Osacom 8700 Controller (Same as Inst &Amp; Maint (1l4000b-9)

June 1997

No.1 L4000B -9

C O N T R O L L E R

~stributor I' you do not understand

HEN Corporation

We really appreciate you to purchase our products. There are some mistakes on this manual, and the following list describes the corrections of the mistakes. We apologize for any inconvenience this clerical error has caused and will do our best to see that such errors do not occur.

TABLE 0.0.0.1 List of Errata (113)

Page

1-16

1-17

1-17

1-18

1-21

1-24

1-25

2-8

2-10

2-25

Mistakes

5. The location of breaker in the control unit is shown in Fig.=

____ Braker Handle

2. The Control units contains many ... of them while is ON may ... needs to be opened with the ... ... of a failure, never any of ...

5. Ensure that the ground of each of is ...

3. Connect connectors are all the same

type connectors but have ...

1. Connect connector CN16 of Teaching box to CN16

2. Connect optical fiber connector to IC124 of !$jg&

m. (1) Operation Status (LED ...

4. ... OC LED of also ... 5. Overvoltage of main power supply

The main power supply is ... . ... deceleration is w.

ELED502's Status] ON indicates Voltage Drop (below

[2nd bit's Function When ON] ... SW1 on m, causing ...

Section

1.2.1

Fig.1.2.2.1

Inthe WARNING

1.2.3

1.3.1

1.3.2

1.3.3

2.3.2

Table 2.4.2.1

LED GREEN RED

@ @

Table 2.8.2.1

Table 2.8.3.1

Corrections

5. The location of breaker in the control unit is shown in Fig.=

Handle

2. The Control units contains many ... of them while is ON may ... needs to be opened with the ... ... of a failure, never @&& any of ...

5. Ensure that the ground of each of is ...

3. Connect connectors

are all the same type connectors but have ...

1. Connect connector CN16 of Teaching box to CNl6 pJ -.

2. Connect optical fiber connector to lC124 of A Board

(1) Operation Status (LED ...

4. ... OC LED of also ... 5. Overvoltage of main power supply

The main power supply is ... . ... deceleration is w.

[LED5023 Status] ON indicates Voltage Drop (below 3.J$Jv>

[2nd bit's Function When ON] ... SW1 on M, causing ...


ry contact (Relay CR22) MRON m, DC24V

... and the

5-15

-

5-20

5-42

2nd Item of

-1

5th Item of

-1

Line 3 of (2)

Check connection and connect it properly.

LED 100 on Motion control board OFF(0N in the condition.)

... be also displayed for & failures.)

Check connection and connect it properly.

LED 100 on Motion Control board OFF(0N in the condition.)

... be also displayed for failures.)


Correction

Switch box

Motion control board or Servo Control board

Reduce the voltage

Reduce the load

[Part] Memory lithium

[I te mf

[Item]

[Item]

[Remarks]

..... voltage range by the

Page

5-49

5-54

5-55

6-2

7-4 7-6 7-1 0

7-18

7-34 7-36 7-38 7-40

Al-1

A1-3

Section

. 2nd, 3rd, 5th and 6th items of paK Cause1

5th and 10th items of /Action/

6th and 8th items of

/Possible Cause1

4th item of

/Action] 9th item of

-1

Ref No.9 in 6.4 List of In- spection Items

Ref No. a -2

Ref No. @

Ref. No.

Ref No. @ in TABLE 1.1.1.1

Line 3

Mistakes

Switch Box

Motion control board or Servo Control board fi?ilur

Reduce the voltage

Reduce the a load

[Part] Memory lithium

[Item]

[Item]

[Item]

[Remarks]

..... voltage range by the

This instruction manual describes instruction of installation and maintenance for Manipulator, ROBOT CONTROL UNIT and its peripheral equipments such as the Teach Pendant, Operation Box and so on. Read and understand the entire contents of this manual, with special emphasis on the safety devices throughout the manual, before installing, operating or maintaining the Manipulator, Robot Control Unit, and its peripheral equipments. These equipments such as the Manipulator, Robot Control Unit, its peripheral equipments and these instructions are for use only by persons trained and experienced in the safe operation of the above mentioned equipments. Do not allow untrained persons t o install, operate, or maintain these equipments. Contact your distributor i f you do not fully understand these instructions. Following Instruction manuals are provided for these equipments. These instruction manuals shall be referred where necessary in accordance with installation, operation and maintenance.

Model GOlS Model VOlS Model VlOS Model V20S Model V40S Model WOl S OSACOM SUPER 8700 OSACOM SUPER 8700 OSACOM SUPER 8700 OSACOM SUPER 8700 INDUSTRIAL ROBOT

MANIPULATOR MANIPULATOR MANIPULATOR MANIPULATOR MANIPULATOR MANIPULATOR CONTROLLER TEACH l NG INTERFACE WITH JIG OPTION SAFETY WARNING

TRAINING COURSES

The equipments such as the Manipulator, Robot Control Unit, its peripheral equipments and these instructions are for use only by persons trained and experienced in the safe operation of the above mentioned equipments. Therefore, DAIHEN Corporation provides various training courses such as the SAFETY, OPERATION, MAINTENANCE and so on.For the details, contact your distributor or DAIHEN Corporation.

1 LIMITED WARRANTY / DAIHEN Corporation warrants this equipment against defects in parts and workmanship, which have occurred under the appropriate service and maintenance conditions including the periodic inspection described in the manual, for shorter period of either 14 months after B/L date of shipment f rom Japan, or 2000 hours actual working time from the date of delivery of equipment to the original user. This warranty shall be invalidated by any abuse, misuse, misapplication or improper installation of the original user. DAIHEN, at its option, will repair or replace any equipments during the warranty period, which DAIHEN, upon inspection, shall determine to be defective in material and/or workmanship. The foregoing shall constitute the sole remedy any breach of DAIHEN's warranty.

DAIHEN MAKES NO WARRANTIES, EITHER EXPRESS OR IMPLIED, EXCEPT AS PROVIDED HEREIN, INCLUDING WITHOUT LIMITATION THEREOF, WARRANTIES AS TO MARKETABILITY, MERCHANTABILITY, FOR A PARTICULAR PURPOSE OF USE, OR AGAINST INFRINGEMENT OF ANY PATENT.IN NO EVENT SHALL DAIHEN BE LIABLE FOR ANY DIRECT, INCIDENTAL OR CONSEQUENTIAL DAMAGES OF ANY NATURE, OR LOSSES OR EXPENSES RESULTING FROM ANY DEFECTIVE PRODUCT OR THE USE OF ANY PRODUCT.

I SAFETY WARNING / THE FOLLOWING ROBOTIC SAFETY SHALL BE KEPT STRICTLY.IF NOT, SERIOUS PERSONAL INJURY OR LOSS OF LIFE IS CAUSED.

A. GENERAL INFORMATION AND SAFETY

19.11 General

Information presented in this section and on various labels, tags, and plates on the unit pertains t o equipment design, installation, operation, maintenance, and troubleshooting which should be read, understood, and followed for the safe and effective use of this equipment.

A.2 Safety

The installation, operation, maintenance, and troubleshooting of arc welding robots require practices and procedures which ensure personal safety and the safety of others. Therefore, this equipment is to be installed, operated, and maintained only by qualified persons in accordance with the safety standard which is applied for your country such as ANSI/RIA document, "American National Standard For Industrial Robots Systems - Safety Requirements" and all other safety material found in this Section and throughout the entire manual. In addition, follow all other codes as applicable to the application. See Arc Welding Safety Precautions Sections in the welding power supply Owner's Manual for safety precautions regarding the operation of arc welding power supplies and welding equipment.

B. SAFETY ALERT SYMBC)L AND SIGNAL WORDS

The following safety alert symbol and signal words are used throughout this manual to call attention t o and identify different levels of hazard and special instructions.

This safety alert symbol is used with the signal words WARNING and CAUTION t o call attention t o the safety statements.

WARNING statements identify procedures o r practices which must be followed t o avoid serious personal injury o r loss of life.

CAUTION statements identify procedures o r practices which must be followed to avoid minor personal injury o r damage to this equipment.

IMPORTANT statements identify special instructions necessary for the most efficient operation of this equipment.

C. G E N E R A L S A F E T Y REQUIREMENTS

Read, understand and comply with the following safety rules a t robot maintenance.

1 KEEP OUT of robot working envelope when main power is on.

2 STAY ALERT when near robot.

3 KEEP INFORMED about status of robot and general working conditions.

4 HAVE AN EMERGENCY STOP BUTTON IN HAND whenever you are near the robot.

5 UNDERSTAND AND BE FAMILIAR WITH ROBOTIC MOVEMENTS. Robots are unique industrial devices and can present unexpected hazards t o personnel because of their movements.Unpredictable robot motion can occur in even the best designed areas of operation.

6 NEVER STAND with your back toward the robot.

7 NEVER PLACE yourself between robot work stations i f more than one work station is used.

8 THOROUGHLY TRAIN A L L PERSONNEL in robot operation and safety

9 READ robot safety regulation of the country installed robot and PUT INTO EFFECT it.

10 DO NOT REMOVE, DESTROY, OR COVER the WARNING and CAUTION labels on Robot Control Unit and Manipulator.

D. SAFETY REQU l REMENTS FOR l NSTALLATlON (Figure D-I)

The robot cell requires initial safety conditions that are vital for both personnel and equipment. Make safety provisions part of the basic cell design.lmplement the following during installation:

1 Brightly mark floor with distinctive areas identifying Zones 1 and 2 on Figure D-1.

2 Route all cables and hoses so that they will not be damaged and will not clutter the cell f loor space.

3 Protect welding system components f rom spatter, slag, heat, and the general welding environment by locating equipment to minimize exposure.

4 I f any welding components must be located in a high-exposure area, provide proper ' guards o r shields to minimize d i r t and spatter.

5 Consider all necessary jig requirements to include turntables, sliding trays, etc., that will become a part of the application so that the operator does not have t o enter the work envelope(Zone 1).

6 Install pressure-sensitive f loor mats, proximity devices, l imit switches, light curtains, etc., to suit the application and number of work stations so that Emergency Stop will occur i f there is any instruction or violation of the robot work envelope.

7 lnstall chain fences and light batteries around other cell portions that are not t o be violated.

8 Locate Teach Pendant and Operation Box outside robot work envelope.

9 Provide proper Electrostatic Discharge(ESD) protection fo r electronic components in Robot Control Unit and Teach Pendant.

10 MAINTAIN SAFE INTEGRITY OF CELL AT A L L TIMES.

Zone 3

Zone 1 - Robot Work Envelope(Area) Zone 2 - Operator Work Area Zone 3 - Outer Area of Robotic Cell

IMPORTANT : See Instruction manual "MANIPULATOR" fo r vertical space requirements of robot.

Figure D-1 Layout Considerations for a Typical Robotic Cell

E, OPERATOR SAFETY REQUIREMENT Provide proper ventilation for welding areas.Supply fresh air i f required o r use approved breathing device.

Wear approved head and body protection (this includes, but is not limited to, protective headgear, gloves, and safety shoes).

Install approved filter lens into welding helmet to protect eyes f rom arc rays.

Press an EMERGENCY STOP button before entering robot area.

Stay alert for unexpected robot motion o r movement.

Provide arc guard curtains o r shields around the welding area so that arc rays do not injure operator o r other personnel.

Keep robotic cell clean, neat, and orderly.

Close and secure all access doors and panels on components.

Unless i t is specifically necessary to enter the working area of robot system, t o avoid accident, no worker including the operator should enter the working area of robot system. When entering the working area of the robot system for teaching the robot, be sure to check the location and condition of the safety devices such as the EMERGENCY STOP button and DEADMAN SWITCH on the Teach Pendant. And place the EMERGENCY STOP button within the operator's reach for the robot should malfunction.

The robot is keeping the safety speed sufficiently during the teaching mode, however, there is a possibility that the operator is caught in the robot by slow speed.To avoid injury, pay attention to the following:

a) Space requirement for the robotic system cell must allow sufficient area t o include installing robot system components, movement around the work envelope by one o r more operators into and out of the cell.

b) The operator should always have some predetermined escape place. c) Never block the escape place of the operator by the other person o r something. d) I f the operator o r the other worker realize the operator's danger, press the

EMERGENCY STOP button immediately. e) A t the worst, it means that i f the operator was caught in the robot, take the

following procedure.

1) Press the Emergency Stop button immediately. 2) Turn of f the primary power switch of the Robot Control Unit. 3) To avoid fall the robot arm, l i f t the 2nd and 3rd axis of robot by wire ropes. 4) Turn on the primary power switch of the Robot Control Unit again.

(DO NOT TURN ON THE SERVO POWER.) 5) To release the brake, connect pin No. 1 and pin No.2 of terminal block on the

Interlock Board by jumping wire. For search the location of pins, see following Figure E-1.

6 ) To escape the person who was caught in the robot, move the robot arm (the Axis 2).

7) Disconnect the jumping wire, after person escaped.

While operating the system in the automatic operation mode, operator should leave the working area of the robot system.

Figure E-1 Location of Brake release pins

F. SAFETY PROCEDURES DURING TEACHING (PROGRAMMING) Teaching (programming) often requires the operator to enter the robot work envelope. As a result, always do the following during teaching procedures:

1 Move robot slowly (see instruction manual "TEACHING" - Teaching for speed entry information).

2 Always assign and position a watchperson, with an Emergency Stop button in hand, to present and ready during teaching operations.

3 I f jig motion was programmed to operate from external output control, the jig could energize during teaching.Be careful and alert for jig motion.

G. SAFETY CHECKS AFTER ENTERING A PROGRAM

1 Have all unauthorized persons leave robotic cell.

2 Check the operation of all warning devices, such as lamps o r horns.

3 Check and be sure that the robot moves normally through its program sequences using the block operation mode(either step or continuous).

4 Check movement of all jigs, and be sure their operation is normal.

5 Check fo r proper operation of EMERGENCY STOP buttons.

. SAFETY PROCEDURES BEFORE AUTOMAT96 OPERATION

Before starting automatic robot operation, do the following:

1 Verify the correct program number allocation is assigned to the appropriate Starting Box(es).

2 Have all unauthorized persons leave the robotic cell area.

3 Close and secure all gates and guard doors, and energizedight fences, barriers, and curtains as applicable for the entire specific cell.

4 Place all jigs in their normal, start-work positions.

5 Place the robot in the axes origin o r work origin position as required for the operation.

6 Remove all tools f rom the robot work envelope.

7 Place welding workpiece(s) into proper position(s).

8 Place all equipment switches in the proper positions.

I. SAFETY PROCEDURES DURING AUTOMATIC OPERATION

During automatic operation, do the following:

1 Turn of f main power o r press an EMERGENCY STOP button BEFORE entering the robot work envelope.Entry may be required for nozzle, tip, wire, o r gas adjustments o r replacements.

DO NOT ENTER WORK ENVELOPE UNLESS AN EMERGENCY STOP BUTTON IS PRESSED !

2 Be alert for jig movement initiated by an external control signal during operation.

3 Do not allow unauthorized persons to operate controls.

4 I f two o r more Starting Boxes are used, be sure that the operators ful ly understand all procedures and cooperate with each other.

5 Press an EMERGENCY STOP button i f any problem occurs.

6 Since this an arc welding operation, protect operator(s) f rom arc rays, fumes, and hot parts.

7 Be sure that the Automatic mode can only be selected a t a safe location outside the work envelope.

J. SAFETY PROCEDURES AT END OF WORK

1 Place robot welding torch into an area from which movement to axes origin o r work origin positions is possible without striking any objects.This may require manual operation with Teach Pendant.

2 Press an EMERGENCY STOP button to turn of f robot Servo power.

3 Turn off welding power source and all associated equipment. This includes jig power supplies as applicable.

4 Place line disconnect switches for Robot Control Unit and welding power supply in the OFF positions.

5 Allow robot and all equipment to cool.

6 Clean robot, jigs, and entire cell area.

7 Install protective covers over all equipment AFTER proper cooling has occurred to reduce dust and d i r t entry.

I(. SAFETY PROCEDURES DURING INSPECTION, MA1NTEMANCEf ADJUSTMENT, AND SERVICING PROCEDURES

Since these procedures can involve entering the robot work envelope and may require that the main power and servo power are turned on, be sure to always do the following during any maintenance, adjustment, o r repair procedures:

1 Train all service personnel in the functions, operations, and jig movements of the specific robotic cell.

2 Allow only trained and qualified persons to service the robot.

3 Always assign and position a watchperson, with an EMERGENCY STOP button in hand, to be present and ready during any servicing or adjustment procedures.

4 Determine in advance i f the procedure(s) requires an energized robot.When power is not required, turn it off.

5 Determine in advance i f the procedure can be done outside the work envelope.Always work outside the robot work envelope whenever possible.

6 Turn of f o r disable all jig(s) and external equipment not required for the specific procedure.

7 Provide proper Electrostatic Discharge (ESD) protection fo r circuit boards in Robot Control Unit and Teach Pendant.

8 When the procedure is finished, always correctly, securely, and carefully reconnect any wires and reinstall necessary hardware, plugs, covers, and panels.

L. ARC WELDING SAFETY PROCEDURES

Read and understand, and comply with all safety rules at beginning of welding power supply manual in addition t o the following before beginning arc welding operations.

1 Prevent electric shock as follows:

1) INSTALL AND GROUND all equipment according to national, regional, and local codes.

2) DO NOT TOUCH live electrical parts.

3) WEAR DRY INSULATING GLOVES AND CLOTHING; be sure gloves have no holes.

4) DISCONNECT INPUT POWER before installing, inspecting, maintaining, servicing any equipment.

2 Provide proper protection f rom fumes and gases as follows:

1) KEEP YOUR HEAD out of the fumes.

2) USE FORCED EXHAUST VENTILATION at the arc.

3) VENTILATE CELL t o prevent build-up of fumes and gases.

4) I f ventilation is inadequate, USE APPROVED BREATHING DEVICE.

5) READ AND FOLLOW WARNING LABELS on all containers of welding materials.

6) Before use, READ AND UNDERSTAND the manufacture's instructions, Material Safety Data Sheets (MSDSs), and your employer's safety practices.

3 Protect eyes and skin from arc rays ; protect ears from noise as follows:

1) WEAR PROPERLY FITTING WELDING HELMET with proper shade of fi lter lens (See ANSI 249.1).

2) INSTALL ARC PROTECTIVE CURTAINS between operator and the arc.

3) WEAR PROPER SAFETY GLASSES in work area at all times.

4) WEAR PROPER EAR PROTECTION,

5) WEAR PROPER BODY PROTECTION to include woolen clothing, flame-proof apron and gloves, leather leggings, high boots and leather arm and shoulder gauntlets.

4 Prevent f ire and burns cause by hot metal, spatter, slag, and arc sparks as follows:

1 ) KEEP FLAMMABLE MATERIALS out of the robotic cell.

2) Have operator(s) keep their sleeves, pockets, and collars down and buttoned as applicable. Wear pants without cuffs.

3) WATCH for fire.

4) Have a f ire extinguisher nearby, and know how to use it.

5) Allow equipment and work t o cool before handling.

5 Protect compressed gas cylinders from excessive heat, mechanical shocks, and arcs as follows:

1) FASTEN CYLINDERS SECURELY so they cannot fall (use insulated chain or equivalent).

2) INSULATE CYLINDERS from mounts so that they are never grounded or par t of an electrical circuit.

3) KEEP CYLINDERS AWAY from the welding arc and other heat sources.

4) LOCATE CYLINDERS AWAY from personnel and vehicle traff ic patterns.

6 Provide impact protection to all persons in the cell as follows:

1) ALWAYS WEAR PROPER PROTECTIVE HEADGEAR, such as safety helmet, when in the robotic cell.

2) WEAR SHATTER-RESISTANT SAFETY GLASSES a t all times when in the robotic cel I.

7 Since magnetic fields from high currents can affect pacemaker operation, have wearers consult their doctor before going near arc welding operations.

8 TURN OFF robot and welding power source input power before entering work envelope or working on welding power source.

9 Prevent EMC (Electro-Magnetic Compatibility) noise caused by welding arc as follows:

1) KEEP PRECISION DEVICES AWAY from the welding arc.

2 ) Supply primary power to precision devices and welding power supply separately.

M. WARNING LABELS DO NOT REMOVE, DESTROY, or COVER the following labels on the Robot Control Unit and Manipulator. I f following labels become dir ty or peeled off, order spare ones immediately. The locations of these labels are shown in the instruction manual "MANIPULATOR" and "CONTROLLER".

KEEP OUT OF ROBOT AREA WHEN MAIN POWER IS ON.

A WARNING I

Keep out of robot area when main power is on. Read Instruction Manual.

ct ion Manual carefully.

@ Always wear dry insulating gloves. o Insulate yourself f rom the work and the ground. O Do not touch live electrical parts.

Keep your head out of the fumes. @ Ventilate area, or use a breathing device.

@ Do not weld near flammable material. @ Watch for fire; keep extinguisher nearby. 9 Do not locate unit over combustible surfaces.

NOISE c a n damage hear ing.

Wear welding helmet wi th correct filter.

a Read and follow thts label and the lnsrrucrlon Manua l carefully

r Insulate yourself from the work and the ground. r D o not touch live electrical pans

lble surfaces.

* Keep a w a y f rom rnovlng parts.

@ Keep hands, loose clothing, and tools away during operation.

* Keep away from pinch points during operatton. @ Know and understand equrprnent operation before

0 Always wear dry insulating gloves s Insulate yourself from the work and the ground. 8 Do not touch live electrical parts.

Disconnect ~npu t power before servicing

NK3717

@Do not touch live electrical

@Disconnect all power before installing or servicing.

@Multiple sources of voltage may exist inside this

@Keep out of robot area when main power is on.

@Do not locate this device in robot work area.

I I @Read Instruct ion Manual . I

a WARNING ELECTRIC S H O C K can kill.

(D Do not touch l ive electrical parts.

Read this label and Instruction Manual carefully.

O Disconnect all power before installing or servicing.

@ Only qualified persons are to install. operate. or service this equipment according to all codes and employer's safety practices.

.Wear dry insulating gloves and body protection.

@ D o not locate over combustible surfaces.

@ Keep al l panels, covers, and guards securely in place.

eB For protection against fire hazard. Replace only w i th the same type and rating of fuse.

- NC8052

1

A WARNING s Read manual for connection procedures.

@ Connect grounding conductor and input

conductors to proper terminals inside

unit-grounding conductor first.

ee Be sure grounding conductor goes to

a proper earth ground and has less

than 100 ohms of resistance.

Doublecheck grounding conductor,

input voltage, and frequency before

applying power.

NC8055

Contents

Chapter1 Installation 1 1 Configuration ............................................................................................................................................................... 1 . 2

1.1.1 CO~/MAG welding ~ ~ b ~ t standard configuration 1- 2 1.1 . 2 optional ~ ~ ~ i ~ ~ ~ ~ t ................... 1-14

1.2 Connecting primary power Supply .......................................................................................................... 1 - 16 1 . 2 . 1 Connecting primary power Cable 1-16

1 2.2 opening control uni t D~~~ ................................................................................................................... 1 - 17

1 2 3 Grounding ............................................................................................................................................................. 1 - 18 . . 1 3 External Connection .............................................................................................................................................. 1 - 20

1.3.1 Connecting Control Cable 1,2, 3 (BIRBX-1005/BIRBX-8005) 1 - 21 1 . 3.2 connecting hi^^ B~~ ........................................................................................................................ 1-24 1.3.3 Connecting Control Cable 5 (BWCB-5105) o r Welding Interface

(BBWF-0105) 1 -25

1.3.4 connecting operation panel ................................................................................................................. 1 - 27 1 .3. 5 Connecting Starting Box ......................................................................................................................... 1-28 1 . 3.6 Connecting Miscellaneous Option 1-29

1 4 placing printed ~~~~d~ ...................................................................................................................................... 1 - 30 1 . 4. 1 connecting ~~i~ processor ~~~~d 1-30 1 4 2 placing Servo Control Boards 1-31 1 4 3 placing Motion Control Board 1-31 . . 1.4.4 Placing I/() Management Board ....................................................................................................... 1-31

Chapter2 Internal Configuration of Control Unit 2 1 ~~i~ P~~~~~~~~ ~~~~d ~ 3 7 0 0 ~ 2- 5

2.1.1 Functions ............................................................................................................................................................... 2 - 5 2 . 1 . 2 Operation Status Indicator 2- 5 2.1.3 ~ ~ ~ l ~ ~ i ~ ~ ~~i~ P~~~~~~~~ ~~~~d .................................................................................................... 2- 6

2 2 ti^^ control ~~~~d ~ 3 7 0 0 ~ .................................................................................................................... 2- 7 2 2.1 Functions 2 - 7 2.2.2 Operation Status Indicator .................................................................................................................... 2- 7

2.3 1/0 Management Board L3700M (Standard) o r L4024M (Extension) ........................ 2- 8 2.3.1 Functions ............................................................................................................................................................... 2 - 8 2.3.2 operation status ~ ~ d i ~ ~ t ~ ~ .................................................................................................................... 2- 8

2.4 Servo Control Board (SCON) L4268R (or L4000R) and position control ~~~~d (PCON) ~ 4 1 9 0 ~ .............................................................................................. 2- 9

2 4 1 Functions of Servo Control Board 2- 9 . . 2.4.2 operation status ~ ~ d i ~ ~ t ~ ~ ~ of servo control ~~~~d ....................................................... 2- 9

2 4 3 Switch Settings of Servo Control Board ...................................................................................... 2-11 . . 2.4 4 jumper pin settings of servo control ~~~~d 2- 14

2.4.5 punctions of position control ~~~~d ............................................................................................. 2 - 16

2.4.6 Operation Status Indicators of Position Control Board 2- 16

2.4.7 switch settings of position control ~~~~d .............................................................................. 2-16 2.5 Servo Driver Unit ~ 4 0 0 0 ~ (G01) ~ 4 0 0 1 Q (V01) ............................................................................ 2-18 ,

2.5.1 ti^ ti^^^ 2 - 19

2 5 2 operation status ~ ~ d i ~ ~ t ~ ~ ~ .................................................................................................................. 2-19 . . 2 6 Servo power Unit E5499A or E5787A 2-21

2 6 1 Functions ............................................................................................................................................................... 2-21 . . 2.6.2 Operation Status Indicators ................................................................................................................ 2-21

2 7 ~ ~ ~ k ~ l ~ ~ ~ ~~~~d ~ 3 7 0 2 ~ (or ~ 3 7 0 0 ~ ) 2 - 22 2 7 1 Functions 2 - 22 . . 2 7 2 Connectors 2 - 22 . . 2 7 3 switch settings ................................................................................................................................................. 2-23 . .

2.8 Interlock Board L3899Y ..................................................................................................................................... 2-24 2.8.1 ~~~~~i~~~ 2 - 24 2.8.2 Operation Status Indicators ................................................................................................................. 2-24 2 8 3 Switch Settings 2 - 25 . . 2.8.4 Fuses and Connectors ................................................................................................................................. 2-27

2.8 5 Connecting Jig Terminals on Interlock Board ....................................................................... 2-28

2 9 constant voltage power supply ~ - ~ 0 0 2 0 3 ........................................................................................... 2-30 2.9.1 ti^^^ 2 - 30 2 . 9.2 operation status indicators 2-30

............... 2.10 Terminal Block Unit E5741A (Option) and Relay Unit E5685A (Option) 2-32 2 10.1 Functions of Terminal Block Unit 2 - 32

2.10.2 Connecting External Equipment (Jig, etc.) via Terminal Block Units ............. 2-32 2.10.3 ti^^^ of R ~ ] ~ ~ unit ........................................................................................................................ 2-35

2 . 10.4 connectors and J~~~~~ pins on ~~l~~ unit 2-36

...... 2.11 Charging Battery Unit W-LO0471 (Not mounted on IRBCX-532) 2-36 2 11 1 Functions ............................................................................................................................................................. 2-36 . . 2.11.2 ~~~~ifi~~t.~~~ 2-36 2 . 11 . 3 Replacing Charging Battery Unit ................................................................................................. 2-36

2 12 M~~~~~ ~ ~ t t ~ ~ ~ ~ 3 3 9 1 ~ ................................................................................................................................. 2-37 2-12 1 ti^^^ ............................................................................................................................................................ 2-37 2 . 12 . 2 Specifications 2 - 37 2. 12 3 Replacing Memory Battery 2 - 37

2 13 Switch Box E5760 or E5809 ........................................................................................................................... 2-38 2.13 1 Functions ............................................................................................................................................................ 2-38 213.2 Fuse 2-38

2.14 ~ ~ ~ i l i ~ ~ ~ ~~~~~f~~~~~ W - L O O ~ ~ O 2 -40 2 14.1 ~~~~~i~~~ ............................................................................................................................................................. 2-40

2.15 Step-down Transformer (Option) 2 -40 2 . 15 . 1 T~~~~ of step-down ~~~~~f~~~~~~ 2-40 2. 15.2 connecting step-down ~~~~~f~~~~~ 2-41

2.15 3 voltage switching T~~~ of step-down ~~~~~f~~~~~ ....................................................... 2-42 2 16 power Unit E6029A 2 -45

2 16 1 Functions of power Unit 2-45 . . 2 16 2 Specifications of power Unit .............................................................................................................. 2-45 . .

Chapter3 Peripheral Equipment of Robot Control Unit 3 1 hi^^ B~~ ............................................................................................................................................................... 3 - 2

3 1 1 ~~~~~i~~~ ............................................................................................................................................................... 3 - 2 . . 3.1.2 outside view of hi^^ B~~ ........................................................................................................... 3 - 2 3.1.3 Notes on Usage ............................................................................................................................................... 3 - 3 3.1.4 Internal Configuration 3 - 3

3 2 Operation Panel . 3- 4 3.2.1 switches and ti^^^ ............................................................................................................................ 3 - 4 3 2 2 Outside View and Internal Circuit ................................................................................................... 3 - 5 . .

3.3 Operation Box (Option) ................................................................................................................................... 3 - 6 3.3.1 switches and $'Unctions ........................................................................................................................... 3 - 6 3 3 2 Outside View and Internal Circuit ................................................................................................... 3 - 6 . .

3 4 Starting Box (Option) ................................................................................................. 3 - 8 3.4.1 Switches and Functions ............................................................................................................................ 3 - 8 3 . 4 . 2 Connecting Starting Box 3- 9 3.4.3 Outside View and Internal Circuit .................................................................................................. 3-10

3 5 ~ ~ b ~ t ~ ~ d i ~ ~ t ~ d welding power supply (option) ...................................................................... 3-11

3.5.1 Notes on Using Robot Dedicated Welding Power Supply ................... . 3-11 3.5.2 Outside View and Internal Configuration of Robot Dedicated

welding power supply 3-11 3 6 Welding Interface (Option) 3 - 12

3 6 1 Functions 3- 12 . . 3.6.2 Description of parts 3-13 3 6 3 Printed Board E5624G 3- 13 . . 3 6 4 External Connection .................................................................................................................................... 3-15 . . 3.6.5 Operation Sequence 3-16

3 6 6 Internal Circuit ................................................................................................................................................. 3-18 . . 3 7 External Storage (Option) .............................................................................................................................. 3-19

3 7 1 Specifications 3 - 1 g . . 3 7 2 Configuration of External Storage 3-20 . . 3 7 3 Connecting External Storage 3 - 21 . . 3.7.4 Notes on Handling External Storage ............................................................................................. 3-22 3.7.5 Notes on ~ ~ ~ d l i ~ ~ ~l~~~~ ~ i ~ k ~ 3-22

3 8 printer Interface Unit (option) 3-23 3 8 1 Functions 3 - 23 . . 3 8 2 Configuration ..................................................................................................................................................... 3-23 . . 3 8 3 Connecting printer Interface Unit .................................................................................................... 3-25 . .

3 8 3 1 When External Storage is not used 3-25 . . . 3.8.3.2 When External Storage is used ................................................................................................ 3-26

3 8 4 Connecting printer ' .................................. 3-26 . . 3.8.5 Notes on Usage 3-27

Chapter4 Connecting Robot Peripheral Jig (External Axis) 4.1 T~~~~ of Robot peripheral ~i~~ 4 - 2

4.2 connecting peripheral ~i~ to ~ ~ b ~ t control unit ....................................................................... 4 - 3 4.2.1 system configuration ................................................................................................................................ 4 - 3 4.2.2 control cables for peripheral ~i~ 4 - 4

............ 4.3 Internal Switch Settings and Connection Drawings of Robot Control Unit 4- 5 4.3. 1 GOIS+ 1 Axis System 4 - 7

4 3 2 G01S+2 Axis System .................................................................................................................................... 4 - 9 . . 4 3 3 ~ 0 1 ~ + 3 ~~i~ system ............................................................................................. 4-11 . . 4 3.4 VOlS+ 1 Axis System 4- 13

4 3 5 V01S+2 Axis System .................................................................................................................................... 4-15 . . 4 3 6 VOlSS.3 Axis System .................................................................................................................................... 4-17 . .

Chapter5 Troubleshooting 5 1 Symptoms 5 - 15

5 1 1 Nothing Appears on the Teaching Box ......................................................................................... 5-15 . . 5.1 2 The ~ i ~ ~ l ~ ~ on the Teaching Box Is Unsteady ...................................................................... 5-16

5.1 . 3 initial Diagnosis Is ~~t completed ................................................................................................ 5-17

5 1 4 ?'he servo power supply cannot B~ ~~~~~d ON ................................................................. 5-20 . . .............. 5.1.5 The Servo Power Supply Is Shut OFF Immediately When Turned ON 5-21

5.1.6 Manual Manipulation Does Not Function ................................................................................ 5-22

5.2 A Failure Code and A Failure Message Are Displayed ............................................................. 5-23

5.2.1 ~h~ ~ i ~ ~ l ~ ~ of A ~ ~ i l ~ ~ ~ ......................................................................................................................... 5-23 5 2 2 Logical Outputs for Failures 5-26 . . 5.2.3 shock sensor 5-27 5 2 4 Servo power shutoff 5 - 28 . . 5 2 5 software ~ i ~ i ~ ,I ~ i ~ k software ~ i ~ i t .......................................................................................... 5-29 . . 5 2 6 Overrun ................................................................................................................................................................. 5 - 31 . . 5.2 7 ~ ~ ~ ~ ~ ~ i ~ ~ ~ i ~ ~ ~ ~ i l ~ ~ ~ ~ 5 - 32 5 2 8 Data Installation Failures 5 - 34 . . 5.2.9 r \ / ~ ~ ~ ~ ~ ~ ~ ~ i l ~ ~ ~ ~ 5-36

5.2.10 setting E~~~~~ .................................................................................................................................................. 5-37

5 2 11 ABSO Data Failure 5 - 39 . . 5 3 When Servo Failure Occurred ...................................................................................................................... 5-40

5 3 1 How To See the Servo Failure Display 5-40 . . 5.3.2 ~ ~ ~ ~ b l ~ ~ h ~ ~ t i ~ ~ for servo ~ ~ i l ~ ~ ~ ~ ............................................................................................... 5-46

Chapter6 Periodic Inspection 6 1 Warranty period 6-1 6 2 periodic Inspection Schedule 6 - 1 6 3 Notes for Performing Periodic Inspection .......................................................................................... 6-2 6.4 List of Inspection Items 6-2

Chapter7 Parts L is t 7 1 IRBCX-422 Robot Control Unit .................................................................................................................. 7 - 2 7 2 IRBCX-462 Robot Control Unit .................................................................................................................. 7 - 4 7 3 IRBCX-512 Robot Control Unit .................................................................................................................. 7 . 6 7.4 IRBCX-532 Robot Control Unit .................................................................................................................. 7 - 8 7 5 IRBCX-541 Robot Control Unit .................................................................................................................. 7-10 7 6 IRBCX-551 Robot Control Unit .................................................................................................................. 7-12 7.7 BBOpX-3000 Operation panel .................................................................................................................... 7-14 7.8 BBOP-3005 Operation Pane] 7-16 7.9 BBTBX-6008 Teaching Box ............................................................................................................................ 7-18 7.10 BBST-4005 Starting Box .................................................................................................................................. 7-20 7 . 11 BBWF-0105 welding Interface .................................................................................................................... 7-22 7 12 BIRBX-1005 Control Cables 7 - 24

7 12 1 control cable 1 2 3 ~ 0 1 ~ 0 1 ~ 0 1 ) ................................................................................... 7-24 . . , > 9

7 12 2 cables / H~~~ 7 - 24 . . 7.12.3 Control Cable5 (For Almega Auto 11% Robot Control Unit) ............................... 7-25

7 13 BIRBX-8005 Control Cables 7-26

7 13 1 Control Cable 1 2 3 (For V10 ~ 2 0 ) 7-26 . . , , 7.13 2 ~~~l control cable ( F ~ ~ ~ 1 0 ~ 2 0 ) 7-27

9

7 14 BIRBX-6005 Control Cables 7-28

7 14 1 Control Cable 1 2 3 (For V40) ........................................................................................................... 7-28 . . 9 ,

7 14 2 ~~~l control cable ( F ~ ~ ~ 4 0 ) .......................................................................................................... 7-29 . . 7 15 Robot Control Unit for External Axes ............................................................................................... 7-30

7 15 1 IRBCX-422-1 Robot Control Unit 7 - 30 . . 7 15 2 IRBCX-422-2 Robot Control Unit 7-32 . . 7 15 3 IRBCX-422-3 Robot Control Unit 7-34 . . 7 15 4 IRBCX-512-1 Robot Control Unit 7-36 . . 7 15 5 IRBCX-512-2 Robot Control Unit .................................................................................................. 7-38 . . 7 15 6 IRBCX-512-3 Robot Control Unit .................................................................................................. 7-40 . .

