Modatek Level 2 Robot

Training
 Course Overview
Day 1

Equipment Overview
Safety Review
Fault Overview
Power Flow
On/Off Control
Class 1 Fault Troubleshooting
Day 2

CPU Overview
Class 2 Fault Troubleshooting
File Manipulation
Servo Loop Discussion
Robot mastering
Day 3

Servo Amplifier
E-stop Circuitry
Class 3 Troubleshooting
I/O
Day 4

General Mechanical Overview

100i, 120iB Overview
R2000 Overview
120iB/R2000 Hands On
Day 5

120iB/R2000 Hands On
Mastering
Post Test
SYSTEM OVERVIEW
Robot Overview
R-J3i B Controller
R-J3i A Controller
R-J3i A Controller

SOP Board

Panel Board

Controller Disconnect

HSSB Fiber Optic

R-J3i A Standard Operator
Panel
R-J3i A Controller Internal
Components
R-J3i A Controller Internal
Components
R-J3i B Standard Operator Panel

SOP Board

Panel Board

Fan
220 VAC
Single Phase
R-J3i B Controller Internal
Components
6 Axis Servo Amp

Disconnect

Main CPU

Estop PCB

Power Supply

Backplane
R-J3i B Controller Internal
Components

Regenative Discharge Unit Transformer

 Safety Review
Staying Safe While Teaching or Manually Operating the Robot

Advise all personnel who must teach the robot or otherwise manually operate the robot to
observe the following rules:

Before teaching, visually inspect the robot and work envelope to make sure that no
potentially hazardous conditions exist. The work envelope is the area defined by the
maximum motion range of the robot. These include tooling attached to the wrist
flange that extends this range.
The area near the robot must be clean and free of oil, water, or debris.
Only the person with the teach pendant should be in the work envelope.
Know the path that can be used to escape from a moving robot; make sure the
escape path is never blocked.
Test any program being run for the first time in the following manner:
 Using a low motion speed, single step the program for at least one full cycle.
 Using a low motion speed, test run the program continuously for at least one full cycle.
 Using the programmed speed, test run the program continuously for at least one full cycle.
Make sure all personnel are outside the work envelope before running production.
 Staying Safe During Inspection

When inspecting the robot, be sure to

Turn off power at the controller.
If robot motion is not needed for inspecting the electrical
circuits, press the EMERGENCY STOP button on the
operator panel.
If power is needed to check the robot motion or electrical
circuits, be prepared to press the EMERGENCY STOP
button, in an emergency.
Be aware that when you remove a servomotor or brake,
the associated robot arm will fall if it is not supported or
resting on a hard stop. Support the arm on a solid
support before you release the brake.
Staying Safe During Maintenance

When performing maintenance on your robot system,

observe the following rules:
Never enter the work envelope while the robot or a
program is in operation.
Before entering the work envelope, visually inspect the
workcell to make sure no potentially hazardous
conditions exist.
Never wear watches, rings, neckties, scarves, or loose
clothing that could get caught in moving machinery.
Consider all or any overlapping work envelopes of
adjoining robots when standing in a work envelope.
Test the teach pendant for proper operation before
entering the work envelope.
If it is necessary for you to enter the robot work envelope
while power is turned on, you must be sure that you are
in control of the robot. Be sure to take the teach pendant
with you, press the DEADMAN switch, and turn the
teach pendant on. Be prepared to release the
DEADMAN switch to turn off servo power to the robot
immediately.
Whenever possible, perform maintenance with the power
turned off. Before you open the controller front panel or
enter the work envelope, turn off and lock out the 3-
phase power source at the controller.
Be aware that when you remove a servomotor or brake,
the associated robot arm will fall if it is not supported or
resting on a hard stop. Support the arm on a solid
support before you release the brake.
Warning
Lethal voltage is present in the controller
WHENEVER IT IS CONNECTED to a power
source. Be extremely careful to avoid electrical
shock.HIGH VOLTAGE IS PRESENT at the
input side whenever the controller is connected
to a power source. Turning the disconnect or
circuit breaker to the OFF position removes
power from the output side of the device only.

Release or block all stored energy. Before

working on the pneumatic system, shut off the
system air supply and purge the air lines.
Isolate the robot from all remote control signals. If
maintenance must be done when the power is on,
make sure the person inside the work envelope
has sole control of the robot. The teach pendant
must be held by this person.
Make sure personnel cannot get trapped between
the moving robot and other equipment. Know the
path that can be used to escape from a moving
robot. Make sure the escape route is never
blocked.
Use blocks, mechanical stops, and pins to prevent
hazardous movement by the robot. Make sure that
such devices do not create pinch points that could
trap personnel.
Warning
Do not try to remove any mechanical component from the
robot before thoroughly reading and understanding the
procedures in the appropriate manual. Doing so can result in
serious personal injury and component destruction.

