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CRS A255 Service Manual

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A255 Robot
Servic e Manual
UMS-14-504

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  • Page 1 A255 Robot Servic e Manual UMS-14-504...
  • Page 2 Chapter 1: Service tools required. 01-01 Chapter 2: Positional Gain, Home Command, Homing Errors. Chapter 3: A255 Controller Electronics, Auxiliary Board Connectors, Controller AC Power System, Linear Amplifier Module. Chapter 4: Teach Pendant Connector,GPIO Connector,Motor Power Connector, Arm Signal Schematic.
  • Page 3 A255 Robot Service Manual Copyright © 2001 CRS Robotics Corporation RAPL is a trademark of CRS Robotics Corporation and may be used to describe only CRS Robotics products. DOS is a registered trademark and Windows is a trademark of Microsoft Corporation. IBM is a registered trademark of International Business Machines Corporation.
  • Page 4 The information in this document is subject to change without notice. CRS Robotics Corporation makes no warranty of any kind with regard to this material, including, but not limited to, the implied warranties of merchantability and fitness for a particular purpose. CRS Robotics Corporation assumes no responsibility for any errors that may appear in this document.
  • Page 5 Mechanical Service and Repair Procedures for all User- Serviceable Components. Chapter 8 Mechanical Drawings Component Drawings for the A255 Robot Arm. Before attempting to follow a procedure or example, read the entire section first. Throughout this service manual, warnings are marked by an “!” icon in the left margin.

  • Page 6: Table Of Contents

    A255 Robot Service Manual Contents 1 Introduction 1-1 Robot Arm Schematic..............1-1 1-2 Safety Summary................1-2 1-2-1 General Safety Rules ............1-2 1-2-2 Safety and Operation Checks.......... 1-3 1-2-3 Safety Checks For Working Within the Robot’s Workspace..............1-4 1-3 Serial Number Location..............1-5 1-4 Service Tools Required ..............
  • Page 7 2-17-3 RAPL-II Error Messages ..........2-33 2-17-4 The @@DIAG Command..........2-33 2-17-5 "WHERE" Commands ..........2-33 3 Electronics Description 3-1 A255 Controller Electronics ............3-1 3-2 Controller Board ................3-2 3-2-1 Controller Board Components ........3-3 3-2-2 Socketed Components ............ 3-4 3-2-3 Controller Board Connectors ..........
  • Page 8 A255 Robot Service Manual 3-5-3 PWM Amplifiers ............3-56 3-5-4 PWM Amplifier Connectors ........... 3-57 3-5-5 T265 Track Connectors ..........3-58 3-6 Front Panel Display Board ............3-59 3-6-1 Front Panel Display Board Connectors ......3-60 3-7 Encoder Connector Board ............3-61 4 Wiring and Connectors 4-1 Introduction .................
  • Page 9 Contents 5-4 Homing Problems ............... 5-11 5-4-1 056 Checksum Errors ..........5-11 5-4-2 101 Sequence Error............5-11 5-4-3 034-39 Home Fail Error..........5-12 5-5 Digital I/O Problems ..............5-12 5-5-1 Input from External Device Errors ........ 5-12 5-5-2 Output to an External Device ........5-13 5-6 Serial Communication Problems ..........
  • Page 10 A255 Robot Service Manual 7 Mechanical Checks and Adjustments 7-1 A255 Robot Arm General Schematic ..........7-1 7-2 Mechanical Maintenance Schedule ..........7-2 7-2-1 A255 Robot Arm and Controller........7-2 7-2-2 A265 Track Maintenance ..........7-2 7-3 Chain Tension Adjustment............7-4 7-4 Wrist Gears ..................
  • Page 11 Figure 3-7 A255 Motor Power............3-47 Figure 3-8 A255 Position Feedback From Encoders ......3-48 Figure 3-9 A255 Connections to the Auxiliary Board (AB) ....3-49 Figure 3-10 A255 Connections to the Controller Board (CB) ..... 3-50 Figure 3-11 Linear Amplifier Module ..........3-54 Figure 3-12 PWM Amplifier ..............
  • Page 12 A255 Robot Service Manual Figure 8-6 Joint 2 Shaft Assembly............. 8-7 Figure 8-7 Joint 3 Sprocket Assembly..........8-8 Figure 8-8 Neck Assembly..............8-9 Figure 8-9 Motor 1 Assembly............8-10 Figure 8-10 Wrist Motor Assembly........... 8-11...
  • Page 13 Table 3-14 Power Supply Connector ..........3-20 Table 3-15 Auxiliary Board Logic Power Input Connector ....3-21 Table 3-16 Dip Switch Settings for the A255 ........3-22 Table 3-17 Auxiliary Board Diagnostic LED’s ........3-22 Table 3-18 Auxiliary Board Connector Legend........3-24 Table 3-19 CB-1 I/O Board Interconnect..........
  • Page 14 A255 Robot Service Manual Table 3-37 Soft Start Board J4 ............3-44 Table 3-38 Soft Start Board J3 ............3-44 Table 3-39 Power Supply J1 ............. 3-47 Table 3-40 Power Supply J2 ............. 3-47 Table 3-41 Power Filter Board J1 ............. 3-48 Table 3-42 Power Filter Board J2 .............
  • Page 15 (Unconditioned Signals) ..........6-54 Table 6-14 Serial Command Display ..........6-67 Table 6-15 Displayed Value Definitions ..........6-67 Table 6-16 Amplifiers Settings for the A255........6-73 Table 7-1 Scheduled Mechanical Maintenance ........7-2 Table 7-2 T265 Track Scheduled Mechanical Maintenance....7-3...
  • Page 16 A255 Robot Service Manual...

  • Page 17: Introduction

    C H A P T E R 1 1 Introduction Robot Arm Schematic Figure 1-1 Profile of the robot in the "READY" position viewed from the front and the side Figure 1-3 Serial Teach Pendant Figure 1-2 C500 Controller...

  • Page 18: Safety Summary

    The following information should be mandatory reading for all personnel who enter the area within reach of the robot arm. This service manual is not a self-teaching vehicle. It is intended for use only by personnel who have completed the CRS Robotics training course. 1-2-1 General Safety Rules Follow these safety rules to ensure proper operation of the robot arm: 1.

  • Page 19: Safety And Operation Checks

    Ensure that you have followed all the instructions supplied within this manual. BEFORE applying power to the arm, verify that: o The robot is properly installed, mounted, and is stable, (refer to A255 Robot System User Guide for details). o The electrical connections are correct and that the power supplies (voltage, frequency and interference levels) are within the specified ranges, (refer to A255 Robot System User Guide for details).

  • Page 20: Safety Checks For Working Within The Robot's Workspace

    A255 Robot Service Manual 1-2-3 Safety Checks For Working Within the Robot’s Workspace Before entering within the robot’s workspace perform the following checks and safety precautions. o Visually inspect the robot to determine if any conditions exist that can cause malfunctions or injury to persons.

  • Page 21: Serial Number Location

    Chapter 1: Introduction Serial Number Location When calling CRS or your local CRS representative, have your robot and controller serial numbers ready for reference. The CRS Robotics serial number plates are shown in the figures below. Figure 1-4 Controller Serial Number Plate...

  • Page 22: Service Tools Required

    A255 Robot Service Manual Service Tools Required Pliers • Needle-nose pliers • Diagonal cutting pliers • Line-man pliers • Slip-joint pliers • 6" Vice grip pliers Electronic equipment • Anti-static grounding wrist strap • Digital multi-meter with 10 Amp current capacity with probes and clips •...

  • Page 23: Controller Operation

    C H A P T E R 2 2 Controller Operation Introduction Most service procedures for the A255 system require the use of a computer connected to the controller front panel serial communications port. Operate the PC in interactive, immediate mode using a terminal emulator (see sections and 2-10).
  • Page 24 A255 Robot Service Manual To power up the robot: • Switch the main power switch to the ON position. The power turns on and the display reads "A1." During the normal power-up sequence, one or more of the status lights on the panel buttons may flash, depending on resident programs.

  • Page 25: Default Power-Up Parameters

    Chapter 2: Controller Operation Default Power-up Parameters Unless otherwise specified in an AUTOEXEC program (see @@SETUP command in the RAPL-II Programming Manual), the A255 power-up routine automatically sets the various system parameters to default values. Table 2-1 lists these default settings.

  • Page 26: Initialization Logic Sequence

    A255 Robot Service Manual Initialization Logic Sequence The Controller “display” characters (“D1” etc.) indicate the states the system enters at various points in the initialization sequence. START "AE" Initialize Execute Diagnostic "D1" Processor Diagnostic Registers Mode Initialize Flash Input/Output Loaded "AC"...
  • Page 27 Chapter 2: Controller Operation Initialization Logic Sequence (Continued) "A7" "A3" Enable User Fail System Memory Message Fail? Execute "A1" ALLOCATE* Initialize *See Fig. 2-3 Auto System Execute Pendant Sequence Timers Pendant Active? Device "A6" Panel Device "A5" AUTOEXEC Run Program Sign-on Flag? "AUTOEXEC"...

  • Page 28: User Memory Allocation

    A255 Robot Service Manual User Memory Allocation Allocate User Memory PROGRAMS VARIABLES LOCATIONS PATHS HIMEM Proceed? Find User Memory Size Eliminate HIMEM allocation Display total User Memory Auto PATH Memory Enter: Allocate? 5000 bytes #PROGRAMS #VARIABLES #LOCATIONS #PATH POINTS Partition remainder...

  • Page 29: Command Processing Loop

    Chapter 2: Controller Operation Command Processing Loop Once the controller is initialized it uses command processing logic to decide where the next command will come from. Note that the operational mode of the controller is maintained. • If a computer using Robcomm is connected to the controller, then the system expects its next command to come from the computer keyboard in interactive mode.

  • Page 30: Immediate Mode

    A255 Robot Service Manual Immediate Mode Most service procedures for the A255 system are performed in immediate mode from an "interactive" PC computer connected to the controller front panel serial communications port. To terminate from the STP (Serial Teach Pendant) to interactive communication at power-up, choose F2...

  • Page 31: Auto Execute Sequence

    For example, if your A255 robot is mounted on a track, the track remains limp until the track parameter is correctly set (see @@SETUP command in the RAPL-II Programming Manual).

  • Page 32: Arm Power Checks

    A255 Robot Service Manual 2-9-1 Arm Power Checks In the A255 robot system, any signal that permits arm power to be turned on must pass through the following logical "checks" before power can be applied see (Figure 2-1 Initialization Logic Sequence).

  • Page 33: Interactive I/O

    Chapter 2: Controller Operation 2-11 Upon power-up, the Serial Teach Pendant (STP), if connected, becomes the active device by default. To terminate STP communication to the interactive device: • Choose F2 (comm) from the STP Terminal screen. • Start Robcomm and choose Terminal Mode •...

