FANUCS10 Maint

FANUC Robot S-10/S-700
Maintenance and Troubleshooting

Reference Manual
MARMKS17H0885EF
(B-67395E-G/01)
This publication contains proprietary information of FANUC Robotics

North America, Inc., furnished for customer use only. No other uses are
authorized without the express written permission of FANUC Robotics
North America, Inc.
FANUC Robotics North America, Inc.
2000 South Adams Road
Auburn Hills, Michigan 48326-2800
The description and specifications contained in this manual were in effect
at the time this manual was approved for printing. FANUC Robotics
North America, Inc, hereinafter referred to as FANUC Robotics, reserves
the right to discontinue models at any time or to change specifications or
design without notice and without incurring obligations.
FANUC Robotics manuals present descriptions, specifications, drawings,
schematics, bills of material, parts, connections and/or procedures for
installing, disassembling, connecting, operating and programming FANUC
Robotics’ products and/or systems. Such systems consist of robots,
extended axes, robot controllers, application software, the KAREL®
programming language, INSIGHT® vision equipment, and special tools.
FANUC Robotics recommends that only persons who have been trained in
one or more approved FANUC Robotics Training Course(s) be permitted
to install, operate, use, perform procedures on, repair, and/or maintain
FANUC Robotics’ products and/or systems and their respective
components. Approved training necessitates that the courses selected be
relevant to the type of system installed and application performed at the
customer site.
A WARNING
This equipment generates, uses, and can radiate radio
frequency energy and if not installed and used in
accordance with the instruction manual, may cause
interference to radio communications. As temporarily
permitted by regulation, it has not been tested for
compliance with the limits for Class A computing devices
pursuant to subpart J of Part 15 of FCC Rules, which are
designed to provide reasonable protection against such
interference. Operation of the equipment in a residential
area is likely to cause interference, in which case the user,
at his own expense, will be required to take whatever
measure may be required to correct the interference.
FANUC Robotics conducts courses on its systems and products on a

regularly scheduled basis at its headquarters in Auburn Hills, Michigan.
For additional information contact
Training and Documentation Department
Tel: (313)377-7234
FAX: (313)377-7367 or (313)377-7362
Copyright ©1988, 1993 by FANUC Robotics North America, Inc.
All Rights Reserved
The information illustrated or contained herein is not to be reproduced

copied, translated into another language, or transmitted in whole or in part
in any way without the prior written consent of FANUC Robotics North
America, Inc.
KAREL® and INSIGHT® are Registered Trademarks of FANUC

Robotics.
FANUC Robotics reserves all proprietary rights, including but not limited
to trademark and trade name rights, in the following names:
ACCUFLOW®
ARC Mate®
ARC Mate Sr.®
ArcTool ®
DispenseTool®
IntelliTrak®
LaserTool®
MotionParts®
PALLETMATE®
PalletTool®
PaintTool®
PaintWorks®
R-Model J Controller®
Sockets®
SoftParts®
SpotTool®
SureWeld®
TurboMove®
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FANUC Robotics Hotline

For a PRODUCTION robot that is DOWN
call 24 hours a day, 7 days a week
810-377-7159
For all other Troubleshooting and Technical Support

contact your local distributor or call the Hotline
Monday - Friday, 8:00 A.M. - 5:00 P.M. Eastern Time
BEFORE YOU CALL please have your Maintenance and Troubleshooting manual, and the
following information, ready.
INFORMATION DETAILS
Customer Information Include
•caller’s
your company’s name
•phone number
name
• where caller can be reached, including
area code and extension
Robot type On the arm of the robot.
: (A, L, M, P, orS, & 3-digit number)
Controller style Ask your supervisor.
(RA, RB, RC, RF, RG, RG2, RH, RJ, RJ2)
F Number On the identification tag on the robot and controller, near the
cable connection.
Robot serial number On the identification tag located near the cable connection.
(if no F Number is available)
Controller serial number On the controller tag located on the doors.
(if no F Number is available)
Software edition and revision numbers Shown on the CRT or teach pendant status screen during the
power-up sequence.
List of error messages Include
•error message number
•any numbers
message following error message number
• following error message
List of diagnostic LEDs Note the PCB where the LED is located and the LED name or
designation.
History of problem Description of events leading up to the problem.
Application software List
•the
any application software running the system
•a description
line number where the program halted
i
• of what is happening on that line
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TABLE OF CONTENTS
I. OVERVIEW AND CONTROLLER MAINTENANCE
1. INTRODUCTION 1-1
1.1 Structure 1-1
1.2 Problem Conditions and Determining Causes 1-2
1.2.1 Making preliminary check 1-2
1.2.2 Locating the cause of the problem ... 1-2
1.2.3 Checking the mechanical unit 1-3
2. SAFETY . 1-4
2. 1 Personnel Safety Considerations 1-4
2.1.1 General precautions 1-4
2.1.2 Operator safety precautions 1-5
2.1.3 Teacher safety precautions 1-5
2.1.4 Maintenance personnel safety considerations 1-5
2.2 Machine Tool and Peripheral Device Safety Considerations 1-6
2.2.1 Programming precautions 1-6
2.2.2 Mechanical precautions . 1-6
1-6
2.3 Robot Safety Considerations
2.3.1 Operating precautions 1-6
2.3.3 Mechanical precautions 1-7
2.4 End Effector Safety Considerations 1-7
2.4.2 Mechanical precautions 1-7
3. CONTROLLER DESCRIPTIONS 1-8

3.1 General Description 1-8
3.2 External Components 1-21
3. 3 Internal Components 1-27
3.4 Controller Components Specifications 1-30
4. PREVENTIVE MAINTENANCE 1-36

4.1 Daily Checks 1-36
4.2 Monthly Checks (Determined by hours of operation) 1-38
4.3 Quarterly Checks 1-38
4.4 Semiannual Checks 1-38
4.5 3-year Checks 1-38
4.6 Periodic Replacement 1-38
4.7 Maintenance Tools 1-39
5. TROUBLESHOOTING . 1-40
5.1 Introduction . 1-40
5.2 Power Cannot be Turned On...
5.3 Troubleshooting Using Error Codes
.
.
1-40
1-42
5.3.1 Error code 4001 DEADMAN switch 1-42
5.3.2 Error code 4002 emergency stop . 1-43
5.3.3 Error code 4003 pneumatic pressure alarm 1-43
5.3.4 Error code 4004 hand breakage detection 1-44
5.3.5 Error code 4005 robot overtravel 1-44
5.3.6 Error code 4006 relay welding detection 1-44
5.3.7 Error code 4008 TGLS alarm 1-45
5.3.8 Error codes 4009 -
4014 1-47
5.3.9 Error code 4020 velocity ready is off 1-47
5.3.10 Error code 4022 overload . 1-47
5.3.11 Error code 4024 fuse alarm in brake circuits 1-50
5.4 Troubleshooting Servo Amplifier 1-51
6. BACKPLANE PCB (A2 0B-10 02-0860)

6.1 Theory of Operation
... . 1-56
1-56
6.2 Block Diagram 1-56
6.3 Connector/Signal Identification 1-57
6.4 Jumper Settings 1-63
6.5 Fuse 1-64
6.6 Test Points 1-65
6.7 Removal/Replacement 1-65
7. POWER SUPPLY UNIT (A20B-1000-0770) 1-66

7.1 Theory of Operation . 1-66
7.3 Connector /Signal Identification 1-68
7.4 Variable Resistors 1-69
7.5 Fuses 1-71
8. MAIN CPU BOARD (A16B-1211-0040, 0041) 1-76

8. 1 Theory of Operation 1-76
8.3 Connector/Signal Identification
8.4 LEDs .
.. 1-76
1-79
8.6 Removal /Replacement 1-81
9. PATH CPU BOARD (A16B-1211-0030)

... 1-82
1-82
9.4 LEDs 1-85
9.6 Variable Capacitor 1-86
10. SHARED RAM BOARD (A16B-12 11-0860) 1-89

10.1 Theory of Operation 1-89
10.4 LEDs 1-94
11. BUBBLE MEMORY BOARD (A16B-1211-0090, 0091, 0092) 1-97

11.4 Jumper and Switch Settings 1-99
12. AXIS CONTROL BOARD (A16B-1211-0060, 0062) 1-102

12.4 LEDs 1-110
12. 7 Removal/Replacement 1-111
13. REMOTE CRT /KB (A13B-0144-BOO1) 1-112

13.4 CRT /KB Control PCB (A16B-1211-0760)
13.4.1 Connector/signal identification
.... 1-114
1-114
13.4.2 Variable resistors 1-115
13.4.3 Jumper settings 1-116
13.4.4 Test points 1-117
13.4.5 Removal /replacement 1-118
13.5 Keyboard PCB (A86L-0001-0149) 1-119
13.5.1 Connector /signal identification .. 1-119
13.5.2 Removal/replacement 1-119
13.6 CRT Monitor (A61L-0001-0088) 1-120
13.6.1 Connector/signal identification .. 1-120
14. BUILT-IN CRT/KB (A05B-2051-J101, J102) ... 1-121

14.4 CRT/KB Control PCB (A20B-1003-0340)
.... 1-122
1-122
14.4.3 Jumper setting 1-124
14.4.5 Removal/ replacement 1-125
14.5 Keyboard PCB (A86L-0001-0149) 1-126
14.5.2 Removal/replacement
.. 1-126
1-126
14.6 Software Keyboard PCB (A20B-1000-0844) 1-127
14.6.1 Connector/signal identification .. 1-127
14.7 CRT Monitor (A13B-0056-0001) 1-128
14.7.1 Connector /signal identification .. 1-128
14.7.2 Adjustment routine 1-129
14.7.3 Special adjustment 1-130
14.7.4 Troubleshooting flow chart 1-132
15. I/O BASE UNIT (A03B-0801-C012) 1-134

15.1 Theory of Operation . 1-134
15.2 Block Diagram . 1-134
15. A Removal /Replacement 1-136
16. ROBOT CONTROL MODULE (A03B-0801-C462) 1-137

16.3 Connector/Signal Identification .. 1-138
16. A LEDs 1-141
17. DI MODULE 1-147

17.4 LEDs 1-150
18. DO MODULE . 1-152

18.4 LEDs 1-155
18.5 Fuses 1-156
19. ANALOG INPUT MODULE (A03B-0801-C410) 1-162

19.3 Connector/Signal Identification . 1-163
1-164
19.4 Variable Resistors
19.7 Calibration Procedure 1-167
20. ANALOG OUTPUT MODULE (A03B-0801-C411) 1-168

20.3 Connector/Signal Identification .. 1-169
20.4 Variable Resistors 1-170
20.8 Calibration Procedure 1-174
21. FIXED I/O BOARD (A16B-12 11-0750) . 1-176

22. TEACH PENDANT (A05B-2051-C142) 1-181

22.3 Teach Pendant (A05B-2051-C142) 1-182
22.3.1 Connector/signal identification 1-182
22.3.2 Removal/replacement of teach pendant and components 1-183
22.4 Teach Pendant Control PCB (A20B-1002-0980) 1-184
22.4.1 Connector /signal identification 1-184
1-187
22.4.3 Jumper settings
22.4.4 Test points .
22.4.5 Removal/replacement of teach pendant control PCB ..
1-187
1-188
22.5 Keyboard PCB (A20B-1002-0970) 1-189
22.5.2 Removal/replacement of keyboard PCB . 1-189
22.6 LCD Module (A61L-0001-0109) 1-190
22.6.2 Removal/replacement of LCD module 1-190
22.7 LCD Control PCB (A61L-0001-0100 #CB1053RP) 1-191
22.7.2 Removal /replacement of LCD control PCB 1-191
23. POWER INPUT UNIT 1-192

.
23.1 Theory of Operation ..; 1-192
23.3 Power Input Unit 1-196
23.3.1 Fuses 1-198
23.4 Power Input Unit PCB (A16B-1310-0530) 1-201
23.4.1 Connector /signal identification . 1-201
23.4.2 Jumper/shorting strip settings .. 1-206
23.4.3 LEDs 1-208
23.4.4 Fuses 1-209
24. TRANSFORMERS 1-212

24.1 Fuses .... 1-213
24.2 Settings . 1-214
25. HOUR METER 1-215

26. SERVO AMPLIFIER . 1-216

26.1 One-axis Servo Amplifier . 1-217
26.1.1 Theory of operation 1-217
26.1.2 Block diagram . 1-218
26.1.3 Connector /signal identification 1-219
26.1.4 LEDs . 1-222
26.2 Two-axis Servo Amplifier 1-227
26.2.2 Block diagram 1-227
26.2.4 LEDs 1-232
26.2.6 Jumper settings . 1-235
26.2.7 Removal /replacement . 1-236
26.3 Three-axis Servo Amplifier . 1-237
26.3.2 Block diagram 1-237
,26.3.4 LEDs 1-242
26.4 Discharge Unit 1-247
26.4.1 Location of discharge unit
26.4.2 Removal /replacement
.... 1-247
1-247
27. OPERATOR'S PANEL 1-248

28. BATTERY UNIT 1-254

29. OUTLET UNIT AND GROUND CONNECTED LAMP 1-255

29.1 Lamp 1-255
29.2 Fuse 1-255
30. SERVO-ON RELAY UNIT AND SERVO-ON LAMP 1-256

30.1 Connector /Signal Identification .. 1-256
30.2 Lamp 1-256
30. 3 Removal/Replacement 1-257
31. FAN UNIT . 1-258

31.1 Fan Unit for Large Size Cabinet 1-258
31.1.1 Operation of heat exchange system 1-258
31.1.2 Removal /replacement . 1-259
31.2 Fan Unit for Medium Size Cabinet . 1-261
31.2.1 Operation of heat exchange system 1-261
31.2.2 Removal/replacement .... . 1-262
II. S-10 MECHANICAL UNIT MAINTENANCE
1. CONFIGURATION 2-1
.
1 1 0-axis Drive Mechanism 2-2
.
1 2 W-axis Drive Mechanism 2-3
1.3 U-axis Drive Mechanism 2-3
1.4 Y~axis Drive Mechanism 2-4
1.5 B-axis Drive Mechanism 2-4
1.6 a-axis Drive Mechanism 2-5
1.7 Major Component Specifications 2-5 ‘
2. LUBRICATING CONDITION CHECKS 2-8
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3 . TROUBLESHOOTING 2-11
2-11
3.1 General
3.2 Problems and Causes 2-11
3.3 Replacing Parts and Performing Adjustments 2-13
4. ADJUSTMENTS . 2-14
4.1 Adjusting Limit Switches and Dogs 2-14
4.2 0-axis Stroke Modification . 2-17
4.3 Mastering Procedure . 2-20
4.3.1 Introduction 2-20
4.3.2 Mastering procedure 2-20
4.3.3 Zero-degree position 2-22
4.3.4 Mastering using a mastering fixture 2-23
4.4 Adjusting U-axis Bevel Gear Backlash .. 2-27
4.5 Adjusting B-axis Bevel Gear Backlash .. 2-28
5. REPLACING AND ADJUSTING PARTS 2-29

5.1 Replacing 0-axis Motor
5.2 Replacing 0-axis Reducer
.... 2-29
2-31
5.3 Replacing W-axis Motor
5.4 Replacing W-axis Reducer
.... 2-32
2-33
5.5 Replacing U-axis Motor ... 2-34
5.6 Replacing U-axis Reducer. 2-35
5.7 Replacing a-axis Motor and Harmonic Drive 2-36
5.8 Replacing B-axis Motor and Harmonic Drive 2-38
5.9 Replacing y-axis Motor and Reducer 2-40
5.10 Replacing Battery 2-42
6. WIRING AND PIPING . 2-43

6.1 Piping Diagram . 2-43
6.2 Wiring Diagram . 2-43
6.3 Limit Switch Installation Diagram 2-44
6.4 Cable Installation Diagrm . 2-44
7. REPLACING CABLES 2-45

7.1 Cable Forming 2-45
7.2 Replacing Cables 2-46
7.3 Replacing Limit Switch 2-50
III. S-700 MECHANICAL UNIT MAINTENANCE
1. CONFIGURATION . 3-1
1.1 0-axis Drive Mechanism 3-2
1.2 W-axis Drive Mechanism 3-3
1.3 U-axis Drive Mechanism 3-4
1.4 y-axis Drive Mechanism 3-4
1.5 a/B-Axis Drive Mechanism (Offset wrist) 3-5
1.6 a/B-Axis Drive Mechanism (In-line wrist) 3-5
1.7 Major Component Specifications 3-6
2. LUBRICATING CONDITION CHECK 3-11

2.1 Three-month Periodical Check 3-11
2.2 Replacing Drive Mechanism Grease 3-11
2.3 Adding Grease —9-axis Cross Roller Bearing 3-18
3. TROUBLESHOOTING 3-19
3.1 General 3-19
3.2 Failures and Causes 3-19
3.3 Replacing Parts and Performing Adjustments 3-22
4. ADJUSTMENTS . 3-23
4.1 Adjusting Limit Switches and Dogs . 3-23
4.2 Stroke Modification 3-31
4.2.1 0-axis stroke modification 3-31
4.2.2 W-axis stroke modification 3-34
4.3 Mastering Procedure 3-37
4.3.1 Introduction 3-37
4.3.2 Mastering procedure 3-37
4.3.3 Zero-degree position 3-39
4.3.4 Mastering using a mastering fixture 3-40
4.4 Adjusting Bevel Gear Backlash 3-45
5. REPLACING PARTS 3-49

5.1 Replacing 0-axis Motor and
5.2 Replacing W-axis Motor and
Reducer
Reducer
...
... 3-49
3-52
5.3 Replacing U-axis Motor and
5.4 Replacing a/B/y-axis Motor
Reducer ...
and Reducer
3-54
3-56
5.5 Replacing Wrist Unit 3-58
5.6 Replacing Battery 3-59
6. WIRING AND PIPING . 3-60

6.1 Piping Diagram 3-60
6.2 Wiring Diagram 3-60
6.3 Limit Switch Installation Diagram 3-62
6.4 Cable Installation Diagram 3-63
7. REPLACING CABLES 3-64

7.1 Cable Forming 3-64
7.2 Replacing Cables 3-66
7.3 Replacing Limit Switches 3-72
IV. CONNECTIONS
1 . GENERAL 4-1
2. SAFETY PRECAUTIONS .. 4-2

2.1 General 4-2
2.2 Safety Precautions 4-2
3. CONTROLLER CONNECTIONS AND SIGNALS 4-5

3.1 Connection Diagram 4-5
3.1.1 Cable clamp 4-5
3.2 Connections 4-6
3.2.1 Input power connection 4-6
3.2.2 Connection for external on-off control of power supply 4-8
3.2.3 Connection to I/O devices 4-9
3.2.4 Connection to pulse encoder for line tracking 4-11
3.2.5 Controller and peripheral device connections 4-14
3.2.6 Connection for emergency stop control 4-30
3.2.7 Connection to computer 4-32
3.2.8 Connection to remote CRT/KB 4-34
3.3 Setting USAT 4-35
3.4 I/O Module Specifications 4-43
4. S-10 MECHANICAL UNIT 4-61

4. 1 Connection between Controller and Mechanical Unit 4-61
4.2 Connections and Signals between Mechanical Unit
and End Effector 4-64
4.2.1 Connections 4-64
4.2.2 DI/DO standards for end effector control interface 4-65
4.2.3 End effector control interface cable 4-67
4.2.4 Noise suppressors 4-68
4.3 Mechanical Interface 4-69
4. 3. 1 Robot motion area 4-69
4.3.2 Mechanical coupling of end effector to wrist 4-71
4.3.3 Location and dimensions of equipment mounting holes 4-72
4.3.4 Air supply 4-73
5. S-700 MECHANICAL UNIT 4-74

5.1 Connection between Controller and Mechanical Unit . 4-74
5.2 Connections and Signals between Mechanical Unit
and End Effector 4-77
5.2.1 Connections 4-77
5.2.2 DI/DO standards for end effector control interface 4-77
5.2.3 End effector control interface cable 4-77
5.2.4 Noise suppressors 4-77
5.3 Mechanical Interface 4-77
5.3.1 Robot motion area 4-77
5.3.2 Mechanical coupling of end effector to wrist 4-82
5.3.3 Location and dimensions of equipment mounting holes 4-83
5.3.4 Air supply 4-85
V. INSTALLATION
1. S-10 ROBOT . 5-1

1.1 Transportation and Installation 5-1
1.1.1 Transportation . 5-1
1.1.2 Installation 5-3
1.1.3 Maintenance area 5-5
1.2 Assembly During Installation .. 5-6
1.2.1 Robot cables 5-6
1.2.2 Air piping 5-7
1.2.3 Installation specifications 5-8
2. S-700 ROBOT 5-9

2. 1 Transportation and Installation 5-9
2.1.1 Transportation 5-9
2.1.2 Installation 5-10
2.1.3 Maintenance area 5-16
2.2 Assembly During Installation .. 5-17
2.2.1 Robot cables 5-17
2.2.2 Air piping 5-19
2.2.3 Installation specifications 5-20
3. ADJUSTMENTS AND CHECKS DURING INSTALLATION 5-21

3.1 Items to be Checked 5-21
4. INITIAL START UP 5-29

4.1 Description of Initial Start Up 5-29
4.2 Recovery from Alarm Conditions 5-31
4.2.1 General error recovery .... 5-31
4.2.2 Over travel 5-32
4.2.3 Emergency stop 5-32
VI. APPENDIX
APPENDIX 1. INTERNAL CONNECTIONS . 6-1

1.1 S-10 . 6-1
1.2 S-700 . 6-25
1.3 Power Input Unit Connection Diagram 6-38
APPENDIX 2. CABLE SPECIFICATIONS 6-42
APPENDIX 3. PREVENTIVE MAINTENANCE SCHEDULES 6-53

.
3 1 Preventive Maintenance Schedules 6-53
3.2 Preventive Maintenance Check List .... 6-55
APPENDIX 4. SYSTEM VARIELE ALPHABETICAL DESCRIPTIONS

4.1 System Variable Descriptions 6-57
I. OVERVIEW AND CONTROLLER MAINTENANCE
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1. INTRODUCTION
This manual presents a description of the S-10 and S-700 robots and also a
description of the R-H controllers (S-10: A05B-2066-B001/A05B-2067-B001;
S-700: A05B-206 1-BOO1) and each of their components, including component
setting, adjustment and replacement procedures. Preventive maintenance and
troubleshooting methods are also described.
WARNING) Turn off the power or press the EMERGENCY STOP button on the teach
pendant or operator's panel before entering the robot motion area.
1.1 Structure
Fig. 1.1 shows the configuration of the controller and mechanical unit for both
the S-10 and S-700 robots.
CRT/KB pud Operator** pud

CRT/KB panel Operator’* pud
/ÿ
mri
A 1
Operator’s panel
/ ®
Bps OBBo
±_
O 300
MSBa CD
Teach
pendant r"f Teach
pendant
Teach
pendant
CD
S-10 control unit S-10 control unit S-700 control unit
(A05B-2066-B001 ) (A05B-2067-B001) (AO 5B-2061-BOO1)
Medium size cabinet Large size cabinet
jliH O
rs M— - *
i. t.
S-10 mechanical unit S-700 mechanical unit S-700 mechanical unit

(A05B-1204-B202) (A05B-1120-B012) (A05B-1120-B002)
In-line wrist Offset wrist
Fig. 1.1 Configuration of the S-10 and S-700 controller* and mechanical unit*
1-1
The S-10 and S-700 robots are articulated robots with six axes.
The medium size control unit for the S-10 is comprised of the operator’s panel
and the teach pendant. The large size cabinet also includes a built-in CRT/KB.
The control unit for the S-10 or S-700 is comprised of the operator's panel,
CRT/KB and teach pendant. The control unit for the S-700 is also comprised of a
side cabinet.
1.2 Problem Conditions and Determining Causes

To correctly identify the cause of a problem, it is necessary to analyze the
problem conditions accurately. To minimize the downtime caused by these
problems, perform the following checks: First make a preliminary check of items
(a) thru (c). Second, make sure that the problem has not been caused by
incorrect operation or errors in programming. Third, find out whether the
malfunction is in the control unit or the mechanical unit.
1.2.1 Making preliminary check

a) Is the robot being operated normally?
(Check emergency stop, teach pendant ENABLE ON/OFF switch, hold.)
b) Is an error message displayed?
c) When and in what location did the problem occur? What is its frequency?
Note the following:

. Mechanical position where the problem occurred
. Error message displayed
. Problem frequency
. Amount of positioning error
Display of the program position where the problem occurred
. Software series and edition number displayed on the CRT when the power is
turned on.
. System variables
Compare the values set in system variables to the standard values for system
variables set in the control unit.
. Results of interface signal check by using the diagnostic system.
. In what part of program did the problem occur? (program name, line number,
etc.) Is the problem related to the movement of a controlled axis?
1.2.2 Locating the cause of the problem

Identify an abnormal symptom by using the analysis of the above items, and
determine a probable cause of the problem from the following:
a) Error in operation or programming
Operate the robot correctly and note any difference.
b) A problem in a peripheral device, remote control panel, or another externally
connected unit. Check the interface signals between the system and error
messages. If necessary, change the externally connected unit to agree with
the interface diagram.
c) Control unit check
Check to see if any of the LEDs on the PCBs in the control unit are lighted
indicating the cause of an alarm.
If an alarm related to the servo system has occurred, check the LEDs in the
servo amplifier to determine the axis which is the cause of the problem.
Check whether this LED is lighted before turning off the power supply.
1-2
1.2.3 Checking the mechanical unit
Check the following:
a) External damage
Check the mechanical unit for damage due to foreign substances in the unit or
contact with peripheral devices or other external equipment.
b) Excessive load or external force
Is the force required for the movement of the workpiece within the limit
conditions set for the robot?
Has excessive external force been applied?
c) Cables and hose
Are cable connectors securely connected?
Are moving cables and internal cables free of damages, sharp bends, or other
defects?
Are there any air leaks?
d) Smooth movement
Is the servo amplifier functioning normally?
Do the axes decelerate smoothly without any shock when the robot stops?
Are there any abnormal noises or vibrations during movement?
1-3
2. SAFETY
GMFanuc Robotics Corporation (hereafer referred to as GMF Robotics or GMF) is
concerned with the safety and welfare of its customers, their employees, and
their equipment. However GMF does not design or install safety related
equipment and consequently cannot be responsible for ensuring the safety of the
various user personnel. GMF expressly disclaims any such responsibility.
Safety should, however, be given the highest priority in designing and using a
robot system.
Although the user must comply with all federal, state, and municipal laws,
regulations, or guidelines pertaining to safety, the user must also take such
steps as may be necessary to ensure the safety of all personnel.
2.1 Personnel Safety Considerations
2.1.1 General precautions

While GMF cannot be responsible for the safety of the robot system design, GMF
strongly recommends that the following steps be taken to promote the safety of
user personnel. These suggestions are intended to supplement and not replace
any federal, state, or local laws, regulations, or guidelines.
. Train all individuals associated with the robot system in an approved GMF
training course.
. Equip the system with a flashing light or other visual or audible warning
device to indicate when the robot is. operating (i.e. power is applied to the
robot's servo drive units).
. Provide an interlocked barrier guard, such as that shown in Fig. 2.1.1, which
cuts drive power to the servos when a barrier gate is opened.
Fig. 2.1.1 Use of a fence to secure work area
. Ensure that all peripheral devices are properly grounded to minimize the
effects of electromagnetic interference (EMI) and radio-frequency interference
(RFI).
. Locate all controls outside the robot mechanical unit’s work envelope.
. Clearly identify the work envelope of the robot with signs, lines on the
floor, and special barriers.
. Use presence-sensing devices such as light curtains, mats, capacitance
systems, proximity-sensing devices, and vision systems to enhance safety.
. Make provisions for power lockout/tagout.
1-4
2.1.2 Oporator safety precautions
Implement the following measures to safeguard the operator.
. Use anti-tie-down logic to prevent the operator from bypassing safety
measures.
. Install from
a lockout device using an "access code" to prevent unauthorized
persons operating the robot.
. Mount EMERGENCY STOP switches within easy reach of the operator and at
critical points in and around the work cell.
. Where possible, install safety fences, shown in Fig. 2.1.1, to protect against
unauthorized, entry into the work envelope.
. Install special guarding to prevent the operator from reaching into restricted
areas of the work envelope.
2.1.3 Teacher *afety precaution*

Implement the following safety measures to safeguard the program teacher.
. Before teaching, make a visual inspection of the robot and work envelope to
ensure no potentially hazardous conditions exist.
. Before entering the work envelope, confirm that all safeguards are in place.
. When teaching positional data, the teacher must have sole control of the
robot.
. When data is being taught, isolate the robot from all remote control signals
that can cause motion.
. Any program being run for the first time should be tested in the following
manner:
WARNING: The user should remain clear of the robot’s work envelope at all times
when a program is being run.
1. Using a low motion speed, test run the program in the single step
mode for at least one full cycle.
2. Using a low motion speed, test run the program in the continuous
3. Using a higher motion speed, test run the program in the continuous
4. If the program operates correctly for each of the above tests,
install all safety measures and run the program in automatic mode.
. Do not begin an automatic mode of operation until the teacher is clear of the
work envelope.
2.1.4 Maintenance personnel wfety conttderations

Implement the following safety measures to safeguard maintenance personnel.
. Where possible, perform maintenance with- the power off. Implement
lockout /tagout procedures and release or block all stored energy (air, etc.).
. Before entering the work envelope, make a visual inspection of the robot
system to ensure that no potentially hazardous conditions or malfunctions
exist. Functionally test the teach pendant for proper operation before
entering the work envelope.
. When 'maintenance must be performed inside the work envelope with power
applied, those inside the work envelope must have sole control of the robot.
Isolate the robot from all remote control signals.
. Do not place the robot into automatic mode unless all personnel are clear of
the work envelope.
. Place the robot arm in a location that will ensure that personnel will noc be
exposed to a trap point. An escape path should always be provided.
1-5
. Use devices such as blocks, mechanical stops, and pins to prevent hazardous
movement of the robot. Care must be taken to ensure that such devices do not
generate trap points for personnel.
. For some procedures, a second person should be positioned at the operator's
panel. This person must have proper understanding of the robot system and
knowledge of the associated potential hazards.
2.2 Machine Tool and Peripheral Device Safety Considerations
2.2.1 Programming precautions

Implement the following programming safety measures to prevent damage to the
machine tool and other peripheral devices.
. Back-check any limit switches used in the work cell to identify failure before
any component of the work cell can be damaged.
. Implement "failure routines" in robot programs that are designed to provide
appropriate robot actions in the event that a peripheral device or another
robot in the work cell fails.
. Use "handshaking" protocol to ensure that the operations of the robot and the
peripheral device are synchronized.
. Program the robot to check the condition of all peripheral devices during an
operating cycle.
2.2.2 Mechanical precautions

Implement the following mechanical safety measures to prevent damage to the
machine tool and other peripheral devices.
. Ensure that the work cell is clean and free of oil, water, or debris of any
kind.
. Limit the work envelope of the robot through the use of limit switches
(software limits) and mechanical stops to avoid unnecessary movement of the
robot into the work area of the machine tool and peripheral devices.
2.3 Robot Safety Considerations
2.3.1 Operating precautions

Implement the following operating safety measures to prevent damage to the
robot.
. When jogging the robot, use a low speed override to obtain greater control of
the mechanical unit.
. Before pressing any of the manual jog keys on the teach pendant, think of the
robot motions that will result.

Implement the following programming safety measures to prevent damage to the
robot.
. When two or more robots must share the same work area, establish "interference
zones" to provide other robot controllers and peripheral devices with
information regarding the location of the robot mechanical unit during
operation.
. Ensure that the robot program ends with the mechanical unit near the
calibration point.
1-6
Implement the following safety measures to prevent damage to the robot.
. Ensure that the work envelope of the robot is clean and free of oil, water, or
debris of any kind.
. Use circuit breakers to guard against electrical overload.
2.4 End Effector Safety Considerations

The following programming safety measures should be implemented to prevent
damage to the end effector.
. Provide an "open-gripper" command just prior to picking up the workpiece.
. Provide a time delay to allow any actuator (pneumatic, hydraulic, or
electrical) sufficient time to operate after the appropriate input/output
command has been given.
. Use output signals from limit switches in the end effector to verify that the
end effector is operating properly (i.e. a part-in-gripper limit switch).
. Program a reduced deceleration rate as the robot approaches a "pick-up point"
or workpiece to prevent an overshoot of the programmed point.

Implement the following mechanical safety measures to prevent damage to the end
effector.
. Use a safety joint to protect and end-of-arm tooling.
. Design sufficient compliance into the end effector to allow for small
variations in the orientation of the workpiece.
. Install sensors on the end effector (i.e., photoelectric, cats-whisker limit
switch) to detect when the end-of-arm tooling is approaching an obstruction.
. Use a vision system to ensure that the robot mechanical unit and end effector
are oriented properly to pick up the workpiece.
. Use additional hardware to ensure that the workpiece is oriented properly so
that the robot mechanical unit end effector picks up the part correctly.
1-7
3. CONTROLLER DESCRIPTIONS
3.1 General Description

The controller controls servo motors provided for each axis of the robot. It
also controls the end effector and interface signals between the controller and
associated peripheral devices.
S—10 and S-700 robots are controlled by one of the following controllers.
1) A05B-2066-B001 S-10/R-H controller (Medium size cabinet)
2) A05B-2067-B001 S-10/R-H controller (Large size cabinet)
3) A05B-2061-B001 S-700/R-H controller (Latge size cabinet)
The controller contains the following components:
1) Basic control unit (including backplane, power supply unit and control
PCBs)
2) I/O unit
3) Battery unit
4) Circuit breaker
5) Power input unit
6) Servo amplifiers
7) Operator's panel
8) Remote CRT/KB unit or Built-in CRT/KB panel
9) Teach pendant
10) Transformers
11) Fan units
12) Outlet unit
13) Servo-on relay unit
Built-in CRT/KB panel, Outlet unit and Servo-on relay unit are options only for
controllers with large size cabinets.
The connection of each unit is shown in Fig. 3.1 (a)
The function of each unit is shown in Table 3.1.
- (j).
1-8
Modular I/O unit
i£
CNP2 CNP3 cpii ]|}
Power
CNP1 ][ PSU1 supply CPI 3
unit Power input unit
CP14
CNB
jlTvEl
CNA J4_
Vision
engine 1
_l
I
n
CNB
CNA
CNB
3
J
ri
VE2 Vision
engine 2 l Future option
01P0B Vision
CNA CPU board
CNP1
CNP
Shared
CNA][ 01P04 RAM
board
CNOP Operator’s pnael
CD4 Host computer
CNTP
Backplane \ _||J Teach pendant
„„ Main CPU
CNA][ 01P09 board
lH 01P02 Path CPU Pulse encoder

CNA ][ ni pA9
board CA2 ][} for line tracking
][ Bubble memory
CNA 01P08 board
CF91 Robot
mechanical
CF92 unit
CF93
Axis
CNA ][ 01P05 control , CF94
board CV21 CN1N T1
CV22 CN1L Amp. 1 T1
CV23 CN1M T1
CV24
Axis
CF91
CF92
/
— [|[
rOt CN1L
CN1N
CNlMAmp.2 T1
Tl
Tl
CNA ][ 02P05 control
board
CV21
CV22
CNA 3
CNBAT
T { Battery unit
Fig. 3.1 (a) Connection diagram of 6-axis controller (S-10)

(with the modular I/O unit)
1-9
in
CNP2 CNP3
Modular I/O unit
Power CPU ]0—

CNP1 ][ PSUl supply CPI 3
CP14
]d" *7ÿ
CNB Vision I
CNA ] 4_VEl engine 1
J
CNB](j VE2 Vision
Future option
engine 2 i
CNA J
CNB ]d”,01P0B Vision
CNA ] CPU board
CNPl
COP2:
Shared
RAM
CNA ][ 01P04 board CNOP Operator’s pnael
CD4 Host computer
CNTP
Backplane
Main CPU
J Teach pendant
CNA][ 01P09 board
Path CPU ,n Pulse encoder

CNA ][ 01ÿ02 t)0arci CA2 ]Q- for line tracking
Bubble memory
CNA ][ 01P08 board
Robot
CF91
CF92
:} mechanical
unit
CF93 3
CNA ]i: Axis
01P05 control
board
CF94
CV21
CV22
CV23
J&
]D
:i[K
— >> rfl[
-nr
CN1L
CNIM
Amp. 1
T1
T1
f
CV24
CF91
CF92
JO- ~\ -fl[
— fl[
CN1L
CNIM
Amp. 2
T1
T1
p
Axis -DO CNl Amp. 3 T1 (y
board
flO CNl Amp. 4 T1
CV21
CV22
CNA ]
CNBAT
I { Battery unit
Fig. 3.1 (b) Connection diagram of 6-axis controller (S-700)

(with the modular I/O unit)
1-10
CNP2 CNP3
CPU
Power
---
CNP1 ][ PSU1 supply CPI 3 Power input unit
unit
CP14
CNB1 Vision I'l

VE1 engine 1 I
CNA] J
CNB]iT' , “l
Vision I Future
CNA ]jTVE2 engine 2
j option
CNB 3tT01P0B Vision

CPU board
CNA]
CNPl
COP2 ]
Shared
CNA 3t 01P04 RAM
board
CNOP Operator’s panel
CD4 Host computer

CNTP
Backplane \ -j][ Teach pendant
hH Main CPU
CNA][ 01P09 board
01P02 Path CPU

CNA ][ board
CA2 ][} Pulse encoder
for line tracking
Bubble memory
CNA ][ 01P08 board
CNB ][} Power input unit

CNA ][ Fixed I/O board
Robot mechanical unit
CNC
CF91 Robot
mechanical
CF92 unit
CF93
Axis
CNA ][ 01P05 control CF94
board CV21 CN1N T1
CV22 CN1L T1
Amp. 1
CV23 CN1M T1
CV24
CN1N Tl
CF91 Amp. 2
Hit CN1M Tl
CF92
rflfl CN1L Tl
Axis
board CV21
CV22
CNA ]
CNBAT
t=p
Battery unit
Fig. 3.1 (c) Connection diagram of 6-axis controller (S-10)

(with the fixed I/O board)
1-11
CNP2 CNP3
CPU
Power
CNP1 ][ PSUl supply CPI 3
CP14
CNB
CNA
CNB
CNA] 4
if.
CNA] 'A VEl
CNB][T
1ST01P0B
Vision
engine 1
Vision
engine 2
Vision
CPU board
---
CNPl
I
l
1
I
J
Future
option
COP2 ]
Shared
CNA ][ 01P04 RAM CNOP Operator's panel
board
CD4 Host computer
CNTP
Backplane Teach pendant
.~
nr
CNA ] 01P09
Main CPU
board
][ 01P02 Path CPU

CNA board CA2 ]|} Pulse encoder
for line tracking
Bubble memory
CNA ][ 01P08 board
CNB ][} Power input unit

CNA ][ Fixed I/O board
CSC Robot mechanical unit
CF91 Robot
mechanical
CF92 unit
— x
Axis CF93
CNA][ 01P05 control
board
CF94
CV21 ]0 —{][ CN1L T1
Amp. 1
CV22 ~0t CN1M T1
CV23 ]CK
CV24
CF91
CF92
VHJ[
—[][
{IQ
CN1L
CN1M
CNl
Amp. 2
Amp. 3
X
T1
T1
Tl<y
Axis
CNA ][ 02P05 control -oq CN1 Amp. 4 T1(X
board
CV21
CV22
CNA ]
CNBAT
X Battery unit
Fig. 3.1 (d> Connection diagram of 6-axis controller ($-700)

(with the fixed I/O board)
1-12
Backplane CNP2
CNP2
x
CNP3
Backplane CNP3
Shared RAM board COP2

COP4
Robot
CNAO ][ control CNB Power input unit CNl
module
I/O base CNC Robot mechanical unit
unit
CNA1 ][ DI or DO module
o
TP1 O
2
CNA2 ][ DI or DO module o
TP1 Q
12
CNA3 ][ DI or DO module TP1 §
2
CNA4 ] [ DI or DO module TP1 §

12
CNA5 ][ Dior DO module TP1 O
2
CNA6 ][ Dior DO module o
TP1 o
12
CNA7 ][ DI or DO module TP1 8

t2
CNA8 ][ Dior DO module TP1 o
12
Fig. 3.1 (e) Connection diagram of modular I/O unit
1-13
Operator's panel
EMGl Customer's logic

EMG2
CRT/KB {][ Remote CRT/KB
Shared RAM
board CN5 RS-232-C RS-232-C I/O device
E-STOP
button
O
Circuit Servo transformer

breaker
AC mput _5ÿ>
OLC3 F7.8.9
Servo amplifier
0P1, 2
Input
FNR.S <> Fan unit
transformer TF4 200A.B <ÿ
200 CPI CP13

Power
R.S CP2 CPU supply
unit
CP7 CP14
Power input TF3

unit PCB
Control transformer
Robot control 100
module CNB CN1 IN
Shared RAM 10° 6
CN2 OUT Robot
board CNPI mechanical
BRK O
unit
Power input unit
Fig. 3.1 (f) Connectoion diagram of the controller (Remote CRT/KB, operator's panel,
power input unit of medium size cabinet)
1-14
Built-in CRT/KB
Keyboard
I X
Software
keyboard
CN2
CRT/KB
control PCB
CN3
CAS ]D
— D[ CNI
CRT
monitor
CD4 CNI 30-0[ CN2
Operator's panel
EMG1
CN3 EMG2 ? Curtomer’j logic
Shared RAM
E-STOP
button
-<>
Circuit Servo tranfonner

_o''"D-
breaker
-
AC input
3#
Input
-? LC3
O
OP1.2
FNR,S<>
F7, 8, 9
TF1
h Fan unit
transformer TF4 200A.BO
200 CPI CPI 3 Power
R.S CP2 CPU supply
unit
CP7 CP14
Power input
unit PCB
Robot control 100
module CNB
Shared RAM
board CNP1
CNI
CN2
IN
100
OUTT
} Servo
amplifier
BRK o Robot mechanical unit
Power input unit
Fig. 3.1 (g) Connection diagram of the S-10 controller {Built-in CRT/KB, operator's panel,
power input unit, circuit breaker of large size cabinet)
1-15
Built-in CRT/KB
Keyboard
I
CN2
X
CN3
Software
keyboard
CAS CNI
CRT/KB CRT
control PCB monitor
CD4 CNI CN2
Operator's panel
EMG1 Customer’s logic

CN3 EMG2
Shared RAM
E-STOP
button
Servo transformer
AC input
30
_
Disconnect switch
Q"->Q XFL1-3 F7.8.9
LC3 TF1
0P1.2
FNR, S < h Fan unit
Input
transformer TF4 200A, B < >
200 CPI CPI 3 Power

R,S CP2 CPU supply
unit
CP7 CP14
Power input
unit PCB
Robot control 100

module CNB
Shared RAM
board CNPI
CNI
CN2
IN
100
OUT
-} Servo
amplifier
BRKX Robot mechanical unit
Power input unit
Fig. 3.1 (h) Connection diagram of the S-10 controller (Built-in CRT/KB, operator's panel.
power input unit, disconnect switch of large size cabinet)
1-16
Built-in CRT/KB
Keyboard
I
CN2
£
CN3
Software
keyboard
CAS CN1
CRT/KB CRT
control PCB monitor
CD4 CN1 {][ CN2
Operator*! panel
EMG1 „
CN3 EMG2 Y Customer's logic
Shared RAM
E-STOP
button
O'
Circuit Servo tranformer

_breaker
AC input
3*
Input
<> LC3
o
0P1.2
FNR,S<>
F7,8,9 O-
TF1
h Fan unit
transformer TF4 200A, B
200 CPI CPI 3 Power

R,S CP2 cpii supply
unit
CP7 CP14
Power input
unit PCB
Robot control 100
module CNB
Shared RAM
board CNPI
CN1
CN2
IN
100
OUT
} Servo
amplifier
BRK Robot mechanical unit
Power input unit
Fig. 3.1 (i) Connection diagram of the S-700 controller (Built-in CRT/KB, operator's panel,
power input unit, circuit breaker of large size cabinet)
1-17
Built-in CRT/KB
Keyboard
I
CN2 CN3
Software
keyboard
CA5 CN1
CRT/KB CRT
control PCB monitor
CD4 CN1 CN2
Operator’s panel
EMGl , Customer’s logic

CN3 EMG2 Y
Shared RAM CN5

board RS-232-C RS-232-C I/O device
E-STOP
button
O'
AC input
3*
_
Disconnect switch
AFL1-3 -
F7, 8, 9 y
Servo transformer
0
LC3 O
TF1
OP1, 2
FNR.SO- Fan unit

input
transformer TF4 200A.BO
200 CPI CPI 3 Power
R.S CP2 CPII lsupp‘y
unit
CP7 CPI 4
Power input
unit PCB
Robot control 100

module CNB
Shared RAM
board CNPI
CNl
CN2
IN
100
OUT
BRK <S
! Servo
amplifier
Power input unit
Fig. 3.1 (j) Connection diagram of the S-700 controller (Built-in CRT/KB, operator’s panel,
power input unit, disconnect switch of large size cabinet)
1-18
Table 3.1 Component function for the S-10/S-700
Slot No.
Name Function or mod¬ Remarks
ule No.
Backplane Provides the bus connection for
the control PCBs.
PCBs Power supply Supplies the DC voltage to basic PSU1

mounted on unit control unit and the I/O unit
the
backplane Main CPU . Main CPU
.
01P09
board Co-processor interface
.. DRAM, 1 MB or 2 MB
Battery-backed RAM, 64 kB
Path CPU . Path CPU 01P02

board . Co-processor interface
. DRAM, 256 kB
. Calendar clock
. Tracking counter
Shared RAM . RAM, 64 kB . 01P04
board . Optical link
.. RS-422 for teach pendant
RS-232-C for host computer
. RS-232-C for CRT/KB
. RS-232-C for I/O devices
. Operator's panel interface
Bubble memory . Stores system software, system 01P08

board variables and KAREL
application programs
. 1 MB, 1.5 MB or 2 MB
Axis control . Digital servo control (4 axes) 01P05 6-axis

board . Digital servo control (2 axes) 02P05 control¬
ler
I/O unit I/O base unit Bus connection between the

various I/O modules including
the robot control module, DI/DO
modules, and analog I/O modules
1-19
Slot No.
Name Function or mod¬ Remarks
ule No.
PCB Robot . Interface between basic RC01C
mounted control control unit and I/O unit
in I/O module . Robot mechanical unit
base unit interface
. Power input unit interface
DI module Input for peripheral device ID08C,

control ID16C,
(Various types are prepared for ID08D,
input control. Details are ID16D,
described in section 17.) IA08E or
IA16E
DO module Output for peripheral device 0D08B,

control 0D16B,
(Various types are prepared for 0D08C,
output control. Details are 0D16C,
described in section 18.) 0D08G,
0D16G,
0A08D,
0A16D,
0A08E or
0A16E
Analog input Analog input for peripheral AD04A

module device control
(Details are described in
section 19.)
Analog output Analog outputs for peripheral DA02A

module device control
(Details are described in
section 20.)
Fixed I/O board . Robot mechanical unit

interface
. Power input unit interface
Battery unit Batteries for RAH are mounted.
Power input unit . Power ON/OFF control circuit

. Magnetic contactor
. Fuses
. Control transformer (S-10,
medium size)
PCB Input unit . ON/OFF control

mounted in PCB . Relay circuit for emergency
power stop control
input unit . Motor brake control circuit
1-20
Slot No.
Name Function or mod- Remarks
ule No.
Servo amplifier Unit to amplify the PWM signals
and drive the servo motors
Operator's panel . Lamps and switches to operate

the robot
. Connector panel for RS-232-C
. Connector panel for the CRT/KB
. Hour meter (option on vertical
operator's panel, large size
cabinet)
Teach pendant . 40 x 8 characters LCD

. 40 keys and DEADMAN switch
. EMERGENCY STOP button
Trans¬ Servo . AC power drive source for the TF1
former transformer servo amplifiers
. Provides 100 VAC to power
input unit (S-700)
Input . 200 VAC for the power unit TF4

transformer
Fan units . Fans are provided to cool

inside the main or connecting
cabinet.
. Fans are provided to circulate
air inside the main cabinet.
3.2 External Components

Various external components are provided for the R-H controller. They are the
teach pendant, operator's panel and CRT/KB.
There are two types of controller cabinets
—
the medium size and the large
size. Either size cabinet is available for the S-10. Only the large size is
used for the S-700. The built-in CRT/KB and the disconnect handle are options
that are available only for the large size controller.
The external views of the cabinet and the external components are the same for
the three types of controllers.
1-21
lIMfe
RISER
(OPTION)
CD O CD
Fig. 3.2 (a) External view of controller (S-10, medium size cabinet)
n .
*
a 6 ft a a a
UEo
RISER
(OPTION)
Fig. 3.2 (b) External view of controller (S-10, large size cabinet, circuit breaker handle)
1-22
*
n .
0 0 0 0 a
IQEO
RISER
(OPTION)
[=ÿ
Pig. 3.2 (c) External view of controller (S-10, large size cabinet, power
disconnect handle)
*
.
Li
JL a a a o a _2_ a a
™ DBS
RISER
jsr (OPTION) 1
Fig. 3.2 (d) External view of controller (S-700, large size cabinet with side cabinet,
circuit breaker handle)
1-23
.
E n
a s a a A a fl 0 fl
ins •
1
I RISER
pT (OPTION)
CD
Fig. 3.2 (e) External view of controller {S-700, large size cabinet with side cabinet,
power disconnect handle)
o o o
TEACH PENDANT PANEL
EMAILED POPE* 0*
© © ©
R3-232-C CRT/M IN MOT I «
CYCLE CALI MATED USER LED Ml USER LED WT
© © © ©
CYCLE START CALIBRATE USER PBM1 USER MM2
o
FAULT HELD EMER6EKCT STOP
©
FAULT
© OVERTRAVEL
o o ©.
RESET HOLD
o o o
Fig. 3.2 (f) External view of horizontal type operator's panel (S-10 controller)
(Medium size cabinet)
1-24
° TEACCM PENDANT
ENA* LEO
PANEL
ENA*LEO POWER ON
O
° TEACH PENDANT PANEL O
© © © © © ©
IN NOT IN NOT
ON «
CYCLE CALIOIUTED CYCLE CALI MATED I
©
CYCLE STANT
©
CALlflB
© ©
O OFF
O w
FAULT HELD FAULT HELD
© © 0VENT1UVEL © © OVERTRAVEL
FAULT RESET HOLD FAULT RESET HOLD
USER LE0M1 USER LE0N2 REMOTE USER LED Ml USER LEO Ml •EMOTE
ON
©BUM ©
fff <§Ho
USER uSEA.Pl.gr
© 11
O o
RS-»-C crr/n Rs-ta-c

OQ CQ
EMERGENCY STOP ENERSENCY STOP
o o o
o o o o
(For remote CRT/KB) (For built-in CRT/KB)
Fig. 3.2 (g) External view of vertical type operator's panel

(S-10, S-700 controller with large size cabinet)
o
o
O
r
I il I I » i i i i I i n i
_Q m n ~i~n
i 11 i ill Ml I I II
lliiiiiiiilili
o o o
Fig. 3.2 (h) External view of built-in CRT/KB (20° angled)
1-25
~s~ o
o
o
[ooaaaaaao o
r~r~i i g— i
j
I
o o
Fig. 3.2 (i) External view of built-in CRT/KB (40° angled)
370
.
"
2 - -ÿ
§ ]
3 CM
i B III
2 - 3
n
I
&
t
(p
[ n ii
in II JCID-
( TU
\y 400
Fig. 3.2 (j) External view of remote CRT/KB
1-26
B00000EI
SHIFT Coord Start Hold SHIFT
Reset
input
Output
Prgm
Teach ft Vision
Test
Data
Status
Sava
ft Setup
Fite
+Y(2) «(3)
7 8 9
Enter
ftFaul
ftHeld
ftSave
-X(1)
4
-Y(2)
5
-Z<3)
6
ft
ftCycle +X(4)
1 2
«(•)
3 ft
|£-S rv Eip
-X(4) *Y(5) -Z(8)
Del
0
U5 U8 U7 US
U1 U2 U3 U4
o1
Fig. 3.2 (k) External view of the teach pendant
3.3 Internal Components

Various components are mounted in the controller. They are the basic control
unit, I/O unit, servo amplifiers and so on.
For the internal components location diagram, refer to Fig. 3.3.
1-27
Fan 1
Modular I/O unit
Battery unit. Power input unit
Circuit breaker
Backplane
Power supply unit

Control PCBs
Operator’s panel
Servo amp. 1
Fan 2
Servo amp. 2
Input transformer
Ground board
Servo transformer
Fig. 3.3 (a) internal component location (S-10, medium size cabinet)
Fan 1
Modular I/O unit, /
Battery unit
.<zr
m\ Power disconnect switch
Built-in CRT/KB, Power input unit

\
Operator’s panel m
m Backplane
W\
Fan 3.
3
e-
_
Power supply unit
Fan 2
Input transformer
User transformer (option)
\
\ Servo transformer
V Servo amp. 2
Servo amp. 1
Fig. 3.3 (b) Internal component location (S-10, large size cabinet)
1-28
Modular I/O unit Fan 1
~7 / /
Battery unit ,C’

Power disconnect switch
Built-in CRT/KB, Power input unit
B
1=7-
Operator’s panel
Backplane
Fan 3. & Power supply unit
5 Fan 2
6. / Input transformer
User transformer (option)
\
7£
X\ Servo amp. 3
\ Servo amp. 2
Servo transformer
Servo amp. 1
Fan 4
DCU1
Fan 5
Servo amp. 4
1 es
Fig. 3.3 (c) Internal components location (S-700, large size cabinet and side cabinet)
1-29
3.4 Controller Components Specifications
1) Common components for S-10 and S-700
Slot or
module
Unit Fart number No. Size
Basic control unit

-Backplane A20B-1002-0860
-
-
Power supply unit
Main CPU board
-Path CPURAMboard
— ——
1I
A20B-1000-07 70
A16B-1211-0040 ••••• 01P09
A16B-1211-0041
A16B-1211-0030
01009
01P02
2MB DRAM
1MB DRAM
-Shared board A16B-1211-0860 01P04

-Bubble memory board
-Fixed
-
-— A16B-1211-0090
A16B-1211-0091
A16B-1211-0092
01P08
01P08
01P08
2MB
1.5MB
1MB
——
I/O board A16B-1211-0750
-Axis control board ,
1
A16B-1211-0060
A16B-1211-0062
01P05
02P05
Modular I/O unit

-I/O base unit
I/O backplane PCB
A03B-0801-C012
A20B-1002-0450
-Analog
Robot control module A03B-0801-C462 RC01C
-
-DI
input module
Analog output module
A03B-0801-C410
A03B-0801-C411
AD04A
DA02A
- module - -
-
A03B-0801-C420
A03B-0801-C421
,
,
ID08C
ID16C
- A03B-0801-C422 , ID08D
- A03B-0801-C423
-A03B-0801-C424
,
,
ID16D
IA08E
- DO module
-A03B-0801-C425
-A03B-0801-C440
,
.
IA16E
OD08B
-A03B-0801-C441
-A03B-0801-C442
.
.
0D16B
OD08C
-A03B-0801-C443 . 0D16C
-A03B-0801-C444 . OA08D
-A03B-0801-C445 . 0A16D
-A03B-0801-C446 . OA08E
-A03B-0801-C447
-A03B-0801-C448
.
.
0A16E
OD08H
-A03B-0801-C449 . 0D16H
Built-in CRT /KB unit (Large size cabinet)

(20 degree angled) A05B-2051-C101
(40 degree angled) A05B-2051-C102
-CRT monitor A13B-0056-C001
- Control PCB A20B-1003-0340
- Keyboard PCB A86L-000 1-0149
- Software keyboard PCB A20B-1000-0840
1-30
Unit Part number
Remote CRT /KB unit A13B-0144-B001

-CRT monitor A61L-0001-0088
-Control PCB A16B-1211-0760
-Keyboard PCB A86L-0001-0149
-Fan unit A13B-0144-C001
Battery unit
I Battery case
- A98L-0004-0096
i -Battery A98L-0031-0005 (3 units are necessary)
Operator's panel
(Horizontal type) A05B-2045-C122
(Vertical type) A05B-2051-C122 (for Remote CRT/KB)
(Vertical type) A05B-2051-C121 (for Built-in CRT/KB)
Outlet unit A05B-2051-C021
Servo-on lamp
bServo-on relay
Lamp switch
L— Lamp
A05B-2051-C051
A55L-0001-0124#LR22H
A49L-OOO1-OO280AHX-135
Teach pendant A05B-2051-C 142
-Control PCB A20B-1002-0980
-Keyboard PCB A20B-1002-0970
-LCD module A61L-0001-0109
-LCD control board A61L-0001-0100#CB1053RP
1-31
2) S-10 specific components
Unit Part number
Controller
(Medium size cabinet) A05B-2066-B001
(Large size cabinet) A05B-2067-B001
Transformer (Medium size cabinet)

t Servo transformer TF1
Input transformer TF4
A80L-0024-0002
A80L-0012-0010
Transformer (Large size cabinet)
E Servo transformer TF1

Input transformer TF4
User transformer TF5
A80L— 0024-0004
A80L-0012-0010
A80L-0001-0520
----——
Servo amplifier
r— L: U axis (1-0)
M: 0 axis (5RF)
L-N: W axis (5RF)
L: a axis (3-0F)
M: B axis (3-OF)
N: y axis (2-OF)
A06B-6058-H327
A06B-6058-H325
Note) The numbers in parentheses show the motor type.
Fan units (Medium size cabinet)

-
I
1
Fan 1 (2 units) A05B-2045-C901
- Fan 2 A05B-2045-C902
Fan units (Large size cabinet)

Fan 1 (3 units) A05B-2051-C901
F=
-
Fan 2
Fan 3
A05B-2051-C902
A05B-2051-C905
Circuit breaker (Medium size cabinet)

(220/240 VAC input) A60L-0001-0098//3/30A
(380-550 VAC input) A6OL-OOO1-OO9803/15A
(575 VAC input) A60L-0001-0258#SA53H-15
Circuit breaker (Large size cabinet)
(220/240 VAC input) A60L-0001-0188 #N
(380-550 VAC input) A60L-0001-0098i?3/20A
(575 VAC input) A60L-0001-0258#SA53H-15
Circuit breaker with leak detector
(220/240 VAC input) A60L-0001-0116#CA
(380-550 VAC input) A60L-0001-0116#AA
1-32
Unit Part number
Power disconnect switch A60L-0001-0181#175

Power input unit A14B-0076-B321
(220/240 VAC input, Medium size cabinet)
- Power input unit PCB A16B-1310-0530
- Fuse A60L-0001-0042#JGl-30
- Contactor A58L-0001-0094#200V1A1B
(380-550 VAC input, Medium size cabinet)
A16B-1310-0530
E
Power input unit PCB
Fuse A60L-0001-0042#JG1-15
Contactor A58L-0001-0094#200V1A1B
(220/240 VAC input, Large size cabinet)
E Power input unit PCB

Fuse
Contactor
A16B-1310-0530
A60L-0001-0042#JGl-30
A58L-0001-0094#200V1A1B
(380-550 VAC input, Large size cabinet)
E Power input unit PCB

Fuse
Contactor
A16B-1310-0530
A60L-0001-0042#JG1-15
A58L-0001-0094#200V1A1B
(200/240 VAC input, Power disconnect switch, Large cabinet)
- Fuse (FL1-3) A60L-0001-0042#JG2-40
- Fuse (F7-9) A60L-0001-0042#JG1-30
(380-575 VAC input, Power disconnect switch, Large cabinet)
- Fuse (FL1-3) A60L-0001-0042#JGl-20
- Fuse (F7-9) A60L-0001-0042#JG1-15
1-33
3) S-700 specific components
Unit Part number
Controller (Large size cabinet) A05B-2061-B001
Transformer (Large size cabinet)
E
Servo transformer TF1 A80L-0024-0004
Input transformer TF4 A80L-0012-0010
User transformer TF5 A80L-0001-0520
Servo amplifier
L: a axis (1-0B) A06B-6058-H222
HI M: U axis (5RF)
L: B axis (1-0B) A06B-6058-H221
HI M: y axis (1-0B)
- 9 axis (5RF) A06B-6058-H012
- W axis (20F) A06B-6058-H006
Note) The numbers in parentheses show the motor type.
Discharge unit A06B-60 50-H050
Fan units (Large size cabinet)

- Fan 1 A05B-2051-C901
- Fan 2 A05B-2051-C902
- Fan 3 A05B-2051-C905
- Fan 4 A05B-2051-C903
- Fan 5 A05B-2051-C902
Circuit breaker
(220/240 VAC input) A60L-0001-0188#J
(380-550 VAC input) A60L-0001-0098#3/30A
(575 VAC input) A60L-0001-0258#SA53H-20
Circuit breaker with leak detector
(220/240 VAC input) A60L-0001-0116#DA
(380-550 VAC input) A60L-0001-0116#BA
Power disconnect switch A60L-0001-0181#175

Power input unit (220/240 VAC input) A14B-0076-B323
-- Power input unit PCB A16B-1310-0530
- Fuse A60L-0001-0042#JGl-30
Power input unit (380-575 VAC input) A14B-0076-B322
- Fuse A60L-0001-0042#JG1-15
- Contactor A58L-0001-0094//200V1A1B
1-34
Unit Part number

(220/240 VAC input, Power disconnect switch)
-
-
Fuse (FL1-3)
Fuse (F7-9)
A6OL-OOO1-OO420JG2-4O
A60L-0001-0042#JGl-30
—— Contactor A58L-OOO1-OO9402OOV1A1B
(380-575 VAC input, Power disconnect switch)
-
-
Fuse (FL1-3)
Fuse (F7-9)
A60L-0001-0042#JGl-20
A60L-0001-0042#JG1-15
1-35
4. PREVENTIVE MAINTENANCE
Preventive maintenance is based upon the amount of hours of operation of the
robot. Some applications require a robot to be operational for 24 hours a day,
while others require less on-time. If the robot is to operate continually, all
check items should be maintained accordingly. The following chart should be
used as a quick reference guide for preventive maintenance. This chart is based
upon hours of operation and not calendar time. Some items should be checked as
a daily routine by the operator. Quality of the work accomplished by the robot
should be checked to determine the need for maintenance. Use the chart to
indicate minimum preventive maintenance requirements. Hot, dusty, dirty or
other poor environment will accelerate the frequency of maintenance.
Note) Appendix 3 contains a reference matrix of preventive maintenance schedules
and a maintenance check list.
4.1 Daily Checks

Clean each part, and visually check the overall system and component parts for
damage before daily system operation. Check the following items as the occasion
demands .
1) Before automatic operation check items one through eight, listed in Table 4.1
2) After automatic operation, return the robot to the zero position and turn off
the power. Continue the maintenance checks by checking items nine through 10
in Table 4.1.
Table 4.1 Daily preventive maintenance checks
Item Check items Check points
1 When air control Air pressure Check air pressure using the pressure
set is combined gauge on the air regulator. If it does
not meet the specified pressure of
5-7 kg/cm2 (standard 5 kg/cm2), adjust
it using the regulator pressure setting
handle. See Fig. 4.1.
2 Oiler oil Check the drop quantity during wrist or

mist hand motion. If it does not meet the
quantity specified value (1 drop/ 10-20 sec),
adjust it using the oiler control knob.
Under normal usage the oiler becomes
empty in about 10 to 20 days under
normal operation.
3 Oiler oil Check to see that the oiler level is

level within the specified level shown in
Fig. 4.1.
4 Leakage from Check the joints, hoses, etc. for leaks.

hose Repair leaks, or replace parts, as
required.
5 Visual check of cables Refer to II-6.4 (S-10) and III-6.4

(S-700) .
1-36
6 Vibration, abnormal noises, Check to see that each axis moves

and motor heating smoothly.
7 Changing repeatability Check to see that the stop position of

the robot has not deviated from previous
stop positions.
8 Peripheral devices for proper Check whether the peripheral devices

operation operate properly according to commands
from robot.
9 Cleaning and checking of each Clean each part (remove chips, etc.) and
part check component parts for cracks and
flaws.
10 Ventilation portion of control If the ventilation portion of the

unit control unit is dusty, turn off power
and clean the unit.
11 U/W-axis brake Refer to II-3.2 (S-10) and III-3.2

(S-700) .
Oil inlet
3J3ÿ Adjusting knob
Oiler mist amount

o sight gauge
-Lj:
Oiler
/ Pressure gauge
Filter Regulator pressure setting handle
Fig. 4.1 Air control set
1-37
4.2 Monthly Checks (Determined by hours of operation)
Check the following items monthly. Additional inspection areas and times should
be added to the table according to the robot's working conditions, environment,
etc.
Table 4.2 Monthly preventive maintenance checks (or 500 hours)
1 Check lubrication Refer to II-2 (S-10) and III-2 (S-700).
2 Check each part for play and

looseness
3 Check connectors for looseness Push-in connector assembly and retighten

lock ring.
4.3 Quarterly Checks

Check the following items once every three months (or 1000 hours).
Table 4.3 Quarterly preventive maintenance checks
1 Grease Refer to II-2 (S-10) and III-2 (S-700).
4.4 Semiannual Checks

Check the following items once every 6 months (or 2000 hours).
Table 4.4 Semiannual periodic maintenance checks
1 DC power voltage check Check the +5 V, +15 V, +24 V, and -15 V

power supplies of the power unit and the
+24 V, +15 V, and -15 V power supplies of
the servo unit for the specified values.
4.5 3-year Checks

Check the following items once every 3 years.
1 Grease Refer to II-2 (S-10) and III-2 (S-700).
4.6 Periodic Replacement

Replace the following parts when needed.
Item Replaced parts Replace
1 Filter cover on control unit Replace once every two years if needed.
1-38
4.7 Maintenance Tools
The following instruments and tools are required for the maintenance procedures
contained in this manual.
1) Measuring instruments
Instruments Accuracy /To lerance Applications
AC voltmeter AC power voltage measurement. AC power voltage

Tolerance: Less than +2% measurement
DC voltmeter Maximum scale 10 V, 30 V DC power voltage

Tolerance: Less than +1X measurement
(A digital voltmeter is required
20,000 ohm/volt)
Oscilloscope Frequency bandwidth: DC to greater

than 5 MHz, 2 channels
Dial gauge 1/100 mm Measurement of

positioning and
backlash.
Slide calipers 150 mm
2) Tools
Tool Size
Cross-point (+) screwdrivers Large, medium, and small sizes

Conventional (-) screwdrivers Large, medium, and small sizes
Hexagonal wrench key sets (metric)
Adjustable wrenches
M3 -
M16
Medium and small sizes
Pliers Adjustable, long nose
Cutting pliers Diagonal
Grease gun With output pipe and fitting
Pliers for C-retaining ring Internal and external
Dial indicator and stand 0-10 mm range
[ 1-39
5. TROUBLESHOOTING
5.1 Introduction
This section contains information for troubleshooting the system. The material
included here describes the alarms that are involved with hardwired circuits.
Refer to the KAREL System Reference Manual for a description of all of the error
codes.
5.2 Power Cannot be Turned On
Item Cause of trouble Checking procedure Corrective action
1 Input power supply 1) Check whether the circuit

is not connected breaker or disconnect switch
is turned on.
2) Check to see that the pilot

lamp PIL (green LED) is lit in
the power input unit.
(Refer to 23.4.3)
3) When PIL is OFF, make sure

that input power is supplied
at the connection terminal for
200R and 200S on the power
input unit.
4) When power is not supplied to Remove causes of

the power input unit at 200R blown fuse and
and 200S, fuse FI on the replace the fuse.
input transformer TF4 may be
blown.
(Refer to 24.1)
5) When power is supplied to Remove causes of

power input unit and PIL is blown fuses and
OFF, refer to 23.4.4. Fuse replace fuses.
FI, F2, or F3, on the power
input unit may be blown.
2 Alarm lamp is ON 1) Refer to 23.4.3. Make sure

that lamp ALM (red LED) is
OFF. If it is ON, remove the
cause. Press POWER OFF button
once, and then press POWER ON
button to turn power on.
3 Cable connection 1) Make sure that the cables are

correctly connected as shown
in Fig. 5.2.
4 I POWER OFF switch 1) Verify that the POWER OFF Replace POWER OFF
on operator' s button contact is closed. switch.
panel is faulty
1-40
Item Cause of trouble Checking procedure Corrective action
4 POWER OFF switch 2) Verify that two pins "OFF" on

on operator's the power input unit PCB of
panel is faulty the power input unit are
shorted. (Refer to 23.4.1)
5 POWER OFF contact 1) Make sure that OFF and COM are If not shorted,
of external power shorted at TP1 terminal on the short them by
supply ON/OFF power input unit PCB of the using a shorting
power input unit. strip.
(Refer to 23.4.2)
6 POWER ON switch 1) Verify that the contact is Replace POWER ON

on operator's closed when the POWER ON switch.
panel is faulty button is pressed.
2) Make sure that two pins "ON"

on CN2 on the power input unit
PCB of the power input unit
are shorted when the POWER ON
button is pressed.
(Refer to 23.4.2)
Operator’s panel
Operator’s panel PCB

01P04
__ a
OFF 3
(B14)
(A14)
(30)
(29)
CNOP
(30)
(29)
Shared RAM board
(B13) (28) (28)
ON
(A 13) (27) (27)
CN1 CN5 (3) (16) (4) (17) CNP1
(3) (16) (4) (17) CN2
°n4 TPl
<yoNi_
TO
(COM)
vl (OFF)
OFF
s
Note
External power ON/OFF switches Power ON/OFF
control
Power input unit
Note) A jumper wire is necessary between OFF and COM when external power ON/OFF
switches are not available.
Fig. 5.2 Power ON/OFF control
1-41
5.3 Troubleshooting Using Error Codes
The 4000 error codes indicate problems in servo control. The number included
with the error message is interpreted as follows:
008: error on 1st axis

004: error on 2nd axis
002: error on 3rd axis
001: error on 4th axis
5.3.1 Error code 4001 DEADMAN switch

This signal indicates that the teach pendant is enabled and the DEADMAN switch
is not being held. Its function is to indicate a breakage in the circuit string
between the teach pendant and controller. When the switch is held in, the
signal is not active. Releasing the switch, or breaking the cable, will result
in the alarm being displayed. Power to the servo amplifier is removed, and the
robot is placed in an emergency stop condition.
CFT? CNi
Emergency stop (1) (A7)
-cilo- 121
-o o- 121
(4)
i*
m\
Deadman Shared
switch CNTP RAM
(A4)
board
rr c=*
+5V
I RV
+5V
I RV
R-H controller
Common
Teach pendant
selection
circuit "5. 0V Control PCB
Fig. 5.3.1 Error code 4001 DEADMAN switch
1-42
5.3.2 Error code 4002 emergency stop
The emergency stop alarm indicated that one of the E-stop buttons has been
pressed or that the E-stop wiring is defective. EMERGENCY STOP buttons are
located on the teach pendant and on the operator* s panel. Additional buttons
may be connected to the external emergency stop circuit.
Control transformer T1
TF3
s
RLl 100 OUT I
P
100A 100 INI |/tW <>ÿ Servo
I"
100B 100 1N2 J. . 100 OUT2 <t
MCC amplifier
r!2 rll
Operator’s _L_
EMG IN2
panel
RL7
—
OT RELEASE OP1 EMG INC
a
rl6 EMG INI
1 ofo OP2
External
0-0
ESTOP EMG OUT! n
Teach pendant
CNS
i
r Power input unit
EMG OUTC 1
EMGOUT2 {)
Emergency
stop SW
Emergency stop CNOP FN1

2.
——n*-r>
Dead man
6
CNTP
TEMG 12 T
[RVM
bd
53- t TP! 6- RL6
r!4
RU
'm'“l
RI3 m
Gate
switch of
the protective
fence
supply
— -Till--
oip.
DIS
[RV]
ENE
TP1 3
5
19 TP2
or»FL
19
S
rlS
om,
RU
A
i
Hr
,n
- n.n m
TP2 16 CNPI CN2 SS I t
Shared RAM
§n
w
g g
x x * s RLS
board
v» 2 2 «
rlS
*3
«n eg
CN1
CNB -6—
Robot Vt w *f» e*
mechanical
unit
a-d
D1 CNC
32-34 P"
Hand breakage t I I PV
detection
-0-0-* 3r
I
'±Z- Robot control module

Dl module
Robot •HBKD
oveitravel S
Note)
Normally open contact

13 1 — {*3 CNA
1/0 base unit

CNA
*0-0- Normally closed contact
Fig. 5.3.2 Error code 4002 emergency stop
5.3.3 Error code 4003 pneumatic pressure alarm

This alarm indicates that the pneumatic pressure used in the end effector is
abnormal. Check the pneumatic pressure and/or pneumatic pressure input *PPABN
to the controller. The contact *PPABN is normally closed. See section IV-4.2
for the connection of this contact.
Robot mechanical unit Robot control module
End effector +24E

H Dl CNC
+24V 17-20 a-b +24E 22, 32-34
Receiver
•PPABN 14 t •PPABN 9
RV
VCable K91
I
1-43
5.3.4 Error code 4004 hand breakage detection
The hand-break-detect circuit monitors the operating condition of the safety
switch on the end effector. This normally closed switch opens when a crash
occurs and places the robot into a stop condition. This stop resembles an
emergency stop or other major alarm which removes power from the servo amplifier
and applies the brakes.
ContioJ
TF3 i
utngfonncr
-1 100A , 100 INI
100IN2 rl3
RLI 100 0UT1
100QUT2 4
_
Ti
-JMCC Servo
V
amplifier
rl2 rtl
O pen tor 'i _L_
EMC 1N2
panel
0T RELEASE Of) RL7 EMC INC
s
L-QTQ r!6 EMC INI
---
j
E-STOP EMC OUT1 External
:
r EaMnogr
-
* J
_
EMGOUTC "psw
Power input unit
Teach pendant
_ CN5 LZJ=J EMGOUT2
| |
_°:°
jr-
3L
—.
_
Emergency stop
HZ] ,
—-
CNTP
nEMG i2 T
CHOP
[RVH
hd
FN1
FN2
— o J j rower
apply
—-
olo Cate
J
RL2 switch of
Deadman « TPI 4. RL6 the protective
[13 , fence
-JT°T°
(X£>
DIS X ENE
--- --
.
TP1 3
19
s
TP2
oraei.|
19
5
xK
.. IU4*
iU
1 ttm i
[Hr
TP2 16 CNPI CN2
Shared RAM
board
sI
s
CN1
CNB -O—O-
Robot
mechanical
unit
Id
Dl CNC
3J-J4
p]" 2 «
IE
— —-—
Hand breakage
detection
t i
DV
£» .
M 7 I
14 1 Of module
Robot *HBKO 1
IRV Robot control module
overtravel
—
S •ROT
a 1 |RV] CNA CNA
-0ÿ0- Normally open contact I/O base unit

“0ÿ0- Normally closed contact
Note) Refer to the mechanical unit internal connection diagram in Appendix 1 for
circuit wiring in the mechanical unit.
Fig. 5.3.4 Error coda 4004/4005 hand breakage detection and robot overtr8vel
5.3.5 Error code 4005 robot overtravel

Robot overtravel indicates that an axis has exceeded its limits and has
activated a limit switch. All axes employ limit switches that are mounted at
the positive and negative extremes of the motion range and are wired in series.
Robot overtravel alarms indicate that an opening in the series string has
occurred. When this alarm occurs, the power is removed from the drives and
brakes are applied. The robot axis must be moved, until the switch releases,
before resetting is possible. Refer to Fig. 5.3.4.
5.3.6 Error code 4006 relay welding detection

This error indicates the contacts of the emergency stop relay (RL2) on the power
input unit PCB are welded together. If this alarm cannot be reset, replace RL2.
1-44
5.3.7 Error code 4008 TGLS alarm
The function of the TGLS alarm is to indicate a problem in the feedback system.
Each axis pulse encoder's information is monitored in the controller. If a
signal is lost, the alarm is sent, and the robot motion is terminated. Refer to
the following figures.
Robot mechanical unit Axis control board

A16B-1211-0060
ToW, U, 9-axis K92 CF91 W
*ÿ PI
servo motor
—
pulse coder
connectors MIC CF92 U 01P05
DC CF93 8
K93 .C
To a, 0, 7-axis
servo motor
P2 {][ CF94 -r
pulse coder
connectors
Axis control board
A16B-1211-0062
-DU CF91 4 02P05

MC CF92 a
Fig. 5.3 7 (a) Error code 4008 TGLS alarm. S-10
Robot mechanical unit Axis control board

A16B-1211-0060
—
ToW, U, 8-axis K92 CF91 W
PI
servo motor
pulse coder
connectors 0[ CF92 U
01P05
MIC CF93 8
Too, 0,7-axis K93

P2 CF94 7
servo motor
pulse coder
connectors
Axis control board
A16B-1211-0062
MIC CF91 0 O2P05

MIC CF92 o
Fig. 5.3.7 (b) Error code 4008 TGLS alarm, S-700
1-45
CF91 1 0 V 14 PCZA1 CF94 1 0 V 14 PCZA4
8 0H1A 8 OH1B
of 2 0 V *PCZA1 of 2 0 V *PCZA4
9 0H2A 9 0H2B
01P05 3 0 V 16 PCAA1 01P05 3 0 V 16 PCAA4
(W) 10 C8A1 10 C8A4
4 +5 V *PCAA1 (Y) 4 +5 V 17 *PCAA4
11 C4A1 11 C4A4
5 +5 V 18 PCBA1 5 +5 V 18 PCBA4
12 C2A1 12 C2A4
6 +5 V 19 *PCBA1 6 +5 V 19 *PCBA4
13 C1A1 13 C1A4
7 20 REQA1 7 20 REQA4
CF92 1 0 V
8
14 PCZA2 CF91 1 0 V 14 PCZA5
2 0 V
0HA2
15 *PCZA2
8 0HA5
of
9 0HA2 of 2 0 V 15 *PCZA5
V 16 9 0HA5
01P05 3 0
10 C8A2 PCAA2 02P05 3 0 V
10 C8A5
16 PCAA5
(U) 4 +5 V 17 *PCAA2 (6) 4 +5 V 17 *PCAA5
V
11 C4A2 11 C4A5
5 +5 18 PCBA2 5 +5 V 18 PCBA5
12 C2A2 12 C2A5
6 +5 V 19 *PCBA2 6 +5 V 19 *PCBA5
13 C1A2 13 C1A5
7 20 REQA2 7 20 REQA5
CF93 1 0 V
8
14 PCZA3 CF92 1 0 V 14 PCZA6
2
0HA3 8 0HA6
of 0 V 15 *PCZA3 of 2 0 V 15 *PCZA6
9 0HA3 9 0HA6
01P05 3 0 V
10 C8A3
16 PCAA3 02P05 3 0 V 16 PCAA6
(«) 10 C8A6
4 +5 V 11 C4A3
17 *PCAA3 (a) 4 +5 V 17 *PCAA6
5 +5 V 18 PCBA3 11 C4A6
12 C2A3 5 +5 V 18 PCBA6
6 +5 V 19 *PCBA3 6 +5 V 12 C2A6
13 C1A3 13 C1A6
19 *PCBA6
7 20 REQA3 7 20 REQA6
PI (MS3I06B 32AI0S) P2CMS3I06B 32AI0S2)

I B |«PC2A l| A | PCZA I 1 I B rPCZA4| A|PC2A4 1
| E |PCBA I I D |»PCAA l| c| PCAA I | 1 E|PCBA4|D |»PCAA4| C|PCAA4 1
I J| «5V |H| 0H2A [G| QUIA |F |«PCBAll |j| *5V |H| OH2B |G| OHIB |F|»PCB»4|
I M| OV |L | OV | K | +5V | I M| OV |L | OV |K| «5V |
|R| C4AI | P| C6 A 1 |Q| | N|REQA I | |R| C4A4 |P| C8A4 |o| _ N REOA4
| W|PCAA2 1 V |«PCZA2| U|PCZA2 1 T| Cl A I |S| C2A 1 1 I W|PCAA5 1 V |«PCZA5| U|PCZA.5 1 T I CIA4 |SfC2A4 1
I » | »5V |Z|«PCBASj Y|PCBA2|x|«PCAA2l
| 1 | C4A2 | t | C8A2 |<| OV | c| QV | b| «5V |
I i | REOA2 1 1 1 C l A2 | f | C2A2 |
| r | PCAA3 1 1 |«PC2A3| P I PCZA3 | » f o ]
I| CIA5 |«| C2A5 I
| r |PCAA6 q |«PCZA6| ?|PCZA& I » I
M | i l-PCBAj I | PCBA3| i |«PCAA3j | ° |«PCBAfj t |PCBA6 1 » l*PCAA6l
|)| OV |i| «5V |»| | j y I ov 1 1 1 «5v |» | *5v |
lAAl RE0A3| t | OV M RE0A6|1 1 OV
Ad C8A3 ABl Ad CSA6
Ad C2A3 IXlAd C4A3 | |AEl C2A6 | |Aq C4A6 j
|AdSHIELC|AF| Cl A3 | AGEHIELCjAFj CIA6 |
Fig. 5.3.7 (c) Error code 4008 TGLS alarm
1-46
-
5.3.8 Error codes 4009 4014
Error codes 4009 -
4014 indicate a problem on the servo amplifier-
section 5.4 "Troubleshooting Servo Amplifier".
Refer to
5.3.9 Error code 4020 velocity ready is off

TheÿDRDY signal, indicating the servo amplifier is on, has not been received
after *MC0N signal is sent to the servo amplifier PCB. Verify that RYL1 is
operating properly and that 100 V (wire number 100A) is present.
CN3
9 INTL 1 100A
CNl
1“ I;
MCC RLY 1
+24
IJ RV
— 7
DRDY
Buffer
8 INTL 2
IA1 I o
03 MCC
100B
Power amplifier
*MCON +24
Logic RLY 1 JDRDY

— Servo amplifier PCB
5.3.10 Error code 4007 Motor Overheat

An overload alarm indicates that a thermal sensor in the controller has detected
an overload. Sensors are located in the servo amplifiers, servo transformer and
the motors. This condition is usually caused by an axis exceeding its capacity
or duty cycle. All of the sensors are self-resetting after they cool
sufficiently. When the alarm occurs, power is removed from the servo drives,
and robot motion is stopped.
1-47
Servo
transformer Servo amplifier Axis control board
LJJ
51
-ofo 52 I T4
1
-6-
l2
y-,?
SI
Error
detection
—Q£D-J
Heat sink
overheat
CV21
At
01P05
8 CF91
9
PI
TF1
circuit CN1N
CV22
—
—C£LQ |
e
CN1L 8 CF92
I 3
•3
9
IP
§
CV23
8 CF93
Lifl[ÿ=3U 3
T4
Amp. 1 CN1M I TJ
w
j-
9]IP P2
7
=1
CV24
8 CF94
Error
detection
Heat sink
overheat
CN1N
i- v lip -JJ -<fLP-| 0
circuit
13
CV21 02P05
8 CF91
CN1M I c ilD=i
a>
0)
CV22
II 8 CF92
Amp. 2
CN1L
Id o
Uti
Fig. 5.3.10 (a) Error code 4007 Motor Overheat (S-10)
1-48
Servo
transformer Servo amplifier Axis control board
—
T4
01P05
52
0ÿ0-* Robot mechanical unit
2 SI Error Heat sink CV21
-6- 8 CF91
Y~f ? detection overheat
53 circuit
CN1L
ID—i fl[ 9 ] PI
G 6
H 3
CV22
8 CF92
Amp. 1 CN1M 0[ 3 IIP ai;ÿw
T4
§
&T7i
TV1_ Error Heat sink CV23 Z
£ 8 CF93
j-|] -o5b—|U =3
detection
circuit
overheat
CN1L I o
9 ]P P2
Amp. 2 CN1M
CV24
I
8 CF94
9 ]p _j] —CELO ,0
Discharge unit
<Pi
2 r
T4
"1_2_
Amp. 3
si Error
detection
circuit
— CELO-*
Heat sink
overheat
CN1 ]0-
CV21 02P05
§
8 CF91
ip
_Ljj 3
DCU3 T4
’5
3 1
<y I SI Error -oScJ •=
S4 2
I
Amp. 4
?
detection
circuit
Heat sink
overheat
CN1
]P'-fl[
CV22 o
a -5
8 CF92
IP
Fig. 5.3.10 (b) Error code 4007 Motor Overheat (S-700)
1-49
5.3.11 Error code 4024 fuse alarm in brake circuits
The fuse alarm indicates that one or more fuses on the power input unit PCB has
blown. Each fuse contains an internal switch which triggers the alarm when the
fuse blows .
A blown fuse might have been caused by an overload condition or a
short circuit in the brake wiring. By observing which fuse is blown, the
problem area may be narrowed to a group of drives.
Powfcr input unit 3 4

Robot control module 100 VAC rt8
CNB CN1
(16) KS3
DV RL8
—
Robot mechanical
—
Ml
—
0V
TPl
oo
ov
(17)
(18)
K53
KS3
(17)
(18)
r— •—**—»
j Power amp. I
FBI
oÿa
BKF1 K31 J 0) To W-axia motor
3 i 4 BKM1 IC31 ft)
1
(8) KS3 (8) FB2 BKP2 K31 J (m) To f -exit motor
1
DV (9) K53 (9) j Power amp. j <TBKM2 K31
M2
DV
(10)
(11)
K33
K53
(10)
(11)
f=e FB3
4
BKP3 K32
BKM3K32
K32 (h)
K32Q)
ft)
(m)
To Uaxia motor
To roxia motor
[~RVT I
+24E
(4) •PALM
K53
(4)
44 OE ft)
(P) To l-txi* motor
T («.(7) K53 ft). (7) T ft)
(12), (13) K33 (17). (13) I FALX (a) To aoxia motor
X 1
ov ov
Fig. 5.3.11 (a) Error code 4024 fuse alarm on power input unit PCB (S-10)
Power input unit 3 4

Robot control module
CN1
100 VAC
+24E
{= r«8
CNB
(16) K53
DV RL8
Robot mechanical
0V unit
TPl
(17) K53 (17) r* FBI BKF1 K3] Ml
DV (18) KS3 (18) I Power amp.| 3 4 BKM1 K31 (j) To W-axb motor
(8) K53 (8) 1 1 FB2 BKP2 K32 ft!
CAD¬
| POWCT amp.
DY (9) K53 (9) J 3 «— 4 BKM2 K32 (m) To U-axis motor
FB3 M2
(10) K53 (10) BKP3 K32 (h)
o\p-
DV (ID K53 (11) Power imp. 3 4 BKM3K32 (i)
Tod-axis motor
00
+24 E (m) To r«a motor
[RV} I
+24E
(4) •FALM
Ki3
(4)
+24E +24E
0E
(n)
(P) To 0-axis motor
(6). (7) K53 (6). (7) // <r)
T
i
(12). (13) KS3 (12), (13)
J
i
T AVr
FALM (s) To cr-*xij motor
ov ov
Fig. 5.3.11 (b) Error code 4024 fuse alarm on power input unit PCB (S-700)
1-50
5.4 Troubleshooting Servo Amplifier
1) Protection and error detection functions
The servo amplifier has the following functions designed to protect the motor
from overload and to detect an error in servo loop circuits.
No. Kinds of functions Indications Description
1 Overload Overload alarm If the temperature of the radiation

is indicated fin on the servo amplifier or of the
for the servo transformer exceeds a set
control unit value, this overload alarm is
generated.
2 Circuit breaker Circuit If an abnormal current exceeding the

(No-fuse breaker) breaker is rated limit of the breaker is applied
tripped to the motor, this NFB operates,
causing the motor to be stopped by
dynamic braking.
3 High voltage alarm LED HV lights If the DC voltage of the main power
supply is abnormally high, the motor
is stopped by dynamic braking and the
HV lamp lights.
4 Low voltage alarm LED LV lights If control voltage is abnormally low,

the motor is stopped by dynamic
braking and the LV lamp lights.
5 Circuit fault LED HC lights If an abnormally high current flows

detection to the main circuit, the motor is
stopped by dynamic braking and the HC
lamp lights.
LED DC lights If the regenerative discharge circuit

malfunctions, or if the acceleration/
deceleration rate is too high, the
motor is stopped by dynamic braking
and the DC lamp lights.
1-51
2) Troubleshooting
Troubleshooting and fault recovery are discussed in this section.
a) Overload alarm
Item Causes of problems Check procedures Corrective action
1 PCB setting failure Check if SI of PCB is set Set SI properly.

