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SRC-320

1. PSUI PSU2 lo cir o i m o Regenerative brake unit 5 i for EL EH BL XM3000 series N ERR J TH PSU3 Motor power unit m MPU board OOOO o 00000 o j o LOL ILI E alle Top view of interior AC servo driver for axis 2 AC servo driver for axis 3 T O board REMOTE board AC servo driver for axis 1 AC servo driver for axis 4 Option slot M C signal A passos cgo os is TIT ini i y Y T CRS Te S G eus ISk ACER 9 messe gt 2 e 9 9 c gt 7 S Driver safety cover Power switch Power cable PSU board M C power Front view of interior Rear panel PRG No LED E Stop cancel switch LINE
2. X1 Shield 1 j Y 3 to CHASSIS OOO LOLOL OOOK QF1 10A 1 NF1 X19 FG C OUT IN OUT IN X11 X14 X15 BOARD RACK We ut PSUI Zi eSvemv T ib FRONT BOARD xls P X12 X13 X16 gt X70 Circuit protector j x2 55V 12V Mus I 24V H gt S s User 24V e T gt SWI Kej WH3 e L Has S X EX So Z zi WH2 U e B lt X3D XID A L lo a MERI p SS amp Li LI H UT KHR WH4 Axis 4 gt S DRIVER jen S Ss E H Us X3C XIC Eo lO m Axis 3 FL x MPU BOARD DRIVER z 2 X3B XIB ol 9 Axis 2 als m s DRIVER Lr ni FANI mo ox WHI2 Ol r X3A IXIA REAR g WaN BOARD Axis 2 PA a WH10 DRIVER x oO Z x e EC wo 5 8 8 s S y sa s B4 om oo pa 3 X d X80 MOTOR POWER UNIT amp REGENERATIVE BRAKE UNIT matte X s og E mL WHI 84 c jaa gt Q 4 jaa 5 z lt A Z Q e oe Maintenance 2 Outline of Structure 2 4 Connector pin assignment M C POWER X2 M C SIGNAL X3 TEACH X70 connector JL05 6A20 29PC A66F0 DX30A 68P DB 25PF N connector JLO5 2A20 29SC FO DX20A 68
3. SDI SD2 e e I J 3 8 8 8 amp B xy ie I is E E E FA E E Bg 9 del NE o Eel ues E um Note When a driver error occurs the motor main power supply is shut down and you cannot check the voltage in step 4 That is the reason you have to switch to the non use of axis setting 3 Turn ON the controller and execute the MOTOR ON command 4 Use a tester to check that the motor power unit is outputting correctly to each AC servo driver This cannot be checked at the motor power unit it must be checked at the AC servo driver s power connector X1A X1B X1C and X1D see the figure below In this case be sure not to make a short circuit The voltage is as follows W ARN N G E In order to avoid electric shock use an insulating glove when you measure the voltage Measuring point Pin number Standard connector side side XIA XIB at6 and 5 AC source power voltage V2 10 XIC yellow black In case of AC 230 V approx DC 320 V XID
4. eo eG ss SS FS am is J 9 Orange LED M P B Hj i j j Green LED ACF IIR L1 3 LJ 5 L1 ED L1 Green LED MPC E 35 HE E c 8 Execute the MOTOR ON command If the motor power unit s LEDs are all on and no error code is issued inspection is completed Attach the driver safety cover and the front panel 105 Maintenance 5 Motor Power Unit NOTE If all LEDs of the motor power unit are not on there is a possibility of malfunction of the LE motor power unit or PSU board If an error code is issued take corrective action by following the troubleshooting steps Refer to 15 1 Error code table in this volume However if a driver error error 180 to 189 occurs cause of the problem will be found by taking the following steps Refer to these 1 Turn the controller OFF 2 Make a note of the setting of the DIP switch SD2 on the MPU board and set bits 5 to 8 of the SD2 to the off position which means the setting of a non use of axis
5. Filter O e e Fan safety cover 3 Turn ON the controller with the front panel off Check that the fan runs properly 4 Install fan s filter to its original position and install the front panel on the controller 134 Maintenance 12 Cooling Fan 12 2 Fan replacement If the fan is not operating properly replace it by following the steps below 1 Turn OFF the controller and remove the front panel 2 Disconnect the X73 connector from the fan Do not disconnect the earth line and X71 connector 3 Unscrew the four screws that hold the fan in place Remove the fan and fan safety cover Spring washer and flat washer are used with the screw do not lose them 3 44 3 O 3 3 4 Install a new fan together with the fan safety cover Attach the fan safety cover to the side of the fan s motor cable and connect the X73 connector 5 With the front panel off turn ON the controller and check to see that the fan runs prop erly 6 Reattach the front panel 135 Maintenance 13 Front Boa
6. N C AUTI ON B Temperature of the regenerative brake unit PSU unit and AC servo driver may rise depending on the operating condition Check the surface temperature before handling and use the protective gloves if necessary 1 Remove the controller s upper cover and rear panel As the ground wire is connected to the upper cover and rear panel do not pull them unnecessary 2 Turn OFF power to the controller and check the orange LED M P on the front of the motor power unit is faded out completely 3 Disconnect the X80 connector on the regenerative brake unit Regenerative brake unit 129 Maintenance 10 Regenerative Brake Unit 4 Remove the two screws that fasten the regenerative brake unit on the right side of the controller and take out the regenerative brake unit backward 5 Mount the new regenerative brake unit in the controller with the two screws Be sure not to bend the cables forcibly or not to pinch 6 wm Connect the X80 connector to the regenerative brake unit 7 wm Attach the upper cover and rear panel of the controller 8 For the o
7. NOTE Cg 14 1 Additional RS 232C board replacement 1 Turn OFF the controller See the pulse generating board manual for detail of the pulse generating board 2 Loosen the additional RS 232C board s upper and lower set screws and pull the board out by the handle The handle is labeled RS 232C 3 Set the DIP switch SD1 and jumper pins XP1 A H of the new board to the same settings as those of the old board SKP335 1 SCC BOARD o OO000000 c in x v Handle e 4 Insert the board firmly into the original slot and tighten the upper and lower set screws 138 Maintenance 14 Option Boards 14 2 Protected I O board replacement The protected I O board is an I O board that is equipped with a function that protects the internal circuitry from output port misconnections Replace the protected I O board or its parts by following the steps described below 1 Turn off the controller 2 Loosen the upper and lower set screws of the protected I O board and pull the board out by its handle alelelelelelelelololelelelelolole lOOOOOOOOOOOOOOOOCO o g BHBB GHVOd LOALONd O L 8 dMS Handle aS es INE 3 If you are replacing the entire board set the DIP switch SD1 to th
8. PSU3 8 Insert a new PSU3 in the controller and install it on the left panel of the controller 9 Connect the connector X15 and X16 to PSU3 The connector shape of X15 and X16 is same so be careful not to misconnect 10 Insert the AC servo driver for the axis 4 again and secure it with four screws Be sure not to bend the connected cables forcibly or not to pinch 11 Connect the connectors X1D and X3D to the AC servo driver for the axis 4 11 5 E ooo o ie 3 6 a 9 6 Y H C Ia x B Ia i 9 3 A i e S Es Oo E 29 BI LES AR z 11 12 Fix the driver saf
9. REMOTE REMOTE PNP type REMOTE board NPN type REMOTE board Refer to 4 3 4 4 Refer to 4 5 4 6 Functions 4 REMOTE1 4 1 Connecting to REMOTE1 the safeguard switch and emergency stop switch N G AUTION Use emergency stop switch conformed to the related safety standards EN418 Safeguard switch EN60204 1 The interlock switch must be designed and installed such as the contacts are opened by force when the safeguard opens not by spring of the switch itself See EN1088 and EN954 Wire the interlock switch dual redundantly to the double safeguard inputs to prevent malfunction of the safeguard circuits The safeguard must be designed and installed such as it does not close without operator s intention The Latch release switch must be installed at a place where the hazardous area can be looked out An interlock switch of the safeguard safeguard switch should be connected with the cable connector that came as a standard accessory When wiring in case of PNP type refer to 4 3 Pin assignment of REMOTEI PNP type and 4 4 Circuit diagram and example wiring of REMOTEI PNP type In case of NPN type refer to 4 5 Pin assignment of REMOTEI NPN type and 4 6 Circuit diagram and example wiring of REMOTEI NPN type The safeguard input circuit is dual redundant An open safeguard is always detected even if one of the circuits fails An error is displayed in the event of
10. Be sure to use legs Vertical placement 13 Functions 2 Installation 2 4 Power Power specifications Please be sure available power meets the following specifications AC 20010 OV amp IOR Single phase The controller itself consumes a maximum of approximately 200W but actual consumption depends on the manipulator motors Please Power refer to the manipulator manual for manipulator power consumption consumption and then use the following equation to calculate total consumption Rated consumption 200W total manipulator consumption x1 5 When power is turned on approximately 130A 1msec When motor is on approximately 90A 5msec Earth leakage Rated current 10A Peak current breaker in the controller Sensitivity 15mA Ground Be sure to use a grounded power source NOTE If you install an earth leakage breaker in the AC line please use one that does Ee not induce more than 10kHz inverter type If you install a circuit breaker please select one that is bearable against the above mentioned peak current Power plug N W ARN NG W To lockout the power supply unplug the power plug Never directly connect the robot to a factory power supply without using the power plug as this will disable power lockout Be sure to attach the ground wire yellow green of AC power cable to the plug so that it shall be connected to the earth terminal of factory power supply
11. D POWER cable Cable for controller AC power It is composed of two power leads brown blue and a ground wire green yellow PSU board Circuit board for controller manipulator and peripheral units power REMOTE board Interface board having four connectors for REMOTEI amp 2 and RS 232C 20 21 REMOTE1 Connector for safeguard and emergency stop inputs The safeguard input has safety fea tures such as temporary program stop and low power mode The emergency stop input achieves robot emergency stop This input terminal is nor mally closed so that if no cable is connected the robot is in the emergency stop condition and will not operate Connect a normally closed emergency stop switch with the cable connector that came as a standard accessory 5 REMOTE2 Connector specifically for the operating unit option OPU 300 or OPU 320 It can be used in the AUTO mode If there is no cable connected the robot is in the emergency stop condition If you do not use the operating unit connect a normally closed emergency stop switch with the cable connector that came as a standard accessory Further it will be necessary to make a mode switching circuit or similar modification RS 232C 20 21 Connector for the RS 232C serial interface It is used for communication between robots peripheral units or host computers Functions 1 Part Names and Functions MIC SIGNAL This is a connector f
12. Power connector 115 Maintenance 6 AC Servo Driver 9 Connect the power connector and the signal connector to the driver 10 Attach the driver safety cover Driver safety cover 10 10 11 After connecting the earth line the connectors X71 and X73 to the front panel install the front panel to the controller N W ARN NG Bi Be sure to reconnect the earth line yellow green to front panel 12 Refer to 11 Manipulator operation check in this volume for the remaining steps 116 Maintenance 7 MPU Board 7 MPU board 7 1 Layout and function of MPU board parts The MPU board executes programs and controls the manipulator SD3 EBBE ROM MPU L ROM MPU U XP8 ROM DSP XP6 XP5 9 ooo SD1 SD2 o oooo Ja M ETT a T 1 D DIP switches The DIP switches are used to set various software functions The functions are as fol lows
13. 106 Maintenance 5 Motor Power Unit 5 If the above voltage is not outputted there is a possibility of malfunction of the motor power unit or the PSU board 6 After checking the voltage turn off the controller and set bits 5 8 of the MPU board s DIP switch SD2 as they were before 7 Fix the driver safety cover Driver safety cover 7 E 9 J lege L4 rs 6 8 oye 8 8 8 i am 7 le H ze gt 8 Attach the front panel 107 Maintenance 5 Motor Power Unit 5 3 Motor power unit replacement When there is something wrong with the motor power unit replace it by following the steps below W ARN N G W Only trained personnel should be allowed to perform the following operations Trained personnel are those who have taken a robot training course held by the dealer or those who have carefully read the manuals and have equivalent knowledge or skill Controller has the capacitors charged high voltage To avoid an electric shock do not touch the dangerous high voltage parts marked with the orange label until the orange LED of motor power unit is faded
14. 8 N6 NC 9 IN7 OUT 12 N COM 1 NC N8 OUT 13 N9 NC N 10 OUT 14 H NC N12 NC IN 13 41 OUT 15 17 IN 14 NC T i UN N F o2 d F AR Z d ON tA 87 ts Ifcul ter a circuit that supplies 200 volts AC to the motor power unit and three PSUs switching power supply unit that supply 5V 12V 24V and user 24V power to the mother The main power supply circuit is comprised of an earth leakage circuit breaker a noise fil board 2 5 Main power supply c Maintenance 2 Outline of Structure lt lt ddA00 sdddf lt lt ddA00 LNOSJ 2 l a 00 00 mem p CLINA s3MOd YOLOW 912 B N3349 l A79 0 845189 3 hni an 04 0862 02 2 S01F O00 gt gt ru F 2 Amoa aM AU0S0V 277 GUER I QN93 OS ee ee ee ee ee ee eo ES So 0Zx EN A79 INI SISS HO IIto 0 0 0 6 0 0 0 0 0 0 0 9 0 0 I 181 Lid el I I OIVA GYVOE 9100 mE CGISHI0H Ob O nam In OT que 79 i T 8 r YOESMN IN p A t 6615 IN KX p ET gt 0 G419 PS 93094 canta IE T z g OW EE PR Egg if E 5 ZENON gt gt gt Ss IV
15. e e e O Back side of front panel gt Functions 1 Part Names and Functions MPU board and mounting bracket This board containing the CPU forms the nucleus of the controller and controls the vari ous interfaces and executes the programs It has DIP switches SD1 and SD2 The MPU board and the mounting bracket are one piece and the main body is fixed by the mounting bracket You can remove the MPU board by pulling on the bracket 2 MPU board mounting screws Safety cover AC servo driver Motor power unit Cooling fan Front board These screws affix the MPU board mounting bracket to the main body To remove the MPU board loosen the screws and then pull on the mounting bracket Please do not pull the screws This safety cover prevents tools and such from being inserted or dropped into the interior of the controller Unit to control the motors Each servo driver controls one motor Contains the power circuit for the servo drivers and motors as well as the dynamic brake circuit The cooling fan is to fan out the heat generated from the servo drivers to the outside the controller Attached to the back of the front panel The board for indicator Attached to the back of the front panel Functions 1 Part Names and Functions 1 4 Safety features The robot is equipped with safety features that protect it and peripheral
16. 108 Memory check error of internal process If you replaced the ROM initialize the MPU board Refer to the section 7 3 in the maintenance volume Check the voltage of the lithium battery on the MPU board Replace it if the voltage is less than 3 4V Refer to the section 7 2 board Refer to the section 7 3 in the main tenance volume Check the 24V output at PSU Refer to the section 3 3 in the maintenance volume Coprocessor error division by zero Same as error 109 145 Maintenance 15 Trouble Shootin 115 Improper voltage or temperature of motor power sup 1 Clean the filter of cooling fan and inspect ply unit the cooling fan replace it if necessary Refer to the chapter 12 of the maintenance volume If ambient temperature of the controller is over 40 C cool the place where the con troller is Check the motor power unit and replace if necessary Refer to the section 5 3 in the maintenance volume If this error frequently occurs replace or repair MPU board Refer to the section 7 3 in the maintenance volume Ee ea Care ee ee 118 Improper voltage of DCSV Check the 12V output at PSU Refer to the section 3 3 in the maintenance volume Arm is moved too much after switching off the power 1 If you moved the arm manually after of controller switching off the power turn off and on the controller or input RESET 16 Malfunction of Servo CPU dual port RAM Eliminate external
17. ssssssssssseeneeee 105 5 3 Motor power unit replacement ssssssssseen 108 DAC Seno Dnveie i mb D RM eae 111 6 1 Layout and function of AC servo driver parts ssssss 111 6 2 AC servo driver inspection sssssssssseeeem 112 6 3 AC servo driver replacement sss 113 BASSES 117 7 1 Layout and function of MPU board parts ssssssss 117 7 2 Lithium battery inspetion and replacement ssusssss 119 7 3 MPU board and or ROM replacement ssssssssssess 121 3 REMOTE Boardi sce UEM 124 8 1 Layout and function of REMOTE board parts sssssss 124 8 2 REMOTE board and parts replacement ecccceeeeeeeeeecteeeeees 125 oTo Board na an m do I EU E SE C 126 9 1 Layout and function of I O board parts ssssseeeeee 126 9 2 O board and parts replacement ssssssssssssseee 128 10 Regenerative Brake Unit for EL EH BL XM series 129 11 Manipulator Operation Check 131 425 oolind dat Serene a Renee ce db e iE 134 12 1 4 Fan inspection sirenat reti e ree eb eee ceded be cun 134 12 2 Fan replacement sssssssssssssesseeemeemeenen nennen 135 i1osbroDDbBoSrd T dee EU EM 136 13 1 Front board Inspection n tte oe rtt htt ea tete 136 13 2 Front board replacement sssssssssessse 137 Ads Opuonmboatds er Ee C E RET
18. 1 Check the cable connection and change to nected to TEACH port is not possible TEACH mode 2 Devices connected to RS 232C port cannot com 2 Check the cable connection and configura municate tion of RS 232C communication Parity overrun or framing error due to RS 232C re 37 Overtime error of RS 232C communication ee eee es ee ea oe ee The number of FUNCTION FEND is more than 70 Reduce the number of FUNCTION FEND up to 70 Cannot begin a task that has already begun 1 Prohibited command is executed during task execu 1 Press BREAK or STOP key or RESET tion switch 2 Edit mode is selected 2 Exit Edit mode Refer to EDIT com mand in the reference manual 46 Improper voltage of DC24V for customer use Check 24V output at PSU Refer to the section 3 3 in the maintenance volume 2 ce 49 Warning Low battery voltage Backup all of the data immediately before they are lost Then replace the lithium battery on 142 35 Data over 80 characters is transferred to RS 232C port Number of characters per line is up to 79 MPU board with new one Refer to the sec tion 7 2 in the maintenance volume Maintenance 15 Trouble Shootin 50 Optional designation of command is invalid Specified file does not exist 1 Check the file name 2 Check whether the specified file exists or not in file memory CAO E CEP Sl ooo G O File with same name already exists Change fil
19. Servo overflow detection Detects the difference between the position reference and the current position of the manipulator Motor lock detection Detects failure of the motor to respond to motion commands Control power source irregularity detection Detects voltage irregularity of control power source of 5V 12V and 24V Primary power source irregularity detection Detects dropped voltage of AC200V motor main power CPU irregularity detection Detects CPU s irregularity that controls system with a watchdog timer System con trolling CPU and motor controlling CPU always watches over each other Memory irregularity detection Detects check sum error of memory Functions 2 Installation 2 Installation NOTE The controller SRC 320 is not designed for the use in clean room environments If you S use the controller in the clean room take an adequate countermeasure As an example place the controller in a box having a cooling or an exhausting mechanism 2 1 Unpacking N C AUTION W The controller weighs 24kg standard When moving the controller use a hand cart If unavoidable to move it by hand be sure to hold by two persons W Do not hold the pulls on the front panel of the controller when moving Box contents SRC 320 main unit unit 50 pin D sub I O connector clamp hood 1 set Jumper socket 5 pieces REMOTE connector 1 set REMOTE2 connector 1 set TEACH Port connector attached to controller ma
20. ber of nesting loops is 40 Overflow occurred in converting variable Change the value to allowable variable type Parameter specification table exceeds allowable range Subscription of PALET is 0 to 15 Too many characters are on one line intermediate code 1 Mixed operation of character and numerical value is attempted 2 Data tag error of object program 1 Numerical variable error Entry of too many dig its is attempted 2 ASCII character in INPUT statement cannot be converted to numeral N O 1 Specified address does not exist 1 Maximum address is 19 2 Robot operation command is executed as Task 2 to 2 Set robot operation task with SELRB com 16 without SELRB declaration mand 1 Specified I O bit number does not exist 1 Confirm I O board address setting 27 E FEET cu EE 2 File not opened is attempted to access 2 Open the file Confirm the file name 141 Maintenance 15 Trouble Shootin 28 1 NEXT statement corresponding to FOR statement 1 Make NEXT statement is missing 2 WEND statement corresponding to WHILE state 2 Make WEND statement ment is missing 3 SEND statement corresponding to SELECT state 3 Make SEND statement ment is missing 4 ENDIF statement corresponding to IF statement is 4 Make ENDIF statement missing 5 endif statement corresponding to ifdef is missing 5 Make endif statement 1 Communication from a personal computer con
21. forming maintenance please confirm with us Functions 1 Part Names and Functions 1 3 Controller interior The interior of the controller as it appears after removal of the front panel is shown in the figure below Please do not pull hard when removing the front panel A cooling fan and the indicator panel are attached to the front panel and connected to the interior by cables Axis 1 Axis 2 Axis 3 Axis 4 a SD1 SD2 p2 z s meme SS S 8 8 8 878 E N i c 9 ly e la Ia o e 3 e G G I I I I I I Il l I i I I I ein o tet CREE PRAE RU RTL Spat J G G D
22. tor manual Cover removal sec tion in Manipulator manual Lubrication section in Manipulator man ual Replacing the timing belt section in Ma nipulator manual Maintenance 15 Trouble Shooting There is an axis that does not operate Diagnosis Correction See 1 Are DIP switches SD2 1 Confirm that DIP switches SD2 on Section 9 1 in bit 5 to bit 8 on the MPU board set properly The I O port does not operate or another I O port operates Diagnosis Is the I O port wired properly Is the I O connector connected properly Is the board properly inserted Is the power supplied Are DIP switches on the I O board set properly The REMOTES connector does not operate Diagnosis Correction Is the REMOTE3 con nector set properly Is the REMOTE3 con nector wired properly Is the REMOTE3 I O 1 connector con nected properly Is the board properly inserted Is the power supplied the MPU board are set properly Correction 1 Check the wiring on the I O connec tor and load sides Check the position of the connector to be connected the disconnection and the slackness Insert the board as far as it will go and tighten it with two upper and lower screws Check the wiring in which 24V is input to the common terminal of the I O connector and confirm that the power is supplied Confirm that DIP switches SD1 on the I O board are set properly 1 Set the
23. 18 AUTO mode input PE AE zm 10 24 V GND 20 424 V GND 39 Functions 5 When Not Using the Operating Unit 5 2 When not using the operating unit as the console l O 1 REMOTES RS 232C 40 The input port for controlling robot or the device connected to it is collectively referred to as the console In many cases operating unit is used as the console in AUTO mode But when operating unit is not used it is necessary to set up a console elsewhere The input ports at which you can set up the console are as follows I O 1I REMOTE3 RS 232C 20 21 You can set up all functions except the display of operating unit at I O 1 and use it as the console The general procedures for doing so are explained below For details refer to 7 1 0 Remote Set Up REMOTE3 in this volume 1 Set up bits 1 amp 2 of software switch SS1 2 Set up I Os as the remote REMOTE3 3 Wire the REMOTE3 connector When you assign RS 232C as the console use the CONSOLE command Refer to the SPEL III reference manual for details on the CONSOLE command In the case that RS 232C is assigned as the console a personal computer may be used and you will have to send all commands from it 6 I O NOTE NOTE Functions 6 I O I O links your input output equipment The controller comes standard with one I O port on the rear panel enabling you to use 16 inputs and 16 outputs The cable connector for user cable is a stand
24. Always OFF 3to8 Setting of model of A to E manipulator Please do not change these settings SD2 Sets capacity of main memory and file mem Main memory 374KB Main memory 174KB ory when additional File memory 900KB File memory 1 1MB RAM is installed 3 Reserved for system Always OFF 4 Reserved for system Always OFF s Use of axis 2 s 7 U Use of axis 3 s 8 Z Use of axis 4 s N No No No No 65 Functions 9 Switch Types and Jumper Pin Set Up 9 2 Software switches 66 SD1 to 3 are hardware switches Switches that you set using software are called software switches Controller has six such software switches SS1 to 6 You set them from a personal computer The functions of these software switches are shown below See the programming support software manual for details on setting software switches The setting of bits that are labeled Reserved for system cannot be changed Software switch settings are saved even when power is turned off but they are initialized at the system initialization by MPU board DIP switch SD1 1 and all assume the OFF state SS1 REMOTE2 Selection of the remote REMOTE3 I O ing unit Reserved for system 7 o Always OFF Always OFF E Reserved for system o LESE Always OFF Reserved for system Always OFF OFF Execution of en f oo commands when safeguard Disabled Enabled is open in AUTO mode Processing o
25. GOSUB RETURN program has too many nesting 1 Reduce nesting levels Maximum number levels of GOSUB RETURN nesting levels is 10 2 Too large source program is saved 2 Correct program Refer to PRGSIZE command of reference manual Line called by GOTO or GOSUB does not exist Subscription of array variable is beyond specified size 1 Same names of variable label or function exist 1 Do not specify the same name 2 Reserved words are used for variable label or 2 Reserved words are not allowed to use function 3 Name of variable label or function starts with P 3 First letter should be other than P 1 Division by 0 zero is TUUM Correct program as a command Number of parentheses on the left and on the Correct program right are not equal Number of parameters does not match Correct the number of parameters of executed J o line is not within FUNCTION FEND Include program lines between FUNCTION FEND FUNCTION declaration exists between FUNC Describe FEND so that FUNCTION corre TION FEND sponds to FEND Variable declaration is not at a head of statement line Variable declaration is not allowed after multi statements When variable type is dif ferent be sure to change statement line Number of characters on one line is 80 and over Number of characters on one line is up to 79 O Structured program has too many nesting loops Reduce nesting loops Maximum total num