Chapter8 Electrical Connection Diagram

8 1 Electrical Diagram of Robot Control Unit IRBCX-422 462 ................................................. 8 - 1 1

8 2 Electrical Diagram of Robot Control Unit IRBCX-512 .............................................................. 8 - 7

8 3 Electrical Diagram of Robot Control Unit IRBCX-541 .............................................................. 8-13

8.4 Electrical Diagram of Robot Control Unit IRBCX-551 .............................................................. 8-19

8.5 Internal Sequence Diagram of Robot Control Unit .................................................................... 8-25 8.6 Outside Dimensional Drawing of Robot Control Unit ............................................................. 8-33

8.6.1 IRBCX-422 462 512 541 551 ................................................................................................................ 8-33 , t ' I

8 6 2 IRBCX-532 ............................................................................................................................................................. 8-34 . . 8 7 Electrical Diagram of Control Cable 8 - 35

APPENDIX I-WELDING EQUIPMENTS 1.1 connecting ~ ~ b ~ t ~ ~ d i ~ ~ t ~ d Welding power Supply Al - 1

1 . 1.1 ~ ~ t ~ ~ ~ ~ l connecting cable Al - 1 1 1.2 Connecting Cables A1 - 2

1.2 Connecting Welding Interface and Welding Power Supply A l - 3 1 . 2. 1 External Connecting Cable ................................................................................................................ A l - 3 1.2.2 Connecting Method of Cables A l - 4

1 3 TIG Interface E5743 ........................................................................................................................................... A l - 6 1 . 3. 1 A~~~~~~~~~ of TIG interface A l - 6

1 . 3.2 setting J~~~~~ wires of TIG ~ ~ t ~ ~ f ~ ~ ~ Al - 7 1 . 3.3 Connecting TIG Interface Al - 7

1 4 Filler Wire Feed Control Unit EST56 Al - 8

1.4.1 Appearance of Filler Wire Feed Control Unit .................................................................... Al- 8

1 4 2 Connecting Filler Wire Feed Control Unit ............................................................................. A1 - 8 . . 1 5 CUT Interface E5782 ......................................................................................................................................... Al- 9

1 . 5. 1 Appearance of CUT Interface .......................................................................................................... Al- 9 1 .5.2 setting J~~~~~ wires of CUT interface ................................................................................. A1 - 10 1 . 5.3 connecting CUT ~ ~ t ~ ~ f ~ ~ ~ A1 - 10

1 6 Weld Stick Detection Unit E5391 A1 -11

1 .6 . 1 Specifications of Weld Stick Detection Unit ......................................................................... Al-11

1.6 2 Functions of Weld Stick Detection Unit .................................................................................... A1 - 12

1 .6. 3 Connecting Weld Stick Detection Unit ....................................................................................... A1 - 13 1.7 Connection Examples of Various Welding Power Supplies ............................................ A1-15

1 . 7. 1 C02/MAG/MIG Welding Power Supply ................................................................................. A1 - 16

1.7.2 TIG Welding Power Supply ................................................................................................................ A1-22

1 7 3 ~i~ plasma cutt ing power supply ............................................................................................... ~1 -24 . .

Contents

1 . 3 External Connection 1-20

... . 1.3.1 Connecting Control Cable 1,2, 3 (BIRBX-1005/BIRBX-8005) 1 - 21 1 . 3 . 2 connecting hi^^ B~~ 1-24

1.3.3 Connecting Control Cable 5 (BWCB-5105) o r Welding Interface (BBWF-0105) ....................................................................................................................................................... 1-25

1 3 4 Connecting Operation Panel .................................................................................................................... . . 1-27 1 3 5 Connecting Starting Box ............................................................................................................................. . . 1-28 1 3.6 Connecting Miscellaneous Options 1-29

1. Ins ta l la t ion WAKNlNt i

1. Before the installation and connecting cables to the robot ELECTRIC SHOCK control unit, ensure that the switch of the switchboard and the @Do not touch live electrical

breaker in the control unit are installing or servicing.

turned OFF so that no voltage is ources of voltage

being impressed.

2. Install the robot control unit and its peripheral equipment such a s the welding power supply, the starting box,and so on out of the a8 Read instruction manual.

action range of the robot.

3. To install the robot control unit, the welding power supply and the likes on a high place such a s on a frame (over Zm),arrange a working floor just a s shown in Fig.l.1 .for easy adjustment and maintenance.

Fig.1 . l . Installation of robot control unit on high place

T O AVOID DAMAGE T O THE ROBOT CONTROL UNIT, KEEP THE AIR INLET A N D EXHAUST

A CAUTION FAILURE TO CONNECT CN47 T O BATTERIES will cause loss of absolute offset data. 0 Di~connscf input wwar before installing or servicing.

C o n n e c t CN47 to bsttarics bafors using robot CN47 is located on the Icfl rids of the main transformer.

0 Perfom absoluts ofbot adjustment according to Inrtructioo Monval nftsr CN47 is connectad.

0 Whon raplacing banariss, bs sure tho1 the control pawar is on.

.--...

A LAU l IUN 5

1. Install the robot control unit over 20cm away from wall.

2. After completing the installation work, carry out the "Absolute Offset Setting"

Installation 1 - 1

described in the Instruction Manual "TEACHING", so that the attitude of the manipulator and the position coordinate data of the robot control unit should coincide with each other.

"..",, 3. Keep the space for the cable connection

on the side of Robot Control Unit over 30cm away from wall.

\ /

2 . 1 Configuration

1 .I .1 COp/MAG Welding Robot Standard Configuration

1. ALMEGA GOlS Basic Configuration

@ ~ ~ ~ i ~ ~ l ~ t ~ ~ ..................................................................... I R B - Q ~ ( G O ~ S ) ~ Standard accessories

Wrench

Clamping bolts

@ Control Unit IRBCX-422 1

(OSACOM SUPER 8700)

@) Teaching Box .................................................................... BBTBX-6008 1 (Cable 8m)

@ Operation Panel .......................................................... BBOPX-3000 1 (Optional)

@ Control Cable 1 ,2,3 ................................................... BIRBX-1005 lset (3 cables:5m length)

(For Manipulator-Control Unit)

COu'MAG Welding Components

@ Robot Dedicated Welding Power Supply -.-- CPVAS-350 1

a control cable 5 BWCB-5105 1 (Cable length 5m)

(For Control Unit-Robot Dedicated Welding Power Supply)

@ Wire Reel Stand L318H 1

0 ~ ~ b l ~ ~ / ~ ~ ~ ~ ~ BIRB-3005 lset

1 Workpiece Side Welding Cable --.----.-..- L3442B (1) (Cable length 5m)

(For Welding Power Supply-Workpiece)

~ - 2 ~~~~h side welding cable ........................ L2527D (1) (Cable length 5m)

(For Welding Power Supply-Manipulator)

0 3 G~~ H~~~ .................................................................. L2527B (I) (Cable length 5m)

@-4 control cable 4 ~ 3 3 9 2 ~ (1) (Cable length 5m)


@ G~~ ~ ~ ~ ~ l ~ t ~ ~ ............................................................... 5092-320 1 (FCR-8033)

1 - 2 Installation

Installation 1 - 3

2. ALMEGA WOlS Basic Configuration

a ~ ~ ~ i ~ ~ l ~ t ~ ~ 1 ~ ~ - 4 6 1 1 Standard accessories

(WOlS) * Wrench

Clamping bolts

@ Control Unit ..................................................................... IRBCX-462 1

(OSACOM SUPER 8700)

@ hi^^ B~~ BBTBX-6008 1 (Cable 8m)

Operation panel BBopX-3000 1 (Optional)

@ Control Cable 1 2 3 ...................................................... BIRBX-1005 , , lset (3 cables:5m length)


COdMAG Welding Components

@ Robot Dedicated Welding Power Supply .-- CPVAS-350 1

a Control Cable 5 ............................................................. BWCB-5105 1 (Cable length 5m)



@ Wire Feed Unit L6065A 1

@ Cape Hanger .................................................................... L6058D 1

Coaxial power Cable K2863A 1 (2.5m)

@ COz Welding Torch ...................................................... MTX-3502 1

@ Torch Attached Bracket ....................................... L318G 1

@ Torch Gauge Assembly .......................................... L3382G 1

0 ~ ~ b l ~ ~ / ~ ~ ~ ~ ~ BIRB-3005 lset

0 - 1 Workpiece Side Welding Cable -.--..--.--..----- L3442B (I) (Cable length 5m)


0 - 2 Torch Side Welding Cable -..--..-.-------.--------- L2527D (1) (Cable length 5m)


Q-3 G~~ H~~~ ................................................................... ~ 2 5 2 7 ~ (1) (Hose length 5m)

0 - 4 control cable 4 ---.- ........... ~ 3 3 9 2 ~ (1) (Cable length 5 5 m)


@ Gas Regulator ................................................................. 5092-320 1 (FCR-8033)

Q Conduit ................................................................................. Z318D41 1 (3x1)

1 - 4 Installation

3. ALMEGA VOlS Basic Configuration

a Manipulator ...................................................................... IRB-511 1 Standard accessories

(VOlS) Clamping bolts

@ Control Unit .................................................................... IRBCX-512 1

(OSACOM SUPER 8700)

@ Teaching Box .................................................................. BBTBX-6008 1 (Cable 8m)

@ operation panel ........................................................... BBOPX-3000 1 (Optional)

@ Control Cable 1 2 3 ..................................................... BIRBX-1005

, , Iset (3 cables:5 m length)


C02/MAG Welding Components

@ Robot Dedicated Welding Power Supply .-- CPVAS-350 1

a Control Cable 5 ............................................................. BWCB-5105 1 (Cable length 5m)



@ Wire 'Feed Unit L3603A 1

@ Coaxial Power Cable ................................................ K2364A 1 (1.2m)

C02 Welding Torch MTXC-3501 1 (With shock sensor)

@) Torch Attached Bracket ........................................ L6300B 1

@ Torch Gauge Assembly L6300C 1

@ G~~ ~ ~ ~ ~ l ~ t ~ ~ ................................................................ 5092-320 1 (FCR-8033)

@) Conduit .................................................................................. Z318D41 1 (3m)

@ Cables/Hoses ................................................................... BIRB-3005 lset

1 Workpiece Side Welding Cable ...-..-..-------- L3442B (1) (Cable length 5m)


@-2 Torch Side Welding Cable .-------------.-------..... L2527D (I) (Cable length 5m)


@-3 G~~ H~~~ L2527B (1) (Hose length 5m)

@-4 Control Cable 4 ................................................... L3392G (1) (Cable length 5m)


1 - 6 Installation

Installation 1 - 7

4. ALMEGA VlOS Basic Configuration

@ ~ ~ ~ i ~ ~ l ~ ~ ~ ~ IRB-541 ( ~ 1 0 s ) 1 Standard accessories

Clamping bolts


(OSACOM SUPER 8700)


operation panel ............................................................ BBOPX-3000 1 (Optional)

@ Control Cable 1 2 3 ...................................................... BIRBX-8005 , , lset (3 cables:5 m length)


COdMAG Welding Components

@ Robot Dedicated Welding Power Supply -. CPVAS-350 1

a control cable 5 ............................................................. BWCB-5105 1 (Cable length 5m)


@ Wire Reel Stand ............................................................. L318H 1

@ Wire Feed Unit L3603A 1

0 coaxial power cable ................................................ ~ 2 3 6 4 ~ 1 (1.2m)

0 COz Welding Torch MTXC-3501 1 (With shock sensor)

@ Torch Attached Bracket ....................................... L3585p 1

@) Torch Gauge Assembly L3585M 1

G~~ ~ ~ ~ ~ l ~ t ~ ~ 5092-320 1 (FCR-8031)

@ Conduit ................................................................................. Z318D41 1 (3m)

@ ~ ~ b l ~ ~ / ~ ~ ~ ~ ~ .................................................................... BIRB-3005 lset

- 1 Workpiece Side Welding Cable .--.---.--.---.-- L3442B (1) (Cable length 5m)


- 2 Torch Side Welding Cable L2527D (1) (Cable length 5m)


@-3 G~~ H~~~ ................................................................... ~ 2 5 2 7 ~ (1) (Cable length 5m)

0 4 Control Cable 4 .................................................. L3392G (1) (Cable length 5m)


1 - 8 Installation

Installation 1 - 9

5. ALMEGA V20S Basic Configuration

Manipulator ...................................................... IRB-551 0720s) 1 Standard accessories

Clamping bolts


(OSACOM SUPER 8700)


@ operation panel BBOPX-3000 1 (Optional)

@ Control Cable 1 2 3 BIRBX-8005 I , lset (3 cables:5m length)


1 - 1 0 Installation

Installation 1 - 1 1

6. ALMEGA V40S Basic Configuration

a ~ ~ ~ i ~ ~ l ~ ~ ~ ~ IRB - 531 ( ~ 4 0 ~ ) 1 Standard accessories

Clamping bolts

@ Control Unit ...................................................... IRBCX-532 1

(OSACOM SUPER 8700)

@ hi^^ B~~ . BBTBX - 6008 1 (Cable 8m)

a operation panel ......................................... BBOPX-~OOO 1 (Optional)

@ Control Cable 1 2 3 4 .................................. BIRBX-f'j005 , , , lset (4 cables:5 m length)


I - 1 2 Installation

1.1.2 Optional Equipments

The following Equipments are provided as options.

@ Teaching Box

@ Control Cable 1,2,3 (For Manipulator-Control Unit)

Model

BBTBX-6015

a ) For VOlS,GOlS,WOlS

Specifications

Cable Length: 15m

b) For VlOS,V20S

Model I Specifications

BIRBX-8003 I Cable Length: 3m

BIRBX-8010 Cable Length: lOm

BIRBX-8015 I Cable Length:15m

c) For V40S (Control Cable 1,2,3,4)

@ Control Cable 5 (For Control Unit-Almega Auto II )

Model I Specifications

BWCB-5110 I Cable Length: lOrn(Optica1 fiber)

@ Cables/Hose (For Control Unit-Almega Auto II )

BWCB-5115

I Constructions

Cable Length: 15 m (Optical fiber)

Model


--- -

BIRB-3010

BIRB-3015

Specifications

L3375T

L3375V

Control Cable 4

Workpiece Side Welding Cable Gas Hose

L3375E

L3375G

Torch Side Welding Cable

L3375L

L3375N

L3443B

L3444B

Cable Length: lOm

Cable Length: 15m

@ Tool Control Cable

a ) For VlOS,V2OS

b) For V40S

Model

BIRBX-9105

BIRBX-9110

BIRBX-9115

Specifications

Cable Length: 5m

Cable Length: lOm

Cable Length: 15m

0 Operation Box

Model

BIRBX-6105

BIRBX-6110

BIRBX-6115

Model

Specifications

Cable Length: 5m

Cable Length: lOm

Cable Length: 15 m

I Specifications

BBOPX-3005 I Operation Box with 5m cable

BBOPX-3008 I Operation Box with 8m cable

BBOPX-3015

~ ~ t ~ ~ ~ ~ l storage E5777A

External Connecting Cable ..................................................................................................................... E5657L

Cable Assy(l) E5777K

Cable Assy(2) E5777 J

Interface printed Board E5657C

Accessories E5777N

@ Welding Interface E5624A

(For COz o r MAG Welding Power Unit expect CPVAS) @ personal Computer Interface Cable E5623B

(For Personal Computer-Backplane board) 0 Terminal Block Unit E574 1 A

Q Relay uni t E5685A

@ ~ ~ t ~ ~ d ~ d Terminal Block Unit ............................................................................................................ E5766A

@ ~ ~ t ~ ~ d ~ d Relay Unit E5772A

Operation Box with 15m cable

Starting Box


Model

BBST-4005

BBST-4008

BBST-4015

Specifications

Cable Length: 5m

Cable Length: 8m

Cable Length: 15m

1.2 Connecting Primary Power Supply

1.2.1 Connecting Pr imary Power Cable

1. Primary Power Supply

3 phase AC200V (+lo%,- 15%), 50/60Hz

3KVA (GOl,WOl,VOl), 4kVA (VlO),

5kVA (V20), 7kVA (V40)

2. To primary power cable of 3 .5d min. x 3

wires,attach a M4 round crimpstyle

terminal a t the control unit side.

CAUTION Be sure that grounding is carried out a s a prevention against electric shock. For the grounding method, see1.2.3.

Fig. 1.2.1.1 Connecting Primary Power Cable

3. Install a nonfuse breaker (3 phase, 200V) on a leakage breaker between primary

power supply and control unit.

GO1 + 1-3 Axes

4. For wiring both control unit and welding power supply,in order to reduce noise

effects,install separately wiring to primary power supply and grounding terminal.

5. The location of breaker in the control unit is shown in Fig.l.2.1.1.

6. Supply primary power to each of control unit and welding power supply from its

independent power supply

@ NOTE 1. This robot control unit is equipped with inverter circuit to control AC

servo motors. Therefore, if implying a leakage breaker,be sure to specify a leakage breaker for inverter in order to prevent its leakage current generated from the inverter circuit.

2. In the use of high sensitivity type of a leakage breakerjnstall one per control unit.In the case of the collective use among multiple control unit, install one middle sensitivity type leakage breaker for several control units.


1.2.2 Opening Control Unit Door

Door Key - t---7 1. Unlock the upper and lower

/ door keys. Use a minus screwdriver.

Braker .+ I - 2. Turn the breaker handle to "Open Reset" in the direction of the arrow in Fig.1.2.2.1 to

i open the door. At this moment,the primary

i power of the control unit is shut off.

//

Door Key I /-----

Fig.1.2.2.1 Door of control unit

ELECTRIC SHOCK can kill. *Do not touch live electrical

parts. @Disconnect all power

before installing or servicing. .Multiple sources of voltage

may exist inside this enclosure.

If the door needs to be opened with the power ON,for example to check the control unit a t any occurrence of a failure, follow the procedures described below:

Fig. 1.2.2.2 Breaker handle

Unlock the upper and lower door keys. Use a minus screwdriver.

Turn "Release" button to the arrow shown in Fig.1.2.2.2 with a screwdriver,and you may open the door with the power ON.

WARNING 1. Voltage is impressed on the primary side of the breaker even after the

breaker of the control unit is turned OFF. Therefore, in case of opening the door for maintenance, be sure to turn OFF the power source switch.

2. The control units contains many high-voltage components and touching any of them while powere is ON may cause electric shock. Therefore, if the door needs to be opened with the power ON, for example to check the control unit a t any occurrence of a failure, never fouch any of components inside of the unit.


1.2.3 Grounding

For a safety operation, install the grounding arrangement a s shown in Fig.1.2.3.1.

1. For the manipulator, use a MI2 tap located a t the bottom of the body to provide an

independent ground with a grounding cable over 3.5d.

2. For the robot control unit,provide an independent ground with a grounding cable

over 3.5mnT.

The grounding terminal of the control unit is located on the top and the bottom of

the breaker.

3. For the welding power supply,provide an independent ground with a grounding

cable over 14d .

4. Be sure to apply ground resistance below 100 9 .

5. Ensure that the ground of each of 1,2,3,and 4 is separated from one another,as

shown in Fig.l.2.3.1,and never use them together with the grounding cable o r

grounding pole from other electric power.

6. For the use of metallic conduit,duct and cable rack for wiring of grounding cables,

follow the Electrical Installation Technical Standards in your country.

l r ~ s u l a t l n s P l a t e ,

M a n l F u l a t o r Sloe W s ! d i n g C a b l e ( A ) - R o b o t C o n t r o l U n i t

\

W e l r r i n g T o r c h -

e x c e e d i n g 100Q)

n o t l e s s t h a n 3 5mm2 ( w i t h i n :Onj

Fig.1.2.3.1 Grounding

A CAUTION \

Be sure of the danger of imperfect connection of, particularly, the workpiece side cable B, a s shown in Fig.1.2.3.2, which may cause a welding current to flow into the control unit through the motor frame, resulting in damage in the control unit. Similarly, pay attention when using another welding power supply

I for temporary welding of workpiece. I


[ r Read manual for connection procedures. I

A : Torch Side Welding Cable

B : Work Side Welding Cable

Fig. 1.2.3.2 Welding current flowing

into control unit

e Connect grounding conductor and input

conductors to proper terminals inside

unit-grounding conductor first.

e Be sure grounding conductor goes to

a proper earth ground and has less

than 100 ohms of resistance.

e Doublecheck grounding conductor.

input voltage, and frequency before

applying power.


1.3 External Connection Notes on Connection

1. Before connecting cables to the robot control unit,make sure that the switch of the

switch board of the distribution panel and the breaker within the control unit a r e

turned "OFF" s o that no voltage is being impressed.

2 . Make sure that the connections (connectors and terminals) of cables and hoses a r e

tightened.

3. Do not put any load on the cables.

4. Do not cross various cables.

5. Do not install cables under the welding power supply.

6. Separately place the welding cables and other control cables without binding them up.

7. Cables may be installed inside the unit from both the right and left sides.Connect

them in accordance with the description shown in the following pages.

8. As for connecting to the jig,refer to "Interface with Jig" in the instruction manual.

G.B. and servo driver as indicated

@Connect 6N67, CN68, CN69, CN70, CN71 andCN72 of control cable. to Interlock Board as following drawing.

@Connect 6N31, 6N32 and CN33 of starting Box to Interlock Board as in the -Following

as positioner and slider. In case of a single mechanism (one manipulator) system, 613169 and 6N72 are not connected.

@As for details of each cable connection, Read Instruction Manuals.

NC8068


1.3.1 Connecting Control Cable 1,2,3 (BIRBX-1005/BIRBX-8005)

The manipulator and the robot control unit are connected with 3 cables.

CNl ,connectors CN67, 68

and CN51-56.

(1) Connecting Control Cable 1

1. Connect cannon plug CN1 Connecting cannon plug

of Manipulator.

2. Connect connectors CN67

and CN68 to CN67 and CN

*

Duct 68 of Interlock board /

. Servo Driver

L C N I C o n t r o l

C a b l e I

respectively.

Connect connectors CN51-

56 to CN51-56 a re all the

same type connectors but

have different colors to

identify each axis.

After connection,be sure

to check that they are all

correctly connected.

Place the cables connected

to servo Drivers in the

ducts located a t the right

side and the upper part .

Connect a grounding cable

to a grounding plate

mounted on the bottom of

Control Unit.

Fig.l.3.1.1 Connecting Control Cable 1

CAUTION 'I 1. Because this cable is a motor power cable,do not bind it with other signal

cables. 2. Connector CN56 is for V01.

Therefore, if manipulator is GO1,this connector should not be connected. L J


1 CN2,connectors CN7 and 1


CN2 Con t

Connecting cannon plug

Fig.1.3.1.2 Connecting Control Cable 2

+

C a b l

1. Connect cannon plug CN2

to CN2 of Manipulator.

2. Wire along the left side

and connect connector

CN70 to CN70 of Interlock

Board.

3. Connect connector CN7 to

CN7 of Servo Control

Board 1.

A CAUTION 1. Since this cable is the signal cable for encoder, do not bind it with other

motor cables and AC input cables. 2. Connectors of the same type as the connector CN70 a re employed in CN5 in

SCON Board 1 and 2. To avoid damage for printed circuit board, do not mis-connect.

1 - 2 2 Instal lat ion


Inter Fa l o c k

Connecting cannon plug

CN3,connectors CN7 and

CN71

f

G r o u n d i n g P1atcX3

+ 1. Connect cannon plug CN3

to CN3 of Manipulator.

2. Wire along the left side

and connect connector

CN71 to CN71 of Interlock

Board.

3. Connect connector CN7 to

CN7 of Servo Control

Board 2.

Fig.1.3.1.3 Connecting Control Cable 3

1 CAUTION ? 1. Since this cable is the signal cable for encoder, do not bind it with other

motor cables and AC input cables. 2. Connectors of the same type as the connector CN71 a re employed in CN5 in

SCON Board 1 and 2. To avoid damage for printed circuit board, do not mis-connect.


"1.3.2 Connecting Teaching Box

Fig.1.3.2.1 Connecting Teaching Box

Connecting connector CN16 1. Connect connector CN16

of Teaching box to CN16

on the side of Control

Unit.

+


1.3.3 Connecting Control Cable 5 (BWCB-5105) o r Welding Interface (BBWF-0105)

1. Connect connector CN37

to CN37 of Interlock Board.

2. Connect optical fiber

connector to IC124 of Back

plane.

Connecting connector

CN37 and optical fiber

connector

to R o b o t Welding P o w e r SuPP l Y or

*

W e l d i n g Interface

Fig. 1.3.3.1 Connecting Robot Dedicated Welding Power Supply

@ NOTE

I Connect welding interface like control cable (BWCB-5105).

Instal lat ion 1 - 2 5

cover (Fig.a) and fiber cap (Fig.b). (The unclean connection of optical fiber cable causes malfunction of the robot.)

Q a c k P l a n e

C o n n e c t o r C o v e r

(Fig. a) (Fig. b)

Fig.1.3.3.2 Optical Fiber Connector


1.3.4 Connecting Operation Panel

1 Connecting connectors I *

Fig.1.3.4.1 Coilnecting Operation Panel

1. Connect connectors CN28

and CN31 to CN28 and

CN31 of Interlock Board

respectively.


1.3.5 Connecting Starting Box

(Note) Station Nos. and their corresponding

Connector Nos. are a s follows:

Connecting connector

CN3 1

(Le f t S i d e ) I

+ 1. Connect connector CN31 of Starting Box to

CN32-CN36 of Interlock Board and Relay Unit

PCB5 (The Inside o f Door)

I + t o S t a r t i n g B o x

Fig.1.3.5.1 Connecting Starting Box


I .3.6 Connecting Miscellaneous Options

1. Connect Line Master and

Personal Computer to the

following connectors of

Backplane board:

CN19 for Line Master

CN18 for Personal Computer

Fig. 1.3.6.1 Connecting Miscellaneous Options

CAUTION Do not bind all these cables with motor cable.


1.4 Placing Printed Boards Cautions on Placing Printed Boards

1. The printed boards connected to Backplane Board a r e inserted in the slots.After

insertion,in order to prevent imperfect contact of the connector connection which

may cause malfunction due to vibration and shock,ensure that the printed boards a r e

fixed with printed board metal fixing plates (2).

Maln Processor Board /

Motion Control Board /I/O Management Board

Fig.l.4.0.1 Fixing Printed Board

2. After placing the printed boards,be sure to check that the boards a r e all in the

correct slots.Misplacing may damage a board.

1.4.1 Connecting Ma in Processor Board

Connect connectors J l , J 2 of Main Processor Board to connectors 51-4 and 52-4 of

Backplane Board.(See Fig.l.4.O.l)


1.4.2 Placing Servo Control Boards

1. Connect connector CN1 of Servo Control Board 1 to connector 52-2 of Backplane

Board.(See Fig.l.4.O.l)

2. Connect connector CN1 of Servo Control Board 2 to connector 52-1 of Backplane

Board.(See Fig.l.4.0.1)

1.4.3 Placing Motion Control Board

Connect connectors J1,52 of Motion Control Board of connectors 51-3,52-3 of

Backplane Board.

1.4.4 Placing 1/0 Management Board

Connect connectors J1,J2 of I/O Management Board to connectors 51-5,5255 of

Backplane Board.


Chapter 2 Internal Conf igurat ion o f Cont ro l U n i t

Contents

2.2 1 Functions ........................................................................................................................................................

2 2 2 Operation Status Indicator ............................................................................................................. . . 2.3 1/0 Management Board L3700M (Standard) or L4024M (Extension) .................

2 3.1 Functions ........................................................................................................................................................

2 3 2 Operation Status Indicator ............................................................................................................. . . 2.4 Servo Control Board (SCON) L4268R (or L4000R) and

position Control Board (pCON) U1CjOS .........................................................................................

2 4 1 Functions of Servo Control Board . . 2.4.2 Operation Status Indicators of Servo Control Board ..............................................

2.4.3 switch settings of servo control ~~~~d .............................................................................

2 . 4 . 4 Jumper pin Settings of Servo Control Board 2 4 5 Functions of position Control Board ..................................................................................... . . 2.4.6 Operation Status Indicators of Position Control Board ........................................

2 4 7 Switch Settings of position Control Board ....................................................................... . . 2.5 servo ~~i~~~ unit ~ 4 0 0 0 ~ (01) ~ 4 0 0 1 ~ ( ~ 0 1 ) I

2 . In te rna l Con f i gu ra t i on o f Con t ro l U n i t This chapter explains the functions. operation status indicators. and switch settings of

the following components contained in the robot control unit: For IRBCX.422. 462. 512. 541 (1) ~~i~ processor ~~~~d ~ 3 7 0 0 ~ (2) ti^^ control ~~~~d ~ 3 7 0 0 ~

(3) 1/0 Management Board (Standard) ................... L3700M I/() Management Board (Extension) ...................................... L4024M

(4) Servo Control Board ........................................................................... L4268R

(5) Servo Driver Unit (6) Servo power Unit E5787A (7) ~ ~ ~ k ~ l ~ ~ ~ ~~~~d L3702F (8) Interlock Board ........................................................................................ L3899Y (9) Terminal Block Unit (Option) E5741A

Relay Unit (Option) E5685A

00) charging ~ ~ t t ~ ~ ~ unit ...................................................................... W - LO0471 (11) Memory Battery ..................................................................................... L3391V (12) ~ ~ ~ i l i ~ ~ ~ ~~~~~f~~~~~ W - LO0470 03) power Unit E6029A

.O. 0.1 and

Fig.Z.O.O.1 Parts Arrangement Drawing of Robot Control Unit

(IRBCX-422, 462, 512. 541)

Internal Configuration of Control Unit 2 . 1

For IRBCX-551

(I) Main Processor Board ...................................................................... ~ 3 7 0 0 ~ (2) Motion control ~~~~d ...................................................................... ~ 3 7 0 0 ~

(3) 1/0 Management Board (Standard) .... L3700M 1/O Management Board ( ~ ~ t ~ ~ ~ i ~ ~ ) L4024M

(4) Servo Control Board L4268R or position control ~~~~d ~ 4 1 9 0 ~

(5) Servo Driver Unit

(6) Servo power Unit ................................................................................... E5787A (7) Backplane Board ~ 3 7 0 2 ~ (8) Interlock Board ~ 3 8 g g y

(9) constant voltage power supply ................................................ ~ - ~ 0 0 2 0 3 (10) Terminal Block Unit (Option) E5741A

Relay Unit (Option) ............................................................................ E5685A

(11) Charging Battery Unit ...................................................................... w - ~00471

(12) Memory Battery L3391V (13) Switch Box E5760A @4) Auxiliary Transformer w - ~00470

The component arrangement drawing and block diagram are presented in Fig.2.0.0.2 and Fig.2.0.0.4, respectively .

Fig.2.0.0.2 Par t s Arrangement Drawing of Robot Control Unit (IRBCX-551)

2 . 2 Internal Configurat ion of Control Un i t

Arc Sensor Teaching Box Robot Dedicated Welding

Power Supply f Personal f 4 $- computer 1 r

Operation (Operation

Panel Box)

1 t I C N ~ S iCiZ4 CNiQ CNie CN16 I A A A A,

Charging

PCB 1

Backplane Board

Jl-5 J2-5 Jl-4 JZ-4 J1-3 J2-3 JZ-2 J2- I

~ C R I tnjll PCB IS PCB14 PCB13

I/O

(Memory Backup)

Interlock Board

/[PC851 l l I P C ~ O I I 8

Battery Unit

1 Manipulator

F Fo

Operation (Operation

Panel Box)

I Manipulator

2.1 Main Processor Board L3700C 2.1.1 Functions

The Main Processor board controls the overall robot control unit and has the

following functions:

(1) Controls the overall robot system.

(2) Stores data such a s teaching data, system parameters, and calender data.

(3) Controls the external storage.

(4) Communicates with the teaching box.

2.1.2 Operation Status Indicator

(1) Operation Status Indicator (LED100 Red)

This LED illuminates when the processor on the Main Processor board properly

operates. It goes out when the processor does not properly operate due to a drop in

supply voltage or a failure of the Main Processor board. In this event, the Main

Processor board transmits a system down signal to other boards to shut off the

servo power. To replace this printed board due to a failure, follow the steps in 2.1.3.

Fig.2.1.2.1 Outside View of Main Processor Board

Internal Configuration of Control Uni t 2 - 5

2.1.3 Replacing Main Processor Board

The memory on the Main Processor board stores important data such a s teaching

data and system parameters. These data are backed up by a memory battery mounted

outside the Main Processor board.

Therefore, to replace this printed board, follow the steps below:

(1) Store the teaching data and system parameters to the external storage.

(2) Remove the board from the slot. Do not put the removed board on a conductive

material such a s a metal because the data are backed up for several hours by the

condenser mounted on the board.

(3) Place a new Main Processor board in the slot.

(4) Initialize the printed board. (For initialization, see the Teaching instruction

manual.)

(5) Transfer the stored teaching data and system parameters from the external

storage.

2 - 6 Internal Configurat ion of Control Uni t

2.2 Motion Control Board L3700D 2.2.1 Functions

The Motion Control board controls movements of the manipulator and has the


(1) Computes the movement and path of each arm of the manipulator.

(2) Processes various arithmetic operations a t high speed necessary for the above

computations.


(1) Operation Status Indicator (LED100 Red)

This LED illuminates when the processor on the Motion Control board properly

operates. It goes out when the processor does not properly operate due to a failure,

etc. In this event, the Motion Control board outputs a system down signal to shut

off the servo power.

Fig.2.2.2.1 Outside View of Motion Control Board

Internal Configurat ion of Control U n i t 2 - 7

2.3 1/O Management Board L3700M (Standard) or L4024M (Extension) 2.3.1 Functions

The I/O Management board controls input/output signals transmitted within the

robot control unit and from/to peripheral equipment and has the following functions:

(1) Receives various 1/0 signals transmitted within the robot control unit and

from/to the peripheral jig.

(2) Performs logical arithmetic operations responding to each of input/output signals.

(3) Communicates with the peripheral equipment such as the Line Master and a

personal computer.


(I) Operation Status Indication (LED100 Red)

This LED illuminates when the processor on the I/O Management board properly

operates. I t goes out when the processor does not properly operate due to a failure,

etc. In this event, the I/O Management board outputs a system down signal to shut

off the servo power.

Fig.2.3.2.1 Outside View of 11'0 Management Board

2 - 8 Internal Configuration of Control Unit

2.4 Servo Control Board (SCON) L4268R (or L4000R) and

Position Control Board (PCON) L4190S Servo Control board (SCON) is used for IRBCX-422 (GOl), IRBCX-462 (WOl),

IRBCX-512 (VOl), IRBCX-541 (VlO), and IRBCX-551 (V20), while Position Control

board (PCON) is used for IRBCX-532 (V40).

2.4.1 Functions of Servo Control Board

One Servo Control board is capable of controlling the servo system for a maximum

of 3 axes. The functions are a s follows:

(1) Processes arithmetic operations a t high speed necessary to control the servo

system.

(2) Controls the position, speed and current loops in the servo system, and generates

switching signals to drive the servo motors.

(3) Receives encoder signals.

(4) Receives position data from the absolute encoders.

(5) Detects various failures relating to the servo system.

(6) Outputs encoder signals to the Line Master.

2.4.2 Operation Status l nd icators of Servo Control Board

The Servo Control board is equipped with two kinds of LEDs; one is green and the

other is red. In the normal condition, the green LED is ON and the red LED is OFF.

A ON/OFF combination of these LEDs helps you to identify the cause of a failure.

For details, see Table 2.4.2.1.

