R-J2 Controller For Europe - Maintenance Manual B-80525E-1 - 03 PDF

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FANUC Robot series

R-J2 CONTROLLER for Europe
MAINTENANCE MANUAL
B-80525E-1 /03
© MyFANUC 4B16F037DA0D4206AF11776B9FD01ECB
• 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-80525E-1 /03 PREFACE
PREFACE
This manual covers the following models.
Model Abbreviation
FANUC Robot ARC Mate 100 ARC Mate 100
FANUC Robot ARC Mate 120 ARC Mate 120
FANUC Robot ARC Mate 1OOi ARC Mate 1OOi
FANUC Robot ARC Mate 120i ARC Mate 120i
FANUC Robot 8-6 8-6
FANUC Robot S-12 S-12
FANUC Robot ~i M-6i
FANUC Robot M-16i M-16i
FANUC Robot 8-420i F/iW/iS/iUiR 8-420 iF/iW/iS/iUiR
FANUC Robot M-410 1WhWX/iT M-410 1W/iWX
FANUC Robot M-500 M-500
FANUC Robot M-710i/1W M-710i/1W
FANUC Robot A-520i A-520i
(Note) When a description is common to all the types of S-420 i, it simply refers to S-420 i.
When a description is common to all the type of M-410 i, it simply refers to M-410 i.
When a description is common to all the type of M-71 O i, it simply refers to M-71 O i.
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B-80525E-1 /03 Table of contents

PREFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . p-1
1. SAFETY 3
1. OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2. CONFIGURATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.1 EXTERNAL VIEW OF THE R-J2 CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.2 COMPONENT FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
2.3 PREVENTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3. TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
3.1 POWER CANNOT BE TURNED ON................................................. 31
3.2 TROUBLESHOOTING USING THE ERROR CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
3.3 POSITION DEVIATION FOUND IN RETURN TO THE REFERENCE POSITION
(POSITIONING) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
3.4 VIBRATION OBSERVED DURING MOVEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
3.5 MANUAL OPERATION IMPOSSIBLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
4. PRINTED CIRCUIT BOARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164

4.1 MAIN CPU PC BOARDS (Al6B-3200-0042) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
4.2 EMERGENCY STOP CONTROL PC BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
4.3 BACKPLANE PC BOARD ............................................. ·. . . . . . . . . . . . 171
4.4 PROCESS INPUT/OUTPUT PC BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
4.4.1 Process Input/Output PC Board CA (A16B-2201-0470) ................................... 172
4.4.2 Process Input/Output PC Board CB (A16B-2201-0472) ................................... 176
4.4.3 Process Input/Output PC Board DA (A16B-2201-0480) ................................... 178
4.4.4 Process Input/Output PC Board EA (A16B-3200-0230) ................................... 180
5. SERVO AMPLIFIERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184

5.1 SERVO AMPLIFIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
5.2 POWER SUPPLY MODULE (PSM)(M-410i) . . . . . . . . . . . . . . . . . . . . .. . . . . . . .. . . . . . . . . . . .. 189
5.3 SERVO AMPLIFIER MODULE (SVM) (M-410i)....................................... 193
5.4 SERVO AMPLIFIER UNIT {S-900, M-500) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
6. SETTING AND ADJUSTING THE POWER SUPPLY ....................... 205

6.1 BLOCK DIAGRAM OF THE POWER SUPPLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
6.2 CONNECT THE TAP ACCORDING TO THE POWER SUPPLY VOLTAGE . . . . . . . . . . . . . . . . . 209
6.3 SELECTING TRANSFORMER TAPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . .. . . .. . 210
6.4 CHECKING THE TRANSFORMER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
6.5 CHECKINGTHEPOWERSUPPLYUNIT ............................................ 214
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B-80525E-1/03 Table of Contents
7. REPLACING A UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217

7.1 REPLACING A PRINTED CIRCUIT BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . 219
7.1.1 Replacing the Backplane Printed Circuit Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
7.1.2 Replacing the Power Supply Unit or a Printed Circuit Board on the Backplane Printed Circuit Board 221
7.1.3 Replacing the process l/O EA printed circuit board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
7.2 REPLACING A MODULE . . . . .. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . .. .. .. . . . . . 223
7.3 REPLACING THEE-STOP UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
7.4 REPLACING THE EMG PCB (B-CABINET) . . . . . . . . . . . . . . . .. . . .. .. . .. . .. .. .. .. .. . .. .. 226
7.5 REPLACING THE EMG PCB (M-410i) . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
7.6 REPLACING THE 1/0 UNIT MODEL B INTERFACE UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
7.7 REPLACING THE INPUT/OUTPUT UNIT OF MODEL A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
7.7.1 Replacing the Base Unit of the Input/Output Unit of Model A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
7.7.2 Replacing a Module................................................................ 231
7.8 MOUNTING 1/0 UNIT MODEL BON THE DIN RAIL
(USE A RAIL THAT IS 3.5MM WIDE AND 7.5MM HIGH.) . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . 232
7.8.1 The Din Rail is in the Operator's Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
7.9 REPLACING THE TRANSFORMER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
7.10 REPLACING A SERVO AMPLIFIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
7.11 REPLACING THE DISCHARGE RESISTOR UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
7.12 REPLACING THE OPERATOR'S BOX. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . 243
7.13 REPLACING THE MODE SELECTION SWITCH (OPERATOR'S BOX) . . . . . . . . . . . . . . . . . . . 245
7.14 REPLACING THE DOOR INTERLOCK.............................................. 247
7.15 REPLACINGTHENOISEFILTER(OPERATOR'SBOX) ................................ 248
7.16 REPLACING THE TEACH PENDANT ............................................... 250
7.17 REPLACINGTHEE-STOPUNIT................................................... 252
7.18 REPLACING THE BREAKER ...................................................... 258
7.19 REPLACING THE BREAKER UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . 261
7.20 REPLACING THE FAN MOTOR OF THE CABINET . . . . . . .. . . . . . . . . . . . . . . . . . . .. . . . . . . . 262
7.21 REPLACING THE FAN MOTOR OF THE CONTROL UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
7.22 REPLACING A FUSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
7.22.1 Servo Amplifier................................................................... 271
7.22.2 Replacing fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
7.22.3 Power Supply Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
7.22.4 Process Input/Output PC Boards CA, CB, DA and EA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278
7.23 REPLACING A RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279
7.24 REDUNDANTE-STOPUNIT . . . . . . . . .. . .. . . . .. . .. . . . . . . . . . . . . .. . .. . . . .. .. .. . . . . .. . 281
7.25 REPLACING THE BATTERY ...................................................... 285
Ill. CONNECTIONS
1. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289
2. BLOCK DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290
3. ELECTRICAL CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291

3.1 CONNECTION DIAGRAM BETWEEN MECHANICAL UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . 291
3.2 EXTERNAL CABLE WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295
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Table of Contents B-80525E-1 /03
3.2.1 Clamping of Shield Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295

3.2.2 Robot Connection Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300
3.2.3 Teach Pendant Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315
3.2.4 Connecting the Input Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317
3.2.5 Connecting the External Power Supply on/off Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 319
3.2.6 Connecting the External Emergency Stop............................................... 321
4. PERIPHERAL DEVICE, ARC WELDING, AND

END EFFECTOR INTERFACES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325
4.1 PERIPHERAL DEVICE INTERFACE BLOCK DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328
4.1.l When Process J/O Printed Circuit Board CA, CB or EA is Used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328
4.1.2 When Process J/O Printed Cricuit Board DA is Used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 332
4.1.3 When J/O Unit Model A is Used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335
4.1.4 When J/O Unit Model B is Used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 337
4.1.5 When Two or More Process J/O Printed Circuit Boards and J/O Unit
(Model A or Model B) are Used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340
4.2 PERIPHERAL DEVICE INTERFACE COMBINATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 342
4.3 PROCESS UO PRINTED CIRCUIT BOARD SIGNALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343
4.4 INTERFACE FOR PERIPHERAL DEVICES, END EFFECTORS, AND WELDERS . . . . . . . . . . . 347
4.4.1 Peripheral Device and Control Unit Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 347
4.4.2 Connection Between the Mechanical Unit and End Effector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 358
4.4.3 Connection Between the Control Unit and Welder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 360
4.5 DIGITAL UO SIGNAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 364
4.5.1 Peripheral Device Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 364
4.5.2 End Effector Control hiterface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 366
4.5.3 J/O Signal Specifications for ARC-welding Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 368
4.6 SPECIFICATIONS OF THE CABLES USED FOR
PERIPHERAL DEVICES AND WELDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 371
4.6.1 Peripheral Device Interface a Cable (CRM2: Honda Tsushin, 50 Pins) . . . . . . . . . . . . . . . . . . . . . . . . 371
4.6.2 Peripheral Device Interface B Cable (CRM4: Honda Tsushin, 20 Pins) . . . . . . . . . . . . . . . . . . . . . . . 371
4.6.3 ARC Weld Connection Cable (CRWl: Honda Tsushin, 34 Pins) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 372
4.7 CABLE CONNECTION FOR THE PERIPHERAL DEVICES,
END EFFECTORS, AND ARC WELDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 373
4.7.1 Peripheral Device Connection Cable................................................... 373
4.7.2 Peripheral Device Cable Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 375
4.7.3 End Effector Cable Connector.......................... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 377
4.7.4 Recommended Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 378
5. TRANSPORTATION AND INSTALLATION ................................ 379

5.1 TRANSPORTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 379
5.2 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 382
5.2.1 Installation Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 382
5.2.2 Connecting Cables at Installation (Combined Type of i Cabinet) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 385
5.2.3 Connecting Cables at Installation (For Separate Type of i Cabinet) . . . . . . . . . . . . . . . . . . . . . . . . . . . 386
5.3 INSTALLATION CONDITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 390
5.4 ADJUSTMENT AND CHECKS AT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 391
5.5 RESETTING OVERTRAVEL AND EMERGENCY STOP AT INSTALLATION . . . . . . . . . . . . . . 392
5.5.1 Peripheral Device Interface Processing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 392
5.5.2 Resetting Overtravel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 392
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APPENDIX
A. COMPLETE CONNECTION DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 395

A. I COMPLETE CONNECTION DIAGRAM (I-CABINET ; ARC MATE 100,
ARC MATE 120, ARC MATE IOOi, ARC MATE 120i, S-6, S-12, M-6i, M-16i,
S-420i, S-500, S-700, M-710i, A-520i) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 395
A.2 INTERNAL CONNECTION DIAGRAM (B-CABINET; ARC MATE 100,
ARC MATE 120, ARC MATE lOOi, ARC MATE 120i, S-6, S-12, M-6i, M-16i,
S-420i, S-500, S-700, M-710i, A-520i) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 416
A.3 INTERNAL CONNECTION DIAGRAM (M-410i) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 435
A.4 INTERNAL CONNECTION DIAGRAM (M-500/S-900) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 454
B. SPECIFICATIONS OF PERIPHERAL DEVICE INTERFACE . . . . . . . . . . . . . . . . . 471

B.l SIGNALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 471
B.2 SETTING COMMON VOLTAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 473
B.3 1/0 SIGNALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 474
B.3.1 Input Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 474
B.3.2 Output Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 479
B.4 SPECIFICATIONS OF DIGITAL INPUT/OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 483
B.4.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 483
B.4.2 Input/Output Hardware Usable in the R-J2 Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 483
B.4.3 Software Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 483
c-4
I. SAFETY
B-80525E-1 /03 SAFETY 1. SAFETY
1
SAFETY
A IMPORTANT !
Before operating, servicing or in any other way handing the
robot, the "FANUC Robot SAFETY HANDBOOK
(B-80687E)" must be thoroughly studied.
Consider following notes besides the items described in the SAFETY

HANDBOOK.
• Please use approprite lighting (e.g. a handy light) for maintenance
work. The lighting shall not create new dangerous situations.
• Whenever possible, perform maintenance, inspection and adjusting
with the power turned off.
• When replacing parts, be sure to use those specified by FANUC.
• When replacing or installing components, make sure dirt and debris
do not enter the system.
• Be aware that when you remove a servomotor or breke, the assosiated
axis will fall if it is not surpported or resting on a hard stop.
• Make sure personnel cannot get trapped between the moving robot and
other equipment. Know the path that can be used to escape from a
moving robot. Make sure the escape route is never blocked.
• If is necessary to operate the robot during the inspection, pay careful
attention to the robot's motion and be sure to press the EMERGENCY
STOP button immediately when necessary.
• Be careful to slip during maintenance by spilling grease.
• Don't climb on the robot.
• Be careful when touching the hold heat parts below.
• (1) Servo motor (CAUTION LABEL fixed)
• (2) Inside of controller
If touching is unavoidable, wear the protective things (heat resistant
gloves, etc.).
• Do not try to remove any mechanical component from the robot before
thoroughly reading and undestanding the procedures in the manual.
Doing so can result in serious personal injury and component
destruction.
• After the replacement, certainly fix all removed parts that include
screws.
• The motor and reducer are heavy. Be careful at these replacement.
- 3 -
1. SAFETY SAFETY B-80525E-1 /03
• After replacing parts or adjustment, be sure test running according to

following procedure.
1 Using a low motion speed, single step the program for at least one
full cycle.
2 Using a low motion speed, test run the program continuously for
at least one full cycle.
3 As speed is increased, the path may vary slightly. Run through
the program at 5-10% intervals up to 100%.
4 Using the programmed speed, test run the program continuously
for at least one full cycle.
• After maintenance work, must be clean of oil, water, or debris around
the robot.
- 4 -
II. MAINTENANCE
B-80525E-1 /03 MAINTENANCE 1.0VERVIEW
1
OVERVIEW
This manual describes the maintenance and connection of the R-J2 robot
controller (called the R-J2).
Maintenance Part : Troubleshooting, and the setting, adjustment,
and replacement of units
Connection Part: Connection of the R-J2 controller to the robot
mechanical unit and peripheral devices, and
installation of the controller
NOTE
Before entering the robot working area, be sure to turn off the
power to the controller or press the emergency stop button on the
operator's box or teach pendant.
- 7 -
2. CONFIGURATION MAINTENANCE B-80525E-1/03
2
CONFIGURATION
2.1 Fig. 2.1 (a) to (d) show the R-J2.

EXTERNAL VIEW OF
THE R-J2
CONTROLLER
OPERATOR'S BOX
TEACH PENDANT
R-02 CONTROLLER
.... ©
FIG2. I (a) EXTERNAL VIEW OF THE R-02 CONTROLLER

INTEGRATED TYPE .. 8-420i, A-520i, ARC Mate 1OOi, M-6i, M-71 Oi,
REMOTE MOUNT .... ARC Mate 100, ARC Mate 120, ARC Mate 100i, ARC Mate 120i
S-6, S-12, M-6i, M-16i, 8-420i, 5-500, S-700, M-710i, A-520i
Fig.2.1 (a) External View of the R-J2 Controller (i cabinet)
- 8 -
B-80525E-1 /03 MAINTENANCE 2. CONFIGURATION
TEACH PENDANT OPERATOR'S PANEL
0
•
(ARC Mate 100, ARC Mate 120, ARC Mate 100i, ARC Mate 120i,
$-6, S-12, M--6i, M-16i, S-420i, S-500, S-700, M-710i, A-520i)
Fig.2.1 {b) External View of the R-J2 controller {B-Cabinet)
- 9 -
2. CONFIGURATION MAINTENANCE B-80525E-1 /03
~I J 1r 0 ~ Ci
[j
Ea a
0 L~
0 0 0
0
mJ
0
D D ~
.
0
0 0
~
.
0 0
Flg.2.1 (c) External View of the R-J2 controller (B-Cabinet/S-900)
- 10 -
B-80525E-1/03 MAINTENANCE 2. CONFIGURATION
OPERATOR'S BOX
(OPTION)
R-J2 CONTROLLER TEACH PENDANT
-- 8
•
-•- ~
-- B
•
-•-
•
M-410i CABINET IS INSTALLED
IN THE ROBOT MOUNT.
EXTERNAL VIEW OF R-J2(M-410i CABINET)
Flg.2.1 (d) External View of the R-J2 controller (M-41 Oi Cabinet)
- 11 -
f61 I 0 0 o ~
----
.-. DODD
0 le@
0 0
0
0 0
Fig.2.1 (e) External View of the R-J2 (B-Cabinet/M-500, M-410i)
- 12 -
The R-12 consists of the units shown in Fig. 2.1 (e) to (i).
The appearance and components may slightly differ depending on the
controlled robot, application, and options used.
OPERATOR'S BOX
BREAKER
TEACH PENDANT
OPTICAL ISOLATION UNIT

or 6-AXIS AMPLIFIER MAIN CPU PCB
NOISE FILTER
FAN PSU PCB

FAN (OPTION PCB)
DOOR INTERLOCK SWITCH

DISCHARGE RESISTOR
E-STOP UNIT
LOUVER
EMERGENCY STOP
CONTROL PCB TRANSFORMER
R-J2(i-CABINET) INNER MOUNTING DIAGRAM
Fig.2.1 (f) R-J2 Inner mounting diagram (i Cabinet)
- 13 -
TEACH PENDANT
SERVO AMPLIFIER PC BOARD FOR

EMERGENCY STOP
MODE SELECTION SWITCH CONTROL
(OPTION)
MAIN COU PC BOARD
POWER SUPPLY UNIT
OPTION PC BOARD.
I/O UNIT MODEL A

OR
I/O UNIT MODEL B
BREAKER
FAN 2
TRANSFORMER
..
FAN 3
E-STOP UNIT
OPTICAL ISOLATOR
UNIT (NOTE I )
(ARC Mate 100, ARC Mate 120, ARC Mate 100i, ARC Mate 120i,
$-6, S-12, M-6i, M-16i, 8-420i, 5-500, S-700, M-710i, A-520i)
Fig.2.1 (g) R-J2 Interior (B Cabinet)
- 14 -
TEACH PENDANT
SERVO AMPLIFIER 3
ADDITIONAL CABINET SERVO AMPLIFIER 4
2 FAN I
PC BOARD FOR
EMERGENCY STOP
CONTROL
MAIN CPU
PC BOARD
POWER SUPPLY
UNIT
~U--+1---l:l::I;;;;;;- OPTION PC BOARD
I/O UNIT MODEL A

or
I/O UNIT MODEL B
BREAKER
FAN 2
TRANSFORMER
SERVO AMPLIFIER 2
FAN 3 SERVO AMPLIFIER I
Fig.2.1 {h} R-J2 Controller Interior (B-Cabinet/S-900)
- 15 -
SERVO AMPLIFIER 6
SERVO AMPLIFIER 5
BREAKER UNIT
FAN 4
ADDITIONAL
FAN 5 TRANSFORMER
(ADDITIONAL CABINET I)
E-STOP UNIT2
ISCHARGE UNIT
FAN 6
FAN 7
(ADDITIONAL CABINET 2)
Fig.2.1 (i) R-J2 Controller Interior (B-Cabinet/5-900)
- 16 -
POWER SUPPLY MODULE I SERVO MODULE I
2
SERVO MODULE 3
SERVO MODULE 4
DELAYED-OFF
REDUNDANT
MCC UNIT
BATTERY
TRANSFORMER TAP
BREAKER
I/O UNIT MODEL A
OR
I/O UNIT MODEL B
TRANSFORMER
OPTION PC BOARD FOR BRAKE
POWER SUPPLY UNIT
MAIN CPU PC BOARD
FAN 2 BOARD FOR EMERGENCY STOP CONTROL
Fig.2.1 (j) R-J2 Controller Interior (M-410i Cabinet)
- 17 -
SERVO MODULEI
SERVO MODULEI FAN I

SERVO MODULEI
PC BOARD FOR EMERGENCY
STOP CONTROL
MAIN CPU PC BOARD
POWER SUPPLY UNIT
OPTION PC BOARD
I/O UNIT MODEL A

OR
I/O UNIT MODEL B
AN 2
TRANSFORMER
FAN 3
SERVO MODULE 4
POWER SUPPLY MODULE

DELAYED-OFF
REDUNDANT MCC UNIT
TEACH PENDANT
FAN 4
FAN 5
Fig.2.1 (k) R-J2 Controller Interior (B-Cabinet1M-410i}
- 18 -
SERVO AMPLIFIER I
ADDITIONAL SERVO AMPLIFIER 2
FAN I PC BOARD FOR
PANEL EMERGENCY STOP
CONTROL
MAIN CPU
PC BOARD
POWER SUPPLY
UNIT
OPTION PC BOARD
UNIT MODEL A
UNIT MODEL B
BREAKER
FAN 2
TRANSFORMER
E-STOP UNIT
SERVO AMPLIFIER 4
SERVO AMPLIFIER 3
TEACH PENDANT
DISCHARGE
UNIT
FAN 4
FAN 5
(INTERIOR OF ADDITIONAL CABINET)
Fig.2.1 (I} R-J2 Controller Interior (B-Cabinet/M-500)
- 19 -
NOTE
The following parts are added for EMC standards.
NOISE FILTER and FERRITE CORE

OPERATOR'S BOX
NOISE FILTER
FERRITE CORE
Fig.2.1 (m) Additional Parts for EMC (I-Cabinet)
- 20 -
NOTE
NOISE FILTER
BREAKER
NOISE FILTER
Fig.2.1 (n) Additional Parts for EMC (B-Cabinet)
- 21 -
NOTE
NOISE FILTER and FERRITE CORE
OPERATOR'S BOX
NOISE FILTER
MAIN CPU
EMG PCB
FERRITE CORE
(MAIN CPU JRF2 - EMG PCB JRF2)
(MAIN CPU JRVI - EMG PCB JRVI)
Fig.2.1 (o) Additional Parts for EMC (M-41 Oi)
- 22 -
Correspondence between robot and amplifier

J1 J2 J3 J4 JS J6
ARC Mate 100 A06B-6076-H005 OR H105
ARC Mate 120, ARC Mate 120i A06B-6076-H004 OR H104
$-6
A06B-6076-H005 OR H105
M-16i
S-12 A06B-6076-H004 OR H104
$-420i A06B-6076-H001 OR H101
S-500
A06B-6076-H002 OR H102
A-520i
S-700 A06B-6076-H003 OR H103
AMP1 AMP3 AMP5 AMP2 AMP4 AMP6
S-900 A068 A06B A06B A06B A06B A068

--6089 --6089 --6089 --6089 --6089 --6089
-H106 -H105 -H106 -H105 -H106 -H105
A06B-6087-H115 (PSM)
AMP1 AMP2 AMP3 AMP4

M-410i :..---------r----------------·-·-- ·- -----------·~-·---·~ !---~-------------- -----~--~-~-~~---~--~--
A068 A068 A068 A06B

--6079 --6079 --6079 --6079
-H106 -H106 -H106 -H103
AMP1 AMP3/M AMP2 AMP3/L AMP4

~----~---- --·----·--·-·-·----··------ ---------------------- --~------------- ----·-----------~ -----~---~----
M-500 A068 A068 A06B A06B A068

--6089 --6089 --6089 --6089 --6089
-H106 -H206 -H105 -H206 -H104
ARC Mate 1OOi, M--6i A06B-6076-H105
M-710i A06B-6076-H106
- 23 -
2. CONFIGURATION MAINTENANCE B--80525E-1 /03
Fig. 2.1 (o) shows the block diagram of R-J2.
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(ARC Mate 100, ARC Mate 120, ARC Mate 100i, ARC Mate 120i, $-6, S-12, M4», M-16i, $-420i, 5-500, S-700,
M-71 Oi, A-520i)
24
Fig. 2.1 (p) shows block diagram of R-J2.
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? ->_J-
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u u uo
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Fig.2.1 (q) Block Diagram of R-J2 (B-Cabinet)

{ARC Mate 100, ARC Mate 120, ARC Mate 100i, ARC Mate 120i, $-6, S-12, M-6i, M-16i, $-420i, 5-500, S-700,
M-710i, A-520i)
25
!"
()
0
z
'Tl
I = BACKPLANE PC BOAR~ I G5
c
JJ
- - ~
POWER SUPPLY UNIT MAIN CPU PC BOARD 5
z
.,, BATTERY
=·:....N --
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al 200VAC
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Fig.2.1 (s) Block Diagram of R-J2 (M-410i)
27
2.2 - Main CPU PC board

COMPONENT The main CPU PC board contains a microprocessor, its peripheral
circuits, memory, a serial interface to connect a unit such as a teach
FUNCTIONS pendant, and operator's panel control circuit. The main CPU controls
servo mechanism positioning and servo amplifier voltages.
- 1/0 printed circuit board, FANUC 1/0 Unit MODEL-A and MODEL
B
Various types of printed circuit boards are provided forapplications
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.
- Printed circuit board for emergency stop control
This printed circuit board controls the emergency stop system
(including overtravel and Wrist breakdown).
- Power supply unit
The power supply unit converts the AC power to various levels of DC
power. It contains batteries to back up data memory.
- Backplane printed circuit board
The 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 servo motor power amplification.
- Operator's box/operator's panel
Buttons and LEDs on the operator's box are used to start the robot and
to indicate the robot status. The box has a port for the serial interface
to an external device. 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. The transformer accepts a line voltage
from 200 to 575 VAC according to tap setting.
- Fan unit
The fan unit cools the inside of the controller.
- Circuit breaker
If the electric system in the controller malfunctions, or if abnormal
input power causes high current in the system, the input power is
connected to the circuit breaker to protect the equipment.
- Regenerative discharge registance
This unit is connected to a servo amplifier to discharge the back
electromotive force generated in the servo motor.
- 28 -
B--80525E-1 /03 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 turned 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 60 days.
When a B-cabinet is used, clean the filter installed at the air inlet
on the side of the control unit. When an i-cabinet is used, clean
the louver on the back of the control unit.
(d) Periodic inspection performed every six months
i-cabinet: Remove the top cover, louver, and back panel (if
possible), then remove any dirt and dust from the
inside of the transformer room. Wipe off dirt and
dust from the fan and transformer.
B-cabinet: Remove the back panel, then remove any dirt and
dust from the inside. Wipe off dirt and dust from the
fan and transformer.
(2) Maintenance tools
It is recommended that the following maintenance tools be prepared:
(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
Pliers
Long-nose pliers
Cutting pliers
- 29 -
3. TROUBLESHOOTING MAINTENANCE B-80525E-1/03
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 for releasing program alarms.
- 30 -
B-80525E-1/03 MAINTENANCE 3. TROUBLESHOOTING
3.1
POWER CANNOT BE
TURNED ON
• Check1 Check that the circuit breaker is on and has not tripped.
Corrective action: Turn on the circuit breaker.
• Check2 Check whether the LED (PIL: green) on the power supply unit is on.
Corrective action: If the LED is not on, 200 VAC is not supplied to the
power supply unit Fmd the cause. Investigate the cause
according to the overall circuit diagram in Appendix.
• Check3 Check whether the OFF and COM signals are connected on the terminal
block on the panel printed circuit board.
Corrective action: If OFF and COM are not connected : If the external
ON/OFF function is not used. connect the external ON
and OFF lines. If the external ON and OFF lines are
already connected. check the mating contacts and the
cable.
• Check4 Checks 1 to 3 above confirm that 200 VAC power is supplied to connector
CPl of the power supply unit and that the ON/OFF switch functions
normally. So check the power supply unit using the following procedure:
If the LED (PIL: green) on the power supply unit is not on
a) Fuses Fl is blown : See corrective action (I).
b) None of the above fuses blown : Check that 200 VAC is supplied
to connector CPI again.
If it is supplied, replace the power
supply unit.
If the LED (ALM: red) on the power supply unit is on
a) Fuse F3 blown : See corrective action (2).
b) Fuse F4 blown : See corrective action (3).
c) None of the above fuses blown [d) is also probable] :
A printed circuit board or unit that
uses a DC supply voltage (+5 V,
+24 V, or ± I5 V) is faulty.
d) None of the above fuses blown : Check that 200 VAC is supplied
to connector CPI. If it is supplied
replace the power supply unit.
Corrective action : If the power supply unit is not
faulty, replace the operator's box
or operator's panel.
- 31 -
3. TROUBLESHOOTING MAINTENANCE B-80525E-1 /03
Corrective action 1 Causes of blown fuses Fl and corrective action

(a) Short-circuit in the surge absorber VSll
VS 11 is inserted to absorb surge voltage between input lines.
If the surge voltage is excessive or sustained, excessively high
voltage is applied to VS 11 and a failure occurs in the short-circuit
mode, causing Fl to blow. If a short-circuit occurs in VS 11, and
there is not spare part, the system is permitted to operate without
VS 11. In this case, however, obtain and install a new VS 11 as
soon as possible.
VSll ordering number: A50L-2001-0122#G43lk
(b) Short-circuit of diode stack DBll
(c) Short-circuit between D and Sin switching transistors Q21 and
Q22
(d) Short-circuit between diodes D31 and D32
(e) The secondary power supply module is faulty:
If one of the causes (b) to (e) above is detected, replace the power
supply unit with a spare unit.
The codes for Fl is: A60L-0001-0245#GP75
Corrective action 2 Causes of blown fuse F3 and corrective action

The device connected to connector CP5 of the power supply unit may be
faulty. If no device is connected to CP5 or the connected device is normal,
the+24 V power used in a printed circuit board connected to the backplane
is faulty.
The code ofF3 is A60L-0001-0075#5.0:
Corrective action 3 Causes of blown fuse F4 and corrective action

The device connected to connector CP6 of the power supply unit may be
faulty. If no device is connected to CP6 or the connected device is normal,
the +24E used in a printed circuit board connected to the backplane is
faulty.
The code of F4 is A60L-0001-0046#5.0.
- 32 -
B-80525E-1 /03 MAINTENANCE 3. TROUBLESHOOTING
3.2
TROUBLESHOOTING (1) SRV0--001 SVALl Operator panel E-stop
USING THE ERROR (Explanation) The emergency stop button on the operator's box or
CODE operator's panel is pressed.
(Action) Release the emergency stop button pressed on the
operator's box or operator's panel.
~------~ Operator's box

D I•
~ ~
. . = - - [- - - - . , . ]
o oe
Emergency stop
button
--
-0 -·0 -0 D
I •
Operator's panel
(B--08.binet)
m-a 0 ..
D
6 ~I==~~ D D H
ra=~---=-_J
-- --
0 0 -- Emergency stop
button
55
(2) SRV0--002 SVALl Teach pendant E-stop

(Explanation) The emergency stop button on the teach pendant was
pressed.
(Action) Release the emergency stop button on the teach
pendant.
~=========~=EMERGENCY STOP BUTTON
- 33 -
(3) SRV0-003 SVALl Deadman switch released

(Explanation) The teach pendant is valid, but the deadman switch is
not pressed.
(Action) Press the deadman switch to run the robot.
0
0
DEADMAN SWITCH
(4) SRVQ-004 SVALl Fence open

(Explanation) On the terminal block of the panel printed circuit
board, no connection is made between FENCEl and
FENCE2. If a safety fence is connected between
FENCEl and FENCE2, the door of the safety fence
is open.
(Action 1) If a safety fence is connected, close the door.
(Action 2) Check the switch and cable connected to FENCEl
andFENCE2.
(Action 3) Make a connection between FENCEl and FENCE2.
- 34 -
Panel printed circuit board
0 0
0 0
FENCE 1 FENCE2
(5) SRV0-005 SVALl Robot overtravel

(Explanation) The robot has gone beyond an axis/direction hardware
limit switch. The robot is designed so that nonnally it
will neither go out of each axial movable range
(software limit) nor reach any hardware limit. It is
however factory-set in an overtravel state for
convenience of packing.
(Action) I.Release axes from overtravel using the overtravel
release screen [OT_RELEASE].
2.Hold down the shift key and press the RESET button
to reset the alarm condition.
3. While still holding down the shift key, jog-feed the
robot until its overtraveled axes return within the
movable range.
(6) SRVQ-006 SVALl Hand broken
(Explanation) If a safety joint is used, it is broken. If the joint is not
broken, the voltage of the HBK signal in the robot
connection cable is 0 V for some reason.
(Action) l.Hold down the shift key and press the alarm reset
button to reset the alarm condition.
2. While still holding down the shift key, jog-feed the
robot until the tool moves to the working area.
A. Exchange the safety joint.
B. Check the cables.
(7) SRVQ-007 SVALl External E-stop
board, no connection is made between EMGINl and
EMGIN2. If an external emergency stop switch is
connected between EMGINl and EMGIN2, the
switch is pressed.
(Action 1) If an external emergency stop switch is connected,
releases the switch.
(Action 2) Check the switch and cable connected to EMGINl
andEMGIN2.
(Action 3) Make a connection between EMGINl and EMGIN2.
- 35
0 o~o ~l[~~~@~mllo 0 0
Ls ITBd~~ r ~~TBOPs;+ S3[~1 ov S2- S3+ FG
~ o D 1~1 ~ ~ r; -:ilflll ~
~ ~~1 1118§111 JlM3 I ggg 111182111
BOPI L ~ --
EMGIN SVON ES TOP EMGOUT
0 0 ° rti~-~~m1. 0 °
EMGIN 1 / ~ EMGIN 2
(8) SRV0-009 SVALl Pneumatic pressure alarm

(Explanation) While checking the air pressure, an abnormal air
pressure was detected. If the air pressure is normal,
the PPABN signal in the robot connection cable
became abnormal for some reason.
(Action) If the pneumatic pressure is normal, check the cables.
(9) SRV0-014 WARN Fan motor abnormal
(Explanation) A fan motor in the backplane is abnormal.
(Action) Check the fan motor and its cables. Replace them if
necessary.
Fan motor
- 36 -
(10)SRV0-015 SVALl 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 using the air conditioner.
(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 backplane PC board is
defective, replace the backplane unit.
FAN MOTOR
i-CABINET
- 37 -
FAN MOTOR
FAN MOTOR
FAN MOTOR B-CABINET

(ARC Mate 100, ARC Mate 120, ARC Mate 100i,ARCMate 120i, 5-6, S-12, M--6i, M-16i,5-420i, S-500, S-700, M-710i,A-520i)
ADDITIONAL CABINET I
ADDITIONAL CABINET 2 FAN MOTOR
FAN MOTOR
..
FAN MOTOR
B-CABINET/S-900
- 38 -
FAN MOTOR FAN MOTOR
FAN MOTOR FAN MOTOR
(ADDITIONAL CABINET I) (ADDITIONAL CABINET 2)

B-CABINET/S-900
- 39 -
FAN MOTOR
FAN MOTOR
M410i CABINET
- 40 -
FAN MOTOR
FAN MOTOR
FAN MOTOR
FAN MOTOR
M-41 OiB-cabinet
- 41 -
3. TROUBLESHOOTING MAINTENANCE B--80525E-1/03
FAN 2
FAN 3
FAN 4
FAN 5
M-500
- 42 -
(ll)SRV0-018 SVALl Brake abnormal

(Explanation) An excessive break current is detected. When the
ARC Mate 100, ARC Mate 120, ARC Mate 120i,
S-6. S-12, M-16i, S-420i, S-500, S-700, or
A-520i, ARC Mate lOOi, M-6i, M-710i is used, the
seven-segment LED on the servo amplifier indicates
1. When the S-900, M-4 lOi, or M-500 is used, the
LED (red) on the emergency stop control printed
circuit board lights.
(Action 1) Check the robot connection cable (RMI) and cables
internal to the mechanical section for a short-circuit
and connection to the ground.
(Action 2) Replace the servo amplifier (when the ARC Mate
100, ARC Mate 120, ARC Mate 120i, S-6, S-12,
M-l6i, S-420i, S-500, S-700, or A-520i, ARC
Mate 1OOi, M-6i, M-71 Oi is used), the emergency
stop control printed circuit board (when the S-900,
M-410i, or M-500 is used).
- 43 -
SERVO AMPLIFIER
i-CABINET
SERVO AMPLIFIER
6Y (')(')(')DDo
6Y 6Y 6Y 6Y
(') \q11u&
B-CABINET
(ARC Mate 100, ARC Mate 120, ARC Mate 1OOi, ARC Mate 120i,
8--6, S-12, M-6i, M-16i, S-420i, S-500, S-700, M-710i, A-520i)
- 44 -
PC BOARD FOR
EMERGENCY STOP
CONTROL
S-900
PC BOARD FOR EMERGENCY STOP CONTROL
M-410i
- 45 -

STOP CONTROL
M-41 Oi &-cabinet
- 46 -
PC BOARD FOR
EMERGENCY STOP
CONTROL
M-500
- 47 -
(12) SRV0-019 SVALl SVON input

board, no connection is made between SVONl and
SVON2. If a switch is connected between SVONl
and SVON2, the switch is pressed.
(Action 1) If a switch is connected, releases the switch.
(Action 2) Check the switch and cable connected to SVONl and
SVON2.
(Action 3) Make a connection between SVONl and SVON2.
0 0
0 0
SVON1~~N2
(13)SRV0-021 SVALl SRDY off (Group: i Axis: j)
(Explanation) The HRDY is on and the SRDY is off, although there
is no other cause of an alarm. (HRDY is a signal with
which the host directs the servo system whether to
tum on or off the servo amplifier MCC. SRDY is a
signal with which the servo system informs the host
whether the MCC is turned on.)
If the servo amplifier MCC cannot be turned on when
directed so, it is most likely that a servo amplifier
alarm has occurred. If a servo amplifier alarm has
been detected, the host will not issue this alarm
(SRDY off). To sum up, this alarm indicates that the
MCC cannot be turned on for an unknown reason.
(Action 1) Check that the door is completely closed. Check that
the door switch operates normally. (In case of
i--cabinet)
(Action 2) Check the input voltage (200 VAC) to the servo
amplifier. If it is 170 VAC or lower, check the line
voltage.
(Action 3) Replace the emergency stop control PC board.
(Action 4) Replace the main CPU PC board.
(Action 5) Check the cable between the servo amplifier and the
CPU PC board, and replace it if necessary.
(Action 6) Replace the servo amplifier.
- 48
SERVO AMPLIFIER MAIN CPU

PC BOARD
DOOR SWITCH
PC BOARD FOR
EMERGENCY
STOP CONTROL
i-CABINET
PC BOARD FOR EMERGENCY MAIN CPU PC BOARD

STOP CONTROL
SERVO AMPLIFIER
oooaaaooooaaa
B-CABINET
(ARC Mate 100, ARC Mate 120, ARC Mate 100i, ARC Mate 120i, S-6, S-12, M-6i, M-16i, &-420i, S-500, S-700,
M-710i, A-520i)
- 49 -
SERVO AMPLIFIER 3
SERVO AMPLIFIER 4
PC BOARD FOR
EMERGENCY STOP
CONTROL
MAIN CPU
PC BOARD
SERVO AMPLIFIER 2
SERVO AMPLIFIER I
S-900
SERVO AMPLIFIER 6
SERVO AMPLIFIER 5
D D
(INTERIOR OF ADDITIONAL CABINET I) (INTERIOR OF ADDITIONAL CABINET 2)

B-CABINET/S-900
- 50 -
SERVO MODULE 2
SERVO MODULE 3
SERVO MODULE 4
MAIN CPU PC BOARD

M410i CABINET
- 51 -
SERVO MODULE 3 PC BOARD FOR EMERGENCY

STOP CONTROL
MAIN CPU PC
SERVO MODULE 1
BOARD
SERVO MODULE4
POWER SUPPLY MODULE
M-41 Oi B--cabinet
- 52 -
SERVO AMPLIFIER I
SERVO AMPLIFIER 2
PC BOARD FOR
EMERGENCY STOP
CONTROL
MAIN CPU
PC BOARD
SERVO AMPLIFIER 4
SERVO AMPLIFIER 3
M-500
- 53 -
(14)SRV0-022 SVALl SRDY on (Group: i Axis : j)

(Explanation) When the HRDY is about to go on, the SRDY is
already on. (HRDY is a signal with which the host
directs the servo system whether to tum on or off the
servo amplifier MCC. SRDY is a signal with which
the servo system informs the host whether the MCC
is turned on.
(Action 3) Check the cable between the servo amplifier and the
CPU PC board, and replace it if necessary.

PC BOARD
PC BOARD FOR
EMERGENCY
STOP CONTROL
i-CABINET
- 54 -

STOP CONTROL
SERVO AMPLIFIER
B-CABINET
(ARC Mate 100, ARC Mate 120, ARC Mate 100i, ARC Mate 120i, S--6, S-12, M--6i, M-16i, 8-420i, S-500, S-700, M-710i, A-520i)
SERVO AMPLIFIER 3
SERVO AMPLIFIER 4
PC BOARD FOR
EMERGENCY STOP
CONTROL
MAIN CPU
PC BOARD
SERVO AMPLIFIER 2
SERVO AMPLIFIER I
S-900
- 55 -
SERVO AMPLIFIER 6
SERVO AMPLIFIER 5

B-CABINET/S-900
- 56 -
SERVO MODULE 2
SERVO MODULE 3
SERVO MODULE 4
MAIN CPU PC BOARD

M410i CABINET
- 57 -

STOP CONTROL
SERVO MODULE 1
MAIN CPU
PC BOARD
POWER SUPPLY MODULE
M-41 Oi &-cabinet
- 58 -
PC BOARD FOR
EMERGENCY STOP
CONTROL
MAIN CPU
PC BOARD
SERVO AMPLIFIER 4
SERVO AMPLIFIER 3
M-500
- 59 -
(15)SRV0--023 SVALI Stop error excess (Group: i Axis: j)

(Explanation) When the servo is at stop, the position error is
abnormally large.
(Action 1) 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 2) Check each phase voltage 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 3) If the line voltage is 170 VAC or higher, replace the
servo amplifier.
(Action 4) Cheak continuity of motor power cables.
(Action 5) Replace the motor.

PC BOARD
PC BOARD FOR
EMERGENCY
STOP CONTROL
i-CABINET
- 60 -

STOP CONTROL
SERVO AMPLIFIER
B-CABINET
(ARC Mate 100, ARC Mate 120, ARC Mate 100i, ARC Mate 120i, $-6, S-12, M--6i, M-16i, 5-420i, S-500, S-700, M-710i, A-520i)
SERVO AMPLIFIER 3
SERVO AMPLIFIER 4
PC BOARD FOR
EMERGENCY STOP
CONTROL
MAIN CPU
PC BOARD
SERVO AMPLIFIER 2
SERVO AMPLIFIER I
S-900
- 61 -
SERVO AMPLIFIER 6
SERVO AMPLIFIER 5

B-CABINET/S-900
- 62 -
SERVO MODULE I
SERVO MODULE 2
SERVO MODULE 3
SERVO MODULE 4
MAIN CPU PC BOARD

M410i CABINET
- 63 -
SERVO MODULE 1
MAIN CPU
PC BOARD
POWER SUPPLY MODULE
M-41 Oi 8--cabinet
- 64 -
SERVO AMPLIFIER I
SERVO AMPLIFIER 2
PC BOARD FOR
EMERGENCY STOP
CONTROL
MAIN CPU
PC BOARD
SERVO AMPLIFIER 4
SERVO AMPLIFIER 3
M-500
(16)SRV0-024 SVALl Move error excess (Group: i Axis: j)

(Explanation) When the robot is running, its position error is greater
than a specified value ($PARAM _ GROOP.
$MOVER _ OFFST or $PARAM _ GROUP.
$TRKERRLIM). It is likely that the robot cannot
follow the speed specified by program.
(Action) Take the same actions as described for the above
alarm.
(17)SRV0-025 SVALI Motn dt overflow (Group: i Axis: j)
(Explanation) The specified value is too great.
(18)SRV0-026 WARN2 Motor speed limit (Group : i Axis : j)
(Explanation) A value higher than the maximum motor speed
($PARAM_GROUP.$MOT_SPD_LIM) was
specified. The actual motor speed is clamped to the
maximum speed
(19)SRV0-027 WARN Robot not mastered (Group : i)
(Explanation) An attempt was made to calibrate the robot, but the
necessary adjustment had not been completed.
(Action) Make the adjustment on the positioning menu (6
System.positioning].
- 65
(20)SRV0-030 SVALl Brake on hold (Group: i)

(Explanation) This alann occurs when the robot pauses, if the brake
on hold function has been enabled ($SCR.
$BRKHOLD _ ENB = 1). Disable the function if it is
not necessary.
(Action) Disable [Servo-off during pause] on the general
setting menu [6 Setting.general].
(2l)SRV0-031 SVALl User servo alarm (Group: i)
(Explanation) A user servo alarm occurred.
(22)SRV0-033 WARN Robot not calibrated (Group : i)
(Explanation) An attempt was made to set up a reference point for
simplified adjustment, but the robot had not been
calibrated.
(Action) Calibrate the robot.
1. Supply power.
2.Set up a simplified adjustment reference point
using [Positioning] on the positioning menu.
(23)SRV0-034 WARN Ref pos not set (Group: i)
(Explanation) An attempt was made to perform simplified
adjustment, but the reference point had not been set
up.
(Action) Set up a simplified adjustment reference point on the
positioning menu.
(24)SRV0-035 WARN2 Joint speed limit (Group: i Axis : j)
(Explanation) A value higher than the maximum axis speed
($PARAM_GROUP.$JNTVELLIM) was specified.
Each actual axis speed is clamped to the maximum
speed.
(25)SRV0-036 SVALl Inpos time over (Group : i Axis : j)
(Explanation) The robot did not get to the effective area ($PARAM _
GROUP.$ STOPfOL) even after the position check
monitoring time ($PARAM _ GROUP. $INPOS _
TIME) elapsed
(Action) Take the same actions as for SRV0-23 (large position
error at a stop).
(26)SRV0-037 SVALl Imstp input (Group: ij)
(Explanation) The *IMSTP signal for a peripheral device interface
was input.
(Action) Tum on the *IMSTP signal.
(27)SRV0-038 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.
(Action) Perform APC reset and remaster robot (RES-PCA)
1.Press MENUS.
2.Select SYSTEM.
3.Press Fl, [TYPE].
4.Select System Variables.
5.Move the cursor to $ MCR.
6.Press ENTER.
- 66
7.Move the cursor to$ SPC_RESET.

8.Press F4, TRVE. The display will reset to false.
This is normal.
9.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)SRV0-039 SVALl Motor speed excess (Group : i Axis : j)
(Explanation) The motor speed was too high to be used in vector
acceleration/deceleration control.
(Action) Specify a lower speed with the teach pendant.
(29)SRV0-041 SVAL2 MOFAL alarm (Group: i Axis :j)
(Explanation) The command value was too high.
(Action 1) Exchange axis module.
(Action 2) Exchange Main CPU.
(30)SRV0-042 MCAL alarm (Group : i Axis : j)
(Explanation) This alarm indicates that a deposit has been detected
in the magnetic contactor, which is built into the servo
amplifier. When an attempt was made to close the
contactor, a contact was already closed. A deposit can
be detected when an attempt is made to close a
contactor on which a deposit has been formed.
Number 2 (ARC Mate 100, ARC Mate 120, ARC
Mate 120i, S-6, S-12, M-16i, S-420i, S-500,
S-700, A-520i, ARC Mate lOOi, M-6i, M-710i) is
displayed on the servo amplifier LED display.
(Action 1) Check fuses Fl, F2, and F3 of the line filter unit (or
transformer). If they have blown, replace them.
(When Fl, F2, and F3 blow, alarms OHALl, and
MCAL are displayed on the teach pendant when the
control unit is turned on.
(Action 2) Check the cable between the servo amplifier and
Main CPU printed circuit board. If it is defective,
replace it. (When the connection is broken, alarms
OHALl and MCAL are displayed on the teach
pendant at the same time.)
(Action 4) Replace the Main CPU printed circuit board.
- 67 -
SERVO AMPLIFIER
i-CABINET
SERVO AMPLIFIER
e1Y 6) 6) 6) DDo
dY 6Y dY 6Y
6) \q11u~
B-CABINET
(ARC Mate 100, ARC Mate 120, ARC Mate 100i, ARC Mate 120i, 8-6, S-12, M-6i, M-16i,
S-420i, s-500, S-700, M-71 Oi, A-520i)
- 68 -
MAIN CPU
PC BOARD
SERVO AMPLIFIER 2
SERVO AMPLIFIER I
S-900
SERVO AMPLIFIER 6
SERVO AMPLIFIER 5

B-CABINET/S-900
- 69 -
SERVO MODULE I
POWER SUPPLY MODULE SERVO MODULE 2
SERVO MODULE 3
SERVO MODULE 4
MAIN CPU PC BOARD

M410i CABINET
- 70 -
SERVO MODULE 3
SERVO MODULE 1
POWER SUPPLY MODULE
M-41 Oi B--cabinet
- 71 -
SERVO AMPLIFIER I
SERVO AMPLIFIER 2
MAIN CPU
PC BOARD
SERVO AMPLIFIER 4
SERVO AMPLIFIER 3
M-500
(3l)SRV0-043 SVALl 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.) In case of (ARC Mate 100, ARC Mate 120,
ARC Mate 1OOi, ARC Mate 120i, S--6, S-12, M-6i,
M-16i, S-420i, S-500, S-700, M-710i, A-5201)
- 72 -
(Action) If the servo amplifier LED indicates "8" (DCOH

alarm): (This alarm occurs when a thermostat detects
that the regenerative resistor is overheated.)
-This alann is likely to occur when the regenerative
discharge energy is high because of frequent
acceleration /deceleration or a vertical axis being used.
In this case, ease the conditions under which the robot
is used.
-Disconnect the cable from connector CN8A of the
servo amplifier, then check the continuity between
pins 1 and 2 of the cable. If a non-continuity is
detected, replace the regenerative resistor.
-Disconnect the cable from terminals Rl and R2 of
the servo amplifier, then measure the resistance of
the cable. If it is other than 4Q, replace the
regenerative resistor.
-Replace the servo amplifier.
For S-900 and M-500
(Actionl) When number 4 (DCSW alarm) is displayed on the
servo amplifier display (the DCSW alarm is issued
when the regenerative transistor holds the on state for
one second or more),
-The short-period (about one second) regenerative
energy may be excessive due to a large load being
applied to the robot. Reduce the load so that it does
not exceed the rated value.
(Action2) When number 5 (DCOH alarm) is displayed on the
servo amplifier display (the DCOH alarm is issued
when the thermostat detects overheating of the
regenerative resistor),
-Frequent acceleration/deceleration or large
regenerative energy at the gravity axis may cause
this alarm to be issued. Ease the use conditions.
-When a transformer is not being used, check that
THl and TH2 of the servo amplifier are
short-circuited.
-When a transformer is being used, check the wiring
of the thermostat.
-A phase of the power supplied to the servo amplifier
may be missed. Check the wiring.
- 73 -
3. TROUBLESHOOTING MAINTENANCE B-a0525E-1/03
SERVO AMPLIFIER
DISCHARGE
RESISTOR
i-CABINET (ARC Mate 100, ARC Mate 120, ARC Mate 100i, ARC Mate 120i, s-6, S-12, M-6i, M-16i, 8-420i, s-500, S-700,
M-710i, A-520i)
DISCHARGE
RESISTOR
B-CABINET
(ARC Mate 100, ARC Mate 120, ARC Mate 100i, ARC Mate 120i, $-6, S-12, M-6i, M-16i, $-420i, 8-500, S-700, M-710i, A-5201)
- 74 -
SERVO AMPLIFIER 3
ADDITIONAL CABINET I SERVO AMPLIFIER 4
ADDITIONAL CABINET 2
•
SERVO AMPLIFIER 2
SERVO AMPLIFIER I
THI
TH2
MAIN TRANSFORMER ADDITIONAL TRANSFORMER
B-CABINET/S-900
- 75 -
SERVO AMPLIFIER 6
SERVO AMPLIFIER 5
DISCHARGE
UNIT

B-CABINET/S-900
- 76 -
SERVO
2
TRANSFORMER
SERVO AMPLIFIER 4
SERVO AMPLIFIER 3
DISCHARGE
UNIT
MAIN TRANSFORMER
M-500
- 77 -
(32)SRV0-044 SVALl HVAL alarm (Group: i Axis : j)

SRV0-154 SVALl HVAL alarm (Group: i Axis: j)
(Explanation) The OC voltage (OC link voltage) of the main circuit
power supply is abnormally high. The servo amplifier
LED indicates "7". (ARC Mate 100, ARC Mate 120,
ARC Mate lOOi, ARC Mate 120i, S-6, S-12, M-6i,
M-16i, S-420i, S-500, S-700, M-710i, A-520i)
'l'(S-900, M-500).
(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 may result in the
HVAL alarm even when the three-phase input
voltage is within the rating.
- 78 -
SERVO AMPLIFIER
i-CABINET
SERVO AMPLIFIER
@ ~ () ~ OOo
@ 6Y@6Y
~ \~nu~
B-CABINET
(ARC Mate 100, ARC Mate 120, ARC Mate 100i, ARC Mate 120i, 8-6, S-12, M-6i, M-16i, S-420i, 8-500, S-700, M-710i,
A-520i)
- 79 -
SERVO AMPLIFIER 3
•
SERVO AMPLIFIER 2
SERVO AMPLIFIER I
B-CABINET/S-900
SERVO AMPLIFIER 6
SERVO AMPLIFIER 5

B-CABINET/S-900
- 80 -
SERVO MODULE I
SERVO MODULE 2
SERVO MODULE 4
M410i CABINET
SERVO AMPLIFIER I
SERVO AMPLIFIER 2
SERVO AMPLIFIER 4
SERVO AMPLIFIER 3
M-500
- 81 -
SERVO MODULE 3
POWER SUPPLY MODULE
M-41 Oi B-cabinet
- 82 -
(33)SRV0-045 SVALl HCAL alarm (Group: i Axis: j)

