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Robot SR-3+A/U: Operator'S Manual

This document is the operator's manual for the FANUC Robot SR-3iA/U, detailing safety precautions, operational procedures, and maintenance guidelines. It emphasizes the importance of reading the safety handbook and following safety protocols to ensure safe operation. The manual also includes information on personnel roles, emergency procedures, and warnings related to robot operation.

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0% found this document useful (0 votes)

254 views100 pages

Robot SR-3+A/U: Operator'S Manual

Uploaded by

Cle M

We take content rights seriously. If you suspect this is your content, claim it here.

Available Formats

Download as PDF, TXT or read online on Scribd

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< Robot SR-3+A/U

MECHANICAL UNIT
OPERATOR'S MANUAL

B-84424EN/02

© FANUC CORPORATION, 2022

Translation of the original instruction

The original language of this manual is English. The other language manuals are a
translation from the English one.

Thank you very much for purchasing FANUC Robot.

Before using the Robot, be sure to read the "FANUC Robot series SAFETY HANDBOOK
(B-80687EN)" and understand the content.

• No part of this manual may be reproduced in any form.

• All specifications and designs are subject to change without notice.

The products in this manual are controlled based on Japan’s “Foreign Exchange and
Foreign Trade Law”. The export from Japan may be subject to an export license by the
government of Japan.
Further, re-export to another country may be subject to the license of the government of
the country from where the product is re-exported. Furthermore, the product may also be
controlled by re-export regulations of the United States government.
Should you wish to export or re-export these products, please contact FANUC for advice.

In this manual, we endeavor to include all pertinent matters. There are, however, a very
large number of operations that must not or cannot be performed, and if the manual
contained them all, it would be enormous in volume. It is, therefore, requested to assume
that any operations that are not explicitly described as being possible are "not possible".

B-84424EN/02 SAFETY PRECAUTIONS

SAFETY PRECAUTIONS
This chapter describes the precautions which must be followed to enable the safe use of the robot. Before
using the robot, be sure to read this chapter thoroughly.

For detailed functions of the robot operation, read the relevant operator's manual to understand fully its
specification.

For the safety of the operator and the system, follow all safety precautions when operating a robot and its
peripheral equipment installed in a work cell.
For safe use of FANUC robots, you must read and follow the instructions in “FANUC Robot series
SAFETY HANDBOOK (B-80687EN)”.

1 PERSONNEL
Personnel can be classified as follows.

Operator:
• Turns the robot controller power ON/OFF
• Starts the robot program from operator panel

Programmer or Teaching operator:

• Operates the robot
• Teaches the robot inside the safeguarded space

Maintenance technician:
• Operates the robot
• Teaches the robot inside the safeguarded space
• Performs maintenance (repair, adjustment, replacement)

- The operator is not allowed to work in the safeguarded space.

- The programmer or teaching operator and maintenance technician are allowed to work in the
safeguarded space.
- Based on the "Ordinance on Industrial Safety and Health" in Japan or laws in each country, to work
inside the robot set safeguarded space, the followings is required:
• Perform risk assessment for the entire robot system.
• Based on the risk assessment result, all personnel must take appropriate professional safety
training courses.

Table 1 (a) lists the work outside the safeguarded space. In this table, the symbol “” means the work
allowed to be carried out by the specified personnel.

Table 1 (a) List of work outside the Safeguarded Space

Programmer or Maintenance
Operator
Teaching operator technician
Turn power ON/OFF to Robot controller   
Select operating mode (AUTO/T1/T2)  
Select remote/local mode  
Select robot program with teach pendant  
Select robot program with external device  
Start robot program with operator’s panel   
Start robot program with teach pendant  

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SAFETY PRECAUTIONS B-84424EN/02

Programmer or Maintenance
Operator
Teaching operator technician
Reset alarm with operator’s panel  
Reset alarm with teach pendant  
Set data on teach pendant  
Teaching with teach pendant  
Emergency stop with operator’s panel   
Emergency stop with teach pendant   
Operator’s panel maintenance 
Teach pendant maintenance 

During robot operation, programming and maintenance, the operator, programmer, teaching operator and
maintenance technician take care of their safety using at least the following safety protectors.

 Use clothes, uniform, overall adequate for the work

 Safety shoes
 Helmet

2 DEFINITION OF SAFETY NOTATIONS

To ensure the safety of users and prevent damage to the machine, this manual indicates each precaution on
safety with "WARNING" or "CAUTION" according to its severity. Supplementary information is
indicated by "NOTE". Read the contents of each "WARNING", "CAUTION" and "NOTE" before using
the robot.

Symbol Definitions
Used if hazard resulting in the death or serious injury of the user will be expected to
WARNING occur if he or she fails to follow the approved procedure.
Used if a hazard resulting in the minor or moderate injury of the user, or equipment
CAUTION damage may be expected to occur if he or she fails to follow the approved
procedure.
Used if a supplementary explanation not related to any of WARNING and CAUTION
NOTE is to be indicated.

s-2

B-84424EN/02 SAFETY PRECAUTIONS

3 PROCEDURE TO MOVE ARM WITHOUT

DRIVE POWER IN EMERGENCY OR
ABNORMAL SITUATIONS
For emergency or abnormal situations (e.g. persons trapped in or pinched by the robot), turn off the robot
controller immediately, change robot posture by directly pressing robot arm and release the worker. In case
of J3-axis, to release the brake, press the brake release button as shown in Figure during turning on the
controller power. If J3-axis brake cannot be released even if turning on controller power, open the cover,
loosen the J3 unit mounting bolts, and release engagement between the belt and the pulley.

WARNING
If the belt was released from pulley, J3-axis will fall and may cause injury of the
personnel. Therefore, it is strongly recommended to take adequate measures
such as supporting the J3-axis by a block etc. before releasing a brake.

Controller
制御装置

ケーブル外す
Remove the cable

J3-axis
J3軸

支え
Support J3-axis brake release button
J3軸ブレーキ解除ボタン

Cover
カバー

Fig. 3 (a) J3-axis brake release button

NOTE
Contact your local FANUC representative for method of adjusting belt tension
when restoring.

s-3

SAFETY PRECAUTIONS B-84424EN/02

Bolts
緩めるボルトto be loosened

J3ユニット
J3 unit

Fig. 3 (b) Bolt position to be loosened

4 PRECAUTIONS FOR MECHANISMS

NOTE
1 Never move J1 or J2 by applying pressure to the ball-screw spline.
2 Please do not wipe out the grease on the ball screw spline.

s-4

B-84424EN/02 SAFETY PRECAUTIONS

5 BEHAVIOR OF MOTION AT
SINGULARITIES
In SR-3iA/U, the posture where the center of rotation of the J1 axis and the center of rotation of the J4 axis
overlap is the singular point (singular posture).
The singular point is the boundary of the configuration (LEFT / RIGHT) that represents the left or right of
the arm.
The behavior at and near the singular point is as follows.

Fig. 5 (a) Posture at the singularity

Motion to singular point

If the taught position is a singular point, or if the robot's current position is a singular point, the robot cannot
execute the motion except for Joint motion or Joint jog feed.

Motion that passes near the singular point

Even if the taught position is not a singular point, J1-axis may rotate at high speed if the motion passes near
the singular point in the middle of the motion (except for Joint motion).
In T1/T2/AUTO mode, to prevent such behavior, the “SRVO-114 Singularity Detected” alarm or the
“MOTN-018 Position not reachable (G:xx)” alarm will be posted when attempting to execute a motion that
passes through an area within 5 mm of the singular point. No alarm is generated for movements exceeding
5 mm from the singularity, but the closer the trajectory is to the singularity, the more the movement may
vibrate or the elbow of the arm may rotate at high speed.

Singularity avoidance function

When the singularity avoidance function is enabled, a Linear motion that passes near the singular point is
automatically executed as Joint motion. In this case, the Linear motion that passes near the singular point
can be executed. However, in case of tracking motion, singularity avoidance function is not available.
When using the tracking motion, set the robot and the conveyor position so that the robot does not pass the
singular point.
For details on general settings and functions related to the singularity avoidance function, please refer to
the Optional Function OPERATOR'S MANUAL (B-83284EN-2).
s-5

SAFETY PRECAUTIONS B-84424EN/02

6 WARNING & CAUTION LABEL

(1) Operating space and payload label

Fig. 6 (a) Operating space and payload label

(2) Grease caution label

ボールねじスプラインのグリースは
拭き取らないでください。
Do not wipe out the grease
applied to the ball screw spline.
不要擦去滚珠丝杠花键上的润滑脂。

Fig. 6 (b) Caution label

Description グリース注意ラベル
作領域、可搬質量ラベル
Do not wipe out the grease applied to the ball screw spline.

s-6

B-84424EN/02 PREFACE

PREFACE
This manual explains operation procedures for the following mechanical units:

Mechanical unit
Model name Maximum load
specification No.
FANUC Robot SR-3iA/U A05B-1541-B201 3kg

The label stating the mechanical unit specification number is affixed in the position shown below. Before
reading this manual, verify the specification number of the mechanical unit.

(1)
TYPE (2)
NO. (3)
DATE (4) WEIGHT (5) Kg

Position of label indicating mechanical unit specification number

TABLE 1）
(1) (2) (3) (4) (5)
WEIGHT kg
CONTENTS Model name TYPE No. DATE (Without
controller)
PRODUCTION
FANUC Robot SERIAL NO. YEAR AND
LETTERS A05B-1541-B201 27
SR-3iA/U IS PRINTED MONTH ARE
PRINTED

p-1

PREFACE B-84424EN/02

RELATED MANUALS
For the FANUC Robot series, the following manuals are available:

SAFETY HANDBOOK B-80687EN Intended readers :

All persons who use the FANUC Robot and system Operator, system designer
designer must read and understand Topics :
thoroughly this handbook Safety items for robot system design, operation,
maintenance
R-30iB Compact Plus OPERATOR’S MANUAL Intended readers :
controller Basic Operation Operator, programmer, maintenance technician,
B-83284EN system designer
Alarm Code List Topics :
B-83284EN-1 Robot functions, operations, programming, setup,
Optional Function interfaces, alarms
B-83284EN-2 Use :
Robot operation, teaching, system design
MAINTENANCE MANUAL Intended readers :
B-84035EN Maintenance technician, system designer
Topics :
Installation, start-up, connection, maintenance
Use :
Installation, start-up, connection, maintenance

This manual uses following terms.

Name Terms in this manual

Connection cable between robot and controller Robot connection cable
Robot mechanical unit Mechanical unit

p-2

B-84424EN/02 TABLE OF CONTENTS

TABLE OF CONTENTS
SAFETY PRECAUTIONS........................................................................... s-1

PREFACE ..................................................................................................p-1

1 TRANSPORTATION AND INSTALLATION .......................................... 1

1.1 TRANSPORTATION...................................................................................... 1
1.2 INSTALLATION ............................................................................................. 3
1.2.1 Installation Example ................................................................................................. 5
1.3 MAINTENANCE AREA .................................................................................. 8
1.4 INSTALLATION CONDITIONS ...................................................................... 8
2 CONNECTION WITH THE CONTROLLER ............................................ 9
3 BASIC SPECIFICATIONS ................................................................... 10
3.1 ROBOT CONFIGURATION ......................................................................... 10
3.1.1 Tool flange option .................................................................................................. 13
3.2 MECHANICAL UNIT OPERATING SPACE AND INTERFERENCE AREA . 14
3.3 ZERO POINT POSITION AND MOTION LIMIT ........................................... 16
3.4 WRIST LOAD CONDITIONS ....................................................................... 22
4 EQUIPMENT INSTALLATION TO THE ROBOT ................................. 23
4.1 END EFFECTOR INSTALLATION TO WRIST ............................................ 23
4.2 EQUIPMENT MOUNTING FACE ................................................................ 26
4.3 PAYLOAD SETTING ................................................................................... 29
5 PIPING AND WIRING TO THE END EFFECTOR ................................ 35
5.1 AIR SUPPLY................................................................................................ 36
5.2 AIR SUPPLY AND EE (RI/RO) INETRFACE ............................................... 37
6 AXIS LIMIT SETUP .............................................................................. 41
6.1 CHANGE AXIS LIMIT BY DCS (OPTION)................................................... 41
6.2 J4-AXIS MOTION RANGE EXTENSION BY CONTINUOUS ROTATION
FUNCTION .................................................................................................. 44
7 CHECKS AND MAINTENANCE .......................................................... 46
7.1 CHECKS AND MAINTENANCE .................................................................. 46
7.1.1 Daily Checks .......................................................................................................... 46
7.1.2 Periodic Check and Maintenance ........................................................................... 47
7.2 CHECK POINTS .......................................................................................... 49
7.2.1 Confirmation of Oil Seepage .................................................................................. 49
7.2.2 Confirmation of the Air Control Set and Air Purge kit (option) ............................ 50
7.2.3 Check the Connectors ............................................................................................. 50
7.2.4 Check of Mechanical Stopper ................................................................................ 51
7.3 MAINTENANCE........................................................................................... 53
7.3.1 Replacing the Batteries (1-Year Periodic Maintenance) ........................................ 53
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TABLE OF CONTENTS B-84424EN/02

7.3.2 Replenish the Grease of the Ball Screw Spline (6 months (1920 hours) checks) .. 56
7.4 STORAGE ................................................................................................... 56
8 MASTERING ........................................................................................ 57
8.1 OVERVIEW ................................................................................................. 57
8.2 RESETTING ALARMS AND PREPARING FOR MASTERING ................... 58
8.3 ZERO POSITION MASTERING .................................................................. 59
8.4 QUICK MASTERING ................................................................................... 62
8.5 QUICK MASTERING FOR SINGLE AXIS ................................................... 64
8.6 SINGLE AXIS MASTERING ........................................................................ 66
8.7 MASTERING DATA ENTRY ........................................................................ 68
8.8 VERIFYING MASTERING ........................................................................... 70
8.9 MASTERING BACKUP AND RESTORATION WHEN CONTINUOUS
ROTATION ENABLED ................................................................................ 70
9 TROUBLESHOOTING ......................................................................... 71
9.1 TROUBLESHOOTING................................................................................. 71

APPENDIX
A PERIODIC MAINTENANCE TABLE .................................................... 81
B STRENGTH OF BOLT AND BOLT TORQUE LIST ............................. 84

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B-84424EN/02 1. TRANSPORTATION AND INSTALLATION

1 TRANSPORTATION AND INSTALLATION

1.1 TRANSPORTATION
Unpack and install the robot by three people. The following shows unpacking and installation procedure.

1 Unpacking

Caution!
Store the robot in an angle.
The grease may leak once lay down the robot.

2 Picking up

Caution!
Do not remove the wrap until the robot is installed.
The robot arm may move once the wrap is removed.

Caution!
Do not handle the robot near the red
Circles in the diagram.
You may damage the robot.
。

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1. TRANSPORTATION AND INSTALLATION B-84424EN/02

3 Installation

Caution!
Three people are required to install the robot.
Two person should hold the robot and third person should
tighten 6 bolts.

4 Removing the wrap

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B-84424EN/02 1. TRANSPORTATION AND INSTALLATION

1.2 INSTALLATION
Fig. 1.2 (a) shows the robot base dimensions.

CAUTION
Flatness of robot installation surface must be less than or equal to 0.5mm.
Inclination of robot installation surface must be less than or equal to 0.5.
If robot base is placed on uneven ground, it may result in the base breakage or
low performance of the robot.