  • Page 34: Important Codes

    2-12 A255 Robot Service Manual Important Codes <Ctrl-C> and <Ctrl-X> which, when received, cause an immediate halt of arm motion and program execution, and result in causing communication to reset. Characters received by the controller's I/O device pass through a "ring- buffer”.

  • Page 35: Host Interface Communication (Aci Operation)

    Chapter 2: Controller Operation 2-13 2-11 Host Interface Communication (ACI Operation) Upon power-up, communication between the robot controller and a host (interactive) computer is in Advanced Communications Interface (ACI) mode. The ACI mode transmits software data across the communications link, for example, when loading a program.

  • Page 36: Communication Errors Reported At The Controller

    2-14 A255 Robot Service Manual 2-11-2 Communication Errors Reported at the Controller End At the controller end of the data communication link, error messages are interpreted in the RAPL-II system language. For the purpose of debugging the communication, display such errors at the host computer by issuing the @@RS status display command.

  • Page 37: Digital I/O Operation

    Chapter 2: Controller Operation 2-15 2-12 Digital I/O Operation The I/O Enable line is a signal path from the controller board to the auxiliary board. During normal operation, the controller board issues a Watchdog signal to relay circuitry on the auxiliary board. The I/O Enable signal does not begin until the robot computer completes its start-up initialization routine.

  • Page 38: Servo Operation

    2-16 A255 Robot Service Manual 2-13 Servo Operation The servo system operates as illustrated and described below. Figure 2-6 Servo Block Diagram 2-13-1 COMMAND INTERPRETER The COMMAND INTERPRETER (not represented in the drawing) is a software process that interprets RAPL-II commands issued from the interactive device or the stored program.

  • Page 39: Command Generator

    (one for each axis) on a time basis. The time of each position update varies depending upon the mode of operation, but typical intervals range from 10 to 30 msec. For A255 robots, the servo loop is always updated at 1 msec intervals.

  • Page 40: Positional Gain

    The output of this stage is called the command signal. The A255 controller uses a PID control gain with a proportional gain of 12, an Integral gain of 0.05, and a differential gain of 100. The PID...

  • Page 41: D/A Converter

    Chapter 2: Controller Operation 2-19 2-13-7 D/A Converter The D/A Converter (digital to analog) is part of the circuitry on the controller board's servo axis circuit. Its function is to convert the digital signal from the computer to an analog voltage. The relationship between the digital and analog values is controlled by two trim-pots on the controller board next to the 60 pin box headers.

  • Page 42: Encoder

    A255 Robot Service Manual 2-13-10 Encoder The A255 encoders are incremental optical kit-type units mounted directly on the motor shafts. The encoders use optical quality plastic disks with 1000 lines per revolution for positional feedback. Each disk has one reference marker pulse per revolution which is aligned during the homing procedure.

  • Page 43: Integrator

    Chapter 2: Controller Operation 2-21 2-13-12 Integrator The integrator is a software counter that reads the value in the hardware counter on the axis circuit each time the position loop closes. The hardware counter rolls over whenever the value exceeds the12 bit limit or counts down from 0.
  • Page 44 2-22 A255 Robot Service Manual 4. Consider the case of a motor whose current commanded position is 18000 pulses, and in the next interval a 20 pulses change in position is demanded. If the current position is actually 17981 pulses, there is an error of 19 pulses.

  • Page 45: Homing Procedure

    Home Command With the homing command, you can home the robot system, without having to precisely position the A255 robot arm manually. Versions of RAPL-II (the robot system software) from 2.38 and up use the simple "HOME" command. The following table lists the commands.

  • Page 46: Zero Position

    2-24 A255 Robot Service Manual 2-14-2 Zero Position The zero position is a specific arm pose which is used as a starting point for calculating joint angle measurements for all Cartesian locations. In this pose, all arm axes positions register zero. This pose is also called the CALRDY position because the @CALRDY command can be used to move the arm to that position.

  • Page 47: Home Range

    Chapter 2: Controller Operation 2-25 2-14-6 Home Range The Home Range for each joint is the full rotation of the encoder disk leading up to the Zero Cross Pulse that defines the Calibration Position. Before the homing procedure, you must move each joint to within the range indicated by the home alignment marks on the robot arm, see Figure 2-8 Alignment Test Strip.

  • Page 48: Homing Errors

    2-26 A255 Robot Service Manual 2-15 Homing Errors In order to achieve correct homing, the following systems and components must be intact and operating correctly: 1. Encoder Zero-Cross pulse 2. Zero-Cross pulse wiring 3. PID logic 4. Calibration memory integrity Any failure will lead to an error during the HOME sequence.
  • Page 49 Chapter 2: Controller Operation 2-27 RAPL-II Error 056 - Calibration Checksum This error indicates that memory containing the arm calibration registers is corrupt. To recover the calibration: • Use the Memory/Calibrate/Send menu item to send the contents of the file called SRS_#### to the robot. You can locate this file on the distribution disk that is sent with each system in the directory “CAL”.

  • Page 50: Gripper Operation

    2-16-1 Air Gripper The A255 arm contains a 2-way air solenoid valve for the operation of a small gripper or other small air-powered devices attached to the end of the tool flange. The valve operates from a 12 VDC circuit on the auxiliary board.

  • Page 51: Software Diagnostics

    2-29 2-17 Software Diagnostics Several software procedures can be used to determine errors in the use of CRS robot systems. These procedures require the use of Robcomm-II software to correctly diagnose and repair the errors. Software detectable errors include: •...
  • Page 52 2-30 A255 Robot Service Manual System (or Parameter) Memory System memory contains the parameters used for normal system operation. All servo parameters, communication parameters, peripheral axis parameters, memory allocation information, etc. are stored here. Parameter memory is located in battery backed-up RAM and is normally retained during power-off.

  • Page 53: Memory Checksums

    Chapter 2: Controller Operation 2-31 Calibration Memory This memory contains calibration information for the particular robot arm run by the controller. It may also contain calibration information for any extra axes that have been installed in the controller. Calibration memory is maintained when power is removed from the system. Calibration memory is vital for robot operation.
  • Page 54 2-32 A255 Robot Service Manual The robot calibration position is maintained with its own checksum. Before the robot is allowed to HOME, the integrity of the calibration is confirmed. If there is an error, then homing stops and the robot is not permitted any complex moves until the error is cleared.

  • Page 55: Rapl-Ii Error Messages

    Chapter 2: Controller Operation 2-33 2-17-3 RAPL-II Error Messages RAPL-II monitors robot operations for error conditions. When an error is detected, RAPL-II stops robot motion and program execution, if any, displays an error message on the interactive device, or on the teach pendant if it is plugged in and enabled.
  • Page 56 2-34 A255 Robot Service Manual...

  • Page 57: Electronics Description

    C H A P T E R 3 3 Electronics Description A255 Controller Electronics The A255 controller box is divided into three main compartments for electronic hardware. The upper compartment houses the robot control electronics. The lower compartment contains the AC power supply, main power start-up circuitry, and the power filter board.

  • Page 58: Controller Board

    A255 Robot Service Manual Controller Board The controller board (Figure 3-1) is the controller's upper large printed circuit board. The controller board is responsible for the communications, data processing, and memory functions of the robot system. Figure 3--1 Controller Board...

  • Page 59: Controller Board Components

    Chapter 3: Electronics Description 3-2-1 Controller Board Components The controller board contains the following components: An Intel 80286 16-bit microprocessor and Intel 80287-2 math co-processor, running at a master clock frequency of 11.05 MHz. Transputer Inmos 4 serial port crossbar linked multiprocessor, running at 20 MHz for servo loop control.

  • Page 60: Socketed Components

    A255 Robot Service Manual 256 Kbytes of Random Access Memory is provided for user programming and computer "scratch-pad" space. The RAM chips have an external lithium battery which will retain the memory contents for up to 10 years. Flash ROM 512 Kbytes RAM is in use for system firmware with 512 Kbytes available for user memory backup.

  • Page 61: Table 3-3 Jp25 Test Strip (Condition Signals)

    Chapter 3: Electronics Description JP25 Test Strip (Condition Signals) Signal Signal Table 3-3 JP25 Test Strip (Condition Signals)

  • Page 62: Controller Board Connectors

    A255 Robot Service Manual 3-2-3 Controller Board Connectors Figure 3-2 below shows the controller board’s connector locations. See legend (Table 3-3) and pin-outs in tables that follow. Figure 3-2 Controller Board Connector Locations...

  • Page 63: Table 3-4 Controller Board Connectors Legend

    Chapter 3: Electronics Description Label Description Aux Board Connector #1 Interconnect Communication Port Teach Pendant Connector Transputer Network UP Transputer Network DOWN Aux Board Connector #2 Interconnect Encoder Connector Encoder Power Connector Amp Expansion Power Supply Aux Board Power Connector Table 3-4 Controller Board Connectors Legend...

  • Page 64: Table 3-5 Ab-2 I/O Board Interconnect

    A255 Robot Service Manual CB-J1 Connector Name AB-2 I/O Board Interconnect Connector Type 60 Pin Ansely Header Destination AB-J2 SCC-23-001 Pin # Function Signature Description Hex0 Display Data (LSB) Hex1 Display Data Hex2 Display Data Hex3 Display Data Hex4 Display Data...
  • Page 65 Chapter 3: Electronics Description CB-J1 (Continued) Pin # Function Signature Description GPI6 General Purpose user input #6 GPO7 General Purpose user output #7 GPI7 General Purpose user input #7 GPO8 General Purpose user output #8 GPI8 General Purpose user input #8 GPO9 General Purpose user output #9 GPI9...

  • Page 66: Table 3-6 Communications Port Connector

    3-10 A255 Robot Service Manual CB-J2 Connector Name Communications Port Connector Connector Type 26 Pin Ansely Destination Front Panel Chassis-Mount DB25 Connector SCC-23-107 Pin # Function Signature Description not used RS-232C Receive signal RS-232C Transmit signal CTS- RS-232C Clear To Send...

  • Page 67: Table 3-7 Teach Pendant Connector

    Chapter 3: Electronics Description 3-11 CB-J3 Connector Name Teach Pendant Connector Connector Type 16 Pin Ansely Destination Front Panel Chassis-Mount Cannon 10 Pin Connector SCC-23-514 Pin # Function Signature Description Inst- Teach pendant installed RS-232C Transmit signal to the teach pendant RS-232C Receive signal from the teach pendant Power...