Be aware that when you remove a servomotor or brake, the

associated robot arm will fall if it is not supported or resting on
a hard stop. Support the arm on a solid support before you
release the brake.
When replacing or installing components, make sure dirt and
debris do not enter the system.
Use only specified parts for replacement. To avoid fires and
damage to parts in the controller, never use nonspecified
fuses.
Before restarting a robot, make sure no one is inside the work
envelope; be sure that the robot and all external devices are
operating normally.
 Lab Assignment 1
Identify Major Components
Fault Classification Overview

Class 1 Fault
Class 2 Fault
Class 3 Fault
Class 4 Fault
Class 1 Fault Overview
Symptoms
● Dead controller/teach pendant screen is blank

Potential Causes
● Problem with AC power to controller
● Circuit Breaker
● Transformer
● Problem with controller DC power circuit
● Teach pendant/cable problem
● Problem with power supply unit
● Problem with the On/Off circuit
● Cables
Class 2 Fault Overview

Symptoms
● Teach pendant locked up, no response

Potential Causes
● Corrupt software
● CPU/DRAM module
● FROM/SRAM module
● Teach pendant/cable problem
● Problem with power supply unit or backplane
Class 3 Fault Overview
Symptoms
● Fault light is on
● KM1 and KM2 are off, no power to servos
● Diagnostic message displayed on screen

Potential Causes
● Servo amp
● Motors/SPC’s
● Emergency stop circuit
● Emergency stop circuit board
● Emergency stop unit including KM1 and KM2
● Panel board
● Cables
Class 4 Fault Overview

Symptoms
● Robot will run only when cell interface is not required
● Can run programs from the teach pendant

Potential Causes
● No comm with PLC, weld controller, etc.
● Faulty limit switch, prox., etc.
Fuse Based Troubleshooting
Power Supply Fuse Locations

F1: Fuse for AC input

F3: Fuse for +24 E
F4: Fuse for +24 V
Class 1 Fault Troubleshooting
● Symptoms review
● Dead controller/teach pendant screen is blank

● Potential Causes review

● Problem with AC power to controller
● Circuit Breaker
● Transformer
● Problem with controller DC power circuit
● Teach pendant/cable problem
● Problem with power supply unit
● Problem with the On/Off circuit
● Cables
Transformer Wiring Diagram
Transformer Location
Power Supply Unit
Fuse F1 CP1 220 VAC in

CP2 and CP3 220 VAC out

Fuse F3 24E

Fuse F4 24V

PIL LED

CP5 24V
CP6 24E

CP4 ON/OFF and Alarm Circuit

ALM LED
On/Off Circuit Diagram
Troubleshooting by LEDs on
Power Supply Unit
 Panel Board
TBOP3 CRM64
External On/Off 24V & Estop

TBOP4 JRS11
Estops and other HSSB
External circuits TP&On/Off

CRT9 TBOP6
Mode Select Estop relay
Switch outputs

CRM65 CRP5
Non teach Hour meter
Enable device
CRS16
CRT8 TP
Push-buttons
And LEDs CRM62
Robot Disconnect
 Panel Board
D1 & D2
SVON 1&2
Fuse F1
External 24V
Fuse 2
TP 24V

RDY LED
PON LED Com with
5V power Main board

CRM63
Optional Digital
Input
Troubleshooting by LEDs on Panel Board
24V Power Flow
 Backplane

Option Board Fan (24V)

(ArcLink, Process
I/O)

Power Supply

Main Board
 Lab Assignment 2
Use a fault code to determine which
fuse has blown
 Lab Assignment 2b
Remove and Replace the Panel Board.
 Lab Assignment 3

Use the symptom to determine the

class of fault

Use a knowledge of lights and LEDs to

determine the class of the fault
 Class 2 Fault
Symptoms
● Teach pendant locked up, no response
Potential Causes
● Corrupt software
● CPU/DRAM module
● FROM/SRAM module
● Teach pendant/cable problem
● Problem with power supply unit or
backplane
Class 2 Fault Troubleshooting
● Cold start the controller
● Re-seat all circuit boards
● Check LED indicators
● Swap/replace TP and/or cable if necessary
● Replace plug-in chips on Main board if
available
● Reinstall software
● Replace Main Board
● Replace PSU
Main Board
CP8 Battery JRL5
High Speed Digital Input