26. Input No 3 Input No 4 Input No 5 Input No 6 Input No 7 Input No 8 15 common GND E i 11 Input No 8 i aan 7 12 Input No 9 m MEN Abbreviated 42 Functions 6 I O 6 2 Output circuit PNP type Rated output voltage DC 12 to 24V 10 P channel power MOS FET Output circuit diagram and example of connections I O 1 GND DC Pers sa Sessa sacs ssSSseSssaSsess 5 1 L I i i I i I I i i i Output No 0 1 4 I vs L 1 xe ZN M Inductor r N 1 I i i EET i 1 1 420 Output No 1 i Same circuit as above Ij L e a ne asp ove 1 421 output No 2 i i reu a a O a i J 11 4 22 Output No 3 i eg eee ECC ee ee 11 423 Output No 4 i a tn O E RE z i t 24 Output No 5 I I een ae ean oe aa 4 i t 4 25 Output No 6 i L4 p 4 I it 26 Output No 7 1 H i r1 gue 1 i I 428 Output No 8 I 1 Dudes chia ee sae ta i I 4 29 Output No 9 H ie ae CS A a E Y Abbreviated 43 Output common GND 44 Output common DC 45 Output common DC 46 Output common DC 43 Functions 6 I O 6 3 Customer use power supply A power supply for customer use is supplied to each I O conn
27. or grounded 10 Other than the above 1 Eliminate external noise source and execute VERINIT com mand Refer to the section 2 6 in the functions volume 2 If this error frequently occurs replace or repair the MPU board Refer to the section 7 3 in the maintenance vol ume Check disconnection of the motor power line in manipulator and controller Refer to the manipulator manual and 2 3 Diagram of cable connections in the maintenance volume of this man 1 Eliminate external noise source and execute VERINIT com mand Refer to the section 2 6 in the functions volume If no external noise source exists replace MPU board Refer to the section 7 3 in the maintenance volume 2 Check actual weight and set proper WEIGHT Refer to the section Load weight and the WEIGHT setting of ma nipulator manual 3 Reduce operation speed of robot Refer to ACCEL SPEED and WEIGHT command of the reference manual 4 Check each axis motion moving by the hand Verify appro priate lubrication or replace reduction gear Refer to the manipulator manual 5 Check the tension of timing belt Tighten or replace if neces sary Refer to the section Replacing the timing belt of manipulator manual 6 Inspect the cooling fan Replace it if necessary the section 12 2 of the maintenance volume Refer to 7 Clean the filter of cooling fan the maintenance volume Refer to the section 12 1 of 8 Cool the pl
28. Environmental requirements ssssssssssseseeeeeenee 12 2 3 Vertical placement sssssssssssssseseeseeemeereren enne 13 2 4 POWOEu dodge eie tette m test les ite A Ie rudes a iva 14 2 5 Cable connections essen 16 2 6 Noise countermeasures ssssssssssseeeeeeemeene nnne 19 AEAGHRIPOIL rom e mU E tee 21 3 1 Personal computer connection ececeeccececeeeeeeeeneeceeeeeeeteeseneeeeees 22 3 2 Teaching pendant TP 320 connection sssssseses 23 3 3 TEACH port connector E STOP CANCEL connector 23 3 4 E STOP CANCEL switch use ssssssssseee eem 24 3 5 Pin assignment of TEACH port 25 Bl 1 I Eee ae reer Pore we UE 26 4 1 Connecting to REMOTE1 the safeguard switch and emergency StOD SWIIClI A 10e etr eti e Sn cee ay ret el ias 27 4 2 Safeguard input functions sssssseee 29 4 3 Pin assignment of REMOTE1 PNP type 32 4 4 Circuit diagram and example wiring of REMOTE1 PNP type 34 4 5 Pin assignment of REMOTE1 NPN type eeemmmIHMI 35 4 6 Circuit diagram and example wiring of REMOTE1 NPN type 37 When Not Using the Operating Unit 38 5 1 Operating unit disconnected REMOTE2 sse 38 5 2 When not using the operating unit as a console 40 Tuo uU T 41 6 1 Input circuit PNP type reinii da e daie 42 6 2 Output cir
29. I O remote connector prop erly from the SPEL Editor or SPEL for Windows 2 Check the wiring on the REMOTE3 connector and load sides 3 Check the disconnection and slack ness of the connector and cable and connect them firmly Insert the board as far as it will go and tighten it with two upper and lower screws Check the wiring in which 24V is input to the common terminal of the REMOTE3 I O 1 connector and confirm that the power is supplied Functions volume Section 6 in Functions volume Section 6 in Functions volume Section 9 2 in Maintenance volume Section 6 in Functions volume Section 9 1 in Maintenance volume See SPEL Editor or SPEL for Windows manual Section 7 in Functions volume Section 6 in Functions volume Section 9 2 in Maintenance volume Section 6 in Functions volume 165 Maintenance 15 Trouble Shooting The operating unit does not operate Diagnosis Correction See 1 Is the cable connected 1 Check the connection cable of the oper properly ating unit 2 Does the operating Turn off the power of the controller then unit switch operate turn on the power of the controller again normally while pressing the three keys T and of the operating unit at the same time The switch state is displayed on the screen Confirm that the display changes every time each switch is pressed If the display does not change the operating unit is
30. Motor Power Unit Block diagram ES EC FG AC 200V AR X20 e i BN BNA FG A 15A Fl RT3300 LED LED Motor power control MPC AFL MPC THS SSR Voltage Ber eee monitoring peru LED circuit T X21 X24 M P pc5soy Rectifier iL d circuit Jj Y DCOV AC servo U V W driver Dynamic brake control Dynamic brake circuit U V W X25 X26 AC servo motor EL EH FG AC 200V ig ve Q E i XM3000 LED LED Motor power control Rre um MPC A FL MPC THS SSR Voltage i monitoring poc LED circuit i X21 X24 M P nc250V Rectifier 2 circuit I Y DCOV AC servo driver Dynamic brake control Dynamic ENS brake circuit U V W X25 X26 AC servo motor 104 Maintenance 5 Motor Power Unit 5 2 Motor power unit inspection Inspect the motor power unit by following the steps below N W A R N N G B Only trained personnel should be allowed to perform the following operations Trained personnel are those who have taken a robot training course held by the dealer or those who have carefully read
31. SD1 Bit No Function ON OFF ne eee Initializes CPU control data MORET 1 System initialization Does not initialize when power is turned on 2 Reserved for system Always off 3to 8 Setting of manipulator A E model Do not change these settings E Sets capacity of main memory Main memory 374KB Main memory 174KB and file memory when you File memory 900KB File memory 1 1MB add additional RAM 3 Reserved for system Always off Reserved forem Aways of ee Reserved for system Pe Jg 3 es oom mea alala BS es Use of axis 1 Use of axis 3 Use of axis 4 1to4 Reserved for system E e Always off oo c e COD g zo e 117 Maintenance 7 MPU Board DIP switches have been correctly set at the factory on the basis of your specifications Careless changes to these settings could cause system failure Please be careful not to change the setting of bits which are shown as Reserved for system When replacing the MPU board DIP switches of a new board have to be set the same way as the current board You can display the current settings of the DIP switches us ing the SPEL Editor or SPEL for Windows Before replacement it is better to display and record the current settings just in case See the SPEL Editor manual or SPEL for Windows manual for information on how to display the settings The shaded cells in the tables above are standard factory setting
32. The AC power cable is not equipped with a plug Please attach a plug that is suitable for the power outlets in your area The following table shows color of the wire of the power cable Eo a 14 Functions 2 Installation For reference specifications of the AC power cable included with the controller appear below 41 wires 0 26 mm AWG 14 Conductor Brown blue AC power green yellow ground Insulator UL Style No 1015 Sheath 10 5 mm typical 3 5m Cable length 15 Functions 2 Installation 2 5 Cable connections N W ARN N G E Be certain that the power has been turned off controller power before you plug or unplug any of the cables linking the manipulator and controller Failure to do so could cause electrification and malfunction N C AUTION B When installing the cable between the manipulator and the controller make sure the M CODEs matching codes match The M CODEs are written on the yellow labels which appear on the back sides of both the manipulator and the controller Also make sure that the length of the power cable and signal cable correspond to the length which appear on the yellow labels mentioned above It is necessary to connect the various cables as shown in the figure below in order for the robot to operate J M C power cable r e MC signal cable Manipulator gt iui REMOTE1 0 Safeguard etc REMOTE2
33. a failure Therefore we recommend dual redundant wiring for the safety gate interlock switch If an open safeguard is detected by the safeguard input circuit the signal will be latched and even after the door is closed it will not be recognized as such until the latch release signal is input This has been provided as a means of preventing the kind of confusion that can easily arise during the construction of a robot system when operator and the robot system itself perceive the state of the safeguard differently that is when one believes the door is open while the other perceives it as being closed For example when faulty ad justment causes a difference in the state of the door and the state of the interlock switch or when the door closes without the operator intending for it to be closed etc If the REMOTE board jumper pins XP4 and XP5 are set between 1 2 the safeguard open signal will be latched This is the standard factory setting For releasing it wire a normally open type switch between pin 9 and 22 If the jumper pins XP4 and XP5 are set between 2 3 the signal will not be latched 27 Functions 4 REMOTE1 Use an interlock switch that opens when the safeguard opens The safeguard input func tions when the safeguard input terminals open and activates the low power state A power source should be connected to pin 10 or 11 and 23 or 24 for the interlock switch Connect additional emergen
34. be corrected 1 Is the bolt that installs a manipulator tightened firmly Is the tension of a timing belt proper Does a remarkable play occur when the power is turned off and when the arm is moved manually Does the operating time of a robot exceed 8 000 hours in all Does the operating time of a robot exceed 15 000 hours in all Is there no strong noise source in the neighbor hood 7 For except the above Diagnosis Correction 1 Confirm that the manipula tor is firmly fixed to the base table frame Push the timing belt and tighten the belt again or re place if it is loosen Check the main fastening bolt of the arm and confirm that the bolt is not loosened Examine the replacement of reduction gears in each axis Examine the replacement of an axis 43 ball screw spline unit Take measures against the noise 7 Replace the MPU board 7 2 Replace the AC servo driver 7 3 Replace the motor Base table section in Manipulator man ual Replacing the tim ing belt section in Manipulator manual Section 2 6 in Func tions volume Section 7 3 in Main tenance volume Section 6 3 in Main tenance volume Motor replace ment section in Manipulator manual The positioning point is shifted but the shifted point can be corrected Diagnosis Correction 1 Is the position of periph 1 Confirm the fixing screws of eral equipment not the peripheral equipmen
35. connector Fuse Power connector E Enix in 0000 00000 7 OC 5 7T Attach the power connector and signal connector to a new driver The capacitance is different depending on the manipulator model and the axis Make sure of the driver model which is indicated on the label attached to the side surface The corresponding driver to each manipulator is listed in the following table 114 Maintenance 6 AC Servo Driver 100 W ZA007109 R13ZA00710900 CACR 01 SU23GC ABS ZA007108 R13ZA00710800 CACR AS SU23GC ABS 200w zA007110 R13ZA00711000 CACR 02 SU23GC ABS 100W zA007109 R13ZA00710900 CACR 01 SU23GC ABS EL 400 W ZA007111 R13ZA00711100 CACR 04 SU23GC ABS ra 200w zA007110 R13ZA00711000 CACR 02 SU23GC ABS 100 W ZA007109 R13ZA00710900 CACR 01 SU23GC ABS caes zaari I cicer 200W ZA007110 R13ZA00711000 CACR 02 SU23GC ABS e cas ea a fi a00w zaono riszaooriowo caceansuasce BNACED a Attach the power connector correctly If connected pins are in different position the earth NOTE eS leakage breaker of your factory may trip and the controller may be damaged 8 Mount the driver to the controller and secure it with the four set screws Be sure not to bend the connected cables forcibly or not to pinch il Se 8 Signal connector
36. considered to be de fective Is the operation mode Check the parameter of OPUNIT com OPUNIT of operating unit se mand Some of the functions of operat command in lected properly ing unit are restricted depend on the pa Reference rameter of OPUNIT manual 166 Maintenance 15 Trouble Shooting 15 3 Communication list for failure and trouble If a trouble that does not apply to the description on the preceding pages occurs please copy the communication list on next page enter necessary items and send it to service center by facsimile Send the version data program list and position data simultaneously as required After confirming the contents of the trouble we examine the countermea sures to be taken and contact you 167 Maintenance 15 Trouble Shooting Communication list for failure and trouble Company name Phone Facsimile Manipulator name P Controller name SRC 320 Described in the signature serial No label of a manipulator M CODE Total current conduction duration Described in the M CODE label of a manipulator or controller Displayed when the HOUR command is executed Trouble occurrence date Contents Enter in full detail as far as possible 1 Which type is the trouble Error code abnormal sound vibration generation frequency reproducibility etc 2 When does the trouble occur When the power is turned on during MOTOR ON MCAL and during opera tion etc 3 D
37. equipment However these features are strictly to guard against unforeseen circumstances To ensure safety it is very important that you implement the maintenance inspections described in Maintenance volume of this manual and manipulator manual and that you use the robot correctly The robot is equipped with the following safety features If these features do not function properly refer to 15 Trouble Shooting in Maintenance volume herein and eliminate the cause of trouble Emergency stop switch The optional PC cable for SPEL Editor or SPEL for Windows OPU 300 OPU 320 and TP 320 are all equipped with emergency stop switch The REMOTEI connector of the controller has an emergency stop input terminal that allows you to connect an add on emergency stop switch All the emergency stop switches are connected normally closed When any of the emergency stop switches is pushed the relay for the dynamic brake is activated to shut down the motor power for the robot the emergency status Temporary stop through input from the safeguard The robot temporarily stops operating when you open and close the safeguard Be sure to connect the safeguard switch to the REMOTE connector of the controller Low power mode This mode suppresses motor output The robot automatically enters Low power mode and operates at a controlled slower speed when it is in TEACH mode a mode in which teaching and other operations are performed When the
38. error of RAIOC E Memory check error of ROM Replace the ROM chips on the MPU board 100 Device communication error Check device address connections or MAX DEV setting MPU error by malfunction of hardware 1 Eliminate external noise source and execute VERINIT command Refer to the section 2 6 in the functions volume 2 If this error frequently occurs replace or repair MPU board Refer to the section 7 3 in the maintenance volume 102 Incorrect voltage of the DC7V or DC12V Check the 12V output at PSU Refer to the section 3 3 in the maintenance volume 103 Malfunction of robot control Same as error 101 104 Improper voltage of the DC12V Check the 12V output at PSU Refer to the section 3 3 in the maintenance volume Communication error in internal process error in internal process Same as error 101 Communication buffer overflow of internal process Same as error 101 107 Check sum error of robot model data 1 Check the setting of the DIP switch SD1 on the MPU board Refer to the specifications table in the manipulator manual If the setting is correct replace the MPU board Refer to the section 7 3 in the maintenance volume in the maintenance volume Replace or repair the MPU board Refer to the section 7 3 in the maintenance volume 109 Parameter is abnormal cannot display Turn off and on the controller execute VERINIT command If this error still exists replace the MPU
39. following devices TP 320 option TEACH port connector attached to the TEACH port when shipped PC cable for SPEL Editor or SPEL for Windows option N W A R N N G SPEL Editor and SPEL for Windows are designed so that the robot is operated from outside the safeguarded space for program development Be sure to use the teaching pendant with an enable switch and emergency stop switch when performing the teaching operation within the safeguard space Use PC cable with the label SRC 300 or PC cable with an enable switch Cables without the label have a normally open emergency stop switch that does not function properly exposing you to dangers 8 E STOP CANCEL switch with light Pushing the E STOP CANCEL switch when replacing the TEACH port connector men tioned above prevents emergency stop Functions 1 Part Names and Functions W ARN N G It is dangerous to operate the robot when either of the following symptoms ap pears E The light stays lit even after you take your hand off the CANCEL switch The light does not turn on when you push the CANCEL switch even though the robot is not in the emergency stop condition Either of these conditions indicates the possibility that the emergency stop switch connected to TEACH port is inoperable and needs repair PRG No LED This is a 7 segment 2 digit LED that shows the program number under normal conditions When an error occurs the LED will a
40. j ins XP1 pene oh e anp DS DEN short open short open on the motor power unit short NOTE The controller settings are different depend on the arm length or the stroke even a if the manipulators are the same types or series Refer to the settings of the dip switch SD1 written in the Specifications in the manipulator manual for de tails NOTE Also the controller settings are different depend on the length of the power ca S ble and signal cable Be sure to connect the controller and the manipulator with the cables corresponds to the length appear on the M CODE label Functions 1 Part Names and Functions 1 Part Names and Functions 1 1 Front panel Q Q D D POWER switch Controller power switch There are a leakage indication button yellow and a test button red at right of the controller power switch 2 TEACH port RS 232C connector for connecting a programming unit such as a personal computer This can be used when in the TEACH Mode The baud rate is 9600bps bits per second For safety the robot stops functioning if this connector is disconnected During operation please connect any of the
41. jump between 2 3 67 Functions 9 Switch Types and Jumper Pin Set Up 9 4 Locations of DIP switches and jumper pins on MPU board The position of the DIP switches and jumper pins XP on the MPU board are shown in the figure below I _ l O SD3 XP4 BBBH momo XP2 ROM MPU L XP3 momo XP1 ROM MPU U XP8 ROM DSP XPG PS OOoO0 SD1 SD2 o OOOO0 l 1 12345678 Each DIP switch has bit levers Flipping a bit oni EEEE EE lever to the ON position gives them an on setting Bit lever ON side NOTE Follow the steps described in 7 MPU board in Maintenance volume herein when you gt pullout the MPU board 68 Functions 10 Options 10 Options The following options have their own manuals Please see the each manual for details e Operating unit OPU 300 or OPU 320 e Teaching unit TP 320 e Programming support software SPEL Editor SPEL for Windows e Pulse generating board be installed in controller Here we explain the options that can be installed in the controller except above items Please adhere closely to the following instructions and install options correctly if you want to change the specifications of your robot controller by yourself 10 1 Option types and board current consumption The table below lists the options that ca
42. noise source and execute VERINIT command Refer to the section 2 6 in the functions volume Check arm position data Move the arms to a taught point manually and display the numbers of pulse of this point If the val ues of current are different too much from the numbers of pulse of taught point cali brate the manipulator Refer to the sec tion Calibration in manipulator manual 121 Executed invalid command under emergency stop Release emergency stop status One of condition TEACH REMOTE or REMOTE2 Improper type of data is used 124 Numeric value is out of allowable range ERU XYLIM command 127 Specified ARM is not defined 1 Use already defined arm number S T C NN 128 Specified TOOL is not defined 1 Use already defined tool number m Boateng a 129 LIMZ error 1 Z axis value of target position with JUMP com 1 Set Z axis value of target position lower mand is higher than specified LIMZ value than LIMZ value or set LIMZ value higher than Z axis value of target position Arm reached the limit of motion range 2 Z axis value of current position with JUMP com 2 Set Z axis value of current position lower mand is higher than specified LIMZ value than LIMZ value or set LIMZ value higher than Z axis value of current position 146 Maintenance 15 Trouble Shootin 130 Different LOCAL attribute is specified Define LOCAL by LOCAL command 131 Specified LOCAL is not defined 1 Specify al
43. out completely When the orange LED is faded out the high voltage capacitors are discharged o pere 8 i 9 8 Orange LED M P N C AUTION B Temperature of the AC servo driver PSU and regenerative brake unit may rise depending on the operating condition Check the surface temperature before handling and use the protective gloves if necessary 1 Turn the controller OFF and pull out the power plug from the power source 2 Remove the front panel 3 Disconnect the earth line and connectors X71 and X73 from the back side of front panel 4 Remove the upper cover from the controller As the earth line is connected to the up per cover do not pull the cover unnecessarily 5 wm Remove the upper safety cover of the motor power unit by taking out the two set screws M e e cmq HUN 5 L loo00L c md o oocoo LR A L JLQ 8 i99 5 108 Maintenance 5 Motor Power Unit 6 Remove the driver safety cover by taking out the three sc
44. plug from power source so that the controller is locked out 3 Remove the four front panel mounting screws and take off the front panel On the inside of the front panel there is a cooling fan Do not pull hard when taking off the front panel as it is connected to the inside by a cable 4 The MPU board is fastened with a screw on the right and left Loosen the two screws Do not pull out the screws because it will drop the nuts into the controller 5 wm Hook your finger on the board bracket and pull the board out 6 wm Install two RAMs on the MPU board into sockets U11 and U12 Be careful to always try to keep from touching any of the components Be careful with the direction of RAM See the drawing below pm 5s Fl O SD3 XP4 ago Omo XP2 ROM MPU L XP3 Omo XP1 ROM MPU U MPU board XPS U11 ROM DSP XP6__XP5 U12 M OOOO SD1 SD2 Oo OOOOO l 4 MPU board bracket LLLLLELELELELELIELLLILE 4 SRAM type x 2 pcs 71 Functions 72 10 Options NOTE NOTE 7 8 9 Plug the jumper socket into jumper pin XP6 Use one of 5 jumper sockets which are shipped with controller By this jumper socket the additional RAM module will be backed up by battery Do not disassemble other jumper pins Se
45. program executed from the very begin ning the robot controller must have been reset in the state where RESET out is being output Input of this signal moves the manipulator to the home posi tion Input of this signal specifies the program to load at input of START to execute a program For further details refer to SPEL III Reference manual for PRGNO command MCAL Input of this signal executes calibration Motor Power ON Input of this signal turns the motor power ON Motor Power OFF Input of this signal turns the motor power OFF The validity of the input signal depends on the console settings or the selected mode Refer to 7 3 Valid invalid input signals in this chapter 50 Functions 7 I O Remote Set Up REMOTES REMOTES Output Signal Functions This signal is output when the robot controller is in the reset state Make sure that this signal is being output and that the START RESET output signal is NOT being output when the following signals input to the REMOTE3 START HOME MOTOR ON MOTOR OFF MCAL and Program No This signal is output while execution of a program is on hold Execution of a program will be put on hold at the input of PAUSE PAUSE input signal and the robot will stop operating When the pause process completes this PAUSE output signal will be output This signal is output when the robot controller is either execut ing a program or undertaking a command Make sure that this s
46. safeguard is opened while the robot is in AUTO mode the robot temporarily stops operating and enters Low power mode Enable switch The optional PC cable for SPEL Editor or SPEL for Windows is equipped with enable switch The robot temporarily stops operating when both the safeguard and the enable switch are open making it safe to perform teaching operations Mode switch with key The operating unit is equipped with a mode switch that can only be operated with the use ofa key Removing the key when the robot is in TEACH mode prevents the robot from switching to AUTO mode making it safe to perform teaching operations See the operating unit manual Dynamic brake Dynamic brake circuit consists of a relay that switches the connection of motor power line to make a short circuit on the motor side or to connect to the AC servo driver When emergency stop is input or the following malfunction is detected the dynamic brake activates and stops the rotation of motor Functions 10 1 Part Names and Functions Overheating detection A thermostat inside the controller detects overheating Encoder discontinuity detection Detects discontinuity of the signal wire from the motor encoder to the controller Overload detection Detects loads that exceed the capacity of the motor Torque irregularity detection Detects irregular motor output Speed irregularity detection Detects irregularities in motor speed
47. the emergency stop condi tion If you are not using a personal computer or TP 320 connect the TEACH port con nector The TEACH port connector is connected to the TEACH port prior to shipping When changing connectors do so while pushing E STOP CANCEL switch to the left of the TEACH port to avoid the emergency stop condition It is dangerous to operate the robot when either of the following symptoms ap N WARNING pears E The light stays lit even after you take your hand off the CANCEL switch E The light does not turn on when you push the CANCEL switch even though the robot is not in the emergency stop condition Either of these conditions indicates the possibility that the emergency stop switch connected to TEACH port is inoperable and needs repair 21 Functions 3 TEACH Port 3 1 Personal computer connection N W AR N N G W SPEL Editor and SPEL for Windows are designed so that the robot is operated from outside the safeguarded space for program development Be sure to use the teaching pendant with an enable switch and emergency stop switch when performing the teaching operation within the safeguard space Wi Use PC cable with the label SRC 300 or PC cable with an enable switch Cables without the label have a normally open emergency stop switch that does not function properly exposing you to dangers The following is information on connecting a personal computer Programming is done by a pe
