YASKAWA NXC 100 Controller MAINTENANCE MANUAL

NXC100

MAINTENANCE MANUAL

Upon receipt of the product and prior to initial operation, read these instructions thoroughly, and retain for future reference.

MOTOMAN INSTRUCTIONS

NXC100 INSTRUCTIONS

NXC100 REPLACEMENT MANUAL

Part Number: 163524-1CD

Revision: 0

MANUAL NO. RE-CHO-A105 1

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163524-1CD

MANDATORY

• This manual explains maintenance procedures of the NXC100 system.

Read this manual carefully and be sure to understand its contents before handling the NXC100.

• General items related to safety are listed in the NXC100 Instructions. To ensure correct and safe operation, carefully read the NXC100

Instructions before reading this manual.

CAUTION

• Some drawings in this manual are shown with the protective covers or shields removed for clarity. Be sure all covers and shields are replaced before 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 lost, contact a Yaskawa

Motoman representative to order a new copy. The representatives are listed on the back cover. Be sure to tell the representative the manual number listed on the front cover.

• Yaskawa Motoman is not responsible for incidents arising from unauthorized modification of its products. Unauthorized modification voids your product’s warranty.

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Notes for Safe Operation

Read this manual carefully before maintenance or inspection of the NXC100.

In this manual, the Notes for Safe Operation are classified as “WARNING,” “CAUTION,”

“MANDATORY,” or ”PROHIBITED.”

WARNING

CAUTION

Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury to personnel.

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 practices.

MANDATORY

Always be sure to follow explicitly the items listed under this heading.

PROHIBITED

Must never be performed.

Even items described as “CAUTION” may result in a serious accident in some situations. At any rate, be sure to follow these important items.

NOTE

To ensure safe and efficient operation at all times, be sure to follow all instructions, even if not designated as “CAUTION” and “WARNING.” iii

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WARNING

• Before maintenance, inspection, and wiring, check that servo power is turned OFF when the emergency stop buttons on the front face of the

NXC100 and programming pendant are pressed.

When the servo power is turned OFF, the SERVO ON LED on the programming pendant is turned OFF.

Injury or damage to machinery may result if the emergency stop circuit cannot stop the manipulator during an emergency. The manipulator should not be used if the emergency stop buttons do not function.

Emergency Stop Button

• Once the emergency stop button is released, clear the cell of all items which could interfere with the operation of the manipulator. Then turn the servo power ON.

Injury may result from unintentional or unexpected manipulator motion.

TURN

Release of Emergency Stop

• Observe the following precautions when performing teaching operations within the P-point maximum envelope of the manipulator :

- View the manipulator from the front whenever possible.

- Always follow the predetermined operating procedure.

- Ensure that you have a safe place to retreat in case of emergency.

Improper or unintended manipulator operation may result in injury.

• Confirm that no persons are present in the P-point maximum envelope of the manipulator and that you are in a safe location before:

- Turning ON the NXC100 power

- Moving the manipulator with the programming pendant

- Running the system in the check mode

- Performing automatic operations

Injury may result if anyone enters the P-point maximum envelope of the manipulator during operation. Always press an emergency stop button immediately if there are problems.The emergency stop buttons are located on the front face of the NXC100 and the programming pendant.

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CAUTION

• Perform the following inspection procedures prior to conducting manipulator teaching. If problems are found, repair them immediately, and be sure that all other necessary processing has been performed.

-Check for problems in manipulator movement.

-Check for damage to insulation and sheathing of external wires.

• Always return the programming pendant to the user’s designated place after use.

The programming pendant can be damaged if it is left in the P-point maximum envelope of the manipulator, on the floor, or near fixtures.

• Read and understand the Explanation of Warning Labels in the NXC100

Instructions before operating the manipulator.

Definition of Terms Used Often in This Manual

The MOTOMAN manipulator is the YASKAWA industrial robot product.

The manipulator usually consists of the controller, the programming pendant, and supply cables.

In this manual, the equipment is designated as follows.

Equipment Manual Designation

NXC100 Controller

NXC100 Programming Pendant

NXC100

Programming Pendant

Cable between the manipulator and the controller Manipulator cable v

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Descriptions of the programming pendant keys, buttons, and displays are shown as follows:

Equipment

Programming

Pendant

Character Keys

Symbol Keys

Axis Keys

Numeric Keys

Keys pressed simultaneously

Displays

Manual Designation

The keys which have characters printed on them are denoted with [ ].

ex. [ENTER]

The keys which have a symbol printed on them are not denoted with [ ] but depicted with a small picture.

ex. page key

GO BACK

PAGE

The cursor key is an exception, and a picture is not shown.

“Axis Keys” and “Numeric Keys” are generic names for the keys for axis operation and number input.

When two keys are to be pressed simultaneously, the keys are shown with a “+” sign between them, ex. [SHIFT]+[COORD]

The menu displayed in the programming pendant is denoted with { }.

ex. {JOB}

Description of the Operation Procedure

In the explanation of the operation procedure, the expression "Select • • • " means that the cursor is moved to the object item and the SELECT key is pressed, or that the item is directly selected by touching the screen.

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1 Equipment Configuration

1.1 Arrangement of Units and Circuit Boards

. . . . . . . . . . 1

-

1



Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

1.2 Signal Flow

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

-

2

2 Security System

2.1 Protection Through Security Mode Settings

. . . . . . . . 2

-

1

2.1.1 Security Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1



Changing the Security Mode . . . . . . . . . . . . . . . . . . . . . . . . .2-5

2.1.2 User ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7



Changing a User ID. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7

3 Inspections

3.1 Inspection Schedule

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

-

1

3.2 Inspection Items

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

-

2

3.3 Cable Inspection

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

-

2

3.4 Inspection of Whole Exterior

. . . . . . . . . . . . . . . . . . . . . . . 3

-

3

3.5 Inspection of Air Filter

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

-

3

3.6 Inspection of Cover Mounting Screws

. . . . . . . . . . . . . . 3

-

4

3.7 Inspection of Emergency Stop Button

. . . . . . . . . . . . . . 3

-

4

3.8 Inspection of Enable Switch

. . . . . . . . . . . . . . . . . . . . . . . 3

-

4

3.9 Battery Inspection

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

-

5

4 Preparation before Replacing Parts

4.1 Creating a Check Program

. . . . . . . . . . . . . . . . . . . . . . . . 4

-

4

4.2 Saving of the NXC100 Data

. . . . . . . . . . . . . . . . . . . . . . . 4

-

5

5 Replacing Parts

5.1 Replacing NXC100 Parts

. . . . . . . . . . . . . . . . . . . . . . . . . . 5

-

1

5.1.1 Replacing the Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2



Replacement Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2

5.1.2 Checking and Replacing Fuses. . . . . . . . . . . . . . . . . . . . . . . . .5-3

5.1.3 Replacing the Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3

5.2 Replacing the NXC100

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

-

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5.3 Supplied Parts List

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

-

5

5.4 Recommended Spare Parts

. . . . . . . . . . . . . . . . . . . . . . . . 5

-

6

6 Operations after Replacing Parts

6.1 Home Position Calibration

. . . . . . . . . . . . . . . . . . . . . . . . . . 6

-

2

6.1.1 Home Position Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

6.1.2 Calibrating Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4



Registering All Axes at One Time. . . . . . . . . . . . . . . . . . . . . 6-4



Registering Individual Axes . . . . . . . . . . . . . . . . . . . . . . . . . 6-6



Changing the Absolute Data. . . . . . . . . . . . . . . . . . . . . . . . . 6-7



Clearing Absolute Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

6.1.3 Manipulator Home Position. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9

6.2 Position Deviation Check Using the Check Program

. . . 6

-

10

6.3 Verifying the Check Program

. . . . . . . . . . . . . . . . . . . . . . 6

-

11

6.3.1 Verifying the Check Program Operation . . . . . . . . . . . . . . . . . 6-11

6.3.2 Verifying the Check Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11

6.3.3 Home Position Data Correction . . . . . . . . . . . . . . . . . . . . . . . 6-12

6.4 Setting the Second Home Position (Check Point)

. . . . 6

-

13

6.4.1 Purpose of Position Check Operation. . . . . . . . . . . . . . . . . . . 6-15

6.4.2 Procedure for the Second Home Position Setting (Check Point) . . 6-17

6.4.3 Procedure after the Alarm. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18

6.5 Loading the NXC100 Data

. . . . . . . . . . . . . . . . . . . . . . . . 6

-

20

7 System Diagnosis

7.1 System Version

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

-

1

7.2 Manipulator Model

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

-

2

7.3 Input/Output Status

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

-

3

7.3.1 Universal Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3



Universal Input Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3



Universal Input Simple Window . . . . . . . . . . . . . . . . . . . . . . 7-3

7.3.2 Universal Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4



Universal Output Window . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4



Universal Output Simple Window . . . . . . . . . . . . . . . . . . . . . 7-4



Modifying the Output Status . . . . . . . . . . . . . . . . . . . . . . . . . 7-5

7.3.3 Specific Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6



Specific Input Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6



Specific Input Simple Window . . . . . . . . . . . . . . . . . . . . . . . 7-6

7.3.4 Specific Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7



Specific Output Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7



Specific Output Simple Window . . . . . . . . . . . . . . . . . . . . . . 7-7

7.3.5 RIN Input. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8



RIN Input Window. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8

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7.3.6 Signal Number Search . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-9



Direct Search on the Universal/Specified

Input/Output Window. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-10



Search from the Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-11

7.3.7 Relay Number Search . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-12



Direct Search on the Universal/Specified

Input/Output Window. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-13



Search from the Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-14

7.3.8 Modification of the Signal Name . . . . . . . . . . . . . . . . . . . . . . .7-15



Direct Modification on the Universal/Specified

Input/Output Window. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-15



Modification from the Menu . . . . . . . . . . . . . . . . . . . . . . . . .7-16

7.4 System Monitoring Time Display

. . . . . . . . . . . . . . . . . . 7

-

17

7.4.1 System Monitoring Time Display Window . . . . . . . . . . . . . . . .7-17

7.4.2 Individual Window of the System Monitoring Time Display . . . .7-18

7.4.3 Clearing the System Monitoring Time Display. . . . . . . . . . . . .7-19

7.5 Alarm History

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

-

20

7.5.1 Alarm History Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-20

7.5.2 Clearing the Alarm History. . . . . . . . . . . . . . . . . . . . . . . . . . . .7-21

7.6 I/O Message History

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

-

22

7.6.1 I/O Message History Window . . . . . . . . . . . . . . . . . . . . . . . . .7-22



Search . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-22

7.6.2 Clearing the I/O Message History . . . . . . . . . . . . . . . . . . . . . .7-23

7.7 Position Data When Power is Turned ON/OFF

. . . . 7

-

24

7.7.1 Power ON/OFF Position Window . . . . . . . . . . . . . . . . . . . . . .7-24

7.8 Current Position

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

-

25

7.8.1 Current Position Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-25

7.9 Servo Monitoring

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

-

26

7.9.1 Servo Monitor Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-26

7.9.2 Changing the Monitor Items . . . . . . . . . . . . . . . . . . . . . . . . . .7-27

7.9.3 Clearing Maximum Torque Data . . . . . . . . . . . . . . . . . . . . . . .7-28

8 Alarm

8.1 Outline of Alarm

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

-

1

8.2 Alarm Display

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

-

2

8.2.1 Displaying and Releasing Alarm . . . . . . . . . . . . . . . . . . . . . . . .8-2



Releasing Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-2

8.2.2 Special Alarm Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-3



Sub Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-3



Multiple SERVOPACK System . . . . . . . . . . . . . . . . . . . . . . .8-3



Independent Control Function (Optional) . . . . . . . . . . . . . . .8-4

8.3 Alarm Message List

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

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9 Error

9.1 Error Message List

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

-

1

9.1.1 System and General Operation . . . . . . . . . . . . . . . . . . . . . . . . 9-2

9.1.2 Editing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5

9.1.3 Job Defined Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5

9.1.4 External Memory Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9

9.1.5 Concurrent I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-15

9.1.6 Maintenance Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-16

10 LED Indicators

10.1 7-Segment LED and Battery Alarm LED Indicators

. . . 10

-

1

10.2 7 SEG-LED Indicator

. . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

-

2



7 SEG-LED Indicator Status (1-digit indication)

of Each Unit at Error Occurrence . . . . . . . . . . . . . . . . . . . . 10-3



7 SEG-LED Indicator Status (4 digit-indication)

of Each Unit at Error Occurrence . . . . . . . . . . . . . . . . . . . . 10-5 x

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1.1 Arrangement of Units and Circuit Boards

1 Equipment Configuration

The NXC100 is comprised of individual units and modules (circuit boards).

This section explains the configuration of the NXC100 equipment.

1.1 Arrangement of Units and Circuit Boards



Configuration

X32

PPESP

PBESP

FAN guard

(Installed in the controller)

I/O circuit board

JANCD-NIO30B-1

Safety ciruit board

JANCD-NIF30B-1

AXIS circuit board

SGDR-AXC01B

FAN guard

(Installed in the controller)

CB circuit board

SGDR-COBCB030GAB

AMP1

SGDR-SDCCA02AAB

Resistor

RF70 50 ΩK

Surge absorber

RAV-781BWZ-4

Filter

SUP-EL10-E1R-6

Handle

Power supply

CPS-320F

CA circuit board

SGDR-COBCA01AB

Power-ON circuit board

JANCD-NTU30B

CPU circuit board

JANCD-NCP30

FAN

Left-Inner face

AMP2

SGDR-SDCCA01AAB

Fuse (

×2)

NXC100 Configuration

1-1

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1.2 Signal Flow

1.2 Signal Flow

EXTENTION SIGNAL

X62

SON1,SON2

BON1,2

SVMAIN1,2

SVMXOK1 4

SVMXOKCOM

SPM0D1 3

SPMODCOM

JANCD-NBB31

CNA4

CPS-320F

FILTER FUSE MAIN SW

(R-IN)CN02

(R-IN,R-OUT)CN03

(LINE)CN04

CN01

SUP

FILTER

FUFAN1,2

AC

FAN

AC

FAN

JANCD-NCP30

USB VGA2

CNCF1

Compact

FLASH

PARAREL PS/2

CN16

TB1

COM1

LAN1 LAND

(EXON)CNPB

FAN4

FAN5

X41

SINGLE PHASE

AC200/220V

X32

CPU RESET INPUT/OUTPUT

X52

HOST RS-232C (UNDER DEVELOPMENT)

X51

HOST ETHERNET (UNDER DEVELOPMENT)

PROGRAMING

PENDANT

X81

PPESP

PBESP

HOST I/O

DI01 DI12

DO0 DO13

(DUMMY CONNECTOR HB0370381) to HOST

SAFETY CIRCUIT

INPUT/OUTPUT

(DUMMY CONNECTOR HB0470233)

SVON,CHKOUT

FST1,2/SSP

SAFE1,2/FORCE1,2

EXSVON

EXHOLD

EXDSW

EXESP1,2

X33

X61

CNA5

CNA6

JANCD-NIF30B-1

OPTION PCI BOARD

(OPTION)

CN1

CNLED

CND

JANCD-NIO30B-1

CN1

JANCD-NSP30

CN3

CNLED2

CN1

BAT

7SEG LED

FUSE

BATTERY

CN6

EMERGENCY STOP SW

CN2

CN3

X53

M-II(DISTRIBUTED I/O)

X55

CERF to AXIS BOARD (UNPOPULATED)

SON1,SON2

BON1,2

SPMOD1 3

SPMODCOM

SON1,SON2

BON1,2

SPMOD1 3

SPMODCOM

X63

X64

ANALOG SENSOR OUTPUT

X72

X11

X12

JANCD-NCU31

CN1

CN2

X21

X22

CNB15

CNA1

CNA2

CNA7

DC

FAN

DC

FAN

DC

FAN

SGDR-AXC01B

LED

JANCD-NPA30

(OPTION)

CNLED1

CN03A

CN4

CN2

CN52A

CNBT

CN1

X71

CM53A

CMO3B

CN02

X31

ANALOG MONITOR SIGNAL

X54

CERF TO AXIS BOARD

CNB17 CNB17

SGDR-AXD01A

(OPTION)

CN51A

JANCD-NTU30B

CN3

CNB11 CN4

SGDR-COBCA01AB

CN1

CN1B

M-II

CN1A

CN2

CN9

+17V

CN10 CN14

CN11

SGDR-COBCB030GAB

CN1

CN3

CN8

100V/200V SWITCH

SGDR-SDCCA02AAB

AMP1

CN1

CN2

CN3

+17V

CN4

CN7

CN5

PN

SGDR-SDCCA01AAB

AMP2

CN1

CN2

CN3

CN4

CN7

CN5

+17V

PN

SGDR-SDCCA0 AAA

AMP3 CN1

CN2

CN3

CN4

CN7

CN5

+17V

PN

CN2

CN13

CN5

PN

CN6 CN7 CN12

RF70

50k

Ω

6 AXES (MANIPULATOR)

24V

SGDR-FBA02

5V

S AXIS

MOTOR

L AXIS

MOTOR

U AXIS

MOTOR

R AXIS

MOTOR

B AXIS

MOTOR

T AXIS

MOTOR

1-2

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2.1 Protection Through Security Mode Settings

2 Security System

2.1 Protection Through Security Mode Settings

The NXC100 modes setting are protected by a security system. The system allows operation and modification of settings according to operator clearance. Be sure operators have the correct level of training for each level to which they are granted access.

2.1.1

Security Mode

There 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”, “-”, “.”.

Security Mode

Operation Mode

Editing Mode

Management

Mode

Security Mode Descriptions

Explanation

This mode allows basic operation of the robot (stopping, starting, etc.) for people operating the robot work on the line.

This mode allows the operator to teach and edit jobs and robot settings.

This mode allows those authorized to set up and maintain robot system: parameters, system time and modifying user

IDs.

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2.1 Protection Through Security Mode Settings

JOB

Main Menu

VARIABLE

IN/OUT

*1

Teach mode only

*2

Play mode only

Menu & Security Mode

Sub Menu

JOB

SELECT JOB

CREATE NEW JOB

*1

MASTER JOB

JOB CAPACITY

RES. START (JOB)

*1

RES. STATUS

*2

CYCLE

BYTE

INTEGER

DOUBLE

REAL

STRING

POSITION (ROBOT)

POSITION (BASE)

POSITION (ST)

LOCAL VARIABLE

EXTERNAL INPUT

EXTERNAL OUTPUT

UNIVERSAL INPUT

UNIVERSAL OUTPUT

SPECIFIC INPUT

SPECIFIC OUTPUT

RIN

CPRIN

REGISTER

AUXILIARY RELAY

CONTROL INPUT

PSEUDO INPUT SIG

NETWORK INPUT

NETWORK OUTPUT

ANALOG OUTPUT

SV POWER STATUS

LADDER PROGRAM

I/O ALARM

I/O MESSAGE

Allowed Security Mode

DISPLAY EDIT

Operation

Operation

Edit

Operation

Operation

Edit

Operation

Edit

Operation

Edit

Edit

-

Edit

-

Operation

Operation

Operation

Operation

Operation

Operation

Operation

Operation

Operation

Operation

Operation

Operation

Operation

Operation

Edit

Edit

Edit

Operation

Edit

Edit

Edit

Edit

Edit

Operation

Edit

-

-

-

-

Edit

-

-

-

Operation

Edit

Edit

Edit

Edit

Edit

Edit

Edit

-

-

-

-

-

Management

-

-

-

Edit -

Management Management

Management Management

Management Management

2-2

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2.1 Protection Through Security Mode Settings

ROBOT

Main Menu

SYSTEM INFO

FD/CF

*1

Teach mode only

Menu & Security Mode

Sub Menu

CURRENT POSITION

COMMAND POSITION

SERVO MONITOR

WORK HOME POS

SECOND HOME POS

DROP AMOUNT

POWER ON/OFF POS

TOOL

INTERFERENCE

SHOCK SENS LEVEL

USER COORDINATE

HOME POSITION

MANIPULATOR TYPE

3.ROBOT CALIBRATION

ANALOG MONITOR

OVERRUN&S-SENSOR

*1

LIMIT RELEASE

*1

ARM CONTROL

*1

SHIFT VALUE

VERSION

MONITORING TIME

ALARM HISTORY

I/O MSG HISTORY

SECURITY

LOAD

SAVE

VERIFY

DELETE

DEVICE

FOLDER

Allowed Security Mode

DISPLAY EDIT

Operation

Operation

Management -

-

-

Operation

Operation

Edit

Edit

Management Management

Operation -

Edit Edit

Management Management

Operation

Edit

Management

Edit

Management Management

Management -

Edit Edit

Management Management

Edit

Edit

Edit

Management

Management Management

Operation -

Operation

Operation

Operation

Operation

-

Management

Management

Management

Operation

Edit

Operation

Operation

Operation

Operation

Edit

Operation

-

-

-

-

Operation

Management

2-3

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2.1 Protection Through Security Mode Settings

Main Menu

PARAMETER

SETUP

HANDLING

GENERAL

COMMON TO ALL APPLI-

CATIONS

*1

Teach mode only

Menu & Security Mode

Sub Menu

S1CxG

S2C

S3C

S4C

A1P

A2P

A3P

A4P

RS

S1E

S2E

S3E

S4E

TEACHING COND

OPERATE COND

DATE/TIME

GRP COMBINATION

RESERVE JOB NAME

USER ID

SET SPEED

KEY ALLOCATION

*1

RES. START (CNCT)

HANDLING DIAGNOSIS

WEAVING

GENERAL DIAG.

I/O VARIABLE CUSTOMIZE

Allowed Security Mode

DISPLAY EDIT

Management Management

Management Management

Management Management

Management Management

Management Management

Management Management

Management Management

Management Management

Management Management

Management Management

Management Management

Management Management

Management Management

Edit Edit

Management Management

Management Management

Management Management

Edit

Edit

Edit

Edit

Management Management

Management Management

Management Management

Operation Edit

Operation

Operation

Operation

Edit

Edit

Operation

2-4

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2.1 Protection Through Security Mode Settings



Changing the Security Mode

Operation

1 Select {SYSTEM INFO} under the main menu.

The sub menu appears.

Explanation

2 Select {SECURITY}.

T

JOB

DOUT

MOVE

END

ARC WELDING

VARIABLE

B001

IN/OUT

In Out

ROBOT

FD/CF

CF

PARAMETER

VERSION

SETUP

MONITORING TIME

DISPLAY SETUP

I/O MSG HISTORY

SYSTEM INFO

SECURITY

Main Menu Short Cut

Turn on servo power

Note: Icons for the main menu such as arc welding system differ depending on the system being used.

The selection window of security mode appears.

DATA

JOB

DOUT

MOVE

END

ARC WELDING

EDIT

DISPLAY UTILITY

SECURITY

FD/CF

CF

PARAMETER

MODE

SETUP VARIABLE

B001

IN/OUT

In Out

ROBOT

EDITING MODE

T

SYSTEM INFO

Main Menu Short Cut Turn on servo power

3 Press [SELECT] and select

"SECURITY MODE".

DATA

JOB

DOUT

MOVE

END

ARC WELDING

EDIT

FD/CF

CF

DISPLAY UTILITY

SECURITY

PARAMETER

MODE

SETUP

VARIABLE

B001

IN/OUT

In Out

ROBOT

SYSTEM INFO

Main Menu Short Cut

OPERATING MODE

EDITING MODE

MANAGEMENT MODE

Turn on servo power

T

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17/245

2.1 Protection Through Security Mode Settings

Operation

4 Input the user ID.

5 Press [ENTER].

The user ID input window appears.

DATA

JOB

DOUT

END

ARC WELDING

EDIT DISPLAY UTILITY

SECURITY

FD/CF

CF

PARAMETER

MODE

SETUP

VARIABLE

B001

IN/OUT

In Out

ROBOT

SYSTEM INFO

Main Menu Short Cut

Explanation

Password =

Turn on servo power

T

SUPPLE

-MENT

At the factory, the following below user ID number is preset.

• Editing Mode:[00000000]

• Management Mode:[99999999]

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.

2-6

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2.1 Protection Through Security Mode Settings

2.1.2

User ID

User ID is requested when Editing Mode or Management Mode is operated.

User ID must be between 4 characters and 8, and they must be numbers and symbols (“0 to

9”,“-” and “.”).

 Changing a User ID

In order to change the user ID, the NXC100 must be in Editing Mode or Management Mode.

Higher security modes can make changes the user ID of to lower security modes.

Operation

1 Select {SETUP} under the main menu.

2 Select {USER ID}.

Explanation

The sub menu appears.

DATA

JOB

DOUT

MOVE

END

ARC WELDING

EDIT DISPLAY UTILITY

FD/CF

CF

TEACHING COND

PARAMETER

OPERATE COND

VARIABLE

B001

IN/OUT

In Out

ROBOT

DATE/TIME

SETUP

GRP COMBINATION

DISPLAY SETUP

Aa

RESERVE JOB

NAME

*** USER ID

SYSTEM INFO

SET SPEED

Main Menu Short Cut

KEY ALLOCATION

The USER ID window appears.

DATA

JOB

MOVE

END

ARC WELDING

EDIT DISPLAY UTILITY

USER ID

FD/CF

CF

PARAMETER

EDITING MODE

SETUP

VARIABLE

B001

IN/OUT

In Out

ROBOT

MANAGEMENT MODE

********

********

SYSTEM INFO

Main Menu Short Cut

T

T

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2.1 Protection Through Security Mode Settings

Operation

3 Select the desired ID.

4 Input current ID and press

[ENTER].

5 Input new ID and press

[ENTER].

Explanation

The character input line appears, and the message "Input current

ID no. (4 to 8 digits)" is shown.

DATA

JOB

DOUT

MOVE

END

ARC WELDING

EDIT DISPLAY UTILITY

USER ID

FD/CF

CF

PARAMETER

EDITING MODE

Password =

T

SETUP

VARIABLE

B001

IN/OUT

In Out

ROBOT

MANAGEMENT MODE ********

SYSTEM INFO

Main Menu

Short Cut

Input current ID no. (4 to 8 digits)

When the correct user ID is entered, a new ID is requested to be input. "Input new ID no.(4 to 8 digits)" appears.

DATA

JOB

DOUT

MOVE

END

ARC WELDING

EDIT

FD/CF

CF

DISPLAY UTILITY

SECURITY

PARAMETER

EDITING MODE

SETUP

VARIABLE

B001

IN/OUT

In Out

ROBOT

MANAGEMENT MODE

Password =

********

T

SYSTEM INFO

Main Menu

User ID is changed.

Short Cut Input current ID no. (4 to 8 digits)

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3.1 Inspection Schedule

3 Inspections

WARNING

• Before conducting maintenance, inspection or wiring, turn OFF all supplied power (including the compressed air) to the robotic system, lock the switch in the "OFF" position and put up a warning sign, such as

"DO NOT TURN ON THE POWER".

• The robotic system does not have the switch to turn OFF the power.

Turn OFF the switch in the host system to which the robotic system is connected.

Failure to observe this caution may result in electric shock or injury.

CAUTION

• Maintenance and inspections must be performed by specified personnel.

Failure to observe this caution may result in electric shock or injury.

3.1 Inspection Schedule

Proper inspections are essential not only to assure that mechanism will be able to function for a long period, but also to prevent malfunctions and assure safe operation.

The inspection intervals should be based on the power supply ON time.

Inspection intervals are displayed in the following three levels by taking it as a standard that the NXC100 is used for 6,000 hours per year.

• Weekly inspection

• Every 6-month inspection

• After 5-year inspection (overhaul)

Weekly inspection and every 6-month inspection are essential mainly to assure safe operation and assure that the mechanism is able to function for a long period. These inspections can be conducted at the customer’s facilities (on-site inspections).

Conduct these on-site periodical inspections according to the inspection schedule in " 3.2

Inspection Items ".

In addition, Yaskawa recommends the complete check (including the items which cannot be done on-site) at Yaskawa as a preventive maintenance after 5 years (30,000 hours).

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3.2 Inspection Items

3.2 Inspection Items

The inspection items are classified into three types of operations:

• The operation which can be performed by personnel authorized by the user.

• The operation which can be performed by personnel being trained.

• The operation which is performed by Yaskawa.

Only specified personnel are to do the inspection work.





Working area and manipulator



Air filter









Items

*1

Cables

Cable connection

Cover mounting screws

Emergency stop button

Enable switch



Battery

Daily













Schedule

6-Month

3000H

Cycle











Overhaul

30,000H Cycle

(Every 5 years)

Method

Operation

Inspection

Charge

Specified

Personnel

Licensee

Service

Company

Visual

Visual

Visual

Visual

Screwdriver

Function check

Function check

Visual

Check for damage, etc. Replace if necessary.

Check for damage and outside cracks.

Check for damage, dirt, etc. Replace if necessary.

Tighten loose screws. Replace if necessary.

Tighten loose screws. Replace if necessary.

































NOTE

• Conduct inspections of the items No.1 to No.5 with the equipment fully de-energized.

• Conduct inspections of the items No.6 to No.8 with the equipment energized.

3.3 Cable Inspection

Verify that no damage or deterioration is found on the power cables, programming pendant cables, and I/O cables connected to the NXC100. Cables with severe damage and deterioration may result in malfunction and failure. Replace with new cables.

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3.4 Inspection of Whole Exterior

3.4 Inspection of Whole Exterior

Conduct inspections of the exterior of the NXC100 and programming pendant. If any damage is found on the switches and connectors, replace them with new ones promptly. Furthermore, if the rated nameplates and warning labels are hard to be seen due to dirt on them, remove the dirt so that the contents of the nameplates and warning labels can be confirmed.

3.5 Inspection of Air Filter

The NXC100 has air filters in seven positions as shown below.

Verify extent of dust and dirt of air filters. Replace the air filter with new one as necessary.

ON

OFF

F1

FU1

FU2

SOURCE

SOURCE

X52

X51

F2

X31

BATTERY

FUSE

X81 AC FUSE : F1, F2

15A / 250V

SLOW BLOW

I/O FUSE : F1, F2, F3, F4

3.15A / 250V

FAST BLOW

NXC100 electric shock or burn

Turn off and lock out

Contact may cause

208/110 VAC PRESENT system power before servicing

HAZAARDOUS VOLTAGE

WARNING

HEAVY OBJECT

Can cause muscle strain or back injury. Use lifting aids

& proper lifting technjques when removing or replacing

WARNING

X21

X72 X11

X12

FAN3 FAN2

X54 X53

X62

X55

X71

PPESP PPESP

X64 - X63

Air Filter Positions

3-3

23/245

3.6 Inspection of Cover Mounting Screws

3.6 Inspection of Cover Mounting Screws

Check for loose screws that fastens covers and connectors. Tighten the loose screws as necessary.

3.7 Inspection of Emergency Stop Button

The emergency stop buttons are located on both the front face of the NXC100 and the programming pendant. Before operating the manipulator, confirm that the servo power turns

OFF by pressing each emergency stop button on the front face of the NXC100 and programming pendant after the servo ON.

3.8 Inspection of Enable Switch

The programing pendant is equipped with a three-position enable switch. Perform the following operation to confirm the enable switch operates.

1. Set the mode switch on the programming pendant to "TEACH".

REMOTE

PLAY

TEACH

2. Press [SERVO ON READY] on the programming pendant. The [SERVO ON] lamp blinks.

Blinking

SERVO

ON

READY

SERVO ON

3. When the enable switch is squeezed lightly, the servo power is turned ON.

When the enable switch is squeezed tightly or released, the servo power is turned

OFF.

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3.9 Battery Inspection

NOTE

If the [SERVO ON] lamp does not light in previous operation (2), check the following:

• The emergency stop button on the front face of the NXC100 is pressed.

• The emergency stop button on the programming pendant is pressed.

• The emergency stop signal is input from external.

If the servo is not turned ON in a previous operation (3), check the following:

• A major alarm is occurring.

3.9 Battery Inspection

The NXC100 has a battery that backs up the important program files for user data in the

CMOS memory.

A battery alarm indicates when a battery has expired and must be replaced. The message

"Memory battery weak" appears at the bottom of the programming pendant display.

The way to replace the battery is described in " 5.1.1 Replacing the Battery ".

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4 Preparation before Replacing Parts

WARNING

• Before operating the manipulator, check that the SERVO ON lamp turns

OFF when the emergency stop buttons on the front face of the NXC100 and the programming pendant are pressed.

Injury or damage to machinery may result if the manipulator cannot be stopped in case of an emergency.

• Observe the following precautions when performing teaching operations within the P-point maximum envelope of the manipulator :

- View the manipulator from the front whenever possible.

- Always follow the predetermined operating procedure.

- Ensure that you have a safe place to retreat in case of emergency.

Improper or unintended manipulator operation may result in injury.

• Confirm that no persons are present in the P-point maximum envelope of the manipulator and that you are in a safe location before:

- Turning ON the NXC100 power.

- Moving the manipulator with the programming pendant

Injury may result if anyone enters the P-point maximum envelope of the manipulator during operation.

• Always press the emergency stop button immediately if there are problems.

Emergency stop buttons are located at the upper right corner of the front face of the

NXC100 and on the upper right of the programming pendant.

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CAUTION

• Perform the following inspection procedures prior to conducting manipulator teaching. If problems are found, repair them immediately, and be sure that all other necessary processing has been performed.

- Check for problems in manipulator movement.

- Check for damage to insulation and sheathing of external wires.

• Always return the programming pendant to the user’s designated place after use.

The programming pendant can be damaged if it is left in the P-point maximum envelope of the manipulator, on the floor, or near fixtures.

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The following flowchart shows the operations for replacing parts.

Start

Creating a check program : Chapter 4

Replacing parts : Chapter 5

Home position calibration

Position deviation check using the check program

: Chapter 6

No

OK?

Yes

End

This chapter describes how to create a check program as a preparation for replacing parts.

The check program is a program to check the position deviation. If positions are deviated, home position calibration is required. For the calibration, this program data is used to correct the home position data. In the following cases particularly, the home position calibration using

the check program is needed. Be sure to create a check program referring to " 4.1 Creating a

Check Program ".

• Change in the combination of the manipulator and NXC100

• Replacement of the motor or absolute encoder

• Clearing stored memory (by replacement of weak battery, etc.)

• Home position deviation caused by hitting the manipulator against a workpiece, etc.

Furthermore, in case that the NXC100 itself is replaced due to controller failure, etc., all the data need to be saved and loaded. When replacing the NXC100, make sure to perform saving and loading of the data.

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4.1 Creating a Check Program

4.1 Creating a Check Program

To check position deviation 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.

Enlarged View

4-4

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4.2 Saving of the NXC100 Data

4.2 Saving of the NXC100 Data

Before replacing the NXC100, make sure to follow the instructions below to save data.

The saved data are used in" 6.5 Loading the NXC100 Data ".

The Compact Flash cards are used to save and load the NXC100 data. The following listed below are Yaskawa’s recommended Compact Flash cards. Product performance cannot be guaranteed when using Compact Flash cards other than those listed below.

NOTE

Type



: SDCFBI-64-EPP-80 (By SanDisk, Inc., 64MB)

Type



: CFI-064MBA (By Hagiwara Sys-Com Co., Ltd., 64MB)

Type



: CFC-064MBA (By Hagiwara Sys-Com Co., Ltd, 64MB)

128MB Compact Flash cards of the above types can also be used.

Operation

1 Turn OFF the power supply to the NXC100.

2 Open the Compact Flash slot cover of the programming pendant and insert the

Compact Flash card. Then close the cover.

Explanation

REMOTE

PLAY

TEACH START HOLD

!?

Compact Flash slot

3 Turn ON the power supply to the NXC100 while pressing the [MAIN MENU] key

MAIN

MENU

.

Release your finger from the

[MAIN MENU] key

MAIN

MENU

after three seconds.

Make sure the inserting direction of the Compact Flash card before inserting it into the slot.

X-

S-

Y-

L

LAYOUT

MULTI

COORD

MAIN

MENU

DIRECT

OPEN

SHORT

CUT

SERVO

ON

READY

GO BACK

PAGE

AREA

!?

ASSIST

CANCEL

X+

S+

Y+

L

SERVO ON

HIGH

SPEED

X-

R-

Y

X+

R+

Y+

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3 (cont’d)

Operation

4.2 Saving of the NXC100 Data

Explanation

The main menu window of the maintenance mode appears on the programming pendant display approximately after forty seconds.

SYSTEM

FILE

TOOL

CF

4 Select {TOOL} under the main menu.

Main Menu Short Cut

Maintenance mode

If the above window is not displayed, turn OFF the power supply to the NXC100 and try the step 3 again.

The sub menu appears.

SYSTEM

FILE

TOOL

CF

CompactFlash

5 Select {CompactFlash}.

Main Menu Short Cut

Maintenance mode

The CMOS SAVE/LOAD display appears.

SYSTEM

FILE

TOOL

CF

CMOS SAVE

CMOS LOAD

Main Menu

Short Cut

Maintenance mode

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4.2 Saving of the NXC100 Data

Operation

6 Move the cursor to "CMOS

SAVE" and press [SELECT].

Explanation

The confirmation dialog box appears.

SYSTEM

FILE

CMOS SAVE

CMOS LOAD

TOOL

CF

Save?

YES NO

7 Select "YES".

Main Menu Short Cut Maintenance mode

The CMOS data are saved in the Compact Flash card in the programming pendant slot.

CAUTION

• If the CMOS data are already saved in the

Compact Flash card in the programming pendant slot, the following display appears.

If the data need to be saved, move the data to the different location or change the Compact

Flash card with a different one, and save the data.

Select "YES" on the touch panel if the CMOS data can be overwritten.

SYSTEM

FILE

TOOL

CF

CMOS SAVE

CMOS LOAD

YES

Overwrite?

CMOS.BIN

NO

Main Menu Short Cut

Maintenance mode

PROHIBITED

• Do not turn OFF the power supply to the

NXC100 while the CMOS data are saved.

The CMOS data cannot be saved normally in the

Compact Flash card in the programming pendant slot.

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Operation

8 Saving is completed.

4.2 Saving of the NXC100 Data

Explanation

If the programming pendant blips approximately after forty seconds from the start of data saving, saving of CMOS data is completed. Turn OFF the power supply to the NXC100.

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5.1 Replacing NXC100 Parts

5 Replacing Parts

5.1 Replacing NXC100 Parts

WARNING

• Before conducting maintenance, inspection or wiring, turn OFF all supplied power (including the compressed air) to the robotic system, lock the switch in the "OFF" position and put up a a warning sign, such as "DO NOT TURN ON THE POWER".

CAUTION

• Maintenance and inspections must be performed by specified personnel.

Failure to observe this caution may result in electric shock or injury.

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5.1 Replacing NXC100 Parts

5.1.1

Replacing the Battery

Replace the battery immediately if a battery alarm occurs. Replace the battery within two hours after the main switch turns OFF.

(The battery alarms appear on the programing pendant display.)

 Replacement Procedure

1. Remove the battery cover on the front face of the NXC100. Remove the battery connector (CN2) to uninstall the battery.

2. Mount a new battery and connect the battery connector (CN2).

X52

ON(I)

ON

F1

FU1

FU2

SOURCE

SOURCE

OFF

OFF(O) F2

X51

X31

BATTERY

FUSE

X81 AC FUSE : F1, F2

15A / 250V

SLOW BLOW

I/O FUSE : F1, F2, F3, F4

3.15A / 250V

FAST BLOW

Position of Battery Cover

I/O fuse

NXC100

Battery

Battery connector: CN2

The View after Battery Cover is Removed

5-2

35/245

5.1 Replacing NXC100 Parts

5.1.2

Checking and Replacing Fuses

The types of fuses on power supply contactor unit (JZRCR-NTUoo) are as follows.

Fuse Name

Main Fuse for Power

Supply Protection

I/O Protection Fuse

Brake Protection

Fuse

Fuse for Fan

Position

Front of the

NXC100

Inside of the battery cover

Inside of the battery cover

Front of the

NXC100

Type

314010, 250V, 10A,

φ 6 × 32 mm, Time lag fuse

2173.15, 250V, 3.15A,

φ 5 × 20 mm, Fast-Acting fuse

SMP50, 5A, Time lag fuse

213001, 250V, 1A,

φ 5 × 20 mm, Time lag fuse

Manufacturer

Littelfuse, Inc.

Littelfuse, Inc.

Daito Communication

Apparatus Co., Ltd.

Littelfuse, Inc.

Main fuse for power supply protection

Fuse for fans

Brake protection fuse

(Inside of the battery cover)

I/O protection fuse

(Inside of the battery cover)

X52

ON(I)

ON

F1

FU1

FU2

SOURCE

SOURCE

OFF

OFF(O)

F2

X51

X31

BATTERY

FUSE

X81 AC FUSE : F1, F2

15A / 250V

SLOW BLOW

I/O FUSE : F1, F2, F3, F4

3.15A / 250V

FAST BLOW

NXC100

Fuse Position

If a fuse appears to be blown (see " 8.3 Alarm Message List "), remove each fuse shown

above and check the continuity with an electric tester. If the fuse is blown, replace it with the same type of fuse (supplied).

NOTE

Determine and correct the cause of the blown fuse. If the problem is uncorrected, the fuse may blow again.

5.1.3

Replacing the Air Filter

If an air filter is covered with dust and dirt, replace the air filter with new one promptly.

Remove knurled screws to uninstall the filter cover, and replace the air filter.

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5.2 Replacing the NXC100

5.2 Replacing the NXC100

WARNING

• Before conducting maintenance, inspection or wiring, turn OFF all supplied power (including the compressed air) to the robotic system, lock the switch in the "OFF" position and put up a a warning sign, such as "DO NOT TURN ON THE POWER".

CAUTION

• Maintenance and inspections must be performed by specified personnel.

Failure to observe this caution may result in electric shock or injury.

If the NXC100 itself is replaced due to controller failure, etc., refer to " NXC100

CONTROLLER REPLACEMENT MANUAL" (HW0483908) to perform the replacement.

Replacement must be performed by specified personnel.

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5.3 Supplied Parts List

5.3 Supplied Parts List

The following list shows the supplied parts of the NXC100

No.

1

2

3

4

5

6

7

8

9

10

11

10A

Item

Ceramic fuse

3.15A

Glass-Tube fuse

1A

Glass-Tube fuse

5A

Alarm fuse

WAGO Connector wiring tool

1

Dummy connector 1

Dummy connector

Terminal connector

Connector

Connector

Connector

Qty

2

4

2

2

1

1

1

1

1

Type

314010, 250V, 10A,

Time lag fuse, φ 6 × 32 mm

(Littelfuse, Inc.)

2173.15, 250V, 3.15A, Fast-Acting fuse,

φ 5 × 20 mm

(Littelfuse, Inc.)

213001, 250V, 1A,

Time lag fuse, φ 5 × 20 mm

(Littelfuse, Inc.)

SMP50, 5A, Time lag fuse

(Daito Communication Apparatus Co., Ltd.)

231-131

(WAGO Corporation)

HB0480081

(Yaskawa Electric Corporation)

HB0470233

(Yaskawa Electric Corporation)

HB0480075

(Yaskawa Electric Corporation)

231-104/026-000

(WAGO Corporation)

721-104/026-000

(WAGO Corporation)

721-104/026-000

(WAGO Corporation)

For power supply protection

F1, F2

Remarks

For I/O protection

F1 to F4

For fans

FUFAN1, FUFAN2

For brake protection

X32, PPESP, PBESP

Wiring tool

For X33

For X61

For X54

For X32

For PPESP

For PBESP

5-5

38/245

5.4 Recommended Spare Parts

5.4 Recommended Spare Parts

CAUTION

• Make sure to use the recommended spare parts and components as listed below.