  • Page 68: Table 3-8 Transputer Up Connector

    3-12 A255 Robot Service Manual CB-J4 Connector Name Transputer Up Connector Connector Type 10 Pin Ansely (Staggered Nomenclature) Destination Rear Panel Chassis-Mount Connector (Optional) SCC-23-008 Pin # Function Signature Description URst+ RS-422 Reset from master URst- RS-422 Reset from master (complementary)

  • Page 69: Table 3-9 Transputer Down Connector

    Chapter 3: Electronics Description 3-13 CB-J5 Connector Name Transputer Down Connector Connector Type 10 Pin Ansely (Staggered Nomenclature) Destination Rear Panel Chassis-Mount Connector (Optional) SCC-23-008A Pin # Function Signature Description DRst+ RS-422 Reset to slave DRst- RS-422 Reset to slave (complementary) DErr+ RS-422 Error from slave...

  • Page 70: Table 3-10 Ab -1 Connector

    3-14 A255 Robot Service Manual CB-J6 Connector Name AB-1 Connector Connector Type 60 Pin Ansely (staggered nomenclature) Destination AB-J1 SCC-23-001 Pin # Function Signature Description Vcom1 Analog Command voltage for axis 1 Vcom5 Analog Command voltage for axis 5 Vcom2...
  • Page 71 Chapter 3: Electronics Description 3-15 CB-J6 (Continued) Pin # Function Signature Description NSW7 Negative Travel switch for axis 7 TSW7 Thermal switch for axis 7 HSW8 Homing switch for axis 8 PSW8 Positive Travel switch for axis 8 NSW8 Negative Travel switch for axis 8 TSW8 Thermal switch for axis 8 TPEStop+...

  • Page 72: Table 3-11 Encoder Connector

    3-16 A255 Robot Service Manual CB-J7 Connector Name Encoder Connector Connector Type 50 Pin Ansely (staggered nomenclature) Destination Encoder Feedback Connector SCC-23-110 Pin # Function Signature Description RS-422 Axis 1 Channel A input RS-422 Axis 1 Channel A input (complementary)
  • Page 73 Chapter 3: Electronics Description 3-17 CB-J7 (Continued) Pin # Function Signature Description RS-422 Axis 6 Channel Z input RS-422 Axis 6 Channel Z input (complementary) No Connect Shield No Connect SGPos Analog Servo gripper position SGTor Analog Servo gripper torque (not used) AirGrip- Power Solenoid return...

  • Page 74: Table 3-12 Encoder Power Connector

    3-18 A255 Robot Service Manual CB-J8 Connector Name Encoder Power Connector Connector Type 10 Pin Ansely (staggered nomenclature) Destination Encoder Connector SCC-23-210 Pin # Function Signature Description +5Enc 5 Volts Isolated encoder supply Ground: Encoder power supply return +5Enc 5 Volts...

  • Page 75: Table 3-13 Amp Expansion Connector

    Chapter 3: Electronics Description 3-19 CB-J9 Connector Name Amp Expansion Connector Connector Type 34 Pin Ansely (staggered nomenclature) Destination Amplifier Expansion Connector SCC-23-511 (Optional) Pin # Function Signature Description RS-422 Axis 6 Channel A input RS-422 Axis 6 Channel A input (complementary) RS-422 Axis 6 Channel B input RS-422...

  • Page 76: Table 3-14 Power Supply Connector

    3-20 A255 Robot Service Manual CB-J10 Connector Name Power Supply Connector Connector Type 10 Pin MOLEX Destination Power Supply - 10 Pin MOLEX SCC-23-106 or SCC-23-606 Pin # Function Signature Description +5 V Power +5 Volt supply to the controllerboard...

  • Page 77: Table 3-15 Auxiliary Board Logic Power Input Connector

    Chapter 3: Electronics Description 3-21 CB-J13 Connector Name Aux Board Logic Power Input Connector Connector Type 8 Pin Molex Destination Auxiliary Board SCC-23-005 or SCC23-105 Pin # Function Signature Description +5 V Power +5 Volt supply to the auxiliary board Key for the connector +5 V Power...

  • Page 78: Auxiliary Board

    Auxiliary Board DIP Switch One DIP switch is used to set the auxiliary board configuration for various operational modes (Figure 3-3). For the A255, the factory installation settings for 1 and 4 are in the OFF position, while 2 and 3 are in the ON position.

  • Page 79: Auxiliary Board Connectors

    Chapter 3: Electronics Description 3-23 3-3-3 Auxiliary Board Connectors Figure 3-4 shows the locations for all auxiliary board connectors and socketed components. See the legend (Table 3-18) and pin-outs in the tables that follow. Figure 3-4 Auxiliary Board Connectors and Socketed Components Locations...
  • Page 80 Description Controller Board #1 Interconnect Controller Board #2 Interconnect Front Panel Control/Display Connector Linear Amp Vcom Connector Proximity Switch Signal Connector (not used in A255) Fuse Connector Brake/Air Gripper Signal Connector PWM Vcom and Signal Connector GPIO Connector SYSIO Connector...

  • Page 81: Table 3-19 Cb-1 I/O Board Interconnect

    Chapter 3: Electronics Description 3-25 AB-J1 Connector Name CB-1 I/O Board Interconnect Connector Type 60 Pin Ansely Header Destination CB-J6 SCC-23-001 Pin # Function Signature Description Vcom1 Analog Command voltage for axis 1 Vcom5 Analog Command voltage for axis 5 Vcom2 Analog Command voltage for axis 2...
  • Page 82 3-26 A255 Robot Service Manual AB-J1 (Continued) Pin # Function Signature Description HSW8 Homing switch for axis 8 TPEStop+ Teach pendant e-stop contact pair TPEStop- LiveMan+ Teach pendant liveman switch contact pair Liveman- Brakeoff+ Switch Brake relay source (flow through to exp Amp ctr)

  • Page 83: Table 3-20 Cb-2 I/O Board Interconnect

    Chapter 3: Electronics Description 3-27 AB-J2 Connector Name CB-2 I/O Board interconnect Connector Type 60 Pin Ansely Header Destination CB-J1 SCC-23-001 Pin # Function Signature Description Hex0 Display Data (LSB) Hex1 Display Data Hex2 Display Data Hex3 Display Data Hex4 Display Data Hex5 Display Data...
  • Page 84 3-28 A255 Robot Service Manual AB-J2 (Continued) Pin # Function Signature Description GPO4 General Purpose user output #4 GPI4 General Purpose user input #4 GPO5 General Purpose user output #5 GPI5 General Purpose user input #5 GPO6 General Purpose user output #6...

  • Page 85: Table 3-21 Display/Control Connector

    Chapter 3: Electronics Description 3-29 AB-J3 Connector Name Display/Control Connector Connector Type 26 Pin Ansely Header Destination Front Panel Displays, Switches SCC-23-012 Pin # Function Signature Description +5 V Logic power +12 V Digit0 Hex Display FPESTOP- Switch ESTOP Digit1 Hex Display FPMOMSW+ Switch...

  • Page 86: Table 3-22 Linear Amp Vcom Connector

    3-30 A255 Robot Service Manual AB-J4 Connector Name Linear Amp Vcom Connector Connector Type 9 Pin Molex Destination Linear Amp Module(s) SCC-23-015 Pin # Function Signature Description Vcom1 Analog Command voltage for axis 1 Vcom2 Analog Command voltage for axis 2...

  • Page 87: Table 3-23 Home Switch/Brake Connector

    Chapter 3: Electronics Description 3-31 AB-J5 Connector Name Home Switch Connector Type 9 Pin Molex Destination CPC-24, Back Panel SCC-23-024 Pin # Function Signature Description HSW1 24 V Home Switch #1 HSW2 24 V Home Switch #2 HSW3 24 V Home Switch #3 HSW4 24 V...

  • Page 88: Table 3-24 Relay/Power Fuse Connector

    3-32 A255 Robot Service Manual AB-J6 Connector Name Relay/Power Fuse Connector Connector Type 7 Pin Molex Destination Fuse Panel SCC-23-021 Pin # Function Signature Description SGBF Analog/Pwr Servo gripper control signal, before fuse SGAF Analog/Pwr Servo gripper control signal, after fuse...

  • Page 89: Table 3-25 Air Gripper/Brake Power Connector

    Chapter 3: Electronics Description 3-33 AB-J7 Connector Name Air Gripper/Brake Power Connector Connector Type 5 Pin Molex Destination Encoder Connector Board SCC-23-133 Pin # Function Signature Description Servogripper ±15 V Motor 380 mA max @12 V AirGripOut 12 V Solenoid 300 mA max @ 12 V Brake Power 35 V Motor voltage used for brakes fuse @ 2 A...

  • Page 90: Table 3-26 Vo3Pwm

    3-34 A255 Robot Service Manual AB-J8 Connector Name V03PWM Connector Type 16 Pin Ansely Header Destination PWM, Common Harness SCC-23-013 Pin # Function Signature Description PWMENA Global enables for PWM amplifiers Analog ±10 V signal to amplifier Vcom1 PWMENA Global enables for PWM amplifier Analog ±10 V signal to amplifier...

  • Page 91: Table 3-27 General Purpose I/O Connector

    Chapter 3: Electronics Description 3-35 AB-J9 Connector Name General Purpose I/O Connector Connector Type 50 Pin Ansely Header Destination Back Panel GPIO SCC-23-023 Pin # Function Signature Description +24 V 24 VDC Optional Source for 24 V, internal +24 V 24-40 VDC Iso Power, externally supplied GPI1...
  • Page 92 3-36 A255 Robot Service Manual AB-J9 (Continued) Pin # Function Signature Description GPO11 Opto General Purpose output #11 GPO12 Opto General Purpose output #12 Shield GPO13NC Relay General Purpose output #13, Normally closed contact GPO13NO Relay General Purpose output #13, Normally open contact...

  • Page 93: Table 3-28 Sysio Connector

    Chapter 3: Electronics Description 3-37 AB-J10 Connector Name SYSIO Connector Connector Type 26 Pin Ansely Header Destination Back Panel, DB25 SCC-23-022 Pin # Function Signature Description +24 VDC Power Optional Source for external I/O, internal supply +24 VDC Power Optional Source for external I/O, internal supply 24-40 VDC Isolated external power Opto...