Front
正面

202
1 J1-axis
12 J1軸回転中心

8.5
92.5 rotation center

Hole for
3
位置決め用穴 8
6

88
positioning

114
O
B
詳細 B B
Section
A A

245
O 11.8

114
O 6.7

C
6.8
92.5 92.5
Section C-C
断面 C-C
248 (6か所)
(6 places) 92.5 ±0.1
(O6 H8)
5

断面 A-A
Section A-A

Fig. 1.2 (a) Dimensions of the robot base

Fig. 1.2 (b) and Table 1.2 (a) indicate the force and moment applied to the base plate at the time of Power-
off stop of the robot. Table 1.2 (b), (c), (d) and (e) indicate the stopping distance and time of the J1 to J3
axis until the robot stopping by Power-Off stop and by Smooth stop after input of the stop signal. Refer to
the data when considering the strength of the installation face.

NOTE
Stopping times and distances in Table 1.2 (b), (c), (d) and (e) are reference
values measured in accordance with ISO 10218-1. Please measure and check
the actual values, since it varies depending on robot individual, load condition
and operation program. Stopping times and distances in Table 1.2 (b) and (d)
are affected by the robot's operating status and the number of servo-off stops.
Please measure and check the actual values periodically.

Table 1.2 (a) Force and moment that acts on J1 base

Force in Vertical Horizontal Force in
Vertical moment direction moment Horizontal direction
MV(Nm) FV(N) MH(Nm) FH(N)
During stillness 39.4 294.0 0 0
During acceleration or
211.9 323.8 205.3 664.5
deceleration
During Power-Off stop 335.7 394.6 217.6 1019.4

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1. TRANSPORTATION AND INSTALLATION B-84424EN/02

Table 1.2 (b) Stopping time and distance until the robot stopping by Power-Off stop after input of stop signal
(standard)
J1 J2 J3
Stopping time [ms] 151 85 66
SR-3iA/U Stopping angle [deg] (rad) (J1, J2-axis)
52.6 (0.92) 36.7 (0.64) 47.9
Stopping distance [mm] (J3-axis)

Table 1.2 (c) Stopping time and distance until the robot stopping by Smooth stop after input of stop signal
(standard)
J1 J2 J3
Stopping time [ms] 154 122 120
SR-3iA/U Stopping angle [deg] (rad) (J1, J2-axis)
53.5 (0.93) 59.9 (1.05) 64.9
Stopping distance [mm] (J3-axis)

Table 1.2 (d) Stopping time and distance until the robot stopping by Power-Off stop after input of stop signal
(bellows option)
J1 J2 J3
Stopping time [ms] 178 94 77
SR-3iA/U Stopping angle [deg] (rad) (J1, J2-axis)
59.4 (1.04) 39.6 (0.70) 51.2
Stopping distance [mm] (J3-axis)

Table 1.2 (e) Stopping time and distance until the robot stopping by Smooth stop after input of stop signal
(bellows option)
J1 J2 J3
Stopping time [ms] 176 128 128
SR-3iA/U Stopping angle [deg] (rad) (J1, J2-axis)
54.8 (0.96) 59.9 (1.05) 64.9
Stopping distance [mm] (J3-axis)

FH
FV

MH
Fig. 1.2 (b) Force and moment that acts on J1 base

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B-84424EN/02 1. TRANSPORTATION AND INSTALLATION

1.2.1 Installation Example

Fig. 1.2.1 (a) show three examples of the robot installation. Fasten the robot base with four M6 x 15 (Tensile
strength 1200N/mm2 or more) with regulated torque 12Nm. If compatibility must be maintained in teaching
the robot after the robot mechanical unit is replaced, use the locating surface.

Robot J1 base
ロボット J1ベース

固定ボルト
Robot mounting bolt
M6X15(6本)
M6 x 15 (6 pcs)
引張強度 strength:：1200N/mm 以上
2
Tensile 1200N/mm 2 or more
締付トルク：12Nm
Tightening torque: 12Nm

Fig. 1.2.1 (a) Installation Example

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1. TRANSPORTATION AND INSTALLATION B-84424EN/02

Fig. 1.2.1 (b) shows example of design dimension of pedestal. Fig 1.2.1 (c) shows the caution for designing
the pedestal.

50 960 960

820
1720
150

150 150

820
370

B
断面 A-A
Section A-A
1720

150

50
150

250
370

Pedestal mounting bolts

架台固定用ボルト
M16 x 50 (16 pcs)
210 20
M16X50
Tensile (16本)
strength 400N/mm2 2 or more
150

引張強度400Nmm
Tightening 以上
torque 98Nm (10kgfm)
締付トルク98Nm(10kgfm)

147.5
Detail
詳細BB
20

150
150

150 150 150

184
150

A A
184
1730

625

C
Floor
敷板plate
25

Pedestal mounting bolts

M16 (9ケミカルアンカー
pcs)
TensileM16(9本)
strength 400N/mm2 or2 more
引張強度400Nmm
Tightening 以上
torque 98Nm (10kgfm)
締付トルク98Nm(10kgfm)
32

(埋め込み深さ)

Detail C
詳細 C
(Depth)
130
130

Fig. 1.2.1 (b) Example of design dimension of pedestal

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B-84424EN/02 1. TRANSPORTATION AND INSTALLATION

Maintenance hole : Make a clearance to remove the J1 arm upper side cover
メンテナンスホール：J1アーム上面カバーを外せるスペースを設けること
J1-axisJ1軸回転中心
rotation center

90.5
153
155

Fig. 1.2.1 (c) Caution for pedestal design

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1. TRANSPORTATION AND INSTALLATION B-84424EN/02

1.3 MAINTENANCE AREA

Fig.1.3 (a) shows the maintenance area of the mechanical unit. If maintenance space is no secured,
maintenance work may not be possible. Please consider installation layout of equipment. See Chapter 8 for
the mastering.

0
113
O
J1-axis rotation center
464

J1軸回転中心
202
464

408 397 325

350
639
500

Fig. 1.3 (a) Maintenance area

1.4 INSTALLATION CONDITIONS

Refer to the specifications found in Section 3.1.

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B-84424EN/02 2. CONNECTION WITH THE CONTROLLER

2 CONNECTION WITH THE CONTROLLER

The robot is connected with the controller via the power cable and signal cable. Connect each cables to the
controller Please be sure to connect the earth cable. For details on air and option cables, see Chapter 5.

WARNING
Before turning on controller power, be sure to connect the robot and controller
with the earth line (ground). Otherwise, there is the risk of electrical shock.

CAUTION
1 Before connecting the cables, be sure to turn off the controller power.
2 Don’t use 10m or longer coiled cable without first untying it. The long coiled
cable will heat up and become damaged.

Controller
制御装置

Robot
ロボット機構部
mechanical unit
Power, signal cable
動力、信号ケーブル
A
Earth line
アース線

Air
エア

For earth terminal

アース

Clamp for power

動力、信号線クランプ
and signal View
矢視A A
Fig. 2 (a) Cable connection

-9-

3. BASIC SPECIFICATIONS B-84424EN/02

3 BASIC SPECIFICATIONS
3.1 ROBOT CONFIGURATION

J1ベースカバー
J1 base cover
J1軸用ACサーボモータ
AC servo motor for J1-axis motor

J1ベース
J1 base

J1J1アーム
arm

AC servo motor for J2-axis motor

J2軸用ACサーボモータ

J3軸用ブレーキユニット
Brake unit for J3-axis

J4軸用ACサーボモータ
AC servo motor for J4-axis motor

ACJ3軸用ACサーボモータ
servo motor for J3-axis motor

J2アーム
J2 arm

J3/J4J3/J4 ball screw spline エンドエフェクタ取付面

End effector mounting face
ボールねじスプライン

Fig. 3.1 (a) Mechanical unit configuration

- 10 -

B-84424EN/02 3. BASIC SPECIFICATIONS

+
-
J1

J2
- +
+
- + J3
-
J4
Fig. 3.1 (b) Each axis coordinates

Y X

Z
Z
Fig. 3.1 (c) Mechanical interface coordinates

NOTE
The end effector mounting face center is 0, 0, 0 of the mechanical interface
coordinates.

- 11 -

3. BASIC SPECIFICATIONS B-84424EN/02

Specifications (NOTE 1)
SR-3iA/U
Type Scara type
Controlled axis 4-axis (J1, J2, J3, J4)
Installation Ceiling
±225 (610/s)
J1
±3.93 rad (10.65rad/s)
±225 (840/s)
J2
Motion range ±3.93 rad (14.66rad/s)
(Maximum speed) J3 140mm (1500mm/s)
(NOTE 2)
±720 (3000/s)
±12.57 rad (52.36rad/s)
J4
Continuous rotation is available.
(NOTE 3)
Max. load capacity at wrist 3kg
Allowable inertia
J4-axis 0.06 kg m2
At wrist
J1+J2-axis ±0.01mm
Repeatability J3-axis ±0.01mm
J4-axis ±0.004deg
Cables and air for Standard RI x 4/RO x 4,  6mm x 1, 4mm x 2
user Option RI x 4,  6mm x 1 ,Solenoid valve x 2
Drive method Electric servo drive by AC servo motor
Mass 27kg
Dust proof and drip proof Conform to IP20
mechanism Conform to IP65 (option, NOTE 4)
Acoustic noise level 70dB or less (NOTE 5)
Ambient temperature: 0 to 45°C (NOTE 6)
Ambient humidity: Normally 75%RH or less.
(No condensation allowed.)
Short time (within one month) Max 95%RH
Installation environment
(No condensation allowed.)
(NOTE 7)
Vibration acceleration : 4.9m/s2 (0.5G) or less
Free of corrosive gases
Free of heavy dust, metal dust
No splash of water, water vapor, cutting oil and cleaning fluid

NOTE
1 Even if the robot is used according to the defined specifications, motion programs might shorten
reducer life or cause the robot to overheat. Use ROBOGUIDE for further evaluation before
running production.
2 During short distance motions, the axis speed may not reach the maximum value stated.
3 This is an option. Refer to Section 6.2.
4 Except external battery box. External battery box conform to IP20.
5 This value is equivalent continuous A-weighted sound pressure level that applied with ISO11201
(EN31201). This value is measured with the following conditions.
- Maximum load and speed
- Operating mode is AUTO
6 When robot is used in low temperature environment that is near to 0ºC, or robot is not operated
for a long time in the environment that is less than 0ºC in a holiday or the night, because viscous
resistance of the drive train is so big that may cause occurrence of collision detect alarm (SRVO-
050) etc. In this case, we recommend performing the warm up operation for several minutes.
7 Contact the service representative when using in a place that does not meet the conditions.
- Installation environment is relaxed when the option for conform to IP65 are specified. Refer
to next page for details.

- 12 -

B-84424EN/02 3. BASIC SPECIFICATIONS

The following table lists the IEC60529-based Severe dust/liquid protection characteristics of the SR-3iA/U

IP65 specification
(A05B-1541-H502
Standard
+ A05B-1541-H301,H302
+A05B-1541-J102)
Main body Conform toIP20 Conform to IP65
Controller Conform to IP20 Conform to IP20

NOTE
Definition of IP code (Protection structure rating)
Definition of IP 20
2→Materials which diameter is larger than 12mm does not intrude internal.
0→No protection against water
Definition of IP 65
6→Dust-tight: Complete protection against contact
5→Protection from water jet：Direct water projected in jets against the
enclosure from any direction shall have no harmful effects.

Performance of resistant chemicals and resistant solvents

(1) The robot cannot be used with the following liquids. Potentially these liquids will cause irreversible
damage to the rubber parts (such as: gaskets, oil seals, O-rings etc.). (As exception to this only liquids
tested and approved by FANUC can be used with the robot.)
(a) Organic solvents
(b) Cutting fluid or detergent including chlorine / gasoline
(c) Amine type cutting fluid or detergent
(d) Acid, alkali and liquid causing rust
(e) Other liquids or solutions, that will harm NBR or CR rubber
(2) Do not use unconfirmed liquid.
(3) Do not use the robot immersed in water, neither temporary nor permanent. Robot must not be wet
permanently.

3.1.1 Tool flange option

A tool flange (A05B-1116-K113) is prepared as an option for installation to the wrist.

 Mass of the tool flange is 0.16kg.

 Refer to Section 3.2 and 4.2 for the operating space and the equipment mounting surface when
installing the tool flange.
 Refer to Section 4.3 for load information of the tool flange.
 The wrist load condition (Section 3.4) is same without the flange.

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3. BASIC SPECIFICATIONS B-84424EN/02

3.2 MECHANICAL UNIT OPERATING SPACE AND

INTERFERENCE AREA
Fig. 3.2 (a), (b) shows the robot operating space. When installing peripheral equipment, be careful not to
interfere with the robot and its operating space.

O 700
Operating space
ofJ4軸中心動作領域
J4-axis rotation
center

°
225 225
225° °

22
5°
101
101

5°
22
22
5° 225°
22
5°

157 88
676.4

440

478
140

140

175 175 J4軸回転中心

J4-axis rotation center
When tool flange option is specified
ツールフランジオプション選択時

Fig. 3.2 (a) Operating space

- 14 -

B-84424EN/02 3. BASIC SPECIFICATIONS

O 700
Operating space
J4軸中心動作領域
of J4-axis rotation
center

°
225 225
225° °

22
5°
101
101

5°
22
22
5° 225°
22
5°

157 88
772

535

573
140

140
175 175
J4-axis rotation center
J4軸回転中心 When tool flange option is specified
ツールフランジオプション選択時

Fig. 3.2 (b) Operating space (bellows option)

- 15 -

3. BASIC SPECIFICATIONS B-84424EN/02

3.3 ZERO POINT POSITION AND MOTION LIMIT

A zero point and motion range are provided for each controlled axis. Exceeding the software motion limit
of a controlled axis is called overtravel (OT). Overtravel is detected at both ends of the motion limit for
each axis. The robot cannot exceed the motion range unless there is a loss of the zero point position due to
abnormalities in servo system or a system error. In addition, a mechanical stopper is also used to limit
maximum motion and to improve safety.

Fig. 3.3 (a), (b) shows the position of the mechanical stopper. Don’t reconstruct the mechanical stopper. If
you do, there is a possibility that the robot will not stop normally.

J3軸機械式ストッパ
J3-axis mechanical stopper
（マイナス側）
(minus side)

J3軸機械式ストッパ
J3-axis mechanical stopper
（プラス側）
(plus side)

Fig. 3.3 (a) Position of mechanical stopper

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B-84424EN/02 3. BASIC SPECIFICATIONS

J3-axis mechanical stopper

J3軸機械式ストッパ
(minus side)
（マイナス側）

J3-axis mechanical stopper

J3軸機械式ストッパ
(plus side)
（プラス側）

Fig. 3.3 (b) Position of mechanical stopper (bellows option)

- 17 -

3. BASIC SPECIFICATIONS B-84424EN/02

Fig. 3.3 (c) to (f) show the zero point, motion limit and maximum stopping distance (stopping distance in
condition of max speed and max load) of each axis.

When J1-axis mechanical stopper is necessary, contact your local FANUC representative.

Only in case of the J3-axis, when the robot comes in contact with the mechanical stopper, it may deform.
When the mechanical stopper is deformed, replacement is needed. Contact FANUC about replacing J3-axis
mechanical stopper.