as specified.
2 Thermostat of the servo Remove the wires connected Check the friction
transformer is open. to transformer terminals 51 torque.
and 54 and measure the Replace the
resistance across them. transformer.
The normal value is 10 ohms
or less* if the circuit is
open (more than 100
kilo-ohms)* the thermostat
is open.
If the thermostat is open
and the surface tempe¬
rature of the transformer
is 80 to 90° C, check
the motor current.
If the surface temperature
is 60° or less* the trans¬
former is defective.
3 Radiation fins of the Check the motor current. Reduce the load.
unit are overheated.
4 Thermostat of the servo Check the motor current. Reduce the load on
motor is open. Check to see if the the motor.
friction in the robot
mechanical part is
excessively large.
5 Thermostat of the Verify the acceleration/ Adjust the acceler¬

discharge unit is open. deceleration time of the ation/deceleration
motor. rate.
1-52
b) Circuit breaker is tripped
1 Circuit breaker is The operating condition of Reset the breaker

tripped. the breaker is as after turning off
illustrated below. the power supply.
This button pops (If the breaker
0 / out when the

circuit breaker is
tripped. Depress
cannot be reset
immediately, wait
for about 10
d this button after
turning off the
minutes before
resetting it.)
power supply to
reset the circuit
breaker.
2 Diode module DS or The circuit breaker is Replace diode
other parts are defect¬ tripped just when turning module DS or servo
ive in servo amplifier. on the power supply after amplifier.
the corrective action in
Item 1 is taken.
3 Mechanical unit Observe the servo amplifier Remove the

malfunctions. PCB using an oscilloscope overload.
to determine if the load
current of the motor
exceeds the rated current
during rapid movement.
Refer to section 26.
c) HV alarm
1 Input AC power voltage Check if the servo trans¬ Repair tap

is higher than former taps are properly connection.
specified. connected.
2 Servo motor is Check if the insulation Replace motor.

defective. resistance is normal
between the motor armature
(power line) and the body.
3 Load inertia is Increase the

excessive. acceleration/
deceleration time
constant.
4 PCB is defective. If HV alarm occurs without Replace the PCB.

any defect in items 1, 2,
3, the PCB is defective.
1-53
5 The regenerative Determine if the re¬ Replace the PCB,

discharge unit is generative discharge discharge transis¬
defective. circuit is defective tor, or discharge
and that the wiring is unit.
properly connected.
d) LV alarm
1 Input AC power voltage Check if the input AC power Correct the tap
is lower than voltage and tap connection connection.
specified. of servo transformer are
correct.
2 +5 V supply circuit is Check if +5 V is normal. Replace the PCB.

defective.
3 PCB is defective. If LV alarm occurs and Replace the PCB.

items 1 and 2 are not
defective, the PCB is
defective.
e) HC alarm
1 Wrong connection of HC alarm does not occur Reconnect the

motor power line when the power supply is motor power line
turned on after the motor correctly.
power line has been
disconnected. (Since the
gravity axis may drop in
this case, support it or
disconnect the drive cable
of gravity axis brake.)
1-54
2 Transistor module is Check if HC alarm occurs Replace transistor

defective. when the power supply is module.
turned on after disconnect¬ Check resistance
ing the power line accord- between Ci-Ei
to item 1. Turn off the (i=l, 2, .•
• t 6)
power supply, remove PCB,
and check the right termi¬
nal of the transistors
module with a circuit
tester. The transistor
module is defective if the
resistance between termi¬
nals is several ohms
(within 10 ohms).
3 Internal short-circuit Check motor windings for Replace motor.

failure of motor normal insulation.
windings
4 PCB is defective. If HC alarm occurs and Replace PCB.

items 1, 2, 3 are not
defective, the PCB is
defective.
f) Machine vibrates
1 Position loop gain is Check the related system Set the system
not set correctly. variable. variable properly.
2 Pulse coder signal is Check whether the pulse Replace the pulse
defective. coder signal cable (Cl, C2, coder signal
C4 and C8) is disconnected. cable.
<$>
B1
B2
B3
B4
B5
B6
+ © ©< ©
© <5> ©
u v w
© ©<
o
©
V
§; Cl, C3, C5 © : El, E2 ® : E3, C4
E5, C6 © : E2, E4, E6
Fig. 5.4 Layout and circuit diagram of transistor module
1-55
6. BACKPLANE PCB (A20B-1002-0860)
The backplane PCB Is used to Interconnect the power supply unit and the control
PCBs by means of the backplane bus. Connector CNP1 is dedicated for the power
supply unit; the others are for control PCBs.
Control PCBs are connected by means of electrical buses on the backplane PCB.
The three types of buses and their use are as follows:
Bus Connector Use
- System bus CNA0-CNA10 For the main system PCBs such as Main CPU,
Path CPU, Axis control and others
- Vision engine
interface
CNB10
CNBV1-CNBV2
Interface for vision CPU and Vision engine 1
and 2
- Vision engine
interconnection
CNAV1-CNAV2 Local bus for Vision engine 1 and 2
The backplane PCB has several connectors other than the 96-pin connectors. The
connectors CNP2 and CNP3 are used to provide voltage to peripheral units such as
the modular I/O unit. Connector CA27 is used for the battery input. Connector
CNP4 and the test points (TEST, HIGH, LOW) are used only at production test.
The backplane PCB also has resistors and resistor modules. The resistors are
used within the circuitry for clocks and serial data transfer. The resistor
modules are used to pull up the tri-state signals on each bus.
6.2 Block Diagram

Vision interface
Voltage
Voltage for
battery back-up -<]8 §[>-'“
cn
Voltage source 04
§
2*r>-A£CP
03 03
SÿB
£
Svl 8 8
System bus
/ Vision interconnection
1-56
04
5 D
at ©
ca
5
a
CQ
§ §
CQ
o
g 5555555555 5 5•< 5< -< s
5
CNAO (System-bus, CCU*)
a b c AMO Address modifier #0 - #2

--2 23: Global
32 SYSCLK1 +5 V SUBCLK1 GA01 address bus #1 - #23
31
30
SYSCLK2
GA13
+5
+5
V
V
0 V
AM2
GDOO
*GAS
- 15: Global data bus #0 - #15
Global address strobe
29 GA12 +5 V AMI R/W Read/Write
28 GA11 0 V AMO *GUDS Global data strobe high byte
27 GA10 0 V GA23 *GLDS Global data strobe low byte
26 GAO 9 +5 V GA22 *GDTACK Global data acknowledge
25 GAO 8 +5 V GA21 *GBR Global bus request
24 GAO 7 +5 V GA20 *BGIN Bus ground in
23 GAO 6 0 V GA19 *BG0UT Bus ground out
22 GAO 5 0 V GA18 *GBERR Global bus error
21 GAO 4 +15 V GA17 *GBBSY Global bus busy
20 GA03 +15 V GA16 *SYSTMR System timer
19 GAO 2 0 V GA15 *ITP Interpolation start
18 GA01 0 V GA14 *ITPL Interpolation lock
17 *GAS -15 V *GDTACK *IDSTB ID strobe
16 *GUDS -15 V *GBERR SYSCLK1
0 V System closk (16.384 MHz)
15
14
*GLDS
R/W 0 V
*EN
*SYSCLR
SYSCLK2
SUBCLK1 } Subsidiary clock #1
13 *SYSEMG +24 V *SYSFAIL *SYSCLR System clear
12 *GBR +24 V *SYSTMR *SYSFAIL System fail
11 *BGIN 0 V *ITP *SYSEMG System emergency
10 *BG0UT 0 V *ITPL SDO Serial data out
09 *GBBSY *PF EN SDI Serial data in
08 GD07 *IDSTB GD15 *PF Power off interrupt
07 GD06 0 V GDI 4 VBAT Battery power
06 GD05 0 V GDI 3 EN
05 GD04 SDO GDI 2 Power enabled
*EN
04 GD03 SDI GDI 1 "*EN" is a reverse logic signal of "EN".
03 GD02 0 V GD10 0 V : Reference for supply voltage
02 GD01 0 V GD09 +5 V : +5 VDC power supply for
01 GDOO VBAT GD08 digital logic circuit
+24 V : +24 VDC power supply for 1/0
*CCU: Central Control Unit interface
+15 V
-15 V } +15 VDC power supply for
memory backup
1-57
CNA1 - 10 (System bus)
a b c AMO Address modifier #0 - #2

- 223s Global
-- 15:: Global
32 SYSCLK +5 V SUBCLK GA01 address bus #1 - #23
31 0 V +5 V 0 V GD00 Global data bus #0 - #15
30 GA13 +5 V AM2 *GAS address strobe
29 GA12 +5 V AMI R/W : Read/Write
28 GA11 0 V AMO *GUDS : Global data strobe high byte
27 GA10 0 V GA23 *GLDS : Global data strobe low byte
26 GA09 +5 V GA22 *GDTACK : Global data acknowledge
25 GAO8 +5 V GA21 *GBR : Blobal bus request
24 GAO 7 +5 V GA20 *BGIN : Bus ground in
23 GAO 6 0 V GA19 *BG0UT : Bus ground out
22 GAO 5 0 V GA18 *GBERR : Global bus error
21 GAO 4 +15 V GA17 *GBBSY : Global bus busy
20 GAO3 +15 V GA16 *SYSTMR : System timer
19 GAO 2 0 V GA15 *ITP : Interpolation start
18 GA01 0 V GA14 *ITPL : Interpolation lock
17 *GAS -15 V *GDTACK *IDSTB : ID strobe
16 *GUDS -15 V *GBERR *USED : Slot used
15 *GLDS 0 V *EN SYSCLK : System clock (16.384 MHz)
14 R/W 0 V *SYSCLR SUBCLK1 s Subsidiary clock #1
13 *SYSEMG +24 V *SYSFAIL *SYSCLR : System clear
12 *GBR +24 V *SYSTMR *SYSFAIL : System fail
11 *BGIN • 0 V *ITP *SYSEMG : System emergency
10 *BG0UT 0 V *ITPL SDO : Serial data out
09 *GBBSY SDI SDO SDI : Serial data in
08 GD07 *IDSTB GD15 VBAT : Battery power
07 GD06 0 V GD14 *EN : Power enabled
05 GD04 *USED GDI 2 +5 V : +5 VDC power supply for
04 GD03 GD11 digital logic circuit
03 GD02 0 V GD10 +24 V : +24 VDC power supply for I/O
02 GD01 0 V GD09 interface
01 GDOO VBAT GD08 +15 V
-15 V } +15 VDC power supply for
memory backup
1-58
CNAV1, 2 (Vision engine interconnection)
A B C 6MCLK Clock (6 MHz)

32 6MCLK +5 V *QADC BMWD Bit map window
31 0 V +5 V 0 V (EXDISP) (External display timing)
30 (NC) +5 V QA (EXVSYN) (External V sync.)
29 BMWD +5 V (NC) (EXHSYN) (External H sync.)
28 EXDISP 0 V D7 *DSPTM Display timing
27 EXVSYN 0 V D6 VSYNC V sync.
26 EXHSYN +5 V D5 HSYNC H sync.
25 *DSPTM +5 V D4 CHRD Character overlay
24 VSYNC +5 V D3 OUTWD Output window
23 HSYNC 0 V D2 RUNLNG Runlength
22 CHRD 0 V D1 *XAOVR X address over
21 OUTWD (+15 V) DO *YAOVR Y address over
20 RUNLNG (+15 V) *MCD2 BNRC Binary output
19 (NC) 0 V *MCD3 *LDXDCT Load X down counter
18 *XA0VR 0 V *STRB *DCTDN Count down X
17 *YA0VR (-15 V) MSABE RDBRAM Read Buffer RAM (BRAM)
16 BNRC (-15 V) *RUNLE WTBRAM Write BRAM
15 (NC) 0 V *RLWD ACNTBF Address count enable for BRAM
14 *LDXDCT 0 V ISSYN APSBF Address preset for BRAM
13 XDCTDN (+24 V) ISASL *WD08 Write DO 8
12 RDBRAM (+24 V) *MCD5 *WD02 Write DO 2
11 WTBRAM 0 V ISACO *CTEY0 Count enable YO
10 ACNTBF 0 V ISAC1 *BL0E BRAM output latche enable
09 APSBF *WD08 ISPCKE *QADC Clock (12 MHz)
08 IDB7A *WD02 IDB7B QA Clock (12 MHz)
07
06
IDB6A
IDB5A
0 V
0 V
IDB6B
IDB5B
DO - 7 8-bit data bus for inter
engine
05
ro4
IDB4A
IDB3A
*CTEY0
*BL0E
IDB4B
IDB3B
*MCD2
*MCD3 } Modal command strobe 2-3
03 IDB2A 0 V IDB2B (*STRB) (Strobe for future option)
02 IDB1A 0 V IDB1B MSABE Master access enable
01 IDB0A ( -) IDB0B *RUNLE Runlength enable
*RLWD Runlength window
Signals in parentheses are not used, ISSYN ISP sync.
ISASL ISP address select
*MCD5 Modal command strobe 5
ISACO ISP address control 0
ISAC1 ISP address control 1
ISPCKE ISP clock enable
IDB0A-7A Image data bus A
IDB0B-7B Image data bus B
+5 V +5 V power
0 V 0 V
1-59
CNBV1, 2; CNB10 (Vision engine interface)
A B C *C12MM Clock (12 MHz)

32 *C12MM +5 V *C24MM *C24MM Clock (24 MHz)
31
30
0 V
MAB13
+5
+5
V
V
0 V
(NC)
MAB1
READ
- 17: Address bus
Read /Write
l 29 MAB12 +5 V (NC) MPUDS Upper byte data strobe
28 MAB11 0 V (NC) MPLDS Lower byte data strobe
27 MAB10 0 V (NC) *FMRDU Read frame memory upper byte
26 MAB9 +5 V (NC) *FMRDL Read frame memory lower byte
25 MAB8 +5 V IOSEL *FMWU Write frame memory upper byte
24 MAB7 +5 V (NC) *FMWL Write frame memory lower byte
23 MAB6 0 V CRTR/W *IRDRAW Interrupt from ACRTC
22 MAB5 0 V RS *SDBE System data bus enable for
21 MAB4 (+15 V) MAB17 ACRTC
20 MAB3 (+15 V) MAB16 IOSEL Input/output select
19 MAB2 0 V MAB15 CRTR/W Read/Write for ACRTC
18 MAB1 0 V MAB14 RS Register select for ACRTC
17 READ (-15 V) *DTDRAW *DTDRAW DATACK from ACRTC
16 MPUDS (-15 V) *FMRDY *FMRDY Ready from frame memory
15 MPLDS 0 V *INHM *INHM Access inhibit to MPU
14 *FMRDU 0 V *PORM *PORM Power on reset
13 *FMRDL (+24 V) *CSCRT *CSCRT Chip select for ACRTC
12 *FMWU (+24 V) *WED0 *WED0 Write enable for DO
11 *FMWL 0 V RFREQ REREQ Refresh request to frame
10 *IRDRAW 0 V (NC) memory
09
08
(NC)
MDB7
*SDBE
(NC)
(NC)
MDB15
MDBO - 15: 16-bit data bus
07 MDB6 0 V MDB14
06 MDB5 0 V MDB13
05 MDB4 (NC) MDB12
04 MDB3 (NO MDB11
03 MDB2 0 V MDB10
02 MDB1 0 V MDB9
01 MDBO ( -) MDB8
1-60
CNP1
A B C +5 V
32 TH COM TL +15 V
31 *PF EN -15 V : DC output
30 +15 V +24 V
29 +5 V +15 V +15 V 0 V
28 +5 V +5 V -15 V TH
27 +5 V +5 V +5 V TL . For
'
test (for variation of
+10% in +5 V)
26 +5 V +5 V +5 V COM
25 +5 V +5 V +5 V *?F : Power failure
24 +5 V +5 V +5 V EN : Enable
23 +5 V +5 V +5 V
22 +5 V +5 V +5 V
21 +5 V +5 V +5 V
20 +5 V +5 V +5 V
19 +5 V +5 V +5 V
18 +5 V +5 V +5 V
17 +5 V +5 V +5 V
16 0 V 0 V +5 V
15 0 V 0 V 0 V
14 0 V 0 V 0 V
13 0 V 0 V 0 V
12 0 V 0 V 0 V
11 0 V 0 V 0 V
10 0 V 0 V 0 V
09 0 V 0 V 0 V
08 0 V 0 V 0 V
07 0 V 0 V 0 V
06 0 V 0 V 0 V
05 0 V 0 V 0 V
04 0 V 0 V 0 V
03 0 V 0 V 0 V
02 0 V 0 V 0 V
01 +24 V +24 V +24 V
1-61
l
CNP2
01 +15 V *PF: Power off interrupt

02 0 V EN : Power enabled
03 *PF
04 EN
05 0 V
06 -15 V
CNP3
01 +5 V +5 V : +5 VDC power source

02 +5 V 0 V :0V (Ground)
03 0 V +24 E: +24 VDC power source
04 0 V
05 +24 E
06 +24 E
CNP4
01 HI HI
02 TEST TEST : For test (for variation of +10% in +5 V)
03 L0 LO
CA27
01 VBAT VBAT: Battery power

02 0 V
03 0 V
1-62
6.4 Jumper Settings
Standard
Jumpers Uses
setting
PI Jumpers PI -
P9 correspond to CNA1 9. If a PCB is
in the slot n, the jumper Pn is set to 0 side* if not
-
it is set to V side, (n = 1 9)
(0 is Occupied and V is Vacant.)
-
P2
For example, there are PCBs on CNAO, 1, 2, 3, 8 and 9.

P3 The jumper settings are as follows:
P4
PI o figFI v
P2
P5 P3
P4
P6
P5
P7 P6
P7 0 V
P8
P8
P9
P9
Gs a!
g D
a§ 2
CO
g g g
>
SO CQ
CO
rs
2 >
<
oo
<
<o
< 5 O
< < 5g 2
g
g g g g g g g g g g g g
a a a a a a ooa
P9 P8 P7 P6 P5 P4 P3 n PI
Location of jumpers
1-63
6.5 Fuse
Q D
a
Causes and corrective actions for blown fuses.

The basic control unit is provided with a fuse at the battery input end as shown
in Fig. 6.5. The following description covers the causes of a blown fuse.
The blown fuse shows a white failure display in Indicator

the indicator as shown in the figure at the right.
a) A part inside the Backplane PCB may be shorted.
b) A part inside the Main CPU PCB may be shorted. 0\
c) A part inside the Path CPU PCB may be shorted. o
Specification number of fuse: A60L-0001-0046#0. 32
Replace the fuse with one having the same specification number,
CA27 CNA1-10
I
01
Battery 11
lI
T 02 1 1 02b
ii
I I 03b
Fig. 6.5 Fuse at battery input
1-64
6.6 Test Points
Test points Contents
HI For variation of +10% in +5 V.

short
TEST HI : +10%
TEST TEST LO : -10%
Note) These are used only at

LO production test.
as £
g D
as 2 >
g S g05
03 05
HI-
n <
z <
z < < < < < < <
6 g g g g g g g g g g
© 2
s:
g
TEST
LO
6.7 Removal/Replacement
1) Procedure
8 Remove all boards on the backplane.

Detach the cables.
© CA27 CNP2 ®
© CNP3
(2.
(© Remove the backplane by loosening four screws.
s'
(4) For mounting a new backplane, reverse the above procedure.
1-65
7. POWER SUPPLY UNIT (A20B-1000-0770)
The power supply unit produces DC voltages for distribution and use throughout
the controller. All DC voltages for the basic control unit and the modular 1/0
unit are supplied from this unit. Additional DC voltages are supplied by other
PCBs for specific purposes.
An input voltage of 200 VAC is rectified, filtered, and regulated for the DC
voltage levels of +5 V, +15 V, -15 V, and +24 V.
The power supply unit is protected from an overcurrent of AC input by two fuses
located on the unit. These fuses have an internal switch that trips to flag the
alarm to the input unit when the device is blown.
One other fuse exists on the power supply unit. This fuse is connected to the
+24 volt line labelled +24 E that supplies the following circuits:
... 1/0
overtravel
emergency stop
. hand breakage circuits
.Overcurrent
other +24 volt
the regulator protect the power supply
limiting characteristics of
from overload or short circuit. When the voltage monitor on the power supply
detects a drop in output voltage, excluding +24 E, it flags an alarm to the
controller. There are no LEDs or variable resistors for the user to monitor or
adjust. All voltage levels are passed through smoothing circuits that ensure
outputs are of the proper level for logic circuits.
1-66
R ®
AC INPUT
CIRCUIT
cpri Fl 1
CfVO
} NF1 1 DSl 1
Auxiliary
supply
Mil
n1 Dll
w
Power
A15
+ 1 [07
AO A0
A15
+V
QlS(VCEJ -,_fV
QI4
3
+V
:tD24
+24 regulator
T14
M.A. DS12
•0/
I
W
r -i
I
I
I
I
CHI 1
F={
B A
L-
__
—
L* i Smoothing
I
flI
CHI 3
t
4
+uC67
+ C28
C30
FI4
<r\J>
0T2
VS 1 2
+24
CPI 4
I-@+24
CP14
CPI 2
+15
X—@+15
®+24E ro
03
O
o
7T
D
<s
0)
AC INPUT switch TT- SD +240CL ovp CP12

£ + 31 C 1 2
Cl 3
(80kHz) 'Ir MAC Shut down A10 +15V
n converter t
CP 1/1 F 1 2 IP
Q.y -1D25 control
0
TT
S ®--Ucr\o D36 DSB NR2 RG12
XL XI +>+
CPU TI3 T12 -15V regulator
G @ AisBPiaÿ + HC36
4
rrr
A10
-O- -o
AO
PC
t Pre driver
M12
DSl 3
DS21
DSl 4
CH12
Smoothing" OVP C43 to
C£U
I
"15CP12
T
+5
—I ®+5
1
CPUT —
- @-15
, Dummy
/VVlFa R68 XT i;DS15
D C 4. +UC47
C83 load R50 0T1 CPI 2
I
160kHz IC57 CTP1
J-
DS22
DS23
m* C$14 C84 @0V
_
AO +5V regulator J- CPI 4
0T1 +50CL +240CL 0T2 MAC CPI 2
Ml 3 h 2£ t H ip +50CL
JP—
| .< ca
J.
c+i y* DSB
A15
T
VCC|*
r-
!
Reference A5
O UO fl!
+5V control
PWM control
O
m.
VCL Voltage monitor
5L +24V control
M.A. control
Control
signal
1
DSB
PFB
X
+5
CPU
@ EN
regulator
O.C.L., P.CX. «&LQ_ ( OCX. ) circuit NR&
GNDI j VNR T
L +
AO
u. A10 co a: u. 32 CPU
o
LJ
< AIO AIO
<
£ C50+l5S C f< 5J5
2 >1ÿ
z cu
®*PF
oC
A18 R59 1ÿ40 AIO

T
Voltage D4I CN
NR2 Fll
Fl2
RYU M
ADJ R70 AO R75 monitor 65 £5
VR11! AO
R71
CONNECTION TEST
fiR76
AO FTTT
MI4
®©
NR2 VNR
CPI 3 [
Power unit
AI5
R72
*o Other PSU interface
HI @sm HI TEST LO LEVEL < 77? interface ««•
TEST @CPU o a=D +4.5 V
o o o +5.0V
LO CPU R73 o +5.5 V
®
AO
k© © ra
©
© © i
© © <
o o
POWER SUPPLY UNIT

CP12
A20B-1000-0770 on
o Ld
¥
CP14 CPI 3 cpii
1-68
CP12 CP 13 (Input unit PCB)
A B C 06 ALD
32 TH COM TL 05 ALC
31 *PF EN 04
30 +15 V NR2 VNR 03 PF
29 +5 V +15 V +15 V 02 PFH
28 +5 V +5 V -15 V 01 PFL
27 +5 V +5 V +5 V
i_26 +5 V +5 V +5 V ALD
: Alarm output
25 +5 V +5 V +5 V ALC
24 +5 V +5 V +5 V PF
23 +5 V +5 V +5 V PFH : Power failure
22 +5 V +5 V +5 V PFL
21 +5 V +5 V +5 V
20 +5 V +5 V +5 V CP14 (I/O unit)
19 +5 V +5 V +5 V
18 +5 V +5 V +5 V 06 +24 E
17 +5 V +5 V +5 V 05 +24 V
16 0 V 0 V +5 V 04 0 V
15 0 V 0 V 0 V 03 0 V
14 0 V 0 V 0 V 02 +5 V
13 0 V 0 V 0 V 01 +5 V
12 0 V 0 V 0 V
11 0 V 0 V 0 V CP11 (Input unit PCB)
10 0 V 0 V 0 V
09 0 V 0 V 0 V 03 G
08 0 V 0 V 0 V 02 200S
07 0 V 0 V 0 V 01 200R
06 0 V 0 V 0 V
05 0 V 0 V 0 V G : Ground
04
03
0
0
V
V
0
0
V
V
0 V
0 V
200S
200R ) : 200 VAC input
02 0 V 0 V 0 V
01 +24 V +24 V +24 V
+5 V, +15 V, -15 V, +24 E, 0 V: DC output-

TH
TL : For test (for variation of +10% in +5 V)
COM
*PF : Power failure
EN : Enable
NR2
VNR
: Not used

This power supply unit contains no adjusting or setting points that require
adjusting routinely. The reference voltage A10 (=10.00 V) has already been
adjusted during tests of this unit. Always check reference voltage A10 whenever
the power supply unit is replaced. The location of VR11 and A10 is shown in
Fig. 7.4. If A10 voltage is deviated, adjust it to 10.00 V by turning VR11.
(Use a digital voltmeter.) The voltage increases when turning VR11 clockwise.
1-69
a b c
t
Io o
i
11
©
32 H T L
31 WEN I
30 3EMSS
29 1 +15
28 EH
27
26
25
24
Tl
23 t o o a
22 +5
;sJ
21
20
O 19
for View with
1 18
17 back
>anel
the cover
removed
*A
c 16
I •D 15
O •< 14
e 13 + CPI 2 + o o -
Fll 12 fl
2. 7.5A
12 BLUE 2 00/220VAC
11 input fuse
X
s? 10 JO
2
re
*
9
8
7
6
5
0
CPI 6
VR1 1
IgJjAlO ADJ.
POWER SUPPLY UNIT
A20B-1000-0770
1 I
F14
2A
+24E fuse
4
3
1 +24
o=
I ™ 2 3456789
/? CP14
BROWN
g)E5r CP13
WHITE
0
—\ r
f CPU
black «o=
o j=y
&
E 1 1 2 3
i gs3°if sg 123456 123456

pm
200/220 VAC input
yM°lol?ll IfclfcN \TR

To power PCB Input Unit !
7.5 Fuses
Refer to Fig. 7.4 for the position of the fuses.
The power supply unit is provided with fuses Fll to F12 at the input end, and
F14 at +24 E output terminal. The following description covers causes and
actions to be taken when these fuses are blown.
(X) Cause and remedies of a blown Fll or F12 fuse
a) Short-circuit of diode stack DS11
b) Short-circuit between C-E of switching transistors Q14, Q15
c) Short-circuit of diodes D24, D25
d) Short-circuit between C-E of transistor in auxiliary power supply circuit
Mil
Replace with the spare power supply unit, if the parts described in (a)
(d) are found to be shorted.
-
Specification number of Fll to F12: A60L-0001-0101#P475H
Replace with fuses having the same specification number.
(D Causes and remedies of a blown F14 fuse.
a) The +24 E power cable to I/O base unit or a part inside the I/O unit may
be shorted.
b) The +24 E power line may be in contact with the other power line or cause
a ground fault by the robot mechanical unit side wiring. Remove CP14,
and check them carefully.
Specification number of F14: A60L-0001-0046#2. 0
Replace with a fuse having the same specification number.
s
A20B-1000-0770
-ÿh024 -a-D25
Q15
Q14
MU
DS11
CP12
Fig. 7.5 Position of components on the power supply unit

(The unit cover is removed in the. above figure)
1-71
7.6 Test Points
The meanings of the test points on the power supply unit are as follows. (See
Fig. 7.6)
Test points Symbol Contents Waveform
CP16 CTP2 Pre-driver signal of

+5 V regulator 11.5
— 13 Msec.
nr 30V
u ov
CP16 CTP1 +5 V control

11.5 - 13 wee.
ir:I
CP16 AO 0 V
CP16 A15 14.5 - 15.5 VDC

CP16 INH When "INH" is shorted
to 0 V, overcurrent
alarm of +5 VDC output
is neglected. This
terminal is used for
testing only.
CP16 A10 Reference voltage

adjustable by variable
10.000 - 10.007 VDC
resistor VR11.
CP16 SDC Shut down control

signal. When the +24V
_ +24 v
power is turned off,
+24 V output is cut
off by this signal.
7\
i
A.-
*5V
SDC ov
CP16 CTP4 +15 V control

20 - 25V
0V
30 - 40 MSCC.
1-72
F Triangle wave
jv
/ -ov
1
5.75 - 6.S Msec.
PC +5 V control
1.2V
-OV
11.5 - 13.0 Msec.
A, B Terminals for the

+24V
current measurement
of +24 V and +24 E I
output.
OV -J--I
TO B A
C, D Terminals for the

current measurement .
I
of +5 V output.
VI
ov I
TO
D C
1-73
A
O
oB
CP12
O
_ D
O
_PC
oF
CP16
oc CPU CPI 3
Fig. 7.6 Location of test points on the power supply unit

(The unit cover is removed in the above figure)
1-74
PSUl'
Backplane
Power
supply
unit Connector to
backplane PCB
I I
I l!
I i!i
cpii CPI*
CP13f
1) Procedure
8 Disconnect cables of connectors CP11, CP13 and CP14.

Detach the power supply unit by removing four screws. The power supply
unit is connected to the backplane PCB of the basic control unit by the
connector shown by a dotted line in the figure.
(5) For mounting new power supply unit, reverse the above procedure.
Caution) Always check reference voltage A10 whenever the power supply unit is
replaced.
1-75
8. MAIN CPU BOARD (A16B-1 211-0040, 0041)

The main CPU board processes the KAREL language system, file operations, and
system 1/0.
The board contains the local memory for a microprocessor. The memory is
organized by four (-0041) or eight (-0040) DRAM modules, the total capacity is
1 MB (-0041) or 2 MB (-0040).
The system software is loaded into the DRAM from bubble memory.
In addition to the DRAM, there is a 64 kB battery-backed RAM. The board can be
equipped with a floating-point coprocessor chip as an optional feature.
The system bus interface allows when the microprocessor to access the shared
resources on the system bus.
8.2 Block Diagram

To backplane
I CNA 1
Battery voltage
o
System bus
1MB oi 2MB interface
ORAM 64kBRAM
n n
n
Micro¬ FPCP
processor Clock
12MHz . interface
O
CN1 J
For development purposes only
<
z
u 5
T
1-76
CNA (Main CPU)
a b c AMO 2- Address modifier 00 --

02
32 SYSCLK +5 V SUBCLK GAOl -
23: Global address bus 01 023
31
30
0 V
GA13
+5
+5
V
V
0 V
AM2 *GAS
-
GDOO 15: Global data bus 00 -
Global address strobe
#15
29 GA12 +5 V AMI R/W Read/Write

25 GAO8 +5 V GA21 *GBR Global bus request
24 GA07 +5 V GA20 *BGIN Bus ground in
20 GAO 3 +15 V GA16 *SYSTMR System timer
18 GAOl 0 V GA14 *ITPL Interpolation lock
16 *GUDS -15 V *GBERR *USED Slot used
15 *GLDS 0 V *EN SYSCLK System clock (16.384 MHz)
14 R7W 0 V *SYSCLR SUBCLK1 Subsidiary clock #1
10 *BGOUT 0 V *ITPL SDO Serial data out
09 *GBBSY SDI SDO SDI Serial data in
08 GD07 *IDSTB GD15 VBAT Battery power
07 GD06 0 V GDI 4 *EN Power enabled
06 GD05 0 V GD13 0 V Reference for supply voltage
05 GD04 *USED GDI 2 +5 V +5 VDC power supply for
02 GD01 0 V GD09 Interface
01 GDOO VBAT GD08 +15 V +15 VDC power supply for
-15 V
: memory
backup
1-77
CN1 (Test PCB)
C B A This connector is not used.

32 *IPL2 +5 V *IPL1
31 *IPL0 +5 V A23
30 A22 +5 V A21
29 A20 +5 V A19
28 A18 0 V A17
27 A16 0 V A15
26 A14 +5 V A13
25 A12 +5 V All
24 A10 +5 V A09
23 A08 0 V AO 7
22 A06 0 V A05
21 A04 AO 3
20 A02 +15 V A01
19 *EPEX 0 V *AS
18 *VMA 0 V *UDS
17 E *LDS
16 *VPA -15 V R/W
15 *RES 0 V *NMIE
14 *BERR 0 V FCO
13 *HALT FC1
12 *RST +24 V FC2
11 *INH 0 V D15
10 D14 0 V D13
09 D12 TH Dll
08 DIO *DTKI D09
07 D08 TL D07
06 D06 CO D05
05 D04 *PF EN
04 D03 *BR *DTAK
03 D02 *BGC
02 D01 0 V *BGAK
01 DOO *BGI *CLK
1-78
8.4 LEDs
LED 1 Meanings Status
A Not used
(Yellow)
B Not used
(Yellow)
C Not used
(Yellow)
D Not used
LED 2 Meanings Status
A DRAM parity alarm Parity alarm occurs, accessing dynamic-RAM

(Red) on main CPU PCB.
B SRAM parity alarm Parity alarm occurs, accessing static-RAM

(Red) main CPU PCB.
C
Not used
D
LED2
©®
®©
f LED!
(A)©
®©
1-79
8.5 Test Points
G 0 V (ground)
TEST This terminal is used in

software debugging
O
G
OG
<
§ §
GOO TEST
T
1-80
01P09
©— Tj
a
Backplane PCB
1) Procedure
.
I Detach PCB by loosening the screws (D
Mount new PCB.
2) Caution
If the PCB being replaced has the optional IC, check that the IC mounted on
the new PCB has the same specification.
O
[-
Optional 1C
1-81
9. PATH CPU BOARD (A16B-1211-0030)
The path CPU board calculates path information and provides it to the servo
system.
The board contains the local memory for a microprocessor. The memory size is
256 kB, organized by DRAMs.
The executive software is loaded into the DRAM from bubble memory after power
up.
The board can be equipped with a floating-point coprocessor chip and a line
tracking counter as optional features.
The board has an overheat sensor and a battery-operated calendar clock, which
provides the R-H controller with an absolute date and time base. The overheat
sensor detects abnormal temperature rise and signals it to the path CPU via a
digital input. The critical temperature is 65°C.
The global bus interface allows the microprocessor to access the shared
resources on the system bus.
9.2 Block Diagram

To backplane
I CNA
256 kB Overheat System but

DRAM sensor interface
u <>
Micro¬
processor
_ Clock
12MHz
_
-
FPCP
interface
Calendar
clock
Line
tracking
counter
I CN1 ~J I CA2 I
For development From pulse encoder
purposes only for line tracking
1-82
<
Z
u 5
T
CNA (Path CPU)
a b c AMO - 2 23: Global

Address modifier #0 - #2
32
31
SYSCLK
0 V
+5
+5 V
V SUBCLK
0 V
GA01
GD00
-- 15: Global address bus #1 - #23
data bus #0 - #15
30 GA13 +5 V AM2 *GAS : Global address strobe
28 GA11 0 V AMO *GUDS : data strobe high byte
Global
27 GA10 0 V GA23 *GLDS : data strobe low byte
Global
26 GAO 9 +5 V GA22 *GDTACK : Global
data acknowledge
25 GAO8 +5 V GA2 1 *GBR : Global
bus request
24 GAO 7 +5 V GA20 *BGIN :
Bus ground in
23 GAO 6 0 V GA19 *BG0UT :
Bus ground out
22 GAO 5 0 V GA18 *GBERR :
Global bus error
21 GAO 4 +15 V GA1 7 *GBBSY :
Global bus busy
20 GAO 3 +15 V GA16 *SYSTMR :
System timer
19 GAO 2 0 V GA1 5 *ITP :
Interpolation start
18 GA01 0 V GA14 *ITPL :
Interpolation lock
17 *GAS -15 V *GDTACK *IDSTB :
ID strobe
16 *GUDS -15 V *GBERR USED :
Slot used
:
14 R/W 0 V *SYSCLR SUBCLK1 :
Subsidiary clock #1
13 *SYSEMG +24 V *SYSFAIL *SYSCLR :
System clear
12 *GBR +24 V *SYSTMR :
*SYS FAIL System fail
11 *BGIN 0 V *ITP *SYSEMG :
System emergency
10 *BGOUT 0 V *ITPL SD0 :
Serial data out
09 *GBBSY SDI SD0 SDI :
Serial data in
08 GD07 * IDSTB GD 15 VBAT :
Battery power
07 GD06 0 V GDI 4 *EN :
Power enabled
06 GD05 0 V GDI 3 0 V :
Reference for supply voltage
05 GD04 *USED GDI 2 +5 V :
+5 VDC power supply for
04 GD03 GD 11 digital logic circuit
01 GD00 VBAT GD08 +15 V
-15 V ) +15 VDC power supply for
memory backup
1-83
CA2 (Position coder)
14 PCZ 01 0 V PCZ
02 0 V
: Z-phase of Position Coder
15 *PCZ 08 *PCZ
16 PCA 09 03 0 V PCA
04 +5 V : A-phase of Position Coder
17 *PCA 10 *PCA
18 PCB 11 05 +5 V PCB
: B-phase of Position Coder
19 *PCB 12 06 +5 V *PCB
20 SG 13 07
CN1 (Test PCB)
C B A This connector is not used.

32 *IPL2 +5 V *IPL1
31 *IPL0 +5 V A23
30 A22 +5 V A21
29 A20 +5 V A19
28 A18 0 V A17
27 A16 0 V A15
26 A14 +5 V A13
25 A12 +5 V All
24 A10 +5 V A0 9
23 A0 8 0 V A0 7
22 A06 0 V A05
21 A04 A0 3
20 A0 2 +15 V A01
19 *EPEX 0 V *AS
18 *VMA 0 V *UDS
17 E *LDS
16 *VPA -15 V R/W
15 *RES 0 V *NMIE
14 *BEER 0 V FC0
13 *HALT FC1
12 *RST +24 V FC2
11 *INH 0 V D15
10 D14 0 V D13
09 D12 TH Dll
08 D10 *DTKI D09 .
07 D08 TL D07
06 D06 CO D05
05 D04 *PF EN
04 D03 *BR *DTAK
03 D02 *BGC
02 D01 0 V *BGAK
01 D00 *BGI *CLK
1-84
9.4 LEDs
LED 1 Meaning Status
A Not used
(Yellow)
B Not used
(Yellow)
C Not used
(Yellow)
D Not used
LED Meaning Status
LED2 DRAM parity alarm Parity alarm occurs, accessing dynamic-RAM

(Red) on path CPU PCB.
q /I LED2
Ct
3ÿ
f LEDl
®©
®©
1-85
9.5 Jumper Settings
Standard
Jumper bses
setting
PI W O Pulse width adjustment of the 16.384 MHz clock.

o Change the setting so that the waveform at test
2 o point C16 is as shown in section 9.7. (The setting
PI was adjusted before shipping.)
o
> a
C16M
O 8
[°
0
PI
< §
§
L«J
9.6 Variable Capacitor

The variable capacitor CK4 is used for minute adjustment of the frequency for
RTC (Real Time Controller; M6242). The frequency is measured at 64 Hz using a
frequency counter. CK4 was adjusted before shipping. (Refer to section 9.7 for
the location of the RTC test point) .
If CK4 requires adjustment:
0 Connect frequency counter to test point RTC.
0 Adjust CK4 until frequency equals 64 Hz.
CK4
z
CJ
<
5 g
1-86
9.7 Test Points
Test points Contents Waveform
G 0 V (ground)
0 V 0 V (ground)
+5 V Supply voltage for logic +5 VDC
+15 V Supply voltage +15 VDC
-15 V Supply voltage -15 VDC
+24 V Supply voltage +24 VDC
C16M Clock for main system 3.5V

(16.384 MHz)
ov
U-61 nsec -1
software debugging.
RTC Real Time Control

This terminal is used in
minute adjustment of the
frequency for RTC (M6242) .
G RTCO
O
C16M o
o
+5VO
OV O
+15VO
-15V O
+24V O
G
O
<
z g
o TEST
O OG
T
Location of test points
1-87
01F02
—
CD
©
Backplane PCB
1) Procedure
(D Detach PCB by loosening the screws (T)
(2) Mount new PCB.
.
2) Caution
If the PCB being replaced has the optional IC, check that the IC mounted on
the new PCB has the same specification.
rn
o
o [
[“
Optional IC
1-88
10. SHARED RAM BOARD (A16B-1211-0860)

The shared RAM board is an essential module in the R-H controller, functioning
as a central control module for the System BUS.
It provides a system clock, clear, timer, and other important signals. Four
serial ports are available; Direct Memory Access (DMA) data transfer capability
is supported for some. The shared RAM is used not only by the processors on the
bus but also by an optical link for the I/O unit. The shared ROM contains a
diagnostic program and an initial program loader. Processors are designed to
run with this ROM first after power up. The board also contains drivers and
receivers to drive LED displays and to receive push button status signals from
the operator panel and to send and receive signals from the teach pendant,
RS-232-C interface and the power input unit interface.
Four LEDs are located on the shared RAM PCB. The LEDs indicate system errors.
Note) The system can be operated without the teach pendant by plugging a teach
pendant bypass plug into CNTP.
10.2 Block Diagram
{ CNA
System
bus
interface
ns Buf. DMAC
J>
RAM
Bus
ROM control
SCC1 SCC2
Modular
I/O COP2 t t
I DV/RV I I DV/RV I I DV/RV I
f
1 CNPI -
I 1 CNTP -
I 1 CD4A ) { CNOP
Power Teach RS-232-C Operator panel
input unit pendant device
interface
1-89
<
§
<
5
5
T aJ
CO
CNA

32
31
SYSCLK1
SYSCLK2
+5 V
+5 V
SUBCLK1
0 V
GA01
GD00
data bus #0 - #15
30 GA13 +5 V AM2 *GAS Global address strobe
29 GA12 +5 V AMI R/W Read /Write
25 GAO8 +5 V GA21 *GBR Global bus request
23 GAO 6 0 V GA19 *BGOUT Bus ground out
20 GA03 +15 V GA16 *SYSTMR System timer
16 *GUDS -15 V *GBERR SYSCLK1 System clock (16.384 MHz)
15 *GLDS 0 V *EN SYSCLK2
14 R/W 0 V *SYSCLR SUBCLK1 Subsidiary clock #1
10 *BGOUT 0 V *ITPL SDO Serial data out
09 *GBBSY *PF EN SDI Serial data in
08 GD07 *IDSTB GDI 5 *PF Power off interrupt
07 GD06 0 V GD14 VBAT Battery power
06 GD05 0 V GDI 3 EN
Power enabled
05 GD04 SDO GDI 2 *EN
04 GD03 SDI GDI 1 "*EN" is a reverse logic signal of "EN".
03 GD02 0 V GD 10 0 V : Reference for supply voltage
02 GD01 0 V GD09 +5 V : +5 VDC power supply for
01 GD00 VBAT GD08 digital logic circuit
+24 V : +24 VDC power supply for I/O
Interface
+15 V| +15 VDC power supply for
#
-15 V j ‘ memory backup
1-90
CD4A
RS-232-C port A
14 +24 VR 01 RDA : Receiving data

08 RDA
15 09 SDA
02 SDA : Sending data
16 03 RSA : Request to send
10
17 0 V 04 CSA : Clear to send
11
18 DRA 05 ERA DRA : Data set ready
12 Data terminal ready
19 CSA 06 ERA :
13 +24 VDC power supply for
20 RSA 07 +24 VR :
RS-232-C port
0 V : 0 V
CNTP •v
RS-422 for teach pendant
14 *RDTP 01 RDTP RDTP 1 Receiving data from teach

08
*RDTP j
#
*
15 *SDTP 02 SDTP pendant
09
16 TP 2 03 TP1 "*RDTP" is a reverse logic signal of
10 TP3
17 0 V
11 TP4
04 "RDTP".
18 0 V 05 SDTP
19 0 V
12 EMG
13
06 *SDTP } * Sending data to teach pendant
20 07 +24F TP1 : Status signal of EMERGENCY
STOP button and deadman switch
TP2 : Status signal of EMERGENCY
STOP button and DISABLE/ENABLE
switch
EMG : Common line signal for TP1 and
TP2
TP3 : Extra E-stop contact output
TP4
+24 F : +24 VDC power supply for teach
pendant
0 V : 0 V
1-91
CNOP
RS-232-C ports and DI/DO for operator’s panel
01 | RSB 33 RSC TPENBL Teach pendant enabled LED

02 0 V 34 0 V PENBL Panel enabled LED
19 RDB In cycle LED
03 ERB 35 ERC INCYC
20 0 V NOTCAL Not calibrated LED
04 DRB 36 DRC
21 SDB 37 CSC ULED1 User LED #1
05 CSB 22 0 V
06 TP 3 38 0 V ULED2 User LED #2
23 RDC 39 PENBL FAULT Fault LED
07 C START
24 0 V 40 TPENBL HELD Held LED
08 CALIB
SDC
09 FRESET 25 41 INCYC CSTART Cycle start button
26 0 V 42 NOTCAL CALIB Calibrate button
10 HOLD
27 0N1 43 FAULT UPB1 User panel button #1
11 OTREL
28 ON 2 HELD UPB2 User panel button #2
12 REMOTE 29 OFF1 44
13 UPB1 45 ULED1 FRESET Fault reset button
30 0FF2 Hold button
14 UPB2 46 ULED2 HOLD
31 0 V 47 +24 V OTREL Overtravel release button
15 ESTOP
32 0 V
16 +24 F
17 +24 F
48
49
+24 V
+24 V
0N1
ON 2 ) Contact of the Power ON button
(normally open)
18 TP 4 50 0FF1 I Contact of the Power OFF button
OFF2
!
I
(normally closed)
REMOTE: Remote switch
ESTOP : Emergency stop switch
RDB : Receiving data
SDB : Sending data
RSB : Request to send
CSB : Clear to send
DRB : Data set ready
ERB : Data terminal ready
The six signals listed above are for the
RS-232-C interface.
RDC : Receiving data
SDC : Sending data
RSC : Request to send
CSC : Clear to send
DRC : Data set ready
ERC : Data terminal ready
Above 6 signals are contact of CRT/KB
interface.
TP3
TP4 )
: Extra E-stop contact output
+24 F : +24 VDC power connection for
RS-232-C interface
+24 V +24 VDC power connection for
0 V operator's panel
1-92
CNPI
Input unit interface
1 +24 F 8
14 0 V OTREL : OVERTRAVEL RELEASE button
2 +24 F 15 0 V ONI Contact of the POWER ON button
9
3 ONI 16 ON 2 ON 2 (normally open)
10 17 OFF 2 0FF1 Contact of the POWER OFF button
4 OFF1
11 (normally closed)
5 OTREL 18 OFF 2
12
6 TP 1 19 TP 2 TP1 : Status signal of EMERGENCY STOP
7 +24 F
13 20 0 V button and DEADMAN switch
TP 2 : Status signal of EMERGENCY STOP
button and DISABLE/ENABLE
switch
+24 F +24 VDC power connection for
0 V power input unit interface
C0P2
OPTIN OPTIN : Optical input signal from

OPTOUT modular I/O unit
OPTOUT : Optical output signal to
modular I/O unit
1-93
10.4 LEDs
LEDs Meanings Status
A System fail This indicates that at least one module is

(Red) malfunctioning .
This signal is asserted illuminating the
LED when the main CPU PCB hr path CPU PCB is
malfunctioning .
B System emergency This indicates a system emergency.
(Red) The causes are as follows:
. AC power failure
. The watch-dog timer timeout
. Error in serial data communication
C Not used One of the following battery problems.
D Battery alarm This indicates the following battery problems:

(Red) . The battery unit is not connected.
. Fuse on the backplane PCB is blown.
. The voltage of the battery becomes less than 3.6 VDC.
r o
\
\
© © \\
I [
[
[Z
© ©\
\
\
1-94
10.5 Test Points
G 0 V (ground)
+5 V Supply voltage for logic +5 VDC
+12 V Supply voltage for RS-232-C +12 VDC

and RS-422 driver
-12 V Supply voltage for RS-232-C -12 VDC

and RS-422 driver
*C8M Clock for bus controller

(8.192 MHz)
nr
I- 122 nsec -4 ov
C16M Clock for main system 3SV

(16.384 MHz)
JAJ.
k- -I
61 nsec
C32M Clock source for C8M and C16M

(32.768 Mhz)
nr 31 nsec -I
3JV
ov

software debugging
*RES This terminal is used in

software debugging.
OG
+1?V °112V
C16M O TEST CU
o
o
° 0*RES 5
C32M
O G <
O 0+5V 8
*C8M
I
s
CU
<
2
CJ GO
I£
2
U
x COP2
_r
1-95
01P04
B
©~ÿJ
Backplane PCB
1
a>
1) Procedure
QD Disconnect cables from the PCB.
© Detach PCB by loosening the screws (2) .
(4) For mounting new PCB, reverse the above procedure.
A CAUTION
Make sure the teach pendant cable is plugged into the teach
pendant connector (CNTP) not the serial port connector
(CD4A). Otherwise, damage to equipment could occur.
1-96
11. BUBBLE MEMORY BOARD (A16B-1211-0090, 0091, 0092)
The bubble memory board is a non volatile mass-storage device used for storing
the system software, system variables, and KAREL application programs.
There are three types of bubble memory boards.
A16B-1211-0090: 2 MB
A16B-1211-0091: 1.5 MB
A16B-1211-0092: 1 MB
The bubble memory devices are controlled by the controller LSI circuit on the
board; data is transferred between the bubble memory board and the other boards
by the system bus. Since the DMA (Direct Memory Access) function is supported,
the data transfer operation is done by hardware once it has been initiated by
software.
A factory-programmed EPROM stores the defective loop information for all bubble
memory devices on the board.
11.2 Block Diagram

To backplane
I CNA |
Bubble
memory
E
System bus
devices interface
n
DV/RV
Bubble
memory
E
controller
TT
DMA
E
EPROM controller
<
6
1-97
CNA (Bubble memory)

32
31
SYSCLK
0 V
+5 V
+5 V
SUBCLK
0 V
GA01
GDOO
data bus tiO - #15
30 GA13 +5 V AM2 *GAS : Global address strobe
28 GA11 0 V AMO *GUDS : Global data strobe high byte
27 GA10 0 V GA23 *GLDS : Global data strobe low byte
26 GAO 9 +5 V GA22 *GDTACK : Global data acknowledge
25 GAO8 +5 V GA21 *GBR : Global bus request
24 GAO 7 +5 V GA20 *BGIN : Bus ground in
23 GAO 6 0 V GA19 *BG0DT : Bus ground out
22 GA05 0 V GA18 *GBERR : Global bus error
21 GAO 4 +15 V GA17 *GBBSY : Global bus busy
20 GAO3 +15 V GA16 *SYSTMR : System timer
19 GAO 2 0 V GA15 *ITP : Interpolation start
18 GA01 0 V GA14 *ITPL : Interpolation lock
17 *GAS -15 V *GDTACK *IDSTB : ID strobe
16 *GUDS -15 V *GBERR USED : Slot used
15 *GLDS 0 V *EN SYSCLK : System clock (16.384 MHz)
14 R/W 0 V *SYSCLR SUBCLK1 : Subsidiary clock #1
13 *SYSEMG +24 V *SYSFAIL *SYSCLR : System clear
12 *GBR +24 V *S,YSTMR *SYSFAIL : System fall
11 *BGIN 0 V *ITP *SYSEMG : System emergency
10 *BG0UT 0 V *ITPL SDO : Serial data out
09 *GBBSY SDI SDO SDI : Serial data in
08 GD07 *IDSTB GD15 VBAT : Battery power
07 GD06 0 V GD14 *EN : Power enabled
05 GD04 *USED GD12 +5 V : +5 VDC power supply for
01 GDOO VBAT GD08 +15 V +15 VDC power supply for
-15 V : memory
backup
1-98
11.4 Jumper and Switch Settings
Standard
Jumpers Uses
setting
PI B |oÿl A
P2 A
B side setting is selected in software debugging

P3 B [oBga| A only. In normal use, all must be set to A side.
P4 B !°ÿ|A
P5 B l°gggi| A
Standard
Switch Uses
setting
SW1 OFF ON : NOT USED

OFF: Normal mode
C3 P5
P4 ON
P3
P2 § swi [>>
PI OFF
<
5
T J J
Location of jumpers Location of switch
1-99
11.5 Test Points
G 0 V
HB1 These test points are used for

erasing the bubble memory
devices.
HB2 If "ERASE" and "HBn" are
short-circuited, the
corresponding device MBMn
HB3 will be erased, (n = 1 4) -
Test point Device
HB4 ERASE - HB1 : MBM1
ERASE - HB2 : MBM2
ERASE - HB3 : MBM3
ERASE ERASE - HB4 : MBM4
G
O
MBM2 MBM4
MBM1 MBM3
ERASE O
OG HB4 O
HB3 0
HB2 0
HB1 0
<
z OG
o
1
1-100
01P08/01P15
CD—sj
Backplane PCB
1) Procedure
0 Detach PCB by loosening the screws Q.
(5) Mount new PCB.
NOTE Refer to the R-H Controller System Software Installation

Kit documentation for information on reloading system software.
1-101
12. AXIS CONTROL BOARD (A16B-1211-0060, 0062)

The axis control board receives the motion commands from the path CPU and moves
the robot's axes.
There are two types of axis control boards.
A16B-1211-0060: 4-axis control

A16B-1211-0062: 2-axis control
For every two axes, one high-speed microprocessor provides full digital servo
control based on modern digital control theory.
The microprocessor has 16 kB RAM. The software is loaded into RAM by the main
CPU via the system bus.
The servo interface contains a custom LSI circuit, A/D converter and some glue
(miscellaneous) logic.
For each axis, two connectors are located on the front end of the board. One is
a position feedback from the pulse encoder on the motor. The other is a
connector to the servo amplifier, which generates the motor power proportional
to the torque command from the axis control board.
The board has a feedback loss detect circuit that indicates an error when the
pulse encoder cable is disconnected. If the servo amplifier detects an error,
the board receives the information via a digital input.
1-102
12.2 Block Diagram
To backplane
I CNA
7>
System bus
interface
s
n
Buffer
n
Buffer
7>
16 kB
RAM -
V
Micro*
processor
16 kB
RAM -K
A A
\- — N Micro¬
processor
Servo
interface
*
— \ Servo
interface
Servo
interface
-
-
S
N
s
— Servo
interface
DI/DO DI/DO
Feedback Feedback
loss detct loss detect
| CV21 1 1 CF9I~T |CV22 1 |CF92T I CV23 1 1 CF93T |CV24 1 |CF941
To servo amplifiers From pulse encoders
1-103
12.3 Connector/Siganl Identification
The relationship between the axis numbers, axis names, and the connectors on the
axis control PCB, robot mechanical unit, and servo amplifiers is shown in Table
12.3 (a) and (b).
Table 12.3 (a) S-10
Axis Axis Axis Axis Servo

Feedback Connector Velocity
Software Hardware Axis control control Amp. Connector
connector on robot connector
No. No._ PCB PCB No.
2 1. W CF91 PI CV21 CN1N
3 2 0 CF92 PI CV22 1 CN1L

1 1
1 3 e CF93 PI CV23 CN1M
4 4 r CF94 P2 CV24 CN1N
5 5 6 CF91 P2 CV21 2 CN1M

2 2
6 6 a CF92 P2 CV22 CN1L
Table 12.3(b) S-700

Software Hardware 'Axis control control Amp. Connector
No. No. PCB
connector on robot PCB
connector
No.
2 1 W CF91 PI CV21 4 CN1
3 2 U CF92 PI CV22 1 CN1M

1 1
i 3 e CF93 PI CV23 3 CN1
4 4 r CF94 P2 CV24 2 CN1M
5 5 8 CF91 P2 CV21 2 CN1L

2 2
6 6 a CF92 P2 CV22 1 CN1L
1-104
m *ÿ«
zz
<S
sa
ZZ
as
g< S3
88
Connector position (Side view of PCB)
m •*
5
«
zz N
Z
-<r «N es
r* CN
ZZ Z
cn
0\ ON os
8& &
V <N
Ov ON 3
88 6
a a
A16B-1211 -0060 -0062
1-105
CNA (Axis control)
32
a
SYSCLK +5 V
b c
SUBCLK
AMO
GA01
--2 23: Global
address bus #1 - #23
31
30
0 V
GA13
+5 V
+5 V
0 V
AM2
GD00
*GAS
- Global address
15: Global data bus #0 - #15
strobe
29 GA12 +5 V AMI R/W Read /Write
25 GAO 8 +5 V GA2 1 *GBR Global bus request
20 GAO 3 +15 V GA16 *SYSTMR System timer
16 *GUDS -15 V *GBERR USED Slot used
14 R/W 0 V *SYSCLR SUBCLK1 Subsidiary clock #1
11 *BGIN 0. V *ITP *SYSEMG System emergency
10 *BG0UT 0 V *ITPL SDO Serial data out
09 *GBBSY SDI SDO SDI Serial data in
08 GD07 *IDSTB GD15 VBAT Battery power
07 GD06 0 V GDI 4 *EN Power enabled
06 GDQ5 0 V GD13 0 V Reference for supply voltage
05 GD04 *USED GDI 2 +5 V +5 VDC power supply for
01 GD00 VBAT GD08 +15 V
-15 V ) +15 VDC power supply for
memory backup
1-106
For 1st axis CF91
1
2
0 V
0 V
8 0H1A1
14
15
PCZA1
*PCZA1
CF91
OH1
- CF94
9 0H2A1 PCAA1 0H2
: Motor overheat
3 0 V 16
10 C8A1
4 +5 V 17 *PCAA1 C8
11 C4A1
18 PCBA1 C4
5 +5 V C2A1 : Gray code from pulse coder
12 19 *PCBA1 C2
6 +5 V 13 C1A1
7 20 REQA1 Cl
PCZ
*PCZ
: Z-phase of pulse coder
For 2nd axis CF92
PCA '
1 0 V 14 PCZA2 : A-phase of pulse coder
8 0H1A2 *PCA
2 0 V 15 *PCZA2
9 0H2A2 PCB
3 0 V 16 PCAA2 *PCB
: B-phase of pulse coder
10 C8A2 *PCAA2
4 +5 V 17 ; Request signal for absolute
11 C4A2 18 PCBA2
REQ
5 +5 V pulse coder
12 C2A2
6 +5
7
V
13 C1A2
19
20
*PCBA2
REQA2
Suffix A1
number 1-6.
-
A6 represents the axis
For 3rd axis CF93

1 0 V 14 PCZA3
0 V
8 0H1A3 15 *PCZA3
2
9 0H2A3
3 0 V 16 PCAA3
10 C8A3
4 +5 V 17 *PCAA3
5 +5 V
11 C4A3 18 PCBA3
12 C2A3
19 *PCBA3
6 +5 V
13 Cl A3
20 REQA2
7
For 4th axis CF94

1 0 V 14 PCZA4
8 0H1A4
2 0 V 15 *PCZA4
9 0H2A4
3 0 V 16 PCAA4
10 C8A4 *PCAA4
4 +5 V 17
11 C4A4
18 PCBA4
5 +5 V
6 +5 V
12 C2A4
19 *PCBA4
13 C1A4
7 20 REQA4
For 5th axis CF91

1 0 V 14 PCZA5 (CF91 of the second axis control board
8 0H1A5 02P05)
2 0 V 15 *PCZA5
3 0 V
9 0H2A5 16 PCAA5
10 C8A5
4 +5 V 17 *PCAA5
11 C4A5 18 PCBA5
5 +5 V
12 C2A5 *PCBA5
6 +5 V 19
13 C1A5
20 REQA5
7
For 6th axis CF92

1 0 V 14 PCZA6 (CF92 of the second axis control board
8 0H1A6 02P05)
2 0 V 15 *PCZA6
9 0H1A6
3 0 V 16 PCAA6
10 C8A6
4 +5 V 17 *PCAA6
11 C4A6
PCBA6
5 +5 V 18
12 C2A6
6 +5 V 19 *PCBA6
13 C1A6
REQA6
7 20
1-107
For 1st axis CV21
01
*PWMAA1
C*ALM1) 14
*PWMDA1
(*ALM8)
CV21
*PWMA
- CV24
08 IRA1
*PWMB
02 COMAA1 15 C0MDA1
: (Note width
*PWMC Pulse modulator
09 GDRA1
*PWMD 2)
*PWMBA1
03 (*ALM2) 16 *PWMEA1
*PWME
10 ISA1
*PWMF
04 COMBA1 17 C0MEA1
COMA
11 GDSA1 COMB
*PWMCA1
05 (*ALM4) 18 *PWMFA1
COMC
12 *MCONAl
COMD
: Common signals for PWM
06 C0MCA1 19 C0MFA1
COME
13 GND
COMF
07 *DRDYA1 20
GDR : Feedback current of
R-phase
For 2nd axis CV22 GDS : Feedback current of
S-phase
*PWMAA2 *PWMDA2 GND : Ground for feedback
01 (*ALM1) 14 (*ALM8) current
02 C0MAA2
08 IRA2
15 COMDA2
Note 1) Suffix A1 -
A6 represents
the axis number 1-6.
*PWMBA2
09 GDRA2
Note 2) PWM signal pins are used
03 (*ALM2) 16 *PWMEA2
bidirectionally. Normally
10 ISA2
they are outputs. When the
04 C0MBA2 17 C0MEA2
servo amplifier is alarming,
*PWMCA2
11 GDSA2 they become inputs. Names
05 18 *PWMFA2
(*ALM4) in parentheses are alarm
12 *MCONA2
signals in such a case.
06 COMCA 2 19 COMFA2
13 GND
07 *DRDYA2 20
For 3rd axis CV23
*PWMAA3 *PWMDA3
01 (*ALM1) 14 (*ALM8)
08 IRA3
02 C0MAA3 15 COMDA3
09 GDRA3
*PWMBA3
03 16 *PWMEA3
(*ALM2)
10 ISA3
04 C0MBA3 17 C0MEA3
11 GDSA3
*PWMCA3
05 (*ALM4) 18 *PWMFA3
12 *MC0NA3
06 C0MCA3 19 COMFA3
13 GND
07 *DRDYA3 20
1-108
For 4th axis CV24
*PWMAA4 *PWMDA4
01 (*ALM1) 14 (*ALM8)
08 IRA4
02 C0MAA4 15 C0MDA4
09 GDRA4
*PWMBA4
03 (*ALM2) 16 *PWMEA4
10 ISA4
04 C0MBA4 C0MEA4
11 GDSA4
*PWMCA4
05 (*ALM4)
18 *PWMFA4
12 *MC0NA4
06 C0MCA4 19 C0MFA4
13 GND
07 *DRDYA4 20
For 5th axis CV21
*PWMAA5 *PWMDA5 (CV21 of the second axis control

01 (*ALM1) 14 (*ALM8) board 02P05)
08 IRA5
02 C0MAA5 15 C0MDA5
09 GDRA5
*PWHBA5
03 (*ALM2)
16 *PWMEA5
10 ISA5
04 C0MBA5 17 C0MEA5
*PWMCA5
11 GDSA5
05 (*ALM4)
18 *PWMFA5
12 *MC0NA5
06 C0MCA5 19 C0MFA5
13 GND
07 *DRDYA5 20
For 5th axis CV22
*PWMAA6 *PWMDA6 (CV22 of the second axis control

01 (*ALM1) 14 (*ALM8) board 02P05)
08 IRA6
02 C0HAA6 C0MDA6
09 GDRA6
*PWMBA6
03 (*ALM2) 16 *PWMEA6
10 ISA6
04 C0MBA6 17 C0MEA6
' 11 GDSA6
ns *PWMCA6 18 *PWMFA6
(*ALM4)
12 *MC0NA6
06 C0MCA6 19 C0MFA6
13 GND
07 *DRDYA6 20
1-109
12.4 LEDs
LED Meanings Status
SALM Servo alarm 1. Parity alarm occurs, accessing static-RAM

on the axis control PCB.
2. Watch dog time out.
m
<N
—
<s
«
SALMQ
sa
gs
bfe
<
3 SS5
12.5 Jumper Settings

T
Standard
Jumper Uses
setting
PI > A: This PCB is used in "R-H" system.

B: This PCB is used in "R-G" system.
03 o In this system, it must be set to A side.
m
CN CN
SS
T CN
[tt. |ooo| CN CN
A PI B
n
S'
_
o'
b&
<
IJ CN
cr\ o\
bfe
L _ik
1-110
12.6 Test Points
G 0 V (ground)
G
O
G
O
g<
G
O
01P05
o
CD-2
Backplane PCB
1) Procedure
(j) Disconnect cables from the PCB.
(2) Detach PCB by loosening the screws (D .
(3) For mounting new PCB, reverse the above procedure.
2) Caution
When connecting cables, be careful to the match cables and connectors on PCB.
1-111
13. REMOTE CRT/KB (A13B-0144-B001)
The remote CRT/KB is a portable terminal which contains a 12" CRT display and a
full ASCII keyboard.
The remote CRT /KB is connected to the R-H controller at its RS-232-C port and is
used as a user interface.
The unit is composed of a 12" monochrome CRT, a membrane keyboard, a fan unit
and a control board. The control board has a microprocessor that processes
serial communication, key-scanning and CRT display information. The CRT control
circuit generates a video signal based on the data in the video RAM.
All DC power used in the unit is supplied from the R-H controller. The +24 V
provided via RS-232-C cable is a source for the DC-DC converter.
13.2 Block Diagram .
Fan unit
+24V
+12V
+5V
-X2V
_ DC-DC
converter
Video
RAM
+24V
12” CRT T RS-232-C
Video
> CRT
control
Micro¬
processor
R-H
controller
EPROM
32 kB
Keyboard 3 Keyboard
interface
RAM
Control board
1-112
Bade tide of the CRT/KB unit
Remote CRT/KB side Controller side
1 14 +24 V 1 FG
8 RD 14
2 15 2 SD
9 SD 16 CD 3 RD
3 10 16
4 11
17 SG 4 RS
17
5 ER 18 DR 5 CS
12 19 CS 18
6
13
6 DR
20 RS 7 19
7 SG
20 ER
8 CD
9 21
22
10
11
23
12 24
13 25 +24 V
FG : Frame ground
RD : Received data
RS-232-C data signal
SD : Transmitted data
RS : Request to send
ER :
RS-232-C control signal
Data terminal ready
SG : Signal ground
+24 V: +24 VDC power source for the remote CRT /KB
1-113
CN3
CN1 CAS CD4 CN2
Front view of the CRT/KB control PCB
CN1
1 0 V l : +12 VDC power source for the

2 +12 V J CRT unit
3 0 V
4 0 V
5 +12 V
6 +12 V
CA5
1 14 *VIDE0 : Video signal for CRT

8
2 15 *INCINT: Increased intensity
9 0 V
3 16 HSYNC : Horizontal synchronous CRT
10 0 V
4 *INCINT 17 control signal
11 0 V control
5 VSYNC 18 VSYNC : Vertical synchronous
12 0 V signal
6 HSYNC 19 control signal
13 0 V
7 *VIDE0 20 0 V : 0 V (ground level)
CD4
1 14 RS ER
8
2 15 SD
9
3 ER 16 RD
4
10
17 SG RS
: Refer to Sec. 13.3
5 11
18 SG
12 SD
6 19 +24 V
13 RD
7 20 +24 V
1-114
CN2
1
2
*KEY1
*KEY2
8 *C0M7
14 *COMO
*C0M1
*COMO - 9: Common of the key switch
(from the CRT/KB control PCB)
*KEY0 - 7: Input signal of key switch
9 *C0M8
3 *KEY3 16 *C0M2
10 *C0M9
4 *KEY4 *C0M3 status (to the CRT/KB control
11 *LED2 PCB)
5 *KEY5 18 *C0M4
12 *LED1
6 *KEY6 19 *C0M5
7 *KEY7
13 *KEY0
20 *C0M6
*LED1
*LED2 ) Input signal of LED status
: (from the
CRT/KB control PCB)
CN3
1 +24 V +24 V : +24 VDC power source for

2 GND the fan unit
GND : 0 V
13.42 Variable resistors
Name Function Adjustment
VR1 Adjustment of the Adjust the VR1 so that the voltage at M+5 V"
+5 V voltage is within a range of 5 V + 0.1 V.
VR2 Adjustment of the Adjust the VR2 so that the voltage at "+1-2—V”
+12 V voltage is within a range of 12 V + 0. 1 V.
O +5V (Test point)

O VR1
O +5V (Test point)
O VR2
O +12V (Test point)
Location of variable resistors
1-115
13.4.3 Jumper setting!
Standard
Jumpers
setting
Uses
ST1 Character generator selection:

A ° B
Select A side: KANA + ALPHA NUMERIC
Select B side: ALPHA NUMERIC
ST2 A O W/M B
to Not used (all B side)
ST6
ST1 D
ST2 Q
ST3 g
ST4
D
ST5
ST6
D
0
Location of jumpers
1-116
13.4.4 Test points
CLK9M System clock for the > 2.4V

CRT /KB control PCB
ov
108 nsec -l
CLKTV Character clock for > 2.4V
the CRT /KB control PCB
ov
370 nsec -I
*D0TCLK Dot clock for the > 2.4V
CRT/KB control PCB J~Y_J ov
*CLR Power on signal for >2.4 VDC

the CRT/KB control PCB
+24 V Power source for this

unit
+22 - +24 VDC
+12 V Supply voltage for CRT +12 VDC + 0.1 V
unit and RS-232-C
driver
-12 V Supply voltage for -12 VDC + 0.1 V

RS-232-C driver
+5 V Supply voltage for the +5 VDC + 0.1 V

control circuit
GND 0 V
o +5V
O +5V
OGND
O +24V O -12V O CLKTV
O CLK9M O *DOTCLK+24VQ
O +12V CLR O
1-117
13.4.5 R emoval/replacement
1) Procedure
(T) Remove the top cover by loosening four screws.
I —o
(2) Remove the PCB by loosening two screws.
&
Rear
© Disconnect cables from the PCB.

© For mounting a new PCB, reverse the above procedure.
1-118
13.5 Keyboard PCB (A86L-0001-0149)
(Top view)
L
_ !
Al
A2
*KEY0
*KEY2
B1
B2
*KEY1
*KEY3
*KEY0
*LED1
-7
B3
: Refer to Sec. 13.4.1
A3 *KEY4 *KEY5 *LED2
A4
A5
*KEY6
*LED1
B4
B5
*KEY7
*LED2
*COMO -9
A6 *C0M0 B6 *C0M1
A7 *C0M2 B7 *C0M3
A8 *C0M4 B8 *C0M5
A9 *C0M6 B9 *C0M7
A10 *C0M8 BIO *C0M9
1) Procedure
(T) Remove the keyboard panel by loosening four screws.
Panel
(?) Disconnect the connector.

(3) Remove the keyboard by loosening six nuts.
2
Panel
Backside of
the keyboard
© For mounting a new keyboard, reverse the above procedure.
1-119
13.6 CRT Monitor (A61L-0001-0088)
CN1
CN2
Front Real
CRT monitor PCB
View of the part-mounting side
CN1
1 *VIDEO 14
2 HSYNC
8 0 V
9 0 V 15 HSYNC
3 VSYNC 16 VSYNC : Refer to 13.4.1
10 0 V
4 17
11 0 V
5 18 0 V
12 0 V
6 19
7 13
20
CN2
1
2
0 V
+12 V ) : Refer to Sec. 13.4.1
3 0 V
4 0 V
5 +12 V
6 +12 V
1-120
14. BUILT-IN CRT/KB (A05B-2051-J101, J102)

The built-in CRT/KB is a console which contains a 9" CRT display and a full
ASCII keyboard.
The built-in CRT/KB is connected to the shared RAM board at its RS-232-C port
and is used as a user interface.
The unit is composed of a 9" monochrome CRT, a membrane keyboard, a software
keyboard and a control board. The control board has a microprocessor that
processes serial communication, key-scanning and CRT display information. The
CRT control circuit generates a video signal based on the data in the video RAM.
All DC power used in the unit is converted from the +24 V provided via RS-232-C
cable.
14.2 Block Diagram
+24V
_
--
9” CRT Video
Video RAM
I
+5V
-12V
+12V
— DC-DC
converter
Micro¬
+24V
Shared
RAM
CRT control processor board
Software
keyboard
EPROM
32 kB
Keyboard
Keyboard interface
RAM
Control board
(Rear side view) 0

CD4
CD4
1
2
8
9
SD
RD
14 +24 V RD
SD
:
Received data
:
Transmitted data signal}
RS-232-C data
3 16 RS :
Request to send RS-232-C
10
4 17 SG ER :
Data terminal control signal
5 11
18 ER ready
6 12
19 RS SG : Signal ground
7 13
20 +24 V: +24 VDC power source for the
remote CRT /KB
1-121
A20B-1003-0340
CAS CD4
CN2
"CNT CN3 [
Front view of the CRT/KB control PCB
CN1
1 0 V +24 VDC power source for

2 +24 V ’ the CRT unit
3 0 V
4 0 V
5 +24 V
6 +24 V
CA5
1 *VIDEO
8 0 V
14 *VIDEO : Video signal for CRT
2 HSYNC 15 *INCINT: Increased intensity
9 0 V
3 VSYNC
V
16 HSYNC : Horizontal synchronous
10 0 CRT
4 *INCINT 11 0 V
17 control signal
18 control
5 VSYNC : Vertical synchronous
12 0 V signal
6 19 control signal
13
7 20 0 V : 0 V (ground level)
CD4
1
8 SD
14 +24 V SD : Transmitted data RS-232-C
2 15 RD : Received data data signal
9 RD
3 16 RS : Request to send RS-232-C
10
4 17 SG ER : Data terminal control signal
5 11 18 ER ready
12
6 19 RS SG : Signal ground
13
7 20 +24 V: +24 VDC power source for the
remote CRT /KB
1-122
CN2
A1
A2
*KEYQ
*KEY2
B1
B2
*KEY1
*KEY3
*COMO - 7: Common of-- the key switch
A3 *KEY4 B3 *KEY5 *KEY0 - 9.: Input signal of key switch
A4 *KEY6 B4 *KEY7 status (to the CRT /KB control
A5 *LED1 B5 *LED2 PCB)
A6 *COMO B6 *C0M1 LED1 Input signal of LED status
A7 *C0M2 B7 *C0M3 LED2 *
A8 *C0M4 B8 *C0M5
A9 *C0M6 B9 *COM7
A10 *COM8 BIO *C0M9
CN3
A1 *KY1 B1 *SC0M *SCOM : Common of the softkey switch

A2
A3
*KY2
*KY3
B2
B3
*KY1 - 7 :. Input signal of softkey
switch status
A4 *KY4 B4 *KY7 (from the CRT/KB control PCB)
A5 *KY5 B5 *KY6
1-123
14.4.2 Variable resistor*
Name Function Adjustment
VR1 Adjustment of the Adjust the VR1 so that the voltage at "+5 V” is
+5 V voltage within a range of 5V + 0.1 V.
O VRl
O +5V
(Test point)
Location of variable resistors
14.4.3 Jumper setting
Standard
Jumper
setting
Uses
ST1 Character generator selection:

A ° B Select A side: KANA + ALPHA NUMERIC
Select B side: ALPHA NUMERIC
ST1 0
Location of jumpers
1-124
14.4.4 Te*t point*
CLK9M System clock for the > 2.4V
_r
CRT/KB control PCB
OV
108 nsec
CLKTV Character clock for > 2.4V

the CRT /KB control PCB j~\ OV
k- 370 nsec -1
*D0TCLK Dot clock for the > 2.4V
CRT/KB control PCB j~\_r OV
*CLR Power on signal for >2.4 VDC

the CRT/KB control PCB
+24 V Power source for this +22 - +24 VDC

unit
+12 V Supply voltage for +12 VDC + 0.1 V

CRT unit and RS-232-C
driver
-12 V Supply voltage for -12 VDC + 0.1 V

RS-232-C driver
+5 V Supply voltage for the +5 VDC + 0.1 V

control circuit
GND 0 V
7
-
'
•ni
Screws (M3)
L A20B-1003-0340
1) Procedure
(I) Disconnect cables from the CRT/KB control PCB.
I Detach the CRT /KB control PCB by loosening the four screws.
For mounting the PCB, reverse the above procedure.
1-125
14.5 Keyboard PCB (A86L-0001-0149)
14.5.1 Connector/iigrwl identification
L !
(Top view)
A1
A2
*K£Y0
*KEY2
B1
B2
*KEY1
*KEY3
*KEYO -7
*LED1
A3 *KEY4 B3 *KEY5 *LED2
: Refer to Sec. 13.4.1
A4
A5
*KEY6
*LED1
B4
B5
*KEY7
*LED2
*C0M0 -9
A6 *COMO B6 *C0M1
A7 *C0M2 B7 *C0M3
A8 *C0M4 B8 *C0M5
A9 *C0H6 B9 *C0M7
A10 *C0M8 BIO *C0M9
O O <3
<5> o
©
A86L-0001-0149
(T) Remove the CRT/KB control PCB, according to Sec. 14.4.5.

(2) Disconnect cables from the keyboard PCB.
© Remove the nuts © from the keyboard mounting plate, and detach the
keyboard PCB along with the mounting plate. (The mounting plate and PCB are
attached. )
© Remove the key sheet from the keyboard mounting plate. (The key sheet
adheres to the keyboard mounting plate.)
© For mounting the PCB, reverse the above procedure.
1-126
14.6 Software Keyboard PCB (A20B-1000-0844)
POP
A1 *KYD1 B1 * COMOO *COMOO ; Common of key switch

A2
A3
*KYD2
*KYD3
B2
B3
*KYD1 - 7: Input signal of key switch
status
A4 *KYD4 B4 *KYD7
A5 *KYD5 B5 *KYD6
©
oOO— - Do
|<4
Ol TV®
Front view of CRT/KB panel Rear view of the CRT escutcheon
© Disconnect the flat cable for software keyboard from the PCB.
© Remove four screws © fixing the CRT escutcheon, and detach the software
keyboard PCB along with the CRT escutcheon.
8 Detach the software keyboard PCB by loosening the two screws ©.

For mounting the PCB, reverse the above procedure.
1-127
14.7 CRT Monitor (A13B-0056-0001)
/
/
ip:
CN2
CN1
Rear view of the CRT monitor
CN2
1 2 3 4 5 6
0 V 0 V +24 V +24 V
+24 V
0 V | #
Supply voltage for CRT monitor
CN1
14 01 VIDEO VIDEO : Video signal

08 0 V
HSYNC : Horizontal sync, signal
15 02 H SYNC
VSYNC : Vertical sync, signal
09 0 V
HIGH VIDEO : High brightness video
signal
16 03 V SYNC
H VIDEO RET.: 0 V for "HIGH VIDEO"
10 0 V HIGH
17 04
0 V : 0 V
H VIDEO VIDEO
11
18
RET.
05
12 0 V
19 06
13
20 07
1-128
14.7.2 Adjustment routine
The CRT character display controls are set at the factory and generally will not
require major adjustment. To adjust brightness (B) and contrast (C) , turn the
corresponding variable resistors mounted on the side of the CRT display unit
(Fig. 14.7.2).
Caution) Keep fingers and tools away from the display unit when first turning
the power on, because an extremely high initial voltage, between 10 and
11 kV, is present.
Note) If a signal cable is disconnected, the entire CRT screen will go blank.
1) Adjusting Brightness (variable resistor B)

This control knob (variable resistor B) controls the overall brightness of
the CRT screen.
a) Adjust the brightness control knob (variable resistor B) to the brightest
level possible before the raster (scanning line) appears on the screen.
b) If the raster appears during the contrast (variable resistor C) or other
screen adjustment, use the brightness control (variable resistor B) to
eliminate it.
2) Adjusting Contrast (variable resistor C)
The contrast knob controls the difference between the brightest and darkest
picture elements.
a) Adjust the contrast control knob (variable resistor C) until display
characters achieve an easy-to-read brightness level.
b) Do not apply too much contrast, as this can distort the characters and
make them difficult to read.
Deflection coil setscrew

(Tilt adjustment)
WIDTH
'CN2 Deflection coil
$_1_\ Centering magnet
o FOCUS
-0
“(B)
a
nr H.HOLD -Kg
y- Contrast o VUN -<g

(O HEIGHT -(§
Distortion V.HOLD -<g
adjusting
Regulator magnet Fuse CRT display unit
unit A13B-0056-C001
Note) The CRT display unit includes the regulator unit.
Fig. 14.7.2 Adjustment position (Rear view of display unit)
1-129
14.7.3 Special adjustment
If Che CRT picture is distored or diced, Che adjusting magnets located on the
CRT display unit (Fig. 14.7.3 (a)) will correct these problems.
Bringing the magnets closer to or farther from the cathode ray deflects the
scanning beam to the desired result - .
Generally, adjustments are not required unless a CRT component, such as a CRT
deflection coil, has been newly installed.
1) Picture distortion and position adjustments are made using the deflection
coil distortion adjusting magnets, centering magnet, and deflection coil set
screw. To avoid an electric shock, adjust them after turning the power off.
Magnet for adjusting the distortion at the upper left
of the CRT screen
Magnet for adjusting By removing the retaining spring, this magnet can be
the distortion at upper rotated to adjust the picture.
right of the CRT screen
.Centering magnet
The picture moves vertically
and laterally when the two
centering magnets are turned
at the same time.
'ÿ
Magnet for removing
Magnet for adjusting distortion at the lower
the right lower distortion left of the CRT screen
Deflection coil setscrew

By loosening this screw, the deflection
coil can be rotated, and the parallelism
of the picture can be adjusted.
Fig. 14.7.3 (a) Adjustment position (Rear view of CRT)
1-130
2) Adjustments for synchronization (vertical and horizontal), focus, linearity,
width and height are made by using the variable resistors and adjustable coil
located on the PCB in the CRT display unit.
L
WIDTH Changes the horizontal picture size
WIDTH -
FOCUS Sharpens characters FOCUS- @

H.HOLD
V.LIN
Stops the picture from shifting horizontally
(Horizontal synchronization)
Equalizes character sizes vertically in
the upper and lower parts of the screen
H. HOLD
m I
Edge connector
i
m
oo
(Vertical amplitude) V.LIN
I
HEIGHT Changes vertical picture size
(Vertical amplitude)
Stops the picture from rolling vertically
HEIGHT m I
I
V. HOLD
(Vertical synchronization) V. HOLD m 1
3) Fuse VI
CRT display unit power fuse 1.6 A, 125 V.
(Surge protection type)
FUSE
d L J
I
I
0 0
[3
Fig. 14.7.3 (b) Adjusting devices
6.4 ns CRT unit

A13B-0056-C001
HSYNC
1.5 VSYNC
ns
_ _ HSYNC VIDEO
. . . . .. .
18 ms C HVIDEO C Regulator unit CRT display unit
— n !n!
.llllllll. . llllllllllli llilF
1 ms *1 !ÿ
'
VSYNC
VIDEO
N
4
N
1
HYIDEO
II
Brightness Contrast
\
/ Edge connector
+24VDC
C C
N 24V -» 12 V
N Regulator
CRT/KB control PCB 2
5
A20B-1003-0340
Fig. 14.7.3 (c) CRT unit block diagram
1-131
14.7.4 T roubleshooting flow chart
1) No display
Suit
\
Turn ofT CRT 3 minutes It 12 VDC volute
after turning on the No present between OV
end CRT display unit No
power supply. fuse?
Is the picture bright
white at OFF?
Yes
Yes
Does the picture become Disconnect the edge con¬ Is 24VDC applied
white when brightness No nect or which connects to regulator unit?
is at maximum? CRT display unit regulator. (Fig. 14.7.3 (c))
Does the resisunce value CNS (1, 2 24V)
(JOOkfl) change between CN5 (3, 4 « OV)
connector terminals B-D CNS(S.6-N.O
and also between con¬ Yes (See Note 2)
nector terminals C-D when
Yes turning the (B) brightness
VR (See Note II
(Fig. 14.7.3 (a))
No Yes No
Does a waveform appear
at VD03 terminal of
CRT/KB control PCB
A20B-1003-0340
Disconnect the edge con¬

No nector which connects
Yes CRT display unit and Yes
regulator.
Does waveform appear
across OV (terminal A)
and VIDEO (J)
(Fig. 14.7.3 (b)>
No
24 V DC is not
CRT/KB control PCB Regulator unit CRT display unit being fed from
A20B-1003-0340 or is defective. is defective. control unit.
control circuit is
defective.
CRT display unit A13B-0056-C001

Note i) VR: Variable resistor
Note 2) Check cable connector pins after disconnecting the connector.
1-132
2) Picture shifts
Sun
1
Does a normal waveform appear Disconnect the edge connector Does the picture stop moving when
CRT/KB
at check terminal of Yes Fig. 14.7.3 (b)) which connects Yes V. HOLD and H. HOLD (Fig. 14.7.3
control PCB (Fig. 14.7.3 (c))? CRT display unit end the regulator (b)) of display unit are turned?
unit
HSYNC Does e HSYNC wevef onn
(Horizontal sync signal) (Fig. 14.7.3 (b)) appear at edge
Cycle : About 64»uee. connector terminal F7
Width : About 15»aec. Does VSYNC waveform appeal
VSYNC at edge connector terminal JC7 No
(Vertical sync signal)
Cycle : About 18msec
Width : About 1msec.
No No
CRT/KB control PCB is Regula tor unit is CRT display unit

defective. defect! is defective.
A20B-1003-0340
CRT display unit A13B-0056-C001
Remove four screws holding the CRT monitor, and detach the CRT monitor.
-o
Smews
CRT monitor
1-133
15. I/O BASE UNIT (A03B-0801-C012)

The I/O base unit serves as the bus connection between the various I/O modules
including the robot control module, the DI module, the 00 module, the analog
input module, and the analog output module.
15.2 Block Diagram

8 76 543 210
DC power
Ul
I/O bus
A20B-1002*0450
A03B-0801-C012
CN A8 CN A7 CN A6 CNA5 CNA4 CNA3 CNA2 CNA1 CNAO
CNP2
0
CNP3
0
CNP2
01 +15 V +15 V
02 GND -15 V : DC power supply from the basic
03 N.C control unit
GND
04 EN EN : DC voltage output enable
05 GND signal
06 -15 V N.C : No connection
CNP3
01 +5 V +5 V
02 +5 V +24 V DC power supply from the power
03 GND :
+24 E unit
04 GND GND
05 +24 V +24 E is +24 VDC for robot control
06 +24 E module.
1-134
CNAO
C B A AO-2 : Address bus for the I/O

32 AO +5 V modules
31 A2 +5 V A1 DO-7 : Data bus for the I/O modules
30 D1 +5 V DO DP : parity bit of the data bus
29 D3 +5 V D2 R/W : Read /write control signal for
28 D5 GND D4 the I/O modules
27 D7 GND D6 *DS : Data strobe signal for the I/O
26 R/W GND DP modules
25 *BE GND *DS *BE : Bus enable signal for the I/O
24 *P0R GND RDY modules
23 *ERR0 GND *ERRI *P0R : Power-on reset signal
22 ITPS GND *RID RDY : Ready signal from the I/O
21 +24 V GND ST modules
20 +24 V -15 V +15 V *ERR0 : Error signal detected in
19 +24 E -15 V +15 V the robot control module
18 *CS2 *CS1 *ERRI : Error signal detected in
17 *CS4 *CS3 the I/O modules
16 *CS6 *CS5 ITPS : Signal to synchronize
15 *CS8 *CS7 the interpolation
14 *CS10 *CS9 *RID ; Read strobe for ID code of
13 *SA0 *SA1 the I/O modules
12 *SA2 *SA3 ST : Start signal
11 AOR AIR *CS1-10 : Card select for the I/O module
10 A2R *D0R (slot 1-10)
09 - *D1R *D2R *SA0-3 : Slot address for external I/O
08 *D3R *D4R bus
07 *D5R *D6R A0R-A2R : Address bus for external I/O
06 *D7R *DPR bus
05 RCK1 RCK2 *D0R-D7R: Data bus for external I/O bus
04 *EXRDY RCK3 RWR *DPR : Parity bit of the external
03 *10CRDY *ERR0R *DSR data bus
02 *EXRCK *ERRIR *BER RCK1-3 : Selecting signal of additional
01 EN RDYR *RIDR I/O base unit (not used)
RWR : Read/write signal for external
1/0 bus
*EXRDY : Ready signal from additional I/O base unit (not used)
*DSR : Data strobe signal for external 1/0 bus
*ERROR : Error signal detected in the robot control module
*I0CRDY : Interface module ready for external 1/0 bus
*BER : Bus enable signal for external 1/0 bus
*ERRIR : Error signal detected in additional I/O base unit (not used)
*EXRCK : Additional 1/0 base unit existing signal
*RIDR : Read strobe for ID code of I/O modules on additional I/O base unit
(not used)
RDYR Ready signal from additional I/O base unit (not used)
EN : DC voltage output enable signal from the power unit
+24 V
+24 E
+15 V
: DC voltage inputs
-15 V
+5 V
GND
1-135
CNA1-8
C B A Connector CNA1-8 are used for the

32 AO +5 V *CS connection with I/O modules.
31 A2 +5 V A1 "CNA1" corresponds with slot 1 and
30 D1 +5 V DO "CNA2" with slot 2, and so on.
29 D3 +5 V D2 The signal meanings are described in
28 D5 GND D4 the "CNAO" explanation.
27 D7 GND D6
26 R7W GND DP
25 *BE GND *DS
24 *POR GND RDY
23 *ERR0 GND *ERRI
22 ITPS GND *RID ;
21 +24 V GND ST
20 +24 V -15 V +15 V
19 +24 E -15 V +15 V
18
17
16
15
14
13
12
11
10
09
08
07
06
05
04
03
02
01
1) Procedure
1 Remove the 1/0 modules in the I/O base unit according to Sec. 16-20.
2 Disconnect all cables (f) from the 1/0 base unit.
I Disconnect the ground wire (3) .
The 1/0 base unit can be removed by loosening four screws ©.
© For mounting new I/O base unit, reverse the above procedure.
©: I/O base unit © >©

CND
7
‘O fk
CNC
3
1-136
16. ROBOT CONTROL MODULE (A03B-0801-C462)
The external view of the robot control module is shown in the following figure.
Note
ii
o
O
II
Note) "RC01C" means the robot control module.
The robot control module is connected to the I/O base unit. The robot control
module serves as an interface between the shared RAM board and the I/O base unit
through fiber optic communications. Information is received from and
transmitted to the cables, other I/O modules, or circuitry. LEDs indicate
circuit performance.
A section of 8/16 converter converts 16 bits data bus width of shared RAM PCB to
8 bits data bus width. RAM is used on this module to store address translation
data.
I/O modules are mapped on the memory area of the main processor according to the
contents of the RAM. The mapping arrangement is independent of the physical
arrangement of the modules.
Robot control module also serves as an interface for data transfer from the
robot and the operator's panel. Eight input and eight output lines are wired to
the robot for customer selected interfacing. Along with these lines on the CNC
connector are lines for signals such as hand breakage, overtravel, near zero,
and other robot indicators.
Connector CNB is the internal connection of the controller. A voltage of
+24 VDC for the input or output signals of this module is connected to the power
input unit through CNB. Information from relays such as the fuse alarm,
relay welding, and other inputs is fed to this module. The robot control module
also drives the brake on /off control signals.
1-137
16.2 Block Diagram
To I/O base unit
CNA
1
Buffer il
Address
buffer
Data
<>
buffer
.
n I/O bus
Timing control
a
0V +5V
8 bits
A 8/1* 8MHz
width V converter 0 cm
7V
16 bits
T Interface control
clock
t. width .y
V
RAM C
E/O
v> V
77
A*
Buffer Buffer
<7
Decoder
Latch
TF
O <>
RV/DV £> RV/DV
o
I CNB | | CNC | 1COP3 i
To power To robot To shared RAM
input unit mechanical unit board
rkT
CNB
CNA
CNC
COP4
1-138
CNA
A B C AO-2 : Address bus for the I/O

32 +5 V AO modules
31 A1 +5 V A2 DO-7 : Data bus for the I/O modules
30 DO +5 V D1 DP : Parity bit of the data bus
29 D2 +5 V D3 R/W : Read/write control signal for
28 D4 GND D5 the I/O modules
27 D6 GND D7 *DS : Data strobe signal for the I/O
26 DP GND R/W modules
25 *DS GND *BE *BE : Bus enable signal for the I/O
24 *RDY GND *POR modules
23 *ERRI GND *ERR0 *POR : Power-on reset signal
22 *RID GND ITPS RDY : Ready signal from the I/O
21 ST GND modules
20 *ERRO : Error signal detected in
19 the robot control module
18 *CS1 *CS2 *CS11 *ERRI : Error signal detected in
17 *CS3 *CS4 *CS12 the I/O modules
16 *CS5 *CS6 *CS13 ITPS : Signal to synchronize
15 *CS7 *CS8 *CS14 the interpolation
14 *CS9 *CS10 *CS15 *RID : Read strobe for ID code of
13 *SA1 *SA0 SDOUT the I/O modules
12 *SA3 *SA2 SDIN ST : Start signal
11 AIR AOR *0PT0FF *CS1-10 : Card select for the I/O module
10 *D0R A2R *IOCON (slot 1-10)
09 *D2R *D1R *CS11-15
08 *D4R *D3R SDOUT
07 *D6R *D5R SDIN : Not used
06 *DPR *D7R *0PT0FF
05 RCK2 RCK1 *IOCON
04 RWR RCK3 *EXRDY *SA0-3 : Slot address for external I/O
03 *DSR *ERROR *10CRDY bus
02 *BER *ERRIR *EXRCK A0R-A2R : Address bus for external I/O
01 *RIDR RDYR EN bus
*D0R-D7R: Data bus for external I/O bus
*DPR : Parity bit of the external data bus
RCK1-3 : Selecting signal of additional I/O base unit (not used)
RWR : Read/write signal for external I/O bus
*EXRDY : Ready signal from additional I/O base unit (not used)
*DSR : Data strobe signal for external I/O bus
*ERR0R : Error signal detected in the robot control module
*I0CRDY : Interface module ready for external I/O bus
*BER : Bus enable signal for external I/O bus
*ERRIR : Error signal detected in additional I/O base unit (not used)
*EXRCK : Additional I/O base unit existing signal
*RIDR : Read strobe for ID code of I/O modules on additional I/O base unit
(not used)
RDYR : Ready signal from additional I/O base unit (not used)
EN : DC voltage output enable signal from the power input unit
+5 V
GND
: DC voltage
1-139
CNB
14 HBKD1 01 *ROT : Robot overtravel signal

15 HBKD2 08 BKR21 02 *R0T RLWD : Relay welding signal detected
16 *BKRE 09 BKR22 03 RLWD in the power input unit
17 BKR11 10 BKR31 04 *FALM *FALM : Fuse alarm of the brake
18 BKR12 11 BKR32 05 *EMGTP control circuit
19 12 0 E 06 +24 E *EMGTP : Emergency stop signal from
20 13 0 E 07 +24 E the teach pendant
BKR21 Contact signal of the 2nd
BKR22 brake release
BKR31 Contact signal of the 3rd
BKR32 brake release
HBKD1
HBKD2 ) Contact signal of the
' breakage detection
hand
*BKRE : Brake release enable

BKR11 Contact signal of the 1st
BKR12 ’ brake release
+24 E : DC voltage
0 E
CNC
23 RD01 01 RDI1 The connector "CNC" is used for the

24 RD02 13 *R0T 02 RDI2 interface with the mechanical unit.
25 RD03 14 *HBKD 03 RDI3 RDI1-8 : General purpose DIs
26 RD04 15 NZ1 04 RDI4 RD01-8 : General purpose DOs
27 RD05 16 NZ2 05 RDI5 *R0T : Robot overtravel signal
28 RD06 17 NZ3 06 RDI6 *HBKD : Hand breakage detection
29 RD07 18 NZ4 07 RDI7 ALML : DO for the alarm lamp
30 RD08 19 NZ5 08 RDI8 OPRL : DO for the operation lamp
31 OPRL 20 NZ6 09 *PPABN *PPABN
32 +24 E 21 ALML 10 0 E NZ6 )
: Not used
33 +24 E 22 +24 E 11 0 E NZ1-5 : Near zero signals
34 +24 E 12 0 E +24 E
0 E 1 : DC voltage for DI & DO’s
C0P4
OPTIN OPTIN : Optical input signal from

OPTOUT the shared RAM PCB
OPTOUT : Optical output signal to
the shared RAM PCB
1-140
16.4 LEOs
Error indicator LEDs are mounted on the front panel of the robot control module
(RC01C) to indicate an error which may occur during data transfer between basic
control unit and RC01C or between RC01C and I/O module.
I/O module means robot control module, DI module, DO module, analog input module
or analog output module.
Error indicator LEDs
TOUTO O 3
1}
M
T3 O 02 i SA
ER2 O O 1
Lt o oo J
Oil
BA
Oo J
A
0
XL
Error indicator
(red) — Error module
indict tor
(yellow)
— These LEDs are used to locate

a parity error.
1-141
Error contents
Error display
Name of error Error contents Causes
TOUT ER3 ER2 ER1
Normal operation
o o o CLOCK STOP An error occurred 1. Optical cable

during data transfer is disconnect-
o o CARRIER STOP between RC01C and the ed.
shared RAH board. 2. Optical con¬
o o SIGNAL FORM nector is not
ERROR sufficiently
connected.
o FORMAT ERROR 3. Optical
connector tip
o o OVERRUN ERROR is dirty.
4. RC01C is
o ERROR WORD defective.
o o TIME OUT ERROR

5. Shared RAM
board is
defective.
o PARITY ERROR A parity error was 1. I/O module is
detected during data defective.
transfer between RC01C 2. RC01C is
and I/O module, or a defective.
parity error occurred
in RAM of RC01C. In
this case, the mounting
base number of the data
transfer module in
trouble and the slot
number are displayed in
SA3-SA0 and BA1-0.
SA3-SA0: Slot number
(binary display)
BA1, BAO: Base number
(binary display)
Example)
Base #1, slot #5
SA3 SA2 SA1 SAO BA1 BAO
0 10 10 1
Slot #5 Base #1
0: Goes out
1: Lights
If both slot number and

base number are "0",
there is a parity error
of RAM in RC01C.
o: Lamp lights
Lamp goes out
1-142
Standard
Jumpers
setting
Uses
PI A B Selecting common voltage for

A B A B
RDI: When PI is set to A
side, a pneumatic pressure |i-2KD E\m
alarm will occur. OV common +24V common
P2 A B Short-circuit *HBKD input. A B A B

o lagan ami
•HBKD U •HBKD is
effective short-circuited
[H,
P2
-I
PI
9
Location of jumpers
(The plastic cover is removed in the above figure)
Refer to Sec. 16.7 for the plastic case disassembly method.
1-143
16.6 Test Points
The meanings of the test points on the robot control module are as follows.
TDIS When TP 3 is connected to GND,

the time out error detected in
robot control module is
disabled. This test point is
used for development.
+5 V +5 VDC
CLK 8 MHz clock
-I 1 ov
125 mec
DVO DVO indicates that the reset

is initiated by the software.
GND 0 V
o TDIS
0+5V
° CLK
OOV
ODVO
Note) In the above figure, the plastic cover is removed. Refer to Sec. 16.7 for
the plastic case disassembly method.
1-144
1) Removing robot control module from I/O base unit
SlotO
I
0
—n
© m I/O base unit
4
a) Procedure
® Disconnect the cable from the robot control module (RC01C).
.
I Detach RC01C -by loosening two screws (2)
For mounting the new RC01C, reverse the above procedure.
b) Setting
Set the new RC01C correctly using the original RC01C as a reference.
2) Plastic case disassembly method
Case
Panel
©
Cover
®o
© Using both thumbs push the positions © on the cover in the direction of
s
the arrows.
Slide the cover off.
The panel can be detached by pushing the center of the panel from
direction (f) until it is curved.
1-145
3) Detaching the PCB from the plastic case
Case
PCB
©c5'" /
<=>®
©ÿ
© Remove PCB mounting screws © .

