R-J2 Controller - Maintenance Manual B-80525E - 04 PDF

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R-J2 CONTROLLER
MAINTENANCE MANUAL
B-80525E/04
© MyFANUC 52A9AC62A7B54C9B885F92EB64690154
• 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/04 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 100i ARC Mate 1OOi
FANUC Robot ARC Mate 120i ARC Mate 120i
FANUC Robot 8-6 S-6
FANUC Robot S-12 S-12
FANUC Robot M-6i M-6i
FANUC Robot &-420i FhW/iS/iUiR S-420 iF/iW/iS/iUiR
FANUC Robot &-450US/U S-450
FANUC Robot M-4101W/iWX M-4101W/iWX
FANUC Robot M-500 M-500
FANUC Robot M-710i/iW M-710i/iW
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-41 O i, it simply refers to M-41 O i.
When a description is common to all the type of M-710 i, it simply refers to M-710 i.
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B-80525E/04 Table of Contents

PREFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . p-1
I SAFETY PRECAUTIONS
1. SAFETY PRECAUTIONS 3
1.1 OPERATOR SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.1. l Operator Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1.2 Safety of the Teach Pendant Operator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.1.3 Safety During Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.2 SAFETY OF THE TOOLS AND PERIPHERAL DEVICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.2.1 Precautions in Progranuning . . . . . . . . . . . . . . . . . . . . . . • . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.2.2 Precautions for Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.3 SAFETY OF THE ROBOT MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.3.1 Precautions in Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.3.2 Precautions in Progranuning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.3.3 Precautions for Mechanisms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.4 SAFETY OF THE END EFFECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.4.1 Precautions in Progranuning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.5 SAFETY IN MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1. OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2. CONFIGURATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.1 EXTERNAL VIEW OF THE CONTROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.2 COMPONENT FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
2.3 PREVENTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
3. TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
3.1 POWER CANNOT BE TURNED ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
3.2 TROUBLESHOOTING USING THE ERROR CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
3.3 POSIDON DEVIATION FOUND IN RETURN TO THE REFERENCE POSITION
(POSITIONING) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
3.4 VIBRATION OBSERVED DURING MOVEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
3.5 MANUAL OPERATION IMPOSSIBLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
4. PRINTED CIRCUIT BOARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196

4.1 MAIN CPU PC BOARDS (A16B-3200---0040).......................................... 197
4.2 EMERGENCY STOP CONTROL PC BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
4.3 BACKPLANE PC BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
4.4 PROCESS INPUT/OUTPUT PC BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
4.4.l Process Input/Output PC Board CA (A16B-2201-0470) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
4.4.2 Process Input/Output PC Board CB (A16B-2201-0472) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
4.4.3 Process Input/Output PC Board DA (A16B-2201-0480) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
4.4.4 Process 1/0 Printed Board EA (A16B-3200-0230) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
4.4.5 Additional Axis Control Printed Board (A16B-2200-0820) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
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Table of contents B-80525E/04
5. SERVO AMPLIFIERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218

5.1 SERVO AMPLIFIER FOR (ARC MATE 100, ARC MATE 120, ARC MATE lOOi,
ARC MATE 120i, S-6, S-12, M-6, M-16i, S-420i, S-500, S-700, M-400i, M-710i, A-520i) . . . . 220
5.2 POWER SUPPLY !MODULE (PSM) (A06B-6087-H115) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
5.3 SERVO AMPLIFIER MODULE (SVM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
5.4 SERVO AMPLIFIER (A06B-6066-H006) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
5.5 SERVO AMPLIFIER UNIT (A06B-6089-H106) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
6. SETTING AND ADJUSTING THE POWER SUPPLY ....................... 248

6.1 BLOCK DIAGRAM OF THE POWER SUPPLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
6.2 SELECTING TRANSFORMER TAPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
6.3 CHECKING THE LINE FILTER UNIT AND TRANSFORMER . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
6.4 CHECKING THE POWER SUPPLY UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
7. REPLACING A UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260

7.1 REPLACING A PRINTED CIRCUIT BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
7.1.l Replacing the Backplane Printed Circuit Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262
7.1.2 Replacing the Power Supply Unit or a Printed Circuit Board on the
Backplane Printed Circuit Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265
7.1.3 Replacing the process 1/0 EA printed circuit board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
7.2 REPLACING A MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
7.3 REPLACING THE 1/0 UNIT MODEL B INTERFACE UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
7.4 REPLACING THE INPUT/OUTPUT UNIT OF MODEL A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
7.4.1 Replacing the Base Unit of the Input/Output Unit of Model A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
7.4.2 Replacing a Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
7.5 MOUNTING 1/0 UNIT MODEL B ON THE DIN RAIL
(USE A RAIL THAT IS 3.5MM WIDE AND 7.5MM HIGH.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
7.5.1 The DIN Rail is in the Operator's Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
7.6 REPLACING THE TRANSFORMER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
7.7 REPLACING A SERVO AMPLIFIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
7.8 REPLACING THE OPERATOR'S BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
7.9 REPLACING THE TEACH PENDANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
7.10 REPLACING THE FAN MOTOR OF THE CONTROL UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283
7.11 REPLACEMENT OF FUSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
7 .11.l Transformer, line filter unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
7 .11.2 Servo Amplifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286
7 .11.3 Replacing Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287
7 .11.4 Power Supply Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
7.11.5 Process Input/Output Printed Circuit Boards CA, CB, DA and EA . . . . . . . . . . . . . . . . . . . . . . . . . . . 295
7.12 REPLACING A RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296
7.13 REPLACINGTHEBATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299
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B-80525E/04 Table of contents
Ill CONNECTIONS
1. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
2. BLOCK DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304
3. ELECTRICAL CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305

3.1 CONNECTION DIAGRAM BETWEEN MECHANICAL UNITS . . . . . . . . . . . . . . . . . . . . . . . . . . 305
3.2 EXTERNAL CABLE WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310
3.2.l Robot Connection Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310
3.2.2 Teach Pendant Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335
3.2.3 Connecting the Input Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336
3.2.4 Connecting the External Power Supply ON/OFF Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341
3.2.5 Connecting the External Emergency Stop............................................... 343
4. PERIPHERAL DEVICE, ARC WELDING,

AND END EFFECTOR INTERFACES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 347
4.1 PERIPHERAL DEVICE INTERFACE BLOCK DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350
4.1.l When Process 1/0 Printed Circuit Board CA, CB or EA is used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350
4.1.2 When Process 1/0 Printed Cricuit Board DA is used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 353
4.1.3 When 1/0 Unit Model A is used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 356
4.1.4 When 1/0 Unit Model Bis used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 358
4.1.5 When Two or more Process 1/0 Printed Circuit Boards and 1/0 Unit
(Model A or Model B) are used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 361
4.2 PERIPHERAL DEVICE INTERFACE COMBINATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363
4.3 PROCESS I/O PRINTED CIRCUIT BOARD SIGNALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 364
4.4 INTERFACE FOR PERIPHERAL DEVICES, END EFFECTORS, AND WELDERS . . . . . . . . . . . 368
4.4.1 Peripheral Device and Control Unit Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 368
4.4.2 Connection Between the Mechanical Unit and End Effector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 379
4.4.3 Connection Between the Control Unit and Welder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 381
4.5 DIGITAL I/O SIGNAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 385
4.5.1 Peripheral Device Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 385
4.5.2 End Effector Control Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 387
4.5.3 1/0 Signal Specifications for ARC-Welding Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 389
4.6 SPECIFICATIONS OF THE CABLES USED FOR PERIPHERAL DEVICES
AND WELDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 392
4.6.1 Peripheral Device Interface A Cable (CRM2: Honda Tsushin, 50 pins) . . . . . . . . . . . . . . . . . . . . . . . 392
4.6.2 Peripheral Device Interface B Cable (CRM4: Honda Tsushin, 20 pins) . . . . . . . . . . . . . . . . . . . . . . . 392
4.6.3 ARC Weld Connection Cable (CRWl: Honda Tsushin, 34 pins)............................. 393
4.7 CABLE CONNECTION FOR THE PERIPHERAL DEVICES, END EFFECTORS,
AND ARC WELDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 394
4.7.1 Peripheral Device Connection Cable................................................... 394
4.7.2 Peripheral Device Cable Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 396
4.7.3 End Effector Cable Connector........................................................ 398
4.7.4 Recommended Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 399
4.8 QUICK CHANGE (I-CABINET) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 400
4.8.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 400
4.8.2 Flowchart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
4.8.3 Replacement front cabinet unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
4.8.4 Hardware items required for quick change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
4.8.5 Notes on quick change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
4.8.6 Faulty unit replacement procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
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5. TRANSPORTATION AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 418

5.1 TRANSPORTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 418
5.2 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419
5.2.1 Installation Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419
5.2.2 Connecting Cables at Installation (Combined Type of i Cabinet) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 421
5.2.3 Separate-Type Control Unit of i Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 425
5.3 INSTALLATION CONDITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 426
5.4 ADJUSTMENT AND CHECKS AT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 427
5.5 RESETTING OVERTRAVEL AND EMERGENCY STOP AT INSTALLATION . . . . . . . . . . . . . . 428
5.5.1 Peripheral Device Interface Processing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 428
5.5.2 Resetting Overtravel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 428
APPENDIX
A. TOTAL CONNECTION DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 431

Al I-CABINET (ARC MATE 100, ARC MATE 120, ARC MATE 100i, ARC MATE 120i, S--6,
S-12, M--6i, M-16i, S-420i, S-500, S-700, M-400i, M-710i, A-520i) . . . . . . . . . . . . . . . . . . . . . . 431
A.2 B-CABINET (ARC MATE 100, ARC MATE 120, ARC MATE 100i, ARC MATE 120i, S--6,
S-12, M--6i, M-16i, S-420i, S-500, S-700, M-400i, M-710i, A-520i) . . . . . . . . . . . . . . . . . . . . . . 453
A.3 CABINET OF S-800/M-500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 472
A.4 CABINET OF M-41 Oi AND S-450 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 494
A.5 B-CABINET OF S-900 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 522
B. SPECIFICATIONS OF PERIPHERAL DEVICE INTERFACE . . . . . . . . . . . . . . . . . 542

B.1 SIGNALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 542
B.2 SETTING COMMON VOLTAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 544
B.3 1/0 SIGNALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 544
B.3.1 Input Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 544
B.3.2 Output signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 550
B.4 SPECIFICATIONS OF DIGITAL INPUT/OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 554
B.4.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 554
B.4.2 Input/Output Hardware Usable in the R-J2 Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 554
B.4.3 Software Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 554
C. DIAGRAM OF POWER SUPPLY PATH ................................... 555
c-4
I SAFETY PRECAUTIONS
B-80525E/04 SAFETY PRECAUTIONS 1. SAFETY PRECAUTIONS
1
SAFETY PRECAUTIONS
For the safety of the operator and the system, follow all safety precautions
when operating a robot and its peripheral devices installed in a work cell.
1.1 Operator safety is the primary safety consideration. Because it is very

dangerous to enter the operating space of the robot during automatic
OPERATOR SAFETY operation, adequate safety precautions must be observed.
The following lists the general safety precautions. Careful consideration
must be made to ensure operator safety.
(1) Have the robot system operators attend the training courses held by
FANUC.
FANUC provides various training courses. Contact our sales office for details.
(2) Even when the robot is stationary, it is possible that the robot is still
ready to move state and is waiting for a signal. In this state, the robot
is regarded as still in motion. To ensure operator safety, provide the
system with an alarm to indicate visually or aurally that the robot is
in motion.
(3) Install a safety fence with a gate so that no operator can enter the work
area without passing through the gate. Equip the gate with an
interlock that stops the robot when the gate is opened.
The controller is designed to receive this interlock signal. When the gate is
opened and this signal received, the controller stops the robot in an emergen-
cy. For connection, see Fig. 1.1 (a).
(4) Provide the peripheral devices with appropriate grounding (Class 1,

Class 2, or Class 3).
(5) Try to install the peripheral devices outside the work area.
(6) Draw an outline on the floor, clearly indicating the range of the robot
motion, including the tools such as a hand.
(7) Install a mat switch or photoelectric switch on the floor with an
interlock to a visual or aural alarm that stops the robot when an
operator enters the work area.
(8) If necessary, install a safety lock so that no one except the operator
in charge can tum on the power of the robot.
The circuit breaker installed in the controller is designed to disable anyone

from turning it on when it is locked with a padlock.
3
1. SAFETY PRECAUTIONS SAFETY PRECAUTIONS B-80525E/04
(9) When adjusting each peripheral device independently, be sure to tum

off the power of the robot.
Limit switch which operates

when the gate is opened.
Limit switch for

the safety gate
Printed circuit board for
-------<~---<>FENCE 1 operator's box
'--------------oFENCE2 Note) Terminals FENCEl and FENCE2 are

on the PC board in the operator's box.
Fig.1.1 (a) Safety Fence and Safety Gate
- 4
1.1.1 The operator is a person who operates the robot system. In this sense, a
Operator Safety worker who operates the teach pendant is also an operator. However, this
section does not apply to teach pendant operators.
( 1) If it is not necessary for the robot to operate, tum off the power of the
robot controller or press the EMERGENCY STOP button, and then
proceed with necessary work.
(2) Operate the robot system at a location outside the work area.
(3) Install a safety fence with a safety gate to prevent any worker other
than the operator from entering the work area unexpectedly and also
to prevent the worker from entering a dangerous area.
(4) Install an EMERGENCY STOP button within the operator's reach.
The robot controller is designed to be connected to an external EMER-

GENCY STOP button. With this connection, the controller stops the robot
operation when the external EMERGENCY STOP button is pressed. See the
diagram below for connection.
External EMERGENCY STOP button

/"1\"\ operator's box
r-0 I r EMGIN1
'------------0 EMGIN2
Note) Connect to EMGIN1 and EMGIN2.

Terminals EMGIN1 and EMGIN2 are on the PC board in the
operator's box.
Fig.1.1 (b) Connection Diagram for External Emergency Stop Switch
- 5 -
1.1.2 While teaching the robot, it is necessary for the operator to enter the work
Safety of the Teach area of the robot. It is particularly necessary to ensure the safety of the
teach pendant operator.
Pendant Operator
(1) Unless it is specifically necessary to enter the robot work area, carry
out all tasks outside the area.
(2) Before teaching the robot, check that the robot and its peripheral
devices are all in the normal operating condition.
(3) When entering the robot work area and teaching the robot, be sure to
check the location and condition of the safety devices (such as the
EMERGENCY STOP button and the deadman's switch on the teach
pendant).
The teach pendant supplied by FANUC is provided with a teach pendant en-
able switch and a deadman's switch in addition to the EMERGENCY STOP
button. The functions of each switch are as follows.
EMERGENCY STOP button : Pressing this button stops the robot in an
emergency, irrespective to the condition of
the teach pendant enable switch.
Deadman's switch The function depends on the state of the
teach pendant enable switch.
When the enable switch is on - Releasing the finger from the dead
man's switch stops the robot in an
emergency.
When the enable switch is off - The deadman's switch is ineffective.
NOTE
The deadman's switch is provided so that the robot operation can
be stopped simply by releasing finger from the teach pendant in
case of emergency.
(4) The teach pendant operator should pay careful attention so that no
other workers enter the robot work area.
NOTE
In addition to the above, the teach pendant enable switch and the
deadman's switch also have the following function.
By pressing the deadman's switch while the enable switch is on,
the emergency stop factor (normally the safety gate) connected
to FENCE1 and FENCE2 of the controller is invalidated. In this
case, it is possible for an operator to enter the fence during teach
operation without pressing the EMERGENCY STOP button. In
other words, the system understands that the combined
operations of pressing the teach pendant enable switch and
pressing the dead man's switch indicates the start of teaching. The
teach pendant operator should be well aware that the safety gate
is not functional under this condition and bear full responsibility to
ensure that no one enters the fence during teaching.
- 6 -
(5) When entering the robot work area, the teach pendant operator should
enable the teach pendant whenever he or she enters the robot work
area. In particular, while the teach pendant enable switch is off, make
certain that no start command is sent to the robot from any operator's
panel other than the teach pendant.
The teach pendant, operator's box, and peripheral device interface send
each robot start signal. However the validity of each signal changes as fol-
lows depending on the mode of the teach pendant enable switch and the re-
mote switch on the operator's panel.
Teach pen-
dantenable Remote Teach Operator's Peripheral
switch switch pendant panel devices
On Independent Allowed to Not allowed Not allowed

start
Off Remote OFF Not allowed Allowed to Not allowed
start
Off Remote ON Not allowed Not allowed Allowed to
start
(6) To start the system using the operator's box, make certain that nobody
is in the robot work area and that there are no abnormal conditions in
the robot work area.
(7) When a program is completed, be sure to carry out a test run according
to the procedure below.
(a) Run the program for at least one operation cycle in the single step
mode at low speed.
(b) Run the program for at least one operation cycle in the continuous
operation mode at low speed.
(c) Run the program for one operation cycle in the continuous
operation mode at the intermediate speed and check that no
abnormalities occur due to a delay in timing.
(d) Run the program for one operation cycle in the continuous
operation mode at the normal operating speed and check that the
system operates automatically without trouble.
(e) After checking the completeness of the program through the test
run above, execute it in the automatic operation mode.
(8) While operating the system in the automatic operation mode, the
teach pendant operator should leave the robot work area.
1.1.3 For the safety of maintenance personnel, pay utmost attention to the
Safety During following.
Maintenance (1) Except when specifically necessary, tum off the power of the
controller while carrying out maintenance. Lock the power switch,
if necessary, so that no other person can tum it on.
(2) When disconnecting the pneumatic system, be sure to reduce the
supply pressure.
(3) Before the start of teaching, check that the robot and its peripheral
devices are all in the normal operating condition.
(4) If it is necessary to enter the robot work area for maintenance when
the power is turned on, the worker should indicate that the machine
is being serviced and make certain that no one starts the robot
unexpectedly.
- 7
(5) Do not operate the robot in the automatic mode while anybody is in
the robot work area.
(6) When it is necessary to maintain the robot alongside a wall or
instrument, or when multiple workers are working nearby, make
certain that their escape path is not obstructed.
(7) When a tool is mounted on the robot, or when any moving device
other than the robot is installed, such as belt conveyor, pay careful
attention to its motion.
(8) If necessary, have a worker who is familiar with the robot system
stand beside the operator's panel and observe the work being
performed. If any danger arises, the worker should be ready to press
the EMERGENCY STOP button at any time.
(9) When replacing or reinstalling components, take care to prevent
foreign matter from entering the system.
(10) When handling each unit or printed circuit board in the controller
during inspection, tum off the power of the controller and also tum
off the circuit breaker to protect against electric shock.
(ll)When replacing parts, be sure to use those specified by FANUC.
In particular, never use fuses or other parts of non-specified ratings.
They may cause a fire or result in damage to the components in the
controller.
8
1.2
SAFETY OF THE
TOOLS AND
PERIPHERAL
DEVICES
1.2.1
Precautions in ( 1) Use a limit switch or other sensor to detect a dangerous condition and,
Programming if necessary, design the program to stop the robot when the sensor
signal is received.
(2) Design the program to stop the robot when an abnormal condition
occurs in any other robots or peripheral devices, even though the
robot itself is normal.
(3) For a system in which the robot and its peripheral devices are in
synchronous motion, particular care must be taken in programming
so that they do not interfere with each other.
(4) Provide a suitable interface between the robot and its peripheral
devices so that the robot can detect the states of all devices in the
system and can be stopped according to the states.
1.2.2
Precautions for (1) Keep the component cells of the robot system clean, and operate the
Mechanism robot in an environment free of grease, water, and dust.
(2) Employ a limit switch or mechanical stopper to limit the robot motion
so that the robot does not come into contact with its peripheral devices
or tools.
- 9 -
1.3
SAFETY OF THE
ROBOT MECHANISM
1.3.1
Precautions in (1) When operating the robot in the jog mode, set it at an appropriate
Operation speed so that the operator can manage the robot in any eventuality.
(2) Before pressing the jog key, be sure you know in advance what
motion the robot will perform in the jog mode.
1.3.2
Precautions in ( 1) When the work areas of robots overlap, make certain that the motions
Programming of the robots do not interfere with each other.
(2) Be sure to specify the predetermined work origin in a motion program
for the robot and program the motion so that it starts from the origin
and terminates at the origin.
Make it possible for the operator to easily distinguish at a glance that
the robot motion has terminated.
1.3.3
Precautions for (1) Keep the work area of the robot clean, and operate the robot in an
Mechanisms environment free of grease, water, and dust.
- 10 -
1.4
SAFETY OF THE END
EFFECTOR
1.4.1
Precautions in (1) To control the pneumatic, hydraulic and electric actuators, carefully
Programming consider the necessary time delay after issuing each control command
up to actual motion and ensure safe control.
(2) Provide the end effector with a limit switch, and control the robot
system by monitoring the state of the end effector.
- 11 -
1.5
SAFETY IN (1) Never enter the robot work area while the robot is operating. Turn off
the power before entering the robot work area for inspection and
MAINTENANCE maintenance.
(2) If it is necessary to enter the robot work area with the power turned
on, first press the EMERGENCY STOP button on the operator's box.
(3) When replacing or reinstalling components, take care to prevent
foreign matter from entering the system.
When replacing the parts in the pneumatic system, be sure to reduce
the pressure in the piping to zero by turning the pressure control on
the air regulator.
(4) When handling each unit or printed circuit board in the controller
during inspection, turn off the power of the controller and turn off the
circuit breaker to protect against electric shock.
(5) When replacing parts, be sure to use those specified by FANUC.
In particular, never use fuses or other parts of non-specified ratings.
They may cause a fire or result in damage to the components in the
controller.
(6) Before restarting the robot, be sure to check that no one is in the robot
work area and that the robot and its peripheral devices are all in the
normal operating state.
- 12 -
II MAINTENANCE
B-80525E/04 MAINTENANCE 1. OVERVIEW
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.
- 15 -
2. CONFIGURATION MAINTENANCE B-80525E/04
2
CONFIGURATION
2.1 Fig. 2.1 (a) to (d) show the R-J2.

EXTERNAL VIEW OF
THE CONTROLLER
Operator's box
(option)
Teach pendant
R-J2 controller
1111111111111111111 111111111111011111
·-
©
Integrated type ARC Mate 100i, M-6i, S420i, A520i, M-710i

Remote mount type ARC Mate 100, ARC Mate 120, ARC Mate 100i, ARC Mate 120i
86, S-12, M-6i, M-16i, S-420i, S-500, S-700, M-400i, M-710i, A520i
Fig.2.1 (a) External View of the R-J2 Controller (i cabinet)
- 16 -
B-80525E/04 MAINTENANCE 2. CONFIGURATION
Teach pendant
Operator's pendant
(ARC Mate 100, ARC Mate 120, ARC Mate 1OOi, ARC Mate 120i, 5-6, S-12, M-6i, M-16i
8-420i, 8-450, 8-500, S-700, S-800, M-500, M-410i, M-710i, A-520i)
Fig.2.1 {b) External View of the R-J2 controller {B-Cabinet)
- 17 -
c:::[IJ o o <> o
l~!!!!'!!!'!!!'!!!IJ!l!lld ..... o Ci 'Ei
0
0 ~~~(@
0
0
D0
~
.
0 0
Fig.2.1 (c) External View of the R-J2 controller (B-Cabinet) ($-900)
- 18 -
Operator's box
(option)
R-J2 Control unit Teach pendant
-- B
•
-r.J -
•
-- B
•
---
Cabinet for M-41 Oi is
• installed in robot's frame .
Fig.2.1 (d) External View of the R-J2 controller (Cabinet for M-410i) (M410i)
- 19 -
The R-J2 consists of the units shown in Fig. 2.1 (e) to (1).
The appearance and components may slightly differ depending on the
controlled robot, application, and options used.
Operator's box Circuit breaker

(option)
Operator's panel
FANUC Handy File Teach pendant

0
•• Lf ··~--~
• <!>. at . ~I--~.
~g~oo
~ tj •• &ii
Main CPU printed

Servo amplifier for 6 axes circuit board
PC board for
operator's box
Power supply unit
(Optional printed circuit board)
Backplane
Regenerative discharge registance
Circuit breaker
Louver
Printed circuit board for emergecy stop
control
Transformer
Magnetic
contactor (MCC)
Fig.2.1 (e) R-J2 Controller Interior (i Cabinet)
- 20 -
Fan 1
Printed board for emergecy stop
Servo amplifier
control
Main CPU printed board

Operator's panel
Power supply unit
Optional printed board
1/0 unit model A or model B
Braker
Fan2
Line filter or transformer
Fan 3
Fig.2.1 (f) R-J2 Controller Interior (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-400i, A-520i)
- 21 -
FANUC Handy File

Teach pendant
I~ Fan 1
Printed board for emergecy stop
~;;;;;;;;;;;~~;:;;:;~~ control
Power supply unit
Braker
Fan3 Fan2
q,t,1,~J..1-- transformer or Line filter
Servo amplifier 1
Fig.2.1 (g) R-J2 Controller Interior (B-Cabinet) ($-800)
- 22 -
Regenerative discharge unit
Additional cabinet
Conversion printed board

Power supply unit
Printed board for emergecy

stop control
Braker
Fan2
transformer or Line filter
Servo amplifier 2
Fan3
Servo amplifier 1
Servo amplifier 6
Teach pendant
Servo amplifier 5
Additional contactor
FANUC Handy File
Fan4
Fan 5
(Additional cabinet interior)
Fig.2.1 (h) R-J2 Controller Interior (B-Cabinet) (S-900)
- 23 -
Servo module 1
Power supply module 1
Servo module 3
Servo module 4
Fan 1
MCC
Battery unit
Trans tap
1/0 unit model B
Braker
1/0 unit model A or B
transformer for brake
Fan2 Printed board for emergecy stop control
Fig.2.1 (i) R-J2 Controller Interior (Cabinet for M-410i)
- 24 -
Servo module 1
Servo module 2
Servo module 3
Emergency stop control

printed board
Operator's panel Main CPU printed board
Power supply unit
1/0 unit model A

or
1/0 unit model B
Braker
Fan2
J~~~~~~~~j~J!,£!~t~L__ Line filter

or
Transformer
Fan3
Power supply module
Fig.2.1 O> R-J2 Controller Interior (B-Cabinet) (M-410i)
- 25 -

Fan 1
Servo amplifier 2
Servo amplifier 1 Conversion printed board

Operator's panel
Power supply unit
Braker
Fan2
Servo amplifier 4
Fan3
Servo amplifier 3
Fig.2.1 (k} R-J2 Controller Interior (B-cabinet} (M-500)
- 26 -
Servo module 2
Servo module 1
Servo module 4

printed board
Operator's panel Main CPU printed board
Power supply unit
Additional axis control

printed board
1/0 unit model A

or
1/0 unit model B
Braker
Fan2
i"7t>"m17''---- Line filter

or
Transformer
Fan3
Power supply module
Fig.2.1 {I) R-J2 Controller Interior {B-Cabinet) ($-450)
- 27 -
Robots and servo amplifier

J1 J2 J3 J4 JS JS J7
ARC Mate 100 A06B-6076-H005 (6-axis AMP) or A06B-6076-H105
ARC Mate 120 A06B-6076-H004 (6-axis AMP) or A06B-6076-H104
ARC Mate 120i
ARC Mate A06B-6076-H105 (6-axis amplifier)
100i/M-6i
8-6 A06B-6076-H005 (6-axis AMP) or A06B-6076-H105
S-12, M-16i A06B-6076-H004 (6-axis AMP) or A06B-6076-H104
S-420i A06B-6076-H001 (6-axis AMP) or A06B-6076-H101
S-450 A06B-6077-H111 (PSM)
AMP1/L AMP1/M AMP2/M AMP2/L AMP3/L AMP3/M AMP4
A06B A06B A06B A06B A06B A06B S-4505:
--6079 --6079 --6079 --6079 --6079 --6079 A06B-6079
-H206 -H206 -H207 -H207 -H206 -H206 -H104
S-450L:
A06B-6079
-H101
S-500 A06B-6076-H002 (6-axis AMP) or A06B-6076-H102
A-520i
M-400i
S-700 A06B-6076-H103 (6-axis AMP) or A06B-6076-H103
S-800 AMP1 AMP2 AMP3 AMP4/M AMP4/M AMPS
A06B A06B A06B A06B A06B A06B
--60S9 --60S9 --60S9 --60S9 --60S9 --60S9
-H10S -H10S -H10S -H20S -H20S -H10S
S-900 AMP1 AMP3 AMPS AMP2 AMP4 AMP6
--6066 --6066 --6066 --6066 --6066 --6066
-HOOS -HOOS -HOOS -H006 -H006 -H006
AMP1 AMP3 AMPS AMP2 AMP4 AMP6
--60S9 --60S9 --60S9 --60S9 --60S9 --60S9
-H106 -H106 -H106 -H10S -H10S -H10S
M410i A06B-60S7-H11S (PSM)
AMP1 AMP2 AMP3 AMP4
M-500
A06B
--6079
-H106
AMP1
A06B
A06B
--6079
-H106
AMP3/M
A06B
A06B
--6079
-H106
AMP2
A06B
A06B
--6079
-H103
AMP3/L
A06B
C>< AMP4
A06B
--60S9 --60S9 --60S9 --60S9 --60S9
-H106 -H206 -H10S -H206 -H104
M-710i A06B--6076-H 106 (6-axis amplifier)
- 28 -
The 2.1 (m) to (q) show the block diagram of the R-J2.
Periphera Handy File External