  • Page 94: Table 3-29 Ax1-3 Circuit Breaker Connector

    3-38 A255 Robot Service Manual AB-J11 Connector Name Ax1-3 Circuit Breaker Connector Connector Type 7 Pin Molex Destination Breakers SCC-23-021 Pin # Function Signature Description Ax1AF Motor Power Motor 1 after fuse (breaker) Ax1BF Motor Power Motor 1 before fuse (breaker)

  • Page 95: Table 3-30 Ax4-6 Circuit Breaker Connector

    Chapter 3: Electronics Description 3-39 AB-J12 Connector Name Ax4-6 Circuit Breaker Connector Connector Type 7 Pin Molex Destination Breakers SCC-23-021 Pin # Function Signature Description Ax4AF Motor Power Motor 4 after fuse (breaker) Ax4BF Motor Power Motor 4 before fuse (breaker) Ax5AF Motor Power Motor 5 after fuse (breaker)

  • Page 96: Table 3-31 Linear Amp Power Supply Out Connector

    3-40 A255 Robot Service Manual AB-J13 Connector Name Linear Amp Power Supply Out Connector Connector Type 7 Pin Molex Destination Linear Amplifier, Power Ctr SCC-23-019 Pin # Function Signature Description +35 VDC ±10% Vout+ Linear PS+ Vout+ +35 VDC Linear PS+ -35 VDC ±10%...

  • Page 97: Table 3-32 Pwm Amp Power Supply Out Connector

    Chapter 3: Electronics Description 3-41 AB-J14 Connector Name PWM Amp Power Supply Out Connector Connector Type 7 Pin Molex Destination Copley PWM Amp Power Connector SCC-23-016 Pin # Function Signature Description Vout+ 63 V PWM supply to amplifiers Vout+ 63 V PWM supply to amplifiers Vout+ 63 V...

  • Page 98: Table 3-33 High Voltage Power Supply In Connector

    3-42 A255 Robot Service Manual AB-J15 Connector Name High Voltage Power Supply In Connector Connector Type 11 Pin Molex Destination Capacitor Power Board (PB) SCC-23-117 Pin # Function Signature Description 12 V 12 V Logic power level, to be used by external arm power control...

  • Page 99: Table 3-34 Power Supply Connector

    Chapter 3: Electronics Description 3-43 AB-J16 Connector Name Power Supply Connector Connector Type 8 Pin Molex Destination CB-J13 SCC-23-005 or SCC-23-105 Pin # Function Signature Description +5 V Power +5 V supply to the Auxiliary Board +5 V Power +5 V supply to the Auxiliary Board Power Return for +5 V, +12 V, -12 V and +24 V Power...

  • Page 100: Controller Ac Power System

    • PWM amplifier power enters via a 45 VAC secondary tap. It is rectified and filtered to provide a 64 VDC supply to the amplifier modules. (This applies only to the A255 Track axes). 3-3-5 Soft Start Board...

  • Page 101: Figure 3-5 Primary Power Circuit A255

    Chapter 3: Electronics Description 3-45 230 VAC 115 VAC 100 VAC AC.F2 AC.F1 Figure 3-5 Primary Power Circuit A255...

  • Page 102: Figure 3-6 Primary Power Circuit T265/A465/T475

    3-46 A255 Robot Service Manual 230 VAC 115 VAC 100 VAC AC.F2 AC.F1 Figure 3-6 Primary Power Circuit T265/A465/T475...

  • Page 103: Figure 3-7 A255 Motor Power

    Chapter 3: Electronics Description 3-47 Figure 3-7 A255 Motor Power...

  • Page 104: Figure 3-8 A255 Position Feedback From Encoders

    ENC_SING_CH ENC? RP1.3 CPC-57 RP1.4 CPC-57 RP1.8 CPC-57 ENC_SING_CH ENC? RP1.20 CPC-57 RP1.21 CPC-57 RP1.28 CPC-57 ENC_SING_CH ENC? RP1.22 CPC-57 RP1.23 CPC-57 RP1.31 CPC-57 ENC_SING_CH ENC? RP1.36 CPC-57 RP1.37 CPC-57 RP1.50 CPC-57 ENC_SING_CH Figure 3-8 A255 Position Feedback From Encoders...

  • Page 105: Figure 3-9 A255 Connections To The Auxiliary Board (Ab)

    Chapter 3: Electronics Description 3-49 Figure 3-9 A255 Connections to the Auxiliary Board (AB)

  • Page 106: Figure 3-10 A255 Connections To The Controller Board (Cb)

    3-50 A255 Robot Service Manual Figure 3-10 A255 Connections to the Controller Board (CB)

  • Page 107: Computer Power Supply And Amplifier Power

    Chapter 3: Electronics Description 3-51 Computer Power Supply and Amplifier Power The computer power supply is a switching mode supply with four output voltages. 1. +5 VDC at 6.0 A 3. -12 VDC at 0.5 A 2. +12 VDC at 1.0 A 4.

  • Page 108: Power Filter Board

    3-52 A255 Robot Service Manual 3-4-2 Power Filter Board This board, located in the amplifier section, takes power coming from the transformer via rectifiers and filters it for the required amplifiers. Note: See AC.CAP1 in figures and 3.8. Function +65 V...

  • Page 109: Linear Amp/Brake/Gripper Power

    Chapter 3: Electronics Description 3-53 3-4-3 Linear Amp/Brake/Gripper Power This power supply consists of a step-down transformer (50 VAC at 7 A), a bridge rectifier, and two filter capacitors on the power filter board. The output is ±35 VDC at 10 A and is unregulated. As soon as arm power is turned on, power feeds to the servo gripper circuit, and to the linear amplifiers.

  • Page 110: Amplifier Electronics

    3-54 A255 Robot Service Manual Amplifier Electronics The amplifiers are located in the right hand side of the controller compartment. Quantity Module Number Location SEC-13-903 -or- Right Side of Compartment SEC-920-001* * For PWM amp serial numbers greater than PWMXXX The DC Amplifiers drive each axis of the robot arm.

  • Page 111: Linear Amplifier Connectors

    Linear Amplifier Connectors The following tables refer to the Amplifier Module connectors, see Figure 3-11 Linear Amplifier Module, and Figure 3-7 A255 Motor Power. Note: See LA1 and LA2 in Figure 3-7 A255 Motor Power. 1. The 4-pin Molex VCOM Input connector labeled Vin, connects the command signals from the servo axis output to the amplifier module.

  • Page 112: Pwm Amplifiers

    3-56 A255 Robot Service Manual J1 Connector For a pin-out of the J1 connector refer to Table 3-21 Display/Control Connector. 3-5-3 PWM Amplifiers The T265 track system contains one Copley Model 900-12 PWM amplifier in axis 6. The amplifier is fed with a 64 VDC rail voltage from the capacitor board, and provided with ±10 V command signals from the...

  • Page 113: Pwm Amplifier Connectors

    Chapter 3: Electronics Description 3-57 3-5-4 PWM Amplifier Connectors Refer to the following tables for the pin-outs of the PWM amplifier connectors: 4 Pin Power Connector Type Remarks Passive +HV, the high-voltage DC power input Output Out- , or negative output Output Out+ , or positive output Passive...

  • Page 114: T265 Track Connectors

    3-58 A255 Robot Service Manual 3-5-5 T265 Track Connectors The following table shows the track amplifier wiring as the signals are passed from the Copley Amp Phoenix connector through to the 14 pin Amp Motor Power connector. Signal Passage of the Signal Through the Connectors...

  • Page 115: Front Panel Display Board

    Chapter 3: Electronics Description 3-59 Front Panel Display Board Part Number SEC-23-300T The display board contains the main user controls and status display. It has five user accessible momentary contact switches and a 2-digit LED display. J2 E-Stop Connector Function E-Stop+ E-Stop- Table 3-53 E-Stop Connector...

  • Page 116: Front Panel Display Board Connectors

    3-60 A255 Robot Service Manual 3-6-1 Front Panel Display Board Connectors The following tables list the pin-outs for the front panel display board connectors. Pin # Function Description Logic power +12 V Digit0 Hex Display FPESTOP- ESTOP Digit1 Hex Display...

  • Page 117: Encoder Connector Board

    Chapter 3: Electronics Description 3-61 Encoder Connector Board Part Number S-SEC-23-204T The following tables list the pin-outs for the encoder board connectors. Pin # Function Description Axis 1 Channel A input Axis 1 Channel A input (complementary) Axis 1 Channel B input Axis 1 Channel B input (complementary) Axis 1 Channel Z input Axis 1 Channel Z input (complementary)

  • Page 118: Table 3-57 Encoder Connector Board J2

    3-62 A255 Robot Service Manual Pin # Function Description +5Enc Isolated encoder supply Ground: Encoder power supply return +5Enc Isolated encoder supply Ground: Encoder power supply return +5Enc Isolated encoder supply Ground: Encoder power supply return +5Enc Isolated encoder supply...

  • Page 119: Wiring And Connectors

    Front Panel Connectors • Rear Panel Connectors • Arm Wiring Harnesses • Front Panel Connectors Front Panel Connectors The A255 controller front-panel connections are shown in Figure 4-1. Figure 4-1 A255 Controller front panel connectors with access door flipped down.

  • Page 120: Teach Pendant Connector

    A255 Robot Service Manual 4-2-1 Teach Pendant Connector The teach pendant connector is located at the upper left of the controller front panel. It is either a Cannon KPT style 10 pin connector, or an AMP style 9 pin connector. The teach pendant controls the robot arm when the robot is in Manual Mode.

  • Page 121: Communication Serial Connector

    This is a standard 25-pin D type female receptacle. Signal level compatibility is maintained with RS232 standard. In addition, it provides power connections on unused pins and supplies power for the CRS Robotics RS422 conversion option. Baud rates from 50 to 38400 are supported.

  • Page 122: Controller Rear Panel Connectors

    A255 Robot Service Manual Controller Rear Panel Connectors The controller rear panel, shown in Figure 4-2, contains the connectors for interfacing to the robot arm, as well as general I/O interfacing connectors include: • System I/O (SYSIO) • General Purpose I/O (GPIO) •...

  • Page 123: System I/O (Sysio)

    Chapter 4: Arm and External Controller Connectors 4-3-1 System I/O (SYSIO) The SYSIO connector provides access to the front panel switch signals, permitting these functions to be controlled from a remote location. The pin-out is shown in Table 4-3. Refer to the pin-out diagram on this page and not the actual numbers on the connector.

  • Page 124: Figure 4-3 C500 Sysio Connector Description

    A255 Robot Service Manual SYSIO Connector Figure 4-3 C500 SYSIO connector description.

  • Page 125: General Purpose I/O (Gpio)

    Chapter 4: Arm and External Controller Connectors 4-3-2 General Purpose I/O (GPIO) The GPIO connector allows the controller to control or monitor other machines. Refer to the pin-out diagram on this page and not to the actual numbers on the connector. Each connector manufacturer may use a different standard.
  • Page 126 A255 Robot Service Manual GPIO DD 50 Connector (Continued) Pin # Function Signature Description GPO11 Opto General Purpose output #11 GPO12 Opto General Purpose output #12 Shield GPO13NC Relay General Purpose output #13, Normally closed contact GPO13NO Relay General Purpose output #13, Normally open...

