Fanuc R-J Controller Series Electrical Connection and Maintenance Manual

SYSTEM R-J Controller Series
Electrical Connection and

Maintenance Manual
MARMMTRBL02303E
This publication contains proprietary information of FANUC Robotics
North America, Inc. furnished for customer use only. No other uses are
authorized without the express written permission of FANUC Robotics
North America, Inc.
FANUC Robotics North America, Inc.
2000 South Adams Road
Auburn Hills, Michigan 483262800
The descriptions and specifications contained in this manual were in effect

at the time this manual was approved for printing. FANUC Robotics
North America, Inc, hereinafter referred to as FANUC Robotics, reserves
the right to discontinue models at any time or to change specifications or
design without notice and without incurring obligations.
FANUC Robotics manuals present descriptions, specifications, drawings,
schematics, bills of material, parts, connections and/or procedures for
installing, disassembling, connecting, operating and programming FANUC
Robotics products and/or systems. Such systems consist of robots,
extended axes, robot controllers, application software, the KAREL
programming language, INSIGHT vision equipment, and special tools.
FANUC Robotics recommends that only persons who have been trained in
one or more approved FANUC Robotics Training Course(s) be permitted
to install, operate, use, perform procedures on, repair, and/or maintain
FANUC Robotics products and/or systems and their respective
components. Approved training necessitates that the courses selected be
relevant to the type of system installed and application performed at the
customer site.
WARNING
This equipment generates, uses, and can radiate radio
frequency energy and if not installed and used in
accordance with the instruction manual, may cause
interference to radio communications. As temporarily
permitted by regulation, it has not been tested for
compliance with the limits for Class A computing devices
pursuant to subpart J of Part 15 of FCC Rules, which are
designed to provide reasonable protection against such
interference. Operation of the equipment in a residential
area is likely to cause interference, in which case the user,
at his own expense, will be required to take whatever
measure may be required to correct the interference.
FANUC Robotics conducts courses on its systems and products on a

regularly scheduled basis at the companys world headquarters in Auburn
Hills, Michigan. For additional information contact
FANUC Robotics North America, Inc.
Training and Documentation Department
2000 South Adams Road
Auburn Hills, Michigan 483262800
Tel: (810)3777234
FAX: (810)3777367 or (810)3777362
Copyright 1995, 1996 by FANUC Robotics North America, Inc.

All Rights Reserved
The information illustrated or contained herein is not to be reproduced,
copied, translated into another language, or transmitted in whole or in part
in any way without the prior written consent of FANUC Robotics North
America, Inc.
AccuStat, ArcTool, DispenseTool, FANUC LASER DRILL,
KAREL, INSIGHT, INSIGHT II, PaintTool, PaintWorks,
PalletTool, SOCKETS, SOFT PARTS SpotTool,
TorchMate, and YagTool, are Registered Trademarks of FANUC
Robotics.
FANUC Robotics reserves all proprietary rights, including but not limited
to trademark and trade name rights, in the following names:
AccuFlow
ARC Mate
ARC Mate Sr.
IntelliTrak
LaserTool
MotionParts
PaintWorks II
PalletMate
SureWeld
TurboMove
FANUC Robotics Hotline

For a PRODUCTION robot that is DOWN
call 24 hours a day, 7 days a week
810-377-7159
For all other Troubleshooting and Technical Support
contact your local distributor or call the Hotline
Monday Friday, 8:00 A.M. 5:00 P.M. Eastern Time
BEFORE YOU CALL please have your Maintenance and Troubleshooting manual, and the
following information, ready.
INFORMATION
DETAILS
Customer Information
Include
your companys name
callers name
phone number where caller can be reached, including
area code and extension
Robot type
(A, L, M, P, or S, & 3-digit number)
On the arm of the robot.
Controller style
(RA, RB, RC, RF, RG, RG2, RH, RJ, RJ2)
Ask your supervisor.
F Number
On the identification tag on the robot and controller, near

the cable connection.
Robot serial number

(if no F Number is available)
On the identification tag located near the cable connection.
Controller serial number

(if no F Number is available)
On the controller tag located on the doors.
Software edition and revision numbers
Shown on the CRT or teach pendant status screen during

the power-up sequence.
List of error messages
Include
error message number
message following error message number
any numbers following error message
List of diagnostic LEDs
Note the PCB where the LED is located and the LED name
or designation.
History of problem
Description of events leading up to the problem.
Application software
List
any application software running the system
the line number where the program halted
a description of what is happening on that line
MARMMTRBL02303E
Preface
vii
Purpose of this Manual
The SYSTEM R-J Controller Series Electrical Connection and

Maintenance Manual provides specific information regarding FANUC
Robotics electrical hardware. The information contained within the
manual has been arranged so that it can answer specific questions quickly
and accurately.
How to Use this

Manual
Use this table to locate specific information in the manual.

If you want to
Refer to
Find information about a specific topic
Table of Contents
Identify the components of the SYSTEM R-J

controller
Chapter 1, Overview
Use diagnostic and controller initialization

utilities
Chapter 2, Diagnostic
Screens
View status information on teach pendant

screens and using other indicators
Chapter 3, Lights and LEDs
Perform troubleshooting procedures and

identify specific errors
Chapter 4, Troubleshooting
Look at fuse information or replace a fuse
Chapter 5, Replacing a Fuse
Release the brakes
Chapter 6, Brake Release
Turn outputs on or off and simulate inputs
Chapter 7, Controlling I/O
Master the robot
Chapter 8, Mastering
Replace controller components
Chapter 9, Replacing
Components
Adjust switch settings and potentiometers

on printed circuit boards
Chapter 10, Board

Adjustments
Find controller connection schematics and

connector configurations
Chapter 11, Connections
Find connection information and

Input/Output specifications
Chapter 12, Complete Wiring

Diagrams
Find complete schematics of the controller

circuitry
Chapter 13, Prints
Use controller transportation and installation

information
Appendix A, Transportation
and Installation
viii
Conventions Used in
this Manual
PREFACE
MARMMTRBL02303E
This manual includes information essential to the safety of personnel,

equipment, software, and data. This information is indicated by headings
and boxes in the text.
WARNING
Information appearing under WARNING concerns the
protection of personnel. It is boxed and in bold type to set
it apart from other text.
CAUTION
Information appearing under CAUTION concerns the protection
of equipment, software, and data. It is boxed to set it apart
from other text.
NOTE Information appearing next to NOTE concerns related information

or useful hints.
MARMMTRBL02303E
Table of Contents
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ix
vii
xxv
Chapter 1
OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11
1.1 BACKPLANE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.2 MAIN CPU PRINTED CIRCUIT BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.3 AXIS CONTROL PRINTED CIRCUIT BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.4 POWER SUPPLY UNIT PRINTED CIRCUIT BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.5 EMERGENCY STOP CONTROL PRINTED CIRCUIT BOARD . . . . . . . . . . . . . . . . . . . . . .
1.6 SERVO AMPLIFIERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.7 DCR AND DBR UNIT A05B-2302-C080 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.8 DISCHARGE UNIT A05B-2312-C100 FOR M-500 A05B-2313-C100 FOR S-900 . . . . . . .
1.9 MULTI-TAP TRANSFORMER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.10 INTERFACE DEVICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.10.1 Modular I/O Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.10.2 Process I/O Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.10.3 ABRIO and Genius I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.11 FUSED FLANGE DISCONNECT AND CIRCUIT BREAKER . . . . . . . . . . . . . . . . . . . . . . .
1.12 USER TRANSFORMER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.13 OPERATOR PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.14 TEACH PENDANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.15 HEAT EXCHANGE AND FANS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
17
18
111
112
113
114
121
122
123
126
127
131
133
134
137
137
139
141
Chapter 2
DIAGNOSTIC SCREENS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
21
2.1 SAFETY SIGNAL STATUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.2 POSITION STATUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3 ROBOT AXES STATUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.4 ALARM LOG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.5 VERSION IDENTIFICATION STATUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.6 MEMORY STATUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
22
24
27
28
210
213
Chapter 3
LIGHTS AND LEDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
31
3.1 TEACH PENDANT DIAGNOSTIC LEDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2 OPERATOR PANEL DIAGNOSTIC LEDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3 CIRCUIT BOARD DIAGNOSTIC LEDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3.1 Emergency Control Board (EMG) Diagnostic LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
32
33
34
36
TABLE OF CONTENTS
x
3.3.2
3.3.3
3.3.4
3.3.5
3.3.6
3.3.7
3.3.8
3.3.9
MARMMTRBL02303E
Power Supply Unit (PSU) Diagnostic LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Axis Control Board Diagnostic LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main CPU Board Diagnostic LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Servo Amplifier Diagnostic LED (7-Segment Display) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Modular I/O LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
(Optional) Process I/O Board Diagnostic LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
R-H MAP INTERFACE LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
R-H ABRIO LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
37
38
312
313
314
315
316
317
Chapter 4
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
41
4.1 CLASS 1 FAULT TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.2 CLASS 2 FAULTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3 CLASS 3 FAULT TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3.1 SRVO-001 ER_SVAL1 Operator Panel EStop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3.2 SRVO-002 ER_SVAL1 Teach Pendant Estop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3.3 SRVO-003 ER_SVAL1 Deadman switch released . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3.4 SRVO-004 ER_SVAL1 Fence open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3.5 SRVO-005 ER_SVAL1 Robot Overtravel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3.6 SRVO-006 ER_SVAL1 Hand Broken . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3.7 SRVO-007 ER_SVAL1 External emergency stops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3.8 SRVO-008 ER_SVAL Brake fuse blown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3.9 SRVO-011 ER_SVAL1 TP Released While Enabled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3.10 SRVO-012 ER_SVAL1 Power Failure Recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3.11 SRVO-014 Fan Motor Abnormal (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3.12 SRVO-015 ER_SVAL1 System Over Heat (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . .
4.3.13 SRVO-021 ER_SVAL1 SRDY off (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3.14 SRVO-022 ER_SVAL1 SRDY on (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3.15 SRVO-023 ER_SVAL1 Stop Error Excess (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . .
4.3.16 SRVO-024 ER_SVAL1 Move Error Excess (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . .
4.3.17 SRVO-026 ER_WARN Motor Speed Limit (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . .
4.3.18 SRVO-027 ER_WARN Robot Not Mastered (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . .
4.3.19 SRVO-033 ER_WARN Robot Not Calibrated (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . .
4.3.20 SRVO-035 ER_WARN Joint Speed Limit (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . .
4.3.21 SRVO-036 Imposition Time Over (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3.22 SRVO-037 ER_SVAL1 IMSTP Input (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3.23 SRVO-038 PULSE MISMATCH (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3.24 SRVO-042 ER_SVAL2 MCAL Alarm (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3.25 SRVO-043 ER_SVAL2 DCAL Alarm (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3.26 SRVO-044 ER_SVAL2 HVAL Alarm (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3.27 SRVO-045 ER_SVAL2 HCAL Alarm (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . . . . .
42
416
418
419
422
424
426
428
430
432
436
440
440
440
442
444
444
445
445
445
445
445
446
446
446
447
447
448
449
450
MARMMTRBL02303E
4.3.28
4.3.29
4.3.30
4.3.31
4.3.32
4.3.33
4.3.34
4.3.35
4.3.36
4.3.37
4.3.38
4.3.39
4.3.40
4.3.41
4.3.42
4.3.43
4.3.44
4.3.45
4.3.46
4.3.47
4.3.48
4.3.49
4.3.50
4.3.51
4.3.52
4.3.53
4.3.54
4.3.55
4.3.56
TABLE OF CONTENTS
SRVO-046 ER_SVAL2 OVC Alarm (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SRVO-047 ER_SVAL2 LVAL Alarm (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SRVO-049 ER_SVAL2 OHAL1 Alarm (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . . . .
SRVO-050 ER_SVAL1 CLALM Alarm (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . . . .
SRVO-051 ER_SVAL2 CUER Alarm (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . . . . .
SRVO-061 ER_SVAL2 CKAL Alarm (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . . . . .
SRVO-062 ER_SVAL2 BZAL Alarm (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SRVO-063 ER_SVAL2 RCAL Alarm (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SRVO-064 ER_SVAL2 PHAL Alarm (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SRVO-065 ER_WARN BLAL Alarm (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SRVO-066 ER_SVAL2 CSAL Alarm (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SRVO-067 ER_SVAL2 OHAL2 Alarm (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . . . .
SRVO-068 ER_SVAL2 DTERR Alarm (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . . . .
SRVO-069 ER_SVAL2 CRCERR Alarm (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . . .
SRVO-070 ER_SVAL2 STBERR Alarm (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . . .
SRVO-071 ER_SVAL2 SPHAL Alarm (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . . . .
SRVO-081 ER_WARN EROFL Alarm (Track encoder:n) . . . . . . . . . . . . . . . . . . . . . . . . . .
SRVO-082 ER_WARN DAL Alarm (Track encoder:n) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SRVO-083 ER_WARN CKAL Alarm (Track encoder:n) . . . . . . . . . . . . . . . . . . . . . . . . . . .
SRVO-084 ER_WARN BZAL Alarm (Track encoder:n) . . . . . . . . . . . . . . . . . . . . . . . . . . .
SRVO-085 ER_WARN RCAL Alarm (Track encoder:n) . . . . . . . . . . . . . . . . . . . . . . . . . . .
SRVO-086 ER_WARN PHAL Alarm (Track encoder:n) . . . . . . . . . . . . . . . . . . . . . . . . . . .
SRVO-087 ER_WARN BLAL Alarm (Track encoder:n) . . . . . . . . . . . . . . . . . . . . . . . . . . .
SRVO-088 ER_WARN CSAL Alarm (Track encoder:n) . . . . . . . . . . . . . . . . . . . . . . . . . . .
SRVO-089 ER_WARN OHAL2 Alarm (Track encoder:n) . . . . . . . . . . . . . . . . . . . . . . . . . .
SRVO-090 ER_WARN DTERR Alarm (Track encoder:n) . . . . . . . . . . . . . . . . . . . . . . . . . .
SRVO-091 ER_WARN CRCERR Alarm (Track encoder:n) . . . . . . . . . . . . . . . . . . . . . . . .
SRVO-092 ER_WARN STBERR Alarm (Track encoder:n) . . . . . . . . . . . . . . . . . . . . . . . .
SRVO-093 ER_WARN SPHAL Alarm (Track encoder:n) . . . . . . . . . . . . . . . . . . . . . . . . . .
xi
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452
453
453
454
454
455
456
456
456
457
457
458
458
459
459
459
460
460
460
460
460
461
461
461
461
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461
Chapter 5
REPLACING A FUSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
51
5.1 MULTI-TAP TRANSFORMER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.2 SERVO AMPLIFIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.3 POWER SUPPLY UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.4 EMERGENCY STOP CONTROL PC BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.5 PROCESS INPUT/OUTPUT PC BOARDS AA, AB, CA, CB, AND DA . . . . . . . . . . . . . . . .
5.6 PROCESS INPUT/OUTPUT PC BOARDS BA AND BB . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.7 MODULAR I/O UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.8 AC OUTLET UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
51
53
54
55
56
57
58
59
TABLE OF CONTENTS
xii
MARMMTRBL02303E
Chapter 6
BRAKE RELEASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
61
Chapter 7
CONTROLLING I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
71
7.1 FORCING OUTPUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.2 SIMULATING INPUTS AND OUTPUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.3 SOP I/O STATUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
72
74
75
Chapter 8
MASTERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
81
8.1 MASTERING TO A FIXTURE (FIXTURE POSITION MASTER) . . . . . . . . . . . . . . . . . . . . .

8.2 ZERO DEGREE MASTERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.3 SINGLE AXIS MASTERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.4 QUICK MASTERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
82
85
88
811
Chapter 9
REPLACING COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
91
9.1 REPLACING THE BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.2 REPLACING A RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.3 REPLACING A PRINTED CIRCUIT BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.3.1 Replacing the Backplane Printed Circuit Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.3.2 Replacing a Component on the Backplane Printed Circuit Board . . . . . . . . . . . . . . . . . . . . .
9.4 REPLACING A MODULE ON THE MAIN CPU OR AXIS CONTROL BOARD . . . . . . . . .
9.5 REPLACING THE PROCESS INPUT/OUTPUT PRINTED CIRCUIT BOARD
AA, AB, BA OR BB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.6 REPLACING COMPONENTS OF THE MODULAR INPUT/OUTPUT UNIT
REFER TO CHAPTER 1 FOR PART NUMBERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.6.1 Replacing the Base Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.6.2 Replacing a Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.7 REPLACING THE MULTI-TAP TRANSFORMER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.8 REPLACING A SERVO AMPLIFIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.9 REPLACING THE OPERATOR PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.10 REPLACING THE FAN MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.11 REPLACING THE DISCHARGE RESISTOR (DCR) AND DYNAMIC BRAKE (DBR)
UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.12 REPLACING THE REGENERATIVE DISCHARGE UNIT . . . . . . . . . . . . . . . . . . . . . . . . .
9.13 REPLACING THE OPTIONAL WARNING LIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.14 REPLACING A SERIAL PULSE CODER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
92
94
95
96
97
98
911
912
912
914
916
917
918
919
921
923
924
925
MARMMTRBL02303E
TABLE OF CONTENTS
xiii
Chapter 10
BOARD ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
101
10.1 AXIS CONTROL BOARD JUMPERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.2 PROCESS I/O BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.2.1 Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.2.2 Potentiometers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.2.3 Output Drivers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.3 BUILTIN CRT/KB UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.4 EMG BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
101
102
105
106
107
108
1010
Chapter 11
CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
111
11.1 MECHANICAL CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11.1.1 Robot Connection Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.1.2 Connecting the Input Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.1.3 Connecting the External Power Supply ON/OFF Switch . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.1.4 External Emergency Stop Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.2 PERIPHERAL DEVICE, ARC WELDING, AND END EFFECTOR INTERFACES . . . . . .
11.2.1 Peripheral Device Interface Combination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.2.2 Process I/O Printed Circuit Board AA or AB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.2.3 Process I/O Printed Circuit Board BA or BB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.2.4 Process I/O Printed Circuit Board CA or CB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.2.5 Process I/O Printed Circuit Board DA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.2.6 Process I/O Printed Circuit Board with the Modular I/O Unit . . . . . . . . . . . . . . . . . . . . . . .
11.2.7 Two or More Process I/O Boards with the Modular I/O Unit . . . . . . . . . . . . . . . . . . . . . . . .
11.2.8 Peripheral Device and Control Unit Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.2.9 Mechanical Unit and End Effector Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.2.10 Control Unit and Welder Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.2.11 Peripheral Device Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.2.12 End Effector Control Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.2.13 Arc Welding Interface Process I/O AA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.2.14 Modular I/O Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.2.15 Modular I/O Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.3 SPECIFICATIONS OF THE CABLES USED FOR PERIPHERAL DEVICES
AND WELDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.3.1 Peripheral Device Interface A Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.3.2 Peripheral Device Interface B Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.3.3 Arc Welding Interface Connection Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.4 CABLE CONNECTION FOR THE PERIPHERAL DEVICES, END EFFECTORS,
AND ARC WELDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.4.1 Peripheral Device Connection Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
112
114
118
1110
1111
1113
1115
1116
1117
1118
1119
1120
1121
1122
1139
1142
1146
1148
1149
1151
1155
1165
1165
1165
1166
1167
1167
TABLE OF CONTENTS
xiv
11.4.2
11.4.3
11.4.4
11.4.5
MARMMTRBL02303E
Arc Welding Interface Connection Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Peripheral Device Cable Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
End Effector Cable Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Recommended Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1168
1169
1172
1174
Chapter 12
COMPLETE WIRING DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
121
Chapter 13
PRINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
131
Appendix A
TRANSPORTATION AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A1
A.1 TRANSPORTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A.2 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A.2.1 Installation Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A.2.2 Assembly During Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A.2.3 Installation Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A.2.4 Adjustment and Checks at Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A.2.5 Resetting Overtravel and Emergency Stop at Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .
A1
A2
A2
A3
A4
A5
A6
List of Procedures
Procedure 21
Procedure 22
Procedure 23
Procedure 24
Procedure 25
Procedure 26
Procedure 61
Procedure 71
Procedure 72
Procedure 73
Procedure 81
Procedure 82
Procedure 83
Procedure 84
Procedure 85
Procedure 91
Procedure 92
Procedure 93
Procedure 94
Displaying Safety Signal Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Displaying Position Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Displaying the Axis Status Pulse Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Displaying the Alarm Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Displaying the Version Identification Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Displaying Memory Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Releasing the Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Forcing Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Simulating and Unsimulating Inputs and Outputs . . . . . . . . . . . . . . . . . . . . . . . . .
Displaying and Forcing SOP I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mastering to a Fixture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mastering to Zero Degrees . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mastering a Single Axis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Recording the Quick Master Reference Position . . . . . . . . . . . . . . . . . . . . . . . . . .
Quick Mastering the Robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing the Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing the SPC Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing the Backplane Printed Circuit Board . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing a Component on the Backplane Printed Circuit Board . . . . . . . . . . . .
23
25
27
29
211
213
61
72
74
76
82
85
88
811
813
92
93
96
97
MARMMTRBL02303E
Procedure 95
Procedure 96
Procedure 97
Procedure 98
Procedure 99
Procedure 910
Procedure 911
Procedure 912
Procedure 913
Procedure 914
Procedure 915
TABLE OF CONTENTS
Replacing the Base Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing the Interface Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing an I/O Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing the Multi-Tap Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing a Servo Amplifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing the Operator Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing the Fan Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing the Discharge Resistor (DCR) and Dynamic Brake Resistor (DBR) unit
Replacing the Regenerative Discharge Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing the Optional Warning Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing a Serial Pulse Coder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
xv
912
914
914
916
917
918
919
921
923
924
925
List of Figures
Figure 11. Cabinet Exterior, B-Size Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 12. Cabinet Exterior, B-Size Controller with Regenerative Discharge Unit . . . . . . . . . . .
Figure 13. Cabinet Exterior, B-Size Controller with Optional Side Cabinet . . . . . . . . . . . . . . . . .
Figure 14. Cabinet Exterior, C-Size Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 15. Cabinet Interior, B-Size Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 16. Cabinet Interior, C-Size Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 17. Backplane with R-H Style Extended Backplane . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 18. Main CPU Board Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 19. Axis Control Board Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 110. Power Supply Unit Printed Circuit Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 111. Emergency Stop Control Printed Circuit Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 112. Servo Amplifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 113. Mounting Locations of Servo Amplifiers Robot with 6-amplifiers . . . . . . . . . . . .
Figure 114. Mounting Locations of Servo Amplifiers for the A-510 . . . . . . . . . . . . . . . . . . . . . .
Figure 115. Mounting Locations of Servo Amplifiers for the Arc Mate/ Arc Mate 100/S-6,
Arc Mate Sr./S-5/S-10 and L-1000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 116. Mounting Locations of Servo Amplifiers for the S-500/S-700 and M-400 . . . . . . . .
Figure 117. Mounting Locations of Servo Amplifiers for the S-420 and S-800 . . . . . . . . . . . . . .
Figure 118. Mounting Locations of Servo Amplifiers for the S-420 and the DCR & DBR Unit .
Figure 119. Mounting Locations of Servo Amplifiers for the M-500 . . . . . . . . . . . . . . . . . . . . . .
Figure 120. Mounting Locations of Servo Amplifiers for the S-900 . . . . . . . . . . . . . . . . . . . . . . .
Figure 121. DCR and DBR Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 122. Discharge Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 123. Multi-Tap Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 124. Multi-Tap Transformer A80L00260013#A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 125. Modular I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 126. Process I/O Printed Circuit Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 127. Fused Flange Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 128. Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 129. User Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12
12
13
14
15
16
17
19
111
112
113
114
115
116
116
117
117
118
118
119
121
122
124
125
127
131
135
135
137
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Figure 130. Operator Panel, B-Size Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 131. Operator Panel, C-Size Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 132. Teach Pendant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 133. Heat Exchange System, B-Size Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 134. Heat Exchange System, C-Size Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 21. Default PowerUp Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 22. Alarm Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 31. Teach Pendant LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 32. Operator Panel LEDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 33. Circuit Board Diagnostic LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 34. Emergency Control Board (EMG) Diagnostic LEDs . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 35. Power Supply Unit (PSU) Diagnostic LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 36. Axis Control Board Diagnostic LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 37. Main CPU Board Diagnostic LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 38. Modular I/O LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 39. Process I/O Board Diagnostic LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 310. RH MAP LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 311. R-H ABRIO LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 41. 24 Volt (24E) Power Distribution Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 42. 24 Volt (24V) Power Distribution Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 43. Operator Panel E-Stop Circuitry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 44. Teach Pendant E-Stop Circuitry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 45. Deadman Switch Circuitry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 46. Fence Open Circuitry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 47. Robot Overtravel Circuitry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 48. Hand Broken Circuitry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 49. External Emergency Stop Circuitry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 410. Brake Fuse Blown Circuitry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 411. Backplane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 412. System Over Heat Circuitry Drawing 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 413. System Over Heat Circuitry Drawing 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 51. Replacing a Fuse of the Transformer Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 52. Replacing the Fuse of a Servo Amplifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 53. Replacing a Fuse of the Power Supply Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 54. Replacing the Fuse on the Emergency Stop Control PC Board . . . . . . . . . . . . . . . . . .
Figure 55. Replacing the Fuse of the Process Input/Output PC Board AA, AB, CA, CB, or DA
Figure 56. Replacing the Fuse of the Process Input/Output PC Board BA or BB . . . . . . . . . . . .
Figure 57. Replacing the Fuse of the AC Outlet Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 91. Replacing the Battery (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 92. Replacing a Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 93. Replacing the Backplane Printed Circuit Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 94. Replacing Printed Circuit Boards on the Backplane Printed Circuit Board . . . . . . . . .
138
138
140
141
142
21
28
32
33
35
36
37
38
312
314
315
316
317
410
413
421
423
425
427
429
431
435
439
441
442
443
52
53
54
55
56
57
59
92
94
96
97
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Figure 95. Moving the Latches on the End of the Module Socket . . . . . . . . . . . . . . . . . . . . . . . .
98
Figure 96. Installing a New Module at an Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
98
Figure 97. Pushing in the Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
99
Figure 98. Mounting Locations of the Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
910
Figure 99. Replacing the Process Input/Output Printed Circuit Board AA, AB, BA, or BB . . . .
911
Figure 910. Replacing the Base Unit of the Modular Input/Output Unit . . . . . . . . . . . . . . . . . . .
913
Figure 911. Removing and Replacing a Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
915
Figure 912. Removing and Replacing a Terminal Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
915
Figure 913. Replacing the Multi-Tap Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
916
Figure 914. Replacing a Servo Amplifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
917
Figure 915. Replacing the Operator Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
918
Figure 916. Replacing the Fan Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
920
Figure 917. Discharge Resistor (DCR) and Dynamic Brake Resistor (DBR) Unit . . . . . . . . . . . .
922
Figure 918. Replacing the Regenerative Discharge Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
923
Figure 919. Removing the Pulse Coder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
926
Figure 101. Axis Control Board Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
101
Figure 102. Process I/O Board AA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
102
Figure 103. Process I/O Board AB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
102
Figure 104. Process I/O Board BA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
103
Figure 105. Process I/O Board BB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
103
Figure 106. Process I/O Board CA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
104
Figure 107. Process I/O Board CB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
104
Figure 108. Process I/O Board DA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
105
Figure 109. Front View Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
109
Figure 1010. Jumper Setting CRT/KB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
109
Figure 1011. EMG board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1010
Figure 111. Block Diagram of Electrical Interface Connection . . . . . . . . . . . . . . . . . . . . . . . . . . .
111
Figure 112. Mechanical Connection Diagram for S-420, S-500, S-700, S-800, and M-400 . . . . .
112
Figure 113. Mechanical Connection Diagram for ARC Mate, ARC Mate 100/S-6, ARC Mate Sr.,
A-510, and L-1000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
112
Figure 114. Mechanical Connection Diagram, Common Part . . . . . . . . . . . . . . . . . . . . . . . . . . . .
113
Figure 115. Connection to Servo Amplifiers and Mechanical Unit for S-420 . . . . . . . . . . . . . . . .
114
Figure 116. Connection to Servo Amplifiers and Mechanical Unit for S-420, S-420D, ARC Mate,
S-5, ARC Mate 100/S-6, ARC Mate Sr., S-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
114
115
115
116
Figure 1110. Connection to Servo Amplifiers and Mechanical Unit for A-510 . . . . . . . . . . . . . .
116
Figure 1111. Connection to Servo Amplifiers and Mechanical Unit for M-400 and M-500 . . . . .
117
Figure 1112. Connection to Servo Amplifiers and Mechanical Unit for L-1000 . . . . . . . . . . . . .
117
Figure 1113. Input Power Supply Connection, Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . .
119
Figure 1114. Input Power Supply Connection, Fused Flange Disconnect . . . . . . . . . . . . . . . . . . .
119
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Figure 1115. External Power Supply ON/OFF Switch Connection . . . . . . . . . . . . . . . . . . . . . . . .

Figure 1116. External Emergency Stop Output Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1117. External Emergency Stop Input Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1118. Locations of Peripheral Device Interfaces, B-Size Controller . . . . . . . . . . . . . . . . .
Figure 1119. Locations of Peripheral Devices, C-Size Controller . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1120. Peripheral Device Interface Combination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1121. Process I/O Printed Circuit Board AA or AB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1122. Process I/O Printed Circuit Board BA or BB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1123. Process I/O Printed Circuit Board CA or CB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1124. Process I/O Printed Circuit Board DA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1125. Process I/O Printed Circuit Board with Modular I/O . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1126. Two or More Process I/O Boards and the I/O Unit (Model A) . . . . . . . . . . . . . . . .
Figure 1127. Peripheral Device and Control Unit Connection -A1/A2 . . . . . . . . . . . . . . . . . . . . .
Figure 1128. Peripheral Device and Control Unit Connection -A3/A4 . . . . . . . . . . . . . . . . . . . . .
Figure 1129. Peripheral Device and Control Unit Connection - B1/B2 . . . . . . . . . . . . . . . . . . . .
Figure 1130. Peripheral Device and Control Unit Connection -C1 . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1131. Peripheral Device Interface Control for A1, A2, A3, and A4 . . . . . . . . . . . . . . . . .
Figure 1132. Peripheral Device Interface for A1, A2, A3, and A4 . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1133. Peripheral Device Control Interface B1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1134. Peripheral Device Control Interface B2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1135. Peripheral Device Control Interface C1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1141. Mechanical Unit and End Effector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1142. End Effector Pin Configuration Arc Mate/S-5, Arc Mate Sr/S-10, S-420, S-500,
S-700, S-800, S-900, M-400 and M-500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1143. End Effector Pin Configuration Arc Mate 100/S-6 . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1144. End Effector Pin Configuration A-510 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1145. End Effector Pin Configuration L-1000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1146. Control Unit and Welder Connection - CRW1/CRW2 . . . . . . . . . . . . . . . . . . . . . . .
Figure 1147. Control Unit and Welder Connection - CRW1 Analog Signal Assignment . . . . . . .
Figure 1148. Control Unit and Welder Connection - CRW1 Digital Signal Assignment . . . . . . .
Figure 1149. Control Unit and Welder Connection - CRW2 Analog Signal Assignment . . . . . . .
Figure 1150. Peripheral Device Interface A Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1151. Peripheral Device Interface B Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1152. Arc Welder Connection Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1153. Peripheral Device Cable Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1154. Arc Welder Cable Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1155. Peripheral Device Cable Connector for A and B(Honda Tsushin Kogyo) . . . . . . . .
1110
1111
1112
1113
1114
1115
1116
1117
1118
1119
1120
1121
1125
1126
1127
1128
1129
1130
1131
1132
1133
1134
1135
1136
1137
1138
1139
1140
1140
1141
1141
1142
1143
1144
1145
1165
1165
1166
1167
1168
1169
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Figure 1156. Peripheral Device Connector for A and B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 1157. Peripheral Device Interface Cable C Connector (Phoenix Contact) . . . . . . . . . . . .
Figure 1158. Elbow Type Connector S-5, S-10, S-420, S-500, S-700, S-800, M-400, M-500,
ARC Mate, ARC Mate 100/S-6, ARC Mate Sr. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1159. Connector L-1000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 121. Internal Connection Diagram S-420, S-800 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 122. Internal Connection Diagram S420 with three Servo Amplifiers, S420D) . . . . . . .
Figure 123. Internal Connection Diagram ARC Mate, ARC Mate Sr., ARC Mate 100/S-6, S-5,
and S-10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 124. Internal Connection Diagram S-500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 125. Internal Connection Diagram S-700 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 126. Internal Connection Diagram S900 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 127. Internal Connection Diagram A-510 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 128. Internal Connection Diagram M-400 (5-axes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 129. Internal Connection Diagram M400 (4 axes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1210. Internal Connection Diagram M500 (5 axes) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1211. Internal Connection Diagram M500 (4 axes) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1212. Internal Connection Diagram L-1000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1213. Internal Connection Diagram Emergency Stop Control PCB . . . . . . . . . . . . . .
Figure 1214. Internal Connection Diagram Power Supply Unit . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1215. Internal Connection Diagram - Main CPU; Axis Control Board . . . . . . . . . . . . . . .
Figure 1216. Internal Connection Diagram Servo Amplifier Connection S-420, ARC Mate/S-5,
ARC Mate Sr./S-10, ARC Mate 100/S-6, S-500, S-700, and S-800 . . . . . . . . . . . . . .
Figure 1217. Internal Connection Diagram Servo Amplifier Connection A-510, L-1000,
and M-400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1218. Internal Connection Diagram Servo Amplifier Connection S-900 and M-500 . . .
Figure 1219. Internal Connection Diagram Modular I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1220. Internal Connection Diagram Teach Pendant . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1221. Internal Connection Diagram Main CPU Interface . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1222. Internal Connection Diagram Axis Control Board Interface . . . . . . . . . . . . . . . . .
Figure 1223. Internal Connection Diagram ARC Mate/S-5, ARC Mate Sr./S-10,
ARC Mate 100/S-6, S-420, S-500 and S-800 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1224. Internal Connection Diagram S-700 and A-510 . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1225. Internal Connection Diagram M-400 and L-1000 . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1226. Internal Connection Diagram - M400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1227. External Connection Diagram M-500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1228. External Connection Diagram S-900 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1229. External Connection Diagram Process I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1230. External Connection Diagram Process I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1231. External Connection Diagram Teach Pendant . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1232. Motor Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 131. R-J Control Signal and Power Distribution Overview . . . . . . . . . . . . . . . . . . . . . . . .
Figure 132. Main AC Power Distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Figure 133. AC Power Distribution With Optional 115VAC Secondary . . . . . . . . . . . . . . . . . . . .

Figure 134. Power Supply Unit (PSU) With Power ON/OFF Circuit . . . . . . . . . . . . . . . . . . . . . .
Figure 135. EMG Stop & Brake Connection 100 VAC E-Stop Circuit 100 VDC Brake
Circuit (1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 136. EMG Stop and Brake Connection 100 VDC Brake Circuit (2 of 2) . . . . . . . . . . . . .
Figure 137. EMG Stop and Brake Connection 24 VDC E-Stop Circuit (1 of 2) . . . . . . . . . . . . .
Figure 138. EMG Stop and Brake Connection 24VDC E-Stop Circuit (2 of 2) Modular
I/O Power Distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 139. Overheat and Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1310. Single Axis Servo Amplifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1311. Dual Axis Servo Amplifier (With Dynamic Brakes) . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1312. Dual Axis Servo Amplifier (Without Dynamic Brakes) . . . . . . . . . . . . . . . . . . . . . .
Figure 1313. Discharge Resistor and Dynamic Brake Unit (For Amp With No Dynamic Brake)
Figure 1314. LSI Module All Servo Amplifiers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1315. DV-M Module Servo Amplifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1316. ALM-M Module Servo Amplifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 1317. Teach Pendant Power And Data Signal Interconnection . . . . . . . . . . . . . . . . . . . . .
Figure A1. Transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure A2. Installation Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure A3. Assembly During Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure A4. Peripheral Device Interface Processing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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11. Main CPU Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12. Axis Control Board Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13. Servo Amplifiers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14. Multi-Tap Transformer Part Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15. Selecting Transformer Taps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16. Selecting Transformer Taps for Transformer A80L00260013#A . . . . . . . . . . . . . .
17. Digital Input Module Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
18. Digital Output Module Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
19. I/O Module Part Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
110. Process I/O Board Part Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
111. Circuit Breaker, B-Size Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
112. Circuit Breaker and Fused Flange Disconnect Switch, C-Size Cabinet . . . . . . . . . .
113. Part Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
114. Teach Pendant Part Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
21. Safety Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
22. Axis Status Pulse Screen Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
23. Version Identification Status Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24. Memory Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
31. Teach Pendant Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Standard Operator Panel C-Size Controller Status Indicators . . . . . . . . . . . . . . . . . . .

Emergency Control Board (EMG) Diagnostic LEDs . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting Axis Control Board Diagnostic LEDs . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting Main CPU Board Diagnostic LEDs . . . . . . . . . . . . . . . . . . . . . . . . .
Servo Amplifier LED Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Modular I/O LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Process I/O Board Diagnostic LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
R-H MAP LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
R-H ABRIO LED Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting Procedure 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Class 2 Faults Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SRVO-001 Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SRVO-002 Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SRVO-003 Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SRVO-005 Troubleshooting Procedure 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SRVO-005 Troubleshooting Procedure 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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434. SRVO-062 Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

51. Multi-Tap Transformer Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
52. Power supply unit for four-slot backplane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
53. Power supply unit for six-slot backplane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
54. Modular I/O Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
71. Standard Operator Panel Input Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
72. Standard Operator Panel Output Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
81. Mastering Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
91. Relay Part Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
101. Axis Control Board Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
102. Process I/O Board Jumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
103. Process I/O Board Potentiometer Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
104. Output Drivers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
105. SBK Jumper Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
111. Example of Leakage Current Circuit Breaker for Inverters . . . . . . . . . . . . . . . . . . .
112. External Emergency Stop Output Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
113. External Emergency Stop Input Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
114. Peripheral Device Interface Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
115. Process I/O Printed Circuit Board AA or AB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
116. Process I/O Printed Circuit Board BA or BB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
117. Process I/O Printed Circuit Board CA or CB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
118. Process I/O Printed Circuit Board DA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
119. Process I/O Printed Circuit Board DA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1110. Two or More Process I/O Boards and the I/O Unit (Model A) . . . . . . . . . . . . . . . .
1111. Process I/O Printed Circuit Board Signals, DI Signals . . . . . . . . . . . . . . . . . . . . . .
1112. Process I/O Printed Circuit Board Signals, DO Signals . . . . . . . . . . . . . . . . . . . . .
1113. Applicable Process I/O Printed Circuit Board - A1/A2 . . . . . . . . . . . . . . . . . . . . .
1114. Applicable Process I/O Printed Circuit Board - A3/A4 . . . . . . . . . . . . . . . . . . . . .
1115. Applicable Process I/O Printed Circuit Board - B1/B2 . . . . . . . . . . . . . . . . . . . . . .
1116. Applicable Process I/O Printed Circuit Board - C1 . . . . . . . . . . . . . . . . . . . . . . . .
1117. Applicable Process I/O Printed Circuit Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1118. Peripheral Device Interface Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1119. End Effector Control Interface Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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1122
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1125
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1120. Arc Welding Interface Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1121. Input Modules AID32A and AID32B, Nonisolated . . . . . . . . . . . . . . . . . . . . . . .
1122. Input Modules AID16C and AID16D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1123. Input Modules AID32E and AID32F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1124. Input Module AIA16G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1125. Output Module AOD32A, Non-isolated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1126. Output Modules AOD08C and AOD08D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1127. Output Modules AOD16C and AOD16D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1128. Output Module AOD32C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1129. Output Module AOD32D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1130. Output Modules AOA05E and AOA08E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1131. Output Module AOA12F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1132. Output Modules AOR08G and AOR16G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1133. Output Module ADA02A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1134. Analog Input Module AAD04A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1135. Peripheral Device Cable Connector for A and B . . . . . . . . . . . . . . . . . . . . . . . . . .
1136. Symbols Used in Figure 1155 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1137. Peripheral Device Cable Connector for A and B . . . . . . . . . . . . . . . . . . . . . . . . . .
1138. Symbols Used in Figure 1156 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1139. Peripheral Device Interface Cable C Connector Specifications . . . . . . . . . . . . . . .
1140. Connection Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1141. Recommended Cable for Peripheral Device Connection . . . . . . . . . . . . . . . . . . . .
1142. Recommended Cable for End Effector Connection . . . . . . . . . . . . . . . . . . . . . . . .
A1. Installation Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A2. Adjustment and Checks at Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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SAFETY
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Safety
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FANUC Robotics is not and does not represent itself as an expert in safety
systems, safety equipment, or the specific safety aspects of your company
and/or its work force. It is the responsibility of the owner, employer, or
user to take all necessary steps to guarantee the safety of all personnel in
the workplace.
The appropriate level of safety for your application and installation can
best be determined by safety system professionals. FANUC Robotics
therefore, recommends that each customer consult with such professionals
in order to provide a workplace that allows for the safe application, use,
and operation of FANUC Robotic systems.
Additionally, as the owner, employer, or user of a robotic system, it is your
responsibility to arrange for the training of the operator of a robot system
to recognize and respond to known hazards associated with your robotic
system and to be aware of the recommended operating procedures for your
particular application and robot installation.
FANUC Robotics therefore, recommends that all personnel who intend to
operate, program, repair, or otherwise use the robotics system be trained in
an approved FANUC Robotics training course and become familiar with
the proper operation of the system. Persons responsible for programming
the systemincluding the design, implementation, and debugging of
application programsmust be familiar with the recommended
programming procedures for your application and robot installation.
The following guidelines are provided to emphasize the importance of
safety in the workplace.
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CONSIDERING
SAFETY FOR YOUR
ROBOT
INSTALLATION
SAFETY
MARMMTRBL02303E
Safety is essential whenever robots are used. Keep in mind the following
factors with regard to safety:

The safety of people and equipment

Use of safety enhancing devices
Techniques for safe teaching and manual operation of the robot(s)
Techniques for safe automatic operation of the robot(s)
Regular scheduled inspection of the robot and workcell
Proper maintenance of the robot
Keeping People and

Equipment Safe
The safety of people is always of primary importance in any

situation. However, equipment must be kept safe, too. When
prioritizing how to apply safety to your robotic system, consider
People
External devices
Robot(s)
Tooling
Workpiece
Using Safety
Enhancing Devices
Always give appropriate attention to the work area that surrounds the
robot. The safety of the work area can be enhanced by the installation of
some or all of the following devices:
Safety fences, barriers, or chains
Light curtains
Interlocks
Pressure mats
Floor markings
Warning lights
Mechanical stops
EMERGENCY STOP buttons
DEADMAN switches
Setting Up a Safe
Workcell
A safe workcell is essential to protect people and equipment. Observe the

following guidelines to ensure that the workcell is set up safely. These
suggestions are intended to supplement and not replace existing federal,
state, and local laws, regulations, and guidelines that pertain to safety.
Sponsor your personnel for training in approved FANUC Robotics

training course(s) related to your application. Never permit untrained
personnel to operate the robots.
Install a lockout device that uses an access code to prevent

unauthorized persons from operating the robot.
Use antitiedown logic to prevent the operator from bypassing safety

measures.
Arrange the workcell so the operator faces the workcell and can see
what is going on inside the cell.
MARMMTRBL02303E
SAFETY
xxvii
Clearly identify the work envelope of each robot in the system with
floor markings, signs, and special barriers. The work envelope is the
area defined by the maximum motion range of the robot, including any
tooling attached to the wrist flange that extend this range.
Position all controllers outside the robot work envelope.
Never rely on software as the primary safety element.
Mount an adequate number of EMERGENCY STOP buttons or

switches within easy reach of the operator and at critical points inside
and around the outside of the workcell.
Install flashing lights and/or audible warning devices that activate

whenever the robot is operating, that is, whenever power is applied to
the servo drive system.
Wherever possible, install safety fences to protect against unauthorized

entry by personnel into the work envelope.
Install special guarding that prevents the operator from reaching into
restricted areas of the work envelope.
Use interlocks.
Use presence or proximity sensing devices such as light curtains, mats,

and capacitance and vision systems to enhance safety.
Periodically check the safety joints or safety clutches that can be

optionally installed between the robot wrist flange and tooling. If the
tooling strikes an object, these devices dislodge, remove power from
the system, and help to minimize damage to the tooling and robot.
Make sure all external devices are properly filtered, grounded,

shielded, and suppressed to prevent hazardous motion due to the
effects of electromagnetic interference (EMI), radio frequency
interference (RFI), and electrostatic discharge (ESD).
Make provisions for power lockout/tagout at the controller.
Eliminate pinch points. Pinch points are areas where personnel could
get trapped between a moving robot and other equipment.
Provide enough room inside the workcell to permit personnel to teach

the robot and perform maintenance safely.
Program the robot to load and unload material safely.
If high voltage electrostatics are present, be sure to provide appropriate

interlocks, warning, and beacons.
If materials are being applied at dangerously high pressure, provide

electrical interlocks for lockout of material flow and pressure.
xxviii
Staying Safe While

Teaching or Manually
Operating the Robot
SAFETY
MARMMTRBL02303E
Advise all personnel who must teach the robot or otherwise manually
operate the robot to observe the following rules:
Know whether or not you are using an intrinsically safe teach pendant
if you are working in a hazardous environment.
Before teaching, visually inspect the robot and work envelope to make
sure that no potentially hazardous conditions exist. The work
envelope is the area defined by the maximum motion range of the
robot. These include tooling attached to the wrist flange that extends
this range.
The area near the robot must be clean and free of oil, water, or debris.
Immediately report unsafe working conditions to the supervisor or
safety department.
FANUC Robotics recommends that no one enter the work envelope of

a robot that is on. However, if you must enter the work envelope, be
sure all safeguards are in place, and check the teach pendant
DEADMAN switch for proper operation. Take the teach pendant with
you, turn it on, and be prepared to release the DEADMAN switch.
Only the person with the teach pendant should be in the work
envelope.
Know the path that can be used to escape from a moving robot; make
sure the escape path is never blocked.
Isolate the robot from all remote control signals that can cause motion
while data is being taught.
Test any program being run for the first time in the following manner:
WARNING
Stay outside the robot work envelope whenever a program
is being run. Failure to do so can result in injury.
Using a low motion speed, single step the program for at least one
full cycle.
Using a low motion speed, test run the program continuously for
at least one full cycle.
Using the programmed speed, test run the program continuously

for at least one full cycle.
Make sure all personnel are outside the work envelope before running
production.
MARMMTRBL02303E
Staying Safe During

Production Operation
Staying Safe During

Inspection
SAFETY
xxix
Advise all personnel who operate the robot during production to observe
the following rules:
Know the entire workcell area. The workcell includes the robot and its
work envelope, plus the area occupied by all external devices and
other equipment with which the robot interacts.
Understand the complete task the robot is programmed to perform

before initiating production operation.
Make sure all personnel are outside the work envelope before
operating the robot.
Never enter or allow others to enter the work envelope during

production operation of the robot.
Know the location and status of all switches, sensors, and control
signals that could cause the robot to move.
Know where the EMERGENCY STOP buttons are located on both the
robot control and external control devices. Be prepared to press these
buttons in an emergency.
Never assume that a program is complete if the robot is not moving.