* The motion range can be changed. For information on how to change the motion range, see Chapter
6, "AXIS LIMIT SETUP".

ソフトウェアによる制限
Software restriction

°
+ 225
- 2
25°

+225 v ストロークエンド
+225 (上限)
Stroke end (upper limit)
-225v Stroke
-225 ストロークエンド (下限)
end (lower limit)

注) 機械式ストッパはありません。
NOTE) There is no mechanical stopper.
Fig. 3.3 (c) J1-axis motion limit

NOTE
If the arm is pushed by hand J1-axis moved to the outside of the motion area, it
might cause cable twisted and cable failure. Do not change the J1-axis position
when the present position is unknown.

- 18 -

B-84424EN/02 3. BASIC SPECIFICATIONS

ソフトウェアによる制限
Software restriction

-225 Stroke end (lower

-225v ストロークエンド (下限)limit) +225 Stroke
+225 end (upper(上限)
v ストロークエンド limit)

25°

- 2
+ 2

25°
NOTE)
注)There is no mechanical stopper.
機械式ストッパはありません。
Fig. 3.3 (d) J2-axis motion limit

NOTE
If the arm is pushed by hand J2-axis moved to the outside of the motion area, it
might cause cable twisted and cable failure. Do not change the J2-axis position
when the present position is unknown.

- 19 -

3. BASIC SPECIFICATIONS B-84424EN/02

+3mm+3mm The maximum stopping

最大停止距離 (位置)
Distance (position)

0mm ストロークエンド (上限)

0mm Stroke end (upper limit)

-140mm -140mm
ストロークエンド (下限)
Stroke end (lower limit)
-143mm The maximum stopping
-143mm 最大停止距離 (位置)
Distance (position)

Fig. 3.3 (e) J3-axis motion limit

+1.5mm The maximum stopping

+1.5mm 最大停止距離 (位置)
Distance (position)

0mm ストロークエンド (上限)

0mm Stroke end (upper limit)

-140mm -140mm
ストロークエンド (下限)
Stroke end (lower limit)
-143mm The maximum stopping
-143mm 最大停止距離 (位置)
Distance (position)

Fig. 3.3 (f) J3-axis motion limit (bellows option)

- 20 -

B-84424EN/02 3. BASIC SPECIFICATIONS

ソフトウェアによる制限
Software restriction
+720°
+720°ストロークエンド（上限）
+720º Stroke end (upper limit)

-720°ストロークエンド（下限）
-720º Stroke end (lower limit)

0°

-720°

NOTE) There is no mechanical stopper.

注) 機械式ストッパはありません。

Fig. 3.3 (g) J4-axis motion limit

- 21 -

3. BASIC SPECIFICATIONS B-84424EN/02

3.4 WRIST LOAD CONDITIONS

Fig. 3.4 (a) shows diagram to limit loads applied to the wrist. The robot might vibrate even if wrist load in
in wrist load diagram. At this time, reduce the acceleration.
 Apply a load within the region indicated in the graph.
 For the zero point and the motion range of the J3-axis, refer to Fig.3.3 (d) in Section 3.3.
 See Section 4.1 about the mounting of an end effector.

10cm
14.8cm
23.5cm
X, Y (cm)

3kg
12cm
15cm 2kg

20cm 1kg

Z(cm)

Fig. 3.4 (a) Wrist load diagram

CAUTION
･ This diagram shows standard allowable wrist load values.
･ Use this information to make sure that your wrist load moment and inertia values
are allowed.
･ Be especially careful when determining your wrist load inertia because the
inertia will vary depending on the shape of the load.

- 22 -

4. EQUIPMENT INSTALLATION
B-84424EN/02 TO THE ROBOT

4 EQUIPMENT INSTALLATION TO THE

ROBOT
4.1 END EFFECTOR INSTALLATION TO WRIST
Fig. 4.1 (a), (b), (c) shows the end effector mounting face. Fasten the bolt for attaching the end effector
referring to Appendix B for the tightening torque.

CAUTION
Observe the following when installing the device because end effector mounting
face may damaged.
1. When attaching a flange, fix it with a friction fastener and do not fix it only with
a set screw.
2. When using a set screw, adhere the screw tip to the width across flats.
3. The tooling coupling depth to wrist flange should be shorter than the flange
coupling length.

When installing the equipment using the friction type fastening fixture, make the surface pressure on the
friction surface less than 70N/mm2.
(reference)
Allowable maximum thrust force at the end effector tip : 150N
Allowable maximum torque at the end effector tip : 16Nm
29(h7 area)

9
6

Inside diameter O 14

18
0
O 20 h7 -0.021

Fig. 4.1 (a) End effector mounting face

- 23 -

4. EQUIPMENT INSTALLATION
TO THE ROBOT B-84424EN/02

When bellows option are specified

When installing the equipment using the friction type fastening fixture, make the surface pressure on the
friction surface less than 110N/mm2.
(reference)
Allowable maximum thrust force at the end effector tip : 150N
Allowable maximum torque at the end effector tip : 16Nm

Machining groove for positioning

by clamping screw (ball type)
31 (h7 area)
39

23
9

A A
6

18
0
O 20 h7 -0.021
2. 5

°
23.45
R

SECTION A-A
Fig. 4.1 (b) End effector mounting face (bellows option)

- 24 -

4. EQUIPMENT INSTALLATION
B-84424EN/02 TO THE ROBOT

When tool flange option are specified

Apply grease(* ) to the tool flange fixing bolt(M4 x 20) to secure the axial tension, and tighten it at 4.5Nm.
(* Do not use grease containing molybdenum disulfide.)
The end effector locates it using a fitting, the pin hole of [B] of a [A] part or the [D] part and fixes it using
a tap of [C]. Choose the length of the bolts to be used so that engagement length is 6mm to 8mm.
・Tighten the fixing bolts with the following torque.
・Set the load parameter of the end effector including the tool flange. (Refer to Section 4.3)

Hexagon socket head bolt (Tensile strength 1200N/mm2 or more)

Nominal Tightening torque N･m (kgf･cm)
diameter Upper limit Lower limit
M5 7.9 (81) 5.6 (57)

Mechanical Interface
Coodinate system
Y

Z
M4X20
66
38
O 18
18
6 minimum

+0.021
O 20 H7 0 [D]
h8 area

0
O 40 h8 -0.039 [A]

+0.012
O 5 H7 0 Depth 5 [B]
45 °

4-M5 Depth 8 [C]

equally spaced
1.5
O3

Fig. 4.1 (c) End effector mounting face (tool flange option)

- 25 -

4. EQUIPMENT INSTALLATION
TO THE ROBOT B-84424EN/02

4.2 EQUIPMENT MOUNTING FACE

As shown in Fig. 4.2 (a), (b) and (c) tapped holes are provided to install equipment to the robot.

CAUTION
1 Never perform additional machining operations such as drilling or tapping on the
robot body. This can seriously affect the safety and functions of the robot.
2 Note that the use of a tapped hole not shown in the following figure is not
assured. Please do not tighten both with the tightening bolts used for mechanical
unit.

20 113
h
oug

4-M4 Depth 9 30 57 2-M4 Through

Thr

For equipment fixation For cable fixation

Not for other equipment
14

4-M4 Depth 9
O

14.25

For equipment fixation

30
50

A
12
50

14.25

2-M4 Depth 9 DETAIL A

For equipment fixation 20 57

Fig. 4.2 (a) Equipment mounting faces

- 26 -

4. EQUIPMENT INSTALLATION
B-84424EN/02 TO THE ROBOT

20 113
4-M4 Depth 9 30 57
For equipment fixation

4-M4 Depth 9
For equipment fixation
30
50

12
50

2-M4 Depth 9
For equipment fixation 20 57

Fig. 4.2 (b) Equipment mounting faces (bellows option)

- 27 -

4. EQUIPMENT INSTALLATION
TO THE ROBOT B-84424EN/02

O 18

B
38

18
6
(H7,h8 area)

+0.021
O 20 H7 0
B
0
O 40 h8 -0.039

SECTION B-B

4-M5 depth 8
equally spaced O 5 H7
+0.012
0 depth 5
A
°
45

.5
31
O
DETAIL A
Fig. 4.2 (c) Equipment mounting faces (tool flange option)

- 28 -

4. EQUIPMENT INSTALLATION
B-84424EN/02 TO THE ROBOT

4.3 PAYLOAD SETTING

CAUTION
Set the correct load condition parameter before the robot runs. Do not operate
the robot when its payload is exceeded or incorrect. Do not exceed the allowable
payload including connection cables and its swing. Operation in with the robot
over payload may result in troubles such as reducer life reduction.

NOTE
Explanation in this chapter is for when teach pendant (option) is selected.

Overview
Payload setting is a setting of the payload which is mounted on the robot. It consists of payload data such
as weight, center of gravity, etc. Setting appropriate payload data can bring the following effects:
● Improvement in motion performance (such as reduction of vibration and cycle time)
● More effective performance of functions related to dynamics (such as collision detection and gravity
compensation).
Wrong payload data can cause vibration, mis-detection of collision, and so on. For effective use of the robot,
set appropriate data of the load such as a hand, a workpiece, and an armload (equipment mounted on the
robot arm, not on the face plate).

You can set the payload data using “Motion Performance screens". In these screens, you can set up 10
schedules of payload setting. If you set up two or more payload schedules in advance, you can achieve
appropriate payload setting only by switching the schedule number according to changing of actual payload.
You can also change the schedule number using program instruction which you can place anywhere in TP
program. (Refer to the Subsection 4.10 PAYLOAD INSTRUCTION of the Controller Operator’s manual
(BASIC FUNCTION)(B-83284EN).

As an option function, “Payload Identification” is available. This function enables the robot to calculate
load information automatically.

Motion Performance Screens (Payload setting screen)

You can set the payload data using “Motion Performance screens". Motion Performance screens consist of
list screen, payload setting screen and armload setting screen.

Table 4.3 (a) Motion Performance screen

Screen name Description
MOTION PERFORMANCE A screen to display the list of payload schedules (No. 1 ~ No. 10).
(List screen) You can also check or switch the active schedule number in this screen.
MOTION / PAYLOAD SET A screen for detailed payload data for each schedule.
You can display or modify the values of payload weight, gravity center position and
inertia in this screen.
This screen is provided for each individual payload setting number.
MOTION / ARMLOAD SET A screen for armload (equipments mounted on the robot arm, not on the face plate).
You can set the weight of equipments mounted on such as J2 base and J3 arm.

The following description is a procedure to show Motion Performance screen, to input payload data and to
activate the payload schedule. You can also modify the setting values later.

NOTE
Depending on the combination of robot model and option, the payload data may
be set in advance.

- 29 -

4. EQUIPMENT INSTALLATION
TO THE ROBOT B-84424EN/02

Step
1 Press the [MENU] key to display the screen menu.
2 Press “0 NEXT”, then select “6 SYSTEM”.
3 Press F1 [TYPE] to display the screen switch menu.
4 Select “Motion”. The list screen (“MOTION PERFORMANCE” screen) appears. (If a screen other
than the list screen appears, press the [PREV] key several times until the list screen appears.) For a
multi-group system, if you want to go to the list screen of the other group, press F2, "GROUP" then
enter the group number you like.

MOTION PERFORMANCE JOINT 10%

Group1
No. PAYLOAD[kg] Comment
1 3.00 [ ]
2 0.00 [ ]
3 0.00 [ ]
4 0.00 [ ]
5 0.00 [ ]
6 0.00 [ ]
7 0.00 [ ]
8 0.00 [ ]
9 0.00 [ ]
10 0.00 [ ]

Active PAYLOAD number =0

[ TYPE] GROUP DETAIL ARMLOAD SETIND >

NOTE
Up to 10 of payload data can be set as standard. The number of payload data
can be increased up to 256 by the following way. (up to 32 in R-30iB Mate)
a. Turn on the controller with [PREV] and [NEXT] key pressed.
b. Select “3 Controlled start”.
c. Press the [MENU] key.
d. Select “4 Variables”
e. Set the number of payload data to the system variable $PLST_SCHNUM.
f. Restart (power off/on) the controller and "Control start" again.
g. Press the [FCTN] key.
h. Select “1 START (COLD)”.

5 Move the cursor to the schedule number you want to set up, and press F3, "DETAIL" to display
PAYLOAD SET screen of the selected schedule number.

MOTION PAYLOAD SET JOINT 10%

Group 1
1 Schedule No[ 1]:[Comment ]
2 PAYLOAD [kg] 3.00
3 PAYLOAD CENTER X [cm] 0.00
4 PAYLOAD CENTER Y [cm] 0.00
5 PAYLOAD CENTER Z [cm] 1.50
6 PAYLOAD INERTIA X [kgfcms^2] 0.10
7 PAYLOAD INERTIA Y [kgfcms^2] 0.01
8 PAYLOAD INERTIA Z [kgfcms^2] 0.10

[TYPE] GROUP NUMBER DEFAULT HELP

- 30 -

4. EQUIPMENT INSTALLATION
B-84424EN/02 TO THE ROBOT
6 Enter the weight, gravity center position of the load, and inertia about its gravity center.
If required, you can enter the comment. The entered comment is displayed in list screen.

The X, Y, and Z directions displayed in the PAYLOAD SET screen correspond to those in the default
tool coordinate system (“default” means no Tool frame is set).

Center of robot
エンドエフェクタ
取付面中心
end effector mounting face
xg(cm)

zg(cm)
2
Iy(kgf・cm・s)

Center of
gravity Mass m (kg)
2
Iz(kgf・cm・s)

2
Ix(kgf・cm・s)
X
yg(cm)

Center of
gravity

Fig. 4.3 (a) Standard tool coordinate

m：Mass (kg)
xg：Center of gravity x direction (m)
yg：Center of gravity y direction (m)
zg：Center of gravity z direction (m)
Ix：Inertia at the center of the gravity (around the axis in the x direction through the center of gravity) (kgm^2)
Iy：Inertia at the center of the gravity (around the axis in the y direction through the center of gravity) (kgm^2)
Iz：Inertia at the center of the gravity (around the axis in the z direction through the center of gravity) (kgm^2)

- 31 -

4. EQUIPMENT INSTALLATION
TO THE ROBOT B-84424EN/02

W：Mass
W：質量 (kg) (kg)
J：Inertia 2)
(kgm(kgm^2)
J：イナーシャ
a, b,l,l,rr ：Length
a,b, ；長さ (m) (m)

Expressions for calculating inertia around the center

重心回りのイナーシャ計算式（形状イナーシャ）
of gravity (geometric inertia)

r r

a l
b

a 2 ＋b 2 l2 r2 2r 2
J i ＝W J i ＝W J i ＝W J i ＝W
12 12 2 5

Fig. 4.3 (b) Calculating center of the gravity inertia

If you synthesize multiple loads, calculate it for z direction using theorem of parallel axis. (Fig.4.3 (c))

Jg=(J1+W1L12)+ (J2+W2L22)

a
W1 g
W
b
J1
Jg

L1 J2
L2
W2
Fig. 4.3 (c) Calculating the combined inertia which is consist of two elements

W1,W2: Mass (kg)

W: Total of W1,W2 (kg)
J1 : Inertia at the center of the gravity of load W1 (kgm2)
J2 : Inertia at the center of the gravity of load W2 (kgm2)
Jg: Total load inertia (kgm2)
L1 : Distance between parallel axes of a and g
L2 : Distance between parallel axes of b and g
a : Axis which passes center of the gravity of the load W1
b : Axis which passes center of the gravity of the load W2
g : Axis which passes center of the gravity of the total load W

- 32 -

4. EQUIPMENT INSTALLATION
B-84424EN/02 TO THE ROBOT

NOTE
1 If the shape is simple, you can estimate the inertia as shown in Fig. 4.3 (b).
In addition, there are method by using CAD data and using LOAD ESTIMATION
function. If there is a known inertia value such as manufacturer's ready-made
products, use the value. If the load is composed of the tool and the workpiece,
calculate the mass, center of the gravity and the inertia of the composite load.
(Fig. 4.3 (c))
For LOAD ESTIMATION function, refer to CONTROLLER OPERATOR’S
MANUL (Optional FUNCTION)(B-83284EN-2).
2 Confirm the input units in the payload setting screen. If necessary convert
values using the equation below.
1kgfcms^2 = 0.098kgm^2 (=980kgcm^2)

When you change the value, a confirmation message “Path and Cycle time will change. Set it?”
appears. Press F4, "YES" or F5, "NO".
Then, you may see a message “Load is OVER spec! Accept?”. This message indicates the load exceeds
the capacity of the robot. Reconfigure your system so that the load does not exceed the capacity.
In another case, you may see a message “Load is close to capacity! Accept?”. This message indicates
the load is close to capacity although it does not exceed the capacity.