Internal Configuration of Control Un i t 2 - 9

Table 2.4.2.1 LED Indications of Servo Control Board

1 1 The encoder cable is disconnected or unconnected. Power is not supplied to the encoders. Encoder failure.

2. Overheat of power transistor The motor load is too large.

3. Unconnected cable between Servo driver and Servo Control board. 4. Overcurrent (The OC LED of Servodriver also illuminates.)

The motor load is too large. Any setting of motor selector rotary dip switches, 3/4/5 is wrong. The motor cable is short-circuited. The ramps of motor acceleration/deceleration are too large.

The main power supply is abnormal. The ramp of motor deceleration is toolarge. (Error detected in the hardware)

1. Normal 2. Motor overheat

The motor load is too large.

I

1 1 3. Undervoltage of main power supply

1 5. Overvoltage of main power supply

I I The main power supply is abnormal. The primary supply voltage has dropped.

1 I The connectors of the main power supply and control power supply

I I are disconnected or unconnected. 4. Halt signal input 5. Over limit of momentary current

The motor load is too large. Any setting of motor selector rotary dip switches, 3/4/5 is wrong The motor cable is short-circuited. The ramps of motor acceleration/deceleration are too large.

6. Over limit of speed detection 7. Over limit of position deviation 8. Overcurrent

The motor load is large. Any setting of motor selector rotary dip switches, 3/4/5 is wrong. The ramps of motor acceleration/deceleration are too large. (Error detected in the software)

1. Voltage drop of Servo Control board 2. No input of synchronizing signal

Synchronizing signal between Servo Control board and Motion Control board is abnormal.

3. Imperfect cable connection between Servo driver and Servo Control board 1 / 4. Supolv voltage drop or power shut-off within Servo driver

A * " - 0 0 / Supply voltage drop of Servo Control board

@: ON 0: OFF

2 - 1 0 Internal Configuration of Control Unit

2.4.3 Switch Settings of Servo Control Board

(1) Reset Switch SW1

This switch causes the Servo Control board to be reset.

Normally, it does not need to be pressed.

SW 1 but

is a P u s h ton switch

/- 0 Green LED

0 R e d LED -r

Location o f each switch

SW2-SW8 are rotary s w i t c h e s

Fig 2.4.3.1 Location of Each Switch on Servo Control Board

(2) Board Identify Switch SW2

The robot control unit is equipped with multiple Servo Control boards. This switch

is used to set a identification number to define the servo system (axes) controlled by

the Servo Control board. For a standard ALMEGA G01, W01, V01, V10, o r V20, the

switch is preset a s shown in the Table 2.4.3.1:

Table 2.4.3.1 SW2 Settings

Printed Board No. / Slot NO. I SW2 Setting I Servo System Controlled

PCB12 (SCON3) 51 - 12 / 5 2 - 1 2 1 External Axis ( o ~ t i o n )

PCB14 (SCON1)

PCB13 (SCON2)

External Axis

51 -2 52-2 51-1 52-1

PCBll(SCON4) (option)

-

* 1: A standard control unit does not have a slot. Internal Configuration of Control Uni t 2 - 1 1

1

2

51-11*1 52-11

GO1/WO1/V01/V10/V20: Axes 1-3 GOl/WOl: Axes 4/5 VOl/VlO/V20: Axes 4-6

4 External Axis

(3) Axis Setting Switches SW3, SW4, and SW5

Theses switches a r e used to set moving axes of the manipulator controlled by the

Servo Control Board. One board capable of controlling up to 3 axes has 3 switches,

SW3, SW4, and SW5. The settings and corresponding moving axes a r e shown in

Table 2.4.3.2:

Table 2.4.3.2 SW3, SW4, and SW5 Settings

SW3/4/5 Settings 1 Corrsponding Axes of Manipulator

1 GOl/WOI: Axes 4/5, and unused axes

/ G01: Axes 1/2

1

2

1 VOl : Axes 21'3

V01: Axes 4/5/6

GO1 : Axis 3

1 V01: Axis 1

1 V10: Axes 4/5/6

/ V20: Axes 4/5/6 WO1 :Axis3

1 V10: Axes 2/3

V10/W01: Axis 1 V20: Axes 1/2/3

The settings, 3, 5, 6, 9 and F, do not correspond to moving axes of the manipulator.

E

(4) Switch to set the number of controlled axes SW6

WOl: Axis 2

This switch is used to set the number of axes in the servo system controlled by the

Servo Control board. The settings and number of controlled axes a r e shown in Table

VOl/VlO/V20 : SCONl (PCB14)/ SCON2 (PCB13)

GO1 : SCONl (PCB14)

Table 2.4.3.3 SW6 Settings

2 1 1 / External axis, etc.

SW6 Setting

2 - 1 2 Internal Configuration of Control Un i t

NO. of Controlled Axes Example of Application

(5) Spare Switches SW7 and SW8 (not provided on L4268R) Normally, set them to 0.

(6) Standard settings of Switches

For a standard robot control unit, the switches described above a r e preset as

shown in Tables 2.4.3.4 through 2.4.3.8: (These settings may vary, for example, if an

external axis is added. Therefore, be sure to check the settings before replacing the

Servo Control board.)

Table 2.4.3.4 Settings for IRBCX -422 (ALMEGA G01)

Table 2.4.3.5 Settings for IRBCX-462 (ALMEGA W01)

Table 2.4.3.6 Settings for IRBCX - 512 (ALMEGA V01)

P r i n t e d B o a r d Axis 1 1 1 1 1 1 1 Manipulator SW2 SW3 SW4 SW5 SW6 SW7 SW8 1 60. Controlled

SW4

4

0

Manipulator

GO 1

SW2

1

2

Table 2.4.3.7 Settings for IRBCX-541 (ALMEGA VlO)

SW5

2

0

Printed Board

NO.

PCB14 (SCON1)

PCB13(SCON2)

SW3

4

0

vo 1

Axis

Controlled

Axes 1-3

Axes4-5

Table 2.4.3.8 Settings for IRBCX - 541 (ALMEGA V20)

SW6

0

1

PCB14 (SCON1)

PCB13 (SCON2)

Internal Configuration of Control Un i t 2 - 1 3

SW7

0

0

Axes 1-3

Axes 4-6

SW4

C

A

Manipulator

v10

SW8

0

0

SW2

1

2

1

2

SW5

C

A

SW3

D

A

Printed Board

No.

PCB14(SCONl)

PCB13(SCON2)

SW3

D

B

Manipulator

v20

SW6

0

0

Axis

Controlled

Axes l -3

Axes4-6

Axis

Controlled

Axes l -3

Axes 4-6

Printed Board

NO.

PCB14(SCONl)

PCB13 (SCON2)

8

1

SW4

D

B

SW2

1

2

7

1

SW5

D

B

SW6

0

0

7

1

0

0

0

0

0

0

2.4.4 Jumper Pin Settings of Servo Control Board

The Servo Control board is equipped with the following jumper pins used for various

settings:

(1) JT1: Setting for detection on/off of voltage drop of the servo motor driving power.

Normally, close 1-2 (to detect on).

(2) JT2: Setting for detection on/off of encoder disconnection of each axis connected

to the Servo Control board.

Normally, set the jumper pins which correspond to the axes connected to the servo

system a s ON, and the jumper pins which correspond to the axes unconnected a s

OFF. If the jumper pin which corresponds to an axis unconnected to the servo

system is set a s ON, an error message is displayed.

The axes numbers used for Servo Control board and ON/OFF settings a re shown

in Table 2.4.3.9:

Table 2.4.3.9 Axes Nos. and Settings for Detection ON/OFF of Disconnectioii

Corresponding Axis No* I Detection ON I Detection OFF --

1

2

Servo Control board but not of the manipulator.

3

(3) JT3: Normally, close 2-3

Close 8 - 9

Close 5 - 6

(4) Standard settings of Jumper pins

For a standard robot control unit, the jumper pins described above are preset a s

shown in Tables 2.4.3.10. and 2.4.3.11 (These settings may vary, for example, if an

external axis is added.

Therefore, be sure to check the settings before replacing the Servo Control board.)

Table 2.4.3.10 Settings for IRBCX-422/462 (ALMEGA GOl/WOl)

Close 7 - 8

Close 4 - 5

* The corresponding axis number is a axis number used for

Close 2 - 3

Printed Board Axis Manipulator 1 Controlled 1 1

Close 1 - 2


GOl/WOl PCB14 (SCON1)

PCB13 (SCON2)

Axes 1-3

Axes 4-5

Close 1-2

Close 1-2

Close 8-9, 5-6, 2-3

Close 8-9, 5-6, 1-2

Close 2-3

Close 2-3

Table 2.4.3.11 Settings for IRBCX-512/-541-1'551 (ALMEGA VOi/VlO/V20)

Fig. 2.4.4.1 Outside View of Servo Control Board


JT3

Close 2-3

Close 2-3

JT1

Close 1-2

Close 1-2

Axis

Controlled

Axes 1-3

Axes 4-6

Manipulator

v01/v10/v20

JT2

Close 8-9, 5-6, 2-3

Close 8-9, 5-6, 1-2

Printed Board

NO.

PCB14 (SCON1)

PCB13 (SCON2)

2.4.5 Functions of Position Control Board

One Position Control board capable of controlling the servo system of a maximum of

3 axes has the following functions:

(1) Receives position data from the absolute encoders.

(2) Converts a specified position received from the Main board to a specified speed.

(3) Detects Servo failures.

NOTE

Position Control boards used for OSACOM 8700 are not compatible with those for 6800 (IRBC-421/-511/-531) due to differences in the specifications.

2.4.6 Operation Status Indicators of Position Control Board

The Position Control board is equipped with the following indicators:

(1) LED 1 (Red) ON when an encoder is abnormal.

This LED illuminates when failure is detected in any encoder of three axes.

(2) LED 2 (Red) ON when monitored speed is abnormal.

This LED illuminates when the speed of any of three axes exceeds the monitoring

limit during teaching or manual manipulation.

The speed monitoring value is set with SW 1-3.

(3) LED 3 (Green) ON when the CPU properly operates.

This LED illuminates when the CPU on the Position Control board operates

properly, and goes out when the CPU does not properly operate due to failure, etc.

2.4.7 Switch Settings of Position Control Board

For a standard robot control unit for ALMEGA V40, the switches a re preset a s

shown in Tables 2.4.7.1 and 2.4.7.2:

Table 2.4.7.1 DSl/DS2/DS3 Settings for IRBCX-532 (ALMEGA V40)

2 - 1 6 Internal Configuration of Control Uni t

PCB14 (PCON1)

PCB13 (PCON2)

Axes 1 - 3

Axes 4 - 6

ON

OFF

ON

O F F 0

0

0

0000

0000

0

0

0000

000

00

00

0

0

0

0

0

0

0

0

00

00

Fig. 2.4.7.1 Outside View of Position Control Board

Table 2.4.7.2 RSWl/RSWZ/RSW3 Settings for IRBCX-532 (ALMEGA V40)

Internal Configurat ion of Control U n i t 2 - 1 7

RSW3

F

F

RSW2

F

F

RSWl

F

F

Printed Board No.

PCB14 (PCON1)

PCB13 (PCON2)

Axis Controlled

Axes 1 - 3

Axes 4 - 6

2.5 Servo Driver Unit L4000Q (GOI), L4001Q (V01) This unit consists of a set of servo drivers, and these types depend on the motor

capacity and quantity required for each manipulator type, as shown in Tables 2.5.0.1

through 2.5.0.6: (Some of the configurations may vary, for example, if a n external axis

is added.)

Table 2.5.0.1 Configuration of Servo Driver Unit IRBCX-422 (ALMEGA G01)

Manipulator / Servo Driver NO. 1 Par t NO. / Spec. 1 Capacity

Table 2.5.0.2 Confinuration of Servo Drive Unit IRBCX-462 (ALMEGA W01)

Axis Driven

GO 1

Table 2.5.0.3 Configuration of Servo Drive Unit IRBCX-512 (ALMEGA V01)

Table 2.5.0.4 Configuration of Servo Driver Unit IRBCX-541 (ALMEGA V10)

SD 1

SD2


5096-138

5096-139


Manipulator

v20

W-LO0455

W-LOO456

2 - 1 8 Internal Configurat ion of Control Unit

Servo Driver No.

SDl

SD2

Manipulator

30A X2+ 15A X 1

15AX2

Axes 1-3

Axes 4 - 5

Par t No.

5096-159

5096-155

Servo Driver NO. SDI

Spec.

W-LOO568

W-LOO553

Par t No. 5096-1 15

Capacity

50A X 3

15AX3

Spec. W-LOO395

Axis Driven

Axes 1-3

Axes 4 - 6

Capacity 2.5kw

Axis Driven Axis 1

2.5.1 Functions

The Servo Driver supplies power to the servo motors in response to a control signal

transmitted from the Servo Control board, and has the following functions:

(1) Converts a control signal transmitted from the Servo Control board to power for

driving the servo motors and supplies the power to the servo motors.

(2) Indicates failures detected in the servo motor driving system on the servo driver

panel and transmits the data to the Servo Control board.

(3) Detects the current of each servo motor and transmits the data to the Servo

Control board.

2.5.2 Operation Status Indicators

The servo driver panel is equipped with 4 kinds of LEDs; RDY (Green), OH (Red),

OC (Red) and OV (Red). When a servo failure occurs, the indications of these LEDs

allow you to identify the possible cause. The LED indications and possible causes a re

shown in Table 2.5.2.1.

Table 2.5.2.1 LED Indications and Possible Causes

(@:ON, 0 : O F F ) ( * :Possible Cause)


0

*

*

0

*

*

*

*

L E

Cause

@

*

*

RDY(green)

OH (red)

OC (red)

OV (red)

0 0

*

*

*

@

0 0 0 0 @ @ @ @ 0 0 0 0 @ @ @ @ 0 0 @ @ 0 0 @ @ 0 0 @ @ 0 0 @ ~ @

0 @ 0 @ 0 @ 0 @ 0 @ 0 @ 0 @ 0 1 @

Motor main voltage over

385V

Motor main voltage below

170V.

Power transistor heating

error in any axis.

Overcurrent in any axis

Blown fuse of any axis

Overvoltage in any axis

Servo Control board in the

reset state

0

*

@

*

*

0

* * * * * * * *

I

@

*

*

*

*

@

*

*

@

* * * * * * * *

*

0

*

@

*

*

*

0

* * * *

*

*

@

*

*

*

*

*

Power I/F Board

CN3, CN5, CN7

connected to

Manipulator

(motor)

Servo Control Board

CN4, CN6, CN8, connected to Servo Power Supply Unit connected connector

fo r Servo Control Board

Glass Tube Fuse 5A-15.4 specified Driver (200W rnax.)

10A-30.4 specified Driver (500W min.)

10A-50A specified Driver (1200W)

Fig. 2.5.2.1 Outside View of Servo Driver


2.6 Servo Power Unit E5499A or E5787A

2.6.1 Functions

This unit supplies power for driving the servo motors, and has the following

functions:

(1) Supplies DC (Direct Current) voltage of the power source for driving the servo

motors to the servo drivers.

(2) Absorbs the regenerative voltage produced by the servo motors.

Fig. 2.6.2.1 Panel of Servo Power Unit


(1) POWER LED (Green)


0 0

O

0

T B l O

o C N 6 5 0

This LED illuminates when the 3-phase

ACZOOV is supplied to the Servo Power unit by

turning on the servo power. If it is not ON,

check whether the 3-phase ACZOOV is supplied

a t each of terminals, R, S, and T of TB10, a s

the primary power phases could be lost.

(2) RE.GEN LED (Yellow)

This LED illuminates when the Servo Power

unit is absorbing the regenerative voltage

produced by the motors. It repeats ON and

OFF during a normal automatic operation.

If it stays ON, check the voltage a t terminals

P-N, a s the output voltage of the Servo Power

unit may have increased. (The proper output

voltage; DC280V)

2.7 Backplane Board L3702F (or L3700F) 2.7.1 Functions

This printed board relays signals transmitted from each printed board in the robot

control unit, and has the following functions:

(1) Relays bus signals within printed boards such a s Main Processor board, Motion

Control board, 1/0 Management board, and Servo Control boards.

(2) Relays signals transmitted from the peripheral equipment connected to the robot

control unit to each printed board.

2.7.2 Connectors The Backplane board is equipped with the connectors shown in Table 2.7.2.1 to

connect peripheral equipment.

Table 2.7.2.1 Connectors on Backplane Board

Connector Equipment to be connected Spare Teaching box

CN18 Personal com~u te r , etc. CN19 / Line h4aster

O SCON3 SCON2 SCDN! IKON0 CSP VAIN OPTION IX) O

v

IC124 (Optical Fiber)

Fig. 2.7.2.1 Outside View of Backplane Board (L3702F)

(L3700F does not has a slot for SCON3.)

Welding interface o r Robot dedicated welding power unit


2.7.3 Switch Settings

(1) Jumper Pin (JP10) (Not provided for L3700F)

This jumper pin is set to select whether a 3rd Servo Control board (SCON3) is used

or not. Open it if the control unit is equipped with a 3rd Servo Control board to

connect an external axis (axes), or close it if only 2 Servo Control boards for a

single robot system. (See Table 2.7.3.1.)

Table 2.7.3.1 JPlO Settings

3 boards (for system using an external axis) I Open

-

The number of Servo Control boards mounted

2 boards (for single system)

(2) Dip Switch: DSW 100

The Backplane board is equipped with a dip switch to confirm that the connected

mechanism (Manipulator) matches the mechanism configuration defined in the

system program. Set the switch according to the manipulator type to be connected,

as shown in Table 2.7.3.2:

Table 2.7.3.2 DSWlOO Settings

JPlO Setting

Close

1 DSWlOO Settincrs Manipulator Type

IRB-5ll(VOl) 1 y: 1 1 [O 1 !: IRB-541(V10)

IRB - 551(V20) ON OFF

- -

IRB-421(G01)

IRB-461(W01)

.d

The settings in Table 2.7.3.2 are for a standard control unit, and may vary if an

external axis is added.

ON

OFF

-

IRB-531(V40)

Internal Configuration of Control Unit 2 - 2 3

4 1

ON

ON

OFF

2 3

ON

OFF

OFF

ON

ON

ON ON

2.8 l nterlock Board L3899Y 2.8.1 Functions

This printed board controls various internal and external 1/0 signals of the control

unit, and has the following functions:

(1) Controls the sequence circuits of the high voltage system and 24V system.

(2) Receives general and specialized input signals of Operation panel, Starting box, etc.

(3) Controls general and specialized output signals of Operation panel, Starting box,

etc.

(4) Controls the manipulator brakes.

(5) Charges the absolute encoder charging batteries when the primary power is ON,

and supplies the backup power to the absolute encoders from the charging batteries

when the power is shut off.

(6) Detects overdischarge and abnormal voltage by monitoring the voltages of the

charging batteries, and cuts off the charging batteries from the load when

overdischarge is detected.

(7) Outputs signals to reset the absolute encoders.


The interlock board is equipped with LEDs shown in Table 2.8.2.1 to indicate the

operation s ta tus of the sequence circuits in the control unit.

Table 2.8.2.1 Operation Status Indicators of Interlock Board -

LEDNa

LED101 1 (Green)

LED203 1 (Green) 1 Teach Mode 1 ON indicates Teach Mode

LED201

LED202

LED204 1 (Green) I Running 1 ON indicates Running

Function

Servo Power ON

LED205 1 (Green) / Halted 1 ON indicates Halted

Status

ON indicates Servo Power ON

(Green)

(Green)

LED303 I (Green) 1 Servo ON Permit / ON indicates Servo ON Permit

Teaching Box Servo ON

Auto Mode

LED301

~ ~ ~ 3 0 2

ON indicates Teaching Box Servo ON

ON indicates Auto Mode

Shock Sensor

(Green)

(Green)

LED304 OFF indicates that the shock sensor is

operating. (Green)

Shock Sensor ON

Servo Shut Off

Emergency Stop

ON indicates Servo Shut Off when the

shock sensor operates

OFF indicates Servo Shut Off

OFF indicates Emergency Stop


LEDNa

Voltage Drop of LED502 1 (Red) 1

Charging Battery

Function

Auto Mode Input

Teach Mode Input

Start Nal Input

Start Na2 Input

Start No.3 Input

Halt Input

Charging Current ON

LED401

LED402

LED403

LED404

LED405

LED406

LED501

ON indicates Voltage Drop

(below 380V)

Overvoltage of 0 1 (Red) 1

Charging Battery

Status

ON indicates Auto Mode Input

ON indicates Teach Mode Input

ON indicates Start Nal Input ON

ON indicates Start No.2 Input ON

ON indicates Start Na3 Input ON

ON indicates Halt Input

ON indicates Charging

(Green)

(Green)

(Green)

(Green)

(Green)

(Green)

(Green)

ON indicates Overvoltage

LED601

LED602

2.8.3 Switch Settings

(1) Reset Switch SWl

This push button switch causes the absolute encoder data of all the axes to be

cleared to 0. In order to set the absolute offset values, for example, when the robot

is installed, it is necessary to reset the absolute encoders by pressing this switch.

Do not press it for any purpose other than this. If you do, the origin of the robot

LED603

will change.

(2) Reset Mask Switch DSWl

This dip switch is used to prohibit the absolute encoder data from being carelessly

reset. The function and setting corresponding to each bit of this switch for a

standard control unit are shown in Table 2.8.3.1:

Table 2.8.3.1 DSWl Settings

(Green)

(Green)

(Green)

I ON 1 causing resetting the absolute encoders with the teaching box to be

Overrun Detection Input (1)


invalid.

OFF disables a reset switch SW1 on Interlockboard, causing

OFF indicates Overrun of any of axes 1-3.



Function

OFF disables any reset signal input from Motion Control board,

DSWl


Setting


2 ON resetting the absolute encoders to be invalid.

(3) Jumper Pin Settings

The interlock board is equipped with jumper pins shown in Table 2.8.3.2. Set these

jumper pins according to your robot system configuration.

Jumper Pi1

JP301


Table 2.8.3.2 Jumper Pin Settings of Interlock Board

Function Sets Emergency Stop inputs of Terminal Block

it and Relay unit ON/OFF. If the control unit equipped with Terminal block unit o r Relay unit,

be sure to open this jumper pin. I Sets Emergency Stop input of Operation panel (or Operation box) ON/OFF. To connect the Operation panel (or Operation box), be sure to open this jumper pin. Sets Emergency Stop input of Starting box 2 ON/ OFF. To connect the Starting box 2, be sure to open this jumper pin. Sets Emergency Stop input of Starting box 3 ON/ OFF. To connect the Starting box 3, be sure to open this jumper pin. Selects connection (CN40 o r TB1) of Shock Sensor Input signal. To connect Shock Sensor Input signal to CN40 via External Axis board, open this jumper pin, o r to connect to TB1, close it. (A standard control unit is not equipped with External Axis board.) Sets detection ON/OFF of charging circuit failure of External Axis board. If the control unit is equipped with External Axis board, open this jumper pin. Sets Overrun Detect signal connected to CN71 ON/ OFF. If the manipulator connected to CN71 via Control cable 3 is equipped with a overrun detect switch, open this jumper pin (ON). Sets Overrun Detect signal connected to CN72 ON/ OFF. To use any external axis (such as a slider and positioner) and connect a Overrun detect switch for external axis to CN72, open this jumper pin (ON). Sets Encoder Cable Connection Check signal for external axis ON/OFF. To use any external axis, open this jumper pin (ON) according to the number of external axes.

Standard Setting Close (if equipped with neither Terminal unit nor Relay unit) Open (if equipped with Operation panel (or Operation box))

Close (not to connect Starting box 2) Close (not to connect Starting box 3) Close (terminals 4-5 of TB1 not to connect a shock sensor)

Close (if not equipped with External Axis board)

Close (not to use any external axis)



2.8.4 Fuses and Connectors

The interlock board is equipped with fuses shown in Table 2.8.4.1.

To replace a blown fuse, remove the cause, and use a fuse which has the same rating.

Table 2.8.4.1 Fuses on Interlock Board

Fuse Na

250V, 3A 1 tube fuse

I , Rating

Power supply for releasing the manipulator brakes

F2

Application

F3

The Interlock board is equipped with the connectors shown in Table 2.8.5.lto connect

peripheral equipment:

250V, 1A

glass tube fuse

F4

Table 2.8.4.2. Connectors on Interlock Board

AClOOV power supply for the welding interface

250V, 3A

glass tube fuse 24V system in the control unit

250V, 2A

glass tube fuse

1 Operation box (Start I)

AC8.5V for charging

Connector Peripheral Equipment to be connected

CN33 1 Starting box 3

I

I

CN32 Starting box 2

CN67

CN68

Manipulator (power supply for brakes)

Manipulator (power supply for brakes)

CN69

CN70

When Operation box and Starting boxes are connected, set also the jumper pins a s

External axis (power supply for brake)

Manipulator (overrun, batteries, et'c.)

CN71

CN72

shown in Table 2.8.3.2.

Manipulator (overrun, batteries, etc.)

External axis (power supply for brake)


2.8.5 Connecting J i g Terminals on Interlock Board

(1) Connecting TB1

1 Emergency Stop Input Terminals (1 - 3)

Used to connect a n external emergency stop switch. For the use of multiple switches, connect in series. If this switch is not used, close terminals 1-3 with a jumper wire.

Servo OFF Input Terminals (2-3) Used to connect a n external Servo OFF switch. If this switch is not used, close terminals 2-3 with a jumper wire.

Shock Sensor Input Terminals (4-5) Used to connect-a shock sensor but not via a Control cable. If a shock sensor is not used, close JP305 and terminals 4-5 with a jumper wire.

Input Common (6 and 7) These a r e common terminals of

l-----l terminals 8- 14.

I @ IIServo ON Indicator Lamp Output Terminal (8) I-, To mount a n external Servo ON

I indicator lamp, connect to terminal 8-INCOM (terminals 61'7). (Connectable indicator lamp must be; DC24V and current consum~t ion not I @ Il \greater than 0.1A.)

o ode Switching Input Terminals (9/10) 171 To input Auto/Teach modes through - I I \ an external switch, connect to these I @ lJ \ terminals - INCOM.

'start Input Terminals (11/12/13) To input Starts(l/2/3) through an external switch, connect to these terminals - INCOM.

Halt Input Terminal (14)

0 To input Halt through a n external switch, connect to this terminal - INCOM.

\ Servo ON Input Terminals (15-16) To turn on the servo power through a n external switch, connect to terminals 15-16.


(2) Connecting TB2

Emergency Stop Output Terminals(1-2) Open between terminals 1-2 during emergency stop.

,Mode State Output Terminals (3/4) Closed between terminal 3-OCOM in Auto mode, and between terminal 4 - OCOM in Teach mode.

Start/Halt Output Terminals (5/6) Closed between terminal 5-OCOM in a starting statet, and between terminal 6-OCOM in a halted state.

Output Common Terminal (7) Common terminal of terminals 3-6.

I @ 1' / Output (Indicator Lamp) Common Terminal (8) Common terminal to connect indicator lamps to terminals 9- 14.

Indicator lamp Output Terminals (9 - 14) The indicator lamp connected to each terminal illuminate in the following state: (Connectable indicator lamps must be; DC24V and current consumption not greater than 0.1A.l

LAMP1 (Terminal 9) : Auto Mode LAMP2 (Terminal 10): Teach Mode LAMP3 (Terminal 11): Star t 1 LAMP4 (Terminal 12): Star t 2 LAMP5 (Terminal 13): Star t 3 LAMP6 (Terminal 14): Halt

Servo ON Terminals (15-16) Closed between terminals 15- 16 in a servo ON state.


Fig. 2.8.5.1 Outside View of Interlock Board

2.9 Constant Voltage Power Supply W-LO0203

2.9.1 Functions

This unit supplies power to the printed boards, etc. in the control unit, and has the


(I) Supplies DC5V, DC+ 15V, DC- 15V, and DC24V to each of the units, printed boards,

etc.

(2) Indicates the output state of each voltage with LED.


This unit is equipped with a LED per voltage supplied by the constant voltage power

to indicate the operation status.

As the LED may illuminate even if the output voltage is not a proper value, check


each voltage with a tester, etc. The normal range of each output voltage is shown in

Table 2.9.2.1:

Table 2.9.2.1 Output Voltages of Constant Voltage Power Supply Unit

Current Consumption

6A

Output Voltage

5V

Normal Voltage Range

5.OOV-5.2OV

CAUTION 1. The GNDs for 5V and t 15V power supplies are shared in the constant

voltage power supply unit. 2. The OV side terminal of 24V power supply is isolated from the GND

terminals for 5V, 2 15V power supplies. 3. The output voltages of the constant voltage power unit are pre-adjusted in

the normal range. However, if any voltage is not in the normal range due to, for example, replacement of the unit, it can be changed by adjusting the potentiometer. (Because overvoltage may damage the printed board, etc., care care should be taken to adjust it.)

+5V power supply f 24V power supply +/-I5 power supply I I I

/ Potentiometer for adjusting 24V output voltage

/potentiometer for adjusting 5V output voltage

Fig.2.9.2.1 Bottom View of Constant Voltage Power Unit

(3 u '

5Y t15Y -15V 24V

0 0 0 0

5v

5v

DM3

O M

+15V

GM) CN42

-1sv

2%'

ov

FG

*$I CN4 1

T B 5

\ f l L/

Fig.2.9.2.2 Front View of Constant Voltage Power Unit


2.m Terminal Block Unit E5741A (Option) and Relay Unit E5685A (Option)

2.IO.1 Functions of Terminal Block Unit

This printed board connects 1/0 signals of external equipment such as a jig, and has

the following functions:

(1) Receives 20 general physical inputs.

(2) Outputs 20 general physical outputs with open collector.

The specifications of a relay, etc. connectable to terminals must be; DC30V and

current not greater than 100mA. (For detailed explanations of general physical

inputs/outputs, refer to the instruction manual for "Interfacing with Jig" .)

WARNING To use a Terminal Block unit o r Rely unit, open jumper pin JP301 on Interlock board, as shown in Table 2.8.3.2.

2.10.2 Connecting External Equipment (Jig, etc.) via Terminal Block Units

To connect external equipment (such a s a jig) to the Terminal Block unit, refer to

the following circuit configurations:

(1) Input Circuit Configuration (TB13/14)

The inputs transmitted from external equipment a re connected to the robot control

unit through the Terminal Block unit of the circuit configuration shown in Fig.2.10.2.1.

The maximum DC30V/10mA flows through switches connected to the input terminals

of the Terminal Block unit.

4 " ~ o b o t Control Unit Ci

I Ti313

I

Fig. 2.10.2.1 Input Circuit Configuration


(2) Output Circuit Configuration (TB111'12)

The outputs transmitted from the robot control unit a r e connected t o external

equipment through the Terminal Block unit of the circuit configuration shown in Fig.

2.10.2.2. The specifications of a relay, etc. connectable to the output terminals of the

Terminal Block unit must be; DC24V and current not greater than 100mA.

For load of a relay, etc. to be

connected, at tach a diode for

absorbing surge o r a surge

absorber.

Tai 1 n

TIT Fig. 2.10.2.2 Output Circuit Configuration

(3) Connecting External Power Supply for Outputs

The external power supply for outputs of the Terminal Block unit can be connected

as shown in Fig. 2.10.2.3:

Fig. 2.10.2.3 External Power Supply to Terminal Block Unit


T B 1 3 T B 1 4 in ' 0 A ] 1-1;Fl FC23 T B l I T B 1 2 C N 2 2 t-

O O @ O O O @ O O @ O O O O O O O O O O O O O O O O 0- 0

Fig. 2.10.2.4 Outside View of Terminal Block Unit

(4) Fuse

The Terminal Block unit is equipped with a fuse as shown in Table 2.10.2.1. If the

fuse is blown, replace with a fuse that has the same rating after removing the cause.

Table 2.10.2.1 Fuse on Terminal Block Unit

Fuse No. 1 Rating 1 Application


250V, 2A 1 Glass tube fuse 24V system for external outputs

2.10.3 Functions of Relay Unit

Like a terminal block unit, this printed board connects 1/0 signals of external

equipment such as a jig, and has the following functions:

(1) Receives 20 general physical inputs.

(2) Outputs 20 general physical outputs with relay contact.

(3) Connects up to 3 Starting boxes.

Fig. 2.10.3.1 Outside View of Relay Unit


2.10.4 Connectors and Jumper Pins on Relay Unit

The Relay Unit is equipped with connectors to connect Starting boxes, as shown in

Table 2.10.4.1. When Starting boxes a r e connected, set also jumper pins.

Table 2.10.4.1 Connectors on Relay Unit

CN35 / Starting Box 5 1 To connect Starting Box 5, be sure to OPEN JP2.

Connector

CN34

2.1 1 Charging Battery Unit W-LO0471 (Not mounted on I RBCX-532)

2.1 1 .I Functions

The control unit is equipped with a charging battery unit to backup the da ta of the

absolute encoders used for the manipulator. This battery unit is charged while the

control power supply is turned on and supplies backup power to the encoders while the

control power supply is shut off. Therefore, if the robot is not used for a long time, the

residual battery capacity may not be enough to supply power t o the encoders. In this

case, before performing automatic operation, be sure to carry out the manipulator

origin alignment.

Starting Box

Starting Box 4

CN36

2.1 1.2 Specifications

Nominal voltage

Capacity

Discharge voltage

Note

To connect Starting Box 4, be sure to OPEN JP1.

2.OV X 2(2 charging batteries in series)

25AH

3.8V-4.2V (when load is connected)

Starting Box 6

2.1 1.3 Replacing Charging Battery Unit

The charging batteries degrade in the course of repetitive charges and discharges.

Therefore, the unit must be replaced with a new one each time the 3 year periodic

inspection is performed.

To replace it, follow the steps below:

(1) Run the origin check program (P999) by block operation, and confirm that the

alignment marks match a t the origin. If not matched, mark that position with a

layout line.

To connect Starting Box 6, be sure to OPEN JP3.


(2) Remove the unit together with the connecting cable from CN47 of Interlock board

while the control power supply is turned on.

(3) Attach the cable to a new battery unit and connect to CN47 of Interlock Board.

(4) Run the origin check program (P999) by block operation, and check that the

alignment marks match a s (1).

A WARNING 1. If the charging battery unit is removed when the control power supply is

turned off, the data of the absolute encoders will be lost. 2. The output of the charging battery unit is supplied to the absolute encoder of

each axis through CN70/CN71 of Interlock board and CN2/CN3 of Manipulator. Therefore, regardless of the ON/OFF status of the control power supply, if these connectors are disconnected, the data of the absolute encoders will be lost. When these connectors were removed to perform maintenance, inspection, etc., be sure to carry out the origin alignment.

3. The battery backup duration may be shortened depending on the operating condition of the robot, the ambient temperature, etc.

2.12 Memory Battery L3391V

2.12.1 Functions

The Memory Battery has a function to backup the data, such a s teaching data and

system parameters, stored in the memory on Main Processor board, and supplies

backup power to Main processor board via Backplane board.

2.12.2 Specifications

Type

Nominal voltage

Primary lithium battery

3.0V

2.12.3 Replacing Memory Battery

Though the life of the memory battery varies according to the operating condition

and environment, etc., replace it with a new one when Alarm indicating a battery

voltage drop is displayed or each time the 3 year periodic inspection is performed.

To replace the memory battery, follow the steps below:

(1) Store the teaching data and the system parameters to the external storage.

Internal Configurat ion of Control U n i t 2 - 3 7

(2) Remove the memory battery from CN4 of Backplane board while the control power

supply is turned on.

(3) Connect a new memory battery to CN4.

(4) Transfer the teaching data and the system parameters from the external storage.

CAUTION (1) Replace the memory battery that has been used for more than 3 years, even

if the voltage is normal.

(2) Because the memory battery is not a charging battery, never charge it. Otherwise, it will be damaged.

(3) The battery backup duration may be shortened depending on the operating condition, the ambient temperature, etc.

2.13 Switch Box E5760 or E5809

2.13.1 Functions

The Switch Box has the following functions:

(1) Supplies AC200V and lOOV to each unit in the control unit after eliminating a noise

from the primary power.

(2) Supplies DC5V to the servo drivers and absolute encoders.

(3) Turns the servo power supply ON/OFF.

(4) Supplies AClOOV to the external storage. (Rating: 1A)

2.13.2 Fuse

The switch box is equipped with a fuse shown in Table 2.13.2.1

When the fuse is blown, remove the cause, and replace with a new one that has the

rating below:

Table 2.13.2.1 Fuse on Switch Box

Fuse N a m e Rating 1 Application - = 1 2 5 v / l ~ 1 100V power supply for external storage

Glass tube fuse


cm74 - A a W V

-OUTPUT I Z O A I

_I

AC 1 OOV INPUT

T

S

R

-

- A C Z W V I NPUT

-

E

Fig. 2.13.1.1 Outside View of Switch Box

Internal Configuration of Control Uni t 2 - 3 9

2.14 Auxiliary Transformer W-LO0470 2.14.1 Func t ions

The auxiliary transformer TF1 has the following functions:

(1) Outputs AC8.5V used for power supply to charge the charging battery unit.