The robot could be waiting for an input signal that will permit it to
continue activity.
If the robot is running in a pattern, do not assume it will continue to

run in the same pattern.
Never try to stop the robot, or break its motion, with your body. The
only way to stop robot motion immediately is to press an
EMERGENCY STOP button located on the controller panel, teach
pendant, or emergency stop stations around the workcell.
When inspecting the robot, be sure to

Turn off power at the controller.
Lock out and tag out the power source at the controller according to
the policies of your plant.
Turn off the compressed air source and relieve the air pressure.
If robot motion is not needed for inspecting the electrical circuits,

press the EMERGENCY STOP button on the operator panel.
If power is needed to check the robot motion or electrical circuits, be

prepared to press the EMERGENCY STOP button, in an emergency.
xxx
Staying Safe During

Maintenance
SAFETY
MARMMTRBL02303E
When performing maintenance on your robot system, observe the

following rules:
Never enter the work envelope while the robot or a program is in

operation.
Before entering the work envelope, visually inspect the workcell to

make sure no potentially hazardous conditions exist.
Consider all or any overlapping work envelopes of adjoining robots

when standing in a work envelope.
Test the teach pendant for proper operation before entering the work
envelope.
If it is necessary for you to enter the robot work envelope while power
is turned on, you must be sure that you are in control of the robot. Be
sure to take the teach pendant with you, press the DEADMAN switch,
and turn the teach pendant on. Be prepared to release the DEADMAN
switch to turn off servo power to the robot immediately.
Whenever possible, perform maintenance with the power turned off.

Before you open the controller front panel or enter the work envelope,
turn off and lock out the 3phase power source at the controller.
WARNING
Lethal voltage is present in the controller WHENEVER IT IS
CONNECTED to a power source. Be extremely careful to
avoid electrical shock.
Turning the disconnect or circuit breaker to the OFF
position removes power from the output side of the device
only. High voltage is always present at the input side
whenever the controller is connected to a power source.
Release or block all stored energy. Before working on the pneumatic

system, shut off the system air supply and purge the air lines.
Isolate the robot from all remote control signals. If maintenance must
be done when the power is on, make sure the person inside the work
envelope has sole control of the robot. The teach pendant must be
held by this person.
Make sure personnel cannot get trapped between the moving robot and
other equipment. Know the path that can be used to escape from a
moving robot. Make sure the escape route is never blocked.
Use blocks, mechanical stops, and pins to prevent hazardous

movement by the robot. Make sure that such devices do not create
pinch points that could trap personnel.
MARMMTRBL02303E
SAFETY
xxxi
WARNING
Do not try to remove any mechanical component from the
robot before thoroughly reading and understanding the
procedures in the appropriate manual. Doing so can result
in serious personal injury and component destruction.
Be aware that when you remove a servomotor or brake, the associated

axis will fall if it is not supported or resting on a hard stop.
When replacing or installing components, make sure dirt and debris do

not enter the system.
Use only specified parts for replacement. To avoid fires and damage
to parts in the controller, never use nonspecified fuses.
Before restarting a robot, make sure no one is inside the work

envelope; be sure that the robot and all external devices are operating
normally.
KEEPING MACHINE
TOOLS AND
EXTERNAL
DEVICES SAFE
Certain programming and mechanical measures are useful in keeping the

machine tools and other external devices safe. These measures are
outlined below.
Programming Safety
Precautions
Implement the following programming safety measures to prevent damage

to machine tools and other external devices.
Mechanical Safety
Precautions
Backcheck limit switches in the workcell to make sure they do not

fail.
Implement failure routines in programs that will provide appropriate

robot actions if an external device or another robot in the workcell
fails.
Use handshaking protocol to synchronize robot and external device

operations.
Program the robot to check the condition of all external devices during
an operating cycle.
Implement the following mechanical safety measures to prevent damage to

machine tools and other external devices.
Make sure the workcell is clean and free of oil, water, and debris.
Use software limits, limit switches, and mechanical hardstops to

prevent undesired movement of the robot into the work area of
machine tools and external devices.
xxxii
KEEPING THE
ROBOT SAFE
Operating Safety
Precautions
SAFETY
Observe the following operating and programming guidelines to prevent

damage to the robot.
The following measures are designed to prevent damage to the robot
during operation.

Programming Safety
Precautions
MARMMTRBL02303E
Use a low override speed to increase your control over the robot when
jogging the robot.
Visualize the movement the robot will make before you press the jog
keys on the teach pendant.
Make sure the work envelope is clean and free of oil, water, or debris.
Use circuit breakers to guard against electrical overload.
The following safety measures are designed to prevent damage to the robot
during programming:
Establish interference zones to prevent collisions when two or more

robots share a work area.
Make sure that the program ends with the robot near or at the home
position.
Be aware of signals or other operations that could trigger operation of

tooling resulting in personal injury or equipment damage.
In dispensing applications, be aware of all safety guidelines with

respect to the dispensing materials.
NOTE Any deviation from the methods and safety practices described in
this manual must conform to the approved standards of your company. If
you have questions, see your supervisor.
MARMMTRBL02303E
ADDITIONAL
SAFETY
CONSIDERATIONS
FOR PAINT ROBOT
INSTALLATIONS
SAFETY
xxxiii
Process technicians are sometimes required to enter the paint booth, for
example, during daily or routine calibration or while teaching new paths to
a robot. Maintenance personal also must work inside the paint booth
periodically.
Whenever personnel are working inside the paint booth, ventilation
equipment must be used. Instruction on the proper use of ventilating
equipment usually is provided by the paint shop supervisor.
Although paint booth hazards have been minimized, potential dangers still
exist. Therefore, todays highly automated paint booth requires that
process and maintenance personnel have full awareness of the system and
its capabilities. They must understand the interaction that occurs between
the vehicle moving along the conveyor and the robot(s), hood/deck and
door opening devices, and highvoltage electrostatic tools.
Paint robots are operated in three modes:

Teach or manual mode

Automatic mode, including production and exercise operation
Diagnostic mode
During both teach and automatic modes, the robots in the paint booth will
follow a predetermined pattern of movements. In teach mode, the process
technician teaches (programs) paint paths using the teach pendant.
In automatic mode, robot operation is initiated at the System Controller
Center (SCC), Manual Control Panel (MCP), if available, or Manual Paint
Station (MPS), if available, and can be monitored from outside the paint
booth. All personnel must remain outside of the booth or in a designated
safe area within the booth whenever automatic mode is initiated at the
SCC, MCP, or MPS.
In automatic mode, the robots will execute the path movements they were
taught during teach mode, but generally at production speeds.
When process and maintenance personnel run diagnostic routines that
require them to remain in the paint booth, they must stay in a designated
safe area.
xxxiv
Paint System Safety

Features
SAFETY
MARMMTRBL02303E
Process technicians and maintenance personnel must become totally

familiar with the equipment and its capabilities. To minimize the risk of
injury when working near robots and related equipment, personnel must
comply strictly with the procedures in the manuals.
This section provides information about the safety features that are
included in the paint system and also explains the way the robot interacts
with other equipment in the system.
The paint system includes the following safety features:
Most paint booths have red warning beacons that illuminate when the
robots are armed and ready to paint. Your booth might have other
kinds of indicators. Learn what these are.
Some paint booths have a blue beacon that, when illuminated,

indicates that the electrostatic devices are enabled. Your booth might
have other kinds of indicators. Learn what these are.
EMERGENCY STOP buttons are located on the Manual Control

Panel (MCP), or Manual Paint Station (MPS) panel, if supplied, inside
the booth, or on the System Controller Center (SCC) outside the
booth. Also, EMERGENCY STOP buttons are located near the
interior corners of each booth, and on the robot controller and teach
pendant. Become familiar with the locations of all ESTOP buttons.
An intrinsically safe teach pendant is used when teaching in hazardous

paint atmospheres.
A DEADMAN switch is located on each teach pendant. When this

switch is held in, power is applied to the robot servo system. If the
engaged DEADMAN switch is released during robot operation, power
is removed from the servo system, all axis brakes are applied, and the
robot comes to an EMERGENCY STOP. Safety interlocks within the
system might also ESTOP other robots.
WARNING
An EMERGENCY STOP will occur if the DEADMAN switch
is released on a bypassed robot.
Overtravel by robot axes is prevented by software limits. All of the

major and minor axes are governed by software limits. Limit switches
and hardstops also limit travel by the major axes.
MARMMTRBL02303E
SAFETY
xxxv
EMERGENCY STOP limit switches and photoelectric eyes might be

part of your system. Limit switches, located on the entrance/exit doors
of each booth, will EMERGENCY STOP all equipment in the booth if
a door is opened while the system is operating in automatic or manual
mode. For some systems,signals to these switches are bypassed when
the switch on the SCC is in teach mode.
When present, photoelectric eyes are sometimes used to monitor
unauthorized intrusion through the entrance/exit silhouette openings.
Staying Safe While

Operating the Paint
Robot
System status is monitored by computer. Severe conditions result in

automatic system shutdown.
When you work in or near the paint booth, observe the following rules, in
addition to all rules for safe operation that apply to all robot systems.
WARNING
Observe all safety rules and guidelines to avoid injury.
WARNING
OPTIONAL SAFETY DEVICE
Your robot may have a red flashing warning light. This is
an optional operator warning. It indicates:
D The robot is powered on
D The robot is armed (servo power on) and can move at
any time.
FANUC Robotics recommends that no one enter the work
envelope of a robot that is on. However, if you must enter
the work envelope, be sure all safeguards are in place, and
check the teach pendant DEADMAN switch for proper
operation. Take the tach pendant with you, turn it on, and
be prepared to release the DEADMAN switch. Only the
person with the teach pendant should be in the work
envelope.
Know the work area of the entire paint station (workcell).
Know the work envelope of the robot and hood/deck and door opening
devices.
Be aware of overlapping work envelopes of adjacent robots.
Know where all red, mushroomshaped EMERGENCY STOP buttons

are located.
Know the location and status of all switches, sensors, and/or control
signals that might cause the robot, conveyor, and opening devices to
move.
xxxvi
Staying Safe During

Maintenance
SAFETY
MARMMTRBL02303E
Make sure that the work area near the robot is clean and free of water,
oil, and debris. Report unsafe conditions to your supervisor.
Become familiar with the complete task the robot will perform
BEFORE starting automatic mode.
Make sure all personnel are outside the paint booth before turning on
power to the robot servo system.
Never enter the work envelope or paint booth before turning on power
to the robot servo system.
Never enter the work envelope during automatic operation unless a

safe area has been designated.
Never wear watches, rings, neckties, scarves, or loose clothing that

could get caught in moving machinery.
Remove all metallic objects, such as rings, watches, and belts, before
entering a booth when the electrostatic devices are enabled.
Stay out of areas where you might get trapped between a moving
robot, conveyor, or opening device and another object.
Be aware of signals and/or operations that could result in the triggering

of guns or bells.
Be aware of all safety precautions when dispensing of paint is

required.
Follow the procedures described in this manual.
When you perform maintenance on the painter system, observe the

following rules, and all other maintenance safety rules that apply to all
robot installations. Only qualified, trained service or maintenance
personnel should perform repair work on a robot.
Paint robots operate in a potentially explosive environment. Use

caution when working with electric tools.
When a maintenance technician is repairing or adjusting a robot, the

work area is under the control of that technician. All personnel not
participating in the maintenance must stay out of the area.
For some maintenance procedures, station a second person at the

control panel within reach of the EMERGENCY STOP button. This
person must understand the robot and associated potential hazards.
Be sure all covers and inspection plates are in good repair and in place.
Always return the robot to the home position before you disarm it.
MARMMTRBL02303E
SAFETY
xxxvii
Never use machine power to aid in removing any component from the
robot.
During robot operations, be aware of the robots movements. Excess

vibration, unusual sounds, and so forth, can alert you to potential
problems.
Whenever possible, turn off the main electrical disconnect before you
clean the robot.
xxxviii
SAFETY
MARMMTRBL02303E
When using vinyl resin observe the following:
Wear eye protection and protective gloves during application and

removal
Adequate ventilation is required. Overexposure could cause

drowsiness or skin and eye irritation.
If there is contact with the skin, wash with water.

When using paint remover observe the following:
Eye protection, protective rubber gloves, boots, and apron are

required during booth cleaning.
Adequate ventilation is required. Overexposure could cause

drowsiness.
If there is contact with the skin or eyes, rinse with water for at
least 15 minutes.
MARMMTRBL02303E
OVERVIEW
11
The SYSTEM R-J Robot and controller consists of software, a robot, and
the SYSTEM R-J controller. The application software runs on the R-J
controller and is written to perform a specific task.
The SYSTEM RJ controller contains the computer that operates the
robot. It executes a user-defined program to perform the following
functions:
Supply drive power to the servomotors of an attached robot and, in

some cases, to motor-driven auxiliary devices to move the robot
through a series of program motions.
Supply drive power to the servomotors of an attached robot and, in

some cases, to motor-driven auxiliary devices comprising additional
axes, such as door openers, and/or hood/deck openers used in
conjunction with robot programs.
Send control signals to process devices and other peripheral

equipment.
Initiate and monitor the purge system of the robot and sometimes
associated opening devices.
The controller consists of modular circuit boards and components housed

in a cabinet. The controller is housed in either a B-size or C-size cabinet.
The controller consists of modular circuit boards and components housed
in a C-size cabinet.
Figure 11, Figure 12, and Figure 13 illustrate an external view of the
B-size cabinet and Figure 14 illustrates an external view of a C-size
cabinet. Figure 15 illustrates an internal view of a B-size cabinet and
Figure 16 illustrates an internal view of a C-size cabinet.
Figure 14 illustrates an external view of a C-size cabinet. Figure 17
illustrates an internal view of a C-size cabinet.
1. OVERVIEW
MARMMTRBL02303E
12
Figure 11. Cabinet Exterior, B-Size Controller
Teach
pendant
Figure 12. Cabinet Exterior, B-Size Controller with Regenerative Discharge Unit
Regenerative
Discharge
Unit
Teach
pendant
1. OVERVIEW
13
MARMMTRBL02303E
Figure 13. Cabinet Exterior, B-Size Controller with Optional Side Cabinet
Optional Side Cabinet
Teach
pendant
1. OVERVIEW
MARMMTRBL02303E
14
Figure 14. Cabinet Exterior, C-Size Controller
Teach
pendant
1. OVERVIEW
15
MARMMTRBL02303E
Figure 15. Cabinet Interior, B-Size Controller

Regenerative discharge unit
Servo amplifier 4
Fan 1
Servo amplifier 3
Additional cabinet
Operators panel
Main CPU printed
circuit board
Axis control printed
circuit board
Power supply unit
Printed circuit board for
emergency stop control
Process I/O printed
circuit board or
I/O unit model A
Circuit breaker
Fan 2
Servo amplifier 6
Servo amplifier 5
Transformer or
line filter unit
Servo amplifier 1
Fan 3
Servo amplifier 2
Teach pendant
Fan 4
Fan 5
Components for all models are placed in identical places except for the
servo amplifier. Refer to Section 1.6 for information on the servo
amplifiers locations for different robot models.
1. OVERVIEW
MARMMTRBL02303E
16
Figure 16. Cabinet Interior, C-Size Controller

Operator panel
Extended
Back plane
Modular I/O rack or

Process I/O rack
Power disconnect
Servo amplifier #1
Main CPU
Servo amplifier #2
Fuses FL13
Servo amplifier #3
Axis control board

Power supply unit
Servo amplifier #4 and #5
Emergency stop
control board
Servo amplifier #6
Option 1 and 2 slots
User transformer
Multitap transformer
1. OVERVIEW
17
MARMMTRBL02303E
Figure 17. Cabinet Interior, C-Size Controller
Operator panel
Servo Amplifiers
Contact Signal
Transducer
STAHL
Extended
ISBs
Back plane
STBI Term Strip

Purge 24V DC
Power Supply
Power disconnect
Main CPU
Fuses FL13
Transit Board
Axis control board

Power supply unit
Emergency stop
control board
BDX
ISB Unit
ALC
Relay
SPC Battery
Unit
User transformer
1. OVERVIEW
MARMMTRBL02303E
18
1.1
The control unit printed circuit boards are mounted on the backplane
printed circuit board. The backplane provides the bus structure for
communication between the various printed circuit boards in the controller.
A thermostat for sensing the temperature in the controller is mounted on
the backplane. If the internal temperature exceeds specifications (65C),
the controller will generate a system overheat alarm.
BACKPLANE
4-Slot A20B-1004-0420 or
A20B-2000-0800
6-Slot A20B-1004-0590 or
A20B-2000-0920
Two different backplane printed circuit boards are available both for the 4and 6-slot printed circuit board. Either of these printed circuit boards are
interchangeable.
The RH style extended backplane is available for using R-H style printed
circuit boards, such as MAP 3.0 and ABRIO. Figure 18 shows the
backplane with the R-H style extended backplane attached.
R-H Style Extended

Backplane
A20B-1004-0510
CNB15
CNA15
CNA14
CNBV2
CNAV2
JNAT
CNBV1
CNAV1
Figure 18. Backplane with R-H Style Extended Backplane
NOTE The A20B-2000-0800 and the A20B-2000-0920 printed circuit

boards have an additional connector that is not used in robot applications.
1. OVERVIEW
19
MARMMTRBL02303E
1.2
MAIN CPU PRINTED
CIRCUIT BOARD
A16B-2200-0840 to
A16B-2200-0843
The main CPU printed circuit board is mounted on the backplane in the
slot marked MAIN. It contains the CPU and the volatile and non-volatile
memory used by the controller.
The Main CPU printed circuit board also acts as the interface between the
controller and the operator and attached devices, through connections to:

The I/O unit(s)

The teach pendant
One or more generalpurpose serial communication ports
An optional built-in or remote computer terminal (CRT/KB)
The operator panel lights and pushbuttons
A super capacitor on the Main CPU printed circuit board maintains voltage
to the CMOS RAM for short periods of time (less than an hour) if
removed from the backplane. A connector, BAT-VBAT, is supplied to
connect the battery from the Power Supply Unit to the Main CPU printed
circuit board when the Power Supply Unit or Main CPU is removed from
the controller for an extended period of time. This will supply voltage to
the CMOS memory so the stored data is not lost.
The main CPU consists of a main motherboard with several daughter
modules installed perpendicular to it. The modules are small printed
circuit boards with components surface-mounted on both sides. The
modules are installed in sockets, allowing them to be changed quickly and
easily.
Flash ROM Module contains System and Application Software.
CMOS RAM Module stores user programs, system variables, I/O

configuration files, and mastering data.
SLC2 Module controls I/O communication.
M32i Module controls communication between the flash ROM,
CMOS, micro processor and boot ROM chip.
SCC Module controls communication with the operator panel.
Optional SCC Module communicates with any optional serial ports.

Figure 19 shows the board layout. Table 11 lists the part numbers for
the modules attached on the board.
1. OVERVIEW
MARMMTRBL02303E
110
Figure 19. Main CPU Board Layout
Flash ROM module
Optional SCC module
CMOS RAM module (option)
SLC2 module
M32i module
CMOS RAM module (standard)
SCC module
NOTE Options are shown in phantom print.
1. OVERVIEW
111
MARMMTRBL02303E
Table 11.
Name
Main CPU Modules
Part Number
CMOS RAM module
A20B-2900-0500, 0501
Flash ROM module
A20B-2900-0480, 0482
M32I module
A20B-2900-0450
SCC module
A20B-2900-0430
SLC2 module
A20B-2900-0440, 0442
Optional SCC module
A20B-2900-0490, 0491, 0492
Remarks
MAIN CPU printed circuit board
NOTE CMOS RAM modules are replaced in pairs (two standard modules
or two optional modules).
1. OVERVIEW
MARMMTRBL02303E
112
1.3
AXIS CONTROL
PRINTED CIRCUIT
BOARD
A16B-2200-0852 to
A16B-2200-0855
The axis control printed circuit board is mounted on the backplane in the
slot marked AXIS. It performs the following functions:
Receives command signals from the main CPU board, and receives
axis position and velocity signals from the serial pulse coders.
Compares the command signal with the axis position signal and
generates pulse-width-modulated axis drive signals. These signals
switch the drive transistors on the servo amplifiers on and off applying
power to the servo motors.
Monitors the status of the hand breakage and axis overtravel switches
in the mechanical unit.
Is the interface for the Robot Input (RI) and Robot Output (RO) I/O
signals.
Figure 110 shows the axis control board layout. Table 12 lists the part
numbers for the modules attached on the board.
Figure 110. Axis Control Board Layout
Servo control module (for axis 9 and 10)

Servo interface module (for axis 5 and 6)
NOTE Options are shown in phantom print.

Table 12.
Name
Servo interface module
Servo control module
Axis Control Board Modules
Part Number
A20B-2900-0380
A20B-2900-0160
Remarks
Axis control printed circuit board
1. OVERVIEW
113
MARMMTRBL02303E
1.4
POWER SUPPLY UNIT
PRINTED CIRCUIT
BOARD
4-Slot Backplane
A16B-12120471
6-Slot Backplane
A16B-1212-0531
The power supply unit printed circuit board is mounted on the backplane
in the slot marked PSU.
The power supply unit printed circuit board is supplied with 210 VAC
from the multi-tap transformer and produces the following DC voltages:
+24V used
For inputs, outputs receivers, drivers, and relays.

As the power source for the teach pendant power supply circuitry.
+15, 15, +5 used for logic circuitry within the controller.
The power supply unit printed circuit board also contains the ON/OFF
logic circuits used by the controller.
CAUTION
The CMOS RAM backup battery is mounted on the power
supply unit printed circuit board. If the board is removed from
the controller for longer than 30 minutes, all software in the
controller might be lost.
Figure 111. Power Supply Unit Printed Circuit Board

PSU
F5: 0.3A fuse for

auxiliary
power supply
Battery cover
PSU
F1 and F2:
Fuses for AC input
10-A for 6-slot backplane
7.5A for 4-slot backplane
PIL: green LED
for indicating the AC
power supply status
Battery
ALM: Red LED

for indicating
an alarm
F4:5Afuse for +24E

F3: Fuse for +24V
5-A slow blow for
6-slot backplane
3.2A slow blow for
4-slot backplane
(with battery cover removed)
1. OVERVIEW
MARMMTRBL02303E
114
1.5
EMERGENCY STOP
CONTROL PRINTED
CIRCUIT BOARD
The emergency stop control printed circuit board is mounted on the

backplane in the slot marked EMG. It contains the circuits that:
Supply 100VAC to the servo amplifiers magnetic control contactors

(MCCs) during normal operation.
A16B-1212-0540
Turn off 100VAC for the MCC during fault conditions such as:
A16B-1212-0730
Turn off 100VAC for the MCC during fault conditions such as:
Emergency stop
Axis overtravel
Safety fence open
Teach pendant DEADMAN switch
Hand breakage detection
Supply power to the motor brakes to release them during normal

operation. Brake power is turned off (applying motor brakes) during
major alarm conditions, or when regulated by the software.
Supply power to the motor brakes to release them during normal

operation. Brake power is turned off (applying motor brakes) during
major alarm conditions, or when regulated by the software. There is a
second brake circuit that is manually operated by a front panel key
switch. This key switch operated circuit provides a method to move
the robot manually should servo power fail, or when mastering is
required.
Monitor and control the purge system through a piggy-back style PCB,
purge control A16B16000520. This PCB is mounted internally
within the EMG PCB.
Supply 24VDC required for SPC encoder operation through the 24 to

5VDC converter unit located within the robot base and switched on
through the purge complete relay contacts of RL-1 for protection from
explosive gases.
Figure 112 shows the emergency stop control printed circuit board
layout.
1. OVERVIEW
115
MARMMTRBL02303E
Figure 112. Emergency Stop Control Printed Circuit Board
EMG
PCB
1. OVERVIEW
MARMMTRBL02303E
116
Figure 113. Emergency Stop Control PC Board
DS2
F1
DS1
F2
RL16
FUSE
RL1 RL2
RL4
CRR5
RL3
LED M1
LED M2
RL2
RL4 TIMER
RL1
RL3
RL6
RL5
RL8
CNPG
Purge Control PCB
RL7
RL9
CRT
CRX
1. OVERVIEW
117
MARMMTRBL02303E
1.6
SERVO AMPLIFIERS
Refer to Table 13 for
part numbers.
The servo amplifiers are mounted on the back wall of the controller. The
servo amplifier amplifies the drive signal from the axis control printed
circuit board and supplies it to the servomotor.
Servo amplifiers are supplied in single, double or triple-axis
configurations. Several different models of each configuration are used in
various FANUC robot controllers.
CAUTION
While two servo amplifiers might look identical, they might have
quite different output power capabilities. If you replace a servo
amplifier, make sure that the new unit has the same part
number as the old one. Otherwise, the servo amplifier or
servomotor might be damaged or destroyed.
See Figure 114 for a servo amplifier.
Figure 114. Servo Amplifier
Circuit breaker
LED
Terminal board T1
1. OVERVIEW
MARMMTRBL02303E
118
MCC Coil
Each servo amplifier has its own DC power supply, which is supplied
3-phase 210 VAC from the multi-tap transformer. The power lines
supplying the DC power supply are switched on and off by a magnetic
contactor (relay) called the Magnetic Control Contractor (MCC).
The MCC coil is energized by 100 VAC from the emergency stop control
printed circuit board. The MCC coil voltage is turned off during major
fault conditions or when regulated by the software.
When the MCC is turned off, its normally-closed contacts connect the
motor power leads together through low-resistance, high-power resistors,
stopping the motor immediately.
Circuit Breaker
The servo amplifier circuitry is protected by a circuit breaker. The reset

lever for the circuit breaker is visible on the front panel of the servo
amplifier. Refer to Section 1.9 for more information on the multi-tap
transformer.
Fault Detection
Each servo amplifier has fault detection circuits that detect such conditions
as excessive motor current and servo amplifier power supply failure.
A pair of terminals on the servo amplifier can be connected to a
temperature-sensing switch in the multi-tap transformer. If the switch
opens, the controller will signal a SRVO0043 DCAL alarm.
Servo Amplifier
Configuration
Table 13 lists the servo amplifiers for several FANUC robots.

Figure 115 shows the mounting locations of the servo amplifiers.
Servo Amplifier
Configuration
Table 13 lists the servo amplifiers for the P-155 robot and optional
auxiliary devices.. Figure 123 shows the mounting locations of the servo
amplifiers.
Figure 115. Mounting Locations of Servo Amplifiers Robot with 6-amplifiers
SLOT 4 SLOT 5 SLOT 6
SLOT 1 SLOT 2 SLOT 3
1. OVERVIEW
119
MARMMTRBL02303E
Figure 116. Mounting Locations of Servo Amplifiers for the A-510
Figure 117. Mounting Locations of Servo Amplifiers for the Arc Mate/
Arc Mate 100/S-6, Arc Mate Sr./S-5/S-10 and L-1000
1. OVERVIEW
120
MARMMTRBL02303E
Figure 118. Mounting Locations of Servo Amplifiers for the S-500/S-700 and
M-400
Figure 119. Mounting Locations of Servo Amplifiers for the S-420 and S-800
1. OVERVIEW
121
MARMMTRBL02303E
Figure 120. Mounting Locations of Servo Amplifiers for the S-420 and the DCR &
DBR Unit
(S420) With 3 2-Axis Servo Amplifiers; S420D
Figure 121. Mounting Locations of Servo Amplifiers for the M-500
1. OVERVIEW
MARMMTRBL02303E
122
Figure 122. Mounting Locations of Servo Amplifiers for the S-900
Figure 123. Mounting Locations of Servo Amplifiers.

Amp 1
Amp 2 Amp 3
Axis 1
Axis 4
Axis 2
Axis 5
Amp 4 Amp 5
Axis 7
Axis 8
Axis 9
Axis 3
Axis 6
1. OVERVIEW
123
MARMMTRBL02303E
NOTE In Table 13, the part number of the specific amplifier is

A06B-6066-HXXX.
Table 13.
Machine Type
Servo Amplifiers
Servo
Amplifier 1
Servo
Amplifier 2
Servo
Amplifier 3
ARC Mate
S-5
H281
L;Axis 4/
M;Axis 1
H223
L;Axis 5/
M;Axis 2
H223
L;Axis 6/
M;Axis 3
ARC Mate
100/S-6
H234
L;Axis 4/
M;Axis 1
H224
L;Axis 5/
M;Axis 2
H223
L;Axis 6/
M;Axis 3
ARC Mate Sr.

S-10
H234
L;Axis 4/
M;Axis 1
H234
L;Axis 5/
M;Axis 2
H233
L;Axis 6/
M;Axis 3
H235
Axes 1 & 4
H235
Axes 2 & 5
H235
Axes 3 & 6
P-155
Servo
Amplifier 4
Servo
Amplifier 5
H005
Axis 7
Door Opener
H233
Axes 8 & 9
Hood & Deck
H244
Axes 8 & 9
S-420
(with five amplifiers)
H011
Axis 1
H006
Axis 2
H006
Axis 3
H244
L;Axis 5/
M;Axis 4
H291
L;Axis 4/
M;Axis 1
H291
L;Axis 5/
M;Axis 2
H291
L;Axis 6/
M;Axis 3
DCR & DBR

Unit
S-500
H011
Axis 1
H006
Axis 2
H234
L;Axis 4/
M;Axis 3
H233
L;Axis 6/
M;Axis 5
S700
H012
Axis 1
H006
Axis 2
H234
L;Axis 4/
M;Axis 3
H233
L;Axis 6/
M;Axis 5
S-800
H011
Axis 1
H006
Axis 6
H006
Axis 3
H260
L;Axis 5/
M;Axis 4
H006
Axis 6
S900
H008
Axis 1
H006
Axis 4
H008
Axis 2
H006
Axis 5
H008
Axis 3
M-400
H006
Axis 1
H011
Axis 2
H234
L;Axis 4/
M;Axis 3
H003
Axis 5
M-500
H008
Axis 1
H006
Axis 3
H244
L;Axis 4/
M;Axis 2
H004
Axis 5
A-510
H233
L;Axis 3/
M;Axis 1
H223
L;Axis 4/
M;Axis 2
L-1000
H234
L;Axis 4/
M;Axis 1
H234
L;Axis 5/
M;Axis 2
S-420 and S-420D

(with three 2-axis
amplifiers)
H003
Axis 3
Servo
Amplifier 6
H004
Axis 6
H006
Axis 6
1. OVERVIEW
MARMMTRBL02303E
124
1.7
DCR AND DBR UNIT
A05B-2302-C080
The Discharge Resistor (DCR) and Dynamic Brake Resistor (DBR) unit is
used in R-J controllers with three 2-axis amplifiers. It contains the
dynamic braking resistors and regenerative discharge resistors built into
the other model servo amplifiers. At the loss of either MCON (Motor
Control Connected) signal from the axis control module to the servo
amplifier, that amplifier turns off the 100C signal to the DBR (Dynamic
Braking) and DCR (Discharge Resistor) unit and its associated MCC.
This turns off the MCC contactor (one for each major and minor axis on
the DBR and DCR unit) for that amplifier, and engages the dynamic
brakes through the normally closed contacts of the corresponding MCC.
At the loss of the 100VAC from the emergency stop circuit, all of the
MCC contactors are turned off, engaging all of the dynamic brakes.
When the MCC deenergizes, it opens its normally open contact, relaying
no interlock (INTL).
The regenerative discharge resistor and its associated thermal switch, for
each amplifier, is mounted to the back of the DBR and DCR unit.
The thermal switches of transformer TF1, is also connected to the DBR
and DCR unit.
Figure 124. DCR and DBR Unit
1. OVERVIEW
125
MARMMTRBL02303E
1.8
DISCHARGE UNIT
A05B-2312-C100 for M-500
A05B-2313-C100 for S-900
A discharge unit, mounted on top of the controller, is used with the M-500
and S-900 robot models. This unit is connected to axis 1 on the M-500
and axes 1, 3, and 5 on the S-900.
The unit consists of low-resistance high-power resistors used to dissipate
the counter electromotive force generated by the servo motors when they
are shut off. Thermo overload switches connected to the overheat
terminals on the servo amplifiers are also in the discharge unit. Fans in the
discharge unit are used to cool the unit.
Figure 125. Discharge Unit
1. OVERVIEW
MARMMTRBL02303E
126
1.9
MULTI-TAP
TRANSFORMER
Refer to Table 14 for part
numbers.
The multitap transformer is located on the floor of the controller on the

right side.
The multi-tap transformer is supplied 3phase AC from the main
disconnect or circuit breaker. This supply voltage can be from 220 575
volts. To accommodate the various levels of supply, tap selections are
provided on the primary side of the transformer.
The transformer supplies the following output voltages:

3phase 210 VAC for the servo amplifiers

1phase 210 VAC for the backplanemounted components
1phase 210 VAC for the IBRC module
1phase 210 VAC for the 24VDC Purge Power Supply
1phase 100 VAC for the brakes and servo amplifiermounted MCCs
NOTE Transformer A80L00260013#A also supplies 115VAC for the

user receptacle.
Two seriesconnected thermostats are mounted on the transformer. They
are connected to fault detection circuitry in one servo amplifier. If the
transformer overheats, the controller will signal a SRVO0043 DCAL
alarm.
Figure 126 and Figure 127 show the transformers, and Table 14,
Table 15, and Table 16 lists the information necessary for selecting a
proper primary tap.
Figure 126 shows the transformers, and Table 14, and Table 15 lists
the information necessary for selecting a proper primary tap.
Table 14.
Multi-Tap Transformer Part Numbers
Transformer Type
7.5kVA
S-420, S-500, S-800,
M-500
ARC Mate Sr., S-700,
M-400, L-1000, S-10
ARC Mate, Arc Mate
100/S-6, A-510, S-5
S-420 with 3 2-axis
Servo Amplifiers; S-420D
S-900
Part Number
A80L00260010#A
A80L-0026-0010#A
A80L-0024-0010#A
A80L-0022-0007#A
A80L-0026-0013#A
A80L-0026-0010#A Main cabinet
A80L-0024-0011#A Side cabinet
1. OVERVIEW
127
MARMMTRBL02303E
Figure 126. Multi-Tap Transformer

1
575V
550V
500V
480V
460V
240/415V
220V/380V
F4
7.5
F1
F5
7.5
13
F2
2
3
4
5
6
7
F3
A1
A2
23
31
41
32
42
14
24
0V
575V
550V
500V
480V
460V
240/415V
220V/380V
9
10
11
12
13
14
15
16
0V
575V
550V
500V
480V
460V
240/415V
220V/380V
17
18
19
20
21
22
23
24
0V
Table 15.
Selecting Transformer Taps

Primary Tap
S pply Voltage
Supply
L1
L2
L3
Jumper
220
15
23
7-24, 15-8, 23-16
240
14
22
6-24, 14-8, 22-16
380
15
23
415
14
22
460
13
21
480
12
20
500
11
19
550
10
18
575
17
8-16-24
Connection Type
1. OVERVIEW
MARMMTRBL02303E
128
Figure 127. Multi-Tap Transformer A80L00260013#A
575V
480V
220V/380V
0V
F4
5A
F5
5A
F6
F7
F1
F2
1
2
3
F3
575V
480V
220V/380V
5
6
7
100V
41
100V
42
220
43
220
44
115
46
G
47
TOH1
51
TOH2
52
13
A1
A2
23
31
41
32
42
575V
480V
220V/380V
0V
14
9
10
11
12
24
Table 16. Selecting Transformer Taps for Transformer

A80L00260013#A
Primary Tap
S pply Voltage
Supply
Connection Type
L1
L2
L3
Jumper
220
11
4-7, 8-11, 12-3
380
11
480
10
4, 8, 12
575
1. OVERVIEW
129
MARMMTRBL02303E
1.10
INTERFACE DEVICES
The interface between the controller and peripheral devices is provided by

input and output signals from one or more of the following:
Modular I/O Unit
Process I/O printed circuit board
A printed circuit board specializing in communicating with a logic

controller, which includes
ABRIO for communication to an Allen-Bradley PLC

Genius I/O for communication to a GE Fanuc programmable
controller
Digital I/O to/from the robot through the axis control board.
1. OVERVIEW
MARMMTRBL02303E
130
1.10.1
The modular I/O unit provides communication between the controller and
various peripheral devices. See Figure 128.
Modular I/O Unit
Figure 128.
Interface Module
Modular I/O
I/O Module
Modular I/O Rack

(Backplane)
Slot 2
Slot 1
Slot I/F
I/O Module
Interface Module
The modular I/O unit uses the following communication modes:

Discrete (On or Off) input and output signal lines at 24VDC or
120VAC. Outputs can be sink or source outputs.
Analog signal lines, which can vary from 10VDC to +10VDC
The modular I/O unit consists of the following:
The base unit
The interface module
Various discrete input and output (I/O) modules
The control can use as many as 64 modular I/O modules concatenated
(daisychained) together on multiple racks.
A single modular I/O unit is referred to as rack 1. The I/O modules are
located in slots 1 to 5 or 1 - 10, depending on the model used.
Base Unit
5 I/O Module Slot
A03B-0807-C002
10 I/O Module Slot
A03B-0807-C001
The base unit is the backplane for the modular I/O unit. The interface
module and the I/O modules plug into it.
The base unit has no LEDs, fuses, or electrical connections, except for the
module sockets.
The first slot to the left (I/F) always contains the interface module. The
other slots are used for the I/O modules.
1. OVERVIEW
131
MARMMTRBL02303E
Interface Module
With 1 Rack
A03B-0807-C011
For Additional Rack
A03B-0807-C012
The interface module transfers data between the main CPU and the I/O
modules.
The interface module is connected to the JD4 connector on the main CPU
printed circuit board through connector JD1B. The interface module is
always mounted in the I/F (first) slot.
Discrete Input Modules

Refer to Table 17 and
Table 19 for specifications
and part numbers.
Discrete input modules receive 24VDC or 120VAC signals on their

terminals and relay the data to the interface module.
Discrete Output Modules

Table 19 for specifications
and part numbers.
Discrete output modules transmit 24VDC or 120VAC signals on their

terminals under command of the interface module.
1. OVERVIEW
MARMMTRBL02303E
132
Table 17.
Input Type
Non-isolated
DC input
Optically
isolated
DC input
inp t
AC input
Rated
Voltage
24VDC
Rated
Current
7.5 mA
32
External
Connection
Connector
No-display
AID32B
24VDC
7.5 mA
Both
Maximum
2 ms
32
Connector
No-display
AID16C
24 VDC
7.5 mA
NEG
Maximum
20 ms
16
Terminal block Provided
AID16D
24VDC
7.5 mA
POS
Maximum
20 ms
16
AID32E
24VDC
7.5 mA
Both
Maximum
20 ms
32
Connector
No-display
AID32F
24VDC
7.5 mA
Both
Maximum
2 ms
32
Connector
No-display
AIA16G
100~
120VAC
10.5 mA
(120VAC)
16
* Polarity is defined as follows:
Not-Fused
DC output
AC output
Module
Name
AOD332A
Both
Response
Time
Maximum
20 ms
ON Max 35 ms
OFF Max 45 ms
Points
LED Display
2A
NEG
(Sink)
AOD08D
2A
POS
(Source)
Fused
AOD16C
0.5 A
NEG
(Sink)
16
Not fused
AOD16D
0.5 A
POS
(Source)
16
Not fused
AOD32C
0.3 A
NEG
(Sink)
32
Connector
Not
provided
Not fused
AOD32D
0.3 A
POS
(Source)
32
Connector
Not
provided
Not fused
100 ~
240 VAC
2A
Fused
1A
Fused
AOA12F
100 ~
120 VAC
0.5 A
12
Fused
AOR08G
Maximum
250 VAC
/30 VD
4A
Not fused
2A
16
Not fused
AOD08C
AOA05E
AOR16G
Rated
Voltage
5~
24 VDC
12 ~
24 VDC
Digital Output Module Specifications

LED
Display
Not
provided
AOA08E
Relay
output
Polarity*
Negative: 0 V common (current source type); ON when input is at low level.

Positive: 24 V common (current sink type); ON when input is at high level.
Table 18.
Output
Type
Not fused
DC output
Fused
DC output
Digital Input Module Specifications
Module
Name
AID32A
* Polarity is defined as follows:
Maximum
Polarity* Points
Current
0.3A
NEG
32
Points/
Common
8
External
Connection
Connector
Fuses
Not fused
Fused
Negative:0 V common (current sink type); output is at low level when ON.
Positive: 24 V common (current source type); output is at high level when ON.
1. OVERVIEW
133
MARMMTRBL02303E
Table 19.
I/O Module Part Numbers

Part Number
Name
DC input
module
Non-isolated
32 points
20 ms
AID32A
A03B-0807-C101
32 points
2 ms
AID32B
A03B-0807-C102
16 points
NEG
AID16C
A03B-0807-C103
16 points
POS
AID16D
A03B-0807-C104
32 points
20 ms
AID32E
A03B-0807-C105
32 points
2 ms
AID32F
A03B-0807-C106
AIA16G
A03B-0807-C107
32 points
NEG
A0D32A
A03B-0807-C162
8 points
NEG
AOD08C
A03B-0807-C151
8 points
POS
AOD08D
A03B-0807-C152
16 points
NEG
AOD16C
A03B-0807-C153
16 points
POS
AOD16D
A03B-0807-C154
32 points
NEG
AOD32C
A03B-0807-C155
32 points
POS
AOD32D
AO3B-0807-C156
5 points, 2 A AOA05E
A03B-0807-C157
8 points
1A
AOA08E
A03B-0807-C158
12 points
0.5 A
AOA12F
A03B-0807-C159
8 points
4A
AOR08G
A03B-0807-C160
16 points
2A
AOR16G
A03B-0807-C161
Analog input module
AAD04A
A03B-0807-C051
Analog output module
ADA02A
A03B-0807-C052
Optically
isolated
AC input module
16 points
DC output
Not fused
module
Fused
Not fused
AC output module
Relay output module
1. OVERVIEW
MARMMTRBL02303E
134
1.10.2
Process I/O Board
part numbers.
The process I/O printed circuit board provides communication between the
R-J controller on various peripheral devices.
The process I/O board uses:
Discrete input lines - Inputs are 24 volt sensing receivers. Common

voltage can be selected as +24VDC or ground.
Discrete output lines - Outputs are 24 volt sinking or sourcing

devices.
Analog input lines - Analog inputs are A D converters sensing an

analog signal 10VDC to 0V or 0V to +10VDC, providing a digital
signal to the processor.
Analog output lines - Analog outputs are D A converters that

output an analog signal 10VDC to 0V or 0V to +10VDC based on a
command from the processor.
Figure 129. Process I/O Printed Circuit Board
1. OVERVIEW
135
MARMMTRBL02303E
Figure 130. Process I/O Printed Circuit Board
Refer to Chapter 10, Board Adjustments, for the location of the output
drivers.
1. OVERVIEW
MARMMTRBL02303E
136
Table 110.
No.
Name
Process I/O Board Part Numbers

Number of I/O
Points
Part Number
DI
DO
D/A
Remarks
A/D
Process I/O printed circuit board AA
A16B-2200-0780
40
40
Standard (with welding interface)
Process I/O printed circuit board AB
A16B-2200-0782
40
40
Standard (without welding interface)
Process I/O printed circuit board BA
A16B-2201-0510
(weld interface)
A20B-2000-0540
32
32
Source type DO (with welding

interface)
Process I/O printed circuit board BB
A16B-2201-0510
32
32
Process I/O printed circuit board CA
A16B-2201-0470
40
40
Process I/O printed circuit board CB
A16B-2201-0472
40
40
Process I/O printed circuit board DA
A16B-2201-0480
96
96
Source type DO (without welding

interface)
Backplane installation type (with
welding interface)
Backplane installation type (without
welding interface)
welding interface)
1. OVERVIEW
137
MARMMTRBL02303E
1.10.3
ABRIO and Genius I/O
ABRIO
R-H style: A16B-2200-0430
(requires R-H adapter
backplane)
R-J style: A05B-2300-J120
and A05B-2300-J130
(requires R-J six-slot
backplane)
Genius I/O
A16B-2200-0310 (requires
R-H adapter backplane)
The ABRIO and Genius I/O printed circuit boards use serial
communication to interface to a programmable controller. These printed
circuit boards are used for communicating control information between the
SYSTEM R-J controller and the programmable controller.
Refer to the following manuals for information on these boards.

A Users Guide to the FANUC Robotics Remote I/O Interface for an

Allen-Bradley PLC
A Users Guide to the FANUC Robotics Genius Network Interface for
GEFanuc (R-H Style Board in R-J Controller)
1. OVERVIEW
138
1.11
FUSED FLANGE
DISCONNECT AND
CIRCUIT BREAKER
1.12
MARMMTRBL02303E
The SYSTEM R-J controller is supplied with either a fused flange

disconnect or a circuit breaker.
The SYSTEM R-J controller is supplied with a fused flange disconnect.
FUSED FLANGE
DISCONNECT
Fused Flange Disconnect
Refer to Table 112 for fuse
sizes, current rating, and part
numbers.
The fused flange disconnect provides overcurrent protection supply

through three fuses; one for each leg of the 3phase supply. See
Figure 131.
Circuit Breaker
The circuit breaker provides overcurrent protection to the controller and

the supply. The circuit breaker is available with or without ground fault
protection. See Figure 132.

