

CNGB
(J1–J3 ground)

CNGC
(J4 ground)

CN6
(Brake control)

Fig.3.1 (c) Mechanical Connection Unit (M–410i/A–cabinet integrated type)

NOTE
This cable is not included. It must be supplied by the
customer.

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R-J3 Robot

CRF1
(Pulse coder signal)
RP1
Pulse coder EE
J1–J4 End effector
RDI/RDO
HBK/ROT (Note)
CRM30
(RDI/RDO signal)

CRM37A
(HBK signal)

CRM37B
(ROT signal)

CNJ1A RM2
(J1 motor power) Motor power
J1/J2/J3
(Note 1) CNJ1B RM3
(J1 motor power) Motor power
J1/J2/J3
CNJ2A
(J2 motor power)

(Note 1) CNJ2B
(J2 motor power)

CNJ3A
(J3 motor power)

(Note 1) CNJ3B
(J3 motor power)
Motor power
CNJ4
J4/RM1
(J4 motor power)
Motor brake

CNGA
(J1–J3 ground)

(Note 1) CNGB
(J1–J3 ground)

CNGC
(J4 ground)

CN6
(Brake control)

Fig.3.1 (d) Mechanical Connection Diagram (M–410i/A–cabinet remote type, B–cabinet)

NOTE
This cable is not included. It must be supplied by the
customer.

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R–J3 Robot

CRF1 Pulse coder

Pulse coder signal J1

Pulse coder
J2

Pulse coder
J3/J4

Pulse coder
J5/J6

CRM30 EE
(RDI/RDO signal) End effector

(Note1)
CRM37A
(HBK signal)

CRM37B
ROT signal
(ROT signal)

CNJ1A Motor power

(J1 motor power) J1–J6
Motor brake
CNJ2A
(J2 motor power)

CNJ3A
(J3 motor power)

CNJ4A
(J4 motor power)

CNJ5A
(J5 motor power)

CNJ6A
(J6 motor power)

CNGA
(J1–J3 ground)

CNGB
(J1–J3 ground)

CN6
(Brake control)

CRW1
Welding device
(Process I/O board)
(Note2)

Fig.3.1 (e) Mechanical Connection Diagram (ARC Mate 100i /120i, M–6i, M–16i /integrated type A–cabinet)

NOTE
1 This cable is not included. It must be supplied by the
customer.
2 This cable is able to connect in case of ARC Mate 100i or
ARC Mate 120i

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R–J3 Robot

EE
CRF1 Pulse coder End effector
(Pulse coder signal) J1 – J6
RDI/RDO (Note1)
CRM30 HBK/ROT
(RDI/RDO signal)

CRM37A
(HBK signal)
CRM37B
(ROT signal)

CNJ1A Motor power

J1–J6
(J1 motor power)
Motor brake
CNJ2A
(J2 motor power)

CNJ3A
(J3 motor power)

CNJ4
(J4 motor power)

CNJ5
(J4 motor power)

CNJ6
(J4 motor power)

CNGA
(J1–J3 ground)

CNGB
(J1–J3 ground)

CN6
(Brake control)

CNGB
(J1–J3 ground)

CRW1
Welding device
(process I/O board) (Note2)

Fig.3.1 (f) Mechanical Connection Diagram

(ARC Mate 50i /100i /120i, M–6i/16i, F–200i, LR Mate 200i, 200i/A–cabinet remote type and B–cabinet)

NOTE
1 This cable is not included. It must be supplied by the
customer.
2 This cable is able to connect in case of ARC Mate 100i or
ARC Mate 120i

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R–J3 Robot

CRF1 Pulse coder

(Pulse coder signal) J1

Pulse coder
J2/J3
Pulse coder
J4

EE
CRM30
End effector
(RDI/RDO signal)

CRM37A (Note)
(HBK signal)

Motor power
CNJ1A
J1–J3
(J1 motor power)
Motor brake
CNJ2A
(J2 motor power)

CNJ3A
(J3 motor power)

CNJ4
Motor power
(J4 motor power) J4

CNGA
(J1–J3 ground)

CNGB
(J1–J3 ground)

CN6
(Brake control)

Fig.3.1 (g) Mechanical Connection Diagram (A–520i /A–cabinet integrated type)

NOTE
This cable is not included. It must be supplied by the
customer.

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3. ELECTRICAL CONNECTIONS CONNECTIONS B–80945EN/02

R–J3 Robot

Pulse coder
CRF1 EE
J1–J4 End effector
(Pulse coder signal) RDI/RDO
HBK/ROT (Note)

CRM30
(RDI/RDO signal)

CRM37A
(HBK signal)

Motor power
CNJ1A
J1–J4
(J1 motor power)
Motor brake
CNJ2A
(J2 motor power)

CNJ3A
(J3 motor power)

CNJ4
(J4 motor power)

CNGA
(J1–J3 ground)

CNGB
(J1–J3 ground)

CN6
(Brake control)

Fig.3.1 (h) Mechanical Connection Diagram (A–520i /A–cabinet remote type and B–cabinet)

NOTE
This cable is not included. It must be supplied by the
customer.

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R-J3 Robot

RP1
CRF1 Pulse coder
J1–J6 End effector
(Pulse coder signal)
RDI/RDO
HBK/ROT (Note)
CRM30
(RDI/RDO signal)

CRM37A
(HBK signal)

CRM37B
(ROT signal)
RM2
CNJ1A Motor power
(J1 motor power) J1/J2
CNJ1B
(J1 motor power)

CNJ2A
(J2 motor power)

CNJ2B
(J2 motor power)

CNJ3A Motor power

(J3 motor power) J3/J4/J5/J6
Motor brake
CNJ3B
(J3 motor power)

CNJ4
(J4 motor power)

CNJ5
(J5 motor power)

CNJ6
(J6 motor power)

CNGA
(J1–J3 ground)

CNGB
(J1–J3 ground)

CNGC
(J4–J6 ground)

CN6
(Brake control)

Fig.3.1 (i) Mechanical Connection Diagram (S–500i /A–cabinet remote type and B–cabinet)

NOTE
This cable is not included. It must be supplied by the
customer.

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R-J3 Robot

RP1
CRF1 Pulse coder
J1–J5 End effector
(Pulse coder signal)
RDI/RDO
HBK/ROT (Note)
CRM30
(RDI/RDO signal)

CRM37A
(HBK signal)

CRM37B
(ROT signal)

CNJ1A RM2
(J1 motor power) Motor power
J1/J2
CNJ1B
(J1 motor power)

CNJ2A RM3
(J3 motor power) Motor power
J3/J4
CNJ2B
(J3 motor power)

CNJ3A
(J2 motor power)

CNJ3B
(J2 motor power)

CNJ4
(J4 motor power)

CNJ5 Motor power

(J5 motor power) J5
Motor brake
CNJ6
(J6 motor power)

CNGA
(J1–J3 ground)

CNGB
(J1–J3 ground)

CNGC
(J4–J6 ground)

CN6
(Brake control)

Fig.3.1 (j) Mechanical Connection Diagram (M–500i /A–cabinet remote type and B–cabinet)

NOTE
This cable is not included. It must be supplied by the
customer.

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R-J3

CRS1 Teach pendant

(Panel board)

CRM2, CRM4 (NOTE1) Peripheral device

(Process I/O)

Port A (NOTE2) Handy File

(Operator box
Operator panel)

Port B (NOTE3) External device

(Operator box
Operator panel)

JD17 (NOTE3) External device

(Operator box
Operator panel)

CD38, JD43 (NOTE3) Ethernet

(Main board)

L1
L2 Input power
Breaker
L3
G

EX–ON External power

Panel board (NOTE3)
EX–COM
(TBOP1) ON/OFF switch
EX–OFF

Panel board EMGIN1 (NOTE3) External emergency

(TBOP1) EMGIN2 stop switch

Panel board FENCE1 (NOTE3) Fence

(TBOP1) FENCE2

Panel board SVOFF1 (NOTE3) Servo off switch

(TBOP1) SVOFF2

Fig.3.1 (k) Mechanical Connection

NOTE
1 For detail of the peripheral device connection, see the section of peripheral device interface.
2 This cable is included in the FANUC Handy File. (Not supported in North America.)
3 This cable is not included. It must be supplied by the customer.

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3. ELECTRICAL CONNECTIONS CONNECTIONS B–80945EN/02

3.2
EXTERNAL CABLE
WIRING DIAGRAM

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3.2.1
Robot Connection
Cables
Applied model : S–430iF, S–430iR/130, S–430iC, M–710i
Cabinet : Integrated type A–cabinet

Robot

Motor power/brake
J1M
J2M
J3M
J4M–J6M
Brake

Pulse coder
RDI/RDO
HBK

ROT

D Detail of cable connection to servo amplifier

R–J3 (Servo amplifier) Robot

Pulse coder
(Pulse coder, RDI/RDO
HBK)
ROT
Motor power/brake
(J4M, J5M, J6M, BK)
Motor power
(J1M)
Motor power
(J2M)
Motor power
(J3M)

Fig.3.2.1 (a) Robot Connection Cable

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3. ELECTRICAL CONNECTIONS CONNECTIONS B–80945EN/02

Applied model : S–430iF, S–430iR/130, S–430iC, M–710i

Cabinet : Remote type A–cabinet

Robot

Motor power/brake

RM1
RM2

Pulse coder
RDI/RDO
HBK
ROT
RP1

EARTH

D Detail of cable connection to servo amplifier

R–J3 (Servo amplifier) Robot

Pulse coder
RP1
(Pulse coder, RDI/RDO
HBK, ROT)
Motor power/brake
RM1
(J4M, J5M, J6M, BK)

RM2
(J1M, J2M, J3M)

Fig.3.2.1 (b) Robot Connection Cable

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B–80945EN/02 CONNECTIONS 3. ELECTRICAL CONNECTIONS

Applied model : S–430iW, S–430iL, S–430iR/165, S–430iR/Press HT/Press HS, S–430iU, S–900i
Cabinet : Integrated type A–cabinet

Robot

Motor power/brake
J1M
J2M
J3M
J4M–J6M
Brake

Pulse coder
RDI/RDO
HBK

ROT

D Detail of cable connection to servo amplifier

R–J3 (Servo amplifier)

Robot

Pulse coder
(Pulse coder, RDI/RDO
HBK)
ROT
Motor power/brake
(J4M, J5M, J6M, BK)
Motor power
(J1M)
Motor power
(J2M)
Motor power
(J3M)

Fig.3.2.1 (c) Robot Connection Cable

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Applied model : S–430iW, S–430iL, S–430iR/165, S–430iR/Press HT/Press HS, S–430iU, S–900i
Cabinet : Remote type A–cabinet

Robot

Motor power/brake

RM1
RM2
RM3

Pulse coder
RDI/RDO
HBK
ROT
RP1

EARTH

D Detail of cable connection to servo amplifier

R–J3 (Servo amplifier) Robot

Pulse coder
RP1
(Pulse coder, RDI/RDO
HBK, ROT)
Motor power/brake
RM1
(J4M, J5M, J6M, BK)

RM2
(J1M, J2M, J3M)
RM3
(J1M, J2M, J3M)

Fig.3.2.1 (d) Robot Connection Cable

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Applied model : M–410i

Cabinet : Integrated type A–cabinet

Robot

Motor power/brake
J1M
J2M
J3M
J4M, Brake

Pulse coder
RDI/RDO
HBK

ROT

D Detail of cable connection to servo amplifier

R–J3 (Servo amplifier) Robot

Pulse coder
(Pulse coder, RDI/RDO
HBK)
ROT
Motor power/brake
(J4M, BK)
Motor power
(J1M)
Motor power
(J2M)
Motor power
(J3M)

Fig.3.2.1 (e) Robot Connection Cable

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3. ELECTRICAL CONNECTIONS CONNECTIONS B–80945EN/02

Applied model : M–410i

Cabinet : Remote type A–cabinet

Robot

Motor power/brake

RM1
RM2
RM3

Pulse coder
RDI/RDO
HBK
ROT
RP1

EARTH

D Detail of cable connection to servo amplifier

R–J3 (Servo amplifier) Robot

Pulse coder
RP1
(Pulse coder, RDI/RDO
HBK, ROT)
Motor power/brake
RM1
(J4M, J5M, J6M, BK)

RM2
(J1M, J2M, J3M)
RM3
(J1M, J2M, J3M)

Fig.3.2.1 (f) Robot Connection Cable

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B–80945EN/02 CONNECTIONS 3. ELECTRICAL CONNECTIONS

Applied model : ARC Mate 100i/120i, M–6i/16i

Cabinet : Integrated type A–cabinet
Robot
Motor power/
brake
J1M–J6M brake

Pulse coder
RDI/RDO
HBK

ROT

D Detail of cable connection to servo amplifier.

R–J3 (Servo amplifier) Robot

Pulse coder
(Pulse coder,RDI/RDO
HBK)
ROT
Motor power/brake
(J1M–J6M/;brake)

Fig.3.2.1 (g) Robot Connection Cable

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3. ELECTRICAL CONNECTIONS CONNECTIONS B–80945EN/02

Applied model : ARC Mate 50i/100i/120i, M–6i/16i, F–200i, LR Mate 200i, SR Mate 200i
Cabinet : Remote type A–cabinet

Robot

Motor power/
brake
RM1

Pulse coder
RDI/RDO
HBK
ROT
RP1

EARTH

D Detail of cable connection to servo amplifier.

R–J3 (Servo amplifier) Robot

Pulse coder
(Pulse coder,RDI/RDO,
HBK,ROT)

Motor power/brake
RM1
(J1M–J6M/brake)

Fig.3.2.1 (h) Robot Connection Cable

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B–80945EN/02 CONNECTIONS 3. ELECTRICAL CONNECTIONS

Applied model : A–520i

Cabinet : Integrated type A–cabinet

Robot

Motor power/
brake
J1M–J3M brake

J4M

Pulse coder
RDI/RDO
HBK

D Detail of cable connection to servo amplifier.

R–J3 (Servo amplifier) Robot

Pulse coder
(Pulse coder,RDI/RDO,
HBK)

Motor power/brake
(J1M–J3M, BK)

Motor power
(J4M)

Fig.3.2.1 (i) Robot Connection Cable

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3. ELECTRICAL CONNECTIONS CONNECTIONS B–80945EN/02

Applied model : A–520i

Cabinet : Remote type A–cabinet

Robot
Motor power/
brake
RM1

Pulse coder
RDI/RDO
HBK
RP1

EARTH

D Detail of cable connection to servo amplifier.

R–J3 (Servo amplifier) Robot

Pulse coder
RPI
(Pulse coder,RDI/RDO,
HBK)
Motor power/brake
RM1
(J1M–J4M/brake)

Fig.3.2.1 (j) Robot Connection Cable

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B–80945EN/02 CONNECTIONS 3. ELECTRICAL CONNECTIONS

Applied model : S–500i

Cabinet : Remote type A–cabinet

Robot

Motor power/
brake
RM1
RM2

Pulse coder
RDI/RDO
HBK
ROT
RP1

EARTH

D Detail of cable connection to servo amplifier.

R–J3 (Servo amplifier) Robot

Pulse coder
RP1
(Pulse coder,RDI/RDO,
HBK, ROT)

Motor power/brake
RM1
(J3M, J4M, J5M, J6M, BK)

RM2
(J1M, J2M)

Fig.3.2.1 (k) Robot Connection Cable

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3. ELECTRICAL CONNECTIONS CONNECTIONS B–80945EN/02

Applied model : M–500i

Cabinet : Remote type A–cabinet

Robot

Motor power/
brake
RM1
RM2
RM3

Pulse coder
RDI/RDO
HBK
ROT
RP1

EARTH

D Detail of cable connection to servo amplifier.

R–J3 (Servo amplifier) Robot

Pulse coder
RPI
(Pulse coder, RDI/RDO,
HBK, ROT)
Motor power/brake

Fig.3.2.1 (l) Robot Connection Cable

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B–80945EN/02 CONNECTIONS 3. ELECTRICAL CONNECTIONS

Applied model : S–430iF, S–430iR/130, S–430iC, M–710i

Cabinet : B–cabinet

Robot

Motor power/
brake
RM1
RM2

Pulse coder
RDI/RDO
HBK
ROT
RP1

Ground

D Detail of cable connection to servo amplifier.

R–J3 (Servo amplifier) Robot

Pulse coder
(Pulse coder,RDI/RDO,
HBK,ROT)

Motor power/brake
RM1
(J1M, J5M, J6M, BK)
RM2
(J1M, J2M, J3M)

Fig.3.2.1 (m) Robot Connection Cable

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3. ELECTRICAL CONNECTIONS CONNECTIONS B–80945EN/02

Applied model : S–430iW, S–430iL, S–430iR/165, S–430iR/Press HT/Press HS, S–430iU, S–900i
Cabinet : B–cabinet

Robot

Motor power/
brake
RM1
RM2
RM3
Pulse coder
RDI/RDO
HBK
ROT
RP1

Ground

D Detail of cable connection to servo amplifier.