(2) Outputs AClOOV used for releasing the brakes, for the welding interface, for

driving the magnetic switches, and for the external storage.

2.15 Step-down Transformer (Option) The primary input voltage of the control unit is; 3-phase AC200V+10% and - 15%

(50/60Hz). To apply the input voltage other than the above rating, the step-down

transformer is available, which can step down the voltage of the power supplied t o the

control unit to 200V.

2.E.1 T y p e s of Step-down T r a n s f o r m e r s

Table 2.15.1.1 shows the types and capacities of Step-down transformers. I t is

necessary to select a n appropriate transformer according to the system configuration

(capacity of the load).

Table 2.15.1.1 Types of Step-down Transformers

T ip - 1 Capacity Examples of Applicable

System Configuration (Note)

/ Single G01, W01 o r V01, GO1 + 2 W-LO0246 3kVA built-in

1 / external axes, and V01 + 1 external axis

W-LO0557

Built-in type: Built in the control unit

Separate type: Installed outside the control unit

W-LO0558

A CAUTION \

These examples a r e given for your reference. To select a step-down transformer, contact DAIHEN.

7kVA separate


Single V10, V20, o r V40, GO1 + 3-7

external axes, and V01 + 2-6 ext.

l2kVA separate Systems using the number of axes

more than the above

2.15.2 Connecting Step-down Transformer

The way of connecting a step-down transformer depends on the type, Built-in o r

Separate, as shown in Fig.2.15.2.1 o r Fig.2.15.2.2, respectively:

- - -- I - - ~ r e a k e r sGC- down power un i t PsKF

Primary

Power

Supply

~ r a n s f o k e r (Built-in) Switch Box SBI

Primary

Power

Supply

1 Robot Control Unit - - - - - - -- i

Fig.2.15.2.1 Connecting Step-down Transformer (Built-in Type)

-.."------ - - - - -- - - - - Step-d0wn 1 r Breaker Power Unit PSI

Breaker Transformer . , NFRl Switch BOX S B ~

Fig.2.15.2.2 Connecting Step-down Transformer (Separate Type)


2.15.3 Voltage Switching Taps of Step-down Transformer

The step-down transformer is applicable to the primary-side input voltages; ACISO,

200, 208, 220, 230, 240, 380, 400, 415, 440, 460, 480, and 515V. As shown in Fig. 2.15.3.1,

the step-down transformer is equipped with voltage switchiilg taps to select a voltage

from among these voltages. According to the voltage of the power supply used, switch

the taps by connecting jumper wires a s shown in Table 2.15.3.1.:

Fig. 2.15.3.1 Voltage Switching Taps of Step-down Transformer

Fig. 2.15.3.2 Internal Circuit of Step-down Transformer


b WARNING T o safeguard against electric shock, before attempting to switch the voltage taps , make su re tha t no voltage is impressed to the step-down transformer. In addition, some safety measures should be taken, for example, by providing a

notice plate indicating "Working" a t the switch of the power source s o tha t the control unit cannot be carelessly energized during the work.

Supply

Voltage

Table 2.15.3.1 Connecting Jumpers According t o Pr imary Supply Voltage

P r i m a r y T a p

P r imary

Second-

a r y T a p

J u m p e r C o n n e c t i o n


220V

230V

240V

380V

400V

415V

U-U8, U4-U12, U4-V, V-V8, V4-V12, V4-W, W-W8, W4-W12, W4-U



U1-U8, US-V, V1-V8, V9-W, W1-W8, W9-U

U2-U8, U10-V, V2-V8, V10-W, W2-W8, W10-U

U3-U8, U11-V, V3-V8, V11-W, W3-W8, W11-U

R-TI ,

R1-S,

and

S1-T

Fig. 2.15.3.3 Connection Example of Input Voltage 240V

i 6 0 Fig. 2.15.3.4 Connection Example of Input Voltage 415V

unit. Before turning on the power supply, be sure to check that the jumper wire connections a r e correct and appropriate to the actually supplied voltage.


2.1 6 Power Unit E6029A 2.16.1 Functions of Power Unit

The Power Unit is the one to supply to the printed boards and the like used within

the control unit, and has the following function:

(1) Function to remove noise from the primary power source and to supply AC2OOV

and AClOOV to the units within the control unit.

(2) Function to supply DC5V,+ 15V, -15V, 24V power, and s o on to the units and

printed boards.

(3) Function to supply DC5.5V power to the Servo Control board and the absolute

encoder.

(4) Function to supply AClOOV power to External Memory Unit.

(5) Function to turn ON/OFF the servo power.

2.16.2 Specifications of Power Unit (1) Rated Output Voltage/Current DC5.5V 3A

DC5.2V 10A

DC+15V 0.5A

DC-15V 0.5A

DC24.2V 1.5A

(2) Dimensions 300(H) X 125(W) ~250(D)mm

(Inside Layout of Unit) (Front View of Panal)

Fig.2.16.2.1 Outside View of Power Unit and Inside Layout of Unit


2.16.3 Output Voltage of Power Unit The normal range of each output voltage of the Power Unit is as shown in TABLE

2.16.3.1.

Each output voltage of the Power Unit is set within the normal range a t shipment,

however when to exchange units due to failure o r so, confirm the voltage of the output

terminal in the table below

DC 5.5V 1 5.40-5.50V (no load) CN136 0-0 ( 0 : +) 1

TABLE 2.16.3.1 Output Voltage of Power Unit

I 5.10-5.2OV (with load) CN42 0-0 ( 0 : +) I PSU2-VR2

Adjustment Portion

Input Voltage

PSUl -VR1

15.0-15.4V (no load)

Terminal for Checking

TB16 @-@-a CNl50 0-0 CN135 0-0 ( 0 : +)

Rated Voltage

3 q5 AC2OOV

1 q5 AClOOV

5.05-5.25V (with load)

None

Normal Voltage RANGE

180-220V (no load)

90-110V (no load)

CN2A 0-0 ( 0 : +)

CN2B 0-0 ( 0 : -I-)

None

24.1-24.3V (no load) I CN41 @-@ (@ : +) I

-15.0%- 15.4V (no load)

CAUTION

1. Values marked with "no load" in the normal voltage range in TABLE 2.16.3.1 a r e ones measured with connector unconnected. While those marked with "with load" a re values measured with connector connected.

2. The GND of DC5V power source, that of +15V, and that of - 15V a r e in common within the Power Unit.

3. The terminal of DC24V power source a t 0 V side is insulated from the GND terminal of 5V, + 15V, and - 15V.

i

CN2A @--@ (0 : -1

CN2B @-@ (0: -1


T e r m i n a l B l o c k

,/' N -I OJ - + L_JOLED i

VFI 1

Fig.2.16.3.1 Pa r t s Layout of Constant Voltage Unit (PSU1)

F o r

CN6 CN5 CN4

Fig.2.16.3.2 P a r t s Layout of Constant Voltage Unit (PSU2)

4 8 Internal Configuration of Control Uni t

F o r

2.16.4 Fuse of Power Unit

The Power Unit contains the fuse shown in TABLE 2.16.4.1.

When to exchange fuses due to melting, first remove the cause and exchange the

defective fuse with a new one of the same rating.

TABLE 2.16.4.1 Fuse of Power Unit

2.16.5 Connectors of Power Unit

The Power Unit is equipped with connectors shown in TABLE 2.16.5.1 to supply

Fuse NO.

F1

power source to units inside.

Application

AClOOV Power Source for

Floppy Disk Storage Unit

Rating

250V,lA

Glass Tube Fuse

( $6.4~3Omm)

TABLE 2.16.5.1 Connectors of Power Unit

P a r t No.

4610-008

CN42 1 (Internal) j Backplane Board (CN10) 5V, t15V

CN2 / (Internal) i Servo Driver 1 (CN2) 5V, i- 15V

CN2B / (Internal) i Servo Driver 2 (CN2) 5V, ?c 15V

CN2C / (Internal Spare) Servo Driver 3 (CN2) 5V, t 15V

CN137 I (Internal Spare) Servo Control Board 3 (CN6) 5.5V

CN135

CN136

CN138 / (Internal) Interlock Board (CN38)

(Internal) j Servo Control Board 1 (CN6) 5.5V

(Internal) j Servo Control Board 2 (CN6) 5.5V

CN150 / (Internal) j AC Outlet AClOOV

A CAUTION > To avoid damage for the components of Robot Coutrol Unit, never use the

internal spare and internal connectors in TABLE 2.16.5.1 for other purpose.


Chapter 3 Peripheral Equipment o f Robot Control Un i t

Contents

3.1 Teaching Box ......................................................................................................................................................

3.1.1 Functions

3.1 . 2 Outside View of Teaching Box

3 1 3 Notes on Usage ........................................................................................................................................ . .

3.1 . 4 Internal Configuration .......................................................................................................................

3.2 operation panel ...................................................

3.2.1 switches and ti^^^

3.2 2 outside view and ~ ~ t ~ ~ ~ ~ l circuit ............................................................................................

3 3 Operation Box (Option)

3 3 1 Switches and Functions ..................................................................................................................... . .

3.3 2 Outside View and Internal Circuit

3 4 Starting Box (Option) ................................................................................................................................

3 4 1 Switches and Functions . . 3.4.2 connecting starting B~~ ..................................................................................................................

3 4 3 Outside View and Internal Circuit ........................................................................................... . . 3.5 Robot Dedicated Welding power Supply (option) .............................................................

3.5.1 Notes on Using Robot Dedicated Welding Power Supply

3.5.2 Outside View and Internal Configuration of Robot Dedicated

Welding Power Supply .........................................................................................................................

3.6 Welding Interface (Option)

3 6 1 Functions . .

3 . 6 . 2 Description of parts

3 6 3 printed Board E5624G ........................................................................................................................ . .

3 6 4 External Connection ............................................................................................................................. . . 3.6 5 Operation Sequence ...............................................................................................................................

3. Per iphera l Equipment o f Robot C o n t r o l U n i t This chapter describes the peripheral equipment connected to the robot control unit,

including:

(1) Teaching Box

(2) Operation Panel

(3) Operation Box (Option)

(4) Starting Box (Option)

(5) Robot Dedicated Welding Power Unit (Option)

(6) Welding Interface (Option)

(7) External Storage (Option)

(8) Printer Interface (Option)

BQ$ WARN l NG

I Be sure to install these peripheral equipment outside the robot working area.

Peripheral Equipment of Robot Control Un i t 3 - 1

3.1 Teaching Box

3.1.1 Functions

The teaching box is used to teach robot task programs, and has the following

functions:

(1) Transmits various key operations necessary for teaching works to the robot

control unit.

(2) Displays the contents of a task program and the robot operation status on the

liquid crystal display unit.

(3) Turns on the servo power supplied to the robot by the push button switch being

operated.

(4) Stops the robot in emergency by the push button switch being operated.

3.1.2 Outside View of Teaching Box

The outside view of each type of Teaching Box is shown in Fig.3.1.2.1:

Fig.3.1.2.1 outside View of Teaching Box

3 - 2 Peripheral Equipment of Robot Control Uni t

3.1.3 Notes on Usage

(1) The teaching box is equipped with precision parts . Because a shock may damage

these parts , be careful not to drop or hit it when you handle it.

(2) The ambient temperature in the environment may cause the dark background of

the LCD unit o r slowdown of changing characters displayed on the screen, but these

incidents do not indicate a failure.

(3) The LCD unit and a EL lamp used for back light which a r e in long service cause

the blurred characters on the screen and deteriorate illumination. In these events, it

is recommended that the LCD unit and EL lamp be replaced.

3.1.4 Internal Configurat ion

The internal circuit of the teaching box is shown in Fig.3.1.4.1:

TEACHING BOX -- - - - - - - - - - - - - - - - -. - - - -. - - . - - - - - - - ROBOT CONTROL

Fig.3.1.4.1 Internal Circuit of Teaching Box

Peripheral Equipment of Robot Control Unit 3 - 3

3.2 Operation Panel The Operation Panel mounted on the door of the control unit is equipped with switches

to switch robot operation modes, to turn on the servo power, and to start/halt the robot.

The control unit must be installed in a place which allows the operator to operate the

operation panel outside the dangerous area. Note that the operation panel is not

available if the operation box is installed outside the control unit, o r if the jig control

panel is substituted for its functions.

3.2.1 Switches and Functions

(1) Servo ON (SERVO ON) Switch @ This switch is used to turn on the servo power when the initial diagnosis is

completed following the control power ON, and illuminates when the servo power is

turned on.

(2) Teach (TEACH) Switch @

This button is used to change a robot operation mode to Teach mode, and

illuminates when the robot is in teach mode.

It has the same effect a s that of the Teach Mode key on the teaching box.

(3) Auto (AUTO) Switch

This button is used to change a robot operation mode to Auto mode, and

illuminates when the robot is in auto mode.

(4) START switch @

This button is used to activate automatic operation of a program assigned to the

switch when the robot is in auto mode, and illuminates during automatic operation

of the program.

Before operating automatic operation of the robot, be sure that all personnel a re

clear of the dangerous area.

(5) STOP switch @

This button is used to halt the robot during automatic operation, and illuminates

during a halt of the robot. It has the same effect a s that of the Stop key on the

teaching box.

(6) EMERGENCY Stop switch @

This button is used to stop the robot in emergency. Pressing it causes the servo

power to be shut off so that the brakes will be engaged. To cancel the Emergency

Stop, turn this button to the arrow.

For detailed procedures for switching a robot operation mode, for automatic

operation, and for recovery from the state of emergency stop, refer to the "Teaching"

instruction manual.


3.2.2 Outside View and Internal Circui t

L - - - J

Ik L---J

m T I C CWI4TICN

OSACOM

Fig.3.2.2.1 Outside View of Operation Panel

------- I(0Doratlon Box) 1

E merrsncr s t o p I I I I I

I I 24E I Start dlsDla1 1 I H a l t dlsDlaY I

I I

S e r v o ON I I

T e a c h node selectlonl ~ u t o mode selection I Servo @i dlsDlaY I I

I I I

T e a c h n o d s dlsPlaJ I Auto mode dlSDlaY I

c - '-&!A - - - - - - - - - - - -I

Fig.3.2.2.2 Internal Circuit of Operation Panel

WARN l NG

1. To connect the operation panel, open JP302 of Interlock board. 2. Though it is possible to connect a s tar t signal connector CN31 of the

operation panel to any of starting box connectors CN31-CN33 of Interlock board, normally connect to CN31 (Start 1).

Peripheral Equipment of Robot Control Uni t 3 - 5

3.3 Operation Box (Option) When the control unit is located too far for the operator to operate the operation

panel, the operation box can be provided outside the control unit to substitute for the

functions of the operation panel. If the operation box is employed, the operation panel

is not available.

WARNING

Be sure to fix the operation box outside the dangerous area.

3.3.1 Switches and Functions The functions of the switches are all the same a s those of the operation panel.

3.3.2 Outside View and Internal Circuit The outside view and internal circuit of the operation box a re shown in Fig.3.3.2.1

and Fig.3.3.2.2, respectively:

S E? - @ ! + i t I S7,RT STOP

Fig.3.3.2.1 Outside View of Operation Box


SERVO ON

TEACH I NG

ALJTO

STOP

START

-

0 0 @

TEACH I NG

AUTO

STOP

START

0- PBZ I 902 EMERGENCY STOP

46 j SERVO ON

Fig.3.3.2.2 Internal Circuit of Operation Box

WARNING 1. To connect the operation box,

open JP302 of Interlock board. 2. To connect the operation box,

Relay cable (E5785F) is required.

3. Though it is possible to connect CN31 of Relay cable to any of Starting box connectors CN31-CN33 of Interlock board, normally connect to CN31 (Start 1).

CN31 CN30 ( i n t e r l o c k ( O o e r a t i o n

B o a r d b o x )

CN28 ( I n t e r l o c ~

B o a r d

-LI

Fig.3.3.2.3 Relay Cable for Operation Box

Peripheral Equipment of Robot Control Uni t 3 - 7

3.4 Starting Box (Option) If the robot is used in the Multi-station system, install a Starting box a t each station.

The standard robot control unit is capable of controlling up to 3 stations (with the

operation panel and 2 starting boxes), and adding an optional relay unit enables it to

control up to 6 stations.

A WARNING

I Be sure to fix any Starting box outside the dangerous area.

3.4.1 Switches and Functions

(1) START

This switch is used in auto mode of the robot to initiate automatic operation of a

program assigned to that station, and illuminates during automatic operation of the

program.

Before performing automatic operation, ensure that all personnel a re clear of the

dangerous area.

(2) STOP

This button is used to halt the robot, and illuminates during a halt of the robot.

It has the same effect a s that of the Stop key on the teaching box.

(3) Emergency Stop

This switch is used to stop the robot in emergency. Pressing it causes the servo

power to be shut off so that the brakes will be engaged. To cancel the Emergency

Stop, turn this button to the arrow.

For detailed procedures for automatic operation and for recovery from the state

of emergency stop, refer to the "Teaching" instruction manual.

3 - 8 Peripheral Equipment of Robot Control Un i t

3.4.2 Connecting Starting Box

To use a Starting box, connect it to the connector corresponding to the relevant

station number, and open the jumper pin o r pins corresponding to that connector.

For station numbers and their corresponding connectors/jumper pins, see Table 3.4.2.1.

Without the corresponding jumper pin or pins being opened, the Emergency Stop

switch on that Starting box does not function.

For detailed procedures for assigning a task program to each station, refer to the

"Teaching" instruction manual.

Table 3.4.2.1 Station Nos. and Corresponding Connectors

Remarks

Jumper

Pin to

Open

Location of

Connector/

Jumper Pin

1

Preset

Jumper Pin

Setting

2

3

Peripheral Equipment of Robot Control Un i t 3 - 9

CN31

--

4

5

6

CN32

CN33

JP302

CN34

CN35

CN36

JP303

JP304

Interlock

board

Close

JP301/

J P 1

JP301/

JP2

JP301/

JP3

Open

JP301: Inter-

lock board

JPl/JPZ/JP3/

CN34/CN35/

CN36: Relay

board (option)

Normally, to connect

Operation panel.

Close

Close

Close

If Relay board is

not included, close

JP301.

3.4.3 Outside View and Internal Circuit

The outside view and internal circuit of the Starting box are shown in Fig.3.4.3.1 and

Fig.3.4.3.2, respectively:

Fig.3.4.3.1 Outside View of Starting Box w

STOP

START

STOP

* T ~ EMERGENCY STOP

Fig.3.4.3.2 Internal Circuit of Starting Box

3 - 1 0 Peripheral Equipment of Robot Control Uni t

3.5 Robot Dedicated Welding Power Supply (Option) The Robot Dedicated Welding Power Supply is equipped with the built-in interface

communicating with the robot.

Rated Input I 18kVA I 29kVA 1 17kVA

The following 3 types of robot dedicated welding power supplies a re available a s shown

in TABLE 3.5.0.1

TABLE 3.5.0.1 Specifications of Robot Dedicated Welding Power Supply

Input Voltage

Allowable R a n ~ e

Name

Type

Almega Auto II 350

CPVAS-350

Almega Auto 11 500

CPVAS-500

Rated Frequency

Welding Method

Output Current Range I 40-350A I 40-500A I 40-350A

Almega Fuzzy Auto

CPDA-350

50/60Hz

COJMAG Welding

Rated Output Current

Rated Load Voltage

Dimensions (W x D x H) 1 360 X 550 X 650 1 440 X 610 X 880 1 350 X 510 X 795

350A

36V

Output Voltage Range

Rated Service Rate

3.5.1 Notes on Using Robot Dedicated Welding Power Supply (I) The interface circuit of the robot dedicated power supply is internally energized.

Therefore, turn on the robot dedicated welding power supply prior to the power

supply of the robot control unit.

If the robot control unit is energized first, which will cause the robot dedicated

power supply to be unconnected.

(2) Optical fiber is used for connection between the robot control unit and the robot

dedicated welding power supply.

Handle it with care, because bending optical fiber or the unclean connector

connection may cause communication failure.

(3) When the connector part becomes dirty, wipe the dirt off with a dry soft cloth.

Insert the optical fiber connector firm enough to be locked.

500A

45V

15-36V

50%

Weight (kg)

3.5.2 Outside View and Internal Configuration of Robot Dedicated Welding Power Supply

The outside view and the internal configuration of Robot Dedicated Welding Power

Supply are shown in each Instruction manual.

350A

36V

Peripheral Equipment of Robot Control Unit 3 - 1 1

15-45V

100%

52

14-36V

60%

100 61

3.6 Welding Interface (Option) When a general semiautolnatic welding power supply which has no built-in function of

interface with the robot is employed, the Welding Interface is required for the use with the robot.

3.6."1unctions The welding Interface has the following functions to control the welding power

supply according to the data transmitted from the robot control unit:

(1) Transmits a startup command to the welding machine according to the robot task program.

(2) Outputs the instructed voltage to the welding power supply by conditions taught in the task program according to the welding characteristic data stored in the system parameter file.

(3) Controls the wire feed unit and the gas electromagnetic valve. (4) Checks the arc s tar t failure, no arc generation, and wire stick a t the welding end.

3 - 1 2 Peripheral

- Fig.3.6.1.1 Outside View of Welding Interface

Equipment of Robot Control Unit

3.6.2 Description of Parts (1) Power Indication Lamp

AClOOV is supplied to the Welding Interface from the robot control unit. When power is normally supplied to the Welding Interface, an indicator mounted on the front face panel of the Welding Interface illuminates. If the indicator does not illuminate, in spite of power ON a t the robot control unit, check fuse F1 in the Welding Interface or the fuse F2 on the Interlock Board within the robot control unit for melting.

(2) Gas Check Switch Gas check switch is arranged a t the front face of the Welding Interface a s shown

in Fig.3.6.1.1. Turning this switch upward causes the gas electromagnetic valve to be opened, and

the supply of shield gas may be supplied and checked. (Normally turn this switch downward.)

3.6.3 Printed Board E5624G

V o l t a g e I R a n g e

REF1 S w i t c h i n g

REF2 S w i t c h i n g

F22l I A I

la GAS Va I v e

LED25 LED22

L E ~ GAS V a l v e

SOL

TP9 TPlO TPIZ T P l l

V o l t a s a C o n n a n d S l s n a l C u r r e n t Conmand S l s n a l

Fig.3.6.3.1 Parts Arrangement of Printed Board E5624G


(I) Operation Status Indicators of Printed Board E5624G TABLE 3.6.3.1 shows the functions of LEDs on the printed board E5624G to

indicate the operation status of the Welding Interface.

TABLE 3.6.3.1 Operation Status Indicators of Printed Board E5624G

Operation Status ON while welding

LED No.

LED 21

LED 24 (Red)

LED 25 (Red)

(2) Setting Switches of Printed Board E5624G The following switches are arranged on the printed board E5624G within the

Function Welding Startup Indicator

LED 27 (Red)

Welding Interface to set the command voltage and polarity to meet welding

(Red) *This is lit when a welding startup command

LED 22 .This is lit when wire inching/retract operation is operation

(Red) carried out from the Teaching Box.

the welding power supply. Wire Feed Normal/Reverse Rotation Indicator *This illuminates when wire feed motor rotation is reversed.

Wire Stick Check Indicator *This illuminates when the Welding Interface is checking wire stick.

power supply.

LED 23 (Red)

ON during wire retracting

ON a t welding end.However, it will not illuminate if wire stick "Not Check" is selected in the system parameter.

Gas Valve Operation Indicator .This illumintes when open command of the gas electromagnetic valve is being output.

ON during a gas check and welding

(REF1 1 Current Switching ( of a current command signal to be transmitted to

Wire Feed Indicator .This illuminates when a wire feed command signal is being output to the wire feed unit and

TABLE 3.6.3.2 Switches of Printed Board E5624G

Switching)

ON while welding and wire inching/retracting

the welding power supply. In the case of TIG welding power supply, it switches

Remarks This switch switches the voltage range and polarity

Switch SWll

Functions Instructed Welding

instructed voltage range and polarity proper to the welding power supply used.

SW12 (REF2 Switching)

For the voltage range and polarity of a command signal proper to each of welding power supplies, refer to TABLE 3.6.3.3

3 - 1 4 Peripheral Equipment of Robot Control Unit

Voltage can be selected in the range of 0 - 5V, 0 - 10V, 0 - 15V, 0 - 22V, and polarity of either positive (+)/negative (-), connect jumper pins according to the

Instructed Welding Voltage Switching

the setting of base current command signal. This switch switches the voltage range and polarity of a voltage command signal to be transmitted to the welding power supply. In the case of TIG welding power supply, it switches the setting of filler wire feed command signal.

TABLE 3.6.3.3 Instructed Voltage Range based on Type of Welding Machine

3.6.4 External Connection

Connection of the Welding Interface and the welding power supply requires

exchanging signals, a s shown in Fig.3.6.4.1

As for the kinds of cables for various welding power supplies and connecting method

of the Welding Interface and various welding power supplies, refer to the APPENDIX 1.

Peripheral Equipment of Robot Control Un i t 3 - 1 5

Welding Power

supply

C02/MAG Welding Machine

CPMS-350/500

CPXS-350/500

TRM( W)-350/500

TRA-350/500

CPV-350/500

CPVB-350

CPVP-350

CPVPA-350

CPVWP-350

CPVMB-180

TIG Welding Machine

VRTP-300

AEP(AES)-300

MRHS-300

AVP-300

Air Plasma Cutting Machine

TRC-120

Instructed Welding Voltage

Switching Switch SW12

Instructed Welding Current

Switching Switch SWll

(REF2

Voltage Range

15V

15V

15V

-

15V

-

(REF1

Voltage Range

15V

15V

15V

15V

1 OV

1OV

Switching)

Polarity

Negative

Positive

Positive

-

Negative

-

Switching)

Polarity

Negative

Positive

Positive

Negative

Positive

Positive

C u r r e n t C k e

WCR [ C u r r e n t Checx r e l a y ) i

I

V e l d i n s Powsr F e l l u r e 1 I I

I & w e l d i n s Power F e l l u r e 21

Fig.3.6.4.1 External Connection of Welding Interface

3.6.5 Operation Sequence The Welding Interface outputs signals shown in the timing chart. Fig.3.6.5.1, to the

welding power supply according to the instructions of welding start/end and wire inching transmitted from the robot control unit and the setting of the system parameters.

CAUTION 3

Fig.3.6.5.1 shows an example of operation sequence of the Welding Interface, and the actual action may vary with the kinds of welding power supply and the contents of system parameter setting.

'. /


Signal Name

I l l

Welding

Startup

(Totch

Switch)

Signal Rating

Dry contact (Relay CR21)

OMRON LY2, DC24V

MAX: 5A, AC1 lOV, DC24V

MIN:O.lA, DC5V

Timing Chart

Wire

Inching

ON/OFF

Instructed


OMRON LY2, DC24V

MAX:2.5A, ACllOV, DC24V

MIN:O.lA, DC5V

0-15V DC

MAX: 50mA Current

(REF 1)

I l l

ON I ! : , , , 6 I I , $ I

~fl, I t , , / I , # ,

I I 1 1 1 I , ,

(Polarity depends on the

welding power supply.)

Instructed 0-15V DC

MAX: 50mA Voltage

(REF 2) (Polarity depends on the

welding power supply.)

Wire Feed

Motor

ON/OFF

I I I l l 1 1 1

d i f Slowdown

r - - - - - - - - - -


OMRON LY2, DC24V

MAX:5A, ACllOV, DC24V

MIN:O.lA, DC5V

Gas Valve

ON/OFF

I I . , . , . . ,

I I I I I I

; ;!lot S t a r t Voltage i / i j j ! ,

DC 24V output

MAX 200mA

! Hot S t a r t Time : S t i c k Cancel l a r a t i o n

8 . ? I 8 , , a , ! I , , ,

GAS Pref low I : I , I

I GAS A f t e r f

I / , I

AS : : : : AE , , , ,

Wire Stick DC 24V output

Check 100mA constant current

YJCR-ON WCR-OFF

Fig.3.6.5.1 Example of Operation Sequence of the Welding Interface

Fig.3.6.5.1 shows one example of the operation sequence of the Welding Interface. Therefore, the actual operation may differ according to the type of welding power supply used and parameter setting.

Peripheral Equipment of Robot Control U n i t 3 - 1 7

3.6.6 Internal Circuit Internal circuit of the Welding Interface is shown in Fig. 3.6.6.1 Fig.3.6.6.1 shows a simplified circuit to explain the internal configuration of the

Welding Interface.


3.7 External Storage (Option) The external storage can be connected to transfer data from the robot control unit to

a floppy disk. For detailed operating procedures, refer to the "Teaching" instruction

manual.

3.7.1 Specifications

Operating temperature 1 5-35°C

Item Name

Type Memorv medium

Specifications Floppy disk storage E5777 3.5in. 2HD floppy disk

Allowable nono~eratinrr vibration I 2G max.

Nonoperating temperature Ambient humidity Floating dust Allowable o~eratinrr vibration

Allowable operating shock I 5G max.(lOms max.)

-20-60°C 20-80%(Noncondensing) Not serious 0.5G max.

Allowable nonoperating shock I 15G max.(lOms max.) Dimensions I 130 X 50 X 25Omm

(Le f t )

P o r e r S*l tch C o n n e c t o r

I 1

F u s s (0. 5 A )

Power C a b l e

/ O D e r a t I n 6 Lamu

\ E l e c t B u t t o n

F l o u p r D l s t i n l e t

(Front I

Fig.3.7.1.1 Outside View of External Storage


3.7.2 Configuration of External Storage

The external storage consists of the components shown in Table 3.7.2.1 and Fig.

Table 3.7.2.1 Configuration of Floppy Disk Storage

( )indicates an optional attachment.

A CAUTION

As a floppy disk is not included, the user needs to prepare a 3.5in. 2HD floppy disk.

OSACOM Sup\er 8700

T h e components I n the broten

r--- I Ins are oPtlonal attachments

F I O P P Y D ~ s x Memorr

L L-- ------------I

------- Fig.3.7.2.1 Configuration of External Storage

lcNg51

Fig.3.7.2.2 Outside View of Connecting Cable


3.7.3 Connecting External Storage To connect the external storage, be sure to turn off the robot control unit and the

external storage, and then follow the steps below:

(1) Attach FDD interface printed board (E5657C) on the door inside face of the

control unit.

(2) Remove the connector cover on the control unit front door, attach connector

CN95 of connecting cable @ (E5777K), and then connect the other connector FC2 to

connector FC2 of FDD interface printed board. (Insert an attachment dustproof

packing between the door and the connector.)

(3) Connect connector FC3A of connecting cable @ (E5777J) to connector FC1 of FDD

interface printed board, and also the other connector FC3 to connector FC3 of Main

Processor board in the robot control unit.

(4) Connect connector CN95 of external connecting cable O(E5657L)

to the connector of the cable attached in above (2), and also the other connector CN90

to the connector on the back of the external storage.

(5) Connect the power cable plug of the external storage to the plug socket on the side

face of the control unit.

A CAUTION > I Do not use this plug socket for any purposes other than to connect to the exter I I nal storage. I

F r l n t e d O a e r l

Ma ~n Processor

Prln!ed E o 3 r d flxlns b o a r d (Ac.9 SS. :.j j Y ESTn:Il

0 C 3 5 1 ? E5777J

Fig.3.7.3.1 Illustration for Connecting External Storage


3.7.4 Notes on Handling External Storage

(1) Before connecting the external storage, be sure to turn off the control unit and

the external storage.

(2) For power supply of the external storage, use the plug socket on the side face of

the robot control unit.

(3) To use the external storage, turn on the external storage prior to robot control

unit.

(4) When a floppy disk exists in the external storage, turning on/off the external

storage o r the robot control unit may destroy the data on the floppy disk. Before

turning on/off, remember to remove the disk from the external strage.

(5) When not using the external storage, store it in a dust free condition.

(6) Take care to prevent the external storage from shock such a s falling and hitting

shocks.

3.7.5 Notes on Handling Floppy Disks

(1) Store your floppy disks in a specialized case.

(2) Keep materials which produce magnetic fields, such a s a magnetic stone, away

from the floppy disks. Magnetic fields may destroy the data on the disk. Due to the

same reason, do not leave the disk in the robot control unit.

(3) Excessive force o r a heavy load, or dropping may damage the floppy disk. Take

care to protect the disks from harm.

(4) When the environment has rapidly changed, leave the floppy disk in the new

environment for several hours before you use it.


3.8 Printer Interface Unit (Option) The printer interface can be connected to print the contents o r a list of Task

programs and various Condition files with a printer (equivalent to NEC PC-PRZO1)

For detailed procedures for operating the printer output feature, refer to the

"Teaching" instruction manual.

3.8.1 Functions

(1) The contents of Task programs, various Condition files, and user parameters can

be printed.

(2) A list of Task programs or various Condition files can be printed.

3.8.2 Configuration

The printer interface consists of the components shown in Table 3.8.2.1 and Fig.

3.8.2.1:

Table 3.8.2.1 Configuration of Printer Interface

L CAUTION \

A printer and printer cable (Printer <- -+ Control unit front face) are not included. The user needs to prepare a PC-PRZO1 (NEC) type printer and a printer cable (such a s a commercial printer cable connectable between your printer and a NEC PC 9801 personal computer, except note types).


Ref .No.

0 0

0

@

0

Drawing Na

E5802C

E580ZB

E5802D

E5802E

E5802F

Item

Printed board

Mounting board

Cable (1)

Cable (2)

Attachments

Q'ty

1

(1)

(1)

(1)

(1)

Remarks

Printer interface

Mounting board and screws

Control unit front face +--+ Printed board

Main Processor board c-, Printed board

Rubber packing and Display board

Main

Robot control unit

1 -4,

Printer cable P Printer d

Fig.3.8.2.1 Configuration of Printer Interface

Cable (1) E5802D Cable (2) E5802E

Fig.3.8.2.2 Outside View of Connecting Cable

3 - 2 4 Peripheral Equipment of Robot Control U n i t

3.8.3 Connecting Printer Interface Unit To connect the printer interface, be sure to turn off the robot control unit, and then

follow the steps below. Note that these steps depend on whether the external storage

is used o r not.

3.8.3.1 When External Storage is not used

(1) Fix the printed board mounting board on the inside face of the control unit door

with screws.

(2) Attach a supporter to the mounting board, and then fix the printer interface

with screws.

(3) Remove the connector cover on the door, and then glue a dustproof rubber

packing from the inside.

(4) Insert cable (1) (E5802D) from the outside of the case, fix connector CN96 with

round vis and nut, and then connect the other connector FC30 to the printer

interface printed board.

(5) Connect connector FC3 of cable (2) (E5802E) to connector FC3 of Printer

interface printed board, and then connect the other connector FC3 to FC3 of Main

Processor board in the control unit. (FC1 is not connected.)

A CAUTION \

The plug socket on the side face of the control unit is used only for the external storage. Be sure to provide another power supply for printer.

/'

0 Printed baord board E5802B

& Cable (1) Printer cable E5802D

Printer interface printed board E5802C

A Main Processor board

@ Cable (2) E5802E

Fig.3.8.3.1 Connecting Printer Interface When External Storage is not used


3.8.3.2 When External Storage is used

(I) Unscrew the FDD interface printed board mounted on the inside face of the

control unit door, and then fix it with a supporter included in the printer interface

unit.

(2) Fix the printer interface over the FDD interface unit with screws.

(3) Remove the connector cover on the door, and glue a dustproof rubber packing

from the inside.

(4) Insert cable (1) (E5802D) from the outside of the case, fix connector CN96 with

screw and nut, and then connect the other connector FC30 to the printer interface

printed board.

(5) Remove the cable connecting FC1 of the FDD interface to FC3 of Main

Processor board. Connect connectors FC1 and FC3 of cable (2) (E5802E) to

connector FC1 of FDD interface printed board and connector FC3 of Printer

interface printed board, respectively, and then connect the other connector FC3 to

FC3 of Main Processor board.

3.8.4 Connecting Pr in te r

(I) Place the printer on a stable place such a s the control unit.

(2) Connect connector of the printer parallel interface (Centronics type) to CN96 on

the front face of the control unit with a printer cable. External connecting cable E5757C

Printed board mounting board E5802B

\ @ Cable (2) E5802E

Cable E5777J

Fig.3.8.4.1 Connecting Printer Interface When External Storage is in use


3.8.5 Notes on Usage

(1) Before connecting the printer interface unit, be sure to turn off the robot control

unit.