48. the manuals and have equivalent knowledge or skill E To avoid an electric shock do not touch the dangerous high voltage parts marked with the orange label when the power is ON 1 Turn the controller OFF and pull out the power plug from the power source 2 Remove the front panel Do not disconnect the connectors that are attached to the back of the front panel 3 Wait until the orange LED M P on the front of the motor power unit is faded out wm completely 4 Remove the driver safety cover by taking out the three screws Driver safety cover 4 9 meses poonam le Ce I du vs UE ra o 4 E 5 Check that the connectors X20 to 26 and X28 X29 attached to the motor power unit are securely attached If the connection is loose reconnect it securely 6 wm With the front panel off plug the power cord and turn the controller ON 7 Check that the green LED ACF on the front of the motor power unit is lit The or ange LED is dimly lit
49. the table below 73 Functions 11 Specifications 11 Specifications 11 1 Standard specifications 4 axis simultaneous software AC servo control Speed control 1 to 100 programmable Accelera tion Decel eration control Point to point control Continuous path control Memory media RAM disk Racked Up by Hum banery Battery life 5 years in normal temperatures 50 pin D Sub 1 pcs 24kg standard AC 200 to 230V 10 Single phase 50 60Hz 1400W max differ with manipulator models Emergency stop switch CPU irregularity detection Enable switch Servo overflow detection Dynamic brake Overheating detection Overload detection Encoder discontinuity detection Motor lock detection Speed irregularity detection Mode switch with key Torque irregularity detection Low power mode Memory irregularity detection Control power source irregularity detection Primary power source irregularity detection Temporary stop through input form safeguard Environmental requirements 5 to 40 C s 10 to 80 96 Relative n nmidity with no condensation Control method 1 to 100 programmable Automatic acceleration Safety functions 74 11 Specifications Functions 11 2 Outer dimensions unit mm IOU 10 QEZ M 445 30 25 460 ss 4 30 43
50. with a functional interlock switch on the safe guard It is dangerous to operate the system with the switch wound in tape 26 NOTE or without the on off conditions since the safeguard input functions will not operate REMOTE I has input terminals for the safeguard and the emergency stop In order to maintain a safe working zone it is necessary to erect a safety enclosure around the manipulator The interlock switch of this safeguard should be connected to RE MOTEI Safety functions such as momentary interruption of the program and switch to low power mode are activated when the safeguard is opened Further the extended emergency stop input terminals are used when additional emergency stop switches are added or the operating unit is not used PNP type or NPN type remote board is available The pin assignments are different be tween each type remote boards Confirm which type you select and refer to appropriate section of this manual when wiring Although NPN type remote board is not labeled PNP type remote board is labeled as the drawing below O P TYPE label O P TYPE REMOTE1 RS 232C REMOTE1 RS 232C dC Jb dC 35 Oo co BI o REMOTE2 He iS s Ed iS sS RI 2 m amp n E is E m amp n E Ds e eC slo B e 909 oC We el jo G jo
51. 0 480 OS OOT 0 25 60 120 9c 0c OL SI 17 fn 23 5 75 Functions 11 Specifications 76 Maintenance The maintenance volume describes the maintenance procedure for each part in controller SRC 320 Maintenance 1 Outline of Maintenance 1 Outline of Maintenance 1 1 Safety precautions on maintenance Please carefully read this manual and other related manuals before performing any routine maintenance N WARNING B Only trained personnel should be allowed to operate perform function testing and maintain this robot and the robot system Trained personnel are those who have taken a robot training course held by the dealer on a regular basics or those who have carefully read the manuals and have equivalent knowledge or skill B When you execute the maintenance work or the inspection of the controller be sure to take the specified locking procedure for each robot system before start ing the work Do not touch the high voltage dangerous part to avoid an elec tric shock Be sure to turn the power of the controller off pull out the power plug from the power source and wait 2 minutes or more to discharge the ca pacitors before starting maintenance E Do not test the manipulator within the safegua
52. 0100 for MPU board Lithium battery ZA006002 R13ZA00600200 for MPU board connector type 169 Maintenance 16 Maintenance Parts List RS 232C driver Z1526301 R13Z152630100 PF for REMOTE board Cooling fan ZA006501 R13ZA00650100 Hybrid IC for input 21526303 R13Z152630300 SEPOOSA d c SLM oari Hybrid IC for output NPN Z1526304 R13Z152630400 SEP007 for protected I O board or REMOTE Hybrid IC for output PNP Z1526305 R13ZI52630500 SEP008 board Transistor array 21062620 R13Z106262000 for standard I O board ZA006401 R13ZA00640100 PC cable with emergency stop 7002102 R13ZA00210200 with E STOP switch switch PC cable with enable switch 74002101 R13ZA00210100 c enable EN PC cable adaptor 25 25 pins a PC cable adaptor 25 9 pins Po D C EM NN p NK 170
53. 09 125 m o sd emhspa v 26 42 58 74 90 106 122 4 upmraspse m orgoz m3 3 0 0 I5 12 28 44 60 76 MO ERE 7 a4 so 46 62 78 o4 n0 126 42 i9 Owpw 0 16 3248 64 80 96 11244 Output common GND 21 2 18 34 50 66 82 98 114 Output common GND 22 3 r9 ss st 67 83 99 115 47 24 V output 23 4 20 se s2 68 s4 100 116 48 24 Vowpur 24 5 J21 37 53 69 85 101 117 2s 6 22 38 54 70 86 102 118 50 324 VGNDoupur 47 Functions 7 I O Remote Set Up REMOTES 7 O Remote Set Up REMOTES You can set up a remote function in I O 1 and use it as REMOTE3 You can use this as the console when in AUTO mode in place of operating unit OPU 300 or OPU 320 to im plement various controls 7 1 Remote set up The input output number and functions of I O 1 that can be set up as REMOTE3 are as shown in the pin assignment chart on the next page You can select and use functions in dividually Input output for which you have not set up a remote function can be used as a normal I O You can easily set them up using the Remote Set Up of SPEL Editor or SPEL for Win dows See those manuals for details N W ARNING E Before setting up a remote always confirm that connections match remote functions An output function at which you have set up a remote automati cally outputs in accordance with the state of the controller Connections that differ from the setting ca
54. 138 14 1 Additional RS 232C board replacement 138 14 2 Protected I O board replacement ssssssssssss 139 LOS rOUDIGS SHOOUNGE easy soma en RU PME 140 15 1 Error code table einai e ee ae Pe dua 140 15 2 Troubles whose error codes are not displayed 157 15 3 Check list during inquiry seen 167 16 Maintenance Parts List sss 169 Functions The Functions volume describes the basic functions of the controller Please refer to sections in this volume for safety features connection to the other peripheral equipment and standard settings Functions Various combinations of controller settings and specifications Various combinations of controller settings and specifications The various settings and the specifications of the controller are different depend on the ma nipulator models Therefore be sure to connect the controller to the manipulator with the same M CODE See the following table of the specifications and settings for each manipulator models i not exist exist not exist motor specification MPUUas MPUUax MPU board ROM name MPULas MPULax DSP as DSP ax Setting of the jumper pins XP3 200W ABS tti f the j ins XPI PEDE Or QUIM Sr paas short short open open short on the motor power unit OOOO O see mees oos os exist motor specification MPUUae MPU board ROM name MPULae DSP as ae jumper pins ae tti f the
55. Corporation Other brand and product names are trade marks or registered trademarks of the respective holders Please direct any inquiries about the use of this manual to SRC 320 controller manual SEIKO EPSON CORPORATION Sales Engineering Group TEL 81 266 24 2004 FAX 81 266 24 2017 iii Safety Precautions Please carefully read this manual and any other manuals before installing this robot system and definitely before connecting cables Keep this manual in a handy location for easy access at all times This sign indicates that a danger of serious injury or death NN WARN l N G will exist if the instruction thereunder is not followed This sign indicates that ignoring the instruction there under A CAUTION may cause harm to people or physical damage to equip ment and facilities N WARNING The robot system manufacturer supplier must design and construct robot sys tems in accordance with the principles described in Safety section of the User s manual Please read user s manual first This robot has been designed and manufactured strictly for use in a normal indoor environment Do not use the robot in an environment that exceeds the conditions set forth in the manuals for the manipulator and controller Do not use the robot outside of the usage conditions and product specifica tions described in the manuals Doing so will not only adversely affect the life of the product but may also present a serious safety
56. E 0 command in reference man mand is different ual Function not supported for this manipulator 149 The command can not be used in MOTOR ON condi tion 150 Motion command is executed under MOTOR OFF condition 147 Maintenance 15 Trouble Shooting 151 Positioning cannot be completed by specified FINE 1 Check disconnection of motor power cir cuit or loose connection Then check the motor power unit and the voltage of AC servo driver Refer to the section 5 2 of the maintenance volume 2 Eliminate binding factor such as an obstacle if arm is bound 3 Check each axis motion moving by hand Secure the arm locking bolts tightly if looseness of them are found Also check each reduction gear Verify appropriate lubrication or replace if necessary Refer to the manipulator manual 4 In other case than the above replace motor AC servo driver and or MPU board Re fer to the section Motor replacement of the manipulator manual the section 6 3 and or 7 3 in the maintenance volume of this manual 153 CP motion cannot decelerate and stop in specified 1 Prepare enough deceleration distance distance 2 Don t finish operation with CP motion without deceleration 154 The axis 4 movement exceeds limit of its movement There is limit for axis 4 movement of the ro bot which has ball screw spline unit 155 Communication error with Servo CPU at internal process 156 Malfunc
57. E board parts The REMOTE board controls 7 segment display of the front panel as well as REMOTEI REMOTE2 and RS 232C 20 and 21 E a 2 o o XP9 D E XP8 XP7 XP4 XP5 XP6 XP2 D 1 XP3 Handle E E bo EPSON SKP345 2 REMOTE BOARD D Jumper pins XP2 to 8 The functions of the jumper pins are described in the table below Do not change the setting of XP1 Function when shorted Setting Also outputs for emergency stop occurrence Also outputs for error occurrence 1 2 Latches the state of safeguard open 2 3 Does not latch the state of safeguard open dumper ane Uses one contact safeguard switch 1 2 Outputs the safeguard status that CPU recognized Jump 1 and 2 2 3 Outputs the actual safeguard status Reserved for system Factory set and fixed Jump 2 and 3 TEACH interface RS 232C 21 interface MC145406P RS 232C 20 interface REMOTE2 OPU interface 124 Maintenance 8 REMOTE Board 8 2 REMOTE board and parts replacement N C AUTI ON B When connecting or disconnecting the REMOTE board make sure the power is turned OFF B Mount REMOTE board in fixed slot labeled REMOTE If the REMOTE board is not functioning properly replace it or the parts in question by following the steps below 1 Turn OFF t
58. EMOTE1 PNP type Input circuit Emergency stop input current 100mA typical Safeguard input current 2mA typical for 24V input Output circuit Rated output voltage DC 12 to 24V 10 Maximum output current 250mA 1 output Power MOS FET Example wiring REMOTEI T2 ii 6 Emergency stop input TEACH REMOTE2 19 Dynamic brake relay VCC V o 7 Safeguard input 1 Latch S M t circuit vee 20 MCI v v 1 B XP6 8 Safeguard input 2 D Latch 1 t circuit k vee i 21 3 V olo Y 9 Latch release input Pllgl 1 e e XP4 XP5 il 22 1 2 Latched i 2 3 Unlatched p GND DC cae aes 2 System error output d is e e a a Inductor es e Pe oe ee ee ee ee Ec m 15 JE stop condition output Same circuit as above i e L 7 9 XS o a NEM REALE IRE F 3 Safeguard output Same circuit as above e L ar Sc te Ge es ope ah 1 16 Enable condition output Same circuit as above NP L nee 4 High power condition output Same circuit as above 4 DORT Im E ee 4 17
59. EPSON ROBOT CONTROLLER SRC 320 EM010C898F ROBOT CONTROLLER SRC 320 Rev 7 Copyright 1995 2001 SEIKO EPSON CORPORATION All rights reserved i WARRANTY The robot and its optional parts are shipped to our customers only after being subjected to the strictest quality controls tests and inspections to certify its compliance with our high performance standards Product malfunctions resulting from normal handling or operation will be repaired free of charge during the normal warranty period Please ask your Regional Sales Office for warranty period information However customers will be charged for repairs in the following cases even if they occur during the war ranty period 1 Damage or malfunction caused by improper use which is not described in the manual or careless use 2 Malfunctions caused by customers unauthorized disassembly 3 Damage due to improper adjustments or unauthorized repair attempts 4 Damage caused by natural disasters such as earthquake flood etc Warnings Cautions Usage 1 If the robot or associated equipment is used outside of the usage conditions and product specifications described in the manuals this warranty is void 2 If you do not follow the WARNINGS and CAUTIONS in this manual we cannot be responsible for any malfunction or accident even if the result is injury or death 3 We cannot foresee all possible dangers and consequences Therefore this manu
60. Motor Power OFF input Motor Power output 40 Ins 330 ms MCAL input MCAL output HOME input SM EE HOME output GENS dde 57 Functions 7 I O Remote Set Up REMOTES Timing chart for program execution START input RESET output turns OFF and START output turns ON 5ms after the input of START while at the RESET state In case of specifying the program No by binary code Turn ON the Program No within 5ms before START input and hold it while the program is executed The Controller must be at the RESET state The program No input will be ignored if entered when the Controller is not at RESET state If the binary code specifies zero 0 that means to designate the program and the position data already in the main memory START input E o ee START output i Y RESET output Program No input Hold the data to the program end PAUSE input and RESET input PAUSE output turns ON and START output turns OFF 230ms after input of PAUSE but only when the QP command is ON When the QP command is OFF PAUSE output will not turn ON until the arms are stopped Once there is PAUSE input it requires at least 230ms before input of START START output will be ON 15ms after the START input for restarting and the PAUSE output will turn OFF When RESET is input during the PAUSE state it takes 800ms for RESET output to turn ON and PAUSE output to turn OFF There is a brief output of START immediately be fore the RE
61. Motor power condition output Same circuit as above d LL 10 11 Common GND 23 24 Common DC 424V 0 1 T L Abnormal occurrence 14 relay contact output AX Contact rating AC 250 V 1 A yK DC30V1A Cas 9 24 V 12 13 24 V output Caution System error 9 V0 Qmm XP2 GND 25 26 424 V GND output Emergency stop o enne e e XP3 v Internal 24 V power Hor B Current capacity 1 A max E Do not use internal controller power and external power simultaneously as it N CAUTION can result in damage Functions 4 REMOTE1 4 5 Pin assignment of REMOTE1 NPN type The pin assignment of the REMOTE connector for NPN type is as shown below E Pins 12 13 and 25 26 are for user s 24V power This is the same as the power on I O so please be careful of the power capacity N CAUTION The pins for an emergency stop circuit are both connected to the internal 24V power from the controller Please follow the wiring examples to con nect your emergency stop circuit Any other wiring than sampled should be avoided 1 Abnormal occurrence relay l SEE QUIS Relay contact output upon occurrence of sys 14 Abnormal occurrence relay tem error contact output Output from system error CPU inoperable Emergency stop output Output from emergency stop condition Safeguard output Output from safeguard when open Enable condition output Output f
62. N B i os 0 o2 8 SS ie XQT amp amp wo E START END RESET RESET START otg 2 ie 8 Gage j c i IER HIGH 3 oog JY z 2 H STOP E EER AB POWER LOW MOTOR ON F EEG 2 mt 9 amp 38 E Pause E Low power state High power state P PAUSE code input from TEACH port PAUSE command E ENABLE switch input from TEACH port Command execution direct commands except for motion commands is not affected the enable switch and safeguard 30 Functions 4 REMOTE1 The Low Power High Power state selection differs as shown below based on the combina tion of the safeguard status open closed and power mode set by POWER command POWER LOW LP ON POWER HIGH LP OFF Low power state Safeguard closed High power state In order to achieve high power state follow the procedure below 1 Close the safeguard after confirming that there is no person in the safeguard 2 Push the latch release switch In case that the jumper pins XP4 and XP5 on remote board are set between and 2 3 Enter the POWER HIGH or LP OFF command Any of the following conditions causes cancellation of the POWER HIGH LP OFF com mand and selection of the low power state Switching between TEACH and AUTO modes Execution of the POWER LOW LP ON command Execution of the RESET command for an error requiring reset or turning on the power again Execution of the MOTOR ON command Pushing the STO
63. No STATUS LED Front board Cooling fan Filter TEACH port Front panel Back side of front panel 82 Maintenance 2 Outline of Structure 2 3 Diagram of cable connections Xl Shield Y Al c LL Z PE D to CHASSIS OOOOOOOO00O OOO0O c QFIQ0A E f E 5 NF1 X19 FG C JOUT IN 2t JOUT IN X11 X14 X15 BOARD BACK PSUI roO esvia2v PSU2 PSUS
64. Operating unit I or REMOTE2 connector Controller lo OPE ONDE 10 Ground Programming unit PC or 6 TEACH port Teaching pendant or TEACH port connector J D V0 1 REMOTES gt Input output unit le 8 RS 232C 20 21 gt Peripheral unit host computer etc D M C power cable Cables with 17 pin round connectors on both ends Connect the female connector to the manipulator POWER connector and the male connec tor to the controller M C POWER connector Insert the connectors and rotate clockwise until you hear a click 16 M C signal cable Functions 2 Installation Cables with 68 pin square connectors on both ends Connect the signal cable to the manipulator SIGNAL connector and controller M C SIG NAL respectively Using the two fitting screws attached to the connectors tighten down the connectors so that they will not come loose 8 Safeguard switch connection REMOTE1 REMOTE2 Please be absolutely certain to erect a safety enclosure around the robot area Connect that safeguard switch to the input terminal of the REMOTE safeguard Since this input terminal is normally closed the robot will not operate normally if the safeguard switch is not installed Details of the connector are included in 4 REMOTE1 in this volume Connect the optional operating unit OPU 300 or OPU 320 to REMOTE2 Please refer to the separate manual for the operating unit for details I
65. P key Pushing the Ctrl C keys 31 Functions 4 REMOTE1 4 3 Pin assignment of REMOTE 1 PNP type The pin assignment of the REMOTE connector for PNP type is as shown below E Pins 12 13 and 25 26 are for user s 24V power This is the same as the power on I O so please be careful of the power capacity N CAUTION The pins for an emergency stop circuit are both connected to the internal 24V power from the controller Please follow the wiring examples to con nect your emergency stop circuit Any other wiring than sampled should be avoided 1 Abnormal occurrence relay l contact output Relay contact output upon occurrence of sys 14 Abnormal occurrence relay tem error contact output Output from system error CPU inoperable Emergency stop output Output from emergency stop condition Safeguard output Output from safeguard when open Enable condition output Output from enable condition High power output Output from high power condition BR o o MEET URN Ct ERE RT fer Emergency stop input For connection to normally closed emergency Emergency stop input stop switch Safeguard input 1 Safeguard input 1 m For connection to safeguard input Ec Safeguard input 2 Safeguard input 2 EN Latch release input For connection to normally open switch that Latch release input release the latch of safeguard open Common GND For supply power for REMOTE internal Common DC circuit Common GND For supply pow
66. Replace the AC servo driver Refer to the section 6 3 in the maintenance volume 187 o Driver detected improper torque speed 189 Encoder S phase signal is not transmitted within pre determined period of time 191 Encoder overspeed Confirm whether any axis moved at power on If axis 3 moved inspect the axis 3 brake Refer to the section Replacing the brake of manipulator manual 382 Encoder data eor 000 193 Encoder battery error 1 Check the voltage of the battery on the sig nalrelay board Replace it if the voltage is less than 2 8V Refer to the section Re placing the signal relay board of the manipulator manual 2 Check disconnection of line between the motor encoder and signal relay board Refer to the manipulator manual 194 Encoder check sum error Calibrate the axis Refer to the section Calibration of manipulator manual If this problem still exists replace the motor Refer to the section Motor replacement of manipulator manual 154 Maintenance 15 Trouble Shooting Encoder backup error 1 This is the error shown after replacing motor with absolute encoder 2 The battery voltage on signal relay board is im proper 3 The voltage of encoder power ENC 5V is im proper 4 Other than the above Framing error of encoder data 1 This is the error shown after replacing motor with absolute encoder 2 Strong external noise source exists 3 O
67. S DB 25ST N S1 oiu Via D T a m A z A G Z IQo av UJ li N G Ov UJ w w N N p N N N wi gt Nn N N N N UA O 3 4 lt 0 ESTOP E STOP Z Z AJQ Z Q N lt Ei N T Cx eS fe tre te te te AIJAI INe o w lt N z Nj 22 3HOME ENC 5V ENC 5V 85 Maintenance 2 Outline of Structure PNP type REMOTE board T O board REMOTEI REMOTE2 Cable side ENTE vo connector 0126 3000VE 0120 3000VE Controller side num UE connector 0226 52A2JL 0220 52A2JL Pin 1 E STOP RS 232C 20 RS 232C 21 DE 9SF DESP JB9P 5 SG 5 NC 5 e fesom o xc 5 rs suem s react es jam ew e mpew sfe 86 DE 9SF DESP JB9P I O 1 DB 50PF N DB 50ST N S1 Iw 29 ours IN3 30 NC IN4 OUT 10 rs ave nc gt 7 worm OUT COM Maintenance 2 Outline of Structure NPN type REMOTE board T O board REMOTEI REMOTE2 RS 232C 20 RS 232C 21 I O 1 Cable side connector 10126 3000VE 10120 3000VE DE 9SF N DE 9SF N DB 50PF N Controller side connector 10226 52A2JL 10220 52A2JL DESP JB9P DESP JB9P DB 50ST N S1 Pin 1 RLY 1 DG IN COM 0 26 OUT7 5 jI 30 NC 3 N3 s Nc 6 ina at fourio 8 E3 5 NC 5 ESTOP efeso s wc s HEB HESS ER Pee fo av Ts hepew foo
68. SET operations are to be completed In order to turn OFF the Program No input it would have to be at least 10ms past after RESET output is turned OFF START input START output 230 ms 230 ms 5 ms PAUSE input EX PAUSE output RESET input RESET output oL IE Program No input 58 Functions 7 I O Remote Set Up REMOTES Timing chart for safeguard input Safeguard output turns ON 5ms after the input of Safeguard while at the START state After 320ms PAUSE output turns ON and START output turns OFF The PAUSE state is maintained while the Safeguard input is ON the Safeguard open is latched Safeguard output turns OFF 5ms after the Safeguard input turns OFF when the safety door is closed Close the safety door to turn OFF the input of Safeguard and turn ON the Latch Release input to restart While PAUSE output is ON RESET can be input Safeguard input E 1 5 ms 5ms Safeguard output o o E START output o oee PAUSE output se cS 59 Functions 7 I O Remote Set Up REMOTES Timing chart for TEACH mode and AUTO mode Regardless of whether operating in TEACH mode or AUTO mode if you switch modes during execution there will be a pause and then the controller will be reset The charts below show a switch to TEACH mode when AUTO mode was operating Switching modes in the START state It takes 230ms for mode output to switch when you switch modes i
69. SU3 and the related devices below Maintenance 3 PSU Check for PSU1 and the related devices If there is malfunction short circuit somewhere in the 5V power circuit that is output from PSUI the upper circuit protector will activate and the 8A button should come out If there is malfunction short circuit somewhere in the 12V power circuit the lower cir cuit protector will activate and the 1A button should come out 1 Turn OFF power to the controller and check that the orange LED M P on the front of the motor power unit is faded out completely B Controller has the capacitors charged high voltage To avoid an electric N WARNING P Erg e shock do not touch the dangerous high voltage parts marked with the orange label until the orange LED of motor power unit is faded out completely When the orange LED is faded out the high voltage capacitors are discharged me oF Ts 6 Ss 8 8 8 omero iI 2 Detach one of the device whose power is supplied from PSU1 as shown in the previous table 3 2 Power supplies from PSU Refer to the described method of disconnect ing for replacing each part W ARN N G E Temperature of PSU may rise depending on the operating condit
70. Ss RUTER o ZApert cay 7 i 100 Lov TD E BEX M E b i 91x EnSd SIX INE uu pp MESS B 5 B FG YOESNMH IBI y Oo p b619 5 618 I lt lt 94 IBI o amp FM FT INE gt 2 20 9813 OVI E Sg EOS pU 5 o zr zav Q Arat gt gt 380 771 SRI M rem e ZEX IE IBI ds lt EIX znsd PIX ursa o specu amp i8 H08 LI 1 gn z 30 9419 g Me EEN E um E as o e azi gt G NNOSB 1 cM N3 HH po 79 01 Z1 SZH pjerus cC zo BO O3 i 1 GND SO gers G8 5j ERES ic i oc Ut2 g Gm 6 GU SOON peus Gn ey mu E ms0 X KS 1409 19v 4 TE i i 100 NI i e d n zb lobi aD Gg USB NE zs LAN 80 vui vm al D LEX mao y 19 140 o OVI L L 5 ZIX LASd c O Oo eb C am 88 Maintenance 3 PSU 3 PSU 3 1 PSU layout PSU2 PSUI mmmmmmiim ommmmm for EL EH BL XM3000 series 4 ULUUUUUUUMUUUUL UUW Y PSU3 9 i AL MPU board Motor power unit OR LR RJA S iR PSU comprises three switching power supplies PSU1 PSU2 PSU3 that output the vari ous voltages used inside the controller The voltages output by each power supply are shown below Model Input voltage Output voltage PSUI LWTS0H 522 AC 200 t