SRV0-148 SVALl HCAL alarm (Group: i Axis: j)
SRV0-149 SVALl HCAL alarm (Group: i Axis: j)
SRV0-150 SVALl IPMAL 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
(HCl to HC6) corresponding to the HCAL alarm
above the 7-segment LED (For ARC Mate 100, ARC
Mate 120, ARC Mate lOOi, ARC Mate 120i, S-6,
S-12, M-6i, M-16i, S-420i, S-500, S-700, M-710i,
A-520i) or Servo amplifier one of '1' '8' '9' '6' of
LED (For S-900, M-410i, M-500) lights.
(Action 1) Disconnect the motor power lines from the servo
amplifier terminals, supply power, and see if the
alarm occurs again. If the alarm occurs, replace the
servo amplifier.
amplifier terminals, and check the insulation of each
motor power line (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.
amplifier terminals, 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.
- 83 -
SERVO AMPLIFIER
i-CABINET
SERVO AMPLIFIER
0000000000000
B--CABINET
(ARC Mate 100, ARC Mate 120, ARC Mate 100i, ARC Mate 120i, S-6, S-12, M--6i, M-16i, 8-420i, S-500, S-700, M-710i,
A-520i)
- 84 -
SERVO AMPLIFIER 3
ADDITIONAL CABINET SERVO AMPLIFIER 4
SERVO AMPLIFIER 2
SERVO AMPLIFIER I
B-CABINET/S-900
SERVO AMPLIFIER 6
SERVO AMPLIFIER 5

B-CABINET/S-900
- 85 -
SERVO MODULE I
SERVO MODULE 2
SERVO MODULE 4
M410i CABINET
SERVO AMPLIFIER I
SERVO AMPLIFIER 2
SERVO AMPLIFIER 4
SERVO AMPLIFIER 3
M-500
- 86 -
SERVO MODULE 3
SERVO MODULE 1
POWER SUPPLY MODULE
M-41 Oi B-cabinet
- 87 -
(34)SRV0-046 SVAL2 OVC alarm (Group : i Axis : j)

(Explanation) This alarm is issued to prevent the motor from
thermal damage that may 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. If the
technical data of the robot such as duty cycle or load
weight is higher than the rating, reduce it to within the
rating.
(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 5) Replace the motor.
SERVO AMPLIFIER 3
SERVO AMPLIFIER 2
SERVO AMPLIFIER I
B-CABINET/S-900
- 88 -
SERVO AMPLIFIER 6
SERVO AMPLIFIER 5

B-CABINET/S-900
SERVO MODULE I
SERVO MODULE 2
SERVO MODULE 4
M410i CABINET
- 89 -
SERVO MODULE 3
SERVO MODULE 2
SERVO MODULE 1
..
POWER SUPPLY MODULE
M-41 Oi B--cabinet
- 90 -
SERVO AMPLIFIER 4
SERVO AMPLIFIER 3
M-500
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 OHAL 1
Thermal relay in the separate regenerative dis-
charge unit DCAL
HCAL 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 may be damaged, or the magnet of the motor may 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
- 91 -
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 bum before the thermal relay detects an abnormally high
temperature.
Temperature
Start Stop Start Stop Start

I I I I I
I I I I I Thermal time constant
Temperature at
which the winding
starts to bum
~ - -- ~ ---:- - --:- ---i- -/~ of the motor is high.
Thermal time constant

I I I I// /I of the thermal relay is
I I -~---r / I low.
).___ I / / / I --- -- ___j,,,/' I

~"_~_v,// I I I
/;> I "V I I I
/' I I I I I
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.
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
theOVC
Ratedcontinuouscurrent - - - - - - - - - - - - - - - - - - -
Time
Fig.2 Relationship between the OVC and OVL alarms
- 92 -
NOTE
The relationship shown in Fig. 2 is taken into consideration
for the OVC alarm. The motor may not be hot even if the
OVC alarm has occurred. In this case, do not change the
parameters to relax protection.
(35)SRV0-047 SVALl LVAL alarm (Group: i Axis : j)

SRV0-143 SVALl LVAL alarm (Group: i Axis: j)
SRV0-144 SVALl LVAL alarm (Group: i Axis : j)
(Explanation) When the external magnetic contactor for the servo
amplifier is turned on, the DC voltage (DC link
voltage) of the main power supply is abnormally low,
or the control power supply voltage (+5 V, etc.) is
abnormally low.
(Action 1) If the servo amplifier LED indicates "6" (For ARC
Mate 100, ARC Mate 120, ARC Mate lOOi, ARC
Mate 120i, S--6, S-12, M--6i, M-l6i, S-420i, S-500,
S-700, M-710i, A-520i) or indicates "2" (For
S-900,M-410i,M-500):
(This alarm occurs if the control power supply
voltage (+5 V etc.) is abnormally low.)
-Check the phase voltage of the three-phase input
power (200 VAC) to the servo amplifier. If it is 170
(Action 2) If the servo amplifier LED indicates "3" (For S-900,
M-500) or "4" (For ARC Mate 100, ARC Mate 120,
ARC Mate lOOi, ARC Mate 120i, S--6, S-12, M--6i,
M-16i, S-420i, S-500, S-700, M-410i, M-710i,
A-520i, ARC Mate lOOi, M--6i, M-710i)
(This alarm occurs when the DC voltage (DC link
voltage) of the main circuit power supply is
abnormally low.)
- 93 -
SERVO AMPLIFIER
i-CABINET
SERVO AMPLIFIER
B-CABINET
(ARC Mate 100, ARC Mate 120, ARC Mate 100i, ARC Mate 120i, &-6, &-12, M-6i, M-16i, &-420i, &-500, S-700, M-710i,
A-520i)
- 94 -
SERVO AMPLIFIER 3
.
SERVO AMPLIFIER 2
SERVO AMPLIFIER I
B-CABINET/S-900
SERVO AMPLIFIER 6
SERVO AMPLIFIER 5

B-CABINET/S-900
- 95 -
SERVO MODULE I
SERVO MODULE 2
SERVO MODULE 4
M410i CABINET
SERVO AMPLIFIER I
SERVO AMPLIFIER 2
SERVO AMPLIFIER 4
SERVO AMPLIFIER 3
M-500
- 96 -
SERVO MODULE 3
SERVO MODULE 1
POWER SUPPLY MODULE
M-41 Oi B-cabinet
- 97 -
(36)SRV0--049 SVALl OHALl alarm (Group: i Axis: j)

SRV0-141 SVALl OHALl alarm (Group: i Axis: j)
(Explanation) The thermostat in the servo amplifier or transformer
worked. The servo amplifier LED indicates "3" .(For
ARC Mate 100, ARC Mate 120, ARC Mate lOOi,
ARC Mate 120i, S-6, S-12, M-6i, M-l6i, S-420i,
S-500, S-700, M-710i, A-520i):
rating.
(Action 2) Clean fans, louver (i-cabinet) or filter (B-cabinet)
(Action 3) When fuses Fl, F2, and F3 of the line filter unit (or
transformer) have blown (for the B cabinet), replace
them. (When they blow, alarms OH ALI, and MCAL
are displayed on the teach pendant when the control
unit is turned on.)
(Action 5) Replace the trans former.
- 98 -
SERVO AMPLIFIER
i-CABINET
SERVO AMPLIFIER
6Y 0) 0) 0) DDo
6Y 6Y6Y6Y
0) \bu&
B--CABINET
(ARC Mate 100, ARC Mate 120, ARC Mate 100i, ARC Mate 120i, 5-6, S-12, M-6i, M-16i, S-420i, S-500, S-700, M-710i,
A-520i)
- 99 -
SERVO
ADDITIONAL CABINET I 4
•
SERVO AMPLIFIER 2
SERVO AMPLIFIER I
B-CABINET/S-900
SERVO AMPLIFIER 6
SERVO AMPLIFIER 5

B-CABINET/S-900
- 100 -
SERVO MODULE I
SERVO MODULE 2
SERVO MODULE 4
M410i CABINET
SERVO AMPLIFIER I
SERVO AMPLIFIER 2
•
SERVO AMPLIFIER 4
SERVO AMPLIFIER 3
M-500
- 101 -
SERVO MODULE 3
SERVO MODULE 1
POWER SUPPLY MODULE
M-41 Oi B--cabinet
- 102 -
B--80525E-1 /03 MAINTENANCE 3. TROUBLESHOOTING
(37)SRV0-050 SVALl 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
(Action 4) Check motor power cables, replace if necessary.
- 103 -
SERVO AMPLIFIER
i-CABINET
SERVO AMPLIFIER
& ~ ~ ~ DDo
@ @@@
~ \q11n&
B-CABINET
(ARC Mate 100, ARC Mate 120, ARC Mate 1OOi, ARC Mate 120i, &-6, S-12, M-6i, M-16i, &-420i, 8-500, S-700, M-71 Oi, A-520i)
- 104 -
B-S0525E-1 /03 MAINTENANCE 3. TROUBLESHOOTING
SERVO MODULE 3
SERVO MODULE 2
SERVO MODULE I
OWER SUPPLY MODULE

B-CABINET/S-800
SERVO AMPLIFIER 3
SERVO AMPLIFIER 2
SERVO AMPLIFIER I
B-CABINET/S-900
- 105 -
SERVO AMPLIFIER 6
SERVO AMPLIFIER 5
~,,.___,
B-CABINET/S-900
SERVO MODULE I
SERVO MODULE 2
SERVO MODULE 4
M410i CABINET
- 106 -
SERVO MODULE 3
SERVO MODULE 1
..
POWER SUPPLY MODULE
M-41 Oi B-cabinet
- 107 -
SERVO AMPLIFIER I
SERVO AMPLIFIER 2
SERVO AMPLIFIER 4
SERVO AMPLIFIER 3
M-500
- 108 -
(38)SRV0-051 SVAL2 CUER alarm (Group : i Axis : j)

(Explanation) The offset of the current feedback value is abnormally
high.
SERVO AMPLIFIER
MAIN CPU
PC BOARD
i-CABINET
MAIN CPU
PC BOARD
SERVO AMPLIFIER
B--CABINET
(ARC Mate 100,ARCMate 120,ARC Mate 1OOi,ARC Mate 120i, &-6, S-12, M-6i, M-16i,&-420i, s-500, S-700, M-710i,A-520i)
- 109 -
MAIN CPU
PC BOARD
SERVO AMPLIFIER 2
SERVO AMPLIFIER I
S-900
SERVO AMPLIFIER 6
SERVO AMPLIFIER 5

B-CABINET/S-900
- 110 -
(39)SRV0-053 ER_WARN Disturbance Excess

(Explanation) The estimated external disturbance exceed the
maximum allowable value.
This error may occur if acute acceleration/
deceleration is applied while acceleration override is
specified, or if an excessive load is applied.
If the high-sensitivity collision detection option or
smart and easy package option is being used, this
error indicates that the load setting may be invalid.
(Action) Check that an excessive load is not being applied, and
that the load setting is correct.
If a lower detection sensitivity load is acceptable
when acceleration override is being used, increase the
setting for the maximum allowable value on the
status/disturbance display.
(40)SRV0-054 DSM Memory Error
(Explanation) An access to the servo module memory fails.
(Action) Replace the servo module.
(41)SRV0-062 SVAL2 BZAL alarm (Group : i Axis : j)
(Explanation) This alarm occurs if no battery for pulse coder
absolute-position backup is connected.
A probable cause is a broken battery cable in the
robot.
(Action) Remove the cause of the alarm, and set the system
variable $MCR.$SPC_RESET to TRUE, then
supply power again. After this, mastering is required.
(42)SRV0-064 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) The DTERR, CRCERR, or STBERR alarm
may trigger the PHAL alarm. In this case, there is no
actual cause for the PHAL alarm.
(43)SRV0-065 WARN BLAL alarm (Group : i Axis : j)
(Explanation) The OIC battery voltage for the pulse coder is lower
than the rating.
(Action) Replace the battery.
(If this alarm occurs, tum 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.
(44)SRV0-067 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.
rating.
- 111
(Action 2) When power is supplied to the motor after it has

become sufficiently cool, if the alarm still occurs,
replace the motor.
(45)SRV0--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
(46)SRV0--069 SVAL2 CRCERR alarm (Group: i Axis: j)
(Explanation) The serial data has changed during communication.
- See actions on SRVO - 070
(47)SRV0--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 4) Replace the cable between the emergency stop
control PC board and main CPU.
(Action 6) Replace the pulse coder.
(Action 7) Replace the robot interconnection cable (for the pulse
coder).
- 112 -

PC BOARD
PC BOARD FOR
EMERGENCY
STOP CONTROL
i-CABINET
- 113 -

STOP CONTROL
SERVO AMPLIFIER
B-CABINET
(ARC Mate 100, ARC Mate 120, ARC Mate 100i, ARC Mate 120i, 5-6, S-12, M--6i, M-16i, $-420i, S-500, S-700, M-710i,
A-520i)
SERVO AMPLIFIER 3
SERVO AMPLIFIER 4
PC BOARD FOR
EMERGENCY STOP
CONTROL
SERVO AMPLIFIER 2
SERVO AMPLIFIER I
S-900
- 114 -
SERVO AMPLIFIER 6
SERVO AMPLIFIER 5

B-CABINET/S-900
SERVO MODULE I

M-410i
- 115 -
SERVO MODULE 3
SERVO MODULE 1
POWER SUPPLY MODULE
M-41 Oi B--cabinet
- 116 -
SERVO AMPLIFIER I
SERVO AMPLIFIER 2
PC BOARD FOR
EMERGENCY STOP
CONTROL
SERVO AMPLIFIER 4
SERVO AMPLIFIER 3
M-500
(48)SRV0--071 SVAL2 SPHAL alarm (Group: i Axis: j)

(Explanation) The feedback speed is abnormally high (3750 rpm or
higher).
(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) If the load weight of the robot is higher than the rating,
reduce it to within the working range. (The torque
command may have encountered saturation in an area
where the maximum speed is higher than 3200 rpm.)
(Action 3) Replace the pulse coder.
(49)SRV0-072 SVAL2 PMAL alarm (Group: i Axis :j)
(Explanation) It is likely that the pulse coder is abnormal.
(Action) Replace the pulse coder and remaster.
(50)SRV0--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.
(5l)SRV0--074 SVAL2 LDAL alarm (Group: i Axis : j)
(Explanation) The LED in the pulse coder is broken.
(Action) Replace the pulse coder, and remaster.
(52)SRV0-075 WARN Pulse not established (Group : i Axis : j)
(Explanation) The absolute position of the pulse coder cannot be
established.
- 117
(Action) Reset the alarm, and jog-feed the robot along the axis
on which the alarm has occurred until the same alarm
will not occur again. (Jog one motor revolution)
(53)SRV0--081 WARN EROFL alarm (Track enc: i)
(Explanation) The pulse counter for line tracking has overflowed.
(Action) Contact the FANUC service center.
(54)SRV0--084 WARN BZAL alarm (Track enc : i)
(Explanation) This alann occurs if the backup battery for the absolute
position of the pulse coder has not been connected. See
the description about the BZAL alarm (SRVD--062).
(55)SRV0--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 (SRVQ--064).
(56)SRV0--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 (SRVQ--065).
(57)SRV0--089 WARN OHAL2 alarm (Track enc : i)
(Explanation) The motor has overheated. See the description about
the OHAL2 alarm (SRVQ--067).
(58)SRV0--090 WARN DTERR alarm (Track enc: i)
(Explanation) Communication between the pulse coder and main
CPU PC board is abnormal. See the description about
the DTERR alarm (SRVQ--068).
(59)SRV0--091 WARN CRCERR alarm (Track enc : i)
the CRCERR alarm (SRV0--069).
(60)SRV0--092 WARN STBERR alarm (Track enc : i)
the STBERR alarm (SRVD--070).
(61)SRV0--093 WARN SPMAL alarm (Track enc : i)
(Explanation) This alann occurs if the current position data from the
pulse coder is higher than the previous position data.
See the description about the SPHAL alann
(SRV0--071).
(62)SRV0--094 WARN PMAL alarm (Track enc: i)
(Explanation) It is likely that the pulse coder is abnormal. See the
description about the PMAL alarm (SRVQ--072).
(63)SRV0--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 (SRVQ--073).
(64)SRV0--096 WARN LDAL alarm (Track enc : i)
(Explanation) The LED in the pulse coder is broken. See the
description about the LDAL alarm (SRV0--074).
(65)SRV0--097 WARN Palse not established (enc: i)
- 118 -
(Explanation) The absolute position of the pulse coder cannot be

established. See the description about (SRV0-075).
Pulse not established.
(66)SRV0-145 SVALl LVAL alarm (Group: i Axis: j)
(Explanation) When the external magnetic contactor for the servo
amplifier is turned on, the DC voltage (DC link
voltage) of the main power supply is abnormally low.
(Action) If the servo amplifier LED indicates "4" or "5" (For
ARC Mate 120i, S-6, S-12, M-6i, M-16i, S-420i,
S-500, S-700, M-710i, A-520i: ), "2" or "3" (For
S-900, M-500)
(This alarm occurs when the DC current (DC link
voltage) of the main circuit power supply is
abnormally low.)
- 119 -
3. TROUBLESHOOTING MAINTENANCE B--80525E-1 /03
SERVO AMPLIFIER
i-CABINET
SERVO AMPLIFIER
6Y ~ ~ ~ DDo
@ 6Y6Y6Y
~ \bn&
B-CABINET
{ARC Mate 100, ARC Mate 120, ARC Mate 1OOi, ARC Mate 120i, s-6, S-12, M-6i, M-16i, S-420i, S-500, S-700,
M-710i, A-520i)
- 120 -
SERVO AMPLIFIER 4
SERVO AMPLIFIER 3
M-500
SERVO AMPLIFIER 3
SERVO AMPLIFIER 4
SERVO AMPLIFIER 2
SERVO AMPLIFIER I
S-900
- 121 -
SERVO AMPLIFIER 6
SERVO AMPLIFIER 5

B-CABINET/S-900
(67)SRV0-152 SVALl IPMAL alarm (Group: i Axis: j)

(Explanation) An error was detected in the IPM of a servo amplifier.
Servo amplifier LED indicates one of '8.' '9.', 'b.'.
(Action) Replace the servo amplifier.
- 122 -
SERVO MODULE 4
SERVO MODULE 3
SERVO MODULE 2
SERVO MODULE I 1,Z'.~;::=~~:::3;::::::::==rf71
M-410i
- 123 -
SERVO MODULE 3
SERVO MODULE 1
POWER SUPPLY MODULE
M-41 Oi B--cabinet
- 124 -
(68)SRV0-153 SVALl CHGAL alarm (Group: i Axis: j)

(Explanation) The main circuit of the power supply module could
not be charged within the specified time. Number '5'
is displayed on the LED display.
(Action) Replace the power supply module.
SERVO MODULE 4
SERVO MODULE 3
SERVO MODULE
SERVO MODULE I
M-410i
(69)SRV0-164, -166, -167

(Explanation) A digital servo module (DSM) which does not match
the currently loaded servo parameters is mounted.
(Action) Replace the axis module, or initialize the robot by
means of control start.
Initializing the robot will load the appropriate servo
parameters for the DSM. Note, however, that the new
parameters may cause the robot's performance or
paths to differ from those obtained with the previous
parameters.
(70)SRV0-165 Panel (SVON Abnormal) E-stop
(Explanation) An invalid +24V is connected to SVON or EXGEX
in the operator's panel
(Action) Turn off the power, then correct the wiring of SVON
or EXGEM in the operator's panel.
- 125 -
SERVO MODULE 3
SERVO MODULE 1
POWER SUPPLY MODULE
M-41 Oi B--cabinet
- 126 -
Fused-based troubleshooting
The alarms issued and symptoms observed when the fuses mounted on
printed circuit boards and units have blown are described below together
with corrective actions required.
( 1) When the fuses of the power supply unit have blown
Fl: Fuse for AC input
F3: Fuse for +24 V
F4: Fuse for +24 E
Name Symptom observed when fuse has blown Action
F1 The LED (PIL: Green) of the power supply unit does not 1 Check the units (fans) and cables connected to the
light, and the power cannot be turned on. CP2 and CP3 connectors of the power supply unit to
see if there is any short circuit.
2 Replace the power supply unit.
F3 The power, when turned on, is immediately turned off. 1 Check the printed circuit boards, units, and cables
At this time, the LED (ALM: Red) lights. using +24 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.
F4 An alarm such as forovertravel, hand breakage, IMSTP 1 Check the printed circuit boards, units, and cables
input (depending on the peripheral equipment interface using +24 E according to the power supply system
state) is output on the teach pendant. diagram. Replace a faulty printed circuit board, unit,
or cable if any.
- 127 -
P9U ..
F1
Fuse for
AC Input
POWER
SUPPLY
UNIT
LED:PIL
LED:ALM
F45A
- 128 -
(2) Servo amplifier fuse (ARC Mate 100, ARC Mate 120, ARC Mate
lOOi, ARC Mate 120i, S-6, S-12, M-6i, M-16i, S-420i, S-500,
S-700, M-710i, A-520i)
FUSE 1: For transformer and regenerative resistance thermostat
detection
Fl, F2 :For protection of servo amplifier internal circuit
FUSE1 The OHAL 1 alarm is output on the teach pendant, and 1 Check if the cables connected to the CN7B, CN8A,
the seven-segment LED on the servo amplifier indi- and CN8B connectors of the servo amplifier are con-
cates 3. nected to the ground.
2 Replace the regenerative resistance.
3 Replace the transformer.
4 Replace the servo amplifier.
F1 The OHAL 1 alarm is output on the teach pendant, and 1 Check if the cables connected to three phase input
F2 the seven-segment LED on the servo amplifier indicate of servo amplifier is defective.
3. 2 Replace the servo amplifier.
FUSE 1
Servo amplifier
FUSE
F1,F2
i-Gabinet
- 129 -
FUSE1
FUSE FUSE
F1 F2
- 130 -
(3) Servo amplifier fuses (S-800, S-900, N-410i, M-500)

Fl: Fuse for power supply module control (M-410i)
F2: Fuse for servo module control (M-410i)
FUSE: Fuse for servo amplifier control (S-900, S-800, M-500)
F1 The seven-segment LED does not light. 1 ReplaCEI the power supply module, servo module, or
F2 servo amplifier.
FUSE1
SERVO AMPLIFIER 3
ADDITIONAL CABINET I
•
SERVO AMPLIFIER 2
SERVO AMPLIFIER I
B-CABINET/S-900
- 131 -
SERVO AMPLIFIER 6
SERVO AMPLIFIER 5

B-CABINET/S-900
SERVO MODULE I
SERVO MODULE 2
SERVO MODULE 4
M410i CABINET
- 132 -
SERVO MODULE 3
SERVO MODULE 1
POWER SUPPLY MODULE
M-41 Oi B--cabinet
- 133 -
SERVO AMPLIFIER I
SERVO AMPLIFIER 2
SERVO AMPLIFIER 4
SERVO AMPLIFIER 3
M-500
- 134 -
--·m->-····
Fuse
f2
-
AC SERVO
AMPLIFIER
C uri11
... ~
STAn.8
---
··-
Fuse
Power supply module Servo module Servo amplifier
- 135 -
(4) Fuses on the emergency stop control printed circuit board (B-cabinet)
Fl: Fuse for brake control
F2: Fuse for +24 E
F1 The LED (red) on the emergency stop control printed 1 Check if the robot connection cable (RM1) and
circuit board lights.(*1) cables internal to the mechanical section are con-
nected to the ground or are short-circuited.
2 Replace the emergency stop control printed circuit
board.
F2 The LED (red) on the emergency stop control printed 1 Check if the robot connection cable (RP1) and
circuit board lights, and the overtravel alann is output on cables internal to the mechanical section are con-
the teach pendant. nected to the ground or are short-circuited.
2 Replace the emergency stop control printed circuit
board.
*1 Ifno additional axis is used with the ARC Mate 100, ARC Mate 120,ARCMate lOOi,ARCMate 120i, S--6, S-12, M--6i, M-16i, S-420i,
S-500,S-700,M-710i,A-520ithebrakecontrolcircuitontheemergencystopcontrolprintedcircuitboardisnotused:theFlfusedoes
not blow.
Emergency stop control

printed board
•
B-Cabinet
(ARC Mate 100, ARC Mate 120, ARC Mate 100i, ARC Mate 120i, $-6, S-12, M--6i, M-16i, S-420i, S-500, S-700,
M-710i, A-520i)
- 136 -
PC Board for
EMERGENCY
STOP control
M410i CABINET
PC BOARD FOR
EMERGENCY STOP
CONTROL
S-900
- 137 -

STOP CONTROL
M-41 Oi &-cabinet
- 138 -
PC BOARD FOR
EMERGENCY STOP
CONTROL
FAN 3
M-500
- 139 -
I
0 0 0
0 0
""if!il
I
- ~I
lll<if!il
A16B- I 2 I 2-09;m,mm
~~
Iii..,
-
..,"'a:
LL
..,>a: ;;:I
1!51
I
F2
FUSE I
F2 D iq I
;; I
~I
.1
.. II
iq
iq
~I
°L::ll •I)
t!i!ti
FUSE
.1...
DOD
F1
©
I=1
© !I
21
fi ...
$ •1
$
.ii11
DIJ DD
©
© 11...
© ii
$ i1
0 0 I
I
Emergercy stop control printed board
- 140 -
(5) Fuse on the process 1/0 printed circuit board

FUSEl: Fuse for +24 E
FUSE The LED (ALM-2 or FALM) on the process 1/0 printed 1 Check if the cables and peripheral equipment con-
circuit board lights, and an alann such as IMSTP input nected to the process 1/0 printed circuit board are
is output on the teach pendant. (The display data de- normal.
pends on state of peripheral equipment connection.) 2 Replace the process 1/0 printed circuit board.
LED:ALM-2
+ + + + + +
000
Process input/oulput
PC boards CA, CB, and DA + +
CA CB DA
- 141 -
Process 1/0 PC board EA
~O Al68-3200-02~ - - -
~
{]
0 . .P•l "
- • • • "PIM:
MlllYC "•• ·
P•.t Lj •• 0
Lj
D
FUSEI
•
GNOI
<(
DVI I C\I DVI
::t:
DVl2 0:
u
DV2 ~
Al.MO
DV7 ~ DV3
DVB El ~
DV4 FAUi
AI6
.&
~ 00 ~
••••••••
A1' Al3 AI2 AIIMIUT2 PMV
00 AOUTI 0 0
FUSE LED: FALM
- 142 -
TROUBLESHOOTING The printed circuit boards and servo amplifier are provided with alarm
BASED ON LED INDICATIONS LEDs and status LEDs. The LED statuses and corresponding
troubleshooting procedures are described below.
MAIN CPU PC BOARD

;u..+..-+--1-1 POWER SUPPLY UNIT
...ui.--1--+-~PROCESS I/O
PC BOARD
CA/CB/DA
SERVO AMPLIFIER
i-CABINET
MAIN CPU
PC BOARD
t1Y {J {J {J DOD ]..ll,,l:ll--1J--1t---t-rr-r P0 WE R SUPPLY

UNIT
tlY tlY tlY tlY F======n
~ ;; \\\\11n& PROCESS I/O

PC BOARD
CA/CB/DA
B-CABINET
- 143 -
SERVO MODULE 4
SRVO MODULE 3
SERVO MODULE 2
SERVO MODULE I
POWER SUPPLY MODULE
PC BOARD
FOR EMERGENCY
STOP CONTROL
PROCESS I/O PC BOARD CA/CB/DA

POWER SUPPLY UNIT
MAIN CPU PC BOARD
M-410i CABINET
- 144 -

SERVO MODULE 3 STOP CONTROL
MAIN CPU PC BOARD
SERVO MODULE 2 POWER SUPPLY UNIT
SERVO MODULE 1
PROCESS 1/0 PC
BOARD CNCB/DA
POWER SUPPLY MODULE
M-410i B-cabinet
- 145 -
SERVO AMPLIFIER 3
SERVO AMPLIFIER 4
PC BOARD FOR
EMERGENCY STOP
CONTROL
MAIN CPU
PC BOARD
POWER SUPPLY
UNIT
•
SERVO AMPLIFIER 2
SERVO AMPLIFIER I
S-900
SERVO AMPLIFIER 6
SERVO AMPLIFIER 5 E-STOP UNI 2
E-STOP UNIT I
BREAKER
UNIT
(INTERIOR OF ADDITIONAL CABINET I} (INTERIOR OF ADDITIONAL CABINET 2)

R-J2 CONTROLLER INTERIOR(B-CABINET/S-900)
-146 -
SERVO AMPLIFIER I
SERVO AMPLIFIER 2
PC BOARD FOR
EMERGENCY STOP
CONTROL
MAIN CPU
PC BOARD
POWER SUPPLY
UNIT
SERVO AMPLIFIER 4
SERVO AMPLIFIER 3
M-500
- 147 -
(1) TROUBLESHOOTING USING THE LEDS ON THE MAIN CPU

PRINTED CIRCUIT BOARD
To troubleshoot an alann that arises before the teach pendant is ready
to display, check the status LEDs (green) on the axis control PC 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 1to11, in the
order described. If an alann is detected, the step in which the alann
occurred can be determined from which LEDs are lit.
Step LED Action to be taken

1: After power-on, all LEDs *[Actlon1]Replacetheflash ROM module.
are lit.
EP
1 I I 4
* [Action2]Replace the SRAM module.
[Actlon3]Replace the corresponding axis module.
STA111S
••••
-
MMll CJCJCJ -
[Actlon4]Replace the main CPU PC board.
2: Each printed circuit board is * [Actlon]Replace the main CPU PC board.
initialized.
EP
1 I I 4
STA'IW CJCJCJCJ
MMll_CJCJCJ -
.........
3: The timer is initialized. * [Action]Replace the main CPU PC board.
EP
I I I 4
-
STA1W CJCJCJ•
MMll CJCJCJ_
-
4: The communication port is * [Action1] Replace the main CPU PC board.
initialized.
EP
I I I 4
STA'IW CJCJ•CJ
MMll _CJCJCJ
........- -
-
5: The software is initialized. *[Action1]Replace the main CPU PC board.
CJl * [Actlon2]Replace the flash ROM module.
-
I It I 4
STA111S CJCJ••
MMll CJCJCJ -
-
* If the main CPU PC board or SAAM module is replaced, the contents of memory (parameters, specified data, etc.) will be lost. Prior to
replacing the unit, therefore, make a backup copy of the data. Similarly, make a backup copy of the current data when replacing the
flash ROM module with one of a later software edition.
-148 -
Step LED Action to be taken

6: The software is initialized. *(Actlon1]Replace the SRAM module.
0 * [Action2]Replace the main CPU PC board.
7: The software is initialized.

--
lrA'llll
.__.,..
I I I•
CJ•CJCJ
CJCJCJ _
;-
*(Action1]Replace the SRAM module.
0 * [Action2] Replace the main CPU PC board.

--
..........
I I I 4
lrA'llll CJ•CJ•
CJCJCJ -
* [Action3] Replace the flash ROM module.
[Actlon]Replace the flash ROM module.
0
--
lrA1US
..........
I I I •
CJ••CJ
CJCJCJ -
[Action]Replace the axis module.
0
I I I 4
lrA'IW CJ•••
10:The software is initialized.

---
M.MW_CJCJCJ-
* [Action1] Replace the SRAM module.
0 * [Actlon2] Replace the main CPU PC board.
.....
lrA1US
_...-
I I I •
•CJCJCJ
CJCJCJ -
-
11: Communication with the [Action1]Replace the teach pendant.

teach pendant is executed. 0 [Actlon2] Replace the cable of the teach pendant.
---
I I I 4
lrA'IW •CJ•• * [Action3] Replace the main CPU PC board.
CJCJCJ -
If the main CPU PC board or SRAM module is replaced, the contents of memory (parameters, specified data, etc.) will be lost. Prior to
replacing the unit, therefore, make a backup copy of the data. Similarly, make a backup copy of the current data when replacing the
Cl
.
0
Main CPU printed circuit board
- 149 -
Color Description
[Description~A parity alarm occurred in the RAM of the main CPU PC board.
~]
[Action1] eplace the DRAM module.
Red * [Actlon2] Replace the SRAM module.
* [Action3] Replace the main CPU PC board.
[Description] An NMI occurred in the LSI chip (ABC) on the main CPU PC board.
[Action1~ Replace the axis module.
™
* [Actlon2 Replace the main CPU PC board.
Red
~Description]A servo alarm occurred on the main CPU PC board.
~gj
Action11 Replace the corre~ondin8 axis module.
Red * [Action2 Replace the main PU P board.
[Descriftion]An NMI occurred in the LSI chip (SLC2) of the main CPU PC board.
~·]
* [Action Replace the main CPU PC board.
Red
[Descrlption]A SYSFAIL occurred.
bid] Red
lAction1] Replace the corre~ondin8 axis module.
* Action2] Replace the main PU P board.
[Descrlron] The battery voltage has fallen to below the prescribed level.
™
* [Action Replace the battery on the power supply unit.
Red Note) To prevent data loss, before replacing the battery, tum the control unit on.
* If the main CPU PC board or SAAM module is replaced, the contents of memory (parameters, specified data, etc.) will be lost. Prior to
replacing the unit, therefore, make a backup copy of the data. Similar1y, make a backup copy of the current data when replacing the
CJ
.
•
I SBAM . . . .
I QBAMm•
I 6!!1fmpMtiJ1Jj
I Ax!amo@&iJ&Jlii
Battery cover
[Battery replacement]
(1) Tum on the control unit.
(2) Remove the battery cover from the power supply unit, by
grasping both the top and bottom of the battery cover.
(3) Disconnect the cable and remove the battery.
(4) Connect a new battery and replace the battery cover.
(5) Tum the control unit off.
Battery
- 150 -
* LEDs on power supply unit

LED Description and action to be taken
_ ..
,.,._ ....
-- .-·
[Description] A power supply alann occurred.
[Actlon1]
[Actlon2]
Check whether fuse F3 (+24 V) or F4 (+24 E) on the power supply unit has blown.
Replace if necessary.
Check the printed circuit boards, units, and cables using the DC power supply (+5 V,
___
.....
&mT * [Actlon3]
±15 V, +24 V, +24 E). Replace any failed components.
Replace the power supply unit.
....
=---=-,_,.
PIL-~
AUi-.
f( CP4
~
[Description] If the LED is not lit, the power supply unit is not connected to the 200 VAC supply.
[Actlon1 J Check whether fuse F1 on the power supply unit has blown. Replace if necessary.
* [Action2] Replace the power supply unit
PIL-~
AUi- 0
f( CP4
~
Power supply replacement must be completed within 30 minutes. {The power supply unit contains the backup battery for the SAAM module
of the main CPU PC board.)
Fl
F3
F4
- 151 -
3. TROUBLESHOOTING MAINTENANCE B--80525E-1 /03
LEDs on the emergency-stop PCB

LED indication Phenomena and countermeasures
[Description] The brake fuse (F1) or +24 V fuse (F2) has blown, or the brake over-<:urrent alarm
has been issued.
[Action1] Check whether fuse F1 or F2 on the emergency-stop PCB has blown. If it has
blown, replace it.
[Action2] Check whether the robot cable and mechanical unit cable are short-<:ircuited to
ground or any metal object.
[Action3] Replace the emergency-stop PCB.
[Description] If the LED does not light, 100 VAC power is probably not being supplied to the brake.
[Action1] If the system is in the emergency-stop state, release it.
[Action2] Check that 100 VAC is being output to the terminal box of the transformer or line filter.
[Description] If the LED does not light, the brake has not yet been released.
[Action2] Replace the main CPU PCB.
0 0
0
-
AllB-1212~
ODD
ITO DD
0
- 152 -
(2) ALARM LEDS ON THE PROCESS 1/0 PRINTED CIRCUIT

BOARD
Alarm LED Description and action to be taken
Process 1/0 CA/CB/DA Process 1/0 EA [Description] A communication alarm occurred between the main CPU PC board and process
1/0 PC board.
[Action1] Replace the process 1/0 PC board.
* [Action2] Replace the main CPU PC board.
E!1
1 2 3 4
I [Action3] Replace the 1/0 link connection cable.
----
STATUS DODD ALMO
ALARM •DD
--- -
D
FALM
Process 1/0 CA/CB/DA Process 1/0 EA [Description] A fuse on the process 1/0 PC board is blown.
[Action1] Replace the blown fuse on the process 1/0 PC board.
[Action2] Examine the cables and peripheral devices connected to the process 1/0 PC board.
Replace any failed components.
STATUS
E!1
1 2 3 4
DODD
D
ALMO
[Action3] Replace the process 1/0 PC board.
ALARM •DD
___..-- - -
-
I
FALM
If the main CPU PC board is replaced, the contents of memory (parameters, specified data, etc.) will be lost. Prior to replacing the unit,
therefore, make a backup copy of the data.
Fuse
For process 1/0 printed circuit board CA/CB/DA

Specificalion: AGOL-0001-0046#2.0
D~ DD
D Fuse
D D
For process 1/0 printed circuit board EA
Specificalion: AGOL-0001-0046#2.0
- 153 -
* LEDs on servo amplifier (For ARC Mate 100, ARC Mate 120, ARC
Mate lOOi, ARC Mate 120i, S-6, S-12, M-6i, M-16i, S-420i, S-500,
S-700, M-710i, A-520i)
The servo amplifier has alarm LEDs and a seven-segment LED.
Troubleshoot the alarm indicated by the LEDs, referring also to the
alarm indication on the teach pendant.
456 WO
OJ OJ OJ OJ
0
HC
0 OJ OJ OJ
0 123
0
~
0
0
0 LED
0
0 0 0
Name LED Description

Brake failure The brake control circuit in the servo amplifier is defective.
Corresponding alarm
Servo---018 Brake failure
Electromagnetic contactor This alarm is issued when a contact of the electromagnetic contactor
2
melt alarm melts.
The corresponding alarm is:

Servo---042 MCAL Alarm
Servo amplifier overheat The thermostat in the servo amplifier or transformer tripped or the
j fuses F1, F2 in the servo amplifier blow.
Corresponding alarm
Servo---049 OHAL 1 Alarm
Insufficient DC link voltage
Insufficient control supply

y The DC voltage being supplied to the main circuit is too low.
Corresponding alarm
Servo-047 LVAL Alarm
The voltage being supplied to the control circuit (+5 V) is too low.
b
voltage
Corresponding alarm
- 154 -

Excessive voltage The DC voltage being supplied to the main circuit is too high.
Excessive regenerative dis-

l Corresponding alarm
Servo-044 HVAL Alarm
The regenerative discharge energy is too high.
B
charge
Corresponding alarm
Servo-043 DCAL Alarm
Servo amplifier not ready The electromagnetic contactor for the main power supply is open. The
amplifier is not ready to drive the motor.
--
Servo amplifier ready The electromagnetic contactor for the main power supply is closed.
D
The amplifier 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 HCl to HC6, above the
7-segment LED, the LED corresponding to the axis
on which HCAL occurred lights (red).
WD (LEDS)
[Description] A watch-dog alarm occurred on the servo amplifier
control PC board.
The WD LED (LEDS) on the servo amplifier is lit.
- 155 -
*LED on power supply incdnle (PSM) (M410i)
==
==
=
= =
=
=
=
= =
=
=
=
=
===
=
==
II II I
- ;::::=r=
1~11~1
~
'
I 1=
I
.,
Ii
II II l
- 156 -
When an alarm is issued, the red LED lights, and the corresponding alarm
number is displayed on the seven-segment LED display on the front panel
of the power supply module.
Input overcurrent An over-current was detected in the input circuit.
I SRV0-148 HCAL alarm
Fan alarm The cooling fan, built into the power supply module, is defective.
2 SRV0-150 FSAL alarm
Overload alarm The temperature of the semiconductor heat sink is too high.
~ SRV0-141 OHAL alarm
y
Low voltage alarm for DC link The DC voltage of the main circuit is too low.
SRV0-145 LVALalarm
In sufficieat charge alarm for The DC voltage of the main circuit has not reached the required level (insufficient
5
DC link pre-charge}.
SRV0-153 CHGAL alarm
Input power missing phase A phase of the input power is missing.
b
alarm
SRV0-143 PSFLAL alarm
Overvoltage alarm for DC link The DC voltage of the main circuit is too high.
Hardware error alarm

l SRV0-154 HVALalarm
The control circuit is defective.
B
The following messages do not indicate alarm states. They indicate
normal operation modes.
NOT READY The motor is not ready to operate.
READY The required DC voltage has been reached. The motor is ready to run.
- 157 -
* LED on servo module (SVM)
LED
c
(]
I==
Ei
......____
~~~®
-
- 6o6n6
~~~
_, v
~~~®
I==
0
~
~~§~~1
WiiD - · -
0 ~~
~
- 158 -
An alarm is indicated at the seven-segment LED display on the front

panel of the servo amplifier module.
Low voltage alarm for control The control-power voltage (+5 V) is too low. Alternatively, the clock is erroneous.
power
(LV5V)
Low voltage alarm for DC link

2 SRV0-144 LVAL alarm
The DC voltage of the main-circuit power supply is too low.
5
(LCDC)
SRV0-146 LVAL alarm
Overcarrent alarm An excessive over-current was detected in the motor of the one-axis amplifier or
B
(HCL) in the L-axis motor of the two-axis amplifier.
SRV0-149 HLAL alarm
Overcarrent alarm
(HCM)
g An excessive over-current was detected in the M-axis motor of the two-axis ampli-
fier.
SRV0-149 HCAL alarm
Overcarrent alarm An excessive over-current was detected in the L- and M-axis motors of the two-
5
(HCLM) axis motor.
SRV0-149 HCAL alarm
IPMalarm An error was detected in the IPM of a 1-axis amplifier or the L-axis IPM of a 2-axis
(HCL) or 3-axis amplifier.
EL SRV0-152 IPMALalarm
IPMalarm An error was detected in the M-axis IPM of a 2-axis or 3-axis amplifier.
(HCM)
g. SRV0-152 IPMAL alarm
IPMalarm An error was detected in the L-axis and M-axis IPMs of a2-axis or 3-axis amplifier.
5.
(HCLM)
SRV0-152 IPMAL alarm

Amp The motor is not ready to operate.
NOT READY
-
Amp The required DC voltage has been reached. The motor is ready to run.
D
READY
- 159 -
* LED on servo amplifier (S-900 and M-500)

The servo amplifier has a seven-segment LED display. If an alarm
is issued, take appropriate action according to the message displayed
on the teach pendant.
LED

Overvoltage alarm The DC voltage of the main-circuit power supply is too high.
(HV)
Alann message: Servo - 044 HVAL alarm
I
Low voltage alarm for control The power voltage (+5 V) supplied to the control circuit is too low.
power
(LCDC)
2 Alann message: Servo-047 LVALalarm
Low voltage alann for DC link The DC voltage of the main-circuit power supply is too low.
~
(LVDC)
Alann message: Servo - 047 LVAL alarm
y
Regenerative control circuit The short-period regenerative discharge energy is high.
alarm
(DCSW) Alann message: Servo - 043 DCAL alann
Over regenerative discharge The average regenerative discharge energy is high.

alann
(DCOH)
5 Alann message: Servo - 043 DCAL alarm
- 160 -

Deposition of magneticcontac- A deposit was detected on the contact of the magnetic contactor. Any deposit on
the contact is detected immediately after the magnetic contactor activation com-
l
tor
(MCC) mand is specified.
Alarm message: Servo - 042 MCAL alarm
Overcarrent alarm An excessively high current was detected in the main circuit of the one-axis
B
(HCL) amplifier or the L-axis main circuit of the two-axis amplifier.
Alarm message: Servo - 045 HCAL alarm
Overcarrent alarm An excessively high current was detected in the M-axis main circuit of the two-
(HCM)
g axis amplifier.
Overcarrent alarm An excessively hit current was detected in the L- and M-axis main circuits of
b
(HCLM) the two-axis amp ifier.
Amplifier NOT READY The magnetic contactor in the servo amplifier is open. The motor is not ready to
operate.
-
Amplifier READY The magnetic contactor in the servo amplifier is closed. The motor is ready to
D
run. (This state is the normal operation state.)
L-axis IPM alarm (IPML) This alarm is issued when the intelligent power module (IPM) of the L-axis de-
B• tacts an alarm.
The corresponding alarm is: Servo - 152 IPMAL alarm
M-axis IPM alarm (IPMM) This alarm is issued when the intelligent power module (IPM) of the M-axis de-
g• tects an alarm.
LIM-axis IPM Blann (IPMLM) This alarm is issued when the intelligent power modules (IPMs) of the L-axis and
b• M-axis detect an alarm.
Circuit breaker The circuit breaker is When an abnormal current exceeding the operating current of the circuit breaker
set to off. flows, the circuit breaker trips.
NOTE
When the circuit breaker of the servo amplifier is set to off, the DC link undervoltage
alarm (LVDC) is issued.
- 161 -
3.3
POSITION DEVIATION (Check 1) On the status screen, check the position deviation in the
FOUND IN RETURN stopped state. To display the position deviation, press the
screen selection key, and select STATUS from the menu.
TO THE REFERENCE
Press the TYPE (Fl) key, select AXIS from the menu, then
POSITION press the PULSE (F4) key.
(POSITIONING) (Corrective action)
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 or other faulty parts.
(Check 4) If checks 1to3 show normal results
(Corrective action)
Replace the pulse coder and axis control printed circuit
board.
3.4
VIBRATION (Check 1) Check the settings of parameters such as the position loop
gain parameter.
OBSERVED DURING (Corrective action)
MOVEMENT Correct parameters.
(Check 2) Check the mechanical unit for backlash.
(Corrective action)
Replace a faulty key or other faulty parts.
3.5 The following explains checking and corrective action required if the
robot cannot be operated manually after the controller is turned on:
MANUAL
OPERATION (1) Check and corrective action to be made if manual operation is
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.
- 162 -
(Check 4) Check whether the HOLD signal of the peripheral device

control interface is on (hold status). (Check whether the
hold lamp on the teach pendant is on.)
(Corrective action)
Tum off the HOLD signal of the peripheral device control
interface.
(Check 5) Check whether the previous manual operation has been
completed.
(Corrective action)
If the robot cannot be placed in the effective area because of
the offset of the speed command voltage preventing the
previous operation from being completed, check the
position deviation on the status screen, and change the
setting.
(Check 6) Check whether the controller is in the alarm status.
(Corrective action)
Release the alarm.
(2) Check and corrective action to be taken if the program cannot be
executed
(Check 1) Check whether the ENBL signal for the peripheral-device
control interface is on.
(Corrective action)
Put the peripheral-device control interface in the ENBL
state.
(Check 2) Check whether the HOLD signal for the peripheral-device
control interface is on. (Check whether the HOLD lamp on
the teach pendant is on.)
(Corrective action)
If the HOLD signal is on, tum it off. If the HOLD switch
is on, tum 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.
- 163 -
4. PRINTED CIRCUIT BOARDS MAINTENANCE B-80525E-1 /03
4
PRINTED CIRCUIT BOARDS
The printed circuit boards are factory-set for operation. Usually, the user
need not 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 use of the test pins and meanings of the LED
indications.
Fig. 4 shows the printed circuit board of the control unit. The control unit
PC board consists of a main printed circuit board and some modules
installed perpendicular to the main PC board.
The control unit PC board has interface connectors, LED indicators, and
a plastic panel at the front. At the rear, there is a backplane connector.
The module is a small PC board in which components are
surface-mounted on both sides. On one edge, it has a connector electrode
which fits into a module socket on the main PC board of the control unit.
This connection enable the module to be replaced easily. Different
modules are available for different functions. The signal array of the
module connector depends on the function. The function of the module
determines the socket to which the module is installed on the main PC
board of the control unit. If the module is installed to the wrong socket,
it will not work. It may cause failure.
LED indicator
Module
Edge
connector I Interface connector
I
I
I
I
Backplane connector I
I
~
c=J
c=J
Main PC board of the control unit
Front panel
Fig.4 Configuration of the Control Unit PC Board
- 164 -
B-80525E-1 /03 MAINTENANCE 4. PRINTED CIRCUIT BOARDS
4.1
MAIN CPU PRINTED
CIRCUIT BOARDS
(A 168-3200-0042)
TOTAL VERSION
0
>
SPI g;
o~8
D
.
II!!
I
FLASH ROM MODULE
CMOS RAM MODULE
DRAM MODULE
11I
ei 0
I DV2 II
~OiO!!
DV I
AXIS MODULE ( 0 I , J2)
AXIS MODULE(03,J4)
AXIS MODULE(05,J6)
...
~
I
I
I
0 0
0 0
0 0
I'..,,. - - JRYI
11- WI ROBOT JllF2
I
Fig.4.1 Main CPU printed circuit board
( 1) Test pins
Name Use
GND
P5V
P15V
M15V For testing the printed circuit board
P24V
P24E
LOAD
(2) Set pin

Name Use
SP1 Only for testing the printed circuit board
Note) If the set pin is removed, the RAM on the PC board is
disconnected from the backup circuit. Because no
power is supplied, therefore, the data stored in RAM
may be lost. Always connect the set pin.
- 165 -
(3) LEDs
Color Description
I ii
A parity alarm occurred in a CMOS RAM module or
10-0l
10• Red
10•
O• DRAM module on the main CPU board.
I ii
oo-OJ
NMI occurred in the LSl(ABC) on the main CPU
10• Red
10•
O• printed circuit board.
I ii
oo-a Servo alarm occurred on the main CPU printed
oo- Red
10•
D• circuit board.
I ii
NMI occurred in the LSl(SLC2) on the main CPU
ID-a
ID•
DD•
Red
O• board.
I ii
oo-a
•D•
DD•
Red SYSTEM FAIL occurred.
O•
I ii
The battery voltage is insufficient.
OD•0 - a
1 Red
DD•
D•
Replace the battery.
I ij
01-0l
01•
DI•
Green Indicates the operating status of the system.
••
(4) Relationship between driver chips and DO signals

Driver chip order code: A76L-0151-0062
Driver chip DO signal
DV1 RD01, RD02, RD03, RD04
DV2 RD05, RD06, RD07, RD08
- 166 -
4.2 A20B-1006-0300
EMERGENCY STOP
CONTROL PRINTED RLY2 RLY6
0 CRRl5 r - - , 0
CIRCUIT BOARD
I
BB I 0
I
I ~~
I
L _J -cJ)-- o~ CRR20
II
'-..
•0
f")
0
I
'°
0
0
N
LL
I 0:::
ro J
0 I") "<j-
(\j LL LL
<C 0::: 0:::
(__) (__)
0 CRM9 CRM·I I0
Fig.4.2 (a) Emergency stop control PC board
- 167 -
4. PRINTED CIRCUIT BOARDS MAINTENANCE B-80525E-1/03
A16B-1212-0930
Total version
0
0 0 0
0
0 mupf
- C\I
IJ.
a:
"""")
•ipy
-1
"1
I
F2
I
[Q] ~I
~I
Cllll6
n
([] D
-....,........
D
DOD
0
0
DIJ DD 0 0
Fig.4.2 (b) Emergency stop control PC board
- 168 -
B-80525E-1/03 MAINTENANCE 4. PRINTED CIRCUIT BOARDS
A16B-1212-0931
Total version
0
0
0
- ->
!!j
:;:I
SI
I
I
"I
~I
~I
.. 1
"1
...
"I
•
-
..."I
•!I
ii I
:I
11
ODD !I
i1
•11
ii
DIJ DD
ffi 11..
ffi ii
0
ffi 11
0 0 0 I
I
~ _
1
__
sD
BCRR~ _-~!I--=--~ __ :1
Fig.4.2 (c) Emergency stop control PC board
- 169-
(1) Settings
Symbol Standard Description

setting
COM A Common-voltage setting
A: +24V
B: OV
HBK B *HBK signal enabled/disabled
A: Disabled
B: Enabled
SBK1 Open
SBK2 Brake-sensitivity adjustment
(note)
Notes
NOTE
Not provided for A20B-1006-0300.
(2) LED indication

LED Description
A brake fuse alarm or brake over-current alarm

Red has been issued.
Green 100 VAC power is supplied to the brake.
Brake state (when the brake is released, the

Green LED lights.)
- 170 -
4.3 (A20B-2001-0670)
BACKPLANE Total version
PRINTED CIRCUIT
BOARD 0 0 0 0
CA39 CA44
D
I-
'
LO.
I
L
1° 0
<( <( ~ <( o._ <(
z 9 z
er:
;c;;
z z
J J J
0
C\J
'
~
~D
0 0 0 0 0
Fig.4.3 (a) Backplane PC Board
(A20B-2001-0860)
Total version
0 0
CA39
D
I-
<(
LO
<(
•'
:8 L
? <(
0
o._
z er:
)~
0 zJ z
I
J J
'
al
0
C\J
<
~D
0 0 0
Fig.4.3 (b) Backplane PC Board
(A20B-2001-0990)
5 slot back plane
Total version
A20B-2001-0990
u--
I
- - -
~
0 0 - 0 0 0 0 -
0
o
0 CA398
D
CA«
D
I-
<(
~I
<( .....
::E
<(
0
a..
-<( C\J
<(
t')
<(
zJ 0.:: •z zJ zJ z zJ
J g: J J
0
I
;:;
0
N
~D ~D
I
'---- ~
~
~
r- 0 '---- - 0 0 '---- 0 0 0 0 0
Fig.4.3 (c) Backplane PC Board
- 171 -
4. PRINTED CIRCUIT BOARDS MAINTENANCE ~525E-1/03
4.4
PROCESS
INPUT/OUTPUT
PRINTED CIRCUIT
BOARD
4.4.1
Process Input/Output
Printed Circuit Board
CA (A168-2201-0470)
0
• • • • • .JNA
11111 PW PIMVMllllCPIM
I IIEIERVED I 0
...
i
General
~
.I
-~1
DVl2 DV6
• DVll DV5
DVIO DV4
I
DV9 DV3
ova DV2
DV7 DVI
.IMS J>4A
LED 0
0
0
Ifill I II I !
~ IBCDBn nnn~ =+=CijJ g:;;:::I
Fig.4.4.1 Process Input/Output PC Board CA
- 172 -
(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
Al1 Channel 1
Al2 Channel 2
Al3 Channel 3 For measuring the voltage of the analog input
Al4 Channel 4 signal (analog/digital)
Al5 Channel 5
Al6 Channel 6
AOUT1 Channel 1 For measuring the voltage of the analog output
AOUT2 Channel 2 signal (digital/analog)
(2) Settings
Name Standard Description
setting
UDl1 to UDl20
ICOM1
(Connector CRM2A) The common voltage is
UDl21 to UDl40 adjusted to:
ICOM2 Side A
(Connector CRM2B) Side A +24 Vcommon
SideB OVcommon
WDI01 to WDIOB
ICOM3
(Connector CRW1)
SP1 Channel 1 The polarity of the output voltage

is switched to:
Open
Strapped: Negative(-)
SP2 Channel 2 Open Positive(+)
- 173 -
(3) Adjustment
VRl: 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 AOUTl and
rotate VRl 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 OVF test pin is different from the common OV test
pin.)
VR3: Adjusts the reference supply voltage of the digital/analog
converter.
Connect the digital voltmeter to test pin Pl OV and rotate VR3
until the meter reads 10.0 ±0.1 V.
(4) LEDs
Color Description
\;1 . 01 1~1
1 I0-1]
aa•
DD•
) D•
Red
A communication alarm occurred between
the main CPU and process input/output.
\ii 1~1
1 DO-I]
•a-
DD•
Red
A fuse (FUSE 1) in the process input/output
blew.
) D•
- 174 -
B--80525E-1 /03 MAINTENANCE 4. PRINTED CIRCUIT BOARDS
(5) Correspondence between driver chips and DO signals

Ordering code for the driver chips: A76L-0151-0062
DV1 CMDENBL, SYSRDY, PROGRUN, PAUSED
DV2 HELD, FALT, ATPERCH, TPENBL
DV3 BATALM, BUSY, ACK1/SN01, ACK2/SN02
DV4 ACK3/SN03, ACK4/SN04, ACK5/SN05, ACK6/SN06
DV5 ACK7/SN07, ACK8/SN08, SNACK, RESERVED
DV6 SD001, SD002, SD003, SD004
DV7 SD005, SD006, SD007, SD008
DV8 SD009, SD010, SD011, SD012
DV9 SD013, SD014, SD015, SD016
DV10 SD017, SD018, SD019, SD020
DV11 WD001, WD002, WD003, WD004
DV12 WD005, WD006, WD007, WD008
RESERVED For replacement
- 175 -
4. PRINTED CIRCUIT BOARDS MAINTENANCE 8-80525E-1 /03
4.4.2
CB (A16B-2201-0472)
-
0
I
l 0
I
•••••
INl2 PSY P2'V MllM:PllM:
I IRESERVED
JNA
0
>
General '
18
0
I
•
1-0-t- ~-:-~-t - ~1
. --0-V
DV9
DV8
DV7
DV3
DV2
DVI
I
1\!5 E!1 .-C=R"-'M=2B...___ _ _--. ~~A
0 CRM2A
0
0
m
Fig.4.4.2 Process Input/Output PC Board CB
( 1) Test pins
Name Use
P24V +24V
PSV +SV
P15VC +15V
M15VC -15V
GND1 GND
GND2 GND
(2) Settings
setting
UDl1 to UDl20 The common voltage is
ICOM1
(Connector CRM2A) adjusted to:
Side A
UDl21 to UDl40 Side A +24 Vcommon
ICOM2 SideB OVcommon
(Connector CRM2B)
- 176 -
(3) LEDs
Color Description
\H 1~1
•a-a
aa-
aa-
I a.
Red
the main CPU and process inpuVoutput.
\H 1~1
DD-a
10-
aa•
a•
Red
A fuse (FUSE 1) in the process inpuVoutput
blew.

DV3 2BATALM, BUSY, ACK1/SN01, ACK2/SNO
DV6 SD001, SD002, SD003, SD004
DV7 SD005, SD006, SD007, SD008
DVB SD009, SD010, SD011, SD012
DV9 SD013, SD014, S0015, SD016
DV10 SD017, SD018, S0019, SD020
- 177 -
4. PRINTED CIRCUIT BOARDS MAINTENANCE B--80525E-1 /03
4.4.3
PC Board DA
(A 168-2201-0480)
rl I
l
•
0
JNA
FUQI 0
>
I DV24 I DV22 I 81
"I' I DV23 I DV2 I I I
"'~"'
~ESERVEI DVl4 DV7 Total version
•
I
POV
DV20 DVl3 DV6 ...
0
...,,
•• DVl9
DVl8
DV12
DVI I
DV5
DV4 ~i
DVl7 DVIO DV3
CRM4B CRM2D
DVl6
DVl5
• DV9
ova
DV2
DVI
CRM2B ~B~A
r- ~
I
~~~~ H
CRM4A CRM2C CRM2A
0
0
aa ng
LEO 0
0
l I -
Fig.4.4.3 Process VO PC board DA
( 1) Test pins
Name Description
P24V +24V
P5V +5V
GND1 GND
GND2 GND
(2) Settings

setting
UDI01 to20
ICOM1
(Connector CRM2A)
UDl21 to40 The common voltage is
ICOM2
(Connector CRM2B) adjusted to:
Side A
UDl41 to60 Side A +24Vcommon
ICOM3 SideB OVcommon
(Connector CRM2C)
UDl61to80
ICOM4
(Connector CRM2D)
- 178 -
(3) LEDs
Color Description
.,. a
'&i
l
1~1
oo..
oo..
I D•
Red
\ &i
I
00·
10..
oo..
) D•
a i1~1
Red
below.