Table 112 for current rating
and part numbers.
The fused flange disconnect and the circuit breaker also provide a means
for shutting off power to the controller and locking the power out.
WARNING
Turning the disconnect or circuit breaker to the OFF
position removes power from the output side of the device
only. High voltage is always present at the input side
whenever the controller is connected to a power source.
WARNING
Turning the disconnect to the OFF position removes power
from the output side of the device only. High voltage is
always present at the input side whenever the controller is
connected to a power source.
1. OVERVIEW
139
MARMMTRBL02303E
Figure 131. Fused Flange Disconnect

MAIN
DISCONNECT
Fuse Block
FL1 FL2 FL3
Figure 132. Circuit Breaker
1. OVERVIEW
MARMMTRBL02303E
140
Table 111.
Circuit Breaker, B-Size Cabinet
Input
Voltage
g
Circuit Breaker
Current
Current
Part Number
50A
A60L-0001-0347
#B030S
30A
A60L-0001-0306 #BA
380
416
460
480
500
550
30A
A60L-0001-0347
#B015S
20A
A60L-0001-0306 #AA
15A
A60L-0001-0258
#SA538-15
Table 112.
Cabinet
Input
Voltage
Part Number
220
240
575
Circuit Breaker
Circuit Breaker with Ground

Fault
Not Available
Circuit Breaker and Fused Flange Disconnect Switch, C-Size
Circuit Breaker with Ground

Fault
Current
Part Number
Current
Part Number
220
240
50A
A60L0001-0308 #F050
50A
A60L0001-0306 #DA
380
416
460
480
500
550
30A
A60L0001-0347
#B030S
30A
A60L0001-0307
#B20B3
575
20A
A60L0001-0258
#SA53H-20
Fused Flange Disconnect Switch

Fuse
Size
Part Number
5A
A60L0001-0181 #175
Fuse A60L0001-0042
#JG2-50
30A
A60L0001-0181 #175
Fuse A60L0001-0042
#JG1-30
Not Available
Table 113.
Fused Flange Disconnect Switch, C-Size Cabinet

Fused Flange Disconnect Switch
Inputt
Inp
Voltage
220
240
380
416
460
480
500
550
575
Fuse
Size
Part Number
50A
A60L0001-0181 #175
Fuse A60L0001-0042 #JG2-50
30A
A60L0001-0181 #175
Fuse A60L0001-0042 #JG1-30
1. OVERVIEW
141
MARMMTRBL02303E
1.13
USER TRANSFORMER
C-size controllers might contain an optional user transformer. It supplies

120VAC single-phase power to a NEMA outlet receptacle. It is located on
the lower left side of the controller.
A80L-0001-0520
Figure 133. User Transformer
User Transformer
TF2
1.14
OPERATOR PANEL
Refer to Table 112 for part
numbers.
Pushbuttons and LEDs on the Operator Panel are used to control the robot
and to indicate robot status. It might be equipped with one or both of the
following:
Remote CRT/KB port for connecting a terminal to the controller.
DB25 connector for serial interface (external disk drive, for example)
Disconnectable teach pendant port with a switch so the robot can be

operated without the teach pendant connected.
1. OVERVIEW
MARMMTRBL02303E
142
An emergency stop button on the operator panel places the robot into the
emergency stop condition. The operator panel LED functions are
described in Chapter 3, Lights and LEDs.
Figure 134 shows the operator panel on a B-size controller. Figure 135
shows the operator panel on a C-size controller.
Figure 136 shows the operator panel on a C-size controller.
Figure 134. Operator Panel, B-Size Controller

BATTERY
TEACH PENDANT
ENABLED
HOUR METER
RS232C
CRT/KB
FAULT
FAULT RESET
HOLD
USER LED#1
USER PB#1
CYCLE START
USER LED#2
REMOTE
USER PB#2
REMOTE
ON
ALARM
OFF
EMERGENCY
STOP
LOCAL
Figure 135. Operator Panel, C-Size Controller
BATTERY
ALARM
CYCLE START
ON
TEACH PENDANT
ENABLED
HOLD
OFF
FAULT
FAULT RESET
REMOTE
USER LED#1
REMOTE
USER PB#1
LOCAL
USER LED#2
USER PB#2
HOUR METER
RS232C
CRT/KB
EMERGENCY STOP
1. OVERVIEW
143
MARMMTRBL02303E
Figure 136. Operator Panel, C-Size Controller
BATTERY
ALARM
CYCLE START
ON
TEACH PENDANT
ENABLED
HOLD
OFF
FAULT
FAULT RESET
PURGE
COMPLETE
REMOTE
PURGE ENABLE
REMOTE
LOCAL
PURGE
FAULT
BRAKE ENABLE
ON
HOUR METER
OFF
RS232C
CRT/KB
TEACH PENDANT
CONNECT/
DISCONNECT
Optional
EMERGENCY STOP
Table 114.
Part Numbers
Controller
Without Disconnectable
Teach Pendant
B-Size
A05B-2302-C020
C-size with Built-In A05B-2301-C001
CRT/KB
C-size with
A05B-2301-C002
Remote CRT/KB
Table 115.
With Disconnectable Teach

Pendant
A05B-2302-C021
A05B-2301-C003
A05B-2301-C004
Part Numbers
Controller
Without Disconnectable
Teach Pendant
C-size with Built-In A05B-2308H190
CRT/KB
C-size with
A05B-2308H191
Remote CRT/KB
With Disconnectable Teach

Pendant
A05B-2308H192
A05B-2308H193
1. OVERVIEW
144
1.15
TEACH PENDANT
part numbers.
MARMMTRBL02303E
The teach pendant is a hand held device used for operating and
programming the robot. Keys on the teach pendant are used to enter data,
jog the robot, and to display menus.
The pendant has a liquid crystal display 16 lines long by 40 characters
wide. The teach pendant also has an emergency stop button that places the
robot into an emergency stop condition.
A deadman switch is mounted on the back of the teach pendant. It must be
held in while the teach pendant is turned on. If it is released while the
teach pendant is turned on, the robot will enter a fault condition similar to
emergency stop.
WARNING
The robot will become fully functional and capable of being
started at the operator panel if the teach pendant is turned
off and the fence circuit is not installed or closed. When
working in the robot envelope, ALWAYS CARRY THE
TEACH PENDANT and ALWAYS HAVE THE TEACH
PENDANT ENABLED.
Seven of the keys on the teach pendant provide different functions

depending on the software in the controller. Eleven LEDs display status of
the system. LEDs are different based on software operating in the
controller. When a nonintrinsic safe teach pendant is used, there are
eleven LEDs that display status of the system. LEDs are different based
on software operating in the controller.
Refer to Chapter 3, Lights and LEDs, for an explanation of the LEDs.
The teach pendant used with the P-155 robot is an Intrinsically Safe
device. It is powered by 8VDC, converted from 24VDC by the Intrinsic
Barrier unit, part number A20B-1005-0240, mounted on the rear of the
enclosure front door.
1. OVERVIEW
145
MARMMTRBL02303E
Figure 137. Teach Pendant
LCD Display
LEDs
Emergency Stop
Button
DEADMAN
Switches
Application-Dependant Keys
Table 116.
Teach Pendant Part Numbers
Application
Intrinsically Safe
NonIntrinsically Safe
Part Number
A05B-2308-H300
A05B-2301-H305
CAUTION
The intrinsically safe teach pendant and the non-intrinsically
safe teach pendant are not interchangeable and will damage
the controller, teach pendant cable, and teach pendant if the
incorrect model is attempted to be used.
Teach Pendant Intrinsically

Safe Barrier PCB
A05B2308C040
The teach pendant Intrinsically Safe Barrier PCB is mounted to the inside
of the cabinet door. The two main connectors, CRS1 and CRS2 join the
intrinsically safe teach pendant with the Main CPU. It is used to ensure
that there not be enough energy to induce a spark within the teach pendant.
This is accomplished by lowering the voltage and limiting current to the
teach pendant through the use of Intrinsically Safe Barriers (refer to
Section 1.19) and opto-isolation chips.
Table 117.
Teach Pendant Part Numbers
Application
Spot Welding
Material Handling
Arc Welding
Sealing
General Use
Part Number
A05B-2301-C300
A05B-2301-C301
A05B-2301-C302
A05B-2301-C303
A05B-2301-C305
Comment
Japanese
1. OVERVIEW
MARMMTRBL02303E
146
Table 117. (Contd) Teach Pendant Part Numbers
Application
Spot Welding
Material Handling
Arc Welding
Sealing
General Use
Part Number
A05B-2301-C310
A05B-2301-C311
A05B-2301-C312
A05B-2301-C313
A05B-2301-C315
Comment
English
g
1. OVERVIEW
147
MARMMTRBL02303E
1.16
HEAT EXCHANGE AND
FANS
Refer to Figure 139 for
part numbers
The temperature in the controller is kept within operating range through

the use of an air-to-air heat exchange system. The controller is sealed to
prohibit outside air from entering. Internal controller air is circulated by
fans around the inside of the controller and downward through the internal
side of the heat exchange unit. Outside air is circulated upward through
the external side of the heat exchange unit also by using a fan. This
process cools the inside air.
Fans are provided on the printed circuit board racks mounted on the
backplane to circulate air over the printed circuit boards.
Cooling fins connected to the servo amplifiers are within the heat
exchange unit to keep the heat generated by the servo power circuits out of
the controller.
Figure 138 shows the heat exchange system for a B-size controller.
Figure 139 shows the heat exchange system for a C-size controller.
Figure 139 shows the heat exchange system for a C-size controller.
Figure 138. Heat Exchange System, B-Size Controller
FANS
FAN 1
Fan Unit
A05B-2302-C901
Fan (Alone)
A90L-0001-0219 #A
AIR FLOW
INTERNAL AIR
OUTSIDE AIR
FAN 3
Fan Unit
A05B-2302-C902
Fan (Alone)
A90L-0001-0213 #A
OUTSIDE AIR IN
FAN 2
Fan Unit
A05B-2302-C900
Fan (Alone)
A90L-0001-0213 #A
1. OVERVIEW
MARMMTRBL02303E
148
Figure 139. Heat Exchange System, C-Size Controller
Fan (Alone)
A90L-0001-0378
FAN 1
Fan Unit
A05B-2301-C901
Fan (Alone)
A90L-0001-0219 #A
AIR FLOW
INTERNAL
AIR
OUTSIDE
AIR
FANS
FAN 2
Fan Unit
A05B-2302-C900
Fan (Alone)
A90L-0001-0213#A
FAN 3
Fan Unit
A02B0056-C904
Fan Alone
A90L-0001-0219 #A
1.17
PURGE SYSTEM
IBRC
A15200010020
OUTSIDE AIR IN
The IBRC is an intrinsically safe barrier unit that is used as part of the
purge system required in the P-155 robot. It has ten photo-isolated relays.
It provides an intrinsically safe barrier for the following signals:

PS-1 Pressure Switch #1 (used for the robot purge system)

FS1 Flow Switch #1 (used for the robot purge system)
FS2 Flow Switch #2 (used for opening device purge system)
ROT/FOT Robot Overtravel Switches (FOT is not applicable)
PS3 Pressure Switch #3 (used for opening device purge system)
EOAT 1 & 2 Not presently used
AUX HBLD Auxiliary Hand Broken (used with Color Trak System)
HBKD Hand Broken (used when a collision detect device is installed)
TPCO Teach Pendant Connect/Disconnect (used when a remote
pendant port is installed in the paint booth. Connected to a
connect/disconnect switch mounted on the pendant port)
1. OVERVIEW
MARMMTRBL02303E
149
The IBRC requires 210VAC from a secondary winding of TF1 to operate.
Internal circuitry provides 20VDC to the hazardous side terminals which
are isolated from the safe side terminals and their voltage of 24VDC.
There are ten red LEDs, one for each device used in the field. There are a
pair of terminals, labeled Px and Nx, for each hazardous signal, while the
corresponding safe side terminals have Ax, Bx, and Cx. Cx is the 24VDC
input, and Ax and Bx are the normally open and normally closed contact
outputs respectively. When voltage is being applied to the field switch
device contacts and they are closed, the IBRC LED will be illuminated for
that particular contact. Should a jumper be installed across the P and N
terminals, the LED for those terminals will be illuminated.
With plant air supplied to the robot, and power available to the IBRC
through the disconnect switch in the ON position, PS-1 LED should be
illuminated.
1.18
PURGE UNIT POWER
SUPPLY
A05B2308C040
The Purge Unit Power Supply is a 24VDC auxiliary power supply used
exclusively for the purge system. It is mounted alongside the IBRC unit.
It provides voltage necessary to energize the purge solenoid valve within
the robot and opening devices when applicable. It also provides 24VDC to
the relay coils mounted on the piggy-back Purge Control PCB in the EMG
module.
It requires 210VAC supplied by TF1 and is internally fused by two fuses
mounted on the power supply PCB itself, F-11 and F-12.
1.19
INTRINSICALLY SAFE
BARRIERS (STAHL)
ISBM890131280XX
The Intrinsically Safety Barriers (ISB) are mounted to the left of the IBRC
unit. They are used in the purge system similar to the IBRC unit, in that
they restrict power that may cause a spark. The solenoid of the purge
valve requires 24VDC, and is internally located within the robot cavity.
The internal atmosphere is to be considered hazardous prior to purging,
therefore an Intrinsically SafeBarrier device is used to prevent possible
sparking. Two of these devices will be used if opening devices are also
incorporated with the robot; one for the robot purge solenoid valve, and
the other for the opening device purge solenoid.
They are similar to a fuse. If one should be found defective, it must be
replaced by a known good Intrinsically Safe Barrier, discarding the
defective one.
1. OVERVIEW
150
MARMMTRBL02303E
WARNING
When replacing this Stahl Intrinsically Safe Barrier device, pay
careful attention to exact model or part number. Many models
appear physically identical, but have different power ratings.
Also, careful observance of which end of the device is
considered to be the SAFE side, or the HAZARDOUS side
is critical. Typically the end with the Blue colored cap should
be connected to the device located in the HAZARDOUS zone.
1.20
TRANSIT BOARD
A05B2308C030
The Transit Board is a PCB mounted on the internal side of the R-J
controller cabinet, equipped only with connectors and associated cabling
that route control signals and data to various locations within the P-155
R-J controller. It is a passive device used for interfacing purposes.
MARMMTRBL02303E
DIAGNOSTIC SCREENS
21
Various builtin diagnostic screens reveal important information regarding
the status of the SYSTEM R-J Controller. These screens with
explanations of the screen data are presented in this section.
Figure 21. Default PowerUp Screen
UTILITY Hints
JOINT 10 %
MENUS Provides a list of all menus.
FCTNS Provides helpful functions.
SELECT, EDIT, DATA, POSN, I/O, STAT
Displays menus with those names.
Function keys with [] show more
choices.
F1 [ TYPE ] function key lists related
screens with a menu.
[ TYPE ]
OFF
MENUS Key
Used to select the
teach pendant menus
SELECT Key
Used to SELECT and
create programs
HELP
ON
DATA Key
Examine and change
data register contents
EDIT Key
Used to edit a
particular program
The UTILITY Hints screen, shown in Figure 21, is the first screen to
appear in the menu structure; this is the starting level to the rest of the
diagnostic screens. Most operations begin by pressing MENUS. The F1,
[TYPE] function key will show submenus within any menu shown on the
screen.
This chapter contains information about the following diagnostic screens:
Safety signals
Position display
Robot Axes motion
Alarm log
Version IDs
Memory
2. DIAGNOSTIC SCREENS
22
MARMMTRBL02303E
2.1
SAFETY SIGNAL
STATUS
The STATUS Safety signal screen displays the status of safety-related

control signals coming into the controller.
The safety signal screen displays the current state (TRUE or FALSE) of
each safety signal. You cannot change the condition of the safety signal
using this screen. Table 21 lists and describes each safety signal. Use
Procedure 21 to display safety signal status.
Table 21.
SAFETY
SIGNAL
Safety Signals
DESCRIPTION
SOP E-Stop
Indicates whether the EMERGENCY STOP button on the operator panel has been pressed. The
status is TRUE if the operator panel EMERGENCY STOP button has been pressed.
TP E-Stop
Indicates whether the EMERGENCY STOP button on the teach pendant has been pressed. The
status is TRUE if the teach pendant EMERGENCY STOP button has been pressed.
Ext E-Stop
Indicates whether an external emergency exists. The status is TRUE if the external emergency stop
contacts are open on the emergency control PCB (EMG) and the following conditions exist:
SOP E-STOP is FALSE
TP E-Stop is FALSE
Hand Broken is FALSE
Overtravel is FALSE
If any one of these conditions is TRUE, Ext EStop is displayed as FALSE even though the external
emergency stop switch could be open.
Fence Open
Indicates whether the safety fence switch is open. The status is TRUE if the safety fence terminals
are open on the emergency control (EMG) PCB. This does not require the teach pendant to be
enabled.
TP Deadman
Indicates when either the left or right teach pendant DEADMAN switch is pressed. The status is
TRUE if either DEADMAN switch is pressed.
TP Enable
Indicates whether the teach pendant ON/OFF switch is ON. The status is TRUE when the teach
pendant ON/OFF switch is ON.
Overtravel
Indicates whether the robot has moved beyond its overtravel limits. The status is TRUE when the
robot has moved beyond its overtravel limits tripping the overtravel switch.
Low Air Alarm
Indicates whether the air pressure has decreased below the acceptable limit. Low Air Alarm is
usually connected to an air pressure sensing device. The status is TRUE when the air pressure is
below the acceptable limit. You must set the $PARAM_GROUP[1].$PPABN_ENBL system variable
to TRUE to use this signal.
23
MARMMTRBL02303E
Procedure 21
Step
Displaying Safety Signal Status

1 Press MENUS.
2 Select STATUS.
3 Press F1, [TYPE].
4 Select Safety Signal. You will see a screen similar to the following.
STATUS Safety
1
2
3
4
5
6
7
8
9
10
SIGNAL NAME
SOP EStop:
EStop:
SOP
TP EStop:
Ext EStop:
Fence Open:
TP Deadman:
TP Enable:
Hand Broken:
Overtravel:
Low Air Alarm
Belt Broken:
[ TYPE ]
JOINT
STATUS
TRUE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
FALSE
10 %
1/10
24
2.2
POSITION STATUS
MARMMTRBL02303E
The POSITION screen displays positional information in joint angles or

Cartesian coordinates. The positional information on this screen is
updated continuously when the robot moves. You cannot change the
displayed information using this screen.
NOTE E1, E2, and E3 indicate extended axis positional information if
extended axes are installed in your system.
Joint
The joint screen displays positional information in degrees for each robot
axis. Tool indicates the number of the active tool frame.
User
The user screen displays positional information in Cartesian coordinates

based on the user frame. Tool indicates the number of the active tool
frame. Frame indicates the number of the active user frame.
World
The world screen displays positional information in Cartesian coordinates

based on the world frame. Tool indicates the number of the active tool
frame.
Use Procedure 22 to display position status.
25
MARMMTRBL02303E
Procedure 22
Step
Displaying Position Status

1 Press MENUS.
2 Select POSITION.
3 Select the appropriate coordinate system.
For joint, press F2, JNT. You will see a screen similar to the
following.
POSITION
Joint
J1:
J4:
E1:
JOINT
.001 J2:
.000 J5:
.001 E2:
[ TYPE ]
JNT
10.028 J3:
34.998 J6:
.001 E3:
USER
10 %
Tool: 1
35.025
.001
.001
WORLD
NOTE E1: , E1:, and E3 are displayed only if you have extended axes.
For user, press F3, USER. You will see a screen similar to the
following.
POSITION
User
USER
Frame: 0
Configuration: F, 0, 0, 0
x: 1906.256 y:
.041
w: 178.752 p: 89.963
E1:
.001 E2:
.001
[ TYPE ]
JNT
USER
10 %
Tool: 1
z: 361.121
r:
1.249
E3:
.001
WORLD
26
MARMMTRBL02303E
For world, press F4, WORLD. You will see a screen similar to
the following.
POSITION
World
WORLD
Configuration: F, 0, 0, 0
x: 1906.256 y:
.041
w: 178.752 p: 89.963
E1:
.001 E2:
.001
[ TYPE ]
JNT
USER
10 %
Tool: 1
z: 361.121
r:
1.249
E3:
.001
WORLD
27
MARMMTRBL02303E
2.3
ROBOT AXES STATUS
The robot axes status screen displays information for each robot axis. This
information is continually updated. Use this information when you call
the FANUC Robotics Hotline if a problem occurs with your robot.
The Axis Status Pulse screen displays information about axis motion.
Table 22 lists and describes each kind of information displayed on this
screen.
Use Procedure 23 to display the axis status pulse screen.
Table 22.
Axis Status Pulse Screen Items
ITEM
DESCRIPTION
Motion
Command
Displays the desired value of the Absolute Pulse Coder (APC) when the robot gets to the position
commanded by the controller.
Machine Pulse
Shows the actual APC count as read by the controller.
Position Error
Displays the difference between the commanded APC count versus the actual APC count.
You cannot change any information on this screen except for the group
number. Group number only applies if you have multiple groups;
otherwise, it remains as 1.
Procedure 23
Step
Displaying the Axis Status Pulse Screen

1 Press MENUS.
2 Select STATUS.
3 Press F1, [TYPE].
4 Select Axis.
5 Display the status screen you want:
For Pulse, press F4, PULSE.
STATUS
J1:
J1:
J2:
J3:
J4:
J5:
J6:
JOINT
Position
Error
0
0
0
0
0
0
[ TYPE ]
STATUS1
Machine
Pulse
00000000
00000000
00000000
00000000
00000000
00000000
STATUS2
10 %
GRP [ 1]
Motion
Command
0
0
0
0
0
0
PULSE
GRP# >
MARMMTRBL02303E
28
2.4
ALARM LOG
The Alarm Log displays a list of the 100 most recent alarms. Figure 22
shows an example of the Alarm Log.
Figure 22. Alarm Log
1
2
3
SRVO049 OHAL 1 alarm (Group=1 Axis=6)

PROGRAM
LINE 4
Alarm
JOINT 10%
1/100
1 SRVO049 OHAL 1 alarm (Group:1 Axis:6)
2 SRVO042 MCAL 1 Alarm (Group:1 Axis:6)
3 R E S E T
[ TYPE ]
CLEAR
HELP
The areas of the Alarm Log are as follows:

1. This is the most recent alarm message. This message will be
displayed in this line regardless of the screen you choose.
2. Indicates the program name and line number of program last having
been acted upon.
3. Lists all of the alarm messages, up to 100, with the most recent alarm
on the top of the list. When the RESET key is pressed, a RESET is
logged on the alarm message screen.
4. Indicates the line number the cursor is on in proportion to how many
lines numbers available.
Use Procedure 24 to display the Alarm Log.
29
MARMMTRBL02303E
Procedure 24
Condition
Step
Displaying the Alarm Log

An error has occurred.
1 Press MENUS.
2 Select ALARM.
3 Press F1, [TYPE].
4 Select Alarm Log. The alarm log will be displayed. This lists all
errors. See the following screen for an example.
SRVO002 Teach pendant emergency stop
TEST1
LINE 15
ABORTED
Alarm
WORLD 100 %
1/100
1 SRVO002 Teach pendant emergency sto
2 SRVO001 Operator panel emergency st
3 R E S E T
4 SRVO029 Robot calibrated (Group:1)
5 SRVO001 Operator panel emergency st
6 SRVO012 Power fail recovery
7 INTP127 Power fail detected
8 SRVO047 LVAL alarm (Group:1 Axis:5)
9 SRVO047 LVAL alarm (Group:1 Axis:4)
10 SRVO002 Teach pendant emergency sto
[ TYPE ]
CLEAR
HELP
The most recent error is number 1.

5 To display the motion log, which lists only motion-related errors,
press F1, [TYPE], and select Motion Log.
6 To display the system log, which displays only system errors, press
F1, [TYPE], and select System Log.
7 To display the application log, which displays only
application-related errors, press F1, [TYPE], and select Appl Log.
8 To display more information about an error, move the cursor to the
error and press F5, HELP. The error help screen displays information
specific to the error you selected. When you are finished viewing the
information, press PREV.
9 To remove all of the error messages displayed on the screen, press
F4, CLEAR.
210
MARMMTRBL02303E
2.5
VERSION
IDENTIFICATION
STATUS
The STATUS Version IDs screen displays information specific to your

controller. Use this information when you call the FANUC Robotics
Hotline if a problem occurs with your controller. You cannot change the
information displayed on this screen. Table 23 lists and describes the
version identification status information.
Table 23. Version Identification Status Items
VERSION ID ITEM
DESCRIPTION
Appl/Tool
The name of the application package.
Appl/Tool ID
The version number of the application package.
Robot Model
The robot model name, the torque on the wrist, and the type of wrist.
S/W Serial Number
The software order number for the disk set.
Core Name
The name of the core software.
Core ID
The version number of the core software.
Library Name
The name of the robot library.
Library ID
The version number of the robot library.
Servo Code ID
The version of servo parameters installed.
Mot Param ID
The software version for the software that controls motion
Update #110
The name and software version for which a post-release software update has been
installed.
Build ID
Internal software version information.
Use Procedure 25 to display version identification status.
211
MARMMTRBL02303E
Procedure 25
Step
Displaying the Version Identification Status

1 Press MENUS.
2 Select STATUS.
3 Press F1, [TYPE].
4 Select Version ID. You will see a screen similar to the following.
STATUS Version ID
ITEM:
1 Appl/Tool:
2 Appl/Tool ID:
3 Robot Name:
4 S/W Serial Number:
5 Core Name:
6 Core ID:
7 Library Name:
8 Library ID:
9 Servo Code ID:
10 Mot Param ID:
11 Update #1:
JOINT
10 %
SOFTWARE:
Std System Core
V3.06P
S500INLN
F00000
Std System Core
V3.06
Std Robot Library
V3.06P
J03.00
V1.00
Uninitialized
20 Update #10:
21 Build ID:
Uninitialized
V3.06
02/13/9X
[ TYPE ] SOFTWARE
MOT_ID
MOT_INF
SER_PAR
5 Press the key that corresponds to the version ID status screen you want
to display:
To display software version information, press F2,

SOFTWARE.
To display motor types for each axis, press F3, MOT_ID. You
will see a screen similar to the following.
STATUS Version IDs

1
1:
2:
3:
4:
5:
6:
7:
8:
9:
10:
GRP:
1
1
1
1
1
1
*
*
*
*
AXIS:
1
2
3
4
5
6
*
*
*
*
[ TYPE ] SOFTWARE
JOINT
MOTOR ID:
AC20
AC20F
AC20F
AC10
AC10
AC10
Uninitialized
Uninitialized
Uninitialized
Uninitialized
MOT_ID
MOT_INF
10 %
1/16
SER_PAR
212
MARMMTRBL02303E
To display the motor information for each axis, press F4,

MOT_INF. You will see a screen similar to the following.
STATUS Version IDs

GRP:
AXIS:
1
11: 1
2: 1
2
3: 1
3
4: 1
4
5: 1
5
6: 1
6
7: *
*
8: *
*
9: *
*
10: *
*
[ TYPE ] SOFTWARE
JOINT
10 %
MOTOR INFO:
1/16
H1 DSP1L
H2 DSP1M
H3 DSP2L
H4 DSP2M
H5 DSP3L
H6 DSP3M
Uninitialized
Uninitialized
Uninitialized
Uninitialized
MOT_ID
MOT_INF
SER_PAR
To display the servo parameters for each axis, press F5,

SER_PAR. You will see a screen similar to the following.
STATUS Version IDs

GRP:
AXIS:
1
1: 1
1
2: 1
2
3: 1
3
4: 1
4
5: 1
5
6: 1
6
7: *
*
8: *
*
9: *
*
10: *
*
[ TYPE ] SOFTWARE
JOINT
10 %
SERVO PARAM ID:
1/16
PO1.00
PO1.00
PO1.00
P01.00
PO1.00
P01.00
Uninitialized
Uninitialized
Uninitialized
Uninitialized
MOT_ID
MOT_INF
SER_PAR
213
MARMMTRBL02303E
2.6
The STATUS Memory screen displays information about controller

memory. Table 24 lists and describes each memory status item. Use
Procedure 26 to display memory status.
MEMORY STATUS
Table 24. Memory Status

MEMORY STATUS
DESCRIPTION
User
Indicates the amount of memory for user programs: teach pendant programs and KAREL
programs.
Total indicates the original size of the memory area.
Free indicates how much memory is available.
Largest Free indicates the largest contiguous segment of available memory.
System
Indicates the amount of memory for system information: FDICT (dictionary files that
define what is displayed on the screens), F-PROG (application, operating system, and
option files), and C-WORK (temporary memory used for system operations).
Total indicates the original size of the memory area.
Free indicates how much memory is available.
Largest Free indicates the largest contiguous segment.
Hardware
Indicates the total amount of memory in FROM and CMOS RAM.
Procedure 26
Step
Displaying Memory Status

1 Press MENUS.
2 Select STATUS.
3 Press F1, [TYPE].
4 Select Memory. You will see a screen similar to the following.
STATUS Memory
USER
TOTAL
KAREL
2921.0KB
TPE
150.0KB
SYSTEM
F-DICT
320.0KB
FPROG
512.0KB
CWORK 1023.9KB
HARDWARE
FROM
2.0MB
CMOS
4.0MB
[ TYPE ]
JOINT
100 %
FREE
LRGST FREE
2062.0KB 1939.9KB
71.2KB
70.1KB
18.2KB
91.3KB
552.8KB
18.2KB
91.3KB
547.6KB
MARMMTRBL02303E
LIGHTS AND LEDS

31
This chapter describes the lights and LEDs you can use for diagnostics:

Teach pendant LEDs

Operator panel LEDs
Circuit board diagnostic LEDs
3. LIGHTS AND LEDS

MARMMTRBL02303E
32
3.1
TEACH PENDANT
DIAGNOSTIC LEDS
The non-intrinsically safe teach pendant has several LEDs to assist you in
determining the status of the controller. Figure 31 shows the teach
pendant LEDs. Table 31 lists and describes the teach pendant LEDs.
The LEDs whose labels are blank vary depending on the particular
application.
On the Intrinsically Safe Teach Pendant, these LEDs are simulated by
symbols on the teach pendant display.
Refer to the Setup and Operations Manual for your application for
information on application-specific LEDs.
Figure 31. Teach Pendant LEDs
ApplicationSpecific
LEDs
FAULT
HOLD
STEP
BUSY
RUNNING
JOINT
XYZ
TOOL
OFF
Table 31.
ON
Teach Pendant Status Indicators
INDICATOR
DESCRIPTION
FAULT
Indicates that a fault condition has occurred.
HOLD
Indicates that the robot is in a hold condition. HOLD is not on continuously during a hold condition.
STEP
Indicates that the robot is in step mode.
BUSY
Indicates that the controller is processing information.
RUNNING
Indicates that a program is being executed.
JOINT
Indicates that the current jog coordinate system is JOINT.
XYZ
Indicates that the current jog coordinate system is WORLDFRAME, JOGFRAME, or USERFRAME.
XYZ
Indicates that the current jog coordinate system is JOG frame or WORLD.
TOOL
Indicates that the current jog coordinate system is TOOL.
3. LIGHTS AND LEDS
33
MARMMTRBL02303E
3.2
OPERATOR PANEL
DIAGNOSTIC LEDS
The operator panel has several LEDs to assist you in determining the
status of the controller. Figure 32 shows the operator panel LEDs.
Table 32 lists and describes the operator panel LEDs.
Figure 32. Operator Panel LEDS
BATTERY
ALARM
CYCLE START
ON
TEACH PENDANT
ENABLED
HOLD
OFF
FAULT
FAULT RESET
USER LED#1
USER PB#1
USER LED#2
USER PB#2
RS232C
REMOTE
REMOTE
LOCAL
HOUR METER
CRT/KB
EMERGENCY STOP
3. LIGHTS AND LEDS

MARMMTRBL02303E
34
Figure 33. Operator Panel LEDS
BATTERY
ALARM
CYCLE START
ON
TEACH PENDANT
ENABLED
HOLD
OFF
FAULT

FAULT RESET
PURGE
COMPLETE
REMOTE
PURGE ENABLE
REMOTE
LOCAL
PURGE
FAULT
BRAKE ENABLE
ON
OFF
RS232C
CRT/KB
HOUR METER
TEACH PENDANT
CONNECT/
DISCONNECT
Optional
EMERGENCY STOP
Table 32.
INDICATOR
BATTERY ALARM
TEACH PENDANT ENABLED
FAULT
REMOTE
USER LED #1
USER LED #2
PURGE COMPLETE
Standard Operator Panel C-Size Controller Status Indicators
DESCRIPTION
Indicates that the backup battery voltage is low. Replace the battery, using
Procedure 9-1.
Indicates that the teach pendant is enabled and has motion control.
Indicates a fault condition has occurred.
Indicates that robot motion can only be started by a PLC or other remote device. The
operator panel cycle start pushbutton cannot cause robot motion. This is determined
by the position of the REMOTE/LOCAL keyswitch.
User-defined and accessible from a KAREL program or macros.
User-defined and accessible from a KAREL program or macros.
Identifies that the robot cavities have been purged and are presently at the prescribed
pressure as outlined in the P-155 Mechanical Service Manual.
This LED must be illuminated in order to turn power on to the R-J controller.
Indicates a fault exists with the purge system.
Indicates that the purge cycle has started. You can now release the pushbutton if you
are holding it.
POWER ON PUSHBUTTON LED
Indicates that the robot is powered on.
CYCLE START PUSHBUTTON LED Indicates that the robot is currently running a program
HOLD
Indicates that the robot is in a software hold condition.
PURGE FAULT
PURGE ENABLE PUSHBUTTON
3. LIGHTS AND LEDS
35
MARMMTRBL02303E
3.3
CIRCUIT BOARD
DIAGNOSTIC LEDS
The RJ Controller contains several diagnostic LEDs within the controller.

They are on the circuit boards that plug into the backplane, on the servo
amplifiers, and on the modular I/O unit. Figure 34 shows an overview of
the circuit board diagnostic LEDs. Refer to the sections that follow for
descriptions of the following circuit board diagnostic LEDs:

Emergency control board (EMG)

Power supply unit (PSU)
Axis control board
Main CPU board
Servo amplifier
Contact signal transducer (IBRC)
Modular I/O (optional)
Process I/O board (optional)
RH MAP Interface (optional)
ABRIO printed circuit board (optional)
3. LIGHTS AND LEDS

MARMMTRBL02303E
36
Figure 34. Circuit Board Diagnostic LEDs
OPTIONAL
INTERFACE
MODULE LEDS
Section 3.3.7
OPTIONAL
PROCESS I/O
BOARD LEDS
Section 3.3.8
OPTIONAL I/O
MODULE LEDS
Section 3.3.7
MAIN CPU
BOARD LEDS
Section 3.3.4
AXIS
CONTROL
BOARD LEDS
Section 3.3.3
PSU BOARD
LEDS
Section 3.3.2
EMG BOARD
LEDS
Section 3.3.1
SERVO
AMPLIFIER
DIAGNOSTIC
LED (7SEG)
Section 3.3.5
3. LIGHTS AND LEDS
37
MARMMTRBL02303E
Figure 35. Circuit Board Diagnostic LEDs
INTERFACE
MODULE LEDS
Section 3.3.7
IBRC LEDS
I/O
MODULE LEDS
Section 3.3.7
OPTIONAL
KRIO/GEF/MAP
MODULES
Sections 3.3.10
and 3.3.11
MAIN CPU
BOARD LEDS
Section 3.3.4
AXIS
CONTROL
BOARD LEDS
Section 3.3.3
PSU BOARD
LEDS
Section 3.3.2
EMG BOARD
LEDS
Section 3.3.1
SERVO
AMPLIFIER
DIAGNOSTIC
LED (7SEG)
Section 3.3.5
3. LIGHTS AND LEDS

MARMMTRBL02303E
38
3.3.1
Emergency Control
Board (EMG)
Diagnostic LEDs
Figure 37 shows the emergency control board (EMG) diagnostic LEDs.

Table 34 lists and describes each LED.
Figure 36. Emergency Control Board (EMG) Diagnostic LEDs
SON
BRKL
BRK1
BRK4
BRK2
BRK5
BRK3
BRK6
FALM
3. LIGHTS AND LEDS
39
MARMMTRBL02303E
Figure 37. Emergency Control Board (EMG) Diagnostic LEDs
BRK4
NOT USED
BRK5
BRK6
FALM
Table 33.
BRK1
SON
BRK2
BRK3
Emergency Control Board (EMG) Diagnostic LEDs
LED
SON
(Green)
BRK 1*
(Green)
BRK2*
(Green)
BRK3*
(Green)
FALM
(red)
Name
Servo on
BRK4*
(Green)
BRK5*
(Green)
Brake Circuit 4
Release
Brake Circuit 5
Release
Brake Circuit 1
Release
Brake Circuit 2
Release
Brake Circuit 3
Release
Fuse alarm of
the brake circuit
Description
When this LED lights, 100 VAC is supplied to the
servo amplifier MCC coils.
When this LED lights, axis 1 brake is energized.
When this LED lights, axis 2 and 3 brakes are
energized.
When this LED lights, axis 4, 5, and 6 brakes are
energized.
This LED lights if the brake-fuse is blown or a
voltage spike has occurred. Refer to Servo Alarm
SRVO-008.
When this LED lights, auxiliary axis are energized.
3. LIGHTS AND LEDS

MARMMTRBL02303E
310
Table 33. (Contd) Emergency Control Board (EMG) Diagnostic LEDs

LED
BRK6*
(Green)
BRKL
Table 34.
Name
Brake Circuit 6
Release
Manual Brake
Release
Description
Brakes are released by the front panel keyswitch
Emergency Control Board (EMG) Diagnostic LEDs
LED
SON
(Green)
BRK 1*
(Green)
BRK2*
(Green)
BRK3*
(Green)
FALM
(red)
Name
Servo on
BRK4*
(Green)
BRK5*
(Green)
BRK6*
(Green)
Brake Circuit 4
Release
Brake Circuit 5
Release
Brake Circuit 6
Release
Brake Circuit 1
Release
Brake Circuit 2
Release
Brake Circuit 3
Release
Fuse alarm of
the brake circuit
Description
When this LED lights, 100 VAC is supplied to the
servo amplifier MCC coils.
When this LED lights, brake circuit 1 is energized.
This LED lights if the 100 VAC brake-fuse is blown
or a voltage spike has occurred. Refer to Servo
Alarm SRVO-008.
When this LED lights, brake circuit 6 are energized.
* Refer to robot-specific electrical maintenance for brake connections.
3. LIGHTS AND LEDS
311
MARMMTRBL02303E
3.3.2
Figure 38 shows each power supply unit (PSU) diagnostic LED.
Power Supply Unit

(PSU) Diagnostic LEDs
Figure 38. Power Supply Unit (PSU) Diagnostic LEDs
PSU
Power Input LED (PIL) LED

This LED lights if 200 VAC is being supplied to the PSU
from Transformer TF1 (Main disconnect is on), if fuses
F1, F2, or F5 (on circuit board) are not blown, and the
power supply internal circuitry is okay.
ALM (Fuse Alarm) LED
This LED will light if fuse F3 is blown and/or there
are any DC power circuit malfunctions.
3. LIGHTS AND LEDS

MARMMTRBL02303E
312
3.3.3
Axis Control Board
Diagnostic LEDs
The four green status LEDs will also light on the axis control printed
circuit board at power on and then change during software initialization.
See Figure 39.
Figure 39. Axis Control Board Diagnostic LEDs
STATUS
ALARM
Table 35 contains supplementary troubleshooting information.
3. LIGHTS AND LEDS
313
MARMMTRBL02303E
Table 35.
Troubleshooting Axis Control Board Diagnostic LEDs
Remarks
LEDs
Procedure
Normally, all four green LEDs

1. Replace the axis control board.
come on when the robot is
2. Test FROM* and CMOS from the BMON screen and
turned on. They then turn off
replace as necessary.
and come back on as software
3. Reload software if a defective FROM or CMOS is found,
loads and circuits are tested.
otherwise replace the main CPU and then reload
This procedure should only be
software.
used when the four LEDs
come on and stay on without
turning off or FLASH.
Lights go out and initialization

of each printed circuit board
begins.
STATUS
ALARM
STATUS
ALARM
1. Check the power supply output voltages. Replace if

necessary.
Timer initialization
STATUS
ALARM

software.
1
Initialization of communication
STATUS
ALARM

software.
Initialization of software
STATUS
ALARM

software.
STATUS
ALARM

software.
STATUS
ALARM

software.
STATUS
ALARM

software.
1
STATUS
ALARM

software.
1. Replace the axis control printed circuit board.
3. LIGHTS AND LEDS

MARMMTRBL02303E
314
Table 35. (Contd) Troubleshooting Axis Control Board Diagnostic LEDs

LEDs
1
Remarks
3
STATUS
ALARM
Procedure
software.
STATUS
ALARM
Communication to teach
pendant
1. Replace the teach pendant.

2. Replace the teach pendant cable.
3. Replace the main CPU.
4. Reload software.
STATUS
ALARM
Communication to process I/O

or modular I/O
Turn off controller power. Disconnect the cable from

connector JD4 of the main CPU and cold start the controller.
If the light pattern is normal, replace the device that the cable
connects to: process I/O module or modular I/O interface unit.
Otherwise:
1. Replace the I/O connection cable.
3. Reload software.
STATUS
ALARM

software.
STATUS
ALARM

software.
Teach pendant banner page

displayed
1. Replace the teach pendant.
STATUS
ALARM
STATUS
ALARM

software.
1
STATUS
ALARM
Robot is working fine
3. LIGHTS AND LEDS
315
MARMMTRBL02303E
Table 35. (Contd) Troubleshooting Axis Control Board Diagnostic LEDs

LEDs
Remarks
Servo alarm on Axis Control

printed circuit board.
1. Replace the Axis Control printed circuit board.
(SYSFAIL)
Voltage level too low on *EN
signal
1. If the controller has an ABRIO board or a MAP board,

turn off controller power. Remove the two boards and
cold start the controller. If the light pattern is normal,
replace the ABRIO or MAP board device that the cable
connects to: process I/O module or modular I/O
interface unit.
STATUS
ALARM
STATUS
ALARM
Procedure
2. Check the power supply output voltages. Replace if

necessary.
software.
* The Flash ROM test checks for cleared FROM. If you test FROM you must first
clear the FROM.
NOTE 1: After replacing the main CPU printed circuit board, CMOS RAM modules,
or FROM module, you must perform a complete software load.
NOTE 2: If Axis Control alarm LEDs occur with LEDs on the Main CPU,
troubleshoot the Main CPU alarm LEDs first.
CAUTION
While working with the power supply unit, Main CPU, and axis
control modules, be advised of the following:
There are static-sensitive devices on the Main CPU and
axis control modules. Wear a grounded wrist strap devices
and observe anti-static safety precautions when handling
this equipment.
When removing the power supply unit or main CPU, the
battery backup is disconnected and must be reconnected
within 30 minutes or a loss of memory will occur.
3. LIGHTS AND LEDS

MARMMTRBL02303E
316
3.3.4
The Main CPU printed circuit board alarm LEDs are shown in
Figure 310. Table 36 provides supplementary troubleshooting
information.
Main CPU Board

Diagnostic LEDs
Figure 310. Main CPU Board Diagnostic LEDs
3 4
STATUS
ALARM
Table 36.
Remarks
LEDs
1
Troubleshooting Main CPU Board Diagnostic LEDs
STATUS
ALARM
Parity alarm on CMOS

RAM in the Main CPU.
Procedure
1. Test CMOS from the BMON screen and replace as necessary.
2. Reload software.
The battery voltage that

backs up the MAIN CPU
CMOS RAM memory is
low.
Replace the battery, using Procedure 91.
An error is encountered
in the serial link.
Turn off the controller. Disconnect the cable from connector JD4 of the
main CPU and cold start the controller. If the light pattern is normal,
replace the device that the cable connects to: process I/O module or
modular I/O interface unit.
STATUS
ALARM
STATUS
ALARM
Otherwise:
1. Test FROM and CMOS from the BMON screen and replace as
necessary.
2. Reload software.
1
STATUS
ALARM
Normal status
Controller should be operational.
3. LIGHTS AND LEDS
317
MARMMTRBL02303E
3.3.5
Table 37 shows and describes each servo amplifier diagnostic LED.
Servo Amplifier
Diagnostic LED
(7-Segment Display)
Table 37.
Name
Overvoltage(HV)
Indication
Servo Amplifier LED Functions

Description
An abnormally high DC voltage was detected in the power supply of the main circuit
of the servo amplifier.
Refer to Error code: SRVO-044 for troubleshooting information.
Insufficient voltage of the

control power supply
(LV5V)
An abnormally low voltage was detected in the control power supply of the servo
amplifier. (Rating: +5V)
Insufficient DC link
voltage (LVDC)
An abnormally low DC voltage was detected in the power supply of the main circuit
of the servo amplifier.
Faulty regenerative
control circuit (DCSW)
The regenerative energy discharge was too large for a short time. This alarm occurs
when the regenerative energy discharge circuit is defective.
Excessive regenerative
discharge (DCOH)
The average regenerative energy discharge was too large. This alarm occurs when
the frequency of acceleration and deceleration exceeds a predetermined value.
Servo amplifier overheat

(OH)
The thermostat in the servo amplifier operated. (Thermostat contact opened)

Welded electromagnetic
contactor (MCC)
The contacts of the MCC contactor in the servo amplifier are stuck together.
Overcurrent (HCL)
An overcurrent was detected in the oneaxis servo amplifier or the Laxis circuit of
the twoaxis servo amplifier.
Overcurrent (HCM)
An overcurrent was detected in the Maxis circuit of the twoaxis servo amplifier.
Overcurrent (HCLM)
An overcurrent was detected in both the Laxis and Maxis circuit of the twoaxis
servo amplifier.
Servo amplifier not ready

Servo amplifier ready
The MCC contactor in the servo amplifier is turned off. The amplifier is unarmed and
cannot drive the motor. See teach pendant display for error code information.
The MCC contactor in the servo amplifier is turned on. The amplifier is armed and
can drive the motor.
NOTE Refer to Chapter 4, Troubleshooting, for more information.
3. LIGHTS AND LEDS

MARMMTRBL02303E
318
3.3.6
Contact Signal
Transducer (IBRC)
The LEDs associated with the IBRC are indicators that input terminals P
and N have been closed in the circuit loop for that LEDs channel.
Figure 311 shows the IBRC.
Figure 311. IBRC
3. LIGHTS AND LEDS
319
MARMMTRBL02303E
3.3.7
Modular I/O LEDs
The LEDs associated with module I/O are on the interface module printed
circuit board and on each I/O module. Figure 312 shows the modular I/O
LEDs. Table 38 describes each modular I/O LED.
Figure 312. Modular I/O LEDs
LEDS
PWR
LINK
A0 1 2 3 4 5 6 7
BAI
LEDS
BAO
B0 1 2 3 4 5 6 7
AIF0IA
JD1B
JD1A
CP32
JD2
INTERFACE MODULE
Table 38.
I/O MODULE
Modular I/O LEDs
LED
PWR
Link
Location
Interface
module
Interface
module
BA1
Interface
module
BA0
Interface
module
A01234567
B01234567
I/O Module
Description
ON: The interface module is supplied with
24 VDC power.
ON: The I/O Link is operating properly.
Normally, this LED lights several seconds
after the power is turned on.
These LEDs indicate that a fault has
occurred in the modular I/O system.
Indicates if the input or output is on.
3. LIGHTS AND LEDS

MARMMTRBL02303E
320
3.3.8
(Optional) Process I/O
Board Diagnostic LEDs
CB, DA Process I/O
Board (side view)
Figure 313 shows the process I/O board diagnostic LEDs. Table 71
shows and describes each process I/O board diagnostic LED.
Figure 313. Process I/O Board Diagnostic LEDs
AA, AB, BB, BA, CA Process I/O Board

(front view)
ALM0
FALM
STATUS
ALARM
Table 39.
ALM0
FALM
Process I/O Board Diagnostic LEDs
CB, DA
AA, AB, BB, BA, CA
Color
Process
I/O PCB
ALM0
Description
Red
A communication alarm occurred between the

main CPU and process I/O board. Check
cabling from Main CPU to I/O board. Replace I/O
board.
Red
A fuse (FUSE 1) in the process I/O board blew.