71. a one contact switch be sure to short the jumper pin XP6 on the REMOTE board so that the other input to which a switch is not connected will be connected internally 25 13 o 26 A rta 26 N A am Sy 14 1 14 15 1 REMOTE connector Cable side REMOTE connector details for wiring Controller side Functions 4 REMOTE1 4 6 Circuit diagram and example wiring of REMOTE1 NPN type Input circuit Emergency stop input current 100mA typical Safeguard input current 2mA typical for 24V input Output circuit Rated output voltage DC12 to 24V 10 Example wiring REMOTE1 s Me 6 Emergency stop input TEACH REMOTE2 19 Dynamic brake relay VCC V 9 i 2 7 Safeguard input 1 Latch ifi 20 circuit VCC 9 ES 9l XP6 3 le i 8 Safeguard input 2 atch T 21 circuit voc 4 alte i v 7y olo 9 Latch release input Xp4 99 xps t d 2 1 2 Lat
72. able resistor RV1 as follows When the voltage islow turn RV1 clockwise 1 2 graduation When the voltage is high turn RV1 counterclockwise 1 2 graduation After adjusting the variable resistor firmly insert the PSU board back into the desig nated slot labeled PSU and repeat steps 4 to 6 If the voltage value is within the specified range turn the controller OFF and attach the X131 connector to the axis 3 motor Return the connectors X31 and X131 to its original position referring the chapter of Replacing the Motors in the manipulator manual If you pulled out the PSU board be sure to re tighten its upper and lower set screws Maintenance 5 Motor Power Unit 5 Motor Power Unit 5 1 Layout and function of motor power unit parts The motor power unit consists of the motor main power supply circuit to the AC servo driver and the dynamic brake circuit i foem menu eese eere XPI Y X24 X23 X22 X21 HLI M P HL2 ACF aHL3 MPC X25 X26 x29 For EL EH BL XM3000 series X28 1 LED HL1 HL2 HL3 A description of the monitoring performed by the LED in the motor power unit is shown in table Description of display when on HLI1 Motor main power supply is being output HL2 ACF AC power supply is being input HL3 MPC Motor is on 2 Jumper pins XP1 103 Maintenance 5
73. acceleration ACCEL command in subtle movement within value Reference manual 10 mm with the arm spread 8 Is the operation that coin 8 Change the speed and SPEED ACCEL cides with the characteris tic vibration frequency of the arm not performed acceleration slightly The arm vibrates during low speed operation command in Refer ence manual Diagnosis Correction See 1 Does vibration occur in only a low speed area 2 Does the level vary with the arm position vibration 2 1 If vibration occurs in a high speed area see No precision cannot be obtained during in stallation and The arm vibrates The resid ual vibration during positioning completion is high described previously This phenomenon is not abnormal because the input rotation of reduction gears resonates with respect to the characteristic vibration fre quency determined by Change the speed before use the arm position 163 Maintenance 15 Trouble Shooting An abnormal sound is generated during operation An abnormal sound is generated during stop Diagnosis Correction 164 Diagnosis Correction Assign the generation source by operating the system via a single shaft or operating it manually 1 Is the tension of a timing belt proper 2 Does the axis 3 brake operate normally Does the cover or ca ble not strike against anything else Is the fixing screw of the cover not loose I
74. ace where the controller is 9 Check disconnection of the motor power line in manipulator and controller Refer to the manipulator manual and 2 3 Diagram of cable connection in the maintenance volume of this manual 10 Replace the AC servo driver the maintenance volume Refer to the section 6 3 of 151 Maintenance 15 Trouble Shooting 181 Driver overload e When the red LED on the front of the AC servo driver is off 1 External noise source exists 1 Eliminate external noise source and execute VER INIT command Refer to the section 2 6 in the functions volume If no external noise source exists replace the MPU e When the red LED on the front of the AC board Refer to the section 7 3 in the maintenance servo driver is lit volume 2 Weight of the end effector and work piece 2 Check actual weight and set proper WEIGHT exceeds rated payload Refer to the section Load weight and the WEIGHT setting of manipulator manual 3 Motion duty of manipulator is too much 3 Reduce operation speed of the robot Refer to ACCEL SPEED and WEIGHT command of the reference manual 4 Mechanical load is added on axis 4 Check each axis motion moving by the hand Ver ify appropriate lubrication or replace the reduction gear Referto the manipulator manual 5 Tension of the timing belt is not proper 5 Check tension of the timing belt Tighten or replace if necessary Refer to the section Replacing th
75. al cannot warn the user of all possible hazards SERVICE CENTER Contact the following service center for robot repairs inspections or adjustments Please have the model name Serial No or M CODE software version and a description of the prob lem ready when you call If service center information is not indicated here please contact the supplier office for your region as listed in the following SUPPLIERS section SUPPLIERS Japan amp Others SEIKO EPSON CORPORATION North amp South America Europe NOTICE TRADEMARKS Okaya Plant No 2 1 16 15 Daiei cho Okaya shi Nagano ken 394 0025 Japan TEL 81 266 23 0020 switchboard 81 266 24 2004 direct FAX 81 266 24 2017 EPSON AMERICA INC Factory Automation Robotics 18300 Central Avenue Carson CA 90746 TEL 562 290 5900 FAX 562 290 5999 E MAIL info robots epson com EPSON DEUTSCHLAND GmbH Factory Automation Division Zuelpicher Str 6 D 40546 Duesseldorf TEL 49 211 5603 391 Inside Sales FAX 49 211 5603 444 E MAIL robot infos epson de E No part of this manual may be copied or reproduced without authorization BI The content of this manual is subject to change without notice B We ask that you please notify us if you should find any errors in this manual or if you have any comments regarding its content Microsoft is a registered trademark and Windows and Windows logo are registered trademarks of the Microsoft
76. an enable switch Cables without the label have a normally open emergency stop switch that does not function properly exposing you to dangers 17 Functions 2 Installation Q WVO 1 If you have input output units connect them to this connector The details regarding I Os appear in 6 I Os in this volume and details regarding RE MOTES appear in 7 I O Remote Set Up in this volume RS 232C 20 21 If you have communications units connect them to this connector Details of this connector appear in 8 RS 232C in this volume 18 Functions 2 Installation 2 6 Noise countermeasures Please pay attention to the following points when wiring the system To ground the controller chassis is very important not only for prevention from electric shock but also for reducing the electric noise influence around the controller There fore be sure to connect the yellow green wire in the power cable of the controller to the earth terminal of the factory power supply See the section Power Plug in 2 4 Power in this chapter Do not tap into a power source which is supplying power to a piece of equipment which may cause noise Useatwisted pair motor power line Do not run AC power lines and DC power lines in the same wiring duct and separate them by at least 200 mm For example separate the AC motor power line and the controller power line by at least 200 mm from the sensor or valve I O l
77. ard 5 Firmly insert the new PSU board all the way into the designated slot labeled PSU and re tighten the screws 101 Maintenance 4 PSU Board 4 4 ENC 5V encoder 5V power supply adjustment N WARNING B Only trained personnel should be allowed to perform the following operations Trained personnel are those who have taken a robot training course held by the dealer or those who have carefully read the manuals and have equivalent knowledge or skill 102 3 4 5 6 7 8 9 YY wm wa Turn the controller OFF Disconnect the power connector X131 of the axis 3 motor of the manipulator Refer to the chapter of Replacing the Motors in the manipulator manual For safety reasons set the controller in TEACH mode then turn ON the controller Pull the X31 connector closest to the servo motor s encoder of the manipulator to the outside Refer to the wiring schematics Outline of connection and Block dia gram in the manipulator manual There is no need to disconnect the X31 connector Measure the voltage at EGND and ENC 5V of the X31 connector that you pulled out without disconnecting Check that the voltage is between 4 80V and 5 05V BN BL CL XM3000 RT3300 in No 8 in No 7 m ES EL EC EH BNA CL pin No 13 pin No 12 If the voltage is not within the specified range turn the controller OFF then pull out the PSU board and adjust its vari
78. ard accessory If you install additional I O boards you can use 16 inputs and 16 outputs multiplied by the number of I O boards The maximum number of input and output point is 128 When you are connecting wires see 2 6 Noise countermeasures in this volume PNP type or NPN type I O board is available The pin assignments are different between each type I O boards Confirm which type you select and refer to appropriate section of this manual when wiring Although NPN type I O board is not labeled PNP type I O board is labeled as the drawing below P TYPE label P TYPE o o e PNP type I O board NPN type I O board Refer to 6 1 6 4 Refer to 6 5 6 8 All output bits will be turned off when an emergency stop switch is pressed and reset proc ess such as by RESET command is done In case of emergency stop condition output status can be held by the setting of software switch SS1 Refer to 9 2 Software switches in this volume 41 Functions 6 I O 6 1 Input circuit PNP type Input voltage range DC 12 to 24V 10 ON voltage DC 10 8V min OFF voltage DC4V max 5mA typical with input of DC 24V Input circuit diagram and wiring example GND DC Input No 0 7 common GND 2 Input No 0 La O ee SS ee c 4 Same circuit as above 3 Input No 1 oO i 4 Input No 2 va
79. are limited when the safeguard is opened The robot operation speed cannot be increased beyond the fixed value which depends on the type of robot when the safeguard is opened In addition although the robot can operate by executing a program or command regardless of whether the safeguard is open or closed it will quickly pause in either state if the safe guard is opened or closed during operation To operate the robot at high speed close the safeguard and change the power mode to high by using POWER HIGH command Refer to the SPEL III reference manual for details on POWER command For your reference POWER LOW equals LP ON and POWER HIGH equals LP OFF When power is applied to the controller the initial start up corresponds to POWER LOW so that the robot is always in low power state p gn p by executing POWER LOW by executing POWER HIGH m gt PAUSE l M PAUSE Eg se 8 POWER LOW MOTOR ON E Be is alg POWER HIGH SE 8 o mu em 25 POWER LOW S2 El STE ge MOTOR ON D 3 Ims dum z P3 8 XAT d so RESET START EE EHE RESET EU END Jz j A j o at E 3 C 83 amp els POWER HIGH g Ts 2 S dba um ups 93 9 alo f S ee AES ZS 34 a 320 sm ed gs a ak 23 PowERLOW 55 E W S MOTOR O
80. as no problem execute the MOTOR ON command and the motion command If the robot moves properly the inspection is now completed If an error occurs and the red LED on the AC servo driver turns ON when using the MOTOR ON or motion command refer to 15 Error Code Table in this volume and eliminate the cause of error Maintenance 6 AC Servo Driver 6 3 AC servo driver replacement If the AC servo driver is not functioning properly replace it by following the steps below The steps are same for each driver W ARN N G W Only trained personnel should be allowed to perform the following operations Trained personnel are those who have taken a robot training course held by the dealer or those who have carefully read the manuals and have equivalent knowledge or skill Controller has the capacitors charged high voltage To avoid an electric shock do not touch the dangerous high voltage parts marked with the orange label until the orange LED of motor power unit is faded out completely When the orange LED is faded out the high voltage capacitors are discharged e amp Orange LED M P N C AUTION E Temperature of AC servo driver unit may rise depending on the operating condition Check the surface temperatur
81. ation there is a quick pause and the robot switches to Low Power state Additionally attempting to start a program with the safeguard open results in a quick pause and the robot does not move To continue normal operation from the PAUSE condition follow the procedure below 1 Close the safeguard after confirming that there is no person in the safeguard 2 Push the latch release switch 3 Push the START switch Input a START signal when REMOTE3 is the console Low power mode High power mode xecuting POWER LOW by executing POWER HIGH Low power state RESET PAUSE START RESET RESET PAUSE L safeguard open signal latched unlatched POWER LOW MOTOR ON POWER HIGH S o g O Close and open signal unlatched Close and open signal unlatched Close and open signal lt Open PAUSE RS RESET signal unlatched xe UR UW Ma Qo ood Og hemes oO 52 OU ON Pe oc i T Low power state High power state 29 Functions 4 REMOTE1 In case of S NET mode commands execution direct commands except for motion com mands is not affected by the safeguard TEACH mode In TEACH mode it is possible to operate the robot regardless of whether the safeguard is opened or closed However the robot operation speed and torque
82. ave to be backed up before replace ment NOTE Before replacing ROM chips or MPU board back up all of the data Ee Refer to SPEL Editor manual or SPEL for Windows manual for how to back up Replace MPU board or the parts in question by following the steps below N W ARN N G B Only trained personnel should be allowed to perform the following operations Trained personnel are those who have taken a robot training course held by the dealer or those who have carefully read the manuals and have equivalent knowledge or skill Controller has the capacitors charged high voltage To avoid an electric shock do not touch the dangerous high voltage parts marked with the orange label until the orange LED of motor power unit is faded out completely When the orange LED is faded out the high voltage capacitors are discharged e amp Orange LED M P 1 Turn OFF the controller and remove the front panel Do not disconnect the connec tors from the back side of front panel 2 Loosen the two screws that fasten the MPU board s mounting bracket then pull out the mounting bracket forward horizontally Be careful not to pull the screws or they will be removed from the mounting bracket Mounting bracket Fixing screw
83. btained during installation Diagnosis Correction 1 Is the bolt that in 1 Confirm that the manipulator is Installation method stalls a manipulator tightened firmly Does the arm not touch the peripheral equipment Does no play exist in the base table frame Is vibration not propagated from pe ripheral equipment Does no overload occur Is the fixing screw of the end effector not loosened Is the tension of a timing belt proper firmly fixed to the frame Take care that the arm does not touch the peripheral equipment Check the rigidity and horizon tally of the base table frame and reinforce it as required Install the manipulator away from the vibration source or take vibra tion isolating measures against the base table frame Set the weight speed and accel eration corresponding to the load Confirm the fixing screw of the end effector Push the timing belt and tighten the belt again or replace if it is loose section in the Ma nipulator manual Base table section in the Manipulator manual Base table section in the Manipulator manual The end effector and operation accel eration deceleration speed section in Manipulator manual Replacing the tim ing belt section in Manipulator manual 161 Maintenance 15 Trouble Shooting No precision is obtained during operation the position is shifted and the shifted posi tion cannot
84. can be input regardless of the mode but other signals can be input only in AUTO mode Input it only after you have confirmed that it is in AUTO mode e Mode switch e Safeguard e Emergency stop e Restart from pause except when pause was initiated by using the Esc key ON OFF Power 43s RESET output aus Eme ms START output Loo d AUTO input 30 ms TEACH input AUTO output ee OEES TEACH output E a Functions 7 I O Remote Set Up REMOTES Timing chart for motor power ON etc When RESET output is ON and the signals shown in the chart below are input START output turns ON and RESET output turns OFF After this input is executed START out put turns OFF and RESET output turns ON When Motor Power ON is input Motor Power output turns ON after 530ms After this it is possible to input MCAL and HOME which command the robot to operate If these are input when the motor power is OFF an error occurs When MCAL is input MCAL output turns ON in 40ms After MCAL operations are completed MCAL output turns OFF When HOME is input the robot moves to the set standby position While the robot is po sitioning itself in the standby position HOME output is ON When Motor Power OFF is input Motor Power output turns OFF in 330ms 5 ms 5ms 5 ms 5ms SS Se START output RESET output 10 ms_ 10 ms_ 10 ms_ 10 ms Motor Power ON input L M E 330ms
85. ce volume 1 Program contains 400 or more variables 1 Number of variables is up to 399 2 Registration of backup variables is too many 2 Refer to LIBSIZE command in the refer ence manual 84 Compiled object program is too long Reduce size of program Restored file by RESTORE command is too long 85 86 Memory check error in system work area Initialize MPU board by SYSINIT commend 87 Check sum error of file Delete DEL the erroneous file If this error frequently occurs replace or repair the MPU board Refer to the section 7 3 in the main tenance volume 89 I O board communication error Input RESET command c tempted ee NN Sr emewemamawam 0 1 Number of parameters for command is improper In WAIT SW command specified condition is not satisfied within specified period of time 95 5V for encoder is improper Check the 12V output at PSU Refer to the section 3 3 in the maintenance volume Memory error of system control parameter 1 Eliminate external noise source and execute VERINIT command Refer to the section 2 6 in the functions volume 2 Check the voltage of the lithium battery on MPU board Replace it if the voltage is less than 3 4V Refer to the section 7 2 in the maintenance volume 3 If this error frequently occurs replace or repair the MPU board Refer to the sec tion 7 3 in the maintenance volume 144 Maintenance 15 Trouble Shootin Parameter check sum
86. ce volume describes the maintenance procedure and part replacement Robot controller manual A manual that describes the robot controller who executes an operating software and controls I O and the servo mechanism The functions volume describes connecting the robot to the peripheral equipment and basic robot settings The maintenance volume describes the such things as a power supply circuit sche matics parts replacement trouble shooting etc Reference manual A manual that describes the commands for the SPEL III robot language Operating unit manual option A manual for the operating unit that describes such things as operating methods Programming support software manual option A manual for the program development support software It describes such things as operating environment and operating methods of SPEL Editor or SPEL for Win dows We provide two kinds of software SPEL Editor for MS DOS and SPEL for Win dows for Microsoft Windows We also provide Vision Guide the integrated ro bot vision system as an option of SPEL for Windows Teaching pendant manual option A manual for the teaching pendant It describes such things as how to operate the teaching pendant FOREWORD This manual specifies matters that you need to know to use the controller SRC 320 Please thoroughly read this and other related manuals before using the equipment In this manual for the controller some of the funct
87. ched SE 1 2 3 Unlatched v y Fen maumd eed GND DC T GE l 2 System error output uh t E Inductor i Dara AE TEN UEM QU 15 E stop condition output Same circuit as above _L SS edere 3 Safeguard output Same circuit as above L M pz oe A agate 16 J Enable condition output Same circuit as above i ssec icr 4 High power condition output Same circuit as above Fs oe he ee A 17 Motor power condition output Same circuit as above Eug eee e reu esee 10 11 Common DC 23 24 Common GND i 24 V C Abnormal occurrence 14 relay contact output Contact rating AC 250 V 1 A Y DC30V1A 9 24 V 12 13 24 V output Caution System error GND Emergency stop LIP 25 26 Error XP3 v Internal 24 V power CES Current capacity 1 A max E Do not use internal controller power and external power simultaneously as it N CAUTION can result in damage Functions 5 When Not Using the Operating Unit 5 When Not Using the Operating Unit 5 1 Connect the optional operating unit OPU 300 or OPU 320 to the REMOTE2 connector If you do not connect the operating unit then you need to connect the REMOTE2 connec tor that came standard with the controller and take the following additional steps e Make a TEACH AUTO mode switching circuit Connect an emergency stop switch Or if you connect the operating unit to the REMOTE2 connector but only
88. cover 97 Maintenance 3 PSU PSU3 replacement 1 Turn OFF the controller unplug the controller s power cord and wait about two min utes 2 Remove the controller s front panel As various cables are connected to the front panel do not pull the panel unnecessarily 3 Disconnect the earth line and the two connectors X71 and X73 from the back side of the front panel 4 Remove the driver safety cover by taking out the three screws Driver safety cover 4 E 9 6 S g UW 8 9 6 D c lal lal L 4 5 Remove the AC servo driver unit of axis 4 e Disconnect the connectors X1D and X3D from the AC servo driver for the axis 4 e Remove the four screws that hold the driver unit in place e Pull the driver unit forward and out from the controller AC servo driver unit for axis 4 5 C G 6 Disconnect the connectors X15 and X16 from PSU3 98 Maintenance 3 PSU 7 Loosen two screws fixing PSU3 at the left panel of the controller and pull out PSU3 from the controller o E M T o IU MI
89. ctor X42 at3lc and 32c 4 95 to 5 15 5V PSUI see drawing at 30c and 29c 114to 12 6 below at28c and 29c 114 to 126 12V Fan connector X73 at 1 red and 2 black 22 8 to 25 2 24V PSU2 UO board 1 0 connector at 47 or 48 and 49 or 50 22 8 to 25 2 PSU3 Variable resistor VR1 adjustment hole e 28c 29c 30c 31c 32c You can adjust the 5V using the variable resistor VR1 on the PSUI To make ad justments insert a cross head screwdriver through the variable resistor adjustment hole on the PSU cover B PSU has the high voltage parts When you adjust the 5V if a screwdriver touches around the variable resistor you may get an electric shock Insert the screwdriver straight to the variable resistor and be careful not to touch anything else 92 5 wm If all the tested data are within the proper range inspection of PSU is now completed Install the upper cover of the controller and connect the M C POWER cable If the measured voltage of PSU1 is not proper replace PSUI referring 3 4 PSU unit replacement in this chapter Still when the voltage does not return normally pro ceed to the next section Check for PSU1 and the related devices If the measured voltage of PSU2 and or PSU3 is not proper proceed to the section Check for PSU2 P
90. cuit PNP type ss erarintan ikani aaiae 43 6 3 Customer use power supply ssssssssse eee 44 6 4 Pin assignment of I O PNP type 44 6 5 Input circuit NPN type mem menn 45 6 6 Output circuit NPN IDE caei ee r E meme 46 6 7 Customer use power supply sssssssssse eee 47 6 8 Pin assignment of I O NPN type seemmHH 47 1 0 Remote Set Up REMOTES cece tees 48 7 1 Remote SCUUD iniisa aanere e Dead rte ded a aed ea rade s 48 7 2 REMOTES input output Signals ccccceceeeeeeeeceeceeeeeeeseeseceeeeees 49 7 3 Valid invalid input Signals sssee m 52 1 4 Timing charts 2 2 ene be eec ete pec i Rt dE rece epe oe de 55 SRA ZZ Con EM 62 8 1 Communications cable ssssssee eme 62 8 2 Communicatin preparations sssssssssseee 64 9 Switch Types and Jumper Pin Set Up 65 9 1 MPU board DIP switches sssssssemeee e 65 9 2 Software SwWitChes 2 oes eie lad gene iet me M Oe ened 66 9 3 MPU board jumper pins sssssssememe nenne 67 9 4 Locations of DIP switches and jumper pins on MPU board 68 10gOpuOns ee UM EE 69 10 1 Option types and board current consumption sssss 69 10 2 Additional l O board tees Doe ete aa neus 70 10 3 Additionial RAM eR evs tad ena IEEE UE ees 71 10 4 Additional RS 232C board ssssssssessee
91. cy stop switches between pin 6 and 19 If you do not need additional emergency stop switches shorten pin 6 and 19 After connecting switches make sure that each switch functions properly by the following procedure For your safety these checks are recommended to be done at first of all 1 Close the safeguard and push the latch release switch when the REMOTE board jumper pins XP4 and XP5 are set between 1 and 2 2 Open the safeguard 3 Make sure that SAFE GUARD LED on the front panel will light If a personal computer on which SPEL Editor or SPEL for Windows is running is connected to the TEACH port the message to show the safeguard is open is displayed on the screen Refer to the SPEL Editor or SPEL for Windows manual for details 4 Close the safeguard a If the jumper pins XP4 and XP5 on remote board are set between 1 and 2 SAFE GUARD LED still lights b If the jumper pins XP4 and XP5 on remote board are set between 2 and 3 SAFE GUARD LED will go off 5 In case of 4 a press a latch release switch then SAFE GUARD LED will go off Emergency stop switch 28 When wiring in case of PNP type refer to 4 3 Pin assignment of REMOTE PNP type 4 4 Circuit diagram and example wiring of REMOTEI PNP type In case of NPN type refer to 4 5 Pin assignment of REMOTEI NPN type 4 6 Circuit diagram and example wiring of REMOTEI NPN type 1 Turn on th
92. d s DIP switches and jumper pins to the same position as those on the old board Insert MPU board in the specified slot and push it in firmly Tighten fixing screws of mounting bracket of MPU board Turn on bit 1 of the MPU board s DIP switch SD1 then turn ON the controller The controller is initialized by this step SD1 8 6 8 Sls 8 6 Look at the controller s front panel and check that e The E STOP LED and S ERR LED are off Error No is not displayed The TEACH LED or AUTO LED is lit Maintenance 7 MPU Board 6 Turn OFF the controller Then after setting bit 1 of the DIP switch SD1 to the off 7 8 wm position install the front panel on the controller Turn ON the controller again execute the following commands NEW Deletes the source program CLEAR Clears the position data VERINIT Initializes the system parameters FORMAT Formats the file memory Restore all of backed up data Refer to the SPEL Editor manual or SPEL for Win dows for how to restore 123 Maintenance 8 REMOTE Board 8 REMOTE Board 8 1 Layout and function of REMOT
93. d 2 of SD2 to the on position initialize memory by SYSINIT command Executing SYS INIT clears all data in main memory object program backup variables point data and source program Restore all of backed up data to main memory SS 3t S JEINCIE TE Program Point Backup Variable Object all clear Ok NE See the SPEL III reference manual for details on these commands Functions 10 Options 12 Restoring files Return the files that you backed up earlier to the controller See SPEL Editor or SPEL for Windows manual for details 10 4 Additional RS 232C board Two channels of RS 232C are on one board Install the RS 232C simply by plugging the board into an option slot Refer to 10 1 Option types and board current consumption in this chapter The board has DIP switch SD1 and jumper pin XP1 These have been correctly set at the factory so please do not change them The addresses of the additional RS 232C are 22 23 Connector pin assignments and compatible connector are the same as those for 20 21 See 8 RS 232C in this vol ume for details The additional addresses 22 23 are for general communications You cannot use the CONSOLE command to specify them as the console in AUTO mode Please use either 20 or 21 when you want to make the RS 232C the console For your reference settings of DIP switch SD1 and jumper pin SP1 are shown DIP switch SD1 All bits off Jumper pins XP1 A to H see
