HEN Controller Manual Corrections

June 1997
No.1 L4000B -9
CONTROLLER
~stributor you do not understand I'
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 Section 1.2.1 Mistakes 5. The location of breaker in the control unit is shown in Fig.= 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...
1-17 1-17
Fig.1.2.2.1 Inthe WARNING
____ Handle Braker

2. The Control units contains many... of them while is ON may... needs to be opened with the ... any of ... ...of a failure, never
5. Ensure that the ground of each of is...
1-18
1.2.3
1-21
1.3.1
3. Connect connectors are all the same type connectors but have ...
3. Connect connectors are all the same type connectors but have ... 1. Connect connector CN16 of Teaching box to C N l 6 p J
1-24
1.3.2
1. Connect connector CN16 of Teaching box to CN16
.1-25 1.3.3 2. Connect optical fiber $g connector to IC124 of ! j & 2. Connect optical fiber connector to lC124 of A Board (LED... (1) Operation Status (LED...
m.
2-8 2-10
2.3.2 Table 2.4.2.1
(1) Operation Status
also... 4. ...OC LED of LED GREEN RED 5. Overvoltage of main power supply The main power supply is ... . @ @ ... deceleration is
w.
4. ...OC LED of also... 5. Overvoltage of main power supply The main power supply is ... . ... deceleration is [LED5023 Status] ON indicates Voltage Drop >JJ v$ (below .3
w.
2-25
Table 2.8.2.1
ELED502's Status] ON indicates Voltage Drop (below [2nd bit's Function When ON] ... SW1 on causing ...
Table 2.8.3.1
m ,
[2nd bit's Function When ON] ... SW1 on M causing ... ,
TABLE 0.0.0.1 List of Errata (213)
ry contact (Relay CR22) MRON DC24V
m,
...and the
5-15
2nd Item of
15-20 5th Item of
Check connection and connect it properly. LED 100 on Motion control board OFF(0N in the condition.)
Check connection and connect it properly. LED 100 on Motion Control board OFF(0N in the condition.)
...be also displayed for
1-
5-42
Line 3 of (2)
...be also displayed for & failures.)
failures.)
TABLE 0.0.0.1 List of Errata (313) Page 5-49 Section Mistakes Correction Switch box
. 2nd, 3rd, 5th Switch Box

and 6th items of
paK
Cause1
5th and 10th items of
/Action/
5-54
6th and 8th items of
/Possible
Cause1
4th item of
Motion control board or Servo Control board fi?ilur
Motion control board or Servo Control board
Reduce the voltage
Reduce the voltage Reduce the load
/Action]
5-55 9th item of
16-2
a load
Reduce the
Ref No.9 in [Part] 6.4 List of In- Memory lithium spection Items Ref No.
[Part] Memory lithium
7-4 7-6 7-10 7-18
a-2
[Item]
[Ite mf
Ref No. @
[Item]
[Item]
7-34 7-36 7-38 7-40 Al-1
Ref. No.
[Item]
[Item]
Ref No. @ in [Remarks] TABLE 1.1.1.1 Line 3
[Remarks]
A1-3
..... voltage range by the
..... 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 o r 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 if 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 f o r 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 o r 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 from Japan, o r 2000 hours actual working time from the date of delivery of equipment t o the original user. This warranty shall be invalidated by any abuse, misuse, misapplication o r improper installation of the original user. DAIHEN, at its option, will repair o r replace any equipments during the warranty period, which DAIHEN, upon inspection, shall determine t o 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 A N Y DIRECT, INCIDENTAL OR CONSEQUENTIAL DAMAGES OF ANY NATURE, OR LOSSES OR EXPENSES RESULTING FROM ANY DEFECTIVE PRODUCT OR THE USE OF A N Y 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

1.1 91
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 f o r 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 t o be installed, operated, and maintained only b y qualified persons in accordance with the safety standard which is applied f o r your country such as ANSI/RIA document, "American National Standard F o r Industrial Robots Systems Safety Requirements" and all other safety material found in this Section and throughout the entire manual. I n addition, follow all other codes as applicable t o the application. See A r c Welding Safety Precautions Sections in the welding power supply Owner's Manual f o r 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 t o 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 t o avoid minor personal injury o r damage t o this equipment. IMPORTANT statements identify special instructions necessary f o r the most efficient operation o f this equipment.
C.
1
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. 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
H A V E A N EMERGENCY STOP BUTTON I N HAND whenever you are near the robot.
5 UNDERSTAND A N D BE F A M I L I A R 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 if 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 lNSTALLATlON (Figure D-I)

The robot cell requires initial safety conditions that are vital f o r both personnel and equipment. Make safety provisions part of the basic cell design.lmplement the following during installation:
1
2
3
Brightly mark floor with distinctive areas identifying Zones 1 and 2 on Figure D-1. Route all cables and hoses so that they will not be damaged and will not clutter the cell floor space. Protect welding system components from spatter, slag, heat, and the general welding environment by locating equipment t o minimize exposure. I f any welding components must be located in a high-exposure area, provide proper guards o r shields t o minimize d i r t and spatter.
4
'
5 Consider all necessary jig requirements t o 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).
Install pressure-sensitive floor mats, proximity devices, limit switches, light curtains, etc., t o suit the application and number of work stations so that Emergency Stop will occur if there is any instruction or violation of the robot work envelope. 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 f o r electronic components in

Robot Control Unit and Teach Pendant.
10 M A I N T A I N SAFE INTEGRITY OF CELL A T 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" f o r vertical space requirements of robot. Figure D-1 Layout Considerations f o r a Typical Robotic Cell
E,
OPERATOR SAFETY REQUIREMENT

Provide proper ventilation for welding areas.Supply fresh air if 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 t o protect eyes f r o m arc rays. Press an EMERGENCY STOP button before entering robot area. Stay alert f o r 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 t o 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 f o r teaching the robot, be sure t o 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 t o the following: a) Space requirement f o r 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 if the operator was caught in the robot, take the following procedure.
1) Press the Emergency Stop button immediately. 2) Turn off the primary power switch of the Robot Control Unit. 3) To avoid fall the robot arm, lift 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 t o enter the robot work envelope. As a result, always do the following during teaching procedures:
1 Move robot slowly (see instruction manual "TEACHING"

information).
- Teaching f o r
speed entry
2 Always assign and position a watchperson, with an Emergency Stop button in hand, t o present and ready during teaching operations.
3
I f jig motion was programmed t o operate from external output control, the jig could energize during teaching.Be careful and alert f o r 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 f o 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 t o the appropriate Starting
Box(es).
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 f o r 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 f o r the operation.
6
Remove all tools f r o m the robot work envelope. Place welding workpiece(s) into proper position(s). Place all equipment switches in the proper positions.
7
8
I. SAFETY PROCEDURES DURING AUTOMATIC OPERATION

During automatic operation, do the following:
1 Turn off main power o r press an EMERGENCY STOP button BEFORE entering the robot work envelope.Entry may be required f o r nozzle, tip, wire, o r gas adjustments o r replacements.
DO NOT ENTER WORK ENVELOPE UNLESS A N EMERGENCY STOP BUTTON IS PRESSED !
2 Be alert f o r jig movement initiated by an external control signal during operation.

3
Do not allow unauthorized persons t o operate controls. I f two o r more Starting Boxes are used, be sure that the operators fully understand all procedures and cooperate with each other.
5 Press an EMERGENCY STOP button if any problem occurs.

6 Since this an arc welding operation, protect operator(s) from arc rays, fumes, and hot parts.
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 t o 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 t o turn off 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 f o r Robot Control Unit and welding power supply in the
OFF positions.
5 Allow robot and all equipment t o cool.

6 Clean robot, jigs, and entire cell area.
Install protective covers over all equipment AFTER proper cooling has occurred t o 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 t o 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 t o service the robot.
3 Always assign and position a watchperson, with an EMERGENCY STOP button in hand, t o be present and ready during any servicing or adjustment procedures.
4 Determine in advance if the procedure(s) requires an energized robot.When power is

not required, t u r n 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 o f f o r disable all jig(s) and external equipment not required f o r the specific procedure.
7 Provide proper Electrostatic Discharge (ESD) protection f o 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 a t beginning of welding power supply manual in addition t o the following before beginning arc welding operations.
Prevent electric shock as follows:
1) INSTALL A N D GROUND all equipment according t o national, regional, and local

codes.
2) DO NOT TOUCH live electrical parts.
3) WEAR DRY INSULATING GLOVES A N D CLOTHING; be sure gloves have no holes.

4) DISCONNECT INPUT POWER before installing, inspecting, maintaining, servicing any equipment. 2
Provide proper protection f r o m fumes and gases as follows:
1) KEEP YOUR HEAD out of the fumes.

2) USE FORCED EXHAUST VENTILATION a t 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 A N D FOLLOW WARNING LABELS on all containers of welding materials.

6) Before use, READ A N D 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 filter 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 t o include woolen clothing, flame-proof apron and gloves, leather leggings, high boots and leather arm and shoulder gauntlets.
4 Prevent fire 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 f o r fire. 4) Have a fire extinguisher nearby, and know how t o 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 o r equivalent).
2) INSULATE CYLINDERS from mounts so that they are never grounded o r p a r 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 traffic patterns.
6 Provide impact protection t o 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 o r 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 t o precision devices and welding power supply separately.
M. WARNING LABELS
DO NOT REMOVE, DESTROY, o r COVER the following labels on the Robot Control Unit and Manipulator. I f following labels become dirty 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
Keep out of robot area when m a i n power is on. Read Instruction Manual.
c t i o n Manual carefully.
@ Always wear dry insulating gloves.
o Insulate yourself f r o m the work and the ground.

O D o not touch live electrical parts.
Keep your head out of the fumes. Ventilate area, or use a breathing device.
@ D o not w e l d near flammable material.

@
W a t c h for fire; keep extinguisher nearby.
9 D o not locate unit over combustible surfaces.
N O I S E c a n d a m a g e hearing.
Wear welding helmet w i t h correct filter.
a Read and follow thts label and the lnsrrucrlon M a n u a l carefully
r r
Insulate yourself from the w o r k and the ground. D o not touch live electrical pans
lble surfaces.
* Keep
@
a w a y f r o m rnovlng parts. Keep hands, loose clothing, and tools away during operation.
* Keep
@
a w a y from pinch points during operatton. K n o w and understand equrprnent operation before
0 Always wear dry insulating gloves
s Insulate
yourself from the work and the ground.
8 D o not touch live electrical parts.
Disconnect ~ n p u tpower 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. @ D o not locate this device in robot work area. @Read Instruction M a n u a l .
a WARNING
E L E C T R I C S H O C K c a n kill.
Do not touch live 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 all panels, covers, and guards securely in place. e For protection against fire hazard. B Replace only w i t h the same type and rating of fuse.
(D
NC8052
A WARNING
s Read
@
manual for connection procedures.
Connect grounding conductor and input conductors to proper terminals inside unit-grounding conductor first.
e Be sure grounding conductor goes t o e

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 ............................................................................................................................................................... 1.1.1 CO~/MAGwelding ~ ~ standard ~ b configuration t 1.1.2 optional ~ ~ ................... ~ i ~ ~ ~ Connecting primary power Supply .......................................................................................................... 1.2 1.2.1 Connecting primary power Cable 1 2.2 opening control u n i t D~~~ ................................................................................................................... 1.2 .3 Grounding ............................................................................................................................................................. 1 3 External Connection ..............................................................................................................................................
1. 2 1- 2 1-14 ~ 1- 16 1-16 1- 17 1- 18 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 1.3.4 connecting operation panel ................................................................................................................. -27 1.3.5 Connecting Starting Box ......................................................................................................................... 1-28 1.3.6 Connecting Miscellaneous Option 1-29 placing printed ~~~~d~ ...................................................................................................................................... 1- 30 14 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 1-31 1.4.4 Placing I/() Management Board .......................................................................................................
Chapter2 Internal Configuration of Control Unit
2 1 ~~i~ P~~~~~~~~ ~~~~d ~ 3 7 0 0 ~ 2.1.1 Functions ............................................................................................................................................................... 2.1.2 Operation Status Indicator 2.1.3 ~ ~~~i~ P~~~~~~~~ l ~ ~~~~d .................................................................................................... ~ ~ i ~ 2 2 ti^^ control ~~~~d ~ 3 7 0 0 ~ .................................................................................................................... 2 2.1 Functions 2.2.2 Operation Status Indicator ....................................................................................................................
222~ 222-
5 5 5 6 7 7 7 8 8 8
22.3 1/0 Management Board L3700M (Standard) o r L4024M (Extension) ........................ 22.3.1 Functions ............................................................................................................................................................... 22.3.2 operation status ~ ~ d .................................................................................................................... i ~ ~ t ~ ~ 22.4 Servo Control Board (SCON) L4268R (or L4000R) and position control ~~~~d (PCON) ~ 4 1 9 0 ~ .............................................................................................. 2.4 .1 Functions of Servo Control Board ~ dof servo ~ ~~~~d ~ i ~ control t ....................................................... ~ ~ 2.4.2 operation status ~ Switch Settings of Servo Control Board ...................................................................................... 2.4 .3
2- 9 2- 9 2- 9 2-11
2- 14 2.4 4 jumper settings of servo pin control ~~~~d punctions of position control ~~~~d ............................................................................................. 2 - 16 2.4.5 2.4.6 Operation Status Indicators of Position Control Board 2- 16
2.4.7 switch settings of position control ~~~~d .............................................................................. 2.5 Servo Driver Unit ~ 4 0 0 (G01) , ~ 4 0 0 1 Q 0 ~ (V01) ............................................................................ 2.5.1 ti^ ti^^^ ~ d.................................................................................................................. i ~ ~ t ~ ~ ~ 2 .5 .2 operation status ~ 2 6 Servo power Unit E5499A or E5787A 2 .6 .1 Functions ............................................................................................................................................................... 2.6.2 Operation Status Indicators ................................................................................................................ 27 ~ ~ ~~~~d ~ ~ 7 0 (or k 3 7 0 0 ~ ) 3 2 ~~ ~ l ~ ~ ~ 2 .7 .1 Functions 2 .7 .2 Connectors 2 .7 .3 switch settings ................................................................................................................................................. 2.8 Interlock Board L3899Y ..................................................................................................................................... 2.8.1 ~~~~~i~~~ 2.8.2 Operation Status Indicators ................................................................................................................. 2 .8.3 Switch Settings 2.8.4 Fuses and Connectors ................................................................................................................................. 2.8 5 Connecting Jig Terminals on Interlock Board ....................................................................... 03 2 9 constant voltage power supply ~ - ~ 0 0 2........................................................................................... 2.9.1 ti^^^ 2 .9.2 operation status indicators 2.10 Terminal Block Unit E5741A (Option) and Relay Unit E5685A (Option) 2 10.1 Functions of Terminal Block Unit
...............
2-16 2-18 2 - 19 2-19 2-21 2-21 2-21 2 - 22 2 -22 2 - 22 2-23 2-24 2 -24 2-24 2 - 25 2-27 2-28 2-30 2 -30 2-30 2-32 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
pins on ~~l~~ unit 2 .10.4 connectors and J~~~~~ 2.11 Charging Battery Unit W-LO0471 (Not mounted on IRBCX-532) ...... 2 .11.1 Functions ............................................................................................................................................................. 2.11.2 ~~~~ifi~~t.~~~ 2 .11.3 Replacing Charging Battery Unit ................................................................................................. ~~ 3 3 9 ................................................................................................................................. t 1 ~ t ~ ~ ~ 2 12 M~~~~~ ~ 2-12 1 ti^^^ ............................................................................................................................................................ 2 .12.2 Specifications 2. 12 3 Replacing Memory Battery 2 13 Switch Box E5760 or E5809 ........................................................................................................................... 2.13 1 Functions ............................................................................................................................................................ 213.2 Fuse 2.14 ~ ~ ~ ~~~~~f~~~~~ i l i - L O O ~ ~ O~ W ~ 2 14.1 ~~~~~i~~~............................................................................................................................................................. 2.15 Step-down Transformer (Option) 2 .15.1 T~~~~of step-down ~~~~~f~~~~~~ 2. 15.2 connecting step-down ~~~~~f~~~~~
2.15 3 voltage switching T~~~ of step-down ~~~~~f~~~~~ ....................................................... 2 16 power Unit E6029A 2 .16.1 Functions of power Unit 2 .16.2 Specifications of power Unit ..............................................................................................................
2-36 2-36 2-36 2-36 2-36 2-37 2-37 2 -37 2 -37 2-38 2-38 2-38 2 -40 2-40 2 -40 2-40 2-41 2-42 2 -45 2-45 2-45
Chapter3
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 ........................................................................................................................... - 6 3 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 ~ ~ ~ ~ d ~welding t ~ dsupply b i ~ t ~ power (option) ......................................................................3-11 35
. 3-11 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 3-11 3 6 Welding Interface (Option) 3 - 12 3.6.1 Functions 3- 12 3.6.2 Description of parts 3-13 3- 13 3.6.3 Printed Board E5624G 3-15 3.6.4 External Connection .................................................................................................................................... 3.6.5 Operation Sequence 3-16 3-18 3.6.6 Internal Circuit ................................................................................................................................................. 3 7 External Storage (Option) .............................................................................................................................. 3-19 3.7.1 Specifications 3 - 1g 3.7.2 Configuration of External Storage 3-20 3.7.3 Connecting External Storage 3 -21 3-22 3.7.4 Notes on Handling External Storage ............................................................................................. 3.7.5 Notes on ~ ~ ~ d ~ ii ~ ~k ~l~~~~ l ~ ~ 3-22 3-23 3 8 printer Interface Unit (option) 3.8 .1 Functions 3 -23 3-23 3.8 .2 Configuration ..................................................................................................................................................... 3.8 .3 Connecting printer Interface Unit ....................................................................................................3-25
Peripheral Equipment of Robot Control Unit
3-25 3.8 .3.1 When External Storage is not used 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~~
~ control unit ....................................................................... b ~ t 4.2 connecting peripheral ~i~ to ~ 4.2.1 system configuration ................................................................................................................................ 4.2.2 control cables for peripheral ~i~ 4.3 Internal Switch Settings and Connection Drawings of Robot Control Unit 4.3. 1 GOIS+ 1 Axis System 4 .3 .2 G01S+2 Axis System 4 .3.3 ~ 0 1 ~ ~~i~ system + 3 4 3.4 VOlS+ 1 Axis System 4 .3 .5 V01S+2 Axis System 4 .3 .6 VOlSS.3 Axis System
Chapter5 Troubleshooting
.................................................................................................................................... .............................................................................................
............
4-2 4-3 4-3 4-4 4- 5 4- 7 4-9 4-11 4- 13 4-15 4-17
.................................................................................................................................... ....................................................................................................................................
5 1 Symptoms 5 - 15 Nothing Appears on the Teaching Box ......................................................................................... 5-15 5.1.1 i on the~Teaching Box l Unsteady ...................................................................... 5-16 ~ Is ~ ~ 5.1 2 The ~ 5-17 5.1 .3 initial Diagnosis Is ~~t completed ................................................................................................ power supply cannot B~ ~~~~~d ON ................................................................. 5-20 5.1.4 ?'he servo 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 i of A ~~ ~......................................................................................................................... 5-23 ~ i l l ~ ~ ~ ~ ~ 5.2.1 ~h~ ~ 5-26 5 .2.2 Logical Outputs for Failures 5.2.3 shock sensor 5-27 5.2.4 Servo power shutoff 5 - 28 ~ ~ k~ i i t 5-29 5.2.5 software i ~ ~ i software ~ i ~.......................................................................................... Overrun ................................................................................................................................................................. 5 - 31 5.2 .6 5.2 7 ~ ~~ ~ ~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 - 39 5 .2.11 ABSO Data Failure When Servo Failure Occurred ...................................................................................................................... 5-40 53 5-40 5 .3.1 How To See the Servo Failure Display ~ ~ ~ ~ b servo ~ h ~ ............................................................................................... 5-46 ~ for l ~ ~ ~ ~i t i l ~ ~ ~ ~ ~ 5.3.2
, I
Chapter6 Periodic Inspection
61 62 63 6.4
Warranty period periodic Inspection Schedule Notes for Performing Periodic Inspection List of Inspection Items
..........................................................................................
6-1 6-1 6-2 6-2
Chapter7
Parts L i s t
71 72 73 7.4 75 76 7.7 7.8 7.9 7.10
IRBCX-422 Robot Control Unit .................................................................................................................. IRBCX-462 Robot Control Unit .................................................................................................................. IRBCX-512 Robot Control Unit .................................................................................................................. IRBCX-532 Robot Control Unit .................................................................................................................. IRBCX-541 Robot Control Unit .................................................................................................................. IRBCX-551 Robot Control Unit .................................................................................................................. BBOpX-3000 Operation panel .................................................................................................................... BBOP-3005 Operation Pane] BBTBX-6008 Teaching Box ............................................................................................................................ BBST-4005 Starting Box .................................................................................................................................. 7.11 BBWF-0105 welding Interface .................................................................................................................... 7 12 BIRBX-1005 Control Cables 7 .12.1 control cable 1,2 > 3 ~ 0 ~1 0 ~ 1 1 ) ................................................................................... 0 7 .12.2 cables / H~~~
9
7-2 7-4 7. 6 7-8 7-10 7-12 7-14 7-16 7-18 7-20 7-22 7 -24 7-24 7 -24 7-26 7-26 7-27 7-28 7-28 7-29 7-30 7 -30 7-32 7-34 7-36 7-38 7-40
7.12.3 Control Cable5 (For Almega Auto 11% Robot Control Unit) 7 13 BIRBX-8005 Control Cables
............................... 7-25
7.13.1 Control Cable 1,2 ,3 (For V10 ~ 2 0 ) 7.13 2 ~~~l control cable ( F ~ ~1 ~~ 0 ) 02 7 14 BIRBX-6005 Control Cables 7.14.1 Control Cable 1 2 3 (For V40) ........................................................................................................... 4 ).......................................................................................................... 7 .14.2 ~~~l control cable ( F ~ ~ 0 ~ 7 15 Robot Control Unit for External Axes ............................................................................................... 7.15.1 IRBCX-422-1 Robot Control Unit 7.15.2 IRBCX-422-2 Robot Control Unit 7 .15.3 IRBCX-422-3 Robot Control Unit 7 .15.4 IRBCX-512-1 Robot Control Unit 7 .15.5 IRBCX-512-2 Robot Control Unit .................................................................................................. 7.15.6 IRBCX-512-3 Robot Control Unit ..................................................................................................
9 9 ,
Chapter8
81 82 83 8.4 8.5 8.6 8.6.1 IRBCX-422 462 512 541 551 ................................................................................................................ 8 .6.2 IRBCX-532 ............................................................................................................................................................. 8 7 Electrical Diagram of Control Cable
1
Electrical Connection Diagram Electrical Diagram of Robot Control Unit IRBCX-422 462 ................................................. Electrical Diagram of Robot Control Unit IRBCX-512 .............................................................. Electrical Diagram of Robot Control Unit IRBCX-541 .............................................................. Electrical Diagram of Robot Control Unit IRBCX-551 .............................................................. Internal Sequence Diagram of Robot Control Unit .................................................................... Outside Dimensional Drawing of Robot Control Unit .............................................................
, t
'
8-1 8-7 8-13 8-19 8-25 8-33 8-33 8-34 8 - 35
APPENDIX I-WELDING EQUIPMENTS 1.1 connecting ~ ~ ~ ~b d ~Welding t power Supply i ~ t~ ~ d 1.1.1 ~ ~connecting cable t ~ ~ ~ ~ 1 1.2 Connecting Cables
Al- 1 Al- 1 A1 - 2 Al- 3 Al- 3 Al- 4 Al- 6 Al- 6 ~
1.2 Connecting Welding Interface a n d Welding Power Supply 1.2. 1 External Connecting Cable ................................................................................................................ 1.2.2 Connecting Method of Cables 1 3 TIG Interface E5743 ........................................................................................................................................... 1.3. 1 A~~~~~~~~~ of TIG interface
7 wires of TIG ~ ~ t ~ ~ f Al- ~ 1.3.2 setting J~~~~~ 1.3.3 Connecting TIG Interface Al- 7 1 4 Filler Wire Feed Control Unit EST56 Al- 8 Al- 8 1.4.1 Appearance of Filler Wire Feed Control Unit .................................................................... Connecting Filler Wire Feed Control Unit ............................................................................. A1 - 8 1.4 .2 1 5 CUT Interface E5782 ......................................................................................................................................... Al- 9 Al- 9 1.5. 1 Appearance of CUT Interface .......................................................................................................... 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 1.61 Specifications of Weld Stick Detection Unit ......................................................................... . 1.6 2 Functions of Weld Stick Detection Unit .................................................................................... 1.6.3 Connecting Weld Stick Detection Unit ....................................................................................... 1.7 Connection Examples of Various Welding Power Supplies ............................................ 1.7. 1 C02/MAG/MIG Welding Power Supply ................................................................................. 1.7.2 TIG Welding Power Supply ................................................................................................................ 1.7.3 ~i~ plasma cutting power supply ............................................................................................... Al-11 A1 - 12 A1 - 13 A1-15 A1 - 16 A1-22 ~1 -24
Contents
1.3 External Connection 1.3.1 Connecting Control Cable 1,2,3 (BIRBX-1005/BIRBX-8005) 1.3.2 connecting hi^^ B~~
... .
1-20 1- 21 1-24 1-25 1-27 1-28 1-29
1.3.3 Connecting Control Cable 5 (BWCB-5105) o r Welding Interface (BBWF-0105) ....................................................................................................................................................... 1.3.4 Connecting Operation Panel .................................................................................................................... 1.3.5 Connecting Starting Box ............................................................................................................................. 1 3.6 Connecting Miscellaneous Options
1.
Installation
WAKNlNti
1. Before the installation and connecting cables to the robot control unit, ensure that the switch of the switchboard and the breaker in the control unit a r e turned OFF s o that no voltage is being impressed.
ELECTRIC SHOCK
@ D o not touch live electrical
installing or servicing. ources of voltage
2. Install the robot control unit and its peripheral equipment such a s the welding power supply, the starting box,and s o on out of the 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.
a Read instruction manual. 8
Fig.1 . l . Installation of robot control unit on high place
L A U l IUN
1. Install the robot control unit over 20cm away from wall.
T O AVOID D A M A G E T O T H E R O B O T C O N T R O L UNIT, KEEP T H E AIR I N L E T A N D E X H A U S T
2. After completing the installation work, carry out the "Absolute Offset Setting" described in the Instruction Manual "TEACHING", s o 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.
CAUTION
FAILURE T O CONNECT C N 4 7 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 P e r f o m absoluts o f b o t adjustment according to Inrtructioo Monval nftsr CN47 is connectad. 0 Whon raplacing banariss, bs sure tho1 the control
pawar is on.
.--... "..",,
Installation
1-1
2.1 Configuration 1.I .1 COp/MAG Welding Robot Standard Configuration