© Draw the PCB out of the case in the direction ©.
1-146
17. Dl MODULE
The external view of the DI module is shown in the following figure.
Note
V
9
Note) The code marked on the upper side of the front panel indicates the type of
DI module.
I D 08 C
Indicates DI module
Indicates I)C or AC power
Indicates the numbers of points (08 or 16)
Indicates the type (C, D or E)
The DI module has the following specification numbers:
ID08C A03B-0801-C420
ID16C A03B-0801-C421
ID08D A03B-0801-C422
ID16D A03B-0801-C423
IA08E A03B-0801-C424
IA16E A03B-0801-C425

The DI module provides the user with the means of interfacing peripheral
equipment inputs to the controller. AC or DC type modules are available for
this purpose.
The DI module connects to the I/O base unit through the CNA connector.
Interfacing is completed by connecting input lines to the CNT terminal strips.
Eight and sixteen channel input modules can be selected for interfacing.
The DI module also acts as a level converter because AC and DC inputs may be
accessing the controller.
All interface signals are converted to logic-level +5 volts before being placed
on the I/O bus.
LEDs are mounted on the module to monitor each input line. These LEDs light
when an input is fired to the controller.
1-147
17.2 Block Diagram
To I/O base unit
CNA
<7 \/
Address Buffet
n
decoder
Latch
ID#
>
Receiver
\'fr
z\
T
Receiver
n CNT
To user’s interface
it I,
CNA
CNT
1-148
CNA
a b c *CS Card select

32 *cs +5 V AO AO Address signal
31 +5 V DO-7 Data bus
30 DO +5 V Dl DP Parity bit of the data bus
29 D2 +5 V D3 R/W Read/write control signal
28 D4 0 V D5 *DS Data strobe signal
27 D6 0 V D7 *BE Bus enable signal
26 DP 0 V R/W *ERRI Error signal detected in
25 *DS 0 V *BE the DI module
24 0 V *RID : Read strobe for ID code
23 *ERRI 0 V +5 V
22 *RID 0 V 0 V
: DC voltage
21 0 V
20
19
18
17
16
15
14
13
12
11
10
09
08
07
06
05
04
03
02
01
CNT
Refer to IV-3.2.5 for terminal CNT.
1-149
17.4 LEDs
The DI module is provided with LEDs for indicating the on/off conditions of each
input signal.
ID08CID16C IA08E, IA16E

1D08D, ID16D
u u
m E
01
Yellow LEO EI 01 Yellow LED
02 EI 02
03 a 03
gas 04 04
COM l 1L2
05 05
06 06
gas 07 07
-as 08 08
COM2 Sas 2L2 gas
09 gas
10 gas 09 10
11 gas 11
gas
12 gas 12
COM3 3L2 gas
13 gas 13
14 gas 14
15 gas 15
[ÿEl El 16 gas 16
COM4, gas
gas
4L2 gas
gas
n n
LED: Light* ........... Input turn* on.
Goes out turns off ••• •Input turn* off.
1-150
17.5 Removat/Replacement
o o O
0
£A
2
s' * "
o
o_o o
3 A.
1) Procedure
0 Disconnect cables from DI- module.
Disconnect the terminal board by loosening the two screws (a) shown in
the following figure and, while holding its upper and lower ends, pulling
out the entire terminal board.
For disconnecting the wiring, open the nameplate.
The nameplate is opened by pulling it out, while holding it at 0 shown
in the following figure.
Terminal board
c
c
© e
%
c
g
g
c
c Nameplate
© c
c
—to©
© Detach DI module by loosening the screws © .

© For mounting new DI module, reverse the above procedure, replacing the
terminal board on the new DI module with the original terminal board.
2) Cautions
Mount the terminal board removed from the replacement DI module on the old DI
module before returning the module for repair.
1-151
18. DO MODULE
The external view of the DO module is shown in the following figure.
\0
Note
I] OD08B
v
a
Note) The code marked on the upper side of the front panel indicates the type of
DO module.
0 D 08 B
Indicates DO module
Indicates I)C or AC power
Indicates the number of points (08 or 16)
Indicates the type (B, C, D, E or H)
The DO module has the following specification numbers:
OD08B A03B-0801-C440
OD16B A03B-0801-C441
OD08C A03B-0801-C442
0D16C A03B-0801-C443
OA08D A03B-0801-C444
0A16D A03B-0801-C445
OA08E A03B-0801-C446
0A16E A03B-0801-C447
OA08H A03B-080I-C448
0A16H A03B-0801-C449
The DO module provides outputs to the user for interfacing. AC or DC type
outputs are available and cover a range of output current capacities. Eight and
sixteen channel output modules are available.
Data is taken from the I/O base unit through the CNA connector and conditioned
to be output by means of the CNT terminal strips. The DO module provides the
level conversion from logic level to the signal level specified by the module.
LEDs monitor each output as the output is fired by the controller. Fuses on
each module protect the equipment from overcurrent conditions.
1-152
18.2 Block Diagram
To I/O base unit
CNA
\s
Address Buffer
decoder Fuse alarm
7\
ID#
\z
Latch
s
Buffer
n
Driver f ----- r~
n CNT
To user's interface
18.3 Connector/Signal identification
nl
CNA
CNT
1-153
CNA
a b c *CS Card select

32 *CS +5 V AO AO Address signal
31 +5 V DO-7 Data bus
30 DO +5 V Dl DP Parity bit of the data bus
29 D2 +5 V D3 R/W Read /write control signal
28 D4 0 V D5 *DS Data strobe signal
27 D6 0 V D7 *BE Bus enable signal
26 DP 0 V R/W *P0R Power-on reset
25 *DS 0 V *BE *ERR0 Error signal detected in
24 0 V *POR the I/O interface module
23 *ERRI 0 V *ERRO *ERRI : Error signal detected in
22 *RID 0 V the DI module
21 0 V *RID : Read strobe for ID code
20 +5 V : DC voltage
19 0 V
18
17
16
15
14
13
12
11
10
09
08
07
06
05
04
03
02
01
CNT
1-154
18r4ÿEDs
ThA DOjmodule is provided with LEDs for indicating the on/off conditions of each
outpue signal.
OD08B, OD16B OA08D. OA16D OA08E.OA16E OD08H, OD16H

OD08C. OD16C
Yellow LED Yellow LED .Yellow LEO Yellow LED
u u u u
m zm
i£ 01
02
01
02
01
02
01
02
I©1° 03 03 03 SHE 03
[®I° 04 SHE 04 SHE 04 SEE 04
COM P LI LI FU
SE
1
SEE
01° os 0$ 03 0$
l©f° 06 06 SHE 06 06
[®I°07 07 07 07
|©|e 08 SHE 08 SHE 08 SEE 08
COM |(x)|0 LI SHE LI FU
SE COM
1
©|o 09 09 09 SHE 09
10 10 10 SHE 10
l®|o 11 -HE u u n
1(51° 12 12 12 12
COM ©lo LI LI SHE VI 2
SHE
©1° 13 13 13 13
©1° 14 SHE 14 SHE 14 SHE 14I$
©1° IS SHE IS SHE IS SHE
16 SHE 16 SHE 16FU SHE 16
COM |©|o LI SHE FU LI SHE SE COM SHE FU
[SE FU L2 SHE SE L2 SHE 2
SHE SE
® 1® 1 [§ÿ! G*
n n n n
LED : Lights Output turns on.
Goes out Output turns off.
]
1-155
l
18.5 Fuses
The DO module is provided with a built-in fuse for every common. If these fuses
are blown, the fuse-alarm indicator LED of the corresponding module lights to
indicate the fuse failure. The following figures shown the mounting positions
of the fuse-alarm indicator LEDs of each module and the mounting positions of
fuses.
In the figure the plastic cover is removed. Refer to Sec. 16.7 for the plastic
case disassembly method.
Module name 0D08B, 0D16B
Mounting posi¬
tions of fuse- u
alarm indicator
LEDs and mounting m c ©
positions of 01
fuses 02
03
COM
04
0$
li
06
07
COM
08
09 ©
§1
PBIBI 10
n
12
COM
13
§1
14
15
16
COM
mm\ \
FU
SE si
C ©
n Fuie alarm LED (red)
Indicator
If one of four fuses FUl -

FU4 is blown,
the above fuse alarm LED lights. 'N OJ
The blown fuse shows a white failure O
display in the indicator shown at the right.
Correspondence
between fuses and Fuse number FUl FU2 FU3 FU4
output terminals
Output number 01 - 04 05 - 08 09 - 12 13 - 16
1-156
Module name OD08C, 0D16C
Mounting posi¬
tions of fuse-
alarm indicator
LEDs and mounting m c ©
positions of 01
fuses 02
03
COM
04
sills;
03
0«
07
COM
08
09
10
©
alls
11
12
COM
13
14
Jl
13
1«
COM SHE FU
SE 11
£ CO
c. ©
n
\ Fuse alum LED (red) Indicator
If one of eight fuses FI -

F8 is blown,
the above fuse alarm LED lights. CL
O
The blown fuse shows a white failure
Correspondence
between fuses and Fuse number FI F2 F3 F4 F5 F6 F7 F8
output terminals
Output number
01 03 05 07 09 11 13 15
02 04 06 08 10 12 14 16
1-157
Module name OA08D , 0A16D
Mounting posi¬
tions of fuse-
alarm indicator u c ©
LEDs and mounting
positions of
m 01
fuses
02
03
LI
04
SMB 03
is
06
07
LI
08
1,
09 ©
Zm 10
11
12
Ll SMEI
13
14
is
IS
16
..." .•
Ll
L2
FU
SE 12
n\ c ©
\ Fiue alarm LEO (tell)

Indicator
If one of four fuses FI -

F4 is blown,
the above fuse
The blown fuse
alarm LED lights.
shows a white failure
a
O
Correspondence
between fuses and Fuse number FI F2 F3 F4
output terminals
Output number 01 - 04 05 - 08 09 - 12 13 - 16
1-158
Module name . 0A08E, 0A16E
Mounting posi¬
tions of fuse-
alarm indicator u c ©
LEDs and mounting
positions of
[O 01
~L
fuses
0)o 02
0{o 03
[© o<
U I© FU
SE FI F2
®|e 03 Fuse ilsrm
®T© 06 LED #1
®|0 02
loot
LI FU
t .
®|0 09 Fuse alarm © F4 F3
®jo 10 LED #2
ou
[© 12
FU
LI Ssl
alarm
LED #3 FS F6
®lo 14
©|o »
P 16
FU
LI t.
L2 ©lo Fuse alum
® LED #4 n F8 _r
C ©
n
F8 is blown, the above fuse
alarm LED lights. Correspondence between fuse and LED is
as follows.
FI- F8 have no alarm indicators. Replace the fuse where
the inside fuse element is blown.
Correspondence
between fuses and Alarm LED Mo. #1 E2 #3 #4
output terminals
Fuse number FI F2 F3 F4 F5 F6 F7 F8
01 03 05 07 09 11 13 15
Output number
02 04 06 08 10 12 14 16
1-159
Module name 0D08H, 0D16H
Mounting posi¬
tions of fuse-
alarm indicator
u c ©
LEDs and mounting
positions of
mm ot
fuses 02
03
+DC
1
04
OS
Jls
06
-Mi 07
COM
1
08
09
to
©
ells
u
12
2 13
14
211 £
IS
16
COM
FU
SE E IS CO
lx.
_r
J2L \ c ©
Fuse alarm LED (red) Indicator
\
F8 is blown,
the above fuse alarm LED lights. O.
The blown fuse shows a white failure O
Correspondence
between fuses and Fuse number FI F2 F3 F4 F5 F6 F7 F8
output terminals
Output number
01 03 05 07 09 11 13 15
02 04 06 08 10 12 14 16
1-160
o o o 0
/? /PI
/
o
o o o
I) Procedure
® Disconnect cables from DO module.
The nameplate is opened by pulling it out, while holding it at shown ©
Terminal board
c
© c
c
§
c
c
§ Nameplate
© c
c
fc
<== ©
© Detach DO module by loosening the screws ©.

(|) For mounting new DO module, reverse the above procedure replacing the
terminal board on the new DO module by the original terminal board.
2) Cautions
Mount the terminal board removed from the replacement DO module on the old DO
1-161
19. ANALOG INPUT MODULE (A03B-0801-C410)
The external view of the analog input module is shown in the following figure.
- — Note
Note) ‘AD04A* means the analog

input module.

The analog input module provides the user with a means for interfacing
peripheral equipment analog inputs to the controller. This device connects to
the I/O base unit through the CNA connector. Interfacing is completed by
connecting input lines to the CNT terminal strips. A four channel input module
is available.
For interfacing, the analog input module also acts as an A/D converter because
analog inputs may be accessing the controller. All interface signals are
converted to the digital value before being placed on the I/O bus.
19.2 Block Diagram

To I/O base unit
CNA
<>
n
Address
decoder Buffer
{ ID#
Latch
A/D
converter
8 MHz |'AMP |
clock
Analog
multiplexer
“7>
CNT
1-162
r\ X
CNA
CNT
CNA
a b c *CS : Card select

32 *CS +5 V AO AO-3 : Address signal
31 A1 +5 V A2 DO-7 : Data bus
29 D2 +5 V D3 R/W : Read/write control signal
28 D4 0 V D5 *BE : Bus enable signal
27 D6 0 V D7 *P0R : Power-on reset
26 DP 0 V R/W *ERRI : Error signal detected in
25 0 V *BE the analog input module
24 0 V *P0R *RID : Read strobe for ID code
23 *ERRI 0 V +15 V
22 *R1D 0 V -15 V
21 0 V +5 V : DC voltage
20 +15 V -15 V 0 V
19 +15 V -15 V
18
17
16
15
14
13
12
11
10
09
08
07
06
05
04
03
02
01
CNT
1-163
Ten variable resistors are located on the analog input module (AD04A). Refer to
Sec. 19.7 for the adjusting method.
The variable resistors VR3 and VR4 are used for the gain adjustment of the
operation-amplifiers.
The variable resistor VR5 is used for the balance adjustment between two
.
ope ra t ion-ampl if iers
the gain adjustment of the
The variable resistor VR6 is used for
operation-amplifiers.
The variable resistor VR12 is used for the offset adjustment of the A/D
converter.
The variable resistor VR11 is used for the gain adjustment of the A/D converter.
The variable resistors VR7, VR8, VR9 and VR10 are used for the adjustment of the
input resistance.
19.5 Test Points

The meanings of the test points on the analog input module are as follows.
Test points Symbol Contents Waveform (voltage)
TP1 Used for test. Common for TP3

Input common selected
by multiplexer.
TP2 Output of the Common for TP4

operation-amplifiers
whose input is "TP1".
TP 3 Used for test.

Analog input selected
-10 V - +10 V (Reference is TP1)
by multiplexer.
TP 4 Output of the
operation-amplifiers
-10 V - +10 V (Reference is TP2)
whose input is "TPS".
TP5 Differential voltage

between TP4 and TP 2.
-10 V - +10 V
TP 6 Input to the A/D
converter.
-10 V - +10 V
TP7 +15 V +15 VDC power +15 VDC

TP8 -15 V -15 VDC power -15 VDC
TP10 +5 V +5 VDC power +5 VDC

TP9 GND 0 V
TP11
1-164
TP12 INH Used for test.

By connecting TP12 to
TP 11 (GND), all the
analog input is
neglected (disconnect¬
ed) to the A/D
converter input.
VR7
TP7
o
o CNT1
CNT2
TPS CNT3
o
-ISV
o CNT4
VR8
CNT5
TP9 CKT6
o
GND VR9
CNT7
o CNT8
O TP1 CNT9
O TP2 CNT10
O TP3 VR10 CNT11
Note)
TP10 TP11 TP1J O TP4 o CNT12 In the left figure
o o o CNT13
the plutic cover h removed.
Refer to sec. 16.7 for
GND INH O VRS the plutic cere duusembly
CNT14
Qm O VR6 method.
VR3 O
CNT15
VR4 O CNT16
TP6
o VRU
CNT17
o CNT18
CNT19
O
VR12 CNT20
CNT2I
Fig. 19.5 Location of test points and variable resistors on the analog input module
1-165
O 0 O
(41 41 <41
0
O
0 0 0
©H'
2
1) Procedure
(I) Disconnect cables from the analog Input module.
Disconnect the terminal board by loosening the two screws ©
shown in
the following figure andi while holding its upper and lower ends, pulling
The nameplate is opened by pulling it out, while holding It at © shown
Terminal board
© gg
Res
— C3 0
g
g
I
c
c
Nameplate
© g
¥ C= 0
0 Detach analog input module by loosening the screws 0.
0 For mounting new analog input module, reverse the above procedure.
2) Adjusting
3) Cautions
Mount the terminal board removed from the replacement module on the old
1-166
19.7 Calibration Procedure
Obtain the following equipment:
.. Voltage source (resolution 1 mV)
Voltage meter (resolution 0.1 mV)
. Resistance meter (resolution 0.01 ohm)
Calibrate as follows.
1. Input 0.000 V to TP1 and TP3.
2. Adjust VR3 until the voltage at TP5 becomes 0.0 mV.
4. Input +5 V to TP1 and TP3.
6. Input 0.000 V to TP1 and input +10.000 V to TP3.
7. Adjust VR6 until the voltage at TP6 becomes +9.768 V.
8. Input 0.000 V to TP1 and input -10.000 V to TP3.
9. Adjust VR12 until the display for analog inputs on the KAREL controller AI0
screen (Note) becomes F830 (hex) .
10. Input 0.000 V to TP1 and input +10.000 V to TP3.
II. Adjust VR11 until the display for analog inputs on the KAREL controller AI0
screen becomes 07D0 (hex) .
12. Input 0.000 V to TP1 and TP3.
13. Confirm that the display for analog inputs on the KAREL controller AI0
screen is 0000.
14. Repeat steps 8 through 13 until all conditions are met.
15. Adjust VR7 until the resistance between CNT(2) and CNT(3) becomes 250.0
ohms.
ohms.
17. Adjust VR9 until the resistance between CNT(10) and CNT(ll) becomes 250.0
ohms.
ohms.
Note) The KAREL controller AIO screen can be displayed on the CRT/KB by pressing
STATUS (F2) on the POWER UP screen, followed by I/O (F3) on the STATUS
screen, and AIO (F4) on the I/O screen.
1-167
20. ANALOG OUTPUT MODULE (A03B-0801-C411)
The external view of- the analog output module is shown in the following figure.
A
*
Note
Note) *DA02A’ means the analog

output module.

The analog output module provides analog outputs to the user for interfacing. A
two channel output module is available.
Data is taken from the I/O base unit through the CNA connector and conditioned
to be output through the CNT terminal strips. This module also provides D/A >
conversion from the digital value.
20.2 Block Diagram

To I/O base unit
CNA
<> \7
Address
decoder
31
Buffer
i ID* E
37
Latch
D/A
converter
Current Voltage
amplifier amplifier
V V
CNT
1-168
ft
CNA
CNT
CNA
a b c *CS : Card select

32 *CS +5 V AO AO-2 : Address signal
31 A1 +5 V A2 DO-7 : Data bus
29 D2 4-5 V D3 R/W : Read/write control signal
28 D4 0 V D5 *BE : Bus enable signal
27 D6 0 V D7 *DS : Data strobe signal
26 DP 0 V R/W *BE : Bus enable signal
25 *DS 0 V *BE *P0R : Power-on reset
24 0 V *P0R *ERR0 : Error signal detected in
23 *ERRI 0 V *ERR0 the I/O interface module
22 *RID 0 V *ERRI : Error signal detected in
21 0 V 4-24 V the analog output module
20 4-15 V -15 V 4-24 V *RID : Read strobe for ID code
19 4-15 V -15 V 4-24 V
18 4-15 V
17 4-5 V : DC voltage
16 -15 V
15 0 V
14
13
12
11
10
09
08
07
06
05
04
03
02
01
CNT
1-169
Twelve variable resistors are located on the analog output module (DA02A) .
Refer to Sec. 20.8 for the adjusting method.
The variable resistors VRA1 and VRB1 are used for the offset adjustment of the
D/A converter. VRA1 is provided for channel 1 output and VRB1 is for channel 2
output.
voltage amplifiers. VRA2 is provided for channel 1 output and VRB2 is for
channel 2 output.
The variable resistors VRA5 and VRB5 are used for the gain adjustment of the
voltage amplifiers. VRA5 is for channel 1 and VRB5 is for channel 2.
V/I conversion circuit. VRA3 is for channel 1 and VRB3 is for channel 2.
The variable resistors, VRA4 and VRB4 are used for the balance adjustment of the
V/I conversion circuit. VRA4 is for channel 1 and VRB4 is for channel 2.
The variable resistors VRA6 and VRB6 are used for the gain adjustment of the V/I
conversion circuit. VRA6 is for channel 1 and VRB6 is for channel 2.
Standard
Jumpers Uses
setting
SI This jumper is used only for the offset and balance

*jrÿ~nr* adjustment of the V/I conversion circuit for channel
1. Refer to Sec. 20.8 for the setting method. The
standard setting is always open.
S2 This jumper is used only for the offset and balance

I- • • I adjustment of the V/I conversion circuit for channel
2. Refer to Sec. 20.8 for the setting method. The
standard setting is always open.
1-170
20.6 Test Points
The meanings of the test points on the analog output module are as follows.
PA1 Output of the D/A

converter of channel 1
-10 V - +10 V
PA2 Output of the voltage

amplifier of channel 1
-10 V - +10 V
PA3 Used for the offset

PA4 and balance adjustment
of the V/I conversion
circuit of channel 1.
Refer to Sec. 20.8 for
details.
PB1 Output of the D/A

converter of channel 2
-10 V - +10 V
PB2 Output of the voltage

amplifier of channel 2
-10 - +10 V
PB3 Used for the offset

PB4 and balance adjustment
of the V/I conversion
circuit of channel 1.
Refer to Sec. 20.8 for
details.
+15 V +15 VDC power +15 VDC
-15 V -15 VDC power -15 VDC
GND 0 V
1-171
+5V GND -15VGND+15V
o o
° O O
O O O o
PA4
VRA3 VRA4 VRA6
PA3
o
VRA2
O
VRA1 PA20VRA5
O O
PA1 VRB2
o
PB20
PB3
VRB3 VRB4 VRB6
O O O
°
VRB1 PB4
O GND
O O
PB1
o
+SV GND +24V -12V +12V GND -5V

O O O O o O o
Fig. 20.6 Location of test points and variable resistors on the analog output module
The plastic cover is removed in the above figure. Refer to Sec. 16.7 for the
plastic case disassembly method.
1-172
o o o
/7\ {A 6
X
o
OOP
1
ffiÿf
1) Procedure
®
G>
— -Hi
Disconnect cables from above analog output module (DA02A)
.
The nameplate is opened" by pulling it out, while holding it at shown ©
Terminal board
|le=
® %
(5
g
g
g
1 Nameplate
® g£=
g
G
«=> ®
© Detach analog input module by loosening the screws ©.
(3) For mounting new DA02A, reverse the above procedure.
2) Adjusting
Adjust the PCB correctly after replacement.
3) Setting
Set new DA02A correctly using the original DA02A as a reference.
4) Cautions
Mount the terminal board removed from the replacement module on the old
module before returning it for repair.
1-173
20.8 Calibration Procedure
Obtain the following equipment:
.Voltage meter (resolution 0.1 mV)
.Current meter (resolution 1 uA)
Calibrate the Analog output channel 1 as follows:
1. From the KCL> prompt, type in the following:

SET PORT AOUTCn] *= 0 where n is the port number.
This command will force a 0 V output.
2. Adjust VRA1 until 0 V is measured at PA1.

SET PORT AOUTCn] 2000 where n is the port number.
This command will force a +10 V output.

SET PORT A0UT[n] * -2000 where n is the port number.
This command will force a -10 V output.
7. Confirm that -10 V is measured at PA2.

SET PORT A0UT[n] * 0 where n is the port number.
9. Set the jumper SI to 0 V side (or connect PA4 to 0 V).
10. Turn VRA3 clockwise until it stops: then turn it again counterclockwise
until 0 V is measured at PA2. Stop immediately when the voltage at PA2
reaches 0 V, otherwise the offset of the V/I converter cannot be adjusted
correctly.
11. Set the jumper SI to +12 V side (or connect PA4 to +12 V).
12. Adjust VRA4 until the voltage between PA3 and PA4 becomes 0 V.
13. Remove the jumper SI (PA4 should be open).
14. Connect a current meter between CNT(3) and CNT(4).

SET PORT AOUT Cn] « 1000 where n is the port number.
This command will force a 20 mA output.
16. Adjust VRA6 until 20 mA is measured.
1-174
Calibrate the Analog output channel 2 as follows:

SET PORT AOUT[n] = 0 where n is the port number.
This command will force a 0 V output.
2. Adjust VRB1 until 0 V is measured at PB1.

SET PORT AOUT[n] = 2000 where n is the port number.
This command will force a +10 V output.

SET PORT A0UT[n] = -2000 where n is the port number.
This command will force a -10 V output.
7. Confirm that -10 V is measured at PB2.

SET PORT A0UT[nj = 0 where n is the port number.
9. Set the jumper SI to 0 V side (or connect PB4 to 0 V).
10. Turn VRB3- clockwise until it stops, then turn it again counterclockwise
until 0 V is measured at PB2. Stop immediately when the voltage at PB2
reaches 0 V, otherwise the offset of the V/I converter cannot be adjusted
correctly.
11. Set the jumper SI to +12 V side (or connect PB4 to +12 V).
12. Adjust VRB4 until the voltage between PB3 and PB4 becomes 0 V.
13. Remove the jumper SI (PB4 should be open).
14. Connect a current meter between CNT(3) and CNT(4).

SET PORT AOUTCnj = 1000 where n is the port number.
This command will force a 20 mA output.
16. Adjust VRB6 until 20 mA is measured.
1-175
21. FIXED I/O BOARD (A16B-1211-0750)
The fixed I/O board is a single I/O board, which is installed in the controller
backplane. The board provides an interface to the robot mechanical unit and
user system.
Signal lines are connected to the appropriate connector from the fixed I/O
board. CNC is used for connection to the mechanical unit, and CNB is used for
connection to the power input unit. CN1 and CN2 are used for user I/O.
The fixed I/O board is connected to the shared RAM board via a serial link,
which is Identical to the optical link system used in the modular I/O unit. The
I/O controller (IOC) receives a serial data signal, converts it to parallel
data, and provides the data to the drivers DV. The Inputs from CN1, CN2, CNB
and CNC are received by the receivers RV, and the IOC converts them into a
serial data stream.
21.2 Block Diagram
To Backplane
CNA
SDI SDO
IOC
7
/Decoder\ Buffer Buffer
7>
\7
3 Utch I
o
H*H -3 RV
f
hI
CNC
To robot
I I CNB
To power input
| CN2
T user devices
] CN1
To user devices
mechanical unit unit
1-176
CNl
CN2
CNB
CNA
CNC
CNA
32
a
+5
b
V
c *BGIN : Bus ground In
*BGOUT : Bus ground out } Wired together
in the board
31 0 V +5 V 0 V SDI : Serial data in
30 +5 V SDO : Serial data out
29 +5 V *EN : Reverse logic signal of power
28 0 V enable
27 0 V *SYSCLR: System clear
26 -+5 V 0 V
25 +5 V +5 V
24 +5 V +24 V : DC voltage
23 0 V +15 V
22 0 V -15 Vj
21 +15 V
20 +15 V
19 0 V
18 0 V
17 -15 V
16 -15 V
15 0 V *EN
14 0 V *SYSCLR
13 +24 V
12 +24 V
11 *BG1N 0 V
10 *BG0UT 0 V
09 SDI SDO
08
07 0 V
06 0 V
05
04
03 0 V
02 0 V
01
1-177
CN1
33
34
UDOl
UD02
19
20
0 E
0 E
01
02
UDI1
UDI2
UDI1
UD01
-- 32: User DI
2A: User DO
35 UD03 21 0 E 03 UDI3 0 E : Common of UDIs and UDOs
36 UD04 22 04 UDI4
37 UD05 23 05 UDI5
38 UD06 24 UDI17 06 UDI6
39 UD07 25 UDI18 07 UDI7
40 UD08 26 UDI19 08 UDI8
41 UD09 27 UDI20 09 UDI9
42 UD010 28 UDI21 10 UDI10
43 UDOll 29 UDI22 11 UDI11
44 UD012 30 UDI23 12 UDI12
45 UD013 31 UDI24 13 UDI13
46 UD014 32 14 UDI14
47 UDOl 5 15 UDI15
48 UD016 16 UDI16
49 0 E 17 0 E
50 0 E 18
CN2
14 UD017 08 UDI31 01 UDI25

15 UDOl 8 09 UDI32 02 UDI26
16 UD019 10 0 E 03 UDI27
17 UD020 11 0 E 04 UDI28
18 UD021 12 UD024 05 UDI29
19 UD022 13 0 E 06 UDI30
20 UD023 07
CNB
14 HBKD1 01 *R0T : Robot overtravel signal

15 HBKD2 08 BKR21 02 *R0T RLWD : Relay welding signal detected
16 *BKRE 09 BKR22 03 RLWD In the Input unit
17 BKR11 10 BKR31 04 *FALM *FALM : Fuse alarm of the brake
18 BKR12 11 BKR32 05 *EMGTP control circuit
19 12 0 E 06 +24 E *EMGTP : Emergency stop signal from
20 13 0 E 07 +24 E the teach pendant
BKR21
BKR22 ) *
Contact signal of the 2nd
brake release
BKR32 brake release
HBKD1
HBKD2
*BKRE
! *
Contact signal of the hand
breakage detection
: Brake release enable
BKR12 brake release
+24 V : DC voltage
0 Vj
1-178
CNC
23 RD01 01 RDI1 The connector "CNC" is used for the

24 RD02 13 *R0T 02 RDI2 Interface with the mechanical unit.
25
26
RD03
RD04
14 *HBKD
15 NZ1
03
04
RDI3
RDI4
RDI1
RD01
--
8: General purpose DIs
8: General purpose DOs
27 RD05 16 NZ2 05 RDI5 *R0T : Robot overtravel signal
28 RD06 17 NZ3 06 RDI6 *HBKD : Hand breakage detection
29 RD07 18 NZ4 07 RDI7 ALML : DO for the alarm lamp
30 RD08 19 NZ5 08 RDI8 OPRL : DO for the operation lamp
31
32
OPRL 20 NZ6
+24 E 21 ALML
09 *PPABN
10 0 E
*PPABN
NZ6 )
: Not used
33
34
+24 E 22
+24 E
+24 E 11
12
0 E
0 E
NZ1
+24 E
- 5 : Near zero signals
: DC voltage for DI and DO’s
0 V
Standard
Jumpers Uses
setting
PI Selecting common voltage for

*B
A
\om\
B
RDI: When PI is set to A
side, a pneumatic pressure
im*o\ A
0V common +24V common

alarm will occur.
P2 A 8 Short-circuit *HBKD input. A B A* B
mm mrz\
•HBKD ij
£0111
•HBKDii
effective ihort-ciicuited
CN1
CN2
CNB
PI
CNA P2 CNC
Location of jumpers
1-179
1
OPTl
©
Backplane
1) Procedure
8® Disconnect cables from the fixed I/O board.

Detach PCB by loosening two screws (2) .
For mounting new PCB, reverse the above procedure.
1-180
22. TEACH PENDANT (A05B-2051-C142)

The teach pendant provides a means of inputting jog commands through a keyboard.
It also displays messages from the robot controller to the user. The teach
pendant is cabled to the connector CNTP of the shared RAM board. CNTP is an
RS-422 serial port connector. Data is transmitted and received between the main
CPU and the teach pendant via this serial port. The power source is +24 VDC,
which is supplied by the controller via the same cable. The teach pendant
control PCB coverts +24 V to +5 V, -5 V, and +3.4 V. The +5 V is used for the
logic on the PCB and the liquid crystal display (LCD) control. The -5 V (VEE)
and +3.4 V (VO) are used to drive the LCD. The LCD module has a back light,
which throws light on the back of the LCD panel. The back light is driven by
the +24 V power.
One microprocessor is used for communication with the controller, reading keyed
information and displaying the information on the LCD. One ROM is responsible
for supporting system operating software to the teach pendant.
An EMERGENCY STOP button and a DEADMAN switch are provided for the user's
safety.
An ENABLE ON/OFF switch is provided for control of the DEADMAN switch and
selected software functions.
Note) The system can be operated without the teach pendant by plugging the teach
pendant bypass plug into the CNTP.
22.2 Block Diagram
To shared RAM board

CNTP
CN1 I
7> +24V
+24V CN6
RV/DV
1
Power
source
EMEROTNCÿÿ 7> 9.216MHz dock
TTT
CPU OSC Q +5V-5V+3.4V
JM; Clock
_ if _,
=0 switch
DEADMAN
Latch
.j
V
- Buffei C
J
\jt
— «.
-ÿ
pw
2
LCD
control
PCB
OFF switch
—-
ENABLE ON/ »CN7C
— RV
Key
address
$ ROM Buffer
— LCD module
with back light
detector Latch f Teach pendant
CN3
I \7
T
control PCB
A20B-1002-0980
p <>
CNK
Keyboard PCB
1-181
22.3 Teach Pendant (A05B-2051-C142)
i- LCD display
-Q- -0-
@000000
©
BSBHS
BEHSBE2I& Keypad
O
?: 00015]
5T00SISI
£000®
[slfalfsiral -
21
EMERGENCY STOP
button -a Connectoi to the shared RAM board
ENABLE
ON/OFF switch
\ \
-C&-
-<$>-
DEADMAN switch
2 1
SD
*SD } : Sending data
•SD SD "*SD" is a reverse logic signal of "SD".
5 4 3 RD
•RD RD *RD
: Receiving data
9 8 6
+24V TP2 TP1 EMG
"*RD" is a reverse logic signal of "RD".
12 11 10 Note) Above signals are RS-422
TP3 0V ov interface.
14 13 EMG : EMERGENCY STOP +24 VDC which
FG TP4 comes from the controller
TP1 : Status signal of EMERGENCY STOP
button and DEADMAN switch
EMG TP2 : Status signal of EMERGENCY STOP
-EMG button and ENABLE ON/OFF switch
TP3,TP4: Extra contact output of
o- TP3
EMERGENCY STOP button
j—O * +24 V : +24 VDC for logic circuit
TP4
DEADMAN 0 V : Signal ground
TP1 FG : Frame ground
ENBLE
TP2
1-182
22.3.2 Removal/repiacemant of teach pendant and components
1) Unit (Teach pendant)
a) Procedure
I Disconnect the cable.

Replace the teach pendant
with a new one, and connect
the cable.
P
l ©
2) Component (EMERGENCY STOP button)
a) Procedure
I Disconnect the cable.

Remove the back-cover by
loosening six screws ® .
.
I Disconnect the cable ©
Remove the EMERGENCY STOP
button by loosening part © .
rO
© For mounting a new button,

reverse the above procedure.
2
A CAUTION I
Make sure the teach pendant cable is plugged into the teach
pendant connector (CNTP) not the serial port connector
(CD4A). Otherwise, damage to equipment could occur.
1-183
3) Component (ENABLE ON/OFF switch) fO
s
a) Procedure
Disconnect the cable.
Remove the back cover by
loosening six screws (2) .
. 2
I Disconnect cable (D
Remove the ENABLE ON/OFF
switch.
(D For mounting a new switch,
3,
22.4 Teach Pendant Control PCB (A20B-1002-0980)
CN2
C3 CN6
CN5
CN3D
n
CN7
_I
CN1
rniin
I CN4
1-184
CN1
a b Refer to Sec. 22.3.1 for the signal

10 names.
09 TP 3 TP 4
08
07 0 V EMG
06 0 V 0 V
05 0 V +24 V
04 TP 2 TP1
03
02 *RD RD
01 *SD SD
CN2
01 VSS(OV) VSS(0 V) :0V

02 VDD(+5V) VDD(+5 V) : +5 VDC power supply
03 VO(+3.4V) VOC+3.4 V): Power source to drive LCD
04 RS RS : Resistor select to LCD
05 RW controller
06 E RW : Read/write control to LCD
07 DBO controller
08 DB1 E : Read enable to LCD
09 DB2 controller
10
11
DB3
DB4
DBO - 7 : Data bus to /from LCD
controller
12 DB5 *CS : Chip select to LCD
13 DB6 controller
14 DB7 *RES : Reset signal to LCD
15 *CS controller
16 *RES VEE(-5 V) : Power source to drive LCD
17 VEE(-5V)
18
19
20
CN3
01
a
*KEY00
b
*KEY01
*KEY00 - 07: Output signal of keyswitch
status to the teach pendant
02 *KEY02 *KEY03 control PCB
03 *KEY04 *KEY05 *KC0M0 - 5 : Common of the keyswitch
04 *KEY06 *KEY07 from the teach pendant
05 *KC0M0 *KC0M1 control PCB
06 *KCOM2 *KC0M3 *LED1 -7 : Drive signal of LED display
07 *KC0M4 *KC0M5 +5 V : Common of LEDs
08 *LED1 *LED2
09 *LED3 *LED4
10 *LED5 *LED6
11 *LED7
12 +5 V
1-185
CN4
01 EMG1 EMG1, 2: The status of the EMERGENCY

02 EMG2 STOP button (normally closed)
04 EMG4 STOP button (normally open)
CN5

02 EMG6 STOP button (normally closed)
used for TP3/TP4
CN6
01 +24 V
02 0 V
+24 V
0 V I : Power source for LCD back light
CN7
01 ENB1 ENB1, 2: The status of the ENABLE ON/OFF

02 ENB2 switch (closed in "ENABLE")
03 ENB3 ENB3, 4: The status of the ENABLE ON/OFF
04 ENB4 switch (open in "ENABLE")
22.4.2 Variable resistors
Symbol Function Adjustment
VR1 +5 V adjustment Adjust VR1 until +5 V is observed at test point

+5 V.
VR2 V0 adjustment Adjust VR2 until +3.4 V is observed at test
point V0.
C9M •RES
o o
CLWD
SI o
ES 0V
o
o+SV
o+SL
o -5L
ov VR2VR1
o o
+24V
0S2
F ig. 22.4.2 Location of variable resistors, jumpers and test points
1-186
Standard
Jumpers Uses
setting
SI Used for production testing only

mk
Short
S2 o o Not used
Open
See Fig. 22.4.2 for location of SI and S2.
22.4.4 Test points

The meanings of the test points on the teach pendant control PCB are as follows.
*RES Used for emulation of

power on reset: When
*RES is connected to G
terminal, the circuit
is reset as though it
were powered up. This
is used for software
debugging only.
CLWD Short-circuit of watch

dog alarm detection:
When CLWD is connected
to G terminal, the
watch dog alarm
detection is disabled.
This is used for
software debugging
only.
C9M Clock for MPU of the

teach pendant.
_
\ r
3.5V
ov
108.5 nsec
+24 V +24 VDC voltage +22.0 - +24.4 VDC

+5 V +5 VDC voltage +4.85 - +5.15 VDC
1-187
+5 L Voltage supplied
to the LCD module
+4.85 - +5.15 VDC (Equals +5 V)
-5 L -4.85 - -5.15 VDC
VO +3.4 VDC
See Fig. 22.4.2 for location of test points.
22.4.5 Removal/replacement of teach pendant control PCB
s
1) Procedure
Disconnect the cable.
Remove the back cover by
loosening six screws (§)
(D Disconnect the cables from
.
rO
the teach pendant control PCB.
© Detach the teach pendant
control PCB by loosening six
screws ©. 2
© Detach the LCD control PCB
according to Sec. 22.7.2.
© For mounting the new teach
pendant control PCB, reverse
the above procedure.
2) Setting
Set the new teach pendant control
PCB correctly using the original 1
PCB as a reference.
3) Adjustment 4 5
Adjust the teach pendant control
PCB correctly after replacement.
4) Cautions
Check the ROM No. and edition
3
number between the old and the new
PCBs. 3
4 Teach pendant
control PCB
1-188
22.5 Keyboard PCB (A20B-1002-0970)
O
Connector to the O
teach pendant
control PCB CN3
o
(mounted on the Top view
O
back side) o
o
01
A
*KEY00
B
*KEY01
*KEY00 - 07: status
Output signal of keyswitch
to the teach pendant
02 *KEY02 *KEY03 control PCB
03 *KEY04 *KEY05 *KCOMO - 5 : Common of the keyswitch
04 *KEY06 *KEY07 from the teach pendant
05 *KCOM0 *KC0M1 control PCB
06 *KC0M2 *KC0M3 *LED1 - 7 : Drive signal of LED display
07 *KC0M4 -*KC0M5 +5 V : Common of LEDs
08 *LED1 *LED2
09 *LED3 *LED4
10 *LED5 *LED6
11 *LED7
12 -1-5 V
22.5.2 Removal/replacament of keyboard PCB
1) Procedure
(I) Remove the cover and the teach
pendant control PCB according
to Sec. 22.4.5.
®.
I Remove the screws and spacers
Detach the keyboard PCB by
loosening two screws (5) . 2 Keyboard
PCB
2
@ For mounting a new PCB, reverse I
1-189
22.6 LCD Module (A61 L-0001-0109)
Cable CNX
2 Real view
&= CN2
CN1
01 Dl 02 FLM Dl, D2
03 M 04 CL1 CL1, CL2 Control signals to drive
05 CL 2 06 D2 FLM : LCD
07 VDD(+5V) 08 VSS(OV) M
09 VEE(-5V) 09 V0(+3.4V) VDD(+5 V)
VSS(0 V)
VEE(-5 V) : Power source to drive LCD
V0 (+3. 4 V)
CN2
01 +24 V
02 0 V
+24 V
0 V ) Power source to drive
the LCD back light
22.6.2 Removal/replacement of LCD module

1) Procedure
© Remove the cover and the teach
to Sec. 22.4.5. 3
© Disconnect cable ©. 3
© Detach the LCD module by
loosening four screws ©. 2
© For mounting a new module,
1-190
22.7 LCD Control PCB (A61 L-0001-0100 #CB1053RP)
22.7.1 Connactor/iignal identification
r*
:”VJ
CN2 Top view
CN1
CN1
01 D1 02 FLM Dl, D2
03 M 04 CL1 CL1, CL 2 Control signals to drive
05 CL 2 06 D2 FLM ‘ LCD
07 VDD(+5V) 08 VSS(OV) M
09 VEE(-5V) 10 V0(+3.4V) VDD(+5 V)
VSS(0 V)
VEE(-5 V) : Power source to drive LCD
V0 (+3. 4 V)
CN2
01 VSS(OV) VSS(0 V) :0V

02 VDD(+5V) VDD(+5 V) : +5 VDC power supply
03 VO (+3. 4V) V0(+3.4 V): Power source to drive LCD
04 RS RS : Resistor select to LCD
05 RW controller
06 E RV : Read/write control to LCD
07 DB0 controller
08 DB1 E : Read enable to LCD
09 DB2 controller
10
11
DB3
DB4
DB0 -7 : Data bus to/from LCD
controller
12 DBS *CS : Chip select to LCD
13 DB6 controller
14 DB7 *RES : Reset signal to LCD
15 *CS controller
16 *RES VEE(-5 V) : Power source to drive LCD
17 VEE(-5V)
18
19 3
20
22.7.2 Removai/replacoment of LCD control PCB 2

1) Procedure
(1) Remove the cover and the teach
to Sec. 22.4.5.
© Disconnect the cable ©.
© Detach the LCD control PCB by
loosening four screws ©.
© For mounting a new PCB, reverse
1-191
23. POWER INPUT UNIT
Described in this section are:
The theory of operation of AC power control (23.1)
The block diagram of AC power control . (23.-2)
The power input unit excluding PCB (23.3)
The power input unit PCB (23.4)

AC power is supplied to the controller by the power input unit. The power input
unit brings in three phase power from the main supply through the circuit
breaker or the disconnect switch with fuses and distributes the power to the
servo transformer and the power input unit PCB.
The power input unit consists of the line contactor (LC3), fuses F7 - F9, the
control transformer (TF3) , and the power input unit PCB. Three phase AC inputs
are connected to the circuit breaker. Their outputs are connected to the servo
transformer through the line contactor (LC3) and fuses F7 -
F9. LC3 is
energized from the power input unit PCB (A16B-1311-0530) start up circuitry.
This supplies three phase power to the servo transformer. The servo transformer
outputs 200 VAC for servo drive power. The power input unit PCB also supplies
200 VAC to the control transformer (TF3), which supplies 100 VAC back to the
power input unit PCB.
In the case that the controller is equipped with a disconnect switch instead of
-
a circuit breaker, the fuses FL1 FL3 are mounted on the power input unit.
Three phase AC inputs are connected to the disconnect switch and its outputs are
connected to the servo transformer through the fuses FL1 - FL3, the line
contactor (LC3) and fuses F7- F9. Other part is as described above.
The power input unit PCB receives 200 VAC from the input transformer (TF4) .
Primary power for TF4 comes from the circuit breaker through fuse FI. The power
input unit PCB controls the start up sequence. Once the start sequence has
completed, the power input unit PCB controls 100 VAC for . the overtravel and
emergency stop circuitry, the brake circuits, the optional hour meter and the
magnetic circuit contactor (MCC) on the servo amplifier. The power input unit
PCB also controls the 200 VAC that supplies power to the fan, the DC power
supply unit and the control transformer (TF3) .
Eight LEDs PIL, ALM, BK1, BK2, BK3, S.ON, FALM and FALM2 are on the power input
unit PCB. PIL indicates that power is supplied. ALM indicates that an alarm
signal has been received. BK1, BK2 and BK3 indicate brake ON/OFF status. S.ON
indicates 100 VAC ON/OFF status to the servos. FALM and FALM2 indicate a fuse
blown alarm.
1-192
23.2 Block Diagram
Circuit Power input unit

AC input brtaktt LC3 Servo
3* cTo- To servo
6
F7-9 trans. amplifier
TF1
LCR/LCS
FNR
FI FNS
Power input unit PCS Fan
200R Fuse 200A
Input 200S LC1/LC2 200B
trans. vH F1'2 O O
TF4
Trans. Rn TF3
Control
transformer
Power supply
unit 0*13 ALC/ALP C
P
r 100 INI
100 1N2 Power supply unit
1 ON/OFF LC11LC2 200A
circuitry C 200B
ALA/ALB F
External
ON/OFF
P1L
44 ALM 2
Fll
F12
RY12
O- | CP I 3 |
ON/OFF
O JcT ToCPuJ
E-STOP 2 100 VAC RL2
control
EMGIN1/2/COM relays 1-7
FN1/FN2 RL1 100 0UT1 Q

100 0UT2 Servo
SON amp.
MCC
*ROT, HBKD, PPABN
C
J RL8
BKP1-3
BRKE ,A-
{RU)-3”
BKR
-if'
X BKM1-3 Motor
brake
FALM
1-2
4 Brake
BK1-3 driver
A14B-0076-B320, B321
Fig. 23.2 (a) Block diagram of power input unit, S-10

(Medium size cabinet)
l 1-193
1
Circuit Power input unit
AC input LC3 Servo
-
3® O O- O F7-9 trans.
TF1
To servo
amplifier
LCR/LCS
©O FNR.
FI FNS
Power input unit PCS Fan
Input
trans.
TF4
200R
200S
Fuse
Ch- Fl-2
Trans,
LC1/LC2
TJ
HO O-
— 200A
O 200B
100 INI
Power supply
unit CP13 ALC/ALD C
P
r IOOIN2
Power supply unit

1 ON/OFF LClILC2y 200A
circuitry C 200B
ALA/ALB P
Externa!
ON/OFF
6 PIL
44 ALM 2
FU
F12
RY12
O | CP13 |
ON/OFF ToCPUj
O
E-STOP N
100 VAC RL2
control
EMG1N1/2/COM relays 1-7
FN1/FN2 RL1 100 0UT1
4 SON 100OUT2 Servo
amp.
MCC
*ROT, HBKD, PPABN J
BRKE
BKR
C
-(RU)-J — RL8
I1
t
BKP1-3
BKM1-3 Motor
brake
4 FALM
1-2
4 Brake
BK1-3 driver
A14B-0076-B322, B323
Fig. 23.2 (b) Block diagram of power input unit, S-10/S-700

(Large size cabinet, circuit breaker)
1-194
Disconnect switch Power input unit
AC input LC3 Servo
<TÿO- o.o To servo
30 ] FL1-3 [ F7-9 trans. amplifier
TF1
(uz)
LCR/LCS
FNR
FI FNS
Power input unit PCB Fan
200R Fuse 200A
Input 20 OS LC1/LC2 200B
trans.
TF4
o o
Tans. I T1
100 INI
F3
100 1N2
O-
Power su
unit CPI r ALC/AIT cp
1 ON/OFF 200A
Power supply unit
circuitry LCULC2 C 200B
ALA/ALB P Fll
External
ON/OFF
O- PIL
4 ALM 2 F12
RY12
O | CPI 3 |
ON/OFF
O
ToCPuJ
E-STOP N*
100 VAC RL2
control
EMGIN 1/2/COM relays 1-7
FN1/FN2 100OUT1
O-
4 SON
RL1 100OUT2 Servo
amp.
MCC
•
*ROT, HBKD, PPABN J RL8

BKP1-3
BRKE C
O Motor
BKM1-3
BKR brake
FALM
1-2
4 Brake
BK1-3 driver
A14B-0076-B324, B32S
Fig. 23.2 (c) Block diagram of power input unit, S-10/S-700

(Large size cabinet, disconnect switch)
1-195
23.3 Power Input Unit
There are six types o£ power input units and one of them is used being based on
the cabinet types, the AC input voltage, and the power disconnection device.
Specification
AC input voltage
220/240 VAC 380/415/460/480

500/550/575 VAC
Medium size
A14B-0076-B321 A14B-0076-B320
cabinet Circuit breaker
including
Power leakage breaker
disconnect A14B-0076-B323 A14B-0076-B322
Large size device
cabinet
Disconnect switch A14B-0076-B325 A14B-0076-B324
Differences in internal configurations among those units are shown in the block
diagrams Fig. 23.2 (a) through (c). Differences by the AC input voltage are the
wire color of AC lines and capacity of fuses. Location of components is shown
in Fig. 23.3 (a). Main components are:
PCB : Power input unit PCB
LC3 : Line contactor
F7
FL1
-- 9 : Fuses for servo transformer
3: Fuses for AC input power
TF3 : Control transformer
o o o o o o
From
© © © disconnect
switch
TF3
FL1 FL2 FL3
P From P
P From circuit C circuit C
C B breaker B To input
breaker and
B © to input
transformer
and
to input
mr transformer
LC3 LC3 transformer LC3
ra©i
o ©
F7 F8 F9 F7 F8 F9
F7 F8 F9
e © © ©. To servo & § To servo
To servo transformer transformer
transformer
A A n A A A
A14B-0076-B320, B321 A14B-0076-B322, B323 A14BW76-B324, B325
Fig. 23.3 (a) Location of power input unit components
1-196
Power input unit
A14B-0076-B320. B321
LC3
o -o-
F8 To servo
220-575 VAC it o transformer
F9
input
it O
220
rCh :1
La 7ÿO1!IQQAO
COM|!|IOOBU VAC
To fan unit [ L_±.
To servo amp.
(100 VAO
Ti „ AAA
x,.1 X
tn 211 ii
I

A16B-1311-0530
I
--
TTTT
- -g g
5
88
N «
8S
v
Fig. 23.3 (b) Power input unit circuitry (Medium size cabinet)
Power input unit

A14B-0076-B322, B323
LC3
F7
it CD-
F8
220-575 VAC n o To servo
transformer
input
u a
rCH
LC3 :] From servo
transformer
t :] To servo amp.
r
To fan unit (100 VAC)
A11 A AAA
III I | |
A A
l I TTTT
Ii§ 211 £ 5
<N «N
2 2 feg
§ §11

A16B-1311-0530
Fig. 23.3 (c) Power input unit circuitry (Large size cabinet, breaker)
1-197
Power input unh
A14B4076-B324.B325 .
FL1 U3
F7
CD- O
FU F8
220-575 VAC o o To servo
transformer
input FL3 F9
CD O
rOi :] From servo
transformer
LC3
To fan unit [: :] To servo amp.
(100 VAC)
4 \A A A A A AA
/|Vÿ yjv yjv A A
I I TTTt
«
*£§
£ Sii Is §
556S
I ii
O O
Power Input unit PCB

A16B-1311-0530
Fig. 23.3 (d) Power input unit circuitry (Large size cabinet, disconnect switch)
23.3.1 Fuses
Fuse specification is shown below.
S-10 and S-700 controllers
Power input unit specification A14B-0076- | 1 1 1 1 11 |
B321, B323 B325 B320, B322 B324
AC input
220/240 VAC 380/415/460/480/500/
voltage 550/575 VAC
A60L-0001-0042 A60L-0001-0042 A60L-0001-0042 A60L-0001-0042
F7-9
0JG1-3O #JGl-30 #JG1-15 #JG1-15
Fuse
A60L-0001-0042 A60L-0001-0042
FL1-3 #JG2-40 #JGl-20
Refer to Fig. 23.3 (a) for location of fuses.
1-198
1) Power input unit
a) Procedure
(1) Disconnect all cables from the power input unit PCB.
© Disconnect all cables ©from the power input unit.
© The power input unit can be removed by loosening four screws © .
@ For mounting new power input unit* reverse the above procedure.
P
?T£
FLl FL2 FU
3
1®
LC3
2
F7 F8 F9
jT
Front view of power input unit

2) Line contactor (LC3)
a) Procedure
(I) Disconnect all cables ©
from the line contactor.
©.
I The line contactor can be removed by loosening two screws
For mounting new line contactor, reverse the above procedure.
TF3
Power ir Line contactor
input
unit ft LC3
F7 F8 F9
Front view of the power input unit
1-199
3) Control transformer (TF3)
a) Procedure
(D Disconnect all cables (I) from the transformer.
© The transformer can be removed by loosening four screws ©.
<D For mounting new transformer, reverse the above procedure.
Control transformer TF3
% o
X
\rtrhr'
—
I
©
©
Power
input
unit
/ ©
©
©—1 3
LC3
Front view of power Input unit
1-200
23.4 Power Input Unit PCB (A16B-1310-0530)
23.4.1 Cormector/signa! identification
CPI CPJ
200A
fa CP3
§
B CP4
B
fa
n
B
i
CP8
U
CP7 11
T?1
TAe
CJO
koJrl<?*5l*Y Fig. 23.4.1 Location of terminals and connectors on the power input unit PCB
ews.ee
C. O EMGIN1
Co M D i TVW~* ( OA
Vr—,4EMGOUT1 EMGINC
Emergency stop control inputs from external
equipment
’logi. EMGIN2
IcvSjW EMGOUTC
EMG0UT1
EMGOUT? Emergency stop control outputs for external
fjPtX EMGOUTC
OP1 equipment
f»c;e. EMG0UT2
OP2
EMG1N1
ENGINC
BKP1
BKM1 } : 1st brake control output
BKP2
ENGIN2 : 2nd brake control output
BPM2
100OUT1 BKP3
100OUT2 BKM3
: 3rd brake control output
BKP1 BKP is a positive side output, and BKM is a negative
BKM1 side output.
BKP2
BKM2
0P1
0P2 } Input of the emergency stop on the
operator’s panel
BKP3
BKM3
ON
!
FNl
FN2
ON
Input of the gate switch of the protective
fence
OFF OFF
Connection terminals for external ON/OFF
control switches (Note)
COM COM
FNl
FN2
100 0UT1
100 0UT2 J : 100 VDC power output (for servo amp.)
Note) Refer to Sec 23.4.2 for the connection information.
1-201
The relationship between the signals is as follows.
Contact Contact
100 VAC output 100 VDC output
for the servo between between
for the motor
amplifiers EMG0UT1 and EMGOUTC and
Status
brake
EMGOUTC EMG0UT2
Normal (Noteÿfc 100 VAC 100 VDC Closed Open
(Robot can be ON ON
operated)
EMGIN1-EMGINC OFF OFF Open Closed

(open)
EMGINC-EMGIN2 OFF OFF Closed Open

(open)
Other OFF OFF Open Closed

emergency stop
status
(includes
"ROT" or "EMG"
of TP •••)
E-STOP button
is pressed
E-STOP button ON OFF Closed Open

is released
but RESET has
not been
pressed
Note) Normal status means that "EMGIN1" and "EMGINC" are shorted, "EMGINC11 and
,,EMGIN2,, are shorted, and any other emergency stop conditions have not
occurred.
1-202
CPI
01 PFL PFL
02 PFH PFH : Power ON/OFF leading signal
03 PF PF
04
05 ALC These contact signals are output to the power supply
06 ALD unit before power is normally turned on or normally
turned off by the ON/OFF button provided on the
operator's panel or an external ON/OFF button. As shown
in the diagram, PFL/PF are connected prior to the AC
input unit coming on after the ON button has been
pressed. PF/PFH are connected at least 150 ms after the
OFF button is pressed. Loss of the PFL signal indicates
to the power supply unit that power is going off.
re
Power input unit CP13 Power supply unit
CPI-1 PFL -1
CP1-2 PFH -2
CPI-3 PF
-3
ON button OFF button
r '
ON/OFF
leading
signal \ RY 1 relay operation
AC input ON
JL>0 >150ms
ALC
ALD ! : Alarm signal detected by the power supply unit
This contact signal is given from the power supply unit

when the EN signal of the power supply unit goes low.
The EN signal goes low when the DC output voltages,
being monitored by a voltage monitoring circuit on the
power supply unit, fall outside of the specified range.
When this signal is given, the AL relay in the power
input unit energizes and latches in to turn off the AC
input power.
Power supply unit CP13 CPI

-5 ALC Power input unit
-5
ryl2
V-I
1 4)
ALD
Open normally
Closed when an alarm occurs
i The alarm LED lights. The power, off button must be

pressed to release the latched AL relay in order to
recover from this alarm.
L 1-203
CP 2 - CP 4
01 200A 200A
02 200B 200B : 200 VAC power source for the power supply unit
03 GND GND : 0 V (ground)
CP3 and CP4: These connectors are not used.
CP7
01 +24 E: +24 V (External use from power supply unit)

02 0 V: Ground
03 0 V +24 V: +24 V from power supply unit
04 0 V
05 +24 V
06 +24 E
CP8
01 +24 F +24 F: +24 V (via fuse F10)

02 0 V 0 V: Ground
03
CN1
14 HBKD1 08 BKR21 01 0TREL OTREL : Overtravel release signal from

15 HBKD2 09 BKR22 02 *R0T the operator’s panel through
16 *BKRE 10 BKR31 03 RLWD the robot control module
17 BKR11 11 BKR32 04 *FALM *R0T : Robot overtravel signal from
18 BKR12 12 0 V 05 *EMGTP the mechanical unit through
19 13 0 V 06 +24 E the robot control module
20 07 +24 E RLWD : Relay welding signal to
the robot control module
*FALM : Fuse alarm of the brake
control circuit
*EMGTP : Emergency stop signal of
the teach pendant
+24 E : +24 VDC to the robot control
module
BKR12 *
brake release
BKR21 Contact signal of the 2nd
BKR22 brake release
BKR32 brake release
HBKD1 Contact signal of the hand
HBKD2 breakage detection
*BKRE : Brake release enable
1-204
CN2
01 +24 F 14 0 V +24 F: +24 V to CNPI on shared RAM board

08
02 +24 F 15 0 V OTREL: Overtravel release signal from
09
03 ONI 16 ON 2 the operator panel through CNPI
10 17 OFF 2 on the shared RAM board
04 0FF1 11
05 OTREL 12 18 TP1 : Status signal of EMERGENCY STOP
06 TP1 19 TP 2 button and DEADMAN switch on
13
07 +24 F 20 0 V the teach pendant
CN2 is connected to CNPI on the TP2 : Status signal of EMERGENCY STOP
shared RAM board. button and DISABLE/ENABLE switch
on the teach pendant
ONI
ON2 Connection with ON/OFF switch
OFF1 * provided on the operator's panel
OFF2
0 V : Ground
CONNECTION TERMINALS
200A
200B } : 200 VAC power output to the control transformer
LCR Control signal output of the line contactor (LC3) for the servo
:
LCS transformer
FNR
: 200 VAC power output for fan units
FNS
200R
200S } : 200 VAC power input for the power input unit PCB
100IN1 : 100 VAC power (output of control transformer)
100IN2
100OUT2 }
100OUT1 : 100 VAC power output (same as TP1,
9 and 10)
ALA
ALB } : Connection terminals for an external alarm
Connection terminals of the door interlock switch
DILI
DIL2 } : These terminals are not used. When these are not used, these should
be shorted.
+24 F : +24 V fuse line
0 V : Ground
1-205
23.4.2 Jumper/shorting strip settings
ALA
a
&
TPl
TP1
When the terminals "EMGINl", "EMGINC", (M3 terminals)
and "EMGIN2" on TPl are not used, the EMGOUT1
terminals should be shorted. The EMGOUTC
setting method is as follows. EMGOUT2
When the terminals "EMGINl" and 1 OP1
"EMGINC" are used, remove the shorting
strip (T) .
And when "EMGINC" and
-do-(g) £
OP2
EMGINl
"EMGIN2" are used, remove External
emergency stop
or limit s ©
ENG1NC
ENGIN2
<3J0-©
"OFF" and "COM" of terminal TPl should switches
100 OUT1
be shorted when the external ON/OFF 100 OUT2
control is not used. 2
BKPl
When the external ON/OFF control is
BKM1
used, the connection is shown below.
BKP2
BKM2
"FN1" and "FN2" of terminal TPl should BKP3
be shorted when the gate switch of the
BKM3
protective fence is not used. Power © 1ÿ ON
When the gate switch of the protective
fence is not used, the connection is
ON
nf Co;
Cl
/ m
OFF
©
m
shown below. COM
OFF FN1
FN2
ON/OFF switch
externally furnished Remove this shorting strip
for ON-OFF control when the external power
supply ON/OFF switch is used.
1-206
LED Meaning Status
TPl
S. ON Servo on 100 VAC is supplied to the
c (amber) servo amplifier, when this
( LED lights.
PCB
< /(.A16B-m0-0S10) BK1 1st brake is When this LED lights, the brake on axis 1
(
c
(amber) released
S-700 is released._
on the S-10 is released. Axes 2 and 3 on the
When this LED lights, the brakes on axes 2

c BK2 2nd brake is
and 3 on the S-10 is released. Axis 1 on the
S. ON (amber) released
(
S-700 is released.
< BK3 3rd brake is When this LED lights, the brakes on axes 4,
C
<2 BKl
5, and 6 on both the S-10 and S-700 are
(amber) released
c released.
<2
( BK2 FALM
(red)
Fuse alarm If one of three fuses F4 - F6
( of the brake is blown, this LED lights.
<S BK3 circuit
C
C FALM
<e PIL PIL Pilot lamp PIL lights while the power is
(
<2 (amber) supplied to the terminal TPl
AIM
C "200R" and "200S" if F3 is not
c <2 blown.
c <2
C
FALM2 ALM Alarm lamp ALM lights when the power
(red) input unit PCB receives an
c alarm signal from the power
(2
c unit. (Note)
FALM2 Fuse alarm If fuse F10 is blown, this LED

(red) of the +24 F lights.
supply
Note) When ALM lights, the line contactors LC1, LC2 and LC3 turn off.
LC1 and LC2 are installed on the power input unit PCB, and LC3 is on the power
input unit. The controller power cannot be turned on under this condition, to
reset this condition, the power supply must be turned off, or the POWER OFF
button (either the controller POWER OFF button or external POWER OFF button)
must be pressed.
Caution) Even when the controller power has been turned off, power is still
applied to the input unit and the amber PIL LED will be lit. Before
touching any part of the input unit be sure that the PIL is off and the
circuit breaker /disconnect switch is off.
1-207
TP1
Remove this shorting strip (M3 terminals)
when the gate switch of
the protective fence is used. -
s OFF
© COM
Gate switch of
the protective © FN1
fence.
FN2
ALA and ALB terminals should be left open when an external $larm is not used.
When an external alarm Is used, the connection Is as follows.
Faston terminal
Alarm switch
X \
r CQ EG
<] EC
ALA
ALB
"DILI" and "DIL2" terminals are not used In the power Input unit FCB. When
these terminals are open, the controller cannot be turned on.
23.4.3 LEDs
Eight LEDs, S.ON, BK1, BK2, BK3, FALM, PIL, ALM and FALM2 are provided with the
power input unit PCB.
1-208
23.4.4 FUMS
Seven fuses are installed in the power input unit PCB.
FI, F2 Input fuses of 200 VAC line
F3 Input fuse of the control circuit
F4, F5, F6 Fuses of the brake control line
F10 Input fuse of 24 VDC line
Each fuse specification is as follows.
Fuse number Specification
FI, F2 A60L-0001-0101i?P4100H
F3 A60L-0001-0172#DM03
F4, F5, F6 A60L-0001-0046#2. 0
F10 A60L-0001-0046#5. 0
If one of the three fuses F4 -

F6 Is blown the FALM LED lights. If F10 is blown
the FALM2 LED lights. The blown fuse shows a white failure display in the
indicator shown below.
Indicator
Fl F2
rn
£SS
Fig. 23.4.4 Location of fuias on power input unit PCB
1-209
23.4.5 Test points
C Output of the diode about 25 VDC

bridge to convert AC
to DC voltage
B Cathode of the Zener about 22 VDC

diode (ZD1)
E DC power voltage of 21 to 22 VDC

the input unit PCB
circuit
0 V 0 V reference for 0 V
output of bridge
o ov
E °OOB
C
TP1
Fig. 23.4.5 Location of test points on power input unit PCB
1-210
23.4.6 Removal/repiacament
1) Power Input unit PCB
a) Procedure
® Disconnect cables from the power input unit PCB.
(2) Detach the PCB by loosening the five screws (2)
(3) For mounting the PCB, reverse the above procedure.
.
o- I
Fig. 23.4.6 (a) Left side view of power input unit PCB
2) Component (relay)
Relay removal direction Relay removal direction
ft ft
Spring removal Relay
“v direction Securing spring
Relay
Securing
spring C= =0 Spring Jremoval
V direction
Socket
Socket
Fig. 23.4.6 <b| Relays LC1, LC2, RL1, Fig. 23.4.6 (c) Relay RS1
RL2, RL7, RL8, RS2
Remove the spring that clamps the relay to its socket by pulling it in the
direction indicated by the arrow ( cr£> ) shown above. Then remove the relay by
pulling it in the direction ( ) shown above.
1-211
24. TRANSFORMERS
Four transformers (servo, input, control and user) are installed in the
controller.
Servo transformer : Provides power for servo amplifiers
Input transformer- : Provides 200 VAC for power supply unit, fan units, control
transformer and power input unit.
Control transformer: Provides 100 VAC for servo amplifiers and motor brakes.
User transformer : Provides 115 VAC for user (option).
Specifications of transformers are as follows.
S-10 S-700
Medium size Large size Large size
cabinet cabinet cabinet
Servo A80L-0024-0002 A80L-0024-0004 A80L-0024-0004

transformer
TF1
Input A80L-0012-0010 A80L-0012-0010 A80L-0012-0010

transformer
TF4
Control A80L-0001-0342 Not available Not available

transformer (an integral (100 VAC is (100 VAC is
TF3 part of power provided by provided by
input unit) servo servo
transformer) transformer)
User Not available A80L-0001-0520 A80L-0001-0520

transformer
TF5
1-212
24.1 Fuses
1) Servo transformer TF1
FI - F3: Fuses for 200 VAC output (30 A)
A60L-0001-0042#JGl-30
F4 - F5: Fuses for 100 VAC output (3.5 A)
A60L-0001-0101#P435H
rJiA-i
|— 30A F4F5
§
FI F2 F3
-w « O
00
«« r> » O'
i
R
6
EEBBHMEEEEB
2 22 2 22 4- 4-
r» «e
’wWrs w> 2 £
MEHMEEMEE ©
n Vt \6 MN MN
3IEE ±EEEEEEEEE
\
Front view
Note) Fuses on the servo transformer are provided only for the large size
cabinet.
2) Input transformer TF4

FIs Input fuse
A6OL-OOO1-O1930FH-32F
m TBl *
ET S7S FI 10A
El sso
El soo TB2
3ET 480
El EE
ET
460
200A m
ET
440
4JS 200B m
SI
Et 380
ET 240
220
COM
IS
1-213
3) User transformer
FI: Input fuse of user transformer TF5
A60L-0001-0042#JG1-10
F2: Output fuse of user transformer TF5
A60L-0001-0042#JGl-20
TBl
±
m
i±i 57S L_ F2
ES >0A 20A \l
M,«r
SSO
m
m
500
480
EE 460 U EE
EE 440
Ll EE 115 VAC.9.6A
EE L2 EE
— —
415
EE 380
L2 EE
DIEJ
V E3
mitB
240
\IE 220
EE COM
m
4
24.2 Settings
1) Servo transformer TF1
Connect the jumpers as follows.
Power supply Connection of primary tap

voltage Connecting style
U V W Jumper
220 7 15 23 8-15 16-23 24-7
240 6 Delta
14 22 8-14 16-22 24-6
380 7 15 23
415
6 14 22
440
460 5 13 21
480 4 12 8-16 16-24 Star
20
500 3 11 19
550 2 10 18
575 1 9 17
2) Input transformer TF4

Select the correct tap so that the power supply voltage is within +10% to
-15% of the tap voltage.
3) User transformer
Select the correct tap so that the power supply voltage is within +10% to
-15% of the tap voltage.
1-214
25. HOUR METER
25.1 Connector/Signal identification
n Terminals: 100 VAC input

'terminals for
Terminals hour meter
(Rear view of the hour meter)
1) Procedure
ID Disconnect cables (I) from the hour meter.
The hour meter can be removed by loosening two nuts (f) •
2) For mounting new hour meter, reverse the above procedure.
.Hour meter
'©
©
(Rear side of the operator’s panel)
1-215
26. SERVO AMPLIFIER
In the S-10 R-H controller, two three-axis servo amplifiers are used.
In the S-700 R-H controller, two one-axis servo amplifiers and two two-axis
servo amplifiers are used to drive each axis.
The relationship between the axes numbers, axes names, and the connectors on the
axis control PCB, robot mechanical unit, and servo amplifiers is shown in Table
26 (a) and (b) .
Table 26 (a) S-10

Software Hardware Axis control Feedback Connector Velocity
control Amp. Connector
No. Ho. PCB connector on robot connector
PCB No.
2 1 U CF91 PI CV21 CN1N
3 2 U CF92 PI CV22 1 CN1L

1 1
1 3 0 CF93 PI CV23 CN1M
4 4 Y CF94 P2 CV24 CN1N
5 5 B CF91 P2 CV21 2 CN1M

2 2
6 6 a CF92 P2 CV22 CN1L
Table 26(b) S-700

Software Hardware control
Axis control Amp. Connector
No. No. PCB
connector on robot PCB
connector
No.
2 1 W CF91 PI CV21 4 CN1
3 2 U CF92 PI CV22 1 CN1M

1 1
1 3 0 CF93 Pi CV23 3 CN1
4 4 Y CF94 P2 CV24 2 CNIM
5 5 B CF91 P2 CV21 2 CN1L

2 2
6 6 a CF92 P2 CV22 1 CN1L
1-216
26.1 One-axis Servo Amplifier
This type of amplifier is used in the S-700 controller. The part numbers are as
follows.
S-700
A06B-60 58-H006 (W)

A06B-6058-H012 (0)
26.1.1 Theory of operation

The servo amplifier drives an AC servo motor. It consists of two parts, the
power amplifier (unit base) and the servo amplifier PCB.
The power amplifier employs three-phase power supply for the main circuit and
single phase 100 VAC for the braking contact. An input voltage of three-phase
power is rectified and filtered by the diode bridge and the capacitor for the DC
voltage power supply. The DC voltage is converted to three-phase current by the
three-phase transistor bridge which is driven by the pulse width modulation
(PWM) signals from the servo amplifier PCB through CN3 and CN4.
The current of the motor is detected by the current detecting resistors and
transmitted to the servo amplifier PCB through CN3. Then it is sent to the axis
control board via CN1. The regenerative discharge circuit is in the power
amplifier to absorb the energy from the motor.
The servo amplifier PCB also has the alarm circuit for the protection of the
servo control system.
The LEDs on the servo amplifier PCB indicate the alarm condition when the alarm
circuit operates.
1-217
26.1.2 Block diagram
R
T1
A FT7J n Current
detector
T1
5 U
AC servo
motor
Discharge 6 V
200 VAC S l
30 T 2
m control
circuit 7 W
V
—-
100 VAC
10
#
iOOA
——
(IOOBT4
L
3
6—
MCC
ill LSJ
i A
Ch 4
To axis
control board
To discharge
unit (Amp. 4)
TOH
c CN1
1
Servo amplifier PCB
A20B-1003-0090
9.2 T4
No connection TOH
(Amp. 3) T
2 Receiver Driver $2
To power
circuit
CO
2
Alarm detect
T4 &
+5V.+24V
+ 15V, -15V
J _
- Power supply
circuit
DRDY HV HC LV DC OH
ijz* i?
A20B-1003-0090
Block diagram of the servo amplifier PCB
1-218
O O
A20B~|003*0090
W
CN4
Lr
ru
CN3
Lr
CNl
T1 ]
A
1-219
T1
A R
R, S, T : 200 VAC three phase
100A, 100B: 100 VAC single phase
S
U, V, W : Three phase output for motor
1
: Ground terminal
2 T
3 100A
4 100B
5 U
6 V
7 W O Hi.
8 O Hi.
T2
LCG : Collector of transistor Q1
4 LCG
HCA : DC main power supply
5
6 HCA
T4
T0H1, T0H2: Transformer overheat input
1 TOH1
2 T0H2
CN1
*PWMA *PWMD IR, GDR Phase-R current
01 (*ALM1) 08 IR 14 (ALM8) IS, GDS Phase-S current
*MC0N MCC control
02 COMA 09 GDR 15 COMD
*DKDY Servo ready
*PWMB GND Ground
03 (*ALM2) 10 IS 16 *PWME *PWMA(*ALM1) ,COMA PWM signals and
*PWMB(*ALM2) , COMB their commons
04 COMB 11 GDS 17 COME
*PWMC (*ALM4) , COMC *PWMA, *PWMB, *PWMC
*PWMC *PWMD( ALM8) ,COMD and *PWMD are bidi¬
05 12 *MC0N 18 *PWMF
(*ALM4) *PWME, COME rectional. When an
*PWMF, C0MF alarm is signalled
06 COMC 13 GND 19 COMF
to the axis control
board, these lines
07 *DRDY 20
become outputs and
they are referred
to as *ALM1, *ALM2,
*ALM4 and *ALM8 ,
respectively.
1-220
CN3
01 DB DB : Base signal for transistor D

02 FB FB : Base signal. for transistor F
03 VL VL : Emitter signal for transistor B, D, F, G
04 TH1 TH1, TH2 : Overheat of heatsink
05 TH2 RLY : Precharge control relay
06 RLY 20V : 20 VDC for precharge control relay
07 20V ITLK : Interlock of contactor
08 ITLK 100A, 100B: 100 VAC
09 100A MCC : Magnetic contactor control
10 100B CDU1, CDU2: Current detect of U phase
11 MCC CDVI, CDV2: Current detect of V phase
12 CDU1
13 CDU2
14 CDV1
15 CDV2
CN4
01 GC GC : Collector signal for transistor G

02 GB GB : Base signal for transistor G
03 VDR VDR, VDS, VDT: 200 VAC for DC power supply
04 VDS FG : Frame ground
05 VDT VH1 : Current detect of DC link
06 FG VH2 : Positive voltage of DC link
07 VH1 AB : Base signal for transistor A
08 VH2 AE : Emitter signal for transistor A
09 AB CB : Base signal for transistor C
10 AE CE : Emitter signal for transistor C
11 CB EB : Base signal for transistor E
12 CE EE : Emitter signal for transistor E
13 EB BB : Base signal for transistor B
14 EE
15 BB
1-221
26.1.4 LEDs
LED Function Conditions
HV High voltage The DC voltage of the main power supply is higher than
(R) alarm 450 V.
a. AC power supply is higher than the specified range.
b. The regenerative energy discharge circuit becomes
defective, which includes the PCB, the transistor Ql,
and discharge resistor or the separately mounted
discharge unit.
c. Servo motor or the power cable for motor insulation is
defective.
d. Load inertia is excessive.
HC High current The DC current through the main DC power supply is too
(R) alarm high.
a. Transistor module is defective.
b. Short-circuit failure in the motor or the cable.
c. PCB is defective.
LV Low voltage Regulated power supply +15 V or +5 V on PCB is abnormally

(R) alarm low.
a. AC input power supply is lower than specified.
b. PCB is defective.
DC Discharge On time of the discharge transistor Ql is too long (over

(R) circuit several seconds) or its capacity to discharge is
alarm overloaded.
a. Transistor Ql or PCB is defective.
b. Acceleration/deceleration frequency is too high.
c. The setting of jumper S2 is .improper.
Refer to 26.1.6 for proper settings.
OH Overheat Some thermostat in the controller has operated.

(R) alarm a. The thermostat at the heat-sink on servo amplifier.
b. The thermostat in the servo transformer.
c. The thermostat in the regenerative discharge unit.
DRDY Servo amp. MCC turns on and motor is energized.

(G) ready
1-222
A2OB-1003-0090
rx
CN4
L_r
O HV
o LV
HC
(RED)
fL
DC
OH
CN3
QDRDY (GREEN)
If
on I El
Location of LEDs on A20B-1003-0090
1-223
26.1.5 Test points
CHI *PWMA A-phase PWM signal
CH7 IR R-phase current
CH8 IS S-phase current
CH9 0 V 0 V (Ground)
CH10 +5 V +5 VDC
CH11 +15 V +15 VDC
CH12 -15 V -15 VDC
CH13 +24 V +24 VDC
A20B-100V0090
ru
CN4
Lr
ru
O CHI 3
OCH12 CN3
OCHU
O CH10
OCH9
OCHS L_r
O CH7
O CHI
Oil \E]
Location of test points on A20B-1003-0090
1-224
26.1.6 Jumper setting*
S-700
Axis
Jumper
No.
ifl n n #4 Meaning
U j a fiT7 0 W
TOH setting
SI H L When the overheat signal is not provided.
to T4, the SI setting should be H side.
DC alarm setting
S2 L H When the discharge unit is not added,
the S2 setting should be L side.
Symbols #1 - if 4 show the servo amp. No.
A20B*1003-0090
r~L
CN4
Lr
a
CN3
Lr
HD
S2
CNl 5} QD
Location of jumper settings
1-225
26.1.7 Removal/replacament
1) Unit
a) Remove the cables connected to the connector CN1 and terminals Tl, T2 and
T4.
Unclamp connectors are follows:
. CN1
(T) Squeeze the clamp release
to remove the connector. <=C> c
i j
_
. Clamp
» v3 release
b) Loosen two mounting screws at

the bottom. Mounting screws, top
c) Remove two mounting screws at
the top and remove the unit.
Mounting screws, bottom
2) Component
a) PCB
Push to release
8 Release six PCB holders.