Product performance cannot be guaranteed when using spare parts other than those listed below.

[Ranking of Spare Parts]

• Rank A: Expendable and frequently replaced parts

• Rank B: Parts for which replacement may be necessary as a result of frequent operation

• Rank C: Drive unit

Recommended Spare Parts

Rank

C

C

C

Parts

No.

1

2

3

Fan

Fan

Fan

Fuse

Name Type

HB0470220

HB0470221

SMP50, 5A

Manufacturer

Minebea Co., Ltd.

Royal Electric

Co., Ltd.

Minebea Co., Ltd.

Qty

3

2

3

2

Qty per

Unit

1

1

1

1

Remarks

Fan type: 2406KL-05W-B59-

L00

Fan type: S40E7R

Fan type: 4710PS-22T-B30-

B00

For brake

A

A

A

A

4

5

6

7

Fuse

Fuse

Fuse

2173.15

314010

213001

Daito Communication Apparatus

Co., Ltd.

Littelfuse Inc.

Littelfuse Inc.

Littelfuse Inc.

4

2

2

1

1

1

250V, 3.15A

For I/O

250V, 10A

For power supply

250V, 1A

For fans

A 8

Battery

Air filter

ER6VC3N Toshiba Corporation

Japan Vilene

Company, Ltd.

1

7

1

7

A 9

PS/150

340 mm

×

130 mm

×

18 mm,

90 mm

×

33 mm

×

t8 mm,

40 mm

×

23 mm

×

t8 mm,

65 mm

×

13 mm

×

t8 mm,

77 mm

×

103 mm

×

t8 mm,

112 mm

×

57 mm

×

t8 mm,

120 mm

×

60 mm

×

t8 mm, one for each

5-6

39/245

6 Operations after Replacing Parts

WARNING

• Before operating the manipulator, check that the SERVO ON lamp turns

OFF when the emergency stop buttons on the front face of the NXC100 and the programming pendant are pressed.

Injury or damage to machinery may result if the manipulator cannot be stopped in case of an emergency.

• Observe the following precautions when performing teaching operations within the P-point maximum envelope of the manipulator :

- View the manipulator from the front whenever possible.

- Always follow the predetermined operating procedure.

- Ensure that you have a safe place to retreat in case of emergency.

Improper or unintended manipulator operation may result in injury.

• Confirm that no persons are present in the P-point maximum envelope of the manipulator and that you are in a safe location before:

- Turning ON the NXC100 power.

- Moving the manipulator with the programming pendant

Injury may result if anyone enters the P-point maximum envelope of the manipulator during operation.

• Always press the emergency stop button immediately if there are problems.

Emergency stop buttons are located on the front face of the NXC100 and on the upper right of the programming pendant.

6-1

40/245

6.1 Home Position Calibration

CAUTION

• Perform the following inspection procedures prior to conducting manipulator teaching. If problems are found, repair them immediately, and be sure that all other necessary processing has been performed.

- Check for problems in manipulator movement.

- Check for damage to insulation and sheathing of external wires.

• Always return the programming pendant to the user’s designated place after use.

The programming pendant can be damaged if it is left in the P-point maximum envelope of the manipulator, on the floor, or near fixtures.

6.1 Home Position Calibration

6.1.1

Home Position Calibration

NOTE

Teaching and playback are not possible before home position calibration is completed.

In a system with two or more manipulators, the home position of all the manipulators must be calibrated before starting teaching or playback.

Set the security mode to the management mode to perform home position calibration.

Home position calibration is an operation in which the home position and absolute encoder position coincide. Although this operation is performed prior to shipment at the factory, the following cases require this operation to be performed again.

• Change in the combination of the manipulator and NXC100

• Replacement of the motor or absolute encoder

• Clearing stored memory (by replacement of NCP30 circuit board, weak battery, etc.)

• Home position deviation caused by hitting the manipulator against a workpiece, etc.

To calibrate the home position, use the axis keys to calibrate the mark for the home position on each axis so that the manipulator can take its posture for the home position. There are two operations for home position calibration:

• All the axes can be moved at the same time

• Axes can be moved individually

If the absolute data of the home position is already known, set the absolute data again after

6-2

41/245

6.1 Home Position Calibration completing home position registration.

Home Position

SUPPLE

-MENT

The home position is the position with the pulse value "0" for each axis. The deviation values between the home position and the control reference position are set to parameters. The deviation values are specified as an angle in units of 1/1000 °, and vary

depending on manipulator types. See " 6.1.3 Manipulator Home Position ".

6-3

42/245

6.1 Home Position Calibration

6.1.2

Calibrating Operation

 Registering All Axes at One Time

Operation

1 Select {ROBOT} under the main menu.

2 Select {HOME POSITION}.

Explanation

The HOME POSITIONING window appears.

DATA

JOB

DOUT

END

ARC WELDING

VARIABLE

B001

IN/OUT

In Out

EDIT DISPLAY UTILITY

FD/CF

CF

PARAMETER

SETUP

DISPLAY SETUP

Aa

HOME POSITIONING

SELECT

R1: S

L

U

R

B

T













ROBOT

ABSOLUTE DATA

T

SYSTEM INFO

PAGE

Main Menu Short Cut

3 Select {DISPLAY} under the menu, or select "PAGE" to display the selection window for the control group,

GO BACK

or press

PAGE

.

The pull-down menu appears.

DATA

JOB

DOUT

MOVE

END

ARC WELDING

VARIABLE

B001

IN/OUT

In Out

EDIT DISPLAY UTILITY

CF

ROBOT 2

PARAMETER

STATION 1

SETUP

HOME POSITIONING

SELECT

R1: S

L

U

R

B

T













DISPLAY SETUP

Aa

ROBOT

ABSOLUTE DATA

T

SYSTEM INFO

PAGE

Main Menu Short Cut

DATA

JOB

DOUT

MOVE

END

ARC WELDING

VARIABLE

B001

IN/OUT

In Out

EDIT DISPLAY

FD/CF

CF

PARAMETER

SETUP

DISPLAY SETUP

Aa

UTILITY

HOME POSITIONING

SELECT

R1: S

L

U

R

B

T













ROBOT

ABSOLUTE DATA

T

SYSTEM INFO

R1

R2

S1

:ROBOT1

:ROBOT2

:STATION1

PAGE

Main Menu Short Cut

4 Select the desired control group.

6-4

43/245

6.1 Home Position Calibration

5 Select {EDIT} under the menu.

Operation Explanation

The pull-down menu appears.

DATA

JOB

DOUT

MOVE

END

ARC WELDING

VARIABLE

B001

IN/OUT

In Out

EDIT DISPLAY UTILITY

CF

PARAMETER

SETUP

HOME POSITIONING

SELECT

R1: S

L

U

R

B

T













DISPLAY SETUP

Aa

ROBOT

ABSOLUTE DATA

T

SYSTEM INFO

PAGE

Main Menu Short Cut

6 Select {SELECT ALL AXES}.

The confirmation dialog box appears.

DATA

JOB

DOUT

MOVE

END

ARC WELDING

VARIABLE

B001

IN/OUT

In Out

EDIT DISPLAY UTILITY

FD/CF

CF

PARAMETER

SETUP

DISPLAY SEUTP

Aa

HOME POSITIONING

SELECT

R1: S

L

B

T

U

R

ABSOLUTE DATA











NO

T

ROBOT

SYSTEM INFO

PAGE

Main Menu Short Cut

7 Select “YES.” Displayed position data of all axes are registered as home position.

When “NO” is selected, the registration will be canceled.

6-5

44/245

6.1 Home Position Calibration



Registering Individual Axes

Operation

1 Select {ROBOT} under the main menu.

2 Select {HOME POSITION}.

3 Select the desired control group.

Explanation

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 axis to be registered.

5 Select "YES".

DATA

JOB

DOUT

MOVE

END

ARC WELDING

VARIABLE

B001

IN/OUT

In Out

ROBOT

EDIT DISPLAY UTILITY

FD/CF

CF

PARAMETER

SETUP

DISPLAY SETUP

Aa

HOME POSITIONING

SELECT

R1: S

L

U

R

B

T













ABSOLUTE DATA

-278

30154

-217

T

SYSTEM INFO

PAGE

Main Menu Short Cut

The confirmation dialog box appears.

DATA

JOB

DOUT

MOVE

END

ARC WELDING

VARIABLE

B001

IN/OUT

In Out

EDIT DISPLAY

FD/CF

CF

PARAMETER

SETUP

UTILITY

HOME POSITIONING

R1: S

L

U

R

B

SELECT











T

DISPLAY SETUP

Aa

ROBOT

ABSOLUTE DATA

-278

30154

NO

T

SYSTEM INFO

PAGE

Main Menu Short Cut

Displayed position data of the axis are registered as home position.

When “NO” is selected, the registration will be canceled.

6-6

45/245

6.1 Home Position Calibration

 Changing the Absolute Data

To change the absolute data of the axis when home position calibration is completed, perform the following:

Explanation Operation

1 Select {ROBOT} under the main menu.

2 Select {HOME POSITION}.

3 Select the desired control group.

4 Select the absolute data to be registered.

Perform steps 3 and 4 which have been described in "

Registering All Axes at One Time " to select the desired control

group.

The number can now be entered.

DATA

JOB

DOUT

END

ARC WELDING

VARIABLE

B001

IN/OUT

In Out

EDIT DISPLAY UTILITY

FD/CF

CF

PARAMETER

SETUP

DISPLAY SETUP

Aa

HOME POSITIONING

SELECT

R1: S

L

B

T

U

R













ROBOT

ABSOLUTE DATA

30154

-278

-29912

-217

7745

15881

T

SYSTEM INFO

PAGE

Main Menu

Short Cut

5 Enter the absolute data using the numeric keys.

6 Press [ENTER].

Absolute data are modified.

6-7

46/245

6.1 Home Position Calibration



Clearing Absolute Data

Operation

1 Select {ROBOT} under the main menu.

2 Select {HOME POSITION}.

Explanation

3 Select {DATA} under the menu.

4 Select {CLEAR ALL DATA}.

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.

The pull-down menu appears.

DATA

CLEAR ALL DATA

DOUT

MOVE

END

ARC WELDING

VARIABLE

B001

IN/OUT

In Out

EDIT DISPLAY UTILITY

FD/CF

CF

PARAMETER

SETUP

DISPLAY SETUP

Aa

HOME POSITIONING

SELECT

R1: S

L

U

R

B

T













ROBOT

ABSOLUTE DATA

-278

30154

-29912

-217

7745

15881

T

SYSTEM INFO

PAGE

Main Menu Short Cut

The confirmation dialog box appears.

DATA

JOB

DOUT

MOVE

END

ARC WELDING

VARIABLE

B001

IN/OUT

In Out

EDIT

DISPLAY

UTILITY

FD/CF

CF

PARAMETER

SETUP

DISPLAY SETUP

Aa

HOME POSITIONING

R1: S

L

U

R

B

T

SELECT

ABSOLUTE DATA











YES



-278

30154

-29912

-217

7745

15881

NO

T

ROBOT

SYSTEM INFO

PAGE

Main Menu Short Cut

5 Select "YES".

The all absolute data are cleared.

When "NO" is selected, the operation will be canceled.

DATA

JOB

DOUT

MOVE

END

ARC WELDING

VARIABLE

B001

IN/OUT

In Out

EDIT DISPLAY

FD/CF

CF

PARAMETER

SETUP

DISPLAY SETUP

Aa

UTILITY

HOME POSITIONING

SELECT

R1: S

L

U

R

B

T













ROBOT

ABSOLUTE DATA

T

SYSTEM INFO

PAGE

Main Menu Short Cut

6-8

47/245

6.1 Home Position Calibration

6.1.3

Manipulator Home Position

With the MOTOMAN-HP3, the home position is as follows.

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

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

°)

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

°)

NOTE

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

6-9

48/245

6.2 Position Deviation Check Using the Check Program

6.2 Position Deviation Check Using the Check

Program

Use the check program to check if positions are deviated with the following procedure.

1. Call up the check program in which the check point is taught (the job for the check point) and operate 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 " 6.4 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 was hit against a workpiece, move all axes, to the check point by joint motion. Then,

proceed to " 6.3.3 Home Position Data Correction ".

Enlarged View

6-10

49/245

6.3 Verifying the Check Program

6.3 Verifying the Check Program

6.3.1

Verifying the Check Program Operation

Call up the check program in which the check point is taught (the job for the check point) and operate the manipulator at low speed.

6.3.2

Verifying the Check Point

Use the check program to check if positions are deviated. If the tool tip points the check point exactly as shown in the following figure, there is no deviation from the position. 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 was hit against a workpiece, move all axes, to the check point by joint motion.

Enlarged View

6-11

50/245

6.3 Verifying the Check Program

6.3.3

Home Position Data Correction

When there is a deviation from the positions, correct the home position data with the following procedure.

1. Check the values of the following pulses. (If there is no deviation, the following two values coincide.)

• Command position pulse of the check point which was taught in advance

• Current position pulse where the manipulator (tool tip) was moved to the check point after performing the check program

Displaying the Command Position Pulse

Operation

1 Select {ROBOT} under the main menu.

2 Select {COMMAND

POSITION}.

Explanation

The command position pulse values appear.

Note the values.

Displaying the Current Position Pulse

Operation

1 Select {ROBOT} under the main menu.

2 Select {CURRENT

POSITION}.

Explanation

The current position pulse values appear.

Note the values.

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 the HOME POSITIONING window, add the difference pulse value to the absolute data of the axis whose motor or encoder, etc. was replaced.

4. Modify the home position data by following the procedures described in " 6.1.2

Calibrating Operation ".

5. Confirm that the command position pulse and the current position pulse coincide.

The home position data have been corrected. Proceed to " 6.4 Setting the Second

Home Position (Check Point) ".

6-12

51/245

6.4 Setting the Second Home Position (Check Point)

6.4 Setting the Second Home Position (Check Point)

WARNING

• Be aware of safety hazards when performing the position confirmation of the second home position (check point).

Abnormality of the PG system may be a cause for alarm. The manipulator may operate in an unexpected manner, and there is a risk of damage to equipment or injury to personnel.

• Before operating the manipulator, check that the SERVO ON lamp goes out when the emergency stop buttons on the front face of

NXC100 and the programming pendant are pressed.

Injury or damage to machinery may result if the manipulator cannot be stopped in case of an emergency.

• Observe the following precautions when performing teaching operations within the P-point maximum envelope of the manipulator :

- View the manipulator from the front whenever possible.

- Always follow the predetermined operating procedure.

- Ensure that you have a safe place to retreat in case of emergency.

Improper or unintended manipulator operation may result in injury.

• Prior to performing the following operations, be sure that no one is in the P-point maximum envelope of the manipulator, and be sure that you are in a safe place when:

- Turning ON the NXC100 power

- Moving the manipulator with the programming pendant

- Running the system in the check mode

- Performing automatic operations

Injury may result from contact with the manipulator if persons enter the P-point maximum envelope of the manipulator.

• Always press the emergency stop button immediately if there are problems.

Emergency stop buttons are attached on the front face of the NXC100 and the programming pendant.

6-13

52/245

6.4 Setting the Second Home Position (Check Point)

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.

- Always return the programming pendant to the user’s designated place after use.

If the programming pendant is inadvertently left on the manipulator, a fixture, or on the floor, the manipulator or a tool could collide with it during manipulator movement, possibly causing injury or equipment damage.

6-14

53/245

6.4 Setting the Second Home Position (Check Point)

6.4.1

Purpose of Position Check Operation

If the absolute number of rotation detected at power supply ON does not match the data stored in the absolute encoder the last time the power supply was turned off, an alarm is issued when the controller power is turned ON.

There are two possible causes of this alarm:

• Error in the PG system

• The manipulator was moved after the power supply was turned OFF.

If there is an error with the PG system, the manipulator may 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.

"OUT OF RANGE (ABSO DATA)" alarm occurs

Reset alarm

Turn ON servo power

Procedure After Alarm Occurs



Position confirmation operation



Compare second home position (check point)* pulses with current position pulses

OK

NG

Alarm occurs again



Correct defective axis

• Replace PG system

• Home position calibration

∗ Position checking point

Playback possible



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" is performed.

6-15

54/245

6.4 Setting the Second Home Position (Check Point)

 Pulse Difference Check

The pulse number at the second home position is compared with that at the current position. If the difference is within the allowable range, playback is enabled. If not, the alarm occurs again.

• The allowable range pulse is the number of pulses per rotation of the motor (PPR data).

• The initial value of the second home position is the home position (where all axes are at

pulse 0). The second home position can be changed. For details, refer to " 6.4.2

Procedure for the Second Home Position Setting (Check Point) ".

 Alarm Occurrence

If the alarm occurs again, there may be an error in the PG system. 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.

However, as a rule, always perform "CONFIRM POSITION".

Under the above special conditions, the manipulator moves as follows:

After starting, the manipulator moves at low speed (1/10 of the maximum speed) to the step indicated by the cursor. If it is stopped and restarted during this motion, the low speed setting is retained until the step at cursor is reached. Regardless of cycle setting, the manipulator stops after the cursor step is reached. Starting the manipulator again then moves it at the programmed speed and cycle of the job.

6-16

55/245

6.4 Setting the Second Home Position (Check Point)

6.4.2

Procedure for the Second Home Position Setting

(Check Point)

Apart from the "home position" of the manipulator, the second home position can be set up as a check point for absolute data. Use the following steps to set the specified point.

If two or more manipulators or stations are controlled by one controller, the second home position must be set for each manipulator or station.

Operation

1 Select {ROBOT} under the main menu.

2 Select {SECOND HOME

POS}.

Explanation

The SECOND HOME POS window appears.

The message “Available to move to and modify specified point” is shown.

DATA

JOB

DOUT

END

ARC WELDING

VARIABLE

B001

EDIT DISPLAY

FD/CF

CF

PARAMETER

SETUP

UTILITY

SECOND HOME POS

SPECIFIED

R1: S

L

U

R

B

T

0

0

0

0

0

0

IN/OUT

In Out

DISPLAY SETUP

Aa

ROBOT

T

CURRENT

0

0

0

0

0

0

DIFFERENCE

0

0

0

0

0

0

SYSTEM INFO

PAGE

Available to move to and modfy specified point Main Menu Short Cut

3

GO BACK

Press the page key ,

PAGE

or select "PAGE" to display the selection window for the control group.

The group axes by which the second home position is set is selected when there are two or more group axes.

DATA

JOB

DOUT

MOVE

END

ARC WELDING

VARIABLE

B001

EDIT

FD/CF

CF

SETUP

DISPLAY UTILITY

PARAMETER

SECOND HOME POS

SPECIFIED

R1: S

L

U

R

B

T

0

0

0

0

0

0

CURRENT

0

0

0

0

0

0

T

DIFFERENCE

0

0

0

0

0

0

IN/OUT

In Out

DISPLAY SETUP

Aa

ROBOT

SYSTEM INFO

R1

S1

S2

:ROBOT1

:STATION1

:STATION2

PAGE

Main Menu Short Cut

Available to move to and modify specified point

4 Press the axis keys.

5 Press [MODIFY] and

[ENTER].

Move the manipulator to the new second home position.

The second home position is changed.

6-17

56/245

6.4 Setting the Second Home Position (Check Point)

6.4.3

Procedure after the Alarm

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 operate in an unexpected manner, and there is a risk of damage to equipment or injury to personnel.

If the "OUT OF RANGE (ABSO DATA)" alarm occurs, perform the followings

• Reset the alarm

• Turn Servo power ON and confirm the second home position. After the confirmation, if the PG system is found to be the cause of the alarm, perform the necessary operation, such as replacing the PG, etc.

The robot current position data when turning main power supply OFF and ON can be confirmed in “POWER ON/OFF POS" window.

SUPPLE-

MENT

Refer to " 7.7 Position Data When Power is Turned ON/OFF " for details on the

“POWER ON/OFF POS" window.

Operation

1 Select {ROBOT} under the main menu.

2 Select {SECOND HOME

POS}.

Explanation

The SECOND HOME POS window appears.

DATA

JOB

DOUT

MOVE

END

ARC WELDING

VARIABLE

B001

EDIT DISPLAY

FD/CF

CF

PARAMETER

SETUP

UTILITY

SECOND HOME POS

SPECIFIED

R1: S

L

U

R

B

T

0

0

0

0

0

0

IN/OUT

In Out

DISPLAY SETUP

Aa

ROBOT

CURRENT

0

0

0

0

0

0

T

DIFFERENCE

0

0

0

0

0

0

SYSTEM INFO

Main Menu Short Cut

PAGE

Availabel to move to or modify specified point

6-18

57/245

6.4 Setting the Second Home Position (Check Point)

3

Operation

GO BACK

Press the page key ,

PAGE

or select "PAGE" to display the selection window for the control group.

The group axes by which the second home position is set is selected when there are two or more group axes.

DATA

JOB

DOUT

MOVE

END

ARC WELDING

VARIABLE

B001

EDIT DISPLAY UTILITY

FD/CF

CF

PARAMETER

SETUP

SECOND HOME POS

SPECIFIED

R1: S

L

U

R

B

T

0

0

0

0

0

0

IN/OUT

In Out

DISPLAY SETUP

Aa

CURRENT

0

0

0

0

0

0

T

DIFFERENCE

0

0

0

0

0

0

ROBOT

SYSTEM INFO

R1

S1

S2

:ROBOT1

:STATION1

:STATION2

PAGE

Main Menu Short Cut

Explanation

Available to move to and modify specified point

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 error is beyond the allowed range, the alarm occurs again.

6-19

58/245

6.5 Loading the NXC100 Data

6.5 Loading the NXC100 Data

After replacing the NXC100, make sure to follow the instructions below to load the NXC100 data. Load the NXC100 data from the Compact Flash card that has been used to save the

data as described in " 4.2 Saving of the NXC100 Data ".

1

2

Operation

Turn OFF the power supply to the NXC100.

Open the Comapct Flash slot cover of the programming pendant and insert the Compact Flash card. Then close the cover.

REMOTE

PLAY

TEACH START HOLD

Explanation

Compact Flash slot

!?

3 Turn ON the power supply to the NXC100 while pressing the [MAIN MENU]

MAIN

key .

Release your finger from the

[MAIN MENU] key

MAIN

MENU

after three seconds.

Make sure the inserting direction of the Compact Flash card before inserting it into the slot.

X-

S-

Y-

L

LAYOUT

MULTI

COORD

MAIN

MENU

DIRECT

OPEN

SHORT

CUT

SERVO

ON

READY

GO BACK

PAGE

AREA

!?

ASSIST

CANCEL

X+

S+

SERVO ON

HIGH

SPEED

X-

R-

X+

R+

Y+

L

Y

Y+

6-20

59/245

6.5 Loading the NXC100 Data

3 (cont’d)

Operation Explanation

The main menu window of the maintenance mode appears on the programming pendant display approximately after forty seconds.

SYSTEM

FILE

TOOL

CF

Main Menu Short Cut

Maintenance mode

4 Select {SYSTEM} under the main menu.

5 Select {SECURITY}.

If the above window is not displayed, turn OFF the power supply to the NXC100 and try the step 3 again.

The sub menu appears.

The SECURITY MODE selection window appears.

SYSTEM

FILE

SECURITY MODE

SECURITY MODE EDITING MODE

TOOL

CF

6 Press [SELECT] to select

"MANAGEMENT MODE".

Main Menu Short Cut

Maintenance mode

The SECURITY MODE selection dialog box appears.

SYSTEM

FILE

SECURITY MODE

SECURITY MODE

OPERATING MODE

EDITING MODE

MANAGEMENT MODE

TOOL

CF

Main Menu Short Cut

Maintenance mode

6-21

60/245

7

Operation

Input the user ID.

6.5 Loading the NXC100 Data

Explanation

The user ID input window appears.

The user ID of the Management mode can now be input.

SYSTEM

FILE

SECURITY

Password=

MODE

TOOL

CF

Main Menu Short Cut

Maintenance mode

SUPPLE-

MENT

At the factory, following user ID is preset.

Management mode: [99999999]

8

9

Press [ENTER].

Select {TOOL} under the main menu.

The security mode is changed to the Management mode.

The sub menu appears.

SYSTEM

FILE

TOOL

CF

CompactFlash

10 Select {CompactFlash}.

Main Menu Short Cut

Maintenance mode

The CMOS SAVE/LOAD display appears.

SYSTEM

FILE

TOOL

CF

CMOS SAVE

CMOS LOAD

Main Menu Short Cut Maintenance mode

6-22

61/245

6.5 Loading the NXC100 Data

Operation

11 Move the cursor to "CMOS

LOAD" and press

[SELECT].

Explanation

The confirmation dialog box appears.

SYSTEM

FILE

CMOS SAVE

CMOS LOAD

TOOL

CF

Load?

YES NO

12 Select "YES".

Maintenance mode Main Menu

Short Cut

The CMOS data are loaded to the NXC100 from the Compact

Flash card in the programming pendant.

PROHIBITED

• The hourglass icon appears on the programming pendant display while the CMOS data are loaded.

Do not turn OFF the power supply to the NXC100 while the

CMOS data are loaded.

Failure to observe this instruction may destroy the

CMOS data.

SYSTEM

FILE

TOOL

CF

CMOS SAVE

CMOS LOAD

The hourglass icon appears while the

CMOS data are loaded.

Main Menu Short Cut

Maintenance mode

13 Loading is completed.

If the programming pendant blips approximately after sixty seconds from the start of data loading and the hourglass icon disappears, loading of CMOS data is completed. Turn OFF the power supply to the NXC100.

6-23

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7 System Diagnosis

7.1 System Version

It is possible to check the system CPU version information as follows.

Explanation Operation

1 Select {SYSTEM INFO} under the main menu.

2 Select {VERSION}.

The VERSION window appears.

DATA

VERSION

SYSTEM

PARAM

MODEL

APPLI

LANG

EDIT DISPLAY UTILITY

NS3.12.00A(US)-00

1.92

EA1400N-A0*

ARC WELD

3.12-00-00 / 3.12-00-00

CPU

NCP01

NPP01

AX*#0

SYSTEM ROM

3.12

3.10-00

********

BOOT ROM

--------

1.58

********

Main Menu Short Cut

7.1 System Version

7-1

63/245

7.2 Manipulator Model

7.2 Manipulator Model

It is possible to check the manipulator model as follows.

Operation

1 Select {ROBOT} under the main menu.

2 Select {MANIPULATOR

TYPE}.

Explanation

The ROBOT AXIS CONFIG window appears.

DATA EDIT

ROBOT AXIS CONFIG

AXIS CONFIGURATION

DISPLAY

R1: EA1400-A0*

S1: TURN-1

0011-1111

0000-0001

UTILITY

Main Menu Short Cut

7-2

64/245

7.3 Input/Output Status

7.3 Input/Output Status

7.3.1

Universal Input

The status of input signal which is referred to by input instruction of a job can be confirmed.

 Universal Input Window

Operation Explanation

1 Select {IN/OUT} under the main menu.

2 Select {UNIVERSAL INPUT}.

The UNIVERSAL INPUT window appears.

DATA EDIT DISPLAY UTILITY

UNIVERSAL INPUT

GROUP IG#001

IN#0001 #00010

IN#0002 #00011

IN#0003 #00012

IN#0004 #00013

IN#0005 #00014

IN#0006 #00015

IN#0007 #00016

IN#0008 #00017

0:DEC. 00:HEX.

















PAGE

Main Menu Short Cut

 Universal Input Simple Window

Operation Explanation

1 Select {IN/OUT} under the main menu.

2 Select {UNIVERSAL INPUT}.

The UNIVERSAL INPUT window appears.

2 Select {SIMPLE} from the pull-down menu of

{DISPLAY}.

The UNIVERSAL INPUT simple window appears.

DATA EDIT

UNIVERSAL INPUT

NO.

#0001X

#0002X

#0003X

#0004X

#0005X

#0006X

#0007X

#0008X

#0009X

#0010X

#0011X

#0012X

#0013X

DISPLAY UTILITY

7654_3210

0000_0000

0000_0000

0000_0000

0000_0000

0000_0000

0000_0000

0000_0000

0000_0000

0000_0000

0000_0000

0000_0000

0000_0000

0000_0000

Main Menu Short Cut

7-3

65/245

7.3 Input/Output Status

7.3.2

Universal Output

The status of the output signal set by the output instruction can be confirmed and modified.



Universal Output Window

Operation

1 Select {IN/OUT} under the main menu.

2 Select {UNIVERSAL

OUTPUT}.

Explanation

The UNIVERSAL OUTPUT window appears.

DATA EDIT DISPLAY

UNIVERSAL OUTPUT

GROUP

0G#01

OUT#0001 #10010

OUT#0002 #10011

OUT#0003 #10012

OUT#0004 #10013

OUT#0005 #10014

OUT#0006 #10015

OUT#0007 #10016

OUT#0008 #10017













UTILITY

3:DEC. 03:HEX.

PAGE

Main Menu

Short Cut



Universal Output Simple Window

Operation

1 Select {IN/OUT} under the main menu.

2 Select {UNIVERSAL

OUTPUT}.

3 Select {SIMPLE} from the pull-down menu of

{DISPLAY}.

Explanation

The UNIVERSAL OUTPUT window appears.

The UNIVERSAL OUTPUT simple window appears.

DATA EDIT

UNIVERSAL OUTPUT

NO.

#1001X

#1002X

#1003X

#1004X

#1005X

#1006X

#1007X

#1008X

#1009X

#1010X

#1011X

#1012X

#1013X

DISPLAY

7654_3210

0000_0011

0000_0010

0000_0000

0000_0000

0000_0000

0000_0000

0000_0000

0000_0000

0000_0000

0000_0000

0000_0000

0000_0000

0000_0000

UTILITY

Main Menu

Short Cut

7-4

66/245

7.3 Input/Output Status

 Modifying the Output Status

The status of universal output signal can be changed by the operation below.

Operation

1 Select the desired output signal number.

2 Press [INTER LOCK] +

[SELECT].

Explanation

Select the status of the desired output signal, “ the UNIVERSAL OUTPUT window.

 ” or “”, in

The status is changed. (  :ON status,  :OFF status)

DATA EDIT DISPLAY UTILITY

UNIVERSAL OUTPUT

GROUP

OUT#0001 #10010

OUT#0002 #10011

OUT#0003 #10012

OUT#0004 #10013

OUT#0005 #10014

OUT#0006 #10015

OUT#0007 #10016

OUT#0008 #10017













3:DEC. 03:HEX.

PAGE

Main Menu Short Cut

NOTE

The status of universal output signal can be changed only when the mode is set to the teach mode.

7-5

67/245

7.3 Input/Output Status

7.3.3

Specific Input

 Specific Input Window

Operation

1 Select {IN/OUT} under the main menu.

2 Select {SPECIFIC INPUT}.

Explanation

The SPECIFIED INPUT window appears.

DATA EDIT

SPECIFIED INPUT

GROUP

SIN#0001 #40010

SIN#0002 #40011

SIN#0003 #40012

SIN#0004 #40013

SIN#0005 #40014

SIN#0006 #40015

SIN#0007 #40016

SIN#0008 #40017

DISPLAY UTILITY

















0:DEC. 00:HEX.

SYSTEM ALM REQ

SYSTEM MSG REQ

USER ALM REQ

USER MSG REQ

ALM/ERR RESET

SPEED LIMIT

PAGE

Main Menu Short Cut

 Specific Input Simple Window

Operation

1 Select {IN/OUT} under the main menu.

2 Select {SPECIFIC INPUT}.

2 Select {SIMPLE} from the pull-down menu of

{DISPLAY}.

Explanation

The SPECIFIED INPUT window appears.

The SPECIFIED INPUT simple window appears.

DATA EDIT

SPECIFIED INPUT

NO.

#4001X

#4002X

#4003X

#4004X

#4005X

#4006X

#4007X

#4008X

#4009X

#4010X

#4011X

#4012X

#4013X

DISPLAY

UTILITY

7654_3210

0000_0000

0000_0000

0000_0000

0000_0000

0000_0000

1000_0000

0000_0000

0000_0000

0000_0000

0000_0000

0000_0000

0000_0000

0000_0000

Main Menu Short Cut

7-6

68/245

7.3 Input/Output Status

7.3.4

Specific Output

 Specific Output Window

Operation Explanation

1 Select {IN/OUT} under the main menu.

2 Select {SPECIFIC OUTPUT}.

The SPECIFIED OUTPUT window appears.

DATA EDIT

SPECIFIED OUTPUT

GROUP

SOUT#0001 #50010

SOUT#0002 #50011

SOUT#0003 #50012

SOUT#0004 #50013

SOUT#0005 #50014

SOUT#0006 #50015

SOUT#0007 #50016

SOUT#0008 #50017

DISPLAY

UTILITY

















0:DEC. 00:HEX.

MAJOR ALM OCCUR

MINOR ALM OCCUR

SYSTEM ALM OCCUR

USER ALM OCCUR

ERROR OCCUR

MEMORY BTRY WEAK

ENCDR BTRY WEAK

COOLING FAN ERR

PAGE

Main Menu Short Cut

 Specific Output Simple Window

Operation Explanation

1 Select {IN/OUT} under the main menu.

2 Select {SPECIFIC OUTPUT}.

The SPECIFIED OUTPUT window appears.

2 Select {SIMPLE} from the pull-down menu of

{DISPLAY}.

The SPECIFIED OUTPUT simple window appears.

DATA EDIT

SPECIFIED OUTPUT

NO.

#1001X

#1002X

#1003X

#1004X

#1005X

#1006X

#1007X

#1008X

#1009X

#1010X

#1011X

#1012X

#1013X

DISPLAY UTILITY

7654 _ 3210

0000_0000

0000_0000

0000_0000

0000_0000

0000_1010

0000_0000

0000_0000

0000_0110

0000_0000

0000_0000

0000_0000

0000_0000

0000_0000

Main Menu

Short Cut

7-7

69/245

7.3 Input/Output Status

7.3.5

RIN Input

 RIN Input Window

Operation

1 Select {IN/OUT} under the main menu.

2 Select {RIN}.

Explanation

The RIN window appears.

DATA

RIN INPUT 1

RIN#001

RIN#002

RIN#003

RIN#004

RIN#005

EDIT

DISPLAY











UTILITY

DIRECT IN1 (SERVO)

DIRECT IN2 (SERVO)

DIRECT IN3 (SERVO)

DIRECT IN4 (SERVO)

DIRECT IN5 (SERVO)

Main Menu

Short Cut

7-8

70/245

7.3 Input/Output Status

7.3.6

Signal Number Search

A search can be made for a signal number of a universal input, universal output, specific input, and specific output.

Signal No.

DATA EDIT DISPLAY UTILITY

UNIVERSAL INPUT

GROUP IG#001 IG#01

IN#0001 #00010

IN#0002 #00011

IN#0003 #00012

IN#0004 #00013

IN#0005 #00014

IN#0006 #00015

IN#0007 #00016

IN#0008 #00017

0:DEC. 00:HEX.

















PAGE

Main Menu Short Cut

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

7-9

71/245

7.3 Input/Output Status



Direct Search on the Universal/Specified Input/Output Window

Operation Explanation

1 Move the cursor to a signal number in the UNIVERSAL/

SPECIFIED INPUT/OUTPUT window, and press

[SELECT].

Numeric values can now be entered.

DATA EDIT

UNIVERSAL INPUT

GROUP IG#001

#00010

IN#0002 #00011

IN#0003 #00012

IN#0004 #00013

IN#0005 #00014

IN#0006 #00015

IN#0007 #00016

IN#0008 #00017

DISPLAY UTILITY

0:DEC. 00:HEX.

















PAGE

Main Menu Short Cut

2 Enter the signal number to be searched.

3 Press [ENTER] to start the search.

Type the signal number in the number input line.

The page where the signal number exists appers.

DATA EDIT

UNIVERSAL INPUT

GROUP IG#006

IN#0041 #00060

IN#0042 #00061

IN#0043 #00062

IN#0044 #00063

IN#0045 #00064

IN#0046 #00065

IN#0047 #00066

IN#0048 #00067

DISPLAY UTILITY

0:DEC. 00:HEX.

















PAGE

Main Menu Short Cut

7-10

72/245

7.3 Input/Output Status



Search from the Menu

Operation Explanation

1 Select {EDIT} under the menu in the UNIVERSAL/

SPECIFIED INPUT/OUTPUT window.

The pull-down menu appears.

DATA EDIT

IN#0007 #00016

DISPLAY UTILITY

GROUP

SEARCH SIGNAL

NO.

IG#001

IN#0001 #00010

IN#0003 #00012

IN#0004 #00013

IN#0005 #00014

0:DEC. 00:HEX.

















2 Select {SEARCH SIGNAL

NO.}.

PAGE

Main Menu Short Cut

Numeric values can now be entered.

DATA EDIT

UNIVERSAL INPUT

GROUP IG#001

#00010

IN#0002 #00011

IN#0003 #00012

IN#0004 #00013

IN#0005 #00014

IN#0006 #00015

IN#0007 #00016

IN#0008 #00017

DISPLAY UTILITY

0:DEC. 00:HEX.

















PAGE

Main Menu Short Cut

3 Enter the signal number to be searched.

4 Press [ENTER] to start the search.

Type the signal number in the number input line.

The page where the signal number exists appears.

7-11

73/245

7.3 Input/Output Status

7.3.7

Relay Number Search

A search can be made for a relay number of a universal input, universal output, specific input, and specific output.

DATA EDIT DISPLAY UTILITY

UNIVERSAL INPUT

GROUP IG#001

IN#0001 #00010

IN#0002 #00011

IN#0003 #00012

IN#0004 #00013

IN#0005 #00014

IN#0006 #00015

IN#0007 #00016

IN#0008 #00017

0:DEC. 00:HEX.

















PAGE

Main Menu Short Cut

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

7-12

74/245

7.3 Input/Output Status



Direct Search on the Universal/Specified Input/Output Window

Operation Explanation

1 Move the cursor to a relay number in the UNIVERSAL/

SPECIFIED INPUT/OUTPUT window, and press

[SELECT].

Numeric values can now be entered.

DATA EDIT DISPLAY

UNIVERSAL INPUT

GROUP IG#001

IN#0001

IN#0002 #00011

IN#0003 #00012

IN#0004 #00013

IN#0005 #00014

IN#0006 #00015

IN#0007 #00016

IN#0008 #00017

UTILITY

0:DEC. 00:HEX.

















PAGE

Turn on servo power Main Menu Short Cut

2 Enter the relay number to be searched.

3 Press [ENTER] to start the search.

Type the relay number in the number input line.

The page where the relay number exists appers.

DATA EDIT DISPLAY UTILITY

UNIVERSAL INPUT

GROUP IG#005

IN#0033 #00050

IN#0034 #00051

IN#0035 #00052

IN#0036 #00053

IN#0037 #00054

IN#0038 #00055

IN#0039 #00056

IN#0040 #00057

0:DEC. 00:HEX.

















Main Menu Short Cut

PAGE

Turn on servo power

7-13

75/245

7.3 Input/Output Status



Search from the Menu

Operation Explanation

1 Select {EDIT} under the menu in the UNIVERSAL/

SPECIFIED INPUT/OUTPUT window.

The pull-down menu appears.

DATA EDIT DISPLAY UTILITY

GROUP

SEARCH SIGNAL

NO.

IG#001

IN#0003 #00012

IN#0004 #00013

IN#0005 #00014

IN#0007 #00016

0:DEC. 00:HEX.

















2 Select {SEARCH RELAY

SIGNAL NO.}.

PAGE

Turn on servo power Main Menu Short Cut

Numeric values can now be entered.

DATA EDIT DISPLAY

UNIVERSAL INPUT

GROUP

IG#001

IN#0001

IN#0002 #00011

IN#0003 #00012

IN#0004 #00013

IN#0005 #00014

IN#0006 #00015

IN#0007 #00016

IN#0008 #00017

UTILITY

0:DEC. 00:HEX.

















PAGE

Turn on servo power Main Menu

Short Cut

3 Enter the relay number to be searched.

4 Press [ENTER] to start the search.

Type the relay number in the number input line.

The page where the relay number exists appears.

7-14

76/245

7.3 Input/Output Status

7.3.8

Modification of the Signal Name

The name of the universal input or output signal can be modified.

DATA EDIT DISPLAY

UNIVERSAL INPUT

GROUP IG#001

IN#0001 #00010

IN#0002 #00011

IN#0003 #00012

IN#0004 #00013

IN#0005 #00014

IN#0006 #00015

IN#0007 #00016

IN#0008 #00017

UTILITY

0:DEC. 00:HEX.

















PAGE

Main Menu Short Cut

The name can be modified in the following two ways.

• Direct modification on the

UNIVERSAL/SPECIFIED INPUT/OUTPUT window

.

• Modification from the menu

 Direct Modification on the Universal/Specified Input/Output Window

Operation Explanation

1 Move the cursor to the signal name to be modified in the

UNIVERSAL/SPECIFIED

INPUT/OUTPUT window, and press [SELECT].

2 Enter the signal name.

3 Press [ENTER].

The window for character input appears.

New signal name is registered.

DATA EDIT

UNIVERSAL INPUT

GROUP IG#001

IN#0001 #00010

IN#0002 #00011

IN#0003 #00012

IN#0004 #00013

IN#0005 #00014

IN#0006 #00015

IN#0007 #00016

IN#0008 #00017

DISPLAY UTILITY

0:DEC. 00:HEX.

















TEST SIGNAL

PAGE

Main Menu Short Cut

7-15

77/245

7.3 Input/Output Status

 Modification from the Menu

Operation Explanation

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.

DATA EDIT DISPLAY UTILITY

GROUP

SEARCH SIGNAL

NO.

IN#0001 #00010

IN#0003 #00012

IN#0004 #00013

IN#0005 #00014

IN#0006 #00015

IN#0007 #00016

0:DEC. 00:HEX.

















TEST SIGNAL

3

4

5

Select {RENAME}.

Enter the signal name.

Press [ENTER].

PAGE

Main Menu Short Cut

The window for character input appears.

New signal name is registered.

DATA EDIT DISPLAY

UNIVERSAL INPUT

GROUP IG#001

IN#0001 #00010

IN#0002 #00011

IN#0003 #00012

IN#0004 #00013

IN#0005 #00014

IN#0006 #00015

IN#0007 #00016

IN#0008 #00017

UTILITY

0:DEC. 00:HEX.

















TEST SIGNAL

PAGE

Main Menu Short Cut

7-16

78/245

7.4 System Monitoring Time Display

7.4 System Monitoring Time Display

7.4.1

System Monitoring Time Display Window

The status of system operation, e.g. power ON time, can be checked.

Operation

1 Select {SYSTEM INFO}.

2 Select {MONITORING

TIME}.

Explanation

The SYS MONITORING TIME window appears.

DATA EDIT DISPLAY

SYS MONITORING TIME

CONTROL POWER TIME

49:40’13

SERVO POWER TIME

43:51’25

PLAYBACK TIME

43:47’19

MOVING TIME

40:12’47

OPERATING TIME

25:28’49

UTILITY

(2005/07/23 14:58 )

(2005/07/23 14:58 )

(2005/07/23 14:58 )

(2005/07/23 14:58 )

(2005/07/23 14:58 )

PAGE

Main Menu Short Cut



CONTROL POWER TIME

Displays the cumulative time that the main power supply has been ON.



SERVO POWER TIME

Displays the cumulative time that the servo power supply has been ON.



PLAYBACK TIME

Displays the cumulative time during which playback was executed.



MOVING TIME

Displays the cumulative time that the manipulator was in motion.