1. ALMEGA GOlS Basic Configuration @ ~ ~ ~ ..................................................................... i ~ ~ l I R B - Q ~ ( G O~~ S ) ~ ~ t ~ Standard accessories Wrench Clamping bolts
@
Control Unit (OSACOM SUPER 8700) Teaching Box .................................................................... Operation Panel
IRBCX-422
@ ) @
@
BBTBX-6008
1 1
(Cable 8m) (Optional)
.......................................................... BBOPX-3000
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 1 (Cable length 5m)
a
@
control cable 5 ( F o r Control Unit-Robot Wire Reel Stand
BWCB-5105
Dedicated Welding Power Supply) L318H 1
0 ~
1
BIRB-3005 ~ ~
~ lset ~
Workpiece Side Welding Cable
--.----.-..L3442B
(1) (1)
(Cable length 5m) (Cable length 5m)
( F o r Welding Power Supply-Workpiece) ~ - ~~~~h side welding cable ........................ L2527D 2 (For Welding Power Supply-Manipulator) 0 3 G~~ H~~~ .................................................................. L2527B @-4 control cable 4 ~ 3 3 9 2 ~
(I) (1)
(For Welding Power Supply-Manipulator)

@
G~~ ~
~ ............................................................... ~ ~
5092-320 l
t(FCR-8033) ~
-2
Installation
Installation
-3
2. ALMEGA WOlS Basic Configuration ~ ~ ~ i ~ ~
1 ~ ~ - 4t 6 1 ~ (WOlS)
~ 1
~ Standard accessories
*
Wrench Clamping bolts
Control Unit
.....................................................................
IRBCX-462
1 1 1 (Cable 8m) (Optional)
(OSACOM SUPER 8700) hi^^ B~~ Operation panel
BBTBX-6008 BBopX-3000 BIRBX-1005
Control Cable 1,2,3 ...................................................... (For Manipulator-Control Unit)
lset ( 3 cables:5m length)
COdMAG Welding Components
@ Robot Dedicated Welding Power Supply .-- CPVAS-350
1 1 (Cable length 5m)
a
@
Control Cable 5
.............................................................
BWCB-5105
(For Control Unit-Robot Wire Reel Stand Wire Feed Unit Cape Hanger
Dedicated Welding Power Supply) L318H 1 L6065A L6058D K2863A MTX-3502 L318G L3382G BIRB-3005 ~ ~ 1 1 1 1 1 1 ~ lset ~ (I) ~ (2.5m)
@ @
....................................................................
Coaxial power Cable

@ @ @
COz Welding Torch
...................................................... .......................................
..........................................
Torch Attached Bracket Torch Gauge Assembly ~ ~ b l
0 - 1 Workpiece Side Welding Cable -.--..--.--..----L3442B ( F o r Welding Power Supply-Workpiece) 0-2 Q-3 Torch Side Welding Cable
-..--..-.-------.--------L2527D
(Cable length 5m)
(1)
(Cable length 5m)
(For Welding Power Supply-Manipulator) G~~ H~~~ ................................................................... ~2527~

- -........... -.
(1) (Hose length 5m)

(1) (Cable length 5 5 m)
0 - 4 control cable 4
~3392~
@ Q
(For Welding Power Supply-Manipulator) Gas Regulator ................................................................. 5092-320 Conduit

.................................................................................
1 1
(FCR-8033) (3x1)
Z318D41
-4
Installation
3. ALMEGA VOlS Basic Configuration Manipulator ......................................................................
a
@
IRB-511 (VOlS) IRBCX-512
Standard accessories Clamping bolts
Control Unit
....................................................................
@ @
(OSACOM SUPER 8700) Teaching Box .................................................................. operation panel

...........................................................
.....................................................
BBTBX-6008 BBOPX-3000 BIRBX-1005
1 1
(Cable 8 m ) (Optional)
Control Cable 1,2 ,3
Iset (3 cables:5 m length)
Unit)
C02/MAG Welding Components
@ Robot Dedicated Welding Power Supply .-- CPVAS-350
1 1 (Cable length 5 m )
a
@
@
Control Cable 5
.............................................................
BWCB-5105
( F o r Control Unit-Robot Wire Reel Stand Wire 'Feed Unit Coaxial Power Cable C 0 2 Welding Torch
@)
@ @
Dedicated Welding Power Supply) L318H L3603A 1 1 1

1
................................................
K2364A MTXC-3501
(1.2m) (With shock sensor)
Torch Attached Bracket Torch Gauge Assembly G~~ ~ Conduit
........................................
L6300B L6300C 5092-320 l Z318D41 BIRB-3005 ~
1 1 1 1 lset (1) (Cable length 5m) t(FCR-8033) ~ (3m) ~
~................................................................ ~ ~
.................................................................................. ...................................................................
@)
@
Cables/Hoses
Workpiece Side Welding Cable
...-..-..-------L3442B
(For Welding Power Supply-Workpiece)

@-2
Torch Side Welding Cable
.-------------.-------..... L2527D
(I) (1) (1)
(Cable length 5m) (Hose length 5m) (Cable length 5m)
( F o r Welding Power Supply-Manipulator) @-3 G~~ H~~~ L2527B @-4 Control Cable 4
...................................................
L3392G
(For Welding Power Supply-Manipulator)
1-6
Installation
Installation
-7
4. ALMEGA VlOS Basic Configuration @ ~ ~ ~
IRB-541 ( ~ 1 0 s1 ) ~ Standard accessories ~ ~ l Clamping bolts
Control Unit (OSACOM SUPER 8700) hi^^ B~~ operation panel

............................................................
......................................................
IRBCX-541
BBTBX-6008 BBOPX-3000 BIRBX-8005
1 1
Control Cable 1,2,3
lset ( 3 cables:5 m length)
( F o r Manipulator-Control
Unit)
COdMAG Welding Components
@ Robot Dedicated Welding Power Supply
-.
a
@ @
control cable 5
.............................................................
CPVAS-350 BWCB-5105
1 1
(Cable length 5m)
( F o r Control Unit-Robot Dedicated Welding Power Supply) Wire Reel Stand ............................................................. L318H 1 Wire Feed Unit
................................................
L3603A ~ 2 3 6 4 ~ MTXC-3501
.......................................
1 1 1 1 1 ~
1
0 coaxial power cable

0 COz Welding Torch
@
(1.2m) (With shock sensor)
Torch Attached Bracket Torch Gauge Assembly
L3585p L3585M
@ )
G~~ ~
@ @
5092-320 l Z318D41 BIRB-3005 ~ ~
t(FCR-8031) ~
Conduit ~ ~
.................................................................................
b..................................................................../ l ~ ~
(3m) ~ lset ~ ~
- 1 Workpiece Side Welding Cable
.--.---.--.---.-L3442B
(1) (1) (1) (1)
(Cable length 5m)
(For Welding Power Supply-Workpiece) - 2 Torch Side Welding Cable L2527D (Cable length 5m)
(For Welding Power Supply-Manipulator) @-3 G~~ H~~~ ................................................................... ~ 2 5 2 7 ~ 0 4 Control Cable 4
..................................................
L3392G
( F o r Welding Power Supply-Manipulator)
-8
Installation
Installation
1 -9
5. ALMEGA V20S Basic Configuration Manipulator Control Unit (OSACOM SUPER 8700)
@
......................................................
IRB-551 0720s) IRBCX-551
1 1
Standard accessories Clamping bolts
hi^^ B~~
operation panel Control Cable 1 2 3
I ,
BBTBX-6008 BBOPX-3000 BIRBX-8005 Unit)
(Cable 8 m ) (Optional)
@ @
lset (3 cables:5m length)
1-10
Installation
Installation
1-1 1
6. ALMEGA V40S Basic Configuration a ~ ~ ~
IRB - 531 ( ~ 4 0 ~ ) Standard accessories i ~ 1 ~ l

Clamping bolts
Control Unit
......................................................
IRBCX-532
(OSACOM SUPER 8700)

@
hi^^ B~~
operation panel
.........................................
..................................
BBTBX - 6008 BBOPX-~OOO

BIRBX-f'j005
1 1
a
@
Control Cable 1,2,3,4
lset (4 cables:5 m length)
Unit)
I -1 2
Installation
Installation
1- 1 3
1.1.2 Optional Equipments

The following Equipments a r e provided as options.
@ Teaching Box
Model BBTBX-6015 Specifications Cable Length: 15m
@ Control Cable 1,2,3 (For Manipulator-Control

a ) F o r VOlS,GOlS,WOlS
Unit)
b) F o r VlOS,V20S Model BIRBX-8003 BIRBX-8010 BIRBX-8015
I
I
Specifications Cable Length: 3m Cable Length: lOm
Cable Length:15m
c) F o r V40S (Control Cable 1,2,3,4)
@ Control Cable 5 (For Control Unit-Almega

Model BWCB-5110 BWCB-5115
Auto II )
I I
Specifications Cable Length: lOrn(Optica1 fiber) Cable Length: 15m (Optical fiber)
@ Cables/Hose (For Control Unit-Almega

Model
- -
Auto II ) Specifications
I
L3375T L3375V
Constructions Torch Side Workpiece Side Control Gas Hose Welding Cable Welding Cable Cable 4 L3375E L3375G L3375L L3375N
BIRB-3010 BIRB-3015
L3443B Cable Length: lOm L3444B Cable Length: 15m
-1
Installation
@ Tool Control Cable

a ) F o r VlOS,V2OS Model BIRBX-9105 BIRBX-9110 BIRBX-9115 b) F o r V40S Model BIRBX-6105 BIRBX-6110 BIRBX-6115 Specifications Cable Length: 5m Cable Length: lOm Cable Length: 15m Specifications Cable Length: 5m Cable Length: lOm Cable Length: 15m
Operation Box Model BBOPX-3005 BBOPX-3008 BBOPX-3015 Starting Box Model BBST-4005 BBST-4008 BBST-4015 ~ ~storage t Specifications Cable Length: 5m Cable Length: 8m Cable Length: 15m ~ ~ ~ ~ l E5777A E5657L E5777K E5777J E5657C E5777N E5624A E5623B E574 1A E5685A
............................................................................................................
I I I
Specifications Operation Box with 5m cable Operation Box with 8m cable Operation Box with 15m cable
External Connecting Cable Cable Assy(l) Cable Assy(2) Interface printed Board
@
.....................................................................................................................
Accessories Welding Interface (For COz o r MAG Welding Power Unit expect CPVAS) personal Computer Interface Cable (For Personal Computer-Backplane Terminal Block Unit Relay u n i t ~ ~ ~ ~ t Terminal Block ~ d ~ ~ d Unit t Relay Unit d ~ d ~ ~ board)
0
Q
@
E5766A E5772A
Installation
-1
1.2 Connecting Primary Power Supply

1.2.1 Connecting P r i m a r y 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 . 5 d 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. F o r 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. F o r 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.
1-1 6
Installation
1.2.2 Opening Control Unit Door

Door Key t---7 1. Unlock the upper and lower
/
Braker
door keys. Use a minus screwdriver. 2. Turn the breaker handle to "Open Reset" in the direction of the arrow in Fig.1.2.2.1 to open the door. At this moment,the primary power of the control unit is shut off.
.+
I
//
Door Key
/-----
ELECTRIC SHOCK can kill.

* D o not touch live electrical parts. @Disconnect all power before installing or servicing. .Multiple sources of voltage m a y exist inside this enclosure.
Fig.1.2.2.1 Door of control unit
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:
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.
Fig.1.2.2.2 Breaker handle

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.
Installation
1-17
1.2.3 Grounding
F o r 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 a n 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. F o r the welding power supply,provide an independent ground with a grounding cable over 1 4 d .
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 sP l a t e ,
Welrring Torch
M a n l F u l a t o r Sloe W s ! d i n g C a b l e ( A )
Robot Control Unit
n o t less than
3 5mm2
(within
:Onj
e x c e e d i n g 100Q)
Fig.1.2.3.1 Grounding
A
I
1
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 for temporary welding of workpiece.
-1 8
Installation
r Read manual for connection procedures.
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.
A : Torch Side Welding Cable
B : Work Side Welding Cable
Fig. 1.2.3.2 Welding current flowing into control unit
Installation
1-1 9
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 f o r 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
1-2 0
Installation
1.3.1 Connecting Control Cable 1,2,3 (BIRBX-1005/BIRBX-8005)

The manipulator and the robot control unit a r e connected with 3 cables.
(1) Connecting Control Cable 1

Connecting cannon plug CNl ,connectors CN67, 68 and CN51-56.
*
Duct /
1. Connect cannon plug CN1 of Manipulator.

2. Connect connectors CN67
and CN68 t o CN67 and CN 68 of Interlock board respectively. Connect connectors CN5156 to CN51-56 a r e all the
.Servo
same type connectors but have different colors to identify each axis. After connection,be sure to check that they a r e 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.
Driver
L C C o In t r o l N Cable I
Fig.l.3.1.1 Connecting Control Cable 1
CAUTION 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
' I
Installation
1-2 1
1 CN2,connectors CN7 and 1
Connecting cannon plug
1. Connect cannon plug CN2

t o CN2 of Manipulator. 2. Wire along the left side and connect connector CN70 t o CN70 of Interlock Board. 3. Connect connector CN7 t o CN7 of Servo Control Board 1.
CN2
Con t
Cab l
Fig.1.3.1.2 Connecting Control Cable 2
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 r e employed in CN5 in SCON Board 1 and 2. To avoid damage for printed circuit board, do not mis-connect.
1-2 2
Installation

Connecting cannon plug CN3,connectors CN7 and CN71
1. Connect cannon plug CN3 t o CN3 of Manipulator.

2. Wire along the left side
Inter l o c k
Fa
f
and connect connector CN71 t o CN71 of Interlock Board. 3. Connect connector CN7 t o CN7 of Servo Control Board 2.
Grounding
P1atcX3
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 a s the connector CN71 a r e employed in CN5 in SCON Board 1 and 2. To avoid damage for printed circuit board, do not mis-connect.
Installation
1-2 3
"1.3.2 Connecting Teaching Box

Connecting connector CN16
1. Connect connector CN16 of Teaching box to CN16 on the side of Control Unit.
Fig.1.3.2.1 Connecting Teaching Box
1-2 4
Installation
1.3.3 Connecting Control Cable 5 (BWCB-5105) o r Welding Interface (BBWF-0105)
Connecting connector CN37 and optical fiber connector
1. Connect connector CN37 t o CN37 of Interlock Board. 2. Connect optical fiber connector t o IC124 of Back plane.
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
@
I
NOTE Connect welding interface like control cable (BWCB-5105).
Installation
1-2 5
cover (Fig.a) and fiber cap (Fig.b). (The unclean connection of optical fiber cable causes malfunction of the robot.)
Qac kP l a n e
Connector Cover
(Fig. a ) Fig.1.3.3.2 Optical Fiber Connector
(Fig. b)
-2
Installation
1.3.4 Connecting Operation Panel
Connecting connectors
I *
1. Connect connectors CN28 and CN31 t o CN28 and CN31 of Interlock Board respectively.
Fig.1.3.4.1 Coilnecting Operation Panel
Installation
1-2 7
1.3.5 Connecting Starting Box

Connecting connector CN31
1. Connect connector CN31 of Starting Box to CN32-CN36 of Interlock Board and Relay Unit
(Note) Station Nos. and their corresponding Connector Nos. a r e a s follows:
(Left S i d e )
+to
Starting
Box
PCB5 (The Inside o f Door)

Fig.1.3.5.1 Connecting Starting Box
1
-2
Installation
I .3.6 Connecting Miscellaneous Options

1. Connect Line Master and Personal Computer t o 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.
Installation
-2
1.4
Placing Printed Boards

Cautions on Placing Printed Boards 1. The printed boards connected t o 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 t h a t 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 M a i n 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 -3 0
Installation
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 0Management Board /

Connect connectors J1,J2 of I/O Management Board to connectors 51-5,5255 of Backplane Board.
Installation
1 -3 1
Chapter 2
Internal C o n f i g u r a t i o n o f Control Unit

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 ....................................................................... ~~i~~~unit ~ 4 0 0 (01) ~ 4 0 0 (1~~ 1 ) 0~ 0 2.5 servo
I
2.
Internal Configuration of Control Unit

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 ~3700~ (2) ti^^ control ~~~~d ~3700~
(3) 1/0 Management Board (Standard)
................... L3700M I/() Management Board (Extension) ...................................... L4024M L4268R (4) Servo Control Board ........................................................................... (5) Servo Driver Unit (6) Servo power Unit E5787A (7) ~ ~ ~~~~d ~ k ~ l L3702F ~ (8) Interlock Board ........................................................................................ L3899Y (9) Terminal Block Unit (Option) E5741A Relay Unit (Option) E5685A ~unit ...................................................................... t t ~ ~ W - LO0471 ~ 00) charging ~ (11) Memory Battery ..................................................................................... L3391V (12) ~ ~ ~ ~~~~~f~~~~~ i l i ~ ~ ~ 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)
2. 1
F o r IRBCX-551 (I) Main Processor Board (2) Motion control ~~~~d
......................................................................
......................................................................
~3700~ ~3700~ L3700M iL4024M~ ) ~ L4268R ~4190~ E5787A ~3702~ ~38ggy ~-~00203 E5741A E5685A w -~ 0 0 4 7 1 L3391V E5760A w -~ 0 0 4 7 0
(3) 1/0 Management Board (Standard)

1/O Management Board ( ~ (4) Servo Control Board or position control ~~~~d ~
....
Servo Driver Unit Servo power Unit ................................................................................... Backplane Board Interlock Board (9) constant voltage power supply ................................................ (10) Terminal Block Unit (Option) Relay Unit (Option) ............................................................................ (11) Charging Battery Unit ...................................................................... (12) Memory Battery (13) Switch Box @4) Auxiliary Transformer
(5) (6) (7) (8)
The component arrangement drawing and block diagram a r e presented in Fig.2.0.0.2 and Fig.2.0.0.4, respectively .
Fig.2.0.0.2 P a r t s Arrangement Drawing of Robot Control Unit (IRBCX-551)
2. 2
Internal Configuration of Control U n i t
Arc Sensor Teaching Box Robot Dedicated Welding Power Supply Personal
4 $A A
computer
ICN~S
A,
CNie CN16
iCiZ4 CNiQ
I
PCB 1
Backplane Board
(Memory Backup)
Jl-5 J2-5 Jl-4 JZ-4 J1-3 J2-3 JZ-2 ~CRI PCB14 J2- I
tnjll PCB13
PCB IS
I/O
Operation Panel (Operation Box)
Interlock Board
/[PC851 l l I P C ~ O I
Charging Battery
Unit
Manipulator
F Fo
Operation Panel (Operation Box)
Manipulator
2.1
Main Processor Board L3700C

Functions
The Main Processor board controls the overall robot control unit and has the following functions:
2.1.1
(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

This LED illuminates when the processor on the Main Processor board properly operates. It goes out when the processor does not properly operate due t o a drop in supply voltage o r 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.
(1) Operation Status Indicator (LED100 Red)
Fig.2.1.2.1 Outside View of Main Processor Board
-5
2.1.3
Replacing Main Processor Board

The memory on the Main Processor board stores important data such a s teaching
d a t a and system parameters. These data a r e 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 a r e 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
2.2
Motion Control Board L3700D

Functions
The Motion Control board controls movements of the manipulator and has the following functions:
2.2.1
(1) Computes the movement and path of each a r m of the manipulator.

(2) Processes various arithmetic operations a t high speed necessary for the above computations.
2.2.2 Operation Status Indicator

(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
2 -7
2.3
1/O Management Board L3700M (Standard) or L4024M (Extension)

Functions
The I/O Management board controls input/output signals transmitted within the robot control unit and from/to peripheral equipment and h a s the following functions:
2.3.1
(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.
2.3.2
Operation Status Indicator

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 t o a failure, etc. In this event, the I/O Management board outputs a system down signal t o shut off the servo power.
(I) Operation Status Indication (LED100 Red)
1 0 Fig.2.3.2.1 Outside View of 1'
Management Board
2 -8
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 a r e 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.
2 -9
Table 2.4.2.1 LED Indications of Servo Control Board
I I
I1
II
1
0
2
/
0
The encoder cable is disconnected o r 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 a r e too large. 5. Overvoltage of main power supply 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. 3. Undervoltage of main power supply The main power supply is abnormal. The primary supply voltage has dropped. The connectors of the main power supply and control power supply a r e disconnected o r 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 a r e 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 a r e 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 4. Supolv voltage drop o r power shut-off within Servo driver " Supply voltage drop of Servo Control board @: ON 0: OFF
A *
-1
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.
SW1 is a Push
but ton switch
/SW2-SW8 are rotary
0 Green LED
r
0 R e d LED
Location of each switch
switches
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. PCB14 (SCON1) PCB13 (SCON2) PCB12 (SCON3) (o~tion) PCBll(SCON4) (option)
-
Slot NO. I SW2 Setting 51 -2 1 52-2 51-1 2 52-1 51 - 12 52-12 51-11*1 4 52-11
Servo System Controlled GO1/WO1/V01/V10/V20: Axes 1-3 GOl/WOl: Axes 4/5 VOl/VlO/V20: Axes 4-6 External Axis External Axis External Axis
* 1: A standard control unit does not have a slot.