JD5A and JD5B

RS232

JD17
RS232C & RS485

JD1A
Fanuc I/O

JRS11
HSSB to Panel PCB

TBDL Model B

COP10B FSSB

CD38 Ethernet
Main Board

Battery
3V Lithium

7 Segment Display

Status LEDs

Ethernet Status LEDs

Main Board LED Indicators
Main Board – 7 Segment LED Indicators
 BACKING UP AND RESTORING
FILES
SETTING THE DEFAULT DEVICE

Setting the default device specifies which device to use when manipulating
programs and files. You must set the default device before you can perform
any program or file manipulations, including formatting a memory card. The
following devices are allowed, if available:

Serial printer - A serial printer connected to a controller port.

Flash File Storage disk (FR:) - Built-in storage for controller system files.

Memory card (MC:) - Displayed if the memory card interface is installed.

Memory device (MD:) - Treats the controller’s program memory as if it were

a file device.
BACKING UP AND RESTORING
FILES
RAM disk - specified by RD:.

Floppy disk - A floppy disk drive connected to a controller port,

such as the PS-100, PS-110, or PS-200.

Memory file device (MF:) - A composite device that searches

the RAM disk (RD:) and flash file storage disk (FR:) devices, in
that order, for a specified file.

F-ROM Device (FRD:) (for use only with the Controller Version
Upgrade option)
 BACKING UP FILES

When you back up a file you save it from controller memory to a storage device so that you have a
second copy of the file.

Program Files
When you back up program files, all teach pendant program files currently loaded onto controller
memory (listed on the SELECT menu) and default motion instruction files (DF_xxxx.DF)will be
saved to the default device

System Files
System files are binary files that store values for system variables, servo parameter data, and
mastering data. They contain information specific to the controller, robot, and software.

Application Teach Pendant Program Files

Application teach pendant program files are teach pendant program files with file type .TP, .DF,
or .MN.

Error Log Files

Error log files are ASCII files that give a snapshot of the errors in the system. They can be backed
up to the default device, but cannot be restored or loaded into the controller. Two kinds of error log
files are backed up: ERRALL.LS and ERRACT.LS.
 CONTROLLER BACKUP AND RESTORE

Controller backup and restore allows an R-J3i B controller to back

up and restore controller memory. This capability is divided into two
parts:

Controller backup is performed at Controlled start. During

controller backup, the entire contents of controller memory are
copied to files on the designated device.

Controller restore is performed from the Boot Monitor (BMON).

During controller restore, all of FROM and SRAM is cleared and
then files previously created using the controller backup procedure
are loaded from the default device.
 Lab Assignment 4

Backup and restore files

Controller Backup and Restore

 Lab Assignment 5

Use a knowledge of lights and LEDs to

troubleshoot a class 2 fault
Servo Loop
Servo Motor
 Servo Motor Function
Positional feedback is generated by an encoder
Encoder is mechanically coupled to the motor
shaft
 Servo Motor Function
As the motor turns a voltage pulse is generated by a
photocell as light is allowed through the encoder disk
The voltage pulse is converted to a serial signal for the
CPU
The position of the motor is stored in the encoder which
is battery backed to maintain position in case of
dissassembly
 MASTERING
OVERVIEW

When you master a robot you define the physical location of the robot by
synchronizing the mechanical information with the robot’s positional
information.

When the controller is shut down under normal conditions, each serial pulse
coder’s present reading is maintained in the pulse coder by backup
batteries on the robot.

When the controller is turned on, the controller requests the stored reading
from the serial pulse coder. When the controller receives the pulse coder
reading, the servo system can operate normally. This process is called
calibration . Calibration occurs automatically each time the controller is
turned on.

When pulse coder backup battery power is interrupted while the controller is
powered down, calibration fails at power up and the only robot motion
possible is joint mode jogging. To restore proper operation, the robot must
be mastered and calibrated.
SINGLE AXIS MASTERING
You can master a single axis of any robot
provided that there is a reference mark at
a known position on that axis.

When a single axis of a robot is mastered,

mastering data for the other axes remains
unchanged.
Steps

Jog the unmastered axis of the robot to the single axis

mastering position.
Press MENUS.
Select SYSTEM.
Press F1, [TYPE].
Select Master/Cal. You will see a screen similar to the
following.