CAUTION
Don’t install a load which exceeds the capacity of the robot because overload
can cause a life loss of the reducer.

7 If you want to go to the screen of the other schedule number, press F3, "NUMBER" then enter the
schedule number you like. For a multi-group system, if you want to go to the screen of the other group,
press F2, "GROUP" then enter the group number you like.
8 Activate payload schedule you are going to use. Press the [PREV] key to go back to the list screen,
press F5, "SETIND", and enter the index number of payload schedule you are going to use.

NOTE
The initial schedule number is 0. In order to activate the payload setting you
entered, you need to set the schedule number to 1-10. If the schedule number is
0, the system uses the default payload value which is shown in the screen
before you change the value.

- 33 -

4. EQUIPMENT INSTALLATION
TO THE ROBOT B-84424EN/02

When the tool flange (option) is specified, consider the following load information.

Y PAYLOAD [kg] 0.16

PAYLOAD CENTER X [cm] 0.00
PAYLOAD CENTER Y [cm] 0.00
PAYLOAD CENTER Z [cm] 0.35
PAYLOAD INERTIA X [kgfcms2] 0.0008
PAYLOAD INERTIA Y [kgfcms2] 0.0008
PAYLOAD INERTIA Z [kgfcms2] 0.0004
X
(ロボット正面方向)
(Robot front direction)
Z

Fig. 4.3 (b) Load information of the tool flange (option)

- 34 -

5. PIPING AND WIRING TO

B-84424EN/02 THE END EFFECTOR

5 PIPING AND WIRING TO THE END

EFFECTOR
WARNING
• Only use appropriately-specified mechanical unit cables.
• Do not add user cables or hoses inside of the mechanical unit.
• Please do not obstruct the movement of the mechanical unit cable when cables
are added to the outside of the mechanical unit.
• Please do not perform remodeling (adding a protective cover, or secure an
additional outside cable) that obstructs the behavior of the cable.
• When external equipment is installed on the robot, make sure that it does not
interfere with other parts of the robot.
• Cut and discard any unnecessary length of wire strand of the end effector (hand)
cable. Insulate the cable with seal tape. (See Fig. 5 (a))
• If you have end effector wiring and a process that develops static electricity,
keep the end effector wiring as far away from the process as possible. If the
end effector and process must remain close, be sure to insulate the cable.
• Be sure to seal the connectors of the user cable and terminal parts of all cables
to prevent water from entering the mechanical unit. Also, attach the cover to the
unused connector. Especially in case of IP65 specification, attach the optional
cap (A05B-1139-K051) to the EE interface to ensure the dustproof and
waterproof performance.
• Frequently check that connectors are tight and cable jackets are not damaged.
• When precautions are not followed, damage to cables might occur. Cable failure
may result in incorrect function of the end effector, robot faults, or damage to
robot electrical hardware. In addition, electric shock could occur when touching
the power cables.

End effector (hand) cable

Insulation processing
Cut unnecessary length of unused wire strand

Fig. 5 (a) Treatment method of end effector (hand) cable

- 35 -

5. PIPING AND WIRING TO

THE END EFFECTOR B-84424EN/02

5.1 AIR SUPPLY

Air supply holes (φ4 and φ6) exists on the J1–axis connector panel for end effector as shown in Section 5.2.
There is a mechanical unit cable which includes solenoid valve as shown in Table 5.1 (a).
When the solenoid valve is replaced, the entire manifold should be replaced.

Table 5.1 (a) Optional solenoid valves

Mechanical unit Solenoid (Manifold)
Model Description Remarks RO
cable spec. spec.
Path 3 air piping, RO
A05B-1541-H201 SR-3iA/U connector output ― ― ―
(without solenoid valve)
A97L-0218-0153#D2
A05B-1541-H202 SR-3iA/U Double solenoids x 2 (manufactured by 2 position x 2 RO1 to 4
SMC)
Available section area of the solenoid valve：1.95mm2 (CV value：0.11)

NOTE
Attach an air filter with a mesh size of 5µm or better on the upstream side near
the robot. Compressed air including much drainage causes valve malfunctions.
Take action to prevent the entry of drainage, and also drain the air filter
periodically.

Supply air pressure 0.49 to 0.69MPa (5 to 7kgf/cm2), Setting: 0.49MPa (5kgf/cm2)

Air pressure
Amount of consumption Maximum instantaneous amount 120Nl/min (0.12Nm3/min)
* The air should be dry. Do not use oiled compressed air.

- 36 -

5. PIPING AND WIRING TO

B-84424EN/02 THE END EFFECTOR

5.2 AIR SUPPLY AND EE (RI/RO) INETRFACE

Fig. 5.2 (a) and (b) show air supply and EE (RI/RO) interface position.

B
Fig. 5.2 (a) Air supply and EE (RI/RO) interface position

- 37 -

5. PIPING AND WIRING TO

THE END EFFECTOR B-84424EN/02

Air inlet 1
φ 6エア入口1
O6 air)
(user
(ユーザエア)
Airエア入口2
inlet 2
φ 4O4
(user air)
(ユーザエア)
Air inlet 3
C
エア入口3
φ 4O4
(user air)
(ユーザエア)

Air outlet 1
エア出口1
M5
M5depth
深さ5 5
EE interface (user air)
(ユーザエア)
EEインタフェース
(RI
(RI xx44,, RO
RO xx 4)
4)
Air outlet 2
エア出口2
M5 depth 5
M5 深さ5
(user air)
(ユーザエア)
Air outlet 3
エア出口3
M5
M5 depth
深さ5 5
(user air)
(ユーザエア)
Detail
詳細CC
View
矢視AA View B
矢視 B
Mechanical unit cable spec. : A05B-1541-H201
機構部内ケーブル仕様：A05B-1541-H201

Air inlet 1
エア入口1
φO66
(user air)
(ユーザエア)

Air inlet 2
エア入口2
φO44
(air for soleniod
(電磁弁用エア)
valve)
D

EE interface
EEインタフェース
(RI x4)
(RI x 4)

Air outlet 1
エア出口1
M5 depth 5
M5 深さ5
RO3
RO3
M5
M5depth
深さ55
RO4
RO4
M5 深さ5
M5 depth 5
RO1
RO1
M5
M5depth
深さ55
RO2
RO2
M5
M5 depth
深さ5 5 Detail
詳細DD
View
矢視AA View
矢視BB
Mechanical unit cable spec. : A05B-1541-H202
機構部内ケーブル仕様：A05B-1541-H202
Fig. 5.2 (b) Air supply and EE (RI/RO) interface

- 38 -

5. PIPING AND WIRING TO

B-84424EN/02 THE END EFFECTOR
Fig. 5.2 (c), (d) show pin layout for EE interface (RI/RO).

EEEEインタフェース
interface (RI/RO) (output)
(RI/RO) (出力側)
8 RO4 9 24VR 1 RI1
End
エンド
7 RO3 12 10 XPPABN 2 RI2
6 RO2 11 0V 3 RI3
effector
エフェクタ
5 RO1 4 RI4

Outside FANUC delivery scope

お客様にてご用意ください
Controller
制御装置 XPPABN
XPPABN pressure
: 空圧異常 abnormal

Fig. 5.2 (c) EE (RI/RO) interface (When A05B-1541-H201 is specified)

EE EEインタフェース
interface (RI/RO) (output)
(RI/RO) (出力側)
8 9 24VR 1 RI1 End
エンド
7 12 10 XPPABN 2 RI2
effector
エフェクタ
6 11 0V 3 RI3
5 4 RI4

Outside FANUC delivery scope

お客様にてご用意ください
Controller XPPABN
XPPABN pressure
: 空圧異常abnormal
制御装置

Fig. 5.2 (d) EE (RI/RO) interface

(When A05B-1541-H202 is specified)

NOTE
For wiring of the peripheral device to the EE interface, refer to “CONNECTIONS
WITH EQUIPMENT” of manuals below, too.
MAINTENANCE MANUAL (B-84035EN)

Connector specifications
Table 5.2 (a) show the connector parts supported by the EE interface. Some of these parts are available as
an option from FANUC. (Table 5.2 (b))

Table 5.2 (a) Supported connector (user side)

Maker Manufacturer specification Remarks
Straight type connector (12 pins)
Plug: RM15WTPZ-12P(76)
∗indicates an applicable cable diameter selected from the following:
Clamp: JR13WCC-*(72) ∗ : φ 5，6，7，8，9，10mm
Hirose Electric
Co. Ltd. Elbow type connector (12 pins)
Plug: RM15WTLP-12P(33)
∗indicates an applicable cable diameter selected from the following:
Clamp: JR13WCC-*(72) ∗ : φ 5，6，7，8，9，10mm

Table 5.2 (b) Supported option

Option specification Remarks
Straight type connector (12-pins)
A05B-1137-J057
Applicable cable diameter : 8mm
Elbow type connector (12-pins)
A05B-1137-J058
Applicable cable diameter : 9mm

- 39 -

5. PIPING AND WIRING TO

THE END EFFECTOR B-84424EN/02

Table 5.2 (c) Specification of the cap

Parts name Specifications
Cap (EE) A97L-0118-0757#21

NOTE
For details, such as the dimensions, refer to the related catalogs offered by the
respective manufacturers, or contact your local FANUC representative.

- 40 -

B-84424EN/02 6. AXIS LIMIT SETUP

6 AXIS LIMIT SETUP

When axis limits are defined, the motion range of the robot can be changed from the standard value. The
motion range of the robot axes can be restricted because of:

- Used motion range limitations

- Tools and peripheral equipment interfere each other in some areas.
- Length of the cable or hose attached to the application is limited.
The software method used to prevent the robot from going beyond the necessary motion range.
- Axis limit by DCS (All axes)

WARNING
Changing the motion range of any axis affects the operation range of the robot.
To avoid trouble, carefully consider a possible effect of the change to the
movable range of each axis in advance. Otherwise, it is likely that an unexpected
condition occurs; for example, an alarm may occur in a previous taught position.

NOTE
Explanation in this chapter is for when teach pendant (option) is selected.

6.1 CHANGE AXIS LIMIT BY DCS (OPTION)

The robot motion can be restricted with DCS (Dual check safety) function. For J2/J3-axis, the same effect
as an adjustable mechanical stopper can be obtained.
The robot motion can be restricted at any angle and position if it is in robot motion area. DCS functions are
certified to meet the requirements of International Standard ISO13849-1 and IEC61508 approved by
certificate authority. If only the operating space is set using Joint Position Check, the robot stops after it
goes beyond the workspace. When the motor power is shut down, the robot’s momentum causes it to move
some distance before it completely stops. The actual "Robot Stop Position" will be beyond the workspace.
To stop the robot within the robot workspace, use the DCS Stop Position Prediction function. The stop
position prediction is disabled by default.

As an example, we shows the procedure to set ±90° for J2-axis in here. Refer to Dual check safety
function Operator’s Manual (B-83184EN) for details of other setting, function and DCS stop position
prediction.

Setting procedure
1 Press the [MENU] key to display the screen menu.
2 Press [0 NEXT] and press [6 SYSTEM].
3 Press the F1 ([TYPE]).
4 Select [DCS]. The following screen will be displayed.

AUTO
DCS JOINT 1%

1 Joint position check

2 Stop position prediction

[TYPE] APPLY DETAIL UNDO

- 41 -

6. AXIS LIMIT SETUP B-84424EN/02

5 Move the cursor to [1 Joint position check], then press the [DETAIL].

AUTO
DCS JOINT 1%
Join Position check
No. G A Status Comment
1 DISABLE 1 1 ---- [ ]
2 DISABLE 1 1 ---- [ ]
3 DISABLE 1 1 ---- [ ]
4 DISABLE 1 1 ---- [ ]
5 DISABLE 1 1 ---- [ ]
6 DISABLE 1 1 ---- [ ]
7 DISABLE 1 1 ---- [ ]
8 DISABLE 1 1 ---- [ ]
9 DISABLE 1 1 ---- [ ]
10 DISABLE 1 1 ---- [ ]

[TYPE] DETAIL

6 Move the cursor to [1], then press the [DETAIL].

AUTO
DCS JOINT 1%
No. 1 Status:
1 Comment [*********************]
2 Enable/Disable DISABLE
3 Group 1
4 Axis 1
5 Safe side:
Position (deg):
Current: 0.000
6 Upper limit : 0.000
7 Lower limit : 0.000
8 Stop type: Power-off stop

[TYPE] PREV NEXT UNDO

7 Move the cursor to [DISABLE], then press [CHOICE], set the status to [ENABLE].
8 Move the cursor to [Group], then input the robot group number, then press the [ENTER] key.
9 Move the cursor to [Axis], then input “2”, then press the [ENTER] key.
10 Move the cursor to [Upper limit] right side, then input “90”, then press the [ENTER] key.
11 Move the cursor to [Lower limit] right side, then input “-90”, then press the [ENTER] key.

WARNING
If only the operating space is set using Joint Position Check, the robot stops
after it goes beyond the workspace. When the motor power is shut down, the
robot’s momentum causes it to move some distance before it completely stops.
The actual "Robot Stop Position" will be beyond the workspace. To stop the
robot within the robot workspace, use the DCS Stop Position Prediction function.
The stop position prediction is disabled by default.

AUTO
DCS JOINT 1%
No. 1 Status:
1 Comment [*********************]
2 Enable/Disable ENABLE
3 Group 1
4 Axis 2
5 Safe side:
Position (deg):
Current: 0.000
6 Upper limit : +90.000
7 Lower limit : -90.000
8 Stop type: Power-off stop

[TYPE] PREV NEXT UNDO

- 42 -

B-84424EN/02 6. AXIS LIMIT SETUP

12 Press the [PREV] key two times, back to the first screen.

AUTO
DCS JOINT 1%

1 Joint position check UNSF PEND

2 Stop position prediction

[TYPE] APPLY DETAIL UNDO

13 Press the [APPLY].

14 Input 4-digit password, then press the [ENTER] key. (Password default setting is “1111”.)
15 The following screen will be displayed, then press the [OK].