94. d function of AC servo driver parts U U ABS label ABS for ES EL EC EH 4 BNA BNA CL Signal connector 3 P 1 Red 1 Green 2 E 1 LED The LED on the front of the AC servo driver shows the following conditions POWER 5V power supply being input 2 Power connectors X1A X1D Pin assignments for the power connectors are shown below 1 Brown Motor Wphase a of mor 3 Re Morr Vhs comete Vga of mar ae dca Black DCOV Main circuit power supply common 0 volts DC DC300V Motor main circuit power supply 3 Fuse The AC servo driver is equipped with a fuse to protect against over current from the motor main power supply 111 Maintenance 6 AC Servo Driver 6 2 AC servo driver inspection Inspect the AC servo driver by following the steps below N WARNING N CAUTION 1 2 3 wm 4 112 E Only trained personnel should be allowed to perform the following operations Trained personnel are those who have taken a robot training course held by the dealer or those who have carefully read the manuals and have equivalent knowledge or skill Controller has the capacitors charged high voltage To avoid an electric shock do not touch the dangerous high voltage parts marked with the orange lab
95. e 3 If you are replacing the entire board set the DIP switch SD1 in the same way as on the original board and affix the attached I O number label to the designated spot on the handle When you are replacing a fuse or the transistor array simply replace the part in ques tion without changing the settings on the DIP switch 4 Firmly insert the I O board into the original slot and tighten the upper and lower set screws 5 Connect the I O connectors 128 Maintenance 10 Regenerative Brake Unit 10 Regenerative Brake Unit for EL EH BL XM3000 series The controller for EL EH BL and XM3000 series has a regenerative brake unit If the regenerative brake unit is not operating properly replace it by following the steps below N W ARN NG B Only trained personnel should be allowed to perform the following operations Trained personnel are those who have taken a robot training course held by the dealer or those who have carefully read the manuals and have equivalent knowledge or skill Controller has the capacitors charged high voltage To avoid an electric shock do not touch the dangerous high voltage parts marked with the orange label until the orange LED of motor power unit is faded out completely When the orange LED is faded out the high voltage capacitors are discharged e amp Orange LED M P
96. e timing belt of manipulator manual 6 Arm is bound 6 Eliminate binding factor such as an obstacle 7 Arm hit an obstacle 7 Prevent arm from hitting 8 Axis 3 brake cannot be released 8 If the brake cannot be released with the brake re lease button at MOTOR OFF check the wire of brake If brake does not release at MOTOR ON in spect the brake control signal circuit Refer to the section Re placing the brake of manipulator man ual 9 The motor power line is shorted or 9 Check disconnection of the motor power line in ma grounded nipulator and controller Refer to the manipulator manual and 2 3 Diagram of cable connection in the maintenance volume of this manual 10 Other than the above 10 Replace the AC servo driver Refer to the sec tion 6 3 of the maintenance volume 182 Driver detected overspeed 152 Maintenance 15 Trouble Shooting 183 Driver detected locked motor e When the red LED on the front of the AC servo driver is off 1 External noise source exists e When the red LED on the front of the AC servo driver is lit 2 The motor power line is shorted or grounded 3 Mechanical load is added on axis 4 Tension of the timing belt is not proper 5 Arm is bound 6 Axis 3 brake cannot be released 7 Arm hit an obstacle 8 Other than the above Driver detected improper motion e When the red LED on the front of the AC servo driver is off 1 External
97. e Equipment to be con nected to REMOTEI Was the resetting per formed Is the emergency stop circuit not disconnected 1 Insert the connector securely and tighten it with two fixing screws Connect the normally closed emergency stop switch Connect the supplied REMOTE2 connector when an operating unit is not connected Connect the supplied TEACH port connector when a PC cable personal computer or teaching pendant is not connected to the TEACH port For a supplied emergency stop switch turn the switch clockwise and unlock it For TEACH mode execute the RESET command If the operating unit is in the AUTO mode of the console press the RESET switch If the REMOTES connector is in the AUTO mode of the console input a RESET sig nal For S NET mode execute the RESET command 7 If the circuit is disconnected re pair it Chapter 4 in Functions volume Section 4 1 in Functions volume Chapter 5 in Functions volume Section 3 3 in Functions volume 159 Maintenance 15 Trouble Shooting The system does not operate at a set speed Diagnosis Correction 1 Does the SAFE D 1 Close the safeguard GUARD LED on in dicator panel not light 1 2 Check that the safeguard switch circuit is not dis connected and adjust so that the safeguard input terminal is closed Is the POWER com 2 Change the power mode to high POWER LP mand set to HIGH by using POWER HIGH or LP co
98. e before handling and use the pro tective gloves if necessary E Check the model name and mount it on proper location when replace the AC servo driver 1 Turn OFF the controller pull out the power plug from the power source 2 Remove the front panel and disconnect the earth line the connectors X71 and X73 from the back side of the front panel 3 Remove the driver s safety cover by taking out the three set screws Driver safety cover 3 113 Maintenance 6 AC Servo Driver 4 Disconnect the driver s power connector X1A X1B X1C or X1D and signal con nector X3A X3B X3C or X3D AC servo driver of axis 2 AC servo driver of axis 1 AC servo driver of axis 3 AC servo driver of axis 4 porond po 5 Remove the four upper and lower screws that hold the driver in place then pull the driver out 6 Use a tester to check whether the fuse of the driver that you removed is blown A blown fuse may indicate a short circuited motor power line Therefore before re placing the driver inspect the motor and the motor power line 5 D y Signal
99. e controller and press the emergency stop switch 2 Make sure that E STOP LED on the front panel will light 3 Execute MOTOR ON command from a personal computer or TP 320 or OPU 300 OPU 320 while E STOP LED lights 4 Error 121 will be issued 3 wm Execute RESET command then E STOP LED will go off Functions 4 REMOTE1 4 2 Safeguard input functions The basic function of the safeguard input is to increase safety by stopping the robot and regulating the motor output when the safeguard is opened When the safeguard is opened closed while the robot is running a program or is in the direct command condition it will quickly pause and turn into the Low Power state It is not possible to operate the manipulator at high speeds in this state The methods to resume normal operation after quick pause are as follows Push the start switch on operating unit Press RESUME key if you use teaching pendant TP 320 Input a START signal to REMOTE3 when console is REMOTE3 See section 7 I O Remote Set Up REMOTE3 in this volume There are differences in robot operation when in the TEACH or AUTO modes The safeguard input functions for each mode are explained below In addition refer to the Operating unit SPEL Editor or SPEL for Windows manuals for details on the operating methods AUTO mode In AUTO mode the safeguard must be closed for the robot to operate When the safe guard is opened during oper
100. e is added However if the robot is operated for 250 hours or longer per month inspection schedule is different In this case each step of inspection should be added in every 250 hours 750 hours 1500 hours and 3000 hours operation Monthly 250 H inspection Monthly 250 H inspection Monthly 250 H P Quarterly 750 H inspection inspection Monthly 250 H inspection g o ud o o e an g 2 M s a Monthly 250 H inspection 2 Monthly 250 H 7 Quarterly 750 H y Biannual 1500 H inspection inspection inspection Monthly 250 H inspection Monthly 250 H inspection i Monthly 250 H 9 Quarterly 750 H inspection inspection Monthly 250 H inspection Monthly 250 H inspection P Monthly 250 H B Quarterly 750 H E Biannual 1500 H Annual 3000 H inspection inspection inspection inspection Monthly 250 H inspection Maintenance 1 Outline of Maintenance Inspections Inspection while the power is OFF Be sure to turn off the power Check looseness of External connectors connectors on controller If looseness is found plug it in Connectors on boards securely or tighten inside controller Visually check for external defect Clean if necessary Check clogging of Refer to 12 Cooling controller filter Fan in this volume SloInpe COnSTMONOF Inside controller boards in controller Inspection while the power is ON or while manipulator is moving Emer
101. e name or delete existed file in file memory and save it 1 Filename is incorrect 2 Filename cannot be changed by NAME command Same name already exists No available space in file memory Backup the files on disk if necessary delete the unnecessary files Refer to the SPEL for Windows manual or SPEL Editor manual for detail of backup operation 1 Filename is more than 8 characters 2 File cannot be opened Disk reading error The file cannot be loaded Delete DEL the erroneous file Ba NH 61 62 63 64 If same error occurs in other files reformat the file memory by FORMAT command memory with FORMAT command 8 ee eed aa 70 meeneema LL A a 72 cresma NN 73 ecksmenorofsoncepogam iP 74 Ciesksumenorofenca pean p 75 1 Undeclared or undefined Function or variable is used 2 Specified function is not supported Invalid commands executed TM O O C1 143 Maintenance 15 Trouble Shootin Point number is improper 77 78 Use of undefined position data is attempted Define point Refer to PNTSIZE command in reference manual Hu ec BWE o 81 System error of internal process 1 Eliminate external noise source Refer to the section 2 6 in the functions volume 2 Check storage condition of the MPU board and looseness of connectors on the board If this error frequently occurs replace or repair the MPU board Refer to the sec tion 7 3 in the maintenan
102. e same settings as the original board and affix the attached I O number label to the handle DIP switch settings are the same as for a standard I O board I O 4 48 to 63 Turn 1 amp 2 on OP3 slot I O 6 80 to 95 Turn 1 amp 3 on OPS slot I O 7 96 to 111 Turn 2 amp 3 on OP6 slot I O 8 112 to 127 Turn 1 2 amp 3 on OP7 slot To replace the hybrid IC SEP007 for NPN SEP008 for PNP lift it straight upward and insert a new IC into the socket making sure to place it in the correct direction After inserting the IC push it down diagonally like the original 4 Insert the board firmly into the original slot and tighten the upper and lower set screws 139 Maintenance 15 Trouble Shooting 15 Trouble Shooting This chapter describes causes and remedies of trouble Refer to section 15 1 when error code is displayed Refer to section 15 2 for troubles which error code is not displayed When a trouble occurs refer to this chapter and find the cause and remedy If the trouble is not described in this chapter contact the service center with the Communication list for failure and trouble described in section 15 3 15 1 Error code table There are three major categories of errors In this table they are indicated as follows 123 Errors that do not require RESET to be executed to recover 123 italic Errors that RESET command should be executed to recover 123 italic with und
103. ector This power supply is used for all I Os as well as for REMOTE and REMOTE2 The current capacitance is 1A Do not use this internal power supply together with an external power source as do ing so causes controller failure Pin number of each I O connector a 47 O 48 49 50 Output voltage DC 24 V ZS Current capacitance 1 A max T 6 4 Pin assignment of I O PNP type 44 Only I O 1 is standard but the pin assignment of I O 2 and other optional I Os are shown in the table below See 10 2 Additional I O board in this volume for information on how to install additional I O ports H H Signal name HEU 2 2 4 an 5 erpi EXEEENBSBRRE common 7 B E m 2 Input 0 16 32 48 64 80 96 112127 a a a i a ED a eis els sf fo leash ea tal oa a keene los ailsalee eo lies a Si aisles ee RENE 4 20 36 52 68 84 100 116131 output 10 26 42 58 74 90 106 122 7 5 21 37 53 69 85 101 11732 ouput 11 27 43 59 75 91 107 123 BILLARD TRI XE 7 23 39 55 71 87 103 119 34 output 12 28 44 60 76 92 108 124 Ex ung 10 to to to to to to to to common 15 31 47 63 79 95 111 127 11 mpa 8 24 40 56 72 88 104 120 36 output 13 29 45 61 77 93 109 125 iz o 25 41 emhspa v 26 42 58 74 90 106 122 4 oupr4sjse z orgoz 3 3 0 0 I5 12 28 44 60 76 Fa O 7 a4 so 46 62 78 o4 n0 126 42 i9 Owp
104. ectors X71 and X72 from the front board Do not disconnect the ground wire attached to the front panel and the X73 connector Unscrew the four screws that hold the board in place then the acrylic plate and mount ing bracket come off at the same time One of the four screws has a crown washer to gether do not lose it 3 3 A crown washer is inserted into this screw Make sure that HL8 to 12 LED lamps on a new board are not bent If they are bent return to the straight position Install the acrylic plate mounting bracket and the new front board to the front panel in this order and fix them with screws Be sure to insert the crown washer into the marked screw in above figure This screw connects the to the frame ground to avoid the noise The crown washer makes this connection securely Attach the connectors X71 and X72 to the new front board Attach the front panel to the controller 137 Maintenance 14 Option Boards 14 Option Boards N C AUTION E When connecting or disconnecting the option boards make sure the power is turned OFF B Mount the option boards in the fixed slots OP1 to 7 79 6 6 6 e B
105. ed outward There must also be room behind the controller so that one can attach and remove cables and boards Do not remove the legs on the underside of the controller 12 Functions 2 Installation 2 3 Vertical placement Standard controller placement is horizontal In the event that vertical placement is un avoidable please do so following the points below 1 Use the left side as the new bottom see figure below 2 Remove the four legs mounted on the original bottom Remove them by inserting a flat screwdriver between the bottom and the legs 3 Insert the legs into the four holes on the left side Be sure to use the legs and not set the controller directly on the floor You may remove the bottom side mounting bracket if it is in the way 4 The top surface corresponding to the right side when the controller is placed horizon tally has two holes Using some type of lid be sure to cover the holes to prevent wa ter or metal shaving penetration 5 Placing the controller vertically is inherently unstable Use the mounting bracket to mount the controller to prevent it from tipping over Mounting bracket Leg holes 4 1 9 9L f rj L B yok jn The mounting bracket can be removed by removing Left side face these four screws Legs 4 Mounting bracket Mount to base table beam or similar location
106. el until the orange LED of motor power unit is faded out completely When the orange LED is faded out the high voltage capacitors are discharged amp Orange LED M P E Temperature of AC servo driver unit may rise depending on the operating condition Check the surface temperature before handling and use the pro tective gloves if necessary Turn OFF the controller and remove the front panel Do not disconnect the connec tors from the back of front panel Check that the connectors attached to the AC servo driver units are securely attached If the connection is loose reconnect it securely With the front panel off turn the controller ON and execute the MOTOR ON command If the state of the LED lamps located on the front of the AC servo drivers is as shown below the AC servo drivers have no problem The green LED is lit The red LED is off If the green LED is off power is not supplied to the AC servo driver There are pos sibilities that power connector s connection is not correct or the AC servo driver s malfunction If the red LED is lit control power supply 45V 24V is improper Find the part of malfunction referring the section of PSU inspection and eliminate the cause If the state of the LED lamps h
107. emergency stop button 6 7 8 9 Turn ON the controller Execute the MOTOR ON command and check that No error is displayed Click sound when it s relayed of the motor power unit in the controller is heard No unexpected motion occurs Manipulator is excited normally Perform the steps 4 to 6 for the other axes and check that they magnetize normally After confirming that all axes excite normally set all the bits 5 to 8 of the DIP switch SD2 to on and install the front panel on the controller Input TSPEED to confirm the specified value For the safety reasons set TSPEED 1 10 For BN BL BL CL XM3000 and RT3300 series execute MCAL command and check the robot operates normally If the error 237 occur when you execute the MCAL command turn the controller off turn the axis 4 between 180 and 360 and perform steps 6 to 9 again 11 Execute JUMP and other operation commands to check whether the manipulator stops in the correct position 12 If the position is correct set TSPEED as you confirmed in the step 9 133 Maintenance 12 Cooling Fan 12 Cooling Fan 12 1 Fan inspection Inspect the fan clean the filter by following the steps below 1 Turn OFF the controller and remove the front panel Do not disconnect the cables from the back side of the front panel 2 Pull out the fan s filter It is attached to the back of the front panel Clean it by vac uum cleaner or wash and dry
108. en the light does turn on the cause of the emergency stop is on the TEACH port side When the light does not turn on the cause of the emergency stop is in either REMOTEI or REMOTE2 on the rear panel of the controller O Switch pressed Switch released Emergency stop cause The emergency stop is pressed on the Lit Unlit TEACH port side or the connector is not connected properly In emergency stop condition The emergency stop is pressed in ei ther REMOTE or REMOTE2 or Unlit Unlit emergency stop input terminals are not wired 24 Functions 3 TEACH Port 3 5 Pin assignment of TEACH port Wiring example The pin assignment for the TEACH port is as shown below 1 FG 13 TEACH 1 ooooooooooo QOOOOOOOOCOOG 14 25 DMSW input normally open enable switch input If you prefer to use your own connection cable please use a shielded cable and use the following example wiring diagram as a reference for wiring your cable Since the pin numbers on the personal computer side may differ depending on the type of computer please refer to the computer manual Also in order to ensure safe operation be sure include an emergency stop switch and an enable switch TEACH port RS 232C port of PC Pin number 1 E STOP switch normally closed Enable switch normally open 25 Functions 4 REMOTE1 4 REMOTE1 N W ARN NG E Be sure to operate the system
109. enenenenns 73 11A Specifications ee EM I MEE 74 11 1 Standard specifications sssssssssssseeeeee 74 11 2 Outer dimensions eere deter pene ede aaa eun eed 75 Maintenance Volume 1 Outline of Maintenance 78 1 1 Safety precautions on maintenance sse 78 1 2 Maintenance schedule and inspections sssssssssss 79 2 uter SIIGIUTOce tette EIS 81 2 1 Fixing screws of panels eese trente nec 81 2 2 Location of parts deed nete tee e aa ne dea 82 2 3 Diagram of cable connections sssseseeeee 83 2 4 Connector pin assignment sss ee 85 2 5 Main power supply circuits sssssssseeseenneee 88 ooo or eem Eg IMEEM 89 3 1 PSU layout ir aec abt e a e es s 89 3 2 Power supplies from PSU sss 90 3 9 PSU inspection ee ee LE Ex cde Ae 91 3 4 PSU replacement sssssssssssssessemereneren enne 96 ANPSU BOanGs htc dc teh mte 100 4 1 Layout and function of PSU board parts 100 4 2 Errors related to the PSU board ssssssssssssss 101 4 3 PSU board inspection and replacement ssssesssss 101 4 4 ENC 5V encoder 5V power supply adjustment 102 SMotor Rowen pb oc ce tU 103 5 1 Layout and function of motor power unit parts ssssssss 103 5 2 Motor power unit inspection
110. eplace the MPU board See the next section to re place the MPU board Insert the MPU board in the specified slot and push it in firmly Tighten fixing screws of mounting bracket of MPU board Turn on bit 1 of the MPU board s DIP switch SD1 then turn ON the controller The controller is initialized by this step SD1 9 lp ole Y Look at the controller s front panel and check that e The E STOP LED and S ERR LED are off Error No is not displayed e The TEACH LED or AUTO LED is lit Turn OFF the controller Then after setting bit 1 of the DIP switch SD1 to the off position install the front panel on the controller Turn ON the controller again execute the following commands NEW Deletes the source program CLEAR Clears the position data VERINIT Initializes the system parameters FORMAT Formats the file memory Restore all of backed up data Refer to the SPEL Editor manual or SPEL for Win dows for how to restore Maintenance 7 MPU Board 7 3 MPU board and or ROM replacement The data such as programs point data and settings are stored in RAM on the MPU board When replace ROM chips or MPU board the data h
111. er line in manipulator Refer to the manipulator manual 3 Check cable damage or loose connection between the controller s rear panel and mother board and AC servo driver Refer to 2 3 Diagram of cable con nection in the maintenance volume 4 Eliminate external noise source tion 2 6 in the functions volume Refer to the sec 5 In other case than the above replace the MPU board Refer to the section 7 3 in the maintenance volume Try the following remedies 1 to 11 1 Check disconnection of the motor power line in ma nipulator and controller Refer to the manipulator manual and 2 3 Diagram of cable connection in the maintenance volume of this manual 2 If the red ALARM LED on AC servo driver is lit check disconnection or miscontact of signal line in the following ein manipulator e signal cable between the controller s rear panel and mother board and AC servo driver 3 Inspect the motor power unit Refer to the section 5 2 in the maintenance volume 4 Check each axis motion moving by the hand Ver ify appropriate lubrication or replace the reduction gear Refer to the manipulator manual 5 Check tension of the timing belt Tighten or re place if necessary Refer to the section Replacing the timing belt of manipulator manual 6 Eliminate binding factor such as an obstacle 7 If the brake cannot be released with the brake release button at MOTOR OFF check the wire
112. er for REMOTEI internal Common DC circuit 24V output 24V power output terminals for controller 24V GND output interior 24V output 24V power output terminals for controller 24V GND output interior 32 Functions 4 REMOTE1 These are normally closed contacts which open upon the occurrence of a system error By using the jumper pins on the REMOTE board it is possible to output other condi tions Function when shorted outputs for emergency stop occurrence XP3 also outputs for error occurrence There is a possibility that there will be no output if the internal controller 24V power is abnormal 2 There are two safeguard inputs provided for REMOTEI When the status of two in puts is different CPU will take the safeguard input circuit as malfunction and will is sue anerror Therefore it s recommendable to use a two contacts switch If it s not avoidable to use a one contact switch be sure to short the jumper pin XP6 on the REMOTE board so that the other input to which a switch is not connected will be connected internally 25 13 26 A ae 2 A a 14 1 14 O 15 1 REMOTE connector Cable side REMOTE connector details for wiring Controller side 33 Functions 4 REMOTE1 4 4 Circuit diagram and example wiring of R
113. er s power and measure the voltage listed in the table below W ARN N G E Be careful not to touch the dangerous high voltage parts marked with the or ange label when checking the voltage PSU2 at 1 red and 2 black 22 8 to 25 2 PSU3 at 1 red and 2 black 22 8 to 25 2 Mother board If the measured voltage from PSU2 or PSU3 is not proper replace the PSU referring the replacement procedure in the next section 3 4 If there is an error feedback despite the normal voltages at the PSUs suspect the device connected to PSU2 or PSU3 for causing that error Follow the steps below to define the device that is causing the error 4 Turn OFF the power of controller and pull out the power plug from the power source And check that the orange LED M P on the front of the motor power unit is faded out completely N W ARNIN G E Controller has the capacitors charged high voltage To avoid an electric shock do not touch the dangerous high voltage parts marked with the orange label until the orange LED of motor power unit is faded out completely When the orange LED is faded out the high voltage capacitors are discharged O E E Oran
114. erline Errors that the power should be turned off once and on again to recover owe O S 1 1 FOR statement corresponding to NEXT statement 1 Make FOR statement is missing 2 WHILE statement corresponding to WEND state 2 Make WHILE statement ment is missing 3 SELECT statement corresponding to SEND state 3 Make SELECT statement ment is missing 4 IF statement corresponding to ELSE ENDIF 4 Make IF statement statement is missing 1 Syntax error 1 Correct syntax 2 Undefined variable is used in command 2 Use the variables which were already com piled and registered 3 Undefined array is used as an array 3 Use the variables which were already com piled and registered 4 Batch file is attempted to execute without specify 4 Make path for the batch file ing path GOSUB statement is absent while RETURN state Make GOSUB statement or delete RETURN ment is present statement statements in total 2 Program contains 410 or more labels 2 Reduce label 1 Too large parameter is entered 2 Numeral beyond specified range is entered 3 Argument is abnormal 4 Undefined parameter is used 5 Undefined PALET is used 6 Null string is specified 1 Numeral or variable is overflowed 1 Reduce numeral or variable 2 Undefined address is specified 1 Program contains 851 or more GOTO and GOSUB 1 Reduce GOTO or GOSUB statement 140 Maintenance 15 Trouble Shootin 1
115. ety cover Driver safety cover 12 9 EE 9 8 8 8 9 8 c aa lo P N Q Lj 12 13 Reconnect the earth line connectors X71 and X73 to the front panel and fix the front panel to the controller N W ARN NG E Be sure to reconnect the earth line to front panel 99 Maintenance 4 PSU Board 4 PSU board 4 1 Layout and function of PSU board parts The PSU board outputs and monitors the power supplies that are used by the controller manipulator and other peripheral equipment j D d 2 XH XB g 4 OIRVI A XJ2 2 SKP327 PSU BOARD Handle XP2 XPI DOO L 3 1 Fuse F1 A 2A fuse for over current protection and protection against abnormalities in the inter nal 24 voltage supplied to the servo driver and so on 2 Test pins XJ1 XJ2 XJ3 Test pins for measuring the power supply voltages XJ2 ENC 5V check XJ3 5V check 3 Jumper pins XP1 XP2 Jumper pins are set in accordance with the specification for the manipulator s electro magnetic brake Do not change the settings 4 Variable resistor RV 1 Variable resist