R–J3 (Servo amplifier) Robot

Pulse coder
RP1
(Pulse coder,RDI/RDO,
HBK,ROT)
Motor power/brake
RM1
(J4M, J5M, J6M, BK)

RM2
(J1M, J2M, J3M)
RM3
(J1M, J2M, J3M)

Fig.3.2.1 (n) Robot Connection Cable

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B–80945EN/02 CONNECTIONS 3. ELECTRICAL CONNECTIONS

Applied model : M–410i

Cabinet : B–cabinet

Robot

Motor power/
brake
RM1
RM2
RM3
Pulse coder
RDI/RDO
HBK
ROT
RP1

Ground

D Detail of cable connection to servo amplifier.

R–J3 (Servo amplifier) Robot

Pulse coder
RP1
(Pulse coder, RDI/RDO,
HBK, ROT)

Motor power/brake
RM1
(J4M, BK)

RM2
(J1M, J2M, J3M)
RM3
(J1M, J2M, J3M)

Fig.3.2.1 (o) Robot Connection Cable

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3. ELECTRICAL CONNECTIONS CONNECTIONS B–80945EN/02

Applied model : ARC Mate 50i/100i/120i, M–6i/16i, A–520i, F–200i, LR Mate 200i, SR Mate 200i
Cabinet : B–cabinet

Robot

Motor power/
brake

RM1

Pulse coder
RDI/RDO
HBK
ROT

RP1

Ground

D Detail of cable connection to servo amplifier.

R–J3 (Servo amplifier) Robot

Pulse coder
RP1
(Pulse coder,RDI/RDO,
HBK,ROT)
Motor power/brake
RM1
(J4M–J6M, BK)

Fig.3.2.1 (p) Robot Connection Cable

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B–80945EN/02 CONNECTIONS 3. ELECTRICAL CONNECTIONS

Applied model : S–500i

Cabinet : B–cabinet

Robot

Motor power/
brake

RM1
RM2

Pulse coder
RDI/RDO
HBK
ROT
RP1

Ground

D Detail of cable connection to servo amplifier.

R–J3 (Servo amplifier) Robot

Pulse coder
RP1
(Pulse coder, RDI/RDO,
HBK, ROT)

Motor power/brake
RM1
(J3M, J4M, J5M, J6M,
BK)
RM2
(J1M, J2M)

Fig.3.2.1 (q) Robot Connection Cable

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3. ELECTRICAL CONNECTIONS CONNECTIONS B–80945EN/02

Applied model : M–500i

Cabinet : B–cabinet

Robot

Motor power/
brake

Pulse coder

Ground

D Detail of cable connection to servo amplifier.

R–J3 (Servo amplifier) Robot

Pulse coder
RP1
(Pulse coder, RDI/RDO,
HBK, ROT)

Motor power/brake
RM1
(J5M, BK)

RM2
(J1M, J2M)
RM3
(J3M, J4M)

Fig.3.2.1 (r) Robot Connection Cable

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B–80945EN/02 CONNECTIONS 3. ELECTRICAL CONNECTIONS

3.2.2 (1) Teach pendant cable

Teach Pendant Cable The teach pendant connection cable is connected to the operator box
as follows. This figure applies to all robot models.

Operator box Type A

Teach pendant

Panel board CRS1

Teach pendant connection cable

Operator box Type B

Panel board CRS1

Teach pendant

Teach pendant connection cable

In case of B–cabinet
Teach pendant
Panel board
CRS1

Teach pendant connection cable

Fig.3.2.2 Teach Pendant Cable

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3. ELECTRICAL CONNECTIONS CONNECTIONS B–80945EN/02

3.2.3 Considering the robot power capacity and the circuit breaker capacity,
Connecting the Input connect the power supply whose voltage conforms to the installation
conditions to the terminal located above the circuit breaker.
Power
Provide a class–D or better ground.
The resistance to the ground must not exceed 100W.
Be sure to ground the work table or jig used by an arc welding robot or
the like so that it can handle a large current.
Use a thick wire to withstand the maximum current used.
Selection of an input transformer tap is necessary depending on the input
voltage.
The tap is set to the specified voltage before shipment. However, check
it referring to section 6.2 in “Maintenance” before supplying power
(before the breaker switch is turned on).
The motor is driven by the PWM inverter system using a power transistor
bridge. If the servo amplifier is used without a transformer, a
high-frequency leakage current flows through the stray capacitance
between the ground and the motor coils, power cable, and amplifier. This
might cause the leakage-current circuit breaker or leakage-protection
relay installed in the path of the power supply to cut out.
Use the following leakage current circuit breaker for inverters to prevent
incorrect operation.

Example of Leakage Current Circuit Breaker for Inverters

Manufacture Type
Fuji Electric Co., Ltd. EG A series
SG A series
Hitachi, Ltd. ES100C type
ES225C type
Matsushita Electric Leakage current circuit breaker, C type
Works, Ltd. Leakage current circuit breaker, KC type

Fig. 3.2.3 shows the cable connection.

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B–80945EN/02 CONNECTIONS 3. ELECTRICAL CONNECTIONS

A–cabinet

(Note) Always replace the cover

after completeting the wiring

Operator box Type A Operator box Type B

Power supply cable connects through the cord grip.

Fig.3.2.3 (a) Input Power Supply Connection (A–cabinet)

B–cabinet

(Note) Always replace

Input power supply the cover after
cable completing

Fig.3.2.3 (b) Input Power Supply Connection (B–cabinet)

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3. ELECTRICAL CONNECTIONS CONNECTIONS B–80945EN/02

3.2.4 The External Power On/Off signal turns on and off the power supply from
Connecting the the outside of the control unit, and is connected as follows.
External Power Supply
ON/OFF Switch
Operator box Type A

Panel board TBOP2

Operator box Type B

Panel board TBOP2

In case of B–cabinet
Panel board
TBOP2

Fig.3.2.4 (a) Connection of the external power supply ON/OFF switch

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B–80945EN/02 CONNECTIONS 3. ELECTRICAL CONNECTIONS

Remove the shorting jumper between

OFF1 OFF2 between 3 and 4 of
TBOP when the external ON/OFF
switch is used.
N.O. N.C.
Power ON Power OFF

External power supply ON/OFF switch

Panel board

Use a contact conforming to the following : Voltage rating : 50 VDC, 100mA or more

The power supply on/off timing chart is as follows

EX–ON–EX–COM

EX–OFF–EX–COM

Power on
TON y 0.5 sec, TOFF y 0.5 sec, TOFF–ON y 5 sec

Fig.3.2.4 (b) Connection of the external power supply switch ON and OFF

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3. ELECTRICAL CONNECTIONS CONNECTIONS B–80945EN/02

3.2.5
Connecting the
External Emergency
Stop
Operator box Type A

Panel board TBOP1

Operator box Type B

Panel board TBOP1

In case of B–cabinet

Panel board
TBOP1

Fig.3.2.5 (a) Connection of the external emergency stop

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B–80945EN/02 CONNECTIONS 3. ELECTRICAL CONNECTIONS

External emergency stop output

ESTOP1

ESTOP2

Panel board

Signal Description Current, voltage

EMGOUT1 Emergency stop output signals. The contact is open
if an emergency stop occurs or the power is turned off.
EMGOUTC The contact is closed during normal operation. Rated contact:
250 VAC, 5-A or
EMGOUT2 Emergency stop output signals. The contact is closed 30 VAC, 5A resistor load
if an emergency stop occurs or the power is turned off.
EMGOUTC The contact is open during normal operation.
Emergency stop output signals of the teach pendant
ESTOP1 and operator’s panel. The contact is opened if which Rated contact:
emergency stop button or emergency stop button of 24 VDC, 0.1-A resistor
ESTOP2 operator’s panel is pressed. The contact is closed load
during normal operation.

Fig.3.2.5 (b) External emergency stop output

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3. ELECTRICAL CONNECTIONS CONNECTIONS B–80945EN/02

External emergency stop input

After you connect an external emergency stop switch and safety fence door switch, be sure to check the operation
of those switches, the emergency stop switch on the operator panel, and the emergency stop switch on the teach
pendant.
Servo off input switch

Safety fence switch

External emergency stop switch

Connected at the factory.
Remove the short board to use.

Panel board

Use a contact rated at 250 V, 10 A or more on the printed circuit board for emergency stop control.

Signal Description Current, voltage

Connect the contacts of the external emergency stop switch
EMGIN1 to these terminals. When using the contacts of a relay or con-
Open and close of
tactor instead of the switch, connect a spark killer to the coil
24VDC 0.1A
EMGIN2 of the relay or contactor, to suppress noise.
When these terminals are not used, jumper them.
These signals are used to stop the robot when the door on the
safety fence is open.
FENCE1
While the deadman’s switch on the teach pendant is pressed Open and close of
and the teach pendant is enabled, these signals are ignored 24VDC 0.1A
FENCE2
and an emergency stop does not occur.
If these signals are not used, short these terminals.
Connect the contacts of the servo–on input switch to these
SVOFF1 terminals. When using the contacts of a relay or contactor
Open and close of
instead of the switch, connect a spark killer to the coil of the
24VDC 0.1A
SVOFFF2 relay or contactor, to suppress noise. When these terminals
are not used, jumper them.

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Connecting external on/off and external emergency stop signal input/output wires

Details of the signal wires are shown below:

Bare wire length: 8 to 9 mm

Compliant wire size: 0.08 to 2.5 mm2

If you want to use a rod terminal, select one that is suitable for the wire shown above.
The following table lists recommended products (manufactured by Weissmuller).

Wire (mm2) Specification Remark

0.5 H0.5/14
0.75 H0.75/14 With (Crimping tool : PZ3, PZ4, PZ6/5)
insulation
1.0 H1.0/14 cover
1.5 H1.5/14
2.5 H2.5/14

How to attach signal wires to connectors

Manipulation slot

Flat–blade screwdriver

Plug connector block

Signal wire

1. Detach the plug connector block from the panel board.

2. Insert the tip of a flat–blade screwdriver into the manipulation slot and push down its handle.
3. Insert the end of the signal wire into the wire slot.
4. Pull out the screwdriver.
5. Attach the plug connector block to the panel board.

Do not insert a wire into the wire hole of a plug connector or pull it out with the plug connector
block mounted on the panel board; otherwise, the panel board may be damaged.

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PERIPHERAL DEVICE, ARC WELDING, AND END EFFECTOR

4 INTERFACES

R-J3 I/O peripheral device interfaces include printed circuit boards and
a unit selected according to the applications. Table 4 (a) lists details of
the printed–circuit boards and units. Table 4 (b) lists the units that can be
installed in the operator box. Figure 4 shows the locations of these boards
and units.
Table 4 (a) Peripheral Device Interface Types
Number of I/O points (NOTE1)
No. Name Drawing number Remarks
DI DO D/A A/D
1 Process I/O board EA A05B-2400-J024 40 40 2 6 Installed in the operator box
2 Process I/O board EB A05B-2400-J025 40 40 0 0 Installed in the operator box
3 Process I/O board FA A05B-2400-J030 96 96 0 0 Installed in the operator box
4 Process I/O board CA A05B–2300–J030 40 40 2 6 Installed in back plane
5 Process I/O board CB A05B–2300–J031 40 40 0 0 Installed in back plane
6 Process I/O board DA A05B–2300–J035 96 96 0 0 Installed in back plane
I/O Unit–MODEL A A05B-2400-J001 Depending on selected I/O mod- It is available to install it in the operator
(A–cabinet) (Base and interface unit) ule. box type B (NOTE2)
7
I/O Unit–MODEL A A05B-2401-J001
(B–cabinet) (Base and interface unit)
8 I/O Unit–MODEL B A05B–2400–J005 Depending on selected I/O unit. Interface unit is installed in the A–cabinet.
9 Process I/O board GA A05B–2400–J031 40 40 2 0 Installed in the operator box

NOTE
1 General purpose I/O (SDI/SDO) is a number which subtract an exclusive signal from the table
value.
Example : Process I/O board EB
Table value Exclusive DI General purpose DI
DI; 40 – 18 = 22 points
Table value Exclusive DO General purpose DO
DO; 40 – 20 = 20 points
2 When you want to mount I/O unit model A in the operator box (Type B), consult our service
representative.

Table 4 (b) Units that can be Installed in the Operator Box

No. Name and size Specified drawing number Unit that can be installed
1 Operator box type A A05B–2400–H200 (in English) 1. Process I/O board EA
Width : 410 mm A05B–2400–H201 (in Japanese) 2. Process I/O board EB
Height : 290 mm 3. Process I/O board FA
Depth : 200 mm 4. I/O unit model B base unit and expansion unit
2 Operator box type B A05B–2400–H202 (in English) 1. Process I/O board EA
Width : 410 mm A05B–2400–H203 (in Japanese) 2. Process I/O board EB
Height : 490 mm 3. Process I/O board FA
Depth : 280 mm 4. I/O unit model A
5. I/O unit model B base unit and expansion unit

NOTE
The I/O unit model B interface unit is installed in the
A–cabinet.

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 4. PERIPHERAL DEVICE, ARC WELDING,
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Process I/O board

Operator box Type A I/O unit model B (Each one of
basic unit and expanded unit)

I/O unit model B

Expanded unit
Interface unit Basic unit
To peripheral device

Process I/O board

I/O unit model A (five slots)
I/O unit model B (Each one of basic unit and expanded unit)
Operator box Type B

I/O unit model A (five slots)

I/O unit model B

Expanded unit
Basic unit
Interface unit
To peripheral device
Process I/O printed board

A–cabinet Main board B–cabinet

I/O unit model B

Interface unit I/O unit model A or I/O unit model B
I/O unit modelB (Figure is I/O unit model A (5 slots))

Expanded unit

Basic unit

Interface unit

Fig.4 Locations of Peripheral Device Interfaces

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4. PERIPHERAL DEVICE, ARC WELDING,
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4.1 Following are a block diagram of the peripheral device interface and the
specifications.
PERIPHERAL
DEVICE INTERFACE
BLOCK DIAGRAM

4.1.1
When Process I/O
Board EA or EB or GA
is used (A–Cabinet)

i–cabinet Operator box

Main board Panel board

Process Peripheral
I/O board device
JD1A K01A EA/EB/GA
CRS9
(JD4)
K24

JRS8 JD1B
K50A
CRM2A
CP5
K50B
CRM2B

CRW1 or CRW7 K45

(NOTE 2)
Operator box
connection cable CRW2

Fig.4.1.1 Block diagram of the process I/O board EA, EB and GA

NOTE
1. CRW1 and CRW2 are not provided for process I/O board
EB.
2. In case of process I/O board EA : CRW1
In case of process I/O board GA : CRW7

Cable
Item number Name Drawing number Remarks

Common K01A Operator box connection cable A05B–2400–H232 Connected length : 5m

A05B–2400–H233 Connected length : 10m
A05B–2400–H234 Connected length : 2m
K24 I/O link cable A05B–2400–J100 For process I/O board
For operator box K50A Peripheral device connection cable A05B–2400–J200 Connected length : 10m (one)
type A K50B
A05B–2400–J201 Connected length : 20m (one)
A05B–2400–J202 Connected length : 30m (one)
K45 Welding device connection cable A05B–2400–J230 Connected length : 7m (one)
(For process I/O board EA)
A05B–2400–J231 Connected length : 14m (one)
Welding device connection cable A05B–2400–J246 Connected length : 3m (one)
(For process I/O board GA)
A05B–2400–J247 Connected length : 7m (one)
A05B–2400–J248 Connected length : 14m (one)

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 4. PERIPHERAL DEVICE, ARC WELDING,
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Cable
Item number Name Drawing number Remarks

For operator box K50A Operator box connection cable A05B–2400–J203 Connected length : 10m (one)
type B K50B
A05B–2400–J204 Connected length : 20m (one)
A05B–2400–J205 Connected length : 30m (one)
K45 Welding device connection cable A05B–2400–J232 Connected length : 7m (one)
(For process I/O board EA)
A05B–2400–J233 Connected length : 14m (one)
Welding device connection cable A05B–2400–J242 Connected length : 3m (one)
(For process I/O board GA)
A05B–2400–J238 Connected length : 7m (one)
A05B–2400–J239 Connected length : 14m (one)

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4.1.2
When Process I/O
Board FA is Used
(A–cabinet)

A–cabinet Operator box

Main board Panel board

Process I/O Peripheral
board FA device
JD1A K01A
CRS9
(JD4)
K24

JRS8 JD1B
K50A
CRM2A
CP5
K50B
CRM2B

K50C
CRM2C

Operator box K50D

connection cable CRM2D

K51A
CRM4A

K51B
CRM4B

Fig.4.1.2 Block diagram of the process I/O board FA

Item Cable Name Drawing number Remarks

number
Common K01A Operator box connection cable A05B–2400–H232 Connected length : 5m
A05B–2400–H233 Connected length : 10m
A05B–2400–H234 Connected length : 2m
K24 I/O link cable A05B–2400–J100 For process I/O board
For operator K50A Peripheral device connection cable A05B–2400–J200 Connected length : 10m (one)
box type A K50B
K50C A05B–2400–J201 Connected length : 20m (one)
K50D A05B–2400–J202 Connected length : 30m (one)
K51A Peripheral device connection cable A05B–2400–J250 Connected length : 10m (one)
K51B
A05B–2400–J251 Connected length : 20m (one)
A05B–2400–J252 Connected length : 30m (one)
For operator K50A Peripheral device connection cable A05B–2400–J200 Connected length : 10m (one)
box type B K50B
K50C A05B–2400–J204 Connected length : 20m (one)
K50D A05B–2400–J205 Connected length : 30m (one)
K51A Peripheral device connection cable TBD (Note) Connected length : 10m (one)
K51B
TBD (Note) Connected length : 20m (one)
TBD (Note) Connected length : 30m (one)

NOTE
Consult our service representative.