Driver chip DOslgnal
DV4 ACK3/SN03, ACK4/SN04, ACK5/8N05, ACK6/8N06
DV5 ACK7/8N07,ACK8/SN08,5NACK,RE8ERVED
DV6 8D001,SD002,8D003,8D004
DV7 8D005,SD006,SD007,SD008
DV8 80009, SD010, SD011, 80012
DV9 80013, 80014, SD015, SD016
DV10 80017, SD018, 80019, SD020
DV11 AD021, SD022, 80023, SD024
DV12 80025, 80026, S0027, SD028
DV13 80029, SD030, 50031, SD032
DV14 80033, 80034, 50035, 80036
DV15 80037, SD038, 50039, 80040
DV16 80041, 80042, 80043, 80044
DV17 80045, 80046, 80047, SD048
DV18 80049, 50050, S0051, 80052
DV19 80053, 80054, 80055, 80056
DV20 80057, 80058, 80059, 80060
- 179 -
4.4.4
EA (A168-3200-0230)
•
~o·ff.~
Al68-3200-02~
0 ~ PIOV
0
•••••••• •
GNlf' MUM" PllM: GN>2 0
~o I
Total version
PllVF MUM: P&VC N.I
a
D
~
FUSEI
Lj
I DV6 I 0
•
GIDI
CRWI
DVI I < DVI
C\J
IQ :::;::
~o
DVl2 C\J a:: DV2 ~
DV7
:::;::
a::
u
u
DV3
......
15
DV8 ~ ~
DV4 ......
Al6 ~ lLj DV5
& AI4 Al3 All AI IAOUfl ES'
00 ••••••••
"""''
PMY
0 0 ~· 0 0
- 180 -
(1) Test pins

Name Use
P24V +24V
PSV +5V
P15VC +15V
M15VC -15V For measuring the DC supply voltage
GND1 GND
GND2 GND
P4.8
For measuring the reference voltage of the
PlOV +10V
digital/analog converter
P15VF +15V
M15VF -15V Power for the digital/analog converter
GNDF GND
Al1 Channel 1
Al2 Channel 2
Al3 Channel 3 For measuring the voltage of the analog input
Al4 Channel4 signal (analog/digital)
Al5 Channel 5
Al6 Channel 6
AOUT1 Channel 1 For measuring the voltage of the analog output
AOUT2 Channel 2 signal (digital/analog)
(2) Settings

setting
UDl1 to UDl20
ICOM1
(Connector CRM2A) The common voltage is
UDl21 to UDl40 adjusted to:
ICOM2 Side A
(Connector CRM2B) Side A +24 Vcommon
SideB OVcommon
WDIOl to WDI08
ICOM3
(Connector CRW1)
SPl Channel 1 The polarity of the output voltage

is switched to:
Open
Strapped: Negative(-)
SP2 Channel2 Open Positive (+)
- 181 -
(3) Adjustment
VRl: 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 AOUTl and
rotate VRl 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 OVF test pin is different from the common OV test
pin.)
VR3: Adjusts the reference supply voltage of the digital/analog
converter.
Connect the digital voltmeter to test pin PlOV 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 by the user.
(4) LEDs
Color Description
I
ALMO
Red
D
FALM
D
ALMO A fuse (FUSE 1) in the process input/output
Red
blew.
I
FALM
- 182 -

DVS SD001, SD002, SD003, SD004
DV7 SD005, SDOOS, S0007, SD008
DVB SD009, SD010, S0011, SD012
DV9 SD013, SD014, S0015, SD016
DV10 SD017, SD018, SD019, SD020
DV11 W0001, WD002, WD003, WD004
DV12 W0005, WDOOS, WD007, WD008
- 183 -
5. SERVO AMPLIFIERS MAINTENANCE B-80525E-1 /03
5
SERVO AMPLIFIERS
The servo amplifiers are factory-set for operation. Usually, the user need
not 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.
Correspondence between robot and amplifier
J1 J2 J3 J4 JS J6
ARC Mate 100 A06B-6076--H005 OR H105
ARC Mate 120, ARC Mate 120i A06B-6076-H004 OR H104
S-6,
A06B-6076--H005 OR H 105
M-16i
S-12 A06B-6076--H004 OR H 104
S-420i A06B-6076--H001 OR H101
S-500
A06B-6076--H002 OR H102
A-520i
S-700 A06B-6076--H003 OR H103
AMP1 AMP3 AMPS AMP2 AMP4 AMP6

············-······················ ................................... ··································· ................................... ................................... ...................................
S-900 A06B A06B A06B A06B A06B A06B
-6089 -6089 -6089 -6089 -6089 -6089
-H106 -H105 -H106 -H105 -H106 -H105
A06B-6087-H115 (PSM)
AMP1 AMP2 AMP3 AMP4

M-410i .................................... ··-··············-················· .................................... ······························-·--- ........................................................................
A06B A06B A06B A06B
-6079 -6079 -6079 -6079
-H106 -H106 -H106 -H103
AMP1 AMP3/M AMP2 AMP3/L AMP4

·······················-···-·----- ------··-··---------······-········ ················--················· ·························--------·· ·······-----·····-············-···· ...................................
M-500 A06B A06B A06B A06B A06B
-6089 -6089 -6089 -6089 -6089
-H106 -H206 -H105 -H206 -H104
ARC Mate 100i, M-6i A06B-6076--H105
M-710i A06B-6076--H106
- 184 -
B-80525E-1 /03 MAINTENANCE 5. SERVO AMPLIFIERS
5.1 (For ARC Mate 100, ARC Mate 120, ARC Mate lOOi, ARC Mate 120i,
S-6, S-12, M-6i, M-16i, S-420i, S-500, S-700, M-710i, A-520i)
SERVO AMPLIFIER
Machine Specification
ARC Mate100, S-6 A06B-6076-C005orA06B-6076-C105
ARC Mate120, S-12 A06B-6076-C004orA06B-6076-C104
S-420i A06B-6076-C001 orA06B-6076-C101
S-500, A-520i A06B-6076-C002orA06B-6076-C102
S-700 A06B-6076-C003 or A06B-6076-C103
ARC Mate 1OOi, M-6i A06B-6076-C105
M-710i A06B-6076-C106
If optical isolation unit is not mounted to operator's box, servo amplifier

can be used only A06B-6076-C101 to C106.
(ARC Mate 100, ARC Mate 120, ARC Mate 120i, S-6, S-12, M-16i,
S-420i, S-500, S-700, A-520i)
Fig.5.1(a) Outline Drawings
- 185 -
5. SERVO AMPLIFIERS MAINTENANCE B-80525E-1/03
Fig. 5.1 shows the terminal boards of servo amplifiers.
JS-axis
output
JS-axis
output
J3-axis
output
J4-axis
output
J1-axis
output 2U
0
J2-axis
output
Regenerative
} resistance
c::= == ==::J
connection
0
... c:::
!......OLTD
==-·-1
TYlllC:::====::J
==::J terminal
GNDterminal AC input
(200VAC to 230VAC)
Fig.5.1(b) Terminal Boards of Servo Amplifiers
- 186 -
LED on servo amplifier

The servo amplifier has alarm LEDs and a seven-segment LED.
Troubleshoot the alarm indicated by the LEDs, referring also to the alarm
indication on the teach pendant.
456 WO
DIDI(] DI
0
HC (](](]
0
0 123
0
~
0
0
0 LED
0

Brake failure The brake control circuit in the servo amplifier is defective.
Electromagnetic contactor This alarm is issued when a contact of the electromagnetic contactor
2
melt alarm melts.
The corresponding alarm is: Servo 042 - MCAL alarm
Servo amplifier overheat The thermostat in the servo amplifier or transformer tripped or the
j
fuses F1, F2 in the servo amplifier blow.
Corresponding alarm
Servo-049 OHAL 1 Alarm
Insufficient DC link voltage

(LVDC)
Insufficient control supply

y The DC voltage being supplied to the main circuit is too low.
Corresponding alarm
The voltage being supplied to the control circuit (+5 V) is too low.
b
voltage
(LVSV) Corresponding alarm
- 187 -

Excessive voltage The DC voltage being supplied to the main circuit is too high.
l
(HV)
Corresponding alarm
Servo--044 HVAL Alarm
Excessive regenerative dis- The regenerative discharge energy is too high.
El
charge
Corresponding alarm
Servo--043 DCAL Alarm
Servo amplifier not ready The electromagnetic contactor for the main power supply is open. The amplifier
is not ready to drive the motor.
--
Servo amplifier ready The electromagnetic contactor for the main power suppl) is closed. The amplifi-
D
er 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 HCl to HC6, above the
7-segment LED, the LED corresponding to the axis
on which HCAL occurred lights (red).
WD (LEDS)
[Description] A watch-dog alarm occurred on the servo amplifier
control PC board.
The WD LED (LEDS) on the servo amplifier is lit.
- 188 -
5.2 Power supply imodule (PSM) (A06B-6087-C115)

POWER SUPPLY
MODULE (PSM)
(M-410i)
==
=
= =
=
=
=
= =
=
=
=
=
= =
=
=
=
===
- 189 -
Positions of test points
IR
IS
+24V
+5V
ov
Fig. Test Points
Test point Description

IR L1 phase (R phase) current
IS L2 phase (S phase) current
+24V,
+5V, Control power
ov
- 190-
B-80525E-1/03 MAINTENANCE 5. SERVO AMPLIFIERS
Position of the status LED display
Position of the STATUS LEDs
STATUS
PIL
ALM LI
Status indication
No. O n-L- J
Off -+~ Description
A lit LED is indicated by -.

PIL, power-on indication, does not light.
1. PIL
ALM
D Control power not tumed on
PSM not ready.

2.
PIL
ALM
D Power is not being supplied to the main cir-
cuit.
Emergency stop state
3. PIL
ALM 1:r1nl
o _IU
PSM ready.
Power is being supplied to the main circuit.
The PSM is ready to operate.
Alarm.
~
PIL
I The PSM is not ready to run.
ALM
4.
Alarm codes are indi-
cated with numbers
starting from 01.
- 191 -
LED display indicating alarms

When an alarm is issued, the red LED lights, and the corresponding
alarm number is displayed by the seven-segment LED display on the
front panel of the power supply module.
Input overcurrent An over-current was detected in the input circuit.
I
Fanalann The cooling fan, built into the power supply module, is defective.
2
Overload alann The temperature of the semiconductor heat sink is too high.
~
Low voltage alann for DC link
y The DC voltage of the main circuit is too low.
In sufficieat charge alann for The DC voltage of the main circuit has not reached the required level (insufficient
5
DC link pre-charge).
Input power missing phase A phase of the input power is missing.
b
alann
Overvoltage alann for DC link The DC voltage of the main circuit is too high.
Hardware error alann

l The control circuit is defective.
B
NOT READY The motor is not ready to operate.
READY The required DC voltage has been reached. The motor is ready to run.
- 192-
5.3 Servo module (SVM) (A06B--6079-Cl03)

SERVO AMPLIFIER
MODULE (SVM)
(M-410i)
ll
-1111111
.-- =~ - -
= ~~
= Fi
.._ llllUI ~ ~ ~ -
- 193 -
Servo module (SVM) (A06B-6079-Cl06)
IEi
]
= ~~~~
-
c:
-
'--- ~~~~~~
.. !it::::Zil
·~~~(])~
' . v
.... !it::::Zil
.... !it::::Zil
l!C:Z!I
c::::::J
•lllW1ll
1111110111
. .
~~~(])~
~~@~
"""'=
D
'--
0
---
- 194-
8-80525E-1/03 MAINTENANCE 5. SERVO AMPLIFIERS
Setting
~1
.. :;;;;;;;...:
_,-imi
~
m CXI
~SI
mCXI
[;] u m.Js2
111l
-
c:::J
JXI
+MY
I
L ==
==
1uc:::n1
I
I
I
I
I
I
JX1A
l•CJ•I
..
JXll
!'Jml
llCJll
llCJDI
IBCJll
2111 l•CJ•I
2lf llCJBI
1¥1 IDCJDI
!ft• IBCJll
1:1m:1
====
m1====
,_L'ID
.. ====
-·-1
0
Name Setting Description

S1 Open These setting pin are used for internal circuit.
S2 Short These setting pin must not be changed.
- 195 -
5. SERVO AMPLIFIERS MAINTENANCE B-80525E-1 /03
An alarm is indicated at the seven-segment LED display on the front

panel of the servo amplifier module.
Fan alarm The fan built into the servo amplifier module is defective.
{FAL)
I
Low voltage alarm for control The control-power voltage {+5 V) is too low. Alternatively, the clock is erro-
2
power neous.
{LV5V)
Low voltage alarm for DC link The DC voltage of the main-circuit power supply is too low.
{LCDC)
5
Overcarrent alarm An excessive over-current was detected in the motor of the one-axis amplifier
B
{HCL) or in the L-axis motor of the two-axis amplifier.
g
Overcarrent alarm An excessive over-current was detected in the M-axis motor of the two-axis
{HCM) amplifier.
Overcarrent alarm An excessive over-current was detected in the L- and M-axis motors of the
5
{HCLM) two-axis motor.
IPMalarm An error was detected in the IPM of a 1-axis amplifier or the L-axis IPM of a
{HCL)
IPMalarm
B. 2-axis amplifier.
An error was detected in the M-axis IPM of a 2-axis amplifier.

{HCM)
IPMalarm
9. An error was detected in the L-axis and M--axis IPMs of a 2-axis amplifier.
5.
{HCLM)

Amp The motor is not ready to operate.
NOT READY
-
Amp The required DC voltage has been reached. The motor is ready to run.
D
READY
- 196-
Interface of supply module and servo module terminal unit
TBI
~
~
:l!!laiiirrol
illC LI
L;·
L ..
t ii =
TB2
TB2
- 197 -
5. SERVO AMPLIFIERS MAINTENANCE B-a0525E-1/03
5.4 Servo amplifier (A06B--6089-C106)

SERVO AMPLIFIER
UNIT {S-900, M...;.soo)
0 0
0
LED
No fuse braker
Terminal unit Tl
0 0
- 198 -
Servo amplifier (A06B-6089-C104, C105)
~~m~~ ~~~~~~
~~m~~ ~mm~ No fuse braker
mm~~ ~mm~ -
M: SEIMI UNIT
Cserle&
mm~~ ~mm~
mm~~ ~mm~ LED
m~m~ ~mm~
- 199 -
Servo amplifier (A06B-6089-C206)
~~mm m~~m
m~m~ ~~~~m No fuse braker
m~~m ~~~~m -
AC SERVO UNIT
Gfurles
mmmm~~m
mmmmmm LED
~~mmmmm
- 200 -
Setting
OFF ON
t8: -+ON
1
El
0
0
0
0
0 0
Set the switch as follows

1 ON
2 OFF
3 ON (In case of A06B-6089-Cl06, set switch OFF)
4 ON (In case of A06B-6089-Cl06, set switch OFF)
- 201 -
Interface of the Servo-Amplifier Terminal Block

The following table lists the interface signals of the terminal box of
the servo amplifier.
Terminal No. Symbol Description Remarks
1 PE (G) Amplifier ground

2 L1 (R) AC power input
3 L2 (S) (200 to 230 VAC)
4 L3 (T)
7 RL1 Point of contact relay for
8 RL2 dynamic brake.
9 u Outputs to an AC motor
10 v
11 w
12 G Motor ground
13 L1C Control power inputs L1 (R) and L 1C, and L2 (S) and L2C are usually con-
14 L2C (200 to 230 VAC) nected(Note 1).
15 TH1 Thermostat input signals Usually connected(Note 2).

16 TH2
17 RC For a regenerative resistor RC and RI are usually connected(Note 3).
18 RI
19 RE
20 UL Output to an AC motor These terminals are not prepared for 1 axis servo amplifier.
21 VL
22 WL
23 GL Motor ground
24 FAN1 Power for the cooling fan in Provided only for A06B-6089-H106(Note 4).
the separate regenerative dis-
25 FAN2 charge unit
NOTE
1 These terminals are used to input the power for controlling the servo amplifier. L2 (S) and L 1C, as well
as L3 {T) and L2C are usually connected. R-J2 controller controls the control and power sections
separately.
2 To use a transformer or a separate regenerative discharge unit, remove the jumper plate, then connect
the transformer or the overheat signal of the separate regenerative discharge unit between the TH1 and
TH2 terminals of the servo amplifier.
3 To use a separate regenerative discharge unit, connect it between the RC and RE terminals. -
4 To use a separate regenerative discharge unit, connect the power pins of the cooling fan of the unit to these
terminals.
- 202 -
TYPe LED indication Description

Overvoltage alann This alann is issued when the DC voltage of the main circuit power supply unit is abnor-
(HV) mallyhigh.
I
Control power supply This alann is issued when the control power supply voltage is abnormally low.
undervoltage alarm
(LV)
2
DC link undervoltage This alarm is issued when the DC voltage of the main circuit power supply unit is abnor-
~
alarm (LVDC) mally low. This alann is also issued when the circuit breaker has tripped.
Regenerative control
circuit abnormality
alarm (DCSW) y This alarm is issued in any of the following cases:
- When a very high regenerative discharge energy is output in a short tine
- When the regenerative discharge circuit is faulty
Excessive regenera- This alarm is issued in any of the following cases:

tive discharge alarm
(DCOH)
5 -When the average regenerative discharge energy is too high (for example, when the
frequency of acceleration/deceleration is too high)
-When a connected transformer is overheated
Dynamic brake circuit This alarm is issued when the relay contact for the dynamic brake has melted.
abnormality alarm
(DBRLY)
b
- 203 -
TYPe LED indication Description

L-axis overcurrent This alarm is issued when an abnormally high current flows through the motor of the
alarm (HCL)
B L-axis.
M-axis overcurrent This alarm is issued when an abnormally high current flows through the motor of the
alarm (HCM)
g M-axis.
UM-axis overcurrent This alarm is issued when an abnormally high current flows through the motors of the
alarm (HCLM)
b L-axis and M-axis.
L-axis IPM alarm This alarm is issued when the intelligent power module (IPM) of the L-axis detects an
(IPML)
B• alarm.("1)
M-axis IPM alarm This alarm is issued when the intelligent power module (IPM) of the M-axis detects an
(IPMM)
g alarm.("1)
LIM-axis IPM alarm

• This alarm is issued when the intelligent power modules (IPMs) of the L-axis and M-axis
(IPMLM)
b• detect an alarrn.("1)
Circuit breaker The circuit breaker is When an abnormal. current exceeding the operating current of the circuit breaker flows,
set to off. the circuit breaker trips.
NOTE
1 The alarms detected by the IPM include:
Overcurrent
- Overheat
- Decrease in IPM control power supply voltage
2 When the circuit breaker of the servo amplifier is set to off,
the DC link undervoltage alarm (LVDC) is issued.
In the normal operating mode, the seven-segment LED on the front of the
servo amplifier provides the indications below.
TYPe LED Indication Description
Amplifier not ready This indicates that the servo amplifier is not ready to drive the motor.
-
Amplifier ready This indicates that the servo amplifier is ready to drive the motor.
- 204 -
6. SEITING AND ADJUSTING

B-80525E-1/03 MAINTENANCE THE POWER SUPPLY
6
SETTING AND ADJUSTING THE POWER SUPPLY
The power supply is factory-set for operation. Usually, ~e user need not
set or adjust it.
This chapter describes settings and adjustment required if a defective
power supply unit is replaced.
- 205 -
6. SETTING AND ADJUSTING

THE POWER SUPPLY MAINTENANCE EHJ0525E-1/03
6.1
BLOCK DIAGRAM OF
THE POWER SUPPLY
E-STOP
TRANSFORJER UNIT SERVO AMPLIFIER
SUPPLY VOLTAGE TO THE TRANSFORMER
ROBOT
+24E +5V
+24V +15V -15V +5V
+24E IIO UNIT
+5V
TEACH PENDANT
+24V
1-W>> >
<"<t"<l"IO>IO +24V OPERATOR'S BOX
ID C\I C\1-IO-
> ++++ t
/PANEL
Flg.6.1 (a) Block Diagram of the Power Supply

(ARC Mate 100, ARC Mate 120, ARC Mate 100i, ARC Mate 120i, 8-6, S-12, M-6i, M-16i, s-420i, $-500, S-700,
M-71 Oi, A-520i)
- 206 -

B--80525E-1 /03 MAINTENANCE THE POWER SUPPLY
DELAYED-OFF
REDANDANT
TRANSFPRMER MCC UNIT
SERVO AMPLIFIER
POWER INPUT OF AC210V
220 TO 500VAC CIRCUITl
rljREAKERT
][ LAC2 IOV
ACIOOV
SUPPLY VOLTAAGE TO THE TRANSFORMER
A CX4
POWER SI.PPLY UNIT

,_, =--CPI h ROBOT
u
~ [ .-----L-
CP2
CP3 n
D
1-1
rl ~
-
MOTOR
+24E. +24V CP 5 h+24V

~
BRAKE
~ +15V,+5V CP 6 u PULSE
-15V ~ 0+24E BATTERY CODER
CP8 I I~
~
~VBAT
er
....... 0
I-
~
-ca=
PC BOARD FOR DERGENCY
CRM9 11
n
u
loc9ov
0 lJ._
w
~
w
CRR20 n
u
I JRF2 CRFI n+5V
L u
r-{ JRVI
MAIN CPU
PC BOARD
JRF2 -i+24E +5V
~
~IT
,__,_ JRVI n-15V +5V
,_ u
CRMIO h+24E
JDIA ll+5V
u
I/O UNIT
I
u TEACH PENDANT I
CRSI h+24V
u
PANE~
1--W>> >
JRMIO h+24V
<i: "<t"<tl.O>LO
CO C\J C\J - LO - u PRATOR'S
>++++I
Fig.6.1 (b) Block Diagram of the Power Supply (M-500, S-900)
- 207 -

THE POWER SUPPLY MAINTENANCE B-80525E-1 /03
DELAYED-OFF
REDANDANT
TRANSFPRMER MCC UNIT PSM SVM
POWER INPUT OF ] [ IAC2 I OV IO
220 TO 500VAC CIRCUITl IAC2 l OV C\I
lBREAKER'u------<.r-T ---Cl-=~ - a::
Q_ a::
I I ----0-lA""C'-'-1-"0""0_,__,V u u
L_J l ,J
SUPPLY VOLTAAGE TO THE TRANSFORMER .._--++-----1~ ex 1A
r CX4
.....__ ___,L cx2BQ-[ cx2A
POWER SUPPLY UNIT ROBOT

,__.. CPlnr---:======:::::----t-~
CP28t----ot ~
---=~
MOTOR
CP3n1-------======='~f---_J
~~+24V .------+-----1 BRAKE
~0+2 4 E BATTERY
:::: VBA T CP81~l------jl t---i
,.....
PC BOARD FCR EMERGENCY
STCP CONTROL
r-"~rlr
.-----to ~~
~w~D=C~9~0~V_ _ __._,__~ ~
CRR20i.,__ _ _ _~
w
I JRF2 CRF I h+5V

.---------lL>-- -ul--=-'----~
r-{ JRVI
MAIN CPU
PC BOARD
JRF21+24E +5V
_J
JRV I I - 15V +5V

_J
CRMIOl~+~2~4~E--------~ I/O UNIT

_J I
JDIAl~+~5~V------------~
w
CRSln~+~2~4~V------------~
TEACH PENDANT I
w
PANE~
t--W>> > JRMIOn~+~2~4~V _ _ _ _ _ _ _ _ _ _ _ _ _____,
<: '<t '<t IO > IO PRATOR'S
a:J C\I C\I -
IO -
>++++I w
Fig.6.1 (c) Block Diagram of the Power Supply (M-41 Oi)
_·_ 208 -

6.2
CONNECT THE TAP
ACCORDING TO THE
POWER SUPPLY
VOLTAGE
CONNECT THE TAP ACCORDING TO THE POWER SUPPLY VOLTAGE

A80L--0026-o014# A (ARC Mate 100,
ARC Mate 120, ARC Mate 1OOi, ARC
Mate 120i, 8-6, S-12, M-6i, M-16i,
$-420i, S-500, S-700, M-710i, A-520i) L IA o-:;.;il*-"":i~..-----.
A80L-0026-o014# C (M-41 Oi) L IB o-"'""'""'"--":...w..<.l<----<
INPUT VOLTAGE:440-500V
CONNECT THE CABLE FROM THE
CIRCUIT BREAKER TO SIDE A.
INPUT VOLTAGE:380-415V
CONNECT THE CABLE FROM THE
CIRCUIT BREAKER TO SIDE B.
Flg.6.2 Block Diagram of the Power Supply (i C&binat)
- 209 -

THE POWER SUPPLY MAINTENANCE B-80525E-1/03
6.3 (B cabinet/Main Transformer)

Connect the Taps so that the supply voltage range from +10% to -15%
SELECTING of tap voltage.
TRANSFORMER
Primary tap Connecting
TAPS Supply voltage
L1 L2 L3 Jumper type
220 5 10 15
19-20,21-22,23--24 !::::.
380 5 10 15
415 4 9 14
460 3 8 13
16-17-18 y
480 2 7 12
500 1 6 11
+ + + L::.Y _,, I
_i
500VA
480VA --,,
• ~ ~ ii
460VA -A
415VA
220VA/380VA -..
~
~~~~g~~~~;i~~ t<.
lglglglgl~glglglgl~glgl - ..
500VB --,
480VB I
460VB "
415VB
220VB/380VB '
.
+
-i~~~J~~-1~~=1~~~~ +
500VC "::~
480VC ....
_ 11
-
-I
I
lglglglglglglglglglglglglglglgl 460VC - A
415VC
220VC/380VC '" -- I
-I
IA·~~
~~~~ ~~ °' It<.
EEOVA
ova - , 7 .. I
l~lglglglglglgl
ovc
0 0 0 0 OVA
Tl T2 T3 220Va 0. ' - 1 -
L.LJ LJ LJ LJ ova
220VC ''
ovc
220VA 0. ~
+ + + -;!;-
Flg.6.3 (a) Selecting transfonner taps (B cabinet/Main Transformer)
- 210-

(B cabinet/Additional Transformer)
Connect the Taps so that the supply voltage range from +10% to -15%
of tap voltage.
Primary tap Connecting
Supply voltage
L1 L2 L3 Jumper type
220 5 10 15
16-17, 18-19,20-21 6
380 5 10 15
415 4 9 14
460 3 8 13
16-18-20 y
480 2 7 12
500 1 6 11
6Y _,,
_i
I
500VA
480VA --.
-.
460VA -A
415VA
220VA/380VA
500VB -,- &..
480VB c ...
460VB c<I
415VB c
220VB/380VB
~ I I
_!
-- .
500VC ':TTI:f
480VC
460VC
.,,~ I
415VC
220VC/380VC "' I
~1
11 11 . , . . , .... I
.I !I
-1-1 ..1. ~ .1 ~I ·I ·~ =I !!I t!I :!~ !I !1 ~1 !!1 !I 1 •I
11 y -- OVA
220VB 0-
OVB
•
-
~
0
220VC
ovc -
220VA 0- '--
IBIBIBIBIBIBIBIBIBIBIBIBIBIBIBIBIBIBIBIBIBI ..i.- o------------4
Fig.6.3 (b) Selectlng transformer taps (B cabinet/Additional Transformer)
- 211 -
6. SETIING AND ADJUSTING

6.4 •Checking the voltage

CHECKING THE When replacing the transformer, check the voltage at the points marked
in the figure below. When checking the voltage, do not touch the
TRANSFORMER
components.
A high voltage is applied to transformer.
CD Across Tl and T2, T2 and T3, T3 and Tl of breaker

(210VAC for servo amplifier)
® Across 30 and 32 of terminal (210VAC for the control unit)
@ Across 25 and 27 of terminal (lOOVAC for servo amplifier)
TRANSFORMER
+ +
+ +
Flg.6.4 (a) Checking the transformer (Main Transformer)
- 212 -

• Checking the voltage

When replacing the transformer, check the voltage at the points marked
in the figure below. When checking the voltage, do not touch the
components.
A high voltage is applied to transformer.
CD Across Tl and T2, T2 and T3, T3 and Tl of terminal
(210VAC for servo amplifier)
® Across 25 and 27 of terminal (210VAC for the control unit)
@ Across 22 and 23 of terminal (lOOVAC for servo amplifier)
@ i i ~i ~- "'N ....,
0
gig~
- -
i , ~
{V§,=
> 2a- ;;g
t- t-
I- ..........
I~ I~
I
•mn1u1ug11•ma1ag
I II i~H II~
11 11 11 "220V
 ...
c ~ -1 -; -~ -; -~ -~ -~ -~ -~ ~ ~ ..
@
0
[; Q Q ~g Q Q Q Q Q Q Q Q Q Q Q Q Q Q Q
3 2 I
Fig.6.4 (b) Checking the transformer (B cabinet/Additional Transformer)
- 213 -

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

CHECKING THE
Table 6.5 Rating of the Power Supply Unit
POWER SUPPLY
UNIT Maximum
Output Rated voltage Tolerance Remarks
rated current
+5V +5V ±3% 25.6A
+15V +15V ±5% 0.5A
-15V -15V ±5% 0.?A
+24V +24V ±10% 2.0A
+24E +24E ±10% 2.5A

Power supply unit: A16B-1212-0871
Figs. 6.5(a) and 6.5(b) show the interface and block diagram of the power
supply unit respectively.
- 214 -
CPI I
iI.!.
m
l~IUlJ ~
CP7
. 0
l+l
I •• Ii--
::::.:i .: l
~E.il I
r=- lr-..IC!..
I.... lt:j
Fl~B
r CP2
CP3
CBl-63)
(Al-A3)
1 lj..-~!~~ 57
~~ li.'iil ., ,
!i~
ir~
U~
I :: I :~ I ::
:!!
'; : :( I c9M I 50 I~~ p
L
D
7.5Afusefor
AC Input ~
L
D I/ I I I A1 A2 A3
en
ii'
a
......
1111
•
•
96 '-
•
r
..- '-,
,___
c '-: J 36
'+B\7' -' •
95 c ..- :_, ::i . ., 35
,_qy_, _, ·
'-l.
..., •
rim·
1• i
i
1rim·!
~
,t:tj
.)
R2
CP8
S2 G2
i
n
83
82
...1... 23
22
Battery cover L.: t.:..,,..
2 I
~
-
1111 81 21 Batte Z
N 9, 80 20 ry BAT- BAT+ ~
ti: ;. 79 I9 PIL . Z
1111 78 18 . )>
.,, 77 17 Green LED for z
o 76 16 indicating the AC CP4 ~
I ~~ :~ power supply status ... 81 82 83
en
c 73
72
13
12 ALM:
-=o
r.;~- _,/""' AL FA F8
:g
~
7I
~~
II
190 \
Red LED for
indicating an alarm I 1~~•
r• .•-•
1 AI A2 A3
fi
:::i 68 8 ON OFF COM
UlJJl
;:;: 67 7
~~
64
63
~T
~
_,_ov
AT~T+
~ ~
3
T
4 r:noT. F4
·
5Afusefor+24E
cP5
CP6
CBl-83)
CAl-A3> -I~
m
-1
!'>
0 I• • L <==I 8I 82 83 ffi G>

F3: +24V OV "'C)>
SA fuse for +24V - o Z
(Slow blow) (After the battery
cover is for removed)
I I I I
AI A2 A3 ::IE C
m ~
+24E OV JJ c..
enc:
c:cn
"'C .....
"'C
!:( G>
z
!'>
-I(/)
:i: m
m~
BLOCK
DIAGRAM ~-----r--L:::===~~
I r
AC
OUTPUT
•
+24E
+24V
+24E I~
~)>
(3
:::0 z
(J)O
I
:i +24V C)>
+15V
ov
:gE
~~
-I
R
I I I -15V z
!!
cc
I ffif I I G>
Oi
C.n s IB~ Li_,,, J DC
..-. L._J L _J
OUTPUT
~
m IG l L ±5? I L I
~------------+5V
[
~
c I AC INPUT
iii'
cc --f-'~ s:
)>
z
--
N
O'I
ii;
3
0
.:::s'...
ID L -- - - - - - - --
HI
TEST
AL ~4V
I MA5V
9 ~----BAT+
'!'..___(----BAT-
-I
m
z
)>
z
()
- - - - - - _I _J I I m
"ti
--, LO
i... I
en
c I H2 1
'ti I I
'2.
'< I ON__J
c: t I I
::I
;::;:
I COM I -EN
_J
-------, - OFF
H 11
I
I
CONNECTION TEST
HI TEST LO LEVEL +- I
0 ~ +4 5V I
i
0 0 0 +5.0V
~ 0 +5 5V
I L _______ _
L ____ _
T
0
(,)
B-80525E-1 /03 MAINTENANCE 7. REPLACING A UNIT
7
REPLACING A UNIT
In the case of the i-cabinet, the top covers can be removed from the
cabinet. Removing the top covers facilitates the replacement of units
during maintenance. The top covers are removed as follows:
•Front top cover

CD Loosen the screws and remove the side brackets which secure the top
covers.
® Open the door, then loosen the screws which secure the front top
cover (these screws are only finger-tight and do not require the use of
a tool to remove them).
@ Remove the front top cover.
CD
- 217 -
7. REPLACING A UNIT MAINTENANCE B-80525E-1/03
•Rear top cover

CD Loosen the screws and remove the side brackets which secure the top
covers.
® Loosen the knurled screws and remove the rear louver.
@ Loosen the three knurled screws which secure the rear top cover.
© Remove the rear top cover.
CD
©
//
®
- 218 -
7.1 When replacing a printed circuit board, take the following precautions:
REPLACING A (a) Before starting replacement, check that the power of the
controller is locked and tagged out.
PRINTED CIRCUIT
(b) When removing the printed circuit board, do not touch
BOARD semiconductor components on it and do not let the components
touch other components.
(c) Check that the printed circuit board to be installed is correctly set
and adjusted.
(d) If required, correctly adjust the printed circuit board after
replacement.
(e) When replacing the backplane printed circuit board, power
supply unit, or main CPU printed circuit board (including the
modules), the parameters and data specified for the robot may be
lost. Before starting replacement, store the data in a storage
device such as the FANUC Handy File.
(f) Connect the cables removed for replacement to the original
positions. If the markings are complicated, write them down
before removing the cables.
AcAUTION
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 before proceeding.
AcAUTION
When either the power supply or main CPU printed circuit
boards are removed from the controller.the data storage
battery is disconnected. All boards must be reinstalled properly
within half an hour to avoid data loss.
7.1.1 Ordering codes:

Replacing the A05B-2316-C105 (3-slot backplane printed circuit board)
AOSB-2316-C 107 (2-slot backplane printed circuit board)
Backplane Printed AOSB-2316-Clll (5-slot backplane printed circuit board)
Circuit Board
(a) When replacing the backplane printed circuit board, remove the
entire rack. Remove the power supply unit and printed circuit
board following the procedure described in Section 7.1.2.
(b) Remove the ground cable from the backplane printed circuit
board.
(c) Loosen the two screws fastening the rack at the top. Then remove
the two screws fastening the rack at the bottom and replace the
rack.
-219 -
7. REPLACING A UNIT MAINTENANCE B-8052SE-1/03
( "t) )
Nuts or screws (depending on the cabinet)
i cabinet MS nuts A30L-0010-0050#MS

B cabinet MS screws A6-SW2NA-5X12S
Fig.7.1.1 Replacing the Backplane Printed Circuit Board
- 220 -
7.1.2
Replacing the Power (a) Turn the power off and remove the cable from the power supply
Supply Unit or a unit or printed circuit board to be replaced.
Printed Circuit Board (b) Hold the handles at the top and bottom of the front panel of the
on the Backplane power supply unit or printed circuit board. The latches of the
control unit rack are released. Holding the handles in this state,
Printed Circuit Board pull out the unit or printed circuit board.
(c) Insert a new power supply unit or printed circuit board into the
slot of the control unit rack. Carefully push it into the slot until
the front panel is latched at the top and bottom.
Name Ordering code

Power supply unit A16B-1212-0871 (NOTE)
Main CPU printed circuit board A168-3200-0042
Process input/output printed circuit
A16B-2201-0470,0472,0480
board
NOTE
In case of exchange the power supply unit, it should be
used edition after 1OC to comply with EMC standard.
Main CPU printed circuit board (NOTE 1)

Power supply unit (NOTE 2)
Precess input/output printed circuit board CA,
CB or DA
Fig.7.1.2 Replacing the Power Supply Unit and Printed Circuit Board on the Backplane Printed Circuit Board
- 221 -
7.1.3 Specification : A16B-3200-0230

Replacing the (a) Open the operation box door, then disconnect the cables from the
process UO EA process 1/0 printed circuit board.
printed circuit board (b) Remove the two MS nuts which secure the process 1/0 printed
circuit board, then replace the board.
M5nut(x2)
A30L-0010-0050#M5
- 222 -
7.2
REPLACING A (1) Move the latches at both ends of the module socket toward the
outside. The spring of the contact tilts the module. (See Fig. 7.2 (a).)
MODULE
(2) If the tilted module touches the next module, it may be difficult to
remove it. In this case, release the latches of the next module as
described in step (1) above.
(3) Now the module is free in the socket. Pull out the module carefully
in a straight line. Do not pull it out in an arc. The contact of the socket
or module may be damaged.
(4) Install a new module in the socket at an angle. Push it into the socket
until the bottom of the module reaches the bottom of the socket
groove. (See Fig. 7.2 (b).)
(5) Push the module in the top edge so that the module stands upright.
(See Fig. 7.2 (c).)
(6) Check that the module is latched properly at both ends of the socket.
If it is insufficiently latched, the electrical contact may be improper
and a malfunction may occur.
Fig.7.2 (a)
Pin 1
Fig.7.2 (b)
- 223 -
Fig.7.2 (c)
Mounting locations of the modules
Mounting position of module
0 0
>
SPI g;
o~
D
0
~
~
I
CMOS RAM MODULE
FLASH ROM MODULE DRAM MODULE
11I
910
AXIS MODULE ( J I , J2) I
~
AXIS MODULE(J3,J4) I
DV2 11
DVI
AXIS MODULE(J5,J6) ~- I
~~QI
0 ICJI 0 0
0
0
D 0
0
0
0
Main CPU PC BOARD

Fig.7.2 (d) Mounting position of modules
Name Ordering Code
Axis module A20B-2902--0060

A20B-2902--0070
Rash ROM module A20B-2902--0370
A208-2902--0371
A20B-2902--0372
A20B-2902--0373
DRAM module A20B-2902--0021
A20B-2902--0020orA20B-2902--0531
A20B-2900-0650orA20B-2902--0530
CMOS module A20B-2902--0211
A20B-2902--0210
A20B-2902--0380
- 224 -
B-80525E-1/03 MAINTENANCE 7. REPLACING A UNIT
7.3 Ordering code : A05B-2350-C010

REPLACING THE (a) Remove the cable from the E-stop unit.
E-STOP UNIT (b) Remove the 2 screws fastening the E-stop unit, and replace the
E-stop unit.
M5 SCREW(2 PIECES)
Fig.7.3 Replacing the E-stop unit
- 225 -
7.4 Ordering code: Al6B-1212-0930

(ARC Mate 100, ARC Mate 120, ARC Mate lOOi, ARC
REPLACING THE Mate 120i, S-6, S-12, M-6i, M-16i, S-420i, S-500,
EMG PCB S-700, M-710i, A-520i)
(B-CABINET) A16B-1212-0931 (S-800, M-500, M-4101)
(a) Remove the cable from EMO PCB.
(b) Remove the 2 screws fastening the EMO PCB, and replace the
EMO PCB.
M5 SCREW(2 PIECES)
REPLACING THE EMG PCB

(8-CABINET)
- 226 -
7.5 Ordering code: A16B-1212--0931

REPLACING THE (a) Remove the cable from EMG PCB.
EMG PCB (M-4101) (b) Remove the 2 screws fastening the EMG PCB, and replace the
EMGPCB.
·~M5 SCREW(2 PIECES)
REPLACING THE EMG PCB

(M-410i)
- 227 -
7.6 To replace the distributed 1/0 (Model B) interface unit, perform the
following steps:
REPLACING THE 1/0
UNIT MODEL B Ill Unplug the cables from the upper left comer of the interface module.
INTERFACE UNIT (2J Unplug the cables from the bracket of the interface module adapter
plate.
ill] Remove the nuts holding the interface module adapter plate to the
controller wall and remove the plate from the controller.
@] Disconnect the wiring harness from the interface unit. If
necessary.mark the wires so that they can be connected to the new
unit in the proper places.
[5] Remove the nuts holding the interface module to the adapter plate
and remove the module from the plate.
[6] Install the new interface module by performing these steps in reverse
order.
Mounting location of 110 unit model B interface unit
(i cabinet)
rn=~~~~~~~~
~~~~~~~~
Mounting hole
g ~~~~~~~~
110 unit model B interface unit

(with metal mounting plate)
Fig.7.6(a) Replacing 1/0 unit MODEL B Interface Unit
- 228 -
1/0 unit model B

interface unit
Mounting location of 1/0 unit model B (B-cabinet)
1/0 unit model B

interface unit
1/0 unit model B

basic unit
Mounting location of 1/0 unit model B (Cabinet for M-41 Oi)
Fig.7.6(b) Replacing 110 unit MODEL B Interface Unit
- 229 -
7.7
REPLACING THE
INPUT/OUTPUT UNIT
OF MODEL A
7.7.1
Replacing the Base IIl Remove the 1/0 modules from the base unit.
Unit of the 111 Loosen the upper two mounting screws.
Input/Output Unit of
Lal Remove the lower two mounting screws and replace the base unit.
Model A
Ordering code: A03B-0807-J002
M4 screw (4 pieces)
Fig.7.7.1 Replacing the Base Unit of the Input/Output Unit of Model A
- 230 -
7.7.2 An interface module and input/output module can be easily installed in

and removed from the base unit, as described below.
Replacing a Module
Removing the Interface
Module rn Turn off and lock out the controller.
[2] Disconnect the signal and power cables from the interface module.
[J] Press the latch on the bottom of the module and rotate the module
· toward you and up.
Installing the Interface

Module rn Turn off and lock out the controller.
[2] Engage the hook at the top rear of the module with the bar above the
base unit socket.
[J] Rotate the module downward until the latch engages.
@) Reconnect the signal and power cables to the interface module.
Removing an 1/0 Module

rn Turn off and lock out the controller.
[2] Remove the wiring harness block.(See Fig.7.7.2.)
(a) Lift the latch at the lower left comer of the module window.
(b) Rotate the block toward you and down.
[J] press the latch on the bottom of the module and rotate the module
toward you and up.(See Fig.7.7.2.)
Installing an 1/0 Module

rn Turn off and lock out the controller.
[2] Engage the hook at the top read of the module with the bar above the
base unit socket.
[3] Rotate the module downward until the latch engages .
0
...---
Flg.7.7.2 Replacing the module
- 231 -
7.8 To remove a distributed 1/0 (Model B) unit mounted on a DIN

rail,perform the following steps:
MOUNTING 1/0 UNIT
MODEL B ON THE
DIN RAIL (USE A RAIL
THAT IS 3.5MM WIDE
AND 7.5MM HIGH.)
7.8.1
The Din Rail is in the III Disconnect the wiring harness from the unit. If necessary.mark the
Operator's Box. wires so that they can be connected to the new unit in the proper
places.
III Remove the screws holding the retainer plates to the unit and remove
the retainer plates.
[J] Slide the unit upward and lift it out of the DIN rail.
Metal support for direct installation

DIN rail or installation on the DIN rail
(b)
Basic unit
\__ Metal support for installation on the DIN rail __/
To install a distributed I/O(Model B)unit mounted on a DIN rail,perform

the following steps:
III Hook the lower tabs of the 1/0 unit mounting brackets over the lower
lip of the DIN rail.
111 Lay the 1/0 unit in the DIN rail.
[J] Slide the 1/0 unit downward. The upper tabs of the mounting
brackets will engage the upper lip of the DIN rail.
[4] Position the retainer plates over the mounting brackets and install the
screws.
[fil Reconnect the wiring harness.
- 232 -
7.9 (i cabine)
Ordering code
REPLACING THE
power supply
TRANSFORMER voltage
Ordering code Robot
ARC Mate 100, ARC Mate
120, ARC Mate 1OOi, ARC
380 to 415 Mate 120i, 8-6, S-12,
A80L-0026-0014#A M-6i, M-16i, 8-420i,
440 to 500
S-500, S-700, M-710i,
A-520i
380 to 415 M-410i
A80L-0026-0014#C
440 to 500
[I] Lock out and tag out power to the robot.

[2] Disconnect the cables connecting the controller to the robot.
[ill Remove the controller cabinet from the robot using the quick change
procedure described in Section 4.10.
AWARNING
Support the front module of the controller before disengaging
the latches. Otherwise.the module could fall and injure
personnel and damage equipment.
@I Remove the front module of the controller by disengaging the four

latches.
[fil Disconnect the cable from the voltage setting tap.
IBJ Remove the voltage setting tap and its plate from the cabinet.
Ill Remove the nuts securing the transformer.
!ID Remove the transformer.
TRANSFORMER
MOUNTING LOCATION OF TRANSFORMER
VOLTAGE SETTING TAP

M6 NUT AND GROUND.WASHER
M6 NUT
- 233 -
(M-410i)
Ordering code: A08L-0026-0014#C
(a) Remove the 4 bolts, and remove the transformer cover.
(b) Remove the 3 bolts, and remove the cable cover.
(c) Remove the transformer cable.
(d) Remove the 4 bolts fastening the transformer, and replace the
transformer.
M5 BOLT M6 BOLTS
(2 PIECES)
TRANSFORMER CABLE
M6 BOLTS
(4 PIECES)
,
___...,
_J
' M6 BOLTS
' {4 PIECES)
CABLE COVER
TRANSFORMER
TRANSFORMER COVER
- 234 -
(B cabinet)
[II Tum off and lock out the controller.
[2J Remove the acrylic covers from the transformer and ALC relay.
[J] Disconnect the wiring harnesses and ground wire from the
transformer.
@] Disconnect the three wires from the bottom of the ALC relay.
!ID After removing the eight screws fastening the transformer,remove
the transformer. Put a new transformer on the rail in the controller and
push it into the controller along the rail. Then reinstall the screws.
IID Reconnect the wires and harnesses.
III Reinstall the acrylic covers.
Fig.7.9 Replacing the Transformer
Ordering code
Power supply Ordering code Robot
vottage
500,480 $--420i, 8-500
460,415 ABOL-0026--0010#8 M-500, M-710i,
380,220 M-410i
ARC Mate 100,

500,480 ARC Mate 120,
ARC Mate 120i,
460,415 A80L-0024-0Q10#B $-6, S-12, M-16i,
380,220 S-700, A-520i,
ARC Mate 1OOi, M-6i
500,480 ABOL-0026--0010#8
460,415 (Main cabinet) S-900
A80L-0024-0Q11#B
380,220 (Additional cabinet)
- 235 -
7.10 For ARC Mate 100, ARC Mate 120, ARC Mate lOOi, ARC Mate 120i,
S-6, S-12, M--6i, M-16i, S-420i, S-500, S-700, M-710i, A-520i
REPLACING A Ordering code : A06B--6076--C001 to COOS or A06B--6076--C101 to
SERVO AMPLIFIER C106
[j] Disconnect all wires,cables,and harnesses from the servo amplifier.
If necessary,mark each wire,cable,and harness so that it can be
correctly connected to the new servo amplifier when it is installed.
[2:) Remove the four mounting nuts from the servo amplifier.
CTI Lift the servo amplifier off of the studs and out of the cabinet.
FERRITE CORECX2)
9~
0 0
0 0
0 0
0 0
0 0
0 0
0
0
LD
ARC Mate100, $-6 A06B-6076-C005 or A06B-6076-C105
ARC Mate120, S-12,
A06B-6076-C004 or A06B-6076-C104
ARC Mate 120i, M-16i
S-420i A06B-6076-C001 or A06B-6076-C101
8-500, A-520i A06B-6076-C002orA06B-6076-C102
S-700 A06B-6076-C003orA06B-6076-C103
- 236 -
ARC Mate 100i, ~i A06B-6076-C105
M-710i A06B-6076-C106
If optical isolation unit is not mounted to operator's box, servo amplifier
can be used only A06B-6076--C101 to C106.
a series amplifier (for the M-410i)
rn Disconnect all wires,cables,and harnesses from the servo amplifier.
If necessary,mark each wire,cable,and harness so that it can be
[21 Remove the mounting screws from the servo amplifier.
raJ Remove the servo amplifier from the cabinet.
1
-ace
Power supply module Servo module (1) Servo module (2)
Power supply module

Robot model Drawing No.
M-410i A06B-6087-C115
Servo module ( 1)
M-410i A06B-6079-C106
Servo module (2)

M-410i A06B-6079-C103
237
cseries amplifier (for the S-900, M-500)

[I) Disconnect all wires,cables,and harnesses from the servo amplifier.
If necessary,mark each wire,cable,and ·harness so that it can be
III Remove the mounting screws from the servo amplifier.
[ID Remove the servo amplifier from the cabinet.
/ /
ef
/ ef
/
A06B-6089-C106
A06B-6089-C105
A06B-6089-C104
- 238 -
7.11 (i-cabinet)
Ordering code: A040L--0001-0407
REPLACING THE
DISCHARGE (a) Remove the cable from the terminal block.
RESISTOR UNIT (b) Remove the screws fastening the discharge resistor unit, and
replace the discharge resistor unit.
--7
7 /
/
/
Terminal block
M5
M5 Nuts(2pieces)
ljL,...~~~~~~Discharge resister
Fig.7.11 (a) Replacing the discharge resistor unit (I-cabinet)
- 239 -
(B-<:abinet: ARC Mate 100, ARC Mate 120, ARC Mate lOOi, ARC Mate
120i, S-6, S-12, M-6i, M-16i, S-420i, S-500, S-700, M-710i, A-520i)
Ordering code : A40L-0001-0407
(a) Remove the 4 screws fastening the plate, and remove the plate.
(b) Remove the cable from the discharge resistor.
(c) Remove the 8 screws fastening the discharge resistor, and replace
the discharge resistor.
M4 SCREW(8 PIECES)
DISCHARGE RESISTOR
A40L-OOOl-0407
PLATE
,,
~""M4 SCREW(4 PIECES)
Ftg.7.11 (b) Replacing the discharge resistor unit
(ARC Mate 100, ARC Mate 120, ARC Mate 100i, ARC Mate 120i, &-6, S-12, M-6i, M-16i, $-420i, 8-500, S-700,
M-710i, A-520i)
-240-
B-ao525E-1/03 MAINTENANCE 7. REPLACING A UNIT
(S-900)
Ordering code: A05B-2313-C102
(a) Remove the cable from E-stop unit and discharge unit.
(b) Remove the 4 screws fastening the E-syop unit.
Remove the 6 screws fastening the discharge unit, and replace the
discharge unit.
E-STOP
-STOP UNIT
M4 SCREW(6 PIECES)
SCREW(4 PIECES)
Flg.7.11 (c) Replacing the discharge resistor unit (Additional cabinet 2 for 8-900)
-241 -
(M-500)
Ordering code : AOSB-231~102
(a) Remove the cable from the discharge unit.