AUTO
DCS JOINT 1%
Verify (diff)
F Number : F0000
VERSION : HandlingTool
$VERSION : V7.7097 9/1/2015
DATE: 17-7-28 19;44
DCS Version: V2. 0. 11

---Joint Position Check-----------------

No. G A Status Comment
1 EBABLE 1 2 CHGD [
2 ENABLE 1 2 ---- [
3 DISABLE 1 2 ---- [
ALL OK QUIT

[CHGD] on the right side of [1 Joint position check] will change to [PEND].

AUTO
DCS JOINT 1%

1 Joint position check UNSF PEND

2 Stop position prediction

[TYPE] APPLY DETAIL UNDO

16 Cycle the power of the controller in the cold start mode so the new settings are enabled.

WARNING
You must cycle the power of the controller to enable the new setting. If you fail to
do so, the robot does not work normally and it may injure personnel or damage
the equipment.

- 43 -

6. AXIS LIMIT SETUP B-84424EN/02

6.2 J4-AXIS MOTION RANGE EXTENSION BY CONTINUOUS

ROTATION FUNCTION
The continuous rotation function allows continuous and limitless rotation about the final axis or an
additional rotation axis of the robot in one direction.
For SR-3iA/U, the final axis J4-axis can be the target of this function.
For the general setup and details of continuous rotation function, refer to “Optional Function
OPERATOR’S MANUAL” (B-83284EN-2).
When you set up J4-axis axis of the robot as a continuous rotation axis, keep in mind the following
limitation.
1 Joint Position Check of Dual Check Safety function is not available for J3 and J4-axes.
2 When you load a previous backup (all backup, etc.) including the mastering data, do it with the
following procedure. During the procedure (1) to (3), do not change the position of the robot axes.
(1) Write down the current Mastering Data ($DMR_GRP[group].$MASTER_COUN[axis]) or save
a Mastering data file (SYSMAST.SV). This file is also included in all backup.
(2) Restore the previous backup.
(3) Restore the mastering data you made in step (1). You can restore it either by directly entering the
mastering data to system variable or loading SYSMAST.SV.

Sometime
過去の (1) (1)Save mastering data (2) Restore previous all backup (3) Restore the mastering data
マスタリングデータの保存 (2) 過去の全バックアップの復元 (3) マスタリングデータの復元
in 一時点
the past

Backup
保存 Backup
保存 Restore
復元 Restore
復元
ALL backup
全バックアップ Current mastering data
現在のマスタリングデータ

Fig. 6.2 (a) Restoration of a previous all backup after continuous rotation.

NOTE
When the continuous rotation is enabled with SR-3iA/U, you cannot load a
previous mastering data even if you have not done a remastering since then.
(see Fig. 6.2 (b))
If you load the data, the J3-axis position will become incorrect.
In such a case, remaster J3-axis.

- 44 -

B-84424EN/02 6. AXIS LIMIT SETUP

Continuous
連続回転動作 rotation

Backup
保存 Restore
復元

過去のマスタリングデータ
Previous mastering data

Fig. 6.2 (b) Example of wrong procedure of loading a previous mastering data

When setting the J4-axis of the robot as a continuous rotation axis, the following pop-up window is
displayed.

Fig.6.2 (c) Pop-up window of caution

- 45 -

7. CHECKS AND MAINTENANCE B-84424EN/02

7 CHECKS AND MAINTENANCE

Optimum performance of the robot can be maintained by performing the checks and maintenance
procedures presented in this chapter. (See APPENDIX A PERIODIC MAINTENANCE TABLE.)

NOTE
The periodic maintenance procedures described in this chapter assume that the
FANUC robot is used for up to 3840 hours a year. In cases where robot use
exceeds 3840 hours/year, adjust the given maintenance frequencies
accordingly. The ratio of actual operating time/year vs. the 3840 hours/year
should be used to calculate the new (higher) frequencies. For example, when
using the robot 7680 hours a year, the maintenance frequency should be
doubled – i.e. the time interval should be divided by 2.

7.1 CHECKS AND MAINTENANCE

7.1.1 Daily Checks

Clean each part, and visually check component parts for damage before daily system operation. Check the
following items when necessary.

Check items Check points and management

Check to see if there is oil on the sealed part of each joint. If there is an oil seepage,
Oil seepage clean it.
⇒“7.2.1 Confirmation of Oil Seepage”
Air control set (When air control set or air purge kit is used)
Air purge kit ⇒“7.2.2 Confirmation of the Air Control Set and Air Purge kit”
Check whether vibration or abnormal noises occur.
Vibration, When vibration or abnormal noises occur, perform measures referring to the following
abnormal noises section:
⇒“9.1 TROUBLESHOOTING” (symptom : Vibration, Noise)
Check that the taught positions of the robot have not deviated from the previously taught
positions. If displacement occurs, perform the measures as described in the following
Positioning accuracy
section:
⇒“9.1 TROUBLESHOOTING” (Symptom : Displacement)
Peripheral equipment Check whether the peripheral equipment operates properly according to commands from
for proper operation the robot and the peripheral equipment.
Check that the end effector drops 2 mm or less when servo power is turned off.
If the end effector (hand) drops, perform the measures as described in the following
Brakes for each axis
section:
⇒“9.1 TROUBLESHOOTING” (symptom : Dropping axis)
Check whether unexpected warnings occur in the alarm screen on the teach pendant. If
Warnings unexpected warnings occur, perform the measures as described in the following manual:
⇒“OPERATOR’S MANUAL (Alarm Code List) (B-83284EN-1)”

- 46 -

B-84424EN/02 7. CHECKS AND MAINTENANCE

7.1.2 Periodic Check and Maintenance

Check the following items at the intervals recommended below based on the period or the accumulated
operating time, whichever comes first. (○ : Item needs to be performed.)

Check and maintenance intervals

(Period, Accumulated operating time) Check and Periodic
Check points, management and
1 3 6 1 1.5 2 4 maintenance maintenance
month months months year years years years
maintenance method
item No.
320h 960h 1920h 3840h 5760h 7680h 15360h

○ ○ Cleaning the Confirm that the controller

Only controller ventilation system is not dusty. If
14
1st ventilation dust has accumulated, remove it.
check system
○ Check for Check whether the robot has
external external damage or peeling paint
damage or due to contact with the peripheral
peeling paint devices. If unintended contact has
occurred, eliminate the cause. Also, 1
if the external damage is serious,
and causes a problem in which the
robot will not operate, replace the
damaged parts.
○ Check for Check whether the robot is
water subjected to water or cutting oils. If
2
water is found, remove the cause
and wipe off the liquid.
○ ○ Check for Check whether the cable connected
Only damages to the teach pendant, operation box
1st to the teach and robot are unevenly twisted or
check pendant cable, damaged. If damage is found,
the operation replace the damaged cables.
13
box connection
cable
or the robot
connection
cable
○ ○ Check for Check whether the end effector
Only damage to the cables are unevenly twisted or
8
1st end effector damaged. If damage is found,
Check (hand) cable replace the damaged cables.
○ ○ Check the Check the exposed connectors.
Only exposed ⇒“7.2.3 Check the Connectors”
3
1st connectors
check
○ ○ Retightening Retighten the end effector mounting
Only the end effector bolts.
1st mounting bolts Refer to the following section for
4
check tightening torque information:
⇒“4.1 END EFFECTOR
INSTALLATION TO WRIST”

- 47 -

7. CHECKS AND MAINTENANCE B-84424EN/02

Check and maintenance intervals

○ ○ Retightening Retighten the robot installation bolts,

Only the external bolts that have been removed for
1st main bolts inspection, and bolts exposed to the
check outside. Refer to the recommended
bolt tightening torque guidelines at
the end of the manual. An adhesive
to prevent bolts from loosening is
5
applied to some bolts. If the bolts
are tightened with greater than the
recommended torque, the adhesive
might be removed.
Therefore, follow the recommended
bolt tightening torque guidelines
when retightening the bolts.
○ ○ Check the fixed Check that there is no evidence of a
Only mechanical collision on the fixed mechanical
1st stopper r stopper, and check that the stopper
6
check mounting bolts are not loose.
⇒“7.2.4 Check of Fixed
Mechanical Stopper”
○ ○ Clean spatters, Check that spatters, sawdust, or
Only sawdust and dust does not exist on the robot
1st dust main body. If dust has accumulated,
7
check remove it. Especially, clean the
robot movable parts well (each
joint).
○ Replacing the Replace the mechanical unit
mechanical unit batteries. Regardless of operating
batteries time, replace batteries at these 9
intervals.
⇒“7.3.1 Replacing the Batteries”
○ Replenish Grease ball screw spline
grease to ball ⇒“7.3.3 Replenish the Grease of 10
screw spline the Ball Screw Spline”
○ Confirm belt Confirm the belt tension.
tension Contact your local FANUC
11
representative for information
regarding adjusting the belt tension.
○ Replacing the Replace the mechanical unit cable
mechanical unit Contact your local FANUC
12
cable representative for information
regarding replacing the cable.
○ Replacing the Replace the controller batteries.
controller Regardless of operating time,
batteries replace batteries at 4 years.
15
⇒“Chapter 7 Replacing batteries
of MAINTENANCE MANUAL (B-
84035EN)”

- 48 -

B-84424EN/02 7. CHECKS AND MAINTENANCE

7.2 CHECK POINTS

7.2.1 Confirmation of Oil Seepage

Check items
Check to see whether there is an oil seepage on the rotating parts of each joint axis.

Fig. 7.2.1 (a) Check points of oil seepage

Management
 Oil might accumulate on the outside of the seal lip depending on the movement condition or
environment of the axis. If the oil changes to a state of liquid，the oil might fall depending on the axis
movement. To prevent oil spots, be sure to wipe away any accumulated oil under the axis components
before you operate the robot.
 If you must wipe oil frequently, perform the measures below.
⇒“9.1 TROUBLESHOOTING” (symptom：Grease leakage)

- 49 -

7. CHECKS AND MAINTENANCE B-84424EN/02

7.2.2 Confirmation of the Air Control Set and Air Purge kit (option)
When an air control set or an purge kit is used, check the items below.

Item Check items Check points

Check air pressure using the pressure gauge on the air control set as shown in
1 Air pressure Fig.7.2.2 (a). If it does not meet the specified pressure of 0.49MPa (5 kgf/cm2), adjust it
using the regulator pressure setting handle.
Leakage from Check the joints, tubes, etc. for leaks.
2
hose Repair leaks, or replace parts, as required.
Check drain and release it. If the quantity of the drained liquid is significant, examine
3 Drain
the setting of the air dryer on the air supply side.

Pressure
Adjusting Knob 2-6.5 x 16.5
Long hole

Rc1/4
AIR OUTLET

Pressure gauge

Rc1/4
AIR SUPPLY

Fig. 7.2.2 (a) Air control set (option)

7.2.3 Check the Connectors

Inspection points of the connectors
 Robot connection cables, earth terminal and user cables

Check items
 Circular connector : Check the connector for tightness by turning it manually.
 Earth/Ground terminal : Check the terminal for tightness.

Fig. 7.2.3 (a) Cable clamp and connector Inspection points

- 50 -

B-84424EN/02 7. CHECKS AND MAINTENANCE

7.2.4 Check of Mechanical Stopper

 Check that there is no evidence of a collision on the fixed mechanical stopper and the adjustable
mechanical stopper. If there is evidence of a collision on the stopper, replace the parts.
 Check the tightness of the stopper mounting bolts. If they are loose, retighten them.
 In case of bellows option, it is unnecessary to check the plus side stopper.

J3軸機械式ストッパ
J3-axis mechanical stopper
（マイナス側）
(minus side)

J3軸機械式ストッパ
J3-axis mechanical stopper
（プラス側）
(plus side)

Fig. 7.2.4 (a) Position of mechanical stopper

WARNING
Operate the robot without the cover is very dangerous. Be sure to fix the cover
with bolts after check. If noise occurs, the cover might not be fixed. Confirm the
bolts are not loose.

1 Change the J2-axis position so that the J2 arm cover can be removed.
2 Turn off controller power.
3 Loosen the J2 arm cover bolt (1), and remove the J2 arm cover (2).
4 In case of gasket option, remove the gasket (3).
5 After check, assembled it in the reversed sequence.

- 51 -

7. CHECKS AND MAINTENANCE B-84424EN/02

Fig. 7.2.4 (b) Removing the J2 arm cover

SR-3iA/U
Parts name Specifications Q’ty LOCTITE Torque (N-m)
1 COVER BOLT A290-7541-X429 6 1.2
2 J2 ARM COVER A290-7541-X402 1
3 GASKET (*1) A290-7541-X460 1
(*1) When antirust bolt and gasket option is specified

- 52 -

B-84424EN/02 7. CHECKS AND MAINTENANCE

7.3 MAINTENANCE

7.3.1 Replacing the Batteries (1-Year Periodic Maintenance)

The position data of each axis is preserved by the backup batteries. Replace them every year. Also use the
following procedure to replace them when the backup battery voltage drop alarm occurs.

Procedure of replacing the battery (if built-in batteries are specified)

1 Press the EMERGENCY STOP button to prohibit the robot motion.

CAUTION
Be sure to keep the power supply turned on. Replacing the batteries with the
power supply turned off causes all current position data to be lost. If this occurs,
mastering will be required again.

2 Remove the battery case cap. (Fig. 7.3.1 (a)) If it cannot be removed, tap it on the side with a plastic
hammer.
3 Loosen the plate screw and take off the lid of the battery box and replace the battery. The battery can
be taken out by pulling the stick which is in the center of the battery box.
4 Assemble them by reversing the sequence. Pay attention to the direction of batteries.

Battery can be taken out

この棒を引っ張ると
by pulling this stick
バッテリが取り出せます。

Case cap
ケースキャップ
Battery case
バッテリケース Battery spec.:A98L-0031-0027
バッテリ仕様:A98L-0031-0027
(1.5V -Volt C LR14 Alkaline Batteries 4 pcs)
(1.5V 単2形アルカリ乾電池 4本)
Fig. 7.3.1 (a) Replacing the battery (if built-in batteries are specified)

- 53 -

7. CHECKS AND MAINTENANCE B-84424EN/02

Procedure for replacing the battery (if external batteries are specified)
1 Press the EMERGENCY STOP button to prohibit the robot motion.

2 Uncap the battery case (Fig. 7.3.1 (b)).

3 Take out the old batteries from the battery case.
4 Insert new batteries into the battery case while observing their correct orientation.
5 Cap the battery case.

別置バッテリボックス
External battery case

バッテリケーブル
Battery cable
径約O5mm
Diameter about φ5mm
(MaxOφ5.5mm)
(最大 5.5mm)
長さ 5m
Length 5m

Battery spec.:A98L-0031-0005
バッテリ仕様:A98L-0031-0005
バッテリケース
Battery case (1.5V -Volt D LR20 Alkaline
(1.5V 単1形アルカリ乾電池 4本)Batteries 4 pcs) Case cap
ケースキャップ

Fig. 7.3.1 (b) Replacing the battery (if external batteries are specified)

- 54 -

B-84424EN/02 7. CHECKS AND MAINTENANCE

Fig. 7.3.1 (c) shows the external size of external battery box.
When the battery box needs to be built into the control cabinet, etc., refer to the external dimensions shown
in Fig. 7.3.1 (c).
The battery box can be fixed by using M4 flat–head screws. (The bolts do not come with the system.)
A maximum of six terminals can be attached to the backplane of the battery box.