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 4. PERIPHERAL DEVICE, ARC WELDING,
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4.1.3
When Process I/O
Board CA or CB is
Used (B–cabinet)
B–cabinet
Main board Process Peripheral
I/O board device
CA/CB
JD1A K24
JD4A
(JD4)
K50A
CRM2A

JD4B K50B
CRM2B

K45
CRW1

CRW2

Process
I/O board
CA/CB

JD4A
CRM2A

JD4B
CRM2B

CRW1

CRW2

Fig.4.1.3 Block diagram of the process I/O board CA and CB

NOTE
CRW1 and CRW2 are not provided for process I/O board
CB

Cable Name Drawing number Remarks

number
K24 I/O link cable A05B–2400–J050 Between main board and process I/O
I/O link cable A05B–2400–J051 Between process I/O and process I/O
K50A Peripheral device connection cable A05B–2401–J100 Connected length 10m (one)
K50B A05B–2401–J101 Connected length 20m (one)
A05B–2401–J102 Connected length 30m (one)
K45 Welding device connection cable A05B–2401–J230 Connected length 7m (one)
A05B–2401–J221 Connected length 14m (one)

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4. PERIPHERAL DEVICE, ARC WELDING,
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4.1.4
When Process I/O
Board DA is Used
(B–cabinet)
B–cabinet
Main board Process I/O Peripheral
board DA device
JD1A K24
JD4A
(JD4)
K50A
CRM2A

JD4B K50B
CRM2B

K50C
CRM2C

K50D
CRM2D

K51A
CRM4A

K51B
CRM4B

Process I/O
board DA

JD4A
CRM2A

JD4B
CRM2B

CRM2C

CRM2D

CRM4A

CRM4B

Fig.4.1.4 Block diagram of the process I/O board DA

Cable Name Drawing number Remarks

number
K24 I/O link cable A05B–2400–J050 Between main board and process I/O
I/O link cable A05B–2400–J051 Between process I/O and process I/O
K50A, Peripheral device connection cable A05B–2401–J100 Connected length 10m (one)
K50B,
K50C, A05B–2401–J101 Connected length 20m (one)
K50D A05B–2401–J102 Connected length 30m (one)
K51A Welding device connection cable A05B–2401–J120 Connected length 10m (one)
K51B
A05B–2401–J121 Connected length 20m (one)
A05B–2401–J122 Connected length 30m (one)

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 4. PERIPHERAL DEVICE, ARC WELDING,
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4.1.5
When I/O Unit–MODEL
A is Used

4.1.5.1
In case of A–cabinet

A–cabinet Operator box

Main board Panel board

K01A
JD1A
CRS9
(JD4)
K25
JRS8

JD1A JD1B CP32 Peripheral

device
Operator box
connection cable
Interface module

K54
Back plane (5–slot)

K54

K54

K54

K54

Fig.4.1.5.1 Block diagram of I/O Unit–A (in case of A–cabinet)

Cable
Item Name Drawing number Remarks
number
Common K01A Operator box connection cable A05B–2400–H232 Connected length : 5m
A05B–2400–H233 Connected length : 10m
A05B–2400–H234 Connected length : 2m
K25 I/O Link cable A05B–2400–J101 For I/O Unit–A
For operator box K54 Peripheral device connection cable ____ Must be supplied by the customer.
type A
For operator box K54 Peripheral device connection cable ____ Must be supplied by the customer.
type B

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4. PERIPHERAL DEVICE, ARC WELDING,
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4.1.5.2
In case of B–cabinet

Operator box

Main board

JD1A
K25
(JD4)

Peripheral
device

Interface module

K54

K54

K54

K54

K54

Fig.4.1.5.2 Block diagram of I/O Unit–A (In case of B–cabinet)

Cable
Item Name Drawing number Remarks
number
Common K25 I/O link cable — Included in A05B–2401–J001
For operator K54 Peripheral device connection cable — Must be supplied by the cus-
box type A tomer.
For operator K54 Peripheral device connection cable — Must be supplied by the cus-
box type B tomer.

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 4. PERIPHERAL DEVICE, ARC WELDING,
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4.1.6
When I/O Unit–MODEL
B is Used
4.1.6.1
In case of A–cabinet

Main A–cabinet
board
I/O Unit–B
K10 Interface unit
JD1A S1+ CRS7
JD1B To robot
(JD4) S1–

S2+ CRS8A
JD1A
S2–
Power
24V S3+ CRS8B
supply
unit CP6 0V S3–
K11
K01A

Peripheral
Panel
board device
I/O Unit–B
CRS9 basic unit
JRS8

K26 +24V K54

CRP14
0V

S+
K27A S–

I/O Unit–B
expanded unit

K27B
K54
+24V
0V
S+
S–

Fig.4.1.6.1 Block diagram of I/O Unit–B (in case of A–cabinet)

Item Cable Name Drawing number Remarks

number
Common K01A Operator box connection cable A05B–2400–H232 Connected length : 5m
A05B–2400–H233 Connected length : 10m
A05B–2400–H234 Connected length : 2m
K10 I/O link cable A05B–2400–J060 Connected length : 5m
Common K11 I/O Unit–B connection cable (Note) Connected length : 5m
(Note) Connected length : 10m
(Note) Connected length : 2m
K26 +24V power supply connection cable (Note) For I/O unit model B
For operator box type A K54 Peripheral device connection cable –––– Must be supplied by the customer.
For operator box type B K54 Peripheral device connection cable –––– Must be supplied by the customer.

NOTE
Consult our service representative.

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4. PERIPHERAL DEVICE, ARC WELDING,
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4.1.6.2
In case of B–cabinet

B–cabinet

I/O Unit–B
Main board Interface unit

K10
JD1A
JD1B S1+ To robot
(JD4) S1–

JD1A S2+
S2–

Power +24V
0V S3+
supply unit
S3–

K10
CP6 K11 Peripheral
device
I/O Unit–B
basic unit

K26 K54
+24V
0V
S+
S–

I/O Unit–B
expanded unit

+24V
0V K54
S+
S–

Fig.4.1.6.2 Block diagram of I/O Unit–B (in case of B–cabinet)

Cable Name Drawing number Remarks

number
K10 I/O link cable A05B–2401–J053
K11 I/O Unit–B connection cable (Note)
K26 +24V power supply connection cable (Note)
K54 Preipheral device connection cable — Must be supplied by the cus-
tommer

NOTE
Consult our service representative.

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 4. PERIPHERAL DEVICE, ARC WELDING,
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4.1.7
(a) In case of A–cabinet
When Two or more The following figure shows the connection when two or more process
Process I/O Printed I/O boards and I/O unit (model A or model B) are used.
Circuit Boards and I/O In case of A–cabinet, one of above–mentioned units can be mounted
Unit (Model A or Model in the operator box.
B) are Used However, I/O Unit–A cannot be mounted in the operator box type A.

Main A–cabinet
board
I/O unit model B
K10 Interface unit
JD1A S1+ CRS7
JD1B Robot mechanical unit
(JD4) S1–

S2+ CRS8A
JD1A
S2–
Power CRS8B
supply 24V S3+
unit CP6 0V S3–

CP6
K01A

Operator box
Pannel Selection
board Process I/O
CRS9 board
K24
JRS8 JD1B

JD1A

CRP14 CP5
K25

I/O unit model A

inter face module
JD1B

JD1A

CP32

Back plane (five slots)

I/O unit model B base unit

+24V
0V
K27A
K11 S+
S–

I/O unit model B expanded unit

K27B +24V
0V
S+
S–

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4. PERIPHERAL DEVICE, ARC WELDING,
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(b) In case of B–cabinet.

When several units of the process I/O PCB, I/O Unit–A, or I/O
Unit–B are used, connect them as shown below.

B–cabinet
Main board
Process
I/O board
JD1A A05B–2401–J050
JD4A DC power is supplied
(JD4) from the back plane.
JD4B

Process
I/O board
A05B–2401–J051
JD4A

JD4B

I/O Unit–A
Included in model
Interface module
A base unit
JD1B

JD1A

CP32

Back plane (5–slot)

I/O Unit–B
A05B–2401–J053 Interface unit

JD1B S1+
S1–
Power supply
unit JD1A
S2+
S2–
+24V
CP6
0V S3+
S3–

I/O Unit–B
+24V basic module
0V
S+
S–

I/O Unit–B
+24V expanded unit
0V
S+
S–

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4.2
PERIPHERAL
DEVICE INTERFACE
COMBINATION
4.2.1 Only one of the following peripheral device interfaces can be used in
A–cabinet.
In Case of A–Cabinet
D Process I/O board EA.
D Process I/O board EB.
D Process I/O board FA.
D I/O unit Model A (5 slots) (not available for operator box type A)
D I/O unit Model B (Interface unit + Basic unit + Expanded unit)
If you want to use more than one interface unit in combination in case of
A–cabinet, you need another box. Contact a FANUC sales representative
for details.

4.2.2 One board or one unit is used

In Case of B–Cabinet Combination C Process I/O board CA/CB (40 points)
Combination D Process I/O board DA
(96 points)
Combination E I/O Unit–A/B
Two boards/units are used in combination
Combination CC Process I/O board CA/CB (40 points)
+
Process I/O board CA/CB (40 points)
Combination CE Process I/O board CA/CB (40 points)
+
I/O Unit–A/B

Combination DC Process I/O board DA (96 points)

+
Process I/O board CA/CB (40 points)
Combination DD Process I/O board DA (96 points)
+
Process I/O board DA (96 points)
Combination DE Process I/O board DA (96 points)
+
I/O Unit–A/B

Three boards/units are used in combination

Combination CCE Process I/O board CA/CB (40 points)
+
Process I/O board CA/CB (40 points)
+
I/O Unit–A/B
Combination DCE Process I/O board DA (96 points)
+
Process I/O board CA/CB (40 points)
+
I/O Unit–A/B
Combination DDE Process I/O board DA (96 points)
+
Process I/O board DA (96 points)
+
I/O Unit–A/B

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4.3 There are 18 exclusive data inputs (DI) and 20 exclusive data outputs
(DO) for a process I/O board.
PROCESS I/O
These signals are allocated to the process I/O board connected first when
BOARD SIGNALS two or more printed boards are combined. (General signals SDI/SDO are
allocated to the second and the following process I/O boards.)
The common voltage of the DI signals input to pins 1 to 4 of connector
CRM2A is clamped +24 V (common) in each process I/O board.
Table 4.3 shows signals of a process I/O board.

Table 4.3 Process I/O Board Signals (1/4)

(DI signals)
Connector Signal name Description Remarks
number
CRM2A-1 *IMSTP Immediate stop Clamped at +24 V
common
CRM2A-2 *HOLD Temporary stop Clamped at +24 V
common
CRM2A-3 *SFSD Safe speed Clamped at +24 V
common
CRM2A-4 CSTOPI Cycle stop Clamped at +24 V
common
CRM2A-5 FAULT RESET External reset
CRM2A-6 START Start
CRM2A-7 HOME Return to home
position
CRM2A-8 ENBL Operation enabled
CRM2A-9 RSR1 Robot service request
PNS1 Program number Option
selection
CRM2A-10 RSR2 Robot service request
PNS2 Program number Option
selection
CRM2A-11 RSR3 Robot service request
PNS3 Program number Option
selection
CRM2A-12 RSR4 Robot service request
PNS4 Program number Option
selection
CRM2A-13 RSR5 Robot service request
PNS5 Program number Option
selection
CRM2A-14 RSR6 Robot service request
PNS6 Program number Option
selection
CRM2A-15 RSR7 Robot service request
PNS7 Program number Option
selection

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Table4.3 Process I/O Board Signals (2/4)

(DI signals)
Connector Signal name Description Remarks
number
CRM2A-16 RSR8 Robot service request
PNS8 Program number Option
selection
CRM2A-29 PNSTROBE PNS strobe
CRM2A-30 PROD START Start of automatic
operation
CRM2A-31 SDI01 Peripheral device General signal
status
CRM2A-32 SDI02
CRM2B-1 SDI03
CRM2B-2 SDI04
CRM2B-3 SDI05
CRM2B-4 SDI06
CRM2B-5 SDI07
CRM2B-6 SDI08
CRM2B-7 SDI09
CRM2B-8 SDI10
CRMSB-9 SDI11
CRM2B-10 SDI12
CRM2B-11 SDI13
CRM2B-12 SDI14
CRM2B-13 SDI15
CRM2B-14 SDI16
CRM2B-15 SDI17
CRM2B-16 SDI18
CRM2B-29 SDI19
CRM2B-30 SDI20
CRM2B-31 SDI21
CRM2B-32 SDI22

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Table4.3 Process I/O Board Signals (3/4)

(DO signals)
Connector Signal name Description Remarks
number
CRM2A-33 CMDENBL During automatic
operation
CRM2A-34 SYSRDY Preparation
completed
CRM2A-35 PROGRUN Program running
CRM2A-36 PAUSED Program being
interrupted
CRM2A-38 HELD During temporary stop
CRM2A-39 FAULT Alarm
CRM2A-40 ATPERCH Home position
CRM2A-41 TPENBL Teach pendant
enabled
CRM2A-43 BATALM Battery voltage drop
CRM2A-44 BUSY During operation
CRM2A-45 ACK1 Robot service request
acceptance
SNO1 Selected program Option
number
CRM2A-46 ACK2 Robot service request
acceptance
SNO2 Selected program Option
number
CRM2A-19 ACK3 Robot service request
acceptance
SNO3 Selected program Option
number
CRM2A-20 ACK4 Robot service request
acceptance
SNO4 Selected program Option
number
CRM2A-21 ACK5 Robot service request
acceptance
SNO5 Selected program Option
number
CRM2A-22 ACK6 Robot service request
acceptance
SNO6 Selected program Option
number
CRM2A-24 ACK7 Robot service request
acceptance
SNO7 Selected program Option
number
CRM2A-25 ACK8 Robot service request
acceptance
SNO8 Selected program Option
number

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Table4.3 Process I/O Board Signals (4/4)

(DO signals)
Connector Signal name Description Remarks
number
CRM2A-26 SNACK Response signal to
PNS
CRM2A-27 RESERVED
CRM2B-33 SDO01 Peripheral device General signal
control signal
CRM2B-34 SDO02
CRM2B-35 SDO03
CRM2B-36 SDO04
CRM2B-38 SDO05
CRM2B-39 SDO06
CRM2B-40 SDO07
CRM2B-41 SDO08
CRM2B-43 SDO09
CRM2B-44 SDO10
CRMSB-45 SDO11
CRM2B-46 SDO12
CRM2B-19 SDO13
CRM2B-20 SDO14
CRM2B-21 SDO15
CRM2B-22 SDO16
CRM2B-24 SDO17
CRM2B-25 SDO18
CRM2B-26 SDO19
CRM2B-27 SDO20

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4.4
INTERFACE FOR
PERIPHERAL
DEVICES, END
EFFECTORS, AND
WELDERS
4.4.1
Peripheral Device and
Control Unit Connection
Control unit
Peripheral device control interface A1
CRM2A
1 *IMSTP 33 CMDENBL
2 *HOLD 34 SYSRDY
19 ACK3/SNO3
3 *SFSPD 35 PROGRUN
20 ACK4/SNO4
4 CSTOPI 36 PAUSED
21 ACK5/SNO5
5 FAULT RESET 37 COM–A1
22 ACK6/SNO6
6 START 38 HELD
23 COM–A4
7 HOME 39 FAULT
24 ACK7/SNO7
8 ENBL 40 ATPERCH
25 ACK8/SNO8 Peripheral
9 RSR1/PNS1 41 TPENBL
26 SNACK device A1
10 RSR2/PNS2 42 COM–A2
27 RESERVED
11 RSR3/PNS3 43 BATALM
28 COM–A5
12 RSR4/PNS4 44 BUSY
29 PNSTROBE
13 RSR5/PNS5 45 ACK1/SNO1
14 30 PROD START
RSR6/PNS6 46 ACK2/SNO2
31 SDI01
15 RSR7/PNS7 47 COM–A3
32 SDI02
16 RSR8/PNS8 48
17 0V 49 +24E
18 0V 50 +24E

Peripheral device control interface A2

1 SDI03 CRM2B 33 SDO01
2 SDI04 34 SDO02
19 SDO13
3 SDI05 35 SDO03
20 SDO14
4 SDI06 36 SDO04
21 SDO15
5 SDI07 37 COM–B1
22 SDO16
6 SDI08 38 SDO05
23 COM–B4
7 SDI09 39 SDO06
24 SDO17
8 SDI10 40 SDO07
25 SDO18 Peripheral
9 SDI11 41 SDO08
26 SDO19 device A2
10 SDI12 42 COM–B2
27 SDO20
11 SDI13 43 SDO09
28 COM–B5
12 SDI14 44 SDO10
29 SDI19
13 SDI15 45 SDO11
30 SDI20
14 SDI16 46 SDO12
31 SDI21
15 SDI17 47 COM–B3
32 SDI22
16 SDI18 48
17 0V 49 +24E
18 0V 50 +24E

NOTE
1 The peripheral device connection cables are optional.
2 All of COM-** are connected to 0 V.