  • Page 127: Figure 4-4 C500 Gpio Connector Description

    Chapter 4: Arm and External Controller Connectors GPIO Connector Figure 4-4 C500 GPIO connector description.

  • Page 128: Robot Feedback Connector

    4-10 A255 Robot Service Manual 4-3-3 Robot Feedback Connector The robot feedback connector provides channels for six axes of single- ended encoder feedback and encoder supply voltage, in addition to the servo gripper feedback and control, brake power, air gripper solenoid supply and control.
  • Page 129 Chapter 4: Arm and External Controller Connectors 4-11 Robot Feedback Connector Continued Signal Name Signal Description RS422+, 200 Khz max pulse rate RS422+, 200 Khz max pulse rate RS422+, 200 Khz max pulse rate RS422+, 200 Khz max pulse rate RS422+, 200 Khz max pulse rate ±1 V SGRIPTRQ...

  • Page 130: Motor Power Connector

    4-12 A255 Robot Service Manual 4-3-4 Motor Power Connector A255 Arm Connector Controller End Pin # On Pin # On Signal Name Signal Description A255 Arm Controller ± Motor1+ Motor power 25 V @ 2 A max Motor1- Motor power return ±...

  • Page 131: Table 4-7 Expansion Amplifier Connector Pin Signal Descriptions

    Chapter 4: Arm and External Controller Connectors 4-13 4-3-4-1 Expansion Amplifier Connector (Optional) The expansion amplifier connector connects the servo expansion axis signals to an external amplifier. It accepts feedback from incremental optical encoders on the extra axis motors to the same servo axis. Custom ordered controllers may have a slight variation of this connector.

  • Page 132: Arm Wiring Harnesses

    Hirose connector on the left side of the upper link (about 2 inches from the wrist). The air solenoid wiring and pneumatic line terminate on an air solenoid located in the upper arm. Note: For a pin-out description of the A255 main harness connector refer to section 4-3-3 Robot Feedback...

  • Page 133: Encoder Connectors

    Chapter 4: Arm and External Controller Connectors 4-15 4-4-1 Encoder Connectors Figure 4-5 Encoder Connector (RP-17) Joint 1 Pin # Function Pin # Function +5 V CH Z CH A CH-B MOT- MOT + Table 4-8 Joint 1 Encoder Connector (RP-17) Joints 2, 3, 4, 5 Pin # Function...

  • Page 134: External Connectors

    4-16 A255 Robot Service Manual 4-4-2 External Connectors The external connectors consist of the Robot Feedback Connector, (see section 4-12 the Motor Power Umbilical Connector and the Servo Gripper Connector (below). Pin # Function Pin # Function S/A G+ SGRIP torque...
  • Page 135 Chapter 4: Arm and External Controller Connectors 4-17 Pin # Function Pin # Function +12 VDC Torque Feedback S/A GND (Servo Gripper) G- (Air Solenoid) Position Feedback VMG+ VMG- Table 4-12 Link 2 Cable Connector (RP-17)

  • Page 136: Arm Signal Connector Schematic

    4-18 A255 Robot Service Manual Arm Signal Connector Schematic Servo Gripper Female RP-17 Connector (see Table 4-10) RP17 RP17 (see table 3-58) (see table 3-57) Figure 4-6 Arm Signal Connector Schematic...

  • Page 137: Diagnostics And Troubleshooting

    This chapter provides directions for troubleshooting problems and describes field serviceable procedures for the A255 and A465 robot arms. Procedures and tests specific to the A255 or A465 arm are marked as such. To service a problem, use the following table to find a description...

  • Page 138: Arm Power Problems

    A255 Robot Service Manual Arm Power Problems For additional information on the requirements for arm power operation (refer to section 2-9 Requirements for Arm Power). 5-2-1 Arm Power Cannot Be Turned On Controller Operation Checks RE1.1 Is main power applied? Check if the front panel Status Display is illuminated.

  • Page 139: Arm Power Turns Off With Error "40" Display

    Chapter 5: Diagnostics and Troubleshooting 5-2-2 Arm Power Turns Off with Error “40” Display This may happen immediately or when the arm is moved. Circuit Breaker Checks RE4.7 Check the continuity of the circuit breakers. Check for popped breakers on the front panel of the controller. The breaker sensing shuts off arm power when a breaker opens.

  • Page 140: Arm Power Indicator On Front Panel Comes On But All Joints Of The Arm Stay Limp

    A255 Robot Service Manual 5-2-3 Arm Power Indicator on Front Panel Comes On But All Joints of the Arm Stay Limp Is the arm LIMP? - Use the STATUS command to check. Feedback Checks RE5.2 Check for encoder feedback signals on the controller board.

  • Page 141: Arm Power" Error Message Seen But Arm Power Indicator Still On

    Chapter 5: Diagnostics and Troubleshooting 5-2-4 "ARM POWER" Error Message Seen but Arm Power Indicator Still On Controller Signal Checks RE3.2 Indicates a failure of the ARM ON signal from the auxiliary board to the controller board. 5-2-5 Arm Power Indicator Comes On, One Axis Stays Limp, No "AXIS OUT"...

  • Page 142: Arm Power Indicator Comes On, One Axis Stays Limp

    A255 Robot Service Manual 5-2-6 Arm Power Indicator Comes On, One Axis Stays Limp, "AXIS OUT" Error When the Axis in Question is Moved This is a feed forward problem. Use the @LOFB RESET command to remove the check for the loss of feedback. The @LOFB RESET command prevents the "AXIS OUT"...

  • Page 143: Servo Problems

    Chapter 5: Diagnostics and Troubleshooting Servo Problems For an understanding of the servo system operation (see section 2.13 Servo Operation). 5-3-1 One Axis Runs Away as Soon as Power is Applied Controller Signals RE7.3 With arm power removed, check for an encoder feedback problem with the W1 command.

  • Page 144: One Axis Limp Until Command Given, Then Runs Away

    A255 Robot Service Manual If the feedback is functioning then: The problem is in the forward part of the servo control loop. Amplifier Servo Signal Level Checks RE8.4 Check for a good ground connection to the controller board. Check the motor brush polarity (see section...

  • Page 145: All Axes Run Away Simultaneously

    Wiring Check RE4.10 Does the robot position jump in only one position of the joint? Determine if the break is in the main or wrist harness. Replacement of the these harnesses should be done at an authorized CRS repair depot.

  • Page 146: Robot Position Changes Slowly In One Axis (Drift)

    5-10 A255 Robot Service Manual 5-3-5 Robot Position Changes Slowly in One Axis (Drift) This problem is further identified in that it is cleared up after homing the arm. The servo is injected with noise which is misinterpreted as legitimate position change pulses by the controller board.

  • Page 147: Homing Problems

    5-4-2 101 Sequence Error This error will only appear in the A465 and A255 Track axes. It indicates that the homing routine was unable to successfully complete its cycle. To check for the presence of arm power perform the following checks.

  • Page 148: Digital I/O Problems

    If the external wiring is correct: • Send either the CB/AB assembly or whole controller to CRS for service. If there is no state change on the input (measured by a meter at the rear panel): •...

  • Page 149: Output To An External Device

    Chapter 5: Diagnostics and Troubleshooting 5-13 5-5-2 Output to an External Device If an output to an external device is not switching properly: • Check the signal at the rear panel GPIO. DS2002 Chips The DS2002 are socketed chips located at U7 (SYSIO), and U8/9 (GPIO) on the Auxiliary Board assembly, which only control the outputs.

  • Page 150: Serial Communication Problems

    5-14 A255 Robot Service Manual Serial Communication Problems For a complete description of the requirements for terminal or serial communication (refer to sections 2-9 Requirments for Arm Power section 2-10 Requirements for Interactive Communication. • Ensure correct baud rate etc. on the terminal or host computer. After a restart you can view the default serial communication values.

  • Page 151: Recurring Memory "Failures

    Chapter 5: Diagnostics and Troubleshooting 5-15 Recurring Memory "Failures" Perform a system restart with factory parameters. See the @@SETUP command in the RAPL-II Programming Manual. Controller Internal Visual Checks RE2.1 Check for correct insertion of all the socketed components on the controller board.

  • Page 152: Servo Gripper Problems

    5-16 A255 Robot Service Manual Servo Gripper Problems To diagnose and repair a gripper problem, follow the procedure described in this section. For more detailed information refer to the Servo Gripper User’s Guide. Signal Level Checks RE4.3 Check the continuity of servo gripper wiring...

  • Page 153: Connector Visual Inspection

    Chapter 5: Diagnostics and Troubleshooting 5-17 • If the displayed position does not smoothly count up or down: a) Check the servo potentiometer, refer to section 5-8-9 Servo Potentiometer Check. b) If the servo potentiometer is not correctly positioned, set servo potentiometer position, refer to section 5-8-10 Set Servo Potentiometer...

  • Page 154: Motor Driver Output Test

    5-18 A255 Robot Service Manual 5-8-5 Motor Driver Output Test Check that the controller is providing motor drive voltage to the servo gripper. The procedure requires a PC with Robcomm for Windows software and a voltmeter (DVM). Warning! Wear a grounded wrist strap for the following procedure. Electronic components inside the controller can be damaged by electrostatic discharge.

  • Page 155: Finger Position Feedback Test

    Chapter 5: Diagnostics and Troubleshooting 5-19 5-8-6 Finger Position Feedback Test This procedure tests the gripper feedback circuitry (needed for position mode) with a program that slowly moves the fingers while continuously monitoring the feedback signal. The procedure requires a PC with Robcomm for Windows software.

  • Page 156: Finger Position Feedback Continuity Test

    5-20 A255 Robot Service Manual 5-8-7 Finger Position Feedback Continuity Test This checks the availability of feedback voltage to the servo gripper feedback circuit. The procedure requires a voltmeter (DVM). Warning! Wear a grounded wrist strap for the following procedure. Electronic components inside the controller can be damaged by electrostatic discharge.

  • Page 157: Servo Gripper Motor Test

    Chapter 5: Diagnostics and Troubleshooting 5-21 5-8-8 Servo Gripper Motor Test This checks for a damaged gripper motor by measuring armature resistance at the motor terminals. This procedure requires an Ohm-meter. 1. Disconnect the servo-gripper cable from the robot upper arm and remove the gripper from the tool flange.

  • Page 158: Set Servo Potentiometer Position

    5-22 A255 Robot Service Manual 5-8-10 Set Servo Potentiometer Position This procedure correctly positions servo potentiometer travel, relative to the pinion. This should be done only after Procedure 5 has failed, indicating faulty feedback, or after the installation of a new servo pot.

  • Page 159: Air Gripper Problems

    Chapter 5: Diagnostics and Troubleshooting 5-23 Air Gripper Problems Check the voltage to the air gripper at both the controller and the arm. Controller Signal Level Check RE3.18 Check air gripper driver output. Arm Signal Level Checks 1. Remove the wrist covers. 2.