(2) The plug socket mounted on the side face of the control unit is used only for the

external storage. Provide another power supply for printer.

(3) For details of printer operations, refer to the instrucion manual for your printer

type.


Chapter 4 Connecting Robot Peripheral J ig (External Axis)

Contents

4 . 1 Types of Robot Peripheral Jigs ..........................................................................................................

4.2 connecting peripheral j ig to ~ ~ b ~ t control un i t ...............................................................

4 2 1 System Configuration ........................................................................................................................... . .

4 2 2 Control Cables for peripheral Jig ............................................................................................ . .

4.3 Internal Switch Settings and Connection Drawings of Robot Control Unit ....

4 . 3 . 1 GOIS + 1 Axis System

4.3.2 GO1S+2 Axis System ...........................................................................................................................

4 3 3 ~ 0 1 ~ + 3 ~~i~ system ..................................... : ..................................................................................... . . 4.3.4 VOlS+ 1 Axis System

4.3.5 V01S+2 Axis System ...........................................................................................................................

4 3 6 VOlS+ 3 Axis System ........................................................................................................................... . .

4. Connect ing Robot Per iphera l J ig This chapter provides information of the connections of Jig Control cables and of the

settings of various switches in the robot control unit which are necessary to connect a

robot peripheral jig, such as a positioner or sliders, or a combination of them to the robot

control unit.

In order to combine a robot peripheral jig with the robot, it is necessary to install data

including system parameters into the robot control unit according to the system

configuration. For details of the procedures, refer to the "Teaching" instruction manual.

4 - 1 Connecting Robot Peripheral J ig

4.1 Types of Robot Peripheral Jigs

As peripheral jigs that can be combined with the robot, DAIHEN provides the products

listed in Table 4.1.0.1:

Table 4.1.0.1 Robot Peripheral Jigs

Moving Axis No.

Axis 1 Axis 2 t Item Specification

Maximum payload 200kg 1 4 1 - Positioner

RPH-500

RPH- 1000

RPlS-1000

Maximum payload 500kg



head stock

1-axis side positioner

Maximum payload 300kg 1 7 / 7

1-axis double

support positioner

Z-axis double

support positioner Maximum payload 150kg 1 C I C

RPlD-200

RPlD-500

RPlD-1000

Maximum payload 300kg 1 C I C

2-axis tilt




Maximum payload 500kg 1 8 1 8

positioner

4

8

8

Maximumpayload lOOOkg 1 8 1 8

-

-

-

Traverse stroke 4.9m

Turntable

Portable slider

Standard slider

Traverse stroke 5.9m / 7 / -

RP1T-500

RPlT-1000

RSB-1000

RSB-2000

RSR-2900

RSR-3900

I RSR-6900 / Traverse stroke 6.9m / 7 / -

/ RSR-1900P / Traverse stroke 1.9m 1 7 1 -







8

8

4

4

7

7

Slider with

a connecting wagon

Connecting Robot Peripheral J i g 4 - 2

-

-

-

-

-

-

RSR-5900P

RSR-2900P

RSR-3900P

RSR-4900P

* Moving axis numbers are used to set the Servo Control boards described later in

this chapter.





7

7

7

7 -

-

-

-

4.2 Connecting Peripheral Jig to Robot Control Unit 4.2.1 System Configuration

Aside from the manipulator, it is possible to connect up to a total of 3 axes of

peripheral jigs to the standard robot control unit.

Some typical examples of this system configuration are presented in Table 4.2.1.1:

Table 4.2.1.1 Examples of System Configuration

Peripheral Jig Q'ty of Control

Cables for

of axes Peripheral Jig

1 axis

GO1

1 -axis positioner

1 -axis slider

3 axes

1 set

2 axes

1 axis

-

-

I I I I

1-axis slider

2 sets

1 set

Z-axis positioner

1-axis slider

1-axis positioner

1 -axis slider

VO 1

Z-axis positioner

-

4 - 3 Connecting Robot Peripheral J i g

-

1-axis positioner

3 sets

2 axes

3 axes

2 sets

Z-axis positioner

1 -axis slider

1-axis slider

-

1-axis positioner

Z-axis positioner 3 sets

4.2.2 Control Cables f o r Per ipheral J i g

A peripheral jig is connected to the robot control unit with Control cables listed in

Table 4.2.2.1. To connect a 1-axis peripheral jig, a set of 2 Control cables-one motor

cable (Control Cable 1) and one encoder cable (Control Cable 2)-is required:

Table 4.2.2.1 Control Cables for Peripheral Jig

Type

BIRBX-7003

BIRBX-7005

BIRBX-7010

BIRBX-7015

BIRBX-7103

BIRBX-7105

external axis

to robot V01,

Component

Item 1 p a r t NO. ~ ' t y

- -

BIRBX-7110

Control Cable 1

Control Cable 2

Control Cable 1

Control Cable 2

Control Cable 1

Control Cable 2

Control Cable 1

Control Cable 2

Control Cable 1

Control Cable 2

Control Cable 1

Control Cable 2

o r any external

axis t o G01.

Cable length

-

Control Cable 1

Control Cable 2

BIRBX-7115

Connecting Robot Peripheral J i g 4 - 4

Remarks

L4029B00

L4029C00

L4030B00

L4030C00

L4031B00

L4031C00

L4032B00

L4032C00

L4034B00

L4034C00

L4035B00

L4035C00

L4036B00

L4036C00

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

Control Cable 1

Control Cable 2

L4037B00

L4037C00

3m

5m

10m

15m

3m

5m

These cables

a re used to

connect one

external axis

to robot V01.

These cables

a re used to

connect more

than one

4.3 Internal Switch Settings and Connection Drawings of Robot Control Unit

In order to connect a robot peripheral jig such a s a positioner o r slider to the robot

control unit, it is necessary to change the settings of the switches and jumper pins on

each printed board in the control unit. These settings a re presented in Tables 4.3.0.1 and

4.3.0.2:

Table 4.3.0.1 List of Switches and Jumper Pins on Servo Control Boards

I JT1 I Jumper pin to detect voltage drop of the servo motor d r i v i n ~ power

Servo Control

Board 1

1 SW3 I Moving axis setting switch (Axis 4)

SW5 SW6

SW7/8

JT2

JT3 SW2

/ SW4 I Moving axis setting switch (Axis 5)

Moving axis setting switch (Axis 3) Switch to set the number of control axes Spare switches

Jumper pin to switch detecting encoder disconnection ON/OFF Spare jumper pin Board identifvina switch

Board 2

(SCON2)

Servo Control SW5 SW6

SW7/8

I SW4 I Movinn axis setting switch (Axis 8)

Moving axis setting switch (Axis 6) Switch to set the number of control axes Spare switches Jumper pin to detect voltage drop of the servo motor driving power

JT2

JT3 SW2 SW3

Jumper pin to switch detecting encoder disconnection ON/OFF Spare jumper pin Board identifying switch Moving axis set tin^ switch (Axis 7)

Board 3

(SCON3)

Servo Control

I Tm, 1 Jumper pin to switch detecting encoder

SW5 SW6

SW7/8

JT1

Moving axis setting switch (Axis 9) Switch to set the number of control axes Spare switches Jumper pin to detect voltage drop of the servo motor driving power

4 - 5 Connecting Robot Peripheral J i g

cl lL

JT3 disconnection ON/OFF Spare jumper pin

Table 4.3.0.2 List of Switches and Jumper Pins for Backplane Board and Interlock Board

Printed Board I Switch and Jumper Pin Ref.No. I Item I Ref.Na I Item

PCB 2

PCB 1

Interlock

board

DSWlOO Dip switch to check the mechanism

Backplane configuration

board Jumper pin to set detecting SCON 3 hardware failure ON/OFF Jumper pin to set detecting charging

JP601 Jumper pin to set Axis 6 overrun detect s i ~ n a l ON/OFF

/ JP602 / Jumper pin to set Axes 7 - 9 overrun detect signal ON/OFF

JP603 Jumper pin to set External Axis board

JP701

Connecting Robot Peripheral Jig 4 - 6

4.3.1 GO1 S + 1 -Axis System

(1) Example of System Configuration

Table 4.3.1.1 GOlSf l-Axis System Configuration

1 Axis Configuration

System Configuration

Manipulator GO1

(2) Switch Settings of Servo Control Boards

Table 4.3.1.2 Switch Settings of Servo Control Boards

* For SW5 of SCON2, refer to Table 4.1.0.1 and set the value of the moving axis

number applicable to the peripheral jig.

PCB13 (SCON2)

(3) Jumper Pin Settings of Servo Control Boards

Axes 4 - 6

PCB14 ( S C O N ~ ) Axes 1 - 3 1 Close 1-2 / Close 8-9. 5-6, 2-3 / Close 2-3

Table 4.3.1.3 Jumper Pin Settings of Servo Control Boards

2 0 0 * 0 0

(4) Switch/Jumper Pin Settings of Backplane Board

Table 4.3.1.4 Switch/Jumper Pin Settings of Backplane Board

0

JT3 Printed Board 1 Axes Controlled 1 JT1

- -

PCB13 (SCON2)

JT2

Axes 4 - 6

Printed Board

(5) Jumper Pin Settings of Interlock Board


PCB 1

Close 1-2

JPlO 1

ON

JP501 JP601 JP602 JP603 Board I I I I

4 - 7 Connecting Robot Peripheral Jig

Close 8-9, 5-6, 2-3

JP701

1 - 8 1 2 - 7 3 - 6 1 4 - 5

Close 2-3

2

ON

I I I

Close

3

ON

PCB2

4

Close Open Close

OFF

Close

Close

Close Close Close

Fig. 4.3.1.1 Connection Drawing of External Cables for GO1+1-Axis (Digital)

Connecting Robot Peripheral Jig 4 - 8

4.3.2 GO1 S + 2-Axis System (1) Example of System Configuration

Table 4.3.2.1 GOlS+2-Axis System Configuration


Manipulator GO1

1-axis positioner (1P)



Printed Board 1 Axes Controlled 1 SW2 / SW3 I SW4 / SW5 1 SW6 / SW7 / SW8 -

PCB14 (SCON1)

PCB13 (SCON2)

* F o r SW3/SW4 of SCON3, refer to Table 4.1.0.1 and set the values of the moving

axis numbers applicable to the peripheral jig(s).

PCB12 (SCON~)/ Axes 71'8



Axes 1 - 3

Axes 4/5

3

PCB14 (SCONI)/ Axes 1 - 3 1 Close 1-2 1 Close 8-9, 5-6, 2-3 / Close 2-3

1 4 4 2

2 0 0 0

Printed Board Axes Controlled 1 JT1

PCB13 (SCON~)/ Axes 41'5 1 Close 1-2 / Close 8-9, 5-6, 1-2 1 Close 2-3

* 1

JT2


*

JT3

-

PCB12 ( S C O N ~ ) ~ Axes 7/8

Table 4.3.2.4 Switch/Jumper Pins Settings of Backplane Board

0 0 0

0 0

0

Close 1-2

I I I I I

P C B ~ I ON I ON I ON I OFF I open

Printed Board


1

Close 8-9, 5-6, 1-2 Close 2-3

DSWlOO

1 1 2 1 3 1 4

0

JPlO

Table 4.3.2.5 Jumper Pins Settings of Interlock Board

PCB2 / Close I Close I Open / Close I Open / Close I Close I Close

0

Printed I Board

4 - 9 Connecting Robot Peripheral J ig

JP701 JP501 JP601 JP602 JP603

1 - 8 2 - 7 3 - 6 4 - 5

'ewer Supply

Fig. 4.3.2.1 Connection Drawing of External Cables for GO1 +2-Axis (Digital)

Connecting Robot Peripheral J ig 4 - 1 0

4.3.3 GO1 S i-3-Axis System (1) Example of System Configuration

Table 4.3.3.1 GOlS + 3-Axis System Configuration

Axis Configuration


GOlS + 1-axis slider (1s) +



Printed Board 1 Axes Controlled 1 SW2 ] SW3 1 SW4 I SW5 1 SW6 1 SW7 1 SW8

PCB14 (SCONI)~ Axes 1 - 3 1 1 1 4 1 4 1 2 1 0 1 0 1 0

*For SW3 - SW5 of SCON3, refer to Table 4.1.0.1 and set the values of the moving

axis numbers applicable to the peripheral jigs.



PCB12 (SCON~)/ Axes 7 - 9 1 Close 1-2 / Close 8-9, 5-6, 2-3 / Close 2-3

PCB13 ( S C O N ~ ) ~ Axes 41'5


Table 4.3.3.4 Switcli/Jumper Pins Settings of Backplane Board

Close 1-2

PCBI 1 ON 1 ON I ON / OFF / Open

Printed Board


Table 4.3.3.5 Jumper Pins Settings of Interlock Board

Close 8-9, 5-6, 1-2 Close 2-3

DSWlOO

1 1 2 1 3 1 4

4 - 1 1 Connecting Robot Peripheral J i g

JPlO

Printed

Board

PCB2

JP501

Close

JP601

Close

JP602

Open

JP603

Close

JP701

1 - 8

Open

2 - 7

Close

3 - 6

Close

4 - 5

Close

Fig. 4.3.3.1 Connection Drawing of External Cables for GO1 + 3-Axis (Digital)

Connecting Robot Peripheral J i g 4 - 1 2

(1) Example of System Configuration

Table 4.3.4.1 VOlS+ l-Axis System Configuration

Axis Configuration



Table 4.3.4.2 Switch Settings for Servo Control Boards

* F o r SW3 of SCON3, refer to Table 4.1.0.1 and set the value of the moving axis

number applicable to the peripheral jig.



(4) Switch/Jumper Pin Settings for Backplane Board

Table 4.3.4.4 Switch/Jumper Pins Settings of Backplane Board

PCBI I OFF I ON I ON I OFF I Open

Printed Board



4 - I 3 Connecting Robot Peripheral J i g

DSWlOO

1 1 2 1 3 1 4 JPlO

Fig. 4.3.4.1 Connection Drawing of External Cables for VO1+1-Axis (Digital)

Connecting Robot Peripheral J ig 4 - 1 4

4.3.5 VOl S 4-2-Axis System (1) Example of System Configuration

Table 4.3.5.1 VOlS+2-Axis System Configuration

Axis Configuration


Manipulator V01



* F o r SW3/SW4 of SCON3, refer to Table 4.1.0.1, and set the values of the moving

axis numbers according to your peripheral jig(s).



(4) Switch/Jumper Pin Settings for Backplane Board


Printed Board 1 JPlO



JP501 JP601 JP602 JP603 printed Board 1 I 1 I

4 - 1 5 Connecting Robot Peripheral J i g

JP701

1 - 8 / 2 - 7 3 - 6 4 - 5 I I I I I

Close Close Close Open PCB2 Open Close Close Close

Fig. 4.3.5.1 Connection Drawing of External Cables for V01 + 2-Axis (Digital)

Connecting Robot Peripheral J i g 4 - 1 6

4.3.6 VO1 S +3-Axis System (1) Example of System Configuration

Table 4.3.6.1 VOlS+3-Axis System Configuration

Axis Configuration

2-Axis positioner (2P)


VOlS + 1-axis slider (1s) +



* F o r SW3 - SW5 of SCON3, refer to Table 4.1.0.1 and set the values of the moving

axis numbers applicable to the peripheral jigs.

SCON 1



Manipulator V01

SCON 2

Ax-3 Ax-1

SCON 3

Ax-2

PCB13 (SCONX)/ Axes 4 - 6 1 Close 1-2 1 Close 8-9, 5-6, 2-3 1 Close 2-3

Ax-6

1 s

Ax-4

--

Printed Board

PCB14 (SCON1)

Ax-9

2P

Ax-7 Ax-5


Ax-8

Axes Controlled

Axes 1 - 3

-

PCB12 ( S C O N ~ ) ~ Axis 7 - 9


JT1

Close 1-2

Close 1-2

(5 ) Jumper Pin Settings of Interlock Board

Printed Board


JT2

Close 8-9, 5-6, 2-3

Close 8-9, 5-6, 2-3

JT3

Close 2-3

Close 2-3

DSWlOO

1 1 2 1 3 1 4

- .- I I I I I I I I

PCB2 I Close / Close I Open I Close I O ~ e n / Close I Close / Close

JPlO

JP501 JP601 JP602 JP603 Printed Board 1 I I 1

4 - 1 7 Connecting Robot Peripheral Jig

JP701

rn 4 - 5

1

CN,O,C TO external asis AS-9

CNlOlB To external arls AS-8

CNlolA To externel axis AX-7

cai To iManipiilator

gig To external axis AX-9

TO external axis AX-8

gig; To external axis AX-7

MZ TO Menipulator

m3 To Manipulator

Fig. 4.3.6.1 Connection Drawing of External Cables for V01+3-Axis (Digital)

Connecting Robot Peripheral Jig 4 - 1 8

CAUTION 1. Before connecting the peripheral jig(s), it is necessary to set a system

parameter to define what number of axis in the entire system each moving axis of the peripheral jig(s) should be assigned to. Any peripheral jig must be connected in accordance with this definition. Incorrect connection may not only cause malfunction or unexpected motion but also damage the jig(s).

2. In principle, the moving axis numbers of peripheral jigs a re defined in accordance with priority below:

Lower

Axis Nos.

Higher

Slider

2-axis positioner

tilt axis

I 2-axis positioner

table axis + I-axis positioner r

4 - I 9 Connecting Robot Peripheral J ig

5. Troubleshoot ing This chapter describes solutions for failures that may occur during operations of the robot.

Failures a r e mainly divided into 3 groups according to the symptoms :

* Where the servo power supply cannot be turned on, nothing appears on the teaching

box, etc. (see Table 5.1.)

* Where a failure code and a failure message a re highlighted (See Table 5.2.)

* Where a failure message except the above is displayed (See Table 5.3)

These failures a r e listed in Table 5.1 through Table 5.3. When a failure occurred, refer to

them to find a solution. If you need replace par ts such as boards, contact DAIHEN.

Table 5.1. Symptoms

box. 1

Symptoms

Nothing appears on the teaching

--

The display on the teaching box For details, see section 5.1.2.

Solution

For details, see section 5.1.1.

is unsteady. 1 Initial diagnosis is not completed.

The servo power supply cannot

For details, see section 5.1.3


be turned on.

The servo power supply is shut

function. I

Fo r details, see section 5.1.5.

off immediately when turned on.

Manual manipulation does not

Troubleshooting 5 - 1


EMERGENCSTOP --.RELEASE

Table 5.2. Failure Codes and Messages

SHOCK-S ERR -+RESET EA0040 1 -XXXX SERVO DOWN +RESET

Solution

Pull the Emergency Stop button (or Code / Message

EA00101-XXXX o r emergency stop signal was entered. During automatic operation

Cause The Emergency Stop button

the torch interfered

1) The servo power was shut off due to a n unidentified cause.

2) The hand was released

cancel the emergency stop signal) and press SERVO ON button. For details, see section 5.2.3.

1 from the deadman switch.


1 EA10201-XXXX WIF TIMEOUT --. RESET

Communication trouble between Welding Interface and I/O management board during welding. The specified Arc Star t

After pressing the RESET key, turn on the SERVO POWER and restart . If not recovered, turn the CONTROL POWER off and on again. Create a n Arc Star t Condition file.

NO ASC FILE 1 Condition file does not exist. I --. RESET EA50101-XXXX NO AEC FILE

NO WFP FILE / Patterned Weaving 1 Condition file.

-> RESET EA50102-XXXX

-+ RESET

The specified Arc End Condition file does not exist.

EA50102-XXXX NO WAX FILE

Create a n Arc End Condition file.

The specified Fixed

Condition file does not exist. The specified Axis Weaving Condition file does exist.

Create a Fixed Patterned Weaving

Create a n Axis Weaving Condition file.

+ RESET

-+ RESET EA50103-XXXX NO ASM FILE

EA50103-XXXX NO AEM FILE + RESET EA50104-XXXX NO OFS FILE

The specified Multi-pass Welding Star t file does not

exist. The specified Multi-pass Welding End file does not

Create a Multi-pass Welding Star t file.

exist. The specified Offset Condition file does not exist

Create a Multi-pass Welding End file.

Create a n Offset Condition file.

NO CL PRG. 1 to call. I RESET

EA50105-XXXX

NO J F PRG. / to jump to. I

There is no Task program

-+ RESET EA50106-XXXX

--. RESET

Create a Task program to call.

5 - 2 Troubleshooting

There is no Task program Create a Task program to jump to.

Code / Message EA50107-XXXX NO PM -+ RESET

Cause Solution --

Add a Point Mark instruction. There is no point mark to jump to.

EA50110-XXXX C1 TEACH ERR -. RESET EA50111-XXXX

There is no reference point for the former half of a :ircular arc. There is no reference point For the latter half of a nircular arc.

A circular arc is formed by 3 points. Add a reference point.

-

A circular arc is formed by 3 points. Add a reference point. C2 TEACH ERR

-+ RESET EA50112-XXXX COORD.ERROR -+ RESET

Teaching of the target/ reference points for an circular arc in the different coordinate systems.

Teach all 3 points in the same coordinate system to form a circular arc.

EA50113-XXXX SAME POINT C + RESET

The target and reference points for a circular arc are the same. The number of time counts exceeded 9.

Teach again to form a circular arc.

The max. number of timers that can count time a t one time during automatic operation is 9. Check the setting time of each instruction of S, R, N, and F.

EA50114-XXXX 11'0 TIMER -+ RESET

EA50120-XXXX CALL NESTING OVER -+RESET EA50201 -XXXX S.LIMIT * * * * -+ RESET

The nest has overflown due to program calls.

Calling in the call destination program is possible but limited to the maximum 4 layers. Check the the DroEram.

The robot has reached the software limit.


EA50202-XXXX LNKS.LIMITM * -+ RESET

The robot has reached the link software limit.

Check the s tar t allocation and assign the correct Task program number.

EA50301 -XXXX NO PROGRAM + RESET EA50302-XXXX NO PROGRAM -. RESET

The Task program assigned to the station does not exist.

The Task program with the number entered does not exist. Task program No. has not been entered into the port s~ecified.

Enter the correct Task program number.

Enter a Task program number EA50303-XXXX NO PROGRAM I -+ RESET EA50401 -XXXX ON TIME OUT -+ RESET

No ON input within the specified monitoring time.

Check the input status of the external control signals and the teaching data.

EA50402-XXXX OFF TIME OUT -+ RESET

No OFF input within the specified monitoring time.


Code / Message EA50701 -XXXX OPTION ERROR + RESET EA50702-XXXX OPTION ERROR + RESET EA50704-XXXX OPTION ERROR -> RESET EA50705-XXXX OPTION ERROR + RESET EA50706-XXXX OPTION ERROR -. RESET EA50708-XXXX OPTION ERROR + RESET EA50709-XXXX OPTION ERROR + RESET EB00301-XXXX OVER RUN -> RESET EB 10404-XXXX CALC. IMPOS. + RESET

EB10710-00XX DATA ERROR + RESET EC10206-XXXX COMUCTN ERR +POWER OFF

Cause

The software for Synchromotion has not been installed. The software for Multipass Welding has not been installed. The software for External Axis Shift has not been installed. The software for welding monitor has not been installed. The software for PM8700 has not been installed.

--

The software for Endress Rotation has not been installed. The software for Super Arc Sensor has not been installed. The manipulator overran.

1) A positioning instruction P is taught base on Work o r Tool coordinate system in the synchromotion system.

2) The panipulator is unable to move a t a position on the path taught with a

Linear o r Circular interpolation instruction.

The Task program contains a damaged instruction.

Communication between boards cannot be made correctly.

Solution If you want to use the optional function, purchase its optional software. Press the RESET key to continue the operation.


1) Modify the relevant instruction P to a

synchromotion instruction HP, o r t ry teaching based on the Base o r World coordinate system again.

2) Correct the taught positions(start/end points). If the manipulator is unable to move, correct the position d a t a of the relevant instruction in search mode o r by using the PC editing system.

Delete the damaged instruction and add a n instruction. If the failure recurs, delete the Task program. For details, see section 5.2.7.


Code / Message EC10208-XXXX COM. ERR +POWER OFF

teaching box failure. I

Cause I/O management board or

EC10209-XXXX DPRAM ERROR -. POWER OFF

Solution For details, see section 5.2.7.

Main board o r I/O management board failure.

EC10210-XXXX COM LSI ERR + POWER OFF

Motion control board failure.

/ Replace the Motion control board.

EC10403-XXXX CALC.ERR -. POWER OFF

Motion control board failure.

Replace the Motion control board.

EC10504-XXXX DC24V ERROR + POWER OFF

DC24V power supply failure. Replace the DC24V power supply.

ECl0505-XXXX DC15V ERROR +POWER OFF

1) DC15V power supply 1) Replace the DC15V power supply. failure.

2) Connector (CN24) is 2) Check the CN42 connection. disconnected.

Data installation can not be EC10601-XXXX NO FILE +POWER OFF

For details, see section 5.2.8. performed correctly.

EC10603-XXXX PCB MISMATCH

SCON/PCON Board is not in place.Or, imperfect

NO SYS FILE -. POWER OFF EC10801 -XXXX ROM ERROR -, POWER OFF EC10802-XXXX RAM ERROR -. POWER OFF

Check the SCON/PCON board connection.

+ POWER OFF EC10605-XXXX

control data is not found o r is insufficient.

If not recoverd, contact DAIHEN

contact. Multi-synchromotion

Misplacement of EPROM, o r imperfect contact.

Install the system parameters again.


The identified board o r RAM on that board is broken.

EC1 1301-XXXX I/O PORT ERR

I/O management board failure.

TB LCD ERROR + POWER OFF

Replace the mother board.

-+ POWER OFF EC11401-XXXX


Teaching box LCD failure. Replace the teaching box.

Code / Message EC20101 -XXXX MOTOR ERROR + POWER OFF

EC20102-XXXX AXIS SET ERR --. POWER OFF

A 00201-XXXX SHOCKS ALARM --. RESET A 00301-XXXX OVER RUN -+ RESET

A 10301-XXXX TEMP. ERROR -> RESET A 10404-XXXX CALC. IMPOS. + RESET

A 10502-XXXX CMOS BATTERY -> RESET A 10503-XXXX ABS BATTERY -+ RESET

A 10601 -XXXX NO FILE + RESET

Cause The system parameter setting for motor is wrong, o r any setting of the SCON board rotary switches 3-5 is wrong. The system parameter setting for motor is wrong, o r the setting of the SCON board rotary switch 6 is wrong. The torch interfered in Auto mode but not during automatic operation. Overrun was detected during initial-diagnosis.

The temperature in the controller exceeded 60°C

1) A positioning instruction P is taught base on Work o r Tool coordinate system in the synchromotion system.

2) The panipulator is unable to move a t a position on the path taught with a Linear o r Circular interpolat ion instruction.

The voltage of the memory battery dropped below 2.5V.

1) The voltage of the charging battery dropped.

2) Imperfect connection of Connector(CN47). Data installation cannot be performed correctly.

Solution For details, see section 5.2.10


After initial diagnosis is completed, perform manual manipulation while holding down the SERVO ON button to escape from overrun. Turn off the control power supply and leave the robot a s it is until the temperature decrease below 60°C 1) Modify the relevant instruction P to a

synchromotion instruction HP, o r t ry teaching based on the Base o r World coordinate system again.

2) Correct the taught positions(start/ end points). If the manipulator is unable to move, correct the position da ta of the relevant instruction in search mode o r by using the PC editing system.

Save all the da ta by using the external storage.

1) Charge the battery, o r replace the charging battery. Be sure to perform the absolute offset adjustment.

2) Check the CN47 connection. For details, see section 5.2.8.


Code / Message A 10710-XXXX DATA ERROR - RESET A 11102-XXXX ABS MISMATCH -+ RESET A 11103-XXXX ABS DATA OUT -+ RESET

A 30201-XXXX OVER TRCKNG.

RESTART

A 30203-XXXX ARC UNSTABLE -+ RESTART

A 30205-XXXX PARA.CALC. +RESTART A 30208-XXXX OVER DETECT. +RESTART

A 30209-XXXX OVER DIST. -+ RESTART

A 30210-XXXX OVER SRCHNG -. RESTART

A 30211-XXXX OVER DIST. +RESTART

A 30213-XXXX OVER SRCHNG. -> RESTART

Cause The Task program contains a damaged instruction.

Position deviation has occurred.

The absolute offset data have been destroyed o r absolute encoders have not been reset. During seam tracking by the a r c sensor, the resultant vector length in horizontal and vertical directions exceeded the specified value. During seam tracking by the a r c sensor, the frequency ra te that the average current exceeds the allowance exceeded defined rate. During automatic editing of parameters, arithmetic problem occurred. During wire extension detection (SFO), the deviation exceeded the specified allowable limit. During wire extension detection (SFO), the searching distance exceeded the specified maximum. During unidirectional search (SFl) , the deviation exceeded the specified allowable limit. During unidirectional search (SFl) , the searching distance exceeded the specified maximum. During patterned search (SFZ), the deviation exceeded the s~eci f ied limit.

Solution Delete the damaged instruction and add a n instruction. If the failure recurs, delete the Task program. For details, section 5.2.1 1.

Reset the encoders and perform the absolute offset adjustment.

See the Arc Sensor instruction manual.


Code / Message A 30214-XXXX OVER DIST. -.. RESTART

A 30215-XXXX SF2 CMD. ERR -.. RESTART A 30216-XXXX SF2 PRM.OVER -. RESTART A 30217-XXXX SF2 PRM.OVER -. RESTART A 30218-XXXX SF2 OVERLAP + RESTART A 30220-XXXX TS RANGE ERR -.. RESTART A 30221-XXXX A.S.TRNS.ERR + RESTART A 40101-XXXX A.S. FAILURE -+ RESTART

A 40102-XXXX WIRE STICK + RESTART A 40103-XXXX OUT OF ARC --.. RESTART A 40201-XXXX WPS NOT RDY --.. RESTART

A 40201-XXXX WPS NOT RDY -. RESET

Cause

During patterned search search (SF2), the searching distance exceeded the specified maximum. The SF2 file (Search Pattern file) contains a n invalid command other than SF2. A SF2 parameter setting is outside the setting range.

A SF2 parameter condition is wrong.

The SF2 s t a r t position and vector specified position a re the same. Teaching of AS o r AE in the touch section.

Communication with the a rc sensor cannot be made.

The a r c was not generated within the set time after a welding s t a r t signal being input. Wire was sticked.

The a r c is out.

The robot dedicated welding power unit o r welding interface has not been connected.

Communication trouble between the robot and welding interface or the robot dedicated welding power unit.

-

Solution See the Arc Sensor instruction manual

Press the START button to res tar t

Cut the deposited wire. After that , press the START button to res tar t welding

Press the START button.

1) Check the connection between the controller and the robot dedicated power unit o r welding interface.

2) Turn the robot dedicated power unit ON.

Turn the CONTROL POWER off and on again.


OUT O F WIRE / the wire was broken. 1 START button.

Code / Message A 40202-XXXX WPS ABNORMAL -+ RESTART A 40301-XXXX

-t RESTART 1 I A 40302-XXXX LACK O F GAS + RESTART

Cause Problem of ALMEGA AUTO I1 o r ALMEGA FUZZY AUTO. During automatic operation

The gas pressure is too low. Displayed only if a detector is provided. There is no cooling water.

Solution Remove the cause of the problem of ALMEGA AUTO II o r ALMEGA FUZZY AUTO. Remove the cause. After that , press the

Remove the cause. After that , press the START button.

A 40303-XXXX LACK OF WATK -+ RESTART

Remove the cause. After that , press the START button.

A 50101-XXXX NO ASC FILE + RESET

The specified Arc Star t Condition file does not exist.

Create a n Arc Star t Condition file.

A 50101-XXXX NO AEC FILE -. RESET

The specified Arc End Condition file does not exist.

Create a n Arc End Condition file.

Create a Fixed Patterned Weaving Condition file.

A 50102-XXXX NO WFP FILE -+ RESET A 50102-XXXX NO WAX FILE + RESET

Create a n Axis Weaving Condition file.

The specified Fixed Patterned Weaving Condition file does not exist. The specified Axis Weaving Condition file does exist.

A 50103-XXXX NO ASM FILE -> RESET

The specified Multi-pass Welding Star t file does not

Create a Multi-pass Welding Star t file.

exist. The specified Multi-pass Create a Multi-pass Welding End file. A 50103-XXXX

NO AEM FILE + RESET

Welding End file does not exist.

A 50104-XXXX NO OFS FILE -+ RESET

The specified Offset Condition file does not exist.

Create a n Offset Condition file.

A 50105-XXXX NO CL PRG. -. RESET

There is no Task program to call.

Create a Task program to call.

A 50106-XXXX NO J F PRG. -. RESET

There is no Task program to to jump to.

Create a Task program to jump to.

A 50107-XXXX NO P M -+ RESET

There is no point mark to jump to.

Add a Point Mark instruction.


Code / Messag' A 50110-XXXX C1 TEACH ERR + RESET A 50111-XXXX C2 TEACH ERR -. RESET A 50112-XXXX COORD. ERROR + RESET

A 50113-XXXX SAME POINT C -, RESET A 50114-XXXX I/O TIMER -> RESET

A 50120-XXXX CALL NESTING OVER -.RESET

A 50201-XXXX S.LIMIT * * * * -+ RESET A 50202-XXXX LNKS.LIMITM * + RESET A 50401-XXXX ON TIME OUT -+ RESET A 50402-XXXX OFF TIME OUT -, RESET A 50501-XXXX SERVO OFF +SERVO ON

A 50502-XXXX OUT O F START ENABLE AREA

Cause There is no reference point for the former half of a

circular arc. There is no reference point fo r the latter half of a circular arc. Teaching of the target and reference points for circular a r c in the different coordinate systems. The target and reference points for a circular a r c a r e the same. The number of timer counts exceeded 9.

The nest has overflown due to program calls.

The robot has reached the software limit.

The robot has reached the link software limit.

No ON input within the specified monitoring time.

No OFF input within the specified monitoring time

Servo ON when the mode was changed to AUTO. Or, the servo power supply was turned on before automatic operation o r after com~let ion of the iob. Outside the Star t Enable Area

Solution A circular a rc is formed by 3 points. Add a reference point.

A circular a r c is formed by 3 points. Add a reference point.

Teach all 3 points in the same coordinate system to form a circular arc.

Teach again to form a circular a r c can be made.

The max. number of timers that can count time a t one time during automatic operation is 9. Check the setting time of each instruction of S, R, N, and F. Calling in the call destination program is possible, but limited to the maximum 4 layers. Check the program. For details, see section 5.2.5.

Check the input s ta tus of the external control signals and the teaching data .

Turn the servo power supply ON.

Perform manual operation to move the manipulator to within the Star t Enable Area.

5 - 1 0 Troubleshooting

OPTION ERROR -+ RESET A 50702-XXXX OPTION ERROR + RESET A 50704-XXXX

Solution After completion of initial diagnosis, perform the absolute offset adjustment.

If you want to use the optional function,

Code / Message A 50601-XXXX ABSO ERROR -+ RESET A 50701-XXXX

purchase its optional software. installed. Press the RESET key to continue the

Welding has not been

Cause After initialization of the memory, ABSO setting has not been performed. The software for

installed. The software for External

OPTION ERROR -+ RESET

Axis Shift has not been installed.

A 50705-XXXX OPTION ERROR

The software for welding monitor has not been

4 RESET A 50706-XXXX

A 50708-XXXX OPTION ERROR

installed. The PM8700 software has

OPTION ERROR RESET

The software for Endress Rotation has not been

not been installed

OPTION ERROR / Arc Sensor has not been 1 + RESET A 50709-XXXX

-+ RESET

installed. The software for Super

I 00201-XXXX SHOCK SENSOR +RELEASE

I 10208-XXXX COM. ERROR -+ RESET

installed. This occurs during escape from Shock Sensor Error or Shock Sensor Alarm, or when the torch interfered in Teach mode. The user parameter setting of CRT ON/OFF was ON wlien the CRT power supply was turned off. During automatic operation,

COM. ERROR 1 trouble occurred in the CRT 1 -+ RESTART 1 communication circuit due 1 I 11202-XXXX LIMIT SPD. -+ RESET


Press the reset key on CRT to switch the display to the teaching box.

Automatic operation will continue.

/ the meclianism.

to some cause. In synchronous Cartesian manual manipulation, the sub mechanism is unable to synchronize with the main

Troubleshooting 5 - 1 1

Increase the speed of manual manipulation.