Replace fuse. If fuse blows again, replace board.
Green
Indicates the operations status of the process I/O

board.
STATUS
ALARM
ALM0
Process
I/O PCB
FALM
FALM
STATUS
ALARM
Process
I/O PCB
1
STATUS
ALARM
3. LIGHTS AND LEDS
321
MARMMTRBL02303E
3.3.9
Table 310 shows and describes each process I/O board diagnostic LED.
(Optional) Process I/O

Board Diagnostic LEDs
Table 310. Process I/O Board LEDs
RED
A communication alarm
occurred between the
main CPU and process
input/output. Check
cabling from Main CPU to
I/O board. Replace I/O
board.
RED
A fuse (FUSE 1) in the

process input/output blew.
Replace fuse. If fuse
blows again, replace
board.
GREEN
Indicates the operations

status of the Process I/O
Board.
Process
I/O PCB
1
STATUS
ALARM
STATUS
ALARM
Process
I/O PCB
1
STATUS
ALARM
Process
I/O PCB
1
STATUS
ALARM
3. LIGHTS AND LEDS

MARMMTRBL02303E
322
3.3.10
R-H MAP INTERFACE
LEDs
Figure 314 shows each RH MAP Interface LED. Table 311 describes
each LED.
Figure 314. RH MAP LEDs
Table 311.
R-H MAP LEDs
LED
Meaning
A
System fail
(RED)
B
C
D
Not used
Not used
Not used
Status
This LED is briefly turned on during power up/down by the
MAP interface board. This LED is turned on when a system
failure has occurred in the MAP interface board or other
subsystems in the controller. Therefore, the problem might
not exist with the MAP interface board.
3. LIGHTS AND LEDS
323
MARMMTRBL02303E
3.3.11
Figure 41 shows and Table 312 describes the R-H ABRIO LEDs.
R-H ABRIO LEDs
Figure 41. R-H ABRIO LEDs
POWER
ACTIVE
INTERBRD
FAULT
PC COMM
FAULT
PROC
FAULT
LED
POWER (green)
Table 312. R-H ABRIO LED Descriptions

On
Flashing
There is power to the ABRIO board.
Not applicable
Off
There is no power
to the ABRIO
board.
ACTIVE (green)
The ABRIO board is communicating with the

PLCs remote I/O scanner and the PLC is in
run mode. Input and output data in the ABRIO
board is being updated.
The PLC is in PROGRAM or

TEST mode and the input and
output data to the interface is
being updated.
A No Update condition is
indicated by the PLC remote I/O
scanner.
Indicates an error in the rack
address setup. Error is possibly
an invalid value or an invalid
combination of starting module
group and rack size settings.
In conjunction
with one of the
other red LEDs
being on or
flashing indicates
an interface fault.
There is no
communication
with the PLCs
remote I/O
scanner.
INTERBOARD
COMMUNICATION
FAULT (red)
Communication between the ABRIO board and

the R-J controller has been broken. This might
be due to the inability of the ABRIO board to
gain access to the Common RAM or a
checksum error in the R-J output data.
Communication with the PLCs remote I/O
scanner is stopped.
An error in communications
between the ABRIO board and
the R-J controller has occurred.
Communication with the PLCs
remote I/O scanner is stopped.
The ABRIO board did not
detect the R-J controllers
operational code after power up
or reset.
Normal operation
PC
COMMUNICATIONS
FAULT (red)
ABRIO board is not communicating properly

with the PLC remote I/O scanner. The remote
I/O scanner might be faulted or a problem
might exist on the serial channel.
Not applicable
Normal operation
PROCESSOR
FAULT (red)
This LED is normally on for to 2 seconds

during initialization to indicate that the ABRIO
board is performing its power up diagnostics.
The LED is turned off after diagnostics have
been completed successfully and the R-J
controllers operation code has been set. If,
after initialization, this LED is on, this indicates
a fault in the ABRIO board hardware (RAM
integrity, EPROM checksum, or CPU watchdog
timeout). Communication with the PLCs
remote I/O scanner and with the R-J controller
has been stopped. When this LED is on, all
other LEDs except Power should be off.
This LED flashes along with the

ACTIVE LED to indicate that an
invalid rack address has been
set up via the DIP switches on
the ABRIO board.
No faults exist
with the remote
I/O CPU or
related circuitry.
MARMMTRBL02303E
TROUBLESHOOTING
41
This chapter describes the steps used to repair electrical faults in the robot.
WARNING
The procedures described in this section require you to
work with high voltage circuits. Carelessness or
inattention can kill you. Do not attempt any of these
procedures unless you are trained and experienced in
electrical repair.
Electrical faults are divided into three classes of symptoms:

A Class 1 Fault is a malfunction that prevents the controller from

operating. The main contactor might or might not be energized. No
text is displayed on the teach pendant.
A Class 2 Fault is a malfunction that prevents the bootROM from

turning the system over to the application software. Text will be
displayed on the the teach pendant, but the teach pendant display will
be frozen and will not respond to keypad entries.
A Class 3 Fault is a malfunction that prevents the robot from

operating normally, even though the application software is running.
A numbered alarm message will be displayed on the teach pendant.
You can access teach pendant menus and diagnostic screens during a
Class 3 fault.
If your robot has a class 1 fault, refer to Section 4.1.

4. TROUBLESHOOTING
MARMMTRBL02303E
42
4.1
To enable the user with a quick reference guide to powering on a P-155

controller, the following steps and events should be followed:
POWER ON
SEQUENCE
Procedure 41
Step
Purge Sequence
1 With the main disconnect ON, you should observe:

Purge complete LED out

Purge enable pushbutton (purging) lamp out
ON pushbutton lamp out
Purge fault LED on
2 Push and hold the purge enable pushbutton. You should observe

Purge solenoid engages when minimum pressure requirements are

met.
Purge fault LED goes out
Purging lamp (behind purge enable pushbutton) lights.
At this point you can release the purge enable pushbutton, no change
should occur.
3 At the end of the 5 minute purge, the purging lamp (behind the purge
enable pushbutton) will go out and the purge complete LED lights.
Also, the purge solenoid shuts off.
Procedure 42
Step
Enabling Power
1 With purge complete, you should observe:

Purge complete LED on

Purge enable pushbutton (purging) lamp out
ON pushbutton lamp out
Purge fault LED out
2 Push the ON pushbutton. You should observe:

ON pushbutton lamp lights

Main CPU and axis control PCBs go through internal diagnostics
At the end of diagnostics the MCC contactor on all servo amplifiers will
energize and click. The teach pendant should be energized and the
controller ready to operate manually.
4. TROUBLESHOOTING
43
MARMMTRBL02303E
4.2
CLASS 1 FAULT
TROUBLESHOOTING
How to use the

Troubleshooting Tables
This section contains troubleshooting information for Class 1 Faults.

A Class 1 fault prevents the controller from operating. The main ALC
contactor might or might not be energized. The Purge Complete light
might or might not be on. No text is displayed on the teach pendant or
CRT.
This section contains several tables. Each table provides procedures to
correct the fault. To troubleshoot a Class 1 fault, always start at
Table 44. Perform the procedures in order. You will either correct the
fault using Table 44 or it will refer you to another table in this section.
Use the other tables only when Table 44 refers you to them.
Class 1 Fault Condition
If the following conditions are true, follow the steps in Table 44.

The main disconnect is UP (on).

The ON button has been pushed.
The power on sequence (Section 4.1) has been attempted.
The controller does not operate.
4. TROUBLESHOOTING
MARMMTRBL02303E
44
Without turning off the main disconnect, open the controller door:
Release the disconnect latch by turning the screw to the lower right of the
disconnect handle.
Table 41.
Troubleshooting Procedure 1
Illustration
Troubleshooting Procedure
1. Find the Purge Complete light on the SOP.
The light is on indicating that the purge cycle was successful.
If the light is on go to Table 45.
If the light is off continue.
Chapter 13
Print Reference
0806
H
OL
D
Purge
Complete
Light
2. Find the Purge Fault LED on the SOP.

If the LED is on go to Step 4.
If the light is out continue.
H
OL
D
Purge
Fault
0806
4. TROUBLESHOOTING
45
MARMMTRBL02303E
Table 41. (Contd) Troubleshooting Procedure 1

Illustration
3. Press and hold the Purge Enable pushbutton on the SOP until it
lights (1 5 seconds) and then release.
After the purge cycle is completed, the Purge Complete light
should come on.
If the Purge Complete light comes on test the controller for
proper operation.
If the Purge Enable (purging) or Purge Complete light does
not come on and/or the Purge Fault light comes on
continue.
Chapter 13
Print Reference
0805
0806
0810
H
OL
D
Purge
Fault
Light
4. Turn off the power disconnect handle.

5. Connect jumper wires between terminals P1 and N1, and
between terminals P2 and N2 on the IBRC.
These terminals are the inputs for the robot-mounted air
pressure and air flow switches.
If opening devices are used, you will also need to jumper
between P3 and N3, and P5 and N5. These auxiliary
inputs are for the pressure switch and flow switch for an
opener.
0821
0822
0834
0835
0825
0826
6. Turn on the power disconnect handle.

7. Press and hold the Purge Enable pushbutton on the SOP until
it lights (1 5 seconds) and then release.
If the purge circuit is cycling, the purge enable lamp (purging)
should stay lit until the 5 minute purge is complete. The
Purge Fault LED will be out.
If the purge enable (purging) lamp does not stay lit, replace
the purge control PCB (piggy-back to EMG control PCB).
If the purge enable (purging) lamp will not light, go to Table
42.
If, during the purge cycle, the Purge Fault LED lights, go to
Table 42.
If, after the 5 minute purge cycle, the Purge Complete light
comes on, locate and repair the break in the air pressure
and/or air flow switch circuits to the robot.
If the purge is too long or too short, the timer on the purge
control PCB is incorrectly set or damaged. Repair or replace
it.
0805
0808
0811
0806
0943
4. TROUBLESHOOTING
MARMMTRBL02303E
46
Table 42.
Illustration
Chapter 13
Print Reference
1. Observe on the IBRC Unit that:

Red lights on the IBRC panel indicate that 200 VAC is
supplied to it.
If all of the lights are off continue.
If one or more of the lights are on go to Table 43.
2. Measure the AC voltage coming into the IBRC unit.

You should see 200 240 VAC.
If the voltage is OK replace the IBRC Unit.
0710
TF1
43
If there is no voltage troubleshoot the AC power distribution

circuit shown at the right.
G
44
1
2
FRA
CONTACT SIGNAL
TRANSDUCER IBRC
20VDC PSU
15ma MAX.
(+) ()
Table 43.
1. Observe the LEDs of channels 1 and 5 on the IBRC unit. If
either of these LEDs are out it implies that one or more cavities of
the robot is missing minimum air pressure. In the case of channel
5, if there are no auxiliary pressure switches, it could be that the
jumper across terminals P5 and N5 has come loose.
Check that there is sufficient maintenance air at the robot.
Check cables between robot and controller.
If LEDs 1 and 5 are lit continue.
Illustration
Chapter 13
Print Reference
0819
0826
If either LED 1 and 5 are out go to Step 8.

2. Turn off the power disconnect handle.
3. Reseat the following connectors:
Contact signal transducer (IBRC) connector CRX
Purge transit board connector CRX3
Purge transit board connector CRX1
Purge control PCB (mounted with EMG control PCB)
connector CRX.
4. Turn on the power disconnect handle.
0819 thru
0843
0925 thru
0950
4. TROUBLESHOOTING
47
MARMMTRBL02303E

Illustration
5. Observe on the SOP that:

Purge fault LED is lit
Chapter 13
Print Reference
0810
H
OL
D
Purge
Fault
6. Re-initiate the purge sequence. See Section 4.1.

If the controller does not operate properly, continue.
7. Measure the DC voltage between the white and black wires in
the wiring harness at connector CRX5 (A1 and A2) of the Transit
Board.
You should see 24 VDC.
If the voltage is OK go to Step 10.
0815
If there is no voltage replace the Purge Power Supply Board

(PSU2).
Note: The Purge Power Supply Board (PSU2) contains two
fuses that can be checked after the board is removed from the
controller.
If you wish, you can perform the following steps after the board
is removed:
1. Check the fuses.
2. If a fuse is bad, replace it and reinstall PSU2.
3. If a fuse blows again, replace PSU2.
8. If, on the IBRC unit, channel 5 LED is out, jumper terminals P5
to N5 and observe if the LED lights.
If the LED does not light
replace the IBRC unit.
If the LED lights repair the auxiliary flow switch or wiring for
proper operation or replace the jumper when auxiliary flow
switch is not used.
0825
4. TROUBLESHOOTING
MARMMTRBL02303E
48
Illustration
9. If channel 1 LED is out, jumper terminals P1 to N1 and observe

if the LED lights.
If the LED does not light
replace the IBRC unit.
Chapter 13
Print Reference
0821
If the LED lights repair the flow switch or wiring for proper
operation.
10. Repair or replace the following in the order shown:
Purge enable switch
IBRC unit
Purge control PCB (mounted piggy-back on the EMG control
PCB)
Cable 2003-T526 (1.6M) between SOP (CRX) and transit
board (CRX2)
Cable 2003-T233 (2M) between purge control PCB and
IBRC unit.
Table 44.
Table 45.
1. Find the green PIL light in the center of the PSU module.
The light is on indicating 200VAC to PSU through F5.
If the light is on go to Table 43.
Illustration
PSU Module
Chapter 13
Print Reference
0218
0216
02-19
If the light is off continue.
F1 and F2: 10-A fuses

for AC input
PIL: Green LED
power supply status
2. Check fuses F1 and F2 in the top center of the PSU module. If

no flag shows, turn off power. Pull fuses F1 and F2 from the PSU
and check the fuse with an ohmmeter.
A white flag in the center of the fuse indicates it is bad. F1 &
2 monitor incoming 200VAC to PSU.
If fuse(s) are good, go to step 4, otherwise continue.
PSU Module
0208
0210
02-8
F1 and F2: 10-A

fuses for AC
input
02-10
4. TROUBLESHOOTING
49
MARMMTRBL02303E

Illustration
3. If one or both of the fuses are bad

a. Turn off power at the main disconnect switch.
b. Unplug CP2 and CP3.
c. Replace any bad fuse(s).
d. Turn the main disconnect switch on, but do not press the
ON button.
Chapter 13
Print Reference
0218 thru
0223
0219
02-18 thru 02-22
If the fuse(s) blow again Replace the PSU.

If the PIL light comes on go to step 8.
4. Disconnect CP1 at the top of the PSU module. Measure the
voltage coming into the PSU on the two red wires in the harness
connector (S and R).
You should see 200VAC.
If the voltage is ok Continue.
If no voltage go to Table 42.
5. Turn the main disconnect off, pull the PSU module out and
remove the fuse, F5, (located near the middle of the printed circuit
board).
0208 thru 0210
PSU Module
02-08
CP1
3 G
2 S
1 R
0215
PSU Module
02-16
F5: 0.3-A Fuse

for auxiliary
power supply
6. Using an ohmmeter, check fuse.

If the fuse is good Replace the PSU.
0215
02-16
If the fuse is bad Continue.

7. Replace fuse F5, insert the PSU module, and turn on the controller.
If the class1 fault is still present replace the PSU
PSU Module
F5: 0.3-A Fuse

for auxiliary
power supply
4. TROUBLESHOOTING
MARMMTRBL02303E
410
8. If the PIL light is on,
Turn off the main disconnect switch and, using an ohmmeter,
test for a short in the wiring harness at CP2 and CP3.
Illustration
PSU Module
Chapter 13
Print Reference
02-19
0218 thru
0223
02-18 thru 02-22
F1 and F2: 10-A

fuses for AC
input
9. If no short is evident, reconnect CP2 and CP3 and turn the

main disconnect switch on. Press the Power ON pushbutton and
check for proper operation.
10. If the PIL light goes out, fuse(s) F1 and/or F2 have blown
again due to a short in one of the following:
Wiring harness to ALC relay coil
ALC relay coil
Wiring harness to fans (check in particular where cable and
front door hinge point meet).
Fan motor shorted.
Repair short, replace fuse(s) and go to Step 9.
If the PIL light stays on, check controller for proper operation.
0209
0126
0209
0203 thru
0208
02-08
01-26
02-08
02-22
4. TROUBLESHOOTING
411
MARMMTRBL02303E
Table 46.
Table 47.
Illustration
1. Measure the AC voltage between Multitap transformer terminals 43 and 44 of TF1.
You should see 200 VAC.
If voltage is present Replace or repair harness between
PSU and transformer.
If voltage is not present or incorrect Continue.
Multi-Tap Transformer
43
Chapter 13
Print Reference
01-22
44
F4 F5
5A 5A
2. Check transformer tap settings.

As shown in Section 1.9. (Should be Plant 3-phase voltage)
If the tap settings are incorrect Correct.
01-14
If the tap settings are correct Continue.
3. Check AC voltage between transformer primary terminals.

Plant 3-phase voltage.
If voltage proper is present Replace multi-tap transformer.
01-14
If incorrect or no voltage is present Continue.

4. Check AC voltage between bottom terminals of FL1, FL2, &
FL3.
If voltage is present Replace or repair wiring harness
between transformer and fuse unit.
Fuse Block
FL1 FL2 FL3
01-05,
01-07,
01-09
If voltage is not present Continue.

5. Check AC voltage between top terminals of FL1, FL2, and FL3.
If voltage is present F1, F2, F3 is/are blown. Replace bad
fuse. If it blows again, replace the multitap transformer.
01-05,
01-07,
01-09

6. Check AC voltage between terminals at bottom of main disconnect switch.
If voltage is present Replace or repair wiring harness
between fuse unit and main disconnect switch.
Main
Disconnect
Switch
01-05,
01-07,
01-09

7. Check AC voltage between terminals at top of disconnect.
Replace main disconnect switch if voltage is present;
otherwise, contact plant maintenance.
FL1, FL2, FL3
01-05,
01-07,
01-09
4. TROUBLESHOOTING
MARMMTRBL02303E
412
Table 48.
Table 49.
1. Check the red alarm light in the center of the PSU module.
The alarm light should be off.
If the light is ON Go to Table 410.
Illustration
PSU Module
Chapter 13
Print Reference
02-14
If the light is ON Go to Table 411.

If the light is OFF Continue.
ALM: Red LED
F4: 5-Afuse for +24E

F3: 5-AS slowblow
fuse for +24V
2. Check the LED displays on the servo amplifier.

If any LED is on Go to Table 413 .
If any LED is on Go to Table 45.
If no LEDs are on Continue.
08-24 thru 08-26

09-23 thru 09-25
08-09 thru 08-12
09-11 thru 09-13
10-11 thru 10-13
4. TROUBLESHOOTING
413
MARMMTRBL02303E

3. Listen and look for main cabinet cooling fans to be running.
Fans should be running indicating 200VAC to ALC relay.
If fans are not running Continue.
If fans are running Go to step 5.
Illustration
Chapter 13
Print Reference
02-02 thru 08-08
02-02 thru 02-08
FAN 1
REAR
FRONT
FAN 2
FAN 3
CONTROLLER SIDE VIEW
4. Check for 200 VAC at CP2 or CP3.
You should see 200 VAC 10VAC.
If there is 200VAC Repair the wiring to the fans and the ALC
relay and check the controller for proper operation.
02-18 thru
02-21
PSU Module
02-18 thru 02-22
If there is not 200VAC Go to step 8.
5. Check for 200VAC at ALC relay on A1 & A2.

You should see 200VAC 10VAC.
If voltage is not correct or missing Repair the wiring
harness coil between the PSU and the coil of the ALC relay.
Check the controller for proper operation.
01-25, 01-27
A1
A2
3
ALC
If voltage is present Continue.
4. TROUBLESHOOTING
MARMMTRBL02303E
414
Illustration
Chapter 13
Print Reference
6. Check for 200VAC at the ALC relay between 2 & 4, 4& 6, and 2
& 6.
You should see 200 VAC.
If voltage is not correct or missing Check fuses F1, F2,
and F3. If the fuses are ok, replace the multitap transformer.
01-27
If voltage is present Turn power off and repair wiring

between ALC contactor and servo amplifiers.
F1
13
31
32
F2
F3
A1
A2
3
ALC
2 4
If an external OFF button or door interlock is used Test for

continuity of the external OFF, and DIL circuits, and repair it if
necessary.
23
41
42
14
7. Check the connector CRR4 on the EMG module for jumpers
between terminals 10 (EX-COM) and 12 (EX-OFF) and terminals
14 (DIL1) and 16 (DIL2).
If you use an external OFF button or door interlock, there will
be a wire on each terminal.
If the terminals are connected with a jumper wire check for no
loose screws and good contact.
01-27
01-22
24
02-06
02-28 thru 02-33
CRR4
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
100OUT3
EMGOU2
100OUT4
EMGOUTC
FENCE1
EMGOUT1
FENCE2
EX-ON
0V
EX-COM
0V
EX-OFF
5v
DIL1
15V
DIL2
-15V
EMGB1
+24V
EMGB2
4. TROUBLESHOOTING
415
MARMMTRBL02303E

Illustration
Chapter 13
Print Reference
7. Check the connector on the EMG module for jumpers between

terminals 32 (EX-COM) and 31 (EX-OFF) and terminals 30 (DIL1)
and 29 (DIL2).
If you use an external OFF button or door interlock, there will
be a wire on each terminal.
If the terminals are connected with a jumper wire check for
loose screws and good contact.
02-28 thru 02-33
29 32
If an external OFF button or door interlock is used Test for

continuity of the external OFF, and DIL circuits, and repair it if
necessary.
8. On the EMG board, connect 10 (Ex-COM) to ground with a

jumper wire; then momentarily connect 8 (ExON) to
10 (Ex-COM).
Controller should turn on.
If the controller turns on There is a break in the on/off
switch circuit. Repair or replace.
02-28 thru 02-33
If the controller does not turn on Replace the PSU module.

PSU
9. On the Power Supply Unit, momentarily jumper the following

connections:
CP4 connector terminal 1 (ON) to CP4 connector terminal 3
(COM)
CP4 connector terminal 3 (COM) to ground
The controller should turn on.
If the controller turns on there is a break on the ON/OFF
switch circuit. Repair or replace.
If the controller does not turn on continue.
02-16
4. TROUBLESHOOTING
MARMMTRBL02303E
416
Table 410.
Table 411.
1. Check fuse F3 at the bottom of the PSU.
A white flag in the center of the fuse indicates it is bad and
that 24 power is missing.
If the fuse is blown There might be a short circuit in one of
the following:
Backplane
24VDC Cooling Fans for module card cage
Process I/O 24 VDC supply
CRT/KB
Main CPU Module
Axis Module
Modular I/O 24 VDC supply
Option #1
Option #2
Extended Backplane
Illustration
Chapter 13
Print Reference
02-24
PSU Module
02-23
ALM: Red LED

for indicating an
alarm

F3: 5-AS slow-blow
fuse for +24V
Isolate the short and repair it.

If the fuse is good Continue. See NO TAG.
2. Turn off the controller. Measure the resistance between the
following terminals of CRR4 on the EMG module:
Terminal 9 (0V) and Terminal 15 (+15)
Terminal 9 (0V) and Terminal 17 (15)
Terminal 9 (0V) and Terminal 13 (+5)
Look for greater than 100 ohms at each measurement.
If all readings are ok Replace the PSU.
If all readings are not ok Continue.
NOTE A low reading means shorted power to ground

through or because of an EMG, Main CPU, PSU, Fence,
or Axis board. Remove them one at a time until you get
a normal reading. Replace the defective board.
06-24 thru 06-36
CRR4
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
100OUT3
EMGOU2
100OUT4
EMGOUTC
FENCE1
EMGOUT1
FENCE2
EX-ON
0V
EX-COM
0V
EX-OFF
5v
DIL1
15V
DIL2
-15V
EMGB1
+24V
EMGB2
4. TROUBLESHOOTING
417
MARMMTRBL02303E

2. Turn off the controller. Measure the resistance between the
following terminals on the EMG module:
Ground and Terminal 39 (15)
Ground and Terminal 38 (+15)
Ground and Terminal 40 (+5)
Look for greater than 100 ohms at each measurement.
If all readings are ok Replace the PSU.
Illustration
Chapter 13
Print Reference
EMG
0934
0932
0931
If all readings are not ok Continue.
NOTE A low reading means shorted power to ground

through or because of the Main CPU, PSU, Fence, or
Axis board EMG. Remove them one at a time until you
get a normal reading. Replace the defective board.
40
39
38
4. TROUBLESHOOTING
MARMMTRBL02303E
418
Figure 51. 24 Volt (24E) Power Distribution Chart
4. TROUBLESHOOTING
419
MARMMTRBL02303E
Table 412.
Table 413.
1. Turn the power disconnect switch on and press the power on
pushbutton. Check the lights on the operator panel.
Any light on indicates 24E to the operator panel. This can
also be checked by measuring for 24VDC between terminals
5 and 9 of the EMG connector CRR4.
If any light is on Go to Table 414.
If the lights are not on Continue.
1. Turn the power disconnect switch on and press the power on

pushbutton. Check the lights on the operator panel.
Any light on indicates 24E to operator panel. This can also
be checked by measuring for 24VDC between terminals 62
and Ground of the EMG control PCB.
If any light is on Go to Table 415.
If the lights are not on Continue.
2. Check fuse F4 at the bottom of the PSU module. If no flag

shows, check the fuse with an ohmmeter.
White flag in the center of the fuse indicates it is bad.
If the fuse is good Replace the PSU
If the fuse is bad Continue.
Illustration
Chapter 13
Print Reference
06-25
06-29
H
O
L
D
H
O
L
D
PSU Module
02-23
02-31
02-23
06-25
06-29
ALM: Red LED for

indicating an alarm

F3: 5-AS slow-blow
fuse for +24V
4. TROUBLESHOOTING
MARMMTRBL02303E
420
3. Turn off power, disconnect fence circuit or remove jumper, and
connect an ohmmeter between Fence1 terminal 36 and Ground
on the EMG module.
If it does not show continuity (greater than 500 ohms),
replace fuse F4 and check the controller for proper
operation.
If it does show continuity (less than 10 ohms), a
component is shorted, loading the 24E voltage supply.
Illustration
Chapter 13
Print Reference
09-50
EMG
0V 56
0V 55
36
3. Turn off power, disconnect fence circuit or remove jumper, and

connect an ohmmeter between Fence1 and 0V (CRR4 pin5 & 9 or
11) on EMG module.
If it does not show continuity (greater than 500 ohms),
replace fuse F4 and check the controller for proper
operation.
If it does show continuity (less than 500 ohms), a
component is shorted, loading the 24E voltage supply.
4. To find the shorted component, watch the ohmmeter while you

disconnect or remove the following parts in order:
Main CPU
Axis
Option #1
Option #2
EMG
Cards on the extended backplane one at a time
If the ohmmeter shows greater than 500 ohms, the part is
OK. If the ohmmeter shows under 500 ohms, the part is
defective.
If it still does not work Follow the short out to the failed
component and replace. See Figure 52.
06-25
CRR4
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
100OUT3
EMGOU2
100OUT4
EMGOUTC
FENCE1
EMGOUT1
FENCE2
EX-ON
0V
EX-COM
0V
EX-OFF
5v
DIL1
15V
DIL2
-15V
EMGB1
+24V
EMGB2
4. TROUBLESHOOTING
421
MARMMTRBL02303E
Figure 52. 24 Volt (24V) Power Distribution Chart
4. TROUBLESHOOTING
MARMMTRBL02303E
422
Figure 53. Tracing a Short on 24E
4. TROUBLESHOOTING
423
MARMMTRBL02303E
Table 414.
Table 415.
Illustration
1. Press the OFF button. Press and hold USER PB1 and USER
PB2 and press the ON button.
If the BMON> prompt appears Treat the problem as a
Class 2 Fault; otherwise, continue.
Operator Panel
H
O
L
D
USER
PB1
USER
PB2
1. Press the OFF button. Press and hold PURGE ENABLE

press the ON button.
If the BMON> prompt appears Treat the problem as a
Class 2 Fault; otherwise, continue.
Chapter 13
Print Reference
ON
OFF
Operator Panel
H
OL
D
Purge
Enable
Button
ON
08-05
02-13
4. TROUBLESHOOTING
MARMMTRBL02303E
424
Illustration
2. If you have not done so already, measure the 24E voltage at

the EMG module connector CRR4 on terminals 5 (FENCE1) and
9 (0VDC) for 24VDC (10%). If the 24VE voltage is missing or out
of tolerance, go to Table 412.
Chapter 13
Print Reference
06-25
06-29
CRR4
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
2. If you have not done so already, measure the 24E voltage at

the EMG module on terminals 36 and Ground. for 24VDC (10%).
If the 24VE signal is missing or out of tolerance, go to Table 413.
100OUT3
EMGOU2
100OUT4
EMGOUTC
FENCE1
EMGOUT1
FENCE2
EX-ON
0V
EX-COM
0V
EX-OFF
5v
DIL1
15V
DIL2
-15V
EMGB1
+24V
EMGB2
0950
EMG
0V 56
0V 55
36
4. TROUBLESHOOTING
425
MARMMTRBL02303E

3. On the teach pendant, look for any lit LEDs or screen display.
If there is no display the 24T power supplying the teach
pendant ISB unit is most likely missing. Visually check the
teach pendant cable K0402003T908 (10/20M) for damage.
If the 24T signal is missing or out of tolerance the following will
correct the problem. Replace the following, in order, one at a
time:
3
4
5
6
7
Replace the teach pendant cable.

Replace the ISB unit.
Replace the EMG module.
Replace the Main CPU printed circuit board.
Replace the backplane.
4. If there are LEDs or a screen display, there is a communication

fault between the Main CPU printed circuit board and the teach
pendant.
Replace the following in order, one at a time.
Teach pendant cable
Teach pendant
Main CPU module
Illustration
Chapter 13
Print Reference
05-23
4. TROUBLESHOOTING
MARMMTRBL02303E
426
4.3
CLASS 2 FAULTS
A Class 2 Fault is indicated by frozen text (letters or numbers) displayed

on the teach pendant. This situation is an indication of a problem with the
Main CPU printed circuit board caused by either the memory, processor,
the board itself, or a bad teach pendant cable.
Table 416.
Class 2 Faults Troubleshooting Procedure
1. Is the Battery light on the main CPU module on?
If the Battery light is on replace the battery. Refer to Procedure 91.
1
STATUS
ALARM
Battery Light
2. Perform a cold start of the controller.

3. Is a red light on the axis control board turned on?
If a red light is on replace the axis control board.
4. Are all four green LEDs on the axis control board turned on?
If all four green LEDs are on go to step 5.
If all four green LEDs are not on troubleshoot the controller using Table 35 in Chapter 3, Lights and LEDs.
5. Turn the controller off. Hold down Purge Enable pushbutton and press the ON button.
Check the teach pendant cable by swapping it with a known working cable or by doing a continuity test.
Does the BMON> prompt appear on the teach pendant? If it does not appear, replace the main CPU printed circuit
board and reload software.
CAUTION
Continuing beyond this point will erase all software stored in the controller
including all taught positions in your application. It will also require a software
reload which will take at least two hours. Do not do this unless your controller
actually has a Class 2 fault.
4. TROUBLESHOOTING
427
MARMMTRBL02303E
Table 416. (Contd) Class 2 Faults Troubleshooting Procedure

6. Perform the following steps on the teach pendant:
a. Press the NEXT key twice.
b. Press F2, DIAG.
c. Press ENTER.
The prompt changes to DIAG> (diagnostic monitor).
d. Press the NEXT key.
e
Press F3, TEST.
f.
Press F1, CMOS.
g. Press ENTER.
The teach pendant will display a message that gives you an opportunity to exit without destroying the contents of CMOS
memory.
h. Press 1 if you want to continue with the test.
7. The CMOS memory test will take a few minutes to run. If an error is encountered, an address and good and bad data are
displayed on the teach pendant or CRT/KB. Record the address and refer to following to determine the board that failed.
Error Code
F1000000 F10FFFFF
F1100000 F11FFFFF
F1200000 F12FFFFF
F1300000 F13FFFFF
Replace Board
7MK1 (RAM MODULE) (STANDARD)
MJ1 (RAM MODULE) (STANDARD)
MH1 (RAM MODULE) (OPTION)
MG1 (RAM MODULE) (OPTION)
Replace defective memory boards as necessary and reload software. If the CMOs memory test passes, continue.
8. Perform the following steps on the teach pendant:
a. Press the NEXT key.
b. Press F1, EXIT.
c. Press ENTER.
d. Press the NEXT key.
e. Press F1, CLEAR.
f.
Press F2, FROM.
g. Press ENTER.
h. Press the NEXT key.
i.
Press F1, EXIT.
j.
Press the NEXT key twice.
k. Press F2, DIAG.

l.
Press ENTER.
m. Press F3, TEST.

n. Press F4, FROM.
o. Press ENTER.
The teach pendant will display a message that gives you an opportunity to exit without destroying the
contents of Flash ROM memory.
p. Press 1 if you want to continue with the test.
The Flash ROM memory test will take a few minutes to run. If an error is encountered, replace the Flash
ROM board and reload software. Otherwise, continue.
9. The hardware in your controller is OK. Reload your system application software.
4. TROUBLESHOOTING
428
4.4
CLASS 3 FAULT
TROUBLESHOOTING
MARMMTRBL02303E
This section contains troubleshooting information for Class 3 Faults. You

are here if the teach pendant displays a fault message on the teach pendant
screen.
1. Press the MENU key on the teach pendant.
2. Select ALARM from the menu.
3. Refer to the appropriate subsection in this section and follow the
troubleshooting procedure. The subsections that follow are arranged
in numerical error code order.
4. TROUBLESHOOTING
429
MARMMTRBL02303E
4.4.1
The operator panel emergency stop push button is pressed.
SRVO-001 ER_SVAL1
Operator Panel EStop
Remedy: Twist the operator panel emergency stop push button clockwise
to release. Press reset.
If the problem still exists, it is caused by an open circuit in the emergency
stop circuit or a bad Main CPU. Perform the troubleshooting procedure in
the following table.
Table 417.
SRVO-001 Troubleshooting Procedure

Illustration
1. Remove and reconnect:
CN1 on the Operator Interface board
CN5 on the Operator Interface board
JRM5 on the Main CPU
Check for proper operation.
If the problem still exists go to step 2.
Main CPU Printed Circuit Board
JRM5 connector
Operator Interface Printed Circuit Board
Operator panel,
rear face
CN1 connector
CN3 connector
Chapter 13
Print Reference
03-17
03-28
4. TROUBLESHOOTING
MARMMTRBL02303E
430
Table 417. (Contd) SRVO-001 Troubleshooting Procedure
Illustration
Chapter 13
Print Reference
2. Perform the following steps:
03-17
a. Turn off the controller.

b. At the operator panel emergency stop button,
remove the two blue wires and connect (strap) them
together.
c. Turn on the controller.
If the error message is cleared replace the
emergency stop button.
If the error message reappears go to step 3.
ESTOP REAR VIEW

Main CPU Printed Circuit Board
03-25
a. Replace the cable between connector JRM5 at the

Main CPU module and the operator interface printed
circuit board.
b. Turn on the controller.
If the error message is cleared check the
controller for proper operation.
If the error message reappears replace the Main
CPU module.
JRM5 connector
PIN 1
PIN 26
PIN 25
PIN 50
4. TROUBLESHOOTING
431
MARMMTRBL02303E
Figure 54. Operator Panel E-Stop Circuitry
4. TROUBLESHOOTING
MARMMTRBL02303E
432
4.4.2
The teach pendant emergency stop push button is pressed.
SRVO-002 ER_SVAL1
Teach Pendant Estop
Remedy: Twist the teach pendant emergency stop push button clockwise
to release. Press reset.
If the problem still exists, it is caused by the loss of 24VDC to the teach
pendant relay RLY2 or the 5 VDC signal to the matrix decoding from the
normally closed contact of the teach pendant relay RLY2.
Any of the following can cause this problem:

A defective teach pendant emergency stop switch.

A defective component on the teach pendant printed circuit board.
Loss of 24VDC to the E-STOP switch (not part of the teach pendant
power).
This loss of power can be caused by a bad teach pendant emergency
stop switch, a broken wire in the teach pendant cable, or a bad EMG
module on relay RL-10. In most cases, you can fix it by replacing the
teach pendant.
If you want to troubleshoot the problem further, perform the following

troubleshooting procedure:
Table 418.
Chapter 13
Print Reference
Perform the following steps:

a. Turn off power to the controller.
b. Remove the seven screws holding the teach pendant back in place.
c. Remove the teach pendant back cover.
d. Slide the E-stop wiring connector half way off connector CNEMG1.
e. Carefully energize the teach pendant and measure the DC voltage of CNEMG1 and
either of the GND test points on the teach pendant.
At pin 2, if there is 24VDC (5 VDC) Measure pin 1. If 0VDC, go to step f.
15-33
At pin 1, if there is no 24VDC (5 VDC) Replace the teach pendant emergency stop
switch.
If voltage is found Replace the teach pendant.
f.
If no voltage is found, replace the teach pendant cable, and test for proper operation.
g. If the problem still exists, replace the EMG module.
Figure 55
4. TROUBLESHOOTING
433
MARMMTRBL02303E
Figure 55. Teach Pendant E-Stop Circuitry

JRS1 MAIN (RS422/TEACH PENDANT) HONDA High Density
9
7
5
3
1
TPDSC
EMGB1
TXTP
RXTP
4
*RXTP
10
9
+24T
+24T
16
15
EMGB2 EMGB1
20
0V
10
8
6
4
2
+24T
EMGB2
0V
*TXTP
*RXTP
3
RXTP
8
14
19
0V
2
*TXTP
7
1
TXTP
6
13
12
EMGEN EMGDM
18
17
TPDSC
Teach Pendant
External Connector CN1
Male HIROSE
20
18
16
14
12
19
17
15
13
11
5
11
EMGTP
+24T
EMGTP
EMGDM
EMGEN
0V
4. TROUBLESHOOTING
MARMMTRBL02303E
434
4.4.3
The teach pendant deadman switch is released while the teach pendant is
enabled.
SRVO-003 ER_SVAL1
Deadman switch
released
Remedy: Press and hold the teach pendant deadman switch. Press reset.
If the problem still exists, it is caused by:
A defective teach pendant deadman switch
A defective component on the teach pendant printed circuit board
A possible break in the circuitry between the teach pendant and the
Main CPU.
In most cases, you can fix it by replacing the teach pendant.
If you want to troubleshoot the problem further, perform the following
troubleshooting procedure:
Table 419.
Chapter 13
Print Reference

a. Remove power from the controller.
b. Remove the seven screws holding the teach pendant back in place.
15-25
15-30
c. Remove the teach pendant back but leave all electrical connectors in place.
d. Press each deadman switch bar while watching the switch body inside the teach pendant.
e. Make sure that the copper strip presses the switch actuator all the way into the switch body.
You should be able to hear and feel it click into place.
If the actuator is frozen or will not click sharply replace the switch.
2. Perform the following steps for each deadman switch:
a. Slide the wiring connector half way off the circuit board connector.
b. Measure the resistance between:
Pins 1 and 2
Pins 3 and 4
When the deadman switch is not pressed, there is continuity between pins 1 and 2 and no
continuity between pins 3 and 4
When the deadman switch is pressed, there is no continuity between pins 1 and 2 and
continuity between pins 3 and 4.
If one or more measurements are bad replace the deadman switch assembly.
If the measurements are good replace the teach pendant.
15-25
15-30
4. TROUBLESHOOTING
435
MARMMTRBL02303E
Figure 56. Deadman Switch Circuitry
4. TROUBLESHOOTING
436
4.4.4
SRVO-041
MOFAL Alarm
(Group:i Axis:j)
MARMMTRBL02303E
The motion command after the ramping algorithm in the servo software
exceeded one word. Contact the FANUC Robotics Hotline for more
information. DO NOT INCLUDE IN MANUAL!!!!!!
4. TROUBLESHOOTING
437
MARMMTRBL02303E
4.4.5
The safety fence gate is open.
SRVO-004 ER_SVAL1
Fence open
Remedy: Close the gate. Several gates in the workcell might be

involved.
If the problem still exists, perform the following troubleshooting
procedure:
Table 420.
1. Perform the following steps to determine if a safety fence is
installed:
a. Look at terminals 5 and 7 on the EMG module connector
CRR4.
b. Check for a jumper connecting the terminals or a wire on
each terminal.
If a jumper is present go to step 2.
If two wires are present go to step 3.
2. Measure the resistance between the two terminals.

If there is continuity replace the EMG module. If the
problem still exists, replace the axis control printed circuit
board.
If there is no continuity repair or replace the jumper.
3. Measure the resistance between the two wires.

If there is continuity replace the EMG module. If the
problem still exists, replace the axis control printed circuit
board.
If there is no continuity locate and repair the break in the
safety fence switch circuit between the two terminals.
Illustration
Chapter 13
Print Reference
06-24 thru 06-26
CRR4
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
100OUT3
EMGOU2
100OUT4
EMGOUTC
FENCE1
EMGOUT1
FENCE2
EX-ON
0V
EX COM
EX-COM
0V
EX-OFF
5v
DIL1
15V
DIL2
-15V
EMGB1
+24V
EMGB2
4. TROUBLESHOOTING
MARMMTRBL02303E
438
Figure 57. Fence Open Circuitry
4. TROUBLESHOOTING
439
MARMMTRBL02303E
4.4.6
SRVO-005 ER_SVAL1
Robot Overtravel
An overtravel error occurs when one or more of the robot axes move
beyond the software motion limits, tripping an overtravel limit switch.
Table 421.
SRVO-005 Troubleshooting Procedure 1
1. If you have not already done so, continuously press and hold
the DEADMAN switch and turn the teach pendant ON/OFF switch
to ON.
2. Hold down the SHIFT key and press RESET.
3. Press COORD until you select the JOINT coordinate system.
4. Jog the axis in overtravel off of the overtravel switch.
If you cannot jog the robot off of the overtravel switch the
wrong motion inhibit flag has been set; therefore, continue to
the next step. Otherwise, the axis (or axes) are no longer in
overtravel and you can end the procedure now.
5. Cold start the controller and go to Step 1 in this procedure. If
the overtravel still cannot be cleared, continue to Step 6.
NOTE In some instances, the screen will indicate a FALSE for a
given axis when a TRUE should be set because of the way
overtravel is read in software. It is best to perform the following
procedure on all of the axes.
6. Press MENUS.
7. Select MANUAL FCTNS.
8. Press F1, [TYPE].
9. Select OT Release. See the following screen for an example.
10. Move the cursor to the OT PLUS or OT MINUS value of the
axis in overtravel. The status of OT PLUS or OT MINUS for that
axis is TRUE.
11. Press and hold SHIFT and press F2, RELEASE.
12. Press and hold SHIFT and press RESET.
13. Press COORD until you select the JOINT coordinate system.
14. Continuously press and hold the DEADMAN switch and turn
the teach pendant ON/OFF switch to ON.
15. Jog the axis off of the overtravel switch.
16. Turn the teach pendant ON/OFF switch OFF and release the
DEADMAN switch.
Illustration
Chapter 13
Print Reference
05-08 thru 05-20
4. TROUBLESHOOTING
MARMMTRBL02303E
440
If the problem still exists, it is caused by an open circuit in the overtravel

switch circuit or by a defective axis control board or EMG module.
Try the following steps in order, checking for proper operation after each.
Table 422.
SRVO-005 Troubleshooting Procedure 2
1. Remove all connectors from the axis control board and reseat them, starting with connector CRM1.
2. If spare boards are available, temporarily replace the EMG board and axis control board.
3. Using the schematic drawings and an ohmmeter, check the overtravel switches in the robot and their
wiring for continuity.
4. Replace the cable between axis control board connector CRM1 and the robot.
Figure 58. Robot Overtravel Circuitry
Reference
4. TROUBLESHOOTING
441
MARMMTRBL02303E
4.4.7
SRVO-006 ER_SVAL1
Hand Broken
A hand breakage error occurs when the hand (wrist) breakage detection
switch or aux hand breakage detection switch is tripped.
Remedy:
If you are not using the hand broken function, ensure that the HBK
jumper on the axis control printed circuit board is set to the A side.
If you are using the hand broken function, perform the following steps:
1. If you have not already done so, continuously press and hold the
DEADMAN switch and turn the teach pendant ON/OFF switch to ON.
2. Hold down the SHIFT key and press RESET. The robot can now be
moved.
3. Jog the robot to a safe position off of the limit switch.
4. Turn the teach pendant ON/OFF switch to OFF and release the
DEADMAN switch.
4. TROUBLESHOOTING
MARMMTRBL02303E
442

procedure:
Table 423.