  • Page 160: Controller Boot-Up Problems

    5-24 A255 Robot Service Manual 5-10 Controller Boot-up Problems The controller should boot-up and display “A1” on the front panel. When this does not occur refer to section 2-4 Initialization Logic Sequence and determine where the controller has failed. With the exception of “A1” or “A7”, reload your firmware as if it has become corrupt.

  • Page 161: Serial Teach Pendant Problems

    Chapter 5: Diagnostics and Troubleshooting 5-25 5-11 Serial Teach Pendant Problems No Screen 1. Remove the serial teach pendant connector. Refer to section 4-2-1 Teach Pendant Connector. 2. Measure the supply voltage with reference to the ground. A = pendant installed (5.1 Vdc) C = ground F = Vcc (5.1 Vdc) 3.

  • Page 162: Serial Teach Pendant Parameters

    Serial Teach Pendant Parameters Parameters for the teach pendant's operation are set to factory standards at CRS. Should your teach pendant exhibit unusual operation, it may be necessary to reconfigure its parameters. Note: Custom configurations many be required for special applications.

  • Page 163: Function Key Settings

    Chapter 5: Diagnostics and Troubleshooting 5-27 5-11-2 Function Key Settings To access the function key settings: 1. Press Ctrl + Shift + F2 at the same time. The following prompt appears: Select function key 2. Select the function key whose setting you want to change, for example press F1, F2, F3, or F4.

  • Page 164: Ac Power Problems

    5-28 A255 Robot Service Manual 5-12 AC Power Problems AC Power Checks Check the major components that bring the in-coming AC to the computer power supply or to the transformer. RE1.3 Check or replace the AC line fuse(s) to determine if the power line is intact.

  • Page 165: Service Repair Checks

    A465 robot arms. Electrical problems that require further diagnosis are numbered and prefixed with RE (for Repair Electrical). Procedures and tests specific to the A255 or A465 arm are marked as such. The procedures described under any of these topics are not in any particular order.

  • Page 166: Figure 3-1 Controller Board

    A255 Robot Service Manual RE2 Controller Internal Visual Checks Controller visual checks made internally with the lid removed. These do not require specialized tools or instruments. Pg. # RE2.1 Check Controller Board Components 6-11 RE2.2 Check Internal RS-232 Connector 6-12 RE2.3 Check Servo Gripper, Brake, Linear, and PWM...
  • Page 167 Chapter 6: Service Repair Checks RE3.14 Check Programmable Interrupt Controller (PIC) 6-33 Initialization and Function RE3.15 RS232 Serial Ground Current Loop Check 6-34 RE3.16 Check RESET Chip Function 6-35 RE3.17 Replace Serial Device Drivers 6-36 RE3.18 Check Air Gripper Driver Output 6-36 RE3.19 Check Function of AC Components 6-37...
  • Page 168 A255 Robot Service Manual RE6 Controller Electronic Module Replacement Procedures Field service replacement procedures Pg. # RE6.1 Replace Controller Electronics 6-56 RE6.2 Replace Front Panel Display Board 6-57 RE6.3 Replace Encoder Connector Board 6-57 RE6.4 Replace Power Filter Board 6-58 RE6.5...

  • Page 169: Figure 3-11 Linear Amplifier Module

    Chapter 6: Service Repair Checks RE8 Amplifier Servo Signal Level Checks Procedures related to electronics in the controller amplifier circuitry. Pg. # RE8.1 Check Voltage Supply From Auxiliary Board to PWM 6-69 Amplifier Module RE8.2 Check Voltage Supply From the Auxiliary Board to the 6-70 Linear Amplifier Module RE8.3 Check Continuity of the DC Amp to the Rear Panel...

  • Page 170: 6-1 Controller External Checks

    A255 Robot Service Manual 6-1 Controller External Checks RE1.1 Check For Main Power Purpose To determine if AC power is applied to the controller. Method 1. Switch the main power switch to the ON position. 2. Check the status display; look for any activity on the display.
  • Page 171 RAPL firmware. It may be necessary to reload the RAPL firmware, refer to RE7.2 Reload Firmware. • If the status code appears to be different after each boot-up, it may be necessary to reload RAPL firmware or contact CRS for assistance.
  • Page 172 A255 Robot Service Manual RE1.5 Check “ARM ENABLED” Switch Purpose To determine if the arm power signal is enabled. Method 1. Turn main power on. 2. In Robcomm, go to the terminal emulator and obtain the prompt. 3. Type the RAPL command ENABLE <CR>. A list of parameters appears.
  • Page 173 Chapter 6: Service Repair Checks 2. Unplug the connectors from the rear panel. 3. Test the continuity of the e-stop contacts at pins 19 and 20 of the SYSIO. 4. The amplifier expansion arm on signals may be enabled by the dip switch on the auxiliary board.

  • Page 174: Table 6-1 Front Panel Fuses

    6-10 A255 Robot Service Manual RE1.8 Check Front Panel Fuses Purpose To check the integrity of the three front panel fuses. Method 1. Turn off main power. 2. Flip down the front panel lid. 3. Unscrew the fuse caps to remove the screws.

  • Page 175: 6-2 Controller Internal Visual Checks

    Chapter 6: Service Repair Checks 6-11 6-2 Controller Internal Visual Checks RE2.1 Check Controller Board Components Purpose To determine if any of the socketed chips in the controller board have been removed partially or completely. Method 1. With main power off, remove the controller lid. 2.
  • Page 176 6-12 A255 Robot Service Manual RE2.2 Check Internal RS-232 Connector Purpose To check the internal RS-232 connector. Method The RS-232 connections to the controller board is located in the right front of the controller. It consists of a ribbon cable (on most controllers) which goes from the front panel receptacle to the header designated as J2 on the controller board.

  • Page 177: Table 6-4 Internal Fuse Location

    Chapter 6: Service Repair Checks 6-13 Fuse Designation Fuses Location Fuse Supplies Voltage To: Linear Amp Fuse Linear Amp positive rail Servo gripper Amp positive rail Brake fuse (F4) Linear Amp Fuse Linear Amp negative rail Servo gripper Amp negative rail PWM Fuse PWM rail voltage Brake Fuse...
  • Page 178 CPC-24 Connector to the Auxiliary Board The signals from the homing proximity switches of the A465 and Track axes of the A255 are carried through the harness from the rear panel CPC-24 connector to the auxiliary board. After opto-isolation on the Auxiliary board, the signals (TTL level) are then fed to the controller board via the 60 pin ribbon cable.
  • Page 179 Chapter 6: Service Repair Checks 6-15 RE2.7 Check Diagnostic LED’s (Auxiliary Boards REV 1.3 and Above) Purpose To check the diagnostic LED’s. Method Use the diagnostic LED’s to diagnose problems in the power supply, e-stop lines, arm power watchdog, and in the linear rail voltage. 1.
  • Page 180 6-16 A255 Robot Service Manual D61 + 12 Volt Signal This is the supply voltage used in the controller electronics as well as in the arm electronics. Without the proper voltage the controller would not have a reference voltage established and various symptoms of failure would be exhibited such as improper voltage offset on the amplifiers, and erratic arm and gripper operation.
  • Page 181 Chapter 6: Service Repair Checks 6-17 D64 Teach Pendant E-Stop This stage of the e-stop can be bypassed by the: 1. Teach Pendant E-Stop Button 2. Override Plug 3. Auxiliary DIP switch setting S1 #1 If the teach pendant is connected to the front panel connectors, make sure that it is connected securely.
  • Page 182 6-18 A255 Robot Service Manual D66 REMOTE (SYSIO) E-Stop The illumination of this LED indicates that the SYSIO e-stop is closed- circuited. The LED turns off when the e-stop contacts are open. The SYSIO e-stop contacts are available on pins 19 and 20 of the SYSIO connectors on the rear panel.

  • Page 183: 6-3 Controller Internal Function Checks

    Chapter 6: Service Repair Checks 6-19 6-3 Controller Internal Function Checks RE3.1 Check Arm Power Enabling Circuits The arm power enabling circuit consists of two subsections: a controller board main processor generated watchdog signal and a series of e-stop contacts in a daisy chain configuration. If the watchdog is not present, or if one of the e-stop contacts is open, arm power can not be turned on.
  • Page 184 6-20 A255 Robot Service Manual 6. If the e-stop LEDs can not be made to turn on or the auxiliary board is not equipped with these LEDs then some other e-stop checks can be made. Make sure that the teach pendant is connected or the override plug is installed and that all e-stop contacts are closed (buttons are not depressed).
  • Page 185 Chapter 6: Service Repair Checks 6-21 RE3.2 Check Arm Power On Signal When arm power is off, the joint servos are in LIMP mode. When the arm is at a location, and power is applied, the servo command register resides at that location.
  • Page 186 6-22 A255 Robot Service Manual RE3.3 Check Power Fail Indicator (PFI) The PFI informs the computer when a fatal power drop is imminent. This prevents the computer from being caught in the middle of a read/write cycle when the power supply voltage drops. Circuitry on the Aux. Board...
  • Page 187 Chapter 6: Service Repair Checks 6-23 RE3.4 Check Voltage Supply to Brake Circuits The brakes receive power from the linear power supply through the two auxiliary board fuses F1 and F2. The brake voltage is then fed to the encoder connector board. Purpose To check the voltage supply to the brake circuits.
  • Page 188 6-24 A255 Robot Service Manual RE3.5 Check UART Initialization Purpose To verify that the UART chips have been correctly initialized by the CPU during a power up. Method 1. Turn the controller on. 2. Ensure that you are properly grounded before touching any circuit boards inside the controller.
  • Page 189 Chapter 6: Service Repair Checks 6-25 RE3.6 Check Programmable Interval Timer (PIT) Purpose To determine if the programmable interval timer on the controller board is functioning correctly. Method 1. Remove the lid of the controller. 2. Ensure that you are properly grounded before touching any circuit inside the controller.
  • Page 190 6-26 A255 Robot Service Manual RE3.7 Check Serial Terminal Device 0 Receive Function Note: Refer to section 2-10 Requirements for Interactive Communication and section 2-11 Host Interface Communication (ACI Operation) for a clear understanding of the requirements for serial communication.
  • Page 191 Chapter 6: Service Repair Checks 6-27 RE3.8 Check Serial Terminal Device 0 Transmit Function Note: Refer to section 2-10 Requirements for Interactive Communication and section 2-11 Host Interface Communication (ACI Operation) for a clear understanding of the requirements for serial communication.
  • Page 192 6-28 A255 Robot Service Manual RE3.9 Check Serial Device 1 Receive Function Note: Refer to sections 2-10 2-11 for a clear understanding of the requirements for serial communication. Device 0 is the default serial channel which supports the teach pendant.
  • Page 193 Chapter 6: Service Repair Checks 6-29 RE3.10 Check Serial Device 1 Transmit Function Note: Refer to sections 2-10 2-11 for a clear understanding of the requirements for serial communication. Device 0 is the default serial channel which supports the teach pendant.
  • Page 194 6-30 A255 Robot Service Manual RE3.11 Check Function of Controller Board (Alone) Purpose To determine if the controller board is functioning properly while excluding all peripheral equipment which could be detrimental to its performance. Method 1. Disconnect main power and remove the lid of the controller.
  • Page 195 Chapter 6: Service Repair Checks 6-31 RE3.12 Check the Computer Power Supply Signal to the Controller Board The connection from the computer power supply to the controller board is critical to the operation of the controller. If the contacts get dirty or lose their effectiveness, the operating voltage at the controller board could drop, causing a failure.
  • Page 196 9. Observe the voltage. The -12 Volt signals should be within ±1.5 Volts DC of the nominal level. This voltage cannot be adjusted on the power supply. If it is outside the specified range, contact CRS. +24 Volt check: 10. Place a scope or a digital voltmeter probe into the controller board power supply connector, J10 position 10.

