R88D-GN_-ML2 (AC Servo Drives)

Chapter 8
Troubleshooting
8-1 Error Processing ................................................ 8-1
Preliminary Checks When a Problem Occurs .......................8-1
Precautions When Troubleshooting......................................8-2
Replacing the Servomotor and Servo Drive..........................8-2
8-2 Alarm Table........................................................ 8-3
8-3 Troubleshooting ................................................. 8-7
Error Diagnosis Using the Displayed Alarm Codes ..............8-7
Error Diagnosis Using the Displayed Warning Codes ..........8-14
Error Diagnosis Using the Operating Status .........................8-15
8-4 Overload Characteristics
(Electronic Thermal Function) ............................ 8-20
Overload Characteristics Graphs ..........................................8-20
8-5 Periodic Maintenance......................................... 8-21
Servomotor Service Life........................................................8-21
Servo Drive Service Life .......................................................8-22
Replacing the Absolute Encoder Battery ..............................8-23
8-1 Error Processing
8-1 Error Processing
Preliminary Checks When a Problem Occurs
This section explains the preliminary checks and analytical tools required to determine the cause of
a problem.
„ Checking the Power Supply Voltage
ΠCheck the voltage at the power supply input terminals.
Main Circuit Power Supply Input Terminals (L1, L3)
R88D-GN@L-ML2 (50 W to 400 W): Single-phase, 100 to 115 VAC (85 to 127 V), 50/60 Hz
R88D-GN@H-ML2 (100 W to 1.5 kW): Single-phase, 200 to 240 VAC (170 to 264 V), 50/60 Hz
Main Circuit Power Supply Input Terminals (L1, L2, L3)
R88D-GN@H-ML2 (750 W to 7.5 kW): Three-phase, 200 to 240 VAC (170 to 264 V), 50/60 Hz
Control Circuit Power Supply Input Terminals (L1C, L2C)
R88D-GN@L-ML2: Single-phase, 100 to 115 VAC (85 to 127 V), 50/60 Hz
R88D-GN@H-ML2: Single-phase, 200 to 240 VAC (170 to 264 V), 50/60 Hz
If the voltage is outside of this range, there is a risk of operation failure, so be sure that the power
supply is correct.
ΠCheck the voltage of the sequence input power supply. (+24 VIN Terminal (CN1 pin 1))
Within the range of 11 to 25 VDC
If the voltage is outside of this range, there is a risk of operation failure, so be sure that the power
supply is correct.
Troubleshooting
8
„ Checking Whether an Alarm Has Occurred
ΠEvaluate the problem using the 7-segment LED display on the front panel.
You can also evaluate the problem by using the R88A-PR02G Parameter Unit.
ΠCX-Drive can also be used for the display. The operation status can also be monitored.
Check the load status, including data trace.
ΠWhen an alarm has occurred:
Check the alarm code that is displayed (@@) and evaluate the problem based on the alarm that is
indicated.
ΠWhen an alarm has not occurred:
Make an analysis according to the problem.
8-1
8-1 Error Processing
Precautions When Troubleshooting
When checking and verifying I/O after a problem has occurred, the Servo Drive may suddenly start
to operate or suddenly stop, so always take the following precautions.
You should assume that anything not described in this manual is not possible with this product.
„ Precautions
ΠDisconnect the cable before checking for wire breakage. Even if you test conduction with the cable
connected, test results may not be accurate due to conduction via bypassing circuit.
ΠIf the encoder signal is lost, the Servomotor may run away, or an error may occur. Be sure to
disconnect the Servomotor from the mechanical system before checking the encoder signal.
ΠWhen performing tests, first check that there are no persons in the vicinity of the equipment, and
that the equipment will not be damaged even if the Servomotor runs away. Before performing the
tests, verify that you can immediately stop the machine using an emergency stop even if the
Servomotor runs away.
Replacing the Servomotor and Servo Drive
Use the following procedure to replace the Servomotor or Servo Drive.
„ Replacing the Servomotor
1. Replace the Servomotor.
2. Perform origin position alignment (for position control).
Œ When the Servomotor is replaced, the Servomotor’s origin position (phase Z) may deviate, so
origin alignment must be performed.
Œ Refer to the Position Controller’s manual for details on performing origin alignment.
3. Set up the absolute encoder.
ΠIf a Servomotor with an absolute encoder is used, the absolute value data in the absolute encoder
will be cleared when the Servomotor is replaced, so setup is again required. The rotation data will
be different from before the Servomotor was replaced, so reset the initial Motion Control Unit
parameters.