(b) Remove the 6 screws fastening the discharge unit, and replace the
discharge unit.
\ M4 SCREW(6 PIECES)
Fig.7.11 (d) Replacing the discharge resistor unit (Additional cabinet for M-500)
- 242 -
7.12 Ordering code : A05B-2350--C032, C033, C036

REPLACING THE (a) Open the door of the operator box and remove the clamp plate
from the cable inlet. (two M4 screws)
OPERATOR'S BOX
(b) Disconnect all cables from the operator box and replace the
operator box.
(c) To replace only the operator box printed circuit board, replace it
together with its mounting plate.
(d) Disconnect the cable from the operator box printed circuit board,
remove the four nuts securing the metal plate, then replace the
operator box printed circuit board.
Table Operator's Box
Specifications Indications in Remarks
A058-2350-C032 English ARC Mate 100, ARC Mate 120, ARC Mate
120i, S-6, S-12, M-t6i, 5-420i, S-500,
S-700, A-520i
With optical isolation unit.
A058-2350--C033 English M-41 Oi Without optical isolation unit.
A058-2350--C036 English ARC Mate 100, ARC Mate 120, ARC Mate
120i, S-6, S-12, M-16i, 5-420i, S-500,
S-700, A-520i, M-410i, M-6i, M-710i
Wrth noise filter.
A05B-2350--C039 English ARC Mate 1OOi
Wrth noise filter.
/ OPERATOR'S BOX
(A05B-2350-C033, C036, C039)
•
~ M5A30L-OOI0-0050#M5
NUTS(4 PIECES)
OPERATOR'S BOX PC BOARD
A20B-1006-0740
- 243 -
Replacing the operator's panel

(a) Remove the cable from the operator panel.
(b) Remove the six nuts fastening the operator panel and replace the
operator's panel.
(c) When replacing only the operator panel printed circuit board,
replace it together with the metal plate.
(d) After removing the cable from the operator panel printed circuit
board, remove the four nuts fastening the metal plate. Then
replace the operator's panel printed circuit board.
OPERATOR'S PANEL(BACK SIDE)
OPERATOR'S PANEL PC BOARD M5 NUTS(4 PIECES)

A20B-1006-0741 A30L-OOI0-0050#M5
- 244 -
7.13 Ordering code: A05B-2350-D020

REPLACING THE (a) Remove the cable from mode selection switch.
MODE SELECTION (b) Remove the 6 screws fastening the switch plate, and replace the
mode selection switch.
SWITCH
(OPERATOR'S BOX)
D
1--- ~
~
I •
0 -
0
DJ
o ..
DJ
/
/ -ti
.........
@
0
/
/
rn ~
fj)
"
\ M4 SCREW(6 PIECES)
Fig.7.13 (a) Replacing the mode selection switch {Operator's box)
- 245 -
(B-cabinet)
(a) Remove the cable from mode selection switch.
(b) Remove the 2 nuts fastening switch plate, and replace the mode
selection switch.
M5 NUTS(2 PIECES)
Flg.7.13 (b) Replacing the mode selection switch (Operator's box)
-246-
7.14 Ordering code: A55L-0001-0195#KP791 (Switch)

A55L-0001-0195#KY (Key)
REPLACING THE
DOOR INTERLOCK (a) Remove the cable from the door interlock switch.
(b) Remove the screws fastening the door interlock switch or key,
and replace the switch or key.
M5 Screw(2pieces)
A6-SW2NA-5X12S
(--Door interlock switch
M4 Screw{2pieces)
Key A6-SW2NA-4X30S
M5 Nu t ( 2 p i e c e s )
A30L-0010-0050#M5
Flg.7.14 Replacing the door interlock
- 247 -
7.15 Ordering code: A?OL-0001-056#50

REPLACING THE (a) Remove the 4 nuts fastening the cover, and remove the cover.
NOISE FILTER (b) Remove the cable from noise filter.
(OPERATOR'S BOX) (c) Remove the 4 nuts fastening the noise filter, and replace the noise
filter.
OPERATOR'S BOX
NOISE FILTER
COVER
·~
M5 NUTS(8 PIECES)
Fig.7.15 (a) Replacing the noise filter (Operator's box)
- 248 -
(B-cabinet)
Ordering code: A?OL-0001-056#50
(a) Remove the 4 screws fastening the cover, and remove the cover.
(b) Remove the cable from noise filter.
(c) Remove the 4 screws fastening the noise filter, slide the noise
filter to the left side, and replace the noise filter.
M4 SCREW
(4 PIECES
FOR COVER)
COVER
NOISE FILTER
~ ~
~M5 SCREW(4 PIECES.NOISE FILTER)

Rg.7.15 {b) Replacing the noise filter (B-Cablnet)
- 249 -
7. REPLACING A UNIT MAINTENANCE 8-80525E-1/03
7.16 Ordering code: See Table 7.16.

REPLACING THE After removing the cable from the teach pendant, replace the teach
pendant.
TEACH PENDANT
OD 0 0 0 DO
0000000
0080000
0000000
0000000
0000000
0000000
DODO
0000000
Fig.7.16 Replacing the Teach Pendant
Table 7.16 Ordering Code
Ordering code Use

A05B-2301-C330 Spot welding
A05B-2301-C331 Material handling
A05B-2301-C332 ARC welding
A05B-2301-C333 Sealing
A05B-2301-C335 General use
- 250 -
8-80525E-1 /03 MAINTENANCE 7. REPLACING A UNIT
NOTE) In case of exchange the teach pendant, it should be used

manufacture date after 1995 september to comply with EMC
standard.
TEACH PENDANT
TYPE A05B-230 I -C33*/
v Manufacture
da t e
NO. ND*** I 1995 09 I

I FANUC LTD - •• .WNI I
Teach pendant
0
0
- 251 -
7.17 (i-cabinet for ARC Mate 100, ARC Mate 120, ARC Mate lOOi, ARC
Mate 120i, S-6, S-12, M-6i, M-16i, S-420i, S-500, S-700, M-710i,
REPLACING THE A-520i)
E-STOP UNIT Ordering code: A05B-2350-C090
(a) Remove the cable from E-stop unit.
(b) Remove the 2 screws fastening the E-stop unit, and replace the
E-stop unit.
ti ti
~ M5 SCREW{2 PIECES)
Flg.7.17 (a) Replacing the E-stop unit
(i-cabinet for ARC Mate 100, ARC Mate 120, ARC Mate 100i, ARC Mate 120i, S-6, S-12, M-6i, M-16i, $-420i, $-500,
S-700, M-710i, A-520i)
- 252 -
(B-cabinet for ARC Mate 100, ARC Mate 120, ARC Mate lOOi, ARC
Mate 120i, S-6, S-12, M-6i, M-16i, S-420i, S-500, S-700, M-710i,
A-520i)
E-stop unit.
M5 SCREW(2 PIECES)
Fig.7.17 (b) Replacing the E-stop unit

(B-cabinet for ARC Mate 100, ARC Mate 120, ARC Mate 100i, ARC Mate 120i, s-&, S-12, M-6i, M-16i, s-420i,
$-500,S-700,M-710i,A-520i1
- 253 -
7. REPLACING A UNIT MAINTENANCE S-80525E-1/03
(S-900)
Ordering code: A05B-2302--C402 (1 unit)
E-stop unit.
E-STOP
I
,,
,,
M5 SCREW(2 PIECES FOR ONE UNIT)
Flg.7.17 (c) Replacing the E-stop unit (Additional cabinet 2 for 8-900)
- 254-
(M-4101)
E-stop unit.
fl fl
-----M4 SCREW(4 PIECES)
Flg.7.17 (d) Replacing the E-stop unit (M-410.')
- 255 -
(M-4 lOi B-cabinet)

E-stop unit.
" "---------- M4 SCREW(4 PIECES)

Fig.7.17 (e) Replacing the E-stop unit (M-410i EH:abinet)
- 256 -
B-a0525E-1/03 MAINTENANCE 7. REPLACING A UNIT
(M-500)
E-stop unit.
E-STOP UNIT
/
/
,-------------- M5 SCREW ( 2 PIECES l
Fig.7.17 (f) Replacing the E-stop unit (M-500)
- 257 -
7.18 Ordering code: A60L-0001-034l#AI

A60L-0001-0342#D (Handle)
REPLACING THE
BREAKER (a) Remove the cables from the break.er.
(b) Remove the screws fastening the break.er, and replace the break.er.
Handle
OPERATOR'S BOX
M4 Screw(4pieces)
Flg.7.18 (a) Replacing the breaker
- 258 -
(B-cabinet)
Ordering code: A60L-0001-0306#AA (Breaker: 20A)
A60L-0001-0306#BA (Breaker: 30A)
A60L-OOO 1-0310#20AA (Handle)
A60L-0001-0307#B20B3-N (Cover)
(a) Remove the cover and cable from breaker.
(b) Remove the 2 screws fastening the breaker, and replace the
breaker.
\
\ BREAKER
HANDLE
COVER
M4 SCREW(2 PIECES)
Fig.7.18 (b) Replacing the breaker (B-Cabinet)
- 259 -
7. REPLACING A UNIT MAINTENANCE B-80525E-1 /03
(M-410i)
Ordering code: A60L-0001-0306#AA (Breaker: 20A)
A60L-0001-0306#BA (Breaker: 30A)
A60L-OOO 1-0310#20AA (Handle)
A60L-0001-0307#B20B3-N (Cover)
(a) Remove the cover and cable from breaker.
(b) Remove the 2 screws fastening the breaker, and replace the
breaker.
-~
M4 SCREW(2 PIECES)
Fig.7.18 (c) Replacing the breaker (M-410.1
- 260 -
7.19 (S-900)
Ordering code: A05B-2313--C250
REPLACING THE
BREAKER UNIT (a) Remove the cable from the breaker unit.
(b) Remove the 2 screws fastening the breaker unit, and replace the
breaker unit.
M4 SCREW(2 PIECES)
(ADDITIONAL CABINET I)
Fig.7.19 Replacing the breaker unit
- 261 -
7.20 Ordering code: A05B-2350-C900 : door (inside of cabinet)

A05B-2350-C901: door (outside of cabinet)
REPLACING THE A05B-2350-C902 : real panel
FAN MOTOR OF THE
(a) Remove the cable of the fan unit.
CABINET
(b) Remove the screws (nuts) fastening the fan unit, and replace the
fan unit.
',"" M5 Nut(4pieces)
Fan unit
A05B-2350-C900
Fan unit
A05B-2350-C901
--
M3 Screw(4pieces)
Flg.7.20 {a) Replacing the fan motor of the cabinet
- 262 -
Fa n un i t ( 2 p i e ces ) F i n g e r gu a r d M5 S c r e w
A05B-2350-C902 (2pieces) (4pieces)
- 263 -
(B--cabinet/Main cabinet)
A05B-2302-C901
A05B-2302-C902
(a) Remove the cable from fan unit.
(b) Remove the 4 (2) screws fastening the fan unit, and replace the
fan unit.
M4 SCREW(2 PIECES)
M4 SCREW
oooaooooooooo (4 PIECES)
D \
A05B-2302-C900
A05B-2302-C902
SCREW(4 PIECES)
Fig.7.20 (b) Replacing the fan motor of the cabinet (B-cabinet/Main cabinet)
- 264 -
(B-cabinet/Additional cabinet)
A05B-2051-C905
(b) Remove the 4 nuts fastening the fan unit, and replace the fan unit.
A05B-2051-C905
M5 NUTS(4 PIECES)
•
•
A05B-2051-C904
• •
• ··--=---M5 NUTS ( 4 PIECES)
Fig.7.20 (c) Replacing the fan motor of the cabinet (B-cabinet/Additional cabinet)
- 265 -
(M-410i)
(b) Remove the 4 screws fastening the fan unit, and replace the fan
unit.
1111m1111111111~ 1111111111111111111 CD
G
FAN UNIT
A05B-2350-C901
/
/
M4 SCREW(4 PIECES) /
CD
FAN UNIT
Fig.7.20 (d) Replacing the fan motor of the cabinet (M-410i)
- 266 -
(M-410i)
A05B-2301-C902
(b) Remove the 4 screws (nuts) fastening the fan unit, and replace
the fan unit.
',"" M4 NUT
(4 PIECES)
FAN UNIT
A05B-2350-C903
FAN UNIT
A05B-2301-C902
M4 SCREW
(4 PIECES)
Fig.7.20 (e) Replacing the fan motor of the cabinet (M-410i)
- 267 -
(M-410i)
(a) Remove the 4 bolts, and remove the transformer cover.
(b) Remove the 3 bolts, and remove the cable cover.
(c) Remove the fan writ cable.
(d) Remove the 4 screws fastening the fan writ, and replace the fan
writ.
M5 BOLT M6 BOLTS
(2 PIECES)
FAN UNIT CABLE
---·
M6 BOLT
(4 PIECES)
CABLE COVER
"
/ TRANSFORMER
"
/ ~M4(4 SCREW
PIECES)
TRANSFORMER COVER
Fig.7.20 (f) Replacing the fan motor of the cabinet (M-410.")
- 268 -
7.21 Ordering code: A90L-0001-0378 (for a two-slot rack, one for one unit)
A90L-0001-0385#A(for a one-slot rack, two for one unit)
REPLACING THE
FAN MOTOR OF THE (1) Replace the control unit printed circuit board placed below the fan
motor to be replaced, following the procedure described in Section
CONTROL UNIT 7.1.2.
(2) The cable suspended from the fan motor is connected to the backplane
PC board which is mounted deep in the slot. Holding the connector,
remove the cable from the backplane printed circuit board.
(3) Open the lid at the top of the control unit rack. The lid can be opened
by placing the tip of a flat-blade screwdriver into the center hole at the
front of the lid and moving the screwdriver like a lever in the direction
of (3) in Fig. 7.16 to release the latch.
(4) Fully open the lid and take the fan motor out. As the fan motor is not
screwed to the rack, it can be removed easily.
(5) Install a new fan motor. Suspend the cable through the hole at the
back of the rack.
(6) Close the lid until it is latched.
(7) Connect the cable of the fan motor to the connector on the backplane
PC board. Suspend the center of the cable on the hook in the back of
the rack.
(8) Install the removed control unit printed circuit board following the
procedure described in Section 7 .1.2.
- 269 -
I
Fan motor I
I
I
Cab lei
I
l ,,. ,,.
Connect er
_,.
#,,. " I\
/
/
/
/
/
Back plane /
Fig.7.21 Replacing the Fan Motor
- 270 -
7.22
REPLACING A FUSE
7.22.1 FUSEl: For detecting a ground on the thermostat
Servo Amplifier Fl, F2 : For internal circuit of servo amplifier
Fuse No. Rated current Ordering code
FUSE1 0.3A A60L--0001--0175#0.3A
F1,F2 2A A60L--0001--0245#GP20
FUSEI
5\@]
5W@
3\@]
3W@
FUSE FUSE
Fl F2
- 271 -
Power suplly module

Fl: Fuse for AC input
F1 2A ASOL-0001-0245
F2 2A A60L-0001-GP20
7.22.2
Replacing fuses (1) Make sure that the recharge-under-way LED (red) is off.
The recharge-under-way LED (red) is at the center of terminal board
TB 1. Open the cover at the top of the module, and check the LED.
ForM-410i
TB1
~1 ----.I I
ForS--450
Recharge-under-way LED =
(2) Remove the face plate.
ForM-410i Face plate
~
t
/
D
D
Remove the face c
the~
plate by inserting
tip of a flat-blade
screwdriver at the c
hooks (six) on the
face plate.
c
/
-
- 272 -
ForM-450 Face plate
/
;;.
t
-
Remove the face
platebyinserting ~ c
CJ =
the tip of a
= ¢
flat-blade
screwdriver at c ¢
the hooks (four)
on the faceplate.
/
-
(3) Remove connector PCB.
ForM-410i
Remove the self-tapping screws holding down
connector PCB, and shift it inthe direction indicated
II with an arrow (left) to remove the printed-circuit

board.
Connector PCB
(4) Remove the case
ForM-410i
Screws (eight) Flange surface

\ I Remove the screws
(eight) fastening the
0 Fan cases, and remove the
c:::> case by pulling it off the
flange surface.
Heat
sink Case
- 273 -
Fors-450
w ~:~ -1 i.~~e~fM~.:1
Case 1 ~
(chassis)
~C case and the screws (5 x M4)

::::JC holding down the terminal board.
:=JC
(5) Replace the fuses according to the figure below.
F1 t=:i
I
Fig. 7.22.2 Locations of the Fuses
- 274 -
8-80525E-1 /03 MAINTENANCE 7. REPLACING A UNIT
Servo module
F2 : For control power supply
F2 3.2A A60L--0001--0290#LM32C
MlUD I
Fuse2
... [D]
.... llLJDI
.... llLJDI
$fl\11 llLJol
•!ID]
mllLJDI
•llLJDI
9' llLJDI
1
c::::::::J "' !ID]
- 275 -
7. REPLACING A UNIT MAINTENANCE EH30525E-1 /03
7.22.3 Fl : Fuse for AC input

Power Supply Unit F3 : Fuse for +24V
F4: Fuse for +24E
F1 7.SA A60L-0001-0245#GP75
F3 SA A60L-0001-0075#S.O
F4 SA A60L-0001-0046#S.0
PSU Bl
,~~ F1: 7.5A

fuse for AC input
S FlF 250V
7.5A
~=~~
6lft:ll""''""'"'"
=:If{;
7f.£ll"7~l,"C"'F~~·
i;~~l, "'C"Hl
..........
CAUTION
---
1.11111 .... &.m
PM11. lllllT .
F3 : 5AS (slow-blow)
fuse for +24V
F4:5A
fuse for +24E
Fig.7.22.3 Replacing a Fuse of the Power Supply Unit
- 276 -
Emergency stop control printed board

Fl : Fuse for brake power supply
F2 : Fuse for +23E
F1 SA A60L-0001-0046#5.0
F2 0.32A A60L-0001-0046#0.32
0 0 0
-
0
0
°'"Pi'
"'"Pi'
Al68-1212·09~
N
LL. Fuse2
...,
a::
Fuse1
DOD
DIJ DD
0 0
- 277 -
7.22.4 FUSE : 2.0-A fuse for +24V

Process Input/Output Ordering code : A60L-0001-0046#2.0
PC Boards CA, CB, DA
and EA
0 000
Fuse
Process input/output
PC boards CA, CB, and DA
Fig.7.22.4 Replacing the Fuse of the Process Input/Output PC Board CA,

CB, or DA
D~ DD
0 Fuse
D D
For process 1/0 printed circuit board EA
Specificalion: A60L-0001-0046#2.0
- 278 -
7.23 If used for a long time, a relay's contacts may fail to provide a satisfactory
connection or may weld together. If this occurs, replace the relay as
REPLACING A described below:
RELAY PC board for emergency stop control
RLY2 : To disconnect the MCC in the event of an emergency
stop
Ordering code : A58L-0001-0192#1509A
RLY6 : To disconnect the standby charging line in the event
of an emergency stop
Ordering code : A58L-0001--0422#3232K
Relay
0 CRRl5 0
0
) J
) I
-c:D- o~ CRR20
II
I-----'--'-----'--.
........
•
0
I")
0
I
"°
0
0
I
co
0 l"'j .q-
C\J l.J.... l.J....
<!'.'. Cl::: Cl:::
uu
0 CRM9 CRMI 10
Fig.7.23 PC board for emergency stop board
-279 -
7. REPLACING A UNIT MAINTENANCE B--80525E-1 /03
Emergency-stop control printed circuit board

RLl: Used for cutting off the reserved charging power (200 VAC)
upon an emergency stop
RL2: Used for cutting off MCC (200 VAC) upon an emergency stop
RL3: Used for cutting off the brake power (100 VAC) upon an
emergency stop
RL4, RL5, and RL6: Used for controlling the brake
Fuse No. Ordering code
RL1 A58L-0001-0422#3232K
RL2 A58L-0001-0192#1509A
RL3, RL4, RL5, A58L-0001-0192#1472R
RL6
0 0
0 0
0 ""'Pi'
-
A168-1212-0'JJllim
..,"-
<>: ..,><>:
""'Pi'
- 280 -
7.24 (i-cabinet)
Redundant E-stop unit
REDUNDANT
KA10,KA11,KA12,KA13,KA14
E-STOP UNIT
Ordering code: A58L--0001--0303#24S
Fig.7.24 {a) Redundant E-stop unit {i-cabinet)
- 281 -
(B-cabinet: ARC Mate 100, ARC Mate 120, ARC Mate lOOi, ARC Mate
120i, S-6, S-12, M-6i, M-16i, S-420i, S-500, S-700, M-710i, A-520i)
KA10,KA11,KA12
Ordering code: A58L-0001-0303#24S
~
I
--
®'v' VA@ @lfll @@ @@
- --
10 @ uo@ @I@ @@ @@
-I
0
0 0~
..... I I
10
- _J
0 I
ICAIO ICAll
flL flL fl I
I ( ) ( ) ( ) I
I ~ ~ ~
I
I I
I I
LU u u
I I
0
I I
0 I ©© D
,-;::::=.
I
$ $
I _J
$ $
I $ $
I ®•®
s•s
I $ $ I
®•@
I s•@ I
$ @
I ®•@
I s•s
$ @
I $
@
$
$
'-~
L $ $
0I 1©© $ $ I
D
,1,
y=
Fig.7.24 (b) Redundant E-stop unit (B-cabinet)
- 282 -
(B-cabinet: S-900, M-500)

KOl, K02, K03
~
'!'
n..,,. s ':'.'L
- rm- '17 ~
'I' •
~ EB EB EB ~
E9 T E9
l I ©©
- T_J ses
sis ,-;:=::.
I
I ses
sis r
I s•@ I
I s•s I
I
s $
s $
... ___ l,'--
-(l s $ I
TI ©©
E9
i;:i:; ~
Ci::\ Ci::\ t.:i::\
E9
i;:i:;
~I
- -
I
~@ @@ "'@ @@ @@ ~1
00 @@ @Ci'l @@ @ell @©J

0
~I
I~ 1J ~KDI II ~Km II ~KOS
~
w w ,J,
c:y=
Fig.7.24 (c) Redundant E-stop unit (B-cablnet)
- 283 -
(M-410i)
KAOl, KA02, KA03
Fig.7.24 (d) Redundant E-stop unit (M-410i)
- 284 -
7.25 The battery needs to be replaced at following condition.

REPLACING THE • 1 year without power-on of controller.
BATTERY •About 5 years with normal use (8 hours/day, 5 days/week).
•Exchange the battey within one month after "BATTERY ALARM" on
operator's panel or "No Battery Power in PSU" alarm on teach pendant.
NOTE
Make sure press the EMERGENCY STOP BUTTON when
replacing the battey.
(1) Use a lithium battery (ordering drawing number: A98L-0031-0012).

(2) Turn on the R-J2. (The battery can be replaced when the power is
turned on and off. If the power is turned off, the battery must be
replaced within 30 minutes. If the power is turned off and the battery
is removed for 30 minutes or more, the contents of the memory on the
main CPU PC board may be lost.)
(3) Remove the battery case from the front panel of the power supply
unit. The case can be removed easily by holding the top and bottom
of it and pulling.
Front panel of the

power supply unit
Battery case
Battery
(ordering drawing number: A98L-0031-0012)
(4) Remove the connector from the battery.
- 285 -
BATTERY Cable connector
PC panel of the
power supply unit
(5) Replace the battery and reconnect the connector.

(6) Install the battery case.
(7) Turn off the R-J2.
- 286 -
Ill. CONNECTIONS
B-80525E-1 /03 CONNECTIONS 1. GENERAL
1
GENERAL
This section describes the electrical interface connections in the R-J2. It

also includes information about installation of the R-J2.
- 289 -
2. BLOCK DIAGRAM CONNECTIONS B-80525E-1 /03
2
BLOCK DIAGRAM
Fig. 2 is a block diagram of electrical interface connections with the R-J2.
R-J2
Pneumatic pressure source
:
~--I
Mechanical unit End effector
I I
Operator's box
l- I
I
Teach pendant
I
(Note 4)
or
operator's panel
I (RS-232-C) (Note 2)
I I
I FANUC Handy File
I I
Peripheral device A
Peripheral device B
Welder
(RS-232-C) (Note 3)
(RS-422/485) (Note 3)
AC power source
(Note 1) : Indicates electrical connection.

- - - - - - : Indicates mechanical connection.
(Note 2) A remote display is connected.
For more information, contact our service section.
(Note 3) Optional RS-232-C or Rs-4221485 interface.
(Note 4) The teach pendant can be connected in either of two ways:
1. Through the operator's box (i--cabinet)
2. Directly to the control unit (B--cabinet)
Fig.2 Block Diagram of Electrical Interface Connection
- 290 -
B-80525E-1/03 CONNECTIONS 3. ELECTRICAL CONNECTIONS
3
ELECTRICAL CONNECTIONS
3.1
CONNECTION Fig. 3.1 (a) and 3.1 (e) show mechanical connection diagrams.
DIAGRAM BETWEEN
MECHANICAL UNIT
R-J2 Robot
Pulse coder
t--------- J1/J2/J3
Pulse coder
i---------
J4/J 5/J6
,_____ Motor power

J1
Servo amplifier
terminal frame
Motor brake
i--------+- Limitswitch
o-oq~_En_d_e_ffecto -~
__
r
(Note) This cable is not included. It must be supplied by the customer.
Flg.3.1 (a) Mechanical Connection Diagram

(i cabinet:ARC Mate 100, ARC Mate 120, ARC Mate 100i, ARC Mate 120i, s-6, S-12, M-6i, M-16i, 8-420i, S-SOO,
S-700, M-710i, A-520i)
- 291 -
3. ELECTRICAL CONNECTIONS CONNECTIONS B-80525E-1/03
Fig. 3.1 (b), (c) show mechanical connection diagram
R-J2 ROBOT
CRFI
(Pll.SE CODER SIGNAL)
CRMIO
r-~-,...~~~~-+- PULSE CODER
(.J l-.J6)
o--od
(NOTE I)
END EFFECTOR
(PU..SE CODER SIGNAL)

CRMI I
(ROT)
MOTOR POWER Ml
(.J4-.J6)
SERVO AMPLIFIER { MOTOR BRAKE
TERMINAL FRAME [J-~~--t~~~~~+-
MOTOR POWER M2
(.JI -.J3)
CRR5
(BRAKE CONTROL)
,--~~~on~~WE~W~E-R~~
(NOTE 2) 4_
{Note 1) This cable is not included. It must be supplied by customer.

(Note 2) This cable is available in case of 5--500 and S-700.
Flg.3.1 (b) Mechanical Connection Diagram (B cabinet: s-420i/S-60~700/S-900, M-710i)
R-J2 ROBOT
CRFI
(PULSE CODER SIGNAL)
PULSE CODER
(.Jl-.J6) 0---0 qEND EFFECTOR
CRMIO (NOTE I)
(Pll.SE CODER SIGNAL)
CRMI I
(ROT)
SERVO AMPLIFIER
TERMINAL FRAME
CRR5
!BRAKE CONTROL)
D~~~-onL_.~WE~LD-ER~~
(NOTE 2) 4_
(Note 1) This cable is not included. It must be supplied by customer.
(Note 2) This cable is available in case of ARC Mate100 and ARC Mate120.
Fig.3.1 (c) Mechanical connection Diagram

(B cabinet: s-6/S-12JM-16i, ARC Mate100/ARC Mate120, ARC Mate 120i, A-520i, ARC Mate 100i/M-6i)
- 292 -
R-J2 ROBOT
CRFI
!PULSE CODER SIGNAL l PULSE CODER
(Jh.J6)
~~
CRMIO
(PULSE CODER SIGNAL) END EFFECTOR
CRMI I
CROTl LIMIT SWITCH
MOTOR POWER JI
SERVO AMPLIFIER
TERMINAL FRAME
MOTOR POWER J2
MOTOR POWER J3
MOTOR POWER J4
CRR5
MOTOR BRAKE
(BRAKE CONTROL)
(Note 1) This cable is not included. It must be supplied by the customer.
Flg.3.1 (d) Mechanical connection Diagram (M-410i)
R-J2 Robot
CRFI
(Pulse coder signal)
Pulse coder
Jl-J5 o-oq
Note 1
End effector
CRMIO
CRDI/RDO)
CRMI I
(ROT)
Servo amplifier Motor power M1

J2/4/5
terminal frame
Motor brake
Servo amplifier Motor power M2
terminal frame Jl/3
CRR5
(Brake control)
(Note 1) This cable is not included. It must be supplied by the customer.
Flg.3.1 (e) Mechanical Connection Diagram (M-500)
- 293 -
3. ELECTRICAL CONNECTIONS CONNECTIONS B-80525E-1 /03
R-J2
CRS1
(Main CPU) J oq.____Te_achp_enda_nt____.
TEACH PENDANT 1--~~~~~~~~~--'
(Operator's box) (Note 1)
(Process 1/0)
'----~(N_m_e2~>---~orl..._
~ 4__Peripheral
___ _~
device
Port 1 (Note3)
orl FANUC
(Operator's box 1--~~~~~~~~~___, Y.__~H_and~y_Fl_le~~~
or operator's panel)
JD17 1--~~-(~N_o_re_4_,_N_m_e_s~>~~-__,Orl.y__ _External

_ _ _ _ ____.
device
(Main CPU)
Disconnect switch
q'-~~-ln_p_ut_pow~~e_r~~-'
PC board Note4 External power
for operator's panel
{TBOP2) ON/OFF swich
PC board EMGIN1 ~==:::::=----..!:(N...::o:..::te:....4.:..!.)_ _ _ _-1 External emergency

for operator's panel EMGIN2 stop swich
{TBOP1)
(Note 1) The teach pendant can be connected in either of two ways:

1. Through the operator's box or operator's panel
2. Directly to the control unit
(Note2) For more information about connection of peripheral devices,
see the description of the peripheral device interface in this manual.
(Note3) This cable is provided with the FANUC Handy File.
(Note4) Not included. Must be supplied by the customer.
(Notes) For details of connecting on external device interface to enable expansion, refer to
the section explaining on external device interface.
Fig.3.1 (f) Mechanical Connection Diagram
- 294 -
B-80525E-1 /03 CONNECTIONS 3. ELECTRICAL CONNECTIONS
3.2
EXTERNAL CABLE
WIRING DIAGRAM
3.2.1 Operator's box cable (Signal) (i-cabinet)

Clamping of Shield
Cable
OPERATOR'S BOX
OPERATOR'S BOX SIGNAL CABLE

(SHIELDED CABLE)
/
SHIELD PLATE
CABLE CLAMP
FIX THIS CABLE WITH THE CABLE CLAMP
AFTER STRIP THE SHEATH.
i-CABINET
SHIELD PLATE
- 295 -
Operator's box cable (Signal) (M-410i)
OPERATOR'S BOX
OPERATOR'S BOX SIGNAL CABLE

(SHIELDED CABLE)
/
CABLE CLAMP
SHIELD PLATE
CABLE CLAMP
- 296 -
Teach pendant cable (B-cabinet)
MAIN CPU PCB
TEACH PENDANT
SHIELD PLA E \
TEACH PENDANT CABLE
(SHIELDED CABLE)
CABLE CLAMP
FIX THIS CABLE TO USE THE CABLE CLAMP
- 297 -
Robot connection cable (i-cabinet/separate type)
ROBOT CONNECTION CABLE

. . .--........,......._,,/(SHIELDED CABLE)
CABLE(NO SHIELD)
i-CABINET
VIEW FROM "A"
CABLE CLAMP
FIX THIS CABLE TO USE THE CABLE CLAMP
ROBOT ROBOT CONNECTION CABLE

ARC Mate 120, RP1 RM1 -
ARC Mate 120i
ARC Mate 100 RP1 RM1 -
$-6, M-16i RP1 RM1 -
S-12 RP1 RM1 -
5-420i RP1 RM1 RM2
S-500 RP1 RM1 RM2
S-700 RP1 RM1 RM2
$-520i RP1 RM1 -
ARC Mate 1OOi RP1 RM1 -
M-6i RP1 RM1 -
S-710i RP1 RM1 RM2
- 298 -
Robot connection cable (B-cabinet)
SERVO AMPLIFIER
ROBOT
CONNECTION CABLE
(SHIELDED CABLE)
ROBOT
CONNECTOR
PANEL
JL..oijll.l.!--~--....-...-...-...--"...it'~~~~-----:-'\~~~~~~---t~o~---'
EARTH CABLE
CABLE CLAMP (NO SHIELD)
SHIELD PLATE
SCREW FIX THESE CABLES WITH
CFOR EARTH CABLE) THE CABLE CLAMP
ROBOT ROBOT CONNECTION CABLE

ARC Mate 120, RP1 RM1 - - -
ARC Mate 120i
ARC Mate 100 RP1 RM1 - - -
8-6 RP1 RM1 - - -
S-12, M-16i RP1 RM1 - - -
8-420i RP1 RM1 RM2 - -
S-500 RP1 RM1 RM2 - -
A-700 RP1 RM1 RM2 - -
S-520i RP1 RM1 - - -
M-900 RP1 RM1 RM2 RM3 RBK
M-500 RP1 RM1 RM2 - -
ARC Mate 1OOi RP1 RM1 - - -
M-6i RP1 RM1 - - -
M-710i RP1 RM1 RM2 - -
- 299 -
3.2.2 (In case of combined type S-420i, ARC Mate lOOi, M-6i, M-710i)
Robot Connection
Cables
EMERGENCY STOP ROBOT 8-420i

CONTROL BOARD ARC Mate 1OOi
g~~~ M-6i, M-71 Oi
PULSE CODER
RDI/O,HBK
i'+-1'1'-f'-f-+'t-"->'~------i MOTOR POWER

MOTOR BRAKE
MAIN CPU BOARD
CRMIO
·DETAILS OF CABLE CONNECTION TO THE SERVO AMPLIFIER

R-02 ROBOT S-420i
EMERGENCY
MAIN CPU STOP ARC Mate 1OOi
AMP BOARD CONTROL
M--6i
BOARD
M-710i
5U 6U CRF3
5V 6V
5W 6W
CN6 CRMIO CRF4
3U 4U G
3V 4V G
3W 4W G
IU 2U G
IV 2V G
IW 2W G
PULSE CODER
'----+-----1 JI/ J2/ J3
- - - - r - - - - - - - ; J4/ J5/ J6
-------......-----. RDI/O, HBK

-----------......-----.MOTOR BRAKE
MOTOR POWER
i-----......-----; JIM
~---t II
1------; 11 t----r------1 J2M
o-----111i-----......-----...J3M
----~---~-----------!
t-----;11t----r-------iJ4M
r-----111i-----..----...J5M
~---111t----t------iJ6M
- 300 -
(In case of separate type S-420i, M-710i)
EMERGENCY STOP
CONTROL BOARD
CRF3 ROBOT S-420i M-710i
CRF4
CRMI I
EARTH
PULSE CODER
RDI/RDO
HBK
ROT
Pl
MOTOR POWER
MOTOR BRAKE
Ml
M2
MAIN CPU BOARD

CRMIO
• Details of cable connection to the servo amplifier
R-J2 ROBOT S-420i

AMP MAIN CPU EMERGEN:Y
STOP CONTROL
M-710i
BOARD BOARD
5U 6U CRF3
5V 6V
5W 6W
CN6 CRMIO CRF4
3U 4U G
3V 4V G
3W 4W G CRMI I
IU 2U G
IV 2V G
IW 2W G
......__ ___,,_ _--1---n [ PULSE

pI CODER
(PULSE CODER,
RDI/RDO,HBK,ROTJ
MOTOR POWER/BRAKE
'----------~---4---n [ Ml
(.J4M,J5M,J6M,BKl
....-1--.n[ M2
(JIM,J2M,J3M)
- 301 -
(In case of separate type S-6, S-12, M-16i, ARC MatelOO, ARC
Mate120, ARC Mate 120i, ARC Mate lOOi, M-6i)
EMERGENCY STOP
CONTROL BOARD ROBOT
CRF3 8-6
CRF4 S-12
CRMI I M-16i
ARC Mate 100
ARC Mate 120
ARC Mate 120i
ARC Mate 1OOi
M-6i
EARTH
PULSE CODER
RDI/RDO
HBK
ROT
Pl
MOTOR POWER
MOTOR BRAKE
Ml
MAIN CPU BOARD

CRMIO
SERVO AMPLIFIER
CN6
- 302 -
(In case of separate type S-500)
EMERGENCY STOP
CONTROL BOARD
CRF3 ROBOT S-500
CRF4
CRMI I
EARTH
PULSE CODER
RDI/RDO
HBK
ROT
Pl
MOTOR POWER
MOTOR BRAKE
Ml
M2
MAIN CPU BOARD

CRMIO
SERVO AMPLIFIER
CN6
R-J2 ROBOT S-500

MAIN CPU a.ERGENCY
AMP BOARD STCP CONTRa..
BOARD
5U 6U CRF3
5V 6V
5W 6W
CN6 CRMIO CRF4
3U 4U G
3V 4V G
3W 4W G CRMI I
IU 2U G
IV 2V G
IW 2W G
PULSE CODER
'-------"~---1----n [ pI
(PULSE CODER
ROI/RDO,HBK ,ROTJ
MOTOR POWER/BRAKE
'----------~--l>----n[ Ml
(J3M,J4M,J5M,
J6M,BKl
..-1--.n[ M2
(JIM,J2M)
- 303 -
(In case of separate type S-700)
EMERGENCY STOP
CONTROL BOARD
,,..- CRF3 ROBOT S-700
CRF4
/ CRMI I
/ EARTH
PULSE CODER
RDI/RDO
HBK
ROT
Pl
MOTOR POWER
MOTOR BRAKE
Ml
M2
MAIN CPU BOARD
CRMIO
SERVO AMPLIFIER
CN6
R-J2 ROBOT S-700

MAIN CPU EMERGENCY
AMP BOARD STOP CONTROL
BOARD
5U CRF3
5V
5W
CN6 CRMIO CRF4
3U 4U G
3V 4V G
3W 4W G CRMI I
IU 2U G
IV 2V G
IW 2W G
PULSE CODER
'-------~----+--~•[Pl
(PULSE CODER
RDI/RDO,HBK,ROT)
MOTOR POWER/BRAKE
'----------~-+---<I [ Ml
(J3M,J4M,J5M,
J6M,BK)
..--+-----<I [ M2
(JIM.J2Ml
- 304 -
(In case of B cabinet/S-420i, M-710i)
EMERGENCY STOP UNIT

CRFI
CRMI I
MAIN CPU BOARD
CRMIO
ROBOT 5-420i M-710i
MOTOR POWER
MOTOR BRAKE
Ml
M2
R-J2 ROBOT S-420i

~
MAIN CPU STCP cr.tlTRIL M-710i
AMP BOARD BOARD
5U 6U CRFI
5V 6V
5W 6W
CN6 CRMIO
3U 4U G
3V 4V G
3W 4W G CRMI I
IU 2U G
IV 2V G
IW 2W G
PULSE CODER
'---~~--'..._~____.~____...,[ Pl
!PULSE CODER,
RDI/RDO,HBK ,ROTl
MOTOR POWER/BRAKE
~~----;f---'..._~--+-"'~~-"'~~~~~~~~~~-1-~-n[ Ml
(J4M,.J5M,J6M,BK)
'--~~----'..._~~--'"~~~~~~~~~~~~~~-1----n[ M2
(JIM,J2M,J3Ml
- 305 -
(In case ofB cabinet S-6, S-12, M-16i, ARC MatelOO, ARC Matel20,
ARC Mate 120i, ARC Mate lOOi, M-6i)
EMERGENCY STOP UNIT

CRFI
CRMI I
MAIN CPU BOARD
CRMIO
ROBOT
8-6
S-12
M-16i
ARC Mate 100
ARC Mate 120
ARC Mate 120i
ARC Mate 1OOi
M-6i
MOTOR POWER
MOTOR BRAKE
Ml
PULSE CODER
RDI/RDO
HBK
ROT
Pl
....- - - - - - - - - - 0 EARTH
R-J2 ROBOT
EIERGENCY
MAIN CPU STOP 8-6
AMP BOARD CCNTRCl. S-12
BOARD M-16i
ARC Mate 100
ARC Mate 120
5U 6U CRFI ARC Mate 120i
5V 6V ARC Mate 1OOi
5W 6W M-6i
CN6 CRMIO
3U 4U G
3V 4V G
3W 4W G CRMI I
G
IU 2U G
IV 2V G
IW 2W
PULSE CODER
[ Pl
(PULSE CODER,
RDI/RDO,HBK,ROTl
MOTOR POWER/BRAKE
[ Ml
(JIM,.J2M,.J3M,J4M
,.J5M,.J6M,BK)
- 306 -
(In case of B cabinetJS-500)
EMERGENCY STOP UNIT

CRFI
ROBOT S-500
MOTOR POWER
MOTOR BRAKE
Ml
M2
PULSE CODER
RDI/ROO
HBK
ROT
Pl
j<:....<w.1.i""""'~L..-...............,.......,.......,~liflll.'----------oEARTH
R-J2 ROBOT S-500

D£RGe.CY
AMP MAIN CPU STCP CCM'RCl.
BOARD BOARD
5U 6U CRFI
5Y 6V
5W 6W
CN6 CRMIO
3U 4U G
3V 4V G
3W 4W G CRMI I
G
IU 2U
IV 2V G
IW 2W G
_ _ ____,....__ ___...._____,, [ PULSE

pI CODER
(PULSE CODER,
RDI/ROO,HBK ,ROT)
MOTOR
MI
'-----1,__,..___ __....._ ___,._ _ _ _ _ _ _ _ _ _ POWER/BRAKE
.....__..n [
CJ3M,.J4M,.J5M,.J6M
_ _ ___,..___ __,.,_ _ _ _ _ _ _ _ _ _ _ _ _ _+---n[ M2,BK)
(JIM,J2M)
- 307 -
(In case of B cabinet/S-700)
EMERGENCY STOP UNIT

CRFI
MAIN CPU BOARD

CRMIO
ROBOT S-700
MOTOR POWER
MOTOR BRAKE
Ml
M2
PlLSE CODER
RDI/RDO
HBK
ROT
Pl
l'--!~lti...IC..L.-....,........,.._....._....._..~~;__~~~~~~~~~QEARTH
R-J2 ROBOT S-700

AMP MAIN CPU EIERGEN:Y
STCP CCMRa..
BOARD BOARD
5U 6U CRFI
5V 6V
5W 6W
CN6 CRMIO
3U 4U G
3V 4V G
3W 4W G CRMI I
G
IU 2U G
IV 2V
IW 2W G
PULSE CODER
Pl
(PULSE CODER,
RDI/ROO,HBK ,ROTl
MOTOR POWER/BRAKE
Ml
(JIM,J3M,J4M,J5M
,J6M,BKl
M2
CJ2Ml
- 308 -
(In case of B cabinet/S-900)
ROBOT CONNECTION CABLE(B-CABINET/S-900)
MAIN CPU BOARD

CRMIO
CONVERSION BOARD
CRR5
EMERGENCY STOP
CONTROL BOARD
CRF3, CRF4, CRM I I
AMP 4
AMP 3
ROBOT
T S-900
---oEARTH
Ml
M2
M3
BK
MAIN CABINET Pl
ROBOT
AMPI AMP2 AMP3 AMP4 AMP5 AMP6 MAIN CPU CONVERSION EMERGOCY
STCP CONTRIX. S-900
BOARD BOARD BOARD
CRF3
9 9 9 9 9 9
10 10 10 10 10 10 CRF4
CRMIO CRR5
II II II II II II
12 12 12 12 12 12
[ pI
[BK
[MI
[ M2
[ M3
- 309 -
(In case of M-41 Oi)
SERVO MODULE 4
SERVO MODULE 3
SERVO MODULE 2
SERVO MODULE I -r;Z~;;:::::::::::S~:::3;==:::::;:r-t71
ROBOT M-410i
EMERGENCY
STOP CONTROL
BOARD
CRR5
CRMI I
CRFI
MAIN CPU BOARD

CRMIO
• Details of cable connection to the servo module
R-J2 ROBOT M-410i

SERVO MODULE EMERGENCY
MAIN CPU STOP
BOARD CONTROL
I 2 3 4 BOARD
..--oU ..--oU ..--oU ..--ou CRFI

~v 'r--<>V ..--ov ..--ov
r-0
CRMIO CRMI I
r-<>W >---<>W >---<>W "--oW r-0
r-0
r-<>PE ~PE ,._....,PE >---<>PE CRR5
r-D
JIP
--
-- J2P/J3P
' --
'~
J4P
RDI/ROO
ROT
I\..
JIB
11'--D
I)
= J2B/J3B
JIM
'- J2M
' J3M
" J4M/J4B
- 310-
(In case of B-cabinet/M-500)
EMERGENCY STOP
CONTROL
BOARD
CRR5, CRM I I
MAIN CPU
BOARD ROBOT M-500
CRMIO
MOTOR POWER/
BRAKE
RMI
RM2
PULSE CODER
ROI/ROD
HBK
ROT
RPI
l"-6.....,-"------=t~1~=======:=:::::::::__ ___J.iEARTH
R-J2 ROBOT M-500

SERVO AMPLIFIER
2 3 4
9 9 9
10 10 CRMIO
11 11 11
12 12
PULSE CODER
---"""-+---+---~ I [ RP I
(PULSE CODER,
RDl/RDO,HBK,ROTl
MOTOR POWER/BRAKE
'-'"------"'----------"'--1----.n [ RM I
(J2M,J4M,J5M,BKl
~-____,......__ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _+ - - - - n [ RM2
CJIM,J3Ml
- 311 -
(In case of Combined type A-520i)
EMERGENCY STOP
CONTROL BOARD
CRF3
CRF4 ROBOT A-520i
PULSE CODER
RDI/0,HBK
~'-l'+-!-'1......-'-------i MOTOR POWER

MOTOR BRAKE
R-J2 ROBOT A-520i

BERGENCY
MAIN CPU STOP
AMP BOARD CONTRCl..
BOARD
CRF3
CN6 CRMIO CRF4

3U 4U G
3V 4V G
3W 4W
IU 2U G
IV 2V G
IW 2W
PULSE CODER
1 - - - - - - - - - i JI /J2/J3
' - - - - + - - - - - - ! J4
'---------1---__, RDI/O .HBK
' - - - - - - - - - - - - - + - - - - - 1 MOTOR BRAKE
MOTOR POWER
,.----1DCl----r--__,JIM
____,,____ _______
....__ _,__
1 - - - - - n n - - - - - - - - - i J2M
____,1 - - - - - n n - - - - - - - - - i J3M
'-----I 11 1---------. J4M
- 312 -
B-a0525E-1/03 CONNECTIONS 3. ELECTRICAL CONNECTIONS
(In case of separate type A-520i)
EMERGENCY STOP
CONTROL BOARD
CRF3 ROBOT A-520i
CRF4
CRMI I
EARTH
PULSE CODER
RDI/RDO
HBK
ROT
Pl
MOTOR POWER
MOTOR BRAKE
Ml
MAIN CPU BOARD
CRMIO
SERVO AMPLIFIER
CN6
R-J2 ROBOT A-520i

MAIN CPU EMERGENCY
AMP BOARD STCP CONTRCl.
BOARD
CRF3
CN6 CRMIO CRF4

3U 4U G
3V 4V G
3W 4W CRMI I
IU 2U G
IV 2V G
IW 2W
PULSE CODER
C Pl
(PULSE CODER,
RDI/RDO,HBK,ROT)
MOTOR POWER/BRAKE
C Ml
CJIM,J2M,J3M,
JM4,BK)
- 313 -
(In case of B-cabinet/M-41 Oi)
SERVO MODULE I
SERVO MODULE 2
SERVO MODULE 3
ROBOT M-410i
MOTOR POWER/BR
RMI
RM2
RM3
RBK
PULSE COOER
RDI/RDO
HBI<
ROT
!~~~~~~~~~~~~~~~~~~-::!:__==~~RPI
~ EARTH
~---~
R-J2 ROBOT M-410i

SERVO MODULE MAIN CPU EMERGENCY
DNTROI.. PC
STOP PowER SI.PPL~
I 2 3 4 PC BOARD BOARD uNIT
..--oU ..--oU ..--ou ..--oU CRFI

,__.,v ,--[]
..--ov ..--ov ..--oV
CRMIO CRMI I
............ w 1----<>W ..--ow ,__.,w
r--0
,__.,PE 1---<>PE ..--oPE L--<>PE CRR5 CP2
r-0 r{]
PULSE CODER
-[ r~SE
-
COOER,ROI/ROO,
H!K,ROT)
MOTOR BRAKE
- C RBI<
MOTOR POWER
--- [
[ RMICJl,J4l
RM2(J2l
-[
\.
- RM3(J3l
- · 314 -
3.2.3 (1) Teach pendant

Teach Pendant Cable The teach pendune cable is connected the operator's box as follows.
This figure applies to all device types.
OPERATOR'S BOX
PORT TEACH PENDANT
"TEACH PENDANT"
--
0
TEACH PENDANT CABLE
Fig.3.2.3 (a) Teach Pendant Cable
- 315 -
SERVO TEACH
AMPLIFIER PENDANT
CPU BOARD
TEACH
PENDANT CABLE
Flg.3.2.3 (b) Teach Pendant Cable (In case of B cabinet)
- 316 -
3.2.4 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 Supply
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.
Selection of an input transformer tap is necessary depending on the input
voltage.
The tap is set before shipment. However, check it referring to section 6.2
in "Maintenance" when changing the input voltage and before supplying
power (before the breaker switch is turned on).
The square of cable must be over than 6 mm 2·
Select the cable which is able to withstand the stress given by the external
influence.
·-----------
i-cabinet, M-410i (operation box)
8-cabinet
Maximum short current
375A
340A
Use a bar lead.~

The square of cable
must be covered than
6mm~
Operator' S panel
Breaker
Operator' S box
(option)
Fig.3.2.4 (a) Input Power Supply Connection (Operator's box-breaker)
- 317 -
The square of cable must

/ be over than 6 mm2
r,==,rr==;>;===i=====I:="
..._(___.O 0
PE
NOTE) ATTACH THE COVER AFTER

CONNECTING THE CABLE
Fig.3.2.4 (b) Input Power Supply Connection (B cabinet)
- 318 -
3.2.5 The External Power On/Off signal turns on and off the power supply from
Connecting the the outside the control unit, and is connected as follows.
External Power Supply
on/off Switch
T; ; O; ; R; ; '; ; S; ; P; ; A; ; NilET-L-i. -f-~jl - ; ~ ; ~ ;-~ ~ ~- -1CODE

n;;O;;;;P;;;;E;;;;R;;;;A
2
GRIP (PG I l
TO EXTERNAL POWER SUPPLY

ON/OFF SWITCH
PC BOARD FOR
OPERATOR'S PANEL
Fig.3.2.5 (a) Connecting the External Power Supply ON/OFF Switch (Operator's Box)
PC BOARD FOR
OPERATOR'S PANEL
..
TO EXTERNAL POWER SUPPLY
ON/OFF SWITCH
Fig.3.2.5 (b) Connecting the External Power Supply ON/OFF Switch (B caibnet)
- 319 -
REMOVE THE JUMPER WHEN THE EXTERNAL

POWER SUPPLY ON/OFF SWITCH IS USED.
. - - - - - - - - - - - - O f ) ON
r-------c~ COM
~/
.-------10:t> OFF
0 0
POWER ON POWER OFF

EXTERNAL POWER SUPPLY ON/OFF SWITCH
0 0
PC BOARD FOR OPERATOR'S PANEL
USE A CONTACT CONFORMING TO THE FOLLOWING:VOLTAGE RATING:50VDC,

CURRENT1IOOmA OR MORE. THE POWER SUPPLY ON/OFF TIMING CHART IS
AS FOLLOWS.
EX-ON - EX-COM ~
\ I~----
I ;
EX-OFF - EX-COM
POWER ON ---\==--=---=---~\
TON ;;::o.5sec ,ToFF;::;0.5sec .ToFF-ON;;::5sec
Fig.3.2.5 External Power Supply ON/OFF Switch Connection
- 320 -
3.2.6
Connecting the
External Emergency
Stop
CODE GRIP(PG21)
OPERATOR'S PANEL
EXTERNAL EMERGENCY STOP INPUT/OUTPUT
PC BOARD FOR
OPERATOR'S PANEL
Fig.3.2.6 (a) Connecting the External Emergency Stop (Operator's Box)
EXTERNAL EMERGENCY STOP