  • Page 197: Table 6-6 Input Signals

    Chapter 6: Service Repair Checks 6-33 RE3.14 Check Programmable Interrupt Controller (PIC) Initialization and Function Purpose To determine if the programmable interrupt controller on the controller board is functioning correctly. Method 1. Ensure that you are properly grounded before touching any circuit boards inside the controller.
  • Page 198 6-34 A255 Robot Service Manual RE3.15 RS232 Serial Ground Current Loop Check The official standard for RS232 defines pin 1 as an earth (shield) ground and pin 7 as an electrical ground (0 VDC). If the two are joined together at either, or both ends of a serial cable a current loop may form.
  • Page 199 Chapter 6: Service Repair Checks 6-35 RE3.16 Check RESET Chip Function The reset chip is an 82C284 device located at U2 of the controller board. It resets the CPU when the power supply output is unstable. The chip receives power line status information from the auxiliary board via the reset line which comes in at the 60 pin ribbon cable at J1 on the controller board.
  • Page 200 6-36 A255 Robot Service Manual RE3.17 Replace Serial Device Drivers The controller board includes two driver chips which convert TTL signals to RS232 levels. These chips are more likely to be damaged than the UART itself in cases of over voltage, static discharge, short circuiting, or other line problems.
  • Page 201 Chapter 6: Service Repair Checks 6-37 RE3.19 Check Function of AC Components Purpose To check that AC power is present in the lower assemblies. Method 1. Listen for the fan. The operation of the fan is a good indicator the AC power is reaching the lower assemblies.
  • Page 202 6-38 A255 Robot Service Manual RE3.20 Check for Watchdog Signal The controller board main processor generates a watchdog as a result of the execution of a priority software loop. This signal feeds through each major gate array chip on the controller board. The watchdog (a 500 Hz square wave) feeds to the auxiliary board, where it activates a monostable device.
  • Page 203 Chapter 6: Service Repair Checks 6-39 RE3.21 Check Power to Front Panel Display Board The front display board requires Vcc and ground to operate properly. It obtains these voltages along with all of the necessary signals (TTL level) through one ribbon cable. An additional Molex style connector permits the front panel e-stop switch to connect to the auxiliary board.
  • Page 204 6-40 A255 Robot Service Manual RE3.22 Check the Function of the AC Soft Start Board Check the functionality of the AC Soft Start board if the AC main fuses blow upon start-up. Purpose To check the function of the AC Soft Start board.

  • Page 205: Wiring Diagnostic Checks For The Controller, Arm, And Umbilical Cables

    Chapter 6: Service Repair Checks 6-41 6-4 Wiring Diagnostic Checks for the Controller, Arm, and Umbilical Cables RE4.1 Check Continuity of AC Line Cord Purpose To determine if AC power from the socket is reaching the controller. Method 1. Disconnect the AC cord from the rear panel of the controller. Leave it plugged into the wall socket.

  • Page 206: Table 6-7 Signal Feedback Signals Directly From Encoders

    6-42 A255 Robot Service Manual Method Each signal from the encoder travels through several wiring harnesses and connectors. Refer to Chapter 4 for pin-outs for all these signals. 1. Trace a wiring fault in this signal path by disconnecting the motor from the motor connector.
  • Page 207 Chapter 6: Service Repair Checks 6-43 RE4.3 Check Continuity of Servo Gripper Wiring Correct servo gripper operation is dependent upon the transmission of the following signals: motor plus and minus, position reference and signal, and ground. Purpose To check the continuity of servo gripper wiring. Method Each signal from the gripper travels through several wiring harnesses and connectors.
  • Page 208 6-44 A255 Robot Service Manual RE4.4 Check the Continuity of the E-Stop Switch Purpose To determine if there is a break in the signal path of the arm power shut off circuitry switch. Method 1. With the power off, remove the lid of the controller.
  • Page 209 Chapter 6: Service Repair Checks 6-45 RE4.6 Check Continuity of Motor Wiring Correct servo operation depends on correct connection of the output of the DC amplifiers to the motor commutation circuitry. Purpose To check the continuity of the motor wiring. Method 1.

  • Page 210: Table 6-8 Breaker Circuit Pin Measurements

    6-46 A255 Robot Service Manual RE4.7 Check Continuity of Circuit Breaker The power to each motor of the robot travels through a circuit breaker. Sometimes, when a breaker is tripped it loses its ability to reset. Purpose To test the integrity and continuity of the circuit breaker.
  • Page 211 Table 4-7 Expansion Amplifier Connector Pin Signal Descriptions. 5. Replace broken pins in the cable or send them to CRS for repair or replacement. 6. Ensure that the cable shield grounds are connected to the controller. 7. The cable connectors have locking rings. If these are broken the cable will not provide a solid connection.

  • Page 212: Table 6-9 Proximity Sensor Wiring On Auxiliary Board

    Proximity sensor signals pass from the motor power umbilical directly to the auxiliary board. The signals are optically isolated on that board. Note: The A255 arm does not use proximity sensors. The A465 Arm/Track and the A255 Track axis use proximity sensors.
  • Page 213 To check the A465s three harnesses, follow procedure B. A465 Harness Check. A255 Main Harness Check The A255 contains only one main harness. To detect a break in the harness move only those axes that flex a particular portion of the harness and monitor the feedback.
  • Page 214 6-50 A255 Robot Service Manual A465 Harness Checks There are three harness checks for the A465: • the main harness check • the elbow harness check • the wrist harness check To check the main harness 1. Execute the "W1" command.

  • Page 215: 6-5 Controller Board Servo Loop Signal Checks

    Chapter 6: Service Repair Checks 6-51 6-5 Controller Board Servo Loop Signal Checks RE5.1 Check and Adjust Vcom Output From the Controller Board The amplifiers drive the robot motor relays on an analog command voltage from the controller board. An incorrect voltage command affects robot performance.
  • Page 216 6-52 A255 Robot Service Manual 10. Set the motor velocity command to 114 for all motors. Issue the following commands: >>LIMP >>NOLIMP >>MOTOR 1,114 >>MOTOR 2,114 >>MOTOR 3,114 >>MOTOR 4,114 >>MOTOR 5,114 >>MOTOR 6,114 11. Adjust the gain potentiometer to +10 V ±0.05 V.

  • Page 217: Table 6-12 Jp25 Test Strip (Condition Signals)

    It is a pulse which occurs once every encoder revolution. Note: The A465 uses the compliment signal A*, B*, and Z*, while the A255 does not. Purpose To check channels A and B at encoder input to controller board.

  • Page 218: Table 6-13 Feedback Signals Directly From Encoders (Unconditioned Signals)

    6-54 A255 Robot Service Manual Result The test passes if both signals appear as described. JP25 Test Strip Signal Signal Table 6-12 JP25 Test Strip (Condition Signals) Feedback Signals From Encoder Signal Chip Signal Chip Signal Chip Table 6-13 Feedback Signals Directly From Encoders (Unconditioned Signals)
  • Page 219 Chapter 6: Service Repair Checks 6-55 RE5.3 Check Encoder Supply Output From Controller Board The power for the encoder optics and electronics is sourced from the controller board. This is a 5 V and ground that is fed through the encoder connector.

  • Page 220: 6-6 Controller Module Replacement Procedures

    Auxiliary boards. Note: The Power Jumper cable between J13 on the Controller Board and J16 on the Aux. Board on an A255 set is supplied with the assembly and it does not require to be disconnected. 5. Remove the four screws that hold the mounting plate to the controller chassis.
  • Page 221 Chapter 6: Service Repair Checks 6-57 Be very careful, use the proper polarity when installing this connector since the key may be located directly in the center. The connector locking mechanism locks with the appropriate key when inserted correctly. If replacing an AB6xxx series auxiliary board, with an AB6xxx series board, the additional supplied connector is not needed.
  • Page 222 6-58 A255 Robot Service Manual RE6.4 Replace Power Filter Board Purpose To replace the power filter board. Method 1. With main power off and AC unplugged, remove the controller lid. 2. Ensure that you are properly grounded before touching any circuit boards inside the controller.
  • Page 223 Chapter 6: Service Repair Checks 6-59 RE6.6 Replace Cooling Fan Purpose To replace the cooling fan. Method 1. Ensure that the power to the controller is off. 2. Remove the controller lid. 3. Remove the electronics assembly, refer to RE6.1 Replace Controller Electronics.
  • Page 224 6-60 A255 Robot Service Manual RE6.7 Replace Computer Power Supply Purpose To replace the computer power supply. Method 1. With main power off and AC unplugged, remove the controller lid. 2. Ensure that you are properly grounded before touching any circuit boards inside the controller.
  • Page 225 Chapter 6: Service Repair Checks 6-61 RE6.8 Replace PWM Amplifier Module Purpose To replace the PWM amplifier module. Method 1. Ensure that the power to the controller is off. 2. Remove the controller lid. 3. Ensure that you are properly grounded before touching any circuit boards inside the controller.
  • Page 226 6-62 A255 Robot Service Manual RE6.9 Replace PWM Amplifier Module Purpose To replace the PWM amplifier module. Method 1. Ensure that the power to the controller is off. 2. Remove the controller lid. 3. Ensure that you are properly grounded before touching any circuit boards inside the controller.

  • Page 227: 6-7 Software Checks

    Chapter 6: Service Repair Checks 6-63 6-7 Software Checks RE7.1 Diagnostic Start The purpose of the diagnostic start is to boot the controller directly into the diagnostic mode. This may be necessary if the firmware has been corrupted. Purpose To perform a diagnostic start. Method 1.