OPERATING TIME

Displays the cumulative time spent in operation. For example, if the manipulator is used for spot welding, it displays the amount of time spent in spot welding; if the manipulator is used for handling, it displays the time spent in handling.

7-17

79/245

7.4 System Monitoring Time Display

7.4.2

Individual Window of the System Monitoring Time Display

GO BACK

If the page key

PAGE

is pressed, or "PAGE" is selected to display the selection window for the system monitoring time display, the servo power time, playback time, moving time, and eachapplication operating time by each control group are individually displayed.

DATA EDIT DISPLAY UTILITY

SERVO POWER TIME

ROBOT1

STATION1

STATION2

(2005/07/23 14:58 )

43:51’25

(2005/07/23 14:58 )

43:51’25

(2005/07/23 14:58 )

43:51’25

DATA

EDIT

PLAYBACK TIME

ROBOT1

STATION1

STATION2

DISPLAY UTILITY

(2005/07/23 14:58 )

43:47’17

(2005/07/23 14:58 )

43:47’17

(2005/07/23 14:58 )

0: 0’ 0

DATA EDIT

MOVING TIME

ROBOT1

STATION1

STATION2

DISPLAY UTILITY

(2005/07/23 14:58 )

40:12’17

(2005/07/23 14:58 )

40:12’17

0: 0’ 0

(2005/07/23 14:58 )

DATA EDIT

OPERATING TIME

APPLI1

DISPLAY UTILITY

(2005/07/23 14:58 )

25:28’49

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.

7-18

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7.4 System Monitoring Time Display

7.4.3

Clearing the System Monitoring Time Display

The moving time 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.

Operation Explanation

1 Select the time to be cleared.

The confirmation dialog box appears.

DATA EDIT DISPLAY

SYS MONITORING TIME

UTILITY

CONTROL POWER TIME

49:40’13

SERVO POWER TIME

43:51’25

PLAYBACK TIME

(2005/07/23 14:58 )

(2005/07/23 14:58 )

(2005/07/23 14:58 )

MOVING TIME

43:47’19

40:12’47

OPERATING TIME

25:28’49

YES

Initialize?

MOVING TIME

2 Select “YES.”

PAGE

Main Menu Short Cut

The cumulative time value at the cursor line is reset to 0, and a new time measurement begins.

DATA EDIT DISPLAY

SYS MONITORING TIME

UTILITY

CONTROL POWER TIME

49:40’13

(2005/07/23 14:58 )

SERVO POWER TIME (2005/07/23 14:58 )

43:51’25

PLAYBACK TIME (2005/07/23 14:58 )

43:47’19

MOVING TIME

0: 0’ 0

(2005/07/23 14:58 )

OPERATING TIME

25:28’49

(2005/07/23 14:58 )

PAGE

Main Menu Short Cut

7-19

81/245

7.5 Alarm History

7.5 Alarm History

7.5.1

Alarm History Window

The alarm history can be confirmed in the alarm history window. There are five types of alarm history windows: the "MAJOR ALARM" window, the "MINOR ALARM" window, the "USER

ALARM (SYSTEM)" window, the "USER ALARM (USER)" window, and the "OFF-LINE

ALARM" window. Each window shows the alarm code and the date and time.

Operation

1 Select {SYSTEM INFO} under the main menu.

2 Select {ALARM HISTORY}.

Explanation

The alarm history window appears.

DATA EDIT

MINOR ALARM

CODE

01 4200

DISPLAY

DATE

2005/07/23

UTILITY

CLOCK

15:01

SYSTEM ERROR (FILE DATA)

[1]

JOB ******** LINE **** STEP ***

PAGE

Main Menu

Short Cut

3

GO BACK

Press the page key

PAGE

to change the window, or select

"PAGE" to display the selection window for the alarm windows.

GO BACK

Each time the page key

PAGE

is pressed, the window changes

"MAJOR ALARM""MINOR ALARM""USER

ALARM(SYSTEM)”"USER ALARM(USER)""OFF-LINE

ALARM".

DATA EDIT

MINOR ALARM

CODE

01 4200

DISPLAY

DATE

2005/07/23

UTILITY

CLOCK

15:01

SYSTEM ERROR (FILE DATA)

[1]

MAJOR ALARM

MINOR ALARM

USER ALARM (SYSTEM)

PAGE

Main Menu Short Cut

7-20

82/245

7.5 Alarm History

7.5.2

Clearing the Alarm History

The history of the minor alarms and the user alarms (system and user) can be cleared.

Operation

1 Display the alarm history window to be cleared.

2 Select {DATA} under the menu.

Explanation

The pull-down menu "CLEAR HISTORY" appears.

DATA EDIT DISPLAY UTILITY

01 4200

DATE

2005/07/23

CLOCK

15:01

3 Select {CLEAR HISTORY}.

SYSTEM ERROR (FILE DATA)

[1]

JOB ******** LINE **** STEP ***

PAGE

Main Menu Short Cut

The confirmation dialog box appears.

DATA EDIT

MINOR ALARM

CODE

01 4200

DISPLAY

DATE

2005/07/23

UTILITY

TIME

15:01

4 Select “YES.”

Initialize?

YES

SYSTEM ERROR (FILE DATA)

[1]

JOB ******** LINE **** STEP ***

NO

PAGE

Main Menu Short Cut

The alarm history displayed is reset.

7-21

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7.6 I/O Message History

7.6 I/O Message History

7.6.1

I/O Message History Window

The I/O message history can be confirmed in the I/O MESSAGE HISTORY window.

The I/O MESSAGE HISTORY window shows the date and time, job name, line number, and step number of the I/O message that appeared on the window.

Operation Explanation

1 Select {SYSTEM INFO} under the main menu.

2 Select {I/O MSG HISTORY}.

The I/O MESSAGE HISTORY window appears.

DATA EDIT

I/O MESSAGE HISTORY

DISPLAY UTILITY

0001 GAS SHORTAGE

0002 WIRE SHORTAGE

0003

0004

0005

0006

0007

DATE:1999/06/16 12:00

JOB NAME:ARCON LINE:0006 STEP:004

Main Menu Short Cut

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.



Search

Use the following operation to search for the I/O message history.

Explanation Operation

1 Select {EDIT} under the menu.

2 Select {SEARCH}.

3 Enter the history No.

4 Press [ENTER].

The character input line appears.

The search for the input history number begins, and the I/O message is displayed.

7-22

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7.6 I/O Message History

7.6.2

Clearing the I/O Message History

Use the following operation to clear the I/O message history.

Operation

1 Select {DATA} under the menu.

2 Select {CLEAR HISTORY}.

Explanation

The confirmation dialog box appears.

DATA EDIT

I/O MESSAGE HISTORY

DISPLAY UTILITY

0001 GAS SHORTAGE

0002 WIRE SHORTAGE

0003

0004

0005

0006

0007

YES

Initialize?

NO

DATE:1999/06/16 12:00

JOB NAME:ARCON LINE:0006 STEP:004

Main Menu

Short Cut

3 Select “YES.” The displayed I/O message history is cleared.

7-23

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7.7 Position Data When Power is Turned ON/OFF

7.7 Position Data When Power is Turned ON/OFF

7.7.1

Power ON/OFF Position Window

The Power ON/OFF position window shows 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.

Operation

1 Select {ROBOT} under the main menu.

2 Select {POWER ON/OFF

POS}.

Explanation

The POWER ON/OFF POSITION window appears.

DATA EDIT DISPLAY UTILITY

POWER ON/OFF POSITION

OFF POS ON POS DIFFERENCE

R1: S

L

U

R

B

T

4775

8225

960

-336

-202

-10

4120

8225

960

-336

-203

-11

665

0

0

0

1

1

PAGE

Main Menu Short Cut

7-24

86/245

7.8 Current Position

7.8.1

Current Position Window

Operation

1 Select {ROBOT} under the main menu.

2 Select {CURRENT

POSITION} under the sub menu.

Explanation

The CURRENT POSITION window appears.

DATA EDIT DISPLAY UTILITY

CURRENT POSITION

COORDINATE PULSE TOOL 00

S1: S

R

B

L

U

T

0

0

0

0

0

0

7.8 Current Position

Main Menu

Short Cut

3 Select the types of coordinates to be displayed.

The pull-down menu appears.

DATA EDIT DISPLAY UTILITY

CURRENT POSITION

COORDINATE PULSE

S1: S

R

B

L

U

PULSE

BASE 0

ROBOT

USER

0

0

0

T 0

TOOL 00

PAGE

PAGE

Main Menu Short Cut

4 Select the desired coordinate system.

The type of coordinates being displayed is changed.

DATA EDIT DISPLAY UTILITY

CURRENT POSITION

COORDINATE: BASE

TOOL 00

R1:

X

Y

Z

915.00 mm

0.000 mm

765.000 mm

<ROBOT TYPE>

FRONT S< 180

UP R< 180

FLIP T< 180

Rx

Ry

Rz

180.00 deg.

0.00 deg.

0.00 deg.

PAGE

Main Menu Short Cut

7-25

87/245

7.9 Servo Monitoring

7.9 Servo Monitoring

7.9.1

Servo Monitor Window

The servo monitor window shows the servo-related data of each axis.

Monitor Items

FEEDBACK PULSE

ERROR PULSE

SPEED DEVIATION

SPEED INST

FEEDBACK SPEED

TORQUE SPEC

MAX. TORQUE

ENCODER ROTATE SUM

IN 1 TURN POSITION

MOTOR ABSOLUTE

Description

Feedback position (actual position) of each axis

“0” at the home position

Difference between the command position and the feedback position of each axis

Difference between the command speed and the feedback speed of each axis

Speed reference of each axis

Feedback speed (actual speed) of each axis

Torque reference of each axis

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

Accumulated number of encoder rotation when the control power supply of each axis is turned

ON

Position after one rotation of the encoder when the control power supply of each axis is turned

ON

Absolute value of the motor is calculated by adding the position in one rotation to the sum of the accumulated rotations when the control power supply of each axis is turned ON.

7-26

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7.9 Servo Monitoring

7.9.2

Changing the Monitor Items

Operation Explanation

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.

DATA EDIT

DISPLAY

UTILITY

SERVO MONITOR

FEEDBACK PULSE

R1: S

L

U

R

B

T

1805

234

995

123

237

2432

ERROR PULSE

300

0

0

0

0

0

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.

DATA

EDIT

SERVO MONITOR

DISPLAY

UTILITY

R1:

U

R

S

L

B

T

234

995

123

237

2432

ERROR PULSE

300

0

0

0

0

0

5 Select MONITOR ITEM 1 or

2, and view the sub-menu choices by the cursor key .

The sub-menu choices appear.

DATA EDIT

SERVO MONITOR

R1: S

L

U

R

B

T

DISPLAY UTILITY

234

123

2432

IN 1 TURN

ERROR PULSE

300

0

0

0

0

0

0

0

0

0

0

FEEDBACK SPEED

TORQUE SPEC

MAX TORQUE

ENCODER ROTATE SUM

6 Select a menu.

The type of monitor-related information is changed.

DATA

EDIT DISPLAY

SERVO MONITOR

SPEED INST

R1: S

L

U

R

B

T

4000

0

0

0

0

0

UTILITY

ERROR PULSE

300

0

0

0

0

0

7-27

89/245

7.9 Servo Monitoring

7.9.3

Clearing Maximum Torque Data

The data for the maximum torque can be cleared when the maximum torque-related information is being displayed.

Operation

1 Select {DATA} under the menu.

2 Select {MAX. TORQUE}.

Explanation

The clear max torque window appears.

DATA

EDIT

DISPLAY

UTILITY

CLEAR MAX. TORQUE

MAX TORQUE

ERROR PULSE

R1: S

R

B

L

U

T

30

70

80

20

40

30

300

0

0

0

0

0

The maximum torque data is cleared.

DATA EDIT DISPLAY UTILITY

SERVO MONITOR

MAX TORQUE

FEEDBACK PULSE

R1: S

R

B

L

U

T

0

0

0

0

0

0

0

0

0

0

0

0

7-28

90/245

8.1 Outline of Alarm

8 Alarm

8.1 Outline of Alarm

When an alarm of level 0 to 3 (major alarm) occurs, the servo power supply is turned OFF.

Alarm Code Classification

Alarm Code

0

1 to

3

4 to

8

9

Alarm Level

Level 0 (Major alarm)

(Off line alarm : Initial diagnosis/

Hardware diagnosis alarm)

Level 1 to 3 (Major alarm)

Level 4 to 8 (Minor alarm)

Level 9 (Minor alarm)

(I/O alarm)

Alarm Reset Method

It is not possible to reset by "RESET" under the ALARM window 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.

It is not possible to reset by "RESET" under the ALARM window 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.

After correcting the cause, it is possible to reset by "RESET" under the ALARM window or the system input signal (Alarm reset).

After correcting the cause for which the system input signal for the system or user alarm request turns ON, it is possible to reset by "RESET" under the ALARM window or the system input signal (Alarm reset).

8-1

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8.2 Alarm Display

8.2 Alarm Display

8.2.1

Displaying and Releasing Alarm

If an alarm occurs during operation, the manipulator stops immediately and the

ALARM window appears on the programming pendant indicating that the machine was stopped by an alarm.

ALARM No.

JOB

ALARM

EDIT DISPLAY UTILITY

ALARM 4100

ALARM 4321

ALARM 4315

1

OVERRUN (ROBOT)

SLURBT

OVERLOAD (MOMENT)

SLURBT

COLLISION DETECT

RESET

Main Menu Short Cut

If more than one alarm occurs simultaneously, all the alarms are displayed. Scroll the viewing area with the cursor key to view the alarm that is not currently displayed on the viewing area.

The following operations are available in the alarm status: 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}.

 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 specific signal "ALARM RESET" when using an external input signal

(specific input).

• Major Alarms

If a severe alarm such as hardware failure occurs, servo power is automatically shut OFF and the manipulator stops. Turn OFF the main power supply, remove the cause of the alarm, and then turn ON the power supply again.

8-2

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8.2 Alarm Display

8.2.2

Special Alarm Display

 Sub Data

Sub data such as data for the axis where the alarm occurred, may also be displayed for some alarms.

• Decimal data

Without signs: 0 to 65535

With signs: -32768 to 32767

• Binary data

The alarm occurrence data becomes “1”.

With 8 bits: 0000_0001

With 16 bits: 00000001_00000001

• Axis data

The axis where the alarm occurred is highlighted.

With robot axis: Robots 1 to 4

[ S L U R B T ]

With base axis: Robots 1 to 4

[ 1 2 3 ]

With station axis: Stations 1 to 12

[ 1 2 3 ]

• XYZ coordinate data

The coordinates where the alarm occurred are highlighted.

[ X Y Z ]

[ X Y Z Tx Ty Tz ]

• 123 data

The data for which the alarm occurred is highlighted.

[ 1 2 3 ]

• Control group data

The control group where the alarm occurred is highlighted.

[ R1 R2 S1 S2 S3 ]

 Multiple SERVOPACK System

In a system using more than one SERVOPACK, the number of the SERVOPACK where the alarm occurred is also displayed. The S1 switch of the AXA01 circuit board shows the

SERVOPACK number.

SV#1: SERVOPACK 1 (AXA01 circuit board S1 switch: 0)

SV#2: SERVOPACK 2 (AXA01 circuit board S1 switch: 1)

SV#3: SERVOPACK 3 (AXA01 circuit board S1 switch: 2)

SV#4: SERVOPACK 4 (AXA01 circuit board S1 switch: 3)

8-3

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8.2 Alarm Display

 Independent Control Function (Optional)

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)

TASK#6: Sub-task6 job (SUB6)

TASK#7: Sub-task7 job (SUB7)

8-4

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8.3 Alarm Message List

8.3 Alarm Message List

CAUTION

Before handling the system control circuit board “JANCD-NIF ∗∗−∗ ” for any remedies, consult YASKAWA representative. To handle the JANCD-NIF

∗∗−∗

, personnel must be appropriately skilled in maintenance mode operation.

JANCD-NIF

∗∗−∗

backs up very important file data for the user program with a battery.

Careless operation may delete registered data.

Alarm

Number

20

Message

CPU

COMMUNICA

TION ERROR

Alarm Message List

Sub

Code

Cause

An error occurred in communications between boards when the control power turned ON.

10

• No response was sent from the optional board #1.

20

• No response was sent from the optional board #2.

50

51

52

53

• No response was sent from the servo board #1.

• No response was sent from the servo board #2.

• No response was sent from the servo board #3.

• No response was sent from the servo board #4.

Remedy

• Turn the power OFF then back ON.

• Check that the optional board is correctly inserted.

• If the error occurs again, contact your

Yaskawa representative.

• Turn the power OFF then back ON.

• Check the connections of communications cable, terminator terminal, and the station number settings.

If the error occurs again, contact your Yaskawa representative.

8-5

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8.3 Alarm Message List

Alarm

Number

21

30

60

Alarm Message List

Message

Sub

Code

Cause

COMMUNICA

TION ERROR

(SERVO)

50

51

52

53

An error occurred in communications with the servo board #1.

• The communications CPU for the servo board #1 detected an error when the control power turned

ON.

An error occurred in communications with the servo board #2.

• The communications CPU for the servo board #2 detected an error when the control power turned

ON.

An error occurred in communications with the servo board #3.

• The communications CPU for the servo board #3 detected an error when the control power turned

ON.

An error occurred in communications with the servo board #4.

• The communications CPU for the servo board #4 detected an error when the control power turned

ON.

ROM ERROR The system program file is damaged.

1

• The NCP01 system program is damaged.

10

• The system program of optional board #1 is damaged.

20

• The system program of optional board #2 is damaged.

50

• The system program of servo board #1 is damaged.

51

• The system program of servo board #2 is damaged.

52

• The system program of servo board #3 is damaged.

53

COMMUNICA

TION ERROR

(I/O

MODULE)

1 to

15

• The system program of servo board #4 is damaged.

An error was detected in communications with an I/O module board when the control power turned ON.

Remedy

• Turn the power OFF then back ON.

• Check the connections of communications cable, terminator terminal, and the station number settings.

If the error occurs again, contact your Yaskawa representative.

If the error occurs again, contact your Yaskawa representative.

• Turn the power OFF then back ON.

• Check the connections of communications cable, terminator terminal, and the station number settings.

If the error occurs again, contact your Yaskawa representative.

*1

"AXC#



" may be displayed as "AXA#



" depending on the software version.

8-6

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8.3 Alarm Message List

Alarm Message List

Alarm

Number

100

101

102

103

103

Message

COMMUNICA

TION ERROR

(AXC#1)

*1

1

Sub

Code

COMMUNICA

TION ERROR

(AXC#2)

COMMUNICA

TION ERROR

(AXC#3)

(AXC#4)

*1

*1

COMMUNICA

TION ERROR

*1

COMMUNICA

TION ERROR

(AXC#4)

*1

2

1

2

1

2

1

2

Cause Remedy

An error occurred in communications with the servo board #1.

• The error was detected during the check of the CERF communication watchdog data.

An error occurred in communications with the servo board #1.

• The error was detected during the check of the number of the CERF communications.

An error occurred in communications with the servo board #2.

• The error was detected during the check of the CERF communication watchdog data.

An error occurred in communications with the servo board #2.

• The error was detected during the check of the number of the CERF communications.

An error occurred in communications with the servo board #3.

• The error was detected during the check of the CERF communication watchdog data.

An error occurred in communications with the servo board #3.

• The error was detected during the check of the number of the CERF communications.

An error occurred in communications with the servo board #4.

• The error was detected during the check of the CERF communication watchdog data.

An error occurred in communications with the servo board #4.

• The error was detected during the check of the number of the CERF communications.

• Turn the power OFF then back ON.

If the error occurs again, contact your Yaskawa representative.

• Turn the power OFF then back ON.

If the error occurs again, contact your Yaskawa representative.

• Turn the power OFF then back ON.

If the error occurs again, contact your Yaskawa representative.

*1

"AXC#" may be displayed as "AXA#" depending on the software version.

8-7

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8.3 Alarm Message List

Alarm

Number

200

Message

MEMORY

ERROR

(PARAMETE

R FILE)

210

220

230

240

MEMORY

ERROR

(SYSTEM

CONFIG-

DATA)

MEMORY

ERROR

(JOB MNG

DATA)

Alarm Message List

Sub

Code

Cause

11

12

13

14

7

8

9

10

15

0

5

6

3

4

1

2

The parameter file is damaged.

0 RC parameter

RO parameter

SV parameter

SVM parameter

SC parameter

SD parameter

CIO parameter

FD parameter

AP parameter

RS parameter

SE parameter

SVC parameter

AMC parameter

SVP parameter

MF parameter

SVS parameter

The system configuration information data are damaged.

0

1

2

3

MEMORY

ERROR

(LADDER

PRG FILE)

MEMORRY

ERROR

(DEVICENET

ALLOC FL)

0

0

1

The management data of job files are damaged.

The job files are damaged.

The management data of position data files are damaged.

The memory play file is damaged.

The concurrent I/O ladder program is damaged.

The DeviceNet allocation file1 is damaged.

The DeviceNet allocation file2 is damaged.

Remedy

• Initialize the corresponding parameter file in the maintenance mode.

If the error occurs again, contact your Yaskawa representative.

• Initialize the system.

If the error occurs again, contact your Yaskawa representative.

• Initialize the job files in the maintenance mode.

If the error occurs again, contact your Yaskawa representative.

• Initialize the memory play file.

If the error occurs again, contact your Yaskawa representative.

• Initialize the concurrent I/O ladder program.

If the error occurs again, contact your Yaskawa representative.

• Use the IO module setting screen in the maintenance mode to initialize the DeviceNet allocation file.

If the error occurs again, contact your Yaskawa representative.

8-8

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8.3 Alarm Message List

Alarm

Number

300

300

310

320

330

Message

VERIFY

ERROR

(SYSTEM

CONFIG-

DATA)

VERIFY

ERROR

(SYSTEM

CONFIG-

DATA)

Alarm Message List

2

Sub

Code

3

4

5

7

8

0

Cause Remedy

The setting of concurrent I/O parameter is incorrect.

An invalid value is set for the segment clock.

Inconsistency was detected in axis-related parameters.

Inconsistency was detected in sensor parameters.

The set optional functions are different from those of the mounted optional board.

The function designation for the concurrent I/O parameter is incorrect.

The CMOS memory capacity is different from its initial setting.

Set a correct module for the concurrent I/O parameter in the maintenance mode.

Set a correct value for the segment clock.

Correctly set the axis-related parameters.

Correctly set the sensor parameters.

Use the functions of the mounted optional board.

Set the correct module for the concurrent

I/O parameter in the maintenance mode.

Initialize the system or use a NIF board with correct CMOS capacity.

VERIFY

ERROR

(CMOS

MEMORY

SIZE)

VERIFY

ERROR

(I/O

MODULE)

VERIFY

ERROR

(SENSOR

FUNCTION)

1 to

15

16

17

0

The connected I/O module is different from the function of the set I/O module.

The I/O module connected to the PCI bus is different from the function of the set I/

O module.

Inconsistency was detected in the application setting parameters.

Connect a correct I/O module.

Correctly set the application setting parameters.

8-9

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8.3 Alarm Message List

Alarm

Number

350

370

390

400

Alarm Message List

Message

VERIFY

ERROR

(DEVICENET

ALLOC FL)

Sub

Code

0

1

2

10

11

12

Cause

The station No. specified by the DeviceNet allocation file1 is incorrect (the station

No. is out of the allowable range, or the specified station board is not the

DeviceNet master).

The MAC_ID specified by the DeviceNet allocation file1 is not consistent with the MAC_ID of the specified station board.

Inconsistency was detected in the scan list of the

DeviceNet allocation file1.

The station No. specified by the DeviceNet allocation file2 is incorrect (the station

No. is out of the allowable range, or the specified board is not the DeviceNet master).

The MAC_ID specified by the DeviceNet allocation file2 is not consistent with the MAC_ID of the specified station board.

Inconsistency was found in the scan list of the

DeviceNet allocation file2.

The designation in the parameter is different from the connected welding timer.

VERIFY

ERROR

(SPOT

POWER

SOURCE I/F)

VERIFY

ERROR

(SEGMENT

CLOCK)

PARAMETER

TRANSMISSI

ON ERROR

0

1

2

50 to

53

The segment clock value which is out of allowable range is set.

The set value of segment clock is insufficient for communication with the servo board.

Communication cannot be performed with the servo board

An error occurred during the parameter/file transfer to the servo board.

Remedy

• Use the IO module setting screen in the maintenance mode to initialize the DeviceNet allocation file.

If the error occurs again, contact your Yaskawa representative.

Set a correct value for the welding timer designation.

• Set a correct value for the segment clock.

If the error occurs again, contact your Yaskawa representative.

• Set a correct value, which is larger than the current value, for the segment clock.

If the error occurs again, contact your Yaskawa representative.

• Turn the power OFF then back ON.

If the error occurs again, contact your Yaskawa representative.

*1

"NCP30 CF" may be displayed as "NCP01 CF" depending on the software version.

8-10

100/245

8.3 Alarm Message List

Alarm

Number

410

Message

MODE

CHANGE

ERROR

420

500

510

520

600

601

602

603

604

605

606

607

DEVICENET

ALLOC FL

TRANSMIT

ERR

SEGMENT

PROC NOT

READY

SOFTWARE

VERSION

UNMATCH

AXIS LIMIT

OVER

MEDAR

STATUS

ERROR

MEDAR

DIAGNOSIS

ERROR

MEDAR

VERSION

ERROR

MEDAR

REVISION

ERROR

MEDAR

MODE

CHANGE

ERROR

MEDAR

SCHEDULE

TRANSMIT

ERROR

MEDAR

ERROR1

MEDAR

ERROR2

Alarm Message List

0

1

---

---

0

Sub

Code

---

Cause Remedy

An error occurred during startup sequence processing with the servo

CPU, and the system did not startup normally.

The DeviceNet allocation file1 could not be transmitted to the specified station.

The DeviceNet allocation file2 could not be transmitted to the specified station.

Motion command processing was not completed within the specified time.

The combination of the main system program and the servo system program is incorrect.

• Turn the power OFF then back ON.

If the error occurs again, contact your Yaskawa representative.

• Verify the connection state of the DeviceNet board specified by the DeviceNet allocation file.

• Use the IO module setting screen in the maintenance mode to initialize the

DeviceNet allocation file.

If the error occurs again, contact your Yaskawa representative.

• Turn the power OFF then back ON.

If the error occurs again, contact your Yaskawa representative.

Correct the combination.

More axes than the set value are used.

Refer to the instruction manual for the MEDAR function.

• Set the control group in the maintenance mode with the connectable number of axes.

If the error occurs again, contact your Yaskawa representative.

Refer to the instruction manual for the MEDAR function.

---

---

---

---

---

---

---

Refer to the instruction manual for the MEDAR function.

Refer to the instruction manual for the MEDAR function.

Refer to the instruction manual for the MEDAR function.

Refer to the instruction manual for the MEDAR function.

Refer to the instruction manual for the MEDAR function.

Refer to the instruction manual for the MEDAR function.

Refer to the instruction manual for the MEDAR function.

Refer to the instruction manual for the MEDAR function.

Refer to the instruction manual for the MEDAR function.

Refer to the instruction manual for the MEDAR function.

Refer to the instruction manual for the MEDAR function.

Refer to the instruction manual for the MEDAR function.

Refer to the instruction manual for the MEDAR function.

Refer to the instruction manual for the MEDAR function.

8-11

101/245

8.3 Alarm Message List

Alarm Message List

Alarm

Number

Message

Sub

Code

Cause Remedy

608

609

610

710

720

MEDAR

WELDER

TYPE

MISMATCH

MEDER

PARAMETER

ERROR

MEDAR

STEPPER

TRANSMIT

ERROR

LADDER

INITIALIZE

ERROR

LADDER

PROGRAM

ERROR

---

---

---

---

1

Refer to the instruction manual for the MEDAR function.

Refer to the instruction manual for the MEDAR function.

Refer to the instruction manual for the MEDAR function.

The ladder could not be initialized successfully.

An error was found in the relay No. specification.

Refer to the instruction manual for the MEDAR function.

Refer to the instruction manual for the MEDAR function.

Refer to the instruction manual for the MEDAR function.

Refer to the instruction manual for the MEDAR function.

• Use a correct ladder program.

If the error occurs again, contact your Yaskawa representative.

2

An error was found in the register

No. specification.

3

An incorrect instruction was entered.

720 LADDER

PROGRAM

ERROR

6

7

4

5

8

Output register is used redundantly.

• Use a correct ladder program.

Output relay is used redundantly.

If the error occurs again, contact your Yaskawa representative.

Unconnected relay exists.

The STR instructions are overused.

The AND-STR instructions are overused.

9

A syntax error was found in the

CNT instruction.

10

The head of the block starts with an instruction other than the STR instruction.

11

The memory capacity is exceeded due to excessive machine codes.

12

The last instruction is not the END instruction.

13

An error was found in the PART instruction.

14

An error was found in the GOUT instruction.

15

16

17

The No. of operand is incorrect.

The constant value is incorrect.

The step capacity exceeds the memory capacity.

18

The operation instructions are overused.

19

A syntax error was found in the

CNT instruction or TMR instruction.

20

A syntax error was found in the

JMP-LABEL instructions.

21

The label of JMP destination does not exist.

*1

"NCP30" and "AXC#



" are respectively displayed as "NCP01" and "AXA#



"

8-12

102/245

8.3 Alarm Message List

Alarm

Number

801

802

810

Message

FILE LOAD

ERROR

(NCP30

CF)

*1

FILE LOAD

ERROR

(NCP30

CF)

*1

TOYOPUC

ALLOC DEF

ERROR

Alarm Message List

Sub

Code

File

No.

Cause Remedy

The file in the NCP30 CF could not be retrieved correctly.

• Perform "DATA REBUILD" in the maintenance mode.

If the error occurs again, contact your Yaskawa representative.

Error code

An error occurred in access to the

NCP30 CF.

0

1

• Perform "DATA REBUILD" in the maintenance mode.

If the error occurs again, contact your Yaskawa representative.

Verify that the TOYOPUC board is normally installed.

Verify and modify the allocation configuration data for the

TOYOPUC.

3

4

The TOYOPUC board cannot be identified

An error was found in the input/output direction data of allocation configuration.

In the output side setting of allocation configuration data, the specified R-register start No. for the

TOYOPUC exceeds the R-register limit.

In the output side setting of allocation configuration data, the set number to use the input side Rregister of the TOYOPUC exceeds the R-register limit.

*1

"AXC#" is displayed as "AXA#" depending on the software version.

8-13

103/245

8.3 Alarm Message List

Alarm

Number

810

Message

TOYOPUC

ALLOC DEF

ERROR

Alarm Message List

Sub

Code

5

8

9

10

12

14

16

18

20

22

23

30

31

32

Cause Remedy

In the output side setting of allocation configuration data, the set number to use the M-register of concurrent I/O exceeds the M-register limit.

An error was found in the type set for output direction of allocation configuration data.

An error was found in the type set for input direction of allocation configuration data.

An error was found in the type specified for system data of allocation configuration data.

An error was found in the specified number of registers which are used by the system data "CURR.POS.

(PULSE)" of allocation configuration.

An error was found in the specified number of registers which are used by the system data "CURR.POS.

(XYZ)" of allocation configuration.

An error was found in the specified number of registers which are used by the system data "WELDING

INFO." of allocation configuration.

An error was found in the specified number of registers which are used by the system data "TASK INFO." of allocation configuration.

An error was found in the specified number of registers which are used by the system data "EXECUTE

PROGRAM INFO." of allocation configuration.

An error was found in the specified number of registers which are used by the system data "INST. MES-

SAGE" of allocation configuration.

An error was found in the specified number of registers which are used by the system data.

In the input side setting of allocation configuration data, the specified Rregister start No. for the TOYOPUC exceeds the R-register limit.

In the input side setting of allocation configuration data, the set number to use the input side R-register of the TOYOPUC exceeds the R-register limit.

In the input side setting of allocation configuration data, the set number to use the M-register of concurrent

I/O exceeds the M-register limit.

Verify and modify the allocation configuration data for the

TOYOPUC.

8-14

104/245

8.3 Alarm Message List

Alarm

Number

810

900

910

911

912

920

930

950

951

952

953

Alarm Message List

Message

TOYOPUC

ALLOC DEF

ERROR

Sub

Code

34

41

42

44

45

Cause Remedy

An error was found in the specified number of registers which are used by the system data "standard time setting data" of allocation configuration.

In the output side setting of allocation configuration data, some of the

TOYOPUC’s R-registers are specified redundantly.

In the output side setting of allocation configuration data, some of the

M-registers of concurrent I/O are specified redundantly.

In the input side setting of allocation configuration data, some of the

TOYOPUC’s R-registers are specified redundantly.

In the input side setting of allocation configuration data, some of the Mregisters of concurrent I/O are specified redundantly.

A system operation error occurred.

Verify and modify the allocation configuration data for the

TOYOPUC.

• Turn the power OFF then back ON.

If the error occurs again, contact your Yaskawa representative.

WATCHDOG

TIMER

ERROR (NIF

BOARD)

CPU ERROR

(NCP30)

*1

---

CPU ERROR

(NCP02#1)

CPU ERROR

(NCP02#2)

BUS ERROR

(NCP30)

CPU HANG

UP ERROR

(NCP30)

*1

*1

CPU ERROR

(AXC#1)

*1

CPU ERROR

(AXC#2)

*1

CPU ERROR

(AXC#3)

*1

CPU ERROR

(AXC#4)

*1

Vect or

No.

An error was detected in the

CPU.

100 An error was detected in the

CPU of the optional board#1.

100 An error was detected in the

CPU of the optional board#2.

1 The JL chip does not operate normally.

0

100

100

Power lost is detected

An error was detected in the CPU of servo board #1.

An error was detected in the CPU of servo board #2.

• Turn the power ON again.

• If the error occurs again, there may be a failure in the NCP30 board. Contact your

Yaskawa representative.

• Turn the power ON again.

• If the error occurs again, there may be a failure in the corresponding optional board.

Contact your Yaskawa representative.

• Turn the power ON again.

• If the error occurs again, there may be a failure in the NCP30 board. Contact your

Yaskawa representative.

• Verify the state of primary power supply.

• Verify the CPS power supply.

If the error occurs again, contact your Yaskawa representative.

• Turn the power ON again.

• If the error occurs again, there may be a failure in the corresponding servo board.

Contact your Yaskawa representative.

100

100

An error was detected in the CPU of servo board #3.

An error was detected in the CPU of servo board #4.

8-15

105/245

8.3 Alarm Message List

Alarm

Number

1000

Message

ROM ERROR

(NCP30)

*1

1001 ROM ERROR

(AXC01)

*1

Alarm Message List

Sub

Code

1

1

∗

Cause Remedy

An error occurred in the board or system software

(ROM).

• A checksum error occurred in the main ROM.

A checksum error occurred in the board or the

EEPROM.

(

∗: axis No.)

• Turn the power ON again.

• If the error occurs again, there may be a failure in the NCP30 board. Contact your

Yaskawa representative.

• Turn the power OFF then back ON.

If the error occurs again, contact your Yaskawa representative.

1001 ROM ERROR

(AXC01)

*1

20

21

22

23

24

25

26

The SRDY signal did not turn ON after the WRITE

ENABLE command was written. (EEPROM WRITE

ENABLE error)

The SRDY signal did not turn ON after the WRITE

PROTECT command was written. (EEPROM WRITE

PROTECT error)

The SRDY signal did not turn ON after the ERASE command was written.

(EEPROM ERASE error)

The SRDY signal did not turn ON after the CLEAR command was written.

(EEPROM CLEAR error)

The SRDY signal did not turn ON after data were written. (EEPROM writing error)

The SRDY signal did not turn ON after data were read. (EEPROM reading error)

The written data were rejected at verification.

(EEPROM verify error)

• Turn the power OFF then back ON.

If the error occurs again, contact your Yaskawa representative.

8-16

106/245

8.3 Alarm Message List

Alarm

Number

1030

Message

MEMORY

ERROR

(PARAMETE

R FILE)

Alarm Message List

Sub

Code

Cause

An error was detected at memory check.

0

• The memory for RC parameter file is damaged.

1

• The memory for RO parameter file is damaged.

2

• The memory for SV parameter file is damaged.

3

• The memory for SVM parameter file is damaged.

4

• The memory for SC parameter file is damaged.

5

• The memory for SD parameter file is damaged.

6

• The memory for CIO parameter file is damaged.

7

• The memory for FD parameter file is damaged.

8

• The memory for AP parameter file is damaged.

9

• The memory for RS parameter file is damaged.

10

• The memory for SE parameter file is damaged.

11

• The memory for SVC parameter file is damaged.

12

• The memory for AMC parameter file is damaged.

13

• The memory for SVP parameter file is damaged.

14

• The memory for MF parameter file is damaged.

Remedy

Initialize the appropriate parameter file in the maintenance mode, and then load the appropriate parameter file saved in the external memory device.

1030 MEMORY

ERROR

(PARAMETE

R FILE)

An error was detected at memory check.

15

• The memory for SVS parameter file is damaged.

Initialize the appropriate parameter file in the maintenance mode, and then load the appropriate parameter file saved in the external memory device.

8-17

107/245

8.3 Alarm Message List

Alarm

Number

1031

Message

MEMORY

ERROR

(MOTION1)

Alarm Message List

Sub

Code

Cause

2

3

The file data used by MOTION are damaged.

1

• The home position calibration file is damaged.

• The tool file is damaged.

• The user coordinates file is damaged.

4

• The robot calibration file is damaged.

5

• The tool calibration file is damaged.

6

• The weaving amplitude condition file is damaged.

7

• The home position correction data file is damaged.

8

• The conveyor calibration file is damaged.

9

• The arm and tool interference prevention file is damaged.

20

21

• The weaving file is damaged.

• The Power Source condition data file is damaged.

22

• The welding condition auxiliary file is damaged.

23

• The arc start condition file is damaged.

24

• The arc end condition file is damaged.

25

• The COMARC condition file is damaged.

26

• The COMARC data file is damaged.

27

• The path correction condition file is damaged.

28

• The painting characteristics file is damaged.

29

• The painting condition file is damaged.

30

• The multi-layer index file is damaged.

31

• The multi-layer condition file is damaged.

32

• The sensor monitoring condition file is damaged.

33

• The name position file is damaged.

34

• The conveyor condition file is damaged.

35

• The Press characteristics file is damaged.

Remedy

Initialize the damaged file in the maintenance mode.

8-18

108/245

8.3 Alarm Message List

Alarm

Number

1031

Message

MEMORY

ERROR

(MOTION1)

Alarm Message List

Sub

Code

Cause

58

59

60

The file data used by MOTION are damaged.

36

• The servo float condition file is damaged.

37

• The spot welding Power Source condition data file is damaged.

38

• The air-gun condition file is damaged.

39

• The motor-gun condition file is damaged.

40

41

• The gun pressure file is damaged.

• The dry-spotting gun pressure file is damaged.

42

• The anticipation OT# output file is damaged.

43

• The anticipation OG# output file is damaged.

44

• The handling condition file is damaged.

45

46

• The form cut file is damaged.

• The spot (user) I/O allocation file is damaged.

47

• The linear servo float condition file is damaged.

48

• The macro definition file is damaged.

49

• The seal amount correction condition file (spray) is damaged.

50

• The seal amount correction condition file (undercoating) is damaged.

51

52

• The arc monitor file is damaged.

• The motor-gun condition auxiliary file is damaged.

53

• The job registration table is damaged.

54

• The painting device condition file is damaged.

55

• The painting system file is damaged.

56

• The painting condition file is damaged.

57

• The paint characteristics file is damaged.

• The EVB gun file is damaged.

• The paint filling file is damaged.

• The welding pulse condition file is damaged.

61

62

• The clearance file is damaged.

• The linear scale condition file is damaged.

63

• The gauging sensor file is damaged.

Remedy

Initialize the damaged file in the maintenance mode.

8-19

109/245

8.3 Alarm Message List

Alarm

Number

1050

Message

SET-UP

PROCESS

ERROR

(SYSCON)

1051

1100

SET-UP

PROCESS

ERROR

(MOTION)

SYSTEM

ERROR

Alarm Message List

Sub

Code

Cause

1

2

An error occurred in the setup process of MOTION when the control power turned ON.

1

• The servo control section was not started up.

2

• The position data of when the power supply had turned OFF could not be transmitted to the servo control section.

3

An error occurred in the setup processing of the system when the control power turned ON (Setup error).

The motion instruction did not start up. (motion instruction setup incomplete.)

An error occurred in the setup processing of the system when the control power turned ON

(Processing timeout).

The motion instruction did not start up. (Setup of the servo control circuit board and NCP02 circuit board incomplete, parameter setting value error)

• The servo control section could not receive the position data of when the power supply had turned OFF.

5

• The request to turn ON the PG power supply for the mounted axis could not be sent.

6

• The PG power supply for the mounted axis could not turn ON.

7

• The request to prepare a feedback pulse could not be sent.

8

• The feedback pulse could not be prepared.

9

• The request to initialize the arithmetic section could not be sent.

10

• The arithmetic section could not be initialized.

11

• The request to prepare the current value could not be sent.

12

---

• The current value could not be prepared.

An unknown alarm was detected because of noise or control error.

Remedy

• Turn the power OFF then back ON.

If the error occurs again, contact your Yaskawa representative.

• Turn the power OFF then back ON.

If the error occurs again, contact your Yaskawa representative.

Contact your Yaskawa representative.

8-20

110/245

8.3 Alarm Message List

Alarm

Number

1101

1102

1103

1104

Message

SYSTEM

ERROR

(SYSTEM 1)

SYSTEM

ERROR

(SYSTEM 2)

SYSTEM

ERROR

(EVENT)

SYSTEM

ERROR

(CIO)

Alarm Message List

Sub

Code

---

---

---

---

Cause Remedy

An error occurred during the system control check.

An error occurred during the system control check.

An error occurred during the system event data control check.

An error occurred during the system I/O control check. (I/

O circuit board communications error, C I/O parameter setting value error etc.)

• Turn the power OFF then back ON.

If the error occurs again, contact your Yaskawa representative.

• Turn the power OFF then back ON.

If the error occurs again, contact your Yaskawa representative.

• Turn the power OFF then back ON.

If the error occurs again, contact your Yaskawa representative.

• Check the I/O signal line connectors and cables.

• Reset the I/O module in maintenance mode.

• Turn the power ON again.

• If the error occurs again, there may be a failure in the NIF circuit board and/or NIO circuit board. Contact your Yaskawa representative.

8-21

111/245

8.3 Alarm Message List

Alarm Message List

Alarm

Number

Message

Sub

Code

Cause Remedy

1105 SYSTEM

ERROR

(SERVO)

0

1

2

3

4

5

6

7

8

9

10

11

12

No processing corresponds to the command code sent from MOTION.

Illegal command data

(parameter) is received from

MOTION.

An error occurred in the file transfer sequence at execution of motion command.

The data size for the file transfer was over housing size at executing a motion command.

An optional function was commanded to be executed while another optional function was in execution.

The request to change standardization time was sent without permission.

The motor instruction standardization time is out of the allowable range.

The KP parameter input value is out of the allowable range.

The KP parameter input value for two degrees of freedom control is out of the allowable range.

No processing corresponds to the command code sent from MOTION.

An uncontrollable axis was designated.

An attempt was made to apply the brake to the motor while the power was being supplied.

An attempt was made to supply power to the motor while the brake was applied to the motor.

• Turn the power OFF then back ON.

If the error occurs again, contact your Yaskawa representative.

14 An error occurred in the encoder power supply

*1

"NIF30" may be displayed as "NIF01" depending on the software version.