SYSTEM Master/Cal

1 FIXTURE POSITIONMASTER
2 ZERO POSITION MASTER
3 QUICK MASTER
4 SINGLE AXIS MASTER
5 SET QUICK MASTER REF
6 CALIBRATE

Press ’ENTER’ or number key to select.

Move the cursor to SINGLE AXIS
MASTER and press ENTER. You will see
a screen similar to the following.

SINGLE AXIS MASTER

ACTUAL POS (MSTR POS) (SEL) [ST]
J1 0.000 ( 0.000) (0) [2]
J2 3.514 ( 35.000) (0) [0]
J3 -7.164 ( -100.000) (0) [2]
J4 -35.366 ( 0.000) (0) [2]
J5 -1.275 ( -80.000) (0) [2]
J6 4.571 ( 0.000) (0) [2]
E1 0.000 ( 0.000) (0) [0]
E2 0.000 ( 0.000) (0) [0]
E3 0.000 ( 0.000) (0) [0]
Move the cursor to SINGLE AXIS
MASTER and press ENTER. You will see
a screen similar to the following.

SINGLE AXIS MASTER

ACTUAL POS (MSTR POS) (SEL) [ST]
J1 0.000 ( 0.000) (0) [2]
J2 3.514 ( 35.000) (0) [0]
J3 -7.164 ( -100.000) (0) [2]
J4 -35.366 ( 0.000) (0) [2]
J5 -1.275 ( -80.000) (0) [2]
J6 4.571 ( 0.000) (0) [2]
E1 0.000 ( 0.000) (0) [0]
E2 0.000 ( 0.000) (0) [0]
E3 0.000 ( 0.000) (0) [0]
 QUICK MASTERING

Quick mastering allows you to minimize the time

required to remaster the robot using a reference position
you established when the robot was properly mastered.

Record the quick master reference position when the

robot is properly mastered.

If calibration fails because pulse coder backup battery

power has been interrupted, you can use this reference
position to master the robot in a minimum amount of time.
 Setting The Quick Master
Reference
Align each axis of
the robot with the
reference mark you
have chosen as a SYSTEM Master/Cal

1 FIXTURE POSITIONMASTER
quick master 2 ZERO POSITION MASTER
3 QUICK MASTER

reference position. 4 SINGLE AXIS MASTER

5 SET QUICK MASTER REF
6 CALIBRATE

Press ’ENTER’ or number key to select.

Move the cursor to

SET QUICK
MASTER REF and
press ENTER
Quick Mastering the Robot
Jog the robot to the quick
master reference position
that has previously been
recorded.
SYSTEM Master/Cal
Move the cursor to QUICK
MASTER and press 1 FIXTURE POSITIONMASTER
2 ZERO POSITION MASTER
ENTER. 3 QUICK MASTER
4 SINGLE AXIS MASTER
Press F4, YES. Mastering 5 SET QUICK MASTER REF
6 CALIBRATE
will be performed Press ’ENTER’ or number key to select.
automatically.
Move the cursor to
CALIBRATE and press
ENTER
ZERO DEGREE MASTERING

When you master to zero degrees, you

position all axes at their zero degree
witness marks and record their serial pulse
coder readings.
ZERO DEGREE MASTERING

Using the joint coordinate system,

jog each axis of the robot to the
SYSTEM Master/Cal
zero degree witness mark. 1 FIXTURE POSITIONMASTER
2 ZERO POSITION MASTER

Select Master/Cal. 3 QUICK MASTER

4 SINGLE AXIS MASTER
5 SET QUICK MASTER REF
6 CALIBRATE
Select Zero Position Master Press ’ENTER’ or number key to
select.

Select Calibrate
 Lab Assignment 6

Perform zero degree mastering

Perform single axis mastering
Perform quick mastering
Servo Amplifier
 Servo Amplifier
The 6 channel servo amplifier is responsible for
controlling servo motor power, motor brakes,
overtravel and handbroken (if used).
The amplifier receives the 6 encoder pulse
signals.
 Servo Amplifier
The amplifier takes the command signals
generated on the main board for all six
robot axes and uses transistor modules to
switch a DC bus voltage out to the proper
servo motors.
CRR38A,B CNGA,B CNJ5 CNJ6
220V Input Motor Ground Axis 5 motor Axis motor
connection connection connection

CNJ4 CNJ3 CRF7 COP10B COP10A

Axis 4 motor Axis 3 motor SPC Feedback FSSB Aux Axis
Connection connection ROT,HBK FSSB
CRR64 CRR68 CRM39 CRM67
Motor brake DC Link Aux Axis DC power&
connection Aux axis brake signal interlock signal