Pull up PCB from connectors
CN3, CN4.
PCB,
A
TT zr
PCB holder
r
%
Tl
1-226
26.2 Two-axis Servo Amplifier
follows.
S-700
A06B-6058-H221 (fi, y)
A06B-6058-H222 (U, a)
(PWM) signals from the servo amplifier PCB through C1I3, CN4L and CN4M.
transmitted to the servo amplifier PCB through CN3. Then it is sent to the axis
control board via CN1L and CN1H. The regenerative discharge circuit is in the
power amplifier to absorb the energy from the motor.
circuit operates.
Tl
7T7T7 Cur rent

detector AC servo motor
To servo
transformer
200V AC 3o
(iSREE t m
+ Discharge
control circuit
lilts Dynamic
5V k UL .O}
VL_ J
brake
St circuit
7T7T71 Current
detector
AC servo
motor
WES' i
spaO
l yl
liliif
I JE
X
XJS
CN3 CN4L CN4M
To axis control board CN1L
Servo amplifier PCB
A16B-1200-0720
To axis control board CN1M
To servo transformer
overheat sensor
(Note)
Note) Connected on Amp. 1, U and a. Not used on Amp. 2, B and y.
1-227
2
U
7> Receiver Driver 5
Z s
O
5 Receiver Driver
I s
Alarm detect c= 2
T4 <> T
+5V.+24V Power supply
+15V.-15V circuit
DRDY HV HC LV DC OH
Block diagram of the servo amplifier PCB (Two-axis type)
O O
ca
A 16B-1 200-0720
ru
CN4
L
Lr
Side view
ru
CN4
M
UU
Lr
CN1M CN1L
P<
CN3
CN1L
CN1M,
Lr
S
T1
A A
1-228
T1
A R
100A, 100B : 100 VAC single phase
UL, VL, WL
1 S
UM, VM, WM
s Three phase output for motor
2 T : Ground terminal
3 100A
4 100B
5L UL
6L VL
7L WL
5M UM
6M VM o >
7M WM O -I"
T2
4 LCG
5
6 HCA
T4

1 T0H1
2 T0H2
1-229
CN3
01 VH VH : Detect signal for HC alarm

02 VHV VHV.VDR.VDS.VDT: Detect signal for discharge circuit
03 VDR (200 VAC for DC power supply)
04 VDS NFG : Ground for noise filter
05 VDT LCG : Collector signal for discharge circuit
06 NFG LBG : Base signal for discharge circuit
07 LCG LEG : Emitter signal for discharge circuit
08 LBG 100A : 100 VAC
09 LEG MCC : Contactor control
10 100A INTL1, INTL2 : Interlock of contactor
11 MCC TH1, TH2 : Overheat of heat sink
12 INTL1
13 INTL2
14 TH1
15 TH2
CN4L
01 VHL VHL : Collector signal for transistor of L-axis

02 LBAL LBAL : Base signal for transistor A of L-axis
03 LBBL LEAL : Emitter signal for transistor A of L-axis
04 LEAL LBBL : Base signal for transistor B of L-axis
05 LBCL LBCL J Base signal for transistor C of L-axis
06 LBDL ' LECL : Emitter signal for transistor C of L-axis
07 LECL LBDL J Base signal for transistor D of L-axis
08 LBEL LBEL : Base signal for transistor E of L-axis
09 LBFL LEEL : Emitter signal for transistor E of L-axis
10 LEEL LBFL : Base signal for transistor F of L-axis
11 LEL LEL : Emitter signal for transistor of L-axis
12 CDU1L CDU1L, CDU2L: Current detect of U phase of L-axis
13 CDU2L CDV1L, CDV2L: Current detect of V phase of L-axis
14 CDV1L
15 CDV2L
CN4M
01 VHM VHM : Collector signal for transistor of M-axis

02 LB AM LB AM : Base signal for transistor A of M-axis
03 LBBM LEAM : Emitter signal for transistor A of M-axis
04 LEAM LBBM : Base signal for transistor B of M-axis
05 LBCM LBCM : Base signal for transistor C of M-axis
06 LBDM LECM : Emitter signal for transistor C of M-axis
07 LECM LBDM : Base signal for transistor D of M-axis
08 LB EM LB EM : Base signal for transistor E of M-axis
09 LBFM LEEM Emitter signal for transistor E of M-axis
10 LEEM LBFM : Base signal for transistor F of M-axis
11 LEM LEM : Emitter signal for transistor of M-axis
12 CDU1M CDU1M, CDU2M: Current detect of U phase of M-axis
13 CDU2M CDV1M, CDV2M: Current detect of V phase of M-axis
14 CDV1M
15 CDV2M
1-230
CN1L L-axis servo interface signals
*PWMAL *PWMDL *PWMAL(*ALM1), COMAL ' PWM signals and

01 14
(*ALM1)
08 IRL
(*ALH8) *PWMBL ( *ALM2 ) , COMBL their commons
*PWMCL (*ALM4) , COMCL PWMA through PWMD
02 COMAL 15 COMDL
09 GDRL *PWMDL (*ALM8) , COMDL are also used to
*PWMBL *PWMEL, COMEL send an alarm
03 (*ALM2) 16 *PWMEL *PWMFL, COMFL
10 ISL
code.
04 COMBL 17 COMEL
IRL, GDRL : Phase-R current
11 GDSL ISL, GDSL : Phase-S current
*PWMCL *MCONL : MCC control
05 (*ALM4) 18 *PWMFL
12 *MC0NL *DRDYL : Servo amp. ready
06 COMCL 19 COMFL
GND : Ground
13 GND
07 *DRDYL 20
CN1M M-axis servo interface signals
*PWMAM *PWMDM *PWMAM(*ALM1) , C0MAM ’ PWM signals and

01 (*ALM1) 14 (*ALM8)
08 IRM
*PWMBM(*ALM2) ,C0MBM their commons
*PWMCM(*ALM4) ,C0MCM PWMA through PWMD
02 COMAM 15 COMDM
*PWMDM(*ALM8) , C0MDM are also used to
09 GDRM
*PWMBM *PWMEM, COMEM send an alarm
03 (*ALM2) 16 *PWMEM
*PWMFM, COMFM code.
10 ISM
04 COMBM 17 COMEM
IRM, GDRM : Phase-R current
11 GDSM ISM, GDSM : Phase-S current
*PWMCM *MCONM : MCC control
05 (*ALM4) 18 *PWMFM
12 *MCONM *DRDYM : Servo amp. ready
06 COMCM 19 COMFM
GND : Ground
13 GND
07 *DRDYM 20
1-231
26.2.4 LEDs
HV High voltage The DC voltage of the main power supply is higher than
(R) alarm 450 V.
a. AC power supply is higher than the specified range.
b. The regenerative energy discharge circuit becomes
defective, which includes the PCB, the transistor Ql,
and discharge resistor or the separately mounted
discharge unit.
c. Servo motor or the power cable for motor insulation is
defective.
d. Load inertia is excessive.
HC High current The DC current through the main DC power supply is too
(R) alarm high.
a. Transistor module is defective.
b. Short-circuit failure in the motor or the cable.
c. PCB is defective.
LV Low voltage Regulated power supply +15 V or +5 V on PCB is abnormally

(R) alarm low.
b. PCB is defective.

alarm overloaded.
c. The setting of jumper S2 is improper.
Refer to 26.2.6 for proper settings.

(G) ready
1-232
A16B-1200*0720
fL
CH4
L
LT
ru
CN4
M
HV
HC
LV (RED)
LT
DC
OH ru
CN3
ODRDY
(GREEN)
CN1IC
_r
CN1L
Location of LEDs
1-233
l
26.2.5 Test points
Test points Symbol Contents
CH1L, M *PWMA A-phase PWM signal
CH7L, M IR R-phase current
CH8L, M IS S-phase current
CH9 0 V 0 V (Ground)
CH10 +5 V +5 VDC
CH11 +15 V +15 VDC

CH12 -15 V -15 VDC
CH13 +24 V +24 VDC
AI6S-12004720
fL
CN4
L
Lr
FL
CN4
M
® CHI 3
Lr
® CHI2
© CHI l
© OHIO
ri
© CHS
© CHUi
® CH7M CN3
© CH8L
© CH7L
© CH1M
® CH1L _r
CN1M
CN1L
Location of test points on A16B-1200-0720
1-234
Axis
Jumper
No.
ft 1 n #3 #4 Meaning
U 1 ot MY e w
TOH setting
SI L H When the overheat signal is not provided
DC alarm setting
S2 L L When the discharge unit is not added,
Symbols #1 - #4 show the servo amp. No.
A16B-120WJ720
fL
CS4
L
Lr
CN4
M
Lr
a si ru
CN3
_r
CN1M
CN1L
Location of the jumpers
1-235
26.2.7 Removal/raplacamsnt
1) Unit
a) Remove the cables connected to the connector CN1L, CN1M and terminals Tl,
T2 and T4.
. CN1L, CN1M
(T) Squeeze the clamp release
to remove the connector.
I
Clamp
<=> <= a <=J release

the bottom.
the top and remove the unit.
Mounting screws, top
2) Component
Mounting screws, bottom
a) PCB
(D Release six PCB holders.
(2) Pull up PCB from connectors CN3, CN4L, CN4M.
Push to release
PCB,
A
"J
sL PCB holder
1-236
26.3 Three-axis Servo Amplifier
.
f ollows The NEW amplifier replaces the CURRENT amplifier.
ROBOT BASIC SPECIFICATION CURRENT AMPLIFIER NEW AMPLIFIER
S-10 Medium A05B-2066-H021 A06B-6058—H327 A06B-6058-H333
A06B-605&-H325 A06B-6058-H331
S-10 Large A05B—2067—H021 A06B-6058— H327 A06B-6058-H333
A06B-6O58—H325 A06B-6058-H331
(PWM) signals from the servo amplifier PCB through CN4L, CN4M and CN4N.
transmitted to the servo amplifier PCB through CN4L, CN4M and CN4N. Then it is
sent to the axis control board via CN1L, CN1M and CN1N. The regenerative
discharge circuit is in the power amplifier to absorb the energy from the motor.
circuit operates.
T1
E <9
Tl AC i»:rvo
—
A Cuncnt dckctor motor
+ 5LIUL
-ryr0"0—
To wrvo
tramtormer
200 VAC 3©
Ii TV1
i
JZLJ
-LV* Cl -
O
f m. Discharge
control circuit
IHHÿ
-
-r-7?
H-pfcO
U> namit
I brake
circuit
I0OA 3
i i -d i Current
det ector 5M 1 UM
AC servo
motor
X
{ MCC
TOTct'
100 B
--O-
-1
5 I 1 Dynamic
brake
Jf circuit
Current AC servo
o
detector motor
SN
T 55)
7M:
in Et i u
Dynamic
jjjy ss,
CN3
1
CN4L
1 CN4M CN4N
To axis control board CN1L
To axis control board CN1M

Servo amplifier PCB
A16B-1 100-0220
To axis control board CNIN
To servo transformer -OT4

overheat sensor (Note)
Note) Connected on Amp. 1 (W, U, 0). Not used on Amp. 2 (a, B, y) .

1-237
26.3.3 Connector/iignal identification
A16B*1100*0220
r~L
CN3
u IS
ri,
CN4
Lr
ru
CN4
N
I CK1L| | CN1M I I CN1N | 0

T1

A R 100A, 100B : 100 VAC single phase
UL, VL, WL]
1 S
UM, VM, WM : Three phase output for motor
UN, VN, WN
2 T
: Ground terminal
3 100A
4 100B
5L UL
6L VL
7L WL
5M UM
6M VM
7M WM
5N UN
6N VN O H"
7N WN O H"
1-238
T2

4 LCG
5
6 HCA
T4
1 T0H1
2 T0H2
CN1L L-axis servo interface signals
*PWMAL *PWMDL *PWMAL ( *ALM1) , COMAL : PWM signals and

01 08 IRL 14 *PWMBL(*ALM2) ,COMBL
(*ALM1) (*ALM8) their commons
*PWMCL (*ALM4) .COMCL PWMA through PWMD
02 COMAL 09 GDRL 15 COMDL *PWMDL(*ALM8) ,COMDL are also used to
*PWMBL *PWMEL, COMEL send an alarm
03 (*ALM2) 10 ISL 16 *PWMEL
*PWMFL, COMFL code.
IRL, GDRL : Phase-R current
04 COMBL 11 GDSL 17 COMEL
ISL, GDSL : Phase-S current
*PWMCL *MCONL : MCC control
05 (*ALM4) 12 *MCONL 18 *PWMFL
*DRDYL : Servo amp. ready
06 COMCL 13 GND 19 COMFL
GND : Ground
07 *DRDYL 20
CN1M M-axis servo interface signals
*PWMAM *PWMDM *PWMAM(*ALM1) , C0MAM : PWM signals and

01 08 IRM 14
(*ALM1) (*ALM8) *PWMBM(*ALM2) .COMBM their commons
*PWMCM (*ALM4 ) , C0MCM PWMA through PWMD
02 C0MAM 09 GDRM 15 C0MDM *PWMDM(*ALM8) .C0MDM are also used to
*PWMBM *PWMEM, COMEM send an alarm
03 (*ALM2)
10 ISM 16 *PWMEM
*PWMFM, COMFM code.
IRM, GDRM : Phase-R current
04 COMBM 11 GDSM 17 C0MEM
ISM, GDSM : Phase-S current
*PWMCM *MC0NM : MCC control
05 12 *MCONM 18 *PWMFM
(*ALM4) *DRDYM : Servo amp. ready
06
GND : Ground
COMCM 13 GND 19 COMFM
07 *DRDYM 20
1-239
CN1N N-axis servo interface signals
*PWMAN *PWMDN *PWMAN(*ALM1), COMAN ’ : PWM signals and

01 (*ALM1) 08 IRN 14 (*ALM8) *PWMBN (*ALM2 ) , COMBN their commons
*PWMCN(*ALM4) .COMCN PWMA through PWMD
02 COMAN 09 GDRN 15 COMDN
*PWMDN (*ALM8) , COMDN are also used to
*PWMBN *PWMEN, COMEN send an alarm
03 (*ALM2) 10 ISN 16 *PWMEN
*PWMFN, COMFN code.
IRN, GDRN : Phase-R current
04 COMBN 11 GDSN 17 COMEN ISN, GDSN : Phase-S current
*PWMCN
18
*MCONN : MCC control
05 12 *MCONN *PWMFN
(*ALM4) *DRDYN : Servo amp. ready
13 GND 19
GND : Ground
06 COMCN COMFN
07 *DRDYN 20
CN3
01 TH2 VH : Detect signal for HC alarm

02 TH1 VHV,VDR,VDS,VDT: Detect signal for discharge circuit
03 INTL2 (200 VAC for DC power supply)
04 INTL1 NFG : Ground for noise filter
05 MCC LCG : Collector signal for discharge circuit
06 100A LBG : Base signal for discharge circuit
07 LEG LEG : Emitter signal for discharge circuit
08 LBG 100A : 100 VAC
09 LCG MCC : Contactor control
10 NFG INTL1, INTL2 : Interlock of contactor
11 VDT TH1, TH2 : Overheat of heat sink
12 VDS
13 VDR
14 VHV
15 VH
CN4L
01 VHL VHL : Collector signal for transistor of L-axis

02 LBAL LBAL : Base signal for transistor A of L-axis
03 LBBL LEAL : Emitter signal for transistor A of L-axis
04 LEAL LBBL : Base signal for transistor B of L-axis
05 LBCL LBCL : Base signal for transistor C of L-axis
06 LBDL LECL : Emitter signal for transistor C of L-axis
07 LECL LBDL : Base signal for transistor D of L-axis
08 LBEL LBEL : Base signal for transistor E of L-axis
09 LBFL LEEL : Emitter signal for transistor E of L-axis
10 LEEL LBFL : Base signal for transistor F of L-axis
11 LEL LEL : Emitter signal for transistor of L-axis
12 CDU1L CDU1L, CDU2L: Current detect of U phase of L-axis
13 CDU2L CDV1L, CDV2L: Current detect of V phase of L-axis
14 CDV1L
15 CDV2L
1-240
CN4M
01 VHM VHM : Collector signal for transistor of M-axis

02 LB AM LBAM : Base signal for transistor A of M-axis
03 LBBM LEAM : Emitter signal for transistor A of M-axis
04 LEAM LBBM : Base signal for transistor B of M-axis
05 LB CM LBCM : Base signal for transistor C of M-axis
06 LBDM LECM : Emitter signal for transistor C of M-axis
07 LECM LBDM : Base signal for transistor D of M-axis
08 LBEM LBEM : Base signal for transistor E of M-axis
09 LBFM LEEM : Emitter signal for transistor E of M-axis
10 LEEM LBFM : Base signal for transistor F of M-axis
11 LEM LEM : Emitter signal for transistor of M-axis
12 CDU1M CDU1M, CDU2M; Current detect of U phase of M-axis
13 CDU2M CD VIM, CDV2M: Current detect of V phase of M-axis
14 CDV1M
15 CDV2M
CN4N
01 VHN VHN : Collector signal for transistor of N-axis

02 LBAN LB AN : Base signal for transistor A of N-axis
03 LBBN LEAN : Emitter signal for transistor A of N-axis
04 LEAN LBBN : Base signal for transistor B of N-axis
05 LBCN LBCN : Base signal for transistor C of N-axis
06 LBDN LECN : Emitter signal for transistor C of N-axis
07 LECN LBDN : Base signal for transistor D of N-axis
08 LBEN LBEN : Base signal for transistor E of N-axis
09 LBFN LEEN : Emitter signal for transistor E of N-axis
10 LEEN LBFN : Base signal for transistor F of N-axis
11 LEN LEN : Emitter signal for transistor of N-axis
12 CDU1N CDU1N, CDU2N: Current detect of U phase of N-axis
13 CDU2N CDV1N, CDV2N: Current detect of V phase of N-axis
14 CDV1N
15 CDV2N
1-241
26.3.4 LEDs
HV High voltage The DC voltage of the main power supply is higher than 450 V.
(R) alarm a AC power supply is higher than the specified range.
b The generative energy discharge circuit becomes defective, which includes
the PCB, the transistor Ql, and discharge resistor or the separately mounted
discharge unit.
c Servo motor or the power cable for the motor is defective.
d Load inertia is excessive.
e Discharge unit is being used too much.
The DC current through the main DC power supply is too high.
HC High current
(R) alarm a Transistor module is defective!
b Short circuit failure in the motor or the cable
c PCB is defective
d “CAUTION - with this alarm, swapping boards can cause the new board to blow”
LV Low voltage Regulated power supply for +15 V or +5 V on PCB is abnormally
(R) alarm low.
.
b PCB is defective.

alarm overloaded.
c. The setting of jumper S2 is improper.
Refer to 26.3.6 for proper setting.


(G) ready
1-242
A16B-1100-0220
XI
CN3 CN4
L
XJ Lx
rx
CN4
M
Lf
O DRDY (GREEN)
HV
rx
HC CN4
LV (RED) N
DC
DH
LX
| CN1L | |CN1M | | CN1N | 0
Location of LEDs on A16B-1100-0220
XI A16B-1100-0330/02A
n
CN3 CN4
L
XJ Lf
rx
CN4
M
O DRDY (Green)
~ LX
HCl.
HCM
HCN
n,
OH (Red)
DC
HV CN4
LV J N
5V (Green)
LX
|CN1L | [CN1M | |CN1N | [3
Location of LEDs on A16B-1100-0330/02A
1-243
26.3.5 Test points
Test points Symbol Contents
CH1L, M, N >' }WMA A-phase PWM signal
CH7L, M, N : v R-phase current
CH8L, M, N : > S-phase current
CH9, 9L, M, N ( V 0 V (Ground)
CH10 4 5 V +5 VDC
CH11 4 15 V +15 VDC
CH12 -15 V -15 VDC
CH13 +24 V +24 VDC
A16B-1100-0220 A16B-1100-0330/02A
n, n n
CN4 CN4
CN3 L CN3 L
IS U Lr
ru ru
CN4 CN4
M M
CHI 3
CHI 2 Lr
® CHll
© CH10
CH9
fL SI
mm CH7L ru
CH8L
aa
CH9L OCH9M CH9N
CN4
N a CH13
CHll
S2 CH7M
CH8M
CN4
N
CH8L ©CH8M CH8N CH10 CH7N
CH7L
CH1L
O CH7M
©CH1M
CH7N
CHIN •i,
CH9
CH12
vm CH8N
CH9
IS Lr
CN1L CN1M |CNIN EE] CN1L | CN1M CNIN FT
Location of test points on Location of test points on
A16B-1100-0220 A16B-1100-0330/02A
1-244
26.3.6 Jumper setting*
Axis
Jumper
Amp. 1 Amp. 2 Meaning
:.'o.
W | U | Q 7T_jT~a
TOH setting
SI L H When the overheat signal is not provided
DC alarm setting
S2 L L When the discharge unit is not added,
A16B-1100-0220 A16B-1100-0330/02A
JI n 11 n
CN4 CN4
CN3 L CN3 L
u is
rL
CN4 CN4
M M
IS
ru |-L
CN4 Jumper CN4

N SI [|S2 N
“H" setting
SI QQS2 Lf IS
| CN1L CN1M | |CHIN | \TA\ |CNIL| |CNIM| I CN1N | 0
Location of jumpers A16B-1100-0220 Location of jumpers A16B-1100-0330/02A
1-245
26.3.7 Removal/replac8ment
1) Unit
a) Remove the cables connected to the connector CN1L, CN1M, CN1N and
terminals Tl, T2 and T4.
. CN1L, CN1M, CN1N
(D Squeeze the clamp release
to remove the connector.
damp
release

the bottom.
the top and remove the unit. Mounting screws, top
V'l
2) Component Mounting screws, bottom

a) PCB
I Release six PCB holders.

Pull up PCB from connectors CN3, CN4L, CN4M, CN4N.
PCB Push to release

PCB.
A
IT 3
PCB holder
r
u
1-246
26.4 Discharge Unit
26.4.1 Location of discharge unit
S-700
—art
DOJI
26.4.2 Removal/repiacement
1) Specification
A06B-6050-H050
©
2) Procedure
© £
Disconnect cables from the
discharge unit. ©
© Remove the unit by loosening
two screws ©.
3) Caution
V
When discharge units have been replaced, check that units are correctly
oriented.
Top
o
ran
C4
ft
Bottom
DCU1
1-247
27. OPERATOR'S PANEL
There are three types of operator's panels.
- Horizontal type operator's panel
This type is used in the S-10 controllers with medium size cabinet. See Fig.
3.2 (f).
- This
Vertical type operator's panel for remote CRT/KB
type is used in the S-10 and S-700 controllers with large size cabinets.
An RS-232-C serial port connector named CRT/KB is on the panel and is used to
connect the remote CRT/KB unit. See Fig. 3.2 (g).
- Vertical type operator's panel for built-in CRT/KB
This type is used in the S-10 and S-700 controllers with large size cabinets.
Since the RS-232-C port cable is routed inside the cabinet, the connector for
CRT/KB is not available on the panel. See Fig. 3.2 (g).
1) Horizontal type operator's panel (A05B-2045-C122)
(Front view) How meter

(Option)
L
mum
* ®
i
®
-
—
mu «o u»m an UMX
dÿdcrb ® ®
f-1 • i o **
$mx miM IW
L © ®
O' SK ~ ’rH' A
o
\Connector foe EMERGENCY STOP bottom
CRT/KB interface
Connector for RS-232-C Interface
(Rear view)
Connection of the hour meter
\
Operator’s
panel PCB
A208-1003-0040
H
Connection of the EMERGENCY
STOP button
EMG1 [o
EMG2 [o~
I CNS , 1
/
OP1.0P2
(Note)
Connection of the
EMERGENCY STOP contact
Connector for shared RAM interface
Note) For customer use, a contact output is available at this terminal.

Contacts of EMERGENCY STOP buttons on the operator's panel and the teach
pendant are connected in series and appear at this terminal.
1-248
2) Vertical type operator's panel for remote CRT/KB (A05B-2051-C122)
(Front view)
rue* rtNOMTT rtML O
mo ON
@ @ @ •
M
CTCU BMW I •»
©
crp-£
©
irÿrr o
HOT
© © MI1UML
Naur mm
tma UM
mm
MU UM
B«won
m
• e © ©
Connector for
remote CRT/KB
Connector for
RS-232-C interface
o
irtcrt
r""i
i
o o
>
i
i
i
wr/a
r-
t
i
i
_i
o,
Hour meteT
(option)
EMERGENCY
STOP button
(Rear view) O

A20B-1003-0040
Connection of the hour meter O o
\
Vn
Connection of the Connector for shared
JL
ol lo
EMGl
EMG2 a I CNS
/
RAM interface
OP1 OP2
o
(Note)

1-249
3) Vertical type operator's panel for built-in CRT/KB (A05B-2051-C121)
(Front view)
1UCH MtfMMT »AML O
tMUUS
© ©
MOT
©
cmi CAUBMIf* I »
© ©
rmIT
0 MU
o **
© © OWOmUML
FAULT tan
MS* UM*
MU
B «ÿ
© ©
o
0 Hour meter (option)
n*n-e O
Connector for i
RS-232-C interface i
II 1W
I
i EMERGENCY STOP button
L-J
O
(Rear view) o o

A20B-1003-0041
o o
\ Connector for built-in CRT/KB

Ti interface
Connection of the CN3

*
I I I I EMG1 O
Connector for shared RAM
EMG2 to interface
Ol [o | CNS
OP1 OP2
o o
7
(Note)

1-250
CN5 (connector for shared RAM interface)
33 RSC 19 RDB 1 RSB TPENBL TEACH PENDANT ENABLED LED

34 0 V 20 0 V 2 0 V PENBL PANEL ENABLED LED
35 ERC 21 SDB 3 ERB INCYC IN CYCLE LED
36 DRC 22 0 V 4 DRB NOTCAL NOT CALIBRATED LED
37 CSC 23 RDC 5 CSB ULED1 USER LED #1
38 0 V 24 0 V 6 TP3 ULED2 USER LED #2
39 PENBL 25 SDC 7 CSTART Fault FAULT LED
40 TPENBL 26 0 V 8 CALIB HELD HELD LED
41 INCYC 27 ONI 9 FRESET C START CYCLE START button
42 NOTCAL 28 ON 2 10 HOLD CALIB CALIBRATE button
43 FAULT 29 0FF1 11 OTREL UPB1 USER PB #1
44 HELD 30 OFF 2 12 REMOTE UPB2 USER PB #2
45 ULED1 31 0 V 13 UPB1 FRESET FAULT RESET button
46 ULED2 32 0 V 14 UPB2 HOLD HOLD button
47 +24 V 15 ESTOP OTREL OVERTRAVEL RELEASE button
+24 F
48
49
+24 V
+24 V
16
17 +24 F
ONI
0N2 1 Contact of the POWER ON button
(normally open)
50 18 TP4 0FF1
OFF2 } Contact of the POWER OFF button
(normally closed)
CN3 (built-in CRT /KB interface) REMOTE REMOTE switch
ESTOP EMERGENCY STOP switch
1 8 RDC 14 +24 V RDB Receiving data
2 9 SDC 15 SDB Sending data
3 10 16 RSB Request to send
4 11 17 0 V CSB Clear to send
5 ERC 12 18 DRC DRB Data set ready
6 13 19 CSC ERB Data terminal ready
7 20 RSC The six signals listed above are for
the RS-232-C interface
RDC : Receiving data
SDC : Sending data
RSC : Request to send
CSC : Clear to send
DRC : Data set ready
ERC : Data terminal ready
The six signals listed above are for
the CRT/KB interface
TP3 I
TP4 ) : Extra emergency stop output
+24 F
:
+24 VDC power connection for
0 V RS-232-C interface
+24 V +24 VDC power connection for
0 V ' operator's panel
1-251
Contact output of emergency stop
1 EMG1 EMG1 1 #
Contact output of emergency
2 EMG2 EMG2 j *
stop buttons
Connection of emergency stop

— oTo-oTo-
Op. panel Teach pendant
EMG1
EMG2
0P1 1 >
Emergency stop contact which is
*
0P2 J used to interrupt 100 VAC for
servo amp's.
OP1 OP2
100A
100B ) 100 VAC which is available when
there are no emergency stop
conditions.
100A 100B
Connector for RS-232-C interface
1 FG 14 RDB Receiving data

2 SDB 15 SDB Sending data
3 RDB 16 RSB Request to send
4 RSB 17 CSB Clear to send
5 CSB 18 DRB Data set ready
6 DRB 19 ERB Data terminal ready
7 0 E 20 ERB FG Frame ground
8 21 +24 R: +24 V power supply for RS-232-C
9 22 drive
10 23 0 E :0V
11 24
12 25 +24 R
13
Connector for CRT /KB interface
1 FG 14 RDC : Receiving data

2 SDC 15 SDC : Sending data
3 RDC 16 RSC : Request to send
4 RSC 17 CSC : Clear to send
5 CSC 18 DRC : Data set ready
6 DRC 19 ERC : Data terminal ready
7 0 V 20 ERC FG : Frame ground
8 21 +24 V: +24 V power supply for CRT/KB
9 22 drive
10 23 0 V :0V
11 24
12 25 +24 V
13
1-252
1) Unit
a) Procedure
(I) Disconnect all cables from the operator’s panel.
I Remove the operator's panel by loosening six screws (2).

For mounting new unit, reverse the above procedure.
©
T
Operator’s
© panel Operator's
panel
2)—©
\
©
T
Vertical type Horizontal type

2) Component (lamps and switches)
a) Procedure
$ Disconnect the soldered wire from lamp or switch.

Remove the lamp or switch by loosening the nuts.
(3) For mounting new lamp or switch, reverse the above procedure.
3) Component (EMERGENCY STOP button)
a) Procedure
(I) Disconnect all cables © from the EMERGENCY STOP button.
(2) Remove the top of button by loosening a screw ©.
(3) Remove the button by loosening a ring © .
© For mounting new button, reverse the above procedure.
l
T
nt i i i t i in
©
1-253
28. BATTERY UNIT
Backplane connector
1 VB VB: Battery (+ side)
2 OV OV: Battery (- side)
3 ‘Battery case
Backplane connector
Various data of the user program is saved in the RAM by back-up batteries.
These batteries should be replaced with new ones annually. When the voltage of
the batteries becomes too low, CRT and teach pendant display shows: “10017 Backup Battery Low Voltage.”
Change them according to following procedure:
1) Procedure
8Keep the controller power on.

Open the front door of the controller.
8Remove the battery case cap.

Take out old batteries from the battery case.
© Set the new batteries into the battery case. Pay attention to the
direction of batteries.
© Put the case cap on the battery case.
© ©
Batteries
Battery case cap
1-254
29. OUTLET UNIT AND GROUND CONNECTED LAMP
29.1 Lamp
A lamp called Ground Connected Lamp is installed under the handle of the main
cabinet. Its lighting indicates that the one terminal (L2) of the outlet is
connected to the ground and 115 VAC is output to the secondary side of the user
transformer. When this lamp is pressed in halfway, it goes out. When it is
pressed in all the way, the lamp lights again. Its lighting indicates that
115 VAC is output to the secondary side of user transformer.
29.2 Fuse
.....
One fuse is installed in the outlet unit. This fuse is provided for the output
of the outlet terminals.
Fuse specification A60L-0001-0101#PL475L
o
© Q-- FI
©
o o
Location of fuse on the outlet unit
1) Unit (Ground Connected lamp)
a) Procedure
© Remove the ring ©
from the Ground Connected lamp.
The Ground Connected lamp can be removed with connection cables
attached.
© Disconnect all cables from the lamp.
© For mounting new lamp, reverse the above procedure.
Front view of the lamp
2) Component (lamp)
a) Procedure
© Remove the Ground Connected lamp, according to the above procedure
©, ©•
s Remove the cap of the lamp.
For mounting new lamp, reverse the above procedure.
Cap
1-255
30. SERVO-ON RELAY UNIT AND SERVO-ON LAMP
O
100A
100B } : 100 VAC input for servo-on
relay unit
SVON1 © RL9 SV0N1
SVONC
Relay output terminals
: SV0N1 --
SVONC; Normally open
SVONC © SV0N2. SVONC SV0N2; Normally closed
SVON2 ©
100A ©
O
100B ©
30.2 Lamp
A lamp called servo-on lamp is installed under the ground connected lamp of the
main cabinet. Its lighting indicates that 100 VAC is supplied to the servo
amplifiers. When this lamp is pressed in halfway, it goes out. When it is
pressed in all the way, the lamp lights again. Its lighting indicates that
100 VAC is available in the controller.
]
m
Ground connected lamp
. Servo-on lamp
1-256
1) Unit (servo-on relay unit)
a) Procedure
Op Disconnect all cables ©
from the servo-on relay unit.
© The servo-on relay unit can be removed by loosening two screws ©.
© For mounting new unit, reverse the above procedure.
CD— I
2) Component (relay)
Remove the spring that clamps the relay to its socket by pulling it in the
direction indicated by the arrow ( ) shown above. Then remove the relay
by pulling it in the direction ( ) shown above.
Relay removal direction
ft
<=P Spring removal direction
Relay
\ Securing spring
Socket
Relay RL8
3) Unit (servo-on lamp)

a) Procedure
D Remove the ring ©
from the servo-on lamp.
2) The servo-on lamp can be removed with connection cables attached.
5) Disconnect all cables from the lamp.
4) For mounting new lamp, reverse the above procedure.
<D
4) Component (lamp)
a) Procedure
© Remove the servo-on lamp, according to the above procedure ©, ©.
(2) Remove the cap of the lamp.
© For mounting new lamp, reverse the above procedure.
Cap
1-257
31. FAN UNIT
31.1 Fan Unit for Large Size Cabinet

31.1.1 Operation of heat exchange system 7
Fan 4 V Fan 1
i
i
i
i
V
i
:|.. €>
l
y r Fan 5
5 i
i
6>
Fan 2
0
/
/
1
Location of fan units
The controller incorporates an air-to-air heat exchange system. The electric

components of the controller are isolated from outside air except for the bottom
segment of the side cabinet where the servo transformer and discharge units are
installed. Air flow direction is as shown below.
Fanl
I J
Fan 4
11
Fan3 I,
FanS
Fan2
Main cabinet
Air flow Side cabinet
1-258
1) Fan 1
a) Specification
7
& \
A05B-2051-C901 (fan unit) i
A90L-0001-0043 (fan motor)
b) Procedure
*
(T) Disconnect the cables from ©
the fan unit.
(2) Remove the unit by loosening © 4
©©
four screws (2) .
(5) Disconnect the cables from
the fan motors.
(4) Remove the fan motor from
the plate by loosening four
screws (§) .
(|) Remove the finger guard from
the fan motor by loosening
four screws • © mounting
a new fan motor, reverse the 11
—
above procedure. &
Airflow
2) Fan 2
1
a) Specification v /yy
A05B-2051-C902 (fan unit)

A90L-0001-0213#A (fan motor) i /
i
b) Procedure
2
(T) Disconnect the cables from
the fan unit. rcr--'
(2) Remove the unit by loosening i
four screws (2) .
For mounting
a new fan unit, reverse the
above procedure. 2 2.
3) Fan 3 I
a) Specification
A90L-0001-0043 (fan motor)
b) Procedure
© Disconnect the cables from
3
©
©
Ofw
the fan unit.
© Remove the unit by loosening
four screws (2) . ©i ©i
© Disconnect the cable from
the fan motor.
© Remove the fan motor from
screws (4) . A
© Remove the finger guard from
four screws (5) .
For mounting
a new fan motor, reverse the
above procedure. ©@©@ Aif flow
1-259
4) Fan 4 1
a) Specification
A90L-0001-0213#A (fan motor)
b) Procedure
Disconnect the cables from
the fan unit. A
(?) Remove the unit by loosening
©
four screws (?) .
For mounting
a new fan unit, reverse the V
above procedure.
<D © Air flow
5) Fan 5
a) Specification
A9OL-OOO1-O2130A (fan motor)
b) Procedure
Same as the Fan 2.
1-260
31.2 Fan Unit for Medium Size Cabinet
31.2.1 Operation of heat exchange system
Fan 1
/
A.
fA-
LW
Fan 2
Location of fan units
The controller incorporates an air-to-air heat exchange system. The electric

components of the controller are isolated with outside air. Air flow
direction is as shown below.
->
I T
Fan 1
V
/,
Fan 2
Air flow
1-261
31.2.2 Removal/replacement 3
1) Fan 1
a) Specification
A05B-2045-C901 (fan unit) 1
A90L-0001-0099#A (fan motor)
b) Procedure
©
©
Disconnect cables from the
fan unit.
Remove the unit by loosening
four screws (2) .
CD i
®
© Disconnect cables from fan
@
motors.
Remove the fan motor from
®
screws ©.
© Remove the finger guard from 4
four screws © .
For mounting a new fan motor,
urn
fir
(111
R H
Airflow
2) Fan 2
2
a) Specification
A90L-0001-0049 (fan motor)
b) Procedure
© Remove the fan unit by
loosening four screws © . /
© Disconnect the cables from
©
the unit.
Remove the fan motor from
the plate by loosening two
</ (MJ7
screws ©.
For mounting a new fan motor,
reverse the above procedure. i
3
1-262
32. ABSOLUTE PULSE CODER
The Absolute Pulse Coder is made up of a rotating mechanism, an LED, a code
disk, photo cells, and a signal processing circuit. The code disk contains
several slits. As the disk rotates on a shaft the slits in the disk alternately
block and permit light to the photo cells.
The photo cells receive the interrupted light beams which the signal processing
circuit converts to digital electrical signals. The signals are amplified and
transformed into a square wave-form of C-MOS level as PA and PB in Hybrid IC 1.
Signals PA and PB are applied to the Feedback Pulse Detector and the Output
Selector contained in the LSI chip. The Feedback Pulse Detector generates plus
and minus pulses according to the rotary direction of the code disk. A 28-bit
counter increments the plus pulses and decrements the minus pulses.
The REQ Signal Receiver is a level converter to C-MOS level. The absolute pulse
coder receives the data request signal, REQ. The Data Converter translates the
32 bits of data, 28 bits of counter data and A bits of alarm data into serial
data. At the same time, the Output Selector selects signals from the Data
Converter, and the serial data is transmitted to the controller through two
pairs of phase signals as A, *A, B, and *B. Following the data transmission,
the Output Selector selects signals PA and PB and position control operation is
available.
The Absolute Pulse Coder also has a Power Selector in Hybrid IC 1. When
+5 volts is not applied to the pulse coder from the power supply, the power
select circuit obtains power from the battery unit.
1-263
w
VS)
VO
s
Absolute puke coder CLK TCI
Io
(F) TC2 &
AC servo motor
m
Clock -1 (W) R
EQ_n S
EE
Photo diode
generator
(HYB, 2)
nk “REQ" signal
receiver (HYB, 4)
<9 XREQ
3
“I
o o o oo Custom LSI (2600 gates) i
oo oo oo "REQ"
l
l
I
LED DETEC- I
TOR Axis Control Board
i
M i
Feed back pulse Counter I
I
I detector M 28 bits
Servo CPU.
i
TO
V
i
I
Amplifier
I
Data converter
I
VR1
(A)
Alarm
4 bits =2 A, B phase
32 bits data to \ p/°
IC=!
ro VR2
ON (B)
4S I
A
t-i Driver •A
VR3
(Z)
Amplifier
(A, B)(HYB, 1) PB<ÿ
~~
1 > -f~
I
Driver
B Counter
K-J
rCl. i-r« cs i
VR5 Output selector I Z
L
(C)
Driver
Amplifier
(C, 2) (HYB, 3)
r
: ) CI-C8
Battery Tl? +5V
T
Power selector
(HYB, 1)
fir PA
VR4
(V)
l (and detecting battery voltage)
jfr Dr
PBi_r~L_r
AC servo motor
Power Signal
Battery
Standard type
Signal (MS 3102A 22-14P)
A A L +5V A, *A, B, *B : Count signal

B *A M 0V Z, *Z : Reference signal
C B N SHIELD Cl, C2, C4, C8: Phase control signal for AC servo
D *B P 0H1 motor
E Z R OH 2 +5V, 0V : Power supply from controller
F *Z S REQ 0H1, 0H2 : Over heat signal of servo motor
G Cl T +6 A REQ : Data request signal
H C2 U OVA +6V, OVA : Power supply from battery unit
J C4 V
K C8
Battery (MS3102A 10SL-4P)
I A | +6VB | B | OVB +6VB, OVB : Power supply from battery unit

Signal
Wire color Signal Wire color Signal

Black *A Gray 0V
Blue *B Orange REQ
Green *Z Red/White +6A
Orange /White C2 Gray /White OVA
Brown/White C4 Red (thick) +6B
Purple /White C8 Gray (thick) OVB
Red +5
1-265
V.R. Standard setting Remarks
VR1 Adjustment of the duty of A or *A

(A) (Pulse coder outputs)
Duty “ 50:50
VR2 Adjustment of the duty of B or *B

(B) (Pulse coder outputs)
Duty * 50:50
VR3 Adjustment of the level of Z and ZR

(Z) (Photo diodes outputs)
Note
ZR vi
V2 V1.V2 J 15 mV
Z
VR4 Adjustment of the voltage of T1

(V) T1 voltage = 4 jÿ).04V
(When +6A or +6B are supplied 6V, and +5V is off)
VR5 Adjustment of CS level which is the comparison

(C) level of Cl, C2, C4, C8 (Photo diode outputs).
C1-C8
T2
CS
AF VI. v: 2 15 mV
Note) VR3 is used for the adjustment of the both *Z and C2, C4, C8 signals-
Trimmer capacitors
V.R. Standard setting Remarks
TCI Adjustment of the frequency of CLK

(F) F = 10 kHz
TC2 Adjustment of the low level width of CLK

(W) Low level width = 600 ns
1-266
3) Output waveform
a) Count signal
Aw.
*A
(Note) 1
Bw
B EL
•B
(Note)
rr
U-l
0.45*T £ Aw, Bw 2 0.55 T 'H' 2 2.4 volt
0. 14*T £ a, b, c, d fLf 2 0.4 volt
Upper drawing shows the waveform with CW rotation. When the shaft is
rotated in CCW direction (viewed from shaft end), signals ’’A’1 and "ÿA" are
interchanged with B and *B respectively.
b) Reference signal
I Zw
1
•z
(Note)
1 *T < Zw < 3*T ’H* 2 2.4 volt

’L' £ 0.4 volt
1-267
32.5 Test Points
1) When or "+6B" are supplied 6 V, and "+5V" is off.
Test points Specifications
T1 Voltage 3.96 V - A. 04 V
TO Voltage 1.5 V - 2.5 V

ON Voltage 63.93 V
BT Voltage 63.93 V
CT Voltage £0.05 V
CLK Waveform
TL
T
580 nS TL S 620 nS
98 MS % T £ 102 MS
AM Waveform Inverse waveform of ’’CLK"
2) When ”+5" is supplied 5V, and "+6A" and "+6B" are off.
Test points Specifications
T1 Voltage 64. 7 V
TO Voltage 1.5 V - 2.5 V

ON Voltage 64.7 V
BT Voltage £0.05 V
CT Voltage 64.7 V
CLK Frequency 1.1 MHz - 1.9 MHz

AM Voltage 64.7 V
XREQ Duty 64.5 V (When "REQ” is supplied 0 V.)

£0.4 V (When "REQ" is supplied 10 V.)
PA Duty 45:55 - 55:45 (When the shaft is rotating.)
PB Duty 45:55 - 55:45 (When the shaft is rotating.)
1-268
c) Phase control signal for AC servo motor
Cl
— —
t 2t
C2
C4
4t
— 2t 4t
8t
C8
8t 8t
’H' * 2.4 volt

’L* £ 0.4 volt
The drawing above shows the waveform with CW rotation. When the shaft is
rotated in CCW direction, signal "C8" has an inverted waveform.
32.6.1 Replacing pulse coder
1) Replacing pulse coder
The method written here is applicable to AC servo motor models 0, 5, 10, 20,
30 and 30R. It is impossible to remove the pulse coder from the other motor
models (2-0, 1-0, 3-0, 4-0, 5-0), because, for those types, the pulse coder
itself is directly assembled onto the motor shaft.
a) Remove the defective pulse coder.
© Remove rubber cap.
© Unfasten bolt (T) .
m Unfasten screw (2) .
© Remove pulse coder (+attachments) from the motor shaft.
b) Mount new (good) pulse coder.
(T) Mount pulse coder (+attachments) on the motor shaft. Notice that both
a tooth (of coupling) and a groove (of pulse coder) are just fitted
together. Care should be taken, for fitting length is short.
.
I Connect both shafts by bolt (I)
Adjust marking-off line between attachments of pulse coder and motor
housing .
© Fasten screw ©.
1-269
Attachments
Pulse coder
Motor shaft
Pulse coder shaft
©
BoltCD (M S)
V//////A
Coupling I
1 Rubber cap
1
Ii K Scrtw©(M 4)
Mark-offline
Motor housing
2) Checking the phase-relationship

The method written here is applicable to all models of FANUC AC servo motors.
OD Connect V and W of motor power line.
Qp Excite motor at rated DC current from U to V and W. (U: +, V and W: -)
Qy Supply 5 VDC to the pulse coder, and check signals of Cl C8. Correct
pattern is as follows.
-
Cl C2 C4 C8
1 1 1 1
or 1 1 1 0 (Note) (1: HIGH, 0: LOW)
Note) C8 is "0" for CCW rotation.

Rated DC current at the check of phase relationship is as follows:
o
u MOTOR MODEL 3-0, 4-0 1.2 A
1-0, 2-0 4 A
0.5 9 A
o 10 15 A
20, 30 30 A
3OR 40 A
w
1-2 70
32.6.2 Replacing batteries
Caution) Be sure that the power source from the controller is on before removing
or replacing batteries. If there is no power to the absolute pulse
coders* remastering of theÿmechanical unit will be required.
1) Removing dead batteries
Unfasten two screws (T) and remove the lid.
$ Remove dead batteries.
2) Mounting new batteries
(I) Mount four new alkaline manganese dioxide batteries. Check their
polarity to ensure they are installed correctly.
© Fasten two screws (p to attach the lid.
•creWT)
/
m
\ ® ® /
Battery case for absolute pulse coder
1-271
II. S-10 MECHANICAL UNIT MAINTENANCE
t.
!
!
!
I
i
i,
'
/
t
1. CONFIGURATION
Fig* 1 shows the configuration, of the mechanical unit*
a-axis AC servomotor
!
V 9 Wrist unit
7-axis AC servomotor
U-axis AC servomotor /J-axis AC servomotor
.3
tUv-
mm
U-axis arm
H » «
v\
e
TT W-axis arm
W-axis base
W-axis AC servomotor
I
[
[ \ 0-axis base
Terminal unit
Fig. 1 Mechanical unit configuration (S-10)
2-1
1.1 0-axis Drive Mechanism
Fig. 1.1 shows the 0-axis drive mechanism.
The rotation of the AC servomotor is decelerated by the RV reducer. The 0-axis
drive is responsible for rotating the entire robot assembly.
Note) For manual movement, the 0-axis moves in the rotary direction of the
manual crank.
Box wrench with rachet A

(Manual Crank)
\ W-axis base
Cover
Reducer \
trr
\>
a
*
\ Hexagon head
(width 14)
Bracket
£ [
V
model 5RF
q—g 0-axis base
Fig. 1.1 0-axis drive mechanism (S-10)
2-2
1.2 W-axis Drive Mechanism
Fig. 1.2 shows W-axis drive mechanism. The rotation of the AC servomotor is
decelerated by the reducer and rotates the W-axis. The RV reducer supports the
W-axis arm.
Note) For manual movement, the W-axis moves in the rotary direction of the
manual crank.
Hexagon head W-axis arm
(width 14)
t W-axis base
Box wrench with ratchet

/
(Manual crank)
43'
Cover
Reducer
7111S
7 W-axis AC servomotor
model 5RF
Section A-A (Refer to Fig. 1.1)
Fig. 1.2 W-axis drive mechanism (S-10)
1.3 U-axis Drive Mechanism

Fig. 1.3 shows the U-axis mechanism. The rotation of the AC servomotor is
decelerated by the reducer and rotates the U-axis unit. The U-axis unit is
supported by the U-axis RV reducer.
Note) For manual movement, the U-axis moves in the direction opposite to the
rotary direction of the manual crank.
Box wrench with ratchet

(Manual crank)
\
Cover Hexagon head (width 11)
. t
Reducer W-axis arm
U-axis AC servomotor
model 1-OB ’fro
\W
Bevel gear
Section A-A (Refer to Fig. 1.4)
Fig. 1.3 U-axis drive mechanism (S-10)
2-3
1.4 7’ax's Drive Mechanism
Fig. 1.4 shows the y-axis drive mechanism. The rotation of the AC servomotor is
decelerated by the harmonic drive and rotates the U-axis arm. The U-axis arm is
supported by the U-axis housing via the reducer and cross roller bearing.
Cross roller bearing-
Reducer U-axis housing
7-axis AC servomotor U-axis arm

model model 2-OSB
A IL >
7
A
i
— JT
t
¥
U-axis AC servomotor
model 1-OB with brake
W-axis arm
Fig. 1.4 y-axis drive mechanism (S-10)
1.5 0-axis Drive Mechanism

Fig. 1.5 shows the S-axis drive mechanism. The rotation of the AC servomotor is
decelerated by the harmonic drive and rotates the o-axis unit via the bevel
gear.
ot-axis unit
/3-axis AC servo motor

model 3-OFB
Harmonic drive Bevel gear
2-4
1.6 a-axis Drive Mechanism
Fig. 1.6 shows the a-axis drive mechanism. The rotation of the AC servomotor is
decelerated by the harmonic drive and rotates the output flange.
or-axis AC servomotor Harmonic drive

model 3-OFB
Output flange
Fig. 1.6 a-axis drive mechanism (S-10)
1.7 Major Component Specifications

1) Motor
Specification Axis Remarks
A06B-0345-B231 Q AC 5RF with brake
A06B-0345-B231 W AC 5RF with brake
A06B-0522-B351 U AC 1-0 with brake
A06B-0310-B351 Y AC 2-OS with brake
A06B-0368-B231 8 AC 3-OF with brake

(A05B-1204-J091) (Connector remodeling specification)
A06B-0368-B231 a AC 3-OF with brake

(A05B-1204-J091) (Connector remodeling specification)
2-5
2) Reducer
Specification Axis
A97L-0118-0801#121 e
A97L-0118-0801#153 W
A97L-0118-0802# 105 U
A97L-0118-0803#53. 5 Y
A97L-0118-0804 6
A97L-0118-0805 a
3) Unit
X',. Specification Remarks
A290-7 204-V201 0 cable guide unit
A290-7204-V202 0 terminal unit
A290-7204-V501 Wrist unit
A290-7204-V512 a-axis unit
4) Gear
Specification Axis
A290-7204-X411 U
A290-7204-X412 U
A290-7204-X511 8
A290-7204-X512 B
2-6
5) Shim
Specification Remarks
A290-7204-X421 0. 3t X411, For adjusting U-axis bevel gear

A290-7204-X422 0. It X412
A290-7 204-X430 0. 15t
A290-7204-X521 0. 5t X511 Wrist unit

A290-7204-X522 O.lt For adjusting 8-axis bevel gear
A290-7204-X523 0.03t
A290-7204-X529 0.15t
A290-7204-X524 0. 5t X512
A290-7204-X525 O.lt
A290-7 204-X526 0. 03t
A290-7204-X530 0. 15t
6) Cover
Specification Remarks
A290-7204-X305 W-axis motor cover
A290-7204-X410 U-axis motor cover
A290-7204-X323 W-axis cable cover
A290-7204-X324 U-axis cable cover
A290-7204-X325 G-axis cable cover
7) Cross roller bearing
Specification Axis
A97L-0001-0907//8016CS y
A97L-0118-05 13//5013CS 8
A97L-01 18-0513//4010CS a
2-7
2. LUBRICATING CONDITION CHECKS
1) Monthly check
Check the following once a month.
Item Check item Checking procedure
1 Lubrication of Remove the cover and check the gear surface for
B-axis wrist presence of oil, damage, smut and foreign substances.
gear box
2) Grease check
Never perform greasing procedures before turning off power. Oil is used in
the air route. Grease is used in other portions.
a) Applying grease
i) Apply grease normally every 3 months.
ii) For the greasing points and the greasing procedure, see Fig. 2 and
Table 2 (a).
iii) Parts not specified in Table 2 (a) need not be greased, since they
are grease-sealed bearings or oilless bearings.
Table 2 (a) Greasing Points
Item Greasing point Grease Qty Method of greasing
1 a-axis harmonic Harmonic grease 10 cc Pull out the plug for air
drive SK-1 vent, replace it with the
grease nipple which is
2 6-axis harmonic Harmonic grease 10 cc attached and apply grease
drive SK-1 to it.
(If the grease nipple
interferes with the welding
wire, etc., replace it
again with the plug after
greasing.)
3 6-axis gear box Molynoc grease 10 cc Remove the cover and supply
2 grease about 1/2 of gear
box capacity.
2-8
Table 2 (b) Recommended Lubricants
Oil (Air control set)
Mobil Oil DTE Oil Light
Esso Standard Tellesso 32
Shell Oil Shell Turbo Oil T32
Mitsubishi Oil Diamond Turbine Oil 32
Nippon Oil FBK Turbine 32
Idemitsu Kosan Daphne Turbine Oil 32
Maruzen Oil Special A Turbine Oil 32
3) 3-year check
Change grease for reducers of 0, W, U, and y axes and U-axis gear box every 3
years or 20,000 hours. Use the following procedure:
a) Remove the Q (W, U, y) grease nipple and the 0 (W, U) plug shown in Fig. 2
(b).
b) Blow in air through the hole from which the 0 (W, U, y) plug has been
removed to remove grease completely through the other hole.
c) Fit the Q (W, U, y) grease nipple and apply the grease specified in Table
2 (c).
d) Remount the Q (W, U, y) plug.
4) Cross Roller Bearing
Insert 5 cc of grease into the Gamma-axis cross roller bearing grease nipple. Rotate the axis to
achieve even disbursement of lubricant.
Table 2 (c) Locations Requiring 3-year Lubrication
Grease
Qty
(cc)
Nippon Oil Shell Oil
0-axis reducer EPNOC GREASE NO. 0 SHELL AL VANIA 150

EP GREASE RO
W-axis reducer 130
U-axis reducer 130
U-axis gear box 130
y-axis reducer 100
Cross-roller bearing MOLYNOC GREASE SHELL ALVANIA #2 | 5
2-9
'W-
'
7-axis straight plug /3-axis grease nipple 7-axis grease nipple

(RV reducer) (Harmonic drive) (RV reducer)
Gamma-axis cross roller bearing
/3-axis gear box (3-axis straight plug
(Bevel gear) (Harmonic drive)
fib
I Ii
2| U-axis grease nipple

U-axis straight plug
/ z/ a-axis straight plug
a-axis grease nipple
(Harmonic drive)
NJ U-axis grease nipple (Bevel gear)
(RV reducer)
NJ
l
K-*
8 O-axis straight plug
“•
<3
(RV reducer)
¥/\
TJ
h SO 4+1!ÿ-
mV
U-axis straight plug
3
<8 ?
b
(RV reducer)
\
z m 2}
W-axis grease nipple
W-axis plug
(RV reducer)
-
0-axis grease nipple

(RV reducer)
![
o
3. TROUBLESHOOTING
3.1 General
The source of mechanical unit problems may be difficult to find because of
overlapping causes. Problems may become further complicated, if they are not
corrected properly. Therefore, it is necessary to keep an accurate record of
problems and to take proper corrective actions.
3.2 Problems and Causes

Major problems in mechanical unit and their probable causes are listed below:
1) Robot will not calibrate.

a) (Cause) Voltage of the memory backup battery is low.
(Measure) Replace battery. (Refer to 5.10)
2) Position error
a) (Cause) Robot struck an obstacle.
(Measure) Revise the teaching points.
b) (Cause) Robot or peripheral machine is not firmly mounted.
(Measure) Mount firmly.
c) (Cause) Excessive Load.
(Measure) Reduce the load or speed.
d) (Cause) System variables are not standard.
(Measure) Change the system variables to standard settings.
e) (Cause) A cable is disconnected or broken.
(Measure) Replace the cable. (Refer to 7.2)
f) (Cause) APC abnormal.
(Measure) Replace the motor. (Refer to 5.1
g) (Cause) Excessive backlash.
-
5.9)
(Measure) See below.
3) The robot vibrates.

a) (Cause) The robot is not bolted securely on the floor.
(Measure) Tighten the bolts firmly.
b) (Cause) The floor itself vibrates.
(Especially when the robot is installed on the second floor and
higher. )
(Measure) Change the robot mounting place.
c) (Cause) Excessive Load.
(Measure) Reduce load or speed.
d) (Cause) The adjustment of the servo is faulty.
(Measure) Adjust the servo. (Consult GMFanuc)
e) (Cause) A cable is broken.
f) (Cause) Not grounded.
(Measure) Ground the robot.
g) (Cause) The motor or reducer is faulty.
(Measure) Replace the motor or reducer. (Refer to 5.1
h) (Cause) The axis control board PCB is faulty.
5.9)-
(Measure) Replace the axis control board PCB.
i) (Cause) The time constant is faulty.
(Measure) Revise time constant. (Refer to the KAREL System Reference r
Manual. )
j) (Cause) Excessive backlash.
(Measure) See below. 'is
-i
2-11
4) Excessive backlash
a) (Cause) Screws and pins are loose.
(Measure) Tighten screws. Coat the specified area with LOCTITE.
b) (Cause) The reducer is faulty.
(Measure) Replace the reducer. (Refer to 5.1
c) (Cause)
5.9)-
The adjustment of the gear backlash is faulty.
(Measure) Adjust the gear backlash. (Refer to 4.6
d) (Cause) A gear is worn.
4.7) -
(Measure) Replace the gear. (Consult GMFanuc)
e) (Cause) A bearing is worn.
(Measure) Replace the bearing. (Consult GMFanuc)
f) (Cause) A casing is broken.
(Measure) Replace the broken parts. (Consult GMFanuc)
k
5) Abnormal noise
a) (Cause) Grease/oil to the gear or reducer is insufficient.
(Measure) Grease. (Refer to 5.1
b) (Cause)
- 5.9)
Dust is in the gear or reducer.
(Measure) Flash and then grease. (Refer to 5.1
c) (Cause)
5.9) -
(Measure) Adjust the backlash. (Refer to 4.4
-
4.5)

f) (Cause) The adjustment of servo constants is faulty.
(Measure) Adjust servo constants correctly. (Consult GMFanuc)
6) Abnormal heat
(Measure) Grease. (Refer to 2)
b) (Cause) Nonspecified grease/oil is used.
(Measure) Replace the grease/oil. (Refer to 2)
c) (Cause) Overload.
(Measure) Decrease the load or speed.
d) (Cause) The adjustment of the gear backlash is faulty.
(Measure)
e) (Cause)
Adjust the backlash. (Refer to 4.4
The time constant is faulty.
-
4.5)
(Measure) Revise time constant. (Consult GMFanuc)
7) Drop of an axis when the power is turned off.

a) (Cause) Brake gap is noticeable.
b) (Cause) Brake drive relay is defective.
-
5.9)
(Measure) Replace the relay. (Refer to I, 23.4.6)

A 5 mm drop of the W or U axis is normal when power is interrupted while the
robot was not moving or when an emergency stop is made.
8) Leakage of grease/oil
a) (Cause) 0-ring 2, oil seal 2, or packing is broken.
pw. b) (Cause) Casing is broken.
c) (Cause) Screws are loose.
(Measure) Tighten screws.
[
2-12
Backlash less chan Che amounts shown in Che Cable is noc abnormal.
Table 3.2 (b) Axis backlash
e w u r B a
Angle conversion (min.) 1.5 1.5 1.5 3 8 3
DisplacemenC conversion 0.67 0.31 0.26 0.26 0.70 0.26

(mm) (1529) (700) (600) (300) (300) (300)
NoCe) The values of displacemenC conversion values shows backlash in Che

roCacing direcCion aC Che disCance from Che axis center, shown in ?
parencheses. >
f.
Table 3.2 (c) Allowable falling value
Ac power off 5.0 mm
AC emergency sCop 5.0 mm
3.3 Replacing Parts and Performing Adjustments

Adjustment is necessary whenever a part was replaced.
The table below shows the parts that require replacing and the items that
require adjustment.
Part to be replaced or function

Adjustment
to be changed
Replacement of cable (a) Forming of cable

(b) Limit switch
(c) Mastering
Replacement of limit switch (a) Limit switch and dog
0-axis stroke change (a) Dog mounting position, limit

switch
(b) Stop mounting position
(c) System variable
Replacement of batteries Replace them keeping power unit on.

(Replace every year) No adjustment is necessary.
2-13
4. ADJUSTMENTS
Mechanical parts have been adjusted to the optimum condition at the time of
shipment from our company. Therefore, they normally need not be adjusted by the
customer at the time of delivery.
Adjustments should be made as specified in this section after a long period of
use or after replacing a part.
4.1 Adjusting Limit Switches and Dogs

1) Zero position and working limit
Each controlled axis has its own home position and working limit area
(stroke).
The robot is controlled not to move beyond its working limit unless the servo
system fails or a system error in which the zero position is lost occurs.
When the controlled axis reaches its working limit, it is called overtravel
(OT). Overtravel for basic three axes (0-, W-, and U-axis) is detected by a
mechanical dog and a limit switch. If an alarm is generated, the robot
stops. Mechanical stops are provided at either end of each axis.
Fig. 4.1 (a) (g) show the zero positions of OT detection dogs, the
mechanical stops, and the motion limits (stroke) of each axis.
Adjust the limit switch and the dog so that the OT alarm is generated at the
position shown below:
0*
300*
+ 1 507+OT -0T\- I 50/
7k 4\ $
v/
f.
Stroke end Stroke end
Mechanical stop Mechanical stop
Note) The stroke can be changed.
Fig. 4.1 (a) 0-axis rotation (300°) (S-10)
2-14
Stroke end
Mechanical stop rL Stroke
135°
0*
-0T
+90* Stroke end
ID Mechanical stop
•HQT
Note) The motion range is limited by the U-axis position.
Fig. 4.1 (b) W-axis rotation (S-10)
Stroke end
\ + 1 20*
Stroke
265°
0*
Stroke end
-145*
Note) The motion range is limited by the W-axis position.
Fig. 4.1 (c) U-axis rotation (S-10)
0* Stroke
380°
+ I 93*
Mechanical stop f \\ - I 93*
Mechanical stop
+ 1,90-
Stroke end / - 190-
Stroke end
Note) 0T limit switches are not used in the y-axis.
Fig. 4.1 (d) y-axis wrist rotation (S-10)
2-15
Stroke end
Mechanical stop
Stroke
>140* 280°
0*
Mechanical stop \ /
- I 40*
Stroke end
Note) 0T limit switches are not used in the B-axis .

Fig. 4.1 (e) 0-axis rotation (S-10)
0* Stroke
540°
+270* . -270*
Note) The 0T limit switch and mechanical stop are not used in the a-axis.
Fig. 4.1 (f) a-axis wrist rotation (S-10)
2-16
-Stroke end
Mechanical stop
-0T
in
vO
+0T
1 %ÿ
tag Stroke end
! Mechanical stop
Note) The allowable range for the relative angle between the W-axis and U-axis
arms is a minimum of 15° and a maximum of 165°.
Fig. 4.1 (g) W/U limit interference angles (S-10)

4.2 6 -axis Stroke Modification
It is possible to limit the 6-axis stroke as required by the surroundings for
the robot. The stroke can be changed as shown in Fig. 4.2 (a) by changing the
dog position or the mechanical stop.
Include the position where the mastering jig is used (either one of 6 = 0°,
+90°, -90°), select the + and -
0T limits from the following:
Note) Standard stroke

Front
+ 1S* -IS* -150° to +150°
+30* ±0* -30°
+ 45*. -45° +0° -0°
+15° -15°
+ 60*, -60° +30° -30°
+45° -45°
+7S* —75° +60° -60°
+75° -75°
+90* -90*
+90° -90°
+105° -105°
+ 10S* -105* +120° -120°
-120* +135° -135°
+ 120 +150° l -150°
+ 135* -13S*
+ 150* -ISO*
Fig. 4.2 (a) Changing the 0-axis stroke (S-10)
2-17
1) Changing the dog and mechanical stop positions
Change the dog and mechanical stop positions according to the desired stroke
position as shown in Fig. 4.2 (b) .
+ 6CT
+90* +30*\\
+75* +45'
> I 05! + 1 5*
'+ I 20° +0°
« /
•k' +d
+ 135°
Front
Standard ± | 50*
& s>
-135°
A” K. t-6
v®
c 1 20* 05° - I 5" -0#
k- I
-75" -45!/
-90° -SO',
-60"
Note) The figure shows the top view of the 6-axis base.
Fig. 4.2 (b) Changing the dog and mechanical stop positions (S-10)
2-18
a) Changing the minimum and maximum command pulses
$L0WERLIMS[1 ]: O-axis stroke lower limit in radians
$UPPERLIMS[1 ]: Q-axis stroke upper limit in radians
Set a numeral so that upper pulse should always be greater than lower
pulse.
$L0WERLIMS[1] $UPPERLIMS[1]
Position (O-axis stroke lower limit
in radians) __ in radians) _
(O-axis stroke upper limit
-150° -2.617993878
-135° -2.356194490 -2.356194490
-120° -2.094395102 -2.094395102
-105° -1.832595714 -1.832595714
-90° -1.570796326 -1.570796326
-75° -1.308996939 -1.308996939

-60° -1.047197551 -1.047197551
-45° -0.785398163 -0.785398163
-30° -0.523598775 -0.523598775

-15° -0.261799387 -0.261799387
0° 0.0 0.0
+15° 0.261799387 0.261799387

+30° 0.523598775 0.523598775
+45° 0.785398163 0.785398163
+60° 1.047197551 1.047197551
+75° 1.308996939 1.308996939

+90° 1.570796326 1.570796326
+105° 1.832595714 1.832595714
+120° 2.094395102 2.094395102

+135° 2.356194490 2.356194490
+150° 2.617993878
2-19
4.3 Mastering Procedure
4.3.1 Introduction
This procedure describes the mastering procedure for a robot with an absolute
pulse coder system. No operation is required for calibration with this system.
The robot is automatically calibrated when power is turned on and the system
becomes ready. Mastering is the establishment of an absolute reference point
(or known location) as the mastering position of the robot. The known location
can be the zero position (determined by aligning the zero witness marks on a
particular axis or by making precise measurements according to specified
distances) or a location determined by moving the axis into a mastering fixture.
The method used for determining the known location is dependent on the robot
model and is described in detail in Sections 4.3.3 and 4.3.4.
Using a mastering fixture is the most accurate and recommended mastering
procedure. Note that the same mastering fixture should be used for all robots
in a system.
Mastering is done at the factory and generally is not required as part of the
daily operation. Mastering will need to be done when a mechanical part has been
replaced or altered, if the system variables dealing with mastering have been
lost or changed, or if the positional information from the absolute pulse coders
has been lost.
4.3.2 Mastering procedure
1. Power up the controller.
2. Turn REMOTE ON/OFF switch ON. (die**. c )

3. Using the CRT/KB, call up the KCL display screen.
4. Using the teach pendant, jog the mechanical unit to the mastering position
described in Section 4.3.3.
2-20
5. Using the CRT/KB (with REMOTE switch turned to ON) enter UHL in response
to the KCL> prompt
6. In response to the UTIL> prompt enter MASTER.
7. Enter Y in response to the displayed question “Are you sure?”
8. At the prompt “Mastering at 0 degrees Y/N?” enter

Y if you are mastering at the zero-degree position or
N if you are mastering using a mastering fixture.
9. Press ENTER twice.
10. Power down and up.
2-21
4.3.3 Zero-degree position
The zero-degree position of the S-10 robot is shown i Fig. 4.3.3.
0-axis
[ÿ»*:;riiiil
*01111? mM
t-3
\5L
SSJl
m or-axis
Us
7
7 -axis
U-axis \
W-axis
*ÿ
W\
m L
ft- -to)
mm r~W
0-axis
I
[
Fig. 4.3.3 Zero degree position marks of each axis (S-10)
2-22
4.3.4 Mastering using a mastering fixture
The robot has been mastered at the time of shipment. If the present value
stored via the APC (Absolute Pulse Coder) differs from the actual position of
each axis after a major component of the robot mechanical unit has been
replaced, mastering is to be carried out to set the robot geometric position.
Select one of 9 = 0°, -90° or +90° according to the working area.
The robot should be calibrated to satisfy the following conditions.
. Make the robot’s base level. (1 mm/base)
. Remove the wrist hand and related parts.
. Do not allow an external force to be applied to the robot.
Note) The axis stroke is not checked during mastering. Be especially careful,
therefore, regarding the robot axes movement.
1) Mastering procedure
If it is necessary to change the mastering point of the 9 axis, change the
system variable $MASTER_P0S[1] before mastering according to the following
procedure:

2. At the KCL> prompt, enter SET VAR$MASTER_P0S[1] =
-1.570796326: 9 = -90°
1.570796326: 9 = 90°
0: 9=0°.
3. When the KCL> prompt reappears, enter SSAVE SYS_STANDARD.
a) Assemble the mastering fixture
i) Assembly of fixture base
Assemble the fixture base as shown in Fig. 4.3.4 (a)
< Bolt M5x20 (three)
k it
i
Bolt M5x20 (four)
Fig. 4.3.4 (a) Assembly of fixture base (S-10)
2-23
ii) Mounting on robot body
After selecting the mastering position from among 0 = 0°, -90° or
90°, mount the fixture on the 0-axis base using bolts and pins.
Locating pin 08
Bolt M10x30 (Two)
tf = +90*
Positioning pin 48
I 1
0=-9O* 6 = 0'
o Q«
Fig. 4.3.4 (b) Mounting on robot body (S-10)
iii) Mounting of dial indicators

Mount six dial indicators on the base as shown in Fig. 4.3.4 (c) and
set all the indicators to 3.00 mm using a calibration block. (Note
that the dial indicator may break if the bolts are tightened too
much) .
O
o
Clamp
o No . 4 - No . 3
Indicator
3 mm
No . 6 n m
No . 5 n © No . Bolt MSxlO \
No .2 Calibration block
Fig. 4.3.4 (c) Mounting dial indicators (S-10)
2-24
iv) Mounting fixture on wrist
Jog the robot to the position where a = 6 = y = 0° and mount the
fixture on the a-axis as shown in Fig, 4.4 (d). At this time, if it
touches a mechanical stop at -190° and +190° position of yaxis, set
the y-axis to 0° rotating it in the opposite direction.
.. . Mounting attitude
a = 0°
0=0°
t = 0°
v.-
Position pin
Bolt M6xl6 (four)
Fig. 4.3.4 (d) Mounting fixture on wrist (S-10)
b) Mastering procedure
Align each axis with the mastering fixture by jogging. To prevent an
error due to the axis backlash at this time, turn the dial indicator so
that it reads a higher value to reach the specified position. If the dial
indicator was turned in the opposite direction by mistake, repeat the
procedure from the beginning.
i) Move the robot slowly so that the dial indicator comes to the center
of the marking line on the fixture mounted on the wrist.
O
Marking line center
/ No . 4 No . 3
7 o
•V
N o .6
Marking line
No .5 No .2
n n No . I
Fig. 4.3.4 (e) Dial indicator positioning (S-10)
2-25
ii) Move the a axis so that the readings of dial indicators No.l and No. 5
are identical.
iii) Jog the 0 and y axes so that the readings of dial indicators No. 4 and
No. 5 are identical and that the reading of dial indicator No. 3 is
3,00 mm. If the readings of dial indicators No.l and No. 2 are not
the same at this time, make a correction so that they are identical.
iv) Jog the W, U and B axes so that the readings of dial indicators No. 2,
No. 5 and No. 6 are 3.00 mm.
v) Check that the readings of all dial indicators are 3.00 mm after the
above operation.
vi) Perform the mastering procedure described in Section 4.3.2.
e 6 /
X n
•l
e 0° (-90°, 90°)
w 70°
Mastering fixture
U -125°
Y 0°
B -55°
a 0°
Fig. 4.3.4 (f) Mastering position
2-26
4.4 Adjusting U-axis Bevel Gear Backlash
(T) Remove the U-axis motor (Refer to 5.5)
8 Remove
Remove
(?) Remove
the
the
the
U-axis reducer (Refer to 5.6)
four M5 x 16 bolts, holder and gear D unit.
four M5 x 16 bolts, holder and gear C unit.
(5) Adjust the backlash within 0.05 -
0.15 mm using shims (A290-7204-X421/X422/
X430) .
© Reassemble reversing the above procedure. Coat the bolts and pins removed
in steps (T) -
© lightly with LOCTITE and tighten the bolts with the
specified torque. (See Fig. 4.6, 5.5 and 5.6)
(7) After adjustment, apply grease according to Section 2 "LUBRICATING CONDITION
CHECKS."
Bolt M5xl6 (four) Bolt M5xl6 (four)
(LOCTITE 262) (LOCTITE 262)
U housing
Holder
Holder Bearing gear C
Bearing gear D Shim

A290-7 204-X421
X422
Shim X430
A290-7204-X421
X422
X430
0ÿ
Cover
Button-head bolt M6x8 (three)
Fig. 4.4 Adjusting U-axis bevel gear backlash (S-10)
2-27
4.5 Adjusting 0-axis Bevel Gear Backlash
© Remove the a-axis, motor cover and then the a-axis unit from the bracket.
(Refer to 5.7 ® ©)
© Remove the wrist unit from the U-axis arm. (Refer(Refer to 5.8 ©, ©)
© Remove to 5.8 © ®) -
s$
the B-axis motor and the harmonic drive.
Remove six M4xl2 bolts, holder, and gear A unit.
Remove four M5x20 bolts, two taper pins, and then the bracket.
Remove eight M5xl2 bolts, holder, and gear B unit.
Adjust the backlash to a maximum of 0.02 mm at a distance of 300 mm measured
from the center of rotation. Ose shims (A290-7204-X521 X526/X529/X530) - .
(8) Reassemble reversing the above procedure. When assembling the holder
removed in step © , the position of the bolt for the stop should be at the
base of U-axis arm.
Coat the bolts and pins removed in steps ® -
© lightly with LOCTITE, and
tighten the bolts with a specified torque. (See Fig. 4.7, 5.7 (a), 5.8 (a)
and (b)).
Note) Assemble the oil seal so that its lip Bolt M5x20 (four)
should face the cross roller side. (LOCTITE 262)
Taper pin $5x20 (two)

(LOCTITE 242)
Bolt M4xl2 (six)
(LOCTITE 262)
Bracket
V /
On seal
Holder
Stop bolt
Holder
X
Bearing gear A Bolt M5xl2 (eight)
(LOCTITE 262)
Cross roller bearing

Shim gear B
A290-7204-X524
X525 Shim
X526 A290-7204-X521
X530 X522
X523
0-axis housing X529
Fig. 4.5 Adjusting 0-axis bevel gear backlash
2-28
5. REPLACING AND ADJUSTING PARTS
When a part is replaced, certain adjustments are required.
Parts requiring replacing and the items that require adjustment are listed
below.
Replacement parts Adjustment item
6-axis motor (a) Mastering

(b) Dog adjustment
W- and U-axis motor (a) Mastering
a-, 8- and y-axis motor (a) Mastering
e-, W- and U-axis reducer (a) Mastering

(b) Dog adjustment
Y-axis reducer, a-, and B-axis harmonic drive (a) Mastering
5.1 Replacing 0-axis Motor

(D Remove two bolts mounting the upper part of the cable guide to the W-axis
base.
© Remove the stop and the dog from the bracket.
© Remove the. connector box and remove the connector of the 6-axis motor.
© Remove eight M8x25 bolts and two d8x30 spring pins mounting the bracket to
the 6-axis base, and lift the mechanical unit. At this time, take care not
to apply excessive force to the cable, cable guide, and connector box.
I Remove four M10x25 motor mounting bolts, and pull out the motor downward.
Remove the C-ring, washer, input gear, coupling, and the draw bolt, and then
pull out the input spline.
(2) Replace the motor and reassemble reversing the above procedure. Apply
LOCTITE lightly to the bolts and the draw bolt pins removed in steps ©
.
© Tighten bolts and draw bolts with the specified torque. (Refer to
-
Fig. 5.1)
2-29
M6 button-head bolts
(2 pcs)
Spring pins .
<>8x30 (8 pcs) Vi*
M8x20 (8 pcs)
(LOCTITE No. 262 and
damp torque 380 kg.cm) i
Ml 0x40 (2 pcs)
M6 button bolts
(4 pcs)
* .
i
Dog L r
DogR
Stop
sj
Cable guide
(6 pcs) Q W-axis base
Connector box
o Seal washer
Packing
—
Bracket Cr M10x25 (4 pcs)
model 5RF
Cring
IB- Washer
Input gear
Draw bolt
i 0-axis base
LOCTITE No. 262 and

fyClamp torque 122 kg.cm)
Coupling
Input spline
u <5 IN' BE
Fig. 5.1 (a) Replacing 6 -axis motor (S-10)
2-30
5.2 Replacing 0-axis Reducer
(J) Remove two M6 button-head bolts mounting the upper part of the cable guide*
to W-axis base.
I© Remove the stop and the dog from the bracket.

Remove the rear cover from the W-axis.
Remove three Ml 2x40 bolts and two dl0x30 taper pins mounting the W base to
the 9-axis reducer, and lift the mechanical unit. At this time, take care
not to apply excessive force to the cable, cable guide, and connector box.
© Remove eight M6x30 bolts and two d5x20 taper pins mounting the G-axis
reducer to the bracket, and replace the reducer.
© Reassemble reversing the above procedure. Apply a thin coat of LOCTITE to
the bolts and pins removed in steps and © ©.
Tighten the bolts with the
specified torque. See Fig. 5.2.
© Grease each part, referring to section 2.
M6 button-head bolts (2 pcs)

Cover
M6 button-head bolts (2 pcs)
Taper pins 010x30 (2 pcs)
—
(LOCTITE No. 242)
Ml 2x40 (3 pcs)
(LOCTITE No. 262,
and Clamp torque
1040 kg.cm) .ÿ*
Ml 0x40 (2 pcs)
(4 pcs)
Dog L
Dog R
Stop
Cable guide
ij) V
W-axis base
(6 pcs)
Q M8x30 (8 pcs)
(LOCTITE No. 262 and
Clamp torque 30 kg.cm)
Connector box
TLOCTTTE No. 242)
O-ring (small)
Reducer
(large)
tliQj Bracket
0-axis base
ft
*4
Fig. 5.2 Replacing d-axi$ reducer (S-10)

2-31
5.3 Replacing W-axis Motor
(I) Press the W-axis against the mechanical stop or support the axis so it
cannot move.
© Remove the side cover from the W-axis base and then the W-axis motor
connector.
I Remove four M10x25 bolts and the motor.

Remove the C-ring and pull out the input gear and the coupling. Remove the
draw bolt and pull out the input spline. (See Fig. 5.1.)
(D After replacing the motor, reassemble reversing the above procedure. Apply
LOCTITE lightly to the bolts, the draw bolt, and pins removed in steps Q)
and © . Tighten bolts with specified torque (See Fig. 5. 1/5. 3).
\o\
W-axis motor
el
Cover
Seal washer
Packing
M6 button-head bolt
M10x25 (four)
(LOCTITE 262)
Fig. 5.3 Replacing W-axis motor (S-10)
2-32
5.4 Replacing W-axis Reducer
© Press the W-axis against the rear mechanical stop or support the axis so it
cannot move.
© Remove clamps from below the W-axis base and side of W-axis arm in order to
pull a cable out. If the cable can not be pulled enough, remove the
connector of upper U-axis. (Refer to 7.2 and Fig- (a) ~ (c).) ©
© Remove three M12x40 bolts, two taper pins, and then the W-axis arm
from the W-axis base.
© Remove eight M8x30 bolts, two 48x30 taper pins mounting the W-axis reducer
to the W-axis base, and then the reducer.
© Replace the reducer, and reassemble reversing the above procedure. Lightly
apply LOCTITE to the bolts and pins removed in steps and Tighten © ©.
bolts with the specified torque.
© After replacement, apply grease according to Section "LUBRICATING ©
CONDITION CHECKS."
Plate
O-ring (small)
M6 button head bolt (two pcs)
O-iing (large)
O-ring \ *8 \N'\ S'
\
Ml 2x40 (three pcs)
(LOCTITE 262, Clamp torque
1040 kg.cm)
Taper pin 010x30 (three pcs)
(LOCTETE 242)
Paper
pinÿ>8x30 (two pcs)
y,
M
a /
Reducer Paper pin <>8x30 (two pcs)
(LOCTITE 262, Clamp Torque 380 kg.cm)
NS
Fig. 5.4 Replacing W-axis reducer (S-10)
2-33
5.5 Replacing U*axis Motor
(I) Press the (J-axis against the mechanical stop or support the axis so it
cannot move.
© Remove the U-axis motor cover, U-axis cover, and then the U-axis motor
connector.
© Remove four M6xl6 bolts and the motor.
© Remove the hexagonal bolts from the motor shaft, and pull out the input
spline.
© After replacing the motor, reassemble reversing the above procedure. Apply
LOCTITE lightly to bolts, nuts and pins removed in steps © and © .
Tighten bolts with the specified torque. (See Fig. 5.5)
Cover
Button head bolt Apply sealant No. 1211

M6x8 (8 pcs) to surrounding four faces
U-axis motor
M6xl6 (four)
(LOCTITE 262)
Spline shaft Packing
Fig. 5.5 Replacing U-axis motor (S-10)
2-34
5.6 Replacing U-axis Reducer
(j) Press the U-axis against the mechanical stop or support the axis so it
cannot move.
(2) Remove the cable connected from W-axis arm to the U-axis. (Refer to 7.2 (T)
and Fig. (a) and (b).)
(3) Remove four M10x40 bolts, two taper pins, and then the U-axis unit
from the W-axis arm.
@ Remove eight M6x30 bolts, two taper pins, mounting the U-axis reducer
to the U-axis unit and then the reducer.
d) Replace the reducer and reassemble reversing the above procedure. Lightly
apply LOCTITE to the bolts and pins removed in steps (3) and @ Tighten .
bolts with the specified torque.
(§) After replacement, apply grease according to Section (3) "LUBRICATING
CONDITION CHECKS."
O-ring (large) O-ring Taper pins 08x25 (2 pcs)

(LOCTITE 242)
O-ring (small)
Reducer Ml 0x40 (four)
(LOCTITE 262
o<
(LOCTITE 242)
M6x30 (eight)
(LOCTITE 262,
Fig. 5.6 Replacing U-axis reducer (S-10)
2-35
5.7 Replacing a-axis Motor and Harmonic Drive
(D Remove the a-axis motor cover and the a-axis motor connector.
(2) Remove four M5xl6 bolts and then the a-axis unit from the bracket.
(3) Remove six M5xl6 bolts and then the a-axis motor from the bracket.
4) Remove a screw M3x6, a bolt M3xl0, and then the wave generator from the
motor shaft.
© If only the motor is replaced, reassemble reversing above procedure after
replacing the motor. Apply LOCTITE lightly to bolts removed at (2)
(See Fig. 5.7 (a) and (b))
(5) - .
Button-head bolt
a-axis motor cover ? M4x6 C4 pcs)
I
Apply sealant No. 1211
to the surrounding face
jO
Bracket
/•
a-axis unit
Fig. 5.7 (a) Replacing a-axis motor (S-10)

Bolt M5xl6 (four pcs)
(LOCTITE 262)
Screw M3x6
(LOCTITE 262)
\
a-axis motor
I Shim
N
Packing Wave generator
% e
Washer

(LOCTITE 262)
/-

(LOCTITE 262)
Fig. 5.7 (b) Replacing a-axis motor (S-10)
2-36
s
©
©
Remove
Remove
Remove
Remove
six M5x20 bolts and the flange unit from a-axis housing.
six M4xl6 bolts, two
six M4xl2 bolts and two
eight M5x20 bolts and two
pins, and the circular spline S.
pins and the circular spline D.
taper pins from the flange unit
removed in step , and remove the flange, the holder, and the cross roller
©
bearing. (The cross roller bearing must be replaced.)
© Replace the flex spline, the circular splines S and D, and the wave
generator, and reassemble reversing above procedure. At this time, lightly
apply LOCTITE to the bolts and pins removed in steps (2) (§) Tighten - .
bolts with specified torque.
<S> After replacement, apply grease according to Section 2.
a-axis housing
Circular spline S
Pin 04x14 (two pcs)
N (LOCTITE 242)
Flex spline
Pin 04x10 (two pcs)
Bolt M4xl6 (six pcs) (LOCTITE 242)
(LOCTITE 262
v Circular spline D
Bolt
M4xl2 (six pcs)
(LOCTITE 262,
clamp torque 45 kg.cm) o'
Bolt M5x20 (four pcs) i vW
(LOCTITE 262)
10
,9
Flange unit
a.
Taper pin
04x16(two pcs) Bolt
(LOCTITE 242) M5x20 (six pcs)
\ (LOCTITE 262)
Shaft
to
OS'
Holder
Holder o'
Oil seal
.0
Collar
. Flange
Note) Assemble oil seal so that the lip faces the cross roller side.
Fig. 5.7 (c) Replacing a-axis harmonic drive (S-10)
2-37
5.8 Replacing /J-axis Motor and Harmonic Drive
(T) Remove the cable cover from the O-axis arm and then the B-axis motor
connector. (Refer to 7.2 (2) and Fig. 7.2 (a) to (f).)
(2) Remove four M5x30 bolts and a spring pin, and remove the wrist unit
from the U-axis arm.
I Remove four M4xl2 bolts and then the motor.

Remove the plate and pull out the wave generator.
(5) If only the motor is replaced, reassemble reversing above procedure after
replacing the motor. Apply LOCTITE lightly to the bolts and pins removed in
steps (2) -
©. (See Fig. 5.8 (a))
U-aim

(LOCTITE 262)
A
«
A
» 0-axis motor
V
Wrist unit
Screw M3x6
(LOCTITE 262)
,4
I J
0-axis motor I
Washer
.
N
Oj Spring pin
(1 pc)
Wave generator \ %
\
Bolt M3xl0 (one pc) s

(LOCTITE 262) Packing '
(LOCTITE 262)
Plate %
Bolt M5x30 (four pcs)
N.
(LOCTITE 262)
Fig. 5.8 (a) Replacing 0-axis motor (S-10)
2-38
© Remove six M5x20 bolts and the two <ÿ4x20 spring pins, and remove the holder
from the 8-axis housing.
(7) Remove six M5xl6 bolts, two taper pins, the flex spline and the
holder.
(§) Remove six M5x25 bolts, two taper pins, and then the circular spline
from the holder.
(f) Replace the flex spline, the circular spline, and the wave generator, and
reassemble reversing above procedure. At this time, lightly apply LOCTITE
to all the the bolts and pins removed in steps (2)
with the specified torque. (See Fig. 5.8 (a) and (b))
(§) Tighten bolts - .
(1§) After replacement, apply grease according to Section 2.
Bolt M5x20 (four pcs)

(LOCTITE 262)
«
•S'- Holder
Bolt
Taper pin (LOCTITE 262,
<4x20 (two pcs) damp torque 92 kg.cm)
(LOCTITE 242) v
Holder *r
Flex spline
Wrist unit
Taper pin
$5x20 (two pcs)
(LOCTITE 242)
z''
IT /-
I
Holder
Circular spline
Taper pin \
04x20 (two pcs)
7V
»
(LOCTITE 242)
Bolt M5x25 (six pcs)

(LOCTITE 262, Clamp torque 92 kg.cm)
Fig. 5.8 (b) Replacing 0-axis harmonic drive (S-10)
2-39
5.9 Replacing y-axis Motor and Reducer
(I) Remove the U-axis cover and U-axis motor connector.
I© Remove the four M6x20 bolts mounting the motor and then the motor.
Remove the hexagonal nuts and the draw bolts.
If only the motor is replaced, reassemble reversing above procedure after
replacing the motor. Apply LOCTITE lightly to the bolts and nuts removed in
steps (2) and ©
• Apply a thin coat of LOCTITE on the hexagonal nut of the
motor shaft and tighten to the specified torque. (See Fig. 5.9 (a).)
Cover
Bolt 6x20
(four pcs) *51 Draw bolt
(LOCTITE 638,
Button-head!
bolt M6x8
v \ e,
Input spline
(eight pcs)
Hexagon unit (two pcs)
I
7-axis motor
V *
N Packing
Apply sealant 1211 to

surrounding four faces
Pig. 5.9 (a) Replacing y-axis motor (S-10)
2-40
I Remove four M6xl6 bolts, and then the holder.
Remove four M6x55 bolts.
I Remove eight M5x35 bolts, and then the' reducer from the U-axis housing.
Replace the- reducer and reassemble reversing the above procedure. At this
time, lightly apply LOCTITE to bolts and nuts removed in steps (2) (7) - .
Tighten nuts with specified torque. (Refer to 5.9 © and Fig. (b).)
@ After replacement, apply grease according to Section 2.
Bolt M5x35 (eight pcs)

(LOCTITE 262,
u
clamp torque 92 kg.cm)
Holder
if N
. Bolt
M6xl6 (four pcs)
Bolt M6x55 (six pcs)

(LOCTITE 262,
clamp torque 157 kg.cm)
Fig. 5.9 (b) Replacing 7-axis reducer (S-10)
2-41
5.10 Replacing Battery
The data of the home position of each of the robot axes is stored by the
Absolute Pulse Coder, which is powered by the backup batteries. The batteries
must be replaced every year. They should be replaced as follows.
1) Turn the power on.
Press the EMERGENCY STOP button to prohibit the robot operation.
2) Remove the battery case cap.
3) Remove the old batteries from the battery case.
4) Set the new batteries in the battery case. Pay careful attention to the
direction of each battery.
5) Remount the battery case cap.
Battery case
o Battery
Case cap
O
©,
s 0
XU
Battery specifications: A98L-0031-0005, 4 batteries, 1.5 V, size D
Fig. 5.10 Replacing batteries (S*10)
2-42
6. WIRING AND PIPING
6.1 Piping Diagram

Fig. 6.1 shows the internal piping diagram of the mechanical unit.
Panel union
PT1/8 female
Pf
±1!
Panel union
PT1/4 female
Fig. 6.1 Piping diagram (S-10)
6.2 Wiring Diagram

Fig. 6.2 shows mechanical unit wiring diagram.
Controller Mechanical unit

0-axis motor W-axis motor U-axis motor
0-axis
K92 PI
connector box
KlOjl T
66
_m
6 6
n_ 666
K93 P2 Battery
K 1 02
— T“0D-
MID-
11 7-axis motor
B-axis motor
K31 Ml
K I 03
K32 M2 K 1 04
*0T
-0
K I 06 -QD-
-0D-
HJD-j _
ot-axis motor •
K91 D1
K I 05
WOT
(JOT
Ml 2K I 07 -0D-
End effector
Fig. 6.2 Mechanical unit wiring diagram (S-10)
2-43
6.3 Limit Switch Installation Diagram
Fig. 6.3 shows the installation diagram for the limit switches.
!i—|c=daÿ-
j
U-axis OT limit twitch

I •
W-axii OT limit twitch

1
C!
1 6-exit OT hmit twitch
Fig. 6.3 Limit switch installation diagram (S-TO)
6.4 Cable Installation Diagram

Visually check the following:
1) Check the whether connecting cables in the robot rotational part are
distorted or bent by the robot rotation.
2) Check whether the routing of the cables connected to the W- and U-axes is
distorted or bent by the elbow motion.
3) Check whether the routing of the cables connected to the end effector is
suitable to the wrist motion or the service motion of the robot.
In Fig. 6.4 the installation diagram for the cables in the mechanical unit is
shown. K 1 06
{
ESSiP!
I®$
K 1 07
l
IS!
P
I
K I0I '
K I 02
K I 03
K 1 04
K I 05 .
Of
&
Fig. 6.4 Mechanical unit cable installation diagram (S-10)
2-44
7. REPLACING CABLES
A broken or damaged cable should be replaced as specified In this section. If
the pulse coder cable (K101, K102, K106, K107) connector is disconnected the
motor loses its absolute position. When the motor loses its absolute position,
mastering must be carried out.
7.1 Cable Forming

When mounting the replaced cable with clamps and tie wraps, clamp it at the
positions specified in Table 7.1. Unless the cable is clamped at the specified
positions, the cable may be broken due to excessive sagging or tension.
Table 7.1 Cable damping positions (S-10)
Stamp Cable clamping position Stamp Cable No.