15 The segment clock was not the specified value.

17 An attempt was made to turn ON the servo while the

112/245

8.3 Alarm Message List

Alarm Message List

Alarm

Number

Message

Sub

Code

Cause Remedy

1105 SYSTEM

ERROR

(SERVO)

37

40

43

47

60

61

63

68

69

80

81

82

83

The manipulator (B-axis) passed the singular point while the linear servo float was ON.

The axes for which the servo were attempted to be turned ON were not connected to the contactor.

The servo ON command was executed while the encoder was in alarm status.

The alarm number is illegal.

The axis endless function is set enabled for motor guns.

The axis endless function is set enabled for the encoder for which this function cannot be used.

The axis endless function cannot be used for the encoders manufactured by

Tamagawa Seiki Co., Ltd.

An error occurred while the axis endless function was being used.

The home position detecting function was used for the axis for which the axis endless function was enabled.

The servo float function was used for the axis for which the axis endless function was enabled.

An axis number that is not for gun change was specified.

An axis number that is not for gun change was specified.

The PG power supply of the axis for gun change is ON.

The servo power supply of the axis for gun change is

ON.

Correct the job so that the manipulator (B-axis) does not pass the singular point while the linear servo float is ON.

• Check the wiring to the contactor.

If the error occurs again, contact your Yaskawa representative.

• Turn the power OFF then back ON.

If the error occurs again, contact your Yaskawa representative.

Disable the axis endless function of motor guns axis.

Disable the axis endless function for the encoder.

• Turn the power OFF then back ON.

If the error occurs again, contact your Yaskawa representative.

Disable either the axis endless function or the home position detection function.

Disable the axis endless function, or do not use the servo float function.

• Turn the power OFF then back ON.

If the error occurs again, contact your Yaskawa representative.

90 The gun number allocated to the specified physical axis is different from the

*1

"NIF30" may be displayed as "NIF01" depending on the software version.

number.

91 The gun pressure file number is incorrect.

8-23

113/245

8.3 Alarm Message List

Alarm

Number

1105

Message

SYSTEM

ERROR

(SERVO)

Alarm Message List

Sub

Code

Cause

104 The sequence was untimely executed in the generalpurpose 4ms process although it was not the execution timing.

105 The sequence was untimely executed in the dynamics calculation process although it was not the execution timing.

106 The sequence was untimely executed in the dynamics compensation process although it was not the execution timing.

107 The sequence was untimely executed in the servo communications CERF sending process although it was not the execution timing.

108 The sequence was untimely executed in the servo communications CERF receiving process although it was not the execution timing.

109 The sequence was untimely executed in the segment_R process although it was not the execution timing.

111 The sequence was untimely executed in the segment_E process although it was not the execution timing.

112 The sequence was untimely executed in the segment_OPT1 process although it was not the execution timing.

113 The sequence was untimely executed in the segment_OPT2 process although it was not the execution timing.

114 The sequence was untimely executed in the segment_OPT3 process although it was not the execution timing.

120 A general-purpose 10ms process did not complete within the time set on the

Remedy

• Turn the power OFF then back ON.

If the error occurs again, contact your Yaskawa representative.

114/245

8.3 Alarm Message List

Alarm Message List

Alarm

Number

Message

Sub

Code

Cause Remedy

1105 SYSTEM

ERROR

(SERVO)

126 The dynamics compensation process did not complete within the time set on the scheduling table.

127 The CERF transmission process did not complete within the time set on the scheduling table.

128 The dynamics calculation process did not complete within the time set on the scheduling table.

129 The CERF receiving process did not complete within the time set on the scheduling table.

130 The segment_R process did not complete within the time set on the scheduling table.

131 The segment_E process did not complete within the time set on the scheduling table.

132 The segment_OPT1 process did not complete within the time set on the scheduling table.

133 The segment_OPT2 process did not complete within the time set on the scheduling table.

134 The segment_OPT3 process did not complete within the time set on the scheduling table.

• Turn the power OFF then back ON.

If the error occurs again, contact your Yaskawa representative.

150 The segment clock in the

ROM for spot welding is different from the specified

*1

"NIF30" may be displayed as "NIF01" depending on the software version.

151 The averaging time is not an even number. (times)

152 An attempt to use a function that is not allowed in the current ROM was made.

154 An error occurred in realtime data transmission of

SVSPOT Executing bit sent from MOTION.

16

∗

The illegal data are stored in the averaging buffer. (

∗: axis No.)

17

∗

The sum value in the averaging buffer is incorrect.

(

∗: axis No.)

8-25

115/245

8.3 Alarm Message List

Alarm

Number

1105

Message

SYSTEM

ERROR

(SERVO)

Alarm Message List

Sub

Code

Cause

206 The transfer of collision detecting sensitivity setting file was not successfully completed.

207 The tool file transfer was not successfully completed.

208 The transfer of linear servo float condition file was not successfully completed.

209 The transfer of gun condition auxiliary file was not successfully completed.

300 A logical error occurred in the parameter for modification of resolution which was calculated by the parameter specified by

CMOS.

302 A logical error occurred in the parameter.

500 Inconsistency of FP register.

600 An uncontrolled axis was specified when the instruction for group change was executed.

602 The PG power supply of the axis for group change is ON.

603 The servo power supply of the axis for group change is

ON.

700 An error occurred in motor control mode switching process.

800 The observer and collision detection function are set disabled although the broken belt detection function is set enabled.

90

∗

Vibration was detected in the serial encoder. (

∗: axis

No.)

1000 The check item number of

SVD parameter is unmatched.

1001 The check item number of

SV parameter is unmatched.

1002 The check item number of

SVM parameter is unmatched.

1003 The check item number of

SVP parameter is unmatched.

8-26

Remedy

• Turn the power OFF then back ON.

If the error occurs again, contact your Yaskawa representative.

116/245

8.3 Alarm Message List

Alarm

Number

1105

1200

1204

1204

Alarm Message List

Message

SYSTEM

ERROR

(SERVO)

HIGH

TEMPERATU

RE

COMMUNICA

TION ERROR

(IO MODULE)

---

COMMUNICA-

TION ERROR

(IO MODULE)

0000

_000

0_

0000

_000

1

****_

****_

****_

***0

Sub

Code

Cause

201

∗ The status setting to base block is different from that of base block signal writing to

JL056.

(

∗: axis No.)

202

∗ The status setting to base block is different from that of base block signal reading from micro program.

(

∗: axis No.)

203

∗ The mechanical brake remains locked although the base block is released.

(

∗: axis No.)

204

∗ The mechanical brake is not locked although the base block turns ON.

(

∗: axis No.)

2100 The operating software is not used in the targeted board.

2101 The requested function cannot be performed.

3280

7

An error occurred in the first encoder communications.

The temperature inside the controller (CPS power supply unit) is too high.

Communications and power supply error occurred in the

I/O circuit board. (standard I/

O of NIF unit)

Communications and power supply error occurred in the

I/O circuit board. (standard I/

O of NIF unit)

∗: 0 is correct. 1 is incorrect.

Bit position of 1 shows the station number of incorrect I/

O circuit board.

Remedy

• Turn the power OFF then back ON.

If the error occurs again, contact your Yaskawa representative.

• Confirm the communication data line and motor specification.

If the error occurs again, contact your Yaskawa representative.

Check if the in-panel cooling fan correctly operates.

• Check the noise source and take countermeasures to reduce the noise.

• Reset the I/O module in maintenance mode.

• Turn the power ON again.

• If the error occurs again, there may be a failure in the NIF circuit board. Contact your

Yaskawa representative.

• Check the I/O signal line (NIF-I/O circuit board) connectors and cables.

• Check the connection of the I/O circuit board and the external device.

• Check the noise source and take countermeasures to reduce the noise.

• Reset the I/O module in maintenance mode.

• Turn the power ON again.

• If the error occurs again, there may be a failure in the NIF circuit board. Contact your

Yaskawa representative.

8-27

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8.3 Alarm Message List

Alarm

Number

1207

1208

1209

1210

Alarm Message List

Message

BROKEN B_ON

RELAY FUSE

(NIF30)

*1

BROKEN S_ON

RELAY FUSE

(NIF30)

*1

EXTERNAL WDT

BROKEN

(NIF30)

*1

SERIAL COM-

MUNICATION

TOGGLE CHECK

ERROR

(NIF30)

*1

∗

Sub

Code

---

---

0000

_00 ∗

∗

0000

_00 ∗

Cause

The brake relay fuse was blown.

The servo-ON relay fuse was blown.

Defective watchdog timer circuit that checks the safety circuit

0000_0001: 1 signal (PLD1) error

0000_0010: 2 signal (PLD1) error

Checking error of toggle that switches double checking safety circuits in cycle of 1 ms

0000_0001: 1 signal (PLD1) error

0000_0010: 2 signal (PLD1) error

Remedy

• Turn the power ON again.

• If the error occurs again, there may be a failure in the NIF circuit board. Contact your

Yaskawa representative.

• Turn the power ON again.

• If the error occurs again, there may be a failure in the NIF circuit board. Contact your

Yaskawa representative.

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8.3 Alarm Message List

Alarm

Number

1211

Message

INPUT

COMPARISON

ERROR

(NIF)

Alarm Message List

Sub

Code

****_

****_

****_

****_

Cause Remedy

The signal does not have a match signal as a result the mutual check of a dual signal.

0000_0000_0000_0001:

Panel signal emergency stop signal (PBESP) unmatched error

0000_0000_0000_0010:

Programming pendant emergency stop signal

(PPESP) unmatched error

0000_0000_0000_0100:

External emergency stop signal (EXESP) unmatched error

0000_0000_0000_1000:

System CPU error

(ERRCPU) unmatched error

0000_0000_0001_0000:

Servo ON condition signal

(SYSRDY) unmatched error

0000_0000_0010_0000:

Safety plug signal (SAF) unmatched error

0000_0000_0100_0000:

Servo ON signal (SVON) unmatched error

0000_0000_1000_0000:

External servo ON signal

(EXSVON) unmatched error

0000_0001_0000_0000:

Unused

0000_0010_0000_0000:

Maintenance signal

(MAINTE) unmatched error

0000_0100_0000_0001:

Enable switch signal (DSW) unmatched error

0000_1000_0000_0001:

Unused

0001_0000_0000_0000:

External enable switch

(EXDSW) unmatched error

0010_0000_0000_0000:

Unused

0100_0000_0000_0000:

Safety speed mode selection (SSP) unmatched error

1000_0000_0000_0000:

Full speed test (FST) unmatched error

Check the signal.

8-29

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8.3 Alarm Message List

Alarm

Number

1212

1213

1214

1215

1216

1217

1218

1219

Message

PLD MUTUAL

MONITOR

ERROR

(NIF30)

*1

MUTUAL WDT

ERROR

(NIF30)

*1

PBESP RELAY

STICKING

PPESP RELAY

STICKING

EXESP RELAY

STICKING

S_ON RELAY

STICKING

B_ON RELAY

STICKING

ANOTHER PLD

EXT WDT

ERROR (NIF

BOARD)

Alarm Message List

Sub

Code

0000

_00

∗

∗

Cause

0000

_00

∗

∗

0000

_00

∗

∗

0000

_00

∗

∗

0000

_00

∗

∗

0000

_00

∗

∗

0000

_00

∗

∗

0000

_00

∗

∗

The input comparison error occurred.

0000_0001: 1 signal (PLD1) error

0000_0010: 2 signal (PLD2) error

The input comparison error occurred.

0000_0001: 1 signal (PLD1) error

0000_0010: 2 signal (PLD2) error

The emergency stop button

PBESP of the NXC100 front door is melted and stuck.

0000_0001: 1 signal (PLD1) error

0000_0010: 2 signal (PLD2) error

The emergency stop button of programming pendant

PPESP is melted and stuck.

0000_0001: 1 signal (PLD1) error

0000_0010: 2 signal (PLD2) error

The external emergency stop button EXESP is melted and stuck.

0000_0001: 1 signal (PLD1) error

0000_0010: 2 signal (PLD2) error

The servo-ON relay is melted and stuck.

0000_0001: 1 signal (PLD1) error

0000_0010: 2 signal (PLD2) error

The brake relay is melted and stuck.

0000_0001: 1 signal (PLD1) error

0000_0010: 2 signal (PLD2) error

The watchdog timer checking the safety circuit is incorrect.

Remedy

Check the one of PPESP, PBESP,

EXESP, and SAF signals.

Check the one of PPESP, PBESP,

EXESP, and SAF signals.

• Confirm that the cable is not short-circuited.

• Replace if necessary.

• Confirm that the cable is not short-circuited.

• Replace if necessary.

• Confirm that the cable is not short-circuited.

• Replace if necessary.

• Turn the power ON again.

• If the error occurs again, there may be a failure in the servo relay. Contact your

Yaskawa representative.

• Turn the power ON again.

• If the error occurs again, there may be a failure in the brake relay. Contact your

Yaskawa representative.

• Turn the power ON again.

• If the error occurs again, there may be a failure in the NIF board. Contact your

Yaskawa representative.

8-30

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8.3 Alarm Message List

Alarm

Number

1220

1221

Alarm Message List

Message

LAN COMMUNI-

CATION PARAM-

ETER ERROR

2

3

ETHERNET

RESET ERROR

1

Sub

Code

1

2

3

4

60

61

62

63

Cause Remedy

Incorrect setting of the IP address which is used in the

Ethernet function.

Incorrect setting of the subnet mask which is used in the Ethernet function.

Incorrect setting of the default gateway which is used in the Ethernet function.

An error occurred in the device initialization process of the Ethernet function.

An error occurred in the IP address setting process of the Ethernet function.

An error occurred in the subnet mask setting process of the Ethernet function.

An error occurred in the default gateway setting process of the Ehternet function.

An error occurred in the

DHCP initialization process of the Ethernet function.

An error occurred in the

DHCP interface of the

Ethernet function.

The data acquisition process from the server did not complete within regulated time.

The data acquired from the server were found illegal in the DHCP of the Ethernet function.

Set the correct IP address.

Set the correct subnet mask.

Set the correct default gateway.

• Turn the power OFF then back ON.

If the error occurs again, contact your Yaskawa representative.

Verify the DHCP server operation and the network status.

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8.3 Alarm Message List

Alarm

Number

1221

1223

1224

1225

1300

1301

Message

ETHERNET

RESET ERROR

PLD MONITOR1

ERROR

(NIF30)

*1

PLD MONITOR2

ERROR

(NIF30)

*1

PLD MONITOR3

ERROR

(NIF30)

*1

SERVO CPU

SYNCHRONI

ZING ERROR

COMMUNICA

TION ERROR

(SERVO)

Alarm Message List

Sub

Code

Cause Remedy

70

71

72

An error occurred in the

DNS resolver initialization process of the Ethernet function.

An error occurred in the

DNS resolver setting of the

Ethernet function.

The parameter setting error occurred in the DNS resolver setting of the

Ethernet function.

The mode error occurred in the DNS resolver setting of the Ethernet function.

• Verify the domain name and the DNSrelated settings.

• When the DHCP is used, verify the DHCP server operation and the network status.

73

• Verify the domain name and the DNSrelated settings.

• When the DHCP is used, verify the DHCP server operation and the network status.

0000

_00

∗

∗

0000

_00

∗

∗

0000

_00

∗

---

∗

The watchdog timer circuit which checks the safety circuit is damaged.

0000_0001: 1 signal (PLD1) error

0000_0010: 2 signal (PLD2) error

An error occurred in the watchdog timer which checks the safety circuit.

An error occurred due to the occurrence of input comparison error.

0000_0001: 1 signal (PLD1) error

0000_0010: 2 signal (PLD2) error

A synchronization error occurred between CPUs.

• Erroneous communications occurred between the main CPU board and the servo control circuit board due to:

- Defective board

- Incorrect connection

• Turn the power OFF then back ON.

• If the error occurs again, there may be a failure in the NIF circuit board. Contact your

Yaskawa representative.

Check the one of PPESP, PBESP,

EXESP, and SAF signals.

• Correct the cable connection or replace the cable.

• Turn the power ON again.

• If the error occurs again, there may be a failure in the NCP30 board and/or servo control circuit board. Contact your Yaskawa representative.

0

1

2

3

Erroneous communications occurred between main CPU board and servo control circuit board due to the defective board or the incorrect connection.

4

Communication status error

• Correct the cable connection or replace the cable.

Watchdog timer error

• Turn the power ON again.

JL040 alarm

Communication status error

Data consistency error

• If the error occurs again, there may be a failure in the NCP30 board and/or servo control circuit board. Contact your Yaskawa representative.

8-32

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8.3 Alarm Message List

Alarm

Number

1302

1303

Alarm Message List

Message

COMMUNICA

TION ERROR

(SERVO I/O)

ARITHMETIC

ERROR

(SERVO)

Sub

Code

Cause

Erroneous communications occurred between the contactor unit

(for I/Os, manipulators, and external axes) and servo control circuit board due to the defective board or the incorrect connection.

1 No interrupt from servo I/O communications (JL080) occurred.

(Communication loop back)

2

The servo I/O communications

(JL080) received status is incorrect.

(No interrupt)

4 The servo I/O communications

(JL080) buffer switch status is incorrect.

(Watchdog timer error)

5

The servo I/O communications

(JL080) receiving status is incorrect.

(Command timeout)

∗∗10

The communications loop back value of servo I/O communications

(JL080) is incorrect.

(Communication loop back)

(

∗∗

: station number of the connected unit)

∗∗11 The received address of

JL080 is unmatched with the sent address.

(

∗∗: station number of the connected unit)

∗∗12 The received buffer of JL080 is incorrect.

(

∗∗: station number of the connected unit)

XYY

YZ

An error occurred in control arithmetic process or parameter arithmetic process.

The data [X ] indicates the generation process.

10000: Observer control

20000: High-precision path

control

30000: Dynamics

40000: Disturbance observer

control

The data [ YYY ] indicates the alarm contents.

The data [ Z] indicates the physical axis number.

Remedy

• Correct the cable connection or replace the cable.

• Turn the power ON again.

• If the error occurs again, there may be a failure in the contactor circuit board and/or servo control circuit board. Contact your

Yaskawa representative.

• Turn the power OFF then back ON after cooling the power supply unit.

If the error occurs again, contact your Yaskawa representative.

• Turn the power OFF then back ON.

If the error occurs again, contact your Yaskawa representative.

8-33

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8.3 Alarm Message List

Alarm

Number

1304

1306

1307

1308

1309

1310

1311

1312

1321

1322

1325

1326

Message

EX-AXIS

BOARD NOT

INSTALLED

AMPLIFIER

TYPE

MISMATCH

ENCODER

TYPE

MISMATCH

CONVERTER

TYPE

MISMATCH

HARDWARE

ERROR

(CONVERTER)

CHARGE

ERROR

(CONVERTER)

A/D DETECTION

ERROR

(CONVERTER)

ID ERROR

(CONVERTER)

BRAKE BOARD

ERROR

BRAKE BOARD

STICKING

---

---

---

---

---

COMMUNICA

TION ERROR

(ENCODER)

DEFECTIVE

ENCODER

ABSOLUTE

DATA

Alarm Message List

Sub

Code

---

Cause

---

• The external board is not mounted although an external axis is specified.

• "With external axes" is specified for the system without external axes.

The amplifier type setting is incorrect.

Physical axis bit

Physical axis bit

---

The encoder type (motor model) setting is incorrect.

The converter model set in the system configuration is different from that of the one mounted.

Converter hardware is incorrect.

---

---

Converter hardware is incorrect.

Converter hardware is incorrect.

ID error is sent from the converter.

Brake signal is incorrect.

The cutout relay for the brake board main circuit is melted and stuck.

Communication error occurred between the encoder and the servo control circuit board due to:

- Misconnection of encoder

- Noise from external devices

- Incorrect motor type

- Defective servo control circuit board or encoder

An error occurred in the encoder position detecting circuit.

Remedy

Mount an external board or correct the external axis selection parameter.

Set the installed amplifier type in the system configuration.

Set the installed motor type in the system configuration.

Set the mounted converter model in system configuration.

• Turn the power OFF then back ON.

• If the error occurs again, there may be a failure in the converter board. Contact your

Yaskawa representative.

• Turn the power OFF then back ON.

• If the error occurs again, there may be a failure in the contactor circuit board.

Contact your Yaskawa representative.

• Correct the encoder connection.

• Check for noise.

• Confirm the motor type.

• Turn the power OFF then back ON.

• If the error occurs again, there may be a failure in the servo control circuit board.

Contact your Yaskawa representative.

• Turn the power OFF then back ON.

If the error occurs again, replace the motor of the corresponding axis.

8-34

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8.3 Alarm Message List

Alarm Message List

Alarm

Number

1327

1328

1329

1330

1331

1332

1333

1335

Message

ENCODER

OVER

SPEED

DEFECTIVE

SERIAL

ENCODER

DEFECTIVE

SERIAL

ENCODER

COMMAND

MICRO

PROGRAM

TRANSMIT

ERROR

CONVERTER-

CHARGE

ERROR

(CONVERTER)

POSITION

ERROR

POSITION

ERROR

(SERIAL

ENCODER)

INCOMPLET

E ENCODER

RESET

---

Sub

Code

---

---

---

---

---

---

---

Cause Remedy

The control power supply turned ON while the encoder was rotating (at more than 400min

-1

).

- The axis was in free-fall state.

- Defective encoder

Internal parameter error of the serial encoder

• The encoder fault may be the cause.

No response of encoder reset completion at the occurrence of encoder backup error.

The encoder fault may be the cause.

Defective servo control circuit board (Occurred only when the control power supply turned ON.)

Charge error is sent from the converter.

• Stop the manipulator motion and then turn

ON the control power supply to check if the error occurs.

If the error occurs, the encoder is defective.

Replace the motor for the axis.

• Turn the power OFF then back ON.

If the error occurs again, replace the motor of the corresponding axis.

• Turn the power OFF then back ON.

If the error occurs again, replace the motor (encoder) of the corresponding axis.

• Turn the power OFF then back ON.

• If the error occurs again, there may be a failure in the servo control circuit board.

Contact your Yaskawa representative.

• Turn the power OFF then back ON.

• If the error occurs again, there may be a failure in the converter board. Contact your

Yaskawa representative.

The number of pulses generated by one motor rotation does not agree with the specified value due to:

- Noise from external devices

- Defective board

- Motor failure

The number of pulses generated by one motor rotation does not agree with the specified value due to:

- Noise from external devices

- Defective board

- Motor failure

The encoder resetting did not complete. No battery may be connected.

• Check for the external noise.

• Provide noise protection such as installing a ferrite core if required.

• If the error occurs again, there may be a failure in the servo control circuit board.

Contact your Yaskawa representative.

• Connect a battery to the encoder.

If the error still occurs after having connected a battery, the encoder fault may be the cause.

8-35

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8.3 Alarm Message List

Alarm

Number

1343

Message

COMMUNICA-

TION ERROR

(CONVERTER)

Alarm Message List

Sub

Code

Cause

No response from the converter.

∗01

Communications status error

(

∗: converter No.)

∗02

Command timeout

(

∗: converter No.)

∗03

Sent buffer FULL

(

∗: converter No.)

∗04

CRC-16 error

(

∗: converter No.)

∗05

Error code received

(

∗: converter No.)

∗06

Received command error

(

∗: converter No.)

Remedy

• Turn the power OFF then back ON after cooling the power supply unit.

If the error occurs again, contact your Yaskawa representative.

8-36

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8.3 Alarm Message List

Alarm

Number

1345

Message

SAFETY CIR-

CUIT SIGNAL

UNMATCH

(SERVO)

Alarm Message List

Sub

Code

Cause

XYY Unmatched signal was detected in the doublecheck of the receive data to the power-ON unit.

Remedy

• Check the wiring of the unmatched signal.

• Turn the power ON again.

• If the error occurs again, there may be a failure in the contactor circuit board and/or servo circuit board. Contact your Yaskawa representative.

The data show the No. of power-ON unit and the unmatched signal.

XPower-ON unit

0: Power-ON unit1 (TU#1)

1: Power-ON unit2 (TU#2)

2: Power-ON unit3 (TU#3)

3: Power-ON unit4 (TU#4)

4: Power-ON unit5 (TU#5)

5: Power-ON unit6 (TU#6)

YYUnmatched signal

01: KMMA signal unmatched error

02: SVMAIN signal unmatched error

03: SVMAIN1



2 signal unmatched error

04: IORDY signal unmatched error

05: ONEN signal unmatched error

06: FUCUT signal unmatched error

07: SHOCK1 signal unmatched error

08: EXOT signal unmatched error

09: OT signal unmatched error

10: TUSONER signal unmatched error

11: SVCMPER signal unmatched error

12: TCER signal unmatched error

13: SON_OUT signal unmatched error

14: BRRVER signal unmatched error

8-37

127/245

8.3 Alarm Message List

Alarm

Number

1345

1349

1350

1352

1355

1356

Message

SAFETY CIR-

CUIT SIGNAL

UNMATCH

(SERVO)

POWER

LOST

DETECTION

CONTACTOR

UNIT TYPE

UNMATCH

---

---

SERIAL

CORRECTIO

N FAILED

SERIAL ENC

MULTITURN

LIMIT ERR

INVALID AXIS

SPECIFICATI

ON ERROR

---

---

---

Alarm Message List

Sub

Code

Cause

XYY 60: Error due to unmatched output signal for servo board failure

61: Error due to unmatched signal for the main contactor state (closed contact)

62: Error due to unmatched signal for the main contactor state (open contact)

63: Error due to unmatched input signal for the main contractor control relay

64: Error due to unmatched input signal for the OT recovery

65: Error due to unmatched input signal for the external

WDT

66: Error due to unmatched

1FB input signal: the brake release control signal

Remedy

• Check the wiring of the unmatched signal.

• Turn the power ON again.

• If the error occurs again, there may be a failure in the contactor circuit board and/or servo circuit board. Contact your Yaskawa representative.

E.g.)

Sub Code: 208

EXOT signal of the Power-

ON unit2 (TU#2) is unmatched.

The power to the motor became unstable.

The mounted board type is unmatched. The safety settings have been set for a controller that does not meet the specifications outlined in the safety standards.

An error was detected in bit shifting compensation.

• Turn the power OFF then back ON.

If the error occurs again, contact your Yaskawa representative.

Check the board type and replace if necessary.

Encoder multi-turn limit quantity error

A task request was sent to an axis of the group that was disabled by the group separation function.

• Turn the power OFF then back ON.

If the error occurs again, contact your Yaskawa representative.

• Turn the power OFF then back ON.

If the error occurs again, replace the motor (encode) for axis.

• Turn the power OFF then back ON.

If the error occurs again, contact your Yaskawa representative.

8-38

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8.3 Alarm Message List

Alarm Message List

Alarm

Number

1357

1360

1500

1501

1502

1503

1504

1505

1506

1507

1508

1509

1510

1511

Message

PRESS ERROR

PA NOT

INSTALLED

PLD INTERNAL

MUTUAL MONI-

TOR ERROR

(SERVO I/O)

SVMX RELAY

STICKING

(SERVO I/O)

TACTOR

STICKING

(SERVO I/O)

INPUT COMPAR-

ISON ERROR

(SERVO I/O)

---

---

---

---

TUSON RELAY

STICKING

(SERVO I/O)

---

B_ON RELAY

FUSE BREAK-

DOWN (SERVO

I/O)

MAIN TACTOR

RELAY FUSE

BREAKDOWN

(SERVO I/O)

S_ON RELAY

FUSE BREAK-

DOWN (SERVO

I/O)

MUTUAL WDT

ERROR

(SERVO I/O)

EXTERNAL WDT

OVER

(SERVO I/O)

---

---

---

---

---

EXTERNAL WDT

BREAKDOWN

(SERVO I/O)

---

SERIAL COM-

MUNICATION

TOGGLE CHECK

ERROR

(SERVO I/O)

---

Sub

Code

---

---

Cause Remedy

The position or speed value exceeded the limit value during pressuring after gun electrode hit the welded target. The motion after gun electrode hits the welded target is incorrect.

The prealigner is not mounted although use of the prealigner has been selected.

PLD internal mutual monitoring error is sent from the TU circuit board.

SVMX relay sticking is sent from the TU circuit board.

Check the job.

Check the prealigner connection.

• Turn the power OFF then back ON.

• If the error occurs again, there may be a failure in the TU circuit board. Contact your

Yaskawa representative.

Contactor sticking is sent from the TU circuit board.

Input comparison error is sent from the TU circuit board.

TUSON relay breakdown is sent from the TU circuit board.

B_ON relay fuse breakdown is sent from the TU circuit board.

Main contactor relay fuse breakdown is sent from the

TU circuit board.

S_ON relay fuse breakdown is sent from the TU circuit board.

Mutual WDT error is sent from the TU circuit board.

• Turn the power OFF then back ON.

• If the error occurs again, there may be a failure in the TU circuit board. Contact your

Yaskawa representative.

PLD internal mutual monitoring error is sent from the TU circuit board.

External WDT breakdown is sent from the TU circuit board.

Serial communication toggle check error is sent from the

TU circuit board.

8-39

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8.3 Alarm Message List

Alarm Message List

Alarm

Number

1512

1513

1514

Message

POWER SUP-

PLY FAN ALARM

(SERVO)

POWER

SUPPLY

OVERHEAT

(SERVO)

OVERHEAT

(AMPLIFIER)

Sub

Code

---

---

---

1515

1516

4000

4001

4002

4003

4004

4005

4006

SON_OUT

RELAY STICK-

ING

(SERVO)

BRRCER RELAY

STICKING

(SERVO I/O)

MEMORY

ERROR

(TOOL FILE)

MEMORY

ERROR

(USER

COORD

FILE)

MEMORY

ERROR

(SV MON

SIGNAL FILE)

MEMORY

ERROR

(WEAVING

FILE)

MEMORY

ERROR

(HOME POS

FILE)

MEMORY

ERROR

(SECOND

HOME POS)

MEMORY

ERROR

(POWER

SOURCE

COND)

---

---

---

---

---

---

---

---

---

Cause Remedy

The fan of the power supply unit is incorrect.

The power supply unit overheated.

Amplifier overheated.

• Turn the power OFF then back ON.

If the error occurs again, contact your Yaskawa representative.

• Turn the power OFF then back ON after cooling the power supply unit.

If the error occurs again, contact your Yaskawa representative.

• Turn the power OFF then back ON after cooling the amplifier.

If the error occurs again, contact your Yaskawa representative.

• Turn the power OFF then back ON.

• If the error occurs again, there may be a failure in the TU circuit board. Contact your

Yaskawa representative.

SON_OUT relay sticking is sent from the TU circuit board.

BRRCER relay sticking is sent form the TU circuit board.

An error was detected at memory check.

• The memory for the tool file is damaged.

An error was detected at memory check.

• The memory for the user coordinates file is damaged.

Initialize the tool file in maintenance mode, and then load the tool file saved in the external memory device.

Initialize the user coordinates file in maintenance mode, and then load the user coordinates file saved in the external memory device.

An error was detected at memory check.

• The memory for the servo monitor signal file is damaged.

An error was detected at memory check.

• The memory for the weaving condition file is damaged.

An error was detected at memory check.

• The memory for the home positioning file is damaged.

An error was detected at memory check.

• The memory for the second home position file is damaged.

An error was detected at memory check.

• The memory for the arc welding

Power Source condition file is damaged.

Initialize the servo monitor signal file in maintenance mode, and then load the servo monitor signal file saved in the external memory device.

Initialize the weaving condition file in maintenance mode, and then load the weaving condition file saved in the external memory device.

• Reset the alarm, and set the home positioning data (absolute data) again.

• Load the home positioning file saved in the external memory device.

Load the second home position file saved in the external memory device.

Initialize the arc welding Power

Source condition file in the maintenance mode, and then load the arc welding Power Source condition file saved in the external memory device.

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8.3 Alarm Message List

Alarm

Number

4007

Message

MEMORY

ERROR

(ARC START

COND FILE)

4008

4009

4010

4012

4013

4014

4017

4018

4019

MEMORY

ERROR

(ARC END

COND FILE)

MEMORY

ERROR

(ARC AUX

COND FILE)

MEMORY

ERROR

(COM-ARC

COND FILE)

MEMORY

ERROR

(LINK

SERVOFLOA

T)

MEMORY

ERROR

(LINEAR

SERVOFLOA

T)

MEMORY

ERROR

(ROBOT

CARIB FILE)

MEMORY

ERROR

(POWER

SRC USER

DEF)

MEMORY

ERROR

(LADDER

PRG FILE)

MEMORY

ERROR

(CUTTING

COND FILE)

Alarm Message List

Sub

Code

---

---

---

---

---

---

---

---

---

---

Cause Remedy

An error was detected at memory check.

• The memory for the arc start condition file is damaged.

An error was detected at memory check.

• The memory for the arc end condition file is damaged.

An error was detected at memory check.

• The memory for the arc auxiliary condition file is damaged.

An error was detected at memory check.

• The memory for the COM-ARC condition file is damaged.

An error was detected at memory check.

• The memory for the link servo float condition file is damaged.

An error was detected at memory check.

• The memory for the linear servo float condition file is damaged.

An error was detected at memory check.

• The memory for the file for calibration between manipulators is damaged.

An error was detected at memory check.

• The memory for the Power Source characteristics user definition file is damaged.

An error was detected at memory check.

• The memory for the ladder program file is damaged.

An error was detected at memory check.

• The memory for the user coordinates file is damaged.

Initialize the arc start condition file in the maintenance mode, and then load the arc start condition file saved in the external memory device.

Initialize the arc end condition file in the maintenance mode, and then load the arc end condition file saved in the external memory device.

Initialize the arc auxiliary condition file in the maintenance mode, and then load the arc auxiliary condition file saved in the external memory device.

Initialize the COM-ARC condition file in the maintenance mode, and then load the COM-ARC condition file saved in the external memory device.

Initialize the link servo float condition file in the maintenance mode, and then load the link servo float condition file saved in the external memory device.

Initialize the linear servo float condition file in the maintenance mode, and then load the linear servo float condition file saved in the external memory device.

Initialize the file for calibration between manipulators in the maintenance mode, and then load the file for calibration between manipulators saved in the external memory device.

Initialize the Power Source characteristics user definition file in the maintenance mode, and then load the Power Source characteristics user definition file saved in the external memory device.

Initialize the ladder program file in the maintenance mode, and then load the ladder program file saved in the external memory device.

Initialize the user coordinates file in the maintenance mode, and then load the user coordinates file saved in the external memory device.

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8.3 Alarm Message List

Alarm Message List

Alarm

Number

4020

4021

Message

MEMORY

ERROR

(WORK

HOME POS

FILE)

MEMORY

ERROR

(CONVEYOR

COND FILE)

---

Sub

Code

---

4025

4028

4031

4032

4033

4034

MEMORY

ERROR

(INTERRUPT

JOB FILE)

MEMORY

ERROR

(SENSOR

MON COND

FILE)

MEMORY

ERROR

(GUN COND

FILE)

MEMORY

ERROR

(SPOT WELD

COND)

MEMORY

ERROR

(GUN

PRESSURE

FILE)

MEMORY

ERROR

(ANTICIPATI

ON OT FILE)

---

---

---

---

---

---

Cause

An error was detected at memory check.

• The memory for the work home position file is damaged.

Remedy

Initialize the work home position file.

An error was detected at memory check.

• The memory for the conveyor condition file is damaged.

An error was detected at memory check.

• The memory for the interrupt job file is damaged.

An error was detected at memory check.

• The memory for the sensor monitoring condition file is damaged.

An error was detected at memory check.

• The memory for the spot welding gun condition file is damaged.

An error was detected at memory check.

• The memory for the spot welding

Power Source condition file is damaged.

An error was detected at memory check.

• The memory for the gun pressure file is damaged.

Initialize the conveyor condition file in the maintenance mode, and then load the conveyor condition file saved in the external memory device.

Initialize the interrupt job file in the maintenance mode, and then load the interrupt job file saved in the external memory device.

Initialize the sensor monitoring condition file in the maintenance mode, and then load the sensor monitoring condition file saved in the external memory device.

Initialize the spot welding gun condition file in the maintenance mode, and then load the spot welding gun condition file saved in the external memory device.

Initialize the spot welding SPOT

WELD condition file in the maintenance mode, and then load the spot welding Power Source condition file saved in the external memory device.

Initialize the gun pressure file in the maintenance mode, and then load the gun pressure file saved in the external memory device.

4035

4036

MEMORY

ERROR

(ANTICIPATI

ON OG FILE)

MEMORY

ERROR

(WEARING

FILE)

---

---

An error was detected at memory check.

• The memory for the anticipation outputs (OT) file is damaged.

An error was detected at memory check.

• The memory for the anticipation outputs (OG) file is damaged.

An error was detected at memory check.

• The memory for the wear amount file is damaged.

Initialize the anticipation outputs file in the maintenance mode, and then load the anticipation outputs file saved in the external memory device.

Initialize the anticipation outputs file in the maintenance mode, and then load the anticipation outputs file saved in the external memory device.

Initialize the wear amount file in the maintenance mode, and then load the wear amount file saved in the external memory device.

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8.3 Alarm Message List

Alarm Message List

Alarm

Number

4037

4038

4039

4040

4041

4042

4043

4044

4045

4046

Message

MEMORY

ERROR

(STROKE

POSITION)

MEMORY

ERROR

(PRESSURE

FILE)

MEMORY

ERROR

(VISION

CALIBRATIO

N)

MEMORY

ERROR

(WELDING

PULSE

COND FILE)

MEMORY

ERROR

(WELDING

PULSE

SELECTION

FILE)

MEMORY

ERROR

(CONVEYOR

CALIBRATIO

N)

MEMORY

ERROR

(FORM CUT

FILE)

MEMORY

ERROR

(SHOCK

LEVEL FILE)

MEMORY

ERROR

(SPOT IO

ALLOCATE

FL)

MEMORY

ERROR

(VISION

FILE)

---

---

---

---

---

---

---

---

Sub

Code

---

---

Cause Remedy

An error was detected at memory check.

• The memory for the FULL/SHORT

OPEN position setting file is damaged.

An error was detected at memory check.

• The memory for the dry-spotting pressure file is damaged.

An error was detected at memory check.

• The memory for the form cut file is damaged.

An error was detected at memory check.

• The memory for the shock level file is damaged.

An error was detected at memory check.

• The memory for the spot I/O allocation file is damaged.

An error was detected at memory check.

• The memory for the vision condition file is damaged.

An error was detected at memory check.

• The memory for the vision calibration file is damaged.

Initialize the FULL/SHORT OPEN position setting file in the maintenance mode, and then load the FULL/SHORT OPEN position setting file saved in the external memory device.

Initialize the dry-spotting pressure file in the maintenance mode, and then load the dry-spotting pressure file saved in the external memory device.

Initialize the form cut file in the maintenance mode, and then load the form cut file saved in the external memory device.

Initialize the shock level file in the maintenance mode, and then load the shock level file saved in the external memory device.

Initialize the spot I/O allocation file in the maintenance mode, and then load the spot

I/O allocation file saved in the external memory device.

Initialize the vision condition file in the maintenance mode, and then load the vision condition file saved in the external memory device.

Initialize the vision calibration file in the maintenance mode, and then load the vision calibration file saved in the external memory device.

An error was detected at memory check.

• The memory for the welding pulse condition file is damaged.

An error was detected at memory check.

• The memory for the welding pulse selection file is damaged.

An error was detected at memory check.

• The memory for the conveyor calibration file is damaged.

Initialize the welding pulse condition file in the maintenance mode, and then load the welding pulse condition file saved in the external memory device.

Initialize the welding pulse selection file in the maintenance mode, and then load the welding pulse selection file saved in the external memory device.

Initialize the conveyor calibration file in the maintenance mode, and then load the conveyor calibration file saved in the external memory device.

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8.3 Alarm Message List

Alarm

Number

4047

4048

Message

MEMORY

ERROR

(MACRO

DEFINITION

FILE)

MEMORY

ERROR

(SERVO S-

GUN FILE)

---

4049

4050

4051

4052

4053

4054

4055

MEMORY

ERROR

(PASTE

QUAN

COMPENSAT

ION FILE)

MEMORY

ERROR

(AXIS I/O

ALLOCATION

FILE)

MEMORY

ERROR

(GUN COND

AUX FILE)

MEMORY

ERROR

(TOOL

INTERFERE

NCE FILE)

MEMORY

ERROR

(PAINTING

SYSTEM

CONFIGURA

TION)

MEMORY

ERROR

(PAINTING

SPECIAL)

MEMORY

ERROR

(CCV-PAINT

TABLE)

---

---

---

---

---

---

---

Alarm Message List

Sub

Code

---

Cause

An error was detected at memory check.

• The memory for the macro definition file is damaged.

An error was detected at memory check.

• The memory for the sealer gun characteristics file is damaged.

An error was detected at memory check.

• The memory for the painting amount correction file is damaged.

Remedy

Initialize the macro definition file in the maintenance mode, and then load the macro definition file saved in the external memory device.

Initialize the sealer gun characteristics file in the maintenance mode, and then load the sealer gun characteristics file saved in the external memory device.

Initialize the painting amount correction file in the maintenance mode, and then load the painting amount correction file saved in the external memory device.

An error was detected at memory check.

• The memory for the axis motion I/

O allocation file is damaged.

An error was detected at memory check.

• The memory for the gun characteristics auxiliary file is damaged.

An error was detected at memory check.

• The memory for the tool interference file is damaged.

Initialize the axis motion I/O allocation file in the maintenance mode, and then load the axis motion

I/O allocation file saved in the external memory device.

Initialize the gun characteristics auxiliary file in the maintenance mode, and then load the gun characteristics auxiliary file saved in the external memory device.

Initialize the tool interference file in the maintenance mode, and then load the tool interference file saved in the external memory device.

An error was detected at memory check.

• The memory for the painting system setting file is damaged.

Initialize the painting system setting file in the maintenance mode, and then load the painting system setting file saved in the external memory device.

An error was detected at memory check.

• The memory for the painting device characteristics file is damaged.

An error was detected at memory check.

• The memory for the painting CCV file is damaged.

Initialize the painting device characteristics file in the maintenance mode, and then load the painting device characteristics file saved in the external memory device.

Initialize the painting CCV file in the maintenance mode, and then load the painting CCV file saved in the external memory device.

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8.3 Alarm Message List

Alarm

Number

4056

4057

4058

4059

4060

4061

4062

Message

MEMORY

ERROR

(PLUG

VOLUME

FILE)

MEMORY

ERROR

(EVB GUN

COND)

MEMORY

ERROR

(EVB

TURBINE

COND)

MEMORY

ERROR

(EVB PAINT

COND)

MEMORY

ERROR

(CLEARANC

E FILE)

MEMORY

ERROR

(GAGING

SENSOR

FILE)

MEMORY

ERROR

(LINEAR

SCALE FILE)

---

---

---

---

---

---

Alarm Message List

Sub

Code

---

Cause Remedy

An error was detected at memory check.

• The memory for the paint filling file is damaged.

Initialize the paint filling file in the maintenance mode, and then load the paint filling file saved in the external memory device.

An error was detected at memory check.

• The memory for the EVB gun file is damaged.

An error was detected at memory check.

• The memory for the EVB turbine file is damaged.

An error was detected at memory check.

• The memory for the EVB paint file is damaged.

An error was detected at memory check.

• The memory for the clearance file is damaged.

An error was detected at memory check.

• The memory for the gaging sensor file is damaged.

Initialize the EVB gun file in the maintenance mode, and then load the EVB gun file saved in the external memory device.

Initialize the EVB turbine file in the maintenance mode, and then load the EVB turbine file saved in the external memory device.