CRR45C CRR45B CNJ2 CNJ1 CRR45A

Discharge Discharge Axis 2 motor Axis 1 motor Discharge
Resistor resistor connection connection resistor
CRR65A,B F2 F1 CXS2A
Aux. axis motor Voltage Spike Voltage Spike Emergency stop
Brake connection protection protection signal for aux axis

DIO19 DIO18 DIO17 CRR63A,B,C CRM68

Aux brake RDO5-RDO8 RDO1-RDO4 Discharge resistor Aux axis
Signals thermals overtravel
FS1
Control Power
circuit protection

FS3
Regenative discharge
Thermal power protection

FS2
24E Power Protection
Servo Amplifier
DC Link Circuit
Power Amplifier
Servo Amplifier LEDs
 Lab Assignment 7

Remove the servo amplifier

Replaced the servo amplifier
Class 3 Fault Troubleshooting
Symptoms

Fault light is on
KM1 and KM2 are off, no power to servos
Diagnostic message displayed on screen

Potential Causes

Servo amp
Motors/SPC’s
Emergency stop circuit
Emergency stop circuit board
Emergency stop unit including KM1 and KM2
Panel board
Cables
Dual E-Stop Chain
E-Stop Unit
220V input QF2
From transformer Circuit breaker

CRM67 CP6
Interlock signals 24E from PSU
To servo amp (24V)

CRM73 CRM64
Transformer overheat Signals from
panel board

CRM72 CNMC2
Aux E-stop Pre-charge
Output

CNMC3 CRR66
KM1 & KM2 Aux. Axis amp
Contacts 220 VAC power
CRM71 CP5A
Robot off Optional 24V
From PSU

CRM70 CNMC1
Door Interlock 220 VAC from
transformer
for precharge

XT4 CP2
KM1 and KM2 Signals from
Aux contacts panel board

CP2A 220V output

220VAC option to servo amp
 Lab Assignment 7b

Remove the Emergency Stop Unit

Replaced the Emergency Stop Unit
 E-Stop Unit LEDs
LED 1
LED 2 Status of
Status Of Relay KA1
Relay KA2

LED 3
Status Of
Relay KA3
E-Stop Unit LEDs
E-Stop Unit LEDs
E-Stop Unit LEDs
 Panel Board E-Stop Connections
KA21&KA22
Estop condition contact
output relays

TBOP4
Estops and other TBOP6
External circuits Estop relay outputs
Panel Board E-Stop Connections
 Lab Assignment 8

Use the symptom to determine the

class of fault.

Use knowledge of servo loop, E-stop

loop, etc. to determine the cause of the
fault.
 INPUT/OUTPUT (I/O)
Overview

Inputs and outputs (I/O) are electrical

signals that enable the controller to
communicate with the robot, end-of-arm
tooling, and other external devices, such
as sensors and actuators.
 Kinds of I/O
Analog
Digital
Group
User Operator Panel (UOP)
PLC
Standard Operator Panel (SOP)
Robot
 Analog

An analog I/O signal (AI or AO) is an input

or output voltage that has a value within
the range of the I/O board or module used.
Analog input devices convert external
analog signals into numeric signals for use
by the controller.
Typical values of analog inputs and
outputs are from -10 volts to 0 volts, or
from 0 volts to +10 volts.
 Digital

A digital I/O signal (DI or DO) is a control

signal sent to or from the controller.

Digital signals can have only one of two

possible states: ON or OFF.
 Group
Group I/O signals (GI or GO) are made up of a
sequence of digital I/O signals. These are
interpreted as a binary integer.

A group signal is a group of up to 16 ones (1)

and zeros (0), indicated ON or OFF. Each bit in
group input or output is a single digital input or
output line. Unused bits are assigned a "0."