Teach device emergency
Sensor ICRT/KB Stop
pendant External
com~ter Prin~~
- on/off
r
r~~ E
[ :::J
u
en
I0 I
(\J
Peripheral
-~
I M device
~ I0 I I(/)
(\J
I
Q)x n 1:QO:: (/)
Cl:: C:::J C:::J C:::J C;::J
a.o u I
O.o
.. I
-
=
I
I
I
I
~~~+--~~-- - ~l~--~I- - - - - - - - - + - - + - c- i- ---i------
I I 0
0
1Ji
(/)
......
H
0
i (/)
[ :::J
I D- - J I Process 1/0
or
0-----_J 1/0 unit
"E model A
<1:1 modeL.6
0
.0
"'C n 1/0 signal (FANUC 1/0 Link) I
~
u
"E -~
n Robot RDl/RDO sianal
<1:1 u
0
:::>
§ ] a..
() OPulse coder signal OI
~ c:
·o "(ij Printed
"'C ::!: circuit board
~ n Servo signal for emergency
-~
u
Q)
c: stop control
<1:1
a.
.:.:
0
<1:1
CD In
·c::3 u
>-
a.
a.
I l :3
en
Q) I 0-
0==
a.. Transformer
Battery_ over heat signal
~-
u u
<( <(
> >
0 0
0 -
C\I N
- ,-~-
Fan
I ~
Transformer )O>---- ~ - 0
~
0 [ [ ]t-----+11-- !~ 0
<( C\I C')
Fig.2.1 (m) Block Diagram of the R-J2 (i-Cabinet) (ARC Mate 100, ARC Mate 120, ARC Mate 1OOi, ARC Mate
120i, 5-6, S-12, M-6i, M-16i, 5-420i, S-500, S-700, M-400i, M-710i, A-520i)
- 29 -
Teach
pendanl
-
Periphera Handy File External
device
Senso~ CRT/KB
com~ er Prin,Nr
emergellC!
~:ma1
on/off
c:J Robot Peripheral
device
-
0 =u 1
0
u
C;::J C;::J C;::J 0
l~gj ~
l")'<t I")
l~Ji ~
l~O'. ~
---~~~~~- - -
I
1--~~~~~~~--+-~~~+-~~-+----1~
I
I
I
I
I[}-- I
10-----_J
"E
<ti
101-----Dl
0
..c I n 1/0 siqnal (FANUC 1/0 Link)
"t:l
IU
"E ~ I n Robot RDl/RDO sianal

<ti -~ IU
0
..c ::::>
·3 J a.
() I DPulse coder signal DI
I:! c:
·c:; "(ij Printed
"t:l
::2 circuit board
~ for emergency
-~ I n Servo signal
Q)
c: stop control
<ti
a.
.>It.
0
<ti
al
~
:J
>. n
a.
a.
LI
l :J
(/)
[ 0--
~
==
0
a. Transformer
Battery~ over heat signal
u u
<( <(
> >
0 0
0
(\) (\J
Fan
Transformer or
line filter unit ')0>----0
rn-+- 1- ()
~g
~
c: LO
080
I <( C\I C')
Fig.2.1 (n) Block Diagram of the R-J2 (B-Cabinet) (ARC Mate 100, ARC Mate 120, ARC Mate 1OOi, ARC
Mate 120i, 5-6, S-12, M-6i, M-16i, 8-420i, S-500, S-700, M-400i, M-710i, A-520i)
- 30 -
Periphera
---
External
Teach device Hancfy FilE emergency
pendant Sensor CRT/KB Stop
External
computer Prin~
-
~-G
~
c:::;::J c:;::::i
9u u
I'C\J C\JC\J
f")-.;t
I
C\J
I")
Peripheral
device
IC\J I
I CJ)
C\J
I ~
CJJO:: CJ)
10:: a::
r - - _J
----------- ~ ~ ---+-------
I 0
0
I CJ)
I
= '
H
0
0-
I I
CJ)
=
10--_J Process 1/0
or
I [}-----0 J 1/0 unit
model A
moct.eLJ3
I n 1/0 signal (FANUC 1/0 Link)
"E
cu n Robot RDl/RDO signal
0 1
.c I U
"E
cu
J
"C
~ I DPulse coder signal DI ==
-~
0
.c :::> Printed servo amplifier
·:; a..
0 circuit board I D-{] J
~
·c:; c:
"iii I 0,__S_erv_o_s~ig_na_l_ 0I for emergency
"C
.l!l
c:
:::!!: stop control '-c::_9-= =
-~
9I__stop
T
(])
c: c:::;::J c:::;::J E_m_e_rg_e_n_c_y_
cu signal
a.
..l<:
0
[~ .------
cu
CD
[ [}----
~
::;,
>-
a.
a.
] ::;,
rn [ 0-- Transformer over heat signal
lD
;r;
0
a.. 210VAC
rm=
Battery>--- u u u
(J
(Servo power
<( <( <(
> > > supply)
0 0 0
0 - 0
C\J C\J -
':: ~
~)
Fan
Transformer or
AC reactor
Fig.2.1 (o) Block Diagram of the R-J2 (B-Cabinet) (S-SOO, S-900, M-500)
- 31
Teach
Periphera Handy File
dsee~;~r CRT/KB
-Ext_e_m_a1-3
~rgency Robot Peripheral
pendant External device
co"2E..uter Printer on/off
'----'c:::;:::J=--"----.__J
u
I
(\J
I")
(\J
I
(/)
Cl'.:
-~~------ - -
I
1------..,.------+----+----+---1- .--- r- ---+------
I 0
0
I (/)
I =
(ij
c:
Cl
'
H
0
(/)
I Cl)
"iii
(D
=
I 0---- I .s
-~
Process 110
10-----_J ~"ii)
c:
a. <tS
(J)
8
CJ)
or
1/0 unit
model A
ID 0] 0 a.
"'
"3
a.. mod~
"E
<tS I C 1/0 signal (FANUC 1/0 Link) '--c_1--
0
.c
""O n Robot RDl/RDO sional
2c: 'LI
] -~ I OPulse coder signal

"E =>
Cl.
<tS
0
.c
u
c:
"(ii
3 ::?!
!::!
·c:;
""O
2c:
-~ c:
(J)
c: -~""O i 0
<tS
Ci I OServo signal O] !l!s"E I 01 - - - - -
~ §.5 <ISO
0
<tS U 0..0
ID
servo amplifier
I Q1----~ (C series)
·c:::I 8]
>.
Ci
a.
I O,_______,
] ::I
Cl)
I 0-- Transformer
over heat signal
9I
Qj
3: u u u
<( <( <(
0
Cl. >
0
>
0
>
0
Battery~ 0 - 0 210VAC
(\I (\I -
(Servo power supply)
,- u
Fan
ID---+-
~
Transformer or "S o
line filter unit < io1----<0 g.:g
080
<(NM
I
Fig.2.1 (p) Block Diagram of the R-J2 (B-Cabinet) (S-900)
- 32 -
Periphera External
Teach Handy File
device emeqiency
CRT/KB Stop
pendant Sensor External
- com~ter Pril]W on/off
J~~ c::J
c:::;::J
-.....
U)
1a--1 u
I
(\J
I")
(\J
Peripheral
device
~Q)
a.
x
0
ID
ID
•
I
encr.
er.
en
I
er. C:::J C:::J C:::J C:::J

-
0 .0
I
- I
I
I -- - -
I
0
I 0
en
~
I iii
c:
Ol a.
>. "en
H
0
I 0- I ·u; a.
:> =
(D
10--...J "'O ~
a.
U)
Process 1/0
0
0
a.
:> ~ or
Q)
U) 0
a. 1/0 unit
"E I/)
Qi ..... model A
3
~
CG 3: mod~B
0
.0 a.. a.
0
:2
"C
1/0 signal (FANUC 1/0 Link) ~
~ ID I
~
'[ Robot RDl/RDO signal ID
"E
CG :::>
a..
ID
~I l (.)
C:::J C:::J
·:; c:
·a; ID Pulse coder signal D[ ~~
e
·c:; :2 Printed
"C circuit board IQ--{] J Servo module
2c:
·g_ I DServo signal 0[
for emergency
--
Q)
c:
CG
a.
~
0
CG
ID
stop control
-
c;:::i
-
c;:::i
L[
-II --
ID
Power supply module
·c:::I I[}-- Energency
-- ---
>.
a.
a. ID
stop signal er- er
::I
U) Qi
I l Qi
:= I 0- (.)
3:
0
a.~
0
a.. ~~~
r4rn
0 Q) a.
'-<Joi
~en=>
Battery - Qi ~ U)
C\I
u
-- <( n :>
>
0
0
(\J
LI
(.)
:2
:2
·- - e I-
Fan
~
0.....
-
'"' - ,~--
Qi
§
m-+s~
Q) .....
EO
.... 0
.E CG .E
U) 00-0 -~~
U) Q) c:
c: ..... ~ (.) g"
~(.)
I-~
I- I ~ C\I C')
Fig.2.1 (q) Block Diagram of the R-J2 (Cabinet) (S-450, M-410i)
- 33 -
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. These are connected with FANUC 1/0 Link.
- 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.
- 34 -
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
- 35 -
3. TROUBLESHOOTING MAINTENANCE B-80525E/04
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.
- 36 -
B-80525E/04 MAINTENANCE 3. TROUBLESHOOTING
3.1
POWER CANNOT BE
TURNED ON
• Check1 Check that the circuit breaker is on and has not tripped.
Corrective action: Tum 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 Find 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 1to3 above confirm that 200 VAC power is supplied to connector
CPI 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 (1).
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
Check if the +24 V external connection cable is connected to 0 V or
ground.
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 + 15 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
operater 's panel.
- 37 -
• Corrective action 1 Causes of blown fuses Fl and corrective action

(a) Short-circuit in the surge absorber VSll
VSll 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
VSll. In this case, however, obtain and install a new VSll as
soon as possible.
VSll ordering number: ASOL-2001-0122#G431k
(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-0001-024S#GP7S
Corrective action 2 Causes of blown fuse F3 and corrective action

The device connected to connector CPS of the power supply unit may be
faulty. If no device is connected to CPS 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-0001-007S#S.O:
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 ofF4 is A60L-0001-0046#S.O.
- 38 -
3.2
TROUBLESHOOTING (1) SRVO-OOl SVALl Operator panel E-stop
USING THE ERROR (Explanation) The emergency stop button on the operator's box or
operator's panel is pressed.
CODE (Action) Release the emergency stop button pressed on the
operator's box or operator's panel.
~------~ Operator's box
ooe
Emergency stop
button
--
-0 0 -0 D
t •
Operator's panel
(B-cabinet)
Kiil-o 0 ..
D
6 ~~:::::::::=:::::--....
D D o
0 --
r,;::=~ii\--=_J Emergency stop
button
0
oo
(2) SRV0-002 SVALl Teach pendant E-stop

(Explanation) The emergency stop button on the operator's panel
was pressed.
(Action) Release the emergency stop button on the teach
pendant.
Emergency stop button
- 39 -
(3) SRVQ-003 SVALl Deadman switch released

(Explanation) The teach pendant is valid, but the deadman's switch
is not pressed.
(Action) Press the deadman switch to run the robot.
\\ 0
~;....... l
0
0
Deadman switch
(4) SRV0--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.
Panel printed circuit board
0 0
0 0
0 Ell 0
FENCE 1 / ~ FENCE 2
- 40 -
(5) SRV0-005 SVALl Robot overtravel

(Explanation) The robot has gone beyond an axis/direction hardware
limit switch. The robot is designed so that normally 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 1) 1) 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.
(Action 2) Check fuse F4 of the power supply unit. If the fuse
has blown, replace it with a new one.
(Action 3) When a B--cabinet is used, check fuse F2 of the
emergency stop control printed circuit board. If the
fuse has blown, replace it with a new one.
(Action 4) Check the overtravel connection cable (i--cabinet
integration type) or robot connection cable (RPl) for
a connection to the ground.
(Action 5) Replace the emergency stop control printed circuit
board.
(6) SRV0-006 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 1) I.Hold down the shift key and press the alarm reset
button to reset the alarm condition.
(Action 2) While still holding down the shift key, jog-feed the
robot until the tool moves to the working area.
1) Exchange the safety joint.
2) Check the cables.
(7) SRV0-007 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.
- 41 -
0
0 ° 10000~~~~00~~~001. 0
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
- 42 -
(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
- 43 -
Fan motor
Fan motor 8-Cabinet

(ARC Mate 100, ARC Mate 120, ARC Mate 100i, ARC Mate 120i, 8-6, S-12i, M-6i, M-16i, 8-420i, S-500, S-700i,
M-400i, A-520)
- 44 -
Fan motor
Fan motor
(8-800)
Fan motor
Fan motor
Fan motor
{M-500)
Fan motor
- 45 -
Fan motor
Additional cabinet
Fan motor
Fan motor
Fan motor
Fan motor
B-Cabinet/S-900
- 46 -
Fan motor
Fan motor
Cabinet for M-41 Oi
- 47 -
(ll)SRV0-018 SVALl Brake abnormal

(Explanation) An excessive break current is detected. When the
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-400i, M-710i or A-520i is used,
the seven-segment LED on the servo amplifier
indicates 1. When the S-800, M-410i, M-500 or
S-450 is used, the LED (red) on the emergency stop
control printed circuit board lights. When the S-900
is used, the LED (red) on the conversion printed
circuit board or the emergency stop control printed
circuit board lights.
(Action 1) Check the robot connection cable (RMl) 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 lOOi, ARC Mate
l20i, S-6. S-12, M-6i, M-l6i, S-420i, S-500,
S-700, M-400i, M-710i or A-520i is used), the
emergency stop control printed circuit board (when
the S-450, S-800, M-4 lOi, or M-500 is used), or the
conversion printed circuit board or the emergency
stop control printed circuit board (the conversion
printed circuit board is not installed.) (when the
S-900 is used).
Servo amplifier
i-Cabinet
- 48 -
Servo amplifier
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-400i,
M-710i, A-520i)
- 49 -
5-800
printed board
M-500
- 50 -

printed board
(M-410i)
(S-900)
- 51 -

printed board
$-450, M-41 Oi (B-Cabinet)
- 52 -
(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
0 E& 0
SVON 1/ ~ SVON 2
- 53 -
(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 oft). 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.
Servo amplifier Main CPU

emergency stop control
MCC
- 54 -
~0525E/04 MAINTENANCE 3. TROUBLESHOOTING
Emergency stop control Main CPU

printed board
Servo amplifier
B--Cabinet
(ARC Mate 100, ARC Mate 120, ARC Mate 100i, ARC Mate 120i, S-6, S-12, M-6i, M-16i, S-420i, S-500, S-700, M-400i, M-710i,
A-520i)
- 55 -

printed board
Servo amplifier 5
0000000000000
5-800 Servo amplifier 2

Servo amplifier 1
Main CPU
Servo amplifier 2
Servo amplifier 1
Servo amplifier 4
M-500
Servo amplifier 3
- 56 -
Servo amplifier 4
Servo amplifier 3
Additional cabinet

printed board
•
Servo amplifier 2
Servo amplifier 1
Servo amplifier 6
Servo amplifier 5
B-CabineVS-900
- 57 -
3. TROUBLESHOOTING MAINTENANCE B--80525E/04
Servo module 4
Servo module 3
Servo module 2
Servo module 1
Power supply module
Emergency stop control printed board
Cabinet for M-41 Oi
- 58 -
Servo module 3
Emergency control printed board
Servo module 2 Main CPU printed board
Servo module 1
Power supply module Servo module 4
M-41 Oi (B-Cabinet)
- 59 -
Servo module 4
Servo module 3 Emergency stop control printed board
Servo module 2
Servo module 1
Power supply module
8-450
- 60 -
(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.
Servo amplifier
Main CPU

- 61 -

printed board
Servo amplifier
B-Cabinet
(ARC Mate 100, ARC Mate 120, ARC Mate 100i, ARC Mate 120i, S-6, S-12, M--6i, M-16i, s-420i, S-500, S-700, M-400i, M-710i,
A-520i)
- 62 -

printed board
Servo amplifier 5
Servo amplifier 2
Servo amplifier 1
8-800
Main CPU
Servo amplifier 2
Servo amplifier 1
0000000000000
M-500
- 63 -
Servo amplifier 3

printed board
Servo amplifier 2
Servo amplifier 1
Servo amplifier 6
Servo amplifier 5
B-CabineVS-900
- 64 -
Servo module 4
Servo module 3
Servo module 2
Servo module 1
Power supply module
Cabinet for M-41 Oi
- 65 -
Servo module 3
Servo module 1
M-41 Oi (B-Cabinet)
- 66 -
Servo module 4
Servo module 2
Servo module 1
Power supply module
S-450
- 67 -
3. TROUBLESHOOTING MAINTENANCE 8-80525E/04
(15)SRV0--023 SVALl 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) Check continuity of motor power cables.
(Action 5) Replace the motor.
Servo amplifier
Main CPU

- 68 -

printed board
Servo amplifier
8-Cabinet
(ARC Mate 100, ARC Mate 120, ARC Mate 100i, ARC Mate 120i, S-6, S-12, M--6i, M-16i, s-420i, S-500, S-700, M-400i, M-710i,
A-520i)
- 69 -

printed board
Servo amplifier 2
Servo amplifier 1
5-800

printed board
Servo amplifier 2
Servo amplifier 1
0000000000000
Servo amplifier 4
Servo amplifier 3
M-500
- 70 -
Additional cabinet

printed board
Servo amplifier 2
Servo amplifier 1
Servo amplifier 6
Servo amplifier 5
~111'----------YI
B-Cabinet/S-900
- 71 -
Servo module 4
Servo module 3
Servo module 2
Servo module 1
Power supply module
Cabinet for M-41 Oi
- 72 -
Servo module 3
Servo module 1
M-41 Oi (B-Cabinet)
- 73 -
Servo module 4
Servo module 2
Servo module 1
Power supply module
5--450
(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 SVALl Motn dt overflow (Group: i Axis: j)
(Explanation) The specified value is too great.
- 74 -
(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].
(20)SRV0-030 SVALl Brake on hold (Group: i)
(Explanation) This alarm occurs when the robot pauses, if the brake
on hold function has been enabled ($SCR.
$BRKHOLD _ ENB = 1). Disable the function if it is
not necessary.
(Action) Disable [Servo-off during pause] on the general
setting menu [6 Setting.general].
(21)SRV0-031 SVALl User servo alarm (Group: i)
(Explanation) A user servo alarm occurred.
(22)SRV0-033 WARN Robot not calibrated (Group: i)
(Explanation) An attempt was made to set up a reference point for
simplified adjustment, but the robot had not been
calibrated.
(Action) Calibrate the robot.
1.Supply power.
2.Set up a simplified adjustment reference point
using [Positioning] on the positioning menu.
(23)SRV0-034 WARN Ref pos not set (Group: i)
(Explanation) An attempt was made to perform simplified
adjustment, but the reference point had not been set
up.
(Action) Set up a simplified adjustment reference point on the
positioning menu.
(24)SRV0-035 WARN2 Joint speed limit (Group : i Axis : j)
(Explanation) A value higher than the maximum axis speed
($PARAM_GROUP.$JNTVELLIM) was specified.
Each actual axis speed is clamped to the maximwn
speed.
(25)SRV0-036 SVALl Inpos time over (Group: i Axis: j)
(Explanation) The robot did not get to the effective area ($PARAM _
GROUP.$ STOPTOL) even after the position check
monitoring time ($PARAM _ GROUP. $INPOS _
TIME) elapsed.
(Action) Take the same actions as for 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.
- 75
(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.
7. Move the cursor to $SPC_RESET.
8. Press F4, TRUE. 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 recessary 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. '2'
(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-400i, M-710i, A-520i) or '7'
(S-900) 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.
- 76
Servo amplifier
i-Cabinet
Servo amplifier
B-Cabinet
(ARCMate100,ARCMate120,ARCMate100i,ARCMate120i,5-6,S-12,~i,M-16i,5-420i,S-500,S-700,M-400i,M-710i,A-520i)
- 77 -
Servo amplifier 2
Servo amplifier 1
B-Cabinet/S-900
- 78 -
(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 lOOi, ARC Mate 120i, S-6, S-12, M-6i,
M-16i, S-420i, S-500, S-700, M-400i, M-710i and
A520i.
(Action) If the servo amplifier LED indicates "8" (DCOH
alarm): (This alarm occurs when a thermostat detects
that the regenerative resistor is overheated.)
-This alarm 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--contimity 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-800, S-900 and M-500
(Action!) 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.
- 79 -
-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.
Servo amplifier
Regenerative registance
i cabinet (ARC Mate 100, ARC Mate 120,

ARC Mate 1OOi, ARC Mate 120i, 5-6, S-12,
M-6i, M-16i, S-420i, S-500, S-700,
M-400i, M-710i, A-520i)
- 80 -
Servo amplifier
@ (j (j (j 000
@ ~@@
(j ; ; \q11n&
Regenerative
registance
B-Cabinet
(ARC Mate 100, ARC Mate 120, ARC Mate 100i, ARC Mate 120i, S-6, S-12, M-6i, M-16i, S-420i, S-500, S-700, M-400i, M-710i,
A-520i)
- 81 -
Servo amplifier 5
Servo amplifier 4
Servo amplifier 2
Servo amplifier 1
8-800
Servo amplifier 2
Servo amplifier 1
Servo amplifier 3
M-500
- 82 -
Servo amplifier 4
Servo amplifier 3
Servo amplifier 2
Servo amplifier 1
Servo amplifier 6
Servo amplifier 5
B-Cabinet/S-900
- 83 -
(32)SRV0-044 SVALl HVAL alarm (Group : i Axis : j)

SRV0-154 SVALl HVAL alarm (Group: i Axis: j)
(Explanation) The DC voltage (DC link voltage) of the main circuit
power supply is abnormally high. The servo amplifier
LED indicates ''7". (ARC Mate 100, ARC Mate 120,
M-16i, S-420i, S-450, S-500, S-700, M-410i,
M-400i, M-7101) or 'l'(S-800, S-900 and 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.
Servo amplifier
i-Cabinet
- 84 -
Servo amplifier
8-Cabinet
(ARC Mate 100, ARC Mate 120, ARC Mate 100i, ARC Mate 120i, S-6, S-12, ~i. M-16i, &-420i, S-500, S-700, M-400i, M-710i,
A-520i)
- 85 -
Servo amplifier 5
Servo amplifier 4
Servo amplifier 2
Servo amplifier 1
s-aoo
Servo amplifier 2
Servo amplifier 1
Servo amplifier 4
Servo amplifier 3
M-500
- 86 -
Regenerafive discharge unit
Servo amplifier 2
Servo amplifier 1
Servo amplifier 5
B-Cabinet/S-900
- 87 -
Servo module 4
Servo module 3
Servo module 2
Servo module 1
Power supply module
Cabinet for M-41 Oi
- 88 -
Servo module 3
Servo module 2
Servo module 1
M-41 Oi {B--Cabinet)
- 89 -
Servo module 4
Servo module 3
Servo module 2
Servo module 1
Power supply module
8-450
- 90 -
(33)SRV0-045 SVALl HCAL alarm (Group : i Axis : j)

SRV0-149 SVALl HCAL alarm (Group: i Axis: j)
SRV0-152 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-l6i, S-420i, S-500, S-700, A-520i)
orServoamplifieroneof '1' '8' '9' '6' ofLED(For
S-800, S-900, M-410i, M-500, M-400i, M-710i)
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.
Servo amplifier
i-Cabinet
- 91 -
Servo amplifier
8-Cabinet
(ARC Mate 100, ARC Mate 120, ARC Mate 100i,ARC Mate 120i, 8-6, S-12, M-6i, M-16i, 8-420i, S-500, S-700, M-400i,
M-71 Oi, A-520i)
- 92 -
Servo amplifier 5
Servo amplifier 4
Servo amplifier 1
S-800
Servo amplifier 2
Servo amplifier 1
Servo amplifier 3
M-500
- 93 -
Servo amplifier 2
Servo amplifier 1
B-Cabinet/S-900
- 94 -
Servo module 4
Servo module 3
Servo module 2
Servo module 1
Power supply module
Cabinet for M-41 Oi
- 95 -
Servo module 3
Servo module 2
Servo module 1
M-41 Oi (B-Cabinet)
- 96 -
Servo module 4
Servo module 3
Servo module 2
Servo module 1
Power supply module
$-450
- 97 -
(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.
i-Cabinet
- 98 -
Servo amplifier
Main CPU
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-400i, M-710i, A-520i)
- 99 -
Servo amplifier 5
Servo amplifier 4
Servo amplifier 1
8-800
Servo amplifier 2
Servo amplifier 1
Servo amplifier 4
Servo amplifier 3
M-500
- 100 -
Servo amplifier 2
Servo amplifier 1
B-CabineVS-900
- 101 -
Servo module 4
Servo module 3
Servo module 2
Servo module 1
Power supply module
Cabinet for M-41 Oi
- 102 -
Servo module 3
Servo module 2
Servo module 1
M-41 Oi (B--Cabinet)
- 103 -
Servo module 4
Servo module 3
Servo module 2
Servo module 1
Power supply module
8-450
- 104 -
Reference Relationships among the OVC, OVL, and HC alarms

Overview
This section points out the differences among the OVC, OVL, and HC
alarms and describes the purpose of each alarm.
Alarm detection section
Abbreviation Designation Detection section
ovc Overcurrent alarm Servo software
OVL Overload alarm Thermal relay in the motor OHAL2
Thermal relay in the servo amplifier OHAL1
Thermal relay in the separate regenerative dis-
charge unit DCAL
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
motor, which has a large mass, becomes higher than the time constant
of the thermal relay, because these two components are different in
material, structure, and dimension. Therefore, if the motor repeats to
start and stop within a short time as shown in Fig. 1, the temperature rise
in the motor is steeper than that in the thermal relay, thus causing the
motor to burn before the thermal relay detects an abnormally high
temperature.
Temperature
Start Stop Start Stop Start

I I I I
I I I I Thermal time constant
Temperature at
which the winding I I
- - - - , - - -1- - - -1- - - , - -/-1
I I /1 of the motor is high.
starts to bum
Thermal time constant
I I I I// /I of the thermal relay is
I I .~----r / I low.
,l I ///1 ----~ I
~~'---,J/ / I I I
1 /;__,- I "V I I I
I? I I
Time
Fig.1 Relationship between the temperatures of the motor and thermal relay on start/stop cycles
- 105 -
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 ' '-
'-
'-
'-
Ratedcontinuouscurrent - - - - - - - - - - - - - - - - - - -
Fig.2 Relationship between the OVC and OVL alarms
NOTE
The relationship shown in Fig. 2 is taken into consideration
for the OVC alarm. The motor may not be hot even if the
OVC alarm has occurred. In this case, do not change the
parameters to relax protection.
- 106 -
(35)SRV0-047 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-16i, S-420i, S-500,
S-700, M-400i, M-710i, A-520i) or indicates "2"
(For S-450, S-800, 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)
(This alarm occurs when the DC voltage (DC link
voltage) of the main circuit power supply is
abnormally low.)
(Action 3) If the servo amplifier LED indicates "7" (For S-900)
-This alarm indicates that a deposit has been detected
in the magnetic contactor.
See (30)SRV0-042 MCAL alarm.
Servo amplifier
i-Cabinet
- 107 -
Servo amplifier
B--Cabinet
(ARC Mate 100, ARC Mate 120, ARC Mate 100i, ARC Mate 120i, S-6, S-12, M-6i, M-16i, 5-420i, S-500, S-700,
M-400i, M-710i, A-520i)
- 108 -
Servo amplifier 5
Servo amplifier 4
Servo amplifier 2
Servo amplifier 1
s-soo
Servo amplifier 2
Servo amplifier 1
Servo amplifier 3
M-500
- 109 -
Servo amplifier 2
Servo amplifier 1
Servo amplifier 5
{Additional cabinet interior)
B-CabineVS-900
- 110 -
Servo module 4
Servo module 3
Servo module 2
Servo module 1
Power supply module
Cabinet for M-41 Oi
- 111 -
Servo module 3
Servo module 2
Servo module 1
- 112 -
~0525E/04 MAINTENANCE 3. TROUBLESHOOTING
Servo module 4
Servo module 3
Servo module 2
Servo module 1
Power supply module
$-450
- 113 -
(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. Alternatively, fuse Fl or F2 in the servo
amplifier has blown (ARC Mate 100, ARC Mate 120,
M-16i, S-420i, S-450, S-500, S-700, M-400i,
M-710i and A-520i). The servo amplifier LED
indicates "3".(For ARC Mate 100, ARC Mate 120,
M-16i, S-420i, S-450, S-500, S-700, M-410i,
M-400i, M-710i, A-520i) or indicates "6" (For
S-900):
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 ALl, and MCAL
are displayed on the teach pendant when the control
unit is turned on.)
(Action 4) Investigate the cable connected to the threephase
input of the servo anplifier. If an error is found,
eliminate the causa, then replace fuses Fl and F2 of
the servo amplifier.
(Action 6) Replace the trans former.
Servo amplifier
i-Cabinet
- 114 -
Servo amplifier
B-Cabinet
(ARC Mate 100, ARC Mate 120, ARC Mate 1OOi, ARC Mate 120i, 5-6, S-12, M--6i, M-16i, 5-420i, S-500, S-700,
M-400i, M-710i, A-520i)
- 115 -
Servo amplifier 4 ~-----~
Servo amplifier 2
Servo amplifier 1
B-CabineVS-900
- 116 -
Servo module 4
Servo module 3
Servo module 2
Servo module 1
Power supply module
Cabinet for M-41 Oi
- 117 -
Servo module 3
Servo module 2
Servo module 1
M-41 Oi (B-Cabinet)
- 118 -
Servo module 4
Servo module 3
Servo module 2
Servo module 1
Power supply module
S-450
- 119 -
(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.
Servo amplifier
i-Cabinet
- 120 -
Servo amplifier
B--Cabinet
(ARC Mate 100, ARC Mate 120, ARC Mate 1OOi, ARC Mate 120i, 8-6, S-12, M-6i, M-16i, 8-420i, 8-500, S-700,
M-400i, M-710i, A-520i)
- 121 -
Servo amplifier 5
Servo amplifier 4
Servo amplifier 2
Servo amplifier 1
8-800
Servo amplifier 2
Servo amplifier 1
M-500 Servo amplifier 3
- 122 -
Servo amplifier 2
Servo amplifier 1
B-Cabinet/S-900
- 123 -
Servo module 4
Servo module 3
Servo module 2
Servo module 1
Power supply module
Cabinet for M-41 Oi
- 124 -
Servo module 3
Servo module 2
Servo module 1
M-41 Oi (B-Cabinet)
- 125 -
Servo module 4
Servo module 3
Servo module 2
Servo module 1
Power supply module
S-450
(38)SRV0-051 SVAL2 CUER alarm (Group: i Axis: j)

(Explanation) The offset of the current feedback value is abnormally
high.
- 126 -
Servo amplifier
Main CPU
i-Cabinet
B-Cabinet
(ARC Mate 100, ARC Mate 120, ARC Mate 1OOi, ARC Mate 120i, S-6, S-12, M-6i, M-16i, 5-420i, S-500, S-700,
M-400i, M-71 Oi, A-520i)
- 127 -
Servo amplifier 5
Servo amplifier 4
Main CPU
Servo amplifier 2
Servo amplifier 1
s-soo
Servo amplifier 2
Servo amplifier 1
Main CPU
Servo amplifier 4
Servo amplifier 3
M-500
- 128 -
Servo amplifier 2
Servo amplifier 1
Servo amplifier 6
Servo amplifier 5
lti I F-----------1' I
{Additional cabinet interior)
B-Cabinet/S-900
- 129 -
Servo module 4
Servo module 3
Servo module 2
Servo module 1
Power supply module
Cabinet for M-41 Oi
- 130 -
Servo module 3
Servo module 2
Servo module 1
M-41 Oi (B-Cabinet)
- 131 -
Servo module 4
Servo module 3
Servo module 2
Servo module 1
Power supply module
S-450
(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.
- 132 -
(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, adjustment 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 battery voltage for the pulse coder is lower than
the rating.
(Action) Replace the battery.
(If this alarm occurs, turn on the AC power and
replace the battery as soon as possible. A delay in
battery replacement may result in the BZAL alarm
being detected. In this case, the position data will be
lost. Once the position data is lost, mastering will
become necessary.
(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.
(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 SRV0-070
(46)SRV0-069 SVAL2 CRCERR alarm (Group: i Axis :j)
(Explanation) The serial data has changed during communication.
-See actions on SRV0-070
- 133 -
(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).

- 134 -

printed board
Servo amplifier
.
8-Cabinet
(ARC Mate 100, ARC Mate 120, ARC Mate 1OOi, ARC Mate 120i, 8-6, S-12, M-6i, M-16i, 8-420i, S-500, S-700,
M-400i, M-710i, A-520i)
- 135 -
Servo amplifier 5
Servo amplifier 4
Servo amplifier 2
Servo amplifier 1
s-aoo
Servo amplifier 2
Servo amplifier 1
Servo amplifier 3
M-500
- 136 -

printed board
Servo amplifier 2
Servo amplifier 1
Servo amplifier 6
Servo amplifier 5
B-Cabinet/S-900
- 137 -
Servo module 4
Servo module 3
Servo module 2
Servo module 1
Power supply module

Cabinet for M-41 Oi
- 138 -
B--80525E/04 MAINTENANCE 3. TROUBLESHOOTING
Servo module 3
Servo module 1
M-41 Oi (B-Cabinet)
- 139 -
Servo module 4
Servo module 2
Servo module 1
Power supply module
$-450
(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.
- 140 -
(Action) Make a simplified adjustment and enhance the

shielding.
(Sl)SRV0-074 SVAL2 LDAL alarm (Group : i Axis : j)
(Explanation) The LED in the pulse coder is broken.
(Action) Replace the pulse coder, and make the remaster.
(52)SRV0-075 WARN Pulse not established (Group: i Axis: j)
(Explanation) The absolute position of the pulse coder cannot be
established.
(Action) Reset the alarm, and jog-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 alarm occurs if the backup battery for the absolute
position of the pulse coder has not been connected. See
the description about the BZAL alarm (SRV0-062).
(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 (SRV0-064).
(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 (SRV0-065).
(57)SRV0-089 WARN OHAL2 alarm (Track enc : i)
(Explanation) The motor has overheated. See the description about
the OHAL2 alarm (SRV0-067).
(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 (SRV0-068).
(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 (SRV0-070).
(61)SRV0-093 WARN SPMAL alarm (Track enc : i)
(Explanation) This alarm occurs if the current position data from the
pulse coder is higher than the previous position data.
See the description about the SPHAL alarm
(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 (SRV0-072).
- 141
(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 (SRVQ-074).
(65)SRV0-097 WARN Palse not established (enc: i)
(Explanation) The absolute position of the pulse coder cannot be
established. See the description about (SRVQ-075).
Pulse not established.
(66)SRV0-145 SVALl LVAL alarm (Group: i Axis :j)
SRV0-146 SVALl LVAL alarm (Group: i Axis :j)
SRV0-147 SVALl LVALalarm(Group: i Axis :j)
(Explanation) When the external magnetic contactor for the servo
amplifier is turned on, the DC current (DC link
voltage) of the main power supply is abnormally low.
(Action) If the servo amplifier LED indicates "4" or "5" (For
ARC MatelOO, ARC Mate120, ARC Mate lOOi,
ARC Mate 120i, S-6, S-12, M-6i, M-16i, S-420i,
S-450, S-500, S-700, M-410i, M-400i, M-710i,
A-520i), "2" or "3" (For M-500) (This alarm occurs
when the DC current (DC link voltage) of the main
circuit power supply is abnormally low.)
Servo amplifier
i-Cabinet
- 142 -
Servo amplifier
B-Cabinet
(ARC Mate 100, ARC Mate 120,ARC Mate 100i,ARC Mate 120i, 5-6, S-12, M-6i, M-16i, 5-420i, S-500, S-700,
M-400i, M-710i, A-520i)
- 143 -
(67)SRV0-150 SVALl FSAL alarm (Group: i Axis :j)

(Explanation) The cooling fan of power supply module stopped
rotating. Number '2' is displayed on the LED display.
(Action) Replace the power supply module.
Servo module 4
Servo module 3
Servo module 2
Servo module 1
Power supply module
Cabinet for M-41 Oi
- 144 -
Servo module 3
Servo module 2
Servo module 1
- 145 -
Servo module 4
Servo module 3
Servo module 2
Servo module 1
Power supply module
5-450
- 146 -
(68)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.
Servo module 4
Servo module 3 ~~
s ervo module 2-..._ / .........._ "" /
Servo module1-L'
......._
" " v
// --~ ? ... / /v ~""
·; -
ml
., ~
-
;- ;-
j ~
-,,
~~
0
[ - -
/
~ ~ / rf=iZi'I
.. -~
lr--tP,,
II
[ /,,/ ~ ]I /
~ -·"""'·
i> v
I
- ~ ~
v·
/ /
I IV
u
/ / V/
M-410i
- 147 -
Servo amplifier 5
Servo amplifier 4
Servo amplifier 2
Servo amplifier 1
s-soo
Servo amplifier 2
Servo amplifier 1
Servo amplifier 3
M-500
- 148 -
(69)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.
(70)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.
(71)SRV0-165 Panel (SVON Abnormal) E-stop
(Explanation) An invalid +24V is connected to SVON or EXGEX
in the operator's panel.
(Action) Tum off the power, then correct the wiring of SVON
or EXGEM in the operator's panel.
Servo module 4
Servo module 3
Servo module 2
Servo module 1
Power supply module
Cabinet for M-41 Oi
- 149 -
Servo module 3
Servo module 2
Servo module 1
M-41 Oi (B-Cabinet)
- 150 -
Servo module 4
Servo module 3
Servo module 2
Servo module 1
Power supply module
5-450
- 151 -
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.
- 152 -
P9U Bl
F1
Fuse for
AC Input
Power supply unit
LED: PIL
LED :ALM
L CH CH
+ICV:•MI=
f<
;rn1
FllllY NUIY
TIASFIA
F35AS
(Slow blow)
Fusefor+24V
F45A
- 153 -
(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-400i, M-710i, A-520i)
FUSEl: 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
i-Cabinet
- 154 -
FUSE 1
FUSE
F1,F2
B--Cabinet
- 155 -
FUSE1
FUSE FUSE
F1 F2
- 156 -
(3) Servo amplifier fuses (S-450, S-800, S-900, M-410i, M-500)

Fl: Fuse for power supply module control (S-450, M-41 Oi)
F2: Fuse for servo module control (S-450, M-41 Oi)
FUSE: Fuse for servo amplifier control (S-900, S-800, M-500)
F1 The seven-segment LED does not light. 1 Replace the power supply module, servo module, or
F2 servo amplifier.
FUSE1
Servo module 4
Servo module 3
Servo module 2
Servo module 1
Power supply module
Cabinet for M-41 Oi
- 157 -
Servo amplifier 3
Servo amplifier 2
Servo amplifier 1
Servo amplifier 5
S-900
- 158 -
Servo amplifier 5
Servo amplifier 4
Servo amplifier 2
Servo amplifier 1
$-800
Servo amplifier 2
Servo amplifier 1
Servo amplifier 4
M-500 Servo amplifier 3
- 159 -
Servo module 3
Servo module 2
Servo module 1
M-41 Oi (B-Cabinet)
- 160 -
Servo module 4
Servo module 3
Servo module 2
Servo module 1
Power supply module
$--450
- 161 -
LED
-·--·· Fuse
-
F2
AC SERVO
AMPLIFIER
c llfill
.... ~
STATl.8
~
---
A
LI L2 La
·-
......
@ 0 Q} @
Fuse
Note See 7.12.1

forthe location offuse.
Power supply module Servo module Servo amplifier
- 162 -
(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 overt ravel alarm is output on cables internal to the mechanical section are con-
the teach pendant. nected to the ground or are short-circuited.
board.
*l Ifnoadditionalax.isisusedwiththeARCmate 100,ARCMate 120,ARCMate lOOi,ARCMate l20i, S-6, S-l2,M-6i,M-l6i, S420i,

S-500, S-700, M-400i, M-71 Oi or A-520i the brake controlcircuiton the emergency stop control printed circuit board is not used: the Fl
fuse does not blow.

printed board
.
B-Cabinet
(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-400i, M-710i, A-520i)
- 163 -

printed board
S-800

printed board
M-500
- 164 -

printed board
Cabinet for M-410i
- 165 -
Servo module 3
Servo module 2
Servo module 1
M-41 Oi (8-Cabinet)
- 166 -
Servo module 4
Servo module 3
Servo module 2
Servo module 1
Power supply module
$-450
- 167 -
3. TROUBLESHOOTING MAINTENANCE B--a0525E/04
Emergercy stop control printed board
- 168 -
B--80525E/04 MAINTENANCE 3. TROUBLESHOOTING
(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 alarm 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
+ +
+ +
+ +
Fuse
Process input/output
PC boards CA, CB, and DA
+ +
CA
DA
- 169 -
~
0 Al 66-3200-02~ - - -
O IHlF Ml5VF P15VC Gl'll2 ~ PIOV 0
•P15VF
• •Ml5VC
• • P5VC
• • P4•.8 LJ.
~u
D
FUSEI
•
GN>I
CRWI <(
DVI I (\J DVI
en ::E
DVl2 (\J
::E 0::
u
DV2 ~
;
0:: ALMO
DV7 u DV3
DVB ~
DV4 FAl.14
AI6
&
~ LJLJ
00 ••••••••
AI4 Al3 A.12 AI IAOUT2
ADUTI
P24Y
0 0
LED: FALM
FUSE1
Process 1/0 EA
- 170 -
(6) Fuse on the conversion printed circuit board (S-900)

FUSE: Fuse for brake control
FUSE The LED (red) on the emergency stop control printed 1 Check if the robot connection cable (RM1) and
circuit board lights. cables internal to the mechanical section are con-
nected to the ground or are short-circuited.
board.
Conversion PCB
- 171 -
0 000
0
-JRVI l/F
000
-·-·
.Ml
.Ml
-4
-·
.N4
m
- l
-·
.Nl
.NI
~ :11
[J]
AI 6B- I 2 I 2-091..,_ -
CllllS
FUSE
a
- 172 -
(7) Transformer/line filter fuses

Fl, F2, F3: Fuses for servo three-phase input voltage
F4, F5: Fuses for 100 VAC
F1 or The LVAL (DCLK) alarm is output on the teach pendant, 1 Check if the cables and units connected to the three-
F3 and the seven-segment LED on the servo amplifier in- phase input voltage source are normal.
dicates 4.
F2 only The DCAL alarm is output on the teach pendant, and 1 Check if the cables and units connected to the three-
the seven-segment LED on the servo amplifier indi- phase input voltage source are normal.
cates 8.
F1,F2 The LVAL (DCLK) alarm is output on the teach pendant, 1 Check if the cables and units connected to the three-
F1,F3 and the seven-segment LED on the servo amplifier in- phase input voltage source are normal.
F2, F3 dicates 4.
F1~F3
F4or The LED (green) on the emergency stop control printed 1 Check if the transformer/line filter, emergency stop
FS circuit board does not light, and the motor brake cannot control printed circuit board, and connection cables
be released.(*1) are normal.
NOTE
If no additional axis is used with models such as ARC Mate 100, ARC Mate 120, ARC Mate 1OOi,
ARC Mate 120i, 5-6, S-12, M-6i, M-16i, 8-420i, S-500, S-700, M-400i, M-710i or A-520i
which do not use a sixth-axis servo amplifier, the brake control circuit on the emergency stop
control printed circuit board is not used. This means that even if the F4 or FS fuse blows, the
robot operates normally.
- 173 -
(B cabinetfor ARC Mate 100, ARC Mate 120, ARC Mate 1OOi, ARC Mate 120i, $--6, S-12, M-6i, M-16i, $-420i, S-500, S-700,
8-800, S-900, M-400i, M-710i, A-520i)
Fuses Fuses Fuses
Fuses FI F2 F3
Transformer Line filter
(B cabinet for 8-450, M-41 Oi)
Fuses Fuses Fuses Fuses
Transformer AC reactor
NOTE
Check that the PIL lamp on the power unit is not lit. Then,
replace the blown fuse.
- 174 -
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 printed circuit board
Power supply unit
~-1--+-t--r Process 1/0 printed circuit

board CA/CB/DA
Rocess 1/0 printed

board CA/CB/DA
B-Cabinet
- 175 -
Servo module 1
Power supply unit
Process 1/0 printed board

CA/CB/DA
Power supply module
Servo module 4
M-41 Oi ( B-Cabinet)
Servo module 4
Servo module 3

printed board
Rocess 1/0 printed board CA/CB/DA

Power supply unit
Cabinet for M-41 Oi
- 176 -
Additional cabinet

Power supply unit
Process 1/0 printed board

CA/CB/DA
.
Servo amplifier 2
Servo amplifier 1
Servo amplifier 5
B-Cabinet/S-900
- 177 -
3. TROUBLESHOOTING MAINTENANCE S-80525E/04
Servo module 4
Servo module 3
Power supply unit

Servo module 2
Servo module 1
Process 1/0 printed

board CA/CB/DA
Power supply module
5-450
Process 1/0 printed board EA
Operator's box
- 178 -
(1) TROUBLESHOOTING USING THE LEDS ON THE MAIN CPU

PRINTED CIRCUIT BOARD
To troubleshoot an alarm that arises before the teach pendant is ready
to display, check the status LEDs (green) on the main CPU 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 alarm is detected, the step in which the alarm
occurred can be determined from which LEDs are lit.
Step LED Action to be taken
1: After power-on, all * [Action1] Replace the flash ROM module.
LEDs are lit. * [Action2] Replace the SRAM module.
EJl
1 l 3 4
[Action3] Replace the corresponding axis module.
[Action4] Replace the main CPU PC board.
STATUS • • • •
ALAD_DDD-
.__.......
2: Each printed circuit * [Action]Replace the main CPU PC board.
board is initialized.
EJl
1 1 a 4
STATUS DODD
Al.AD ODD-
.__.......
3: The timer is initialized. * [Action]Replace the main CPU PC board.
EJl
1 2 a 4
STATUS ODD•
---
Al.AD
D'=-D -
4: The communication *[Action1]Replace the main CPU PC board.

port is initialized.
EJl
1 1 a 4
STATUS DD•D
---
Al.AD DOD-
5: The software is initial- *[Action1]Replace the main CPU PC board.

ized. * [Action2] Replace the flash ROM module.
EJl
1 1 a 4
STATUS DD••
--- oi:::_o_
Al.AD
* If the main CPU PC board or SRAM module is replaced, the contents of memory (parameters, specified data,
etc.) will be lost. Prior toreplacing 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.
:
I $AAMmgit!k!
- 179 -
Step LED Action to be taken

6: The software is initial- * [Action1] Replace the SRAM module.
ized. * [Action2]Replace the main CPU PC board.
EJl
a•
1 2
STATUS D•DD
Al.MM ooo _
__..-
7: The software is initial- * [Action1) Replace the SRAM module.

ized. * [Action2] Replace the main CPU PC board.
EJl
1 1 a•
* [Action3) Replace the flash ROM module.
STATUS
Al.MM
o•o•
_ooo ___
..__.
8: The software is initial- [Action]Replace the flash ROM module.
ized.
EJl
1 1 a 4
STATUS
Al.MM
o••o
DOD _
__..,. -
9: The software is initial- [Action]Replace the axis module.
ized.
E5l
a•
1 1
o•••
--
STATUS
Al.MM DOD_
1O: The software is initial- * [Action1] Replace the SRAM module.

ized. * [Action2]Replace the main CPU PC board.
E5l
1 1 a 4
STATUS
--
•DOD
Al.MM DOD _
11: Communication with the [Action1]Replace the teach pendant.

[Action2]Replace the cable of the teach pendant.
teach pendant is
executed. E5l
a4
1 1
* [Action3]Replace the main CPU PC board.
STATUS •o••
*
--
Al.MM DOD_
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
.
0
-
cc
- 180 -
LED Color Description

[Description] A parity alarm occurred in the RAM of the main CPU PC board.
[Action1]
0 Red
* [Action2]
Replace the DRAM module.
Replace the SRAM module.
=iii~
- * [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.
0 * [Action2] Replace the main CPU PC board.
=
-
I I I 4
0000
c••
Red
[Description] A servo alarm occurred on the main CPU PC board.

0 Red
mMM * [Action2] Replace the main CPU PC board.
co•
-
[Description] An NMI occurred in the LSI chip (SLC2) of the main CPU PC board.
0
I I I 4
Red
*[Action] Replace the main CPU PC board.
1M1W CICCO
.... ••CJ
-
[Description] A SYSFAIL occurred.
0 Red
mMM
c•o
* [Action2] Replace the main CPU PC board.
-
[Description] The battery voltage has fallen to below the prescribed level.
0 *[Action] Replace the battery on the power supply unit.
=
-
I I I 4
0000
•cc
Red
Note) To prevent data loss, before replacing the battery, tum the control
unit on.
* 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
.
0
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
- 181 -
* LEDs on power supply unit

LED Description and action to be taken
[Description] A power supply alarm occurred.
[Action1] Check whether fuse F3 (+24 V) or F4 (+24 E) on the power supply unit
--
CMITI
_,,,ua
,,,.. MAii
--·-
..... _,_
-
Niii •
_,.,._
•YW1111M
..r.
[Action2]
has blown.
Replace if necessary.
Check the printed circuit boards, units, and cables using the DC power
supply (+5 V, ±15 V, +24 V, +24 E). Replace any failed components.
....,.. °' llal.
* [Action3] Replace the power supply unit.
_ _
...
....---
CMITI
t.nmlMllu.
--·-
--·-
NITI •
_,.,._
_,.,
•YWl'lllllll
......
[Description] If the LED is not lit, the power supply unit is not connected to the 200
[Action1]
* [Action2]
VAC supply.
Check whether fuse F1 on the power supply unit has blown. Replace if
necessary.
Replace the power supply unit.
PIL -Ii:]
~p;IQ:]
Ir
~
* Power supply replacement must be completed within 30 minutes. (The power supply unit contains the backup
battery for the SRAM module of the main CPU PC board.)
.... DI
Fl
F3
F4
- 182 -
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-current 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-circuited 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
0
0 •'Pf
A.168-121~
- •'Pf
-1
l1
I
F2
I
~ ii1
Iii
;cl
.I
.1
"1
~I
".:lc::iiil
•
= I
DOD
ii
II
i!!i
1:
DD DD
1:~I
ii
11
I
I
- 183 -
LEDs on the conversion PCB
LED indication Phenomena and countermeasures

[Description] The brake fuse has blown, or the brake over-current alarm has been
issued.
[Action1] Check whether the fuse on the conversion PCB has blown. If it has blown,
replace it.
[Action2) Check whether the robot cable and mechanical unit cable are
short-circuited to ground or any metal object.
[Action3] Replace the conversion 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 for the transformer
or line filter.
[Action3] Replace the conversion PCB.
[Description] If the LED does not light, the brake has not yet been released.
[Action1) Replace the conversion PCB.
[Action2) Replace the main CPU PCB.
0 0
:.·"
000
Al68-1212-o91 . . . . -
- 184 -
(2) ALARM LEDS ON THE PROCESS I/O 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.
~
1 2 3 4
DODD
I [Action1]
* [Action2]
[Action3]
Replace the process 1/0 PC board.
Replace the main CPU PC board.
Replace the 1/0 link connection cable.
------
STATUS 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 2 3 4
D [Action3]
1/0 PC board.
Replace any failed components.
Replace the process 1/0 PC board.
---
STATUS DODD ALMO
ALARM D•D
- -
I
c....---
FALM
D
D
D~
Fuse
Fuse
For process 1/0 printed circuit board CA/CB/DA

Specificalion: A601--0001-0046#2.0 Do D
Process input/output PC board EA
- 185 -
* LEDs on servo amplifier (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-400i, 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 WD
0
HC IJIJIJ IJ
0 IJIJIJ
0 123
0
0
0
0 @ LED
0
0 000000 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
Servo-047 LVAL Alarm
- 186 -

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(LED8)
[Description] A watch-dog alarm occurred on the servo amplifier
control PC board.
The WD LED (LEDS) on the servo amplifier is lit.
- 187 -
* LED on power supply included (PSM) (M41 Oi)
==
= =
=
=
= =
=
=
=
=
= =
=
=
=
=
==
=
=
LED
Weight 10.7Kg
- 188 -
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 alann
Fanalann The cooling fan, built into the power supply module, is defective.
2 SRV0-150 FSAL alann
Overload alann The temperature of the semiconductor heat sink is too high.
=3 SRV0-141 OHAL alann
Low voltage alarm for DC link
y The DC voltage of the main circuit is too low.
SRV0-145 LVAL alann
In sufficieat charge alann for The DC voltage of the main circuit has not reached the required level (insufficient
5
DC link pre-charge).
SRV0-153 CHGAL alann
Input power missing phase A phase of the input power is missing.

alann
b SRV0-143 PSFLAL alann
Overvoltage alann for DC link The DC voltage of the main circuit is too high.
l SRV0-154 HVAL alann
The control circuit is defective.

Hardware error alann
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.
- 189 -
* LED on servo amplifier module (SVM)
LED
]
=
~~~®
~
]
c: ....---
~~~~
~
~-~
~~~~
,_, IV
~~
~~~
-----------
- 190 -
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 erro-
power
(LV5V)
2 neous.
SRV0-144 LVAL alarm
Low voltage alarm for DC link The DC voltage of the main-circuit power supply is too low.
(LCDC)
5 SRV0-146 LVAL alarm
Overcarrent alarm An excessive over-current was detected in the motor of the one-axis amplifier
(HCL)
B or in the L-axis motor of the two-axis amplifier.
SRV0-149 HLAL alarm
An excessive over-current was detected in the M-axis motor of the two-axis

Overcarrent alarm
(HCM)
g amplifier.
SRV0-149 HCAL alarm
Overcarrent alarm An excessive over-current was detected in the L- and M-axis motors of the
5
(HCLM) two-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
(HCL)
B 2-axis or 3-axis amplifier.
SRV0-152 IPMAL alarm
An error was detected in the M-axis IPM of a 2-axis or 3-axis amplifier.

IPM alarm
(HCM)
g SRV0-152 IPMAL alarm
IPMalarm An error was detected in the L-axis and M-axis IPMs of a 2-axis or 3-axis am-
5
(HCLM) plifier.
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
- 191 -
*LED on servo amplifier unit (S-800, 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 alann 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 LVAL alann
Low voltage alann for DC link The DC voltage of the main-circuit power supply is too low.
(LVDC)
=3 Alann message: Servo - 047 LVAL alarm
y
Regenerative control circuit The short-period regenerative discharge energy is high.
alann
(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 alann
Amplifier over heating The thennostat in the servo amplifier unit tripped.
(OH)
b Alann message: Servo - 049 OHALI alarm
- 192 -

Deposition of magneticcontac- A deposit was detected on the contact of the magnetic contactor. Any deposit on
l
tor the contact is detected immediately after the magnetic contactor activation com-
(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 high current was detected in the L- and M-axis main circuits of
b
(HCLM) the two-axis amplifier.
Amplifier NOT READY The magnetic contactor in the servo amplifier unit is open. The motor is not
ready to operate.
-
Amplifier READY The mar-netic contactor in the servo amplifier unit is closed. The motor is ready
D
to 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•
tects 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.
UM-axis IPM alarm (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 unit is set to off, the DC link
undervoltage alarm (LVDC) is issued.
- 193 -
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 main CPU 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)
Tum 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.
- 194 -
(Check 4) Check whether the HOLD signal of the peripheral device

control interface or the HOLD switch on the operator's panel
is on (hold status). (Check whether the hold lamp on the
teach pendant is on.)
(Corrective action)
Tum off the HOLD signal of the peripheral device control
interface or the HOLD switch on the operator's panel.
(Check 5) Check whether the previous manual operation has been
completed.
(Corrective action)
If the robot cannot be placed in the effective area because of
the offset of the speed command voltage preventing the
previous operation from being completed, check the
position deviation on the status screen, and change the
setting.
(Check 6) Check whether the controller is in the alarm status.
(Corrective action)
Release the alarm.
(2) Check and corrective action to be taken if the program cannot be
executed
(Check 1) Check whether the ENBL signal for the peripheral-device
control interface is on.
(Corrective action)
Put the peripheral-device control interface in the ENBL
state.
(Check 2) Check whether the HOLD signal for the peripheral-device
control interface is on. Also check whether the HOLD
switch on the operator's panel is on. (Check whether the
HOLD lamp on the teach pendant is on.)
(Corrective action)
If the HOLD signal is on, 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.
- 195 -
4. PRINTED CIRCUIT BOARDS MAINTENANCE B-80525E/04
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 the Control Unit PC Board
- 196 -
B-80525E/04 MAINTENANCE 4. PRINTED CIRCUIT BOARDS
4.1
MAIN CPU PC
BOARDS
(A 168-3200-0040)
Total version
SPI
~
CJ id
o?
~
~
~C-M_O_S~RA-M~m-od_u_le~~~~~~----,1 II
Flash ROM module DRAM module I
ei 0
Axis module (J1, J2) I

Axis module (J3, J4)
DV2 II DV I
Axis module (JS, J6)
ow~~
0 I c=J I a 0
0
0
D 0
0
0
0
H Ii~
....... !i~
,., ;i ~~ iii
a
il~i
Ii~
!i li I 1un 11111• - JRV1 I
1~1 I
>
_c
I
;:;!ii ..5
'> - - • · · - - · - JRF21
m; §] ,JWW1J1 I[ I mi: l
l
I
oo-
a! 88:
Fig.4.1 Main CPU printed circuit board
(1) Test pins

Name Use
GND
PSV
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.
- 197 -
(3) LEDs
Color Description
I ij
10-0l
ID•
ID•
Red
A parity alarm occurred in a CMOS RAM module or
DRAM module on the main CPU board.
O•
I &i
oo-Ol
ID•
ID•
Red
NMI occurred in the LSl(ABC) on the main CPU
printed circuit board.
O•
I &i
oo-Ol
DO•
l[]oo
Red
Servo alarm occurred on the main CPU printed
circuit board.
O•
I ij
10-0I
ID•
O[]oo
Red
NMI occurred in the LSl(SLC2) on the main CPU
board.
O•
I ij
oo-Ol
10•
O[]oo
O•
Red SYSTEM FAIL occurred.
I ij
10-a
00•
O[]oo
Red
The battery voltage is insufficient.
Replace the battery.
O•
I ij
01-0l
01-
DI• Green Indicates the operating status of the system.
I•
(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
- 198 -
~0525E/04 MAINTENANCE 4. PRINTED CIRCUIT BOARDS
4.2 A20B-1006-0300
EMERGENCY STOP
RLY2 RLY6
CONTROL PC
BOARD
0 CRRl5 ,- - , 0
I
BB I
0
I
I
I
L _J -D>- o~ CRR20
II
•
"-..
0
I")
0
I
...0
0
0 0J
LL
I 0:::
co J
0
(\J rv:> LL
LL """"'"
<C 0::: 0:::
(_) (_)
0 CRM9 CRMI 10
Fig.4.2 (a) Emergency stop control PC board
- 199 -
4. PRINTED CIRCUIT BOARDS MAINTENANCE B--80525E/04
Al6B-1212-0930
Total version
0
I
0 0 0
0 0
llllip:jl I
!~
-
18Cip:jl
i~
.,1
(\I
,
LL
0::
u::I
31
F2
~ ~I
~I
..,I
sq
.. 1
sq I
...
sq I
...
sq I
alHl6
!.DD
...-
<t11 olj 21 i!
DD ;~
i;J;J!ll
~~
..... 1
EB llil
DOD 21
i;i;Jiii
EB
EB
EB
EB
t
!I
...
llil
i
:1
!!1
DIJ DD
EB 11
...
EB Ell
...
EB !I
0
0 0 0
Fig.4.2 (b) Emergency stop control PC board
- 200 -
~0525E/04 MAINTENANCE 4. PRINTED CIRCUIT BOARDS
Al6B-1212-0931
Total version
0
0 0 0
0
0 (!JI~
-
Ill(~
N -
LL
a::
>
a::
:;:I
""") """)
ts I
F2
~ •\=II SJ I
•\=18 ~I
•'=II :I
.....
l\=/8 ... 1
~I
l\=11 SJ., I
B\=/I ~I IO
CRHl6 .,_
!LI D i!
'til al] 21 CRHl5
i;i;i!i ~:J
DD i~
....... 1
EB 11
DOD
J
21
EB :1
15 ....
EB IJ
EB 11
IO
EB ~I
DO DD
EB 11...
EB ii
EB i1
0
0 0 0 I
I
Fig.4.2 (c) Emergency stop control PC board
- 201 -
( 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.)
- 202 -
Conversion PCB (S-900) A16B-1212-0910
Total version
0 0
0 0
0 0
0 0
ii
~~·..
~'..
m []
Fig.4.2 {d} Conversion PCB
(1) 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.)
- 203 -
4.3 (A20B-2001-0670)
BACKPLANE PC Total version
BOARD
0 0
CA44
D
I- 0
<( o_ <(
z z z
J J J
~D
0 0 0 0 0
Fig.4.3 {a) Backplane PC Board

(A20B-2001-0860)
2 slot back plane Total version
A20B-2001-0860 I
L- 0 0
CA39
0
D
I
I-
<(
LD
<(
•
'
>J)
Cl()
?
2:
<(
0
o_
z 0::: 0
0
z z
I
J J ~ J J
CD
0
"'
""
~D
r- 0 - 0 0
Fig.4.3 {b) Backplane PC Board

(A20B-2001-0990)
5 slot back plane
Total version
A20B-2001-0990 I
L- 0 / o o 0 0 0 0 0
fl o CA39B
D
CA44
D
I- mI 0
0::. L (\J I")
<( <( ' <( Cl. <( <( <(
z z z z z z
J Jg:: J J J J J
?
0
0
~
~D co
0
"'
<
~D
fl- 0 0 0 0 0 0 0 0
Fig.4.3 {c) Backplane PC Board
- 204 -
4.4
PROCESS
INPUT/OUTPUT PC
BOARD
4.4.1
Process Input/Output
PC Board CA
(A 168-2201-0470)
0
• • • • • JNA
EiNJ2 PIY P24Y •l&VCPUWC
I IRESERVED I 0
>
~
I\)
~
General t
-~i
DVl2 DV6
DVI I DV5
DVIO DV4
I
DV9 DV3
DV8 DV2
'l""I' CRM2B
DV7 DVI
JOO! JD4A
CRM2A
l~ l~
·t ·~
I ! ! +
ml~IH I !
ft ft Hrm1~ +
~ + l1IJl BPEO
Fig.4.4.1 Process Input/Output PC Board CA
- 205 -
(1) Test pins

Name Use
P24V +24V
PSV +SV
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)
AIS Channel 5
Al6 Channel 6
AOUT1 Channel 1 For measuring the voltage of the analog output
AOUT2 Channel 2 signal (digital/analog)
(2) Settings
Standard Description
Name
setting
UDl1 to UDl20
ICOM1
(Connector CRM2A) The common voltage is
UDl21 to UD140 adjusted to:
ICOM2 Side A
(Connector CRM2B) Side A +24 Vcommon
Side B OVcommon
WDI01 to WDI08
ICOM3
(Connector CRW1)
SP1 Channel 1 The polarity of the output voltage

is switched to:
Open
Strapped: Negative(-)
SP2 Channel 2 Open Positive (+)
- 206 -
(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 .1:::101
aa•
ID•
aa•
OJ Red
A communication alarm occurred between
the main CPU and process input/output.
D•
\ ;~ 1~1
aa-OJ
ID•
aa•
C•
Red
A fuse (FUSE 1) in the process input/output
blew.
- 207 -
(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
DVS ACK7/SN07, ACK8/SN08, SNACK, RESERVED
DV6 SD001, SD002, SD003, SD004
DV7 SDOOS, SD006, SD007, SD008
DVB SD009, SD010, SD011, SD012
DV9 SD013, SD014, SD015, SD016
DV10 SD017, SD018, SD019, SD020
DV11 WD001, WD002, WD003, WD004
DV12 WDOOS, WD006, WD007, WD008
RESERVED For replacement
- 208 -
4.4.2
PC Board CB
{A16B-2201-0472)
....--- I
0
l 0
l .....
I I I
GNIZ P9¥ P2'Y MUIVCPllM:
RE!iE?'IED
JNA
0
~
$I
I\)
I\)
General £
I
0
revision No.
.
~
DV6
DVIO
DV5
DV4
~r
I
DV9 DV3
DV8 DV2
DV7 DVI
rea• CRM2B
- -
.Jl48 J04A
0 CRM2A
0
0 ng
LED 0
mrt a
l:i l:i
m lff;===:====;-:ftl :
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
Name Standard Description

setting
UDl1 to UDl20 The common voltage is
ICOM1
(Connector CRM2A) adjusted to:
Side A
UDl21 to UDl40 Side A +24 Vcommon
ICOM2 SideB OV common
(Connector CRM28)
- 209 -
(3) LEDs
Color Description
\ii 1~1
I
ID-[]
aa..
aa•
D•
Red
\ ~! i1~1
•i
I
DD-a
IC-
aa•
a•
Red
blew.

DV3 2BATALM, BUSY, ACK1/SN01, ACK2/SNO
DV5 ACK7/SN07, ACK8/SN08, SNACK, RESERVED
DV6 SD001, SD002, SD003, SD004
DV7 SD005, SD006, SD007, SD008
ova SD009, SD010, SD011, SD012
DV9 SD013, SD014, SD015, SD016
DV10 SD017, SD018, SD019, SD020
- 210 -
4.4.3
PC Board DA
{A16B-2201-0480)
oT I
l
•
0
D
FUSEI
.JNA
0
~
I DV24 I DV22 I
•• I DV23 I DV21 I ~
"'"'~
...• RESERVE[ DVl4 DV7
Total version ...'
0.
0
DV20 DVl3 DV6
...,,
DVl9
DVl8
DVl2
DVI I
DV5
DV4 ~i
DVl7 DVIO OV3
CRM4B
CRM4A
BU
CRM20
CRM2C
DVl6
DVl5
• DV9
DVB
DV2
DVI
CRM2B
CRM2A
i~
.A:l48 JD4A
,-- ,--
I
0
0
0
l I
aaaa ~
aa ng
LEO 0
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
UDI01to20
ICOM1
(Connector CRM2A)
UDl21to40 The common voltage is
ICOM2
(Connector CRM2B) adjusted to:
Side A
UDl41to60 Side A +24 V common
ICOM3 SideB OV common
(Connector CRM2C)
UDl61to80
ICOM4
(Connector CRM2D)
- 211 -
(3) LEDs
Color Description
.,.,,_.,,
a
\~s •og
.....
m
"'5 a
I ID-
DON Red
DO .. the main CPU and process input/output.
0•
.,......
.....
\ii •og
m
a
oo- A fuse (FUSE 1) in the process input/output
1 IDN
OD ..
D• 0 Red
below.

Ordering code for the driver chips: A 76L-0151-0062
DV4 ACK3/SN03, ACK4/SN04, ACKS/SNOS, ACK6/SN06
DVS ACK7/SN07, ACK8/SN08, SNACK, RESERVED
DV6 SD001, SD002, SD003, SD004
DV7 SDOOS, SD006, SD007, SD008
DV8 SD009, SD010, SD011, SD012
DV9 SD013, SD014, SD015, SD016
DV10 SD017, SD018, SD019, SD020
DV11 AD021, SD022, SD023, SD024
DV12 SD025, SD026, SD027, SD028
DV13 SD029, SD030, SD031, SD032
DV14 SD033, SD034, SD035, SD036
DV15 SD037, SD038, SD039, SD040
DV16 SD041, SD042, SD043, SD044
DV17 SD045, SD046, SD047, SD048
DV18 SD049, SDOSO, SD051, SD052
DV19 SD053, SD054, SDOSS, SD056
DV20 SD057, SD058, SD059, SD060
- 212 -
4.4.4
Process 1/0 Printed
Board EA
(A 168-320~230)
O{]
0
0
p
A 166-3200-02~ - - -
0••• Pl5VF
VF. . .VC• • •
M15VC ~vc P•.a
LJ P.V O
D ~
~
FUSEI
~ 0
"""'
CRWI <(
•
OVI I (I)
(\J DVI
L
DVl2 (\J
L
l'.l'.: DV2 ~
l'.l'.:
u Al.MO
DV7 ~ u DV3
DVB ~ ~
DV4 FALM
AI6 ~ LjLj DV5
s ~
••••••••
AI4 AI3 AI2 Al I AOUT2 P24V
~I
00 ACUTI 0 0 0 0
- 213 -
(1) Test pins

Name Use
P24V +24V
PSV +SV
P15VC +15V
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)
AIS Channel 5
Al6 Channel6
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
WDI01 to WDI08
ICOM3
(Connector CRW1)
SP1 Channel 1 The polarity of the output voltage

is switched to:
Open
Strapped: Negative(-)
SP2 Channel 2 Open Positive (+)
- 214 -
(3) Adjustment
VR 1: Adjusts the gain of channel 1.
Execute a robot program and set AOUT[l] to 4095 on the teach
pendant. Connect a digital voltmeter to test pin AOUTl and
rotate VRl until the meter reads 12.0 V.
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.
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
Red
blew.
I
FALM
- 215 -

DV6 SD001, SD002, SD003, SD004
DV7 SD005, SD006, SD007, SD008
DVB SD009, SD010, SD011, SD012
DV9 SD013, SD014, SD015, SD016
DV10 SD017, SD018, SD019, SD020
DV11 WD001, WD002, WD003, WD004
DV12 WD005, WD006, WD007, WD008
- 216 -
4.4.5
Additional Axis Control
Printed Board
{A 168-2200-0820)
Total version
I \
l
pi~:
0 o>
• r
•
GND3 P24E
Ml5V
• •
Pl5V
~
~
G 2
g
Ii
Axismodule(Additional1- 2-axis\\ I~
\~
I Ax•mod"~(Additional3-,4-M•l
0
I Axismodule{Additional5-,6-axis} I 0
I Axis module (Additional 7-, 6-axis) I

GNOI
•
I Axismodule(Additiona19-, 10-axis) I
...-- - - ....--- .--- - ...-- ....-- ...-- - - ....-- - .--- .--- - ..----- ...----- - - - ....--
0 0 0
0 0 0
0 0 0
-....---- -....----- -....---- - -,...--
ill ill il ill ill ID ID wID ill ID ID
Fig.4.4.5 Additional axis printed board
( 1) Checking pins
Name Description
GND
PSV
P15V For checking the printed board
M15V
P24E
- 217 -
5. SERVO AMPLIFIERS MAINTENANCE B-80525E/04
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.
- 218 -
B-80525E/04 MAINTENANCE 5. SERVO AMPLIFIERS
Robots and servo amplifier

J1 J2 J3 J4 JS J6 J7
ARC Mate 100 A06B--6076-HOOS (6-axis AMP) or A06B-6076-H1 OS
ARC Mate 120 A06B--6076-H004 (6-axis AMP) or A06B-6076-H104
ARC Mate 120i
ARC Mate A06B--6076-H10S (6-axis amplifier)
100i/M--6i
S--6 A06B--6076-HOOS (6-axis AMP) or A06B--6076-H1 OS
S-12, M-16i A06B--6076-H004 (6-axis AMP) or A06B-6076-H104
8-420i A06B--6076-H001 (6-axis AMP) or A06B--6076-H101
8-4SO A06B--6077-H111 (PSM)
AMP1/L AMP1/M AMP2/M AMP2/L AMP3/L AMP3/M AMP4
A06B A06B A06B A06B A06B A06B 8-4SOS:
--6079 --6079 --6079 --6079 --6079 --6079 A06B-6079
-H206 -H206 -H207 -H207 -H206 -H206 -H104
8-4SOL:
A06B--6079
-H101
s-soo A06B--6076-H002 (6-axis AMP) or A06B--6076-H102
A-S20i
M-400i
S-700 A06B--6076-H103 (6-axis AMP) or A06B--6076-H103
8-800 AMP1 AMP2 AMP3 AMP4/M AMP4/M AMPS
--60S9 --60S9 --60S9 --60S9 --60S9 --60S9
-H10S -H10S -H10S -H20S -H20S -H10S
S-900 AMP1 AMP3 AMPS AMP2 AMP4 AMP6
--6066 --6066 --6066 --6066 --6066 --6066
-HOOS -HOOS -HOOS -H006 -H006 -H006
AMP1 AMP3 AMPS AMP2 AMP4 AMP6
--60S9 --60S9 --60S9 --60S9 --60S9 --60S9
-H106 -H106 -H106 -H10S -H10S -H10S
M410i A06B-60S7-H11S (PSM)
AMP1 AMP2 AMP3 AMP4
M-SOO
A06B
--6079
-H106
AMP1
A06B
A06B
--6079
-H106
AMP3/M
A06B
A06B
--6079
-H106
AMP2
A06B
A06B
--6079
-H103
AMP3/L
A06B
C>< AMP4
A06B
--60S9 --60S9 --60S9 --60S9 --60S9
-H106 -H206 -H10S -H206 -H104
M-710i A06B--6076-H106 (6-axis amplifier)
- 219 -
5.1
SERVO AMPLIFIER Machine Specification
ARC Mate100, S-6 A06B-6076-H005orA06B-6076-H105
FOR (ARC Mate 100,
ARC Mate120, ARC Mate 120i,
ARC Mate 120, ARC S-12, M-16i A06B-6076-H004orA06B-6076-H104
Mate 1OOi, ARC Mate ARC Mate100i, M-6i A06B-6076-H105

S-420i A06B-6076-H001orA06B-6076-H101
120i, S-6, S-12, M-6, S-500, A-520i, M-400i A06B-6076-H002orA06B-6076-H102
M-16i, S-420i, S-500, S-700 A06B-6076-H003orA06B-6076-H103
S-700, M-400i, M-710i A06B-6076-H106
M-71 Oi, A-520i)
I
I
~~~
I
I
I
,o 0
Fig.5.1 (a) Outline Drawings
- 220 -
Fig. 5.1 (b) shows the terminal boards of servo amplifiers.
=========~=====i:- - - ~ 0
I
JS-axis
output
J6-axis
output
J3-axis
output
J4-axis
output
J1-axis
output
J2-axis
output
Regenerative
resistance
==== connection
}
0
- c::= ==
nNc::::::===:=::J
, ....,,, LrD
:=::J
-·-'
terminal
GNDterminal AC input
(200VAC to 230VAC)
Fig.5.1 (b) Terminal Boards of Servo Amplifiers
- 221 -
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.
0
0 456 WD
0
HC IJIJIJ iJ
0 IJIJIJ
0 123
0
0
0
0 @ LED
0
0
LD
0 0 0

Brake failure The brake control circuit in the seNo amplifier is defective.
Electromagnetic contactor This alarm is issued when a contact of the electromagnetic contactor
2
melt alarm melts.
The corresponding alarm is: SeNo 042 - MCAL alarm
SeNo amplifier overheat The thermostat in the seNo amplifier or transformer tripped or the
j
fuses F1 , F2 in the seNo amplifier blow.
Corresponding alarm
SeNo-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
SeNo-047 LVAL Alarm
The voltage being supplied to the control circuit (+5 V) is too low.
b
voltage
(LVSV) Corresponding alarm
SeNo-047 LVAL Alarm
- 222 -

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.
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. 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).
WO (LEDS)
[Description] A watch-dog alarm occurred on the servo amplifier
control PC board.
The WD LED (LED8) on the servo amplifier is lit.
- 223 -
5.2
POWER SUPPLY
IMODULE (PSM)
(A06B-6087-H115)
LED
FANUC
POWER SlFPI.. y IQllL£
!tm..;,~;;:;;;,tt'
DUO Hl:xiif l!W'
um HTPl~Ht=.
Hllll I•. 11-HIU

SUllNtt .mm 11u
~.~
+IV
OY
L1 L2 L3
A ..====
lYPI c::::::==~
====
!.....,LTD-·-!
@ 0 e @
Fig.(For M-410i)
- 224 -
Positions of test points
IR
IS
+24V
+SV
OV
Fig. Test Points
Test point Description

IR L 1 phase (R phase) current
IS L2 phase (S phase) current
+24V,
+SV, Control power
OV
- 225 -
Position of the status LED display
Position of the STATUS LEDs
STATUS
PIL
ALM [EJ
Status indication
No. on·3 Description

ott·~--
A lit LED is indicated by -.
PIL, power-on indication, does not light.

1. PIL
ALM
D Control power not turned on
PSM not ready.

2.
PIL
ALM
D Power is not being supplied to the main cir-
cuit.
Emergency stop state
PSM ready.
PIL
3.
ALM I :nn
o/_//_/ I
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 .
- 226 -
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
Fan alarm The cooling fan, built into the power supply module, is defective.
2
Overload alarm The temperature of the semiconductor heat sink is too high.
~
Low voltage alarm for DC link
y The DC voltage of the main circuit is too low.
In sufficieat charge alarm for The DC voltage of the main circuit has not reached the required level (insufficient
DC link
5 pre-charge).
Input power missing phase A phase of the input power is missing.

alarm
b
Overvoltage alarm for DC link The DC voltage of the main circuit is too high.
l
Hardware error alarm 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.
- 227 -
5.3
SERVO AMPLIFIER Servo amplifier module (SVM) (A06B-6079-H103) for M-410i
MODULE (SVM) (A06B-6079-H104) for S-450
(A06B-6079-H206) for S-450
1111111
-= I=
I=
I=
=
..___ 1111111 \ ~ ~ -
- 228 -
Servo amplifier module (SVM) (A06B-6079-Hl01)
...,. lc:::JI
..... lc:::JI
~· lc:::JI
2rrJttt:::Jlll
!Pi'lDll
- 229 -
Servo amplifier module (SVM) (A06B-6079-H106)
... llLJll
•••llLJDI
.... [D]J
111•[0]]
c:::::J . .
~
""\.
~ Ll
[JI
rnrn ~ ~
QI [II
- ~~ A ~ W"
- 230 -
Servo amplifier module (SVM) (A06B-6079-H208, H207)
- 231 -
(1) Setting
BATTERY
Elsi
B_js2
IAf F2
[ill;&A
C=:J
CllAll8E +24V
I
To make a setting, remove the jumper plug
L using a tool such as a pair of long-nosed
pliers.
JX!i rnCJ~I
JX1A l~CJ~I
JX18 rnCJ
~d l~CJ1
~d2 l~CJ
~1 rnCJ I
mirrnCJ~I
~"V 1 rnCJ~I
~~ ~11P l~CJ~I
Name Setting Description

S1 Open These setting pin are used for internal circuit.
These setting pin must not be changed.
S2 Short
- 232 -
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-<:ircuit 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.
IPM alarm An error was detected in the IPM of a 1 -axis amplifier or the L-axis IPM of a
B
(HCL) 2-axis amplifier.
g
IPM alarm An error was detected in the M-axis IPM of a 2-axis amplifier.
(HCM)
IPMalarm An error was detected in the L-axis and M-axis IPMs of a 2-axis amplifier.
(HCLM)
5
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
- 233 -
5. SERVO AMPLIFIERS MAINTENANCE B--80525E/04
Interface of supply module and servo amplifier module terminal unit
TBI
~
~
::1s1Jail~
illt:. LI
Lt;·
L'
l ::
TB2
TB2 TB2
UM VM WM PE
UL VL WL PE
0 0
- 234 -
5.4
SERVO AMPLIFIER
(A06B-6066-H006)
Servo amplifier (A06B-6066-H006)
" " >

~~'°
~~i;o
LED
No fuse braker Terminal unit Tl
==
= ===
= = ==
====
=
= =
= = = ==
====
=
= ==
= = = ==
====
=
= =
===
= ====
====
= =
==== ====
= ==
=
===== ====
= ==
- 235 -
Servo amplifier (A06B-6066-H008)
I
0
LED
No fuse braker
Terminal unit Tl
c:::::::::J ===:J c:::::::::J

c:::::::::J ===:J c:::::::::J c:::::::::J
c:::::::::J =
=
= =
c:::::::::J ===:J c:::::::::J
====i= =
= ==
= =
=
= ===:J =
= = =
= = =
=
=
=
===:J
===:J =
= ==
= ===
=
=
=
===:J
===:J =
= =
= =
= =
=
=
===:J
=
===:J c:::::::::J
===:J
= =
=== =
0
~-~ 'v=='
11 111 ~
11 111 'v=='
11 11
11 111 'v=='
0
II__~ ~
- 236 -
Interface of the Servo-Amplifier Terminal Block

The following figure shows the terminal box of the servo amplifier.
{A06B-6066-H006)
(A06B-6066-H008)
0
Tl l PE (G) 1 PE (G)
Tl
13 LlC ..._ 2 LI (R) 2 LI( Rl
..._ 3 L2(S)
14 LZC
13 LIC
Lf 3
L2 (5)
15 Tiil 4 L3(T)
[ Tl
14 L2C
Lf 4
L3(T)
16 TH2 5 JOOA 5 !OOA

15 THI
[ 17
RC 6 1008
[ 16 TH2
6 1008
18 RI 1 MCI 7 MCI
17 RC
g
19 RE MC2
[ 18 RI
8 MC2
9 u 9 u
19 RE
10 y
10 v
24 FAHi
11 'f
11 w
25 FAN2
12 G 0 12 G
One-axis servo amplifier
Fig.5.2 Servo-Amplifier Terminal Block
- 237 -
5. SERVO AMPLIFIERS MAINTENANCE 8-80525E/04
Interface of the Serv~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
(200 to 230 VAC)
3 L2 (S)
4 L3 (T)
5 100A Emergency-stop input
(100 VAC)
6 1008
7 MC1 Magnetic contactor break con- (Note 4)
firmation signal
8 MC2
9 u Outputs to an AC motor
10 v
11 w
12 G Motor ground
13 L1C Control power inputs L 1 (R) and L1C, and L2 (S) and L2C are usually connected( note 1).
(200 to 230 VAC)
14 L2C
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 unit.
21 VL
22 WL
23 GL Motor ground
24 FAN1 Power for the cooling fan in Provided only for A06B-6066-H008(note 5).
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 L1C, as well
as L3 (T) and L2C are usually connected. To conform to the European standard, the European-version
R-J 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. For the
S-900, connect the regenerative discharge resistor of the regenerative discharge unit between the
terminals. Keep the RC and RI terminals connected.
4. These terminals output the state signal of the contact used for checking whether power is supplied to the
servo amplifier. The output signal is the contact-b signal of the magnetic contactor, which controls the
power supplied to the main circuit of the servo amplifier. When power is not supplied to the main circuit,
the on signal is output.
Rating: 24 VDC, current between 10 mA and 0.3 A inclusive.
5. To use a separate regenerative discharge unit, connect the power pins of the cooling fan of the unit to these
terminals.
- 238 -
Alarm LED Display

An alarm is displayed on a seven-segment LED display.
Overvoltage alarm The DC power voltage of the main circuit of the servo amplifier is too high.
(HV)
Alarm message: Error code - 044
I
Low voltage alarm for The control power voltage (+5 V) of the servo amplifier is too low.
control power
(LV5V)
2 Alarm message: Error code - 047
Low voltage alarm for The DC power voltage of the main circuit of the servo amplifier is too low.
~
DC link
(LVDC) Alarm message: Error code - 047
y
Regenerative control The short-period regenerative discharge energy is high. This occurs when the regenera-
circuit alarm tive discharge circuit is defective.
(DCSW)
Over regenerative dis- The avera~e regenerative discharge energy is high. This occurs when acceleration/de-
5
charge alarm celeration 1s applied frequently.
(DCOH) When the overheat signal of the transformer is connected, this alarm is issued if the
transformer overheats.
For the A06B-6066--H008, if the fuse for the fan blows, this alarm is issued.

Amplifier over heating The thermostat of the servo amplifier was activated.
(OH)
b Alarm message: Error code - 049
Deposition of magnet- A deposit is present on a contact of the magnetic contactor of the servo amplifier.
l
ic contactor
(MCC) Alarm message: Error code - 042
Overcarrent alarm An excessively high current was detected in the main circuit of the one-axis servo ampli-
B
(HCL) tier or the L-axis main circuit of the two-axis servo amplifier.
Overcarrent alarm An excessively high current was detected in the M-axis main circuit of the two-axis ser-
(HCM)
g vo amplifier.
Overcarrent alarm An excessively high current was detected in the L- and M-axis main circuits of the two--
b
(HCLM) axis servo amplifier.
Amplifier The magnetic contactor of the servo amplifier is open. The motor is not ready to operate.
NOT READY
-
Amplifier READY The magnetic contactor of the servo amplifier is closed. The motor is ready to run.
D
Circuit Breaker
The circuit breaker opens if a current exceeding the rated operation
current of the breaker is detected in the servo amplifier. When the
circuit breaker is open, close it.
- 239 -
5.5
SERVO AMPLIFIER
Servo amplifier unit (A06B-6089-H106)
UNIT
(A06B-6089-H106)
0 0
0
Et
LED
No fuse braker
Terminal unit Tl
0 0
- 240 -
Servo amplifier unit (A06B-6089-H104, H105)
~~mm ~~~~m
~m~~~ mmm No fuse braker
~m~~~ mmm -
At. SERVO UNIT
cm series
~mm~mmm
~mm~mmm LED
~mm~ ~~~~m
- 241 -
Servo amplifier unit (A06B-6089-H206, H208)
~mm~ ~mml
~mm~ m~m[ No fuse braker
~m~~~ m~m~
ll'IUIUD
AC SERVO UlllT
ca:lseries
~~~~~~ m~m~
m~~m ~~m~~ LED
m~~m ~~m~~
- 242 -
Setting
OFF ON
Switch
v
~
~
4
3
2
1
-tON
EJ
0 0
0 0
0 0
Set the switch as follows

1 ON
2 OFF
3 ON (In case of A06B-6089-H106, set switch OFF)
4 ON (In case of A06B-6089-H106, set switch OFF)
- 243 -
Interface of the Servo-Amplifier Unit Terminal Block

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

2 L 1 (R) AC power input
(200 to 230 VAC)
3 L2 ($)
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 L 1 (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 unit.
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 L1C, as well
as L3 (T) and L2C are usually connected. R-J 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.
- 244 -
Type LED indication Description

Overvoltage alarm This alarm is issued when the DC voltage of the main circuit power supply unit is abnor-
(HV) mallyhigh.
Control power supply This alarm 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)
j mally low. This alarm 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 time
- 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
- 245 -

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
alarm (HCM)
g This alarm is issued when an abnormally high current flows through the motor of the
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

(IPMM)
g• This alarm is issued when the intelligent power module (IPM) of the M-axis detects an
alarm.(*1)
UM-axis IPM alarm This alarm is issued when the intelligent power modules (IPMs) of the L-axis and M-axis
(IPMLM)
b• detect an alarm.(*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 unit is set to
off, the DC link undervoltage alarm (LVDC) is issued.
- 246 -
In the normal operating mode, the seven-segment LED on the front of the
servo amplifier provides the indications below.
Amplifier not ready This indicates that the servo amplifier unit is not ready to drive the motor.
-
Amplifier ready This indicates that the servo amplifier unit is ready to drive the motor.
- 247 -
6. SETTING AND ADJUSTING

THE POWER SUPPLY MAINTENANCE B-80525E/04
6
SETTING AND ADJUSTING THE POWER SUPPLY
The power supply is factory-set for operation. Usually, the user need not
set or adjust it.
This chapter describes settings and adjustment required if a defective
power supply unit is replaced.
- 248 -

B-80525E/04 MAINTENANCE THE POWER SUPPLY
6.1
BLOCK DIAGRAM OF
THE POWER SUPPLY
Trans former Servo amplifier

210VAC I r--
][
: Amplifier
Power input of Circuit I I CNI
200 to 575VAC breaker
1,1
L
210VAC
Supply voltage to the transformer:

200 to 575 VAC
rl JRVI
j{ CN6
Power supply untt

Robot
,__;-----<f~ n
w
CP2
Eo~
0
[
Fan
CP3 h
- _l_ w @
+24E,+24V~ 0+24V : Brake I
~
~+15V,+5V CP
-15V 6
I--"-'--'- 0+24E Battery
......, e
~
- VBAT CP8
I :~
~

PC boar
I
CRRl5
n-
D
µ End
CRR20 h effector
I I
µ
CRF3
-{ JRF2 CRF4 n+5V

u
Main CPU PC board
JRF2 h+24E +5V

w
;:I JRVI n+24V. +I 5V. --- I 5V +5V
w
r
~-
CRMIO n+24E Process input/output

u PC board
JOIA h+5V
w
CRSI n+24V
w
~ Teach pendant
f-W>> > JRMIO n+24V

<( "<t "<t LO > LO
Operator's panel
COC\JC\J-LO-
>++++I
u
Fig.6.1 (a) Block Diagram of the Power Supply (i cabinet)
- 249 -

MCC Servo amplifie1

Trans former
lAC2 I OV
l
Power input of
200 to 575VAC
Circuit
breaker T
][ AC210V
ACIOOV

200 to 575 VAC
Fan
@
Po~~ n Robot
u
CP2 n
u
- [ _L
CP3
D
+24E, +24V CP 5 o+24V
Motor
Brake
~ +15V,+5V CP
-15V
6
- - 0+24E
Pulse
Battery coder.
~
I
VBAT CP8 I
.....,I
End
PCooco=
0
effector
lloc90V
µ
CRR15n
r'
µ
r JRF2
t--
CRFI n+5V
L LJ
~JRVI
Main CPU PC ooard
JRF2 1+24E +5V

_J
~IT
JRVI l-15V +5V
,_ _J
CRMIO 1+24E
Process input/output I
PC board
u
JDIA 1+5V
_J
Teach pendant
CRSI 1+24V
_J
I
1-W>> > JRMIO 1+24V
<C"<t"<tLO>LO
en C\I C\I - LO - _J Operator's panel
>++++I I
Fig.6.1 (b) Block Diagram of the Power Supply (B-Cabinet)
- 250 -

Servo amplifier
Trans former
~-----o-~-Am~plifier
lAC21 OV
Power input of Circuit0---0-- IAC2 I ov
200 to 575VAC breake ] [ IAC 1oov

200 to 575 VAC
~o:~~r-----;==~~=.-------t~ Robot
CP2 f::t----ol @
-=[ CP3f:: l '-----+----iMoto
---;::: ~f::+24V ~--+----t Brak
~0+24E ~+--_,Puls
od
CP81-1------1 1--~
1
_ VBAT
Emergency stop control ~----t] End

,,. "~~ .... effector
r' CRRl5~
,_,1---1---~
CRF3
---{~ ~01-+=5~V-+------+-~
Conversion printed
boarjL' ~1loc9o
~µrD=C~9=0~V----~
~JRVI
Main CPU PC board
JRF211+24E +5V
_J
1->->--I
-~=
,_
~l-15V
_J
+5V
CRM I 0 ll-+-"2""4""'E_ _ _ _ _ _ _ __, ProcessinpuVoutput I

_J PC board
~J1-+~5~V------------~
Teach pendant I
__Q§j_J1-+~2~4~V------------~
1-W>> >
<"<t"<tl.O>l.O JRMIOJ1-+~2~4~V----------------1
a:J(\JC\J-1.0- Operator's panel I
>+ + + + t
Fig.6.1 (c) Block Diagram of the Power Supply (5-900)
- 251 -

6.2 (i cabinet)
Select a transformer and tap according to the supply voltage. Select a
SELECTING transformer tap such that the supply voltage is +10% to -15% of the
TRANSFORMER induced voltage.
TAPS Supply voltage Specification Transformer specification
500 to 575 A80L-0026-0016
A05B-2350-H260
440 to 480 A80L-0024-0015
380 to 415 A80L-0026-0014
A05B-235o-H261
220 to 240 A80L-0024-0013
380 to400 A80L-0026-0015
A05B-2350-H262
200 to 220 A80L-0024-0014
Transformer
Mounting locations of transformer
Voltage setting tap Core
Structure of transformer
- 252 -

Connect the tap according to the supply voltage.
L I A o->:i"f*-"1-k*-7------..,
(1) H260 L I B n-"=-"'---="'-"'-'-----<
L2A e>--»_,,_,,.----"f-*"""'"'...,.._,>--~
L2B o-===--="'-"'-'---"f----<
L3A e>-7--7*---'T"'*'T---ir---..,
L3B o--=t-"'-"'---="'-"'-~~---<
Input voltage: 500-575V

Connect the cable from the circuit breaker to side A.
Input voltage: 44o-480V
Connect the cable from the circuit breaker to side B. \ERMINAL BLOCK
t::.;220/240V
(2) H261 LI : ::38QL4 I 5Y
GI
~;
t::.;220/240V I
~: : ::38QL4 I5Y
!::.;220/240V
~: I
~: : ::380/4 I 5V
Input voltage: 220-240
G1-L2, G2-L3, G3-L1
~:
Input voltage: 38o-415
G1-G2-G3 ~
TERMINAL BLOCK
!::.;200/220V
(3)H262 LI : :V380L400Y
GI
~;
t::.;200/220V I
~:
L 2 : Y · 380/ 400V
G2 OV
t::.;200/220V
L3 : Y · 380/ 400V I
Input voltage: 200-220

G1-L2, G2-L3, G3-L 1
G3 OV ~:
~
Input voltage: 38o-400
G1-G2-G3
TERMINAL BLOCK
- 253 -

(B-cabinet)
Connect taps so that the supply voltage ranges from -15% to +10%,
relative to the tap voltage.
Transformer
+ + +
•
i•i•i•i•i•I•
BB
.. ....
EEEI
I I 0
+1 I-~ ~1-1-~ ~i·F ~~I• I
@@@ EJ +
I 3 5
I I I I
i·i· i~ 111·l•i:1i•1;• I• 5•i• :•
I I
...
+ + +
(ARC Mate 100, ARC Mate 120, ARC Mate 100i, ARC Mate 120i, 5--6, S-12, 5-6i,
M-16i, S-420, S-500, S-700, S-SOO, S-900, M-500i, M-400i, M-710i, A-520)
575v..,.,..----,,
550V ~----t I
+ t1 I + 500V 0 ¥ - - - 1 1
480V 1>*---11
0
[ n_ Y 460V OT----11
240V/4 I 5V O.it---11
220V /380V D - ' - - - - - 1 1
.c.L i a • ~11~11~ ~ OV01t--~
.o.lo,___~~___,IL__---'~~ E g~g~ ~:::;:J====~

500V o - t i - - - - 1 1
'[ ETEJ D 480V o-t<-----11
460V o+'t---11
+ i~hhi:si-i+i•i•i-i=i•icl-iooia v •-- "" + 240V I 4 I 5V o-til!!'"----, I
!~4.........,,.~~. . . ~
220V /380V t>-""~---11,
I
~--~,~~-~,~@-~,~~-~r IOllOllO ovo-r--~,
g• 1• i· ;.;.. c• i11 ls i• =·iii laia =· 575V a+.--~,

550V u - r . - - - - 1 1
500V o-"'5;,,_---11
480V ~'f-"--11
460V 0"'11r---l I
240V/4 I 5V ~'f----11
220V /380V o-~---11
+ + +
(S-450,M-410i)
Connection of taps on the primary coil Connectio

Supply voltage
L1 L2 L3 Connection line ntype
220 7 15 23 7-24, 15-8,23-16 !!..
240 6 14 22 6-24, 14-8,22-16
380 7 15 23
415 6 14 22
460 5 13 21
y
480 4 12 20 8-16-24
500 3 11 19
550 2 10 18
575 1 9 17
- 254 -

6.3 (a) Checking fuses Fl to F5

CHECKING THE LINE Check that the ratings of fuses Fl to F5 are as specified.
(b) Checking voltages
FILTER UNIT AND
When the line filter unit or transformer is replaced, check the
TRANSFORMER following voltages at the locations shown below. A high voltage is
applied to the line filter unit and transformer. Be careful not to touch
them when checking the voltages.
DJ Voltages between terminals 1 and 3, 1 and 5, and 3 and 5 of
magnetic contactor ALC (voltages: 210 VAC, supplied to the
servo amplifier)
[2] Voltage between terminals 43 and 44 of the terminal block
(voltage: 220 VAC, supplied to the control unit)
[J] Voltage between terminals 41 and 42 of the terminal block
(voltage: 100 VAC, supplied to the servo amplifier)
Line filter unit

+ + +
....
I
+ 1~1.1.i.i;l.~p'~~~ Go
H
EJ +
G
EJ
+ +
[l] [ZJ
Transformer
+ + +
•
BG~
+ +
Fig.6.3 (a) B-cabinet: ARC Mate 100, ARC Mate 120, ARC Mate 100i, ARC Mate 120i, ~. S-12, M-6i,
M-16i, 5-420i, 5-500, S-700, 5-800, 5-900, M-500, M-400i, M-710i, A-520i
- 255 -

(B-Cabinet : S-450, M-41 Oi)
Transformer
AC reactor
+ + +
88 0
0$0$ l"lnlnl
+ +
ITl
Fig.6.3 {b) Checking the line unit and transformer
- 256 -

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

CHECKING THE Table 6.4 Rating of the Power Supply Unit
POWER SUPPLY
Maximum
UNIT Output Rated voltage Tolerance Remarks
rated current
+5V +5V ±3% 25.6A
+15V +15V ±5% 0.5A
-15V -15V ±5% 0.7A
+24V +24V ±10% 2.0A
+24E +24E ±10% 2.5A

Power supply unit: A16B-1212-0871
Figs. 6.4( a) and 6.4(b) show the interface and block diagram of the power
supply unit respectively.
- 257 -
!'>
-Hn
Im
m~
CPI ""C-
oz
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:CZ
I ~ I ttlj (/) 0
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NUii DI -co
CP2 (Bl-B3) ""C c...
CP7 1.10 l~·~r
CP3 (Al-A3) !:(~
-I
Bl B2 B3
~[ z
G)
i.~ F1: RI SI GI
.I""l.
!!
cg 57
7 .5A fuse for
~~... Al A2 A3
I I6 ! I £0
11~ I cm-1 ~ I56 AC input
i:n I~ .-- ,_ 1
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R2 82 G2
Ill • L ,+5'{_,_ " ~~
--
5'
96
95[
r:::: -:
: :J
]36
35
~B
S' · .-ov' • . CPS
IATilllY CIATTDY
Battery cover~
tml fml~I
82 + 15 22
;.n 83gr;~23
CD 81 21
0 g_("\ 'J() Battery
N BA
V1
00
...
- ~ I~
z
=
CD )>
PIL:
"tJ Green LED for
z
0 CP4
indicating the AC I I~
...~ power supply status Bl B2 B3
(JI ..,._
PIL.-o
c ALM: r; ... AL FA FB
'1::1
'1::1 Red LED for
-< indicating an alarm Al A2 A3
c:
:I r.:L.11: ON OFF COM
;::;: , - 1·• .•
'fDJ]Im
F4: CP5 (Bl-B3)
5A fuse for +24E CP6 (Al-A3)
I+ +II--- f'.... F3: Bl B2 B3

0 r=--=
fuse for +24V - +24V ov
5A -
(Slow blow)
~
(After the battery
cover is removed)
Al I A2
A3 I1
+24E OV II
0
(]I
N
(]I
~
..,..
(]1
i
+24E
-,--
~
BLOCK +24E
DIAGRAM I L::::RI
I :1 R2
AC
I L::::~~ OUTPUT +24V
t
IFg~ +15V
py1il ~ ov
Fl
.R '~; -15V
.,, I EJ' 111 11 ~11 I H5
ca· r -
a, 1~~G_I_
~ IS ~L._JL.J DC
~ OUTPUT
L
1
CD H3
0n IG I +5V
~ I
0 I AC INPUT I
m·
I I s::
IQ
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I H6 1
6
iil I ~----BAT +
N 3 I AL-
Vl 'L.__(----BAT-
I I~
l.O 0 HI---~ z
I )>
'::t'
-.. TEST-+
z
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CD I~----~
L _ _ _ _ _ _ _ l.J
"O
I - I Im
-, LO- L =!::._ _ _ _ _ _ _ _ _ 1 _ _ - .J
~
CD
...(/) _ _ _ _ _ _J
c
"'C
"'C
-<
c: ........,f-+-__,-EN
:I
;:::;: ~
____ _J c~~~ CJ)
,-------,. OFF----+~-+----. m
H 11 --i ~
I Iz
I
m G>
"'ti)>
CONNECTION TEST
HI TEST LO LEVEL I oz
0 <:WKl +4 5V I
:EO
ml>
0 0 0 +5 ov :co
<:WKl 0 +5 5V
I L ___________ _ (/) c....
L _ _ _ _ _ _ .J
cc
"'ti (/)
"'ti ::::l
rZ
~ (j)
7. REPLACING A UNIT MAINTENANCE B-80525E/04
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.
[2) 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).
[3] Remove the front top cover.
- 260 -
B-80525E/04 MAINTENANCE 7. REPLACING A UNIT
• Rear top cover

[I] Loosen the screws and remove the side brackets which secure the top
covers.
[2] Loosen the knurled screws and remove the rear louver.
[3] Loosen the three knurled screws which secure the rear top cover.
@] Remove the rear top cover.
[jJ
- 261 -
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: A05B-2316-C105 (3-slot backplane printed circuit

Replacing the board)
A05B-2316-C107 (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.
- 262 -
Backplane
circuit
(~)
Nuts or screws (depending on the cabinet)
i cabinet M5 nuts A30L-001~050#M5
B cabinet M5 screws A6-SW2NA-5X12S
Fig.7.1.1 (a) Replacing the Backplane Printed Circuit Board
- 263 -
Main CPU P.C board
I:=.:.:.. ::I ~~ H DI
] \ I [
Battery
{A98L-0031-0012)
Fig.7.1.1 (b) Connection of Battery
- 264 -
B--80525E/04 MAINTENANCE 7. REPLACING A UNIT
7.1.2
Replacing the Power (a) Tum the power off and remove the cable from the power supply
unit or printed circuit board to be replaced.
Supply Unit or a
(b) Hold the handles at the top and bottom of the front panel of the
Printed Circuit Board power supply unit or printed circuit board. The latches of the
on the Backplane 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
Main CPU printed circuit board A 168-3200-0040
Process inpuUoutput printed circuit
A16B-2201-0470, 0472, 0480
board
Additional axis control printed cir-
A 168-2202-0820
cuit board
Main CPU printed circuit board (NOTE 1)
Power supply unit (NOTE2)

Precess inpuUoutput printed circuit board CA,
CB or DA or additional axis control printed
circuit board (If five slots are provided on the
backplane, the process 1/0 printed circuit
board and additional axis control printed circuit
board can be mounted simultaneously.)
I i-, I
I I I'
I I J
I I I
I I I
I I
I I
I I
I I
I I
I
I(
Fig.7.1.2 Replacing the Power Supply Unit and Printed Circuit Board on the Backplane Printed Circuit Board
- 265 -
7.1.3 Specification: A16B-3200--0230

Replacing the (a) Open the operation box door, then disconnect the cables from the
process 1/0 printed circuit board.
process 1/0 EA
(b) Remove the two MS huts which secure the process 1/0 printed
printed circuit board circuit board, then replace the board.
It
\ MS nut (x 2)
A30L-0010-0050#M5
7.2
REPLACING A ( 1) Move the latches at both ends of the module socket toward the
outside. The spring of the contacttilts 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.
- 266 -
Fig.7.2 (a)
Pin 1
Fig.7.2 (b)
Fig.7.2 (c)
- 267 -
~._ _. _sh-ort_ _.~l,._ -=-L-ong___.l

Fit the recess on the
module over the lab
in the module socket.
Fig.7.2 (d)
Mounting locations of the modules
o>
SPI
CJ
~
o~
II!!!'
~I
I
_C_M_O_S_m-od_u_le---------,11
Flush ROM module I DRAM module el •

I
I Axis module (J1, J2) I
I Axis module (J3, J4) I
I Axis module (JS. J6) I
0 0 0
0 0 0
0 0 0
Main CPU printed

circuit board
Fig.7.2 (e) Mounting locations of the modules
Name Specification
Axis module A20B-2902-0060or
A20B-2902-0070
Flush ROM module A20B-2902-0370
A20B-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
- 268 -
~0525E/04 MAINTENANCE 7. REPLACING A UNIT
7.3 To replace the distributed I/O (Model B) interface unit, perform the
following steps:
REPLACING THE 1/0
DJ Unplug the cables from the upper left comer of the interface module.
UNIT MODEL B
[2] Unplug the cables from the bracket of the interface module adapter
INTERFACE UNIT plate.
[J] 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.
ffi] Remove the nuts holding the interface module to the adapter plate
and remove the module from the plate.
llil Install the new interface module by performing these steps in reverse
order.
Mounting location of 1/0 unit model B interface unit
(i cabinet)
IDllOI ~~~~~~~~
IDDD
lllillJI
~~~~~~~~
Mounting hole
g ~~~~~~~~
1/0 unit model B interface unit