Initialize the EVB paint file in the maintenance mode, and then load the EVB paint file saved in the external memory device.

Initialize the clearance file in the maintenance mode, and then load the clearance file saved in the external memory device.

Initialize the gaging sensor file in the maintenance mode, and then load the gaging sensor file saved in the external memory device.

4063

4064

4065

MEMORY

ERROR

(CONVEYOR

COND

SUPP.)

MEMORY

ERROR

(WEAVING

SYNCHRONI

ZING WELD

FILE)

MEMORY

ERROR

(I/F PANEL

FILE)

---

---

---

An error was detected at memory check.

• The memory for the linear scale condition file is damaged.

An error was detected at memory check.

• The memory for the conveyor condition auxiliary file is damaged.

An error was detected at memory check.

• The memory for the weaving synchronizing welding condition file is damaged.

An error was detected at memory check.

• The memory for the I/F panel file is damaged.

Initialize the linear scale condition file in the maintenance mode, and then load the linear scale condition file saved in the external memory device.

Initialize the conveyor condition auxiliary file in the maintenance mode, and then load the conveyor condition auxiliary file saved in the external memory device.

Initialize the weaving synchronizing welding condition file in the maintenance mode, and then load the weaving synchronizing welding condition file saved in the external memory device.

Initialize the I/F panel file in the maintenance mode, and then load the I/F panel file saved in the external memory device.

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8.3 Alarm Message List

Alarm

Number

4069

4100

4101

4102

4103

Message

MEMORY

ERROR

(PALLETIZIN

G COND

FILE)

Alarm Message List

Sub

Code

---

Cause

An error was detected at memory check.

• The memory for the palletizing condition file is damaged.

Remedy

Initialize the palletizing condition file in the maintenance mode, and then load the palletizing condition file saved in the external memory device.

OVERRUN

(ROBOT

AXIS)

OVERRUN

(EXTERNAL

AXIS)

SYSTEM

DATA HAS

BEEN

CHANGED

PARALLEL

START

INSTRUCTIO

N ERROR

---

---

1

An error occurred in the independent control startup operation.

1

• Sub task being executed:

Although a job is being executed by instructed sub task, an attempt was made to execute another job by the sub task.

2

• Group axis being used:

The job operated by another sub task uses the same group axis.

3

One of the manipulator overrun limit switches activated.

One of the external-axis overrun limit switches activated.

The system parameters are modified.

• An attempt was made to turn ON the servo power supply after having modified the system parameters.

The data indicates the cause of alarm.

1: System parameter modified

• Multiple start of same job:

The job that was tried to be started was executed by another sub task.

4

• Unregistered master job:

Although the master job was not registered, an attempt was made to execute PSTART SUB (job name omitted).

5

• Synchronization instruction error:

When restarted by PSTART, synchronization instruction status of the sub task under interruption was different from the status to restart.

6

• Stopped by an alarm:

An attempt was made to start the sub task which is stopped by an alarm.

Move back the manipulator out of the overrun limit switch range.

(Refer to the INSTRUCTIONS.)

Move back the external axis out of the overrun limit switch range.

(Refer to the INSTRUCTIONS.)

Turn the power OFF then back ON.

Complete the sub task by PWAIT command.

Check the job to be started and the execution timing for start command again.

Register the master job for sub task.

Check the job to be started and the execution timing for start command again.

Reset the alarm, and then start the sub task.

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8.3 Alarm Message List

Alarm

Number

4104

4105

4106

4107

4109

4110

4111

4112

Alarm Message List

WRONG

EXECUTION

OF LOAD

INST

WRONG

EXECUTION

OF SAVE

INST

WRONG

EXECUTION

OF DELETE

INST

OUT OF

RANGE

(ABSO DATA)

DC24V

POWER

SUPPLY

FAILURE (I/

O)

Message

---

---

---

---

0000

_00

∗

Sub

Code

∗

Cause Remedy

An error occurred when an instruction was executed by the data transmission DCI function. The data indicates the cause of alarm.

(Refer to the manual for

Data Transmission Function for details.)

An error occurred when an instruction was executed by the data transmission DCI function. The data indicates the cause of alarm.

(Refer to the manual for

Data Transmission Function for details.)

An error occurred when an instruction was executed by the data transmission DCI function. The data indicates the cause of alarm.

(Refer to the manual for

Data Transmission Function for details.)

The position difference between when the power was turned OFF and when the power was turned ON again exceeded the tolerance for the manipulator or a station.

Reset the alarm, and then remove the cause according to the alarm data.

Reset the alarm, and then remove the cause according to the alarm data.

Reset the alarm, and then remove the cause according to the alarm data.

• Move the manipulator or station to the zero position by the axis operation and check the home position alignment marks (the arrow).

• If the zero position does not match the home position, check if there is no error in the PG system of the axis for which the alarm occurred.

The external 24V power for

I/Os is not output.

0000_0001: Fuse blown

(NIF01 unit)

0000_0011: External 24 V power supply error

• Check if the fuse of robot I/F unit (NIF) is not blown.

• Check the 24V external power supply.

• Check the communications cable for the I/O module

If the error occurs again, contact your Yaskawa representative.

The shock sensor activated.

Remove the cause of shock sensor activation.

SHOCK

SENSOR

ACTIVATION

BRAKE FUSE

BREAKDOW

N

DATA

SENDING

ERROR

---

--The brake fuse blew out.

1

2

An error occurred during data transmission.

3

• Retry over of NAK

• Retry over for timeout in timer A

• Retry over for mutual response error

Replace the fuse.

Reset the alarm, and then remove the cause.

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8.3 Alarm Message List

Alarm

Number

4113

4114

4115

4116

4117

Message

DATA

RECEIVING

ERROR

TRANSMISSI

ON

HARDWARE

ERROR

TRANSMISSI

ON SYSTEM

BLOCK

TRANSMISSI

ON SYSTEM

ERROR

BRAKE

POWER

ERROR

---

Alarm Message List

Sub

Code

Cause

1

2

An error occurred during data transmission.

• Reception timeout (timer A)

• Reception timeout (timer B)

3

4

• Heading length is too short.

• Heading length is too long.

5

6

• The header No. error

• The text length exceeded 256 characters.

An error occurred during data transmission.

1

2

3

3

4

1

2

• Overrun error

• Parity error

• Framing error

• Transmission timeout (timer A)

5

• Transmission timeout (timer B)

An error occurred during data transmission.

(This alarm occurs when received data cause inconsistency on the system although the transmission protocol is correct. Mainly, this alarm occurs due to an illegal transmission or erroneous report at the data sending side.)

• Received EOT while waiting ACK.

• Received EOT while waiting ENQ.

• Received EOT before last block reception.

4

---

• Received codes other than EOT after last block reception.

An error occurred during data transmission.

Remedy

Reset the alarm, and then remove the cause.

Reset the alarm, and then remove the cause.

Reset the alarm, and then remove the cause.

If the error occurs again, contact your Yaskawa representative.

The power for brake is not output.

An error occurred due to ground fault or short circuit of the brake wiring. Or the fuse of optional unit

(NBP) or brake release unit (NBU) is blown.

• Verify the brake wiring. If the fuse is blown, check the wiring, then replace the fuse.

If the error occurs again, contact your Yaskawa representative.

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8.3 Alarm Message List

Alarm

Number

4130

Message

NETWORK

APPLICATIO

N ERROR

Alarm Message List

1

Sub

Code

2

3

4

5

6

50

51

52

53

54

55

Cause Remedy

An error occurred when the notification of the APP task re-initialization was processed in the Ethernet function.

An error occurred when the re-initialization response was received in the Ethernet function.

The incomplete task of reinitialization was unsuccessfully completed in the Ethernet function.

An error occurred when the semaphore for reinitialization was received in the Ethernet function.

An error occurred when the re-initialization mail was sent in the Ethernet function.

An error occurred in the exclusive process of the storage area control table of the Ethernet function.

An error occurred in the data size written to PCI of the

Ethernet funciton.

An error occurred when the request to write PCI data was received in the Ethernet function.

The request of the undefined transmission was received in the Ethernet function.

An error occurred in the transmission request of the

Ethernet function.

The transmission request without data was received in the Ethernet function.

The transmission request of illegal data length was received in the Ethernet function.

• Rotate the mode selector switch on the programming pendant to release the mode setting which has been set to "REMOTE", then rotate the switch again to set back to

"REMOTE".

• If the error occurs again after releasing the mode setting of the switch and setting back to "REMOTE", turn the power OFF then back ON.

If the error occurs again, contact your Yaskawa representative.

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8.3 Alarm Message List

Alarm

Number

4131

Message

UDP

COMMUNICA

TION ERROR

4131

4132

UDP

COMMUNICA

TION ERROR

TCP

COMMUNICA

TION ERROR

Alarm Message List

Sub

Code

Cause

1

2

3

4

An error occurred in the creation of receiving socket during the UDP process of the Ethernet function.

An error occurred in the creation of transmission socket during the UDP process of the Ethernet function.

Illegal data were received in the UDP process of the

Ethernet function.

Transmission error occurred in the UDP process of the

Ethernet function.

5 The SELECT operation was not successfully completed in the UDP process of the

Ethernet function.

100 The re-initialization notification of illegal data length was received in the

UDP process of the

Ethernet function.

101 The re-initialization notification of illegal data was received in the UDP process of the Ethernet function.

102 The PCI write process was not successfully completed in the UDP process of the

Ethernet function.

103 The transmission request of illegal data length was received in the UDP process of the Ethernet function.

104 The transmission request of illegal data was received in the UDP process of the

Ethernet function.

1 The socket table was not successfully created in the

TCP process of the Ethernet function.

2 An error occurred in the process of the TCP server initialization of the Ethernet function.

Remedy

• Rotate the mode selector switch on the programming pendant to release the mode setting which has been set to "REMOTE", then rotate the switch again to set back to

"REMOTE".

• If the error occurs again after releasing the mode setting of the switch and setting back to "REMOTE", turn the power OFF then back ON.

If the error occurs again, contact your Yaskawa representative.

• Rotate the mode selector switch on the programming pendant to release the mode setting which has been set to "REMOTE", then rotate the switch again to set back to

"REMOTE".

• If the error occurs again after releasing the mode setting of the switch and setting back to "REMOTE", turn the power OFF then back ON.

If the error occurs again, contact your Yaskawa representative.

• Rotate the mode selector switch on the programming pendant to release the mode setting which has been set to "REMOTE", then rotate the switch again to set back to

"REMOTE".

• If the error occurs again after releasing the mode setting of the switch and setting back to "REMOTE", turn the power OFF then back ON.

If the error occurs again, contact your Yaskawa representative.

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8.3 Alarm Message List

Alarm

Number

4135

Message

TOYOPUC

RUN STOP

4136

4137

4138

4139

TOYOPUC

MAJOR

ERROR

SETUALM

ERROR

SVON

ERROR

PRINT

ERROR

Alarm Message List

0

Sub

Code

0

1

2

3

1

2

3

---

---

Cause Remedy

TOYOPUC is in stopped state.

The PCI bus state of the

TOYOPUC turns to "ER".

An error occurred in the processing on the

TOYOPUC side.

INTRB time-out error

An error occurred in the PCI bus communication processing of the

TOYOPUC.

The INTPC does not turn to

"1" five seconds after the

PCI command is issued.

An error occurred in the PCI bus communication processing of the

TOYOPUC.

Error in the state of interrupt register1

An error occurred in the PCI bus communication processing of the

TOYOPUC

An error occurred at

SETUALM instruction execution.

Alarm code specification error

An error occurred at

SETUALM instruction execution.

Task specification error

An error occurred at

SETUALM instruction execution.

Motion mode specification error

An error occurred at SVON instruction execution.

SVON is disabled.

An error occurred at PRINT instruction execution.

PRINT output conversion spec (character string specification) error

Use the PCwin, etc. to run the

TOYOPUC, then reset the alarm for the NXC100, or turn ON the power supply again.

Turn ON the power supply again.

Verify the TOYOPUC LED status and take appropriate measures by referring to the TOYOPUC instruction manual.

Turn ON the power supply again.

Contact the manufacturer.

Turn ON the power supply again.

Contact the manufacturer.

Specify the alarm in the range 8000 to 8999.

Specify the task in the range 0 to 4

(7 at expansion).

Set the motion mode to 0 or 1.

• Verify that the external servo ON (EXSVON) is short-circuited.

• Verify that the concurrent I/O signal #80031

(servo ON condition1) and #80033 (servo

ON condition2) are turned ON.

Review the PRINT output conversion spec (character string specification).

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8.3 Alarm Message List

Alarm

Number

4140

4141

4200

Message

DIALOG

ERROR

SNTP

ERROR

SYSTEM

ERROR

(FILE DATA)

Alarm Message List

Sub

Code

Cause

3

4

An error occurred at execution of the DIALOG instruction.

1 DIALOG instruction control error

2 Messages and buttons are not registere.

Buttons are not registered.

1

The length of character string was exceeded.

The error on setting of time difference value occurred in the SNTP process of the

Ethernet function.

2

3

4

5

The error on setting of timeout value occurred in the

SNTP process of the

Ethernet function.

The error on setting of reference interval value occurred in the SNTP process of the Ethernet function.

The IP address error occurred in the SNTP process of the Ethernet function.

Time-out occurred in the

SNTP process of the

Ethernet function.

6

7

8

9

---

The server time is not synchronized in the SNTP process of the Ethernet function.

The SNTP process of the

Ethernet function is not compliant with the version that the server sent.

Illegal parameters were found in the SNTP process of the Ethernet function.

The SNTP process of the

Ethernet function was not successfully completed.

An error occurred during the access to file data (during file edition or external memory device operation).

Remedy

• Reset the alarm, and then try again.

• Turn the power OFF and back ON.

Review DIALOG instruction.

• Turn the power OFF and back ON.

If the error occurs again, contact your Yaskawa representative.

• Correctly set the IP address of the SNTP server.

• If the DHCP is used, verify the DHCP server operation and the network status.

Verify the SNTP server operation and the network status.

Verify the SNTP server operation.

Use the server compliant with the

SNTP version 3.

• Verify the SNTP related settings.

If the error occurs again, contact your Yaskawa representative.

• Reset the alarm, and then try again.

• Turn the power OFF then back ON.

If the error occurs again, contact your Yaskawa representative.

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8.3 Alarm Message List

Alarm

Number

4201

Message

SYSTEM

ERROR

(JOB)

Alarm Message List

Sub

Code

Cause Remedy

An error occurred when accessing to job data.

-1

• An error occurred in parameter specification.

-2

-3

• Access time exceeded the limit.

• The access to a job could not be performed with the specified job name.

-4

• The character not allowed was used as a job name.

-5

• A job was newly created with the same name of the job already specified in the memory.

-6

• The allowable job registration area (memory) was exceeded.

-7

-8

-9

-10

-11

-12

-13

-14

-16

-18

-19

-20

-99

• A job was newly created with the same name of the undefined job already specified in the memory.

• A job data in the memory was destroyed.

• Reset the alarm, and then try again.

• Turn the power OFF then back ON.

If the error occurs again, contact your Yaskawa representative.

• An error occurred in step number of the accessed job.

• A job specified at job search did not exist in the memory.

• There was an instruction that did not exist in a job because of inconsistency of the system software.

• Unused handles were lacking when an attempt was made to open a job.

Delete unused jobs and/or expand

CMOS.

• A job that did not exist in the memory was specified.

• An attempt was made to change the contents for the job prohibited from being edited.

• Reset the alarm, and then try again.

• Turn the power OFF then back ON.

If the error occurs again, contact your Yaskawa representative.

Release the prohibition and change it.

• An error occurred in handle value.

• Reset the alarm, and then try again.

• An error occurred in job data control system.

• Turn the power OFF then back ON.

If the error occurs again, contact your Yaskawa representative.

• An error occurred in sequence number of the accessed job.

Check the NCP01 and NCP02 software versions before/after updating.

• The number of instructions added to a job exceeded 9999.

• The number of steps added to a job exceeded 9999.

• Reset the alarm, and then try again.

• Turn the power OFF then back ON.

If the error occurs again, contact your Yaskawa representative.

Delete unnecessary instructions and add new instructions.

Delete unnecessary steps and add new steps.

• Reset the alarm, and then try again.

• Turn the power OFF then back ON.

If the error occurs again, contact your Yaskawa representative.

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8.3 Alarm Message List

Alarm Message List

Alarm

Number

Message

Sub

Code

Cause Remedy

4202 SYSTEM

ERROR

(JOB)

2

3

An error occurred when accessing to job data.

1

• An error occurred in parameter specification.

• Access time exceeded the limit.

• The access to a job could not be performed with the specified job name.

4

• The character not allowed was used as a job name.

5

• A job was newly created with the same name of the job already specified in the memory.

6

• The allowable job registration area (memory) was exceeded.

7

8

9

10

11

12

13

14

16

18

19

20

• Reset the alarm, and then try again.

• Turn the power OFF then back ON.

If the error occurs again, contact your Yaskawa representative.

• An error occurred in step number of the accessed job.

• A job specified at job search did not exist in the memory.

• There was an instruction that did not exist in a job because of inconsistency of the system software.

• Unused handles were lacking when an attempt was made to open a job.

Delete unused jobs and/or expand

CMOS.

• A job that did not exist in the memory was specified.

• An attempt was made to change the contents for the job prohibited from being edited.

• Reset the alarm, and then try again.

• Turn the power OFF then back ON.

If the error occurs again, contact your Yaskawa representative.

Release the prohibition and change it.

• An error occurred in handle value.

• Reset the alarm, and then try again.

• An error occurred in job data control system.

• Turn the power OFF then back ON.

If the error occurs again, contact your Yaskawa representative.

• An error occurred in sequence number of the accessed job.

Check the NCP01 and NCP02 software versions before/after updating.

• The number of instructions added to a job exceeded 9999.

• The number of steps added to a job exceeded 9999.

• A job was newly created with the same name of the undefined job

• Reset the alarm, and then try again.

• Turn the power OFF then back ON.

If the error occurs again, contact your Yaskawa representative.

Delete unnecessary instructions and add new instructions.

Delete unnecessary steps and add new steps.

• Reset the alarm, and then try again.

• Turn the power OFF then back ON.

*1

"NCP30" may be displayed as "NCP01" depending on the software version.

99

• A job data in the memory was destroyed.

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8.3 Alarm Message List

Alarm

Number

4203

Message

SYSTEM

ERROR

(POSITION

DATA)

Sub

Code

Cause

An error occurred in position data control process.

-1

• The memory area for position data is lacking at the initialization of the position data control process.

-2

• The number of axes for all the control groups is zero at the initialization of the position data control process

-3

• The number of axes for position data is zero.

-4

Alarm Message List

Remedy

Initialize the job in the maintenance mode.

• When the data is loaded from the external memory, the control axis for external memory is different from that for system. Initialize the job.

• When a point is added, the job is not initialized after the control axis for system was changed to a different control group by system configuration. Initialize the job.

Initialize the job in the maintenance mode.

-5

-6

-7

-8

• The number of stored position data exceeded the maximum stored data at the initialization of the position data control process.

• The memory size of the position data exceeded the maximum memory size at the initialization of the position data control process.

• Unused position data file is destroyed.

• Unused position data file does not exist.

• Position data file is destroyed.

Delete unnecessary steps (position data) and add position data.

Initialize the job in the maintenance mode.

-9

-10

-11

• Position data control information is destroyed.

• An error occurred in specified position data number.

• Position data is not registered.

If the error occurs again, contact your Yaskawa representative.

-12

-13

-14

-15

-16

-17

• An attempt was made to access the undefined position data.

• An attempt was made to access the position data for the undefined control group.

• Position data control is not initialized.

• The number of axes for the control groups exceeded the limit.

• An error occurred in exclusive control.

• An error occurred in exceptional control.

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8.3 Alarm Message List

Alarm

Number

4204

4206

Message

SYSTEM

ERROR

(POSITION

DATA)

SYSTEM

ERROR

(TRANSMISS

ION)

Alarm Message List

Sub

Code

Cause

An error occurred in position data control process.

1

• The memory area for position data is lacking at the initialization of the position data control process.

2

• The number of axes for all the control groups is zero at the initialization of the position data control process

3

• The number of axes for position data is zero.

4

5

6

7

8

9

10

11

12

13

14

15

16

17

---

Initialize the job in the maintenance mode.

Remedy

• When the data is loaded from the external memory, the control axis for external memory is different from that for system. Initialize the job.

• When a point is added, the job is not initialized after the control axis for system was changed to a different control group by system configuration. Initialize the job.

Initialize the job in the maintenance mode.

• The number of stored position data exceeded the maximum stored data at the initialization of the position data control process.

• The memory size of the position data exceeded the maximum memory size at the initialization of the position data control process.

• Unused position data file is destroyed.

• Unused position data file does not exist.

• Position data file is destroyed.

• An attempt was made to access the undefined position data.

• An attempt was made to access the position data for the undefined control group.

• Position data control is not initialized.

• The number of axes for the control groups exceeded the limit.

• An error occurred in exclusive control.

• An error occurred in exceptional control.

An error occurred in data transmission.

Delete unnecessary steps (position data) and add position data.

Initialize the job in the maintenance mode.

• Position data control information is destroyed.

• An error occurred in specified position data number.

• Position data is not registered.

If the error occurs again, contact your Yaskawa representative.

• Turn the power OFF then back ON.

If the error occurs again, contact your Yaskawa representative.

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8.3 Alarm Message List

Alarm

Number

4207

Message

SYSTEM

ERROR

(MOTION)

Alarm Message List

Sub

Code

Cause

30

31

32

33

22

23

24

25

18

19

20

21

14

15

16

17

10

11

12

A system error occurred in

MOTION.

1

• An interrupt undefined in the main command from the system control section occurred.

2

• An interrupt undefined in the sub command from the system control section occurred.

3

• The interrupt command that was sent previously from the system control section is being processed.

4

• An error was detected in the interrupt command data from the system control section.

5

• An undefined command was detected in the sub segment task of MOTION.

6

• An undefined command was detected in the servo-related processing of MOTION.

7

• An undefined command was detected in the offline processing task of MOTION.

8

• An undefined command was detected in the utility task of

MOTION.

• Task Token is not generated.

• Mail-box Token is not generated.

• Semaphore Token is not generated.

13

• Memory-pool Token is not generated.

• RMS receiving data error

• RMS sending data error

• RMS receiving unit error

• RMS sending unit error

• Task generation error

• Mail-box generation error

• Semaphore generation error

• Token pointer error

• TCB area overflow

• Stack area overflow

• Mail-box area overflow

• Semaphore area overflow

• Main command error

• MSS system - ID number error

• HA-MSS system number error

• Incorrect control group designation

34

• Offline bank semaphore reception error

8-57

Remedy

• Reset the alarm, and then try again.

• Turn the power OFF then back ON.

If the error occurs again, contact your Yaskawa representative.

147/245

8.3 Alarm Message List

Alarm

Number

4207

Message

SYSTEM

ERROR

(MOTION)

Alarm Message List

Sub

Code

Cause

54

55

56

57

50

51

52

53

A system error occurred in

MOTION.

36

37

• Offline HA processing timeout

38

• DM_BANK flag error (DM_BANK conversion processing)

• S

→ M offline processing command type error

39

• SL data transmission request function error

40

• Error in designation of application in the request of general-purpose data preset for each application.

41

• Error in the parameter to prepare the speed data table

42

• Error in the parameter to prepare the global-variable control table

43

• Error in the parameter to prepare the axis control table

44

• Error in the parameter to prepare the online servo-constant modification table

45

• Mail-box of sequence task is not ready.

46

47

• Control-group usage undefined

• Segment task polling command error

48

49

• Physical axis number error

• The control group impossible to release the brake

• Sub-segment request FULL

• Sub-segment process timeout

• Data latch request FULL

• Data latch process timeout

• AXIS command request FULL

• AXIS command process timeout

• Positioning monitor request FULL

• Positioning monitor process timeout

58

• Failed AXIS servo OFF command request during emergency stop

60

61

• Memory pool area overflow

• Conversion primary expression for

Power Source command

↔ EW command not prepared

62

• Duplicated request error during master control-group tracking

63

• GVM shared resource semaphore error

64

65

• Job queue DEQUE error

• Conversion primary expression for painting device command

↔ EW command not prepared

Remedy

• Reset the alarm, and then try again.

• Turn the power OFF then back ON.

If the error occurs again, contact your Yaskawa representative.

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8.3 Alarm Message List

Alarm

Number

4207

Message

SYSTEM

ERROR

(MOTION)

Alarm Message List

Sub

Code

Cause

A system error occurred in

MOTION.

67

• Unknown mode data (Without

TEACH/PLAY mode data)

68

• Shift-value output timeout of the general-purpose sensor

69

71

• Interrupt main status set

• System number error at the master side in twin synchronous system

72

• No data link added to the command

73

• Setting status error of the user coordinates file

75

76

• Previous path data reference error

• Target position preparation error in arc-retry shift motion mode

77

• Request to compensate position error of the axis that is not endless axis

79

80

• Inner track zone status error

• Instruction queue and instruction system data area overflow

81

82

• Offline answer bank flag error

• Path and trace queue ENQUE

BANK error

83

• Pending and block end request

FULL

84

85

• Base axis file type error

• Output buffer SYSCON for automatic test data in use

86

• Conversion completion status for

AXIS section feedback latch data not established

87

88

• Sensor number (SL#) error

• File C1 through C3 for calibration between manipulators not set

89

• File C1 through C3 for conveyor calibration not set

90

• HA function error

(conv_pos_data())

91

• HA function error

(conv_shift_data())

92

• HA function error

(trans_angle_to_pulse())

93

• HA function error

(trans_pulse_to_angle())

94

• HA function error

(conv_pulse_to_angle())

95

• HA function error

(pr_atinf_pos_make())

96

• HA function error

(make_pos_data())

100

• Control-group axis configuration information parameter error

8-59

Remedy

• Reset the alarm, and then try again.

• Turn the power OFF then back ON.

If the error occurs again, contact your Yaskawa representative.

149/245

8.3 Alarm Message List

Alarm

Number

4207

Message

SYSTEM

ERROR

(MOTION)

Alarm Message List

Sub

Code

Cause

A system error occurred in

MOTION.

101

• Error in the parameter for the table for physical axes

102

• Error in the parameter for the table for physical TU

103

• Excessive number of control group axes in use

104

• JOG and PLAY maximum speed setting parameter error

120

• Job argument over

121

• Job argument stack overflow

122

• Job argument stack underflow

123

• Designation error of the fetched feedback pulse area at preparation of current value

128

• Timeout for waiting permission to modify the number of averaging times

129

• Object undefined for CLEAR instruction

130

• No space in RT_BANK setting area for correction-amount data

131

• Queue operation error for variable write-in history at prereading (at

ENQUE)

132

• Queue operation error for variable write-in history at prereading (at

DEQUE)

133

• Queue operation error for variable write-in history at prereading

(undefined operation)

134

• Queue operation error for variable write-in history at prereading

(data length too long)

135

• Queue operation error for scoreboard setting history (at ENQUE)

136

• Queue operation error for scoreboard setting history (at DEQUE)

137

• Queue operation error for scoreboard setting history (undefined operation)

138

• Queue operation error for scoreboard setting history (data length too long)

139

• Queue operation error for instruction execution (at ENQUE)

140

• Queue operation error for instruction execution (at DEQUE)

141

• Queue operation error for instruction execution (undefined operation)

142

• Queue operation error for instruction execution (data length too long)

143

• Queue operation error for WORK

ID conveyor (at ENQUE)

8-60

Remedy

• Reset the alarm, and then try again.

• Turn the power OFF then back ON.

If the error occurs again, contact your Yaskawa representative.

150/245

8.3 Alarm Message List

Alarm

Number

4207

Message

SYSTEM

ERROR

(MOTION)

Alarm Message List

Sub

Code

Cause

A system error occurred in

MOTION.

144

• Queue operation error for WORK

ID conveyor (at DEQUE)

145

• Queue operation error for WORK

ID conveyor (undefined operation)

146

• Queue operation error for WORK

ID conveyor (data length too long)

147

• Queue operation error for WORK

IN/OUT checking conveyor (at

ENQUE)

148

• Queue operation error for WORK

IN/OUT checking conveyor (at

DEQUE)

149

• Queue operation error for WORK

IN/OUT checking conveyor

(undefined operation)

150

• Queue operation error for WORK

IN/OUT checking conveyor (data length too long)

151

• Queue operation error for waiting for semaphore for LOCK instruction (at ENQUE)

152

• Queue operation error for waiting for semaphore for LOCK instruction (at DEQUE)

153

• Queue operation error for waiting for semaphore for LOCK instruction (undefined operation)

154

• Queue operation error for waiting for semaphore for LOCK instruction (data length too long)

222

• Impossible to execute system exclusive for system job

223

• Event queue number range exceeded

224

• No motor-gun control group for

ESRCH instruction

225

• The number of WORK ID data and the MAX. WORK FIND COUNT unmatched (MOTION

≠ CV)

226

• The number of WORK IN/OUT data and the MAX. WORK FIND

COUNT unmatched (MOTION

≠

CV)

227

• Excessive number of schedulings for execution of instructions

228

• Instruction execution scheduling impossible

229

• Illegal 1st-line move instruction at execution of +SMOV instruction

230

• Impossible to execute the slave circular interpolation and the master circular interpolation at the same time

Remedy

• Reset the alarm, and then try again.

• Turn the power OFF then back ON.

If the error occurs again, contact your Yaskawa representative.

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8.3 Alarm Message List

Alarm

Number

4207

Message

SYSTEM

ERROR

(MOTION)

Alarm Message List

Sub

Code

Cause

A system error occurred in

MOTION.

231

• Impossible to execute the slave spline interpolation and the master spline interpolation at the same time

232

• Illegal index value for a +MOVx instruction

233

• No xth-line move instruction exists where the master control group belongs.

234

• Marking error for WORK ID conveyor queue (empty queue)

235

• Marking error for WORK IN/OUT conveyor queue (empty queue)

236

• Data error 1 at restarting after an emergency stop (actual status and the data status unmatched)

237

• Data error 2 at restarting after an emergency stop (actual status and the data status unmatched)

238

• Data error 3 at restarting after an emergency stop (actual status and the data status unmatched)

239

• Timeout for receiving segment data output request

240

• The number which designates the setting area of correction amount in RT_BANK exceeded the limit value.

241

• Task error of the function calling source (cv_sync_intr ( ))

242

• No control group for motor gun for clearance move instruction

243

• Motor gun condition file number error (including gun pressure file)

244

• GETTOOLW manipulator designation error

245

• Overflow of entry number for instruction execution

246

• Data latch processing (function number overflow)

247

• Data latch processing (real-time status number overflow)

248

• Failed to set a timer unit. (No allocation space for timer unit setting)

249

• Segment data missing (seg_t_req was not received in time.)

250

• GETS instruction internal error

251

• SETFILE undefined file

252

• GETFILE undefined file

253

• The parameter was destroyed when a GETPRM instruction was executed.

254

• Null pointer assignment detected

Remedy

• Reset the alarm, and then try again.

• Turn the power OFF then back ON.

If the error occurs again, contact your Yaskawa representative.

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8.3 Alarm Message List

Alarm

Number

4207

Message

SYSTEM

ERROR

(MOTION)

Alarm Message List

Sub

Code

Cause

A system error occurred in

MOTION.

255

• Function or other processing parameter error

1000

• System clock (RTC) setting error

1001

• System task priority arrangement error

1002

• VxWorks primitive error

(msgQCreate)

1003

• VxWorks primitive error

(msgQSend)

1004

• VxWorks primitive error

(msgQReceive)

1005

• VxWorks primitive error

(semBCreate)

1006

• VxWorks primitive error

(semGive)

1007

• VxWorks primitive error

(semTake)

2000

• Failed system job environment configuration

Remedy

• Reset the alarm, and then try again.

• Turn the power OFF then back ON.

If the error occurs again, contact your Yaskawa representative.

8-63

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8.3 Alarm Message List

Alarm

Number

4208

Message

SYSTEM

ERROR

(ARITH)

Alarm Message List

Sub

Code

Cause

6

7

8

3

4

1

2

A system error occurred in the path control section.

• Prereading task is not completed.

• The answer bank flag is already set.

• Inner path motion is impossible.

• Error in the number of position data

5

• The averaging buffer in the arithmetic section is destroyed.

• No previous bank exists.

• The answer bank flag is ON.

• An error occurred in preparation of current position.

9

• Mails could not correctly be received in the current task.

10

• Spline-curve path designation error

11

• The previous bank’s prereading conversion could not correctly be completed.

12

• A manipulator designation error occurred at JOG operation using the external reference point.

13

• Designation error of cubic interference coordinates

14

• Path control position data error of prereading bank

15

• Weaving control position data error of prereading bank

16

• Station/base axis motion command error

18

• User coordinates number error

Remedy

• Reset the alarm, and then try again.

If the error occurs again, contact your Yaskawa representative.

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8.3 Alarm Message List

Alarm

Number

4208

Message

SYSTEM

ERROR

(ARITH)

41

42

43

Sub

Code

Cause

A system error occurred in the path control section.

19

• Processing error in re-preparation of segment control data

20

• Prereading task not completed at master in twin synchronous system

21

• Zero division occurred at observer operation.

22

• Processing error in optimized acceleration/deceleration control

23

24

• Dynamic model arithmetic error

• Speed limit control error

(excessive moment of gravity)

25

26

• Square root of a negative number

• The system number is not set at master in twin synchronous system.

27

• Designation error of control group for servo sealer gun

28

• Designation error of control condition for servo sealer gun

29

30

• FORMCUT internal control error

• Arm interference check error

(radius data referencing mistake)

31

• Arm interference check error

(miscalculation using direct kinematics)

32

• Arm interference check error (Laxis expansion flag setting error)

33

• Arm interference check error

(check-point re-setting error)

34

• Impossible to edit the averaging buffer (zero division)

35

• No master-group is designated at preparation of master-tool user coordinates.

37

• Gauging function error (command designation error)

38

• A coordinated motion was attempted using the Following function.

39

Alarm Message List

Remedy

• Reset the alarm, and then try again.

If the error occurs again, contact your Yaskawa representative.

The coordinated motion cannot be performed by the Following function.

Change the setting so that only the manipulator moves.

Set a positive value for the bending speed.

40

• Zero or a negative value is set for the bending speed of the

Following function.

• Zero or a negative value is set for the bending stroke of the

Following function.

• Pulse linked JOG function error

• Special JOG operation error

• Following function error (The used manipulator model does not support 7-axis Following Control.)

Set a positive value for the bending stroke.

• Reset the alarm, and then try again.

If the error occurs again, contact your Yaskawa representative.

8-65

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8.3 Alarm Message List

Alarm

Number

4209

Message

OFFLINE

SYSTEM

ERROR

(ARITH)

Alarm Message List

Sub

Code

Cause

A system error occurred in the offline position-data preparation section.

100

• Data setting error in offline data bank

101

• Data setting error in offline answer bank

102

• OFF_USER_POS occupation control error

103

• OFF_USER_POS valid control error

104

• Mail-receiving error of offline task

105

• Offline occupation control error

106

• Designation error for offline cubic interference coordinates

107

• OFF_USER_ROT_POS occupation control error

108

• OFF_USER_ROT_POS valid control error

109

• OFF_CV_CALIB_POS occupation control error

110

• OFF_CV_CALIB_POS valid control error

111

• Incorrect teaching for offline conveyor tracking turntable function

112

• No manipulator is designated for offline conveyor tracking turntable function.

Remedy

• Reset the alarm, and then try again.

If the error occurs again, contact your Yaskawa representative.

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8.3 Alarm Message List

Alarm

Number

4210

4220

4221

4222

4223

Message

SYSTEM

ERROR

(Local variable)

SERVO

POWER OFF

FOR JOB

SERVO

POWER OFF

FOR JOB

INPUT

COMPARISON

ERROR

(DSW)

SAFE

CIRCUIT

SIGNAL

DISAGREEM

ENT

(SERVO)

Alarm Message List

Sub

Code

Cause

An error occurred in local variable control process.

-1

-2

• Local variable is not used.

• Memory area for local variable could not be obtained.

-3

• No unused handle value exists when local variable area is created.

-4

• An error occurred in exclusive control.

-5

• Handle value is invalid for specified local variable.

-6

• Handle value is incorrect for specified local variable.

-7

• An error occurred when memory area for local variable was released.

-8

• An error occurred when memory area for local variable was registered.

-9

• Local variable control process is not initialized.

-10

• Local variable area shared heap area.

-11

---

---

0000

_00*

*

1

2

3

• An error occurred in exclusive control.

The servo power is not supplied to the job control group axis (control group for subcode) to be operated.

The servo power is not supplied to the job control group axis (control group for subcode) to be operated.

A dual signal is mutually checking with the result that

Enable switch (DSW and

EXDSW) I/O signal does not have a match signal as a result the mutual check of a dual signal.

0000_0001: DSW

0000_0010: EXDSW

A safety circuit signal error occurred in I/O unit.

A safety circuit signal error occurred in I/O unit.

A safety circuit signal error occurred in I/O unit.

Remedy

• Reset the alarm, and then try again.

• Turn the power OFF then back ON.

If the error occurs again, contact your Yaskawa representative.

Turn OFF the servo power supply, and then turn ON the servo power supply for the group axis to be operated.

Turn OFF the servo power supply, and then turn ON the servo power supply for the group axis to be operated.

Check the enable switch (DSW and

EXDSW) I/O signal.

Check the wiring of the safety circuit signal cables connected to the I/O contactor unit.

8-67

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8.3 Alarm Message List

Alarm

Number

4224

Message

MEMORY

PLAY FILE

ERROR

4225 SPEED

ERROR

(NCP30)

*1

Alarm Message List

Sub

Code

Cause

An error occurred in memory play file.

-1

• An error occurred in control process.

-2

• The arrangement address information is destroyed for memory play file system.

-3

• The fixed control information is destroyed for memory play file system.

-4

• The memory play file number is incorrect.

-5

• An attempt was made to newly register the memory play file under use.

-6

• An error occurred in checking written sampling data when the data was written to CMOS.

-7

• An attempt was made to access an unused memory play file data.

-8

-9

• The memory play file is destroyed.

• The memory area for sampling data is full.

-10

• The sampling data is destroyed.

Remedy

Needs investigation. Contact your

Yaskawa representative.

-11

• Data in control process is incorrect.

-12

• The sampling data is scanned only at top or end position.

-13

• The memory play file system is not initialized.

-14

• The offset value is out of range at sampling data scanning.

--The speed exceeded the limit due to:

- Motor cable disconnection

- Incorrect motor type

- Motor failure

- Defective board

- External force applied to manipulator, etc.

Check the motor, board, manipulator motion (influence by external force), and taught orientation.

8-68

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8.3 Alarm Message List

Alarm Message List

Alarm

Number

4228

4300

4301

4302

Message

WRONG

DATA

SERVO

PARAMETER

ERROR

CONTACTOR

ERROR

---

---

BRAKE

CIRCUIT

ERROR

Sub

Code

---

Cause Remedy

Chain inconsistency between the Job instruction file and position file due to following factors:

 Overlapped chain with the same

position data

 Unregistered position data is

chained with the Job instructio

file.

 Registered position data is not

chained.

• Reset the alarm, and then select WORNG

DATA LOG under SETUP in maintenance mode to check the factor of the inconsistency.

• Select RESTORE under the pull-down menu UTILITY to restore the system. If it succeeds in restoration, the indication in the screen changes from "OCCURRED

ON" to "RESTORED ON". Then, turn the control power ON.

For the factor , check the position of the corresponding file, then correct the position.

For the factor , register the position of the corresponding file again.

• If it fails in restoration, refer to "NXC100

OPTIONS INSTRUCTIONS FOR JOB

DATA SIMPLIFIED RESTORATION

FUNCTION (HW0483260)", and restore the file system.

For details, refer to

"NXC100 OPTIONS

INSTRUCTIONS FOR JOB

DATA SIMPLIFIED

RESTORATION FUNCTION

(HW0483260)".

The parameter input value is out of the allowable range.

Reset the value within the allowable range.

---

An error occurred in the contactor due to a defective contactor unit or circuit board.

• The contactor of contactor unit did not turn ON at servo ON.

• The signal from the contactor turned OFF while the servo was

ON.

• The signal from the contactor remains ON when the servo turned OFF at emergency stop.

• The contactor turned ON while the servo was OFF for emergency stop.

• The brake relay signal did not turn

ON when the servo turned ON.

• The brake relay signal turned OFF while the servo was ON.

• The brake signal remains ON when the servo turned OFF at emergency stop.

• The brake signal turned ON while the servo was OFF for emergency stop.

• Reset the alarm, and then turn ON the servo again.

• Check the 24-V power supply for I/O.

• Reset the alarm, and then turn ON the servo again.

• If the error occurs again, there may be a failure in the contactor circuit board and/or servo control circuit board. Contact your

Yaskawa representative.

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8.3 Alarm Message List

Alarm Message List

Alarm

Number

4303

Message

CONVERTER

READY

SIGNAL

ERROR

Sub

Code

---

4304

4305

4306

CONVERTER

INPUT

POWER

ERROR

CONVERTER

CIRCUIT

CHARGE

ERROR

AMPLIFIER

READY

SIGNAL

ERROR

---

---

---

Cause Remedy

• No response of charge completion was sent from the converter when the servo turned ON.

• The SERVO READY signal turned

OFF while the servo was ON.

• The SERVO READY signal remains ON when the servo turned OFF at emergency stop.

• The SERVO READY signal turned

ON while the servo was OFF for emergency stop.

• The primary power supply voltage is too low.

• The voltage dropped.

• Defective servo control and/or converter

• No response of primary power supply input was sent from the converter when the servo turned

ON.

• The READY 1 signal remains ON when the servo turned OFF at emergency stop.

• The READY 1 signal turned ON while the servo was OFF for emergency stop.

• Incorrect wiring or voltage drop of primary power supply

• Defective servo control and/or converter

• No response (READY 2 signal) of charge completion was sent from the converter when the servo turned ON.

• The READY 2 signal turned OFF while the servo was ON.

• The READY 2 signal remains ON when the servo turned OFF at emergency stop.

• The READY 2 signal turned ON while the servo was OFF for emergency stop.

• Incorrect wiring and/or voltage drop of primary power supply

• Defective servo control circuit board, converter, and/or amplifier

• No response "Power ON" was sent from the amplifier when the servo turned ON.

• The amplifier READY signal turned OFF while the servo was

ON.

• The amplifier READY signal remains ON when the servo turned OFF at emergency stop.

• The amplifier READY signal turned ON while the servo was

OFF for emergency stop.

• Defective servo control circuit board, converter, and/or amplifier

• Reset the alarm, and then turn ON the servo again.

• Check the primary power supply voltage.

• If the error occurs again, there may be a failure in the servo control circuit board and/ or converter board. Contact your Yaskawa representative.

• Check the wiring for the primary power supply of the SERVOPACK.

• Confirm that the power supply voltage is

170V or more.

• If the error occurs again, there may be a failure in the servo control circuit board and/ or converter board. Contact your Yaskawa representative.

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8.3 Alarm Message List

Alarm

Number

4307

4308

4309

4310

4311

4312

4313

4314

Message

SERVO ON

SPEED

ERROR

VOLTAGE

DROP

(CONVERTE

R)

DEFECTIVE

ENCODER

INTERNAL

DATA

ENCODER

OVERHEAT

ENCODER

BACK-UP

ERROR

ENCODER

BATTERY

ERROR

SERIAL

ENCODER

OVER HEAT

SERIAL

ENCODER

BATTERY

ERROR

Alarm Message List

Sub

Code

---

---

---

---

---

---

---

---

Cause Remedy

The motion speed of the encoder before the dynamic brake turns OFF in servo

ON sequence exceeded the threshold for a certain period.