116. example Emergency Stop input all p M 5 ms SS Emergency Stop output START output RESET output Motor Power output 15ms RESET input Motor Power ON input DENEN S 630 ms Timing chart for errors RESET output turns ON and START output turns OFF 300ms after an error occurs in the START state Relevant output also turns off depending on what is being executed and what kind of error occurred RESET input is sometimes necessary to cancel the error state Error output turns OFF Sms after RESET is input START output turns ON momentarily just before completion of RESET operations At least 630ms are necessary after PAUSE input before other input can be made Error output __ 300 ms Pe START output RESET output 20 ms RESET input M NE 630 ms 61 Functions 8 RS 232C 8 RS 232C The standard controller is equipped with 2 channel RS 232C so that you can connect pe ripheral equipment or a host computer to the robot and perform data communications and centralized control 8 1 Communications cable Pin assignments 62 A communications cable is not supplied Use 9 pin D sub connector for the communications cable Use shielded twisted pair leads for the cable Clamp the shield to the hood as a noise countermeasure See 2 6 Noise countermeasures in this volume The pin assignments of the RS 232C connectors are as follows i Notation i Signa
117. f output se y o5 ome uring emergency stop 7 Message Tan EJ E E guage selection ogg p Pe ore EPOR Serman f N SS2 SS3 SS4 Functions 9 Switch Types and Jumper Pin Set Up SS5 U coordinate conversion of LOCAL command dependent value dependent Reserved for system a Always OFF Reserved for system mea Always OFF CMOVE CARG command operation Passes near the Passes through the specified point specified point Reserved for system a Always OFF gest Reserved for system fF Always OFF SS6 Execution of SFREE command to 1 Disabled Enabled axis 4 Execution of SFREE command to 2 Disabled Enabled axis 3 Execution of SFREE command to axis 2 3 Execution of SFREE command to 4 Disabled Enabled axis 1 Disabled Enabled Execution of operation command 5 l ay Enabled Disabled when there is a non excitation axis Reserved for system Always OFF Reserved for system fF Always OFF uw Reserved for system i es a Always OFF 9 3 MPU board jumper pins NOTE There are seven jumper pins on the MPU board However only XP6 can be set by such things as specification changes Never change the settings of other jumper pins as doing so may interfere with the functions of the robot XP1 to 4 Reserved for system Differs by model Backup power supply for addi xz XP6 Jump when there is additional RAM XP7 Reserved for system Normally
118. f signal cable 1 Check signal line of Z phase 2 If the line has no problem replace motor Incorrect ball screw spline axis setting Set the bit 7 and 8 of SD2 on the MPU board to ON Refer to the section 9 1 of the func tions volume 155 Maintenance 15 Trouble Shooting 236 Current position calculated by the sensor and encoder 1 Connect the manipulator and the controller Z phase is out of the default RANGE value with the same M CODE 2 If the arm has been hit an obstacle there is a possibility of mechanical position deviation Execute MCORG command Refer to MCORG command in reference manual 3 Other than the above contact authorized dealer with its VER data ata is improper onfirm the M of manipulator an 7 HTEST data is improp 1 Confi he M CODE of ipul d controller If they are different connect the ones with same M CODE 2 If axis 4 has rotated more than 180 while the power is off turn off the controller power once and return axis 4 around the previous position 3 If the arm has been hit an obstacle there is a possibility of mechanical position deviation Execute MCORG command Refer to MCORG command in reference manual 2 38 39 40 02 Specified directory does not exist 301 1 Cannot delete specified directory because does not exist 2 Cannot delete specified directory because includes files 3 Unable to create directory 1 Specified directory already e
119. f the operating unit is not being used connect a normally closed emergency stop switch with the REMOTE2 connector that came as a standard accessory If nothing is connected the robot will be in the Emergency Stop mode and will not function Details concerning necessary procedures when the operating unit is not being used appear in 5 When not us ing the operating unit in this volume 5 PE F GND terminal connections 8 TEACH port The PE terminal is for connection to the ground frame ground We recommend connecting the PE terminal when several robots are used in a line or when a peripheral control unit such as a sequencer is used in the system Use wiring having a diameter equal to or greater than AWG 16 to connect to the PE terminal Connect any one of the following units If nothing is connected the robot will be in the Emergency Stop mode and will not function The details of these connectors are included in 3 Teach Port in this volume e PC cable for SPEL Editor or SPEL for Windows option e Teaching pendant TP 320 option e TEACH port connector N W ARN l N G E SPEL Editor and SPEL for Windows are designed so that the robot is operated from outside the safeguarded space for program development Be sure to use the teaching pendant with an enable switch and emergency stop switch when performing the teaching operation within the safeguard space B Use PC cable with the label SRC 300 or PC cable with
120. ff when SAFE is not input TEACH AUTO Either TEACH or AUTO is lit 7 segment display All display 0 HL1 RES Red Off HL2 HALT Red Off HL3 WDT Red Off HL4 Yellow lit HL5 Yellow Blinking HL6 X Green lit HL7 Y Green lit HL8 Z Green HL9 U Green AC servo driver POWER Green lit ALARM Red Off Motor power unit M P Dimly lit ACF lit MPC Off 131 Maintenance 11 Manipulator Operation Check SAFE GUARD E STOP S ERR 7 segment display eue Indicator panel gt TEACH a A AUTO MPU board n 0101016 o o0000 HL6 7 8 9 HL3 1 2 4 5 C oonuud MPC ACP M P POWER ALARM H ALARM 4 Turn OFF the controller 5 Use bits 5 to 8 of the MPU board s DIP switch SD2 to set only the axis whose opera tion you are to check to exists The setting of exists of each axis is shown below Axis 1 only exists ON OFF OFF OFF Axis 2 only exists OFF ON OFF OFF Axis 3 only exists OFF OFF ON ON Axis 4 only exists OFF OFF ON ON Always set as both axis 3 and axis 4 exist even if you only check the operation of one of them 132 NOTE Maintenance 11 Manipulator Operation Check Perform the following check steps from a position in which you can immediately press the
121. g parts are re quired for additional I Os Please make certain that you get all parts at the time of purchase e I O board 1 e 50 pin D sub I O connector 1 set e Label sheet 1 Please follow the steps below to install additional I Os 1 Turn off the controller 2 Peel the connector number label from the label sheet and affix it to the handle of the I O board 3 Set the I O board s DIP switches To identify I O boards set DIP switch SD1 on each board in accordance with the fol lowing table 4 Insert the board into the option slot and secure it See the 6 4 Pin assignment of I O PNP type or 6 8 Pin assignment of I O NPN type in this volume for information on setting up connector signals Functions 10 Options 10 3 Additional RAM Standard file memory is 100KByte You can expand file memory to 1 1MByte by adding two RAM modules You can also set DIP switches to expand main memory if you are unable to run a long program on the standard main memory alone Follow the steps below when installing additional RAM 1 Before installation Back up all files in file memory before attempting to install additional RAM To use the additional RAM you must perform a formatting operation which erases all files in the controller s file memory Make backups of files from the personal computer See SPEL Editor or SPEL for Windows manual for details 2 Turn off the controller power and then unplug the power
122. ge LED M P I 94 5 N WARNING Maintenance 3 PSU If the Error 110 the error at PSU2 occurs disconnect all the parts equipment whose power is supplied from PSU2 The previous table Power supplies from PSU list all such parts Refer to the described method of disconnecting for replac ing each part B Temperature of PSU may rise depending on the operating condition Check the surface temperature before handling and use the protective gloves if nec essary 6 N WARNING Once all the parts are disconnected reconnect each part back to PSU2 one by one Each time a part is reconnected turn ON the Controller to measure the voltage at the 24V terminal using the X73 cooling fan connector The problematic part can be defined by measuring this voltage each time the part is reconnected The problem atic part should indicate the out of spec voltage when reconnected and measured E Do not touch the inside the controller while the controller power is ON B When connecting or disconnecting boards or connectors be sure to turn OFF the power of controller 7 8 9 If the Error 46 the error at PSU3 occurs disconnect the following connectors and boards one by one to determine the cause Test by turning ON t
123. gency stop switch on operating unit Check if each switch External emergency for stopping robot stop switch movement works properly or not PAUSE switch on op ey unit Check if eerie wi Other switches on op switches function 1 erating unit properly 2 inside control Check if interlock Interlock with periph function properly eral equipment Check if safeguard switch functions Safeguard properly axis by swinging cables Check if any mal Strange sound and vi functions occur or bration during robot not motion 80 2 Outline of Structure 2 1 Fixing screws of panels Maintenance 2 Outline of Structure Covers of a controller can be taken off by loosening the following screws 1 Screws for upper cover 4 pieces 2 Screws for front panel 4 pieces 3 Screws for rear panel 8 pieces OX Ll hs ey Upper cover 1 1 1 Io e 2 Front panel 2 2 3 81 Maintenance 2 Outline of Structure 2 2 Location of parts
124. gram No selection input 4 8 Program No selection input 6 s3 o O 9 Program No selection input 7 Doo ee o 10 Input common 8 to 15 35 12 a e mf o o 0 7 O 5 tof a of C Hur eco To 7 a Output common GND or DC 24V output 25 Program No selection output 6 the case of PNP I O 50 s 17 e EE 33 050 Qo 080 26 oc I O connector o o controller side oe 086 18 20 o 9e CS 34 6 1 49 Functions 7 l O Remote Set Up REMOTES REMOTES Input Signal Functions RESET PAUSE START HOME Program No selection 2 22 and 2 This signal is used for 1 initializing an error state 2 inter rupting a program The robot controller will be reset at the input of this signal If the robot controller needs to be reset during execution of a program make sure that the signals are input as follows 1 Input PAUSE 2 Make sure that the PAUSE output signal is out 3 Input RESET This signal is used to stop program for the moment This signal temporarily stops the program from being exe cuted In order to resume the operation or to finish the pro gram 1 Wait to receive PAUSE output from the robot controller 2 Input START to resume operation or RESET to finish the program signal This signal is used to 1 initiate execution of program 2 resume operation from the pause state In order to have the
125. h I O board by setting the bits of DIP switch SD1 as shown in the table below C on mee presen Soasi o o 2 Output transistor array U8 to 11 A transistor array that drives output ports The transistor array is replaceable since it is mounted in the IC socket Table below shows the I O bit numbers and their corre spondence to the IC No 126 Maintenance 9 I O Board 3 Fuses F1 F2 The fuses protect the internal circuitry from output port misconnections Please use the following fuse Standard ULCS 61M 2 2A The following table shows I O bit numbers which the fuses protect yt 127 Maintenance 9 I O board 9 2 I O board and parts replacement C AUTI ON E When connecting or disconnecting the I O board make sure the power is turned OFF B Mount I O boards in fixed slots If the I O board is not functioning properly replace it or its parts by following the steps below 1 Turn OFF the controller and disconnect the I O connectors that are attached to the I O board 2 After loosening the I O board s upper and lower set screws pull the board out by the handle T O board TATIONE EDT 2 aa 9 9 9 2 e e amp ERE 22 22 gt a U a ce e le e yo a 2 Handl
126. he Controller each time a connector board is disconnected if the error will be canceled the REMOTEI connector REMOTE2 connector I O connectors and I O boards If the error cannot be canceled in above 7 it is most likely that the PSU board or REMOTE board is causing the error Replace each board one by one with a new board The problematic board can be determined if the error state should disappear when replaced with the new board Once the problematic device is determined and replaced with the good one reconnect all the parts However the M C POWER connector must be left unconnected 10 When all the parts except for the M C POWER connector are reconnected check and be sure that they are connected properly Turn ON the Controller Check that there should be no error indication 11 Attach the regenerative brake unit to the controller and connect X80 referring to 10 Regenerative Brake Unit of this volume when the manipulator is EL EH BL or XM3000 series 12 Install the upper cover of the controller and connect the M C POWER cable to the M C POWER connector Now the procedure is completed 95 Maintenance 3 PSU 3 4 PSU replacement If the AC input voltage is normal while the DC output voltage is out of the normal range replace the PSU in question by following the steps below N W ARN NG B Only trained personnel should be allowed to perform the following operations Trained personnel are those
127. he controller and disconnect all the connectors that are attached to the REMOTE board 2 After loosening the remote board s upper and lower set screws pull the board out by the handle REMOTE board L D E d e T9 e Je T Je TF p a Ije 8 4 T e 9 8 In PI a zi t C Nue e o le e jo ie e a T z yeo 2 Handle 3 If you are replacing the entire board set the jumper pins of the new board in the same way as those on the old board If you are replacing the RS 232C driver pull it out of the IC socket being careful not to touch the surrounding devices Mount the new IC being sure to place it in the proper direction 4 Insert the REMOTE board in the specified slot labeled REMOTE and push it in firmly Tighten the upper and lower set screws 5 Reconnect the connectors 125 Maintenance 9 I O board 9 O Board 9 1 Layout and functions of I O board parts Each I O board controls 16 inputs and 16 outputs 3 F2 Lin 2 oin en o Q 1 Handle ON n 3 NOSd4d QVOG O I C6c dMS 8688 en 1 DIP switch SD1 Assign the bit numbers of eac
128. i FRONT BOARD a g al X12 X13 X16 a i Circuit protector i x2 5V 12V as Zs 24V j gt RS us User 424V xn D gt swi lt WH3 A L r a Q X L SO Xs WH2 Z L 8 O z s G lt X3D XID za A L lo e XA X gt u L Dv WH4 Axis 4 S a DRIVER E h 1S a a H 2 P lt X3C X1C PA I Axis 3 BIL x MPU BOARD DRIVER 5 2 X3B XIB a X73 Ox Axis 2 r4 E DRIVER El zn FANI T 4 WHI2 2m s N e X3A xia REAR a WH BOARD Axis xp s al a WHIO DRIVER gt lt Kel Z si S e WHI3 PE al al zie ua Nel og gt Pane BD X B aan ez PUE MOTOR POWER UNIT eni oO SUE fa P lt D o gr z i WHI 83 Maintenance 2 Outline of Structure
129. ignal is NOT being output and that the START RESET output signal is being output when the following sig nals input to the REMOTE3 START HOME MOTOR ON MOTOR OFF MCAL and Program No This signal is output when the manipulator is in the home HOME or standby position Program No selection This signal outputs the program number loaded in the main 22 21 27 2 memory This signal is being output during calibration while MCAL is MCAL being executed Motor Power ON This signal is output when the motor power is ON This signal is output when an error occurs Error This signal turns OFF at the input of RESET when the error is canceled The console settings or mode selection is irrelevant to output of any of the above output signals 51 Functions 7 I O Remote Set Up REMOTES 7 3 Valid Invalid input signals The validity of input from REMOTE3 and operating unit OPU 300 or OPU 320 in each mode changes as shown below depending on such conditions as the setup of software switch SS1 and the console selection In the case of REMOTE3 input is invalid if the remote has not been set up Functions of bits 1 and 2 of software switch SS1 OFF REMOTE2 SS1 1 Selection of the remote REMOTES I O OPU 300 OPU 320 Factory settings standard specification TEACH mode In TEACH mode the console is the teaching pendant TP 320 or a personal computer con Console is nected to TEACH port In this case a
130. in unit 1 piece 11 Functions 2 Installation 2 2 Environmental requirements In order to maximize the functions of the SRC 320 controller and to use it in a safe manner an appropriate environment is necessary Please place the controller in an environment which satisfies the following conditions Momentary power inter 10 ms maximum rupt Environment Install indoors Place in a well ventilated area Keep away from direct sunlight Keep away from dust oil salinity metal powder or other contaminants Keep away from flammable or corrosive solvents and gases Keep away from water Keep away from shocks or vibrations Keep away from sources of electronic noise If it s not avoidable to use the controller in the environment that does not fulfill the above mentioned conditions take an adequate countermeasure for the actual environment As an example cover the controller with a box having a cooling mechanism In addition the controller is not designed for the use in clean room environments If the controller is used in the clean room place the controller in a box having a cooling or an exhausting mechanism Base table Use a base table that is at least 100 mm off the floor Placing the controller directly on the floor could allow dust penetration leading to malfunction Space Allow at least 50 mm on each side There must be room in front of the controller so that the entire controller can be pull
131. ines and do not bundle both sets of wiring with the same cable tie Also it is preferable to cross the different lines as shown below KE AC line duct 200 mm or more DC line duct For I O lines use a shield and clamp the shield to the attached I O connector interior Shield Twisted pair line Cable clamp Shield to FG Use a shielded wire for REMOTE and REMOTEO and clamp the shield to the interior of the connectors 19 Functions 2 Installation 20 For such induction elements as relays and solenoid valves connected to an I O be sure to use elements which have surge suppressors If surge suppressors are not used in sert an element such as a rectifying diode as close as possible to the inductors as shown below Choose rectifying diodes adequate to the inductors Inductor oO OOM Diode For AC motors induction motor 3 phase induction units etc in such things as con veyors which start go forward and backwards regularly install a spark killer between the lines The spark killer is more efficient the closer it is to the motor Functions 3 TEACH Port 3 TEACH Port This port is used for such tasks as programming teaching and debugging and is connected to a personal computer or teaching pendant TP 320 option This port becomes a con sole port when in the TEACH mode If nothing is connected to the TEACH port the robot will enter
132. ion Check the surface temperature before handling and use the protective gloves if nec essary 3 Turn ON the controller s power and check whether the circuit protector activates 4 Measure the voltages from PSUI listed in the previous table E Do not touch the inside the controller while the controller power is ON N WARNING B When connecting or disconnecting boards or connectors be sure to turn OFF the power of controller 5 wm Repeat step 2 to 4 for each device whose power is supplied by PSU1 Find and re place the device that the circuit protector does not activate or the voltage from PSUI returns normally while the device is disconnected 6 Turn ON the controller s power Confirm that the circuit protectors are not activated and the measured voltages are within the normal voltage range 7 Install the upper cover of the controller and connect the M C POWER cable Now the procedure is completed 93 Maintenance 3 PSU Check for PSU2 PSU3 and the related devices EL EH 1 Disconnect the X80 connector on regenerative brake unit and remove the regenerative brake unit from the controller referring to 10 Regenerative Brake Unit of this volume XM3000 when the manipulator is EL EH BL or XM3000 series 2 Remove the X32 and X33 connectors from the mother board Disconnect the X65 connector first if these connectors are difficult to disconnect 3 Turn ON the controll
133. ional features are listed separately ac cording to each model of manipulator it may be connected to Please refer to the de scription of the relevant model as specified with the initials as follows ES EC If your manipulator model is either ES or EC series refer to this section EL EH If your manipulator model is either EL or EH series refer to this section If your manipulator model is either BN or BNA CL type refer to this BN BNA section L If your manipulator model is either BL or BL CL type refer to this sec tion XM3000 If your manipulator model is XM3000 series refer to this section RT3300 If your manipulator model is RT3300 series refer to this section The improvements at Rev 4 e The MPU board facilitates easier installation of the Lithium battery The improvements at Rev 5 e The mistakes of the circuit diagram on page 34 ware corrected The improvements at Rev 6 e The wrong pin assignment of X12 in the circuit diagram on page 88 is corrected vii TABLE OF CONTENTS Functions Volume viii Various combinations of controller settings and specifications 2 Part Names and Functions 3 A Erontpaneb ssim eco per teni editt oan iude 3 1 2 Rear panelir is dto teen D tuii Du uet 5 1 3 Controller interior sssssssssssseeeeneneenen enne 7 1 4 Safety features aep a LEONE EEE 9 Anstallatuonee enc mE MM US 11 2 1 Unpackirig 2 rig d ee UR b es 11 2 2
134. is connected to the upper cover do not pull it unnecessar ily 2 Check the button of two circuit protectors on the side surface of PSU1 Proceed to the step 4 if both buttons have not come out Button of circuit protector Not activated status 3 If the button should come out it means that the power supply circuit connected with PSU1 is short circuited somewhere Turn OFF the power to the controller and depress the circuit protector button Then turn ON the power again and recheck whether the circuit protectors will activate or not NOTE If the short circuit current is small a circuit protector may not activate immediately Ee Please watch the status for a while If the circuit protector is activated again proceed to the next section Check for PSU1 and the related devices 4 If the circuit protectors are not activated check the output voltage from each PSU Measure the DC voltage of each of the parts shown below Check that they are within the specified normal voltage range E Be careful not to touch the dangerous high voltage parts marked with the or N WARN NG ange label when checking the voltage 91 Maintenance 3 PSU N WARNING san MPU conne
135. isplay on the panels The indicator panel of a controller The sensor monitor of a manipulator Enter the number gt 000 oad O LED that lights Paint out the O oo 4 LED displays inside controller Remove the front panel Paint out the LED that lights LED on MPU board W D T RES HALT J zT LED of motor power unit M P ACP LED of AC servo driver MPC axis 1 axis2 axis3 axis 4 POWER POWER POWER POWER g Q Q e Q TTT wT IOT ALARM RS fri 168 Maintenance 16 Maintenance Parts List 16 Maintenance Parts List exons misc attached a ABS label MPU board for ABS ZA004014 R13ZA00401400 SKP326 3 for ES EL EC EH BNA and BNA CL STE SMS Standard I O board NPN Protected I O board NPN Protected I O board PNP Prarie EL a a M ee a Par Dmm e pee suns zem razao uw o aereas zamnenr mmzwerom sss O o Ragone akon zamma mnzweowwe snos i 60 s driver for INC R13ZA00710200 eae I Gua driver for INC eae 23 dw driver for INC oe 23 aa driver for INC NEU 23 m driver for INC M 23 Lithium battery solder type 21526001 R13Z15260
136. it to the normally closed safety door input terminal of the REMOTEI connector on the rear panel of the controller Failure to do so will result in improper robot operation Connect the cable firmly Do not put a heavy thing on the cable or bend it extremely This may damage the cable If abnormality occurs in the signal cable a robot may malfunction When installing the cable between the manipulator and the controller make sure the M CODEs matching codes match The M CODEs are written on the yellow labels which appear on the back sides of both the manipulator and the controller Also make sure that the length of the power cable and signal cable correspond to the length which appear on the yellow labels mentioned above NOTE The appearance of the controller is the same for all however the various settings CS and the specifications are different depend on the manipulator models Refer to the table on the page 2 for the details of the various combinations of controller settings and specification Manuals vi User s manual A manual that gives a general description of robots It describes such things as safety precautions operating methods teaching methods programming methods and file management Please read user s manual first Manipulator manual A manual for the manipulator itself The basic volume describes safety tips to be observed by the user prior to in setting up the equipment The maintenan
137. l direction Carier detection Send data Wiring example Functions 8 RS 232C A common wiring example is shown below Controller Connected equipment connector Clamp hood The following example is for CS control Because the controller does not perform RS control it cannot control transmissions from the connected equipment Controller Connected equipment connector Clamp hood n this example controller side CS input uses RS output of the connected equipment Wire as appropriate in accordance with the specifications of the connected equipment 63 Functions 8 RS 232C 8 2 Communication preparations 64 To communicate using the controller and connected equipment it is necessary to make the communication method configuration of both RS 232C ports the same You must use the CONFIG command to set the following e Transmission speed baud rate e Character bit number e Parity e Stop bit number e Communication protocol e XON XOFF control e CS control The standard controller has two RS 232 ports 20 and 21 You can determine the con figuration of both ports Which channel you use is determined by specifying that port number 20 or 21 See the manuals that came with the equipment that you connect for information on configuration settings There are two basic commands that you use for communication PRINT and INPUT PRINT data output from the con