(with metal mounting plate)
Fig.7.3 (a) Replacing 1/0 unit MODEL B Interface unit
- 269 -
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.7.3 (b) Replacing 1/0 unit MODEL B Interface unit
- 270 -
7.4
REPLACING THE
INPUT/OUTPUT UNIT
OF MODEL A
7.4.1
Replacing the Base [I) Remove the I/O modules from the base unit.
Unit of the C2:I Loosen the upper two mounting screws.
Input/Output Unit of [] Remove the lower two mounting screws and replace the base unit.
Model A Ordering code: A03B-0807-J002
M4 screw (4 pieces)
i;;;a.-1;;;;t- ~-i;;;;,.-i;;;;;;z-i;;;;,.-
/
/
/
•/[~~~~~
Fig.7.4.1 Replacing the Base Unit of the Input/Output Unit of Model A
- 271 -
7.4.2 An interface module and input/output module can be easily installed in

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

Module IT! Turn off and lock out the controller.
[2] Disconnect the signal and power cables from the interface module.
[3] Press the latch on the bottom of the module and rotate the module
toward you and up.
Installing the Interface

Module IT! 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.
[3] Rotate the module downward until the latch engages.
@] Reconnect the signal and power cables to the interface module.
Removing an 1/0 Module

IT! Turn off and lock out the controller.
[2] Remove the wiring harness block.(See Fig.7.4.2.)
(a) Lift the latch at the lower left comer of the module window.
(b) Rotate the block toward you and down.
[3] press the latch on the bottom of the module and rotate the module
toward you and up.(See Fig.7.4.2.)
Installing an 1/0 Module

IT! 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.
---t!!ll-
0
Fig.7.4.2 Replacing the module
- 272 -
7.5 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.SMM WIDE
AND 7.SMM HIGH.)
7.5.1
The DIN Rail is in the DJ 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.
[2] Remove the screws holding the retainer plates to the unit and remove
the retainer plates.
[] Slide the unit upward and lift it out of the DIN rail.
Metal support tor direct installation

DIN rail or installation on the DIN rail
(b) (b)
Basic unit
I
0
I
(a) (a)
\ _ _ Metal support tor installation on the DIN rail _ _ /
To install a distributed I/O(Model B)unit mounted on a DIN rail,perform

the following steps:
DJ Hook the lower tabs of the 1/0 unit mounting brackets over the lower
lip of the DIN rail.
[2] Lay the 1/0 unit in the DIN rail.
[] Slide the 1/0 unit downward. The upper tabs of the mounting
brackets will engage the upper lip of the DIN rail.
@] Position the retainer plates over the mounting brackets and install the
screws.
[fil Reconnect the wiring harness.
- 273 -
7.6 (i cabinet)
Ordering code
REPLACING THE
Ordering code
TRANSFORMER Supply voltage Machine for transformer
ARC Mate 100, ARC Mate 120,
ARC Mate 120i, S-6, S-12,
500 to 575 A80L-0026-0016
M-16i, S-420i, S-500, S-700,
A-520i, S-710i, M-400i
440to 480 M-410i ABOL-0026-0016#8
ARC Mate 100i, M-6i A80L-0024-0015
380to 415 A80L-0026-0014
M-16i, S-420i, S-500, S-700,
A-520i, M-710i, M-400i
220 to 240 M-410i A80L-0026-0014#8
ARC Mate 100i, M-6i A80L-0024-0013
380 to 400 ABOL-0026-0015
M-16i, S-420i, S-500, S-700,
A-520i, M- 710i, M-400i
200 to 220 M-410i A80L-0026-0015#8
ARC Mate 100i, M-6i A80L-0024-0014
Supply voltage Machine Ordering code

for line filter
200to 220 ARC Mate 1OOi, M-6i A81 L-0001-0137
[TI Lock out and tag out power to the robot.

[2] Disconnect the cables connecting the controller to the robot.
ral 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.
@] Remove the front module of the controller by disengaging the four

latches.
[fil Disconnect the cable from the voltage setting tap.
[ill Remove the voltage setting tap and its plate from the cabinet.
[l] Remove the nuts securing the transformer.
llil Remove the transformer.
- 274 -
Transformer
Fig.7.6 (a) Mounting location of transformer (1/2)
Voltage setting tap M6 nut and ground washer
M6 nut
Fig.7.6 (a) Mounting location of transformer (2/2)
(B cabinet)
Table7.6 Specifications of Line Filter Unit and Transformer (B cabinet)
Unit Applicable robot model Specification No.

All models A81L--0001--0128
S-800, M-500 A81 L--0001--0112
Line filter unit
8-450 A81L--0001--0130
M-410i (8-cabinet) A81L--0001--0129
A80L--0026--0010#D
8-420i, S-500 or
M-710i, M-400i A80L--0026--0013#B
(Note1)
ARC Mate 120, S-700,
S-12, A-520i,
A80L--0024--0010#F
Transformer ARC Mate 100i, ARC Mate
120i, M-6i, M-16i
ARC Mate 100, S-6 A80L--0022--0007#D
S-800, M-500 A80L--0026--0010#A
8-450 A80L--0026--0018
M-41 Oi (8-cabinet) A80L--0026--0017
A81 L--0001--0112 (Main cabinet)
Line filter unit S-900 (Note2) A81 L--0001--0116
(Additional cabinet)
- 275 -
Unit Applicable robot model Specification No.

A81L-0026-0010#A
(Main cabinet)
Transformer S-900 (Note2)
A81 L-0024-0011
(Additional cabinet)
NOTE
1 Input voltage: 220, 380, 400, 415, 460, 480, 500, or 575 V for
A80L-0026-0010#D
220, 380, 480, or 575 V for A80L-0026-0013#B
2 In case of S-900, Line filter unit or Transformer is installed in
both of Main locker and Additional locker.
Specifications: See Table 7 .6.

[]] Tum off and lock out the controller.
[2J Remove the acrylic covers from the transformer and ALC relay.
[1] Disconnect the wiring harnesses and ground wire from the
transformer.
@] Disconnect the three wires from the bottom of the ALC relay.
[fil 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.
[ID Reconnect the wires and harnesses.
[1J Reinstall the acrylic covers.
Eight MS mounting screws
Fig.7.6 {b) Replacing the Line Filter Unit or Transformer
- 276 -
7.7 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-400i, M-710i,
REPLACING A
A-520i
SERVO AMPLIFIER Ordering code : A06B-6076-H001 to HOOS or A06B-6076-H101 to
H106
ITl 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.
[2J Remove the four mounting nuts from the servo amplifier.
[3] Lift the servo amplifier off of the studs and out of the cabinet.
- 277 -
For S-450 or M-410i

[II Disconnect all wires,cables,and harnesses from the servo amplifier.
[2] Remove the mounting screws from the servo amplifier.
[] Remove the servo amplifier from the cabinet.
ni
bf~
EEEE
/ /
Power supply module Servo module (1) Servo module (2)
Power supply module

Robot model Drawing No.
M-410i A06B--6087-H115
S-450 A06B--6077-H111
Servo module (1)

M-410i A06B--6079-H106
S-450 A06B--6079-H206
A06B--6079-H207
- 278 -
Servo module (2)

M-410i A06B-6079-H103
S-450 A06B-6079-H101 or
A06B-6079-H104
ForS-800,S-900,:M:-500
DJ Disconnect all wires,cables,and harnesses from the servo amplifier.
[ZJ Remove the mounting screws from the servo amplifier.
(3) Remove the servo amplifier from the cabinet.
/ /
ef
/ ef
/
A06B-6066-H008 A06B-6066-H006
A06B-6089-H106 A06B-6089-H 104
A06B-6089-H105
A06B-6089-H206
A06B-6089-H208
- 279 -
7.8 Ordering code : See follwing table

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
A05B-2350-C029 English 1/0 Unit Model A and Model B can be mounted.
A05B-2350-C023 1/0 Unit Model B can be mounted.

Japanese
A05B-2350-C026 1/0 Unit Model A and Model B can be mounted.
A05B-2350-C037 English Only for ARC Mate 1OOi

A05B-2350-C038 Japanese Only for ARC Mate 1OOi
,..rzJ.___ _ _--1/@J
o~'----~V
Operator's box (option)
D /
o/
e e
\ M5 nuts (4pieces)
A30L-0010-0050#M5
- 280 -
Replacing the operator's panel

Specifications: A05B-2351-C020 (panel with Japanese legends)
A05B-2351-C021 (panel with English legends)
(a) Disconnect the cable connected to the operator panel
(b) Remove the six nuts securing the panel, then replace the panel.
(c) When only the operator-panel printed circuit board is to be
replaced, replace it together with the attached metal sheet.
(d) Disconnect the cable connected to the operator-panel printed
circuit board. Remove the four nuts securing the metal sheet,
then replace the board.
'f-- --- ------

\;;--=££B_.::... ____ _
aggbl g
"r - - - Q-'-0. -Q. -Q. -
,,,
I I
I I I
,,, 000~
I 1I bJ bJ iJ ·~
I II
Operator's panel (rear)
Four M4 nuts
A30L-0010-0050#M4
- 281 -
7.9 Ordering code: See Table 7.9.

REPLACING THE After removing the cable from the teach pendant, replace the teach
pendant.
TEACH PENDANT
OD DD 0 DO
0000000
0
oDoDOOO
0000000
0000000
0000000
DDDDDOO
DDDDOOO
ODDO
Fig.7.9 Replacing the Teach Pendant
Table7.9 Ordering Codes for the Teach Pendants

Ordering code Use Remarks
A05B-2301-C300 Spot welding English
A05B-2301-C301 Material handling
A05B-2301-C302 Arc welding
A05B-2301-C303 Sealing
A05B-2301-C305 General use
A05B-2301-C310 Spot welding Japanese
A05B-2301-C311 Material handling
A05B-2301-C312 Arc welding
A05B-2301-C313 Sealing
A05B-2301-C315 General use
- 282 -
7.10 Ordering code: A90L-0001-0378 (for a two-slot rack, one for one unit)
A90L-OOO 1-0385#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
printed circuit 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 .9 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
printed circuit 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.
- 283 -
(3)
(4)~
Fan motor
I
I
I
I
I
Cable I
I
I
\//
,.,....,.,.... \
,.,. . ,.,. . ,.,. . Ee(
Connector
Back plane
Fig.7.10 Replacing the Fan Motor
- 284 -
7.11 When a fuse inside the control unit has blown, troubleshoot, take a proper
corrective action, and replace the fuse.
REPLACEMENT OF
FUSES
7.11.1 Fl, F2, F3: Fuses for input voltage

F4, F5: Fuses for 100 VAC
Transformer, line filter
unit Fuse No. Model Rating Specification
F1,F2,F3 ARC Mate 120, S-12, S-420i,
S-500, S-700, 8-800, S-900,
M-71 Oi, ARC Mate 1OOi, ARC Mate 30A A60L--0001--0358#JSIF-30
120i, M-6i, M-16i, S-450, M-410i,
M-500, M-400i
ARC Mate 100, ARC Mate 100i,
20A A60L--0001--0042#JSl-20
s-6
F4,F5 S-420i, S-500, S-800, ARC Mate
120, ARC Mate 120i, S-12, S-700,
S-900 ARC Mate 1OOi, M-6i, SA A60L--0001-0101#P450H
M-16i, M-710i, M-500, M-400i,
S-450, M-410i
ARC Mate 100, s-6, A-520i 3.5A A60L--0001--0101#P435H
(B-cabinet: ARC Mate 100, ARC Mate 120, ARC Mate 100i, ARC Mate 120i, s-6, S-12, M-6i, M-16i, S-420i, S-500, S-700, S-900,
8-800, M-500, M-710i, A-520i) Fuse Fuse Fuse
( FI F2 F3 Fl F2 F3
Transformer
Line filter
(B-cabinet: S-450, M-41 Oi)
Fuse Fuse Fuse Fuse
Transformer AC reactor
NOTE
Turn off the main breaker before replacing a fuse.
Fig.7.11 Replacing Fuses on Transformer/Line Filter Unit
- 285 -
If a fuse blows in the control unit, examine the cause and take action to
eliminate the cause. Then replace the fuse.
7.11.2 FUSEl For detecting a ground on the thermostat

Fl,F2 For protecting a servo amplifier internal circuit
Servo Amplifier
Fuse No. Rated current Ordering code
FUSE1 0.3A A60L-0001-0175#0.3A
F1, F2 2A A60L-0001-0245#GP20
Fuse1
5\@]
5WO
3\@]
3WO
Fuse F1 Fuse F2
Fig.7.11.2 Replacing a fuse
- 286 -
Power suplly module

Fl : Fuse for AC input
F1 2A A60L-0001-0295
F2 2A A60L-0001-GP20
7.11.3
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.
For M-410i
TB1 Tcharge-<mder-way LED
I
ForS-450
Recharge-under-way LED =
(2) Remove the face plate.
ForM-410i Face plate
~
t
/
D
D
Remove the face ~ c
plate by inserting
the tip of a flat-
blade screwdriv- c
er at the hooks
(six) on the face
plate. c
- 287 -
ForS-450 Face plate

t
v
Remove the CJ =
face plate by
inserting the
~ cc = <>
tip of a tlat-
blade screw-
driver at the
<>
hooks (tour)
on the face
plate.
(3) Remove connector PCB.
For M-410i
Remove the self-tapping screws holding
down connector PCB, and shift it in the direc-
Ill tion indicated with an arrow (left) to remove

the printed-circuit board.
Connector PCB
(4) Remove the case
For M-410i
Screws (eight) Flange surface
\ 0 0
I Remove the screws
olllo Fan
(eight) fastening the
cases, and remove
the case by pulling it
off the flange sur-
~
Heat face.
sink Case
- 288 -
ForS-450
Case 1 -+
(chassis)
l~~~:~J: $l
Remove the screws fastening
:=JC the case and the screws (5 x
~C M4) holding down the terminal
:=JC board.
(5) Replace the fuses according to the figure below.
F1 c::i
I
Fig. 7.12 Locations of the Fuses
- 289 -
Servo module
F2 3.2A A60L-0001-0290#LM32C
F2 : For control power supply
..,.,..., Fuse2
I;]
!;Joa
c:;:i
I
I
- ·e_::
[=::J I I
... llLJDI
.... llLJDI
.... llLJDI
~·llLJDI
lm'llLJDI
2'1TllLJU
llLJll
!Pf' llLJll
wllLJll
L==::J
- 290 -
Servo amplifer
Fl Fuse for control power supply
Specification A60L-0001-0175#3.2A (A06B-6066-H006)-,
A60L-0001-0359 (A06B-6089-H104,
H105, H106, H206, H208)
F2,F3 Fuse for Fan motor (A06B-6066-H008 only)
Specification A60L-0001-0101# P405H
F2 Fuse for Fan motor (A06B-6089-H106 only)
Specification A60L-0001-0359
(A06Ekl066-H008)
0
,... -- -
I
Fuse F1
Fuse F1
Fuse F2 F3
(A06Ekl089-H106)
0
TI
./ F1
·· .. F2
0
--- --·~---
- 291 -
7. REPLACING A UNIT MAINTENANCE B-80S2SE/04
7.11.4 Fl : Fuse for AC input

Power Supply Unit F3: Fuse for +24V
F4 : Fuse for +24E
F1 7.SA A60L-0001-024S#GP7S
F3 SA A60L-0001-007S#S.O
F4 SA A60L-0001-0046#S.O
F1: 7.SA
fuse for AC input
-1I3
m
PIL F3 : SAS (slow-blow)
ALM- e fuse for +24V
r:•24V::+24E=
CPI CPl
F4:SA
I
1
1A IA fuse for +24E
Fig.7.11.4 Power Supply Unit
- 292 -

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 Oll'Pf
-
AI68- I212-09l!llm
""~
Fuse2
Fuse1
DOD
OIJ DD
0 0
- 293 -

FUSE : Fuse for brake power supply
FUSE 5A A60L-0001-0046#5.0
0 000
0
000
Fuse
A16B-1212-091 l l t m -
- 294 -
7.11.5 FUSEl : 2.0-A fuse for +24V

Process Input/Output Ordering code : A60L-0001-0046#2.0
Printed Circuit Boards
CA, CB, DA and EA
Fuse
Process input/output
printed circuit board CA, CB, and DA
D
D
Fuse
Do D
Process input/output printed circuit board EA
Fig.7.11.5 Replacing the Fuse of the Process Input/Output Printed Circuit

Board CA, CB, or DA
- 295 -
7.12 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 printed circuit 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
II
•
'-..
0
I")
0
I
'°
0
0
0 CRM9 CRMI 10
Fig.7.12 Printed Circuit Board for emergency stop board
- 296 -
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 offMCC (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, RL6 A58L-0001-0192#1472R
0 0 0
0 0
""'Pi
-
AI6B- I212-09l!lllm
N
LL
0:
--,
>
0:
--,
""'Pi
- 297 -
Conversion printed circuit board (S-900) A16B-1212-0910
0 000
0
000
Relay
Al6B-1212-091.,.__
RLl : For control brake

Ordering number A58L-0001-0192#1472R
- 298 -
7.13
REPLACING THE ( 1) Use a lithium battery (ordering drawing number: A98L-0031-0012).
BATTERY (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 printed circuit 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)
Fig.7.13 (a) Replacing the Battery (1)
(4) Remove the connector from the battery.
BATTERY Cable connector
Fig.7.13 (b) Replacing the Battery (2)
(5) Replace the battery and reconnect the connector.

(6) Install the battery case.
(7) Turn off the R-J2.
- 299 -
Ill CONNECTIONS
B-80525E/04 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-12.
- 303 -
2. BLOCK DIAGRAM CONNECTIONS B-80525E/04
2 BLOCK DIAGRAM
Fig. 2 is a block diagram of electrical interface connections with the R-J2.
R-J2
Pneumatic pressure source
I
I
~--1
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
I
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-422/485 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
- 304 -
B-80525E/04 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 UNITS
R-J2 Robot
Pulse coder
1---------+-
J 1/J2/J 3
1 - - - - - - - - - + - Pulse coder
J4/J5/J6
1-----+- Motor power

J1
Servo amplifier
terminal frame
1--~--+- Motor power
J4/J5/J6
Motor brake
1 - - - - - - - - - + - Limit switch
D--0 d~--E-nd_e_ff_e_ct_or-~
(Note) This cable is not included. It must be supplied by the customer.
Fig.3.1 (a) Mechanical Connection Diagram (i cabinet:ARC Mate100, ARC Mate120, ARC Mate 100i, ARC Mate 120i,
5-6, S-12, M-6i, M-16i, 5-420i, $-500, S-700, M-400i, M-710i, A-520i)
- 305 -
3. ELECTRICAL CONNECTIONS CONNECTIONS B-80525E/04
R-J2 Robot
CRFI
(Pulse coder signal)
t---~-----+--
Pulse coder
JI -J6 -----1
0--0 qL___ E_n_d_e_ff_ec_t_or_ __,
Note 1
CRMIO
(RDI/RDOl
CRMI I
(ROT)
Servo amplifier Motor power M1

r~---~----+--J4/5/6
terminal
Motor brake
Servo amplifier , >-----+--------+--Motor power M2
terminal J I /2/3
CRR5
(Brake control)
----Dd Welder
(Note 1) This cable is not included. It must be supplied by customer.

(Note 2) It is able to connect for 5-500 and S-700.
Fig.3.1 (b) Mechanical Connection Diagram (B cabinet: 5-420i/5-450/S-SOO/S-700/5-800/S-900/M-400i/M-710i)
R-J2 Robot
CRFI
t---~-----+--
Pulse coder
JI -J6 _ _ ___,
0--0 q'---__ E_n_d_e_ff_e_ct_o_r_ __,
CRMIO Note 1
(RDI/RDOl
CRMI I
(ROT)

terminal l }---------,,------+--JI -J6
Motor brake
CRR5
(Brake control)
Oc-----Note-2 ----10 q
~------~
Welder
(Note 1) This cable is not included. It must be supplied by customer.

(Note 2) It is able to connect for ARC Mate100, ARC Mate120 and ARC Mate 100i.
Fig.3.1 (c) Mechanical connection Diagram

(B cabinet: 5-6/S-12/ARC Mate100/ARC Mate120, ARC Mate 100i/M-6i, ARC Mate 120i/M-16i, A-520i)
- 306 -
R-J2 Robot
CRFI Pulse coder

JI -J6
CRMIO
CRDI/RDOl
CRMI I
o-oq
Note 1
End effector
(ROT) Limit switch
Motor power J1
Motor power J2
Servo amplifier
terminal frame
Motor power J3
Motor power J4
Motor brake
(Note 1) This cable is not included. It must be supplied by the customer.
Fig.3.1 (d) Mechanical Connection Diagram (M-410i)
- 307 -
R-J2 Robot
CRFI
1----~------+--
Pulse coder
.J I -.J5 ---<
D-0 q,___E_n_d_e_ff_ec_t_or-~
CRMIO Note 1
(RDI/RDO)
CRMI I
(ROT)
Lr---..,....-------r-.J2/4/5
terminal frame Motor brake
Servo amplifier L J - - - - - + - - - - - - - + - Motor power M2

terminal frame .J I /3
CRR5
(Brake control)
(Note 1) This cable is not included. It must be supplied by the customer.
Fig.3.1 (e) Mechanical Connection Diagram (M-500)
- 308 -
S-CS0525E/04 CONNECTIONS 3. ELECTRICAL CONNECTIONS
R-J2
CRS1
(Main CPU) Joq~_Teachp_endan~t
TEACH PENDANT ~~~~~~~~~~~~
(Operator's box) (Note 1)
~~~~-(_N_o_te_2_)~~~~---<0 Peripheral device

(Process 1/0)
Port 1
(Operator's box
~~~~-(N_m_e_s)~~~~-10rlL_~-F-AN_u_c~~~---'
Ll_ Handy File
or operator's panel)
~~~-(N_o_re_4_._N_ot_e_s_)~~~~orl_~~~~~~~~
y__ External device
(Main CPU)
Disconnect switch
or Braker q~~~-ln_p_u_t_p_ow~er~~~
PC board EX-ON Note4 External power
for operator's box EX-COM
(TBOP2) EX-OFF ON/OFF swich
PC board External emergency

for operator's box 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
(Note 2) For more infonnation about connection of peripheral devices,
see the description of the peripheral device interface in this manual.
(Note 3) This cable is provided with the FANUC Handy File.
(Note4) Not included. Must be supplied by the customer.
(Note 5) 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
- 309 -
3.2
EXTERNAL CABLE
WIRING DIAGRAM
3.2.1
Robot Connection (In case of combined type ARC Mate lOOi, M-6i, S-420i, M-710i)
Cables
ARC Mate 1OOi, M-6i,
M-710i, S-420i
Pulse coder
RDl/O.HBK
- 310 -
• Details of cable connection to the servo amplifier
R-J2
Robot
PC board for
PC board for ARC Mate 100i,
emergency
AMP
main CPU ARC Mate 120i,
stop control M-6i, M-16i,
S-420i, M-71 Oi
5U 6U CRF3
5V 6V
5W 6W
CN6 CRM10 CRF4
3U 4U G
3V 4V G
3W 4W G
1U 2U G
1V 2V G
1W 2W G
Pulse coder
J1/J2/J3
J4/J5/J6
RDl/O.HBK
Motor brake
White Motor power
J1M
Black
J2M
Green
J3M
J4M
J5M
J6M
Note) The motor power cables have connectors of different colors to

prevent incorrect connection.
Connector name Color

J1M White
J2M Black
J3M Green
J4M White
J5M Black
J6M Green
Fig.3.2.1 (a) Robot Connection Cables

(Combined type ARC Mate 100i, ARC Mate 120i, M-6i, M-16i, S-420i, M-710i)
- 311 -
(In case of separate type S-420i, M-710i)
Robots-420i, M-710i
....---
/ EARTH
/
Pulse coder
RDI/RDO
HBK
ROT
RP1
Motor power/brake
RM1
RM2
Main CPU PC board

CRM10
Servo amplifier
CN6
- 312 -
R-J2 RobotS-420i, M-71 Oi

PC board for PC board for
AMP emergency
main CPU sto control
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-----4" I [ RP1
(Pulse coder, RDl/RDO
HBK, ROT)
Motor power/brake
' - - - - - - - - - - - - - - 1 - - - - < i [ RM1
(J4M,J5M,J6M,BKJ
J6M
J5M
--+-----<l [ RM2
J4M (JIM,J2M,J3Ml
J3M
J2M
JIM


J1M White
J2M Black
J3M Green
J4M White
J5M Black
J6M Green
Fig.3.2.1 (b) Robot Connection Cable (Separate type 8-420i, M-710i)
- 313 -
(In case of separate type S-6, S-12, ARC MatelOO, ARC Mate120, ARC
Mate 120i, ARC Mate lOOi, M-6i, M-16i)
PC board for emergency

stop control
Robot
s-6
~ S-12
/ M-16i
/ ARC Mate 100
ARC Mate 120
ARC Mate 1OOi
ARC Mate 120i
EARTH
Pulse coder
RDI/RDO
HBK
ROT
RP1
Motor power/brake
RM1
Main CPU PC board

CRM10
Servo amplifier
CN6
- 314 -
R--J2 Robot
PC board for s-s
AMP (6--axis amplifier) PC board for
emergency S-12
main CPU sto control ARC Mate 100
ARC Mate 120
5U 6U CRF3 ARC Mate 120i
5V 6V ARC Mate 1OOi
5W 6W M-6i
CN6 CRMIO CRF4 M-16i
3U 4U G
3V 4V G
3W 4W G CRMI I
IU 2U G
IV 2V G
IW 2W G
Pulse coder
C RP1
HBK, ROT)
Motor power/brake
C RM1
(JIM,J2M,J3M,
J6M J4M,J5M,J6M,BKl
J5M
J4M
J3M
J2M
JIM


J1M White
J2M Black
J3M Green
J4M White
J5M Black
J6M Green
Fig.3.2.1 (c) Robot Connection Cable

(Separate type $-6, S-12, ARC Mate100, ARC Mate120, ARC Mate 100i, ARC Mate 120i, M-6i, M-16i)
- 315 -
(In case of separate type S-500)
Emergency stop
control PC board
CRF3 RobotS-500
CRF4
~ CRMI I
/ EARTH
/
Pulse coder
RDI/RDO
HBK
ROT
RP1
Motor power/brake
RM1
RM2
Servo amplifier
CN6
- 316 -
R-J2 RobotS-500
PC board for
AMP (6--axis amplifier) PC board for emergency
main CPU stop control
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
[ RP1
HBK, ROT)
Motor power/brake
[ RM1
(JIM,J3M,J4M,
J6M J5M,J6M,BK)
J5M
,.-+--I I [ RM2
J4M (J2Ml
J3M
J2M
JIM


J1M White
J2M Black
J3M Green
J4M White
J5M Black
J6M Green
Fig.3.2.1 (d) Robot Connection Cable (Separate type S-500)
- 317 -
(In case of separate type S-700)
Emergency stop
control PC board
CRF3 RobotS-700
,, CRF4
CRMI I
/ EARTH
/
Pulse coder
RDI/RDO
HBK
ROT
RP1
Motor power/brake
RM1
RM2
Main CPU PC board

CRM10
Servo amplifier
CN6
- 318 -
R-J2 RobotS-700
PC board for
AMP (6--axis amplifier) PC board for
emergency
main CPU stop control
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
[ P1
HBK, ROT)
Motor power/brake
c: Ml
(JIM,J3M,J4M,
J6M J5M,J6M,BK)
J5M
J4M
c: M2
(J2Ml
J3M
J2M
JIM


J1M White
J2M Black
J3M Green
J4M White
J5M Black
J6M Green
Fig.3.2.1 (e) Robot Connection Cable (Separate type S-700)
- 319 -
(In case of B cabinet/S-420i, M-710i)
Amplifier
CN6
Emergency stop control PC board

CRF1
CRM11
Main CPU PC board

CRM10 Robot5-420i, M-710i
Motor
power/brake
RM1
RM2
Pulse coder
RDI/RDO
HBK
ROT
RP1
1£----.....,...,..-..,~~~~~~"-=="Y-r~!l>'-~~~~~~~~~~-v EARTH
R-J2 Robot 5-420i, M-71 Oi

AMP (&-axis amplifier) emergency
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
~---~----+------! IL RP1
HBK, ROT)
Motor power/brake
C RM1
(J4M,J5M,J6M,BKl
~---~-----'-------------------+--~ i [ RM2
(JIM,J2M,J3M)
Fig.3.2.1 (f) Robot Connection Cable (B cabinet/$-420i/M-710i)
- 320 -
(In case of B cabinet S--6, S-12, ARC MatelOO, ARC Mate120, ARC
Mate lOOi, ARC Mate 120i, M-6i, M-16i)
Amplifier
CN6
CRF1
CRM11
Main CPU PC board Robot S-12, ARC Mate 100,

CRM10 ARC Mate 120, &-6, ARC Mate
100i, ARC Mate 120i, M-6i,
M-16i
Motor
power/brake
RMI
Pulse coder
RDI/RDO
HBK
ROT
RPI
~"""='"""""'-=~~"-="-="-=~:lt't-~!>'-~~~~~~~~~--uEARTH
R-J2 Robot
PC board for $-6
PC board for S-12
main CPU sto control ARC Mat e JOO
ARC Mat e 120
5U 6U CRF3 ARC Mate 1OOi,
5V 6V ARC Mate 120i,
5W 6W M-6i, M-16i
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 1[ RP1
HBK, ROT)
Motor power/brake
[ RM1
(JIM,J2M,J3M,
J4M,J5M,J6M,BKl
Fig.3.2.1 (g) Robot Connection Cable

(B cabinet/$-6, S-12, ARC Mate100, ARC Mate120, ARC Mate 100i, ARC Mate 120i, M-6i, M-16i)
- 321 -
(In case of B cabinet/S-500)
Amplifier
CN6

CRF1
CRM11
Main CPU PC board

CRM10
RobotS-500
Motor
power/brake
RM1
RM2
Pulse coder
RDI/RDO
HBK
ROT
RP1
i<---'""""'""""""'-"""--'~~~~~~on- i l f f l : , ' ' - - - - - - - - - - - - u EARTH
Pulse coder
'----------"----+-----; I [ RP1
(Pulse coder, ROI/ADO
HBK, ROT)
Motor power/brake
[ RM1
(J3M,J4M,J5M,
J6M,BK)
'-~~~_,_~~~-----'>~~~~~~~~~~~~~~~~--t-~--u[ RM2
(JIM,J2Ml
Fig.3.2.1 (h) Robot Connection Cable (B cabinet/5-500)
- 322 -
Amplifier
CN6
Emergency stop
control PC board
CRF1
CRM11
Main CPU PC board

CRM10
RobotS-700
Motor
power/brake
RM1
RM2
Pulse coder
ROI/ROD
HBK
ROT
RP1
l<'-_,,="="~=-=-~~'-=--="'-"'odt'-~ k l l l > - ' - - - - - - - - - - - - - - 0 EARTH
R-J2 RobotS-700

AMP (6-axis amplifier) emergency
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
'-------'~---+-----! I [ RP1
HBK, ROT)
Motor power/brake
[ RM1
(JIM,J3M,J4M,
J5M,J6M,BK)
'-------'~-------------------1------1 I [ RM2
(J2Ml
Fig.3.2.1 (i) Robot Connection Cable (B cabinet/S-700)
- 323 -
Emergency stop
Servo modules control PC board
CRR5, CRM11
Servo module4
Servo module3
Robots-BOO
Servo module2
Servo module1
Motor power/brake
RMI
RM2
Pulse coder
RDI/RDO
HBK
ROT
RPI
EARTH
Power supply module
R-J2 Robots-BOO
Servo module PC board for PC board for
emergency
1 2 3 4 5 main CPU stoo control
,--o2Q CRFI
,--<>9 ,--<>9 ,--<>9 ,--<>9 ,--<>9 ,--{]
~
ro21
r---<> I 0 ,.--<>I 0 r---<> I 0 r---<> I 0 ,.--<>I 0 CRMIO CRM I I
~
1<>22 ,--{]
'--<>I I ,.--<>I I '--<>I I r---<> I I ,.--<> I I
~
ro23 CRR5
r---<> I 2 ,.--<>I 2 '--<> 12 '--<> 12 ,.--<>I 2 r{]
Pulse coder
' '-
-[ RPI
HBK, ROT)
Motor power/brake
' '- \..
-[ RMI
(J4M,J5M,J6M,BK)
' ' [ RM2

(JIM,J2M,J3Ml
Fig.3.2.1 (j) Robot Connection Cable ($-800)
- 324 -
Robot
PC board PC board for S-900
AMP1 AMP2 Conversion
AMP3 AMP4 AMPS AMP6 for main
PC board
emergency
CPU stop control
CRF3
9 9 9 9 9 9
10 10 10 10 10 10
CRMIO CRR5
11 11 11 11 11 11
12 12 12 12 12 12
RP1
RBK
RM1
RM2
RM3
Fig.3.2.1 (k) Robot Connection Cable (B cabinet/S-900)
- 325 -
(In case of M-41 Oi)

Servo module4
Servo module3
Servo module2
Servo module1
Robot M-41 Oi
Emergency stop
control PC board
CRR5
CRM11
CRF1
R-J2 Robot M-41 Oi

emergency
1 2 3 4 main CPU stop control
,--oLJ r--<>U ,--oLJ ,--oU CRFI

,---[]
V-------0 v r--<>V V-------0 v V-------0 v
CRMIO CRMI I
V-------0 w r--<>W lr--<>W lr--<>W ,---[] ,---[]
lr-----<>PE r--<>PE v-------o PE v-------o p E CRR5
-0
Pulse coder
.JIP
I'.
- .J2P/.J3P
-- .J4P
RDI/RDO
ROT
I'-. .JIB
1'--o - .J2B/.J3B
\. ~
.JIM
\.
.J2M
' \.
.J3M
' .J4M/.J4B
Fig.3.2.1 (I) Robot Connection Cable (B cabinet/cabinet for M-41 Oi)
- 326 · -
(In case of B cabinet/M-500)
Emergency stop
Servo amplifier2 control PC board
CRR5, CRM11
Servo amplifier1
RobotM-500
Servo amplifier4
Servo amplifier3
Motor power/brake
RMI
RM2
Pulse coder
RDI/RDO
HBK
ROT
RPI
IL-<.,y,&~~~~~~~~-.lt't;Jj:~~============::_~~~--6 EARTH
Power supply module
R-J2 RobotM-500
Servo module PC board fo1 t'v ooard for
emergency
1 2 3 4 main CPU ston control
,-----020 CRFI
,--09 ,--09 r-<>9 r-<>9
c-- <>21 rD
~10 ,-oiO r-<>IO r-<>IO CRMIO CRMI I
r--<> I I ,-oi I
c-- <>22
r-<>ll r-<>ll rD ~
c-- <>23 CRR5
r-<>12 r-<>12 ,--<> 12 ,--<> 12 r{]
Pulse coder
\.
t.J [ RPI
HBK, ROT)
, Motor power/brake
" \.
\.
~ L RMI
(J2M,J4M,J5M,BK)
\..
" ~ C: RM2
(JIM,J3M)
Fig.3.2.1 (m) Robot Connection Cable (B cabinet/M-500)
- 327 -
(In case of A-520i)

CRF3
CRF4
;["""
CRM11 Robot A-520i
/
/
Pulse coder
RDI/O,HBK
Servo module CN6

R~2 Robot A-520i
AMP main CPU emergency
CRF3
CN6 CRMIO CRF4

3U 4U
3V 4V
3W 4W G
IU 2U G
IV 2V G
IW 2W G
Pulse coder
I'----+-----! JI I J2/ J3
'-----+------lJ4
'--------+------;ROI/O,HBK
' - - - - - - - - - - - - - - + - - - - - - 1 Motor power/brake
Note) Each connector used for a motor power cable has a different color for protection against wrong connection.
Connector Color Connector Color
JIM White J4M White
J2M Black
J3M Green
Fig.3.2.1 (n) Robot Connection Cable (B cabinet/A-520i)
- 328 -
(In case of Separate type A-520i)

CRF3 Robot S-420.
CRF4 I
~ CRM11
/ EARTH
/
Pulse coder
RDI/RDO
HBK
ROT
RPI
Motor power/brake
RMI
Servo module CN6

R-J2 Robot A-520i
AMP main CPU emergency
CRF3
CN6 CRMIO CRF4

3U 4U
3V 4V
3W 4W G CRMI I
IU 2U G
IV 2V G
IW 2W G
Pulse coder
' - - - - - " - - - - - 1 - - - - - f l n RP I
HBK, ROT)
'---------------,....-+--o d ~M~tor power/brake
CJ I M-J4M ,BK)
Each connector used for a motor power cable has a different colorfor protection against wrong connection.
JIM White J4M White
J2M Black
J3M Green
Fig.3.2.1 (o) Robot Connection Cable (Separate type A-520i)
- 329 -
(In case of A-520i)
Amplifier
CN6
Emergency stop
control PC board
CRF1
CRM11
Main CPU PC board

CRM10
Robot A-520i
Motor
power/brake
RMI
Pulse coder
RDI/RDO
HBK
ROT
RPI
~---=-"""'-==-~~~=--=--'=--""""~-t-lifl>"'"-~~~~~~~~~~-v EARTH
R-J2 Robot A-520i

PC board for PC board to
CRFI
CN6 CRMIO
3U 4U
3V 4V
3W 4W G CRMI I
IU 2U G
IV 2V G
IW 2W G
Pulse coder
----~---r---u [ RP1
HBK, ROT)
Motor power/brake
----~---~~---~------------r------;1[ RMI
(JIM-J4M,BK)
Fig.3.2.1 (p) Robot Connection Cable (B cabinet/A-520i)
- 330 -
(In case of Separate type M-400i)

FAN4 terminal Emergency stop control printed board
unit A, B CRF3 .
CRF 4 Robot M-4001
~ CRM11
/ EARTH
/ Pulse coder
RDl/RDO
HBK
ROT
RPI
Motor
power/brake
RMI
RM2
• Detail of cable connection to the servo amplifier
R-J2 Robot M-400i

Main CPU Emergency FAN4
AMP printed st.op control Terminal
board printed board
5U CRF3
5V
5W AB
CN6 CRM I 0 CRF4
3U 4U
3V 4V G
3W 4W G CRMI I
IU 2U G
IV 2V G
IW 2W G
Pulse coder
----~-----t--+-t I [ RP1
HBK, ROT)
Motor power/brake
-----------~~---+---< 1 [ RM1
(J3M, J4M, J5M, BK,
Fan)
~---+--1 I [ RM2
(J1M, J2M)
Note) Each connector used for a motor power cable has a different color for protection against wrong connection.
JIM White J4M White
J2M Black J5M Black
J3M Green
Fig.3.2.1 (q) Robot Connection Cable (Separated type M-400i)
- 331 -
(In case of B-cabinet/M-400i)
Amplifier Power supply unit

CN6 CP3
Emergency stop
control printed board
CRF1
CRM11

CRM10
Robot M-400i
Motor
power/brake
RMI
RM2
Pulse coder
RDl/RDO
HBK
ROT
RPI
~-=i=-.....:~-=~=-=~~~-="'Y-t-~'-------------v EARTH
R-J2 Robot M-400i

Main CPU Emergency Power
Amplifier (&-axis amplifier) printed of stop control supply
board printed board unit
5U CRFI
5V
5W
CN6 CRM/O CP3
3U 4U
3V 4V G
3W 4W G CRMI I
IU 2U G
IV 2V G
IW 2W G
Pulse coder
..____ _ __,,__ _ _-+---+---l I [ RP1
HBK, ROT)
Motor power/brake
'----+-~---t-~--~-----------~--+--u[ RM1
(J3M, J4M, J5M, BK,
Fan)
~---~---~~-------------------t---u[ RM2
(JIM,J2Ml
Fig.3.2.1 (r) Robot Connection Cable (B cabinet/M-400i)
- 332 -
(In case of S-450 (B-cabinet))

Servo module 1
Servo module 2
Servo module 4 CRR5
!..-.---+-+---------~....- CRM11
CRF1

CRM10
Additional axis control Robot&-450

printed board
JF7
Motor power/
brake
RMI
RM2
RM3
Pulse coder
RDI/RDO
HBK
ROT
RPI
12 I~~~~~~~~~~~~~~~~~§§~(!__=======-~ EARTH
RP2
R-J2 Robot&-450
Servo module Main CPU Emergency stop Additional
printed control printed axis control
I 2 3 4 board hn<>rd nrinted board
r--0UL r--0UL r--0UL r--OU CRFI

r--0UM r--0UM r--0UM
1-f--<>VL 1-f--<>VL v- 1-oVL
,---{]
l----<>V
r---oVM 1,--oVM l----<>VM CRMIO CRMI I
v-t-oWL
r--<>WM
v-1-oWL
r--<>WM
v- t-oWL
r--<>WM
1,--ow
,---{] ~
v-t-oPE v-f--<>PE 1-t-oPE 1,--oPE CRR5 JF7
r--<>PE r--<>PE 1,--opE
r--0 r--0
Pulse coder
'--'
c RPI (J1-J6)
HBK, ROT)
'--' C RP2 (J7)
Motor power/brake
'--' [ RM1 (J4, J5, J6)
'--' C RM2 (J1, J2, J3)
'--' C RM3 (J7)
Fig.3.2.1 (s) Robot Connection Cable (B-Cabinet/$-450)
- 333 -
(In case of M-410i (B-cabinet))
Servo module 1
Senk> module 3 CRR5
A""T---1--+--------,v- CRM11
CRF1

CRM10
Servo module 4 Robot M-41 Oi
Motor
power/brake
RMI
RM2
RM3
RBK
R-J2 Robot M-41 Oi

Servo module Main CPU Emergency sto~ Power
printed control printed supply
I 2 3 4 board board unit
,--<>LJ ,--<>LJ ,--<>LJ u CRFI

r-{]
1----oV 1----oV 1----oV ~v
CRMIO CRMI I
1---oW 1----oW ~w ,-----{]
1---oW
,--0
i---oPE 1---oPE v--<>PE 1---oPE CRR5 CP2
,------0 ,------0
Pulse coder
- RPI
(Pulse coder,
RDl/RDO, HBK, ROT)
Motor brake
~ RBK
Motor power
~ RMI (JI ,J4l
\._
~ RM2(J2)
\ -u RM3(J3)
Fig.3.2.1 (t) Robot Connection Cable (B-cabinet/M-410i)
- 334 -
~0525E/04 CONNECTIONS 3. ELECTRICAL CONNECTIONS
3.2.2 (1) Teach pendant

Teach Pendant Cable The robot connection cable is connected the operator's box as
follows. This figure applies to all device types.
Operator's box Port Teach pendant

(option) ''Teach pendanf'
0000000
0000000
00e 0080000
0000000
Kiil-o 0000000
0000000
§§§§BBB
o~
Teach pendant cable
Fig.3.2.2 (a) Teach Pendant Cable
- 335 -
Amplifier
Teach pendant
Main CPU PC board
CRM6
Teach pendant cable
Fig.3.2.2 (b) Teach Pendant Cable (In case of B cabinet)
3.2.3 Considering the robot power capacity and the circuit breaker capacity,
Connecting the Input connect the power supply whose voltage conforms to the installation
conditions to the terminal located above the circuit breaker.
Power Supply
Use a ground of class 3 or better. The resistance to ground must not exceed
lOOQ.
Be sure to ground the work table or jig used by an arc welding robot or
the like so that it can handle a large current.
Use a thick wire to withstand the maximum current used.
Selection of an input transformer tap is necessary depending on the input
voltage.
The tap is set 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 motor is driven by the PWM inverter system using the power
transistor bridge. If the servo amplifier is used without a transformer, a
high-frequency leakage current flows through the stray capacitance
between the ground and the motor coils, power cable, and amplifier. This
may cause the leakage-current circuit breaker or leakage-protection relay
installed in the path of the power supply to cut out.
- 336 -
Use the following leakage current circuit breaker for inverters to prevent
incorrect operation.
Example of Leakage Current Circuit Breaker for Inverters
Manufacture Type
Fuji Electric Co., Ltd. EGA series
SG A series
Hitachi, Ltd. ESIOOCtype
ES225C type
Matsushita Electric Works, Leakage current circuit breaker, C type
Ltd. Leakage current circuit breaker, KC type
Fig. 3.2.3 shows the cable connection.
Use a bar lead.

(Recommended type:
H6.0/20 or H6.0/26,
manufactured by Nihon Weissmuller)
Operator's box
Operator's panel (option)
Fig.3.2.3 (a) Input Power Supply Connection (Operator's box-disconnect switch)
- 337 -
Note) Always replace the cover

after completing the wiring.
Operator's panel
Breaker
Fig.3.2.3 (b) Input Power Supply Connection (Operator's box-breaker)
- 338 -
KOi
KOi

Fig.3.2.3 (c) Input Power Supply Connection (B cabinet)
- 339 -
KOi
/ /1
I V
Fig.3.2.3 (d) Input Power Supply Connection (M-410i)
- . 340 -
3.2.4 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
Panel pc board
Operator's panel
To external power
supply ON/OFF
Operator's box
To external power
supply ON/OFF
B---cabinet
- 341 -
Remove the jumper when the external

power supply ON/OFF switch is used.
.-----o~a
ON
COM
OFF
&(
Power ON Power OFF
External power supply ON/OFF switch
PC board for operator's panel
Use a contact conforming to the following: Voltage rating: 50 VDC, current: 100mA or more
The power supply on/off liming chart is as follows
EX-ON-EX-COM
r
\
l Fri
I I
___
:
_
EX-OFF-EX-COM
Power on
-------T-\---------\
~---------~
TON ;;::: 0.5 sec, TOFF ;;::: 0.5 sec, T OFF-ON ;;::: 5 sec
Fig.3.2.4 External Power Supply ON/OFF Switch Connection
- 342 -
3.2.5
Connecting the
External Emergency
Stop
Panel pc board
Operator's panel
Operator's box
Operator's panel
To external emergency
stop ON/OFF
~abinet
- 343 -
External emergency stop output
0 0
0 0
Panel pc board
Signal
EMGOUT1 J Description
Emergency stop output signals. The contact is open if an
emergency stop occurs or the power is turned off. The
contact is closed during normal operation.
Current, voltage
Rated contact:
250 VAC, 5-A resistor load
J
EMGOUTC
EMGOUT2 Emergency stop output signals. The contact is closed if an

emergency stop occurs or the power is turned off. The
contact is open during normal operation.
EMGOUTC
ESTOP1 Emergency stop output signals of the teach pendant and
ESTOP2
(Option)
J operator's panel. The contact is opened if which emergen-
cy stop switch is pressed. The contact is closed during
normal operation.
Rated contact:
24 VDC, 0.1-A resistor load
M4 screws are provided on the terminal. Use crimp terminals 9 mm wide or less.
Fig.3.2.5 Connecting the External Emergency Stop
- 344 -
External emergency stop input
After connecting an external emergency stop switch and safety fence door switch, be sure to check the operations
of those switches, the emergency stop switch on the operator's panel, and the emergency stop switch on the teach
pendant.
0 0
0 0
~~ Connected at the factory.

Remove the jumperprior to use.
r
Extemol eme<geocy •top •wUd>
~~~~~~~~--1.
:o
/
0
EMGINI
EMGIN2
Door switch on safety tense
FENCE I
~~----------"= FENCE2
• - FOR CONNECTION TO ORY CONTACTS ONLY.

- SERIOUS DAMAGE MAY RESULT IF CONNECTED
TO POWER SOURCE.
Use a contact rated at 250 V, 1O A or more on the printed circuit board for emergency stop control.
Signal Description Current, voltage
EMGIN1 J Connect the contacts of the external emergency stop switch to

these terminals. When using the contacts of a relay or contactor
instead of the switch, connect a spark killer to the coil of the relay or
Open and close of
24VDC 0.1A
EMGIN2 contactor, to suppress noise.
When these terminals are not used, jumper them.
These signals are used to stop the robot when the door on the safe-
FENCE'] ty fence is open.

While the deadman's switch on the teach pendant is pressed and Open and close of
the teach pendant enable switch is validated, these signals are 24VDC 0.1A
FENCE2 ignored and an emergency stop does not occur.
If these signals are not used, short these terminals.
M3 screws are provided on the terminal. Use crimp terminals 9 mm wide or less.
- 345 -
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
0 0
Connected at the factory.

Remove the jumperprior
to use.
Servo on input switch.
--+~----:o SYON I
· o SVON2
• - FOR CONNECTION TO DRY CONTACTS ONLY.