Internal Configuration of Control U n i t 2
-1
(3) Axis Setting Switches SW3, SW4, and SW5

Theses switches a r e used t o set moving axes of the manipulator controlled by the Servo Control Board. One board capable of controlling up t o 3 axes h a s 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
Corrsponding Axes of Manipulator GOl/WOI: Axes 4/5, and unused axes V01: Axes 4/5/6 GO1 : Axis 3
1
1 2
/ 1 1 / 1
E
G01: Axes 1/2 VOl : Axes 3 2 1 ' V01: Axis 1 V10: Axes 4/5/6 V20: Axes 4/5/6 V10: Axes 2/3 V10/W01: Axis 1 V20: Axes 1/2/3 WOl: Axis 2 WO1 :Axis3
The settings, 3, 5, 6, 9 and F, do not correspond t o moving axes of the manipulator.
(4) Switch t o set the number of controlled axes SW6

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
Table 2.4.3.3 SW6 Settings SW6 Setting
NO. of Controlled Axes
Example of Application VOl/VlO/V20 : SCONl (PCB14)/ SCON2 (PCB13) GO1 : SCONl (PCB14)
External axis, etc.
-1
(5) Spare Switches SW7 and SW8 (not provided on L4268R) Normally, set them t o 0.
(6) Standard settings of Switches
F o r 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 t o check the settings before replacing the Servo Control board.) Table 2.4.3.4 Settings for IRBCX -422 (ALMEGA G01) Manipulator Printed Board Axis Controlled Axes 1-3 Axes4-5 SW2 SW3 SW4 SW5 SW6 SW7 SW8 1
2
NO.
PCB14 (SCON1) PCB13(SCON2)
G 1 O
4 0
4 0
2 0
0 1
0 0
0 0
Table 2.4.3.5 Settings for IRBCX-462 (ALMEGA W01)
Table 2.4.3.6 Settings for IRBCX - 512 (ALMEGA V01) Manipulator
PrintedBoard
Axis Controlled Axes 1-3 Axes 4-6
1 1 1 1 1 1 1
1 2 8 1 7 1 7 1 0 0 0 0 SW2 SW3 SW4 SW5 SW6 1
2
60.
PCB14 (SCON1) PCB13 (SCON2)
SW2 SW3 SW4 SW5 SW6 SW7 SW8 0 0
vo 1
Table 2.4.3.7 Settings for IRBCX-541 (ALMEGA VlO) Printed Board Manipulator Axis Controlled Axesl-3 Axes4-6
No.
PCB14(SCONl) PCB13(SCON2)
v10
D
A
C A
C A
0 0
Table 2.4.3.8 Settings for IRBCX - 541 (ALMEGA V20) Printed Board Manipulator Axis Controlled Axesl-3 Axes 4-6 SW2 SW3 SW4 SW5 SW6 1
2
NO.
PCB14(SCONl) PCB13 (SCON2)
v20
D
B
D
B
0 0
2-1 3
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 a n 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 r e 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

Close 8 Close 5 Close 2
-
1
2
9 6 3
Close 7 Close 4 Close 1
8 5 2
* The corresponding axis number is a axis number used for

Servo Control board but not of the manipulator.
(3) JT3: Normally, close 2-3

(4) Standard settings of Jumper pins For a standard robot control unit, the jumper pins described above a r e preset a s shown in Tables 2.4.3.10. and 2.4.3.11 (These settings may vary, for example, if a n 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 Printed Board Manipulator PCB14 (SCON1) GOl/WOl PCB13 (SCON2) (ALMEGA GOl/WOl)
Axis Controlled Axes 1-3 Axes 4-5
1
Close 1-2 Close 1-2
1
Close 8-9, 5-6, 2-3 Close 8-9, 5-6, 1-2 Close 2-3 Close 2-3
-1
Table 2.4.3.11 Settings for IRBCX-512/-541-1'551 Manipulator Printed Board Axis Controlled Axes 1-3 Axes 4-6 JT1 Close 1-2 Close 1-2
(ALMEGA VOi/VlO/V20) JT2 Close 8-9, 5-6, 2-3 Close 8-9, 5-6, 1-2 JT3 Close 2-3 Close 2-3
NO.
PCB14 (SCON1) PCB13 (SCON2)
v01/v10/v20
Fig. 2.4.4.1 Outside View of Servo Control Board
2-1 5
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 a r e 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 a n 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 r e 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)
PCB14 (PCON1)
Axes 1
ON OFF ON
00
PCB13 (PCON2)
Axes 4
OFF0
0000 0000 0 0 00 0 0 00 0 0 0000 000 0 0 00
-1
Table 2.4.7.2 RSWl/RSWZ/RSW3 Settings for IRBCX-532 (ALMEGA V40) Printed Board No. PCB14 (PCON1) PCB13 (PCON2) Axis Controlled Axes 1 Axes 4
-
RSWl
RSW2
RSW3
3
6
F F
F F
F
F
Fig. 2.4.7.1 Outside View of Position Control Board
2-1 7
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 G 1 O
/ Servo Driver NO. 1

SD 1 SD2
P a r t NO. 5096-139
Spec. W-LOO456
Capacity 30A X2+ 15A X 1 15AX2
Axis Driven Axes 1-3 Axes 4 - 5
5096-138 W-LO0455
Table 2.5.0.2 Confinuration of Servo Drive Unit IRBCX-462 (ALMEGA W01)
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)
Table 2.5.0.5 Configuration of Servo Driver Unit IRBCX-551 (ALMEGA V20) Manipulator v20 Servo Driver No. P a r t No. SDl SD2 5096-159 5096-155 Spec. W-LOO568 W-LOO553 Capacity 50A X 3 15AX3 Axis Driven Axes 1-3 Axes 4 - 6
Table 2.5.0.6 Configuration of Servo Driver Unit IRBCX-532 (ALMEGA V40) Axis Driven Capacity Spec. Manipulator Servo Driver NO. P a r t No. 2.5kw SDI 5096-115 W-LOO395 Axis 1
2-1 8
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 t o identify the possible cause. The LED indications and possible causes a r e shown in Table 2.5.2.1. Table 2.5.2.1 LED Indications and Possible Causes RDY(green) L E OH (red) OC (red) Cause OV (red) 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 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@0@0@0@0
@ @
@ @ @ ~ @ 1@
* * * * * * * *
* * * * * * * *
* * * *
* * * * * * * * * * * * * * * * *
* * *
* *
I
* *
* * *
* *
* *
*
(@:ON,0 : O F F )
(
* :Possible Cause)
2-1 9
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 f o 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
2-2 0
2.6
Servo Power Unit E5499A or E5787A

Functions
This unit supplies power for driving the servo motors, and has the following functions:
2.6.1
(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.
2.6.2

(1) POWER LED (Green)
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
O 0
a t each of terminals, R, S, and T of TB10, a s the primary power phases could be lost.
TBlO
(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
oCN65
voltage; DC280V)
Fig. 2.6.2.1 Panel of Servo Power Unit
-2
2.7
Backplane Board L3702F (or L3700F)

Functions
This printed board relays signals transmitted from each printed board in the robot control unit, and has the following functions:
2.7.1
(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 t o be connected Spare Teaching box Personal c o m ~ u t e retc. , Line h4aster Welding interface o r Robot dedicated welding power unit
CN18 CN19 IC124 (Optical Fiber)
SCON3
SCON2
SCDN! IKON0
CSP VAIN OPTION IX)
Fig. 2.7.2.1 Outside View of Backplane Board (L3702F) (L3700F does not has a slot for SCON3.)
2
-2
2.7.3
Switch Settings
This jumper pin is set to select whether a 3rd Servo Control board (SCON3) is used o r not. Open it if the control unit is equipped with a 3rd Servo Control board to connect a n external axis (axes), o r 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
-
(1) Jumper Pin (JP10) (Not provided for L3700F)
The number of Servo Control boards mounted 2 boards (for single system) 3 boards (for system using an external axis)
JPlO Setting Close
Open
(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 Manipulator Type
-
1
1 ON OFF
DSWlOO Settincrs
. d
2 ON ON
3 ON
4 ON ON
IRB-421(G01) IRB-461(W01) IRB-5ll(VOl) IRB-541(V10) IRB - 551(V20)

-
1 y: 1 1 1 !:
OFF
[O
ON OFF
OFF OFF ON ON
IRB-531(V40)
The settings in Table 2.7.3.2 a r e for a standard control unit, and may vary if an external axis is added.
2 -2 3
2.8
l nterlock Board L3899Y

Functions
This printed board controls various internal and external 1/0 signals of the control unit, and h a s the following functions:
2.8.1
(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 t o 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 t o reset the absolute encoders.
2.8.2

The interlock board is equipped with LEDs shown in Table 2.8.2.1 t o indicate the
operation s t a t u s of the sequence circuits in the control unit. Table 2.8.2.1 Operation Status Indicators of Interlock Board
-
LEDNa LED101 LED201 LED202 LED203
Function Servo Power ON Teaching Box Servo ON Auto Mode Teach Mode Running Halted Servo Shut Off Emergency Stop Servo ON Permit Shock Sensor
Status ON indicates Servo Power ON ON indicates Teaching Box Servo ON ON indicates Auto Mode
1 (Green)
(Green) (Green)
1 (Green) 1 LED204 1 (Green) I LED205 1 (Green) /

LED301 (Green) ~ ~ ~ 3 0 2 (Green) LED303 LED304
1 ON indicates Teach Mode 1 ON indicates Running 1 ON indicates Halted

O F F indicates Servo Shut Off O F F indicates Emergency Stop
I (Green) 1
(Green)
/ ON indicates Servo ON Permit

O F F indicates that the shock sensor is operating. ON indicates Servo Shut Off when the
Shock Sensor ON
2-2 4
shock sensor operates
LEDNa LED401 LED402 LED403 LED404 LED405 LED406 LED501 LED502 (Green) (Green) (Green) (Green) (Green) (Green)
Function Auto Mode Input Teach Mode Input Start Nal Input Start Na2 Input o3 Start N . Input Halt Input
Status ON indicates Auto Mode Input ON indicates Teach Mode Input ON indicates Start Nal Input ON o2 ON indicates Start N . Input ON ON indicates Start Na3 Input ON ON indicates Halt Input ON indicates Charging ON indicates Voltage Drop (below 380V) ON indicates Overvoltage OFF indicates Overrun of any of axes 1-3. OFF indicates Overrun of any of axes 1-6.
0 LED601 LED602 LED603
1 1
(Green) (Red)
(Red) (Green) (Green) (Green)
1 1
Charging Current ON Voltage Drop of Charging Battery Overvoltage of Charging Battery Overrun Detection Input (1) Overrun Detection Input (2)
Overrun Detection Input (3) OFF indicates Overrun of any of axes 1-9.
2.8.3
Switch Settings
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 will change.
(1) Reset Switch SWl
(2) Reset Mask Switch DSWl

This dip switch is used to prohibit the absolute encoder d a t a from being carelessly reset. The function and setting corresponding to each bit of this switch for a standard control unit a r e shown in Table 2.8.3.1: Table 2.8.3.1 DSWl Settings DSWl Setting Function
I
2
ON
OFF disables any reset signal input from Motion Control board, causing resetting the absolute encoders with the teaching box to be invalid. OFF disables a reset switch SW1 on Interlockboard, causing
ON
resetting the absolute encoders to be invalid.

-2
(3) Jumper Pin Settings

The interlock board is equipped with jumper pins shown in Table 2.8.3.2. Set these jumper pins according t o your robot system configuration. Table 2.8.3.2 Jumper Pin Settings of Interlock Board Jumper Pi1 JP301 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 s u r e t o open this jumper pin. I Sets Emergency Stop input of Operation panel ( o r Operation box) ON/OFF. To connect the Operation panel ( o r Operation box), be sure t o open this jumper pin. Sets Emergency Stop input of Starting box 2 ON/ OFF. To connect the Starting box 2, be sure t o 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 t o CN40 via External Axis board, open this jumper pin, o r t o connect t o 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 t o 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 t o CN72, open this jumper pin (ON). Sets Encoder Cable Connection Check signal for external axis ON/OFF. To use a n y external axis, open this jumper pin (ON) according t o the number of external axes. Standard Setting Close (if equipped with neither Terminal unit nor Relay unit) Open (if equipped with Operation panel ( o r Operation box)) Close (not t o connect Starting box 2) Close (not t o connect Starting box 3) Close (terminals 4-5 of TB1 not t o connect a shock sensor)
Close (if not equipped with External Axis board) Close (not t o use a n y external axis) Close (not to use any external axis)
Close (not to use a n y external axis)
2 -2 6
2.8.4
Fuses a n d 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
a Fuse N
Rating
1
F2 F3 F4
Application Power supply for releasing the manipulator brakes
250V, 3A tube fuse 250V, 1A
AClOOV power supply for the welding interface glass tube fuse 250V, 3A 24V system in the control unit glass tube fuse 250V, 2A glass tube fuse AC8.5V for charging
The Interlock board is equipped with the connectors shown in Table 2.8.5.lto connect peripheral equipment:
Table 2.8.4.2. Connectors on Interlock Board
Connector
I
Peripheral Equipment to be connected Operation box (Start I)

I
CN32 CN33 CN67 CN68 CN69 CN70 CN71 CN72
Starting box 2
Starting box 3 Manipulator (power supply for brakes) Manipulator (power supply for brakes) External axis (power supply for brake) Manipulator (overrun, batteries, et'c.) Manipulator (overrun, batteries, etc.) External axis (power supply for brake)
When Operation box and Starting boxes a r e connected, set also the jumper pins a s shown in Table 2.8.3.2.
2 -2 7
2.8.5
Connecting J i g Terminals on Interlock Board

1Emergency Stop Input Terminals (1 - 3) Used t o connect a n external emergency stop switch. F o r 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 terminals 8- 14.
(1) Connecting TB1
l-----l
I , I
IIServo
Il 1 I o ode 7 1 - I
I I
@
@
ON Indicator Lamp Output Terminal (8) To mount a n external Servo ON indicator lamp, connect t o terminal 1) ' 8-INCOM (terminals 67. (Connectable indicator lamp must be; DC24V and current c o n s u m ~ t i o n not \greater than 0.1A.)
lJ \\
Switching Input Terminals (9/10) To input Auto/Teach modes through a n external switch, connect t o these terminals - INCOM.
'start Input Terminals (11/12/13) To input Starts(l/2/3) through a n external switch, connect t o these terminals - INCOM. Halt Input Terminal (14) To input Halt through a n external switch, connect t o 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
(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. Output (Indicator Lamp) Common Terminal (8) Common terminal t o connect indicator lamps t o terminals 9- 14. Indicator lamp Output Terminals (9 - 14) The indicator lamp connected t o each terminal illuminate in the following state: (Connectable indicator lamps must be; DC24V and current consumption not greater than 0.1A.l LAMP1 (Terminal LAMP2 (Terminal LAMP3 (Terminal LAMP4 (Terminal LAMP5 (Terminal LAMP6 (Terminal
'1 /
9) : Auto Mode 10): Teach Mode 11): S t a r t 1 12): S t a r t 2 13): S t a r t 3 14): Halt
Servo ON Terminals (15-16) Closed between terminals 15- 16 in a servo ON state.
2-2 9
Fig. 2.8.5.1 Outside View of Interlock Board
2.9
2.9.1
Constant Voltage Power Supply W-LO0203

Functions
This unit supplies power to the printed boards, etc. in the control unit, and has the following functions:
(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.
2.9.2 Operation Status Indicators

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 Output Voltage 5V Normal Voltage Range 5.OOV-5.2OV Current Consumption 6A
-3
CAUTION 1. The GNDs for 5V and t15V power supplies a r e shared in the constant voltage power supply unit. 2. The O side terminal of 24V power supply is isolated from the GND V terminals for 5V, 2 15V power supplies. 3. The output voltages of the constant voltage power unit a r e 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.)
( 3
u '
5Y
t15Y -15V 24V
0000
5v
5v
DM3
O M
+5V power supply

I
f 24V
power supply +/-I5

I
power supply
+15V
GM)
-1sv 2' %
CN42
ov
FG
*$I
CN4 1
TB5
/potentiometer
Potentiometer for adjusting 24V output voltage for adjusting 5V output voltage
\
fl
L/
Fig.2.9.2.1 Bottom View of Constant Voltage Power Unit
Fig.2.9.2.2 Front View of Constant Voltage Power Unit
2-3 1
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 h a s 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 t o
the following circuit configurations:
(1) Input Circuit Configuration (TB13/14)

The inputs transmitted from external equipment a r e connected t o 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 t o the input terminals of the Terminal Block unit.
4 " ~ o b o Control Unit t Ci I Ti313
Fig. 2.10.2.1 Input Circuit Configuration

2 -3 2
(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 t o the output terminals of the Terminal Block unit must be; DC24V and current not greater than 100mA.
F o r load of a relay, etc. t o be connected, attach 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 t o Terminal Block Unit

2-3 3
'
TB13 TBl
0
TB14
FC23
TB12
11 l -; F
C N 2 2 t0
i n
OO@OOO@OO@OOOOOOOOOOOOOOOO
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 h a s the same rating after removing the cause.
Table 2.10.2.1 Fuse on Terminal Block Unit Fuse No.
Rating 250V, 2A Glass tube fuse
Application 24V system for external outputs
2 -3 4
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 h a s the following functions:
(1) Receives 20 general physical inputs.
(2) Outputs 20 general physical outputs with relay contact.

(3) Connects up t o 3 Starting boxes.
Fig. 2.10.3.1 Outside View of Relay Unit
2 -3 5
2.10.4 Connectors and Jumper Pins on Relay Unit

The Relay Unit is equipped with connectors t o 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 Connector CN34 CN35 CN36 Starting Box Note
Starting Box 4 To connect Starting Box 4, be sure to OPEN JP1.
/ Starting Box 5 1 To connect Starting Box 5,be sure t o OPEN JP2.

Starting Box 6 To connect Starting Box 6, be sure t o OPEN JP3.
2.1 1
Charging Battery Unit W-LO0471 (Not mounted on IRBCX-532)

The control unit is equipped with a charging battery unit to backup the d a t a 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 t o the encoders while the control power supply is shut off. Therefore, if the robot is not used f o r a long time, the residual battery capacity may not be enough t o supply power t o the encoders. In this case, before performing automatic operation, be sure t o c a r r y out the manipulator origin alignment.
2.1 1.I Functions
2.1 1.2 Specifications

Nominal voltage Capacity Discharge voltage 2.OV X 2(2 charging batteries in series) 25AH 3.8V-4.2V (when load is connected)
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 t h a t the
alignment m a r k s match a t the origin. If not matched, mark that position with a layout line.
2 -3 6
(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).
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 a r e 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

Functions
The Memory Battery has a function to backup the data, such a s teaching d a t a and system parameters, stored in the memory on Main Processor board, and supplies backup power to Main processor board via Backplane board.
2.12.1
2.12.2
Specifications
Primary lithium battery 3.0V
Type Nominal voltage
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 o r 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.
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 d a t a and the system parameters from the external storage.
CAUTION (1) Replace the memory battery that h a s 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
2.13.1
Switch Box E5760 or E5809

Functions
The Switch Box h a s 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 t o the servo drivers and absolute encoders.
(3) Turns the servo power supply ON/OFF. (4) Supplies AClOOV t o 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 t h a t h a s the rating below:
-=
2 -3 8
Table 2.13.2.1 Fuse on Switch Box Rating
Fuse N a m e
1 2 5 v / l ~ Glass tube fuse
Application 100V power supply for external storage
- cm74
-OUTPUT
A a W V IZOAI
_I
AC 1 OOV INPUT
S
R
-
-I -
ACZWV NPUT
Fig. 2.13.1.1 Outside View of Switch Box
2 -3 9
2.14
Auxiliary Transformer W-LO0470

Functions
The auxiliary transformer TF1 h a s the following functions:
2.14.1
(1) Outputs AC8.5V used for power supply t o 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 t o 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 t o the system configuration (capacity of the load). Table 2.15.1.1 Types of Step-down Transformers Tip-
Examples of Applicable Capacity
W-LO0246
3kVA built-in
/
/
System Configuration (Note) Single G01, W01 o r V01, GO1 external axes, and V01
+2
W-LO0557 7kVA separate
+ 1 external axis Single V10, V20, o r V40, GO1 + 3-7 external axes, and V01 + 2-6 ext.
Systems using the number of axes more than the above
W-LO0558 l2kVA separate
Built-in type: Built in the control unit Separate type: Installed outside the control unit
CAUTION These examples a r e given for your reference. To select a step-down transformer, contact DAIHEN.
2 -4 0
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
Primary Power Supply
--
~ r a n s f o k e (Built-in) r
sGC- down
--
power u n i t Switch Box SBI
PsKF
Robot Control Unit

--
--
--
--
i
SB~
Fig.2.15.2.1 Connecting Step-down Transformer (Built-in Type)
-.."-----Breaker Primary Power Supply
Step-d0wn Transformer .
1r
,
- - - -- - - Breaker Power Unit PSI

NFRl
Switch
BOX
Fig.2.15.2.2 Connecting Step-down Transformer (Separate Type)
2 -4 1
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 t a p s t o select a voltage from among these voltages. According to the voltage of the power supply used, switch the t a p s 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
-4
WARNING T o safeguard against electric shock, before attempting t o switch the voltage t a p s , make s u r e t h a t n o voltage is impressed t o the step-down transformer. In addition, some safety measures should be taken, f o r example, by providing a notice plate indicating "Working" a t the switch of the power source s o t h a t the control unit cannot be carelessly energized during the work.
Table 2.15.3.1 Connecting J u m p e r s According t o P r i m a r y Supply Voltage Primary Supply Voltage J u m p e r Connection SecondP r i m a r y T a p ary Tap
220V 230V 240V 380V 400V 415V
U-U8, U4-U12, U4-V, V-V8, V4-V12, V4-W, W-W8, W4-W12, W4-U U-U8, U5-U13, U5-V, V-V8, V5-V13, V5-W, W-W8, W5-W13, W5-U U-U8, U6-U14, U6-V, V-V8, V6-V14, V6-W, W-W8, W6-W14, W6-U U1-U8, US-V, V1-V8, V9-W, W1-W8, W9-U and U2-U8, U10-V, V2-V8, V10-W, W2-W8, W10-U U3-U8, U11-V, V3-V8, V11-W, W3-W8, W11-U S1-T R-TI, R1-S,
2 -4 3
Fig. 2.15.3.3 Connection Example of Input Voltage 240V
Fig. 2.15.3.4 Connection Example of Input Voltage 415V
unit. Before turning on the power supply, be sure t o check t h a t the jumper wire connections a r e correct and appropriate t o the actually supplied voltage.
2 -4 4
2.1 6
Power Unit E6029A 2.16.1 Functions of Power Unit

The Power Unit is the one t o supply t o the printed boards and the like used within the control unit, a n d h a s the following function:
(1) Function t o remove noise from the primary power source and t o supply AC2OOV
a n d AClOOV t o the units within the control unit. (2) Function t o supply DC5V,+ 15V, -15V, 24V power, and s o on t o the units and printed boards. (3) Function t o supply DC5.5V power to the Servo Control board and the absolute encoder. (4) Function t o supply AClOOV power t o External Memory Unit. (5) Function t o turn ON/OFF the servo power.
2.16.2
Specifications of Power Unit

DC5.5V 3A DC5.2V 10A DC+15V 0.5A DC-15V 0.5A DC24.2V 1.5A 300(H) X 125(W) ~250(D)mm
(1) Rated Output Voltage/Current
(2) Dimensions
(Inside Layout of Unit)
( F r o n t View of Panal)
Fig.2.16.2.1 Outside View of Power Unit and Inside Layout of Unit

Internal Configuration of Control Unit 2
-4 5
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 t o exchange units due to failure o r so, confirm the voltage of the output terminal in the table below TABLE 2.16.3.1 Output Voltage of Power Unit Rated Voltage Normal Voltage RANGE 180-220V 90-110V (no load) (no load) Terminal for Checking TB16 Adjustment Portion Input Voltage
3 q5 AC2OOV
1 q5 AClOOV
@-@-a
( 0 : +) ( 0 : +)
DC 5.5V
1
I
5.40-5.50V
(no load)
0-0 CN135 0-0 CN136 0-0

CNl50
PSUl -VR1
1
I
PSU2-VR2
5.10-5.2OV
(with load)
CN42 0-0 ( 0 : +) CN2A 0-0 ( 0 : +) CN2B 0-0 ( 0 : -I-)
5.05-5.25V
(with load)
None 15.0-15.4V (no load)
None -15.0%15.4V (no load)
(0-1 : CN2B @-@ (0: -1

CN2A @--@
24.1-24.3V
CAUTION
(no load)
CN41 @-@ (@ : +)
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 r e 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
Internal Configuration of Control Unit 2 -4 7
Terminal Block
, ' /
N
-I
OJ
+ L_JOLED
VFI 1
Fig.2.16.3.1 P a r t s Layout of Constant Voltage Unit (PSU1)
For
For
CN6
CN5
CN4
Fig.2.16.3.2 P a r t s Layout of Constant Voltage Unit (PSU2)

4 8
2.16.4
Fuse of Power Unit

The Power Unit contains the fuse shown in TABLE 2.16.4.1. When t o exchange fuses due t o melting, first remove the cause a n d exchange the
defective fuse with a new one of the same rating.
TABLE 2.16.4.1 Fuse of Power Unit Fuse NO. Rating 250V,lA F1 Glass Tube Fuse
( $6.4~3Omm)
Application AClOOV Power Source for
P a r t No.
4610-008 Floppy Disk Storage Unit
2.16.5
Connectors of Power Unit

The Power Unit is equipped with connectors shown in TABLE 2.16.5.1 t o supply
power source t o units inside. TABLE 2.16.5.1 Connectors of Power Unit
CN42 CN2 CN2B CN2C CN135 CN136 CN137 CN138 CN150
1 (Internal)
/ (Internal)
j Backplane Board (CN10)
5V,t15V 5V, i- 15V 5V, ?c 15V 5V, t 15V
i Servo Driver 1 (CN2) i Servo Driver 2 (CN2)

Servo Driver 3 (CN2)
/ (Internal)
/ (Internal Spare)
(Internal) (Internal)
j Servo Control Board 1 (CN6) 5.5V

j Servo Control Board 2 (CN6) 5.5V
Servo Control Board 3 (CN6) 5.5V Interlock Board (CN38)
j AC Outlet
I (Internal Spare)
/ (Internal) / (Internal)
AClOOV
CAUTION T o avoid damage for the components of Robot Coutrol Unit, never use the internal s p a r e a n d internal connectors in TABLE 2.16.5.1 for other purpose.
>
2 -4 9
Chapter 3
Peripheral Equipment o f Robot Control U n 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 ~ 3 3 Operation Box (Option) 3.3.1 Switches and Functions
~circuit t ............................................................................................ l ~ ~ ~ ~
.....................................................................................................................
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.
P e r i p h e r a 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 Be s u r e t o install these peripheral equipment outside the robot working area.
Peripheral Equipment of Robot Control U n i t
3-1
3.1
Teaching Box
Functions
The teaching box is used to teach robot task programs, and has the following functions:
3.1.1
(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
3.1.3
Notes on Usage
these parts, be careful not t o drop o r hit it when you handle it.
(1) The teaching box is equipped with precision parts. Because a shock may damage
(2) The ambient temperature in the environment may cause the d a r k 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 Configuration
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

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 r e 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 -4
3.2.2 Outside View and Internal Circuit
Ik
L---J
L---J
m T I C CWI4TICN
OSACOM
Fig.3.2.2.1 Outside View of Operation Panel
------I(0Doratlon Box) Emerrsncr s t o p
I I I I I
I
24E
Start dlsDla1 1
I
I
H a l t dlsDlaY S e r v o ON
I I I I
I
I
T e a c h node selectlonl ~ u t omode selection I Servo @ dlsDlaY i I

I
I T e a c h n o d s dlsPlaJ I
c --' & A !
Auto mode dlSDlaY I - - - -- - - - - - - -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 t a r 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).
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.