138. ll inputs from the remotes are invalid regardless of TEACH port the setting of SS1 SS1 1 software switch setting input fom REMOTES pM T a Program number input ose qu x Motor power on input C e eS Motor power off input Oo o E LOC om a a por arcum NECK EE Program number input Input from REMOTE2 Input from OPU 300 OPU 320 MCAL input Motor power on input Motor power off input Invalid 52 AUTO mode Console is REMOTES3 or operating unit Functions 7 I O Remote Set Up REMOTES In AUTO mode when you use the CONSOLE command to select OP as the console the remote which was specified by software switch SS1 1 is the console All input from the SS1 1 software switch setting OFF ON remote that was selected as the console is valid RESET input PAUSE input START input HOME input Program number input MCAL input Motor power on input Input from REMOTE3 Motor power off input RESET input PAUSE input START input HOME input Program number input MCAL input Motor power on input Input from REMOTE2 Input from OPU 300 OPU 320 Motor power off input V Valid Only restart after a pause is valid Invalid 53 Functions 7 I O Remote Set Up REMOTES AUTO mode Console is RS 232C In AUTO mode when you used the CONSOLE command to select either 20 or 21 of RS 232C as the console the device con
139. lternately show the following information Error task number two digits indicates that the error is not related to an axis LINE NO STATUS LED When a program is being executed this shows the line number of the program being exe cuted When an error occurs the error number is shown Indicator panel LED The individual LEDs show the following information E STOP Emergency stop Lights under emergency stop SAFE GUARD Safeguard Lights when safeguard is open TEACH Teach Lights when in TEACH mode AUTO Lights when in AUTO mode S ERR Lights when CPU is inoperable NOTE When a system error has occurred please be careful since LEDs other than S ERR and E CE STOP may not function properly Front panel mounting screws Removing these four screws allows front panel removal The front panel has a circuit board and cooling fan attached by cables When removing the front panel please do not pull hard Mounting bracket These are brackets for mounting the controller Use these brackets to mount the controller to a post of a base table stand or other suitable location The brackets alone cannot sup port the controller Functions 1 Part Names and Functions 1 2 Rear panel y a a oe en a fe i e c 9 fi kle G Te m Ef
140. m mand in Refer Is the LP command OFF command ence manual set to OFF Are TSPEED and or 3 Set them to high speed as re TSPEED and or TSPEEDS not set to quired The operation speed is TSPEEDS command low speed low in Reference manual The operation speed is low Diagnosis Correction 1 Is the WEIGHT pa 1 Measure the weight of the end The end effector rameter set corre effector and conveyed object and operation accel sponding to the load and set the measured value in eration deceleration the parameter of a WEIGHT speed section in command Manipulator manual Is LIMZ set to less When the axis 3 stroke is than 150 mm in the lower than 150 mm during model with an axis 3 horizontal movement the auto stroke of more than matic acceleration function is 150 mm activated and the operation speed becomes low The motor is turned on excited but it does not operate Diagnosis Correction 1 Does the SAFE 1 1 Connect the normally closed Chapter 4 in Func GUARD LED on the safeguard switch to the safe tions volume indicator panel not guard input terminal of the light REMOTE connector Close the safeguard Check that the safeguard switch circuit is not discon nected and adjust so that the safeguard input terminal is closed 2 Does the PAUSE LED 2 Cancel the PAUSE input of the not light REMOTES T O 1 connector 160 Maintenance 15 Trouble Shooting No precision is o
141. mi Output common GND 45 Output common GND 46 Output common GND R 46 Functions 6 I O 6 7 Customer use power supply A power supply for customer use is supplied to each I O connector This power supply is used for all I Os as well as for REMOTE and REMOTE2 The current capacitance is 1A Do not use this internal power supply together with an external power source as do ing so causes controller failure Pin number of each I O connector eo 47 O 48 49 50 Output voltage DC 24 V uim Current capacitance 1 A max T 6 8 Pin assignment of I O NPN type Only I O 1 is standard but the pin assignment of I O 2 and other optional I Os are shown in the table below See 10 2 Additional I O board in this volume for information on how to install additional I O ports 8 H Signal name cio 2 ET 4 ERES a Ger hte re Tee eat Pere common 7 i E S 2 input 0 16 32 48 64 80 96 112127 ic el el a al af a eis els rr soln DESC cen Sta EEREESERTOUES OSC Ce e 4 20 36 52 68 84 100 116131 output 10 26 42 58 74 90 106 122 7 5 21 37 53 69 85 101 11732 ouput 11 27 43 59 75 91 107 123 BILLARD TAI IST 7 23 39 55 71 87 103 119 34 output 12 28 44 60 76 92 108 124 Ex ung 10 to to to to to to to to common 15 31 47 63 79 95 111 127 11 mpa 8 24 40 56 7288 104 120 36 output 13 29 45 61 77 93 1
142. n be installed inside the controller You can install any of the options with the exception of additional RAM by inserting a board into the op tion slot OP slot on the rear panel Additional I O board 250mA Additional RS 232C board 250mA The combined current capacitance of all option slots is approximately 3A 45V The total board current consumption of options must not exceed this value The required power supply at each input output of I Os is 24V This is different from the board power supply of option slots The steps to install a board in option slot is as follows 1 Turn the controller off 2 Loosen the two fixing screw of a plate which covers option slot and remove the plate You can use any board with any of the available option slots 3 Firmly insert the option board until the mounting bracket touches the rear panel 4 Fasten the mounting bracket with the two screws Be sure to tighten the two screws Option slot 1 to 7 CARTEL oe ee ER ayaa I e qed Pic AS Aek 8 n lp le o o o o o la 3 IJ I aj 69 Functions 10 Options 10 2 Additional I O board 70 The standard controller has 16 I Os but you can increase this number up to 128 I Os Additional I Os come in units of 16 16 inputs 16 outputs The followin
143. n lead to failure of peripheral equipment N C AUTI ON E After setting up the I O remote either keep a written record of the setup or use the MKVER command to keep the information as a file If system initialization is performed using bit 1 of the MPU board s DIP switch SD1 the I O remote setting is also canceled and it will revert to a normal I O It will be necessary to accurately reset the remote on the basis of the data you have kept on record Output performs its function with only the remote setup described above but if an input function is desired it is necessary to set up such that REMOTE3 is the console Select the remote by using bit 1 of software switch SS1 See SPEL Editor or SPEL for Windows manual for instructions on setting the software switch The function of SSI is as follows Refer to 7 3 Valid Invalid input signals of this chapter for details OFF SS1 1 Selection of the remote REMOTES I O ER Factory settings standard specification 48 Functions 7 I O Remote Set Up REMOTES 7 2 REMOTES input output signals The arrangement of signals that can be set up as REMOTES is shown in the table below Input output number has also been included in the table since you may also use them Refer to the wiring examples in 6 I O in this volume when you connect wires Pin assignment Pin Pin 1 inputcommondto7 C 29 Motor power on output 9 as NNNM 6 Pro
144. n the START state Timing for RESET output to come ON differs depending on what is being executed at the time Immediately prior to completion of RESET operations START RESET output turns ON OFF momentarily AUTO input TEACH input NN AUTO output a Te TEACH output TAN TEM ts s START output i Differs depending on what is being executed met RESET output OMS Mode switching in the PAUSE condition When there is a mode switch in the PAUSE state mode output switches after 230ms and RESET output turns ON after 1100ms Immediately prior to completion of RESET op erations START RESET output turns ON OFF momentarily AUTO input ee TEACH input s ie AUTO output cM TEACH output EET VEN IE START output ooo camem VE RESET output ee ee 60 Functions 7 I O Remote Set Up REMOTES Timing chart for emergency stop Emergency Stop input can be input at any time During the emergency stop state only RESET input for canceling the emergency stop can be input Emergency Stop output turns ON 5ms after Emergency Stop is input In 270ms START output turns OFF and RESET output turns ON Emergency Stop output turns ON 5ms after RESET is input when in the emergency stop condition START output turns ON momentarily just before completion of RESET op erations After RESET input at least 630ms are necessary before other input can be made In the chart below Motor Power ON input is used as an
145. nected to the port that you selected is the console In this case nearly all input from the remote is invalid Only PAUSE and START input signals can be made valid by software switch SS1 SS1 1 software switch setting Input from REMOTES ee ES gnome Program number input boo do o7 4 Motor power on input a o Motor power off input a o a oe tee ee p Loc 7 Program number input Input from REMOTE2 Input from OPU 300 OPU 320 MCAL input Motor power on input Motor power off input V Valid Only restart after a pause is valid except when the Esc key was used to initiate a pause Invalid RESET PAUSE and START input 54 RESET PAUSE and START input is possible as shown in the table below depending on the implementation of the program Other signals can only be input when the program is not being executed When program is not During execution of During pause being executed program RESETipu O x O Cinterrupy PAUSE input X OX sTARTinpt O O ome Functions 7 I O Remote Set Up REMOTES 7 4 Timing charts Response timing for REMOTES3 input signals is basically as follows Signals input from REMOTE 1 and REMOTE are also shown Input signal Safeguard input REMOTEI AUTO mode input REMOTE2 TEACH mode input REMOTE2 Notes regarding input signals The timing charts and the times referred to in the explanation of the
146. noise source exists e When the red LED on the front of the AC servo driver is lit 2 Encoder signal line has problem 3 Other than the above 1 Eliminate external noise source and execute VERINIT command Refer to the section 2 6 in the functions volume If no external noise source exists replace the MPU board Refer to the section 7 3 in the maintenance volume 2 Check disconnection of the motor power line in manipulator and controller Refer to the ma nipulator manual and 2 3 Diagram of cable connection in the maintenance volume of this manual 3 Check each axis motion moving by the hand Verify appropriate lubrication or replace the re duction gear Refer to the manipulator man ual 4 Check tension of the timing belt Tighten or re place if necessary Refer to the section Re placing the timing belt of manipulator manual 5 Eliminate binding factor such as an obstacle 6 If the brake cannot be released with the brake release button at MOTOR OFF check the wire of brake If brake does not release at MOTOR ON inspect the brake control signal circuit Refer to the section Replacing the brake of manipulator manual 7 Prevent arm from hitting 8 Replace the AC servo driver Refer to the sec tion 6 3 of the maintenance volume 1 Eliminate external noise source and execute VERINIT command Refer to the section 2 6 in the functions volume If no external n
147. o 230V X11 5V 12V X12 to X31 PSU2 RWS30A 24 B AC 200 to 230V X14 Internal 24V X13 to X32 PSU3 RWS30A 24 B AC 200 to 230V X15 24V for user X16 to X33 89 Maintenance 3 PSU 3 2 Power supplies from PSU PSUI PSU2 PSU3 5V RON nk e User To be disconnected at vec 47v ENE sv 12y 24V 24V 5V O O www o 9 9 sms mwomwe o o o o pw wwe o 0 ema O Internal Additional Parts RS 232C board O Front board E peeo Motor power unit Cooling fan EN M C signals C a Connectors REMOTEI O REMOTE connector mew vore of o Jo Jmevorecomeo No einen vo E a ee e mem 9 9 L react comacor 90 Maintenance 3 PSU 3 3 PSU inspection N W ARN NG W Only trained personnel should be allowed to perform the following operations Trained personnel are those who have taken a robot training course held by the dealer or those who have carefully read the manuals and have equivalent knowledge or skill To avoid an electric shock do not touch the dangerous high voltage parts marked with the orange label For safety be sure to remove M C POWER cable from the M C POWER con nector at the rear panel of controller so that the manipulator should not move accidentally 1 Loosen the four screws that fasten the upper cover and remove the upper cover from the controller As the earth line
148. of MPU board Fixing screw g c Sls 8 8 i la la NOTE MPU board should be placed on an insulator S p 121 Maintenance 7 MPU Board 122 3 ROM replacement 4 5 wm When replacing the ROM be careful not to touch any other devices on the board and not to damage the board The MPU board has three ROM chips Names of ROM such as MPU L MPU U and DSP are printed beside ROM sockets ROM chips have labels on which ROM names and versions are written Refer to the following J L J L O SD3 XP4 EBBE m O XP2 ROM MPU L XP3 O m XP1 ROM MPU U XP8 ROM DSP XP6 XP5 ll OOOO SD1 SD2 o O00000 I I Check the version of the new ROM chips and the position to which it is to be mounted then mount it on to the board Be certain to attach the ROM chips in the correct direc tion by aligning the hollows of the ROM chips and sockets When replacing the MPU board Transfer the ROM from the old board to the new Set the new boar
149. of brake If the brake does not release at MOTOR ON inspect the brake control signal circuit Refer to the section Re placing the brake of manipulator manual 8 Prevent arm from hitting 9 Take the same remedy as 2 If there is no problem in 2 replace AC servo driver and or MPU board Refer to the section 6 3 and or 7 3 of the mainte nance volume 10 Eliminate external noise source tion 2 6 in the functions volume 11 Replace the AC servo driver and or MPU board Refer to the section 6 3 and or 7 3 of the mainte nance volume Refer to the sec Maintenance 15 Trouble Shootin Motor torque overload 175 Hardware malfunction related Servo CPU 173 Robot is in low power state Motor output power is limited 180 Communication check sum error of Servo CPU Instructive motor torque is abnormal Servo adjustment mode is selected Driver overheat overcurrent e When the red LED on the front of the AC servo driver is off 1 External noise source exists e When the red LED on the front of the AC servo driver is lit 2 Weight of the end effector and work piece exceeds rated pay load 3 Motion duty of manipulator is too much 4 Mechanical load is added on axis 5 Tension of the timing belt is not proper 6 The cooling fan is not function ing 7 The filter is clogged 8 Ambient temperature around con troller is over 40 C 9 The motor power line is shorted
150. of the servo driver Refer to the section 6 2 of the maintenance volume 4 Other than the above 4 Consider the following Connection of the MPU board Replace U15 and U16 SCC on the MPU board Replace the MPU board Replace the AC servo driver Replace the motor 184 Cuneeremraueeees 165 NOTICE Encoder is initialized 1 This error is displayed when encoder is ini tialized and controller power is switched on Repeat turning the power off and on twice 2 In other case than the above check whether RES wire of encoder shorted with other line or not 166 Servo calculation overflow 167 Malfunction of Servo CPU hardware Replace or repair the MPU board Refer to the section 7 3 in the maintenance volume 8 ervo CPU s communication error with Sub CPU a o 149 Maintenance 15 Trouble Shooting 169 Servo overspeed 170 Servo overflow 150 1 Motor power line has problem 2 Encoder signal line has problem 3 Motor power unit is not outputting cor rectly to servo driver 4 Mechanical load is added on axis 5 Tension of timing belt is not proper 6 Arm is bound 7 Axis 3 brake cannot be released 8 Arm hit an obstacle 9 Manipulator moved unexpectedly 10 External noise source exists 11 Other than the above 1 Check whether the M C signal cable is surely con nected 2 Check disconnection or miscontact of the encod
151. oise source exists replace MPU board Refer to the section 7 3 in the mainte nance volume Check disconnection or miscontact of the signal line in the following e in manipulator signal cable between the controller s rear panel and mother board and AC servo driver Replace the motor and or AC servo driver Refer to the section Motor replacement of the manipulator manual and or the section 6 3 in the maintenance volume of this manual 153 Maintenance 15 Trouble Shooting Encoder signal disconnection Same as error 184 Malfunction of driver s CPU e When the red LED on the front of the AC servo driver is off 1 External noise source exists 1 Eliminate external noise source and execute VERINIT command Refer to the section 2 6 in the functions volume If no external noise source exists replace e When the red LED on the front of the AC servo the MPU board Refer to the section 7 3 driver is lit in the maintenance volume 2 The cable between AC servo driver and mother Check disconnection of line or looseness of board has problem the connectors between AC servo driver and mother board Refer to the section 2 3 in the maintenance manual 3 424V output at PSU is improper Check whether POWER LED green on the front of AC servo driver is lit or not If the LED is off check the 24V output at PSU Refer to the section 3 3 in the maintenance volume 4 Other than the above 4
152. or RV1 is used to regulate the 5V power supply voltage of the servo mo tor s encoder Voltage increases when you turn the variable resistor clockwise 100 Maintenance 4 PSU Board 4 2 Errors related to the PSU board PSU board error numbers and causes are shown in the following table S ERR VCC power supply voltage deterioration User s 24V power supply voltage deterioration Momentary AC power service interruption 5V power supply voltage deterioration 24V power supply voltage deterioration Motor main power supply voltage deterioration 4 3 PSU board inspection and replacement E Make sure the power is turned OFF when connecting or disconnecting the N WARNING N C AUTION B Mount circuit boards of a controller in fixed slots 1 Turn OFF the controller and position it so that you can remove the board PSU board to avoid an electric shock 2 After loosening the PSU board s upper and lower set screws pull the board forward by the handle 2 PSU board i e 2 Handle 3 Check that the fuse F1 is still good and that the wires inside the fuse are straight 4 If PSU board has a malfunction it is necessary to replace it After replacing the board set the new PSU board s jumper pins XP1 and XP2 in the same way as the original bo
153. or signals from such things as the robot motor encoder or calibration sensor Connect the signal cable attached to the manipulator M C POWER Connector for robot power source Connect the power cable attached to the manipulator 9 VO 1 50 pin D sub input output connector 16 inputs 16 outputs The cable connector is a standard attachment Option slot Seven slots which can accommodate boards for such things as additional I O and additional RS 232C boards Any slot can be used qd PE F GND terminal A terminal for ground wire connection frame ground Please use this terminal if another ground wire is used in addition to the one included with the power cable 2 M CODE label A label on which the M CODE matching code with the manipulator is shown Also the length of the power cable and signal cable is shown on this label N C AUTION B The manipulator has the same M CODE label affixed to it When connect ing the manipulator and the controller make sure the M CODEs correspond E When installing the cable between manipulator and controller make sure that the length of the power cable and signal cable corresponds to the length writ ten on the M CODE label 3 Serial No label A label on which the serial number is shown MT label Labels that carry a special specification number These are affixed to special specification robots Robots having this label have special maintenance requirements When per
154. peration confirmation after replacement see the following chapter 11 Ma nipulator Operation Check 130 Maintenance 11 Manipulator Operation Check 11 Manipulator Operation Check N W ARN N G B Only trained personnel should be allowed to perform the following operations Trained personnel are those who have taken a robot training course held by the dealer or those who have carefully read the manuals and have equivalent knowledge or skill Here we explain how to check the operation of the manipulator after you have replaced boards units or other items If an abnormality occurs during the check reinspect the part that was replaced 1 Recheck the cables and connectors to or in the vicinity of the parts that you replaced Turn off the controller and remove the front panel 2 Turn off bits 5 to 8 of the MPU board s DIP switch SD2 Nonuse of axis setting Refer to the table of step 5 SD2 8 ss 8 6 3 Turn on the controller and check the LED status in the following table Front panel S ERR Off Indicator panel E STOP Off when E STOP is not input SAFE GUARD O
155. problem Only trained personnel should be allowed to design install operate perform function testing and maintain this robot and the robot system Trained personnel are those who have taken a robot training course held by the dealer on a regular basis or those who have carefully read the manuals and have equivalent knowledge or skill Be certain that the power has been turned off controller power before you plug or unplug any of the cables linking the manipulator and controller Failure to do so could cause electric shock and malfunction Do not touch the parts in the controller carelessly to avoid an electric shock and damage the controller The controller has the high voltage parts When you maintenance the controller refer to the maintenance volume and follow the description Do not operate the robot system when either of the following symptoms ap pears the light stays lit even after you take your hand off the CANCEL switch or the light does not turn on when you push the CANCEL switch even though the robot is not in the emergency stop condition Either of these conditions indicates the possibility that the emergency stop switch connected to TEACH port is inoperable Use PC cable with the label SRC 300 or PC cable with an enable switch Cables without the label have a normally open emergency stop switch that does not function properly exposing you to dangers N CAUTION Connect the interlock switch circu
156. r power unit E 7 o Upper safety cover of the motor power unit J Y lo S 14 O00 0 d o jooooc o o ILL iT 8 9 97 9 i9 14 15 Return the AC servo driver unit of axis 1 Mount it with the four screws and attach the connectors X1A and X3A Be sure not to bend the connected cables forcibly or not to pinch 16 Attach the driver safety cover Driver safety cover 16 t3 e LE a 6 9 9 8 SS A E 16 15 17 Attach the upper cover of the controller 18 After connecting the earth line connectors X71 and X73 to the front panel attach the panel to the controller N WARNING WI Be sure to reconnect the earth line yellow green to front panel 19 Refer to 11 Manipulator operation check in this volume for the remaining steps 110 Maintenance 6 AC Servo Driver 6 AC Servo Driver 6 1 Layout an
157. rd 13 Front board 13 1 Front board inspection 1 Check that the following displays on the front panel function properly Checkpoint What to check The line numbers are correctly dis 7 segment display PII oo when the program is executed AUTO LED The LED is lit or AUTO mode TEACH LED HL10 The LED is lit during TEACH mode The LED is lit by the emergency stop E STOP LED HL11 input from either the REMOTE1 REMOTE2 or TEACH connectors SAFE GUARD LED HL12 The LED is lit by the safeguard open signal input 2 Check whether the E STOP CANCEL switch works by checking the following While pressing the E STOP CANCEL switch when the manipulator is not in the emergency stop state unplug the connector from the TEACH port The manipulator should not enter the emergency stop state The E STOP CANCEL LED should come on n this state when you remove your finger from the E STOP CANCEL switch it should be in the emergency stop state SAFE GUARD LED 7 segment LED E STOP LED S ERR LED E STOP CANCEL LED TEACH LED o AUTO LED TEACH port E STOP CANCEL switch 136 Maintenance 13 Front Board 13 2 Front board replacement If the front board is not operating properly replace it by following the steps below 1 2 3 wm 4 5 6 7 wm S Turn the controller OFF and remove the front panel Disconnect the conn
158. rd after replacing parts E Use proper maintenance parts for the robot controller If incorrect parts such as for other controllers are used severe difficulties could be caused All outer covers panels of the controller the front panel the rear panel and the upper cover are connected to the protective bonding circuit with a yellow green wire grounding If you need to open those covers panels and disconnect the wire to the protective bonding circuit during maintenance be sure to recon nect it after the maintenance work N CAUTION Temperature of AC servo driver unit and PSU and regenerative brake unit may rise depending on operation Check the surface temperature before handling and use protective gloves if necessary Do not take off any parts and units not described in this manual Do not per form maintenance using different procedures that are described in this manual NOTE Backup all necessary programs point data and robot system data before you start mainte S nance 78 Maintenance 1 Outline of Maintenance 1 2 Maintenance schedule and inspections Proper inspection steps are essential to prevent troubles and to maintain safety This section describes maintenance inspection schedule and procedure so be sure to do inspection as follows Maintenance Inspection schedule Inspection procedure is divided into such five stages as daily monthly quarterly biannu ally and annually as each on
159. ready defined LOCAL number 2 Define LOCAL by LOCAL command 132 HOFS value is out of allowable range HOFS should be in the range of 40960 to 40960 133 HOME command is attempted even though certain Engage all axes by SLOCK command before axes are not engaged HOME operation 134 Change of arm attribute in CP control Arm attribute cannot be changed in CP control 135 SFREE is attempted for axis that cannot be disengaged Check the setting of software switch SS6 Refer to the section 9 2 of the functions vol ume 136 Improper number many or few of point data is speci Refer to CURVE command of the reference fied by CURVE manual 137 Point data specified by CURVE contain point which Refer to CURVE command of the reference has different arm attribute manual 138 Free curve cannot be made by CURVE Verify that no two successive points overlap one another 139 Restart of CVMOVE motion after quick pause is at Restarting CVMOVE motion after quick pause tempted is impossible Only axis 4 movement is attempted in CP control Improper point data for ARC command In ARC command specified points are too close or points are on straight line Refer to ARC command in reference manual HOME position is not defined Define home position by HOMESET com mand Motion command is executed under SFREE condition Engage all axes by SLOCK 147 The value of 4th and 6th parameter in BASE 0 com Refer to BAS