Code / Message I 11401-XXXX CRT ABNMAL * RESTART I 30100-XXXX L. S. TRNS. ERR -> RESET I 30203-XXXX ARC UNSTABLE

RESEST

I 30204-XXXX WELD SHRTG. -> RESET I 30205-XXXX PARA.CALC. + RESET I 30208-XXXX OVER DETECT -+ RESET

I 30209-XXXX OVER DIST. -+ RESET

I 30210-XXXX OVER SRCHNG -+ RESET

I 30211-XXXX OVER DIST. -. RESET

I 30213-XXXX OVER SRCHNG. -. RESET I 30214-XXXX OVER DIST. + RESET

I 30221-XXXX A. S. TRNS. ERR -+ RESET

Cause Trouble occured in the CRT printed board.

Communictation with laser sensor cannot be made.

During seam tracking by the a r c sensor, the frequency that the average current exceeds the allowance exceeded the defined data. The welding time was not enough during automatic editing of parameters. During automatic editing of parameters, arithmetic problem occured. During wire extension detection (SFO), the deviation exceeded the specified allowable limit. During wire extension detection (SFO), the searching distance exceeded the specified maximum. During unidirectional search (SFl) , the deviation exceeded the specified allowable limit. During unidirectional search (SFl) , the searching distance exceeded the specified maximum. During patterned search (SF2), the deviation exceeded the specified limit. During patterned search search (SF21 , the searching distance exceeded the specified maximum. Communication with the arc sensor cannot be made.

Solution Trun off and on the CONTROL POWER.

Connect the laser sensor

For details, see the Arc Sensor instruction manual.


CRT DISCNNCT can not be made. + RESET

Solution To use CRT, turn on CRT first, and then the controller.

I 30302-XXXX CRT INVALID -+ RESET I 40201-XXXX WPS NOT RDY -+ RESET

The user parameter setting of CRT ON/OFF will be changed to OFF. 1) The robot dedicated

welding power unit o r welding interface is not connected.

2) The robot dedicated power unit is OFF.

Push RESET key

1) Check the connection between the controller and the welding interface.

2) Turn the robot dedicated power unit ON.

I 40301-XXXX OUT O F WIRE -+ RESET

The residual wire is not enough. Displayed if a detector is provided.

Supply the wire.


Failure Message

COM DATA ERR XX-YY

XX: 03 o r 85 YY: 01 - 05 SVC error

board). 1

Table 5.3 Failure Messages

Servo Control board 1

Cause Failure was detected a t Servo Control board (SCON

malfunctioned.

Solution For details, see section 5.3.2.

The servo power supply was I shut off due to a n 1 unexrsected cause. I The temperature in the 1 con troller has I extraordinarily increased. Trouble occurred in the Servo driver unit. 1 Trouble occurred in the I Servo Control board. The servo driver unit is unable to be set in the servo 1 ON state. I The position deviation I exceeded the set value. I The commanded speed I exceeded the set value. Servo Control board malfunctioned. 1 Trouble occurred when the I servo power supply was 1

1 and then on again.

turned on. Control program failure.

1 If this failure recurs, note down

Turn off the control power supply

I the information displayed on the

displayed on the teaching box and contact DAIHEN.

Control program failure.


teaching box and contact DAIHEN. Note down the information

5. 1 Symptoms

5.1.1 NothingAppearsontheTeaching Box

1 Symptom 1

Nothing

appears on the

teaching box

and all LEDs

on the

keyboard a re

OFF.

Primary power

supply indicator

lamp OFF.

(ON in the

normal state)

U Cooling fan not U I rotating

1 LEDs of

I constant voltage

power unit(5V,

1- 15V) is

/ flickering palely. I

_I No primary power L

Loss of V phase

(wire 5) of

primary power

1 1 power unit(5V, I 1 primary power 1 -

All LEDs on

Interlock board

a re OFF. (In

normal state,

LEDs 301, 302,

304, 601, 602 and

603 are ON.)

LEDs of

constant voltage -

f 15V 24V) a re 1 1 OFF.

Loss of W phase

(wire 6) of

I supply

I primary power supply / -

I and connect correctly. I

Check the voltage of

each phase of the

of Interlock board H connection and connect / Imperfect contact

CN41 - constant 1 / it properly. 1

Check the flat cable

voltage power unit 1 I


Interlock board

failure.

Replace the Interlock

board.

I Possible Cause I I Action I

Imperfect contact

of backplane

board FCll -

Interlock board

FCll


connection and connect

it properly.

24V is not supply Check 24V of Interlock

1 to teaching box.

Replace the cable.

/ board.

The display of

the teaching

box is

unsteady and

flickers.

5. "1 2 The Display on the Teaching Box Is Unsteady

- 1 Red LED on

Servo Control

board ON

LEDs(red) on

servo driver

flickering

I Action I Check the voltage on 1 1 primary power 1 / the primary power


supply (below AC / supply.

5. 1.3 Initial Diagnosis Is Not Completed

1 Symptom 1

The display

"START

DIAGNOSIS"

stays on the

teaching box.

I Check Item I

"COMUCTN

ERR"

( Communication

error) is

displayed a t the

right top of the

teaching box

screen.

i Nothing is

displayed a t the

right top of the

teaching box

I screen. I

I Possible Cause I

4 Refer to 5.2.7 in this part.

1 1/0 management U Check that I/O

1 board failure 1 management board is 1 I connected correctly. I

Replace the I/O

management board.

1 stops a t step1 / I 1 of initial

The teaching

box display

I diagnosis. I

P

"NO FILE" is

displayed a t the

-

right top of the I

Refer to 5.2.8 in this part.

teaching box I I screen. I

Nothing is

displayed a t the

right top of the

teaching box

screen.

I Action I

i 1/0 management

board failure

Check that 1/0

management board is

connected correctly.

I 1 Replace the I/O

I management board. I


1 Symptom 1 The teaching

box display

stops a t step2

of initial

The teaching

box display

stops a t step3

of initial

I "NO FILE" is

displayed a t the

right top of the

teaching box

screen.

Nothing is

displayed a t the

right top of the

teaching box

screen.

"NO FILE" is

displayed a t the

right top of the

teaching box

screen.

--A Refer to 5.2.8 in this part. I

Motion control Check that Motion control board is

I Action I

/ Replace the Motion 1

Refer to 5.2.8 in this part .

"WPS NOT

RDY" is

displayed a t the

right top of the

teaching box

screen.

1 control board.

Welding interface

o r robot dedicated

1 welding power unit 1 1 not connected.

Check that the welding

interface o r robot

dedicated welding

power unit is connected

correctly.

1 Nothing is 1/0 management U Check that 1/0

Turn on the robot

dedicated welding -

I unit OFF

] displayed a t the / / board failure I management board I

I power unit.

1 right top of the /

Robot dedicated

welding power

I is connected correctly.

-

1 teaching box I - I screen. I / Replace the I/O 1


I 1

management board.

The teaching

box display

stops a t step4

of initial

I Check Item 1 I Possible Cause I

"NO FILE" is

displayed a t the

right top of tlie

teaching box

screen.

Refer to 5.2.8 in this part.

"A.S.TRNS.ERRfl

is displayed a t

the right top of

the teaching box

screen.

Arc sensor unit Check that the Arc

I not connected. sensor is connected

Nothing is Arc sensor unit Check that Arc sensor

Arc sensor unit

OFF

1 displayed a t the

Turn on the Arc

sensor unit.

right top of the

teaching box

1 failure 1 is connected correctly. I

Replace the Arc sensor 7


screen. I unit.

5.1.4 The Servo Power Supply Cannot Be Turned ON

The servo

power cannot

be turned on.

I Action I

Interlock board

LEDs 203/301/

303 OFF (ON in

the normal

condition)

I

Red LED on

Electromagnetic

contactor MS1

not ON

each Servo

1- failure p -

contactor MS1.

- Electromagnetic

contactor MS1

Control board

Replace the

electromagnetic

ON (only green

ON in the

normal

condition)

I I

OH/OC/OV

LEDs on each

Servo driver ON

(only RDY ON

in the normal

condition)

Motion control

board OFF (ON

1 in the norm-a1 I I condition) I

LED 303 on

Interlock board

ON (OFF in the

normal

condition)

Check the voltage on

primary power the primary power

supply(3-phase 200

V) (Below AC150V)

Replace the Motion


I board failure 1 control board. 1

5 .1 .5 The Servo Power Is Shut OFF Immediately When Turned ON

I Symptom I I Check Item I I Possible Cause I

The servo

power is shut

off while

"SERVO ON"

stays 011 the

teaching box

screen.

LEDs 101/301/

303(green) on

Interlock board

OFF (ON in the

normal

condition)

Motion control

Servo Control

board failure

4 Main board failure 1 I LEDs 101/301/ H I/O management

303/ 203 ( green )

on Interlock

I board OFF (ON I I in the normal) I

I board failure 1

Check that each board I is in place. , 1 Replace faulty board. 1


5. 1 .6 Manual Manipulat ion Does Not Function

1 can moves by 1

Only one axis

of axes 1 - 6

/ manual I I / manipulation. 1

Only axes 4/5/ -

6 move by

Check the connections

of servo driver

Bad connection of

motor line

/ manual

-

/ manipulation. I

Able to move

axes 1/2/3 by

manual

None of axes

1-6 moves by 1 I manual I 1 manipulation. 1

manipulation

1 connectors CN51-56. 1

H Disconnection of Replace the cable.

/ motor line

Motor failure Replace the motor.

1 No power supply

to axes 4/5/6 servo

drivers

{ Check the connections I I of servo driver

connectors CN4, CN6,

and CN8.

CR3A/CR3B

contacts on

Interlock board

OFF (ON in the

normal

condition)

Bad connection of

motor line I-

] Redace the cable. 1

Check the connection

of control cable 1.

(Manipulator-side CN1)

Disconnection of

motor line

function set ON 1 1 function OFF.

Machine lock


-side CN1)

-

Set the machine lock

Replace the control

cable 1. (Manipulator

5. 2 Failure Codes and Failure Messages

5.2. 1 The Display of A Failure

If a failure occurred, a failure code and a failure message are displayed on the

teaching box.

(Example) Emergency Stop

+ Failure code

EMERGENCSTOP * Failure message

+RELEASE

A failure code is displayed in the following format:

a : Indicates the severity of a failure (Error, Alarm, or Information)

- Error (EA/EB/EC)

The Error class includes failures, such a s failures of parts and internal data,

which cause the operation to be disabled unless the causes are removed, o r

which can cause harm to the system and operators if the operation is

continued.

- Alarm (A)

The Alarm class includes failures which can develop to Errors unless measures

are taken soon, or which require a simple operation, check, or action before

the operation is carried on though they may not cause harm to the system and

operators.

- Information (I)

The Information class includes failures which should be told to the operator

and peripheral equipment though they do not cause trouble to continue the

operation, or which can develop to Alarms later.


b: Indicates the cause of failure.

- Urgent Failure (0)

This includes failures which cause the system to be stopped a s a last resort

when a failure handling action such a s a detection or stop cannot be taken

due to the occurrence of another failure.

- Control Failure (1)

This includes internal control system failures being detected a t the main board ,

motion control board, I/O management board and the teaching box.

- Servo Failure (2)

This includes servo system failures being detected a t servo control boards and

servo drivers.

- Peripheral Equipment Failure (3)

This includes failures relating to peripheral equipment (optional equipment)

such a s sensors.

- Welding Failure (4)

This includes welding failures being detected a t the welding power supply and

the welding interface.

- Operational Failure (5)

This includes failures relating to operations such a s misoperations.

c: Shows the more detailed cause of b.

d: Indicates the unit where the failure occurred (called a unit code) o r detailed

information of the failure.

For unit codes, see Table 5.4.

e: Indicates the mode (called a mode code) or detailed information of the failure.

For mode codes, see Table 5.5.


Table 5.4. Unit Codes

Note) PCON: Position control board SCON: Servo control board

Table 5.5. Mode Codes

Code

0 0 0 1 0 2 0 3 0 4

0 5 0 6 0 7 0 8 0 9 1 1 1 2 1 3 1 4 1 5 1 6 2 1 2 2 2 3 2 4 2 5 2 6 2 7 2 8 2 9 3 0 3 1 3 2 3 3 3 4 3 5 3 6 3 7 3 8

Code 1 Mode I Function

Diagnosis Teach

Teaching

Unit

Main board Motion control board 1/0 management board Teaching box Welding interface o r ALMEGA AUTO II or ALMEGA FUZZY AUTO Interlock board Backplane board

Analog board External axis board PCON/SCON board 1 PCON/SCON board 2 PCON/SCON board 3 PCON/SCON board 4 PCON/SCON board 5 PCON/SCON board 6 PCON/SCON board 1 Axis 1 PCON/SCON board 1 Axis 2 PCON/SCON board 1 Axis 3 PCON/SCON board 2 Axis 4 PCON/SCON board 2 Axis 5 PCON/SCON board 2 Axis 6 PCON/SCON board 3 Axis 7 PCON/SCON board 3 Axis 8 PCON/SCON board 3 Axis 9 PCON/SCON board 4 Axis 10 PCON/SCON board 4 Axis 11 PCON/SCON board 4 Axis 12 PCON/SCON board 5 Axis 13 PCON/SCON board 5 Axis 14 PCON/SCON board 5 Axis 15 PCON/SCON board 6 Axis 16 PCON/SCON board 6 Axis 17 PCON/SCON board 6 Axis 18


Code

6 1 6 2 6 3 6 4 6 5 6 6 6 7 6 8 6 9 7 0 7 1 7 2 7 3 7 4 7 5 7 6 7 7 7 8 8 0 8 1 8 2 8 3 8 4 8 5 8 6 9 0 9 1 9 2 9 3

1 0

2 0

Unit

Axis 1 servo driver Axis 2 servo driver Axis 3 servo driver Axis 4 servo driver Axis 5 servo driver Axis 6 servo driver Axis 7 servo driver Axis 8 servo driver Axis 9 servo driver Axis 10 servo driver Axis 11 servo driver Axis 12 servo driver Axis 13 servo driver Axis 14 servo driver Axis 15 servo driver Axis 16 servo driver Axis 17 servo driver Axis 18 servo driver Personal computer Arc sensor

Laser sensor Main board of CRT unit CRTC board of CRT unit External storage

Printer I/F

Auto

Remote control

5.2.2 Logical Outputs fo r Fai lures

Failure output ports a r e provided to inform external devices of the cause, severity,

and solution of a failure:

Table 5.5 Logical Outputs for Failures

Name I Logical Output Por t No

Urgent Failure I 0 2 0 1

Control Failure 1 0 2 0 2

Servo Failure 1 0 2 0 3

Peripheral Equipment Failure

Welding Failure

Alarm 1 0 2 1 2

0 2 0 4

0 2 0 5

Operational Failure

Error

0 2 0 6

0 2 1 1

--

Information

ABSO Adjust Request

0 2 1 3

0 2 0 8

Reset Request

Star t Request

For details of these output ports, see the instruction manual "Interface With Jig".

0 2 0 9

0 2 7 0

Failure Code


0 3 7 0 - 0 3 7 4

5.2.3 Shock Sensor

Shock Sensor is a failure which occurs when the torch hits a peripheral jig.

Shock Sensor Er ro r (during automatic operation)

EA00210-XXXX

SHOCK-S ERR

-+ RESET

* Shock Sensor Alarm (in Auto mode but not during automatic operation)

-1 1 SHOCKS ALARM 1 / -> RESET I

Shock Sensor Information (in Teach mode o r during a n escape from Shock Sensor

Error or Alarm)

SHOCK SENSOR

+RELEASE

Solution

0 If the torch is equipped with a shook sensor

Perform manual manipulation in the direction which allows Shock Sensor to be

cancelled.

(B) If the torch is not equipped with a shock sensor

Short-circuit pins 4 - 5 of terminal block TB1 on the Interlock board.


5.2 .4 Servo Power Shutoff

This failure occurs when:

A failure occurred and was momentarily removed.

* You release the hand from the deadman switch, provided that the teaching box is

equipped with a deadman switch.

The output form of failure varies with the setting of the user parameter

"ABNOMALTY ENCODE" available for setting the teaching box key s ta tus

Table 5.7 Differences of Output Form according to Special Failure Output ON/OFF

/ SERVO DOWN erased after being 1 (Automatically reset after

Setting

ON

1 1 output for 2 seconds. / being output for 2 sec.)

Display of Failure

EA00401-01XX

Solution

(A) When the setting is OFF

OFF

(Default)

After being displayed on the teaching box for 2 seconds, the failure is

Cancellation

Automatically

automatically erased. Then, turn on the servo power supply.

Output Signal

Failure Code(0374-370)

EA00401-01XX

SERVO DOWN

+ RESET

IB) When the setting is ON

After pressing the RESET key, turn on the servo power supply.

In case of this failure, because it is automatically cancelled, you can carry on the

operation you a r e doing, or can restart the automatic operation.

By the RESET key o r

Reset input.

If this failure recurs during automatic operation, the shock sensor may be working.

In this case, correct the path o r attitude to avoid interference with the jig.

Urgent failure (0201)

Error (0221)

Reset Request (0209)

Failure Code (0374 - 370)


The "ABNOMLTY ENCODE" ON setting affects the signals being output when the

following failures occur:

Emergency Stop

1 EMERGENCSTOP 1

Servo OFF

/ SERVO OFF I

If the setting is ON, Urgent Failure (0201)

and Error (0211) a re not output.

If the setting is ON, Operational Failure (0205)

and Alarm (0212) a r e not output.

5.2.5 Software Limit /L ink Software L im i t

(1) Software Limit Failure

This failure is detected when the mechanism attempts to move out of the working

area .

* Teach mode

p G i z x q 1 S.LIMIT XYZZ I 1 +MANUAL OPE. 1

* Auto mode

EA50201-0110

S.LIMIT XYZZ

X: Mechanism number

Y: Axis number (Displays the lowest axis number if multiple axes a r e involved)

Z: Axis information (Displays the Soft Limit of each axis a s bit information)

Tens' place 1 Unit's place

Axis Axis Axis Axis Axis Axis


(Example] When Software Limit occurs a t Axes 4 and 5

Tens' place 1 Unit's place

Axis Axis Axis Axis Axis Axis

In this case, "28" is displayed a t the ZZ.

Solution

(A) Teach mode

Perform manual manipulation in the direction which allows the Software Limit

to be cancelled.

03) Auto mode

After pressing the RESET key, turn on the servo power supply. Then,

perform manual manipulation in the direction which allows the Software Limit to

be cancelled.

(2) Link Software Limit

This failure occurs when the mechanisms could interfere with each other.

Teach mode

-1 +MANUAL OPE.

Auto mode

YY: Axis numbers (For example, if "23" is displayed, this indicates that Link

Software Limit has occurred a t axes 2 and 3.)

Solution

(A) Teach mode

Perform manual manipulation in the direction which allows the Link Software

Limit to be cancelled.

03) Auto mode

After pressing the RESET key, turn on the servo power supply. Then, perform

manual manipulation in the direction which allows the Link Software Limit t o

be cancelled.


5.2.6 Overrun

This failure occurs when the robot overruns.

EB00301 -XXXX

OVER RUN

-+ RESET

Solution

After pressing the RESET key, perform manual manipulation in the direction

which allows Overrun to be cancelled, while holding the SERVO CN button down

If this failure occurs though the robot has not overrun, the cause may be the

following:

(A) Any one of JP 501, 502, and 503 on the Interlock board is not short-circuited.

-,Short-circuit it.

(B) 24V is not supplied to Interlock board.

+Check the connection between CN 41 of the Int' .-lock board and CN41 of

the constant voltage power supply.

(C) The fuse on the Interlock board is blown.

+Replace the fuse.

(D) Interlock board failure.

+Replace the Interlock board.


5.2.7 Communication Fai lures

(1) Board To Board Communication Failure

This failure occurs when communication cannot be performed correctly between

boards.

EC10206-YYXX

COMUCTN ERR

-+ POWER OFF

Y Y : 0 1 ... Main Board - Motion Control Board Communication Failure

0 2 Main Board - 1/0 Management Board

Comniunication Failure

0 3 ... Main Board - Teaching Box Communication Failure

Solution

02) YY:O1

Make sure that the Motion control board or EPROM on the Motion control

board is placed correctly.

(B) YY:02

Make sure that the I/O management board o r EPROM on the 1/0 management

board is placed correctly.

(C) YY:03

Make sure that the Main board o r EPROM on the Main board is placed

correctly.

(2) Echo Back Communication Failure

This is 1/0 management board or Teaching box failure.

EC10208-YYXX

COM. ERR

-+ POWER OFF

Y Y : 0 2 Main Board - 1/0 Management Board.

0 3 .-. Main Board - Teaching Box


Solution

(A) Y Y : O 2

Replace the I/O management board.

(13) Y Y : 0 3

Replace the teaching box.

(3) DPRAM Failure

This is Main board o r 1 /0 management board failure.

EC10209-YYXX

DPRAM ERROR

-+ POWER OFF

Y Y : 0 0 Main board - Motion control board.

0 2 ..- Motion control board - 1/0 management board.

Solution

(A) Y Y : O O

Replace the Main Board.

03) Y Y : 0 2

Replace the 1 /0 management board.


5.2.8 Data Installation Failures

This failure is detected when data (files) necessary to operate the robot do not exist.

If this failure is detected, it is necessary to create a required file with the System

Initialize function.

(1) Data Installation Error

p i K i E F 1 NO FILE 1 1 +-POWER OFF 1 Y Y Y Y : 0 1 0 0 -.. Can't find System Parameter file.

0 1 0 1 ... Can't find Manual Operating Speed Table file.

0 1 0 2 .-. Can't find Block Operating Speed Table file.

0 2 0 0 Can't find Sequencer file.

Solution

0 YYYY: 0100

If your system consists of a single robot unit, select the "SYSTEM" function

key with the System Initialize function and create a System Parameter file. Then,

set the offset adjusting values and the tool parameters.

If your system consists of multiple mechanisms, select the "SPECIAL" function

key with the System Initialize function and load the system parameters from the

external storage.

u3) YYYY: 0101

Select the "MANUAL" function key with the System Initialize function and

create a Manual Operating Speed Table file.

(C) YYYY: 0102

Select the "BLOCK" function key with the System Initialize function and create

a Block Operating Speed Table file.

(Dl YYYY: 0200

Select the "SQ" function key with the System Initialize function and create a

Sequencer file.


(2) Data Installation Alarm

A 10601-YYYY

NO FILE

+POWER OFF

Y Y Y Y : 0 2 0 1 .-. Can't find Welding Characteristic Data file.

0 2 0 2 Can't find Welding Control file.

0 2 0 3 ..- Can't find Current Conversion Table.

8 1 0 0 ... Can't find Arc Sensor file.

8 4 0 0 Can't find Laser Sensor file.

Solution

(A) YYYY : 0201, 0202, o r 0203

Select the "WELD" function key with the System Initialize function and

create a file.

(E3) YYYY: 8100

Select the "ARC-S" function key with the System Initialize function and

create a Arc Sensor file.

(C) YYYY: 8400

Select the "LASER-S" function key with the System Initialize function and

create a Laser Sensor file.


5.2.9 Memory Fai lures

(1) ROM Failure

This failure is detected when the EPROM o r board is broken o r the wrong EPROM

is inserted.

EC10801 -YY00

ROM ERROR

+POWER OFF

Y Y : 0 0 ... Main board

0 1 Motion control board

0 2 -.. I/O management board

0 3 ... Teaching box

Solution

Replace the EPROM on the identified board o r that board itself.

(2) RAM Failure

The identified board is failure.

EC10802-YY00

RAM ERROR

+ POWER OFF

Y Y : 0 0 Main board

0 1 ..- Motion control board

0 2 4 . . 1/0 management board

0 3 ... Teaching box

Solution

Replace the identified board.


5. 2.10 Setting Errors (1) Motor Setting Failure

This failure occurs when the system parameter setting for rnotor type differs from

the SCON board setting for motor type.

EC20101-XXXX

MOTOR ERROR

-+ POWER OFF

Solution

Turn off the control power supply, set the rotary switches SW 3 - SW 5 on the SCON

boards to the correct values.

The following table shows the SCON board rotary switch setting for each mechanism:

Table 5.8 Rotary Switch Settings for Axis Motors of Manipulator

1 SCON for Base Axes I SCON for Wrist Axes

V40 I SCON not in use for V40

Manipulator

PSB series 1

Axis 1

S W 3

Table 5.9 Rotary Switch Settings for Slider Motor

RSR series I 7

Slider


Axis 2

S W 4

Relevant switch setting of SCON SW3 to SW5

Axis 3

S W 5

Axis 4

S W 3

Axis 5

S W 4

Axis 6

S W 5

1 Relevant switch / Relevant switch

Table 5.10 Rotary Switch Settings for Positioner

/ setting of SW3 -SW5 / setting of SW3 -SW5

Axis 1

(2) Axis Setting Failure

This failure occurs when the SCON board rotary switch setting for the number of

controlled axes is wrong.

Axis 2

EC20102-XXXX

AXIS SET ERR

-+ POWER OFF

Solution

Turn off the control power supply and set the SCON board rotary switch SW 5 to the

correct value.

The following table shows the SCON board SW5 setting for the number of controlled

axes:

Table 5.11 SCON Board SW5 Settings for the Number of Controlled Axes

SW6 Setting I Controlled Axes


5.2.1 1 ABSO Data Failure

This failure is detected when the difference is larger than the allowance in

comparison with the encoder value given when the servo power is shut off and that

when turned on. The allowance and check ON/OFF a r e set in "FUNC OF ABSO DATA

CHECK" of the user parameters for setting the system status.

A 11102-YYXX

ABS MISMATCH

-+RESET

YY: 11 - 15 ... SCON/PCON board No.1 - No. 5 (See the unit code table.)

Solution

Run Task program P999 used for checking the origin by block operation and check

the marks. If these marks do not align, reset the absolute encoders and perform the

absolute offset adjustment. If the marks align, the absolute offset values a r e correct.


5. 3 When Servo Failure Occurred 5.3. 1 How to see the Servo Failure Display

This section describes how to see the Servo Failure Code. When Servo Failure

occurred, the Teach Pendant displays the abnormal axis and information of the

failure as shown in Fig.5.1.

Servo Failure can be identified in detail according to:

* Failure category No.

Message (not displayed in some cases)

Failure information codes

t t t

Column : a b e d

Fig.5.1 Example of Servo Failure Display

+Failure category No.

+-Message

I Failure information

codes


(1) Failure Category No.

When Servo Failure occurred, the Teach Pendant displays the following:

"SERVO ABN * * "

A number is displayed a t " * * ", by which the detailed failure can be identified

a s shown in Table 5.12:

Table 5.12 Failure Category Nos.


Meaning

Failure was detected a t Servo Control

Board.

Servo Control Board malfunctioned.

Servo power was shut off due to

unknown cause.

The temperature extremely increased in

the control unit.

Failure occurred in the Servo Driver

Unit

(For details, see Table 5.14 and 5.15)

Failure occurred in the Servo Driver

Unit.

(For details, see Table 5.14 and 5.15)

The Servo Driver cannot be energized.

The position deviation exceeded the set

value.

The commanded speed exceeded the set

value.

The commanded voltage exceeded the

set value.

Failure occurred when the servo power

was turned on.

* *

3

4

6

7

8

9

1 0

1 2

1 3

1 4

9 9

Name of Failure

Servo Control Board error

CPU failure of SCON Board

Servo power shutoff

Overheat in the Control Unit

Servo Driver failure

Position output failure

Abnormal position/speed

loop ON state

Beyond the position deviation

limit

Beyond the speed command

limit

Beyond the current command

limit

Failure a t the servo startup

(2) Message (not displayed in some cases)

For Servo Failure 8 "Servo Driver Unit failure", a message and failure

information codes a r e displayed to give more detailed information.(These

information may be also displayed for othe failures.)

The content of a message corresponds to the failure information codes, and is

displayed a s shown below. If multiple failure a r e detected, only the earliest failure is

displayed.

Mechanism [No. 11Axis [No. 21 [Failure information]

[No. 11 indicates the number of the mechanism where failure was detected.

This number corresponds to any of mechanism numbers 1 - 4 of LEDs which a r e

illuminated by selecting the Axis Changeover key "MECHANISM".

[N0.21 indicates the axis number of the mechanism displayed a t [No. 11.

Note that this number is not an axis number used in the entire control unit.

[Failure information] shows the information of a detected failure, for example:

- MECHA * * AXS MOTOR 0-HEAT(Motor Overheat a t Mechanism * Axis * ) - MECHA * * AXS ENCODER ABN.(Encoder Failure a t Mechanism * Axis * ) - MECHA * * AXS POWTR.0-HEAT

(Power Transistor Overheat a t Mechanism * Axis * ) - MECHA * * AXS OVER CURRENT(0ver Current a t Mechanism * Axis * ) - MECHA * * AXS CURRENT ABN.

(Instantaneous Current Limit Over a t Mechanism * Axis * ) - MECHA * * AXS OVER LOAD (Over Load a t Mechanism * Axis * ) - MECHA * * AXS OVER SPEED

(Speed exceeding detectable limit a t Mechanism * Axis * ) - MECHA * * AXS OVER DEVIAT.

(Position Deviation Limit Over a t Mechanism * Axis * ) - UNIT * OVER VOLTAGE(0ver Voltage a t Unit * ) - UNIT * LACK VOLTAGE(Low Voltage a t Unit * ) - UNIT * STOP INVRTR(1nverter Disconnect a t Unit * ) - UNIT * A/D ABNORMAL(Fai1ure of A/D signal line a t Unit * ) - UNIT * STOP SIGNAL (Stop signal input a t Unit * )


(3) Failure information codes

The abnormal par t can be identified from Fig.5.1, as shown in Table 5.13:

Table 5.13 Interpretations of Codes

0000 indicates that that part is normal, while any number (displayed in the

hexadecimal notation) except 0000 indicates that that par t is not normal.

Furthermore, the detailed failure can be identified by the number.


d

Failure of

Axis 3

Failure of

Axis 6

Failure of

Axis 9

Failure of

Axis 12

Failure of

Axis 15

Column -+

UNIT 1

(Axes 1-31

UNIT 2

(Axes 4-6)

UNIT 3

(Axes 7-9)

UNIT 4

(Axes 10-12)

UNIT 5

(Axes 13-15)

b

Failure of

Axis 1

Failure of

Axis 4

Failure of

Axis 7

Failure of

Axis 10

Failure of

Axis 13

a

Failure of P a r t common

to each axis

Failure of Par t common

to each axis

Failure of P a r t common

to each axis


to each axis


to each axis

c

Failure of

Axis 2

Failure of

Axis 5

Failure of

Axis 8

Failure of

Axis 11

Failure of

Axis 14

a ) Failures Common to Each Axis

When a number, except 0000, is displayed a t column a in Fig.5.1, a failure can be

identified from Table 5.14

Table 5.14 Common Failure Codes

Code I Meaning

Overvoltage of Main power

+This bit sometimes

(Main power off) indicates that the

0004

0008

Disconnection of Inverter signal line servo power is shut

Failure of A/D signal line off, and in that case

0010

0020

Codes in Table 5.14 a r e displayed in the hexadecimal notation on the Teach

Pendant.

If multiple failures occur, a sum of these codes is displayed.

not failure.

0100

(Example1 Meaning of Failure a t column "a" of UNIT 1

Input of Stop signal

0004 : Disconnection of the inverter signal line of the first Servo Control board

+) 0008 : Failure of the A/D signal line of the first Servo Control board

OOOC : Disconnection of the inverter signal line (0004H) and failure of the A/D

signal line (0008H) of the first Servo Control board (0004H + 0008H)


b ) Failure Codes of Each Axis

When a number, except 0000, is displayed a t column b, c, o r d in Fig.5.1, a failure

can be identified from Table 5.15:

Table 5.15 Failure Codes of Each Axis

I Overheat of power transistor

Code

0 0 0 1

0 0 0 2

I Overcurrent

Meaning

Motor overheat

Encoder failure

I Over limit of momentary current

I Overload

I Over limit of detectable speed

Codes in Table 5.13 a re displayed in the hexadecimal notation on the Teach

Pendant.

If multiple failures occur a t one time, a sum of these codes is displayed.

0 2 0 0

(Example] Meaning of Failure a t column "c" of UNIT 2

Over limit of position deviation

0001 : Overheat of Axis 5 motor

+) 0004 : Overheat of Axis 5 power transistor

0005 : Motor Overheat(0001H) and Power Transistor Overheat(0004H) of Axis 5

(0001H + 0004H)


5.3.2 Troubleshooting for Servo Failures

1 Symptom 1 I Check Item 1 I Possible Cause 1

Servo Failure

1 4 1 CPU failure of

Refer to (3) of section 5.

3.1 to remove the cause.

SCON board

Failure detail

codes not "0000"

Servo Failure

3

1 Servo gFailur-e t

-

SCON board

Servo power

-

shutoff

Red LED ON

and green LED

OFF on Servo

error -

li Imperfect contact H Check that the Servo I I / of Servo Control

Take some measures to

protect from noise.

All failure codes

showing "0000"

Noise affecting the

servo system

I Control board is in 1

- -

I Control board

I I board. 1 place.

Servo con- Replace the Servo

Problem of system Install the system

board failure 1 Control board.

Noise affecting the Take some measures to

parameters 1 parameters again.

Red LED on

Motion control 1 board ON 1 servo system

Incorrect

placement of

Motion control

1 protect from noise.

Motion control

board or Servo

Control board

failure

Make sure that the

Motion control board

is placed correctly.

Replace the Motion

control o r Servo

Control board.


Control board

and Servo driver

flickering. + Slow rotation of

the fan I lOOV outlet

I below 75V I

I Action I Low voltage on Verify the voltage on

primary power the primary power

supply (below AC

I5OV)

the controller Ambient temp. Use within the I

Replace the cooling

unit.

1 over the allowance 1 1 allowable temperature. I

P

Servo Failure

7

Replace the Backplane

Overheat in

Temperature in

the controller

-

over 60°C.


-

the controller

under 60°C.

Cooling unit

failure

I element failure

-

1 board. I

Servo Failure

Servo driver

failure

Display of

Servo Failure

I on teaching box 1 /SERVO ABN 8 / 1

I Power supply

indicator lamp

U N I T ~ :-

showing "0002"

Loss of U phase

(wire 4) of

primary power

supply (3-phase

"UNIT1 LACK

VOLTAGE " a t

Q,"OOO2" a t

UNITla, and

INVRTR" a t

@ a , and "0002"

a t UNIT2 @ shown

Imperfect contact

of cable connecting

servo driver CN1

for axis shown by

"000C" o r "0002"

and Servo Ctrl.

board CN2, or

cable connecting

servo driver CN2

and power unit

1 Replace the breaker. I

-

1 Make sure that the

cable connection is

correct.

Verify the voltage on

each of the primary

side phases before

connecting.

Replace the cable. m

I Replace the cable.

"UNIT1 LACK

VOLTAGE" a t

Q , and "0002"

a t UNIT1 @ and


I ,

LED 301 (OUT1)

on relay unit ON

Motion control

board failure

- ---- Replace the Motion

control board.

"UNIT2 LACK

VOLTAGE a t @, " 0002 " a t UNIT1

@, and UNIT2

@, "0002" a t

UNIT^@@@ and

UNIT2 @ shown

--

Possible Cause I Action I

Imperfect contact

of control cable 2

(manipulator CN2

and CN7 on Servo

Control board 1)

Imperfect contact

of cable connecting

CN6 on Servo

Control board 1

and switch box

CN135

Make sure that the

control cable

connection is correct.

/ Replace the cable.

I Make sure that the

cable connection is

correct.

/ Replace the cable.

Switch box failure Replace the Switch box

1 of control cable 3 1 ~ m ~ e r f e c ~ ~

(manipulator CN3

and CN7 on Servo

Control board 2)

Make sure that the

control cable

-

I connection is correct. 1

Replace the cable. + Imperfect contact

of cable connecting

CN6 on Servo

Control board 2

and switch box CN

136

1 Make sure that the

cable connection is

correct

-

Replace the cable. + Switch box failure Replace the Switch box


"MECHAl 0 AXS OVER

LOAD" a t @, "0020" a t any of

UNITl m, and UNIT2 @@ @ shown

Possible Cause I I Action I

Imperfect contact Make sure that the

control cable

connection is correct.

1 Disconnection of Replace the cable.

I motor line

"MECHAl 0 AXS CURRENT

ABN" a t @ "0010"at any of

UNITl m and UNIT2

shown

" M E C H A 1 0

AXS OVER

CURRENT"

current a t @, and "0008" a t

any of UNITl @ @@ ,and UNIT2

m shown

Wrong dip switch Check the dip switch

1 setting on Servo 1 1 setting and set I

----- Fuse blown by Check the fuse.