Fig. 7.3.1 (a) External dimensions of the battery box

- 55 -

7. CHECKS AND MAINTENANCE B-84424EN/02

7.3.2 Replenish the Grease of the Ball Screw Spline

(6 months (1920 hours) checks)
Supply grease to ball screw spline at the intervals recommended below based on every 6 months or 1920
hours, whichever comes first. See Table 7.3.2 (a) for the grease name and the quantity.

Table 7.3.2 (a) Grease for 6-months (1920 hours) periodical replacement
Supply position Quantity Grease name
Ball screw spline Proper quantity Spec: A98L-0040-0329

NOTE
The following maintenance kits are prepared for the greasing.
- Grease in tube: A05B-1541-K201 (grease in tube (70g))

WARNING
Operate the robot without the cover is very dangerous. Be sure to fix the cover
with bolts after greasing. If noise occurs, the cover might not be fixed. Confirm
the bolts are not loose.

1 According to subsection 7.2.4, remove the J2 arm cover.

2 Supply new grease to the ball screw spline grooved with a cylinder referring to Fig. 7.3.2 (a).
3 Assembled it in the reversed sequence.

Apply grease to ball screw

注射器を使って
ボールねじスプラインの溝に
spline groove with a cylinder.
グリースを塗布すること

Fig. 7.3.2 (a) Applying grease of ball screw spline

7.4 STORAGE
When storing the robot, place it on a level surface with the same posture that was used for transportation.
(See Section 1.1.)

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B-84424EN/02 8. MASTERING

8 MASTERING
Mastering associates the angle of each robot axis with the pulse count value supplied from the absolute
Pulsecoder connected to the corresponding axis motor. To be specific, mastering is an operation for
obtaining the pulse count value; corresponding to the zero position.

NOTE
Explanation in this chapter is for when teach pendant (option) is selected.

8.1 OVERVIEW
The current position of the robot is determined according to the pulse count value supplied from the
Pulsecoder on each axis.
Mastering is factory-performed. It is unnecessary to perform mastering in daily operations. However,
mastering becomes necessary after:
 Motor replacement.
 Pulsecoder replacement
 Reducer replacement
 Cable replacement
 Batteries for pulse count backup in the mechanical unit have gone dead

CAUTION
Robot data (including mastering data) and Pulsecoder data are backed up by
their respective backup batteries. Data will be lost if the batteries die. Replace
the batteries in the controller and mechanical units periodically. An alarm will
alert you when battery voltage is low.

Types of Mastering
Table 8.1 (a) describes the following mastering methods.

Table 8.1 (a) Type of mastering

Fixture position This is performed using a mastering fixture before the machine is shipped from the
mastering factory.
Zero-position mastering This is performed with all axes set at the 0-degree position. A zero-position mark
(witness mark (witness mark) is attached to each robot axis. This mastering is performed with all axes
mastering) aligned to their respective witness marks.
This is performed at a user-specified position. The corresponding count value is
obtained from the rotation count of the Pulsecoder connected to the relevant motor and
Quick mastering
the rotation angle within one rotation. Quick mastering uses the fact that the absolute
value of a rotation angle within one rotation will not be lost. (All axes at the same time)
This is performed at a user-specified position for one axis. The corresponding count
Quick mastering for value is obtained from the rotation count of the Pulsecoder connected to the relevant
single axis motor and the rotation angle within one rotation. Quick mastering uses the fact that the
absolute value of a rotation angle within one rotation will not be lost.
This is performed for one axis at a time. The mastering position for each axis can be
Single-axis mastering
specified by the user. This is useful in performing mastering on a specific axis.
Mastering data entry Mastering data is entered directly.

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8. MASTERING B-84424EN/02

Once mastering is performed, you must carry out positioning (calibration). Positioning is an operation in
which the controller reads the pulse count value to sense the current position of the robot.

This section describes zero-position mastering, quick mastering, quick mastering for single axis, single-
axis mastering, and mastering data entry. For more detailed mastering (fixture position mastering), contact
your local FANUC representative.

CAUTION
1 If mastering is performed incorrectly, the robot may behave unexpectedly. This is
very dangerous. For this reason, the Master/Cal screen is designed to appear
only when the $MASTER_ENB system variable is 1 or 2. After performing
positioning, press F5, ([DONE]) on the Master/Cal screen. The $MASTER_ENB
system variable is then reset to 0 automatically, and the Master/Cal screen will
disappear.
2 Before performing mastering, it is recommended that you back up the current
mastering data.

8.2 RESETTING ALARMS AND PREPARING FOR

MASTERING
Before performing mastering because a motor has been replaced, it is necessary to release the relevant alarm
and display the positioning menu.

Alarm displayed
“SRVO-062 BZAL” or “SRVO-075 Pulse not established”

Procedure
1 Display the positioning menu by following the steps 1 to 6.
1 Press the [MENU] key.
2 Press [0 NEXT] and select [6 SYSTEM].
3 Press F1 ([TYPE]), and select [Variable] from the menu.
4 Place the cursor on $MASTER_ENB, then key in “1” and press the [ENTER] key.
5 Press F1 ([TYPE]), and select [Master/Cal] from the menu.
6 Select the desired mastering type from the [Master/Cal] menu.

2 To reset the “SRVO-062 BZAL” alarm, follow steps 1 to 5.

1 Press the [MENU] key.
2 Press [0 NEXT] and select [6 SYSTEM].
3 Press F1 ([TYPE]), and select [Master/Cal] from the menu.
4 Press F3 ([RES_PCA]), then press F4 ([YES]).
5 Cycle power of the controller.

3 To reset the “SRVO-075 Pulse not established” alarm, follow the steps 1 to 2.
1 After cycling controller power, the message “SRVO-075 Pulse not established” appears again.
2 Move the axis for which the message mentioned above has appeared in either direction till the
alarm disappears when you press the [RESET] key.

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B-84424EN/02 8. MASTERING

8.3 ZERO POSITION MASTERING

Zero-position mastering (witness mark mastering) is performed with all axes set at the 0-degree position.
A zero-position mark (witness mark) is attached to each robot axis. (Fig.8.3 (a)) This mastering is performed
with all axes set at the 0-degree position using their respective witness marks.
Zero-position mastering involves a visual check, and might not be highly accurate. It should be used only
as a quick-fix method.

Zero-position Mastering Procedure

1 Press the [MENU] key to display the screen menu.
2 Select [0 NEXT] and press [6 SYSTEM].
3 Press F1 [TYPE], display the screen change menu.
4 Select [Master/Cal]. The positioning screen will be displayed.

SYSTEM Master/Cal AUTO JOINT 10 %

TORQUE = [ON ]
1 FIXTURE POSITION MASTER
2 ZERO POSITION MASTER
3 QUICK MASTER
4 QUICK MASTER FOR SINGLE AXIS
5 SINGLE AXIS MASTER
6 SET QUICK MASTER REF
7 CALIBRATE
Press 'ENTER' or number key to select.

[ TYPE ] LOAD RES_PCA DONE

5 Release brake control, and jog the robot into a posture for mastering.

NOTE
Brake control can be released by setting the system variables as follows:
$PARAM_GROUP.SV_OFF_ALL : FALSE
$PARAM_GROUP.SV_OFF_ENB[*] : FALSE (for all axes)
After changing the system variables, turn off the controller power and on again.

6 Select [2 ZERO POSITION MASTER]. Press F4 [YES].

SYSTEM Master/Cal AUTO JOINT 10 %

TORQUE = [ON ]
1 FIXTURE POSITION MASTER
2 ZERO POSITION MASTER
3 QUICK MASTER
4 QUICK MASTER FOR SINGLE AXIS
5 SINGLE AXIS MASTER
6 SET QUICK MASTER REF
7 CALIBRATE
Robot Mastered! Mastering Data:
<0> <11808249> <38767856>
<9873638> <0> <0>
[ TYPE ] LOAD RES_PCA DONE

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8. MASTERING B-84424EN/02

7 Select [7 CALIBRATE] and press F4 [YES]. Mastering will be performed automatically.

Alternatively, turn off the controller power and on again. Turning on the power always causes
positioning to be performed.

SYSTEM Master/Cal AUTO JOINT 10 %

TORQUE = [ON ]
1 FIXTURE POSITION MASTER
2 ZERO POSITION MASTER
3 QUICK MASTER
4 QUICK MASTER FOR SINGLE AXIS
5 SINGLE AXIS MASTER
6 SET QUICK MASTER REF
7 CALIBRATE
Robot Calibrated! Cur Jnt Ang(deg):
< 0.0000> < 0.0000> < 0.0000>
< 0.0000> < 0.0000> < 0.0000>

8 After positioning is completed, press F5 [DONE].

DONE

9 Return brake control to original setting, and turn off the controller power and on again.

Table 8.3 (a) Posture with position marks aligned

Axis Position
J1-axis 0 deg
J2-axis 0 deg
J3-axis 0 mm
J4-axis 0 deg

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B-84424EN/02 8. MASTERING

Scribe
けがき線 J1mark J1

Scribe
けがき線 J2
mark J2

J3
2 mm

J4
Match the metal plate and
J4
the notch of the stopper
板金とストッパの切り欠きを合わせる

Fig. 8.3 (a) Marking position

NOTE
At J1-axis and J2-axis, 0 degree position and ±360 degree positon is same
appearance. If zero position mastering is performed at the except the 0 degree
positon, the mechanical unit cable is twisted and it might cause cable failure.
If you cannot understand the 0 degree position, contact your local FANUC
representative.

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8. MASTERING B-84424EN/02

8.4 QUICK MASTERING

Quick mastering is performed at a user-specified position for each axis. The pulse count value is obtained
from the rotation times of the Pulsecoder connected to the relevant motor and the rotation angle within one
rotation. Quick mastering uses the fact that the absolute value of a rotation angle within one rotation will
not be lost.

Quick mastering is factory-performed at the position indicated in Table 8.3 (a). If possible, do not change
the setting.

If it is impossible to set the robot at the position mentioned above, it is necessary to re-set the quick
mastering reference position using the following method. (It would be convenient to set up a marker that
can work in place of the witness mark.)

CAUTION
1 Quick mastering can be used, if the pulse count value is lost, for example,
because a low voltage has been detected on the backup battery for the pulse
counter.
2 Quick mastering cannot be used, after the motor is replaced or after the
mastering data is lost from the robot controller.

Procedure for Recording the Quick Mastering Reference Position

1 Select [6 SYSTEM].
2 Select [Master/Cal]. The positioning screen will be displayed.

SYSTEM Master/Cal AUTO JOINT 10 %

[ TYPE ] LOAD RES_PCA DONE

3 Release brake control, and jog the robot to the quick mastering reference position.
4 Select [6 SET QUICK MASTER REF] and press F4 [YES]. Quick mastering reference position is
saved.

5 SINGLE AXIS MASTER

6 SET QUICK MASTER REF
7 CALIBRATE

CAUTION
If the robot has lost mastering data due to mechanical disassembly or repair, you
cannot perform this procedure. In this case, perform Fixture position mastering
or Zero position mastering to restore mastering data.
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B-84424EN/02 8. MASTERING

Procedure of Quick Mastering

1 Display the Master/Cal screen.

SYSTEM Master/Cal AUTO JOINT 10 %

TORQUE = [ON ]
1 FIXTURE POSITION MASTER
2 ZERO POSITION MASTER
3 QUICK MASTER
4 QUICK MASTER FOR SINGLE AXIS
5 SINGLE AXIS MASTER
6 SET QUICK MASTER REF
7 CALIBRATE
Robot Not Mastered!

Quick master? [NO]

2 Release brake control, and jog the robot to the quick mastering reference position.
3 Move the cursor to [3 QUICK MASTER] and press the [ENTER] key. Press F4 [YES]. Quick
mastering data is memorized.

2 ZERO POSITION MASTER

3 QUICK MASTER
4 QUICK MASTER FOR SINGLE AXIS

4 Move the cursor to [7 CALIBRATE] and press the [ENTER] key. Calibration is executed.
Calibration can also be executed by cycling power.
5 After completing the calibration, press F5 [DONE].

DONE

6 Return brake control to original setting, and turn off the controller power and on again.

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8. MASTERING B-84424EN/02

8.5 QUICK MASTERING FOR SINGLE AXIS

Quick mastering for a single axis is performed at a user-specified position for one axis. The pulse count
value is obtained from the rotation times of the Pulsecoder connected to the relevant motor and the rotation
angle within one rotation. Quick mastering uses the fact that the absolute value of a rotation angle within
one rotation will not be lost.

Quick mastering is factory-performed at the position indicated in Table 8.3 (a). If possible, do not change
the setting.

If setting the robot at the position mentioned above is impossible, you must re-set the quick mastering
reference position using the following method. (It would be convenient to set up a marker that can work in
place of the witness mark.)

Procedure for Recording the Quick Mastering Reference Position

1 Select [6 SYSTEM].
2 Select [Master/Cal]. The positioning screen will be displayed.

SYSTEM Master/Cal AUTO JOINT 10 %

[ TYPE ] LOAD RES_PCA DONE

3 Release brake control, and jog the robot to the quick mastering reference position.
4 Select [6 SET QUICK MASTER REF] and press F4 [YES]. Quick mastering reference position is
saved.

5 SINGLE AXIS MASTER

6 SET QUICK MASTER REF
7 CALIBRATE

CAUTION
If the robot has lost mastering data due to mechanical disassembly or repair, you
cannot perform this procedure. In this case, perform Fixture position mastering
or zero –position mastering to restore mastering data.
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B-84424EN/02 8. MASTERING

Procedure of Quick Mastering for single axis

1 Display the Master/Cal screen.

SYSTEM Master/Cal AUTO JOINT 10 %

TORQUE = [ON ]
1 FIXTURE POSITION MASTER
2 ZERO POSITION MASTER
3 QUICK MASTER
4 QUICK MASTER FOR SINGLE AXIS
5 SINGLE AXIS MASTER
6 SET QUICK MASTER REF
7 CALIBRATE
Robot Not Mastered!

Quick master? [NO]

2 Select [4 QUICK MASTER FOR SINGLE AXIS]. You will see the quick master for single axis screen.

SINGLE AXIS MASTER AUTO JOINT 10%

1/9
ACTUAL POS (MSTR POS) (SEL) [ST]
J1 0.000 ( 0.000) (0) [2]
J2 0.000 ( 0.000) (0) [2]
J3 0.000 ( 0.000) (0) [2]
J4 0.000 ( 0.000) (0) [2]
J5 0.000 ( 0.000) (0) [2]
J6 0.000 ( 0.000) (0) [0]
E1 0.000 ( 0.000) (0) [0]
E2 0.000 ( 0.000) (0) [0]
E3 0.000 ( 0.000) (0) [0]

EXEC

3 Move the cursor to the (SEL] column for the unmastered axis and press the numeric key [1]. Setting
of (SEL) is available for one or more axes.