Illustration
Reference
1. Remove power from the controller by

turning off the disconnect switch.
2. Test the end effector switch and its wires at

the robot for continuity.
If there is no continuity replace or repair
the switch or its wires.
If there is continuity continue.
3. Set the HBK jumper on the axis control

board to the A side and test the robot for
proper operation.
If the fault is fixed replace the cable
between axis control board connector
CRM1 and the robot. Be sure to reset the
HBK jumper on the axis control board to the
B side.
If the fault is not fixed replace the axis
control board.
NOTE: When replacing the axis control
module, ensure that the on-board jumpers
on the replacement board match those on
the original board.
COM
JUMPER
Figure 59. Hand Broken Circuitry
HBK
JUMPER
4. TROUBLESHOOTING
443
MARMMTRBL02303E
4.4.8
SRVO-007 ER_SVAL1
External emergency
stops
An external emergency stop button somewhere in the workcell has been

pressed. External emergency stop is signaled whenever the 100V to the
servo amplifiers is not present, and the operator panel emergency stop,
teach pendant emergency stop, overtravel, and hand broken signals are not
asserted.
Remedy: Locate and release the external emergency stop button. Press
reset on the operator panel or teach pendant.
procedure:
4. TROUBLESHOOTING
MARMMTRBL02303E
444
Table 424.

Illustration
CRR3

a. Locate terminals 6, 8, and 10 on connector CRR3 of the
EMG module.
b. Check for jumpers between:
6 and 8
8 and 10
or else wires attached to the terminals. Wires indicate that
an external emergency stop is
connected to the controller.
If there is no jumper connecting the terminals or there are
no wires on each terminal verify that no external emergency
stop should be installed and replace the missing jumper.
If a jumper is present or if wires are present go to step 2.
Chapter 13
Print Reference
EMG
1 100IN1
2 OP1
3 100IN2
4 OP2
5 100IN3
6 EMGIN1
7 100IN4
8 EMGINC
9
10 EMGIN2
11 100OUT1
12 100OUT1
13 100OUT2
14 100OUT2
15 BKP4
16 BKM4
17 BKP5
18 BKM5
19 BKP6
20 BKM6
03-08, 03-09, 03-10
2. With controller power off, on the EMG module, measure the

resistance on CRR3 between:
6 and 8
8 and 10
If there is continuity go to step 3.
03-08, 03-09
03-09, 03-10
If there is no continuity repair or replace the jumper or locate

and repair the break in the external emergency stop circuit.
3. With controller power off, on the EMG module, measure the
resistance on CRR3 between terminals 2 and 4.
If there is continuity go to step 4.
If there is no continuity verify that the 100VAC contacts on
the operator panel emergency stop button are operating
properly.
03-06, 03-07
4. With controller power on, on the EMG module, measure the AC

voltage on CRR3 between terminals 1 and 3.
Is the voltage 100VAC 10%?
If the voltage is within tolerance replace EMG
If the voltage is not within tolerance go to step 5.
03-04
5. With controller power on, measure the AC voltage at transformer

TF1, terminals 41 and 42, for
100VAC 10%.
If the voltage is within tolerance repair or replace the wiring
between TF1 terminals 41 and 42 and EMG module CRR3
terminals 1 and 3.
If voltage is out of tolerance continue.
41 42
F4 F5
5A 5A
01-33, 01-34
4. TROUBLESHOOTING
445
MARMMTRBL02303E

6. At the ALC relay, terminals 23 and 13, measure again for
100VAC 10%.
If the voltage is within tolerance check for proper operation
of the ALC relay.
Illustration
01-26
13
A1
A2
23
31
41
32
42
14
7. Remove power from the controller, and with an ohmmeter test
fuses F4 and F5.
If F4 and F5 are good transformer TF1 is not outputting
100VAC on its secondary legs and needs replacing.
Chapter 13
Print Reference
24
41 42
F4 F5
5A 5A
01-23
4. TROUBLESHOOTING
MARMMTRBL02303E
446
Figure 510. External Emergency Stop Circuitry
4. TROUBLESHOOTING
447
MARMMTRBL02303E
4.4.9
Indicates one of two symptoms:
SRVO-008 ER_SVAL
Brake fuse blown

The 5A brake fuse on the EMG module has blown.

A momentary surge of high current was detected in the brake circuit.
The FALM LED on the EMG module will be lit.
Remedy: By turning power off momentarily and then back on you will
reset the circuit and the LED will go out if the fault is caused by a current
surge.
If the fault does not reset or if it reoccurs frequently, perform the
following troubleshooting procedure:
Table 425.
1. Turn off the controller at the main disconnect and open
the cabinet door.
2. Remove all of the connectors on the front of the EMG
module and pull out the module.
3.Check the 5A fuse and replace it if necessary.
4. Place the EMG control printed circuit board back in its

slot and plug all connectors back into it.

Illustration
Chapter 13
Print Reference
EMG
PCB
03-19
4. TROUBLESHOOTING
MARMMTRBL02303E
448
Illustration
5. Using an ohmmeter, test the continuity between

CRR3, terminal 19 and the following points to test for a
shorted brake coil:
CRR5 pins 1B, 2B, 3B, 1D, 2D, 3D
CRR3 terminals 16, 18, and 20 (extended
axes only)
A short or resistance lower than 50 ohms could cause
the fuse to blow or the sensor to trip. Replace the
motor on the axis with the shorted brake coil.
If the resistance is OK continue.
Chapter 13
Print Reference
CRR3
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
100IN1
OP1
100IN2
OP2
100IN3
EMGIN1
100IN4
EMGINC
04-10 thru 04-38
EMGIN2
100OUT1
100OUT1
100OUT2
100OUT2
BKP4
BKM4
BKP5
BKM5
BKP6
BKM6
BRK4
NOT
USED
BRK5
BRK6
FALM
D CB A
BRK
CRR5
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
VIOLET
BKM3
BKM3
BKM3
6. With the controller door open and all connectors and

plugs reattached, energize the controller.
If the FALM light comes on replace the EMG
module.
BRK1
SON
BRK2
BRK3
100OUT3
EMGOU2
100OUT4
EMGOUTC
FENCE1
EMGOUT1
FENCE2
EX-ON
0V
EX-COM
0V
EX-OFF
5v
DIL1
15V
DIL2
-15V
EMGB1
+24V
EMGB2
CRR4
BLUE
BKP3
BKP3
BKP3
VIOLET
BKM2
BKM2
BKM1
BLUE
BKP2
BKP2
BKP1
03-32
4. TROUBLESHOOTING
449
MARMMTRBL02303E

Illustration
Chapter 13
Print Reference
7. Power up the robot and jog the robot to verify robot

operation.
If the FALM light comes on replace the EMG
module.
EMG CONTROL MODULE
SENSITIVITY
JUMPER
1
SET
9. If this problem occurs occasionally, change the SET

jumper from 2 to 1 on the EMG module.
0337
4. TROUBLESHOOTING
MARMMTRBL02303E
450
Figure 511. Brake Fuse Blown Circuitry
4. TROUBLESHOOTING
451
MARMMTRBL02303E
4.4.10
Teach pendant deadman switch released while enabled.
SRVO-011
ER_SVAL1
TP Released While
Enabled
Remedy: Press the deadman switch, then press RESET.
4.4.11
Normal power is on (hot start).
SRVO-012
ER_SVAL1
Power Failure
Recovery
Remedy: This message is normal and does not indicate a problem.
4.4.12
One or all of the 24VDC cooling fans in the backplane cage are not
running.
SRVO-014
Fan Motor Abnormal
(Group:i Axis:j)
Each double-board board cage in the backplane has a cooling fan mounted
in its top. Each fan contains a centrifugal switch that opens when the fan
is not running.
Table 426.
1. With power on, test whether each fan is turning by passing a strip of paper over the top of each
board cage.
All fans are turning go to step 3.
One fan is motionless continue.
2. Remove the circuit boards from the board cage with the motionless fan. Reconnect the four-wire
connector on the backplane behind the board cage. Reinstall the boards and power up the controller.
If the fault is not fixed replace the fan.
3. One of the fans or the axis control board is probably defective. Determine which part is bad by
temporarily replacing it with a known-good part.
If the fault is not fixed continue.
4.Replace the backplane.
Chapter 13
Print Reference
4. TROUBLESHOOTING
MARMMTRBL02303E
452
Figure 512. Backplane
AXIS
BACKPLANE
24V
CA39C
1
+24VDC
CA39C
2
+0VDC
5V
E71
RV
*FMM
JRA2
13
ALM
(SVRO 014
FAN MOTOR
ABNORMAL)
CA39C
3
ALMC
OPTION 1 & 2 PCB

COOLING FAN
CENTRIFUGAL
IC13
CA39B
1
+24VDC
CA39B
2
+0VDC
CA39B
3
IC11
CA39A
1
CA39A
2
0V
CA39A
3
IC12
0V
ALMB
AXIS & MAIN PCB

COOLING FAN
CENTRIFUGAL
+24VDC
+0VDC
ALMA
CENTRIFUGAL
EMG & PSU PCB

COOLING FAN
4. TROUBLESHOOTING
453
MARMMTRBL02303E
4.4.13
SRVO-015
ER_SVAL1
System Over Heat
(Group:i Axis:j)
The temperature in the controller is too high, or the overheat sensor

located on the backplane has opened.
Table 427.
Line No. Reference

Chapter 13
1. Clean the controller air filter, allow the controller to cool down, and cold start the controller.
2. Check the heat exchanger fans for operation.
If the fans run ok replace the axis control board.
If one or more fans do not work continue.
3. Check the AC voltage at the terminals of the non-working fan(s).
If the voltage is 180VAC 220VAC replace the fan(s).
If the voltage is out of tolerance replace or repair the fan motor wiring harness.
Figure 513. System Over Heat Circuitry Drawing 1
02-02
02-04
02-07
4. TROUBLESHOOTING
MARMMTRBL02303E
454
Figure 514. System Over Heat Circuitry Drawing 2
4. TROUBLESHOOTING
455
MARMMTRBL02303E
4.4.14
SRVO-021
ER_SVAL1
SRDY off
(Group:i Axis:j)
The axis control board sends a signal to the servo amplifiers in order to
energize the MCC contactors and turn on the servo amplifiers. When a
servo amplifier MCC coil is turned on, it sends a signal back to the axis
control board. If the axis control board sends its signal and does not
receive the reply within a few milliseconds, this alarm occurs.
Table 428.
1. Does the alarm occur on three or more axes?
YES repair or replace the wiring harness between the EMG board and terminals 5 and 6 of the
servo amplifier in the far left position.
Line No. Reference

Chapter 13
08-17
09-18
10-17
09-01 thru 09-09
NO continue
2. Disconnect and reseat the signal cable between the axis control board and the affected servo
amplifier. If necessary, continue.
3. Exchange the axis control board-to-servo amplifier cable between the affected axis and a knowngood axis. Be sure to switch both ends of the cables.
10-01 thru 10-18
Does the fault message change to indicate a different axis?

YES replace the bad cable.
NO continue
4. Replace the axis control board. If the problem continues, replace the affected servo amplifier.
4.4.15
SRVO-022
ER_SVAL1
SRDY on
(Group:i Axis:j)
The axis control board sends a signal to the servo amplifiers in order to
energize the MCC contactors and turn on the servo amplifiers. When a
servo amplifier MCC coil is turned on, it sends a signal back to the axis
control board. If the axis control board receives the reply signal without
having sent its request signal, this alarm occurs.
Table 429.
1. Exchange the axis control board-to-servo amplifier cable between the affected axis and a knowngood axis. Be sure to switch both ends of the cables.
Does the fault message change to indicate a different axis?
YES replace the bad cable.
NO continue
2.Replace the axis control board. If the problem continues, replace the affected servo amplifier.
Line No. Reference

Chapter 13
09-01 thru 09-09
08-01 thru 08-18
10-10 thru 10-18
4. TROUBLESHOOTING
MARMMTRBL02303E
456
4.4.16
SRVO-023
ER_SVAL1
Stop Error Excess
(Group:i Axis:j)
The axis position is too far from its commanded position when the robot is
stopping, or the robot is stopped and it will not move. The torque
necessary to decelerate an overloaded motor could cause this alarm to
occur.
Table 430.
Line No. Reference

Chapter 13
1. Is the load over the specification?

If it is over Reduce the load.
2. Check for a binding axis. Repair if required.
If the load is within the specification and the axes are not binding Go to step 3.
3. Is the three phase input voltage lower than the FANUC specification (170V ~253V)?
If it is lower The maximum torque of the motor decreases. Increase the input voltage within the
rated voltage. Check transformer TF1 for proper tap settings.
08-24, 25, 26
09-23, 24, 25
10-23, 24, 25
4. Replace the servo amplifier.

If the alarm occurs again Go to step 4.
5. Replace the motor.
4.4.17
SRVO-024
ER_SVAL1
Move Error Excess
(Group:i Axis:j)
4.4.18
SRVO-026
ER_WARN
Motor Speed Limit
(Group:i Axis:j)
4.4.19
SRVO-027
ER_WARN
Robot Not Mastered
(Group:i Axis:j)
The servo error is too big when the robot is moving, or the robot moves
when it is supposed to be stopped.
Remedy: Same as SRVO-023, Stop Error Excess.
The motor cannot rotate as fast as the calculated speed required for the
current motion
Remedy: Even though this is just a warning, every attempt should be
made to eliminate this error by modifying the programmed speed or
motion.
The system variable $master_done is set to FALSE.

Remedy: Master the robot.
4. TROUBLESHOOTING
457
MARMMTRBL02303E
4.4.20
SRVO-033
ER_WARN
Robot Not Calibrated
(Group:i Axis:j)
4.4.21
SRVO-035
ER_WARN
Joint Speed Limit
(Group:i Axis:j)
4.4.22
SRVO-036
Imposition Time Over
(Group:i Axis:j)
The system variable $calibrate is set to FALSE.

Remedy: Calibrate the robot.
Joint cannot rotate as fast as the calculated speed required for the current
motion.
Remedy: Even though this is just a warning, every attempt should be
made to eliminate this error by modifying the programmed or motion
speed.
The robot is not in position for the specified period, or the servo error is in
excess of the commanded position when the robot is stopping, or the robot
is stopped and it will not move. The torque necessary to decelerate an
overloaded motor could cause this alarm to occur.
Table 431.
Line No. Reference

Chapter 13
1. Is the load over the specification?

If it is over Reduce the load.
2. Check for a binding axis. Repair if required.
If the load is within the specification and the axes are not binding Go to step 3.
3. Is the three phase input voltage to the servo amplifier lower than the FANUC specification
(170V ~253V)?
If it is lower Check transformer TF1 for the proper tap setting.
08-24, 25, 26
09-23, 24, 25
10-23, 24, 25
5. Replace the motor.
4.4.23
SRVO-037
ER_SVAL1
IMSTP Input
(Group:i Axis:j)
IMSTP (immediate stop) UOP input asserted.

Remedy: If using a UOP, determine the cause and repair. If not using
UOP, select the I/O menus and zero UOP mapping.
4. TROUBLESHOOTING
MARMMTRBL02303E
458
4.4.24
When the controller was powered up, one or more of its axes was at a
different position from when it was powered off. This might occur when a
motor is replaced or when a CPU from one controller is installed in
another.
SRVO-038
PULSE MISMATCH
(Group:i Axis:j)
Remedy: Perform the following procedure:
Table 432.
Line No. Reference

Chapter 13
1. Press MENUS.
2. Select SYSTEM.
3. Press F1, [TYPE].
4. Select System Variables.
5. Move the cursor to $MCR.
6. Press ENTER.
7. Move the cursor to $SPC_RESET.
8. Press F4, TRUE. The display will reset to false. This is normal.
9. Press RESET.
The fault condition should reset. If the controller is still faulted with additional servo-related
errors, cold start the controller.
It might be necessary to remaster the robot.
4.4.25
SRVO-042
ER_SVAL2
MCAL Alarm
(Group:i Axis:j)
The servo amplifier magnetic contactor (MCC) is welded closed. If the

contact of the magnetic contactor is already closed when the contactor is
turned on, this alarm circuit regards the contact as welded closed and the
MCC alarm occurs.
Table 433.
1. Does this alarm occur with SRVO-049?
If SRVO-049 occurs Check for the absence of input three-phase voltage to the servo amplifer.
Correct as necessary.
If SRVO-049 does not occur Go to step 2
2. Does this alarm occur with the OH1 alarm?
If OH1 alarm occurs Turn off the controller power for fifteen seconds and turn it on again. If still
present, remove and replace the connector CN1 or CN2 of the problem axis and check its
associated cable and connector at the axis module.
If OH1 alarm does not occur Go to step 3.
Line No. Reference

Chapter 13
08-24, 25, 26
09-23, 24, 25
10-23, 24, 25
4. TROUBLESHOOTING
MARMMTRBL02303E
4.4.26
SRVO-041
MOFAL Alarm
(Group:i Axis:j)
459
The motion command after the ramping algorithm in the servo software
exceeded one word. Contact the FANUC Robotics Hotline for more
information. DO NOT INCLUDE IN MANUAL!!!!!!
4. TROUBLESHOOTING
MARMMTRBL02303E
460
4.4.27
SRVO-043
ER_SVAL2
DCAL Alarm
(Group:i Axis:j)
The regenerative energy produced by the motor exceeded the specification.

NOTE Energy feedback from motor to the amplifier is called regenerative
energy. This occurs when the axis is being slowed down. The amplifier
discharges this energy by converting it to heat energy through the
discharge resistor. If the charged energy exceeds the discharged energy,
this alarm occurs.
Remedy: Check the LED of the amplifier, then perform the following
troubleshooting procedure.
Table 434.
Chapter 13
Print Reference
1. Is 4 or 5 indicated on the servo amplifier 7-segment display?

If indicated Go to step 2 if 4 is indicated.
Go to step 3 if 5 is indicated.
If not indicated Check for short to ground or an open circuit in the PWMC line of the specified
axis between the axis control printed circuit board and servo amplifier (connector JV-1 7). Swap
the axis control printed circuit board.
2. A 4 is indicated (DCSW alarm) when the regenerative transistor is on continuously for one
second or longer. Reduce the load of the robot.
If the error still exists Replace the servo amplifier.
3. 5 is indicated (DCOH alarm). The DCOH alarm is caused when the regenerative resistor
overheats and is sensed by the thermostat or the thermostat in transformer TF1 opens.
If the average regenerative energy is excessive This alarm occurs when the
acceleration/deceleration frequency is high or gravity energy at the axis is large. Relax the
operating conditions.
For robots with extended axes: When a separate regenerative discharge unit or power
transformer for the servo controller is used, check the wiring for the thermostat according to the
connection diagrams for proper wiring.
If the thermostat is incorrectly wired or is defective When a separate regenerative discharge
unit or power transformer for the servo controller is used, check the wiring for the thermostat
according to the connection diagrams.
08-03, 09-03
11-03, 12-03
11-37, 12-37
08-37, 09-37
11-39, 12-39
08-39, 09-39
4. TROUBLESHOOTING
461
MARMMTRBL02303E
4.4.28
SRVO-044
ER_SVAL2
HVAL Alarm
(Group:i Axis:j)
The DC voltage on the main power circuit of the servo amplifier exceeded
specification.
Remedy: Check the three-phase voltage to the servo amplifier input. It
should not exceed 253 VAC phase-to-phase. Check the cabling between
the servo amplifier and the axis control printed circuit board if no alarm is
indicated on the servo amplifier 7-segment display.
procedure:
Table 435.
1. Is the voltage of the threephase input servo to the amplifier higher than 253 VAC?
If it is higher Check transformer TF1 taps.
Chapter 13
Print Reference
08-24, 25, 26
09-23, 24, 25
01-38
2. Is the load of the robot within the specification? This alarm can be caused by the charge of the
regenerative energy when the load exceeds the specification.
If it exceeds the specification Reduce the load of the robot.
3. Check the connection of the Separated Regenerative Discharge Unit. If one is being used, it should
be wired across terminals 17 and 19 of T1 and connected to terminals 1 and 2 of T3 on the discharge
unit. There should be no jumper connecting terminals 17 and 18.
If connected incorrectly Connect correctly.
4. Check the resistance of the built-in regenerative resistor of the amplifier or that of the separate
regenerative resistor (14 ohms) across terminals 17 and 19 of T1.
If the value of the resistance is incorrect Replace the regenerative discharge unit or servo
amplifier.
5. For robots with extended axes: The operating condition might not be appropriate for the
specification of the motor or the amplifier.
If this occurs Relax the operating condition.
11-39
4. TROUBLESHOOTING
MARMMTRBL02303E
462
4.4.29
The current in the main power circuit of the servo amplifier exceeded
specification. The servo amplifier LED should display 8, 9, or 6.
SRVO-045
ER_SVAL2
HCAL Alarm
(Group:i Axis:j)
Remedy: If no alarm is indicated on the servo amplifier 7-segment

display, check the cabling between the servo amplifier (CN1) and the axis
control printed circuit board (JV1-10).
procedure:
Table 436.
Chapter 13
Print Reference
1. Disconnect the motor power lines from the amplifier terminals and turn on the power. This alarm will
re-occur if
The transistor module (TM) is defective.
Resistor R3 has opened or raised resistance.
The servo amplifier is defective.
If an HCAL alarm occurs Replace these components as necessary or replace the servo
amplifier.
08-24, 25, 26
09-23, 24, 25
10-23, 24, 25
2. Remove the motor power lines from the amplifier terminals and check the continuity between GND
and each of the lines U, V, and W that go to the motor.
If any are short-circuited Go to step 3.
08-24, 25, 26
09-23, 24, 25
10-23, 24, 25
If all are not shorted Go to step 4.

3. Remove the power lines from the motor connectors (J1-6) and recheck the continuity between GND
and each of the lines U, V, and W to the robot motor.
If any are shorted The motor is defective. Replace the motor.
08-24, 25, 26
09-23, 24, 25
10-23, 24, 25
If all are open The power lines to the motor are defective. Replace the cable.
4. Remove the motor power lines from the amplifier terminals and measure the resistance
between U-V, V-W, and W-U on the servo amplifier using a measuring instrument sensitive
enough to detect small resistances.
If the three measured values are the same Go to step 5.
08-24, 25, 26
09-23, 24, 25
10-23, 24, 25
If the three measured values are different Go to step 6.

5. Remove the power lines from the motor connectors and remeasure the resistance between U-V,
V-W, and W-U using a measuring instrument sensitive enough to detect small resistances.
If the three measured values are the same The power lines are defective. Replace the cable.
08-24, 25, 26
09-23, 24, 25
10-23, 24, 25
If the three measured values are different The motor is defective. Replace the motor.
8. Replace the serial pulse coder on the motor.
9. Check whether you are using the robot under conditions that exceed the specification. For
example, load, duty, and so forth. If there is no mechanical reason (binding and so forth) to cause this
alarm, this alarm might occur under conditions that exceed the specification. If you are using the robot
over the specification, relax the operating conditions.
08-12, 13
4. TROUBLESHOOTING
463
MARMMTRBL02303E
4.4.30
SRVO-046
ER_SVAL2
OVC Alarm
(Group:i Axis:j)
The average current calculated by the servo software exceeded

specification.
Remedy: Reduce the load on the robot.
procedure:
Table 437.
Chapter 13
Print Reference
1. Is the three-phase AC input power to the servo amplifier lower than 200 VAC?
If it is lower or missing Check transformer TF1 taps and fuses.
08-24, 25, 26
09-23, 24, 25
10-23, 24, 25
01-15, 16

If the alarm occurs again The motor is defective.
08-11, 12, 13
4. TROUBLESHOOTING
MARMMTRBL02303E
464
4.4.31
SRVO-047
ER_SVAL2
LVAL Alarm
(Group:i Axis:j)
The DC voltage on the main power circuit of the servo amplifier is lower
than the specification even though the MCC is on.
Remedy: If no alarm is indicated on the servo amplifier LED, check the
cabling between the servo amplifier and the axis control printed circuit
board.
procedure:
Table 438.
1. Does the LED of the amplifier indicate 2?
a. Check for 200VAC input power to terminals 13 and 14 of the servo amplifier. If low or missing,
check transformer TF1 taps and fuses.
Chapter 13
Print Reference
08-23, 24, 25
09-23, 24, 25
10-23, 24, 25
b. If 200VAC is present, replace the servo amplifier.

2. Does the LED of the amplifier indicate 3? A 3 indicates the DC current in the main power circuit
is too low
a. Check the three-phase 200VAC input voltage to the servo amplifier.
If the voltage is lower than 200VAC Check the transformer TF1 taps and fuses.
b. Did the circuit breaker on the servo amplifier trip? (If a circuit breaker trips, this alarm will occur.)
If a circuit breaker trips Turn on the breaker. If it trips again, replace the servo amplifier.
3. Does the LED of the amplifier indicate a 7? This alarm could occur when the contact of the
magnetic contactor is melted (welded together).
Refer to the SRVO-042 MCAL Alarm.
08-23, 24, 25
09-23, 24, 25
10-23, 24, 25
4. TROUBLESHOOTING
465
MARMMTRBL02303E
4.4.32
SRVO-049
ER_SVAL2
OHAL1 Alarm
(Group:i Axis:j)
The servo amplifier overheated. Servo amplifier LED indicates a 6.

This alarm indicates that the thermal switch mounted on the PC board of
the specified axis has opened.
Remedy: Check the fans and the heat exchange unit for proper operation.
procedure:
Table 439.
1. If the servo amplifier 7-segment display shows , check the cabling between the servo amplifier
(CN1) and axis control module (JV1-6).
Chapter 13
Print Reference
08-01 thru 08-08
09-01 thru 09-09
10-10 thru 10-18
2. Relax the operating condition.

If the alarm no longer occurs The operating condition of the robot exceeded the specification.
3.Replace the servo amplifier.
4.4.33
SRVO-050
ER_SVAL1
CLALM Alarm
(Group:i Axis:j)
The servo software detected a disturbance torque that was too high or a
collision occurred and tripped a collision detection alarm.
Remedy: Reset the robot by using the teach pendant RESET button and
jog the robot away from obstructions.
procedure:
Table 440.
1. Does the load exceed the specifications? (When the robot moves over the specifications, the estimated disturbance torque might become larger and this alarm could occur.)
If the load exceeds the specifications Lower the load to within the specifications.
2. Is the three-phase AC input voltage to the servo amplifier lower than the rated voltage (200VAC)?
If it is lower Check transformer TF1 taps and fuses.
Chapter 13
Print Reference
08-23, 24, 25
09-23, 24, 25
10-23, 24, 25
01-38
4. TROUBLESHOOTING
MARMMTRBL02303E
466
4.4.34
The feedback current is abnormal.
SRVO-051
ER_SVAL2
CUER Alarm
(Group:i Axis:j)
Table 441.
If the alarm still occurs Go to step 2.
Chapter 13
Print Reference
08-11, 12, 13
2. Replace the servo amplifier. If the alarm continues, go to step 3.

3. Replace the pulse coder and master the robot.
4.4.35
The clock for the rotation counter in the pulse coder is abnormal.
SRVO-061
ER_SVAL2
CKAL Alarm
(Group:i Axis:j)
Table 442.
1. Did a SRVO-068 DTERR, or SRVO-069 CRCERR, or a SRVO-070 STBERR occur with this alarm?
YES disregard SRVO_061 and refer to the remedy of any of the other three alarms.
If no alarms occur Replace the pulse coder on the specified axis and master the robot.
Chapter 13
Print Reference
4. TROUBLESHOOTING
467
MARMMTRBL02303E
4.4.36
The battery voltage for the pulse coders is zero volts.
SRVO-062
ER_SVAL2
BZAL Alarm
(Group:i Axis:j)
Table 443.
YES disregard the BZAL alarm and refer to the procedure for the other alarm (SRVO_68
SRVO_70).
NO Continue
2. Did this alarm message list only one axis?
YES Check the battery cable for the pulse coder of the axis listed in the alarm message.
Reconnect, repair, or replace as necessary. Go to Step 4.
NO Continue
3. Press the teach pendant emergency stop button. Turn the controller on. Check the batteries behind
the black plastic hatch in the base of the controller.
Are the batteries ok?
YES Repair or replace the battery compartment cable. Go to Step 4.
NO Replace the batteries. Go to Step 4.
4. a. Press MENUS.
b. Select SYSTEM.
c. Press F1, [TYPE].
d. Select System Variables.
e. Move the cursor to $MCR.
f. Press ENTER.
g. Move the cursor to $SPC_RESET.
h. Press F4, TRUE. The display will reset to false. This is normal.
i. Press RESET. The fault condition should reset. If the controller is still faulted with additional
servo-related errors, cold start the controller.
It might be necessary to remaster the robot.
Chapter 13
Print Reference
4. TROUBLESHOOTING
MARMMTRBL02303E
468
4.4.37
The built-in rotation counter on the pulse coder is abnormal.
SRVO-063
ER_SVAL2
RCAL Alarm
(Group:i Axis:j)
Table 444.
Chapter 13
Print Reference
NO Replace the pulse coder on the specified axis and master the robot.
4.4.38
SRVO-064
ER_SVAL2
PHAL Alarm
(Group:i Axis:j)
The relationship between the analog signals on the pulse coder are
abnormal.
Table 445.
Chapter 13
Print Reference
NO Replace the pulse coder on the specified axis and master the robot.
4.4.39
The pulse coder batteries are low.
SRVO-065
ER_WARN
BLAL Alarm
(Group:i Axis:j)
Table 446.
NO Replace the APC backup batteries. Remaster the robot if necessary.
NOTE Replace the battery as soon as possible when this alarm occurs, otherwise, if the battery voltage goes to zero volts, the robot will require remastering.
Chapter 13
Print Reference
4. TROUBLESHOOTING
469
MARMMTRBL02303E
4.4.40
The pulse coder ROM checksum data are abnormal.
SRVO-066
ER_SVAL2
CSAL Alarm
(Group:i Axis:j)
Table 447.
Chapter 13
Print Reference
If no alarms occur Replace the pulse coder on the specified axis and master the robot.
4.4.41
The pulse coder overheated.
SRVO-067
ER_SVAL2
OHAL2 Alarm
(Group:i Axis:j)
Table 448.
YES disregard SRVO-067 and refer to the remedy of any of the other three alarms.
2. Does the operating condition (load, duty) exceed the specifications?
If the operating condition exceeds the specifications Relax the operating condition within the
specification. (Reduce the load, change the program, etc.)
3. Turn off the controller and when the temperature of the motor returns to normal, turn it back on.
If the alarm immediately occurs again The built-in thermostat in the pulse coder is defective.
Replace the pulse coder.
If the alarm occurs again, but not immediately the motor is generating too much heat. Replace
the motor.
Chapter 13
Print Reference
07-22
4. TROUBLESHOOTING
MARMMTRBL02303E
470
4.4.42
SRVO-068
ER_SVAL2
DTERR Alarm
(Group:i Axis:j)
The axis control printed circuit board sent the serial data request signal to
the pulse coder, but did not receive serial data from the pulse coder.
Table 449.
Chapter 13
Print Reference
1. Check for connection and continuity of the feedback cable. Repair or replace if necessary.
08-16, 17, 18

08-01 thru 10
3. Replace the pulse coder and master the robot.
4.4.43
SRVO-069
ER_SVAL2
CRCERR Alarm
(Group:i Axis:j)
The serial data from the pulse coder changed during communication to the
axis control printed circuit board.
Refer to the SRVO_068 remedy.
4. TROUBLESHOOTING
471
MARMMTRBL02303E
4.4.44
SRVO-070
ER_SVAL2
STBERR Alarm
(Group:i Axis:j)
4.4.45
SRVO-071
ER_SVAL2
SPHAL Alarm
(Group:i Axis:j)
The communication stop and start bits are abnormal.

Refer to the SRVO-068 remedy.
The feedback velocity exceeds the specifications.

procedure:
Table 450.
Chapter 13
Print Reference
1. Does this alarm occur with any other alarm?

If another alarm occurs This alarm is caused by another alarm of the serial pulse coder. Refer to
the other alarm for details.
2. Reduce the load within the specifications.
4.4.46
Line Tracking Overflow Error.
SRVO-081
ER_WARN
EROFL Alarm
(Track encoder:n)
Table 451.
1. Check the connection between the controller and the line tracking device (absolute encoder or
pulse generator).
2. Check that the line speed is within the FANUC specification.
If the line speed is not within the specification Relax the line speed.
Chapter 13
Print Reference
4. TROUBLESHOOTING
MARMMTRBL02303E
472
4.4.47
SRVO-082
ER_WARN
DAL Alarm
(Track encoder:n)
Line Tracking Pulse coder is disconnected.

Remedy: Check axis control printed circuit board for proper line tracking
cable connections.
procedure:
Table 452.
Chapter 13
Print Reference

2. Replace the pulse coder.
4.4.48
SRVO-083
ER_WARN
CKAL Alarm
(Track encoder:n)
4.4.49
SRVO-084
ER_WARN
BZAL Alarm
(Track encoder:n)
4.4.50
SRVO-085
ER_WARN
RCAL Alarm
(Track encoder:n)
4.4.51
SRVO-086
ER_WARN
PHAL Alarm
(Track encoder:n)
The clock for the rotation counter in the line tracking pulse coder is
abnormal.
Remedy: Refer to SRVO-061 remedy.
The battery voltage for the line tracking pulse coder is zero volts.
The built-in rotation counter on the line tracking pulse coder is abnormal.
The relationship between the analog signals on the line tracking pulse
coder are abnormal.
4. TROUBLESHOOTING
473
MARMMTRBL02303E
4.4.52
SRVO-087
ER_WARN
BLAL Alarm
(Track encoder:n)
4.4.53
SRVO-088
ER_WARN
CSAL Alarm
(Track encoder:n)
4.4.54
SRVO-089
ER_WARN
OHAL2 Alarm
(Track encoder:n)
4.4.55
SRVO-090
ER_WARN
DTERR Alarm
(Track encoder:n)
4.4.56
SRVO-091
ER_WARN
CRCERR Alarm
(Track encoder:n)
4.4.57
SRVO-092
ER_WARN
STBERR Alarm
(Track encoder:n)
4.4.58
SRVO-093
ER_WARN
SPHAL Alarm
(Track encoder:n)
The line tracking pulse coder batteries are low.

The line tracking pulse coder ROM checksum data is abnormal.

The line tracking pulse coder overheated.

The axis control printed circuit board sent the request signal, but did not
receive serial data from the line tracking pulse coder.
The serial data from the line tracking pulse coder changed during
communication to the axis control printed circuit board.
The communication stop and start bits for line tracking axis are abnormal.
The feedback velocity exceeds the specification for line tracking axis.
MARMMTRBL02303E
REPLACING A FUSE
51
If a fuse blows in the control unit, eliminate the cause, then replace the
fuse.
5.1
MULTI-TAP
TRANSFORMER
F2, F2, and F3 : Fuses for three-phase 200 VAC servo power
F4 and F5
: Fuses for 100 VAC
Refer to Table 51.
Table 51.
Multi-Tap Transformer Fuses
Fuse Number
F1, F2, F3
F1, F2, F3
F4, F5
F4, F5
F6, F7
Machine
S-420, S-500,
S-800, S-900,
M-500
P-155
ARC Mate SR.,
S-700, M-400,
L-1000, S-10
ARC Mate, Arc
Mate 100, A-510,
S-5
P-155
S-420, S-500,
S-800, S-900,
M-500
ARC Mate Sr.,
ARC Mate, S-5,
Arc Mate 100,
S-10, L-1000,
S-700, M-400,
A-510
S-420, 3-servo
amplifier
configuration
Rated
Current
30A
A60L-0001-0042#JG130
30A
20A
A60L-0001-0042#JG130
A60L-0001-0042#JG120
10A
A60L0001-0042#JG1-10
7.5A
7.5A
A60L-0001-0101#P475H
A60L-0001-0101#P475H
5A
A60L-0001-0101#P450H
10A
A60L-0001-0042#JG1-10
Part Number
5. REPLACING A FUSE
MARMMTRBL02303E
52
Figure 61. Replacing a Fuse of the Transformer Unit
Fuse
Fuse
Fuse
Fuse
Fuse
Fuse
Fuse
WARNING
Before replacing a fuse, turn power off and lock out the
controller.
5. REPLACING A FUSE
53
MARMMTRBL02303E
5.2
SERVO AMPLIFIER
FUSE 1
: Fuse for control power supply
Part number: A60L-0001-0175#3.2A
FUSE 2 and 3 : Fuse for fan motors (only for one axis servo amplifier,
A06B-6066-H008)
Part number: A60L00010101#P405
Figure 62. Replacing the Fuse of a Servo Amplifier
F1
F2
F3
LED
Terminal board T1
Circuit breaker
5. REPLACING A FUSE
MARMMTRBL02303E
54
5.3
POWER SUPPLY UNIT
F1 and F2
F3
F4
F5
:
:
:
:
Fuses for AC input

Fuse for +24V
Fuse for +24E
Fuse for auxiliary power supply
Table 52.
Power supply unit for four-slot backplane
Fuse number
F1, F2
F3
F4
F5
Table 53.
Rated current
7.5A
3.2A
5A
0.3A
Part Number
A60L-0001-0245#GP75
A60L-0001-0075#3.2
A60L-0001-0046#5.0
A60L-0001-0290#LM03
Power supply unit for six-slot backplane
Fuse number
F1, F2
F3
F4
F5
Rated current
10A
5A
5A
0.3A
Part Number
A60L-0001-0245#G100
A60L-0001-0075#5.0
A60L-0001-0046#5.0
A60L-0001-0290#LM03
Figure 63. Replacing a Fuse of the Power Supply Unit

PSU
F5: 0.3A fuse for

auxiliary
power supply
Battery cover
PSU
F1 and F2:
Fuses for AC input
10-A for 6-slot backplane
7.5A for 4-slot backplane
PIL: green LED
power supply status
Battery
ALM: Red LED

for indicating
an alarm
F4:5Afuse for +24E

F3: Fuse for +24V
5-A slow blow for
6-slot backplane
3.2A slow blow for
4-slot backplane
(with battery cover removed)
5. REPLACING A FUSE
55
MARMMTRBL02303E
5.4
EMERGENCY STOP
CONTROL PC BOARD
FUSE
: 5.0 A brake circuit fuse
Part number: A60L-0001-0046#5.0
FUSE
: F1, F2, 3.2A Manual brake circuit fuse
Part number: A60L-0001-0175#3.2A
Figure 64. Replacing the Fuse on the Emergency Stop Control PC Board
F1
F2
FUSE
5. REPLACING A FUSE
MARMMTRBL02303E
56
Figure 65. Replacing the Fuse on the Emergency Stop Control PC Board
EMG
PCB
Fuse
5.5
PURGE POWER
SUPPLY
A05B2047C181
FUSE: F11, F12, 3.2A AC Input Line Fuses

Part Number: A60L00010175#3.2
5. REPLACING A FUSE
57
MARMMTRBL02303E
Figure 66. Purge Power Supply
Cover
F12
F11
Purge Power Supply
5. REPLACING A FUSE
MARMMTRBL02303E
58
5.6
PROCESS
INPUT/OUTPUT PC
BOARDS AA, AB, CA,
CB, AND DA
FUSE 1
: 2.0-A fuse for +24V
Part number: A60L-0001-0046#2.0
Figure 67. Replacing the Fuse of the Process Input/Output PC Board AA, AB,
CA, CB, or DA
Fuse
Fuse
Process input/output
PC boards AA and AB
Process input/output
PC boards CA, CB and DA
5. REPLACING A FUSE
59
MARMMTRBL02303E
5.7
PROCESS
INPUT/OUTPUT PC
BOARDS BA AND BB
FUSE 1 to 8 : 6.3 A fuses for +24V

Part number: A60L-0001-0046#6.3
Figure 68. Replacing the Fuse of the Process Input/Output PC Board BA or BB
Fuse
Process input/output PC boards BA and BB
5. REPLACING A FUSE
MARMMTRBL02303E
510
5.8
MODULAR I/O UNIT
The modules listed below have built-in fuses. If a fuse blows, remove the
cause, then replace the fuse with a spare.
Table 54.
Modular I/O Unit
Module
Interface module A1F01A
Interface module A1F01B
Output module with 8 DC
points AOD08C
Output module with 8 DC
points AOD08D
Output module with 5 AC
points AOA05E
points AOA08E
points AOA12F
Indication
PWR is off
PWR is off
F is on
Rating
3.2A
3.2A
5A
Fuse Specification
A60L-0001-0290=LN32
A60L-0001-0290=LM32
A60L-0001-0260=5R00
F is on
5A
A60L-0001-0260=5R00
F is on
3.15A
A60L-0001-0276=3.15
F is on
3.15A
A60L-0001-0276=3.15
F is on
3.15A
A60L-0001-0276=3.15
The fuses are on the PC boards in the modules.
5. REPLACING A FUSE
511
MARMMTRBL02303E
5.9
AC OUTLET UNIT
FUSE
: 2.0 A fuse for 100 VAC
Part number: A60L-0001-0101#P420H
Figure 69. Replacing the Fuse of the AC Outlet Unit
Fuse
MARMMTRBL02303E
BRAKE RELEASE
61
To perform some troubleshooting and error recovery procedures, you
might have to release the brakes. Use Procedure 61 to release the brakes.
Procedure 61
Releasing the Brakes
NOTE Clear all E-stops before proceeding.

Step
1 Press and release the EMERGENCY STOP button.

NOTE Do not press RESET. The servos must be off to release the
brakes.
2 Press MENUS.
3 Select NEXT PAGE.
4 Select SYSTEM.
5 Press F1, [TYPE].
6 Select Brake Ctrl. See the following screen for an example.
SYSTEM Brake Crtl
AXIS
SELECTED
1
NO
2
NO
3
NO
4
NO
5
NO
6
NO
7
NO
8
NO
9
NO
JOINT
10%
BRAKE STATE
ENGAGED
ENGAGED
ENGAGED
ENGAGED
ENGAGED
ENGAGED
ENGAGED
ENGAGED
ENGAGED
[TYPE] ENGSEL RELSEL
YES
NO
>
7 Highlight the number of the axis you want to release or engage.
WARNING
Releasing a brake could cause the robot to move. To
STOP the robot immediately, press the EMERGENCY STOP
button or press F2, ENGSEL to engage the brake.
6. BRAKE RELEASE
MARMMTRBL02303E
62
8 To release or engage a single brake:
a Select an axis to be released or engaged; press F4, YES.

NOTE To release axis 3 you must select both axis 2 and axis 3.
b Release the brake on the selected axis; hold down the shift key
and press F3, RELSEL.
c Engage the brake on the selected axis; press F2, ENGSEL.
9 To release ALL brakes:
a Press NEXT, > to display the next page of function keys.
SYSTEM Brake Crtl
AXIS
SELECTED
1
NO
2
NO
3
NO
4
NO
5
NO
6
NO
7
NO
8
NO
9
NO
JOINT
10%
BRAKE STATE
ENGAGED
ENGAGED
ENGAGED
ENGAGED
ENGAGED
ENGAGED
ENGAGED
ENGAGED
ENGAGED
[TYPE] ENGALL RELALL
GROUP
>
WARNING
The following step will release all brakes even though they
have not been selected by pressing F4, YES. This could
result in robot movement. Be prepared for all brakes to be
released, as personnel could be injured, or equipment
damaged.
b Hold down the SHIFT key and press F3, RELALL to release all
of the brakes.
10
To engage ALL brakes:

a Press the F2, ENGALL to engage all of the brakes.
11 When you are finished, press RESET.