/ Control board

I over current flow / I

1 correctly.


/ to servo driver I Replace the fuse

1 Symptom 1 I Check Item I

"MECHA1 O A X

S OVER DEVIA

T." a t @and

"0200" a t any of

~ ~ 1 ~ 1 m , a n d

UNIT2

shown

"UNIT1 STOP

INVRTR" a t @ and "0004" a t

UNITl@ shown

[ Possible Cause I

The origins of Perform absolute

mechanical stopper

and software limit

I offset adjustment. I

Imperfect contact Check the encoder

/ that axis. 1 / of encoder cable

Disconnection of Replace the encoder

1 cable connection of

Motor failure Replace the motor.

/ encoder cable

Disconnection of Replace the cable.

/ cable.

I motor line

--r/ Imperfect contact

I / of flat cable

connecting Servo

Control board and

"UNIT2 STOP

INVRTR" a t @ 1 -4 and "0004" a t /--

I UNIT2 @ shown /

I servo driver

-

Make sure that the


connection.

-

I is placed correctly.

Disconnection of

flat cable

board failure

Replace the servo

-4 Replace the flat cable. 1

I Servo Control board I


failure driver.

I Symptom I

"MECHA10

OVERCURRENT'

a t @. and "0008"

a t any of UNITl

shown

I "MECHA10

AXS CURRENT

ABN." a t @, and

"0010" a t any of

UNITl

I Action 1

"MECHA10

AXS CURRENT

ABN." a t @, and

"0010" a t any of

UNIT2

shown

- - Blown fuse on Check the fuse.

servo driver o r

-

robot overrun

I

/ Cancel the overrun.

1 Wrong flat cable

1 connection between 1 I Servo Control / 1 board and servo 1 1 driver (Base axes) 1

Wrong encoder

cable connection

(CN7) between

Servo Control

board (Base axes)

and (Wrist axes).

1 Check the cable I 1 connection and connect 1 correctly.

Note)

Check the fuse on the

I servo driver indicated I 1 because it may be 1 / blown.

1 Check the encoder

cable connections and

connect correctly.


Replace the servo

driver.

- -

Servo driver

failure

- -

All detail codes

showing "0000"

-

Both red and

green LEDs on

Servo Control

board ON

Servo system I failure

I Only green LED

on Servo Control

I board ON

"MOTOR

0-HEAT" at@,

and "0001" a t

any of 1 shown 1

--( Refer to (3) of section 5. 1 3.1 to remove the cause.

r/ Overload on the H Reduce the load.

I manipulator I

1 driving mechanism I Defective

adjustment to the

I of the machine I

Check the machine.

--( "ENCODER

ABNMat 8 , and

"0001" a t any of

m shown

Replace the motor.

Check the encoder

of encoder cable 1 cable connections

and connect

I correctly. I Disconnection of Replace the encoder

Replace the servo

I encoder cable.

/ AT" a t 8, and I I failure. / driver.

1 cable. I

1 "0004" a any of 1 I m shown !


Servo Failure I 9 t Position

output failure

Servo Failure l-2L.J Abnormal

position/speed

loop ON state

I Possible Cause I Action I

" A/D Imperfect contact Check the cable

Replace the encoder.

Replace the servo

-

/ shown

ABNORMAL1' a t I / of cable in servo 1 1 connection and connect I

"OVER SPEED"

a t @ and "0100"

a t any of @@@ 1 failure

"OVER VOLT- Reduce the

[ driver.

@ and "0008" a t driver. 1 correctly.

( shown 1

AGE" a t @ and

"0008" a t @

) board 1 board 1 is placed correctly.

voltage on ACBOOV primaryside voltage.

Replace the Motion

Incorrect placement

of Motion control

--- -

board or Servo control board or Servo

board or Servo control board or Servo

Make sure that the

Motion control board Red LED 3 on

Motion control

Detail f a r 1 I Refer to (3) of section 5. 1

Check the printed

board is placed

correctly.

-

codes not "0000" 1 3.1 to remove the cause. /


Green LED on

Servo Control

board OFF

Incorrect

placement of Servo

Control board

---- -

I Symptom 1

Servo Failure

Beyond the

position

deviation limit

1 Check Item I I Possible Cause I I Action 1

Re-install the system

Replace the fuse.

showing "0000" 1

/ I Interlock board I

Noise affecting the Take some measures to

parameters parameters.

None of Axesl- 6

operable by

manual

system

I manipulation /

I protect from noise.

Imperfect contact

of motor line

i Check the connections I I of Servo driver

I connectors CN51- CN56. I

I operation I

Failure a t Problem of system Re-install the system

Reduce the mechanical

load.

highspeed 1 I parameters parameters. I

Too large load -

Beyond the

Failure a t

highspeed

/ operation

1 1 6 operable by I 1 of motor line / of the motor power I

speed

command limit

I / manual I I line.

--( None of Axes 1 - Check the connection

/ manipulation

Noise affecting Take some measures to

1 the system

Beyond the

current

1 protect from noise.

command limit

Reduce the mechani

cal load.

1 operation Take some measures

Servo Failure

14

- -

Failure when

starting


4 Too heavy

1 the system 1 to protect from noise. /

I Symptom I I Check Item I Possible Cause I

servo s tar tup

- Servo Failure

99

Failure a t the 1 according t o the

Perform the same

checks as those of

Servo Failure 8

1 servo failure display on

/ the teaching box.


Chapter 6 Periodic Inspection

Contents

6. Per iodic Inspect ion 6.1 Warranty Period

(1) DAIHEN provides free repair for any defect in the product which arises out of

defective workmanship during the warranty period- a shorter period of either one year

after the date of the takeover o r 2000 hours of the cumulative operating time-, provided

that the product is properly used, maintained, and inspected in accordance with the

instructions described in the manuals.

(2) The warranty does not include free repair for:

01$ Any defects arising out of mis-operation o r improper operation

(B) Any defects arising out of repair o r reconstruction done by the user o r a third

party

(C) Any damages and failures caused by natural disasters such as earthquakes, fires

and floods

(Dl Any defects arising out of improper transfer o r storage of the product after the

takeover

(E) Any other defects that a r e not covered in (1)

(3) This warranty is only applicable to the robot equipment installed in Japan.

6.2 Periodic lnspection Schedule The periodic inspection is a n indispensable activity for safety and efficient operation of

the robot, and should be conducted in accordance with the following schedules:

Routine inspection / Daily inspection before and after operation

3 month inspection / Inspection a t each 500 hour interval

6 month inspection / Inspection a t each 1000 hour interval

1 year inspection 1 Inspection a t each 2000 hour interval

3 year inspection 1 Inspection a t each 6000 hour interval

6 year inspection I Inspection a t each 12000 hour interval

These inspection intervals a r e based on the standard operating hours (8 hours/day).

Periodic lnspection 6 - 1

6.3 Notes for Performing Periodic lnspection (1) The periodic inspection should be carried out by o r in the presence of personnel who

attended a national o r DAIHEN special training course and a DAIHEN maintenance

training course.

(Refer to the Regulations on Industrial Robots, Art.19 and Art.36, Para.32.)

(2) Before performing maintenance/inspection works, be sure to turn the external

switchboard OFF. If not, the primary voltage is impressed to the breaker in the

control unit even if the breaker is turned off. Take some measures to prevent the

power source from being carelessly turned on during inspection, for example, by

providing a notice plate indicating "Inspection".

CAUTION 3

For routine inspection items, refer to the "Safety Management" instruction manual.

\ 2

6.4 L is t of lnspection Items

6 - 2 Periodic Inspection

7

8 9 --

0

0

Interface

Cooling unit

Charging batteries 0 Memory lithium batter Replace.

Grease, fume, and dust

pp

found.

Clean up.

Replace.

C h a p t e r 7 P a r t s L i s t

Contents

7.12 BIRBX-1005 control cables 7-24

7.12 1 control cable 1 2 3 ( F ~ ~ ~ 0 1 ~ 0 1 ~ 0 1 ) 7-24 , f 8 t

7 12 2 cables / H~~~ .................................................................................................................................................... 7-24 . . 7.12.3 Control Cable5 (For Almega Auto II- Robot Control Unit) 7-25

This chapter presents par ts lists of the standard robot control units including their

peripheral equipments. Because these par ts numbers could be different from those available for

special products, when placing a n order for replacement, you a r e requested product number

marked on the brand plate of the robot control unit along with the par ts numbers.

For delivery and price of maintenance parts , contact a robot distributor o r a DAIHEN sales

representative.

Par tsL is t 7 - 1

7.1 IRBCX-422 Robot Control Unit (Fig. 7.1.0.1)

* :Use the par ts marked " * " for Robot Control Unit shipped as TIG Welding o r Plasma

Cutting Specifications.

7 - 2 Parts List

P a r t s No. 4810-912

E6029A00

4519-009

4610-008

4814-017

4814-018

4805-027

4600-317

4600-341

5096-138

5096-156 * 5096-139

5096-157 * E5787A00

L4000R00

L4268R00 * L3700D00

L3700COO

L3700M00

L4024M00

L3702F00

L3899YOO

E5741A00

E5685A00

5096-095

5096-140

L4000E00

4614-046

4739-272

4739-273

4732-017

3364-005

3364-123

Q'ty 1

1

(1)

(1)

(1)

(1) 4

1

1

1

1

1

2

Drawing No. /Type

W-LOO470

E6029A00

NDHOO3

lA, AC125V

RWS15A-5

LWQ130-5FF4

4715PS-20T-B30

AH164-ZSWM1

NPA10-2H-WS

W-LO0455 o r

W-LOO554

W-LO0456 o r

W-LOO555

E5787A00

L4000R00 o r

L4268R00

Ref Na

0 0

0 - 1

0 - 2

0 - 3

0 - 4

0 @ 0

@

0

Item

Auxiliary Transformer

Power Unit

Noise Filter

Glass Fiber Fuse

Constant Voltage Power Supply


Cooling Fan

Lamp

Neon Lamp

Servo Driver Unit

Servo Driver Unit

Servo Power Unit

P.C.B.(Servo Control)

0 8

8

@ 8

@

0 @ 8 @ 0 8 @ @ 8

P.C.B.(Motion Control) pp

P.C.B.(Main Processor)

P.C.B.(I/O Management, Standard type)

P.C.B.(I/O Management, Extended Type)

~ . C . ~ . ( ~ a c k ~ l a n e )

P.C.B.(Interlock) P.C.B.(Terminal Block) o r

P.C.B.(Relay) Memory Battery

Charging Battery

Cooling Unit

Auto Breaker

Breaker Handle

Door Key Handle

AC Socket

Eye Bolt

Hanger

L3700COO

L3700M00

L4024M00

L3702F00

L3899YOO

E5741 A00

E5685A00

W-LOO233

W-LOO471

L4000E00

SA33B-30A

BZ-N2OB

A-120-1

AC-T04FB04

M12-ZMC

A-1042B-7

1

1

1

1

1

1

1

1

1

1

1

1

2

1

2

1

Fig.7.1 .O. 1 IRBCX-422 Robot Control Unit

Parts List 7 - 3

7.2 I RBCX-462 Robot Control Unit (Fig. 7.2.0.1)

Servo Driver Unit

* :Use the parts marked " * " for Robot Control Unit shipped a s TIG Welding o r Plasma


7 - 4 Parts List

Fig.7.2.0.1 IRBCX-462 Robot Control Unit

Parts List 7 - 5

7.3 I RBCX-512 Robot Control Unit (Fig. 7.3.0.1)



7 - 6 Parts List

Ref No.

0 0

0 - 1

0 - 2

0 - 3

0 - 4

@

Item


Power Unit

Noise Filter

Magnetic Contact



Cooling Fan

Drawing No./Type

W-LOO470

E6029A00

NDH003

lA, AC125V

RWS15A-5

LWQ130-5FF4

4715PS-20T-B30

Q'ty 1

1

(1)

(1)

(1)

(1)

4

@ 0

8

0

P a r t s NO.

4810-912

E6029A00

4519-009

4610-008

4814-017

4814-018

4805-027

1

1

1

1

4600-317

4600-341

5096-136

5096-154 * 5096-137

5096-155 * --

Lamp

Neon Lamp

Servo Driver Unit

Servo Driver Unit

E5787A00

L4000R00

L4268R00 * L3700D00

L3700COO

L3700M00

L4024M00

L3702F00

L3899YOO

E5741A00

E5685A00

5096-095

5096-140

L4000E00

4614-046

4739-272

4739-273

4732-017

3364-005

3364-123

8

0

0 8

8

@ @

8

0 @ 8 @ 8 @ @ @ 8

AH164-ZSWM1

NPA10-2H-WS

W-LO0393 o r

W-LOO552

W-LO0394 o r

W-LOO553

Servo Power Unit


P.C.B.(Motion Control)




P.C.B.(Backplane)

P.C.B.(Interlock)

P.C.B.(Terminal Block) o r

P.C.B.(Relay)

Memory Battery

Charging Battery

Cooling Unit

Auto Breaker

Breaker Handle

Door Key Handle

AC Socket

Eye Bolt

Hanger

E5787A00

L4000R00 o r

L4268R00

L3700D00

L3700COO

L3700M00

L4024M00

L3702F00

L3899YOO

E5741A00

E5685A00

W-LOO233

W-LOO471

L4000E00

SA33B-30A

BZ-N20B

A-120-1

AC-T04FB04

M12-ZMC

A-1042B-7

1

2

1

1

1

1

1

1

1

1

1

1

1

1

2

1

2

1

Par tsL is t 7 - 7

7.4 IRBCX-532 Robot Control Unit (Fig. 7.4.0.1 >

Mark 33 shows the different parts from IRBCX-512.

% @ % 0

- 1

% @ % 8 33 @

@ 8 @

7 - 8 Parts L is t

P.C.B.(Break Unit)

Cooling Unit

Cooling Fan

Auto Breaker

Breaker Handle

Door Key Handle

AC Socket

Eye Bolt

Hanger

E5735A00

L3887E00

1099302

SA53B-50A

BZ-N20B

A-120-1

AC-T04FB04

M12-ZMC

A-1042B-7

1

1

(4) 1

1

3

1

2

1

E5735C00

L3887E00

4805-031

4614-039

4739-272

4739-273

4732-017

3364-005

3364-123

Fig.7.4.0.1 IRBCX-532 Robot Control Unit Parts L i s t 7 - 9

7.5 I RBCX-541 Robot Control Unit (Fig. 7.5.0.11

* :Use the par ts marked " * " for Robot Control Unit shipped a s TIG Welding o r Plasma


Mark 33 shows the different parts from IRBCX-512.

0 8 @ @ @ 0

7 - 1 0 Par ts L i s t

Auto Breaker

Breaker Handle

Door Key Handle

AC Socket

Eye Bolt

Hanger

SA33B-30A

BZ-N2OB

A-120-1

AC-T04FB04

M12-ZMC

A-1042B-7

1

1

2

1

2

1

4614-046

4739-272

4739-273

4732-017

3364-005

3364-123

Parts L is t 7 - 1 1

7.6 IRBCX-551 Robot Control Unit (Fig. 7.6.0.1)

Servo Driver Unit



Mark % shows the different parts from IRBCX-512.

Parts List 7 - 1 3

7.7 BBOPX-3000 Operation Panel (Fig. 7.7.0.1 > Ref No. I Item 1 Drawing No. /Type I Q'ty 1 P a r t s NO.

I I I I

0 I Push Button Switch 1 AVN3OlN-R 1 1

0

4250-023

0

@

7 - 1 4 Parts List

Illuminated Push Button Switch

0

@



AH164-TLR11E3

Panel

Protection Cover Assy

AH164-TLY 1 lE3

AH164-TLGl lE3

2

E5761B01

4250-069

2

1

4250-070

4250-071

1

1

E5761B01

Fig.7.7.0.1 BBOPX-3000 Operation Panel

Parts List 7 - I 5

7.8 BBOP-3008 Operation Box (Fig. 7.8.0.1)

LED Lamp

0 Dust Proof Cover

@ Protection Cover

0 Panel

7 - 1 6 Parts List

Fig7.8.0.1 BBOP-3008 Operation Box

PartsList 7 - 1 7

7.9 BBTBX-6008 Teaching Box (Fig. 7.9.0.1 ) Ref NO. I Item / Drawing No./Type I Q'ty 1 Par t s No.

% I Printed Board I I I

Cable Assy

Sheet Keyboard

Sheet-key Cover

Liquid Crystal Unit

Window Sheet

Ultraviolet Cut-off Filter

Push Button Switch (Emergency Stop)

Push Button Switch (Servo ON)

Push Button Switch (Light)

Lamp Bracket

Pilot Lamp

Panel

Case

I Protective Sheet

Handle

7 - 1 8 Parts List

Insulating Sheet 2 E5680B04

W-LOO588

E5680B07

E5680H00

NB10146

E5680B08

W-36233

MB-2011-8K

MB-2065

B-113 El0

2.2V, 0.25A

E5680B02

E5680B01

E5680B03

W-LOO230

E5680B04

1

1

1

1

1

1

1

1

1

1

1

1

1

1

5096-184

E5680B07

E5680H00

NB10146

E5680B08

4250-021

4250-028

4250-029

4600-327

4600-304

E5680B02

E5680B01

E5680B03

3364-006

7."1 BBST-4005 Starting Box (Fig. 7.10.0.1 ) Ref Na I Item 1 DrawingNa/Type / Q'ty / P a r t s NO.

@ I Illuminated Push Button Switch (G) / AH164-TLGllE3 / 1 1 4250-071

I I I 6

I LED Lamp

@I I Illuminated Push Button Switch (R) / AH164-TLRllE3 / 1 / 4250-069

0 Protection Cover

1 AB6M-VIR 0

--

8 Panel

4250-082 Push Button Switch

0 Case / E6039B01 / 1 / E6039B01

8 Connector

7 - 2 0 Parts List

fig.7.10.0.1 BBST-4005 Start ing Box

Parts List 7 - 2 1

7.1 1 BBWF-0105 Welding Interface (Fig. 7.11.0.1)

Ref NO.

0

0 0 @

0 @ 0

@

@

@

0

@ 8

0 8

@

63

0 @

8

@ @ @,

8

Drawing No. /Type

W-35692

199-RK

250V 2A

250V 0.5A

250V 2A

250V 1A

NSA-015-50P

109S091 or

MU925S-11

GGlOV 1R

S-332R

E5136E00

E5136F00

E5624G00

E5620C00

HS25RE-4

HS25RE-6

SRCN2A-21-10s

25-5BD

SG-22A

LY2-DH2 DC24V

G4D-212P-200

DC24V

LY2-DH2 DC24V

LY2-DH2 DC24V

G-2VN-234P

L3497YOO

Item


Indicator

Glass Tube Fuse

Glass Tube Fuse

Glass Tube Fuse

Glass Tube Fuse

Power Supply

Small Fan

Coil Resistor

Toggle Switch

Printed Board

Printed Board

Printed Board

Printed Board

Metal Plug Socket (4 Poles)


Metal Plug Socket (10 poles)


Grommet

Relay

Relay

Relay

Relay

Relay

Cable Assy

Q'ty

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

3

1

1

1

1

1

(5 m >

Parts NO.

4810-910

4600-307

4610-009

4610-011

4610-009

4610-008

4814-007

4805-025

4504-109

4251-026

E5136E00

E5136F00

E5624G00

E5620C00

4730-006

4730-010

4730-602

4730-008

3364-117

4341-101

4340-608

4341-101

4341-101

4341-126

L3497Y 00

Fig.7.11.0.1 BBWF-0105 Welding Interface


7.1 2 BI RBX-1005 Control Cables (Fig. 7.12.0.1)

7.12.1 Control Cable 1,2,3 or GOl,WOl,VOl) (1) BIRBX-1003 L3996A (3rd

0 0

0 Control Cable2 (5m) CN2 L3997COO 1 L3997COO

0 Control Cable3 (5m) CN3 L3997D00 1 L3997D00

(2) BIRBX-1005 L3997A (5m)

(3) BIRBX-1010 L3998A (10m)

Ref NO. Item Drawing N o . / ~ y ~ e Q'ty Par ts NO.

0 Control Cable1 (lorn) CN1 L3998B00 1 L3998B00

Q'ty 1

Drawing No./Type

L3996B00

Ref Na

0 Control Cable2 (3m) CN2

Control Cable3 (3m) CN3

@ I Control Cable2 (10m) CN2 / L3998C00 I 1 / L3998COO

Parts Na

L3996B00

Item


Parts NO.

L3997B00

0 I Control Cable3 (10m) CN3 1 L3998D00 / 1 1 L3998D00

L3996COO

L3996D00

Ref NO.

0 Drawing No./Type

L3997B00

Item

Control Cable1 (5m) CNl

1

1

Q'ty 1

Ref No.

0

7.12.2 Cables/ Hose

L3996COO

L3996D00

0 I Control Cable3 (15m) CN3

Item

Control Cable1 (l5m) CN1

L3999D00 I 1 1 L3999D00

@ I Workpiece Side Welding Cable(5m) I L3442B00 / 1 I L3442B00

Ref NO.

@ 0

0 I Control Cable4(5m) CN4 I L3392G00 / 1 1 L3392G00

Drawing Na/Type

L3999B00

(2) BIRB-3010 L3443A (10m)

Ref Na I Item l ~ r a w i n ~ NO. / ~ y ~ e l Q'ty 1 Parts No.

Item

Gas Hose (5m)

Torch Side Welding Cable (5m)

@ I Gas Hose (10m)

Q'ty 1

0 I Torch Side Welding Cable (lorn11 L3375E00 I 1 I L3375E00

Par ts No. L3999B00

Drawing Na/Type

L2527B00

L2527D00

@ I Workpiece Side Welding Cable(l0rn) I L3375L00 / 1 I L3375LOO

0 I Control Cable4(lOm) CN4 / L3443B00 / 1 1 L3443B00

7 - 2 4 Parts List

Q'ty 1

1

Par ts Na

L2527B00

L2527D00

@ ( Workpiece Side Welding Cable(l5m) 1 L3375N00 ( 1 ( L3375N00

Ref No. @ 0

I Control Cable4 (15rn) CN4 I L3444B00 I 1 I L3444B00

7.12.3 Control Ca ble5 (For Al mega Auto I1 -- Robot Control Unit)

Item

Gas Hose (15m)

Torch Side Welding Cable (15m)

(2) BWCB-5110 L3512A (10m)

Ref No. I Item l ~ r a w i n ~ ~ o . / T ~ ~ e l Q'ty I P a r t s NO.

Drawing No./Type

L3375VOO

L3375G00

Ref Na

@

@ I Control Cable5 (lorn) Optical Fibed L3512B00 r 1 rL3512Bo0-

Q'ty 1

1

Item

Control Cable5 (5m) Optical Fiber

/ Workpiece

Par t s Na L3375VOO

L3375G00

Ref No. @

U Manipulator

Drawing No./Type

L3392Y00

l.----J Fig.7.12.0.1 Control Cables

Item

Control Cable5 (15m) Optical Fiber


Q'ty 1

P a r t s No. L3392YOO

Drawing Na /Type

L3513B00 Q'ty

1

Par t s No.

L3513B00

7.13 BI RBX-8005 Control Cables (Fig. 7.13.0.1)

7.13.1 Control Cable 1,2,3 (For V10,V20)

(1) BIRBX-8003 L4309A (3m)

7 - 2 6 Parts List

7.13.2 Tool Control Cable (For VIO,V20)

(1) BIRBX-9105 L4357A (5m)

Ref NO.

@

Robot Coiitrol Unit IRBCX-541,551

Item

Tool Control Cable (5m) CN4

Ref NO.

0

Ref No.

@

Fig.7.13.0.1 Control Cables

Q'ty

1

Parts L i s t 7 - 2 7

Drawing Na/Type

L4357F00

Item


Parts NO.

L4358F00

Item


Drawing Na/Type

L4358F00

Q'ty

1

Drawing No./Type

L4359F00

Parts NO.

L4357F00

Q'ty

1

Par ts No.

L4359F00

7.14 B I RBX-6005 Control Cables (Fig. 7.14.0.1)

7.14.1 Control Cable 1 2 3 (For V40)

(1) BIRBX-6005 L4177A (5m)

Ref No.

0

0

0

@

7 - 2 8 Parts List

Item

Control Cable1 (lorn) CNI

Control Cable2 (lorn) CN2


Control Cable4 (lorn) CIS4

P a r t s No.

L3909B00

L3909COO

L4179D00

L4179E00

Ref No.

0

0

0

@

Drawing Na/Type

L3908B00

L3908COO

L4178D00

L4178E00

Item

Control Cable1 (l5m) CN1


Control Cable3 (15rn) CN3


Q'ty

1

1

1

1

Drawing No./Type

L3909B00

L3909COO

L4179D00

L4179E00

Par t s No.

L3908B00

L3908COO

L4178D00

L4178E00

Q'ty

1

1

1

1

7.14.2 Tool Control Cable(ForV40)

(1) BIRBX-6105 L4209A (5m)

P a r t s NO.

L4177F00

Ref NO.

0

Robot Control Unit IRBCX-532

P a r t s No.

L4178F00

Ref Na

0

Fig.7.14.0.1 Control Cables

Item


Ref Na

0

PartsList 7 - 2 9

Drawing No. /Type

L4178F00

Item


Item


Drawing No. /Type

L4177F00

Q'ty

1

Q'ty

1

Drawing No./Type

L4179F00

Q'ty

1

P a r t s NO.

L4179F00

7.1 5 Robot Control Unit for External Axes 7.15.1 IRBCX-422-1 Robot Control Unit (Fig. 7.15.1.1)

* :Use the par ts marked " * " for Robot Control Unit shipped a s TIC Welding o r Plasma


Mark % shows the different parts from IRBCX-422.

Servo Driver Unit


@ @ 0 8 @ @ 8

Cooling Unit

Auto Breaker

Breaker Handle

Door Key Handle

AC Socket

Eye Bolt

Hanger

L4000E00

SA33B-30A

BZ-N2OB

A-120-1

AC-T04FB04

M12-ZMC

A-1042B-7

1

1

1

2

1

2

1

L4000E00

4614-046

4739-272

4739-273

4732-017

3364-005

3364-123

Fig.7.15.1.1 IRBCX-422-1 Robot Control Unit

Parts List 7 - 3 1

0 - 1 I Noise Filter

7.15.2 IRBCX-422-2 Robot Control Uni t (Fig. 7.15.2.1)

Glass Fiber Fuse lA, AC125V (1) 4610-008

Constant Voltage Power Supply RWS15A-5 (1) 4814-017 - Constant Voltage Power Supply LWQ130-5FF4 il) 4814-018

Coolinn Fan 4715PS-20T-B30 5 4805-027

Lamp / AH164-ZSWM1 I 1 1 4600-317

0 I Neon Lamp 1 NPAlO-2H-WS 1 1 / 4600-341

Q'ty 1

1

Drawing Na /Type

W-LOO470

E6029A00

Ref Na

0 % 0

@ Servo Driver Unit

P a r t s No. 4810-912

E6029A00

Item


Power Unit

0 Servo Driver Unit I I I

8 Servo Power Unit E5787A00 1 E5787A00


P.C.B.(Motion Control) L3700D00 1 L3700D00

P.C.B.(Main Processor) L3700COO 1 L3700COO

P.C.B.(I/O Management, Standard type) L3700M00 1 L3700M00

P.C.B.(I/O Management, Extended Type) L4024M00 1 L4024M00

P.C.B.(Backplane) L3702F00 1 L3702F00

P.C.B.(Interlock) L3899YOO 1 L3899YOO

P.C.B.(Terminal Block) o r E574 1 A00 E574 1 A00 1

P.C.B.(Relay) E5685A00 E5685A00

Memory Battery W-LOO233 1 5096-095

Charging Battery W-LOO471 1 5096-140

Cooling Unit L4000E00 1 L4000E00

Auto Breaker SA33B-30A 1 4614-046

Breaker Handle BZ-N2OB 1 4739-272

Door Key Handle A-120-1 2 4739-273

AC Socket AC-T04FB04 1 4732-017

Eye Bolt M12-ZMC 2 3364-005

Hanger A-1042B-7 1 3364-123

Servo Driver Unit W-LOO606 1 5096-174

* :Use the par ts marked " * " for Robot Control Unit shipped as TIG Welding o r P l a s m a


Mark % shows the different par ts from IRBCX-422.

7 - 3 2 Parts List

Parts List 7 - 3 3

7.15.3 IRBCX-422-3 Robot Control Unit (Fig. 7.15.3.1)

* :Use the pa r t s marked " * " for Robot Control Unit shipped as TIG Welding o r Plasm a


Mark % shows the different par ts from IRBCX-422.

Ref No.

0 0

0 - 1

0 - 2

0 - 3

0 - 4

0 @ 0

7 - 3 4 Parts List

Item


Power Unit

Noise Filter

Glass Fiber Fuse



Cooling Fan

L a m p

Neon L a m p

Servo Driver Unit

Drawing Na /Type

W-LOO470

E6029A00

NDHOO3

lA, AC125V

RWS15A-5

LWQ130-5FF4

4715PS-20T-B30

AH164-ZSWM1

NPA10-2H-WS

W-LO0455 o r

Q'ty 1

1

(1)

(1)

(1)

(1) 7

1

1

P a r t s Na 4810-912

E6029A00

4519-009

4610-008

4814-017

4814-018

4805-027

4600-317

4600-341

5096-138


Servo Driver Unit


% @ Servo Driver Unit W-LOO605 1 5096-173



Mark 3% shows the different parts from IRBCX-512.

7 - 3 6 Parts List


* :Use the par ts marked " * " for Robot Control Unit shipped a s TIG Welding o r Plasma


Marli % shows the different parts from IRBCX-512.

Ref No.

0 0

0 - 1

0 - 2

0 - 3

0 - 4

0 @ 0

@

0

8

93 @

0 a 0

0 8

7 - 3 8 Parts List

Item


Power Unit

Noise Filter

Glass Fiber Fuse



Cooling Fan

Lamp

Neon Lamp

Servo Driver Unit

Servo Driver Unit

Servo Driver Unit





p.C.B.(I/O Management, Extended Type)

P.C.B.(Backplane)

P.C.B.(Interlock)


Drawing No./Type

W-LOO470

E6029A00

NDH003

1A, ACl25V

RWS15A-5

LWQ130-5FF4

4715PS-20T-B30

AH164-ZSWM1

NPA10-2H-WS

W-LO0393 o r -

W-LOO552

W-LO0394 o r -

W-LOO553

E5787A00

L4000R00 o r

L4268R00

L3700D00

L3700COO

L3700M00

L4024M00

L3702F00

L3899YOO

E5741A00

E5685A00

5096-095

5096-140

L4000E00

@ 1 P.C.B.(Relay)

@ @ @

Q'ty 1

1

(1)

(1)

(1)

(1)

5

1

1

1

1

1

3

1

1

1

1

1

1

Par t s Na

4810-912

E6029A00

4519-009

4610-008

4814-017

4814-018

4805-027

4600-317

4600-341

5096-136

5096-154 * 5096-137

5096-155 * E5787A00

L4000R00

L4268R00 * L3700D00

L3700COO

L3700M00

L4024M00

L3702F00

L3899YOO

E574 1 A00

M e n ory Battery

Charging Battery

Coolimg Unit

W-J_iOO233

W-LOO471

L4000E00

1

1

1

Fig. 7.15.5.1 IRBCX-512-2 Robot Control Unit





Mark 5% shows the different par ts from IRBCX-512.

Ref Na

0 0

0 - 1

0 - 2

0 - 3

0 - 4

0 @ 0

8

0

8

5% @

('Dl

Item


Power Unit

Noise Filter

Glass Fiber Fuse



Cooling Fan

Lamp

Neon Lamp

Servo Driver Unit

Servo Driver Unit

Servo Driver Unit



Drawing No./Type

W-LOO470

E6029A00

NDHOO3

lA, AC125V

RWS15A-5

LWQ130-5FF4

4715PS-201'-B30

AH164-ZSWMI

NPA10-2H-WS

W-LO0393 o r

W-LOO552

W-LO0392 o r

W-LOO553

E5787A00

L4000R00 o r -

L4268R00

L3700D00

L3700M00

L4024M00

L3702F00

L3899YOO

E574 1 A00

E5685A00

5096-095

5096-140

L4000E00

4614-046

4739-272

4739-273

4732-017

3364-005

3364-123

5096-154

8

@ 8

@

0 @ 8 0 @ @

Q'ty 1

1

(1)

(1)

(1)

(1)

5

1

1

1

1

1

3

1

1



P.C.B.(Backplane)

P.C.B.(Interlock)


P.C.B.(Relay)

Memory Battery

Charging Battery

Cooling Unit

Auto Breaker

Breaker Handle

Door Key Handle

P a r t s NO.

4810-912

E6029A00

4519-009

4610-008

4814-017

4814-018

4805-027

4600-317

4600-341

5096-136

5096-154 * 5096-137

5096-155 * E5787A00

L4000R00

L4268R00 * L3700D00 -- L3700COO

8 AC Socket 1

L3700M00

L4024M00

L3702F00

L3899YOO

E5741A00

E5685A00

W-LOO233

W-LOO471

L4000E00

SA33B-30A

BZ-N2OB

A-120-1

- @ 8

5% @

1

1

1

1

1

1

1

1

1

1

2

Eye Bolt

Hanger

Servo Driver Unit

M12-ZMC

A-1042B-7

W-LOO552

2

1

1


Par ts L i s t 7 - 4 1

Electr ical Connection Diagram

Contents

8.1 Electrical Diagram of Robot Control Uni t IRBCX-422, 462

Electr ical Connection D i a g r a m 8 - 1

bEO

EEO

ZEO

I € 0

Note)Accordlns to the use of PC% or PCB3 and also PCB5 or PCD4. BACWLANE BOARD tho nuns and vlrs No. of each tarnlnsl should be followad:

PC8 l PC88 PCB4 RESERVE 2 4 E l W T l 9 0 0 RESERVE 24EIQIJTI 900 COML 8 8 0 2 4 E l W T 1 8 0 0 COME 8 9 5 24E lOUT l Q00 COMZ 9 9 1 24E lOUT l 8 0 0 CUM7 8 9 6 24E lOUT l 900 COM3 8 9 2 24E lOUT l 9 0 0 COMB 9 9 7 2 4 E I W T l 900 COM4 8 8 3 Z4EIOUTI 8 0 0 COM9 9 9 8 24E lOUT l 800 CQMS 8 8 4 2 4 E I W T I 8 0 0 COMlO 8 9 9 Z I E I W T I 800

8121T871 ITBQlT

TUX(INAL BLOCK VI4IT EXT. 1ERMIML BLOCK U N I T I

CHRG ALMZ

3 BK COM

BK A

BKB

%& ::;+

VBAT-

BAT 5) OVERLS9r @ OISCON3. @J OVERCOM3 @

OE1"1 LAMP @

+cz~vOfi

BRAKE* @)

VBAT+

VBAT-

B R E A K

B R E A K

GN) GN)

GN)

BGT MA BAT BAT OVERRUN L S I OVERRUN L S 2 OVERRUN L S 3 OVERRUN

GNI GN)

GN)

BAT BAT B4T OVERRUN L S 4 OVERRUN 1 5 5 OVERRUN L S 6 2 4 W SHOCK SENSOR

N I PUL

I LAMP

I _ _ - - - \ .--_

Electrical Diagram of Robot Control Unit IRBCX-422, 462 (4/6)

CN 2

A+ 1 PA

A- 1 PA.

B+ 1 PB

B- 1 PEW

s + 1 PC

S- 1 PC.

ABS + i ABS

ABS - 1 ABSU

R-OND 1 R-OND 5E 1 + 5 . 5 v

GNDE I GNDE 1

A+2 PA

A - 2 PA.

B+2 PB

8 - 2 PB.

S+ 2 PC

5 - 2 PC.

ABS + 2 ABS

ABS - 2 ABSl

R-GND 2 R-GNO 5 E Z +5.5V

G N M 2 GNDE2

A+3 PA

A-3 P A 1

B + 3 P B

8 - 3 PBm

S + 3 PC

S-3 PC.