• The servo power supply turned

ON while the manipulator (motor and encoder) was moving.

The DC power voltage supplied to the

SERVOPACK amplifier dropped below 143V due to:

- Low voltage of the primary

power supply

- Open phase

- Defective converter

- Defective servo control

circuit board

Serial encoder internal parameter error occurred.

The control power supply cannot be turned ON while the manipulator is moving.

Stop the manipulator motion, and then turn ON the servo power supply.

• Check the wiring for the primary power supply of the SERVOPACK.

• Confirm that the power supply voltage is

170V or more.

• If the error occurs again, there may be a failure in the servo control circuit board and/ or converter board. Contact your Yaskawa representative.

The temperature of the encoder exceeded 100

°C.

• Encoder thermistor failure

• Encoder resetting (initialization) not completed

• The position data in the encoder was lost due to the voltage drop of encoder backup battery.

Encoder backup battery voltage is too low.

• The voltage of the encoder backup battery is below 2.8V.

The position data may be lost.

The temperature of the encoder exceeded 100

°C.

• Encoder thermistor failure

• Reset the alarm, and then perform the home positioning again. Turn the power

OFF then back ON.

If the error occurs again, replace the motor of the corresponding axis.

• Review the load condition and ambient operating temperature.

• Confirm that the primary power supply voltage is 200V + 10%.

• If the error occurs again, replace the motor.

Otherwise, there may be a failure in the servo control circuit board. Contact your

Yaskawa representative.

• Reset the alarm, and then perform the home positioning again. Confirm that the encoder backup battery voltage is 2.8V or more.

If the error occurs again, replace the encoder (motor).

Confirm that the encoder backup battery voltage is 2.8V or more. If not, replace the battery.

Encoder backup battery voltage is too low.

• The voltage of the encoder backup battery is below 2.8V.

The position data may be lost.

• Review the load condition and ambient operating temperature.

• Confirm that the primary power supply voltage is 200V + 10%.

• If the error occurs again, replace the motor.

Otherwise, there may be a failure in the servo control circuit board. Contact your

Yaskawa representative.

Confirm that the encoder backup battery voltage is 2.8V or more. If not, replace the battery.

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8.3 Alarm Message List

Alarm

Number

4315

4316

4317

4318

4320

4321

4322

4323

Message

COLLISION

DETECT

PRESSURE

DATA LIMIT

PRE-LOAD

ERROR

SERIAL

ENCODER

CORRECT

LIMITATION

OVER

OVER LOAD

(CONTINUE)

---

OVER LOAD

(INSTANT)

AMPLIFIER

OVER LOAD

(CONTINUE)

AMPLIFIER

OVER LOAD

(INSTANT)

Alarm Message List

Sub

Code

---

---

---

---

Cause Remedy

• A collision was detected because of the interference between the manipulator and a peripheral device.

• The external force applied to the robot exceeded the threshold.

The pressure set in the gun pressure file or dry spotting pressure file exceeded the maximum pressure set in the gun condition file.

The motor does not operate in the pre-load process.

The speed feedback value of the serial encoder exceeded the allowable limit.

• Reset the alarm, and then remove the object or move the manipulator back to a safe position.

If the alarm cannot be reset, invalidate the collision detection level setting file or set the detection level higher.

Reset the pressure value in the gun pressure file or dry spotting pressure file below the maximum pressure value.

Adjust the gun opening.

• Turn the power OFF then back ON.

If the error occurs again, contact your Yaskawa representative.

---

---

---

The motor torque continuously exceeded the rated torque for a certain period due to:

- Motor cable disconnection

- Incorrect motor type

- Motor failure

- Defective board

- External force applied to manipulator, etc.

The torque a several times as much as the rated torque has been applied to the motor due to:

- Motor cable disconnection

- Incorrect motor type

- Motor failure

- Defective board

- External force applied to manipulator, etc.

The current a several times as much as the rated current has continuously flown in the amplifier for a certain period.

The torque a several times as much as the motor rated torque has continuously been applied for a certain period.

Check the motor, board, manipulator motion (influence by external force), and taught orientation.

Check the motor, board, manipulator motion (influence by external force), and taught orientation.

• Check the wiring and connection for the motor power line, board, cable disconnection, motor type, manipulator interferences,

SERVOPACK, and board, etc.

Replace if necessary.

• Check the wiring and connection for the motor power line, motor type, manipulator interference, SERVOPACK, and circuit boards.

Replace if necessary.

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8.3 Alarm Message List

Alarm Message List

Alarm

Number

4324

Message

CONVERTER

OVER LOAD

Sub

Code

---

4326

4327

4328

4329

4330

SPEED

ERROR

MOTOR

ROTATION

ERROR

SERVO

TRACKING

ERROR

POSITION

ERROR

---

---

---

---

---

Cause Remedy

The total load value of all the motors connected to the converter exceeded the converter rating.

The speed exceeded the limit due to:

- Motor cable disconnection

- Incorrect motor type

- Motor failure

- Defective board

- External force applied to manipulator, etc.

While the motor is accelerating, the direction of the torque and the speed was detected as being the opposite of what it was supposed to be.

The axis deviated from the specified position and motion path beyond the allowable range.

Review the manipulator operating condition such as reducing the teaching speed, etc.

Check the motor, board, manipulator motion (influence by external force), and taught orientation.

Check the wiring and connection for the encoder and the motor power line.

The number of pulses generated by one motor rotation does not agree with the specified value due to:

- Noise from external devices

- Defective board

- Motor failure

The read speed monitoring level signal is disconnected.

• Check the manipulator interferences and motor power line.

Replace the motor if the problem is not resolved. Otherwise, there may be a failure in the servo control circuit board. Contact your Yaskawa representative.

• Check for the external noise.

• Provide noise protection such as installing a ferrite core if required.

Replace the motor if the problem is not resolved. Otherwise, there may be a failure in the servo control circuit board. Contact your Yaskawa representative.

Check the connection cables for speed monitoring unit.

4331

4332

SPEED

MONITORIN

G

INSTRUCTIO

N CABLE

DISCONNEC

TION

SPEED

MONITORIN

G LEVEL

ERROR

POSITION

ERROR

(SERIAL

ENCODER)

---

---

Illegal speed monitoring level

The number of pulses generated by one motor rotation does not agree with the specified value due to:

- Noise from external devices

- Defective board

- Motor failure

• Turn the power OFF and back ON.

• If the error occurs again, there may be a failure in the AXC01 circuit board. Contact your Yaskawa representative.

• Check for the external noise.

• Provide noise protection such as installing a ferrite core if required.

Replace the motor if the problem is not resolved. Otherwise, there may be a failure in the servo control circuit board. Contact your Yaskawa representative.

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8.3 Alarm Message List

Alarm

Number

4334

4335

4336

4337

4338

4339

Message

OVER

VOLTAGE

(CONVERTE

R)

EARTH

FAULT

OPEN

PHASE

(Converter)

OVER

CURRENT

(AMPLIFIER)

REGENERAT

ION ERROR

(CONVERTE

R)

INPUT

POWER

OVER

VOLTAGE

(CONV)

Alarm Message List

Sub

Code

---

---

---

---

---

---

Cause Remedy

The DC voltage supplied to the amplifier exceeded 420V due to:

- Overloaded

- Converter failure

- Defective servo control circuit board

Ground fault of the motor power line occurred due to:

- Motor failure

- Ground fault of motor line or lead cables

- Defective servo control circuit board

- Defective SERVOPACK

• Check the primary power supply voltage.

• Reduce the teaching speed and check if the error occurs. If the error does not occur with the reduced speed, review the load condition.

• If the error occurs again, there may be a failure in the converter board. Contact your

Yaskawa representative.

• Check the motion connection.

• Remove the motor connector to check the conduction.

If there is conduction, the lead cable may have a failure. Replace the lead cable.

if there is no failure in the lead cable, replace the motor.

• If the error occurs again, there may be a failure in the servo control circuit board.

Contact your Yaskawa representative.

• Correct the SERVOPACK primary power supply connection,

• Confirm that the power supply voltage is more than 170V.

• If the error occurs again, there may be a failure in the servo control circuit board.

Contact your Yaskawa representative.

The SERVOPACK primary power supply is open-phase due to:

- Misconnection of primary power supply

- Lowered primary power supply voltage

- Defective servo control circuit board

- Defective converter

Ground fault of the motor power line occurred due to:

- Motor failure

- Ground fault of motor line or lead cables

- Defective servo control circuit board

- Defective amplifier

The regenerative energy at motor deceleration is too large.

- The primary power supply voltage is too high (above

242V)

- Converter failure

- Defective servo control circuit board

The SERVOPACK primary power supply voltage exceeded 242V.

• Check the motion connection.

• Remove the motor connector to check the conduction. If there is conduction, replace the lead cable; if there is no conduction, replace the servo control circuit board.

• If no fault is found, turn OFF the power supply to cool down the motor. If this natural cooling solves the problem, the load condition and ambient operating temperature must be reviewed and corrected.

• Review the load condition and teaching speed.

• Confirm that the power supply voltage is

220V

±10%.

• If the error occurs again, there may be a failure in the servo control circuit board.

Contact your Yaskawa representative.

• Confirm that the power supply voltage is

220V

±10%.

• If the error occurs again, there may be a failure in the servo control circuit board and/ or converter board. Contact your Yaskawa representative.

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8.3 Alarm Message List

Alarm Message List

Alarm

Number

4340

4344

4345

4346

4347

4348

4349

4350

4351

Message

TEMPERATU

RE ERROR

(CONVERTE

R)

LINEAR

SERVO

FLOAT

COORDINAT

ES TYPE

UNMATCH

LINEAR

SERVO

FLOAT TOOL

POSE

CONTROL

SPECIFICATI

ON ERROR

LINEAR

SERVO

FLOAT

EXECUTION

ERROR

BELT

DISCONNEC

TION

DETECTION

LINEAR

SERVO

FLOAT

TRACKING

ERROR

LINK SERVO

FLOAT

ERROR

LINK SERVO

FLOAT

LIMITATION

TORQUE

RANGE

ERROR

LINEAR

SERVO

FLOAT

LIMITATION

TORQUE

RANGE

ERROR

---

---

---

---

---

---

---

---

Sub

Code

---

Cause Remedy

SERVOPACK (converter) overheat

The deviation of X, Y, and Zaxis exceeded the allowable limit while the linear servo float was in execution.

• Review the load condition and ambient temperature.

• Confirm that the power supply voltage is

220V

±10%.

• If the error occurs again, there may be a failure in the servo control circuit board and/ or converter board. Contact your Yaskawa representative.

Check the job.

The link servo float can not be executed while the linear servo float is in execution.

The limit torque of the link servo float condition file is outside the specified range.

The limit torque of the linear servo float condition file is outside the specified range.

While the linear servo float was in execution, another request of linear servo float execution was sent with a different coordinates specified.

A logical error occurred in the designation for tool orientation control of the linear servo float.

While the servo float was in execution, the linear servo float can not be executed.

The driving belt may be disconnected because the torque decreased below the normal value.

Check the job.

Set the limit torque of the link servo float condition file again.

Set the limit torque of the linear servo float condition file again.

Check the job.

• Reset the alarm, and then try again.

• Turn the power OFF then back ON.

If the error occurs again, contact your Yaskawa representative.

Check the job.

Check the belt, and replace it if necessary.

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8.3 Alarm Message List

Alarm

Number

4352

4353

4354

4355

4356

4357

4358

4359

4360

4365

Message

TWIN DRIVE

OVER

DEVIATION

DEFECTIVE

TAUGHT POINT

(ENDLESS)

FILE NO.

ERROR

(SHOCK LEVEL)

EXTERNAL

PRES DETECT

(SERVOFLOAT)

ARM CTRL

PARAMETER

ERR

(OBSERVER)

IMPOSSIBLE

SRCH

(EQUALIZE

TEACH)

DUPLICATE

PRESS ERROR

CONVERTER

ERROR

WAFER ALIGN-

MENT ERROR

(SERVO)

EXCESSIVE

DETECTION

RANGE

(GUN ELEC-

TRODE HIT

POINT)

Alarm Message List

Sub

Code

---

---

---

---

---

---

---

---

Cause Remedy

The deviation of the position error pulse from the twin drive axis exceeded the allowable limit with twin drive function.

Endless motion impossible

• The feedback pulse value exceeded the maximum value

(maximum number of pulses

±

536870912)

The collision detection file for exclusive use for the

SVSPOT is used with the

SHCKSET instruction.

An external force above the threshold was detected on the servo-float executing axis.

The search of motor-gun equalizing function cannot be executed because no observer (including collision detection) is specified.

The manipulator orientation at the execution of search of the motor-gun equalizing function is the orientation for the singular point.

The pressuring instruction was executed with manual pressurization during pressuring.

An error occurred in the converter.

Check the load.

Reset the alarm.

Do not use the collision detection file for exclusive use for the

SVSPOT with the SHCKSET instruction.

Check the job.

If the error occurs again, contact your Yaskawa representative.

Check the job.

Do not execute the pressuring instruction with manual pressurization during pressuring.

• Turn the power OFF then back ON.

• If the error occurs again, there may be a failure in the servo control circuit board and/ or converter board. Contact your Yaskawa representative.

Check the connection of prealigner.

Deci mal data

Phys ical axis bit

An error occurred in communications with the prealigner.

In comparison to the position, where the gun electrode hits the welded target, at the previous wear detection, the position during pressuring exceeded the allowable limit which had been set in the motion limit for which the fixed

(movable) gun electrode hits the welded target.

• The error could occur due to the tip removed or the tip mis-installation. Verify the pressuring status.

• Adjust the set value of the gun condition file.

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8.3 Alarm Message List

Alarm

Number

4366

4367

4371

4372

4400

Message

GUN BENDING

CORRECTION

ERROR

ROBOT POSI-

TION ERROR

SYSTEM

ERROR

(SERVO)

SERVO ON SIG-

NAL ERROR

NOT READY

(ARITH)

Alarm Message List

Sub

Code

Cntrl grp bit desi gnati on

Cntrl grp bit desi gnati on

Deci mal data

---

Cause

The function of gun bending correction was performed to the model which was not supported for the function.

The manipulator orientation at pressuring is the orientation for the singular point.

The independent brake control was performed in TU which was not supported for the control.

The servo OFF status is sent from TU.

• Invalidate the bending correction function.

• Contact your Yaskawa representative.

Check the job.

Remedy

• Turn the power OFF then back ON.

If the error occurs again, contact your Yaskawa representative.

• Turn the power OFF then back ON.

If the error occurs again, contact your Yaskawa representative.

The arithmetic process for motion control did not complete within regulated time.

1

• No motion command was prepared.

2

• The arithmetic processing section is not ready for JOG operation.

3

• The arithmetic processing section is not ready for the playback operation.

4

• The prereading processing in the arithmetic processing section has not completed.

5

• The arithmetic processing section is not ready for the timer follow-up of the conveyor tracking function.

6

• The prereading processing in the arithmetic processing section has not completed when specifying the target position.

• Reset the alarm, and then try again.

• Turn the power OFF then back ON.

If the error occurs again, contact your Yaskawa representative.

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8.3 Alarm Message List

Alarm

Number

4401

Message

SEQUENCE

TASK

CONTROL

ERROR

Alarm Message List

Sub

Code

Cause

5

6

An error occurred in job execution process.

1

• Unused A_BANK does not exist in the prereading processing of move instruction.

2

• Unused bank priority does not exist in the prereading processing of move instruction.

• A_BANK pointer is not set.

• A_BANK conversion could not be performed.

7

• The specified A_BANK number does not exist.

20

• An error occurred when system number (MSS) was obtained.

21

• An error occurred in RMS960 system call.

22

• Undefined interrupt command was received.

23

24

• Job start condition is not defined.

• An error occurred in instruction prefetch queue operation.

26

29

• Intermediate code is not defined.

• Instruction prereading processing has not been completed normally.

30

• An error occurred in job data change.

31

• The specified sequence number at job execution start is incorrect.

32

• The added area for interruption command is incorrect.

33

• System number (MSS) for interruption command is incorrect.

38

• An error occurred at start of twin synchronous operation.

39

• An error occurred when SYNC specification was reset.

Remedy

• Reset the alarm, and then try again.

• Turn the power OFF then back ON.

If the error occurs again, contact your Yaskawa representative.

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8.3 Alarm Message List

Alarm

Number

4401

4402

Message

SEQUENCE

TASK

CONTROL

ERROR

UNDEFINED

COMMAND

(ARITH)

Alarm Message List

Sub

Code

Cause

An error occurred in job execution process.

41

• An error occurred in occupation control group setting in MOTION.

45

• An error occurred in path/trace control.

47

• An error occurred when waiting for a completion of main system task

(job) in SYNC specification.

48

• An attempt was made to execute an instruction that could not be executed at line sequence execution.

80

• An exceptional error occurred in job execution process.

100

• Main processing command is incorrect in prereading processing.

101

• Subprocessing command is incorrect in prereading processing.

102

• Prereading processing has not been completed at job execution.

103

• A_BANK conversion has not been completed.

104

• System number (MSS) is incorrect in prereading processing.

105

• An error occurred in instruction prefetch queue operation in prereading processing.

106

• An error occurred at IES switching in prereading processing.

An undefined command was issued to the path control section.

Remedy

• Reset the alarm, and then try again.

• Turn the power OFF then back ON.

If the error occurs again, contact your Yaskawa representative.

• Reset the alarm, and then try again.

If the error occurs again, contact your Yaskawa representative.

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8.3 Alarm Message List

Alarm

Number

4404

Message

ARITHMETIC

ERROR

Alarm Message List

Sub

Code

Cause

An error occurred in the arithmetic process for coordinates.

1

• The S-arm and L-arm of a scalar type manipulator are aligned in a straight line. Interpolation such as linear and circular interpolation is impossible in such orientation.

2

• When a vertically-articulated manipulator was moved by a special linear interpolation, the Raxis angle could not correctly be calculated.

3

• When a vertically-articulated manipulator was moved by a special linear interpolation, the Laxis angle could not correctly be calculated.

4

• The L-arm and U-arm of a vertically-articulated manipulator are aligned in a straight line.

Interpolation such as linear and circular interpolation is impossible in such orientation.

6

• The L-arm and U-arm of a vertically-articulated manipulator are aligned in a straight line.

Interpolation such as linear and circular interpolation is impossible in such orientation.

7

• The TCP of the manipulator is out of working envelope.

Remedy

• Change the positions so that two arms are not aligned in a straight line.

• Change the step (move instruction), where the alarm occurred, to MOVJ.

Change the position in the step

(move instruction) where the alarm occurred.

• Change the positions so that two arms are not aligned in a straight line.

• Change the step (move instruction), where the alarm occurred, to MOVJ.

4405 SELECT

ERROR

(PARAMETE

R)

8

9

1

• Interpolation such as linear and circular interpolation cannot be performed with this manipulator.

• Specified motion cannot be performed with this manipulator.

A parameter error occurred in the path control section.

• Selection error of motion system parameter

• Perform the teaching again so that the TCP of the manipulator is always within the working envelope.

• Change the shift value so that the TCP of the manipulator is always within the working envelope.

Change the step (move instruction), where the alarm occurred, to MOVJ.

Correct the taught point.

• Reset the alarm, and turn the power OFF then back ON.

If the error occurs again, contact your Yaskawa representative.

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8.3 Alarm Message List

Alarm

Number

4406

4407

4408

4409

4410

4411

Alarm Message List

Message

GROUP AXIS

CONTROL

ERROR

TWO STEPS

SAME

POSITION

(CIRC)

TWO STEPS

SAME

POSITION

(SPLINE)

TWO STEPS

SAME

POSITION (3

POINTS)

TWO STEPS

SAME

POSITION

(WEAV)

TEACH

ERROR

(SPLINE)

Sub

Code

Cause

8

9

4

5

2

3

6

An internal control error occurred in a coordinated motion.

1

• Designation error for master and slave

• Slave designation error

• Slave interpolation error

• No designation of master axis

• No designation of slave axis

• Master-axis designation error for

JOG motion

7

• Slave-axis designation error for

JOG motion

• Occupation control error

• Designation error of occupation control for JOG motion

10

• Designation error of occupation control for Bank position

11

• Designation error of occupation control group for tracking motion

12

---

---

---

---

---

• No master and slave designated for tracking motion

Among three taught points in a circular interpolation step, two or three points are on the same point.

Among three taught points in a spline interpolation step, two or three points are on the same point.

Among three taught points to create an user coordinate system, two or three points are on the same point.

Among three taught points

(start, end, and reference points) to create a weaving coordinate system, two or three points are on the same point.

The spline interpolation could not correctly be performed.

• The distance between the teaching points in the spline interpolation section is not equidistant.

Remedy

• Reset the alarm, and then try again.

If the error occurs again, contact your Yaskawa representative.

Teach the different 3 points again.

Teach the different 3 points again.

Teach the different 3 points again.

Teach the different 3 points again.

Teach the positions so that the distance between the teaching points is even.

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8.3 Alarm Message List

Alarm Message List

Alarm

Number

4412

Message

IMPOSSIBLE

LINEAR

MOTION (L/

U)

Sub

Code

---

4413

4414

4415

4416

4417

4418

4419

4420

4421

4422

IMPOSSIBLE

LINEAR

MOTION (S/

L)

EXCESSIVE

SEGMENT

(LOW

SPEED)

EXCESSIVE

SEGMENT

(HIGH

SPEED)

PULSE LIMIT

(MIN.)

PULSE LIMIT

(MAX.)

CUBE LIMIT

(MIN.)

CUBE LIMIT

(MAX.)

SPECIAL

SOFTLIMIT

(MIN.)

SPECIAL

SOFTLIMIT

(MAX.)

MECHANICA

L

INTERFERE

NCE (MIN.)

---

---

---

---

---

---

---

0

0

0

Cause Remedy

Interpolation motion could not be performed because of different form of L- and Uaxes.

• In case the form (folded direction) of L- and U-axes at start point and end point are different except for

MOVJ instructions, the manipulator cannot move.

Interpolation motion could not be performed because of different form of S- and Laxes.

• In case the form (folded direction) of S- and L-axes at start point and end point are different except for

MOVJ instructions, the manipulator cannot move.

The manipulator motion speed exceeded the limit

(LOW level).

• Perform the teaching again to make the form of L- and U-axes same at start point and end point.

• Use a MOVJ instruction.

• Perform the teaching again to make the form of S- and L-axes same at start point and end point.

• Use a MOVJ instruction.

The manipulator motion speed exceeded the limit

(HIGH level).

The manipulator exceeded its motion limit (pulse limit) in the negative (

−) direction.

The manipulator exceeded its motion limit (pulse limit) in the positive (+) direction.

The manipulator TCP exceeded its motion limit

(cube limit) in the negative

(

−) direction.

The manipulator TCP exceeded its motion limit

(cube limit) in the positive

(+) direction.

The manipulator exceeded its motion limit (special software limit) in the negative (

−) direction.

The manipulator exceeded its motion limit (special software limit) in the positive

(+) direction.

The manipulator exceeded its minimum-angle motion limit. (Mechanical interference)

• Reduce the speed in the step (move instruction) where the alarm occurred.

• The manipulator may be near the singular point. Change the position and orientation of the manipulator.

• Reduce the speed in the step (move instruction) where the alarm occurred.

• The manipulator may be near the singular point. Change the position and orientation of the manipulator.

Change the manipulator position in the step (move instruction) where the alarm occurred.

Change the manipulator position in the step (move instruction) where the alarm occurred.

Change the position in the step

(move instruction) where the alarm occurred.

Change the position in the step

(move instruction) where the alarm occurred.

Change the position in the step

(move instruction) where the alarm occurred.

Change the position in the step

(move instruction) where the alarm occurred.

Change the position in the step

(move instruction) where the alarm occurred.

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8.3 Alarm Message List

Alarm

Number

4423

4424

4425

4426

4427

4428

Message

MECHANICA

L

INTERFERE

NCE (MAX.)

SPECIAL

MECHANICA

L INTRF

(MIN.)

SPECIAL

MECHANICA

L INTRF

(MAX.)

PULSE

MECHANICA

L LIMIT

(MIN.)

PULSE

MECHANICA

L LIMIT

(MAX.)

SEGMENT

CONTROL

ERROR

Alarm Message List

Sub

Code

Cause Remedy

0

0

0

---

8

9

6

7

The manipulator exceeded its maximum-angle motion limit. (Mechanical interference)

The manipulator exceeded its minimum-angle motion limit. (Special mechanical interference)

The manipulator exceeded its maximum-angle motion limit. (Special mechanical interference)

The manipulator exceeded its motion limit (mechanical limit) in the negative (

−) direction.

• The segment was received although the previous segment had not been sent.

Change the position in the step

(move instruction) where the alarm occurred.

Change the position in the step

(move instruction) where the alarm occurred.

Change the position in the step

(move instruction) where the alarm occurred.

Change the position in the step

(move instruction) where the alarm occurred.

3

4

5

1

2

--The manipulator exceeded its motion limit (mechanical limit) in the positive (+) direction.

An error occurred in the real-time processing section that controls the arithmetic section.

Change the position in the step

(move instruction) where the alarm occurred.

• RT-buffer control command error • Reset the alarm, and then try again.

• Segment-receiving control command error

• No bank priority

• Turn the power OFF then back ON.

If the error occurs again, contact your Yaskawa representative.

• Answer error at MOVE simulating

• The value of bank_refresh_flag(x) exceeded its limit.

• Bank refreshing timing error

• RT-buffer setting timing error

• RT-buffer tracking option error

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8.3 Alarm Message List

Alarm

Number

4429

Message

WRONG

SPECIFIED

CONTROL

GROUP

Alarm Message List

Sub

Code

Cause

15

16

17

5

6

3

4

1

2

An error occurred in the manipulator information at job execution.

• Control group not designated

• Slave control-group error

• Master control-group error

• Master and Slave control-group error

• Control-group error for a job file

• Control-group error for a user coordinate file

7

• Control-group error for a calibration file between manipulators

8

• Control-group error for a tool calibration file

9

• Control-group error for a reference point

10

• Control-group error for prereading-calculation start point

(for adv_st_pos)

11

• Control-group error for the current-value preset position

12

• Control-group error for the conveyor prereading-calculation start point

13

14

• Occupation control-group error

• Control-group error for multi-layer sampling

• Control-group error for servo hand

• MRESET control-group error

• Control-group error for generalpurpose area of path correction amount

18

• Control-group error for a conveyor calibration file

19

• Control-group error for the prereading-calculation start point

(for dm_st_pos)

Remedy

• Reset the alarm, and then try again.

• Turn the power OFF then back ON.

If the error occurs again, contact your Yaskawa representative.

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8.3 Alarm Message List

Alarm

Number

4430

4431

Alarm Message List

Message

Sub

Code

Cause

CPU

COMMUNICA

TION ERROR

An error occurred in interrupt process between CPUs.

1

• Interrupt processing error between MOTION and system control section

2

• Interrupt processing error between MOTION and SL#1

3

• Interrupt processing error between MOTION and SL#2

4

• Interrupt processing error between MOTION and SL#3

5

• Interrupt processing error between MOTION and SL#4

6

• Interrupt processing error between MOTION and CV#1

7

• Interrupt processing error between MOTION and CV#2

8

9

• Interrupt processing error between MOTION and PS#2

JHM ERROR Data error occurred in job control process.

1

• An error occurred in JMS system call when an attempt was made to open a job.

2

• No space was found in job handle value storage area when an attempt was made to open a job.

3

4

• Interrupt processing error between MOTION and PS#1

• No job handle was found.

• Job control proprietary is incorrect.

5

• Job control proprietary could not be changed.

6

• An error occurred in exclusive control.

Remedy

• Reset the alarm, and then try again.

• Turn the power OFF then back ON.

If the error occurs again, contact your Yaskawa representative.

• Reset the alarm, and then try again.

• Turn the power OFF then back ON.

If the error occurs again, contact your Yaskawa representative.

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8.3 Alarm Message List

Alarm

Number

4432

Message

INSTRUCTIO

N

INTERPRETE

R ERROR

Alarm Message List

Sub

Code

Cause

4

5

6

An error occurred in instruction interpretation/execution process.

1

• The intermediate code of the instruction that is to be executed is incorrect.

3

• Destination (variable) tag arrangement is incorrect.

• Tag data type is incorrect.

• Box number is incorrect.

• An error occurred in block separation processing of intermediate code.

8

• Box number definition is duplicated.

9

• Undefined instruction was found at block separation of intermediate code.

10

11

• IPRM is not set.

• An error occurred in tag data search process.

Remedy

• Reset the alarm, reselect the job, and then try again.

• Delete the instruction where an alarm occurred, and then reregister and execute the instruction.

• Delete the job where an alarm occurred, and then reregister and execute the job.

If the error occurs again, contact your Yaskawa representative.

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8.3 Alarm Message List

Alarm

Number

4432

4433

Message

INSTRUCTIO

N

INTERPRETE

R ERROR

UNDEFINED

GLOBAL

VARIABLE

Alarm Message List

Sub

Code

Cause

An error occurred in instruction interpretation/execution process.

12

• An error occurred move instruction search process.

13

• An error occurred reference point search process.

14

• Variable information does not exist.

16

• An error occurred at position file data reading.

17

18

• Variable data type is not defined.

• An instruction is included with incorrect intermediate code in expression instruction.

19

• The syntax in expression instruction is incorrect.

20

• The tag data length is zero when tag data is read.

21

22

• The necessary tag data is not set.

• The object to be processed was secret variable in position file control process, so it could not be processed.

23

• The object to be processed was position type variable in position file control process, so it could not be processed.

24

• Job argument settings do not match when a variable is given and/or taken between jobs.

25

• An attempt was made to perform undefined operation at four-rule operation instruction.

26

• Arithmetic stack used for expression operation exceeded.

27

• Arithmetic stack used for expression operation is empty.

28

• Operation items are lacking in expression operation and operation processing cannot be performed.

254

• Access mechanism for old parameters is used.

255

• An exceptional error occurred.

The global variable is not defined.

0

• The set data for byte type variable

(S1D parameter) area is incorrect.

1

• The set data for integer type variable (S1D parameter) area is incorrect.

2

• The set data for double-precision integer-type variable (S1D parameter) area is incorrect.

3

• The set data for real type variable

(S1D parameter) area is incorrect.

Remedy

• Reset the alarm, reselect the job, and then try again.

• Delete the instruction where an alarm occurred, and then reregister and execute the instruction.

• Delete the job where an alarm occurred, and then reregister and execute the job.

If the error occurs again, contact your Yaskawa representative.

Needs investigation. Contact your

Yaskawa representative.

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8.3 Alarm Message List

Alarm

Number

4433

4435

4436

4437

4438

4439

4440

Message

UNDEFINED

GLOBAL

VARIABLE

UNDEFINED

LOCAL

VARIABLE

LESS THAN 3

STEP

(CIRCULAR)

LESS THAN 3

STEP

(SPLINE)

UNDEFINED

JOB

UNDEFINED

LAVEL

UNDEFINED

RETURN JOB

Alarm Message List

Sub

Code

Cause

The global variable is not defined.

4

• The set data for character-string type variable (S1D parameter) area is incorrect.

5

• The set data for robot-axis position-type variable (S1D parameter) area is incorrect.

6

• The set data for base-axis position-type variable (S1D parameter) area is incorrect.

7

• The set data for station-axis position-type variable (S1D parameter) area is incorrect.

The local variable is not defined.

0

• The byte type variable is not defined.

1

• The integer type variable is not defined.

2

• The double-precision integer-type variable is not defined.

3

• The real-number type variable is not defined.

4

• The character-string type variable is not defined.

5

• The robot-axis position-type variable is not defined.

6

• The base-axis position-type variable is not defined.

7

---

---

---

---

---

• The station-axis position-type variable is not defined.

An error occurred in circular interpolation instruction execution.

• There is no continuous three points or more for circular interpolation step.

An error occurred in spline interpolation instruction execution.

• There is no continuous three points or more for spline interpolation step.

The job to be executed is not registered in the memory.

An error occurred in label jump execution.

• The label for jump destination does not exist in the job.

Call source job does not exist in the job call stack.

Remedy

Needs investigation. Contact your

Yaskawa representative.

Set the number of local variables to be used in the job header.

Reset the alarm, and then perform teaching so that circulation interpolation steps are continuous three points or more.

Reset the alarm, and then perform teaching so that spline interpolation steps are continuous three points or more.

• Reset the alarm, and then register the job.

• Delete the CALL/JUMP instruction where an alarm occurred.

• Reset the alarm, and then register the label.

• Delete the JUMP instruction where an alarm occurred.

• Reset the alarm, and then execute the master (start) job.

• Delete the RET instruction.

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8.3 Alarm Message List

Alarm

Number

4441

4444

4445

Message

LACK OF

LOCAL

VARIABLE

AREA

UNSUCCESS

FUL FINE

POSITIONIN

G

DATA

PRESET

ERROR

Alarm Message List

Sub

Code

---

---

Cause Remedy

An error occurred when memory area for local variable was obtained.

• Memory area is lacking because too many local variables in the job are used.

When PL = 0 or an external servo turned OFF, the number of the servo error pulses did not fall in the limit range that had been set in a parameter, within the specified time.

Reset the alarm, and then reduce the number of local variables to be used.

• Reset the alarm, and then check if external force is applied to the manipulator. If external force is applied to the manipulator, move the manipulator by the axis operation, etc. to remove the external force. Then, try again.

• If the error occurs again although no external force is applied to the manipulator, re-insert the system CPU board correctly.

If the error occurs again, contact your Yaskawa representative.

Data error occurred at job prereading reinterpretation.

1

• The token for prereading processing could not be obtained.

2

3

4

• The prereading processing has not been completed within the time, and the waiting time for completion exceeded the limit.

• The prereading operation processing has not been completed within the time, and the waiting time for completion exceeded the limit.

• An error occurred in prereading operation process.

5

• A_BANK conversion has not been completed.

255

• An exceptional error occurred in job execution process.

• Reset the alarm, reselect the job, and then try again.

If the error occurs again, contact your Yaskawa representative.

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8.3 Alarm Message List

Alarm

Number

4446

Message

OVER

VARIABLE

LIMIT

Alarm Message List

Sub

Code

Cause

The variable value exceeded the limit.

0 The variable value exceeded the limit.

1

2

The value for the binary (0/

1) data type variable exceeded the limit.

The value for the signed 1byte data type variable is less than the minimum value.

4

6

8

3277

0

The value for the signed 2byte data type variable is less than the minimum value.

The value for the signed 4byte data type variable is less than the minimum value.

The value for the realnumber 4-byte data type variable is less than the minimum value.

The value for the signed 1byte data type variable exceeded the maximum value.

3277

1

3277

2

The value for the unsigned

1-byte data type variable exceeded the maximum value.

The value for the signed 2byte data type variable exceeded the maximum value.

Remedy

Change the variable data type for storage or correct the job, so that the variable value is within the limit.

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8.3 Alarm Message List

Alarm

Number

4446

4447

Message

OVER

VARIABLE

LIMIT

DEFECTIVE

TAUGHT

POINT

(CIRC)

Alarm Message List

Sub

Code

Cause

The variable value exceeded the limit.

3277

3

The value for the unsigned

2-byte data type variable exceeded the maximum value.

3277

4

3277

5

The value for the signed 4byte data type variable exceeded the maximum value.

The value for the unsigned

4-byte data type variable exceeded the maximum value.

3277

6

3278

0

3278

1

3278

2

The value for the realnumber 4-byte data type variable exceeded the maximum value.

The value for the labelname type variable exceeded the maximum value.

The value for the job-name type variable exceeded the maximum value.

The value for the characterstring type variable exceeded the maximum value.

3278

3

0

The value for comment type variable exceeded the maximum value.

Incorrect teaching of circular interpolation steps

• The three points taught for the circular interpolation step lie in a straight line.

Remedy

Change the variable data type for storage or correct the job, so that the variable value is within the limit.

Teach the 3 points again so that they do not lie in a straight line.

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8.3 Alarm Message List

Alarm

Number

4448

4448

4449

Message

WEAVING

CONTROL

ERROR

Alarm Message List

Sub

Code

Cause

An error occurred in weaving control.

1

• Weaving control-group designation error

WEAVING

CONTROL

ERROR

UNMATCHED

POSNVAR

DATA

ERROR

4

• When the speed is specified by weaving time in the weaving file, zero or the negative value is set for the weaving time.

5

• When the speed is specified by frequency in the weaving file, zero or the negative value is set for the frequency.

6

• When the timer mode is specified in the weaving file, a negative value is set for the timer value.

7

• For triangle or L-type weaving, zero is set for the vertical or horizontal distance.

8

9

• The distance between the point P and the TCP could not be calculated in wrist weaving.

10

An error occurred in weaving control.

11

• The Y-direction element of circular coordinate system for circular wrist weaving could not be calculated.

12

• The distance between the point P and the TCP could not be calculated in circular wrist weaving.

• The X-direction element of circular coordinate system for circular wrist weaving could not be calculated.

14

• Weaving basic-orientation calculation error

15

• The coordinate control axis designation for the reference point is different from actual control axis.

---

• Calculation error of horizontal- and wall-direction vector for weaving

The storage destination data

(pulse/Cartesian) is different from the storage source data.

Remedy

• Reset the alarm, and then try again.

If the error occurs again, contact your Yaskawa representative.

Reset the value 0.1 seconds or more.

Reset the value 0.1 Hz or more.

Set a positive value for the timer value.

Set a positive value for the vertical and horizontal distance.

Internal control error. If the error occurs again, contact your Yaskawa representative.

Set the correct dimensions in the tool data.

Contact your Yaskawa representative.

• Reset the alarm, and then try again.

If the error occurs again, contact your Yaskawa representative.

Match the position type variable data type for the storage source/ destination.

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8.3 Alarm Message List

Alarm

Number

4450

4451

4452

Message

FILE NO.

ERROR

UNDEFINED

REFERENCE

STACK

MORE THAN

8 (JOB CALL)

Alarm Message List

Sub

Code

Cause

An error occurred in tool file number check.

1 An error occurred in tool file number check.

2

3

An error occurred in user coordinate file number check.

An error occurred in calibration file number check between the manipulators.

4

5

6

7

8

An error occurred in tool calibration file number check.

An error occurred in reference point number check.

An error occurred in weaving file number check.

An error occurred in check for welding start condition file number.

An error occurred in check for welding end condition file number.

9

10

11

12

13

14

---

---

An error occurred in conveyor characteristic file number check.

An error occurred in press characteristic file number check.

An error occurred in gun characteristic file number check.

An error occurred in conveyor calibration file number check.

An error occurred in argument number check.

An error occurred in check for motor gun characteristic file number.

The reference point

(reference point number in binary for subcode) is not registered or is insufficient.

An attempt was made to add more than eight stacks in the job call stack.

Remedy

• Reset the alarm, reselect the job, and then try again.

If the error occurs again, contact your Yaskawa representative.

Register the reference point.

Reset the alarm, and then correct the job so that the number of nests for CALL instruction is eight or less.

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8.3 Alarm Message List

Alarm

Number

4453

4454

4455

4456

4457

4459

4460

4461

4462

4463

Message

OVER

VARIABLE

NO.

UNDEFINED

WELDER

CONDITION

FILE

UNDEFINED

ARC START

COND FILE

UNDEFINED

ARC END

COND FILE

WRONG

WELDER

SELECTION

EXCESSIVE

INSTRUCTIO

N EQUATION

ZERO

DEVIDED

OCCURREN

CE

UNDEFINED

AUTO WELD

RELEASE

COND

---

UNDEFINED

POSITION

FOR ARC

RETRY

PARITY

ERROR

Alarm Message List

Sub

Code

---

---

---

---

---

---

---

Cause Remedy

The variable number (the variable number which an attempt was made to use for subcode) is out of range.

The arc welding characteristic file cannot be accessed.

• The arc welding characteristic file is not set.

The welding start condition file cannot be accessed.

• The welding start condition file is not set.

The welding end condition file cannot be accessed.

• The welding end condition file is not set.

An error occurred in welder type check.

• The reference unit for the welding voltage and the welder type

(independent/unified) do not match.

An error occurred in expression operation.

• The operation is impossible because the expression is too long.

An error occurred in operation instruction.

• Zero division occurred.

Correct the job using the variable number within the range.

Complete the settings for the arc welding characteristic file.

Complete the settings for the welding start condition file.

Complete the settings for the welding end condition file.

Correct the reference unit for the welding voltage.

Separate the operation expression, shorten the expression, and then register it to a job.

Do not divide by zero.

---

---

An error occurred in automatic welding release conditions.

• The number of welding release condition is zero for arc auxiliary file.

An error occurred at arc retry execution.

• The arc retry has been set, but no move instruction exists following

ARCON instruction.

An error occurred in data for user I/O group.

• The parity check for user I/O group detected the data error.

Set the number of times of welding release condition, and then try again.

Set the move instruction following

ARCON instruction.

Check the parity data of the user I/O group.

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8.3 Alarm Message List

Alarm

Number

4464

4465

4466

4467

Message

OVER BCD

RANGE

OVER

BINARY

RANGE

(PARITY)

OFFLINE

UNDEFINED

COMMAND

(ARITH)

USER

COORDINAT

ES

GENERATIO

N STEP

SHORTAGE

0

Alarm Message List

Sub

Code

---

---

0

Cause Remedy

The BCD value exceeded the limit.

• An attempt was made to output a value above the maximum value that can be expressed in Binary

Coded Decimal: 99 (decimal) when no parity check is specified, and 79 (decimal) when parity check is specified.

• An attempt was made to read a data that cannot be expressed in

Binary Coded Decimal (a data whose lower or upper 4 bits exceeded 9 in decimal) in the variable.

The binary data exceeded the limit.

• An attempt was made to output a value that exceeded 127

(decimal) to the user I/O when parity check was specified.

An undefined command was issued to the offline positiondata preparation section.

• Correct the data.

• Correct the data designation (Binary or

BCD) or parity check designation (with or without.)

• Correct the data.

• Correct the parity check designation.

• Reset the alarm, and then try again.

If the error occurs again, contact your Yaskawa representative.

An error occurred at user coordinate creation by a job.

• The number of steps was lacking for a job for user coordinate creation.

Be sure that the number of steps will be three or more.

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8.3 Alarm Message List

Alarm

Number

4468

Message

ROBOT

CALIBRATIO

N DATA

ERROR

4469

4470

ROBOT

CALIBRATIO

N FRAME

ERROR

ROBOT

CALIBRATIO

N STEP

SHORTAGE

5

0

Alarm Message List

Sub

Code

Cause

The calibration data between manipulators could not correctly be prepared.

1

• The calibration between manipulators cannot be executed for this model.

• Reset the alarm, and then try again.

If the error occurs again, contact your Yaskawa representative.

Correct the number of steps for a job.

Remedy

2

• The master group and the slave group are set to the same group.

3

4

5

6

7

8

9

• Incorrect designation of the control group for master group

• Incorrect designation of the control group for slave group

• Incorrect designation of the occupation control group for calibration data

• Incorrect designation of the enabling control group for calibration data

• Among three points in the mastergroup’s calibration data, two or three points are on the same point.

• Among three points in the slavegroup’s calibration data, two or three points are on the same point.

• The number of the teaching points for calibration data is insufficient.

The conversion coordinates for calibration between manipulators could not be prepared.