280 Clamp position
ep
PI l WP K 101
l530
1
UP
2200
2T7U
3 I 20
3430 XUs TP
P2 PP K I 02
I 80 o aP
I 400
X 2040',
-C
I 23 IQ
c 2960
O 3270
s 6M
I K I 03
Ml
<=s o
WM
UM
280J I 560 UBK
o TM
M2 rBK K 1 04
I 80 o PM
I 390 o «M
2030 ~
2300 ,,
2950
3260
‘ x
P2I EE K I 05
g-Q<M
l 450
2-45
7.2 Replacing Cables
1) Replacing cables K101, K102, K103, K104
(D After removing the U-axis cover, cut the tie wrap to remove the connector
and two clamps. (Fig. 7.2 (a))
(2) Remove the U-axis and W-axis cable covers and the W-axis arm clamps (2
clamps), cut the tie wrap, and pull out the cable from under the W-axis
arm. (Fig. 7.2 (b))
(D Remove the W-axis motor cover and disconnect the connector.
Remove the W-axis base clamps (2 clamps) and cut the tie wrap. (Fig. 7.2
(c))
I© Disconnect the end effector connector and air hose. (Fig. 7.2 (d))
Remove the ©-axis cable cover and the cable guide from the W-axis base.
Remove the ©-axis connector box from the ©-axis base and pull it out
toward you together with the cable guide.
8© Disconnect the ©-axis motor connector.

Cut the cable guide tie wrap.
Remove the ©-axis connector box cover A, cut the tie wrap, and then
remove the cover B.
8 Replace the cable and mount the new cable reversing the above procedure.
Remaster the robot (Refer to 4.3.)
U-axis cover
Apply sealant 1211

to surrounding four face
M6 button-head bolt
S
Cable cover
[fÿ
./
Fig. 7.2 (a) Replacing cables K101, K102, K103, K104, K105 (S-10)
2-46
U-axis cable cover
Cable damp
Cable damp
• W-axis cable cover
Fig. 7.2 (b) Replacing cables K101. K102, K103, K104, K105 (S-10)
W-axis motor cover
I
Tie wrap
A A N,
Connector air tube for
end effector Clamp
Fig. 7.2 (c) Replacing cables K101, K102, K103, K104. K105 (S-10)
2-47
!?
i
Clamp
Cable guide
Tie wrap
0-axis cable cover.
Cover A
kO
Cover B
0
0-axis connector box
Fig. 72 (d) Replacing cables K101, K102. K103, K104, K105 (S-10)
2) Replacing cables K106 and K107

(D Remove the U-axis cover and the connector marked with P2, M2 BP and BM
(Fig. 7.2 (e)) (Remove the connector marked with BP and BM if only K106
is replaced)
(2) Remove the U-axis arm cover and remove two M6 button head bolts mounting
the cable cover and slide the cover forward.
(D Remove the clamp and draw out the cable together with the connector.
(Fig. 7.2 (f))
© Cut the tie-wrap and disconnect the connector.
(5) Replace cable K106.
I Remove the a-axis motor cover and the connector. (Fig. 7.2 (f))
Remove B-axis covers A and B, and the clamp. Cut the tie wrap.
© Pull out the tube together with the cable and draw out the end connector
via the gear box.
(g) Replace the cable after removing it from behind the U-axis arm.
Reassemble reversing the above procedure. (Apply sealant No. 1211 to the
B-housing groove)
© Reassemble the clamp and the cover just as before, connecting each
connector.
(0) Remaster the robot. (Refer to 4.3.)
2-48
Cover
Cover
Apply sealant No. 1211

to surrounding four faces
j© Rubber cover
Cable cover
Button-head bolt
M6x8 (eight pcs) To slide
Button-head bolt (two pcs)

I
M4 button-head bolt (two pcs)

i
Fig. 7.2 («) Replacing cables K106, K107 (S-10)
Pull out damp

and connector
Tie wrap
fl
M4 button-head
bolt (two pcs)
a-axis motor cover
T
Button-head bolt
M4x6 (four pcs) Rubber bush Tie wrap
r-
0-axis cover A 11
U' 6
• Clamp
Heat-shrinkable tube
3
I i 4.: i
1* ii
' Tube Bevel gear
' i
0-axis cover B * il '

Cable
I Tube
Fig. 7.2 (f) Replacing cables K106, K107 (S-10)
2-49
7.3 Replacing Limit Switch
1) 0-axis OT limit switch (cable K105)
(T) Remove the rear cover of the W axis
(2) Remove the limit switch mounting plate from the stop.
(3) Remove the limit switch from the plate.
(?) Remove the cover below the switch and disconnect the cable crimp
terminal. Replace the limit switch.
(D Mount the new limit switch reversing the above procedure.
(D Check that the limit switch operates accurately at the overtravel
position.
(2) Check that the limit switch does not operate in the 0-axis motion range.
LOJ
r0\
J Plate
Cover
Limit switch
Fig. 7.3 (a) Replacing d-axis limit switch (S*10)
2-50
'
III. S-700 MECHANICAL UNIT MAINTENANCE
&
1
:
r-v-
i
i
1. CONFIGURATION
Fig. 1 (a), (b) show the configuration of the mechanical unit.
7-axis AC servomotor Wrist unit
o-axis AC .
servomotor 0-axis AC !
servomotor
U-axisAC
servomotor
-<ÿ
3-
W-axis arm
U-axisarm
m
s
» W-axis base
>/
gyiasis
JL d e-axis AC servomotor f-
no* 6-axis base

QO«.
Fig.1 (a) Mechanical unit configuration (S-700 offset wrist)
7-axis AC servomotor Wrist unit

•y-axis AC
servomotor
.
1*0
*1 0-axis AC
n servomotor 3s &
rrj
I
r
St
ii U-axisarm
iiiSil
U-axisAC
servomotor W-axis arm
I© o o
-o-
—
>
-
W-axis base
i
6
o
TO
r<
6 -axis AC servomotor
.*•aa-* S-axis base

paaij t.
Fig. 1 (b) Mechanical unit configuration (S-700 in-line wrist)
3-1
1.1 e-axis Drive Mechanism
Fig. 1.1 shows the 6-axis drive mechanism.
The rotation of the AC servomotor (model 5F) is decelerated by the reducer and
rotates the table. The table is supported by the cross roller bearing.
Table
m
Holder
9-axis reducer i
9-axis base
]
3-2
1.2 W-axis Drive Mechanism
Fig. 1.2 shows the W-axis drive mechanism.
The rotation of AC servomotor (model 20F) is decelerated by the reducer via the
bevel gear and rotates the W-axis arm.
W-axis arm
m W-axis reducer
rW
Bevel gear
£1 W-axis AC servomotor
W-axis base
Fig. 1.2 W-axis drive mechanism (S-700)
3-3
1.3 U-axis Drive Mechanism
Fig. 1.3 shows the U-axis drive mechanism.
The rotation of the AC servomotor (model 5F) is decelerated by the reducer via
the bevel gear and rotates the U-axis arm.
W-axisaim
U-axis arm
U-axis AC
servomotor
r1
l-M
Bevel gear
v \
X
-U-axis reducer
Fig. 1.3 U-axis drive mechanism (S-700)
1.4 y-axis Drive Mechanism

Fig. 1.4 shows the y-axis drive mechanism.
The rotation of the AC servomotor (model 1-0B/1-0HB) is decelerated by the
reducer after being reduced by the helical gear and rotate the y axis (the
U-axis arm) .
7-axis reducer
U-axis arm
©
ns v_ Helical gear
Fig. 1.4 y-axis drive mechanism (S-700)
3-4
1.5 a/p-axis Drive Mechanism (offset wrist)
Fig. 1.5 shows the a/B-axis drive mechanism of the offset wrist. The revolution
of the motor (model 1-OB/1-0HB) is transmitted to the wrist via the drive shaft
after the revolution speed is reduced by gears.
For the 8 axis, the revolution of the drive shaft is input to the B-axis reducer
via bevel gears and output directly to the B axis. On the other hand, for the
a axis, the drive shaft revolution is transmitted via bevel gears and input to
the a-axis reducer to revolve the a-axis output flange.
a-axis output flange

\
Bevel gear 'li
Helical gear
a-axis AC ' a-axis reducer

servomotor
w
Drive shaft
0-axis reducer
Bevel gear
0-axis AC
>
servomotor
Fig. 1.5 a//3-axis drive mechanism (S-700, offset wrist)
1.6 a//3-axis Drive Mechanism (In-line)

Fig. 1.6 shows the a/B-axis drive mechanism of the in-line wrist. The
revolution of the motor (model 1-0B/1-0HB) is transmitted to the wrist via the
drive shaft after the revolution speed is reduced by gears.
For the B axis, the revolution of the drive shaft is input to the B-axis reducer
via bevel gears and output directly to the B axis. On the other hand, for the
a axis, the drive shaft revolution is transmitted via bevel and helical gears
and input to the a-axis reducer to revolve the a-axis output flange.
Helical gear Helical gear a-axis output flange
a-axis AC Bevel
servomotor Drive shaft Bevel gear gear
>
0-axis AC a-axis reducer
servomotor
0-axis reducer
Fig. 1.6 a//3-axis drive mechanism (S-700, in-line wrist)
3-5
1.7 Major Component Specifications
1) Motor
a) Mechanical unit specification: A05B-1120-B001/B011
Specification Model Axis
A06B-0345-B231 5RF Q, U
A06B-0352-B731 20F W
A06B-0524-B351 1-OHB a. 8, Y
b) Mechanical unit specification: A05B-1120-B002/B012
Specification Model Axis
A06B-0345-B231 5RF 0, U
A06B-0352-B731 20F W
A06B-0522-B351 1-OB a, fi, Y
2) Reducer
Specification Axis
A97L-0118-0399# 135-12 9 0
A9 7L-0118-0392#135A-129 W
A97L-01 18-0393#60A-121 U
A97L-0118-0394#30A-41 Y
A97L-0118-0395#15A-57 B (Offset)
A97L-0118-0396#15A-57 8 (In-line) a
3) Wrist unit
Specification Axis
A290-7120-T501 Offset wrist
A290-7 1 20-T5 11 In-line wrist
3-6
4) Gear
Specification Axis
A290-7 120-X306 W
A290-7120-X307 W
A290-7 120-X406 U
A290-71 20-X407 U
A290-7120-X411 a
A290-7120-X412 a
A290-7120-X413 fl
A290-7 120- X4 14 6
A290-7120-X415 Y
A290-7120-X416 Y
A290-7120-X506 fl
A290-7120-X507 S (OFFSET)
A290-7120-X508 a
A290-7120-X509 a (OFFSET)
A290-7 120-X510 a (OFFSET)
A290-7120-X558 fl (IN-LINE)
A290-7I20-X560 a (IN-LINE)
A290-7120-X561 a (IN-LINE)
A290-7 120-X562 a (IN-LINE)
A290-7 I20-X563 a (IN-LINE)
3-7
5) Shim
Specification Axis
A290-7120-X327, X329 (0.1T, 0.3T) W
A290-7 120-X330, X332 (0.1T, 0.3T) W
A290-7 120-X434, X436 (0.1T, 0.3T) U
A290-7120-X437, X439 (0. IT, 0.3T) U
A290-7120-X440, X442 (0.1T, 0.3T) U
A290-7120- X516, X518 (0. IT, 0.3T) 8
A290-7120-X519, X521 (0. IT, 0.3T) 8
A290-7120-X522, X524 (0.1T, 0. 3T) a
A290-7120-X525, X527 (0. IT, 0.3T) a
A290-7120-X566, X568 (0, IT, 0.3T) a (IN-LINE)
3-8
6) Bearing
Specification Bearing No. Axis
A97L-0001-0192//00D000A 6800DDU a
A97L-0001-0192//0300000 6803 a
A97L-0001-0192#0400000 6804 a (IN-LINE)
A97L-0001-0192//0500000 6805 a (IN-LINE)
A97L-0001-0192 #0800000 6808 B
A97L-0001-0192#21Z0O0A 6821ZZ U
A97L-0001-0193#0000000 6900 a
A97L-0001-0193 #0100000 6901 B (IN-LINE)
A97L-OOOI-OI93#06OOOOO 6906 B
A97L-0001-019300700000 6907 S» Y
A97L-0001-0193//0800000 6908 U, B, y
A97L-0001-0193 #1300000 6913 W
A97L-00Ol-0193#26ZO0OA 6926ZZ W
A97L-0001-0194//05ZOOQA 6005ZZ B
A97L-0001-0194 #0800000 6008 W
A97L-0001-0198#00AW000 7000A a
A97L-0001-0198#02AWO0O 7002A a, B
A97L-0118-05 19#7903A 7903A a
A97L-0118-0519#7906A 7906A U
A97L-000 1-090 7#35020CS RB35020CS e
3-9
7) Cover
Specification Axis
A290-7120-X213 6
A290-7120-X214 6
A290-7120-X309 W
A290-7120-X318 W
A290-7120-X319 W
A290-7120-X320 W
A290-7120-X321 W
A290-7120-X322 W
A290-7120-X323 W
A290-7120-X325 W
A290-7120-X333 W
A290-7120-X409 U
A290-7120-X431 U
A290-7120-X513 W, U, a/S
A290-7120-X554 a/8
A290-7 120-X564 a/S
3-10
2. LUBRICATING CONDITION CHECK
2.1 Three-month Periodical Check

Be sure co check the following items every three months:
Item Check Item Check Contents
1 Lubricating condition of the gear Remove the cover and check the
box for the wrist grease level and if the grease is
abnormally contaminated.
2 Lubricating condition of the Remove the cover and check the

U-axis gear box grease level and if the grease is
3 Lubricating condition of the Remove the cover and check the

W-axis gear box grease level and if the grease is
2.2 Replacing Drive Mechanism Grease

Replace the grease in the reducers of 0, W, and U axes, and in the W-axis gear
box, wrist gear box, and the wrist unit every three years or 2000 hours. Be
sure to use the specified grease for replacement.
Note) Be sure to apply grease to the grease nipple according to the procedure
described in this manual. Greasing without opening the grease discharge
port may cause the seal to be broken and grease to leak. Do not apply
grease daily.
Table 2.2 Spedified grease for three-month periodical replacement
Grease Amount Specified Grease
9-axis reducer 500 cc EPNOC AP 0 of Nippon Sekiyu
W-axis reducer 2000 cc
u-axis reducer 650 cc
Wrist gear box 1200 cc
Offset wrist 500 cc
In-line wrist 600 cc
3-11
1) Replacing grease in the 0-axis reducer
© Remove the cover (rubber cap) on the side of the 0-axis base and the back
of the W base.
(2) Remove the grease nipple on the side of the ©-axis base. (Grease
discharge port)
© Apply grease to the grease nipple (grease injection port) on the side of
the W-axis base.
© Continue applying grease until the grease discharged from the grease
discharge port is clean. The standard grease injection amount is 500 cc.
I Mount the grease nipple on the side of the 0-axis base.

Mount the cover.
Note 1) If grease is not discharged from the grease discharge port when 500 cc
or more of grease is injected or if only a small amount of grease is
discharged from the port, be sure to check for grease leakage caused by
a damaged seal or other reasons.
Note 2) For a robot mounted on the ceiling, the locations of the grease
injection port and grease discharge port are reversed.
z o
3
o -_
A-
_
/OpQQ..
< ol t
e-axis grease nipple
Fig. 2.2 (a) Replacing grease in 6-axis reducer (S-700)
3-12
2) Replacing of grease in W-axis reducer
(T) Remove the W-axis cover.
© Set the W-axis to a position of approximately 0 degrees.
(3) Remove the grease discharge port cover. (Wipe off the grease coming out
from the grease discharge port at this time.)
© Apply approximately 800 cc of grease to grease nipple 1.
© Apply grease to grease nipple 2.
© Continue injecting grease until the grease discharged from the grease
discharge port becomes clean. The standard amount of grease to be
injected to grease nipple 2 is 1200 cc.
(7) Mount the grease discharge port cover.
© Mount the W-axis coyer.
Note 1) If grease is not discharged from the grease discharge port when grease
of 1200 cc or more is injected or if only a small amount of grease is
Note 2) Be sure to remove the W-axis cover before setting the W-axis to the 0
degree position because the W-axis cover cannot be removed within the
range of 50 to -50 degrees.
Note 3) For a robot mounted on the ceiling the locations of the grease injection
port and discharge port are same as those for the robot mounted on the
floor.
—
Packing
o. sp
.
U|L Grease discharge port
cover for the W-axis
gear box
Grease
o'
Standard grease amount
W=0°
/
A
Grease nipple 2 for
the W-axis gear box
Grease discharge
port cover for
the W-axis gear box
O.
V V
M Grease nipple 1
IQ=H) for the W-axis
/ gear box
> o O
d
W cover
Fig. 2.2 (b) Replacing grease for W-axis reducer (S-700)
3-13
3) Replacing grease in the U-axis reducer
® Remove the U-axis cover.
© Set the U axis to a position of approximately 90 degrees.
© Apply approximately 100 cc of grease to grease nipple 1.
© Apply grease to grease nipple 2.
© Continue injecting grease until the grease discharged from the grease
injected from grease nipple 2 is 550 cc.
® Mount the grease discharge port cover.
© Mount the U-axis cover.
of 550 cc or more is injected or if only a small amount of grease is
Note 2) Be sure to remove the U-axis cover before setting the W axis to the 90
degree position because the U-axis cover cannot be removed within the
Note 3) For the robot mounted on the ceiling the locations of the grease
injection port and discharge ports are same as those for the robot
mounted on the floor.
—
Packing
'lb
1
Grease discharge port cover
‘ for the U-axis gear box
Grease
U=90°
Grease nipple 2 for

the U-axis gear box
a Grease discharge
port cover
< for the U-axis gear box
TT
T
z
Grease nipple 1 for
the U-axis gear box
U cover
Fig. 2.2 (c) Replacing grease in U-axis reducer (S-700)
3-14
4) Replacing grease in the wrist gear box
(T) Set the U axis to a position of approximately 0 degrees and y axis to a
position of approximately 90 degrees.
® Apply grease to the grease nipple.
@ Continue injecting grease until the grease discharged from the grease
injected is 1200 cc.
0 Mount the grease discharge port cover.
of 1200 cc or more is charged or if only a small amount of grease is
Note 2) Be sure to remove the W-axis cover before setting the W axis to the 0
degree position because the W-axis cover cannot be removed within the
Packing
(O
yT
\s— Grease discharge port cover
A I gear
for the wrist box
O. .o
Grease oy
o o
Grease discharge port cover

for the wrist gear box
U=0°
7=90°
T
©
foQi
o
Grease nipple for the
wrist gear box
Fig. 2.2 (d) Replacement of grease in wrist gear box (S-700)
3-15
5) Replacing grease in offset wrist
® Set the U axis to a position of approximately 0 degrees and the y axis to
a position of approximately 90 or -90 degrees.
© Remove grease discharge port cover 1. (Wipe off the grease coming out
(D Apply grease to the grease nipple.
© Continue injecting grease until the grease discharged from grease
discharge port 1 becomes clean.
© Mount grease discharge port cover 1.
© Remove grease discharge port cover 2. (Wipe off the grease coming out
® Apply grease to the grease nipple.
(§) Continue injecting grease until the grease discharged from grease
® Mount grease discharge port cover 2.
Note 1) The standard amount of grease to be injected is 500 cc.
Note 2) Be sure to remove the Wÿaxis cover before setting the W axis to the 0
degree position because. the W-axis cover cannot be removed within the
1=901-90*
Wrist discharge port cover 1

U=0°
•• TX
Wrist grease nipple
Fig. 2.2 (e) Replacing grease in wrist (S-700 offset wrist)
3-16
6) Replacing grease in the in-line wrist
(T) Set the U axis and y axis to a position of approximately 0 degree.
© Remove grease discharge port plug 1.
© Apply grease to the grease nipple.
(D Mount grease discharge port plug 1.
© Remove grease discharge port plug 2. (Wipe off the grease coming out
@ Apply grease to the grease nipple.
© Mount grease discharge port plug 2.
@ Remove grease discharge port plug 3 and apply grease to the grease nipple
in the same manner as above.
® Mount grease discharge port plug 3.
Note 1) The standard amount of grease to be injected is 600 cc.

Note 2) For the robot mounted on the ceiling the locations of the grease
injection port and discharge port are same as those for the robot
mounted on the floor.
u=o°
Wrist discharge port plug 2

7=0°
n-
lL_
fis
-9
GL} _
\.o :a
IS*
n
C-
Wrist outlet plug 1
F
V
• 4
° :
O A
a
•
Wr
4
Wrist grease nipple
Fig. 2.2 if) Replacing grease in wrist (S-700) (in-line wrist)
3-17
--
2.3 Adding Grease e-axis Cross Roller Bearing
Add the grease in the 0-axis cross roller bearing every 2000 hrs. If, however,
the installation environment of the robot is bad, be sure to add grease when
necessary. If water is poured over the robot, be sure to change grease
immediately.
For the greasing points and method, see Fig. 2.3 and Table 2.3 (a).
Table 2.3 (a) Greasing points (S-700)
Item Greasing point Grease Greasing amount Greasing method
1 0-axis cross Shell 10 cc Apply grease to the

roller bearing ALVANIA No. 2 (Two points) grease nipple.
Table 2.3(b) Grease (S-700)
Grease
Mobil oil MOBILAC GREASE No. 2
ESSO standard oil VICON No. 2
Shell oil SHELL ALVANIA No. 2
Mitsubishi oil DIAMOND MULTIPURPOSE GREASE No. 2
Nihon oil No. 2 EPNOC
Idemitsu oil DAPHNE COLONEX GREASE No. 2
Maruzen oil UMAX No. 2
& 3
«ÿ
9-axis grease nipple
W
S3
.
Fig. 2.3 Greasing points (S-700)
3-18
3. TROUBLESHOOTING
3.1 General
The source of mechanical unit failures may be difficult to find because of
overlapping causes. Failures may become further complicated, if they are not
corrected properly. Therefore, it is necessary to keep an accurate record of
problems and to take proper corrective actions.
3.2 Failures and Causes

Major failures in mechanical unit and their causes are listed below:
1) Robot does not calibrate.

a) (Cause) Voltage of the memory backup battery is low.
(Measure) Replace battery. (Refer to 5.6)
2) Position error
a) (Cause) Robot struck an obstacle.
(Measure) Revise the teaching points.
b) (Cause) Robot is not firmly mounted.
c) (Cause) Peripheral, device is not properly positioned.
d) (Cause) Excessive load.
(Measure) Reduce the load. Ease moving conditions.
e) (Cause) System variables are not standard.
(Measure) Change the system variables to standard settings. (Refer to
the KAREL System Reference Manual.)
f) (Cause) A cable is disconnected or broken. (Pulse coder cable)
g) (Cause) APC abnormal.
(Measure)
h) (Cause)
Replace the motor. (Refer to 5.1 - 5.5)
Excessive backlash in mechanical unit. See next page.
(Measure) Adjust the backlash. (Refer to 4.4)
3) The robot vibrates.

a) (Cause) The robot is not bolted securely on the floor.
(Measure) Tighten the bolts firmly.
b) (Cause) The floor itself vibrates.
(Especially when the robot is installed on the second floor and
higher. )
(Measure) Change the robot mounting place.
c) (Cause) Excessive load.
(Measure) Reduce load. Ease moving conditions.
d) (Cause) The adjustment of the servo is faulty.
(Measure) Adjust the servo. (Consult GMFanuc)
e) (Cause) A cable is broken.
f) (Cause) Not grounded.
(Measure) Ground the robot. (Refer to 7.2)
g) (Cause) The motor is faulty.
h) (Cause) The reducer is faulty.
-
5.5)
(Measure) Replace the reducer. (Refer to 5. 1 -

5.5)
3-19
i) (Cause) The time constant is faulty.
(Measure) Revise time constant. (Refer to the KAREL System Reference
Manual. )
j ) (Cause) Excessive backlash. See below.
4) Excessive backlash
a) (Cause) Screws and pins are loose.
(Measure) Tighten screws. (Coat the specified area with LOCTITE. )
b) (Cause) The reducer is faulty.
c) (Cause)
- 5.5)
(Measure) Adjust the gear backlash. (Refer to 4.4)
(Measure) Replace the gear. (Consult GMFanuc.)
(Measure) Replace the bearing. (Consult GMFanuc.)
f) (Cause) A casing is broken.
(Measure) Replace the broken parts. (Consult GMFanuc.)
5) Abnormal noise
(Measure) Grease. (Refer to 2.2
b) (Cause)
-2.3)
Dust is in the gear or reducer.
(Measure) Flash and then grease. (Refer to 2.2
c) (Cause) Excessive bearing pressure
-
2.3)
(Measure) Adjust the pressure for the bearing. (Consult GMFanuc)

d) (Cause) The reducer is faulty.
e) (Cause)
- 5.5)
(Measure) Adjust the backlash. (Consult GMFanuc)
f) (Cause) A gear is worn.
g) (Cause) A bearing is worn.
h) (Cause) A cable bearing is broken.
i) (Cause) The adjustment of servo constants is faulty.
(Measure) Adjust the servo constants. (Consult GMFanuc)
6) Abnormal heat
(Measure)
b) (Cause)
Grease. (Refer to 2.2 - 2.3)
Nonspecified grease/oil is used.
(Measure)
c) (Cause)
Replace the grease/oil. (Refer to 2.2 - 2.3)
Excessive bearing pressure (Consult GMFanuc)
(Measure) Adjust the pressure for the bearing.
d) (Cause) Overload.
(Measure) Decrease the load or speed.
e) (Cause) The adjustment of the gear backlash is faulty.
(Measure) Adjust the backlash. (Consult GMFanuc)
f) (Cause) The time constant is faulty.
(Measure) Revise time constant. (Refer to the KAREL System Reference
Manual . )
3-20
7) Drop of an axis when the power is turned off.
a) (Cause) Brake gap is noticeable.
b) (Cause) Brake drive relay is defective.
- 5.5)
(Measure) Replace the relay. (Refer to 5.1 - 5.5)
8) Leakage of grease/oil
a) (Cause) O-ring, oil seal or packing is broken.
(Measure) Replace the broken parts.
b) (Cause) Casing is broken.
c) (Cause) Screws are loose.
(Measure) Tighten screws.
Table 3.2 (a) Allowable backlash value (S-700)
0 W U y 8 a
Angle conversion (min. ) 2.6 1.8 1.9 3.7 3.9 4.8
Displacement conversion 1.19 0.36 0.40 0.17 0.18 0.28

(mm) (1600) (700) (715) (160) (160) (200)
Note) The value converted into displacement indicates the backlash in the rotary
direction within the distance (shown in parentheses) from the center of
each axis.
The value is measured each axis by itself. If affected by few axes, add
allowable backlash value of relative axes.
Table 3.2 (b) Allowable falling value (S-700)
At power off 1.5 mm
At emergency stop 2. 0 mm
3-21
3.3 Replacing Parts and Performing Adjustments
After replacing a part, an adjustment is always required. The following table
shows the required replacements and adjustments.
Replacement part or function

Adj ustment
to be changed
Motor (a) Mastering
Cable (a) Routing and securing cable

(b) Limit switch
(c) Mastering
Limit switch (a) Limit switch and dog
Wrist unit (a) Output flange backlash

(b) Mastering
6-axis stroke (a) Limit switch and dog

W-axis stroke (b) Stop mounting position
(9-axis only)
(c) System variable
Battery Replace them keeping power on.

(Replace periodically once every No adjustment is needed.
year.)
3-22
4. ADJUSTMENTS
Mechanical parts have been adjusted to the optimum condition at the time of
shipment from our company. Therefore, they normally need not be adjusted by the
customer at the time of delivery.
Adjustments should be made as specified in this section after a long period of
use or after replacing a part.
4.1 Adjusting Limit Switches and Dogs

1) Zero position and working limit
Each controlled axis has its own zero position and motion limit area.
Operation range of each control axis is limited by a mechanical dog.
When the controlled axis reaches its working limit, it is called Overtravel
(OT) . Overtravel on each axis is detected at both extremes. The robot is
controlled so as to operate within the operation range unless a servo system
error causing the the loss of positional information or a system error
occurs.
Fig. 4.1 (a) - (g) show the zero positions and motion limits of each axis.
0°
Stroke
300°
+ I 50} r I 50}
OT OT
o
Vo
K
Mechanical Mechanical
stop stop
Note) The stroke can be changed.
Fig. 4.1 (a) 0-axis rotation (S-700)
3-23
0°
Stioke
.O'
£>/ /'0
N 180° kOi°
\
\ o
-90° + 90
\ /w Mechanical
Mechanical stop 0T 0T stop
Note) The motion range is limited by the U-axis position.
Fig. 4.1 (b) W-axis rotation (S-700)
Stioke
390°
0°
+270°
-120°
Stroke end
Stroke end
Note) The motion range is limited by the W-axis position.
Fig. 4.1 (c) U-axis rotation (S-700)
3-24
0°
Stroke
380°
-190°
+ I 90°i
Note) The 0T limit switch and mechanical stop are not used for the Y axis.
Fig. 4.1 (d) Y-axis wrist rotation (S-700)
3-25
0°
Stroke
380s
-190°
«»ÿ
+ I 90°l
Note) The 0T limit switch is not used for the S axis.
Fig. 4.1 (e) /3-axis wrist rotation (S-700)
0°
Stroke
540°
+ 270° -270°
T
Note) The 0T limit switch and a mechanical stop are not used for the a axis.
Fig. 4.1 (f) a-axis wrist rotation (S-700)
3-26
0°
Oo
to h
Stroke end
Mechanical
stop or
OT
Mechanical stop Stroke end
Note) The allowable range for the relative angle between the W-axis and U-axis
arms is a minimum of 10° and a maximum of 270°.
Fig. 4.1 (g) W/U limit interference angles (S-700)
3-27
2) Adjustment method
a) ©-axis adjustment method
® Move the 9-axis to the end of the stroke.
(2) Press the EMERGENCY STOP button and remove the rear cover from the W
base.
(2) Loosen the bolt at the alotted hole of the dog and move the dog under
the proximity switch.
© Using the slotted hole of the proximity switch mounting plate, adjust
the distance between the proximity switch and the dog (to
approximately 1 mm) .
At this time, check that the proximity switch lamp lights.
(D Shift the dog to a point approximately 5 mm away from the point where
the lamp of the proximity switch goes off and mount the dog.
© Check that the stroke and operation limit are as shown in Fig. 4.1
(a).
® Mount the cover of the W base.
O O
£5ÿ A
o
P
to o
J
o <c-
'o
u
[
V 0-axis dog
to
0 IO
o to
[ P
c p o, 3
c .O Q
p Q,
oo£
o o
Lamp for checking

proximity switch
m A
W base
i
Arrow A Proximity switch mounting plate
Fig. 4.1 (h) Adjustment of 0-axis OT (S-700)
3-28
b) W-axis adjustment method
8 Move the W axis to the end of the stroke.

Press the EMERGENCY STOP button. Remove the side cover.
(3) Loosen the bolt at the slotted hole of the dog and move the dog to the
position where the limit switch contacts.
© Adjust the limit switch position within the specified position.
(Loosen the bolt mounting the limit switch and use the slotted hole to
adjust the limit switch position.)
© Shift the dog position to a point 5 mm away from the point where the
limit switch is released and mount the dog.
(b).
® Mount the side cover.
Cover
o ©
W-axis limit switch

.0 o.
W-axis dog
W-axis dog
|l
RJ
Ms
II
/m\
Play for limit switch
Fig. 4.1 (i) Asjustment of W-axis OT (S-700)
3-29
c) U-axis adjustment method
© Move the U axis to the end of the stroke.
(2) Press the EMERGENCY STOP button. Remove the side cover.
(2) Loosen the bolt mounting the limit switch.
© Adjust the limit switch position so that the limit switch is turned on
at a point two to three degrees from the stroke end and mount the
limit switch.
(g).
© Mount the side cover.
O
Limit switch mounting plate
A
Dog (U=0°)
Cover
'A w
7 £ l
Loosen the screw and adjust
in the direction of the arrow.
|l
S.S
#!
11
Play for limit switch
Fig. 4.1 (j) Adjustment of U-axis OT (S-700)
3-30
4.2 Stroke Modification
4.2.1 0-axis stroke modification

It is possible to limit the O-axis stroke as required by the surroundings for
the robot. The stroke can be changed as shown in Fig. 4.2.1 (a). It can be
changed in increments of 15° according to the OT stroke by changing the dog
position, the mechanical stop or system variable.
The stroke must always include either 0° (front) or +90° for mastering. In
addition, select the + and -
sides from the following:
Front
+30*
+ I 5*
•
±0* - I 5*-30’
+45° -45*
+60* -60*
+75* -75*
+ 90* -90*
+ 105* -105*
+ 120* -120*
•+ I 35* * - I 35*
+ 150* - I 50*
Note 1) Standard stroke
-150° - +150°
Note 2) Always keep the stroke within the range from -150* to +150“
when changing it.
Stroke setting range

Mastering position
+ side - side
0° +150° - +15* -15° - -150*
+90° +150° - +105° +75° - -150*
-90° +150° - -75° -105° - -150°
Fig. 4.2.1 (a) 8 -axis stroke modification (S-700)
3-31
1) Changing the dog and mechanical stop positions
Change the dog and mechanical stop positions according to the desired stroke
position as shown in Fig. 4.2.1 (b).
Front
-135 135°
- I 20°, + 120°
Standard ±150"
+ 105°
.4- A,
[9J
•i
V®
-90°
9i
* o o m.
91
<o
o o
o>
SL+90°
9 f®, 9
p O
-75° •7 +75°
p o
\9 fir
vo o;
-60° o > i o
®.
£7+60°
o \ / y /+ w
-45°
•
2-
+45°
ar
C®
-30° + 30°
%SDÿ
15° i (gBi + 1 5°
-0° +0°
Note) Top view of 0-axis.
Fig. 4.2.1 (b) Changing dog and mechanical stop positions (S-700)
3-32
a) Changing the minimum and maximum command pulses
$L0WERLIMS[1]: 0-axis stroke lower limit pulse
$UPPERLIMS[1]: 0-axis stroke upper limit pulse
Set a numeral so that upper pulse should always be greater than lower
pulse.
$L0WERLIMS[1] $UPPERLIMS[1]
Position
_
(0-axis stroke lower limit
pulses) pulses)_
(0-axis stroke upper limit
-150° -2.617993878
-135° -2.356194490 -2.356194490
-120° -2.094395102 -2.094395102
-105° -1.832595714 -1.832595714

-90° -1.570796326 -1.570796326
-75° -1.308996939 -1.308996939
-60° -1.047197551 -1.047197551
-45° -0.785398163 -0.785398163
-30° -0.523598775 -0.523598775
-15° -0.261799387 -0.261799387
0° 0.0 0.0
+15° 0.261799387 0.261799387
+30° 0.523598775 0.523598775
+45° 0.785398163 0.785398163
+60° 1.047197551 1.047197551
+75° 1.308996939 1.308996939
+90° 1.570796326 1.570796326
+105° 1.832595714 1.832595714
+120° 2.094395102 2.094395102
+135° 2.356194490 2.356194490
+150° 2.617993878
3-33
4.2.2 W-axis stroke modification
The W-axis stroke can be limited as required by the surroundings of the robot.
a) Changing the dog position
The stroke can be changed at every 10 degrees as shown in Fig. 4.2.2 (a). It
can be changed in according to the OT stroke by changing the dog position.
Select the stroke from these on the + side and -
side including the mastering
point of 60° shown in this figure.
Note) Mechanical stop cannot be changed.
Upward
+ | 0* ±0*- | 0*
+20° -20*
+30* -30*
+40“ -40*
+50* -50*
+60* -60*
+70° -70*
+80* -80*
Front +90* -90* Rear
Note) Standard stroke

-90° - +90°
Stroke setting range
Mastering position
+ side - side
+60° +90° - +60° +60° - -90°
Fig. 4.2.2 (a) W-axis stroke modification (S-700)
3-34
b) Changing the minimum and maximum command pulses
$L0WERLIMS[2] : W-axis stroke lower limit pulse
$UPPERLIMS[2]: W-axis stroke upper limit pulse
Position $L0WERLIMS[2] $UPPERLIMS[2]
-90° -1.570796321
-80° -1.396263396
-70° -1.221730472
-60° -1.047197547
-50° -0.872664623
-40° -0.698131698
-30° -0.523598774
-20° -0.349065849
-10° -0.174532925
-0° 0.0
+0° 0.0
+10° 0. 174532925
+20° 0.349065849
+30° 0.523598774
+40° 0.698131698
+50° 0.872664623
+60° 1.047197547
+70° 1.221730472
+80° 1.396263396
+90° 1.570796321
3-35
1) Dog position change
Change the dog position according to the desired stroke position as shown in
Fig. 4.2.2 (b).
-0° +0°
-10° + I 0°
-20° + 20°
-30° + 30°
,o o
-40° I 7 + 40°
-50° +50°
-60° + 60°
-70° &
r/
+ 70°
-80°
0 Standard ±90°
B +80°
Front I 2 2 J
Fig. 4.2.2 (b) W-axis stroke modification (S-700)
3-36
4.3 Mastering Procedure
4.3.1 Introduction
This procedure describes the mastering procedure for a robot with an absolute
pulse coder system. No operation is required for calibration with this system.
The robot is automatically calibrated when power is turned on and the system
becomes ready. Mastering is the establishment of an absolute reference point
(or known location) as the mastering position of the robot. The known location
can be the zero position (determined by aligning the zero witness marks on a
particular axis or by making precise measurements according to specified
distances) or a location determined by moving the axis into a mastering fixture.
The method used for determining the known location is dependent on the robot
model and is described in detail in Sections 4.3.3 and 4.3.4.
Using a mastering fixture is the most accurate and recommended mastering
procedure. Note that the same mastering fixture should be used for all robots
in a system.
Mastering is done at the factory and generally is not required as part of the
daily operation. Mastering will need to be done when a mechanical part has been
replaced or altered, if the system variables dealing with mastering have been
lost or changed, or if the positional information from the absolute pulse coders
has been lost.
4.3.2 Mastering procedure
1. Power up the controller.
2. Turn REMOTE ON/OFF switch ON.
4. Using the teach pendant, jog the mechanical unit to the mastering position
described in Section 4.3.3.
3-37
5. Using the CRT/KB (with REMOTE switch turned to ON) enter UTIL in response
to the KCL> prompt
6. In response to the UTIL> prompt enter MASTER.
7. Enter Y in response to the displayed question “Are you sure?”
8. At the prompt “Mastering at 0 degrees Y/N?” enter:

Y if you are mastering at the zero-degree position or
N if you are mastering using a mastering fixture.
9. Press ENTER twice.
10. Power down and up.
3-38
4.3.3 Zero-degree position
The zero-degree position of the S-700 robot is shown in Fig. 4.3.3.
8
a
F=pMI
,-QSmm M
VIEW B
VIEW C
B
fis
&
8
O
§
I C
I
J
§ €
Offset wrist In-line wrist
<ÿ
Slf
O
93
J
BE 8:
<> A
ujo •U1
y._ VIEW A
cm 5=ÿ
Co
Fig. 4.3.3 Zero degree marks of each axis
3-39
4.3.4 Mastering using a mastering fixture
When a major part of the robot mechanical unit is replaced and the actual
position of each axis is not the same as the current value stored through an
absolute pulse coder (APC) , mastering is required to establish the actual
position of the robot.
When mastering the robot, meet the following conditions:
. Level the robot mounting base. It should not deviate from the horizontal by
more than 1 mm.
. Remove the hand and other parts from the wrist.
. Make sure that nothing is leaning on or pushing against the robot.
Note) since the axis stroke is not limited during mastering, be careful around
equipment that is normally protected by the motion limits.
1) Mastering procedure
If it is necessary to change the mastering point of the 0-axis, change the
system variable $MASTER_P0S[1] value before mastering according to the
following procedure:

2. At the KCL> prompt, enter SET VAR $MASTER_P0S[1]=
-1.570796327 0 = -90°
1.570796327 0 = 90°
0 0 = 0°
3. When the KCL> prompt reappears, enter SSAVE SYS_STANDARD.
a) Mount the mastering fixture

i) Mounting the mastering fixture on the robot main frame.
Mount two blocks and six dial indicators on the mastering fixture as
shown in Figure 4.3.4 (a). If the bolts are tightened too hard, the
dial indicator can be broken.
Next, remove the side cover of the 0-axis base of the robot main
frame and mount the fixture on the base.
If three bolts are mounted on the back of the fixture, it is easy to
mount the fixture on the base.
Besides the mastering position where 0 = Zero degree, mastering can
be done at 0 = +90 degrees. In this case, to ensure accuracy,
perform mastering at same point as the point for the previous
mastering. At shipment, mastering is performed at the point of 0 =
Zero degree. Therefore, be sure to perform mastering at the point
of G = Zero degree if there is no problem.
3-40
'
Blocks (Two)
Dial indicators (Six)
Clamps (Six)
Bolts MSxlO (Six) (Do not tighten
? y
the bolts too hard. Be sure to check
that the dial indicator can move
Bolts M8x25
i
l i
smoothly when tightening the
bolts.)
(Three)
u 0
(9 © 0
o M3
-M Bolts M8x2S (Four)
Pins (Two)
Fig. 4.3.4 (a) Mounting mastering fixture on robot main frame (S-700)
ii) Calibrating dial indicators

Mount the calibration block using collars, pins, and bolts as shown
in Fig.’ 4.3.4 (b) and adjust each dial indicator to indicate 3.00
+0.02 mm.
When calibration of the dial indicators has been completed, remove
the calibration block carefully and mount it on the position shown
in Fig. 4.3.4 (c). At this time, be sure to check that the tip of
each dial indicator moves smoothly.
3-41
Dial indicator No. 4

Dial Tidicator No. 5
Collar Calibration block

gauge No. 2
>> Pinj (Two)

Dial indicator No. 1 0
G.
c §c
Bolts M6x60 (Two)
0
c &
c <?.

"V®
Fig. 4.3.4 (b) Dial indicator calibration (S-700)
Calibration block
luo I
o Q\
y o
o O
o O 1® o o
Oo oO
HL®
Fig. 4.3.4 (c) Calibration block mounting position after completion of calibration (S-700)
3-42
iii) Mounting fixture on wrist
Jog the wrist to the position where a 8 y = =
0 degree, and mount =
the fixture on the a-axis flange as shown in Fig. 4.3.4 (d) Note .
that the fixture mounting surfaces of the offset wrist and of
in-line wrist are reversed.
a
£K
Offset wrist
HltOl
re Sj) Bolts Ml 0x35 (Four)
Pins 010 (Two)
0 0
0
to
C
N.
01
In-line wrist
Bolts Ml 0x35 (Four)
Pins 010 (Two)
Fig. 4.3.4 (d) Mounting fixture on wrist (S-700)
b) Mastering procedure
i) First, master the robot to the zero-degree alignment described in
section 4.3.3. This mastering operation allows the setting of the
temporary coordinate origin of the robot that enables the use of the
Cartesian coordinate system for the following mastering operations
and easy alignment of the mastering fixture.
ii) Set the robot in the mastering position shown in Fig. 4.3.4 (e).
Note that the a-axis and y-axis positions are different for the
offset wrist and in-line wrist.
Align the mastering fixture according to the following procedure:
0 Move the robot gradually to the position where the fixture
mounted on the wrist touches the dial indicators. At this time,
pre-adjust each axis so that dial indicators No.l, No. 2, No. 3,
No. 4, and No. 5 touch the fixture almost simultaneously.
0 Move the y-axis so that dial indicators No.l and No. 2 indicate
the same value.
3-43
© Move the o-axis so that dial indicators No. 4 and No. 5 indicate
the same value.
© Set the Cartesian coordinate system and move the wrist in the Y
direction so that dial indicators No. 4 and No. 5 indicate 3.00
+0.02 mm. If dial indicator No.l and No. 2 indicate different
values, return to step © .
© Move the B-axis so that dial indicators No. 2 and No. 3 indicate
the same value.
© Jogging in the world coordinate system, move the wrist in the
X-axis and Y-axis 'directions so that dial indicators No.l and
No. 6 indicate 3.00+0.02 mm.
© At completion of the above steps, check that all dial indicators
indicate 3.00 +0.02 mm.
iii) Perform the mastering procedure described in Section 4.3.2, starting
at Step © .
o
'O'
/
/
1
m -2 mIS &
INI
0 = -90°, 0°, 90° 0 = -90°, 0°, 90°

w = 60° W = 60°
U = -110° U = -110°
Y = -90° Y = 0°
13 = -70° B = -70°
a = 90° a = 0°
Fig. 4.3.4 (e) Mastering position (S-700)
3-44
4.4 Adjusting Bevel Gear Backlash
1) W-axis bevel gear
$ Remove the W-axis motor. (Refer to 5.2)

Remove the W-axis reducer. (Refer to 5.2)
(2) Remove the four M6x20 bolts and gear WM unit (V302).
© Remove the four M6x20 bolts and gear WR unit (V301).
-
© Adjust the backlash within 0.05 0. 1 mm (on P.C.D.) using shims (X327,
X329, X330, X332). When using a dial indicator, put it to the bottom of
the gear (see Fig. 3.4 (a)) and adjust the backlash within 0.015
mm.
0.03 -
© Reassemble reversing the above procedure. Apply L0CTITE to the bolts.
M6X20 Measuring point

(Dial indicator)
it i W-axis reducer
i
jfli!Ul&D I
Gear WR unit (V301)
Shim (X327. X329)
§3
*
Shim (X330, X332)
Gear WM unit (V302)
W-axis motor
Fig. 4.4 (a) Adjusting W-axis bevel gear backlash
3-45
2) U-axis bevel gear
® Remove the U-axis motor (Refer to 5. 3)
(D Remove the U-axis reducer (Refer to 5.3)
QD Remove the four M6x20 bolts and gear UM unit (V402).
.
I Remove the four M6x20 bolts and gear UR unit (V401)
Adjust the backlash within 0.05
X436, X437, X439) . -
0. 1 mm (on P.C.D.) using shims (X434,
When using a dial indicator, put it to the bottom of
the gear (see Fig. 3.4 (b)) and adjust the backlash within 0.02 0.04 -
mm.
© Reassemble reversing the above procedure. Apply LOCTITE to the bolts.
Shim (X437, X439)
Gear IIM unit (V402)
U-axis motor
a *M6X2i
16X21
\i
w
Shim (X434, X436)
Measuring point
(Dial indicator)
Gear UR unit (V401)
U-axis reducer
Fig. 4.4 (b) Adjusting U-axis bevel gear backlash
3-46
3) B-axis bevel gear (OFFSET WRIST)
(D Remove the wrist unit.
(2) Remove the B-axis reducer.
CD Remove the four M4xl2 bolts and gear a/B unit (V501).
@ Remove the gear BR (X507) .
-
© Adjust the backlash within 0.05 0. 1 mm (on P.C.D.) using shims (X516,
X518, X519, X521). When using a dial indicator, put it to the tooth of
the gear.
© Reassemble reversing the above procedure. Apply LOCTITE to the bolts.
4) a-axis bevel gear (OFFSET WRIST)
(T) Remove the wrist unit.
I© Remove the B-axis and a-axis reducer.

Remove the four M4xl2 bolts and gear a/B unit (V501).
Remove the gear A (X509) .
I Remove the gear a unit.
Adjust the backlash within 0.05 -
X524, X525, X527). When using a dial indicator, put it to the tooth of
the gear.
(7) Reassemble reversing the above procedure. Apply LOCTITE to the bolts.
Note) When adjusting the B-axis bevel gear, be sure to adjust the a-axis bevel
gear (a/B gear unit), too.
a-axis reducer
Shim (X525, X527)-
Gear a unit CV502)
7
Gear A (X509)
Shim (X522, X524)
iP
(3-axis reducer
F
Shim (X516.XS18)
Gear alt3 unit (V501) A Shim (X519.X521)

Gear BR (X507)
Shim (X522, X524)

Gear A (XS09)
Shim (X522, X524)
Fig. 4.4 (c) Adjusting a/0-axis bevel gear backlash (offset wrist)
3-47
5) B-axis bevel gear (IN-LINE WRIST)
Q Remove the wrist unit.
(2) Remove the fl-axis reducer.
@ Remove the four M4xl2 bolts and gear a/fl unit (V501).
@ Remove the gear BR (X558).
© Adjust the backlash within 0.05 -
X518, X519, X521). When using a dial indicator, put it to the bottom of
the gear (see Fig. 3.4 (d)) and adjust the backlash 0.06 0.13 mm.
(6) Reassemble reversing the above procedure. Apply LOCTITE to the bolts.
-
6) a-axis bevel gear (IN-LINE WRIST)
(I) Remove the wrist unit.
(2) Remove the a-axis reducer.
(|) Remove the wrist casing (X552).
(4) Remove the gear a/S unit (V501), gear A (X560), gear al unit (V512), gear
a2 unit (V511).
(5) Adjust the backlash within 0.05 -
0. 1 mm (on P.ClD.) using shims (X522,
X524, X525, X527, X566, X568). When using a dial indicator, put it to
the tooth of helical gear (see Fig. 3.4 (d)) and adjust the backlash 0.13
-0.25 mm (tangential direction).
(D Reassemble reversing the above procedure. Apply LOCTITE to the bolts.
Note) When adjusting the B-axis bevel gear, be sure to adjust the a-axis bevel
gear (a/B gear unit), too.
Gear a2 unit (V512)
Gear A (X560) Measuring point Shim (XS66, XS68)

(Dial gauge)
Shim (X566, X568) Shim (XS25, XS27)
Gear a2 unit (VS11)
Gear a/p unit (V501)
Shim (X516, X518)
TO
Shim (X522, X524)
Measuring point
(Dial indicator)
__
i I U JF= ==j \ — at-axis reducer
T -
' Wrist casing (X5S2)
v*i Shim (XS19, X521)
Gear BR (XS58)
0-axis reducer
Fig. 4.4 (d) Adjusting a//3-axis bevel gear backlash (in-line wrist)
3-48
5. REPLACING PARTS
5.1 Replacing 6 -axis Motor and Reducer

1) Replacing the 9-axis motor
I Set the W axis close to +90 degrees.

Remove the bottom cover and plate and three side covers from the W-axis
base.
I Remove the 9-axis motor connector.

Remove the motor mounting bolt (M10x20) and the motor from the bottom
window of the W-axis base.
(D Remove the C ring and pull off the input gear and coupling. Remove the
draw bolt and pull off the input spline.
(§) Replace the motor and mount it reversing the above procedure. Apply
LOCTITE (No. 242) to the draw bolt.
ran
Packing
Ii
v...
Cover Plate
Input spline
/
Draw bolt
Coupling
T T
o C3 o
input gear
Washer
C-ring
4-
V
IXCll
Cover
Fig. 5.1 (a) Replacing d-axis motor (S-700)
3-49
2) Replacing the 0-axis reducer
(D Remove the air hose and EE cable from the EE connector panel.
© Remove the motor connectors of all axes.
(5) Remove the pin and clamp from the 0-axis cable and push the cable into
the base.
8 Remove the M10x30 bolt and spring pin mounted on the W-axis base.
Hang the W/U-axis unit being careful of the cable and remove it from the
0-axis unit.
© After removing the 0-axis connector panel and ground line, remove the
cable and cable track.
© Remove the 0-axis motor mounting bolt (M10x20) and the motor.
© Remove the bolts (M10x25) mounting the holder to the cross roller bearing
and remove the holder.
© Remove the M12x60 bolt and dl0x30 taper pin mounting the table to the
reducer.
@ Remove the table together with the holder and cross roller bearing, and
then the 0-ring.
(Q) Remove the reducer and the bolt (Ml 4x110) and taper pin (ÿ13x40) mounting
the reducer to the 0-axis base.
Remove the reducer and replace it.
Mount the new reducer reversing the above procedure. Polish the reducer
mounting surface and motor flange mounting surface with an oilstone.
Apply LOCTITE (No. 262) to the bolts removed in steps 9 and 11
LOCTITE (No. 242) to the taper pins removed in steps 9 and 11
..
Apply
Ream
the hole and insert the pin.
Be sure to mount the 0-ring on the specified position.
(Q) Apply grease.
Note) Be sure to tighten the reducer mounting bolts with the following
tightening torque:
M14xll0... 2090 kg. cm
M12x60.... 1310 kg. cm
3-30
/TVV
_/
O C3 o
W-axis unit ' /X
Pin
run B -axis AC servomotor
El
Clamp
r Packing
Holder
Table unit
]
9 -axis reducer '

O-ring
9-axis base
IIXI 4B. c . rxin
..
Fig. 5.1 (b) Replacing 0-axis reducer (S-700)
3-51
5.2 Replacing W-axis Motor and Reducer
1) Replacing the W-axis motor
(T) Remove the plug and move the W axis manually using a box wrench with a
width of 13 mm until it lightly touches the rubber stop.
f ' © Remove the cover.
© Remove the cable from the motor.
I Remove the motor mounting bolt (M12x30) and the motor.

Remove the spline from the motor.
(5) Replace the motor and mount the new motor reversing the above procedure.
Apply LOCTITE (No. 242) to the motor screw.
Note) For manual movement, the W axis moves in the rotary direction of the
manual crank.
Hexagonal head CWidth 13 mm)
Sn Phig Box wrench
ro
94 s
X
2
S
<
Manual crank
Packing
Nut Cover 1
Washer
Spline
Manual crank
rotary direction
W-axis motor
W-axis stop
/
/I
Cover 2
Oil
l
Fig. 5.2 (a) Replacing W-axis motor (S-700)
3-52
2) Replacing the W-axis reducer
(I) Remove the plug and move the W axis manually using a box wrench with a
(2) Remove the bolt (M12x55) and taper pin W13x30) mounting the cover to the
reducer, and remove the cover and 0-ring.
I Remove the bolt (M14xl20) and taper pin (ÿ13x40) mounting the reducer.
Remove the reducer and replace it.
(D Mount the new reducer reversing the above procedure.
Polish the reducer mounting surface and motor flange mounting surface
with an oilstone. Apply LOCTITE (No. 262) to the bolts removed in steps
(D and (3). Apply LOCTITE (No. 242) to the taper pins removed in steps
© and ©. Ream the hole and insert the pin. Be sure to mount the
0-ring on the specified position.
© Apply grease.
Note 1) Be sure to tighten the reducer mounting bolts with the following
tightening torque:
M14xl20 2090 kg. cm
M12x55 1310 kg. cm
Note 2) For manual movement, the W axis moves in the rotary direction of the
manual crank.
Hexagonal head (Width 13 mm)
Plug Box wrench
@
94 2
X
o
Q.
<
Manual crank
W-axis reducer Cover Plug
O-ring
E*
nr
Fig. 5.2 (b) Replacing W-axis reducer (S-700)
3-53
5.3 Replacing U-axis Motor and Reducer
1) Replacing the U-axis motor
(T) Remove the plug and move the U axis manually using a box wrench with a
© Remove the cover.
(3) Remove the cable from the motor.
i Remove the motor mounting bolt (M10x20) and the motor.

Remove the spline from the motor.
(6) Replace the motor and mount the new motor reversing the above procedure.
Apply LOCTITE (No. 242) to the motor screw.
Note) For manual movement, the U axis moves in the rotary direction of the
manual cranck.
A Hexagonal head (Width 13)
Plug Box wrench
\ y
22 «T»
<N
*
2
o.
a.
<
Manual Crank
Cover
V
U-axis stop
a o/ o
__1
7 O-ring
U-axis motor
Manual crank
rotary direction
v.
Spline
Fig. 5.3 (a) Replacing U-axis motor (S-700)
3-54
2) Replacing the U-axis reducer
(T) Remove the plug and move the U axis manually using a box wrench with a
2
( ) Remove the bolt (M8x50) and taper pin (ÿ8x30) mounting the cover to the
reducer, and remove the cover and O-ring.
Q) Remove the bolt (M12x85) and taper pin (ÿ10x40) mounting the reducer
after removing the taper pin in the reducer.
(§) Remove the reducer and replace it.
(5) Mount the new reducer reversing the above procedure. Polish the reducer
Apply LOCTITE (No. 262) to the bolts removed in steps (2) and Apply ®.
LOCTITE (No. 242) to the taper pins removed in steps (2) and (|) Ream .
the hole and insert the pin. Be sure to mount the 0-ring on the
specified position.
(§) Apply grease.
tightening torques
.
M12x85 •• 1310 kg. cm
M8x50 380 kg. cm
Note 2) For manual movement, the U axis moves in the rotary direction of the
manual crank.
Hexagonal head (Width 13 mm)
72 Plug
Box wrench
c
*1 •El •
<1
!Q
X
Oi
Manual crank
U-axis reducer Cover Plug
cF D
• « n. »i
©
0 ©
O-ring
BOS
Taper pin in the reducer
<?10x40 taper pin

Fig. 5.3 (b) Replacing U-axis reducer (S-700)
3-55
5.4 Replacing a//3/y-axis Motor and Reducer
1) Replacing the a/8/y-axis motor
Q Remove the loads such as a hand and end effector from the wrist.
0 Drain grease from the gear box. (Note 2)
0 Remove the motor mounting bolt (M6xl6) and the motor using the exclusive
T-wrench.
0 Remove the nut and the gear.
0 Replace the motor and mount the new motor reversing the above procedure.
(First, mount the B-axis motor.)
0 Add new grease.
Note 1) The three motors of the wrist can be mounted to any mounting hole.
Therefore, be sure to mount the motor with the gear on the correct
mounting position. >Si‘\ •
Note 2) When place the robot (U ** -90°) where no grease drop at motor
replacement, it is not required to drain grease.
Note 3) When removing the bolts indicated by an arrow, use the exclusive long
T-wrench (A05B-1120-J047) .
Gear mounted on each motor
Axis a B Y a T
of gear _
Outer diameter
Large Medium Small P
Shape
c53 T? /
m 7
(Note 3) N
Helical gear
a-axis motor Rear view
Washer
Packing Nut
Helical gear
0-axis motor Washer
f?
Packing Nut
Helical gear
7-axis motor Washer
t L
Packing Nut
Fig. 5.4 (a) Replacing a/|3/y-axis motor (S-700)
3-56
2) Replacing the y-axis reducer
(I) Remove the loads such as a hand and end effector from the wrist.
©
©
Drain grease from the gear box.
Remove the arm mounting bolt (M8x30) and the spring pin
remove the arm unit.
and .
© Remove the bolt (M12x30) and taper pin (M8x25), and remove the adapter.
© Remove the bolt (M8x40) and taper pin (ÿ6x25) mounting the reducer.
© Remove the reducer and replace it.
(7) Mount the new reducer reversing the above procedure. Polish the reducer
Apply LOCTITE (No. 262) to the bolts removed in steps and © Apply .
LOCTITE (No. 242) to the taper pins removed in steps © and © Ream .
the hole and insert the pin. Be sure to mount the O-ring on the
specified position.
(D Apply grease.
tightening torque:
M12x30 ...
.... 1310 kg. cm
M8x40 380 kg. cm
7-axis reducer Adapter Arm unit
I h
o a—
* I
O-ring
\
Fig. 5.4 (b) Replacing y-axis reducer (S-700)
3-57
5.5 Replacing Wrist Unit
© Remove the loads such as a hand and end effector from the wrist.
© Drain grease from the wrist unit.
© Remove the wrist unit mounting bolt (M8x25) and spring pin (d6x20) , and
remove the wrist unit.
@ Replace the wrist unit and mount the new wrist unit reversing the above
procedure.
(5) Apply grease.
Wrist unit
U-axis arm O-ring '

Iv A0
- l"‘W
u
->
Fig. 5.5 (a) Replacing wrist unit (S-700, offset wrist)
Wrist unit
U-axis arm O-ring
6° O'
-> p
•g. o o9
m i
Fig. 5.5 (b) Replacing wrist unit (S-700, in-line wrist)
3-58
5.6 Replacing Battery
The positional data of each robot axis is stored by the pulse coder, which is
powered by a backup battery. The battery needs to be replaced every year
according to the following procedure:
(T) Turn on the power and press the EMERGENCY STOP button to prohibit the robot
motion.
© Remove the lid from the battery case.
© Remove the batteries from the battery case.
© Remount the new batteries. Confirm the pole direction.
(5) Remount the lid.
>
\ c )
/
7 I
9
i i
© (»
©
& o c
4
Lid la
Batteries
c DQ%
-
Battery case
o
2. O
Remount batteries in correct
direction as shown in the
figure.
Battery spec: A98L-0031-0005, 4 pcs., 1.5V, size D
Fig. 5.6 Replacing battery (S-700)
3-59
6. WIRING AND PIPING
6.1 Piping Diagram

Fig. 6.1 shows the piping diagram of the mechanical unit.
Z I
>
Panel union PT 1/8 female

w \
Air hose $8 H
i
l
\
\ V
a M
/
V
—
Fig. 6.1 Piping diagram (S-700)
•©
Panel union
PT 1/8 female
6.2 Wiring Diagram

Table 6.2 shows the cable list and Fig. 6.2 shows the wiring diagram of the
mechanical unit.
Table 6.2 Cable list IS-700)
Cable Specification Remarks
K101 A660-8007-T038 9, W, U pulse coder
K102 A660-8007-T039 a, !3, y pulse coder
K103 A660-4002-T87 1 0, W power, brake
K.104 A660-1120-D001 ct, 6, y, U power, brake
K105 A660-8007-T040 DI/DO, limit switch
K106 A660-1120-D002 0 proximity switch
3-60
! r ;
CONTROLLER MECHANICAL UNIT
Z!
K92
PI
KI0I
CP
e
6 MOTOR
/
—
[M U
-[P U MOTOR
P
M
§
i
£h
Oi
tn
K93
P2
BATTERY
K I 02
—
[M W
[p W MOTOR '
—
[M r
[B
r MOTOR
Ml
—
LO
ON
§
g.
K31
oc K I 03
< [M $
B
/> MOTOR
2.
M2
2
K32 K I 04
C
—
S' DI
K91 K I 05 [M a
§
' H »OT C WB « MOTOR
K 1 06
r*-WOT °i EE
OljrFI
]D—
6.3 Limit Switch Installation Diagram
Fig. 6.3 shows the installation diagram for the limit switches in the mechanical
unit.
!7
U-axis OT limit switch
W-axii OT limit switch
V
\
9-axis OT
proximitely switch
1
r
O
Fig. 6.3 Limit switch installation diagram (S-700)
3-62
6.4 Cable Installation Diagram
Check the appearance of each cable for any faults.
1) Remove the W-axis base and the side cover of the W-axis arm and check for
rubbing of the cables when the W axis and U axis are moved.
Also check if the cables are caught in the cover.
2) Check whether the routing of the cables connected to the end effector is
suitable to the wrist motion or the service motion of the robot.
Fig. 6.4 shows the installation diagram for the cables in the mechanical
unit.
mm
fa!
K101
K102
K104
lid
iiiHlift
TT K105
I
\
/
/r_
i-i-
r% -r
lio \ . qUJ
K103 \
c \
o
O K106
) =h=
l L
']
Fig. 6.4 Cable installation diagram (S-700)
3-63
7. REPLACING CABLES
A broken or damaged cable should be. replaced as specified in this section. If
the pulse coder cable (K101, K102) connector is disconnected at the same time
that the pulse coder cable to the battery is disconnected the motor loses its
absolute position. Therefore mastering is required to reteach the present
position. Be careful to disconnect only one set of cables carrying power to the
pulse coder at one time.
7.1 Cable Forming

When mounting the replaced cable with clamps and tie wraps, clamp it at the
positions specified in Table 8.1. Unless the cable is clamped at the specified
positions, the cable may be broken due to excessive sagging or tension.
3-64
Table 7.1 Cable clamping positions (S-700)
Stamp Cable clamping position Stamp Cable No.
Clamping position
ep
PI Yl WP -K 1 0 1
38tÿ
l3S<ÿ
23 If
*6 UP
332fl 368g.
O TP
P2
Y O HP K I 02
I Cm *p
38Cÿ_
!3Sÿ,
23 Ifl
274ÿ
366g
'v
W
Ml K I 03
WM
34c;
I 3I
3?7g
2
UM
M2 —
l cm
a
05
rM
r BK
0M K I 04
—
340,.
»3Kÿ <Ctt 0BK
22 7j)
270<ÿ l!=j=CDi «M
328fr 364Q 1 cm «BK
3420
2840
24 10
C.
Dl ==Ctt EE K I 05
I
J-2£U 34Cÿ,
>3I<ÿ
270ÿ
328ÿ
364Q
3-65
7.2 Replacing Cables
0 Remove the U axis and cut the tie wrap mounting the connectors. (See Fig.
7.2 (a).)
(2) Remove all connectors.
© Remove the end effector plate and remove the connectors.
© Remove the side cover of the W-axis arm and remove the plate clamping the
cables.
© Cut the tie wrap and pull out the cables.
U-axis covex
Cut the tie wrap and remove

the connectors.
_ .
\
I
a-i \
Cl
End effector plate /l
©
"i Remove the plate and

cut the tie wrap.
B
a \
Pull out the cables
W-axis aim cover
Fig. 7.2 (a) Replacing cables (S-700)
3-66
(6) Remove the side cover of the W-axis base and remove the plate and cable
guide clamping the cable. (See Fig. 7.2 (b).)
® Cut the tie wrap and pull out the cables.
Cable guide
Remove the plate and

cut the tie wrap.
Pull out the cables

W-axis base cover
\
Tim
Fig. 12 (b) Replacing cables (S-700)
(D Remove the lower cover of the W-axis base. (See Fig. 7.2 (c).)
(2) Pull off the cable guide pin and remove the plate from the support. (See
Fig. 7.2 (d).)
Cable guide
Plate
o! o o 5o W-axis base cover
oo>
to
[
[
[
o o
0\\«
FBI if
«p
n
$3 a
Oo
Fig. 12 (c) Replacing cables (S-700)
3-67
/
Q
a
©
hm
Plate
9-axis base cover
Fig. 72 (d) Replacing cables (S-700)
@ Remove the side cover of the 0-axis base and remove the plate clamping the
cables. (See Fig. 7.2 (e).)
Pin
Cable track
Support Plate
o' oj
t
1
o 1
ll $
r
'Qi 1
Plate
Fig. 7.2 (e) Replacing cables (S-700)
3-68
(Q) Remove the 9-axis connector panel and pull it halfway off. (See Fig. 7.2
(f).)
<Q Remove the ground line and pull the 0-axis connector panel completely off
with the cable track.
o’
DT
f=y*ap-
LJ-QQQ.
0-axis connector panel
/ Pull it toward you with the cable track.
Fig. 7.2 (f) Replacing cables (S-700)
(Q) Open the cover of the cable track with a screw driver and pull out the
cables. (See Fig. 7.2 (g).)
Cut all tie wraps and remove the connectors from the 0-axis connector panel.
Replace the cables and mount the new cables reversing the above procedure.
Fig. 7.2 (g) shows the sequence of cables in the cable track. When mounting
the cables, be especially careful of the clamping positions and be sure to
form the cables, especially in the movable parts of the W and U axes, so
that they are not pulled even when the arm moves in a full stroke.
(6) The connectors to be connected to the a-axis, 8-axis, and y-axis motors can
easily be misconnected. Therefore, be sure to check each cable tag
carefully. (A wrong connection may causes the robot to run abnormally.)
(£7) Mount the connected cables to the correct places, one by one, in the order
shown in Fig. 7.2 (h).
@ When all the connectors have been mounted, band the required points on the
cables with the wraps as tight as possible so that the cables do not come
out.
(Q When all the cables have been mounted, move the robot slowly to check that
there is no rubbing of the cables.
When mounting the cover, take great care so that it does not catch the
cables .
3-69
o
©
a/
0
Strike the “ 0 ” part with a plastic
0 hammer for mounting the cover.
0
0
[0
/A0 0
o 0
o
<Ko 0
o, 0 Open the cover using
© 0 a screw driver
o 0 Upper side
LSW
EE
AIR
- UP
wp
OP
WM
OM
P2
- M2
Lower side
Partition plate
Cable sequence in the cable track
Fig. 72 (g) Replacing cables (S-700)
3-70
p a 7
® \9 ® j8 ® Brake
,6 ,5 i4
® © Power
or or © Pulse coder
Connector layout and mounting sequence
rtss the cables between motors.
Band each connector

with a tie wrap.
0 0 a
Band the cables at each required
D point with a tie wrap.
Fig. 7.2 (h) Replacing cables (S-700)
3-71
7.3 Replacing Limit Switches
1) Replacing 9-axis OT proximity switch
Q Remove the rear cover of the W-axis base.
(5) Remove the switch plate.
© Remove the proximity switch from the plate.
I Remove the connector and replace the proximity switch (cable K106).
Mount the new proximity switch reversing the above procedure.
(5) Check that the proximity switch normally operates at the overtravel
position.
(7) Check that the proximity switch does not operate within the 8-axis
operation range. (See section 4.1 "Adjusting Limit Switch and Dog".)
Switch plate
3
Cover
fv _7|
b.
Oj
O o a
Proximity twitch
©
o O
i.
> 4J
-aa*
o
oaa.
o o
ck.
Fig. 7.3 (a) Replacing 0-axis proximity switch (S-700)
3-72
2) Replacing W-axis OT limit switch
Remove the side cover of the W-axis base.
$(3) Remove the limit switch plate.
Remove the limit switch from the plate.
© Open the limit switch and remove the cable.
© Replace the limit switch and mount the new limit switch reversing the
above procedure.
Check that the limit switch normally operates at the overtravel position.
X Check that the limit switch does not operate within the W-axis operation
range. (See section 4.1 "Adjusting Limit Switch and Dog".)
W-axis limit switch
D
limit switch plate
Plate
o o
o .1
o o
Fig. 7.3 (b) Replacing W-axis limit switch (S-700)
3-73
3) Replacing U-axis OT limit switch
§ Remove the side

Remove
the cover of the
limit switch plate.
W-axis arm.
© Remove the limit switch from the plate.

© Open the limit switch and remove the cable.
© Replace the limit switch and mount the new limit switch reversing the
above removal procedure.
© Check that the limit switch normally operates at the overtravel position.
© Check that the limit switch does not operate within the U-axis operation
range. (See section 4.1 "Adjusting Limit Switch and Dog".)
J
U-axis limit switch o
O
Plate
Limit switch plate

O
m
0
i
ws
Fig. 7.3 (c) Replacing U-axis limit switch (S-700)
3-74
r
IV. CONNECTIONS
r
;
•i
1
!
:
:
1
1. GENERAL
This section describes the connections between the mechanical and electrical
interfaces in the robot mechanical unit and control unit and instructions for
installing the robot.
1.1 Block Diagram

The block diagram of the robot connections is shown in Fig. 1.1.
Pneumatic pressure source

Controller
T
unit (a) _
Robot mechanical End effector
Peripheral devices (b)
Teach pendant (c)
Remote CRT/KB (d)
I/O devices (e)
Computer (0
_
Pulse encoder for line
tracking (g)
mechanical connection
Input power source (h)
electrical connection
Fig. 1.1 Block diagram of the robot connection
1) Controller
The controller interfaces electrically with the following devices:
a) Robot mechanical unit
b) Peripheral devices
c) Teach pendant
d) Remote CRT /KB
e) I/O devices
f) Computer
g) Pulse encoder for line tracking
h) Input power source
2) Mechanical unit
a) End effector
This is a mechanical mounting face used for mounting the end effector of
hand, etc. to the robot wrist. It also supplies pneumatic pressure and
electrical signals for controlling the end effector.
b) Installation holes
There are holes in the base of the mechanical unit for mounting it to the
floor. For details refer to V -
1.1.2 and 2.1.2.
I 4-1
I
2. SAFETY PRECAUTIONS
2.1 General
Care should be taken to protect workers and machines (robot and peripheral
devices) when operating a system which combines the robot with peripheral
devices. It should be noted that the robot may move suddenly when it receives a
motion command signal. First ensure workers' safety and, then, safe operation
of the peripheral devices and the robot. Fig. 2.1 shows the priority of safety
measures.
Worker
Peripheral
device*
Robot
\ Workpieces
7
and tools
Fig. 2.1 Priority of safety measures
2JZ Safety Precautions

1) Worker's safety
Worker's safety must be ensured during the operation of a machining cell. It
is very dangerous to enter the operating space of the robot during operation
of the system. If it is necessary to do this, follow the protective measures
given below.
If it is necessary for any reason to enter the robot area, stop the robot
using the following procedures:
If power is not required, turn off the control unit power source.
If air pressure is not required, turn off the pneumatic system air pressure.
If it is necessary to inspect robot motion, check it, while monitoring the
robot motion, 'and place the EMERGENCY STOP button where It can be pressed
quickly if necessary.
If entry into the operating space of the robot is going to be necessary, take
the following precautions:
a) Construct a protective fence around the system (Fig. 2.2 (a)).
Provide a safety gate. Its operation should be such that no one can enter
the operating space without opening the gate.
4-2
Provide a limit switch which operates
when the ptc is opened.
>•*
Fig. 2.2 (a) Protective fence
Provide a limit switch which operates when the gate is opened, and connect
it to the power input unit according to Fig. 2.2 (b).
The contact of the limit switch should be "ON" when the gate is closed; it
should be "OFF" when the gate is opened.
The rating of the contact should be more than 0.3 A at 24 VDC.
Controller
FN1
The contact u “ON"
when the gate u closed. Input unit
Fig. 2.2 (b) Connection of the gate limit switch
b) Mount a mat switch or photoelectric switch on the floor to issue an alarm

by means of a buzzer, light, etc., if a worker enters the operating space.
If it is necessary, stop the robot operation using the same switch.
c) Mount a limit switch with a tactile bar on the robot to stop it if it
comes in contact with something.
2) Machine safety
Take the following precautions to prevent damage to the peripheral devices
and the robot.
a) Setting the motion range
If the system service range is narrower than the motion range of the
robot, the system variables which control the motion range of the robot
can be set from the CRT/KB so that the motion range of the robot does not
exceed the service range.
b) Using robot interlock signals
The robot has several kinds of terminals for receiving external interlock
signals. The robot can be held or stopped by these signals. To use them,
set up control circuits on the peripheral devices that will be activated
when there is a possibility of damage to the equipment.
c) Use a limit switch with a tactile bar
In order to prevent injury to a worker or damage to the robot, a limit
switch with tactile bar can be used.
4-3
3) The limit switch with a tactile bar
When using a limit switch with a tactile bar, use one which provides a
circuit with normally closed contacts as shown in Fig. 2.2 (c). The rating
of the contact should be more than 4 A at 100 VAC.
«6.s
Wire spring
ISO
4-M4X12 21
mounting hole
T I
75-5 NC3 NC4
59.510.2 70.2
6T7 Fi I 1 NCI NO
ta\
29.4i0.2l \
16.5
28
40.5 2-M5X20 37
45.6
Fig. 2.2 (c) Example of a limit switch
The electrical connection of limit switches with tactile bars is shown in

Fig. 2.2 (d).
Controller
-0=v_£> >EMG1
LI L2 INI ?W«. P :e> 1 )
Normally closed contacts Input unit
EMG
INC
LI L2
-Oarj- OiO EMG
Normally closed contacts DI module in the I/O unit
COM
Fig. 2J2 (d) Example of connections
The normally closed contacts when several limit switches are used should be
connected in series to the input unit of the controller. The other normally
closed contacts should be connected in series to the DI module in the 1/0
unit of the controller.
4-4
3. CONTROLLER CONNECTIONS AND SIGNALS
3.1 Connection Diagram
Fig. 3. 1 shows the connections of the controller with the exception of those
between the controller and the mechanical unit. They are described in
CONNECTIONS section 4.1.
Controller
•1
Modular I/O unit or fixed 1/0 > Peripheral devices
K57
Shared RAM board CNTP -JJ Teach pendant
Built-in operator’s panel K70

connection for CRT/KB JLr -JJ Remote CRT/KB
Built-in operator’s panel in

*1
connector for RS-232-C -Q( I/O devices
•1
Shared RAM board CD4 {K Computer
•1 Pulse coder for line

Path CPU board CA2 tracking
•1
Circuit breaker U.V.W.G -C AC power source
{
Input unit i EOF
EON
COM
•1 , External power supply
* ON/OFF switch
Note) Cables marked with *1 are provided by the customer.
Fig. 3.1 Connection diagram
3.1.1 Cable clamp

Cables led into this controller should be clamped by the method shown below.
This cable clamp treatment is not only for cable support but also for
shield-treatment. It is very important for the stable operation of this robot
system that this be performed. Peel the sheath partially as shown below and
expose the shield. Push the cable and clamp it by the cable clamp. The cable
clamp is attached to the control unit. The ground board is prepared at the
bottom of the cabinet.
lr Ground board
Cable
— Cable clamp
-n E
E
3
E
0
E
o
nj
Fig. 3.1.1 Cable damp
4-5
3.2 Connections
3.2.1 Input power connection
Circuit breaker
tujvjw
•
i
G
& ©©
MS terminal Cover
Z (MO
3$ AC power
Note) Mount the cover after. cabling.
Fig. 3.2.1 (a) Input power connection (S-10 controller, medium size cabinet)
&
B
0
3 2
l£_
u7
W. 3$ AC power
Note) See Fig. 3.2.1 (a) for details of breaker connection
Fig. 3.2.1 (b) Input power connection (Large size cabinet,

circuit breaker or circuit breaker with leak detector)
4-6
Disconnect switch
\
22
-
/V II'
5P
/
/V
3$ AC power
u
n V w
c
I
©
o
•I
©
M5 terminal
o
a
d
%
Note) Mount the cover after cabling.
Fig. 3.2.1 (c) Input power connection (Large size cabinet, disconnect switch)
4-7
3.2.2 Connection for external on-off control of power supply
O (TPl )
EMC
OUT!
EMC
OUTC
EMC
OUT2
OP2
tNU
IS I
EMC
INC
EMC
UTI SYON
OLT
w\ 100
OUT:
BKP1 BKRI
0 BKM]
BKP2 8KR2
BKM 2
BKP3 BKR3
0 r
M4 terminals
a
<§) ® ON P1L
*o5 <H <§> OFF ALM
& fewer
«© COM
FN1
OFF
FN2 FUSE
ALM2/I
This figure shows the medium size
cabinet. The large size cabinet is ON/OFF switch externally
CTnilar to this. furnished for ON/OFF O
control
Remove this shorting strip when the external
power supply ON/OFF switch is used.
Fig. 3.2.2 Power input unit TP1 terminal
On/Off Control by Alarm Circuitry

To control power externally, a relay can be connected across the ALA and ALB
terminals on the input unit PCB. Note that these terminals are not on the
connector (TPl) but on the PCB itself. This should be a normally closed but
held open switch. Shorting these two terminals together causes controller
operating power to be lost. Recovery can be achieved by first pressing the OFF
button on the controller.
Normally closed
held open
Input unit PCB
-<*4*>
|
—
=1 ALA
I ALB
4-8
3.2.3 Connection to I/O devices
When the controller is used with a built-in operator's panel, I/O devices which
have RS-232-C interface can be connected to the connector provided on the
built-in operator's panel.
1 1 fnTl
RS-232-C
V> connector
m
•
•• o
••• a
«
o once
o
OOP* O
} I/O devices
(RS-232-C)
Large size cabinet Medium size cabinet
Convotler
I FG 25p D-subminiature
14 connector
2 SD (Female)
3 RD
16
4 RS
S cs
18
6 OR
19
7
8
SC
CD
20 ER
Built-in operator’s
panel connector
RS-232-C
lo¬ ot I/O devices (RS-232-Q
9
10
23
11
24
12
+24 R
13
Note) Pin 25 has +24 V for power supply to offline storage devices.
It cannot be used for I/O devices.
4-9
Regarding the meaning of the signals, refer to the figure shown below.
{>
_
SD (send data)
<F RD (receive data)
-ÿ> i RS (request to send)

"! Connect RS to CS
RS-232-C interface -<ÿ - 1 > CS (dear to send) J when CS is not used.
< > ER (data terminal ready) I 1I Connect ER to DR

DR (data set ready) __P when DR is not used.
;
— i » CD (carrier detect)
SG (signal ground)
I
Connect ER to CD. always.
I \Connect to signal ground of I/O device
FG (frame ground)
I
Signals ON/OFF voltage levels are given in the following table.
Less than -3V More than +3 V
Function OFF ON
Signal condition Marking Spacing
Cable connections between the controller and the I/O device should be as
follows:
Conuoller I/O device

SD i3fcr-< »
RD
RS
CS
ER
DR
SC<K
FC IT
Cable: 20 x0.18 mm1
with unified shield
4-10
3.2.4 Connection to pulse encoder for line tracking
01P02
zw Path CPU
'board
0 CA2 X
fZ.
0 To pulse encoder
for line tracking
Medium size cabinet
Fig. 3.2.4 (a) Connection to pulse encoder for line tracking

(S-10, medium size cabinet)
&
-r
y —Ayp— Path CPU board
01P02
CA2
3
7]
To pulse encoder
for line tracking
Note) Connection to the S-700 controller is similar to that shown in this

figure.
Fig. 3.2.4 (b) Connection to pulse encoder for line tracking (S-10 controller,
large size cabinet circuit breaker or circuit breaker with leak detector)
4-11
01P02 Path CPU board
CA2
(MRE-20RMA) Pulse encodes inputs (Male)
1 2 3 4 S 6 7 MR-20LFH
oy OV ov sv sv sv / Pulse encoder
33
X 14
8
IS
9
16
10
17
11
18
12
19
13
20
CA2 for line tracking
PCZ •PCZ PCA •PCA PCB •PCB
PCA Drives should

Phase A
PCB
t S=ta-
I
beSN7S113
(product ofTl)
or equivalent.
4-
Phase B
it i
i
PCZ
Reference
detection V. *PCZ
5V
t i
5V
ft
ft
Consumption of +SV
should be less than 0.3A
5V
OV ft
I
ov A
OV
01P02
7IT
r \
“
Pulse encoder
8 pairs of unified shield cable (cable material: 0.3 mm3)

cable length should be less than SO m.
Peel the sheath of cable and attach the cable to the ground board of the
controller cabinet by means of the cable clamp metal fixture.
4-12
Pulse input signals
Phase A and phase B signals are used for pulse input. The difference of phase
between both signals should be 90 degrees.
Phase A
Phase B I 1
Normal rotation
Phase A I 1 I
Phase B J
Inverse rotation
Phase A, B and reference detection signals should satisfy the following

requirements.
Phase A
Phase B
— - Id td
*P
td
tw
tP
td td
—-
Reference
detection
J
td > 1 MS
tp> 10 MS
tw: more than tp
4-13
3.2.5 Controller and peripheral device connections
—
The R—H controller has two I/O options for communication with peripheral devices
a fixed I/O board or a modular I/O system- The fixed I/O board is a single
board system installed in the backplane. The modular I/O system hardware
includes the I/O rack and I/O modules. Various types of modules can be added to
the modular I/O.
Modular Input/Output System
The modular I/O structure provides a hardware interface to the I/O system.
Signal lines are connected to the I/O modules, which reside in the controller
I/O rack. Differing types of I/O modules can be used to connect various types
of electrical signals. The I/O rack communicates I/O status information to the
controller through an internal serial data link. The connections for the
modular I/O system are shown in Fig. 3.2.5 (a).
One I/O rack shown in Fig. 3.2.5 (b), (c) , is provided with the KAREL modular
I/O system. The I/O rack has a capacity of nine I/O modules. One slot on the
I/O rack, Slot 0, is reserved for the robot control module. The remaining eight
slots on the I/O rack are available for user-defined I/O modules.
I/O base unit

Robot control module
CNA0[ ] qQP4
Backplane Off Cpf
A20B-1002-0860
CNP2 CNP2 CNA1 [
1 To shared
RAM board
To robot
To power
CNP3 CNP3 CNA2 [ input unit
CNA3 [
CNA4 £ User I/O slots
CNP3
CNB
CNA5 [ i *5v
I
a 1 BKR2I E HS<DI I 2
2 •ROT9 BKR22 EE H5-C02 I 3 OV
BXR31 E •5«<REI
3 RLWD A 0V
iq
i i) BKR32 IE
A «r ALM 5 -24V
5 »;MGTP E B*=?i2 CNA6 [
OV 6 -24E
6 E OV E
7 3?
CNP2
CNA7 [ i -15V
CNC 2 0v
3
»; son 23 RZO l
21 RDI2
3! RD13
ROT 2a
«HBKD 55
NZI it
2302
R333
CNA8 £ 4
5
6 -
EN
OV
I5v
*1 RDle RQQa
5i RDI5 NZ2 n s;o5
s: P0I6 NZ3 ?e 2306
7! RDI7
NZ4 SS S3Q7
NZ5 SC
a; .
t- ?O;B
PPA5N
NZ6 3 1
ALML
D_0V_r2M -24£
3303
C=RL
,2
OV
OV
- 33 -2Z£
gal
Fig. 3.2.5 (a) Modular I/O structure
4-14
Modular 1/0 unit
/
— (f -
Modular I/O unit

62 ////,
VZ 1 1:
V®f
m B
m
01
7K? 0
l v
__
Note) Location of modular I/O unit in the S-700
controller is similar to this figure.
Fig. 3.2.5 (bf Location of modular I/O unit Fig. 3.2.5 (c) Location of modular I/O unit
/
(S-10 controller, medium size cabinet) (S-10 controller, large size cabinet)
The modular I/O system supports the following number of signals:
- ANumber of DI/DO
maximum of 64 user digital input signals and 64 user output signals are
available.
- Number of group inputs/outputs

A maximum of five group inputs and five group outputs are available.
- ANumber of analog inputs /outputs

maximum of five analog inputs and five analog outputs are available.
- Hand signals
A maximum of four hand signals are available.
- The
Robot dedicated I/O (RDI/RDO)
robot control module has eight input lines and eight output lines
which are available at the wrist of most robot models.
4-15
Table 3.5 Fixed I/O board input -
FEATURE/CAPABILITY VALUE/DESCRIPTION
Digital Input Signal Standards
Type Grounding type voltage receiver
--
Rated Input Voltage +20 28 VDC (logic 1 "closed")
0 +4 VDC (logic 0 "open")
Maximum Input Voltage +28 VDC
Input Impedance About 3.3 kohra
Response Time 5 - 20 ms
Attachment Side Contact Standards
Rated Contact Capacity 30 VDC, 16A or over
Input Signal Width More than 200 ms (ON and OFF)
Contact Bounce Time Shorter than 5 ms
Closed Circuit Resistance Lower than 100 ohm
Open Circuit Resistance Higher than 100 kohm
(Robot side)
A-fTrtn. vm
(Robot side) +24 For UDI
+24V For RDI
n4 3.3 kn
i T'l
— (T RV - +3.3 kn
Level conversion
circuit
Level conversion
circuit
RV
(Signal) (Signal)
Apply +24V from the robot
side as an input voltage.
Peripheral devices contact signal fTj r t
Robot Receiver output signal

(Chattering: Less than 5 ms)
[Z?
sU
r
Tc
-
Tc = 5 20 msec
4-16
-
Table 3.6 Fixed I/O board output
FEATURE/CAPABILITY VALUE/DESCRIPTION
Rated Voltage 24 VDC
Maximum Applied Voltage 30 VDC
Maximum Load Current 0.2 A
Transistor Type NPN
Output Pulse Width 200 ms +8 ms
Saturation Voltage at About 1.0 V

Turn-On Time
Note: Outputs are 24 V, 200 mA sinking current devices
Damper Diode
--
Rated peak reverse dielectric strength Higher than 100 V
Rated effective forward current Higher than 1 A
If a relay, solenoid, or other inductive device is used as a load, you
must connect a reverse-biased diode in parallel with the load to prevent
the generation of a high counter electromotive voltage across the output
when the output is switched off.
Dimmer Resistor
If an incandescent lamp is used as a load, you must connect a protective
resistor across the output terminals to prevent a destructive load current
surge when the output is switched on.
6 uVPUT
(Robot side) Damper Diode (Robot side) £INK
/ +24V +24V
T I*
—<T
777
Lower than 0.2A
t 0V
7T7
H Protective (Dimmer) resistor
ov
4-17
Fixed Input/Output System
The fixed I/O system is a single I/O board which is Installed in the controller
backplane. Signal lines are connected to one of four connectors:
- CNI: 50 pin male, for application DI/DO.