NOTE If you are unable to jog the robot after releasing the brakes, press
and release the EMERGENCY STOP button, and then press RESET to
clear the fault.
MARMMTRBL02303E
CONTROLLING I/O
71
Controlling I/O allows you to test the I/O in your system for proper
function during testing operation. Controlling I/O includes

Forcing outputs
Simulating inputs and outputs
SOP I/O
7. CONTROLLING I/O
72
MARMMTRBL02303E
7.1
FORCING OUTPUTS
Forcing outputs is turning output signals on or off. Outputs can also be

forced within a program using I/O instructions. Use Procedure 71 to
force outputs outside of a program.
Refer to the application Specific Setup and Operations Manual for
information on using program I/O instructions.
NOTE RO[1] and RO[2] control HAND 1, and RO[3] and RO[4] control
HAND 2.
Procedure 71
Condition
Step
Forcing Outputs

The outputs you are forcing have been configured.
1 Press MENUS.
2 Select I/O.
3 Press F1, [TYPE].
4 Select the type of output you want to force: digital, analog, group,
robot, UOP, or SOP.
WARNING
Forcing digital outputs causes connected devices to
function. Make certain you know what the digital output is
connected to and how it will function before forcing it;
otherwise, injury to personnel or damage to equipment can
occur.
7. CONTROLLING I/O
73
MARMMTRBL02303E
For digital outputs for example, you will see a screen similar to the
following.
I/O Digital Out
#
SIM STATUS
DO[
1] U
OFF
DO[
2] U
ON
DO[
3] U
OFF
DO[
4] U
OFF
DO[
5] U
OFF
DO[
6] U
ON
DO[
7] U
OFF
DO[
8] U
OFF
DO[
9] U
OFF
DO[ 10] U
OFF
[ TYPE ]
DO[
4] U
OFF
CONFIG
WORLD
[
[
[
[
[
[
[
[
[
[
IN/OUT
10%
]
]
]
]
]
]
]
]
]
]
SIMULATE UNSIM
5 Move the cursor to the STATUS of the output you want to force.
6 Press the function key that corresponds to the value you want.
For digital, robot, UOP, and SOP outputs, press
AO[
4] U
12H
F4 for ON
F5 for OFF
For analog and group outputs, move the cursor to value, and use the
numeric keys to type the value. Value entry is always in decimal
format. To change the displayed value from decimal to hexadecimal,
press F4, FORMAT. Hexadecimal numbers are followed by an H
on the screen.
7. CONTROLLING I/O
74
MARMMTRBL02303E
7.2
SIMULATING INPUTS
AND OUTPUTS
Procedure 72
Condition
Step
Simulating inputs and outputs is forcing inputs and outputs without signals
entering or leaving the controller. Simulate I/O to test program logic and
motion when I/O devices and signals are not set up. You can simulate
digital, analog, and group I/O only; you cannot simulate robot, UOP, or
SOP I/O. When you are finished simulating a signal, you can reset, or
unsimulate, it. Use Procedure 72 to simulate and unsimulate I/O.
Simulating and Unsimulating Inputs and Outputs

The input or output has been configured.
1 Press MENUS.
2 Select I/O.
3 Press F1, [TYPE].
4 Select the type of input or output you want to simulate: digital,
analog, or group.
For digital inputs for example, you will see a screen similar to the
following.
I/O Digital Input
#
SIM STATUS
DI[
1] U
OFF
DI[
2] S
ON
DI[
3] U
OFF
DI[
4] U
OFF
DI[
5] U
OFF
DI[
6] U
ON
DI[
7] U
OFF
DI[
8] S
OFF
DI[
9] U
OFF
DI[ 10] U
OFF
[ TYPE ]
CONFIG
WORLD
[
[
[
[
[
[
[
[
[
[
IN/OUT
10%
]
]
]
]
]
]
]
]
]
]
SIMULATE UNSIM
5 If you simulate a signal, you can force the status by setting it to a

value. When the signal is unsimulated, its actual status is displayed.
DO[
4]
OFF
6 Move the cursor to the SIM column of the signal you want to simulate.
U means the signal is not simulated or unsimulated.
S means the signal is simulated.
7 Simulate or unsimulate the signal.

To simulate, press F4, SIMULATE.
To unsimulate, press F5, UNSIM.
8 To unsimulate all simulated signals, press FCTN and then select

UNSIM ALL I/O.
7. CONTROLLING I/O
75
MARMMTRBL02303E
7.3
SOP I/O STATUS
The I/O SOP screen indicates the status of the standard operator panel
signals. SOP input signals (SI) and SOP output signals (SO) correspond
to internal controller software Panel Digital Input signals (PDI) and Panel
Digital Output signals (PDO). Refer to Table 71 and Table 72.
Table 71.
SI
PDI
EMERGENCY
STOP
FAULT RESET
REMOTE
HOLD
CYCLE START
715
816
Standard Operator Panel Input Signals
Function
NOT USED
Description
Input signal is normally turned ON, indicating that the EMERGENCY STOP button is
not being pressed.
Input signal is normally turned OFF, indicating that the FAULT RESET button is not
being pressed.
Input signal is normally turned OFF, indicating that the controller is not set to remote.
Input signal is normally turned ON, indicating that the HOLD push button is not
being pressed.
Input signal is normally turned OFF, indicating that the CYCLE START push button
is not being pressed.
Open for additional PDI.
Table 72.
Standard Operator Panel Output Signals
SO
PDO
Function
Description
REMOTE LED
Output signal indicates the controller is set to remote.
CYCLE START
Output signal indicates the CYCLE START button has been pressed or a program is
running.
HOLD
FAULT LED
BATTERY ALARM
TEACH PENDANT
ENABLED
Output signal indicates the teach pendant is enabled.
815
916
NOT USED
Open for additional PDO.
Output signal indicates the HOLD button has been pressed or a hold condition exists.
Output signal indicates a fault has occurred.
Output signal indicates the voltage in the battery is low.
Use Procedure 73 to display and force SOP I/O.
7. CONTROLLING I/O
76
MARMMTRBL02303E
Procedure 73
Step
Displaying and Forcing SOP I/O

1 Press MENUS.
2 Select I/O.
3 Press F1, [TYPE].
4 Select SOP. You will see a screen similar to the following.
I/O SOP Out

#
SO[
SO[
SO[
SO[
SO[
SO[
SO[
SO[
SO[
SO[
STATUS
1] OFF
OFF
2] OFF
3] OFF
4] OFF
5] OFF
6] OFF
7] OFF
8] OFF
9] OFF
10] OFF
[ TYPE ]
JOINT
[
[
[
[
[
[
[
[
[
[
10 %
]
]
]
]
]
]
]
]
]
]
IN/OUT
ON
OFF
To change between the display of the input and output screens, press
F3, IN/OUT.
To move quickly through the information, press and hold the SHIFT
key and press the down or up arrow keys.
NOTE You can only view the status of input signals. Input signals cannot
be forced.
5 To force an output signal, move the cursor to the output you want to
change:
To turn on an output signal, press F4, ON.
To turn off an output signal, press F5, OFF.
MARMMTRBL02303E
MASTERING
81
When you master a robot you define the physical location of the robot by
synchronizing the mechanical information with the robots positional
information. A robot must be mastered to operate properly. Robots are
usually mastered before they leave FANUC Robotics. However, it is
possible that a robot might lose its mastering data and require to be
remastered.
You can master the robot using several different methods. Refer to
Table 81 to select the method that best meets your needs.
Table 81.
Mastering Methods
Mastering Method
Mastering to a fixture
(Fixture Position
Master)
Mastering to zero
degrees
Single axis mastering
Recording the quick

master reference
position
Quick mastering
Robot
Models
All
When to Use
When mastery was lost due to

mechanical disassembly or repair.
When a quick master reference position
was not previously set.
Method of choice for P- and A-series
robots. Used for S- and M-series robots
when extreme precision is required.
M-series When mastery was lost due to
mechanical disassembly or repair.
S-series
When a quick master reference position
was not previously set.
Method of choice for S- and M-series
robots when extreme precision is not
required.
M-series When mastery was lost due to mechanical
S-series disassembly or repair of a single axis (usually
due to motor replacement).
All
To record mastering data as a reference for
future quick mastering.
All
To retrieve mastering data that has been

stored as a quick master reference position
when mastery is lost due to an electrical or
software problem. Do not use if mastery was
lost due to mechanical disassembly or repair.
If you are using a FANUC Robotics A-series or P-series robot you must
use a mastering fixture to master your robot. Refer to the Mechanical
Service Manual specific to your robot model for procedures on how to set
up and use a mastering fixture.
If you are using a FANUC Robotics M-series or S-series robot you can
either master to a fixture or you can master to zero degrees. Refer to the
Mechanical Service Manual specific to your robot model for more
information on mastering using a fixture.
Quick mastering is a convenient way to master an M-series or S-series
robot after you have recorded a reference position. You cannot quick
master a robot unless the reference position was taught before mastering
was lost.
8. MASTERING
MARMMTRBL02303E
82
CAUTION
Record the quick master reference position after the robot is
installed to preserve the factory mastering settings for future
remastering.
8.1
MASTERING TO A
FIXTURE (FIXTURE
POSITION MASTER)
When you master to a fixture, you use a mastering fixture to align the
robot axes and then record the position. You can master any robot to a
fixture. If you have a P-series or A-series robot, you must master it to a
fixture.
Use Procedure 81 to master to a fixture.
Procedure 81
Condition
Step
Mastering to a Fixture

You have the appropriate mastering fixture for your robot.
1 Press SYSTEM.
2 Press F1, [TYPE].
3 Select Master/Cal.
If Master/Cal is not listed on the [TYPE] menu, do the following;
otherwise, continue to Step 4.
a Select VARIABLE from the [TYPE] menu.
b Move the cursor to $MASTER_ENB.
c Press the numeric key 1 and then press ENTER on the teach
pendant.
d Press F1, [TYPE].
e Select Master/Cal. See the following screen for an example.
SYSTEM Master/Cal
1
2
3
4
5
6
JOINT 10%
FIXTURE POSITION MASTER

ZERO POSITION MASTER
QUICK MASTER
SINGLE AXIS MASTER
SET QUICK MASTER REF
CALIBRATE
Press ENTER or number key to select.
[ TYPE ]
LOAD
8. MASTERING
83
MARMMTRBL02303E
SYSTEM Master/Cal
1
2
3
4
5
6
JOINT 10%

QUICK MASTER
SINGLE AXIS MASTER
CALIBRATE
[ TYPE ]
LOAD
RES_PCA
4 If you are resetting a pulse coder alarm,

a Press F3, RES_PCA. See the following screen for an example.
SYSTEM Master/Cal
1
2
3
4
5
6
JOINT 10%

QUICK MASTER
SINGLE AXIS MASTER
CALIBRATE
Reset pulse coder alarm? [NO]

[ TYPE ]
YES
NO
b Press F4, YES. See the following screen for an example.

SYSTEM Master/Cal
1
2
3
4
5
6
JOINT 10%

QUICK MASTER
SINGLE AXIS MASTER
CALIBRATE
Pulse coder alarm reset!
[ TYPE ]
LOAD
RES_PCA
5 Refer to the Mechanical Service Manual or Mechanical Connection

and Maintenance Manual specific to your robot model for the
procedures on how to set up and use a mastering fixture.
8. MASTERING
MARMMTRBL02303E
84
6 Select Fixture Position Master.
7 Press F4, YES. Mastering will be performed automatically.

8 Continue to Step 9.
9 Select Calibrate.
10
Press F4, YES.
11 Perform a cold start.

a Turn off the robot.
b Press and continue pressing the FAULT RESET button on the
operator panel.
c While still pressing FAULT RESET, press the ON button on the
operator panel.
8. MASTERING
85
MARMMTRBL02303E
8.2
When you master to zero degrees, you position all axes at their zero degree
witness marks and record the zero degree position. You can master any
M-series or S-series robot to zero degrees.
ZERO DEGREE
MASTERING
Use Procedure 82 to master to zero degrees.

Procedure 82
Step
Mastering to Zero Degrees

1 Press SYSTEM.
2 Press F1, [TYPE].
pendant.
d Press F1, [TYPE].
SYSTEM Master/Cal
1
2
3
4
5
6
JOINT 10%

QUICK MASTER
SINGLE AXIS MASTER
CALIBRATE
[ TYPE ]
LOAD
8. MASTERING
MARMMTRBL02303E
86
SYSTEM Master/Cal
1
2
3
4
5
6
JOINT 10%

QUICK MASTER
SINGLE AXIS MASTER
CALIBRATE
[ TYPE ]
LOAD
RES_PCA
4 If you are resetting a pulse coder alarm,

a Press F3, RES_PCA. See the following screen for an example.
SYSTEM Master/Cal
1
2
3
4
5
6
JOINT 10%

QUICK MASTER
SINGLE AXIS MASTER
CALIBRATE
Reset pulse coder alarm? [NO]

[ TYPE ]
YES
NO
b Press F4, YES. See the following screen for an example.

SYSTEM Master/Cal
1
2
3
4
5
6
JOINT 10%

QUICK MASTER
SINGLE AXIS MASTER
CALIBRATE
Pulse coder alarm reset!
[ TYPE ]
LOAD
RES_PCA
5 Align the witness marks on the robot.

6 Select Zero Position Master.
8. MASTERING
87
MARMMTRBL02303E
7 Press F4, YES. Mastering will be performed automatically.

8 Select Calibrate.
9 Press F4, YES.

10
Perform a cold start.

operator panel.
operator panel.
8. MASTERING
MARMMTRBL02303E
88
8.3
You can master a single axis of an M-series or S-series robot when mastery
was lost due to mechanical disassembly or repair of a single axis, usually
due to motor replacement.
SINGLE AXIS
MASTERING
Use Procedure 83 to master a single axis.

Procedure 83
Step
Mastering a Single Axis

1 Clear any servo faults that prevent you from jogging the robot.
a Press MENUS.
b Select SYSTEM.
c Press F1, [TYPE].
d Select Variables.
e Move the cursor to $MCR and press ENTER.
f Move the cursor to $SPC_RESET and press F4, TRUE.
The value will change to TRUE momentarily, and will then change to
FALSE.
g If the value does not change to TRUE momentarily, repeat
Step 1.
h Press RESET on the operator panel.
2 Using the JOINT coordinate system, jog the unmastered axis to the
zero degree position.
3 Press MENUS.
4 Select SYSTEM.
5 Press F1, [TYPE].
pendant.
d Press F1, [TYPE].
8. MASTERING
89
MARMMTRBL02303E
SYSTEM Master/Cal
1
2
3
4
5
6
JOINT 10%

QUICK MASTER
SINGLE AXIS MASTER
CALIBRATE
[ TYPE ]
LOAD
RES_PCA
7 Select 4, Single Axis Master. See the following screen for an

example.
SINGLE AXIS MASTER

ACTUAL POS
J1
0.000
J2
3.514
J3
7.164
J4 357.366
J5
1.275
J6
4.571
E1
0.000
E2
0.000
E3
0.000
[ TYPE ]
(MSTR POS)
(
0.000)
( 35.000)
(100.000)
(
0.000)
( 80.000)
(
0.000)
(
0.000)
(
0.000)
(
0.000)
JOINT 10%
1/9
(SEL) [ST]
(0)
[2]
(0)
[0]
(0)
[2]
(0)
[2]
(0)
[2]
(0)
[2]
(0)
[0]
(0)
[0]
(0)
[0]
GROUP
EXEC
8 Move the cursor to the MSTR POS column for the unmastered axis
and press the 0 key.
9 Continuously press and hold the DEADMAN switch and turn the
teach pendant ON/OFF switch to ON.
10
Move the cursor to the SEL column for the unmastered axis and press
the numeric key 1.
11 Press ENTER.
12
Press F5, EXEC. Mastering will be performed automatically.
13
Press PREV.
14
Select Calibrate.
15
Press F4, YES.
8. MASTERING
MARMMTRBL02303E
810
16

operator panel.
operator panel.
8. MASTERING
811
MARMMTRBL02303E
8.4
QUICK MASTERING
Quick mastering allows you to minimize the time required to remaster the
robot using a reference position you established when the robot was
properly mastered. You cannot quick master the robot unless you have
previously recorded this quick master reference position.
Record the quick master reference position when the robot is properly
mastered. The best time to record the quick master reference position is
when the robot is still factory-mastered.
If you lose mastery due to an electrical or software problem, you can use
this reference position to master the robot in a minimum amount of time.
If you lose mastery due to mechanical disassembly or repair, you must
master to a fixture or perform zero degree mastering.
You can define a quick master reference position and perform quick
mastering on any robot model.
Use Procedure 84 to record the quick master reference position. Use
Procedure 85 to quick master the robot.
CAUTION
Record the quick master reference position after the robot is
installed to preserve the factory mastering settings for future
remastering.
Procedure 84
Condition
Recording the Quick Master Reference Position

The robot is properly mastered.
1 Align the witness marks on the robot. This is the zero position, which
will be the quick master reference position.
If you have a P-series or A-series robot, jog all robot axes to zero
degrees and scribe witness marks on each axis.
2 Press MENUS.
3 Select SYSTEM.
4 Press F1, [TYPE].
pendant.
8. MASTERING
MARMMTRBL02303E
812
d Press F1, [TYPE].
SYSTEM Master/Cal
1
2
3
4
5
6
JOINT 10%

QUICK MASTER
SINGLE AXIS MASTER
CALIBRATE
[ TYPE ]
LOAD
6 Move the cursor to SET QUICK MASTER REF and press ENTER.
Set quick master ref? [NO]
7 Press F4, YES.

8 Perform a cold start.
operator panel.
operator panel.
8. MASTERING
813
MARMMTRBL02303E
Procedure 85
Condition
Quick Mastering the Robot

The robot has lost mastery due to an electrical or software problem.
NOTE If the robot has lost mastery due to mechanical disassembly or

repair, you cannot perform this procedure. In this case, master to a fixture
or master to zero degrees to restore robot mastery.

The quick master reference position was recorded before the robot lost
mastery.
1 Jog the robot to the quick master reference position (zero degree
position).
2 Press MENUS.
3 Select SYSTEM.
4 Press F1, [TYPE].
pendant.
d Press F1, [TYPE].
SYSTEM Master/Cal
1
2
3
4
5
6
JOINT 10%

QUICK MASTER
SINGLE AXIS MASTER
CALIBRATE
[ TYPE ]
LOAD
6 Move the cursor to QUICK MASTER and press ENTER.

Quick master? [NO]
7 Press F4, YES.
8. MASTERING
MARMMTRBL02303E
814
8 Move the cursor to CALIBRATE and press ENTER
9 Press F4, YES.
10

operator panel.
operator panel.
MARMMTRBL02303E
REPLACING COMPONENTS
91
This chapter describes replacement of the following items:

Batteries
Relays
Printed Circuit Boards (PCB)
Modules
Process I/O Boards
Modular I/O Components
Transformers
Servo Amplifiers
Operator Panel
Fan Motors
Replacing the Discharge Resistor (DCR) and Dynamic Brake Resistor
(DRB) unit
Replacing the Regenerative Discharge unit
Replacing the Optional Warning Light
Replacing Serial Pulse coders
NOTE To replace output drivers on the process I/O boards, refer to

Chapter 10.
9. REPLACING COMPONENTS
MARMMTRBL02303E
92
9.1
FANUC Robotics recommends that all batteries be changed immediately

prior to production start up. Change the batteries annually to assure
reliable robot performance. Use Procedure 91 to replace the battery:
Use Procedure 92 to replace the SPC battery.
REPLACING THE
BATTERY
Procedure 91
Step
Replacing the Battery

1 Get the new battery. (number: A98L-0031-0007)
2 Power down and lock out the controller.
CAUTION
The battery must be replaced within 30 minutes. If the power is
turned off and the battery is removed for 30 minutes or more,
the contents of the memory on the main CPU printed circuit
board may be lost.
WARNING
Do not short circuit or incinerate a discarded battery.
Follow your companys procedures for disposing of lithium
batteries.
WARNING
3 Remove the battery case from the front panel of the power supply unit.
The case can be removed easily by squeezing the top and bottom of it
and pulling.
Figure 101. Replacing the Battery (1)
BATTERY
Cable connector
Front panel of the

power supply unit
Battery
(ordering drawing
number:
A98L-0031-0007)
Battery case
Front panel of the

power supply unit
PC board
connector
4 Remove the connector from the battery.
Battery
93
MARMMTRBL02303E
5 Replace the battery and reconnect the connector.

6 Install the battery case.
Procedure 92
Step
Replacing the SPC Batteries

1 Get four new alkaline Dcell batteries.
2 Turn on the controller.
3 Press the operator panel Emergency Stop button and the teach pendant
Emergency Stop button.
4 Turn on the teach pendant and take it with you into the workcell.
5 Remove the black plastic battery cover on the base of the robot.
6 Remove the old batteries.
7 Insert the new batteries. The new batteries must be arranged as
follows:
Upper left positive end out.
Upper right negative end out.
Lower left negative end out.
Lower right positive end out.
8 Replace the battery cover.
9 Cold start the controller. The teach pendant might display a
SRVO065 BLAL alarm. This is normal. It will reset when you cold
start the controller.
MARMMTRBL02303E
94
9.2
A relay may fail after it is used for a long time. The relay or its circuit
board must be replaced. Relays RL1-RL6 on the EMG board are
replaceable.
REPLACING A RELAY
Figure 102. Replacing a Relay
DS2
F1
DS1
F2
RL16
FUSE
RL1 RL2
RL4
RL3
LED M1
LED M2
RL4 TIMER
6
8
CNPG
5
7
TM1
TM2
CRX
95
MARMMTRBL02303E
Figure 103. Replacing a Relay
Relay
Table 91.
Relay Part Numbers
Name
RL1
RL2
RL3
RL4
RL5, RL6
Table 92.
Part Numbers
A58L00010192#1472R
A58L00010192#1192D
Relay Part Numbers
Name
RL1, RL2
RL3, RL16
RL4
RL5, RL8, RL10,
RL15
RL5, RL6
Part Numbers
A58L00010192#1472R
A58L00010192#1509A
A58L00010192#1192D
A58L00010260#234PH24
A58L00010192#1192D
MARMMTRBL02303E
96
9.2.1
Part Number: A16B16000520
Purge Control PCB
Table 93.
PCB Relay Part Numbers
Name
RL4 Timer Relay
RL1, RL3, RL5, RL9
Part Numbers
A58L00010269#B24
A58L00010260#234PH24
MARMMTRBL02303E
9.3
REPLACING A
PRINTED CIRCUIT
BOARD
97
When replacing a printed circuit board, take the following precautions:

1. Before starting replacement, power down and lock out the controller.
2. When removing the printed circuit board, do not touch semiconductor
components on it and do not let the components touch other
components.
3. Wear a grounded wrist strap. Do not remove the new board from its
conductive bag until you are ready to install it.
4. Check that any jumpers on the printed circuit board to be installed are
correctly set.
5. When replacing the main CPU printed circuit board, all software
stored in the controller will be lost. Before starting replacement, back
up your user programs, mastering data, and system variable data onto a
floppy disk.
6. Connect the cables removed for replacement to the original positions.
If the cable markings are missing or unclear, retag them before
disconnecting them.
MARMMTRBL02303E
98
9.3.1
Use Procedure 93 to replace the backplane printed circuit board. The

backplane printed circuit board and the yellow board rack are removed and
replaced as one unit.
Replacing the
Backplane Printed
Circuit Board
Refer to Chapter 1 for part
numbers.
Procedure 93
Step
Replacing the Backplane Printed Circuit Board

1 Remove the battery from the power supply unit and plug it into the
battery connector on the front panel of the main CPU.
2 Remove all printed circuit boards from the backplane. Use
Procedure 94 .
3 Disconnect the ground wire from the backplane printed circuit board.
4 Remove the two or three mounting screws at the bottom of the rack.
5 Loosen the two or three mounting screws at the top of the rack and
remove the rack/backplane assembly.
6 Install the new rack/backplane assembly in reverse order. Be sure to
move the battery back to the power supply unit from the main CPU.
Figure 104. Replacing the Backplane Printed Circuit Board
Backplane
PC board
M5 mounting screw
99
MARMMTRBL02303E
9.3.2
Use Procedure 94 to replace a component on the backplane printed

circuit board.
Replacing a
Component on the
Backplane Printed
Circuit Board
numbers.
Procedure 94
Step
Replacing a Component on the Backplane Printed Circuit

Board
NOTE When the main CPU is replaced, all software stored in the
controller will be lost. If possible, back up your user programs, mastering
data, and system variable data on a floppy disk before starting
replacement.
1 Turn off and lock out the controller.
2 Disconnect any cables and harnesses on the component to be replaced.
3 Squeeze the latch tabs at the top and bottom of the component and pull
the component straight out.
4 Set any jumpers on the new component to match the component being
replaced.
5 Insert the new component into the proper slot of the backplane rack.
Carefully press it into the slot until the latches engage at the top and
bottom.
6 Reconnect all cables and harnesses.
Figure 105. Replacing Printed Circuit Boards on the Backplane Printed Circuit
Board
Process input/output PC board CA, CB, or DA
Main CPU board (*1)
Axis control PC board
Power supply unit (*2)
Emergency stop control PC board
MARMMTRBL02303E
910
9.4
REPLACING A
MODULE ON THE
MAIN CPU OR AXIS
CONTROL BOARD
Use the following procedure to replace a module:

1. Move the latches at both ends of the module socket toward the outside.
The spring of the contact tilts the module. See Figure 106.
Figure 106. Moving the Latches on the End of the Module Socket

numbers.
2. If the tilted module touches the next module, it might be difficult to

remove it. In this case, release the latches of the next module as
described in step 1 above.
3. Now the module is free in the socket. Pull out the module carefully in
a straight line. Do not pull it out in an arc. The contacts of the socket
or module might be damaged.
4. Install a new module in the socket at an angle. Push it into the socket
until the bottom of the module reaches the bottom of the socket
groove. Be sure you have the module facing in the proper direction.
align the groove in the module with the tab as shown in Figure 107.
Figure 107. Installing a New Module at an Angle
Short
Long
Fit the recess on
the module over
the tab in the
module socket.
911
MARMMTRBL02303E
5. Push the module in the top edge so that the module stands upright.
See Figure 108.
Figure 108. Pushing in the Module
6. Check that the module is latched properly at both ends of the socket.
If it is insufficiently latched, the electrical contact might be improper
and a malfunction could occur.
MARMMTRBL02303E
912
Figure 109 shows the mounting locations of the modules.

Figure 109. Mounting Locations of the Modules
FLASH
Flash ROM module
Optional SCC module
SLC2 module
M321 module
SCC module
Main CPU PC board

Axis control PC board
913
MARMMTRBL02303E
9.5
REPLACING THE
PROCESS
INPUT/OUTPUT
PRINTED CIRCUIT
BOARD AA, AB, BA OR
BB
Part numbers: A16B-2200-0780, A16B-2200-0782, and A16B-2201-0510

1. Remove the cable from the process input/output printed circuit board
to be replaced.
2. Remove the two screws from the left side of the process input/output
printed circuit board.
3. Remove the board by pulling outward to the left.
4. Replace the printed circuit board with a new one.

numbers.
5. Replace the two screws removed in step 2.

6. Replace the cables.
NOTE For replacing output drivers on the process I/O boards refer to
Chapter 10.
Figure 1010. Replacing the Process Input/Output Printed Circuit Board AA, AB,
BA, or BB
M4 screw
MARMMTRBL02303E
914
9.6
REPLACING
COMPONENTS OF THE
MODULAR
INPUT/OUTPUT UNIT
numbers.
9.6.1
Use the information in this section to replace the following components of

the modular I/O unit:

Base Unit
Modules
Servo Amplifier
Operator Panel
Fan Motor
Discharge Resistor (DCR) and Dynamic Brake Resistor (DBR) Unit
Regenerative Discharge Unit
Optional Warning Light
Serial Pulse Coder
Use Procedure 95 to replace the base unit.
Replacing the Base

Unit
Ordering code:
A03B-0807-J002
Procedure 95
Step
Replacing the Base Unit

1 Remove the I/O modules from the base unit.
2 Loosen the upper two mounting screws.
3 Remove the lower two mounting screws and replace the base unit.
915
MARMMTRBL02303E
Figure 1011. Replacing the Base Unit of the Modular Input/Output Unit
M4 screw
MARMMTRBL02303E
916
9.6.2
Replacing a Module
Procedure 96
Removing the Interface
Module
Replacing the Interface Module

2 Disconnect the signal and power cables from the interface module.
3 Press the latch on the bottom of the module and rotate the module
toward you and up.
Installing the Interface

Module
1 Engage the hook at the top rear of the module with the bar above the
base unit socket.
2 Rotate the module downward until the latch engages.
3 Reconnect the signal and power cables to the interface module.
Procedure 97
Removing an I/O Module
Replacing an I/O Module

2 Remove the wiring harness block. (See Figure 1013.)
a Lift the latch at the lower left corner of the module window.
b Rotate the block toward you and down.
3 Press the latch on the bottom of the module and rotate the module
toward you and up. (See Figure 1012.)
Installing an I/O Module
1 Engage the hook at the top read of the module with the bar above the
base unit socket.
2 Rotate the module downward until the latch engages.
917
MARMMTRBL02303E
Figure 1012. Removing and Replacing a Module
3 Install the wiring harness block.

a Engage the hook at the bottom rear of the block with the bar at the
bottom of the module.
b Rotate the block upward until the latch engages.
Figure 1013. Removing and Replacing a Terminal Block
MARMMTRBL02303E
918
9.7
Use Procedure 98 to replace the multi-tap transformer.
REPLACING THE
MULTI-TAP
TRANSFORMER
numbers.
Procedure 98
Condition
Step
Replacing the Multi-Tap Transformer

The controller is turned off and locked out.
1 Remove the acrylic covers from the transformer and ALC relay.
2 Disconnect the wiring harnesses and ground wire from the transformer.
3 Disconnect the three wires from the bottom of the ALC relay.
4 After removing the eight screws fastening the transformer, remove the
transformer. Put a new transformer on the rail in the controller and
push it into the controller along the rail. Then reinstall the screws.
5 Reconnect the wires and harnesses.
6 Reinstall the acrylic covers.
Figure 1014. Replacing the Multi-Tap Transformer
M5 screws
919
MARMMTRBL02303E
9.8
Use Procedure 99 to replace a servo amplifier.
REPLACING A SERVO
AMPLIFIER
numbers.
Procedure 99
Condition
Step
Replacing a Servo Amplifier

1 Remove the five bus bars from the servo amplifier bank.
2 Disconnect the wires from the servo amplifier terminal strip. Remove
the two screws fastening the servo amplifier and remove the amplifier.
3 Set the terminal strip jumpers on the new servo amplifier to match
those of the one you removed.
4 Install the new servo amplifier by following these steps in reverse
order.
Figure 1015. Replacing a Servo Amplifier
M5 screw
MARMMTRBL02303E
920
9.9
Use Procedure 910 to replace the operator panel.
REPLACING THE
OPERATOR PANEL
numbers.
Procedure 910
Condition
Step
Replacing the Operator Panel

1 Remove the cable from the operator panel.

2 Remove the six nuts fastening the operator panel and replace the
operator panel.
3 When replacing only the operator panel printed circuit board, replace it
together with the metal plate.
4 After removing the cable from the operator panel printed circuit board,
remove the four nuts fastening the metal plate. Then replace the
operators panel printed circuit board.
Figure 1016. Replacing the Operator Panel
Operator panel
(rear face)
M4 nuts
(4 pieces)
921
MARMMTRBL02303E
9.10
Use Procedure 911 to replace the fan motor.
REPLACING THE FAN

MOTOR
numbers.
Procedure 911
Condition
Step
Replacing the Fan Motor

1 Remove the printed circuit board located below the fan motor to be
replaced, following Procedure 94 .
2 The cable connected to the fan motor is connected to the backplane
printed circuit board in the slot. Holding the connector, remove the
cable from the backplane printed circuit board.
3 Open the lid at the top of the backplane rack by placing the tip of a
flatblade screwdriver into the center hole at the front of the lid and
moving the screwdriver like a lever in the direction in Figure 1017 to
release the latch.
4 Remove the fan motor.
5 Install a new fan motor. Route the cable through the hole at the back
of the rack.
6 Close the lid until it is latched.
7 Connect the cable of the fan motor to the connector on the backplane
printed circuit board. Suspend the center of the cable on the hook in
the back of the rack.
8 Reinstall the removed printed circuit board using the procedure
described in Section 9.3.2.
MARMMTRBL02303E
922
Figure 1017. Replacing the Fan Motor
(3)
(4)
Fan motor
Cable
Connector
Backplane PC board
923
MARMMTRBL02303E
9.11
REPLACING THE
DISCHARGE
RESISTOR (DCR) AND
DYNAMIC BRAKE
(DBR) UNIT
Procedure 912
Condition
Step
Use Procedure 912 to replace the discharge resistor (DCR) and dynamic
brake resistor (DBR) unit.
Replacing the Discharge Resistor (DCR) and Dynamic Brake

Resistor (DBR) unit

1 Use FANUC part number A05B-2302-C080 to replace the DCR and

DBR unit.
2 Remove the cable from the DCR and DBR unit to be replaced.
3 Remove the two screws fastening the DCR and DBR unit and replace
it.
4 Reattach the cable to the new DCR and DCR unit.
MARMMTRBL02303E
924
Figure 1018. Discharge Resistor (DCR) and Dynamic Brake Resistor (DBR) Unit
M5 SCREW (2 pieces)
925
MARMMTRBL02303E
9.12
Use Procedure 913 to replace the regenerative discharge unit.
REPLACING THE
REGENERATIVE
DISCHARGE UNIT
Procedure 913
Condition
Step
Replacing the Regenerative Discharge Unit

1 Use FANUC part number A05B-2312-C100 for the M-500, and part
number A05B-2313-C100 for the S-900, for replacement of the
regenerative discharge unit.
2 Disconnect the cable connected to the regenerative discharge unit.
3 Remove the four M5 screws fastening the discharge unit. Then
replace the unit.
Figure 1019. Replacing the Regenerative Discharge Unit
Four M5 fastening screws
MARMMTRBL02303E
926
9.13
Use Procedure 914 to replace the optional warning light.
REPLACING THE
OPTIONAL WARNING
LIGHT
Procedure 914
Condition
Step
Replacing the Optional Warning Light

1 Use FANUC part number LAMPXVAL74C024X to replace the

warning light.
2 Remove the existing light assembly from the robot and replace with
the new light assembly.
3 Reconnect the replacement light assembly.
927
MARMMTRBL02303E
9.14
Use Procedure 915 to replace a serial pulse coder.
REPLACING A SERIAL
PULSE CODER
Procedure 915
Replacing a Serial Pulse Coder
NOTE The robot will have to be remastered after this procedure.

Condition
Step
1 Remove the cables from the pulse coder. Refer to Figure 1020.
2 Remove the screws holding the pulse coder cable connector to the
pulse coder housing.
3 Retract the rubber boot on the inside of the pulse coder cable
connector.
4 Remove the snap ring on the inside of the pulse coder cable connector.
5 Detach the pulse coder cable from the pulse coder housing.
CAUTION
In the next step, be sure to remove the correct bolts, as shown
in Figure 1020. Removing the wrong bolts can destroy the
pulse coder.
6 Remove the four M4 bolts attaching the pulse coder to the motor.
7 Position the new pulse coder on the motor so that the Oldham
coupling engages. If there are witness marks on the pulse coder case
and the motor case, make sure that they line up.
8 Install the four M4 bolts.
9 Attach the pulse coder cable to the pulse coder housing.
10
Install the snap ring on the inside of the pulse coder cable connector.
11 Reposition the rubber boot on the inside of the pulse coder cable
connector.
12
Replace the screws holding the pulse coder cable connector to the
pulse coder housing.
13
Install the screws holding the pulse coder housing to the motor.
14
Attach the cables to the pulse coder housing.
MARMMTRBL02303E
928
Figure 1020. Removing the Pulse Coder
Caution: Do not remove the screws from these four ribbed holes.
The serial pulse coder will seperate and be destroyed
M4 Mounting Bolt Holes
10
BOARD ADJUSTMENTS
101
MARMMTRBL02303E
This chapter contains information about components located on some

printed circuit boards that require adjustment. These components include
jumpers and potentiometers.
10.1
AXIS CONTROL
BOARD JUMPERS
You can set jumpers on the axis control board. Figure 111 shows an
illustration of the axis control board. Table 101 lists the standard
settings for the jumpers found on the axis control board.
Figure 111. Axis Control Board Jumpers
Table 101.
Name
COM
B
JUMPER
HBK
JUMPER
Axis Control Board Jumpers

Standard setting
Description
COM
Side A
Side A: The RI lines use 0V for the

common reference
Side B:The RI lines use +24 for the
common reference
HBK
Side B
Side A: The hand breakage detect feature

is not used.
Side B: The hand breakage detect feature
is used.
10. BOARD ADJUSTMENTS

MARMMTRBL02303E
102
10.2
PROCESS I/O BOARD
The process I/O board has jumpers, potentiometers you can adjust, and
output drivers you can replace. The process I/O boards are shown in
Figures 102 through Figure 108.
Figure 112. Process I/O Board AA
Figure 113. Process I/O Board AB
103
MARMMTRBL02303E
Figure 114. Process I/O Board BA
Figure 115. Process I/O Board BB

MARMMTRBL02303E
104
Figure 116. Process I/O Board CA
Figure 117. Process I/O Board CB
105
MARMMTRBL02303E
Figure 118. Process I/O Board DA
10.2.1
Jumpers
Table 102 lists the standard settings for the jumpers located on the
process I/O board.
Table 102.
Process I/O Board Jumpers

Name
ICOM1
UDI1 to UDI20
(Connector CRM2A)
ICOM2
UDI21 to UDI40
(Connector CRM2B)
ICOM3
WI01 to WI08
(Connector CRW1)
See Note
SP1
Channel 1
SP2
Channel 2
Standard
setting
Description
The common voltage is adjusted to
Side A: 0 V common
Side B: +24 V common
Side A
NOTE: Set ICOM3 to B side to use
WDI2 as weld detect input.
Open
The polarity of the output voltage is

switched to
Strapped: Negative ()
Open: Positive (+)

MARMMTRBL02303E
106
10.2.2
Potentiometers
Table 103 lists the process I/O board potentiometers and the adjustments
you can make to them.
Table 103.
Process I/O Board Potentiometer Adjustments
Potentiometer
Description
Adjustment
Adjusts the gain of

channel 1
Execute a robot program and set AO[1] to

4095 on the teach pendant. Connect a
digital voltmeter to test pin AO1 and rotate
VR1 until the meter reads 12.0 V. Connect
the negative () lead of the digital voltmeter
to test pin 0VF.
Adjusts the gain of

channel 2
Execute a robot program and set AO[2] to

4095 on the teach pendant. Connect the
digital voltmeter to test pin AO2 and rotate
VR2 until the meter reads 12.0 V. Connect
the negative () lead of the digital voltmeter
to test pin 0VF. (The 0VF test pin is
different from the common 0V test pin.)
Adjusts the
reference supply
voltage of the
digital/analog
converter
Connect the digital voltmeter to test pin

P10V and rotate VR3 until the meter reads
10.00 0.1 V.
VR1
VR2
VR3
107
MARMMTRBL02303E
10.2.3
Table 104 lists the output drivers for each process I/O board.
Output Drivers
Table 104.
Output Drivers
DO Signal
Driver
AA
AB
BA
BB
CA
CB
DA
DV1
CMDENBL, SYSRDY, PROGRUN, PAUSED
DV2
HELD, FAULT, ATPERCH, TPENBL
DV3
BATALM, BUSY, ACK1/SNO1, ACK2/SNO2
DV4
ACK3/SNO3, ACK4/SNO4, ACK5/SNO5, ACK6/SNO6
DV5
ACK7/SNO7, ACK8/SNO8, SNACK, RESERVED
DV6
SO01, SO02, SO03, SO04
DV7
SO05, SO06, SO07, SO08
DV8
SO09, SO10, SO11, SO12
DV9
SO13, SO14, SO15, SO16
DV10
SO17, SO18, SO19, SO20
DV11
WO01, WO02,
WO03, WO04
WO01, WO02,
WO03, WO04
SO21, SO22,
SO23, SO24
DV12
WO05, WO06,
WO07, WO08
WO05, WO06,
WO07, WO08
SO25, SO26,
SO27, SO28
DV13
SO29, SO30,
SO31, SO32,
DV14
SO33, SO34,
SO35, SO36
DV15
SO37, SO38,
SO39, SO40
DV16
SO41, SO42,
SO43, SO44
DV17
SO45, SO46,
SO47, SO48
DV18
SO49, SO50,
SO51, SO52
DV19
SO53, SO54,
SO55, SO56
DV20
SO57, SO58,
SO59, SO60
DV21
SO61, SO62,
SO63, SO64
DV22
SO65, SO66,
SO67, SO68
DV23
SO69, SO70,
SO71, SO72
DV24
SO73, SO74,
SO75, SO76
RESERVED
To be used for
replacement
To be used for
replacement
To be used for
replacement

MARMMTRBL02303E
108
10.3
BUILTIN CRT/KB UNIT
This section contains information about adjusting the built-in CRT/KB

unit.
CRT Display Unit
The following can be adjusted at the CRT Display Unit:
20 CRT/KB
A05B-2051-J101

40 CRT/KB
A05B-2301-J130
Brightness (BRIGHT)
Contrast (CONT)
Focus
Horizontal size (H-SIZE)
Vertical size (V-SIZE)
Horizontal Hold (H-HOLD)
Vertical Hold(V-HOLD)
Vertical linearity (V-LIN)
CAUTION
Keep fingers and tools away from the CRT display unit when
first turning the power on. Use caution at the display unit
anytime when power is on because 10-11 KV is present.
Brightness
Turn to the brightest level possible before roster (scanning lines) appear on
the screen.
Contrast
Adjust the CONT variable resistor until display characters achieve an

easy to read brightness level. Too much contrast can distort the characters.
Focus
Adjust FOCUS variable resistor to sharpen characters.
Horizontal Size (Width)
Adjust the HSIZE coil if picture width appears too small or distorted
on the sides.
Vertical Size (Height)
Adjust the VSIZE variable resistor if the picture height appears too
small or distorted at the top.
Horizontal Hold
Adjust the HHOLD variable resistor if the picture rolls or shifts

horizontally (or diagonally).
Vertical Hold (V-HOLD)
Adjust the VHOLD variable resistor if the picture rolls vertically.
Vertical Linearity (V-LIN)
Adjust the VLIN variable resistor to obtain equal character size

vertically in the upper and lower parts of the screen.
109
MARMMTRBL02303E
The following can be adjusted at the CRT/KB Control Board:

+ 5VDC power supply
Refer to Figure 119 and adjust as follows:

+5VDC supply: Monitor the +5 VDC test point and adjust variable
resistor VR1 until + 5VDC 0.1V is obtained.
Jumper ST1
Refer to Figure 1110 for jumper setting.

Figure 119. Front View Control Board
VR1
Test point +5V
ST1
Figure 1110. Jumper Setting CRT/KB
Jumper
Standard
setting
ST1
A
SIDE A = KANA +
ALPHA NUMERIC
SIDE B = ALPHA
NUMERIC

MARMMTRBL02303E
1010
10.4
The EMG board contains a jumper which controls the sensitivity of the
brake alarm circuit. Refer to SRVO_ALARM 008.
EMG BOARD
Figure 1111.
EMG board
EMG
PCB
Table 105.
SBK Jumper Settings
Standard Setting
NAME
S-5, S-10, Arc Mate, Arc

Mate 100/S-6, Arc Mate
Sr., A-510, L-1000,
S-900, M-500
SBK1
Open
S-500, S-700, S-800,

M-400
Side 2
SBK2
SBK3
SBK4
SBK5
SBK6
SET
S-420, S-420D
Description
The sensitivity of a brake is adjusted

(for a swiveling axis).
Open
Side 2
Side 1
The sensitivity for the fuse alarm of a

brake is adjusted to :
Side 1: Special setting
Side 2: Standard setting
MARMMTRBL02303E
11
CONNECTIONS
111
This chapter describes the electrical interface connections in the R-J
controller. Figure 121 is a block diagram of electrical interface
connections with the R-J controller.
Figure 121. Block Diagram of Electrical Interface Connection
Pneumatic pressure
Purge Source
ISB
Unit
Teach Pendant (ISTP)
ABKR I/O
GEF I/O
Modular I/O
Disk Drive
*1:
*2:
A remote display is connected.

Optional RS-232-C or RS-422/485 interface.
11. CONNECTIONS
MARMMTRBL02303E
112
11.1
MECHANICAL
CONNECTIONS
Figure 122 through Figure 1212 show connection diagrams to the

mechanical units.
Figure 122. Mechanical Connection Diagram for S-420, S-500, S-700, S-800, and
M-400
*1:
*2:
This cable is not included. It must be supplied by the customer.

Can be connected when the robot is S-500 or S-700.
Figure 123. Mechanical Connection Diagram for ARC Mate, ARC Mate 100/S-6,
ARC Mate Sr., A-510, and L-1000
*1:
*2:
This cable is not included. It must be supplied by the customer.