- SERIOUS DAMAGE 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.
- 346 -

~0525E/04 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 VO points
No. Name Drawing number Remarks
DI DO D/A AID
Process 1/0 printed circuit A05B-2300-J030 40 40 2 6 Backplane installation
1 board CA type (with welding inter-
face)
Process 1/0 printed circuit A05B-2300-J031 40 40 - - Backplane installation
2 board CB type (without welding in-
terface)
Process 1/0 printed circuit A05B-2300-J035 Note Note - - Backplane installation
3 board DA 80 80 type (without welding in-
terface)
Process 1/0 printed circuit A058-2300--J040 40 40 2 6 For ARC Mate 1OOi
board EA Operator's box installation
4
type (without welding in-
terface)
1/0 unit model A - Depending on a selected (Note 3)
5
1/0 model.
1/0 unit model B A058-2300--J001 Depending on a selected Interface unit
6
unit.
NOTE
1 Process 1/0 PC 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.
- 347 -

AND END EFFECTOR INTERFACES CONNECTIONS B-80525E/04
Operator's box Note) Some operator's boxes

(option) support the connection of
0 1/0 unit model A. For details,
-~ contact your FANUC
. o. ~ 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
Operator's box Process 1/0 EA
CRM2B
CRM2A
For peripheral device
- 348 -

B-80525E/04 CONNECTIONS AND END EFFECTOR INTERFACES
Main CPU PC board
Process 1/0 PC board

CA/CB/DA
--+«-+-----<+-+------ 1/0 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
Process 1/0 Printed Circuit board

Main CPU Printed Circuit board
Emergency stop control Printed Circuit board
Fig.4 (c) Locations of Peripheral Device Interfaces (Cabinet for M-410i)
- 349 -

4.1
PERIPHERAL
DEVICE INTERFACE
BLOCK DIAGRAM
4.1.1
When Process 1/0
Printed Circuit Board
CA, CB or EA is used
In case of i cabinet
Main CPU printed Process 1/0 printed circuit
circuit board board (CA/CB)
D
KSOA
DPeripheral device
J01------D
K10 CRM2A
JD1A JD4A
CRM2B
D
K50B
DPeripheral device
JD4B CRW1
D
K45
DWelding device
CRW2
D
CRWl and CRW2 are not provided for process I/O printed circuit board.
Process 1/0
CA/CB/DA
- 350 -

Cable Drawing
Name Remarks
number number
Process 1/0 A05B-235o-J R-J2 controller
K10 connection 100 internal cable
cable A
Peripheral de- A05B-235o-J Connected length :

vice 210 7m
connection Honda Tsushin,
Process 1/0 K50A cable 50,34pins : one to one
printed circuit K50B
board for CA K45 Peripheral de- A05B-235o-J Connected length :
vice 211 14m
cable 50,34pins : one to one
vice 200 7m
Process 1/0 cable 50pins : one to one
K50A
printed circuit
K50B Peripheral de- A05B-235o-J Connected length :
board for CB
vice 201 14m
cable 50pins : one to one
vice 240 7m
K50A cable 50pins : one to one
K50B Peripheral de- A05B-235o-J Connected length :
vice 241 14m
Process 1/0 cable 50pins : one to one
printed circuit
board for EA Welding de- A05B-235o-J Connected length :
vice connec- 250 7m
tion cable Honda Tsushin,
34pins
K45
Welding de- A05B-235o-J Connected length :
vice connec- 251 14m
tion cable Honda Tsushin,
34pins
- 351 -

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

printed rcuit board (CA/CB)
K50A
circuit board
CRM2A
D D
Peripheral device
JD1A
JD .JD4A
CRM2B
D K50B
D
Peripheral device
K45
.JD4B CRWJ
D K46
D
Welder
CRW2
D D
Analog signal input
Process 1/0 printed

circuit board (CA/CB)
o~--K_5_o_c___ D
Peripheral device
D K50D D
Peripheral device
(Note1) CRW1 and CRW2 are not provided for process 1/0 printed circuit board CB.
(Note2) In case of M-410i, process 1/0 is specified only one sheet.
- 352 -

Cable
Name Drawing number Remarks
number
K10 Process 1/0 connection cable A05B-230o-J013 Internal cable of R-J control unit
Internal cable of R-J control unit
K11 Process 1/0 connection cable A05B-230o-J014
For connecting additional PC board
Connected length : 7m
AOSB-2302-J 113
Honda Tsushin, 50pins : one to one
K50A
K50B Connected length : 14m
Peripheral device connecting cable AOSB-2302-J 114
K50C Honda Tsushin, 50pins : one to one
K50D
AOSB-2302-J 115
A05B-2302-J273 Connected length : 3m
A05B-2302-J274 Connected length : 6m
K45 Welder connecting cable
A05B-2302-J275
In case of Tig welding it is impossible to use
This cable is not included

K46 Peripheral device connecting cable
It must be supplied by customer
4.1.2
When Process 1/0
Printed Cricuit Board
DA is used

circuit board board (DA)
DD K50A
D
JDr----D[
K10 CRM2A Peripheral device
JD1A JD4A
CRM2B
DD K50B
D Peripheral device
[ JD4B CRM2C
JD K50C
D Peripheral device
CRM2D
JD K50D
D Peripheral device
- 353 -

(i cabinet)
To peripheral device
Cable Drawing Remarks

Name Group
number number
Process 1/0 A05B-2350- R-J2 controller
K10 connection PB1 J100 internal cable
cable A
Peripheral A05B-2350- Connected length :

Process device J220 7m
PC7
1/0 K50A connection Honda Tsushin,
printed K50B cable 50pins : one to one
circuit K50C Peripheral A05B-2350- Connected length :
board for K50D device J221 14m
DA PCS
cable 50pins : one to one
- 354 -

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

printed circuit board (DA)
circuit board CRM2A D
K50A
D Peripheral device
JD1A
OD D
K50B
K50C
D Peripheral device
D D Peripheral device
K500
K51A
CRM4B
D
K51B
D Peripheral device
Process 1/0 printed

circuit board (DA) K50E
CRM2A D D Peripheral device
K50F
CRM2B
CRM2C
D
K50G
K50H
D Peripheral device
CRM20
CRM4A
D
K51C
D Peripheral device
CRM4B
D
K510
D Peripheral device
(Note) In case of M-410i, process 1/0 is specified only one sheet.
Cable
number
K10 Process 1/0 connection cable A058-2300-J013 Internal cable of R-J control unit
K11 Process 1/0 connection cable A058-2300-J014
For connecting additional printed circuit board
A05B-2302-J113
K50 Connected length : 14m
A-H Peripheral device connecting cable A05B-2302-J114
Connected length: 30m
A05B-2302-J115
A05B-2302-J120
K51 Connected length : 14m
A-D Welder connection cable A058-2302-J121 Honda Tsushin, 20pins : one to one
A05B-2302-J122 Honda Tsushin, 20pins : one to one
- 355 -

4.1.3 In case of i cabinet

When 1/0 Unit Model A
is used
Main CPU Printed circuit

printed board
circuit board
TBOP3
+24V
ov
JD1A D JRM10
1/0 unit model A power

JD1A connection cable
1/0 unit model A

connection cable~
JD1A JD1B CP32

1/0 base unit
b
K54
Ql
c:
ca
c..
b
K54
~
0
ca
al
pO K54
D
Peripheral
device welder
K54
b
K54
b
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 1/0 unit mainframe.
Peripheral device connection Not included.
- - ----
cable Must be supplied by the customer.
- 356 -

In case of B cabinet/cabinet for M-4 lOi
Power
supply unit
CPS D Kl6
Main CPU
printed
circuit
board
JD1A
DD~l Kl5
<( co (\J
M
0 0 Q_
J J u
1/0 base unit
-
DD K54
D
DD K54
D
DD K54
D > Peripheral device
Welder
DD K54
D
DD K54
D ~
Refer to model A 1/0 manual for more details.
Cable
number
K15 1/0 unit model A connection cable ---- Attached to 1/0 unit mainframe

K16 1/0 unit model A connection cable ---- Attached to 1/0 unit mainframe
This cable is not included
K54 Peripheral device connecting cable ---- It must be supplied by customer
- 357 -

4.1.4 In case of i cabinet

When 1/0 Unit Model B
is used
In control unit
Main CPU
printed
circuit 1/0 unit model B
board Interface unit
JD1A
JD---0 JD1B
S1+
S1-
CRS7 Mechanical unit
end effector
S2+ CRS8A
D JD1A S2-
Power 24V S3+ CRS8B

supply unit ov S3-
CP6
Printed circuit TBOP3

board for +24V 0 (}-----------<..-------------,
operator's box OV
1/0 unit model B 24V
Basic unit OV
CRS9
S+ DI/DO
S2+ c Hr-----+-----< 1 S-
S2- FG
Peripheral
device
1/0 unit model B 24V
Basic unit OV
S+ DI/DO
S-
FG
In operator's box
Refer to model B 1/0 manual for more details.
Cable Remarks
Name Group Drawing number
number
- 1/0 unit model B connection cable - ---- R-J2 controller unit internal cable
- 1/0 unit model B connection cable - ---- R-J2 controller unit internal cable
Peripheral device connection Not included.
- - ----
cable Must be supplied by the customer
- 358 -

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

(a) Connect terminals S2+ and S2- of terminal block TBOP3 on the
panel PCB to terminals S+ and S- of the Model B, as shown
below.
(b) Connect terminals +24V and OV of terminal block TBOP3 on the
panel PCB to terminals +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)
M3terminal
FANUC
Panel printed board
1/0 unit model B M3terminal
- 359 -

In case of B cabinet/cabinet for M-41 Oi
- -
Internal control unit
Main CPU
printed
circuit 1/0 unit model B
board
Interface unit
JDIA 0---0[ JDIB SI+
SI-
S2+
Mechanical
unit end
effector
[ JOIA S2-
S3+ ) - - -
S3-
1/0 unit model B ~
Basic unit I
Power S4+
supply unit S4- ~ S+
I
DI/DC
s-
CP4 ) 24V FG J
ov I
24V 24V Periphe ral

ov ~
ov device
1/0 unit model B

1
Expanded unit I
DI/DC
I
J
- -
-
Peripheral
control 1/0 unit model B 1
I
Basic unit
I DI/DC
S+
s- I
FG J
24V Periphe ral

ov device
I I
1/0 unit model B ,l
Expanded unit ~
S+ DI/DC
) s- I
FG J
24V
ov
-
Cable
Name Group Drawing number Remarks
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
Peripheral device connection This cable is not included
K**
cable
- ---- It must be supplied by customer
- 360 -

4.1.5 (a) In case of cabinet i

When Two or more The following figure shows the connection when two or more process
1/0 printed circuit boards and 1/0 unit (model A or model B) are used.
Process 1/0 Printed
1 process 1/0 CA/CB/DAs and 1 1/0 unit model A or 1/0 unit model
Circuit Boards and 1/0 B can be installed in one cabinet, operator's box.
Unit {Model A or Model
B) are used
In controller
Main CPU
printed
circuit board Process 1/0 printed 110 unit model B
circutt board Interface untt
SI+ CRS7
JDIA JD4A JDIB SI-
S2+
CRS8A
JD4B JDIA S2-
Power 24V S3+ CRS8B

supply unit ov S3-
CP6
Printed circutt + V TBOP3

24
board for OV 00-----i..--------------~
operator's box
1/0 untt model B >
Basic unit ~~
1/0 unit model B >

Basic unit ~~
S+
s-
FG
N
I")
fl_
u
1/0 base unit
1/0 untt model A

OD
~====~
~=po
~=po
:=:=========:::
po
.__________,p D
- 361 -

(b) B cabinet and M-41 Oi cabinet

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

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

board (CA/CB/DA)
Power supply unit JD4A
JD4B
K15
CPS
1/0 unit model B JD1A JD1B CP32

K12 Interface unit
JD1B
Interface module
JD1A
1/0
,~ _ _,, +24V
OV
base
S+,S-,FG unit
S+, s-, 1/0 unit model B

FG basic unit
~---u+24V
ov
Cable
number
K12 Process 1/0 connection cable ---- For connecting additional pc board
others See 4.1.1 to 4.1.3
- 362 -

4.2 The peripheral device interlace can be used with combinations of process
1/0 PC boards CA, CB, DA and EA as well as 1/0 unit models A and B.
PERIPHERAL
Fig. 4.2 shows the combinations.
DEVICE INTERFACE
COMBINATION (a) i cabinet
[1-board]
Combination A Combination B Combination C Combination D
CA/CB/EA (40 points) DA (80 points) I I 110 unit model A I I 110 unit model B
[2-board combination]
Combination AC Combination AD Combination BC Combination BO
CA/CB (40 points) CA/CB (40 points) DA (80 points) DA (80 points)
+ + + +
1/0 unit model A 110 unit model B 110 unit model A 1/0 unit model B
Fig.4.2 Peripheral Device Interface Combination
(b) B cabinet, M410i cabinet
[1-board]
Combination C Combination D Combination E
I CA/CB (40 points) I ~I _o_A_ _ (_96_po_in_ts_)~ 110 unit model A

or model B
Combination CC Combination CE
CA/CB (40 points) CA/CB (40 points)

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

+ + +
CA/CB (40 points) DA
110 unit model A
(96 points) 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)
+ + +
110 unit model A 110 unit model A 110 unit model A
or model B or model B or model B
- 363 -

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
PRINTED CIRCUIT These signals are allocated to the process 1/0 printed circuit board
BOARD SIGNALS connected first when two or more printed boards are combined. (General
signals SDI/SDO are allocated to the second and the following process
1/0 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
- 364 -

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

(DI signals)
Connector
number
CRM2A-16 RSRB Robot service request
selection
CRM2A-29 PNSTROBE PNS strobe
CRM2A-30 PROD START Start of automatic
operation
CRM2A-31 SDI01 Peripheral device General signal
status
CRM2A-32 SDI02
CRM2B-1 SDI03
CRM2B-2 SDI04
CRM2B-3 SDI05
CRM2B-4 SDI06
CRM2B-5 SDI07
CRM2B-6 SDI08
CRM2B-7 SDI09
CRM2B-8 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
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
- 365 -

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

(DO signals)
Connector
number
CRM2A-44 BUSY During operation
CRM2A-45 ACK1 Robot service request
acceptance
SN01 Selected program Option
number
acceptance
number
acceptance
number
acceptance
number
CRM2A-21 ACKS Robot service request
acceptance
SNOS Selected program Option
number
acceptance
number
CRM2A-24 ACK? Robot service request
acceptance
number
acceptance
SNOB Selected program Option
number
CRM2A-26 SNACK Response signal to
PNS
CRM2A-27 RESERVED
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
- 366 -

Table4.3 Process VO Printed Circuit Board Signals (Continued)

(DI signals)
Connector
number
CRM2B-44 SD010 Reripheral device General signal
control signal
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
- 367 -

AND END EFFECTOR INTERFACES CONNECTIONS B-80S2SE/04
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 3S PROGRUN
20 ACK4/SN04
4 CSTOPI 36 PAUSED
21 ACKS/SNOS
s FAULT RESET
22 ACK6/SN06
37 COM-A1
6 START 38 HELD
23 COM-A4
7 HOME 39 FAULT
24 ACK7/SN07
8 ENBL 40 ATPERCH
9 RSR1/PNS1
2S
26
ACK8/SN08
SNACK
41 TPENBL JD D[ Peripheral
device A1
10 RSR2/PNS2 42 COM-A2
27 RESERVED
11 RSR3/PNS3 43 BATALM
28 COM-AS
12 RSR4/PNS4 44 BUSY
29 PNSTROBE
13 RSRS/PNSS 4S ACK1/SN01
14 30 PROD START
RSR6/PNS6 46 ACK2/SN02
31 SDI01
1S RSR7/PNS7 47 COM-A3
32 SDI02
16 RSR8/PNS8 48
17 ov 49 +24E
18 ov so +24E
Peripheral device control interface A2

CRM2B
1 SDI03 33 SD001
2 SDI04 34 SD002
19 SDI03
3 SDIOS 3S SD003
20 SDl14
4 SDI06 36 SD004
21 SDl1S
s SDI07
22 SDl16
37 COM-B1
6 SDI08 38 SDOOS
23 COM-B4
7 SDI09 39 SD006
24 SDl17
8 SDl10 40 SD007
9 SDl11
2S
26
SDl18
SDl19
41 SD008 OD D[ Peripheral
deviceA2
10 SDl12 42 COM-B2
27 SD20
11 SDl13 43 SD009
28 COM-BS
12 SDl14 44 SD010
29 SDl19
13 SDl1S 4S SD011
30 SDl20
14 SDl16 46 SD012
31 SDl21
1S SDl17 47 COM-B3
32 SDl22
16 SDl18 48
17 OV 49 +24E
18 OV so +24E
- 368 -

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

Type Specifications CRM2A CRM2B
CA A05B-2300-J030 0 0
CB A058-2300-J031 0 0
DA A05B-2300-J035 0 0
EA A05B-2300-J040 0 0
- 369 -

Control unit
CRM2C
1 SOl23 33 S0021
2 SOl24 34 S0022
19 S0033
3 SOl25 35 S0023
20 S0034
4 SOl26 36 S0024
21 S0035
5 SDl27 37 COM-C1
22 S0036
6 SOl28 38 S0025
23 COM-C4
7 SOl29 39 S0026
24 S0037
8 SOl30 40 S0027
9 SOl31
25
26
S0038
S0039
41 S0028 DD D[ Pripheral
deviceA3
10 SOl32 42 COM-C2
27 S0040
11 S0133 43 S0029
28 COM-C5
12 SOl34 44 S0030
29 SOl39
13 SOl35 45 S0031
30 SOl40
14 SOl36 46 S0032
31 SOl41
15 SOl37 47 COM-C3
32 SOl42
16 SOl38 48
17 OV 49 +24E
18 ov 50 +24E

CRM20
1 SOl43 33 S0041
2 SOl44 34 S0042
19 S0053
3 SOl45 35 S0043
20 S0054
4 SOl46 36 S0044
21 S0055
5 SOl47 37 COM-01
22 S0056
6 SOl48 38 S0045
23 COM-04
7 SOl49 39 SD046
24 S0057
8 SOl54 40 S0047
9 SOl51
25
26
S0058
S0059
41 S0048 OD D[ Pripheral
deviceA4
10 SOl52 42 COM-02
27 S0060
11 SOl53 43 S0049
28 COM-05
12 SOl54 44 S0050
29 SOl59
13 SOl55 45 S0051
30 SOl60
14 SOl56 46 S0052
31 SOl61
15 SOl57 47 COM-03
32 SOl62
16 SOl58 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 1/0 printed circuit board

Type Specifications CRM2C CRM2D
CA A05B-2300-J030
CB A05B-2300-J031
DA A05B-2300-J035 0 0
EA A05B-2300-J040
- 370 -

Control unit Connector pin No. Peripheral device

(peripheral device control interface A 1)
+24E
CRM2A (49,50)
Receiver circuit
*IMSTP------l RV
*HOLD------l RV
*SFSPD------l RV
CSTOP1------l RV
7TT
FAULT RESET RV
START RV
HOME RV
ENBL RV
RSR1/PNS1 RV
RSR2/PNS2 RV
RSR3/PNS3 RV
RSR4/PNS4 RV
RSR5/PNS5 RV
RSR6/PNS6 RV
RSR7/PNS7 RV
CRM2A 16
RSR8/PNS8 RV
PNSROBE RV
CRM2 30
PROD START RV
CRM2A 31
SDI01 RV
CRM2A 32
SDI02 RV
+24E
Lo B
A
Common setting
pin (ICOM1)
NOTE
This is a connection diagram for +24v common.
- 371 -


(peripheral device control interface A 1)
Receiver circuit LOAD

- ~I -
~RELAY 11 -
DV CRM2A (33)
I/
CM DEN BL
~ ~
CRM2A (34) 1 1
SYSRDY DV I I LOAD I
I CRM2A 135) 1 1
PROGRUN DV I I LOAD I
I CRM2Al36) 1
LOAD II
PAUSED DV I I
I CRM2A (38)
HELD DV I : LOAD:
I CRM2A (39)
FAULT DV I : LOAD:
I CRM2Al40l
ATPERCH DV I : LOAD:
I CRM2A (41) I LOAD I
TPENBL DV I I I
I CRM2A(43)
BATALM DV I : LOAD:
CRM2A (44)
BUSY DV : LOAD:
CRM2A (45)
ACK1/SN01 DV : LOAD:
CRM2A (46)
ACK2/SN02 DV : LOAD:
CRM2A 119)
ACK3/SN03 I DV : LOAD:
I CRM2A 120) 1 1
ACK4/SN04 I DV I LOAD I
I CRM2A (21) 1 1
I CRM2A (22)
ACK6/SN06 I DV : LOAD:
I CRM2A (24)
I CRM2A(25) I
ACK8/SN08 DV I LOAD I
I CRM2A 126),
SNACK I DV : LOAD:
CRM2A 127),
:LOAD~
I
RESERVED I DV
CRM2A(23,28,37,
42,47) '77>.
VD ®-----
J- OV +24V
+24 V regulated
power supply
- 372 -


(peripheral device control interface A2)
+24E
CRM2B (49,50)
Receiver circuit
SDI03 RV
SDI04 RV
SDIOS RV
SDI06 RV
SDI07 RV
SDI08 RV
SDI09 RV
SDl10 RV
SDl11 RV
SDl12 RV
SDl13 RV
SDl14 RV
SDl15 RV
SDl16 RV
SDl17 RV
SDl18 RV
CRM2B (29)
SDl19 RV
30
SDl20 RV
31
SDl21 RV
32
SDl22 RV
+24E
Lo B
A
Common setting
pin (ICOM2)
NOTE
This is a connection diagram for +24V common.
- 373 -

Control unit Peripheral device

Connector pin No. LOAD

- f;;;i -
~RELAY 11
I I CRM2B (33)
SD001 I DV I
~
~
I I CRM2B (34) 1 1
SD002 I DV I I
LOAD I
I I CRM2B {35) 1 1
SD003 I DV I I LOAD I
I I CRM2B (36) I LOAD I
SD004 I DV I I I
I I CRM2B (38)
SD005 I DV I : LOAD:
I I CRM2B 139)
I I CRM2B 140)
I I CRM2B (41)
I I CRM2B 143)
I I CRM2B (44)
I I CRM2B (45)
I I CRM2B (46)
I I CRM2B 119)
I I CRM2B 120) 1 1
I I CRM2B (21) 1 1
SD015 DV
I I I LOAD I
I I CRM2B (22)
SD016 DV I LOAD I
I I I I
I I CRM2B (24)
CRM2B (25)
SD018
I
I DV
I
I I LOAD I
I I CRM2B (26)
I I CRM2B (27)
CRM2A(23,28,37,
42,47)
-
""" @-+
J- ov +24V
+24 V regulated
power supply
- 374 -


Connector pin No.
+24E
CRM2C (49,50)
Receiver circuit
SDl23 - - - - - ; RV
so124------< RV
so12s------< RV
SDl26------< RV
so121------< RV
SDl28 - - - - - ; RV
SDl29 - - - - - ; RV
SDl30 - - - - - ; RV
so1s1------< RV
SDl32 - - - - - ; RV
so133------< RV
SDl34 RV
SDl35 - - - - - ; RV
SDl36 - - - - - ; RV
so1s1------< RV
SDl38 - - - - - ;
~-~
RV
SDl39 - - - - - ; RV
SDl40 RV
SDl41 RV
SDl42 - - - - - ; RV
+24E
Lo B , J------>----< , A
Common setting
pin (ICOM3)
NOTE
- 375 -



- f:;;I -
~RELAY 11 -
CRM2C (33)
SD021 DV
~ ~
I CRM2C(34}, 1
SD022 I DV I
LOAD II
I CRM2C (35),
SD023 I DV : LOAD:
I CRM2C 136)
SD024 I DV : LOAD:
I CRM2C (38)
SD025 I DV : LOAD:
I CRM2C 139)
SD026 I DV : LOAD:
I CRM2C (40), II LOAD 1
SD027 I DV I
I CRM2C (41)
SD028 I DV : LOAD:
I CRM2C 143) 1
LOAD II
SD029 I DV I
I CRM2C (44} 1
SD030 I DV II LOAD I
I CRM2C (45) I LOAD I

SD031 I DV I I
I CRM2C 146) 1 1
SD032 I DV I LOAD I
I CRM2C 119)
I I CRM2C (20)
I CRM2C 121)
SD035 DV I : LOAD I
CRM2C (22}
SD036 DV
I
I I LOAD I
I CRM2C (24) 1 1
SD037 DV I I LOAD I
I CRM2C 125)
SD038 DV I I LOAD I
I CRM2C (26) 1 1
SD039 DV I I LOAD I
CRM2C (27), I LOAD I
SD040 DV 1 I I
CRM2C(23,28,37,
42,47) /77>.
@-e-
J- """
ov
+24 V regulated
power supply
+24V
- 376 -


Connector pin No.
+24E
CRM2D (49,50)
Receiver circuit
so143----'._____RV
_ _,
so144----' RV
SDl4S----' RV
SDl46 -----i RV
SDl47 -----i RV
SDl4S----1 RV
SDl49----' RV
SDl40 - - - - - i RV
so1s1----I RV
SDl52 RV
SDl53 -----i RV
SDl54 RV
SDISS-------1 RV
SDl56----' RV
SDl57---~ RV
SDl58 RV
SDl59 RV
SDl60 RV
SDl61 RV
SD162---- RV
+24E
~ B ,,___'------',A
Common setting
pin (ICOM4)
NOTE
- 377 -



- t;.i -
~RELAY 11 -
CRM2D (33)
SD041 DV
~ ~
CRM2D (34)
I CRM2D 135) 1 1
I CRM2Dl36)
SD044 DV I : LOAD:
I CRM2D {38)
SD045 DV I : LOAD:
I CRM2D (39)
SD046 DV I : LOAD:
I CRM2D 140)
SD047 DV I : LOAD:
I CRM2D {41)
SD048 DV I : LOAD:
I CRM2D (43)
SD049 DV I : LOAD:
I CRM2D (44) 1 1
SD050 I DV I I
LOAD I
I CRM2D (45} I LOAD I
SD051 I DV I I I
I CRM2D 146) 1 1
SD052 DV I I LOAD I
I CRM2D (19)
I I CRM2D (20)
I CRM2D (21)
I CRM2D (22)
SD056 DV I I LOAD:
I I CRM2D (24)
SD057 DV I : LOAD:
I I CRM2D 125)
SD058 DV I LOAD:
I I CRM2D {26), 1 1
I I CRM2D 127) 1 1
SD060 I DV I I
LOAD I
CRM2D{23,28,37,
42,47) /77x
(@-+-
J-
~
ov +24V
+24 V regulated
power supply
- 378 -

4.4.2
Connection Between
the Mechanical Unit
and End Effector
Mechanical
unit EE
3 4
RD03 RD04
0-0 End effector
RD07 RD08
- 379 -

Connector pin No. End effector

Mechanical unit (end-effector interface)
~V EE(l7, 18, 19, 20)
+24V Pin for setting
~K ~nable or disable
Wrist breakage Receiver circuit

EE(?)
detection signal *HBK RV I
,.- Tfr .. EE(9)
RDil RV
... EE(lO)
I
Input signals
RDI2 RV T
indicating the EE(ll)
states of the
-< RDI3 RV .. I
I
end effector
RDI4 EE(12)
RV . l
EE(l5)
RDI5 RV .. l
EE(l6)
RDI6 RV ... I
EE(24)
RDI7 RV .. I
RV EE(l3)
'- RDI8 •• I
Pneumatic *PPABN EE(l4)
RV
pressure abnormal
+24V .
•• I
signal
LB Pin for swi~chi~
A
common signals
(RD ICOM)
DV EE(l) LOAD
,.-
~
~
RDOl
~ ~
EE(2)
RD02 DV I
LOAD I - -
Signals for EE(3)
controlling the ~ RD03 DV I LOAD I - -
end effector
DV EE(4)
RD04 I I LOAD I---"
EE(5)
RD05 DV LOAD f---<
EE(6)
RD06 I DV LOAD ~
EE(21)
RD07 DV LOAD I - -
EE(22)
RD08 DV LOAD I - -
'-
EE(8)
-Jr Jr
NOTE
1. This is a connection diagram for +24V common.
2. The connector pin numbers of the end effector depend on
the robot.
- 380 -

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 W005
06 WDI2
17
18
28 W006 00--0[ Welder
07 WDI3 29 W007
19 ov
08 WDI4
20 ov 30 woos
09 WDI5 31 WDI+
10 WDI6
21 ov 32 WDI-
11 WDI7
22 ov 33 +24E
12 WDIB 34 +24E
Analog input interface

CRW2
01 14 ADCH3
08 ADCH6
02 15 COMA03
09 CDMA06
03 16 ADCH3
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 A05B-2300-J030
CB A05B-2300-J031 0 0
DA A05B-2300-J035
EA A05B-2300-J040 0 0
Note1) Welder and peripheral device connection cable is option.
- 381 -

Control unit Welder

(Welding interface)
Connector pin number MS connector pin number
CRWI (I)
{ OACHI A
Welding voltage
command signal CRWI (2)
CAMDAI B The input impedance
shall be more than 3.3k.Q
high-pass filter shall be
CRW I (3)
{ OACH2 E provided.
Wire speed
command signal CRW I (4)
CAMDA2 F
CRWI ( 13)
J
Welding voltage { ADCHI
detection signal CRWI ( 14)
CAMADI K
Output signals
without ripples.
CRWI ( 15)
{ ADCH2 L
Welding current
detector signal CRWI ( 16)
CAMAD2 M
R=100Q or more
CRWI (31 l N
Wire soldering
detector signal { WDI+
WDI-
CRW I (32) p
e e
Welding power supply
- 382 -

Control unit Welder

(Welding interface)
DV LOAD
~
CRWI (23) R ,....__
Welding start WDOl
signal
l CRWI (24) s
~
Gas signal WD02 I DV I I LOAD f--
WD04 I CRW I (26) u
Wire inching
(positive) signal
DV I LOAD f--
Wire inching WD05 I CRW I (27) v
I DV LOAD f--
(negative) signal
ov CRW I ( I 9. 20 l a ~
ov CRW I ( 2 I • 22 l b
Iav +24
+24V regulated
n"r power supply
Receiver circuit
CRWI (6) d
Arc detection
signal
Gas shortage
WDI2
WDI3
RV
RV
.... I
CRWI (7) e
detection signal
Wire cut
...
AAA I
CRW I (8) f
detection signal
WDI4 RV ...
.. I
Cooling water
shortage detection WDI 5
signal
RV ...
CRWI (9)
I
CRWI ( 10)
g
h
-
Welding power
supplu abnomality
WDI6 RV ...
... I
signal
+24V
B A
Common swit~hin;---;J,-
set~in
l COM3)
CRWI ( 19,20) n
ov
CRWI (21,22) m
ov
TiT
Shield s
FG (cabinet ground)
7.T
- 383 -


(Analog input interface)
ADCH3
CRW2( 15)
CAMAD3
CRW2( 16)
ADCH4
CRW2( 17)
CAMAD4
Output signals without
ripples.
CRW2( 18)
ADCH5
CRW2C 19)
CAMAD5
CRW2(8)
ADCH6
CRW2(9)
CAMAD6
- 384 -

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
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
- 385 -

(2) Input signals in peripheral device interface A

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

Type Grounded voltage receiver
Rated input voltage Contact close
: +20 V to +28 V
Contact open
: 0Vto+4 V
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 nor 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 I/O printed circuit board CRM2
*IMSTP, *HOLD, *SFSD, CSTOPI, FAULT RESET, START,
HOME, ENBL, RSRl to RSR8, PNS 1 to PNS8, PNSTROBE,
PROD START, SDil to SDI22
- 386 -

4.5.2
End Effector Control (1) Output signals
Interface Example of connection
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
- 387 -

(2) Input signal

Example of connection
+24V
3.3kQ
+24V
~B
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 20ms
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 ; 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 the end effector control interface
RDil to RDI8, *HBK, *PPABN
- 388 -

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
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: 1 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 O. 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
- 389 -

(2) Digital input signal specifications for arc-welding interface
Example connection
+24VICOM
BA°J,_
3.3kn
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
TB: Chattering of 5 ms or less
Tc: 5to20 ms
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
- 390 -

(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 -t-
NOTE on use
NOTE
Output a signal with no ripple.
(Wire deposit detection: WDI+ and WDI-)
Example connection
Welder
--6--------l"l +
max.
+15V 85mA
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.
- 391 -

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)
6J 'o
Process 1/0 Peripheral
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
(MR20LFH) (MR20LMH)
G bI
Process 1/0 Peripheral
device
CRM4*
Honda Tsushin
MR20RMA Honda Tsushin's MR20RFH
Supplied with an ordered cable
- 392 -

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 1/0
CRWI
Japan Aviation Electronics
Industry Ltd.
MS3102A28-21 S
Honda Tsushin Japan Aviation Electronics
Standard position of guide key
MR34RFA Industry Ltd.
MS3108B28-21P
MS3057-16
- 393 -

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
CRWI
Operator's box Process 1/0 EA
CRM2B
CRM2A
rr---1'1
For peripheral device
Note : Tight the clamp with hand.

Metallic clamp Do not use pliers.
External shield
Shield plate
Noise protection: Remove a part of the sheath of a peripheral cable to expose the outside shield.
Secure the cable to the shield plate with the metallic clamp at the exposed position.
Fig.4.7.1 (a) Peripheral Device Cable Connection (i cabinet)
- 394 -

Process 1/0 printed circuit board

CA/CB/DA
1/0 unit model A

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

Do not use pliers.
Metallic clamp
External shield
Shield plate
Noise protection: Remove a part of the sheath of a peripheral cable to expose the outside shield.
Secure the cable to the shield plate with the metallic clamp at the exposed position.
Fig.4.7.1 (b) Peripheral Device Cable Connection (B cabinet)
- 395 -

4.7.2
Peripheral Device (1) Fig. 4.7.2 shows the connector for peripheral device cables A and B.
Cable Connector
.-- 1--
r'r\
u
·1 I
MR-50L
HONDA
I I
I. ( B)
A
( D)
Connector Applicable Dimensions

Remark
specifications interface A (B) c (D)
MR50LMH CRM2 67.9 73.5 44.8 18 Honda Tsushin Kogyo,
50 pins
MR20LMH CRM4 39.3 44.9 39.8 17 Honda Tsushin Kogyo,
20 pins
Symbol Name
[j] Connector cover
[2J Cable clamp screw
[3J Connector clamp spring
@) Connector clamp screw
[fil Connector 50 pins (male) MR50MH
20 pins (male) MR20MH
Fig.4.7.2 (a) Peripheral Device Cable Connector (Honda Tsushin Kogyo)
- 396 -

(2) Peripheral device connector
MR50RFH,MR20RFH
2-M2
B
A
Di men-
Connector Applicable sions Remark
specifications interface
A B
MR50RFH (CRM2) 61.4 56.4 Honda Tsushin Kogyo,
50 pins
MR20RFH (CRM4) 39.3 44.9 Honda Tsushin Kogyo,
20 pins
Symbol Name
ITl Connector clamp screw
[2J Screw 02.6_8
CT] Connector (MR50RFH)
(MR20RFH)
Fig.4.7.2 (b) Peripheral Device Connector (Honda Tsushin Kogyo)
- 397 -

4.7.3
End Effector Cable (1) Connector
Connector
A M30x1 E 033
B 63.0 F 11.2
c 54.5 G 24.7
D 9.6 to 15.0 (Inside diameter)
Manufactured by Daiichi Denshi Kogyo JMLP2524M
Fig.4.7.3 {a) Connector {Elbow type)
A M30x1 E 033
B 54.1 F 11.2
c 37.5 G 24.7
D 9.6 to 15.0 (Inside diameter)
Manufactured by Daiichi Denshi Kogyo JMLP2524M
Fig.4.7.3 {b) Connector {Straight type)
- 398 -

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 Configura- diameter
(mm) resistance current
(mm) ti on (mm)
(nlkm) (A)
50 A66L-0001-0042 01.05 7/0.18 1.5 012.5 106 1.6
AWG24
20 A66L-OOO 1-0041 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 Configura- diameter
(mm) resistance current
(mm) ti on (mm)
(nlkm) (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
- 399 -

4.8
QUICK CHANGE
(i-cabinet)
4.8.1 With R-J2, the cabinet is so structured that it can be divided into a front
General cabinet unit and rear cabinet unit to allow immediate control unit
replacement if a failure occurs. The front cabinet unit houses units such
as a servo amplifier and control printed circuit board. The rear cabinet
unit houses units such as a transformer and emergency stop control unit.
If a failure in the control unit cannot be located easily and requires a long
troubleshooting time before recovery, operation can be resumed in about
15 minutes (excluding a time required to back up data such as programs)
by replacing the front cabinet unit. This replacement operation is referred
to as quick change. (Note that if an alarm associated with the emergency
stop system is issued, the operator's box and emergency stop control unit
mounted in the rear cabinet unit must be checked first.)
Step 1: Start of work

Disconnect the cables connecting
the front and rear units.
Front cabinet unit Rear cabinet unit
Step 2: Separating the front unit from the rear unit

Remove the brackets joining the front
unit and rear unit, then pull out the front
cabinet unit toward you.
- 400 -

Step 3: Replacement unit installation

Install a replacement unit.
Replacement unit
Step 4: Cable connection and start-up

Connect the cables by reversing the pro-
cedure used to disconnect the cables,
then load the backup data for start-up.
- 401 -

4.8.2
Flowchart
Occurrence of failure
Back up contents of memory

if not backed up yet(*1)(*3).
Start quick change.
Prepare replacement unit.
]~-······
Remove faulty cabinet unit.
Install replacement unit.
Read memory of faulty cabinet

unit via memory card, for
example, into replacement unit.
(Refer to the description offile 1/0
in the o erator's manual. *3
Start up control unit.
NO Perform operation indicated in *2.
NO
Cables wired correctly?

Printed circuit board specification Perform work such as laying
s same as those of faulty cabinet cables neatly and storing used
unit? tools.
Memory read normally?
Restart control unit. If control unit

cannot be started yet, contact
FANUC service center.
End of quick change
- 402 -

NOTE
1 In backup operation, save all of the TPE program, system
files, and applications. Also save the options of position
registers and pallet registers, if included. For backup
operation, see *3 below, and also refer to the description of
file 1/0 in the operator's manual.
2 When the alarm "Servo -38 Pulse count mismatch" is
issued, take action according to the following procedure:
1 Display the system variable screen.
2 Set $MCR.$SPC_RESET to TRUE.
($MCR.$SPC_RESET is reset to FALSE immediately
after being set to TRUE, but this poses no problem.)
3 Set $DMR_GRP.$MASTER_DONE to TRUE.
4 Turn off the power.
3 Two types of external memory units are available; memory
cards and Handy Files. A memory card allows data to be
saved and read at high speed. (When a system requires
about 15 minutes to save system data and programs with
a Handy File, for example, the same information can be
saved using a memory card in about 30 seconds.) The
method of using a memory card is described below.
(1) Installing a memory card

- Install the memory card interface printed circuit board (referred to
as the interface printed circuit board) in the slot next to the power
supply unit as shown below.
- Before installing or removing the interface printed circuit board,
turn off the power to the control unit. Otherwise, the interface
printed circuit board, memory card, and backplane and so forth can
be damaged. Moreover, install the interface printed circuit board
securely. If the interface printed circuit board is not installed
securely, a malfunction can occur.
Remove the blank plate

next to the power
supply unit.
Power supply unit
- 403 -

(2) Setting
[I] Install the interface printed circuit board in the control unit, then
insert the memory card into the interface printed circuit board.
[2] Tum on the power to the control unit.
[] Press the SCREEN SELECT key on the teach pendant, then select
7 (File).
@] Press the F5 key (Function) on the teach pendant, then select 1
(Switch Unit).
ffi] The upper part of the teach pendant screen displays selectable
units. Select 3 (Memory Card (MC:)). The left end of the fourth
line from the top of the teach pendant screen displays MC: *. *.
NOTE
If Memory Card (MC:) is not displayed, check the
connection of the interface printed circuit board.
lli] This makes the memory card usable. Operations such as save,
read, and list processing can be performed using the same
procedures as used for the Handy File. (Refer to the description
of file I/O in the operator's manual.)
NOTE
If the setting procedure above is used, the Handy File
cannot be used. To use the Handy File, select 1 (Serial
Floppy Disk) in step 5.
(3) Memory card initialization

As with a floppy disk, a memory card must be initialized before it can
be used. (Set the switch on the memory card to the middle position
to release write protection.)
[I] Select Memory Card (MC:) in (2) above.
[2] Press the SCREEN SELECT key on the teach pendant, then select
7 (File).
[] Press the F5 key (Function) on the teach pendant, then select
Format.
@] The teach pendant screen prompts the user for confirmation.
Press the F4 key (Yes).
ffi] The system asks you to enter a volume label. Press the INPUT
key.
- 404 -

4.8.3 A replacement front cabinet unit for quick change contains units such as
Replacement front a control printed circuit board, servo amplifier, and fan.
cabinet unit The configuration of the control printed circuit board, in particular, varies
from one system to another. So, prepare a replacement front cabinet unit
carefully. The configuration of major options is described below.
Model B unit (option)
Power supply unit
1) The servo amplifier specification varies from one model of robot to

another.
2) The control printed circuit board consists of backplanes, a main CPU
printed circuit board, power supply unit, option printed circuit board,
and model B unit (option). The main CPU printed circuit board and
power supply unit are always necessary. For a system with no option
printed circuit board mounted, two slots of backplanes can be
specified. However, when an option printed circuit board is used,
three slots of backplanes are required.
3) On the main CPU printed circuit board, various modules are
mounted. These modules must have the same specifications as those
of the system before replacement.
- 405 -

4.8.4 The following items are required for quick change:

Hardware items
required for quick
1. Replacement cabinet unit (This unit must have the same
change specifications as the faulty unit. Pay attention to the option
configuration. No replacement is allowed between different
models of robots.)
2. External memory unit such as a memory card to which the
contents of memory of the faulty unit are saved
3. Flat-blade screwdriver
4. Phillips screwdriver
4.8.5 Be sure to read this section before starting quick change.

Notes on quick change - Quick change must be performed by two persons.
- Required data must already be saved to an external memory unit
such as a memory card.
- Be sure to tum off the main power supply unit connected to the
control unit before starting quick change.
- A replacement unit for quick change must have an FROM module
with the same contents as those of the faulty unit, and must already
have its initial start work completed.
4.8.6 Replace a faulty unit with a replacement unit according to steps [TI
Faulty unit through@].
replacement procedure OJ Person A: Remove the two brackets securing the top cover, then
open the door of the control unit.
Person B: Check that the main power supply unit connected to the
control unit is turned off. Manually loosen the cap of
the cord grip securing the power cable, then pull the
rubber ring installed on the cable toward you. Next,
remove the four mounting screws securing the side
plate with a flat-blade screwdriver, then set the breaker
mounted in the control unit to off (when the control unit
has no breaker, set the breaker mounted in the
operator's box, for example, to off.) Then, separate the
side plate as shown below. At this time, leave the
cables connected.
- 406 -

Cord grip
Rubber ring
Cap
Brackets (2 locations)
Side plate mounting screws

Each screw can be removed by rotating it by a one-fourth turn.
Power cable
Operator's box cable
- 407 -

Person A is to perform steps [Zl-1 to [Z]-4. Person B is to perform step

[Zl-5.
[Zl-1 Open the door of the front cabinet unit, then disconnect the
cables below.
- Cables connected to CPl and CP2 of the power supply unit
- Cables connected to JF21, JRMlO, JDlA, JD17, JRM3, and
CRM 10 of the main CPU printed circuit board (When a process IJO
printed circuit board and model B unit are mounted, the cable
connected to JDlA need not be disconnected. See 2-2.)
- Cables connected to CN7B, CN8B, CNl, and CN6
- 408 -

Model B unit

or ME-NET printed circuit board
Servo amplifier
Servo amplifier Main CPU printed circuit board Power supply unit
0
CPI
CN8B
0
0
0 JF21
0
0
0
ei---JRMIO
0 0
JDIA
0 r-=iil!+--- JD I 7
~'llt-t----JRM3
11nuUl1l!H---- CRM I
0 000000 0 0 0
- 409 -

IIl-2 When a process I/O printed circuit board, ME-NET printed

circuit board, and model B unit are mounted, disconnect the
cables and fixing plate below in addition to the cables listed in
IIl-1.
- Cables connected to JD4B, CRM2, and CRWl of the process I/O
printed circuit board, and cable fixing plate
- Cable connected to Ll (or L2) of the ME-NET printed circuit
board
- Cables connected to JDlA, CRS7, CRS8A, and CRS8B of the
model B unit
- 410 -

Peripheralequipmen
connection cables
Fixing plate for peripheral

equipment connection cables

or ME-NET printed circuit board
Process 1/0 printed circuit board ME-NET printed circuit board

CA CB DA
JD48 JDIA 1/0 model B unit
LI
L2
CRS7
CRS8A
Peripheral equipment connection interface
- 411 -

[2]-3 Loosen the cable holders located on the near side of the cabinet,
then pull out the cables disconnected in steps [2]-1 and [2]-2.
[2]-4 Disconnect the cables connected to the two Faston terminals

located in the inner left part of the cabinet.
Fasten terminal
- 412 -

[Z]-5 Disconnect the cables below from the breaker room.

- Cables connected to JRF2, CRM9, and CRM15 of the emergency
stop control printed circuit board
- Cables (screwed at three locations) connected to the secondary side
(pins 2, 4, and 6) of the MCC
- Relay connectors for robot connection cables(*l)
NOTE
The robot connection cables consist of six cables, J1 M to
J6M. The J1 M to J6M cables are connected using relay
connectors. (These connectors have a strong mating
power.) These cables can be pulled out of the cabinet so
that the cables can be easily connected or disconnected.
When disconnecting the cables, pull the cables out of the
cabinet to make the work easier to perform.
- 413 -

Emergency stop control printed

circuit board
MCC
Pull the cables out of the cabinet.
x~
Disconnectthe cables while holding down the lock on the top of
the connector.
J1-J3 connector
Emergency stop control printed
circuit board Lock
JRF2
I Robot side cables
CRMl5
CRM9
J4-J6 connector
- 414 -

B--80525E/04 CONNECTIONS AND END EFFECTOR INTERFACES
[31 Separate the front cabinet unit from the rear cabinet unit
The front cabinet unit weighs about 40 kg. This work must be
performed by two persons. While one person is holding the front
cabinet unit, the other person is to remove the lower brackets and the
upper brackets. Next, the two persons gradually pull the front cabinet
unit about 10 cm toward the near side. (When there is a step between
the front cabinet unit and the floor, be careful not to drop the front
cabinet unit.) In this state, the cables drop through openings for
cables on the front and rear cabinet units. Ensuring that the cables do
not tangle, separate the front cabinet unit.
(Front cabinet unit) (Rear cabinet unit)
ITF'='v-k~----J--.'1hL-------~ Bracket
(two brackets each on
the right and left side)
Cables
Opening for cables
- 415 -

@] Install a replacement unit by reversing steps 1 through 3, observing

the notes below.
Notes on connection of the front and rear cabinet units:
- When running the cables through the openings for cables, run the
robot connection cables on the near side, and run the other cables
on the far side.
- Ensure that the cables are not caught between the front and rear
cabinet units. For easier work, connect the relay connectors for the
robot connection cables outside the cabinet, then push the
connectors into the front cabinet unit.
- Ensure that the cables connected to the Faston terminals located in
the inner left part of the front cabinet unit are not caught between
the front and rear cabinet units.
- When making connections to the connectors and terminals, be
careful not to make wrong connections by checking the wire marks
and stamps provided on the cables. (The connectors for the robot
connection cables have different colors. Match these colors when
making connections.)
- 416 -

Front cabinet uni Rear cabinet unit
Colors of robot connection

cable connectors
Connector No. Color
JI White
J2 Black
Cables other than the robot
Robot connection cables connection cables
J3 Green
(to be run on the near side) (to be run on the far side) J4 White
J5 Black
0 J6 Green
Make a connection outside the Ensure thatthecables are not caught between
cabinet, then push the connectors the front and rear cabinet units.
into the front cabinet unit.
- 417 -
5. TRANSPORTATION AND
INSTALLATION CONNECTIONS B-80525E/04
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.
I I I Io o o t:i
b
CJ CJ r=I
0 0 0 ll!!illl
r=I Cl • 181
(I-cabinet separate type) (B-cabinet)
Fig.5.1 Transportation
- 418 -
B-80525E/04 CONNECTIONS INSTALLATION
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
~
MAINTENIANCE
SPACE
I
I
F~~~:::--------t ------- _J
I")
CfJ
LO
Fig.5.2.1 (a) Installation Area (Separate type i cabinet)
- 419 -
0
0
r------,
100 740
------,
0
Control unit Control unit lO Control unit
lO
500 500
______ J
L-------+-----'
0
0
0
Fig.5.2.1 {b) Installation Area {B cabinet: ARC Mate100, ARC Mate120, ARC Mate 100i, ARC Mate 120i, $-6, S-12,
M-6i, M-16i, 8-420i, 8-450, S-SOO, S-700, 8-800, M-410i, M-500, M-400i, M-710i, A-520i)
r------, ------.,
100 400 740
Additional Control unit 0
Control unit Control unit
locker locker LO
LO
500 500
______ J
L - - - - - - -;-------'
0
0
0
Fig.5.2.1 {c) Installation Area {S-900)
- 420 -
5.2.2
Connecting Cables at
Installation
(Combined Type of i
Cabinet
D I
Operator's box
Input power cable
Teach pendant
--
©
Peripheral device connection cable
Fig.5.2.2(a) Connecting Cables at Installation
- 421 -
Separate type of i
cabinet
Operator's box
o oa
Kiit-5
o@
Input power cable
Teach pendant
Robot mechanical unit connection cable

©
Peripheral device connection cable
Fig.5.2.2 (b) Connecting Cables at Installation (i cabinet)
- 422 -
(B cabinet)
I I I Io o o b
b
0 c Cl
0 0 0 ~
CICllD~
0 Teach pendant connection
e
Robot mechanical unit
connection cable
Peripheral device
connection cable
Input power cable connection
Welding interface
connection cable
Fig.5.2.2 (c) Connecting Cables at Installation (B cabinet)
- 423 -
(Cabinet for M-410i)
Operator's box
connection
00e
ii-Ci
El~
.... CD
B connection
Input power cable

Cabinet for M41 Oi is installed
in Robot's frame
Peripheral device
connection cable
Fig.5.2.2 {d) Connecting Cables at Installation (Cabinet for M-410i)
- 424 -
5.2.3 (ARC MatelOO, ARC Mate120, ARC Mate lOOi, ARC Mate 120i, S-6,
Separate-Type Control S-12, M-6i, M-16i, S-420i, S-500, S-700, M-710i, A-520i)
Unit of i Cabinet 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
Fig.5.2.3 Assembly of Controller
- 425 -
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, 380, 415, 460, 480, 500, 550, or
575 V +10%-15%, 50/60 q1 Hz
Input power source capac- ARC Mate 100, S--6, ARC 2.5kVA
ity Mate 1OOi, M-6i, M-16i
ARC Mate 120, ARC Mate 3kVA
120i, S-12, A-520i
S-700, M-710i 6.5kVA
S-500, M-400i 7kVA
S-420i, 8--800, M-41 Oi, 12kVA
M-500, S-450
S-900 18kVA
Average power consump- ARC Mate 100, ARC Mate 120, 1.0KW
ti on ARC Mate 120i, S-6, S-12,
ARC Mate100i, M-6i, M-16i
S-500, S-700, M-71 Oi, 1.7KW
M-400i
M-500, A-520i 2.0KW
S-420i, 8--800, M-41 Oi, 2.5KW
S-450
S-900 3.5KW
Permissible ambient temper- All models OxC to45xC
ature
Permissible ambient humid- All models 75% RH or less, non-condensing, up to 95% RH for a lim-
ity ited 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 serious vibration, consult with your FANUC sales repre-
sentative.
Weight of control unit B cabinet 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.
- 426 -
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 Turn 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 turn the power on. Check the output voltage. (See
II MAINTENANCE 6.3.)
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. Turn 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.
- 427 -
5.5 An overtravel and emergency stop occur when the robot is operated for
the first time after it is installed and the mechanical and control units are
RESETTING wired. This section describes how to reset the overtravel and emergency
OVERTRAVEL AND stop.
EMERGENCY STOP Remove the red plate fastening the swiveling axis beforehand.
AT INSTALLATION The J2 and J3 axes are pressed against the hard stops at shipment.
Therefore, an overtravel alarm occurs when the power is turned on after
installation.
The robot enters the emergency stop state when the peripheral device
control interlace 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
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.
- 428 -
APPENDIX
B-80525E/04 APPENDIX A. TOTAL CONNECTION DIAGRAM
A TOTAL CONNECTION DIAGRAM
A.1
I-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-400i, M-710i,
A-520i}
- 431 -
A. TOTAL CONNECTION DIAGRAM APPENDIX B-80525E/04
L3--+-.,.......---+---o
G--+--~--+-~
)
I I
I I
IN CASE OF I I I
OPERATION BOX B TERMINAL
(OPTION) I I I I BREAKER BLOCK
I I I I ,..-,-....
"t-l-L- --o Io-- - --0--0- - ~
I I I ...-h..
c 1-L- --<>I<>-- - --0--<>-1---.J
I I ....-'-..
cl- - --<> - --0---<>-r---..J
I
L-- - - ,
POWER SUPPLY
BACKPLANE UNIT
CPI
.JNPO CP2
CP3
MAIN CPU F A n R ) OO
.JRVI
.JRF2
CRMIO "!~--------------------------,
" I
.JRA5 .JOIA FANUC I/O LINK I
(OPTION) I
.JF21 LINE TRACKING

(OPTION)
CRSI If--------------------------------------
" l
I
.JDl7 I~ - - - - - - - - - - - - ~~ RS-232-C/RS-485 INTERFACE B I
" " (OPTION) I
.JRM3 1~ ~~31.P~~b. .Q~12._o- - - - - -' - - OPERAr1ct.i60x - - , I
" I (OPTION) l, I
"
.JRMIO I f---------------1I CRS1l1
f'
~-----~ ~~Ml o, I I
TEACH PENOANT I ~," "
RS-232-C INTERFACE I I RS-232-C I 11 f- - - - - - ~ I RS-232-C INTERFACE I
r - - - - - - - - , RS-232-C/RS-485 INTERFACE A I
I OPTION PCB I EMERGENCY STOP I f'" "
I I I I
ri I L----------.J
.JNA
I 1 I (REFER TO PAGE OF 'OPERATION BOX')
11 I
LJ I
I I
I I
Fig.A.1 (a) Total Diagram (ARC Mate 100i, M-6i 5-420i, M-710i, A-520i)
- 432 -
r I - ~
OCR UNIT
'> ROBOT
I I ,> ARC Mate 1OOi
I I
(!N CASE OF M--6i, 5-420i,
I I
I I STAND ALONE TYPE) ,,, M-400i, M-710ii A520i
I
I
I
I
I I
r---------~ II
'-'L
RM2
Jl-J3 MOTOR POWER
I
r--' r - - - - - - - - - 1 1"'
1 RMI
l
l I
-I ::: ->---
->--- :: I I L,. J4-J6 MOTOR POWER
AND JI -J6 MOTOR BRAKE
~ I I
,--,
I I (IN CASE OF
AC3 AC2 ACI CN I RI R2 CNBA I : INTEGRATED TYPE)
-0[ CN7B
6-AXIS AMP
1-U. V ,W,G 'l JI MOTOR POWER
2-U,V,W,G )
J2 MOTOR POWER
-0[ CNBB 3-U,V,W,G
4-U,V,W,G 'l
J3
J4
MOTOR
MOTOR
POWER
POWER
D[ CNI
5-U,V,W,G
6-U,V,W,G
CN6
OD
J
)
I
J5
J6
MOTOR
MOTOR
POWER
POWER
Jl-J6 MOTOR BRAKE

CN7A
~
J, (IN CASE OF
ST AND ALONE TYPE)
'"
r - - - - - - - - - - 1 II RPI
F=i I JI -J6 PULSE CODER
I AND RDI/RDO
CRM9
-0[ CRRl5 CRF3

J[} J
PULSE CODER
Jl/J2/J3
E-STOP UNIT
j
I }IN CASE OF
INTEGRATED TYPE)
CRF4
JD I
PULSE CODER
J4/J5/J6
I
CRMI I Jf~--~~---------- -- ROT
(OPTION)
D[
I DOOR INTERLOCK
L'
JRF2 I SWITCH
CRMl5
JD :\ ~°I
~(INST ANDCASEALONE
______________________________________________: '\__________
OF
TYPE l
f--- RDI/RDO, HBK
(OPTION)
(IN CASE OF
INTEGRATED TYPE)
TEACH
PENDANT
- 433 -
;VPCC
,,..r---.--~----<)--. ~2
:'J',- .:c-•:c -- -------:~:----__,,

:':::::-c:~ -:
:01sE '.'.':2
------~:"--:---~ 111.c+--r--~-5~'.....;--~·_,6:__ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
,A-c-~
lt-, -::.-"SC: :;F
:;p~;;AT:C'·, ::;.- .. -ERMINAL.
~
' . I
--~ j
i.
::::::-: :"~ BLJO<
- - - - - - - -: :::- - - -·- -<::--.:- - - J
- - - - - - -.: - - · - ....:-:::- - - - ...

:::- - j_
- - - - - -: :- - --- _, - -c-::r - - - - -
~L~~~~~~~~~~
~
_·1r::
_.:/'/' ':,;:-[- - - - - - - - - - - - - - - - - - -
,....
-~~?~!~·--------------------------------------
- :...;L
,:~M C h!---------------------
,__;1_
-'-' .l i ,r - - - - - - - - - - - - - - f ~.~1\JUC .r:;o LI~¥

::JPTIONI
... .-.::. - - - - - - - - - - - - - - - 1 _:.\IE TRACKir--;G
'OP"."IONI
:RS - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
,D c ~~-_ - - - - - - - - - - - - :; RS-232-C/RS-485 INTERFACE B

,, (OPTIONl
... P~J n~-_-..13~3 ,:?::_~L-~:~og_ _ - - - _r_- - (pffiAT:i:~ -eQ'; - - -
COPTIQNj
~=?~•t C ~~ ~ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ CRS: ~~~f-----------------
f"ll""1
RS-232-C: t: ~ - - - - - .i · RS-232-C :NTERFACE

:-•"-J
(REFER TO PAGE JF 'JPER•T:JN BCX
Fig.A.1 {b) Total Diagram ($-500, S-700, S-6, S-12, M-16i, ARC Mate 100, ARC Mate 120, ARC Mate 120i, M-400i)
- 434 -
,-:)------0----C-r
'--'.:--0--0-----0-
~!-':s :cf'.~,1t:c::o'~ ::s
"ROM ~.'-CH ROBOT .
qEFER : C o AGE :F
'RCBCT ':O~NEC-IC>J' qcac-:-
s - s,::c
s--:-·::C
:::i- ,:;.
.!..=-c \"! ! : ~
!Q·: -'Ai:~
CN7A
~,:;.!
~L..! - ~~ :i"J'_.s::: ::::o:::~