SINGLE AXIS MASTER AUTO JOINT 10%

1/9
ACTUAL POS (MSTR POS) (SEL) [ST]
J5 0.000 ( 0.000) (0) [2]
J6 0.000 ( 0.000) (0) [0]
EXEC

4 Turn off brake control, then jog the robot to the quick mastering reference position.
5 Press F5 [EXEC]. Mastering is performed. So, (SEL) is reset to 0, and [ST] is re-set to 2.
6 Move the cursor to [7 CALIBRATE] and press the [ENTER] key. Calibration is executed.
Calibration can also be executed by cycling power.
7 After completing the calibration, press F5 [DONE].

DONE

8 Return brake control to original setting, and turn off the controller power and on again.

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8. MASTERING B-84424EN/02

8.6 SINGLE AXIS MASTERING

Single axis mastering is performed for one axis at a time. The mastering position for each axis can be
specified by the user.
Single axis mastering can be used, if mastering data for a specific axis is lost, for example, because a low
voltage has been detected on the pulse counter backup battery or because the Pulsecoder has been replaced.

SINGLE AXIS MASTER AUTO JOINT 10%

EXEC

Table 8.6 (a) Items set in single axis mastering

Item Description
Current position The current position of the robot is displayed for each axis in degree or mm units.
(ACTUAL AXIS)
Mastering position A mastering position is specified for an axis to be subjected to single axis mastering. It
(MSTR POS) would be convenient to set to it to the 0_ position.
SEL This item is set to 1 for an axis to be subjected to single axis mastering. Usually, it is 0.
ST This item indicates whether single axis mastering has been completed for the
corresponding axis. It cannot be changed directly by the user.
The value of the item is reflected in $EACHMST_DON
(1 to 9).
0 : Mastering data has been lost. Single axis mastering is necessary.
1 : Mastering data has been lost. (Mastering has been performed only for the other
interactive axes.) Single axis mastering is necessary.
2 : Mastering has been completed.

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B-84424EN/02 8. MASTERING

Procedure of Single axis mastering

1 Select [6 SYSTEM].
2 Select [Master/Cal]. The positioning screen will be displayed.

SYSTEM Master/Cal AUTO JOINT 10 %

[ TYPE ] LOAD RES_PCA DONE

3 Select [5 SINGLE AXIS MASTER]. The following screen will be displayed.

SINGLE AXIS MASTER AUTO JOINT 10%

EXEC

4 Move the cursor to the [SEL] column for the unmastered axis and press the numeric key [1]. Setting
of [SEL] is available for one or more axes.
5 Turn off brake control, then jog the robot to the mastering position.
6 Enter axis data for the mastering position.
7 Press F5 [EXEC]. Mastering is performed. So, [SEL] is reset to 0, and [ST] is re-set to 2 or 1.

SINGLE AXIS MASTER AUTO JOINT 10%

6/9
ACTUAL POS (MSTR POS) (SEL) [ST]
J1 0.000 ( 0.000) (0) [2]
J2 0.000 ( 0.000) (0) [2]
J3 0.000 ( 0.000) (0) [2]
J4 0.000 ( 0.000) (0) [2]
J5 0.000 ( 0.000) (0) [2]
J6 90.000 ( 0.000) (1) [0]
E1 0.000 ( 0.000) (0) [0]
E2 0.000 ( 0.000) (0) [0]
E3 0.000 ( 0.000) (0) [0]

EXEC

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8. MASTERING B-84424EN/02

8 When single axis mastering is completed, press the [PREV] key to resume the previous screen.

SYSTEM Master/Cal AUTO JOINT 10 %

[ TYPE ] LOAD RES_PCA DONE

9 Select [7 CALIBRATE], then press F4 [YES]. Positioning is performed. Alternatively, turn off the
controller power and on again. Positioning is performed.
10 After positioning is completed, press F5 [DONE].

DONE

11 Return brake control to original setting, and turn off the controller power and on again.

8.7 MASTERING DATA ENTRY

This function enables mastering data values to be assigned directly to a system variable. It can be used if
mastering data has been lost but the pulse count is preserved.

Mastering data entry method

1 Press the [MENU] key, then press [0 NEXT] and select [6 SYSTEM].
2 Press F1 [TYPE]. Select [Variables]. The system variable screen will be displayed.

SYSTEM Variables AUTO JOINT 10%

1/669
1 $AAVM_GRP AAVM_GRP_T
2 $AAVM_WRK AAVM_WRK_T
3 $ABSPOS_GRP ABSPOS_GRP_T
4 $ACC_MAXLMT 0
5 $ACC_MINLMT 0
6 $ACC_PRE_EXE 0

[ TYPE ] DETAIL

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B-84424EN/02 8. MASTERING
3 Change the mastering data.
The mastering data is saved to the $DMR_GRP.$MASTER_COUN system variable.

SYSTEM Variables AUTO JOINT 10%

1/669
135 $DMR_GRP DMR_GRP_T
136 $DMSW_CFG DMSW_CFG_T

[ TYPE ]

4 Select $DMR_GRP.

SYSTEM Variables AUTO JOINT 10%

$DMR_GRP 1/1
1 [1] DMR_GRP_T

[ TYPE ] DETAIL

SYSTEM Variables AUTO JOINT 10%

$DMR_GRP 1/29
1 $MASTER_DONE FALSE
2 $OT_MINUS [9] of BOOLEAN
3 $OT_PLUS [9] of BOOLEAN
4 $NASTER_COUN [9] of INTEGER
5 $REF_DONE FALSE
6 $REF_POS [9] of REAL

[ TYPE ] TRUE FALSE

5 Select $MASTER_COUN, and enter the mastering data you have recorded.

SYSTEM Variables AUTO JOINT 10%

$DMR_GRP[1].$MASTER_COUN 1/9
1 [1] 95678329
2 [2] 10223045
3 [3] 3020442
4 [4] 30405503
5 [5] 0
6 [6] 0
7 [7] 0
8 [8] 0
9 [9] 0

[ TYPE ]

6 Press the [PREV] key.

7 Set $MASTER_DONE to TRUE.

SYSTEM Variables AUTO JOINT 10%

$DMR_GRP 1/29
1 $MASTER_DONE TRUE
2 $OT_MINUS [9] of BOOLEAN

[ TYPE ] TRUE FALSE

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8. MASTERING B-84424EN/02

8 Display the positioning screen, and select [7 CALIBRATE], then press F4 [YES].
9 After completing positioning, press F5 [DONE].

DONE

8.8 VERIFYING MASTERING

1 How to verify that the robot is mastered properly:
Usually, positioning is performed automatically when the power is turned on. To check whether
mastering has been performed correctly, examine if the current displayed position matches the actual
robot position by using one or more of the procedures described below:
(1) Reproduce a particular point in a program. Check whether the point agrees with the specified
position.
(2) Set all axes of the robot to their 0-degree (0 rad) positions. Check that the zero-degree position
marks indicated in Section 8.3 are aligned. There is no need to use a visual aid.
If the displayed and actual positions do not match, the counter value for a Pulsecoder may have
been invalidated as a result of an alarm described in 2. Alternatively, the mastering data in system
variable $DMR_GRP.$MASTER_COUN may have been overwritten as a result of an operation
error or some other reason.
Compare the data with the values indicated on the supplied data sheet. This system variable is
overwritten whenever mastering is performed. Whenever mastering is performed, record the
value of the system variable on the data sheet.
2 Alarm types displayed during mastering and their solution method:
(1) BZAL alarm
This alarm is displayed if the Pulsecoder's backup battery voltage decreases to 0 V while the
power to the controller is disconnected. Furthermore, if the Pulsecoder connector is removed for
cable replacement, etc. this alarm is displayed as the voltage decreases to 0. Check to see if the
alarm will disappear by performing a pulse reset (See Section 8.2.). Then, cycle controller power
and check if the alarm disappears or not.
The battery may be drained if the alarm is still displayed. Perform a pulse reset, and turn off and
on the controller power after replacing the battery. Note that, if this alarm is displayed, all the
original data held by the Pulsecoder will be lost. Mastering is required.
(2) BLAL alarm
This alarm is displayed if the voltage of the Pulsecoder's backup battery has fallen to a level
where backup is no longer possible. If this alarm is displayed, replace the battery with a new one
immediately while keeping the power turned on. Check whether the current position data is valid,
using the procedure described in 1.
(3) Alarm notification like CKAL, RCAL, PHAL, CSAL, DTERR, CRCERR, STBERR, and
SPHAL may have trouble with Pulsecoder, contact your local FANUC representative.

8.9 MASTERING BACKUP AND RESTORATION WHEN

CONTINUOUS ROTATION ENABLED
Refer to Section 6.2 for backup and restoration of mastering data when the continuous rotation is enabled.

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B-84424EN/02 9. TROUBLESHOOTING

9 TROUBLESHOOTING
The source of mechanical unit problems may be difficult to locate because of overlapping causes. Problems
may become further complicated, if they are not corrected properly. Therefore, you must keep an accurate
record of problems and take proper corrective actions.

9.1 TROUBLESHOOTING
Table 9.1 (a) shows the problems that may occur in the mechanical unit and their probable causes. If you
cannot pinpoint the cause of a failure or which measures to take, contact your local FANUC representative.
For troubleshooting except the mechanical unit, refer to “CONTROLLER MAINTENANCE MANUAL
(B-84035EN)” and Alarm Code List (B-83284EN-1).

Table 9.1 (a) Troubleshooting

Symptom Description Cause Measure
Vibration - The J1 base lifts off the [J1 base fastening] - If a bolt is loose, apply
Noise floor plate as the robot - It is likely that the robot J1 LOCTITE and tighten it to
operates. base is not securely the appropriate torque.
- There is a gap between the fastened to the floor plate. - Adjust the floor plate
J1 base and floor plate. - Probable causes are a surface flatness to within
- A J1 base retaining bolt is loose bolt, an insufficient the specified tolerance.
loose. degree of surface flatness, - If there is any
or contamination caught contamination between the
between the robot and floor J1 base and floor plate,
plate. remove it.
- If the robot is not securely
fastened to the floor plate,
the J1 base lifts the floor
plate as the robot operates,
allowing the base and floor
plates to strike each other.
That, in turn, leads to
vibration.
- The rack or floor plate [Rack or floor] - Reinforce the rack or floor
vibrates during operation of - It is likely that the rack or to make it more rigid.
the robot. floor is not rigid enough. - If reinforcing the rack or
- If they are not rigid enough, floor is impossible, modify
counterforce deforms the the robot control program;
rack or floor, and is doing so might reduce the
responsible for the vibration.
vibration.

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9. TROUBLESHOOTING B-84424EN/02

Symptom Description Cause Measure

Vibration - Vibration becomes more [Overload] - Check the maximum load
Noise serious when the robot - It is likely that the load on that the robot can handle
(Continued) adopts a specific posture. the robot is greater than once more. If the robot is
- If the operating speed of the maximum rating. found to be overloaded,
the robot is reduced, - It is likely that the robot reduce the load, or modify
vibration stops. control program is too the robot control program.
- Vibration is most noticeable demanding for the robot - Vibration in a specific
when the robot is hardware. portion can be reduced by
accelerating. modifying the robot control
- Vibration occurs when two program while slowing the
or more axes operate at robot and reducing its
the same time. acceleration (to minimize
the influence on the entire
cycle time).
- Vibration was first noticed [Bearing, ball screw spline or - Operate one axis at a time
after the robot collided with reducer] to determine which axis is
an object or the robot was - It is likely that the collision vibrating.
overloaded for a long or overload applied an - Remove the motor, and
period. excessive force to the drive replace the gear, the
- Cyclical vibration and noise mechanism, thus damaging bearing, the ball screw
occur. the rolling surface of a spline and the reducer. For
bearing, ball screw spline the spec. of parts and the
or reducer. method of replacement,
- It is likely that prolonged contact your local FANUC
use of the robot while representative.
overloaded caused fretting - Using the robot within its
of rolling surface of a maximum rating prevents
bearing, ball screw spline problems with the drive
or reducer due to resulting mechanism.
metal fatigue.
- It is likely that
contamination which was
caught in a bearing, ball
screw spline or within a
reducer caused damage on
the rolling surface of the
bearing, or reducer.
- It is likely that
contamination which was
caught in a bearing, ball
screw spline or within a
reducer cause vibration.

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B-84424EN/02 9. TROUBLESHOOTING

Symptom Description Cause Measure

Vibration - The cause of problem [Controller, cable, and motor] - Refer to the Controller
Noise cannot be identified from - If a failure occurs in a Maintenance Manual for
(Continued) examination of the floor, controller circuit, preventing troubleshooting related to
rack, or mechanical unit. control commands from the controller and amplifier.
being supplied to the motor - Replace the motor of the
normally, or preventing axis that is vibrating, and
motor information from check whether vibration still
being sent to the controller occurs. For the method of
normally, vibration might replacement, contact your
occur. local FANUC
- A Pulsecoder defect may representative.
be the cause of the - If vibration occurs only
vibration as the motor when the robot assumes a
cannot propagate the specific posture, it is likely
accurate position. that there is a mechanical
- If the motor becomes problem.
defective, vibration might - Check whether the cable
occur because the motor jacket of the robot
cannot deliver its rated connection cable is
performance. damaged. If so, replace the
- If a power line in a movable connection cable, and
cable of the mechanical check whether vibration still
unit has an intermittent occurs.
break, vibration might - Check whether the power
occur because the motor cable jacket is damaged. If
cannot accurately respond so, replace the power
to commands. cable, and check whether
- If a Pulsecoder wire in a vibration still occurs.
movable part of the - Check that the robot is
mechanical unit has an supplied with the rated
intermittent break, vibration voltage.
might occur because - Check that the robot
commands cannot be sent control parameter is set to
to the motor accurately. a valid value. If it is set to
- If a robot connection cable an invalid value, correct
has an intermittent break, them. Contact your local
vibration might occur. FANUC representative for
- If the power cable between further information if
them has an intermittent necessary.
break, vibration might - Contact your local FANUC
occur. representative if performing
- If the power source voltage the belt check.
drops below the rating,
vibration might occur.
- The robot may vibrate
when the invalid value
parameter was set.