INPUT/OUTPUT
Fig.3.2.6 (b) Connecting the External Emergency Stop (B cabinet)
- 321 -
EXTERNAL EMERGENCY STOP OUTPUT
SIGNAL DESCRIPTION CURRENT.VOLTAGE

EMGOUTI IN THIS CONTACT IS BROKEN. EMERGENCY
EMGOUTC J STOP OR POWER OFF CONDITION.
IN THIS CONTACT IS CLOSED, NO-EMER-
GENCY STOP CONDITION.
RATED CONTACT:
250VAC,5A
RESISTOR LOAD
EMGOUT2 IN THIS CONTACT IS CLOSED. EMERGENCY
EMGOUTC J STOP OR POWER OFF CONDITION.
IN THIS CONTACT IS BROKEN, NO-EMER-
GENCY STOP CONDITION.
ESTOPI THIS IS EMERGENCY OUTPUT SIGNAL THAT RATED CONTACT:
ESTOP2 J IS BROKEN WHEN OPERATOR'S PANEL OR
TEACH PENDANT EMERGENCY STOP BUTTON
IS PUSHED.
24VDC,O. IA
RESISTOR LOAD
M4 SCREW ARE PROVIDED ON THE TEMINALS

USE CRIMP TERMINALS 9 mm WIDE OR LESS.
Fig.3.2.6 (c) Connecting the External Emergency Stop
- 322 -
EXTERNAL EMERGENCY STOP INPUT
EXTERNAL EMERGENCY
STOP SWITCH
I
@@@@
'-l..Y '-l..Y REMOVE THE JUMPER PRIOR
TO USE.
c:=---.
-
? . :o · o
EMGIN I
EMGIN2
c::
SAFETY FENCE
~~~~~~~~~~~~~~~~---1.
:o o
FENCE I
FENCE2
• • FOR CONNECTION TO DRY CONTACTS ONLY.

- SERIOUS DAMAGE MAY RESULT IF CONNECTED
TO POWER SOURCE.
SIGNAL DESCRIPTION CURRENT

VOLTAGE
EMGINI Connect the contacts of the external 24DVC
EMGIN2 J emergency stop switch to these terminals.
When using the contacts of a relay or
contactor instead of the switch, connect a
O. IA
OPEN/
spark killer to the coil of the relay or contactor, CLOSE
to suppress noise.
When these terminals are not used, jumper
them.
FENCE I THESE SIGNALS ARE USED TO STOP 24VDC

FENCE2 J THE ROBOT WHEN THE SAFETY FENCE
IS OPEN. WHEN Tl OR T2 MODE IS
SELECTED BY MODE SELECTION
O. IA
OPEN/
SWITCH, THIS SIGNAL IS IGNORED CLOSE
AND EMERGENCY STOP DOES NOT
OCCUR.
M4 SCREWS ARE PROVIDED ON THE TERMINAL.

USE CRIMP TERMINALS 9mm WIDE OR LESS.
- 323 -
Servo on input
After connecting a servo on input switch, be sure to check the operations of the switch, the emergency stop
switch on the operator's panel, and the emergency stop switch on the teach pendant.
0 0
FG
!ii 0
;;:
0 0
ID 0
Connected at the factory.

Remove the jumperprior
to use.
---+.-----.--,:o
Servo on input switch.
SVON I - -
. o SVON2
• - FOR CONNECTION TO ORY CONTACTS ONLY.

- SERIOUS OAMA6E MAY RESULT IF CONNECTED
TO POWER SOURCE.
Signal Description Current, voltage
SVON1 J Connect the contacts of the servo-on input switch to these termi-
nals. When using the contacts of a relay or contactor instead of the
switch, connect a spark killer to the coil of the relay or contactor, to
suppress noise. When these terminals are not used, jumper them.
24 VDC/0.1 A switch
on/off
SVON2
M4 screws are provided on the terminal. Use crimp terminals 9mm wide or less.
- 324-
4. PERIPHERAL DEVICE, ARC WELDING,

B-80525E-1 /03 CONNECTIONS AND END EFFECTOR INTERFACES
PERIPHERAL DEVICE, ARC WELDING, AND END EFFECTOR
4 INTERFACES
R-J2 I/O peripheral device interfaces include printed circuit boards and
a unit selected according to the applications. Table 4 lists the printed
circuit boards and unit. Fig. 4 shows their locations.
Table 4 Peripheral Device Interface Types
Number of UO points
No. Name Drawing number Remarks
DI DO D/A AID
Process 110 printed circuit A05B-2300-J030 40 40 2 6 Backplane installation type
1
board CA (with welding interface)
2
Process 1/0 printed circuit A05B-2300-J031 40 40 - - Backplane installation type
board CB (without welding interface)
3
Process 1/0 printed circuit A05B-2300-J035 Note Note - - Backplane installation type
board DA 80 80 (without welding interface)
Process 1/0 printed circuit A05B-2300-J040 40 40 2 6 For ARC Mate 1OOi
4 board EA Operator's box installation
type (with welding interface)
5
1/0 unit model A - Depending on a selected 1/0 (Note 3)
model.
6 1/0 unit model B A05B-2300--J001 Depending on a selected unit. Interface unit
NOTE
1 Process 1/0 printed circuit board DA of i cabinet has 96 input
points and 96 output points. Because of cable restrictions,
only 80 input points and 80 output points can be used.
2 General purpose 1/0 (SDl/SDO) is a number which subtract
an exclusive signal from the table value.
Example: Process 1/0 printed circuit board CA
Table value Exclusive DI General purpose DI
DI; 40 18 = 22 points
Table value Exclusive DO General purpose DO
DO; 40 20 = 20 points
3 When you want to mount 1/0 unit model A in the operation
box, consult FANUC.
- 325 -

AND END EFFECTOR INTERFACES CONNECTIONS B-80525E-1 /03
Operator's box Note) Some operator's boxes

(option) support the connection of
1/0 unit model A. For details,
contact your FANUC
sales representative.
Basic unit of
1/0 unit model B
Process 1/0
CA/CB/DA
To peripheral device
Interface unit of 1/0 unit model B
Fig.4 (a) Locations of Peripheral Device Interfaces (i cabinet)
CRWI
Process 1/0 EA
Operator's box
CRM2B
CRM2A
- 326 -

Emergency stop control printed

circuit board Main CPU printed circuit board
Process 1/0 printed circuit board

CNCB/DA
-++!---+----+<-+------ 110 unit MODEL A

or
1/0 unit MODEL B
Fig.4 (b) Locations of Peripheral Device Interfaces (B cabinet)
1/0 unit model B
1/0 unit model A

or
1/0 unit model B

Emergency stop control printed circuit board
Fig.4 (c) Locations of Peripheral Device Interfaces (Cabinet for M-410i)
- 327 -

AND END EFFECTOR INTERFACES CONNECTIONS B-80525E-1/03
4.1
PERIPHERAL
DEVICE INTERFACE
BLOCK DIAGRAM
4.1.1
When Process 1/0
CA, CB or EA is Used
Main CPU printed Process 1/0 printed circuit

circuit board board (CA/CB/EA)
D0-----1
K10 CRM2A
D
K50A
0
Peripheral device
JD1A
D JD4A
CRM2B
D
K50B
0
Peripheral device
JD4B CRW1
D
K45
0
Wolder
CRW2
D
CRWl and CRW2 are not provided for process 1/0 printed circuit board
CB.
- 328 -

B-80525E-1/03 CONNECTIONS AND END EFFECTOR INTERFACES
In case of i cabinet
CRW1
Process VO EA
Operator's box
CRM2B
CRM2A
To peripheral
device
- 329 -

Cable Drawing
Name Remarks
number number
Process 1/0 A05B-2350-- R-J2 controller
K10 connection J100 internal cable
cable A
Peripheral A05B-2350-- Connected length :

device J210 7m
Process connection Honda Tsushin, 50,34pins : one
K50A cable to one
1/0PC
K50B
board for Peripheral A05B-235Q-- Connected length :
K45
CA device J211 14m
connection Honda Tsushin, 50,34pins : one
cable to one
Peripheral A05B-235Q-- Connected length :
device J200 7m
Process connection Honda Tsushin, 50pins : one to
l/OPC K50A cable one
board for K50B Peripheral A05B-235Q-- Connected length :
CB device J201 14m
connection Honda Tsushin, 50pins : one to
cable one
Peripheral A05B-235Q-- Connected length :
device J260 7m
Process connection Honda Tsushin, 50,34pins : one
K50A cable to one
1/0 PC
K50B
board for Peripheral A05B-235Q-- Connected length :
K45
EA device J261 14m
connection Honda Tsushin, 50,34pins : one
cable to one
- 330 -

In case of B--cabinet, cabinet for M-41 Oi
Main CPU Process VO printed ci

printed rcuit board (CA/CB)
circuit board
JD1A 0-.. . .--...- JD4A

CRM2A
D K50A
D Peripheral device
CRM2B
D K50B
D Peripheral device
JD4B CRWI
D K45
D Welder
CRW2
D K46
D Analog signal input
(Note1) CRW1 and CRW2 are not provided for process VO printed circuit board CB.
(Note2) In case of M-410i, process 1/0 is specified only one sheet.
Cable
Name Drawing number Remarks
number
K10 Process 1/0 connection cable A05B-2300-J013 Internal cable of R-J control unit
Internal cable of R-J control unit
K11 Process 1/0 connection cable A05B-2300-J014
For connecting additional PC board
Connected length : 7m
A05B-2302-J113
Honda Tsushin, 50pins : one to one
K50A
K50B Connected length : 14m
Peripheral device connecting cable A05B-2302-J114
K50C Honda Tsushin, 50pins : one to one
K50D
A05B-2302-J115
A05B-2302-J273 Connected length : 3m
A05B-2302-J274 Connected length : Sm
K45 Welder connecting cable
A05B-2302-J275
In case of lig welding it is impossible to use
This cable is not included
K46 Peripheral device connecting cable ---- It must be supplied by customer
- 331 -

4.1.2
When Process 1/0
Printed Cricuit Board
DA is Used
Main CPU printed Process 110 printed circuit

circuit board board (DA)
JD1A DD;-------i
K10
JD4A
CRM2A
0 K50A
0 Peripheral device
CRM2B 0 K50B
0 Peripheral device
JD4B CRM2C 0 K50C

DPeripheral device
CRM2D 0 K50D
0 Peripheral device
- 332 -

(i cabinet)
Cable Drawing
Name Group Remarks
number number
Process l/O A05B-2350- R-J2 controller
K10 connection PB1 J100 internal cable
cable A
Peripheral A05B-2350- Connected length :

device J220 7m
PC7
Process K50A connection Honda Tsushin,
VOPC K50B cable 50pins : one to one
board for K50C Peripheral A05B-2350- Connected length :
DA K50D device J221 14m
PCS
connection Honda Tsushin,
cable 50plns : one to one
- 333 -

In case of B cabinet, cabinet for M-4 lOi
Main CPU Process 1/0 printed

printed circuit board (DA)
circuit board
CRM2A D~-----0 K50A
Peripheral device
JD1A
D D1---.-.-.--=--D
K50B
Peripheral device
D,__--~--O
K50C
Peripheral device
0~-----0 K50D
Peripheral device
D K51A
D
t---.....__.........,_ _ Peripheral device
D~-----0 K51B
Peripheral device
Process 1/0 printed

circuit board (DA)
CRM2A 0 K50E
D Peripheral device
0 K50F
D Peripheral device
JD4B
D K50G
D Peripheral device
D K50H
K51C
D Peripheral device
D K51D
D Peripheral device
CRM4B
D D Peripheral device
(Note) In case of M-410i, process 1/0 is specified only one sheet.
Csble
number
K10 Process 110 connection cable A05B-2300-J013 Internal cable of R-J control unit
K11 Process 110 connection cable A05B-2300-J014
For connecting additional printed circuit board
A05B-2302-J113
K50 Connected length : 14m
Peripheral device connecting cable A05B-2302-J114
A-H Honda Tsushin, 50pins : one to one
A05B-2302-J115
A05B-2302-J120
K51 Connected length : 14m
Welder connection cable A05B-2302-J121
A-D Honda Tsushin, 20pins : one to one
A05B-2302-J122
- 334 -

4.1.3
When 1/0 Unit Model A
is Used
Main CPU Printed circuit Operator's box (Note)

printed board panel
circuit board TBOP3
+24V
JD1A J JRM10
OV
JD1A
VO unit model A VO unit model A

connection cable power connection cable
c( m ~
..,Ei ..,
Ei D..
0
l/Obaseunit
CD
r::
p K54
..!!!
~
m
a.
p K54
po K54 Peripheral
device welder
p K54
p K54
1/0 unit model A is mounted in the operator's box.

Refer to 1/0 model A manual for more details.
Cable
Name Group Drawing number Remarks
number
Operator's box internal cable.
- 1/0 unit model A connection cable - ---- Attached to the 1/0 unit mainframe.
1/0 unit model A power connection Operator's box internal cable.
- cable
- ---- Attached to the VO unit mainframe.
Not included.
- Peripheral device connection cable - ---- Must be supplied by the customer.
- 335 -

In case of B cabinet/cabinet for M-410i

Power
supply unit
CPS Kl6
Main CPU
PC board
JD1A oD~--...!.K~lc.::5::..,______,
VO base unit
K54
Q)
r::
OD D
..\'!! K54
~
~
l:l.
OD D
K54 Peripheral device
DD D Welder
K54
OD D
K54
OD D
Refer to VO model A manual for more details.
Cable
number
K15 VO unit model A connection cable
Attached to VO unit mainframe
K16 VO unit model A connection cable
Attached to VO unit mainframe
K54 Peripheral device connecting cable
It must be supplied by customer
- 336 - .

4.1.4 Connection to 1/0 Unit Model B, installed in the operator's box

When 1/0 Unit Model B (a) Connect tenninals S2+ and S2-oftenninal block TBOP3 on the
is Used panel PCB to tenninals S+ and S- of the Model B, as shown
below.
(b) Connecttenninals +24V andOVoftenninal blockTBOP3 on the
panel PCB to tenninals +24V and OV of the Model B, as shown
below.
(c) When the +24 V power of the panel PCB is used for LV, the
maximum current is 2 A. If a current exceeding 2 A is required,
use other DC power units to supply power to LV.
Operator's box (option)
0 M3terminal
FANUC
Panel printed board
1/0 unit model B IVl3terminal
- 337 -

Mechanical unit
end effector
Printed circuit TBOP3

board for +24V >u--------+---------.
operator's box OV
VO unit model B > >
Basic unit ~o
S+ DI/DO
s-
FG
Peripheral
device
VO unit model B > >
Basic unit ~0
S+ DI/DO
s-
FG
In operator's box
Cable
number
- VO unit model B connection cable - ---- R-J2 controller unit internal cable
- VO unit model B connection cable - ---- R-J2 controller unit internal cable
Not included.
- Peripheral device connection cable - ---- Must be supplied by the customer
- 338 -

In case of B cabinet/cabinet for M-4 lOi
~------ - --------------- - --------,

Internal control unit
Main CPU
printed
circuit 1/0 unit model B
board
IL___f1 [ Interface unit
Mechanical
JDIA ~ JDIB ~:~,~---------------+-~ unit end
effector
S2+
[ JDIA S2-
S3+
S3-
)--- 1/0 unit model B(~r----t--
Basic unit I
Power S4+
supply unit S4- ~ S+ I DI/DC
'------{)) s-
24V FG
CP4 ov ,l_>----+--
1
24V 24V Peripheral

ov { }---+------{) ov device
1--------1
""" 1/0 unit model B y

Expanded unit I
DI/DC
I
J..
~------+--+--- --------~
Peripheral
control
1/0 unit model Be~>--+-
Basic unit
I DI/DO
S+
---------<J$- I
FG ).
24V Peripheral
--+-----{) ov device
~--~I
1/0 unit model B 9cr----+--

Expanded unit I
DI/DC
'-------{ J
S+
s- I
FG c,1.Jf---+--
24V
'---------<:)) ov
'----------- - --------~
Cable
number
K** 1/0 unit model B connection cable - ---- Internal cable of R-J control unit
K** 1/0 unit model B connection cable - ---- Internal cable of R-J control unit
K** Peripheral device connection cable - ---- It must be supplied by customer
- 339 -

4.1.5 (a) In case of cabinet i

When Two or More The following figure shows the connection when two or more process
Process 1/0 Printed 1/0 printed circuit boards and 1/0 unit (model A or model B) are used.
Circuit Boards and 1/0 1 process 1/0 CA/CB/DAs and 11/0 unit model A or 1/0 unit model
Unit (Model A or Model B can be installed in one cabinet, operator's box.
B}are Used
In controller
Main CPU
printed
circuit board Process VO printed llO unit modal B
clrcuft board lnlllrface unft
SI+ CRS7
JDIA JDIB SI-
S2+ CRSSA
JDIA S2-
CRSSB
r=:h 24V
ov
53+
S3-
LJ
Printed clrcuft + 24 V TBOP3

boardb ovnn-----------------~
operator's box
VO unit model B ~ >
Basic unit NO
JRM2
VO unit model B >

Baslcunft ~~
S+
s-
FG
r-11
- <(
-D
m
-D
II
..,a.
C\I
I
"") "") u
VO base unit
VO unit model A
. DD
l
J DD
DD
DD
~I DD
- 340 -

(b) B cabinet and M-41 Oi cabinet

When several units of the process YO PCB, YO Unit Model A, or YO
Unit Model B are used, connect them as shown below.
One cabinet can include two units of the process YO PCB (CA, CB,
or DA) and one unit of YO Unit Model A or B.
Main CPU printed Process 1/0 printed circuit

circuit board board (CA/CB/DA)
JD4A
JD4B
Process 1/0 printed circuit

board (CA/CB/DA)
Power supply unit JD4A
JD4B
1/0 unit model B JD1A JD1B CP32

K12 Interface unit
JD1B
Interface module
JD1A
____ +24V 1/0

1 0
ov base
S+,S-,FG unit
s+, s-, 1/0 unit model B

FG basic unit
'------n +24V
ov
Cable
number
K12 Process 1/0 connection cable ---- For connecting additional pc board
others See 4.1.1 to 4.1.3
- 341 -

4.2 The peripheral device interface can be used with combinations of process
1/0 printed circuit boards CA, CB, and DA, as well as 1/0 unit models A
PERIPHERAL andB.
DEVICE INTERFACE Fig. 4.2 shows the combinations.
COMBINATION
(a) i cabinet
[1-board]
Combination A Combination B Combination C Combination D
I CA/CB/EA(40 points) I DA (80 points) 111/0 unit model A 11 110 unit model B
[2-board combination]
Combination AC Combination AD Combination BC Combination B
CA/CB (40 points) CA/CB (40 points) DA (80 points) DA (80 points)
+ + + +
110 unit model A 110 unit model B 1/0 unit model A 110 unit model B
Flg.4.2 Perlpheral Device Interface Combination
(b) B cabinet, M410i cabinet
[1-board]
Combination C Combination D Combination E
I CA/CB (40 points) I DA (96 points) I l..__11o_o_~n-~_:_~_1B_1_A___.

Combination CC Combination CE
CA/CB (40 points) CA/CB (40 points)

+ +
CA/CB (40 points) 110 unit model A
ormodelB
Combination DC Combination DD Combination DE
DA (96points) DA (96 points) DA (96 points)

+ + +
1/0 unit model A
CA/CB (40 points) DA (96 oointsl I or model B
Combination CCE Combination DCE Combination DOE
CA/CB (40 points) DA (96 points) DA (96 points)

+ + +
CA/CB (40 points) CA/CB (40 points) DA (96 points)
+ + +
1/0 unit model A 110 unit model A 1/0 unit model A
or model B or model B ormodelB
- 342 -

4.3 There are 18 exclusive data inputs (DI) and 20 exclusive data outputs
(DO) for a process 1/0 printed circuit board.
PROCESS 1/0
These signals are allocated to the process 1/0 printed circuit board
PRINTED CIRCUIT
connected first when two or more printed boards are combined. (General
BOARD SIGNALS signals SDl/SDO are allocated to the second and the following process
110 printed circuit 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 1/0 printed circuit
board.
Table 4.3 shows signals of a process 1/0 printed circuit board.
Table 4.3 Process 1/0 Printed Circuit Board Signals

(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
selection
selection
selection
selection
selection
selection
selection
- 343 -

Table4.3 Process 1/0 Printed Circuit Board Signals (Continued}

(DI signals)
Connector
number
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 SDl10
CRMSB-9 SDl11
CRM2B-10 SDl12
CRM2B-11 SDl13
CRM2B-12 SDl14
CRM2B-13 SDl15
CRM2B-14 SDl16
CRM2B-15 SDl17
CRM2B-16 SDl18
CRM2B-29 SDl19
CRM2B-30 SDl20
CRM2B-31 SDl21
CRM2B-32 SDl22
- 344 -

Table4.3 Process 1/0 Printed Circuit Board Signals (Continued)

(DO signals)
Connector
number
CRM2A-33 CMDENBL During automatic
operation
CRM2A-34 SYSRDY Preparation
completed
CRM2A-35 PROGRUN During regeneration
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
SN01 Selected program Option
number
acceptance
number
acceptance
number
acceptance
number
acceptance
number
acceptance
number
acceptance
number
acceptance
number
CRM2A-26 SNACK Response signal to
PNS
CRM2A-27 RESERVED
- 345 -

Table4.3 Process 1/0 Printed Circuit Board Signals {Continued}

(DO signals)
Connector
number
CRM2B-33 SD001 Peripheral device General signal
control signal
CRM2B-34 SD002
CRM2B-35 SD003
CRM2B-36 SD004
CRM2B-38 SDOOS
CRM2B-39 SD006
CRM2B-40 SD007
CRM2B-41 SD008
CRM2B-43 SD009
CRM2B-44 SD010
CRMSB-45 SD011
CRM2B-46 SD012
CRM2B-19 SD013
CRM2B-20 SD014
CRM2B-21 SD015
CRM2B-22 SD016
CRM2B-24 SD017
CRM2B-25 SD018
CRM2B-26 SD019
CRM2B-27 SD020
- 346 -

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 A 1
CRM2A
1 *IMSTP 33 CMDENBL
2 *HOLD 34 SYSRDY
19 ACK3/SN03
3 *SFSPD 35 PROO RUN
20 ACK4/SN04
4 CSTOPI 36 PAUSED
21 ACK5/SN05
5 FAULT RESET 37 COM-A1
22 ACK61SN06
6 START 38 HELD
23 COM-A4
7 HOME 39 FAULT
24 ACK7/SN07
8 ENBL 40 ATPERCH
9 RSR1/PNS1
25
26
ACK8/SN08
SNACK
41 TPENBL D------0 Pripheral
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/SN01
14 30 PROD START
46
RSR6/PNS6 ACK2/SN02
31 SDI01
15 RSR7/PNS7 47 COM-A3
32 SDI02
16 RSRS/PNSS 48
17 OV 49 +24E
18 ov 50 +24E
Peripheral device control interface A2

1 SDI03 CRM2B 33 SD001
2 SDI04 34 SD002
19 SDI03
3 SDI05 35 SD003
20 SDl14
4 SDI06 36 SD004
21 SDl15
5 SDl07 37 COM-81
22 SDl16
6 SDI08 38 SD005
23 COM-84
7 SDI09 39 SD006
24 SDl17
8 SDl10 40 SD007
9 SDl1
25
26
SDl18
SDl19
41 SD008 Oi-------iO Pripheral
deviceA2
10 SDl12 42 COM-82
27 SD20
11 SDl13 43 SD009
28 COM-85
12 SDl14 44 SD010
29 SDl19
13 SDl15 45 SD011
14 30 SDl20
SDl16 46 SD012
31 SDl21
15 SDl17
32
47 ·coM-83
SDl22
16 SDl18 48
17 OV 49 +24E
18 OV 50 +24E
- 347 -

NOTE
1 The peripheral device connection cables are optional.
2 All of COM-** are connected to 0 V.
Applicable process I/O printed circuit board

CRM2 CRM2
Type Specifications
A B
CA A 168-2201-0470 0 0
CB A16B-2201-0472 0 0
DA A 168-2201-0480 0 0
EA A 168-3200-0230 0 0
- 348 -

Control unit
CRM2C
1 80123 33 80021
2 80124 34 80022
19 80033
3 80125 35 80023
20 800
4 80126 36 80024
21 800
5 80127 37 COM-C1
22 800
6 80128 38 80025
23 COM-C4
7 80129 39 80026
24 80037
8 80130 40 80027
9
10
80131
80132
25
26
$0038
80039
41 80028
COM-C2
DD D[ Pripheral
deviceA3
42
27 80040
11 80133 43 80029
28 COM-CS
12 80134 44 80030
29 80139
13 80135 45 80031
14 30 · 80140
80136 46 80032
31 80141
15 80137 47 COM-C3
32 80142
16 80138 48
17 ov 49 +24E
18 ov 50 +24E

CRM20
1 80143 33 $0041
2 80144 34 80042
19 80153
3 80145 35 80043
20 80154
4 80146 36 80044
21 80155
5 80147 37 COM-01
22 80156
6 80148 38 80045
23 COM-04
7 80149 39 80046
24 SDl57
8 80154 40 80047
9
10
SDl51
80152
25
26
80158
80159
41 SD048
COM-02
JD D[ Pripheral
deviceA4
42
27 8060
11 SDl53 43 SD049
28 COM-05
12 $0154 44 80050
29 SDl59
13 80155 45 80051
30 80160
14 SDl56 46 $0052
31 80161
15 80157 47 COM-03
32 80162
16 80158 48
17 ov 49 +24E
18 OV 50 +24E
NOTE
1 The peripheral device connection cables are optional.
2 All of COM-** are connected to O V.
Applicable process I/O printed circuit board

CRM2 CRM2
Type Specifications
c D
CA A16B-2201-o470
CB A16B-2201-Q472
DA A16B-2201-Q480 0 0
EA A16B-3200-0230
- 349 -

Control unit Connector pin No. Peripheral device

(peripheral device control interface A 1)
+24E
CRM2A 4950
Receiver circuit
*IMSTP
"HOLD
"SFSPD
CSTOPI
ov
FAULT RESET
START
HOME
ENBL
RSR1/PNS1
RSR2/PNS2
RSR3/PNS3
RSR4/PNS4
RSR5/PNS5
RSR6/PNS6
RSR7/PNS7
RSR8/PNS8
PNSROBE
PROD START
$0101
SDI02
+24E B A
Lo common setting
pin (ICOMI) ov
NOTE
This is a connection diagram for +24v common.
- 350 -


Receiver circuit LOAD

- ~I -
~RELAYµ -
DV CRM2A (33)
CMDENBL
v
OV ~
I CRM2A (34) 1 LOAD 1
SYSRDY I DV I I I
I CRM2A 135) 1 LOAD 1
PROGRUN DV I I
I CRM2A (36) II LOAD II
PAUSED I DV
I CRM2A (38) 1 LOAD 1
HELD I DV I I
I CRM2Al39) 1 LOAD 1
FAULT I DV I I
ATPERCH I DV I I
I CRM2A(41) I LOAD I
TPENBL I DV I I
BATALM I DV I I
BUSY I DV I I
I CRM2A(45) I LOAD II
ACK1/SN01 I DV
ACK2/SN02 I DV I I
I CRM2A 119)
ACK3/SN03 I DV : LOAD:
I CRM2A (20)
CRM2A 121)
ACK5/SN05
I
I DV I LOAD:
I CRM2A 122)
CRM2A (24)
ACK7/SN07
I
I DV I LOAD I
CRM2A 125)
ACK8/SN08 DV I LOAD I
CRM2A 126) 1 LOAD 1
SNACK DV I I
CRM2A(27), 1 LOAD 1
RESERVED DV I I
CRM2A(23,28,37,
42,47)
'""
'<:U ®----
J_ OV +24V
+24 V regulated
ov power supply
- 351 -


+24E
CRM2B 49 50
Receiver circuit
80103
80104
8DI05
80106
8DI07
80!08
80109
8Dl10
80111
80112
80113
80114
80115
80116
80117
80118
80119
80120
80121
8Dl22
+24E B A
~
ov
NOTE
This is a connection diagram for +24V common.
- 352 -

Control unit Peripheral device

(peripheral device control interface A2)
Connector pin No. LOAD
5D001
I
I DV
I
I
CRM2B (33)
~ R~v1l -
~
I I CRM2B (34) 1 1
5D002 I DV I I LOAD I
I I CRM2B (35)
5D003 I DV I : LOAD:
I I CRM2B l36) 1 1
I I CRM2B (38)
I I CRM2B l39) LOAD
5D006 I DV I
I
I
I
I
I I CRM2B (40) 1
5D007 I DV I I LOAD 1I
I I CRM2B (41) 1 1
I I CRM2B (43) 1 1
I I CRM2B (44) 1 1
I I CRM2B (45) II LOAD II

5D011 I DV I
I I CRM2B (46) I LOAD
5D012 I DV I I
I
I
I I CRM2B (19)
I I CRM2B l20)
I I CRM2B (21)
I I CRM2B (22)
CRM2B (24)
5D017
I
I DV
I
I I LOAD I
CRM2B 125)
5D018
I
I DV
I
I I LOAD I
I I CRM2B (26) 1 1
I I CRM2B (27). 1
5D020 I DV I I LOAD 1I
CRM2A(23,28,37,
J_
42,47)
-
..,..
ov +24V
®---
+24 V regulated
OV power supply
- 353 -


+24E
CRM2C 49 50
Receiver circuit
SDl23
SDl24
SDl25
SDl26
SDl27
SDl28
SDl29
SDl30
SDl31
SDl32
SDl33
SDl34
SDl35
SDl36
SDl37
SDl38
SDl39
SDl40
SDl41
SDl42
+24E B A
~
ov
NOTE
- 354 -


80021 DV
CRM2C (33)
11 R~Y µ_ ~
~
OV
~
I I CRM2C(34l
80022 I DV I : LOAD:
I I CRM2Cl35\
80024
I
I DV
I
I
CRM2Cl36\
i LOAD [
I I CRM2C(38\
80026
I
I DV
I CRM2Cl39\
: LOAD i
80027
I
I DV
CRM2Cl40\
{LOAD 1
I CRM2Cl41\
80028 I DV 1 : LOAD:
I I CRM2Cl43\
80029 I DV I : LOAD [
80030
I
I DV I
CRM2Cl44\
: LOAD i
I CRM2Cl45) r LOAD 1
80031 I DV I
80032
I
I DV
I
I
CRM2C l46\
i LOAD [
I I CRM2Cf19\
80034
I
I DV
I
I
CRM2C l20\
{LOAD 1 -.
I I CRM2C (21\ I I
80035 I DV I 1LOAD1
CRM2C (22)
80036
I
I DV
I
I : LOAD I ~
CRM2C (24)
-1 LOAD I
I I
80037 I DV I
I I CRM2C f25\ [ ~
80038 I DV I l LOAD I
80039
I
DV
I
I
CRM2C l26l
~LOAD 1
CRM2C l27l
i
...
I
80040 I DV I : LOAD
CRM2C(23,28,37,
J_
ov
42,47)
--
ov +24V
+24 V regulated
power supply
- 355 -


+24E
CRM20 49 50
Receiver circuit
80143
80144
80145
80146
80147
80148
80149
80150
8Dl51
80152
80153
80154
80155
80156
80157
80158
80159
80160
8Dl61
8Dl62
+24E B A
~
ov
NOTE
- 356 -


SD041 DV
CRM2D (33)
~ R~vll ,..___
~
OV
~
I CRM2D (34), 1
SD042 I DV I I LOAD 1I
I I CRM2D {35\ 1
SD043 DV I I LOAD 1I
I I CRM2D {36\. II LOAD II
SD044 I DV I
I I CRM2D (38) LOAD
SD045 I DV I
I
I
I
I
I I CRM2D {39\
SD046 I DV I : LOAD:
I I CRM2D l40\ 1 1
SD047 I DV I I LOAD I
I I CRM2D (41) 1
I I CRM2D l43\ 1 1
I I CRM2D (44) 1 1
I I CRM2D (45) 1 1
SD051 I DV I I
LOAD I
I I CRM2D l46\ 1
I I CRM2D {19\.
I I CRM2D {20\ LOAD
SD054 I DV I I
I
I
I
I I CRM2D (21\
I I CRM2D (22)
I I CRM2D (24) 1 1
SD058
I
DV
I CRM2D l25\
I LOAD I
I CRM2D (26),
I CRM2D {27\. 1 1
SD060 I DV I LOAD I
CRM2D(23,28,37,
42,47)
'"'
""
®--
ov +24V
+24 V regulated
ov power supply
- 357 -

4.4.2
Connection Between
the Mechanical Unit
and End Effector
Mechanical
unit EE
RD02 RD03
End effector
RD07 RD08
- 358 -

Mechanical unit (encl-effector interface) 24y nector pin No. End effector
EE(17, 18. 19, 20)
+24V Pin for setting
~K enable or disable
Wrist breakage Receiver circuit

detection signal *HBK RV ~_.....--....:........:'---'"'-_,...._ _ ___.
RDil----1
ROI2----1
Input signals
indicating the
states of the
RDI3----1
end effector
RD14----1
RDIS----1
RDI6----1
ROl7---'
RDIS----1
Pneumatic *PPABN----1
pressure abnormal
signal +24V
LB o----.i..--<SA
Pin for switchi~ the
LO common signaJS ov
AD (RD I COM)
o_v-+-___EE......(__,1)--0---C~LO~
RDOl --.i--r ~
~
EE(2)
RD02-----1 ov LOAD
Signals for EE(3)
controlling the ROOJ----1 ov LOAD
end effector
EE 4
R004--- ov LOAD
EE(5)
Roos--~ ov LOAD
EE(6)
RD06----1 ov LOAD
EE(21)
RD07---' DV LOAD
EE(22)
RDOS----1 ov LOAD
EE(S)
ov OV
NOTE
1 This is a connection diagram for +24V common.
2 The connector pin numbers of the end effector depend on
the robot.
- 359 -

AND END EFFECTOR INTERFACES CONNECTIONS .B-80525E-1/03
4.4.3
Connection Between
the Control Unit and
Welder
Control unit
Welder interface
CRW1
01 DACHI 23 WOOi
13 ADCHI
02 COMADI 24 WD02
14 COMADI
03 DACH2 25 WD03
15 ADCH2
04 COMAD2 26 WD04
16 COMAD2
05 WDII 27 WD05
06 WDI2
17
18
28 WD06 JD-0[ Welder
07 WDI3 29 ' WD07
WDI4
19 ov
08 30 WD08
09 WDI5
20 ov WO!+
31
WDI6
21 ov
10 32 WDI-
11 WDI7
22 ov +24E
33
12 WDI8 34 +24E
Analog input interface

CRW2
01 14 ADCHJ
08 ADCH6
02 15 COMAD3
09 COMAD6
03 16 ADCHJ
04
10
11
17 COMAD4 00-0[ Peripheral device
05 18 ADCH5
12
06 19 COMAD5
13
07 20
Applicable process 1/0 printed circuit board

Type Drawing number CRW1 CRW2
CA A16B--2201-0470
CB A16B--2201-0472 0 0
DA A168--2201-0480
EA A16B-3200--0230 0 0
Note1) Welder and peripheral device connection cable is option.
- 360 -

Control unit Welder

(Welding interface)
Connector pin number MS connector pin number
CRWI (I J A
{ DACHI
Welding voltage
command signal CRW I (2)
CAMDAI B The input impedance
shall be more than 3.31<.Q
high-pass filter shall be
CRWI (3)
{ DACH2 E provided.
Wire speed
command signal CRWI (4)
CAMDA2 F
CRWI ( 13)
J
Welding voltage { AOCHI
detection signal CRWI ( 14)
CAMADI K
Output signals
without ripples.
CRWI ( 15)
L
Welding current { AOCH2
detector signal CRWI ( 16)
CAMAD2 M
ov
R=100Q or more
CRWI (31) N
Wire soldering
detector signal { WDI+
WDI-
CRWI (32) p
E> e
Welding power supply
- 361 -

Control unit Welder

(Welding interface)
DV LOAD
~
CRWI (231 R
Welding start WDOl
signal
~
Gas signal WD02 DV CRWI (24) s LOAD
Wire inching WD04 ov CRWI (26) u LOAD

(positive) signal
Wire inching WD05 DV CRWI (27) v LOAD
(negative) signal
CRWl(l9,20l a
CRWI (21 ,22) b

+24V regulated
power supply
ov
Receiver circuit
Arc detection WDI2 ---1
d
signal
Gas shortage WDI3 ---1
e
detection signal
Wirecut WDI4 ---i
f
detection signal
Cooling water . WDI5 - - - i g
shortage detection
signal h
Welding power WDI6
supply abnomality
signal +24V
A
Common switching°""""]_
set pin OV
lICOM3)
CRWI ( 19,20) n
CRWI (21,22) m
OV
FG (cabinet ground)
- 362-


(Analog input interface)
ADCH3
CRW2( 15)
CAMAD3
ADCH4 CRW2(16)
CRW2( 17)
CAMAD4
Output signals without
ripples.
ADCH5 CRW2C 18)
CAMAD5 CRW2C 19)
ADCH6 CRW2(8)
CAMAD6 CRW2(9}
OV
- 363 -

4.5 This section describes the specifications of the digital 1/0 signals
interfaced with the peripheral device, end effector, and arc welder.
DIGITAL 1/0 SIGNAL
SPECIFICATIONS
4.5.1
Peripheral Device (1) Output signals in peripheral device interface A
Interface Example of connection
OV OV
ov
Protective resistance
Electrical specifications
Rated voltage 24VDC
Maximum applied voltage 30VDC
Maximum load current 0.2A
Transistor type Open collector NPN
Saturation voltage at connection 1.0 V (approx.)
Spark killer diode

Rated peak reverse voltage 100 Vormore
Rated effective forward current 1 A or more
Note on use
Do not use the +24 V power supply of the robot.
When loading 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 1/0 printed circuit board CRM2
CMDENBL, SYSRDY, PROGRUN, PAUSED, HELD, FAULT,
ATPERCH, TPENBL, BATALM, BUSY, ACKl to ACK8, SNOl to
SN08, SNACK, SDOl to SD020
- 364 -

(2) Input signals in peripheral device interface A

Example of connection
+24V
+24V
Lo B A
ICOM OV
Electrical specifications of the receiver

Type Grounded voltage receiver
Rated input voltage Contact close
: +20 V to +28 V
Contact open
: 0Vto+4V
Maximum applied input voltage +28 VDC
Input impedance 3.3 kQ (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 n or less
Opened circuit resistance 100 kQ or more
Peripheral device
contact signal
Robot receiver signal

Tc Tc Ts ; Chattering 5 ms or less
Tc ; 5to20 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 1/0 printed circuit board CRM2
*IMSTP, *HOLD, *SFSD, CSTOPI, FAULT RESET, START,
HOME, ENBL, RSRl to RSR8, PNSl to PNS8, PNSTROBE,
PROD START, SDil to SDI22
- 365 -

4.5.2
End Effector Control (1) Output signals
Interface Example of connection
OV OV
OV OV
Protective resistance
Electrical specifications
Rated voltage 24VDC
Maximum applied voltage 30VDC
Maximum load current 0.2A
Transistor type Open collector NPN
Saturation voltage at connection 1.0 V (approx.)
Spark killer diode

Rated peak reverse voltage lOOVormore
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 loading 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
RDOl toRD08
- 366-

(2) Input signal

Example of connection
+24V
+24V
~
B A
ICOM OV
Electrical specifications of the receiver

Type Grounded voltage receiver
Rated input voltage : Contact close : +20 V to +28 V
Contact open 0Vto+4 V
Maximum applied input voltage +28 VDC
Input impedance 3.3 kQ (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 Q or less
Opened circuit resistance 100 kQ or more
Peripheral device
contact signal
Robot receiver signal

Tc Tc
Ts ; Chattering 5 ms or less
Tc ; 5to20ms
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
RDil to RDI8, *HBK, *PPABN
- 367 -

4.5.3
1/0 Signal (1) Digital output signal specifications for arc-welding interface
Specifications for
ARC-welding Interface Example connection
Spark killer diode
I +24V
.I. 0.2 A or
'f less
OV
OV
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: I A or more
NOTE on use
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 directly drive a relay or
solenoid, connect a diode preventing back electromotive force
to the load in parallel. To connect a load which generates an
inrush current upon power-on connect a protective resistor.
Applicable signals
- Output signals on the arc-welding interface
- WDOl to WD08
- 368 -

(2) Digital input signal specifications for arc-welding interface
Example connection
+24VICOM
A°lOV
3.3kn
ov
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
Contact signal
for peripheral
Receiver
signal for robot
Tc Tc
T 6 : Chattering of 5 ms or less
Tc: 5to20ms
NOTE on use
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
- WDil to WDI8
- 369 -

(3) Analog output signal specifications for arc-welding interface

(Welding voltage command, wire-feedrate command)
Example connection
Welder
-
0- -IOV >----
- -
ov
NOTE on use
NOTE
Input impedance: 3.3 k 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
0- +IOV--+-
OV-+-
NOTE on use
NOTE
Output a signal with no ripple.
(Wire deposit detection: WDI+ and WDI-)
Example connection
Welder
max. g- +
+15V 85mA
---0-------0
Welding electrode
NOTE on use
NOTE
Connect a resistor of 100 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.
- 370 -

4.6 If the customer manufactures 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

MR50LWFOI MR50LMOI
(MR50LFH) (MR50LMH)
tJ
Process 1/0 Peripheral
C3
device
CRM2•
Honda Tsushin
MR50RMA 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

MR20LWFOI MR20LMOI
CMR20LFH} (MR20LMH}
G 'o [
Process 1/0 Peripheral
device
CRM4*
Honda Tsushin
MR20RMA Honda Tsushin's MR20RFH
Supplied with an ordered cable
- 371 -

4.6.3 Be sure to use our cable for connection of welder.

ARC Weld Connection
Cable (CRW1: Honda
Tsushin, 34 Pins)
ARC welder
Honda Tsushin
MRP34LWMOI
Process VO
CRWI
Japan Aviation Electronics
Industry Ltd.
MS3102A28-21S
Honda Tsushin Japan Aviation Electronics Standard position of guide key
MR34RFA Industry Ltd.
MS3108B28-21P
MS3057-16
- 372 -

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 control unit.
Connection Cable
CRW1
Process VO EA
Operator's box
CRM2B
CRM2A
To peripheral
device
Flg.4.7.1 {a) Peripheral Device Cable Connection (i cabinet)
- 373 -


CA/CB/DA
1/0 unit model A

or
1/0 unit model B
Note: light the clamp with hand.

Do not use pliers.
Metallic clamp
Noise protection: Remove a partofthesheathof 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 (b) Peripheral Device Cable Connection (B cabinet)
- 374 -

B--80525E-1/03 CONNECTIONS AND END EFFECTOR INTERFACES
4.7.2
Peripheral Device (1) Fig. 4. 7.2 shows the connector for peripheral device cables A and B.
Cable Connector
..... -
c~
u
'1 I
MR-50L
HONDA
I
A
( B) (0)
Connector Dimensions
Applicable
specifica- Remark
Interface
tions A (8) c (D)
MR50LMH CRM2 67.9 73.5 44.8 18 Honda Tsushin Kogyo,
50pins
MR20LMH CRM4 39.3 44.9 39.8 17 Honda Tsushin Kogyo,
20pins
Symbol Name
(1) Connector cover
(2) cable clamp screw
(3) Connector clamp spring
(4) Connector clamp screw
(5) Connector 50 pins (male) MR50MH
20 pins (male) MR20MH
Fig.4.7.2 (a) Peripheral Device Cable Connector (Honda Tsushin Kogyo)
- 375 -

(2) Peripheral device connector
MR50RFH,MR20RFH
2-M2
B
A
Connector DImen-
Applicable sions
specifics- Remark
Interface
tions A B
MR50RFH (CRM2) 61.4 56.4 Honda Tsushin Kogyo,
50pins
MR20RFH (CRM4) 39.3 44.9 Honda Tsushin Kogyo,
20pins
Symbol Name
(1) Connector clamp screw
(2) Screw e2.6x8
(3) Connector (MR50RFH)
(MR20RFH)
Flg.4.7.2 (b) Peripheral Device Connector (Honda Tsushin Kogyo)
- 376 -

4.7.3
End Effector Cable ( 1) Connector
Connector
A M30x1 E 933
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
Flg.4.7.3 (a) Connector (Elbow type)
A M30x1 E 933
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
Flg.4.7.3 (b) Connector (Straight type)
- 377 -

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 4.7.5 (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)
Electrical characteris-
Conductor Effective
Sheath tics
Number Wire specifications outside
thickness Conductor Allowable
of wires (FANUC specifications) Diameter Conflgura- diameter
(mm) resistance current
(mm) tion (mm)
(O.Jkm) (A)
50 A66L-0001-0042 01.05 7/0.18 1.5 012.5 106 1.6
AWG24
20 A66L-0001-0041 01.05 7/0.18 1.5 010.5 106 1.6
AWG24
(2) End effector connection cable

Connect an end effector using a heavily protected cable with a
movable wire conforming to the specifications in Table 4.7.5 (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)
Electrical characteris-
Conductor Effective
Sheath tics
Number Wire specifications outside
thickness Conductor Allowable
of wires {FANUC specifications) Diameter Conflgura- diameter
(mm) resistance current
(mm) tion (mm)
(O.Jkm) (A)
6 A66L-0001-0143 01.1 40/0.08 1.0 05.3 91 3.7
AWG24
20 A66L-0001-0144 01.1 40/0.08 1.0 08.6 91 2.3
AWG24
- 378 -
5. TRANSPORTATION AND
B-80525E-1 /03 CONNECTIONS INSTALLATION
5
TRANSPORTATION AND INSTALLATION
5.1 The control unit is transported by a crane. Attach a rope to eye bolts at
the top of the control unit.
TRANSPORTATION
NOTE
A combination control unit is incorporated into the
mechanical unit of the robot.
CRANE NOTE 1. Controller weight 1OOkg

CAPACITY : Min. 150kg 2. Eyebolts complied with
JIS B 1168
3. Quantity
eyebolt: 2 (M10)
sling :1
SLING
CAPACITY : Min. 150kg
oonmm 11111111111111111
Fig.5.1 (a) Transportation (Separate type cabinet}
- 379 -
INSTALLATION CONNECTIONS B-80525E-1 /03
SLING CRANE
CAPACITY : Min. 300kg CAPACITY : Min. 300kg
I I I Io o o o
b
CDE:I
0 0 0 &
E:I E:I •WI
•
NOTE 1. CONTROLLER WEIGHT 180kg
2. EYEBOLTS COMPLIED WITH JIS 8 1168
3. QUANTITY EYEBLOTS : 2 (M10)
SLING : 1
Fig.5.1 (b) Transportation
- 380 -
CRANE NOTE I . CONTROLLER WEIGHT 300KG

CAPACITY:MIN. 500KG 2. EYEBOLTS COMPLIED
WITH JIS B I I 68
3. QUANTITY
EYEBOLTS : 2(Ml2)
SLING SLING : I
CAPACITY:MIN. 500KG
DD 0 0
~000
D DDl:I
:o
b
l:J
0 0 0 S-900
CRANE
CAPACITY:MIN. CONTROLLER WEIGHT 250KG
EYEBOLTS COMPLIED
WITH JIS B I I 68
QUANTITY
SLING EYEBOLTS : 2(M12)
CAPACITY:MIN. SLING : I
0 0
0 0
M-500
Fig.5.1 (c) Transportation ($-900, M-500)
- 381 -
INSTALLATION CONNECTIONS B-80525E-1/03
5.2
INSTALLATION
5.2.1 When installing the control unit, allow the space for maintenance shown
Installation Area in the following figure.
606 600 500

--------,
I
I
g
~
MAINTEt-.~ANCE
SPACE '1
I
I
r===~=~~--t-------_J
Unit:mm
Flg.5.2.1 (a) Installation Area (Separate type I cabinet)
- 382 -
B-80525E-1/03 CONNECTIONS INSTALLATION
0
0
100 740
0
CONTROLLER CONTROLLER- CONTROLLER
500 '° 500
______ J
L-------1--------'
Unit:mm
Flg.5.2.1 (b) Installation Area (B-Cabinet/ARC Mate 100, ARC Mate 120, ARC Mate 100i, ARC Mate 120i, s-&, S-12,
M-6i, M-16i, $-420i, S-SOO, S-700, M-710i, A-520.)
0
0
r-----.,
100 740
-----.,
CONTROLLER {ADDITIONAL{ADOITIONAL CONTROLLER CONTROLLER
CABINET 2) CABINET ll (MAIN CANINET}
00
_ _ _ _ _ _J
L------t---~
Unit:mm
Flg.5.2.1 (c) Installation Area (5-900:with 2 additional cabinets, M-500:with 1 additional cabinet)
- 383 -
•r - -·- - -,•
•L - -.- - _J•
545
515
485 300
~1 1-- ~1
-,.--+i
[~ ]q
ijiiiii-- I
@]
.---------.
. .
0- -0 -0 ·- CJ
0 0 - - "l!!I' Cl
I ' (}\ D CJ 111-u <D
I") (\J
. .
0
[o~o] ~
Unit:mm
Fig.5.2.1 {d) Installation {Operator's Box)
- 384 -
5.2.2
Connecting Cables at
Installation
(Combined Type of i
Cabinet)
OPERATOR'S BOX
[-1> ]q ·----·
- - ._ D
0 0 0 O-
D 0 iii-5 D ©
INPUT POWER CABLE
TEACH PENDANT
1111111111111111m 1111111111111111111
--
©
PERIPHERAL DEVICE CONNECTION CABLE
Fig.5.2.2 Connecting Cables at Installation
- 385 -
INSTALLATION CONNECTIONS B-80525E-1 /03
5.2.3
Connecting Cables at
Installation
(For Separate Type of i
Cabinet)
OPERATOR'S BOX
[~ ]q ·-
-
0
-
0
,.
0
D
••
~
-- - '!!!!' D
D D 11111-u Ci)
INPUT POWER CABLE
TEACH PENDANT
1111111111111111m 1111111111111111111
--
ROBOT MECHANICAL UNIT
© CONNECTION CABLE
PERIPHERAL DEVICE CONNECTION CABLE
Fig.5.2.3 (a) Connecting Cables at Installation (i cabinet)
- 386 -
-- B •
-r.J -
•
M-410i CABINET IS INSTALLED INPUT

IN THE ROBOT PEDESTAL. POWER
CABLE
PERIPHERAL DEVICE
CONNECTION CABLE
Flg.5.2.3 (b) Connecting Cables at Installation (M 410i cabinet)
- 387 -
(5) (5)
-
i
~000 b
b
cco
D :o
. 0
TEACH PEND ANT
• II ROBOT MECHANICAL UNIT

CONNECTION CABLE
~NPUT POWER CABL~

II PERIPHERAL DEVICE
CONNECTION CABLE
II WELDER INTERFACE
CABLE
Flg.5.2.3 (c) Connecting cables at Installation (B cabinet)
- 388 -
Separate-type control unit of i cabinet (ARC MatelOO, ARC Matel20,

ARC Mate 120i, S-6, S-12, M-16i, S420i, S-500, S-700)
The control unit can be separated from the robot. To enable separate
installation of the control unit, an optional robot connection cable is
required.
Robot connection cable

(option)
Controller
- 389 -
5.3
INSTALLATION
CONDITION
Item Model Specifications/condition
Line filter All models Three-phase 200 VAC +10%-15%, 50 q1 Hz;
three-phase 200 to 220 VAC +10%-15%, 60 q1 Hz
Transformer All models Three-phase 220, 240, 360, 415, 460, 480, 500, 550, or 575 V
+10%-15%, 50/60 q1 Hz
Input power source capacity ARC Mate 100, s-6, M-16i, ARC 2.5kVA
Mate 100i, M-6i
ARC Mate 120, ARC Mate 120i, 3kVA
S-12, A-520i
S-700, M-71 Oi 6.5kVA
5-500 7kVA
5-420i, M-410i, M-500 12kVA
S-900 18kVA
Average power consumption ARC Mate 100, ARC Mate 120, 1.0KW
ARC Mate 120i, s-6, S-12, M-16i,
ARC Mate 1OOi, M-6i
5-500, S-700, M-710i 1.7KW
M-500 2.0KW
Average power consumption 5-420i, M-41 Oi 2.5KW
5-900 3.5KW
Permissible ambient temperature All models 0°Cto45°C
Permissible ambient humidity All models 75% RH or less, non-condensing, up to 95% RH for a limited
period (within one month)
Surrounding gas All models No corrosive gas. When using the robot in an environment with
a high concentration of dust or coolant, consult with your FANUC
sales representative.
Vibration All models 0.5 G or less. When using the robot in a location subject to seri-
ous vibration, consult with your FANUC sales representative.
Weight of control unit Bcabinet About 180 kg
i cabinet About 100 kg (front cabinet: About 40 kg, rear cabinet: About 60
kg)
NOTE
As a continuous rating in the above capacity is enough
though, when the robot is rapidly accelerated, the capacity
of the power supply will momentarily need the capacity of
about two times the continuous rating value.
- 390-
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 if the screwed terminal is connected properly.
3 Check that the connectors and printed circuit boards are inserted correctly.
4 Check transformer tap setting. (See II MAINTENANCE 6.3)
5 Tum disconnector and the breaker off and connect the input power cable.
6 Check the input power voltage.
7 Press the EMERGENCY STOP button on the operator's box and tum the power on. Check the output voltage.
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's box. Tum the power on.
11 Check the movement along each axis in the manual jog mode.
12 Check the end effector interface signals.
13 Check the peripheral device control interface signals.
- 391 -
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 alann occurs when the power is turned on after
installation.
The robot enters the emergency stop state when the peripheral device
control interface is not connected.
5.5.1 Take the following actions if signals ·IMSTP, •HOLD, ·SFSD, and
Peripheral Device ENBL are not used.
Interface Processing
CRM2A
+24F
49,50
•IMSTP 1
RV
·HOLD 2
RV
·SFSD 3
RV
ENBL 8
RV Connect the signals to pins 49 and 50 of CRM2A.
5.5.2 Press the reset switch on the operator's panel or the reset key on the teach
pendant.
Resetting Overtravel
Manually move an axis that has overtraveled into the operating range
while pressing the shift key on the teach pendant.
- 392 -
APPENDIX
B-80525E-1/03 APPENDIX A. COMPLETE CONNECTION DIAGRAM
A COMPLETE CONNECTION DIAGRAM
A.1
COMPLETE
CONNECTION
DIAGRAM
(I-CABINET ; ARC
MATE 100, ARC
MATE 120, ARC
MATE 1OOi, ARC
MATE 120i, s-&,
S-12, M-6i, M-16i,
$-420i, s-soo, S-700,
M-710i, A-520i)
- 395 -
THIS CONNECTION IS DEFERENT ?>

~~E~8Hp~~06i; (')
~~ANT
UNIT 'ROBOT COll'ECTION'~080T ~
TR.t.NSFORMER S-4201 -0
( ) / .t.-5201 r-
I I I .t.RC Mato 1001 m
NOISE l-0------Jmc
L~~ M-61 -I
FILTER !IN CASE OF M-7101 m
L2 STANO ALOI£ TYPE J n ARC ~~ : 21 120 I (')
~ili~ 1 1 I I
[" -fi tµ 1 1 r - - - - -U ~-J3 MOTOR POWER Q
I
L3 I r - - - _n Ml ZZ
J. l ) U J4-J6 MOTOR POWER
PE--+-+-;: ANO J 1-J& MOTOR BRAKE m
1 I I
I l ) ":' -a=' CASE OF 9
INTEGRATED TYPE) :::::!
I I CIN
-b
F. JI MOTOR POWER I I I Qz
2-u.v.w.s
R'i-:2.vc_i:.:~§ J2 MOTOR POWER I I I
I~ 3-U.V,W.G J3 MOTOR POWER 0
4-U,V.W.G J4 MOTOR POWER I I I )>
?.~ 5-U.V.W.G
---- 6-U,V,W,G
1' II ,.
,.- B.t.CK PL.t.NE PSU :: :i~ :g:: ~
:u..!. CPI CN6 J 1-J6 MOTOR BRAKE ~
(')-
a: a JNPO CP2 (IN CASE OF
I» CD STANO ALONE TYPEl n.
;3 CP3 r - - - - -uJ ~1-J6 PULSE CODER
.... !!. I l ANO RDI/ROO
CP!I CRM9
CRF3 PULSE CODER >
F.g CRRl5 Jl/.J2/J3 "'D
a: ::::J M.t.IN CPU UN CASE OF "'D
w INTEGRATED TYPE l m
JRVI CRR20
0\
'° CRF4 PULSE CODER
z
f-1 J4/Jl5/J6 c
JRF2 JRF2 I x
~~
.... 5· CRMI 1 ~- - DOOR ---;;NTER~;- - ROT
!OPTION)
!?.ca CRMIO
w ... E-STOP UNIT SWITCH
+I
,_ m JR.t.5 JDIA - n
-u FANUC I/O LINK
I CRMl5 I\ / ...,
:u3
JF21 - -n LINE TRACKING I ~
~1; _ _ _ _ _u _:OP~~ __ L _____ ::-L _l"'i~~~~ TYPE>
Ill ID CRSI
_n RS-232-C/RS-485 - - - I - - - - m~~~jHBK
_.,::::J J017 D- ___ - - I~T,;;,A~ ;;- \~N CASE OF
'!Z U (OPTION) INTEGRATED TYPE)'----------~
?..! JRM3 ~-----..... JRM3;PANEL DI/DO I
JRMIO;
JRMIO TEACH PENDANT I
RS-232-C INTERFACE I
.... RS-232-C/RS-485 INTERFACE A I
EMERGENCY STOP
~ r----, OPERATION BOX I ~
IOPTIONI
rl OPTION PCB CRSI
' .All.t.
n L nt::J
11
OPTICAL _n RS-232-C INTERFACE I
1L ISOLATOR u
____ J
RS-232-C
":'
iT
Ci
c:.>
i REDIJN)ANT
E-STOP
> UNIT
:... TRANSFORMER
( ) I r ( )
iT
~
.E:
- LI! I I I I I~ ~I NJISE c.>
1 1
i... [ ~ ~ "'"" l-o--F-,l~ 1 I h!--> i r·----'- - ' -- - -
:I
!!!. THIS CONNECTION IS DEFERENT
J_ l ) FROM EACH ROBOT.
0 REFER TO PAGE OF
g PE -b-~ll_J 1 'ROBOT CQllNECTION'. ROBOT
:I
---6-- s-eoo
S-700
ACll AC2 AC I CN I S-6
CN7B M2 S-12
!. 6-AXIS N'P ARC Mtlt 100
0 2 u.v.w.o ARCMtle 120
:I 3-U,V,W,G
IC
. .;~fj G
4-U,V,W,G
B-U,V,W,G
Ml
ii '= 6-u.v .w.G

co
; CN6
3
POWER SlPPLY
BACKPLANE
1; UNIT CPI Pl
ID JI -J6 PULSE CODER
JN>() ANO ROI/ROO
!Z CRM9
:I )>
! CRRIB "'O
!,;.) E-STOP I.NIT "'O
\0 m
-.J CRR20 z
0
-~
MAIN CPU
~ x
CRMI I
t
~
.M!F2
?>'
JRAB ---- - - n FANUC
i'(> U- - - - - - -~ (OPTI~l'° LINK 'rn~~jHBK
8
s:
... JF21
j') ~- ____ - U T6P~I~fi<ING ""C
CRSI r
)> ~- - - - -n- - - - - - - - -
::D - - - RS-232-CIRS l ~
0 JRM3 ;PANEL DI/DO u (OPTION) - 4eB INTERFACE B I m
iii: «R/'i#li~l'°" I
JRMIO. CRSI l EJEACH
8z
I... ,.....,...., I ,,,_, z
m
~ r - - - - RS-232-C INlE OPTICAL
ISOLATION on u- - - -U RS-232-C INTERFACE I
n
)> D ~
::D
0
~ ~~ ... I~"'!iW~... RS-232-C
5
z
iii: .Jiii\ 11 I c
(REFER TO PAGE OF 'OPERATION BOX' l
I... 1 I
L----J
~::IJ
~ l>
s:
;:ti-
8s::
""'C
r
~
m
(')
0
z
z
!! m
a:a ~
>
:... 0z
n QF(BREAKERl 0
TRANSFORMER
(I r ( ~ >
440-500V G.>
--a
CD LI
I I 380-415V
3 I I I ~
!!!. AC POWER s::
n SUPPLY I I I NOISE
0 380/415
L2 FILTER SERVO POWER
:::s 440/460 I I 200R,S,T
:::s 480/500 I I I
!. 50/60H• L3 I I )>
l;.)
0
:::s I I PE l ) .,,
""C
PE l m
00
0 l ) 04:- __c--- z
"° ii" - l
a:a 0
i3 AC INPUT
x
3 FOR LOGIC
200A,B
b t~ 1 CN8BO THERMOSTAT
ID FOR OVERHEAT
sr. • CONNECTION TO TRANSFORMER TYPE 3(A80L-0026-0014#Al
:::s POWER CONNECTION OF PRIMARY TAP
SUPPLY CON>IECTING
11 VOLTAGE JUMPER
STYLE
~
ID 440
:::s
·in I 460
480 IL1AIL2AIL3A
~ STAR y
500
I 380 ILIBIL2BIL3B
! 415
25
i-rr
c.>
D r©)AN
irr
CA39A
§
,,
ii"
;..
:...
'ii:
-i
...
~ POWER SUPPLY CPI CP4 CP8
A 168-1212-01171 I
!!?.
CPI 200-240 VAC IN'UT
R
0 D I I ffi] tJl~tl~I Ia:~. IBA~- I
0
~
~ CP2 0---- 200-240 VAC OUTPUT
CP2
OLGl~I
CP3 200-240 VAC OUTPUT
!c;· 0---- CP5
~ )>
POWER ON/OFF
I ~I l{Hd 83
c M'O CP4 0---- ALARM
GfJJ I I "tJ
w ii" "tJ
ca CP3 m
CP5 +24 VDC OUTPUT z
'° ; 0---- CP6
'° 0
3 CP6 +24 voe OUTPUT Bl 82 83
•2olE
0---- 1~1 UlJ I I ov I I x
-h
I» BATTERY CR8 SPECIFICATIDN OF FUSE
2: NAME ~~ ~Wll NOTE USE
~
Fl 7.llA ~~ FAST BLOW Fal IOOV
F3 5.0A II.OW BLOW Flit •24V
~
11 ·-~
,, 5.0A -~~ FAST BLOW FOR o2IE
-a 8s:::
I... "'tJ
en r
c
"a ~
"a m
I~ 0
''
-<c:
~
~-- 0
3 ~~~ z
z
m
~SS
~
I I
. ..~~..,
0z
POWER SUPPLY UNIT 0
~
~
s:
~
r©J"AN (')
JOIB .JRMIO JRF2 .JRVI
0
CI/O LINK) (OPERATION BOX! {ROBOT FEEDBACK) (SERVO AM>LIFIER) :s::
"'O
I RXSLC II ov I ov 26 ov Al PD6 Bl •F'D6 Al IS6 Bl GNDS6 r
BATTERY UNIT r-- ---, 2 •RXSLC 12 OV 2 RTSI 27 CTSI A2 OV B2 ov A2 IR6 B2 GNOR6
FOR MAINTENANCE
-r___ ~~-~VBAT
-0042
0-
D
- - ---l --l I -II I1--
L_ _
I
_J
3 TXSLC 13
4 •TXSLC 14
5 15
ov
ov
ov
3
4
5
ov
DTRI
ov
28
29
30
ov
DSRI
ov
A3
A4
A5
F'Rll6
ov
PD5
B3
B4
B5
•F'RD6
ov
•PDl5
A3
A4
A5
IS5
IR5
IS4
B3
B4
B5
GNOS!5
GN:>R5
GN:lS4
~
(')
.JRVI SERVO AMPLIFIER 6 16 ov 6 TXDI 31 RXDI A6 ov B6 ov A6 IR4 B6 GN)R4
7 17 7 ov 32 ov A7 F'RQ5 B7 •PR05 A7 IS3 B7 GNDS3
0
8 18 +5V 8 RTSA 33 CTSA A8 ov 88 ov A8 IR3 B8 GNDRJ
z
JRF2 9 +5V 19 9 ov 34 ov 1\9 PD4 B9 •PD4 A9 IS2 B9 GNJS2
z
D ROBOT FEEDBACK m
10 20 +5V 10 DTRA 35 DSRA IC ov IC OV AIC IR2 IC GNOR2
II ov 36 ov F'RQ4 II •F'RD4 Al I ISi II GN:lSI ~
i I I I I JF21 o---- LINE TRACKING 12 TXDA 37 RXDA .; ov I ov Al IRI I GN)RI
> 13 •TXTP 38 •RXTP PD3 I •P03 Al •ENBL6 I ov 0
:... .JRA5 .JRMIO TO OPERATION BOX JDl7 14 TXTP 39 RXTI' " ov I ov Al •PWME6 I ov z
Di----- (RS-232C/485)
115 •TX485A 40 •RX485A F'RQ3 I •F'RD3 Al •PWMC6 I ov 0
~ .JRY4
(FOR TEST> I RXDB II TXDB 16 TX485A 41 RX485A ov I ov Al •PWMA6 I ov
2 ov 12 ov 17 ON 42 ov PD2 I •P02 Al •ENBL5 I ov
...OIA 0---- l/O LINK
3 DSRBC 13 DTRB 18 OFF 43 SYON-RV OV I ov Al •PWME5 I ov ~
...017 RS-232C/485 INTERFACE 4 OV 14 ov 19 COM 44 +24V F'RQ2 I •F'RD2 ll •PWMC5 I ov
i.
:I
0---- I OPTION>
5 CTSB 15 RTSB 20 •OPEMG 45 +24V ov ov •PWMA5 ov ~
!!. JRM3 D--- TO OPERATION BOX 6 ov 16 ov 21 •EXEMG 46 +24V POI 121 •POI ""'
A21 •ENBL4 121 OV :s::
7 RX485B 17 TX485B 22 EMGDM 47 +24V ov IZ1 OV •PWME4 ---w-
0 CRSI 0--- TO TEACH PENDANT
PRQI
0 8 •RX485B 18 •TX485B 23 EMGEM 48 +24V •PRO I •PWMC4 ov
:I ~12 CRMIO 0--- RDI/RDO 9 19 +24E 24 •TPEMG 49 EMGBI ov ov •PWMA4 ov
:I og 10 +24E 20 25 SVON-EMG 50 EMGB2 ov ov •ENBLJ ov
I I
ov ov •PWME3 ov )>
~;;;;
00 +5V +5V A2 •PWMC3 2 ov '"O
11.I I
!!er
.j:>. ...J"'"' +5V '"+5V •PWMAJ 2 ov "'O
:I CRSI JF21 VBAT m
+5V '"+5V •ENBL2 "" ov
8 (TEACH PENDANT! {LINE TRACKING) (BATTERY! z
2 ~~~ +5V +5V •PWME2 """ ov
DI "'1-1- 01 TXTP J4 •TXTP I PA II I +5V I +5V I •PWMC2 I ov 0
ca 00
~ RXTP- oa 15 •RXTP I~ IEX:ATI
ullll 09 2 •PA 12 OV +5V +5V •PWMA2 ov x
I I I
03 EMGDM 16 El4GEN
iiJ 10 E-1 3 PB 13 +5V +5V •ENBLI ov
17 ov
3 "' II ~2 4 •PB 14 ov +5V +5V •PWMEI ov
"'"' 05 12
,.
06 •24V
EMllTP 19 ov 5 PZ 15 +5V +5V •PWMCI ov
13
07 •24V 20 -- 6 •PZ 16 ov +5V +5V •PWMAI ov
7 17 +5V +5V •MCON +5V
-b
DI +5V +5V +5V
8 RED 18 •DROY +5V
!l. 9 +5V 19 +5V +5V ov +5V
10 20 +5V +5V +5V ov +5V
J I +5V I +5V I +15V I +5V
+5V +5V +15V +5V
== ov ov ov IW +5V
!!?. CRMIO .JRMJ ov OV ov +5V
:I CROI/RDO) {PDI/PDO) ~·
+24E +24E -15V +5V
0 RIJOI 01 ROii I PDII II OV +24E •BRKALM2 -15V
""' +5V
""I7
"V
c: 15
" RD02
oa
09 ROii
02 ROI2 2 ov 12 PDOI •BRKON2 u· •OTREL ov
... +24V
16 R003 03 ROI3
10 3 ~
''
17 ROCM
ll"I9 ROI4
PDI2 13 PD02 •OTRST -· •ROT ov +24V
II ,05 4 PDI3 14 PD03 SYON •HBK +24V
18 RIJOI "' ROIS M •BRKON ~·
- 19 R006
+24E
12
13
RIJ07
RIJOI ~ RDI6
ov
5 PDI4 15 PD04
-·
RDICOM "" •HBKREL "" •BRKALM "' +24V
~ ~ 6 PDI5 16 PD05
·- 7
8
PDI6
PDI7
17
18
PD06
PD07
9 Tl'OFF 19 +24V
10 +24V 20 P008
MAIN CPU BOARD

i...rr
~
(.>
CNI SERVO AMP

(SERVO CONTROL)
iT
(5
(A)
Al IS6 Bl GNOS6
A2 IR6 B2 GNOR6 SERVO CONTROL ~ CNI
AJ IS!5 BJ GNOS!5
A4 IR5 B4 GNDR5
A5 IS4 B5 GNOS4
"Tl A6 IR4 B6 GNOR4 PRECHARGE [] CNI
~ A7 ISJ B7 GNOSJ
;. EMG CONTROL [J CN7A CONNECTION OF THIS INTERFACE
AS IRJ BS GNDRJ
~ IS REFER TO NEXT PAGE
A9 152 B9 GNOS2 INTERLOCK [J CN7B
.:!I AIC IR2 BIO GNDR2
- All ISi II GNOSI THERMOSTAT FOR OCR [] CNSA
5' Al2 IRI 12 GNDRI THERMOSTAT FOR TRANS [J CN8B
Cf ,m •ENBL6 13 ov
.
:I A14 •PWME6 I~ ov CN9
(FOR TEST>
!!?. Al! •PWMC6 I! ov
0 All •PWMA6 Ill ov
0 Al7 •ENBL5 II ov OCR~:~
:I l418 •PWME5 118 OV
:I ACI CN6
CD Al~ •PWMC5 819 ov SERVO POWER AC2
A2C •PWMA5 ""' ov ACJ
g. A21 •ENBL4 121 ov
)>
:I A22 •PWME4 '"" ov CN6
CNI
c A23 •PWMC4 823 ov (PRECHARGE) (BRAKE)
.j::.. iii' A24 •PWMA4 824 OV
.,,.,,m
0 co Al BRKIP Bl BRK2M
A~ •E'.NBLJ R"' ov z
ii.l A2 BRKJP B2 BRK4M 0
- A2E •PWMEJ R?• ov [i[G2 I A~I I AJ BRK5P BJ BRK6M
3 A21 •PWMCJ 827 ov NOTE x
A4 B4
8 •PWMAJ 828 ov B5 0.3A FAST BLOW
A CN7A/B A5
•ENBL2 "'' ov A6 BRKIM B6 BRK2P
Ill •PWME2 131 ov IEMG CONTROL/INTERLOCK)
A7 BRKJM B7 BRK4P
ber
:;· I •PWMC2 !31 ov I AJ I A2 I Al I AS BRK!5M BS BRK6P
2 •PWMA2 832 ov MCCON I SVOUT ;s=-
j1 ~3 •ENBL I 833 ov
A3A •PWME I 834 ov SERVO AMPLIFIER
w A:ll! •PWMC I 835 OV I BJ IMA~
A3E •PWMA I 836 ROBOT SPECIFICATION
ov
8s::
~ ~7 •MCON 37 +5V S-4201 A06B-6076-COOI or CIOI "C
> 38 •DROY 38 +5V r
3 CNSA/B S-500,A-5201 A06B-6076-C002 or CI02
39 OV 39 +5V
'a (OCR TH/TRANS THl S-700 A06B-6076-COOJ or CIOJ
0 ov 40 +5V ~
§i I +15V 41 +5V A06B-6076-C004 or CI04 (")
CD s-12
•• +1!5V 4: +5V ARC Mate 120 0
...i' A ov 43 +5V S-6 A06B-6076-C005 or CI05 z
•• ov +5V ARC Ma le 100
AA! -15V +5V
- zm
M-61 A06B-6076-CI05
lil -15V +5V ARC M1t1 1001
A4 ov +24V· M-7101 A06B-6076-CI06 ~
A48 ov ' 4 +24V 5
M-121 A06B-6076-CI04
A49 •BRKON 49 +24V ARC M1 ta 1201 z
A50 •BRKALM ·"" +24V c
~
~
s::
;x:i-
S-420i,M-710i(INTEGLATED CABINET) S-420i,M-710i(STAND ALONE) S-4201

M-710i M-7101
8s:::
r
JIM JIM IU L RM2 '"ti
SERVO Alf> SERVO AMP IV .-
(NOTE) [)----- TO JI MOTOR POWER 2 INOTE) IW
1
I1~l vl 1~l 1~] IG ~
:!! J2M J2M 2U m
ca 2V
[)----- TO J2 MOTOR POWER 211
...~ ldulfvl!l2~I 2G 8
J3M J3M 3U z
ca 3V z
[)----- TO J3 MOTOR POWER 3W
liul:s~l:s~l~I 3G
m
--
J4M 4U '
I RMI
i
... [)----- TO J4 MOTOR POWER 4V ~
:I J6M 4W
!!!.. 4G
5z
v !5U
(') !5V c
0 ::c=::>--o [)----- TO Jl5 MOTOR POWER
:I
:I J6M
I G
!5W
!5G
6U ~
CN6 6V
[)----- TO J6 MOTOR POWER CBRAKE) (NOTE)
!. 6W INTER! ACE OF Ml AND M2 ARE RIEFER TO PAGE ~
0 Al BRKIP Bl BRK2M 6G OF 'B CABINET/MECHANICAL INTERFACE'. s::
:I
CN6 A2 BRK3P B2 BRK4M CN6
(Jl-J6) A3 BRK5P B3 BRK6M D
A4 B4
SERVO Alf> A!5 8!5 SERVO AMP
Iill S-4201 :A06B-6076-COOI or CIOI A6 BRKIM 86 BRK2P S·4201;A06B-6076-COOI or CIOI )>
3 M-7101 ;A06B-6076-CI06 A7 BRK3M 87 BRK4P M-710l;A068-6076-CI06 "'tJ
AS 8RK5M 88 BRK6P '"ti
~ m
N
bIll
z
0
5r. CONNECTION OF MOTOR BRAKE
:I x
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.ll
re~ CN6 r "l MOTOR BRAKE
BRKIP
0
> BRKIM : 0---i
3 BRK2P
"S!.
BRK2M 1-------o- : ©---i
i BRK3P
i' I @---i
~ BRK3M
11--___;_I I ~
BRK4P
~ BRK4M I~
?. BRK!5P
BRK!5M : ©---i
f...
Q BRK6P
.::; NOTE) CONNECTION OF MECHANICAL UNIT IS REFER
BRK6M i----+- : 0---i TO MAINTEMANCE MANUAL OF MECHANICAL UNIT.
L .J NOTE
_.
irr
Cs
c.>
'Tl
<?'
.,,,
UI
...
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ARC Mate 100,ARC Mate 120,S-6,S-12(STAND ALONE)
ARC Mate 100i,M-6i
i
7'
ARC Mate 1201,M-12i
CONNECTION CF MOTOR BRAKE §
--
S" (2-BRAKEI
i SERVO A/IP : V
qRMI
:I
"" !NOTE) IW ARC Mt II 100 CN6 r,
!!?. ARC Malt 120
L S-6 BRKIP
2V s-12
&> 2W ARC Miii 1001 l!RK IM
:I M-61
:I 2G l!RK2P
;iu
JV
MOTOR BRAKE
3W l!RK2M
BRK3P
I
I
:I !·4V
4W BRKJM
I~
c
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::131.a !IV
5W BRK"4 :~
niil
i!!::i 6v
I
6V !NOTE) I
6W INTER 'ACE CF MI AN> M2 ARE REFER TO PAGE
OF '8 "~BINET /MECHANICAL INTERFACE' . BRK6P I
!~
017 CN6
!i?.-·
w. :I
tJ
--
BRK6M I
L .J
SERVO AMP NOTE! CONNECTION OF MECHANICAL UNIT IS REFER )>
:.11 ARC Miit 100,S-6 ,AO&B-6076-COO!I or CI05 TO MAINTENANCE MANUAL CF MECHANICAL UNIT .
"'C
~·f ~ =::: :~gl~M~~ 1 :~==~+t:gro: or CI04 "'C
ARC Mala 1201,M-121.,\068-6076-Cl04 m
0
w
"" ~~ ARC Mate 100,ARC Mate 120,S-6,S-12(INTEGRATED CABINET} CONNECTION CF MOTOR BRAKE z
16-BRAKEI 0
n> ARC Mate l00i,M-6i
i!!::I ARC Mate 1201,M-121 x
CN6 r , MOTOR BRAKE
JIM JIM
SERVO A/IP BRK IP
!NOTE) ;x:::::::r--o Q-- TO JI MOTOR POWER 2
1
I,ul vl ,ti ,ii BRKIM
'-gf
~i J2M
l!RK2P 1-----1
----+-~
:
:
0--i
~
~- '1>
GWvl~l#l BRK2M
J3M
f...-n~ BRK3P 8
Ffill:.l~I 8RK3M
r1 ~ s::
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"'IJ
BRK.tP. r
:r:::::::>-0 Q-- TO J4 MOTOR POWER
BRK"4
s... r==+: ~ ~
~~~ m
~ ~ (')
BRK!lll
>
::IJ J6M ~~
CN6
~ - BRK6P
t=t: 0
z
n :r:::::::>-OQ-- TO J6 K>TOR POWER !BRAKE)
BRK6M ~: ~ zm
iii:
II L .J
i NOTE) CONNECTION CF MECHANICAL UNIT IS REFER ~
... TO MAINTEMANCE MANUAL OF MECHANICAL UNIT .
N SERVO AMP
5
~ ARC Ml II I 00, S-6 A068-6076-C005 or CI 05 z
ARC Mt II 120, S- 12A068-6076-C004 or CI 04 c
A068-6076-C I 0!5
ARC Ma II I 00 I , M-61
ARC Mtlt 1201,M-121 A06B-6076-CI04
~ ~
er... ~
WN s:::
;ri-
0
0
s:::
"ti
r
"II
~
m m
0
~
..... 0
z
.:::
- zm
3"
S'
... ~
:I S-500,S-700
!!?. CONNECTION OF MOTOR BRAKE
0z
0 c
0
:I
:I I CN6 r "'1 MOTOR BRAKE
IU [I RMI ~
SERVO AMP IV
(NOTE) IW S-500 BRKIP ~
IG S-700 s:::
I:I 2U BRKIM : 0-J
Cl 2V BRK2P
ii' 2W
cc 2G BRK2M
3U : 0-J
iil JV )>
3 3W BRK3P "'O
3G BRK3M
I 0-J "'O
4U m
4V z
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0-J 0
tr 4G
s· 5U BRK4M x
I jt 5V
5W BRK!5P
5G
6U BRK5M : ©=i
6V (NOTE) BRK6P
J 6W INTER CE OF Ml ANO M2 ARE REFER TO PAGE
:I> 6G OF 'B ABINET/MECHANICAL INTERFACE' . BRK6M
3
'2. CN6 D
---- : L _J
©=i
::::;; NOTE) CONNECTION OF MECHANICAL UNIT IS REFER
iii" TO MAINTEMANCE MANUAL OF MECHANICAL UNIT.
SERVO AMP
l S-5001A06B-6076-C002 or CI02
S-7001A06B-6076-C003 or CI03
-t
C>
s:>
t
.§
iT
cs
"'
~
0
A-520iCINTEGLATED CABINET) A-520i(STAND ALONE) ~
A-5201
SERVO AMP I
SERVO AMP JIM JIM IU d RMI
A06B-6076 A06B-6076 IV I
-C002 or 0-- TO JI MOTOR POWER -C002 or IW
-CI02 l1ul1;11~l1~I -CI02
I I'T~"
IG
J2M J2M 2U
0-- TO .J2 MOTOR POWER 2V
!! ldul;,l2~l2~I 2W
ca 2G
;.. JJM J3M 3U
:... 0-- TO JJ MOTOR POWER JV
l~l!IJ~IJ~I JW
Q JG
J4M 4~
0-- TO J4 MOTOR POWER 4V