.1.'1D ~sr '::;·o:
CRM9
- - - - - - - - ] [ CRR 5
~-STJP ...:!\:T
C~F 4 ]=:____,
--J~~RF2
COCR !NT~PL~O<
sw:--;-cf-'
~J:,-RQC -.51--.
( JPTIJ'i;
~~~~~~~~~~~~~~~~~~~~~~--'i:1
~
- 435 -
"1>
BREAKER
)> OR
:D TERMINAL BLOC~ TYPE I TRANSFORMER b
0 I ,...-,-.... I
LI 200/220V ~
AC POWER LI ' I '
I I 'I 380/400V r
I» SUPPLY I
== I I I I ~GI (')
CD 200/220 I I -L2 200/220V
'T' I I I 0
240/380 L2 -
-...
0 400/415
I
I
I
I
I
I
I I
I I
'I
I
380/400V
f ] z
9 440/460 _G2 z
)>
480/500
550/575 L3
I I ..-'--.. I I I _L3 200/220V
-
~'~ ~·" m
(')
:D 380/400V
I 'i I
0 50/60H• G -I _G3 -I
I I -=
I»
0z
==
CD 0
D , CPID AC POWER
-...
N I
FOR DC POWER SUPPLY UNIT
_o ~ .' CN8BD THERMOSTAT ~
)> FOR OVERHEAT
:D ~
0 s::
I
I»
== TYPE 2 TRANSFORMER I CPI
S' I I '.>'.>0/240V
1,----<:>=-==- )
-+---1
TYPE 1 TRANSFORMER (7.5KVA; A80L--0026-0015,A80L--0024-0014): .S60/4
- l5V
== 0 "Tl GI I
.i 0 -· I I
l~IL±:J
:-·'? POWER CONNECTION OF PRIMARY TAP I., '>'>0/240V
o,_)> SUPPLY
CONNECTING 1'~- ..+-+---'I
STYLE .StlU/4 l5V
VOLTAGE 1 I
? :0:.... JUMPER )>
I G2 I I
=:On 200 I.., '>'>0/240V CN8B "tl
I 3:._. Gl-L2 G2-L3 G3-LI DELTA 6. ...+-+---,! I "tl
.j::.. 220 I I I
"~ --- •
..>tlU/415V I I
\;.) 380
3 m
0\
:::i I» :;I 400
Gl-G2
I G2-G3 STAR y I G3 I I
2 z
5! S' ~ I I I I l±Jj I I 0
I I I I x
):. ~ !!l. I l I I
TYPE 2 TRANSFORMER (7.5KVA; A80L--0026--0014,A80L--0024-0013) I I I I
J,?~ I
Il I "I I
POWER CONNECTION OF PRIMARY TAP I
CONNECTING ~II )
gi~ SUPPLY STYLE I
VOLTAGE JUMPER
I I
220 I I
Gl-L2 G2-L3 G3-LI DELTA 6.
r 240 l I I I
_N 380 I I
Gl-G2 G2-G3 STAR y
415 I I I
TYPE 3 TR ANSFDRMER
LI A 440-480V
I
== l 16 500-575V
-+---'I
F. TYPE 3 TRANSFORMER (7.5KVA; ABOL--0026--0016, ABOL--0024-0015) : I
I
I POWER CONNECTION OF PRIMARY TAP L2A 440-480V ,I
CONNECTING ...+-+---I
...== SUPPLY STYLE l2B 500-575V
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...i CONNECTION OF THIS INTERFACE
N IS REFER TO NEXT PAGE.
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INTERFACE OF MI ANO M2 ARE REFER TO PAGE
6G, OF "B-CABINET /MECHANICAL INTERFACE'
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L _J NOTE
C11
i
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t CONNECTION OF MOTOR BRAKE
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A4 B4 TD MAINTEMANCE MANUAL OF MECHANICAL UNIT
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S-700 I A06B-6076-C003
~
0
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CD BRKIM BRK2P
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AS BRK5M BS BRK6P OF 'B-CABINET /MECHANICAL INTERFACE' .
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A2 ov B2 ov A05B-2350-COIO r
A3 PR06 B3 •PRQ6 (")
A4 OV B4 ov CRF3 ROBOT PULSE CODER
A5 PD5 B5 •PD5 ROBOT FEEDBACK JRF2 D JI -J3 0
A6 ov B6 ov CRF4 ROBOT PULSE CODER z
A7 PR05 B7 •PR05
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m
A8 ov B8 ov (")
A9 PD4 B9 •PD4 SVON/MCON 0[ CRM9 CRMI I tJ ~}------------------ ROBOT OVER TRAVEL SIGNAL -I
AIO ov BIO ov (OPTION)
Al I PR04 Bl I •PR04 MCC CONTROL CRRl5
6z
0[
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Al3 PD3 Bl3 •PD3 D
Al4 ov Bl4 ov ~
Al5 PR03 Bl5 •PRQ3
Al6 ov Bl6 ov CRR20 D PRECHRGE POWER OF SERVO AMP ~
Al7 PD2 Bl7 •PD2 s::
Al8 ov Bl8 ov (Yl
i:k20D1
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A21 POI B21 •PDI
A22 ov B22 ov
200VAC 311l
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m ov }>
I A25 ov B25 '1J
3 A26 ov B26 ov '1J
11>
... A27 +5V B27 +5V m
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t 11> CRM9 CRMI I 0
:I A29 +5V B29 +5V ( EMG CONTROL) (ROBOT OVERTRAVELl (ROBOT FEEDBACK Jl-J3)
I ~ A30 +5V B30 +5V 3 23 P03
13 P02
01 POI
x
(J) A31 +5V B31 +5V 24 •P03 02 •POI
14 •P02
A32 +5V B32 +5V CLJdoN I sv~uT I 25 PR03 03 PROI
() 15 PRQ2
I l•RO~ 26 •PRQ3 04 •PRQI
"C A33 +5V B33 +5V 16 •PR02
27 +5V 05 +5V
A34 +5V B34 +5V 17 +5V
c: 28 +5V 06 +5V
:I 18 +5V
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CRRl5 19 +5V
A36 +5V B36 +5V 30 OV 08 ov
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A37 +5V B37 +5V 31 ov 09 OV
(DOOR INTERLOCK) 21 OV
32 ov 10 ov
A38 +5V B38 +5V 22 OV
3 33 ov II ov
A39 +5V B39 +5V L:3 I 2~n~B I 2~~A I 34 OV 12 ov
A40 +5V B40 +5V la§;d
A41 +5V B41 +5V I CRF4
A42 +5V B42 +5V ~21BI
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A44 ov B44 ov 13 PD5
02 •P04 24 •PD6
CRR20 14 •PD5
A45 +24E B45 +24E 03 PRQ4 25 PRQ6
( MCC CONTROL) 15 PRQ5
A46 +24E B46 ov 04 •PRQ4 26 •PRQ6
16 •PRQ5
B47 •OTREL A3 A2 Al 05 +5V 27 +5V
A47 17 +5V
06 +5V 28 +5V
A48 •OTRST B48 •ROT CXl 200T 200S 200R 18 +5V
07 +5V 29 +5V
A49 SVON B49 •HBK _Jl__ ___fl 19 +5V
08 ov 30 ov
20 ov
A50 RDICOM B50 •HBKREL B3 B2 Bl 09 ov 31 ov
21 ov
(Y) AC3 AC2 ACI 10 OV 32 OV
22 ov
JL__Jl__ II ov 33 ov
12 ov 34 ov
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(J1
PROCESS IIO
MAIN CPU ~
A I 6B-32CC-CC42
CRM2A tJ TYPE CF PROCESS I/O(SINK TYPE)
SPECIFICATION CRM2A CRM2B CRM2C CRM20 CRM4A CRM4B CRWI CRW2

CRM2B D
JOIA JD 0[ J04A CA A 166-220 1-0470 0 0 x x x x 0 0
CRM2C tJ
,------0 [ J04B SDIISDO CB A168-220 1-0472 0 0 x x x x x x
CRM2D tJ DA A168-220 t -0480 0 0 0 0 0 0 x x
CRM4A D EA A 168-3200-0230 0 0 x x x x 0 0
I
CRM4B ] (NOTE) PROCESS IIO EA CAN DESIGNATE ONLY ARC Mato ICCI
JDIA JD4A,B PROCESS IIO EA IS MOUNTED IN OPERATION BOX
(FANUC I/O LINK) (FANUC IIO LINK)
I RX 11 CV I RX II CV CRWI ] TO WELD MACHINE (AID, DI A. WDI/WDO)
2 •RX 12 CV 2 •RX 12 CV
3 TX 13 CV 3 TX 13 CV
CRW2 ] TO ANALOG INTERFACE (AID)
4 •TX 14 CV 4 •TX 14 ov
5 15 CV 5 15 ov
6 16 CV 6 16 CV
7 17 7 •ENBL 17 -15V
8 18 +5V 8 + 15V 18 +5V NEXT IIO LINK DEVICE (SLAVE)
!! 9 +5V 19 9 +5V 19 +24V
ca 10 2C +5V IC +24V 2C +5V
;.
:.. CRM2A CRM2C CRM4A CRWI
-:::: CSDI/SOOJ CSDI/SOOJ CSOI/SOOI (WELD INTERFACE OPTION) )>
01 •IMSTP 33 CMOE/'llL 01 SDI23 33 $0021 01 SOI63 $0061 01 DACHI 23 WOOi
08 $0060 13 AOCHI "tJ
02 •><JLD 34 SYSROY 02 50124 34 $0022 02 SDIU 10
" S0062 02 CAK'.>AI 24 W002
19 ACK3/SN03 19 $0033 09 $0066 14 COMADI "tJ
t
-,...,
0 03
04
•SFSPD
CSTOPI
20 ACK4/SN04
30
36
PROGRl.J'll
PAUSED
03
04
SOI2ei
SDl26
20 80034
35
36
$0023 03
04
SOl6!!5
80166
10 $0067
16
17
$0063
$0064
03
04
DACH2
CAK:IA2
AOCH2
25
26
WD03
W004
m
Ut n 21 ACK5/SN05 21 $0035 II $0068 16
'" COMA02 z
CD O!!S FAl.A..T RESET COM-Al 00 80127 37 COM-Cl 80167 18 COM-El WOII 27 WOOO
$0036 COM-E2
Ill 06 START
22
23
ACK6/SN06
COM-U
~~ HELD 06 50128
22
23 COM-C4
38
=·
$0025 06
°" 80168
12
13 SOI70
19 •24E 06
°" WOI2
17
18
28 woo• 0
Ill 07 HOME FAl.LT 07 S0129 39 SOl26 07 80169 20 ov 07 WOIJ 29 W007 x
24 ACK7 /SN07 !~ 24 S0037 19 ov
=:::: 08 EteL ATPERCH 08 SOI JO 40 $0027 08 wou 30 woo•
25 80038 20 ov
09 RSR I /PNS I TPENBL 09 SOIJI 41 $0028 CRM4B 09 WOIO 31 WOI•
:: "C:~~ 41 26 SDOJ9 21 ov
I0 RSR2/PNS2 COM-A2 10 SOIJ2 42 COM-C2 ISOI/SDOI 10 WOI6 32 WDl-
27 RESERVED :~ 27 SD0.40 22 ov
Il RSRJ/PNSJ BAT ALM II SOIJJ 43 SD029 01 SOI71 14 $0069 II WOI7 33 +2"4E
28 COM-C!S 08 S0073
,,00
12 RSR-4/PNS.4 BUSY 12 SOIJ4 50030 02 SOI72 10 S0070 12 WOI8 34 •24€
:: p~;:E "44 29 SOlJ9 09 S0074
IJJ IJ
14
RSR5/PNS5
RSR6/PNS6
JO PROO ST ART ::
ACKl/SNOI
ACK2/SN02
13
14
SOIJ!S
SOlJ6
30 souo
..
45
46
50031
$0032
03
04
SOI7J
80174
10 $0070
16
17
S0071
S0072 CRW2
JI SOlOI 31 S0l41 II S0076
15 RSR7 /PNS7 47 COM·AJ 15 SDlJ7 47 COM-CJ 80175 18 COM-Fl (MD INTERFACE OPTION)
J2 SOl02 32 80142 12 COM-F2
16 RSR8/PNS8 48 16 SOlJ8 48 06
°" $0176 19 •2"4E 01 14 ADCHJ
13 SOI78 08 AOCH6
17 ov 49 •24E 17 ov 49 +24E 07 S0177 20 ov 02 10 COMA.OJ ;t>
09 COMAD6
18 ov 00 +24E 18 ov 00 +24E 03 16 ADCHJ
10
04 17 COMAD4
II
CRM2B CRM20 18 ADCHO
(SOI/SDOJ (SOI/SOD) 12 d
06
°" 19 COMADO
13
01 SOlOJ 33 50001 01 SOUJ 33 50041 07 20
02 80104 34 $0002 02 SOI44 34 $0042
~
19 SOOIJ 19 S0003 r
03 S010!5 30 $0003 03 80145 35 $0043
20 80014 20 $0054 SPECIFICATION OF PROCESS I/O FUSE (')
04 80106 36 $0004 04 80146 36 50044
21 80015 21 50000
05 SOI07 37 COM-Bl 05 80147 37 COM-DI NOTE
22 SOOl6 22 50006 1i~R~~T1:ctVA~I I 0
06 SOI08 38 50005 06 50148 38 $0040
23 COM-84 23 COM-04 I 2.0A I :.•..c.. I FAST BLOW I z
07 SOI09 39 50006 07 SDI49 39 S0046
24 SOOl7 24 60007
08 80110 40 S0007 08 SDl!S4 40 50007 z
20 S0018 25 $0058
09 SOll I 41 S0008 09 SOl!SI 41 $0048 m
26 SD019 26 60009
10 SOil2 42 COM-82 10 SOI!S2 42 COM-02
27 80020 27 S0060
II SOIIJ 43 50009 II SOl!SJ 43 $0049
28 COM-8!5 28 COM-D!S ~
12 SOil-4 SOOIO 12 80154 44 so°"°
29 80119 29 S0159
13
14
SOI1!5
SOI16
30 80120
..
45
46
SOOl I
$0012
13
14
SOl!S!S
80156
30 $0160
40
46
$0001
$0002
0
z
31 80121 31 SOI61
15 50117 47 COM-83 15 SOI!S7 47 COM-03
32 SDI22 32 80162 0
16 SOil8 48 16 sense 48
17 ov 49 +24E 17 ov 49 •24€ )>
18 ov 50 +24E 18 ov 00 •24€ (j)
]J
)>
s:::
;t>
)>
JJ d
0
iii: ~
r
(')
...i 0
z
~ z
)> m
JJ ("')
0 -I
iii: 0z
a.,,
... -·
CD cp 0
2
I I A~~~:~ ~~~~~jo MODEL B IJ>IIT
N)> A05B-2J50-C I 00 )>
Cl.
~ ... G')
)>-- CP6 b I/D IJ>IIT MODEL B ::D
JJ3 I INTRF ACE UNIT )>
o-- AOJB-0808-COO I
CRS7 s:::
i:m 24V 24V ! n 0--- 6~ ~E~~o~ASE UNIT
Ill~ OV ov
SI+
CD
-CD 3 JDIB SI-
FG CRS8A
... Ill
iii: c - I I A1
6~~~~og~go4o JDIA S2+ 0--- TO MODEL B BASE UNIT
S2- CRSSB OF OPERATION BOX
FG
SJ+ 0--- TO MODEL B BASE UNIT
)>:;:,
g!.?&> SJ- OF OPERATION BOX
I JDIA b FG )>
:·~~ S4•
S4- "'1J
;:: i: !:!: FG "'1J
t ::lag m
0-. z
0
~--
..)>S?, NCD IllC x
J, S?.~
N~lll3
Cl CRS7
..:::,;. .-.. JDIA/JDIB (SI SIGNAL)
I RX II ov
A3 I A2 I Al
y,a 2 •RX 12 ov SI- SI+
... c: J TX IJ ov
4 •TX 14 ov
BJ I B2 I Bl
l'>i 5 15 FG OV +24V
i: iii: 6 16
7 17
~g 8 18 +5V CRS8A
9 +5V 19 (S2 SIGNAL)
a:m 10 20 +5V
,r J 2 I
_.ID CFG) 52- 52+
~---
CRS8B
(SJ SIGNAL)
I
N
I c:Gl s~- SJ• I
?
~
Cl
~=
t
Cl i
~=
~
OPERATION BOX PCB

TEACH PEtl':>ANT
·~v EMGTP J<MIO CU~TD<O '1'
EMERGENCY STOP BUTTON
r••~n•••n
R-J2
MAIN CPU CU~DO••
I
RLDM
EMGOM°' ' DEAD-MAN SWITCH
'
RLEN EMGEN16
ENABLE/DISABLE SWITCH
ov I I Tl ENABLE DISABLE
~OJ
-,, '¥v =mJ:~,

C>'EMG
-1 TPEHl~
~
OV ~
QPEMG.<::J.WL _ ~~ElERGENCY
QPEMG.CZ.WL ___ _
nn~ur t:H 1"-4.
STCP BUTTON
THIS TERMINAL IS OPTION
TPEMG
~~rl&
--§:}Lo-.v-+---fill---------+11--------_..,..-·~ I EMGINI
~
~ I
EXTEllNAL EJERGENCY STCP
11
. -fRvl ov ov
EMGOOT..-'--}---~-t-~1.__
P..,.J __..,SVONSVON21""'~'------QJO-,I SERVO ON/CF' SWITCH
7v-1 I
I
I
~~------- =::::"""~~~~-
L------4~£Ea:o·e•:u"""'
....
24ovccOPTiai>
I I EMGOUTC
I OOVAC/24DYC
I
I ·~v
•24Y I L-- - ::i..
_____
- - - -
L.__-.L~------------ffi - - - - -jO)
:;
HOlR IETER
RV; RECEIVER COPTIONJ
""01
EMERGENCY STOP CONTROL PCB

AXES
..RF2
,PO
___I -6/•PO
-"·---·-<
1-6
CONTROL
..... RLI
RLY5
(leKREL)
Hll<REL
ROT~
'·--· -o--1 RLYI
COTRELJ
,~~
Ir
OTREL -,. I 'y' ~
OTRST ----,,.
ROICDM--+---f---filf-----------------+J~1 ~.,.,•-...,_~-6-
A~ e
B
I
I
I
u I
~ Rl..Y3+RLY4
l ·I
+24E
I I
I I
LY.
~
RLY6
(PRECHARGE)
I
I
----
~-- ---
CRR20X CRR20Y
20<lR
200S
200T
QC
POWER
SUPPLY
POWER
r<>--'-,.
TRANSFORMER
:f=i
--.--
AC POWER
INPUT ]~ 200A l
r-1
2008 I I I
J L_J
Fig.A.1 (n) Emergency Stop Circuit
- 448 -
ROBOT
MECHANICAL L!'lIT
PU.SE
BRAKE MOTOR
J~
v
RCBOT ROT
CRF3 TO MAIN CPU

l CRF4
JRVI
·-·- 1
--
CNI CN6
CAMI I
i ~
•lmTTN PWM.ENBL
MCON,DROY -~~-~
SIBNALS
BRAKE CONTRCl.
""
CRMl5
OOOR
I~OCK I SIGNALS
I CIRCUIT
"" - - - I
6-AEXES SERVO AMPLIFIER
CN7A
··-" CRM9
SVOUT
.r®----- INTERLOCK
~-0
RLY2 CIRCUIT
CMCC-ONJ
·- MCCCI<
CF
SERVO MOTOR
POWER
"' I
I
CRRl!58
MCC UNIT
ON THE POWER TRANS ~
ov
~~
MCCI
MCC2 -0-i
,---,
[... CN86
+~V
--
jp-~
CRRl5A ,_ u ACI
·- v AC2
I j
• AC3
\~
~
OD CNI
om
~ I
l I OISCHARGE
CClllTRO...
CIRCUIT I
- 449 -
DISCONNECT OPERATION BOX
AC POWER
(CABLE)
i'PUT
Ll-
L2-
L3-
G-
=== ==== =~
======= === === === ==:
--------~-----------------~-Ll
---------i~------------------~-G
~; l
r----------1------------,
I I/O UNIT-MODEL B I I/O UNIT-MODEL A I
I BASE UNIT I BASE UNIT I
I !OPTION) I !OPTION! I
I ATION BOX A I OPERATION BOX A I
I ~. 2-lNIT I ~Al'f~aWe I
I ~~~~::1rx B I Sl.PPORTEO I
I > I wr~L A IS MOUNTED. I
I + I ~ > > > I MOOEL B CMNOT to..NTED. I
I ,..<!l... ..!:!! _ _ +_o_.....12, I I
~ --'i-~- -!t7·T-'- _,_ _~0-;-~F'i=~~ - - - - - ~
I/O UNIT-MODEL B ( ~~: ___,._____ I I I +- - ~
SIGNAL CABLE S3+ I I
S3- \_) \_) l l ll JOIA
~ ~~lip
TXSLC-----+--"(J~O~l~A~llll+:c3~>-----------~
•TXSLC-----+---_,lll+:c•~>-------------'
RXSLC-----+---_,IH+!c1~--------------'
•RXSLC-----+-----<11+=c2=>-------------~
(CRSI}
TXTP-----+--(JR_M_l_O~Jitttic1~·r1 --------------------,71 ~11m1 TXTP
•TXTP-----+-----<1trr.~~~~rl-----------------~1,~~~lm1 •TXTP
RXTP-----+----ttrr. ;;t-
138 1 --------------------,1~,5~ 1m1 RXTP
•RXTP-----+----Hl-""""----------------.,,.<!'.,..,v----.;~.7
16 ~1m1 •RXTP TO TEACH PENOANT
(17 19) +24V
OV
~-(_I)
FG
CPORTI l
TXOI
RXOI
RTSI
CTSI
DSR I RS-232-C
OTRI
+24V
ov
(PORT IX} FG
(2)
TXOIX (3)
!NOTE I l RXOIX (4)
+24V;JRMI 0-44,45,46 RTSIX (5)
47,48 CTSIX (6)
OSRIX (20)
(NOTE 2) DTRIX
ov ;JRMI 0-1,3,5,7,9 +24V
(25)
11,26,28 (7)
30,32,34 ov (I)
36,42,43 FG
(JRMIOJ (12)
TXOA (37)
RXOA (8)
RTSA (33)
CTSA (35)
DSRA ( 10)
DTRA
(16)
TX485A (40)
•TX485A (41)
RX485A (15)
•RX485A
(PORT2l (2)
TXDA (3)
RXOA (4)
RTSA (5)
CTSA (6)
DSRA (20)
OTRA
( 14)
TX485A (15)
•TX485A ( 16)
RX485A
•RX485A
+24V
( 17)
(25)
(7)
.....
ov
Cl)
FG
NOTE 1 PORT2 IS OPTION. = FG
Fig.A.1 (o) Operator's Box-1
- 450 -
OPERATION BOX
OPERATION BOX PCB

FROM MAIN CPU A20B-1006-0290(AFTER EDITION 02B)
(JRM3) (CRT3J •
p DOI
p 002
(12)
( 13)
(All
(Bil . LED I I REMOTE
SW4 1C-START
p 003
p 004
(1.4)
( 151
(A21
(821
(NJT l£SOl
. LED2 1F -RESET
p 005 (16) (AJJ CNJT LESO)
( 17) (831
p 006 CNJT LESO)
p 007 (18) (A4l
(NJT l.ESDJ
p 008 (20) (6.4)
(NlT LESO)
p Oii (II (A5l

Ol)T lESOl
p DI2 (3) (851 ~0-
SW6 IF -RESET
CA6}
p DI3 (4)
(51 (861
' SW31REMOTE
p DI4 (NJT LESO> REMOTE LOCAL
(6) (A71
p DI5
p DI6 (7) (871
(NJT LESO)
(NJT LESO)
~ o'o
p DI7 18) CA8l ~0-
SW6 1 F -RESET
(9) (881
TPOFF CNJT LESO)
·¥·
24V
ov
(10.19) •¥Y
(2, 11)
(Al6,A17l
(Al7) . SWI 10N
i!v +¥V
i!v -·-· -·-··-
FROM MAIN CPU (CRSI J
EMGOM
(..RMIO) (22)
23
(12)
3
(16
"'
""'
DEAD-MAN
_,_
EMGEN
EMGBI
49)
!50
I (10)
II - ENABLE/
OISA8LE
EMGB2
RW< ;,QJ ENABI.£ OISA8LE
ov I ov I ~ ~
I I ESTCPI (TBOPI)
ESTCP2
IU
fAI 11
CBI II
Al2
(812)
I
I (TBOPI J
I FEN:EI
FEN:E2 --------- L_-=---~~
CCRT3l- - - - - - --
+24V
+24V ~ CA.16,816} +24V
,.,.._
TPEMG
(24) -__I RNAI (Al3) 0PE"'3AI
(20) I
(813)
CAl5)
OPElllA2
OPENJBI
I I
OPE MG
CA") OPEMGCI
RLTPEM
(814) OPEMGC2 l
ov (TBOPI)
EMGOJT EMGINI
---------- - - -0..,0-,
(21) ov
+24V
ElllIN2
'(TBOPI)
---------- ~----..J
EXE MG
--.____J" SVONI
---------- - - -0..,0-,
SVDN
(25) SVDN2
----------
HOUR METER
~----.J
&J (CRP5)
+24V
I ~ (I)
I
I _,_
12)
+24Y I 12
T ov .v ov (31 HMI
I 3 4
~ EMGOJTI (TBOPI)
I EMGOJT2
{17) EXONI (TB_2f'_gl_ _ _ _ _ _ _ _ __,__

ON ---00--,
COM
(19)
TI
EXCOH
EXOFFI ---------- -----;
OFF
(18)
I CA09l ONI
----------
__,__ ---010--.J
11
(809)
CAIO)
DN2
llf'FI '
I (Bl I 1 llf'F2 I
(CRT3)
- 451 -
'1>
d
);!
r
0
0
z
z
JRMIO JRM3 PORTI PORT IX PORT2 m
(MAIN CPU I/Fl (MAIN CPU I/Fl (RS-232-Ci PORT-I l ( RS-232-C 1 PORT- I ) (RS-232-C 1 PORT-2)
HOt<EA PCRSO HDNJA PCR-E20 D-51.8 2'5P O-SU8 2'5P D-SUB 2'5P ~
MALE MALE FEMALE FEMALE FEMALE
26 ov I ov II OV I POII I FG I FG I FG
14 14 14
27 CTSI 2 RTSI 12 POOi 2 ov 2 TXDI 2 TXOI 2 TXDA
15 15 15
5z
28 ov 3 ov 13 P002 3 POI2 3 RXDI 3 RXDI 3 RXOA
!! 16 16 16
29 OSRI 4 DTRI 14 P003 4 POI3 4 RTSI 4 RTSI 4 RTSA 0
ca 17 17 17
30 ov 5 ov 15 P004 5 PDI4 5 CTSI 5 CTSI 5 CTSA )>
). 18 18 18
31 RXDI 6 TXDI 16 PDD5 6 PDI5 6 DSRI 6 OSRI 6 DSRA
19 19 19 (j)
:.... 32 ov 7 ov 17 PDD6 7 POI6 7 7 ov 7 ov
20 OTRI 20 DTRA
ov 20 OTRI
33 CTSA 8 RTSA 18 PD07 8 PDI7 8 8 8 :0
21 21 21 )>
._..
=s 34 ov 9 ov 19 +24V 9 TPOFF 9 9 9
22 22 22
35 OSRA 10 OTRA 20 PD08 10 +24V 10 10 10 s::::
23 23 23
m 36 OV II ov II II II
24 24 24
37 RXDA 12 TXOA 12 12 12
REMOTE • PDQ I F-RESET= PDI2 25 +24V 25 +24V 25 +24V
38 •RXTP 13 •TXTP 13 13 13
...~ C-START• PD02 REMOTE • POI3
39 RXTP 14 TXTP THIS CCN£CTOR IS OPTION
FAL.LT • PD04 C-START• PDI7 THIS CCN£CTOR IS MCUITED ON THIS CQIN;CTOR ts MOl.NTED ON THIS CCNECTOR IS MCX..M"EO ON
40 •TX48!5A I !5 •RX48!5A EXTERNAL SIOE OF Tl£ BOX INTERNAL SIOE OF TIE BOX INTERNAL SIDE OF THE BOX
=
!. CTPOFFl • POIS
41 RX485A 16 TX485A
0 42 ov 17 ON
JDIA CRSI TBOPI TBOP2 TBOP3
0 43 SVON-RV 18 OFF (I/0 LINK) ( TEACH PENDANT) (EMERGENCY IN/OUT l (EXTERNAL ON/OFF l (MODEL B l
44 +24V 19 COM HOl'()A PCR-E20 H:JNlA liR-208
= 45 +24V 20 OPEMG MALE FEMALE ... ,...,....,_. M4 TERMJNALS ... ,...,....,_. )>
CD
= 46 +24V 21 EXEMG II ov I POII I TXTP 14 •TXTP I EMGINI I EXONI I S2+
8 ""O
47 +24V 22 EMGDM 12 POOi 2 ov 2 RXTP 15 •RXTP 2 EMGIN2 2 EX OFF 2 S2- ""O
.j::. ~ 9
0 48 +24V 23 EMGEN 13 PDD2 3 POI2 3 EMGDM 16 EMGEN 3 FENCE I 3 EXOFFI 3 S3+ m
Vt 10 EMG81
49 EMG81 24 TPEMG 14 PD03 4 POI3 4 17 OV 4 FENCE2 4 S3-
N II EMG82 z
50 EMGB2 25 SVON-EMG 15 PD04 5 PDI4 5 18 5 SVONI 5 +24V
c= 12 EMGTP 0
16 PD05 6 POI5 6 +24T 19 ov 6 SVON2 6 ov
iii" 13
17 P006 7 PDI6 7 +24T 20 FG 7 ESTOPI x
ca
... 18 PD07 8 POI7
THIS ctNECTOR IS IO>ITED ON
8 ESTOP2
Ill CRT3 19 +24V 9 TPOFF EXTERNAL SIDE OF 11£ BOX 9 EMGOUT2
(PANEL SW/LEDl 20 P008 10 +24V 10 EMGOUTC
3 11 EMGOUTI
........ YAMAICHI-3'P
0 / A B
"C I REMOTE C-START CRP6 CRS9
CD 2 CP003l FAULT (DISCONNECT) (I/O LINK)
3 CPD05l CP006l MOLEX-el> MCLEX-4P
a
0 4
5
CP007l
CPDII l
CPD08l
F-RESET
I +24V TXSLC
... 00 2 +24T 2 •TXSLC
ui 6 REMOTE CPOI4l EMGBI RXSLC
CJ 7 CPDI5l CPDI6l
l'~ PANEL DI 3
4 EMGB2
3
4 •RXSLC
8 C-START (TPOFF) 5
0 9 ONI ON2
10 OFFI OFF2
._..
~ II CTI l CT2l
12 CAUTOl (MOOCOM)
13 OPEMGAI OPEMGA2
14 CCPE!4GC1l OPEMGC2
15 OPEMG81 HMI
16 +24V +24V
17 ov
I
~
~
A.2
B-CABINET (ARC
Mate 100, ARC Mate
120, ARC Mate 1OOi,
ARC Mate 120i, S-6,
S-12, M-6i, M-16i,
5-420i, S-500, S-700,
M-400i, M-71 Oi,
A-520i)
- 453 -
MULTI-TAP TRANSFORMER
BREAKER
TFI
L() A~
ALC -
Fl I 2
LI I 550
I 500
I 480 I 4
"'I' 460 I
INPUT VOLT AGE L2 4151240 I
REFER TO I 380/220 6
PAGE 002. I
/--.. 541
L3 av
575
G
l
41
14 415/240
15 380/220
4
0 480
I 460 43
2 415/240
3 380/220
4
51
52
BACK PLANE PSU

CPI
JNPO CP2
CP3
MAIN CPU
JRVI
JRF2
CRMIO
JRA5 JDIA FANUC I/O LINK

(OPTION)
JF21 LINE TRACKING
(OPTION)
CRSI
JDl7 RS-232-C/RS-485 INTERFACE B

(OPTION)
JRM3
ll ~ .._
_
JRMIO
.--------,
OPTION PCB OPERATOR PANEL
.,11 -0 JRM3
JNA
11
'-------0 JRMIO ri_ - - - - - -
LJ
- - - - - --
LJ
I
I
L--------J
Fig.A.2 (a) Total Diagram
- 454 -
ROBOT
MECHANICAL UNIT
RMI
CN8B
RM2
CNI
CN7A
E-STOP PCB
JRVI CRFI RPI
JRF2
JSI
CRM9 JS2
CRMl5 JS3
CRMl6 JS4
CRRl5 JS5
CRR20 JS6 TEACH
PENDANT
CRR21 CRMI I
CRR5
CRR22
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -~ 11 I RS-232-C
- 455 -
;i:i-
MULTI-TAP TRANSFORMER r-;==-~

d
SERVO POWER CONTROL
CII IT BREAKER
TFI
) (2IOVAC)
~
r
0
~ ~•1~ I I 2 ! i
I 575 IL9 rjj 0
~
AC POWER
- ~
I
lblJ 2
-3
550
500
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SUPIPLY I ~ 3 4 I I I z
4 480 SERVO POWER
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46 )/480 : I I I I
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11 l.><T'l:l41 410 I .l-+-.J
POWER CONl'ECTION OF PRIMARY TAP I I I
SUPPLY
CONNECTING
VOLTAGE STYLE
LI L2 L3 .JUMPER ~-l_l_J
220 7 1!5 23 8-1!5 16-23 I 24-7 I I
DELTA /), I I
240 6 14 22 8- 14 I 16-22 I 24-6
380 7 1!5 23
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8-16 16-24
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500 3 II 19
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D @JAN
CA39A
i
~
POWER SUPPLY CPI CP4 CP8

A 16B- I 2 I 2-0870 Bl B2
I B3
R L!
ALES2
FA FB BAT+ BAT-
.,, CPI LBJ I I
ca· I II CP2 200-240 VAC OUTPUT cAiM I
):. L!HF I
N CP2
....... I II CP3 200-240 VAC OUTPUT
CP5
.!?. RI
stflJ B3
c )>
Ljlli2
0 CP4 If--------- POWER ON/OFF +240v ""C
I JNPO I •• ALARM
.,, ""C
~
UI 0 CP3
m
-.i I CP5 I ~ - - - - - - - - +24 voe OUTPUT z
:eID CP6 0
... R2 Bl x
CJ) I I I CP6 +24 voe OUTPUT s[f]d +24E
c ~tt:J
'tJ
'tJ
-< 1 r-B~T~E:Y- - :R~ SPECIFICATION OF FUSE
c: I NAME FUSE POWER
:I
;:; Fl 7.5A 200V
F3 5A +24V
;>:>
F4 5A +24E
d
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r
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0
~~~
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z
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POWER SUPPLY UNIT
~
s::
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~ ~AN d
I CA39A o o--~->---~ JDIB JRMIO JRF2 JRVI ~
(I/O LINK) !OPERATION BOX) CROBOT FEEDBACK J CSERVO AMPLIFIER l r
I RXSLC 11 OY I I OY 1261 OY Al PD6 Bil •PD6 All IS6 IBI GNDS6 ()
BATTERY UNIT r - - - - - - - - ' 2 •RXSLC 12 OY 2 RTSI 27 CTSI A2 OY B21 OY A21 IR6 IB2 GNDR6
MAIN CPU
0
r ,_ ~~ ~A~N_2:~~N:E~ _ J 11111- : 3 TXSLC 13 OY 3 OY280Y A3 PR06 B31 •PR06 AJI IS5 IB3 GNDS5 z
A 16B-3200 YBAT
~J I -------i I 4 oTXSLC 14 OY 4 DTRI 29 DSRI A4 OY B41 OY A4I IR5 IB4 GNDR5
-0040 z
5 15 OY 5 OV300V A5 PD5 B51 •PD5 A51 IS4 IB5 GNDS4 m
JRYI D ;ER~ -A~P~IFIER" 6 16 OY 6 TXDI 31 RXQI A6 OY B61 OY A61 IR4 IB6 GNDR4 ()
7 17 7 OY320Y A7 PR05 B71 •PR05 A71 IS3 IB7 GNDS3 -I
81 1181 +5Y 8 RTSA 33 CTSA A8 OY B81 OY A81 IR3 IB8 GNDR3
JRF2 D ROBOT FEEDBACK 9 +5Y 19 9 OY340Y A9 PD4 B91 •PD4 A91 IS2 IB9 GNDS2 5z
IOI 1201 +5Y I0 DTRA 35 DSRA IAIOI OY IOI OY IAIOI IR2 181 GNDR2
11 OV 36 OV IAI I PR04 I ii •PR04 IAlll ISi 1811 GNDSI 0
JF21 ~ }- - - - - - - - - LINE TRACKING 12 TXDA 37 RXDA Al21 OY 121 OY 121 !RI 181 GNDRI
11 3 • TXTP 38 •RXTP IJI PD3 l81JI •PD3 I JI •ENBL6 18 I ov )>
JOI? 11 4 TXTP 39 RXTP IA141 OY 18141 OY IA141 •PWME6 18141 ov G)
JRMIO D TO OPERATION BOX CRS-232C/485)
JRA5~ ~ ' 15 • TX485A 40 •RX485A IA15 PR03 18151 •PR03 IA15I •PWMC6 18151 ov
JRY4
(FOR TEST) RXDB 111 TXDB 16 TX485A 41 RX485A IA161 OY 18161 OV IA16I •PWMA6 18161 OY ~
2 OY I 12 ov 17 ON 42 OV IA17 PD2 18171 •PD2 IA171 •ENBL5 18171 OY s::
JDIB ~}- - - - - - - - I/O LINK
3 DSRBC I 13 DTRB 18 OFF 43 SYON-RV IA18I OY 181 ov IA18I •PWME5 181 OY
JDl7 ~}- _ _ _ _ _ _ _ _ ~5P~~~~j485 INTERFACE 41 OY 141 OY 19 COM 44 +24V IA19I PR02 191 •PR02 IA19I •PWMC5 181 OY
5 I CTSB 151 RTSB 20 •OPEMG 45 +24V IA201 OY 18201 OY IA20l •PWMA5 162' OY
JRM3 D TO OPERATION BOX 61 OY 161 OY 21 •EXEMG 46 +24Y IA21 PDI 18211 •PDI A211 •ENBL4 1621 OY
7 I RX485B 171 TX485B 22 EMGDM 47 +24Y IA221 OY 18221 OY A221 •PWME4 16221 OV
CRSI D TO TEACH PENDANT
.,, 8 I •RX485B 18l •TX485B 23 EMGEM 48 +24Y IA2JI PROI 18231 •PROI IA2JI •PWMC4 l62JI ov
ie· CRMIO D RDI/RDO 191 +24E 24 •TPEMG 49 EMGBI IA241 OY 18241 OY IA241 •PWMA4 18241 OY
)> ~~~ IOI +24E 20 25 SYON-EMC 50 EMGB2 IA251 OY 18251 OY IA251 •ENBL3 16251 OY
wggg IA261 OY 18261 OY IA26I •PWME3 16261 OY )>
'-> IA271 +5Y 18271 +5Y IA271 •PWMC3 16271 OY "U
5iii IA28, +5Y 16281 +5Y IA28I •PWMA3 18281 OY "U
a..ooo CRSI JF21 VBAT
~ :s IA291 +5Y 291 +5V IA291 •ENBL2 162 OY m
15~~~ CTEACH PENDANT) CLINE TRACKING) !BATTERY)
00 31:: ~JOI +5Y !JOI +5Y IA301 •PWME2 163( OY z
Ill ~gg 01 TXTP
08
,. HXTP I I PA I 11 I EXVBAT IAJI +5V !Jil +5V IAJll •PWMC2 l8JI OY 0
02 RXTP iO •RXTP iAJ21 +5V 16321 +5V IA321 •PWMA2 l8J: OY
s· CJ?CJ?CJ? 0. 21 •PA 1121 OY 2 OY x
OJ EMJOM i6 EMGEN
lo EMGSI 3 PB 13 A3J +5Y 633 +5V A331 •ENBL I l6J OY
0 ''"""' 0. II EMGB2
i7 ov
05 18 41 •PB 1141 OY A34 +5V 634 +5V 341 •PWME I 16341 OY
"'Cl 12 EMGTP
0. +24V i9 ov 5 PZ 15 ,A35 +5V 35 +5V IA351 •PWMC I l6J51 OY
c: 07 +24V
i3 2o AJ6 +5V +5V IA361 •PWMA I 163, OY
;I •PZ 1:;1 OY
AJ7 +5V 7 +5V IAJ71 •MCON l8J +5Y
81 REC 1181 +5Y AJ8 +5V 8 +5V IA381 •DRDY 183 +5Y
9 +5Y 19 A39 +5V 9 +5V IA39I OY 163 +5Y
IOI 1201 +5Y A40 +5V 0 +5V IA40I OY 184, +5Y
A41 +5Y I +5V IA4il +15Y 1641 +5Y
IA421 +'5V 421 +5V IA421 + I 5Y 164: +5Y
IA4JI OY 4JI OV IA4JI OV 184 +5Y
CRM10 JRM3 IA441 OY 441 ov IA441 OV 16441 +5Y
(RDl/RDO) CPDI/PDOl
IA451 +24E 451 +24E IA451 - I 5Y 1845 +5Y
lo4 ROOI 01 ROil I I PD! I 11 11 OY IA461 +24E 46l"BRKALMZ IA461 - 15Y 18461 +5Y
08 ROI7
15 R002 02 ROI2 2 OY 12 POOi 471 •OTREL IA471 OY 18471 +24V
0. ROIS IA47l "BRKONZ
16 ROOO: OJ ROIJ
lo Roi9 3 PDI2 13 PD02 IA481 •OTRST 18481 •ROT IA481 OY 18481 +24V
17 RD04 0. RoI4
II •HBK 4 PDI3 14 PD03 IA491 SYON 491 •HBK IA49I •BRKON 1849 +24V
18 R00!5 ROI!5
12 R007
19 R006 0.
°" ROI6 5 PDI4 15 PD04 IA50I RDICOM 150! •HBKREL IA50i •BRKALM 18501 +24V
i3 R008
20 +24E 07 6 PDI5 16 PD05
°" 7 PDI6 17 PD06
8 PDI7 18 PD07
9 TPOFF 19 +24Y
10 +24Y 20 PD08
MAIN CPU BOARD

~ i
~
SERVO AMP IU
CNI A06B-6076 IV I\)
~
( SERVO CONTROL) -COOi IW J JI MOTOR POWER (J1
IG
Al IS6 Bl GNDS6 2U
SERVO CONTROL CNI
A2 IR6 B2 GNDR6 2V ~
2W J J2 MOTOR POWER
A3 IS5 B3 GNDS5 DJ
A4 IR5 B4 GNDR5 2G
3U
A5 IS4 B5 GNDS4
PRECHARGE CNI 3V
A6 IR4 B6 GNDR4 D ] J J3 MOTOR POWER
3W
A7 IS3 B7 GNDS3 3G
EMG CONTROL D ] CN7A
A8 IR3 B8 GNDR3 4U
A9 IS2 B9 GNDS2 INTERLOCK CN7B 4V
D J 4W J J4 MOTOR POWER
AIO IR2 BIO GNDR2
THERMOSTAT FOR OCR CN8A 4G
Al I ISi 311 GNDSI D ] 5U
Al2 IRI 312 GNDRI 5V
THERMOSTAT FOR TRANS D ] CN8B J J5 MOTOR POWER
Al3 •ENBL6 313 ov 5W
Al4 •PWME6 Bl4 ov J mR TEST) ~~
Al5 •PWMC6 Bl5 OV
RI 6V
Al6 •PWMA6 Bl6 ov OCR 6W J J6 MOTOR POWER
R2
Al7 •ENBL5 Bl7 ov 6G
Al8 •PWME5 BIB ov ACI
Al9 •PWMC5 Bl9 ov AC2 CN6 [ MOTOR BRAKE
SERVO POWER 0------
A20 •PWMA5 B20 OV AC3
.,, A21 •ENBL4 B21 ov
ca· A22 •PWME4 322 ov
;,. A23 •PWMC4 323 ov
A24 •PWMA4 B24 ov
;.,, A25 •ENBL3 B25 ov )>
'.§: A26 •PWME3 B26 ov
A27 OV
"'O
•PWMC3 B27 CNI CN6 "'O
g> A28 •PWMA3 B28 OV ( PRECHARGE l (BRAKE) m
~ A29 •ENBL2 B29 ov z
IO Al BKPI Bl BKM2
A30 •PWME2 B30 ov CJ
~ ~I
AC3AC2 ACI A2 BKP3 B2 BKM4
)> A31 •PWMC2 B31 OV x
A3 BKP5 B3 BKM6
A32 •PWMA2 B32 ov
3 A4 B4
"g_ A33 •ENBL I B33 ov A5 B5
A34 •PWME I B34 ov CN7A/B
::0: (EMG CONTROL/INTERLOCK) A6 BKMI B6 BKP2
A35 •PWMCI B35 ov A7 BKM3 B7 BKP4
...q;· A36 •PWMAI B36 ov A3 A2 Al
A8 BKM5 B8 BKP6
A37 •MCON B37 +5V MC CON SVOUT
A38 •DROY B38 +5V n n
A39 OV B39 +5V B3 B2 Bl
A40 ov B40 +5V
~
MAI NON 24F
A41 + 15V B41 +5V n JL_
A42 +15V B42 +5V d
A43 ov B43 +5V
CNBA/B ~
A44 ov B44 +5V r
CDCR TH/TRANS THl
A45 -15V B45 +5V (")
A4E -15V B46 +5V
A47 ov B47 +24V DCRTH
~!Al 24F 0
A48 ov B48 +24V
z
A49 •BRKON B49 +24V I B3 I B2 I Bl z
A50 •BRKALM B50 +24V TRNSTH\ 24F
m
~
0
z
0
5>
G)
SERVO AMPLIFIER ~
s::
;t>
E-STOP PCB
JRF2 JRVI -I
CROBOT FEEDBACK) CSERVO CONTROL) SERVO CONTROL CRFI TO ROBOT( FEEDBACK) 0
Al PD6 Bl •PD6 Al IS6 Bl GNDS6
D JRVI ~
A2 ov B2 ov A2 IR6 B2 GNDR6 ROBOT FEEDBACK JRF2
r
A3 PR06 B3 •PR06 A3 IS5 B3 GNDS5 D JSI (')
A4 ov B4 ov A4 IR5 B4 GNDR5 0
A5 PD5 B5 •PD5 A5 IS4 B5 GNDS4 E -STOP CONTROL CRM9 JS2 z
A6 ov B6 ov A6 IR4 B6 GNDR4
D z
DOOR INTERLOCK -----{] CRMl5 JS3
A7 PR05 B7 •PR05 A7 IS3 B7 GNDS3 SERVO CONTROL m
AS ov BS ov AS IR3 BS GNDR3 AUX BR AKE CONTROL CRMl6 JS4
("')
-----{] -I
A9 PD4 B9 •PD4 A9 IS2 B9 GNDS2
AIO ov BIO OV AIO IR2 BIO GNDR2 JS5
Al I PR04 Bl I •PR04 Al I ISi Bl I GNDSI
5
E-STOP CONTROL D~ CRR20 JS6
z
Al2 OV Bl2 ov Al2 !RI Bl2 GNDRI
A13 PD3 Bl3 •PD3 Al3 •ENBL6 Bl3
0
ov I OOVAC INPUT FOR BRAKE POWER - - - ----{] CRR21 CRMI I ROBOT OVERTRAVEL
Al4 OV Bl4 ov Al4 •PWME6 Bl4 ov )>
CRR5 MOTOR BRAKE POWER G)
Al5 PR03 Bl5 •PR03 Al~ •PWMC6 Bl5 ov
Al6 ov Bl6 ov Al6 •PWMA6 Bl6 ov I OOVAC OUTPUT FOR AUX MOTOR
:II
CRR22 )>
Al7 PD2 Bl7 •PD2 Al7 •ENBL5 Bl7 ov CC-SERIES AMPLIFIER)
AIB ov BIB ov AIB •PWME5 BIB OV s::
Al9 PR02 Bl9 •PR02 Al9 •PWMC5 Bl9 ov
'Tl A20 ov B20 ov A20 •PWMA5 B20 ov
Ui' A21 POI B21 •POI A21 •ENBL4 B21 ov CRM9 JS 1-JS6 CRFI
CE -STOP CONTROL) CSERVO CONTROL) (PULSE CODER INTERFACE)
)> A22 ov B22 ov A22 •PWME4 B22 ov
;,,, A23 PROI B23 •PROI A23 •PWMC4 B23 ov I IR II IS
A24 ov B24 ov A24 •PWMA4 B24 ov ~oNlsv~uTI 2 GNDR 12 GNDS
A25 OV B25 ov A25 •ENBL3 B25 ov 3 •PWMA 13 •ENBL
)>
:sm
A26 ov B26 OV A26 •PWME3 B26 ov 4 ov 14 ov
3 A27 +5V B27 +5V A27 •PWMC3 B27 ov 5 •PWMC 15 "ti
.j::. CD CRMl5 "ti
A28 +5V B28 +5V A28 •PWMA3 B2B ov (DOOR INTERLOCK) 6 ov 16 m
gj caCD A29 +5V B29 +5V A29 •ENBL2 B29 OV 7 •PWME 17 z
:I A30 +5V B30 +5V A30 •PWME2 B30 ov 3 ~ 8 ov IS 0
A31 +5V B31 +5V A31 •PWMC2 B31 ov 9 •DROY 19 OV 27
'--~~-D--'I~ 43 +5V - 28 II x
~ A32 +5V B32 +5V A32 •PWMA2 B32 ov 10 •MCON 20 ov 44 +5V
ov '12
29 ov r;J
A33 +5V B33 +5V A33 •ENBL I B33 ov 45 +5V
30 +5V
A34 +5V B34 +5V A34 •PWMEI B34 ov 46 +5V '14
~ CRMl6 31 +5V
"C CRR5 47 +5V 70
A35 +5V B35 +5V A31 •PWMC I B35 ov (AUX BRAKE CONTROL) 32 +5V
48 +5V 'i6
c: A36 +5V B36 +5V A36 •PWMAI B36 ov 2 ID 20 30 49 +5V '17
:I
::::;: A37 +5V B37 +5V A37 •MCON B37 +5V BKM3 BKM3 BKM3 50 +5V '"Ta
•BRKON41•6RKON3
A38 +5V 638 +5V A38 •DROY B38 +5V IC 2C 3C
A39 +5V 639 +5V A39 ov B39 +5V
BKP3 BKP3 BKP3
A40 +5V B40 +5V A40 ov B40 +5V
CRR20 IS 26 36 CRMI I
A41 +5V B41 +5V A41 + 15V B41 +5V
( EMG CONTROL) BKMI BKM2 BKM2 (ROBOT OVERTRAVEL)
A42 +5V B42 +5V A42 + 15V B42 +5V
A43 ov B43 ov A43 ov B43 +5V A3 A2 Al IA 2A 3A 3
A44 ov B44 OV A44 ov B44 +5V 200T 200S 200R BKPI BKP2 BKP2 •ROrtd:f]
I
A45 +24E B45 +24E A45 -15V B45 +5V n n
A46 +24E B46 'BRKALMZ A46 -15V B46 +5V 63 B2 Bl
A47 'BRKONZ B47 •OTREL A47 ov B47 +24V AC3 AC2 ACI
n n
A48 •OTRST B48 •ROT A48 ov B48 +24V
A49 SYON 649 •HBK A49 •BRKON B49 +24V
A50 RD I COM B50 •HBKREL A50 •BRKALM B50 +24V CRR21 CRR22
CBRAKE POWER) CIOOVAC OUT)
3 2
~OB IOOAI I OOOUT21 I OOOUT I
E-STOP UNIT
i
~
OPERATOR PANEL
CJRMIO) ( CRSI)
(14) (I)
TXTP (13) ( 14) TXTP
•TXTP •TXTP
RXTP
•RXTP
(39)
(38)
..,,. (2)
(15)
(6,71
( 17 19)
RXTP
•RXTP TO TEACH PEJ{)ANT
+24V
ov
OPERATOR PANEL PCB
A20B- I 006-0290 (AFTER EDITION 026)
av ,....----l!! FG
(JRMIO) ( PORTI)
(6) (2)
TXDI (31) (3) TXDI
RXDI (2) (4) RXDI
RTSI (27) (5) RTSI
CTSI (29) (61
CTSI
DSRI
DTRI
+24V
(41
(NOTE I) +<§V ..... (201
(251
DSR I RS-232-C
DTRI
+24V
ov (NOTE 21 (71
ov
CPORTIX)
(2)
ov av (IJ
FG
TXDIX (3)
(NOTE I) RXDIX 4
+24V:JRMI 0-44,45,46 RTSIX (5)
47,48 CTSIX (6
DSRIX (20)
(NOTE 2) DTRIX
OV :JRMI 0-1,3,5.7,9 (25) +<UV
11.26,28 +24V (7
30,32,34 ov
36,42.43 FG
lllJ
'*'
(JRMIO) (12)
TXDA (37)
RXDA (8)
RTSA (33)
CTSA (35)
DSRA (10)
DTRA
{16)
TX485A (40)
•TX485A (41)
RX485A (15) +~V (~R T4)
- -ov
•RX485A (3)
I - - +24V
(4)
CPORT2l (2) ~
TXDA (3) ov
RXDA (4)
RTSA (5)
CTSA (6)
DSRA (20)
DTRA
TX485A Cl•>
(15)
•TX485A (16)
RX485A ( 17)
•RX485A +i:!Y
(25)
+24V (7)
ov (I) /(0
FG
NOTE: PORT2 IS OPTION. .,,. FG
Fig.A.2 (g) Operator's Panel-1
- 462 -
OPERATOR PANEL
OPERATOR PANEL PCB
FROM MAIN CPU A20B- I 006-0290 (AFTER EDITION 028 l
(CRT3)"
PD01
PD02
(JRM3) ( 12)
(13)
(Al)
CBI) . LED I ; REMOTE
SW4 ;C-START
POD3
POD4
( 14)
( 15)
IA2l
(82)
(NOT lESO)
. LED2; F-RESET
(16) (A3)
PD05 !NOT lESO)
( 17) (83)
PD06 !NOT lESOl
( 18) (A4)
POD7 (NOT UESOJ
(20) (84)
PD08 (NOT lESOl
(I) (A5)
PD I I !NOT lESOl
(3) (85)
PD I2 SW6 ;F-RESET
(4) (A6)
PD I3
(5) (86)
' SW3;REMOTE
PD I4 (NOT lESO) REMOTE LOCAL
PD I5
(6)
(7)
(A.7)
!NOT lESO) ,,,.., o'o
187)
PD I6 (HJT UESOJ
(8) !AB) ~0-
PD I7 SW6; F-RESET
(9) (88)
TPOFF (N'JT UESO)
·~v (Al6,Al7)
+24V
ov
(10,19) +¥V
12, I I} !A17) . SWI ;ON
iJv +24V
iJv -·-· --- ··-
FROM MAIN CPU T (CRSI)
EMGOM
(JRMIO) (22)
f 1-·
(3) "' DEAD-MAN
(23 (16 ~
EMGEN
(49) T 110' ENABLE/
EMGBI DISABLE
EMGB2
150)
RLDM ;QJ Ill
ENABLE DISABLE
ov I ov I <?f:> ~
I I ESTCPI (TBOPI)
ESTtw
IT
CAI I J
Bii
(Al2)
Bl2
I
I (TBOPI)
I FENCE I
---------
+~V
FENCE2
(CRT3)
----- --=---~~
+24V
CAl6,816) +24V
TPEMG
(24) :_J RNAI (AIJ) Ol'El«>AI
""
(20) I
(BIJ)
(A.15)
Dl'El«>A2
Ol'El«>BI
I I
OPEMG 1 (A.14) IPEl«lCI
RLTPEM
(814) IPEl«lC2 I
ov (TBOPI)
EMGOUT EMGINI
EMGIN2 1 --------- L--=---=-~~
----------
+24V (TBOPI)
EXEMG
(21) ov '----..J" SVONI
1 ---------
SVON
(25) SVON2
L--=---~~
I
+~Y
(CR-;;5~ -ij9Q8 ~'%ER - -
I SVON (I)
----<fl I
I (2)
- - - -<f2
•24V I
.1. I
T ov ov (3) >+41
I
.Y
- - --«3 4;,I
(TBOPI) L--_J
EMGOUTI
r EMGOUT2
( 17) EXONI ~B.QP3l_ _ _ _ _ _ _ _ ---'-

ON ---0 0--,
( 19) T
COM
I
EXCOM
l --------- -----~
OFF
118)
I
EXOFFI
(A09) ONI
---------
---'-
---QiO--.J
(809) ON2 I
11 (AIO} CFFI .
I (Biil CFF2
(CRT3l
'
- 463 -
JRMIO JRM3 PORTI PORT IX PORT2 "!>

(MAIN CPU I/Fl (MAIN CPU I/Fl (RS-232-C; PORT-I l (RS-232-C; PORT-I) (RS-232-C; PORT-2)
HONDA PCR50 HONDA PCR-E20 D-SLI! 25P D-SLI! 25P 0-SUB 25P d
26 ov I ov 11 ov I PDII I FG I FG I FG - 14
);!
14 14 r
27 CT51 2 RT51 12 POOi 2 OV 2 TXDI 2 TXDI 2 TXDA_
15 15 15 (')
28 ov 3 ov 13 PD02 3 PDI2 3 RXDI 3 RXDI 3 RXDA_
16 16 - 16
29 D5RI 4 DTRI 14 PD03 4 PDI3 4 RT51 4 RT51 4 RT5A 0
17 17 17
30 OV 5 ov 15 PD04 5 PDI4 5 CT51 5 CT51 - 5 CT5A z
18 18 18
31 RXDI 6 TXDI 16 PD05 6 PDI5 6 05RI 6 D5RI 6 D5RA z
19 19 19
32 ov 7 ov 17 PD06 7 PDI6 7 ov 7 ov 7 ov m
20 DTRI 20 DTRI 20 DTRA (')
33 CT5A 8 RT5A 18 PDD7 8 PDI7 8 8 8
21 21 21 -I
34 ov 9 ov 19 +24V 9 TPDFF 9 9 9 -
22 22 22
35 D5RA 10 DTRA 20 PD08 10 +24V 10 10 10 - 0
23 23 23
36 OV II OV II - 11 II z
24 -
24 '24
37 RXDA 12 TXDA 12 12 12
REMOTE = PDQ I F-RE5ET• PDI2 25 +24V 25 +24V '25 +24V 0
38 •RXTP 13 •TXTP 13 13 13
C-5TART= PD02 REMOTE = PDI3 5>
39 RXTP 14 TXTP THIS CONNECTOR IS OPTION
FAULT = PD04 C-5TART= PDI7 THIS CONNECTOR IS MOUNTED ON THIS CCNNECTDR IS MOUNTED ON THIS CONNECTOR IS HOUNTED ON G)
40 •TX485A 15 •RX485A EXTERNAL SIDE OF THE BOX INTERNAL SIDE OF THE BOX INTERNAL SIDE OF THE BOX
CTPOFF) = POIS
41 RX485A 16 TX485A
42 ov 17 ON
JDIA
~
43 SYON-RV 18 OFF CRSI TBOPI TBOP2 TBOP3 s::
(I/0 LINK) ( TEACH PENDANT) (EMERGENCY IN/OUT) (EXTERNAL ON/OFF) (MODEL B
44 +24V 19 COM
HJNDA PCR-E20 HONDA MR-205
.,, 45 +24V 20 OPE MG MALE
-- FEMALE
-·-·-- M4 TERMUNALS
-··· ·-····-- M4 TERMUNALS M4 TERKJNALS
-····-····--
ca· 46 +24V 21 EXE MG 11 ov I POI I I TXTP 14 •TXTP I EMGINI I EXONI I 52+
8
47 +24V 22 EMGDM 12 POOi 2 ov 2 RXTP 15 •RXTP 2 EMGIN2 2 EXOFF 2 52-
j:.. 9
l;:MGEN
48 +24V 23 EMGEN 13 PD02 3 PDI2 3 EMGDM 16 3 FENCE I 3 EXDFFI 3 53+
j,,, 10 EMGBI
49 EMGBI 24 TPEMG 14 PD03 4 PDI3 4 17 OV 4 FENCE2 4 53-
II EMGB2
:;: 50 EMGB2 25 SVON-EMG 15 PD04 5 PDI4 5 18 5 5VONI 5 +24V
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16 PD05 6 PDI5 6 +24T 19 ov 6 5VON2 6 ov
0 13 ""O
17 PD06 7 PDI6 7 +24T 20 FG 7 E5TOPI
--
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111 18 PD07 8 PDI7 8 E5TDP2
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THIS CONNECTOR IS MOUNTED ON m
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~ CRT3 19 +24V 9 TPDFF EXTERNAL SIDE OF THE BOX 9 EMGDUT2 z
a (PANEL SW/LED) 20 PD08 10 +24V 10 EMGDUTC 0
0
... 11 EMGDUTI x
ui YAMAICHI-34P
I "ti ./ A B
Ill I REMO Tl;: C-5TART CRP6 CRS9
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111 PANEL DD
3 CPD05) (PD06)
MOLEX-SP
---·· - MOLEX-4P
---··
;!; 4 (PD07) CP008)
I +24V I TX5LC
5 (POI I) F-RE5ET
2 +24T 2 •TX5LC
6 REMOTE (PDI4)
PANEL DI 3 EMGBI 3 RX5LC
7 (PDI5) CPDI6) 4 EMGB2 4 •RX5LC
8 C-5TART (TPOFF)
5
9 ONI ON2
10 DFFI DFF2
11 CTI) (T2)
12 (AUTO) (MODCOM)
13 OPEMGA I OPEMGA2
14 COPEMGCI) OPEMGC2
15 OPEMGB I HMI
16 +24V +24V
17 ov :::><::
OPERATOR PANEL
i
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2 RDI7 14 ROIS 26 +24E 3S +24E 50 +24E 62 ov 2 RDI7 14 ROIS 26 +24E 3S +24E 50 +24E 62 ov
~
~ 3 RODI 15 RD02 27 RD03 39 RD04 51 RD05 63 RD06 3 RODI 15 RD02 27 RD03 39 RD04 51 RD05 63 RD06
WO
4 RD07 16 ROOS 2S •ROT 40 •HBK 52 •PPABN 64 4 RD07 16 ROOS 2S •ROT 40 •HBK 52 •PPABN 64
5 +5V 17 +5V 29 +5V 41 ov 53 ov 65 ov 5 +5V 17 +5V 29 +5V 41 ov 53 OV 65 ov
....!..== 6 +5V IS +5V 30 +5V 42 ov 54 ov 66 ov 6 +5V IS +5V 30 +5V 42 ov 54 ov 66 ov
J?. 7 +5V 19 +5V 31 +5V 43 ov 55 OV 67 OV 7 +5V 19 +5V 31 +5V 43 ov 55 ov 67 ov
)> s +5V 20 +5V 32 +5V 44 ov 56 ov 6S ov s +5V 20 +5V 32 +5V 44 ov 56 ov 6S OV
::D SPDJI 21 SPDJ2 33 SPDJ3 45 SPDJ4 57 SPDJ5 69 SPDJ6 SPDJI 21 SPDJ2 33 SPDJ3 SPDJ4
0 9 9 45 57 SPDJ5 69 SPDJ6
10 •SPDJI 22 •SPDJ2 34 •SPDU 46 •SPDJ4 5S •SPDJ5 70 •SPDJ6 I0 •SPDJI 22 •SPDJ2 34 •SPDJ3 46 •SPDJ4 5S •SPOJ5 70 •SPDJ6
== 11 SPROJI 23 SPROJ2 35 SPROJ3 47 SPROJ4 59 SPROJ5 71 SPROJ6 II SPROJI 23 SPROJ2 35 SPROJ3 47 SPROJ4 59 SPROJ5 71 SPROJ6
~
... 12 •SPROJI 24 •SPROJ2 36 •SPROJ3 4S •SPROJ4 60 •SPROJ5 72 •SPROJ6 12 •SPROJI 24 •SPROJ2 36 •SPROJ3 4S •SPROJ4 60 •SPRQJ5 72 •SPROJ6
0 "11
P ca·
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0 N (MOTOR POWER ~ BRAKE) RMI
(MOTOR POWER ~ BRAKE)
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I BKPJI s BKMJI 15 JI I 22 Jl2 29 Jl3 36 JIG
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2 BKPJ2 9 BKMJ2 16 J21 23 J21 30 J23 37 J2G )>
... ~ 3 BKPJ3 10 BKMJ3 17 J51A 24 J52A 31 J53A 3S J5GA
N ':I' 3 BKPJ3 10 BKMJ3 17 J31 24 J32 31 J33 3S J3G "tl
0111
w 4 BKPJ4 II BKMJ4 18 J51B 25 J52B 32 J53B 39 J5GB "tl
:J 4 BKPJ4 II BKMJ4 IS J41 25 J42 32 J43 39 J4G m
UI )> -· 5 BKPJ5 12 BKMJ5 19 J61A 26 J62A 33 J63A 40 J6GA z
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o- 6 BKPJ6 13 BKMJ6 20 J61B 27 J62B 34 J63B 41 J6GB 0
6 BKPJ6 13 BKMJ6 20 J61 27 J62 34 J63 41 J6G
7 14 21 2S 35 42 x
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7 14 21 (J21B) 2S (J22B) 35 (J23B) 42 (J2GB)
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2 RDI7 14 RDI8 26 +24E 38 +24E 50 +24E 62 OV 2 RDI7 14 RDI8 26 +24E 38 +24E 50 +24E 62 OV z
3 RODI 15 RD02 27 RD03 39 RD04 51 RD05 63 RD06 3 RODI 15 RD02 27 RD03 39 RD04 51 RD05 63 RD06
z
m
4 RD07 16 RD08 28 •ROT 40 •HBK 52 •PPABN 64 4 RD07 16 RD08 28 •ROT 40 •HBK 52 •PPABN 64
5 +5V 17 +5V 29 41 OV 53 ov 65 5 +5V 17 +5V 29 +5V 41 OV 53 ov 65 ov ~
6 +5V 18 +5V 30 42 ov 54 OV 66 6 +5V 18 +5V 30 +5V 42 ov 54 ov 66 ov 6
7 +5V 19 +5V 31 43 ov 55 ov 67 7 +5V 19 +5V 31 +5V 43 ov 5!5 ov 67 ov z
8 +5V 20 +5V 32 44 OV 56 OV 68 8 +5V 20 +5V 32 +5V 44 ov 56 ov 68 OV 0
9 SPDJI 21 SPDJ2 33 SPDJ3 45 SPDJ4 57 69 9 SPDJI 21 SPDJ2 33 SPDJ3 45 SPDJ4 57 SPDJ5 69 SPDJ6
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;,,, 12 •SPROJI 24 •SPROJ2 36 •SPROJ3 48 •SPROJ4 60 72 12 •SPROJI 24 •SPROJ2 36 •SPROJ3 48 •SPROJ4 60 •SPROJ5 72 •SPROJ6 s::
e
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:I Jl3 I
I 8 15 JI I 22 Jl2 29 36 JIG BKPJI 8 BKMJI 15 JI IA 22 J22A 29 Jl3A 36 JIGA
[ 2 9 16 J21 23 J22 30 J23 37 J2G 2 BKPJ2 9 BKMJ2 16 JI IB 23 J22B 30 Jl3B 37 JIGB )>
c: 3 BKPJ3 10 BKMJ3 17 J31 24 J32 31 J33 38 J3G 3 BKPJ3 10 BKMJ3 17 J31A 24 J32A 31 J33A 38 J3GA "ti
:I "ti
4 BKPJI 11 BKMJI 18 J41 25 J42 32 J43 39 J4G 4 BKPJ4 11 BKMJ4 18 J31B 25 J32B 32 J33B 39 J3GB m
~ :;:
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5' 13 34 41
0
6 20 27 6 BKPJ6 13 BKMJ6 20 J51 27 J52 34 J53 41 J5G
ID 7 14 21 35 42 7 21 J61 28 J62 35
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2 •RX 12 ov
3 TX 13 CV I
CRW2 [ TO ANALOG INTERFACE ( A/D l
4 •TX 14 ov
5 15 OV
6 16 OV
7 •ENBL 17 -15V
8 + 15V 18 +5V I/O LINK SLAVE
9 +5V 19 +24V
10 +24V 20 +5V
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ca· CRM2A CRM2C CRM4A CRWI
(SOI/SOOJ CSOIISOOJ CSOIISOOJ (WELD INTERFACE OPTION!
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N 01 •IMSTP 33 CMOENBL 01 SDI23 33 50021 01 SOI63
08 S0065
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13 AOCHI
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02 •HOLD 34 SYSRDY 02 SDI2• 34 S0022 02 SOI64 18 S0062 02 CAt«:IAI 24 W002
19 ACK3/$1'Kl3 19 80033 09 S0066 14 COMA.DI '1J
03 •SFSPO 35 PROGRUN 03 SDI2!5 35 S0023 03 SOI~ 16 S0063 03 OACH2 25 W003
20 ACK4/SN04 20 S0034 10 S0067 15 AOCH2 '1J
.j>. 5
-- 04 CSTOPI 36 PAUSED 04 50126 36 S0024 04 SOI66 17 S0064 04 CAMJA2 26 W004
21 ...CK5/SN05 21 S0035 II S0068 16 COMAD2
05 FAULT RESET COM-Al 05 90127 37 COM-Cl 05 $0167 18 COM-El 05 WOii 27 W00!5 m
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°' 06 START >ELD 06 SOI28 38 S0025 06 50168 19 •24E 06 WDI2 28 W006 z
23 COM-A..4 23 COM-C4 13 so no 18
07 HOt-£ FAULT 07 SOI29 39 SOI26 07 SOI69 20 ov 07 WOI3 29 W007 0
24 ACK7 /SN07 !~ 24 $0037 19 ov
08 ENBL ATPERCH 08 $0130 40 S0027 08 WOI4 30 woos
8 25 S0038 20 ov x
09 RSR I /PNS I TPEteL 09 $0131 41 S0028 CRM48 09 WOIO 31 WOI+
~= "~:~~~ 41 26 50039 (SOI/SOO) 21 OV
I0 RSR2/PNS2 COM-A2 10 $0132 42 COM-C2 10 WOI6 32 WOI
~
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27 RESERVED :~ BAT ALM II $0133
27 50040
43 S0029 01 50171 S0069 II WOI7
22 ov 33 •24E
28 COM-A!5 28 COM-C!5 08 S0073
12 RSR4/PNS4 44 BUSY 12 50134 44 S0030 02 80172 $0070 12 WOI8 34 +24E
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29 PNSTROBE 29 50139 09 S0074
a 13 RSR5/PNS5 ACKl/SNOI 13 SOI35 45 S0031 03 SOI73 16 S0071
30 PROO ST ART :: 30 SOI40 10 S0075
14 RSR6/PNS6 ACK2/SN02 14 80136 46 80032 04 SOI74 17 S0072 CRW2
31 $0101 47 31 SOUi II S0076
15 RSR7 /PNS7 COM-AJ ,. $0137 47 COM CJ 05 SOI75 18 COM-F"I (AID INTERFACE OPTION)
32 SOI02 32 SOI42 12 COM-F"2
16 RSR8/PNS8 48 16 SOI38 48 06 SOI76 19 +24E 01 14 AOCH3
13 SOI78 08 AOCH6
17 ov 49 +24E 17 ov 49 +24E 07 SOI77 20 OV 02 COMA03
09 COMA06
18 ov 50 +24E 18 ov 50 +24E 03 16
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04 17 COMA04 ?="
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CRM2B CRM20 05 18 AOCH5
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01 50103 33 $0001 01 SOI43 33 S0041 07 20
02 $0104 34 S0002 02 SOI44 34 S0042
19 50013 19 S0053 ~
03 $0105 35 $0003 03 SOI45 35 S0043
20 $0014 20 S0054 r
04 $0106 36 80004 04 SOI46 36 S0044
21 S0015 21 S0055
05 80107 37 COM-Bl 05 50147 37 COM-DI 0
22 50016 22 S0056
06 80108 38 $0005 06 50148 38 5004!5
23 COM-B4 23 CDM-04 0
07 SOI09 39 S0006 07 90149 39 S0046
24 S0017 24 S0057 z
08 80110 40 $0007 08 901!54 40 S0007
25 SOOl8 25 S0058
09 SOii I 41 80008 09 $01'51 41 S0048 z
26 S0019 26 S0059
10 80112 42 COM-B2 10 90152 42 COM-02 m
27 S0020 27 S0060
II SOil3 43 80009 II 901!53 43 90049
28 COM-8!5 28 COM-05
12 $0114 44 SOOlO 12 50154 44 soooo
29 90119 29 SOI59 ~
13 5011!5 45 $0011 13 90155 45 SOOOI
,. 30 90120 30 $0160
SDI16 46 $0012 14 50156 46 S0052
31 90121 31 $0161
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17 OV 49 +24E 17 OV 49 +24E Cl
18 ov 50 +24E 18 ov 50 +24E
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5-SLOT BASE UNIT 1 A03B-0807-J002 I I I +24V I I RX II ov I SI 11 S5
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m
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I 5 15 5 S3 15 OV -I
D tJ CP32 6 16 6 •S3 16 ov
tJ JDIB 7 17 7 S4 17 ID2 0z
8 18 +5V 8 •S4 18 103
MAIN CPU D tJ JDIA 9 +5V 19 9 IOI 19 0
A I 6B-3200-0040 10 20 +5V 10 20
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BASIC UNIT EXPANSION UNIT "U
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m INTRFACE UNIT I
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MAIN CPU FG
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FG ~WM''° ~H'
S3+
JOIA [ S3- TO BASIC UNIT 3
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S4+
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FG
I
JDIA/JDIB
I RX II ov
2 •RX 12 OV
I/O LINK SLAVE
3 TX 13 ov
4 •TX 14 OV
5 15
6 16
7 17
8 18 +5V
9 +5V 19
10 20 +5V
i
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OPERATION BOX PCB TEACH PEN>ANT

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DERGEN:Y' STOP BUTTON
R-J2 I
MAIN CPU
Rl.IJM
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( l/F IS SN£ AS R-J)
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- 470 -
EMERGENCY CIRCUIT
RC60T
MECHANICAL UNIT
PU.SE
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CONTROL I
CIRCUIT
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A.3
CABINET OF
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BREAKER
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500 I
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REFER TO
PAGE 002.
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BACK PLANE PSU ~FANUNIT
CPI OD
JNPO
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CP3 DD
CP5 DD
MAIN CPU E-STOP PCB

JRVI
DD -0[ JRVI CRFI
OD-
JRF2
OD -0[ JRF2
JSI DD
CRMIO JO dJ[ CRM9 JS2 D
JRA5
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JF21 JD
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JS3 D
JS4 D
CRSI JO '--{][ CRRl5 JS5 D
JDl7 DD L-.{J[ CRR20 Js6D
JRM3 OD -0[ CRR21 CRMI ID
JRMIO JD CRR5 D
CRR22 DD
r-------,
~,J OPTION PCB I
1I I
JNA 1
1I
I
I J
'1 I
L _ _ _ _ _ _ _ .J
Fig.A.3 (a) Total Diagram (5-800)
- 474 -
AMPI AMP2 AMP3 AMP4 AMP5 I

,.... @
LI
L2
- @
LI
L2
- @
LI
L2
- @
LI
L2
,.... @
LI
L2
L3 L3 L3 L3 L3
LIC Tl
"-- LIC Tl '-~
LIC Tl I'-- LIC Tl ,__. LIC Tl
L2C '-- L2C '--~ L2C '-- L2C ,__. L2C
THI THI THI THI THI
TH2 [ TH2 [ TH2 [ TH2 c TH2
- -= - -= LILI ,....... -
VLI ,.......
WL• ,.......
Tl
PE >---
Tl
[ u~
V~ Tl [Uh
V h Tl
[ u~
V~
UM
VM
>---
>--- Tl
u~
[ V~
w~ w~ w~ WM >--- w~
I
PE~ PE~ PE~ PE >--- PE~
CX4 JSIB
........
CX4 JSIB
........
CX4 JSIB
0
CX4JS I BJS2B
7LJLJ LJ LJ
CX4 JSIB
' 7 7
{][
{][
-nr
ROBOT S-800
RMI
RM2
RPI
--:-----1-<lo OPERATOR
.JRM3
.JRMIO
CRSI 0-
I
_I
0- - - - - - - - - - - - - - - - - - - - - - - - - - - - - {~~~ RS-232-C
TEACH PE NDANT
- 475 -
--~
A2 I
BREAKER
,.-,...._
TFI Lg ~-:J SURGE ABSORBER
UNIT
/ I 575 £.L I 2
LI -----o I !..!.I ;> 550
~ I
If\PUT VOLTAGE L2 -----o I o--- ""ii 500
480 I
£2_ 3 4
*
'!\
REFER TO
PAGE 002.
L3 -----0
..............
0---
!~g/240
""-, 380/220 I
il 5 6
G~ ..
..,
ov
575
I
I
I
I~ 10 550
11 500
' 12
13
14
480
460
415/240
il 13 I• 41
15 380/220 .Ei._
THI 23 2• 42
..__ I
16
17
ov
575 ~ ---
I bll 18 550 Fl ,F2,F3 ; 30A
19 500 F4,F5 ; 5A
""O 480
..,I 460 43
"2 415/240
'">3 380/220
44
~·
,[.
nv m-
TH2
51
52
l
BACK PLANE PSU
~FANUNIT
CPI DD
CP2 DD
.JNPO
m CP3 DD
CP5 DD
MAIN CPU E-STOP PCB

.JRVI
OD -0[ .JRVI CRFI
OD---
BK
.JRF2
OD -0[ .JRF2 .JSI DD
CRMIO OD d][ CRM9 .JS2 DD
.JRA5
I .JOIA DD
.JF21 DD
CRSI DD
d][ CRMl5
D[ CRMl6
~[ CRRl5
.JS3
.JS4
.JS5
DD
D
D
.JDl7 OD l__[J[ CRR20 .JS6 D
DD
~g
.JRM3 -0[ CRR21 CRMI I
.JRMIO CRR5 DD-------
CRR22 DD
r-------,
.JNA
~,J OPTION PCB I
11
1I
1
I
I
I
j J
'1 I
L-------_J
Fig.A.3 (b) Total Diagram (M-500)
- 476 -
DISCHARGE UNIT
I
2
3
4
13
14
AMP! AMP2 AMP3 AMP4 I