- has
CN2: 20 pin female, for application* DI/DO
a user operator panel. v
or UOP interface if the system
- CNB: 20 pin male, for brake control.
- CNC: 34 pin male, for RDI/RDO and hand signals

The connections for the fixed I/O system are shown in Fig. 3.2.5 (d) (f).
Signal lines are connected to the appropriate connector from this board. The
-
fixed I/O board does not support analog inputs or outputs.
Fixed I/O
Backplane
A20B-1002*0860
. pc[ Q To robot
CNA4 To power
CNBC Q input unit
CN1[
User I/O
CN2[
CNI CN6
n UDH UDOl i
BKR21 IS H8K0I
>4
B UPI2 E ov 2 UD02 •ROT BKR22 1 6 KSKD2
2
B U0I3 3S U003 3 RIWD BKR31 1 7 •BKRE
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10 U0I5 £ ov m UOQ*
5 U005 A?
4 •FALM
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BKR I I
BKR32 It ei BKR1 2
ov
01 UP16
B! UP17 UDII7m UD06
UP07
6
7 »2*E
EE
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9
01 UP18 31 El UD08
01 UP19 SI UDI19
UOI 18
30! UP09
El UDUO SI UPm 1 20 El UOOIQ
XI uoi 1 1 SI UPI21 El UOQ I 1
m uon2
m UPI22 II UP012 CNC
•ROT m
El UDII3 UP123 El UOQ 1 3
2CI UOI I 4 SI El UP0I4
i ROI l '
2 ROI 2 mEC •HSKP m
RDOl
RQQ2
v
El UDH5 SBl UPI24 XI UP015 3 RPI3 RDQ3
El UOI 16 SI El UOOI6 4 RPI4 E N2I RQ04
XI ov El ov 5 RDI5 E! NZ2
S' RDQ5
El A_J21 ov 6 ROI 6 XI N23
SI RDQ6
7 R0I7 El NZ4
SI ROQ7
8 ROI8 . XI NZ5
El RP08 ->
9 «PPABN 51 N26
3JI
CN2 1C ov si At
11 ov 5!
OC
E
UD0»7 8 vr i UP1 25
UDOl 6 9 U0I31 2 UOI26
UPI32
ii OV i »2*£
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E UOQ <9
ic ov UOI27
X
_
UDQ2Q UOI28
0V
1 1
E UD02I
UD024
5 UQI29
UOQ 22 6 U0I30
i UDC-23 i3 Ov 7
Fig. 3.2.5 (d) Fixed I/O structure
4-18
Fixed I/O board
B
£z CN
Fixed I/O
board
% /Cc CN2
CNB
—&
'
C CNC
"51
sr
Note) Location of fixed I/O board in the S-700
controller is identical with this figure.
Fig. 3.2.5 (e) Location of fixed I/O board Fig. 3.2.5 (f) Location of fixed I/O board
(S-10 controller, medium size cabinet) (S-10 controller, large size cabinet)
With no user operator panel, the fixed 1/0 system has the following user I/O
capabilities:
- DCUser24DI:V non-isolated
32 bit total
receiver
(internally pulled up to +24 V with resistors)
Response time of 20 ms.
Three ground commons.
- Open
User DO: 24 bit total
collector NPN transistor, non-isolated driver
24 V 200 mA current sink.
DC power output not provided.
.Six ground commons.
- RDI/RDO
Eight inputs and eight outputs are provided, located on connector CNC.
A user operator panel in the robot system will use eight DINs and eight DOUTs.
4-19
Input /Output Signal Types
User-defined signals are mapped in the User Signal Assignment Table (USAT) ,
represented by the system variable $USAT. You have access to user-defined
signal types through the following predefined port arrays:
- DIN (digital input)

-- GIN
DOUT (digital output)
(group input)
- AIN (analog
GOUT (group output)
-- AOUT (analog output)

input)
Each element of a port array corresponds to a user-defined signal.

You also have access to a special set of robot hand control signals through the
KAREL language HAND statements, rather than through port arrays.
Discrete I/O (DIN and DOUT)
The DIN and DOUT signal types are interpreted as one-bit ON/OFF signals in
KAREL. The KAREL program has access to these signals as BOOLEAN values. You
can define the polarity of the signals (in eight-bit groups) through $USAT as
either active-high (ON when voltage is applied) or active-low (ON when voltage
is not applied). Either AC or DC I/O modules can be used for DIN and DOUT
signals.
GIN and GOUT Signal Types
The GIN and GOUT signal types provide access to a group of input or output lines
interpreted as an INTEGER in a KAREL program. A group can have a size of 1 to
16 bits, with each bit corresponding to an input or output line, and can start
at any place within the I/O slot. If the group size is defined as less than 16
bits the unused bits are interpreted as binary zeros. Either AC or DC I/O
modules can be used for GIN and GOUT signals.
AIN and AOUT Signal Types
The AIN and AOUT signal types provide access to data in the form of an analog
electrical signal. The analog data is digitized by the system and passed to the
KAREL program as a 16 bit binary number, of which 12 bits or 8 bits are
significant depending on the analog module. The program treats the data as an
INTEGER data type. Table 3.2.5 (a) shows the correspondence between the actual
signal voltage and the value assigned to the AIN or AOUT. These are available
with the modular I/O system.
4-20
Table 3.2.5 (a) Analog signal value/voltage
I/O module in I/O rack

AIN value Input volt. AOUT value Output volt.
(12 significant bits) (12 significant bits)
+2000 +10 V +2000 +10 V
+1000 +5 V (+20 mA) +1000 +5 V (+20 mA)
0 0 V (0 mA) 0 0 V (0 mA)
-1000 -5 V (-20 mA) -1000 -5 V (-20 mA)
-2000 -10 V -2000 -10 V

Either voltage or current range can be' selected:
-10 V . +10 V (voltage input)
-20 mA ... +20 mA (current input)
HAND Signal" Type
The HAND signal type provides a KAREL program with access to two output lines
that work in a coordinated manner to control the tool. The lines are designated
as the open line and the close line. Either AC or DC digital output modules can
be used for HAND signals. The system can support up to four HAND signals.
The following KAREL language statements are provided for controlling the signal,
where "n" is the signal number defined in $USAT:
OPEN HAND[n]
CLOSE HANDCn]
RELAX HANDCn]
Four modes of operation, which allow you to control different types of tools,
are available:
;
-- Mode
Mode 0: Single Line Mode
1: Dual Line Mode
- Modes 2 and 3: Dual Line Pulsed Modes
4-21
UOP Signal Type
The user operator panel (UOP) is any user-supplied device that connects to the
UOP signals. UOP signals have functions resembling those of the operator panel
buttons, switches, and indicator lights on the front of the controller cabinet.
UOP signals also allow you to execute predefined command files from the UOP.
UOP control signals connect indirectly via AC or DC I/O modules in the I/O rack
(or via the fixed I/O board). UOP signals are distinguished from other system-
defined signal types by their mapping in $USAT. UOP signals are used primarily
for system control and status reporting.
The modular I/O system supports 32 UOP control signals. The fixed I/O board
supports 16. Special consideration must be given to safety because the UOP can
cause robot motion through its input signals.
Thirty-two UOP control signals are connected through two I/O modules in the
modular I/O system. Any type of digital 1/0 modules can be used, placed as you
desire, in the I/O rack. For the fixed I/O system the 16 UOP signals are
attached to connector CN2. UOP control signals must be mapped as such in the
UOP input table and UOP output table of the USAT.
For the modular I/O system, sixteen of the UOP control signals are input signals
to the controller. The other 16 signals are outputs. All 16 input signals and
All of the output signals are implemented in the current version of KAREL
software. The remaining output signals are reserved by GMF for use in future
software versions.
Tables 3.2.5 (b) and 3.2.5 (c) list the UOP input and output control signals for
the modular I/O system. Next to the signal name (in parentheses) is the name of
the operator panel button, switch, or indicator light that has a function
similar to the signal. (Refer to the KAREL operations manual for your
controller model for information on operator panel functions.)
Table 3.2.5 (b) Modular I/O UOP input control signals
Number UOP name (Operator panel function)
1 *EST0P (EMERGENCY STOP button)

2 *H0LD (HOLD button)
3 RESET (FAULT RESET button)
4 CALIB (CALIBRATE button)
5 CSTRT (CYCLE START button)
6 CSTOP (CYCLE STOP button)
7 HOME (HOME button)
8 MPROT (MEMORY PROTECT keyswitch)
9 executes KCP U0P1.CF
10 executes KCP_U0P2.CF
16 executes KCP U0P8.CF
Input signals 9 through 16 activate the command files that are indicated by name
in Table 3.2.5 (b). Connection of these UOP input signals is shown in Fig.
3.2.5 (g).
4-22
Internal Input module Peripheral device
address
X (1) 01 Q
•ESTOP
2
(2) 02
V-°- •HOLD
(3) 03
3 j
RESET
(4) 04
4 -6- -o j
CAUB
(5) COM
O-
(6) 05 i
-6- -6-
CSTRT
(7) 06
6 -6- j
CSTOP
(8) 07
7 -o- _1
HOME
8 (9) 08
O
"SpROT
(10) COM
<ÿ
9 (11) 09
O
KCP_UOPl_CF
(12) 10
10 o j
KCP_UOP2_CF
»- (13) 11 j
KCP_UOP3_CF
12 - (14)
O
12
KCP_UOP4_CF
(15) COM
O
(16) 13
13 O -o j
KCP_ UOP5 _CF

14 -
' (17) 14
-6-
KCP_UOP6_CF
(18) 15
15 O o j
KCP_UOP7 _CF
(19) 16
16
KCP_UOP8_CF
(20) COM
0 -o-
Fig. 3.2.5 (g) UOP input connections
4-23
The system variable $UDIN_ENBL enables the upper eight bits of the UOP input
module. If it is FALSE, the upper eight bits of the input module can be used
for other user-defined input signals. $UDIN_ENBL must be set to TRUE in order
for the predefined command procedures to be executed.
Table 3.2.5 (c) Modular I/O UOP output control signals
1
2
CMDENBL
SYSRDY
(UOP only
——
motion control)
(SYSTEM READY light)
3
4
5
6
7
PAUSED
PROGRUN
UNCAL
LOCKED
HELD
(UOP only
(UOP only
——
program paused)
program running)
(NOT CALIBRATED light)
(UOP only LOCK param ON)
(ROBOT HELD light)
8 FAULT (ROBOT FAULT light)
9 TPEN (TEACH PENDANT ENABLED light)
10 UPENBL (PANEL ENABLED light)
11 CSTOP (CYCLE STOP light)
12 reserved for future use
. 16 reserved for future use
The system variable $FULÿ_RMT_OUT enables the upper eight bits of the UOP output
.
module If it is FALSE, the upper eight bits of the output module can be used
for other user-defined output signals. Connection of these UOP output signals
is shown in Fig. 3.2.5 (h).
4-24
Output module
M3 terminal Signal
Internal address (21) +DC
of module card rO-CD
nnfc CMDENBL
1
(2) 02
2- 0ÿ0-
3.2A
O
(3) 03
SYSRDY
3- O PAUSED
(4) 04
4- O PROGRUN
3.2A (5) COM
(6) 05
-
i
5 •UNCAL
a) 06
6- LOCKED
3.2A (8) 07
7- HELD
(9) OS
8- (10) COM
•FAULT
3.2A
(ID 09
9 - (12) 10
TPEN
10- UPENBL
3.2A (13) 11
-
J-
11
(14) 12
12-
(15) COM
3.2A (16)
13
-
13
(17) 14
O Reserved for
future use
14 -6-
3.2A (18) 15
-
15
-
16
(19) 16
J
3.2A (20) COM
O
-
(-)24 48 VDC(+)
-
Fuse break-
09 16 are not mounted on OD08C. age detection 3.
Fig. 3.2.5 (h) UOP output connections
4-25
For the fixed I/O system, eight of the UOP control signals are inputs, and the
other eight are outputs. The UOP signals are available on the CN2 connector on
the fixed I/O board. Tables 3.2.5 (d) and 3.2.5 (e) list the UOP input and
output control signals for the fixed I/O system.
Table 3.2.5 (d) Fixed I/O UOP input control signals
1 *ESTOP (EMERGENCY STOP button)

2 *HOLD (HOLD button)
3 RESET (FAULT RESET button)
4 CALIB (CALIBRATE button)
5 CSTRT (CYCLE START button)
6 CSTOP (CYCLE STOP button)
7 HOME (HOME button)
8 MPROT (MEMORY PROTECT keyswitch)
Table 3.2.5 (a) Fixed I/O UOP output control signals
1
2
CMDENBL
SYSRDY
(UOP only
——
motion control)
(SYSTEM READY light)
3
4
PAUSED
PROGRUN
(UOP only
(UOP only
—
program paused)
program running)
5
6
7
8
UNCAL
LOCKED
HELD
FAULT
(UOP only
—
(NOT CALIBRATED light)
LOCK param ON)
(ROBOT HELD light)
(ROBOT FAULT light)
UOP Signal Interaction
This section describes the interaction of UOP interface signals relative to each
other and to the state of the controller. The timing diagrams are used for
illustrative purposes only and do not represent the actual time difference
between state changes.
The diagrams represent steady-state mode input signals. Reaction to the input
occurs after a new state has been maintained for 200 milliseconds. Input and
output signals are distinguished in the diagrams by an (I) or (0) following the
name .
UOP Motion Control
The following UOP control signals are capable of invoking commands or command
procedures that cause motion:
CALIB (CALIBRATE)
CSTRT (CYCLE START)
HOME
KCP_U0P1 through KCP_U0P8
4-26
As with any motion command, the device from which the command is issued must
have motion control or the command is not executed. The UOP has motion control
under the following conditions:
- The following UOP output signals have the indicated values:
FAULTY = OFF (No fault conditions exist.)

SYSRDY = ON (The system is ready.)
PROGRUN = OFF (No program is being executed.)
TPEN = OFF (Teach pendant is not enabled.)
UPENBL = ON (The UOP is enabled.)
- The
ON.
operator panel REMOTE keyswitch (on the controller cabinet) is set to
- The REMOTE parameter be set to UOP. You can use the KCL>SET PARAM
must
REMOTE UOP command to accomplish this. B.£HOT£ KB,
The UOP must be programmed to check to ensure that it has motion control
(CMDENBL = ON) before issuing motion commands. The controller does not respond
to UOP motion commands while the UOP is not the motion control device.
CALIB Signal
The CALIB signal invokes the calibration sequence. CALIB is a motion command;
do not issue it unless the UOP output CMDENBL = ON (active) .
When the execution of the calibration sequence is complete, the UOP output UNCAL
is turned OFF. (See Fig. 3.2.5 (i).)
CALIBRATE (I) 1
UNCAL (O)
Calibration complete t
Fig. 3.2.5 (i) CALIB timing diagram
CSTRT Signal
The effects of activating CSTRT depend on the controller state and the value of
user-set system variables. In all cases, CSTRT causes the UOP outputs CSTOP,
HELD, and PAUSED to turn OFF. (See Fig. 3.2.5 (j).)
If CSTRT is invoked while execution of a KAREL program is paused (UOP output
PAUSED is ON) program execution is resumed (and PAUSED turns OFF) .
In all other cases (PAUSED OFF when command issued), CSTRT executes a
user-defined KCL command file, specified by the system variable $CYCLE_STRT. If
a file has not been specified, no commands are executed.
CSTRT is a motion command; do not issue it unless the UOP output CMDENBL is ON.
Status of the UOP outputs can be affected by the commands issued by the KCL
command file.
4-27
CSTRTG)
- J
HELD (O)
CSTOP(O)
~ Z ” “
—~ ” L
PAUSED (O) ~
Fig. 3.2.5 (j) CSTRT timing diagram
HOME Signal
The HOME signal executes the predefined command file KCP_HOME.CF. If a file by
that name does not exist, the HOME button executes the KCL> MOVETO $HOME command
using JOINT motion. The system variable $HOME stores a position that you can
define to be the home position for the robot.
A similar system variable, $AUXHOME stores an auxpos, which you can define as
the home position for auxiliary axes. You can then create a command procedure,
using the predefined name KCP_HOME.CF, to move both the robot and the auxiliary
axes to their respective home positions.
HOME is a motion command; do not issue it unless the UOP output CMDENBL is ON.
*HOLD Signal
The *HOLD signal pauses program execution and thus stops motion. *HOLD is ON
when the voltage is zero. Activating *HOLD causes the UOP outputs HELD and
PAUSED to turn ON, and PROGRUN to turn OFF. (See Fig. 3.2.5 (k).)
•HOLD (I)
1
HELD (O)
PAUSED (O)
PROGRUN (O)
_
-
(formerly IN_CYCLE)
J
Fig. 3.2.5 (k) *HOLD timing diagram
You can clear the HOLD condition by issuing any motion command, but you can
clear the PAUSED condition only by executing a KAREL program (for example, by
issuing the KCL> RUN or RESUME commands or pressing the CYCLE_START button.)
4-28
CSTOP Signal
The effect of activating the CSTOP signal depends on the status of the UOP
output UPENBL and the system variable $C_STOP_ENBL.
If UOP output UPENBL is OFF the controller will not respond to CSTOP. In this
case CSTOP has no effect on controller operation. If UPENBL is ON, the CSTOP
input signal sets the system variable $C_STOP to TRUE and turns on the UOP
output signal CSTOP. (See Fig. 3.2.5 (1).)
In addition, if the system variable $C_STOP_ENBL is FALSE, the CSTOP input
signal acts identically to the UOP input signal *HOLD, pausing an executing
program and holding motion.
If $C_STOP_ENBL is TRUE, the CSTOP input signal does not pause the program
automatically. The KAREL language C_STOP function can be used in a program to
test the value of $C_STOP and pause a program if $C_STOP is TRUE.
If JC_STOP_ENBL is TRUE:
UPENBL (O) - ~2-
CSTOP ai
CSTOP (O)
If $C_STOP_ENBL is FALSE:
HELD(O)
PAUSED (O) r
Fifl. 3.2.5 (I) CSTOP timing diagram

RESET Signal
The effect of the RESET input depends on the current status of the controller.
If an error condition exists (FAULT output ON) and the cause of the error has
been removed, RESET resets the error condition. If an error condition does not
exist (FAULT output OFF), RESET clears the message line on the CRT/KB display.
.
(See Fig. 3.2.5 (m) )
With Error Condition in effect:
RESET 0) -
~
FAULT (O) ZT 1
SYSRDY (O) J
Fig. 3.2.5 (m) RESET timing diagram
4-29
4,
3.2.6 Connection for emergency stop control
The connections described in this section are made at the input unit, the
location of which is shown in Fig. 3.2.6.
Safety Fence
This input causes an emergency stop. This emergency stop differs from the
EMERGENCY STOP button on the operator panel only in the error message. This is
a normally open contact held closed by a gate on a safety fence that should be
connected across the terminals FN1 and FN2 on terminal TP1 on the input unit
PCB.
Normally open
held closed
Controller
FN111
Hnput unit
FN
External Emergency Stop
Terminals EMGIN1, EMGINC, and EMGIN2 allow for connection of external emergency
stops. Both place the robot in an emergency stop condition, however the status
of the emergency stop output differs.
TPl
EMGINl
Input unit
EMGINC PCB
EMGIN2
Note) Short when not used.
Emergency Stop Outputs
Emergency stops outputs are provided as shown in the following diagram.
Controller
EMGOUT1
Input unit EMGOUTC
EMGOUT2
When the emergency stop occurs in the controller or from an emergency stop from
EMGINl -EMGINC, the contact between EMG0UT1 and EMGOUTC will be open and the
contact between EMGOUTC and EMG0UT2 will be shorted. The contact specifications
are as follows. The minimum load is 5 VDC and 10 mADC. The maximum voltage of
the contact is 380 VAC or 125 VDC. The maximum current of the contact is 5 A.
The controller also provides the interface of emergency stop inputs which do not
affect the contacts of EMG0UT1, EMGOUTC, and EMG0UT2. They are called EMGINC
and EMGIN2. When this contact is open, the robot is stopped by the emergency
stop, but the contacts "EMG0UT1, EMGOUTC, and EMG0UT2" do not change, allowing
the continued operation of the external equipment.
4-30
o (TP1)
EMC
OUT]
EMC
OUTC
EMC
Externally furnished emergency OUT 2
stop button or limit switch. OPI
-
OP2
<g) © EMC
INI
EMC
© INC
© © EMC
m
W\ OUT1 SYON
100
0 Remove these jumpers

when the external emergency
stop function is used.
OUT2
BKPl BKR1
BKM1
BKP2 BKR2
BKM2
0 Externally furnished
BKP3 BJCR3
SKMJÿ
ON ML
gate switch OFF ALM
COM
FN1
*-<§) FUSE
FNJ ALMS
Remove this shorting

strip when the gate O
switch for the protective
fence is used.
4-31
3.2.7 Connection to computer
The RS-232-C interface is provided for the connection to the computer in the
controller.
£
/’"=ÿri7
V
w Shared RAM
board
mW\
0 01P04
CD4
3
0
CD4.
Shared RAM
board
01P04
Fig. 3.2.7 (a) Connection to computer Fig. 3.2.7 (b) Connection to computer
(Medium size cabinet) (Large size cabinet)
01P04 Shared RAM board
(MR20RFA)
1 2 3 4 5 6 7
ER
8 9 10 11 12 13 Computer
CD4 (RS-232-Q
RD SD
14 13 16 17 18 19 20
+24VR SG DR CS RS
MR-20LMH
4-32
Regarding the meaning of the signals, refer to the figure shown below.
-£>-' > SD (send data)
RS-232-C
interface
c>
->RD
-
--
-<ÿ]
-
1 (receive data)
RS (request to send)
CS (clear to send) -- 1 Connect RS to CS

1 when CS is not used.
- -
» ER (data terminal ready)
DR (data set ready)
-0 SG (signal ground)
Connect ER to DR
J when DR is not used.
l XConnect to signal
ground of computer.
Note) +24 V cannot be used for computer.
ON/OFF voltage levels are given in the following table.
Less than -3 V More than +3 V
Function- OFF ON
Signal condition Marking Spacing
Cable connection between the controller and the computer should be as follows:
Controller Computer
X
Cable: 20 x0.18 mm’
with unified shield
Peel the sheath of cable and attach the cable to the ground board of the
controller cabinet by means of the cable clamp metal fixture.
4-33
3.2.8 Connection to remote CRT/KB
When the controller is used with the built-in operator's panel, the remote
CRT/KB can be connected to the connector provided on the built-in operator's
panel.
fl a a a CRT/KB
connector
m
B ©
o
o
msi®
e } Remote
CRT/KB
piiiiiiiiiiiiiil
lllull'llllllllll!
riiiiiiiiiiiiiiinl
c
Operator’s panel
1 FG
14
2 SD
i RD
16
4 RS
5 CS
18
6 DR
19
7 SG
20 ER
Operator's panel
connector ]D {][ Remote
CRT/KB
8 CD CRT/KB
9
22
10
23
11
12
+24V
13
2SP D-subminiature
female
4-34
3.3 Setting USAT
The User Signal Assignment Table (USAT) , a mapping of the physical signals to
the system software, describes the user I/O hardware configuration to the
controller. UOP and HAND signals are also mapped in the USAT. The table is
stored in the system variable $USAT.
The USAT consists of nine blocks of tables, one for each I/O signal type. Each
block contains a table for each I/O signal of the corresponding type. These
tables contain multiple bytes of data that describe details of the I/O hardware.
The structure of the blocks and the tables within each block vary with the type
of I/O signal. (See Table 3.3 (a))
After you have selected the hardware configuration and I/O types, enter the
appropriate data into the table, making it available for use by the controller.
If you are not using the KAREL System Software Utility Package available from
GMF, perform the following steps for each entry:
1. Determine the appropriate numbers for each of the data fields.
2. Convert each number to binary format using the number of binary bits
specified for the signal type.
3. Configure the data into the appropriate eight-bit binary words.
4. Convert the binary words to decimal format.
$USAT is a system variable ARRAY with each element mapping a group of I/O
signals. To change $USAT ARRAY element number 9 to a value of three, enter KCL>
SET VAR $USAT[9]= 3. (See Table 3.3 (a).)
Like other system variables, $USAT is stored in the file SYSVARS.SV
(through use of the KCL> SSAVE command). Each time you power up the controller
it reads these variables and uses the data from $USAT to understand the I/O
configuration you have selected.
For example, to change $USAT ARRAY element number 9 to a value of 20 from the Non-Positional Data
screen:
1 Highlight the Sysvars option from the program list and press ENTER. This will display an
alphabetical listing of all available system variables.
2 Highlight the $USAT system variable using the up/down arrow keys and press ENTER. This
will display the current value for each of the 98 elements in $USAT.
3 Use the arrow keys to highlight $USAT[9] and press ENTER. Type 20 at the “Enter new
value>” prompt.
4 To save the value to SYSVARS.SV, press the Save File Function key, FI.
Expanded I/O
It is possible to define additional signals besides those defined in $USAT. The information for these defini¬
tionsisstored in the KAREL variable file, EXP_USAT.VR. The structure of the data within this file is similar
to that of $USAT but not the same. The USAT Setting Program supports this expanded table automatically.
Using this program is the only way in which you can set the expanded I/O table. Modifications to the USAT
are still made through the use of the USAT Setting Program, Config I/O menus, on the CRT/KB and teach
pendant. When assignments are made that exceed the standard table size, thedatais added to EXP_USAT.VR
automatically by the Config I/O process. When you exit the USAT Setting Program using the SAVE option,
this file is saved to bubble memory.
A CAUTION
If you delete the EXP_USAT.VR file from bubble memory, you
will need to run the KAREL USAT Setting Program to reset the
expanded I/O table.
4-35
There are now 1000 digital 100 group and 100 analog input and output signals available to access the R-H
modular VO, the fixed I/O board, and the interfaces to GEFanuc and Allen-Bradley programmable
controllers.
In addition, there are another 1000 digital and 100 group and analog signals available for the direct control
of GEFanuc Genius I/O blocks as shown in the following table.
Signal Type Module I/O Genius I/O
Digital (DIN,POUT) 1-1000 1001-2000
Group (GIN,GOUT) 1-100 101-200
Analog (AIN,AOUT) 1-100 101-200
To accommodate the configuration of these signals, an extension to the User Signal Assignment Table
(USAT) has been added. This extension is contained in an expandable KAREL variable file EXFMJSAT.VR
and has a similar structure to the basic USAT stored as a system variable.
For more information on the Genius and Allen-Bradley interfaces refer to, A User's Guide to the GMF Net¬
work Interfacefor GEFanuc or A User’s Guide to the Remote I/O Interfacefor Allen-Bradley.
4-35A
Table 3.3 (a) USAT structure
Element size in
Table number Signal number [n]
number [n] bytes
DIN Tables
USAT[I]
USAT[3]
DIN
DIN
Table
Table
#1
02
DIN[1]
DIN [9]
-- DIN [8]
DIN [16]
2
2
bytes
bytes
USAT[5]
USAT[7]
DIN
DIN
Table
Table
#3
#4
DIN[17]
DIN[253
-- DIN [243
DIN [323
2
2
bytes
bytes
--- DIN
USAT[93 DIN Table #5 DIN[33] DIN[403 2 bytes
USAT[113 DIN Table #6 DIN[413 DIN[483 2 bytes
USAT[133 DIN Table #7 DIN[49] [56 ] 2 bytes
USAT[153 DIN Table #8 DIN[573 - DIN[64] 2 bytes
DOUT Tables
USAT[173 DOUT Table #1 DOUT[ 1] - DOUT[163

DOUT[ 83 2 bytes
USAT[19 3
USAT[213
DOUT
DOUT
Table
Table
#2
#3
DOUT[93
DOUT[ 17]
-- DOUT[243 2
2
bytes
bytes
USAT[23]
USAT[253
DOUT
DOUT
Table
Table
#4
#5
DOUT[ 253
DOUT[ 333
-- DOUT[403
D0UT[32] 2
2
bytes
bytes
USAT[27]
USAT[293
DOUT
DOUT
Table
Table
#6
#7
DOUT[4l3
DOUT[49]
-- DOOT[483
DODT[563
2
2
bytes
bytes
USAT[31] DOUT Table #8 DOUT[57] - DOUT[64] 2 bytes
GIN Tables
USAT[333 GIN Table #1 GIN[1] 3 bytes

USAT[363 GIN Table 02 GIN[23 3 bytes
USAT[393 GIN Table #3 GIN[3] 3 bytes
USAT[42] GIN Table #4 GIN[4] 3 bytes
USAT[45] GIN Table #5 GIN[5] 3 bytes
USATC48] (unused)
GOUT Tables
USAT[49] GOUT Table #1 GOUT[13 3 bytes

USAT [52 3 GOUT Table #2 GOUT[23 3 bytes
USAT[55] GOUT Table #3 GOUT[33 3 bytes
USAT [58 3 GOUT Table #4 GOUT[4 3 3 bytes
USAT[61] GOUT Table #5 GOUT[5] 3 bytes
USAT[643 (unused)
n
AIN Tables
USAT[65] AIN Table If 1 AIN[ 1 ] 2 bytes

USAT[67] AIN Table 02 AIN[2 ] 2 bytes
USAT[69] AIN Table 03 AIN[3 ] 2 bytes
USAT[71] AIN Table #4 AIN[4 ] 2 bytes
USAT[ 73] AIN Table 05 AIN[5 3 2 bytes
4-36
Element size in
Table number Signal number [n]
number [n] bytes
AOUT Tables
USATC75] AOUT Table #1 AOUT[ 1] 2 bytes

USATE77] AOUT Table #2 AOUT[2] 2 bytes
USATC79] AOUT Table #3 AOUTE3] 2 bytes
USATE813 AOUT Table U AOUTEA] 2 bytes
USATC83] AOUT Table #5 AOUTE5] 2 bytes
UOP Input Table
USATE85] Input Table UOP Inputs 1 byte
UOP Output Table
USATE86] Output Table UOP Outputs 1 byte
HAND Signal Tables
USATE87] HAND Table #1 HANDEl] 3 bytes

USATE90] HAND Table #2 HANDE2] 3 bytes
USATE93] HAND Table #3 HANDE33 3 bytes
USATE96] HAND Table U HANDEA] 3 bytes
Digital Input and Output Tables
The two blocks for digital input and digital output each contain eight tables
(DIN Table #1
(a)).
-
DIN Table #8 and DOUT Table #1 DOUT Table #8 in Table 3.3 -
Each table consists of two bytes for configuring the DINs and DOUTs and
describes eight signals, ordered by signal number (DIN Table #1 is for DINEl] -
DINE8], DIN Table #2 is for DINE 9] DINE16], and so on).-
For the modular I/O system data within each table defines the location of the
I/O module for the associated signals. For the fixed I/O system data within
each table determines which signals are associated with the dedicated I/O lines
on the fixed I/O board. Table 3.3 (b) shows the format of the data in the DIN
__
and DOUT tables.
Table 3.3 (b) DIN/DOUT table format

o O O j o O c- |- o
Rack if (A bits) Slot # (A bits) First byte
Base signal if (7 bits)

. M (U <£ V 2 |
_
Polarity (1 bit)
-I.
Second byte
o Rack
—
rack number must be 1.
| (j O o o O I
I/O rack number in which the I/O module is mounted.
o
For fixed I/O
o Slot
—Slot number (on the I/O rack) in which the I/O module is mounted.
For fixed I/O slot number must be 1.
Ihiu 1-8 ~to Oft! f - ft

I l(p+i A-37
l
= IT-
UDI 1- & ~
o Base Signal
- Modular
—
I/O: Signal number on the I/O module that corresponds to the
first DIN or DOUT in the table (1 or 9 for standard applications).
- Fixed I/O: Since the fixed I/O system has dedicated I/O lines and not
moduleSj the base signal does not have the same meaning as for the
modular I/O. Consider the fixed I/O card as an input module with 32
signals and an output module with 24 signals. The numbering of the
signals is as follows:
INPUTS OUTPUTS
Signal name Number Signal name Number
( b ,-T)
RDI1 1 RD01 1
RDI2 2 RD02 2
RDI3 3 ED03 3
RDI4 4 RD04 4
RDI5 5 RD05 5
RDI6 6 RD06 6
RDI7 7 RD07 7
RDI8 8 RD08 8
UDI1 65 UD01 65
UDI2 66 UD02 66
UDI3 . 67 UD03 67
UDI4 68 UD04 68
UDI5 69 UD05 69
UDI6 70 UD06 70
UDI7 71 UD07 71
UDI8 72 UD08 72
UDI9 73 • UD09 73
UDI10 74 UD010 74
UDI11 75 UD011 75
UDI12 76 UD012 76
UDI13 77 UD013 77
UDI14 78 UD014 78
UDI15 79 UD015 79
UDI16 80 UD016 80
UDI17 81 UD017 81
UDI18 82 UD018 82
UDI19 83 UD019 83
UDI20 84 UD020 84
UDI21 85 UD021 85
UDI22 86 UD022 86
UDI23 87 UD023 87
UDI24 88 UD024 88
UDI25 89
UDI26 90
UDI27 91
UDI28 92
UDI29 93
UDI30 94
UDI31 95
UDI32 96
4-38
The UDI/UDO number is always 64 more than the signal name. The numbers
listed in the table are valid as the base signal number when setting the
USAT for the fixed I/O system. As an example, to assign UDI9 UDI16 to -
be DINCl] -
DIN[83, the base signal in $USAT[23 would be 73.
- Polarity —
The polarity of the signal: 0 for active high (ON when voltage
is applied), 1 for active low (ON. when voltage is not applied).
Group Input and Output Tables
The two blocks for group input and group output each contain five tables (GIN
Table #1- GIN Table #5 and GOUT Table #1 -
GOUT Table #5 in Table 3.3 (a)).
Each table consists of three bytes for configuring the GINs and GOUTs and
describes one signal, ordered by signal number (GIN Table #1 is for GIN[1], GIN
Table #2 is for GIN[23» and so on).
Data within each table defines the location of the I/O module for the associated
signal. Table 3.3 (c) shows the format of the data in the GIN and GOUT tables.
Table 3.3(c) GIN/GOUT table format

g°0 \ 60 O (
Rack # (4 bits) Slot # (4 bits) First byte
Base signal # (8 bits) Second byte
Group size (8 bits) Third byte
o Rack
—I/O rack number in which the
I/O module is mounted. For fixed I/O
o Slot
—Slot number (on the I/O rack) in which the I/O module is mounted.
o Base Signal
- Modular
—
I/O: Signal number on the I/O module that corresponds to the
first DIN or DOUT in the table (1 or 9 for standard applications).
- modules
Fixed I/O: Since the fixed I/O system has dedicated I/O lines and
the base signal does not have the same meaning as for
not
the
modular I/O. Consider the fixed I/O board as an input module with 32
signals and an output module with 24 signals. The numbering of the
signals is as follows:
INPUTS OUTPUTS
RDI1 1 RD01 1
RDI2 2 RD02 2
RDI3 3 RD03 3
RDI4 4 RD04 4
RDI5 5 RD05 5
RDI6 6 RD06 6
RDI7 7 RD07 7
RDI8 8 RD08 8
4-39
INPUTS OUTPUTS
UDI1 i 4t 65 UD01 65
UDI2 66 UD02 66
UDI3 67 UD03 67
UDI4 68 UD04 68
UDI5 69 UD05 69
UDI6 70 UD06 70
UDI7 71 UD07 71
UDI8 72 UD08 72
UDI9 73 UD09 73
UDI10 74 UD010 74
UDI11 75 UDOll 75
UDI12 76 UD012 76
UDI13 77 UD013 77
UDI14 78 UD014 78
UDI15 79 UD015 79
UDI16 80 UD016 80
UDI17 81 UD017 81
UDI18 82 UD018 82
UDI19 83 UD019 83
UDI20 84 UD020 84
UDI21 85 UD021 85
UDI22 86 UD022 86
UDI-23 87 UD023 87
UDI24 88 UD024 88
UDI25 89
UDI26 90
UDI27 91
UDI28 92
UDI29 93
UDI30 94
UDI31 95
UDI32 96
The UDI/UDO number is always 64 more than the signal name. The numbers
listed in the table are valid as the base signal number when setting the
USAT for the fixed I/O system. As an example, to assign UDI9 UDI16 to-
be DINCl] -
DIN[8]» the base signal in $USAT[2] would be 73.
o Group Size
— —
Number of binary bits in the group (the number of lines
connected to the I/O module always within the range of 1 to 16).
Analog Input and Output Tables
Analog inputs and outputs are available with the modular I/O system. The two
blocks for analog input and analog output each contain five tables (AIN Table //I
- AIN Table #5 and AOUT Table ifl -
AOUT Table #5 in Table 3.3 (a)).
Each table consists of two bytes for configuring the AINs and AOUTs and
describes one signal, ordered by signal number (AIN Table it l is for AIN[1], AIN
Table #2 is for AIN[2], and so on).
signal. Table 3.3 (d) shows the format of the data in the AIN and AOUT tables.
4-40
Table 3.3 (d) AIN/AOUT table format
Rack # (4 bits) Slot If (4 bits) First byte
Channel # (8 bits) Second byte
o Rack
o Slot
—— I/O rack number in which the I/O module is mounted.
Slot number (on the I/O rack) in which the I/O module is mounted.
o Channel
— Digital/Analog (or Analog/Digital) channel number on the I/O
module which corresponds to the AIN or AOUT for this table.
UOP Input and Output Table
The UOP input and UOP output each have one block containing all of the UOP input
or output signals.
Each table consists of one byte for configuring the UOP inputs and outputs. No
signal number is required for UOP signals.
signal. Table 3.3 (e) shows the format of the data in the UOP tables.
Table 3.3 (e) UOP input/output table format
Rack If (4 bits) Slot If (4 bits) First byte
o Rack
— I/O rack number in which the I/O module is mounted.
For fixed I/O
o Slot
— Slot number (on the I/O rack) In which the I/O module is mounted.
Hand Control Signal Tables
The one block for HAND control signals contains four tables (HAND Table If 1
HAND Table #4 in Table 3.3 (a)).
-
Each table consists of three bytes for configuring the HAND control signals and
describes one signal, ordered by signal number (HAND Table If 1 is for HAND[1],
HAND Table #2 is for HAND[2], and so on).
Data within each table defines the location of the output module (or the number
of the fixed I/O signal) for the associated signal and the mode of operation for
the signal lines. Table 3.3 (f) shows the format of the data in the HAND
tables.
Table 3.3 (f) HAND signal table format
Operation mode If (8 bits) First byte
Rack If (4 bits) Slot If (4 bits) Second byte
Open line If (8 bits) Third byte
4-41
o Operation Mode
-- Mode
Mode
0:
1:
Single
— Operation mode number is defined as follows:
mode
line
Dual line mode
- Mode
Mode 2: Dual pulsed
line mode, 200 msec pulses
- 3:
(Refer to
Dual line pulsed mode, 400 msec pulses
the KAREL System Reference Manual for a detailed description of
each mode.)
o Rack ~ I/O rack number In which the output module is mounted. For fixed
I/O rack number must be 1.
o Slot
— Slot number (on the I/O rack) in which the output module is
mounted. For fixed I/O slot number must be 1.
o Open Line
—Signal number that corresponds to the open line.
signal is the close line.
Setting Unassigned Signals

The next
Unused I/O signals should be left unassigned in the USAT. Use a value of zero
for the rack and slot numbers in the corresponding assignment table.
4-42
3.4 I/O Module Specifications
01 01
02 02
OJ 03
04 04
COM
05 OS
ISS 0
06 06
0? 07
oa oa
cox
09 09
c 10 •10
n i
12
C
sail
13
14
0
\C 15
.0 16
COM
Fig. 3.4 (a) Typical output module
Various 1/0 modules are prepared to connect with peripheral devices. DI/D0
modules are mounted in slot No. 1, 2, 3, 4, 5, 6, 7, 8 or 9 in 1/0 unit. For
the types of DI/D0 modules, refer to Tables 3.4 (a) through (d). For analog
input/output modules, refer to Tables 3.4 (h) through (i). For noise
suppressors, refer to Sec. 4.2.4.
\
Table 3.4 (a) Variety of Dl modules
Low level High level

Module Rated Input Response
input volt Input volt
Nunber of External LED
Fuse
Nunber of
nane voltage current tine (ux) (ÿin)
Inputs connection display coamons
ID16C 24 VDC 9 nA 20 ns 8 V 15 V 16 terainal YES NO 4

block
(M3)
ID06C 24 VDC 9 BA 20 ns 8 V 15 V 8 ditto YES NO 2
ID16D 24 VDC 9 nA 8 V 15 V 16 ditto YES NO 4
ID08D 24 VDC 9 BA 8 V 15 V 8 ditto YES NO 2
50 ns 20 VAC 70 VAC 16 ditto YES NO 4

IA16E 120 VAC 9 sA ’
1A08E 120 VAC 9 sA 50 as 20 VAC 70 VAC 8 ditto YES NO 2
For the connections diagram see Fig. 3.4 (b), (c).

Fig. 3.4 (b): ID16C, ID08C, ID16D, ID08D.
Fig. 3.4 (c): IA16E, IA08E.
For the specifications, refer to Table 3.4 (b), (c).
Table 3.4 (b): DC input specifications ID16C, ID08C, ID16D, ID08D.
Table 3.4 (c): AC input specifications IA16E, IA08E.
4-43
Terminal for M3 screws Internal address
of module card
01 o-(1)
02 (2)
2
03 (3)
3
04 (4)
4
COM 1 (5)
05 (6>
5
06 (7)
6
07 Hi
7
08 (9)
8
COM2 (10)
09 (11)
9
10 o(12)
10
11 (13)
11
12 (14)
12
24 COM3 -o (IS)
13 -6- (16)
13
14 (17)
14
I
IS (18)
<
15
16 -6- (19)
16
24 VDC* COM4 (20)
<
09-16 are not mounted on ID08C, 08D
Fig. 3.4 (b) Dl nKxJulelD16CJID08C, ID16D, ID08D
5 L' *TI©A~> PwrvT POvr/l

C/U&l&tiT /'/oOoT
!
4-44
Table 3.4 (b) DC input specifications
Module
ID08C ID16C ID08D ID16D
Item
Points/module 8 16 8 16
Rated input voltage 24 VDC
Maximum input voltage 30 VDC
Operation voltage (Note 1) ON 15 V or more
OFF 8 V or less
Operation current (Note 1) ON 4.5 mA or more

OFF 2 mA or less
Input current 9 mA typical (24 VDC)
Input impedance 2.5 kfi approx.
Response time (Note 2) OFF ON 20 ms max. 2 ms max.
ON -*ÿ OFF 20 ms max. 2 ms max.
Operation display LED lights when input is ON
External connection method Terminal board connection (M3)
Common points (Note 3) 1 common per 4 points input
Dielectric strength 1 minute under 1000 VAC
Note 1) When the voltage between the input terminal and common terminal is 15 V
or more, or when the current flowing into the input terminal is 4.5 mA
or more, the input signal (contact point) is regarded as ON. When the
input terminal voltage is 8 V or less, or when the input current is 2 mA
or less, the input signal (contact point) is regarded as OFF. When
using proximity switches or photo-electric switches, be careful of
current leakage when the contact point is off. If the current leakage
is 2 mA or more, it will not be regarded as OFF.
Note 2) The response time shown here is the delay time from module input to
output. The actual response time is this value plus the scanning time
which is different for each system configuration.
Note 3) The commons are not connected to each other in the module.
4-45
Terminal for M3 screws
$9 Internal address
of moduk card
/I 01 <D
1
02 (2)
2
03 (3)
3
04 (4)
4
100 - 1 VAC 1U
05H (6)
5
06 (7)
6
07 (8)
7
x •
08 (9)
:• 8
100- VAC 212 fJ
n (10)
09 an
9
10 (12)
10
n <12*
u
12 (14)
12
MW VAC 3L2 (15) 0 c -
13 (16)
13
14 (17)
14
15 (18)
15
16 (19)
16
u—©
100 - 12POVAC 4U (20)
09-16 are not mounted on 1A08E.
Fig. 3.4 (c) 01 module IA16E, IA08E
" \
4-46
Table 3.4 (c) AC input specifications
Module
Item IA08E IA16E
Points /module 8 16
Rated input voltage 100 - 120 VAC, 50/60 Hz

Maximum input voltage 140 VDC
Operation voltage (Note 1) ON 70 V or more
OFF 20 V or less
Operation current (Note 1) ON 5 mA or more
OFF 2 mA or less
Input current 9 mA type (100 VAC)
Input impedance Approx. 12.5 kfl
Response time (Note 2) OFF -ÿ ON 50 ms max.
ON OFF 50 ms max.
Operation display LED lights when input is ON
External connection method Terminal board (M3)
Note 1) When the voltage at the input terminal is 70 V or more, or when the
current flowing into the input terminal is 5 mA or more, the input
signal (contact point) is regarded as ON. When the input terminal
voltage is 20 V or less, or when the input current is 2 mA or less, the
input signal (contact point) is regarded as OFF. When using proximity
switches or photo-electric switches, be careful of current leakage when
the contact point is off. If the current leakage is 2 mA or more, it
will not be regarded as OFF.
Note 2) The response time is the delay time from module input to output. The
actual time is this value plus the scanning time which is different for
each system configuration.
Note 3) The commons are not connected to each other in the module.
4-47
Table 3.4 (d) Variety of DO modules
Rated current OFF state ON state

LED Number of
Hodule Rated Number of External Remarks
leak voltage dlspisy
Fuse
name voltage Per outputs connection cosBons
Each
common
Total current drop
0D16B 24-48 0.5 A 2 A 8 A 0.1 aA 1.0 V 16 terminal YES YES 4 DC

VDC block sink
(M3) output
0D08B 24-48 0.5 A 2 A 4 A 0.1 mA 1.0 V 8 ditto YES YES 2 ditto

VDC
0D16C 24-48 2 A 4 A 16 A 0.5 mA 1.0 V 16 ditto YES YES 4 ditto

VDC
0D08C 24-48 2 A 4 A 8 A 0.5 aA 1.0 V 8 ditto YES YES 2 ditto

VDC
0A16D 120 1.6 A 3.2 A 12.8 A 1.5 aA 1.5 V 16 ditto YES YES 4
VAC
0A08D 120 1.6 A 3.2 A 6.4 A 1.5 aA 1.5 V 8 ditto YES YES 2
VAC
0A16E 240 1.6 A 3.2 A 12.8 A 3 mA 1.5 V 16 ditto YES YES 4

VAC
0A08E 240 1.6 A 3.2 A 6.4 A 3 aA 1.5 V 8 ditto YES YES 2

VAC
0D16H 24-48 2 A 4 A 16 A 0.5 aA 1.0 V 16 ditto YES YES 4 DC

VDC source
output
0D08H 24-48 2 A 4 A 8 A 0.5 aA 1.0 V 8 ditto YES YES 2 ditto

VDC
For the connections diagrams see Fig. 3.4 (d)

Fig. 3.4 (d): 0D16B, OD08B.
- (h).
Fig. 3.4 (e): 0D16C, OD08C.
Fig. 3.4 (f): 0A16D, OA08D.
Fig. 3.4 (g): 0A16E, 0A08E.
Fig. 3.4 (h): 0D16H, OD08H.
For the specifications, refer to Table 3.4 (e)
Table 3.4 (e): DC output specifications 0D16B,
-OD08B.
(i).
Table 3.4 (f): DC output specifications 0D16C, OD08C.

Table 3.4 (g): AC output specifications 0A16D, OA08D.
Table 3.4 (b) : AC output specifications 0A16E, OA08E.
Table 3.4 (i): DC output specifications 0D16H, OD08H.
4-48
Internal address M3 terminal
—
of module card \x (21) 1+DC
r*H=»
uiXsi r-tDADrf 1
I i t*
a> 02
2- rc=>r
Pt
3- 12IA03
4 - (4) 04
tÿr
3*2A (5) koM
5 - (6)
(7)106
OS
tÿT~
6 - tÿr
(8) 07
7
E: &
8 - E=: 3.2A
-0\JO-
121
(10)
08
COM
ill) 09
9 - tÿT'
10 - 112UJ1
Pf
II - (13)
(14)
11
12
T
12 - 3.2A t=r
(15) ICOM
(lfLin
13 - I
|4
- (17) 14
tÿr
lS
16
—
-
(18)
(19)
O
IS
16
T-» T
3.2A
Qÿo ACOM M 24 -48 VDC (ÿ)
Fuse break-
a*c detection **.
09-16 ate not mounted on OD08B.
Fig. 3.4 (d) DO module 0D16B, OD08B
4-49
Table 3.4 (e) DC output specifications
Module
OD08B 0D16B
Item
Points/module 8 16
Rated input voltage 24 - 48 VDC
Output voltage range 50 VDC or less (Note 1)
Max. output current Per output 0.5 A
Per common 2 A
Total 4 A 8 A
Surge-on current
Output voltage drop at ON 1 V max. (Note 6)
Current leakage at OFF 0.1 mA max.
Response time (Note 2) OFF -»ÿ ON 0.3 ms max. (resistance load)
ON -»• OFF 0.3 ms max. (resistance load)
Operation display LED lights when output is ON
External connection method Terminal board (M3)
Fuse (Note 4) 3.2 A/ common
Polarity Exists
(the common is the side)
Note 1) There is no lower limit in output voltage for the output operation, but
the operation display LED of the modules with operation display will dim
if the output voltage is 24 VDC or less.
Note 2) Response time shown here is the delay time from module input to output.
The actual response time is this value plus the scanning time which is
different for each system configuration.
Note 3) The commons are mutually connected to the modules, but the load current
cannot be sent in the internal pattern. The common must always be
connected to the minus side (0 V) of the load current.
Note 4) Fuses are inserted in each common. The red LED at the bottom of the
module front will light if any of the fuses break.
4-50
Note 5) When connecting inductive loads (like relays) to the output, always
connect a diode across the load. When connecting a lamp load, insert
dimmer resistors across the output terminals to decrease current flow to
within the standard limit.
Note 6) Output voltage drop at ON depends on the load current and is expressed
as follows: Vsat = 2 x II (Vsat: Output voltatge drop, I£: load current)
M3 terminal
Internal address W (21)
fie
of module card
2
-crÿo—
3.2A
. (21 02
(3) 03
3
(4)1 04
4
3.2A (S) COM -
_
IZii°6_
5
6 i : -T
3-2A (8) 07
7
(9) 08
8
32A (10) COM -
(11) 09
9 - tSr
(12) 10
10
ii
-
_
3.2A imiu
liiUi2 _
12
3'2A , COM-
tSr
o~~& ,
(IS)
(16)1 13
13
14 <mii± t°r
IS - 3.2A (18) IS
(19li_L6
16
3.2 A
it20),lCQM-
Fuse break¬
09-16 arc not mounted on OD08C. age detection h
Fig. 3.4 (e) DO module OD16C, OD08C
4-51
Table 3.4 (f) DC output specifications
Module
OD08C 0D16C
Item
Points /module 8 16
Rated input voltage 24 - 48 VDC
Output voltage range 50 VDC or less (Note 1)
Max. output current Per output 2 A
Per common 4 A (Note 5)
Total 8 A 16 A
Surge-on current
Output voltage drop at ON 1.0 V max. (Note 7)
Response time (Note 2) OFF ON 0.4 ms max. (resistance load)
ON -ÿ OFF 0.4 ms max. (resistance load)
External connection method Terminal board connectors (M3)
Common points (Note 3) 1 common per 4 points output
Fuse (Note 4) 3.2 A x 2/common
Polarity Exists
(the common is the side)
the operation display LED will dim if the output voltage is 24 VDC or
less.
Note 2) Response time shown here is the delay time from module input to output.
The actual response time is this value plus the scanning time which is
different for each system configuration.
Note 3) The commons are mutually connected to the modules, but the load current
cannot be sent in the internal pattern. The common must always be
connected to the minus side (0 V) of the load current.
Note 4) A fuse is inserted between the following two points of outputs.
(00,01) (02,03) (04,05) (06,07)
(10,11) (12,13) (14,15) (16,17)
Note 5) The output current is limited to 2 A per fuse (group of two points).
4-52
Note 6) When connecting inductive loads (like relays) to the output, always
as follows: Vsat = 2 x IJt (Vsat: Output voltatge drop, !£.: load current)
Internal address v> M3 terminal

of module card r<h
jToToi
tSSr-
3vOH3
i
il>M
2
(3) ,03
TST1
3
(4)104
TST1
4
6.3A L)
tSr
ill
(6)l0S
5 tSr
121 06
6 tSr
m°z.
7 rSr'
121 08
8
6.3A
MH
(11) 09
9 - 02)110
TST’
10 - tSr
n 112411
- iiiiOi
12
6. 3A nsÿu tSr1
(16) 13
13
(170l4_
tSi
14
(18) IS
15
09)116
rSr
16
6.3A (20)1 LI
Fuse break- "3.

a«e detection
100
e
- >20 VAC, + 10%, -15%
09-16 are not mounted on OA08D.
Fig. 3.4 (f) DO module 0A16D, OA08D
4-53
Table 3.4 (g) AC output specifications (100 VAC type)
Module
0A08D 0A16D
Item
Points /module 8 outputs 16 outputs

Output voltage range 85 - 132 VAC
Per common 3.2 A (Note 5)
Total 6.4 A 12.8 A
Surge-on current 10 A (1 cycle) (Note 6)
Output voltage drop at ON 1.5 V max. (peak)
Response time (Note 1) OFF -»ÿ ON 0.2 ms max.
ON -*• OFF 1/2 ms max.

Operation display LED lights when output is turned
on
External connection system Terminal board connectors (M3)
No. of common points (Note 2) 1 common/4 outputs

Fuse (Note 3) 6.3 A/common
Polarity None
Note 1) The response time shows a delay time from an input to an output of the
module. Actual response time is obtained by adding the scan time
determined by the system configuration to the value shown in the above
table.
Note 2) The common lines are interconnected inside the module. However, no load
current is applicable to internal patterns. Always connect each common
to one end of the load power supply.
Note 3) A fuse is inserted in every common line. If one of these fuses is blown
the red LED lights at the bottom part of the front panel of the module.
Note 4) Mount a surge suppressor across the load if an inductive load like a
relay is connected to the output. When connecting a lamp load insert a
dimmer resistor across output terminals to reduce the rush current. Use
the lamp load within the specified value.
4-54
Note 5) In addition to the above limitation, the output current is limited to
1.6 A for every 2-output group shown below.
(00,01) (02,03) (04,05) (06,07)
(10,11) (12,13) (14,15) (16,17)
For example, no load current can be fed to output "Ol", while a 1.6 A
load current is being fed to output "OO".
Note 6) Surge-on current means the maximum surge current which can be sent to
one fuse. When two loads or more are ON simultaneously, the total value
of the surge current which is set to one fuse must be within the above
value .
Internal address M3 terminal
of module card ME
i
-
>Dm M21
2
3.2A i3)lo3 tSr’
3
(4)104
4
3.2 A
mu
tSr
5 - mos r1..iJ
6
I 3.2A
121
ill
06
07
7
19028
tSr1
8 - tS?r~
3.2A (10), LI
(11)109
9
(12). 10
tCSr-
10 rÿi—
3.2A (13). 1 1
11
(14), 12
tST'
12
3.2A (IS) LI
ter'
-o-~o
(16), 13
13
TS2r-'
14
1 3.2A
(17). 14
imii
15
rÿr-
16 imlii
3.2A
Fuse break¬
age detection
(20)1 LI
o
200 - 240 VAC, +J0%, -15%
09-16 are not mounted on OA08K.
Fig. 3.4 (g) DO module OA16E, OA08E
4-55
Table 3.4 (h) AC output specifications (200 VAC type)
Module
Item OA08E 0A16E
Points /module 8 16

Output voltage range 160 - 264 VAC

Per common 3.2 A (Note 5)
Total 6.4 A 12.8 A
Surge-on current 10 A (1 cycle) (Note 6)

Output voltage drop at ON 1.5 V max. (peak)
Leak current at OFF 3 mA max.
Response time (Note 1) OFF -*• ON 0. 2 ms max.
ON OFF 1/2 cycle max.

Operation display LED lights when output is turned
on
External connection system Terminal board connectors (M3)
No. of common outputs (Note 2) 1 common/4 outputs
Fuse (Note 3) 3.2 A x 2 pcs /common

Polarity None
Note 1) The response time shows a delay time from an input to an output of the
module. Actual response time is obtained by adding the scan time
determined by the system configuration to the value shown in the above
table.
Note 2) The common lines are interconnected inside the module. However, no load
current is applicable to internal patterns. Always connect each common
to one end of the load power supply.
Note 3) Two fuses are inserted in every common line. One red LED is mounted for
every two fuses. A corresponding LED lights, if a fuse is blown.
Note 4) Mount a surge suppressor across the load, if an inductive load Like a
relay is connected to the output. When connecting a lamp load insert a
dimmer resistor across output terminals to reduce the rush current. Use
the lamp load within the specified value.
4-56
Note 5) In addition to the above limitation, the output current is limited to
1.6 A for every 2-output group shown below.
(00,01) (02,03) (04,05) (06,07)
(10,11) (12,13) (14,15) (16,17)
For example, no load current can be fed to output "01", while a 1.6 A
load current is being fed to output "00".
Note 6) Surge-on current means the maximum surge current which can be sent to
one fuse. When two loads or more are ON simultaneously, the total value
of the surge current which is sent to one fuse must be within the above
value.
M3 terminal
Internal address //
of module card
mloi
1 (ton
tSUn
2 - -0-0—,
(2)
_ tSr
02
tÿr-
3
4
-
-
3.2A 1DA03
m™.
___ tSr
<6>ioS_ tSÿr-
3.2A 4-48VDC
-O
6 - g _ rÿr-
3.2A (8) 07
7 rÿr-
8
S (9), 08
rS2r~
——..
3.2A (10)
(11).
-
o COM1
09
9 tÿn
10 - B •CTN-O-,
(12) 10
rÿr-
3.2A (13). II
11
t®r
12
3.2A
-O-
(IS). +DC2
tSr
24-48VDC
(16). 13
-- tS2r-
s
13
112)114
14 - tSr1
3.2A (18). IS
IS
09)116
tser-
16
B 3.2A (20)1COM2
Fuse break-
5*
09
— 16 are not mounted on OD08H.
ape detection
Fig. 3.4 (h) DO module OD16H, OD08H
4-57
Table 3.4 (i) DC output specifications
Module
OD08H 0D16H
Item
Po Ints /module 8 16
Rated Input voltage
Output voltage range
24 -48 VDC
50 VDC or less (Note 1)
Max. output current Per output 2 A
Per common 4 A (Note 5)
Total 8 A 16 A
Surge-on current
Output voltage drop at ON 1.0 V max. (Note 7)
Response time (Note 2) OFF -» ON 0.4 ms max, (resistance load)
ON -*ÿ OFF 0.4 ms max, (resistance load)
External connection method Terminal board connectors (M3)
Common points (Note 3) 1 common per 4 points output
Fuse (Note 4) 3.2 A x 2/common
Polarity Exists (the common is the side)
the operation display LED will dim if the output voltage is 24 VDC or
less.
Note 2) The response time shown here is the delay time from module input to
output. The actual response time is this value plus the scanning time
which is different for each system configuration.
Note 3) The commons are not connected to each other in the module. Each common
must always be connected to the minus side (0 V) of the load current.
Note 4) A fuse is inserted between the following two points of outputs.
(00,01) (02,03) (04,05) (06,07)
(10,11) (12,13) (14,15) (16,17)
The red LED at the bottom of the module front will light if any of the
fuses break.
Note 5) The output current is limited to 2 A per fuse (group of two points).
Note 6) When connecting inductive Loads (like relays) to the output, always
as follows: Vsat = 0.5 x If (Vsat: Output voltage drop, If: Load
current)
4-58
Table 3.4 (j) Analog input module
Max
Module Input input External
Analog inputs Resolution Accuracy
name points voltage/ connection
current
AD04A 4
points/
-10 -
+10 VDC 5 mV +0.5Z or +15 V Terminal
(Input resistor 20 pA less +40 mA block
module 1 MG) (M3)
-20 -
+20 mADC
(Input resistor
250 ft)
can be selected.
AD04A (Analof input module)

Volute input
VP1 Channd #0
o1
J-tI0V
inl2
Ss
I
J Not* 1
B gOMiAj
FC1M
a
2Son
cr
VP2 5 Channel •!
V“
IMH
mu
COM217
FC218
a
250A
IMA
Multi¬
plexer AMP
Current input A/D
Channel «2 converter
VP319
3-
fl
m
s20mA
a
L 1P3| 10 IMA
Jr Note 1
JjcoM3(|n 250A
IMA
VPn and (Pn must always JTQJ 12

be shorted for current input.
Note 1: Shielded twist pair cables
(2 cores) are required as VPl.iJ Channel #3
the connecting cable. Cr-
The shield of the cable 1MA
a
should be connected
to the ground board
of the controller by IMA
means of the cable
damp. COM4AJI
25on
FCII6
FC,<Ui
Fig. 3.4 <i) Analog input module connection
4-59
Table 3.4 (k) Analog input module
Resolution
Module Output External
Analog outputs overall Isolated
name points
accuracy
connection
DAO 2A 2
points/
-10 - +10 VDC
(External load*
5 mV, within
20 uA*
0.5%
Not
isolated
Terminal
board (M3)
module resistance more than
1 KS2)
0 -
+20 mA DC
(External load
resistance 0
can be selected,
500 S2) -
DA02A
Voltage output
Voltage 1 VPl Note|

'Li
n }
io kn
or more
Channel D/A VNl
#0 convener
Jr
Voltagi 31IP1
AMP
Load impedance
2 10 kfl
INI
*6
Voltage VP2
AMPÿ-
Channel D/A VN2

*1 converter
Jr Cunent output
Voltage
AMP . zj
7 } soon
or less
Jr I
i
l0A
Load impedance
£. soon
"6
12
O
li6
Note 1: A 2- pair shielded cable must be used as
connection cable. The shield must be
% connected to ground at the load side.
56
Analog output module
Fig 3.4 (j) Analog output module connection
4-60
4. S-10 MECHANICAL UNIT
4.1 Connection between Controller and Mechanical Unit
Axis control board

01P05 K92
CF91-3 PI Signal to pulse encoder
J77
--
(W.U.8) for servo motor (W, U, 8)
A K93 Signal to pulse encoder

01P05 CF94 (7) i P2 for servo motor (7, B, a)
02P05 CF91-2
(fca)
_r~
Robot control module CNC A~~ K91
D1 DI/DO
or fixed I/O board T7
(Note)
Servo amplifier (W, 8) K31 Power to servo motor (W, 6)

Ml Brake to servo motor (W, 9)
Tl
Servo amplifier (U, 7, p, a) K32 Power to servo motor (U, 7, p, a)

Tl M2 Brake to servo motor (U, 7, P, a)
Power input unit BKP1, Ml
BKP2, M2
BKP3.M3
K99
(Ground board)
Fig. 4.1 (a) Interconnection between the controller and the S-10 mechanical unit
by means of robot connection cables
Note) The shield of the cable should be connected to the ground board
of the controller by means of a cable clamp.
4-61
Pi (MS3I06B 32A10S) P2(MS3 I 06B 32AI0S2)
1 B1»PCZA 1 1 A|PCZA 1 | I B pPCZAAj A 1 PCZAA|
fE~|PCBAI |Ot»PCAAl|C|PCAA?1 fE I PCBAA|0 |»PCAA4) C I PCAAA 1
|J| »SV lH| 0H2A I G I CHI A |P(«PC8Alt iJl «5V |H| QH2B |Gl OH 1 8 iFhPCSAdj
|M| OV |L| OV |K 1 -5V | |M!~ OV 111 OV |K| »5V |
|R| C4A1 |P| C8AI~ioT INIREOAI | I R I C4A* |P| CBAATOI N RE0A4
|W|PCAA2 I V KPCZASl U I PCZA2 [T I CIAI lSl C2AI | I W|PCAAS | V |«PCZA3 U|PCZAS I T| CIAA |S 1 C2A4~|
I « I *SV H3;I*?frnr3=nEElFlEgEE |«| »SV |Zt»fy8AÿY|PCBA5|xKPCAA5<
1 f | CAA2 I « I C8A2 | 4| QV 1 { | OV |M »5V I 111 CAAST« I C8AS |d OV 1 1 1 OV I b j *5V 1
TT I l|PgQA2lH CIA2 |tl C2A2 I TM 1 i |REQA5 1 k I C1A5 1 1 1 C2A5 I
| r 1 PCAA3 1 « h PCZA3) P I PCZASl 1 1
a I « t»PCBA3 » I PCBA3 1 a |»PCAA3(
a 1 1 ] PCAA6 1 q }»PCZ*6j 9 I PCZA6 1 11
a
Til
I t»PCBA6< » I PCBA6 1 » hPCAAtj
1 7 1 OV I«1 «5V M *5V I jTI OV 1*1 *5V M -SV |
MREOA3l«l OV I TLiÿ-LTlH OV
[Ad C8A3 AH |ACj C8A6 | A0
|AE] C2A3 rXTlACj CAA3 I |Aq C2A6 | |Ad C4A6 |
UdSHlELdAfl Cl A3 £3JE5»ffiHni
Ml (MS3I06B 28-2IS) M2 (MS3I06B 28-2 1SX)

0 c 8 A 0 C 8 A
AlG AIW AIV AIU A2G A2W A2V A2U
F E E
A3U AlG A1W AI V AIU AAU A2G A2W A2V A2U
R P N R P N
A3V A3U A3G A3W A3V A3V A5U A4G AAW AAV
X I w s
A3G A3W A6G A6W A5V A6U A5G A5W
t d b 1 t d e 6
B k b
BKM2 BKP2 BKM1 BKP1 BKM3 BKP3 BKM2 BKP2
t t 9 a i r p a
8KU3 I BKP3 BKM3 I BKP3
D1
| B|
A| | M| RDS j l| RDM [
RD01
| N |*PRABN |u | +24V |K | RDO
RDQ2
|C| RDQ3 | P| SG |V| •ROT | T| +24V | j|RDl2 |

_
l P| RDQ4 | R| OV |S| OV | H| RDM |
E| RDOS | F| RDQ6 | G| ,HBKD[
Fig. 4.1 (b) Pin assignment of connection in S-10 mechanical unit
4-62
RC01C
01P05 Robot control module
Axis control board
CF91-94
Power input
'unit
a
/02P05
CNC
i K31.K32
OFT1
Fixed I/O board
CNC
C
Servo
Servo
Amp.
2
— -92
K91
K93
my
K92
IfBÿW
Amp.
1 K3I.K32
K92
K93
K91
K99
K31
Fig. 4.1 (c) Connection diagram for the robot connection cables
(S-10, medium size cabinet)
7
01P05 RC01C
Axis control board Robot control module
CF91-94
f?\ 7A.
Power input unit
BKP1 BKM1 -BKP3.BKM3
K3I.K32
OPT1
Fixed I/O board
3 rJJ m CNC
CF91
K91 -92. & 4
Servo
Servo
Amp.
K92 7 2 /
Amp.
i K93
W
K99
K31.K32
K92
K31 S
K93
;9i
Fig. 4.1 (d) Connection diagram for the robot connection cables
(S-10, large size cabinet)
Note) Cable K91 is connected to the robot control module for
modular I/O or to the fixed I/O board for fixed I/O.
4-63
4.2 Connections and Signals between Mechanical Unit and End Effector
4.2.1 Connections
Mechanical unit
1 2 3 4
RDOl RD02 RD03 RD04
6 8 9
RD05 RD06 *HBKD OV RDU
10 11 12 13 14 15
RDC2 RD13 RDI4 RDI8 •PPABN
H ]|] 1 End effector
16 17 18 19 20
+24V +24V +24V +24V
21 22 23 24
Note) Connecting cables are customer provided.

Connector pin No. Eod effector
Mechanic!i wait
*T4 H<17. 18.19,20)
Hand breaJufe Receiver dreuit H<7)

: detection igaal •HBKD j
777
J
RDU
RDU
777 c:: H (9)
H (10)
7ÿ7 Lflr
H (11)
RDI3
End*
effector < 4r
HU2)
RDM j
4r
RDI8 HU 3)
777
•PPABN
77T c HjU)
V O
Hm RV
RDOl j Isolator | |[~ r™rr

H (2)
RD02
H(3>
-6- RV
End- RD03
effector
A
control H(4)
litmli
RDQ4
-6- RV
H{5)
RDOS
1 *v h
H (6)
j RV \
RD06
H (8)
I
7/7" X
»rr- T <> I
77r
4-64
4.2.2 DI/00 standards for end effector control interface
Table 4.2.2 (a) DO signal standards
DI/DO Type Connection type Signal standards Signal
DO Non¬ [Robot side] Rated voltage: RDOl

polarity
non-
Spark
suppression
24
Output
-
48 VDC
voltage range:
RD06
diode
contact 50 VDC or less
DC Max. output current:
output <ÿ>
0.25 A
Iso- Lower (tun
Output voltage drop
Llor 0.25A 24-48 VDC at ON:
(-)
1.5 V max.
Current leakage at OFF:
0.1 nA max.
Response time:
0.2 ms max.
_ 0-1 <ÿ)
Iso¬
lator 24-48 VDC
Protective (-)
resistor I
When using a +24 VDC output signal, the robot

side +24 V power source can be used within +24
VDC +7%, 0.7 A. This power source is required
for driving the small solenoid valve in the end
effector or other devices, within the capacity of
the power supply.
Spark suppression diode

Rated peak inverse voltage Greater than
100 VDC
Rated effective forward current Greater than
1 A
...
If a relay or solenoid is directly connected as a
load, connect a spark suppression diode parallel
with the load.
Protective resistor
When a lamp is used, connect a dimmer resistor to
prevent a rush current when it is turned on.
4-65
Table 4.2.2 (b) Dl signal standards
DI/DO Type Connection type Signal standards Signal
DI Receiver
contact
[Robot side] J
( ) Digital input signal
standards
RD01
RDI8
-
input +24V *PPABN
Type: *HBKD
<D CD Grounding type
— I33?
Level conversion circuit
voltage receiver
Rated input voltage:
+20
0
-28 VDC
(logic "l" closed)
- +4 V
(logic "0" open)
use +24 V from the Max. input voltage:
robot as an input volt¬ +28 VDC
age. Input impedance:
Approx. 3.3 kO.
Response time:
5-20 msec
(2) End effector side

contact standards
Rated contact
capacity:
30 VDC, 16 A or
over
Chattering time:
Shorter than
5 msec
Closed circuit
resistance:
Less than 100 ft
Open circuit
resistance:
Greater than
100 kft
(Signal) (Signal)
Peripheral device contact signal
jr
Robot receiver output signal
(Chattering: Less than 5 msec) Tc Tc = 5

r
- 20 msec
4-66
4.2.3 End effector control interface cable
1) Cable connector specifications
The wrist connector shown in Fig. 4.2.3 is attached to the end effector
interface.
--
B A: M30 X 1
F B: 54.1
C: 37.5
-
' o o o oO
,
O O O O
oo o oo o
oO O oo
o 000 J
tj TP'is
of.
wr
U-|g3
i
Zil
D: 9.6 15.0 (inner diameter)
E: *33
F: 11.2
G: 24.7
(mm)
JMSP2524M (made by Daiichi Denshi Kogyo Co.)
Fig. 4.2.3 Specification of wrist connector
2) Wire specification for the recommended cable

Table 4.2.3 shows an example of recommended wires unshielded cabtyre cable
using ETFE (ethylene-tetraf luoroethylene) as an insulator, conforming to the
specifications shown in this table.
The cable should be long enough to allow the wrist to operate over its full
range without interfering with the end effector.
Table 4.2.3 Cables
Specifications A66L-0001-0143 A66L-0001-0144
No. of cores 6 cores 20 cores
Conductors Diameter mm 1 mm
No. and types 40/0.08 40/0.08

Thickness of sheath 1 mm 1 mm
Outer diameter <tb. 3 mm (58. 6 mm
Conductor resistance 91 a/km 91 a/km
Allowable current 3.7 A 2.3 A
4-67
4.2.4 Noise suppressors
All relays, solenoids, and motors to be used in a machine or on peripheral
devices connected to the controller unit must be provided with noise
suppressors. These suppressors are used also to protect the relay contacts.
Fig. 4.2.4 (a) shows examples of noise suppressors.
DC relay 3 phase motor
— o
DC relay
Diode V06C
(HITACHI)
41
— -1
."H 3 phase
motor
r*soov1
v* j
rin
its
220V AC
3 phase
AC relay
100VAC |
——O ——AC relay, solenoid or motor
risoav iH
rHI
[aiwF_ .200n_,
(FUJITSU)
Spark suppressor
SI -8
(FUJITSU)
Fig. 4.2.4 (a) Noise suppressor examples
1) Dimensions and specifications for DCR2-50D100B
Capaci¬ Toler¬ Rated

9io:‘°
—
76il Resistor
tance ance voltage
-w— 0.5yF +10% 1000VDC 220fi +10% 2W
-
li*I
hole__[ÿ|ÿÿ
Plastic case (black)
2 04.5
'S
_
£
n
/
1.25 mm1 Heat resisting »inyl wire
2) Dimensions and specifications for DCR4-60A55

45il
Capaci¬ Toler¬ Rated
I
» o o o E* — I
tance
0. 2pF
for each
ance
+10%
voltage
550VDC
Resistor
220ft +10% 2W
of three
o_ leads
0.75 mm3 Vinyl wire So
to
I]
Tin plate case
Ccatinc: Gray lacquer
I
Jr Us
56il
4-68
4.3 Mechanical Interface
4.3.1 Robot motion area
Fig. 4.3.1 (a) show the external dimensions of robot. When installing
peripheral devices, be careful that they do not interfere with robot motion.
For installation, use the 4 -
hole on the bases Fig. 4.3.1 (c) shows the
robot motion area.
(220.2139)
Motion range of 0-axis center
358 _ .i 0-axis center
<T670.I340) a / t
Interference area
of the rear of U-axis l
/
kX S
220 -w I
[(213.1161)
600 1 15
218 i
I
TT7
T57
eiSO
si
\ I
(1529.880)
cr
Ir
U<9.683)
c
c Li .U92.446)
"
ft (520.270)
686 450
470 i
Fig. 4.3.1 (a) External dimensions mechanical unit (S>10)
Motion range of
0-axis center
/:
,v
y
N.
/ \
/
/
/
i
Interference area
of the rear of U-axis I
0-axis \
\ rotation center
x
\
/
\ s
Fig. 4.3.1 (b) Robot motion area (S-10)
4-69
088
4 rmmm 0LZ
o
o
o 81
I
8 II
5D
o
o
O I
II
—
O
m
O'
Q
S4£l
T o
OH I
088
o
If)
o
o
ro
\% I I
II II
TLS
1
1 1
M 9[
o
Oi
4 *4
cu
906
—
in ©
• ro
o
098 oo
00 I
o
i
8 a
II ii 6111
OI a
T (J
088
b
6813
6Z.SI «o
oo
A4AV S89
o
O
r-
II
— i
II
088 5
o o
81 cur- 8 "2
i r- OI
LL
OI
II
23
n
T
oo
T JH 088
8 S4£l
CU
4 088
97V
©
°B o
o O *2 If)
°NO ii'
3Q
If) CO
i
ti
2c Z>
—II
i
CU
O'
o
o
Ch 1
II II
—
< UJ
ore i *
Fig. 4.3.1 (c) Operational diagram (S-10)
4-70
4.3.2 Mechanical coupling of end effector to wrist
Fig. 4.3.2 shows the end effector mounting face at the end of the wrist. Mount
the end effector using the hole, position it using the four reamed
holes, and bolt it with the 4-M6 tap. Select the length of the M6 bolt so that
it is within the thickness of the wrist flange (10 mm).
00
_£=
03H8 dep. S
OJ o (equally spaced
rovO on circumference
8 8 06Oh7)
r
I H -H
ig=
1
i°- *3 t— 4-06H8 dep. 10

I 15 equally spaced
on circumference 050
4-M6 tap dep. 10
equally spaced on
circumference 050
Fgi. 4.3.2 End effector mounting face (S-10)
4-71
4.3.3 Location and dimensions of equipment mounting holes
There are three equipment mounting faces as shown in Fig. 4.3.2.
length of the bolt so that the threaded portion is less than 10 mm.
o
2-M6
DPS
4
43
CvJ
-d-
rÿ-
ro
CM
4-M6 Through (plate 2.3 t)
(Pay attention ot rubber sheet)
Equipment
mounting face A
/
<[
14
U-axis
ro
rotation
center
m
in
CO -st
o>
13ÿ
20
\
i
£
M6 button head
(4 pcs)
S-axis rotation center

/
\
50
90
Equipment mounting face A
\
H _
Select the
bolt'X
8-M6 dep. 10
\
J
U-axis rotation center

rÿ, 7
V Equipment mounting face C ••
o I
in
[fi]
165 45 45
PD
\
\. Equipment mounting face B ' -
e-axis rotation center / © Air supply port PT1/8
[ End effector connector
A
Fig. 4.3.3 Equipment mounting face (S-10)
Note 1) When mounting equipment on the mounting face, A and C should conform to
the conditions of the following formula:
1
W + j (A+C) < 13 (kg)
W: Weight of end effector at the end of the wrist (kg)

A: Weight of equipment mounted on the mounting face A (kg)
C: Weight of equipment mounted on the mounting face C (kg)
Note 2) For the equipment mounted on the mounting face B, the weight should t}e
less than 30 kg and the 0-axis inertia should be lower than 35 kg. cm. S .
4-72
4.3.4 Air supply
An air supply port to the end effector is provided at the rear part of the
W-axis base.
The aperture is female PT1/8. Since couplings are not supplied it will be
necessary to prepare couplings according to the hose size (Refer to Fig. 4.3.3.)
4-73
5. S-700 MECHANICAL UNIT
5.1 Connection between Controller Unit and Mechanical Unit
Axis control board

01P05
CF91-3 —
3=
rj K92
PI Signal to pulse encoder
--
(W, U,9) for servo motor (W, U, 0)
01P05 CF94 (7)

nI 1
K93
P2
Signal to pulse encoder
for servo motor (7, 0, a)
02P05 CF91-2
(£.<*)
_r-
Robot control module CNC iWx~~ K91
D1 DI/DO
or fixed I/O board t 1
Servo amplifier (W, U)

T1
— (Note)
K31 Ml Power to servo motor (W, U)
Brake to servo motor (W, U)
Servo amolifier (9, 7, 0, a) K32 Power to servo motor (9, 7, fi, a)

T1 M2 Brake to servo motor (9 , 7, fi, a)
Power input unit BKP1, Ml
BKP2, M2
BKP3, M3
K99
(Ground board) “
Fig. 5.1 (a) Interconnection between the controller and the S-700 mechanical unit
by means of robot connection cables
Note) The shield of cable should be connected to ground board

of the controller by means of cable clamp.
4-74
PI (MS3I06B 32AI0S) P2CMS3I06B 32AI0S2)
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0 c B A D C 8 A
A IG A1W AIV AIU A3G A3W A3V A3U
H E
A2U A>G AIM AIV AIU A4U I A3G A3W A3V A3U
R P R P N
A2V A2U A2G A2W A2V A5V A5U A4G A4W AAV
s T S
A2G A2W A6G AfeW A6V A6U ASG A5W
4 I 4 b
« I B i C
BKMl BKPI BKM2 BKP2 BKH3 | BKP3 BKM1 8KPI
t P I P B
BKM5 BKP3 BKH3 BKP3
01
| M] RDt5 | L| ROM |
A| RDOI
|B RDQ2 |N |*Pf*BN |u 1 +24V |K [ RDO |
|C| RDQ3 | p| SG |v| *ROT | T) +24V| J|RD12
p| RDQ4 B| OV |s| OV j H| RDM
E| R006 | F| RD06 | G| •HBXD |
Fig. 5.1 (b) Pin assignment of connectors in S-700 mechanical unit
4-75
z
Robot control
module RCOIC
/
Tl
& BKPl.2,3
I I BKM1.2.3
K
K91
f
d
I
L
02P05
\
31 01P05 Axil control baud
CF91-CF94
OPT1 fixed I/O baud
CSC
5 iSk®-, II .iC93 PuSf

rt
fS
•J 8*
I! If V\ K31ÿ T_ _L_ÿ 199
131
75 •K32
K31 K92
K32 'ÿÿliVknnrS? K93
K91
[Servo I To main
jAmp. 4| 0 e— cabinet
SIP \
K31
Note) Cable K9I is connected to the robot control module for the modular I/O
or to the fixed I/O board for the fixed I/O.
Fig. 5.1 (c) Connection diagram for the robot connection cables
(S-700/large size cabinet)
4-76
5.2 Connections and Signals between Mechanical Unit and End Effector
5.2.1 Connections
Refer to section 4.2.1.
5.2.2 DI/DO standards for end effector control interface

5.2.3 End effector control interface cable

5.2.4 Noise suppressors

5.3 Mechanical Interface

5.3.1 Robot motion area
Fig. 5.3.1 (a), (b) show the external dimensions of the robot. When installing
peripheral devices, be careful that they do not interfere with the robot motion.
Four d24 holes on the base can be used to be installation.
Fig. 5.3.1 (c), (d) show the robot motion area.
4-77
i_5p°
0*
k)}
\
k)
\
<7,
I IIS
o
600, o
vO
\59ÿ
A ( 100,2416.2)
800 160 (*164)

CM
1700)
\
O
7
O Aÿ E( 159.7, I 198.6)
H ( 1416.2.900) /° Co. B ( I 61 6.2,900)
d
o
0ÿ .0 (290. 2, 662. 4)
Co
Motion area of
(3-axis center
I. C(540.3, 126.2)
G (438 , 100) .00
*In the case of the special flange (option).
Fig. 5.3.1 (a) External dimensions of mechanical unit (S-700, offset wrist)
4-78
/5p°
%
\
to/
\
to
LÿLjjSc>
a wm O
600 o
vO
A( 100,24 I 6.2)
800 200 (*204)

C\J N
'
vD F ( 438 , I 700)
-L
if K
O AV E( 159.7, 1198.6)
H ( ! 4 ! 6 . 2 , 900 ) /0 Cb B( 1616.2,900)
dl
o
O' 0(290.2,662.4)
(b
A-; I
==H
Motion area of
/3-axis center
I. 0(540.3, 126.2)
G ( 438 , 100) .00
*In the case of the special flange (option).
Fig. 5.3.1 (b) External dimensions of mechanical unit (S-700, in-line wrist)
4-79
X
CM
o
CM
>
•o'
O'
O/NN CM
vO
l •
00
vD
006
*S*9SI
4 o
CD
S
a <r 31
•o ooT
006
00Z.I
u_
CM \* p
vO bV
4
vO *d<T B¥
QQ
9*861 I
UJ
o b
o o;
< \ a pj1
O'
ID
2*91172
Fig. 5.3.1 (c) Operational diagram (S-700, offset wrist)
4-80
I
“o' CM
o
5 ~T
VT9T “o'
OJ o
CM
o/X> 4- vO
V.
1 Q
vO
00
vO
“O' - -
* 006
7T7T? »
*921
CD
4 1
o
:1 <r HI
u
00
\>*•
006
00Z.I
LL
CM
vO
vO “o' IL
__. 00A
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o o
c&
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ilr: CD 9*961 I
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t
o
o b
o o;
“o
r- i
a < cn
ID
2 9 I V2
*
Fig. 5.3.1 (d) Operational diagram (S-700, in-line wrist)
4-81
5.3.2 Mechanical coupling of end effector to wrist
Fig. 5.3.2 shows the end effector mounting face of the wrist. Mount the end
effector using the or hole. Position it by two reamed holes.
Bolt it with the six M10 taps. Select the length of M10 bolts to be used to be
within the thickness of the wrist flange (16 mm).
6-MIO DP I 6
-:
EQ.SP
2-0IOH8
DP 15 — v
\
A
\
£{- :
r
I
x
o o
vO
-
r L a
©
IT
(5
V
160
Offset wrist
6-MIO DP I 6
EQ.SP
2-0IOH8 —
DP I 5 _Z\
Pi
«
%
fr
0
3
r
L
X
o o
vD
a
- UF E
E
£ iO
3
<» -t
200
In-line wrist
Fig. 5.3.2 End effector mounting face (S-700)
4-82
5.3.3 Location and dimensions of equipment mounting holes
Two equipment mounting faces are provided as shown in Fig. 5.3.3 (a), (b).
Select the bolt length so that the threaded portion is less than 12 mm.
§ÿ&
/
n
If r
O o oj
m
1
n
O*
S ii
n
vO
K
\
o
8
Z.t{0 I I0
8S
Z.HO90 ID! oi
I
O'
m
I
L- vO
g 1
£ §
I E
f £9 a
f
£
§•
Q
S
o £1 I
o
00
h£i 00
ID
£
&
Q
oo
\ cS.
ft
are8-1 N
o o ro
OJ
o :
Fig. 3 (a) Equipment mounting face (S-700)
4-83
o I O
o
LJH
o
I
C
c f— sp
o
w*y»a1
r\
V X PAY LOAD
x B kg
>b
TOTAL A kg
A + B<30k g
'x
Dimensions and weight limitations for any equipment that

might be mounted on the arm.
Fig. 5.3.3 (b) Dimensions and weight limitations (S-700)
4-84
5.3.4 Air supply
An air-pressure supply port on the front of the U-axis unit is used to supply
air to the end effector. The aperture is a PT 1/8 female. In addition, an
air-pressure supply port for the above-mentioned port is provided on the rear of
the 0-axis base and the aperture is a PT 1/8 female. Since couplings are not
supplied it will be necessary to prepare couplings according to the hose size.
m
/
Air-pressure supply
port PT 1/8 female
I
I
* I
Air hose $8
-r
I
l
\
\ V
\ \
\
a S' ~
j Air-pressure supply
V. -© port PT 1/8 female
Fig. 5.3.4 Air supply port (S-700)
4-85
r r-
V. INSTALLATION
sLt-
C-L
;
;
.
1. S-10 ROBOT
1.1 Transportation and Installation
1.1.1 Transportation
1) Transportation by crane
The robot is transported by lifting. Mount the parts required during
transportation and lift it by attaching a rope to four M16 eye bolts. After
installation, remove the parts for transportation and the stop. (Refer to
Fig. 1.1 (a))
The stops for preventing rotation of the axes in transportation, are mounted
by M12 bolts. Be sure to remove them before operating the robot.
Crane
Rope
Ml 6 eye bolt (4 pcs)
m Stop (2 pcs)
M12x25 bolt (2 pcs)
O A Parts for transportation
T M16x20 bolt (2 pcs)
Robot position
0 : 0°
W- : -50° View from A
n
1
O-Jl
U, : -30°
7 -90°
e : 0°
a 0°
Fig. 1.1.1 (a) Transportation by crane (S-10)
5-1
2) Transportation by forklift
The robot can also be transported using a forklift. (Refer to Fig. 1.1.1
(b)) A forklift bracket can be provided as an option.
Note) Remove this cover M6x8 button- Note) The rear forklift bracket is
head bolt (4 pcs) mounted to the robot as shown
below.
M10 bolt
(2 pcs)
!
Forklift I
Washer
i
\ Forklift bracket
TW
(Front)
/ n.
o lo
U \m»
Forklift bracket
(rear side)
n Robot position
6 : 0° U — StoP (2 pcs)
M12x25 bolt
W : -50° (2 pcs)
U : -30°
7 -90°
& : 0°
a 0°
Fig. 1.1.1 (b) Transportation by forklift (S-10)
5-2
1.1.2 Installation
Mount the robot using anchor bolts to a foundation prepared by the customer.
Fig. 1.1.2 (a) shows the base of a robot body, Fig. 1.1.2 (b) the base diagram,
and Fig. 5.2 (c) foundation installation diagram.
Position the face shown as "XXX" on the provided reference plane or the
positioning pin, and mount the robot securely.
230
360 I .50
Reference face
Ua 306
I
LES Y qY
Hioec »«<|
'. e
e-axis rotating i ir>
C\J
center C\J
4-018 Through
026 facing depth 3 o
O Y Front
4- Trough-hole for 1 £
base bolt
\ 4-M16 Through
Fig. 1.1.2 (a) Dimensions of robot base (S-10)
360
I 80
Leveling plate
A± Fh o
CO
/
J>- Y vO
X
to
° Front
fl-axis rotating center
Through-hole
for base bolt E E
Fig. 1.1.2(b) Base diagram (S-10)
5-3
Anchor bolt M20 :
Leveling plate
"Nr
di z: Nut and washer
\
I
d=15
i
mm\ Base of robot body
•• ••
•« Cement
Fig. 1.1.2 (c) Foundation installation drawing (S-10)
Note) The leveling plate and anchor bolt are to be provided by the customer.
Determine the foundation depth according to the size of the bolts. To
ensure repeatability of the teaching points when the mechanical unit is
replaced, the customer should prepare the installation plate as shown in
Fig. 1.1.2 (d).
Pressed face for

robot base Striking face
Floor
53 9-axis base S3 I Approx. 20 mm
53
t
k
!
Approx. 20 mm
Fig. 1.1.2 (d) Installation plate (S-10)
5-4
1.1.3 Maintenance area
Fig. 1.1.3 <’a'' shows the maintenance area.
r Mastering area (6: 90°)
550
_ 300l
1400
o
O
T Maintenance area
o I I
in
ro
I©in
o
m I
/2gmik
in
o
in
_ o
IP
i i
ro
o I Mastering area (8: 0°)
O
3501 590 350
I
I 300 550 l Mastering area (8 : -90°)
L. J
Fig. 1.1.3 (a) Maintenance area of mechanical unit
The position of the robot during mastering is shown in Fig. 1.1.3 (b) Reserve .
the space shown in Fig. 1.1.3 for this position. 9 = 0° is the position used to
master the robot before shipment. To ensure repeatability when the robot is
remastered allow sufficient space for this position if possible.
e 0° (-90° .90° )
w 70*
U -125°
Mastering fixture I 0°
I £ -55*
A a 0*
Fig. 1.1.3 (b) Mastering attitude (S-10)
5-5
12. Assembly During Installation
1.2.1 Robot cables

When laying a cable between a robot controller and a robot body, the customer is
responsible for preparing the cable duct, etc.
The mechanical unit is shipped with connecting cables unattached (but connected
to the controller). Connect the cables shown in Fig. 1.2.1 to the connector box
of the mechanical unit. When connecting, take care not to damage the cables.
HBs
if
BATTERY
/ * ° \ AIR
m 3 M
7sÿsBggK,
\ «
mtato
« /
W- AJ
Pi M2
1
+
Ml PI Connector
box
rh 4-
I
Fig. 12.1 Connector box of robot mechanical unit (S-10)
5-6
122 Air piping
Fig- 1.2.2 (a) shows the air piping of a robot.
If the air control set is specified as an option, the air hose between the
mechanical unit and the air. control set is attached. Mount the air control set
according to Fig. 1.2.2 (b) .
F »
Panel union
PT1/8 female
m
JL
Panel union
PT1/4 female t
33
J
i
Fig. 1.2J2 (a) Air piping (S-10)
Use turbine oil #90 -

#140 for the air control set, and fill to the specified
level. Mounting bolts are to be provided by the customer.
Oil inlet Adjusting knob 4-M6

a Oiler mist
amount check
-2-4-
T T
«=i
6> @
J® o
&
Oiler
Pressure gauge -s» 63

Regulator
pressure
Filter setting handle .
Fig. 1.2JZ (b) Air control set (S-10)
5-7
1.2.3 Installation specifications
Item Specifications
2 2
Air pressure Pressure 5-7 kg/cm G (Preset pressure 5 kg/cm G)
Consumption Maximum peak: 150 NJl/min, (Note 1)
Weight Approximately 200 kg
Allowable ambient temperature 0 - 45°C

Allowable ambient humidity Normally: less than 75% RH
Short term (within one month) :
less than 90% RH maximum
with no condensation
Atmosphere Free of corrosive gas (Note 2)
Vibration 0.5 G or less
Note 1) This value indicates the capacity of the air control set. Adjust the
air flow to be less than this value.
Note 2) If a robot is used in an environment with high vibration, dust, or
density of cutting oil, consult the service representative.
5-8
2. S-700 ROBOT
2.1 Transportation and Installation

When transporting or installing the robot be careful of the battery cables.
2.1.1 Transportation
1) Transportation using a crane
The robot can be transported by lifting it using a crane. After mounting the
metal fitting installed to prevent rotation of the W and D axes, attach the
ropes to four M16 eye bolts and then lift the robot. After installing the
robot, remove the parts used in transportation and the metal fitting. The
support plate to prevent the 9 axis from rotation during transportation is
mounted by two MIG bolts.
Be sure to remove it before operating the robot.
Cover M10 tap holes using rubber caps applied thin coat of grease.
Crane
Rope
Approx. 1474
-»
Transporting position
W = -95° (Stop)
U = 10° (Stop)
= -90°
1
V
0 = 0°
a = 0°
* * s
CN
g
ao.
Support plate (red) Parts used in transportation
Eye bolts (Ml6)
6
I 150
Center of gravity
Fig. 2.1.1 (a) Transportation using a crane (S-700)
5-9
2) Transportation using a forklift
The robot can also be transported using a forklift. Optional brackets for a
forklift are provided.
Approx. 1474
Transporting position
W = -95° (Stop)
U = 10° (Stop)
7 = -90°
<j = 0; WARNING
= 0°
* <N
ro
<N
0
Do not transport the robot by attaching ropes to

M
eye bolts that are screwed into nuts welded onto
the forklift brackets of the robot. Doing this could
a.
a result in serious injury to either personnel or
equipment.
Forklift bracket
Support plate
(red) CO
& £ 1
/
*3. 652 -32S.
1000
Center of gravity
Fig. 2.1.1 (b) Transportation using a forklift (S-700)
2.1.2 Installation
Use the M20 hexagonal head bolt with strength stress of 12.9 (ISO 898/R: Min.
tensile stress = 120 kg, yield stress = 90% of Min. tensile stress) and 20 nnn
(25 mm: ceiling mount) of thread length Mount the robot to the foundation to be
prepared by the customer using anchor bolts. Fig. 2.1.2 (a) shows the robot
base dimensions and Fig. 2.1.2 (b) is the base diagram. Orient the surface
indicated by "xxxx" to the direction desired or the positioning pins, and bolt
the robot to the direction desired or the positioning pins, and bolt the robot
to the foundation. Three surfaces indicated by "////" can be used for the
mastering fixture. Do not install an obstacle at the surface to be used for
mastering.
When installing the robot on the ceiling, perform the following preparations.
(T) The installation plate shall be a steel plate of 600 x 600 mm with a
thickness of 25 mm minimum.
(2) The strength of the frame shall ensure support for 500 kg*m of the robot
torque and approximately 500 kg of weight in emergency.
Note) The robot installation surface shall be machined and level.
(3) When using the optional cage, mount the robot along with the plate as shown
in Fig. 2.1.2 (e).
5-10
3) Transportation using ceiling-mount .cage
When transporting the ceiling-mount robot, the optional cage can be used.
4
—
© ©
© ©
Fig. 2.1.1 (c> Transportation using ceiling-mount cage
5-11
600
70
in o o
//////////.
O o
Ii. 6 -axis
rotation
center
$ tQ
1§S lO o
in CXI
in in
£ S 10 i S Front
E
f I
Is.
i±i o
t ////////// //////////
A20
r-
90
520
4-M16 thru
4-ÿ24 thru Note) This diagram is viewed

032 spot surface, from the top.
depth 3
Fig. 2.1.2 (a) Robot base dimensions (S-700)
520
260
o
UD
OJ fi-axis rotation center
o
OJ
LO
\ f
/- Front
Anchor bolt
l I
/ through hole
or M20 tap
Fig. 2.1.2 (b) Base diagram (S-700)
5-12
Note) The foundation depth is determined by the size of the bolts.
If the path taught to one robot must be transferred to the new unit when
the robot mechanical unit is exchanged, the customer shall prepare an
installation plate such as shown in Fig. 2.1.2 (c) .
Pressed face for robot base
Positioning pin
(for pressing robot)
Front
4-M20 tap
Approx. 25 mm
O
40
(To the pressed 40
520
face of pin)
M20 520
-4kj£
Positioning pin
Provide suitable holes.
1—4 40
Fig. 2.1.2 (c) Installation plate (S-700)
5-13
Mm. 600
jq
i
s
o
o
{£ Tv Tw
CT5T,
Tw.Te < 500 kgm
*
500 kg
Fig. 2.1.2 (d) Ceiling mount (S-700)
5-14
800
700
A
520
I rl-
4—*
s=
S
r-
8 g
r- CO
4-U-
caj I L,_ -tft
2092 X
\ SS41 (32T)
M20 tap for container

(After remove the container,
use the taps to fix this system.)
4—
-4/ -4- M20 tap for fixing of this system
i
¥
M20 tap for robot’s base
Detail A
Fig. 2.1.2 (e) Ceiling-mount cage (S-700)
5-15
2.1.3 Maintenance area
Fig. 2.1.3 (a) shows the maintenance area.
300 600 300
300
o
o
to
o° Vo
O
o
I
O
O
vD
—
ro
ii r
C“
c
h
oT
5
o
o
ro
V
Maintenance area
Fig. 2.1.3 (a) Maintenance area of mechanical unit (S-700)
5-16
Provide the maintenance area for mastering. Mastering can be done when 0 = 0°,
90° or -90° with the other axes positioned as shown in Fig. 2.1.3 (b). Note
that mastering is done before shipment with 0 = 0°. Use this position if
possible to ensure accurate remastering.
W-axis W-axis
U-axis U-axis
p. (J-axis
p. 0-axis
Y-axis: -90° Y-axis: 0°

a-axis: 90° a-axis: 0°
Fig. 2.1.3 (b) Mastering position (S-700)
2.2 Assembly During Installation

2.2.1 Robot cables
1) Connecting cable
Cable ducts, etc. are to be provided by the customer when the controller and
mechanical unit are connected.
The mechanical unit is shipped with connecting cables unattached. The
cables, however, are attached to the control unit. Connect the cables to the
connector panel as shown in Fig. 2.2.1. When connecting cables be careful
not to damage them.
in
o Pi MI
°
QQ°°
O AW
0.
%
5 oDQQ.'o
o
JBL,
LJpoo..
V \
Tap for grounding (M6)
Fig. 2.2.1 (a) Connector panel of the mechanical unit (S-700)
5-17
2) Using the plate for noise-shield
When it is required to reduce the noise, the optional plate can be used.
Assemble the plate using the following procedures.
(D Remove the connector panel from the base.
© Place the plates 1 and 2 at the both side of the connector panel, and
mount them using M6 bolts.
© Tear the sheaths of cables PI, P2 and D1 at the clamp position.
© Mount the cables PI, P2 and D1 using the cable clamp.
Base .
Plate 2
Connector panel
M6 bolt
-0
i
Cable clamp
Plate 1
Tear the sheath using a cutting knife.