4W
4G
-i
...::I J!5M !5U
!5V
!!. 5W
n 4W 5G
g 6U USED
CN6 6V ]~ (NOTE)
::I !BRAKE) 6W INTE~ CE OF Ml ANO M2 ARE REFER TO PAGE
CD 6G OF 'B :ABINET/MECHANICAL INTERFACE' .
Al BRKIP Bl BRK2M
g. A2 IBRK3Pl 82 (8RK4M) CN6
::I CN6 I I D ~TOR BRAKES (JI ,J3) AJ (BRK!5Pl B3 (BRK6M) D
A4 B4
5?. A!5 B!5
m A6 BRKIM 86 8RK2P )>
ca A7 IBRK3M) 87 lBRK4PJ "ti
.j:>.
ii1 A8 (BRK!5M) 88 IBRK6Pl "ti
0 3 m
VI z
0
bm CONNECTION OF MOTOR BRAKE x
(6-BRAKE)
!l
CN6 r "1 MOTOR BRAKE
~
(/) BRKIP
;:i>
8RKIM : &=] (")
~ BRK2P 0
> BRK2M s:::
3 :~ "'C
"S!. BRKJP NOTE r
L ...J
i- BRKJM ~
m
Zi BRK4P
BRK4M 8z
BRK5P
N
-t zm
S! 8RKl5M
BRK6P
~
NOTEJ CONNECTION OF MECHANICAL UNIT IS REFER
- BRK6M TO MAINTEMANCE MANUAL OF MECHANICAL UNIT. 5
z
0
~
~
s:::
;i>
JRF2
8s:
(ROBOT FEEDBACK) ""CJ
Al P06 Bl •PD6 r
E-STOP UNIT
A2 ov B2 ov A05B-2350-COIO ~
AJ PR06 BJ •PRQ6 m
A4 ov B4 ov CRFJ ROBOT PULSE CODER (')
A5 PD5 B5 •PD5 ROBOT FEEDBACK ~ JRF2 Jl-JJ
A6 ov B6 ov CRF4 ROBOT PULSE CODER 0
!! J4-J6 z
ca A7 PRQ5 B7 •PR05 z
;. A8 ov B8 ov m
:... A9 PD4 B9 •PD4 SVON/MCON [] CRM9 CRMI I 0---------- ROBOT OVER TRAVEL SIGNAL
~II ov I( ov (OPTION) ~
5
- Al I PRQ4 II •PR04 MCC CONTROL [] CRRl5
Al ov I ov
5z
CRM15 DOOR INTERLOCK SWITCH
Al PDJ I •PDJ Cl
I• ov I OV
i...
= I PROJ I •PRQ3
!?.. I ov I ov PRECHRGE POWER OF SERVO AMP ~
CRR20 ~
0 I PD2 I •PD2
0 18 I
~
= ov ov (X)
~~k20 s:
= Al PRQ2 I •PR02
1
OV ov
!;s· I POI 21 •POI
ov 7. ov
=
c PROI 2 •PRQI 200VAC 3• ------------------~ )>
ii'
"A24 ov 24 ov ""O
ca A:. OV ov ""O
A2 ov '""
26 ov m
"""
~ ii1 z
3 +5V 2 +5V 0
+5V 21 +5V CRM9 CRMI I CRFJ I I x
- +5V +5V (EMG CONTROL) (ROBOT OVERTRAVEL) !ROBOT FEEDBACK Jl-JJ)
I b +5V '"'
m +5V 23 PD;J ft~
ID .. ~
AI +5V 131 +5V 3 24 •PDa
!Z lhl~ +5V B32 +5V
CL]dON I~~~T-1 I 21! PR03
26 •PR03
j A3.l +5V BJJ +5V
l·RfffJ 27 +ISV
A34 +5V BJA +5V 28 +5V
m 00
!JI
3 AJ! +5V +5V
CRRl5
29
10
+5V 19
....
+!IV 07 +5V
f\JI +5V +5V ov CMI ov
CD (MCC CONTROL) CRM15 20 ov
AJ1 +5V ""
B31 +5V 31 ov 09 ov
,a !DOOR INTERLOCK) 21 ov
12 ov 10 ov
CD AJ8 +5V 38 +5V 22 ov
11 ov II ov
=
n AJ9 +5V 839 +5V ~Br;~~~-1 3 14 ~ .!.! ov
'< A4C +5V 40 +5V 1 l~I~
A41 +5V +5V CRF4
w A4 +5V +5V (ROBOT FEEDBACK J4-J6)
i;, AA ov
ov
143
'"'"
44
OV
ov
EtJi2 IM~~I I 01 Pii4"" 13 POl5
23 PD6
c: 02 •PD4 24 •PD6
CRR20 14 •P015
A• +24E 4! +24E 03 PR04 25 PRQ6
(AMP PRECHARGEl 15 PRO!I
3= +24E46 OV 04 •PR04 26 •PRQ6
16 •PRO!I
A4 4 •OTREL 05 +15V 27 +5V
17 +l!V
06 +ISV 28 +5Y
(X) 18 +15V
'" 07 +15V 29 +15V
•OTRST "" •ROT
'49 SVON 14~ •HBK 19 +15V
CMI ov 30 ov
20 OY
A!lll RDICOM !!lll •HBKREL 09 OY 31 OY
21 ov
(Y) 10 ov 12 ov I
22 ov
II ov 11 ov I
12 ov 34 ov I I (11
Ii T
...
cs
(,)
MAIN CPU
PROCESS I/O
i
T
A 166-3200-0042 §
CRM2A TYPE OF PROCESS I/O(SINK TYPE)
!! SPECIFICATION CRM2A CRM2C CRM2D CRM4A CRM48 CRWI CRW2
ca CRM2B
;.. JD4A CA Al68•2201-o470 0 0 x x x x 0 0
CRM2C
:... JD4B SOI/SOO CB A 168-220 I -<M72 0 0 x x x x x x
.::: CRM20 DA ... 168-2201-0480 0
-
0 0 0 0 0 x x
CRM4A EA A 168-3200-02:50 0 0 x x x x 0 0
(NOTE) PROCESS I/O EA CAN DESIGNATE ONLY ARC Malo 1001
-a
..JDIA JD4A,B CRM4B
AND ARC Mii o 1201.
!FANUC I/O Lllll() (FANUC I/O Lilll() PROCESS I/O EA IS MOUNTED IN OPERATION BOX.
:I
!!. I RX II ov I RX II ov CRWI TO WELD MACHINE CA/D,D/A,l«>IIWDO)
•
(') 2 •RX 12 ov 2 •RX 12 ov
t---------t--
0 3 TX 13 ov 3 TX 13 ov
:I CRW2 I TO ANALOG INTERFACE CA/Dl
4 •TX 14 ov 4 •TX 14 ov
:I 5 15 OV 5 15 ov
6 16 OV 6 16 ov
!. 7 17 7 •ENBL 17 -15V
0 8 18 +5V 8 +15V 18 +5V '----------------------+--- NEXT I/O Lilll( DEVICE (SLAVE)
:I
9 +5V 19 9 +5V 19 +24V
§?. 10 20 +5V 10 +24V 20 +5V
Ill
ca
~ CRM2A CRWI
(SDIISDO) !SD~) (~) !WELD INTERFACE OPTION) )>
3 01 33 CMDENIL 01 sow 33 SD021 01 8DI63 14 80061 01 IW:HI 23 MX>I "tl
13 ADCHI
02 34 02 1111124 34 02 8016' ,. 02 CAMDAI 24 MlCl2
.j::o. -:=::
03
ACIC3lllN03
ACK.,.,.,. 3'5 PROGAIJN 03 80120
19
20
80033
80034
3'5 03 80165
..
09
10 80067
16 SDll63 03
14
10
COMADI
ADCH2
20 0003
ljl)04
"1J
m
36 PAUSED 04 80126 36 04 80166 17 llC064 04 CAIClAl! 26
21 II 16 WW>2 z
s ~
sz:
·-·--- ·- .
06
80127
80121
22
23
--
CCM-C4
37
31
COM-Cl .
06
IDI67
IDI61
12
13
CCIM-U
80170
19
COM-El
+24E
.
06
- WDII
WDI2
17
I&
27
aa
wooa
WD06
0
:I 07 80129 3' 80126 07 IDI69 20 ov 07 WDII 29 WD07
-- .. -
80130
24 80037
40 80027 WDl4
19 ov 30 WOO&
x
20 SD03I 20 ov
j!. .
09 SDI31
-· 8IXl39 " COM-C2
CRMA8
(901'800)
.
09
10
WOIS
l«>I6
21 ov 31
32
WOI+
M>I-
I
"g 22 ov
~· 80029 01 80171 14 80069 II 1«>17 33 +24E
CON-CO : 80073
-- --
80030 02 SOI72 10 80070 12 M>II 34 •24E
§ SDD31 03 80173
..
09
10
8007'
80070
16 80071
46
"° 80032 04 80174 17 8D072 CRW2 ;i:>
fl) IDUI II S0076
'7 CCIM-C3 1111170 ,. CClM-FI !AID INTERFACE OPTION)
(I) 80142 12 CClM-F2
4t
49 +24E
.
06
07
SOl76
80177
13 mna 19
20
+24E
ov
01
02
.. ADCH6
MXH3
09 COMAD6 8
+24E
..••
16
03 ADCH3
10
a"g
. 04
II
17 CCIMA04 s::
CRM20 ADCHO '"ti
:I. 12
:I
01 80103 33 80001 01 IDI43
ISDI/SDOl
33 ID041
.
06
07
13
. -
19
20
r
S' 02 IDI04 34 02 1111144 34 ~
Q. 19 8001> 19 SOOl53
(')
03
04
80IOG
SDI06
SCIO?
20
21
80014
3ll
36
37
80003
CCIM-81
03
04
IDI"9
SDI46
S0147
20
21
3ll
36
37
SDll63
ID044
COM-DI
SPECIFICATION. OF PROCESS I/O FUSE
RATING RATING NOTE
- m
(")
. 22 80016
. 22 SD006 CUlRENT Vil!..TAGE
~· 06 8010& I& soooo 06 801'8 I& 0
23 CCIM-84 23 2.0A FAST BLOW
c 07 90109 39 80006 07 80149 39 80046
;::;: OI 90110
24
20
-·· --
80017
8001f
40 SD007 OI 80104
24
20
SDoa7
SDOOI
40 80007
z
z
09 SOii I SDOO& 09 SOIBI
-- --
26 80019 26
m 10 90112
27
.
80020
CCIM-82 10 80102
27 80060
..." CCIM-D2 m
(")
II 111113 43 8D009 II 80103 43 80049
2 H H COM-OS
12 SDil4 80010 12 90104 IDOOO -i
29 SDil9 29 SDI"9
a.
...... 13
14
10
111115
90116
90117
30
31
-IDI20
SDI21
..
46
"°
47
80011
80012
CDM•H
13
14
15
8DIH
90196
90197
30
31
-. -
SDI60
SOI61
46
"°
47
IDOOI
CCIM-03
0
z
32 90122 32 SOI62
16 IDII& 48 16 80191 41
17
. ov
ov
49
oo
+24E
+24E
17 ov
ov
49
"°~--
-
+llAE 0
>
" Ci)
~
s::
?>
8s:
'"ti
POWER SUPPLY
~m
Al68-1212-0871 MOOEL B UNIT (")
A05B-23150-CIOO
0
.,, z
I I CP6 I/O UNIT MODEL B z
m
~ INTRFACE UNIT
;:..
b AOJB-0808-COOI CRS7
~
24V 24V 0--- TO MODEL B BASE UNIT
~
ov ov ON THE ROBOT
3 SI+
5z
._.
- .JOIB SI- CRS8A c
3' MAIN CPU FG
.JOIA S2+ 0--- TO MODEL B BASE UNIT
r... I I Al6B-J200-0042 S2- OF OPERATION BOX ~
:I FG CRS8B ::c
!!?. SJ+ 0--- TO MODEL B BASE UNIT l>
.JOIA b SJ- OF OPERATION BOX s:
&> I I FG
:I S4+
:I S4-
FG
!.
0 >
:I "ti
.j:>. c "ti
0 iii" m
00 ca z
0
iil x
3 CRS7
JDIA/JDIB (SI SIGNAL)
I RX 11 ov
-l;
D> 2 •RX 12 ov SAl2-
ImAJ-, I :i. I NOTE
c:r 2.0A FAST BLOW
J TX IJ ov
j 4 •TX 14 ov
5 15 I :: I ~~ I .:~E I
6 16
a 7 17
c 8 18 +5V CRS8A
:I 9 +5V 19 (S2 SIGNAL)
...ii: 10 20 +5V
0
a.
!!.
m
._. CRS8B
(SJ SIGNAL)
Fl s~-1 ~~I
Cs
~
w
A. COMPLETE CONNECTION DIAGRAM APPENDIX B-80525E-1/03
R-J2
•¥V
""""
JRMIO
OPERATION BOX PCB ~ ....rP 1~
0~1,.
,.-~
TEACH PEN>ANT
EMERGENCY STOP BUTTON
MAIN CPU +24Y

EMGB211 ~1
TP84G RY 1J ~MGOll "' r---- DEAD-MAN SWITCH<LEFT ,RIGHT)

..........
i -
ENGEN 1E
ENABLE/DISABLE SWITCH
I
ov
I
I
~
lr2
'"" 0
Tl T~ ~I&o
.. ,.,.,. r- I
ENABLE:
+
DISABLE
-!i'.c- MODE SELECTil»I SWITCH

la>ERATil»I BDXl
~ T2 Tl AUTO
J
lr2X Tnv I_ ·~v
T2X BREAKE CLOSE CLOSE
h-1x TIX I~ AUTO llREN<E BREAl<E CLOSE
:::Jl11 ........ TIX BREAKE
lrl.Tl CLOSE
BREAl<E CLOSE
CLOSE l!REAl(E
ovov
FENCE I
FENCE2 ·---, FENCE
---·- ••• <j> ~V a>ERATOR PANEL

OPEll3 ---® Q ·-~·-"'"'"
I-~·~-,
·-~·-~uD
'44
--..
f":
-1
<OPERATION BOX)
ov
+24V
-J
·--··-- _,.
ElCEMG RV
I E;Q
EHGIHI
EMGINC -1
EXTERNAL EMERGEN:Y STOP
+24V OV SVONI
SEl!VO CH/OF SWITCH
SVl»l-RV RV ( -J SVON2
~,
+i,!V
RV 1 RECEJVER
FOR 01
I
~I
------
ooTnn• n7
-::i__
ov
HOlR l£TER
ov EMGOUT2
~
EMGOUTI I OOVAC/240VC
EMGOUTC .......2
AXES /RF2 ~:~~!:~L _.e. EMERGENCY STOP CONTROL PCB
CllNTRa.
.... RI.YI!
' ···~
(lel<RB..)
-Q--1
-~
-REL RI.YI
ROT
OTREL
-/RVl
...... ,___
ROT
I l
(OTREL)
n
y r'1
OTRST I L_.J:l'. RLY'J+RLY4
'----·~
Li.
lJ
RDI<XlM 0
<N ,.. I
1~ ~ I
I
-~ '--·
D
I
.,.
- ~-
,- - - - - - - - - - - -
CRR20 CRRl!I
200R
200S REDlWANT E-STOP UNIT
200T -
-'r ..-: ."

- : :
POWER
TRANSFORIER
- ...
lr-1 T
T I I I I I ; 11
AC POWER
INPUT J'lc
1iC
I
I
I
:
I I -
:
CP5 1
+24V : i
ov
DC
POWER , 111
II : I
SUPPLY : I
I I I
r- -
~1 1
200A
20C8
I
I
rLl
t-
L... -'
Fig.A.1 (n) Internal Connection Diagram (i-Cabinet, Emergency Stop Circuit)
-410 -
B-80525E-1 /03 APPENDIX A. COMPLETE CONNECTION DIAGRAM
ROBOT
MECHANICAL UNIT
PILSE
MOTOR
RClllOT ROT
CRf3 TO MAIN CPU

l CAF4
~r
.-·- CRMll -
1 f
·-···
DOOR INTERLOCK
I
I~~ 11,~ALM-~
SIGNALS BRAKE CONTROL
6-AEXES SERVO AMPLIFIER

CIRaJIT
CN7A
,t @ -
~
Cllll20
SVWT
INTERLOCK
CIRCUIT
la~ L..}-c5 OF
SEllWI MOTOR
MCCON POWER
_ _ _ _ _ _ _ _ _ _ _ ..J
~
~ .i
i!i ov
CN'lB ~ ·~v
-
i iQ---
~
=
t"~
CNI
I
I~
lI DISCHARGE
CONTROL
CIRaJIT I
- 411 -
CIRCUIT DIAGRAM OF OPEARTION BOX

A05B-2350-C024,C032,C036
(QF)BREAKER
AC POWER INPUT
(CABLE)
["L2
LJ
PE
..r
,
-"1"
...
-
'.}
I
A..
,!...
__r.,
NOISE
FILTER
,i.
~~
LJ
G
l
r -- -- - T --- - - - -, AC POWER
OUTPUT
I/O UNIT-MOOEL B I/O UNIT-MODEL A ICABLE/TO
I BASE UNIT
(OPTION) I BASE UNIT
(OPTION) I R-J2l
I IPERATIC»I llOX A
MAX • 2-1.NIT
I a>ERATION BOX A
NOT Sl.l'PCRTED
ll'ERATION BOX 8
I
IPERATillN BOX 8
I MAX . 2-1.NIT
I Sl.l'PCRTED
NOTE 3
I
I + I
...>N> > > I
IF MOllEL A IS MOl.tlTED.
MODEL 8 CAN«>T MOUNTED .
I
I/) (/) + 0 .JO
L De ~ ---f !f.j ~ ..L - -e;::::o:::i- - - _J
I/O UNIT-MODEL B (S2+

SIGNAL CABLE S2-
SJ+
SJ-
I I it _J
.JOIB
V Vll 1 1 .DIA
~ iH~~~
+
(CRS9l f II
TXSLC 12)
•TXSLC 31
RXSLC 41
•RXSLC
(JRMIO) ( CRSI)
(14) (I)
TXTP 13 14
TXTP
•TXTP 39 (2 •TXTP
RXTP 38 115 RXTP
•RXTP •e• 16,71 •RXTP TO TEACH
17 19 +24V PENDANT
OPERATION BOX PCB dV (I)
ov
A20B-1006-0740,0744 FG
TXDI
IJRMI 0) (61
(311
(2)
3
- ( PORTI)
TXDI
RXOI 14 RXDI
RTSI
CTSI
21
[27
(291
·115
6
lilsa
p;:::
RTSI
CTSI
DSRI
(NOTE I P
• TRI
24V
"
·~= 11
NOTE 2
..... .... 20
(215)
7
>n
a~
~:
+24V
RS-2J2-C
ov dV dV "' ov
(NOTE 2)
(NOTE I)
IPORTIX)
TXDIX
RXDIX
RTSIX
121
I~
14
Cll
- FG
+24V;JRMI 0-44,45,46 151

47,48 CTSIX 6
DSRIX (20
(NOTE 2) DTRIX
OV ;JRMI 0-1,J,5,7.9 [215) •UV
11,26,28 +24V 71
JO,J2,J4 ov II 1111
J6,42 FG
(.JRMI Ol 112)
TXDA 37
RXDA (8)
RTSA [33
CTSA [:l!S)
DSRA (10
DTRA
(16)
TX485A 40)
•TX485A 41•
RX485A (115)
•RX485A
IPORT2l
'"'
~
TXDA 1-<0 (3)

RXDA C/11'
RTSA p;::: (4)
5
CTSA >n
DSRA -<>
or
(6)
(20)
DTRA
TX485A
~
"' (14)
15
•TX485A (16)
RX485A
•RX485A
+24V
(17)
(215)
7
....
ov (I) 1111
FG
NOTE; PORTIX IS OPTION. ,.
Fig.A.1 (o) Internal Connection Diagram (i-Cabinet, Operator's Box-1)
- 412 -
OPERATION BOX
CPERATION BOX PCB

FROM MAIN CPU (.JIMJ) A208-1006-0740,0744 (CRT3l
P001---1-----.._.•.._•,..._<>1_ _ _ _ _ _ __.''.a.•·....
' 1 '--111.----1!>-·----
LEDi ;REMOTE
P002 r 1~1 tA1' • SW4 ,c-STAAT
pro3;--t-----~.:-i..=-
1141
....~-------1.~
..,..,
.,4l<NOT USIIDl ..
PIXl4.---1-----.._.._....,___ _ _ _ _ ___......,'-.111.--~1----~LE02;F-RESET
P005 Ill.I IAJI (NOT USED)
PD06 '17I IAJI (NOT USED)
PIXl7 1 IJtl t •4i (NOT USED)
PD08 1"01 1841 (NOT USED)
Ill .... ,
POI I 1 ti "'", CNOT usi;:R!
,-----f---..1.,.£\!.I
:i~;---f-----~:~:~L-' u,L.fll---__:.,.i:-=_,.=--l='.~~:~~T
PDI4 ::~: ~ ;HOLD REMOTE LOCAL
PDI5·--+-----1'"'1Lll"~"'- 1 71
1 ----.H---__JiJ!IL.A411(NOT USED) ~ --(r-
:i~·---J-----ll-l:RL~:__-l>--1--1----..l.'1!2.1••1L..111.1-ND-T_usi;:R_;J"':))'-----.Jsw6,F-RESET
TPOFF--+----- (g) 188 1 (NOT USEDl
110 1qt v •21-y.,6 4171 MCllE SELECTillN SWITOf
•24V ·- I l l
"L.LL~
ov·---1-----.._.•..... ,.,.,, "' (Cl'£RATIDN BOX)
cJv SWI ;ON ...._ T2 Tl AUTO
IAll (CRT5l ~:rf T2X BRENCE CLOSE CLOSE
(CRP6l
L~:::::::lSitl:::IflT"Vt!-~MIFO~:::::i
AUTO BRENCE BAEAKE CLOSE
TIX BAEAK'E BRENCE CLOSE
~k---+----__,~14ff--~+yv
131 <Ml '"I o 111, T< CLOSE CLOSE llREAICE
av·~ .____L_ _ _ _- - I -·-· ---··-

FROM MAIN CPU OPERATION BOl +¥V ',.,1 CCRSI J I <;> llEMl-MAN
m~ (.JIMIO) M ... , .: _ ~::I
EMGB1::=:=:t:::=:=:=:=:t11:H•~q1~:=:=:=:=:=:=:=:=:=:=::;::r::::t::t:::±"fn~\lt:::=:=:l;:::=:=:=:=:=:t:t::'~,....;J
EMGB2 - ENMLE/
DISM!LE
I
...__,_......,~"'~°"'~:;"'-"".~"' (T8DP I ) I
!~~! Tl.T2 I
r - - - ITPE~
~· '--1-+---'-FENC_,,,,,~E~·~...., - - --
FENCE1 (TBOPI)
- - - =~J
---
! +2/.V +~VIAl6 8161
Jffi3l-
TPEMG---+------1~""'--TPEM~
1241 i.-__J
DPEMG---+------1•~'2~0~1-----------~i---l---4<~A~l5H;i~
(AIJ)
813
IAl41H
DPEMGAI 'j>
I
.. •I
C814l
- -, r- _ __,_ _.......,IAll!.,.>Ol"-" 1ft4 I
EXEMG---+----__,lll-""c2~1~1___L:::Jv I
(TBOPI)
--
EMGOUT - - =~J
SVON-EMG---1-----!llJ<L;!25~lL_____.,__jl_j__ __j__..'.::::j~~ :: :: _ _ _ _ =~J
r sv~ 4ii EMGOOT l:....--4-'~l-(-CRP5
__>_.<f<l I ~R
I ov ~-o'"'v___._....____.=-1*ft4"""1'----«r~
SVON-RV
(43) REU4 !-
Tsvi:lfr"'
•¥V I EMGOUT EMGOUT'
EMGOUTI
CTBOPI I
b 4
I EMGOUTC
~:---+-----1111-'+H
::~:f::---------+-i------l~if~~ON~~ll.lll-"'CTBDP2l .::::: ..::::---- ,:::-_ _!D..._ ::!
OFF 118 111L_'-----'1!,!!!,:1r~ -

1._________. .,rs..,1. . ._11
=-,- - - _,. "
.... 1
~-------------------'(CRT31
- 413 -
'!>
n
JRMIO ~M3 PORT! PORTIX PORT2 0
(MAIN CPU I/Fl (MAIN CPU I/Fl (RS-232-C; PORT-II (RS-232-C; PORT-I) (RS-232-C; PORT-21 s:
tOO\ '?'° JOGAPCR~ 0-~ 0-~ D-~ "'ti
26 ov I ov II ov I PDII I I I FG
r
FG = 141 FG ..... 14 14 TX4811A
27 CTSI 2 RTSI 12 POOi 2 ov 2 TXDI_ 2 TXOI 2 TXOA
UI 15 •TX485A ~
28 ov 3 OV 13 PD02 3 PDI2 3 RXDI_ '3 RxoC 15 3 RXDA
16 ., 16 16 RX485A m
29 OSRI 4 DTRI 14 PD03 PDI3 '4 RTSI RTSI RTSA
17 15 17 17 •RX485A
30 ov 5 ov 19 POD4 '5 PDI4 '5 CTSI CTSI '5 CTSA n
31
32
RXDI
ov
6
7
TXDI
ov
16
17
PDD5
PD06
6
7
PDI5
PDI6
'6 DSRI
19
'7 i-ov '20
18
-
DTRI:
'6
'7
OSRI
ov
18
19
20 DTRI=
6
7
OSRA
ov
18
19
20 DTRA
0
z
J! 33 CTSA a RTSA II P007 .8 PDI7 '8 '8 8
~., 21 21 21 z
ca 3" ov 9 ov 19 +24V 9 - 9 - 9 -
22 22 22 m
35 OSRA 10 OTRA 20 P008 10 +24V 10 10 10
;. 23 - 23 - 23
36 OV II ov II - II - II
:... '24 '24 24
37 RXDA 12 TXDA 12 +24V- 12 12 ~
REMOTE • POO I F-RESET• PDI2 '25 '29 +24V 25 +24V
311 •RXTP 13 •TXTP fl3 13 13
C-START• PD02 REMOTE • PDI3 ' '
:!?.
- FAULT • POD4 HOLD • PDI4 ~~JS~DN ~~JS~CIN
5z
T2X • POIS
:ca: ~ 1: mo ...
JNTERNAL SUE OF TIC IOX 0
TIX • PDI6
C•START• PDI7 CRSI TBOPI TBOP2 TBOP3
;:, (TEACH PEl'DANTl (EMERGENCY IN/OUT) (EXTERNAL ON/OFF) (I/0 UNIT MODEL B I/F)
i. ~
IDllAlll•IOI
- - --- .:.~-
......
!!. ... ... -M•O
I TXTP 14 •TXTP I S2+ ~
0 2 RXTP
a 111 •RXTP 2 2 S2-
0 9 s:
;:, 3 EMGDM 16 3 3 S3+
;:, 10 EMGBI
4 17 ov S3·
II ~2
5 II '11 +24V
12 EMGTP
6 +24T 19 ov 6 ov
I;:, CRT3
7 +24T
13
20
fHIS CCNECTCIR II MDUNTED ON
-FG
)>
(PAJIEL SW/LEO) EXTERNAL SIDI IF TH[ IOX -c
~
c -c
iii' m
~
- ca z
iil CRS9 0
3 (I/O LINK I/Fl CRP!5 JDIA
(HOUR METER) (I/O LINK I/F) x
tGtM PCR-EIO
MDLEX•:IP MALE
I +24V II ov I RXSl.C
-b
I» 2 ov 12 ov 2 •RXSLC
c:r 3 HMI 13 ov 3 TXSl.C
14 ov •TXSl.C
=·
rCD 15
16
ov '5
ov 6
0 17 7
18 8
i... 19 9
20 10
+24V I +24V
a0
.~
. ov
l:D
0
~
N
......
CRT!5
(MOOE SELECTION KEY SWITCH)
YAMUCHl-ICIP
/ A 8
I PDII +24V
2 T2X TIX
3 Tl T2
4 AUTO MOOCOM
5 ov ov
i
T
0
w
REDlN>ANT E-STOP I.NIT