ΠFor details, refer to Absolute Encoder Setup on page 6-6.
„ Replacing the Servo Drive
1. Copy the parameters.
Use the Parameter Unit or CX-Drive to write down all the parameter settings or save them.
2. Replace the Servo Drive.
3. Set the parameters.
Use the Parameter Unit or CX-Drive to set all the parameters.
4. Set up the absolute encoder.
ΠIf a Servomotor with an absolute encoder is used, the absolute value data in the absolute encoder
will be cleared when the Servo Drive is replaced, so setup is again required. The rotation data will
be different from before the Servo Drive was replaced, so reset the initial Motion Control Unit
parameters.
ΠFor details, refer to Absolute Encoder Setup on page 6-6.
8-2
Troubleshooting
8
8-2 Alarm Table
8-2 Alarm Table
„ Protective Functions
The Servo Drive has built-in protective functions. When a protective function is activated, the
Servo Drive turns OFF the alarm output signal (ALM) and switches to the Servo OFF status.
The alarm code will be displayed on the front panel.
Alarm type
Description
---
Protective function that allows the alarm to be reset, and leaves record in the
alarm history.
PR
Protective function that does not allow the alarm to be reset, and requires the
control power supply to be turned OFF and turned ON again after resolving the
problem.
X
Precautions
for Correct Use
ΠAlarms can be reset via the network, CX-Drive or the Parameter Unit.
ΠOverload (alarm code 16) cannot be reset for approximately 10 s after its
occurrence.
ΠIf "HH", "hh", or "yy" is displayed on the Alarm Number display, the built-in
MPU is malfunctioning. Turn OFF the power supply.
„ Warning Function
The Servo Drive issues a warning before a protective function is activated, allowing you to check
overload and other status in advance. A warning is also issued for a network error, allowing you
to check the network status.
Troubleshooting
8
Protective function that does not leave record in the alarm history.
8-3
8-2 Alarm Table
„ Alarms
Alarm
Type
11
X
12
---
13
X
14
PR
15
PR
16
---
18
PR
21
PR
23
PR
24
---
26
---
27
PR
29
---
34
---
36
PR
X
37
PR
X
38
X
40
PR
41
PR
42
PR
44
PR
45
PR
47
---
Error Detection Function
Detection Details and Cause of Error
The DC voltage of the main circuit has
dropped below the specified value.
The DC voltage of the main circuit is
Overvoltage
abnormally high.
Main power supply undervoltage
The DC voltage of the main circuit is low.
Overcurrent flowed to the IGBT. Servomotor
Overcurrent
power line ground fault or short circuit.
The temperature of the Servo Drive radiator
Servo Drive overheat
exceeded the specified value.
Operation was performed with torque
Overload
significantly exceeding the rating for several
seconds to several tens of seconds.
The regenerative energy exceeded the
Regeneration overload
processing capacity of the regeneration
resistor.
Communications between the encoder and
the Servo Drive failed for a specified number
Encoder communications error
of times, thereby activating the error detection
function.
Communications error occurred for the data
Encoder communications data error
from the encoder.
The number of position deviation pulses
Deviation counter overflow
exceeded the Deviation Counter Overflow
Level (Pn209).
The rotation speed of the Servomotor
Overspeed
exceeded the setting of the Overspeed
Detection Level Setting (Pn073).
Command error
The operation command resulted in an error.
The value of the internal deviation counter
Internal deviation counter overflow (internal control unit) exceeded 227
(134217728).
The Servomotor exceeded the allowable
operating range set in the Overrun Limit
Overrun limit error
Setting (Pn026) with respect to the position
command input.
Data in the parameter save area was
Parameter error
corrupted when the data was read from the
EEPROM at power-ON.
The EEPROM write verification data was
Parameter corruption
corrupted when the data was read from the
EEPROM at power-ON.
Forward and Reverse Drive Prohibit Inputs
Drive prohibit input error
(NOT and POT) both became OPEN.
Absolute encoder
The voltage supplied to the absolute encoder
ABS dropped below the specified value.
system down error
Absolute encoder counter
The multi-turn counter of the absolute
ABS encoder exceeded the specified value.
overflow error
The Servomotor rotation speed exceeded the
Absolute encoder
ABS specified value when power to the absolute
overspeed error
encoder is supplied by the battery only.
Absolute encoder
A one-turn counter error was detected.
one-turn counter error
An absolute encoder multi-turn counter or inAbsolute encoder
cremental encoder phase AB signal error was
multi-turn counter error
detected.