Can be connected when the robot is ARC Mate or ARC Mate Sr.
11. CONNECTIONS
113
MARMMTRBL02303E
Figure 124. Mechanical Connection Diagram for Six-Axis Pedestal Mount System
with Battery in Controller
RJ
ROBOT
M1
SERVO AMP
TERMINAL/FRAME
AXIS 1 & 2
C1M1
SERVO AMP
TERMINAL/FRAME
AXIS 3
C1M3
SERVO AMP
TERMINAL/FRAME
AXIS 4,5, & 6
C1M2
M3
M2
AXIS CONTROL
PCB CRF1
(PULSE CODER
SIGNAL)
CRR5 EMG PCB

P & M BRAKE
SIGNALS
P1
C1P1
C1M5
D1
CONTACT SIGNAL
TRANSDUCER
(IBRC)
C1D1 (INTRINSIC)
+6V & 0V
BATT
C1B1 (INTRINSIC)
+24PG & 0V
PURGE CONTROL
PCB
C1P2
GROUND CABLE
DCDC
24V
5V
11. CONNECTIONS
MARMMTRBL02303E
114
Figure 125. Mechanical Connection Diagram for Six-Axis Pedestal Mount System
with Battery in Robot
RJ
ROBOT
M1
SERVO AMP
TERMINAL/FRAME
AXIS 1 & 2
C1M1
SERVO AMP
TERMINAL/FRAME
AXIS 3
C1M3
SERVO AMP
TERMINAL/FRAME
AXIS 4,5, & 6
C1M2
M3
AXIS CONTROL
PCB CRF1
(PULSE CODER
SIGNAL)
CRR5 EMG PCB

P & M BRAKE
SIGNALS
CONTACT SIGNAL
TRANSDUCER
(IBRC)
+24PG & 0V
PURGE CONTROL
PCB
M2
P1
C1P1
C1M5
D1
C1D1 (INTRINSIC)
C1P2
GROUND CABLE
DCDC
24V
5V
11. CONNECTIONS
115
MARMMTRBL02303E
Figure 126. Mechanical Connection Diagram for Catrac Robot Clean-Wall Rail
System with Battery in Controller
RJ
JUNCTION BOX
M1
SERVO AMP
TERMINAL/FRAME
AXIS 1 & 2
C1M1
SERVO AMP
TERMINAL/FRAME
AXIS 3 & 7
C1M3
SERVO AMP
TERMINAL/FRAME
AXIS 4,5, & 6
C1M2
AXIS CONTROL
PCB CRF1
(PULSE CODER
SIGNAL)
ROBOT
M1
C2M1
M3
M3
C2M3
M2
M2
C2M2
P1
P1
C1P1
C2P1
C1M5
C2M5
AXIS CONTROL
PCB JF7
(PULSE CODER
SIGNALAXIS7)
CRR5 EMG PCB

P & M BRAKE
SIGNALS
CONTACT SIGNAL
TRANSDUCER
(IBRC)
+6V & 0V
BATT
+24PG & 0V
PURGE CONTROL
PCB
D1
D1
C1D1 (INTRINSIC)
C2D1 (INTRINSIC)
C1B1 (INTRINSIC)
C2B1 (INTRINSIC)
P2
C1P2
GROUND CABLE
C2P2
GROUND CABLE
DCDC
24V
5V
11. CONNECTIONS
MARMMTRBL02303E
116
Figure 127. Mechanical Connection Diagram for Catrac Robot Clean-Wall Rail
System with Battery in Robot
RJ
JUNCTION BOX
M1
SERVO AMP
TERMINAL/FRAME
AXIS 1 & 2
C1M1
SERVO AMP
TERMINAL/FRAME
AXIS 3 & 7
C1M3
SERVO AMP
TERMINAL/FRAME
AXIS 4,5, & 6
C1M2
AXIS CONTROL
PCB CRF1
(PULSE CODER
SIGNAL)
ROBOT
M1
C2M1
M3
M3
C2M3
M2
M2
C2M2
P1
P1
C1P1
C2P1
C1M5
C2M5
AXIS CONTROL
PCB JF7
(PULSE CODER
SIGNALAXIS7)
CRR5 EMG PCB

P & M BRAKE
SIGNALS
CONTACT SIGNAL
TRANSDUCER
(IBRC)
+24PG & 0V
PURGE CONTROL
PCB
D1
C1D1 (INTRINSIC)
D1
C2D1 (INTRINSIC)
P2
C1P2
GROUND CABLE
C2P2
GROUND CABLE
DCDC
24V
5V
11. CONNECTIONS
117
MARMMTRBL02303E
Figure 128. Mechanical Connection Diagram for SevenAxis Universal Rail

System with Battery in Controller
RJ
ROBOT
M1
SERVO AMP
TERMINAL/FRAME
AXIS 1 & 2
C1M1
SERVO AMP
TERMINAL/FRAME
AXIS 3 & 7
C1M3
SERVO AMP
TERMINAL/FRAME
AXIS 4,5, & 6
C1M2
AXIS CONTROL
PCB CRF1
(PULSE CODER
SIGNAL)
M3
M2
P1
C1P1
AXIS CONTROL
PCB JF7
(PULSE CODER
SIGNALAXIS7)
CRR5 EMG PCB

P & M BRAKE
SIGNALS
CONTACT SIGNAL
TRANSDUCER
(IBRC)
+6V & 0V
BATT
+24PG & 0V
PURGE CONTROL
PCB
C1M5
D1
C1D1 (INTRINSIC)
C1B1 (INTRINSIC)
C1P2
GROUND CABLE
DCDC
24V
5V
11. CONNECTIONS
MARMMTRBL02303E
118
Figure 129. Mechanical Connection Diagram for Seven-Axis Universal Rail

System with Battery inRobot
RJ
ROBOT
M1
SERVO AMP
TERMINAL/FRAME
AXIS 1 & 2
C1M1
SERVO AMP
TERMINAL/FRAME
AXIS 3 & 7
C1M3
SERVO AMP
TERMINAL/FRAME
AXIS 4,5, & 6
C1M2
AXIS CONTROL
PCB CRF1
(PULSE CODER
SIGNAL)
M3
M2
P1
C1P1
AXIS CONTROL
PCB JF7
(PULSE CODER
SIGNALAXIS7)
CRR5 EMG PCB

P & M BRAKE
SIGNALS
CONTACT SIGNAL
TRANSDUCER
(IBRC)
+24PG & 0V
PURGE CONTROL
PCB
C1M5
D1
C1D1 (INTRINSIC)
C1P2
GROUND CABLE
DCDC
24V
5V
11. CONNECTIONS
119
MARMMTRBL02303E

System with Battery in Controller and Junction Box
RJ
JUNCTION BOX
M1
M1
SERVO AMP
TERMINAL/FRAME
AXIS 1 & 2
C1M1
SERVO AMP
TERMINAL/FRAME
AXIS 3 & 7
C1M3
SERVO AMP
TERMINAL/FRAME
AXIS 4,5, & 6
C1M2
AXIS CONTROL
PCB CRF1
(PULSE CODER
SIGNAL)
ROBOT
C2M1
M3
M3
C2M3
M2
M2
C2M2
P1
P1
C1P1
C2P1
C1M5
C2M5
AXIS CONTROL
PCB JF7
(PULSE CODER
SIGNALAXIS7)
CRR5 EMG PCB

P & M BRAKE
SIGNALS
D1
D1
CONTACT SIGNAL
TRANSDUCER
(IBRC)
C1D1 (INTRINSIC)
C2D1 (INTRINSIC)
+6V & 0V
BATT
C1B1 (INTRINSIC)
C2B1 (INTRINSIC)
+24PG & 0V
PURGE CONTROL
PCB
P2
C1P2
GROUND CABLE
C2P2
GROUND CABLE
DCDC
24V
5V
11. CONNECTIONS
MARMMTRBL02303E
1110

System with Battery in Robot and Junction Box
RJ
JUNCTION BOX
M1
SERVO AMP
TERMINAL/FRAME
AXIS 1 & 2
C1M1
SERVO AMP
TERMINAL/FRAME
AXIS 3 & 7
C1M3
SERVO AMP
TERMINAL/FRAME
AXIS 4,5, & 6
C1M2
AXIS CONTROL
PCB CRF1
(PULSE CODER
SIGNAL)
ROBOT
M1
C2M1
M3
M3
C2M3
M2
M2
C2M2
P1
P1
C1P1
C2P1
C1M5
C2M5
AXIS CONTROL
PCB JF7
(PULSE CODER
SIGNALAXIS7)
CRR5 EMG PCB

P & M BRAKE
SIGNALS
D1
CONTACT SIGNAL
TRANSDUCER
(IBRC)
C1D1 (INTRINSIC)
+24PG & 0V
PURGE CONTROL
PCB
C1P2
D1
C2D1 (INTRINSIC)
P2
GROUND CABLE
C2P2
GROUND CABLE
DCDC
24V
5V
11. CONNECTIONS
1111
MARMMTRBL02303E
Figure 1212. Mechanical Connection Diagram, Common Part
(*2)
(*2)
or Floppy Disk Drive
(*3)
(*3)
(*3)
Auto breaker
(*3)
(*3)
*1:
*2:
*3:
K41 is optional. K40 is not required if K41 is specified.

This cable is provided with the FANUC Handy File or the floppy disk drive.
Not included. Must be supplied by the customer.
11. CONNECTIONS
1112
11.1.1
Robot Connection
Cables
MARMMTRBL02303E
For the S-420, cables K70, K71, and K72 are connected as shown in
Figure 1215.
11. CONNECTIONS
1113
MARMMTRBL02303E
11.1.2
For the P-155, cables C1M1, C1M2, C1M3, C1M5 and C1P1 are
connected as shown in Figure 1213 through Figure 1223.
Robot Connection
Cables
AMP 1
Figure 1213. Six-Axis Pedestal
AMP 2
AXIS
AMP 3
EMG
CONTROL
CONTROL
PCB
9
20
21
22
10
11
12
23
9
20
21
22
10
11
12
23
9
20
21
22
PCB
CRF1
10
CRR5
11
12
23
C1P1
<AXIS1
<AXIS2
<AXIS3
C1M5
C1M3
C1M1
<AXIS4
<AXIS5
<AXIS6
ROBOT
M1
C1M2
C1M1
M3
C1M3
M2
C1M2
P1
C1P1
C1M5
11. CONNECTIONS
MARMMTRBL02303E
1114
Figure 1214. Seven-Axis Catrac Robot Clean-Wall Rail
AMP 1
AMP 2
9
20
21
22
10
11
12
23
AMP 3
9
20
21
22
10
11
12
23
20
21
22
AMP 4
AMP 5
10
10
11
11
12
AXIS
EMG
CONTROL
CONTROL
PCB
PCB
CRF1
JF7
CRR5
12
23
C1M5
C1P1
<AXIS1
<AXIS2
<AXIS3
<AXIS7
(EXTENDED)
C1M3
C1M1
<AXIS4
<AXIS5
<AXIS6
C1M2
JUNCTION BOX
ROBOT
M1
C1M1
M1
C2M1
M3
C1M3
M3
C2M3
M2
C1M2
M2
C2M2
P1
P1
C1P1
C2P1
C1M5
C2M5
11. CONNECTIONS
1115
MARMMTRBL02303E
Figure 1215. Connection to Servo Amplifiers and Mechanical Unit for S-420
AXIS
CONTROL
PCB
CRM1
CRF1
K71
K72
K70
For the S-420 with three dual-axis servo amplifiers, ARC Mate, S-5, ARC
Mate Sr., and S-10, cables K70 and K71 are connected as shown in
Figure 1216.
Figure 1216. Connection to Servo Amplifiers and Mechanical Unit for S-420,
S-420D, ARC Mate, S-5, ARC Mate 100/S-6, ARC Mate Sr., S-10
AXIS
CONTROL
PCB
CRM1
CRF1
S-420,
S-420D
ARC Mate
ARCMate100/
S-6,
ARC Mate Sr.
S-10
S-5
K71
K70
11. CONNECTIONS
MARMMTRBL02303E
1116
Figure 1217.
AXIS
CONTROL
PCB
CRM1
CRF1
S-500
K71
K72
K70
Figure 1218.
AXIS
CONTROL
PCB
CRM1
CRF1
S-700
K71
K72
K70
11. CONNECTIONS
1117
MARMMTRBL02303E
Figure 1219
AXIS
CONTROL
PCB
CRM1
CRF1
S-800
K71
K72
K70
For the A-510, cables K70 and K71 are connected as shown in
Figure 1220
Figure 1220. Connection to Servo Amplifiers and Mechanical Unit for A-510
AXIS
CONTROL
PCB
CRM1
Not used
CRF1
A-510
K71
K70
11. CONNECTIONS
MARMMTRBL02303E
1118
For the M-400 and M-500, cables K70, K71, and K72 are connected as
shown in Figure 1221.
Figure 1221. Connection to Servo Amplifiers and Mechanical Unit for M-400 and
M-500
AXIS
CONTROL
PCB
CRM1
CRF1
M-400
M-500
K71
K72
K70
For the L-1000, cables K70 and K71 are connected as shown in
Figure 1222.
Figure 1222. Connection to Servo Amplifiers and Mechanical Unit for L-1000
AXIS
CONTROL
PCB
CRM1
CRF1
L-1000
K71
K70
11. CONNECTIONS
1119
MARMMTRBL02303E
Figure 1223. Seven-Axis Universal Rail

AMP 1
AMP 2
9
20
21
22
10
11
12
23
AMP 3
9
20
21
22
10
11
12
23
20
21
22
AMP 4
AMP 5
10
10
11
11
12
AXIS
EMG
CONTROL
CONTROL
PCB
PCB
CRF1
JF7
CRR5
12
23
C1M5
C1P1
<AXIS1
<AXIS2
<AXIS3
<AXIS7
(EXTENDED)
C1M3
C1M1
<AXIS4
<AXIS5
<AXIS6
C1M2
JUNCTION BOX
ROBOT
M1
C1M1
M1
C2M1
M3
C1M3
M3
C2M3
M2
C1M2
M2
C2M2
P1
P1
C1P1
C2P1
C1M5
C2M5
11. CONNECTIONS
MARMMTRBL02303E
1120
11.1.3
Use the following guidelines when connecting the input power supply:
Connecting the Input

Power Supply
Adjust the input transformer taps depending on the plant input voltage
before supplying power to the robot. Refer to Section 1.9 for the
correct tap setting information.
Consider the robot power capacity and the circuit breaker capacity.
Use the correct gauge wire to withstand the maximum current used.
Connect the power supply to the terminals located above the circuit
breaker or on the top of the disconnect.
Use a ground of class 3 or better.
Be sure to ground the work table or fixture used by an arc welding

robot so that it can handle the large current.
The motor is driven by the PWM inverter system using the power
transistor bridge. If the servo amplifier is used without a transformer, a
high-frequency leakage current flows through the stray capacitance
between the ground and the motor coils, power cable, and amplifier. This
might cause the leakage-current circuit breaker or leakage-protection relay
installed in the path of the power supply to cut out.
If connecting power directly to the servo amplifiers, use the leakage
current circuit breaker listed in Table 111 to prevent incorrect operation.
Table 111.
Example of Leakage Current Circuit Breaker for Inverters
Manufacture
Fuji Electric Co
Co., Ltd
Ltd.
Hitachi Ltd.
Hitachi,
Ltd
Matsushita Electric Works,
Works Ltd.
Ltd
Type
EG A series
SG A series
ES100C type
ES225C type
Leakage current circuit breaker, C type
Leakage current circuit breaker, KC type
Figure 1224 shows the cable connection for a circuit

breaker.Figure 1225 shows the cable connection for a fused flange
disconnect.
Figure 1225 shows the cable connection for a fused flange disconnect.
11. CONNECTIONS
1121
MARMMTRBL02303E
Figure 1224. Input Power Supply Connection, Circuit Breaker
Figure 1225. Input Power Supply Connection, Fused Flange Disconnect
K01
Main
Disconnect
FL1 FL2 FL3
Fuse Block
11. CONNECTIONS
MARMMTRBL02303E
1122
11.1.4
Connecting the
External Power Supply
ON/OFF Switch
The external power on/off signal turns on and off the power supply from
outside of the control unit, and is connected as shown in Figure 1227.
Figure 1226. External Power Supply ON/OFF Switch Connection

19
24
20
EXON
48
33 34
62
31 32
EXOFF
49
25
External power supply ON/OFF switch
Use a contact conforming to the following: Voltage rating: 50 VDC, current: 100 mA or more.
The power supply on/off timing chart is as follows:
11. CONNECTIONS
1123
MARMMTRBL02303E
Figure 1227. External Power Supply ON/OFF Switch Connection

EMG
PCB
Power on
Power off
External power supply ON/OFF switch

Use a contact conforming to the following: Voltage rating: 50 VDC, current: 100 mA or more.
The power supply on/off timing chart is as follows:
11. CONNECTIONS
MARMMTRBL02303E
1124
Figure 1228. External Emergency Stop Output Connection
19
EMG OUT1
24
EMG OUT C
External Emergency
Stop Connection
The external emergency stop connection is shown in Figure 1229 and

Figure 1231 and described in Table 112 and Table 113.
EMG OUT 2
27 28
11.1.5
EMG B1
20
1
62
48
49
25
Emergency Stop
Control PCB
EMGB2
11. CONNECTIONS
1125
MARMMTRBL02303E
Figure 1229. External Emergency Stop Output Connection
EMG
PCB
CRR3
CRR4
Emergency stop
control board
Table 112.
Signal
External Emergency Stop Output Signals

Description
Current,
Voltage
Emergency stop output signals

EMGOUT1
The contact is open if an emergency stop

occurs or the power is turned off.
EMGOUTC
The contact is closed during normal

operation.
EMGOUT2
Emergency stop output signals.
Rated contact:
250 VAC, 5
5-A
A
resistor load
The contact is open during normal operation.

EMGOUTC
EMGB1
The contact is closed if an emergency stop

occurs or the power is turned off.
Emergency stop output signals of the teach
pendant
The contact is open if the emergency stop
button on the teach pendant is pressed.
EMGB2
The contact is closed during normal

operation.
Rated contact:
24 VDC, 0.1-A
resistor load
11. CONNECTIONS
MARMMTRBL02303E
1126
Figure 1230. External Emergency Stop Input Connection
19
45 46
*E1N1
43 44
24
*E1NC
20
62
48
49
*E1NC
External EStops
*E1N2
35 36
*FENCE 1
25
*FENCE 2
* Jumper across switches when not in use.
11. CONNECTIONS
1127
MARMMTRBL02303E
Figure 1231. External Emergency Stop Input Connection
External Emergency stop switch

Connected at
shipment
(Note)
Connect to IMSTP
on the UOP
Printed circuit board
for emergency control
Door switch on safety fence

Connected at
shipment
Note: Connect to EMGIN1 or EMGIN2.
To connect to the external emergency stop input, connect a double-pole

emergency stop switch to both the Emergency Stop printed circuit board
and the peripheral device interface.
Use a contact rated at 250 V, 10 A or more on the Emergency Stop printed
circuit board.
Table 113.
Signal
EMGIN1
EMGINC
EMGIN
EMGIN2
EMGINC
External Emergency Stop Input Signals

Description
Connect one of the external emergency stop
switch circuits to the terminals.
100 VAC, 5 A,
If the external emergency stop switch is
open/close
pressed, the 100 VAC power for the motor is
cut directly. To affect EMGOUT1 or EMGOUT2,
connect to EMGIN1 and EMGINC. To not
affect EMGOUT1 or EMGOUT2, connect to
EMGIN2 and EMGINC.
If these signals are not used, short all external
emergency stop terminals together.
These signals are used to stop the robot when
the door on the safety fence is open.
FENCE1
FENCE2
Current,
Voltage
While the DEADMAN switch on the teach

pendant is pressed and the teach pendant
enable switch is ON, these signals are ignored
and an emergency stop does not occur.
24 VDC, 0.1 A,
open/close
If these signals are not used, short these

terminals.
M3 screws are provided on the terminal. Use crimp terminals 7 mm wide

or less.
11. CONNECTIONS
MARMMTRBL02303E
1128
11.2
PERIPHERAL DEVICE
AND END EFFECTOR
INTERFACES
11.3
PERIPHERAL DEVICE,
ARC WELDING, AND
END EFFECTOR
INTERFACES
No.
Name
The R-J I/O peripheral device interfaces include process I/O printed circuit
boards and/or a modular I/O unit selected according to the applications.
Table 114 lists the printed circuit boards and unit. Figure 1234 shows
the locations.
The R-J I/O peripheral device interfaces include process I/O printed circuit
boards and/or a modular I/O unit selected according to the applications.
Table 114 lists the printed circuit boards and unit. Figure 1232 and
Figure 1233 show their locations.
Table 114.
Peripheral Device Interface Types

Number of I/O
Points
Part Number
Remarks
DI
DO
D/A
A/D
Process I/O printed circuit board AA
A16B-2200-0780
40
40
Standard (with welding interface)
Process I/O printed circuit board AB
A16B-2200-0782
40
40
Standard (without welding interface)
Process I/O printed circuit board BA
A16B-2201-0510
(weld interface)
A20B-2000-0540
32
32
Source type DO (with welding

interface)
Process I/O printed circuit board BB
A16B-2201-0510
32
32
Process I/O printed circuit board CA
A16B-2201-0470
40
40
Process I/O printed circuit board CB
A16B-2201-0472
40
40
Process I/O printed circuit board DA
A16B-2201-0480
96
96
I/O unit model
A03B-0807-C002
Depending on a
selected I/O module
Source type DO (without welding

interface)
Backplane installation type (with
welding interface)
welding interface)
welding interface)
Up to 5 slots
A03B-0807-C001
Up to 10 slots
11. CONNECTIONS
1129
MARMMTRBL02303E
Figure 1232. Locations of Peripheral Device Interfaces, B-Size Controller
Main CPU printed circuit board

Printed circuit board for
emergency stop control

CA/CB/DA
Modular I/O unit or
AA/AB/BA/BB or I/O unit model A
11. CONNECTIONS
MARMMTRBL02303E
1130
Figure 1233. Locations of Peripheral Devices, C-Size Controller
Operator panel
Extended
Back plane
Modular I/O rack or

Process I/O rack
Power disconnect
Main CPU
Servo Amplifiers #1
Fuses FL13
Servo Amplifiers #2
Axis control board
Servo Amplifiers #3
Power supply unit
Emergency stop
control board
Servo Amplifiers #4 and #5

Servo Amplifiers #6
User transformer
11. CONNECTIONS
1131
MARMMTRBL02303E
Figure 1234. Locations of Peripheral Devices, C-Size Controller
Operator panel
Servo Amplifiers
STAHL
ISBs
Extended
Back plane
STBI Term Strip

Purge 24V DC
Power Supply
Power disconnect
Main CPU
Fuses FL13
Transit Board
Axis control board

Power supply unit
Emergency stop
control board
BDX
ISB Unit
ALC
relay
User transformer
11. CONNECTIONS
MARMMTRBL02303E
1132
11.3.1
Peripheral Device
Interface Combination
Process I/O printed circuit board AA, AB, BA, BB, CA, CB, and DA and
an I/O unit can be combined. Figure 1235 shows the combinations.
Figure 1235. Peripheral Device Interface Combination

1 Board
2-Board Combination
3-Board Combination
11. CONNECTIONS
1133
MARMMTRBL02303E
11.3.2
Process I/O Printed
Circuit Board AA or AB
Figure 1236. Process I/O Printed Circuit Board AA or AB
(Additional analog
signal input)
CRW1 and CRW2 are not provided for process I/O printed circuit board BB.
Table 115.
Cable
Number
K10
K50A
K50B
Name
Process I/O Printed Circuit Board AA or AB
Drawing Number
Process I/O connection cable
A05B2300J013
A05B2302J110
Peripheral device connection cable
A05B2302J11
A05B2302J112
K45
Welder connection cable
K46
A05B2302J270
A05B2302J271
A05B2302J272
Remarks
R-J control unit internal cable
Connected length: 7 m
Honda Tsushin, 50 pins: one-to-one
Cannot be used for TIG welding
Not included. Must be supplied by customer.
11. CONNECTIONS
MARMMTRBL02303E
1134
11.3.3
Process I/O Printed
Circuit Board BA or BB
Figure 1237. Process I/O Printed Circuit Board BA or BB
(Additional analog
signal input)
Table 116.
Cable
Number
K10
K52
K53
Process I/O Printed Circuit Board BA or BB
Name
Drawing Number

A05B2300J013
A05B2302J270
A05B2302J271
A05B2302J272
K45
K46
Remarks
11. CONNECTIONS
1135
MARMMTRBL02303E
11.3.4
Process I/O Printed
Circuit Board CA or CB
Figure 1238. Process I/O Printed Circuit Board CA or CB
(Additional analog
signal input)
Table 117.
Cable
Number
K10
K11
K50A,
K50B
K50C
K50D
Process I/O Printed Circuit Board CA or CB
Name
Drawing Number

A05B2300J013
A05B2300J014
A05B2302J113
A05B2302J114
A05B2302J115
K45
K46
A05B2302J273
A05B2302J274
A05B2302J275
Remarks
R-J control unit internal cable (for connecting
additional printed circuit boards)
11. CONNECTIONS
MARMMTRBL02303E
1136
11.3.5
Up to two boards can be installed in one cabinet.
Process I/O Printed

Circuit Board DA
Figure 1239. Process I/O Printed Circuit Board DA
Table 118.
Cable
Number
K10
K11
Process I/O Printed Circuit Board DA
Name
Drawing Number

A05B2300J013
A05B2300J014
A05B2302J113
K50
A-H
A05B2302J114
A05B2302J115
A05B2302J120
K51
A-D
A05B2302J121
A05B2302J122
Remarks
11. CONNECTIONS
1137
MARMMTRBL02303E
11.3.6
Process I/O Printed
Circuit Board with the
Modular I/O Unit
Figure 1240. Process I/O Printed Circuit Board with Modular I/O
Table 119.
Cable
Number
K15
Name
Process I/O Printed Circuit Board DA
Drawing Number
I/O unit connection cable
K16
I/O unit power connection cable
K54
Remarks
R-J control unit internal cable. Attached to the I/O
unit mainframe.
unit mainframe.
11. CONNECTIONS
MARMMTRBL02303E
1138
11.3.7
Two or More Process
I/O Boards with the
Modular I/O Unit
Figure 1241 shows the connection when two or more process I/O printed
circuit boards and the modular I/O unit are used. Up to two process I/O
CA/CB/DAs and 1 process I/O AA/AB/BA/BB or I/O unit model A can
be installed in one cabinet.
Figure 1241. Two or More Process I/O Boards and the I/O Unit (Model A)
Table 1110.
Cable
Number
K10
K11
Two or More Process I/O Boards and the I/O Unit (Model A)
Name
Drawing Number

A05B2300J013
A05B2300J014
K12
A05B-2300-J017
K15
I/O unit connection cable
K16
I/O unit power connection cable
Remarks
R-J control unit internal cable for connecting
additional printed circuit boards.
unit mainframe.
unit mainframe.
11. CONNECTIONS
1139
MARMMTRBL02303E
11.3.8
Peripheral Device and
Control Unit
Connection
There are 18 exclusive data inputs (DI) and 20 exclusive data outputs (DO)
for a process I/O printed circuit board. These signals are allocated to the
process IO printed circuit board connected first when two or more printed
boards are combined. General signals SI/SO are allocated to the second
and the following process I/O printed circuit boards.
The common voltage of the DI signals input to pins 1 to 4 of connector
CRM2A is clamped +24V (common) in each process I/O printed circuit
board. This is also true when multiple boards are combined.
Table 1111 shows signals of a process I/O printed circuit board
Table 1111.
Process I/O Printed Circuit Board Signals, DI Signals
Connector Number
Signal Name
CRM2A-1
*IMSTP
Immediate stop
Clamped at +24V common
CRM2A-2
*HOLD
Temporary stop
CRM2A-3
*SFSD
Safe speed
CRM2A-4
CSTOPI
Cycle stop
CRM2A-5
FAULT RESET
CMR2A-6
START
Start
CRM2A-7
HOME
Return to home position
CRM2A-8
ENBL
Operation enabled
CRM2A-9
RSR1
Robot service request
PNS1
Program number selection
CRM2A-10
RSR2
PNS2
CRM2A-11
RSR3
PNS3
CRM2A-12
RSR4
PNS4
RSR5
PNS5
RSR6
PNS6
CRM2A-15
RSR7
PNS7
CRM2A-16
RSR8
PNS8
CRM2A-29
PNSTROBE
CMR2A-30
PROD START
CRM2A-13
CRM2A-14
Description
Remarks
External reset
PNS strobe
Start of automatic operation
Option
Option
Option
Option
Option
Option
Option
Option
11. CONNECTIONS
MARMMTRBL02303E
1140
Table 1111. (Contd) Process I/O Printed Circuit Board Signals, DI Signals
Connector Number
Signal Name
CRM2A-31
SI01
CRM2A-32
SI02
CRM2B-1
SI03
CRM2B-2
SI04
CRM2B-3
SI05
CRM2B-4
SI06
CRM2B-5
SI07
CRM2B-6
SI08
CRM2B-7
SI09
CRM2B-8
SI10
CRM2B-9
SI11
CRM2B-10
SI12
CRM2B-11
SI13
CRM2B-12
SI14
CRM2B-13
SI15
CRM2B-14
SI16
CRM2B-15
SI17
CRM2B-16
SI18
CRM2B-29
SI19
CRM2B-30
SI20
CRM2B-31
SI21
CRM2B-32
SI22
Connector Number
Signal Name
CRM2A-33
CMDENBL
CRM2A-34
SYSRDY
CRM2A-35
PROGRUN
CRM2A-36
PAUSED
Description
Peripheral device status
Table 1112.
Description
Preparation completed
During regeneration
Program being interrupted
HELD
During temporary stop
FAULT
Alarm
CRM2A-40
ATPERCH
CRM2A-41
TPENBL
Teach pendant enabled
CRM2A-43
BATALM
Battery voltage drop
CRM2A-44
BUSY
During operation
CRM2A-19
Remarks
During automatic operation
CRM2A-39
CRM2A-46
General signal
Process I/O Printed Circuit Board Signals, DO Signals
CRM2A-38
CRM2A-45
Remarks
Home position
ACK1
Robot service request acceptance
SNO1
Selected program number
ACK2
SNO2
ACK3
SNO3
Option
Option
Option
11. CONNECTIONS
1141
MARMMTRBL02303E
Table 1112. (Contd) Process I/O Printed Circuit Board Signals, DO Signals
Connector Number
Signal Name
CRM2A-20
ACK4
SNO4
ACK5
SNO5
ACK6
SNO6
CRM2A-21
CRM2A-22
CRM2A-24
CRM2A-25
Description
Remarks
Option
Option
Option
ACK7
SNO7
ACK8
SNO8
Option
Peripheral device control signal
General signal
CRM2A-26
SNACK
CRM2A-27
RESERVED
CRM2B-33
SO01
CRM2B-34
SO02
CRM2B-35
SO03
CRM2B-36
SO04
CRM2B-38
SO05
CRM2B-39
SO06
CRM2B-40
SO07
CRM2B-41
SO08
CRM2B-43
SO09
CRM2B-44
SO10
CRM2B-45
SO11
CRM2B-46
SO12
CRM2B-19
SO13
CRM2B-20
SO14
CRM2B-21
SO15
CRM2B-22
SO16
CRM2B-24
SO17
CRM2B-25
SO18
CRM2B-26
SO19
CRM2B-27
SO20
Option
11. CONNECTIONS
MARMMTRBL02303E
1142
Figure 1242. Peripheral Device and Control Unit Connection -A1/A2
Note 1: The peripheral device connection cables

are optional.
Note 2: All of COM** are connected 0 V.
Table 1113.
Type
AA
AB
BA
BB
CA
CB
DA
Applicable Process I/O Printed Circuit Board - A1/A2

Specifications
A05B-2300-J001
A05B-2300-J002
A05B-2300-J020
A05B-2300-J021
A05B-2300-J030
A05B-2300-J031
A05B-2300-J035
= applicable = not applicable
CRM2A

CRM2B

11. CONNECTIONS
1143
MARMMTRBL02303E
Figure 1243. Peripheral Device and Control Unit Connection -A3/A4
Note 1: The peripheral device connection cables

are optional.
Table 1114.
Applicable Process I/O Printed Circuit Board - A3/A4
Type
AA
AB
BA
BB
CA
CB
DA
= applicable
= not applicable
Specifications
A05B-2300-J001
A05B-2300-J002
A05B-2300-J020
A05B-2300-J021
A05B-2300-J030
A05B-2300-J031
A05B-2300-J035
CRM2C

CRM2D

11. CONNECTIONS
MARMMTRBL02303E
1144
Figure 1244. Peripheral Device and Control Unit Connection - B1/B2
Note 1: The peripheral device connection

cables are optional.
Table 1115.
Applicable Process I/O Printed Circuit Board - B1/B2
Type
AA
AB
BA
BB
CA
CB
DA
= applicable
= not applicable
Specifications
A05B-2300-J001
A05B-2300-J002
A05B-2300-J020
A05B-2300-J021
A05B-2300-J030
A05B-2300-J031
A05B-2300-J035
CRM4A

CRM4B

11. CONNECTIONS
1145
MARMMTRBL02303E
Figure 1245. Peripheral Device and Control Unit Connection -C1
Note 1: The peripheral device connection cable is not

supplied by FANUC. It must be supplied by the
customer.
Table 1116.
Applicable Process I/O Printed Circuit Board - C1
Type
AA
AB
BA
BB
CA
CB
DA
= applicable
= not applicable
Specifications
A05B-2300-J001
A05B-2300-J002
A05B-2300-J020
A05B-2300-J021
A05B-2300-J030
A05B-2300-J031
A05B-2300-J035
TBI1

TB01

11. CONNECTIONS
MARMMTRBL02303E
1146
Figure 1246. Peripheral Device Interface Control for A1, A2, A3, and A4
Control Unit
A4
A1
Connector pin No.

+24E CRM2A(49,50)
A3
A2
SI43
SI23
SI03
*IMSTP
RV
SI44
SI24
SI04
*HOLD
RV
SI45
SI25
SI05
*SFSPD
RV
SI46
SI26
SI06
*CSTOPI
RV
SI47
SI27
SI07
FAULT RESET
RV
SI48
SI28
SI08
START
RV
SI49
SI29
SI09
HOME
RV
SI50
SI30
SI10
ENBL
RV
SI51
SI31
SI11
RSR1/PNS1
RV
SI52
SI32
SI12
RSR2/PNS2
RV
SI53
SI33
SI13
RSR3/PNS3
RV
SI54
SI34
SI14
RSR4/PNS4
RV
SI55
SI35
SI15
RSR5/PNS5
RV
SI56
SI36
SI16
RSR6/PNS6
RV
SI57
SI37
SI17
RSR7/PNS7
RV
SI58
SI38
SI18
RSR8/PNS8
RV
SI59
SI39
SI19
PNSTROBE
RV
SI60
SI40
SI20
PROD START
RV
SI61
SI41
SI21
SI01
RV
SI62
SI42
SI22
SI02
RV
Note: For A1, CRM2x = CRM2A and ICOMn = ICOM1

For A2, CRM2x = CRM2B and ICOMn = ICOM2
For A3, CRM2x = CRM2C and ICOMn = ICOM3
For A4, CRM2x = CRM2D and ICOMn = ICOM4
CRM2x (1)
CRM2x (2)
CRM2x (3)
CRM2x (4)
CRM2x (5)
CRM2x (6)
CRM2x (7)
CRM2x (8)
CRM2x (9)
CRM2x (10)
CRM2x (11)
CRM2x (12)
CRM2x (13)
CRM2x (14)
CRM2x (15)
CRM2x (16)
CRM2x (29)
CRM2x (30)
CRM2x (31)
CRM2x (32)
+24E
B
Common switching
set pin (ICOMn)
Peripheral device
11. CONNECTIONS
1147
MARMMTRBL02303E
Figure 1247. Peripheral Device Interface for A1, A2, A3, and A4
Control Unit
Connector Pin No.
A4
A3
A2
SO41
SO21
SO01
CMDENBL
SO42
SO22
SO02
SYSRDY
SO43
SO44
SO45
SO46
SO47
SO23
SO24
SO25
SO26
SO27
SO03
SO04
SO05
SO06
SO07
A1
PROGRUN
PAUSED
HELD
FAULT
ATPERCH
Peripheral Device
LOAD
DV
CRM2x(33)
RELAY
DV
DV
DV
DV
DV
DV
SO48
SO28
SO08
TPENBL
DV
SO49
SO29
SO09
BATALM
DV
SO50
SO30
SO10
BUSY
DV
SO51
SO31
SO11
ACK1/SNO1
DV
SO52
SO32
SO12
ACK2/SNO2
DV
SO53
SO33
SO13
ACK3/SNO3
DV
SO54
SO34
SO14
ACK4/SNO4
DV
SO55
SO35
SO15
ACK5/SNO5
DV
SO56
SO36
SO16
ACK6/SNO6
DV
SO57
SO37
SO17
ACK7/SNO7
DV
SO58
SO38
SO18
ACK8/SNO8
DV
SO59
SO39
SO19
SNACK
DV
SO60
SO40
SO20
RESERVED
DV
CRM2x(34)
CRM2x(35)
CRM2x(36)
CRM2x(38)
CRM2x(39)
CRM2x(40)
CRM2x(41)
CRM2x(43)
CRM2x(44)
CRM2x(45)
CRM2x(46)
CRM2x(19)
CRM2x(20)
CRM2x(21)
CRM2x(22)
CRM2x(24)
CRM2x(25)
CRM2x(26)
CRM2x(27)
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
CRM2x(23,28,37,42,47)
Note: For A1, CRM2x = CRM2A

For A2, CRM2x = CRM2B
For A3, CRM2x = CRM2C
For A4, CRM2x = CRM2D
0V
+24V
+24V regulated
power supply
11. CONNECTIONS
MARMMTRBL02303E
1148
Figure 1248. Peripheral Device Control Interface B1
Connector pin No.

+24E CRM4A(49,50)
SI63
RV
SI64
RV
SI65
RV
SI66
RV
SI67
RV
SI68
RV
SI69
RV
SI70
RV
Peripheral device
CRM4A(1)
CRM4A(2)
CRM4A(3)
CRM4A(4)
CRM4A(5)
CRM4A(6)
CRM4A(7)
CRM4A(13)
+24V B
Common Switching
Set Pin
(Icom5)
Connector Pin No.
LOAD
DV
CRM4A(14)
SO61
SO62
SO63
SO64
SO65
SO66
SO67
SO68
DV
DV
DV
DV
DV
DV
DV
CRM4A(15)
CRM4A(16)
CRM4A(17)
CRM4A(8)
CRM4A(9)
CRM4A(10)
CRM4A(11)
RELAY
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
CRM4A(20)
0V
+24V
+24V regulated
power supply
11. CONNECTIONS
1149
MARMMTRBL02303E
Figure 1249. Peripheral Device Control Interface B2
Connector pin No.

+24E CRM4B(49,50)
SI71
RV
SI72
RV
SI73
RV
SI74
RV
SI75
RV
SI76
RV
SI77
RV
SI78
RV
Peripheral device
CRM4B(1)
CRM4B(2)
CRM4B(3)
CRM4B(4)
CRM4B(5)
CRM4B(6)
CRM4B(7)
CRM4B(13)
+24V B
Common Switching
Set Pin
(Icom5)
Connector Pin No.
LOAD
DV
CRM4B(14)
SO69
SO70
DV
SO71
DV
SO72
DV
SO73
DV
SO74
DV
SO75
DV
SO76
DV
CRM4B(15)
CRM4B(16)
CRM4B(17)
CRM4B(8)
CRM4B(9)
CRM4B(10)
CRM4B(11)
RELAY
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
LOAD
CRM4B(20)
0V
+24V
+24V regulated
power supply
11. CONNECTIONS
MARMMTRBL02303E
1150
Figure 1250. Peripheral Device Control Interface C1
Peripheral device
Receiver Circuit
*IMSTP
RV
*HOLD
RV
*SFSPD
RV
CSTOPI
RV
FAULT RESET
RV
START
RV
HOME
ENBL
TBI(1)
TBI(2)
TBI(3)
TBI(4)
TBI(5)
TBI(6)
TBI(7)
RV
TBI(8)
RV
COM1
TBI(9)
COM
(+24V or 0V)
0V TBI(10)
0V
+24V
+24V regulated
power supply
Receiver Circuit
RSR1/PNS1
RV
RSR2/PNS2
RV
RSR3/PNS3
RV
RSR4/PNS4
RV
RSR5/PNS5
RV
RSR6/PNS6
RV
RSR7/PNS7
RV
RSR8/PNS8
RV
TBI(11)
TBI(12)
TBI(13)
TBI(14)
TBI(15)
TBI(16)
TBI(17)
TBI(18)
COM2
TBI(19)
0V TBI(20)
COM
(+24V or 0V)
11. CONNECTIONS
1151
MARMMTRBL02303E
Peripheral device
Receiver Circuit
PNSTROBE
RV
PROD START
RV
SI01
RV
SI02
RV
SI03
RV
SI04
RV
SI05
RV
SI06
RV
TBI(21)
TBI(22)
TBI(23)
TBI(24)
TBI(25)
TBI(26)
TBI(27)
TBI(28)
COM1
TBI(29)
COM
(+24V or 0V)
0V TBI(30)
Receiver Circuit
SI07
RV
SI08
RV
SI09
RV
SI10
RV
SI11
RV
SI12
RV
SI13
RV
SI14
RV
TBI(31)
TBI(32)
TBI(33)
TBI(34)
TBI(35)
TBI(36)
TBI(37)
TBI(38)
COM1
TBI(39)
0V TBI(40)
COM
(+24V or 0V)
11. CONNECTIONS
MARMMTRBL02303E
1152
Control unit
(peripheral device control interface C1)
Peripheral device
+ 24 V regulated
power supply
Internal
circuit
+ 24 V regulated
power supply
Internal
circuit
11. CONNECTIONS
1153
MARMMTRBL02303E
Control unit
Peripheral device
+ 24 V regulated
power supply
Internal
circuit
+ 24 V regulated
power supply
Internal
circuit
11. CONNECTIONS
MARMMTRBL02303E
1154
Control unit
Peripheral device
+ 24 V regulated
power supply
Internal
circuit
+ 24 V regulated
power supply
Internal
circuit
11. CONNECTIONS
1155
MARMMTRBL02303E
Control unit
Peripheral device
+ 24 V regulated
power supply
Internal
circuit
+ 24 V regulated
power supply
Internal
circuit
11. CONNECTIONS
MARMMTRBL02303E
1156
11.3.9
Mechanical Unit and
End Effector
Connection
Figure 1256. Mechanical Unit and End Effector
Mechanical unit
Refer to Figure 11-42 to 1145 for pin

configuration for your specific robot.
+24V B
End Effector
A
Common switching
set pin
11. CONNECTIONS
1157
MARMMTRBL02303E
Figure 1257. End Effector Pin Configuration Arc Mate/S-5, Arc Mate Sr/S-10,
S-420, S-500, S-700, S-800, S-900, M-400 and M-500
End Effector
Figure 1258. End Effector Pin Configuration Arc Mate 100/S-6
End Effector
OR
RDO1
*HBK
0V
RDI1
+24E
11. CONNECTIONS
MARMMTRBL02303E
1158
Figure 1259. End Effector Pin Configuration A-510
End Effector
Figure 1260. End Effector Pin Configuration L-1000
End Effector
11. CONNECTIONS
1159
MARMMTRBL02303E
11.3.10
Control Unit and
Welder Connection
Figure 1261. Control Unit and Welder Connection - CRW1/CRW2
Note: The welder and peripheral device

connection cable are optional.
Table 1117.
Applicable Process I/O Printed Circuit Board
Type
AA
AB
BA
BB
CA
CB
DA
= applicable
= not applicable
Specifications
A05B-2300-J001
A05B-2300-J002
A05B-2300-J020
A05B-2300-J021
A05B-2300-J030
A05B-2300-J031
A05B-2300-J035
CRW1

CRW2

11. CONNECTIONS
1160
MARMMTRBL02303E
Figure 1262. Control Unit and Welder Connection - CRW1 Analog Signal
Assignment
11. CONNECTIONS
1161
MARMMTRBL02303E
Figure 1263. Control Unit and Welder Connection - CRW1 Digital Signal
Assignment
11. CONNECTIONS
1162
MARMMTRBL02303E
Figure 1264. Control Unit and Welder Connection - CRW2 Analog Signal
Assignment
11. CONNECTIONS
1163
MARMMTRBL02303E
11.3.11
Table 1118 contains the specifications of the peripheral device interface.
Peripheral Device
Interface
Table 1118.
Example of Connection
Type
Output signals
in peripheral
device interface
A and B
Peripheral Device Interface Specifications

Signal Standards
Electrical Specifications
Rated voltage:
Maximum applied voltage:
Maximum load current:
Transistor type:
Saturation voltage at connection:
24 VDC
30 VDC
0.2 A
Open collector NPN
1.0 V (approx.)
Spark Killer Diode

Rated peak reverse voltage:
Rated effective forward current:
100 V or more
1 A or more
Note on Use
Do not use the +24V power supply of the robot.
When loading a relay, solenoid, and so on directly,
connect them in parallel with diodes for preventing
back electromotive force. If a load is connected
causing a surge current when a lamp is turned on,
use a protective resistance.
Applicable Signals
Output signals of process I/O printed circuit board CRM2
and CRM4; CMDENBL, SYSRDY, PROGRUN, PAUSED,
HELD, FAULT, ATPERCH, TPENBL, BATALM, BUSY,
ACK1 to ACK8, SNO1 to SNO8, SNACK, SO1 to SO20
Input signals in
peripheral
device interface
A and B
Electrical Specifications of the Receiver

Type:
Grounded voltage receiver
Rated input voltage: Contact closed: +20V to +28V
Contact open: 0V to +4V
Maximum applied
input voltage:
+28 VDC
Input impedance:
3.3 k (approx.)
Response time:
5 ms to 20 ms
Peripheral
device
contact
signal
Robot
receiver
signal
TB: Chattering 5 ms or less

TC: 5 to 20 ms
Specifications of the Peripheral Decive Contact

Rated contact capacity: 30 VDC, 50 mA or more
Input signal width:
200 ms or more (on/off)
Chattering time:
5 ms or less
Closed circuit resistance: 100 or less
Opened circuit resistance: 100 k or more
Note on Use
Apply the +24V power at the robot to the receiver.
However, the above signal specifications must be
satisfied at the robot receiver.
Applicable Signals
Input signals of process I/O printed circuit board CRM2
and CRM4; *IMSTP, *HOLD, *SFSD, CSTOPI, FAULT
RESET, START, HOME, ENBL, RSR1 to RSR8, PNS1 to
PNS8, PNSTROBE, PROD STASRT, SI1 to SI22
11. CONNECTIONS
MARMMTRBL02303E
1164
Table 1118. (Contd) Peripheral Device Interface Specifications

Type
Output signals
in peripheral
device interface
C
Signal Standards
Rated voltage:
24 VDC
30 VDC
1.6 A (*1)
*1: This value is the maximum load current at one point.
When four points on the same common are turned on at
the same time, the maximum load current at one common
is 5.0 A.
Spark Killer Diode
100 V or more
1 A or more
Note on Use
Do not use the +24 V power supply of the robot. When
loading a relay, solenoid, and so on directly, connect them
in parallel with diodes for preventing back electromotive
force. If a load is connected causing a surge current
when a lamp is turned on, use a protective resistance.
Applicable Signals
Output signals of process I/O printed circuit board BA/BB
TBO1; CMDENBL, SYSRDY, PROGRUN, PAUSED,
HELD, FAULT, ATPERCH, TPENBL, BATALM, BUSY,
ACK1 to ACK8, SNO1 to SNO8, SNACK, SO1 to SO12.
Input signals in
peripheral
device interface
C

Type:
Contact open:
0V to +4V
Maximum applied
input voltage:
+28 VDC
Input impedance:
3.3 k (approx.)
Response time:
5 ms to 20 ms
Specifications of the Peripheral Device Contact
Input signal width:
Chattering time:
5 ms or less
Note on Use
Applicable Signals
Input signals of process I/O printed circuit board BA/BB
TBI1; *IMSTP, *HOLD, *SFSD, CSTOPI, FAULT RESET,
START, HOME, ENBL, RSR1 to RSR8, PNS1 to PNS8,
PNSTROBE, PROD STASRT, SI1 to SI24
Peripheral
device
contact
signal
Robot
receiver
signal
TC: 5 to 20 ms
11. CONNECTIONS
1165
MARMMTRBL02303E
11.3.12
End Effector Control
Interface
Table 1119 contains the specifications of the end effector control

interface.
Table 1119.
End Effector Control Interface Signals
Type
Output signals
Signal Standards
Rated voltage:
Transistor type:
24 VDC
30 VDC
0.2 A
Open collector NPN
1.0 V (approx.)
Spark Killer Diode

100 V or more
1 A or more
Note on Use
The +24 V power supply at the robot can be used when
the total current of the welding interface and end effector
interface is 0.7 A or less. When loading a relay, solenoid,
and so on directly, connect them in parallel with diodes for
preventing back electromotive force. If a load is
connected causing a surge current when a lamp is turned
on, use a protective resistance.
Applicable Signals
Output signals of the end effector control interface
RO1 to RO8
Input signal

Type:
Contact open:
0V to +4V
Maximum applied
input voltage:
+28 VDC
Input impedance:
3.3 k (approx.)
Response time:
5 ms to 20 ms
Input signal width:
Chattering time:
5 ms or less
Peripheral
device
contact
signal
Note on Use
Robot
receiver
signal
Applicable Signals
Input signals of the end effector control interface
RI1 toRI 8, *HBK, *PPABN
TC: 5 to 20 ms
11. CONNECTIONS
MARMMTRBL02303E
1166
11.3.13
Table 1120 contains the specifications of the arc welding interface.
Arc Welding Interface

Process I/O AA
Table 1120.
Arc Welding Interface Signals
Type
Digital output
signals
Signal Standards
Rated voltage:
Transistor type:
24 VDC
30 VDC
0.2 A
Open collector NPN
1.0 V (approx.)
Spark Killer Diode

100 V or more
1 A or more
Note on Use
The +24 V power supply at the robot can be used when
the total current of the welding interface and end effector
interface is 0.7 A or less. When loading a relay, solenoid,
and so on directly, connect them in parallel with diodes for
preventing back electromotive force. If a load is
connected causing a surge current when a lamp is turned
on, use a protective resistance.
Applicable Signals
Output signals of the end effector control interface
WO1 to WO8
Digital input
signals

Type:
Contact open:
0V to +4V
Maximum applied
input voltage:
+28 VDC
Input impedance:
3.3 k (approx.)
Response time:
5 ms to 20 ms
Input signal width:
Chattering time:
5 ms or less
Note on Use
Peripheral
device
contact
signal
Applicable Signals
Input signals of the arc welding interface
WI1 to WI8
Robot
receiver
signal
TC: 5 to 20 ms
11. CONNECTIONS
1167
MARMMTRBL02303E
Table 1120. (Contd) Arc Welding Interface Signals

Type
Analog output
signals: welding
voltage
command, wire
feed speed
command
Analog input
signals: welding
voltage
detection,
welding current
detection
Analog input
signal: wire
stick detect
WDI+, WDI
Signal Standards
Note on Use
Input impedance: 3.3 k or more
Install a high-frequency filter.
Note on Use
Output signals without ripples.
Note on Use
The resistance between the positive and negative
terminals on the welder must be 100 or more. The
maximum voltage of this circuit is 80 V. For TIG welding,
connected the wirestick detection signal line, insulating it
from a welding circuit (high frequency).
11. CONNECTIONS
MARMMTRBL02303E
1168
11.3.14
This section describes the connections and specifications for modular I/O
units.
Modular I/O Inputs
Table 1121.
Input Modules AID32A and AID32B, Nonisolated
AID32A
Item
AID32B
Points/module
32 points
32 points
Points/common
16 points/common
16 points/common
Sink/source current
Both directions
Both directions
Input voltage
24VDC +10% 20%
24 VDC +10% 20%
Input current
7.5mA (average)
7.5mA (average)
ON voltage current
Min. 18VDC min. 6 mA
Min. 18 VDC min. 6 mA
OFF voltage current
Max. 6VDC max. 1.5 mA
Respo
OFF ON
nse
Time
Max. 20
ms
ON OFF
Max. 20
ms
This is the value from input to output

in the module. The actual value is
determined by adding it to the
scanning time depending on each
system.
Max. 2 ms
Max. 2 ms
This is the value from input to output

in the module. The actual value is
determined by adding it to the
scanning time depending on each
system.
Input display
Not provided
Not provided
External connection
Connector (HONDA TSUSIN MR-50RMA)
Terminal
connection and
circuitry
: input circuit CM
Internal
Circuit
CMA
A0
A1
A2
A3
A4
A5
A6
A7
B0
B1
B2
B3
B4
B5
B6
B7
29,45
49,50
16
32
48
15
31
47
30
46
12
28
44
11
27
43
10
42
13,17 +24V
14,18 GND
CMC
C0
C1
C2
C3
C4
C5
C6
D7
D0
D1
D2
D3
D4
D5
D6
D7
21,36
40,41
07
24
39
06
23
38
22
37
03
20
35
02
19
34
01
33
04,08 +24V
05,09 GND
+24V or GND can be selected for input common as above figure.