A05B-2350-C090
.!~.
A2~IAI 'T
u
POWER su>PLY llllIT 1~Mts i'
(CP5l
.....I 1~M~3 ~ I
1~~~3 11 ! i
.~113 t,.J' ! : !
r·r.~·c,Ji II
:
:
:
: i i
:
'
~-11
KAIO-v - I !
KAI0-1
i ......
KAl:2~1 KA1;4-I
E-STOP ll\IIT(CRM9l
I....1 11 I 10
!
: 9"1 II 31"'f32
KAI.I-I
ICALQ-2•t11:.-,
i
-s 41 Q~l-2
:
:
KAl3-t
9~a
KMl-11
31"'1 ;sa I
I
'
i T !• 1CAl2-2 : : :
E-STOP ll\IIT(CRRl5) KAU>:3 KAJl-1~11: 111 : : :
..... CJ 2: •1~12-3 : : :
KAl0-:( ~l'.1-4 Ii 2
'--I-
I
: : :
3..-2 7 &l~IH
'
ir .. : SERVO Alol'LIFI ER
'
: ' ti;l-2 "N"2
.... (CN78l
I
llF(32A) r::n::
~I~ KAl~-2
---::.,_....;.!._,!_:
KAfilH
:l
Jt,
'1lnf: ..
:
I
: :
I
:
l
I I SERVO AMPLIFIER
(CNll
L.I
KAl3-4 KAl4-4
I
,,,r -i 2 1110~3 iol..i
]~-UI
1'12T:2
3 I 14 ICIU~ ~ ER
a1rt:•
15
1 16 IClll~ iaiH
5 '""1;-g' 6
1 ISERVO
E-STOP UNIT(CRR20)
u I
L.I
(CN7Al
Alol'LIFI ER
POWER SUPPLY UNIT

(CP2l 1
.....I FAN
-@-
-@-
Flg.A.1 (q) Internal Connection Diagram (i-Cabinet, Redundant E-stop Unit)
-415 -
A.2
INTERNAL
CONNECTION
DIAGRAM
{B-CABINET; ARC
MATE 100, ARC
MATE 120, ARC
MATE 100i, ARC
MATE 120i, ~'
S-12, M-6i, M-1 &i,
$-420i, 8-500, S-700,
M-71 Oi, A-520i)
- 416 -
REOlN:IANT E-STOP UNIT

QF (8REAKER) WITH MCC(REFER TO FIG. I .2(1))
MER
() r J.. ( )
~
r
i
T
LI ~l~- csc.>
I I _JI , I
I I 1 I
.. I
;l, I - L L
L2 I I >f
- I I I
_JI 1 I
I I I
~
I I~
LJ ,I -
[ _jl I L } Ir ocR;r I
PE~ 1 ......
l) ~ lt lit
IN'llf VOLTAGE
~.__Jn II r.A..._.i ,... -- r-
IEFER TO
:ioAGE 002. -'}-i ~ ...... I ROBOT
I( --
.,, 11•
~-
rt r+- I I MECHANICAL UNIT
cS' r1 --
;.. ~c: -- ==>
Q
j..,>
AC3 AC2 ACI CNI RI R2 CN8A
I» {][ CN7B 4U-6U RMI
5' 6 AXES AMP 4V-6Vlp -rn
--
S' {][ CN8B ~=~ ::
.
:II IU-JU {][ RM2
BACKPLAllE PSU IV-JVlT~
!!. CPI CNI IW-JW :; :;
JD [ IG-JG
n
0 )>
CP2
:II JD >---{][ CN7A CN6 JD--
:II ~[
.i:.. CD JNPO CPJ
.,,m.,,
....:i
n JD T .J:, z
CP5
- =
0 ][}
~ E-STOP PCB
0
:II x
S! MAIN CPU JRVI CRFI {][ RPI
I» JRVI
0[ u
ca
iii JRF2
ff JSI
JO
3 JRF2
l~ '--[][ CRM9 JS2
JO ~
CRMIO ]Q 0[ CRMl5 JS3 JO I
-b
I»
JRA5 JDIA - - - - - -n FANUC I/O LINK 0[ CRMl6
a" r JS4 JO
8s::
:;· U U (OPTION) '"C
CRRl5 JS5 JO
JF21
!
I r U
- - - - - - n LINE TRACKING
U (OPTION) CRR20 JS6 JO TEACH
CRSI PENDANT ~
I} CRR21 CRMI I J[}----- m
~E0[
{][ ('")
J017 JO- _n RS-232-C/RS-486 INTERFACE B CRR6 JO
]Q - - - - U (OPTION) 0
JRM3 CRR22 JO z
z
.JRMIO m
JQ
OPERATOR'S
r----., PAllEL
g
OPTION PCB 0
I {][ z
.JRM3 OPTICAL
.RMIO ISOLATOR
JNA I H I DJ--------------------~ 0
I
~~1 ~
L----.J
~
s::
~
()
0
s::
'"O
r
~
m
()
MULTI-TAP TRANSFORMER
OF CBREAKER)
0
Qf"(J2Al
z
/ z
n r -:i n n=-=r-
(LI I '""' m
::!! b!J 4K0
ra I I I I I NOISE >
AC POWER 1 FILTER >
1 I
;:.. SU'PLY .... REDUNDANT ~
t.,, I I I I I I ... -I E-STOP UNIT
~
22013110 I L2 ' ' I 0
I I 1 I I z
.J
,g 41!5
460 c
-5' 480
500 v
I I I I I I I
~
. J_
;- I I .I 1 I I & !500
I L3 ~ I 480
... !50/60H• ~ ,. ~JJ
::I l )
I I ~
!!. "'IOX 1 •ID >
-1!5X lo I ~"]. .,. s::
n '-.PE
I I l . .. -----1 >
0 ) 100 VAC
::I l ) . > THI
::I lPE LLJ~
CD . tn..
- II "00
t::!
'~
- )>
~ YI 13 A~U "ti
::I
.i:.. "ti
c 14 "
I" "
380/21>0 :.o m
00 iii" L.li z
- ra > ) 220 VAC a
> ~-
ill I x
3 16 ov ti
nv -
'" nv
In. 3!5
10 t>V TH2 THERMOSTAT
36 )• FOR OVERHEAT
-b
I»
er I ov
s· AC POWER INPUT ov
11 4
~ CCll\lllECTION TO TF I +
I»
::I llPPLY PRIMARY TAP CNIECTING J,
;OLTAGI LI L2 L3 JUMPER TYPE •
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CP2 - 200-240 VAC OUTPUT LJtI1= I:! I
CP2
CP3 - 200-240 VAC OUTPUT I
CP5
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c!' JNPO CP4 ALARM ~ I I '"C
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CP6 - - - - +24 voe OUTPUT I I s£Lld x
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BATTERY CR8 SPECIFICATION OF FUSE
RATING RATING NOTE USE
! NAME CUIRENT VQ..TAOE ;i:i-
c Fl 7 .l!A FAST llLOW FOR 200V
0 F3 5.0A SLOW llLOW FOR +24V 0
F4 5.0A FAST llLOW FOR +IME 0
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i.
en
c
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POWER SUPPLY UNIT ~

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CAJ9A .JOIB ..RMIO .JRF2 .JRVI 0
(I/0 LIN() (OPERATION BOX) (ROBOT FEEDBACK) (SERVO AMPLIFIER) s::
I RXSLC II ov I ov 26 ov Al PD6 81 •PD6 Al IS6 Bl GNOS6
""IJ
BATTERY l..tllT r-- - 2 •RXSLC 12 ov 2 RTSI 27 CTSI A2 OV B2 ov A2 IR6 B2 GNDR6
r
MAIN CPU FOR MAINTENANCE __J I I--i J TXSLC 13 OV 3 ov 28 ov AJ PR06 BJ •PR06 AJ ISO BJ GNOSl5
A 168-3200 VBAT 0-- - ---I - i i I 1-- I 4 •TXSLC 14 ov 4 DTRI 29 DSRI A4 ov 84 ov A4 IR5 84 GllDR5
~
m
-0042
D L_ _ _J 5 15 ov 5 ov 30 OV A5 PD5 815 •PD5 A5 IS4 B5 GllDS4 (')
.JRVI SERVO AMPLIFIER 6 16 ov 6 TXDI 31 RXDI A6 ov 86 ov A6 IR4 86 GllDR4
7 17 7 ov 32 ov A7 PR05 B7 •PR05 A7 IS3 B7 GNDS3
0
8 18 +5V 8 RTSA 33 CTSA A8 ov Bii ov A8 IR3 B8 GNDRJ
z
.JRF2 D ROBOT FEEDBACK 9 +5V 19 9 ov 34 ov A9 PD4 89 •PD4 A9 IS2 B9 GNDS2
z
10 20 +!IV 10 DTRA 35 OSRA II ov I~ ov II IR2 It GNlR2
m
:!! II OV 36 ov II PR04 •PR04 II ISi II GllDSI
ca .JF21 0---- LINE TRACKING 12 TXDA 37 RXDA 1: ov 1: ov I IRI I GllDR I
~
;,. 13 •TXTP 38 •RXTP I PDJ •PD3 I •ENBL6 I ov 5
N TO OPERATION BOX .J017 14 TXTP 39 RXTP I OV I' ov I •PWl£6 I OV
JRA5 .JRMIO oi----- IRS-232C/485)
z
15 •TX485A 40 •RX48!5A I PRQJ •PR03 I •PWMC6 I ov
_.
a: .JRY4 0
(FOR TEST) I RXDB II TXDB 16 TX485A 41 RX4115A I OV ov I •PWMA6 I ov
2 ov 12 OV 17 ON 42 OV I PD2 •PD2 I •ENBL5 I ov
.JOIA I/O LINK
o---- 3 DSRBC 13 DTR8 18 OFF 43 SVON-RV I ov OV I •PWl£!5 I ov
RS-232C/ 48!5 INTERFACE PRQ2
~JJ
.JDl7 4 ov 14 OV 19 COM 44 +24V I •PRC2 I •PWMC5 I ov
0---- !OPTION) )>
i...:::s !5 CTS8 15 RTSB 20 •OPEMG 45 +24V ov ov ·~ •PWMA5 ov
!!?.. .JRMJ Oi----- TO OPERATION BOX 6 ov 16 ov 21 •EXEMG 46 +24V 121 POI •POI !21 •ENBL4 I ov s::
(') 7 RX4858 17 TX4858 22 E>GDM 47 +24\1 IZ ov OV •PWME4 -av-
CRSI TO TEACH PENDANT ~.
'"
0 0-- 8 •RX4858 18 •TX48!58 23 El«iEM 48 +24V PRQI •PROI ·~- •PWMC4 ov
:::s CRMIO ROI/ROD 9 19 +24E 24 •TPEMG 49 EMG81 ,.,, ov 4i--ov- .,, •PWMA4 ov
:::s ~~ 0-- 10 +24E 20 25 SVON-~MC 50 EMG82 ov ov •ENBLJ OV
I I
....""' OV ov "" •PW1£3 ov
!. +5V •PWMCJ ov >
-0
0 ~
:::s ~~~ +5V ~ •PWMA3 ov -0
.i::. CRSI .JF21 VBAT
N +5V ~ •ENBL2 ov m
c (TEACH PENDANT) (LINE TRACKING) (BATTERY)
0 +5V +5V •PW1£2 OV z
iii' I PA II I +5V I +5V I •PWMC2 I ov c
ca ~~~~~ 2 •PA 12 OV I~ IE~~ATI +5V +5V •PWMA2 ov x
iii I I J PB 13 +5V +5V •ENBLI OV
3 t?lll
4 •PB 14 ov +5V +5V •PWMEI OV
.-. !5 PZ 15 +5V +5V •PWMCI ov
6 •PZ 16 ov +5V +!IV •PWMAI ov
b 7 17 +5V +5V •MCON +!SV
Ill 8 RED 18 +5V +OV +5V •DROY +!SV
!l. 9 +5V 19 +5V +5V ov +5V
:::s 10 20 +5V +5V +l!V ov +5V
~ ul +5V I +5V ut +15V I +!SV
•l!V +5V •ll!V +5V
I: ov ov u ov +5V
!!!. CRMIO .JRMJ ov OV ov +5V
:::s (ROI/ROD) CPDI/PDOl +24E +24E -l!:IV +!SV
........
(') RDOI ,01 ROii I PDII II ov +24E •BRKALM2 ~
-15V +5V
'ti ROI7 ,02
15
" RD02 ""12 2 ov 12 POOi •BRl<ON2 •OTREL u· ov +24V
09
°" ROii
c: 16 RD03 .03 ROI3
_. 10 ROI9 3 PDI2 13 PD02 •OTRST Mi •ROT UI ov .... +24V
17 RD04 04 ROI4
II 4 PDIJ 14 PDOJ SYON ~
•HBK ... •BRKON ~· +24V
,. RDOG ROIS
'"\!_2 RD07
19 RD06 ~
'°" RDI6 5 PDI4 15 PD04 ROICOM - •HBKREL "" •BRKALM "" +24V
"'LL3 ROOe 07
20 •24E OV 6 PDI5 16 PD05
·- - 7
8
PDI6
PDI7
17
18
PD06
PD07
9 TPOFF 19 +24V
10 +24V 20 PD08
MAIN CPU BOARD

iT
o-w
SERVO AMP IU
CNI IA06B-6076 IV
!SERVO CONTROL) -COOi) Ill ) JI MOTOR POWER
Al IS6 Bl GNOS6
SERVO CONTROL.
!.,G
i
'E
~
A2 IR6 B2 GNOR6 CNI 2v c.>
A3 IS5 B3 GNOS5 DD 211 ) J2 MOTOR POWER
A4 IR5 B4 GNOR5 2
A5 IS4 B5 GNOS4 3
PRECHARGE J CNI 3V ) J3 MOTOR POWER
A6 IR4 B6 GNDR4 0 JW
A7 IS3 B7 GNOS3 EMG CONTROL. '.J CN7A JG
A8 IRJ B8 GNORJ 0 4U
!! A9 IS2 B9 GNlS2 INTERLOCK tJ CN7B 4V ) J4 MOTOR POWER
ca IR2 IC GllDR2
0 411
"IC 4G
> ISi II GNOSI Tl£RMOSTAT FOR OCR 0 tJ CN8A 8U
ii,) • IRI I GNORI THERMOSTAT FOR TRANS tJ CN8B 5V J5 MOTOR POWER
'i' •ENBL6 I ov 0 811
•PWME6 I OV tJ CN9 5-
• •PWMC6 I ov (FOR TEST) 6
5' 6V
ii •PWMA6 I ov OCR RI 611 J6 MOTOR POWER
-.
:::s
!!.
• •EllBL5 I
•PWME5 I
•PWMC5 I
ov
ov
ov SERVO POWER
R2
ACI
AC2
6G
CN6 [ 0--
l MOTOR BRAKE
(') •PWMA5 ov AC3
0 •ENBL4 I___!!!_
:::s
:::s •PWME4 ov
•PWMC4 ov
•PWMA4 ov
•ENBL.3 ov
!cs·
:::s )>
•PWME3 6 ov '"O
c •PWMCJ ov CNI CN6 '"O
~ iii' •PWMA3 8 ov IPRECHARGE) (BRAKE) m
N ca •ENBL2 ov BKM2 z
•PWME2 ov Al BKPI Bl 0
- iiJ A2 BKPJ B2 BKM4
3 I •PWMC2 I ov Giil2 I A~I I A3 BKP8 83 BKM6 ><
.I •PWMA2 ov
•ENBLI OV A4 84
•PWMEI OV CN7A/B A5 85
•PWMCI (EMG CONTROL/INTERLOCK) A6 BKMI 86 BKP2
-b
I» ov
•PWMAI ov A7 BKMJ 87 BKP4
!'l. •MCON +5V A8 BKM5 BB BKP6 ;i:.-
j •CROY +5V
ov 3 +8V
tn ov +8V SERVO AMPLIFIER 8
CD s:::
41 +18V I +5V
+15V +5V ROBOT SPECIFICATION ,,
~ ov +8V S-4201 A06B-6076-COOI OJ CIOI
> ov +8V CN8A/B
3 (OCR TH/TRANS TH) S-800.A-5201 A06B-6076-C002 or CI02 ~
-15V +5V m
"2. -HIV +5V S-700 A06B-6076-C003 or CIOJ
(")
4 ov +24V S-12 A06B-6076-C004 or CI04
i 4 ov +24V ARC Malt 120 0
~ 4 •BRKON +24V S-6 A06B-6076-C005 or CI05 z
•BRKAL.M ' +24V ARC Malt 100 z
"" M-61 A06B-6076-CI05 m
ARC Mate 1001
M-7101 A068-6076-CI06 ~
M-121 A06B-6076-CI04 0
ARC Malt 1201 z
0
SERVO AMPLIFIER ~
$!
s:::
;»
E-STOP PCB
JRF2 JRVI
IR060T FEEDBACK) (SERVO CONTROL) SERVO CONTROL ------01 I JRVI CRFI TO ROBOTIFEEDBACK)
8
Al P06 Bl •P06 Al IS6 Bl GNDS6
D>---- s:::
""D
A2 ov 82 ov A2 IR6 B2 GNDR6 ROBOT FEEDBACK r-
A3 PR06 83 •PRC6 A3 IS!5 B3 GN)S5 ~~JRF2 JSI O,____ _
A4 ov 84 ov A4 IR!5 B4 GNDR!5 O,____ _ ~
A!5 PD!5 8!5 •PD!5 A!5 IS4 B5 GNDS4 E-STDP CONTROL CRM9 m
A6 ov B6 OV A6 IR4 B6 GNDR4 O,____ _ (")
DOOR INTERLOCK CRMl!5
A7 PRQ!5 B7 •PRC!5 A7 IS3 87 GNDS3 SERVO CONTROL 0
!! AB ov BB ov AB IR3 BB GNDR3 AUX BRAKE CONTROL CRMl6
O,____ _ z
f,Q
A9 PD4 B9 •P04 A9 IS2 89 GNDS2 z
~ IC ov IC ov AIC IR2 II GNDR2 0--- m
I\) II PRQ4 II •PRQ4 II ISi II GN:>SI
1: E-STOP CONTROL CRR20 0--- ~
ll ov ov 12 IRI I GNDRI
s I P03 I •PD3 I •ENBL6 I ov IOOVAC INPUT FOR BRAKE POWER CRR21 CRMI I
O,____ _ ROBOT OVERTRAVEL
3' I OV 14 ov I •PWME6 I OV
5z
•II PRQ3 I~ •PRC3 Al! •PWMC6 I ov 0--- MOTOR BRAKE POWER
r...
:::s II ov II ov Al6 •PWMA6 I ov IOOVAC OUTPUT FOR AUX MOTOR
c
CRR22 0---- IC-SERIES AMPLIFIER)
e. I PD2 I •PD2 Al •ENBL!5 I ov
I ov II ov I •PWME5 II ov ~
&> I PRQ2 ll •PRQ2 I •PWMC!5 ll ov
.~
:::s ov lit\ ov •PWMA!5 ov ~
:::s '21 POI 21 •POI ""
A21 •ENBL4 I ov CRM9 JSl-JS6 CRFI s::
IZ ov ov •PWME4 ov IE-STOP CONTROL) !SERVO CONTROL) (PULSE CODER INTERFACE)
2 PRQI "'
2 •PRQI """
I&~: •PWMC4 2 OV I IR II IS 1.... 1 B&kJI
ov ~24 ov •PWMA4 ov 2 GNDR 12 GNDS
I-:::s "'~' ,,, "'~' ~ls~~~-J
c ov ov •ENBL3 ov 3 •PWMA 13 •ENBL
"'"' ov ov .,.""' •PWME3 OV 4 ov 14 ov
iii' ""' '"
f,Q ~ +!5V !2 +!5V A2 •PWMC3 ov 5 •PWMC 1!5
CRMl5
.j::..
.,,.,,>
ill +!5V 12 +!5V 428 •PWMA3 ov !DOOR INTERLOCK) 6 ov 16 m
N lO
N 3 +!5V +!5V •ENBL2 ov 7 •PWME 17 z
3 +!5V +!5V •• •PWME2 ov 8 OV 18 0
JI +!5V 31 +5V A31 •PWMC2 31 ov r T IDik150 9 •DROY 19 ov x
.~: +!5V +!5V A32 •PWMA2 ov 10 •MCON 20 ov
+!5V +5V A33 •ENBLI
-b
I» "-'' ov
2: A34 +!5V 3 +5V A34 •PWMEI ov CRMl6
:::s ll:t! +5V +!5V :.: •PWMCI ov (AUX BRAKE CONTROL) .CRR5
,.... "" 48
j2. +!5V ...."'' +5V •PWMAI ov ID 20 30 'ii
A3~ +5V +5V A •MCDN u"" +!5V BKM3 BKM3 BKM3 ISO
m +5V
•••3 +5V •DROY ... , +!5V l•~ON4l•~ON31 IC 2C 3C
3CD 3 +5V 3 +!5V A3 ov ..,. +!5V BKP3 BKPJ BKPJ
4 +!5V ,.. +!5V A4' ov +!5V
caCD ~I +5V 41 +!5V A41 +1!5V I +5V CRR20 IB 2B 3B CRMI I
:::s 4 +!5V +!5V ... +1!5V +!5V IEMG CONTROL) BKMI BKM2 BKM2 CROBOT OVERTRAVELl
n ov ov A43 ov +!5V A3 IA 2A 3A
'< A44 OV OV A44 ov +!5V 200T 3
(/) BKPI BKP2 BKP2
+24E +24E A45 -15V +!5V I l•R€ffJ
S'
,;, +24E
...... •BRKALM2 .. -15V +5V B3
A4 •BRKON2 ... •OTREL u ov +24V AC3
c:
:::s A41 •OTRST w •ROT ov +24V
A4' SVON •HBK
... "" •BRKDN 4 +24V
a ~ RDICOM ""' •HBKREL
""
'""" •BRKALM !IC +24V CRR21 CRR22
!BRAKE POWER) ( IOOVAC OUT)
EE~l 1 ~~1 EEifr211~

(J'I
~
E-STOP UNIT T.~
(A)
OPERATION BOX PCB

(JRMIO) 11.41 A20B-1006-0741 (I
(CRSI)
TXTP 131 14
TXTP
•TXTP •TXTP
RXTP
•RXTP
:<R
...... l 10
lb,/
I
'"
'"
RXTP
•RXTP
~64V TO TE ACH PENDANT
av Cll FG
( PORTI l
CJRMIOl
TXOI TXDI
RXDI RXDI
RTSI MO RTSI
CTSI !!!~
rM
CTSI
OSRI
>O DSR I RS-232-C
OTRI . ..,,.. OTRI
+24V
ov
••
·~
I I
"' av
·-· -I>
gr +24V
ov
(PORTIX) av Cl FG
(NOTE II
TXOIX
RXOIX
"
RTSIX
(NOTE 21
I
+24V;JRMI 0-44,45,46
47.48
CTSIX
OSRIX
OTRIX
OV ,JRMI 0-1 ,3,5,7,9 l?F;I +2'V
11,26,28 +24V
30,32.34 ov 111 l (ff/
36,42 FG
(JRMIOl ''•I
TXOA
RXDA
RTSA
CTSA
OSRA
OTRA
{16) (TBOP3)
TX485A S2 + -
•TX485A
040
IA
S2 ..:Ir -- -- -
RX485A S3 ·~
S3 ~Ir - - -
1!'11
•RX485A +jv
TXDA
CPORT2
+24"~ - - -
RXOA U:!il
0-1 o.
RTSA r ....
CTSA
DSRA
>O
-I>
or I
Jv (NOTE 3)
DTRA ::0
OV;JOIA-11, I2.13,
TX485A 14.1 5, 16
•TX485A
RX485A
•RX485A +..,...
+24V
ov
FG Ill (j'(/ FG
(CRS9)
TXSLC Ill (3) (JDIA) 1
•TXSLC "' " !~~Ee -=-
RXSLC ,'·'... ... RXSLC
•RXSLC lrtU IC. ,,SJ
•RXSLC
av
Fig.A.2 (g) Internal Connection Diagram (i-Cabinet, Operator's Panel-1)
- 424 -
OPERATION BOX
OPERATION BOX PCB
FROM MA IN CPU A20B-1006-0741
(.JRM3) 1121 IAll
(CRT3)
... LEO I , REMOTE
POO I
POO 2
ll:>:l IBll ... SW4 ;C-START
1141 (A2l
POO 3
I 151 £R:>I ...
(NOT USED)
LE02;F-RESET
POO 4
POO5 11'-l £A31 ... LE03;BAT-ALM
P006
I 171 IR:>:l
(NOT USED)
POO 7 I 181 £A41 (NOT USED)
POO 8 (20) IB4l (NOT USED!
POII c II 1.6.Fil
!NOT us~
131 IR51
PO12
(4) l&'-l ,,.. SW6;F-RESET
PD13 SW3;REMOTE
151 IR61 '11'
PD14
16) A71 .... ;HOLD REMOTE LOCAL
PO15 {NOT USEOl
PD16 £71
(8)
IB71
IA81
!NOT us~_> -!l.-~
PO17 SW6,F-RESET
TPOFF (9) {B8) (NOT USED!
110 1qt2.'V +¥YAI'- A17l
+24V MODE SELECTION SWITCH
ov 12 Ill IA171 ... (OPERATION BOX)
T2 Tl AUTO
dv
~
dv (CRTS) ~n
SWI ;ON
T2X BREAK£ CLOSE a.OSE
(CRP6l IAI AUTO BREAK£ BREAKE CLOSE
1A2 T'>V _AUTO
TIX BREAKE BREAKE a.OSE
EMGBI
,131 IR2 TIX I I
114) +2fV IBI Tl ,T:I a.OSE CLOSE BREAKE
EMGB2 ~
I
<Jr;
!AO .ISO L - - - - -,
OPERATION BO> +?(Y
FROM MAI N CPU
EMGDM
(.JRM IO) ,.,.,,
~--
..
11:>1
,
'~
{CRSI) I
EMGEN
EMGBI
(AO\ I IOI I
EMGB2 ~·
I
ESTOPI {TBOPI)
ESTOP:.o I
l~~! Tl .T2 I
A4
'NA
.. ~
r--- TPE~ FENCE I {TBOPI)

- - -- ---
ov
FENCE" -- --- =~J
~_j'v +?!VtAl6 Bl6) +{~RT3)
4V
.. I
TPEMG (24) (Al3) OPEMGAI 9'
TPEM (Bl3) OPEMGA2 I
(20) (Al5) OPEMGBI I
OPEMG (A14l OPEMGCI ,
CBl4) OPEMGC2 I
r - - -, IBl51 HMI
EMGINI ITBOPI
EXEMG (21) L._j'v
EMGOUT
I EMGIN" -
- -
l
-
- - --
- - -- =--st- J
SVON-EMG (25) I I I SVONI
SYON" -
-- -
- - - --
- -- =--st- J
rsv~
~
4i1EMGOUT
+~V Cl) {CRP5l HOUR
i - - METER
(2)
2 b
I ov ov r:v (3) HMI
.± 4
SYON-RV (431 REU4
1sv
~v I EMGOUT EMGOUT2 {TBOPI)
EMGOUTI
r EMGOUTC
ON ( 17) EXONI {TBOP2)
-- --- - _!Il-_ -,
{ 19)
COM (18) I I
I EXC -
EXOFFI l -- - - - - --
OFF
(A09) ONI
-- ,,,_ - -
- -.!:Cr _J
11
I (B09) ON2
(AIOI OFFI
CBI I l OFF2
m
l
I ~
CCRT3)
-425 -
;i>
,-------, (")
JRMIO JRM3 PORTI PORT IX PORT2 0
(MAIN CPU I/F) (MAIN CPU I/F) (RS-232-C, PORT-I) (RS-232-C, PORT-I) (RS-232-C, PORT-2) s::
HCHIA PCR!50 HtN>A PCR-E20 D-SUB 2'5P o-sue 21SP 0-SLB 2!5P ""O
.MALE
·--- MALE
·- -- FEMALE FEMALE FEMALE r
26 ov I ov II OV I POII I FG I FG I FG m
14 '14 - 14 TX485A
27 CTSI 2 RTSI 12 POOi 2 ov 2 TXDI 2 TXDI 2 TXDA
28 OV 13 PD02 3 POI2 3 RXDI
15
3 RXDI
'T5
RXDA
15 •TX485A -i
ov 3 3
16 '16 16 RX485A m
29 DSRI 4 OTRI 14 P003 4 POI3 4 RTSI 4 RTSI 4 RTSA
17 1 17 17 •RX485A (")
30 ov 5 ov 15 P004 5 PDI4 5 CTSI 5 CTSI 5 CTSA
18 '18 18
31 RXDI 6 TXDI 16 PD05 6 PDI5 6 OSRI 6 DSRI 6 DSRA 0
19 19 19
32 ov 7 ov 17 PD06 7 POI6 7 ov 20 7 ov 7 ov z
DTRI 20 DTRI 20 DTRA
33 CTSA 8 RTSA 18 P007 8 PDI7 8 8 8
21 21 21 z
34 ov 9 OV 19 +24V 9 9 9 9
22 22 22 m
i).
35 OSRA 10 DTRA 20 P008 10 +24V 10 10 10 (')
23 23 ,23
N 36 ov II ov 11 11 II -
24 24 -.24 -i
37 RXDA 12 TXDA 12 12 '12
::r REMOTE = POO I F-RESET= PDI2 25 +24V 25 +24V ,251 +24V 1
...... 38 •RXTP 13 •TXTP 13 13 13 6
C-START• P002 REMOTE • POI3 -
-:; 39 RXTP 14 TXTP
40 •TX485A 15 •RX485A
FAULT • PD04 HOLD • PDI4 THIS CCHECTOR IS MOUNTED ON
EXTERNAL SIC£ OF TI£ BOX
THIS CONfECTOR IS OPTICfol
THIS CONECTOR IS MOUNTED ON
INTERNAL SIDE OF_n£ BOX _ _J
THIS CCNECTOR IS MCUITED ON
INTERNAL SIDE OF Tl£ BOX
z
41 RX485A 16 TX485A BAT-ALM• PD05 T2X • PDI5 L 0
~ TIX • PDI6
42 ov 17 ON
-
::I
!!. 43 SVON-RV 18
44 +24V 19
OFF
COM
C-START• PDI7 CRSI
(TEACH PENDANT)
TBOPI
(EMERGENCY IN/OUT)
TBOP2
(EXTERNAL ON/OFF)
TBOP3
(I/O UNIT MODEL B I/F)
HONDA MR-208
~JJ
0 45 +24V 20 OPEMG FEMALE M4 TERMUNALS M4 TERMl.lllA.LS )>
0 46 +24V 21 EXE MG I TXTP 14 •TXTP I EMGINI I S2+
::I 8
47 +24V 22 EMGDM 2 RXTP 15 •RXTP 2 EMGIN2 2 S2- s::
::I 9
CD 48 +24V 23 EMGEN 3 EMGDM 16 EMGEN 3 FENCE I 3 S3+
10 EMGBI
49 EMGBI 24 TPEMG 4 17 ov 4 FENCE2 4 53-
II EMGB2
50 EMGB2 25 SVON-EMG 5 18 5 SVONI 5 +24V
12 EMGTP
g.
::I
6 +24T
13
19 ov 6 SVON2 6 ov
7 +24T 20 FG 7 ESTOPI
)>
c CRT3 8 ESTOP2
THIS CtNECTOR IS MC1.NTED ON ""C
iii' (PANEL SW/LED) EXTERNAL SIDE OF 1l£ BOX 9 EMGOUT2
.j::. CCI 10 EMGOUTC
""C
N YAMAICHI-J4P 11 EMGOUTI
m
iii / A B z
°' 3 I REMOTE C-START 0
2 (POD3) FAULT CRS9
PANEL 00 CRP5 JDIA x
3 BAT-ALM CPD06) ( I/D LINK I/F) (HOUR METER) (I/O LINK I/F)
4 CP007) CPD08) t-KNJA. PCR-E20
MOLEX-.4P
5 (POII) F-RESET MALE
-b
Ill I TXSLC
6 REMOTE HOLD II ov I RXSLC
!l. PANEL OI 2 •TXSLC
7 (POI5) (POI6) 12 ov 2 •RXSLC
3 RXSLC
8 C-START 13 ov 3 TXSLC
4 •RXSLC
9 ONI ON2 14 ov 4 •TXSLC
10 OFFI OFF2 15 ov 5
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R-J2 JRlllO TEADI PENDANT

OPERATION BOX PCB
MAIN CPU •i!Y EMGTI' ~TP +24V
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- 432 -
MOOE SELECTION SWITCH

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BREAKE llREAICE CLOSE
TIX BREAKE llREAICE CLOSE
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:::I ~ ~ JXIB b- DJXIA JXIBI b--- OJXIA JXIB ~ hJXIA JXIBI ~ bJXIA JXIBI
CD
~ FAN UNIT ~ OCXIA
CX2B CX2B ir-- CX2A CX281 l---1 bcx2A CX281
~ b- OCX2A CX28 Ib--- OCX2A
cs· IOCX2A
BACK PLANE PSU
:::I CPI OD
* t---l OCX3 T82 y,.....__
[Ur- TB2
v~
[u~
W>-------. TB2
v~
[u~
W~ T82
v~
[u~
W >------
)>
"C
c •r- ROBOT M-41 0 I "C
+>- JNPO CP2 lbCX4
w iii'
(Cl
OD JSIB .~~ JSIB JSIB
m
-..] m CP3 JSIB '~r-:r -~rr- -~rr- z
.
Ill
tJD -
w RM3 0
CP5 RM2
3 tJD w RMI
x
u
!!::
I
-1...
MAIN CPU E-STOP PCB
Si?.
IJJ JRVI JRVI CRFI JI RPI ;x>
I DD H DD RBK
()
0 0'
Ill JRF2 JRF2 0
DD -0[ JSI
sr.
:::I
OD s:::
CRMIO ~[ CRM9 JS2 "C
!!. OD OD r
JRA5 JDIA OD dJ[ CRMl5 JS3 DD ~
m JF21 DD rn CRMl6 JS4 OD m
CRSI CRRl5 JS5 - ()
--f... tJD rn DD
g 0
J017 DD L{][ CRR20 JS6 TEACH PENDANT z
OD OPERATION BOX
JRM3 L-.{][ CRR21 CRMI I OD-- rOI JRM3 CRSI DD z
-m m
JRMIO ~8== CRR5 OD-- ~[ JRMIO tJo- - - - - -~~ R$-232-C
CRR22
~
OD I 6
z
~(i ~PTIONPCB ~ 0
JNA )>
JL _ _ _ _ I _J
(j)
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0
s::
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r
~
m
("')
!! 0
CCI
> CRR25 CRP7
z
(,.) z
m
(")
.!?.
- -I
E-STOP CONTROL
S' 5
ID 200VAC
... z
DELAYED-OFF
=
e?. REDUNDANT 0
OF(BREAKER) CPI MCC UNIT s;:
(") (j)
0 TRANSFORMER
( ) ( ~ -LI A 440·500V ::IJ
LI -LIB 380-415V )>
i= I I Pi 1 I NOISE - l
AC POWER I FILTER s::
a SUPPLY I I I I L2A 440-500V - ~
0 L2 µ
380/415 ~L2B 380-415V
= 440/460 I' I I I I
480/500
!i2
Ill
CCI
!50/60H• I L3
I I µ I I L3A 440·500V
---'
I r
)"~"'~ )>
::;L3B 380-415V
... I I PE l ) "'O
Ill PE ~ "'tJ
l ---' CPI X-KEY
ti 3 -:!:- f 3
m
00 l) 1 z
20 0A 2;08
* * AC INPUT
I I I I 0
D CPI D CRP7 Y-KEY x
FOR LOGIC
-...f
S?. .d4v
I I I I ;1v 3
(")
Ill CRR25
!2: 2 I 3 4 5
A •24V I •24V I •24V ov
!= TRANSFDRMER(7 5KVA, A80L-0026-0014#C) B MCCON I MCCON I SVON
:;I POWER CONNECTION OF PRIMARY TAP

Ill SUPPLY CONNECTING
VOLTAGE STYLE
= JUMPER
!e. 440
0
460 LIA L2A L3A
480
- STAR y
...j 500
....... 380 LIB L2B L3B
415
f...
S?.
.......
~~
(11
T
0
(,,)
D r@)AN i
CAJ9A T
.,, ~
CH
ii!i
;..
w
Q.
......
-
i:I
!!!.
(')
0
:I
:I POWER SUPPLY CPI CP4 CP8
"I 6B- I 2 I 2-087 I I B3 Bl B2
!6" CPI 200-240 VAC INPUT
R AL FA FB BAT+ BAT-
:I
Df----- I I [fJ] BUJ2 I I
c CP2 0- - - 200-240 VAC OUTPUT Bfl1F I:! I
Jr CP2
ii1 CPJ 200-240 VAC OUTPUT I
D--- CP5
3 RI BJ
CP4 POWER ON/OFF
I I ttlJ ~2
+24Viv
.JNPO 0--- ALARM
~
~
-f
.....
I I .,,.,,>m
CP!S •24 voe OUTPUT CP3 z
"' Ii?. D--- I
CP6 0
&> CP6 0--- +24 voe OUTPUT R2
I I s[[fj Ix
er
5·
1.:!E I [fjLJ
jt. -
SPECIFICATION OF FUSE -
BATTERY CR8
c RATING RATING N01E USE
(') NAME CURRENT Ya.TAG£ "!>
Fl 7 .DA ~~- FAST BLOW FOR 200V
"ti , 0
F:J 8.0A ......... SL.OW BLOW FOR •24V 0
F4 8.0A !£".L. FAST BLOW FOR •24E
CD
s:::
.2 '"ti
tn r-
c
-0 ~
-0 m
-<" 0
c: 0
:I z
3 ~~ii!
I 1<'f z
m
~~~~~ ~
-f
..... !S~~
g <ll!ll! 5
Cl) ............ z
~~9
',"I
c
Nl">ib
~
POWER SUPPLY UNIT
~
s:::
~
CA39A 0-'--- JDIA JRMIO JRF2 JRVI
1110 LINK! IOPERATIIJll BOX) !ROBOT FEEDBACK) (SERVO AMPLIFIER!
8s::
I RXSLC II ov I ov 26 ov Al P06 Bl •PD6 Al IS6 Bl GNOS6 "O
BATTERY UNIT 2 •RXSLC 12 ov 2 RTSI 27 CTSI A2 ov 82 OV A2 IR6 82 GNDR6
I
FOR MAINTENANCE
r__J
MAIN CPU PRQ6
- -I I ----,
3 TXSLC 13 ov 3 OV 28 OV A3 BJ •PR06 A3 IS5 BJ GNDS!5
A I 6B-3200 VBAT 0--- - - - - I ---, I I f-- I ~
-0042 4 •TXSLC 14 OV 4 DTRI 29 OSRI A4 OV B4 ov A4 IR!5 B4 GNOR!5 m
D L_ _ _J 15 115. ov 15 ov 30 ov Al5 PDl5 Bl5 •PDl5 Al5 IS4 Bl5 GNDS4
JRVI SERVO AMPLIFIER (")
6 16 ov 6 TXOI 31 RXOI A6 ov B6 ov A6 IR4 B6 GNOR4
:i 7 17 7 ov 32 ov A7 PR05 87 •PRDl5 A7 IS3 B7 GNOS3 0
8 18 +15V 11 RTSA 33 CTSA A8 ov BS ov A8 IR3 811 GNDR3 z
> JRF2 D ROBOT FEEDBACK 9 +5V 19 9 ov 34 ov A9 P04 B9 •P04 A9 IS2 B9 GNOS2 z
w 10 20 +15V 10 DTRA 35 OSRA IC ov IC ov I~ IR2 IQ GNDR2 m
II ov 36 ov II PR04 II •PRD4 II ISi II GNDSI
~ ...F21 o---- LINE TRACKING 12 TXDA 37 RXDA I ov I OV I IRI I GNORI ~
13 •TXTP 311 •RXTP I PD3 I •PD3 I •EJIBL6 I OV
JRMIO
0,____ _ TO OPERATION BOX JDl7 14 TXTP 39 RXTP I ov I ov I •Plil£6 I ov
JRA5
0z
IRS-232C/4815l 115 •TX4815A 40 •RX4815A I PROJ I •PRD3 I
I •Pln4C6 ov
JRY4
i. I RXOB II 16 TX485A 41 RX4815A I OV I c
!FOR TEST! TXOB I ov I •P*A6 ov
i 2 OV 12 ov 17 IJll 42 OV I PD2 I •PD2 I •EN3Ll5 I ov
JDIB I/O LINK
o---- 3 OSRBC 13 DTRB 18 OFF 43 SVIJll-RV I ov I ov I •PIH::l5 I ov ~
J017 RS-2J2C/4815 INTERFACE 4 ov 14 OV 19 COM 44 +24V I PRD2 I •PR02 I •PWMC5 I ov
g 0---- !OPTION!
15 CTSB 115 RTSB 20 •DPEMG 45 +24V ov ov •P*Al5 ov ~
JRMJ 0--- TO OPERATION BOX 6 OV 16 ov 21 •EXEMG 46 +24V 21 POI I •POI I •EJIBL4 21 ov s::
7 RX48!5B 17 TX48!5B 22 EMGOM 47 •24V ov ~ •PWME4 ~
,_____
CRSI 0-- TO TEACH PENDANT
8 •RX48!5B 111 •TX48!5B 23 EMGEM 48 +24V PRDI •PROI •PWMC4 ,___l!L_
!cs· 9 19 •24E 24 •TPEMG 49 EMG81 ov ov •PljMA4 ov
:::J CRMIO 0-- RDI/RDO
~~~ 10 +24E 20 20 SVON-EMC 150 EMG82 ov ov •EN3L3 '~
ov ov •PWME3 ov )>
~88~ +5V +5V •PWMC3 '"O
~'l''l'o!i +15V +15V •pljM,t\J '"O
:·iilc
CRSI ...F21 YBAT +15V i---;w- •EN3L2 ov m
(TEACH PEllDANT)
~ 3 (LINE TRACKING) I BATTERY I +15V i----+w- •PljM£2
~~
ov z
~~~~ Oii TXTP r•r •TXTP I PA II I +!5V I +15V JI •PWMC2 !JI ov 0
co_, ~ I~ IE~~ATI +15V opljMA2
2 •PA 12 ov +!5V J ov x
o/o/~ &..!!:!!!!!
... 3 P8 13 +15V +15V •EJIBLI ov
oe 4 •P8 14 ov +15V +15V •Plil£ I ov
II?. "'"' 061 +24V ov 15 PZ 115 +5V +5V •PWMCI ov
071 +24V 6 •PZ 16 ov +!5V +!5V •pljMA I ov
&> 7 17 +15V +15V •MCON +15V
c:r 8 RED 18 +15V +!5V +5V •DROY +15V
9 +15V 19 +15V +15V OV J +15V
j 10 20 +15V +15V +15V ov ~· +5V
41 +5V I +15V I +115V 141 +15V
.. +15V +15V •115V •15V
~ ov ov +15V
ov
fs·
CRMIO JRM3 ov ov ov +15V
0 I ROI/RODI CPOI/PDO) +24E +24E U! -115V +15V
....
"ti 01 ROii I PDII II ov +24E ov .... -115V +15V
c: 02 iiDi2 2 ov 12 POOi •OTREL .. OV +24V
03 iiil'fi
- iii iiDii J PDI2 IJ PD02 •OTRST •ROT ov +24V
Gi ROI5 4 PDI3 14 PDOJ SVIJll •HBK ""'
••• •BRKON +24V
iii ROI6 15 PDI4 115 PDD4 RDI COM •HBKREL ·~ •BRKALM +24V
07 ov 6 PDil5 16 PDOl5
7 PDI6 17 PD06
fg...
8 POI7 18 PD07
9 TPOFF 19 +24V
10 +24V 20 PD08
MAIN CPU BOARD

irr
....
cs
Co)
PSM ~
SVM
~
LI DC LINK p U1
SERVO POWER (: L2 p
L3 N N T
>@ ALARM CONTROL 0
~ JXIB .JXIA .JXIB CONTROL POWER(NEXT SVM) w
CONTROL POWER(200VAC) CXIA E-STOP CONTROL
CX2B CX2A CX2B E-STOP CONTROL(NEXT SVM)
:n
ca IJCX2A
)> MCC CONTROL CX3
w
E-STOP CONTROL CX4
s I
:;
TB2[ ~
...lit
:I .JS..!,B .- "1
)"""' '""'"
e.
0 I SERVO CONTROL I
0
:I
:I
CD
~
6'
:I
c
iii' JSIB CXIA(X-KEY)
ca
... (SERVO CONTROL) (CONTROL POWER)
Ill )>
3 I IR 11 IS ""C
.-. 2 GNDR 12 GNDS I2doA I2;oe I P~ I ""C
t 3 •PWMA 13 •ENBL m
4 ov 14 ov z
- 0
5 •PWMC 15
f...
$i?, CX2A/CX2B(X-KEY) x
6 ov 16 ( ESTDP CONTROL)
0 7 •PWME 17
Ill 8 ov 18
tT I.d4v I ;v I E~P I
s· 9 •DROY 19 ov
10 •MCON 20 OV
~!1 ;r>
g> CX3(Y-KEY) ()
(MCC CONTROL) 0
JXIA/JXIB s::
~ (ALARM CONTROL)
w;F~ 2k:ml "'O
J> I IR 11 ALMI r
3 2 GNOR 12 ov m
"2. •PWMA 13 ALM2
-i
::;; 3 m
(5' 4 OV 14 OV CX4(X-KEY)
CESTOP CONTROL) ()
.::. 5 !ALM 15 ALM4
.-. 6 ov 16 ov 0
1 z
7 MCCOFF 17 ALMS I I E~ I.2~v I z
...f 8 ov 18 OV m
Q 9 •CROY 19 CALM ()
~.
._. 10 ov 20 -i
5
z
CJ
PSM(POWER SUPPLY MODULE) ~

JJ
SVM(SERVO MODULE) )>
s::
;i:o-
E-STOP PCB ()
JRF2 JRVI
(ROBOT FEEDBACK) (SERVO CONTROLl SERVO CONTROL CRFI TO ROBOTCFEEDBACKl 0
Al PD6 Bl •PD6 Al IS6 Bl GNDS6
D JRVI D s:
"'O
A2 OV B2 ov A2 IR6 B2 GNDR6 ROBOT FEEDBACK r
.,, A3 PRQ6 B3 •PRQ6 A3 IS5 B3 GNDS5 D JRF2 JSI m
IQ" A4 ov B4 ov A4 IR5 B4 GNDR5 D -I
A!5 PD!5 B!5 •PD!5 A!5 IS4 B5 GNDS4 E-STOP CONTROL D CRM9 JS2 D m
> A6 ov 66 ov A6 IR4 66 GNDR4 ()
(.) DOOR INTERLOCK ----{] CRM15 JS3
A7 PRQ5 67 •PR05 A7 IS3 B7 GNDS3 D I SERVO CONTROL 0
C,Q
._.. A8 ov B8 ov A8 IR3 BS GNDR3 AUX BRAKE CONTROL ----{] CRMl6 JS4 z
A9 PD4 69 •PD4 A9 IS2 69 GNDS2
D z
3" AIO OV BIC ov AIO IR2 BIO GNDR2 JS5 D m
()
-..
CD Al I PRQ4 II •PRQ4 "6.11 ISi Bl I GNDSI
... E-STOP CONTROL JS6 -I
::I Al2 OV 12 ov Al2 !RI 612 GNORI 0~CRR20 D
!!!. Al3 PD3 13 •PD3 Al3 •EN6L6 613 OV IOOVAC INPUT FOR BRAKE POWER -- - --{] CRR21 CRMI I ROBOT OVERTRAVEL 6
(") Al4 ov 14 ov Al4 •PWME6 614 ov D z
0 Al5 PRQ3 Bl5 •PRQ3 Al5 •PWMC6 615 ov CRR5 D MOTOR BRAKE POWER
::I Al6 ov Bl6 OV Al6 •PWMA6 616 ov CJ
CRR22 IOOVAC OUTPUT FOR AUX MOTOR
::I Al7 PD2 Bl7 •PD2 Al7 •ENBL5 817 ov 0---- CC-SERIES AMPLIFIER) 5>
Al8 ov BIS ov Al8 •PWME5 618 ov G)
Pl
::::!: JJ
Al9 PRQ2 Bl9 •PRQ2 Al9 •PWMC5 819 ov
0 A20 ov B20 ov A20 •PWMA5 620 ov )>
::I
A21 POI B21 •POI A21 •ENBL4 621 ov CRM9 JSI -JS6 CRFI s:
0 A22 ov B22 ov A22 •PWME4 22 ov (E-STOP CONTROL) (SERVO CONTROL) (PULSE CODER INTERFACE)
iii" A23 PRQI B23 •PRQI A23 •PWMC4 823 ov I IR 11 IS
C,Q
A24 ov B24 ov A24 •PWMA4 824 ov ~·-~
MCCONyvour 2 GNOR 12 GNDS
iiJ A25 ov B2! ov A25 •ENBL3 825 ov 3 •PWMA 13 •ENBL
3 A26 ov B26 ov A26 •PWME3 826 ov 4 ov 14 ov )>
A27 +5V B27 +5V A27 •PWMC3 627 ov 5 •PWMC 15 -0
i: A28 +5V B28 +5V A28 •PWMA3 628 ov CRMl5
6 ov 16 -0
t (DOOR INTERLOCK l m
N ....J,. A29 +!5V 629 +!5V A29 •ENBL2 829 ov 7 •PWME 17 z
S?. A30 +5V 630 +!5V A30 •PWME2 30 OV 8 ov 18 0
A31 +5V 831 +!5V AJI •PWMC2 631 ov , 3 ,DI~ 9 •DROY 19 ov
&> A32 +5V 632 +5V A32 •PWMA2 832 ov 10 •MCON 20 ov
x
er A33 +!5V B33 +!5V A33 •ENBLI 833 ov
:;· A34 +!5V B34 +!5V A34 •PWMEI 834 ov 46 14
CRMl6
A35 +5V 835 +!5V A35 •PWMCI 635 ov (AUX BRAKE CONTROL) CRR5 47 15
~ 4i 16
A36 +5V B36 +!5V A36 •PWMAI 636 ov I 2 I I ID 2D 3D 17
m A37 +!5V B37 +!5V A37 •MCON 637 +5V BKM3 BKM3 BKM3
.
50 ,.
3 •8RKON41•6RKON3
CD A38 +!5V B38 +!5V A38 •DROY 638 +5V IC 2C 3C
... A39 +!5V B39 +!5V A39 ov 639 +5V
C,Q BKP3 BKP3 BKP3
CD A40 +!5V B40 +!5V A40 OV 840 +5V
::I A41 +!5V B41 +5V A41 +15V 841 +!5V CRR20 IB 2B 3B CRMI I
n A42 +5V B42 +5V A42 +15V 842 +5V ( EMG CONTROL) BKMI BKM2 BKM2 (ROBOT OVERTRAVELl
'< OV B43 A43 IA 2A 3A
A43 ov ov 843 +5V
A44 ov B44 OV A44 ov 844 +5V BKPI BKP2 BKP2 3
~
"O A45 +24E B45 +24E A45 -15V 845 +5V I l•RO~
A46 +24E B46 ov A46 -15V 846 +5V
c: A47 B47 •OTREL A47 ov 847 +24V
::I
;::;:
._.. A48 •OTRST B48 •ROT A48 ov 48 +24V
.-. A49 SVON B4l •HBK 49 •BRKDN 49 +24V
s:: A50 RD I COM B5< •HBKREL 50 •BRKALM 50 +24V CRR21 CRR22
(BRAKE POWER) ( IOOVAC OUT)
J,.
....
g l=:Ho6 I 1I 100A ~T2j1~~~1
(11
E-STOP UNIT
ir
0
Col
CIRCUIT DIAGRAM OF OPEARTION BOX OPERATION BOX

%
!OF l BREAKER
OPERATION BOX PCB ~
(11
FROM MAIN I A20B- I 006-0740 (CRT3) ..
(..RM;!)
POO I 11~1 "" LEOI ,REMOTE
lr"""'1 ,., T
POO:2 "" SW4 ,C-START
IA
Pl 3 ,." '""' (NOT ~Dl
Pl '""
.... LED2, F-RESET
8
!!
•
5 "
( 17) fOll
(NOT USED)
(NOT USED)
c.a ( 18) fUI
'7 CNOT USED)
+ '°n '°4'
~ B (NOT USED)
w r- - -,-------.., fl I
I ""'
, •• 1 !NOT USliRl
-. I/O 1.NIT ·MOOEL B I/O UNIT-MODEL A Ill
BASE I.NIT BASE UNIT 2 ,,,_ SW6;F-RESET
::r I I ,., f«I
!OPTION) !OPTION) 3 .,...., SWl,REMOTE
151 ...
OPERATION BOX A ...,, .t«>LD REMOTE LOCAL
OPERATION SOX A I I • <•I
MAX. 2-LNIT NOT SLPPCRTED 5 ...,, (NOT USED)
OPERA TIClll IOX a 171 ~-!(r-
'=~i!t=xF., .........,..,, Pl ,. (NOT USliRl
18l
--i .
...::I I NOTE 3
I Pl '7 SW6 , F-RESET
~~C~T~., TP' CNOT USED)
!!!. I ' :~~ ,0 t2,4V '2i'Yrn '.~::
I MDX SELECTION SWITCH
·~ lfl ( CPERATIC»il 80X)
0 ...L _ ~- - - _J I -SWI ;ON
0 Ck rl9 """ ra Tl AUTO
JOIB T2X BREAl<E Cl.OSE CLOSE
::I CCRP6) ,., CCR1!~v ~Lt. AUTO 8REAKE 9R£AKE Cl.OSE
::I ,.. ""
fV TIX 9AEAKE 9RtAKE CLOSE
CD ..OIA EMGB •21-v
() TO" IT I , "' CLOSE Cl.08E 8REAKE
EMGB2
:!: ~ L-----,
0 OPERATION BO: -·---··-
FROM MA N CPU <;>
::I TXSLC
CJRMIO)
.,,. ""' (CRSI) I DEAD-MAN
·i~~g EMGOM '""'
5?. EMGEN
I» "" '"' ~~ENABLE/
DI"""-£
c.a
SLC~~~~ TXTP
f3~
I
Al •TXTP ESTOPI ITBOPI) I ENABLE DISABLE )>
RXTP
~,..,,
3 1 ES TOP
I ·-'1111
~"'".. ... ,iit!'I~ •RXTP TO TEACH ?ENOANT -0
-.. +24V -0
ov m1 Tl ,T2 I m
FG
t
w * z
2) (PORT I
0
...f
S!
TXDI
RXDI
RTSI r--- TPE> (TBOPI)
~2 ! ' - i - - - - - -
* x
0 TII I g~: RS-232-C ov !ffi"l>- - - - -
=~J
I» ~11DTRI +~V'A•£. -
+24V
2: (24) (All) OPEMGAI 'i'
111111 69 TPEMG
(PORT IX) OPEMGA2
::I
~1 I llt r I :1111
i ~II~~ I 1201
'~·
TPEM '"ll
Al" MGBI
TXDIX OPEMG
I
~ !NOTE I) RXDIX Al4 I
+24V ,JRMI0-44 .415 ,46 RTSIX 1014 •~•MGCO ;i:>
47,48 CTSIX r - - -, TOT"' '*41
0 DSRIX ()
!NOTE 2) OTRIX EMGINI CTBOPll
OV ,JRMI0-1.3,5,7,9 •UV EXEMG 11211 I -
+24V ~· N2 0
11,26.28 ov ----
----
--- =~J
110!';1 EMGOUT I I SVONI
~U~·34 FG
SVON-EMG
•v ------ s:
0 CJRMIO) (c";;5)- ~ - ~ -
=~J -0
TXDA ·~v
'I'
l... 0sv~ r
Iii RXDA ~EMOOUT 2
RTSA 2 h .JMETER m
I CV ov ;!,,
Ill CTSA 'J' HMI l l 4 -f
OSRA
0 DTRA C4l>REU4 ,~v J EMGO'~ EIOlOUT< CTBOPI) - m
SVON·RV
"P!V E Tl
TX485A I ()
HX485A ( 171 CTBOP2)_ _ _ _
RX485A EXONI _!!!._ -, 0
ON ,.._-
dX48!SA 19 •x ___
COM
...-.>f
CPDRT2l 18 cxOFFI ------ z
OFF - ~ _J
-- TXDA
RXDA
RTSA
CA09l
809
ONI
ON2
-m- - - z
m
CTSA 111' AIO OFFI
DSRA FO ~
...f
0 DTRA
811
(CRT3)
- ~
.;;
TX485A
I•TX485A 6
"1<485A z
•RX485A
+24V 0
ov
FG "'
NOTE; PORTIX IS
..
OPTION. '='" FG ~
~
s:
;i:>
JRMIO JRM3 PORTI PORT IX PORT2 (')
(MAIN CPU I/Fl (MAIN CPU I/Fl (RS-232-C; PORT-I) CRS-232-C; PORT-I) CRS-232-C; PORT-2) 0
HJNOA PCR50 HONDA PCR-E20 0-SU! 25P 0-Sl.9 25P D-SUB 25P s:::
MALE MALE
-- FEMALE FEMALE FEMALE
--
26 OY I OY 11 OY I PDII I FG I FG I FG
'"'O
14 14 14 r
27 CTSI 2 RTSI 12 POOi 2 OY 2 TXDI 2 TXDI 2 TXDA
15 15 15
28 OV 3 OY 13 P002 3 PDI2 3 RXDI 3 RXDI 3 RXDA ~
16 16 16
"11 29 DSRI 4 DTRI 14 PD03 4 PDI3 4 RTSI 4 RTSI 4 RTSA m
'17 17 17
c6' 30 OY 5 OY 15 PD04 5 PDI4 5 CTSI 5 CTSI 5 CTSA ()
'18 18 18
). 31 RXDI 6 TXDI 16 P005 6 PDI5 6 OSRI 6 DSRI 6 OSRA
'19 19 19 0
32 OY 7 OY 17 PD06 7 PDI6 7 OY 7 OY 7 OY
w '20 OTRI 20 DTRI 20 DTRA z
33 CTSA 8 RTSA 18 PD07 8 PDI7 8 8 8
.::; '21 21 '21 z
34 OY 9 OY 19 +24Y 9 TPOFF 9 9 - 9
22 22 '22 m
--
S' 35 05RA 10 DTRA 20 PODS 10 +24Y 10
23
10
23
10
'23
( I)
36 OY 11 OY REMOTE • POOi F-RESET• PDI2 II 11 - II
24 24 '24 ~
37 RXDA 12 TXDA C-START= P002 REMOTE = PDI3 12 12 12 ~25
:I 25 •24V - 25 +24V_ -t-24V
-...
!!?.
38 •RXTP
39 RXTP
13 •TXTP
14 TXTP
FAULT = P004 HOLD
T2X
=
=
PDI4
PDI5
13 13 13
'
THIS CQNIECTCR IS MOUNTED ON
6
z
THIS CONNECTOR IS MOl.NTEO ON THIS CotN!CTOR IS OPTION INTERNAL SIDE OF THE BOX
(") 40 •TX485A 15 •RX485A Tl X = PDI6 EXTERNAL SIDE OF THE BOX THIS CotN!CTOR IS MCIL.NTEO ON 0
0 41 RX485A 16 TX485A INTERNAL SIDE OF THE BOX
C-START= POI7
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- 450 -
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- 453 -
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SUPPLY FILTER 415
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SPECIFICATION llF FUSE
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RATING RATING NOTE USE
~ NAME CURRENT VOLTAGE
7.DA ~~ FAST BLOW FOR 200V
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I CA39A 0 Di---<--- JDIB JRMIO JRF2 JRVI (J1
(I/0 LINK) (OPERATION BOX) (ROBOT FEEDBACK l (SERVO AMPLIFIER)
I I RXSL.C 1111 OV I I OV 1261 OV Al P06 Bl •PD6 Al IS6 Bl GNDS6
iT
BATTERY UNIT i--- - ----i 2 I •RXSL.C I 121 OV 2 RTSI 27 CTSI A2 OV B2 OV A2 IR6 B2 GNDR6 0(,)
MAIN CPU ~ FOR MAINTENANCE __J 3 I TXSL.C 1131 OV 3 ov 28 ov A3 PRQ6 B3 •PRQ6 A3 IS5 B3 GNOS5
Al6B-3200VBAT 0--- - ------l --, I II If-- I
4 I •TXSL.C I 141 OV 4 DTRI 29 DSRI A4 OV B4 OV A4 IR5 B4 GNDR5
-0042 L__ - __J
5 I I 151 ov 5 OV300V A5 P05 B5 •PD5 A5 IS4 B5 GNOS4
JRV I D SERVO AMPLIFIER 6 I I 161 ov 6 TXDI 31 RXO\ A6 OV B6 OV A6 IR4 B6 GNDR4
71 I 17 7 OV320V A7 PRQ5 B7 •PRa5 A7 IS3 B7 GNDS3
8 181 +5V 8 RTSA 33 CTSA A8 av B8 av A8 IR3 B8 GNDR3
JRF2 D ROBOT FEEDBACK 9 I •5V I 19 9 OV340V A9 P04 B9 •PD4 A9 IS2 B9 GNDS2
!! IOI l2DI +5V I0 DTRA 35 DSRA IAIC OV BIC OV AIC IR2 BIO GNDR2
IC II OV 36 OV IAI I PRQ4 Bl I •PRa4 All ISi lll GNDSI
JF21 [ o----- LINE TRACKING I2 TXOA 37 RXDA IA12 OV Bl2 OV Al IR I ll2 GNOR I
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13 •TXTP 38 •RXTP Al31 PD3 IBIJI •PD3 Al •ENBL6 Bl3 OV
~ JOl7
JRMIO [ Oi---- TO OPERATION BOX 14 TXTP 39 RXTP IA\41 ov 18141 ov Al4 •PWME6 Bl4 OV
CD' { RS-232C/ 485 I
JRA5~ ~ 15 •TX485A 40 •RX485A IAil PRQ3 B\51 •PRa3 A15 •PWMC6 Bl5 OV
-- CFOR T~m RXOB 111 TXOB I 6 TX485A 4 I RX485A IAll ov 8161 ov Al6 •PWMA6 Bl< OV
2 OV I 12 OV 17 ON 42 OV IA! P02 Rl71 •PD2 Al7 •ENBL5 Bl OV
JDIA [ I/O LINK
[ 0--- - -
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RS-232C/ 485 INTERFACE 4 ov I 14 OV 191 COM 144 +24V IA19I PRQ2 18191 •PRQ2 Al~ •PWMC5 19 OV
JD\7 [ o----- (OPTION)
5 CTSB I 15 RTSB 201 •OPEMG 145 +24V ·A20 ov 1820! ov A2< •PWMA5 20 OV
~ JRM3 [ 01---- TO OPERATION BOX 6 ov 1\6 ov 21 I •EXEMG 146 +24V IA21 POI B211 •POI A21 •ENBL4 B21 OV
0 7 RX485B I 7 TX485B 221 EMGOM 147 +24V IA2: ov 8221 ov """ •PWME4 822 OV
0 CRSI [ 0----- TO TEACH PENDANT
8 •RX485B 18 •TX485B 231 EMGEM 148 +24V IA2· PRQI ·231 •PRQI A23 •PWMC4 82j OV
:I ~~
:I CRMIO [ 0----- RDI/RDO 9 19 +24E 241 •TPEMG 149 EMGBI IA241 ov 18241 ov A24 •PWMA4 24 OV
00 10 +24E 20 25ISVON-EMGl50 EMGB2 IA25 ov 18251 ov A2 •ENBL3 •~ OV
I
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a IA261 ov 18261 OV A2 •PWME3 26 OV )>
6' lll88
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:I ...JI I A281 +5V 18281 +5V A2 •PWMA3 828 OV
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Vl CRSI JF21 VBAT IA291 +5V 18291 +5V m
0 (TEACH PENDANT) ''"" •ENBL2 829 OV
~~~ {LINE TRACKING) !BATTERY)
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06 +24V
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71 I 17 IA3 +5V .J71 +5V A3 •MCON B37 +5V
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9 +5V 19 IAJ· +5V ·391 +5V A39 OV 83~ +5V ()
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la. IMll +5V ·411 +5V A41 +I 5V 841 +5V
0
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I
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0 08 RDI7 m
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i6 Ro03 03 RDIJ ()
i7 RoOi TO Ror. 3 POI2 13 PD02 •ROT A4! OV 848 +24V
II •HBK
... RoI4
18 R005 05 ROI5 4 POI3 14 PD03 A49 •BRKON 849 +24V 0
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7
PDI5
PDI6
16
17
PD05
PD06
z
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8 PDI7 18 P007 ()
9 TPDFF 19 +24V -I
10 +24V 20 P008 6
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MAIN CPU BOARD :D
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0
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SERVO POWER ~ LJ
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LIC Tl
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CONTROL POWERC200VACl L2C
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zz
E-STOP CONTROL I[ CX4 Tl ~ m
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(TERMINAL BLOCK! (TERMINAL BLOCK) ( ESTOP CONTROL) x
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- 3 L2CSl
I 13 LIC
4 L3CTl
~ 14 L2C
F> '5 ( IOOAl .JSIB/.JS2B
15 THI
6 ( 1006) (SERVO CONTROL!
16 TH2 -~7
RL2 I IR 11 IS
~ 17 RC 2 GNDR 12 GNDS
..0 - 8 RL3
la RI 3 •PWMA 13 •ENBL
(() - 9 U[UMJ 4 ov 14 ov
CD 19 RE
10 V[VMJ 5 •PWMC 15
24 FANI
...< 6 ov 16
0 11 W[WMJ
25 FAN2 _ 12 7 •PWME 17
:I> @ 8 ov 18
3 9 •DROY 19 ov
"2.
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10 •MCON 20 ov
i"
--...
~
01
I\)
01
SERVO AMPLIFIER
T
~
E-STOP PCB
%
0
()'I
JRF2
(ROBOT FEEDBACK)
JRVI
(SERVO CONTROL>
h I\)
SERVO CONTROL 111 JRVI CRFI D TO ROBOT(FEEDBACK) ()'I
Al PD6 Bl •PD6 Al IS6 Bl GNDS6 m