Applicable process I/O board type

EA, EB, FA, CA, CB, DA, GA

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Control unit
Peripheral device control interface A3
SDI23 CRM2C SDO21
1 33
2 SDI24 34 SDO22
19 SDO33
3 SDI25 35 SDO23
20 SDO34
4 SDI26 36 SDO24
21 SDO35
5 SDI27 37 COM–C1
22 SDO36
6 SDI28 38 SDO25
23 COM–C4
7 SDI29 39 SDO26
24 SDO37
8 SDI30 40 SDO27
25 SDO38 Pripheral
9 SDI31 41 SDO28 device A3
26 SDO39
10 SDI32 42 COM–C2
27 SDO40
11 SDI33 43 SDO29
28 COM–C5
12 SDI34 44 SDO30
29 SDI39
13 SDI35 45 SDO31
30 SDI40
14 SDI36 46 SDO32
31 SDI41
15 SDI37 47 COM–C3
32 SDI42
16 SDI38 48
17 0V 49 +24E
18 0V 50 +24E

Peripheral device control interface A4

1 SDI43 CRM2D 33 SDO41
2 SDI44 34 SDO42
19 SDO53
3 SDI45 35 SDO43
20 SDO54
4 SDI46 36 SDO44
21 SDO55
5 SDI47 37 COM–D1
22 SDO56
6 SDI48 38 SDO45
23 COM–D4
7 SDI49 39 SDO46
24 SDO57
8 SDI54 40 SDO47
25 SDO58 Pripheral
9 SDI51 41 SDO48 device A4
26 SDO59
10 SDI52 42 COM–D2
27 SDO60
11 SDI53 43 SDO49
28 COM–D5
12 SDI54 44 SDO50
29 SDI59
13 SDI55 45 SDO51
30 SDI60
14 SDI56 46 SDO52
31 SDI61
15 SDI57 47 COM–D3
32 SDI62
16 SDI58 48
17 0V 49 +24E
18 0V 50 +24E

NOTE
1 The peripheral device connection cables are optional.
2 All of COM-** are connected to 0 V.

Applicable process I/O board type

FA, DA

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Control unit
Peripheral device control interface B1
CRM4A
01 SDI63 14 SDO61
08 SDO65
02 SDI64 15 SDO62
09 SDO66
03 SDI65 16 SDO63
10 SDO67 Peripheral
04 SDI66 17 SDO64
11 SDO68 device B1
05 SDI67 18 COM–E1
12 COM–E2
06 SDI68 19 +24
13 SDI70
07 SDI69 20 0V

Control unit
Peripheral device control interface B1
CRM4B
01 SDI71 14 SDO69
08 SDO73
02 SDI72 15 SDO70
09 SDO74
03 SDI73 16 SDO71
10 SDO75 Peripheral
04 SDI74 17 SDO72
11 SDO76 device B2
05 SDI75 18 COM–F1
12 COM–F2
06 SDI76 19 +24
13 SDI78
07 SDI77 20 0V

NOTE
1 The peripheral device connection cables are optional.
2 All of COM–** are connected to 0V.

Applicable process I/O board type

FA, DA

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Control unit Connector pin No. Peripheral device

(peripheral device control interface A1)
+24E
CRM2A (49,50)
Receiver circuit
CRM2A (1)
*IMSTP RV
CRM2A (2)
*HOLD RV
CRM2A (3)
*SFSPD RV
CRM2A (4)
CSTOPI RV

CRM2A (5)
FAULT RESET RV
CRM2A (6)
START RV
CRM2A (7)
HOME RV
CRM2A (8)
ENBL RV
CRM2A (9)
RSR1/PNS1 RV
CRM2A (10)
RSR2/PNS2 RV
CRM2A (11)
RSR3/PNS3 RV
CRM2A (12)
RSR4/PNS4 RV
CRM2A (13)
RSR5/PNS5 RV
CRM2A (14)
RSR6/PNS6 RV
CRM2A (15)
RSR7/PNS7 RV
CRM2A (16)
RSR8/PNS8 RV
CRM2A (29)
PNSROBE RV
CRM2A (30)
PROD START RV
CRM2A (31)
SDI01 RV
CRM2A (32)
SDI02 RV

+24E
B A

Common setting
pin (ICOM1)

NOTE
This is a connection diagram for +24v common.

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Control unit Connector pin No. Peripheral device

(peripheral device control interface A1)

Receiver circuit LOAD

DV CRM2A (33)

 Â
RELAY
CMDENBL

CRM2A (34)
SYSRDY DV LOAD
CRM2A (35)
PROGRUN DV LOAD
CRM2A (36)
PAUSED DV LOAD
CRM2A (38)
HELD DV LOAD
CRM2A (39)
FAULT DV LOAD
CRM2A (40)
ATPERCH DV LOAD
CRM2A (41)
TPENBL DV LOAD
CRM2A (43)
BATALM DV LOAD
CRM2A (44)
BUSY DV LOAD
CRM2A (45)
ACK1/SNO1 DV LOAD
CRM2A (46)
ACK2/SNO2 DV LOAD
CRM2A (19)
ACK3/SNO3 DV LOAD
CRM2A (20)
ACK4/SNO4 DV LOAD
CRM2A (21)
ACK5/SNO5 DV LOAD
CRM2A (22)
ACK6/SNO6 DV LOAD
CRM2A (24)
ACK7/SNO7 DV LOAD
CRM2A (25)
ACK8/SNO8 DV LOAD
CRM2A (26)
SNACK DV LOAD
CRM2A (27)
RESERVED DV LOAD

CRM2A(23,28,37,
42,47)
0V +24V
+24 V regulated
power supply

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Control unit Connector pin No. Peripheral device

(peripheral device control interface A2)
+24E
CRM2B (49,50)

Receiver circuit
CRM2B (1)
SDI03 RV
CRM2B (2)
SDI04 RV
CRM2B (3)
SDI05 RV
CRM2B (4)
SDI06 RV
CRM2B (5)
SDI07 RV
CRM2B (6)
SDI08 RV
CRM2B (7)
SDI09 RV
CRM2B (8)
SDI10 RV
CRM2B (9)
SDI11 RV
CRM2B (10)
SDI12 RV
CRM2B (11)
SDI13 RV
CRM2B (12)
SDI14 RV
CRM2B (13)
SDI15 RV
CRM2B (14)
SDI16 RV
CRM2B (15)
SDI17 RV
CRM2B (16)
SDI18 RV
CRM2B (29)
SDI19 RV
CRM2B (30)
SDI20 RV
CRM2B (31)
SDI21 RV
CRM2B (32)
SDI22 RV

+24E
B A

Common setting
pin (ICOM2)

NOTE
This is a connection diagram for +24V common.

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Control unit Peripheral device

(peripheral device control interface A2)

Connector pin No. LOAD

CRM2B (33)

Â
SDO01 DV RELAY

CRM2B (34)
SDO02 DV LOAD
CRM2B (35)
SDO03 DV LOAD
CRM2B (36)
SDO04 DV LOAD
CRM2B (38)
SDO05 DV LOAD
CRM2B (39)
SDO06 DV LOAD
CRM2B (40)
SDO07 DV LOAD
CRM2B (41)
SDO08 DV LOAD
CRM2B (43)
SDO09 DV LOAD
CRM2B (44)
SDO10 DV LOAD
CRM2B (45)
SDO11 DV LOAD
CRM2B (46)
SDO12 DV LOAD
CRM2B (19)
SDO13 DV LOAD
CRM2B (20)
SDO14 DV LOAD
CRM2B (21)
SDO15 DV LOAD
CRM2B (22)
SDO16 DV LOAD
CRM2B (24)
SDO17 DV LOAD
CRM2B (25)
SDO18 DV LOAD
CRM2B (26)
SDO19 DV LOAD
CRM2B (27)
SDO20 DV LOAD

CRM2A(23,28,37,
42,47)
0V +24V
+24 V regulated
power supply

254
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Control unit Peripheral device

Connector pin No.
(peripheral device control interface A3)
+24E
CRM2C (49,50)

Receiver circuit
CRM2C (1)
SDI23 RV
CRM2C (2)
SDI24 RV
CRM2C (3)
SDI25 RV
CRM2C (4)
SDI26 RV
CRM2C (5)
SDI27 RV
CRM2C (6)
SDI28 RV
CRM2C (7)
SDI29 RV
CRM2C (8)
SDI30 RV
CRM2C (9)
SDI31 RV
CRM2C (10)
SDI32 RV
CRM2C (11)
SDI33 RV
CRM2C (12)
SDI34 RV
CRM2C (13)
SDI35 RV
CRM2C (14)
SDI36 RV
CRM2C (15)
SDI37 RV
CRM2C (16)
SDI38 RV
CRM2C (29)
SDI39 RV
CRM2C (30)
SDI40 RV
CRM2C (31)
SDI41 RV
CRM2C (32)
SDI42 RV

+24E
B A

Common setting
pin (ICOM3)

NOTE
This is a connection diagram for +24V common.

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Control unit Peripheral device

(peripheral device control interface A3)

Connector pin No. LOAD

CRM2C (33)

 Â
SDO21 DV
RELAY

CRM2C (34)
SDO22 DV LOAD
CRM2C (35)
SDO23 DV LOAD
CRM2C (36)
SDO24 DV LOAD
CRM2C (38)
SDO25 DV LOAD
CRM2C (39)
SDO26 DV LOAD
CRM2C (40)
SDO27 DV LOAD
CRM2C (41)
SDO28 DV LOAD
CRM2C (43)
SDO29 DV LOAD
CRM2C (44)
SDO30 DV LOAD
CRM2C (45)
SDO31 DV LOAD
CRM2C (46)
SDO32 DV LOAD
CRM2C (19)
SDO33 DV LOAD
CRM2C (20)
SDO34 DV LOAD
CRM2C (21)
SDO35 DV LOAD
CRM2C (22)
SDO36 DV LOAD
CRM2C (24)
SDO37 DV LOAD
CRM2C (25)
SDO38 DV LOAD
CRM2C (26)
SDO39 DV LOAD
CRM2C (27)
SDO40 DV LOAD

CRM2C(23,28,37,
42,47)
0V +24V
+24 V regulated
power supply

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Control unit Peripheral device

Connector pin No.
(peripheral device control interface A4)
+24E
CRM2D (49,50)

Receiver circuit
CRM2D (1)
SDI43 RV
CRM2D (2)
SDI44 RV
CRM2D (3)
SDI45 RV
CRM2D (4)
SDI46 RV
CRM2D (5)
SDI47 RV
CRM2D (6)
SDI48 RV
CRM2D (7)
SDI49 RV
CRM2D (8)
SDI50 RV
CRM2D (9)
SDI51 RV
CRM2D (10)
SDI52 RV
CRM2D (11)
SDI53 RV
CRM2D (12)
SDI54 RV
CRM2D (13)
SDI55 RV
CRM2D (14)
SDI56 RV
CRM2D (15)
SDI57 RV
CRM2D (16)
SDI58 RV
CRM2D (29)
SDI59 RV
CRM2D (30)
SDI60 RV
CRM2D (31)
SDI61 RV
CRM2D (32)
SDI62 RV

+24E
B A

Common setting
pin (ICOM4)

NOTE
This is a connection diagram for +24V common.

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Control unit Peripheral device

(peripheral device control interface A4)

Connector pin No. LOAD

CRM2D (33)

 Â
SDO41 DV
RELAY

CRM2D (34)
SDO42 DV LOAD
CRM2D (35)
SDO43 DV LOAD
CRM2D (36)
SDO44 DV LOAD
CRM2D (38)
SDO45 DV LOAD
CRM2D (39)
SDO46 DV LOAD
CRM2D (40)
SDO47 DV LOAD
CRM2D (41)
SDO48 DV LOAD
CRM2D (43)
SDO49 DV LOAD
CRM2D (44)
SDO50 DV LOAD
CRM2D (45)
SDO51 DV LOAD
CRM2D (46)
SDO52 DV LOAD
CRM2D (19)
SDO53 DV LOAD
CRM2D (20)
SDO54 DV LOAD
CRM2D (21)
SDO55 DV LOAD
CRM2D (22)
SDO56 DV LOAD
CRM2D (24)
SDO57 DV LOAD
CRM2D (25)
SDO58 DV LOAD
CRM2D (26)
SDO59 DV LOAD
CRM2D (27)
SDO60 DV LOAD

CRM2D(23,28,37,
42,47)
0V +24V
+24 V regulated
power supply

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Control unit Peripheral device

Connector pin No.
(peripheral device control interface B1)
+24E
CRM4A (19)

Receiver circuit
CRM4A (1)
SDI63 RV
CRM4A (2)
SDI64 RV
CRM4A (3)
SDI65 RV
CRM4A (4)
SDI66 RV
CRM4A (5)
SDI67 RV
CRM4A (6)
SDI68 RV
CRM4A (7)
SDI69 RV
CRM4A (13)
SDI70 RV

+24E B A

Common setting
pin (ICOM5)

Connector pin No. LOAD

CRM4A (14)

 Â
SDO61 DV
RELAY

CRM4A (15)
SDO62 DV LOAD
CRM4A (16)
SDO63 DV LOAD
CRM4A (17)
SDO64 DV LOAD
CRM4A (8)
SDO65 DV LOAD
CRM4A (9)
SDO66 DV LOAD
CRM4A (10)
SDO67 DV LOAD
CRM4A (11)
SDO68 DV LOAD

CRM4A (20)
0V +24V
+24 V regulated
power supply

NOTE
This is a connection diagram for +24V common.

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4. PERIPHERAL DEVICE, ARC WELDING,
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Control unit Peripheral device

Connector pin No.
(peripheral device control interface B2)
+24E
CRM4B (19)

Receiver circuit
CRM4B (1)
SDI71 RV
CRM4B (2)
SDI72 RV
CRM4B (3)
SDI73 RV
CRM4B (4)
SDI74 RV
CRM4B (5)
SDI75 RV
CRM4B (6)
SDI76 RV
CRM4B (7)
SDI77 RV
CRM4B (13)
SDI78 RV

+24E B A

Common setting
pin (ICOM5)

Connector pin No. LOAD

CRM4B (14)

 Â
SDO69 DV
RELAY

CRM4B (15)
SDO70 DV LOAD
CRM4B (16)
SDO71 DV LOAD
CRM4B (17)
SDO72 DV LOAD
CRM4B (8)
SDO73 DV LOAD
CRM4B (9)
SDO74 DV LOAD
CRM4B (10)
SDO75 DV LOAD
CRM4B (11)
SDO76 DV LOAD

CRM4B (20)
0V +24V
+24 V regulated
power supply

NOTE
This is a connection diagram for +24V common.

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4.4.2
Connection Between
the Mechanical Unit EE
and End Effector

NOTE
When hand break signal (*HBK) is not used, the short
connector that is attached on controller should be mounted
on the connector CRM37A at servo amplifier.

Servo amplifier
Main board

CRM37A
Connector

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4. PERIPHERAL DEVICE, ARC WELDING,
AND END EFFECTOR INTERFACES CONNECTIONS B–80945EN/02

Hand breakage
detection signal

RDI9
(Pneumatic pressure
abnormal signal)

(COM1)

NOTE
1 This is a connection diagram for +24V common.
2 The common–level change–over setting pin (COM1) is in
the 6–axis servo amplifier.

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4.4.3
Connection Between
the Control Unit and
Welder

Control unit
Welder interface
CRW1

Welder

Analog input interface

CRW2

Peripheral device

NOTE
Welder and peripheral device connection cable is option.

Applicable process I/O board type

EA, CA

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Control unit
Welder interface
CRW7

Welder

NOTE
Welder and peripheral device connection cable is option.

Applicable process I/O board type

GA

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Control unit Welder

(Welding interface)
Process I/O CA, EA Connector pin number MS connector pin number

Welding voltage
command signal
The input impedance
shall be more than 3.3kΩ
high–pass filter shall be
provided.
Wire speed
command signal

Welding voltage
detection signal

Output signals
without ripples.