The outside view and internal circuit of the operation box a r e shown in Fig.3.3.2.1 and Fig.3.3.2.2, respectively:
S
S7,RT
E?
-@!+it
STOP
Fig.3.3.2.1 Outside View of Operation Box
3-6
-0 0
902
PBZ
I
j
EMERGENCY S T O P SERVO ON SERVO ON TEACH ING ALJTO STOP START
0
@
46
TEACH ING AUTO STOP START
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
(interlock
Board
(Ooeration
box)
CN28
(Interloc~
Board
- I L
Fig.3.3.2.3 Relay Cable for Operation Box
-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 a n optional relay unit enables it to control up to 6 stations.
A
I
3.4.1
WARNING Be sure to fix any Starting box outside the dangerous area.
Switches and Functions

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 r e clear of the dangerous area.
(1) START
(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 t o be shut off so that the brakes will be engaged. To cancel the Emergency Stop, turn this button to the arrow. F o r detailed procedures for automatic operation and for recovery from the state of emergency stop, refer to the "Teaching" instruction manual.
3 -8
3.4.2
Connecting Starting Box

To use a Starting box, connect it t o the connector corresponding t o the relevant
station number, and open the jumper pin o r pins corresponding t o that connector. F o r station numbers and their corresponding connectors/jumper pins, see Table 3.4.2.1. Without the corresponding jumper pin o r pins being opened, the Emergency Stop switch on that Starting box does not function. F o r detailed procedures for assigning a task program to each station, refer t o the "Teaching" instruction manual.
Table 3.4.2.1 Station Nos. and Corresponding Connectors Jumper Pin to Open 1 2 3
-
Location of Connector/ Jumper Pin
Preset Jumper Pin Setting Open Normally, t o connect Operation panel. Remarks
CN31 CN32 CN33 CN34
JP302 JP303 JP304 JP301/
Interlock board Close JP301: InterClose lock board JPl/JPZ/JP3/ CN34/CN35/ CN36: Relay board (option) Close Close
If Relay board is not included, close JP301.
J P1 JP301/
CN35 JP2 JP301/
CN36 JP3
-9

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
STOP
START STOP
* T ~
EMERGENCY STOP
Fig.3.4.3.2 Internal Circuit of Starting Box
-1 0
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. The following 3 types of robot dedicated welding power supplies a r e available a s shown in TABLE 3.5.0.1 TABLE 3.5.0.1 Specifications of Robot Dedicated Welding Power Supply Name Type Rated Input Input Voltage Allowable R a n ~ e Rated Frequency Welding Method Rated Output Current Rated Load Voltage Output Current Range Output Voltage Range Rated Service Rate Dimensions (W x D x H) Weight (kg) 350A 36V 50/60Hz COJMAG Welding 500A 45V 350A 36V Almega Auto II 350 CPVAS-350 Almega Auto 1 500 1 CPVAS-500 Almega Fuzzy Auto CPDA-350
18kVA
29kVA
17kVA
I 1
40-350A 15-36V 50% 360 X 550 X 650 52
I 1
40-500A 15-45V 100% 440 X 610 X 880 100
I 1
40-350A 14-36V 60% 350 X 510 X 795 61
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 o r 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.
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 a r e shown in each Instruction manual.
-1
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 a r c s t a r t failure, no a r c generation, and wire stick a t the welding end.
Fig.3.6.1.1 Outside View of Welding Interface

3-1 2
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, a n 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 o r 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 eI R a n g e
REF2 S w i t c h i n g REF1 S w i t c h i n g F22l I A I
GAS Va I v e
l a
LED25
LED22
L
SOL
GAS
V~ l v e a
TP9
TPlO T P I Z T P l l
V o l t a s a Connand 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

3-1 3
(I) Operation Status Indicators of Printed Board E5624G

TABLE 3.6.3.1 shows the functions of LEDs on the printed board E5624G t o indicate the operation status of the Welding Interface. TABLE 3.6.3.1 Operation Status Indicators of Printed Board E5624G Operation Status Function LED No. ON while welding Welding Startup Indicator LED 21 *This is lit when a welding startup command (Red) LED 22 .This is lit when wire inching/retract operation is (Red) carried out from the Teaching Box. Wire Feed Indicator LED 23 .This illuminates when a wire feed command signal is being output to the wire feed unit and (Red) the welding power supply. Wire Feed Normal/Reverse Rotation Indicator LED 24 *This illuminates when wire feed motor rotation (Red) is reversed. Wire Stick Check Indicator LED 25 *This illuminates when the Welding Interface is (Red) checking wire stick. Gas Valve Operation Indicator LED 27 .This illumintes when open command of the gas (Red) electromagnetic valve is being output. operation ON while welding and wire inching/retracting
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. ON during a gas check and welding
(2) Setting Switches of Printed Board E5624G

The following switches a r e arranged on the printed board E5624G within the Welding Interface to set the command voltage and polarity to meet welding power supply. Switch SWll (REF1 Switching) TABLE 3.6.3.2 Switches of Printed Board E5624G Remarks Functions This switch switches the voltage range and polarity Instructed Welding Current Switching ( of a current command signal to be transmitted to the welding power supply. In the case of TIG welding power supply, it switches the setting of base current command signal. This switch switches the voltage range and polarity SW12 Instructed Welding of a voltage command signal to be transmitted to Voltage Switching (REF2 the welding power supply. Switching) In the case of TIG welding power supply, it switches the setting of filler wire feed command signal. 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 voltage range and polarity proper to the welding power supply used. F o r 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
TABLE 3.6.3.3 Instructed Voltage Range based on Type of Welding Machine Instructed Welding Current 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 1OV Positive
-
Instructed Welding Voltage Switching Switch SW12 (REF2 Switching) Voltage Range Polarity
Switching Switch SWll (REF1 Switching) Voltage Range Polarity
15V
Negative
15V
Negative
15V
Positive
15V
Positive
15V 15V 1O V
Positive Negative Positive
15V
-
Positive
-
15V
Negative
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.
3-1 5
Current Cke
WCR
[ C u r r e n t Checx r e l a y )
V e l d i n s Powsr F e l l u r e 1
&weldins
Power F e l l u r e
21
iI
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
Fig.3.6.5.1 shows a n 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.
' .
3-1 6
Signal Name Welding Startup (Totch Switch) Wire Inching ON/OFF Instructed Current (REF 1) Instructed Voltage (REF 2) Wire Feed Motor ON/OFF
Signal Rating Dry contact (Relay CR21) OMRON LY2, DC24V MAX: 5A, AC1 lOV, DC24V MIN:O.lA, DC5V Dry contact (Relay CR22) OMRON LY2, DC24V MAX:2.5A, ACllOV, DC24V MIN:O.lA, DC5V 0-15V DC
d
Timing Chart
I I
l l
l l
ON
I ! : , , ,
6
~fl,
I I I
,
I
$
t
I
,
, # ,
1 I
I 1
, 1 , 1
l 1
l 1
MAX: 50mA (Polarity depends on the welding power supply.) 0-15V DC MAX: 50mA (Polarity depends on the welding power supply.) Dry contact (Relay CR23) OMRON LY2, DC24V MAX:5A, ACllOV, DC24V MIN:O.lA, DC5V
Slowdown f
r
I
--
-------,
.
I
,
I
.
I
.
I
,
I
;
!
;!lot
S t a r t Voltage
/ i j j
Hot S t a r t Time
S t i c k Cancel l a r a t i o n
8 ?
.I
GAS Preflow
I
,
,
I I
GAS A f t e r f
Gas Valve ON/OFF
DC 24V output MAX 200mA

I
AS
:
,
: ,: ,:
,
AE
Wire Stick Check
DC 24V output 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 t o the type of welding power supply used and parameter setting.
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.
3-1 8
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
Item Name Type Memorv medium Operating temperature Nonoperating temperature Ambient humidity Floating dust vibration Allowable o~eratinrr Allowable nono~eratinrrvibration Allowable operating shock Allowable nonoperating shock Dimensions Specifications Floppy disk storage E5777 3.5in. 2HD floppy disk 5-35C -20-60C 20-80%(Noncondensing) Not serious 0.5G max. 2G max. 5G max.(lOms max.) 15G max.(lOms max.) 130 X 50 X 2O m 5m
I I I
(Left)
P o r e r S*l tch
Connector
/ O D e r a t I n 6 Lamu
\
Elect Button
Fuss
(0. A ) 5
Power C a b l e
Floupr D l s t i n l e t
(Front I
Fig.3.7.1.1 Outside View of External Storage

3-1 9
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 a n 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
r---
T h e components I n the broten I Ins are oPtlonal attachments
F I O P P Y D ~ s xMemorr
-------
L -
------------I
Fig.3.7.2.1 Configuration of External Storage
lcNg51
Fig.3.7.2.2 Outside View of Connecting Cable
3-2 0
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 t o connector FC2 of FDD interface printed board. (Insert a n 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
I
CAUTION Do not use this plug socket for any purposes other than to connect t o the exter nal storage.
>
I I
Frlnted Oaerl
Ma ~n Processor
Prln!ed
Eo3rd
j Y
(Ac.9 SS. : . j
flxlns b o a r d ESTn:Il
0C 3 5 1 ?
E5777J
Fig.3.7.3.1 Illustration for Connecting External Storage

3-2 1
3.7.4
Notes on Handling External Storage

the external storage.
(1) Before connecting the external storage, be sure to turn off the control unit and (2) F o r 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, o r 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 -2 2
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
be printed.
(1) The contents of Task programs, various Condition files, and user parameters can
(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 Ref .No. Item Printed board Mounting board Cable (1) Cable (2) Attachments Drawing Na Q'ty E5802C E580ZB E5802D E5802E E5802F 1 Remarks Printer interface Mounting board and screws Control unit front face Main Processor board
+--+
0 0 0
@
(1) (1) (1) (1)
Printed board Printed board
c , -
0
L
Rubber packing and Display board
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).
-+
3-2 3
Robot control unit
1
-4,
P
Main Printer
Printer cable
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
-2
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.)
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.
& Cable (1)

E5802D
Printer cable
Printer interface printed board E5802C
/ '
Main Processor board
0
Printed baord board E5802B
@ Cable (2) E5802E

Fig.3.8.3.1 Connecting Printer Interface When External Storage is not used
-2
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 t o FC3 of Main Processor board.
3.8.4 Connecting P r i n t e 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 E5777J
@ Cable (2) E5802E
Fig.3.8.4.1 Connecting Printer Interface When External Storage is in use

3
-2
3.8.5
Notes on Usage
unit.
(1) Before connecting the printer interface unit, be sure to turn off the robot control
(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.
-2
Chapter 4
Connecting Robot Peripheral J i g (External Axis)

Contents
4 .1 Types of Robot Peripheral Jigs 4.2 connecting peripheral jig to ~
..........................................................................................................
~ control u n i t ............................................................... b ~ t
4 .2.1 System Configuration ........................................................................................................................... 4 .2.2 Control Cables for peripheral Jig ............................................................................................ 4.3 Internal Switch Settings a n d Connection Drawings of Robot Control Unit 4 .3.1 GOIS + 1 Axis System 4.3.2 GO1S+2 Axis System + 3 4 .3 .3 ~ 0 1 ~ ~~i~ system 4.3.4 VOlS+ 1 Axis System 4.3.5 V01S+2 Axis System
...........................................................................................................................
..................................... :.....................................................................................
....
...........................................................................................................................
4 .3 .6 VOlS+ 3 Axis System ...........................................................................................................................
4.
Connecting R o b o t P e r i p h e r a l J i g
This chapter provides information of the connections of Jig Control cables and of the settings of various switches in the robot control unit which a r e necessary to connect a robot peripheral jig, such as a positioner o r sliders, o r 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.
-1
Connecting Robot Peripheral J i g
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 Item Positioner RPH-500 head stock 1-axis side positioner 1-axis double support positioner Z-axis double support positioner 2-axis tilt positioner Turntable RP1T-500 RPlT-1000 RSB-1000 RSB-2000 RSR-2900 RSR-3900 Standard slider RPH- 1000 RPlS-1000 RPlD-200 RPlD-500 RPlD-1000 Specification Maximum payload Maximum payload 200kg 500kg
t
Moving Axis No. Axis 1 Axis 2 4
Maximum payload 1000kg Maximum payload 1000kg Maximum payload Maximum payload 200kg 500kg 4
-
8
8
Maximum payload 1000kg Maximum payload Maximum payload Maximum payload Maximum payload 300kg 150kg 300kg 500kg
Maximumpayload lOOOkg Maximum payload Traverse stroke Traverse stroke Traverse stroke Traverse stroke Traverse stroke Traverse stroke 500kg 1.0m 2.0m 2.9m 3.9m 4.9m 5.9m 6.9m 1.9m 2.9m 3.9m 4.9m 5.9m
1 1 1 1 1
7 C C
8
8 8
/ I I 1 1
C C
8
8
-
Maximum payload 1000kg
8
4 4 7
Portable slider
I RSR-6900 / Traverse stroke / RSR-1900P / Traverse stroke

Slider with a connecting wagon RSR-2900P RSR-3900P RSR-4900P RSR-5900P Traverse stroke Traverse stroke Traverse stroke Traverse stroke
/ / 1
7
7
7
/ / 1
7 7
7
Moving axis numbers a r e used to set the Servo Control boards described later in this chapter.
4 -2
4.2
Connecting Peripheral Jig to Robot Control Unit

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 a r e presented in Table 4.2.1.1:
4.2.1
Table 4.2.1.1 Examples of System Configuration Peripheral Jig Q'ty of Control Cables for of axes 1-axis positioner 1 axis 1-axis slider Z-axis positioner 2 axes 1-axis slider 1-axis slider
I
Peripheral Jig
-
1 set
GO1
2 sets 1-axis positioner Z-axis positioner

I
3 axes
I
3 sets
I
1 axis
1-axis positioner 1-axis slider
1 set
-
VO 1
2 axes
Z-axis positioner 1-axis slider
2 sets 1-axis positioner Z-axis positioner 1-axis slider
3 axes
3 sets
4 -3
4.2.2
Control Cables f o r Peripheral J i g

A peripheral jig is connected t o 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 Component Type Item Control Cable 1 Control Cable 2 BIRBX-7005 Control Cable 1 Control Cable 2 BIRBX-7010 Control Cable 1 Control Cable 2 Control Cable 1 BIRBX-7015 Control Cable 2 BIRBX-7103 Control Cable 1 Control Cable 2 BIRBX-7105
-
Cable length p a r t NO. L4029B00 L4029C00 L4030B00 L4030C00 L4031B00 L4031C00 L4032B00 L4032C00 L4034B00 L4034C00 L4035B00 L4035C00 L4036B00 L4036C00 L4037B00 L4037C00 ~ ' t y 1 3m
Remarks
BIRBX-7003
1
1 1 1 1 1 1 1 1
These cables 5m a r e used t o connect one 10m external axis t o robot V01. 15m These cables a r e used t o 5m connect more than one external axis t o robot V01, o r any external axis t o G01.
3m
Control Cable 1 Control Cable 2 Control Cable 1
1
1 1 1 1 1
BIRBX-7110
Control Cable 2 Control Cable 1
BIRBX-7115 Control Cable 2
-4
4.3
Internal Switch Settings and Connection Drawings of Robot Control Unit

In order t o connect a robot peripheral jig such a s a positioner o r slider t o the robot
control unit, it is necessary t o change the settings of the switches and jumper pins on each printed board in the control unit. These settings a r e 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
Servo Control Board 1
Servo Control Board 2 (SCON2)
Servo Control Board 3 (SCON3)
SW5 Moving axis setting switch (Axis 3) SW6 Switch to set the number of control axes SW7/8 Spare switches Jumper pin t o detect voltage drop of power JT1 the servo motor d r i v i n ~ Jumper pin to switch detecting encoder JT2 disconnection ON/OFF JT3 Spare jumper pin SW2 Board identifvina switch 1 SW3 I Moving axis setting switch (Axis 4) / SW4 I Moving axis setting switch (Axis 5) SW5 Moving axis setting switch (Axis 6) SW6 Switch t o set the number of control axes SW7/8 Spare switches Jumper pin t o detect voltage drop of the servo motor driving power Jumper pin t o switch detecting encoder JT2 disconnection ON/OFF JT3 Spare jumper pin SW2 Board identifying switch SW3 Moving axis set tin^ switch (Axis 7) I SW4 I Movinn axis setting switch (Axis 8) SW5 Moving axis setting switch (Axis 9) SW6 Switch t o set the number of control axes SW7/8 Spare switches Jumper pin t o detect voltage drop of JT1 the servo motor driving power T, m Jumper pin t o switch detecting encoder cl l L disconnection ON/OFF JT3 Spare jumper pin
-5
Table 4.3.0.2 List of Switches and Jumper Pins for Backplane Board and Interlock Board Printed Board Ref.No. I Item Backplane PCB 1 board
I I
Switch and Jumper Pin Ref.Na I Item Dip switch t o check the mechanism DSWlOO configuration Jumper pin to set detecting SCON 3 hardware failure ON/OFF Jumper pin t o set detecting charging
JP601 Interlock PCB 2 board
JP602 JP603 JP701
Jumper pin t o set Axis 6 overrun detect s i ~ n a ON/OFF l Jumper pin t o set Axes 7 - 9 overrun detect signal ON/OFF Jumper pin to set External Axis board
Connecting Robot Peripheral Jig
4 -6
4.3.1
GO1S
+ 1-Axis System
Table 4.3.1.1 GOlSf l-Axis System Configuration
(1) Example of System Configuration
1
System Configuration
Axis Configuration
Manipulator GO1
(2) Switch Settings of Servo Control Boards

Table 4.3.1.2 Switch Settings of Servo Control Boards
PCB13 (SCON2)
Axes 4 - 6
* F o r SW5 of SCON2, refer to Table 4.1.0.1 and set the value

number applicable t o the peripheral jig.
of the moving axis
(3) Jumper Pin Settings of Servo Control Boards

Table 4.3.1.3 Jumper Pin Settings of Servo Control Boards Printed Board
-
Axes Controlled Axes 1 - 3 Axes 4 - 6
PCB14 ( S C O N ~ ) PCB13 (SCON2)
1 1
JT1 Close 1-2 Close 1-2
JT2
JT3
Close 8-9. 5-6, 2-3 Close 8-9, 5-6, 2-3
Close 2-3 Close 2-3
(4) Switch/Jumper Pin Settings of Backplane Board

Table 4.3.1.4 Switch/Jumper Pin Settings of Backplane Board Printed Board 1 PCB 1 ON 2 ON 3 ON JPlO Close
4
OFF
(5) Jumper Pin Settings of Interlock Board

Table 4.3.1.5 Jumper Pin Settings of Interlock Board
Board PCB2
4 -7
I I I I
JP501 Close JP601 Open JP602 Close
I
I
I
JP701 JP603 Close 1-8 12-7 3 - 6 14-5 Close Close Close Close
Fig. 4.3.1.1 Connection Drawing of External Cables for GO1+1-Axis (Digital)
4 -8
4.3.2
GO1S 2-Axis System

Table 4.3.2.1 GOlS+2-Axis System Configuration System Configuration
Manipulator GO1 1-axis positioner (1P)

Table 4.3.2.2 Switch Settings of Servo Control Boards Printed Board Axes Controlled SW2 SW3 SW4 SW5 SW6 SW7 SW8
PCB14 (SCON1) PCB13 (SCON2) PCB12 ( S C O N ~ ) /
Axes 1 - 3 Axes 4/5 Axes 8 7 1 '
1 2 3
4 0
4 0
2 0 0
0 1 1
0 0 0
0 0 0
* F o r SW3/SW4 of SCON3, refer t o Table 4.1.0.1 and set the values of the moving axis numbers applicable to the peripheral jig(s).

Table 4.3.2.3 Jumper Pin Settings of Servo Control Boards Printed Board PCB14 (SCONI)/ PCB13 (SCON~)/
-
Axes Controlled Axes 1 - 3 Axes 4 5 1 ' Axes 7/8
1
1
JT1 Close 1-2 Close 1-2 Close 1-2
JT2
JT3
Close 8-9, 5-6, 2-3 Close 8-9, 5-6, 1-2 Close 8-9, 5-6, 1-2
Close 2-3 Close 2-3 Close 2-3
PCB12 ( S C O N ~ ) ~

Table 4.3.2.4 Switch/Jumper Pins Settings of Backplane Board Printed Board
I
DSWlOO 1
JPlO 1
I
PCB~
1 I
2 ON
ON
1 I
ON
OFF
open

Table 4.3.2.5 Jumper Pins Settings of Interlock Board Printed Board PCB2
JP501 Close
JP601
JP602
JP603
JP701 1-8 2-7 3-6 4-5
Close
Open
Close
Open
Close
Close
Close
4 -9
'ewer Supply
Fig. 4.3.2.1 Connection Drawing of External Cables for GO1 +2-Axis (Digital)
4-1 0
4.3.3
GO1S i-3-Axis System

Table 4.3.3.1 GOlS System Configuration GOlS
+ 3-Axis System Configuration

Axis Configuration
+ 1-axis slider (1s) +
(2) Switch Settings of Servo Control Boards Table 4.3.3.2 Switch Settings of Servo Control Boards Printed Board
Axes Controlled Axes 1 - 3
1 SW2 ] SW3 1 SW4 I SW5 1 SW6 1 SW7 1 SW8

1
1
PCB14 (SCONI)~
*For SW3 - SW5 of SCON3, refer t o Table 4.1.0.1 and set the values of the moving axis numbers applicable t o the peripheral jigs.

Table 4.3.3.3 Jumper Pin Settings of Servo Control Boards
PCB13 ( S C O N ~ ) ~ PCB12 ( S C O N ~ ) /
Axes 4 5 1 ' Axes 7 - 9
Close 1-2
Close 8-9, 5-6, 1-2
Close 2-3
Close 1-2
Close 8-9, 5-6, 2-3
Close 2-3

Table 4.3.3.4 Switcli/Jumper Pins Settings of Backplane Board Printed Board DSWlOO 1 1 2 1 3 1 4 JPlO
PCBI
ON
ON
ON
OFF
Open

Table 4.3.3.5 Jumper Pins Settings of Interlock Board Printed JP501 Board PCB2 Close Close Open Close JP601 JP602 JP603 1-8 Open JP701 2-7 Close 3-6 Close 4-5 Close
-1
Fig. 4.3.3.1 Connection Drawing of External Cables for GO1
+ 3-Axis (Digital)
4-1 2

Table 4.3.4.1 VOlS+ l-Axis System Configuration Axis Configuration System Configuration

Table 4.3.4.2 Switch Settings for Servo Control Boards
* F o r SW3 of SCON3, refer t o Table 4.1.0.1 and set the value of the moving axis number applicable t o the peripheral jig.