ABS+3 ABS

ABS-3 ABSm

R-OND3 R-OND

5 E 3 +5. 5 V

GNDE3 GNDE3

F G 9-JLF

MAN l PULATOR

AX- 1 ENCODER

AX- 1 ENCODER

PS* ( I

AX-2 MOTOR I

AX-3 ENCODER

I AX-3 1 MOTOR 1

PSZ ( P S I (

Electrical Diagram of Robot Control Unit IRBCX-422, 462 (51'6)

u L-J 4

ul N

a m

I I

I I

I E K I W W L ----------------,

I n 0

I 9 0 LOO I 0 I 0

I

I X z X Z I I

Q W Q W I I -- 0 I \ 0 > - O > N n z m w d I

4 : m b o : $ $ $ : $ , : m l o : E $ y d $ ' m a a a a a a 4 4 n + o a a a a a a 4 < n + o I \ L

0 0 0 m m m

0 0 0 0 0 0 t t P

r - r r - r - rr V T P

0 0 0 0 0 0 0 0 0 r r r

%-J 0 - N - 0 0 0

0 - N

f T P 0 0 0

IC N N N a o a N N N

> u Z . - - - W Z N N N W t j m m m w v < m v u < m v < m u

U

8 - 6 Electrical Connection Diagram

0 - h m ~ u ~ o r r n - - - - - - - - g f l " - - I

c o o o c a 4 t l ! ? r -01 - ? T P V t t T - ? t m m U I C u l L C u I u I U m m Q b &

h N N r . ( \ N m m - r m - -

I

~ ~ w W o =

I 1

0658 0756

GROUNDING NL1 NEON LAMP

AC SOCKET 1-b;: oov

Ft 3'63 UNI PS I

T

1 oov

~ ' - Y - J -

] 32 0 1 5 % tow tow tow a B a J 3 C H 4

SV - GND 27

24, 3 26 OV gJ 25

C

t o SERVO 07 1 A 27 2 GND

28 3 +15v

c@ 071A 27 4 GND

29 5 -15V

2 GND GND 2 27 031D t o BACKPLAE WARD 3 +15V +15V 3 PCB1

4 GND CNlO

5 -15V - 15V 5 29 0310

Electrical Diagram of Robot Control Unit IRBCX-512 (1/6)

r----------1 / ROBOT DEDICATED WELDING I BACKPLANE BOARD / POWER SUPPLY

I I EMRGEWY I STOP I I I ! I

PSl CH42

Electrical Diagram of Robot Control Unit IRBCX-512 ( 2 / 6 )

B A C K P L A N E BOARD PCB1

N o t e ) A c c o r d i n a t o t h e u s e o f PCB5 o r PCB3 a n a a l s o PCB6 o r PCB4. t h e name a n d w i r e No. o f e a c h t e r m i n a l s h o u l d b e f a l l o w e d :

PC85 PC83 PC86 PC84 RESERVE Z4EIOUTI 900 RESERVE Z4EIOUTl 900 COMl 990 Z4EIOUTI 900 COM6 995 24EIOUTl 900 COMZ $01 24ElOUTl 900 COM7 995 24EIOUTI 900

CRZA ESTOP

CRB TEACH

C R I I START

C R 1 3 STOP

L A M P l l A U T O l

L A M P Z I T E A C H )

L A M P 3 l S T A R T I I

LAMP415TARTZ1

L A M P 5 I S T A R T 3 1

L A M P 6 I S T O P I

C R 1 2 SERVO ON

3 BK COM

BKA

BOARD BREAK

BREAK

MANIPULATOR

+czYvOm

BRAKE* @)

OCQOV 181 Q VBAT- @

I LAMP

I ---- L- - - .

Electrical Diagram of Robot Control Unit IRBCX-5 12 (4/6)

$ :, - - - - . - - - - -; G N N N N N N N N N N N m m m m m m m m m m m 0 :;&A:,&;:,g"g :.k&&&:,;,:$?g# :;&A:,A:,11,9g#' m m o a 4 4 I

m m o z 4 4 & " m m o z

4 4 1 a

0 0 0 m m m w w w 0 0 0

0 - N 0 - 0 0 N N N

Electrical Connection Diagram 8 - 1 1

6 - - - - - - - - -;t; N N N N N N N N N N N m m m m m m m m m m m m z & & , A & & $ A g l o g : : & , A & A $ A g i # : & & & & & & & 9 $ B L

m m o 4 4 1

m m o z 4 4 & 0

m m o z 4 4 1 C1

8 - 1 2 Electrical Connection Diagram

8.3 Electrical Diagram of Robot Control Uni t IRBCX-541

- .- - - - - - - -. - - I O P W A T I O N PAML ( O P E R A T I O N BOX);

1 QLT 1 EMERGENCY STOP 1 I

STP,RT 1 1 HALT 1 COM I 2 4 E I 5TAHT INDICATOH I 1 H A L T INDICATOR 1 I

I I

SERVO ON

I TEACH M E S E E C i I M l l

r - - - - - - - - - -1 AUTO Lag SELECTIONI

1 ROBOT DEDICATED WELDING 1 SEAYO ON INDICATOR I I POWER SUPPLY I

I I EIERGENCY TUCH M E IXDIQTOR~

STOP AUTO ----- NDE INDICAIOAJ i

-&N 1 0

s N 1 9 - I 5 V 0902513

(SENSOR)

--------.A

(SPT I CAL F I BER

B A C K P L A N E BOARD

PCB 1

033

I SERVO ON BT 1

034 1


Nots)Aooordlna to t h e u s s a f PC85 o r PC83 and slsa PCB6 or PCE4. t h ~ nsas and r l r e No. o f e a o h terminal s h o u l d b a f o l l o w e d :

BACKPLANE BOARD ?C86 PCB4

PCB 1 RESERVE Z4EIOUTI 900 RESERVE 24EIOUTI 900

mMI 9QO 24EtOUT1 900 COM6 995 24ElOUTl 900 COMZ QQI Z4EIOUTI 900 COM7 996 24EtOUTI 900

COM3 QQZ Z4EtOUT1 900 COM8 997 24ElOUT1 900

COM4 993 24ElOUTl 900 COM9 998 24E(OUil 900

COffi 984 24ElOUT1 900 COMlO 999 24ElOUTI 900

TERMINAL BLOCK UNIT I

EXT OVER1


ESTOP I N T E R L O C K PCB2

3 BK COM

BK A

B K 8

C N 6 1 BOARD +

C N 6 +

C N 6

I I

BREAK

BREAK

TPUT I

CR2A ESTOP

CR6 AUTO

CRB TEACH

CR 1 l START

CR I3 STOP

OUT CQM

2 4 E

LAMP1 I A U T O I

LAMPZITEACH1

L A M P 3 l S T A R T I I

L A M P 4 f S T A R T Z l

LAMPSISTART31

LAMPGISTOPI

C R i Z SERVO ON

OE 181 LAMP @

C N 4 7

\'BAT +

VBAT -

V B A l , VBAT - VBAT+

VBAT-

GN) GN) GN) BAT BAT BAT OVERRUN L S 1 OVERRUN LS2 OVERRUN L S 3 OVERRUN CIECK(GN))

GI@ G N I GtQ BAT BAT BAT OVERRUN LS4 OVERRilN L S 5 OVERRUN L S 6 2 4 W SHOCK SENSOR LAMP

- - - -

MAN I Pi

- -

JLAl


GND

- I5V

CN 2

A+ 1 PA

A- 1 PAR

B+ 1

8- 1

s + 1

s- 1

ABS t 1 ABS

ABS - 1 ABSN

A-OND 1 R-OND 5E l i 5 . 5 V

GNOE l GNDE 1

A + 2 PA

A-2 PAW

B + Z

8- 2

S + 2

S - 2

ABS + 2 ABS

ABS -2 ABSU

R-GND 2 R-GND 5E2 + 5 . 5 V

GNDEZ GNDEZ

A+3 PA

A-3 PAR

B + 3

8 - 3

S + 3

5 - 3

ABS+3 ABS

ABS-3 ABS*

R-GND3 R-GND

5E3 +5. 5 V

GNDE3 GNDE3

FG SH 1 EL0

I I I I I I I I I I I I I I I I I I I I I i I I

AX-1 I

MOTOR

I I 1 E;:R I 1 %:R I

- - - - - - A

MAN I PULATOR

P S I

AX- 1 ENCODER

AX-2 ENCODER

PSZ

AX-3 ENCODER


CT a K I T O LOO W O 1 I t i t i t X O x o x o I I QI 4 2 1

8 - 1 8 Electrical Connection D i a g r a m

A

ACZOOV 3 @ 50/60HZ

NEON LAMP

GRCXJNDING PLATE

SWITCH BOX AClOOV S B 1

v To BACKPLANE


- .- - - - - - - -. - - , GWATION PAKL (OPERATION BOX);

47 EMEEMERCY STOP I

IKiWLCCK 83PRD

r----------1 1 ROBOT DEDICATED WELDING / I POWER SUPPLY

I EWEGENCY STOP

I

(SENSOR)

BACKPLANE BOARD

PCB 1

1 I ! I

I SERVO ON

BT 1


BACKPLANE BOARD PCB1

Nots)Aocordlna to t h e u s e $ I ( PCB5 or X % 3 a n o a l s o PCB6 o r ?C84 t n s n r n s a n d r lrs No. o : e a c h !ersii\ai snould b s ! U I I O W H ~ :

PC85 PC83 . - 'cB~ PC84 iiESERVE 24E I OUT I 300 iilr5tRVE 245 IOU I ! 3 i l U

COMI 960 24EIOUTl 900 .;:)'A6 995 24E IOUT 1 900 COM2 901 24EIOUTI 900 COht-I 396 24E IOUTi YO0

ESTOP I N T E R L O C K

CRZA ESTOP

CR8 TEACH

CR I I START

CR I3 STOP

L A M P I I A U T O I

L A M P Z I T E A C H I

L A M P 3 1 S T A R T I l

L A M P 4 I S T A R T Z 1

L A M P S ( S T A R T 3 1

LAMPGISTOPI

C R l Z SERVO ON

3 BK COM

BKA

B K B

BKC

OVERRUN 1 *

VBAT -

VBAT i

VBAT-

VBAT+

VBAT -

------

B R E A K

BREAK

GN) GN) GN) BAT BAT BAT OVERRUN LS1 OVERRUN LS2 OVERRUN LS3 OVERRUN CtECK(CM))

GND G M GN)

B4T BAT BAT OVERRUN LS4 OVERRUN LS5 OVERRUN LS6 2 4 W SHOCK SENSOR LAMP

M A N I P U L A T O R I I


PS* { P5, {

MAN I PULATOR

/ 1 _---- I I I I I I I I I I I I I I I I I I I I I I I I I

AX-1 I

MOTOR

I I

AX-2 1 1 MOTOR

I

I - - - - - - A

Electrical Diagram of Robot Control Unit IRBCX-551 (51'6)

2 - - - - - - - - - z z y y y y y y y y N ~ ~ m m m m m m m m m m m o Z i & A & l , A h g m s 4 4 m m u l m m m ~ : X : : & r b & 1 , & 1 , 4 i 1 ( H L

m m o 4 4 1 s s z 5 m m o z

4 4 1 o


BKCONT . ILOTIOH CCNlROC DWLO)

I KCIIANISM 1 I - - - - - - -_ I

KCIIANISM 2- r-----

I

I I

IC107 ------ &k l$&- - - - - - - J

(BACKPLANE MND)

Internal Relay Sequence Diagram of Control Unit (3/8)

I m N 0 -

I f f f f 1 0 0 0 0

I I I I I I I I I

I I I I I I I I-

8 - 2 8 Electrical Connection D iagram

IX) MANAGCKNT R)MD

I

I

I I

N I w L ----------- - ---- J

l/O WMG0,GnANr WMD - - - - - - - - - - - - - - - - - - TELUINAL OLKK UilT - - - - - - - - - - - - - - I

I I ICI61

r-------

IWTFZ

I w T F ~ ~

I L - - - - - - - lCI84

I r-------

L - - - - - - - IC165 I

r -------

I I I L ---------------- J


RELAY UNIT I/O M N A C M N T WARD r-------------- I/O MI\NAGDAENT WMD RELAY UN l T

r _ - _ - - - _ - _ - _ - _ _-- - - - - - - - - -__-_--

~ ~ U T E S ~ L- - - - - -

I I C 1 6 2 r - - - - 7 -

I W T E ~ ~ L------

I 1C163r - - - - - -

Internal Relay Sequence Diagram of Control Unit (6 ,

€XI IUMIf4AL OLKK UNIT I/O M N A C M K I D3MD

I I I

L ---------------- J

I/O M E M C M N T NMD r - - - - - - - - - - -

EXT. TEWINAL mKK UNIT 7 r - - - - - - - - - - - - 7

IOUTCG =--j

IOCITC~ I L - - - - - -. - Z4VIGiJTt

I I I


r------------------------------------------------------- 0 - m *

I , , o = L f r f ~ a . 2 g r z o a N 2 ~ ~ - - L o - T u, a r. z ~ z z g g 2 g I I - u - f - - " 5 f Z v - - I -

0 I r3-A-k-i7;J-J-i-i,;3-A-A-17;A-A-A-il;2--!--L-il I

%I I I I I I I I I I I I 8 I I I I I 2 I I I i 1 : -,J I -,J 1 1

d i I

2 I I

/ -ct, i I 3 / I q j l 3 / I +-, I

L-*-*-LJ L - + - + - L A L - . c - I - C J L - + - + - + A L -4 -4-4 ----- 2 - ~ m r m a r - o m o - N m r m o + m o o

m m m m m m m r g E Z g ~ f z ~ g z z_ 5 >


8.6 Outside Dimensional Drawing of Robot Control Uni t


O I L


8.7 Electrical Diagram of Control Cable

8 rii


8 - 3 6 Electrical Connection D iagram

Electr ical Connect ion Diagram 8 - 3 7

APPENDIX 1-WELDING EQUIPMENTS

Contents

1 3 TIG Interface E5743 ................................................................................................................................................. A1 . 6 1.3.1 A~~~~~~~~~ of TIG interface ................................................................................................................. Al- 6 1 . 3.2 setting J~~~~~ wires of TIG l'terface Al - 7 1 3 3 Connecting TIG Interface ........................................................................................................................... A1 - 7 . .

1 5 CUT Interface E5782 ................................................................................................................................................. A1 - 9 1 . 5. 1 Appearance of CUT Interface ............................................................................................................... A l - 9 1 . 5.2 setting J~~~~~ wires of CUT ~ ~ t ~ ~ f ~ ~ ~ ....................................................................................... A1-10 1 . 5 . 3 Connecting CUT Interface A1 - 10

APPENDIX 1-WELDING EQUIPMENTS This chapter describes the connecting method of the peripheral equipment necessary for

the aforementioned Robot Dedicated Welding Power Supply, the Welding Interface, and various welding methods.

This chapter explains the particulars necessary for the combination of the Welding Interface and like with various welding power supplies.

In order to carry out welding by use of those welding power supplies, necessary are the preparation of welding equipment including welding torch and wire feed unit and the likes and the input operation of welding characteristic data.

1 . I Connecting Robot Dedicated Welding Power Supply In this section,the connecting method of the Robot Dedicated Welding Power Supply is

explained with Almega Auto I1 (CPVAS-350) a s an example.

1.1.1 External Connecting Cable The connection of the robot dedicated welding power supply requires the external

connecting cables shown in TABLE 1.1.1.1. TABLE 1.1.1.1 External Connecting Cable

Control Cable 4 (L3392G)

Ref .No.

@

@

@

@

To Manipulator

Control Cable 5

Robot Control

To Manipulator Weldinn Cable

F i g . 1 . 1 Connecting Robot Dedicated Welding Power Supply

APPENDIX 1-WELDING EQUIPMENTS A 1 - 1

Name

Control Cable 5

Control Cable 4 Torch Side Welding Cable Workpiece Side Welding Cable Gas Hose

Connecting Portion

CN31 IC104 ICN4

Part No.

L3392Y

L3392G

L2527D

L3442B

L2527B

Q'ty

1

1

1

1

1

Remarks

BCWB-5105

BIRB-3005 Configuration

1 .I .2 Connecting Cables

A WARNING Turn OFF the switch of the distribution panel and confirm that power supply is shut off prior to the connection of cables.

(1) Connecting Control Cable 5 (BWCB-5105)

Remove the upper cover of the welding power supply.

Lead the connector CN31 side of the control cable through the back side of the

welding power supply to the inside of the welding power supply,and connect the

optical fiber connector to the optical fiber module IC104 of the printed board

P9745W.

Then connect the connector CN31 to CN31 of the printed board P9745W, and place

back the upper cover.

(2) Connecting Control Cable (L3392G)

Connect the control cable to the connector ICN4 of the welding power supply and

the connector CN4 of the manipulator.

(3) Connecting Workpiece Side Welding Cable (L3442B)

Connect the workpiece side welding cable to the - (minus) terminal of the welding

power supply.

(4) Connecting Torch Side Welding Cable (L2527D)

Connect the torch side welding cable to the + (plus) terminal of the welding

power supply.

A 1 - 2 APPENDIX 1-WELDING EQUIPMENTS

1.2 Connecting Welding Interface and Welding Power Supply This section describes the method to connect the aforementioned Welding Interface. When to connect the Welding Interface to welding power supply,as mentioned in the

foregoing chapter,necessary are the setting of the instructed voltage range by the swich of the printed board E5624G within the Welding Interface and the external connection described below.

1.2.1 External Connecting Cable The connection of the Welding Interface and various welding power supplies requires the . ..

external connecting cables as shown in TABLE 1.2.1.1. (TABLE 1.2.1.1. shows an example of CPV-350.)

TABLE 1.2.1.1 External Connecting Cable (for CPV-350)

Terminal Block Grommet

To Workpiece Terminal Block

Ref .No.

O @ @ @

@ @ a @

To Manipulator @ @ @ @ @ To Manipulator

Figl.Z.l.l Connecting Welding Interface and Welding Power Supply

APPENDIX 1-WELDING EQUIPMENTS

Remarks

Cable attached to welding interface Varies with various welding power supplies. Refer to TABLE1.2.1.2 to prepare connecting cables corresponding to welding power supplies used.

BIRB-3005 Configuration

Name

Cable Assembly

Control Cable Control Cable

Detection Cable 1

Detection Cable 2

Control Cable 4 Torch Side Welding Cable Workpiece Side Welding Cable Gas Hose

part N ~ .

L3497Y

E5186E K1754P

K1754F

K1754G

L3392G

LZ527D

L3442B

L2527B

Portion

ICN2 ICN3

For WCR

For detection of weld stick ICN4

Q . ~ ~

1 1

1

1

1

1

TABLE1.2.1.2 Connecting Cables with Various Welding Power Supplies

Welding Power

1.2.2 Connecting Method of Cables A WARNING

Turn OFF the switch of the distribution panel and confirm that power supply is shut off prior to the connection of cables.

Connecting Detection Cable 1 (for WCR) and Detection Cable 2 (for Wire stick)

*Remove the upper cover of the welding power supply.

*Make a hole on the grommet a t the rear portion of the welding power supply.

*Remove the cover of the Welding Interface.

*Make a hole on the grommet with membrane a t the bottom of the Welding

Interface.

*Connect the detection cables 1 and 2 as shown in Fig.1.2.2.1.

*Connect cables to the terminal block a s shown in Fig.1.2.2.1.

*Attach the cover of the Welding Interface.

WELDING INTERFACE ,,Short Circuit Plate

WELDING POWER SUPPLY

& TO WELDING POWER

- M U BE L C D 1 I q-?- - SUPPLY WCR

!J v ?J k!J I I (TERMINAL BLOC

I I L - - - - - - _ - - - - - - - - .- - - - - - - --

TO WELDING POWER SUPPLYOUTPUT

@ TERMINAL

I DETECTING CABLE(2) I

Fig1.2.2.1 Connecting Detection Cables


(2) Fixing Welding Interface After the connection of the detection cables,fix the Welding Interface onto the welding power supply according to the procedures described below: -Remove the hook of the welding interface. *Fix the welding interface to the hanger with the bolts that fix the hook. *Fix the hanger to the welding interface with the eyebolts and bolts for mounting the upper cover of the welding power supply removed in (1) section.

.Fix the upper cover with remaining eyebolts and bolts.

I INTERFACE

I - WELDING POWER SUPPLY

Fig1.2.2.2 Fixation of Welding Interface

(3) Connecting Control Cable (E5186E) Connect one connector of the control cable E5186E to the connector ICN2 of the Welding Interface,and connect another connector to the 4 - pin connector for "Wire Feed UnitVof the welding power supply.

(4) Connecting Control Cable (K1754P) Connect one connector of the control cable K1754P to the connector ICN3 of the Welding Interface,and connect another connector to the 4 - pin connector for "RemoteVof the welding power supply.

(5) Connecting Control Cable 4 (L3392G) Connect the connector of the control cable 4 to the connector ICN4 of the Welding Interface and the connector CN4 of the manipulator.

(6) Connecting Torch Side Welding Cable (L2527D) Connect the torch side welding cable to the + (plus) terminal of the welding power supply - At this moment,connect the terminal of the wire No.2 of the detection cable 2 also to the plus (+) terminal of the welding power supply.

(7) Connecting Workpiece Side Welding Cable (L3442B) Connect the workpiece side welding cable to the minus (-) terminal of the welding power supply. At this moment,connect the terminal of the wire Nal of the detection cable 2 also to the minus (-) terminal of the welding power supply.


1.3 7- I G Interface E5743 This unit is the interface in the case to combine the robot control unit and TIG welding

power supply.

This comprises the filter circuit to reduce high-frequency noise,etc. generated a t TIG

welding.

1.3.1 Appearance of TIG lnterface

7<57<?fflRBr?BiBI 7i5'74VIBPjiR@4f(?3l%(lB) Slslgia fiLlER YlRt RIDER COXTRCL UY lT F l l i t R 1lR6 FEEDER COYTRCL lill1lELOlKC iOER SW??lTi EiDlX PCYUl SWLY

IiCNJI I T \ -1

Fig.l.3.1.1 Appearance of TIG Interface


1.3.2 Setting Jumper Wires of TIG Interface

This unit is equipped with the terminal blocks TB1 and TB2 to connect jumper wires

to correspond to various TIG welding supplies.Connect the jumper wires as shown

TABLE 1.3.2.1 according to the welding power supplies to be employed.

TABLE 1.3.2.1 Connecting Jumper Wires of Terminal Blocks

Supply / TBl(5-pole) / TB2 (10-pole)

TB1 (5-pole) and TB2 (10-pole)

AEP 1 123-122 /

Welding Power

VRTP (S-1) 123-121

@-@, @-63, @-@, a-@

Jumper Wire

AVP 1 VRTP (S-4)

1.3.3 Connecting TIG Interface

In this unit, connecting cables vary with the welding methods and corresponding

types as shown in TABLE 1.3.3.1.Therefore,prepare connecting cables according to

your requirements.

TIG Welding

(without Filler)

TABLE 1.3.3.1 List of TIG interface Connecting Cables

TIG Filler Welding

Connecting Cable Welding Method

Connecting Cable(1) E5239E

Correponding Type

E5749 Connecting Cable(1) E5243E

Connecting Cable(2) E5243F

/ 1 Connecting Cable(5) E5223G

E5750

/ Connecting Cable(6) E5208H

Connecting Cable(2) E5239F

Connecting Cable(3) E5208E

Connecting Cable($) E5208F

APPENDIX 1-WELDING EOUIPMENTS A 1 - 7

I .4 Filler Wire Feed Control Unit E5756 This is the unit to control the TIG filler wire feed speed in the case to combine the

robot control unit and the TIG welding power supply.

1.4.1 Appearance of F i l l e r Wire Feed Control Uni t

Fig.l.4.1.1 Outside View of Filler Wire Feed Control Unit

1.4.2 Connecting F i l l e r Wi re Feed Control Uni t As for the method to connect this unit,refer to the Section 1.7


I .5 CUT lnterface E5782 This unit is the interface in the case to combine the robot control unit and Air

Plasma cutting power supply. This comprises the filter circuit to reduce high-frequency

noise generated a t plasma cutting.

1.5.1 Appearance o f CUT lnterface

Fig. 1.5.1.1 Outside View of CUT Interface


"15.2 Setting Jumper Wires o f CUT Interface

This unit is equipped with the terminal blocks TB1 and TB2 to connect jumper wires

to correspond to various TIG weIding,and plasma cutting power supplies.When to use

Air plasma cutting power supply,there is no need to set these jumper wires,so you may

use the interface with its jumper wires a s set a t shipment from factory. The setting a t

shipment from factory a r e shown in TABLE 1.5.2.1.

TABLE 1.5.2.1 Connecting Jumper Wires of Terminal Blocks

TB1 (5-pole) and TB2 (10-pole)

1.5.3 Connecting Cut Interface

In this unit,connecting cables vary with corresponding types as shown in TABLE

1.5.3.1.

Therefore,prepare connecting cables according to your requirements.

(Setting a t shipment from factory)

TABLE 1.5.3.1 List of CUT Interface Connecting Cables

Cutting Power Jumper Wire

A l - 1 0 APPENDIX 1-WELDING EQUIPMENTS

Corresponding Type

TRC-120

Connecting Cable

E5769B

1.6 Weld Stick Detection Unit E5391 This unit is the device to monitor the welding voltage during TIG welding and output a

detection signal to the external when the value goes down below a specified one.

Name

1.6.1 Specifications of Weld Stick Detection Uni t

/ Weld Stick Detection Unit

Item

Input Power

Specifications

Frequency 50/60Hz

Detection Voltage

(Input Voltage)

I

Up to 40V (AC and DC) 3-phase AC200/220V ( t 10%) 2A

I

Dimensions

Detection Time

Weld Stick Detection

Voltage Level

I I PCB l I

0.0-1.0 second

6.0-7.0 Volt

r - i r - i r - 1 I I I I I I I I I I I I I CR3

L - - - - - I TL /CHI! ~ W C R ; r - - - - -

Q I 1 1 1 1 I I CRZ I I 1 I I I L - - - - - L - J L - J L . - J

Fig.1.6.1.1 Outside View of Weld Stick Detection Unit

APPENDIX 1-WELDING EQUIPMENTS A 1 - 1 1

1.6.2 Functions of Weld Stick Detection Un i t

This unit output an error when the time period in which the welding voltage goes

down below the weld stick detection level during welding (while WCR relay is ON)

exceeds the setting time of the timer (TI).

This timing chart is shown in Fig.1.6.2.1

CR 1 :Welding Voltage Detection Auxiliary Relay

WCR :Welding Current Detection Relay

CR2 ,CR3 :Welding Voltage Detection Star t Relay

T 1 :Weld Stick Detection Output, Detection Delay Timer

Weld Stick

- - - - - - -

I I I I l l I l l I I I I I l l I I I I I I I I l l I l l I I l l I l l I l l I

I I I I l l I I I

I l l I I

I 1 1 1 1 I I l l I l l I

I l l I I l l I l l

I I Abnormal

t:Timer Setting Output

CR1 EFF I 1 ~ 1 ~ I I ~ I I I I I I l l 1 I I l l I I I I I I l l 1 < t I l l l < t I I I I mii""-- 7-i- I l l I

I I I I I

I I I

Fig.1.6.2.1 Timing Chart of Weld Stick Detection

I I l l I I l l

I l l I l l

A 1 - 1 2 APPENDIX 1-WELDING EQUIPMENTS

I

WCR gFF 1 1 1 I I I I l l I

I I I I l l I l l I I

I I I I l l I I I I I I I l l I I I I I I I l l I l l I

I l l I l l I I

I l l ON I l l I l l I l l I

I l l

OFF I 0 1 1 , I l l

I I I I l l I l l I

1.6.3 Connecting Weld Stick Detection Uni t Referring to Fig.l.6.3.1,follow the procedures of connection described below:

A WARNING Turn OFF the switch of the distribution panel and confirm that power supply is shut off prior to the connection of cables.

WELD STICK Welding Power Supply (1) Installing Unit DETECTION UNIT (VRTP-300 S-5 etc.)

Install this unit away from welding

power supply.

(2) Connecting Welding Voltage Detection

Cable

Welding voltage detection cable should

be connected to different printed

boards according to welding power Jcik~elding Power Cable supplies.Refer to TABLE 1.6.3.1 to Torch.WorkPiece

connect the cable.

Install this connecting cable away

from the welding cables.

TABLE 1.6.3.1 Printed Boards to connect Workpiece Welding Torch

Welding Voltage Detection Cable

P6768T P9943T Printed Board % Electric Protection

CN8 Connector

%When to use AEP-300,disconnect the

connector (CN2) of the welding WELD STICK DETECTION UNIT

voltage detection cable,and connect it : to the pins No.5 and No.6 of the

electric protection connector (9-pin

connector) within the welding power

supply.

(3) Connecting WCR Input,Output Cables

Terminal numbers of WCR input cable

vary with welding power supplies.

Refer to TABLE 1.6.3.2 to connect the

cable.

Install this connecting cable away

from the welding cables.

WCR INPUT

WCR OUTPUT

Weld Stick Detection (Abnormal Output)

APPENDIX 1-WELDING EOUIPMENTS A I - 1 3

Install this connecting cable away from other connecting cables.

TABLE 1.6.3.2 Terminal Number to conliect WCR Input Cable

Fig.1.6.3.1 External connection of Weld Stick Detection Unit

Welding Power

Supply Type

Connected place

A 1 - 1 4 APPENDIX ?-WELDING EQUIPMENTS

(4) Connecting Weld Stick Detection Cable

VRTP -300

P.C.B P6773Q

TB CN12 No.7 and 8

(WCR)

AVP -300

P.C.B P6783Q

TB CN12 No.7 and 8

(WCR)

AVP -500

WCR wire No. 162,163

AEP -300

WCR wire No.

59,60

1.7 Connection Examples of Various Welding Power Supplies This section describes the connection of the aforementioned welding interface and the

welding power supplies with the following welding power supplies as examples:

C02/MAG/MIG Welding Power Supply

(1) Almega Auto II 350/500(CPVAS-350/500)

(2) Almega Fuzzy Auto 350(CPDA-350)

(3) Inverter Auto 350TB(CPVB-350)

(4) Inverter Auto TURBO PULSE 350(CPVP-350),Inverter MIG PULSE AUTO 350

(CPVPA-350)

(5) Inverter MIG WAVE PULSE 350/500(CPVWP-350/500)

(6) Transistor PULSE AUTO 350/500(TRA-350/500)

TIG Welding Power Su~rsly

(1) Inverter ACCUTIG 300P/500~(~VP-300/500)

(2) Inverter ACCUTIG 300P/500P(AVP-300/50O)with filler wire feed

(3) Inverter ARGO 300P(VRTP-300),Pulse COMPA 300P(AEP-300)

(4) Inverter ARGO 300P(VRTP-300),Pulse COMPA 300P(AEP-300)with filler wire feed

Air Plasma Cutting Power Supply

(1) Super Plasma D-12000(TRC-120)


WARNING Turn OFF the switch of the distribution panel and confirm that power supply is shut off prior to the connection of cables.

ELECTRIC SHOCK

@Do not touch live electrical

@Disconnect all power before installing or servicing.

@Multiple sources of voltage may exist inside this


1.7.1 CO~/MAG/MIG Welding Power Supply (1) Almega Auto 11 350/500 (CPVAS-350/500)

;g Pswer SaPeiv R o b o t C o n t r o

1 1 I C N 3 C N 2 CNI I Man i n u

B - )

3

Fig. 1.7.1.1 Connection of COJMAG Welding Power Supply,

Almega Auto I[ 350/500 (CPVAS-350/500) A 1 - 1 6 APPENDIX 1-WELDING EQUIPMENTS

(2) Almega Fuzzy Auto 350 (CPDA-350)

Fig. 1.7.1.2 Connection of COJMAG Welding Power Supply,

Almega Fuzzy Auto 350 (CPDA-350)


(3) Inverter Auto 350TB (CPVB-350)

W? 1 d i n g Fower SGPP I Y W e l d i n g Interface CFVB-350

r-----l

--- .- --i

R o b o t C o n t r o l Un

Fig.1.7.1.3 Connection of COu'MAG Welding Power Supply,

Inverter Auto 350TB (CPVB-350)

A 1 - 1 8 APPENDIX $-WELDING EQUIPMENTS

(4) Inverter Auto TURBO PULSE 350(CPVP-350),Inverter MIG PULSE AUTO 350

We i d i ns Power SuPP i V W e l d i n g Interface i 1

CPVP-350/CPVPA-350 E 5 6 2 4 R c b c t C o r , t r o i Ur

Fig. 1.7.1.4 Connection of COz/MAG/MIG Welding Power Supply, Inverter Auto TURBO PULSE 350(CPVP-350)and Inverter MIG PULSE AUTO 350(CPVPA-350)

APPENDIX 1-WELDING EQUIPMENTS A I - 1 9

Fig.1.7.1.5 Connection of MIG Welding Power Supply, Inverter MIG WAVE PULSE 350/500 (CPVWP-350/500)

A 1 - 2 0 APPENDIX 1-WELDING EQUIPMENTS

(6) Transistor PULSE AUTO 350/500(TRA-350/500)

r - - - - - - - - - - - - - -

,#Setting o f P. C. 0. ~ 5 6 2 4 ~ ; REF1 : 15V, iE(P0SITIVE) REF2: 15V. iE(P0SITIVE) i

We id i ns Power S u P P i Y W e l d i n g i n t e r f a c e J

T R A - 3 5 0 / 5 0 0 E5624 R o b o t C o n t r o l U n i t

Fig.1.7.1.6 Connection of MIG Welding Power Supply,

Transistor PULSE AUTO 350/500 (TRA-350/500)


1.7.2 TIG Welding Power Supply (1) Inverter ACCUTIG 300P (AVP-300), Inverter ARGO 300P (VRTP-3001,

I R e m o t e Box Connect the Pemcte Box o f k'eIdi?l Pore? SuPoiY. rn rhsn uss Pulss chirrent. psg

L 'Setis6 b l R C Snt ted bl Rtaote

- -. . -. .. -. - - . -. . .- . - 5243EG3 3-1

Welding Power Supply AvP/VRTP/AEP

Fig. 1.7.2.1 Connection of TIG Welding Power Supply, Inverter ACCUTIG 300P (AVP-300) Inverter ARGO 300P (VRTP-300) and Pulse COMPA 300p(AEP-300)

A 1 - 2 2 APPENDIX I-WELDING EOUIPMENTS

(2) Inverter ACCUTIG 300P (AVP-3001, Inverter ARGO 300P (VRTP-SOO), Pulse COMPA 300P (AEP-300) with filler wire feed

R o c o t C c n t r s i Unit

. --

C1 - . i . C L f r

Welding Power Supply AVP/VRTP/AEP Fig.1.7.2.2 Connection of TIG Welding Power Supply,

Inverter ACCUTIG 300P (AVP-300), Inverter ARGO 300P (VRTP-300) and Pulse COMPA 300P (AEP-300) with filler wire feed


1.7.3 Air Plasma Cutting Power Supply (I) Super Plasma D-12000 (TRC-120)

C b t t i r i p P L v , f r S:';F: Y T F ; - ; ? i

Fig.1.7.3.1 Connection of Air Plasma Power Supply, Super Plasma D-12000 (TRC-120)

- 2 4 APPENDIX 1-WELDING EQUIPMENTS


C r : r z F o r ~ r S T C 1 % VCP E

Fig. 1.7.3.2 Connection of Air Plasma Power Supply ,Super Plasma D-8000 (TRC-81)


Various kinds of welding machines are available from DAlHEN. DAlHEN produces and sells every kinds of welding machines.

ITEMS OF MAIN PRODUCTS

ARC WELDING MACHINES

AC ARC WELDING MACHINES

DC ARC WELDING MACHINES

CO, GAS-SHIELDED ARC WELDING MACHINES

M A G ARC WELDING MACHINES

MIG ARC WELDING MACHINES

TIG ARC WELDING MACHINES

SUBMERGED ARC WELDING MACHINES

NO-GAS-SHIELDED ARC WELDING MACHINES

STUD WELDING MACHINES

AIR PLASMA CUTTING MACHINES

ARC WELDING ROBOT

CO, LASER EQUIPMENTS

Printed in Japan

DAlHEN Corporation 5-1. M i n a m i Senrioka, Settsu, Osaka 566, Japan Phone : 06-317-2506 Facs : 06-317-2583

DAIHEN EUROPE GmbH. Bro~chhofs t rasse 7, 40882 Rat ingen 1, F . R . G E R M A N Y Phone : 02102-444007-8 Facs : 02102-472100

DAIHEN, Inc. DYNAMIC ROBOTICS DIVISION 761 CROSSROADS COURT, V A N D A L I A , OH 45377, U.S.A. Phone : (937)-454-9660 Facs : (937)-454-9661

DAIHEN ASIA (THAILAND) CO.,LTD. 60/86 M u 19, Navanakorn Indust r ia l Estate Phase 3. K l o n g Nueng, K l o n g Luang, Pathumthani 12120 Phone : 5292130-1.5293335-8 Facs : 5292132

Osacom 8700 Controller (Same as Inst &Amp; Maint (1l4000b-9)

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Transcript of Osacom 8700 Controller (Same as Inst &Amp; Maint (1l4000b-9)