@ @ ..--<
@ ..--<
@ ROBOT M-500
..--<'I ,.... LI
LI LI
'2 L2 L2 L2
'3 L3 L3 L3
LIC Tl LIC Tl t--- '-- LIC Tl LIC Tl
I'-- "------<
L2C ~-
L2C '-- '-- L2C '------< L2C
'--~
'--~
'--~
THI
TH2
RC
THI
'------- TH2 c THI
TH2 c THI
TH2
'---~
RE -= -= lA. I-.. -=
'---~
FANI I-..
VL
'---~
FAN2 I-..
WL
~ PE I-..
I-.. ,_., Tl
UM I-.. )"""-,
I-.. ,._, I-.. ,_.,
T i p ,._,
VM
,_.,
r
T i p I-.. WM I-.. Tip
PE ,._,
PE I-.. PE I-.. PE I-..
I
r
CX4 JSIB CX4 JSIB CX4 JS I BJS2E CX4 JSIB
r LJ LJ
LJLJ
L...J L...J
[RMI
-0[ RM2
-n1 RPI
TEACH PENDANT
I
0[
j -- ! iri RS-232-C
_ _ ____/f I
I
I
OPERATOR PANEL
JRM3 CRSI 0- _I I
JRMIO 0- - - _,
- 477 -
TFI
CIRCUIT BREAKER
~ I
LI - - - - - i - - - - - - c I o-fXro------+-- 575
IU.J 2 550
AC POWER 1 I 3 500 I"
SUPPLY I I 4 480 i"
I I -5 460
220/240
380/415
L2 ------1----oi~ I I I -
6
7
415/240
380/220
~gg~~gg .
575 ~
I I
I 8 OV
.
L3-----+----0 ~ 9
ibgj - , 0 550
575
50/60Hz I 11 500 '-
+10% 12 480
-15% 13 460
-14 415/240
G i"
_15 380/220
I; THI
I
I 16 ov I
~
---- 17 575 I
J
IQJ _ 18 550 I
19 500 I
20 480 I
21 460 I
22 415/240 1
23 380/220 I
\II
24 OV JI~ ;ru--
TH2
1
• BREAKER.FUSE SIZE LINE FILTER
INPUT CIRCUIT LEAKAGE
VOLT AGE BREAKER BREAKER
- - - - - - --0-----o+~'V'if'li:l--n---------
50A 50A
- - - - - - - - -o-..'.:2:...--l---o-P'Vlf'l=l--0---------
30A 30A - - - - - - - - - - --0-..::3++---~7'<:/\Pc::~,__--------
20A
• CONNECTION TO TFI
POWER CONNECTION OF PRIMARY TAP
SUPPLY CONNECTING
VOLTAGE STYLE
LI L2 L3 JUMPER
220 7 15 23 8-15 I 16-23 I 24-7
240 6 14 22 8-14 I 16-22 I 24-6
DELTA /:::,.
380 7 15 23
415
6 14 22
440
460 5 13 21 STAR
8-16 16-24
480 4 12 20 y
500 3 II 19
550 2 10 18 ___L ( > - - - - - - - .
575 I 9 17
Fig.A.3 (c) Transformer/Line filter (5-800, M-500)
- 478 -
~-~
L() j ALC
Ar
_
) SERVO POWER CONTROL
(210VACl
I 2
3 4
SERVO POWER
5 6
J
14 41 )
l-f_::.::C-~2:::4+-.::42'.o------.---i----_J!__L_j__L-J--- I00 VAC
210 VAC
THERMOSTAT
FOR OVERHEAT
Fl ,F2,F3 30A
F4,F5 5A
Fl
- 479 -
~
o r©fN -I
0
CA39A
~
r
(')
0
z
z
m
(')
-I
0
z
0
.,, ~
ca· 11 APOWER SUPPL y
CPI CP4 CP8
166-1212-0870
)> I 63
(,) R EL]2
t JAL FA FB I I~
I I CPI 200-240 VAC INPUT B~~. I B~~- I
'.§; D fflJ I A3
I
I I I CP2 200-240 VAC OUTPUT ti ti2
ONOFF COM
c D---- I I
0 CP2
"ti I II CP3 200-240 VAC OUTPUT I
0 D---- CP5
RI
stffJ 63
...~ POWER ON/OFF ~v )>
I JNPO I CP4 D---- ALARM '1J
en ~ I '1J
00
c m
"'"
0 "C I CP5 +24 VDC OUTPUT CP3 z
"C D---- I
CP6
0
-< R2 Bl
I I I CP6 +24 VDC OUTPUT s[[f] x
c: D---- +24E
::I ~tELJ
;::;:
1 r~~T~E:Y- ~R~ - SPECIFICATION OF FUSE

~ I NAME FUSE POWER
0
9 Fl 7.5A 200V
s::: F3 5A +24V
Ji F4 5A •24E
0
s
~~~
~§~§
:5lc1il
c..000
o~~~
<1-1-1-
"'000
__J__J__J
CJJCJJCJJ
NcJ>U,
~
POWER SUPPLY UNIT
~
~
~ ~AN
I CA39A 0 01--~-'---'---~ JDIB JRMIO JRF2 JRVI
(l/O LINK) (OPERATION BOX) CROBOT FEEDBACK l (SERVO AMPLIFIER) t11
I I RXSLC 11 11 OV I I OV 1261 OV Al I PD6

Bl I •PD6 'A I IS6 BI GNDS6
i
BATTERY UNIT ,---- - ---, 2 •RXSLC 12 OV A21 OV
B21 OV A2 IR6 62 GNDR6 ~
21 RTSI 1271 CTSI
FOR MAINTENANCE I __JI I' I 3 TXSLC 13 OV 3 OV280V A31 PR06
B31 •PR06 A3 IS5 63 GNDS5
~~~~-§~~O VBAT [ 0--- - - - - - - i -----, I I 1-- I
4 •TXSLC 14 OV 41 DTRI 1291 DSRI A41 OV
B41 OV A4 IR5 64 GNDR5
-0040 [ 5 15 ov 5 OV300V A51 PD5
B51 •PD5 A5 IS4 65 GNDS4
JRVI
D ~-~
SERVO AMPLIFIER 6 16 ov 61 TXDI 1311 RXDI A61 OV
B61 OV A6 IR4 66 GNDR4
7 17 7 OV320V A71 B71 •PRQ5
PR05 A71 !>:;.> t>/I GNDS3
8 181 +5V 8 RTSA 33 CTSA A81 OV
B81 OV ABI IR3 BBi GNDR3
JRF2 [ D ROBOT FEEDBACK 9 +5V 19 9 OV340V A91 PD4
B91 •PD4 A91 IS2 691 GNDS2
10 201 +5V I0 DTRA 35 DSRA IAIOI OV
1610! OV IAIOI IR2 16101 GNDR2
11 OV 36 OV IAI II PR04
161 II •PR04 IAI ii ISi 161 ii GNDS I
JF21 [ 0---- LINE TRACKING I2 TXDA 37 RXDA IA121 OV
16121 OV IA12I !RI 16121 GNDR I
13 • TXTP 38 •RXTP IA13I PD3
16131 •PD3 IA13I •ENBL6 ~131 ov
JRA5n JDl7 14 TXTP 39 RXTP IA141 OV
16141 ov IA141 •PWME6 !6141 OV
n JRMIO [ 01---- TO OPERATION BOX CRS-232C/ 485 l
15 • TX485A 40 •RX485A Al51 PR03
16151 •PRQ3 IA15I •PWMC6 ~151 ov
lJ u (FOR T~m [ I RXDB II TXDB I6 TX485A 4 I RX485A IA16I OV6161 OV Al61 •PWMA6 16161 ov
2 ov 12 ov 17 ON 42 OV IA171 PD2
6171 •PD2 Al71 •ENBL5 16171 ov
JDIB [ I/O LINK
.,, o---- 3 DSRBC I3 DTRB 18 OFF 43 OV IA181 OV6181 ov !A18l •PWME5 16181 ov
RS-232C/ 485 INTERFACE 4 OV 14 OV 19 COM 44 +24V IA19I 16191 •PR02
PR02 IAl'li •PWMC5 16191 ov
JDl7 [ 0---- (OPTION)
ca· 5 CTSB 15 RTSB 201 •OPEMG 145 +24V IA201 OV
1620! ov IA20I •PWMA5 16201 ov
)> JRM3 [ 0>----- TO OPERATION BOX 6 ov 16 ov 21 I •EXEMG 146 +24V IA211 POI
16211 •PD I IA21I •ENBL4 16211 ov
(.) 7 RX485B 17 TX485B 221 EMGDM 147 +24V IA22l OV
16221 ov IA221 •PWME4 16221 ov
CRSI [ 0-- - - TO TEACH PENDANT
8 •RX485B 18 •TX485B 231 EMGEM 148 +24V IA23I PROI
16231 •PROI IA23I •PWMC4 16231 OV
:!: ~r::a: CRMIO [ 0---- RDI/RDO 9 19 +24E 241 •TPEMG 149 EMGBI IA241 OV
16241 OV A24 •PWMA4 624 OV
10 +24E 20 251 SVON 150 EMGB2 A251 OV
16251 ov A25 •ENBL3 625 OV
Ill
999
w,.... ..... ,.... ,261 ov 16261 ov A26 •PWME3 626 OV )>
== zOOO
s· 271 +5V 16271 +5V ,A27 •PWMC3 627 OV "1J
IA281 +5V 281 +5V A28 •PWMA3 628 OV "1J
0 ~lll CRSI JF21 VBAT IA29I +5V 291 +5V A29 •ENBL2 629 OV m
00 "C (TEACH PENDANT) (BATTERY)
""" CLINE TRACKING) A3C •PWME2 630 OV z
c: o~~~ IA30I +5V 30! +5V
iiit;t;t; 01 TXTP ,. •TXTP PA II I EXVBAT A31 +5V 631 +5V A3 I •PWMC2 631 OV 0
08
RXTP •RXTP
- -'-'-'
~~~
02
OJ EMGDM
0.
TO EMGBI
iO
i6 EMGEN
2
3
•PA
PB
121
13
ov 2 ov A32
A33
+5V
+5V
63<
633
+5V
+5V
A3:
A33
•PWMA2
•ENBL I
632
633
OV
OV
x
04 iT EMGe2 17 ov
05 ii •PB 141 OV A34 +5V 634 +5V A34 •PWME I 634 OV
i2 EMGTP A35 +5V 635 +5V A35 •PWMC I 635 OV
06 +24V i9 ov 5 PZ 15
07 1'24V
13 2o 161 OV A36 +5V 636 +5V A36 •PWMA I 636 OV
6 •PZ
7 17 A37 +5V 3 +5V A37 •MCON 637 +5V
8 REQ 181 +5V A38 +5V 31 +5V ,A38 •DROY 638 +5V
if
9 +5V 19 A39 +5V 3' +5V A39 OV 639 +5V
~ IOI 1201 +5V A40 +5V 41 +5V A40 OV 40 +5V
'A4 I +5V 641 +5V A41 + 15V 41 +5V
;:i>
A42 +5V 642 +5V A42 + I 5V 42 +5V
A43 OV 643 OV A43 OV 643 +5V b
CRSI JRM3 A44 OV 644 OV A44 OV 644 +5V
(TEACH PENDANT! (PDI/PDO)
A4~ +24E 645 +24E A45 - I 5V 64! +5V ~
01 ROii I I POI I 11 11 OV A46 +24E 646 OV A46 - I 5V 641 +5V
r
08 RDI7
02 RDI2 2 OV 12 POOi IA4 16471 •OTREL A47 OV 64 +24V ()
0. RDI8
TO Roi9 OJ Roi3 3 PDI2 13 PD02 A48 •OTRST 648 •ROT A48 OV 641 +24V 0
04 RDI4
iT •HBK 4 PDI3 14 PD03 A49 SVON 649 •HBK A49 •BRKON 649 +24V z
05 RDI5
i2 RD07 A50 •BRKALM 650 +24V
06 RDI6 5 PDI4 15 PD04 A50 RDICOM 650 •HBKREL z
13 RD08
20 +24E 07 Ov 6 PDI5 16 PD05 m
7 PDI6 17 PD06
8 PDI7 18 PD07 ~
9 TPOFF 19 +24V
I0 +24V 20 PDOB
5z
0
5>
G')
::0
v- MAIN CPU BOARD )>
s::
AMPI
'!>
______, @
d
LI ~
r
L2 (")
SERVO POWER ~ L3
LIC Tl
0
CONTROL POWER(200VAC) L2C
z
z
THI m
THERMOSTAT FOR TRANS TH2
~
- / 6
UL z
VL
WL 0
PE
)>
Tl MOTOR POWER Ci)
E-STOP CONTROL [ CX4 UM
VM ~
WM s::
ce·Tl PE
>
(.)
.JSIB .JS2B
:3
en
CD
~
SERVO CONTROL ( ~
0 )>
)> "tJ
"tJ
~ 3 m
00
N ¥: z
:::!! 0
CD AMPI AMP2-4 x
...
Tl Tl CX4(X-KEY)
% (TERMINAL BLOCK) (TERMINAL BLOCK) (ESTOP CONTROL)
Q
9 ---i 3
I @ @ E~P I +2 4V I
s: - 13 LIC
J, 2 LI (R) LI (R)
Q 14 L2C
Q
._.. 3 L2(S) L2(S)
t3l LIC ~ 15
- 4 L3(T) L3(T)
14 L2C 16
5 ( IOOA) ( IOOAl JSIB/JS2B
15 THI 17 RC
6 ( IOOB) ( IOOBl (SERVO CONTROL)
16 TH2 18 RI
7 RL2 7 RL2 I IR 11 IS
17 RC - 19 RE 2 GNDR 12 GNDS
8 RL3 RL3
18 RI - 20 [UL] 3 •PWMA 13 •ENBL
9 U[UM~ U[UM] 4 ov 14 ov
19 RE [VL]
10 V[VM~ V[VM] 5 •PWMC 15
24 FANI [WL] 6 ov 16
11 W[WM2__ W[WM]
25 FAN2 [@J 7 •PWME 17
121 @ J @ 8 ov 18
%
~
9 •DROY 19 ov !)l
10 •MCON 20 ov ~
~
E-STOP PCB
I
JRF2 JRVI
(ROBOT FEEDBACK) (SERVO CONTROL) SERVO CONTROL JRVI CRFI TO ROBOT ( FEEDBACK )
Al P06 Bl •PD6 Al IS6 Bl GNDS6
D
A2 OV B2 ov A2 IR6 B2 GNDR6 ROBOT FEEDBACK JRF2
I~~
A3 PRQ6 B3 •PRQ6 A3 IS5 B3 GNDS5 JSI D
A5 PD5 B5 •PD5 A5 IS4 B5 GNDS4 E -STOP CONTROL CRM9 JS2 D
DOOR INTERLOCK CRMl5 JS3 D
A7 PR05 B7 •PR05 A7 IS3 B7 GNDS3 I SERVO CONTROL
A8 ov B8 ov A8 IR3 B8 GNDR3 AUX BRAKE CONTROL CRMl6 JS4
D
AIO ov BIO ov AIO IR2 BIO GNDR2 JS5 D
Al I PRQ4 Bl I •PRQ4 Al I ISi Bl I GNOSI
E-STOP CONTROL JS6 D
Al2 ov Bl2 OV A12 !RI Bl GNDRI D~ CRR20
Al3 PD3 Bl3 •PD3 Al3 •ENBL6 Bl ov I OOVAC INPUT FOR BRAKE POWER - - - ----(] CRR2 I CRMI I ROBOT OVERTRAVEL
A14 ov Bl4 ov Al4 •PWME6 Bl4 ov D
Al5 PRQ3 Bl5 •PRQ3 Al5 •PWMC6 Bl5 OV CRR5 D MOTOR BRAKE POWER
::!!
ca Al6 ov Bl6 ov Al6 •PWMA6 Bl6 ov I OOVAC OUTPUT FOR AUX MOTOR
CRR22 0----- (C-SERIES AMPLIFIER)
)> Al7 PD2 Bl7 •PD2 A17 •ENBL5 Bl7 ov
(.) Al8 ov Bl8 OV Al8 •PWME5 Bl8 ov
Al9 PRQ2 Bl9 •PRQ2 Al9 •PWMC5 819 ov
§: A20 ov B20 OV A20 •PWMA5 820 ov
A21 POI B21 •POI A21 •ENBL4 B21 OV CRM9 JSI -JS6 CRFI
m A22 OV B22 ov A22 •PWME4 822 ov ( E-STOP CONTROL) (SERVO CONTROL) (PULSE CODER INTERFACE l
3
(1) A23 PRQI B23 •PROI A23 •PWMC4 823 ov I IR II IS
.
ca A24 ov B24 OV A24 •PWMA4 824 ov ~oNlsv~uTI 2 GNDR 12 GNDS
(1) A25 ov B25 ov A25 •ENBL3 B25 ov 3 •PWMA 13 •ENBL
:;, A26 ov B26 ov A26 •PWME3 826 ov 4 ov 14 ov >
n +5V B27 +5V A27 •PWMC3 B27 OV 5 •PWMC 15 "'O
'< A27 CRMl5
+:> "'O
A28 +5V B28 +5V A28 •PWMA3 B28 ov (DOOR INTERLOCK) 6 ov 16 m
00
~ A29 +5V B29 +5V A29 •ENBL2 B29 ov 7 •PWME 17 z
0 3
"C A30 +5V B30 +5V A30 •PWME2 830 OV ~ 8 ov 18 0
+5V
-"'
"'C A31
A32
+5V
+5V
B31
B32
+5V
+5V
A31
A32
•PWMC2
•PWMA2
B31
B32
ov
ov
'--~---'-o_r~ 9
10
•DROY
•MCON
19
20
ov
ov
43
44
+5V
+5V
28 ov ...J..!..!..
12
x
0 29 ov
m A33 +5V B33 +5V A33 •ENBLI B33 OV 45 +5V 13
30 +5V
+5V +5V A34 •PWME I B34 46 +5V J!
A34 B34 ov CRMl6 31 +5V
CRR5 47 +5V 15
A35 +5V B35 +5V A35 •PWMCI B35 OV (AUX BRAKE CONTROL) 32 +5V
48 +5V T6
~ A36 +5V B36 +5V A36 •PWMAI B36 ov 2 ID 20 30 49 +5V 17
0 A37 +5V B37 +5V A37 •MCON 837 +5V BKM3 BKM3 BKM3 50 +5V la
•BRKON41•BRKDN3
5' A38 +5V B38 +5V A38 •DROY B38 +5V IC 2C 3C
s:: A39 +5V B39 +5V A39 ov 839 +5V
BKP3 BKP3 BKP3 ;i>
A40 +5V B40 +5V A40 ov B40 +5V
J. +5V + 15V B41 +5V CRR20 IB 2B 3B CRMI I
0 A41 +5V B41 A41
( EMG CONTROL) BKMI BKM2 BKM2 (ROBOT OVERT RAVEL)
s A42 +5V B42 +5V A42 +15V 842 +5V d
A43 ov B43 ov A43 ov B43 +5V A3 A2 Al IA 2A 3A
A44 ov B44 ov A44 ov B44 +5V 200T 200S 200R BKPI BKP2 BKP2 I ~
r
n n
3 I•Rortd:fj
A45 +24E B45 +24E A45 -15V 845 +5V
A46 -15V B46 +5V B3 B2 Bl (')
A46 +24E B46 ov
A47 B47 •OTREL A47 ov 847 +24V AC3 AC2 ACI 0
A48 •OTRST B48 •ROT A48 OV 848 +24V n n z
A49 SYON B49 •HBK A49 •BRKON B49 +24V z
A50 RD I COM B50 •HBKREL A50 •BRKALM B50 +24V CRR21 CRR22 m
(BRAKE POWER l ( I OOVAC OUT)
3 2
~
~OB IOOA I OOOUT21 I OOOUT I 5
~ z
0
5>
G>
E-STOP UNIT ~
s::
OPERATOR PANEL
TXTP
•TXTP
RXTP
•RXTP
(.JRMIO) ( 14)
(13)
(39)
(38)
(2)
(15)
(I)
( 14)
..
( CRSI l
TXTP
TXTP
RXTP
RXTP TO TEACH POOANT
·~·
(6, 7)
(17 19) +24V
0v
OPERATOR PANEL PCB oV -~(~I)
FG
A20B- I 006-0290(AFTER EDITION 028)
( PORTI)
(.JRMIO) (6) (2)
TXDI (JI l (3) T XDI
RXDI (2) (4) RXDI
RTSI (27) (5)
RTSI
CTSI cTSI
DSRI
DTRI
+24V
ov
(29)
(4)
U«lTE IJ
!NOTE 21
..... ..... (6)
20)
(25)
(7)
DSR I RS-232-C
ov
DTRI
+ 24V
(PORT IX) oV oV (I)
FG
12)
TXDIX (3)
(NOTE I) RXDIX (4)
+24V;.JRM I 0-44, 45, 46 RTSIX 5)
47,48 CTSIX (6)
DSRIX 20)
!NOTE 2) DTRIX
OV ;.JRM 10-1.3,5,7,9 (25) •Z4V
11,26,28 +24V (7)
30,32,34 ov (I) Iii>
36,42,43 FG
C.JRMIO) (12)
TXDA (37)
RXOA (8)
RTSA (33)
CTSA (35)
DSRA (10)
DTRA
TX485A
•TX485A
RX485A
•RX485A
..
(16)
(40)
( )
(15) ·~v (3)
(4)
( RT4l
t - - +24V
(PORT2l (2) t- -ov
TXDA
RXDA
(3) ov
(4)
RTSA (5)
CTSA 16)
DSRA (20)
DTRA
( 14)
TX485A (15)
•TX485A (16)
RX485A
•RX485A
+24V
( 17)
(25)
(7)
.....
ov (I) oV
FG
NOTE; PORT2 rs OPTION. = FG
Fig.A.3 {h) Operator's Panel-1 {Both Models)
- 484 -
OPERATOR PANEL
OPERATOR PANEL PCB
FROM MAIN CPU A20B-1006-0290(AFTER EDITION 028)
(JRM3J (CRT3) .._
p DOI (12) (Ail
LEO I ; REMOTE
p D02 (13} CBI) ~
SW4 ;C-START
p D03 ( 14) (A21
CNOT UESOJ
p 004 (15) (82) ~
LED2; F-RESET
p D05 (16) CA3)
(NOT LESO)
p D06 I 17) CB31 (NOT LESO)
(18) CA41 (NOT l.£SO)
PD07
(20) (8()
PD08 CNOT LESO)
(ii CA51
PD I I (NOT UESOl
(3) (851 ~0-
PD I2 SW6; F-RESET
(4) CA61 _,__
PD I3 SW31REMOTE
(5) (861
PD I4 CNOT l.£SO) REMOTE LOCAL
(6) (A,7)
PD I5
(7) (87)
(NOT l.£SO) .;.,, -'-
00
PD I6 (NOT UESDI
(8) CA8J
PD I7 0- SW6, F -RESET
(9) (881
TPOFF CNOT l.£SOJ
(10.19) +¥V •2f.V (Al6.Al71

+24V
ov (2.11) CAl7) ... SWI ;ON
o'v
FRC»t MAIN CPU
EMGDM
(JRMIO) (221
23
•¥V
* (12)
3
16
(CRSI)
~·-·--··-
..,..
"' DEAD-MAN
EMGEN
1491 T 1101 ENABLE/
EMGBI 50 II DISABLE
EMGB2
RLDM ;QJ ENABLE DISABLE
ov I ov I ~ Ole
I I ESTOPI (TBOPI)
[l
ESTOP2
{Al I)
(81 I)
CA12l
(812
I
I
- - - - - - - - .._ ____ _.
FENCfl CTBOPI J
I FENCf2 ---------- - - -0.,0-,
+24V (CRT3)
+24V T CAl6,816) +24V
TPEMG
(24) -__I RNAI (Al3) CPEMGAI
'""
(813) CPEMGA2
OPEMG
(20) I {Al!5) OPEMJBI I
I RLTPEM (A,14) OPE>G:I
{814) OPE>G:2 I
OV (TBOPI)
EMGOUT EMGINI
EXEMG
(21) OV -__J
+24V
EMGIN2
SVONI
========-=--=- --=---~~
] ----------
(TBOPI)
_____ - - -0.,0-,
....
(25) SVON2
SVON
HOUR METER
zJ
CR-;; -;- - - -
I +24V
(ii 1 5
I
T
~
(2) i'
12
+24V
T
I ov y ov (3) Holl
I 3 4
r
·- EMOOJTI
EMOOJT2
CTBOPI)
(TBOP2) -'--
ON
(17)
T
EXONI
--------- ---ocr-,
COM
(19) EXCC»t
--------- -----~
OFF
( 18)
I
EXCFFI
(A,09) a.II
---------
-'--
---Ol(r-.J
(809) a.12 I
11 CAIO) ~I
I <Bl I) ~2 I
(CRT3)
- 485 -
"!>
JRMIO JRM3 PORTI PORT IX PORT2 d
(MAIN CPU I/Fl (MAIN CPU I/Fl (RS-232-C; PORT-I) CRS-232-C; PORT-I) CRS-232-C; PDRT-2) );!
l-l)N'.)A PCR50 HONDA PCR-E20 o-sua 21SP o-sue2!SP o-sue 25P
MALE MALE FEMALE FEMALE FEMALE r-
26 OV I ov II ov I PDII I FG I FG - 14 - I FG ()
14 14
27 CTSI 2 RTSI 12 PDOI 2 OV 2 TXDI 2 TXDI _ 15 2 TXDA
15 - 15 0
28 ov 3 ov 13 PD02 3 PDI2 3 RXDI 3 RXDI 3 RXDA
16 16 16 z
29 DSRI 4 DTRI 14 PD03 4 PDI3 4 RTSI 4 RTSI_ l7 4 RTSA
17 -
17 z
30 ov 5 ov 15 PD04 5 PDI4 5 CTSI 5 CTSI 5 CTSA
18 18 18 m
31 RXDI 6 TXDI 16 PD05 6 PDI5 6 DSRI 6 DSRI_ 6 DSRA
19 19 19
32 ov 7 ov 17 PD06 7 PDI6 7 ov 7 ov 7 ov
20 DTRI 20 DTRI 20 DTRA ~
33 CTSA 8 RTSA 18 PD07 8 PDI7 8 8 8
21 21 21
34 OV 9 ov 19 +24V 9 TPOFF 9 9 9 6
22 22 22
35 DSRA 10 DTRA 20 PD08 10 +24V 10 10 10 z
23 23 23
36 ov II ov II 11 II
24 24 24 0
37 RXDA 12 TXDA 12 12 12
REMOTE = PDOI F-RESET= PDI2 25 +24V ,_g.5 +24V 25 +24V 5>
38 •RXTP 13 •TXTP 13 '"13 13
C-START= PD02 REMOTE = PDI3 G>
39 RXTP 14 TXTP THIS COl\NECTOR IS OPTION
FAULT = PD04 C-START• PDI7 THIS CDf'.lllECTOR IS MOUNTED ON THIS CQN\IECTOR IS MO..NTEO ON THIS CONECTOR IS MOl.NrEO ON
40 •TX485A 15 •RX485A EXTERNAL SIDE OF Tl-£ BOX INTERNAL SIDE OF THE BOX INTERNAL SIOE OF THE BOX
:c
!! (TPOFF} = PDI8 )>
CCI 41 RX485A 16 TX485A
42 ov 17 ON s:
> 43 ov 18 OFF
JDIA CRSI TBOPI TBOP2 TBOP3
(I/D LINK) (TEACH PENDANT) (EMERGENCY IN/OUT) (EXTERNAL ON/OFF) (MODEL B
w 44 +24V 19 COM
...... HONDA PCR-E20 HONDA t-R-20$
45 +24V 20 OPE MG MALE FEMALE M4 TERMUNALS
- -~ M4 TERM~ALS M4 TERMLNALS
46 +24V 21 EXE MG II ov I PDII I TXTP 14 •TXTP I EMGINI I EXONI I S2+
0
- 8
47 +24V 22 EMGDM 12 PDOI 2 ov 2 RXTP 15 •RXTP 2 EMGIN2 2 EXOFF 2 S2-
9
48 +24V 23 EMGEN 13 PD02 3 PDI2 3 EMGDM 16 EMGEN 3 FENCE I 3 EXOFFI 3 S3+
i... 10 EMGBI
49 EMGBI 24 TPEMG 14 PD03 4 PDI3 4 17 ov 4 FENCE2 4 S3-
II EMGB2
a 50 EMGB2 25 SVON 15 PD04 5 PDI4 5 18 5 SVONI 5 +24V
0 12 EMGTP )>
16 PD05 6 PDI5 6 +24T 19 ov 6 SVON2 6 ov
13 "'C
17 PD06 7 PDI6 7 +24T 20 FG 7 ESTOPI
.j::o. 18 PD07 8 PDI7 8 ESTDP2
"'C
;..,,
00 THIS Cm.NECTOR IS MOLNTEO ON m
DI CRT3 19 +24V 9 TPOFF EXTERNAL SIDE OF Tl£ BOX 9 EMGOUT2 z
°' :s (PANEL SW/LED) 20 PDD8 10 +24V 10 EMGOUTC 0
CD 11 EMGOUTI
YAMAICHI ·34P x
;!; / A B
I REMOTE C-START CRP6 CRS9
2 (POD3) FAULT CDISCONNECTl (I/O LINK)
PANEL DO
3 (PD05) (PD06)
HJLEX-~ MOLEX-4P
~
0 4 (PD07) (PD08) ··---·· -·
9 I +24V I TXSLC
5 (PDII) F-RESET
2 +24T 2 •TXSLC
6 REMOTE (PDI4)
PANEL DI 3 EMGBI 3 RXSLC
7 (PDI5) (POI6)
4 EMGB2 4 •RXSLC
f
0 8 C-START (TPOFF)
5
9 ONI ON2
.s 10 OFFI OFF2
II (Tl) (T2)
12 CAUTO) (MOOCOM}
13 OPEMGAI OPEMGA2
14 (OPEl«lCll OPEMGC2
15 OPEMGBI HMI
16 +24V +24V
17 ov ~
OPERATOR PANEL i
~
RMI
(PULSE CORDER & RDI/RDO}
I RDII 13 RDI2 25 RDI3 37 RDI4 49 RDI5 61 RDI6 U1
2 RDI7 14 RDI8 26 +24E 38 +24E 50 +24E 62 ov

i
3 RDOI 15 RD02 27 RD03 39 RD04 51 RD05 63 RD06
~
4 RD07 16 RD08 28 •ROT 40 •HBK 52 •PPABN 64
5 +5V 17 +5V 29 +5V 41 ov 53 ov 65 ov
6 +5V 18 +5V 30 +5V 42 OV 54 OV 66 OV
7 +5V 19 +5V 31 +5V 43 ov 55 ov 67 ov
8 +5V 20 +5V 32 +5V 44 ov 56 ov 68 ov
9 SPDJI 21 SPDJ2 33 SPDJ3 45 SPDJ4 57 SPDJ5 69 SPDJ6
10 •SPDJI 22 •SPDJ2 34 •SPDU 46 •SPDJ4 58 •SPDJ5 70 •SPDJ6
II SPRQJI 23 SPROJ2 35 SPRQJ3 47 SPRQJ4 59 SPRQJ5 71 SPRQJ6
'Tl
cS' 12 •SPRQJI 24 •SPROJ2 36 •SPROJ3 48 •SPROJ4 60 •SPROJ5 72 •SPROJ6
;,i.
(,)
e
iii:: RMI
CD (MOTOR POWER & BRAKE}
n
:::r
DI I BKPJI 8 BKMJI 15 J41A 22 J42A 29 J43A 36 J4GA
:::s )>
r;· 2 BKPJ2 9 BKMJ2 16 J41B 23 J42B 30 J43B 37 J4GB "'C
!!?. "'C
00 3 BKPJ3 10 BKMJ3 17 J51A 24 J52A 31 J53A 38 J5GA m
....i
""' c: z
:::s 4 BKPJ4 11 BKMJ4 18 J51B 25 J52B 32 J53B 39 J5GB 0
;::;:
5 BKPJ5 12 BKMJ5 19 J61A 26 J62A 33 J63A 40 J6GA x
S'
i 6 BKPJ6 13 BKMJ6 20 J61B 27 J62B 34 J63B 41 J6GB
;. 7 14 21 28 35 42
g
'fg "?'
.._.
RM2 d
(MOTOR POWER}
~
r
(')
0
z
z
m
(')
-i
5z
0
)>
Ci)
S-800 :D
)>
MECHANICAL INTERFACE s::
'!>
RPI RPI d
(PULSE CORDER ~ ROI/ROOl (PULSE CORDER ~ RDI/RDOl
~
r
ROI I I 131 ROI2 1251 ROI3 1371 ROI4 1491 ROI5 161 I ROI6 I ROI I 13 RDI2 25 RDI3 37 RDI4 49 RDI5 61 ROI6
(")
2 ROI7 14 ROIS 26 +24E 3S +24E 50 +24E 62 OV 2 RDI7 14 ROIS 26 +24E 3S +24E 50 +24E 62 OV
0
3 ROO I 15 R002 27 R003 39 R004 5I R005 63 R006 3 ROO I 15 R002 27 R003 39 R004 5I RD05 63 RD06 z
4 R007 16 ROOS 2S •ROT 40 •HBK 52 •PPABN 64 4 R007 16 ROOS 2S •ROT 40 •HBK 52 •PPABN 64 z
m
5 +5V I7 +5V 29 +5V 41 OV 53 OV 65 OV 5 +5V 17 +5V 29 +5V 41 OV 53 OV 65 OV (")
6 +5V IS +5V 30 +5V 42 OV 54 OV 66 OV 6 +5V IS +5V 30 +5V 42 OV 54 OV 66 OV -I
7 +5V 19 +5V 31 +5V 43 OV 55 OV 67 OV 7 +5V 19 +5V 31 +5V 43 OV 55 OV 67 OV 5
S +5V 20 +5V 32 +5V 44 OV 56 OV 68 OV S +5V 20 +5V 32 +5V 44 OV 56 OV 6S OV
z
0
9 SPOJ I 21 SPOJ2 33 SPOJ3 45 SPOJ4 57 SPOJ5 69 9 SPDJ I 21 SPDJ2 33 SPDJ3 45 SPDJ4 57 69
I Ol •SPOJ I l22l •SPOJ2 l34I •SPDU l461 •SPDJ4 l5Sl •SPDJ5 l70 I Ol •SPDJ I l221 •SPDJ2 l341 •SPDU l46l •SPDJ4 l581 170 ~
.,, I 11 SPRQJ I 1231 SPRQJ2 l35I SPRQJ3 l471 SPRQJ4 l59I SPRQJ5 l71 11 ISPRQJI l23ISPRQJ2l35ISPRQJ3l47ISPRQJ4l59I 171 :a
)>
ca· 121 •SPROJI l241 •SPRQJ2 l36l •SPRQJ314Sl •SPROJ4 l60l •SPROJ5 l72 12 I •SPRQJ I I 24 I •SPROJ2 I 36 I •SPROJ3 I 4S I •SPRQJ4 I 60 I 172 s:::
>
(.)
5
-- RMI RMI
=::: (MOTOR POWER ~ BRAKE) (MOTOR POWER ~ BRAKE)
~
'::r I BKPJ I S BKMJ I 15 J2 I A 22 J22A 29 J23A 36 J2GA BKPJ I I S I BKMJ I I 151 J2 I A 1221 J22A 1291 J23A 1361 J2GA
DI )>
::I 2 BKPJ2 9 BKMJ2 16 J2 I B 23 J22B 30 J23B 37 J2GB 2 BKPJ2 9 BKMJ2 16 J2 I B 23 J22B 30 J23B 37 J2GB
c;· "'Cl
3 BKPJ3 10 BKMJ3 17 J41 24 J42 31 J43 3S J4G 3 BKPJ3 I 0 BKMJ3 I7 J4 I 24 J42 31 J43 3S J4G "'Cl
~ !.
00 4 BKPJ4 I I BKMJ4 I S J5 I 25 J52 32 J53 39 J5G 4 BKPJ4 I I BKMJ4 I S 25 32 39
m
00 c: z
::I 5 BKPJ5 I 2 BKMJ5 I 9 26 33 40 51 1121 1191 1261 1331 140 0
;::;:
5'
6 I I 131 1201 1271 1341 141 6 I I 131 1201 1271 1341 141 x
7 IOPBKPJI I 14IOPBKPJ3l21 IOPBKMJI l2BIOPBKMJ3l35l 142 7IOPBKPJII14IOPBKPJ3l21 IOPBKMJI l2SIOPBKMJ3l35I 142
CD
I
1 RM2 RM2
c (MOTOR POWER) (MOTOR POWER)
s
3 J31 2 JI I J31
6 J32 5 Jl2 J32
9 J33 s Jl3 J33
101 J2G
121 J3G 11 JIG 121 J3G
~
M-500 5 AXES M-500 4 AXES

MECHANICAL INTERFACE MECHANICAL INTERFACE ~
~
~
~
PROCESS I/O
MAIN CPU m
A 166-3200-0040
CR2A [ D I TYPE CF PROCESS I/O CSINK TYPE J
i
~
CR2B [
SPECIFICATION CRM2A CRM2B CRM2C CRM2D CRM4A CRM4B CRWI CRW2
.JOIA [ tJ .J04A CR2B [ CA A I 66-220 I -04 70 0 0 x x x x 0 0
----0 tJ .J04B SOI/SOC
CR2B [ CB A I 66-220 I -04 72 0 0 x x x x x x
DA A 168-220 I -0480 0 0 0 0 0 0 x x
CR2B [
.JD4A,B CR2B [
(RS-422/SLC)
I RX II ov CRWI [ TO WELO MACHINE ( A/0, 0/ A, WDI/WDD)
2 •RX 12 ov
3 TX 13 ov I
CRW2' [ TO ANALOG INTERFACE (AID)
4 •TX 14 OV
5 15 OV
6 16 ov
!! 7 •ENBL 17 -15V
cg 8 + 15V 18 +5V I/O LINK SLAVE
)> 9 +5V 19 +24V
(.) 10 +24V 20 +5V
._..
- CRM2A CRM2C CRM4A CRWI
'ti CSOI/SDDJ CSDI/SDOJ (SOI/SOOJ CWELD INTERFACE OPTION l
01 •IMSTP 33 CMDENBL 01 SOI23 33 $0021 01 SOI63 14 $0061 01 DACHI 23 WOOi
OS 50065 13 AOCHI )>
~ 02 •HOLD 34 SYSRDY 02 SDI24 34 $0022 02 $0164 15 SD062 02 CAK>AI 24 W002
CD 19 ACK3/SN03 19 $0033 09 $0066 14 COMAOt '1J
03 •SFSPO 35 PROGRU< 03 50125 35 50023 03 $0165 16 $0063 03 DACH2 25 WD03
I/I 20 ACK4/SN04 20 $0034 10 $0067 15 AOCH2 '1J
04 CSTOPI PAUSED 04 50126 36 $0024 04 SOI66 17 $0064 04 CAKlA2 26 WD04
I/I 21 ACK5/SN05 J6 21 $0035 II $0068 16 COMA02 m
00 05 FAULT RESET COM-Al 05 SDI27 37 COM Cl 05 SDI67 IS COM-El 05 WDII 27 wooo
22 ACK6/SN06 ~~ 22 $0036 12 COM-E2 17
""" 06 START HELD 06 50128 3S $0025 06 SDI68 19 +24E 06 WDI2 2S W006 z
23 COM-A4 23 COM-C4 13 $0170 IS
cs 07 HOME FAULT 07 50129 39 50126 07 SDI69 20 ov 07 WDIJ 29 W007 0
'° 24 ACK7 /SN07 !~ 24 $0037 19 ov
08 Ef\BL ATPERCH OS 50130 40 50027 OS WDI4 30 woos
25 SD03S 20 ov x
09 RSR I /PNS I ~: "':~~08 41 TPEl'el 09 50131 41 S002S CRM4B 09 war• 31 WCI•
26 $0039 21 ov
I0 RSR2/PNS2 COM-A2 10 80132 42 COM-C2 CSOI/SOOJ 10 WDI6 32 war-
27 RESERVED :~ 27 50040 22 ov
II RSRJ/PNSJ BAT ALM II 50133 43 S0029 01 SDl71 14 $0069 II WOI7 33 •24£
t
c
9 12 RSR4/PNS4 ~: p:;~ 44 BUSY 12 SOIJ4
2S
29
COM-C5
SOI39
.. $0030 02 SDI72
OS
09
$0073
$0074
$0070 12 wars 34 +24E
13 RSR5/PNSl5 ACKl/SNOI 13 SOI315 45 $0031 03 SOI73 16
'" $0071
30 PROD ST ART :: 30 SOI40 10 $0075
ii: 14 RSR6/PNS6 ACK2/SND2 14 SDI36 46 S0032 04 SOI74 17 $0072 CRW2
31 SOIOI 31 SOUi II $0076
115 RSR7 /PNS7 47 COM-A3 15 80137 47 COM-CJ 05 SOI75 IS COM-Fl ( A/D INTERFACE OPTION l
J, 32 $0102 48 32 SOI42 12 COM-F2
16 RSRB/PNSB 16 SDI38 4S 06 SOI76 19 +24E 01 14 AOCH3
13 SOI78 OS AOCH6
17 ov 49 +24E 17 ov 49 +24E 07 SOI77 20 ov 02 15 COMA.DJ
.§ 09 COMA06
IS ov 50 +24E IS ov 50 +24E 03 16 AOCH3
10 ~
04 17 CCIMA04
II
CRM2B CRM2D 05 IS AOCH5
12
CSOI/500) (SDI/SOOJ 06 19 COMA.015
13
80143 33 $0041 07
01 50103
SOI04
33
34
SODOI
$0002
01
02 80144 34 $0042
20
d
02
19 $0013 19 50053 ~
03 $01015 35 $0003 03 $01415 35 SOD43
20 80014 20 50054 r
04 SOI06 36 $0004 04 80146 36 SOD44
21 $0015 21 50055 (')
05 SOI07 37 COM-Bl 05 SDI47 37 COM-DI
22 80016 22 50056
06 SDI OB 38 SD005 06 80148 3S $0045
23 COM-84 23 COM-04 0
07 80109 39 $0006 07 $0149 39 $0046
24 $0017 24 50057 z
OS SOilO 40 S0007 OS SOI!54 40 $0007
25 80018 25 S005S
09 SOii I 41 sooos 09 $01!51 41 S004S z
26 $0019 26 50059
10 $0112 42 COM-82 10 SDI52 42 COM-D2 m
27 $0020 27 $0060
II SOil3 43 S0009 II SOI!53 43 $0049
2S COM-85 2S COM-05
12 $0114 44 $0010 12 SOI54 44 50050
29 SDil9 29 $01!59 ~
13 SOI15 45 $0011 13 SOI!5!5 45 $0051
30 SOI20 30 $0160
14 SOil6 46 $0012 14 SOI!56 46 50052 0
31 SOI21 31 $0161
,. SOI17 47 COM-BJ 15 SOI!57 47 COM-03 z
32 SOI22 32 $0162
16 SDil8 4S 16 SOI!58 4S
17 ov 49 •24£ 17 ov 49 +24E CJ
IS ov 50 •24£ IS ov 50 +24E
>
Ci)
PROCESS I/O BOARD(SINK TYPE) ::c
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s::
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I/O UNIT MODEL A d
);!
POWER SUPPLY
r
A I 6B- I 2 I 2-0870 ()
CP32 JDIA/JDIB JD2
MODULAR I/O 0
5-SLOT BASE UNIT 1 A03B-0807-J002 +24V RX II ov SI II S5 z
CP6 [ 2 ov 2 •RX 12 ov 2 •SI 12 •S5 z
0 INTMJl~FUklJ' M~~ULE MODULAR I/O 3 3 TX 13 ov 3 S2 13 S6 m
A03B-0807-JO I I 4 •TX 14 ov 4 •S2 14 •S6 ()
'------io CP32 5 15 5 S3 15 ov -I
6 i6 6 •S3 16 OV
JDIB 17 7 S4 17 ID2
6
8 8 •S4 18 ID3
z
MAIN CPU 0 JDIA 9 +5V 9 IOI 19 0
A I 6B-3200-0040 10 10 20
JD2 5>
.,, G')
JJ
ce· JDIA d Q--- )>
)> s::
c.,
3_..
(§
c:
:I
;:;: )>
I/O UNIT MODEL B
s:: BASIC UNIT EXPANSION UNIT -0
+:- 0 -0
\0 c m
0 m POWER SUPPLY z
r A I 6B- I 2 I 2-0870 0
(!)I +
>
>~
OC'\I
~ LL.en en x
CD CP6 [
....... I/O UNIT MODEL B
INTRF ACE UNIT
I
A03B-0808-COO I
I
0
% L..; 24V
~
24V
~
:
I
) TO BASIC UNIT 2-4
~o SI+
SI-
MAIN CPU
f A I 6B-3200-0040
0 ffB~:: S2- TO BASIC UNIT 2
0
_.. FG
S3+
JDIA [ S3- TO BASIC UNIT 3
FG
~
S4+
S4-
l TO BASIC UNIT 4
FG
JDIA/JDIB
11 RX II I ov
2 •RX 121 ov '--~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~!--~~~~ I/O LINK SLAVE
3 TX 131 ov
•TX 141 ov
15
6 16
7 17
8 181 +5V
9 +5V 191
10 201 +5V i
~
TEACH PENlANT
JRMIO OPERATION BOX PCB
MGTP
EMERGEN:Y STOP BUTTON
R-J2 MGBI
MAIN CPU MG82 I
I ~ ~ RLEN """" DEAD-HAN SWITCH

FENCE
CffMG RV
h~~~~~l-~~~-,--t:l+t==~~·-·~·=t~~
..RMIO
I ., n~M"I :-=:S:--~EMERGENl:V TPEMG ....
J I I I +¥V ~~WO:~)
STOP BUTTON
1-=-y..---flt-------ttt-------<f"-v_~~d+.4V
2
~.~:::-.~ THIS TERMINAL IS OPTICH
TPEMG RV ov I _.. Eli'GINI ~ EXTERNAL EIERGENCY STOP
EXEMG -fRVl EMGINC
- ~~ DGJJT ,!. SVONI
1
SERVO ON/CF SWITCH
OV OV ,,\, Y SVON2
SVON RV Svtf\I I I ESTCPI

n--- l"'1
I '------<lt'E"'ST,_,OP2=- 240VC(OPTJCIO
ov ov I ~---------~"'="""""~'--
IOOYAC/240VC
I I EMGOl.ITC
RV ; RECEIVER
F<lR DI ·~~ ----~~) HClJR METER
(OPTICtO
.p<FI
,... - , L....i::::'i
I I
~ ~L4i""~: ~ilv~"'-'-':+l -:°"'_l_"_+-t-lf-t-,

RL-BK
I I I
I I : : l- i ____
~----·~1~00~·--111-''.l!ll.!--·..___,,1~~..__.._1__,_~,;---=t ~
A I I ~!hli I BRK:: ~ I
=1
~ :::!Eln '-'-1=-=--=-~=BRK:_--C.IH->----
1
~1008~~--IH-'-""'"-'--~~~~l-~~~i---' ~o--r BRAKE CONTRCl.. CIRCUIT

IL_-+-
I 8RK5-7
1--++-+-+-+-1-+-'''------
.......
I '----------
-D
POWER
TRANSFORMER
200R
200S
2001
~-----H~I=o
ACU~~TER-D
-D
]~ DC F=iUPPLY
!'?--'-- ACJ
----r----
I
I
r .-_,
200A
2008 I I
J L-J u
Fig.A.3 {n) Emergency Stop Circuit ($-800, M-500)
- 492 -
EMERGENCY CIRCUIT
ROBOT
MECHANICAL UNIT
PlLSE
...... MOTOR
~
I ~
ROBOT ROT
JSIB
JS2B
CX4
+"'" +¥.V -
··- ISE
W<TROL
MCC UNIT
ON THE POWER TRANS
.,,
n svu
I --
,_ u
- v -. ~~--
•
~-
- 493 -
A.4
CABINET OF M-410i
AND S-450
- 494 -
TRANSFORMER TRANSFORMER
_,LI
LI - - -- -
~
NPUT VOLTAGE
I I
I I
I I
I
I
I
~GI ] -
~ 1111
ACIOOV
-
~
T
EFER TO :::L2
AGE 002 L2 -
I I
...-L..
I I -G2 ]
L3 I I 0 - I I :L3
-
'
G I I
l ) -:}
l ) ~G4
- JlllC
c
- PSM
SURGE ABSORBER
UNIT ~
w
LI
L2 p
*
L3 N
PE
FAN UNIT
- ..,£,
CXIA
.JXIB
CX2B
llJCX2A
BACK PLANE PSU
CPI OD CX3
.JNPO
~[ CP2 DD
CP3 OD
llJCX4
CP5 DD
MAIN CPU E-STOP PCB

.JRVI
DD -0[ .JRVI CRFI D
.JRF2
OD -0[ .JRF2
.JSI DD
CRMIO JD ~[ CRM9 .JS2 0
.JRA5
~[ .JDIA JD
.JF21 JD
Q][ CRMl5
D[ CRMl6
.JS3 D
.JS4 0
CRSI JD D[ CRRl5 .JS5 DD
.JDl7 JD '---{][ CRR20 .JS6 OD
.JRM3 J~ I[ CRR21 CRMI ID
.JRMIO J~ CRR5 0
CRR22 OD
,----,
~fl OPTION PCB
.JNA 11 I
JL ____
I
_J
Fig.A.4 (a) Total Diagram (M-410i)
- 496 -
DELAYED-OFF
MCC UNIT
CPI
- "I AAAI
AMPI AMP2 AMP3 AMP4

SVM SVM SVM SVM
p
N ..
D p
N
p
N
JXIA JXIB JXIA JXIB JXIA JXIB JXIA JXIB[tJ
CX2A CX2B CX2A CX2B CX2A CX2B CX2A cx2ectJ
TB2
[U>-----.
V >-----. TB2
[U•r---
V~
w>--- TB2
[u~
v >------..
W ,____ TB2
[u'~
V•~
W~ ROBOT M-410i
PE•1=
W<>-----.
JSIB JSIB
PEl= JSIB
PEl= JSIB
PEil=
)MOTOR POWER
RDI/RDO
1
ROT
PULSE CODER
MOTOR BRAKE
-
TEACH PENDANT
OPERATION BOX
JRM3 CRSI [
nn
JRMIO 0----- UU RS-232-C
- 497 -
AC REACTOR
OR
TRANSFORMER
BREAKER
/ LI
( I ..-,... ( I LI Fl
INPUT VOLTAGE L2
I I + I I L2 F2
REFER TO
PAGE 002.
L3
I I _....i..._
I I L3 F3
G
I I l ) 43
.:!,.
l ) 44
F4 41
~Ill A A A
F5 42
ACRI
ACR3_
- vv I ---
A
v v
A A
ACR2
ACR4
- A 1- A A
ACR5
- --
v v ACR6
PSM
~
SURGE ABSORBER
UNIT - LI
L2 p
FAN UNIT L3 N
PE
-
BACK PLANE
.JNPO
m
PSU
CPI
CP20
CP30
D
* ~
CXIA
1pcx2A
l'--l OCX3
.JXIB
CX2B
CP50 CX4
MAIN CPU E-STOP PCB
.JRVI D -0[ .JRVI CRFI

DD-
.JRF2
OD -0[ .JRF2
.JSI DD
CRMIO D r-[][ CRM9 .JS2 OD
.JRA5
~[ .JOIA OD
.JF21 DD
L[J[ CRM15
D[ CRMl6
.JS3 OD
.JS4 DD
CRSI D D[ CRRl5 .JS5 OD
.J017 DD '--[][ CRR20 .JS6 OD
.JRM3 D ~[ CRR21 CRMI I OD
.JRMIO DD- CRR5 DG----'
CRR22 OD
, -OPTION
- -PCB- ,
.JNA ~riJ I
I
L ____ _J
Fig.A.4 (b) Total Diagram (M-410i, 8-cabinet)
- 498 -
AMPI AMP2 AMP3 AMP4 ROBOT

SVM SVM SVM SVM M-410i
p p p p
N N N N
JXIA JXIB JXIA JXIB JXIA JXIB JXIA JXIB[0
CX2A CX2B CX2A CX2B CX2A CX2B CX2A CX2Blb
(JI) (J2) (J3) (J4)
TB2
[u>--
v>--
w ,____.. TB2 [U>--
V>--
W>--
TB2
[u~
V >---------
w >--------- TB2
[u~
~ :==
JSIB PE~ JSIB
PEil
= JSIB
PEl = JSIB
PEl =
-0[ RMI
1-{][ RM2
-{][ RM3
-{][ RBK
-{][ RPI
TEACH
PENDANT
-{][
- - - ~~~ RS-232-C
r
OPERATOR
-------0 JRM3 CRS I
-------0 JRMIO
- 499 -
AC REACTOR
OR
TRANSFORMER
BREAKER
() ~
() LI Fl
/LI
Il'I' UT VOLTAGE L2
I I + I I L2 F2
REFER TO
p AGE 002
L3
I I ...-1--.. I I L3 F3
G I I l ) 43
l
l ) 44
' - F4 41
~Ill• A A A
-
F5 42
ACRI_ ACR2
- y
A A A
y
1-
ACR3_
-
v v
A A A I
- ACR4
ACR5
- v v -- ACR6
SURGE ABSORBER PSM

UNIT~
LI
L2 p
FAN UNIT L3 N
PE
BACK PLANE PSU - .,£, JXIB
CPI DDr--+-----------~ CXIA
~[
CX2B
CP2 OD-- 10CX2A
JNPO
CP30Dr-----....,..--------~ ['--l pcx3
CP50Di------+-~---------~--u. CX4
'--------'
MAIN CPU E-STOP PCB

JRVI D1------11--+--+-- ][ JRVI CRFI DD--
JRF2 OOo------t--t---r---1-{][ JRF2 JSI O D t - - - + - - - + - - - - - - - - - - - -
CRM I0 ODo----~ f--0[ CRM9
I
JS20Q1--+-+----------
JDIA OD [[][ CRMl5 JS3]Q1---+---+------------
JRA5
JF21 OD D[ CRMl6 JS4]Q1--+--+-----------
CRS I OOo----~ D[ CRRl5 JS5 ] Q 1 - - + - - + - - - - - - - - - - -
JDl7 OD L{J[ CRR20 JS6 ] Q 1 - - - + - - - + - - - - - - - - - - - -
l__[][ CRR21 CRMll ] Q 1 - - - ' - - - + - - - - - - - - - - - -
CRR5 ] 0------------
CRR22 JD
~-----~f
JNA ~[
JF7]0 \ ~----------------------------
~-----~
Fig.A.4 (c) Total Diagram ($-450)
- 500 -
DELAYED-OFF
MCC UNIT
CRR25~----'"'---'"'-'"-'--~cRP7
CPI
ROBOT
S-450
AMPI AMP2 AMP3 AMP4
SVM SVM SVM SVM
p
"'
p
"'
..
D p
N
.JX IA JXIB JXIA JXIB JXIA JXIB JXIA JXIB[tJ
CX2A CX28 CX2A CX28 CX2A CX2B CX2A CX2B[IJ
LL ,__ LL >--------.. UL )--.,

VL ,__ VL >--------.. VL )--.,
(JI) WL ,__ (J4) WL >--------..
(J5) WL )--.,
(J7)
TB2
PE ~
lM ,____
,____
TB2
PE ~
UM
--
--
TB2
PE
k::--
UM >---
[ u
v )--.,
)--.,
(J2)
JSIB JS28
VM
WM ,____
PE ""=::::-
(J3)
JSIB JS28
VM
WM
--
PE ""=::::-
(J6) VM
JSIB JS28
>---
WM >---
PE ~-
TB2 W>---
PEil
JSIB =
= = = -0[ RM3
-0[ RMI
,-0[ RM2
-0[ RPI
-0[ RP2
TEACH
PENDANT
-0[
(I: - - - - - - - - - - -I - - I- - - ~~~ RS-232-C

I
OPERATOR PANEL o-.J I
{][ JRM3 CRS I D I
{][ JRMIO DD-_)
- 501 -
;»
DELAYED-OFF
MCC UNIT I Id
~
r
E-STOP CONTROL (')
200VAC 0
z
BREAKER
z
OR m
TERMINAL BLOC"- TYPE I TRANSFORMER
(')
l ,......... l .....
LI 200/220V
AC POWER LI ' I '
SUPPLY I I 380/400V 5
I ~I
I I I GI z
200/220 I 'T' I L2 200/220V
240/380 L2 0
I I I 380/400V
400/415
440/460 I I I G2 5>
480/500 I ,......__ I Ci)
550/575 L3
l 'I
L3 200/220V
380/400V
J" "m~ JJ
)>
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cg CPI X-KEY I I S:::
l I '::"
3
j:.. 2doA
I I I 2;oe
:i::. AC INPUT CRP7 Y-KEY
:§; FOR LOGIC 3
;v
I+2~v I I I
.... TYPE I TRANSFORMER (7. 5KVA 1 A80L-0026-0015#6)
CRR25
ii3 4 5
:I CONNECTION OF PRIMARY TAP 2 3
POWER CONNECTING
SUPPLY TYPE 2 TRANSFORMER +24V +24V +24V CV
!!l. VOLTAGE STYLE
0 JUMPER MCCON MCCON SVON I I~
L I 220/240V
... I' 0 ""C
Vl 200 !:::,. 380/415V
3 Gl-L2 G2-L3 GJ-Ll DELTA I m
0 220 I
CD I I GI z
N 380
:::!.. Gl-G2 G2-G3 STAR y k _L2 220/240V 0
400 I
c: I 380/415V
:I
CD
I _G2
x
I
,, _L3 220/240V
::!! TYPE 2 TRANSFORMER (7 .5KVA; A80L-0026-00l 4#Bl
380/415V
POWER CONNECTION OF PRIMARY TAP G3
CONNECTING
i... SUPPLY
VOLTAGE STYLE
JUMPER 111-
220
Gl-L2 G2-L3 G3-LI DELTA !:::,.
240 I I .---L
380
Gl-G2 G2-G3 STAR y
415 I
fg....
TYPE 3 TRANSFORMER ( 7. 5KVA; A80L -0026-00 I 6#B)
TYPE 3 TRANSFORMER
CONNECTING LIA 440·480V 'I
SUPPLY STYLE
VOLTAGE ~UMPER
[lll500::575'7
440
460 LIB L2B L3B L2A 440·480V
L2B 500·575V I
480
- STAR y
~,i I
500
550 LIA L2A L3A L3A 440·480V )
575 L3B 500-575V
.---L
i
~
IN CASE OF
CIRCUIT BREAKER
J"T"'..
LI
AC POWER I
SUPPLY
I
220/240
380/415
L2 1"
460/480
500/550 I
575 A
L3
50/60Hz
+107.
-157.
G
DELAYED-OFF
MCC UNIT
CRR25 . - - - - - - - - - - , CP5
E-STOP CONTROL
CPI
200VAC
TRANSFORMER (
OR ---------+------·L-t----r---+---+--:------r------~
AC REACTOR
--------+-----_/•'---f--.-+--+-..--.-----.--------
• BREAKER FUSE SIZE CPI X-KEY CRP7 Y-KEY

L
INPUT CIRCUIT LEAKAGE
VOLT AGE BREAKER BREAKER L
50A 50A CRR25
5 L_ - - -
A +24V +24V +24V OV
B MCCON MCCON SVON
30A 30A
20A
• CONNECTION TO TFI
SUPPLY CONNECTING
VOLTAGE STYLE
LI L2 L3 .JUMPER L
220 7 15 23 8-15 I 16-23 I 24-7 L __ _
DELTA !::,,
240 6 14 22 8-14 I 16-22 I 24-6
380 7 15 23
L ___ -
415
6 14 22
440
460 5 13 21 STAR
8-16 16-24
480 4 12 20 y
500 3 II 19
550 2 10 18
575 I 9 17
Fig.A.4 (e) Tranformer/Line filter (M-410i, S-450/B-cabinet)
- 504 -
J
TFI
LI 2I 575
550 Fl
DELAYED-OFF
MCC UNIT
6
7
4151240
380/220
II
8 ~ III
9 575
10 550
FI 'F2 'F3
F4,F5
30A
5A I
II
11 500 I
12 480 F4 I I
13 460
o-i-';14~4~1~5"12~4~0:hlr-----l-+---ll 41
l-----'...-0-------,--l-t-i-----)
15 380/220 100 VAC
1----4~2>----i---:--l-.!.....,...----
210 VAC
THERMOSTAT
FOR OVERHEAT
------r-+--t-+--r-J AC REACTOR
I II
IIIIIIIIII
SERVO POWER
·-----TI _____ _J111111lll

·-----lbgj ______ _Jlll11lll
·-----TI ~-----_Jll11lll
..__ _ _ _ _ _44~ _ _ _ _ _ _JI I I I I I
FI 'F2 'F3 30A IIIII
- - - - - _J
III
II~ - - - - - - _JI
F 4 'F5 5A F4 4I
~o--~ ~-- _ _ _ _ _J 111

III
ACRI '-+<>----A_CR_,2r>- _ _ _ _ _ _ _ _J I I
'+C)----AC_R--(4}- - - - - - - - _J I
'-<>----AC_R_,6,_ _ _ _ _ _ _ _ _ _J
AC POWER INPUT
- 505 -
"!>
D @JAN
CA39A
b
;;!
r
(')
0
z
z
m
~
5
z
0
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11 APOWER
I 6B-12 SUPPL y
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)> B3 Bl B2
R [JAL[ [ J 2
FA FB BAT+ BAT-
s::
:i:-
I I CPI Dr---- 200-240 VAC INPUT I tllJ A3
CP2 200-240 VAC OUTPUT ONOFF
~2 COM
s I II [}-- -
c
0 CP2
'ti I II CP3 [}--- 200-240 VAC OUTPUT I
0 CP5
RI
:eCD stLlJ B3
)>
... POWER ON/OFF +240v
(J) I JNPO III CP4 [}--- ALARM ~ "C
c "C
VI m
0 "Cl CP5 +24 voe OUTPUT CP3
O'I "Cl I II [}--- CP6 z
I 0
-< +24 voe OUTPUT
R2
CP6 x
c:
:I
I II [}--- s[[[J .~!E I ~tt:J
;:::;:
1 r-B~T~E:Y- ~:a- SPECIFICATION OF FUSE

(11
t I NAME FUSE POWER
5' Fl 7.5A 200V
F3 5A +24V
F4 5A +24E
Q
...f
..::.
00
.,.,,
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00
I I
woo
Zoo
<"'"'
((mm
D~~
<<<
'°>->-
00
_J _J
Ul Ul
I I
NM
I5:
~
POWER SUPPLY UNIT
~
~ ~AN
I CA39A[j D JDIB JRMIO JRF2 JRVI
(I/O LINK) (OPERATION BOX) (ROBOT FEEDBACK) (SERVO AMPLIFIER) i
I I RXSLC 1111 OV I I CV 1261 CV All PD6 IBll •PD6 Al IS6 Bl GNDS6
BATTERY UNIT r-- 2 •RXSLC 12 OV 2 RTSI 27 CTSI A2 OV B2 OV A2 IR6 B2 GNDR6 ~
FOR MAINTENANCE I
3 TXSLC 13 CV 3 CV 2S CV A31 PR06 B31 •PR06 A3 IS5 B3 GNDS5
__JI - .- - - ,II
~~~~-~~~O VBAT [ Q - - - - - 1 - , I I 11--
-0040 4 •TXSLC 14 CV 4 DTRI 29 OSRI A41 CV B41 CV A4 IR5 B4 GNDR5
~-~ 5 15 CV 5 CV 30 CV A51 PD5 B51 •PD5 A5 IS4 B5 GNDS4
SERVO AMPLIFIER
JRVI [
D 6 16 ov 6 TXDI 31 RXDI A61 CV B61 CV A6 IR4 B6 GNDR4
7 17 7 ov 32 ov A71 PR05 B71 •PR05 A7 IS3 B7 GNDS3
SI 11s1 +5V S RTSA 33 CTSA ASI CV BBi CV AS IR3 BS GNDR3
JRF2 [ D ROBOT FEEDBACK 9 +5V 19 9 OV340V A91 PD4 B91 •PD4 A9 IS2 B9 GNDS2
IOI 1201 +5v I0 DTRA 35 DSRA IAIOI ov 16101 OV IAIO IR2 61C GNDR2
11 CV 36 CV Al II PR04 Bl II •PR04 IAI I ISi Bl I GNDSI
JF21 [ 0---- LINE TRACKING I2 TXDA 37 RXDA Al21 CV 6121 CV "I IRI Bl2 GNDRI
I 3 • TXTP 3S •RXTP IA13I PD3 16131 •PD3 I •ENBL6 1!13 CV
JDl7 I4 TXTP 39 RXTP IA14I CV IB141 CV Al4 •PWME6 Bl4 CV
JRMI 0 D 01-------- TO OPERATION BOX
( RS-232C/ 4S5)
JRA5~ ~ 15 •TX4S5A 40 •RX4S5A IA15I PR03 IB15I •PR03 Al5 •PWMC6 Bl5 CV
(FOR T~m [ RXDB I 11 TXDB 16 TX4S5A 4 I RX4S5A IA161 Ov IB16I CV Al6 •PWMA6 Bl6 OV
2 ov 112 CV 17 ON 42 CV IA17l PD2 16171 •PD2 Al7 •ENBL5 Bl7 CV
JOIB [ o---- I/O LINK
.,, 3 DSRBC I 13 DTRB I SI OFF 1431 CV IA18I CV IBIBI ov Al8 •PWME5 Bl8 OV
RS-232C/ 4S5 INTERFACE 4 ov 114 ov 19 COM 44 +24V !A19I PR02 6191 •PR02 Al9 •PWMC5 Bl9 CV
ca· JOl7 [ 0---- (OPTION)
5 CTSB I 15 RTSB 20 •OPEMG 45 +24V IA20I CV 620! CV A20 •PWMA5 620 CV
)> JRM3 [ TO OPERATION BOX 6 CV 16 OV 21 •EXEMG 46 +24V IA211 POI 6211 •POI A21 •ENBL4 l21 CV
:i:i. 7 RX4S5B I 7 TX4S5B 22 EMGDM 47 +24V IA221 CV 16221 ov A22 •PWME4 l22 CV
CRSI [ TO TEACH PENDANT
o---- S •RX4S5B IS •TX4S5B 23 EMGEM 4S +24V IA23I PROI 16231 •PROI A23 •PWMC4 B23 CV
ca
.._, 00
.,,,.... CRMIO [ 0---- ROI/ROD 9 191 +24E 24 • TPEMG 4 9 EMGB I IA241 CV 16241 ov A24 •PWMA4 B24 CV
00 I Cl +24E 120 25 SVON 50 EMGB2 IA251 Ov IB251 CV A25 •ENBL3 B25 CV
I
"°"' I
Ill
== IA261 CV 16261 CV A26 •PWME3 B26 OV )>
~00
s· <~~ IA27l +5v 16271 +5V A27 •PWMC3 B27 OV "O
..JI I IA28 +5V 328 +5V A28 •PWMA3 B28 CV
Vl 0 0..IDID "O
CRSI JF21 VBAT A29 +5V l29 +5V A29 •ENBL2 629 CV m
'ti ::.::~~ (TEACH PENDANT> (LINE TRACKING) (BATTERY)
s c: ~<< A30 +5V l3C +5V A30 •PWME2 B30 CV z
'°1-1-
0 o
01 TXTP
08
,. •TXTP I I PA I 11 I EXVBAT A31 +5V 631 +5V A31 •PWMC2 B31 CV 0
02 RXTP iO •RXTP 2 CV A32 +5V B32 +5V A32 •PWMA2 832 CV
vfoJ OJ EMGOM
0. i6 EMGEN 21 •PA 1121 CV x
I I iO EMG81 3 PB 13 A33 +5V 633 +5V A33 •ENBL I 833 CV
04 IT EMG82
i7 ov
"'"' 05 i8 41 •PB 1141 OV A34 +5V 634 +5V A34 •PWME I 834 OV
i2 EMGTP
06 +24V j"J i9 ov 5 PZ 15 A35 +5V 635 +5V A35 •PWMC I 835 Ov
01 +24V 20 A36 +5V 636 +5V A36 •PWMA I B36 CV
~I •PZ 1:~1 CV
A37 •5v B37 •5v A37 •MCON B37 +5V
A38 +5V 638 +5V A38 •DROY 838 +5V
if
... S I REO 11 s1 +5V
9 +5V 19 A39 +5V B3 +5V A39 CV B39 +5V
g IOI !20! +5V A40 +5V 64( +5V A40 CV B40 +5V
A41 +5V 641 +5V A4 I + I 5V 41 +5V '1>
A42 +5V 642 +5V A42 + I 5V 342 +5V
A43 CV 643 CV A43 CV B43 +5V b
CRSI JRM3 A44 CV 644 CV A44 CV B44 +5V
( TEACH PENDANT) CPDI/PDO) );!
A45 +24E 64! +24E A45 - I 5V 845 +5V
,. ROOI 01 ROii I I POI I 11 11 OV A46 +24E l46 CV A46 - I 5V l46 +5V
r
08 ROl7
iO R002 02 ROl2 2 OV 12 POOi A47 64 •OTREL A47 CV l47 +24V 0
0. ROIS
i6 Ro03 iO 03 RiITT 3 PDI2 13 PD02
i7 Roi9 04 A48 •OTRST 848 •ROT A48 CV l48 +24 V 0
Roii4 IT -;j:jBi( RoI4
i8 R005 05 Rom 4 PDI3 14 PD03 A49 SVON ,,., •HBK A49 •BRKON 649 +24 V z
i2 R007
i9 R006 j"J 06 ROI6 5 PDI4 15 PD04 A50 RDICOM 65( •HBKREL A50 •BRKALM 850 +24 V z
ROOS
20 ~ 01 ov 6 PDI5 16 PDD5 m
7 PDI6 17 PD06
S PDI7 IS PD07 ~
9 TPOFF 19 +24V 0
I0 +24V 20 PODS z
0
5>
G>
JJ
MAIN CPU BOARD )>
~ s::
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CA39A[ D
d
JV7-JV 16 JF7-JFl4 JF22 );!
(AMPLIFIER I/F) (PULSE CODER FB I/F) CLINE TRACKING) r
I IR II IS I PD II I PA II ()
2 GNDR 12 GNDS 2 •PD 12 OV 2 •PA 12 ov 0
AUX AXIS 3 •PWMA 13 •PWMD 3 13 3 PB 13
Al6B-2200 z
-0820 4 ov 14 ov 4 14 ov 4 •PB 14 ov
5 •PWMB 15 •PWME 5 PRC 15 5 PZ 15
z
JV16 [ 0---- SERVO AMPLIFIER 6 ov 16 ov 6 •PRC 16 ov 6 •PZ 16 ov m
7 •PWMC 17 •PWMF 7 17 7 17
JVl5 [ 0---- AUX AMPLIFIER ~
8 ov 18 ov 8 REC 18 +5V 8 REC 18 +5V
JVl4 [ 0---- AUX AMPLIFIER 9 19 9 +5V 19 9 +5V 19 5
10 •MCON 20 •DROY 10 20 +5V 10 20 +5V z
JVl3 [ 0---- AUX AMPLIFIER
.,, 0
JVl2 [ 0---- AUX AMPLIFIER )>
ca· JRFIA, IB JD29 Ci)
j:,. JVI I [ D---- AUX AMPLIFIER (LINE TRACKING) CRS-232C/422 I/Fl
JN{
~
::D
~ JVIO [ D---- AUX AMPLIFIER I PA II I RXD II TXD ~
:;: 2 •PA 12 ov 2 ov 12 ov s:::
JV9 [ 0---- AUX AMPLIFIER
3 PB 13 3 DSR 13 DTR
)>
- JV8 [ 0---- AUX AMPLIFIER 4 •PB 14 ov 4 ov 14 ov
c. 5 PRC 15 5 CTS 15 RTS
c. JV7 [ D SERVO AMPLIFIER 6 •PRC 16 ov 6 ov 16 ov
c;· 7 PZ 17 7 RX 17 TX
JRFIB [ 0---- LINE TRACKING
8 •PZ 18 +5V 8 •RX 18 •TX
-
:I
!!!.
00
JRFIA [ 0---- LINE TRACKING 9 +5V 19 9 •BRKQN3 19 +24E
"'"
"'"'
99 10 20 +5V 10 +24E 20 •BRKON4
Ill w-- JFl4 [ 0---- MOTOR FEEDBACK
>< )>
~gg '1J
iii" JFl3 [ 0---- MOTOR FEEDBACK
Vl
-'"'"'
o..'' '1J
0 0 ,.,:gig JFl2 [ 0---- MOTOR FEEDBACK m
00 0 ~~~ z
:I
"'•-+· JFI I [ 0---- MOTOR FEEDBACK 0
00
.J.J x
2. JFIO [ MOTOR FEEDBACK
-...
"C
<r<r
"'"' JF9 [
0----
0---- MOTOR FEEDBACK
::::!.
:I
JF8 [ 0---- MOTOR FEEDBACK
Cl)
c.
- JF7 [ D ROBOT FEEDBACK
tr
0 JF22 [ 0---- LINE TRACKING
Ill
...c. JD29 [ 0---- RS-232C/ 422 INTERFACE
I
CTI
s
AUX AXIS CONTROL BOARD