(4) Switch/Jumper Pin Settings for Backplane Board

Table 4.3.4.4 Switch/Jumper Pins Settings of Backplane Board Printed Board DSWlOO 1 1 2 1 3 1 4 JPlO
PCBI
OFF
ON
ON
OFF
Open

Table 4.3.4.5 Jumper Pin Settings of Interlock Board
4 - I3
Fig. 4.3.4.1 Connection Drawing of External Cables for VO1+1-Axis (Digital)
4-1 4
4.3.5 VOl S 4-2-Axis System

Table 4.3.5.1 VOlS+2-Axis System Configuration Axis Configuration System 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 t o your peripheral jig(s).

(4) Switch/Jumper Pin Settings for Backplane Board

Table 4.3.5.4 Switch/Jumper Pin Settings of Backplane Board Printed Board
JPlO

Table 4.3.5.5 Jumper Pin Settings of Interlock Board printed Board PCB2
1 I 1 I
JP501 Close JP601 Close JP602 Open
I I
I I
JP603
I
JP701 1-8 Open
2-7 3 - 6 4 - 5 Close Close Close
Close
-1
Fig. 4.3.5.1 Connection Drawing of External Cables for V01
+ 2-Axis (Digital)
Connecting R o b o t Peripheral J i g
-1
4.3.6
VO1S +3-Axis System

Table 4.3.6.1 VOlS+3-Axis System Configuration Axis Configuration System Configuration VOlS SCON 1 SCON 2 SCON 3 Ax-1 Ax-2 Ax-3 Ax-4 Ax-5 Ax-6 Ax-7 Ax-8 Ax-9
+ 1-axis slider (1s) +
Manipulator V01
1s
2P
2-Axis positioner (2P)

* 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.

--
Printed Board PCB14 (SCON1)

-
Axes Controlled Axes 1 - 3 Axes 4

-
JT1 Close 1-2
JT2 Close 8-9, 5-6, 2-3
JT3 Close 2-3
PCB13 (SCONX)/
Close 1-2 Close 1-2
Close 8-9, 5-6, 2-3 Close 8-9, 5-6, 2-3
Close 2-3 Close 2-3
PCB12 ( S C O N ~ ) ~
Axis 7 - 9

Table 4.3.6.4 Switch/Jumper Pin Settings of Backplane Board Printed Board 1 1 DSWlOO 2 1 3 1 4 JPlO
Printed Board .-
PCB2
1I I II I1
I I
Table 4.3.6.5 Jumper Pin Settings of Interlock Board JP701 JP501 JP601 JP602 JP603
I I
Close
Close
Open
Close
r n
I
O ~ e n Close
4-5
Close
Close
-1 7
Connecting R o b o t Peripheral Jig
CN,O,C
TO external asis A S - 9
To external arls AS-8
CNlOlB
CNlolA
To externel axis AX-7 cai To iManipiilator
gig To external axis AX-9

TO external axis AX-8
gig;
MZ
To external axis AX-7
TO Menipulator
m 3
To Manipulator
Fig. 4.3.6.1 Connection Drawing of External Cables for V01+3-Axis (Digital)
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 o r unexpected motion but also damage the jig(s). 2. In principle, the moving axis numbers of peripheral jigs a r e defined in accordance with priority below:
Lower
Slider
2-axis positioner Axis Nos.
Higher
+ r
tilt axis
2-axis positioner table axis
I-axis positioner
- I9
5.
Troubleshooting
This chapter describes solutions f o r 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 r e 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 t o them t o find a solution. If you need replace p a r t s such as boards, contact DAIHEN.
Table 5.1. Symptoms Symptoms Solution
Nothing appears on the teaching F o r details, see section 5.1.1. box.

-
1
F o r details, see section 5.1.2.
The display on the teaching box is unsteady.
1
F o r details, see section 5.1.4
Initial diagnosis is not completed. F o r details, see section 5.1.3 The servo power supply cannot be turned on. The servo power supply is shut off immediately when turned on. Manual manipulation does not function. F o r details, see section 5.1.6. F o r details, see section 5.1.5.
Troubleshooting
-1
Table 5.2. Failure Codes and Messages Code / Message EA00101-XXXX EMERGENCSTOP --.RELEASE SHOCK-S ERR -+RESET EA0040 1-XXXX SERVO DOWN +RESET Cause The Emergency Stop button o r emergency stop signal was entered. During automatic operation the torch interfered 1) The servo power was shut off due t o a n unidentified cause. 2) The hand was released from the deadman switch. Communication trouble between Welding Interface and I/O management board during welding. The specified Arc S t a r t Condition file does not exist. Solution Pull the Emergency Stop button ( o r cancel the emergency stop signal) and press SERVO ON button. F o r details, see section 5.2.3.
F o r details, see section 5.2.4
NO ASC FILE --. RESET EA50101-XXXX NO AEC FILE > RESET EA50102-XXXX NO WFP FILE RESET EA50102-XXXX NO WAX FILE RESET EA50103-XXXX NO ASM FILE RESET EA50103-XXXX NO AEM FILE RESET EA50104-XXXX NO OFS FILE RESET EA50105-XXXX NO CL PRG. RESET EA50106-XXXX NO J F PRG. --. RESET
+
+
+
+
1
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 S t a r t Condition file.
EA10201-XXXX WIF TIMEOUT --. RESET
Create a n Arc End Condition file. The specified Arc End Condition file does not exist. Create a Fixed Patterned Weaving The specified Fixed Patterned Weaving Condition file. Condition file does not exist. The specified Axis Weaving Create a n Axis Weaving Condition file. Condition file does exist.
The specified Multi-pass Welding S t a r t file does not exist. The specified Multi-pass Welding End file does not exist. The specified Offset Condition file does not exist
Create a Multi-pass Welding S t a r t file.
Create a Multi-pass Welding End file.
Create a n Offset Condition file.
There is no Task program t o call. There is no Task program
I
I
Create a Task program to call.
/ to jump to.
Create a Task program t o jump to.
-2
Troubleshooting
Code / Message EA50107-XXXX NO PM -+ RESET EA50110-XXXX C1 TEACH ERR - RESET . EA50111-XXXX C2 TEACH ERR RESET EA50112-XXXX COORD.ERROR RESET
+ +
Cause There is no point mark to jump to. 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. Teaching of the target/ reference points for an circular a r c in the different coordinate systems. The target and reference points for a circular arc a r e the same. The number of time counts exceeded 9.
Solution Add a Point Mark instruction.

--
A circular a r c 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 arc.
EA50113-XXXX SAME POINT C RESET EA50114-XXXX 1' TIMER 1 0 RESET

+
EA50120-XXXX CALL NESTING OVER -+RESET EA50201-XXXX S.LIMIT * * * * RESET EA50202-XXXX LNKS.LIMITM * RESET EA50301-XXXX NO PROGRAM RESET EA50302-XXXX NO PROGRAM - RESET . EA50303-XXXX NO PROGRAM I RESET EA50401-XXXX ON TIME OUT RESET EA50402-XXXX OFF TIME OUT RESET
+ +
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. The nest has overflown due Calling in the call destination program is possible but limited to the maximum 4 to program calls. layers. Check the the DroEram. For details, see section 5.2.5. The robot has reached the software limit. The robot has reached the link software limit. The Task program assigned Check the s t a r t allocation and assign to the station does not exist. the correct Task program number. The Task program with the number entered does not exist. Task program No. has not been entered into the port s~ecified. No ON input within the specified monitoring time. No OFF input within the specified monitoring time. Enter the correct Task program number.
Enter a Task program number
Check the input status of the external control signals and the teaching data.
+ -
Troubleshooting
5 -3
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
+ + +
Cause The software for Synchromotion h a s not been installed. The software for Multipass Welding h a s not been installed. The software for External Axis Shift h a s not been installed. The software for welding monitor h a s not been installed. The software for PM8700 h a s not been installed.
-
Solution If you want t o use the optional function, purchase its optional software. Press the RESET key t o continue the operation.
The software for Endress Rotation h a s not been installed. The software for Super Arc Sensor has not been installed. F o r details, see section 5.2.6. The manipulator overran.
1) A positioning instruction 1) Modify the relevant instruction P t o a synchromotion instruction HP, o r t r y P is taught base on teaching based on the Base o r World Work o r Tool coordinate coordinate system again. system in the synchromotion system. 2) The panipulator is unable 2) Correct the taught positions(start/end points). If the manipulator is unable to move a t a position on t o move, correct the position d a t a of the path taught with a the relevant instruction in search Linear o r Circular mode o r by using the PC editing interpolation instruction. system. The Task program contains Delete the damaged instruction and add a n instruction. If the failure recurs, a damaged instruction. delete the Task program. F o r details, see section 5.2.7. Communication between boards cannot be made correctly.
EB10710-00XX DATA ERROR RESET EC10206-XXXX COMUCTN ERR +POWER O F F

+
5 -4
Troubleshooting
Code / Message EC10208-XXXX COM. ERR +POWER O F F EC10209-XXXX DPRAM ERROR - POWER O F F . EC10210-XXXX COM LSI ERR + POWER O F F EC10403-XXXX CALC.ERR - POWER O F F . EC10504-XXXX DC24V ERROR + POWER O F F ECl0505-XXXX DC15V ERROR +POWER O F F EC10601-XXXX NO FILE +POWER O F F EC10603-XXXX PCB MISMATCH POWER O F F EC10605-XXXX NO SYS FILE POWER O F F EC10801-XXXX ROM ERROR - POWER O F F , EC10802-XXXX RAM ERROR - POWER O F F . EC1 1301-XXXX I/O PORT ERR -+ POWER O F F EC11401-XXXX TB LCD ERROR + POWER O F F
+
Cause I/O management board o r teaching box failure. Main board o r I/O management board failure. Motion control board failure. Motion control board failure.
Solution F o r details, see section 5.2.7.
Replace the Motion control board.
DC24V power supply failure. Replace the DC24V power supply.
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 F o r details, see section 5.2.8. performed correctly. SCON/PCON Board is not in place.Or, imperfect contact. Multi-synchromotion control d a t a is not found o r is insufficient. Misplacement of EPROM, o r imperfect contact. The identified board o r RAM on that board is broken. I/O management board failure. Teaching box LCD failure. Check the SCON/PCON board connection. Install the system parameters again. If not recoverd, contact DAIHEN F o r details, see section 5.2.9.
-.
Replace the mother board.
Replace the teaching box.
Troubleshooting
5 -5
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
+
+
Code / Message EC20101-XXXX MOTOR ERROR POWER O F F
EC20102-XXXX AXIS SET ERR --. POWER O F F
After initial diagnosis is completed, perform manual manipulation while holding down the SERVO ON button t o escape from overrun. Turn off the control power supply and The temperature in the leave the robot a s it is until the controller exceeded 60C temperature decrease below 60C 1) A positioning instruction 1) Modify the relevant instruction P t o a synchromotion instruction HP, o r t r y P is taught base on Work o r Tool coordinate teaching based on the Base o r World system in the coordinate system again. synchromotion system. 2) The panipulator is unable 2) Correct the taught positions(start/ end points). If the manipulator is t o move a t a position on unable t o move, correct the position the path taught with a d a t a of the relevant instruction in Linear o r Circular search mode o r by using the PC interpolat ion instruction. editing system. The voltage of the memory Save all the d a t a by using the external battery dropped below 2.5V. storage. 1) The voltage of the charging battery dropped. 1) Charge the battery, o r replace the charging battery. Be sure t o perform the absolute 2) Imperfect connection of offset adjustment. 2) Check the CN47 connection. Connector(CN47). Data installation cannot be F o r details, see section 5.2.8. performed correctly.
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.
Solution F o r details, see section 5.2.10
F o r details, see section 5.2.3.
-6
Troubleshooting
+
+
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
Cause The Task program contains a damaged instruction. Position deviation h a s occurred.
Solution Delete the damaged instruction and add a n instruction. If the failure recurs, delete the Task program. F o r details, section 5.2.11.
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
Reset the encoders and perform the The absolute offset d a t a absolute offset adjustment. have been destroyed o r absolute encoders have not been reset. See the Arc Sensor instruction manual. 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 r a t e 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 ~ e c i f i e d limit.
Troubleshooting 5
-7
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
+
+
Solution Cause See the Arc Sensor instruction manual 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 r e the same. Teaching of AS o r AE in the touch section. Communication with the a r c 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. Press the START button t o r e s t a r t
A 40102-XXXX WIRE STICK RESTART A 40103-XXXX OUT O F ARC --.. RESTART A 40201-XXXX WPS NOT RDY --.. RESTART
Cut the deposited wire. After that, press the START button t o r e s t a r t welding Press the START button.
The a r c is out.
A 40201-XXXX WPS NOT RDY - RESET .
The robot dedicated welding 1) Check the connection between the controller and the robot dedicated power unit o r welding power unit o r welding interface. interface h a s not been 2) Turn the robot dedicated power unit connected. ON. Turn the CONTROL POWER off and on Communication trouble again. between the robot and welding interface o r the robot dedicated welding power unit.
5 -8
Troubleshooting
Code / Message A 40202-XXXX WPS ABNORMAL RESTART A 40301-XXXX OUT O F WIRE -t RESTART A 40302-XXXX LACK O F GAS RESTART A 40303-XXXX LACK O F WATK RESTART A 50101-XXXX NO ASC FILE RESET A 50101-XXXX NO AEC FILE - RESET . A 50102-XXXX NO WFP FILE RESET
+
Cause Problem of ALMEGA AUTO I1 o r ALMEGA FUZZY AUTO. During automatic operation the wire was broken.
Solution Remove the cause of the problem of ALMEGA AUTO II o r ALMEGA FUZZY AUTO. Remove the cause. After that, press the START button.
I
The g a s pressure is too low. Remove the cause. After that, press the Displayed only if a detector START button. is provided. Remove the cause. After t h a t , press the There is no cooling water. START button. The specified Arc S t a r t Create a n Arc S t a r t Condition file. Condition file does not exist. The specified Arc End Create a n Arc End Condition file. Condition file does not exist. Create a Fixed Patterned Weaving The specified Fixed Condition file. Patterned Weaving Condition file does not exist. The specified Axis Weaving Create a n Axis Weaving Condition file. Condition file does exist. Create a Multi-pass Welding S t a r t file. The specified Multi-pass Welding S t a r t file does not exist. Create a Multi-pass Welding End file. The specified Multi-pass Welding End file does not exist. The specified Offset Create a n Offset Condition file. Condition file does not exist. There is no Task program to call. There is no Task program to to jump to. There is no point mark to jump to. Create a Task program t o call.
A 50102-XXXX
NO WAX FILE RESET A 50103-XXXX NO ASM FILE > RESET A 50103-XXXX NO AEM FILE RESET A 50104-XXXX NO OFS FILE RESET A 50105-XXXX NO CL PRG. - RESET . A 50106-XXXX NO J F PRG. - RESET . A 50107-XXXX NO P M RESET
+
Create a Task program t o jump to.
Add a Point Mark instruction.
Troubleshooting
5-9
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 >
Cause There is no reference point for the former half of a circular arc. There is no reference point f o 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.
Solution A circular a r c 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 t o form a circular arc. Teach again to form a circular a r c can be made. The max. number of timers t h a t 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 t o the maximum 4 layers. Check the program. F o r details, see section 5.2.5.
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 O F F TIME OUT - RESET , A 50501-XXXX SERVO O F F +SERVO ON
+
The nest h a s overflown due t o program calls.
The robot h a s reached the software limit. The robot has reached the link software limit. No ON input within the specified monitoring time. No O F F input within the specified monitoring time
Check the input s t a t u s of the external control signals and the teaching d a t a .
A 50502-XXXX OUT O F START ENABLE AREA
Turn the servo power supply ON. Servo ON when the mode was changed t o AUTO. Or, the servo power supply was turned on before automatic operation o r after c o m ~ l e t i o n the iob. of Perform manual operation t o move the Outside the S t a r t Enable manipulator t o within the S t a r t Enable Area Area.
-1 0
Troubleshooting
+
+
+
Code / Message
A 50601-XXXX ABSO ERROR RESET A 50701-XXXX OPTION ERROR RESET A 50702-XXXX OPTION ERROR RESET A 50704-XXXX OPTION ERROR RESET A 50705-XXXX OPTION ERROR 4 RESET A 50706-XXXX OPTION ERROR RESET A 50708-XXXX OPTION ERROR RESET A 50709-XXXX OPTION ERROR RESET I 00201-XXXX SHOCK SENSOR +RELEASE
+
Solution Cause After completion of initial diagnosis, After initialization of the memory, ABSO setting has perform the absolute offset adjustment. not been performed. If you want to use the optional function, The software for purchase its optional software. Press the RESET key to continue the installed. 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 PM8700 software has not been installed The software for Endress Rotation has not been installed. The software for Super Arc Sensor has not been installed. This occurs during escape from Shock Sensor Error o r 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, trouble occurred in the CRT communication circuit due to some cause. In synchronous Cartesian manual manipulation, the sub mechanism is unable to synchronize with the main the meclianism.
1
For details, see section 5.2.3.
I 10208-XXXX COM. ERROR RESET
Press the reset key on CRT to switch the display to the teaching box.
COM. ERROR RESTART I 11202-XXXX LIMIT SPD. RESET

+
Automatic operation will continue.
1
Increase the speed of manual manipulation.
Troubleshooting
-1
Code / Message I 11401-XXXX CRT ABNMAL * RESTART I 30100-XXXX L. S. TRNS. ERR > RESET I 30203-XXXX ARC UNSTABLE RESEST
Cause Trouble occured in the CRT printed board. Communictation with laser sensor cannot be made.
Solution Trun off and on the CONTROL POWER.
Connect the laser sensor
-+
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
During seam tracking by F o r details, see the Arc Sensor instruction manual. 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 a r c sensor cannot be made.
-1
Troubleshooting
CRT DISCNNCT RESET I 30302-XXXX CRT INVALID RESET I 40201-XXXX WPS NOT RDY -+ RESET
+
I 40301-XXXX OUT O F WIRE RESET
can not be made. The user parameter setting of CRT ON/OFF will be changed t o OFF. 1) The robot dedicated welding power unit o r welding interface is not connected. 2) The robot dedicated power unit is OFF. The residual wire is not enough. Displayed if a detector is provided.
Solution To use CRT, turn on CRT first, and then the controller. Push RESET key
1) Check the connection between the controller and the welding interface.
2) Turn the robot dedicated power unit ON. Supply the wire.
Troubleshooting
5-1 3
Table 5.3 Failure Messages Failure Message Solution Cause F o r details, see section 5.3.2. Failure was detected a t Servo Control board (SCON board). 1 Servo Control board malfunctioned. The servo power supply was shut off due t o a n unexrsected cause. I The temperature in the con troller h a s extraordinarily increased. Trouble occurred in the 1 Servo driver unit. Trouble occurred in the Servo Control board. The servo driver unit is unable to be set in the servo ON state. I The position deviation exceeded the set value. I The commanded speed exceeded the set value. Servo Control board 1 malfunctioned. Trouble occurred when the servo power supply was turned on. Turn off the control power supply Control program failure. and then on again. If this failure recurs, note down the information displayed on the teaching box and contact DAIHEN. Note down the information Control program failure. displayed on the teaching box and contact DAIHEN.
1
I
1 1
I
I
I
COM DATA ERR XX-YY XX: 03 o r 85 YY: 01 - 05 SVC error
1 1
5-14
Troubleshooting
5. 1
5.1.1
Symptoms
NothingAppearsontheTeaching Box
1 Symptom 1
Nothing appears on the teaching box and all LEDs on the keyboard a r e OFF. Primary power supply indicator lamp OFF. (ON in the normal state)
_I No primary power
L - Check the voltage of
each phase of the primary power supply and connect correctly.
U Cooling fan not U I rotating
I
/
-
1 LEDs of
constant voltage power unit(5V, 1- 15V) is flickering palely. LEDs of constant voltage power unit(5V, f15V 24V) a r e OFF. All LEDs on Interlock board a r e OFF. (In normal state, LEDs 301, 302, 304, 601, 602 and 603 a r e ON.)
Loss of V phase (wire 5) of primary power
11
11
I 1
- (wire
I supply
Loss of W phase 6) of primary power
1
Check the flat cable connection and connect it properly.
Imperfect contact of Interlock board CN41 - constant voltage power unit
H 1 / 1
Interlock board failure.
Replace the Interlock board.
Troubleshooting
-1
I Possible Cause I
Imperfect contact of backplane board FCll Interlock board FCll
Action
Check the flat cable connection and connect it properly. Replace the cable. Check 24V of Interlock board.
1
5. "1 2
24V is not supply to teaching box.
The Display on the Teaching Box Is Unsteady
I
The display of the teaching box is unsteady and flickers.
-
Action
Red LED on Servo Control board ON
1 primary power
supply (below
1 / AC / supply.
Check the voltage on the primary power
LEDs(red) on servo driver flickering
-1
Troubleshooting
5. 1.3
Initial Diagnosis Is Not Completed
1 Symptom 1
The display "START DIAGNOSIS" stays on the teaching box.
Check Item
I Possible Cause I
Action
"COMUCTN ERR" ( Communication error) is displayed a t the right top of the teaching box screen.
4 Refer to 5.2.7 in this part.
i
1
/ I
Nothing is displayed a t the right top of the teaching box I screen. I
1
1
1/0 management board failure
UCheck that I/O 1 management board is 1

I connected correctly.
Replace the I/O management board.
1
I
The teaching - "NO FILE" is displayed a t the box display right top of the stops a t step1 teaching box of initial diagnosis. I I screen.
Refer to 5.2.8 in this part.
II
Nothing is displayed a t the right top of the teaching box screen.
1/0 management board failure
Check that 1/0 management board is connected correctly.
I management board.
1 Replace the I/O

I
Troubleshooting
-1
1 Symptom 1
The teaching box display stops a t step2 of initial
Action
"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.
--A
Motion control
Check that Motion control board is
/ Replace the Motion 1 control board.