(PI .P2.D1 )
Fig. 2.2.1 (b) Assembling plate for noise-shield
5-18
2.2.2 Air piping
Fig. 2.2.2 (a) shows the method used to connect air piping to the robot. If the
air control set is specified as an option, the air pipe between the mechanical
unit and the air control set is attached. Mount the air control set on the
customer-provided mounting port with the specified holes tapped according to the
mounting hole dimensions shown in Fig. 2.2.2 (b) .
Straight nipple PT1/8
\
rrpn
rr «
Air control set (option) Air hose

(8 mm OD, 5 mm ID)
.V 3 mm
00= "S
Customer-
provided parts
P/U
\ Elbow PT3/8
PT3/8
Fig. 2.2.2 (a) Air piping (S-700)
5-19
Use turbine oil #90 to #140 of the air control set, and fill to the specified
level. Mounting bolts are provided by the customer.
4-M6
nfl n 4—±
O
o»
l
J— L <>- <>
63
/
/
Oiler k
u Filter
Fig. 2.22. (b) Air control set (S-700)
2.2.3 Installation specifications
Item Specifications
2
Air pressure Pressure 5-7 kg/cm G (Set pressure 5 kg/ cm2 G)
Air flow Max. peak: 150 N liter/min. (Note 1)
Allowable ambient temperature 0 - 45°C

Weight of mechanical unit Approx. 500 kg
Allowable ambient humidity Usual: Less than 75% RH

Short period (in one month)
: Max. 95% RH or less
Condensation free
Atmosphere Free of corrosive gases (Note 2)
Vibration Less than 0.5 G
Note 1) This value indicates the maximum capacity of the air control set.
Adjust the air flow to be less than this value.
Note 2) Contact the service representative, if the robot is to be used in an
environment or a place subject to severe vibrations, heavy dust, setting
oil splash or other foreign substances.
5-20
3. ADJUSTMENTS AND CHECKS DURING INSTALLATION
For connecting cables between the controller and the mechanical unit of the
robot, refer to IV-4. 1 and 5.1. Check that these cables are connected properly
to the correct axis and that the polarity is correct.
3.1 Items to be Checked

This procedure , describes the adjustment procedures to be followed during
installation of the controller. Adjust the robot in the sequence in which the
items are listed below.
For details, refer to the paragraphs shown in the "Remarks'' column in the
following table.
Item Description Remarks
1 Visually inspect the interior and exterior appear¬ Refer to 3.1 (1)
ances of the control unit and the mechanical unit.
2 Verify that screws on the terminals are tight. Refer to 3.1 (2)
3 Verify that the connectors and PCBs are properly Refer to 3.1 (3)
mounted.
4 Check the following: Refer to 3.1 (4)

Transformer tap setting and fuse size
5 Connect the cables to the control and mechanical Refer to 3. 1 (5)

units.
6 Verify that the circuit breaker is off. Connect Refer to 3.1 (6)
the power input cable.
7 Make sure that the output voltages are not grounded. Refer to 3.1 (7)
8 Check the input voltage. Refer to 3.1 (8)
9 Press the EMERGENCY STOP button on the operator's Refer to 3.1 (9)
panel. Turn on the power supply, and check the
power supply voltages.
10 Check the interface signals from the control unit Refer to 3.1 (10)
to the mechanical unit.
11 Check system variables. Change if necessary. Refer to 3.1 (11)
12 Turn on the power supply, verify that the EMERGENCY Refer to 3.1 (12)
STOP button is released. If it is, release it.
13 Check the movement of each axis when it is manually Refer to 3.1 (13)
jogged.
14 Check the interface signals to the wrist and end Refer to 3.1 (14)
effector.
15 Check the peripheral device connection interface Refer to 3. 1 (15)

signals.
5-21
1) Check the condition of the control unit and the mechanical unit as follows.
Item
Check for dirt or damage on the outside of CRT/KB panel, operator's panel, or
the teach pendant.
Check for loose items inside the cabinet such as PCBs, the power unit, the
input unit, or the servo amplifiers.
Check for any damage to the cables and conduits, etc. (Cover strippings, etc.)
Remove any brackets or braces used to secure the robot axes during shipping.
2) Check that the following terminals are securely connected:
Item
Terminals on the input unit (200R, 200S, 200A, 200B, 100IN1, 100IN2, 1000UT1,
1000UT2, EMGIN1, EMGINC , EMGIN2 , EMG0UT1, EMGOUTC, EMG0UT2, ON, OFF, COM, ALA,
ALB, 0P1, 0P2 , FN1 , FN2, BKP1, Ml, P2, M2, P3, M3)
Terminals on the fuse holders
Terminals on the I/O modules

Terminals on the fan unit
Terminals on the servo amplifier
Terminals on the servo transformer TF1 (Primary side, secondary side)
Terminals on the input transformer TF4 (Primary side, secondary side)
Terminals on the discharge units
Check that terminals are covered, if required.
5-22
3) Verify that all connectors and PCBs are properly mounted.
Item
Are clamp screws in the HONDA connectors tight?
Are nail type fixtures fitted with black connector for power source?
Are nail type fixtures fitted with brown connector for power source?
Are nail type fixtures fitted with white connector for power source?
Are PCB mounting screws for the backplane PCB tight?
Basic control unit

6
\
o
Control PCB > Mounting screws
o
Are PCB mounting screws for the I/O modules tight?
I/O unit
o
I/O PCB Mounting screws
o
c
Are ROMs mounted in the IC sockets on PCB of 01P04, and 01P08?
5-23
4) Check settings of the transformers and fuse size
The location of the power transformers is shown in "I. OVERVIEW AND
CONTROLLER MAINTENANCE 3.3 Internal Components".
Item
Tap setting on the servo transformer (TF1)
Check the transformer primary tap connection to see if the power voltage is
within +10% to -15% of the tap voltage.
If the voltage does not satisfy this condition, select the correct tap.
Primary tide
3 1
t
6
7 2
3
8 _4_
13
9
t
14
10
13
11
16
21
17
22
(f 23
24
18
19
20
±O
Fig. 3.1 (a) The servo transformer TF1 tap selection (input voltage: 480 VAC)
Table 3.1 (a) The servo transformer TF1 primary tap selection
voltage _
Power supply
U V
Connection of primary tap
W Jumper
220 V 7 15 23 8-15 16 - 2322 24-7
240 V
380 V
6
7
14
15
22
23
8-14 16 - 24-6
415 V 6 14 22
460 V 5 13 21
480
500
V
V
4
3
12
11
20
19
8-16 16 - 24
550 V 2 10 18
575 V 1 9 17
5-24
Item
Tap setting on the input transformer (TF4)
Check the transformer primary tap connection to see if the power voltage is
Primary side
575
550
500
480
I 220-S7S I
460
440
415
380
240
220
COM
ICOMI
Fig. 3.1 (b) The input transformer TF4 tap selection (input voltage: 480 VAC)
Item
Tap setting on the user transformer (TF5)
Check the transformer primary tap corrections to see if the power voltage is
575
550 FI F2 TB2 <=
500 10A 20A
480 115 _\
I 220-575 I LI
460
LI 115 VAC, 9.6 A
440
L2
415
L2
380
240 J
220
COM
|COM|
Fig. 3.1 (c) The user transformer TF5 tap selection (input voltage: 480 VAC)
Note 1) Turn off the input power supply to the control unit selecting
transformer taps.
Note 2) U, V, and W in the figure correspond to input power terminals U, V, W.
5-25
Item
Fuse size for AC voltage input types (Refer to I. -OVERVIEW AND CONTROLLER
MAINTENANCE 23.3.1)
5) Connect the cables between the control unit and the mechanical unit
Item
Connect the AC motor power cable and brake cable for each axis
Connect the pulse coder cable for each axis
Connect the robot input/output cable
Connect the teach pendant cable
6) Connecting the power input cable

Turn the circuit breaker/disconnect switch off and then connect the power
input cable.
The power cable should be brought into the cabinet through the bottom of the
cabinet and connected to the U, V and W terminals on the circuit breaker/
disconnect switch. (See IV-3.2.1)
7) Confirm that the following output voltages are not grounded.
Item
Check that the power unit output +5 V is not shorted to 0 V (GND) .

Check that the power unit output +24 V is not shorted to 0 V (GND) .
Check that the power unit output +24 V (+24 E) is not shorted to 0 V (GND) .
Check that the power unit output +15 V is not shorted to 0 V (GND).
Check that the power unit output -15 V is not shorted to 0 V (GND).
8) Confirm that the input power source voltage and frequency are correct.
Item
The input power source voltage is applied as follows.

220/240/380/415/460/480/500/550/575 VAC +10%/-15%
50/60 Hz +1 Hz, 3d
The input power source capacity should be sufficient to power the control unit.
5-26
9) Output voltage check
Press the EMERGENCY STOP button on the operator’s panel. Turn on the power
supply, and check the output voltage.
Item
Check that all fans In the cabinet are working normally.
Check that each power output is within the specified range at the terminals on
the Path CPU board.
(See I. OVERVIEW AND CONTROLLER MAINTENANCE 9.7.)
Check the each power output is within the specified range at the terminals on
the servo amplifier PCB.
(See I. OVERVIEW AND CONTROLLER MAINTENANCE 26.1.5, 26.2.5, 26.3.5.)
Reset the EMERGENCY STOP button on the operator panel.

Press the EMERGENCY STOP button on the teach pendant and verify the display,
which should indicate a teach pendant emergency stop.
10) Check the interface signals of the control unit and mechanical unit of
robot. Press the EMERGENCY STOP button and check the interface signals.
Item
Check the functioning of the +, - overtravel limit switches for all axes by
manually tripping them, and using diagnostics.
Check to see if the position error value is changed by the feedback signal of
the pulse coder on the AXISTAT screen of the diagnostics, when the motor is
rotated using an external force.
11) Check and set various system variables.

Press the EMERGENCY STOP button and check and set the system variables that,
for your system, may require different values than the default values.
12) Release the EMERGENCY STOP button.
Item
If an alarm is produced, correct the problem referring to the error code

tables.
5-27
13) Check the movement of each axis when it is manually jogged.
Refer to section 4 for initial start-up procedures.
Item
Try moving each axis using incremental jog, and see if the axis movement of
the robot follows correctly.
While manually jogging each axis at low override, operate any externally
mounted EMERGENCY STOP button and see if the axis stops and also check that
the axis stops when an overtravel switch is tripped.
Manually jog each axis at various override speeds to make sure that there is
no vibration or overshoot.
14) Check the operation of interface signals of the end effector.
Item
Check the operation of the robot end effector by diagnostics and executing the
commands from the teach pendant.
15) Check the operation of peripheral device connection interface signals.
Item
Check the operation of the peripheral device by diagnostics and executing the
commands from the teach pendant.
5-28
4. INITIAL START UP
The robot is shipped with one or more axes placed on hard stops. This shipping
condition places those axes in an overtravel condition. Prior to initial start
up, the EMERGENCY STOP button should be pressed. After initial start up, you
must reset the EMERGENCY STOP button to remove the emergency stop condition and
move the mechanical unit out of the overtravel condition.
4.1 Description of Initial Start Up

When power is applied to the robot the system software will be loaded
automatically from bubble memory to the DRAM in. the control PCBs. When this has
been completed the controller will be initialized and the KAREL power up display
will appear on the CRT.
The start up procedures are:
1. Press the EMERGENCY STOP button.
2. Turn circuit breaker handle to the ON position.

3. Press the ON button on the operator panel.
The display shown in Fig. 4.1 (a) will appear.
Kara! R-H Controller

BootROM Vl.ll 1-Jen-1R88 10:11:58
Bus Slot Module 10 FC OP AX
_
Mein 0 Shared res 4 3 0
Main 2 Servo Ctrl 5 0 4
Main 5 Path CPU 2 2 1
Mem 6 Mam CPU S 0 3
Mam 7 Bubble mem 8 0 0
Clearing DRAM memories ...

System lost saved 18_Mey-lSB7 10:00:22
Booting MAIN processor/module. 76BK bytes from BMQ: (KAREL_RH )
Booting PATH processor/module. 135K bytes f rom BMO: (KAREl RH >
Booting AXIS processor/module. 53K bytes from BMO: (KAREl RH )
Booting SRVO processor/modulo. 17K bytes from BMO: (KAREL-RH )
Fig. 4.1 (a) Software booting diiplay
During this time the controller software reports the location of each board in
the controller backplane and indicates that the software is booting from bubble
memory to the various DRAMs on the boards.
When this operation is complete, the display shown in Fig. 4.1 (b) appears.
5-29
Initializing KAREL
Fig. 4.1 (b) KAREL initializing display
After the initialization is completed, the display in Fig. 4.1 (c) appears.
ll-Aug-1988 04:41:06
MAIN MENU
KAREL .Controller
CopyrlghtCe) 1065, 1066, 1067. 1066 Off* Robotic*

All Righto lUnml
Software 3.0 ALPHA

Hardware Modal: B-30CR-0FA
ICreate/Edit Prof ram I Dlrplay Statae

Tert/ftua Program Tiilcn
File UtUltlee Setop Controller
Poeltloial Data XO.
HOP Data
Fli Help F3: F3: F4: FSi

F6: FT: F8: F0: KAREL Page FIO:
Fig. 4.1 (c) CRT main menu
5-30
4.2 Recovery from Alarm Conditions
If a user or system error occurs during operation of the robot, an error message
will be displayed on the CRT display and the teach pendant LCD screen.
TEAOi joGsJoixr 1CCK

TEST KT:JHT
1) PESO! Hert Recorded
Coord 2) PICK
9£ Reset > 3) PATH!

V 4} PASS
Recorded
4 soda*
O soda*
4006 WARM robot overtravel
RECCES 10V_LZM 1CV_JHT NUMBER
Fig. 4.2 Teach pendant RESET menu
4.2.1 General error recovery

1) Correct the condition that caused the error message to be displayed.
2) To recover from the error and resume operation, press the RESET function key
(F3) on the teach pendant, shown in Fig. 4.2, or the FAULT RESET button on
the operator's panel, shown in Fig. 4.2.1.
o o o
TEACH PENDAMT PANEL
ENABLED ENABLED
© © ©
ON
RS-232-C CRT/KB IN HOT
CYCLE CALIBRATED USER LED 81 USER LED82
© © © ©
START
CYÿ
USER PB81 USER PB8Z
O 0FF
FAULT HELD EMERGENCY STOP

© © OVERTRAVEL
REMOTE
o o
FAULT
RESET HOLD
o o o
FAULT RESET button
.. Fig. 4.2.1 Operator's panel fault reset control
5-31
42.2 Ovwtraml
When a robot axis overextends its motion limit and trips one of the axis
overtravel limit switches, servo power is shut off by a hard wired relay circuit
and the following overtravel error message is displayed:
4005 WARN ROBOT OVERTRAVEL
To recover from the overtravel perform the following procedure:
1 Press the OVERTRAVEL RELEASE button on the operator panel. This will engage a bypass circuit to supply
power to the servo unit while the overtravel limit switch is pressed
2 Check that the teach pendant is enabled.
3 This alarm can be reset from the teach pendant. Press RESET on the teach pendant, shown in Fig. 3.2, while
holding the DEADMAN switch. Servo power is applied to the mechanical unit as long as a DEADMAN switch
is pressed.
4 Jog the axis in the overtravel condition away from its motion limit
WARNING: If a robot is jogged too far in one direction,
mechanical problems can occur. Perform this procedure carefully.
If more than one axis in an overtravel condition, you can determine which ones are in overtravel and in which
is
direction by the following
5 At the CRT/KB, type in response to the KCL prompt:
KCL>SHOWVAR$OT_MINUS or KCL>SHOW VAR$OT_PLUS
You will see an array of $OT_MINUS[n] or $OT_PLUS[n] where n is the number of the axis. Any element that is
set to TRUE indicates overtravel in the negative ($OT_MINUS) or positive ($OT_PLUS) direction.
6 To allow you to jog these axes out of overtravel, set these system variables to FALSE:
KCL>SET VAR $OT_MINUS[n]=FALSE
KCL>SET VAR $OT_PLUS[n]=FALSE
7 Save the changes by typing: KCL>SSAVE
4.2.3 Eimryency stop
When the emergency stop is executed, servo power is shut off and the following
emergency stop error message is displayed on the CRT:
4002 WARN EMERGENCY STOP XXX
where "XXX" indicates the source of the emergency stop as follows:

XXX = 100 ...
operator panel
200 ...
user operator panel (if equipped)
400 ...
safeguard fence (if equipped)
800 ...
teach pendant
To recover from an emergency stop from the operator panel:
1. Release the operator panel EMERGENCY STOP button by turning the button
clockwise allowing it to unlatch.
2. Press the FAULT RESET button to reset servo power.
To recover from an emergency stop from the teach pendant:
1. Release the teach pendant EMERGENCY STOP button by pressing the button
again.
2. Reset servo power by pressing the RESET softkey. (Teach pendant must be
enabled and servo power must be turned on by holding the DEADMAN switch.)
To recover from an emergency stop from a user-designed device, check the

recommended operating procedures for the particular installation.
5-32
o o o
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Fig. 4.2.3 Emergency stop controls
5-33
7
VI. APPENDIX
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APPENDIX 2 CABLE SPECIFICATIONS
1) S— 10 controller (Medium size cabinet)
Cable Remarks
Specifications
No.
K03 A660-8006-T915#LlR003 CB - PIU Power input
1A
K04 A660-8006-T922//L1R503 PIU - TF1 (Breaker)
(220/240 V)
K06 A660-8006-T924//L1R003 TF4 - PIU
K03 A66O-8OO6-T9140L1ROO3 CB - PIU Power input

IB
K04 A660-8006-T921#LlR503 PIU - TF1 (Breaker)
K06 B66O-8OO6-T9230L1ROO3 TF4 - PIU

(380 -550 V)
K03 A660-8006-T916#L1R003 CB - PIU Power input

1C
K04 A660-8006-T921#LlR503 PIU - TFl (Breaker)
(575 V)
K06 B660-8006-T923#LlR003 TF4 - PIU
K03 A660-8006-T9 18#L1R003 CB - PIU Power input
2A
K04 A660-8006-T922#LlR503 PIU - TFl (Breaker with
leak detector)
K06 B660-8006-T924//L1R003 TF4 - PIU (220/240 V)
K03 A660-8006-T9 17//L1R003 CB - PIU Power input

2B
K04 A660-8006-T921//L1R503 PIU - TFl (Breaker with
leak detector)
K06 A660-8006-T923//L1R003 TF4 - PIU (380 -
575 V)
K12 A660-8006-T658 PIU - FAN AC power connection
K09 A660-8006-T927//L2R203 TF3 - PIU

K20 A660-8006-T929#L2R403 PIU - HM Hour meter
K21 A660-8006-T804//L900R0 TFl - AMP Servo amp. connection
K23 A660-8006-T727#LE PIU - AMP

K71 A660-2003-T230#LlR703KA 01P05 - AMP1
K72 A660-2003-T342//L1R803AA 01P05 - AMP1
K73 A660-2003-T342//L1R703LA 01P05 - AMP1
K74 A66O-2OO3-T23O0L1R5O3YA 01P05 - AMP2

K75 A660-2003-T230#LlR503MA 02P05 - AMP 2
K76 A6 60-200 3-T2 30 #L1R503ZA 02P05 - AMP2
6-42
Cable specifications for S-10 medium size cabinet (continued)
Cable
Specifications Remarks
No.
K31 A660-8007-T047//L7R403 AMP - Ml Robot connection cable (7m)
K32 A660-8007-T048//L7R403 AMP - M2
K91 A660-2003-T308//L9R503BB IOU - D1
K92 A660-4002-T803#L8R003A 01P05 - PI
K93 A660-4002-T804#L8R003A 01/02P05 - P2

K99 A660-8006-T909#L7R503 GROUND
K31 A660-8007-T047#Ll4R43 AMP - Ml Robot connection cable (14 m)
K32 A660-8007-T048//L14R43 AMP - M2

K91 A660-2003-T308#Ll6R53BB IOU - D1
K92 A660-4002-T803//L15R03A 01P05-P1

K93 A660-4002-T804//L15R03A 01/02P05 - P2
K99 A660-8006-T909#L14R53 GROUND
K57 A660-2003-T329//L10R03A 01P04 - TP 10 m Teach pendant
A660-2003-T329#L20R03A 01P04 - TP 20 m
K15 A660-8006-T659//L2R503 OP - PIU Operator’s panel
K52 A660-2003-T27 1//L1R803B 01P04 - OP

K56 A660-2003-T216//L2R103C 01P04 - PIU
K10 A660-2002-T944//L1R503 PIU - PSU Power supply unit
K46 A660-2002-T945//L1R003 PIU - PSU

K47 A660-2002-T949//L1R003A PIU - PSU
K70 A660-8006-T003//L3R003 OP - CRT Remote (3 m) CRT/KB

A660-8006-T003#L7R003 OP - CRT Remote (7m)
K50 A660-8005-T927//L500R0A BAT - BP Battery unit
6-43
Cable specifications for S-10 medium size cabinet (continued)
Cable
No.
K48 A660-2002-T945#LlR003A BP - IOU I/O unit
K49 A660-2002-T949#L1R003B BP - IOU
K41 A66L-6001-0005 #L2R003 01P04 - IOU
K53 A660-2003-T233#L500R0C IOU - PIU

KOI Connected by customer - CB AC power Input
K55 - PIU External power on/off
K60 - PIU Fence
K16 - PIU Peripheral E-stop
K61 - 01P02 Line tracking
K62 - OP RS-232-C
Symbols used in the table

AMP Servo amplifier
BAT Battery unit
BP Backplane
CB Circuit breaker
CRT CRT/KB unit
IOU Modular I/O unit
OP Operator's panel
PIU Power input unit
PSU Power supply unit
TF1 Servo transformer
TF4 Input transformer
TP Teach pendant
0IP05 Axis control board for 4 axes
02P05 Axis control board for 2 axes
Ml ,M2,D1 ,P1 ,P2 : Connector on mechanical unit
6-44
2) S— 10 controller (Large size cabinet)
Cable
No.
K03 A660-8006-T915//L1R303 CB - PIU Power input
1A
K04 A660-8006-T922//L2R503 PIU - TFl (Breaker)
(220/240 V)
K06 A660-8006-T924//L1R503 TF4 - PIU
IB
K04 A660-8006-T92 1//L2R503 PIU - TFl (Breaker)
K06 B660-8006-T923#LlR503 TF4 - PIU

(380 -
550 V)
K03 A660-8006-T916#LlR303 CB - PIU Power input

1C
K04 A660-8006-T921#L2R503 PIU - TFl (Breaker)
(575 V)
K06 A660-8006-T923#LlR503 TF4 - PIU

2A
leak detector)
K06 B660-8006-T924#LlR503 TF4 - PIU (220/240 V)
K03 Aebo-sooeÿntfLmos CB - PIU Power input

2B
leak detector)
K06 A660-8006-T923//L1R503 TF4 - PIU (380 - 575 V)
K03 A660-8006-T920//L600R0 DSW - PIU Power input

3A
K04 A660-8006-T922//L2R203 PIU - TFl (Disconnect
switch)
K06 A660-8006-T924//L1R003 TF4 - PIU (220/240 V)
K03 A660-8006-T9 19//L6O0R0 DSW - PIU Power input

3B
K04 A660-8006-T921//L2R203 PIU - TFl (Disconnect
switch)
K06 A660-8006-T923//L1R003 TF4 - PIU (380 -
575 V)
K.12 A660-8006-T998 PIU - FAN AC power connection
K09 A660-8007-T034//L2R203 TFl - PIU
K.07 A6 60-8006 -T926#L250R3 TF4 - TF5 A User

transformer
A660-8006-T925#L250R3 TF4 - TF5 B
6-45
Cable specifications for M-100 large size cabinet (continued)
Cable
No.
K19 A660-8006-T928 PIU - SVO Servo-on relay
K21 A660-8006-T804#L900R0 TF1 - AMP Servo amp. connection
K23 A660-8006-T727#LE PIU - AMP
K71 A660-2003-T230#LlR703KA 01P05 - AMP1

K72 A660-2003-T342#LlR803AA 01P05 - AMP1
K73 A660-2003-T342//L1R703LA 01P05 - AMP1
K74 A660-2003-T230//L1R503YA 01P05 - AMP2

K75 A660-2003-T230//L1R503MA 02P05 - AMP2
K76 A660-2003-T230//L1R503ZA 02P05 - AMP 2
K31 A660-8007-T047//L7R403 AMP - Ml Robot connection cable (7 m)
K32 A66O-8OO7-TO480L7R4O3 AMP - M2
K91 A660-2003-T308#L9R503BB IOU - D1
K92 A6 60-400 2-T803//L8R003A 01P0S-P1
K93 A6 60-400 2-T804#L8R003A 01/02P05 - P2

K99 A660-8006-T909#L7R503 GROUND
K31 A660-8007-T047#L14R43 AMP - Ml Robot

connection
K32 A660-8007-T048//L14R43 AMP - M2 cable (14 m)
K91 A660-2003-T308//L16R53BB IOU - D1

K92 A660-4002-T803//L15R03A 01P05 - PI
K93 A660-4002-T804#L15R03A 01/02P05 - P2
K99 A660-8006-T909#L14R53 GROUND
K57 A660-2003-T329//L10R03A 01P04 - TP 10 m Teach pendant
A660-2003-T329//L20R03A 01P04 - TP 20 m
6-46
Cable specifications for M-100 large size cabinet (continued)
Cable
No.
K15 A660-8006-T659//L3R803 OP - PIU Operator's panel
K52 A660-2003-T27 1#L2R503B 01P04 - OP
K56 A660-2003-T216//L2R503C 01P04 - PIU
K46 A660-2002-T945//L1R303 PIU - PSU
K47 A660-2002-T949#LlR303A PIU - PSU
K70 A660-2002-T523#L500R0A OP - CRT Built-in CRT /KB
A660-8006-T003#L3R003 OP - CRT Remote (3m)
A66O-8OO6-TOO30L7ROO3 OP - CRT Remote (7 m)
K50 A66O-8OO5-T9270L5OOROA BAT - BP Battery unit
K48 A66O-2OO2-T9450L1ROO3A BP - IOU I/O unit
K49 A660-2002-T949//L1R003B BP - IOU

K41 A66L-6001-0005//L2R003 01P04 - IOU
K53 A660-2003-T233//L800R0C IOU - PIU
K18 Connected by customer SVO Servo-on output
KOI - CB AC power input

K60 - PIU Fence
K62 - OP RS-232-C

AMP Servo amplifier
BAT Battery unit
BP Backplane
CB Circuit breaker
CRT CRT/KB unit
DSW Disconnect switch
6-47
OP Operator's panel
svo Servo-on relay unit
TF3 Control transformer
TF5 User transformer
TP Teach pendant
01P05 Axis control board for A axes
6-48
3) S-700 controller
Cable
No.
1A
K04 A66O-8OO6-T9220L3R3O3 PIU - TFl (Breaker)
(220/240 V)
K06 A660-8006-T924#LlR503 TF4 - PIU
K03 A660-8006-T9144L1R303 CB - PIU Power input
IB
K06 A660-8006-T923//L1R503 TF4 - PIU

(380 -
550 V)
K03 A66O-8OO6-T9160L1R3O3 CB - PIU Power input

1C
(575 V)
K06 A660-8006-T923#L1R503 TF4 - PIU
K03 A66O-8OO6-T9180L1R3O3 CB - PIU Power input
2A
leak detector)
K06 B660-8006-T924#LlR503 TF4 - PIU (220/240 V)
K03 A660-8006-T9 17#L1R303 CB - PIU Power input

2A
leak detector)
K06 A660-8006-T923#LlR503 TF4 - PIU (220/240 V)
K03 A66O-8OO6-T92O0L6OORO DSW - PIU Power input

3A
K04 A660-8006-T922#L3R003 PIU - TFl (Disconnect
switch)
K06 A660-8006-T924//L1R003 TF4 - PIU (220/240 V)
K03 A660-8006-T919 #L600R0 DSW - PIU Power input

3A
K04 A660-8006-T921#L3R003 PIU - TFl (Disconnect
switch)
K06 A660-8006-T923//L1R003 TF4 - PIU (380 -
575 V)
K12 A660-8007-T140 PIU - FAN AC Power connection
K09 A660-8007-T034#L2R203 TF3 - PIU
6-49
Cable specifications for S-700 (continued)
Cable
No.
K07 A660-8006-T9 26#L250R3 TF4 - TF5 A User
transformer
A660-8006-T925//L250R3 TF4 - TF5 B
K19 A660-8006-T928 PIU - SVO Servo-on relay
K21 A660-8006-T829#900RO TF1 - AMP Servo amp. connection
K22 A660-8007-T141#LlR103 TF1 - AMP
K23 A660-8007-T142 PIU - AMP
K25 A660-8006-T887#LlR403 TF1 - AMP1
K27 A660-8007-T143 AMP - DCU1
K71 A660-2Q03-T342#LlR503MA 01P05-AMP

K72 A660-2003-T230#llR903LA 01P05-AMP
K73 A660-2003-T2 30 //L2R603PA 01P05-AMP
K74 A660-2003-T230#LlR903FA 01P05-AMP
K75 A660-2003-T230//L1R803GA 02P05-AMP
K76 A660-2003-T342#LlR703NA 02P05-AMP
K32 A660-8007-T145//L7R503 AMP - M2

K91 A660-2003-T308#L9R503BB IOU - D1
K92 A660-4002-T803//L8R003A 01P05-P1
K93 A660-4002-T804#L8R503A 01/02P05 - P2

K99 A660-8006-T910//L7R503 GROUND
6-50
Cable
No.
K32 A660-8007-T145#L14R53 AMP - M2
K91 A660-2003-T308#L15R03A IOU - D1

K92 A660-4002-T803#L15R03A 01P05-P1
K93 A660-4002-T804#Ll5R03A 01P05 - P2
K99 A660-8006-T910#L14R53 GROUND
K57 A660-2003-T329#L10R03A 01P04 - TP 10 m Teach pendant
A660-2003-T329#L20R03A 01P04 - TP 20 a
K15 A660-8006-T659//L3R803 OP - PIU Operator's panel
K52 A660-2003-T271//L2R503B 01P04 - OP
K56 A660-2003-T216#L2R503C 01P04 - PIU
K.46 A660-2002-T945#LlR303 PIU - PSU
K47 A6 60-200 2-T949#LlR303 PIU - PSU

K70 A660-2002-T532#L500R0A OP - CRT Built-in CRT/KB
K70 A660-8006-T003#L3R003 OP - CRT Remote (3 m)
K70 A66O-SOO6-TOO3#L7ROO3 OP - CRT Remote (7 m)
K50 A660-8005-T927#L500R0A BAT - BP Battery unit
K48 A660-2002-T945#L1R003A BP - IOU I/O unit
K49 A6 60-200 2-T949#LlR003B BP - IOU
K41 A66L-6001-0005#L2R003 01P04 - IOU
K53 A660-2003-T233#L800RQC IOU - PIU
6-51
Cable Remarks
Specifications
No.
K18 Connected by customer - svo Servo-on output
KOI - CB AC power input

K60 - PIU Fence
K62 - OP RS-232-C

AMP Servo amplifier
BAT Battery unit
BP Backplane
CB Circuit breaker
CRT CRT/ KB unit
DSW Disconnect switch
OP Operator's panel
SVO Servo-on relay unit
TF3 Control transformer
TF5 User transformer
TP Teach pendant
6-52
APPENDIX 3 PREVENTIVE MAINTENANCE SCHEDULE
3.1 Preventive Maintenance Schedules
Refer to the maintenance replacement/adjustment sections for exact information

pertaining to these procedures.
350 500 1000 2000 Special As

Check items Daily
hours hours hours hours purpose required
Overall *
system
Greasing *
bearings
Greasing *
cyclo drive Replace
(20000
hrs)
Greasing * Every three

a/ 8 harmonic months
drive (S-10)
Repeatability * *
Visual After
check repair
Mist oil *
Cables * Jc
Visual Replace
check
Ventilation * *
system Access Clean or
doors repair
Backlash * *
Check After re¬
placement
Belts * *
(timing) Check Replace
Brakes *
Ob¬
serve
drop¬
ping
6-53
350 500 1000 2000 Special As
Check items Daily
hours hours hours hours purpose required
Voltage (DC) *
Check
Batteries * *
(RAM memory) Replace Replace
once a
year
6-54
3.2 Preventive Maintenance Check List
Item Schedule Data checked (other than daily)
Air control set: Daily

Air pressure
Oiler oil
mist
Oiler oil
level
Hose leakage
Cables Daily
(visual check)
Vibration Daily
Repeatability Daily
Peripheral Daily
devices
Each part Daily

(clean and check)
Ventilation Daily
Lubrication Monthly
(500 hrs)
Each part Monthly

(for play and (500 hrs)
looseness)
Connectors Monthly
(for looseness) (500 hrs)
Greasing bearings Semi¬

annually
(2000 hrs)
DC power voltage Semi¬

annually
(2000 hrs)
Control PCB Semi¬

offset voltage annually
(2000 hrs)
Lubrication oil Semi¬

annually
(2000 hrs)
6-55
Item Schedule Data checked (other than daily)
Backlash Semi¬
annually
(2000 hrs)
RAM backup Annually

batteries (4000 hrs)
(replacement)
Cyclo drive 20000 hrs

(greasing)
Cable Biennially
(replacement) (8000 hrs)
Timing belt Biennially

(replacement) (8000 hrs)
Harmonic drive Every three

(greasing) months
6-56
'I oO
SYSTEM VARIABLE DESCRIPTIONS
APPENDIX 4
SYSTEM VARIABLE ALPHABETICAL DESCRIPTIONS
System variables are variables that are declared as part of the KAREL
system software. Permanently defined variable names, which begin with a
dollar sign ($), identify system variables.
Some system variables are robot specific, meaning their values depend on the
type of robot that is attached to the system. Other variables reflect the
current status of the system and are constantly being updated. Still others
allow you to define operating parameters for a particular application.
This appendix lists all the system variables available in the KAREL system.
Sections 4.2 and 4.3 in this appendix list the default values for the S-10 and
S-700 robot dependant system variables. Variable names followed by a
are for software version 2.1 and up.
4.1 System Variable Descriptions

This section describes each system variable in alphabetical order. Each
description includes a list with the following information:
Data Type: Power Up:
Minimum/Maximum: Saved:
Program/KCL: Backed Up:
Default:
•“Data Type” indicates the type of value associated with the system
variable. If the type is ARRAY, the length also is included.
•“Minimum/Maximum” lists minimum and maximum values when
they differ from the standard values for each data type.
Software Version 2.0 and Up

6-57
$ACCLE_OVRD System Variable
•“Program/KCL” shows access rights for use in KAREL programs

and for all other uses (KCL).
•effect
“Power Up” indicates whether or not changes to the value take
at
only power up.
•“Saved” indicates whether or not the value is saved by the KCL>
SSAVE command.
•“Backed Up” indicates whether or not the value is restored by the
power fail recovery procedure.
•“Default” indicates the default value for the variable.
The function and any additional details of the system variable are described
following this list.
Unauthorized modification of system variables identified as “reserved for
GMF internal use only” could affect the performance of the KAREL system
adversely.
The names, values, and effects of GMF internal system variables are subject
to change without notice.
$ACCEL_OVRD (acceleration override) *

Data Type: INTEGER Power Up: No
Saved: Yes Default: 0
Program/KCL: RW/RW Backed Up: Yes
Minimum/Maximum: 0/255
$ACCEL_OVRD scales the acceleration time if SUSERELACCEL = TRUE and if the
acceleration option is installed (optional feature). Acceleration time is defined as:
$ACCEL_OVRD
new_accel_time = default jaccel_time t
100
If $ACCEL_OVRD = 0 it is treated as if it were 100. If RELACCEL is defined as
INTEGER user-defined associated data, SUSERELACCEL = TRUE and the relaccel
option is installed, then the acceleration time is defined as:
new_accel_time =dcfault_accel_time *$ACCEL_OVRD *
RELACCEL
10000

6-58
$ACCEL_TIME1 System Variable
$ACCEL_TIME1 (acceleration time 1)

Data Type: INTEGER ARRAY[9] Power Up: Yes
Minimum/Maximum: 1/2560* Saved: Yes
Program/KCL: No/PW Backed Up: No
Default: 320
$ACCEL_TIME1 is an array of times, one per axis, for the first stage of the second order
acceleration/deceleration algorithm for joint motion. The value is in milliseconds (msec).
$ACCEL_TIME1 is set by the KCL> UTILITY SINIT command, and should not be
changed. For auxiliary axes, you are responsible for setting this variable using the Motion
Hardware Setup Program.
‘The maximum value for $ACCEL_TIME1 is limited by the maximum value for each
system (usually 500 msec).
$ACCEL_TIME2 (acceleration time 2 )

Program/KCL: No/PW Backed Up: No
Default: 160
$ACCEL_TIME2 is an array of times, one per axis, for the second stage of the second
order acceleration/deceleration algorithm for joint motion. The value is in milliseconds
(msec).
$ACCEL_TIME2 is set by the KCL> UTILITY SINIT command, and should not be
changed. For auxiliary axes, you are responsible for setting this variable using the Motion
‘The maximum value for $ACCEL_TIME2 is limited by the maximum value for each
$ACCURACYNUM (accuracy number) *

Minimum/Maximum: 0/5 Saved: Yes
Default: 0

6-59
SACCURACYNUM System Variable
$ACCURACYNUM determines which local accuracy area will be used for subsequent
motion (optional feature). The local accuracy area must have been defined and set by the
GMF ACCUSIGHT High Accuracy Option Package. This option is currently supported
only by the A-600 robot.
When SACCURACYNUM = 0, the use of the local accuracy area data is disabled.
$AFRAMENUM1 (auxiliary frame number 1)

Minimum/Maximum: 0/3 Saved: No
Program/KCL: RW/RO Backed Up: Yes
Default: 0
SAFRAMENUM1 is used to connect ah auxiliary axis tracking frame (defined using the
KAREL language built-in DEFAUXFRAME) to a motion statement for auxiliary axis
tracking (optional feature).
A value of 0, the default value, indicates a stationary frame. Values of 1, 2, or 3 indicate
defined auxiliary axis tracking frames. SAFRAMENUM1 is set to 0 each time a program
is executed.
$AFRAMENUM2 (auxiliary frame number 2)

Default: 0
SAFRAMENUM2 is used to connect an auxiliary axis tracking frame (defined using the
KAREL language built-in DEFAUXFRAME) to a motion statement for auxiliary axis
tracking (optional feature).
The default value indicates a stationary frame. Values of 1, 2, or 3 indicate defined
auxiliary axis tracking frames. SAFRAMENUM2 is set to 0 each time a program is
executed.
$ALL_SYSVARS (all system variables)
Data Type: BOOLEAN Backed Up: Yes

Saved: Yes Power Up: No
Program/KCL: NO/RW Default: FALSE

6-60
SAFRAMENUM2 System Variable
$ALL_SYSVARS is accessed using the Non-Positional Data screen on the CRT and the
teach pendant to determine whether a partial or complete list of available system variables
is displayed. If $ALL_SYSVARS is FALSE only commonly used system variables are
displayed. If $ALL_SYSVARS is TRUE all available system variables are displayed.
The following is a list of commonly used system variables. This list cannot be modified.
1 SATPERCH 14 SMOTYPE 27 $SPIN_CTRL

2 SBRK_ON_HOLD 15 SORIENT_TYPE 28 SSPINSPEED
3 SBRK_OUTPUT 16 $OT_MINUS 29 SSPINSPEEDLM
4 SBRK_OUT_ENB 17 $OT_PLUS 30 $STOP_ON_ERR
5 SCNSTNT_PATH 18 $PPABN_ENABL 31 $SV_OFF_ENB
6 SCYCLE_STRT 19 $PWR_NORMAL 32 $SV_OFF_TIME
7 SC_STOP_ENBL 20 SRECOVERABLE 33 STERMTYPE
8 SDECELTOL 21 SROTSPEED 34 $USE_CONFIG
9 SFUL_RMT_OUT 22 SSCN_HLD_NBL 35 SUSEMAXACCEL
10 SGRIDSHIFTS 23 SSEGTERMTYPE 36 $USER_PB1
11 SHOME 24 SSPEED 37 $USER_PB2
12 SJOGFRAME 25 SSPEEDLIM 38 SUTOOL
13 SMIRRORPLANE 26 SSPEEDLIMJNT
$APC_DONE (absolute pulse coder done)
Data Type: BOOLEAN Power Up: No

Program/KCL: NO/PW Saved: No
Power Up: No Backed Up: No
Default: FALSE
$APC_DONE indicates the successful completion of absolute pulse coder (APC)

communication for robots with APC motors when it is TRUE. FALSE indicates
communication has not been successfully completed. The value of $APC_DONE is set and
updated automatically.
$APC_SYSTEM (absolute pulse coder system)
Data Type: BOOLEAN Power Up: Yes

Program/KCL: NO/PW Saved: Yes
Default: TRUE Backed Up: No
$APC_SYSTEM indicates the robot has absolute pulse coder (APC) system hardware for
calibration when it is TRUE. Otherwise, it is FALSE and the robot has incremental
calibration hardware.
The value of $APC_SYSTEM is set by the KCL> UTILITY SINIT command and should
not be changed.

6-61
SAPPROACHTOL System Variable
$APPROACHTOL (approach vector tolerance)

Data Type: REAL Power Up: No
Program/KCL: RW/RW Saved: Yes
Default: 0.0003046096 (1 degree) Backed Up: No
SAPPROACHTOL is used when comparing the z-axis (approach vector) of two positions.
SAPPROACHTOL, along with SLOCTOL. SORIENTTOL, and SCHECKCONFIG, is
used in conjunction with the relational operator “> = <” to compare two positions.
If SAPPROACHTOL is negative, no comparison is made and the approach vectors of the
two positions are “nearly” identical. When SAPPROACHTOL is 0.0 (1 degree), the
approach vectors must be identical in order for the relational operator to return a TRUE
result.
When SAPPROACHTOL is greater than 0 the following test is made:
approachl = approach(posl);
approach2 = approach(pos2);
-
If (ABS(approachl[l] approach2[l] <= SAPPROACHTOL) and
-
(ABS(approachl[2] approach2[2] < = SAPPROACHTOL) and
( ABS(approachl [3] - approach2[3J <= SAPPROACHTOL) then
the approach vectors of the two positions are “nearly” identical.
$ARM_TYPE (arm type)

Program/KCL: NO/PW Backed Up: No
Default: Robot Specific
$ARM_TYPE defines the robot arm type using the integer values 0-5. The meanings
associated with these values depend on which robot is being described.
The value of $ARM_TYPE is set by the KCL> UTILITY SINIT command and should
not be changed.
$ATPERCH (at perch)

Data Type: BOOLEAN Saved: No
Program/KCL: RO/RO Backed Up: No
Power Up: No Default: FALSE

6-62
$ARM_TYPE System Variable
SATPERCH returns TRUE if the robot is at the specified perch position. The variable
will return FALSE if the robot is not at the perch position.
See Also:
$PERCH and SPERCHTOL system variables for more information on setting
the perch position.
$AUXEXTREME1 (auxiliary axis extreme 1)

Progratn/KCL: RW/RO Saved: No
Default: Uninitialized Backed Up: Yes
$AUXEXTREME1 can be used to indicate the extreme auxiliary' axis position of a path
for auxiliary axis tracking (optional feature).
SAUXEXTREMEl is set uninitialized each time a program is executed, meaning extreme
checking will not be performed. You can enable it by assigning a value less than
10,000,000 to $AUXEXTREME1. The assigned value will be used for extreme checking.
Assigning a value greater than 10,000,000 will discontinue extreme checking.
$AUXEXTREME2 (auxiliary axis extreme 2)

Program/KCL: RW/RO Saved: No
SAUXEXTREME2 can be used to indicate the extreme auxiliary axis position of a path
for auxiliary axis tracking (optional feature).
SAUXEXTREME2 is set uninitialized each time a program is executed, meaning extreme
checking will not be performed. You can enable it by assigning a value less than
10,000,000 to SAUXEXTREME2. The assigned value will be used for extreme checking.
Assigning a value greater than 10,000,000 will discontinue extreme checking.
$AUXHOME (auxiliary axes home position)

Data Type: AUXPOS Saved: Yes
Program/KCL: RW/PW Backed Up: Yes
Power Up: No Default: uninitialized
SAUXHOME is a user-definable home position for auxiliary' axes.

6-63
SAUXHOME System Variable
You can include a KCL> MOVETO $AUXHOME command in the predefined command
file KCP_HOME.CF, which is executed by the UOP HOME signal. This command moves
the auxiliary axes to their home position.
You can assign a value that defines a home position for auxiliary axes. The system variable
$HOME represents a user-definable home position for the robot.
See Also:
Chapter 12, KAREL Reference Manual for more information on KCP_HOME.CF
$AUXSPEED (auxiliary axis speed)

Program/KCL: RW/RW Saved: No
Default: 25.0 Backed Up: Yes
SAUXSPEED is used to compute segment times for auxiliary axis motion in conjunction
with SJNTVELLIM. The value of SAUXSPEED is expressed as a percentage between 0
and 100.
$AUX_OFFSET (auxiliary axis offset)
Data Type: VECTOR Power Up: No

Program/KCL: RW/RW Backed Up: No
Default: 0, 0, 0
$AUX_OFFSET is the X, Y, Z location of the integrated auxiliary axes at the position to

be tested by the KAREL built-in functions INRANGE or TINRANGE.
See Also:
Chapter 8, KAREL Reference Manual for more information on integrated
auxiliary axes.
$AUX_ZROSHFT (auxiliary axis zero shift)
Data Type: REAL Saved: No

Power Up: No Default: 0.0
$AUX_ZROSHFT performs a function for auxiliary axis positions similar to that

performed by SUFRAME for the TCP position. It affects the auxiliary axis whose number
is specified by $TRK_AXSNUM. The zero reference point of that auxiliary axis is shifted
using the value of $AUX_ZROSHFT.
$AUX_ZROSHFT is mainly for teaching auxiliary axis positions for auxiliary axis tracking
applications (optional feature).

6-64
SAXISORDER System Variable
$AXISORDER (axis order)

Data Type: INTEGER ARRAY [12] Power Up: Yes
SAXISORDER is a mapping array from software axis index to servo hardware registers. It
indicates which axis is controlled by a particular servo motor.
For example, $AXISORDER[i] = j, where axis index j is connected to servo register i.
(Axis j is controlled by servo motor i.) $AXISORDER[i| = 0 indicates that servo register i
is not used.
The value of SAXISORDER is set by the KCL> UTILITY SINIT command and should
not be changed. For auxiliary axes, you are responsible for setting this variable using the
Motion Hardware Setup Program.
$BELT_ENABLE (belt alarm enable)
Data Type: BOOLEAN Saved: Yes

$BELT_ENABLE enables the belt breakage detection feature. If it is TRUE, the

controller will generate an error message if a drive belt breaks.
Only the A-200 and A-510 robot models are equipped with belt-driven axes. For these,
$BELT_ENABLE should be TRUE. For all other robots, $BELT_EN ABLE should be
set to FALSE.
If your system is equipped with belt-driven auxiliary axes, you can set $BELT_ENABLE
to TRUE to enable belt breakage detection on the auxiliary axes.
$BK_TL1NE (Basic KAREL testing line) *

Default: -1
$BK_TLINE contains the line number used by a Basic KAREL program to start
execution. This variable is set at the teach pendant Test Run menu and is used by Basic
KAREL run time programs. This system variable has been added to be used for Basic
KAREL testing.

6-65
$BRK_ON_HOLD System Variable
$BRK_ON_HOLD (brake on hold)

Default: TRUE
If $BRK_ON_HOLD is enabled, all holds generated by the hardware (by pressing the
HOLD button on the operator panel or UOP or by pressing the HOLD/STEP key on teach
pendant) shut the servo power off after the robot arm decelerates and stops its motion.
Software-generated holds (KAREL HOLD statement, HOLD action, or KCL> HOLD
command) are not affected by this feature.
When the servo power is shut off, the error message "4039 Brake on Hold" is displayed on
the CRT. Use the RESET button or the KCL> RESET command to reset the servo
power after shut down. If the HOLD input is active neither the RESET button or the
KCL> RESET command will reset the servo power. This causes the error "2053 HOLD
active" to be displayed. To inactivate the HOLD condition, release the HOLD button on
the operator panel or the HOLD key on the teach pendant. Next, push the FAULT
RESET button to turn on the servos.
$BRK_OUTPUT (brake output)
Data Type: BOOLEAN ARRAY [9] Saved: No

$BRK_OUTPUT is an array that you can use to set the brake output bits manually if
$BRK_OUT_ENB is TRUE. Note that the elements in this array do not correspond to
individual axes. Several brakes might be released by a single brake output.
See Also:
Enhanced KAREL Operations Manual for robot brake information
$BRK_OUT_ENB (brake output enable)

$BRK_OUT_ENB indicates whether or not manual setting of brake outputs is allowed. If

it is TRUE brakes can be set or released manually as specified by the value of
$BRK_OUTPUT. If it is FALSE brakes cannot be set or released manually.

6-66
$BRK_OUT_ENB System Variable
By default, the value of $BRK_OUT_ENB is set to FALSE. $BRK_OUT_ENB is also set

to FALSE when an emergency stop, overtravel condition, or DEADMAN switch error
occurs.
$CAL (calibrated)
$CAL indicates whether or not the robot has been calibrated. If it is TRUE, the robot is
calibrated. Otherwise, it is FALSE and the robot has not been calibrated or an error that
caused the robot to lose calibration has occurred. The value of $CAL is set and updated
automatically by the system.
$CALIB_POS (calibration position)
Data Type: REAL ARRAY [9] Power Up: No

Default: Robot Specific Backed Up: No
$CALIB_POS defines the calibration position of each axis for robots that require
incremental calibration procedures. During calibration, the robot moves to this position,
which is often called the zero return position, although this position is not necessarily at
zero.
The value of $CALIB_POS is set by the KCL> UTILITY SINIT command and should
not be changed for robot axes. For auxiliary axes, you are responsible for setting this
variable using the Motion Hardware Setup Program.
$CALSIGN (calibration sign)

Data Type: BOOLEAN ARRAY [9] Power Up: Yes
Program/KCL: NO/RW Saved: Yes
$CALSIGN indicates the direction of axis motor rotation during calibration for incremental
encoders. The system uses SCALSIGN to determine the direction it should move to find
the calibration index pulse.
The value of SCALSIGN is set by the KCL> UTILITY SINIT command and should not
be changed for robot axes. For auxiliary axes, you are responsible for setting this variable
using the Motion Hardware Setup Program.

6-67
SCALVELHIGH System Variable
$CALVELH1GH (calibration velocity high)

Default: Robot Specific Backed Up: Yes
SCALVELHIGH indicates the dog-search approach speed for each axis during calibration
of robots with incremental encoders. The value is in millimeters or radians per second
depending on whether the axis is a linear motion axis or a rotational axis.
The value of SCALVELHIGH is set by the KCL> UTILITY SINIT command and
should not be changed for robot axes. For auxiliary axes, you are responsible for setting this
$CALVELLOW (calibration velocity low)

SCALVELLOW indicates the index pulse search speed for each axis during calibration of
robots with incremental encoders. The value is in millimeters or radians per second
depending on whether the axis is a linear motion axis or a rotational axis.
The value of SCALVELLOW is set by the KCL> UTILITY SINIT command and should
not be changed for robot axes. For auxiliary axes, you are responsible for setting this
$CART_ACCEL1 (Cartesian acceleration time 1)
Data Type: INTEGER Power Up: Yes

Default: 224
$CART_ACCEL1 is the length, in ms, of the first stage of the second order
acceleration/deceleration filters for Cartesian motion.
The total acceleration/deceleration time for either linear or circular Cartesian motion
(except where speed override is used) is the sum of $CART_ACCEL1 and
$CART_ACCEL2.

6-68
$CART_ACCEL1 System Variable
The value of $CART_ACCEL1 is set by the KCL> UTILITY SINIT command and
should not be changed for robot axes. For auxiliary axes, you are responsible for setting
this variable using the Motion Hardware Setup Program.
*The maximum value for $CART_ACCEL1 is limited by the maximum value for each
system (usually 500 msec)
$CART_ACCEL2 (Cartesian acceleration time 2)

Default: 128
$CART_ACCEL2 is the length in msec of the second stage of the second order
acceleration/deceleration algorithm for Cartesian motion.
The total acceleration/deceleration time for either linear or circular Cartesian motion
(except where speed override is used) is the sum of $CART_ACCEL1 and
$CART_ACCEL2.
The value of $CART_ACCEL2 is set by the KCL> UTILITY SINIT command and
should not be changed for robot axes. For auxiliary axes, you are responsible for setting
this variable using die Motion Hardware Setup Program.
*The maximum value for $CART_ACCEL2 is limited by the maximum value for each
$CART_AXIS (Cartesian axis)

Default: 0
$CART_AXIS indicates which auxiliary axes, if any, are to be integrated into the
Cartesian calculations for the position of the TCP. Integrated motion of robot and
auxiliary axes is turned on by setting $CART_AXIS to a value other than 0. A value of 0
means that no auxiliary axes will be integrated.
The value of $CART_AXIS is a three-digit decimal number that associates the x, y, and z
components of the world coordinate system with the auxiliary axis numbers for integration.
See Also:
Chapter 8, KAREL Reference Manual

6-69
t
SCHECKCONFIG System Variable
SCHECKCONFIG (check configuration)

SCHECKCONFIG is used to determine if the position configurations should be compared.

SCHECKCONFIG. along with SAPPROACHTOL, SLOCTOL, and SORIENTTOL are
used in conjunction with the relational operator “>=<” to compare two positions.
If SCHECKCONFIG is FALSE, the configurations are not compared and the relational
operator treats the configurations as being “nearly” identical. If SCHECKCONFIG is
TRUE, the configurations are compared by the relational operator.
$CHK_JNT_SPD (check joint speed)

Power Up: No Default: TRUE
$CHK_JNT_SPD indicates whether or not joint speed is checked against the system
variable SJNTVELLIM during Cartesian motion. If it is TRUE, the speed of each joint is
checked against the corresponding joint speed limit and if a limit is exceeded, all joint
speeds are reduced at the same ratio.
Please note that the motor speed limits ($MOT_SPD_LIM) always are checked regardless
of this variable.
See Also:
Chapter 8, KAREL Reference Manual for more information on speed limits
$CMR (command multiplier ratios)

Default: 1

6-70
$CMR System Variable
$CMR defines command multiplier ratios, one per axis. The values of $CMR and $DMR
are used as follows:
motor
OMR EVR Motor
out
Encoder
Detected
DMR
Encoder
Pulses Pulses
The product of commanded pulses multiplied by $CMR is compared with the detected
pulses to drive the error counter either up or down. The resultant error register drives the
motor through a gain constant.
$DMR (detector multiplier ratio) multiplies the encoder pulses to produce detected pulses.
Many system variables are tolerances or other parameters specified in detector pulses.
The value of $CMR is set by the KCL> UTILITY SINIT command and should not be
changed for robot axes. For auxiliary axes, you are responsible for setting this variable
using the Motion Hardware Setup Program.
See Also:
$KV1000 System Variable in this appendix
$CNSTNT_PATH (constant path)

Data Tvpe: BOOLEAN Saved: No
If $CNSTNT_PATH is TRUE the acceleration/deceleration time is adjusted for the

current speed override value (SGENOVERRIDE and SPRGOVERRIDE) so that the path
of the motion will be the same regardless of the speed override value. This adjustment only
applies to the program motions. The acceleration/deceleration time for jogging or for
“MOVE TO” commands, issued by KCL or the teach pendant, will not change.
If it is FALSE, the filter length is not adjusted, meaning the path taken will vary with the
speed override value.
See Also:

6-71
SCOARSETOL System Variable
$COARSETOL (coarse tolerance)

Data Type: INTEGER ARRAY [9] Power Up: No
Program/KCL: NO/RW Backed Up: No
Default: 300
SCOARSETOL is an array of in-position tolerances used to determine when the robot is in

position when STERMTYPE = COARSE. The value is in units of detector pulses (as
explained under $CMR). The tolerance in radians or millimeters is computed as follows:
SCOARSETOL
coarse angle =
$CMR * SENCSCALE
The value of SCOARSETOL is set by the KCL> UTILITY SINIT command and should
not be changed.
$COND_TIME (condition handler scan time)

Program/KCL: NO/PW Backed Up: Yes
Default: 32
$COND_TIME is used to specify the time between scans in a condition handler. The
value, in milliseconds, is rounded to the next lowest multiple of 8 msec. $COND_TIME is
the default scanning time. The actual scanning time is the value you specify in
$SCAN_TIME multiplied by SCOND.TIME.
See Also:
$SCAN_TIME Condition Handler Qualifier in this appendix
WITH Clause, Appendix A, KAREL Reference Manual
for more information on using $COND_TIME and $SCAN_TIME

6-72
$CONFIG_MASK System Variable
$CONFIG_MASK (configuration mask)

Program/KCL: RO/PW Saved: Yes
$CONFIG_MASK indicates which configuration bits are tested in the solution programs.
The value depends on robot type. $CONFIG_MASK also indicates when multiple-turn
joints are used.
$CONFIG_MASK affects the input and display of the configuration string when you
specify or display positions.
The value of $CONFIG_MASK is set by the KCL> UTILITY SINIT command and
should not be changed.
This variable is set up on the characteristics of each model robot. Each bit is defined as
follows:
high
7 6 5 4 3 2 I 0
byte
cflip_flip (256)
-righijcft (512)
-up_down ( 102- > )
-tums_4 (20—S )
-tums_5 (4096)
-tums_6 (8192)
-cfg_right (16384)
-efg_noflip (32768)
low
7 6 5 4 3 2 I 0
byte
-not used
-cfg_up (128)

6-73
$CONFIG_MASK System Variable
The labels in the bit masks have the following meanings:

LABEL j MEANING
|
noflip_flip 1 1 : no noflip_flip ocnfiguration
! 0 : has noflip_flip configuration
_
right_Icft l 1 : no rightjeft configuration
0 : has rightjeft configuration
up_down ] 1 : no up_down configuration
j 0 : has up_down configuration
tums_4 | 1 : no multiple turn for 4th joint
l 0 : has multiple turn for 4th joint
tums_5 i I : no multiple tum for 5th joint
I 0 : has multiple tum for 5th joint
tums_6 | I : no multiple tum for 6th joint
! 0 : has multiple tum for 6th joint
cfg_right 1 : default configuration right
0 : default configuration left
cfg_noflip f 1 : default configuration noflip
j 0 : default configuration flip
cfg_up ; 1 : default configuration up
; 0 : default configuration down
See Also:
Enhanced KAREL Operations Manual for specific robot configuration
information.
$CONTAXISNUM (continuous axis number)

Default: 0
SCONTAXISNUM indicates which axis operates in continuous turn mode (optional

feature) and enables continuous turn for that axis. The only valid values for
SCONTAXISNUM are the highest robot axis number or an auxiliary axis number.
The default value indicates that no axis will operate in continuous mode (all axes operate
normally.)

6-74
$CONTAXISVEL System Variable
$CONTAXISVEL (continuous axis velocity)

SCONTAXISVEL indicates the velocity of continuous turn motion, including both

magnitude and direction. SCONTAXISVEL can have values between -100.0 and
+ 100.0. The magnitude is a percentage of maximum joint speed expressed as a REAL
—
value and a positive or negative direction is indicated by the + or sign.
If SCONTAXISNUM has a value other than 0, the specified axis begins continuous turn
motion with the next motion statement after the value is assigned to SCONTAXISVEL.
The velocity of the continuous turn motion is determined by the value of
SCONTAXISVEL.
The motion terminates during or at the completion of the next motion statement after
SCONTAXISVEL is set back to 0.
The default is set each time a program is run. This means you must assign a value within a
program if you want to use continuous turn mode (optional feature).
See Also:
Continuous Turn Manual for more information
$CUR_CR FRAME (current circular reference frame)
Data Tvpe: POSITION Saved: No

Power Up: No
$CUR_CRFRAME is effective only for circular moves in the Path Relative Frame
(optional feature). $CUR_CRFRAME is updated by the system, which indicates the
current circular reference frame defined by the arc of the motion. It is used in conjunction
with $CUR_PRFRAME and $PFR_RESUME to resume a stopped motion smoothly for
moves in the Path Relative Frame.
See Also:
$TTOOLNUM System Variable in this appendix
$CUR_PRFRAME (current path relative frame)

Data Type: POSITION Saved: No
Power Up: No
$CUR_PRFRAME is effective only for linear moves in Path Relative Frame (optional
feature). $CUR_PRFRAME indicates the current Path Relative Frame with respect to the
World Coordinate Frame and is updated by the system. It is used in conjunction with
$CUR_CRFRAME and $PFR_RESUME to resume a stopped motion for moves in the
Path Relative Frame.

6-75
$CUR_PRFRAME System Variable
$CYCLE_STRT (cycle start)
Data Type: STRING Saved: Yes

Program/KCL: NO/RW Backed Up: Yes
Power Up: No Default: ‘ ’ (blank)
$CYCLE_STRT specifies the KCL command procedure that is executed when the
operator panel CYCLE START button is pressed. If the command procedure is not
found, the system will search for a p-code file of the same name as specified in
$CYCLE_START. If found in RAM, this file will be executed. If it is found in bubble
memory, the file will be loaded before execution.
The command procedure is executed only if a KAREL program is not running or paused.
You are responsible for setting the value of $CYCLE_STRT if you want the CYCLE
START button to execute a command procedure.
See Also:
Enhanced KAREL Operations Manual for more information on setting
SCYCLE.STRT.
$C_STOP (cycle stop)

Program/KCL: NO/RO Backed Up: No
$C_STOP indicates whether or not the UOP CYCLE STOP signal has been activated.
The value of $C_STOP automatically is set to TRUE after CYCLE STOP is activated. It
is set to FALSE after CYCLE START is activated.
$C_STOP_ENBL (cycle stop enable)

CYCLE STOP signal. If it is FALSE,

$C_STOP_ENBL controls the function of the UOP
CYCLE STOP performs the same function as HOLD.
If you set $C_STOP_ENBL to TRUE, the CYCLE STOP button will not pause the
program automatically. You can use the KAREL language C_STOP function in a program
to test the value of $C_STOP and pause a program if SC_STOP is TRUE.

6-76
$C_STOP_ENBL System Variable
$DDCMP_PARAM (DDCMP parameter)
Data Type: INTEGER ARRAY [2] Saved: Yes

Power Up: No
$DDCMP_PARAM is an ARRAY which specifies the DDCMP communications

parameters. The array elements represent the following parameters:
•$DDCMP_PARAM[1] indicates the maximum number (between 0 and 3) of
simultaneous DDCMP connections.
•$DDCMP_PARAM[2] currently is not used.
See Also:
KAREL-MAP Installation and Maintenance Manual
$DECELTOL (deceleration tolerance)

Default: 50
SDECELTOL specifies the percent of deceleration distance that must be covered before a
motion is considered finished and the next segment is permitted to start. It is used with the
VARDECEL termination type.
Setting SDECELTOL to 1 makes VARDECEL nearly equivalent to the NODECEL
termination type. Setting SDECELTOL to 99 makes VARDECEL nearly equivalent to
NOSETTLE!
See Also:
Chapter 8, KAREL Reference Manual for more information on termination types.

6-77
$DELTAFRAME System Variable
SDELTAFRAME (delta frame)

Data Type: POSITION Power Up: No
Default: $NILP Backed Up: No
SDELTAFRAME represents the positional data needed to integrate the robot motion with
an external sensor. The value of SDELTAFRAME is used to provide dynamic path
modification by incorporating it into path planning to change the nominal path.
SDELTAFRAME can be set based on external sensor data, internal auxiliary axes
positions (table coordinates), a generated vector (for weaving applications), or by some
other method. Its value can be with respect to the world coordinate system or the user
frame, based on the application and on the value of STFRAMENUM.
SDELTAFRAME STFRAMENUM Coordinate Frame

location -1 World
location + orientation -2 World
location -3 User Frame
location + orientation -4 User Frame
STFRAMENUM can be set in a KAREL program to determine, in conjunction with

SDELTAFRAME, the desired coordinate system.
See Also:
STFRAMENUM System Variable in this appendix
$DELTATOOL (delta tool)

Program/KCL: RW/RO Backed Up: No
Power Up: No
SDELTATOOL represents the position change with respect to the tool frame based on
external sensor data. The value of SDELTATOOL, is incorporated into path planning to
change the nominal path dynamically. Its value can be used with respect to the tool
coordinate system or the path relative coordinate system attached to the path trajectory
depending on the value of STTOOLNUM.

6-78
SDELTATOOL System Variable
SPELT ATOOL STTOOLNUM Coordinate System

location 1 Tool
location + orientation 2 Tool
disabled 0
location + orientation 0 Path Relative Frame
location -1 Path Relative Frame
location + orientation -2 Path Relative Frame
location —3 Path Relative Frame
location + orientation -4 Path Relative Frame
STTOOLNUM can be set in a KAREL program to determine the desired coordinate

system.
See Also:
STTOOLNUM System Variable in this appendix
$DFLT_PROG (default program)
Data Type: STRING Saved: No

Program/KCL: NO/RO Backed Up: Yes
$DFLT_PROG identifies the default program name that is used by KCL commands and
the teach pendant when you do not specify a program name.
You set the value of $DFLT_PROG using the KCL> DEFAULT command.
$DISPLAY_ON (display on)

Program/KCL: NO/RW Backed Up: Yes
$DISPLAY_ON indicates whether or not a program will be displayed on the CRT/KB as it

is being translated. If the value is TRUE the program is displayed.
If you set it to FALSE, only header information indicating which file is being translated is
displayed. If a translation error occurs, it will also be displayed. Translation will proceed
faster if $DISPLAY_ON is FALSE.
The value of $DISPLAY_ON can be overridden using the /DISPLAY or /NODISPLAY
options with the KCL> TRANSLATE command.

6-79
$DMR System Variable
$DMR (detector multiplier ratio)

$DMR multiplies encoder pulses to produce detected pulses. $DMR is encoded as follows:
0 :0.5 1 : 1.0 2:1.5 3 : 2:0

4 : 2.5 5 : 3.0 6:3.5 7 : 4.0
The value of $DMR is set by the KCL> UTILITY SINIT command and should not be
changed for robot axes. For auxiliary axes, set this variable using only the Motion
See Also:
SCMR System Variable in this appendix
$DO_RECOVER (do recover)
Data Tvpe: BOOLEAN Saved: Yes

$DO_RECOVER indicates whether or not the power fail recovery (optional feature) is
enabled.
At power up, the system loads $DO_RECOVER from bubble memory. If the value of
SDO.RECOVER is TRUE, the system tries to recover. If $DO_RECOVER is FALSE,
the system will not attempt to recover. Also, if the SYSVARS.SV file is not present, the
value of $DO_RECOVER is set to FALSE automatically and the system will not recover.
You are responsible for setting the value of $DO_RECOVER to indicate whether or not
you want the power fail recovery procedure to be executed.
See Also:
Power Fail Recovery R-H Controller Manual for more information

6-80
$DRY_RUN System Variable
$DRY_RUN (dry run)

$DRY_RUN indicates whether or not a program is being run with servo power off and the
robot locked.
The value of $DRY_RUN is set and cleared automatically when the machine LOCK
parameter is set by a KCL command or by the teach pendant.
$DYNAMICFLTR (dynamic filter)

Default: FALSE Backed Up: No
When SDYNAMICFLTR is set to FALSE, the default acceleration/deceleration time

constants at power up are used. When SDYNAMICFLTR is TRUE, the
acceleration/deceleration time constants of the axes are computed dynamically based on the
inertia of the robot at the start and destination positions. Hence, the
acceleration/deceleration time is equal to or shorter than the default case in order to
improve the cycle time.
NOTE
Currently this feature is implemented only on the first joint (0 axis) of
the S-420 robot.
$ENBL_OVRD (enable override)

Program/KCL: RW/RN Backed Up: Yes
$ENBL_OVRD enables the setting of the general override from the teach pendant while
the teach pendant is disabled.
If $ENBL_OVRD is FALSE, the OVERRIDE UP and DOWN keys on the teach pendant
only function when the teach pendant is enabled in order to prevent inadvertent changes to
the robot motion during production.
If $ENBL_OVRD is TRUE, the OVERRIDE keys will work at all times.

6-81
SENCOFFSTS System Variable
$ENBL_OVRD is program accessible so that KAREL program-driven “teaching

programs” can permit an operator to change the override while the teaching program is
running.
$ENCOFFSTS (encoder offsets)

Power Up: Yes
$ENCOFFSTS indicates encoder offsets, one per axis, in command pulses. The formula
for conversion from joint angles to command pulses is:
command pulses [i] =

$ENCOFFSTS [i] + ($ENCSCALES[i] * joint-angled])
The value of SENCOFFSTS is set internally and should not be changed.

See Also:
$CMR and SENCSCALES System Variables in this appendix
$ENCSCALES (encoder scale factor)

Data Type: REAL ARRAY [9] Power Up: Yes
SENCSCALES defines a scaling factor, in counts/unit, used to convert from units to pulses.
It is used in the formula defined for SENCOFFSTS.
The value of SENCSCALES is set by the KCL> UTILITY SINIT command and should
not be changed for robot axes. For auxiliary axes, set this variable using the Motion
$FB_MON_ENB (feedback monitor enable)
Data Type: BOOLEAN ARRAY [9] Saved: Yes

Power Up: Yes Default: TRUE
$FB_MON_ENB indicates whether or not feedback monitor alarm checking is enabled for
each axis.

6-82
SFINETOL System Variable
$FINETOL (fine tolerance)

$FINETOL is an array of in-position tolerances used to determine when the robot is in

position when $TERMTYPE = FINE. The value is in units of detector pulses (as
explained under $CMR).
The value of $FINETOL is set by the KCL> UTILITY SINIT command and should not
be changed. For auxiliary axes, set this variable using the Motion Hardware Setup
Program.
See Also:
SCOARSETOL System Variable in this appendix to compute the tolerance in
radians or millimeters.
$FUL_RMT_OUT (full remote output)

Power Up: No Backed Up: No
Default: FALSE
$FUL_RMT_OUT determines whether 8 or 16 outputs are available for remote interface.

If it is FALSE, only the lower 8 bits are used. If it is TRUE, all 16 bits are used for
remote interface.
See Also:

6-83
$GAINS System Variable
$GAINS (gains)
Default: 20
$GAINS defines an array of gains of the servo system.

The value of $GAINS is set by the KCL> UTILITY SINIT command and should not be
changed. For auxiliary axes, set this variable using the Motion Hardware Setup Program.
$GENOVERRIDE (general override)

Program/KCL: RO/RW Backed Up: No
Default: 10
SGENOVERRIDE, a scaling factor, is expressed as a percentage of the motion speed.

For all programmed motion SGENOVERRIDE is multiplied with SPRGOVERRIDE to
obtain a total override value, which is then multiplied by the motion speed.
As a safety feature, the value of SGENOVERRIDE automatically is set to 10 if you do not
confirm the setting before jogging the robot. You can set the value of SGENOVERRIDE
using the teach pendant OVERRIDE UP and DOWN keys or KCL commands.
$GRID (grid)
SGRID defines the number of detector pulses per revolution of the encoder. The word
"grid" refers to the repeating pattern of lines or pulses produced by an incremental encoder
with each revolution.
The grid is in units of detector pulses. For example, if the actual encoder has 2000 grid
lines per revolution, and a DMR of 4 is used, the detector grid size is 8000 pulses.

6-84
$GRID System Variable
$GRID is encoded as follows:
Formula: gridsize = ($GRID + 1) * 1000

Example : $GRID = 7 : grid size = 8000
$GRID = 3 : grid size = 4000
C$GRID = 6 or 8 is an invalid value.)
The value of SGRID is set by the KCL> UTILITY SINIT command and should not be
changed. For auxiliary axes, set this variable using only the Motion Hardware Setup
Program.
See Also:
$DMR System Variable in this appendix
SGRIDSHIFTS (grid shifts)

Minimum/Maximum: —32768/32767 Saved: Yes
Default: 0
SGRIDSHIFTS is an array of grid shifts for incremental encoders, one per axis, used to
shift the location of the detected encoder index pulse relative to the actual index pulse.
This allows the servo system to be used to adjust the apparent position of the encoder on its
shaft without performing a physical adjustment.
You might need to change the default value following a dog check. Use the KCL>
DOGCHECK command to adjust the value of SGRIDSHIFTS.
See Also:
DOGCHECK command, Appendix B, KAREL Reference Manual
$HOLD (hold)
SHOLD causes robot motion to be held. While $HOLD is TRUE, interpolation of the
motion is suspended; the robot decelerates to a stop and remains stopped until SHOLD is
FALSE.
Pressing the operator panel HOLD button or teach pendant HOLD key sets the value of
SHOLD to TRUE. To set SHOLD to FALSE, use the KCL> RESUME command.

6-85
SHOME System Variable
$HOME (home position)

Data Type: POSITION Saved: Yes
Power Up: No Default: Uninitialized
SHOME is a user-definable home position for the robot. Activating the UOP HOME
signal moves the robot to this position unless a predefined command file, KCP_HOME.CF,
exists, in which case the command file is executed. You can also use the KCL>
MO VETO command to move the robot to the HOME position.
$INC_DEC_DIS (incremental deceleration distance)

Minimum/Maximum: -32768/32767 Saved: Yes
$INC_DEC_DIS indicates the distance for approaching the dog for each axis on robots
with incremental encoders. It is usually expressed in units of negative pulse counts.
For auxiliary axes, you are responsible for setting the value of $INC_DEC_DIS to correctly
define the calibration sequences using the Motion Hardware Setup Program.
$INC_FWD_DIS (incremental forward distance)

SINC_FWD_DIS indicates the distance for moving away from the dog, for each axis on
robots with incremental encoders. It is expressed in units of positive pulse counts.
For auxiliary axes, you are responsible for setting the value of $INC_FWD_DIS to
correctly define the calibration sequences using the Motion Hardware Setup Program.
$INC_OFFSET (incremental offset)
Data Type: REAL ARRAY [9] Saved: Yes


6-86
$INC_OFFSET System Variable
The value of $INC_OFFSET is determined automatically by the mastering procedure. It is

the positive or negative difference in radians (or millimeters in prismatic joints) between
the one-revolution index pulse and the actual calibration position for each axis on robots
with incremental encoders.
When the mastering data has been altered (for example, by replacing a motor), the index
position of the robot will not correspond to the calibration position. By moving the robot
to the mastering position this error can be determined. SINC_OFFSET represents this
value.
$INC_RVS_DIS (incremental reverse distance)

$INC_RVS_DIS indicates the distance for approaching close to the one-revolution index
pulse for each axis on robots with incremental encoders. It is expressed in units of negative
pulse counts.
For auxiliary axes, you are responsible for setting the value of SINC_RVS_DIS to correctly
define the calibration sequences using the Motion Hardware Setup Program.
$INPOSITION (in position)

SINPOSITION is an array of flags indicating the axes that are in position. At the
beginning of a segment the flags are automatically set to FALSE. By the end of the
segment all of the flags are TRUE, indicating each axis is within tolerance for the specified
position.
The value of SINPOSITION is set and updated automatically.
$INTP_STATUS (interpreter status)

Minimum/Maximum: -1/1 Saved: No

6-87
$ INTP_STATUS System Variable
$INTP_STATUS indicates the current status of the program interpreter using the following
values:
—
0
1 = running
= paused
+ 1 = aborted
$INTP_STATUS is set and updated automatically.
$IN_USERMENU (in usermenu)

Program/KCL: RO/RO Backed Up: Yes
$IN_USERMENU indicates USERMENU is displayed on the teach pendant. It is used in

conjunction with $LOCK_TPMENU to tell a program when the teach pendant menu has
been locked to the USERMENU.
$IN_USERMENU automatically is set to TRUE whenever USERMENU is displayed on
the teach pendant.
$IO_TIMEOUT (input/output time-out)

Minimum: 0 Saved: Yes
Default: 0
$IO_TIMEOUT indicates the time-out value in milliseconds. It is used on KAREL

language READ and WRITE statements. An $IO_TIMEOUT value of 0 indicates an
infinite time-out value.
$JNTCALSEQ (joint calibration sequence)

SJNTCALSEQ indicates the sequence in which each axis moves to the calibration position
for incremental calibration.

