Controller
ARM POWER ON
indicator
does not light
(ARM POWER
enabled).
|
Blown bulb.
|
Replace bulb.
|
Joint(s) move
when ARM POWER
applied.
|
a. Board(s) not
securely
seated.
b. Defective
board(s).
c. Defective arm
cable.
d. Defective arm
harness.
e. Defective servo-
motor.
|
a. Check all boards in card
cage to ensure secure
seating.
b. Replace boards in following
sequence, checking if prob-
lem persists after each
replacement.
(1) Digital servo board
of affected joint(s).
(2) Power amplifier board
of affected joint(s).
c. Check arm cable lines of
affected joint for conti-
nuity or shorts. Replace
arm cable if necessary.
d. Check arm harness lines of
affected joint for conti-
nuity or shorts. Replace
arm harness if necessary.
e. Replace servomotor of
affected joint.
|
Joint(s) os-
cillate when
ARM POWER
applied.
|
a. VAL not comp-
atible with
robot arm.
b. Electrical noise, arm
harness not
properly
grounded (found
more likely on
major joints).
c. Electrical
noise; encoder
lines.
d. Faulty digital
servo board.
e. Faulty mechan-
ical drive
train.
f. Servomotor
brake not re-
leased.
|
a. Initialize system; ensure
VAL identification number
matches.
b. Ensure that all grounding
wires are securely attach-
ed (Joint 1 motor base,
upper arm, and forearm).
c. Inspect encoder lines;
ensure lines are properly
shielded.
d. Check seating. Exchange
boards to isolate fault.
Replace faulty board.
e. Inspect drive train for
binding (refer to paragraph
4-4-3).
f. Check for proper electr-
cal connection. Ensure
adequate release voltage
is present at arm harness
connector. No voltage in-
dicates faulty intercon-
nection or voltage supply.
Presence of adequate
voltage indicates faulty
servomotor; replace servo
motor.
|
Joint become
limp when ARM
POWER is re-
moved.
|
Defective servo-
motor brake
(most likely if
only one joint
affected).
|
Replace affected servomotor
or defective connection
|
Joint(s) do
not move in
TEACH mode;
move in
RUN mode.
|
a. Defective teach
pendant
b. Defective
console con-
nector for
teach pendant.
c. Board(s) not
securely
seated.
d. Defective
board(s).
e. Faulty low-volt-
age power
supply.
|
a. Replace defective teach
pendant.
b. Check teach pendant
console connector for bent
or broken pins, loose
wiring, etc.
c. Check all boards in card
cage to ensure secure
seating.
d. Replace boards in the foll-
owing sequence, checking
if problem persists after
each replacement:
(1) Quad serial board
(board at slot J34).
(2) "A" interface board.
(3) "B" interface board.
e. Check connector P138 for
the following voltage levels:
Wire 160 = +24 VDC
Wire 37 = +12 VDC
Wire 50 = 0 VDC
Wire 38 = -12 VDC
Wire 41 = +5 VDC
NOTE
No voltage readings indi-
cate blown power supply
fuse. Loss of single volt-
age indicates blown fuse
for that voltage. Replace
fuse (paragraph 5-5-2-1).
|
Joint(s) do
not move in
RUN and TEACH
modes. |
a. Board(s) not
securely
seated.
b. Defective
board(s).
c. Defective arm
cable.
d. Defective arm
harness.
e. Defective servo-
motor.
|
a. Check all boards in card
cage to ensure secure
seating.
b. Replace boards in following
sequence, and check if
problem persists after
each replacement.
(1) Digital servo board.
(2) "A" interface board.
(3) "B" interface board.
(4) CMOS board.
(5) LSI-11/73 board.
(6) "C" interface board.
(7) Arm cable board (call
RP Automation Field Service
for assistance).
c. Check all arm cable lines
for continuity or shorts.
Replace arm cable if nec-
essary.
d. Check all arm harness lines
for continuity or shorts.
Replace arm harness if
necessary.
d. Replace motor of affected
joint.
|
Joint(s) not
aligning pro-
perly at READY
position.
|
a. Wrong overlay
being used.
b. Faulty electri-
cal connection or electrical
noise.
c. Defective
encoder/potenti-
ometer.
d. Defective A to D
converter on "A"
interface board.
e. Loose mechan-
ical drive com-
ponents.
|
a. Use correct OVERLAY file.
NOTE
1. Ensure POTCAL is per-
formed with system config-
ured as it is normally run.
2. POTCAL should not be
performed with a device
such as an extender board
on the "A" or "B" inter-
face boards, or on arm
signal board, as this will
affect voltage and ground
sensing.
b. Check encoder/potentiometer
wires for continuity. Check
for proper grounding at
arm and controller back-
plane.
c. Replace encoder/potenti-
ometer on affected joint.
Perform POTCAL. Create and
use an OVERLAY file.
d. Replace "A" interface
board. Perform POTCAL;
create and use an overlay
file.
e. Check for loose drive shaft
couplings, slipped gears,
etc. If looseness is
found, tighten mechanical
components, and perform
POTCAL; create and use new
OVERLAY file.
|
Joint(s) move
in a jerking
motion in
TEACH and/or
RUN modes.
|
a. Faulty mechan-
ical drive train.
b. Brakes not
properly re-
leased.
c. Faulty high
power function
board.
d. Faulty
electrical
interconnection.
e. Faulty power
amplifier.
f. Faulty encoder/
potentiometer.
g. Defective
board(s).
|
a. Inspect drive train for
binding (refer to paragraph
4-4-3).
b. Using BRAKE RELEASE SELECT,
check for presence of 24vdc
on pins 3 and 4 on servo-
motor power connector.
c. Inspect fuse on high power
function board; replace if
blown. If fuse blows a
second time, replace board.
Check board seating; re-
place board if faulty.
d. Inspect interfaces. Check
cables for continuity; re-
place if faulty. If arm
harness faulty, call
RP Automation Field Service.
e. If problem is in a minor
joint, replace faulty
power amplifier for that
joint. If problem is in
a major joint, replace
major joint power amplifier
assembly.
f. Replace faulty encoder/
potentiometer. Perform
POTCAL.
g. Replace boards in following
sequence, and check if
problem persists after
each replacement.
(1) Digital servo board.
(2) "B" interface board.
(3) "A" interface board.
(4) LSI-11/73 CPU board.
(5) "C" interface board.
|
Arm moves to
misplaced
locations. |
a. Arm not cali-
brated.
b. Wrong overlay
being used.
c. Faulty calibra-
tion.
d. Defective en-
der/pontentio-
meter. |
a. Calibrate arm.
b. Use correct OVERLAY file.
c. Perform POTCAL. Create
and use an OVERLAY file.
d. Replace encoder/potenti-
ometer on indicated joint.
Perform POTCAL. Create and
use OVERLAY file.
|
Joint runaway;
loss of feed-
back. |
a. Faulty position
(encoder) signal
transfer.
b. Faulty encoder/
potentiometer.
c. Faulty digital
servo board.
|
a. Inspect interfaces. Check
cables for continuity; re-
place if faulty. If arm
harness faulty, call
RP Automation Field Service.
b. Isolate encoder/potenti-
ometer by exchanging har-
ness connections. Replace
servomotor if faulty.
c. Check seating. Exchange
boards to isolate fault.
Replace faulty board.
|
Major joint
drop.
|
a. Defective major
joint power amplifier
assembly.
b. Faulty
electrical
interconnection.
c. Faulty digital
servo board.
|
a. Replace power amplifier
assembly.
b. Inspect interfaces. Check
cables for continuity; re-
place if faulty. If arm
harness faulty, call
RP Automation Field Service.
Check LEDs D3 and D4 on
major joint power amp-
lifier; loss of one light
indicates faulty motor
wiring. Refer to Table
5-16.
c. Check seating. Exchange
boards to isolate fault.
Replace faulty board.
|
Minor joint
drop.
|
a. Faulty power
amplifier.
b. Faulty
electrical
interconnection.
c. Faulty digital
servo board.
|
a. Replace power amplifier.
b. Inspect interfaces. Check
cables for continuity; re-
place if faulty. If arm
harness faulty, call
RP Automation Field Service.
c. Check seating. Exchange
boards to isolate fault.
Replace faulty board.
|
Arm does not
respond cor-
rectly to
commands from
VDT or teach
pendant.
|
a. Faulty teach
pendant or VDT.
b. Faulty
electrical
interconnection
between peri-
pheral and
controller.
c. Internal con-
troller fault.
d. Faulty servo-
motor or joint
drive train.
e. Faulty
electrical
interconnection.
|
a. Replace teach pendant or
VDT with known good one.
b. Inspect interconnection
interfaces. Check inter-
connect cables for
continuity; replace if faulty.
c. Check controller components
as follows:
(1) Ensure low-power supply
is operable. Ensure
low-voltage present at
appropriate peripheral
port.
(2) Check seating of quad
serial board; replace
faulty board.
d. Exchange harness connec-
tions to isolate fault.
Replace servomotor if
faulty. Inspect drive
train.
e. Inspect interfaces. Check
the following cables and
harnesses for continuity:
(1) High-power interconnect
cable.
(2) Low-power interconnect
cable.
(3) Arm harness.
If arm harness is faulty,
contact RP Automation Field
Service. If other cables
are faulty, replace.
|
Gripper fails
to operate.
|
a. No air pressure.
b. Missing (or low)
24 VDC.
c. Defective sol-
enoid.
d. Defective high
power function
board.
e. Defective "C"
interface board.
|
a. Check shop air source,
open supply valves, etc.
b. Check for presence of 24
VDC at disconnected arm
end of arm cable. If 24
VDC is present, reconnect
cable to arm and check
for presence of 24 VDC
at solenoid connecting
wires.
c. Replace solenoid.
d. Replace defective board.
e. Replace defective board.
|
FAULT indica-
tor lit.
The FAULT LED
is located in
the CONTROL
section of the
controller
display panel.
LED is marked
Figure 3-1.
|
a. Brake release
switch faulty.
b. Run indicator
fault on :"C"
interface board.
c. Joint 1,2, or
3 limit switch
activated.
d. Major joint
power amplifier
fault.
e. Minor joint
power amplifier
fault.
f. ESTOP contacts
open.
g. OVERTEMP on "C"
interface board
activated.
h. VAL ESTOP
activated.
i. Servo ESTOP
activated.
|
a. Ensure switch is in NORMAL
position; replace faulty
switch assembly. Check
board seating. Replace
boards in the following
sequence; recheck problem
after each step:
(1) "C" interface board.
(2) High-power function
board.
Replace faulty board.
b. Reinitialize VAL system.
Check low-power supply
voltages; lack of all
voltage readings indicates
blown power supply fuse.
Loss of a single voltage
indicates blown fuse, de-
fective power supply, or
bad connection. Check the
following cables for con-
tinuity; replace if faulty.
(1) P88-P17 "C" to "A"
interface connection.
(2) P89-P28 "C" to "C"
interface connection.
(3) P79-P103 Backplane
interconnection.
Check seating of the fol-
lowing boards. Replace in
the following sequence and
recheck after each step:
(1) LSI-11/73 CPU board.
(2) CMOS board.
(3) DLV-11J quad serial
interface board.
Replace faulty board.
c. Inspect LED on "C" inter-
face board. Determine
affected joint. Reposition
joint using brake release
and reinitialize system.
Inspect limit switch; re-
place if faulty. Check
interfaces and cables for
continuity; replace if
faulty.
d. Inspect LEDs on major joint
power amplifier (refer to
Table 5-17).
e. Inspect LEDs on minor joint
power amplifier (refer to
Table 5-15).
f. Refer to Symptom, "ESTOP
indicator lit."
g. Refer to Table 5-13, Symp-
tom "OVERTEMP indicator
lit".
h. Reinitialize VAL system.
i. Check P79 to P103 cable for
continuity. Replace digital
servo boards in sequence
with known good board.
|
ESTOP LED
indicator lit.
|
ESTOP contacts
open.
|
Check for continuity in
circuit. Inspect all ESTOP
switches on controller and
teach pendant. Ensure teach
pendant is connected or port
is jumpered.
|
JOINT LIMIT
SW. indicator
lit.
Activated when
a major joint
triggers its
limit switch.
|
a. Robot arm has
rotated past
software stop;
limit switch
braking system
triggered.
b. Faulty limit
switch.
c. Faulty electri-
cal interconnec-
tion or poor
ground.
d. "C" interface
board faulty.
|
a. Determine affected joint
(check indicator scales).
Use BRAKE RELEASE selector
switch, reposition arm, and
reinitialize system.
b. Check limit switch for
continuity; replace if
faulty.
c. Inspect interfaces. Check
cables for continuity;
replace if faulty. If arm
harness is faulty, call
RP Automation Field Service.
d. Check seating; replace
faulty board.
|
OVER TEMP
indicator lit.
Indicator
lights when
controller
temperature
exceeds 60 deg C
(140 deg F).
|
a. Overtemperature
switch on "C"
interface board
tripped at 60 deg. C.
b. "C" interface
board faulty.
|
a. Check indicator at "C" in-
terface board. Turn off
power; allow cabinet to
cool. Check for abnormal
heat generation.
b. Check seating; replace
faulty board.
|
Joint 1 (D5),
Joint 2 (D11),
Joint 3 (D23),
Joint 4 (D17),
Joint 5 (D29),
or Joint 6
(D35) ENCODER
FAULT indica-
tor lit.
Broken encoder
LED activates
when power to
encoder is
interrupted
or lines to
encoder sig-
nals are open.
|
a. Broken encoder
wire(s).
b. 5 VDC line is
faulty.
c. Loss of ground.
d. Faulty encoder/
potentiometer.
e. Arm signal board
defective.
|
a. Check continuity of all
signal interconnect cable
connections.
b. Check continuity of 5VDC
wiring to indicated joint.
Check 5 VDC regulator on
arm interconnect board at
robot base; replace if
faulty.
c. Check continuity of wiring
from arm signal board to
indicated joint.
d. Replace faulty encoder/
potentiometer.
e. Replace faulty arm signal
board.
|
OVERCURRENT
indicator
(D11) lit.
|
a. Electrical
system faulty.
b. Degeneracy
in robot arm
(degeneracy is
a mechanical
fault occurring
when Joints 4
and 6 line up
during opera-
tion).
c. Faulty power
amplifier board.
|
a. Check cables and servomotor
for short to ground. Re-
place faulty cable or
servomotor.
b. Revise program to avoid
degeneracy.
c. Replace faulty board.
|
Both UNDER
VOLTAGE (D11)
and OVERCUR-
RENT (D12)
are lit.
|
Power supply
problem in power card
backplane.
|
Check board seating. Check
for presence of 60 VDC and
low voltage at backplane and
low voltage at P108. Replace
cable P107-P108 if faulty.
Replace backplane.
|
MOTOR CURRENT
POSITIVE indi-
cator (D3) or
MOTOR CURRENT
NEGATIVE indi-
cator (D4)
not lit.
|
a. Faulty electrical
connection
internal to
amplifier.
b. Interconnect
wiring open.
|
a. Inspect wire connections
into terminal strip on
power amplifier assembly.
Inspect cable connetion
into base driver. Inspect
connection to inductor for
indicated joint.
b. Check interconnect cable
for continuity; replace if
faulty.
|
MOTOR CURRENT
POSITIVE indi-
cator (D3) and
MOTOR CURRENT
NEGATIVE indi-
cator (D4)
not lit.
In normal
operation,
both indica-
tors are lit.
If motor wire
is open, indi-
cator for op-
posite current
will not
light. If both
indicators are
not lit, motor
voltage is
missing.
|
a. Arm power off.
b. Faulty
electrical
connection from
transformer.
c. Blown fuse.
|
a. Ensure that ARM POWER is
turned on. Refer to Table
5-10, "ARM POWER does not
come on."
b. Check for presence of 85
volts from transformer.
Ensure transformer is
properly tapped. Replace
transformer if faulty.
c. Replace fuse; if fuse
blows a second time, re-
place major joint power
amplifier assembly.
|
SYSTEM OK
indicator (D5)
not lit.
|
a. Faulty
electrical
interconnection.
b. Faulty interface
board.
c. Motor control
board faulty.
|
a. Check wire connections at
terminal block. Inspect
ribbon cable P84-P85.
Replace if faulty.
b. Replace Power Amplifier
Assembly.
c. Replace Power Amplifier
Assembly.
|
OVERCURRENT
indicator (D6)
is lit.
|
a. Motor control
board faulty.
b. Faulty mechan-
ical drive
train.
|
a. Replace Power Amplifier
Assembly.
b. Inspect drive train for
binding (refer to paragraph
5-5-1).
|
OVERSPEED
indicator (D7)
is lit.
|
Not used on PUMA
model 761 and
762.
|
Call RP Automation Field Service
if indicator is lit.
|
CONTROL VOLT-
AGE LOSS (D8)
|
a. Voltage regula-
tor faulty.
b/ Faulty latch.
c. Faulty
electrical
interconnection.
d. Base driver
board faulty.
|
a. Contact RP Automation Field
Service for assistance.
b. Replace Power Amplifier
Assembly.
c. Inspect wire connectors
into terminal strip on
power amplifier assembly.
Inspect cable connections
into motor control. Check
transformer input and out-
put voltages. Replace
power amplifier assembly.
d. Replace Power Amplifier
Assembly.
|
OVERTEMPER-
AUTRE (D9)
|
a. Excessive heat.
b. Base driver
board faulty.
c. Cooling fins
defective.
|
a. Turn off controller; allow
to cool.
b. Replace Power Amplifier
Assembly.
c. Ensure that adequate
space is allowed for air
flow around fins.
|
22 VDC PRESENT
(D10) indica-
tor not lit.
|
a. 22 VDC supply
is faulty.
b. Base driver
board faulty.
|
a. Check for presence of
supply voltage at trans-
former. If 22 VDC supply
is faulty, contact
RP Automation Field Service.
b. Replace Power Amplifier
Assembly.
|
PS FAULT (D15)
indicator lit.
|
a. Brake release
fuse blown.
b. High power
function board
faulty
|
a. Replace blown fuse.
b. Check board seating; re-
place faulty board.
|