Welding current
detector signal

R=100Ω or more

Wire soldering
detector signal

Welding power supply

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Control unit Welder

(Welding interface)
Process I/O CA, EA

Welding start WD01

signal

Gas signal WD02

CRWI (25) T
WD03

Wire inching WD04

(positive) signal
Wire inching WD05
(negative) signal
WD06 CRWI (28) W

WD07 CRWI (29) X

WD08 CRWI (30) Z

a, m

b, n
+24V regulated
power supply

Receiver circuit
CRWI (5) c
WDI1

Arc detection WDI2

signal

Gas shortage WDI3

detection signal
Wire cut
detection signal WDI4

Cooling water WDI5

shortage detection
signal
Welding power WDI6
supplu abnomality
signal CRWI (11) j
WDI7

CRWI (12) k
WDI8

Common switching
set pin

CRWI (33,34)

Shield
FG (cabinet ground)

NOTE
This is the connection for +24V.

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Control unit Peripheral device

(Analog input interface)
Process I/O CA, EA

Output signals without

ripples.

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Control unit (welding interface) Welding machine

Process I/O GA
MS connector pin numbers

Connector pin numbers

Welding voltage CRW7 (1)

command signal DACH (1) A
CRW7 (2)
0 V for analog output COMDA B
Wire speed command CRW7 (3)
DACH (2) C
signal
CRW7 (4)
0 V for analog output COMDA D
CRW7 (6) P
Arc WDI (2) RV
No arc CRW7 (10) R
WDI (6) RV
(power supply error)

+24V

B A

CRW7 (7) T
No gas WDI (3)
CRW7 (8) S
No wire WDI (4)
+24V
CRW7 (33, 34) E

CRW7 (23)
Welding start signal WDO (1) L
CRW7 (24)
DO common WCOM (1) K
CRW7 (29)
Wire inching (+) WDO (4) F
CRW7 (30)
DO common WCOM (4) G
CRW7 (13)
Wire inching (–) WDO (5) H
CRW7 (14)
DO common WCOM (5) J

CRW7 (31) M
Deposition WDI + +
CRW7 (32) N
Deposition WDI – –

NOTE
This is the connection for +24V.

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4.5 This section describes the specifications of the digital I/O signals
interfaced with the peripheral device, end effector, and arc welder.
DIGITAL I/O SIGNAL
SPECIFICATIONS

4.5.1
(1) Output signals in peripheral device interface A
Peripheral Device Example of connection
Interface
Spark killer diode

+24V

0.2 A
or less

0V

+24V

Lamp
0.2 A
or less

0V
Protective resistance

Electrical specifications
Rated voltage : 24 VDC
Maximum applied voltage : 30 VDC
Maximum load current : 0.2 A
Transistor type : Open collector NPN
Saturation voltage at connection : 1.0 V (approx.)

Spark killer diode

Rated peak reverse voltage : 100 V or more
Rated effective forward current : 1 A or more

Note on use
Do not use the +24 V power supply of the robot.
When you load a relay, solenoid, and so on directly, connect them in
parallel with diodes for preventing back electromotive force.
If a load is connected causing a surge current when a lamp is turned
on, use a protective resistance.

Applicable signals
Output signals of process I/O board CRM2 and CRM4
CMDENBL, SYSRDY, PROGRUN, PAUSED, HELD, FAULT,
ATPERCH, TPENBL, BATALM, BUSY, ACK1 to ACK8, SNO1 to
SNO8, SNACK, SDO1 to SDO76

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(2) Input signals in peripheral device interface A

Example of connection

+24V

RV
3.3 kW
+24V

B A
ICOM

Electrical specifications of the receiver

Type : Grounded voltage receiver
Rated input voltage : Contact close
: +20 V to +28 V
Contact open
: 0 V to +4 V
Maximum applied input voltage : +28 VDC
Input impedance : 3.3 kΩ (approx.)
Response time : 5 ms to 20 ms
Specifications of the peripheral device contact
Rated contact capacity : 30 VDC, 50 mA or more
Input signal width : 200 ms or more (on/off)
Chattering time : 5 ms or less
Closed circuit resistance : 100 Ω or less
Opened circuit resistance : 100 kΩ or more

TB (Signal) TB (Signal) TB

Peripheral device
contact signal

Robot receiver signal

TC TC TB ; Chattering 5 ms or less
TC ; 5 to 20 ms

Note on use
Apply the +24 V power at the robot to the receiver.
However, the above signal specifications must be satisfied at the
robot receiver.
Applicable signals
Input signals of process I/O board CRM2 and CRM4
*IMSTP, *HOLD, *SFSD, CSTOPI, FAULT RESET, START,
HOME, ENBL, RSR1 to RSR8, PNS1 to PNS8, PNSTROBE,
PROD START, SDI1 to SDI78

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4.5.2
End Effector Control (1) Output signals
Example of connection
Interface
Spark killer diode

+24V

0.2 A
or less

0V

+24V
Lamp
0.2 A
or less

0V
Protective resistance

Electrical specifications
Rated voltage : 24 VDC
Maximum applied voltage : 30 VDC
Maximum load current : 0.2 A
Transistor type : Open collector NPN
Saturation voltage at connection : 1.0 V (approx.)

Spark killer diode

Rated peak reverse voltage : 100 V or more
Rated effective forward current : 1 A or more

Note on use
The +24 V power supply at the robot can be used when the total
current of the welding interface and end effector interface is 0.7 A or
less.
When you load a relay, solenoid, and so on directly, connect them in
parallel with diodes for preventing back electromotive force.
If a load is connected causing a surge current when a lamp is turned
on, use a protective resistance.

Applicable signals
Output signals of the end effector control interface RDO1 to RDO8

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(2) Input signal

Example of connection

+24V

RV

3.3 kW
+24V

B A
COM1

Electrical specifications of the receiver

Type : Grounded voltage receiver
Rated input voltage : Contact close : +20 V to +28 V
Contact open : 0 V to +4 V
Maximum applied input voltage : +28 VDC
Input impedance : 3.3 kΩ (approx.)
Response time : 5 ms to 20 ms

Specifications of peripheral device contact

Rated contact capacity : 30 VDC, 50 mA or more
Input signal width : 200 ms or more (on/off)
Chattering time : 5 ms or less
Closed circuit resistance : 100 Ω or less
Opened circuit resistance : 100 kΩ or more

TB (Signal) TB (Signal) TB

Peripheral device
contact signal

Robot receiver signal

TC TC
TB ; Chattering 5 ms or less
TC ; 5 to 20 ms

Note on use
Apply the +24 V power at the robot to the receiver.
However, the above signal specifications must be satisfied at the
robot receiver.

Applicable signals
Input signals of the end effector control interface
RDI1 to RDI8, *HBK, *PPABN

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4.5.3
I/O Signal (1) Digital output signal specifications for an arc welding interface
In case of process I/O CA and EA
Specifications for
ARC–Welding Interface Example connection
Spark killer diode

0.2 A or
less

Electrical characteristics
Rated voltage : 24 VDC
Maximum applied voltage : 30 VDC
Maximum load current : 0.2 A
Transistor type : Open–collector NPN
Saturation voltage at on : About 1.0 V
Spark killer diode
Rated peak reverse voltage : 100 V or more
Rated effective forward current : 1 A or more

NOTE
A power voltage of +24 V, provided for the robot, can be
used for interface signals of up to 0.7 A. This limit applies
to the sum of the currents flowing through the arc–welding
and end–effector control interfaces. To drive a relay or
solenoid directly, connect a diode preventing back
electromotive force to the load in parallel. To connect a load
which generates an inrush current when you turn on the
control unit, connect a protective resistor.

Applicable signals
– Output signals on the arc–welding interface
– WDO1 to WDO8

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In case of process I/O GA

Example connection
Spark killer diode

0.3 A or
less

Electrical characteristics
Rated voltage : 24 VDC
Maximum applied voltage : 30 VDC
Maximum load current : 0.3 A
Output type : Relay connection point output
Spark killer diode
Rated peak reverse voltage : 100 V or more
Rated effective forward current : 1 A or more

NOTE
A power voltage of +24 V, provided for the robot, can be
used for interface signals of up to 0.7 A. This limit applies
to the sum of the currents flowing through the arc–welding
and end–effector control interfaces. To drive a relay or
solenoid directly, connect a diode preventing back
electromotive force to the load in parallel. To connect a load
which generates an inrush current when you turn on the
control unit, connect a protective resistor.

Applicable signals
– Output signals on the arc–welding interface
– WDO1 to WDO4

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(2) Digital input signal specifications for arc welding interface

Example connection

Electrical characteristics of receivers

Type: Grounded voltage receiver
Rated input voltage : +20 to +28 V with contacts closed
0 to +4 V when open
Maximum input voltage : +28 VDC
Input impedance : About 3.3 k
Response time : 5 to 20 ms

Contact specifications for peripherals

Rated contact capacity : 30 VDC, 50 mA or more
Input signal width : 200 ms or more for on and off states
Chattering period : 5 ms or less
Closed–circuit resistance : 100 or less
Open–circuit resistance : 100 k or more

(Signal) (Signal)

Contact signal
for peripheral

Receiver
signal for robot

TB: Chattering of 5 ms or less

TC: 5 to 20 ms

NOTE
Supply the +24 V power, provided for the robot, to the
receivers. The receiver signal on the robot must satisfy the
signal timing specified above.

Applicable signals
– Input signals for arc welding interface
– WDI1 to WDI8

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(3) Analog output signal specifications for arc welding interface

(Welding voltage command, wire–feed rate command)
Example connection
Welder

For process I/O CA and EA : –10V to +10V

For process I/O GA : 0V to +15V

0V

NOTE
Input impedance: 3.3 kΩ or more
Connect a high–pass filter.

(4) Analog input signal specifications for arc welding interface

(Welding–voltage detection, welding–current detection)
Example connection
Welder

NOTE
The analog input signal should have no ripple for the circuit
to operate properly.

(Wire deposit detection: WDI+ and WDI–)

Example connection
Welder

Welding electrode

NOTE
Connect a resistor of 100Ω or more between the positive
and negative electrodes of the welder. Isolate the deposit
detection signals for TIG welding from the welding circuit,
which uses high–frequency components. The dielectric
withstand voltage of this circuit is 80 V.

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4.6 If the customer supplies cables, conform to the FANUC standard cables
described in this section.
SPECIFICATIONS OF
(See the description in ”Peripheral Device Interface” in this manual for
THE CABLES USED the specifications of the FANUC standard cables.)
FOR PERIPHERAL
DEVICES AND
WELDERS

4.6.1
Peripheral Device
Interface A Cable
(CRM2: Honda
Tsushin, 50 pins)
Honda Tsushin Honda Tsushin

Process I/O Peripheral

device

Honda Tsushin
Honda Tsushin’s MR50RFH
Supplied with an ordered cable

4.6.2
Peripheral Device
Interface B Cable
(CRM4: Honda
Tsushin, 20 pins)

Honda Tsushin Honda Tsushin

Process I/O Peripheral

device

CRM4*

Honda Tsushin
Honda Tsushin’s MR20RFH
Supplied with an ordered cable

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4.6.3 Be sure to use our cable to connect the welder.

ARC Weld Connection
Cable (CRW1, CRW7:
Honda Tsushin, 34
pins)

ARC welder

Honda Tsushin

Process I/O

CRW1 or CRW7

Japan Aviation Electronics

Industry Ltd.
MS3102A28–21S
Honda Tsushin Japan Aviation Electronics Standard position of guide key
MR34RFA Industry Ltd.
MS3108B28–21P
MS3057–16

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4.7
CABLE
CONNECTION FOR
THE PERIPHERAL
DEVICES, END
EFFECTORS, AND
ARC WELDERS

4.7.1 Fig. 4.7.1 shows the connection of the peripheral device cable in the
Peripheral Device operator box.
Connection Cable
Operator box Type A Operator box Type B
CRW1 or CRW7 CRM2B CRM2A CRW1 or CRW7 CRM2B CRM2A

Process I/O board Process I/O

board

For peripheral device

For peripheral device

Process I/O
CRM2B CRM2A

B–cabinet

CRW1

Metallic clamp

To Peripheral External shield

device

Shield plate
Noise protection: Remove a part of the sheath of a peripheral cable to expose the outside shield.
Secure the cable to the shield plate with the metallic clamp at the exposed position.

Fig.4.7.1 Peripheral Device Cable Connection

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4.7.2
Peripheral Device (1) Fig. 4.7.2 shows the connector for peripheral device cables A and B.
Cable Connector

Connector Applicable Dimensions

Remark
specifications interface A (B) C (D)
MR50LMH CRM2 67.9 73.5 44.8 18 Honda Tsushin Kogyo,
50 pins
MR20LMH CRM4 39.3 44.9 39.8 17 Honda Tsushin Kogyo,
20 pins

Symbol Name

Connector cover
 Cable clamp screw
 Connector clamp spring
 Connector clamp screw
 Connector 50 pins (male) MR50MH
20 pins (male) MR20MH

Fig.4.7.2 (a) Peripheral Device Cable Connector (Honda Tsushin Kogyo)

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(2) Peripheral device connector

Connector Applicable Dimensions

Remark
specifications interface A B
MR50RFH (CRM2) 61.4 56.4 Honda Tsushin Kogyo,
50 pins
MR20RFH (CRM4) 39.3 44.9 Honda Tsushin Kogyo,
20 pins

Symbol Name

Connector clamp screw
 Screw M2.6 8
 Connector (MR50RFH)
(MR20RFH)

Fig.4.7.2 (b) Peripheral Device Connector (Honda Tsushin Kogyo)

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4.7.3
End Effector Cable (1) Connector external view
Connector

A : M301 E : ø33
B : 63.0 F : 11.2
C : 54.5 G : 24.7
D : 9.6 to 15.0 (Inside diameter)
Manufactured by Daiichi Denshi Kogyo JMLP2524M

Fig.4.7.3 (a) Connector (Elbow Type)

A : M301 E : ø33
B : 54.1 F : 11.2
C : 37.5 G : 24.7
D : 9.6 to 15.0 (Inside diameter)
Manufactured by Daiichi Denshi Kogyo JMLP2524M

Fig.4.7.3 (b) Connector (Straight Type)

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4.7.4
Recommended Cables (1) Peripheral device connection cable
Connect a peripheral device using a completely shielded, heavily
protected cable conforming to the specifications in Table 4.7.4 (a).
Allow an extra 50 cm for routing the cable in the control unit.
The maximum cable length is 30 m.

Table 4.7.4 (a) Recommended Cable (for Peripheral Device Connection)

Conductor Effective Electricalcharacteristics
Number Wire specifications Sheath
thickness outside Conductor Allowable
of wires (FANUC specifications) Diameter diameter
(mm) Configuration (mm) resistance current
(mm) (Ω/km) (A)
50 A66L-0001-0042 ø1.05 7/0.18 AWG24 1.5 ø12.5 106 1.6
20 A66L-0001-0041 ø1.05 7/0.18 AWG24 1.5 ø10.5 106 1.6

(2) End effector connection cable

Connect an end effector using a heavily protected cable with a
movable wire conforming to the specifications in Table 4.7.4 (b).
The cable length is determined so that the cable will not interfere with
the end effector and the wrist can move through its full stroke.

Table 4.7.4 (b) Recommended Cable (for End Effector Connection)

Conductor Effective Electricalcharacteristics
Number Wire specifications Sheath
thickness outside Conductor Allowable
of wires (FANUC specifications) Diameter diameter
(mm) Configuration (mm) resistance current
(mm) (Ω/km) (A)
6 A66L-0001-0143 ø1.1 40/0.08 AWG24 1.0 ø5.3 91 3.7
20 A66L-0001-0144 ø1.1 40/0.08 AWG24 1.0 ø8.6 91 2.3

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4.8
CONNECTING THE
COMMUNICATION
UNIT
4.8.1
RS–232C Interface
4.8.1.1 This interface can be connected to a handy file or another communication
Interface unit from FANUC.

RS–232C port

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R–J3
Operator’s panel
Main board connector
(DBM–25S)
1 FG
14
2 SD
15
3 RD
16
i i h 4 RS
17
5 CS
18
6 DR
19
7 SG
20 ER
8
21
9
22
10
23
11
24
12
25 +24V
13

NOTE
1 +24 V can be used as the power supply for FANUC
RS–232–C equipment.
2 Do not connect anything to those pins for which signal
names are not indicated.

4.8.1.2 Generally signals as follows are used in RS–232–C interface.

RS–232–C Interface
Signals R–J3

Output
SD (Send data)

Input
RD (Recieve data)

RS (Request to Send) When CS is not used

short CS and RS.
CS (Enable to send)
When DR is not
used short DR
ER (Ready)
and ER.

DR (Data set ready)

SG (Signal ground)

FG (Frame ground)

Fig.4.8.1.2 RS–232–C interface

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4.8.1.3
Connection between
RS–232–C Interface and
External Device R–J3 External device
SD SD side

RD RD

RS RS

CS CS

ER ER

DR DR

CD CD

SG SG

FG FG

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D The cable for connecting the PG–Mate to the NC should be connected

as shown in the below diagram.