1

• The calibration between manipulators cannot be executed for this model.

2

The calibration function between manipulators cannot be used for this model.

Set the different groups for the master group and the slave group.

• Reset the alarm, and then try again.

If the error occurs again, contact your Yaskawa representative.

Teach the different 3 points again.

Teach the specified number of points for the calibration data.

The calibration function between manipulators cannot be used for this model.

Separate the master group and slave group.

3

4

• The master group and the slave group are in the same group.

• Incorrect designation of the control group for master group

• Incorrect designation of the control group for slave group

• Calibration data setting error

An error occurred at calibration data creation between manipulators.

• The number of steps was lacking for a job for calibration data creation between manipulators.

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8.3 Alarm Message List

Alarm

Number

4471

4472

4473

4474

4475

4476

4477

Alarm Message List

Message

CALIBRATIO

N DATA

ERROR

TOOL

CALIBRATIO

N DATA

ERROR

Sub

Code

Cause

The tool calibration data could not correctly be prepared.

1

• Incorrect number of teaching points for tool calibration

2

3

4

10

0

0

• Incorrect designation of the occupation control group for calibration data

• Incorrect designation of the enabling control group for calibration data

• Incorrect designation of the control group for calibration data

Calibration could not be executed.

The tool calibration data could not correctly be prepared.

Calibration could not be executed.

The alarm occurred in the calculation section could not be reset.

ARITHMETIC

ALARM

RESET

ERROR

WRONG

CONTROL

GROUP AXIS

CANNOT

EXECUTE

JOB

(NO ROBOT)

CANNOT

EDIT (EDIT

LOCKJOB)

SELECT

ERROR

(APPLICATIO

N)

---

0

The CALL/JUMP destination job could not be executed.

• An attempt was made to call or jump to a job whose control group cannot be controlled. (Sub code:

The related control-group)

An attempt was made to execute a job without robot axis.

• The robot axis is not designated for the control-group of the job at execution of a work instruction that uses a manipulator.

An attempt was made to change the data for the job prohibited from being edited.

0

• An attempt was made to change the tag data.

1

• An attempt was made to change the speed tag data.

2

---

• An attempt was made to change the board thickness tag data.

Incorrect selection of application

• When executing a work instruction, the application selection parameter (parameter exclusive for manufacturer) is inconsistent with the application parameter (AP parameter).

(Subcode: Application number)

Remedy

Teach the specified number of points.

• Reset the alarm, and then try again.

If the error occurs again, contact your Yaskawa representative.

• Reset the alarm, and then try again.

If the error occurs again, contact your Yaskawa representative.

• Reset the alarm, and then try again.

If the error occurs again, contact your Yaskawa representative.

• Make the setting in advance so that the control group of the CALL/JUMP designation job is included in that of the

CALL/JUMP source job.

• Use a PSTART instruction when the independent control function is used.

Add the robot axis to the controlgroup of the job.

Release the prohibition.

Needs investigation. Contact your

Yaskawa representative.

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8.3 Alarm Message List

Alarm

Number

4480

4484

4485

4486

4487

4489

Message

SELECT

ERROR

(SENSOR)

WRONG

PORT NO.

(ANALOG

OUTPUT)

WRONG

SELECTION

(SENSOR)

PASS OVER

WRONG

MECH

PARAMETER

FILE

DEFECTIVE

TAUGHT

POINT

(CUTTING)

Sub

Code

---

---

---

---

0

1

2

3

4

Alarm Message List

Cause

Incorrect selection of sensor function

• When executing a work instruction, the sensor application selection parameter (parameter exclusive for manufacturer) is inconsistent with the sensor parameter (SE parameter).

(Subcode: Sensor number)

Incorrect analog output port selection parameter

• The value of the parameter

AxP010 indicating the leading number of analog output port used for arc welding or sealing application was incorrect.

(Subcode: Application number)

When executing a sensor instruction, the robot specified to use the sensor

(system parameter) and the robot specified to use the application (system parameter) are unmatched.

When executing COM-ARC function, the path was beyond the specified pathover monitor zone.

An error occurred in mechanical parameter for the path control section.

The CUT instruction could not be executed.

• The C- and W-axis position at the cutting start position is not zero pulse.

• Zero is set for the cutting radius.

• The cutting machine axis is not mounted.

• This manipulator cannot perform a hexagonal cutting motion.

Remedy

Needs investigation. Contact your

Yaskawa representative.

Correct the parameter value.

Needs investigation. Contact your

Yaskawa representative.

• Remove the cause of the path-over.

• Set the path over radius within the allowable range.

• Reset the alarm, and then try again.

If the error occurs again, contact your Yaskawa representative.

Set zero pulse for the C-and W-axis position at the cutting start position.

Set a value bigger than 0 for the radius.

The CUT instruction can be used for the manipulator with small-circle cutting axis only.

This robot cannot perform a hexagonal cutting motion. Select an other cutting form.

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8.3 Alarm Message List

Alarm

Number

4490

4491

4492

Message

DEFECTIVE

TAUGHT

POINT

(ENDLESS)

CORRECTIO

NAL

DIRECTION

ERROR

POSITION

CORRECTIO

N ERROR

Alarm Message List

Sub

Code

Cause

The Endless motion could not be performed.

1

• After the Endless rotation completed, an attempt was made to execute an interpolation instruction such as MOVL and

MOVC before executing an

MRESET instruction.

2

• The base axis is set as an

Endless rotation axis. The

Endless function cannot be used with the base axis.

3

• An attempt was made to execute the Endless function although the endless axis was not designated.

4

• The Endless axis exceeded the maximum pulse value

(

±536870911).

An error occurred in the calculation section for the correcting direction at path correcting motion.

1

• Control-group designation error for correcting-direction preparation

2

• Designation error for the correcting-direction coordinates

3

• When “any direction” is set for the correcting direction, the correction coordinates is not prepared.

4

• When “any direction” is set for the correcting direction, the reference points (REFP) are taught on the same point.

5

• Designation error for the coordinated motion control axis at the reference point

An error occurred in the calculation section for the correcting direction at path correcting motion.

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-group for the job.

2

• Data unmatched between the correction amount data and the job data:

The valid control-group information that is added to the correction amount data disagrees with the valid control-group for the job.

Remedy

To perform an interpolation motion such as MOVL and MOVC after an

Endless rotation, execute an

MRESET instruction beforehand.

Change the parameter setting that designates the Endless rotation axis.

Correct the rotation amount so that the Endless axis does not exceed the maximum pulse value.

• Reset the alarm, and then try again.

If the error occurs again, contact your Yaskawa representative.

Teach the correcting direction with the reference point (REFP).

Teach the reference points (REFP) so that each point is different.

• Reset the alarm, and then try again.

If the error occurs again, contact your Yaskawa representative.

• Reset the alarm, and then try again.

If the error occurs again, contact your Yaskawa representative.

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8.3 Alarm Message List

Alarm

Number

4493

4494

4494

4495

Message

OVER TOOL

FILE NO.

DEFECTIVE

TAUGHT

POINT

(WEAV)

DEFECTIVE

TAUGHT

POINT

(WEAV)

UNDEFINED

ROBOT

CALIBRATIO

N

Alarm Message List

Sub

Code

---

1

2

---

Cause Remedy

The tool file number exceeded the limit value.

• The tool number for internal control is 25 or more.

Incorrect teaching of weaving motion positions

• The weaving start point and end point are on the same point.

Incorrect teaching of weaving motion positions

• Among the weaving start point, end point, and reference point, two or three points are on the same point.

Calibration between manipulators has not executed.

• A coordinated motion is impossible because no calibration between manipulators has been made.

• Reset the alarm, and turn the power OFF then back ON.

If the error occurs again, contact your Yaskawa representative.

Change the positions so that the weaving start point and end point are different.

Change the positions so that the weaving start point, end point, and reference point are different.

Before using the coordinated motion, execute the calibration between manipulators.

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8.3 Alarm Message List

Alarm

Number

4496

Alarm Message List

Message

PARAMETER

ERROR

Sub

Code

Cause

2

3

Setting error of motion control parameter

1

• The setting of the manipulator number is incorrect.

• Zero is set for the resolution.

• Zero is set in the feedback pulse parameter.

4

• The setting of L-axis ball-screw data is incorrect.

5

• The setting of U-axis ball-screw data is incorrect.

6

• Zero or a negative value is set for

MAXPPS.

7

• Zero or a negative value is set for the maximum acceleration speed.

8

• Zero or a negative value is set for the maximum deceleration speed.

9

• Zero or a negative value is set for the play-mode servo averaging time.

10

• The setting of the manipulator number is incorrect. An undefined type is designated.

11

• The incorrect coordinate system is designated for the cubic interference. An undefined coordinate system is set.

12

13

• The designation of the user coordinates number is incorrect.

A number out of the setting range is set.

The reduction ratio

≤ 0 is output.

14

15

16

17

18

19

20

21

Remedy

• Set a correct value.

If the error occurs again, contact your Yaskawa representative.

• Zero or a negative value is set for the spring constant.

• Zero or a negative value is set for the motor inertia.

• Zero or a negative value is set for the speed calculation constant.

• Dividing number setting error

• Set a correct value for the resolution.

If the error occurs again, contact your Yaskawa representative.

• Set a correct value for the spring constant.

If the error occurs again, contact your Yaskawa representative.

• Set a correct value for the motor inertia.

If the error occurs again, contact your Yaskawa representative.

• Set a correct value for the speed calculation constant.

If the error occurs again, contact your Yaskawa representative.

If the error occurs again, contact your Yaskawa representative.

• Correct the parameter setting.

If the error occurs again, contact your Yaskawa representative.

• The setting of allowable torque for the speed reducer is incorrect.

• The setting of allowable torque for the motor is incorrect.

• The manipulator type is not applicable for torque acceleration/ deceleration.

• Zero or a negative value is set for the balancer.

Do not use the torque acceleration/ deceleration with this manipulator.

• Set a correct value for the balancer.

If the error occurs again, contact your Yaskawa representative.

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8.3 Alarm Message List

Alarm

Number

4496

Message

PARAMETER

ERROR

Alarm Message List

Sub

Code

Cause

Setting error of motion control parameter

22

• The angle of hexagon set for the

CUT instruction is out of the range

"0 degree < angle < 60 degrees".

23

24

25

26

27

28

29

30

31

32

33

34

35

36

37

38

39

40

41

42

43

44

Remedy

• Encoder type designation error

• Observer sampling time error

• Two-degree-of-freedom system

Kp value error

• The setting of torque acceleration/ deceleration designation parameter is incorrect.

• Observer polarity setting error

• The inertia value error for the shift value calculation

• Observer attenuation constant error

• Torque estimation parameter error

• The segment clock error occurred when the PV loop is 1 ms.

• Non-robot axis observer selection error

• Zero is set for the response time constant.

• Set a correct value for the angle of hexagon.

If the error occurs again, contact your Yaskawa representative.

If the error occurs again, contact your Yaskawa representative.

• Correct the parameter setting.

If the error occurs again, contact your Yaskawa representative.

If the error occurs again, contact your Yaskawa representative.

• Efficiency data error

• Zero is set for the averaging time constant.

• Correct the parameter setting.

If the error occurs again, contact your Yaskawa representative.

If the error occurs again, contact your Yaskawa representative.

• The averaging time constant must be set for the optimized acceleration/deceleration control.

• Correct the parameter setting.

If the error occurs again, contact your Yaskawa representative.

If the error occurs again, contact your Yaskawa representative.

• Torque limit ratio data error

• Coulomb friction data error

• Kinematic friction coefficient data error

• The setting in the optimized acceleration/deceleration designation parameter is incorrect.

• An uninstalled function is designated.

• Correct the parameter setting.

If the error occurs again, contact your Yaskawa representative.

• The dynamics-model calculation at the optimized acceleration/ deceleration is invalid.

• Zero is set for the inertia of dynamics fixed model.

• Designation error for dynamicsmodel calculation type

• The optimized acceleration/ deceleration control of speed limit

• Correct the parameter setting.

If the error occurs again, contact your Yaskawa representative.

If the error occurs again, contact your Yaskawa representative.

• Correct the parameter setting.

If the error occurs again, contact your Yaskawa representative.

If the error occurs again, contact your Yaskawa representative.

192/245

8.3 Alarm Message List

Alarm

Number

4496

Alarm Message List

Message

PARAMETER

ERROR

Sub

Code

Cause

Setting error of motion control parameter

45

• The axis designation parameter for the speed limit function is not set.

46

• The setting in the mode designation parameter for the speed limit function is incorrect.

47

• Zero or negative value is set in the allowable braking torque parameter for the speed limit function.

48

• Zero or a negative value is set in the speed adjustment ratio parameter for the speed limit function.

49

• Zero or a negative value is set in the torque limit adjustment ratio parameter for the acceleration/ deceleration tuning.

50

• Zero or a negative value is set in the parameter that sets the shortest acceleration/deceleration time for when the excessive torque is applied at the optimized acceleration/deceleration.

51

• Zero is set for the dimension information "a3" for the SKR manipulator.

52

• The setting of sealer-gun controlgroup parameter for the servo sealer control is incorrect.

53

• The parameter setting for the

Cartesian manipulator X-axis data is incorrect.

54

• The parameter setting for the

Cartesian manipulator Y-axis data is incorrect.

55

• The setting for the Dual-arm manipulator is incorrect.

56

57

60

61

62

70

• Zero or a negative value is set in the FORMCUT maximum acceleration/deceleration time parameter.

• The setting of expanded checkpoint designating bits for the arm interference check is incorrect.

• Zero or a negative value is set for the sphere at the arm interference check point.

• Zero or a negative value is set for the cylinder at the arm interference check point.

• The number of designated check points for the arm interference check is insufficient.

• All of X, Y, and Z value of the expanded check-point 1 for the arm interference check are set to zero.

8-103

Remedy

• Correct the parameter setting.

If the error occurs again, contact your Yaskawa representative.

Correct the parameter setting.

If the error occurs again, contact your Yaskawa representative.

Correct the parameter setting.

If the error occurs again, contact your Yaskawa representative.

Correct the parameter setting.

193/245

8.3 Alarm Message List

Alarm

Number

4496

Message

PARAMETER

ERROR

Alarm Message List

Sub

Code

Cause

Setting error of motion control parameter

71

• All of X, Y, and Z value of the expanded check-point 2 for the arm interference check are set to zero.

85

• The setting of wrist axis angle for tube-incorporated wrist type manipulators or three-roll wrist type manipulators is incorrect.

86

• The special link JOG operation cannot be used with this manipulator.

87

91

92

93

95

• The setting in the parameter for special angle limit check designation is incorrect.

• The setting of the deceleration speed for the path-priority control is less than zero.

• A negative value is set in the roundness parameter for the path-priority control.

• The link parameter for the cutting device is not set.

• The real-time bending correction function is enabled for a controlgroup other than robot axis.

96

97

• Zero is set for the dimension information "a2" for the Arc Cell

Torch Arm type manipulators.

• Zero is set for the deceleration ratio for double T-axis unit of the

V-shaped double T-axis manipulator.

Remedy

Correct the parameter setting.

Change the parameter setting to disable the special link JOG operation for this manipulator.

Correct the parameter setting.

If the error occurs again, contact your Yaskawa representative.

Correct the parameter setting.

This function cannot be used for control groups other than the robot axis. Correct the parameter setting.

Correct the parameter setting.

Correct the parameter setting.

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8.3 Alarm Message List

Alarm

Number

4497

4497

4498

4499

4500

Message

DEFECTIVE

TAUGHT

POINT

(CALIB)

DEFECTIVE

TAUGHT

POINT

(CALIB)

CANNOT

EXECUTE JOB

(NO GRP AXIS)

UNDEFINED

POSITION

VARIABLE

UNDEFINED

USER FRAME

Alarm Message List

Sub

Code

Cause

Incorrect teaching points for calibration between manipulators

1

• Some of the teaching points for master-group are on the same point.

2

• Some of the teaching points for slave-group are on the same point.

3

• The 2nd-axis positions of C3, C4, and C5 of station axes are not the same.

4

5

6

7

Remedy

Perform the teaching again so that the teaching points are different from one another.

• The 1st-axis positions of C1, C2, and C3 of station axes are not the same.

• The 2nd-axis positions of C1, C2, and C3 of station axes are the same.

• The 1st-axis rotation direction of

C3, C4, and C5 of station axes are not the same.

• The 1st-axis (elevation axis) positions of C1, C2, and C3 of station axes are not the same.

Perform the teaching again so that the 2nd-axis positions of C3, C4, and C5 of the station axes are the same.

Perform the teaching again so that the 1st-axis positions of C1, C2, and

C3 of station axes are the same.

Perform the teaching again so that the 2nd-axis positions of C1, C2, and C3 of station axes are not the same.

Perform the teaching again so that the 1st-axis rotation direction of C3,

C4, and C5 of station axes are the same.

Perform the teaching again so that the 1st-axis (elevation axis) positions of C1, C2, and C3 of station axes are the same.

Incorrect teaching points for calibration between manipulators

8

• The 1st-axis (elevation axis) positions of C3, C4, and C5 of station axes are not the same.

---

Perform the teaching again so that the 1st-axis (elevation axis) positions of C3, C4, and C5 of station axes are the same.

Register the instruction in a job with control group.

---

---

An error occurred in a job without control group.

• An attempt was made to execute an instruction that could not be executed in a job without control group.

The position type variable is not registered.

• An attempt was made to use the position type variable that was not set. (Subcode: The variable number)

The user coordinate is not registered.

• An attempt was made to use the user coordinate that was not set.

(Subcode: User coordinate number)

Set the position type variable.

Set the user coordinate.

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8.3 Alarm Message List

Alarm

Number

4501

4502

4505

4506

4507

4508

Message

OUT OF

RANGE

(PARALLEL

PROCESS)

SL BOARD

ON-LINE

ERROR

UNDEFINED

POSITION

FOR ARC ON

UNDEFINED

POS FOR

RESTART

RETURN

REFP POS

ERROR

(SEARCH

MOTION)

SPECIFIED

ERROR

(COORDINAT

E)

Alarm Message List

Sub

Code

Cause

---

---

---

---

---

An invalid coordinate system was specified.

0

• The specified coordinate system does not exist.

1

• Designation error of the master tool coordinate system. This coordinate system cannot be used.

2

Arc-restart-return could not be executed because there was no restart-return step in the job. (Example: A retry request was made while executing a step of the called job.)

Incorrect teaching point for search detection

• The search start point and the motion target point are the same, or the distance between the two points is too short.

• Designation error of the tool coordinate system. This coordinate system cannot be used.

6

The number of tasks exceeded the limit.

• An error occurred in the multi-task control process for the independent control function.

(Sub code: Task number)

An error occurred in option board at power ON. The option board was detected not to operate normally at power ON.

Arc retry could not be executed because there was no step before the

ARCON instruction.

• Designation error of the conveyor coordinate system. This coordinate system cannot be used.

Remedy

• Reset the alarm, and then try again.

If the error occurs again, contact your Yaskawa representative.

• Remove the option board, and insert it properly again.

If the error occurs again, contact your Yaskawa representative.

Register a step before the ARCON instruction.

Reset the alarm, and then reprogram the job.

• Perform the teaching again so that the search start point and the motion target point are not the same.

• Increase the distance between the search start point and the motion target point.

Reset the alarm, and then specify a valid coordinate system.

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8.3 Alarm Message List

Alarm

Number

4508

4509

4510

4511

Message

SPECIFIED

ERROR

(COORDINAT

E)

MFRAME

ERROR

CANNOT

EXECUTE

INSTRUCTIO

N (SQRT)

OUT OF

RANGE

(DROP-

VALUE)

Alarm Message List

Sub

Code

Cause

An invalid coordinate system was specified.

7

• Designation error of the weaving coordinate system. This coordinate system cannot be used.

8

• Designation error of the COMARC coordinate system. This coordinate system cannot be used.

10

• Designation error of the cylindrical coordinate system. This coordinate system cannot be used.

11

• Designation error of the coordinate system for the external reference point. This coordinate system cannot be used.

12

• Designation error of the coordinate system for 3D shifting.

This coordinate system cannot be used.

15

• Designation error of the coordinate system at IMOV for 3D shifting. This coordinate system cannot be used.

16

1

• Designation error of the H-LINK type cylindrical coordinate system. This coordinate system cannot be used.

An error occurred at

MFRAME execution.

---

---

Remedy

Reset the alarm, and then specify a valid coordinate system.

The SQRT instruction could not be executed.

• An attempt was made to calculate the square root of negative value.

(The second argument was negative.)

Incorrect robot position when the servo was turned

ON

The pulse difference of the robot position exceeded the allowable value between when the servo was OFF previously and when the servo was ON this time.

The standard allowable number of pulses is 100.

(Subcode: Control group exceeding the allowable value.)

The master or slave control group is incorrect when the master tool user coordinate is specified.

Correct the job.

Reset the alarm, and then try again.

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8.3 Alarm Message List

Alarm

Number

4512

Message

TWO STEPS

SAME LINE

(3 STEPS)

4513

4514

4515

4516

4517

4518

4519

4520

EXCESSIVE

SEGMENT

(SAFETY: 1)

: LOW

EXCESSIVE

SEGMENT

(SAFETY: 1)

: HIGH

EXCESSIVE

SEGMENT

(SAFETY: 2)

: LOW

EXCESSIVE

SEGMENT

(SAFETY: 2)

: HIGH

SEARCH

MONITOR

SET ERROR

(SERVO)

SEARCH

MON

RELEASE

ERROR

SPHERE

INTRF ERR

(ROBOT)

CALCULATIO

N

AXIS

BLOCKING

Alarm Message List

Sub

Code

---

---

---

---

---

---

---

1

---

Cause Remedy

The teaching points are aligned in a straight line.

• In the user coordinates for calibration between manipulators, three or more teaching points are aligned in a straight line.

At the safety speed 1, the manipulator motion speed exceeded the speed limit value (LOW level).

At the safety speed 1, the manipulator motion speed exceeded the speed limit value (HIGH level).

At the safety speed 2, the manipulator motion speed exceeded the speed limit value (LOW level).

At the safety speed 2, the manipulator motion speed exceeded the speed limit value (HIGH level).

An error occurred in search/ monitoring mode settings in servo section.

• An error occurred in interface with servo section at search/ monitoring mode. (Subcode: The related control-group)

An error occurred in search/ monitoring mode releasing in servo section.

• An error occurred in interface with servo section at search/ monitoring mode. (Subcode: The related control-group)

An error occurred in sphere interference between manipulators.

• No calibration between manipulators has been made.

A motion was commanded for the group axis during axis block at play mode.

(Subcode: The related control-group)

Perform the teaching again so that the teaching points are not aligned in a straight line.

• Reduce the speed of the step (move instruction) where the alarm occurred.

• The manipulator may be near the singular point. Change the position and orientation of the manipulator.

• Reduce the speed of the step (move instruction) where the alarm occurred.

• The manipulator may be near the singular point. Change the position and orientation of the manipulator.

• Reduce the speed of the step (move instruction) where the alarm occurred.

• The manipulator may be near the singular point. Change the position and orientation of the manipulator.

• Reduce the speed of the step (move instruction) where the alarm occurred.

• The manipulator may be near the singular point. Change the position and orientation of the manipulator.

Check the system versions for

NCP30 and AXC01.

Perform the calibration between manipulators.

Reset the alarm, and then try again.

Turn ON the general-purpose input signal set in the parameter.

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8.3 Alarm Message List

Alarm

Number

4521

4522

4524

4525

4527

4528

Alarm Message List

Message

WRONG JOB

TYPE

TAG DATA

CHANGE

PROCESS

ERROR

CANNOT

EXECUTE

INST

(CONCUR

JOB)

SPECIFIED

JOB

EXECUTION

IMPOSSIBILI

TY

UNDEFINED

PORT NO.

(AOUT)

SYNTAX

ERROR

Sub

Code

Cause

Job type is inconsistent.

0000

_000

1

• A robot job was started from the concurrent job at CALL/JUMP instruction execution.

0000

_100

1

1000

_000

1

• A concurrent job was started from the robot job at CALL/JUMP instruction execution.

• A system job was started from the robot job at CALL/JUMP instruction execution.

3

7

An error occurred at tag data change.

2

• An error occurred at instruction read-in.

• The tag is not registered.

---

An error occurred at tag data change.

An error occurred at concurrent job execution.

• There was an unexecutable instruction such as move instruction in the concurrent job.

---

---

---

An error occurred at startup of multi-system job.

• The specified job could not be executed.

Incorrect analog output port number

• The specified analog output port number was not allowed.

An error occurred in the instruction syntax.

• The function and the corresponding instruction data is inconsistent in the system software. (Subcode: Box number)

Remedy

Check that what type of job will be started before starting.

• Correct the job file.

If the error occurs again, contact your Yaskawa representative.

Correct the job.

Needs investigation. Contact your

Yaskawa representative.

Correct the specified analog output port number.

• Needs investigation. Contact your Yaskawa representative.

• If replacement of the system software is necessary, follow the instructions for replacement. After replacement, delete the corresponding instructions, and then reregister them.

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8.3 Alarm Message List

Alarm

Number

4529

4530

4531

4532

Message

TWIN

COORDINAT

ED ERROR

CONVEYOR

SYNCHRONI

ZING ERROR

CONVEYOR

CHARACTER

ISTIC FILE

UNSET

CONVEYOR

SPEED

DOWN

Alarm Message List

Sub

Code

3

Cause

An error occurred at twin synchronization execution.

1

• A job without control group was started by SYNC instruction.

2

• A job only with robot axes was started by SYNC instruction.

3

• A job only with master control group axes was started by SYNC instruction.

4

• At full synchronization, the completion timings of move instructions for the master and the slave disagreed.

5

• At full synchronization, no operation request from the master was sent.

6

• At full synchronization, the execution timings of move instructions for the master and the slave disagreed.

An error occurred in conveyor synchronization execution.

1

• The base axis specification is other than 1 or 2 for conveyor characteristic file.

2

• No robot axis in the job for robot axis tracking

• No base axis in the job for base axis tracking

4

5

10

---

---

• The conveyor board number and conveyor characteristic file number used are incorrect.

• There was no conveyor start position data at prereading processing.

• No base axis in the job for arc tracking

Conveyor characteristic file is not set.

• "Use state" of the conveyor characteristic file set for the job is not set to "1: Use". (Subcode:

Conveyor characteristic file number)

The conveyor speed decreased below the

"Conveyor Lowest Speed" set in the conveyor characteristic file. (conveyor number for subcode.)

Remedy

Specify a R

□+S□job for the job started by SYNC instruction.

• Correct the job.

If the error occurs again, contact your Yaskawa representative.

• Correct the job.

If the error occurs again, contact your Yaskawa representative.

• Reset the alarm, and then try again.

If the error occurs again, contact your Yaskawa representative.

Set "Use state" of conveyor characteristic file set for the job to

"1: Use".

Correct the "Conveyor Lowest

Speed" set in the conveyor characteristic file.

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8.3 Alarm Message List

Alarm

Number

4533

4534

4535

4536

4537

4538

Alarm Message List

CONVEYOR

TRACKING

CALCULATIO

N

Message

ERROR

TORQUE

INTERFERE

NCE

PSEND

ERROR

PRECV

ERROR

OFFLINEMAI

L BOX

PROCESSIN

G ERROR

ROBOT AXIS

TRACKING

IMPOSIBILIT

Y

Sub

Code

Cause

An internal control error occurred at conveyor tracking motion.

1

• Designation error of the conveyor tracking control-group

2

• Designation error of the user coordinates for the conveyor tracking

3

• An attempt was made to use the conveyor tracking function with the slave manipulator at coordinate motion.

4

• Zero is set for the resolution for the turn-table synchronization.

--Excessive interference torque

• The load torque of an axis motor exceeded the allowable value when the manipulator is operating at the specified speed.

An error occurred at PSEND instruction execution.

1

• An attempt was made to send a mail to its own task.

1

2

3

1

• The mail box number is incorrect.

An error occurred at PRECV instruction execution.

• An attempt was made to receive a mail from its own task.

2

3

• The mail data type is inconsistent.

• The mail box number is incorrect.

An error occurred in mail box control in the offline processing section.

• Mail box number error

• Undefined command for mail box operation

3

---

• OFF_MB_IFS pointer is incorrect.

The robot axis tracking could not be executed.

• An attempt was made to execute the SYMOVJ instruction at robot tracking.

Remedy

• Reset the alarm, and then try again.

If the error occurs again, contact your Yaskawa representative.

Set a correct value for the resolution.

• Check if the weight information in the tool file is correctly set.

• Reduce the speed in the step where the alarm occurred.

• Change the position and orientation in the step where the alarm occurred.

Check the destination address.

Check the destination address.

• Reset the alarm, and then try again.

If the error occurs again, contact your Yaskawa representative.

Correct the job.

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8.3 Alarm Message List

Alarm

Number

4539

4539

4540

4541

4542

Message

CORNER R

CONTROL

ERROR

CORNER R

CONTROL

ERROR

JOB QUE

EMPTY

ERROR

INVALID INPUT

STRING (VAL)

MRESET

ERROR

Alarm Message List

Sub

Code

Cause

An internal control error occurred at the Corner-R motion.

1

• The Corner-R motion cannot be used for coordinated motion.

2

3

• An attempt was made to execute the Corner-R motion for the same point.

• The Corner-R zone is taught on a straight line.

Remedy

Do not use the Corner-R motion for coordinated motion.

Perform the teaching again so that the start step and end step are not on the same point.

Perform the teaching again so that the Corner-R zone is not on a strait line.

An internal control error occurred at the Corner-R motion.

4

• The start position or end position for the Corner-R motion could not be calculated inside the start zone or the end zone.

5

• The Corner-R motion cannot be used for coordinated motion (with master manipulators).

6

• Change the setting for the Corner-R radius.

• Perform the teaching again for the start step or end step for Corner-R.

Do not use the Corner-R motion for master manipulators at coordinated motion.

Use a MOVL instruction when using the Corner-R motion.

7

8

9

17

---

• The Corner-R motion cannot be used for MOVC, MOVS, and

EIMOVC instructions.

• The Corner-R motion is disabled during weaving.

• Different tool numbers are set in a

Corner-R zone (for the Corner-R middle step and end step).

• The Corner-R motion is disabled when the higher-order acceleration/deceleration is specified.

• The Corner-R motion is disabled during conveyor tracking.

Do not perform weaving when using the Corner-R motion.

Use the same tool number in a

Corner-R zone.

Disable the higher-order acceleration/deceleration when using the Corner-R motion.

Do not perform the conveyor tracking when using the Corner-R motion.

Set a data to a job queue, and then call "QUE".

---

1

No job queue data

• "QUE" is used in CALL or JUMP instruction under the condition that no job queue is used.

An error occurred at VAL instruction execution.

• An attempt was made to convert a character string that could not be converted to a numerical value.

An error occurred at

MRESET instruction execution.

• An MRESET instruction was executed while no endless axis was designated.

Check the data of character string of conversion source.

• Reset the alarm, and then try again.

If the error occurs again, contact your Yaskawa representative.

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8.3 Alarm Message List

Alarm

Number

4543

4544

4545

4546

4547

4548

4549

4550

Message

JOB CALL

STACK

ERROR

MID$ ERROR

COMMUNICA-

TION SERVICE

ERROR

CANNOT

EXECUTE

SYSTEM JOB

PRIMITIVE

ERROR

CANNOT

OPERATE

SPECIFIED

EVENT QUE

INIEVNT NOT

EXECUTED

CANNOT EXE-

CUTE INST

(USER JOB)

Alarm Message List

Sub

Code

Cause

---

An error occurred at MID$ instruction execution.

1

• The first character of character string to be extracted is null at

MID$ instruction execution.

2

An error occurred at job return.

• At job return, an attempt was made to fetch a data from an empty job call stack or to stack a data in the job call stack that is full.

---

• The extraction start position exceeds the character string length at MID$ instruction execution.

An error occurred at OPEN/

CLOSE instruction execution.

• An error occurred in the communication service at OPEN/

CLOSE instruction execution.

---

---

---

---

---

The system job could not be executed.

• An error in the system number of system job. (Subcode: System number)

A primitive error occurred in the system software.

(Subcode: Error code)

An error occurred at

INIEVNT instruction execution.

• The specified event could not be operated at INIEVNT instruction execution.

An error occurred at

INIEVNT instruction execution.

• INIEVNT instruction was not executed before having executed the event related process.

(Subcode: System number)

The specified instruction in the user job could not be executed. (Subcode:

System number)

Remedy

• Reset the alarm, and then try again.

If the error occurs again, contact your Yaskawa representative.

Check the data of the character string to be extracted.

Check the extraction start position or the data of the character string to be extracted.

• Reset the alarm, and then try again.

If the error occurs again, contact your Yaskawa representative.

• Reset the alarm, and then try again.

If the error occurs again, contact your Yaskawa representative.

• Reset the alarm, and then try again.

If the error occurs again, contact your Yaskawa representative.

• Reset the alarm, and then try again.

If the error occurs again, contact your Yaskawa representative.

Execute an INIEVNT instruction.

Correct the job.

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8.3 Alarm Message List

Alarm

Number

4565

Message

SOFTWARE

UNMATCH

4565 SOFTWARE

UNMATCH

Alarm Message List

Sub

Code

Cause

2

3

4

The used function and the system are inconsistent.

1

• The multi-layer welding function is not used.

• The observer function is not used.

• The TURBO function is not used.

• The COMARC function is not used.

5

• The conveyor/press synchronization function is not used.

6

• The shared motion function is not used.

7

• The layer motion function is not used.

8

• The general sensor function is not used.

9

• The servo float function is not used.

10

• The laser cutting function (with small circle cutter) is not used.

11

• The motor gun function (for spot welding application) is not used.

12

• The speed control function

(VCON/VCOF) is not used.

13

• The servo hand function (for handling application) is not used.

14

• The laser cutting function (for form cutting operation) is not used.

15

• The series communication function between the systems

(PSEND/PRECV) is not used.

16

• The motion extension function is not used.

17

• The bending function is not used.

The used function and the system are inconsistent.

18

• The ME-NET function is not used.

255

• An attempt was made to execute an undefined instruction.

Remedy

• Reset the alarm, and then try again.

If the error occurs again, contact your Yaskawa representative.

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8.3 Alarm Message List

Alarm

Number

4566

4567

4568

4569

4571

4572

4573

4574

Alarm Message List

USER

COORDINAT

ES

Message

GENERATIO

N ERROR

CANNOT

MONITOR

DISTANCE

UNDEFINED

PRESS

CHARACTER

ISTIC FILE

PRESS

RESOLUTIO

N DATA

UNSET

SERVO

FLOAT

MODE

RELEASE

ERROR

UNDEFINED

MOTOR GUN

CONTROL

GRP

SPOT

WELDER

NUMBER

ERROR

---

---

SPOT WELD

COMPLETE

TIME LIMIT

Sub

Code

Cause

5

6

1

2

An internal control error occurred at preparation of a user coordinates.

• The teaching points are incorrect.

3

• The teaching points for usercoordinate turning are incorrect.

An internal control error occurred at preparation of a user coordinates.

• The robot axis is not specified for the control group of the job to prepare the user coordinates.

• Position data error

---

---

---

---

• Setting error of the slave group for user coordinate conversion

The distance could not be monitored when executing a move instruction.

• An attempt was made to execute

MOVJ/MOVS instruction in arc retry or restart operation.

No press characteristic file is set.

• An attempt was made to use the unused press characteristic file in a job. (Subcode: Press characteristic file number)

No press resolution data is set.

• The status of press resolution data to be used in the job was set to "Incomplete". (Subcode: Press characteristic file)

The servo float mode could not be reset when executing a FLOATOF instruction.

---

The control group for the motor gun is not set.

Incorrect spot welder number

• The welder number set in the gun characteristic file is incorrect.

(Subcode: Welder number)

The spot welding did not complete within the specified time.

• Neither the welding completion signal nor the welding error signal was received from the timer conductor within the set time.

(Subcode: Welder number)

MOVC.

State".

"Completed".

Remedy

Perform the teaching again for the user coordinates.

• Reset the alarm, and then try again.

If the error occurs again, contact your Yaskawa representative.

Do not perform the arc retry or restart operation, or change the interpolation instruction to MOVL/

Set the status of press characteristic file to be used in the job to "Used

Set the data, and then press "Data

Set" button to set the status to

• Check the ROM version of servo board.

• Reset the alarm, and then try again.

If the error occurs again, contact your Yaskawa representative.

Restart the setting of configuration in maintenance mode, and correct the setting of motor gun axis.

Correct the welder number set in the gun characteristic file.

• Remove the cause such as disconnection of power supply to the timer conductor, and then try again.

• If the response from the timer takes too long time due to the system layout, increase the set time.

8-115

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8.3 Alarm Message List

Alarm

Number

4575

4576

4577

4578

4579

4580

4581

4583

4584

Message

ERROR IN

WELD START

TIMING SET

ERR IN

MOTOR GUN

CONT MODE

ERR IN

MOTOR GUN

MODE RLSE

SPOT WELD

ERROR

ANTICIPATIO

N CONTROL

ERROR

ANTICIPATIO

N DISTANCE

SHORTAGE

DEFECTIVE

ANTICIPATIO

N FILE

CANNOT

EXECUTE

GUN TYPE

STRWAIT

TIME OUT

Alarm Message List

Sub

Code

Cause

---

---

---

---

Incorrect setting of spot welding start timing

• For motor gun, the welding timing was set to "After First Pressure" while no 2nd pressure was set.

An error occurred when setting the motor gun control mode.

• Though a motor gun control mode setting command was sent to the servo section, no response was received.

An error occurred when resetting the motor gun control mode.

• Though a motor gun control mode resetting command was sent to the servo section, no response was received.

An error occurred when executing spot welding.

• An error occurred when executing welding using the specified system timer conductor.

(Subcode: Welder number)

An error occurred in the anticipation control processing.

1

• No availability in anticipation control

2

---

• The anticipation data exceeded the maximum length.

Anticipation could not be executed at re-painting.

• No return step in re-painting function after emergency stop

An error occurred in the anticipation output file.

1

• Incorrect setting of OT output number for anticipation output file

2

---

• Incorrect setting of OG output number for anticipation output file

An invalid gun type is set.

• The mode impossible to control is set for the gun.

--An error occurred when executing a STRWAIT instruction.

• No confirmation signal specified in the stroke change confirmation instruction was input within the set time.

Remedy

Set the 2nd pressure, or change the start timing.

• Check the ROM version of servo board.

• Reset the alarm, and then try again.

If the error occurs again, contact your Yaskawa representative.

• Check the ROM version of servo board.

• Reset the alarm, and then try again.

If the error occurs again, contact your Yaskawa representative.

Reset the timer conductor where the welding error occurred, and then try again.

Register a move instruction between work instructions.

• Reset the alarm, and then try again.

• Refer to Painting System Additional

Function Manual for details.

Reset the alarm, and then correct the set number.

Change the motion mode set to the gun.

• Remove the cause such as defective limit switch, and then try again.

It the error occurs again, contact your Yaskawa representative.

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8.3 Alarm Message List

Alarm

Number

4585

4587

4587

4591

4592

Alarm Message List

Message

SERVO PART

PG POWER

ON ERROR

MOTOR GUN

CHANGE

ERROR

Sub

Code

Cause

--The PG power supply could not be turned ON.

• The encoder power supply could not be turned ON when turning

ON the control power supply.

An error occurred when changing the gun.

1

• A GUNCHG instruction was executed in the system configuration that did not allow the gun change function.

2

• A GUNCHG/PICK instruction was executed while the motor gun motor was servo ON.

Remedy

Check the cable connection of motor gun encoder.

Check the cable connection of motor gun encoder.

Execute GUNCHG/PICK instruction when the motor gun motor is servo

OFF.

MOTOR GUN

CHANGE

ERROR

SERVO PART

SPEED

CONTROL

MODE

SETTING

ERROR

SERVO PART

SPEED

CONTROL

MODE

RELEASE

ERROR

---

An error occurred when changing the gun.

3

• A GUNCHG/PICK instruction was executed while the ATC was in unchuck status.

4

• A GUNCHG/PLACE instruction was executed while the ATC was in unchuck status.

5

• The encoder power supply could not be turned ON when executing a GUNCHG/PICK instruction.

6

• The encoder power supply could not be turned OFF when executing a GUNCHG/PLACE instruction.

7

• The gun number specified by the

GUNCHG instruction did not agree with the gun identification signal.

8

• The 1st gun axis selection signal is not set when executing the twin-wrist gun change.

9

---

• The right and left gun axis selection signals were duplicated when executing the twin-wrist gun change.

An error occurred at speed control mode setting.

• Though a speed control mode setting command was sent to the servo section, but no response was received.

An error occurred at speed control mode release.

• Though a speed control mode release command was sent to the servo section, but no response was received.

Execute GUNCHG/PICK instruction when the ATC is in chuck status.

Check the cable connection of motor gun encoder.

• Check the gun characteristic file number specified by GUNCHG instruction.

• Check the status of gun identification signal.

Check the 1st gun axis selection signal setting.

Check the setting for the gun axis selection signal.

• Check the ROM version of servo board.

• Reset the alarm, and then try again.

If the error occurs again, contact your Yaskawa representative.

• Check the ROM version of servo board.

• Reset the alarm, and then try again.

If the error occurs again, contact your Yaskawa representative.

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8.3 Alarm Message List

Alarm

Number

4593

4594

Message

SERVO

HAND

CONTROL

MODE

SETTING

ERROR

SERVO

HAND

CONTROL

MODE

RELEASE

ERROR

Alarm Message List

Sub

Code

---

Cause Remedy

An error occurred at servo hand control mode setting.

• Though a servo hand control mode setting command was sent to the servo section, but no response was received.

• Check the ROM version of servo board.

• Reset the alarm, and then try again.

If the error occurs again, contact your Yaskawa representative.

--An error occurred at servo hand control mode setting.

• Though a servo hand control mode release command was sent to the servo section, but no response was received.

• Check the ROM version of servo board.

• Reset the alarm, and then try again.

If the error occurs again, contact your Yaskawa representative.

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8.3 Alarm Message List

Alarm

Number

4595

Message

FORM

CUTTING

MOTION

IMPOSSIBILI

TY

Alarm Message List

Sub

Code

Cause

An internal control error occurred in the Form Cutting motion.

1

2

The setting for radius is incorrect.

• For a circle, it is incorrectly set as: radius

≤ 0, radius < minimum radius value, or radius

> maximum radius value.

• For an ellipse, it is incorrectly set as: radius

≤ 0, radius < minimum radius value/2, or radius

>

(maximum radius/2

− width/2).

The setting for width is incorrect.

• For a rectangle, it is incorrectly set as: width

< 1.0, width > sqrt

(maximum diameter

2

− height

2

), or width

> maximum diameter.

• It is incorrectly set as: width

< 0, width

> maximum diameter −2 × radius.

3

4

5

The setting for height is incorrect.

• For a rectangle, it is incorrectly set as: height

> maximum diameter, height

< minimum diameter/2, or height > sqrt (maximum diameter

2

− width

2

).

The setting for the corner radius is incorrect.

• For a rectangle, it is incorrectly set as: corner radius > width/2 or corner radius > height/2.

The setting for overlap is incorrect.

• For a rectangle, it is incorrectly set as overlap > width/2.

• For a circle, it is incorrectly set as overlap > ABS (2π × radius).

• For an ellipse, it is incorrectly set as overlap > π × radius +ABS

(width/2).

6

7

The setting for the cutting speed is incorrect. It is set as the cutting speed

> maximum linear speed.

• Coordinated motion cannot be used with the Form Cutting motion.