"NO FILE" is displayed a t the right top of the teaching box screen.
"WPS NOT RDY" is displayed a t the right top of the teaching box screen.
1 1
-
Welding interface o r robot dedicated welding power unit not connected.
Check that the welding interface o r robot dedicated welding power unit is connected correctly.
I
] displayed a t the
I screen.
I
Robot dedicated welding power unit OFF 1/0 management board failure
1 Nothing is
1 right top of the / 1 teaching box I
/ /
1
UCheck that 1/0
I management board
/ Replace the I/O
Turn on the robot dedicated welding power unit.
I is connected correctly.
management board.
5 - 1 8 Troubleshooting
I
Check Item
I Possible Cause I
"NO FILE" is displayed a t the right top of tlie teaching box screen. "A.S.TRNS.ERRfl is displayed a t the right top of the teaching box screen.
Arc sensor unit not connected.
Check that the Arc sensor is connected
Arc sensor unit OFF Arc sensor unit failure
Turn on the Arc sensor unit. Check that Arc sensor is connected correctly. Replace the Arc sensor unit.
Nothing is displayed a t the right top of the teaching box screen.
7 I
Troubleshooting
5-2 9
5.1.4
The Servo Power Supply Cannot Be Turned ON
I
The servo power cannot be turned on. Electromagnetic contactor MS1 not ON Electromagnetic contactor MS1 failure
- Replace
Action
1 the electromagnetic contactor MS1.

p
Interlock board LEDs 203/301/ 303 OFF (ON in the normal condition)
I
primary power supply(3-phase 200 V) (Below AC150V)
Check the voltage on the primary power
Red LED on each Servo Control board 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)
1
I
Motion control board OFF (ON in the norm-a1 condition) LED 303 on Interlock board ON (OFF in the normal condition)
I
I
I board failure
5 -2 0
Troubleshooting
5.1.5
The Servo Power Is Shut O F F Immediately When Turned O N
I Symptom I
The servo power is shut off while "SERVO ON" stays 011 the teaching box screen.
Check Item
I Possible Cause I
Motion control
LEDs 101/301/ 303(green) on Interlock board OFF (ON in the normal condition)
I
1
1
Check that each board is in place. Replace faulty board.
1
1
Servo Control board failure
4
I
I
LEDs 101/301/ 303/ 203 ( green ) on Interlock board OFF (ON in the normal)
Main board failure
HI/O management
I board failure
I
I
Troubleshooting
5-2 1
5. 1 . 6
Manual Manipulation Does Not Function
1
/
Only one axis of axes 1 - 6 can moves by manual manipulation.
1
I
Bad connection of motor line
- Check
the connections of servo driver connectors CN51-56.
H Disconnection of
/ motor line
Motor failure
Replace the cable.
Replace the motor.
/ /
Only axes 4/5/ 6 move by manual manipulation.
Able to move axes 1/2/3 by manual manipulation
No power supply to axes 4/5/6 servo drivers
{ Check
the connections of servo driver connectors CN4, CN6, and CN8.
] R e d a c e the cable.
I
1
None of axes 1-6 moves by manual manipulation.
1 I
1
CR3A/CR3B contacts on Interlock board OFF (ON in the normal condition)
Bad connection of motor line
I-
Check the connection of control cable 1. (Manipulator-side CN1) the control cable 1.(Manipulator -side CN1)
Disconnection of motor line
- Replace
Machine lock function set ON
Set the machine lock function OFF.
5-2 2
Troubleshooting
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 a r e displayed on the teaching box.
(Example) Emergency Stop

+
Failure code
EMERGENCSTOP +RELEASE
* Failure message
A failure code is displayed in the following format:
a : Indicates the severity of a failure (Error, Alarm, o r 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 a r e taken soon, o r which require a simple operation, check, o r 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, o r which can develop to Alarms later.
Troubleshooting
5-2 3
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 o r 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) o r detailed information of the failure.
For mode codes, see Table 5.5.
-2 4
Troubleshooting
Table 5.4. Unit Codes Code Unit Main board Motion control board 1/0 management board Teaching box Welding interface o r ALMEGA AUTO II o r 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 PCON/SCON board 1 PCON/SCON board 1 PCON/SCON board 2 PCON/SCON board 2 PCON/SCON board 2 PCON/SCON board 3 PCON/SCON board 3 PCON/SCON board 3 PCON/SCON board 4 PCON/SCON board 4 PCON/SCON board 4 PCON/SCON board 5 PCON/SCON board 5 PCON/SCON board 5 PCON/SCON board 6 PCON/SCON board 6 PCON/SCON board 6 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 80 8 1 82 83 84 85 86 9 0 9 1 9 2 9 3 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
00 01 02 03 04
0 5 06 0 7
08 09 11 1 2 13 14 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 34 3 5 3 6 3 7 3 8
Axis 1 Axis 2 Axis 3 Axis 4 Axis 5 Axis 6 Axis 7 Axis 8 Axis 9 Axis 10 Axis 11 Axis 12 Axis 13 Axis 14 Axis 15 Axis 16 Axis 17 Axis 18
Note) PCON: Position control board
SCON: Servo control board
Table 5.5. Mode Codes Code
Mode Teach
Function Diagnosis Teaching
1 0 2 0
Auto Remote control
Troubleshooting
5-2 5
5.2.2
Logical Outputs f o r Failures

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 Urgent Failure Control Failure Servo Failure Peripheral Equipment Failure Welding Failure Operational Failure Error Alarm
--
I Logical Output P o r t No I 0 2 0 1 1 0 2 0 2
0 2 0 3 0 2 0 4 0 2 0 5 0 2 0 6 0 2 1 1
0 2 1 2 0 2 1 3 0 2 0 8 0 2 0 9 0 2 7 0 0370-0374
Information ABSO Adjust Request Reset Request S t a r t Request Failure Code
F o r details of these output ports, see the instruction manual "Interface With Jig".
5.2.3
Shock Sensor
Shock Sensor is a failure which occurs when the torch hits a peripheral jig.
Shock Sensor E r r o r (during automatic operation) EA00210-XXXX SHOCK-S ERR

+
RESET
1/
Shock Sensor Alarm (in Auto mode but not during automatic operation)
SHOCKS ALARM
>
1
I
E r r o r o r Alarm)
RESET
Shock Sensor Information (in Teach mode o r during a n escape from Shock Sensor
SHOCK SENSOR +RELEASE
Solution
If the torch is equipped with a shook sensor Perform manual manipulation in the direction which allows Shock Sensor t o 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.
Troubleshooting
5 -2 7
5.2.4
Servo Power Shutoff

A failure occurred and was momentarily removed.
*
This failure occurs when:
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 t a t u s
Table 5.7 Differences of Output Form according to Special Failure Output ON/OFF Setting ON Display of Failure Cancellation Automatically erased after being Output Signal
/ SERVO DOWN
1
EA00401-01XX SERVO DOWN
+
EA00401-01XX
1 output for 2 seconds. / being output for 2 sec.)

By the RESET key o r Urgent failure (0201) Reset input. E r r o r (0221) Reset Request (0209) Failure Code (0374
-
Failure Code(0374-370) (Automatically reset after
OFF (Default)
RESET
370)
Solution
(A) When the setting is O F F

After being displayed on the teaching box for 2 seconds, the failure is automatically erased. Then, turn on the servo power supply.
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 c a r r y on the operation you a r e doing, o r can restart the automatic operation.
If this failure recurs during automatic operation, the shock sensor may be working. In this case, correct the path o r attitude t o avoid interference with the jig.
-2
Troubleshooting
The "ABNOMLTY ENCODE" ON setting affects the signals being output when the following failures occur:
Emergency Stop
1 EMERGENCSTOP 1
Servo O F F
If the setting is ON, Urgent Failure (0201) and E r r o r (0211) a r e not output.
If the setting is ON, Operational Failure (0205)
/ SERVO O F F
and Alarm (0212) a r e not output.
5.2.5
Software Limit/Link Software L i m i t

This failure is detected when the mechanism attempts to move out of the working
(1) Software Limit Failure

area.
Teach mode
Auto mode EA50201-0110 S.LIMIT XYZZ
p G i z x q
1 S.LIMIT XYZZ I 1 +MANUAL OPE. 1
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
Unit's place
Axis Axis Axis Axis Axis Axis
Troubleshooting
-2
(Example] When Software Limit occurs a t Axes 4 and 5 Tens' place
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 t o 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 t o be cancelled.
(2) Link Software Limit
This failure occurs when the mechanisms could interfere with each other.
1-
Teach mode
Auto mode
+MANUAL OPE.
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.
( ) Interlock board failure. D

+Replace the Interlock board.
Troubleshooting
5 -3 1
5.2.7
Communication Failures
This failure occurs when communication cannot be performed correctly between boards. EC10206-YYXX COMUCTN ERR
+
(1) Board To Board Communication Failure
POWER O F F
: 0 1
YY
... Main Board - Motion Control Board Communication

Main Board
-
Failure
0 2
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 o r EPROM on the Motion control board is placed correctly.
(B) YY:02
Make s u r e 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 o r Teaching box failure. EC10208-YYXX COM. ERR
+
POWER O F F Main Board - 1/0 Management Board.
YY : 0 2
0 3
5-3 2
Troubleshooting
.-.Main Board - Teaching Box
Solution
(A)
YY:O2 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 Main board

-
YY : 0 0 0 2
Motion control board.

-
..- Motion control board
1/0 management board.
Solution
(A)
YY:OO Replace the Main Board.
03) Y Y : 0 2
Replace the 1 / 0 management board.
Troubleshooting
5-3 3
5.2.8
Data Installation Failures
This failure is detected when d a t a (files) necessary t o operate the robot do not exist. If this failure is detected, it is necessary t o create a required file with the System Initialize function.
(1) Data Installation E r r o r
piKiEF
NO FILE
1 + - P O W E R OFF 1
YYY Y
: 0 1 0 0
1
-.. Can't find System Parameter file.
... Can't find Manual Operating Speed Table file.
.-. Can't find Block Operating
Can't find Sequencer file. Speed Table file.
0 10 1 0 10 2 0 2 0 0
Solution
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.
(l YYYY: 0200 D
Select the "SQ" function key with the System Initialize function and create a Sequencer file.
5-3 4
Troubleshooting
(2) Data Installation Alarm A 10601-YYYY NO FILE +POWER O F F
YYYY : 0 2 0 1
.-. Can't find Welding Characteristic Data file.

Can't find Welding Control file.
0202
0203
..- Can't find Current Conversion
Table.
8100
84 0 0
... Can't find Arc Sensor file.

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:8 0 10
Select the "ARC-S" function key with the System Initialize function and create a Arc Sensor file.
(C) YYYY:8 0 40
Select the "LASER-S" function key with the System Initialize function and create a Laser Sensor file.
Troubleshooting
5 -3 5
5.2.9
Memory Fai lures

This failure is detected when the EPROM o r board is broken o r the wrong EPROM
(1) R O M Failure
is inserted. EC10801-YY00 ROM ERROR +POWER OFF YY : 0 0 0 1 0 2 0 3
... Main board

Motion control board
-.. I/O management board ... 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 Main board
YY : 0 0
0 1 0 2 0 3
..- Motion control board

4..
1/0 management board

Teaching box
...
Solution
Replace the identified board.
5-3 6
Troubleshooting
5. 2.10 Setting Errors

(1) M o t o r 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
Manipulator
SCON for Base Axes
SCON for Wrist Axes
Axis 1 Axis 2 Axis 3 Axis 4 Axis 5 Axis 6 SW3 SW4 SW5 SW3 SW4 SW5
V40
SCON not in use for V40
Table 5.9 Rotary Switch Settings for Slider Motor Slider PSB series RSR series Relevant switch setting of SCON SW3 to SW5
1
I
7
Troubleshooting
-3 7
Table 5.10 Rotary Switch Settings for Positioner
1
/
Axis 1 Relevant switch setting of SW3 -SW5
/
/
Axis 2 Relevant switch setting of SW3 -SW5
(2) Axis Setting Failure
This failure occurs when the SCON board rotary switch setting for the number of controlled axes is wrong. 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
5-3 8
Troubleshooting
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 O F 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.
Troubleshooting
-3
5. 3
When Servo Failure Occurred

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.
5.3. 1
Message (not displayed in some cases) Failure information codes
+Failure category No. +-Message
I Failure information
codes
t
Column :
t
b e
t
d
Fig.5.1 Example of Servo Failure Display
5-4 0
Troubleshooting
(1) Failure Category No.

When Servo Failure occurred, the Teach Pendant displays the following:
"SERVO ABN
* *"
A number is displayed a t " * a s shown in Table 5.12:
* ", by which the detailed failure can be identified
Table 5.12 Failure Category Nos.
**
3
4
Name of Failure Servo Control Board error
Meaning Failure was detected a t Servo Control Board.
CPU failure of SCON Board Servo power shutoff
Servo Control Board malfunctioned. Servo power was shut off due to unknown cause.
Overheat in the Control Unit
The temperature extremely increased in the control unit.
7
Servo Driver failure
Failure occurred in the Servo Driver Unit (For details, see Table 5.14 and 5.15)
Position output failure

9
Failure occurred in the Servo Driver Unit. (For details, see Table 5.14 and 5.15)
Abnormal position/speed 10 loop ON state
The Servo Driver cannot be energized.
Beyond the position deviation The position deviation exceeded the set 12 limit Beyond the speed command 1 3 limit Beyond the current command 14 limit Failure a t the servo startup value. The commanded speed exceeded the set value. The commanded voltage exceeded the set value. Failure occurred when the servo power was turned on.
9 9
Troubleshooting
-4
(2) Message (not displayed in some cases) F o r Servo Failure 8 "Servo Driver Unit failure", a message and failure information codes a r e displayed t o 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 a n axis number used in the entire control unit. [Failure information] shows the information of a detected failure, for example:
* 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 * )
-
MECHA *
5-4 2
Troubleshooting
(3) Failure information codes

The abnormal p a r t can be identified from Fig.5.1, as shown in Table 5.13:
Table 5.13 Interpretations of Codes Column

+
a Failure of P a r t common t o each axis Failure of P a r t common to each axis Failure of P a r t common t o each axis Failure of P a r t common t o each axis Failure of P a r t common t o each axis
c Failure of Axis 2 Failure of Axis 5 Failure of Axis 8 Failure of Axis 11 Failure of Axis 14
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)
Failure of Axis 1 Failure of Axis 4 Failure of Axis 7 Failure of Axis 10 Failure of Axis 13
Failure of Axis 3 Failure of Axis 6 Failure of Axis 9 Failure of Axis 12 Failure of Axis 15
0000 indicates that that part is normal, while any number (displayed in the hexadecimal notation) except 0000 indicates that that p a r t is not normal. Furthermore, the detailed failure can be identified by the number.
Troubleshooting
-4
a ) Failures Common t o 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
Meaning Overvoltage of Main power +This bit sometimes (Main power off) indicates that the servo power is shut off, and in t h a t case not failure.
0004 0008 0010 0020
Disconnection of Inverter signal line Failure of A/D signal line
0100
Input of Stop signal
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.
(Example1
Meaning of Failure a t column " a " of UNIT 1
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
O O : Disconnection of the inverter signal line (0004H) and failure of the A/D OC 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 Code 0001 0 00 2 Motor overheat Encoder failure Meaning
I I
I Overcurrent I Overload
I
0 2 0 0
Overheat of power transistor
Over limit of momentary current
Over limit of detectable speed Over limit of position deviation
Codes in Table 5.13 a r e displayed in the hexadecimal notation on the Teach Pendant. If multiple failures occur a t one time, a sum of these codes is displayed.
(Example]
Meaning of Failure a t column "c" of UNIT 2
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)
Troubleshooting
-4
5.3.2
Troubleshooting for Servo Failures
1 Symptom 1
Servo Failure 3 SCON board error
Check Item
I Possible Cause 1
Refer to (3) of section 5. 3.1 to remove the cause.
- Noise
- Failure detail
codes not "0000"
-
All failure codes showing "0000" Red LED ON and green LED OFF on Servo Control board
affecting the - Take some measures t o protect from noise. servo system
Servo Failure
1 4
CPU failure of SCON board
1
I
liImperfect contact HCheck that the Servo I I Control board is in I / of Servo Control
I I board.
1 place.
o n Servo cboard failure Problem of system parameters Noise affecting the servo system
1
1
Replace the Servo Control board. Install the system parameters again. Take some measures t o protect from noise. Make sure that the Motion control board is placed correctly.
Servo gFailur-e Servo power shutoff
t1
Red LED on Motion control board ON
Incorrect placement of Motion control
Motion control board o r Servo Control board failure
Replace the Motion control o r Servo Control board.
5-4 6
Troubleshooting
I Action I
+
Control board and Servo driver flickering. Slow rotation of the fan
Low voltage on primary power supply (below AC I5OV)
Verify the voltage on the primary power
I
I
P
lOOV outlet below 75V in
I
- Cooling unit
failure
- Replace
Servo Failure 7 Overheat in the controller
- Temperature
the cooling
the controller over 60C.
unit.
1
the controller under 60C.
Ambient temp. over the allowance
1 1 1
Use within the allowable temperature. Replace the Backplane board.
II
I
I element failure
Troubleshooting
5-4 7
Servo Failure Servo driver failure Display of Servo Failure on teaching box /SERVO ABN 8
I
1
/1
Power supply indicator lamp
Loss of U phase (wire 4) of primary power supply (3-phase
Verify the voltage on each of the primary side phases before connecting.
I Replace the cable.

: UNIT~ showing "0002"
1 Replace the breaker.

Imperfect contact of cable connecting servo driver CN1 for axis shown by "000C" o r "0002" and Servo Ctrl. board CN2, o r cable connecting servo driver CN2 and power unit Make sure that the cable connection is correct.
"UNIT1 LACK VOLTAGE " a t Q,"OOO2" a t U N I T l a , and
1m
Replace the cable.
INVRTR" a t
@ a , and "0002" a t UNIT2 @

shown "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.
-4
Troubleshooting
Possible Cause "UNIT2 LACK VOLTAGE a t @, " 0002 " a t UNIT1 @, and UNIT2 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 Switch box failure ~ m ~ e r f of control cable 3 (manipulator CN3 and CN7 on Servo Control board 2)
Action
Make sure that the control cable connection is correct.
/ Replace the cable.
I
1
-
Make sure that the cable connection is correct.
/ Replace the cable.

Replace the Switch box sure e Make ~ ~ that the c control cable I connection is correct. Replace the cable.
1
@, "0002" a t
UNIT^@@@ and UNIT2 @ shown
- Imperfect contact of cable connecting CN6 on Servo Control board 2 and switch box CN 136
Switch box failure
+ 1+
1
Make sure that the cable connection is correct Replace the cable. Replace the Switch box
Troubleshooting
-4
Possible Cause "MECHAl 0 AXS OVER LOAD" a t @, "0020" a t any of UNITl and UNIT2 @@ @ shown Imperfect contact
Action
Make s u r e t h a t the control cable connection is correct. Replace the cable.
m,
1 Disconnection of
I motor line
"MECHAl 0 AXS CURRENT ABN" a t @ "0010"at any of UNITl and UNIT2 shown
1 /
Wrong dip switch setting on Servo Control board
1 1 1
Check the dip switch setting and set correctly.
"MECHA10 AXS OVER CURRENT" current a t @, and "0008" a t any of UNITl @ @@ ,and UNIT2 shown
-----
Fuse blown by over current flow to servo driver
Check the fuse.
I Replace the fuse
-5 0
Troubleshooting
1 Symptom 1
Check Item
[ Possible Cause I
"MECHA1 O A X The origins of S OVER DEVIA mechanical stopper and software limit T." a t @and "0200" a t any of ~ ~ 1 ~ 1 m , a n Imperfect contact d of encoder cable UNIT2 shown
Perform absolute offset adjustment.
1 /
/
Check the encoder cable connection of that axis. Replace the encoder cable. Replace the motor.
Disconnection of encoder cable Motor failure
I
"UNIT1 STOP INVRTR" a t @ and "0004" a t UNITl@ shown
Disconnection of motor line
Replace the cable.
--r/ Imperfect contact

I / of flat cable
I
-
- Check
the flat cable connection.
connecting Servo Control board and servo driver Disconnection of flat cable
- Replace the flat cable. 1 4

I I
Make sure that the Servo Control board is placed correctly.
board failure
-4
1
"UNIT2 STOP INVRTR" a t @ and "0004" a t UNIT2 @ shown
-/
failure
Replace the servo driver.
Troubleshooting
5 -5 1
I Symptom I
"MECHA10 OVERCURRENT' a t @. and "0008" a t any of UNITl shown
-
I
Blown fuse on
servo driver o r robot overrun
Action
Check the fuse.
/ Cancel the overrun.
"MECHA10 AXS CURRENT ABN." a t @, and "0010" a t any of UNITl
1 Wrong flat cable
1 connection between 1 1 connection and connect I1

I Servo Control / 1 board and servo 1 1 driver (Base axes) 1 I 1 /
correctly. Note) Check the fuse on the servo driver indicated because it may be blown. Check the encoder cable connections and connect correctly.
1 Check the cable
I 1
"MECHA10 AXS CURRENT ABN." a t @, and "0010" a t any of UNIT2 shown

-
Wrong encoder cable connection (CN7) between Servo Control board (Base axes) and (Wrist axes).
- Replace the servo All detail codes - Servo driver driver. showing "0000" failure
5-5 2
Troubleshooting
Both red and green LEDs on Servo Control board ON
Servo system failure
to (3) of section 5. I--( Refer remove the cause. 1 3.1 to
I I
Only green LED on Servo Control board ON
1 1
"MOTOR 0-HEAT" at@, and "0001" a t any of shown
r/ Overload on the
I manipulator
Defective adjustment to the driving mechanism of the machine
HReduce the load.

I
Check the machine.
I I
Replace the motor. Check the encoder cable connections
--(
"ENCODER ABNMat 8 , and "0001" a t any of shown
of encoder cable and connect correctly. Disconnection of encoder cable.
I
1
/
Replace the encoder cable. Replace the servo driver.
/ AT" a t 8 , I I failure. and 1 "0004" a any of 1 I mshown !
Troubleshooting
-5
I Possible Cause
-
Action
"OVER SPEED" a t @ and "0100" a t any of @@@ shown A/D ABNORMAL1' a t @ and "0008" a t
"
Replace the encoder. Replace the servo [ driver. Check the cable connection and connect correctly.
1 failure
I /
Imperfect contact of cable in servo driver.
1 1 1
"OVER VOLTAGE" a t @ and "0008" a t @
voltage on ACBOOV
Reduce the primaryside voltage.
shown Red LED 3 on Motion control
1
---
I 9
Servo Failure Position output failure
Incorrect placement of Motion control ) board
board 1
Make sure that the Motion control board is placed correctly.
board o r Servo
control board o r Servo
Green LED on Servo Control board OFF
----
Incorrect placement of Servo Control board
- Check
the printed board is placed correctly.
board o r Servo
Replace the Motion control board o r Servo
l-2L.J
Servo Failure Abnormal position/speed loop ON state
5
Detail f
I Refer to (3)of section 5. 1

1 3.1 to remove the cause. /
codes not "0000"
-5
Troubleshooting
ISymptom 1
Check Item
I Possible Cause I
Action
showing "0000"
parameters
Re-install the system parameters. Replace the fuse.
/ I Interlock board
Noise affecting the system Servo Failure Beyond the position deviation limit None of Axesl- 6 operable by manual manipulation Failure a t highspeed operation Failure a t highspeed operation Axes 1 6 operable by manual manipulation
-
Take some measures to protect from noise.
Imperfect contact of motor line
iCheck the connections I I of Servo driver I connectors CN51- CN56. I

Reduce the mechanical load.
I
-
/
Too large load
Beyond the speed command limit
1 I
Problem of system parameters
Re-install the system parameters.
11
I/ /
--( None of
I 1 of motor line
I
1
Noise affecting the system
/ of the motor power

I line.
Check the connection
Take some measures to protect from noise. Reduce the mechani cal load. Take some measures to protect from noise.
Servo Failure 14 Beyond the current command limit
- Failure
when starting operation
4 Too heavy
1 the system
1
Troubleshooting
5-5 5
I Symptom I
-
I Check Item I
Possible Cause
I
Perform the same checks as those of Servo Failure 8 according t o the servo failure display on the teaching box.
Servo Failure 99 Failure a t the servo s t a r t u p
1
/
5-5 6
Troubleshooting
Chapter 6
Periodic Inspection
Contents
6.
6.1
Periodic Inspect ion

Warranty Period
(1) DAIHEN provides free repair f o r 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
party
a third
(C) Any damages and failures caused by natural disasters such as earthquakes, fires
and floods
(l Any defects arising out of improper transfer o r storage of the product after the D
takeover
(E) Any other defects that a r e not covered in (1)
(3) This warranty is only applicable t o the robot equipment installed in J a p a n .
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 3 month inspection
Daily inspection before and after operation
/ Inspection a t each 500 hour interval
6 month inspection
1 year inspection
/ Inspection a t each 1000 hour interval
1 Inspection a t each 2000 hour interval
3 year inspection 6 year inspection
1 Inspection a t each 6000 hour interval
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 t o the Regulations on Industrial Robots, Art.19 and Art.36, Para.32.)
(2) Before performing maintenance/inspection works, be sure t o 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 t o prevent the power source from being carelessly turned on during inspection, f o r example, by providing a notice plate indicating "Inspection".
6.4
L i s t of lnspection Items
0 0 0
8 9
found. Grease, fume, and Cooling unit Clean up. dust Charging batteries Replace. Memory lithium batter Replace.
Interface
p p
CAUTION F o r routine inspection items, refer to the "Safety Management" instruction manual.
\
6-2
Periodic Inspection
Chapter7
Parts List
Contents
7.12 BIRBX-1005 control cables

f
7-24
8
t
7-24 1 0 7.12 1 control cable 1,2 3 ( F ~ ~0 ~~ 0 ~ 1 1 ) 7.12.2 cables / H~~~ .................................................................................................................................................... 7-24 7.12.3 Control Cable5 (For Almega Auto II- Robot Control Unit) 7-25
This chapter presents p a r t s lists of the standard robot control units including their peripheral equipments. Because these p a r t s numbers could be different from those available f o r 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 p a r t s numbers. F o r delivery and price of maintenance parts, contact a robot distributor o r a representative.
DAIHEN sales
PartsList
7-1
7.1
Ref N a
IRBCX-422 Robot Control Unit (Fig. 7.1.0.1)

Item Auxiliary Transformer Power Unit Noise Filter Glass Fiber Fuse Constant Voltage Power Supply Constant Voltage Power Supply Cooling F a n Lamp Neon Lamp Servo Driver Unit Servo Driver Unit Servo Power Unit P.C.B.(Servo Control) 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 L3700COO L3700M00 L4024M00 L3702F00 L3899YOO E5741A00 E5685A00 W-LOO233 W-LOO471 L4000E00 SA33B-30A BZ-N2OB A-120-1 AC-T04FB04 M12-ZMC A-1042B-7
"
0 0
0-1 0-2 0-3 0-4
Q'ty 1 1
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
0
@
(1) (1) (1) (1) 4 1 1

1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 2 1 2 1
@
0
p p
0 8 8
@
P.C.B.(Motion Control) P.C.B.(Main Processor) P.C.B.(I/O Management, Standard type) P.C.B.(I/O Management, Extended Type) ~.C.~.(~ack~lane) 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
8
@
0
@
8
@
0 8
@ @
* :Use the parts marked * " for Robot Control Unit shipped as TIG Welding o r Plasma
Cutting Specifications.
-2
Parts List
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 L i s t
7-5
7.3
Ref No.
I RBCX-512 Robot Control Unit (Fig.