Absolute encoder
The rotation of the absolute encoder is higher
ABS than the specified value.
status error
Control power supply undervoltage
8-4
8
Troubleshooting
Alarm
Display
8-2 Alarm Table
Alarm
Display
Alarm
Type
48
R
Encoder phase Z error
49
R
Encoder PS signal error
82
R
Node address setting error
83
---
Communications error
84
---
Transmission cycle error
86
---
Watchdog data error
87
X
Emergency stop input error
90
---
Transmission cycle setting error
91
---
SYNC command error
93
R
Parameter setting error
95
R
X
Servomotor non-conformity
Others
R
Other errors
Error Detection Function
Troubleshooting
8
Detection Details and Cause of Error
A phase-Z pulse was not detected
regularly.
A logic error was detected in the PS signal.
The rotary switch for setting the node address
of the Servo Drive was set out of range.
Data received during each MECHATROLINKII communications cycle repeatedly failed,
exceeding the number of times set in the
Communications Control (Pn005).
While actuating MECHATROLINK-II
communications, synchronization frames
(SYNC) were not received according to the
transmission cycle.
Synchronization data exchanged
between the master and slave nodes
during each MECHATROLINK-II
communications cycle resulted in an
error.
The emergency stop input became OPEN.
The transmission cycle setting error when
the MECHATROLINK-II
CONNECT command is received.
A SYNC-related command was issued while
MECHATROLINK-II was in asynchronous
communications mode.
Parameter setting exceeded the allowable
range.
The combination of the Servomotor and
Servo Drive is not appropriate.
The control circuit malfunctioned due to
excessive noise.
An error occurred within the Servo Drive due
to the activation of its self-diagnosis function.
Note The alarm display is in decimal.
For example, if a SYNC command error occurs, "91" will flash on the front panel of the Gseries Servo Drive. The warning code read from the host Position Control Unit (CJ1WNC@71 or CS1W-NC@71) would be 405B.
8-5
8-2 Alarm Table
„ Warnings
Priority
Warning
Code
Warning Detection
Function
94h
Data setting warning
· Command argument setting is out of the range.
· Parameter write failure.
· Command settings are wrong, and others.
95h
Command warning
· Command output conditions are not satisfied.
· Received unsupported command.
· Subcommand output conditions are not satisfied.
96h
ML-II
communications
warning
One or more MECHATROLINK-II communications error
occurred.
90h
Overload warning
85% of the overload alarm trigger level has been
exceeded.
91h
Regeneration
overload warning
85% of the regeneration overload alarm trigger level has
been exceeded.
92h
Battery warning
Voltage of absolute encoder battery has dropped below
3.2 V.
93h
Fan lock warning
The built-in cooling fan stopped, or rotated abnormally.
High
Warning Details
Low
Note 2. When multiple warnings occur, the warning codes are displayed on the front panel in the
order of their priority (shown above).
Note 3. The alarm display is in hexadecimal.
For example, if a regenerative load warning occurs, "91" and "00" will alternately flash on
the front panel of the G-series Servo Drive. The warning code read from the host Position
Control Unit (CJ1W-NC@71 or CS1W-NC@71) would be 4091.
8-6
8
Troubleshooting
Note 1. All warnings are retained. After resolving the problem, clear the alarms and the warnings.
8-3 Troubleshooting
8-3 Troubleshooting
If an error occurs in the machine, determine the error conditions from the alarm indicator and
operating status, identify the cause of the error, and take appropriate countermeasures.
Error Diagnosis Using the Displayed Alarm Codes
Alarm
code
11
Alarm Name
Cause
Control power supply
undervoltage
The voltage between P and N in the
control voltage converter has dropped
below the specified value.
1 The power supply voltage is low. A
momentary power failure occurred.
2 The power supply capacity is
insufficient. The inrush current at
power-ON caused the power
supply voltage to drop.
3 The Servo Drive has failed.
Measure the line voltage between
control power supply L1C and L2C.
1 Resolve the cause of the power
supply voltage drop and/or
momentary power failure.
2 Increase the power supply
capacity.
3 Replace the Servo Drive.
Overvoltage
The voltage between P and N in the
main circuit has exceeded the specified value. The power supply voltage is
too high. Phase advance capacitor
and/or UPS (uninterruptible power
supply) is causing a jump in voltage.
1 Regenerative energy cannot be
absorbed due to a disconnection of
the regeneration resistor.