32 16 8 4 2 1
1 0 0 1 1 0

38
User Operator Panel (UOP) I/O

The User Operator Panel I/O UOP Out

# STATUS
(UOP) provides 18 input UO [ 1] OFF [Cmd enabled
UO [ 2] OFF [System ready
]
]

signals and 20 output, that can UO [ 3] OFF [Prg running

UO [ 4] OFF [Prg paused
]
]
UO [ 5] OFF [Motion held ]
be connected to a remote UO [ 6] OFF [Fault ]
UO [ 7] OFF [At Perch ]
device or a remote operator UO [ 8] OFF [TP enabled
UO [ 9] OFF [Batt alarm ]
]

panel, to control the robot. UO [ 10] OFF [Busy

UO [ 11] OFF [ACK1/SNO1
]
]
UO [ 12] OFF [ACK2/SNO2 ]
UO [ 13] OFF [ACK3/SNO3 ]
UO [ 14] OFF [ACK4/SNO4 ]
Most UOP I/O signals (UI or UO [ 15] OFF [SNO5
UO [ 16] OFF [SNO6
]
]

UO) are active when the robot UO [ 17] OFF [SNO7

UO [ 18] OFF [SNO8
]
]
UO [ 19] OFF [SNACK ]
is in a remote condition. UO [ 20] OFF [Reserved ]

Signals that affect safety are

always active.
 Robot I/O

Robot I/O signals (RI or RO) consist of the

input and output signals between the
controller and the robot.

These signals are sent to the EE (End

Effector) connector located on the robot.
 Configuring I/O
When you configure I/O, you must define the
following for each signal or range of signals you
configure:

First point of range - for digital and UOP I/O only

Last point of range - for digital and UOP I/O only
Rack
Slot
Channel - for analog I/O only
Starting point - for digital, UOP, and group I/O
only
Number of points - for group I/O only
 Rack
Kind of I/O Rack Assignment

The rack is the

physical location on Modular (Model A)
Physical location on which the input or output
modules are mounted. First on SLC
which the input or I/O
chain is Rack 1.

output process I/O Distributed (Model

Rack 0
board or modular I/O B) I/O

module is mounted. Process I/O Rack 0

Allen-Bradley
Remote I/O Rack 16
Interface

DeviceNet Interface Racks 81 - 84

Genius Interface Rack 16

 Slot
Kind of I/O Slot Assignment

The slot is the space Modular (Model A) The space on the rack where the I/O
I/O module is connected.
on the rack where the
Distributed (Model B) Determined by the DIP switch
modular I/O module is I/O settings on the unit.

connected. The Process I/O Begin at Slot 1 for the first unit
meaning of slot
Allen-Bradley Remote
depends on the kind I/O Interface
Slot 1

of I/O you are using. DeviceNet Interface

The slot number is the MAC Id for
the device.

Genius Interface Slot 1

Starting Point (for Digital, Group,
and UOP I/O only)

Starting point is the port number within the

sequence of ports on the board or module.
For modular I/O , the starting point
number refers to the terminal number.
On a distributed basic I/O unit that has
both digital inputs and digital outputs, both
inputs and outputs start at 1.
 Simulating I/O
Simulating I/O allows you to test a
program that uses I/O.

Simulating I/O does not actually send

output signals or receive input signals. I/O
signals can be simulated individually.

If an input signal is simulated it can be set

ON or OFF from the teach pendant.
 Setting Up I/O
Steps
Press MENUS. I/O Digital In
# SIM STATUS
Select I/O. DI [ 1] U OFF [
DI [ 2] U OFF [
]
]
DI [ 3] U OFF [ ]
Press F1, [TYPE]. DI [ 4] U OFF [ ]
DI [ 5] U OFF [ ]
For digital I/O , you DI [ 6] U OFF [
DI [ 7] U OFF [
]
]
will see a screen DI [ 8] U OFF [
DI [ 9] U OFF [
]
]
similar to the following DI [ 10] U OFF [
Sorted by number
]
To configure digital
signals , move the I/O Digital Out
cursor to the signals # RANGE
STAT.
RACK SLOT START

you want to configure 1 DO [ 1- 16] 1 1 1 INVAL

2 DO [ 17- 19] 1 2 6 ACTIV
and press F2, 3 DO [ 20- 24] 0 0 0 UNASG
4 DO [ 25- 28] 1 2 1 ACTIV
CONFIG. You will see 5 DO [ 29- 100] 0 0 0 UNASG
6 DO [ 101- 356] 16 1 1 PEND
a screen similar to the 7 DO [ 357- 390] 0 0 0 UNASG
8 DO [ 391- 398] 1 3 0 INVAL
following. 9 DO [ 399- 400] 0 0 0 UNASG
Power OFF, then ON to enable changes
 Configure Group I/O:
Move the cursor to RACK, type the
value, and press ENTER.