~ i
~
PSM
SVM
SERVO POWER
LI
L2 p OC LINK p
i
~
L3 N N
c PE
JXIB
ALARM CONTROL
JXIA JXIB CONTROL POWER (NEXT SVM l
CONTROL POWER ( 20CVAC l
r CXIA E-STOP CONTROL
CX2B CX2A CX2B E-STOP CONTROL (NEXT SVM l
10CX2A
MCC CONTROL CX3
E -STOP CONTROL CX4
TB2[ ~ MOTOR POWER

J
PE
JS~B I~
.,,
ca· I SERVO CONTROL T
~
.j:>,
-
g>
<! JSIB ex I A(X-KEY)
0 (SERVO CONTROL) (CONTROL POWER l
J>
J> I IR 11 IS "'C
3 2 GNOR 12 GNOS l 2doA I 2;oe I ;E "'C
Vl
0 "2. 3 •PWMA 13 •ENBL m
I.Cl ::;; 4 CV 14 CV
z
a;· •PWMC 15
0
5
... CX2A/CX2B ( X -KEY l x
6 CV 16 ( ESTOP CONTROL)
7 •PWME 17
8 CV 18 l +214v I o~ E;,
-t
UI 9 •DROY 19 CV
F' IC •MCON 20 CV
s: CX3(Y-KEY)
.i. ( MCC CONTROL)
.... JXIA/JX IB ;J>
,g ( ALARM CONTROL) 2
I IR II ALMI
kJFd kkJ
2 GNDR 12 CV
d
3 •PWMA 13 ALM2 ~
4 CV 14 CV CX4(X-KEYl r
( ESTOP CONTROL)
5 IALM 15 ALM4 0
6 ov 16 CV 3
7 MCCOFF 17 ALMS E;, I +2 4V I 0
8 ov 18 CV
z
9 •CROY 19 CALM
z
IC CV 20
m
~
5
z
0
PSM(POWER SUPPLY MODULE) 5>
SVM(SERVO MODULE) G)
:a
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s:
;x>
E-STOP PCB
.JRF2 .JRVI d
(ROBOT FEEDBACK l ( SERVO CONTROL) SERVO CONTROL .JRVI CRFI TO ROBOT ( FEEDBACK l
Al PD6 Bl •PD6 Al IS6 Bl GNDS6
D ~
r
A2 ov B2 ov A2 IR6 B2 GNDR6 ROBOT FEEDBACK .JRF2 (')
A3 PR06 B3 •PR06 A3 IS5 B3 GNDS5 D .JSI
A4 ov B4 ov A4 IR5 B4 GNDR5 0
A5 PD5 B5 •PD5 A5 IS4 B5 GNDS4 E -STOP CONTROL D CRM9 .JS2 z
DOOR INTERLOCK CRMl5 .JS3
z
A7 PR05 B7 •PR05 A7 IS3 B7 GNDS3
-----{] m
SERVO CONTROL (")
AB OV BB ov AB IR3 BB GNDR3 AUX BRAKE CONTROL -----{] CRMl6 .JS4 -I
AIO ov BIO ov AIO IR2 BIO GNDR2 .JS5 0z
Al I PR04 Bl I •PR04 Al I ISi Bl I GNDSI
E-STOP CONTROL ~ CRR20 .JS6
Al2 ov Bl2 OV Al2 IRI Bl2 GNDRI 0
Al3 PD3 Bl3 •PD3 Al3 •ENBL6 Bl3 ov I OOVAC INPUT FOR BRAKE POWER - - - - ---{] CRR2 I CRMI I ROBOT OVERTRAVEL
Al4 ov Bl4 ov Al4 •PWME6 Bl4 ov
5>
G)
.,, A15 PR03 Bl5 •PR03 Al5 •PWMC6 Bl5 ov CRR5 MOTOR BRAKE POWER
Al6 Bl6 Al6 •PWMA6 Bl6 OV
JJ
ca· ov ov CRR22 I OOVAC OUTPUT FOR AUX MOTOR )>
;. Al7 PD2 Bl7 •PD2 Al7 •ENBL5 Bl7 ov CC-SERIES AMPLIFIER)
A18 OV ll8 ov Al8 •PWME5 Bl8 OV
s:::
:i:i. Al9 PR02 ll9 •PR02 Al9 •PWMC5 Bl9 ov
e A20 OV B20 ov A20 •PWMA5 B20 OV
m A21 POI B21 •POI A21 •ENBL4 B21 ov CRM9 .JSl-.JS6 CRFI
( E -STOP CONTROL) (SERVO CONTROL) (PULSE CODER INTERFACE l
3 A22 ov B22 ov A22 •PWME4 B22 ov
...CD A23 PROI B23 •PROI A23 •PWMC4 B23 ov I IR 11 IS
cg A24 ov B24 ov A24 •PWMA4 B24 ov L:J5oN I sv~uT I 2 GNDR 12 GNDS
CD A25 ov B25 OV A25 •ENBL3 B25 ov 3 •PWMA 13 •ENBL
:I )>
n A26 ov B26 ov A26 •PWME3 B26 OV 4 ov 14 ov
'< A27 +5V B27 +5V A27 •PWMC3 B27 ov 5 •PWMC 15 "CJ
Vi CRMl5 "CJ
en A28 +5V B28 +5V A28 •PWMA3 B28 ov CDOOR INTERLOCK l 6 ov 16 m
0 0 A29 +5V B29 +5V A29 •ENBL2 B29 ov 7 •PWME 17 z
"C A30 +5V B30 +5V A30 •PWME2 630 ov 3 ~ B ov IB Cl
- - c:
:I
A31 +5V B31 +5V A31 •PWMC2 B31 ov L--~~-D~I~ 9 •DROY 19 ov 4J +5V
27
28
ov
ov x
A32 +5V B32 +5V A32 •PWMA2 B32 ov 10 •MCON 20 ov +5V
;:::;: •• 29 ov
A33 +5V B33 +5V A33 •ENBLI B33 ov +5V JO +5V
A34 +5V B34 +5V A34 •PWMEI B34 OV CRMl6 •••• +5V JI +5V
CRR5 47 +5V
A35 +5V B35 +5V A35 •PWMCI B35 ov (AUX BRAKE CONTROL) 32 +5V
+5V
I(11 A36 +5V B36 +5V A36 •PWMAI B36 OV 2 ID 20 30 •••• +5V
9 A37 +5V B37 +5V A37 •MCON B37 +5V •BRKON4l•BRKON3 BKM3 BKM3 BKM3 50 +5V
A38 +5V B38 +5V A38 •DROY B38 +5V IC 2C 3C
A39 +5V 39 +5V A39 ov 639 +5V
BKP3 BKP3 BKP3
A40 +5V 40 +5V A40 OV B40 +5V
CRR20 IB 2B 3B CRMI I
f...
0 A41 +5V B41 +5V A41 + 15V B41 +5V
( EMG CONTROL) (ROBOT OVERTRAVELJ
.:::,, A42 +5V B42 +5V A42 + 15V B42 +5V BKMI BKM2 BKM2
A43 OV B43 ov A43 OV B43 +5V A3 A2 Al IA 2A 3A 3
A44 OV B44 ov A44 ov B44 +5V 200T 200S 200R BKPI BKP2 BKP2
n n
A45 +24E B45 +24E A45 -15V B45 +5V
l•RO§[f]
A46 +24E B46 ov A46 -15V B46 +5V B3 B2 Bl
A47 B47 •OTREL A47 OV B47 +24V AC3 AC2 ACI
n n
A48 •OTRST B48 •ROT A48 ov B48 +24V
A49 SYON B49 •HBK A49 •BRKON B49 +24V
A50 RDICOM B50 •HBKREL A50 •BRKALM B50 +24V CRR21 CRR22
(BRAKE POWER l ( I OOV AC OUTJ
3 2
~B IOOAI I OOOUT21 I OOOUT I
E-STOP UNIT
i
~
OPERATION BOX
r----------,------------,
I I/O UNIT-MODEL B I I/O UNIT-MODEL A I
I BASE UNIT I BASE UNIT I
I (OPTION) I (OPTION) I
I OPERATION BOX A I CPERATION BOX A I
I ~Ar~c:rr~ 8 I ~A~~B I
I MAX.2-LNIT I Sl.FPCRTED I
I ~ I ~1frikt. A IS MCUITED. \
I +I C\I > > > I MOOEL B CAN«>T MOl.NTED. I
I r~JE __ +_o_..J-9, I I
L ~..!-•- - ~ .!. §!..!.,_-'- - - -Cf'f=f:'fJ- - - - - _ J
I I .i. 1- J I JDIB
I/O UNIT-MODEL B[~~-t----~ I I I +--J
SIGNAL CABLE 53+ I I
53- \l\IJJll JDIA
~ f:~~~~
TXSLC•~----+--~(JD'-"-'l~A~)&l~J~>---------~
•TXSLC•~----+-----ttt11~'~
1
----------~
RXSLC-----+-----+H-!~11>------------~
•RXSLC•~----+-----t1t<~2~>--------------'
( CRSI)
(I)
( ")
TXTP
(2) TXTP
(1!5) RXTP
(6.7) RXTP TO TEACH PENOANT
( 17 19 + 24V
0v
,,..
~-" FG
( PORTI)
(JRMIO) (2)
TXD I T XDI
RXD I
RTS I
CTS I
(Jll
(2)
(27)
..,
(29)
..•
(J)
(6)
RXDI
RTSI
cTSI
DSR I
DTR I
+24V NJTE I) ..... (201
(25)
DSRI RS-232-C
DTRI
24V
ov (NIJTJ; 2 (7)
~v
(PORT IX)
(2) ~ FG
....,,
TXDIX (J)
(NOTE I) RXDIX
+24V;.JRM 10-44,45,46 RTSIX
47,48 CTSIX (6)
DSRIX (20)
(NOTE 2l DTRIX
ov ,JRM 10-1,3,5,7,9 +24V
(2!5)
11.26.28 ov (7)
30,32.34 1111
36,42.43 FG
(JRMIO) (12)
TXDA (37)
RXDA (8)
RTSA (JJ)
CTSA 135
DSRA (10)
DTRA
TX485A
•TX485A
,..,,
(16)
RX485A c.i >

(15)
•RX485A
(PCJRT2l
TXDA
RXDA
RTSA
"2'
..,
(J)
(5)
CTSA (6)
DSRA 20
DTRA
(I.()
TX485A (1!5)
•TX485A
RX485A
•RX485A
+24V
ov
(16)
(17)
(2!5)
(7)
..,,.
(I)
FG
NOTE 1 PORT2 IS OPTION. ~ FG
Fig.A.4 (k) Operator's Box-1 (M-41 Oi)
- 512 -
OPERATION BOX
OPERATION BOX PCB

FROM MAIN CPU A20B-1006-0290(AFTER EDITION 02B)
(JRM3l (CRT3)
PD01
PD02
(12)
(13)
( 14)
(Al)
(61)
(A2)
.."' LED I ; REMOTE
SW4 ;C-START
p D03 (NOT l.ESOl
p D04 (15) (62)
LED2:F-RESET
(16) CA3l
PD05 (NOT l.ESOl
( 17) (63)
p D06 !NOT l.ESO)
(18) (A4l
p D07 (NOT l.ESOJ
(20) (64)
PD08 (NOT l.ESOJ
Cl) (A5l
PD I I !NOT l.ESOJ
(3) (65) ~0-
PD I2 SW6:F-RESET
(4) CA6J '
PD I3 ~ SW31REMOTE
(5) (66)
PD I4 !NOT l.ESOJ REMOTE LOCAL
(6) (A7)
PD I5
(7) (67)
(NOT l.ESOJ .,;., ....L
0 0
PD I6 !NOT l.ESOJ
(8) CA8) ~0-
PD I7 SW6:F-RESET
(9) (68)
TP OFF !NOT l.ESO)
•¥V
24V
ov
( 10.19) +2fV
(2, 11)
(Al6,Al7)
(Al7) .. SWI ;ON
-dv -dv T~.t. ..... 1 rv-o. ..... J.o.1T
FROM MAIN CPU ·~r (CRSI}

EMGDM
(JRMIO} (22)
( 12'
3) "' OEAD-MAN
,_
'
(23 (16)
EMGEN
(49' I ( 10) ENABLE/
EMGBI (50) (II) DISABLE
EMGB2
RLDM ?QJ ENABLE DISABLE
ov I ov I ~ ~
I I ESTOPI CTBOPI l
ESTOP2
ltr
(Al I)
(Bl I)
(Al2)
(Bl2)
I
I CTBOP I l
FENCE I
I FENCE2 ---------- - - --0,;f>- ,
--------- _ _ _ _ _ .J
+24V
+24V
~ (Al6,Bl6) l~~J3l
c____]
l
(24) RNAI (Al3) OPEMGAI rT"
TPEMG CBl3) OPEMGA2
I I
(20) (Al5) OPEMGBI
OPE MG CAl4) OPEMGCI
I RLTPEM
CBl4) OPEMGC2 I
ov EMGINI
(TBOPI l
EMGOUT
EMGIN2 ---------- L--=--=-~ ~
+24V
----------
(TBOPI l
(21) ov SVONI
EXE MG
(25)
-,_______J'"
SVON2 ---------- L--=--=-~ ~
SVON I - - - HOUR METER - -
~
I +24V
~ Cl) (CRP5l r--,
(2)
-----<j<I I
I - - - --<f2
+24V I
.L I
ov ov (3)
T y ~I- - --«3 4;,I
I L _ _ .J
EMGOUTI (TBOPI}
I EMGOUT2
( 17) EXONI CTBOP2l _L_

ON ( 19)
---------- ---00--,
I EXCOM
COM ( 18) I EXCFFI
-------- ------1
OFF
I CA09J DNI
---------- .,,..L,.
---QiO---'
(B09) ON2 I
11 (AIOJ OFFI
I CBI IJ OFF2 I
(CRT3l
- 513 -
OPERATOR PANEL
CJRMIO) ( 14) (I)
(CRSI)
TXTP ( 13) I 14) TXTP
•TXTP (39) 12) •TXTP
RXTP 138) I 15) RXTP
•RXTP +..,, 16,7) •RXTP TO TEACH PENDANT
I 17 19)
+24V
ov
OPERATOR PANEL PCB 09 (I)
FG
A20B-I006-0290(AFTER EDITION 02B)
(JRMIO) (6) (2)
(PORTI)
TXDI (31) 13) TXDI
RXDI (2) (4) RXDI
RTSI (27) (5) RTSI
CTSI CTSI
...,,. ...,,.
(29) (6)
DSRI (4) (20) DSRI RS-232-C
DTRI (NOTE I) (25)
DTRI
+24V (NOTE 2) (7) +24V
ov ov
(PORT IX) 09 09 Ill
12) FG
TXDIX (3)
(NOTE I) RXDIX (4)
+24V;JRMI 0-44,45,46 RTSIX (5)
47,48 CTSIX (6)
DSRIX (20)
(NOTE 2) DTRIX
OV ;JRMI 0-1 ,3,5,7,9 +24V 125) +2_4V
11 ,26,28 ov (7)
30,32.34 (I) 09
36,42 FG
(JRMIO) ( 12)
TXDA 137)
RXDA 18)
RTSA 133)
CTSA 135)
DSRA I 10)
DTRA
I 16)
TX485A 140)
•TX485A 141)
RX485A I 15)
•RX485A
(PORT2) 12)
TXDA 13)
RXDA 14)
RTSA 15)
CTSA 16)
DSRA 120)
DTRA
I 14)
TX485A I 15)
•TX485A I 16)
RX485A I 17)
•RX485A
+24V 125) +""'
17)
ov
FG II) Oil
= FG
Fig.A.4 (I) Operator's Box-1 (M-410i/S-450/8-cabinet)
- 514 -
OPERATOR PANEL
OPERATOR PANEL PCB
FROM MAIN CPU A20B- I 006-0290CAFTER EDITION 028)
CCRT3)
POO I
CJRM3) {12) (Al) ... LED I ; REMOTE
{ 13) (Bl)
POO2
{14) (A2)
"' SW4 ;C-START
POO3 CNJT LESO)
POO4
(15) (82) ... LED2, F -RESET
(16) (A3)
POO5 (NJT LESOl
{17) (83)
POO6 CNJT LESO)
(18) IA4)
POO7 (NOT LESO)
120) (84)
POO8 Ct«JT LESO)
Ill (A5)
PDI I (t«JT lES())
PD 12
PD 13
(3)
14)
(85)
CA6l
-:-o- SW6, F -RESET
SW3;REMOTE
(0) (86)
PD 14 CNJT LESO) REMOTE LOCAL
16) (A7)
PD 15
17)
CNJT LESO)
~ --'--
00
(87)
PD 16 CNJT LESO)
(8) CA8) ~0-
PD 17 SW6; F -RESET
(9) (88)
TPOF F CNJT lESOl
+2 4V
110.19> +yv •zt.• (Al6,Al7)
ov 12.11) CA17l ... SWI ;ON
FROM MAIN CPU

iW +24V
T
-c!v
CCRSI)
~·-
!"!'>
--··-
(JRMIO) 1221
( 12)
3
_,DEAD-MAN
EMGOM (23) (16) _,
EMGEN
EMGBI •••• I 1101 ENABLE/
i7
(50) (II) DISABLE
EMG82
RLDM ENABLE DISABLE

ov ov ~ ~
+24V I I ESTOPI
ESTCP2
CTBOPI)
[IT I
~__J
+24V
RNAI
+24Y
T
(Al I)
CBI I
Al2
812)
FENCE I
FENCE2
CAl6,816)
CTBOPI)
CCRT3)
+24V
----
- - - - - --~
TPEMG
(24)
(20) I
(Al3)
(813)
CAl5)
OPEMGAI
OPEMGA2
OPEMG81
"" I I
OPEMG
(Al4) OPEHGCI
RLTPEM
(81.4) OPEHGC2 I
ov EM3INI
(TBOPI)
EMGOUT
-----
EMGIN2
- - - - - --=-~
EXEMG
{21) tv ']::~V SVONI
CTBOPI)
-----
SVON
(25) SVON2
CCRP )-HO~ METER -
--=-~
5
~
I +2"4V
T (I)
(2) i'
+2.4V
T
I av (3) Hll
12
3 4
EMGOUTI (TBOPI)
r EMGOUT2
( 17) EXONI CTBOP2) ---'--

ON - - - - -00- -,
COM
(19)
( 18) I
EXCON
EXCFFI
- - - - - - ,_ - -a.o-- _J
OFF - - - - - -
I (A09) ONI ---'--
(809) DN2
11 (A.10) CFFI
I CBI ll CFF2 I
(CRT3)
- 515 -
JRMIO JRM3 PORTI PORT IX PORT2

d
(MAIN CPU I/Fl (MAIN CPU I/Fl (RS-232-C; PORT-I) CRS-232-C; PORT-I) (RS-232-C; PORT-2) ~
r
HONJA PCReO H:NJA PCR-E20 D-SUB 2!5P D-SUB 2!5P 0-SUB 25P
MALE MALE FEMALE FEMALE FEMALE (')
26 OV I ov II ov I POI I I FG I I FG
- I I I FG
14 14 14 0
TXOI TXDI 2 TXDA
27
28
CTSI
ov
2
3
RTSI
OV
12
13
POOi
PD02
2
3
ov
POI2
2
3 RXDI
15
2
3 RXDI
15
- - 3 RXDA
15 z
16 16 16 z
29 DSRI 4 DTRI 14 P003 4 PDI3 4 RTSI 4 RTSI '4 RTSA
17 17 17 m
30 ov 5 ov 15 P004 5 PDI4 5 CTSI '5 CTSI 5 CTSA
18 18 18
31 RXDI 6 TXDI 16 P005 6 PDI5 6 OSRI '6 DSRI '6 DSRA
19 ~7 19 r-; '19
32 ov 7 ov 17 PD06 7 POI6 7 ov OV ov ~
20 DTRI ~8 '20 DTRI '2o DTRA
33 CTSA 8 RTSA 18 P007 8 POI7 8 '8 5
.,, 21 ~9 21 21
34 ov 9 ov 19 +24V 9 TPOFF 9 9 z
ce· 22 '22 22
35 DSRA 10 DTRA 20 PD08 10 +24V 10 10 - 10
23 23 23 - 0
36 ov 11 ov 11 II 11
> 24 24 24
:i:o. 37 RXDA 12 TXDA 12 12 12 )>
REMOTE • PDO I F-RESET• PDI2 25 +24V 25 +24V 25 +24V_
38 •RXTP 13 •TXTP 13 13 .r 13 Ci)
C-START• PD02 REMOTE • POI3
39 RXTP 14 TXTP THIS CCNECTOR IS CPTION
~ FAULT • P004 C-START• POI7 THIS CCN£CTCR IS MOlNTEO ON THIS CONNECTOR IS MOU<TED Cl-4 THIS CCNECTOR IS MOl..NTEO ON ::D
40 •TX485A 15 •RX485A EXTERNAL SIDE OF Tl£ BOX INTERNAL SIDE OF TI£ BOX INTERNAL SIDE OF Tl-£ BOX )>
(TPOFFl • POI8
0 41 RX485A 16 TX485A
42 ov 17 ON
s:::
i 43 OV 18 OFF
JDIA CRSI TBDPI TBOP2 TBOP3
(I/0 LINK) (TEACH PENDANT) (EMERGENCY IN/OUT) (EXTERNAL ON/OFF) (MODEL B
44 +24V 19 COM
HON:>A PCR-E20 H:N:>A fiR·20S
45 +24V 20 OPE MG MALE FEMALE M4 TERN.NA.LS M4 TERKINA.LS M4 TERMUNALS
..,~ 46 +24V 21 EXEMG II ov I POII I TXTP 14 •TXTP I EMGINI I EXONI I S2+
ui 8
47 +24V 22 EMGOM 12 POOi 2 ov 2 RXTP 15 •RXTP 2 EMGIN2 2 EXOFF 2 S2-
9
DJ 48 +24V 23 EMGEN 13 PD02 3 POI2 3 EMGDM 16 EMGEN 3 FENCE I 3 EXDFFI 3 S3+
10 EMGBI
0 49 EMGBI 24 TPEMG 14 P003 4 PDI3 4 17 ov 4 FENCE2 4 S3-
II EMGB2
50 EMGB2 25 SVON 15 PD04 5 PDI4 5 18 5 SVDNI 5 +24V
12 EMGTP )>
16 P005 6 POI5 6 +24T 19 ov 6 SVON2 6 OV
13 1J
17 P006 7 PDI6 7 +24T 20 FG 7 ESTOPI
Ul
1J
18 P007 8 PDI7 8 ESTOP2
......
~
"C
CD CRT3 19 +24V 9 TPOFF
THIS COt-flECTOR IS MOLNTEO ON
EXTERNAL Sil:E OF TI£ BOX 9 EMGOUT2
m
O'I z
(PANEL SW/LED) 20 P008 10 +24V 10 EMGOUTC 0
a 11 EMGOUTI
0
.., YAMAICHI-34P x
111· / A B
"C 2 (P003l FAULT CDISCONNECTl (I/0 LINK)
Ill PANEL DO
:J 3 (PD05) (P006)
MCl..EX-5P
--- MOLEX·4P
CD 4 !PD07l (P008) I +24V I TXSLC
5 !POI I) F-RESET 2 +24T 2 •TXSLC
;!; 6 REMOTE !POI4)
7 !PDI5) !POI6) 4 EMG82 4 •RXSLC
8 C-START (TPOFF)
5
t 9 ONI ON2
U1 10 OFFI OFF2
.c II !Tl l (T2)
12 (AUTO) (MODCOM)
13 OPEMGAI OPEMGA2
f... 14 (IPEl«JCI) OPEMGC2
15 OPEMGBI HMI
c
.:::; 16 +24V +24V
17 ov :><:
OPERATOR PANEL
i
~
PROCESS I/O
MAIN CPU (.11

A 166-3200-0040
CR2A [ D
i
I TYPE OF PROCESS I/O(SINK TYPE) ~
CR2B [
JDIA [ tJ JD4A
CR2B [ CA Al6B-2201-0470 0 0 x x x x 0 0
---D tJ J04B SDI/SOD
CR2B [ CB Al6B-2201-0472 0 0 x x x x x x
DA A 166-220 I -0480 0 0 0 0 0 0 x x
CR2B [
J04A,B CR2B [
CRS-422/SLC)
I RX 11 ov CRWI [ TO WELD MACHINE CA/D,D/A,WDI/WDO)

2 •RX 12 ov
3 TX 13 OV I
CRW2 [ TO ANALOG INTERFACE ( A/D)
4 •TX 14 ov
5 15 ov
6 16 OV
!! 7 •ENBL 17 -15V
ca I/O LINK SLAVE
8 +15V 18 +5V
> 9 +5V 19 +24V
:i:o. 10 +24V 20 +5V
:g CRM2C CRM4A CRWI

CRM2A
'ti (SOI/SOOl (SOI/SOD) (SOI/SOOl (WELD INTERFACE OPTION l
01 •IMSTP 33 CfolJENBL 01 SOI23 33 80021 01 SOI63 14 $0061 01 OACHI 23 WOOi
n
.
0
02 •HOLD 34 SYSROY 02 SOI24 34 S0022 02 SOI64
08 $0068
$0066
15 $0062 02 CAMDAI
13
14
AOCHI
COMADI
24 W002 >
19 ACK3/SN03 19 $0033 09 ""O
Cl> 03 •SFSPO 35 PROGRLt.i 03 SOI25 35 $0023 03 SOI65 16 $0063 03 0ACH2 25 W003
Ill 20 ACK4/SN04 20 $0034 10 $0067 15 ADCH2 ""O
Vt 04 CSTOPI PAUSED 04 SOI26 36 $0024 04 $0166 17 $0064 04 CAMDA2 26 W004
Ill 21 ACK!5/SN0!5 ~~ 21 $0035 II S0068 16 COMA.02 m
...... 05 FAULT RESET COM-Al 05 SOI27 37 COM-Cl 05 50167 18 COM-El 05 WOii 27 WOO!S
22 $0036 12 COM-E2 17 z
-..J =:::: 06 START ~ AC;!'-5:6 JS HELD 06 90128 38 $0025 06 SOI68 19 +24E 06 WOl2 28 WD06
23 COM-C4 13 SOI70 18
0 07 HOME FAULT 07 SOI29 39 $0126 07 SOI69 20 ov 07 WOI3 29 W007 0
24 ACK7 /SN07 !~ 24 $0037 19 ov
08 ENBL ATPERCH 08 $0130 40 $0027 08 wou 30 woos
25 S0038 20 ov x
09 RSR I /PNS I ~ AC:~~8 41 TPENBL 09 $0131 41 $0028 CRM4B 09 W01!5 31 WCI+
26 SOD39 (SOI/SOO) 21 ov
I0 RSR2/PNS2 COM-A2 10 $0132 42 COM-C2 10 WOI6 32 WCI-
27 RESERVED :~ 27 $0040 22 ov
II RSR3/PNS3 BAT ALM II $0133 43 $0029 01 $0171 14 S0069 II WDl7 33 +24E
I
UI
12 RSR4/PNS4 BUSY 12 50134
28 COM-C5
44 S0030 02 SDI72
08 S0073
S0074
15 $0070 12 WOI8 34 +24E
9 ~ P~~;:E 44 29 SDI39 09
13 RSR5/PNS!5 ACKl/SNOI 13 SOI35 40 50031 03 $0173 16 50071
30 PROD ST ART 30 $0140 10 S0075
I4 RSR6/PNS6
:= ACK2/SN02 14 SDI36 46 50032 04 50174 17 50072 CRW2
31 SOIOI 31 50141 II 50076 (A/0 INTERFACE OPTION)
I5 RSR7 /PNS7 47 COM-A3 10 50137 47 COM-CJ 05 SDI7!5 18 COM-Fl
32 SOI02 32 50142 12 COM-F2
I6 RSR6/PNS8 48 16 $0138 48 06 $0176 19 +24E 01 14 ADCH3
...f 13 $0178 08 AOCH6
17 ov 49 •24E 17 ov 49 •24E 07 50177 20 ov 02 10 COMAOJ
0 09 COMA06
.::,, 18 ov 00 +24E 18 ov 00 +24E 03 16 AOCH3 ;i>
10
04 17 COMA04
II
CRM2B CRM2D 05 18 AOCH5
12
(SOI/SOOl (SDI/SDOl 06 19 COMA05
13 d
01 SOI03 33 $0001 01 $0143 33 50041 07 20
02 50104 34 $0002 02 $0144 34 80042
19 $0013 19 $0053 ~
03 SOI05 35 $0003 03 $014!5 35 50043 r
20 50014 20 $0054
04 SOI06 36 S0004 04 SOI46 36 $0044
21 50015 21 $0055 0
05 $0107 37 COM-81 05 $0147 37 COM-DI
22 $0016 22 $0056
06 $0108 38 $0005 06 SDl48 38 $0045 0
23 COM 84 23 COM-04
07 50109 39 $0006 07 $0149 39 S0046 z
24 $0017 24 $0057
08 SOIIO 40 $0007 08 SOI54 40 S0007
25 SOOl8 25 $0058 z
09 SOii I 41 $0008 09 SDI51 41 $0048
26 $0019 26 $0059 m
10 SDil2 42 COM-62 10 SOI02 42 COM-02
27 S0020 27 $0060
II SDI13 43 S0009 II $0153 43 S0049
28 COM 85 28 CDM-05
12 50114 44 $0010 12 SOI54 44 $0050 ~
29 SOil9 29 $0159
13 SDil5 45 SOOll 13 SOI50 45 $0051
30 50120 30 SOI60 5
14 SOil6 46 SOOl2 14 SOI56 46 S0052
31 S0!21 31 SOI61 z
15 SDil7 47 COM-83 15 SOI57 47 COM-03
32 SOI22 32 $0162
16 $0118 48 16 SOI58 48 0
17 ov 49 +24E 17 ov 49 +24E )>
18 ov 50 +24E 18 ov 50 +24E
(j)
:::c
PROCESS I/O BOARO(SINK TYPE) )>
s::
;i>
I/O UNIT MODEL A d
r
~
POWER SUPPLY (')
A 16B-l 2 I 2-0870
CP32 .JDIA/.JOIB .JD2 0
MODULAR I/O
5-SLOT BASE UNIT 1 A03B-0807-.J002 +24V 11 RX II ov I SI II S5 z
CP6 [ D MODULAR I/D 2 ov 12 •RX 12 ov 2 •SI 12 •S5 z
INTERFACE MODULE MODULAR I/O 3 13 TX 13 ov 3 S2 13 S6 m
A03B-0807-.JO I I 4 •TX 14 OV 4 •S2 14 •S6
(')
5 15 5 S3 15 ov -i
'-----10 CP32
6 16 6 •S3 16 ov
.JDIB 7 17 7 S4 17 102
5z
8 18 +5V 8 •S4 18 103
MAIN CPU D .JOIA 9 +5V 19 9 IOI 19 0
A I 6B-3200-0040 10 20 +5V 10
.JD2 20 5>
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ca .JOIAd Q-- )>
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BASIC UNIT !EXPANSION UNIT '1J
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00 m POWER SUPPLY z
r A I 6B- I 2 I 2-0870
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INTRF ACE UNIT
A03B-0808-COO I
24V 2
L.... ov 6~ ) TO BASIC UNIT 2-4
o-~~~~~~~~--t-+-"
~9 SI+
SI- o-~~~~~~~~--t~
MAIN CPU
...f A 16B-3200-0040 pg~:: ~~~ FGO-~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~-+~~~~
j TO BASIC UNIT 2
$!
.._.. S3+ o-~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~-+-~~~~
.JDIA [ S3- TO BASIC UNIT 3

FGo-~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~-+-~~~~
S4+ o-~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~-+-~~~~
S4- TO BASIC UNIT 4

FGo-~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~-+~~~~
.JOIA/.JOIB
RX II ov
•RX 12 ov ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~-t-~~~~- I/O LINK SLAVE
TX 13 ov
•TX 14 OV
15
6 16
7 17
8 18 +5V
9 +5V 19
10 20 +5V
i
~
.!>-
TEAa-t PEt-.DANT
·~v JlMIO OPERATION BOX PCB .k.,TP ~
EMGTP
B<ERGENCY STOP BUTTON
R-J2
MAIN CPU
..."'""""'
~.,
I
RUlM
.......... ' DEAD-MAN SWITCH
RLEN .....,.., _...,
+2...V
B ;,
,
I ~
FEN:EI
FENCE2
.. - '1'
- FENCE
ENABLE DISABLE
·srv =I~J:~,
~ alo
i
=r· ..
I "·-·~2• 1
CPEMG
- ~~MERGENCY STOP BUTTON
T~
~~,..
RV
~~
~18 - THIS TERMINAL IS OPTION

TPac; RV OV ov
I '1'
EXEMG ---fRVl I EMGINI
EMGINC
EXTERNAL EIERGEN:Y STOP
-J.J. ~rO
1 ..,...., SERVO (lll.IQF SWITa-t
SVON
RV i 79-1 I
I
SVIJ'l2
ESTCP2 2.WVC(CPTIC».I)
ov I EMGO.JT2
I v EMGOUTI
I OOVAC/240VC
I I EMGO.JTC
+24V I +2.4.V
RV; RECEIVER L__
FOR DI
L..___-.L ----~~I HOU> METER
(OPTICJIO
~
- JRVI JlVI --·
~]
•nwu" ,1r ~ er-a.mo
AXES '"
CONTRCL
-·--· LOOIC FOR
• AtiiFLIFIER
'---
•BRAKCl'ol#I
- -"-·-· -Q--:¥E
•BRKALM~ ·~~··· f,CRFI TO MOTCR Pll..SE COOER
I (l/F IS SA.ti£ AS R-.J)
PDl-6/•POl-6 I
JlF2 JlF2 .... -·
PR£01-6/•PREO 1-6
I I I
-~
·~ +24E I I +24E ,CRMI I
~
I
I~~
·~
·-·..
>et<REL--<:t-.
I
ROT-@ ,_ _, I ,..-...OTREL
OTREL -.... In-• I I y /"\ROT •ROTIN
OTRST----,.._
i~
ROI COM
•-·-- B~ I
I )J I
I--,
I
DILi
DOOR
CRMl5 I~OCK
I
-...._
.--~-··-~ I~ 1V I I
1 ~RL-OT/1-B< OIL2
~
I
-eRAKONl2
l:V
lou~
I I Ll
.Y.
I I I SVOJT
CRM9
CRMl6
··~~ - I ..- , I MN'nNI
-"-·-·-·-
~
I
I
I
I
I
,.--, ~'=~
~~
..- - , ~o~
1%
I
I
v
,CRR22
I I
I I I I I
- j j
~
I
I BRKl-31 ,CRR5
~;
I
IOOA
·-· .Y. ' BRK4
1008
CRR21
-- r<>~o- r
I
I
BRK5-7
CRR20
~
BRAKE CONTROL CIRCUIT 200R
I
200S
200T
POWER 200R ACI
TRANSFORMER 200S
I I AC2
--i0 200T
I AC3
AC POWER - - i 0
INPUT - - i ]~ DC POWER SUPPLY
~--'--
~I
TRCL
I
I
200A
rl1
I
2008 I I ,_ 1
I L-"
Fig.A.4 (p) Emergency Stop Circuit (S-450, M-410i)
- 520 -
EMERGENCY CIRCUIT
ROBOT
MECHANICAL UNIT
PlLSE
BRAKE MOTOR
I .~
ROBOT ROT
JSIB
JS2B_.L_
CRR25 CRP7 ·~
•"" PSM
ov I CX4 CX2B
.o•v •UV
II ,___::J
,:::I fQl-
"'" I ·~=
II
II
a ~:eTRQ_ I
SVD<
CXJ
··~Jv CX2A
MCCON
1~-~· I r- MCCD<
.§
,...,,..,.
CPI
---- I SVM
~
11~
µ p
AC ~_E.AfTOR
--
on~
I
···r
·1
'T
A A A
•
I
'.
- ~Q-~
N
DELAYED-OFF MCC UNIT
- 521 -
A.5
B-CABINET OF
S-900
- 522 -
IN CASE OF
CIRCUIT BREAKER
LI
)
,..,..._
I~--
-- (
AC POWER
SUPPLY
I
I I
'I" I
220/240 L2 I I-~ I
380/41!5 ) (
460/480 I
500/550 I
57'5
'5()/60HI
+IOX
-15X
L3
) I
I
A
--- I
I
I (
I
I
G I I
)
i I
I
I
I
I
IN CASE OF FUSE LJ<IT I
OISCCHIECT SWITCH
I
'~ I
- - -of-o- - - -li- - I
I
I
I
I
I
L - - 1_ - - -o""t-o- - -
I
-ti- f---
I
I
I I
--- - - -o"-o- - - -H- _ _ _ _ .J
NJTE) OISCCNECT SWITCH IS NOT MOl..NTED

----- a.I B-SIZE CA8lr£T.
-~
• BREAKER.FUSE SIZE • CONNECTION TO TFI AND TF3

DISCONNECT CONNECTION OF PRIMARY TAP
IN>UT CIRCUIT LEAKAGE SWITCH POWER
VOLTAGE BREAKER BREAKER SUPPLY CONNECTING
FLI I FL2 I FL3 VOLTAGE STYLE
LI L2 L3 JUMPER
;~~ 50A 50A 50A
220 7 15 23 8-15 I 16-23 I 24-7
380 240 6 14 22 8-14 I 16-22 I 24-6
DELTA ~
~ 380 7 15 23
~ 415
30A 30A 6 14 22
480 30A 440
STAR
;~~
460 5 13 21
8-16 16-24
480 4 12 20 y
575 20A 500 3 II 19
550 2 10 18
575 I 9 17 AC POWER INPUT
Fig.A.5 (a) Transformer/Line filter (Internal connection)
- 524 -
MULTI - TAP TRANSFORMER -----,:;i

TFI
OR
LINE FILTER
LF
Fl
LD ~~~
I
ALC
2
)
SERVO POWER CONTROL
(210VAC)
SPECIFICATION OF TFI
I 575
I CAPACITY SPECIFICATION
lk.!J 2 550
3
"°° I 7. 5KVA A60L-0026-00 IO#A
• •60 3 4
J """ "''"
£2._
•eo
5
6 .415/2A.O
I -
H._ 5 6
7 I
3801220
Ill -
8 ov Ill I
9 575
I~ 10 550
II 000 (REFER TO PAGE 029)
12 480
IJ •60 F4 13 14 41
I
-
'" .415/2.t.O SPECIFICATION OF TF3
15 380/220 I F5 ) 100 VAC
I THI 23 24 42 SPECIFICATION
16 ov I :ru- - ~--
CAPACITY
17 575 1-~
5KVA A60L-0024-00l I
lllcli 18 550
19 "°°
20 .480
I
21 "60 I 43
22 '415/240 I
23 380/220
44 ) 220 VAC
I
24 ov I ~ 51
TH2
52 ) THERMOSTAT
FOR OVERHEAT AUX. ALC
·l
(IN CASE OF AUX. TRANSFORMER)
AUX TRANSFORMER -----,:;i
Fl .F2.F3 30A TF3
F4.F5 5A OR SERVO POWER CONTROL
AUX.LINE FILTER
LF
Fl
LD -~~
I
ALC
2
) (210VAC)
J ~"~'
I 575
lk.!J 2 550
•5 "°°
3
480
F2 3 4
"60
6 415/240
7 380/220 F3 5 6
•
9
ov
575
I
lbg) 10 550
II 000 (REFER TO PAGE 029)
12 480
F4 13 I• 41
13
14
15
"60
415/240
380/220
THI
-F5 23 2• 4? ) 100 VAC
~
16
17
ov
575
~ ---
ilclJ 18 550
19
20
"°°
480
575
550 21 "60 43
22 415/240
"°°
480 USER TRANSFORMER(OPTION) 23 380/220
44 ) 220 VAC
"60 TF2
••o A60L-OOO 1-0520 24 ov l'I
~ 51
)
415
380 TH2
52 THERMOSTAT
240 I 15V FOR OVERHEAT
·l
220
115 VAC ) Fl ,F2,F3 30A

9. 6A TO OUTLET UNIT F4,F5 5A
- 525 -
~-~
A2 1
BREAKER
TFI
Lo ~-_J
/ LI ---<>,.,..... I 575 .EL I
ALC
2
Ir-PUT VOLTAGE L2 ---0

+ <>------
lb.!J 550
500
480
I £2.. 3 4
REFER TO
PAGE 002
..-1-.... 460
415/240
L3 ---0
380/220 _,R, I 5 6
-
G~ 1!
"
ov
575
I
lib!11 10 550
11 500
12 480
13 460 13 14 41
14 415/240
15 380/220
I> THI 23 24 4~
-
"-....__
16
I
ov 1ll- ---
FI ,F2,F3 30A
I lbll 18
19
"70
550
500
480
I> F4,F5 5A
"'21 460 4~
"'>2 415/240
"73 380/220
44
'>A OV
f'lJ- 51
TH2
;[.
52 l
l ~
BACK PLANE PSU

~FAN UNIT
CPI tJD
JNPO
~[ CP2 tJD
CP3 tJD
CP5 tJD
l
MAIN CPU E-STOP PCB
JRVI
OD -0[ JRVI CRFI
DD--
JRF2
JO -0[ JRF2
JD
JSI
CRMIO JD dJ[ CRM9 JD
JS2
JD
JDIA dJ[ CRMl5 JS3 JD
JRA5
m JF21 JD D[ CRMl6 JS4 JD
CRSI JD L{][ CRRl5 JS5 JD
JDl7 JD '----{][ CRR20 JS6 JD
JRM3 JD -0[ CRR21 CRMI I JD
JRMIO JD CRR5 J[}
CRR22 DD
r- --,
~r; OPTION PCB
1 I
JNA 1
J
L ___ _J
I rr
Fig.A.5 (b) Transformer/Line filter (B-cabinet) (S-900)
- 526 -
SURGE ABSORBER
UNIT
AMPI AMP2 AMP3 AMP4 AMP5 AMP6
,-
@
LI
L2
~)@
LI
L2
,...., @
LI
L2
,-
@
LI
L2
,-
LI
L2
@
-@ LI
L2
L3
LIC Tl
L2C
THI
TH2
L3
' - - ) LIC Tl
...__ ) L2C
[)THI
TH2
- [
L3
LIC Tl
L2C
THI
TH2
,__
L3
LIC Tl
' - - L2C
THI
[ TH2
L3
f'.-1-- LIC Tl
'-1-- L2C
THI
[ TH2
,__
L3
LIC Tl
' - - L2C
THI
[ TH2
-= - - - - -=
[uh
V [u~
........
[uh [Uc~
[Uh
Whh V~ V~
v h
Tl ........ Tl
Tl w)-.,, Tl
w~ T i p ........
Tl V
Wh h
w~
PE>-- PE,_, PE h PE ........ PEh PE~
CX4 JSIB CX4 JSIB CX4 JSIB CX4 JSIB CX4 JSIB CX4 JSIB
L...J L...J L...J LJ LJ LJ LJ LJ
9 9 9 9 9
--- - ---
ROBOT S-900
-0[ RMI
-0[ RM2
-0[ RM3
,--- -0[ RPI
, - {11 RBK
TEACH PENDANT
.JRM3 CRSI D- _)
.JRMIO 0- - - - - - - - - - - - - - ~~ RS-232-C
- 527 -
SERV 0 TRANSFORMER AMPI