  • Page 228: Reload Firmware

    6-64 A255 Robot Service Manual RE7.2 Reload Firmware Load firmware if installing a new electronics assembly, upgrading to a newer RAPL version, or if the controller firmware is corrupt. Purpose To reload the firmware. Method 1. Use the “@@DIAG” command or perform a diagnostic start (RE7.1) to access the diagnostic mode.
  • Page 229 Chapter 6: Service Repair Checks 6-65 RE7.3 Check for Feedback From Encoder With the W1 Command Purpose To determine if the encoder is issuing correct signals and that they are read correctly by the computer. Method 1. Turn on the arm power, issue the LIMP command, and place the robot arm in a stable pose.
  • Page 230 6-66 A255 Robot Service Manual RE7.4 Check for Digital Velocity Command The purpose of checking for the digital velocity command is to determine if the controller is issuing correct signals and that they pass to the amplifier. Purpose To check for the velocity command.

  • Page 231: Table 6-14 Serial Command Display

    Chapter 6: Service Repair Checks 6-67 RE7.5 Check SERIAL Status Information about the serial communication parameters can be displayed with the SERIAL command. Purpose To check the serial status. Method 1. Enter the SERIAL command in the terminal mode. 2. The following display appears: Serial Command Display Display...
  • Page 232 6-68 A255 Robot Service Manual RE7.6 Check @@RS for Remote (ACI) Status Information about the status of ACI communication can be displayed with the "@@RS" command. Purpose To check the @@RS for remote (ACI) status. Method 1. Enter the PASSWORD command in the terminal mode.

  • Page 233: 6-8 Amplifier Servo Signal Level Checks

    Amplifier Module The PWM amplifier module receives power from the auxiliary board. Note: This procedure applies to the A465 arm and Tracks, and the A255 Track axes only. Purpose To check the voltage supply from the Auxiliary Board to the PWM amplifier module.
  • Page 234 6-70 A255 Robot Service Manual RE8.2 Check Voltage Supply From the Auxiliary Board to the Linear Amplifier Module The Linear DC Amp module receives power from the auxiliary board. Purpose To check the voltage supply from the Auxiliary Board to the Linear amplifier module.
  • Page 235 Chapter 6: Service Repair Checks 6-71 RE8.3 Check Continuity of the DC Amp to the Rear Panel Motor Power Connector Check the continuity from the DC Amp to the rear panel motor connector to determine if there is a broken wire in the harness carrying the output from the DC amplifiers to the rear panel.
  • Page 236 6-72 A255 Robot Service Manual RE8.4 Check Axis Ground to DC Amps A good signal ground to the DC amplifier is necessary to establish a reference for the command voltage signal (Vcom). There is one such ground for each amplifier module.

  • Page 237: Table 6-16 Amplifiers Settings For The A255

    Test Point Adjustment Voltage CMC/Tamagawa TP3 (DC Amp) 25 Volts CMC/Tamagawa TP2 (DC Amp) 25 Volts CMC/Tamagawa TP1 (DC Amp) 25 Volts CMC/Tamagawa TP3 (DC Amp) 25 Volts CMC/Tamagawa TP2 (DC Amp) 25 Volts Table 6-16 Amplifiers Settings for the A255...
  • Page 238 6-74 A255 Robot Service Manual 8. Set the axis velocity command to -114. Use the following commands: >>LIMP >>NOLIMP >>MOTOR 1,-114 >>MOTOR 2,-114 >>MOTOR 3,-114 >>MOTOR 4,-114 >>MOTOR 5,-114 >>MOTOR 6,-114 9. Check the amplifier outputs for each channel to see if the voltage changes from +25V to –25V.
  • Page 239 Chapter 6: Service Repair Checks 6-75 RE8.6 Check PWM Enable Signals Purpose To check the output levels of the PWM enable signals. Method 1. Check the following pins on the 22 pin connector to the PWM amplifier, refer to Table 3-51 PWM – 22 Pin Signal Conector for pin locations.

  • Page 240: 6-9 Arm Electronic Checks

    6-76 A255 Robot Service Manual 6-9 Arm Electronic Checks RE9.1 Check for Voltage Supply at Encoder Purpose To determine if power and a good signal ground are present at the encoder. Method 1. Expose the motor/encoder. 2. Remove the cover from the encoder.

  • Page 241: Mechanical Checks And Adjustments

    C H A P T E R 7 7 Mechanical Checks and Adjustments A255 Robot Arm General Schematic Before proceeding to service the robot, study the graphic to familiarize yourself with the robot components. Figure 7-1 A255 Robot Arm General Schematic...

  • Page 242: Mechanical Maintenance Schedule

    A255 Robot Arm and Controller This section describes the recommended maintenance schedule for the mechanical system of the A255 Robot Arm. Maintenance procedures include: cleaning, lubricating, and adjusting the robot during its service life. The recommended maintenance schedule is listed below.

  • Page 243: A265 Track Maintenance

    Chapter 7: Mechanical Checks and Adjustments 7-2-2 A265 Track Maintenance The following items are subject to wear: Inspection Period Inspection Period Maintenance Item 100% Duty Cycle 75% Duty Cycle Brushes 2,000 hours/3 months 4 months (initial inspection period) (initial inspection period) Track Rail Lubrication 100 km or 1 year Track Belt Tension...

  • Page 244: Chain Tension Adjustment

    A255 Robot Service Manual Chain Tension Adjustment Tools Required • Long allen key driver - " AF • #0 Robertson screwdriver • Loctite #601 retaining compound • Heavy molybdenum-based oil To perform a chain tension adjustment: 1. With robot arm power on, check the chain tension on the slack side of the loop when the robot is carrying its expected load.

  • Page 245: Wrist Gears

    Chapter 7: Mechanical Checks and Adjustments Wrist Gears 7-4-1 Wrist Gear Mesh Adjustment Tools Required • Allen keys • Small gear puller To perform a wrist gear adjustment: 1. Remove the gripper and any other components mounted to the wrist flange.
  • Page 246 A255 Robot Service Manual 6. Install the wrist flange on the shaft. a) Install the BHSCS and tighten to ensure the bearing is fully seated on the shoulder of the shaft. Since the shaft had moved in axially, the gear mesh should be tighter than normal. Adjust the set screw slowly until the mesh is just right.

  • Page 247: Wrist Gear Lubrication

    Chapter 7: Mechanical Checks and Adjustments 7-4-2 Wrist Gear Lubrication Tools Required • Allen keys • Small gear puller • High-pressure gear grease Metalon High Tech EP 1.5 Warning! Robots with serial number lower than RC2526 use Dow Corning BR2+ grease. Dow Corning BR2+ grease is black in color. Metalon High Tech EP 1.5 is blue in color.

  • Page 248: Wrist Drive Gears Mesh Adjustment

    A255 Robot Service Manual Wrist Drive Gears Mesh Adjustment Tools Required • Allen keys • Assorted shims • High-pressure gear grease Metalon High Tech EP 1.5 Warning! Robots with serial number lower than RC2526 use Dow Corning BR2+ grease. Dow Corning BR2+ grease is black in color.
  • Page 249 Chapter 7: Mechanical Checks and Adjustments 4. If the mesh of the gears is still rough after adjustment, check for burrs or debris in the gear teeth. If the roughness persists, it may be necessary to shim the motor. 5. Repeat above procedure for the other side of the wrist motor/gear assembly.

  • Page 250: Check Motor Brush Wear

    7-10 A255 Robot Service Manual Check Motor Brush Wear Tools Required • " slot screwdriver • " offset slot screwdriver Warning! Installing the brushes in the wrong places reverses electrical polarity and results in the motor running away uncontrollably when power is applied.

  • Page 251: Encoder Alignment

    Chapter 7: Mechanical Checks and Adjustments 7-11 Encoder Alignment 7-7-1 Introduction If a loss of feedback has been diagnosed and it has been determined that neither wiring nor connectors are the cause, the encoder may be at fault. The positional encoder is a precision optical device which translates rotary motion into a string of directional pulses.

  • Page 252: Axial Adjustment Of The Disk Relative To The Stator

    7-12 A255 Robot Service Manual 7-7-3 Axial Adjustment of the Disk Relative to the Stator This adjusts the optical gap which is critical for operation. If the gap is too large, the light from the source is not "focused" through the grating and the signal is lost, resulting in a loss of feedback.

  • Page 253: Calibrating The Arm

    You need: • A computer with Robcomm for Windows or DOS software • Your A255 Robot Arm distribution software disk The distribution disk contains calibration information stored in the following file. cal\srs_(robot arm serial number).cal The .cal file contains factory defined calibration values for the robot arm.

  • Page 254: Recalibrating The Robot Arm

    At the Send window, choose the correct .cal file to send and click OK. The calibration values download to the controller memory. 6. Home the arm (refer to the A255 Robot System User Guide) or use your own custom homing procedure.
  • Page 255 • Computer with Robcomm software • Your A255 distribution disk, or your own backup, if your system was previously recalibrated. If the distribution disk is lost, you can obtain a copy from your nearest distributor or CRS Robotics. Before you begin: •...
  • Page 256 7-16 A255 Robot Service Manual 2) Adjust All the Joints in Sequence to the Zero (@CALRDY) Position Adjust joints 1, 2, 3, 4, and 5, to their Zero position using the following sequence. Use the following figure as a reference.
  • Page 257 Chapter 7: Mechanical Checks and Adjustments 7-17 Joint 1 1. Type LIMP 1 and press Enter, the waist joint limps. 2. Type W1 and press Enter to display the position of the robot joints in motor pulses. The first number lists the position of axis 1. 3.
  • Page 258 3. Type @@CAL and press Enter. At the prompt, type Y (yes). This resets the controller’s calibration data and homes the arm. 4. If required, pull off and re-apply the homing markers, refer to the A255 Robot System User Guide for details.

  • Page 259: Calibrating An Extra Axis

    1. Re-install the plastic arm covers. 2. Inspect the homing markers and reposition if necessary. Note: New markers can be purchased from CRS Robotics. 3. If you removed the arm tooling earlier, ensure that it is properly installed, aligned, and leveled before running your application.

  • Page 260: Cleaning

    7-20 A255 Robot Service Manual Cleaning All arm components can be cleaned using house-hold cleaning products. Note: The use of some solvents or de-greasers may damage the printed surfaces. 7-9-1 Cleaning the Controller's Fan Filter The controller air filters should be cleaned regularly. This procedure can be used to remove the filters for cleaning or to replace them.

  • Page 261: Mechanical System Drawings

    C H A P T E R 8 8 Mechanical System Drawings Mechanical Drawings This chapter contains drawings of the major components for the A255 Robot arm.
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