CNC External device

SD SD side

RD RD

RS RS

CS CS

ER ER

DR DR

CD

SG SG

FG FG

Prepare the cable with I/O device as follows :

R–J3

SD
RD
RS
CS
SG
ER
DR

Cable : twist 10 pairs 0.18mm2, with shield

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4.8.2
Ethernet Interface
CAUTION
Before connecting or disconnecting cables to and from the
Ethernet board, cut the power supply of R–J3, and make
sure that the power is off.

NOTE
Please inqure of each manufacturer about the construction
of network or the condition of using the equipment except
the Ethernet board (hub, transceiver, cable etc.). When
configuring your network, you must take other sources of
electrical noise into consideration to prevent your network
from being influenced by electrical noise. Make sure that
network wiring is sufficiently separated from power lines
and other sources of electrical noise such as motors, and
ground each of the devices as necessary. Also, a high and
insufficient ground impedance may cause interference
during communications. After installing the machine,
conduct a communications test before you actually start
operating the machine.
We cannot ensure operation that is influenced by network
trouble caused by a device other than the main board.

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4.8.2.1 The main board is provided with a 10BASE–T interface.

Connection to Ethernet Prepare a hub for connecting the Ethernet board to the Ethernet trunk.
The following shows an example of a general connection.

S
S
S

Some devices (hub, transceiver, etc.) that are needed for building a
network do not come in a dust–proof construction. Using such devices in
an atmosphere where they are subjected to dust or oil mist will interfere
with communications or damage the Ethernet board. Be sure to install
such devices in a dust–proof cabinet.

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4.8.2.2 CD38
10BASE–T Connector Pin No. Signal Name Description
(CD38) Pin Assignments 1 TX+ Send +
2 TX– Send –
3 RX+ Receive +
4 Not used
5 Not used
6 RX– Receive –
7 Not used
8 Not used

4.8.2.3 The figure below shows the cable connection between the 10BASE–T
Cable Connection connector (CD38) of the main board and hub.

D For details on shielding, see ”4.8.2.6 Cable clamp and shielding”.

D Keep the total cable length to within 100 m.
Do not extend the cable longer than necessary.

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Example cable connected to the A–cabinet

Partially peel the sheath to expose the shield.

To the hub

Cord clip
(Diameter of the
installation hole on
the plate: 29.5 mm)

For the A–cabinet

Use any connector not in use.

Clamp: A02B–0083–K301
The shield plate comes standard.

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4.8.2.4 Unshielded cable (UTP cable) is commercially available as 10BASE–T

Lead Materials twisted–pair cable. However, be sure to use shielded Category 5
twisted–pair cable (STP) to improve the resistance to electrical noise in
an FA environment. (For details on shielding, see ”4.8.2.6 Cable clamp
and shielding.”

Recommended Cable
Manufacturer Specification
Furukawa Electric Co., Ltd. DTS5087
Nissei Electric Co., Ltd. F–4PFWMF

Inquiries
Manufacturer Contact Address
Furukawa Electric Co., Ltd., Maru–no–uchi 2–6–1, Chiyoda–ku.
Sales Headquarters Tokyo 100–8322
TEL: 03–3286–3126
FAX: 03–3286–3979
Remarks
Nissei Electric Co., Ltd., 3F MU Bldg., Minami–narise 1–9–1,
Machida Branch Machida City, Tokyo 194–0045
TEL: 0427–29–2153
FAX: 0427–29–3375
Overseas Sales Office NISSEI ELECTRIC CO., LTD
1509 Okubo–cho, Hamamatsu–shi
Shizuoka–ken, 432–8006 Japan
TEL: 053–485–4114
FAX: 053–485–6908
E–mail: KYH05470@niftyserve.or.jp
Remarks Cables with connectors at both ends
can be supplied.

NOTE
The recommended cables cannot be connected to movable
portions.

4.8.2.5 Use an 8–pin modular connector (RJ–45) as the twisted–pair cable for the
Connector Specification Ethernet connection.
Hirose Electric Co., Ltd.
CL222–1328–1328 (for STP cable) or equivalent item

4.8.2.6 Shield the cables as like as other cables are shielded. (See 4.7.1)
Cable Clamp and
Shielding

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4.8.2.7 Even if the grounding conditions on the machine are satisfied, electrical
Grounding the Network noise from the machine sometimes enters the communications line and
causes communications interference depending on the installation
conditions and the peripheral environment of the machine. To prevent the
entry of such electrical noise, separating and insulating the machine from
the Ethernet trunk cable and the personal computer effectively reduces the
influence of electrical noise.
The following figure shows an example of such a connection.

Large–scale Network

Small–scale Network

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NOTE
1 The ground between PC/Trunk line side and machine
system side must be separated. If it is impossible to
separate the ground because there is only one grounding
point, connect the ground cable for each system to the
grounding point independently. (Refer Fig.1)
The resistance for grounding must be less than 100–ohm
(Class 3).
The thickness of the ground cable is the same as the
thickness of AC power cable or more. At least thickness of
5.5mm2 is necessary.
2 Please use the HUB that has unshielded interface
connector. FANUC recommends the HCN–7500
(Hitachi–Densen LTD) or equivalent.
3 There is possibility that noise makes the obstacle of
communication even if the ground is separated using the
10BASE–T. In the case of using the Ethernet board under
the worst environment, please separate between the
PC/Trunk line side and machine system side completely
using the 10BASE–FL (Optical fiber media).

Fig.4.8.2.7 Wiring on a Single Ground Point

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5 TRANSPORTATION AND INSTALLATION

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5.1 This section describes the transportation and installation for the control
unit.
TRANSPORTATION
The control unit is transported by a crane. Attach a rope to eye bolts at
the top of the control unit.

NOTE
A combination control unit is incorporated into the
mechanical unit of the robot A–cabinet.

A–cabinet B–cabinet

Fig.5.1 Transportation

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5.2
INSTALLATION

5.2.1 Following is the installation method for A–cabinet remote type and
Installation Method B–cabinet.
When installing the control unit, allow the space for maintenance shown
in the following figure.

A–cabinet

B–cabinet

Fig.5.2.1 (a) External dimension

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Maintenance space Space for

replacing amp.

For fixing bolts

Bolt spec.
M10
M10X12 is
used in
A–cabinet

Fig.5.2.1 (b) Installation Method (Remote Type A–cabinet)

Controller
Controller
Controller

Fig.5.2.1 (c) Installation Method (B–cabinet)

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Following are the installation for the operator boxes.

there are two types of the operator boxes (type A and type B).

Fig.5.2.1 (d) Installation (Operator Box Type A)

Daiashi (gomu)

Fig.5.2.1 (e) Installation (Operator Box Type B)

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5.2.2
Assemble at
Installation (1) A–cabinet integrated type

Breaker box Operator box

Teach pendant
R–J3 controller

Input power connection cable

Peripheral device connection cable

Fig.5.2.2 (a) Assemble at Installation (A–cabinet integrated Type)

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(2) A–cabinet remote type

Breaker box Operator box

Teach pendant
R–J3 controller

Robot connection cable

Input power connection cable

Peripheral device connection cable

Fig.5.2.2 (b) Assemble at Installation (A–cabinet Remote Type)

Teach pendant
connection cable

Robot mechanical unit connection cable

Peripheral device connection cable

Input power connection cable Weld interface connection cable

Fig.5.2.2 (c) Assemble at Installation (B–cabinet)

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5.3
INSTALLATION
CONDITION
Item Model Specifications/condition
Transformer Common to all models 1 : 220 to 240, 380 to 415 VAC (+10%–15%)
2 : 200 to 220, 380 to 400 VAC (+10%–15%)
3 : 440 to 460, 480 to 575 VAC (+10%–15%)
50/60Hz"1Hz 3phases
Input power source capacity ARC Mate 50i, LR Mate 200i 1.2 kVA
ARC Mate 100i, M–6i, SR Mate 200i 2.5 kVA
ARC Mate 120i, M–16i, A–520i 3 kVA
F–200i 5 kVA
S–430iF, S–430iR/130, S–430iC, 12 kVA
M–710i, M–500i
S–500i 7 kVA
S–430iW, S–430iL, S–430iR/165, 15 kVA
S–430iR/Press HT/Press HS,
S–430iU, S–900i, M–410i
Average power consumption ARC Mate 50i, LR Mate 200i 0.5 kW
ARC Mate 100i, ARC Mate120i, 1.0 kW
M–6i, M–16i, F–200i,
SR Mate 200i
S–500i 1.7 kW
A–520i, M–500i 2 kW
S–430iF, S–430iR/130, S–430iC, 2.5 kW
M–710i
S–430iW, S–430iL, S–430iR/165, 3 kW
S–430iR/Press HT/Press HS,
S–430iU, S–900i, M–410i
Permissible ambient tempera- Common to all models 0 to 45_C during operation, and –20 to 60 C during shipment and
ture storage with a temperature coefficient of 1.1_C/min.
Permissible ambient humidity Common to all models Relative humidity: 30% to 95%, non–condensing.
Surrounding gas Common to all models An additional protective provision is necessary if the machine is
installed in an environment in which there are relatively large
amounts of contaminants (dust, dielectric fluid, organic solvent,
acid, corrosive gas, and/or salt).
Vibration Common to all models 0.5 G or less. When using the robot in a location subject to serious
vibration, consult with your FANUC sales representative.
Altitude Common to all models Not higher than 1,000 m above sea level
Ionized and nonionized radi- Common to all models A shielding provision is necessary if the machine is installed in an
ations environmentin which it is exposed to radiations (microwave, ultra-
violet rays, laser beams, and/or X–rays).
Mass of control unit A–cabinet Approx. 140 kg
(S–430iW, S–430iL, S–430iR/165,
S–430iR/Press HT/Press HS,
S–430iU, S–900i, M–410i, M–500i)
A–cabinet Approx. 130 kg
(except for above models)
B–cabinet Approx. 210 kg
(S–430iW, S–430iL, S–430iR/165,
S–430iR/Press HT/Press HS,
S–430iU, S–900i, M–410i, M–500i)
B–cabinet Approx. 200 kg
(except for above models)

NOTE
During rapid acceleration, robot power draw can be twice
the continuous rating value.

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5.4 Adjust the robot according to the following procedure at installation.

ADJUSTMENT AND
CHECKS AT
INSTALLATION

No. Description
1 Visually check the inside and outside of the control unit.
2 Check the screw terminals for proper connection.
3 Check that the connectors and printed circuit boards are firmly connected.
4 Check transformer tap setting. (See II MAINTENANCE section 6.2)
5 Turn the breaker off and connect the input power cable.
6 Check the input power voltage and transformer outputs.
7 Press the EMERGENCY STOP button on the operator panel and turn on the control unit.
8 Check the interface signals between control unit and robot mechanical unit.
9 Check the parameters. If necessary, set them.
10 Release the EMERGENCY STOP button on the operator panel. Turn on the controller.
11 Check the movement along each axis in manual jog mode.
12 Check the end effector interface signals.
13 Check the peripheral device control interface signals.

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5.5 An overtravel and emergency stop occur when the robot is operated for
the first time after it is installed and the mechanical and control units are
RESETTING wired. This section describes how to reset the overtravel and emergency
OVERTRAVEL AND stop.
EMERGENCY STOP Remove the red plate fastening the swiveling axis beforehand.
AT INSTALLATION The J2 and J3 axes are pressed against the hard stops at shipment.
Therefore, an overtravel alarm occurs when the power is turned on after
installation.
The robot can also be in an emergency stop state if the peripheral device
control interface is not connected.

5.5.1 Take the following actions if signals *IMSTP, *HOLD, *SFSD, and
ENBL are not used.
Peripheral Device
Interface Processing CRM2A
+24F
49, 50

*IMSTP 1
RV

*HOLD 2
RV

*SFSD 3
RV

ENBL 4
RV

5.5.2 1) Select [Release] on the overtravel release screen to release each robot
axis from the overtravel state.
Resetting Overtravel
2) Hold down the shift key, and press the reset button to reset the alarm
condition.
3) Still hold down the shift key, and jog to bring all axes into the movable
range.

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B–80945EN/02 APPENDIX A. TOTAL CONNECTION DIAGRAM

A TOTAL CONNECTION DIAGRAM

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Operator
Operator
Box
Panel

Fig.A (a) Total Diagram (A–cabinet)

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A. TOTAL CONNECTION DIAGRAM APPENDIX B–80945EN/02

Fig.A (b) Total Diagram (A–cabinet/panel switch board)

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Fig.A (c) Total Diagram (B–cabinet)

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A. TOTAL CONNECTION DIAGRAM APPENDIX B–80945EN/02

Fig.A (d) Total Diagram (B–cabinet/panel switch board)

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A. TOTAL CONNECTION DIAGRAM APPENDIX B–80945EN/02

L3B

L3A
L2B

L2A
L1B

L1A

Fig.A (e) Transformer (A–cabinet)

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Fig.A (f) Total Diagram (B–cabinet)

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A. TOTAL CONNECTION DIAGRAM APPENDIX B–80945EN/02

Fig.A (g) Power Supply Unit

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Fig.A (h) Main board

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For aux. axis emergency stop

01 AUXEMG
02 SVEMG
TBAUX
TBAUX

Fig.A (i) Emergency Stop Board (A–cabinet)

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For aux. axis emergency stop

01 AUXEMG
02 SVEMG
TBAUX
TBAUX

Fig.A (j) MCC unit (B–cabinet)

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Fig.A (k) 6–axis Servo Amplifier (1/3)

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Fig.A (k) 6–axis Servo Amplifier (2/3) (Exept for M–500i)

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A. TOTAL CONNECTION DIAGRAM APPENDIX B–80945EN/02

Fig.A (k) 6–axis Servo Amplifier (3/3) (M–500i)

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Applied model : S–430iF, S–430iR/130, S–430iC, M–710i

Fig.A (l) Motor Power Connection (S–430iF, S–430iR/130, S–430iC, M–710i)

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Applied model : S–430iW, S–430iL, S–430iR/165, S–430iR/Press HT/Press HS, S–430iU, S–900i

Fig.A (m) Motor Power Connection (S–430iW, S–430iL, S–430iR/165, S–430iR/Press HT/Press HS, S–430iU, S–900i)

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Applied model : M–410i

Fig.A (n) Motor Power Connection M–410i

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Applied model : ARC Mate 100i, M–6i, SR Mate 200i

Fig.A (o) Motor Power Connection ARC Mate 100i, M–6i, SR Mate 200i

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Applied model : ARC Mate 120i, M–16i

Fig.A (p) Motor Power Connection ARC Mate 120i, M–16i

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A. TOTAL CONNECTION DIAGRAM APPENDIX B–80945EN/02

Applied model : A–520i

Fig.A (q) Motor Power Connection A–520i

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Applied model : F–200i

Fig.A (r) Motor Power Connection F–200i

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Applied model : ARC Mate 50i, LR Mate 50i, LR Mate 200i

(option)

(option)

Fig.A (s) Motor Power Connection ARC Mate 50i, LR Mate 200i

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Applied model : S–500i

Fig.A (t) Motor Power Connection S–500i

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A. TOTAL CONNECTION DIAGRAM APPENDIX B–80945EN/02

Applied model : M–500i

Fig.A (u) Motor Power Connection M–500i

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B–80945EN/02 APPENDIX A. TOTAL CONNECTION DIAGRAM

Operator Box
(i–cabinet)

Fig.A (v) Operator Box/operator panel (1/5)

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A. TOTAL CONNECTION DIAGRAM APPENDIX B–80945EN/02

Fig.A (v) Operator Box/operator panel (2/5)

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Fig.A (v) Operator Box/operator panel (3/5)

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A. TOTAL CONNECTION DIAGRAM APPENDIX B–80945EN/02

Fig.A (v) Operator Box/operator panel (panel switch board) (4/5)

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CPR14 (OUT)
CP5 (IN)

Fig.A (v) Operator Box/operator panel (5/5)

339
 Common S–430iF, S–430iR/130,
S–430iC, M–710i
A. TOTAL CONNECTION DIAGRAM

S–430iW, S–430iL, S–430iR/165,

S–430iR/Press HT/Press HS
S–430iU, S–900i

340
APPENDIX

Fig.A (w) Mechanical Interface (S–430i, S–900i, M–710i)

B–80945EN/02
B–80945EN/02 APPENDIX A. TOTAL CONNECTION DIAGRAM

M–410i

Fig.A (x) Mechanical Interface M–410i

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ARC Mate 100i/120i, M–6i/16i,

F–200i, SR Mate 200i

Fig.A (y) Mechanical Interface ARC Mate 100i/120i, M–6i/16i, F–200i, SR Mate 200i, A–520i

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Fig.A (z) Mechanical Interface (S–500i, ARC Mate 50i, LR Mate 200i)

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Fig.A (aa) Mechanical Interface (M–500i)

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I/O Device in Operator Box

Operator Box

Fig.A (ab) I/O Device (A–cabinet operation box) (1/3)

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Fig.A (ab) I/O Device (B–cabinet) (2/3)

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Fig.A (ab) I/O Device (interface) (3/3)

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Fig.A (ac) Emergency Stop Circuit (A–cabinet)

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Fig.A (ad) Emergency Stop Circuit (A–cabinet/panel switch board)

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A. TOTAL CONNECTION DIAGRAM APPENDIX B–80945EN/02

Fig.A (ae) Emergency Stop Circuit (B–cabinet)

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Fig.A (af) Emergency Stop Circuit (B–cabinet/panel switch board)

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B SPECIFICATIONS OF PERIPHERAL DEVICE INTERFACE

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B.1 The following table lists the I/O signals used for the peripheral device
interface in the R-J3 controller.
SIGNALS
Input signals (Refer to B.3.1)
Signal Description
*IMSTP Instantaneous stop signal
*HOLD Hold signal
*SFSPD Safety speed signal
CSTOPI Cycle stop signal
FAULT_RESET Alarm release signal
START Cycle start signal
HOME Robot service request/program number select signal (*1)
ENBL Enabling signal
RSR1/PNS1 Robot service request/program number select signal (*1)
RSR2/PNS2 Robot service request/program number select signal (*1)
RSR3/PNS3 Robot service request/program number select signal (*1)
RSR4/PNS4 Robot service request/program number select signal (*1)
RSR5/PNS5 Robot service request/program number select signal (*1)
RSR6/PNS6 Robot service request/program number select signal (*1)
RSR7/PNS7 Robot service request/program number select signal (*1)
RSR8/PNS8 Robot service request/program number select signal (*1)
PNSTROBE PNS strobe signal
PROD_START Automatic operation start signal
SDI01 General-purpose input signal
SDI02 General-purpose input signal

SDI03 General-purpose input signal

SDI04 General-purpose input signal
SDI05 General-purpose input signal
SDI06 General-purpose input signal
SDI07 General-purpose input signal
SDI08 General-purpose input signal
SDI09 General-purpose input signal
SDI10 General-purpose input signal
SDI11 General-purpose input signal
SDI12 General-purpose input signal
SDI13 General-purpose input signal
SDI14 General-purpose input signal
SDI15 General-purpose input signal
SDI16 General-purpose input signal
SDI17 General-purpose input signal
SDI18 General-purpose input signal
SDI19 General-purpose input signal
SDI20 General-purpose input signal
SDI21 General-purpose input signal
SDI22 General-purpose input signal

*1: RSR : Robot Service Request (RSR5 to RSR8 are optional)

PNS : Program Number Select Input (optional)
Whether RSR is used or PNS is used can be preset.