Item Auxiliary Transformer Power Unit Noise Filter Magnetic Contact Constant Voltage Power Supply Constant Voltage Power Supply Cooling F a n Lamp Neon Lamp Servo Driver Unit Servo Driver Unit Servo Power Unit P.C.B.(Servo Control) P.C.B.(Motion Control) P.C.B.(Main Processor) P.C.B.(I/O Management, Standard type) P.C.B.(I/O Management, Extended Type) 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
"
7.3.0.1)
0
0
0-1 0-2 0-3 0-4
Drawing No./Type W-LOO470 E6029A00 NDH003 l A , AC125V 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 W-LOO233 W-LOO471 L4000E00 SA33B-30A BZ-N20B A-120-1 AC-T04FB04 M12-ZMC A-1042B-7
Q'ty 1 1 (1) (1) (1) (1) 4 1 1 1 1
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 *
@
@
0
8 0
5096-137 5096-155 * 1 2 1 1 1 1 1 1 1 1 1 1 1 1 2 1 2 1 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
@ @
0
@
8 @
8
@ @ @
* :Use the p a r t s marked * " for Robot Control Unit shipped as TIG Welding o r Plasma
7-6
Parts List
PartsList
7-7
7.4
IRBCX-532 Robot Control Unit
(Fig. 7.4.0.1
>
% @ % 0
- 1
P.C.B.(Break Unit) Cooling Unit Cooling F a n 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
% @ % 8 3 @ 3
(4) 1 1
3 1 2 1
E5735C00 L3887E00 4805-031 4614-039 4739-272 4739-273 4732-017 3364-005 3364-123
8
@
Mark 3 shows the different parts from IRBCX-512. 3
7-8
Parts L i s t
Fig.7.4.0.1 IRBCX-532 Robot Control Unit

Parts L i s t
-9
7.5 I RBCX-541 Robot Control Unit (Fig. 7.5.0.11
Auto Breaker Breaker Handle Door Key Handle AC Socket Eye Bolt
SA33B-30A BZ-N2OB A-120-1 AC-T04FB04 M12-ZMC
1 1 2 1 2 1
4614-046 4739-272 4739-273 4732-017 3364-005 3364-123
8
@ @ @
A-1042B-7 Hanger 0 * :Use the p a r t s marked " * " for Robot Control Unit shipped a s TIG Cutting Specifications.
3 Mark 3 shows the different parts from IRBCX-512.
Welding o r Plasma
7-1 0
Parts List
Parts L i s t
7-1 1
7.6 IRBCX-551 Robot Control Unit
(Fig. 7.6.0.1)
Servo Driver Unit
* :Use the p a r t s marked * " for Robot Control Unit shipped as TIG Welding o r
"
Plasma
Cutting Specifications. 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.
0 0 0
@
Item Push Button Switch Illuminated Push Button Switch Illuminated Push Button Switch Illuminated Push Button Switch Panel Protection Cover Assy
1 1
Drawing No. /Type AVN3OlN-R AH164-TLR11E3 AH164-TLY 1lE3 AH164-TLGl lE3 E5761B01
I 1
I
Q'ty 1
2
P a r t s NO. 4250-023 4250-069 4250-070 4250-071 E5761B01
1 1
1
0
@
7-1 4
Parts List
Fig.7.7.0.1 BBOPX-3000 Operation Panel

Parts L i s t
7
-I 5
7.8 BBOP-3008 Operation Box (Fig. 7.8.0.1)
LED Lamp
0
@
Dust Proof Cover Protection Cover Panel
7-1 6
Parts List
Fig7.8.0.1 BBOP-3008 Operation Box

PartsList
7-1 7
7.9
Ref NO.
BBTBX-6008 Teaching Box (Fig. 7.9.0.1 )

Item Printed Board Insulating Sheet 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
I % I
/
I
Drawing No./Type
I
I
Q'ty
1
I
P a r t s N. o
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
2 1 1 1 1 1 1 1 1 1 1 1 1 1 1
E5680B04 5096-184 E5680B07 E5680H00 NB10146 E5680B08 4250-021 4250-028 4250-029 4600-327 4600-304 E5680B02 E5680B01 E5680B03 3364-006
Protective Sheet Handle Cable Assy
-1
Parts List
Parts L i s t
7-1 9
7."1
Ref N a
BBST-4005 Starting Box (Fig. 7.10.0.1 )
I
I
Item Push Button Switch Illuminated Push Button Switch (G)
1
/ /
DrawingNa/Type AB6M-VIR AH164-TLGllE3
/ / /
Q'ty 1 1
P a r t s NO. 4250-082
0
@
I I @I I
1
/
4250-071
LED Lamp
Illuminated Push Button Switch (R) AH164-TLRllE3 1 4250-069
0 8 0 8
Protection Cover Panel Case
E6039B01
E6039B01
Connector
7 - 2 0 Parts List
fig.7.10.0.1 BBST-4005 Starting Box
Parts List
-2
7.1 1
Ref NO.
BBWF-0105 Welding Interface

Item Auxiliary Transformer 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 (6 Poles) Metal Plug Socket (10 poles) Metal Plug Socket (6 Poles)
(Fig. 7.11.0.1)
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
Q'ty 1 1 1 1 1 1 1 1 1 1
1
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
0 0 0
@
0
@
0
@
@ @
0 @ 8 0 8
@
1 1 1 1 1 1 1 3 1 1 1 1 1 (5 m
63
0
@
Grommet Relay Relay Relay Relay Relay Cable Assy
8
@ @
@,
DC24V LY2-DH2 DC24V LY2-DH2 DC24V G-2VN-234P L3497YOO
>
L3497Y00
Fig.7.11.0.1 BBWF-0105 Welding Interface

Parts L i s t
7 -2 3
7.12
7.12.1
BI RBX-1005 Control Cables (Fig. 7.12.0.1)

Control Cable 1,2,3
or GOl,WOl,VOl)
Drawing No./Type Q'ty 1 L3996B00 L3996COO L3996D00 1 1 Parts N a L3996B00 L3996COO L3996D00
(1) BIRBX-1003 L3996A ( 3 r d Item Ref N a Control Cable1 (3m) CN1 0
0 0
Control Cable2 (3m) CN2 Control Cable3 (3m) CN3
(2) BIRBX-1005 L3997A (5m) Item Ref NO. Control Cable1 (5m) CNl 0
Drawing No./Type Q'ty L3997B00 1 L3997COO L3997D00 1 1
Parts NO. L3997B00 L3997COO L3997D00
0 0
(3) BIRBX-1010 L3998A (10m)

Ref NO.
0
@
Item Control Cable1 (lorn) CN1
Drawing N o . / ~ y ~Q'ty e L3998B00 1
Parts NO. L3998B00
L3998C00 L3998D00
1 1
L3998COO L3998D00
Ref N. o
Item Control Cable1 (l5m) CN1
Drawing Na/Type Q'ty L3999B00 1 L3999D00
Parts No. L3999B00
Control Cable3 (15m) CN3
L3999D00
7.12.2 Cables/ Hose

Ref NO. Drawing Na/Type Q'ty L2527B00 1 Gas Hose (5m) 1 L2527D00 Torch Side Welding Cable (5m) Item Parts N a L2527B00 L2527D00
0
@
I
I
Workpiece Side Welding Cable(5m) Control Cable4(5m) CN4
L3442B00 L3392G00
1 1
L3442B00 L3392G00
1
1
(2) BIRB-3010 L3443A (10m) Ref N a Item
l ~ r a w i n ~ ~ y ~ Q'ty NO. / el
Parts N. o L3375E00 L3375LOO L3443B00
I 0 I @ I
@
Gas Hose (10m) Torch Side Welding Cable (lorn11 L3375E00 Workpiece Side Welding Cable(l0rn) Control Cable4(lOm) CN4
0
7-2 4
Parts List
I /
L3375L00 L3443B00
I /
1 1 1
I I
Ref No.
Item Gas Hose (15m) Torch Side Welding Cable (15m) Workpiece Side Welding Cable(l5m) Control Cable4 (15rn) CN4
Drawing No./Type Q'ty 1 L3375VOO
a Parts N
L3375VOO L3375G00 L3375N00 L3444B00
0
@
1 I
L3375G00 L3375N00 L3444B00
1 1 1
7.12.3 Control Ca ble5 (For Al mega Auto I1 -- Robot Control Unit)

Ref N a Drawing No./Type Q'ty Control Cable5 (5m) Optical Fiber 1 L3392Y00 Item P a r t s No. L3392YOO
(2) BWCB-5110 L3512A (10m)

Ref N . o
Item
l~rawin~./T~~el ~o Q'ty
Control Cable5 (lorn) Optical Fibed L3512B00
P a r t s NO.
1 rL3512Bo0-
Ref No.
Drawing N /Type Q'ty a Control Cable5 (15m) Optical Fiber L3513B00 1
Item
P a r t s N. o L3513B00
/ Workpiece
l.----J
Manipulator Fig.7.12.0.1 Control Cables

Parts L i s t
7-2 5
7.13
BI RBX-8005 Control Cables (Fig. 7.13.0.1)

Control Cable 1,2,3 (For V10,V20)
(1) BIRBX-8003 L4309A (3m)
7.13.1
7 -2 6
Parts List
7.13.2
Tool Control Cable (For VIO,V20)

Ref NO. Item Tool Control Cable (5m) CN4 Parts NO. L4357F00
(1) BIRBX-9105 L4357A (5m)

Drawing Na/Type Q'ty L4357F00 1
Ref NO.
Item Tool Control Cable (10m) CN4
Drawing Na/Type Q'ty L4358F00 1
Parts NO. L4358F00
Ref N. o
Drawing No./Type Q'ty L4359F00 1
o Parts N. L4359F00
Robot Coiitrol Unit IRBCX-541,551
Fig.7.13.0.1 Control Cables

Parts L i s t
-2
7.14
B IRBX-6005 Control Cables (Fig. 7.14.0.1)

(1) BIRBX-6005 L4177A (5m)
7.14.1 Control Cable 1 2 3 (For V40)
Ref No.
Item Control Cable1 (lorn) CNI Control Cable2 (lorn) CN2 Control Cable3 (10m) CN3 Control Cable4 (lorn) CIS4
Drawing Na/Type Q'ty L3908B00 L3908COO L4178D00 L4178E00 1 1 1 1
P a r t s N. o L3908B00 L3908COO L4178D00 L4178E00
0 0 0
@
Ref N. o
Item Control Cable1 (l5m) CN1 Control Cable2 (15m) CN2 Control Cable3 (15rn) CN3 Control Cable4 (15m) CN4
Drawing No./Type Q'ty L3909B00 L3909COO L4179D00 L4179E00 1 1 1 1
P a r t s No. L3909B00 L3909COO L4179D00 L4179E00
0 0 0
@
-2
Parts List
7.14.2 Tool Control Cable(ForV40)

(1) BIRBX-6105 L4209A (5m)
Ref NO. Item Tool Control Cable (5m) CN5 Drawing N. /Type Q'ty o L4177F00 1 P a r t s NO. L4177F00
a Ref N
Drawing N. /Type Q'ty o L4178F00 1
P a r t s No. L4178F00
Ref N a
Drawing No./Type Q'ty L4179F00 1
P a r t s NO. L4179F00
Robot Control Unit IRBCX-532
Fig.7.14.0.1 Control Cables

PartsList
7-2 9
7.15
Robot Control Unit for External Axes
7.15.1 IRBCX-422-1 Robot Control Unit (Fig. 7.15.1.1)
Servo Driver Unit
P.C.B.(Servo Control)
@ @
Cooling Unit Auto Breaker Breaker Handle Door Key Handle AC Socket Eye Bolt Hanger Cutting Specifications.
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
0 8 @
@
* :Use the p a r t s marked " * " for Robot Control Unit shipped a s TIC Welding o r P l a s m a
Mark % shows the different parts from IRBCX-422.
Fig.7.15.1.1 IRBCX-422-1 Robot Control Unit
Parts List
-3
7.15.2 Ref N a
IRBCX-422-2 Robot Control Unit (Fig. 7.15.2.1) Drawing N /Type a Item

Auxiliary Transformer Power Unit W-LOO470 E6029A00 lA, AC125V
0 % 0
0-1
Q'ty 1 1
o P a r t s N. 4810-912 E6029A00
4610-008 4814-017 4805-027
Noise Filter Glass Fiber Fuse Constant Voltage Power Supply Constant Voltage Power Supply Coolinn Fan Lamp
(1) RWS15A-5 (1) LWQ130-5FF4 4715PS-20T-B30 5 / AH164-ZSWM1 1
i)4814-018 l
1
0
@
Neon L a m p Servo Driver Unit Servo Driver Unit
NPAlO-2H-WS
1 /
4600-317 4600-341
0
I
Servo Power Unit P.C.B.(Servo Control) P.C.B.(Motion Control) P.C.B.(Main Processor) P.C.B.(I/O Management, Standard type) P.C.B.(I/O Management, Extended Type) 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 Servo Driver Unit
"
E5787A00
E5787A00
L3700D00 L3700COO L3700M00 L4024M00 L3702F00 L3899YOO E574 1A00 E5685A00 W-LOO233 W-LOO471 L4000E00 SA33B-30A BZ-N2OB A-120-1 AC-T04FB04 M12-ZMC A-1042B-7 W-LOO606
1 1 1 1 1 1 1 1 1 1 1 1 2 1 2 1 1
L3700D00 L3700COO L3700M00 L4024M00 L3702F00 L3899YOO E574 1A00 E5685A00 5096-095 5096-140 L4000E00 4614-046 4739-272 4739-273 4732-017 3364-005 3364-123 5096-174
* :Use the parts marked * " for Robot Control Unit shipped as TIG Welding o r P l a s m a
7-3 2
Parts List
Parts List
7-3 3
7.15.3 Ref N. o
IRBCX-422-3 Robot Control Unit (Fig. 7.15.3.1) Item Drawing N /Type a

Auxiliary Transformer Power Unit Noise Filter Glass Fiber Fuse Constant Voltage Power Supply Constant Voltage Power Supply Cooling F a n Lamp Neon L a m p Servo Driver Unit W-LOO470 E6029A00 NDHOO3 lA, AC125V RWS15A-5 LWQ130-5FF4 4715PS-20T-B30 AH164-ZSWM1 NPA10-2H-WS W-LO0455 o r
0 0
0-1 0-2 0-3 0-4
Q'ty 1 1
a Parts N 4810-912
E6029A00 4519-009 4610-008 4814-017 4814-018 4805-027 4600-317 4600-341 5096-138
0
@
(1) (1) (1) (1) 7 1 1
* :Use the p a r t s marked * " for Robot Control Unit shipped as TIG Welding o r Plasm a
"

7
-3 4
Parts List
7.15.4 IRBCX-512-1 Robot Control Unit (Fig. 7.15.4.1)
Servo Driver Unit
P.C.B.(Servo Control)
Servo Driver Unit

"
W-LOO605
5096-173
* :Use the p a r t s marked * " for Robot Control Unit shipped as TIG Welding o r P l a s m a
Cutting Specifications. Mark 3% shows the different parts from IRBCX-512.
7-3 6
Parts List
7.15.5
Ref N. o
IRBCX-512-2 Robot Control Unit (Fig. 7.15.5.1)

Item Auxiliary Transformer Power Unit Noise Filter Glass Fiber Fuse Constant Voltage Power Supply Constant Voltage Power Supply Cooling Fan Lamp Neon L a m p Servo Driver Unit Servo Driver Unit Servo Driver Unit P.C.B.(Servo Control) P.C.B.(Motion Control) P.C.B.(Main Processor) P.C.B.(I/O Management, Standard type) p.C.B.(I/O Management, Extended Type) P.C.B.(Backplane) P.C.B.(Interlock) P.C.B.(Terminal Block) o r P.C.B.(Relay) M e n ory Battery Charging Battery Coolimg Unit W-J_iOO233 W-LOO471 L4000E00
-
0 0
0-1 0-2 0-3 0-4
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
Q'ty 1 1
Parts N a 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 1A00 E5685A00 5096-095 5096-140 L4000E00
(1) (1) (1) (1) 5 1 1

1 1
1
0
@
0
@
8
93 @
3 1 1 1 1 1 1 1
1 1
a
0
0 8
@
@
@ @
* :Use the p a r t s marked * " for Robot Control Unit shipped a s TIG Welding o r Plasma
"
Cutting Specifications. Marli % shows the different parts from IRBCX-512.

7-3 8
Parts List
Fig. 7.15.5.1 IRBCX-512-2 Robot Control Unit
Parts L i s t
7-3 9
7.15.6
a Ref N
IRBCX-512-3 Robot Control Unit (Fig. 7.15.6.1)

Item Auxiliary Transformer Power Unit Noise Filter Glass Fiber Fuse Constant Voltage Power Supply Constant Voltage Power Supply Cooling F a n Lamp Neon L a m p Servo Driver Unit Servo Driver Unit Servo Driver Unit P.C.B.(Servo Control) P.C.B.(Motion Control) P.C.B.(I/O Management, Standard type) P.C.B.(I/O Management, Extended Type) 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 Drawing No./Type W-LOO470 E6029A00 NDHOO3 l A , 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 E5741A00 E5685A00 W-LOO233 W-LOO471 L4000E00 SA33B-30A BZ-N2OB A-120-1 M12-ZMC A-1042B-7 W-LOO552
"
0 0
0-1 0-2 0-3 0-4
Q'ty 1 1
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 *
0
@
(1) (1) (1) (1) 5 1

1 1 1 1
-
0
8
0
8
5% @
(D 'l
8
@
1 - L3700D00 1 L3700COO 1 L3700M00 1 1 1

1
L4024M00 L3702F00 L3899YOO E574 1A00 E5685A00 5096-095 5096-140 L4000E00 4614-046 4739-272 4739-273 4732-017 3364-005 3364-123 5096-154
8
@
0
@
1 1 1 1 1 2
1
8 0
@
Door Key Handle @ 8 -AC Socket
Eye Bolt Hanger Servo Driver Unit
8
5% @
1 1
* :Use the p a r t s marked * " for Robot Control Unit shipped as TIG Welding o r P l a s m a
Cutting Specifications. M a r k 5% shows the different p a r t s from IRBCX-512.
Parts List
7 -4 1
Electrical Connection D i a g r a m
Contents
8.1
Electrical Diagram of Robot Control Unit IRBCX-422, 462
8-1
bEO
EEO
ZEO
I 0
BACWLANE BOARD
PC8 l
C5 Note)Accordlns to the use of PC% or PCB3 and also P B or PCD4. tho nuns and vlrs No. of each tarnlnsl should be followad:
RESERVE COML 8 8 0 COMZ 9 9 1 COM3 8 9 2 COM4 8 8 3 CQMS 8 8 4 24ElWTl 24ElWT1 24ElOUTl 24ElOUTl Z4EIOUTI 24EIWTI 900 800 800 900 800 800 PC88 RESERVE COME 8 9 5 CUM7 8 9 6 COMB 9 9 7 COM9 9 9 8 COMlO 8 9 9 PCB4 24EIQIJTI 24ElOUTl 24ElOUTl 24EIWTl 24ElOUTl ZIEIWTI
900
Q00
900 900
80 0 80 0
8121T871
ITBQlT
TUX(INAL
BLOCK VI4IT
EXT.
1ERMIML BLOCK
UNIT
CHRG ALMZ
BREAK BREAK
GN) GN) GN)
BGT MA N I PUL BAT BAT OVERRUN L S I OVERRUN L S 2 OVERRUN L S 3 OVERRUN
GNI
GN) GN)
3
BK COM BK A BKB
BAT OVERLS9r OISCON3. OVERCOM3
5)
@
@ J
I
I
BAT BAT B4T OVERRUN L S 4 OVERRUN 1 5 5 OVERRUN L S 6 24W SHOCK SENSOR
LAMP
__---
.--_
% &
; : :
OE1"1 LAMP @ iO+ f~ vc z BRAKE*
VBAT-
@)
VBAT+ VBAT-
Electrical Diagram of Robot Control Unit IRBCX-422, 462 (4/6)
CN A+ 1 A- 1 B+ 1 B- 1 s+ 1 S- 1 ABS + i ABS
2
PA PA. PB PEW
PC
MAN l PULATOR
AX- 1
PC. ABS ABSU R-OND +5.5v GNDE 1 PA PA. PB PB. PC PC. ABS ABSl R-GNO +5.5V GNDE2 PA PA1 PB PBm PC PC. ABS ABSm R-OND +5. 5 V GNDE3
9-JLF
E C DR N O E
-1
R-OND 1 5E 1 GNDE I A+2 A-2 B+2 8-2 S+ 2 5-2 ABS + 2 ABS - 2 R-GND 2 5EZ GNM2
AX- 1 E C DR N O E
PS*
A+3 A-3 B+3 8-3 S+3 S-3 ABS+3 ABS-3 R-OND3 5E3 GNDE3 FG
AX-3 E C DR N O E
AX-2 MTR OO
I
I 1 1
AX-3 MTR OO
PSZ
PSI
( (
Electrical
Diagram of
Robot
Control Unit
IRBCX-422,
462 (51'6)
I I I
I I
I I I \
\
L
' m a a a a a a 4 4 n + o a a a a a a 4 < n + o
4:mbo:$$$:$,:mlo:E$yd$
-E
W
90
X
LOO
X Z QW
W 0
I I
----------------,
0
I 0
Q W
I 0
>
n z m w
O > N
I I I I I I
I
~ ~ w W u I U m m Q o = 4 l! o 0 a c o t o ? r -c 1
h N N r . ( \ N
---
0 - h m ~ u ~ o r r n - ? T P V t t T - ? t m m U I C u l
-----gfl"-
--rm
L C u I
b &
m m
0 0 0
m m m
r-rr-
0 0 0
%J -
IC
0 0 0
r-rr
0 0 0
0 0 0
V T P r r r
0 - N 0 0 0
0 0 0
0 - N 0 0 0
N N N
T P
a o a
N N N
>
Z . - - - W v < m v
Z u N N N < m v
t j m m m w < m u
u
4
L J N
u l
8-6
Electrical Connection Diagram
0658 0756
GROUNDING
NL1 NEON LAMP
AC
1: -; b
SOCKET
oov
Ft3 6 UNI T '3
PS I
1 oov
SV GND 2, 4 O V
32 27
5 %
tow tow tow

a B a J 3 C H 4
'
3 26 g 25 J
t o SERVO
07 1A 071A
27 2
28
GND
c@
3 +15v 27 4 GND
29
-15V
2
3
GND +15V
GND
2 27
031D
t o BACKPLAE WARD
PCB1 CNlO
+15V 3
4 GND
5 -15V
- 15V 5
29
0310
Electrical Diagram of Robot Control Unit IRBCX-512 (1/6)
PSl
CH42
/ /
r----------1 ROBOT DEDICATED WELDING POWER SUPPLY
BACKPLANE BOARD
I
I I I I !
I
EMRGEWY STOP
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 RESERVE COMl 990 COMZ $ 1 0 PC83 Z4EIOUTI 900 Z4EIOUTI 900 24ElOUTl 900 PC86 RESERVE COM6 995 COM7 995 PC84 Z4EIOUTl 900 24EIOUTl 900 24EIOUTI 900
BOARD
BREAK
BREAK
MANIPULATOR
CRZA ESTOP
CRB T E A C H C R I I START C R 1 3 STOP
LAMPllAUTOl LAMPZITEACH) LAMP3lSTARTI I LAMP415TARTZ1 LAMP5ISTART31 LAMP6ISTOPI C R 1 2 SERVO ON
3
BK COM BKA
I
IL-
LAMP
- ---- - .
+czYvOm BRAKE*
OCQOV VBAT-
18
@) Q
@
Electrical Diagram of Robot Control Unit IRBCX-5 12 (4/6)
, - G :.k&&&:,;,:$?g# $ : - - - - . - - - -; N N N N N N N N N N :;&A:,&;:,g"g
m m o
4 4
I
m m m m m m m m m m m 0
m m o
4 4
&
"
:;&A:,A:,11,9g#'
4 4
m m o
1
z a
0 0 0
0 0 0 0 - N
m m m w w w
0-00
N N N
-1
-;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 & &m $mA og l o g : & , A & A $ Amg oi # z : & & & & & & & 9 z$ B L : m m m o
4 4
1
--------
&
C1
8- 1 2
8.3 Electrical Diagram of Robot Control U n i t IRBCX-541
I O P W A T I O N PAML (OPERATION BOX); 1 QLT 1 EMERGENCY STOP 1 I STP,RT 1 1 HALT 1 COM I 24E I 5TAHT INDICATOH I 1 HALT INDICATOR 1 I I I SERVO ON
I TEACH M E SEECiIMll AUTO Lg SELECTIONI a SEAYO ON INDICATOR I I I TUCH M E IXDIQTOR~ AUTO- -INDICAIOAJ - NDE ----. A
- .- - - - - - - -. - -
N &
10
s N 1 9
- I5V
0902513
(SENSOR)
r----------1 1 ROBOT DEDICATED WELDING I POWER SUPPLY