A2 ov 62 OV A2 IR6 B2 GNDR6 ROBOT FEEDBACK
.!.
A3 PR06 63 •PRQ6 A3 ISIS 63 GNDSIS JSI D ") 0c.>
A4 ov 64 OV A4 IRIS 64 GNDR5
AIS POIS 65 •PD5 A5 IS4 BIS GNDS4 E-STOP CONTROL D CRM9 JS2 D
A6 ov 66 ov A6 IR4 66 GNDR4 DOOR INTERLOCK - - - --0 CRMl5 JS3
A7 PR05 67 •PRQ5 A7 IS3 67 GNOS3 D I SERVO CONTROL
!!
c.a A8 ov 68 ov A8 IR3 68 GNDR3 AUX BRAKE CONTROL - - - --0 CRMl6 JS4 D
A9 PD4 69 •PD4 A9 IS2 69 GNDS2
> AIO ov BIO ov AIO IR2 BIO GNDR2 JS5 D
:i:.
-e. Al I
Al2
Al3
PR04
OV
P03
II •PRQ4
I<
13 •PD3
ov
Al I
~12
Al3
ISi
IRI
•ENBL6 13
Bl I GNDSI
Bl2 GNDRI
ov
E-STOP CONTROL
IOOVAC INPUT FOR BRAKE POWER - - - --0
r
D~cRR20
CRR21
JS6
CRMI I
D
D ROBOT OVERTRAVEL
:; Al4 ov 14 ov •14 •PWME6 14 ov
CD Al5 PRQ3 Bl5 •PRQ3 Al5 •PWMC6 15 ov CRRl5 D MOTOR BRAKE POWER
A16 ov 816 ov Al! •PWMA6 16 ov IOOVAC OUTPUT FOR AUX MOTOR
-
3
!!!. Al7 PD2 817 •PD2 Al •ENBL5 Bl7 OV
CRR22 D----- (C-SERIES AMPLIFIER)
0 Al8 ov BIS ov Al8 •PWME5 Bl! ov
0 Al PR02 819 •PRQ2 Al9 •PWMCIS Bil ov
:I A21 ov B20 ov A20 •PWMA5 620 ov
A21 POI B21 •POI A21 •ENBL4 B21 ov CRM9 JSl-JS6 CRFI
ill
n A22 ov 2: ov A22 •PWME4 B22 ov (E-STOP CONTROL) (SERVO CONTROL) (PULSE CODER INTERFACE)
=: A23 PRQI 23 •PRQI A23 •PWMC4 23 ov I IR 11 IS
0 OV 24 ov A24 •PWMA4 24 ov 2 GNDR 12 GNDS
:I A24 ~oNlsv~uTI
c A25 OV 21 ov A25 •ENBL3 25 ov 3 •PWMA 13 •ENBL
A26 ov 26 ov A26 •PWME3 26 ov 4 ov 14 ov )>
iii' +5V IR21 +5V "'O
c.a A27 A27 •PWMC3 27 ov CRMl5 5 •PWMC 15 "'O
.i:. A28 +5V 628 +5V A2 •PWMA3 28 ov (DOOR INTERLOCK) 6 ov 16 m
A29 +5V B29 +5V A2 •ENBL2 B29 ov 7 •PWME 17 z
°' A30 +5V 830 +5V A30 •PWME2 B30 ov 8 ov 18 0
A31 +5V 831 +5V A31 •PWMC2 631 ov I 3 loI~ 9 •DROY 19 ov x
A32 +5V B32 +ISV A32 •PWMA2 B3~ OV JO •MCON 20 ov 44
- -;
b A33 +5V B33 +5V A33 •ENBLI 633 OV 45
Ill A34 +5V 834 +5V A34 •PWMEI 634 ov 14
CRMl6 .
47 i5
2: IA35 +5V B35 +5V A35 •PWMCI B3e OV (AUX BRAKE CONTROL) CRR5
4a i6
A36 +5V 636 +5V A31 •PWMAI B36 ov 2 ID 20 30 i7
;x:>
..i
m
A37
A38
+5V B37
+5V B38
+5V
•5V
A3
A38
•MCON B37 +5V
•DROY B38 +5V
•BRKON4l•BRKON3 BKM3
IC
BKM3
2C
BKM3
3C
.
50 18
()
A39 +ISV 639 +ISV A3 ov 839 +ISV BKP3 BKP3 BKP3 0
3
CD A40 +ISV 640 +5V A4 OV 640 +5V
~
A41 +5V 641 +5V A41 + 15V 41 +5V CRR20 IB 26 36 CRMI I s::
c.a ( EMG CONTROL) BKMI BKM2 BKM2 (ROBOT OVERTRAVEL) ""O
CD A42 +ISV 642 +5V A42 +15V 42 +5V r
:I A43 ov 643 OV A43 OV 43 +5V IA 2A 3A m
n A44 OV 644 ov A44 ov 44 +5V BKPI BKP2 BKP2 3 -I
'< I l•Rortdf] m
(/) A45 +24E 45 +24E A45 -15V 45 +ISV
A46 +24E 46 ov A46 -15V 46 +ISV ()
0
"CJ
- A47 47 •OTREL A47 OV 47 +24V 0
c: A48 •OTRST 48 •ROT A48 OV 48 +24V z
A49 SVON 4' •HBK A49 •BRKON 49 +24V z
._.
i A50 RD I COM •HBKREL A50 •BRKALM 50 +24V CRR21 CRR22 m
'"' (BRAKE POWER) ( IOOVAC OUT) ()
-I
~al 1o~A1 ~UT21l~Tll 6
z
0
5>
(j)
E-STOP UNIT :a
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s::
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0
s:
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r
CIRCUIT DIAGRAM OF OPEARTION PANEL OPERATION BOX PCB
m
FROM MAIN Cl A20B- I 006-0741 -I
(JRMJI ,.., CCRT31 A
fAll m
POO LEO I ;REMOTE
>'1 fRI ()
SW4 ;C-START
P002
POO ""' (NOT US~O)
.
f>Rl 0
.,, OPERATION BOX PCB POO LED2 ;F-RESET
(JRMIO) A20B- I 006-0741 (CRSI) PD05 '"
1171 ,...·-· . LEOJ ;BAT-ALM
z
TXTP TXTP POO· (NOT USED) z
=·;. ~
•TXTP ·' . •TXTP
RXTP RXTP POO 7
' , (NOT USED) m
'001
"" ..
:i=. •RXTP 1•, I
•RXTP POO· I (NOT USED)
06 4 V TO Tt ACH PEN:JANT PO ... ~
:;: I (NOT~
dV ,.......l.l.J FG '" ,... SW6 , F-RESET
PO ! "'
,., ,,., 0
(~10)
(PORT!) PO I SWJ;REMOTE
TXOI TXOI '"1
..,.. REMOTE LOCAL z
:; PO I ,., ,HOLD
RXOI RXOI 1071 ""
RTSI RTSI PO ; (NOT USEDI 0
CD f?I --![.._ -c(,-
CTSI CTSI PO ; (NOT USlfll]
OSRI OSRI RS-: 32-C PD 7
.. SW6 , F-RESET
)>
--.,
:I DTRI OTRI
..
!!!. +24V +24V TPOFI ,.t2,'V ce8> (NOT USED) G)
ov ov ' (9~ +
•¥Y.. Iii:. .t.1"1\
IJV IJV .____w +2 I ~~11go;,swtTCH :D
C') <PORTIX) I~\ FG .. Ill Ul7l .
I T2 Tl AUTO
0 ~~:~ l~I rJri rJri SWI ;ON
T2>C l!JREM<E CLOSE CLOSE
>
:I (NOTE I)
+24V ;..RMI 0-44,45,46 RTSIX IAll <CR1!L ~!&. !AUTO BREAl<E BREAl<E CLOSE
s:
:I CTSIX (CRP6) lA21 T IX BREAl<E BREAl<E CLOSE
CD
(NOTE 2)
I 47 .48 OSRIX
OTRIX
'"' EMGBI ·'"
,., +2,'V
,.,. x rTI, T2I CLOSE CLOSE BREAK£
n OV i~MI 0-1,J,5,7,9 ...v EMG82 '"
g: 11 ,26,28 +24V ·-- L----;
J0,J2,J4 ov
:I 36.42 FG ''" ~.¥.
FROM MAiiN CPU {CRSI)
{JRMIO) CJRMIOI I )>
c TXDA '°' """' "" iJ
ii.i" RXOA :~ BWtl
RTSA ... •01 I iJ
.j:>. C.Q CTSA
EMGBI
0\ EMG82 m
OSRA I
N iii OTRA z
,.,"' (TBOPJ) ESTOPI CTBOPI) I
3 TX485A S2+( ESTOP2 0
.-. •TX485A s2-, -
--- -- x
SJ+
·=~~=g~ '" ·yv -- Im Tl. r2 I
(PORT2) '" +~!~I - - --
0
b
Ill
C"
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;~
-
OSRA Jv r--- TPE• ...,lTBOPIJ
______
s· OTRA (NOTE 3) ~
Ll OV;JOIA-11.1 2.13. OV i~N31 - - - - -
=~J
!a TX485A 14, I 5,16 +~V{Al6 616)
.. •TX485A
RX485A (24) ~__j'v <AIJl OPEMGAI 'i'
•RX48"'A TPEMG OPEMGA...,
0 TPEM ••IJ
+24V Al5 I I
ov OPEMG ''°' ~·
FG Al4 MGCI
i., FG "" (814) OPEMGC2
,
Ill (CRS9) . (JOIA) l r- - .., HMI
TXSLC ., TXSLC -
0 •TXSLC •TXSLC - (TBOPI)
fOjl i:Jv EMGINI
... RXSLC RXSLC EXEMG I ,.MG N.... -
•RXSLC •RXSLC EMGOUT
-
111·
"ti
rro SVON-EMG
(25) II SVONI
SVON
------
------
----- -~J
- - - - - - =~J
Ill ·~v Ill CCRP5) c=:JHOUR
rs~ ~EMGOUT 2 ~ b ,J'4ETER
i 1 ov ov nu (3) HMI IJ 4
! (43)REU4 1-~v EMGOUT EMGOUT< (TBOPI)
._. SVON-RV I I
I sV I c
{ 17) EXON!
ON {TB0P21__ - - -
19 ~-:::!
COi ------
18 I
OFF -!l!r ...J
IA091 ON!-..,,-:- - -
~
11 1' (AIO OFFI
~
Bii OFF2
(CRTJ)
~~
C1l
T
0
c.l
,-------,
JRMIO JRM3 PORTI PORT IX PORT2
(MAIN CPU I/F) (MAIN CPU I/F) (RS-232-C, PORT-I) (RS-232-C, PORT-I) (RS-232-C, PORT-2)
~~
HON)A PCR50 HCN>A PCR-E20 0-SUB 25P 0-SUB 25P 0-SUB 2!5P CJ1
....
MALE _ MALE FEMALE FEMALE FEMALE
26 OV I ov II ov I POI I FG I FG 11 FG '
14 '14 TX485A T
27 CTSI 2 RTSI 12 POOi 2 OV TXDI 2 TXOI 12 TXOA
15 '15 •TX485A Cl
28 ov 3 OV 13 PD02 3 PDI2 RXDI 3 RXDI 3 RXDA w
16 '16 RX485A
29 DSRI 4 DTRI 14 PD03 4 PDI3 RTSI 4 RT51 4 RT5A
17 '17 •RX485A
30 ov 5 ov 15 PD04 5 PDI4 CTSI 5 CT51 5 CT5A
18 '18
31 RXDI 6 TXDI 16 PD05 6 PDI5 DSRI 6 DSRI 6 OSRA
19 19
32 ov 7 ov 17 PD06 7 PDI6 ov 7 ov 7 ov
20 DTRI 20 DTRA
33 CTSA 8 RTSA 18 PD07 8 PDI7 8 8 8
21 21
~ 34 ov 9 ov 19 ... 24V 9 9 9 9
22 22
35 DSRA 10 DTRA 20 P008 10 +24V 10 10 10
;,:.. 23 23
36 OV II OV 11 II II
24 24
37 RXOA 12 TXOA 12 12 12
....... REMOTE = POO I F-RESET= PDI2 - 25 +24V 25 +24V_
..;::
""' 38 •RXTP 13 •TXTP 13 13 13
C-START• P002 REMOTE • PDI3
39 RXTP 14 TXTP THIS CCINECTOR IS OPTION THIS CONECTOR IS MOLNTED ON
FAULT • P004 HOLD = PDI4 THIS CONNECTOR IS MCll..NTED ON THIS CONNECTOR IS MOl.NTED ON INTERNAL SIDE OF Tl£ BOX
3" 40 •TX485A 15 •RX485A EXTERNAL SIDE OF 11£ BOX INTERNAL SIDE CIF_2_f£ BOX _ _J
BAT-ALM= P005 T2X • PDI5 L
CD 41 RX485A 16 TX485A
42 17 TIX = PDI6
ov ON
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I/O UNIT MODEL A ~
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Fig.A.4 (n) Internal Connection Diagram (B-CabinetJM-500, S-900 ; Emergency Stop Circuit)
-468 -
EMERGENCY CIRCUIT
ROBOT
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PU.SE
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- 470 -
B. SPECIFICATIONS OF PERIPHERAL
B-80525E-1 /03 APPENDIX DEVICE INTERFACE
SPECIFICATIONS OF PERIPHERAL DEVICE
B INTERFACE
B.1 The following table lists the 1/0 signals used for the peripheral device
interface in the R-J2 controller.
SIGNALS
Input signals
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
ENBL Enabling signal
RSR1/PNS1 Robot service request/program number select signal (•1)
PNSTROBE PNS strobe signal
PROD_START Automatic operation start signal
SDI01 General-purpose input signal

SD104 General-purpose input signal
SDl10 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.
- 471 -
DEVICE INTERFACE APPENDIX B-80525E-1 /03
Output signals
Signal Description
CM DEN BL 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/SN01 RSA acknowledge/Selected program number signal
ACK3/SN03 RSR acknowledge/Selected program number signal
ACK5/SN05 RSR acknowledge/Selected program number signal
SNACK PNS acknowledge signal
--- Not used (for future expansion)
SD001 General-purpose output signal

- 472 -
B-80525E-1/03 APPENDIX DEVICE INTERFACE
8.2 The process 1/0 printed board has a setting pin 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, the user
VOLTAGE can operate the system without being concerned about the setting of the
common voltage.
To ensure safety, the reference voltage of the following four signals,
however, common voltage is set to +24V.
*IMSTP
*HOLD
*SFSPD
CSTOPI
- 473 -
DEVICE INTERFACE APPENDIX B-80525E-1/03
8.3
1/0 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 theu-
nit. At the same time, the alarm display on the teachpen-
dant (the top line) is cleared.
Description : This signal releases only the alarm status. It does nots-
top execution of the program.
(3) Hold signal (input) ·HOLD
Effective At anytime
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's 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.
- 474 -
(4) Start signal (input) START

Effective When the command acceptance enabled signal (output)
CMDENBL is turned on.
See the description of CMDENBL in Section 2.2.1 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
parameter $SHELL_CFG.$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
Function If parameter $SHELL_CFG.$USE_ABORT is set
to DISABLED, the CSTOPI signal releases the pro-
gram 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 immedi ately
cancels the execution of the current pro gram. The
program returns 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
Function If the ENBL signal is turned off, the operation of the
robot or the activation of a program is inhibited, and the
execution of the current program is suspended.
- 475 -
(7) Safety speed signal (input) *SFSPD

Function Use the normally-closed switch because it is a
reverse signal. Usually this switch should be con-
nected to safety fence. It must be set normally on.
- Since the *SFSPD signal is counted as a remote
condition, such input signals as RSR and START to
the peripheral device interface cannot take effect
unless this signal is turned on.
- If this signal is turned from on to off during robot
operation, the execution of the current program is
suspended. 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
details.
Function The user can choose between RSR and PNS
(optional), although they cannot be used simulta-
neously.
- Four input signals, RSRl 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 wait-
ing 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).
- 476 -
B-80525E-1/03 APPENDIX DEVICE INTERFACE
+---------------------------------~-----+
I I·
l!llllllllllllll//llllllll/lllllllllllllll
I 11s I
I 1 Job selection: RSR I RSR or PNS
I 2 RSRl program number: 12 I 0 •• 9999
I 3 RSR2 program number: 23 I o•• 9999
I 4 RSR3 program number: s I o.. 9999
I s RSR4 program number: 64 I o•• 9999
I 6 Base number: 100 I o.. 9999
I 7 Acknowledge: Enabled I Enabled or disabled
I 8 Acknowledge pulse width:. 250 msec I O•• 9999msec
= =
I I
ll TYPE ] I
+----------------------------------------+
- When an RSR is input, the program whose program
name consists of the specified program number plus
a base value is started. For exam pie, if a signal is
input to RSR2 when program number 23 is regis-
tered in RSR2, the program to be started is the one
with the program name calculated from the expres-
. sion
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
signal to an RSR can be selected from the menu. If
so specified, a pulse is output from the signal corre-
sponding to the RSR, one of signals ACK 1 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
RS Rs.
- 477 -
DEVICE INTERFACE APPENDIX B-80525E-1/03
(9) PNS/PNSTROBE (input)
Signal name : PNS : Program number select

PNSTROBE: Strobe input for PNS
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
function cannot be used.
- The eight signals PNSl 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.
+------------------------------+
I I
lllll///l/l//l//l///ll///l/l/l//lll/ll/lll
I 113 I
I 1 Job selection: PNS I RSR or PNS
I 2 Base number: 100 I 0 •• 9999
I 3 Acknowledge pulse width: 250 msec I o.. 9999msec
I I
I I
I I
I
= ..
I
I
I[ TYPE ]
+---------------------------+
If a number other than zero is entered to PNS input, a

program is selected whose program number is the
entered 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.
- 478 -
8. SPECIFICATIONS OF PERIPHERAL
- 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
acknowledge signal SNACK. Using these signals,
peripheral 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 pro-
gram selected by PNS.
· Starting up a program by input of automatic op-
eration start signal PROD_START
· Restarting the program that has been suspended.
Inputting the START signal restarts the program
selected by PNS when $SHELL_CFG.$CONT
_ONLY is set to ENABLED.
· Inputting 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

details.
Function This input signal executes the selected program at the
falling edge when the signal is turned off after being
turned on.
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
REMOTE side.
- Parameter $RMT_MASTER is set to 0 (external
interface).
- Signal *SFSPD is set to on, or in the normal status.
- 479 -
DEVICE INTERFACE APPENDIX 8-80525E-1/03
(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
operation.
(7) Reference point signal (output) ATPERCH

Turned on When the robot is in the reference position specified in
the parameter.
Turned off When the robot is not in the reference position specified
in the parameter.
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.
- 480 -
(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.
(ll)RSR acknowledge signals (output) ACK1/ACK2/ACK3/ACK4
These signals are used together with the RSR function. They can be spe-
cified to be enabled or disabled from the RSR setup menu.
Turned on : When one of signals RSR 1 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 output.
CMDENBL (0)
(The remote conditions need to be satisfied.)
RSR1 (I)
~ ~ The maximum delay is 32 msec.
ACK1 (0)
J< >I (The width of the pulse is set in the parameter.)
RSR2 (I)
ACK2 (0)
· RSR3 (I)
ACK3(0)
RSR4 (I)
ACK4(0)
- 481 -
* Other RSR signals can be accepted even when the ACK signal is being output.
(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 (SNOl to SN08) on the teach pendant. If the num-
ber cannot be represented as an eight-bit number, it
becomes 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
PNSTROBEby (PNS is read within a maximum of 32 msec after PNSTROBE is turned
software. on.)
SN01-8 (0)
SNACK(O)
PROD_START (I)
::Jliol loE (Program execution
,___s_ta_rts_w_it_h_in 32 msec.)
PROGRUN (0)
-482 -
8.4
SPECIFICATIONS OF
DIGITAL
INPUT/OUTPUT
B.4.1 This section describes the external specifications of digital and analog
Overview input/output in the R-J2 controller.
B.4.2 The R-J2 controller can use up to 512 digital input and output points or
Input/Output Hardware an equivalent number of analog input and output points. One analog
input/output point uses the resources equivalent to those used by 16
Usable in the R-J2 digital I/O points. The R-J2 can use a total of up to 512 I/O points.
Controller
The R-J2 controller can use the following I/O hardware.
- Process I/O printed circuit board
- IIO unit model A
- IIO unit model B
The process I/O printed circuit board and the I/O unit model A ro B can
be used together.
B.4.3
Software (1) RDI/RDO
Specifications These are signals sent to the connector at the wrist of the robot.
They cannot be assigned 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
These signals can be assigned. Eight points form a pairs and they are
mapped in units of pairs.
(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 1/0 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 1/0 screen.
- 483 -
ADDITIONAL
INFORMATION
Revision of FA~1JC Robot series R-J2 CONTROLLER MAINTENANCE MANUAL for Europe
1. Type of applied technical documents

Name FANUC Robot series R-J2 CONTROLLER MAINTENANCE MANUAL for Europe
Spec. No./Version B-80525£-1/03
2. Summary of Change
Gruop Name/Outline New, Add, Applicable
Correct, Date
delete
Basic Correct APPENDIX Fig.A. l(n) Emergency Stop Circuit Correct
Function Correct APPENDIX Fig.A.2(m) Emergency Stop Circuit
Optional
function
Unit
-
Maintenance
Parts
Notice
Correction
Another
TITLE FANUC Robot series R-J2 CONTROLLER

MAINTENANCE MANUAL for Europe
01 97. 09. 19 T.OBI ?:;, L.

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DRAW. NO. B-80525E-1/03-1 I CUST.
EDIT. DATE DESIG. DESCRIPTION FANUC LTD I

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-410-
TITLE
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DRAW. NO. B-80525E-1 /03-1
SHEET
EDIT. DATE DESIG. DESCRIPTION FANUC LTD 002/
A. COMPLETE CONNECTION DIAGRAM APPENDIX 8-8052SE-1/03
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- 432 -
TITLE
CUST.
DRAW. NO. B-80525E-1 /03-1
SHEET
EDIT. DATE DESIG. DESCRIPTION FANUC LTD 00313
Revision of FANUC Robot series R-J2 CONTROLLER MAINTENANCE MANUAL for Europe

Name FANUC Robot series R-J2 CONTROLLER MAINTENANCE MANUAL for Europe
Spec. No. /Version B-80525E-1/03
Correct, Date
delete
Basic Correct SRV0-049 SVALI OHAL!alarm(page 98) Correct
-·
Function Correct PROCESS I/0 DA correspondence between
driver chips andDO signals(page 178,179)
-
Correct M-410i cable connection(page 310)
Optional
- function
Unit
Maintenance
Parts
Notice
Correction
Another
-·--

MAINTENANCE MANUAL for Europe
01 97. 11. 26 T.OBI ):I~

DRAW.
NO. B-80525E-1/03-2
I
I
SHEET
CUST.
EDIT. DATE DESIG. DESCR I PTI ON FANUC LTD 001/5

I
3. TROUBLESHOOTING MAINTENANCE 8-80525E-1/03
(36)SRV0-049 SVALl OHALl alarm (Group : i _Axis : j)

SRV0-141 SVALl OHALl alarm (Group: i Axis :j)
(Explanation) The thennostat in the servo amplifier or transformer
worked. The servo amplifier LED indicates "3" .(For
ARC Mate 120i, S-6, S-12, M-6i, M-16i, S-420i,
S-500, S-700, M-710i, A-520i):
rating.
(Action 2) Clean fans, louver Ci-cabinet) or filter (B--cabinet)
"'hen f 1e1 Fl, F2, • ~ f3 of tbe Ji1:1e §It r •mit ( "
'll""'"'l 11Wtsi1Hwttr) ha": blo·'"n (for the P c'hin·r), wp1ac•
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· an displayed H ~e tcaeb penduu "'fteA the i&Rlifil
3 unit is tut J: a )
(Action~ Replace the servo amplifier.
(Action~) Replace the trans former.
4
- 98 -
TITLE
DRAW. NO. B-80525E-1 /03-2 I CUST.
EDIT. DATE DESIG. DESCRIPTION F A N uc L T D !SHEET 001/
'
I
4.4.3
PC Board DA
(A 168-2201-0480)
oT .,..... l
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0
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- Fig.4.4.3 Process 1/0 PC board DA
( 1) Test pins
Name • • Description
P24V +24V
PSV +SV
GND1 GND
GND2 GND
(2) Settings
Name I Standard
setting
Description
ICOM1 UDI01 to20

(Connector CRM2A)
UDl21 to40 The common voltage is
ICOM2
(Connector CRM2B) adjusted to:
Side A
ICOM3
UDl41 to60 Side A : +24 V common
(Connector CRM2C) SideB : OVcommon
UDl61to80
ICOM4
(Connector CRM2D)
(J-OllH ~ • B&
~ IC0/"(5
<C..~"«.wr ck "1<f.l)
Vt>l~lj -to%
ICOHb
- 178 - '"""e...~r c. jtH4B)
TITLE
DRAW. NO. B-80525E-1 /03-2 I CUST.

EDIT. DATE DESIG. DESCRIPTION FANUC LTD I SHEET oo.v
I
B-80525E-1/03 MAINTENANCE 4. PAINTED CIRCUIT BOARDS
(3) LEDs
Color Description
qi a:I
DOM
10-a Red
aa.. the main CPU and process input/output.
O•
I
\ ~~•ii a:::;i
·aII
oo-a
10•
00•
) O•
Red
below.

DV1 CMDENBL. SYSROY, PROGRUN, PAUSED
OV3 BATALM, BUSY, ACK1/SN01, ACK2/SN02
OV5 ACK7/5N07, ACK8/SN08, SNACK, RESERVED
DV6 S0001, S0002, 50003, SD004
DV7 S0005, 50006, 50007, 50008
ova 50009, 50010, 50011, S0012
- OV9
OV10.
50013, 50014, 50015, S0016
S0017, 50018, S0019, 50020
OV11 A0021, 50022, 50023, 50024
OV12 $0025, 50026, S0027, 50028
OV13 S0029, 50030, 50031, 50032 . !
DV14 S0033, S0034, S0035, 50036
i
DV15 i
SD037, S003B, 50039, SD040 i
DV16 S004l, S0042, S0043, SD044

OV17 S0045, S0046, S0047, S0048
DV18 S0049, S0050, SD051, S0052
i
OV19 S0053, S0054, SD055, SD056

DV20 SD057, 50058, SD059. S0060
i)V21 s-eo61.s-\)062.5Bo63. s--eo64
~ -ovn S-Oo6S. s-9066, $-Oo&7. 5fJo 6~
-OV23 s-rfii61. s-fio'lo. s4>o71. s-ao7Z
-OV24 s-f}o73, s-eo'14. s-&o7t, s-0076
- 179 -
TITLE
DRAW. ND. B-80525E-1 /03-2 I CUST.
EDIT. DATE DESIG. DESCRIPTION FANUC LTD ISHEET 0041

I
3. ELECTRICAL CONNECTIONS CONNECTIONS ~525E-1/03
(In case of M-410i)
SERVO MOOULE 4
SERVO MOOULE
SERVO MOOULE
SERVO MOOULE I
ROBOT M-410i
EMERGENCY
STOP CONTROL
BOARD
CRR5
CRMI I
CRFI
MAIN CPU BOARD

CRMIO
• Details of cable connection to the servo module
R-.J2 ROBOT M-410i

SEFIVO MOOU..E EMERGENCY
MAIN CPU STOI>
BOARD CONTROL
I 2 3 4 BOAFIO
,..-oU .......-oU .......-ou .......-oU CRFI

.......-ov
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if-<r J2B/J3B
\. 0 JIM
I J2M
I J3M
\ .J4M/J46
- 310 -
flfLE
DRAW. NO. 8-80525E-1/03-2 CUST.
SHEET
EDIT. DATE DESIG. DESCRIPTION FANUC LTD 005°!
I
-·
Revision of FANUC Robot series R-J2 CONTROLLER for Europe MAINTENANCE MANUAL

Name FANUC Robot series R-J2 CONTROLLER for EuropeMAINTENANCE MANUAL
Spec. No./Version B-80525E-l/03
Correct, Date
delete
Basic Correction of replacing the battery Correct
Function (Page 285) '
Optional
function ,
Unit
-
Maintenance
Parts
Notice
Correction
Another

For Europe MAINTENANCE MANUAL
01 98.09.29 T.OBI
DRAW.
NO. B-805:2SE-1/03-3 I GUST.
EDIT. DATE DESIG. DESCRIPTION FANUC LTD I

SHEET 001/2
I
B-80!525E-1/03 MAINTENANCE 7. REPLACING A UNIT
7.25 The battery needs to be replaced at following condition.

REPLACING THE • I year without power-on of controller.
BATTERY •About 5 years with normal use (8 hours/day, 5 days/week).
•Exchange the battey within one month after "BATrERY ALARM" on
operator's panel or "No Battery Power in PSU" alann on teach pendant.
NOTE
Make sure press the EMERGENCY STOP BUTTON when
replacing the battey.
abou-t. .JO SeCO'flds a vi cl <1) Use a lithium battery (ordering drawing number: A98L-003l-OO12).
(2) Tum on the R-J2! (The battery eui he eep'seeEI maea tfie pe"'eE is
tui-n off tke R- :r 2 • turneJ 11 .. ,~ ff If the p: • 1 is tarn :I :ft; th: 'catt:I') must be
replaced within 30 minutes. If the power is turned off and the battery
is removed for 30 minutes or more, the contents of the memory on the
main CPU PC board may be lost.)
(3} Remove the battery case from the front panel of the power supply
unit. The case can be removed easily by holding the top and bottom
of it and pulling.
Front panel of the ~

power supply unit ~
-
&~·- j
W
Battery
r
(ortlering drawing number: A98L-0031-0012) - - - ~
(4) Remove the connector from the battery.
- 285 -
TITLE
DRAW. NO. B-80525E-1/03-3 I GUST.
EDIT. DATE DESIG. DESCRIPTION F A N uc L T D I

SHEET 002/2
I
B-80525E-1 /03 Index

[A] [E]
Adjustment and Checks at Installation, 391 Electrical Connections, 291
ARC Weld Connection Cable (CRWl: Honda Tsushin Emergency Stop Control Printed Circuit Board, 167
34 Pins), 372 ' End Effector Cable Connector, 377
End Effector Control Interface, 366
External Cable Wiring Diagram, 295
[B] External View of the R-J2 Controller, 8
Backplane Printed Circuit Board, 171
Block Diagram, 290
Block Diagram of the Power Supply, 206
[I]
IJO Signal Specifications for ARC-welding Interface,
368
IJO Signals, 474
[C] Input Signals, 474
Cable Connection for the Peripheral Devices, End Input/Output Hardware Usable in the R-J2 Controller,
Effectors, and ARC Welders, 373 483
Checking the Power Supply Unit, 214 Installation, 382
Checking the Transformer, 212 Installation Area, 382
Clamping of Shield Cable, 295 Installation Condition, 390
Complete Connection Diagram, 395 Interface for Peripheral Devices, End Effectors, and
Welders, 347
Complete Connection Diagram (I-CABINET ; ARC
Mate 100, ARC Mate 120, ARC Mate lOOi, ARC Internal Connection Diagram (B-cabinet; ARC Mate
Mate 120i, S-6, S-12, M-6i, M-16i, S-420i, 100, ARC Mate 120, ARC Mate lOOi, ARC Mate
S-500, S-700, M-710i, A-520i), 395 120i, S-6, S-12, M-6i, M-16i, S-420i, S-500,
S-700, M-710i, A-5201), 416
Component Functions, 28
Internal Connection Diagram (M-4 lOi), 435
Configuration, 8 Internal Connection Diagram (M-500/S-900), 454
Connect the Tap According to the Power Supply Volt-
age, 209
Connecting Cables at Installation (Combined Type of
i Cabinet), 385 [M]
Connecting Cables at Installation (For Separate Type Main CPU Printed Circuit Boards (Al6B-3200-0042),
of i Cabinet), 386 165
MAINTENANCE, 5
Connecting the External Emergency Stop, 321
Manual Operation Impossible, 162
Connecting the External Power Supply on/off Switch
319 ' Mounting IJO Unit Model B on the Din Rail (Use a
Rail That is 3.5mm Wide and 7.5mm High.), 232
Connecting the Input Power Supply, 317
Connection Between the Control Unit and Welder,
360
Connection Between the Mechanical Unit and End
[O]
Effector, 358 Output Signals, 479
Connection Diagram Between Mechanical Unit. 291
[P]
[D] Peripheral Device and Control Unit Connection, 347
Peripheral Device Cable Connector, 375
Digital IJO Signal Specifications, 364
Peripheral Device Connection Cable, 373
i-1
Index B-80525E-1/03
Peripheral Device Interface, 364 Replacing the Breaker Unit, 261

Peripheral Device Interface a Cable (CRM2: Honda Replacing the Discharge Resistor Unit, 239
Tsushin, 50 Pins), 371 Replacing the Door Interlock, 247
Peripheral Device Interface B Cable (CRM4: Honda Replacing the E-Stop Unit, 225
Tsushin, 20 Pins), 371
Replacing the E-stop Unit, 252
Peripheral Device Interface Block Diagram, 328
Replacing the EMG PCB (B-Cabinet), 226
Peripheral Device Interface Combination, 342 Replacing the EMG PCB (M-41 Oi), 227
Peripheral Device Interface Processing, 392 Replacing the Fan Motor of the Cabinet, 262
Peripheral Device, ARC Welding, and End Effector Replacing the Fan Motor of the Control Unit, 269
Interfaces, 325
Replacing the I/O Unit Model B Interface Unit, 228
Position Deviation Found in Return to the Reference
Position (Positioning), 162 Replacing the Input/Output Unit of Model A, 230
Replacing the Mode Selection Switch (Operator's
Power Cannot be Turned on, 31 Box), 245
Power Supply Module (PSM) (M-4101), 189 Replacing the Noise Filter (Operator's Box), 248
Power Supply Unit, 276 Replacing the Operator's Box, 243
Preventive Maintenance, 29 Replacing the Power Supply Unit or a PC Board on
the Backplane Printed Circuit Board, 221
Printed Circuit Boards, 164
Replacing the process I/O EA printed circuit board,
Process I/O Printed Circuit Board Signals, 343 222
Process Input/Output Printed Circuit Board, 172 Replacing the Teach Pendant, 250
Process Input/Output Printed Circuit Board CA Replacing the Transformer, 233
(A16B-2201-0470), 172 Resetting Overtravel, 392
Process Input/Output Printed Circuit Board CB Resetting Overtravel and Emergency Stop at Installa-
(A16B-2201-0472), 176 tion, 392
Process Input/Output Printed Circuit Board DA Robot Connection Cables, 300
(A16B-2201-0480), 178
Process Input/Output Printed Circuit Board EA
(A16B-3200--0230), 180
[S]
Process Input/Output Printed Circuit Boards CA, CB,
DA and EA, 278 SAFETY, 1, 3
Selecting Transformer Taps, 210
Servo Amplifier, 185, 271
[R] Servo Amplifier Module (SVM) (M-41 Oi), 193
Servo Amplifier Unit (S-900, M-500), 198
Recommended Cables, 378
Servo Amplifiers, 184
Redundant E-stop Unit, 281
Setting and Adjusting the Power Supply, 205
Replacing a Fuse, 271
Setting Common Voltage, 473
Replacing a Module, 223, 231 Signals, 467
Replacing a Printed Circuit Board, 219 Software Specifications, 483
Replacing a Relay, 279 Specifications of Digital Input/Output, 483
Replacing a Servo Amplifier, 236 Specifications of Peripheral Device Interface, 471
Replacing a Unit, 217 Specifications of the Cables Used for Peripheral De-
vices and Welders, 371
Replacing fuses, 272
Style Fun, Style Name, Page# Sep, CONNECTIONS,
Replacing the Backplane PC Board. 219 287
Replacing the Base Unit of the Input/Output Unit of
Model A, 230
Replacing the Battery, 285 [T]
Replacing the Breaker, 258 Teach Pendant Cable, 315
i-2
B-80525E-1/03 Index
The Din Rail is in the Operator's Box., 232 [W]

Transportation,379
When 1/0 Unit Model A is Used, 335
Transportation and Installation, 379
When 1/0 Unit Model B is Used, 337
Troubleshooting, 30
When Process 1/0 Printed Circuit Board CA or CB
Troubleshooting Using the Error Code, 33 EA is Used, 328
When Process 1/0 Printed Cricuit Board DA is Used,
332
[V] When 1\vo or More Process 1/0 Printed Circuit
Boards and 1/0 Unit (Model A or Model B) are
Vibration Observed During Movement, 162 Used, 340
i-3
Revision Record
FANUC Robot series R-J2 CONTROLLER for Europe MAINTENANCE MANUAL (B-80525E-1/03)
Addition of descriptions for ARC Mate 100i/M-6i, s-450,

03 Apr.,'97
A-520i, M-400i, M-710i and ARC Mate 120i/M-16i
• Corresponding to EMC standard.

02 Oct., '95
• Addition of descriptions for A-520i and M-500.
01 Apr., '95
Revision Date Contents Revision Date Contents
B-80525E-1/03
111111111111111111111111111111111111111111111111111111111111111111111111111
* B- 80525E- 1 / 03*

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FANUC Robot series

Thank you very much for purchasing FANUC Robot.

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

B-80525E-1 /03 PREFACE

This manual covers the following models.

B-80525E-1 /03 Table of contents

4. PRINTED CIRCUIT BOARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164

5. SERVO AMPLIFIERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184

6. SETTING AND ADJUSTING THE POWER SUPPLY ....................... 205

B-80525E-1/03 Table of Contents

7. REPLACING A UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217

2. BLOCK DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290

3. ELECTRICAL CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291

Table of Contents B-80525E-1 /03

3.2.1 Clamping of Shield Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295

4. PERIPHERAL DEVICE, ARC WELDING, AND

5. TRANSPORTATION AND INSTALLATION ................................ 379

B-80525E-1/03 Table of Contents

A. COMPLETE CONNECTION DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 395

B. SPECIFICATIONS OF PERIPHERAL DEVICE INTERFACE . . . . . . . . . . . . . . . . . 471

B-80525E-1 /03 SAFETY 1. SAFETY

Consider following notes besides the items described in the SAFETY

1. SAFETY SAFETY B-80525E-1 /03

• After replacing parts or adjustment, be sure test running according to

B-80525E-1 /03 MAINTENANCE 1.0VERVIEW

2. CONFIGURATION MAINTENANCE B-80525E-1/03

2.1 Fig. 2.1 (a) to (d) show the R-J2.

FIG2. I (a) EXTERNAL VIEW OF THE R-02 CONTROLLER

Fig.2.1 (a) External View of the R-J2 Controller (i cabinet)

B-80525E-1 /03 MAINTENANCE 2. CONFIGURATION

TEACH PENDANT OPERATOR'S PANEL

Fig.2.1 {b) External View of the R-J2 controller {B-Cabinet)

2. CONFIGURATION MAINTENANCE B-80525E-1 /03

Flg.2.1 (c) External View of the R-J2 controller (B-Cabinet/S-900)

B-80525E-1/03 MAINTENANCE 2. CONFIGURATION

Flg.2.1 (d) External View of the R-J2 controller (M-41 Oi Cabinet)

2. CONFIGURATION MAINTENANCE B-80525E-1/03

Fig.2.1 (e) External View of the R-J2 (B-Cabinet/M-500, M-410i)

B-80525E-1 /03 MAINTENANCE 2. CONFIGURATION

OPTICAL ISOLATION UNIT

FAN PSU PCB

DOOR INTERLOCK SWITCH

R-J2(i-CABINET) INNER MOUNTING DIAGRAM

Fig.2.1 (f) R-J2 Inner mounting diagram (i Cabinet)

2. CONFIGURATION MAINTENANCE B-80525E-1/03

SERVO AMPLIFIER PC BOARD FOR

I/O UNIT MODEL A

Fig.2.1 (g) R-J2 Interior (B Cabinet)

B-80525E-1 /03 MAINTENANCE 2. CONFIGURATION

I/O UNIT MODEL A

Fig.2.1 {h} R-J2 Controller Interior (B-Cabinet/S-900)

2. CONFIGURATION MAINTENANCE B-80525E-1 /03

Fig.2.1 (i) R-J2 Controller Interior (B-Cabinet/5-900)

B-80525E-1 /03 MAINTENANCE 2. CONFIGURATION

POWER SUPPLY MODULE I SERVO MODULE I

Fig.2.1 (j) R-J2 Controller Interior (M-410i Cabinet)

2. CONFIGURATION MAINTENANCE B-80525E-1 /03

SERVO MODULEI FAN I