Note: Make sure to connect all common (CMA, CMC) pins.
11. CONNECTIONS
1169
MARMMTRBL02303E
Table 1122.
Input Modules AID16C and AID16D
AID16C
Item
AID16D
Points/module
16 points
16 points
Points/common
16 points/common
16 points/common
Sink/source current
Source current type
Sink current type
Input voltage
24VDC +10% 20%
24 VDC +10% 20%
Input current
7.5 mA (average)
7.5 mA (average)
ON voltage current
Min. 15VDC min. 4 mA
Min. 15 VDC min. 4 mA
OFF voltage current
Response
Time
OFF ON
Max. 20ms
ON OFF
Max. 20ms
This is the value from input to

output in the module. The
actual value is determined by
adding it to the scanning time
depending on each system.
Max. 20ms
Max. 20ms

Input display
LED display
LED display
External connection
Terminal block connector (20 terminals, M3.5

screw terminal)

screw terminal)
Terminal connection and

circuitry
(C)
(D)
A0
A1
A2
A3
A4
A5
A6
A7
B0
B1
B2
B3
B4
B5
B6
B7
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
FOR AID16C
: input circuit
1
LED
FOR AID16D
: input circuit
LED
1
11. CONNECTIONS
MARMMTRBL02303E
1170
Table 1123.
Input Modules AID32E and AID32F
AID32E
Item
AID32F
Points/module
32 points
32 points
Points/common
8 points/common
8 points/common
Sink/source current
Both directions
Both directions
Input voltage
24VDC +10% 20%
24 VDC +10% 20%
Input current
7.5 mA (average)
7.5mA (average)
ON voltage current
Min. 15VDC min. 4.5 mA
Min. 15VDC min. 4.5 mA
OFF voltage current
Max. 6VDC max. 2 mA
Max. 6VDC max. 2 mA
Response
Time
OFF ON
Max. 20
ms
ON OFF
Max. 20
ms

Max. 2 ms
Max. 2 ms

Input display
Not provided
Not provided
External connection

circuitry
: input circuit CM
CMA
A0
A1
A2
A3
A4
A5
A6
A7
49,50
16
32
48
15
31
47
30
46
CMC
C0
C1
C2
C3
C4
C5
C6
C7
40,41
07
24
39
06
23
38
22
37
CMB
B0
B1
B2
B3
B4
B5
B6
B7
29,45
12
28
44
11
27
43
10
42
CMD
D0
D1
D2
D3
D4
D5
D6
D7
21,36
03
20
35
02
19
34
01
33
11. CONNECTIONS
1171
MARMMTRBL02303E
Table 1124.
Input Module AIA16G

AIA16G
Item
Points/module
16 points
Points/common
16 points/common
Rated load voltage
100 ~ 155VAC 15%
Max. input voltage
132Vrms 50/60Hz
Input current
10.5mArms (120VAC 50Hz)
ON voltage current
74Vrms min. 6mArms
OFF voltage current
20Vrms max. 2.2mArms
Response
Time
OFF ON
Max. 35 ms
ON OFF
Max. 35 ms

Input display
LED display
External connection

screw terminal)
Common
16 points/common

circuitry
A0
A1
A2
A3
A4
A5
A6
A7
B0
B1
B2
B3
B4
B5
B6
B7
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
NC
NC
19
20
: input circuit
LED
19
11. CONNECTIONS
MARMMTRBL02303E
1172
11.3.15
Modular I/O Outputs
Table 1125.
Output Module AOD32A, Non-isolated
Item
AOD32A
Points/module
32 points
Points/common
8 points/common
Sink/source current
Sink current type
Rated load voltage
5 ~ 24VDC +20% 15%
Maximum load current
0.3A (however 2A/common)
Maximum voltage
drop when ON
0.24V (load current 0.8)
Maximum leak current

when OFF
0.1 mA
Response
Time
OFF ON
Max. 1 ms
ON OFF
Max. 1 ms
Output display
Not provided
External connection
Terminal connection
and circuitry
O : output circuit +5~+24
Internal
Circuit
L : load
CM
L
L
L
L
L
L
L
L
+24A
A0
A1
A2
A3
A4
A5
A6
A7
CMA
17
16
32
48
15
31
47
30
46
49,50
O
O
O
O
O
O
O
O
L
L
L
L
L
L
L
L
+24B
B0
B1
B2
B3
B4
B5
B6
B7
CMB
13
12
28
44
11
27
43
10
42
29,45
O
O
O
O
O
O
O
O
L
L
L
L
L
L
L
L
+24C
C0
C1
C2
C3
C4
C5
D6
D7
CMC
08
07
24
39
06
23
38
22
37
40,41
O
O
O
O
O
O
O
O
L
L
L
L
L
L
L
L
+24D
D0
D1
D2
D3
D4
D5
D6
D7
CMD
04
03
20
35
02
19
34
01
33
21,36
O
O
O
O
O
O
O
O
11. CONNECTIONS
1173
MARMMTRBL02303E
Table 1126.
Output Modules AOD08C and AOD08D
AOD08C
Item
AOD08D
Points/module
8 points
8 points
Points/common
8 points/common
8 points/common
Sink/source current
Sink current type
Source current type
Rated load voltage
12 ~ 24VDC +20% 15%
12 ~ 24VDC +20% 15%
2A (however 4A/fuse)
2A (however 4A/fuse)
Limit of load
Refer to load derating curve
Maximum voltage drop

when ON

when OFF
0.1mA
0.1mA
Response
Time
OFF ON
Max. 2 ms
ON OFF
Max. 2 ms

Max. 2 ms
Max. 2 ms

Output display
LED display
LED display
External connection
Terminal block connector (20 terminal, M3.5

screw terminal)

screw terminal)
Fuse
5A, 1 piece for each output A0-A3 and A4-A7
5A, 1 piece for each output A0-A3 and A4-A7
Terminal connection
and circuitry
Fuses
1
load
L
load
3
A0
3
A0
5
L
A1
A1
A2
A2
A3
11
L
A4
12
A5
A4
14
A6
A5
16
A7
10
12
14
16
15
O
A6
17
L
13
15
L
11
13
L
9
10
A3
4
5
7
L
Fuses
1
2
17
18
19
A7
18
19
20
20
Fuses
O : output circuit
O : output circuit
2
Internal
Circuit
20
Internal
Circuit
LED
20
LED
11. CONNECTIONS
MARMMTRBL02303E
1174
Table 1127.
Output Modules AOD16C and AOD16D
AOD16C
Item
AOD16D
Points/module
16 points
16 points
Points/common
8 points/common
8 points/common
Sink/source current
Sink current type
Source current type
Rated load voltage
12 ~ 24VDC +20% 15%
12 ~ 24VDC +20% 15%

when ON

when OFF
0.1mA
0.1mA
Response
Time
OFF ON
Max. 2 ms
ON OFF
Max. 2 ms

Max. 2 ms
Max. 2 ms

Output display
LED display
LED display
External connection

screw terminal)

screw terminal)

circuitry
: load
: load
A0
L
L
A1
A2
A3
A4
A5
A6
A7
1
2
3
4
5
6
8
O
O
O
O
O
O
O
O
A0
L
L
L
A1
A2
A3
L
L
L
L
A4
7
A7
L
+
12
14
15
L
L
L
B5
B6
B7
17
O
O
O
O
10
16
18
19
O
O
O
L
L
L
L
L
L
L
L
O
O
O
O
O
B0
B1
B2
12
13
14
B3
B4
15
B5
B6
B7
17
20
O
O
O
16
O
O
O
18
O
O
19
20
O : output circuit
O : output circuit
1
Internal
Circuit
10
O
O
11
13
B3
B4
B0
B1
B2
10
O
O
A5
A6
11
L
2
3
Internal
Circuit
LED
10
LED
11. CONNECTIONS
1175
MARMMTRBL02303E
Table 1128.
Output Module AOD32C

AOD32C
Item
Points/module
32 points
Points/common
8 points/common
Sink/source current
Sink current type
Rated load voltage
12 ~ 24VDC +20% 15%

when ON

when OFF
0.1mA
Response
Time
OFF ON
Max. 2 ms
ON OFF
Max. 2 ms
This is the value from input to output in the module. The actual value is
determined by adding it to the scanning time depending on each system
system.
Output display
Not provided
External connection

circuitry
O : output circuit
+24
Internal
Circuit
CM
: load
+24A
L
L
L
L
L
L
L
L
L
L
L
L
L
L
L
L
A0
A1
A2
A3
A4
A5
A6
A7
CMA
+24B
B0
B1
B2
B3
B4
B5
B6
B7
CMB
17
16
32
48
15
31
47
30
46
49,50
13
12
28
44
11
27
43
10
42
29,45
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
L
L
L
L
L
L
L
L
+24C
C0
C1
C2
C3
C4
C5
C6
C7
CMC
08
07
24
39
06
23
38
22
L
L
L
L
L
L
L
L
+24D
D0
D1
D2
D3
D4
D5
D6
D7
CMD
04
03
20
35
02
19
34
01
37
40,41
33
21,36
Note: For the common (CMA, CMB CMC, CMD) make sure to use both of them.
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
11. CONNECTIONS
MARMMTRBL02303E
1176
Table 1129.
Output Module AOD32D

AOD32D
Item
Points/module
32 points
Points/common
8 points/common
Sink/source current
Source current type
Rated load voltage
12 ~ 24VDC +20% 15%

when ON

when OFF
0.1mA
Response
Time
OFF ON
Max. 2 ms
ON OFF
Max. 2 ms
This is the value from input to output in the module. The actual value is
determined by adding it to the scanning time depending on each system.
Output display
Not provided
External connection

circuitry
O : output circuit
Internal
Circuit
: load
CMA
CM
L
L
L
L
L
L
L
L
L
L
L
L
L
L
L
L
A0
A1
A2
A3
A4
A5
A6
A7
0A
CMB
B0
B1
B2
B3
B4
B5
B6
B7
0B
49,50
16
32
48
15
31
47
30
46
1B
29,45
12
28
44
11
27
43
10
42
14
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
L
L
L
L
L
L
L
L
CMC
C0
C1
C2
C3
C4
C5
C6
C7
0C
40,41
07
24
39
06
23
38
22
L
L
L
L
L
L
L
L
CMD
D0
D1
D2
D3
D4
D5
D6
D7
0D
21,36
03
20
35
02
19
34
01
37
09
33
05
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
Note: For the common (CMA, CMB CMC, CMD) make sure to use both of them.
11. CONNECTIONS
1177
MARMMTRBL02303E
Table 1130.
Output Modules AOA05E and AOA08E
AOA05E
Item
AOA08E
Points/module
5 points
8 points
Points/common
1 point/common
4 points/common
Rated load voltage
100 ~ 230VAC 15%, 47 ~ 63Hz
100 ~ 230VAC 15%, 47 ~ 63Hz
2A (however 5A/module)
1A (however 2A/common)
Maximum in rush current
25A (1 period)
10A (1 period)
Limit of load

when ON
1.5Vrms
1.5Vrms

when OFF
3.0mA (115VAC), 6.0mA (230VAC)
3.0mA (115VAC), 6.0mA (230VAC)
Response
Time
OFF ON
Max. 1 ms
ON OFF
Half of the
load
frequency
or less

output in the module
module. The

output in the module
module. The
Max. 1 ms
Half of the
load
frequency
or less
Output display
LED display
LED display
External connection

screw terminal)

screw terminal)
Fuse
3.2A, 1 piece for each output A0 ~ A4
3.2A, 1 piece for each output A0 ~ A3 and

A4~ A7

circuitry
1
L
2
O
3
L
A0
A0
A1
5
L
6
A1
A2
O
L
A3
A4
A5
16
18
A6
A7
16
20
18
19
Fuse
20
load
17
19
:
o
u
tp
u
t
c
i
rc
u
i
t
14
15
17
12
13
14
A4
O
Fuse
11
12
15
10
O
13
A3
10
11
A2
7
L
2
3
load
O
: output circuit
LED
LED
10 20
11. CONNECTIONS
MARMMTRBL02303E
1178
Table 1131.
Output Module AOA12F
Item
AOA12F
Points/module
12 points
Points/common
6 points/common
Rated load voltage
100 ~ 115VDC 15% 47 ~ 63Hz
0.5A/point (however 2A/common)
Maximum in rush current
5A (1 period)
Limit of load

when ON
1.5Vrms

when OFF
1.5mA (115 VAC)
Response
Time
OFF ON
Max. 1 ms
ON OFF
Half of the load frequency or less

Output display
LED display
External connection
Terminal block connector (20 terminal, M3.5 screw terminal)
Fuse
3.2A, 1 piece for each output A0 ~ A5 and

B0 ~ B5

circuitry
: load
1
A0
L
L
L
A1
A2
A3
A4
A5
O
2
O
O
O
6
7
8
9
O
O
O
Fuse
10
L
L
L
L
L
L
B0
B1
B2
B3
B4
11
12
O
O
14
O
O
13
15
B5
16
17
18
O
O
O
19
20
Fuse
O : output circuit
LED
9 19
NOTE:
Each output signal group (A0A5 and
B0B5) contains six output signals.
However, each group must have an entire
group of eight signals assigned to it.
For example, A0A5 might be occupied
by digital outputs 1 through 6 and B0B5
might be occupied by digital outputs
9 through 14. Digital outputs 7 and 8 and
digital outputs 15 and 16 are unusuable.
11. CONNECTIONS
1179
MARMMTRBL02303E
Table 1132.
Item
Output Modules AOR08G and AOR16G

AOR08G
AOR16G
Points/module
8 points
8 points
Points/common
1 point/common
4 points/common
Maximum load
30VDC/250VAC, 4A (resistance load)
30VDC/250VAC, 2A (resistance load)
Minimum load
5VDC, 10mA
1A (however 2A/common)
Maximum current
4A/common
Limit of load
Response Time
OFF ON
Max. 15ms
ON OFF
Max. 15ms
This is the value

from input to output in the module.
The actual value is
determined by
adding it to the
scanning time
depending on
each system.
This is the value

from input to output in the module.
The actual value is
determined by
adding it to the
scanning time
depending on
each system.
Max. 15ms
Max. 15ms
Output display
LED display
LED display
External connection
Terminal block connector (20 terminals,

M3.5 screw terminal)
Terminal block connector (20 terminals,

M3.5 screw terminal)
Relay life
Mechanical
Min. 20,000,000 times
Min. 20,000,000 times
Electrical
Min. 100,000 times (resistance load)
Min. 100,000 times (resistance load)

circuitry
1
v
L
A0
A1
A2
A3
v
v
A0
A1
A2
A3
L
L
L
L
L
L
L
A4
A5
A6
A7
8
10
A4
13
A5
15
A6
17
14
A7
19
20
v : Direct current power or alternating

current power
BO
12
B1
B2
B3
13
B4
17
B5
B6
B7
19
14
15
16
L
L
L
L
18
L
10
16
11
L
L
L
L
12
L
4
5
6
11
v
1
L
18
20
: Direct current power or alternating

current power
11. CONNECTIONS
MARMMTRBL02303E
1180
Table 1133.
Output Module ADA02A

ADA02A
Item
Number of output
channels
2 channels/module
Digital input
12-bit binary (2s complement representation)
Analog output
10VDC ~ +10VDC (external load resistance: 10K or more) selectable

0mADC ~ + 20mADC (external load resistance: 400 or less) usable
Input/output
correspondence
Digital Input
Analog Output
+2000
+1000
0
1000
2000
+10V
+5V or +20mA
0V or 0mA
5V
10V
Resolution
5mV or 20 A
Comprehensive accuracy
Voltage output 0.5% (for the full scale)

Current output 1% (for the full scale)
Converting time
1ms or less. NOTE: The converting time is the one only inside the module. The actual
response time is added a scan time that is determined by the system.
Isolation
Photocopier isolation (between output signal and base). However, non-isolation between
output channels.
External connection
At removable terminal block (20 terminals, M3.5 screw terminals)
Number of occupied
output points
82
ADA02A
V0+
Channel 0
D/A
converter
Voltage output
Load
10K ohms or more
Voltage V0
4
amp.
Current
amp.
10+
8
10
10
V1+
Channel 1
D/A
converter
12
Voltage V1
14
amp.
Current 16
amp. 10+
Current output
18
10
20
(Note 1) Use a 2core twisted shielded cable as the connection cable.

(Note 2) Ground the cable shield on the load side
Load
400 ohms or less
11. CONNECTIONS
1181
MARMMTRBL02303E
Table 1134.
Analog Input Module AAD04A

AAD04A
Item
Number of input channels
4 channels/module
Analog input
10VDC to +10VDC (input resistance 4.7M)

20mADC to +20mADC (input resistance: 250 selectable
Digital output
12-bit binary (complementary representation of 2)
Input/output
correspondence
Analog Input
Digital Output
+10V
+5V or +20mA
0V or 0mA
5V or 20mA
10V
+2000
+1000
0
1000
2000
Resolution
5mV or 20 A
Total precision
Voltage input 0.5% (for the full scale)

Current input 1% (for the full scale)
Conversionary time
Maximum 2ms. NOTE: Actual response speed is determined by adding the scanning time
depending on each system to this conversion time.
Maximum input
voltage/current
15V 30mA
Insulation
Photocopier insulation (between output signal and base). However, non-insulation between
output channels.
External connection
At removable terminal block (20 terminals, M3.5 screw terminals)
Number of occupied
output points
82
10+
1
2
11+
Voltage input
V0+
3
V1+
Voltage
supply
V0
5
V1
6
COM0
COM1
8
7
FG0
MULTI
PROCESSOR
9
FG1 10
12+ 11
Current input
250
13+
12
V2+
13
Current
supply
V2
15
V3+
14
16
V3
COM2
17
COM3
18
FG2
19
FG3
20
(Note 1) Though the example above shows the connection of channels 0 and 2, it is just the
same with the channel 1 (I1+, V1+, V1, COM1 and FG1) and the channel 3 (I3+, V3+,
V3, COM3 and FG3).
(Note 2) Either voltage input or current input can be specified for each channel. When current input is specified,
make sure to shortcircuit in + and Vn+.
(Note 3) Use shielded cables of twisted pair for connecting.
11. CONNECTIONS
MARMMTRBL02303E
1182
11.4
SPECIFICATIONS OF
THE CABLES USED
FOR PERIPHERAL
DEVICES AND
WELDERS
11.4.1
Peripheral Device
Interface A Cable
If you manufacture cables, conform to the FANUC standard cables

described in this section. Refer to the description in Peripheral Device
Interface in this manual for the specifications of the FANUC standard
cables.
Figure 1265 shows the peripheral device interface A cable, CRM2:

Honda Tsushin, 50 pins.
Figure 1265. Peripheral Device Interface A Cable
HONDA TSUSHIN
HONDA TSUSHIN
HONDA TSUSHIN
HONDA TSUSHINS
SUPPLIED WITH AN ORDERED CABLE
11.4.2
Peripheral Device
Interface B Cable
Figure 1266 shows the peripheral device interface B cable, CRM4:

Honda Tsushin, 20 pins.
Figure 1266. Peripheral Device Interface B Cable
HONDA TSUSHIN
HONDA TSUSHIN
PERIPHERAL
DEVICE
HONDA TSUSHIN
HONDA TSUSHINS
SUPPLIED WITH AN ORDERED CABLE
11. CONNECTIONS
1183
MARMMTRBL02303E
11.4.3
Connection Cable
Figure 1267 shows the arc welder connection cable, CRW1: Honda
Tsushin, 34 pins.
Figure 1267. Arc Welder Connection Cable
PERIPHERAL
DEVICE
HONDA TSUSHIN
JAPAN AVIATION ELECTRONICS

INDUSTRY, LTD.
JAPAN AVIATION
ELECTRONICS
INDUSTRY, LTD.
STANDARD POSITION
OF GUIDE KEY
HONDA TSUSHIN
Use a welder connection cable conforming to the FANUC specifications.
11. CONNECTIONS
MARMMTRBL02303E
1184
11.5
CABLE CONNECTION
FOR THE PERIPHERAL
DEVICES, END
EFFECTORS, AND ARC
WELDERS
11.5.1
Peripheral Device
Connection Cable
Figure 1268. Peripheral Device Cable Connection
Process I/O printed

circuit board CA/
CB/DA
Process I/O printed
circuit board AA/
AB/BA/BB or I/O
unit model A
Partly cut off the peripheral device

connection cable to expose the
shield jacket, and fasten the jacket
to the shield plate with a clamp to
Shield jacket protect against noise.
Clamp fixture
Shield plate
11. CONNECTIONS
1185
MARMMTRBL02303E
11.5.2
Connection Cable
Figure 1269 shows the connection of the arc welder cable in the control
unit.
Figure 1269. Arc Welder Cable Connection
Process I/O printed

circuit board CA/
CB/DA
Process I/O printed
circuit board AA/
AB/BA/BB
Partly cut off the peripheral device

connection cable to expose the
shield jacket, and fasten the jacket
to the shield plate with a clamp to
protect against noise.
Clamp fixture
Shield jacket
Shield plate
11. CONNECTIONS
MARMMTRBL02303E
1186
11.5.3
Peripheral Device
Cable Connector
Figure 1270, Figure 1271, and Figure 1272 show the connector for
peripheral device cables A, B, and C.
Figure 1270. Peripheral Device Cable Connector for A and B(Honda Tsushin
Kogyo)
Table 1135.
Peripheral Device Cable Connector for A and B
CRM2
A
67.9
Dimensions
(B)
C
73.5 44.8
(D)
18
CRM4
39.3
44.9
17
Connector
Specifications
Applicable
Interface
MR50LMH
MR20LMH
Table 1136.
Symbol

39.8
Remark
Honda Tsushin
Kogyo, 50 pins
Honda Tsushin
Kogyo, 20 pins
Symbols Used in Figure 1270

Name
Connector cover
Cable clamp screw
Connector clamp spring
Connector clamp screw
Connector
50 pins (male)
MR50MH
20 pints (male)
MR20MH
11. CONNECTIONS
1187
MARMMTRBL02303E
Figure 1271. Peripheral Device Connector for A and B
Table 1137.
Peripheral Device Cable Connector for A and B
Connector
Specifications
Applicable
Interface
MR50RFH
MR20RFH
CRM2
CRM4
Table 1138.
Symbol

Dimensions
Remark
A
B
61.4 56.4 Honda Tsushin Kogyo, 50 pins
39.3 44.9 Honda Tsushin Kogyo, 20 pins
Symbols Used in Figure 1271

Name
Connector clamp screw
Screw 2.6 x 8
Connector
(MR50RFH)
(MR20RFH)
11. CONNECTIONS
MARMMTRBL02303E
1188
Figure 1272. Peripheral Device Interface Cable C Connector (Phoenix Contact)
Insert the plug vertically toward the

conductor. Insert the cable in the side
of the plug plate key groove.
Table 1139. Peripheral Device Interface Cable C Connector

Specifications
Number of
Terminals
6
10
Specifications
MVSTBR 2.5/6-ST-5.08
MVSTBR 2.5/10-ST-5.08
Table 1140.
Twisted wires
Solid wire
Wire Jacket
A mm
25.40
45.72
Connection Data
Applicable
Wire Size
AWG12
Rated
Current
12A
Rated
Voltage
AC250V
AWG12
12A
AC250V
Wire End Processing
11. CONNECTIONS
MARMMTRBL02303E
1189
11.5.4
End Effector Cable
Connector
Figure 1273. Elbow Type Connector S-5, S-10, S-420, S-500, S-700, S-800,
M-400, M-500, ARC Mate, ARC Mate 100/S-6, ARC Mate Sr.
11. CONNECTIONS
MARMMTRBL02303E
1190
Figure 1274. Connector L-1000
A:
B:
C:
D:
M22x1
48.82
30.5
3.0 to 9.0 (Inside diameter)
G:
Manufactured by Daiichi Denshi Kogyo JMCR1610
16.6
11. CONNECTIONS
1191
MARMMTRBL02303E
11.5.5
Recommended Cables
Peripheral Device
Connection Cable
Connect a peripheral device using a completely shielded, heavily protected

cable conforming to the specifications in Table 1141. Allow an extra
1.5m for routing the cable in the control unit. The maximum cable length
is 30 m.
Table 1141.
Number
of Wires
Wire
Specifications
(FANUC
Specifications)
Recommended Cable for Peripheral Device Connection
Conductor
Diameter
(mm)
Configuration
Sheath
Thickness
(mm)
Effective
O tside
Outside
Diameter
(mm)
Electrical Characteristics
Conductor
Resistance
(/km)
Allowable
Current (A)
50
A66L-0001-0042
1.05
7/0.18 AWG24
1.5
12.5
106
1.6
20
A66L-0001-0041
1.05
7/0.18 AWG24
1.5
10.5
106
1.6
End Effector Connection

Cable
Connect an end effector using a heavily protected cable with a movable

wire conforming to the specifications in Table 1142. The cable length is
determined so that the cable will not interfere with the end effector and the
wrist can move through its full stroke.
Table 1142.
Number
of Wires
Wire
Specifications
(FANUC
Specifications)
Recommended Cable for End Effector Connection
Conductor
Diameter
(mm)
Configuration
40/0.08
AWG24
40/0.08
AWG24
A66L-0001-0143
1.1
20
A66L-0001-0144
1.1
Sheath
Thickness
(mm)
Effective
O tside
Outside
Diameter
(mm)
1.0
1.0
Electrical Characteristics
Conductor
Resistance
(/km)
Allowable
Current (A)
5.3
91
3.7
8.6
91
2.3
12
COMPLETE WIRING DIAGRAMS

121
MARMMTRBL02303E
Complete wiring for the controller and the robot mechanical unit is shown
in Figure 131 through Figure 1332. The diagrams are valid for all
FANUC Robotics robot models (except where specific robot models are
indicated).
This chapter is useful for verifying the cable connections to all
components within the controller and robot.
12. COMPLETE WIRING DIAGRAMS

MARMMTRBL02303E
122
K022
K.23
CP2
K020
K021
&5
AMP6
K071
K072
Figure 131. Internal Connection Diagram S-420, S-800

MARMMTRBL02303E
123
Figure 132. Internal Connection Diagram S420 with three Servo Amplifiers,
S420D)

MARMMTRBL02303E
124
K022
K023
K021
K020
200VAC
AXIS6
AXIS3
AXIS5
AXIS2
AXIS4
AXIS1
Figure 133. Internal Connection Diagram ARC Mate, ARC Mate Sr., ARC Mate
100/S-6, S-5, and S-10
125
MARMMTRBL02303E
19
26
33
40
18
25
32
39
17
24
31
38
K71
K72
15,16
22, 23
29, 30
36, 37
M1
Figure 134. Internal Connection Diagram S-500

MARMMTRBL02303E
126
Figure 135. Internal Connection Diagram S-700
127
MARMMTRBL02303E
Figure 136. Internal Connection Diagram S900

MARMMTRBL02303E
128
Figure 137. Internal Connection Diagram A-510
129
MARMMTRBL02303E
Figure 138. Internal Connection Diagram M-400 (5-axes)

MARMMTRBL02303E
1210
Figure 139. Internal Connection Diagram M400 (4 axes)
1211
MARMMTRBL02303E

MARMMTRBL02303E
1212
1213
MARMMTRBL02303E
Figure 1312. Internal Connection Diagram L-1000

MARMMTRBL02303E
1214
K036
Figure 1313. Internal Connection Diagram Emergency Stop Control PCB
1215
MARMMTRBL02303E
K022
Figure 1314. Internal Connection Diagram Power Supply Unit

MARMMTRBL02303E
1216
K070
K040
Figure 1315. Internal Connection Diagram - Main CPU; Axis Control Board
1217
MARMMTRBL02303E
S-420 with three-servo amplifier configuration
Figure 1316. Internal Connection Diagram Servo Amplifier Connection S-420,

ARC Mate/S-5, ARC Mate Sr./S-10, ARC Mate 100/S-6, S-500, S-700, and S-800
1218
MARMMTRBL02303E
Figure 1317. Internal Connection Diagram Servo Amplifier Connection A-510,

L-1000, and M-400

MARMMTRBL02303E
1219
Figure 1318. Internal Connection Diagram Servo Amplifier Connection S-900
and M-500

MARMMTRBL02303E
1220
EMERGENCY STOP
K016
K015
Figure 1319. Internal Connection Diagram Modular I/O
1221
MARMMTRBL02303E
K042
K035
K040
K041
Figure 1320. Internal Connection Diagram Teach Pendant
1222
MARMMTRBL02303E
Figure 1321. Internal Connection Diagram Main CPU Interface
1223
MARMMTRBL02303E
Figure 1322. Internal Connection Diagram Axis Control Board Interface
1224
MARMMTRBL02303E
Figure 1323. Internal Connection Diagram ARC Mate/S-5, ARC Mate Sr./S-10,
ARC Mate 100/S-6, S-420, S-500 and S-800
1225
MARMMTRBL02303E
Figure 1324. Internal Connection Diagram S-700 and A-510
1226
MARMMTRBL02303E
Figure 1325. Internal Connection Diagram M-400 and L-1000
1227
MARMMTRBL02303E
Figure 1326. Internal Connection Diagram - M400

MARMMTRBL02303E
1228
Figure 1327. External Connection Diagram M-500
1229
MARMMTRBL02303E
Figure 1328. External Connection Diagram S-900

MARMMTRBL02303E
1230
Figure 1329. External Connection Diagram Process I/O
1231
MARMMTRBL02303E
Figure 1330. External Connection Diagram Process I/O

MARMMTRBL02303E
1232
Figure 1331. External Connection Diagram Teach Pendant
1233
MARMMTRBL02303E
Figure 1332. Motor Table
13
PRINTS
131
MARMMTRBL02303E
This chapter includes all electrical prints.
13. PRINTS
132
NOTES
MARMMTRBL02303E
MARMMTRBL02303E
Figure 141.
13. PRINTS
R-J Control Signal and Power Distribution Overview

Rev. 11/12/96 CD
133
134
NOTES
13. PRINTS
MARMMTRBL02303E
MARMMTRBL02303E
Figure 142.
13. PRINTS
Main AC Power Distribution

Rev. 11/12/96 CD
135
136
NOTES
13. PRINTS
MARMMTRBL02303E
MARMMTRBL02303E
Figure 143.
13. PRINTS
AC Power Distribution With Optional 115VAC Secondary
F6
7.5A
F7
7.5A
46
45
1A
AC POWER DISTRIBUTION WITH

OPTIONAL 115VAC SECONDARY
115 VAC @ 900VAC

TO USER CONNECTION
Rev. 11/12/96 CD
137
138
NOTES
13. PRINTS
MARMMTRBL02303E
MARMMTRBL02303E
Figure 144.
13. PRINTS
Power Supply Unit (PSU) With Power ON/OFF Circuit

Rev. 11/12/96 CD
139
1310
NOTES
13. PRINTS
MARMMTRBL02303E
MARMMTRBL02303E
Figure 145.
13. PRINTS
EMG Stop & Brake Connection 100 VAC E-Stop Circuit 100 VDC Brake Circuit (1 of 2)
Rev. 11/12/96 CD
1311
1312
NOTES
13. PRINTS
MARMMTRBL02303E
MARMMTRBL02303E
Figure 146.
13. PRINTS
EMG Stop and Brake Connection 100 VDC Brake Circuit (2 of 2)
Rev. 11/12/96 CD
1313
1314
NOTES
13. PRINTS
MARMMTRBL02303E
MARMMTRBL02303E
Figure 147.
13. PRINTS
EMG Stop and Brake Connection 24 VDC E-Stop Circuit (1 of 2)

Rev. 11/12/96 CD
1315
1316
NOTES
13. PRINTS
MARMMTRBL02303E
MARMMTRBL02303E
Figure 148.
13. PRINTS
EMG Stop and Brake Connection 24VDC E-Stop Circuit (2 of 2) Modular I/O Power Distribution
Rev. 11/12/96 CD
1317
1318
NOTES
13. PRINTS
MARMMTRBL02303E
MARMMTRBL02303E
Figure 149.
13. PRINTS
Overheat and Cooling

Rev. 11/12/96 CD
1319
1320
NOTES
13. PRINTS
MARMMTRBL02303E
MARMMTRBL02303E
Figure 1410.
13. PRINTS
Single Axis Servo Amplifier

Rev. 11/12/96 CD
1321
1322
NOTES
13. PRINTS
MARMMTRBL02303E
MARMMTRBL02303E
Figure 1411.
13. PRINTS
Dual Axis Servo Amplifier (With Dynamic Brakes)

Rev. 11/12/96 CD
1323
1324
NOTES
13. PRINTS
MARMMTRBL02303E
MARMMTRBL02303E
Figure 1412.
13. PRINTS
Dual Axis Servo Amplifier (Without Dynamic Brakes)

Rev. 11/12/96 CD
1325
1326
NOTES
13. PRINTS
MARMMTRBL02303E
MARMMTRBL02303E
Figure 1413.
13. PRINTS
Discharge Resistor and Dynamic Brake Unit (For Amp With No Dynamic Brake)
Rev. 11/12/96 CD
1327
1328
NOTES
13. PRINTS
MARMMTRBL02303E
MARMMTRBL02303E
Figure 1414.
13. PRINTS
LSI Module All Servo Amplifiers

Rev. 11/12/96 CD
1329
1330
NOTES
13. PRINTS
MARMMTRBL02303E
MARMMTRBL02303E
Figure 1415.
13. PRINTS
DV-M Module Servo Amplifier

Rev. 11/12/96 CD
1331
1332
NOTES
13. PRINTS
MARMMTRBL02303E
MARMMTRBL02303E
Figure 1416.
13. PRINTS
ALM-M Module Servo Amplifier

Rev. 11/12/96 CD
1333
1334
NOTES
13. PRINTS
MARMMTRBL02303E
MARMMTRBL02303E
Figure 1417.
13. PRINTS
Teach Pendant Power And Data Signal Interconnection
Rev. 11/12/96 CD
1335
1336
NOTES
13. PRINTS
MARMMTRBL02303E
MARMMTRBL02303E
TRANSPORTATION AND INSTALLATION

A1
This appendix includes information on transporting and installing an R-J
controller.
A.1
TRANSPORTATION
The control unit is transported by a crane. Attach a rope to eye bolts at the
top of the control unit, as shown in Figure A1.
Figure A1. Transportation
A. TRANSPORTATION AND INSTALLATION
A2
MARMMTRBL02303E
A.2
INSTALLATION
A.2.1
Installation Area
When installing the control unit, allow the space for maintenance shown in
Figure A2.
Figure A2. Installation Area
A3
MARMMTRBL02303E
A.2.2
Assembly During
Installation
Figure A3. Assembly During Installation
A4
MARMMTRBL02303E
Figure A4. Assembly During Installation
A5
MARMMTRBL02303E
A.2.3
Installation Conditions
Table A1.
Model
Item
Line filter
Specifications/Conditions
Common to all models
50 Hz; 200 VAC, +10%, 15%

60 Hz; 200 VAC to 220 VAC, +10%, 15%
50/60 Hz 1 Hz, 3-phase
Transformer
220, 240, 380, 415, 460, 480, 500, 550, 575 VAC,
+10%, 15%
Input power supply capacity
ARC Mate, S-5, A-510
2.5 kVA
ARC Mate Sr., S-10, L-1000
3 kVA
S-700
6.5 kVA
S-500, M-400
7 kVA
S-420, S-800
12 kVA
Average power consumption A-510
0.8 kW
ARC Mate, ARC Mate Sr., S-5, S-10 1.0 kW

L-1000
1.2 kW
S-500, S-700, M-400
1.7 kW
S-420
2.5 kW
Ambient temperature range
0 to 45C
Ambient humidity range
75% RH max.
No condensation
95% RH maximum for up to 1 month
Atmosphere
No corrosive gases
Contact FANUC Robotics when operating the unit where
there is a lot of dust or cutting oil.
Vibration
0.5 G max.
vibration frequently occurs.
Weight of control unit
Table A2.
Model
Item
Line filter
180 kg (approx.)
50 Hz; 200 VAC, +10%, 15%
60 Hz; 200 VAC to 220 VAC, +10%, 15%
Transformer
Input power supply capacity
P-155
220, 240, 380, 415, 460, 480, 500, 550, 575 VAC,
+10%, 15%
Average power consumption P-155

(idle condition)
Ambient temperature range
5 kVA
2.5 kW
0 to 45C
A6
MARMMTRBL02303E
Table A2. (Contd) Installation Conditions

Item
Ambient humidity range
Model
75% RH max.
No condensation
95% RH maximum for up to 1 month
Atmosphere
No corrosive gases
there is a lot of dust or cutting oil.
Vibration
0.5 G max.
vibration frequently occurs.
Weight of control unit
180 kg (approx.)
A7
MARMMTRBL02303E
A.2.4
Adjust the robot according to the procedure in Table A3 at installation.
Adjustment and
Checks at Installation
Table A3.
Adjustment and Checks at Installation

Description
Step
1
Visually check the inside and outside of the control unit.
Check if the screwed terminal is connected properly.
Check that the connectors and printed circuit boards are inserted correctly.
Check transformer tap setting.
Connect control unit and mechanical unit cables.
Turn the breaker or disconnect off and connect the input power cable.
Check the input power voltage.
Press the EMERGENCY STOP button on the operator panel and turn the power on. Check the output voltage.
Check the interface signals between the control unit and robot mechanical unit.
10
Check the parameters. If necessary, set them.
11
Release the EMERGENCY STOP button on the operator panel. Turn the power on.
12
Check the movement along each axis in the manual jog mode.
13
Check the end effector interface signals.
14
Check the peripheral device control interface signals.
A8
A.2.5
Resetting Overtravel
and Emergency Stop at
Installation
MARMMTRBL02303E
An overtravel and emergency stop occur when the robot is operated for the
first time after it is installed and the mechanical and control units are
wired. This section describes how to reset the overtravel and emergency
stop.
Remove the red plate fastening the swiveling axis beforehand. The J2 and
J3 axes are pressed against the hard stops at shipment. Therefore, an
overtravel alarm occurs when the power is turned on after installation.
The robot enters the emergency stop state when the peripheral device
control interface is not connected.
Peripheral Device Interface

Processing
Take the following actions if signals *IMSTP, *HOLD, *SFSD, and

ENBL are not used.
Figure A5. Peripheral Device Interface Processing
Resetting Overtravel
Press the reset switch on the operator panel or the reset key on the teach
pendant. Manually move an axis that has overtraveled into the operating
range while pressing the shift key on the teach pendant.

Fanuc R-J Controller Series Electrical Connection and Maintenance Manual

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Fanuc R-J Controller Series Electrical Connection and Maintenance Manual

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SYSTEM R-J Controller Series

Electrical Connection and

The descriptions and specifications contained in this manual were in effect

FANUC Robotics conducts courses on its systems and products on a

Copyright 1995, 1996 by FANUC Robotics North America, Inc.

FANUC Robotics Hotline

On the arm of the robot.

Ask your supervisor.

On the identification tag on the robot and controller, near

Robot serial number

On the identification tag located near the cable connection.

Controller serial number

On the controller tag located on the doors.

Software edition and revision numbers

Shown on the CRT or teach pendant status screen during

List of error messages

List of diagnostic LEDs

Description of events leading up to the problem.

Purpose of this Manual

The SYSTEM R-J Controller Series Electrical Connection and

How to Use this

Use this table to locate specific information in the manual.

Find information about a specific topic

Identify the components of the SYSTEM R-J

Use diagnostic and controller initialization

View status information on teach pendant

Chapter 3, Lights and LEDs

Perform troubleshooting procedures and

Look at fuse information or replace a fuse

Chapter 5, Replacing a Fuse

Release the brakes

Chapter 6, Brake Release

Turn outputs on or off and simulate inputs

Chapter 7, Controlling I/O

Master the robot

Replace controller components

Adjust switch settings and potentiometers

Chapter 10, Board

Find controller connection schematics and

Chapter 11, Connections

Find connection information and

Chapter 12, Complete Wiring

Find complete schematics of the controller

Chapter 13, Prints

Use controller transportation and installation

This manual includes information essential to the safety of personnel,

NOTE Information appearing next to NOTE concerns related information

2.1 SAFETY SIGNAL STATUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.1 TEACH PENDANT DIAGNOSTIC LEDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Power Supply Unit (PSU) Diagnostic LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1 CLASS 1 FAULT TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SRVO-046 ER_SVAL2 OVC Alarm (Group:i Axis:j) . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.1 MULTI-TAP TRANSFORMER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.1 FORCING OUTPUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.1 MASTERING TO A FIXTURE (FIXTURE POSITION MASTER) . . . . . . . . . . . . . . . . . . . . .

9.1 REPLACING THE BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.1 AXIS CONTROL BOARD JUMPERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11.1 MECHANICAL CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Arc Welding Interface Connection Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Displaying Safety Signal Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Replacing the Base Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 130. Operator Panel, B-Size Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Figure 1115. External Power Supply ON/OFF Switch Connection . . . . . . . . . . . . . . . . . . . . . . . .

Figure 1156. Peripheral Device Connector for A and B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .