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YASKAWA MOTOMAN FS100, Maintenance Manual

The YASKAWA MOTOMAN FS100 is a state-of-the-art robotic system designed to optimize industrial manufacturing processes. Enhance your productivity by downloading the comprehensive Instructions Manual for this product, available for free download exclusively at our website.

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7

Operations After Replacing Parts

7.1 Home Position Calibration

7-10

159645-1CD

RE-CHO-A111

FS100

7.1.3 Manipulator Home Position

With the MOTOMAN-HP20F, the home position is as follows.

NOTE

Other manipulator models have different positions.  Always 
consult the documentation for the correct manipulator 
model.

B-axis center line angle against
U-axis center line (-90

°

)

U-axis angle against horizontal
line on the ground (-0

°)

L-axis angle against vertical
line to the ground (-0

°

)

64 of 348

Summary of Contents for MOTOMAN FS100

Page 1: ...oduct and prior to initial operation read these instructions thoroughly and retain for future reference MOTOMAN INSTRUCTIONS MOTOMAN INSTRUCTIONS FS100 INSTRUCTIONS FS100 OPERATOR S MANUAL FS100 MAINTENANCE MANUAL The FS100 OPERATOR S MANUAL above is applicable to both FS100 and FS100L controllers 1 of 348 ...

Page 2: ...copyrighted property of YASKAWA and may not be sold or redistributed in any way You are welcome to copy this document to your computer or mobile device for easy access but you may not copy the PDF files to another website blog cloud storage site or any other means of storing or distributing online content Printed in the United States of America First Printing 2012 YASKAWA America Inc Motoman Robot...

Page 3: ...re operating this product The drawings and photos in this manual are representative examples and differences may exist between them and the delivered product YASKAWA may modify this model without notice when necessary due to product improvements modifications or changes in specifications If such modification is made the manual number will also be revised If your copy of the manual is damaged or lo...

Page 4: ...sible for providing adequately trained personnel to operate program and maintain the equipment NEVER ALLOW UNTRAINED PERSONNEL TO OPERATE PROGRAM OR REPAIR THE EQUIPMENT We recommend approved YASKAWA training courses for all personnel involved with the operation programming or repair of the equipment This equipment has been tested and found to comply with the limits for a Class A digital device pu...

Page 5: ...hich if not avoided could result in death or serious injury to personnel WARNING Indicates a potentially hazardous situation which if not avoided could result in death or serious injury to personnel CAUTION Indicates a potentially hazardous situation which if not avoided could result in minor or moderate injury to personnel and damage to equipment It may also be used to alert against unsafe practi...

Page 6: ...0 this signal is connected by a jumper cable in the dummy connector To use the signal make sure to supply a new connector and then input it If the signal is input with the jumper cable connected it does not function which may result in personal injury or equipment damage Once the emergency stop button is released clear the cell of all items which could interfere with the operation of the manipulat...

Page 7: ...roblems The emergency stop button is located on the programing pendant CAUTION Perform the following inspection procedures prior to teaching the manipulator If problems are found correct them immediately and be sure that all other necessary tasks have been performed Check for problems in manipulator movement Check for damage to the insulation and sheathing of external wires Return the programming ...

Page 8: ...ted on them are denoted with ex ENTER Symbol Keys The keys which have a symbol printed on them are not denoted with but depicted with a small picture ex PAGE key The Cursor is an exception and a picture is not shown Axis Keys Numeric Keys Axis Keys and Numeric Keys are generic names for the keys for axis operation and number input Keys pressed simultaneously When two keys are to be pressed simulta...

Page 9: ...or damage to equipment Fig Warning Labels The following warning labels are attached to FS100 Observe the precautions on the warning labels Failure to observe this warning may result in injury or damage to equipment Fig Location of Warning Labels WARNING Label B WARNING Label A WARNING Do not enter robot work area WARNING Moving parts may cause injury Heavy Object Warning NP Electric Shock Warning ...

Page 10: ... is not in use In accordance with ANSI RIA R15 06 2012 section 4 2 5 Sources of Energy use lockout tagout procedures during equipment maintenance Refer also to Section 1910 147 29CFR Part 1910 Occupational Safety and Health Standards for General Industry OSHA Mechanical Safety Devices The safe operation of this equipment is ultimately the users responsibility The conditions under which the equipme...

Page 11: ...backup must always be made before any service procedures are done and before any changes are made to options accessories or equipment Any modifications to the controller unit can cause severe personal injury or death as well as damage to the robot Do not make any modifications to the controller unit Making any changes without the written permission from YASKAWA will void the warranty Some operatio...

Page 12: ...ified personnel Summary of Warning Information This manual is provided to help users establish safe conditions for operating the equipment Specific considerations and precautions are also described in the manual but appear in the form of Dangers Warnings Cautions and Notes It is important that users operate the equipment in accordance with this instruction manual and any additional information whi...

Page 13: ...ly 24 to 36 hours for a response to your inquiry Please have the following information ready before you call Customer Support techsupport motoman com NOTE Please use e mail for routine inquiries only If you have an urgent or emergency need for service replacement parts or information you must contact YASKAWA Customer Support at the telephone number shown above System FS100 Primary Application ____...

Page 14: ... Daily Inspections 3 1 3 2 Cooling Fan Inspections 3 3 3 3 Emergency Stop Button Inspections 3 4 3 4 Enable Switch Inspections 3 4 3 5 Battery Inspections 3 5 4 Preparation before Replacing Parts 4 1 4 1 Creating a Check Program 4 3 5 Replacing Parts 5 1 5 1 Fuse Replacement 5 1 5 2 Interior Circulation Fan Replacement 5 3 5 3 Battery Replacement 5 4 5 4 FS100 Replacement 5 8 5 4 1 Backup Device P...

Page 15: ...ting the Second Home Position Check Point 7 14 7 4 1 Purpose of Position Check Operation 7 16 7 4 2 Procedure for the Second Home Position Setting Check Point 7 18 7 4 3 Procedure after the Alarm 7 19 8 System Diagnosis 8 1 8 1 System Version 8 1 8 2 Manipulator Model 8 1 8 3 Input Output Status 8 2 8 3 1 Universal Input 8 2 8 3 1 1 Universal Input Window 8 2 8 3 1 2 Universal Input Simple Window ...

Page 16: ...ual Window of the System Monitoring Time Display 8 17 8 4 3 Clearing the System Monitoring Time Display 8 18 8 5 Alarm History 8 19 8 5 1 Alarm History Window 8 19 8 5 2 Clearing the Alarm History 8 20 8 6 I O Message History 8 21 8 6 1 I O Message History Window 8 21 8 6 1 1 Search 8 21 8 6 2 Clearing the I O Message History 8 22 8 7 Position Data When Power is Turned ON OFF 8 23 8 7 1 Power ON O...

Page 17: ...tal Error 10 18 10 2 2 2 Application Transaction Error 10 18 10 2 2 3 Other Errors 10 18 11 LED Indicator on Each Circuit Board 11 1 11 1 6 LED Spot Indicator on the Main CPU Circuit Board CPU201R 11 2 11 2 7 Segment LED Indicator on the Main CPU Circuit Board CPU201R 11 3 11 2 1 Status of 7 Segment LED Indicator at Error Occurrence 11 4 11 2 2 Status of 7 Segment LED Indicator at Control Power St...

Page 18: ...8AAA Converter unit CSTR COB02AA PWM amplifier module CSTR SDB AAA Major axes control circuit board CSTR IFBM3LA I O relay circuit board CSTR FBBCA8R03CAA Machine safety circuit board JAPMC SF2300R E abbreviated as SF2300R Control circuit board JEPMC CP3201R E abbreviated as CPU 201R Power relay circuit board JEPMC PSD3007R E User I O circuit board for Japan and North America JAPMC IO2308R E abbre...

Page 19: ...CN100 CN101 CN102 CN105 CN55 CN56 CN50 CN51 CSTR MBBCB CSTR MBBCA CSTR MBB CN303 CN301 CN309 CN310 CN302 CN308 CN305 CN306 CN304 CSTR COB02AA CN307 POWER Brake L AXIS MOTOR POWER Brake U AXIS MOTOR POWER Brake T AXIS MOTOR POWER MANIPULATOR Noise filter Two phase 200VAC Control power supply Control power supply Control power supply FBB control Motor power Control power supply Brake release Relay I...

Page 20: ...troLink III CN50 CN51 CSTR MBBCB CSTR MBBCA CSTR MBB CN303 CN301 CN309 CN310 CN302 CN308 CN305 CN306 CN304 CSTR COB02AA CN307 ENCODER S AXIS MOTOR ENCODER L AXIS MOTOR ENCODER U AXIS MOTOR ENCODER T AXIS MOTOR MANIPULATOR Feed back signal Control signal Control power supply Main circuit 24V output 24V4 output 5V output 24V3 output Control power supply Servo control Break power supply FBB control E...

Page 21: ... are three security modes Editing mode and management mode require a user ID The user ID consists of numbers and letters and contains no less than 4 and no more than 8 characters Significant numbers and signs 0 to 9 Table 2 1 Security Mode Descriptions Security Mode Explanation Operation Mode This mode allows basic operation of the robot stopping starting etc for people operating the robot work on...

Page 22: ...dit POSITION BASE Operation Edit POSITION ST Operation Edit LOCAL VARIABLE1 Operation IN OUT EXTERNAL INPUT Operation Edit EXTERNAL OUTPUT Operation Edit UNIVERSAL INPUT Operation Operation UNIVERSAL OUTPUT Operation Operation SPECIFIC INPUT Operation SPECIFIC OUTPUT Operation RIN Operation CPRIN Operation REGISTER Operation Management AUXILIARY RELAY Operation CONTROL INPUT Operation PSEUDO INPUT...

Page 23: ...LOG MONITOR Management Management OVERRUN S SENSOR1 Edit Edit LIMIT RELEASE1 Edit Edit ARM CONTROL1 Management Management SHIFT VALUE Operation HAND VIBRATION CONTROL Operation Management SYSTEM INFO VERSION Operation MONITORING TIME Operation Management ALARM HISTORY Operation Management I O MSG HISTORY Operation Management NETWORK SERVICE Management USER DEFINITION MENU Operation Operation SECUR...

Page 24: ...JOG COND Management Management PLAYBACK COND Management Management FUNCTION COND Management Management DISPLAYING COLOR COND Management Management DATE TIME Management Management GRP COMBINATION Management Management RESERVE JOB NAME Edit Edit USER ID Edit Edit SET SPEED Management Management KEY ALLOCATION Management Management JOG KEY ALLOC Edit Management RES START CNCT Management Management AU...

Page 25: ...ection Through Security Mode Settings FS100 2 1 1 1 Changing the Security Mode 1 Select SYSTEM INFO under the main menu The sub menu appears 2 Select SECURITY The selection window of security mode appears 3 Press SELECT and select SECURITY MODE 25 of 348 ...

Page 26: ... The user ID input window appears 5 Press ENTER The input user ID is compared with the user ID of the selected security mode When the correct user ID is entered the security mode is changed SUPPLE MENT At the factory the following below user ID number is preset Editing Mode 00000000 Management Mode 99999999 26 of 348 ...

Page 27: ...r ID must be between 4 characters and 8 and they must be numbers and symbols 0 to 9 and 2 1 2 1 Changing a User ID In order to change the user ID the FS100 must be in Editing Mode or Management Mode Higher security modes can make changes the user ID of to lower security modes 1 Select SETUP under the main menu The sub menu appears 2 Select USER ID The USER ID window appears 27 of 348 ...

Page 28: ...he desired ID The character input line appears and the message Input current ID no 4 to 8 digits is shown 4 Input current ID and press ENTER When the correct user ID is entered a new ID is requested to be input Input new ID no 4 to 8 digits appears 5 Input new ID and press ENTER User ID is changed 28 of 348 ...

Page 29: ... before operating the FS100 To ensure correct and safe operation carefully read the FS100 INSTRUCTIONS 159644 1CD 3 1 Daily Inspections WARNING Maintenance and inspections should be carried out by the qualified worker Failure to observe this caution may result in electric shock or injury WARNING Do not touch the cooling fan or other equipment while the power is turned ON Failure to observe this ca...

Page 30: ...mounting screws Check for defect or loose of the screws Use screw driver As required Tighten loose screws Cooling fan Check the operation Check visually As required When the power is turned ON Emergency stop button 1 programming pendant Check the operation By activating the button Before the manipulator operation When the SERVO is turned ON Enable switch programming pendant Check the operation By ...

Page 31: ...sive high temperatures inside The interior circulation fan and cooling fan normally operate while the power is turned ON Check if the fans are operating correctly by visual inspection and by feeling air moving into the air inlet and from the outlet Air intake Air intake Air intake Air outlet Air outlet Air outlet Air outlet Air outlet Backside View Cooling fan installing direction Top View Cooling...

Page 32: ...equipped with a three position enable switch Perform the following operations to confirm that the enable switch is firmly operated 1 Set the Mode key on the programming pendant to TEACH Mode key with a switch 2 Press SERVO ON READY on the programming pendant Then SERVO ON lamp blinks 3 When the enable switch is grasped lightly the servo power is turned ON When the enable switch is grasped firmly o...

Page 33: ...attery is weakened to be replaced Also a message Memory battery weak appears on the programming pendant display Refer to section 5 3 Battery Replacement for the battery replacement When the programming pendant is not used be sure to confirm from the LED audit window on the FS100 front door that the battery alarm LED of the CPU unit CPU 201R is not lit up Also the battery alarm status can be confir...

Page 34: ...ctor To use the signal make sure to supply a new connector and then input it If the signal is input with the jumper cable connected it does not function which may result in personal injury or equipment damage Observe the following precautions when performing teaching operations within the manipulator s operating range Be sure to use a lockout device to the safeguarding when going inside Also displ...

Page 35: ...emory by replacement of main CPU board weak battery etc Home position deviation caused by hitting the manipulator against a workpiece etc CAUTION Perform the following inspection procedures prior to conducting manipulator teaching If problems are found repare them immediaterly and be sure that all other necessary processing has been performed Check for problems in manipulator movement Check for da...

Page 36: ...eviation whenever necessary create a program in which a check point is taught the job for the check point In the job for the check point teach two points one as a check point and the other as the point to approach the check point This program checks for any deviation between the tool tip position and the check point Fig 4 1 Enlarged View 36 of 348 ...

Page 37: ...ve this caution may result in electric shock or injury Following fuses1 are mounted in the FS100 Fuse name Where to mount Type Manufacturer I O power supply fuse F1 left side of the following figure Front side of the FS100 0312 600 250V 0 6A 6 3 dia x 32 mm fast blow type Littel Fuse for regenerative resistor cooling fan protection 2 F2 right side of the following figure Front side of the FS100 31...

Page 38: ...11 FS100 If the fuse seems to be blown check its conduction If it is blown replace it with the same type of fuse supplied NOTE If the fuse seems to be blown be sure to investigate its cause or blown again after the replacement F1 F2 Locations of the fuse 38 of 348 ...

Page 39: ...install the fan from the FS100 4 Install the new fan to the FS100 When installing the fan be carefull to its installing direction so that the air is drewn inside the FS100 5 Tighten the screws 3 places to fix the fan and the fan guard 6 Connect all the disconnected plug codes and the ground wirings Connect the plug code securely so that there is no space between the plug code and the fan Also conn...

Page 40: ...wer is turned ON Do NOT open the plate to perform the operation within five minutes after turning OFF the FS100 power supply and primary power source Do NOT touch units or terminal parts within five minutes after turning OFF the FS100 power supply Failure to observe this warning may result in electric shocks Close the top plate as soon as the maintenance work such as the inspection or maintenance ...

Page 41: ...ocedure 1 Uninstall the top plate and loosen the strap which is fixing the battery 2 Disconnect the connector from the battery extension lead wire and remove the battery 3 Connect the new battery to the battery extension lead wire Battery fixing strap Extension lead wire connector 41 of 348 ...

Page 42: ...CHO A111 FS100 4 Fix the battery with the strap Fasten the strap till the third hole of it When fixing the battery put the black lead wire toward inner side of the FS100 Black lead wire Inner side of the controller Fasten the strap till the third hole 42 of 348 ...

Page 43: ... job data and other data may be lost if the message Memory battery weak appears and the breaker is turned OFF for more than 1 hours Fix the battery lead wire to the inner side of the controller The battery might fall off due to the vivration etc if the lead wire is fixed parallel to the controller Do not fix the battery lead parallel to the inner side of the controller Wrong example Inner side of ...

Page 44: ...acked up at this time The FS100 is not tuned ON The programming pendant screen does not appear and so on If the backup of the system CMOS BIN was executed ahead of time use the backup data FS100 replacement 5 4 1 5 4 2 5 4 3 5 4 4 End 4 7 When the system backup cannot be executed Operations at this time yet it was bakced up CMOS BIN ahead of time load the backup data Preparations before replacing ...

Page 45: ...stem backup Perform the backup by CMOS BIN in the maintenance mode The chart below shows the availability of CMOS save and CMOS load in each security mode in the maintenance mode No Manufacturer Model Remarks 1 Hagiwara Solutions Co Ltd MCF10P 256MS 256MB 2 Hagiwara Solutions Co Ltd MCF10P 512MS 512MB 3 Hagiwara Solutions Co Ltd MCF10P A01GS 1GB 4 Hagiwara Solutions Co Ltd MCF10P A02GS 2GB No Manu...

Page 46: ...g pendant When using USB memory instead of CompactFlash mount a USB memory stick to the programming pendant select DEVICE then select USB PENDANT To connect a USB memory stick to the USB device of the main CPU board mount a USB memory stick to the USB device select DEVICE then select USB CONTROLLER 3 Select EX MEMORY under the main menu The sub menu appears 4 Select SAVE The save display appears T...

Page 47: ...ion dialog box appears 6 Select YES Select YES to save the CMOS data into a CompactFlash card When saving the file if the CMOS BIN file already exists in the CompactFlash card the following confirmation dialog box appears 7 Select YES The CMOS BIN file is overwritten in the CompactFlash card 47 of 348 ...

Page 48: ...e primary power supply knife switch wiring circuit breaker etc Failure to observe this warning may result in electric shocks or injury CAUTION Lift move or install the FS100 by two or more persons Approx mass of FS100 20 kg per unit Use a platform truck to carry the FS100 Avoid jarring dropping or hitting the FS100 during handling Failure to observe these cautions may cause the FS100 to fall down ...

Page 49: ...his time Power cable Robot signal cable X21 2BC X11 1BC Back view of the FS100 WARNING Do not turn ON the servo power until the system loading completes even if the FS100 is replaced and the cables are connected TEACH PLAY REMOTE START HOLD X R Y B Z T X R Y B Z T 8 8 X S Y L Z U X S Y L Z U E E SERVO ON HIGH SPEED FAST SLOW SELECT TOOLOF 0 1 TOOLON 2 TOOLON JOB 3 SMOV 4 5 6 SYNCRO SINGLE 7 8 9 TO...

Page 50: ...nge the security mode to the maintenance mode 9 Insert a CompactFlash card into the CompactFlash slot on the programming pendant When using USB memory instead of CompactFlash mount a USB memory stick to the programming pendant select DEVICE then select USB PENDANT To connect a USB memory stick to the USB device of the main CPU board mount a USB memory stick to the USB device select DEVICE then sel...

Page 51: ...arts 5 4 FS100 Replacement FS100 11 Select LOAD The load display appears The items marked with cannot be selected 12 Select CMOS The confirmation dialog box appears 13 Select YES The dialog box Overwrite network configuration appears 51 of 348 ...

Page 52: ... are the same as before and check to be sure that safety is confirmed with the current manipulator position and also confirm these motions shown in the list below After that start the manipulator s operation Confirm that axes can be operated normally in the teach mode Move all axes to the pulse value 0 and confirm that they correspond to the home position Press the emergency stop button on the pro...

Page 53: ... 6A18 10SD D BSS DDK 1 1 Waterproof cable clamp CE3057 10A 1 D DDK 1 1 2 Dummy connector for safety signal short circuit HB1370101 1 YASKAWA Electric Corporation 1 1 3 I O power supply protection fuse 0312 600MXP Littel 1 1 4 WAGO Connector wiring tool 734 230 WAGO 1 5 Fuse for regenerative resistor cooling fan protection 312001 250V 1A Littel 1 HP20F only Accessory No 1 Accessory No 5 Accessory N...

Page 54: ...spare parts for the FS100 Product performance cannot be guaranteed when using spare parts from any company other than YASKAWA Table 6 1 Spare Parts for the FS100 Rank Parts No Name Type Manuf acturer Qty Qty per unit Remark A 1 Battery BR 1 2AA 3 0V Panasonic 1 1 When the battery alarm occurred A 2 I O power supply protection fuse 0312 600MXP Littel 1 1 A 3 Fuse for regenerative resistor cooling f...

Page 55: ...nd then input it If the signal is input with the jumper cable connected it does not function which may result in personal injury or equipment damage Observe the following precautions when performing teaching operations within the manipulator s operating range Be sure to use a lockout device to the safeguarding when going inside Also display the sign that the operation is being performed inside the...

Page 56: ...tions for home position calibration All the axes can be moved at the same time Axes can be moved individually CAUTION Perform the following inspection procedures prior to conducting manipulator teaching If problems are found repare them immediaterly and be sure that all other necessary processing has been performed Check for problems in manipulator movement Check for damage to the insulation and s...

Page 57: ...on FS100 If the absolute data of the home position is already known set the absolute data again after completing home position registration SUPPLE MENT Home Position The home position is the position with the pulse value 0 for each axis See section 7 1 3 Manipulator Home Position 57 of 348 ...

Page 58: ...g Operation 7 1 2 1 Registering All Axes at One Time 1 Select ROBOT under the main menu 2 Select HOME POSITION The HOME POSITIONING window appears 3 Select DISPLAY under the menu or select PAGE to display the selection window for the control group or press page key The pull down menu appears GO BACK PAGE 58 of 348 ...

Page 59: ...0 4 Select the desired control group 5 Select EDIT under the menu The pull down menu appears 6 Select SELECT ALL AXES The confirmation dialog box appears 7 Select YES Displayed position data of all axes are registered as home position When NO is selected the registration will be canceled 59 of 348 ...

Page 60: ...ION 3 Select the desired control group Perform steps 3 and 4 which have been described in section 7 1 2 1 Registering All Axes at One Time to select the desired control group 4 Select the axis to be registered The confirmation dialog box appears 5 Select YES Displayed position data of the axis are registered as home position When NO is selected the registration will be canceled 60 of 348 ...

Page 61: ...eted perform the following 1 Select ROBOT under the main menu 2 Select HOME POSITION 3 Select the desired control group Perform steps 3 and 4 which have been described in Registering All Axes at One Time to select the desired control group 4 Select the absolute data to be registered The number can now be entered 5 Enter the absolute data using the numeric keys 6 Press ENTER Absolute data are modif...

Page 62: ...t ROBOT under the main menu 2 Select HOME POSITION Perform steps 2 3 and 4 which have been described in Registering All Axes at One Time to display the HOME POSITIONING window and select the desired control group 3 Select DATA under the menu The pull down menu appears 4 Select CLEAR ALL DATA The confirmation dialog box appears 62 of 348 ...

Page 63: ...9 159645 1CD RE CHO A111 7 Operations After Replacing Parts 7 1 Home Position Calibration FS100 5 Select YES The all absolute data are cleared When NO is selected the operation will be canceled 63 of 348 ...

Page 64: ...he MOTOMAN HP20F the home position is as follows NOTE Other manipulator models have different positions Always consult the documentation for the correct manipulator model B axis center line angle against U axis center line 90 U axis angle against horizontal line on the ground 0 L axis angle against vertical line to the ground 0 64 of 348 ...

Page 65: ...ate the manipulator at low speed 2 Check the tool tip position If it points the check point exactly as shown in the following figure there is no deviation from the positions Proceed to section 7 4 Setting the Second Home Position Check Point If not there is a deviation When the motor or encoder etc was replaced move the corresponding axis only when the stored memory was cleared or the manipulator ...

Page 66: ...e job for avoiding the position deviation and operate the manipulator at low speed 7 3 2 Checking of the Check Program Check the deviation in to the check point If the tool tip position is deviated there is a deviation When the motor or encoder etc was replaced move the corresponding axis only when the stored memory was cleared or the manipulator was hit against a workpiece move all axes to the ch...

Page 67: ...MAND POSITION 2 Current position pulse where the manipulator tool tip was moved to the check point after performing the check program Displaying the Current Position Pulse I Select ROBOT under the main menu II Select CURRENT POSITION 2 Calculate the difference between the command position pulse and the current position pulse The difference pulse Command position pulse Current position pulse 3 On t...

Page 68: ...nal is connected by a jumper cable in the dummy connector To use the signal make sure to supply a new connector and then input it If the signal is input with the jumper cable connected it does not function which may result in personal injury or equipment damage Observe the following precautions when performing teaching operations within the manipulator s operating range Be sure to use a lockout de...

Page 69: ...all other necessary tasks have been performed Check for problems in manipulator movement Check for damage to the insulation and sheathing of external wires Return the programming pendant to a safe place after use If the programming pendant is inadvertently left on the manipulator on a fixture or on the floor the manipulator or a tool may collide with the programming pendant during manipulator move...

Page 70: ... stall when playback is started If the absolute data allowable range error alarm has occurred playback and test runs will not function and the position must be checked 1 Position Check After the OUT OF RANGE ABSO DATA alarm occurs move to the second home position using the axis keys and perform the position confirmation Playback test runs and FWD operation will not function unless CONFIRM POSITION...

Page 71: ...stem Check the system After adjusting the erroneous axis calibrate the home position of the axis then check the position again NOTE Home position calibration of all the axes at the same time enables playback operations without having to check the position Sometimes in a system with a manipulator that has no brake it is possible to enable playback without position checking after the alarm occurs Ho...

Page 72: ...olled by one FS100 the second home position must be set for each manipulator or station 1 Select ROBOT under the main menu 2 Select SECOND HOME POS The SECOND HOME POS window appears The message Available to move to and modify specified point is shown 3 Press the page key or select PAGE to display the selection window for the control group The group axes by which the second home position is set is...

Page 73: ...he PG etc The robot current position data when turning main power supply OFF and ON can be confirmed in POWER ON OFF POS window 1 Select ROBOT under the main menu 2 Select SECOND HOME POS The SECOND HOME POS window appears WARNING Be aware of safety hazards when performing the position confirmation of the specified point Abnormality of the PG system may be cause for alarm The manipulator may opera...

Page 74: ... when there are two or more group axes 4 Press FWD TCP moves to the second home position The robot moving speed is set as selected manual speed 5 Select DATA under the menu 6 Select CONFIRM POSITION The message Home position checked is shown Pulse data of the second home position and current pulse data are compared If the compared error is in allowed range playback operation can be done If the err...

Page 75: ...stem Version It is possible to check the system CPU version information as follows 1 Select SYSTEM INFO under the main menu 2 Select VERSION The VERSION window appears 8 2 Manipulator Model 1 Select ROBOT under the main menu 2 Select MANIPULATOR TYPE The ROBOT AXIS CONFIG window appears 75 of 348 ...

Page 76: ...n of a job can be confirmed 8 3 1 1 Universal Input Window 1 Select IN OUT under the main menu 2 Select UNIVERSAL INPUT The UNIVERSAL INPUT window appears 8 3 1 2 Universal Input Simple Window 1 Select IN OUT under the main menu 2 Select UNIVERSAL INPUT The UNIVERSAL INPUT window appears 3 Select SIMPLE from the pull down menu of DISPLAY The UNIVERSAL INPUT simple window appears 76 of 348 ...

Page 77: ...d modified 8 3 2 1 Universal Output Window 1 Select IN OUT under the main menu 2 Select UNIVERSAL OUTPUT The UNIVERSAL OUTPUT window appears 8 3 2 2 Universal Output Simple Window 1 Select IN OUT under the main menu 2 Select UNIVERSAL OUTPUT The UNIVERSAL OUTPUT window appears 3 Select SIMPLE from the pull down menu of DISPLAY The UNIVERSAL OUTPUT simple window appears 77 of 348 ...

Page 78: ...n be changed by the operation below 1 Select the desired output signal number Select the status of the desired output signal or in the UNIVERSAL OUTPUT window 2 Press INTER LOCK key SELECT The status is changed ON status OFF status NOTE The status of universal output signal can be changed only when the mode is set to the teach mode INTER LOCK 78 of 348 ...

Page 79: ...1 Select IN OUT under the main menu 2 Select SPECIFIED INPUT The SPECIFIED INPUT window appears 8 3 3 2 Specific Input Simple Window 1 Select IN OUT under the main menu 2 Select SPECIFIED INPUT The SPECIFIED INPUT window appears 3 Select SIMPLE from the pull down menu of DISPLAY The SPECIFIC INPUT simple window appears 79 of 348 ...

Page 80: ...Select IN OUT under the main menu 2 Select SPECIFIED OUTPUT The SPECIFIED OUTPUT window appears 8 3 4 2 Specific Output Simple Window 1 Select IN OUT under the main menu 2 Select SPECIFIED OUTPUT The SPECIFIED OUTPUT window appears 3 Select SIMPLE from the pull down menu of DISPLAY The SPECIFIC OUTPUT simple window appears 80 of 348 ...

Page 81: ...8 7 159645 1CD RE CHO A111 8 System Diagnosis 8 3 Input Output Status FS100 8 3 5 RIN Input 8 3 5 1 RIN Input Window 1 Select IN OUT under the main menu 2 Select RIN The RIN window appears 81 of 348 ...

Page 82: ...er Search A search can be made for a signal number of a universal input universal output system input and system output A search for the signal number can be made in the following two ways Direct search on the UNIVERSAL SPECIFIED INPUT OUTPUT window Search from the menu Signal number 82 of 348 ...

Page 83: ...t Output Window 1 Move the cursor to a signal number in the UNIVERSAL SPECIFIED INPUT OUTPUT window and press SELECT Numeric values can now be entered 2 Enter the signal number to be searched Type the signal number in the number input line 3 Press ENTER to start the search The page where the signal number exists appears 83 of 348 ...

Page 84: ...r the menu in the UNIVERSAL SPECIFIED INPUT OUTPUT window The pull down menu appears 2 Select SEARCH SIGNAL NO Numeric values can now be entered 3 Enter the signal number to be searched Type the signal number in the number input line 4 Press ENTER to start the search The page where the signal number exists appears 84 of 348 ...

Page 85: ...mber Search A search can be made for a relay number of a universal input universal output system input and system output A search for the relay number can be made in the following two ways Direct search on the UNIVERSAL SPECIFIED INPUT OUTPUT window Search from the menu Relay number 85 of 348 ...

Page 86: ...put Output Window 1 Move the cursor to a relay number in the UNIVERSAL SPECIFIED INPUT OUTPUT window and press SELECT Numeric values can now be entered 2 Enter the relay number to be searched Type the relay number in the number input line 3 Press ENTER to start the search The page where the relay number exists appears 86 of 348 ...

Page 87: ... the menu in the UNIVERSAL SPECIFIED INPUT OUTPUT window The pull down menu appears 2 Select SEARCH RELAY SIGNAL NO Numeric values can now be entered 3 Enter the relay number to be searched Type the relay number in the number input line 4 Press ENTER to start the search The page where the relay number exists appears 87 of 348 ...

Page 88: ... two ways Direct modification on the UNIVERSAL SPECIFIED INPUT OUTPUT window Modification from the menu 8 3 8 1 Direct Modification on the Universal Specified Input Output Window 1 Move the cursor to the signal name to be modified in the UNIVERSAL SPECIFIED INPUT OUTPUT window and press SELECT The window for character input appears 2 Enter the signal name 3 Press ENTER New signal name is registere...

Page 89: ...rom the Menu 1 Move the cursor to the signal name to be modified in the UNIVERSAL SPECIFIED INPUT OUTPUT window 2 Select EDIT under the menu The pull down menu appears 3 Select RENAME The window for character input appears 4 Enter the signal name 5 Press ENTER New signal name is registered 89 of 348 ...

Page 90: ...RING TIME The SYS MONITORING TIME window appears 1 CONTROL POWER TIME Displays the cumulative time that the main power supply has been ON 2 SERVO POWER TIME Displays the cumulative time that the servo power supply has been ON 3 PLAYBACK TIME Displays the cumulative time during which playback was executed 4 MOVING TIME Displays the cumulative time that the manipulator was in motion 5 OPERATING TIME...

Page 91: ...ay the selection window for the system monitoring time display the servo power time playback time moving time and each application operating time by each control group are individually displayed NOTE The total time of each control group here is not always the same as the time in the SYS MONITORING TIME window because these windows show time as seen from the individual control group GO BACK PAGE 91...

Page 92: ...and operating time can be cleared and set back to 0 by following procedure These operations can be performed in the SYS MONITORING TIME window or in the individual windows 1 Select the time to be cleared The confirmation dialog box appears 2 Select YES The cumulative time value at the cursor line is reset to 0 and a new time measurement begins 92 of 348 ...

Page 93: ...EM window the USER ALARM USER window and the OFF LINE ALARM window Each window shows the alarm code and the date and time 1 Select SYSTEM INFO under the main menu 2 Select ALARM HISTORY The alarm history window appears 3 Press the page key to change the window or select PAGE to display the selection window for the alarm windows Each time the page key is pressed the window changes MAJOR ALARM MINOR...

Page 94: ...tory of the minor alarms and the user alarms system and user can be cleared 1 Display the alarm history window to be cleared 2 Select DATA under the menu The pull down menu CLEAR HISTORY appears 3 Select CLEAR HISTORY The confirmation dialog box appears 4 Select YES The alarm history displayed is reset 94 of 348 ...

Page 95: ... under the main menu 2 Select I O MSG HISTORY The I O MESSAGE HISTORY window appears Press SELECT and numeric values can now be entered Input the history number and press ENTER The search for the input history number begins and the I O message that appeared on the window is displayed 8 6 1 1 Search Use the following operation to search for the I O message history 1 Select EDIT under the menu 2 Sel...

Page 96: ... A111 FS100 8 6 2 Clearing the I O Message History Use the following operation to clear the I O message history 1 Select DATA under the menu 2 Select CLEAR HISTORY The confirmation dialog box appears 3 Select YES The displayed I O message history is cleared 96 of 348 ...

Page 97: ...the position of the manipulator when power was turned OFF the last time the current position of the manipulator when power was later turned ON and the amount of difference between the two positions When alarm 4107 OUT OF RANGE ABSO DATA occurs the error value of the faulty axes can be verified in this window 1 Select ROBOT under the main menu 2 Select POWER ON OFF POS The POWER ON OFF POSITION win...

Page 98: ... Position Window 1 Select ROBOT under the main menu 2 Select CURRENT POSITION under the sub menu The CURRENT POSITION window appears 3 Select the types of coordinates to be displayed The pull down menu appears 4 Select the desired coordinate system The type of coordinates being displayed is changed 98 of 348 ...

Page 99: ...PEED Feedback speed actual speed of each axis TORQUE SPEC Torque reference of each axis MAX TORQUE Keeps the maximum value of the torque reference of each axis 0 when the maximum torque is cleared or the control power supply is turned ON or OFF ENCODER ROTATE SUM Accumulated number of encoder rotation when the control power supply of each axis is turned ON IN 1 TURN POSITION Position after one rot...

Page 100: ...tor Items 1 Set the security mode to the management mode 2 Select ROBOT under the main menu 3 Select SERVO MONITOR The SERVO MONITOR window appears 4 Select DISPLAY under the menu The pull down menu appears MONITOR ITEM 1 is the data on the left and MONITOR ITEM 2 is the data on the right 100 of 348 ...

Page 101: ... 8 System Diagnosis 8 9 Servo Monitoring FS100 5 Select MONITOR ITEM 1 or 2 and view the sub menu choices by the cursor key The sub menu choices appear 6 Select a menu The type of monitor related information is changed 101 of 348 ...

Page 102: ... 9 1 2 Clearing Maximum Torque Data The data for the maximum torque can be cleared when the maximum torque related information is being displayed 1 Select DATA under the menu The clear max torque window appears 2 Select MAX TORQUE The maximum torque data is cleared 102 of 348 ...

Page 103: ...f the alarm Then turn ON the main power supply again 1 to 3 Level 1 to 3 Major alarm It is not possible to reset by RESET under the ALARM win dow or the system input signal Alarm reset Turn OFF the main power supply and correct the cause of the alarm Then turn ON the main power supply again 4 to 8 Level 4 to 8 Minor alarm After correcting the cause it is possible to reset by RESET under the ALARM ...

Page 104: ...us window change mode change alarm reset and emergency stop If the window is changed to another window during alarm occurrence the ALARM window can be shown again by selecting SYSTEM INFO under the main menu and then selecting ALARM 9 2 1 1 Releasing Alarms Alarms are classified by minor and major alarms Minor Alarms Select RESET on the ALARM window to release alarms Or turn ON the system signal A...

Page 105: ...1 to 2 With base axis Base 1 to 2 With station axis Stations 1 to 3 XYZ coordinate data The coordinates where the alarm occurred are highlighted 123 data The data for which the alarm occurred is highlighted Control group data The control group where the alarm occurred is highlighted 2 Multiple SERVO Control Board System In a system using more than one SERVO control board the number of the SERVO co...

Page 106: ...ional In the independent control function multi task job the tasks that were being done when the alarm occurred are also displayed TASK 0 Master task job TASK 1 Sub task1 job SUB1 TASK 2 Sub task2 job SUB2 TASK 3 Sub task3 job SUB3 TASK 4 Sub task4 job SUB4 TASK 5 Sub task5 job SUB5 106 of 348 ...

Page 107: ...parameter when an alarm occurs 9 3 1 Parameter S2C406 Alarm Details Direct Display 0 Invalid 1 Valid 9 3 2 Display of Alarm Detail Window Page Displays the page number of the alarm whose detail window is currently displayed the total alarm number occurred coincidentally Alarm No Displays the alarm number with decimal 4 digit Sub data Displays the sub code number defined to each alarm Alarm content...

Page 108: ...ne alarm Press this to right left ward to alternate the cause and the measure Cause Displays the cause of an alarm Measure Displays the recovery method from the alarming state Reset button Press this button to reset the alarm Page button Press this button to display the page number inputting area This area appears when several alarms occur at a time 108 of 348 ...

Page 109: ...rsor up and down to select the alarm number to display each ALARM DETAIL window Move Cursor to the right Press Right button on the window or Move Cursor to the left Press Left button on the window or RETURN button or CANCEL When direct display is set it would not return to the above window In case an unresettable alarm occured the ALARM window or its ALARM DETAIL window appears SHIFT GO BACK PAGE ...

Page 110: ... for any remedies personnel must be appropriately skilled in maintenance mode operation CPU 201R is saving important file data for the user program through its battery backup operation Contact your YASKAWA representatives when measures for CPU 201R alarms are considered to be needed Careless operation may delete registered data 110 of 348 ...

Page 111: ...ace the controller Save the CMOS BIN before replacement to be safe Connection failure 1 Turn the power OFF then back ON 2 If the alarm occurs again replace the controller Save the CMOS BIN before replacement to be safe Servo control board failure 1 Turn the power OFF then back ON 2 If the alarm occurs again replace the controller Save the CMOS BIN before replacement to be safe Main CPU board failu...

Page 112: ...oard failure 1 Turn the power OFF then back ON 2 If the alarm occurs again replace the controller Save the CMOS BIN before replacement to be safe 51 The communications CPU for the Servo control board 2 detected an error when the control power turned ON Setting error 1 Turn the power OFF then back ON 2 If the alarm occurs again replace the controller Save the CMOS BIN before replacement to be safe ...

Page 113: ...alarm occurs again replace the controller Save the CMOS BIN before replacement to be safe Main CPU board failure 1 Turn the power OFF then back ON 2 If the alarm occurs again replace the controller Save the CMOS BIN before replacement to be safe 1 An error was detected in communications with the I O module board connected with 1st serial bus when the control power turned ON Setting error 1 Check t...

Page 114: ...m occurs again replace the controller Save the CMOS BIN before replacement to be safe 3 An error was detected in communications with the I O module board connected with 3rd serial bus when the control power turned ON Setting error 1 Check the following settings The rotary switch setting which specifies slot numbers of each I O module I O module settings in maintenance mode Connection failure 1 Tur...

Page 115: ...m occurs again replace the controller Save the CMOS BIN before replacement to be safe 5 An error was detected in communications with the I O module board connected with 5th serial bus when the control power turned ON Setting error 1 Check the following settings The rotary switch setting which specifies slot numbers of each I O module I O module settings in maintenance mode Connection failure 1 Tur...

Page 116: ...m occurs again replace the controller Save the CMOS BIN before replacement to be safe 7 An error was detected in communications with the I O module board connected with 7th serial bus when the control power turned ON Setting error 1 Check the following settings The rotary switch setting which specifies slot numbers of each I O module I O module settings in maintenance mode Connection failure 1 Tur...

Page 117: ...rvo 1 1 The error was detected during the check of the serial communication watchdog data Counter value received from Servo control board is invalid Setting error 1 Turn the power OFF then back ON 2 If the alarm occurs again replace the controller Save the CMOS BIN before replacement to be safe Connection failure 1 Turn the power OFF then back ON 2 If the alarm occurs again replace the controller ...

Page 118: ...nt to be safe Servo control board failure 1 Turn the power OFF then back ON 2 If the alarm occurs again replace the controller Save the CMOS BIN before replacement to be safe Converter unit failure 1 Turn the power OFF then back ON 2 If the alarm occurs again replace the controller Save the CMOS BIN before replacement to be safe Main CPU board failure 1 Turn the power OFF then back ON 2 If the ala...

Page 119: ... replace the controller Save the CMOS BIN before replacement to be safe 2 The SV parameter is damaged Data error 1 Turn the power OFF then back ON 2 If the alarm occurs again initialize the appropriate data in maintenance mode and then load the data saved in the external memory device Main CPU board failure 1 Turn the power OFF then back ON 2 If the alarm occurs again replace the controller Save t...

Page 120: ...m occurs again replace the controller Save the CMOS BIN before replacement to be safe 8 The AP parameter is damaged Data error 1 Turn the power OFF then back ON 2 If the alarm occurs again initialize the appropriate data in maintenance mode and then load the data saved in the external memory device Main CPU board failure 1 Turn the power OFF then back ON 2 If the alarm occurs again replace the con...

Page 121: ...e 14 The MF parameter is damaged Data error 1 Turn the power OFF then back ON 2 If the alarm occurs again initialize the appropriate data in maintenance mode and then load the data saved in the external memory device Main CPU board failure 1 Turn the power OFF then back ON 2 If the alarm occurs again replace the controller Save the CMOS BIN before replacement to be safe 15 The SVS parameter is dam...

Page 122: ...Memory and play back file is damaged Data error 1 Turn the power OFF then back ON 2 If the alarm occurs again initialize the appropriate data in maintenance mode and then load the data saved in the external memory device Main CPU board failure 1 Turn the power OFF then back ON 2 If the alarm occurs again replace the controller Save the CMOS BIN before replacement to be safe 230 MEMORY ERROR LADDER...

Page 123: ...ting error 1 Check the following settings The optional board setting in maintenance mode Main CPU board failure 1 Turn the power OFF then back ON 2 If the alarm occurs again replace the controller Save the CMOS BIN before replacement to be safe 8 IO type error combination impossible to coexist Setting error 1 Check the following settings I O module settings in maintenance mode Main CPU board failu...

Page 124: ...ding IO module Board failure I O module 1 Turn the power OFF then back ON 2 If the alarm occurs again replace the following board Save the CMOS BIN before replace the board to be safe Corresponding IO module Main CPU board failure 1 Turn the power OFF then back ON 2 If the alarm occurs again replace the controller Save the CMOS BIN before replacement to be safe 2 The I O module connected to the se...

Page 125: ... module Main CPU board failure 1 Turn the power OFF then back ON 2 If the alarm occurs again replace the controller Save the CMOS BIN before replacement to be safe 4 The I O module connected to the serial bus 4 is different from the function of the set I O module Setting error 1 Check the following settings The rotary switch setting which specifies slot numbers of each I O module I O module settin...

Page 126: ... 6 is different from the function of the set I O module Setting error 1 Check the following settings The rotary switch setting which specifies slot numbers of each I O module I O module settings in maintenance mode Connection failure 1 Turn the power OFF then back ON 2 If the alarm occurs again check the connecting or inserting state of the following cables or connectors IO module cable of the cor...

Page 127: ...n the power OFF then back ON 2 If the alarm occurs again check the connecting or inserting state of the following cables or connectors IO module cable of the corresponding slot Terminator 24V power of the corresponding IO module Board failure I O module 1 Turn the power OFF then back ON 2 If the alarm occurs again replace the following board Save the CMOS BIN before replace the board to be safe Co...

Page 128: ...of the corresponding node number SV 2 Connection failure 1 Turn the power OFF then back ON 2 If the alarm occurs again replace the controller Save the CMOS BIN before replacement to be safe Servo control board failure 1 Turn the power OFF then back ON 2 If the alarm occurs again replace the controller Save the CMOS BIN before replacement to be safe Main CPU board failure 1 Turn the power OFF then ...

Page 129: ...e 500 SEGMENT PROC NOT READY Setting error 1 Turn the power OFF then back ON 2 If the alarm occurs again replace the controller Save the CMOS BIN before replacement to be safe Main CPU board failure 1 Turn the power OFF then back ON 2 If the alarm occurs again replace the controller Save the CMOS BIN before replacement to be safe 510 SOFTWARE VERSION UNMATCH 50 1st Servo control board s interface ...

Page 130: ...hen back ON 2 If the alarm occurs again replace the controller Save the CMOS BIN before replacement to be safe 3 An incorrect instruction was set Data error 1 Turn the power OFF then back ON 2 If the alarm occurs again initialize the appropriate data in maintenance mode and then load the data saved in the external memory device Main CPU board failure 1 Turn the power OFF then back ON 2 If the alar...

Page 131: ...ntroller Save the CMOS BIN before replacement to be safe 9 A syntax error was found in the CNT instruction Data error 1 Turn the power OFF then back ON 2 If the alarm occurs again initialize the appropriate data in maintenance mode and then load the data saved in the external memory device Main CPU board failure 1 Turn the power OFF then back ON 2 If the alarm occurs again replace the controller S...

Page 132: ... If the alarm occurs again replace the controller Save the CMOS BIN before replacement to be safe 15 The No of operand is incorrect Data error 1 Turn the power OFF then back ON 2 If the alarm occurs again initialize the appropriate data in maintenance mode and then load the data saved in the external memory device Main CPU board failure 1 Turn the power OFF then back ON 2 If the alarm occurs again...

Page 133: ...de and then load the data saved in the external memory device Main CPU board failure 1 Turn the power OFF then back ON 2 If the alarm occurs again replace the controller Save the CMOS BIN before replacement to be safe 21 The label of JMP destination does not exist Data error 1 Turn the power OFF then back ON 2 If the alarm occurs again initialize the appropriate data in maintenance mode and then l...

Page 134: ...d Save the CMOS BIN before replacing the board to be safe 400 A Watchdog err was detected in the Option 4 board CNTR01R board failure 1 Turn the power OFF then back ON 2 If the alarm occurs again replace the CNTR01R board Save the CMOS BIN before replacing the board to be safe 500 A Watchdog err was detected in the Option 5 board CNTR01R board failure 1 Turn the power OFF then back ON 2 If the ala...

Page 135: ...CPU of servo board 2 Connection failure 1 Turn the power OFF then back ON 2 If the alarm occurs again replace the controller Save the CMOS BIN before replacement to be safe Servo control board failure 1 Turn the power OFF then back ON 2 If the alarm occurs again replace the controller Save the CMOS BIN before replacement to be safe Main CPU board failure 1 Turn the power OFF then back ON 2 If the ...

Page 136: ...ntroller to be safe 25 The SRDY signal did not turn ON after data were read EEPROM reading error Servo control board failure 1 Turn the power OFF then back ON 2 If the alarm occurs again replace controller Save the CMOS BIN before replace controller to be safe 26 The written data were rejected at verification EEPROM verify error Servo control board failure 1 Turn the power OFF then back ON 2 If th...

Page 137: ...ure Setting error Memory to work MotoPlus application is insufficient under the combination of current system configuration and its optional function If the alarm occurs again save the CMOS BIN in maintenance mode and then contact your YASKAWA representative about occurrence status operating procedure 11 MotoPlus application process generation failure Setting error Check that the object file is ap...

Page 138: ...riate parameter file in maintenance mode and then load the parameter file saved in the external memory device Main CPU board failure 1 Turn the power OFF then back ON 2 If the alarm occurs again replace controller Save the CMOS BIN before replace controller to be safe 4 S1CxG S2C S3C S4C parameter error Data error 1 Turn the power OFF then back ON 2 If the alarm occurs again initialize the appropr...

Page 139: ...he appropriate parameter file in maintenance mode and then load the parameter file saved in the external memory device Main CPU board failure 1 Turn the power OFF then back ON 2 If the alarm occurs again replace controller Save the CMOS BIN before replace controller to be safe 9 RS parameter error Data error 1 Turn the power OFF then back ON 2 If the alarm occurs again initialize the appropriate p...

Page 140: ... the appropriate parameter file in maintenance mode and then load the parameter file saved in the external memory device Main CPU board failure 1 Turn the power OFF then back ON 2 If the alarm occurs again replace controller Save the CMOS BIN before replace controller to be safe 14 MFxG parameter error Data error 1 Turn the power OFF then back ON 2 If the alarm occurs again initialize the appropri...

Page 141: ...ata in maintenance mode and then load the data saved in the external memory device 4 Robot calibration file Data error 1 Turn the power OFF then back ON 2 If the alarm occurs again initialize the appropriate data in maintenance mode and then load the data saved in the external memory device 5 Tool calibration file Data error 1 Turn the power OFF then back ON 2 If the alarm occurs again initialize ...

Page 142: ...ta in maintenance mode and then load the data saved in the external memory device 48 Macro definition file Data error 1 Turn the power OFF then back ON 2 If the alarm occurs again initialize the appropriate data in maintenance mode and then load the data saved in the external memory device 53 Job registration table Data error 1 Turn the power OFF then back ON 2 If the alarm occurs again initialize...

Page 143: ...eplace controller to be safe Software operation error occurred 1 Turn the power OFF then back ON 2 If the alarm occurs again save the CMOS BIN in maintenance mode and then contact your YASKAWA representative about occurrence status operating procedure 2 The position data of when the power supply was turned OFF cannot be transmitted to the servo control section Servo control board failure 1 Turn th...

Page 144: ...e alarm occurs again replace controller Save the CMOS BIN before replace controller to be safe Software operation error occurred 1 Turn the power OFF then back ON 2 If the alarm occurs again save the CMOS BIN in maintenance mode and then contact your YASKAWA representative about occurrence status operating procedure 10 Unable to initialize ARITH Main CPU board failure 1 Turn the power OFF then bac...

Page 145: ...OS BIN in maintenance mode and then contact your YASKAWA representative about occurrence status operating procedure 1101 SYSTEM ERROR MAN MACHINE MECHA Sub Code 0 to 6 Internal control error in software Software operation error occurred 1 Turn the power OFF then back ON 2 If the alarm occurs again save the CMOS BIN in maintenance mode and then contact your YASKAWA representative about occurrence s...

Page 146: ...tware operation error occurred 1 Turn the power OFF then back ON 2 If the alarm occurs again save the CMOS BIN in maintenance mode and then contact your YASKAWA representative about occurrence status operating procedure Servo control board failure 1 Turn the power OFF then back ON 2 If the alarm occurs again replace controller Save the CMOS BIN before replace controller to be safe 30 The linear se...

Page 147: ...BIN before replace controller to be safe 135 General08ms process dose not complete within the time set by the scheduling table Software operation error occurred 1 Turn the power OFF then back ON 2 If the alarm occurs again save the CMOS BIN in maintenance mode and then contact your YASKAWA representative about occurrence status operating procedure Servo control board failure 1 Turn the power OFF t...

Page 148: ...rn the power OFF then back ON 2 If the alarm occurs again save the CMOS BIN in maintenance mode and then contact your YASKAWA representative about occurrence status operating procedure 160 The interface with the microprogram dose not complete within the time set by the scheduling table Software operation error occurred 1 Turn the power OFF then back ON 2 If the alarm occurs again save the CMOS BIN...

Page 149: ...2 If the alarm occurs again save the CMOS BIN in maintenance mode and then contact your YASKAWA representative about occurrence status operating procedure 1003 The check item number of SVP parameter is unmatched Software operation error occurred 1 Turn the power OFF then back ON 2 If the alarm occurs again save the CMOS BIN in maintenance mode and then contact your YASKAWA representative about occ...

Page 150: ...H TEMPERATURE IN CNTL BOX The temperature rises in the controller Turn the power OFF then back ON after cooling down inside of the controller Connection failure 1 Turn the power OFF then back ON 2 If the alarm occurs again check the connecting state of the following cables The power cables of the cooling fan inside of the converter unit Module failure converter 1 Turn the power OFF then back ON 2 ...

Page 151: ...r OFF then back ON 2 If the alarm occurs again save the CMOS BIN in maintenance mode and then contact your YASKAWA representative about occurrence status operating procedure Main CPU board failure 1 Turn the power OFF then back ON 2 If the alarm occurs again replace controller 2 An error occurred in the IP address setting process of the Ethernet function Setting error 1 Check the following setting...

Page 152: ... power OFF then back ON 2 If the alarm occurs again replace controller 6 An error occurred in the MAC address getting process of the Ethernet function Software operation error occurred 1 Turn the power OFF then back ON 2 If the alarm occurs again save the CMOS BIN in maintenance mode and then contact your YASKAWA representative about occurrence status operating procedure Main CPU board failure 1 T...

Page 153: ...rn the power OFF then back ON 2 If the alarm occurs again save the CMOS BIN in maintenance mode and then contact your YASKAWA representative about occurrence status operating procedure Main CPU board failure 1 Turn the power OFF then back ON 2 If the alarm occurs again replace controller 51 An error occurred in the FTP server task management ID getting process of the Ethernet function Software ope...

Page 154: ...curs again replace controller Save the CMOS BIN before replace controller to be safe Module failure converter 1 Turn the power OFF then back ON 2 If the alarm occurs again replace controller Save the CMOS BIN before replace controller to be safe Servo control board failure 1 Turn the power OFF then back ON 2 If the alarm occurs again replace controller Save the CMOS BIN before replace controller t...

Page 155: ...MOS BIN before replace controller to be safe Software operation error occurred 1 Turn the power OFF then back ON 2 If the alarm occurs again save the CMOS BIN in maintenance mode and then contact your YASKAWA representative about occurrence status operating procedure 1303 ARITHMETIC ERROR SERVO The data X____ indicates the generation process 10000 Observer control 20000 High precision path control...

Page 156: ...ack ON 2 If the alarm occurs again replace controller Save the CMOS BIN before replace controller to be safe 1307 ENCODER TYPE MISMATCH Sub Code Signifies the axis in which the alarm occurred Setting error 1 Check the following settings Check the motor type before and after the replacement When the external axis is mounted check if there is no difference between the motor selected at configuration...

Page 157: ...ccurred 1 Turn the power OFF then back ON 2 If the alarm occurs again save the CMOS BIN in maintenance mode and then contact your YASKAWA representative about occurrence status operating procedure 1311 A D DETECTION ERROR CONVERTER Sub Code Signifies the converter physical number in which the alarm occurred Module failure converter 1 Turn the power OFF then back ON 2 If the alarm occurs again repl...

Page 158: ...he grounding condition of Manipulator Check whether it is installed into the strong magnetic field Check the position after the alarm 1327 ENCODER OVER SPEED Sub Code Signifies the axis in which the alarm occurred Connection failure 1 Turn the power OFF then back ON 2 Turn the servo OFF where the axis does not fall off while turning ON the servo 3 Replace the battery of the alarm occurring axis if...

Page 159: ...and the encoder External axis Cables between the controller and the encoder Module failure encoder 1 Turn the power OFF then back ON 2 If the alarm occurs again replace the encoder Servo control board failure 1 Turn the power OFF then back ON 2 If the alarm occurs again replace controller Save the CMOS BIN before replace controller to be safe 1330 MICRO PROGRAM TRANSMIT ERROR Sub Code Signifies th...

Page 160: ...eck the connecting or inserting state of the following cables Robot axis Cables between the controller and the encoder External axis Cables between the controller and the encoder Connection failure 1 Turn the power OFF then back ON 2 If the alarm occurs again check the connection and insertion of the following cables and connectors Robot axis Cable between encoders EAXA CN508 External axis Cable b...

Page 161: ...area 1406 START SHIFT DATA CNT LMT OVER Work status error Check the work in not shift data and actual the work status within the shift area 1407 START SHIFT DATA POS LMT Work status error Check the work in not shift data and actual the work status within the shift area 1512 POWER SUPPLY FAN ERROR SERVO Connection failure 1 Turn the power OFF then back ON 2 If the alarm occurs again replace control...

Page 162: ... 1 Turn the power OFF then back ON 2 If the alarm occurs again replace controller Save the CMOS BIN before replace controller to be safe Module failure motor 1 Turn the power OFF then back ON 2 If the alarm occurs again replace the motor Servo control board failure 1 Turn the power OFF then back ON 2 If the alarm occurs again replace controller Save the CMOS BIN before replace controller to be saf...

Page 163: ...o be safe 2 Buffer size over Servo control board failure 1 Turn the power OFF then back ON 2 If the alarm occurs again replace controller Save the CMOS BIN before replace controller to be safe 1652 DB ON ERROR SERVO Servo control board failure 1 Turn the power OFF then back ON 2 If the alarm occurs again replace controller Save the CMOS BIN before replace controller to be safe Software operation e...

Page 164: ...detecting function was used for the axis for which the axis endless function was enabled The home position detecting function cannot be used for the axis which the axis endless function was enabled Setting error Disable either the axis endless function or the home position detection function of corresponding axis 2 The servo float function was used for the axis for which the axis endless function ...

Page 165: ...k the JOB 1664 MICRO PRG EXECUTE TIME OVER SV Sub code specifies the axis that alarm occurred Servo control board failure 1 Turn the power OFF then back ON 2 If the alarm occurs again replace controller Save the CMOS BIN before replace controller to be safe 1665 MICRO PROGRAM SYNC ERROR SV Sub code specifies the axis that alarm occurred Servo control board failure 1 Turn the power OFF then back ON...

Page 166: ...occurred in the U V and W phase of motor power line or short circuit has not occurred between these phases Connection failure Check the connection of motor power line Module failure motor 1 Turn the power OFF then back ON 2 If the alarm occurs again replace the motor Servo control board failure 1 Turn the power OFF then back ON 2 If the alarm occurs again replace controller Save the CMOS BIN befor...

Page 167: ...r OFF then back ON 2 If the alarm occurs again replace controller Save the CMOS BIN before replace controller to be safe 1835 M SAFETY WATCHDOG ERROR PLD2 Machine safety board failure 1 Turn the power OFF then back ON 2 If the alarm occurs again replace controller Save the CMOS BIN before replace controller to be safe 1836 M SAFETY WATCHDOG ERROR PLD3 Machine safety board failure 1 Turn the power ...

Page 168: ...Turn the power OFF then back ON 2 If the alarm occurs again replace controller Save the CMOS BIN before replace controller to be safe Machine safety board failure 1 Turn the power OFF then back ON 2 If the alarm occurs again replace controller Save the CMOS BIN before replace controller to be safe 1840 M SAFETY 3 3V LOW VOLTAGE Machine safety board failure 1 Turn the power OFF then back ON 2 If th...

Page 169: ...Main CPU board failure 1 Reset the alarm 2 If the alarm occurs again replace controller Save the CMOS BIN before replace controller to be safe 4004 MEMORY ERROR HOME POS FILE Data error 1 Reset the alarm 2 If the alarm occurs again initialize the home positioning file in maintenance mode and then load the home positioning file saved in the external memory device Main CPU board failure 1 Reset the ...

Page 170: ...eplace controller to be safe 4018 MEMORY ERROR LADDER PRG FILE Data error 1 Reset the alarm 2 If the alarm occurs again initialize the ladder program file in maintenance mode and then load the ladder program file saved in the external memory device Main CPU board failure 1 Reset the alarm 2 If the alarm occurs again replace controller Save the CMOS BIN before replace controller to be safe 4020 MEM...

Page 171: ... Main CPU board failure 1 Reset the alarm 2 If the alarm occurs again replace controller Save the CMOS BIN before replace controller to be safe 4028 MEMORY ERROR SENSOR MON COND FILE Data error 1 Reset the alarm 2 If the alarm occurs again initialize the sensor monitoring condition file in maintenance mode and then load the sensor monitoring condition file saved in the external memory device Main ...

Page 172: ...ror 1 Reset the alarm 2 If the alarm occurs again initialize the vision condition file in maintenance mode and then load the vision condition file saved in the external memory device Main CPU board failure 1 Reset the alarm 2 If the alarm occurs again replace controller Save the CMOS BIN before replace controller to be safe 4043 MEMORY ERROR VISION CALIBRATION Sub Code Page number Data error 1 Res...

Page 173: ...e external memory device Main CPU board failure 1 Reset the alarm 2 If the alarm occurs again replace controller Save the CMOS BIN before replace controller to be safe 4052 MEMORY ERROR TOOL INTERFERENCE Sub Code File number Data error 1 Reset the alarm 2 If the alarm occurs again initialize the tool interference file in maintenance mode and then load the tool interference file saved in the extern...

Page 174: ... FILE OF CORRESPONDING TO LASER TRACKING GAP Data error 1 Reset the alarm 2 If the alarm occurs again initialize the condition file of corresponding to laser tracking gap in maintenance mode and then load the condition file of corresponding to laser tracking gap saved in the external memory device Main CPU board failure 1 Reset the alarm 2 If the alarm occurs again replace controller Save the CMOS...

Page 175: ...r 1 Check the following settings Alarm occurrence status 7 Synchronization task specification of SYNC instruction omit error Setting error 1 Check the following settings Synchronization task specification of SYNC instruction 8 The task is specified by synchronization task of SYNC instruction Setting error 1 Check the following settings Synchronization task specification of SYNC instruction 9 I O j...

Page 176: ...ator or station to the zero position by the axis operation and check the home position alignment marks the arrow 4112 DATA SENDING ERROR 1 Retry over of NAK Communication error 1 Reset the alarm 2 If the alarm occurs again check the communication setting and communication wiring is correct 2 Retry over for timeout in timer A Communication error 1 Reset the alarm 2 If the alarm occurs again check t...

Page 177: ...rrun error Communication error 1 Reset the alarm 2 If the alarm occurs again check the communication setting and communication wiring is correct 2 Parity error Communication error 1 Reset the alarm 2 If the alarm occurs again check the communication setting and communication wiring is correct 3 Framing error Communication error 1 Reset the alarm 2 If the alarm occurs again check the communication ...

Page 178: ... ON 2 If the alarm occurs again replace controller Save the CMOS BIN before replace controller to be safe 4119 FAN ERROR IN CONTROL BOX Sub Code 1 to 4 Signifies the Converter unit No in which the alarm occurred Cooling fan failure 1 Reset the alarm 2 If the alarm occurs again turn the power OFF then back ON 2 If the alarm occurs again replace controller Save the CMOS BIN before replace controller...

Page 179: ...n system and FS100 system 6 Time out occurred during data reception Setting error 1 Check the following settings The communication setting of vision system Connection failure 1 Reset the alarm 2 If the alarm occurs again check the connection of the following cables Cable between vision system and FS100 system 7 The data received from the vision system is incorrect Setting error 1 Check the followi...

Page 180: ...error Software operation error occurred 1 Reset the alarm and then try again 2 If the alarm occurs again save the CMOS BIN in maintenance mode and then contact your YASKAWA representative about occurrence status operating procedure 2 PBOX cannot be edited Setting error 1 Check the following settings I O status of the edit prohibit signal The edit prohibit signal cannot input 3 The source job canno...

Page 181: ...nection between manipulator and Servo control board Move the manipulator to safety place in teach mode 4129 TWIN DRIVE OUT OF RANGE START Sub Code Corresponding master axes and slave axes are displayed by the bit Setting error 1 Check the following settings Pulse error of the master axes and the slave axes Switch to independent movement mode so that the pulse error of the master axes and the slave...

Page 182: ...urn the power OFF then back ON 2 If the alarm occurs again replace controller 6 An error occurred in the exclusive process of the storage area control table of the Ethernet function Software operation error occurred 1 Turn the power OFF then back ON 2 If the alarm occurs again save the CMOS BIN in maintenance mode and then contact your YASKAWA representative about occurrence status operating proce...

Page 183: ...Main CPU board failure 1 Turn the power OFF then back ON 2 If the alarm occurs again replace controller 32 An error occurred in the FTP client task mail receiving process of the Ethernet function Software operation error occurred 1 Turn the power OFF then back ON 2 If the alarm occurs again save the CMOS BIN in maintenance mode and then contact your YASKAWA representative about occurrence status o...

Page 184: ... board failure 1 Turn the power OFF then back ON 2 If the alarm occurs again replace controller 52 The request of the undefined transmission was received in the Ethernet function Software operation error occurred 1 Turn the power OFF then back ON 2 If the alarm occurs again save the CMOS BIN in maintenance mode and then contact your YASKAWA representative about occurrence status operating procedur...

Page 185: ...n the power OFF then back ON 2 If the alarm occurs again replace controller 200 The socket of the Ethernet function was full and was not able to create a socket Software operation error occurred 1 Turn the power OFF then back ON 2 If the alarm occurs again save the CMOS BIN in maintenance mode and then contact your YASKAWA representative about occurrence status operating procedure Main CPU board f...

Page 186: ... 2 If the alarm occurs again replace controller 5 The SELECT operation was not successfully completed in the UDP process of the Ethernet function Software operation error occurred 1 Turn the power OFF then back ON 2 If the alarm occurs again save the CMOS BIN in maintenance mode and then contact your YASKAWA representative about occurrence status operating procedure Main CPU board failure 1 Turn t...

Page 187: ...rd failure 1 Turn the power OFF then back ON 2 If the alarm occurs again replace controller 4132 TCP PROCESS ERROR 1 The socket table was not successfully created in the TCP process of the Ethernet function Software operation error occurred 1 Turn the power OFF then back ON 2 If the alarm occurs again save the CMOS BIN in maintenance mode and then contact your YASKAWA representative about occurren...

Page 188: ... 1 Check the following settings Motion mode specification Set the motion mode to 0 or 1 4138 WRONG EXECUTION OF SVON INST Connection failure 1 Check the following settings Short circuit the external servo ON EXSVON of MXT terminal block Setting error 1 Check the following settings The concurrent I O signal 80031 servo ON condition1 ON The concurrent I O signal 80033 servo ON condition2 ON 4139 WRO...

Page 189: ...ing fieldbus board Main CPU board failure 1 Turn the power OFF then back ON 2 If the alarm occurs again replace the CPU 201R board 4152 TIMING BELT BLOWN Servo control board number SV from which an error was detected Manipulator timing belt is blown Move the manipulator in teach mode to the position where there is no torque on the driving belt 1 Check the timing belt tension 4200 SYSTEM ERROR FILE...

Page 190: ...ave the CMOS BIN in maintenance mode and then contact your YASKAWA representative about occurrence status operating procedure Main CPU board failure 1 Reset the alarm and then try again 2 If the alarm occurs again replace controller Save the CMOS BIN before replace controller to be safe 6 The allowable job registration area memory was exceeded Setting error 1 Check the following settings Delete un...

Page 191: ...eration error occurred 1 Reset the alarm and then try again 2 If the alarm occurs again save the CMOS BIN in maintenance mode and then contact your YASKAWA representative about occurrence status operating procedure Main CPU board failure 1 Reset the alarm and then try again 2 If the alarm occurs again replace controller Save the CMOS BIN before replace controller to be safe 13 A job specified at j...

Page 192: ...then try again 2 If the alarm occurs again replace controller Save the CMOS BIN before replace controller to be safe 24 An error occurred in cluster control Software operation error occurred 1 Reset the alarm and then try again 2 If the alarm occurs again save the CMOS BIN in maintenance mode and then contact your YASKAWA representative about occurrence status operating procedure Main CPU board fa...

Page 193: ...urs again save the CMOS BIN in maintenance mode and then contact your YASKAWA representative about occurrence status operating procedure Main CPU board failure 1 Reset the alarm and then try again 2 If the alarm occurs again replace controller Save the CMOS BIN before replace controller to be safe 4202 SYSTEM ERROR JOB 1 An error occurred in parameter specifications for the access to a job Softwar...

Page 194: ...lize the job file in the maintenance mode and then load the saved job file 4 If the alarm occurs again save the CMOS BIN in maintenance mode and then contact your YASKAWA representative about occurrence status operating procedure 6 The allowable job registration area memory was exceeded Software operation error occurred 1 Reset the alarm 2 If the error occurs again delete unused jobs 3 If the erro...

Page 195: ...ce mode and then load the saved job file 5 If the alarm occurs again save the CMOS BIN in maintenance mode and then contact your YASKAWA representative about occurrence status operating procedure 10 An error occurred in job data control system Software operation error occurred 1 Reset the alarm 2 If the error occurs again delete the job where the alarm occurred 3 If the error occurs again after th...

Page 196: ...operation error occurred 1 Reset the alarm 2 If the error occurs again delete the job where the alarm occurred 3 If the error occurs again after the previous measures were executed initialize the job file in the maintenance mode and then load the saved job file 4 If the alarm occurs again save the CMOS BIN in maintenance mode and then contact your YASKAWA representative about occurrence status ope...

Page 197: ...t the alarm 2 If the error occurs again delete the job where the alarm occurred 3 If the error occurs again after the previous measures were executed initialize the job file in the maintenance mode and then load the saved job file 4 If the alarm occurs again save the CMOS BIN in maintenance mode and then contact your YASKAWA representative about occurrence status operating procedure 22 Failed to e...

Page 198: ...rs again delete the job where the alarm occurred 3 If the error occurs again after the previous measures were executed initialize the job file in the maintenance mode and then load the saved job file 4 If the alarm occurs again save the CMOS BIN in maintenance mode and then contact your YASKAWA representative about occurrence status operating procedure 90 The configuration information for job data...

Page 199: ...peration error occurred 1 Reset the alarm and then try again 2 If the alarm occurs again save the CMOS BIN in maintenance mode and then contact your YASKAWA representative about occurrence status operating procedure Main CPU board failure 1 Reset the alarm and then try again 2 If the alarm occurs again replace controller Save the CMOS BIN before replace controller to be safe 3 The number of axes f...

Page 200: ...rs again save the CMOS BIN in maintenance mode and then contact your YASKAWA representative about occurrence status operating procedure Main CPU board failure 1 Reset the alarm and then try again 2 If the alarm occurs again replace controller Save the CMOS BIN before replace controller to be safe 10 An error occurred in specified position data number Software operation error occurred 1 Reset the a...

Page 201: ...YASKAWA representative about occurrence status operating procedure Main CPU board failure 1 Reset the alarm and then try again 2 If the alarm occurs again replace controller Save the CMOS BIN before replace controller to be safe 4204 SYSTEM ERROR POSITION DATA 1 The number of axes for all the control groups is zero at the initialization of the position data control process Software operation error...

Page 202: ...e alarm 2 If the error occurs again delete the job where the alarm occurred 3 If the error occurs again after the previous measures were executed initialize the job file in the maintenance mode and then load the saved job file 4 If the alarm occurs again save the CMOS BIN in maintenance mode and then contact your YASKAWA representative about occurrence status operating procedure 9 Position data co...

Page 203: ... Reset the alarm 2 If the error occurs again delete the job where the alarm occurred 3 If the error occurs again after the previous measures were executed initialize the job file in the maintenance mode and then load the saved job file 4 If the alarm occurs again save the CMOS BIN in maintenance mode and then contact your YASKAWA representative about occurrence status operating procedure 17 An err...

Page 204: ... interrupt command data from the system control section Software operation error occurred 1 Reset the alarm and then try again 2 If the alarm occurs again save the CMOS BIN in maintenance mode and then contact your YASKAWA representative about occurrence status operating procedure 5 An undefined command was detected in the sub segment task of MOTION section Software operation error occurred 1 Rese...

Page 205: ...are operation error occurred 1 Reset the alarm and then try again 2 If the alarm occurs again save the CMOS BIN in maintenance mode and then contact your YASKAWA representative about occurrence status operating procedure 16 RMS receiving unit error Software operation error occurred 1 Reset the alarm and then try again 2 If the alarm occurs again save the CMOS BIN in maintenance mode and then conta...

Page 206: ...et the alarm and then try again 2 If the alarm occurs again save the CMOS BIN in maintenance mode and then contact your YASKAWA representative about occurrence status operating procedure 33 Incorrect control group designation Software operation error occurred 1 Reset the alarm and then try again 2 If the alarm occurs again save the CMOS BIN in maintenance mode and then contact your YASKAWA represe...

Page 207: ...ting procedure 45 Mail box of sequence task is not ready Software operation error occurred 1 Reset the alarm and then try again 2 If the alarm occurs again save the CMOS BIN in maintenance mode and then contact your YASKAWA representative about occurrence status operating procedure 46 Control group usage undefined Software operation error occurred 1 Reset the alarm and then try again 2 If the alar...

Page 208: ...he alarm and then try again 2 If the alarm occurs again save the CMOS BIN in maintenance mode and then contact your YASKAWA representative about occurrence status operating procedure 55 AXIS command process timeout Software operation error occurred 1 Reset the alarm and then try again 2 If the alarm occurs again save the CMOS BIN in maintenance mode and then contact your YASKAWA representative abo...

Page 209: ...ure 64 Job queue DEQUE error Software operation error occurred 1 Reset the alarm and then try again 2 If the alarm occurs again save the CMOS BIN in maintenance mode and then contact your YASKAWA representative about occurrence status operating procedure 66 Execution system decision table not set Software operation error occurred 1 Reset the alarm and then try again 2 If the alarm occurs again sav...

Page 210: ...Software operation error occurred 1 Reset the alarm and then try again 2 If the alarm occurs again save the CMOS BIN in maintenance mode and then contact your YASKAWA representative about occurrence status operating procedure 80 Instruction queue and instruction system data area overflow Software operation error occurred 1 Reset the alarm and then try again 2 If the alarm occurs again save the CMO...

Page 211: ...rror occurred 1 Reset the alarm and then try again 2 If the alarm occurs again save the CMOS BIN in maintenance mode and then contact your YASKAWA representative about occurrence status operating procedure 90 HA function error conv_pos_data Setting error 1 Check the following settings Correct the job so that the target position data is within the motion range 2 If the alarm occurs again save the C...

Page 212: ...rror occurred 1 Reset the alarm and then try again 2 If the alarm occurs again save the CMOS BIN in maintenance mode and then contact your YASKAWA representative about occurrence status operating procedure 122 Job argument stack underflow Software operation error occurred 1 Reset the alarm and then try again 2 If the alarm occurs again save the CMOS BIN in maintenance mode and then contact your YA...

Page 213: ...reading data length too long Software operation error occurred 1 Reset the alarm and then try again 2 If the alarm occurs again save the CMOS BIN in maintenance mode and then contact your YASKAWA representative about occurrence status operating procedure 135 Queue operation error for score board setting history at ENQUE Software operation error occurred 1 Reset the alarm and then try again 2 If th...

Page 214: ...NQUE Software operation error occurred 1 Reset the alarm and then try again 2 If the alarm occurs again save the CMOS BIN in maintenance mode and then contact your YASKAWA representative about occurrence status operating procedure 144 Queue operation error for WORK ID conveyor at DEQUE Software operation error occurred 1 Reset the alarm and then try again 2 If the alarm occurs again save the CMOS ...

Page 215: ...CK instruction at DEQUE Software operation error occurred 1 Reset the alarm and then try again 2 If the alarm occurs again save the CMOS BIN in maintenance mode and then contact your YASKAWA representative about occurrence status operating procedure 153 Queue operation error for waiting for semaphore for LOCK instruction undefined operation Software operation error occurred 1 Reset the alarm and t...

Page 216: ...ccurred 1 Reset the alarm and then try again 2 If the alarm occurs again save the CMOS BIN in maintenance mode and then contact your YASKAWA representative about occurrence status operating procedure 229 Illegal 1st line move instruction at execution of SMOV instruction Software operation error occurred 1 Reset the alarm and then try again 2 If the alarm occurs again save the CMOS BIN in maintenan...

Page 217: ... stop actual status and the data status unmatched Software operation error occurred 1 Reset the alarm and then try again 2 If the alarm occurs again save the CMOS BIN in maintenance mode and then contact your YASKAWA representative about occurrence status operating procedure 239 Timeout for receiving segment data output request Software operation error occurred 1 Reset the alarm and then try again...

Page 218: ...TS instruction internal error Software operation error occurred 1 Reset the alarm and then try again 2 If the alarm occurs again save the CMOS BIN in maintenance mode and then contact your YASKAWA representative about occurrence status operating procedure 251 SETFILE undefined file Software operation error occurred 1 Reset the alarm and then try again 2 If the alarm occurs again save the CMOS BIN ...

Page 219: ...oftware operation error occurred 1 Reset the alarm and then try again 2 If the alarm occurs again save the CMOS BIN in maintenance mode and then contact your YASKAWA representative about occurrence status operating procedure 264 Heap area obtainment failure Path trace queue Software operation error occurred 1 Reset the alarm and then try again 2 If the alarm occurs again save the CMOS BIN in maint...

Page 220: ...ero timeout Software operation error occurred 1 Reset the alarm and then try again 2 If the alarm occurs again save the CMOS BIN in maintenance mode and then contact your YASKAWA representative about occurrence status operating procedure 1000 System clock RTC setting error Software operation error occurred 1 Reset the alarm and then try again 2 If the alarm occurs again save the CMOS BIN in mainte...

Page 221: ...operation error occurred 1 Reset the alarm and then try again 2 If the alarm occurs again save the CMOS BIN in maintenance mode and then contact your YASKAWA representative about occurrence status operating procedure 6 No previous bank exists Software operation error occurred 1 Reset the alarm and then try again 2 If the alarm occurs again save the CMOS BIN in maintenance mode and then contact you...

Page 222: ...rating procedure 18 User coordinates number error Software operation error occurred 1 Reset the alarm and then try again 2 If the alarm occurs again save the CMOS BIN in maintenance mode and then contact your YASKAWA representative about occurrence status operating procedure 20 Prereading task not completed at master in twin synchronous system Software operation error occurred 1 Reset the alarm an...

Page 223: ...alarm occurs again save the CMOS BIN in maintenance mode and then contact your YASKAWA representative about occurrence status operating procedure 42 Special JOG operation error Software operation error occurred 1 Reset the alarm and then try again 2 If the alarm occurs again save the CMOS BIN in maintenance mode and then contact your YASKAWA representative about occurrence status operating procedu...

Page 224: ...ration error occurred 1 Reset the alarm and then try again 2 If the alarm occurs again save the CMOS BIN in maintenance mode and then contact your YASKAWA representative about occurrence status operating procedure 66 Arithmetic error occurred when calculating acceleration and deceleration time for plucking in prereading processing 1 Software operation error occurred 1 Reset the alarm and then try ...

Page 225: ... contact your YASKAWA representative about occurrence status operating procedure 74 Arithmetic error occurred when calculating acceleration and deceleration for PL control in prereading processing 2 Software operation error occurred 1 Reset the alarm and then try again 2 If the alarm occurs again save the CMOS BIN in maintenance mode and then contact your YASKAWA representative about occurrence st...

Page 226: ... YASKAWA representative about occurrence status operating procedure 89 Operation command group which pre reading is not completed detection error Software operation error occurred 1 Reset the alarm and then try again 2 If the alarm occurs again save the CMOS BIN in maintenance mode and then contact your YASKAWA representative about occurrence status operating procedure 65535 For HA debug use Softw...

Page 227: ...alarm and then try again 2 If the alarm occurs again save the CMOS BIN in maintenance mode and then contact your YASKAWA representative about occurrence status operating procedure 109 OFF_CV_CALIB_POS occupation control error Software operation error occurred 1 Reset the alarm and then try again 2 If the alarm occurs again save the CMOS BIN in maintenance mode and then contact your YASKAWA represe...

Page 228: ...eration error occurred 1 Reset the alarm and then try again 2 If the alarm occurs again save the CMOS BIN in maintenance mode and then contact your YASKAWA representative about occurrence status operating procedure 6 Handle value is incorrect for specified local variable Software operation error occurred 1 Reset the alarm and then try again 2 If the alarm occurs again save the CMOS BIN in maintena...

Page 229: ...he following settings Turn OFF the servo power supply and then turn ON the servo power supply for the group axis to be operated 4221 SERVO POWER OFF FOR JOB Sub Code Control group Setting error Turn OFF the servo power supply and then turn ON the servo power supply for the group axis to be operated 4226 COMMUNICATION SERVICE ERROR 1 The communication channel could not be opened closed at OPEN CLOS...

Page 230: ...DATA LOG under main menu SETUP Execute RESTORE by selecting UTILITY from the pull down menu Load the correct axes configuration 2 If the restoration cannot be completed execute the followings Execute RECONFIRM by selecting UTILITY from the pull down menu 3 If the alarm occurs again save the CMOS BIN in maintenance mode and then contact your YASKAWA representative about occurrence status operating ...

Page 231: ...g error 1 Check the following settings The DHCP server operation If the DHCP is used The network status If the DHCP is used Main CPU board failure 1 Turn the power OFF then back ON 2 If the alarm occurs again replace controller 8 An error occurred in the acquisition process of host name during the network service data creation process of the Ethernet function Setting error 1 Check the following se...

Page 232: ...verter in which the alarm occurred Module failure converter 1 Reset the alarm 2 If the alarm occurs again replace controller Save the CMOS BIN before replace controller to be safe Connection failure 1 Reset the alarm 2 If the alarm occurs again replace controller Save the CMOS BIN before replace controller to be safe 4305 CONVERTER CIRCUIT CHARGE ERROR Sub Code Signifies the physical No of convert...

Page 233: ...IN before replace controller to be safe Servo control board failure 1 Reset the alarm 2 If the alarm occurs again replace controller Save the CMOS BIN before replace controller to be safe 4309 DEFECTIVE ENCODER INTERNAL DATA Sub Code Signifies the axis in which the alarm occurred Connection failure 1 Reset the alarm 2 If the alarm occurs again check the connection and inserting state of the follow...

Page 234: ...s External axis Cable between encoders Module failure encoder 1 Reset the alarm 2 If the alarm occurs again replace the encoder Servo control board failure 1 Reset the alarm 2 If the alarm occurs again replace controller Save the CMOS BIN before replace controller to be safe 4312 ENCODER BATTERY ERROR Module failure encoder battery Replace the battery Connection failure 1 Reset the alarm 2 If the ...

Page 235: ...rd failure 1 Reset the alarm 2 If the alarm occurs again replace controller Save the CMOS BIN before replace controller to be safe Module failure amplifier 1 Reset the alarm 2 If the alarm occurs again replace controller Save the CMOS BIN before replace controller to be safe Module failure motor 1 Reset the alarm 2 If the alarm occurs again replace the motor Maintenance failure Measure the density...

Page 236: ...lure converter 1 Reset the alarm 2 If the alarm occurs again replace controller Save the CMOS BIN before replace controller to be safe 4321 OVERLOAD MOMENT Sub Code Signifies the axis in which the alarm occurred Setting error Check the following settings The tools or the mass of the workpieces Interference error Remove interference with the workpiece and peripheral device Setting error Correct the...

Page 237: ...occurs again replace controller Save the CMOS BIN before replace controller to be safe 4323 AMPLIFIER OVERLOAD MOMENT Sub Code Signifies the axis in which the alarm occurred Setting error Check the following settings The tools or the mass of the workpieces Interference error Remove interference with the workpiece and peripheral device Setting error Correct the job whether load late does not exceed...

Page 238: ...ce the motor Servo control board failure 1 Reset the alarm 2 If the alarm occurs again replace controller Save the CMOS BIN before replace controller to be safe 4327 WRONG MOTOR ROTATION Sub Code Signifies the axis in which the alarm occurred Connection failure 1 Reset the alarm 2 If the alarm occurs again check the connection and inserting state of the following cables and connectors The motor po...

Page 239: ...ce controller Save the CMOS BIN before replace controller to be safe Module failure converter 1 Reset the alarm 2 If the alarm occurs again replace controller Save the CMOS BIN before replace controller to be safe 4329 SAFETY SPEED ERROR SERVO 11 The motion speed at the center of the flange exceeded the specified max speed Setting error Check the following settings Reduction in the motion speed Se...

Page 240: ... Check the following settings Reduction in the motion speed Software operation error occurred 1 Reset the alarm and then try again 2 If the alarm occurs again save the CMOS BIN in maintenance mode and then contact your YASKAWA representative about occurrence status operating procedure Connection failure 1 Reset the alarm 2 If the alarm occurs again check that U V and W phase are appropriately conn...

Page 241: ...rm occurs again replace controller Save the CMOS BIN before replace controller to be safe Module failure converter 1 Reset the alarm 2 If the alarm occurs again replace controller Save the CMOS BIN before replace controller to be safe Servo control board failure 1 Reset the alarm 2 If the alarm occurs again replace controller Save the CMOS BIN before replace controller to be safe 4336 OPEN PHASE C...

Page 242: ...et the alarm 2 If the alarm occurs again replace controller Save the CMOS BIN before replace controller to be safe Module failure Regenerative resistor 1 Reset the alarm 2 If the alarm occurs again replace controller Save the CMOS BIN before replace controller to be safe Module failure converter 1 Reset the alarm 2 If the alarm occurs again replace controller Save the CMOS BIN before replace contr...

Page 243: ...in which the alarm occurred Connection failure Check that the driving belt is not broken Driving belt failure Check the driving belt 4352 TWIN DRIVE OVER DEVIATION Sub Code Signifies the axis in which the alarm occurred Connection failure 1 Reset the alarm 2 If the alarm occurs again replace controller Save the CMOS BIN before replace controller to be safe Cable failure motor power cable 1 Check U...

Page 244: ...rs again save the CMOS BIN in maintenance mode and then contact your YASKAWA representative about occurrence status operating procedure 4 The prereading processing in the arithmetic processing section has not completed Software operation error occurred 1 Reset the alarm and then try again 2 If the alarm occurs again save the CMOS BIN in maintenance mode and then contact your YASKAWA representative...

Page 245: ... operation error occurred 1 Reset the alarm and then try again 2 If the alarm occurs again save the CMOS BIN in maintenance mode and then contact your YASKAWA representative about occurrence status operating procedure 22 Undefined interrupt command was received Software operation error occurred 1 Reset the alarm and then try again 2 If the alarm occurs again save the CMOS BIN in maintenance mode a...

Page 246: ...ct Software operation error occurred 1 Reset the alarm and then try again 2 If the alarm occurs again save the CMOS BIN in maintenance mode and then contact your YASKAWA representative about occurrence status operating procedure 38 An error occurred at start of twin synchronous operation Software operation error occurred 1 Reset the alarm and then try again 2 If the alarm occurs again save the CMO...

Page 247: ...ocessing command is incorrect in prereading processing Software operation error occurred 1 Reset the alarm and then try again 2 If the alarm occurs again save the CMOS BIN in maintenance mode and then contact your YASKAWA representative about occurrence status operating procedure 101 Subprocessing command is incorrect in prereading processing Software operation error occurred 1 Reset the alarm and...

Page 248: ...k the following settings Change the step move instruction where the alarm occurred to MOVJ 10 The setting of the form data for Flip No Flip is not B axis Angle Setting error 1 Check the following settings Set 1 to S2C658 Type data detail settings 11 An attempt was made to pass the B axis zero degree position singular area Setting error 1 Check the following settings Check the teaching position of ...

Page 249: ...rs again save the CMOS BIN in maintenance mode and then contact your YASKAWA representative about occurrence status operating procedure 10 Designation error of occupation control for Bank position Software operation error occurred 1 Reset the alarm and then try again 2 If the alarm occurs again save the CMOS BIN in maintenance mode and then contact your YASKAWA representative about occurrence stat...

Page 250: ...ect positions for manipulators so that the step where the alarm occurred is within the motion range 4424 SPECIAL MECHANICAL INTRF MIN MAX Sub Code Control group and axis Setting error 1 Check the following settings Perform the teaching again to correct positions for manipulators so that the step where the alarm occurred is within the motion range 2 If the manipulator is stopped near the interferen...

Page 251: ... alarm and then try again 2 If the alarm occurs again save the CMOS BIN in maintenance mode and then contact your YASKAWA representative about occurrence status operating procedure 8 RT buffer tracking option error Software operation error occurred 1 Reset the alarm and then try again 2 If the alarm occurs again save the CMOS BIN in maintenance mode and then contact your YASKAWA representative abo...

Page 252: ...y again 2 If the alarm occurs again save the CMOS BIN in maintenance mode and then contact your YASKAWA representative about occurrence status operating procedure 7 Control group error for a calibration file between manipulators Software operation error occurred 1 Reset the alarm and then try again 2 If the alarm occurs again save the CMOS BIN in maintenance mode and then contact your YASKAWA repr...

Page 253: ...ON section and system control section Software operation error occurred 1 Reset the alarm and then try again 2 If the alarm occurs again save the CMOS BIN in maintenance mode and then contact your YASKAWA representative about occurrence status operating procedure 2 Interrupt processing error between MOTION section and SL 1 Software operation error occurred 1 Reset the alarm and then try again 2 If...

Page 254: ... maintenance mode and then contact your YASKAWA representative about occurrence status operating procedure 4 Job control proprietary is incorrect Software operation error occurred 1 Reset the alarm and then try again 2 If the alarm occurs again save the CMOS BIN in maintenance mode and then contact your YASKAWA representative about occurrence status operating procedure 5 Job control proprietary co...

Page 255: ...rmediate code Software operation error occurred 1 Reset the alarm and then try again 2 If the alarm occurs again save the CMOS BIN in maintenance mode and then contact your YASKAWA representative about occurrence status operating procedure 10 IPRM is not set Software operation error occurred 1 Reset the alarm and then try again 2 If the alarm occurs again save the CMOS BIN in maintenance mode and ...

Page 256: ...rs again save the CMOS BIN in maintenance mode and then contact your YASKAWA representative about occurrence status operating procedure 22 The object to be processed was secret variable in position file control process so it could not be processed Software operation error occurred 1 Reset the alarm and then try again 2 If the alarm occurs again save the CMOS BIN in maintenance mode and then contac...

Page 257: ...ters is used Software operation error occurred 1 Reset the alarm and then try again 2 If the alarm occurs again save the CMOS BIN in maintenance mode and then contact your YASKAWA representative about occurrence status operating procedure 255 An exceptional error occurred Software operation error occurred 1 Reset the alarm and then try again 2 If the alarm occurs again save the CMOS BIN in mainten...

Page 258: ...he alarm and then try again 2 If the alarm occurs again save the CMOS BIN in maintenance mode and then contact your YASKAWA representative about occurrence status operating procedure 4435 UNDEFINED LOCAL VARIABLE 0 The byte type variable is not defined Setting error 1 Check the following settings Set the number of local variables to be used in the job header 1 The integer type variable is not defi...

Page 259: ...emove the external force of axis where alarm occurred 4445 DATA PRESET ERROR 1 The token for prereading processing could not be obtained Software operation error occurred 1 Reset the alarm and then try again 2 If the alarm occurs again save the CMOS BIN in maintenance mode and then contact your YASKAWA representative about occurrence status operating procedure 2 The prereading processing has not b...

Page 260: ... The value for the unsigned 1 byte data type variable is less than the minimum value Setting error 1 Check the following settings Check the settings for variable and then correct the job to fall within the input range of the tag 4 The value for the signed 2 byte data type variable is less than the minimum value Setting error 1 Check the following settings Check the settings for variable and then c...

Page 261: ...ngs Check the settings for variable and then correct the job to fall within the input range of the tag 32775 The value for the unsigned 4 byte data type variable exceeded the maximum value Setting error 1 Check the following settings Check the settings for variable and then correct the job to fall within the input range of the tag 32776 The value for the real number 4 byte data type variable excee...

Page 262: ... check Setting error 1 Check the following settings Confirm that the argument number is 1 to 16 15 An error occurred while checking the link linear servo float condition file number Setting error 1 Check the following settings Confirm that the link linear servo float condition file number is within the range of 1 to 8 4451 UNDEFINED REFERENCE POINT Sub Code Reference point number in binary Setting...

Page 263: ...procedure 3 Incorrect designation of the control group for master group Software operation error occurred 1 Reset the alarm and then try again 2 If the alarm occurs again save the CMOS BIN in maintenance mode and then contact your YASKAWA representative about occurrence status operating procedure 4 Incorrect designation of the control group for slave group Software operation error occurred 1 Reset...

Page 264: ...t occurrence status operating procedure 4 Incorrect designation of the control group for slave group Software operation error occurred 1 Reset the alarm and then try again 2 If the alarm occurs again save the CMOS BIN in maintenance mode and then contact your YASKAWA representative about occurrence status operating procedure 5 Calibration data setting error Software operation error occurred 1 Rese...

Page 265: ...roup of the CALL JUMP designation job is included in that of the CALL JUMP source job Don t start the job which including control group under already operation by PSTART 4475 CANNOT EXECUTE JOB NO ROBOT Setting error 1 Check the following settings Add the robot axis to the control group of the job A robot which executed SKILLSND is not defined as using MotoPlus sensor related API Check the combina...

Page 266: ...YASKAWA representative about occurrence status operating procedure 4487 WRONG MECH PARAMETER FILE Software operation error occurred 1 Reset the alarm and then try again 2 If the alarm occurs again save the CMOS BIN in maintenance mode and then contact your YASKAWA representative about occurrence status operating procedure 4490 DEFECTIVE TAUGHT POINT ENDLESS 1 After the Endless rotation completed a...

Page 267: ...the reference point Setting error 1 Check the following settings Match the control group designation of the wall point and weaving execution 4492 POSITION CORRECTION ERROR 1 Data unmatched between the correction amount data and the job data The information about the control groups designated for the series of jobs which is added to the correction amount data does not include the valid control grou...

Page 268: ...alarm and then try again 2 If the alarm occurs again save the CMOS BIN in maintenance mode and then contact your YASKAWA representative about occurrence status operating procedure 5 The setting of U axis ball screw data is incorrect Setting error 1 Reset the alarm and then try again 2 If the alarm occurs again save the CMOS BIN in maintenance mode and then contact your YASKAWA representative about...

Page 269: ... about occurrence status operating procedure 13 The reduction ratio 0 is output Setting error 1 Reset the alarm and then try again 2 If the alarm occurs again save the CMOS BIN in maintenance mode and then contact your YASKAWA representative about occurrence status operating procedure 14 Zero or a negative value is set for the spring constant Setting error 1 Reset the alarm and then try again 2 If...

Page 270: ...se time constant Setting error 1 Reset the alarm and then try again 2 If the alarm occurs again save the CMOS BIN in maintenance mode and then contact your YASKAWA representative about occurrence status operating procedure 35 Zero is set for the averaging time constant Setting error 1 Reset the alarm and then try again 2 If the alarm occurs again save the CMOS BIN in maintenance mode and then cont...

Page 271: ...N in maintenance mode and then contact your YASKAWA representative about occurrence status operating procedure 47 Zero or negative value is set in the allowable braking torque parameter for the speed limit function Setting error 1 Reset the alarm and then try again 2 If the alarm occurs again save the CMOS BIN in maintenance mode and then contact your YASKAWA representative about occurrence status...

Page 272: ...e manipulators or three roll wrist type manipulators is incorrect Setting error 1 Reset the alarm and then try again 2 If the alarm occurs again save the CMOS BIN in maintenance mode and then contact your YASKAWA representative about occurrence status operating procedure 86 The special link JOG operation cannot be used with this manipulator Setting error 1 Reset the alarm and then try again 2 If t...

Page 273: ... alarm and then try again 2 If the alarm occurs again save the CMOS BIN in maintenance mode and then contact your YASKAWA representative about occurrence status operating procedure 121 Incorrect parameter setting to inertia speed control function Setting error 1 Reset the alarm and then try again 2 If the alarm occurs again save the CMOS BIN in maintenance mode and then contact your YASKAWA repres...

Page 274: ...30 An error in the standard expanding point number setting for approximation model Setting error 1 Reset the alarm and then try again 2 If the alarm occurs again save the CMOS BIN in maintenance mode and then contact your YASKAWA representative about occurrence status operating procedure 131 An error in the radius setting for approximation model Setting error 1 Reset the alarm and then try again 2...

Page 275: ...gs Perform the teaching again so that the teaching points are different from one another 2 Some of the teaching points for slave group are on the same point Setting error 1 Check the following settings Perform the teaching again so that the teaching points are different from one another 3 The 2nd axis positions of C3 C4 and C5 of station axes are not the same Setting error 1 Check the following se...

Page 276: ...out occurrence status operating procedure 4502 SL BOARD ON LINE ERROR The option board was detected not to operate normally at power ON Software operation error occurred 1 Reset the alarm and then try again 2 If the alarm occurs again save the CMOS BIN in maintenance mode and then contact your YASKAWA representative about occurrence status operating procedure 4507 REFP POS ERROR SEARCH MOTION Sett...

Page 277: ... cannot be used Setting error 1 Check the following settings Check the settings for the coordinate system which can be used 4509 MFRAME ERROR 1 The master tool user coordinates could not be prepared Setting error 1 Check the following settings Execute the MFRAME instruction in coordinated job when you make the master tool user coordinate 4510 CANNOT EXECUTE INSTRUCTION SQRT Setting error 1 Check t...

Page 278: ...cedure 4521 WRONG JOB TYPE Sub Code 0000_0001 A robot job was started from the concurrent job at CALL JUMP instruction execution 0000_1001 A concurrent job was started from the robot job at CALL JUMP instruction execution 1000_0001 A system job was started from the robot job at CALL JUMP instruction execution Setting error 1 Check the following settings Check the settings for the job to be started...

Page 279: ...eck the following settings Check the job so that the interrupt job will not start up during the back operation 2 An interrupt macro job is started up during the back operation Setting error 1 Check the following settings Check the job so that the interrupt macro job will not start up during the back operation 3 An interrupt job inside the system is started up during the back operation Setting erro...

Page 280: ...nchronous ID number is incorrect Software operation error occurred 1 Reset the alarm and then try again 2 If the alarm occurs again save the CMOS BIN in maintenance mode and then contact your YASKAWA representative about occurrence status operating procedure 8 An attempt was made to execute triple synchronization when specified Sub master for the master was different Setting error 1 Check the foll...

Page 281: ... error occurred 1 Reset the alarm and then try again 2 If the alarm occurs again save the CMOS BIN in maintenance mode and then contact your YASKAWA representative about occurrence status operating procedure 3 An attempt was made to use the conveyor tracking function with the slave manipulator at coordinate motion Setting error 1 Check the following settings The conveyor tracking cannot be execute...

Page 282: ... string type system variable by the other type variable Setting error 1 Check the following settings Obtain as the character string type variable 4538 ROBOT AXIS TRACKING INVALID 0 SYMOVJ instruction is executed at robot axis tracking Setting error 1 Check the following settings Do not use SYMOVJ instruction in robot axis tracking 4539 CORNER R CONTROL ERROR 1 The Corner R motion cannot be used fo...

Page 283: ...g for the Corner R radius small set Timer or PL 0 to a previous line 4540 JOB QUE EMPTY ERROR Setting error 1 Check the following settings Use CALL QUE under the condition that the job data is set to the job queue 4541 INVALID INPUT STRING VAL 1 There was no character string representing a constant in character string to be extracted at VAL instruction execution Setting error 1 Check the following...

Page 284: ...ng an event related instruction 4550 CANNOT EXECUTE INST USER JOB Sub Code System number Setting error 1 Check the following settings This instruction cannot be executed in the system job Correct the job so that the instruction is executed in the user job 4565 SOFTWARE UNMATCH 1 The multi layer welding function is not used Software operation error occurred 1 Reset the alarm and then try again 2 If...

Page 285: ...r occurred 1 Reset the alarm and then try again 2 If the alarm occurs again save the CMOS BIN in maintenance mode and then contact your YASKAWA representative about occurrence status operating procedure 12 The speed control function VCON VCOF is not used Software operation error occurred 1 Reset the alarm and then try again 2 If the alarm occurs again save the CMOS BIN in maintenance mode and then...

Page 286: ...ror occurred 1 Reset the alarm and then try again 2 If the alarm occurs again save the CMOS BIN in maintenance mode and then contact your YASKAWA representative about occurrence status operating procedure 4566 USER FRAME MAKING ERROR 1 The teaching points are incorrect Software operation error occurred 1 Reset the alarm and then try again 2 If the alarm occurs again save the CMOS BIN in maintenanc...

Page 287: ...ROL ERROR 1 No availability in anticipation control Setting error 1 Check the following settings Maximum simultaneous execution number of anticipation control is five Correct the settings for the job so that it is within five 2 The anticipation data exceeded the maximum length Software operation error occurred 1 Reset the alarm and then try again 2 If the alarm occurs again save the CMOS BIN in ma...

Page 288: ...ettings Setting of the radius data 2 The setting for width is incorrect 1 For a rectangle it is incorrectly set as width 1 0 width sqrt maximum diameter2 height2 or width maximum diameter 2 It is incorrectly set as width 0 width maximum diameter 2 radius Setting error 1 Check the following settings Setting of the width data 3 The setting for height is incorrect 1 For a rectangle it is incorrectly ...

Page 289: ...eter S1CxG063 for the Form Cutting motion 9 Zero or a negative value is set in the maximum diameter parameter S1CxG064 for the Form Cutting motion Setting error 1 Check the following settings The setting of the maximum diameter parameter S1CxG064 for the Form Cutting motion 10 Although PLACEMENT or AUTO is set for the start point designation on the FORM CUT SETTING window the FORMAPR instruction w...

Page 290: ...ion data conversion Software operation error occurred 1 Reset the alarm and then try again 2 If the alarm occurs again save the CMOS BIN in maintenance mode and then contact your YASKAWA representative about occurrence status operating procedure 7 Incorrect Cartesian incremental value for offline position data conversion Software operation error occurred 1 Reset the alarm and then try again 2 If t...

Page 291: ... The positions for the mirror shift function could not correctly be calculated at the offline position data conversion Software operation error occurred 1 Reset the alarm and then try again 2 If the alarm occurs again save the CMOS BIN in maintenance mode and then contact your YASKAWA representative about occurrence status operating procedure 20 The positions could not correctly be converted for t...

Page 292: ...ck when the execution of macro instruction was cancelled Software operation error occurred 1 Reset the alarm and then try again 2 If the alarm occurs again save the CMOS BIN in maintenance mode and then contact your YASKAWA representative about occurrence status operating procedure 6 Incorrect macro number Software operation error occurred 1 Reset the alarm and then try again 2 If the alarm occurs...

Page 293: ...Check the following settings Modify the teaching so that the robots indicated by the sub code would not interfere each other Confirm the tool mode tool interference file of the robots indicated by the sub code would not interfere each other 2 If the manipulator is stopped near the interference area by servo OFF it may interfere with the interference area In this case execute the following operatio...

Page 294: ...ck status 4 The group identification signal was not received Setting error 1 Check the following settings Check the settings for group identification signal 5 The specified control group number and the group identification number were unmatched Setting error 1 Check the following settings Check the settings for the specified control group number 6 The encoder PG power supply was OFF when the GRPCH...

Page 295: ...axis data of control group to be disconnected Setting error 1 Check the following settings Check the settings for PSTART instruction 2 An attempt was made to disconnect a control group other than the occupation control group during prereading processing Setting error 1 Check the following settings Check the settings for PSTART instruction 3 An attempt was made to disconnect a control group other t...

Page 296: ... your YASKAWA representative about occurrence status operating procedure 4653 TRQ MEASURE MODE CANCEL ERROR SV Software operation error occurred 1 Reset the alarm and then try again 2 If the alarm occurs again save the CMOS BIN in maintenance mode and then contact your YASKAWA representative about occurrence status operating procedure 4654 WRONG EXECUTION OF SETREG INST 1 An attempt was made to ch...

Page 297: ...form the teaching again to make the form arm folded direction of S and L axes same at start point and end point Change the teaching move instruction to MOVJ instruction Be carefull to the interefernces with peripheral environment because the robot changes its motion 4681 OVER SPEED MainCPU Sub Code Control group and axis Setting error 1 Check the following settings Reduce the speed of the step whe...

Page 298: ...t the offline arm bend position data conversion Setting error 1 Check the following settings The variable position may be out of the robot motion range Check if the variable position is within the robot motion range 5 Incorrect pulse incremental value for offline arm bend position data conversion Setting error 1 Check the following settings The variable position may be out of the robot motion rang...

Page 299: ...ithin the robot motion range 20 Mirror shift position conversion for the offline position data conversion error Setting error 1 Check the following settings The variable position may be out of the robot motion range Check if the variable position is within the robot motion range 22 Coordinate specification error in the new mirror shift conversion for the offline position data conversion Setting er...

Page 300: ...rocedure 4 Library initialize error Software operation error occurred 1 Reset the alarm and then try again 2 If the alarm occurs again save the CMOS BIN in maintenance mode and then contact your YASKAWA representative about occurrence status operating procedure 5 Failed in the generation of the access process Software operation error occurred 1 Reset the alarm and then try again 2 If the alarm occ...

Page 301: ...edure 41 Detect CIP server task request data error Software operation error occurred 1 Reset the alarm and then try again 2 If the alarm occurs again save the CMOS BIN in maintenance mode and then contact your YASKAWA representative about occurrence status operating procedure 50 Detect CIP server task send error Software operation error occurred 1 Reset the alarm and then try again 2 If the alarm ...

Page 302: ...gain save the CMOS BIN in maintenance mode and then contact your YASKAWA representative about occurrence status operating procedure 1041 Failed in the endian conversion Software operation error occurred 1 Reset the alarm and then try again 2 If the alarm occurs again save the CMOS BIN in maintenance mode and then contact your YASKAWA representative about occurrence status operating procedure 1042 ...

Page 303: ...tenance mode and then contact your YASKAWA representative about occurrence status operating procedure 1063 Answer data area overflow Software operation error occurred 1 Reset the alarm and then try again 2 If the alarm occurs again save the CMOS BIN in maintenance mode and then contact your YASKAWA representative about occurrence status operating procedure 1064 In a RC server task receive data are...

Page 304: ...save the CMOS BIN in maintenance mode and then contact your YASKAWA representative about occurrence status operating procedure 1084 In a file server task receive data area overflow Software operation error occurred 1 Reset the alarm and then try again 2 If the alarm occurs again save the CMOS BIN in maintenance mode and then contact your YASKAWA representative about occurrence status operating pro...

Page 305: ...ontact your YASKAWA representative about occurrence status operating procedure 2088 Failed in the endian conversion Software operation error occurred 1 Reset the alarm and then try again 2 If the alarm occurs again save the CMOS BIN in maintenance mode and then contact your YASKAWA representative about occurrence status operating procedure 2089 In a file server task answer data area overflow Softw...

Page 306: ...ce mode and then contact your YASKAWA representative about occurrence status operating procedure 2 Failed in the generation of the file function task Software operation error occurred 1 Reset the alarm and then try again 2 If the alarm occurs again save the CMOS BIN in maintenance mode and then contact your YASKAWA representative about occurrence status operating procedure 3 Failed in the generati...

Page 307: ...KAWA representative about occurrence status operating procedure 513 In RC task there is not the service entry of the request command Software operation error occurred 1 Reset the alarm and then try again 2 If the alarm occurs again save the CMOS BIN in maintenance mode and then contact your YASKAWA representative about occurrence status operating procedure 1130 In a high speed Ethernet task reques...

Page 308: ...then contact your YASKAWA representative about occurrence status operating procedure 3160 In a file task reply packet clear error occurred Software operation error occurred 1 Reset the alarm and then try again 2 If the alarm occurs again save the CMOS BIN in maintenance mode and then contact your YASKAWA representative about occurrence status operating procedure 3161 Failed in the take of the repl...

Page 309: ...ce mode and then contact your YASKAWA representative about occurrence status operating procedure 3168 In a file task reply head error occurred Software operation error occurred 1 Reset the alarm and then try again 2 If the alarm occurs again save the CMOS BIN in maintenance mode and then contact your YASKAWA representative about occurrence status operating procedure 3169 In a file task reply statu...

Page 310: ... the alarm and then try again 2 If the alarm occurs again save the CMOS BIN in maintenance mode and then contact your YASKAWA representative about occurrence status operating procedure 6542 Detect exclusive process error Software operation error occurred 1 Reset the alarm and then try again 2 If the alarm occurs again save the CMOS BIN in maintenance mode and then contact your YASKAWA representati...

Page 311: ...e and then contact your YASKAWA representative about occurrence status operating procedure 7561 In a RC task reply take error detected Software operation error occurred 1 Reset the alarm and then try again 2 If the alarm occurs again save the CMOS BIN in maintenance mode and then contact your YASKAWA representative about occurrence status operating procedure 7562 Failed in the endian conversion So...

Page 312: ... operating procedure 7569 In a RC task reply status error detected Software operation error occurred 1 Reset the alarm and then try again 2 If the alarm occurs again save the CMOS BIN in maintenance mode and then contact your YASKAWA representative about occurrence status operating procedure 4730 MOTION RANGE LIMIT OVER Sub Code Control group Setting error 1 Check the following settings Perform th...

Page 313: ...your YASKAWA representative about occurrence status operating procedure 4826 POWER RELAY ERROR Connection failure 1 Reset the alarm 2 If the alarm occurs again replace controller Save the CMOS BIN before replace controller to be safe Servo control board failure 1 Reset the alarm 2 If the alarm occurs again replace controller Save the CMOS BIN before replace controller to be safe Power relay failur...

Page 314: ... SIGNAL ERROR Enable signal unmatched error 1 Reset the alarm 2 Check the followings There are two point of contact enable switch and only one might be turned ON by how to squeeze Moreover only one might be turned ON when putting it on the place where it is not a plane on the knee etc Connection failure 1 Reset the alarm 2 If the alarm occurs again execute the following operation Replacement of th...

Page 315: ...If the alarm occurs again save the CMOS BIN in maintenance mode and then contact your YASKAWA representative about occurrence status operating procedure 4837 OVERRUN SIGNEAL ERROR OT2 Sub Code Control group Enable signal unmatched error 1 Reset the alarm 2 If the alarm occurs again confirm the followings Select OVERRUN S SENSOR from ROBOT menu to display OVERRUN S SENSOR window The alarm can be re...

Page 316: ...ilure 1 Reset the alarm 2 If the alarm occurs again execute the following operation Replacement of the programming pendant Servo control board failure 1 Reset the alarm 2 If the alarm occurs again save the CMOS BIN in maintenance mode and then contact your YASKAWA representative about occurrence status operating procedure 4840 INTERLOCK CONNECTOR IS USED Sub Code Servo control board from which err...

Page 317: ... occurs again save the CMOS BIN in maintenance mode and then contact your YASKAWA representative about occurrence status operating procedure 3 Detect the cube interference area whose monitoring part is set to whole despite the invalid status of cube arm interference check function Setting error 1 Reset the alarm 2 If the alarm occurs just after loading the cube interference area setting function e...

Page 318: ...IPLE REQUEST SV Software operation error occurred 1 Reset the alarm 2 If the alarm occurs again save the CMOS BIN in maintenance mode and then contact your YASKAWA representative about occurrence status operating procedure 4948 ENCODER ALARM SERVO Software operation error occurred 1 Reset the alarm 2 If the alarm occurs again save the CMOS BIN in maintenance mode and then contact your YASKAWA repr...

Page 319: ...re operation error occurred 1 Reset the alarm 2 If the alarm occurs again save the CMOS BIN in maintenance mode and then contact your YASKAWA representative about occurrence status operating procedure 4962 BRAKE LOCK ERROR SERVO Sub Code Signifies the axis in which the alarm occurred Software operation error occurred 1 Reset the alarm 2 If the alarm occurs again save the CMOS BIN in maintenance mo...

Page 320: ...4973 POSITION ERROR COLLISION DETECT Setting error Confirm the settings of the followings The tool information Work 4980 DESTINATION PULSE LIMIT Setting error 1 Check the following settings Check the position setting for the step move instruction where the alarm occurred 4981 DEST PULSE MECHANICAL LIMIT Setting error 1 Check the following settings Check the position setting for the step move instr...

Page 321: ...nfirm the content of the error then release the error To release the error perform either of the following operations Press CANCEL on programming pendant Input alarm error reset signal system input When two or more errors occur appears in the message display area Activate the message display area and press SELECT to view the list of current errors NOTE An error is different from an alarm because i...

Page 322: ...with teaching position data does not match the tool number selected at the programing pendant 80 Same position in the 3 points 90 Set robot exactly to taught position 100 On overrun recovery status 110 Turn ON servo power 120 Set to PLAY mode 130 No start using external signal 140 No start using P P 150 TEACH LOCK mode ON 160 ENABLE LED ON 170 Servo OFF signal ON 180 TEACH mode select signal ON 19...

Page 323: ...nother file 480 Calibrated at another robot combination 490 Cannot calibrate at this combination 500 Undefined robot calibration data 510 Undefined axis 520 Cannot select two coordinated combination 530 Start reservation mode 540 Not start reservation mode 550 Start reserved JOB change prohibit is set 560 Cannot teach position while soft limit released 590 Register group axis combination SYNCHRO w...

Page 324: ...on t work in the handle operation 810 Servo power supply is limited 820 Modification range over 830 Cannot move while modifying speed 840 Unregistered key 850 Cannot register instruction 860 Please release key registration mode 870 This key cannot be allocated 880 Same relay cannot be set 890 This key has already been registered Cannot register them once 900 Relay No not set 910 Cannot be register...

Page 325: ...ror No Data Error Message Contents 1010 EDIT LOCK mode 1020 Enter correct value 1030 Unauthorized ID No 1050 Enter correct date 1060 Enter correct clock 1070 Enter an ID number in 4 8 figures 1080 Negative value can t be set 1090 Enter correct value START END signal no 325 of 348 ...

Page 326: ...struction possible 2140 Must press ENABLE to modify 2150 Inserting is not possible from this point 2160 Cannot modify or delete this position 2170 Press INSERT to record same step as previous step 2180 Cannot insert data 2190 Cannot delete data 2200 Cannot modify data 2210 Illegal data setting 2220 Display edit instruction 2230 Illegal instruction equation 2240 Excessive instruction equation 2250 ...

Page 327: ...ate editing area 2370 Cannot cut copy NOP and END instructions 2380 Wrong JOB selection 2390 Wrong group axis selection 2400 Cannot move in cut paste editing 2410 When variable is used for speed setting perform a line edit 2420 When variable is used for teach setting perform a line edit 2430 Reverse data not found 2450 Relative JOB not permitted 2460 Specified JOB is already converted 2470 Wrong J...

Page 328: ...on not reset 2640 Incorrect JOB name 2650 Defined JOB name 2660 Register MOVL after circular block 2670 Undefined target JOB 2690 Defined same kind JOB 2710 Relative job can t be shifted with pulse type 2720 Cannot correct position variables 2730 Cannot use robot macro JOB 2740 Cannot use concurrent macro JOB 2750 Cannot use JOB with group axis specification 2760 Cannot insert modify delete for gr...

Page 329: ... error 9 Error other than described above 3100 Total checksum error 3110 Syntax error 3120 HEX code error 1 Specification error of data decode 2 Specification error of EOF record 3 Record type error 4 Total check error of record 3130 Verify error 3140 Wrong pseudo instruction 3150 Concurrent I O record error 1 Format error 2 Ladder program is too long 3 Exceed the range of the data 4 Specification...

Page 330: ...ng for the format 8 Record on the JOB attribute data ATTR is wrong for the format 9 Control group GROUP record is wrong for the format 10 Local variable LVARS record is wrong for the format 11 JOB argument JARGS record is wrong for the format 12 Record on the teaching coordinates for relative job FRAME is wrong for the format 13 Position data coordinates do not match relative job coordinates 3200 ...

Page 331: ... 25 Position vector setting error 26 System error 27 Soft key designate error 28 Numerical input buffer overflow 29 Real type data precision error 30 Element format error 35 BOOL TYPE data error 36 CHAR data error 37 BYTETYPE BINARY HEXADECIMAL BYTE TYPE data error 38 INTEGER TYPE DECIMAL WORD TYPE data error 39 BINARY HEXADECIMAL WORD TYPE data error 40 DOUBLE PRECISION INTEGER TYPE DECIMAL DWORD...

Page 332: ...nnot backup the media 1 Insufficient Compact Flash memory 2 Not accessible to Compact Flash 3470 Database not found 3480 Database access error 3490 Same database exists 3500 Check the media insertion 3501 Check the media insertion 3510 Cannot delete folder Check attribute and inside file 3520 Same folder exists 3530 Cannot load at current security mode 3540 CMOS not compatible 3550 Under automatic...

Page 333: ...10 13 159645 1CD RE CHO A111 10 Error 10 1Error Message FS100 3600 system configuration data not matched 3610 Excessive path 3620 Excess folders Error No Data Error Message Contents 333 of 348 ...

Page 334: ... STR NOT at head of block Need STR NOT XXX Line no 4100 Relay No duplicated in TMR and CNT 4110 Excessive ladder scan time 4120 Concurrent I O memory is full Exceeds memory capacity 10000 steps 4130 END instruction not found END instruction not found 4140 Wrong ladder program Position and number of PART instruction are wrong 4150 Wrong use of GSTR GOUT commands GSTR and GOUT is not used together X...

Page 335: ... 8050 Robot model is not registered 8051 Select model 8060 Cannot get UNIWIRE connection data 8070 DHCP is already set to use for another item 8071 DNS is already set to use for another item 8072 DHCP is not set to use 8073 DNS is not set to use 8074 Device Information not found 8075 Unable to accept same type of boards simultaneously 8076 Ethernet is being used by other function 8080 Non support ...

Page 336: ...ed when the system of the programming pendant becomes unauthorized 10 2 1 Message 10 2 1 1 Fatal Error This message is displayed when the fatal error occurs The message is Fatal application Error although the content of the message box varies depending on the occurence status The programming pendant becomes either of following states 1 The window becomes inoperable 2 The window disappears and blue...

Page 337: ...2 Press OK button to disappear the message box and it becomes operable 10 2 1 3 Other Errors Other errors than mentioned above some can trigger the message box Message Meaning syntax error There is an unauthorized part in internal processing discription expression too complex stack overflow Internal stack has overflowed function nesting depth exceeded Nesting of internal processing is unauthorized...

Page 338: ...ble Please restart the system if the window becomes inoperable 10 2 2 3 Other Errors Most of the cases when an error occurs it is possible to keep the operation after pressing OK button to disappear the message box Please restart the system if the window becomes inoperable Sometimes the message appears due to a specific operation although unstable state of the programming pendant is the main cause...

Page 339: ... for maintenance WARNING To perform this operation it is required to open the door of the control box while power is ON A heavy current AC200V flows inside the control box Do not touch the internal unit Failure to observe this warning may result in electric shock Close the door as soon as the maintenance work such as LED check is completed Failure to observe this warning may result in electric sho...

Page 340: ...e Main CPU Circuit Board CPU201R CPU201R board shows its operation status with 6 LED spot indicator Indication LED Color Board Status when LED is lit SV ON Green While the SERVO power is turned ON RUN Green While in operation ALM 1 Red Occurrence of a major error ALM 2 Red Occurrence of a minor error BAT Red Battery alarm ERR Red Error 6 LED Spot Indicator 340 of 348 ...

Page 341: ... spec Repeat of F 0 2 0 0 Error Cause Error indicati 0 0 0 0 F F 0 4 Address of occurrence Status 7 Segment LED Indicator Immediately after the power is turned ON All 7 SEG indicators light up 8 light up During the start up process Count up from 0 toward d or P Online normal start up d blink every one second Maintenance mode start up F blink every one second PP SWP unconnected P blink every one se...

Page 342: ...Data Storage F0400 Instruction Storage F0600 Alignment F0700 Program F0800 Floating Point Unavailable F0900 Watchdog Timer Error no address indication F0930 CPU Hung Up Error no address indication F0a00 Auxiliary Processor Unavailable F0c00 Fixed Interval Timer F0d00 Watchdog Timer F0e00 Data TLB Error F0f00 Instruction TLB Error F1000 Debug Exception F1100 CPU Signal Process Engine F1200 Floating...

Page 343: ...ies the start up of the booting program 3 Starts the system program transmission 4 Sends the request of the system program start up 5 Starts verifying the existence of other circuit boards Verifies the start up of the system program 6 Acquires hardware information etc of other circuit boards Verifies the IO board status SERVO IF and so on 7 Starts the CMOS data transmission 8 Sends the pre online ...

Page 344: ...t Alarm Occurrence Only when the PP is not connected the FS100 the alarm number is indicated with 4 digit numbers with the letter A at its head If more than one alarm occurred the first alarm numbers indicated Note that the number of the major alarm is indicated if major and minor alarms occurred at a time Indication spec when Alarm 1200 is occurred Repeat of A 1 2 0 0 344 of 348 ...

Page 345: ... indicates its operation status with LED indicator Indication LED Color Board Status when LED is lit PWR Green When the control power is turned ON ALM Red Error is being detected HWBB1 Green CH1 side HWBB is in operation HWBB2 Green CH2 side HWBB is in operation CN1 CN2 CN3 CN4 CN5 CN6 PBESP PPESP DSW SAFF ONEN EXESP ESPOUT DSWOUT HWBB1 EDM1 HWBB2 EDM2 OT1 OT2 24V PWR ALM HWBB1 HWBB2 345 of 348 ...

Page 346: ...s Green LED are lit in sequentially Refer to section 11 4 2 Online normal start up LNK2 blinks every one second Alarm occurrence in the main CPU and SERVO control board communication system The error cause is indicated Refer to section 11 4 1 Normal alarms other than alarms described above ERR is lit Fatal alarm occurrence The error cause and the address where the error has occurred are indicated ...

Page 347: ...are initialization Starts up the SERVO system Starts up each SERVO part initialization Starts up pre online processes LNK2 blinks at 0 3 sec intervals FS100 setup competed SERVO ON enabled LNK2 blinks at 1 sec intervals RDY CN LNK1 ERR CMERR LNK2 ON OFF OFF OFF OFF OFF RDY CN LNK1 ERR CMERR LNK2 OFF OFF OFF OFF OFF OFF RDY CN LNK1 ERR CMERR LNK2 ON OFF OFF OFF OFF OFF RDY CN LNK1 ERR CMERR LNK2 ON...

Page 348: ...V Gurgaon Haryana India Fax 91 124 475 8542 Phone 91 124 475 8500 YASKAWA India Private Ltd Robotics Division YASKAWA Electric China Co Ltd 22F One Corporate Avenue No 222 Hubin Road Huangpu District Shanghai 200021 China Phone 86 21 5385 2200 Fax 㸩86 21 5385 3299 YASKAWA Electric Thailand Co Ltd 59 1st 5th Floor Flourish Building Soi Ratchadapisek 18 Ratchadapisek Road Huaykwang Bangkok 10310 THA...

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