Move the cursor to SLOT, type the I/O Group Out

value, and press ENTER. GO # RACK SLOT START PT
NUM PTS
1 0 0 0 0
Move the cursor to START PT, type 2 0 0 0 0
3 0 0 0 0
the value, and press ENTER. 4 0 0 0 0
5 0 0 0 0
6 0 0 0 0
Move the cursor to NUM PTS, type 7 0 0 0 0
the value, and press ENTER. The 8 0 0 0 0
number of points can be from 1 up 9 0 0 0 0

to and including 16.

 To configure UOP signals
Move the cursor to I/O UOP Out
# STATUS

the signals you want UO [ 1] OFF [Cmd enabled

UO [ 2] OFF [System ready
]
]
UO [ 3] OFF [Prg running ]
to configure and UO [ 4] OFF [Prg paused ]
UO [ 5] OFF [Motion held ]
press F2, CONFIG. UO [ 6] OFF [Fault
UO [ 7] OFF [At Perch
]
]

You will see a screen UO [ 8] OFF [TP enabled

UO [ 9] OFF [Batt alarm ]
]

UO [ 10] OFF [Busy ]

similar to the following. UO [ 11] OFF [ACK1/SNO1 ]
UO [ 12] OFF [ACK2/SNO2 ]
UO [ 13] OFF [ACK3/SNO3 ]
UO [ 14] OFF [ACK4/SNO4 ]
UO [ 15] OFF [SNO5 ]
I/O UOP Out UO [ 16] OFF [SNO6 ]
# RANGE RACK SLOT START STAT UO [ 17] OFF [SNO7 ]
1 UO [ 1- 8] 0 1 1 ACTIV UO [ 18] OFF [SNO8 ]
2 UO [ 9- 16] 0 1 9 ACTIV UO [ 19] OFF [SNACK ]
3 UO [ 17- 20] 0 1 17 ACTIV UO [ 20] OFF [Reserved ]
DISTRIBUTED (MODEL B) I/O
SETUP

Configure the distributed I/O DIP switches.

Set up each basic and extension digital I/O

module.

Set up user I/O signals.

Model B I/O Example Setup
 Setting the DIP Switches
Set the EDSP switch to Q H Communication Speed

the ON position. OFF OFF 1.2 Mbps

OFF ON 600 Kbps

Set the communication
ON OFF 300 Kbps
speed using switches Q
and H.
 Setting the DIP Switches
Set the termination resistors, represented by
switches R1 through R4.
 Examine the terminals for channel 1 (S1+ and S1-)
and set switch R1 as follows:
If one twisted-pair cable is attached to these terminals,
set the switch to ON.
If more than one twisted-pair cable is attached to these
terminals, set the switch to OFF.
Basic Digital I/O Module DIP
Switches
 Basic Digital I/O Module DIP
Switches
Unit Number Settings

16 8 4 2 1

1 OFF OFF OFF OFF ON

2 OFF OFF OFF ON OFF

3 OFF OFF OFF ON ON

4 OFF OFF ON OFF OFF

5 OFF OFF ON OFF ON

6 OFF OFF ON ON OFF

7 OFF OFF ON ON ON
 Basic Digital I/O Module DIP
Switches
Set the termination resistor, represented by
switch R. Examine the terminals for S+ and S-
and set switch R as follows:
 If one twisted-pair cable is attached to these
terminals, set switch R to ON.
 If more than one twisted-pair cable is attached to
these terminals, set switch R to OFF.
Setting Up Model B Basic Digital
I/O Units
Steps
Press MENUS.
Select I/O.
Press F1, [TYPE].
Select I/O Link. You will see a screen similar to
the following.

I/O Link Device

Device Name Comment RackSlot
1 PrcI/O AA [ ]0 1
2 Model B [ ]1 0
3 Model A [ ]2 0
4 Model A [ ]3 0
Setting Up Model B Basic Digital
I/O Units
Move the cursor to Model B and press
F3, DETAIL
Select the base unit product name
Select the appropriate base unit name.

I/O Link Device

Model B Rack 1
Slot Base Exp. Comment
1 B0D16A1 ******* [ ]
2 ******* ******* [ ]
3 ******* ******* [ ]
30 ******* ******* [ ]
General Mechanical Overview
Fasteners

All fasteners on the robot are metric.

Wrenches, hex drivers, torque values
etc. will all be metric.
 Using Loctite

Loctite No. 242 For taper dowel pins.