160. rews Driver safety cover 6 ol Q J mom Je fer ELA 9 8 9 8 9 8 9 8 me x E b d fol 6 mE 7T Remove the AC servo driver power unit unit of axis 1 to facilitate replacement of the motor Remove the connectors X1A and X3A e Remove the four screws that hold the driver unit in place Pull the driver unit forward and out from the controller T AC servo driver unit of axis 1 Q poo oo ooo ponnn 8 Remove the connectors X20 to X26 and X29 of the motor power unit 9 Remove the screws from two places on the right side of the controller 10 Gently pull the motor power unit forward and disconnect the X28 connector 11 Attach the X28 connector to a new motor power unit 12 Be careful not to pinch the X73 connector cable while mounting the motor power unit in the controller and connect the connectors X20 to X26 and X29 13 Tighten the motor power unit with two screws Refer to the figure above Be sure not to bend the connected cables forcibly or not to pinch 109 Maintenance 5 Motor Power Unit 14 Attach the upper safety cover of the moto
161. rom enable condition High power output Output from high power condition R o o 1 S a m Emergency stop input For connection to normally closed emergency Emergency stop input stop switch Safeguard input 1 Safeguard input 1 5 For connection to safeguard input so Safeguard input 2 Safeguard input 2 CENE Latch release input For connection to normally open switch that Latch release input release the latch of safeguard open Common DC For supply power for REMOTEIL internal Common GND circuit Common DC For supply power for REMOTE internal Common GND circuit 24V output 24V power output terminals for controller 24V GND output interior 24V output 24V power output terminals for controller 24V GND output interior 35 Functions 4 REMOTE1 These are normally closed contacts which open upon the occurrence of a system error By using the jumper pins on the REMOTE board it is possible to output other condi tions Function when shorted outputs for emergency stop occurrence 2 36 XP3 also outputs for error occurrence There is a possibility that there will be no output if the internal controller 24V power is abnormal There are two safeguard inputs provided for REMOTE1 When the status of two in puts is different CPU will take the safeguard input circuit as malfunction and will is sue an error Therefore it s recommendable to use a two contacts switch If it s not avoidable to use
162. rsonal computer running the SPEL Editor or SPEL for Win dows There is a special cable PC cable for use between the TEACH port and the personal com puter attached to the SPEL Editor or SPEL for Windows Connect it to the TEACH port This cable has a normally closed emergency stop switch Please set up the configuration of the personal computer s RS 232C port to match the fol lowing protocol for the TEACH port 9600bps 8 bit Even 2 stop V TEACH port Personal computer Controller SPEL Editor or r SPEL for Windows n maur F RS 232C port Manipulator PC cable SRC 300 Use cable with correct label Emergency stop switch normally closed 22 Functions 3 TEACH Port 3 2 Teaching pendant TP 320 connection Teaching operation is possible to be done with a handy teaching pendant TP 320 instead with a personal computer TP 320 is employing both of an emergency stop switch nor mally closed and an enable switch normally open The dedicated cable for the control ler is attached to TP 320 Connect this cable to the TEACH port In TEACH mode the enable switch has to be pressed for robot operation If it is not pressed pause condition will occur as soon as a program or motion command is executed If the enable switch is set free during motion the robot will quickly pau
163. s Jumper pins Jumper pins are used to set various hardware functions XPI to 4 Reserved for system Differs by model XP6 Backup power supply for additional Jump when there is additional RAM RAM XP8 Reserved for system Differs by model Jumper pins have been correctly set at the factory on the basis of your specification Careless changes to these settings could cause system failure Be careful not to change the setting of jumper pins which are shown as Reserved for system When replacing the MPU board jumper pins of a new board have to be set as same as the current board 8 LED The functions of the LED on the MPU board are shown below Lm Act Rea Comes on when the CPUs Medis ma Yeton Dips ats of CPU operons HLS o Jvets d at regular intervals when MPU is operating nor You can change the functions of HL 6 9 as follows by resetting SD3 1 SD3 1 is set to the off position at the factory i Functions Notation Name Color Bit 1 of SD3 is Off Bit 1 of SD3 is On Comes on in low power mode Axis 1 servo end Comes on when manipulator stops Axis 2 servo end Comes on when MCAL and Hos MCORG commands are executed PISIS Serv end Comes on when a servo related Adda ud error occurs 118 Maintenance 7 MPU Board 7 2 Lithium battery inspection and replacement The data such as programs point data and settings are stored in RAM on the MPU board Lithium bat
164. s an abnormal sound generated from reduc tion gears Is an abnormal sound generated from around the ball screw spline shaft of axis 3 1 Push the timing belt and tighten the belt again or replace if it is loose Press the axis 3 brake release button in the MOTOR OFF condition and confirm that the axis 3 operates normally Confirm that the brake works when the button is not pressed If abnormality is found replace the brake Be careful not to touch any thing else Check the fixing screw of the cover and tighten the screw again if it is loose Replace the grease on the re duction gears If the abnormal sound is gener ated still more replace the re duction gears Apply grease to the ball screw spline shaft If the abnormal sound is gener ated still more replace the ball screw spline unit The abnormal sound generated during stop is almost the oscilla tion of a motor owing to the play in a mechanical system 1 Is the tension of a timing belt 1 Push the timing belt and proper tighten the belt again or replace if it is loose Does the operating time of a Examine the replace robot exceed 8 000 hours in ment of reduction gears all in each axis Does the operating time of a Examine the replace robot exceed 15 000 hours in ment of an axis 3 all ball screw spline unit Replacing the timing belt section in Ma nipulator manual Replacing the brake section in Manipula
165. se and a message will be issued To resume robot operation from the condition press the enable switch and RESUME key Refer to TP 320 manual for details In AUTO mode a program or motion command can be executed even if the enable switch is not pressed The condition that a robot can be operated is called the enable condition REMOTE and REMOTE have Enable condition output terminal Make sure that the enable switch functions properly by the following procedure before a teaching operation 1 Switch to TEACH mode 2 Execute a program or motion command while pressing the enable switch 3 Set the enable switch free during motion 4 Make sure that the robot will quickly pause 3 8 TEACH port connector E STOP CANCEL connector The TEACH port has normally closed emergency stop input terminals so that if the ter minals are not closed the unit will enter the emergency stop condition If TP 320 or per sonal computer is not connected install the TEACH port connector that came standard with the controller The internal wiring of the TEACH port connector is as shown below TEACH port TEACH port connector Emergency stop input 10 Emergency stop input 11 Compatible connector 25 pin D sub connector 23 Functions 3 TEACH Port 3 4 E STOP CANCEL switch use N W ARN N G E Never perform teaching or other operations while holding down the E STOP CANCEL switch WI Never use robot when the ligh
166. t shifted Do a play and catch occur 2 Check the main fastening bolt of the arm and confirm that the bolt is not loosened when the power is turned off and when the arm is moved manually 162 Maintenance 15 Trouble Shooting The arm vibrates The residual vibration during positioning completion is high Diagnosis Correction 1 Does no overload occur 1 Set the weight speed and The end effector acceleration corresponding and operation accel to the load eration deceleration speed section in Manipulator manual 2 Is the bolt that install a 2 Confirm that the manipula Base table section manipulator tightened tor is firmly fixed to the in Manipulator man firmly base plate frame ual 3 Is the tension of a timing belt proper 4 Does a remarkable play occur when the power is turned off and when the arm is moved manually 5 Does the operating time of a robot exceed 8 000 hours in all 6 Does the operating time of a robot exceed 15 000 hours in all 3 4 5 6 Push the timing belt and tighten the belt again or re place if it is loose Check the main fastening bolt of the arm and confirm that the bolt is not loosened Examine the replacement of reduction gears in each axis Examine the replacement of an axis 3 ball screw spline unit Replacing the tim ing belt section in Manipulator manual 7 Does vibration occur in 7 Decrease the
167. t is off while pushing E STOP CANCEL switch and when not in the emergency stop condition Do not use robot when the light does not return off though you release the E STOP CANCEL switch ei ther The E STOP CANCEL switch invalidates emergency stop input from the TEACH port Pushing this switch when changing connectors on the TEACH port prevents the emergency stop condition Release the switch after the connector is in place Never perform teaching or other operations while holding down the E STOP CANCEL switch Itis very dangerous because Emergency stop input may not work in this case Before performing teaching operations make certain that the E STOP CANCEL switch and associated circuits are working properly If they are not working properly do not use the robot Please check them as follows This switch has an attached light When not in the emergency stop condition when E STOP LED on the indicator panel of the controller is off pushing the switch turns on the light Removing your hand from the switch turns off the light This is the normal oper ating condition of the switch so please check that it acts accordingly before use If it is not normal the controller needs repair PETENS Switch pressed Switch released When in the emergency stop condition when E STOP LED on the indicator panel of the controller is on there are cases in which pushing the switch turns on the light and does not turn on the light Wh
168. tery supplies DC power to the RAM to maintain this data when controller power off NOTE When the voltage of the lithium battery on the MPU board falls error 49 occurs When ee the error occurs back up all of the data immediately before it is lost Refer to SPEL Editor manual or SPEL for Windows manual for how to back up Ee When replacing lithium battery follow the steps below after backing up data W ARN N G B Only trained personnel should be allowed to perform the following operations Trained personnel are those who have taken a robot training course held by the dealer or those who have carefully read the manuals and have equivalent knowledge or skill Controller has the capacitors charged high voltage To avoid an electric shock do not touch the dangerous high voltage parts marked with the orange label until the orange LED of motor power unit is faded out completely eme d G Orange LED M P c 1 Turn OFF the controller and remove the front panel Do not disconnect the connec tors from the back side of front panel 2 Loosen the two screws that fasten the MPU board s mounting bracket then pull out the mounting bracket forward horizontally Be careful not to pull the screws or they will be removed from
169. the cable to PSU cover PSU fixing plate 5 6 5 pl e E PSU cover X12 pix EIX H X11 X31 6 5 3 Cable clamp Disconnect the four connectors X11 X13 X14 and X31 from the PSU Loosen the three screws and remove the PSU fixing plate with PSU1 PSU2 and PSU cover from the board rack Loosen the two screws at the each side of PSU cover and remove the cover from the PSU fixing plate Remove the fixing screw of the PSU to be replaced Each PSUI and PSU2 is fixed to the fixing plate with two screws from underneath If you loosen those screws PSUI or PSU2 can be removed Then replace it with a new one If you replace PSU1 remove the X12 connector and connect the cable of the X12 connector to a new PSUI Fix the new PSU and attach the PSU cover to the PSU fixing plate Connect X31 and mount the PSU fixing plate to the controller as it was before Pay attention not to pinch the cable 10 Connect X11 X13 and X14 to PSU 11 Fasten the cables to the PSU cover with a cable clamp Handle the cables carefully so that no load or weight is applied 12 Fix the upper
170. the mounting bracket Mounting bracket Fixing screw of MPU board Fixing screw 8 Sls 8 8 m N E s NOTE MPU board should be placed on an insulator S P 3 Use a tester to measure the voltage between the pins of the lithium battery s connector 119 Maintenance 7 MPU Board 120 4 5 6 h 8 wm wm on the board If the measured voltage is below 3 4V the battery is dead or flat Replace it with a new one When removing the old battery cut off the clamp that is holding the battery and disconnect the connector Connect the new battery to the connector and secure it with clamp wae Connector Lithium battery a n oooo o 00000 m clamp When the error 49 low battery voltage is issued if a voltage is 3 4V or more it could mean a failure of the voltage detection circuit Mount the MPU board in the controller fix it securely and turn on the power then check again whether an error is displayed If an error occurs r
171. ther than the above 1 Refer to the section Calibration of the manipulator manual 2 Check the voltage of the battery on signal relay board If the voltage is less than 2 8 V replace the battery Check the ENC 5V voltage at signal con nector of motor If voltage is not proper inspect PSU board and wiring Refer to the section 4 4 of the maintenance volume 3 4 Replace the motor Refer to the section Motor replacement of the manipulator manual 1 Refer to the section Calibration of the manipulator manual 2 Eliminate external noise source and execute VERINIT command Refer to the section 2 6 in the functions volume 3 In other case than the above take the fol lowing procedures Check inserted condition of MPU board Replace the MPU board Refer to the section 7 3 in the maintenance volume Replace the motor Refer to the section Motor replacement of the manipulator manual Overrun error of encoder data Same as error 197 Parity error of encoder data Same as error 197 LONE NEN Home sensor detection error 239 Encoder Z phase signal detection error Refer to the section Motor replacement of the manipulator manual Quick pause interrupted MCORG execution Check whether home sensor LED of manipula tor lights or not while moving the arm by hand If the LED does not light execute MCORG command If the LED lights check discon nection o
172. timing charts should be considered guidelines Actual times differ depending on such things as the number of tasks started up and the commands being executed Do not input signals until after you have checked the output condition of the remotes and determined that the signals can be input The time figures and wavelengths in the timing charts are not proportional Use pulse input for all input signals except those using switches such as the AUTO TEACH mode switch emergency stop input and safeguard input The con troller detects the rise of input signals Set the pulse width of input signals to 10ms or more ON OFF 10 ms or more Avoid overlapping remote input whenever possible Input 1 Input 2 Avoid overlapping Avoid chattering input whenever possible 55 Functions 7 I O Remote Set Up REMOTES The timing chart when power is turned ON 56 Initialization inside the controller is finished and RESET output is turned ON 4 3 seconds after power is turned ON From this point on output from each remote is possible Just before completion of initialization RESET START output turns ON OFF momentarily When you switch modes in the RESET state the new mode s output is turned ON and the earlier mode s output is turned OFF after 30ms When mode output switches START output turns ON momentarily In the example below is of switching from TEACH to AUTO The signals below
173. tion of Servo CPU o of Malfunction of Servo CPU o CPU 7 Robot moved in improper speed Turn off and on the controller 2 Check arm position data Move the arms to a taught point manually and display the numbers of pulse of this point If the val ues of current are different too much from the numbers of pulse of taught point cali brate the manipulator Refer to the sec tion Calibration in manipulator manual If this error frequently occurs replace or repair the MPU board Refer to the sec tion 7 3 in the maintenance volume 148 Maintenance 15 Trouble Shooting 159 Reading error of encoder revolution data 1 External noise exists 1 Eliminate external noise source Refer to the section 2 6 in the functions volume 2 Disconnection of encoder signal line 2 Check disconnection or miscontact of the signal line between the controller s rear panel and mother board and AC servo driver Refer to 2 3 Diagram of cable connection in the maintenance volume If the red ALARM LED on AC servo driver is lit check signal line shown below also in manipulator signal cable 3 Voltage of encoder power source is abnormal 3 wm Check the ENC 5V voltage at signal con nector of motor If voltage is not proper inspect PSU board and wiring Refer to the section 4 4 of the maintenance volume If the green POWER LED on AC servo driver is off check the connection of signal connector
174. troller INPUT data input from the connected equipment See the SPEL III reference manual for details about commands Functions 9 Switch Types and Jumper Pin Set Up 9 Switch Types and Jumper Pin Set Up Many settings are necessary to use the robot s functions correctly Here we explain the settings of the MPU board s jumper pins and DIP switches as well as of software switches You do not need to change the settings as they have been correctly set at the factory on the basis of your specifications Careless changes to these settings could cause system failure Only when specification changes occur after the robot was delivered you should attempt to reset the switches only in strict adherence to the instructions below After you set up the DIP switches and software switches turn on the controller power Turning on the controller power activates the settings You can display the current settings of the DIP switches and software switches using SPEL Editor or SPEL for Windows See those manuals for details The shaded cells in the tables below are standard factory settings Please be careful not to change the settings of bits which are shown as Reserved for system MPU board DIP switches DIP switches SD1 to 3 are located on the MPU board Their functions are shown below SD1 Initializes control data of System initialization CPU when power is Does not initialize turned on Reserved for system Eee 7
175. tting DIP switches Flip bit 1 of DIP switch SD2 on the MPU board to the ON position Also flip bit 2 to the ON position when you want to expand main memory mm 9 9 Sets capacity of main 2 memory and file mem Main memory 374KB Main memory 174KB ory when additional File memory 900KB File memory 1 1MB RAM is installed Once DIP switches are set reinsert the MPU board to the controller Insert MPU board in the specified slot horizontally and push it in firmly Tighten fixing screws of mounting bracket of MPU board 10 Attach the front panel to the controller and turn the controller on 11 Formatting Execute FORMAT A The file memory is formatted without erasing the current file memory contents When A is specified you will be prompted as follows gt FORMAT A RAM disk size adjust OK Y N 2 Then if Y is entered the file memory is formatted and contents size increases When FORMAT is executed the message may be displayed Memory error address xxxxxxxx If the address number which starts with is 00080003 or 00099001 it means the dip switch SD2 on MPU board is set so that additional RAM is installed while it is not installed actually Check if RAMs are installed correctly and execute FORMAT A again If other address is displayed please contact the authorized dis tributor of our robot When you want to increase the size of main memory when you set the bit 1 an
176. use the output function such as a display rather than using it as a console it is necessary to assign the console to another device Operating unit disconnected REMOTE2 Make a TEACH AUTO mode switching circuit Connector REMOTE2 to which you connect the operating unit has a mode switching ter minal Switching of the TEACH AUTO mode can only be done from the REMOTE2 connector So if you do not connect the operating unit make a mode switching circuit using the pin assignment and wiring example for reference For safety reasons a key switch shall be used If nothing is connected to the mode switching terminal TEACH mode will be assumed Connecting an emergency stop switch 38 Pins 5 and 15 of REMOTE2 are for an emergency stop input terminal If operating unit is not connected to REMOTE2 connect emergency stop switch Refer to the figures on the following page Emergency stop input is normally closed If nothing is connected the emergency stop condition will be assumed Both REMOTE and REMOTE2 have an emergency stop input terminal Use an emergency stop switch conformed to the related safety standards EN418 EN60204 1 After connecting emergency stop switch make sure that the switch functions properly by the following procedure 1 Turn on the controller and press the emergency stop switch 2 Make sure that E STOP LED on the front panel will light 3 Execute MOTOR ON command from a personal comp
177. uter or TP 320 or OPU 300 OPU 320 while E STOP LED lights 4 Error 121 will be issued 5 wm Execute RESET command then E STOP LED will go off Pin assignment Wiring example Functions 5 When Not Using the Operating Unit REMOTE2 is a 20 pin connector but only the pins in the table below can be used for wir ing Do not use any other pins under any circumstances as they have not been freed for use Pin No Signal name Pin No Signal name Teach mode input Auto mode input Lw pewew E avon 20 9 20 E 10 m J l K REMOTE2 connector j pce connector Controller side able side J details for wiring J JE NL K 11 Sse M o WS O E The controller has an internal power supply of 24V Do not connect any N CAUTION thing other than the emergency stop switch Emergency stop input current 100mA Typical TEACH AUTO mode input current 5mA Typical for 24V input REMOTE2 Internal 24 V current Power source capacitance 1 A max 24 VO REMOTEI 5 Emergency stop input Caution 5 TEACH is Dynamic brake relay m ieri arira a Dorn i aa mc itcm ifm ngo E F JL l Y I ET 8 TEACH mode input L Aen T 1 NC
178. w 0 16 3248 64 80 96 11244 ouput common KDC 21 2 18 34 50 66 82 98 114 Output common DC 22 3 r9 ss st 67 s3 99 115 47 24 V output 23 4 20 se s2 68 s4 100 116 48 524 Vowpur 24 5 J21 37 53 69 85 101 117 2s 6 22 38 54 70 86 102 118 50 322 VGND owp Functions 6 I O 6 5 Input circuit NPN type Input voltage range DC 12 to 24V 10 ON voltage DC 10 8V min OFF voltage DC4V max 5mA typical with input of DC 24V Input circuit diagram and wiring example GND 4DC Input No 0 7 common 4 DC 2 Input No 0 4 e SCC DUNS E l ircuit as F 3 Input No 1 Same circuit as above i nput NO Boe SS etri etc l Input No 2 7 Input No 3 Input No 4 Input No 5 Input No 6 Input No 7 Input No 8 15 common DC l 11 Input No 8 l 12 Input No 9 Abbreviated 45 Functions 6 I O 6 6 Output circuit NPN type Rated output voltage DCI2 to 24V 10 N channel power MOS FET Output circuit diagram and example of connections I O 1 GND DC Output No 0 L Inductor Output No 1 L Output No 2 Output No 3 Output No 4 Output No 5 Output No 6 Output No 7 Output No 8 Output No 9 wan Abbreviated 43 Output common DC
179. wer plug not 1 Check that the power plug is disconnected inserted properly 2 Is the switching power 2 Check that PSUI is output Section 3 3 in Main PSU1 output normally normally tenance volume The SYS ERROR lamp lights but no error code is displayed Diagnosis Correction 1 Tum on the power again 1 If the system operates nor and confirm that the sys mally the trouble is caused tem operates normally by an instantaneously power failure Do the three red LEDs Check that the ROM on the Section 7 3 in Main RES HSLT WDT on MPU board is mounted tenance volume the MPU board light properly and insert the MPU board securely If the three LEDs red often light re place the MPU board Check that a switching If the output value does not Section 3 3 and 3 4 power PSU1 of 5V is satisfy the specifications in Maintenance vol output properly adjust VR2 to satisfy the re ume quired specifications If the adjustment is impossible re place the PSU 158 Maintenance 15 Trouble Shooting The emergency stop cannot be canceled Diagnosis Correction 1 2 7 Is the REMOTEI con nector not disconnected Is the emergency stop input pin of the RE MOTEI connector not open Is the REMOTE2 con nector not disconnected Is the TEACH port not open Is the emergency stop switch of the connected equipment not pressed e PC cable e Operating unit e Teaching pendant
180. who have taken a robot training course held by the dealer or those who have carefully read the manuals and have equivalent knowledge or skill B Controller has the capacitors charged high voltage To avoid an electric shock do not touch the dangerous high voltage parts marked with the orange label until the orange LED of motor power unit is faded out completely When the orange LED is faded out the high voltage capacitors are discharged e eel eJ I Ld 9 9 8 9 9 dal E For safety be sure to remove M C POWER cable from the M C POWER con nector at the rear panel of controller so that the manipulator should not move le LL Orange LED M P accidentally N C AUTION E Temperature of PSU may rise depending on the operating condition Check the surface temperature before handling and use the protective gloves if nec essary 96 Maintenance 3 PSU PSU1 PSU2 replacement 1 2 3 4 5 6 7 8 9 Turn OFF the controller unplug the controller s power cord and wait about two min utes Remove the controller s upper cover As the earth line is connected to the upper cover do not pull the cover unnecessarily Cut off the cable clamp which fastens
181. xist Change the name 2 The disk is full Specified file or directory does not exist Memory shortage for environment string Maximum memory for environment string is 512 bytes Batch file is too large Maximum memory for batch file is 4KB E880 ooo o 156 Maintenance 15 Trouble Shooting 15 2 Troubles whose error codes are not displayed The troubles whose error codes are not displayed are as described below Send the communication list in the following section 15 3 to the service center when these troubles cannot be restored even if they are diagnosed and treated by the methods de scribed in this section The power cannot be turned on even if the power switch is turned on The SYS ERROR lamp lights but no error code is displayed The emergency stop cannot be canceled The system does not operate at a set speed The operation speed is low The motor is turned on excited but it does not operate No precision is obtained during installation and operation The arm vibrates during positioning completion and low speed operation An abnormal sound is generated during operation and stop There is an axis that does not operate The I O port does not operate or another I O port operates The operating unit does not operate The REMOTES connector does not operate 157 Maintenance 15 Trouble Shooting The power cannot be turned on even if the power switch is turned on Diagnosis Correction 1 Is the po

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