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Output signals (Refer to B.3.2)

Signal Description
CMDENBL Command acceptance enabled signal
SYSRDY System ready signal
PROGRUN Program run signal
PAUSED Program paused signal
HELD Held signal
FAULT Alarm signal
ATPERCH Reference point signal
TPENBL Teach pendant enabled signal
BATALM Battery alarm signal
BUSY Operating signal
ACK1/SNO1 RSR acknowledge/Selected program number signal
ACK2/SNO2 RSR acknowledge/Selected program number signal
ACK3/SNO3 RSR acknowledge/Selected program number signal
ACK4/SNO4 RSR acknowledge/Selected program number signal
ACK5/SNO5 RSR acknowledge/Selected program number signal
ACK6/SNO6 RSR acknowledge/Selected program number signal
ACK7/SNO7 RSR acknowledge/Selected program number signal
ACK8/SNO8 RSR acknowledge/Selected program number signal
SNACK PNS acknowledge signal
______ Not used (for future expansion)

SDO01 General-purpose output signal

SDO02 General-purpose output signal
SDO03 General-purpose output signal
SDO04 General-purpose output signal
SDO05 General-purpose output signal
SDO06 General-purpose output signal
SDO07 General-purpose output signal
SDO08 General-purpose output signal
SDO09 General-purpose output signal
SDO10 General-purpose output signal
SDO11 General-purpose output signal
SDO12 General-purpose output signal
SDO13 General-purpose output signal
SDO14 General-purpose output signal
SDO15 General-purpose output signal
SDO16 General-purpose output signal
SDO17 General-purpose output signal
SDO18 General-purpose output signal
SDO19 General-purpose output signal
SDO20 General-purpose output signal

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B.2 All process I/O printed boards have a jumper to set the common voltage
of input signals to 0 V or 24 V. The system automatically adjusts the
SETTING COMMON polarity by software according to the status of this pin. Therefore, you can
VOLTAGE operate the system without being concerned about the setting of the
common voltage.
To ensure safety, the common reference voltage of the following four
signals remain at +24V.
*IMSTP
*HOLD
*SFSPD
CSTOPI

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B.3
I/O SIGNALS

B.3.1 This section describes the specifications of each input signal.

Input Signals (1) Instantaneous stop signal (input) *IMSTP
Effective : At any time
Function : Use the normally-closed switch because it is a reverse
signal.
The system turns off power to the servo unit when the
*IMSTP is open (turned off). This signal has the same
effect as that of the emergency stop signal, but it is con-
trolled by software. For this reason, use the emergency
stop external interface on the emergency stop control
board for wiring of the emergency stop signal.
Do not use *IMSTP.
(2) Alarm release signal (input) FAULT RESET
Effective : In the alarm status
Function : The FAULT RESET signal releases the alarm status. If
the servo unit has been turned off, it also turns on the
unit. At the same time, the alarm display on the teach
pendant (the top line) is cleared.
Description : This signal releases only the alarm status. It does not re–
start execution of the program.
The robot will keep running if the signal is triggered
”ON” during operation.
(3) Hold signal (input) *HOLD
Effective : At any time
Function : Use the normally-closed switch because it is a reverse
signal.
The *HOLD signal has the same function as the hold
button on the operator panel. It halts the current pro-
gram and stops the operation of the robot. While this
signal is being input, the held signal (output) HELD is
turned on and the robot cannot be operated.

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(4) Start signal (input) START

Effective : When the command acceptance enabled signal (output)
CMDENBL is turned on.
See the description of CMDENBL in Section B.3.2 (1)
for details.
Function : This input signal starts the selected program at the fal-
ling edge when the signal is turned off after being turned
on. Its function differs according to the setting of pa-
rameter $SHELL_CFG.$CONT_ONLY.
- If parameter $SHELL_CFG.$CONT_ONLY is set to
DISABLED, the START signal starts the program
which has been selected from the teach pendant. By
default, the program starts from the current cursor
position.
- If parameter $SHELL_CFG.$CONT_ONLY is set to
ENABLED, the START signal only resumes the
execution of the temporarily held program. To
execute an inactivated program from the start, input
the PROD_START signal.
(5) Cycle stop signal (input) CSTOPI
Effective : At any time
Function : - If parameter $SHELL_CFG.$USE_ABORT is set to
DISABLED, the CSTOPI signal releases the program
from the wait status caused by an RSR. It does not
stop the execution of the current program and allows
it to continue processing (by default).
- If parameter $SHELL_CFG.$USE_ABORT is set to
ENABLED, the CSTOPI signal immediately cancels
the execution of the current program. The program re-
turns to the status in which it was before execution,
and the information for the subprogram to return to the
main program is lost. At the same time, this signal
also releases the program from the wait status caused
by RSR.
(6) Enabling signal (input) ENBL
Effective : At any time
Function : If the ENBL signal is turned off, the operation of the ro-
bot or the activation of a program is inhibited, and the
execution of the current program is suspended.

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(7) Safety speed signal (input) *SFSPD

Effective : At any time
Function : - Use the normally-closed switch because it is a reverse
signal. Usually this switch should be connected to
safety fence. It must be set normally on.
- Since the *SFSPD signal is counted as a remote condi-
tion, such input signals as RSR and START to the pe-
ripheral device interface cannot take effect unless this
signal is turned on.
- If this signal is turned from on to off during robot op-
eration, the execution of the current program is sus-
pended. At the same time, the overriding value is
switched to a preset value (parameter $SCR.
$FENCEOVER.)
- As long as this signal is off, the overriding value can-
not be increased beyond the preset value
($SCR.$SFJOGOVLIM: For jog, $SCR. $SFRU-
NOVLIM : For test execution.)

(8) Robot service request signal (input) RSR1/RSR2/RSR3/RSR4

Effective : When the command acceptance enabled signal (output)
CMDENBL is turned on.
See the description of CMDENBL in Section B.3.2 (1)
for details.
Function : - The user can choose between RSR and PNS (optional),
although they cannot be used simultaneously.
- Four input signals, RSR1 to RSR4, are used.
- If a signal is input to an RSR input, a specified. pro-
gram is started. The program number can be set by a
menu.
- If another program has already started processing, the
newly activated program enters the wait status. As
soon as the current program terminates, the waiting
program starts processing.
- By using an RSR instruction, each RSR in a program
can be enabled or disabled.
- A menu is provided to register the program number of
a specified program when each RSR is input. (Refer
to the application manual for details of the menu).

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- When an RSR is input, the program whose program

name consists of the specified program number plus a
base value is started. For exam ple, if a signal is input
to RSR2 when program number 23 is registered in
RSR2, the program to be started is the one with the pro-
gram name calculated from the expression
RSR + (RSR2 program number + base
number),
i.e., RSR0123.
The base number is stored in parameter
$SHELL_CFG.$JOB_BASE, and can be changed in
a program with a parameter instruction. (For example,
$SHELL_ CFG. $JOB_BASE =100). In this way, the
combination of programs which can be started by
RSRs can be changed.
- Whether the system should output an acknowledge sig-
nal to an RSR can be selected from the menu. If so spe-
cified, a pulse is output from the signal corresponding
to the RSR, one of signals ACK1 to ACK4, when the
input of the RSR is accepted. From the same menu, the
width of the pulse can also be specified.
It is possible to accept other RSRs while outputting an
acknowledge signal.
- Input of a CSTOPIT signal can clear the program queue
waiting for execution after acceptance of RSRs.
(9) PNS/PNSTROBE (input)
Signal name : PNS : Program number select
PNSTROBE: Strobe input for PNS
Effective : When the command acceptance enabled signal (output)
CMDENBL is turned on.
See the description of CMDENBL in Section B.3.2 (1)
for details.
Function : - The PNS/PNSTROBE signal selects whether the RSR
function is used or the PNS function (optional) is
used. If the PNS function is enabled, the RSR func-
tion cannot be used.
- The eight signals PNS1 to PNS8 are used to specify
a program at the instant the strobe signal PNSTROBE
rises.
- A menu is provided to specify the information about
PNS.

359
B. SPECIFICATIONS OF PERIPHERAL
DEVICE INTERFACE APPENDIX B–80945EN/02

If a number other than zero is entered to PNS input, a

program is selected whose program number is the en-
tered value plus the base number. For example, if the
PNS value is 23, the program to be started has the pro-
gram name calculated from the expression
PNS + (entered PNS value + base number),
i.e., PNS0123.
If zero is entered to PNS input, it is cleared as if no selec-
tion has been made.
- A PNS signal, which can only select a program, can-
not execute the selected program. The execution of
the selected program can only be started after input of
automatic operation start signal PROD_START.
- For safety, the selected program cannot be changed
from the teach pendant unless PNSTROBE is turned
off.
- If a program is selected by PNS, the program number
is output to selected program number signal (output)
SNO, and a pulse is output to program selection ac-
knowledge signal SNACK. Using these signals, pe-
ripheral devices can confirm the correct program has
been selected. For the timing of these signals, see the
sections describing SNO and SNACK.
- The following operations are effective for the program
selected by PNS. You can:
· Start up a program by input of automatic operation
start signal PROD_START
· Restart the program that has been suspended.
Inputting the START signal restarts the program
selected by PNS when
$SHELL_CFG.$CONT_ONLY is set to EN-
ABLED.
· Input of CSTOPI cancels execution of the pro-
grams selected by PNS when $SHELL_
CFG.$USE_ ABORT is set to ENABLED.
(10)Automatic operation start signal (input) PROD_START
Effective : When the command acceptance enabled signal (output)
CMDENBL is turned on.
See the description of CMDENBL in Section B.3.2 (1)
for details.
Function : This input signal executes the selected program at the
falling edge when the signal is turned off after being
turned on.

360
 B. SPECIFICATIONS OF PERIPHERAL
B–80945EN/02 APPENDIX DEVICE INTERFACE

B.3.2 This section describes the specifications of output signals for the
Output Signals peripheral device interface.
(1) Command acceptance enabled signal (output) CMDENBL
Turned on : When the remote conditions are satisfied and the system
is not in the alarm status
Turned off : When the remote conditions are not satisfied or the sys-
tem is in the alarm status
The remote conditions are satisfied when all of the following are satis-
fied.
- The teach pendant is in the DISABLED status.
- The remote switch on the operator’s panel is set to RE-
MOTE side.
- System variable $RMT_MASTER is set to 0 (external
interface).
- Signal *SFSPD is set to on, or in the normal status.

(2) System ready signal (output) SYSRDY

Turned on : When power is applied to the motor of the robot.
Turned off : When power is not applied to the motor of the robot.
(3) Program run signal (output) PROGRUN
Turned on : When the program is being executed.
Turned off : When the program is not being executed.
(4) Held signal (output) HELD
This signal is used to check the status of the hold input.
Turned on : When the hold button (or input) is being pressed down
(or turned on).
Turned off : When the hold button (or input) is not being pressed
down (or is turned off).
(5) Program paused signal (output) PAUSED
This signal is used together with output signal PROGRUN to determine
whether a program can be restarted while it is being held.
Turned on : When a program is held and has not been restarted yet.
While this signal is on, the program can be restarted and
retains information such as that to return from a subpro-
gram to the main program.
Turned off : When a program is being executed or is ready to start.
If signal PROGRUN is on, the program is being
executed. If signal PROGRUN is off, the program has
not been executed and can be started from this status.
(6) Alarm status signal (output) FAULT
Turned on : When the system is in the alarm status (or an alarm
which can stop a program execution is detected.) The
indicator lamp does not go on in warning.
Turned off : When the alarm status is released by an alarm release op-
eration.

361
B. SPECIFICATIONS OF PERIPHERAL
DEVICE INTERFACE APPENDIX B–80945EN/02

(7) Reference point signal (output) ATPERCH

Turned on : When the robot is in the reference position specified in
the parameter. (the reference point No.1 in reference
point setup screen.)
Turned off : When the robot is not in the reference position specified
in the parameter. (the reference point No.1 in reference
point setup screen.)
Up to three reference positions can be specified, but this signal is output
when the robot is in the first reference position. For the other two refer-
ence positions, general-purpose signals can be assigned to output as
such. (They can be set from the setup screen.)
(8) Teach pendant enabled signal (output) TPENBL
Turned on : When the teach pendant is enabled.
Turned off : When the teach pendant is disabled.
(9) Battery alarm signal (output) BATALM
Turned on : When the voltage of the battery for the CMOS memory
backup drops below the reference.
Turned off : When the voltage of the battery for the CMOS memory
backup is at the normal level.
(10)Operating signal (output) BUSY
Turned on : When a program is being executed or is being processed
from operation panels such as the teach pendant. (This
has the same function as that of the BUSY lamp on the
teach pendant.)
Turned off : When a program is not being executed nor is being pro-
cessed from operation panels such as the teach pendant.

362
 B. SPECIFICATIONS OF PERIPHERAL
B–80945EN/02 APPENDIX DEVICE INTERFACE

(11)RSR acknowledge signals (output) ACK1/ACK2/ACK3/ACK4

These signals are used together with the RSR function. They can be
specified to be enabled or disabled from the RSR setup menu.
Turned on : When one of the signals from RSR1 to RSR4 is input
and accepted. A pulse whose width is specified from the
menu is output to acknowledge the signal.
Turned off : Normally. Since these signals are always output as
pulses, they are normally in the off status.
The following chart shows the timing of the RSR input and ACK out-
put.

CMDENBL (O)
(The remote conditions need to be satisfied.)

RSR1 (I)

The maximum delay is 32 msec.

ACK1 (O)
(The width of the pulse is set in the parameter.)

RSR2 (I)

ACK2 (O)

RSR3 (I)

ACK3 (O)

RSR4 (I)

ACK4 (O)

* Other RSR signals can be accepted even when the ACK signal is being output.

363
B. SPECIFICATIONS OF PERIPHERAL
DEVICE INTERFACE APPENDIX B–80945EN/02

(12)PNS acknowledge signal (output) SNO/SNACK

These signals are used together with the PNS function.
Turned on : Whenever the PNS function is enabled.
The selected program number is displayed in binary
code (SN01 to SN08) on the teach pendant. If the num-
ber cannot be represented as an eight-bit number, it be-
comes zero.
After selecting a program by PNS, a pulse is output from
signal SNACK as a part of the PNS operation. The
width of the pulse can be specified from the menu. See
the timing chart below.

CMDENBL (O)
(The remote conditions need to be satisfied.)

PNS1-8 (I)
(A value is input.)

PNSTROBE (I)
(A strobe is input for PNS.)

Detection and
processing of
PNSTROBE by (PNS is read within a maximum of 32 msec after PNSTROBE is turned
software. on.)

SNO1-8 (O)

SNACK (O)

PROD_START (I)
(Program execution
starts within 32 msec.)