Loctite No. 262 For threaded bolts.
Loctite No. 518 For gasket sealant.
 Bolt Torquing Sequence
To reduce the possibility of warping parts or breaking bolts,
always torque them in sequence
 Speed Reducers
A mechanical speed reducer is used on all axes
of each robot to reduce motor speed and
increase torque to an appropriate range for
speed and load conditions encountered during
operation. The following types are used:

RV Reducer
Ballscrew
Harmonic Reducer
Gearboxes
 RV Reducer
The rotating vector (RV) reducer is used to
reduce the speed of the servo motor. The RV
reducer allows components to roll and move
smoothly under extreme heat expansion or load
conditions.
 RV Reducer
All parts of the RV speed reducer have a common centre with the
shafts and two cycloidal discs transmit power through the unit.
The discs are mounted at 180 degree opposition to balance the
motion. The result is smooth, quiet operation.
 RV Reducer
The input gear mounted to the servomotor shaft and the
servo motor supply power to rotate the RV Reducer.
The input gear meshes with the three RV drive gears.
As the shaft rotates, the discs oscillate in 180 degree
opposition.
 RV Reducer
Depending on the reduction ratio of the reducer there are one there
are one or two fewer teeth on the cycloidal disc than are pins.
A progressive mis-meshing of rollers and teeth cause the cycloidal
discs to rotate in the direction oppositie of the input shaft.
 Ballscrew
The ballscrew is a speed reducer that converts rotary
motion into linear motion.
The high precision device uses steel balls to carry the
load resulting in quiet, backlash free operation.
 Ballscrew
The input rotation of the motor is applied directly to the lead screw.
As the screw is turned, it forces the ball bearings in the nut to roll,
causing the nut to move along the screw shaft.
The robot axis is typically mounted to the nut, and is driven by it.
 Harmonic Drive
The Harmonic Drive is a compact, high speed reducer. It consists of
three main components:

1. The wave generator, a thin wall ballrace fitted onto an elliptical

former that serves as a high energy torque converter.
 Harmonic Drive
2 The flexspline, a flexible steel ‘can’ with external teeth, fitted
over the wave generator, and elastically deformed by it.

3 The circular spline, an internally toothed solid steel ring

engaging the teeth of the flexspline across the major axis of the
wave generator.
 Harmonic Drive
The flexspline is approximately 1% smaller in diameter than the
circular spline, resulting in its typically having two less teeth on its
outer circumference.
It is held in an elliptical shape by the wave generator and its teeth
engage the circular spline across the major axis of the elipse.
 As soon as the wave generator starts to rotate
clockwise, the zone of tooth engagement travels
with the major elliptical axis.
Each turn of the wave generator moves the
flexspline two teeth counterclockwise on the
circular spline.
90 Degrees 180 Degrees

360 Degrees
 Gearboxes
Gearboxes are used with the 100i, 120i
and 120iB models for reduction.
The reduction is accomplished with spur
and/or pinion gears alone, or in
conjunction with Rotary Vector drives or
Harmonic reducers.
100i J4 Gearbox
100i, 120i, 120iB J5 Gearbox
Mechanical Units Overview

100i

120i

R2000iA
AM100i/M6i CONFIGURATION
J1 AXIS DRIVE MECHANISM
The rotation of the AC servo motor is reduced by the two
step gear reduction and rotates the J2-axis base.
 J2 Axis Drive Mechanism
The rotation of the AC servo motor is reduced by
the reducer and rotates the J2-axis arm.
The J2-axis arm is supported by the J2-axis
base via the reducer
 J3 Axis Drive Mechanism
The rotation of the AC servomotor is reduced by
the reducer and rotates the J4-axis drive
mechanism.
The J3-axis unit is supported by the J4-axis gear
box and the J2-axis arm via the reducer.
 J4 Axis Drive Mechanism
The rotation of the AC servo motor is reduced by
the two step gear reduction and rotates J3-axis
arm.
J5 & J6 Axis Drive Mechanism
The rotation of the AC servomotor is reduced by the
three step gear reduction of J5-axis and rotates the J6-
axis unit.
The rotation of AC servomotor is decelerated by the J6-
axis reducer and rotates the output flange.
 Greasing
Never exceed 1 cc per second
17 PSI will exceed motor seals
AM120iB/M16iB CONFIGURATION
J1 Axis Drive Mechanism
J2 Axis Drive Mechanism
J3 Drive Mechanism
J4 Drive Mechanism
J5 & J6 Drive Mechanism
Greasing
R2000iA Configuration
J1 Axis Drive Mechanism
J2 Axis Drive Mechanism
J3 Axis Drive Mechanism
J4 Drive Mechanism
J5/J6 Axis Drive Mechanism
Greasing