8

9

• Zero or a negative value is set in the minimum diameter parameter

(S1CxG063) for the Form Cutting motion.

• Zero or a negative value is set in 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

8-119

FORMAPR instruction was not executed.

Remedy

Correct the radius data.

Correct the width data.

Correct the height data.

Correct the corner radius data.

Correct the overlap data.

Correct the cutting speed data.

Do not use the coordinated motion.

Correct the setting of the minimum diameter parameter (S1CxG063) for the Form Cutting motion.

Correct the setting of the maximum diameter parameter (S1CxG064) for the Form Cutting motion.

Execute the FORMAPR instruction.

209/245

8.3 Alarm Message List

Alarm

Number

4595

Message

FORM

CUTTING

MOTION

IMPOSSIBILI

TY

Alarm Message List

Sub

Code

An internal control error occurred in the Form Cutting motion.

11

12

13

Cause

• The Cut file setting of the

FORMAPR instruction is different from that of the FORMCUT instruction.

• A FORMAPR instruction was used for the conventional

FORMCUT instruction.

• A form other than a circle, rectangle, and ellipse was designated for the conventional

FORMCUT instruction.

Remedy

The Cut file settings of FORMAPR and FORMCUT instructions must be same.

The FORMAPR instruction cannot be used for the conventional

FORMCUT instruction.

• Change the instruction.

• Needs to validate the new FORMCUT instruction. Contact your Yaskawa representative.

A form other than a circle, rectangle, and ellipse cannot be designated for the conventional FORMCUT instruction.

• Designate a circle, rectangle, or ellipse.

• Needs to validate the new FORMCUT instruction. Contact your Yaskawa representative.

Correct the radius data.

90

• The radius data setting for special circular interpolation is incorrect.

It is incorrectly set as the radius

≤

0.

91

• The arc center coordinates could not be calculated at special circular interpolation. Incorrect teaching may be the cause.

92

• The arc center coordinates could not be calculated at special circular interpolation. Incorrect teaching may be the cause.

93

• The averaging time at special circular interpolation motion is too short.

94

• Because the designated plane included reference points at special circular interpolation motion, the arc center coordinates could not be calculated. Incorrect teaching of the reference point 2 may be the cause.

100

• The arc center position is not set for the special circular interpolation motion.

Perform the teaching again.

• Perform the teaching again so that the moving distance becomes longer.

• Reduce the motion speed.

Perform the teaching again for the reference point 2.

Perform the teaching for the reference point 1 as the arc center position.

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8.3 Alarm Message List

Alarm

Number

4597

Message

OFFLINE

POSITION

DATA

CONVERSIO

N ERROR

Alarm Message List

Sub

Code

Cause

An internal control error occurred at offline position data conversion.

1

• Incorrect information of reference position data for offline position data conversion

2

• Incorrect user-coordinate number designation in the standard position data for offline position data conversion

3

• Incorrect reference-point data for offline position data conversion

4

• The standard position data for offline position data conversion could not correctly be calculated.

Remedy

• Reset the alarm, and then try again.

If the error occurs again, contact your Yaskawa representative.

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8.3 Alarm Message List

Alarm

Number

4597

Message

OFFLINE

POSITION

DATA

CONVERSIO

N ERROR

Alarm Message List

Sub

Code

Cause

An internal control error occurred at offline position data conversion.

5

• Incorrect pulse incremental value for offline position data conversion

6

• The position data could not correctly be added by the pulse incremental value at the offline position data conversion.

7

• Incorrect Cartesian incremental value for offline position data conversion

8

• The position data could not correctly be added by the

Cartesian incremental value at the offline position data conversion.

9

• The position conversion could not be done in the designated coordinate system at the offline position data conversion.

10

• Incorrect incremental value of angle for offline position data conversion

11

• The position data could not correctly be added by the incremental value of angle at the offline position data conversion.

12

• The reverse shift value for 3D shifting could not correctly be calculated at the offline position data conversion.

13

• The reverse shift value for 3D shifting could not correctly be added at the offline position data conversion.

14

• The reverse shift value could not correctly be calculated at the offline position data conversion.

15

• The reverse shift value could not correctly be calculated at the offline position data conversion.

16

• The 3D shifting value could not correctly be added at the offline position data conversion.

17

• The shift value could not correctly be added at the offline position data conversion.

18

• No reference point is specified for the offline position data conversion.

19

• The positions for the mirror shift function could not correctly be calculated at the offline position data conversion.

20

• The positions could not correctly be converted for the mirror shift function at the offline position data conversion.

Remedy

• Reset the alarm, and then try again.

If the error occurs again, contact your Yaskawa representative.

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8.3 Alarm Message List

Alarm

Number

4597

4599

4601

4603

4604

4605

4606

Alarm Message List

Message

OFFLINE

POSITION

DATA

CONVERSIO

N ERROR

SERVO

COMMAND

ERROR

UNDEFINED

GUN COND

FILE

WIRE

STICKING

DESIGNATE

D AXIS

HOME

POSITION

CORRECTIO

N DATA NON-

EXISTING

SETTOOL

ERROR

---

Sub

Code

Cause

An internal control error occurred at offline position data conversion.

21

• The expansion positions for the mirror shift function could not correctly be converted at the offline position data conversion.

22

• Incorrect designation of coordinates for a new mirror-shift conversion function at the offline position data conversion

0

---

---

---

An abnormal response was returned from the servo control section.

The servo control processing has not completed.

The motor gun characteristic file is not set. (Subcode:

Motor gun characteristic file number)

Wire stick occurred at spot welding.

• Wire stick was detected at the welder. (Subcode: Welder number)

No home position correction data of specified axis

GLOBAL

VARIABLE

AREA

OVERFLOW

---

An error occurred when executing a SETTOOL instruction.

• The difference between the current tool constant and a new set value exceeded the allowable range (parameter set value).

The memory area of global variable exceeded the limit value.

• An error occurred in the value of parameter that defines the number of global (user) variables.

Remedy

• Reset the alarm, and then try again.

• Turn the power OFF then back ON.

If the error occurs again, contact your Yaskawa representative.

Complete the settings for the motor gun characteristic file.

Remove the cause of wire stick.

• Reset the alarm, and then try again.

If the error occurs again, contact your Yaskawa representative.

• Check if the tag set value is correct.

• Check if the parameter is set correctly.

Correct the number of global (user) variables to be used, or correct the parameter value.

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8.3 Alarm Message List

Alarm

Number

4607

Message

MACRO

COMMAND

EXECUTION

ERROR

4608

4609

4610

JOB

ARGUMENT

GET ERROR

MEMORY

PLAY FILE

ERROR

MEMORY

PLAY

SAMPLING

ERROR

Alarm Message List

Sub

Code

Cause

2

3

An error occurred when executing a macro instruction.

1

• The execution macro job is not set.

• The interrupt macro job is not set.

• An attempt was made to start the job that could not be started by the macro instruction.

5

1

2

• An error occurred in the operation process of job call stack when the execution of macro instruction was cancelled.

6

• Incorrect macro number

An error occurred when executing a

GETARG instruction.

• The job argument is not set.

• No number of the specified job argument

3

• The data types of job argument disagreed.

An error occurred when executing the memo play operation.

2

• The memory play file was being used in another system.

5

• The control group in the memory play file did not agree with the control group of execution job.

6

• An attempt was made to clear the memory play file by a CLEAR instruction before having executed a MEMOF instruction.

An internal control error occurred at memory play sampling.

1

• Failed to read the memory play sampling data.

2

• Failed to write the memory play sampling data.

3

• Failed to seek the memory play sampling data.

4

• Incorrect mode setting at memory play sampling

5

6

7

8

• Incorrect designation of the control group at memory play sampling

• K/N

< 0 in the memory play sampling section

• The memory play sampling data back-play mode could not be detected.

• The memory play sampling data could not be initialized.

Remedy

Correct the registration of interrupt macro job.

Correct the macro job.

• Reset the alarm, and then try again.

• Turn the power OFF then back ON.

If the error occurs again, contact your Yaskawa representative.

Correct the job.

Correct the job.

• Reset the alarm, and then try again.

If the error occurs again, contact your Yaskawa representative.

Correctly set the memory play mode.

• Reset the alarm, and then try again.

If the error occurs again, contact your Yaskawa representative.

• Reset the alarm, and then try again.

If the error occurs again, contact your Yaskawa representative.

8-124

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8.3 Alarm Message List

Alarm

Number

4611

4612

4613

4613

4614

4615

N

Message

OPTON

INSTRUCTIO

EXECUTION

NUMBER

OVER

TSYNC

ERROR

SERVO

SEALER

GUN

CONTROL

ERROR

SERVO

SEALER

GUN

CONTROL

ERROR

SEALER

GUN

CHARACTER

ISTIC FILE

UNSET

I/O AXIS

MOTION

IMPOSSIBILI

TY (during playback)

0

Alarm Message List

Sub

Code

---

Cause Remedy

An error occurred when executing a OPTON instruction.

• The number of times that the

OPTON instruction was executed exceeded the limit value.

Correct the OPTON instruction.

--An error occurred at the execution of the TSYNC instruction.

• The number of synchronizations

(SNUM) specified by the TSYNC instruction disagreed. (Sub code: the number of synchronizations of the first executed TSYNC)

An internal control error occurred in the servo sealer gun motion.

1

• The function designation parameter is not set.

Set the same number of synchronizations of the TSYNC instruction.

• Set the function designation parameter.

If the error occurs again, contact your Yaskawa representative.

2

3

• No sealer gun axis exists at the job for which the sealer gun control was attempted to be executed.

• No robot axis exists at the job at which an attempt was made to execute sealer gun control.

• Incorrect designation of the control method for sealer gun control

• Correct the job.

If the error occurs again, contact your Yaskawa representative.

4 Set either "1" or "2" for PRM1 control method designation of the

OPTON instruction.

An internal control error occurred in the servo sealer gun motion.

5

• Incorrect designation of the needle position for sealer gun control

6

0

• Incorrect designation of the sealing width for sealer gun control

The servo sealer gun condition file is not set.

If "1" is set for PRM1 of the OPTON instruction, set the PRM2 needle position designation to a value between 0 and 100.

If "2" is set for PRM1 of the OPTON instruction, set PRM2 sealing width designation to a value between 0 and 30.

Set the servo sealer gun condition file.

I/O axis motion could not be performed. (in playback)

• An attempt was made to command a job whose control group was in I/O axis motion.

• Stop the I/O axis motion.

• Correct the job.

8-125

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8.3 Alarm Message List

Alarm

Number

4616

4617

4618

4619

4620

4621

4622

Message

AXIS SHIFT

ERROR

SU AXIS

MOTION

DISABLED

(LR AXIS

POSITION

ERROR)

SHIFT

INSTRUCTIO

N

EXECUTION

ERROR

UNDEFINED

JOB ENTRY

TABLE

ARM (TOOL)

INTERFERE

NCE

WELD COM-

PLETE SIGNAL

ERROR

SELF

INTERFERE

NCE

Alarm Message List

Sub

Code

Cause

An internal control error occurred when shifting the axis.

1

• The file could not be switched because of incorrect start point designation.

2

3

SU-axes cannot move with the current L- and R-axes position.

1

• For the CSL15D manipulator, the motion speed of S- and U-axes exceeded the upper limit.

2

• The calibration file number for axis shifting function is out of the applicable range.

1

• For the CSL15D manipulator, S- and U-axes were going to move regardless of the limit speed "0" when the positions of L- and Raxes exceeded the upper limit.

An internal control error occurred at execution of the

SHIFT instruction.

• For the tool shift with Euler angle

±90 degrees, the shift value for axes other than Y-axis is set.

---

• The control group with which the axis shifting is performed disagrees with the control group set for the axis shifting function in the calibration file.

0

---

0

An error occurred in job registration table.

• The job registration table is not set. (Subcode: Designated registration number)

Arms or tools interfere between manipulators.

• The arm interference check between manipulators detected that manipulator’s arms or tools are interfered.

An error occurred in welding completion signal.

• The welding completion signal was ON when starting the spot welding instruction execution.

(Subcode: Welder number)

The manipulator’s arm interferes with a tool.

• The manipulator’s self interference check detected that the manipulator’s arm interferes with a tool.

Remedy

• Reset the alarm, and then try again.

If the error occurs again, contact your Yaskawa representative.

• Reset the alarm, and then try again.

If the error occurs again, contact your Yaskawa representative.

• Reduce the speed of S- and U-axes.

• Teach the positions of L- and R-axes again so that S- and U-axes can move.

Set the shift value for Y-axis only.

Set the job registration table.

Perform the teaching again to correct positions for manipulators.

Check the settings for welding completion signal.

Perform the teaching again to correct positions for manipulators.

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8.3 Alarm Message List

Alarm

Number

4623

4624

4625

Message

GETPOS

COMMAND

ERROR

PLUG VOLUME

SETTING

ERROR

WRONG

EXECUTION OF

LOADDB INST

Alarm Message List

Sub

Code

Cause

An error occurred when executing a

GETPOS instruction.

1

• An attempt was made to obtain the step that used a local position type variable. (The step with local position type variable cannot be fetched. Example: MOVJ LP000

VJ=25.00)

2

• An attempt was made to obtain the step that used an array position type variable. (The step with array position type variable cannot be fetched. Example:

MOVJ P[0] VJ=25.00)

3

---

• The specified step did not exist.

Incorrect setting of amount of fillings

Remedy

Correct the GETPOS instruction.

Review the setting for the amount of fillings.

-14

-15

-30

-31

-9

-10

-11

-12

-5

-6

-7

-8

-1

-2

-3

-4

1

2

An error occurred when executing a

LOADDB instruction.

4

• No file

• No directory

• There was no directory entry after this point.

• No file name

• File presence error

• Incorrect file name

• The disk is full.

• The directory is full.

• I/O error

• Invalid handle

• Handle overflow

• File has already been opened.

• File attribute error

• Open mode error

• The hardware disk with large capacity is used.

• The door is open.

• The disk is write-protected.

• Card controller access error

• No card

• Reset the alarm, and then try again.

If the error occurs again, contact your Yaskawa representative.

8-127

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8.3 Alarm Message List

Alarm

Number

4625

4626

4627

4628

Message

WRONG

EXECUTION OF

LOADDB INST

IMPOSSIBLE S-

AXIS MOV

(IN SPHERE)

GUN RECOGNI-

TION SINGLE

OFF

WRITE

VARIABLE NO.

MULTI SETTING

Alarm Message List

Sub

Code

Cause

An error occurred when executing a

LOADDB instruction.

-32

• Card drive information readout error

-33

• Partition table error

-34

• No drive number

-35

• No specified partition number

-36

• Cluster size error

-37

• Incorrect number of sectors

-38

• Sector/byte error

-40

• Card not applicable for I/O

-41

• Nonsupported version

-42

• The setting register did not exist.

-43

• Card not applicable for ATA

-44

• Double chain error

-45

• Media error (not fixed disk)

-50

• Media error (not fixed disk)

-51

• Sector read command error

-52

• Sector write command error

--An error occurred at S-axis high-speed rotation.

• The S-axis rotation radius was below the lower limit.

---

---

The gun identification signal was not received. (Subcode:

Gun number)

An error in the variable number setting.

• Duplicated usage of the written destination variable numbers.

(Subcode: Duplicated variable number)

Remedy

• Reset the alarm, and then try again.

If the error occurs again, contact your Yaskawa representative.

Correct the limit distance for S-axis rotation center motion (S1CG067).

Check the gun identification signal.

Correct the written destination variable numbers.

8-128

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8.3 Alarm Message List

Alarm

Number

4629

4629

4630

4632

4633

4634

Message

GROUP

CHANGE

ERROR

GROUP

CHANGE

ERROR

DUPLICATED

GUN NUMBER

UNDEFINED

LNR SCALE FILE

FOLLOWING

ERROR

FOLLOWING

SPEED OVER

Alarm Message List

Sub

Code

Cause

An error occurred when executing the group change function.

1

• The group change parameter was invalid.

2

• The GRPCHG instruction was executed while the external axis motor was servo ON.

3

• The GRPCHG instruction was executed in unchuck status.

4

• The group identification signal was not received.

5

• The specified control group number and the group identification number were unmatched.

6

7

An error occurred when executing the group change function.

8

• The control group that corresponded to the received group identification signal did not exist.

---

• The encoder PG power supply was ON when the GRPCHG was

OFF.

---

The gun numbers were overlapped when executing a SVSPOT instruction.

(Subcode: The overlapped gun number)

The linear scale characteristic file is not set.

(Subcode: Linear scale characteristic file number)

1

0

• The encoder PG power supply was OFF when the GRPCHG was

ON.

An error occurred when executing a FOLLOW instruction.

• An attempt was made to reexecute the FOLLOW instruction after interrupting it.

The manipulator motion speed exceeded the limit during the Following motion.

• With the specified bending speed, the manipulator motion speed exceeds the maximum speed. signal.

file.

Remedy

Validate the group change parameter.

Execute the GRPCHG instruction when the external axis motor was servo OFF.

Execute the GRPCHG instruction in chuck status.

Check the group identification signal.

Check the specified control group number.

Turn ON the encoder PG power supply when GRPCHG is ON.

Turn OFF the encoder PG power supply when GRPCHG is OFF.

Check the group identification

Check the gun numbers.

Set the linear scale characteristic

Re-execute the move instruction executed before the FOLLOW instruction, and then re-execute the

FOLLOW instruction.

• Reduce the bending speed.

• Perform the teaching again so that the manipulator moving distance becomes shorter.

8-129

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8.3 Alarm Message List

Alarm

Number

4635

4636

4637

4638

4639

4640

Message

CANNOT

EXECUTE

COMMON JOB

THICKNESS

ERROR

TRACK CHG

WORK IN/NOT

NOT FOUND

TRACKING CHG

WORK ID NOT

FOUND

SYMOVJ INST

EXECUTE

ERROR

WRONG

EXECUTION OF

PSTART INST

Alarm Message List

Sub

Code

Cause

---

---

---

The called job could not be executed because the specified control group was shared with the called job.

(Subcode: The related control-group)

Incorrect workpiece thickness

(Sub code: Gun number)

No workpiece presence/ absence data at switching the synchronization section.

(Subcode: Conveyor characteristic file number)

--No workpiece type data at switching the synchronization section.

(Subcode: Conveyor characteristic file number)

An internal control error occurred during the SYMOVJ motion.

1

• The moving amount in the orientation at the SYMOVJ motion position could not correctly be calculated.

2

• The conveyor moving amount is not specified for the SYMOVJ motion.

3

• An error occurred in the preparation process of the manipulator motion start position for the SYMOVJ motion.

4

An error occurred when executing a

PSTART instruction.

1

• No axis data of control group to be disconnected

2

• An error occurred in the preparation process of the manipulator motion end position for the SYMOVJ motion.

• An attempt was made to disconnect a control group other than the occupation control group during prereading processing.

3

• An attempt was made to disconnect a control group other than the occupation control group when executing a PSTART instruction.

Remedy

Correct the control group specified by the CALL instruction.

Check the workpiece presence/ absence data for the synchronization section.

Check the workpiece type data for the synchronization section.

• Reset the alarm, and then try again.

If the error occurs again, contact your Yaskawa representative.

Set the conveyor moving amount for the SYMOVJ motion.

• Reset the alarm, and then try again.

If the error occurs again, contact your Yaskawa representative.

Reset the alarm, and then try again.

If the error occurs again, contact your Yaskawa representative.

Correct the PSTART instruction.

8-130

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8.3 Alarm Message List

Alarm

Number

4641

4644

4645

4800

Alarm Message List

Message

CANNOT

EXECUTE JOB

(SEPARATE

GROUP)

SPOT WELDER

I/F ERROR

(ASW)

NOT PERMIT

FIXED-WEAV ON

SWVON

WDT ERROR

(CONVERTER)

Sub

Code

Cause

---

An error occurred between the controller and spot welder.

1

• The controller could not access the welder.

2

The disconnected control group could not be moved.

• The control group disconnected by itself was used for its own move instruction. (Subcode: The disconnected control group used by a move instruction)

• The controller could not send an instruction to the welder because the welder was busy in processing.

3

• The welder could not receive the instruction sent from the controller.

102

• The specified welder number

(system) could not be found.

---

---

Remedy

Do not use the control group disconnected by itself for its own move instruction.

• Reset the alarm, and then try again.

• Turn the power OFF then back ON.

If the error occurs again, contact your Yaskawa representative.

Hover weaving could not be executed.

• The hover weaving is disabled in coordinated motion.

Watchdog timer error in the converter.

No response from the converter.

Check the specified welder number

(system), and specify the correct welder number.

• Correct the job.

• Reset the alarm, and then try again.

• Turn the power OFF then back ON.

If the error occurs again, contact your Yaskawa representative.

• Turn the power OFF then back ON after cooling the power supply unit.

If the error occurs again, contact your Yaskawa representative.

8-131

221/245

9.1 Error Message List

9 Error

9.1 Error Message List

Error warns the operator not to advance to the next operation caused by a wrong operation or the access method when using the programming pendant or an external equipment

(computer, PLC, etc.).

When an error occurs, confirm 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).

NOTE An error is different from an alarm because it does not stop the robot even if it occurred while the robot was operated (during playback).

Main Menu Short Cut

Cannot insert/modify/delete for axis detachment

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.

Cannot load macro job at current security mode

Cannot insert/modify/delete for group axis detachment

Cannot insert/modify/delete for axis detachment

5 / 9

HELP

CLOSE

To view details of the selected error contents, select "HELP". To close the error list, select

"CLOSE". To release all the errors, press [CANCEL].

9-1

222/245

9.1 Error Message List

9.1.1

System and General Operation

Error No.

10

20

30

40

60

70

-

-

-

-

-

Data Error Message

Turn off servo power and perform corrective action

Depress TEACH

Illegal setting for number of variables

Undefined robot position variables

Undefined points (ORG, XX, XY)

Program and current tool different

-

Contents

It cannot be operated while servo power supply is ON.

Out of specified operation mode

Parameter setting error

Position variable cannot be used.

Not registered user coordinates basic 3 points (ORG, XX, XY)

The tool number registered with teaching position data does not match the tool number selected at the programing pendant.

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

240

270

280

290

200

210

212

230

300

310

320

330

130

140

180

190

80

100

110

120

Same position in the 3 points

On overrun recovery status

Turn ON servo power

Set to PLAY mode

No start using external signal

No start using P.P.

TEACH mode select signal ON

Set variable number

Defined group axis

Undefined coordinated robots

Cannot register group combination

While releasing soft limit

Undefined robot

Undefined gun condition file

Lack of number of I/O points

Cannot set same No.

Undefined user frame

Cannot register Master JOB

Cannot operate CHECK-RUN

Cannot operate MACHINE LOCK

9-2

223/245

9.1 Error Message List

520

530

550

420

430

460

500

510

560

590

600

610

620

650

660

Error No.

340

350

380

390

410

680

700

760

770

800

Data

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

XXX

-

-

-

-

-

-

-

-

Error Message

Cannot operate Master JOB

Cannot initialize

Position not checked

Contents

Second home position was not checked.

Can specify servo off by safety relay

Time could not be measured

Incorrect number of taught points

Time could not be measured for

TRT function.

The number of the taught points for tool calibration is incorrect.

Register start reserved JOB

Excess time for measuring

Undefined robot calibration data

Undefined axis

Cannot select two coordinated combination

Start reservation mode

Start reserved JOB change prohibit is set

Cannot teach position while soft limit released

Register group axis combination [SYNCHRO] was pressed for coordinated job which was not registered as group.

Out of setting data range

Cannot use the user coordinate

Select JOB (robot)

Incorrect measured data

Wrong data type of position variable

Defined data

File No.

Wrong CMOS memory board type

Error in start condition set

During robot operation

The gun of designation is not connected

9-3

224/245

Error No.

801

810

820

930

940

950

960

970

-

-

-

-

-

-

-

-

Data Error Message

The group axis of designation is not connection

Servo power supply is limited

Modification range over

Undefined conveyor calibration data

Forced pressure signal ON

Negative correction distance

I/O axis mode requesting

ERRSVCPU signal error

9.1 Error Message List

Contents

9-4

225/245

9.1 Error Message List

9.1.2

Editing

Error No.

1010

1020

1030

1050

1060

1070

1080

Data

-

-

-

-

-

-

-

Error Message

EDIT LOCK mode

Enter correct value

Unauthorized ID No.

Enter correct date

Enter correct clock

Enter an ID number in 4-8 figures

Negative value can’t be set

9.1.3

Job Defined Data

2090

2100

2110

2120

2150

2160

2170

Error No.

2010

2020

2030

2040

2050

2070

2080

2180

2210

2220

2240

-

-

-

-

-

-

-

-

-

-

-

Data

-

-

-

-

-

-

-

Error Message

Incorrect character

Name not entered

Undefined JOB name

Defined JOB name

Address not found

Set robot exactly to taught position

Press INSERT or MODIFY

Only modifying move instruction possible

JOB cannot be edited.

Over soft limit

Cannot insert/alter/delete with servo off

Inserting is not possible from this point

Cannot modify or delete this position

Press INSERT to record same step as previous step

Cannot insert data

Illegal data setting

Display edit instruction

Excessive instruction equation

9-5

Contents

Contents

226/245

9.1 Error Message List

Error No.

2250

2260

2270

2280

2290

2291

2292

2293

5

6

7

8

4

5

2

3

6

7

4

5

8

-

∗

1

2

3

-

∗

1

-

-

-

2

3

∗

1

4

Data Error Message

Unmatched number of parentheses in equation

Wrong group axis selection

Cannot insert any more instruction in

JOB

JOB memory is full

Contents

Lack of position file memories

Lack of JOB registering memories

Lack of instruction file memories

Lack of memory pool

Lack of pass condition file for multilayer

Undefined master JOB

Undefined SUB Master JOB

Undefined MASTER START JOB

Undefined SUB START JOB

Sub-master 1

Sub-master 2

Sub-master 3

Sub-master 4

Sub-master 5

Sub-master 6

Sub-master 7

Sub-master 8

Sub-master 1

Sub-master 2

Sub-master 3

Sub-master 4

Sub-master 5

Sub-master 6

Sub-master 7

Sub-master 8

9-6

227/245

9.1 Error Message List

2560

2570

2580

2590

2600

2610

2620

2630

2340

2360

2370

2510

2520

2530

2540

2550

2551

2450

2470

2480

2500

2390

2400

2430

2440

Error No.

2300

2310

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

-

∗

XXX

-

-

-

-

-

-

-

-

-

-

Data Error Message

Cannot teach JOB without group-axis specification

Same label exists

Pasted data not found

Cannot create editing area

Cannot cut/copy NOP and END instructions

Wrong group axis selection

Cannot move in cut & paste editing

Reverse data not found

Move C-and W-axis to basic position

Relative JOB not permitted

Wrong JOB type

Wrong JOB coordinates setting

Cannot convert the JOB

Cannot correct position in the JOB

Enter JOB name

Illegal step number

Enter step number

Duplicated step number

Duplicated line number

Cannot correct steps of position variables and REFP

The step does not contain speed

The step dose not contain PL/CONT

Soft limit range over

Cannot teach position in concurrent

JOB

Wrong JOB kind

Cannot correct play speed in the JOB

Conveyor position not reset

Line No.

Laser cutting

Contents

9-7

228/245

Error No.

2640

2670

2710

2730

2740

2750

2760

2761

2770

2780

-

-

-

-

Data

-

-

-

-

-

-

Error Message

Incorrect JOB name

Undefined target JOB

Relative job can’t be shifted with pulse type

Cannot use robot macro JOB

Cannot use concurrent macro JOB

Cannot use JOB with group-axis specification

Cannot insert/modify/delete for group axis detachment

Axis is separated.

Cannot add, modify, or delete.

Cannot reverse data of SVSPOTMOV instruction

Arithmetic error

9.1 Error Message List

Contents

9-8

229/245

9.1 Error Message List

9.1.4

External Memory Equipment

Error No.

3010

3020

3030

3040

3050

3060

3070

3080

3090

3110

3120

3130

∗

7

8

5

6

9

-

∗

1

3

4

1

2

4

-

2

3

Data

-

-

-

-

-

-

-

-

Error Message

Floppy disk drive cable not connected

Floppy disk not inserted into floppy disk drive

Floppy disk protection is ON

File not saved on floppy disk or Compact Flash

File saved on floppy disk or Compact

Flash

Out of memory on floppy disk or Compact Flash

Number of files on floppy disk or Compact Flash is full

I/O error on floppy disk or Compact

Flash

Transmission error with floppy disk or

Compact Flash

Syntax error

HEX code error

Verify error

Contents

Framing error

Overrun error

Parity error

Data code error

Data read error

Data write error

Data time out

Serial I/O error

Error other than described above

Specification error of data decode

Specification error of EOF record

Record type error

Total check error of record

9-9

230/245

9.1 Error Message List

Contents Error No.

3140

3150

3160

3170

Data

6

7

-

∗

1

4

5

2

3

-

∗

1

2

3

4

Error Message

Wrong pseudo instruction

Concurrent I/O record error

Cannot load illegal system data

Condition file data error

Format error

Ladder program is too long.

Exceed the range of the data

Specification error of channel No.

Specification error of relay No.

Timer value error

Specification error of timer No.

Format error

Specified file No. is omitted.

Specified tool No. is omitted.

User file is not registered.

9-10

231/245

9.1 Error Message List

Error No.

Data

∗

Error Message

Error in JOB data record

3190

3200

3210

3220

1

2

3

4

5

6

7

8

9

10

11

12

13

5

6

3

4

-

-

∗

2

NOP or END instruction not found

Position No. storage area not found

Syntax error in instruction data

Contents

Record on the number of position data (NPOS) is wrong for the format.

Record on the user coordinate No.

(USER) is wrong for the format.

Record on the tool No. (TOOL) is wrong for the format.

Record on the position data section is wrong for the format.

Record on the robot type of XYZ data (RCONF) is wrong for the format.

Date (DATE) record is wrong for the format.

Comment (COMM) record is wrong for the format.

Record on the JOB attribute data

(ATTR) is wrong for the format.

Control group (GROUP) record is wrong for the format.

Local variable (LVARS) record is wrong for the format.

JOB argument (JARGS) record is wrong for the format.

Record on the teaching coordinates for relative job (FRAME) is wrong for the format.

Position data coordinates do not match relative job coordinates.

Interior control error

Undefined instruction/tag

Instruction/tag shortage

Disuse instruction/tag

Sub instruction

9-11

232/245

Error No.

Data

11

12

13

14

9

10

7

8

15

3220

29

30

35

36

25

26

27

28

37

16

21

22

23

17

18

19

20

24

38

Error Message

9-12

9.1 Error Message List

Contents

No instruction

Invalid instruction

Invalid tag

Invalid character

Undefined intermediate code

Intermediate code shortage

Syntax stack overflow

Syntax stack underflow

Array type tag uncompleted

Tag [ARRAY]

Element type tag uncompleted

Tag [ELEMENT]

Macro JOB unregistered

Input format error

Data size over

MIN value over

MAX value over

Operation expression error

Job call argument setting error

Macro job call argument setting error

Position vector setting error

System error

Soft key designate error

Numerical input buffer overflow

Real type data precision error

Element format error

BOOL TYPE data error

CHAR data error

BYTETYPE, BINARY / HEXADECI-

MAL BYTE TYPE data error

INTEGER TYPE, DECIMAL WORD

TYPE data error

233/245

9.1 Error Message List

3290

3300

3310

3350

3360

3370

3450

3230

3240

3250

3260

3270

3280

Error No.

3220

43

48

49

58

-

44

45

46

47

-

-

-

-

41

42

-

-

-

-

-

-

-

-

Data

39

40

Error Message Contents

BINARY/HEXADECIMAL WORD

TYPE data error

DOUBLE PRECISION INTEGER

TYPE, DECIMAL DWORD TYPE data error

BINARY/HEXADECIMAL WORD

TYPE data error

REAL TYPE data error

LADDER SPECIAL TYPE data error

JCL text

Invalid text

LABEL NAME data error

JOB NAME data error

STRING data error

COMMENT data error

Invalid instruction/tag detection

Syntax not matched

Undefined application

Cannot load this file

Excess input data

Cannot verify this file

Wrong welding condition (STANDARD/

ENHANCED)

Serial port not defined

Serial port being used

Protocol being used

Not enough memory

Invalid folder

Incorrect folder name

Cannot load macro JOB at current security mode

Load in management mode.

9-13

234/245

9.1 Error Message List

3470

3480

3490

3500

3510

3520

3530

Error No.

3460

-

-

-

Data

-

-

-

2

-

∗

1

Error Message

Cannot backup Compact Flash

Database not found

Database access error

Same database exists

Check Compact Flash insertion

Cannot delete folder. Check attribute and inside file

Same folder exists

Cannot load at current security mode

Contents

Insufficient Compact Flash memory.

Not accessible to Compact Flash.

9-14

235/245

9.1 Error Message List

9.1.5

Concurrent I/O

Error No.

4010

4030

4040

4050

4060

4070

4080

4090

4120

4130

4140

4150

4220

4230 -

-

∗

XXX

∗

XXX

∗

XXX

∗

XXX

∗

XXX

∗

XXX

∗

XXX

Data

∗

XXX

∗

XXX

-

-

-

Error Message

Illegal relay No.

Illegal instruction

Relay/register No. duplicated in OUT/

GOUT or arithmetic instruction

The relay is not used

Excess STR-[-NOT] instructions

Excess AND [OR] STR instructions

Syntax error in CNT instructions

Enter STR [-NOT] at head of block

Concurrent I/O memory is full

END instruction not found

Wrong ladder program

Wrong use of GSTR, GOUT commands

Excess TMR/CNT or arithmetic instructions

Syntax error in TMR/CNT instructions

Line No.

Contents

Line No.

Multiple outputs are instructed to the relay or register.

Line No.

Line No.

Line No.

Line No.

Line No.

Need STR [-NOT]

Line No.

Exceeds memory capacity

(10000 steps)

END instruction not found

Position and number of PART instruction are wrong.

GSTR and GOUT is not used together.

Line No.

More than 100 TMR, CNT or arithmetic instruction used

9-15

236/245

Error No.

8010

8020

8030

8031

8040

8041

8050

8060

9.1.6

Maintenance Mode

-

-

-

-

Data

-

-

-

-

Error Message

Too many axes

Too many I/O points

Too many boards (XFB01B (MASTER))

Too many boards (MSC01B)

Memory error (ControlNet output condition)

Memory error (UNIWIRE CONNECT DAT

Robot model is not registered

Cannot get UNIWIRE connection data

9.1 Error Message List

Contents

9-16

237/245

10.1 7-Segment LED and Battery Alarm LED Indicators

10 LED Indicators

10.1 7-Segment LED and Battery Alarm LED Indicators

The NXC100 has the 7-segment LED and battery alarm LED (“BAT” LED) indicators, and the

AXC circuit board has the 7-segment LED indicator as shown below.

For the 7-segment LED indication, see " 10.2 7 SEG-LED Indicator ".

The “BAT” LED is lit when the battery is weak. For the battery replacement, see “5.1

Replacing NXC100 Parts”.

Top View of the NXC100 without the Top Cover

AXIS (AXC) circuit board

SGDR-AXC01B

AXIS circuit board 7-segment LED

(Located inside the top cover)

TB1

P-ON

+5V

+24V

OHT

POWER SUPPLY

CPS-320F

No.

DATE

Fuji Electric Co.,Ltd. JAPAN

1112 13 14 15 16 17 18 19 20

2122 23 24 25 26 27 28 29 30

A

L

B

M

C

N

D

P

E

Q

F G

R S

H

T

J

U

K

V

X31

X52

ON(I) F1

OFF(O) F2

SOURCE

X51

X81

BATTERY

FUSE

AC FUSE F1,F2

15A / 250V

SLOW BLOW

I/O FUSE F1,F2,F3,F4

3.15A / 250V

FAST BLOW

NXC100 7-segment LED

LED Position

Battery alarm LED: "BAT" LED

NXC100

10-1

238/245

10.2 7 SEG-LED Indicator

10.2 7 SEG-LED Indicator

The following tables show the operating status of the NXC100 and AXC circuit board. The operating statuses are indicated by 7 SEG-LED.

[Normal Indication]

Status

Right after applying the power

During the start-up process

After starting up normally

NXC100

NXC100 AXC Circuit Board

All 7-SEG indicators light up.

(‘8’, ‘+’, ‘.’ light up.)

Counts up from ‘O’ toward ‘d’.

‘d’, ‘+’, ‘.’ blink every one second.

[Error Indication]

NXC100

Status

NXC100 AXC Circuit Board

Alarms occurrence in the Main CPU and servo CPU communication system

‘d’, ‘+’, ‘.’ blink every one second.

The error cause is indicated by 7 SEG-

LED.

(See the indication spec



.)

‘d’, ‘+’, ‘.’ blink every one second.

Normal alarms other than alarms described above

Fatal alarms occurrence

The error cause and the address where the error has occurred are indicated by 7 SEG-LED.

(See the indication spec



.)

SUPPLE-

MENT

Indication Spec



E.g.)

The cycle: [F]  [0]  [0]  [3]  [.] is repeated.

: Error cause

Indication Spec



E.g.)

[-]  [0]  [2]  [0]  [0] 

The cycle: [,]  [-]  [0]  [0]  [0]  [0]  [F] 

[F]  [0]  [4] is repeated.

: Error cause

: Address where the error occurred

10-2

239/245

10.2 7 SEG-LED Indicator

 7 SEG-LED Indicator Status (1-digit indication) of Each Unit at Error Occurrence

3

4

5

1

2

All Lit

0

6

D

E

B

C

9

A

7

8

F

P

U

NXC100

The power has been turned ON.

The booting program has started.

The system program has started. (Starts up initializations of various kinds.)

Starts verifying the existence of other circuit boards. (Verifies the start-up of the booting program.)

Starts the system program transmission.

Sends the request of the system program start-up.

Starts verifying the existence of other circuit boards. (Verifies the start-up of the system program.)

Acquires hardware information, etc. of other circuit boards. (Verifies the IO board status, servo IF, and so on.)

Starts the CMOS data transmission.

Sends the pre-online request.

Waits for CERF communication synchronization.

Sends the start-up request of on-line system.

The on-line system has started. (Starts up the initialization task.)

Processes the NXC100 setup completion. (Servo ON enabled)

Alarm occurs at the NXC100 setup.

The maintenance system is starting up.

Communications interrupted between NCP01 and the programming pendant.

Updating system software through network.

10-3

240/245

10.2 7 SEG-LED Indicator

C

D

A

B

7

8

9

5

6

3

4

1

2

All Lit

0

AXC Circuit Board

The power has been turned ON.

The booting program has started. (ROM/RAM/FP register check)

Starts the booting system. (Completes initializations of various kinds.)

Completes the preparation for receiving the system program.

The system program has been received. (Waits for the request of system change.)

The system program has started. (Starts up hardware initializations of various kinds.)

Starts the system. (Completes initializations of various kinds.)

Starts the CMOS data transmission.

Receives the CERF mapping. (Waits for pre-online)

Starts the servo system. (Starts the process of various initializations.)

Waits for CERF communication synchronization. (Completes the process of various initializations.)

Waits for the start-up of on-line system.

Completes the NXC100 setup process. (Servo ON enabled)

10-4

241/245

10.2 7 SEG-LED Indicator

 7 SEG-LED Indicator Status (4 digit-indication) of Each Unit at Error Occurrence

NXC100

0018

0019

001A

001B

001C

001D

001E

001F

0010

0011

0012

0013

0014

0015

0016

0017

0008

0009

000A

000B

000C

000D

000E

000F

0000

0001

0002

0003

0004

0005

0006

0007

Arithmetic error

Debug

NMI

Breakpoint

Overflow

Out of BOUND

Invalid operation code

Device disabled

Double fault

Coprocessor segment overrun

Invalid TSS

Segment absence

Stack segment fault

General protection exception

Page fault

Floating point error

Alignment check

Machine check

SIMD floating point exception

0900 WDT error

10-5

242/245

1400

1500

1600

1700

1800

1900

1A00

1B00

0C00

0D00

0E00

0F00

1000

1100

1200

1300

0400

0500

0600

0700

0800

0900

0A00

0B00

0010

0020

0030

0040

0100

0200

0210

0300

1C00

1D00

1E00

1F00

2000

2100

2200

2300

2400

2500

2600

2700

AXC Circuit Board

ROM error in the boot section

RAM error

FP register error

On-line communications command error

Reset exception

Machine check exception

WDT error

Data access error

Instruction access exception

Alignment exception

Program exception

Unavailable floating point exception

Undefined exception

Undefined exception

System call exception

Trace exception

Undefined exception

Undefined exception

Instruction conversion error exception

Data load conversion error exception

Data store conversion error exception

Instruction breakpoint exception

System management interruption

Undefined exception

Undefined exception

Undefined exception

Undefined exception

Undefined exception

Undefined exception

Undefined exception

Undefined exception

Undefined exception

Undefined exception

Undefined exception

Undefined exception

Undefined exception

Undefined exception

Undefined exception

Undefined exception

Undefined exception

Undefined exception

Undefined exception

10-6

10.2 7 SEG-LED Indicator

243/245

10.2 7 SEG-LED Indicator

2800

2900

2A00

2B00

2C00

2D00

2E00

2F00

3010

3020

3030

3040

AXC Circuit Board

Undefined exception

Undefined exception

Undefined exception

Undefined exception

Undefined exception

Undefined exception

Undefined exception

Undefined exception

Receiving data size error

Receiving data sum error

Receiving data write address error

All receiving data sum error

10-7

244/245

NXC100

MAINTENANCE MANUAL

HEAD OFFICE

2-1 Kurosakishiroishi, Yahatanishi-ku, Kitakyushu 806-0004 Japan

Phone +81-93-645-7745 Fax +81-93-645-7746

YASKAWA America Inc. MOTOMAN Robotics Division

805 Liberty Lane, West Carrollton, OH 45449, U.S.A.

Phone +1-937-847-6200 Fax +1-937-847-6277

YASKAWA Nordic AB

Franska vagen 10, Box 4004, 390 04 Kalmar, Sweden

Phone +46-480-417800 Fax +46-480-417999

YASKAWA Europe GmbH Robotics Division

Kammerfeld strasse 1, 85391 Allershausen, Germany

Phone +49-8166-90-100 Fax +49-8166-90-103

YASKAWA Electric Korea Co., Ltd.

7F, Doore Bldg.; 24, Yeoido-Dong Youngdungpo-ku, Seoul, KOREA

Phone +82-2-784-7844 Fax +82-2-784-8495

YASKAWA Electric (Singapore) PTE Ltd.

151 Lorong Chuan, #04-02A, New Tech Park, Singapore 556741

Phone +65-6282-3003 Fax +65-6289-3003

YASKAWA Electric (Thailand) Co., Ltd.

252/246, 4th Floor. Muang Thai-Phatra Office Tower II Rachadaphisek Road, Huaykwang Bangkok, 10320 Thailand

Phone +66-2-693-2200 Fax +66-2-693-4200

Shougang MOTOMAN Robot Co. Ltd.

No.7, Yongchang-North Road, Beijing E&T Development Area, China 100176

Phone +86-10-6788-2858 Fax +86-10-6788-2878

MOTOMAN Motherson Robotics Ltd.

Plot No.195-196, 1st Floor, Sec.4 IMT Manesar, Gurgaon 122050, Haryana

Phone +91-124-475-8500 Fax +91-124-414-8016

Specifications are subject to change without notice for ongoing product modifications and improvements.

MANUAL NO. RE-CHO-A105 1

245/245