2 Regenerative energy cannot be
absorbed due to the use of an
inappropriate external regeneration
resistor.
3 The Servo Drive has failed.
Measure and check the line voltages
between L1, L2, and L3 of the main
power supply. Input a correct voltage.
Remove the phase advance capacitor.
1 Measure the resistance for the
external regeneration resistor
between terminals B1 and B2 of the
Servo Drive, and check that the
reading is normal. Replace it if
disconnected.
2 Provide the necessary
regeneration resistance and
wattage.
3 Replace the Servo Drive.
Main power supply
undervoltage
With the Undervoltage Alarm Selection
(Pn065) set to 1, the main power
supply between L1 and L3 was
interrupted for longer than the time set
by Momentary Hold Time (Pn06D).
Alternatively, the voltage between P
and N in the main circuit dropped
below the specified value while the
Servo Drive was ON.
1 The power supply voltage is low.
2 A momentary power failure
occurred.
3 The power supply capacity is insufficient - The inrush current at
power-ON caused the power
supply voltage to drop.
4 Missing phase - A single-phase
power supply was used for a threephase Servo Drive.
5 The Servo Drive has failed.
Measure and check the line voltages
between L1, L2, and L3 of the main
power supply.
1 Resolve the cause of the power
supply voltage drop and/or
momentary power failure.
2 Check the setting for the
Momentary Hold Time (Pn06D).
3 Increase the power supply
capacity. Refer to the Servo Drive
specifications for the power supply
capacity.
4 Correctly connect the phases (L1,
L2, and L3) of the power supply.
Connect single-phase 100 V and
single-phase 200 V to L1 and L3.
5 Replace the Servo Drive.
8
Troubleshooting
12
13
8-7
Countermeasure
8-3 Troubleshooting
14
15
16
Alarm Name
Overcurrent
Cause
Countermeasure
The current on the inverter circuit
exceeded the specified value.
1 The Servo Drive has failed.
(Failure of circuit, IGBT parts, etc.)
2 Short circuit on Servomotor lines U,
V, and W.
3 Ground fault on the Servomotor
lines.
4 Servomotor burnout.
5 Contact failure on the Servomotor
lines.
6 The dynamic brake relay has been
consequently welded.
7 The Servomotor is not compatible
with the Servo Drive.
8 The operation command input is
received simultaneously with or
before Servo-ON.
1 If the alarm is triggered
immediately when the Servo Drive
is turned ON with the Servomotor
lines disconnected, replace the
Servo Drive.
2 Check for short circuit in the
Servomotor lines U, V, and W.
Connect the Servomotor lines
correctly.
3 Check the insulation resistance
between Servomotor lines U, V, W
and the ground line. If there is
insulation failure, replace the
Servomotor.
4 Measure the interphase
resistances of the Servomotor. If
they are unbalanced, replace the
Servomotor.
5 Check the connector pins for
connections U, V, and W of the
Servomotor. If they are loose or
have come off, securely fix them.
6 Replace the Servo Drive.
7 Check and match the capacity of
the Servomotor and the Servo
Drive.
8 After the Servo ON, wait for at least
100 ms before inputting an
operation command.
Servo Drive overheat
The temperature of the Servo Drive
radiator or power elements exceeded
the specified value.
1 The Servo Drive's ambient
temperature has exceeded the
specified value. Radiation
performance has dropped.
2 There is excessive load.
1 Reduce the Servo Drive's ambient
temperature, and improve the
cooling conditions.
2 Increase the capacity of the Servomotor. Reduce the effective load
ratio, for example with a longer
acceleration / deceleration time.
Overload
The effective values of the torque
commands have exceeded the overload level set by the Overload Detection Level Setting (Pn072). Operation
is performed with reverse time characteristics.
1 The load is excessive, and the
effective torque has exceeded the
set level and operation has been
performed for a long time.
2 Oscillation, hunching, and vibration
are occurring due to improper gain
adjustment.
3 Servomotor phases are incorrectly
wired and/or are disconnected.
4 The mechanical load is increasing.
There is a problem with the
mechanics.
5 The holding brake is ON.
6 The Servomotor lines are
incorrectly wired between multiple
axes.
Check that the torque (current) waveform is not oscillating, and that it is not
fluctuating significantly in the vertical
direction. Check the overload warning
display and the load ratio.
1 Increase the capacity of the Servo
Drive and Servomotor, or reduce
the load. Or increase the
acceleration / deceleration time to
reduce the effective torque.
2 Readjust the gain to stop oscillation
and hunching.