6-88
SJNTCALSEQ System Variable
The value of SJNTCALSEQ is set by the KCL> UTILITY SINIT command and should
not be changed. For auxiliary axes, you are responsible for setting the value of
SJNTCALSEQ to correctly define the calibration sequences using the Motion Hardware
Setup Program.
$JNTFOLERR (joint following error)

Data Type: INTEGER ARRAY [9] Saved: No
Power Up: No Default: 0
SJNTFOLERR indicates the joint following error. The units are detector pulses.
The value of SJNTFOLERR is set and updated automatically.
$JNTVELLIM (joint velocity limit)

$JNTVELLIM defines joint speed limits in units of radians per second or millimeters per
second for each robot joint. It is used to calculate the speed of all joint interpolated
motion.
If motion speed of any joint exceeds the value of SJNTVELLIM during linear or circular
motion, the robot speed will slow down so that the joint velocity becomes within its limit,
and the warning message, “Joint speed limit used." will be displayed. Since the accuracy
of motion is not guaranteed in this case, this condition should be avoided by reteaching the
positions.
The value of SJNTVELLIM is set by the KCL> UTILITY SINIT command and should
not be increased beyond the default values for robot axes. For auxiliary axes, you are
responsible for setting the value correctly using the Motion Hardware Setup Program.
See Also:
$JOGFRAME (jogging frame)

Power Up: No Default: $NILP

6-89
SJOGFRAME System Variable
SJOGFRAME is used as the frame of reference for jogging when “JOGFRAME” is

selected on the teach pendant. For most cases, it is convenient to set it to the same value
as SUFRAME. It will allow you to jog the robot along the x,y,z direction defined by
SUFRAME.
For some cases you may want to set SJOGFRAME to a different value than SUFRAME.
This will allow you to jog the robot independently of SUFRAME and still permit you to
RECORD positions in reference to SUFRAME.
See Also:
$JOG_COORD System Variable in this appendix
Enhanced Karel Operations Manual
$JOGLOCK (jog lock) *

Program/KCL: RW/NO Backed Up: Yes
SJOGLOCK, together with $JOGLOCK_EN, allow the ISHIFTI keys on the teach pendant
to be locked in the pressed position. This eliminates having to manually hold them down
while jogging the robot.
There are two methods you can use to lock the ISHIFTI keys:
•Press both ISHIFTI keys on the teach pendant when the teach pendant is enabled
and the system variable $JOGLOCK_EN = TRUE.
•Set SJOGLOCK = TRUE from a running KAREL program while the teach
$JOGLOCK_EN
pendant is enabled and = TRUE.
The ISHIFTI keys cannot be locked in place if $JOGLOCK_EN = FALSE.
When the SHIFT keys are locked, an “L” will replace the sign on the top right comer
of the teach pendant screen.
$JOGLOCK_EN will be set to FALSE automatically if you are prompted to enter an
INTEGER or REAL value from the teach pendant when the ISHIFTI keys are locked in
place.' When this occurs, the “L” will change to a
WARNING
If a KAREL RELEASE statement is executed in the program, the
teach pendant will have motion control. Therefore,
SJOGLOCK EN will not be reset and the robot will begin jogging
if the ISHIFTI keys are locked and you press a numeric/jog key in
response to a prompt which asks for an INTEGER or REAL value.

6-90
SJOGLOCK System Variable
See Also:
SJOGLOCK.EN System Variable
Enhanced KAREL Operations Manual for more information on jogging
and teaching.
$JOGLOCK_EN (jog lock enable) *

SJOGLOCK, together with $JOGLOCK_EN, allow the ISHIFT I keys on the teach pendant
to be locked in the pressed position. This eliminates having to hold them down while
jogging the robot. Both SJOGLOCKJEN and SJOGLOCK must be TRUE to lock the
1SHIFT| keys in place.
$JOGLOCK_EN cannot be set from within a KAREL program.
See Also:
SJOGLOCK System Variable
Enhanced KAREL Operations Manual for more information on jogging and teaching.
SJOGWRISTJNT (jog orientation method)

Power Up: No Default:. FALSE
SJOGWRISTJNT indicates the currently selected orientational method for the teach
pendant. The following values are used:
•TRUE = Two angle orientation
•FALSE = Wrist joint orientation
SJOGWRISTJNT is set automatically by the teach pendant by selecting the SETUP key to
display the Setup screen, selecting the Ell SETFRAME function key and then selecting the
EH UJOG function key.
$JOG_COORD (jog coordinate system)


6-91
$JOG_COORD System Variable
$JOG_COORD indicates the currently selected jog coordinate system for the teach
pendant, using the following values:
0 = JOINT
1 = JOGFRAME
2 = WORLDFRAME
3 = TOOLFRAME
4 = AUX AXIS
$JOG_COORD is automatically set by the teach pendant COORD key on the teach
pendant.
$KEPTMIRLIM (KEPT Motion Instruction Record LIMits)

Data Type: INTEGER Saved: Yes
$KEPTMIRLIM is the number of motion instruction records kept in the path planning
system during motion. Adjusting this value makes it possible to recover all interrupted
motions after a servo error (for example, EMERGENCY STOP).
The range of SKEPTMIRLIM is from 0-9 but must be less than or equal to (SNUM_MIR
-3).
See Also:
$NUM_MIR System Variable in this appendix
$KL_USERSTAT (KAREL screen user status line)

$KL_USERSTAT indicates whether the KAREL system or application program has

control of the KAREL screen status line on the CRT/KB.
If $KL_USERSTAT is set to TRUE and a KAREL program is running or paused the
system stops updating the status line, giving control to the program. The predefined
constant CRTSTATUS can be used to write to the status line when $KL_USERSTAT is
TRUE.
If $KL_USERSTAT is set to FALSE the system automatically updates the status line. By
default, $KL_USERSTAT is set to FALSE each time a program is executed. It
automatically resets to FALSE when program execution ends or the program is aborted.

6-92
$KL_USERSTAT System Variable
See Also:
Enhanced KAREL Operations Manual for more information
on CRT/KB screens.
$KNCP_PARAM (KNCP parameter)

Power Up: No
$KNCP_PARAM is an array which specifies NCP communications parameters. The array

elements represent the following parameters:
•SKNCP_PARAM[1] is the number of copies of NCP running DDCMP connections.
By default, the value is set to 1.
•SKNCP_PARAM[2] is the number of copies of NCP running MAP connections. By
default, the value is set to 1.
NOTE
KAREL can run a maximum of 2 copies of NCP. Therefore, the
sum of $KNCP_PARAM[1] and $KNCP_PARAM[2] cannot exceed
2.
•SKNCP_PARAM[3] indicates which severity category of error codes is reported. You

can specify no category, a particular category, or all categories. By default, the value is
set to 0, meaning no errors are reported.
•SKNCP_PARAM[4] is a coded value indicating which “facility” or KAREL subsystem

reports errors. By default, the value is set to 0. meaning no errors are reported.
SKNCP_PARAM[4] enables Subsystems 19-17.
•SKNCP_PARAM[5] is a coded value indicating which “facility” or KAREL subsystem
reports errors. By default, the value is set to 0, meaning no errors are reported.
SKNCP_PARAM[5] enables Subsystems 16-1.
•SKNCP_PARAM[6] currently is not used.
Values are assigned to $KNCP_PARAM by default. However, you might need to change
these values to tailor the system for specific communication applications.
See Also:
SERIAL Communication Reference Manual for more information on setting $KNCP_PARAM

6-93
$LINK_LEN_1 System Variable
$LINK_LEN_1 (link length 1)

$LINK_LEN_1 has a meaning that is robot specific. It is intended primarily to support

multiple versions of a given robot model, where the differences are only in link lengths.
It can also be used in some cases to support multiple versions with other minor differences
in kinematic parameters.
The value of $LINK_LEN_1 is set by the KCL> UTILITY SINIT command and should
not be changed.
$LINK_LEN_2 (link length 2)

$LINK_LEN_2 has a meaning that is robot specific.

The value of $LINK_LEN_2 is set by the KCL> UTILITY SINIT command and should
not be changed.
See Also:
$LINK_LEN_1 System Variable in this appendix to compute the tolerance in radians or millimeters.
$LIST_ON (list on)

$LIST_ON indicates whether or not the language translator will generate a listing file when
a source file is translated. To conserve space, the same file specification, LISTING. LS, is
used for all listing files.
If you set the value to TRUE, a listing file is generated. If you set it to FALSE, a listing
file is not generated and the translation procedure is faster.
The value of $LIST_ON can be overridden using the /LISTING or /NOLISTING options
with the KCL> TRANSLATE command.

6-94
$LOCK_KLMENU System Variable
$LOCK_KLMENU (lock KAREL menu) *

Default: FALSE Saved: No
$LOCK_KLMENU provides KAREL programs with the ability to lock any KAREL
screen or menu displayed on the CRT while a program is running. When a KAREL
screen or menu is locked, all function keys are accessible by the program, however, they
will be blank unless the program writes to them. Setting $LOCK_KLMENU = TRUE
will lock the display of the current KAREL screen or menu.
While the CRT screen is locked, the function key, IFIOI , will not be active. Therefore, the
program has control over which menu is being displayed. The DISPLAYPG built-in must
be used within the program to force a KAREL screen or menu to be displayed.
If $LOCK_KLMENU is FALSE, all system defined function keys will be displayed and
active.
$LOCK_TPMENU (lock teach pendant menu)

$LOCK_TPMENU is a program accessible variable intended for use in “teaching

programs” to prevent novice operators from “escaping” the control of the KAREL
program. KCL command access is also permitted to allow start-up command files to lock
the menu.
If $LOCK_TPMENU is TRUE, the teach pendant is locked at the USERMENU display.
$LOCK_TPMENU can only be used if a program is running.
If USERMENU is not being displayed when $LOCK_TPMENU is first set to TRUE, the
lock function does not take effect until the user selects the USERMENU on the teach
pendant. (The value of $IN_USERMENU indicates whether or not the USERMENU is
has been selected.)
$LOCTOL (location vector tolerance)

Data Tvpe: REAL Saved: Yes

6-95
SLOCTOL System Variable
$LOCTOL is used when comparing the location vector of two positions. SLOCTOL, along
with SAPPROACHTOL, SORIENTTOL, and SCHECKCONFIG is used in conjunction
with the relational operator “>=<” to compare two positions.
If SLOCTOL is negative, no comparison is made and the location vectors of the two
positions are “nearly” identical. When SLOCTOL is 0. the location vectors must be
identical in order for the relational operator to return TRUE.
When SLOCTOL is greater than 0 the following test is made:
loci = LOC(posl);
loc2 = LOC(pos2);
-
If (ABS(locl[l] loc2[1] <= SLOCTOL) and
-
(ABS(locl[2] loc2[2] <= SLOCTOL) and
-
(ABS(locl[3] loc2[3] <= SLOCTOL) then
the location vectors of the two positions are “nearly" identical.
$LOWERLIMS (lower joint limits)

Data Tvpe: REAL ARRAY [9] Power Up: Yes
SLOWERLIMS defines the lower joint limits in radians or millimeters.

The value of SLOWERLIMS is set by the KCL> UTILITY' SINIT command and should
not be changed for robot axes. For auxiliary axes, you are responsible for setting the value
correctly using the Motion Hardware Setup Program.
$M0_KNAME (MAPO node name)
Data Type: STRING[64] Saved: Yes

Power Up: No
$M0_KNAME specifies the port name (application process title) of the specific KAREL
controller for which it is defined. The name must be unique on the MAP network. It is
required to receive connections on the MAPO channel. You are responsible for setting the
value of $M0_KNAME before any associations are attempted on the MAPO channel.
See Also:
KAREL-MAP, Installation and Maintenance

6 - 96
$M1_FNAME System Variable
$M1_FNAME (MAPI foreign node name)

Power Up: No
$M1_FNAME specifies the port name of the foreign application process title to which the
KAREL controller is to be connected when requesting an association on the MAPI
channel. You are responsible for setting the value of $M1_FNAME before any associations
are requested on the MAPI channel.
See Also:
KAREL-MAP. Installation and Maintenance
$M1_KNAME (MAPI node name)

Power Up: No
$M1_KNAME specifies the port name (application process title) of the specific KAREL
controller on which it is defined. The name must be unique on the MAP network. It is
required to initiate connections on the MAPI channel.
You are responsible for setting the value of $M1_KNAME before any associations are
attempted on the MAPI channel.
See Also:
$MANLIM (manual motion speed limit)

Default: 25
SMANLIM, a scaling factor, is expressed as a percentage of the maximum speed for

jogging. For joint motion the maximum speed is SJNTVELIM, and for Cartesian motion it
is $SPEEDLIM. SMANLIM is used to calculate the speed of joint and Cartesian jog
motions as well as the default value of SSPEED.
See Also:

6-97
$MAP_PARAM System Variable
$MAP_PARAM (MAP parameter)

Power Up: No
SMAP_PARAM is an array that specifies MAP communications parameters. The array

elements represent the following parameters:
•$MAP_PARAM
$MAP_PARAM[1] is the data rate of the CIM to INI serial link. It is effective when
= 0. By default, the value is set to 8 which represents 56K bits/sec.
(Maximum value = 9).
•$MAP_PARAM[2] is the time-out value on KAREL-MAIN service associations and
releases. By default, the value is set to 60 seconds, the minimum allowable.
•$MAP_PARAM[3] indicates whether an internal or external clock is used on the MAP
card. By default, the value is set to 0 (internal clock). A value of 1 represents the
external clock.
•$MAP_PARAM[4] is the MG-400 response time-out value. By default, the value is set
to 15 (1.5 seconds).
•$MAP_PARAM[5] disables MMFS syntax checking (Default: 0 = enable, 1 =

disable).
•$MAP_PARAM[6] indicates the MAP/TBI restart time in seconds (Default: 0 = 60
seconds).
•$MAP_PARAM[7] is reserved for future use.
•SMAP_PARAM[8] is reserved for future use.
Values are assigned to $MAP_PARAM by default. However, you might need to change
these values to tailor the system for specific communication applications.
See Also:
SMASTER_DONE (master done)
Data Tvpe: BOOLEAN Saved: Yes

Program'KCL: NO/PW Backed Up: No
SMASTER_DONE indicates whether or not the mastering procedure has been performed.
If it is TRUE, mastering has been done. Currently, $MASTER_DONE is implemented
only for APC systems.
The value of $MASTER_DONE is set and updated automatically.

6-98
$MASTER_POS System Variable
$MASTER_POS (master position)
Data Type: REAL ARRAY [9] Saved: Yes

$MASTER_POS defines the mastering position of the robot as determined by the mastering
fixture. The value of $MASTER_POS is in radians for rotary axes and millimeters for
linear axes.
$MASTER_POS is set by the KCL> UTILITY SINIT command and should not be
changed. For auxiliary axes, you are responsible for setting the value correctly using the
Motion Hardware Setup Program.
$MAXDATAPGMS (maximum data programs)

Default: 21
$MAXDATAPGMS specifies the maximum number of programs for which static variables
can be defined. System variables are counted as one static variable program. The
maximum number of programs available is SMAXDATAPGMS - 1.
$MAXROUTINES (maximum routines)

Default: 300
SMAXROUTINES specifies the maximum number of routines that can be declared in all
of the programs that are loaded in RAM. Each loaded program is also counted as a
routine. Each program or routine is counted only once.
$MIN_ACCTIME (minimum acceleration time)

Default: 160

6-99
$MIN_ACCTIME System Variable
$MIN_ACCTIME defines the minimum acceleration/deceleration time in milliseconds

while the short motion speed up algorithm is used. It is the sum of the first and second
stages.
The value of $MIN_ACCTIME is set by the KCL> UTILITY SINIT command and
should not be changed. For auxiliary axes, you are responsible for setting the value
*The maximum value for SMIN_ACCTIME is limited by the maximum value for each
system (usually 500 msec.)
$MIRRORPLANE (mirror xz-plane)

Program/KCL: RO/RW Saved: Ye
Default: $NILP Backed Up: Yes
SMIRRORPLANE indicates a position whose xz-plane is used as the mirroring plane in the
KCL> MIRROR command, which is part of the optional Mirror Image feature.
When SMIRRORPLANE and SUFRAME are set to nil, data is mirrored about the xz-
plane of the world coordinate system. This is the normal case for mirroring across
assembly lines where the mirrored data is used on a robot that is also rotated by 180
degrees.
You can set the value of SMIRRORPLANE for the optional Mirror Image feature using
either KCL commands or the teach pendant.
$MODEL_ID (model identifier)
Data Type: STRING Saved: No

Power Up: No Default: Robot Specific
$MODEL_ID defines the robot model identifier (name). The string value appears on the
POWER UP screen of the CRT/KB. $MODEL_ID is set by the system and cannot be
changed.
$MOSIGN (motion sign)

Data Type: BOOLEAN ARRAY [9] Power Up: No

6-100
SMOSIGN System Variable
$MOSIGN defines the direction of axis motor rotation for each axis during calibration of
robots with absolute encoders.
The value of SMOSIGN is set by the KCL> UTILITY SINIT command and should not
be changed for robot axes. For auxiliary axes, you are responsible for setting the value
$MOTYPE (motion type)

Default: 6
$MOTYPE defines the type of motion interpolation used for motion statements using the
following values:
6 = JOINT
7 = LINEAR
8 = CIRCULAR
The value of $MOTYPE can be overridden in a path by setting the SEGMOTYPE field in
the standard associated data.
The default value is set each time a program is executed.
$ M OT_S P D_L I M (motor speed li mit)

$MOT_SPD_LIM defines an array of motor speed limits, one per motor, in units of RPM.
The value of $MOT_SPD_LIM is set by the KCL> UTILITY SINIT command and
$MOVEDIST (move distance)

Power Up: No
Software Version 2,0 and Up

6- 101
SMOVEDIST System Variable
SMOVEDIST indicates the Cartesian distance the robot has traveled since the beginning of
the current interval. It is only valid for Cartesian moves. Joint interpolated segments are
treated as zero length segments.
The value of $MOVEDIST is automatically set to zero at the beginning of an interval. It is
updated at the Cartesian interpolation rate appropriate for the segment being interpolated.
The final value of $MOVEDBT remains valid until the next interval begins.
$MOVERRLIM (move error limit)

Minimum/Maximum: 0/32767 Saved: Yes .
$MOVERRLIM defines a motion following the error limit during motion for each axis, in
units of detector pulses. If the following error exceeds its limit while the robot is in motion,
servo power shuts off and the system displays the message “Move error excess.”
The value of SMOVERRLIM is set by the KCL> UTILITY SINIT command and should
not be changed. For auxiliary axes, you are responsible for setting the value correctly using
the Motion Hardware Setup Program.
$MSTUSE_RST (must use reset)

$MSTUSE_RST indicates whether or not pressing the DEADMAN switch while the teach
pendant is enabled will activate servo power automatically.
If it is TRUE, the servo power can be activated only by issuing a RESET using the
operator panel RESET button, the teach pendant RESET softkey, or the KCL> RESET
command. If it is FALSE, servo power is activated automatically by pressing the
DEADMAN switch on the enabled teach pendant.
A value of FALSE allows you to use the DEADMAN switch to control servo power.
$MSTUSE_STRT (must use start)


6- 102
$MSTUSE_STRT System Variable
$MSTUSE_STRT indicates whether or not the START button on the teach pendant must
be held down in order for a program to continue running during a test run. If it is TRUE,
the program continues to run only as long as the START button is held down. If it is
FALSE, the program continues to run even when the START button is released.
As a safety consideration it should remain TRUE except in cases where the application
demands that the user have a free hand during test runs.
$NILP (nil position)

Program/KCL: RO/RO Backed Up: Yes
Power Up: No Default: 0,0,0,0,0,0,’N’
$NILP defines a nil or zero position, which is useful in program assignment statements.
For example, the statement $UTOOL = $NILP assigns a nil position to $UTOOL.
$NLOG_CHAN (network log channel)
Data Tvpe: INTEGER Saved: Yes

$NLOG_CHAN identifies the communication channel to which alarm conditions are to be

reported using the following values:
0 = no device
1 = CO:
4 = C3:
8 = MO:
16 = Ml:
See Also:
$NUM_AUX_AXS (number of auxiliary axes)

Program/KCL: RO/PW Backed Up: No
Default: 0
$NUM_AUX_AXS defines the number of auxiliary axes used in the system. Its value is
used to determine the size of AUXPOS data types.
Software Version 2.0 and UD

6-103
$NUM_AUX_AXS System Variable
The sum of the values of $NUM_AUX_AXS and $NUM_ROB_AXS cannot exceed nine.
The value will be adjusted at power up and the message “2132 $NUM_AUX_AXS
adjusted to n” will appear if the sum of the two variables is greater than nine. The new
value of $NUM_AUX_AXS is 9 - $NUM_ROB_AXS.
If the system has auxiliary axis control (optional feature), the value of $NUM_AUX_AXS
must be set and saved as part of the initial setup procedure using the Motion Hardware
Setup Program.
$NUM_MIR (number of motion instruction records)

Minimum/Maximum: 3/20 Backed Up: No
Default: 10
$NUM_MIR is the number of motion instruction records (internal data structure) to be

created in the system. It affects the maximum number of STOPs to be executed in a row
and the memory size available to the user.
$NUM_ROB_AXS (number of robot axes)

Program/KCL: RO/PW Backed Up: No
$NUM_ROB_AXS defines the number of robot axes for the robot.

The value of $NUM_ROB_AXS is set by the KCL> UTILITY SINIT command and

6-104
$ORIENT_TYPE System Variable
$ORIENT_TYPE (orientation type)

Default: 1 (RSWORLD)
$ORIENT_TYPE indicates the type of orientation control to be used when $MOTYPE is

set to LINEAR motion. The following values are used:
1 = RSWORLD, two angle orientation control
2 = AESWORLD, three angle orientation control
3 = WRISTJOINT, wrist-joint orientation control
For CIRCULAR motion, three angle orientation planning is used regardless of the value of
$ORIENT_TYPE.
The default value of $ORIENT_TYPE is set each time a program is executed.
See Also:
Chapter 8, KAREL Reference Manual for more information on orientation
types.
$ORIENTTOL (orient vector tolerance)

Data Type: REAL Saved: Yes
Power Up: No Default: 0.003046096 (1 degree)
SORIENTTOL is used when comparing the y-axis (orient vector) of two positions.
SORIENTTOL, along with SAPPROACHTOL, SLOCTOL, and SCHECKCONFIG, is
used in conjunction with the relational operator “> = <” to compare two positions.
If SORIENTTOL is negative, no comparison is made and the orient vectors are "nearly"
identical. When SORIENTTOL is 0 die orient vectors must be identical in order for the
relational operator to return TRUE. When SORIENTTOL is greater than 0 the following
test is made:
orientl = orient(posl);
orient2 = orient(pos2) ;
If (ABS(orientl[l] - orient2[l] <= SORIENTTOL) and
(ABS(orientl[2] - orient2[2] <= SORIENTTOL) and
(ABS(orientl[3] - orient2[3] <= SORIENTTOL) then
the orient vectors of the two positions are “nearly” identical.

6-105
$OT_MINUS System Variable
$OT_MINUS (overtravel minus)

$OT_MINUS is an array with each element representing the overtravel condition for the
respective axis. If an element is set TRUE, the corresponding axis has a minus overtravel
condition and can be jogged only in the positive direction. When an overtravel does not
exist, all of the array elements are reset to FALSE.
The appropriate array elements in SOT_MINUS are automatically set to TRUE when an
overtravel occurs in the minus direction, and automatically set back to FALSE when the
condition is corrected.
This variable is saved to the DYNMSTR.DY system file automatically every time its value
is changed and is automatically loaded into the system at power up.
$OT_PLUS (overtravel plus)

$OT_PLUS is an array with each element representing the overtravel condition for the
respective axis. If an element is set TRUE, the corresponding axis has a plus overtravel
condition and can be jogged only in the negative direction. When an overtravel does not
exist, all of the array elements are FALSE.
The appropriate array elements in SOT_PLUS are automatically set to TRUE when an
overtravel occurs in the plus direction, and automatically set back to FALSE when the
condition is corrected.
This variable is saved to the DYNMSTR.DY system file automatically every time its value
is changed and is automatically loaded into the system at power up.
$PATH_NODE (path node)


6-106
$PATH_NODE System Variable
$PATH_NODE indicates the path node to which the robot is moving or has most recently
moved.
After an error, KAREL programs can test to determine the node toward which the robot is
or was most recently moving when the error occurred. For emergency stops or errors that
cause brakes to be applied and drive power to the servo system to be shut off,
$PATH_NODE might be ahead of the robot’s actual position.
The value of $PATH_NODE is set and updated automatically.
$PATHREFPOS (path reference position of path relative frame) *

Power Up: No Default: Uninitialized
SPATHREFPOS is a user-definable position to establish the desired Path Relative Frame

(optional feature).
$PCODR_REF (pulse coder reference)

Power Up: No Default: Robot Specific
For APC systems, $PCODR_REF is the APC counter value of each axis at the reference
position. It is part of the mastering data and is saved into the DYNMSTR.DY file
automatically every time the KCL> MASTER command is executed or the remastering
procedure takes place.
SPENDMOCOUNT (pending motion count)

Data Type: INTEGER Saved: No
SPENDMOCOUNT keeps track of how many motions have been issued but have not yet
been completed. It is automatically incremented each time the program interpreter issues a
motion and decremented each time the motion interpolator finishes a motion.

6-107
$PERCH System Variable
$PERCH (perch)
Data Type: ARRAY[9] of REAL Power Up: Yes
Program/KCL: No/RW Saved: Yes
Backed Up: No Default: 0.00
$PERCH is used to set the perch position. The SATPERCH system variable can be used
to determine if the current position of the robot is the same position as specified by
$PERCH.
For robot axes, $PERCH[i] is in degrees or millimeters depending on the value of
$ROTARY_AXIS. For auxiliary axes, $PERCH[i] is in the coordinates determined by
SENCSCALES. $PERCH is set using the SSETPERCH built-in procedure.
See Also:
SATPERCH and SPERCHTOL System Variables in this appendix
SETPERCH Built-In Procedure, Appendix A, KAREL Reference Manual
$PERCHTOL (perch tolerance)

Data Type: ARRAY[9] of REAL Power Up: Yes
Program/KCL: No/RW Saved: Yes
Backed Up: No Default: -1.0
SPERCHTOL is used to define the tolerance used when the robot position is checked using
SPERCH.
For robot axes, $PERCHTOL[i] is in degrees or millimeters depending on the value of
$ROTARY_AXIS. For auxiliary axes, $PERCHTOL[i] is in the coordinates determined
by SENSCALES. If $PERCHTOL[i] is negative, perch checking is turned off for axis i.
SPERCHTOL is normally set using the built-in function SETPERCH.
See Also:
SATPERCH and SPERCH System Variables in this appendix
SETPERCH Built-In Procedure, Appendix A, KAREL Reference Manual
$PPABN_ENABL (pneumatic pressure abnormal enable)


6-108
$PPABN_ENABL System Variable
$PPABN_ENABL indicates whether or not digital input that indicates abnormal pneumatic
pressure is enabled. If it is TRUE, sensing of low line-pressure input on the robot control
module (for systems with modular I/O) or the fixed I/O board is enabled.
See Also:
$PRF_RESUME (path relative frame resume)

$PRF_RESUME is effective only for linear moves in Path Relative Frame.

If the robot stops during motion, the user can set $PRF_RESUME to TRUE in order for
tile motion to continue without any loss of continuity. Once the motion is resumed,
$PRF_RESUME is reset to FALSE by the system.
See Also:
$CUR_PRFRAME and SCUR_CRFRAME System Variables in this appendix
STTOOLNUM System Variable in this appendix for more
information on Path Relative Frame
$PRGOVERRIDE (program override)

Program/KCL: RW/RO Backed Up: No
Default: 100
$PRGOVERRIDE, a scaling factor, is expressed as a percentage of the motion speed.

For all programmed motion, SPRGOVERRIDE is multiplied by SGENOVERRIDE to
obtain a total override value, which is then multiplied by the motion speed.
SPRGOVERRIDE has no effect for motions other than program motion. You can assign a
value to SPRGOVERRIDE from a program or from the teach pendant.
$PR10RITY
Program/KCL: WO/NO
SPRIORITY can be used only in a condition handler statement WITH clause. This
condition handler qualifier is not a normal system variable. It has write only (WO) access
by programs and cannot be accessed by KCL (NO).

6- 109
$PRIORITY Condition Handier Qualifier
$PRIORITY is used to specify the priority of execution for the indicated routine. An
interrupt routine with a low priority will not be executed until control is returned to the
program from a higher-priority routine. Therefore, the actual priority value specified is not
important; only that one must be larger than the other.
Where $PRIORITY is not specified, a default value of 0 is assumed. Two interrupt
routines that have the same priority value, or default values of 0, can interrupt each other.
See Also:
WITH Clause, Appendix A, KAREL Reference Manual
$PRODUCT_ID (product identifier)
Data Type: STRING[12] Saved: No

Power Up: No Default: ‘R-H’
$PRODUCT_ID allows KAREL programs to determine which controller is being used.

This allows the program to access controller-specific system variables and functions (for
example, 80 columns of the CRT on the R-H controller as opposed to 40 columns on the
R-F controller).
$PROG_BASE (program base) *

Power Up: No Default: ’prog:.’
$PROG_BASE allows Basic and Enhanced KAREL users to select programs by number
from the teach pendant. An ASCII number is appended to $PROG_BASE to form the
program name. When you select PRGM # from the teach pendant you are prompted to
input the program number. For example, if you type “1” in answer to this prompt, you
will be selecting “PROG_01” as the default program name. The program ‘'PROG_01"
must already exist as a program in order for you to select it as the default program.
Two characters are reserved for the program number. This allows for programs to be listed
in order through program #99. $PROG_BASE is limited to a maximum of 10 characters.

6-110
$PTH_MODEL System Variable
$PTH_MODEL (path model)
Data Type: STRING Power Up: No

Program/KCL: NO/RO Saved: No
$PTH_MODEL defines the robot model identifier. The value of $PTH_MODEL matches
the value of $MODEL_ID and is set and used internally. It cannot be changed.
$PTH_VERSION (path version)

$PTH_VERSION identifies the KAREL software version currently in use. The value of
$PTH_VERSION matches the value of $VERSION_ID and is set and used internally. It
cannot be changed.
$PWR_FAIL (power fail)

Power Up: Yes Default: ‘ ’(blank)
$PWR_FAIL specifies the name of the KCL command file that is executed if the system is
in a recoverable state at power up. If no name is specified, a KCL command procedure is
not executed.
You are responsible for setting the value of $PWR_FAIL if you want a command
procedure to be executed at power up when the system is in a recoverable state.
If you assign a command procedure name to $PWR_FAIL the message “Running Power
Fail File file_name” is displayed on the CRTKB at power up. while the procedure is being
executed, where file_name is the command file name.
See Also:
SRECOVERABLE System Variable

6-111
)

$PWR_NORMAL System Variable
$PWR_NORMAL (power normal)

Power Up: Yes Default: ‘ ’ (blank)
$PWR_NORMAL specifies the name of the KCL command file that is executed if the
system is not in a recoverable state at power up and the conditions for using the
$PWR_RESTART command file are not met. If no name is specified, a KCL command
procedure is not executed.
You are responsible for setting the value of $PWR_NORMAL if you want a command
procedure to be executed at power up when the system is not in a recoverable state.
If you assign a command procedure name to $PWR_NORMAL the message “Running
Power Up File file_name” is displayed on the CRT/KB at power up, while the procedure is
being executed, where file_name is the command file name.
See Also:
SRECOVERABLE System Variable
$RECOVERABLE (recoverable)
Program/KCL: NO/RO Backed Up: Yes
SRECOVERABLE indicates whether or not the system is in a recoverable state for the
power fail recovery procedure (optional feature). If it is zero, then the system is in a
recoverable state ($PWR_FAIL is executed). Otherwise, it is a nonzero value and the
system is not recoverable (SPWR_NORMAL is executed).
The value of SRECOVERABLE is set automatically as part of the power fail recovery
procedure.
$REMOTE (remote)

6-112
$REMOTE System Variable
$REMOTE indicates the operator panel REMOTE keyswitch setting. It is TRUE when
the key is set to ON and a remote device has motion control. It is FALSE when the key is
set to OFF and the operator panel has motion control.
The value of SREMOTE is set and updated automatically.
$RESULT (result)
Data Tvpe: INTEGER Saved: No
Program/KCL: RW/RN Backed Up: Yes
Power Up: No
The function of SRESULT depends on how it is used within a program. It allows the
programmer to assign an integer value to a system variable.
The value of SRESULT can be set by the RESULT condition handler action as part of a
WHEN or UNTIL clause.
See Also:
$ROTAR Y_AXIS (rotary axis)

Data Tvpe: BOOLEAN ARRAY [9] Power Up: No
$ROTARY_AXIS is an array, with one element for each axis, indicating whether the axis
is rotary or linear. A value of TRUE indicates a rotary axis and FALSE indicates a linear
axis.
The value of $ROTARY_AXIS is set by the KCL> UTILITY SINIT command and
should not be changed. For auxiliary axes, the default value is TRUE.
$ROTSPEED (rotational speed)

Data Tvpe: REAL Power Up: No
SROTSPEED controls how fast the robot is allowed to rotate the tool center point (TCP)
approach vector for programmed Cartesian motion (linear, circular.) The value is
expressed in radians per second.

6 - 113
$ROTSPEED System Variable
By default, the value of SROTSPEED is set to an uninitialized value each time a program is
executed. If you do not assign a value to SROTSPEED in the program and the speed of
the programmed motion is higher than the value of SROTSPEEDLIM, the warning
message “ROTATION SPEED LIMITS USED” is displayed. The robot speed will then
slow down so that the rotation speed is less than SROTSPEEDLIM
See Also:
SROTSPEEDLIM, SSPINSPEED, SSPINSPEEDLIM System Variables in this appendix
$ROTSPEEDLIM (rotational speed limit)

Program/KCL: RO/RW Backed Up: Yes
SROTSPEEDLIM is the maximum value for the rotational speed of the TCP approach
vector in programmed Cartesian motion. The value is expressed in radians per second.
The default value may be reset to a higher value to increase the speed of the robot. If the
new value is too large, the error message, “Joint velocity Limit (SJNTVELLIM)” will be
displayed.
$RUNWITHERR (run with error)

SRUNWITHERR, when set to TRUE, allows KCL> RUN and KCL> RESUME to
execute while an error is pending. If SRUNWITHERR is FALSE, the error must be
cleared before the KCL> RUN or KCL> RESUME commands will execute. Note that
the program will not be able to issue a motion if an error is pending.
$SCAN_TIME (scan time condition handler qualifier)
Program/KCL: WO/NO
Minimum/Maximum: 1/512
Default: 1
$SCAN_TIME can only be used in a condition handler statement WITH clause. This
condition handler qualifier is not a normal system variable. It cannot be accessed by KCL
(NO) and has write only (WO) access by programs.

6-114
$SCAN_TIME Condition Handler Qualifier
$SCAN_TIME is used to specify the time in milliseconds between scans in a condition

handler. The syntax for $SCAN_TIME = time_in_ms where time_in_ms is an INTEGER
expression.
Actual time_in_ms values will be one of the following: 1, 2, 4, 8, 16, 32, 64, 128, 256,
512, times the value of the $COND_TIME system variable. Any value less than
$COND_TIME will default to the value of $COND_TIME. Any value greater than (512 *
$COND_TIME) ms will default to (512 * $COND_TIME). Any value between one of the
above intervals will default to the next lower value.
See Also:
$COND_TIME System Variable
$SCN_HLD_NBL (screen hold enable)

$SCN_HLD_NBL indicates whether or not the CRT/KB HOLD SCREEN key, which
stops the screen display from scrolling, is enabled. By default, $SCN_HLD_NBL is
TRUE.
$SCREEN_HELD (screen held)

$SCREEN_HELD indicates that scrolling onthe CRT screen is currently being held by the
CRT/KB HOLD SCREEN key. $SCREEN_HELD is updated automatically each time
you press the HOLD SCREEN key.
$SEGFRACTION (segment fraction)


6-115
_
SSEGFRACTION System Variable
SSEGFRACTION indicates what fraction of the current segment has been interpolated.
For example:
0.0 means interpolation is just beginning.
0.5 means interpolation is half done.
1.0 means interpolation is complete, and robot is starting to decelerate toward the
destination
Note that when the value is 1.0, the robot will not be exactly at the indicated position
because of the digital filters. The robot still needs to decelerate. SSEGFRACTION is set
and updated automatically.
$SEGLENGTH (segment length)

$SEG LENGTH indicates the current Cartesian length of a straight line segment or the arc
length of a circular segment as computed by the motion planner for the segment currently
being executed by the motion environment. Joint interpolated segments are treated as zero
length segments.
$SEG LENGTH is set and updated automatically.
$SEGTERMTYPE (segment termination type)

Default: 4 (NODECEL)
SSEGTERMTYPE indicates the default termination type for intermediate path nodes (all
but the last node in a path), using the following values:
1 = FINE
2 = COARSE
3 = NOSETTLE
4 = NODECEL
5 = VARDECEL
If the SEGTERMTYPE associated data field is set to anything other than one of these
values, then SEGTERMTYPE associated data overrides the SSEGTERMTYPE system
variable value. If the SEGTERMTYPE field is left to the default then the type specified
by the value of SSEGTERMTYPE is used.

6-116
SSEGTERMTYPE System Variable
$SEG_TIN!E (segment time)

$SEG_TIME indicates the time required for a motion segment. By specifying a value for
$SEG_TIME, you are specifying the time it will take to complete the segment. The speed
will vary depending on the distance (as opposed to SSPEED in which the speed remains
constant and the time varies).
Motion statements are executed using $SEG_TIME as long as $SEG_TIME has a value
that is greater than 0. $SEG_TIME is set to 0 each time a program is executed. The
segment time is specified in units of milliseconds as an INTEGER value greater than or
equal to 0. A value of 0 indicates SSPEED will be used instead of a segment time.
$SERVO_READY (servo ready)

$SERVO_READY indicates whether or not servo power is active.

The value of $SERVO_READY is set and updated automatically.
$SIMUL_CAL (simultaneous calibration)

$SIMUL_CAL controls whether or not the axes move simultaneously during incremental
calibration. If it is TRUE the axes (or groups of axes) move simultaneously. If it is
FALSE the axes move one at a time.
$SIMUL_CAL has no meaning on robots with an APC system.
$SPEED (speed)
Power Up: No Default: 375*

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$SPEED System Variable
$SPEED is the TCP translation speed of the programmed motions, expressed in mm/sec. It
is used to calculate the speed of sill programmed motion.
*By default, the value of $SPEED is set to the product of SMANLIM/100 multiplied by
$SPEEDLIM each time a program is executed. You can assign a new value within the
program.
See Also:
SSPEEDLIM (speed limit)

SSPEEDLIM is the motion translation speed limit, expressed in mm/sec. It is the

maximum value that can be assigned to $SPEED for Cartesian motion. It is also used in
calculating the speed of Cartesian jog motion.
The default value may be reset as long as it is a valid value specified by the robot
specifications or the error message, “Joint speed limits used** will be displayed.
See Also:
$SPEEDLIMJNT (speed limit joint)

SSPEEDLIMJNT is the maximum value of SSPEED for programmed, joint interpolated

motion. It is used to calculate the motion speed of each joint.
See Also:
$SPINSPEED (spin speed)

Data Tvpe: REAL Power Up: No

6-118
SSPINSPEED System Variable
SSPINSPEED controls how fast the robot is allowed to spin about the tool center point
(TCP) approach vector for programmed Cartesian motion (linear, circular). The value is
expressed in radians per second.
By default, the value of SSPINSPEED is set to an uninitialized value each time a program
is executed. If you do not assign a value to SSPINSPEED in the program, and if the spin
speed of the programmed motion is larger than the value of SSPINSPEEDLIM, the
warning error message “ROTATION SPEED LIMITS USED” is displayed. The robot
will then slow down so that the spin speed is within SSPINSPEEDLIM.
See Also:
SROTSPEED, SROTSPEEDLIM, SSPINSPEEDLM System Variables in this appendix
SSPINSPEEDLM (spin speed limit)

SSPINSPEEDLM is the maximum value for the spin speed about the TCP approach vector
in programmed Cartesian motion. The value is expressed in radians per second.
The default value may be reset to a higher value to increase the speed of the robot. If the
new value is too large, the error message, “Joint velocity Limit (SJNTVELLIM)” will be
displayed.
$SPIN_CTRL (spin control)

Power Up: Yes Default: FALSE
$SPIN_CTRL indicates which type of control is used for 5-axis robots. If it is FALSE,
approach vector control is used. If it is TRUE, spin control is used.
$SRVO_BLOCK1 Reserved for GMF internal use only.

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SSRVOJ3LOCK4 System Variable
$SRV_CODE_ID (servo code identification)
Data Tvpe: STRING Power Up: No

SSRV_CODE_ID is the revision level of the digital servo code. It is set internally and
cannot be changed.
$SRV_PARM_ID (servo parameters identification)
Data Tvpe: STRING Power Up: No

SSRV_PARM_ID is the revision level of the default digital servo parameters. It is set
internally and cannot be changed.
If $SRV_PARAM_ID is blank or uninitialized at power up, the user will be prompted to
enter the Servo Parameter Setting Program disk. This will copy the file KSSP.CF and
execute it. Power down and power up the controller to continue.
SSTOPERLIM (stop error limit)

SSTOPERLIM defines an array of the servo following error tolerances while stopping for
each axis. It is expressed in units of detector pulses.
The value of SSTOPERLIM is set by the KCL> UTILITY SINIT command and should

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$STOP_ON_ERR System Variable
$STOP_ON_ERR (stop on error)

$STOP_ON_ERR indicates whether or not the system stops on a KCL command file error.
If TRUE, execution of the command procedure stops if any error condition is found.
You can set and clear $STOP_ON_ERR within a command procedure to control the
execution of command files depending on desired response to errors.
Note that $STOP_ON_ERR applies only to errors that can be detected by the KCL
command interpreter. For example, a KCL> MOVETO command can cause a solution
error that prevents the motion from proceeding, but the KCL command interpreter will
continue because the motion command itself has succeeded.
$SV_OFF_ENB (servo off enable)
Data Type: BOOLEAN ARRAY [9] Saved: Yes

Power Up: Yes Default: FALSE
$SV_OFF_ENB controls whether or not each servo motor uses a timed servo shutdown
feature. It is used with $SV_OFF_TIME to shut off servo motors after motion has been
completed.
This feature is used primarily for energy saving purposes.
The value of $SV_OFF_ENB is set by the KCL> UTILITY SINIT command and should
not be changed.
$SV_OFF_TIME (servo off time)

Power Up: Yes Default: 10000
$SV_OFF_TIME defines the time interval, in milliseconds, after which the servo motors
are shut down.
The value of $SV_OFF_TIME is set by the KCL> UTILITY SINIT command and should
not be changed.

6-121
$SV_OFF_TIME System Variable
See Also:
$SV_OFF_ENB System Variable in this appendix
$SYNC_GAIN (synchronous compensation gain)

Default: 20
$SYNC_GAIN defines the compensation gain for robot models with dual drive
(synchronous) control.
The value of $SYNC_GAIN is set by the KCL> UTILITY SINIT command and should
not be changed.
$SYNC_M_AXIS (synchronous master axis)

Default: 0
$SYNC_MWAXIS indicates which robot axis motor has been designated as the master axis
for robot models with dual drive (synchronous) control.
The value of $SYNC_M_AXIS is set by the KCL> UTILITY SINIT command and
$SYNC_OFFSET (synchronous compensation offset)

Default: 150
$SYNC_OFFSET defines the compensation offset for robot models with dual drive
The value of $SYNC_OFFSET is set by the KCL> UTILITY SINIT command and

6-122
$SYNC_S_AXIS System Variable
$SYNC_S_AXIS (synchronous slave axis)

Default: 0
$SYNC_S_AXIS indicates which robot axis motor has been designated as the slave axis for
robot models with dual drive, or synchronous, control.
The value of $SYNC_S_AXIS is set by the KCL> UTILITY SINIT command and should
not be changed.
$SYN_ADJ_MOD (synchronous adjust mode)

For robot models with dual drive (synchronous) control, $SYN_ADJ_MOD indicates
whether or not the synchronous adjust mode is enabled.
If it is TRUE, synchronous adjust mode is enabled and you can jog only the master or only
the slave motor. You cannot move any of the other axes while synchronous adjust mode is
enabled. If it is FALSE, you cannot jog the master and slave motors independently.
$SYN_ADJ_MOD should remain FALSE for all normal operation. If it is set to TRUE,
the robot loses its calibration and must be recalibrated after $SYN_ADJ_MOD is set back
to FALSE.
$SYN_ADJ_SEL (synchronous adjust selection)

For robot models with dual drive (synchronous) control, $SYN_ADJ_SEL indicates which
axis, either master or slave, is selected for synchronous adjust mode. If it is TRUE, the
slave axis is selected. If it is FALSE, the master axis is selected.
If you want to adjust the slave axis, you must set $SYN_ADJ_SEL to TRUE.

6-123
$SYN_ERR_CNT System Variable
$SYN_ERR_CNT (synchronous error counter)

$SYN_ERR_CNT is the value of the error counter for robot models with dual drive
$SYN_ERR_LIM (synchronous error limit)

Default: 1000
$SYN_ERR_LIM defines the error limit for robot models with dual drive (synchronous)
control.
The value of $SYN_ERR_LIM is set by the KCL> UTILITY SINIT command and
$TCPEXTREME (tool center point extreme)

STCPEXTREME can be used to indicate the x-extreme position of a path for rail tracking
(optional feature). STCPEXTREME is used to ensure that a path is not executed until this
extreme enters the lower boundary.
STCPEXTREME is set uninitialized each time a program is executed. Extreme checking
is performed only if STFRAMENUM is greater than 1.

6-124
STERMTYPE System Variable
$TERMTYPE (motion termination type)

Default: 2 (COARSE)
STERMTYPE defines the type of motion termination at the end of an interval using the
following values:
1 = FINE
2 = COARSE
3 = NOSETTLE
4 = NODECEL
5 = VARDECEL
The default value of STERMTYPE is set each time a program is executed.
See Also:
$TFRAMENUM (tracking frame number)

Minimum/Maximum: —4/3 Saved: No
Default: 0
STFRAMENUM is used by the motion environment to determine which tracking frame to

use for line tracking and dynamic path modification. If it is 0, SUFRAME is used for all
motions. The values 1, 2, and 3 specify tracking frames 1, 2. and 3. When used in
conjunction with dynamic path modification, the values determine the coordinate frame of
reference as listed in the following table:
STFRAMENUM SDELTAFRAME Coordinate Frame

-1 location World
-2 location + orientation World
-3 location User Frame
-4 location + orientation User Frame
STFRAMENUM is used only for motions caused by the KAREL interpreter. All KCL or
teach pendant motions are always relative to SUFRAME.
See Also:
SDELTAFRAME System Variable in this appendix

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$TP_USERSTAT System Variable
$TP_USERSTAT (teach pendant user status line)

$TP_USERSTAT indicates whether the KAREL system or the application program has
control of the teach pendant status line.
If $TP_USERSTAT is set to TRUE and a KAREL program is running or paused, the
system stops updating the status line, giving control to the program. The predefined
constant TPSTATUS can be used to write to the status line when $TP_USERSTAT is
TRUE.
If $TP_USERSTAT is set to FALSE the system automatically updates the status line. By
default, $TP_USERSTAT is set to FALSE each time a program is executed. It
automatically resets to FALSE when program execution ends or the program is aborted.
$TRK_AXSNUM (tracking auxiliary axis number)

$TRK_AXSNUM is used mainly for teaching positions for auxiliary axis tracking
applications (optional feature). Each element of $TRK_AXSNUM can be assigned an
auxiliary axis number. Then $AUX_ZROSHFT will be applied to the specified axis.
$TSPEED (TCP speed)

STSPEED is the tool center point (TCP) speed estimate. It is derived from the following
equation:
$TSPEED =$TSPEEDSCALE *estim_tcp_speed +STSPEEDOFST
(If STSPEEDSCALE = 1.0 and STSPEEDOFST = 0 then STSPEED is in mm/sec.)

6-126
STSPEED System Variable
The value of $TSPEED is set by the interpolator at the Cartesian update rate for the
current segment. The estimate is passed through the acceleration/deceleration algorithm, so
it will have approximately the same acceleration/deceleration profile as the joints.
See Also:
STSPEEDENBL System Variable in this appendix
$TSPEEDENBL (TCP speed enable)

STSPEEDENBL enables the TCP speed estimation. If it is FALSE, STSPEED is 0.

By default, the value of STSPEEDENBL is set to FALSE.
See Also:
STSPEED System Variable in this appendix
$TSPEEDOFST (TCP speed offset)

Data Tvpe: INTEGER Saved: No
STSPEEDOFST is used in calculating the value of STSPEED when you want STSPEED to
have a value other than zero when the robot is not moving.
You are responsible for setting the value of STSPEEDOFST.
See Also:
$TSPEEDSCALE (TCP speed scale)

Data Tvpe: REAL Saved: No
STSPEEDSCALE, a scaling factor, is used in calculating the value of STSPEED. It is

used to scale the value of STSPEED if mm/sec is not the desired unit.
You are responsible for setting the value of STSPEEDSCALE.
See Also:

6-127
STTOOLNUM System Variable
$TTOOLNUM (tracking tool frame number)

Minimum/Maximum: —4/2 Saved: No
Default: 0
STTOOLNUM is used to indicate how SDELTATOOL is to be applied. Its value

determines whether SDELTATOOL will be with respect to the tool coordinate system or
the path relative coordinate system (attached to the path trajectory). STTOOLNUM can
be set in a KAREL program. The values for STTOOLNUM, SDELTATOOL, and the
coordinate systems used are listed in the following table:
STTOOLNUM SDELTATOOL Coordinate System

1 location Tool
2 location + orientation Tool
0 none
-1 location Path Relative Frame
-2 location + orientation Path Relative Frame
-3 location Path Relative Frame
-4 location + orientation Path Relative Frame
See Also:
SDELTATOOL System Variable in this appendix
$UDIN_ENBL (user definable input enable)

SUDIN_ENBL enables the upper eight bits of the UOP (user operator panel) input module
for user-definable input. If it is FALSE, the upper eight bits of the input module can be
used for other user-defined input signals.
SUDIN_ENBL must be set to TRUE in order for the predefined command procedures
KCP_UOPl through KCP_UOP8 to be executed.

6-128
SUFRAME System Variable
$UFRAME (user frame)

Program/KCL: RW/RW Saved: Yes
Default: $NILP Backed Up: Yes
SUFRAME is the position of a user frame of reference. All programmed positions are
defined with respect to SUFRAME.
Any value you assign to SUFRAME is defined with respect to the world coordinate system.
By default, SUFRAME is identical to the world coordinate system, meaning SUFRAME
= SNILP.
Chapter 8, “Motion”
$UO_POLARITY (user operator panel polarity)

$UO_POLARITY indicates the polarity of user operator panel (UOP) signals. When the
decimal INTEGER is converted to a binary number, each bit of the $UO_POLARITY
value corresponds to a bit in the UOP output value.
If a bit is set to 0, the polarity of the signal is not changed. If a bit is set to 1, the polarity
is inverted.
$UPPERLIMS (upper joint limits)

Data Type: REAL ARRAY [9] Power Up: Yes
SUPPERLIMS defines the upper joint limits, in radians or millimeters.

The value of SUPPERLIMS is set by the KCL> UTILITY SINIT command and should

6- 129
SUSAT System Variable
$USAT (user signal assignment table)

Power Up: Yes Default: 0
SUSAT is an array that corresponds to the User Signal Assignment Table (USAT).
You are responsible for setting the value of SUSAT if you want to use user-definable input
and output.
See Also:
Chapter 13, KAREL Reference Manual for more information on the USAT
$USE_CAL (use calibration procedure)

SUSE_CAL enables or disables automatic calibration. If it is TRUE, automatic

calibration is executed when the operator panel CALIBRATE button is pressed.
If SUSE_CAL is FALSE, the current position of the robot is taken as the zero position for
all axes and the register values are returned to zero when you press the CALIBRATE
button. In this case, the normal calibration procedures are not used.
$USE_CARTACC (use cartesian acceleration) *

Saved: No Default: FALSE
By setting the system variable $USE_CARTACC, path accuracy can be improved for both
position and speed for Cartesian acceleration (optional feature). The improvement becomes
more noticable as speed increases. However, at very high speeds, the motion will not be as
smooth.
When $USE_CARTACC is TRUE, about 60% of the acceleration is performed in
Cartesian space (for example, in the direction of a line for linear motion or along the circle
for circular motion).
SUSE_CARTACC is set to FALSE every time a program is executed. The motion clause,
WITH $USE_CARTACC = TRUE or WITH $USE_CARTACC = FALSE, applies
only to that particular motion.

6-130
$USE_CONFIG System Variable
$USE_CONFIG (use configuration)

$USE_CONFIG indicates how the system handles Cartesian moves where the configuration
is inconsistent from one position to the next. For example, configurations having flip and
noflip configuration are inconsistent with one another.
If the value of $USE_CONFIG is TRUE the inconsistency causes an error that pauses the
program. If the value is FALSE, the motion is carried out, using the joint placement of
the beginning position.
For example, if $USE_CONFIG is FALSE and a move is from a position with a noflip
joint placement to one with a flip joint placement, noflip is used.
Configuration not only includes joint placement (flip, noflip) but also turn number. If
$USE_CONFIG is set to TRUE the turn number from the taught point will be applied to
determine the destination position. If $USE_CONFIG is set to FALSE the turn number
from the taught point will be ignored.
See Also:
$USEMAXACCEL (use maximum acceleration)

$USEM AX ACCEL enables or disables the fast acceleration/deceleration feature. If it is

TRUE the required acceleration time is linearly reduced to improve fast acceleration and
deceleration, reduce the percentage of comer rounding, and improve the cycle time. If it
is FALSE, the normal acceleration time is applied.
By default, $USEMAXACCEL is set to FALSE each time a program is executed.

6-131
$ USERELACCEL System Variable
$USERELACCEL (use relative acceleration)

Data Type: BOOLEAN Power Up:
Saved: Default:
Program/KCL: Backed Up:
If SUSERELACCEL is True, the desired motion will use the $ACCEL_OVRD and
RELACCEL values (optional feature). If $USERELACCEL is False, the acceleration
time defined in $ACCEL_OVRD will be ignored.
$USER_ALARM (user alarm)

Saved: No Default: FALSE
$USER_ALARM can be used to turn off servo power while switching the multiplex
auxiliary axes. If SUSER_ALARM is TRUE, die servo alarm error message, 4037 “User
servo alarm,” will be displayed, the servo power will be dropped and the program will
pause. You must set SUSER_ALARM to FALSE, and press the reset button or use the
RESET KCL command to reset the servo power.
The user alarm is generated by the software and will not affect the emergency stop contact
status.

6-132
$USER_PB1 System Variable
$USER_PB1 (user pushbutton 1) *

$USER_PB1 specifies the KCL command procedure that is executed when the operator
panel USER PB1 button is pressed. If the command procedure is not found, the system
will search for a p-code file of the same name as specified in $USER_PB1. If found in
RAM, this file will be executed. If it is found in bubble memory, the file will be loaded
before execution.
The command procedure is executed whether or not a KAREL program is running. You
are responsible for setting the value of $USER_PB1 if you want the USER PB1 button to
execute a command procedure.
See Also:
Enhanced KAREL Operations Manual for more information on setting $USER_PB1.
$USER_PB2 (user pushbutton 2) *

$USER_PB2 specifies the KCL command procedure that is executed when the operator
panel USER PB2 button is pressed. If the command procedure is not found, the system
will search for a p-code file of the same name as specified in SUSER_PB2. If found in
RAM, this file will be executed. If it is found in bubble memory, the file will be loaded
before execution.
The command procedure is executed whether or not a KAREL program is running. You
are responsible for setting the value of $USER_PB2 if you want the USER PB2 button to
execute a command procedure.
See Also:
Enhanced KAREL Operations Manual for more information on setting $USER_PB2.
$UTOOL (user tool)

Power Up: No Default: $NILP

6- 133
$UTOOL System Variable
$UTOOL defines the location and orientation of the tool that is attached to the faceplate.
The position in $UTOOL is defined with respect to a fixed coordinate system on the robot
faceplate and is the origin of the TOOL FRAME.
By default, the value of $UTOOL is set to $NILP, which means the position of the TCP is
identical to the location and orientation of the faceplate coordinate system.
You must change the value of $UTOOL to define the specific tool you are using.
See Also:
$VERSION_ID (version identifier)

Default: Software Specific Backed Up: No
$VERSION_ID identifies the KAREL software version currently in use. The

$VERSION_ID string appears on the POWER UP screen of the CRT.
The value of $VERSION_ID is set internally.
$WRIST_TYPE (wrist type)

$WRIST_TYPE defines the type of wrist and the number of robot axes used with that
wrist. The meanings associated with the values 0 through 9 depend on which robot is being
described.
The value of $WRIST_TYPE is set by the KCL> UTILITY SINIT command and should
not be changed.

6-134
S-10 SYSTEM VARIABLE DEFAULT VALUES
4.2 S-10 System Variable Default Values

Table 4.2. S-10 System Variable Default Values
S-10 Default Notes

Value
$ACCEL_TIMEirn 352
$ACCEL_TIME1|21 352
SACCEL_TIMElf31 352
SACCEL_TIMElf41 352
$ACCEL_TIME1[51 352
$ACCEL_TIME1[61 352
SACCEL_TIME2fll 32 Payload 1.0 kg
$ACCEL_TIME2f21 32 Payload < 1.0 kg
SACCEL_TIME2f31 32 Payload < 1.0 kg
SACCEL_TIME2r41 32 Payload < 1.0 kg
SACCEL_TIME2[51 32 Payload < 1.0 kg
SACCEL_TIME2f61 32 Payload < 1.0 kg
SACCEL_TIME2[1] ROUND {(payload/2.0)-0.4}*32 Payload > 1.0 kg
SACCEL_TIME2[21 ROUND {(payload/2.0)-0.4}*32 Payload > 1.0 kg
$ACCEL_TIME2[31 ROUND {(payload/2.0)— 0.4}*32 Payload > 1.0 kg
$ACCEL_TIME2f41 ROUND {(payload/2.0) -0.4}*32 Payload > 1.0 kg
SACCEL_TIME2[51 ROUND {(payload/2.0) -0.4j*32 Payload > 1.0 kg
SACCEL_TIME2f61 ROUND {(payload/2.0) -0.4}*32 Payload > 1.0 kg
SAPC_SYSTEM TRUE S-10 has APC system
SARM_TYPE
SAXISORDERfll 2 W
$AXISORDER[21 3 U
SAXISORDERpl 1 e
$AXISORDER[41 4 y
$AXISORDER[51 5 P
$AXISORDER[61 6 a
$BELT_ENABLE FALSE
$BRK_ON_HOLD FALSE
$CART_ACCEL1 224
$CART_ACCEL2 128
SCMRfl] 1 Command multiplier ratio
$CMRf21 1 Command multiplier ratio
$CMR[31 1 Command multiplier ratio
$CMR|41 1 Command multiplier ratio

6- 135
Table 4.2. S-10 System Variable Default Values (Continued)
S-10 Default Notes

Value
$CMRf51 1 Command multiplier ratio
$CMR[61 1 Command multiplier ratio
SCOARSETOLM 300 Detector pulses
$COARSETOLf2] 300 Detector pulses
$COARSETOLf31 300 Detector pulses
$CONFIG_MASK* -12160 11010000 10000000
SDMRfll 7 Detector multiplier ratio = 4
$DMR[21 7 Detector multiplier ratio = 4
SDMRM 7 Detector multiplier ratio = 4
$DMR[5l 7 Detector multiplier ratio = 4
SDMRM 7 Detector multiplier ratio = 4
SDYNAMICFLTR FALSE
SENCSCALESfU 154061.9849 484000/TT counts/rad
SENCSCALESf 21 194805.6503 612000/77- counts/rad
SENCSCALESM 133690.1522 420000/71 counts/rad
SENCSCALSEM 68118.31564 214000/77 counts/rad
$ENCSCALESf51 101859.1636 320000/7T counts/rad
SENCSCALESM 63661.97724 200000/77 counts/rad
$FB_MON_ENBrn TRUE
$FB_MON_ENB[2l TRUE
$FB_MON_ENB[31 TRUE
$FB_MON_ENB[4l TRUE
$FB_MON_ENBM TRUE
$FB_MON_ENBf61 TRUE
SFINETOLM 150 Detector pulses
$FINETOL[21 150 Detector pulses
SFINETOLM 150 Detector pulses
* Refer to $CONFIG_MASK in the System Variable Alphabetical Description of this

handout for definition of the SCONFIG_MASK bits.

6-136
S-10 Default Notes

Value
SFINETOLKl 150 Detector pulses
$FINETOLf61 150 Detector pulses
SGAINSfll 20
SGAINS121 20
$GAINSf31 20
$GAINS[41 20
$GAINSf51 20
$GAINS[6] 20
SGRIDfll 7 8000 pulses/rev
SGRIDRl 7 8000 pulses/rev
SGRIDP1 7 8000 pulses/re%~
$GRIDf41 7 8000 pulses/rev
SGRIDPI 7 8000 pulses/rev
$GRID[61 7 8000 pulses/rev
$JNTVELLIM[1] Depends on mounting angle (refer to the
formula that follows this lisp _
$JNTVELLIM[21 1.570796327 90 deg/sec
SJNTVELLIMpl 2.35619449 135 deg/sec
$JNTVELLIM[5] 4.188790205 240 deg/sec
$LINK_LEN_1 0.0
$LINK_LEN_2 0.0
$LOWERLIMS[l] -2.1617993878
_
Depends on mounting angle (refer to the
formula that follows this list)
SLOWERLIMSPI -0.785398163 -45 deg
SLOWERLIMSPI -2.530727415 -145 deg
$LOWERLIMSf4] -3.316125579 -190 deg
$LOWERLIMSPl
$LOWERLIMS[61
-2.443460953
-4.71238898
— 140 deg
-270 deg
$MASTER_POSm 0.0 Odeg
| $MASTERJPOSf 21 1.221730476 70 deg
| $MASTER_POS[31 -2.181661565 -125 deg

6-137
S-10 Default Notes

Value
$MASTER_POSf41 0.0 0 deg
$MASTER_POS[51 -0.959931088 -55 deg
$MASTER_POSr6] 0.0 0 deg
$MIN_ACCTIMErn 160
$MIN_ACCTIMEf21 160
$MIN_ ACCTIMEf 31 160
$MIN_ACCTIMEf4l 160
$MIN_ACCTIMEr51 160
$MIN_ACCTIMEf61 160
$MOT_SPD_LIM[l ] 2723 rpm (Depends on mounting angle. Refer
to the formula that follows this list.)
$MOT_SPD_LIM[21 2295 rpm
$MOT_SPD_LIMf31 3000 rpm (clamped to 3000 rpm)
$MO VERRLIMf 11 22692 max 2723 rpm, P Gain 20
SMOVERRLIMm 19125 max 2295 rpm, P Gain 20
$MOVERRLIM[31 25000 max 3000 rpm, P Gain 20
SMOVERRLIMRl 17833 max 2140 rpm, P Gain 20
$MOVERRLIM[5l 26666 max 3200 rpm, P Gain 20
$MOVERRLIM[6T 27775 max 3333 rpm, P Gain 20
$NUM_MIR 10
$NUM_ROB_AXS 6
$PPABN_EN ABL FALSE
SROTAR Y_ AXIS!11 TRUE
$ROTARY_AXISr21 TRUE
SROTARY.AXISm TRUE
$ROTARY_AXIS[61 TRUE
$SPIN_CTRL FALSE
SSTOPERLIMfll 500 Detector pulses
$STOPERLIM(21 500 Detector pulses

6- 138
S-10 Default Notes

Value
$STOPERLIMf31 500 Detector pulses
SSTOPERLIMf 4] 500 Detector pulses
SSTOPERLIMfol 500 Detector pulses
$STOPERLIMf6l 500 Detector pulses
$SV_OFF_ENBfll FALSE
$SV_OFF_ENBf2l FALSE
$SV_OFF_ENBf31 FALSE
$SV_OFF_ENBf4] FALSE
$SV_OFF_ENB[51 FALSE
$SV_QFF_ENB[61 FALSE
$SV_OFF_TIME 30000
$UPPERLLMS[1] 2.617993878
_
Depends on mounting angle (refer to the
formula that follows this list)
$UPPERUMS[2] 1.570796327 90 deg
$UPPERLIMS[31 2.094395102 120 deg
$UPPERLLMS[4] 3.316125579 190 deg
$UPPERLIMSr51 2.443460953 140 deg
$UPPERLIMS[61 4.71238898 270 deg

6-139
Formula for computing axis 1 range and joint velocity limit:
Let a be the mounting angle with respect to the horizontal,

and V2 = sqrt(2).
For 0 deg <= a <= 45 deg and 135 deg <= a <= 180 deg
UPPERLIMS = 150 deg

LOWERLIMS = -150 deg
JNTVELLIM = ROUND((130.8 - 58.8*V2*sin(a)) * 25 / 120) * 5 deg/sec
For 45 deg < a < 135 deg
UPPERLIMS = ROUND( ARCSIN(1/(V2 * sin(a))) / 15) * 15

LOWERLIMS = -UPPERLIMS
JNTVELLIM = ROUND( (130.8 - 58.8*ÿ/2*sin(UPPERLIMS)*sin(a)) * 25 / 120) * 5 deg/s
The following tables can be constructed using these formulas:
a (deg) 0 10 20 30 40 45
$UPPERLIMS (deg) 150 150 150 150 150 150
$LOWERLIMS (deg) -150 -150 -150 -150 -150 -150
$JNTVELLIM (deg/s) 135 120 105 95 80 75
a (deg) 50 60 70 80 90 100 110 120 130

$UPPERLIMS (deg) 60 60 45 45 45 45 45 60 60
$LOWERLIMS (deg) -60 -60 -45 -45 -45 -45 -45 -60 -60
$JNTVELLlM (deg/s) 80 70 80 75 75 75 80 70 80
a (deg) 135 140 150 160 170 180

$UPPERLIMS (deg) 150 150 150 150 150 150
$LOWERLIMS (deg) -150 -150 -150 -150 -150 -150
SJNTVELLIM (deg/s) 75 80 95 105 120 135

6- 140
Finally, convert degrees into radians

$UPPERLIMS[1] = UPPERLIMS * IT / 180 rad
$LOWERLIMS[1] = LOWERLIMS * IT / 180 rad
$JNTVELLIM[1] = JNTVELLIM * IT / 180 rad/sec
where IT = 3.141592654
Formula for computing $ACCEL_TIME2 for Axis 1 to 6:

For no load : $ACCEL_TIME2[1] to $ACCEL_TIME2[6] = 32
For payload = 1 kg : $ACCEL_TIME2[1] to $ACCEL_TIME2[6] = 32
For payload = 2 kg to 10 kg :
$ACCEL_TIME2[1] to $ACCEL_TIME2[6] = ROUND((payload/2) -0.4)*32
The following table can be constructed using these formulas:
Payload (kg) 0 1 234567 8 9 10

$ACCEL_TIME2[1] 32 32 32 32 64 64 96 96 128 128 160
to $ACCEL_TIME2[6]

6- 141

S-700 Default Notes

Value
$ACCEL_TIMEiril 384
$ACCEL_TIMElf21 384
$ACCEL_TIME1[31 384
$ACCEL_TIME1f 41 288
$ACCEL_TIMElf51 288
$ACCEL_TIMElf61 288
$ACCEL_TIME2f 1] 192
$ACCEL_TIME2[2l 192
$ACCEL_TIME2f31 192
$ACCEL_TIME2f4l 128
$ACCEL_TIME2f51 128
$ACCEL_TIME2[61 128
$APC_SYSTEM TRUE
$AXISORDERf 1] 2 W
$AXISORDERr2l 3 U
$AXISORDERf3l 1 e
$AXISORDER[4l 6 a
$AXISORDER[51 5 (B
$AXISORDER[61 4 7
$BELT_ENABLE FALSE
$BRK_ON_HOLD FALSE
$CART_ACCEL1 224
$CART_ACCEL2 128
SCMRTjj 1 Command multiplier ratio = 1
$CMR[2l 1 Command multiplier ratio = 1
$CMRf31 1 Command multiplier ratio = 1
$CMR[4l 1 Command multiplier ratio = 1
$CMR[5l 1 Command multiplier ratio - 1
$CMRf61 1 Command multiplier ratio == 1
SCO ARSETOLf 11 300 Detector pulses
$COARSETOL[2l 300 Detector pulses
SCOARSETOLPl 300 Detector pulses
$COARSETOL[51 300 Detector pulses

6-142
S-700 Default Notes

Value
$COARSETOL[6] 300 Detector pulses
$CONFIG_MASK* -12160 11010000 10000000
SDMRfl] 7 Detector multiplier ratio = 4
$DMRf2] 7 Detector multiplier ratio = 4
$DMRf3l 7 Detector multiplier ratio = 4
SDMRKI 7 Detector multiplier ratio - 4
SDMRfcl 7 Detector multiplier ratio = 4
SDYNAMICFLTR FALSE
SENCSCALESfll 164247.9013 516000/IT counts/rad
$ENCSCALESr2] 162974.6617 512000/TT counts/rad
$ENCSCALESf31 186741.7999 1760000/3TT counts/rad
SEN CSCALES[ 41 122830.1678 6560000/17— counts/rad
SENCSCALEST51 122230.9963 384000/-!. counts/rad
$ENCSCALESr61 91265.81056 7168000/25TT counts/rad
$FB_MON_ENBm TRUE
$FB_MON_ENBf2l TRUE
$FB_MON_ENBf31 TRUE
$FB_MON_ENBr41 TRUE
$FB_MON_ENB[5l TRUE
$FB_MON_ENB[61 TRUE
SFINETOLfH 150 Detector pulses
$FINETOL[2l 150 Detector pulses
$FINETOLf3l 150 Detector pulses
SFINETOLjSI 150 Detector pulses
$FINETOL[6] 150 Detector pulses
SGAINSfll 20
$GAINS[21 20
SGAINSPI 20
* Refer to $CONFIG_M$ASK in the System Variable Alphabetical Description of this

handout for definition of the $CONFIG_MASK bits.

6-143
S-700 Default Notes

Value
$GAINSf41 20
$GAINSr51 20
$GAINSr61 20
SGRIDrn 7 means 8000 pulses/rev
$GRIDf2l 7 means 8000 pulses/rev
SGRIDpl 7 means 8000 pulses/rev
$GRIDf4l 7 means 8000 pulses/rev
$GRID[51 7 means 8000 pulses/rev
$GRIDf61 7 means 8000 pulses/rev
$JNTVELLIMf 1] 2.094395102 120 deg/sec
$JNTVELLIMf 31 1.832595715 105 deg/sec
SJNTVELLIMM 3.141592654 180 deg/sec
$JNTVELLIMf51 3.141592654 180 deg/sec
$LINK_LEN_1 0.0
$LINK_LEN_2 0.0
SLOWERLIMSrn -2.617993878 -150 deg
$LOWERLIMSf21 -1.570796327 -90 deg
$LOWERLIMSf31 -2.094395102 -120 deg
$LOWERLIMSf41 -3.316125579 -190 deg
$LOWERLIMSf51 -2.094395102 -120 deg
$LOWERLIMSf61 -4.71238898 -270 deg
$MASTER_POSm 0.0 0 deg
$MASTER_PQSf2l 1.047197551 60 deg
$MASTER_POSf31 -1.919862177 -110 deg
$MASTER_POSf 4] 0.0 Odeg
$MASTER_POSf5l -1.221730476 -70 deg
$MIN_ACCTIMEfll 160
$MIN_ACCTIMEf21 160
$MIN_ACCTIMEf31 160
$MIN_ACCTIMEf41 160
$MIN_ACCTIMEf5l 160

6-144
S-700 Default Notes

Value
$MIN_ACCTIMEr61 160
$MOT_SPD_LIMf 11 2580 rpm
$MOT_SPD_LIM[2] 2258 rpm
$MOT_SPD_LIM[31 3000 rpm (clamped to max. 3000 rpm)
$MQT_SPD_LIM|4] 2932 rpm
$MQT_SPD_LIM[51 2932 rpm
SMOVERRLIMm 22360 gain of 20
$MOVERRLIMf2l 19413 gain of 20
SMOVERRLIMm 26000 gain of 20
$MOVERRLIM[41 24434 max 2932 rpm, gain of 20
$MOVERRLIM[5 1 24434 max 2932 rpm, gain of 20
$NUM_MIR 10
$NUM_ROB_AXS 6
$PPABN_ENABL FALSE
$RQTARY_AXISfll TRUE
$ROTARY_AXISf2l TRUE
$ROTARY_AXISf51 TRUE
$SPIN_CTRL FALSE
SSTOPERLIMf 11 500 Detector pulses
$STOPERLIM[2l 500 Detector pulses
$STOPERLIM|31 500 Detector pulses
$STOPERLIM[41 500 Detector pulses
$SV_OFF_ENBm FALSE
$SV_OFF_ENB|2] FALSE
$SV_OFF_ENB[31 FALSE
$SV_OFF_ENBf4l FALSE
$SV_OFF_ENB[5l FALSE

6- 145
_
S-700 Default Notes

Value
$SV_OFF_TIME 10000
SUPPERLIMSfll 2.617993878 150 deg
$UPPERLIMSf21 1.570796327 90 deg
$UPPERLIMSf4l 3.316125579 190 deg
$UPPERLIMSr51 2.094395102 120 deg
SUPPERLIMSf61 4.71238898 270 deg

6-146

S-700 Default Notes

Value
$ACCEL_TIMEim 384
$ACCEL_TIME1[21 384
$ACCEL_TIME1[31 384
$ACCEL_TIMElf41 288
$ACCEL_TIMElf51 288
$ACCEL_TIME1|61 288
$ACCEL_TIME2fl1 192
$ACCEL_TIME2[21 192
$ACCEL_TIME2f31 192
$ACCEL_TIME2f4l 128
$ACCEL_TIME2f51 128
$ACCEL_TIME2[61 128
$APC_SYSTEM TRUE
SAXISORDERfU 2 W
$AXISORDERf21 I 3 U
$AXISORDER[31 1 9
SAXISORDERDl 6 a
SAXISORDERpl 5
$AXISORDER[61 4 y
$BELT_ENABLE FALSE
$BRK_ON_HOLD FALSE
$CART_ACCEL1 224
$CART_ACCEL2 128
SCMRfll 1 Command multiplier ratio =1
$CMRf21 1 Command multiplier ratio = 1
$CMR[3] 1 Command multiplier ratio = 1
$CMR|4] 1 Command multiplier ratio = 1
$CMR[5] 1 Command multiplier ratio = 1
SC MR [61 1 Con i mand multiplier ratio = 1
SCOARSETOLI 1 1 300 Detector pulses
$COARSETOL[3l '300 Detector pulses
$COARSETOL[4] 300 Detector pulses
SCOARSETOLI 5] 300 Delector pulses
Software Version 2.0

6 - 147
S-700 Default Notes

Value
$COARSETOLf61 300 Detector pulses
$COND_TIME 32
$CONFIG_MASK* -12160 11010000 10000000
$DMR|T1 7 Detector multiplier ratio = 4
$DMRf21 7 Detector multiplier ratio = 4
$DMRf4l 7 Detector multiplier ratio = 4
SDYNAMICFLTR FALSE
SENCSCALESm 164247,9013 516000/ir counts/rad
$ENCSCALES[21 162974.6617 512000/TT counts/rad
$ENCSCALESf31 186741.7999 1760000/3-ir counts/rad
$ENCSCALESf41 122830.1678 6560000/17-rr counts/rad
$ENCSCALES[51 122230.9963 384000/TT counts/rad
$ENCSCALESf61 91265.81056 7168000/25-rr counts/rad
$FB_MON_ENB|Yl TRUE
$FB_MON_ENB[2l TRUE
$FB_MON_ENBr31 TRUE
$FB_MON_ENB[4] TRUE
$FB_MON_ENBf5l TRUE
$FB_MON_ENBf61 TRUE
SFINETOLfH 150 Detector pulses
$FINETOLf2l 150 Detector pulses
$FINETOLf31 150 Detector pulses
$GAiNsrn 20
$GAINSf2l 20
$GAINSr3l 20
* Refer to $CONFIG_M$ASK in the System Variable Alphabetical Description of this

handout for definition of the $CONFIG_MASK bits.

6 - 148
_ SYSTEM VARIABLE DESCRIPTIONS
S-700 Default Notes

Value
$GAINSf4l 20
$GAINSf51 20
$GAINS[61 20
SGRIDfll 7 means 8000 pulses/rev
SGRIDPI 7 means 8000 pulses/rev
$GRIDf4] 7 means 8000 pulses/rev
$GRID[51 7 means 8000 pulses/rev
SJNTVELLIMfH 2.094395102 120 deg/sec
$JNTVELLIMf4l 3.141592654 180 deg/sec
$JNTVELLIMf5l 3.141592654 180 deg/sec
$JNTVELLIM[6l 4.188790205 240 deg/sec
$LINK_LEN_1 0.0
$LINK_LEN_2 0.0
$ LOWERLIMSf 11 -2.617993878 -150 deg
$LOWERLIMS[2l -1.570796327 -90 deg
$LOWERLIMSf 31 -2.094395102 -120 deg
$LOWERLIMSf4l -3.316125579 -190 deg
SLOWERLIMSfSl
$LOWERLIMSf61
-2.094395102
-4.71238898
— 120 deg
-270 deg
$MASTER_POSm 0.0 0 deg
$MASTER_POS[2l 1.047197551 60 deg
$MASTER_POSf31
$MASTER_POSf4l
-1.919862177
0.0
— 110 deg
0 deg
$MASTER_POS[5l -1.221730476 -70 deg
$MIN_ACCTIMEfll 160
$MIN_ACCTIMEf21 160
$MIN_ACCTIME[31 160
$MIN_ACCTIMEf4] 160
$MIN_ACCTIMEf51 160

6 - 149
S-700 Default Notes

Value
$MTN_ACCTIMEf61 160
$MOT_SPD_LIMfl1 25S0 rpm
$MOT_SPD_LIMr2l 2258 rpm
$MOT_SPD_LIMf 31 3000 rpm (clamped to max. 3000 rpm)
$MOT_SPD_LIMf4l 2932 rpm
$MOT_SPD_LIMf51 2932 rpm
$MOT_SPD_LIMf61 2944 rpm
SMOVERRLIMril 22360 gain of 20
$MOVERRLIM[21 19413 gain of 20
$MOVERRLIMf31 26000 gain of 20
$MOVERRLIMf4l 24434 max 2932 rpm. gain of 20
$MOVERRLIMf 5] 24434 max 2932 rpm, gain of 20
$NUM_MIR 10
$NUM_ROB_AXS 6
SPPABNJENABL FALSE
$ROTARY_AXISfll TRUE
$ROTAR Y_AXISf31 TRUE
$ROTARY_AXISf4] TRUE
$SPIN_CTRL FALSE
SSTOPERLIMfll 500 Detector pulses
$STOPERLIMf41 500 Detector pulses
$STOPERLIMr61 500 Detector pulses
$SV_OFF_ENBril FALSE
$SV_OFF_ENBr31 FALSE

6- 150
S-700 Default Notes

Value
$SV_QFF_T1ME 10000
$ UPPERLIMSf11 2.617993878 150 deg
$UPPERLIMSf2l 1.570796327 90 deg
$UPPERLIMSf41 3.316125579 190 deg
SUPPERLIMSfSl 2.094395102 120 deg

6 - 151
f
Revision Record
S-10/S-700 MAINTENANCE REFERENCE MANUAL (B-67395E-G)
04 12-7-89 Section added on Absolute Pulse Coder.

Supplement issued.
03 6-6-89 Appendix 4 revised 6-6-89.

Warning added for Transporting.
02 12-88 Appendix 4 added on 12-5-88.
10-88 Changes made on pages 6-19 and

6-32
05 5-93 Changes made in original and supplement issued.

01 ’88,8
Edition Date Contents Edition Date Contents

f.
r •
>
r-
r.
M -
t-
ir
S-10/S-700 Maintenance and
Troubleshooting Reference Manual
Addendum
MARXMS17H0884EF
Addendum to die S-10/S-700 Maintenance

and Troubleshooting Reference Manual
MARMKS17H0885EF
This publication contains proprietary information of the FANUC Robotics

North America, Inc., furnished for customer use only. No other uses are
authorized without the express written permission of FANUC Robotics
North America, Inc.
The description and specifications contained in this manual were in effect
at the time this manual was approved for printing. FANUC Robotics
North America, Inc, hereinafter referred to as FANUC Robotics, reserves
the right to discontinue models at any time or to change specifications or
design without notice and without incurring obligations.
FANUC Robotics manuals present descriptions, specifications, drawings,
schematics, bills of material, parts, connections and/or procedures for
installing, disassembling, connecting, operating and programming FANUC
Robotics’ products and/or systems. Such systems consist of robots,
extended axes, robot controllers, application software, the KAREL®
programming language, INSIGHT® vision equipment, and special tools.
FANUC Robotics recommends that only persons who have been trained in
one or more approved FANUC Robotics Training Course(s) be permitted
to install, operate, use, perform procedures on, repair, and/or maintain
FANUC Robotics’ products and/or systems and their respective
components. Approved training necessitates that the courses selected be
relevant to the type of system installed and application performed at the
customer site.
A WARNING
This equipment generates, uses, and can radiate radio
frequency energy and if not installed and used in
accordance with the instruction manual, may cause
interference to radio communications. As temporarily
permitted by regulation, it has not been tested for
compliance with the limits for Class A computing devices
pursuant to subpart J of Part 15 of FCC Rules, which are
designed to provide reasonable protection against such
interference. Operation of the equipment in a residential
area is likely to cause interference, in which case the user,
at his own expense, will be required to take whatever
measure may be required to correct the interference.
FANUC Robotics conducts courses on its systems and products on a

regularly scheduled basis at its headquarters in Auburn Hills, Michigan.
For additional information contact
Training and Documentation Department
Tel: (313)377-7234
FAX: (313)377-7367 or (313)377-7362
Copyright ©1993 by FANUC Robotics North America, Inc.
All Rights Reserved
The information illustrated or contained herein is not to be reproduced

copied, translated into another language, or transmitted in whole or in part
in any way without the prior written consent of FANUC Robotics North
America, Inc.
KAREL® and INSIGHT® are Registered Trademarks of FANUC

Robotics.
FANUC Robotics reserves all proprietary rights, including but not limited
to trademark and trade name rights, in the following names:
ACCUFLOW®
ARC Mate®
ARC Mate Sr.®
ArcTool ®
DispenseTool®
IntelliTrak®
LaserTool®
MotionParts®
PALLETMAIE®
PalletTool®
PaintTool®
PaintWorks®
R-Model J Controller®
Sockets®
SoftParts®
SpotTool®
SureWeld®
TurboMove®
The attached pages contain the most recent updates. Please keep this
addendum with the S-10/S-700 Maintenance and Troubleshooting
Reference Manual, part number MARMKS17H0885EF.
CMOS RAM BOARD ( A16B-2200-0760 , 0761 , 0762 )
Theory of Operation
The CMOS RAM board, also called the CMOS Data Memory PCB, IC File
PCB , CMOS Memory PCB, and CMOS RAM PCB, is a non-volatile
mass-storage device. ,It is an alternative to the bubble memory
board and performs the same functions as the bubble memory board,
except as noted in this supplement.
CMOS RAM provides faster data access speed, resulting in
•Faster
Improved power-on time (approximately 2X faster)
•Slightlyapplication/user software loading to RAM
• faster access for file operations
CMOS RAM and bubble memory cannot be mixed in a controller.
Part Numbers
A16 B- 2200-0760 2 Mbyte capacity
A16 B- 2200-0761 1 Mbyte capacity
A16B-2200-0762 512 Kbyte capacity
Capacity Limitations
Only two CMOS RAM boards can be installed in an R-H controller.

This limits the maximum amount of storage to four MBytes.
Power Source
Unlike the bubble memory board, the CMOS RAM board must have DC
power supplied to it at all times, in order to retain stored
data .
When the controller is turned off, power is provided by the same
battery unit that powers the CMOS RAM chips on the path CPU board.
Battery life varies with the total amount of CMOS RAM in the
controller, and the percentage of time that the controller is
turned on.
The worst case condition is with 4 Mbytes of CMOS RAM present

(this is the maximum amount that the controller can accomodate)
and the controller never turned on. In this case, the batteries
would be exhausted after about 220 days.
Under most circumstances, the batteries will last well past the
specified annual replacement,
A capacitor mounted on the CMOS RAM board stores sufficient

charge to maintain memory for about 30 minutes if the board is
removed from the controller or if the batteries are removed while
the controller is turned off.
Connector/Signal Identification
CA27 is a connector on the front edge of the board. It allows

you to attach an R-H Battery Pack ( A98L-0004-0096 ) (Batteries
A98L-0 031-0005 ) with Power Cord ( A660-8005-T927/L2R703 , or
XGMF-04226) if you need to store the board outside of the controller
for longer than 30 minutes.
The connector on the controller battery unit can be plugged

directly into this connector if necessary.
1 VB VB: + Battery
2 0V 0V: - Battery
3 VB
Connector CNA connects the CMOS RAM board to the Backplane PCB.
It has the same configuration as connector CNA of the bubble
memory board.
Lights and Indicators
The CMOS board has a block of four red LEDs, similar to those on the
CPU and shared RAM boards.
They are laid out in the following configuration:
<§> ©
(D ©
LED "A” is a parity alarm lamp, providing the same type of
information as those on the other boards.
LED "D" is a low battery voltage indicator lamp, providing the
same information as LED "D" on the shared RAM board.
LEDs "B" and "C" are not used.
Other Indicators
Operator's Panel User LED # 2 is reassigned as a low battery

indicator lamp and acts as a repeater for the low battery LEDs on
the CMOS RAM and shared RAM boards- It is labelled "BATTERY LOW"
on controllers that use CMOS RAM boards, and the color of the
LED has been changed from green to red. The LED lights when battery
voltage is low or absent.
The "10017 BACKUP BATTERY LOW VOLTAGE" message on the CRT and teach
pendant also indicates that battery voltage is low or absent.
When battery voltage is low, GMFanuc recommends replacing the

batteries before powering down the controller.
Test Points
Two test pins are mounted on the front edge of the board. They
allow you to measure the battery voltage applied to the board.
TESl 0
GND2 0
TESl Approximately +4.5 VDC
GND2 0 VDC
Removal/Replacement
01P0S/01P15
s
r\ BaekpUnePCB
0
c
I) Procedure t
©.
8 Detach PCB by loosening the
Mount new PCB.
screws
Caution
Do not keep the board out of the controller for longer than 30
minutes without connecting an external battery pack to connector
CN27. Otherwise, all data stored on the board could be lost.
J
1. Detach The PCB by loosening the screws (1)

1
2. Mount new PCB
I-

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FANUC Robot S-10/S-700

Maintenance and Troubleshooting

This publication contains proprietary information of FANUC Robotics

FANUC Robotics conducts courses on its systems and products on a

The information illustrated or contained herein is not to be reproduced

KAREL® and INSIGHT® are Registered Trademarks of FANUC

FANUC Robotics Hotline

For all other Troubleshooting and Technical Support

I. OVERVIEW AND CONTROLLER MAINTENANCE

3. CONTROLLER DESCRIPTIONS 1-8

4. PREVENTIVE MAINTENANCE 1-36

6. BACKPLANE PCB (A2 0B-10 02-0860)

7. POWER SUPPLY UNIT (A20B-1000-0770) 1-66

8. MAIN CPU BOARD (A16B-1211-0040, 0041) 1-76

9. PATH CPU BOARD (A16B-1211-0030)

10. SHARED RAM BOARD (A16B-12 11-0860) 1-89

11. BUBBLE MEMORY BOARD (A16B-1211-0090, 0091, 0092) 1-97

12. AXIS CONTROL BOARD (A16B-1211-0060, 0062) 1-102

13. REMOTE CRT /KB (A13B-0144-BOO1) 1-112

14. BUILT-IN CRT/KB (A05B-2051-J101, J102) ... 1-121

15. I/O BASE UNIT (A03B-0801-C012) 1-134

16. ROBOT CONTROL MODULE (A03B-0801-C462) 1-137

17. DI MODULE 1-147

18. DO MODULE . 1-152

19. ANALOG INPUT MODULE (A03B-0801-C410) 1-162

20. ANALOG OUTPUT MODULE (A03B-0801-C411) 1-168

21. FIXED I/O BOARD (A16B-12 11-0750) . 1-176

22. TEACH PENDANT (A05B-2051-C142) 1-181

23. POWER INPUT UNIT 1-192

24. TRANSFORMERS 1-212

25. HOUR METER 1-215

26. SERVO AMPLIFIER . 1-216

27. OPERATOR'S PANEL 1-248

28. BATTERY UNIT 1-254

29. OUTLET UNIT AND GROUND CONNECTED LAMP 1-255

30. SERVO-ON RELAY UNIT AND SERVO-ON LAMP 1-256

31. FAN UNIT . 1-258

II. S-10 MECHANICAL UNIT MAINTENANCE

5. REPLACING AND ADJUSTING PARTS 2-29

6. WIRING AND PIPING . 2-43

7. REPLACING CABLES 2-45

III. S-700 MECHANICAL UNIT MAINTENANCE

2. LUBRICATING CONDITION CHECK 3-11

5. REPLACING PARTS 3-49

6. WIRING AND PIPING . 3-60

7. REPLACING CABLES 3-64

2. SAFETY PRECAUTIONS .. 4-2

3. CONTROLLER CONNECTIONS AND SIGNALS 4-5

4. S-10 MECHANICAL UNIT 4-61

5. S-700 MECHANICAL UNIT 4-74

1. S-10 ROBOT . 5-1

2. S-700 ROBOT 5-9

3. ADJUSTMENTS AND CHECKS DURING INSTALLATION 5-21

4. INITIAL START UP 5-29

APPENDIX 1. INTERNAL CONNECTIONS . 6-1

APPENDIX 2. CABLE SPECIFICATIONS 6-42

APPENDIX 3. PREVENTIVE MAINTENANCE SCHEDULES 6-53

APPENDIX 4. SYSTEM VARIELE ALPHABETICAL DESCRIPTIONS

CRT/KB pud Operator** pud

S-10 mechanical unit S-700 mechanical unit S-700 mechanical unit

1.2 Problem Conditions and Determining Causes

1.2.1 Making preliminary check

Note the following:

2.1.3 Teacher afety precaution