- 73 -

9. TROUBLESHOOTING B-84424EN/02

Symptom Description Cause Measure

Vibration - There is some relationship [Noise from a nearby machine] - Connect the grounding wire
Noise between the vibration of - If the robot is not grounded firmly to ensure a reliable
(Continued) the robot and the operation properly, electrical noise ground potential and
of a machine near the may be induced on the prevent extraneous
robot. grounding wire, preventing electrical noise.
commands from being
transferred accurately, thus
leading to vibration.
- If the robot is grounded at
an unsuitable point, its
grounding potential
becomes unstable, and
noise is likely to be induced
on the grounding line, thus
leading to vibration.
Rattling - While the robot is not [Mechanical unit coupling bolt] - Check that the following
supplied with power, - It is likely that overloading bolts for each axis are tight.
pushing it with the hand or a collision has loosened If any of these bolts is
causes part of the a mounting bolt in the robot loose, apply LOCTITE and
mechanical unit to wobble. mechanical unit. tighten it to the appropriate
- There is a gap on the torque.
mounting face of the - Motor retaining bolt
mechanical unit. - Reducer retaining bolt
- Base retaining bolt
- Arm retaining bolt
- Casting retaining bolt
- End effector retaining
bolt
Motor - The motor overheated due [Ambient temperature] - Reducing the ambient
overheating to a rise in temperature in - It is likely that the motor temperature is the most
the installation area. overheated when the effective means of
- After changing the Robot ambient temperature rose, preventing overheating.
control program or the and could not dissipate the - If there is a source of heat
load, the motor overheated. heat. near the motor, it is
[Operating condition] advisable to install
- It is likely that the shielding to protect the
overcurrent is above the motor from heat radiation.
specified permissive - Relaxing the robot control
average current. program and load condition
is an effective way to
reduce the average
current. Thus, prevent
overheating.
- The teach pendant can be
used to monitor the
average current. Check the
average current when the
robot control program is
running.
- After a control parameter [Parameter] - As for load setting, Input an
(load setting etc.) was - If data input for a appropriate parameter
changed, the motor workpiece is invalid, the referring to Section 4.3.
overheated. robot cannot be accelerate
or decelerate normally, so
the average current
increases, leading to the
motor overheating.
- 74 -

B-84424EN/02 9. TROUBLESHOOTING

Symptom Description Cause Measure

Motor - Symptom other than stated [Mechanical unit problems] - Repair the mechanical unit
overheating above - It is likely that problems while referring to the above
occurred in the mechanical descriptions of vibration,
unit drive mechanism, thus noise, and rattling.
placing an excessive load - Check that, when the servo
on the motor. system is energized, the
[Motor problems] brake is released.
- It is likely that a failure of If the brake remains
the motor brake resulted in applied to the motor all the
the motor running with the time, replace the motor.
brake applied, thus placing - If the average current falls
an excessive load on the
after the motor is replaced,
motor.
it indicates that the first
- It is likely that a failure of
the motor prevented it from motor was faulty.
delivering its rated
performance, thus causing
an excessive current to
flow through the motor.
Grease - Grease is leaking from the [Poor sealing] - If a crack develops in the
leakage mechanical unit. - Probable causes are a casting, sealant can be
crack in the casting, a used as a quick-fix to
damaged oil seal, or a prevent further grease
leakage. However, the
loose seal bolt.
component should be
- A crack in a casting can
replaced as soon as
occur due to excessive possible, because the
force that might be caused crack might extend.
in a collision. - Oil seals are used in the
- An oil seal might be locations stated below.
damaged if extraneous - Inside the reducer
dust scratches the lip of the - Inside the wrist
oil seal. - Seal bolts are used in the
- A loose seal bolt might locations stated below.
allow grease to leak along - Grease inlet
the threads. - Wipe off grease on the ball
- There is a possibility that screw spline adequately.
too much grease is applied
to the ball screw spline.
Dropping - An axis drops because the [Brake drive relay and motor] - Check whether the brake
axis brake failed. - It is likely that the brake drive relay contacts are
- An axis drops gradually drive relay contacts are stuck to each other or not.
when it should be at rest. stuck to each other keeping If they are stuck, replace
the brake current flowing, the relay.
thus preventing the brake
- Replace the motor after
from operating when the
confirming the following
motor is de-energized.
symptoms.
- It is likely that the brake
- Brake shoe is worn out
shoe has worn out or the
- Brake main body is
brake main body is
damaged
damaged, preventing the
- Oil soaked through the
brake from operating
motor
efficiently.
- It is likely that oil or grease
has entered the motor,
causing the brake to slip.

- 75 -

9. TROUBLESHOOTING B-84424EN/02

Symptom Description Cause Measure

Displace- - The robot moves to a point [Mechanical unit problems] - If the repeatability is
ment other than the taught - If the repeatability is unstable, repair the
position. unstable, probable causes mechanical unit by
- The repeatability is not are a failure in the drive referring to the above
within the tolerance. mechanism or a loose bolt. descriptions of vibration,
- If the repeatability becomes noise, and rattling.
stable it is likely that a - If the repeatability is stable,
collision imposed an correct the taught program.
excessive load, leading to The problem will not
slipping on the base reoccur unless another
surface or the mating collision occurs.
surface of an arm or - If the Pulsecoder is faulty,
reducer. replace the motor.
- It is likely that the
Pulsecoder is faulty.
- Displacement occurs only [Peripheral unit displacement] - Correct the setting of the
in a specific peripheral unit. - It is likely that an external peripheral unit position.
force was applied to the - Correct the taught
peripheral unit, thus shifting program.
its position relative to the
robot.
- Displacement occurred [Parameter] - Re-enter the previous
after a parameter was - It is likely that the mastering data, which is
changed. mastering data was known to be correct.
rewritten in such a way that - If correct mastering data is
the robot origin was shifted. unavailable, perform
mastering again.

- 76 -

B-84424EN/02 9. TROUBLESHOOTING

Symptom Description Cause Measure

CLALM - Ambient temperature of the [Peripheral temperature] - Perform a warm up
alarm robot installation location is - When the robot is used in a operation or a low speed
occurred. low temperature
low, CLALM alarm is operation for several
Move error environment that is near to
displayed on the teach minutes.
excess alarm 0ºC, or the robot is not
pendant screen.
occurred. operated for a long time in
- Ambient temperature of the
robot installation position is an environment that is less
low, than 0ºC, there will be a
“Move error excess” alarm large viscous resistance of
is displayed on the teach the drive train immediately
pendant screen. after starting which will
cause the alarm.
- After changing the motion - It is likely that a robot - If a robot collision has
program or the load collision occurred. occurred, press the
condition, the CLALM [RESET] key while
alarm is displayed. pressing the [SHIFT] key.
- After changing the motion Then, jog the robot in the
program or the load opposite direction while
condition, the “Move error pressing the [SHIFT] key.
excess” alarm is displayed. - Check the motion program.
[Overload] - Check the permissible
- It is likely that load value of the robot payload.
exceeded the permissible If the load exceeds the
value. permissible value, reduce
- It is likely that the motion the load or change the
program is too severe for motion program.
the robot. - Consider minimizing the
 Tight motion such as influence on cycle time by
reverse motion using reducing the speed or
“CNT”. acceleration, and changing
 Linear motion occurs the motion program.
near singularity point - Check that the load setting
where axes revolve in is performed correctly.
high speed.
- None of the symptoms - It is likely the vibration - Refer to the Symptoms:
stated above are the occurred. Vibration, Noise section of
problem. this troubleshooting for
more information.
- It is likely that rated voltage - Check that the robot is
is not supplied due to the supplied with the proper
voltage drop. rated voltage.
BZAL alarm - BZAL is displayed on the - The voltage of the memory - Replace the battery.
displayed teach pendant screen. backup battery may be low. - Replace the cable.
- The Pulsecoder cable may
be broken.

- 77 -

APPENDIX

B-84424EN/02 APPENDIX A. PERIODIC MAINTENANCE TABLE

A PERIODIC MAINTENANCE TABLE

- 81 -

A. PERIODIC MAINTENANCE TABLE APPENDIX B-84424EN/02

FANUC Robot SR-3iA/U Periodic Maintenance Table

Accumulated operating First 3 6 9 1 2

Check Grease
time (H) check years
months months months years
time amount
Items 320 960 1920 2880 3840 4800 5760 6720 7680 8640 9600 10560
Check for external
1 damage or peeling paint 0.1H ― ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

2 Check for water 0.1H ― ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

Check the exposed
3 connector. (loosening) 0.2H ― ○ ○ ○

4 Tighten the end effector bolt. 0.2H ― ○ ○ ○

Tighten the cover and main
5 bolt. 1.0H ― ○ ○ ○
Mechanical unit

Check the fixed mechanical

6 stopper. 0.1H ― ○ ○ ○
Clean spatters, sawdust and
7 Dust 1.0H ― ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
Check the end effector
8 (hand) cable 0.1H ― ○ ○ ○
Replacing battery.
9 (if built-in batteries are 0.1H ― ● ●
specified) *3
Greasing the ball screw Proper
10 spline 0.1H quantity ● ● ● ● ●

11 Confirm the belt tension 0.1H ○ ○

Replacing cable of
12 mechanical unit 1.0H ― ●
Check the robot cable, teach
13 pendant cable and robot 0.2H ― ○ ○ ○
Controller

connecting cable
Cleaning the controller
14 ventilation system 0.2H ― ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○

15 Replacing batteries 1 3 0.1H ―

*1 Refer to the “REPLACING UNITS Chapter of “MAINTENANCE” in the following manuals.

CONTROLLER MAINTENANCE MANUAL (B-84035EN)
*2 ●: requires order of parts
○: does not require order of parts
*3 Regardless of the operating time, replace the mechanical unit batteries at 1 year, replace controller
batteries at 4 years.

- 82 -

B-84424EN/02 APPENDIX A. PERIODIC MAINTENANCE TABLE

3 4 5 6 7 8
years years years years years years Item
11520 12480 13440 14400 15360 16320 17280 18240 19200 20160 21120 22080 23040 24000 24960 25920 26880 27840 28800 29760 30720

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ 1

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ 2

○ ○ ○ ○ ○ 3

○ ○ ○ ○ ○ 4

○ ○ ○ ○ ○ 5

○ ○ ○ ○ ○ 6

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ 7

Overhaul
○ ○ ○ ○ ○ 8

● ● ● ● ● 9

● ● ● ● ● ● ● ● ● ● 10

○ ○ ○ ○ ○ 11
● ● 12

○ ○ ○ ○ ○ 13

○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ 14

● 15

- 83 -

B. STRENGTH OF BOLT AND

BOLT TORQUE LIST APPENDIX B-84424EN/02

B STRENGTH OF BOLT AND BOLT TORQUE LIST

NOTE
When applying LOCTITE to a part, spread the LOCTITE on the entire length of
the engaging part of the female thread. If applied to the male threads, poor
adhesion can occur, potentially loosening the bolt. Clean the bolts and the
threaded holes and wipe off any oil on the engaging section. Make sure that
there is no solvent left in the threaded holes. When finished, remove all the
excess LOCTITE when you are finished screwing the bolts into the threaded
holes.

Use the following strength bolts. Comply with any bolt specification instructions.
Hexagon socket head bolt made of steel:
Size M20 or less: Tensile strength 1200N/mm2 or more
Size M22 or more: Tensile strength 1000N/mm2 or more
All size plating bolt: Tensile strength 1000N/mm2 or more
Hexagon bolt, stainless bolt, special shape bolt (button bolt, low-head bolt, flush bolt .etc.)
Tensile strength 400N/mm2 or more
Refer to the following tables if the bolts tightening torque is not specified.

Recommended bolt tightening torques Unit: Nm

Hexagon socket head
button bolt
Hexagon socket head
Hexagon socket head Hexagon socket head Hexagon bolt
bolt
Nominal bolt (stainless steel) flush bolt (steel)
(steel)
diameter Low-head bolt
(steel)
Tightening torque Tightening torque Tightening torque Tightening torque
Upper limit Lower limit Upper limit Lower limit Upper limit Lower limit Upper limit Lower limit
M3 1.8 1.3 0.76 0.53 ―――― ―――― ―――― ―――
M4 4.0 2.8 1.8 1.3 1.8 1.3 1.7 1.2
M5 7.9 5.6 3.4 2.5 4.0 2.8 3.2 2.3
M6 14 9.6 5.8 4.1 7.9 5.6 5.5 3.8
M8 32 23 14 9.8 14 9.6 13 9.3
M10 66 46 27 19 32 23 26 19
M12 110 78 48 33 ―――― ―――― 45 31
(M14) 180 130 76 53 ―――― ―――― 73 51
M16 270 190 120 82 ―――― ―――― 98 69
(M18) 380 260 160 110 ―――― ―――― 140 96
M20 530 370 230 160 ―――― ―――― 190 130
(M22) 730 510 ―――― ―――― ―――― ―――― ―――― ――――
M24 930 650 ―――― ―――― ―――― ―――― ―――― ――――
(M27) 1400 960 ―――― ―――― ―――― ―――― ―――― ――――
M30 1800 1300 ―――― ―――― ―――― ―――― ―――― ――――
M36 3200 2300 ―――― ―――― ―――― ―――― ―――― ――――

- 84 -

B-84424EN/02 INDEX

INDEX
<A> <Q>
AIR SUPPLY .................................................................. 36 QUICK MASTERING .................................................... 62
AIR SUPPLY AND EE (RI/RO) INETRFACE .............. 37 QUICK MASTERING FOR SINGLE AXIS .................. 64
AXIS LIMIT SETUP ...................................................... 41
<R>
<B> Replacing the Batteries (1-Year Periodic Maintenance) . 53
BASIC SPECIFICATIONS ............................................ 10 Replenish the Grease of the Ball Screw Spline (6
months (1920 hours) checks) ....................................... 56
<C> RESETTING ALARMS AND PREPARING FOR
CHANGE AXIS LIMIT BY DCS (OPTION) ................. 41 MASTERING.............................................................. 58
Check of Mechanical Stopper ......................................... 51 ROBOT CONFIGURATION ......................................... 10
CHECK POINTS ............................................................ 49
Check the Connectors...................................................... 50 <S>
CHECKS AND MAINTENANCE ................................. 46 SAFETY PRECAUTIONS ............................................ s-1
Confirmation of Oil Seepage ........................................... 49 SINGLE AXIS MASTERING ........................................ 66
Confirmation of the Air Control Set and Air Purge kit STORAGE ...................................................................... 56
(option) ........................................................................ 50 STRENGTH OF BOLT AND BOLT TORQUE LIST ... 84
CONNECTION WITH THE CONTROLLER .................. 9
<T>
<D> Tool flange option ........................................................... 13
Daily Checks ................................................................... 46 TRANSPORTATION ....................................................... 1
TRANSPORTATION AND INSTALLATION ................ 1
<E> TROUBLESHOOTING .................................................. 71
END EFFECTOR INSTALLATION TO WRIST .......... 23
EQUIPMENT INSTALLATION TO THE ROBOT ....... 23 <V>
EQUIPMENT MOUNTING FACE ................................ 26 VERIFYING MASTERING ........................................... 70

<I> <W>
INSTALLATION .............................................................. 3 WRIST LOAD CONDITIONS ....................................... 22
INSTALLATION CONDITIONS ..................................... 8
Installation Example .......................................................... 5 <Z>
ZERO POINT POSITION AND MOTION LIMIT ........ 16
<J> ZERO POSITION MASTERING ................................... 59
J4-AXIS MOTION RANGE EXTENSION BY
CONTINUOUS ROTATION FUNCTION ................. 44

<M>
MAINTENANCE............................................................ 53
MAINTENANCE AREA .................................................. 8
MASTERING ................................................................. 57
MASTERING BACKUP AND RESTORATION
WHEN CONTINUOUS ROTATION ENABLED ...... 70
MASTERING DATA ENTRY ....................................... 68
MECHANICAL UNIT OPERATING SPACE AND
INTERFERENCE AREA ............................................ 14

<O>
OVERVIEW ................................................................... 57

<P>
PAYLOAD SETTING .................................................... 29
Periodic Check and Maintenance .................................... 47
PERIODIC MAINTENANCE TABLE ........................... 81
PIPING AND WIRING TO THE END EFFECTOR ...... 35
PREFACE ......................................................................p-1

i-1

B-84424EN/02 REVISION RECORD

REVISION RECORD
Edition Date Contents
・Addition of the bellows option, antirust bolt and gasket option, external batteries option
02 Jul., 2024 ・Change of the transportation method
・Correction of errors
01 Mar., 2022

r-1

B-84424EN/02

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