PROGRUN (O)

364
 B. SPECIFICATIONS OF PERIPHERAL
B–80945EN/02 APPENDIX DEVICE INTERFACE

B.4
SPECIFICATIONS OF
DIGITAL AND
ANALOG
INPUT/OUTPUT

B.4.1 This section describes the external specifications of digital and analog
input/output in the R-J3 controller.
Overview

B.4.2 The R-J3 controller can use up to 512 digital input and output points or
an equivalent number of analog input and output points. One analog
Input/Output Hardware
input/output point uses the resources equivalent to those used by 16
Usable in the R-J3 digital I/O points. The R-J3 can use a total of up to 512 I/O points.
Controller
The R-J3 controller can use the following I/O hardware.
- Process I/O printed circuit board
- I/O unit model A
- I/O unit model B
The process I/O printed circuit board and the I/O unit model A or B can
be used together.

B.4.3
(1) RDI/RDO
Software These are signals sent to the connector at the wrist of the robot.
Specifications They cannot be assigned (redefined) and are fixed.
The standard format is eight inputs and eight outputs. The number of
points that can be used for the connector at the wrist depends on the
individual robot.
(2) SDI/SDO
The signal No. that is determined at hardware can be changed by
software operation.
(3) Analog I/O
An analog I/O signal can access the analog I/O port (optional) on the
process I/O printed circuit board or the I/O port on the analog I/O
module (used together with the I/O unit model A).
It reads and writes the digital value converted from the analog value
of the I/O voltage. It means that the value does not always represent
the real I/O voltage.
(4) Group I/O
Group I/O is a function which can input or output multiple DI/DO
signals as binary codes.
Any number of continuous signals of up to 16 bits can be set for its
use.
It can be set in the menu DETAILS on the group I/O screen.

365
C. POWER DISTRIBUTION
CIRCUIT DIAGRAM APPENDIX B–80945EN/02

C POWER DISTRIBUTION CIRCUIT DIAGRAM

Fig.C (a) 200VAC Power supply Circuit Diagram (A–cabinet)

366
 C. POWER DISTRIBUTION
B–80945EN/02 APPENDIX CIRCUIT DIAGRAM

Fig.C (b) 200VAC Power supply Circuit Diagram (B–cabinet)

367
C. POWER DISTRIBUTION
CIRCUIT DIAGRAM APPENDIX B–80945EN/02

Fig.C (c) +5V, +3.3V, +15V, –15V Power Supply Circuit Diagram (A–cabinet)

368
 C. POWER DISTRIBUTION
B–80945EN/02 APPENDIX CIRCUIT DIAGRAM

Fig.C (d) +5V, +3.3V, +15V, –15V Power Supply Circuit Diagram (B–cabinet)

369
C. POWER DISTRIBUTION
CIRCUIT DIAGRAM APPENDIX B–80945EN/02

Robot
intemal S–430i, S–900i
cable

Robot
intemal M–410i
cable

Robot
connection ARC Mate 100i, M–6i, SR Mate 200i
cable

Fig.C (e) Robot Mechanical Unit +5V Power Supply Circuit Diagram (1/4)

370
 C. POWER DISTRIBUTION
B–80945EN/02 APPENDIX CIRCUIT DIAGRAM

Robot
connection
cable

Robot
connection
cable

Robot
connection
cable

Fig.C (e) Robot Mechanical Unit +5V Power Supply Circuit Diagram (2/4)

371
C. POWER DISTRIBUTION
CIRCUIT DIAGRAM APPENDIX B–80945EN/02

Robot
connection
cable

Robot
connection
cable

Robot
connection
cable

Fig.C (e) Robot Mechanical Unit +5V Power Supply Circuit Diagram (3/4)

372
 C. POWER DISTRIBUTION
B–80945EN/02 APPENDIX CIRCUIT DIAGRAM

Robot
connection
cable

Fig.C (e) Robot Mechanical Unit +5V Power Supply Circuit Diagram (4/4)

373
C. POWER DISTRIBUTION
CIRCUIT DIAGRAM APPENDIX B–80945EN/02

Fig.C (f) +24V Power Supply Circuit Diagram (A–cabinet)

374
 C. POWER DISTRIBUTION
B–80945EN/02 APPENDIX CIRCUIT DIAGRAM

Fig.C (g) +24V Power Supply Circuit Diagram (B–cabinet)

375
C. POWER DISTRIBUTION
CIRCUIT DIAGRAM APPENDIX B–80945EN/02

S–430i

M–410i

ARC Mate 100i, M–6i, SR Mate 200i

Fig.C (h) Robot Mechanical Unit +24V Power Supply Circuit Diagram (1/4)

376
 C. POWER DISTRIBUTION
B–80945EN/02 APPENDIX CIRCUIT DIAGRAM

Fig.C (h) Robot Mechanical Unit +24V Power Supply Circuit Diagram (2/4)

377
C. POWER DISTRIBUTION
CIRCUIT DIAGRAM APPENDIX B–80945EN/02

Fig.C (h) Robot Mechanical Unit +24V Power Supply Circuit Diagram (3/4)

378
 C. POWER DISTRIBUTION
B–80945EN/02 APPENDIX CIRCUIT DIAGRAM

Fig.C (h) Robot Mechanical Unit +24V Power Supply Circuit Diagram (4/4)

379
D. OPTICAL FIBER CABLE APPENDIX B–80945EN/02

D OPTICAL FIBER CABLE

The R–J3 uses fiber optic cables for communication between the main
board and servo amplifiers and between the main board and panel board.
Observe the following cautions when handling these fiber optic cables.
Handle fiber optic cables outside the unit (between the control unit and
operator box) with utmost care, especially when installing the unit.
(1) Protection during storage
When the electrical/optical conversion module (mounted on the
printed circuit board) and the fiber optic cable are not in use, their
mating surfaces must be protected with the lid and caps with which
they are supplied. If left uncovered, the mating surfaces are likely to
become dirty, possibly resulting in a poor cable connection.

Electrical/optical conversion module Lid

Fiber optic cable Fiber optic

cable caps

Fig.D(a) Protection of electrical/optical conversion module and fiber

optic cable (when not in use)

380
B–80945EN/02 APPENDIX D. OPTICAL FIBER CABLE

(2) Fiber optic cable

D Although the reinforcing cover of the external optical cable has
sufficient mechanical strength, be careful not to drop heavy objects
on the cable.
D Grasp the optical connector firmly when connecting or
disconnecting the cable. Do not pull on the fiber optic cord itself.
(The maximum tensile strength between the fiber cord and
connector is 2 kg. Applying greater force to the cord is likely to
cause the connector to come off, making the cable unusable.)
Fiber optic cord diameter : 2.2 mm 2 cords
Diameter of cable with reinforced cover : 7.6 mm
Tensile strength : Cable with reinforced cover :75 kg
Fiber optic cord :7 kg per cord
Between fiber optic cord and connector : 2 kg
Minimum bending radius of fiber optic cord :25 mm
Minimum bending radius of cable with reinforced cover : 50 mm
Bending resistance (cable with reinforced cover) :
10 million bending cycles at room temperature
(when the bending radius is 100 mm)
Flame resistance : Equivalent to UL VW–1
Operating temperature : –20 to 70°C

8.2

6.7 19 max. 60 max. 35typ.

21

Code Bush Reinforced cover

Fig.D(b) External dimensions of external optical cable Unit : mm

D Afler it is connected, the optical connector is automatically locked

by the lock levers on its top. To remove the connector, release the
lock levers and pull the connector.
D Although optical connectors cannot be connected in other than the
correct orientation, always take note of the connector’s orientation
before making the connection.
D Take care to keep both parts of the optical connector (cable side and
PCB side) clean. If they become dirty, wipe them with tissue paper
or absorbent cotton to remove dirt. The tissue paper or absorbent
cotton may be moistened with ethyl alcohol. Do not use any
organic solvent other than ethyl alcohol.
D Fix the reinforcing cover by using a cable clamp, as shown in Fig.
D(c), to prevent the weight of the fiber optic cable from being
applied directly to the connecting part of the optical connector.

381
D. OPTICAL FIBER CABLE APPENDIX B–80945EN/02

Optical connector Part of optical fiber cord Part of reinforcing cover

Bending radius of 25 mm or more

(Make the bending radius as large as
possible.)
Bending radius of 50 mm or more
(Make the bending radius as large as possible.)
Cable clamp
(Don’t clamp tight)

Fig.D(c) Fixing the cable with a clamp

D Any superfluous portion of the cable might be wound into a loops.

Should this prove necessary, make sure the diameter of each loop
is at least 150 mm (for an external cable). Winding the cable into
smaller loops can produce sharp curves that exceed the specified
bend radius limit. Such bending can result in transmission loss,
ultimately leading to a communication failure.
D When using a nylon band (cable tie) as a cable clamp, follow the
instructions given below. Also, take care not to apply a bending
force to one particular part of the cable when fixing it with a clamp.
Failing to clamp the cable correctly might cut or damage it.
External cable :
Do not clamp the uncovered portion of the cable with a nylon
band. When clamping the cable by the reinforcing cover, the
clamping force is not an important factor to consider. However,
ensure that the clamping force is as small as possible to ensure
that the reinforcing cover is not deformed by the clamping. If
possible, the clamping force should be 5kg (111bs) or less.

382
B–80945EN/02 APPENDIX E. CARD INTERFACE

E CARD INTERFACE

Connector for card

Card

At inserting the card into connector, please insert it straight.

Fig.E Precautions for card interface

383
B–80945EN/02 Index
[Numbers] [D]
10BASE–T Connector (CD38) Pin Assignments, 290 Digital I/O Signal Specifications, 269

[A] [E]
Electrical Connections, 190
A–Cabinet, 137
Emergency Stop Control PC Board
Adjustment and Checks at Installation, 303 (A20B–1007–0440), 104
Alarm Occurrence Screen, 31 End Effector Cable Connector, 282
ARC Weld Connection Cable (CRW1, CRW7: Honda End Effector Control Interface, 271
Tsushin, 34 pins), 278 Ethernet Interface, 288
Assemble at Installation, 300 External Cable Wiring Diagram, 202
External View of the Controller, 19

[B]
Backplane PC Board, 105
[G]
Grounding the Network, 293
Battery for Memory Backup (3 VDC), 183
Battery Replacement, 183
Block Diagram, 188 [I]
Block Diagram of the Main Power Including Power I/O Signal Specifications for Arc–Welding Interface,
Supply, 130 273
I/O Signals, 356
In Case of A–Cabinet, 237, 239, 243
[C] In Case of B–Cabinet, 238, 240, 243
Cable Clamp and Shielding, 292 Input Signals, 356
Cable Connection, 290 Input/Output Hardware Usable in the R-J2 Controller,
365
Cable Connection for the Peripheral Devices, End Installation, 297
Effectors, and ARC Welders, 279
Installation Condition, 302
Card Interface, 383
Installation Method, 297
Checking the Power Supply Unit, 134
Interface, 284
Component Functions, 26 Interface for Peripheral Devices, End Effectors, and
Configuration, 18 Welders, 248
Connecting the Communication Unit, 284
Connecting the External Emergency Stop, 226 [L]
Connecting the External Power Supply ON/OFF Lead Materials, 292
Switch, 224
Led of Servo Amplifier, 126
Connecting the Input Power , 222
Connection between RS–232–C Interface and Exter-
nal Device, 286 [M]
Connection Between the Control Unit and Welder, Main Board (A16B–3200–0330, –0331), 102
263 Manual Operation Impossible, 100
Connection Between the Mechanical Unit and End Mastering, 35
Effector, 261
MCC Unit Fuse Replacement, 181
Connection Diagram Between Mechanical Units, 191
Connection to Ethernet, 289
Connector Specification, 292
[O]
Operator Safety, 4, 6

i–1
 Index B–80945EN/02

Optical Fiber Cable, 380 Replacing Fuses in the Power Unit, 177
Output Signals, 361 Replacing Fuses in the Servo Amplifier, 176
Replacing Process I/O Boards EA, EB, FA, and GA
(A–Cabinet), 142
[P] Replacing Relays, 182
Panel Board, 108 Replacing Servo Amplifiers, 159
Panel Switch Board, 124 Replacing Side Panel Fan Unit (B–Cabinet), 171
Peripheral Device and Control Unit Connection, 248 Replacing the A–Cabinet Door, 138
Peripheral Device Cable Connector, 280 Replacing the A–Cabinet Louver, 138
Peripheral Device Connection Cable, 279 Replacing the A–Cabinet Rear Panel, 137
Peripheral Device Interface, 269 Replacing the A–Cabinet Top Panel, 137
Peripheral Device Interface A Cable (CRM2: Honda Replacing the AC Fan Motor, 167
Tsushin, 50 pins), 277
Replacing the Backplane Board (Unit), 140
Peripheral Device Interface B Cable (CRM4: Honda
Tsushin, 20 pins), 277 Replacing the Base Unit of the Model A I/O Unit, 162
Peripheral Device Interface Block Diagram, 232 Replacing the Control Section Fan Motor, 166
Peripheral Device Interface Combination, 243 Replacing the Emergency Stop Unit, 157
Peripheral Device, ARC Welding, and End Effector Replacing the Fuse on the Process I/O Boards, 178
Interfaces, 230 Replacing the Heat Exchanger and Door Fan Unit
Position Deviation Found in Return to the Reference (A–Cabinet), 167
Position (Positioning), 98 Replacing the Magnetic Contactor (MCC), 158
Power Cannot be Turned On, 29 Replacing the MCC Unit (B–cabinet), 175
Power Distribution Circuit Diagram, 366 Replacing the Model A I/O Unit, 162
Precautions for Mechanism, 10 Replacing the Model B I/O Unit, 164
Precautions for Mechanisms, 11 Replacing the Operator Panel, 173
Precautions in Operation, 11 Replacing the Panel Board, 143
Precautions in Programming, 10, 11, 12 Replacing the Panel Switch Board, 174
Preventive Maintenance, 27 Replacing the Power Unit and Printed–Circuit Boards
Printed Circuit Boards, 101 on the Backplane Unit, 141
Process I/O Board CA, 115 Replacing the Printed–Circuit Boards, 139
Process I/O Board CB, 118 Replacing the Rear Fan Unit (A–Cabinet), 168
Process I/O Board DA, 120 Replacing the Regenerative Resistance Unit, 155
Process I/O Board EA, 109 Replacing the Teach Pendant, 165
Process I/O Board EB, 111 Replacing the Transformer, 148
Process I/O Board FA, 113 Replacing Top Fan Unit and Door Fan Unit (B–Cabi-
net), 170
Process I/O Board GA, 122
Resetting Overtravel, 304
Process I/O Board Signals, 244
Resetting Overtravel and Emergency Stop at Installa-
tion, 304
Robot Connection Cables, 203
[R]
RS–232–C Interface Signals, 285
Recommended Cables, 283
RS–232C Interface, 284
Replacing a Module, 163
Replacing a Unit, 136
Replacing Cards and Modules on the Main Board, 144 [S]
Replacing Emergency Stop Relays, 182 Safety During Maintenance, 9
Replacing Fuses, 176 Safety in Maintenance, 13

i–2
B–80945EN/02 Index

Safety of the End Effector, 12 Transportation, 296

Safety of the Robot Mechanism, 11 Transportation and Installation, 295
Safety of the Teach Pendant Operator, 7 Troubleshooting, 28
Safety of the Tools and Peripheral Devices, 10 Troubleshooting Based on Fuse, 84
Safety Precautions, 3 Troubleshooting Based ON LED Indications, 89
Safety Signals, 34 Troubleshooting Using the Error Codes, 37
Selecting Transformer Taps, 132
Servo Amplifiers, 125 [V]
Setting and Adjusting the Power Supply, 129 Vibration Observed During Movement, 99
Setting Common Voltage, 355
Setting of Servo Amplifier, 128
Signals, 353
[W]
Warning Label, 14
Software Specifications, 365
When I/O Unit–MODEL A is Used, 237
Specifications of Digital and Analog Input/Output,
365 When I/O Unit–MODEL B is Used, 239
Specifications of Peripheral Device Interface, 352 When Process I/O Board CA or CB is Used (B–cabi-
net), 235
Specifications of the Cables Used for Peripheral
Devices and Welders, 277 When Process I/O Board DA is Used (B–cabinet), 236
When Process I/O Board EA or EB or GA is used
(A–Cabinet), 232
[T] When Process I/O Board FA is Used (A–cabinet), 234
Teach Pendant Cable, 221 When Two or more Process I/O Printed Circuit Boards
and I/O Unit (Model A or Model B) are Used, 241
Total Connection Diagram, 307

i–3
 Revision Record

FANUCĄRobot series R-J3 CONTROLLER MAINTENANCE MANUAL (B–80945EN)

The information for the following robot models are added.

S–430iC, S–430iR/Press HT/Press HS, S–430iU, S–500i,
02 Apr., 2000
S–900i, M–500i, ARC Mate 50i, F–200i, LR Mate 200i,
SR Mate 200i.

01 Oct.,1998

Edition Date Contents Edition Date Contents