I
BACKPLANE BOARD
PCB 1
EIERGENCY STOP
(SPT I CAL F I BER
033
SERVO ON
BT 1
034
BACKPLANE BOARD
PCB 1
Nots)Aooordlna to the 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 eaoh terminal s h o u l d b a f o l l o w e d :
RESERVE mMI 9QO COMZ QQI COM3 QQZ COM4 993 COffi 984 Z4EIOUTI 24EtOUT1 Z4EIOUTI Z4EtOUT1 24ElOUTl 24ElOUT1 900 900 900 900 900 900 ?C86 RESERVE COM6 995 COM7 996 COM8 997 COM9 998 COMlO 999 PCB4 24EIOUTI 24ElOUTl 24EtOUTI 24ElOUT1 24E(OUil 24ElOUTI 900 900 900 900 900 900
TERMINAL BLOCK UNIT
EXT OVER1
---CN6 ESTOP
--
I N T E R L O C K BOARD
PCB2
CN6
BREAK
+
BREAK
CN6
I
I
TPUT I CR2A ESTOP

C R 6 AUTO CRB TEACH CR 1 l S T A R T CR I 3 STOP
GN) GN) GN) BAT BAT BAT OVERRUN LS1 OVERRUN LS2 MAN I PiJ L A l OVERRUN LS3 OVERRUN CIECK(GN))
OUT CQM
24E LAMP1 I A U T O I LAMPZITEACH1 LAMP3lSTARTII LAMP4fSTARTZl LAMPSISTART31 LAMPGISTOPI C R i Z SERVO ON
GI@ GNI
GtQ BAT
3
BK COM BK A BK8 OE LAMP CN47 \'BAT VBAl VBAT
+
BAT BAT OVERRUN LS4 OVERRilN LS5 OVERRUN L S 6 24W SHOCK SENSOR LAMP
1 8 1
@
VBAT -
,
-
VBAT+ VBAT-
CN A+ 1 A- 1
2
PA PAR
MAN IPULATOR
PSI GND
B+ 1
- I5V
8- 1 s+1
sABS
1
ABS ABSN R-OND i5. 5V
AX- 1 ENCODER
I I I I I I
ABS t 1
-1
I I
I I I I I
A-OND 1
5El GNOE l
A+2 A-2 B+Z 8- 2 S+2 S-2 ABS + 2 ABS -2 R-GND 2
GNDE 1
PA PAW
I
I
AX-2 ENCODER
ABS ABSU R-GND +5.5V
5E2 GNDEZ
A+3
GNDEZ
PA PAR
PSZ
A-3 B+3 8-3 S+3 5-3 ABS+3 ABS-3 R-GND3
AX-1 MOTOR AX-3 ENCODER
I I I I I I i I I I
I I
ABS ABS* R-GND +5. 5 V
5E3 GNDE3
GNDE3
SH 1EL0
FG
1 1
------A
R E :;
R % :
CT
T O
LOO
a
t
W O
X O
x o QI
4 2
xo
I 1 I 1
8-1 8
ACZOOV 3
50/60HZ
NEON LAMP
GRCXJNDING PLATE
AClOOV
SWITCH BOX SB1
v
To BACKPLANE
,
47
- .- - - - - - - -. - GWATION PAKL (OPERATIONBOX);
EMEEMERCY STOP I
(SENSOR)
IKiWLCCK 83PRD
r----------1 1 ROBOT DEDICATED WELDING I POWER SUPPLY
BACKPLANE BOARD
PCB 1
I I 1 I !
I
EWEGENCY STOP
SERVO ON
BT 1
Nots)Aocordlna
BACKPLANE BOARD
PCB1
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 nrns a n d r l r s No. o : e a c h !ersii\ai snould b s ! U I I O W H ~ :

PC83
24E I OUT I 300 24EIOUTl 900 24EIOUTI 900 .-'cB~ iilr5tRVE .;:)'A6 995 COht-I 396 PC84 245 IOU I ! 3 i l U 24E IOUT 1 9 0 0 24E IOUTi YO0
PC85
iiESERVE COMI 960
COM2 901
-----ESTOP
INTERLOCK
BREAK
BREAK
GN)
GN)
GN)
OVERRUN 1 *
CRZA ESTOP
BAT BAT BAT OVERRUN LS1 OVERRUN LS2 OVERRUN LS3 OVERRUN CtECK(CM))
MANIPULATOR
I I
C R 8 TEACH CR I I START CR I 3 STOP
GND GM
LAMPIIAUTOI LAMPZITEACHI LAMP31STARTIl LAMP4ISTARTZ1 LAMPS(START31 LAMPGISTOPI C R l Z SERVO ON
GN)
B4T BAT BAT OVERRUN LS4 OVERRUN LS5 OVERRUN LS6
24W
3
BK COM BKA BKB BKC
SHOCK SENSOR LAMP
VBAT VBAT
i
VBATVBAT+ VBAT
_---MAN IP U L A T O R
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 I I I 1
AX-1 MOTOR
1
PS* P5,
AX-2 MOTOR
I
------A
{ {
Electrical Diagram of Robot Control Unit IRBCX-551 (51'6)
-------4 4
- z z y y y y y y y y N ~ m~ m m
1
Z i & A & l , A h g m s
m m o
m m m m m m m m o 4 4 m m u l m m m ~ : X ::&rb&1,&1,4i1(HL m m o z 5
ssz
8-2 4
8-2 5
8-2 6
BKCONT
ILOTIOH CCNlROC DWLO)
IC10 - - - -7 -
&k
-&$l
------J
(BACKPLANE MND)
KIAIM CINS I -------_1
r-----
KIAIM 2CINS
I
Internal Relay Sequence Diagram of Control Unit (3/8)
I f f 1 0 0
f f
0 0
I I I I
I I I I
I
I
I I
I I
I-
8-2 8
IX)
M N G K T R)MD AACN
- - - - - l/O - - -nANr- - - - - - - - WMG0,G - WMD

I
TELUI- - - K UilT L- - - - - NAL OK - - - - -I
I
I
ICI61 r-------
IWTFZ I w T F ~
L
I I
lCI84 r-------
-------
IC165 r-------
---- ---
I
N
----------- - - - - -J
I I I
L
- - - - - - - - - - - - - - - -J
RELAY UNIT
I/O - - - - - N r - - - - - - - -M N A C M - T
WARD
r _ - _ - - - _ - _ - _ - _
I/O MI\NAGDAENT WMD
RELAY U l T N _-----------__-_--
~ ~ U T E S ~
L------
IC162r----7-
I W T E ~ ~
L------
1C163r------
Internal Relay Sequence Diagram of Control Unit (6,
XI IUMIf4AL OK UNIT LK
I/O M N A C M K I DM 3D
r-----------
I/O M E M C M N T NMD
7
EXT. TEWINAL mKK UNIT

r------------7
IOUTCG =--j
I
L
----------------
IOCITC~ I I I I
- - - - - -. -
Z4VIGiJTt
r-------------------------------------------------------
I
I %I 8I 2I 2I
0
r3-A-k-i7;J-J-i-i,;3-A-A-17;A-A-A-il;2--!--L-il
v
r -f o =
~N u -
a .2 2 f - - "
II
g r ~ 5 f Z
m * z - o~ z -
L o - T
z
u,
gg 2 g
r.
I /
II
-ct,
Ii iI
1: /I
-J ,
II
-,J
II II 11
I I
jl
/I
d i +-,
I I I I I I I I
L-*-*-LJ
m r
L-+-+-LA
L-.c-I-CJ
m m
L-+-+-+A
r m
m m
o m
L-4-4-4
----- 2 o m r z_ g5 z >
8-3 2
8.6
Outside Dimensional Drawing of Robot Control Unit
8-3 3
OIL
-3 4
8.7
Electrical Diagram of Control Cable
rii
8-3 5
8-3 6
8-3 7
APPENDIX
1-WELDING EQUIPMENTS
Contents
1 3 TIG Interface E5743 ................................................................................................................................................. A1 . 6 1.3.1 A~~~~~~~~~ of TIG interface ................................................................................................................. A l - 6 wires of TIG l'terface 1.3.2 setting J~~~~~ Al- 7 Connecting TIG Interface ........................................................................................................................... A1 - 7 1.3.3
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 ~ ~ ....................................................................................... A1-10 t ~ ~ f ~ 1.5 .3 Connecting CUT Interface A1 - 10
APPENDIX
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 a r e 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 Connecting Ref .No. Name P a r t No. Q'ty Remarks Portion CN31 L3392Y 1 BCWB-5105 Control Cable 5 @ IC104 1 Control Cable 4 ICN4 L3392G @ Torch Side Welding 1 L2527D @ Cable BIRB-3005 Configuration Workpiece Side 1 L3442B @ Welding Cable 1 L2527B Gas Hose Control Cable 4 (L3392G) 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
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 t o the power supply. (4) Connecting Torch Side Welding Cable (L2527D) Connect the torch side welding cable to the power supply.
-
(minus) terminal of the welding
+ (plus) terminal of the welding
A 1
-2
APPENDIX
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 a r e 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 a n example of CPV-350.) TABLE 1.2.1.1 External Connecting Cable (for CPV-350) Ref .No. 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 ICN2 ICN3 For WCR For detection of weld stick ICN4 Portion
..
part N ~ . Q L3497Y E5186E K1754P K1754F

K1754G L3392G LZ527D L3442B L2527B
1
Remarks
O
@ @ @
@ @
1 1
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.
a
@
1 BIRB-3005 Configuration 1 1 Grommet
Terminal Block
To Workpiece
Terminal Block
To Manipulator
@ @
@ @ @
APPENDIX
To Manipulator
Figl.Z.l.l Connecting Welding Interface and Welding Power Supply

TABLE1.2.1.2 Connecting Cables with Various Welding Power Supplies Welding Power
1.2.2 Connecting Method of Cables
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
&
!J
v ?Jk!J
U BE L
q-?SUPPLY WCR
-
TO WELDING POWER (TERMINALBLOC

-. ----
I I --- - -L
_ ---- - -
- - --
TO WELDING POWER SUPPLYOUTPUT TERMINAL
DETECTING CABLE(2)
Fig1.2.2.1 Connecting Detection Cables
A 1-4
APPENDIX
(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.
INTERFACE
- 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 UnitVofthe 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 t o the (plus) terminal of the welding power supply At this moment,connect the terminal of the wire N . of the detection cable 2 also o2 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 t o the minus (-) terminal of the welding power supply.
APPENDIX 1-WELDING EQUIPMENTS A 1 - 5
1.3 7- I G Interface E5743

This unit is the interface in the case t o 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 o f TIG lnterface
7<57<?fflRBr?BiBI
fiLlER Y t R E COXTRCL UYlT l DR R I
7i5'74VIBPjiR@4f(?3l%(lB)
F l l i t R 1 6 FEEDER COYTRCL lill1lELOlKC O R SW??lTi l R iE
Slslgia EiDlX PCYUl S L WY
IC J i NI
1-
Fig.l.3.1.1 Appearance of TIG Interface
A 1-6
APPENDIX
1.3.2 Setting Jumper Wires of TIG Interface

This unit is equipped with the terminal blocks TB1 and TB2 t o connect jumper wires t o correspond t o various TIG welding supplies.Connect the jumper wires as shown TABLE 1.3.2.1 according t o the welding power supplies t o be employed. TABLE 1.3.2.1 Connecting Jumper Wires of Terminal Blocks TB1 (5-pole) and TB2 (10-pole) Welding Power Supply AEP VRTP (S-1) Jumper Wire
/ 1
TBl(5-pole) 123-122 123-121
/ /
@-@,
TB2 (10-pole)
@-63, @-@,
a-@
AVP VRTP (S-4)
1.3.3
Connecting TIG Interface

In this unit, connecting cables vary with the welding methods and corresponding
connecting cables according t o types as shown in TABLE 1.3.3.1.Therefore,prepare your requirements. TABLE 1.3.3.1 List of TIG interface Connecting Cables Welding Method TIG Welding (without Filler) Correponding Type Connecting Cable Connecting Cable(1) E5243E Connecting Cable(2) E5243F Connecting Cable(1) E5239E Connecting Cable(2) E5239F TIG Filler Welding E5750 Connecting Cable(3) E5208E
E5749
1
/
Connecting Cable($) E5208F Connecting Cable(5) E5223G Connecting Cable(6) E5208H
APPENDIX
1-WELDING EOUIPMENTS A 1 - 7
I .4 Filler Wire Feed Control Unit E5756

This is the unit t o control the TIG filler wire feed speed in the case t o combine the robot control unit and the TIG welding power supply.
1.4.1 Appearance of F i l l e r W i r e Feed Control U n i t
Fig.l.4.1.1 Outside View of Filler Wire Feed Control Unit
1.4.2 Connecting F i l l e r W i r e Feed Control U n i t

As for the method t o connect this unit,refer t o the Section 1.7
A 1-8
APPENDIX
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
APPENDIX
1-WELDING EQUIPMENTS A 1 - 9
"15.2
Setting Jumper Wires o f C U T Interface

This unit is equipped with the terminal blocks TB1 and TB2 t o connect jumper wires
t o correspond t o various TIG weIding,and plasma cutting power supplies.When to use Air plasma cutting power supply,there is no need t o 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) (Setting a t shipment from factory) Cutting Power Jumper Wire
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 t o your requirements.
TABLE 1.5.3.1 List of CUT Interface Connecting Cables Corresponding Type TRC-120 Connecting Cable E5769B
Al -1 0
APPENDIX
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 t o the external when the value goes down below a specified one.
1.6.1
Specifications of Weld Stick Detection U n i t

Item Specifications
Name
/ Weld Stick Detection Unit

50/60Hz
I
Input Power Frequency Detection Voltage (Input Voltage) Detection Time Weld Stick Detection Voltage Level Dimensions
I
Up t o 40V (AC and DC) 3-phase AC200/220V ( t10%) 2A 0.0-1.0 second 6.0-7.0 Volt
I
I
PCB l
r - i r - i r - 1
I
Q
II II
TL
II II
I I I
L
/CHI~ W C R ; !
-----
CR3
r-----
I I
L - J
11
I1
L - J
11 II
L.-J
I I CRZ I L-----
Fig.1.6.1.1 Outside View of Weld Stick Detection Unit

APPENDIX 1-WELDING EQUIPMENTS A 1
-1
1.6.2 Functions of Weld Stick Detection U n 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 WCR CR2 ,CR3 T1
:Welding Voltage Detection Auxiliary Relay :Welding Current Detection Relay :Welding Voltage Detection S t a r t Relay :Weld Stick Detection Output, Detection Delay Timer
Weld Stick
--- ----
CR1
EFF
WCR
gFF
ON OFF
I I I I I I l l l l I I I 1 ~ 1 ~ I Ill1 I Ill1 <t mii""-I 1 1 1 1 I I I I I I I I I

I I
I I I I I I
I l l I l l I l l I l l I I I I I I I I ~ I I I l l I l l l < t
7-iI I l l I l l
I I I I I I I 1 I I l l l l l l 1 l I l l l l l l , l
I I I I l l
l
I I I I l l
l 0
I I I I I I I I I I I I I I I I I I I
I
l l I I l l l l l l l l I I I I I I l l l l l l l l l l I I I I l l l l l l
l l
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 l l
I
I
I I I
I
l l l
l
l l l
l
t:Timer Setting
Abnormal Output
Fig.1.6.2.1 Timing Chart of Weld Stick Detection
A1
-1 2
APPENDIX
1.6.3 Connecting Weld Stick Detection Unit

Referring t o Fig.l.6.3.1,follow the procedures of connection described below:
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 DETECTION UNIT Welding Power Supply (VRTP-300 S-5 etc.)
(1) Installing Unit

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 supplies.Refer to TABLE 1.6.3.1 to connect the cable. Install this connecting cable away from the welding cables. TABLE 1.6.3.1 Printed Boards to connect Welding Voltage Detection Cable Workpiece Welding Torch Jcik~elding Torch.WorkPiece Power Cable
Printed Board
P6768T CN8
P9943T
Electric Protection Connector WELD STICK DETECTION UNIT
%When to use AEP-300,disconnect the connector (CN2) of the welding 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.
APPENDIX 1-WELDING EOUIPMENTS A I- 1 3
WCR INPUT WCR OUTPUT Weld Stick Detection (Abnormal Output)
TABLE 1.6.3.2 Terminal Number t o conliect WCR Input Cable Welding Power Supply Type VRTP -300 P.C.B P6773Q TB CN12 N . and 8 o7 (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 N. o 59,60
Connected place
(4) Connecting Weld Stick Detection Cable

Install this connecting cable away from other connecting cables.
Fig.1.6.3.1 External connection of Weld Stick Detection Unit

A1
-1 4
APPENDIX
?-WELDING EQUIPMENTS
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) (2) Super Plasma D-8000(TRC-81)
WARNING
Turn O F F the switch of the distribution panel and confirm that power supply is shut off prior t o the connection of cables.
ELECTRIC SHOCK
@ D o not touch live electrical @Disconnect all power before installing or servicing. @Multiple sources of voltage may exist inside this
APPENDIX
1-WELDING EQUIPMENTS A 1 - 1 5
1.7.1 CO~/MAG/MIGWelding Power Supply

(1) Almega Auto 11 350/500 (CPVAS-350/500)
;g
Pswer
SaPeiv
Robot Contro
C N 3 C N 2 CNI
I
Man i nu
-)
B 3
Fig. 1.7.1.1 Connection of COJMAG Welding Power Supply, Almega Auto I 350/500 (CPVAS-350/500) [
A1
-16
APPENDIX
(2) Almega Fuzzy Auto 350 (CPDA-350)
Fig. 1.7.1.2 Connection of COJMAG Welding Power Supply, Almega Fuzzy Auto 350 (CPDA-350)
APPENDIX 1-WELDING EQUIPMENTS A 1- 1 7
(3) Inverter Auto 350TB (CPVB-350)
r-----l
Fower SGPP I Y CFVB-350

1 ding
W?
Welding
Interface
- - - .- --i Robot Control
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
Welding
Interface
CPVP-350/CPVPA-350
E5624
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 interface
J
TRA-350/500
E5624
R o b o t Control Unit
Fig.1.7.1.6 Connection of MIG Welding Power Supply, Transistor PULSE AUTO 350/500 (TRA-350/500)
APPENDIX 1-WELDING EQUIPMENTS A 1
-2
1.7.2 TIG Welding Power Supply

(1) Inverter ACCUTIG 300P (AVP-300), Inverter ARGO 300P (VRTP-3001,
Connect the Pemcte Box o f k'eIdi?l Pore? SuPoiY. rhsn uss Pulss chirrent.
L
psg
'Setis6
rn
bl R C Sntted bl Rtaote
R e m o t e Box
.- . . . . -
5 2 4 3 E G 3 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
. --
C1C L f r .-.
i
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
APPENDIX
1-WELDING EQUIPMENTS A 1 - 2 3
1.7.3 Air Plasma Cutting Power Supply

(I) Super Plasma D-12000 (TRC-120)
Cbttirip
PLv,fr 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
(2) Super Plasma D-8000(TRC-81)
Cr:
r z F o r ~ rS
T C 1 %
VCP
Fig. 1.7.3.2 Connection of Air Plasma Power Supply ,Super Plasma D-8000 (TRC-81)
APPENDIX 1-WELDING EQUIPMENTS A 1 - 2 5
Various kinds of welding machines are available from DAlHEN. DAlHEN produces and sells every kinds of welding machines.
ITEMS OF M A I N 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 P L A S M A CUTTING MACHINES ARC WELDING ROBOT CO, LASER EQUIPMENTS
Printed in Japan
DAlHENCorporation
5-1. M i n a m i Senrioka, Settsu, Osaka 566, J a p a n Phone : 06-317-2506 Facs : 06-317-2583
DAIHEN, Inc. DYNAMIC ROBOTICS DIVISION

761 CROSSROADS COURT, V A N D A L I A , O H 45377, U.S.A. Phone : (937)-454-9660 Facs : (937)-454-9661
DAIHEN EUROPE GmbH.

Bro~chhofstrasse 7, 40882 R a t i n g e n 1, F. R. G E R M A N Y Phone : 02102-444007-8 Facs : 02102-472100
DAIHEN ASIA (THAILAND) CO.,LTD.

60/86 M u 19, N a v a n a k o r n I n d u s t r i a l Estate Phase 3. K l o n g Nueng, K l o n g Luang, P a t h u m t h a n i 12120 Phone : 5292130-1.5293335-8 Facs : 5292132

HEN Controller Manual Corrections

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HEN Controller Manual Corrections

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June 1997

~stributor you do not understand I'

Fig.1.2.2.1 Inthe WARNING

____ Handle Braker

1. Connect connector CN16 of Teaching box to CN16

2.3.2 Table 2.4.2.1

(1) Operation Status

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

TABLE 0.0.0.1 List of Errata (213)

ry contact (Relay CR22) MRON DC24V

15-20 5th Item of

...be also displayed for & failures.)

. 2nd, 3rd, 5th Switch Box

6th and 8th items of

Motion control board or Servo Control board fi?ilur

Motion control board or Servo Control board

Reduce the voltage

Reduce the voltage Reduce the load

[Part] Memory lithium

7-4 7-6 7-10 7-18

7-34 7-36 7-38 7-40 Al-1

Ref No. @ in [Remarks] TABLE 1.1.1.1 Line 3

..... voltage range by the

..... voltage range by the

A. GENERAL INFORMATION AND SAFETY

SAFETY ALERT SYMBC)L AND SIGNAL WORDS

WARNING statements identify procedures o r practices which must be followed t o

avoid serious personal injury o r loss of life.

2 STAY ALERT when near robot.

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

SAFETY REQU l REMENTS FOR lNSTALLATlON (Figure D-I)

9 Provide proper Electrostatic Discharge(ESD) protection f o r electronic components in

10 M A I N T A I N SAFE INTEGRITY OF CELL A T A L L TIMES.

OPERATOR SAFETY REQUIREMENT

Location of Brake release pins

F. SAFETY PROCEDURES DURING TEACHING (PROGRAMMING)

1 Move robot slowly (see instruction manual "TEACHING"

G. SAFETY CHECKS AFTER ENTERING A PROGRAM

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

SAFETY PROCEDURES BEFORE AUTOMAT96 OPERATION

Have all unauthorized persons leave the robotic cell area.

I. SAFETY PROCEDURES DURING AUTOMATIC OPERATION

2 Be alert f o r jig movement initiated by an external control signal during operation.

5 Press an EMERGENCY STOP button if any problem occurs.

SAFETY PROCEDURES AT END OF WORK

2 Press an EMERGENCY STOP button t o turn off robot Servo power.

5 Allow robot and all equipment t o cool.

SAFETY PROCEDURES DURING INSPECTION, MA1NTEMANCEf

4 Determine in advance if the procedure(s) requires an energized robot.When power is

7 Provide proper Electrostatic Discharge (ESD) protection f o r circuit boards in Robot

ARC WELDING SAFETY PROCEDURES

Prevent electric shock as follows:

1) INSTALL A N D GROUND all equipment according t o national, regional, and local

2) DO NOT TOUCH live electrical parts.

3) WEAR DRY INSULATING GLOVES A N D CLOTHING; be sure gloves have no holes.

1) KEEP YOUR HEAD out of the fumes.

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

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

5) READ A N D FOLLOW WARNING LABELS on all containers of welding materials.

4) WEAR PROPER EAR PROTECTION,

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

1) ALWAYS WEAR PROPER PROTECTIVE HEADGEAR, such as safety helmet, when

(For Welding Power Supply-Manipulator) G H~ ................................................................... ~2527~