TFI Fl ,F2,F3 30A A06B-6066-H008
OR
~-All
F4,F5 ' 7.5A Tl JI
L !NE FILTER '
A2 1 I3 I 4 I5 I6 I7 18 I 9 24 25
LF
~c _J
11 2~~ 5 6 z 8 9
- -
10 11 121
El I 2
11
> .E2 3 4 -1 J J J
.E3. 5 61
1~ -
I~
fi. I~ 14 41
1Ij1·rn1 .E5_ 2~ "4 42
100 VAC
AMP3
;u:- ~--
A06B-6066-H008
1!1~ >----- Tl J2
Ill I3 I4 I5 I 6 I 7 I 8 I 9 24 25
1!1 43
Ill>
I 220 VAC 44 I 1 2 3 4 5 6 7 8 9 10 11 121
-
l~I
~2 51
52
-1 J J J l
AUX .TRANSFORMER ~-All
TF3
A2 1
I~
OR
AUX .LINE FILTER _J
LF AMP5
l~I El I 2 A06B-6066-H008
1!1>
11>
- Tl J3
E2 3 4 I 3 I 4 I 5 I6 I7 I8 I 9 24 25
.E3.
1~ -
5 6
I1 2 3 4 5 6 7 8 9 10 11 121
I
fi. I~ 14 41 Jj J J
lHI .E5_ 2~ 94 42 100 VAC
;u:- -
~t--
--
43 FAN UNIT
220 VAC 44 - - - -
~
'll- 51 I 3 4 5
TH2 co co co co
52
Fl ,F2,F3 : 20A
F4,F5 5A ,_,
' - - -
DISCHARGE UNIT
A05B-2313-CIOO I
.0
.3
.A
11
I I
,5
n nn I I
·' n_ t') ID < m
"'u
-(\J
Q_ Q_ - 00 uu
.7 u u 0:: 00 uu
0:: -- :E :E
u
'"..
POWER SUPPLY EMERGENCY STOP
Lon
UNIT UNIT
II
loo
, ,,
FAN$$$
,,.
Fig.A.5 (c) Servo Amplifier (Internal connection)
- 528 -
ROBOT S-900
AMP2
A06B-6066-H006
Tl J4 - AC MOTOR
13 14 15 16 17 18 19 I .2
I 4,5
LJ 7,8
I 1 l? l3 4 5 6 7 8 9 10 11 121 10, 11
~
i J II J 3
6
AC MOTOR
J4
9
12 8F/3000
~
2-
AC MOTOR
I
AMP4 4 5 J2
A06B-6066-H006 7 8 ~
Tl J5 10, I I 30F/2500
13 14 15 16 17 18 1_9
AC MOTOR
I 1 l2l3~5~\ 8 9 10 11 121
3
6
9
~
J5
-b I I I 12 8F/3000
J J J ~
I2 - AC MOTOR
4 5 J3
7,8
10 11 30F/2500
AMP6 AC MOTOR
A06B-6066-H006 3
Tl J6 6
13 14 15 16 17 18 19 9
12
9 10 11 12
BK BRAKE (BUILT-IN)
J J J I -
2
BRAKE (BUILT-IN)
3
Tl Tl
(I-AXIS SERVO AMP. ( I -AXIS SERVO AMP. 4
A06B-6066-H006 A06B-6066-H008
TERMINAL BLOCK) TERMINAL BLOCKJ I BRAKE (BUILT-IN)
I PE!Gl I PE(G)
13 LIC 13 LIC 5
2 LI !Rl 2 LI !Rl
14 L2C 14 L2C
3 L2(S) 3 L2(S) 6
15 THI 15 THI
16 TH2
4 L3(TJ
16 TH2
4 L3(TJ BRAKE (BUILT-IN)
!5 IOOA !5 IOOA
17 RC 17 RC 7
1
6 IOOB 6 IOOB
18 RI 18 RI
19 RE
7 MCI
19 RE
7 MCI 8 ~
8 MC2 8 MC2
24 FANI BRAKE (BUILT-IN)
9 u 9 u
10 v
25 FAN2
10 v 9
II w II w I
11 10
12 G 12 G
ID
er BRAKE (BUILT-IN)
er
u CRRl5 11
( MCC CONTROL)
A3 12
~OBI
CON VERSION A2 Al
~
BOARDNIT IOOAI
LJL1!~2 I M~~ II
- 529 -
'1>
CA39A
d
~
r
(')
0
z
z
m
~
5
z
.,, 0
cE" ~
):. CPI CP4 CP8 :a
(n 11 APOWER
I 6B- I 2 SUPPL y
I 2-0870 )>
B3 Bl B2
a: R tJALt ] J 2
FA FB BAT+ BAT-
s::
._.. I CPI I tI1J I I
0 A3
0 I II CP2 I" r- - - - - - - - 200-240 VAC OUTPUT U ttl2
ONOFF COM
"ti u I I
0 CP2
I II CP3 I" r- - - - - - - - 200-240 VAC OUTPUT
:eCD L" CP5
RI
B3
.
(/)
r , POWER ON/OFF
stf1J ~2
~v )>
c I JNPO I CP4 r-------- ALARM I ""C
"C I ""C
Ul "C
w I CP5 +24 voe OUTPUT CP3 m
0 -< CP6 z
c: I 0
::I R2 Bl
;::;: I II CP6 I r- - - - - - - - +24 voe OUTPUT I s[[!J +24E
x
~tt:J
5"
CD
1 r-B~T~E::- :R~ SPECIFICATION OF FUSE
--.
::I I
e!. NAME FUSE POWER
n Fl 7.5A 200V
0
::I F3 5A +24V
::I F4 5A +24E
CD
n
()"
-
2.
I
~~~
999
!!!c;c;c;
2~~~
000
iS;i!;i!;i!
<1-1-1-
"'ooo
_,_,_,
"t"t"t
"'"'"'
i
~
~ @AN
CA39A[ D JDIB JRMIO JRF2 JRVI

(!/O LINK) (OPERATION BOX) (ROBOT FEEDBACK l (SERVO AMPLIFIER)
BATTERY FOR MAINTENANCE
~--------.,
I RXSLC II ov I ov 26 av Al PD6Bl •PD6 Al IS6 Bl GNOS6
i
~
2 •RXSLC 12 ov 2 RTSI 27 CTSI A2 ov B2 ov A2 IR6 B2 GNDR6
1
MAIN J r , 3 TXSLC 13 ov 3 ov 2B ov A3 PR06B3 •PR06 A3 IS5 B3 GNDS5
A 16B-3200 L
CPU VBA T S - - - - - - - - - ~ I
-1 I If--I II
-0040 I . I 4 •TXSLC 14 ov 4 DTRI 29 DSRI A4 ov B4 ov A4 IR5 B4 GNDR5
5 15 ov 5 ov 30 ov A5 PD5 B5 •PD5 A5 IS4 B5 GNOS4
JRVI JD ~0-CoNVERSIONB~ARD 6 16 ov 6 TXDI 31 RXDI A6 ov B6 ov A6 IR4 B6 GNDR4
7 17 7 ov 32 ov A7 PRQ5 B7 •PRQ5 A7 IS3 B7 GNDS3
B IB +5V B RTSA 33 CTSA AB ov BB ov AB IR3 BB GNDR3
JRF2 ROBOT FEEDBACK 9 +5V 19 9 ov 34 ov A9 PD4 B9 •PD4 A9 IS2 B9 GNDS2
JD TO E-STOP UNIT 10 20 +5V 10 DTRA 35 DSRA AIO ovBIO ov AIO IR2 BIO GNDR2
II ov 36 OV Al I PRQ4 Bl I •PR04 Al I ISi Bl I GNDSI
JF21 J ~}-------- LINE TRACKING 12 TXDA 37 RXDA IA12 ovBl ov Al2 !RI Bl: GNDRI
13 •TXTP 3B •RXTP Al~ PD3 Bl •PD3 AIJ •ENBL6 Bl ov
JDl7 14 TXTP 39 RXTP Al4 ovBl4 ov Al4 •PWME6 614 ov
JRA{ JRMIO JD TO OPERATOR PANEL (RS-232C/4B5l
15 •TX4B5A 40 •RX4B5A Al5 PR03 Bl5 •PR03 Al5 •PWMC6 615 ov
u (FOR T~m tJ I RXDB 11 TXDB 16 TX4B5A 41 RX4B5A A16 OV ;16 ov Al6 •PWMA6 Bl6 ov
2 ov 12 ov 17 ON 42 ov Al7 PD2 ;17 •PD2 Al7 •ENBL5 Bl7 ov
JDIB tJ ~}-------- I/O LINK
~ 3 DSRBC 13 DTRB IB OFF 43 ov Al8 ovBl8 ov Al8 •PWME5 Bl ov
RS-232C/ 4B5 INTERFACE 4 ov 14 ov 19 COM 44 +24V Al9 PR02 Bl •PR02 Al9 •PWMC5 Bl ov
;si. JDl7 D ~}-------- (OPTION)
CTI 5 CTSB 15 RTSB 20 •OPEMG 45 +24V A20 ovB2 ov A20 •PWMA5 B2< ov
JRM3 DD TO OPERATOR PANEL 6 ov 16 ov 21 •EXEMG 46 +24V A21 POI B21 •POI A21 •ENBL4 621 ov
~ 7 RX4B5B 17 TX4B5B 22 EMGDM 47 +24V A2< ovB2' ov A22 •PWME4 822 OV
CRSI TO TEACH PENDANT
oc B •RX4B5B IB •TX4B5B 23 EMGEM 4B +24V A23 PROI 23 •PRQI A23 •PWMC4 B23 ov
i: CRMIO RDI/ROO 9 19 +24E 24 •TPEMG 49 EMGBI A24 ov 24 ov A24 •PWMA4 B24 ov
Ill 18~~ OD 10 +24E 20 25 SVON 50 EMGB2 A25 ov 25 OV A25 •ENBL3 B2' OV
s· 'i"i"i'
w,....,....,.... A26 ov 26 ov A26 •PWME3 B2< OV )>
0 z~OO A27 +5V B27 +5V A27 •PWMC3 B27 ov
'ti < 1'31'3 "ti
A28 +5V B21 +5V A28 •PWMA3 B28 ov "ti
Ut c: er di di di CRSI JF21 VBAT
VJ ..-. A29 +5V B2' +5V A29 •ENBL2 B2' ov m
....... (TEACH PENDANT) (LINE TRACKING) (BATTERY)
o~~~ A30 +5V B3< +5V AJO •PWME2 >.>< ov z
S" 01 TXTP 14 •TXT? I PA II I I IEXVBATI A31 +5V B31 +5V A31 •PWMC2 !JI ov 0
~bbb 08
CD _J _J _J 02 RXTP 15 •RXTP
09 2 •PA 12 ov I 21 ov I A32 +5V B32 +5V A32 •PWMA2 !32 ov x
j OJ EMGDM 16 EMGEN
-...
!!!.
~~~ 04
05
10
II
EMGBI
EMGB2
17
18
ov 3
4
PB
•PB
13
14 ov
A33
A34
+5V
+5V
B33
B34
+5V
+5V
A33
A34
•ENBLI
•PWMEI
B33
B34
ov
ov
12 EMGTP
n 06 +24V 19 ov 5 PZ 15 A35 +5V B35 +5V A35 •PWMCI B35 ov
13
0 07 -.24v 20 6 •PZ 16 ov A36 +5V B36 +5V A36 •PWMAI 36 ov
j
j 7 17 A37 +5V B37 +5V A37 •MCON !37 +5V
B REO IB +5V A38 +5V B38 +5V A38 •DROY +5V
~ 9 +5V 19 A3' +5V B3' +5V A39 ov ""
!39 +5V
c;· 10 20 +5V A41 +5V B41 +5V A40 ov B40 +5V
A41 +5V B41 +5V A41 + 15V l41 +5V '1>
2. A42 +5V B4< +5V A42 + 15V >42 +5V
A43 ovB43 ov A43 ov l43 +5V
CRSI JRM3 A44 ovB44 ov A44 ov B44 +5V
(TEACH PENDANT) (POI/POD)
A45 +24E B45 +24E A45 -15V B45 +5V
a);!
14 RODI 01 ROii I PDII II ov A46 +24E B4 ov A46 -15V B46 +5V r
08 ROI7
15 R002 02 ROI2 2 12 POOi A47 B4 •OTREL A47 B47 +24V
09 RDI8 ov ov (")
16 R003 03 ROIJ
10 ROI9 3 PDI2 13 PD02 A48 •OTRST B4 •ROT A48 ov B48 +24V
17 R004 04 ROI4 0
II •HBK 4 PDI3 14 PD03 IA49 SVON B4 •HBK A49 •BRKON 649 +24V
18 R005 05 ROI5
12 R007 z
19 R006 06 ROI6 5 PDI4 15 PD04 A50 RDICOM B5 •HBKREL A50 •BRKALM B5C +24V
13 ROOS z
20 +24E 07 ov 6 PDI5 16 PD05
7 PDI6 17 PD06
m
B PDI7 18 PDD7 ~
9 TPOFF 19 +24V
10 +24V 20 PODS 0
z
0
)>
G)
~ ~
s:
'!>
d
~
r
(")
AMP2 AMP3 AMP4 AMP5 AMP6 0
JI J4 J2 J5 J3 11 J6 z
z
m
(')
CNI CNI CNI CNI CNI
.,, -I
ca· MAIN CPU CONVERSION BOARD
4J
A16B-1212-0910
6z
;t..
(II
JRVI JVI
0
JRVI 0
s 0n n
:JJ )>
0 JV2 Ci)
0 :::0
:J JV3 )>
<
CD s:
JV4
iiJ
s· JV5
:J
"ti JV6
0
~
m CRR5 TO ROBOT BRAKE(MI)
3 )>
CD ""O
...
cc ""O
VI
V) CD CRRl6 m
N :J z
~ 0
(/) x
0
"C
c:J
;::;: E-STOP UNIT
....... A05B-2350-COIO
5'
CD CRF3 ROBOT PULSE CODER
JRF2 Jl-J3
-...
:J
!!!.
JRF2 0 CRF4 ROBOT PULSE CODER
JROBOT 4-J6
n
0
:J
:J CRM9 CRMI I ROBOT OVER TRAVEL SIGNAL
CD <OPTION)
~ I00 VAC CRRl5
s· (FROM TRANSFORMER)
CRMl5 0 SHORT CONNECTOR
2.
CRR20
(X)
CRR20
(Y)
i
~
~
01
I\)
01
JRF2 JRVI
JVl-JVIO,CNl(AMP) CRRl5 CRF3 ~
(ROBOT FEEDBACK) (SERVO AMPLIFIER) (ROBOT FEEDBACK Jl-J3)
(SERVO AMP COMMAND) CMCC CONTROL)
Al PD6 Bl •PD6 Al IS6 Bl GNDS6 23 PD3 _ l3 01 POI
I IR 11 IS PD2
A2 ov B2 ov A2 IR6 B2 GNDR6 Al 24 •PD3 _ l4 02 •POI
2 GNDR 12 GNDS IOoB 100A
A3 PRD6 B3 •PRQ6 A3 IS5 B3 GNDS5
3 •PWMA 13 •PWMD
GTif 25 PR03_ 16
•P02
PRQ2
03 PRQI
A4 OV B4 ov A4 IR5 B4 GNDR5 26 •PRQ3 04 •PRQI
4 ov 14 ov 16 •PR02
w2 Bl 27 +5V 05 +5V
,, A5 PD5 B5 •PD5 A5 IS4 B5 GNDS4 17 +5V
5 •PWMB 15 •PWME ~C2 MCCI 28 +5V '06 +5V
A6 ov B6 ov A6 IR4 B6 GNDR4 18 +5V
ca· 6 ov 16 ov 29 +5V '07 +5V
19 +5V
)> A7 PR05 B7 •PR05 A7 IS3 B7 GNDS3 30 ov '08 ov
7 •PWMC 17 •PWMF 20 ov
AS ov BS ov AS IR3 8S GNDR3 31 ov '09 ov
<n s ov IS ov 32 ov '2i ov 'To ov
A9 PD4 B9 •PD4 A9 IS2 B9 GNDS2 '22 ov
9 19 33 ov ~ '11 ov
AIO ov BIO ov AIO IR2 310 GNDR2
10 •MCON 20 •DROY 34 ov '12 ov
Al I PR04 Bl I •PR04 Al I ISi 311 GNDSI -
0
-co
0 Al2 ov Bl2 ov Al2 !RI 312 GNDRI CRM9 CRF4
::s Al3 PD3 Bl3 •PD3 Al3 •ENBL6 813 ov CMCON, SYON) (ROBOT FEEDBACK J4-J6)
<
CD Al4 ov 314 OV Al4 •PWME6 Bl4 ov
01 PD4 23 PD6
A15 PRQ3 315 •PRQ3 Al5 •PWMC6 Bl5 OV 13 PD5
iil 02 •P04 24 •P06
Al6 ov 316 ov Al6 •PWMA6 Bl6 ov
~oNlsv~uTI 14 •PD5
s· 03 PRC4 25 PRC6
15 PRC5
::s Al7 PD2 Bl7 •PD2 Al7 •ENBL5 Bl7 ov CRR5 04 •PR04 26 •PR06
16 •PRC5
"ti AIS ov BIS OV AIS •PWME5 BIS ov (MOTOR BRAKE) 05 +5V 27 +5V
17 +5V
0 Al9 PR02 Bl9 •PR02 Al9 •PWMC5 Bl9 ov 06 +5V 28 +5V
ID 20 30 18 +5V
ID 07 +5V 29 +5V
A20 OV B20 ov A20 •PWMA5 B20 OV 19 •5V
BKM3 BKM3 BKM3 CRMI I 08 ov 30 ov
m A21 POI B21 •POI A21 •ENBL4 l21 OV 20 ov
CROBOT OVERTRAVEL) 09 ov 31 ov
IC 2C 3C 21 ov )>
3 A22 ov 622 ov A22 •PWME4 l22 OV J_O ov 32 ov
-CD
... A23 PRQI B23 •PROI A23 •PWMC4 23 OV BKP3 BKP3 BKP3 3 J_I
'12
ov
ov
-
22 ov 33
34
ov
ov
"O
"O
VI cc A24 ov B24 ov A24 •PWMA4 824 ov IB 2B 3B m
w CD A25 ov 625 OV A25 •ENBL3 B25 ov
l•ROHJJ
w ::s BKMI BKM2 BKM2 z
n A26 OV B26 ov A26 •PWME3 B26 ov 0
'< IA 2A 3A
A27 +5V B27 +5V A27 •PWMC3 B27 ov x
CJ) BKPI BKP2 BKP2
A2S +5V B2S +5V A2S •PWMA3 B2S ov
0 A29 +5V B29 +5V A29 •ENBL2 B29 ov CRMl5
"g (DOOR INTERLOCK)
-
c: A30
A31
+5V
+5V
330
331
+5V
+5V
A30
A31
•PWME2
•PWMC2
B30
B31
OV
ov
::s
:::; A32 +5V B32 +5V A32 •PWMA2 B32 ov 31~
A33 +5V B33 +5V A33 •EN8LI B33 ov ~~~-o_I~
S' A34 +5V B34 +5V A34 •PWMEI 34 ov
CD A35 +5V B35 +5V A35 •PWMCI 35 ov '?>
--...
::s A36 +5V B36 +5V A36 •PWMA I B36 OV CRRl6
!!. A37 +5V B37 +5V A37 •MCDN B37 +5V CMCON,SVON, IOOVAC) CRRl5
n A3S +5V B3S +5V A3S •DROY B3S +5V
A3 A2 Al
( MCC CONTROL)
b
0 A39 +5V B39 +5V A39 ov B39 +5V A3 A2 Al
);!
::s MCON I SVOUT
A40 +5V B40 +5V A40 OV B40 +5V r
::s ex 200T 200S 200R
CD A41 +5V B41 +5V A41 +15V B41 +5V n n (')
B3 B~
A42 +5V B42 +5V A42 +15V B42 +5V B3 B2 Bl 0
A43 ov B43 ov A43 ov B43 +5V
as· z
~~~~10~ CY AC3 AC2 ACI
::s A44 ov 844 OV A44 ov B44 +5V n n z
- A45 +24E 845 +24E A45 -15V B45 +5V (NOT USED) m
A46 +24E 346 ov A46 -15V B46 +5V
A47 347 •OTREL A47 ov B47 +24V ~
A4S •DTRST 34S •ROT A4S ov B4S +24V
A49 SYON 649 •HBK A49 •BRKON B49 +24V
5z
A50 RDICOM 350 •HBKREL A50 •BRKALM B50 +24V
0
)>
(j)
JJ
)>
:s:::
OPERATOR PANEL
(JRMIO) ( CRSI l
(14) (I)
TXTP (13) (14)
TXTP
•TXTP •TXTP
...,.
(39) (2)
RXTP (38) (15)
RXTP
•RXTP (6,7) •RXTP TO TEAOi POOANT
( 17, 19)
+24V
OPERATOR PANEL PCB IJ'i (I)
ov
A20B- I 006-0290 (AFTER EDITION 026 l FG
( PORTI)
(JRMIO) (6) (2)
TXDI (31) (3) TXDI
RXDI (2) (4) RXDI
RTSI (27) (5) RTSI
CTSI CTSI
DSRI
DTRI
+24V
ov
(29)
(4)
(NOTE I)
(NJTE 2)
...,. ...,.
(6)
(20)
(25)
(7)
DSR I
DTRI
+24V
ov
RS-232-C
(PORT IX) IJ'i IJ'i (I)

(2) FG
TXDIX (3)
(NOTE I l RXDIX (4)
+24V;JRMI 0-44.45,46 RTSIX (5)
47,48 CTSIX (6)
DSRIX (20)
(NOTE 21 DTRIX
OV 1 JRMI 0-1,3,5,7 ,9 (25) ·~v
11 ,26,28 +24V (7)
30,32,34 ov CIJ 11'<>
36,42.43 FG
(JRMIO) (12)
TXOA (37)
RXOA (8)
RTSA (33)
CTSA (35)
DSRA ( 10)
OTRA
(16)
TX485A (40)
•TX485A (41)
RX485A (15) •?!V ( RT4l
•RX485A (3)
(4) t- - +24V
(PORT2l (2) ~ -ov
TXDA
RXDA
(3) Ov
(4)
RTSA (5)
CTSA (6)
DSRA (20)
DTRA
( 14)
TX485A (15)
•TX485A
RX485A
•RX485A
+24V
ov
16
( 17)
(25)
(7)
..,..
FG
(I) IJ'i
NOTE, PORT2 IS OPTION. = FG
Fig.A.5 (h) Operator's Panel-1 (Internal connection)
- 534 -
OPERATOR PANEL
OPERA TOR PANEL PCB
FROM MAIN CPU A20B- I 006-0290(AFTER EDITION 026)
(JRM3) (CRT3) ~
p DOI (12) CAil
~-
LED I : REMOTE
p D02 (13) !Bil SW4 :C-START
p D03 (14) (A2)
!NOT UESO!
p D04 ( 151 (62) LED2: F -RESET
(16) CA3l
PDD5 !NOT UESOl
p D06 ( 17) (63)
!NOT UESOJ
p D07 (18) IA4l !NOT UESO)
(20) (64)
p D08 (NOT LESO)
(I)
p DI I
(3)
p 012
141
PD I3
(5)
p DU
(6)
p 015
(7)
p DI6
(8)
PD I7
(9)
TPOFF
(10,19} •2fV
FROM MAIN CPU

EMGDM~~~>--~~<~J_R_M_l_O~l.....,122 1~~~~~~~~~~~~~~~~~~-'"'"-"'
......
EMGEN~~~1--~~~~--1ft'-'2~
3 ~~~~1--~--..~~~~~~~~~~~-'-'-"'-~I
EMGB1~~~1--~~~~--lll+.!14~9~l~~~-+-~~+-j~~~~~~~~~~~~~I
EMGB2~~~1--~~~~--lll-l"50
""-~~~-+-~~+-~~~~~~o-l.~~~~.l.L!-4ll
RL™
ov I
?>J
ov I
I I ESTCP I (TBOP I )
•2EJ''
I :l :-l-~ ~_._~-+- -1- -+- ~ ~ ~ i=b~:;,._~_
+~V
FENCE I
FENCE2
(Al6,Bl6)
(TBOPI)
--------
!CRT3l _ _ _ _ _ _ _ _ -
+24V
-=---=--~~
(Al3)
(613)
CAl5}
(Al4)
(814)
EMGINI
EMGIN2
SV(t.41
SVON2
-'-
- --00--,
-----;
---QiO--.J
CA09) ONI -1-
(8091 ON2
(AIO) OFFl
(811) OFF2
~~~~~~~~~~~~~~~~~~~~~~ (CRT3)
- 535 -
;i>
d
);!
r
.JRMIO .JRM3 PORTI PORT IX PORT2 ()
(MAIN CPU I/Fl (MAIN CPU I/Fl CRS-232-C; PORT-ll CRS-232-C; PORT-I) (RS-232-C; PORT-2) 0
HONDA PCR!50 HONDA PCR-E20 D-SUB 25P D-SUB 25P D-SUB 25P z
26 ov I ov II ov I PDII I FG , I FG , I FG z
14 ~2 14 14 m
27 CTSI 2 RTSI 12 PDOI 2 ov 2 TXDI TXDI 2 TXDA ()
15 15 15
28 ov 3 ov 13 PD02 3 PDI2 3 RXDI 3 RXDI 3 RXDA
16 16 16 --i
29 DSRI 4 DTRI 14 PD03 4 PDI3 4 RTSI 4 RTSI 4 RTSA
17 17 17
30 ov 5 ov 15 PD04 5 PDI4 5 CTSI 5 CTSI '5 CTSA
18 18 18
TXDI 16 PD05 6 PDI5 6 DSRI 6 DSRI 6 DSRA
6z
31 RXDI 6
19 19 19
32 ov 7 ov 17 PD06 7 PDI6 7 ov 7 ov 7 ov 0
20 DTRI 20 DTRI 20 DTRA
33 CTSA 8 RTSA 18 PD07 8 PDI7 8 8 8
21 '21 21
34 ov 9 ov 19 +24V 9 TPOFF 9 9 9
22 22 22
35 DSRA 10 DTRA 20 PD08 10 +24V 10 10 10
23 '23 23
~:D
36 ov II ov II II II )>
24 24 24
37 RXDA 12 TXDA 12 12 12
REMOTE = PDQ I F-RESET= PDI2 25 +24V 25 +24V 25 +24V s:::
38 •RXTP 13 •TXTP 13 13 13
C-START= PD02 REMOTE • PDI3
39 RXTP 14 TXTP THIS CONNECTOR IS OPTION
FAULT = PD04 C-START= PDI7 THIS CONNECTOR IS MOUNTED ON THIS CCNECTOR IS MOUNTED ON THIS CONNECTOR IS MOUNTED ON
40 •TX485A 15 •RX485A EXTERNAL SIDE OF TI£ BOX INTERNAL SIDE OF THE BOX INTERNAL SIDE OF Tl-E BOX
.,, CTPOFF l • PDI8
41 RX485A 16 TX485A
ca· 42 ov 17 ON
). 43 ov 18 OFF
.JDIA CRSI TBOPI TBOP2 TBOP3
(I/O LINK) (TEACH PENDANT) (EMERGENCY IN/OUT) (EXTERNAL ON/OFFl (MODEL B
u. 44 +24V 19 COM
.-. HOt()A PCR-E20 HOt<DA MR-20S
45 +24V 20 OPE MG MALE
-- FEMALE
------- M4 TERPUllALS
------------ M4 TERMUNALS M4 TERMUNALS
------------
.::: 46 +24V 21 EXEMG II ov I PDII I TXTP 14 •TXTP I EMGINI I EXON! I S2+ )>
0 8
47 +24V 22 EMGDM 12 PDOI 2 ov 2 RXTP 15 •RXTP 2 EMGIN2 2 EXOFF 2 S2- "'O
"C 9 "'O
UI CD 48 +24V 23 EMGEN 13 PD02 3 PDI2 3 EMGDM 16 EMGEN 3 FENCE I 3 EXOFFI 3 S3+
VJ 10 EMGBI m
49 EMGBI 24 TPEMG 14 PD03 4 PDI3 4 17 ov 4 FENCE2 4 S3-
II EMGB2 z
a 50 EMGB2 25 SVON 15 PD04 5 PDI4 5 18 5 SVDNI 5 +24V
°' 0 12 EMGTP 0
... 16 PD05 6 PDI5 6 +24T 19 ov 6 SVON2 6 ov
13 x
ui 17 PD06 7 PDI6 7 +24T 20 FG 7 ESTOPI
"ti 18 PD07 8 PDI7 8 ESTOP2
THIS CONJIECTOR IS NOT MOUNTED ON STAN:>ARO PANEL.
Ill CRT3 19 +24V 9 TPOFF 9 EMGOUT2
:I (PANEL SW/LED) 20 PD08 JO +24V 10 EMGOUTC
CD
11 EMGOUTI
;i; YAMAICHl-34P
/ A B
2 (POD3) FAULT CDISCONNECTl (I/O LINK)
PANEL DO
3 (PD05) (PD06)
MOLEX-5P
----·- -- MOLEX-4P
·---·-
4 CPD07l CPD08l I +24V I TXSLC
5 (POI I l F-RESET +24T •TXSLC
2 2
6 REMOTE (PDI4)
7 (PDI5l CPDI6l 4 EMGB2 4 •RXSLC
8 C-START CTPOFFl 5
9 ONI ON2
10 OFFI OFF2
11 CTI l CT2l
12 (AUTO) CMODCOM)
13 OPEMGAI OPEMGA2
14 ICX'EMGCI l OPEMGC2
15 OPEMGBI HMI
16 +24V +24V
17 OV _;><;;_
<.n
i
~
~
~
()1
RPI RMI RM2

(PULSE CORDER & RDI/RDO) (MOTOR POWER) (MOTOR POWER)
I ROI I 13 RDI2 25 RDI3 37 RDI4 49 RDI5 61 RDI6 a
I JI I
!! 2 RDI7 14 ROIS 26 +24E 3S +24E 50 +24E 62 ov 2 JI I 3 J41
cc 4 Jl2
;:,. 3 RODI 15 RD02 27 RD03 39 RD04 51 RD05 63 RD06 5 Jl2 6 J42
7 Jl3
u. 4 RD07 16 ROOS 2S •ROT 40 •HBK 52 •PPABN 64 s Jl3 9 J43
c::: 10 JIG
5 +5V 17 +5V 29 +5V 41 OV 53 ov 65 ov 11 JIG 12 J4G
b
=:::::
- 6 +5V IS +5V 30 +5V 42 OV 54 ov 66 ov
CD
n 7 +5V 19 +5V 31 +5V 43 OV 55 OV 67 ov
::J'
Ill
:J s +5V 20 +5V 32 +5V 44 ov 56 ov 6S ov RM3
c:;· (MOTOR POWER} )>
9 SPDJI 21 SPDJ2 33 SPDJ3 45 SPDJ4 57 SPDJ5 69 SPDJ6
!!. "'C
Vl c: 10 •SPDJI 22 •SPDJ2 34 •SPDU 46 •SPDJ4 5S •SPDJ5 70 •SPDJ6 "'C
U) m
:J
-..J ;::;: 11 SPRQJI 23 SPRQJ2 35 SPRQJ3 47 SPRQJ4 59 SPRQJ5 71 SPRQJ6 z
0
0 12 •SPROJI 24 •SPROJ2 36 •SPROJ3 4S •SPROJ4 60 •SPROJ5 72 •SPROJ6
0 x
:J
:J
CD
n
i5'
:J
-
:; RBK
CD (MOTOR BRAKE}
-;. ;i>-
I BKPJI 5 BKPJ3 9 BKPJ5 13 17 21
n
CD 2 BKMJI 6 BKMJ3 I 0 BKMJ5 14 IS 22 d
3 BKPJ2 7 BKPJ4 11 BKPJ6 15 19 23 ~
4 BKMJ2 s BKMJ4 12 BKMJ6 16 20 24
r
(")
0
z
z
m
~
6
z
0
)>
G>
~
s:
PROCESS I/O
b
);!
MAIN CPU r
A 168-3200-0040
CR2A [ (")
D I ' TYPE OF PROCESS I/OCSINK TYPE)
CR2B [
0
JDIA [ tJ JD4A SPECIFICATION CRM2A CRM2B CRM2C CRM2D CRM4A CRM4B CRWI CRW2 z
CR2B [ CA A 166-220 I -0470 0 0 x x x x 0 0
z
SDI/SDO m
r---0 tJ JD4B CR2B [ CB Al6B-2201-0472 0 0 x x x x x x
DA A 169-220 I -0480 0 0 0 0 0 0 x x ~
CR2B [
5
JD4A,B CR2B [ , z
( RS-422/SLC) 0
I RX II OV CRWI [ TO WELO MACHINE (A/D,0/A,WOI/WOO)
2 •RX 12 ov ~
3 TX 13 ov I :a
CRW2 [ TO ANALOG INTERFACE ( A/D) )>
4 •TX 14 ov
5 15 OV s::
6 16 ov
7 •ENBL 17 -15V
8 + 15V 18 +5V I/O LINK SLAVE
9 +5V 19 +24V
10 +24V 20 +5V
ca·"Tl
):. CRM2A CRM2C CRM4A CRWI
CSOI/SDOI (SOI/SOOI (SOI/SOC I !WELD INTERFACE OPTION) )>
<n 01 •IMSTP 33 C>«lEN3L 01 SOI23 33 $0021 01 SOI63 14 $0061 01 OACHI 23 WOOi
08 $0060 13 AOCHI "ti
02 •HOLD 34 SYSROY 02 $0124 34 $0022 02 SOI64 15 $0062 02 CAMDAI 24 WD02 "ti
Vl 19 ACK3/SN03 19 $0033 09 $0066 14 COMADI
$0063
(;..)
00
-.c
"Cl
03
04
•SFSPO
CSTOP I
20 ACK4/SN04
30 PROORU<
PAUSED
03
04
$012!5
50126
20 $0034
$0035
35
36
50023
50024
03
04
SDI65
50166
10 $0067
$0068
16
17 $0064
03
04
0ACH2
CAMDA2
15 AOCH2
20
26
WD03
WD04
m
21 ACK5/SN:l5 ~~ 21 II 16 COMAD2 z
05 FAU...T RESET COM-Al 05 $0127 37 COM-Cl 05 $0167 18 COM-El 05 WOII 27 wooo
0 22 50036 12 COM-E2 17 0
n 06 START ~~ Ac;;'_s,:'6 38 >ELD 06 $0128 38 $0025 06 SDI68 19 +24E 06 WOI2 28 W006
23 COM-C4 13 50170 18
07 HOI£ FAlLT 07 50129 39 SOI26 07 SOI69 20 ov 07 WOIJ 29 W007 x
24 ACK7 /st-«l7 !~ 24 $0037 19 OV
08 ENBL ATPERCH 08 SOIJO 40 $0027 08 wou 30 WD08
20 50038 20 ov
m 09 RSR I /PNS l ~ AC~~~8 41 TPENBL 09 SDIJI 41 $0028 CRM4B 09 WOI5 31 WCI+
26 $0039 (SDI/SOC) 21 ov
I0 RSR2/PNS2 COM-A2 10 $0132 42 COM-C2 10 WOI6 32 WCI-
27 RESERVED :~ 27 $0040 22 ov
II RSR3/PNS3 BAT ALM II 50133 43 $0029 01 50171 14 $0069 II WOI7 33 +24E
28 COM-C5 08 $0073
a 12 RSR4/PNS4
~: p~~~:E 44 BUSY 12 50134
29 $0139
44 $0030 02 $0172
09 $0074
15 $0070 12 WOI8 34 '24E
13 RSR5/PNS5 ACKl/SNOI 13 SOI35 45 $0031 03 SDI73 16 $0071
30 PROO ST ART :: 30 $0140 10 $0070
14 RSR6/PNS6 ACK2/SN02 14 SDI36 46 $0032 04 SOI74 17 $0072 CRW2
31 SOIOI 31 SDl41 II $0076
15 RSR7/PNS7 47 COM-A3 10 SDI37 47 COM-CJ 05 SDI75 18 COM-Fl ( A/D INTERFACE OPTION)
32 SOI02 32 SDI42 12 COM-F2
16 RSR8/PNS8 48 16 SDI38 48 06 SDI76 19 +24E 01 14 AOCH3
13 SDI78 08 ADCH6
17 ov 49 +24E 17 ov 49 +24E 07 $0177 20 ov 02 15 COMAD3
09 COMAD6
18 ov 00 +24E 18 ov 50 +24E 03 16 AOCH3
10
04 17 COMAD4
II
CRM2B CRM20 05 18 AOCH5
12
CSDI/SDOl !SDI/SOC) 06 19 COMAD5
13
01 SOI03 33 $0001 01 SDI43 33 S0041 07 20
02 S0104 34 $0002 02 SOI44 34 $0042
19 SOOl3 19 $0053
03 SDI05 35 $0003 03 SOI46 35 SD043
20 SDOl4 20 $0054
04 SOI06 36 $0004 04 SDI46 36 S0044
21 S0015 21 $0055
05 SDI07 37 COM-Bl 05 SDI47 37 COM-DI
22 SOOl6 22 $0056
06 $0108 38 $0005 06 $0!48 38 S0045
23 COM-84 23 COM-04
07 SOl09 39 SD006 07 SDI49 39 SD046
24 S0017 24 $0057
08 SOIIO 40 $0007 08 SDI54 40 $0007
25 S0018 26 $0058
09 SOii I 41 $0008 09 SOI51 41 $0048
26 $0019 26 SD059
10 SOll2 42 COM-82 10 SDI52 42 COM-02
27 $0020 27 $0060
II S0113 43 $0009 II SDI53 43 S0049
26 COM-85 28 COM-05
12 $0114 44 SOOIO 12 $0154 44 $0050
29 S0119 29 SDI69
13 SOI15 45 $0011 13 SOI55 45 $0061
30 SDI20 30 SOI60
14 $0116 46 $0012 14 SDI56 46 $0052
31 S0121 31 $0161
15 SOI17 47 COM-83 ,. SOI57 47 COM-DJ
32 SOI22 32 SDI62
16 $0118 48 16 $0158 48
17 OV 49 +24E 17 ov 49 +24E
18 ov 50 +24E 18 ov 50 +24E
i
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I/O UNIT MODEL A I I~ I\)

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PANEL PCB
,....------, TEACH PE!'EANT
~ EMERGENCY STOP BUTT~
"~~,
R-.J2
MAIN CPU I
RLDM
DEAD-MAN SWITCH
RLEN
ENABLE DISABLE
cP a)o
FENCE
i
RVP'ov~-+l+-------+lt------TPEMG-~-v__...,
T
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TPEMG I
EXE.c; -fRVl I =~~ EXTERNAL EfrERGEN:Y STOP
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RV: RECEIVER
L.._;, ~------------11< - - - -
_ _ _ _ _ ;;r
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CCPTION)
FOR OI
JIF2 JIF2 EMERGENCY STOP CONTROL PCB

AXES
IDITROL
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RL\'!5
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RLYI
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OTRST---...;:t-+-+H------------------11tfllIBliL-:e-:~....=-------7,-+---'~I-,-f-{~}0RL~Y3;;;:;+RL;;-;;Y,.---------------
ROICOM----l----l--111------------------4H"""'-•,....,~L-OJ I ~----rTl
a;; A~e •:m: I --1 1------i. r
HBK-----1-L~~~~------------------------------------------------------------_-_++~~HBK:. ~!!l':'~~~~~~:,P:____,,: ~..____,:__~~~

Ll~-~
RLY6
CPRECHARGEJ
RLY2
CMCC-CtU
~
I
I
CRR20X CRR20Y CRRl!5A

200R
2006
2001
POWER
TRANSFCJRIE:R
IOOA
1006
Fig.A.5 (m} Emergency Stop Circuit
- 540 -
ROBOT
MECHANICAL l.NIT
PLLSE
c
I CRF3
l I CRF4 r
.-·-
I
ROBOT ROT
..... NJTOR
~I
CRMll
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INTERLOCK
CRMl5 ,
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BRAKE
CONTROL
CRRl6 CIRCUIT
-·-·- CRM9 (XJ svoo -, CR"'5
MCCON
~--
~ ..~ ..~
CRRl6 SERVO AMPLIFIER
(Yl (C-SERIESJ
..:Cl CRRl58
MCC2 '"''
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u
LI v
L2
LJ
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G
- 541 -
B. SPECIFICATIONS OF
PERIPHERAL DEVICE INTERFACE APPENDIX B-80525E/04
B SPECIFICATIONS OF PERIPHERAL DEVICE INTERFACE
B.1 The following table lists the I/O signals used for the peripheral device
interface in the R-12 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

80107 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.
- 542 -
B-80525E/04 APPENDIX PERIPHERAL DEVICE INTERFACE
Output signals
Signal Description
CMDENBL Command acceptance enabled signal
SYSRDY System ready signal
PROGRUN Program run signal
PAUSED Program paused signal
HELD Held signal
FAULT Alarm signal
ATPERCH Reference point signal
TPENBL Teach pendant enabled signal
BATALM Battery alarm signal
BUSY Operating signal
ACK1/SN01 RSR acknowledge/Selected program number signal
SNACK PNS acknowledge signal
---- Not used (for future expansion)
SD001 General-purpose output signal

- 543 -
8.2 The process I/O 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, a common voltage is remained at +24V.
*IMSTP
*HOLD
*SFSPD
CS TOPI
8.3
1/0 SIGNALS
8.3.1 This section describes the specifications of each input signal.

Input Signals (1) Instantaneous stop signal (input) *IMSTP
Effective At any time
Function Use the normally-closed switch because it is a reverse
signal.
The system turns off power to the servo unit when the
*IMSTP is open (turned off). This signal has the same
effect as that of the emergency stop signal, but it is con-
trolled by software. For this reason, use the emergency
stop external interface on the emergency stop control
board for wiring of the emergency stop signal.
Do not use *IMSTP.
(2) Alarm release signal (input) FAULT RESET

Effective In the alarm status
Function The FAULT RESET signal releases the alarm status.
If the servo unit has been turned off, it also turns on the
unit. At the same time, the alarm display on the teach-
pendant (the top line) is cleared.
Description : This signal releases only the alarm status. It does not
stop execution of the program.
(3) Hold signal (input) *HOLD

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.
- 544 -
(4) Start signal (input) START

Effective When the command acceptance enabled signal (out-
put) 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_ONLYis set
to DISABLED, the START signal starts the pro-
gram which has been selected from the teach pen-
dant. By default, the program starts from the cur-
rent cursor position.
- If parameter $SHELL_CFG.$CONT_ONLYis 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
program from the wait status caused by an RSR. It
does not stop the execution of the current program
and allows it to continue processing (by default).
If parameter $SHELL_CFG.$USE_ABORT is set
to ENABLED, the CSTOPI signal immediately
cancels the execution of the current program. The
program 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.
- 545 -
PERIPHERAL DEVICE INTERFACE APPENDIX B--80525E/04
(7) Safety speed signal (input) *SFSPD

Effective At anytime
Function Use the normally-closed switch because it is a re-
verse 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.
$FENCEOVER.)
- As long as this signal is off, the overriding value
cannot be increased beyond the preset value
($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 (op-
tional), although they cannot be used simultaneous-
ly.
- 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
waiting program starts processing.
- By using an RSR instruction, each RSR in a pro-
gram 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).
- 546 -
+----------------------------------------+
I I
l!!lll/l/llllllllllllll/ll/l//lllllllllll
I 1/8
I 1 Job selection: RSR RSR or PNS
I 2 RSRl program number: 12 o.. 9999
I 3 RSR2 program number: 23 o.. 9999
I 4 RSR3 program number: 5 o.• 9999
I 5 RSR4 program number: 64 o.. 9999
I 6 Base number: 100 o.• 9999
I 7 Acknowledge: Enabled Enabled or disabled
I 8 Acknowledge pulse width:. 250 msec O•• 9999msec
I
I[ TYPE J
+----------------------------------------+
- 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 ex-
ample, $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 cor-
responding to the RSR, one of signals ACKI 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.
- 547 -
(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 (option-
al) is used. If the PNS function is enabled, the RSR
function cannot be used.
- The eight signals PNS 1 to PNS8 are used to specify
a program at the instant the strobe signal
PNSTROBE rises.
- A menu is provided to specify the information
aboutPNS.
+----------------------------------------+
I
////////l/////l////ll/l//////l//ll///llll
113 I
1 Job selection: PNS I RSR or PNS
2 Base number: 100 I o.. 9999
3 Acknowledge pulse width: 250 msec I O•• 9999msec
I
I
I
I
=
I
[ TYPE ] I
+----------------------------------------+
If a number other than zero is entered to PNS input, a

program is selected whose program number is the en-
tered value plus the base number. For example, if the
PNS value is 23, the program to be started has the pro-
gram name calculated from the expression
PNS +(entered PNS value+ base number),
i.e., PNS0123.
If zero is entered to PNS input, it is cleared as if no
selection has been made.
- A PNS signal, which can only select a program,
cannot execute the selected program. The execu-
tion of the selected program can only be started af-
ter input of automatic operation start signal
PROD_START.
- 548 -
- 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 num-
ber 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 CS TOPI cancels execution of the pro-
grams selected by PNS when $SHELL_ CFG.
$USE_ ABORT is set to ENABLED.
(lO)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.
- 549 -
PERIPHERAL DEVICE INTERFACE APPENDlf B-80525E/04
B.3.2 This section descripes the specifications of output signals for the
Output signals peripheral device in~erface.
(1) Command acceptance enabled signal (output) CMDENBL
Turned on Wqen the remote conditions are satisfied and the sys-
te~ is not in the alarm status
Turned off Wij.en the remote conditions are not satisfied or the sys-
tenjt is in the alarm status
The remote conditilons are satisfied when all of the following are satis-
fied.
- The teach pendant is in the DISABLED status.
I
- h'he remote switch on the operator's panel is set to

iREMOTE side.
- !Parameter $RMT_MASTER is set to 0 (external
iinterface).
- !Signal *SFSPD is set to on, or in the normal status.
(2) System ready signal (output) SYSRDY
Turned on Wl}en power is applied to the motor of the robot.
Turned off : Wij.en power is not applied to the motor of the robot.
(3) Program run sighal (output) PROGRUN
I
Turned on : W~en the program is being executed.

Turned off : W4en the program is not being executed.
i
(4) Held signal (output) HELD

This signal is usedl to check the status of the hold input.
Turned on : Wl}en the hold button (or input) is being pressed down
(or!turned on).
Turned off: Wij.en the hold button (or input) is not being pressed
dot.'n (or is turned off).
(5) Program paused!signal (output) PAUSED
This signal is used together with output signal PROGRUN to deter-
mine whether a pr~gram can be restarted while it is being held.
Turned on : Wqen a program is held and has not been restarted yet.
W~ile this signal is on, the program can be restarted
anc:). retains information such as that to return from a
sutiprogram to the main program.
!
Turned off WU.en a program is being executed or is ready to start.

If ~ignal PROGRUN is on, the program is being
ex~cuted. If signal PROGRUN is off, the program has
no~ been executed and can be started from this status.
(6) Alarm status sig~al (output) FAULT

Turnedon : Wij.en the system is in the alarm status (or an alarm
whkh can stop a program execution is detected.) The
indicator lamp does not go on in warning.
I
Turned off W~en .the alarm status is released by an alarm release

op~ratlon.
I
- 550
(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 speci-
fied in the parameter.
Up to three reference positions can be specified, but this signal is out-
put when the robot is in the first reference position. For the other two
reference positions, general-purpose signals can be assigned to output
as such. (They can be set from the setup screen.)
(8) Teach pendant enabled signal (output) TPENBL

Turned on When the teach pendant is enabled.
Turned off : When the teach pendant is disabled.
(9) Battery alarm signal (output) BATALM

Turned on When the voltage of the battery for the CMOS memory
backup drops below the reference.
Turned off When the voltage of the battery for the CMOS memory
backup is at the normal level.
(lO)Operating signal (output) BUSY
Turned on : When a program is being executed or is being pro-
cessed from operation panels such as the teach pen-
dant. (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 pen-
dant.
(ll)RSR acknowledge signals (output) ACK1/ACK2/ACK3/ACK4
These signals are used together with the RSR function. They can be
specified to be enabled or disabled from the RSR setup menu.
Turned on : When one of signals RSRl to RSR4 is input and ac-
cepted. A pulse whose width is specified from the
menu is output to acknowledge the signal.
Turned off : Normally. Since these signals are always output as
pulses, they are normally in the off status.
The following chart shows the timing of the RSR input and ACK out-
put.
- 551 -
CMDENBL(O)
(The remote conditions need to be satisfied.)
RSR1 (I) ~~I I'--~~~~~~~~~~~~-

->! ~ The maximum delay is 32 msec.
ACK1 (0)
____,I l.__~~~~~~~~~~~~~~~-
1ii( ~I (The width of the pulse is set in the parameter.)
RSR2 (I)
ACK2 (0) I
RSR3 (I) I
ACK3 (0)
I
RSR4(1)
I I
ACK4 (0)
I I
* 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 be-
comes zero.
After selecting a program by PNS, a pulse is output
from signal SNACK as a part of the PNS operation.
The width of the pulse can be specified from the menu.
See the timing chart below.
- 552 -
CMDENBL(O)
(The remote conditions need to be satisfied.)
PNS1-8 (I)
(A value is input.)
PNSTROBE (I)
(A strobe is input for PNS.)
Detection and
processing of
PNSTROBE by (PNS is read within a maximum of 32 msec after PNSTROBE is turned
software. on.)
SN01-8 (0)
SNACK (0)
PROD_START (I)
1--+<s....- starts
___,,)i... (Program execution
within 32 msec.)
PROGRUN (0)
- 553 -
B.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 1/0 points. The R-J2 can use a total of up to 5121/0 points.
Controller
The R-J2 controller can use the following 1/0 hardware.
- Process 1/0 printed circuit board
- 1/0 unit model A
- 1/0 unit model B
The process 1/0 printed circuit board and the 1/0 unit model A or 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 (redefined) and are fixed.
The standard format is eight inputs and eight outputs. The number of
points that can be used for the connector at the wrist depends on the
individual robot.
(2) SDI/SDO
These signals can be assigned (redefined). Eight points form a pairs
and they are assigned in units of pairs.
(3) Analog 1/0
An analog 1/0 signal can access the analog 1/0 port (optional) on the
process 1/0 printed circuit board or the 1/0 port on the analog 1/0
module (used together with the 1/0 unit model A).
It reads and writes the digital value converted from the analog value
of the 1/0 voltage. It means that the value does not always represent
the real 1/0 voltage.
(4) Group 1/0
Group 1/0 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.
- 554 -
B-80525E/04 APPENDIX C. DIAGRAM OF POWER SUPPLY PATH
c DIAGRAM OF POWER SUPPLY PATH
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- 555 -
C. DIAGRAM OF POWER SUPPLY PATH APPENDIX B-80525E/04
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ADDITIONAL
INFORMATION
I
Revision of FANUC Robot series R-J2 CONTROLLER MAINTENANCE MANUAL
1. Type of applied technical documents

Name FANUC Robot series R-J2 CONTROLLER MAINTENANCE MANUAL
Spec. No./Version B-80525E/04
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
Correct APPENDIX Fig.A. 5(m) Emergency Stop Circuit
Optional
function
- Unit
Maintenance
Parts
Notice
Correction
Another
TITLE FANUC Robot series R-J2 CONTROLLER

' MAINTENANCE MANUAL
I CUST.
~/rJ
DRAW.
01 97. 09. 19 T.OBI NO. B-80525E/04-1
EDIT. DATE DESIG. DESCRIPTION FANUC LTD ISHEET 001/4

I
CPERATlON BOX PC8

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- 448 -
TITLE
CUST.
DRAW. NO. B-80525E/04-1
SHEET
EDIT. DATE DESIG. DESCRIPTION FANUC LTD 002/
A. TOTAL CONNECTION DIAGRAM APPENDIX B--80525E/04
....
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Fig.A.2 (m) Emergency Stop Circuit
- 470 -
TITLE
CUST.
DRAW. NO. B-80525E/04-1
SHEET
A. TOTAL CONNECTION DIAGRAM APPENDIX E>-80525E/04
..... O(MM•W4 SWl?CH

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Flg.A.5 (m) Emergency Stop Circuit

I
- 540 -
TITLE
GUST.
DRAW. NO. B-80525E/04-1
SHEET
EDIT. DATE DESIG. DESCRIPTION FANUC LTD
I

Correct, Date
delete
Basic Correct SRV0-019 SVALl SVONlalarm(page 53) Correct
-
Function Correct PROCESS I/0 DA correspondence between
--
driver chips andDO signals(page 211,212)
Correct block diagram of power supply(page 249)
Correct robot connection cable(page 321,326)

- Correct peripheral device interface(page 347)
Correct total connection diagram(page 432,433,438,
456,478,481,504,507)
Optional
function
Unit
Maintenance
Parts
Notice
Correction
--·
Another

MAINTENANCE MANUAL
01 97. 11. 27 T.081

I
V'/c !/A /
DRAW.
NO. 8-80525E/04-2 I CUST.
/.. ~

I
I
(12)SRVO--Ol9 SVALl SYON input

(Explanation) On the term.inal block of the panel printed circuit
board, no connection is made between SVONl and
SVON2. If a switch is connected between SVONI
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 SYON l and
SVON2.
(Action 3) Make a connection between SVONI and SVON2.
0 0
0 Ell 0
- 53 -
TITLE
DRAW. NO. B-80525E/04.:.2 I CUST.
EDIT. DATE DESIG. DESCRIPTION F A N uc L T D I

SHEET 0021
I
I
B--80525E/04 MAINTENANCE 4. PRINTED CIRCUIT BOARDS
4.4.3
PC Board DA
(A 168-2201-0480)
ro-r,~~~~~~~~-''1
n .JNA
0
.Jd.1~-~~
I DV24 I DV22 I
.... I OV2J I OV:Z 1 I
PEW>•EI DV I 4 OV7
0V20 OV I J 0V6
••• 0Vl9
0Vl8
OVl2
DVI I
0V5
OV4
0Vl7 OVIO OVJ
OVl6 •OV9 OV2
0Vl5 0V8 OVI
CRM48 rR~n CRH2B
CRM2C CRM:ZA
Fig.4.4.3 Process VO PC board DA
(1) Test pins

Name Descrip~ion
P24V +24V
PSV +SV
GND1 GND
GND2 GND
(2) Settings

setting
ICOM1 UDI01to20
(Connector CAM2A)
ICOM2 UDl21to40 The common voltage is

(Connector CAM2B) adjusted to:
Side A
UDl41 to 60 Side A : +24 V common
ICOM3 Side B : O V common
(Connector CAM2C)
ICOM4 UDl61to60
(ConnectorCAM2D)
UDI&1 toe€
ICOl15i ((ot\flE.'<:t.D~ C0.114-A)
UDI!I£? tA '16
1co116 CoMec.tot- CRH4B)
-211-
TITLE
DRAW. NO. 8-80525E/04.:...2 CUST.
EDIT. DATE DESIG. DESCRIPTION F A N uc L T D ISHEET 003/

I
I
(3) LEDs
Color Description
q~ i3~1
·o-a
DOM
OOw
O•
Red
the main CPU and process inpuVoutput.
\ zs
~; g~s
DD-
ION
OOw
OJ Red
A fuse (FUSE 1} in the process inpuVoutput
below.
D•
I

DV3 BATALM, BUSY, ACK1/SN01, ACK2/SN02 \
DV4 - ACK3/SN03, ACK4/SN04, ACKS/SNOS, ACK6/SN06

DV6 SD001, SD002, SD003, SD004
DV7 SD005, SD006, SD007, SD008
ova SD009, SD010, SD011, SD012
DV9 SD013, SD014, SD015, SD016
- DV10 SD017, SD018, SD019, SD020
DV11 AD021, SD022, SD023, SD024
DV12 SD025, SD026, SD027, SD028
DV13 SD029, SD030, SD031, S0032
DV14 SD033, SD034, SD035, SD036
DV15 SD037, SD038, SD039, SD040
DV16 SD041, SD042, SD043, SD044
DV17 S0045, SD046, S0047, SD048
OV18 SD049, SD050, S0051, S0052
OV19 SD053, SD054, SD055, SD056
OV20 S0057, SD058, SD059, S0060
--OV21 .Sf)ob1, s-0062. Si>o63, Sf)ot4
' -0 V22
-OV23
-f)v24
--
.s-006S. s-0066, s-0067, sf)ot8
Sf)o61. ~fJfi7o. SfJ07/,
s-0073, s-Do74, s£Jf>
Sf)()
7~. StJo76
72
- 212 -
TITLE
CUST.
DRAW. NO. B-80525E/04'-2
I
EDIT. DATE DESIG. DESCRIPTION FANUC LTD I
SHEET 0041
I

6.1
BLOCK DIAGRAM OF
THE POWER SUPPLY
Trans fonner Servo amplifier

210VAC
L.---J~----0---l Ampllfler
Power input of
200 to 575VAC
Circuit l ][ 1~ ,-----tr CN I
L
breaker
210VAC
o----o---T .
- - [ JRVI
Supply voltage to the transfonner.
200 to 575 VAC
- [ CN6
Power supp6y unit

_........_~
CP21=
r-
\ Robot
I 1 @ Fan
CP31= Motor
-
-
~
~
T ~-+-----< Brake
0•24V
D•24E Pulse
,...., Ba~ery
code
VBAT CP8 I
,..... I
-
Emergency scop con~

PC boar' CRR I 5 "l--
.------l]
f----f----' End
CRR20~f - - - - - ' effector
Main CPU PC board
JRF2n+24E +5V
w
-~l
~~+24V +15V -15V +5V
CRM1on+24E Process inpuVoutput

---wr--=~~---------' PC board
~nr•~5~v _______________,
w Teach pendant
~llr•~2~4~V_ _ _ _ _ _ _ _ _ _ _ _ ____J
_J
f-W>> >
<('<t'<tll'l>tn
CONN-tn-
JRM10Jr•~2~4~V----------------1 Operator's panel
> + + + + 1
I
Flg.6.1 (a) Block Diagram of the Power Supply (I cabinet)
- 249 -
TITLE
DRAW. NO. B-B0525E/04.:...2 CUST.
SHEET
6-80525E/04 CONNECTIONS 3. ELECTRICAL CONNECTIONS
(In case of B cabinet S-6, S-12, ARC MatelOO, ARC Matel20, ARC
Mate lOOi, ARC Mate 120i, M-6i, M-16i)

CRF1
CRM11
Main CPU PC board Robot S-12, ARC Mate 100,

CRM10 ARC Mate 120, 5-6, ARC Mate
100i, ARC Mate 120i, M-Q;,
M-16i
Motor
power/brake
RMI
• Details of cable conn_ection to the servo amplifier
R"'""2 Robot
PC board for PC board for 5-6
AMP (&-axis amplifier) emergency S-12
main CPU sto control ARC Mate 100
ARC Mate 120
5U 6U ~ ARC Mate 100i,
5V 6V ARC Mate 120i,
5W 6W M--Qi, M-16i
CN6 CRMIO
3U 4U G
3V 4V G
3W 4W G CRMI I
IU 2U G
IV 2V G
IW 2W G
Pulse coder
'------"----+----n [ RP1
(Pulse coder, RDVROO
HBK, Ron
Motor power/brake
'----_,,___ _ __,,__ _ _~---------------1----n[ RM1
(.JIM,J2M.J3M,
.J4M,J5M,J6M,BK)
Flg.3.2.1 (g) Robot Connection Cable

(8 cablnet/S-0, S-12, ARC Mate100, ARC Mate120, ARC Mate 100i, ARC Mate 120i, M-oi, M-16i)
- 321 -
TITLE
CUST.
DRAW. NO. B-80525E/04.:..2
SHEET
EDIT. DATE DESIG. DESCRIPTION FANUC LTD 0061
(In case of M-41 Oi)

Servo module4
Servo module1
Robot M-410i
~ff~~;;;~~~~~Wt=t======~---1 Motor power/brake

_ _ ____, Pulse coder
RDI/RDO
HBK
ROT
Emergency stop
control PC board
CARS
CRM11
CRF1
R-J2 Robot M-41 Oi

emergency
1 2 3 4 main CPU stoo control
r--<>U r--<>U r--<>U r--<>U CRFI
1.--<>V 1.--<>V 1.--<>V 1.--<>V rD

CRMIO CRMI I
1.--<>W 1.--<>W 1.--<>W 1.--<>W
rD rD
i.--<>PE !.--<>PE !.--<>PE !.--<>PE CRR5
rD
'-
'-
'-
--
~~
--~
Pulse coder
JIP
J2P/J3P
J<IP
R!lI RElEl ROT

I
~
·Re'f= R-Olf R-fJ i5

JIB
i"-0 = J2B/J3B
'- Q
JIM
'- J2M
'- I
J3M
JdM/JdB
Fig.3.2.1 (1) Robot Connection Cable (8 cabinet/cabinet for M-410i)
- 326 -
TITLE
CUST.
DRAW. NO. B-80525E/04.:...2
SHEET

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 VO points
No. Name Drawing number Remarks
DI DO D/A AID
Process 1/0 printed circuit AOSB-2300-J030 40 40 2 6 Backplane installation '
1 board CA type (with welding inter-
face)
Process 1/0 printed circuit AOSB-2300-J031 40 40 - - Backplane installation
2 board CB type (without welding in-
terface)
Process 1/0 printed circuit AOSB-2300-J035 Note Note - - Backplane installation
3 board DA 80 - 80 type (without welding in-
terface)
Process 1/0 printed circuit AOSB-230o-J040 40 40 2 6 For ARC Mate 100i
board EA Operator's box installation
4
type (~welding in-
terface) with_
-
"
110 unit model A Depending on a selected (Note 3)
5
1/0 model.
1/0 unit model B AOSB-230o-J001 Depending on a selected Interface unit
6
unit.
NOTE
1 Process 1/0 PC 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.
- 347 -
TITLE
CUST.
DRAW. ND. B-80525E/04.:..2
SHEET
m
0
....
APPENDIX IHI0525EJO< IHI052SEJO< APPENDIX A. TOTAL CONNECTION DIAGRAM

A. TOTAL CONNECTION DIAGRAM
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A. TOTAL CONNECTION DIAGRAM APPENDIX B-a0525E.I04
MU. TI-TAP TRANSFORMER

TFI
CIRCUIT BREAKER
~
IL 1 ,~, 1 575
I I 550
IW.J 2
AC POWER I I 1
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I I 5 460 I
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CONNECTION TO TFl
POWER C()N.IECTICN OF' PRIMARY TAP
SU'P\. y COM'£CTING
STYLE
Vtl.TAG[ LI L2 LJ "-""'ER 11:1111
220 7 15 23 6-1~ I 16-23 2A.-7
!:::,
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380
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22
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'15
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STAR
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'3 12 20 y
500 II 19
...L-
550 2 10 18
-=- ~
575 I 9 17
--=
---·
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-- 478 - -
'
TITLE
DRAW.
NQ B-80525E/04~2 I CUST.
SHEET
I
I
m
0
:--'
0 ~ r01AN
)> I CAJ9Ad 0-..1...--_J
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m (110 LI.-<l (OPERATION BOX) (ROBOT FEE06AOH'LIFIERl
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MAIN CPU ~~TmNW~.kc !-:- - ---i 3 TXSLC 13 CV JOV280V Al PR06 83 •PR06 AJ 155 BJ ~
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'
--
- 504 -
TITLE
DRAW.
NO. B-80525E/04'-2 I CUST.
ED IT. DATE DESIG. DESCRIPTION FANUC LTD ISHEET 014/
I
I
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Correct, Date
delete
Basic Correction of replacing the battery Correct
Function (Page 299)
Optional
function
Unit
-
Maintenance
Parts
Notice
Correction
Another

MAINTENANCE MANUAL
01 98.09. 29 T.OBI yJ-t- DRAW.

NO. 8-80525E/04-3 I CUST.
I
a-80525E/04 MAINTENANCE 7. REPLACING A i..JNIT
7.13 abou-tJOsec:onds t\nd t~l"noff the R-:r2.

REPLACING THE (I) Use a lithium battf (ordering drawing number: A98L-003 l-0012).
BATTERY (2) Tum on the R-JZ (The battery b p1 1
b b p ·1
' ' ff If ,b I . , d ff ,b b . . =; 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 printed circuit 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: ASSL-0031-0012)
Fig.7.13 (a} Replacing the Battery (1)
(4) Remove the connector from the battery.
BATTERY Cable connector
printed circuit panel o the

power supply unit
Fig.7.13 (b) Replacing the Battery {2)
(5) Replace the battery and reconnect the connector.

(6) Install the battery case.
(7) Tum off the R-12.
- 299 -
TITLE
CUST.
DRAW. ND. B-80525E/04-3
SHEET
EDIT. DATE DESIG. DESCRIPTION FANUC LTD 002/2
B-80525E/04 Index
[A] Emergency Stop Control PC Board, 199
End Effector Cable Connector, 398
Additional Axis Control Printed Board, 217
End Effector Control Interface, 387
Adjustment and Checks at Installation, 427
External Cable Wiring Diagram, 310
ARC Weld Connection Cable (CRWl: Honda Tsushin,
34 pins), 393 External View of the Controller, 16
[B] [F]
B-CABINET (ARC Mate 100, ARC Mate 120, ARC Faulty unit replace ment procedure, 406
Mate lOOi, S-6, S-12, M-6i, S-420i, S-500, S-700, Flowchart, 402
M-400i, M-710i, A-520i), 453
B-Cabinet of S-900, 522
Backplane PC Board, 204
[H]
Block Diagram, 304
Hardware items required for quick change, 406
Block Diagram of the Power Supply, 249
[I]
[C] I-CABINET (ARC Mate 100, ARC Mate 120, ARC
Cabinet of M-4 lOi AND S-450, 494 Mate lOOi, ARC Mate 120i, S-6, S-12, M-6i,
M-16i, S-420i, S-500, S-700, M-400i, M-710i,
Cabinet of S-800/M-500, 472 A-520i), 431
Cable Connection for the Peripheral Devices, end Ef- 1/0 Signal Specifications for Arc-Welding Interface,
fectors, and ARC Welders, 394 389
Checking the Line Filter Unit and Transformer, 255 1/0 Signals, 544
Checking the Power Supply Unit, 257 Input Signals, 544
Component Functions, 34 Input/Output Hardware Usable in the R-J2 Controller,
Configuration, 16 554
Connecting Cables at Installation (Combined Type of Installation, 419

i Cabinet), 421 Installation Area, 419
Connecting the External Emergency Stop, 343 Installation Condition, 426
Connecting the External Power Supply ON/OFF Interface for Peripheral Devices, End Effectors, and
Switch, 341 Welders, 368
Connecting the Input Power Supply, 336
Connection Between the Control Unit and Welder,
381 [M]
Connection Between the Mechanical Unit and End Main CPU PC Boards (A16B-3200-0040), 197
Effector, 379
Manual Operation Impossible, 194
Connection Diagram Between Mechanical Units, 305
Mounting 1/0 Unit Model B on the Din Rail (Use a
Rail that is 3.5mm wide and 7.5mm high.), 273
[D]
Diagram of Power Supply Path, 555 [N]
Digital 1/0 Signal Specifications, 385 Notes on quick change, 406
[E] [O]
Electrical Connections, 305 Operator Safety, 3, 5
i-1
Index B-62574EN/02
Output signals, 550

[R]
Recommended Cables, 399
Replacement front cabinetunit, 405
[P] Replacement of Fuses, 285
Peripheral Device and Control Unit Connection, 368 Replacing a Module, 266, 272
Peripheral Device Cable Connector, 396 Replacing a Printed Circuit Board, 262
Peripheral Device Connection Cable, 394 Replacing a Relay, 296
Peripheral Device Interface, 385 Replacing a Servo Amplifier, 277
Peripheral Device Interface A Cable (CRM2: Honda Replacing a Unit, 260

Tsushin, 50 pins), 392 Replacing Fuses, 287
Peripheral Device Interface B Cable (CRM4: Honda Replacing the Backplane Printed Circuit Board, 262
Tsushin, 20 pins), 392
Replacing the Base Unit of the Input/Output Unit of
Peripheral Device Interface Block Diagram, 350 Model A, 271
Peripheral Device Interface Combination, 363 Replacing the Battery, 299
Peripheral Device, ARC Welding, and End Effector Replacing the Fan Motor of the Control Unit, 283
Interfaces, 347 Replacing the I/O Unit Model B Interface Unit, 269
Position Deviation Found in Return to the Reference Replacing the Input/Output Unit of Model A, 271
Position (Positioning), 194
Replacing the Operator's Box, 280
Power Cannot be Turned On, 37
Replacing the Power Supply Unit or a Printed Circuit
Power Supply !module (PSM) (A06B-6087-H115), Board on the Backplane Printed Circuit Board, 265
224 Replacing the process I/O EA printed circuit board,
Power Supply Unit, 292 266
Precautions for Mechanism, 9 Replacing the Teach Pendant, 282

Replacing the Transformer, 27 4
Precautions for Mechanisms, 10
Resetting Overtravel, 428
Precautions in Operation, 10
Resetting Overtravel and Emergency Stop at Installa-
Precautions in Programming, 9, 10, 11 tion, 428
Preventive Maintenance, 35 Robot Connection Cables, 310
Printed Circuit Boards, 196
Process I/O Printed Board EA (A16B-3200-0230),
213 [S]
Process I/O Printed Circuit Board Signals, 364 Safety During Maintenance, 7
Process Input/Output PC Board, 205 Safety in Maintenance, 12
Process Input/Output PC Board CA Safety of the End Effector, 11
(A16B-2201-0470), 205 Safety of the Robot Mechanism, 10
Process Input/Output PC Board CB Safety of the Teach Pendant Operator, 6
(A16B-2201-0472), 209
Safety of the Tools and Peripheral Devices, 9
Process Input/Output PC Board DA
(A16B-2201-0480), 211 Safety Precautions, 3
Process Input/Output Printed Circuit Boards CA, CB, Selecting Transformer Taps, 252
DA and EA, 295 Separate-Type Control Unit of i Cabinet, 425
Servo Amplifier, 286
Servo Amplifier (A06B-6066-H006), 235
[Q] Servo Amplifier for (ARC Mate 100, ARC Mate 120,
ARC Mate lOOi, ARC Mate 120i, S-6, S-12, M-6,
Quick Change (i--cabinet), 400 M-16i, S-420i, S-500, S-700, M-400i, M-710i,
A-520i), 220
i-2
B-80525E/04 Index
Servo Amplifier Module (SVM) , 228 Transportation and Installation, 418

Servo Amplifier Unit (A06B-6089-H106), 240 Troubleshooting, 36
Servo Amplifiers, 218 Troubleshooting Using the Error Code, 39
Setting and Adjusting the Power Supply, 248
Setting Common Voltage, 544
Signals, 542 [V]
Software Specifications, 554
Vibration Observed During Movement, 194
Specifications of Digital Input/Output, 554
Specifications of Peripheral Device Interface, 542
Specifications of the Cables used for Peripheral De-
vices and Welders, 392 · [W]
When I/O Unit Model A is used, 356
When I/O Unit Model B is used, 358
[T] When Process I/O Printed Circuit Board CA or CB is
Teach Pendant Cable, 335 used, 350
The DIN Rail is in the Operator's Box., 273 When Process I/O Printed Cricuit Board DA is used,
353
Total Connection Diagram, 431
Transformer, line filter unit, 285 When Two or more Process I/O Printed Circuit Boards
and I/O Unit (Model A or Model B) are used, 361
Transportation, 418
i-3
Revision Record
FANUC Robot series R-J2 CONTROLLER MAINTENANCE MANUAL (B-80525E)
Addition of descriptions for ARC Mate 100i/M-6i, S-450,

04 Apr.,'97
A-520i, M-400i, M-710i and ARC Mate 120i/M-16i
03 Oct., '95 Addition of descriptions for M-500, A-520i
02 Nov., '94 Addition of cabinets
01 Aug., '94
Edition Date Contents Edition Date Contents
B-80525E/04
* B - 8 0 5 2 5 E / 0 4 *

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7169FsvXdKYlOLK9a+B6wfQONdogbjmVKSeDBTdSW4bwD6zkC+2wd68VWEg==

Thank you very much for purchasing FANUC Robot.

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

This manual covers the following models.

B-80525E/04 Table of Contents

4. PRINTED CIRCUIT BOARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196

Table of contents B-80525E/04

5. SERVO AMPLIFIERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218

6. SETTING AND ADJUSTING THE POWER SUPPLY ....................... 248

7. REPLACING A UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260

B-80525E/04 Table of contents

2. BLOCK DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304

3. ELECTRICAL CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305

4. PERIPHERAL DEVICE, ARC WELDING,

Table of contents B-80525E/04

5. TRANSPORTATION AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 418

A. TOTAL CONNECTION DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 431

B. SPECIFICATIONS OF PERIPHERAL DEVICE INTERFACE . . . . . . . . . . . . . . . . . 542

C. DIAGRAM OF POWER SUPPLY PATH ................................... 555

B-80525E/04 SAFETY PRECAUTIONS 1. SAFETY PRECAUTIONS

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

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

The circuit breaker installed in the controller is designed to disable anyone

1. SAFETY PRECAUTIONS SAFETY PRECAUTIONS B-80525E/04

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

Limit switch which operates

Limit switch for

'--------------oFENCE2 Note) Terminals FENCEl and FENCE2 are

Fig.1.1 (a) Safety Fence and Safety Gate

B-80525E/04 SAFETY PRECAUTIONS 1. SAFETY PRECAUTIONS

The robot controller is designed to be connected to an external EMER-

External EMERGENCY STOP button

Note) Connect to EMGIN1 and EMGIN2.

Fig.1.1 (b) Connection Diagram for External Emergency Stop Switch

1. SAFETY PRECAUTIONS SAFETY PRECAUTIONS B-80525E/04

B-80525E/04 SAFETY PRECAUTIONS 1. SAFETY PRECAUTIONS

On Independent Allowed to Not allowed Not allowed

1. SAFETY PRECAUTIONS SAFETY PRECAUTIONS B-80525E/04

B-80525E/04 SAFETY PRECAUTIONS 1. SAFETY PRECAUTIONS

1. SAFETY PRECAUTIONS SAFETY PRECAUTIONS B-80525E/04

B-80525E/04 SAFETY PRECAUTIONS 1. SAFETY PRECAUTIONS

1. SAFETY PRECAUTIONS SAFETY PRECAUTIONS B-80525E/04

B-80525E/04 MAINTENANCE 1. OVERVIEW

2. CONFIGURATION MAINTENANCE B-80525E/04

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

Integrated type ARC Mate 100i, M-6i, S420i, A520i, M-710i

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

B-80525E/04 MAINTENANCE 2. CONFIGURATION

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

2. CONFIGURATION MAINTENANCE B-80525E/04

Fig.2.1 (c) External View of the R-J2 controller (B-Cabinet) ($-900)

B-80525E/04 MAINTENANCE 2. CONFIGURATION

R-J2 Control unit Teach pendant

2. CONFIGURATION MAINTENANCE B-80525E/04

Operator's box Circuit breaker

FANUC Handy File Teach pendant

Main CPU printed

Power supply unit

(Optional printed circuit board)