3 Connect the Servomotor lines as
specified in the wiring diagram.
Replace the cables.
4 Check that the mechanics operate
smoothly.
5 Measure the voltage at the brake
terminal. Turn OFF the brake.
Note You cannot reset the warning
for at least 10 seconds after it
occurred.
8-8
8
Troubleshooting
Alarm
code
8-3 Troubleshooting
Alarm
code
18
21
Troubleshooting
8
23
24
8-9
Alarm Name
Regeneration
overload
Encoder
communications error
Cause
Countermeasure
The regenerative energy exceeded the
capacity of the regeneration resistor.
1 The converter voltage was
increased by regenerative energy
during deceleration due to a large
load inertia. The voltage was
further increased due to insufficient
energy absorption of the
regeneration resistance.
2 Because the Servomotor’s rotation
speed is too high, regenerative
energy cannot be fully absorbed
within the specified deceleration
time.
3 The operating limit of the External
Regeneration Resistor is limited to
10%.
Check the regeneration resistance
load ratio. Continuous regenerative
braking is not acceptable.
1 Check the operation pattern (speed
monitor). Check the regeneration
resistance load ratio and the overregeneration warning display.
Increase the capacity of the
Servomotor and the Servo Drive to
slow down the deceleration time.
Use an External Regeneration
Resistor.
2 Check the operation pattern (speed
monitor). Check the regeneration
resistance load ratio and the overregeneration warning display.
Increase the capacity of the
Servomotor and the Servo Drive to
slow down the deceleration time.
Lower the Servomotor rotation
speed. Use an External
Regeneration Resistor.
3 Set Pn06C to 2.
Communications between the encoder
and the Servo Drive failed for a
specified number of times, thereby
activating the error detection function.
(No response to request from the
Servo Drive.)
Check that the encoder line is properly
connected.
Check that there is no damage to the
encoder due to incorrect connections.
Replace the Servomotor and check
again.
Communications error occurred for the
data from the encoder. Mainly a data
error due to noise. The encoder line is
connected, but the communications
data is erroneous.
ΠCheck that the encoder power supply
voltage is within the range of 4.75 to
5.25 VDC. (If the encoder line is
long.)
ΠIf the Servomotor line and the
encoder line are bound together,
separate them.
ΠCheck that the shield is connected to
FG (frame ground), and that FG is
grounded.
ΠAttach a ferrite core to the encoder
cable. Attach a radio noise filter to the
power cable.
Encoder
communications data
error
Deviation counter
overflow
The number of position deviation
pulses exceeded the Deviation
Counter Overflow Level (Pn209).
1 The Servomotor operation is not
following the commands.
2 The Deviation Counter Overflow
Level (Pn209) is set too low.
Calculate the deviation counter
value based on the command
speed and the position loop gain.
1 Use the speed monitor and torque
monitor to check that the
Servomotor is operating as
commanded. Check that torque is
not saturated. Check that the No. 1
Torque Limit (Pn05E) and the No. 2
Torque Limit (Pn05F) are not too
small.
Check by readjusting the gain,
increasing the acceleration /
deceleration times, and lowering
the speed with the reduced load.
2 Increase the setting for Pn209.
8-3 Troubleshooting
26
27
29
34
36
Alarm Name
Overspeed
Command error
Cause
Countermeasure
The rotation speed of the Servomotor
exceeded the setting of the Overspeed
Detection Level Setting (Pn073).
ΠCheck that excessive speed
commands have not been issued.
ΠIf overshoot is occurring due to
improper gain adjustment, adjust the
gain for the position loop and the
speed loop.
The operation command resulted in an
error.
1 Incorrect value in position
command.
· The amount of change in the
position command (value calculated with the electronic gear ratio)
exceeded the specified value.
· The travel distance required for
acceleration / deceleration,
calculated when starting
positioning, exceeded the
specified value.
2 A MECHATROLINK-II link was
established with the host while
executing a standalone operation
(normal mode autotuning, and jog
operation).
Note If the alarms are cleared
immediately after actuating
communications, this alarm
may be cleared immediately
after it has been issued, and
cannot be read.
3 Multi-turn data on the absolute
encoder was cleared via RS-232
communications after actuating the
MECHATROLINK-II link.
ΠCheck that the operation commands
are correct.
1 Review the operation commands
and settings.
Check the settings. For example,
check that the amount of change
for the position command is not too
large (i.e. interpolation function),
the backlash compensation
amount is not too large, the
backlash compensation time
constant is not too small, the
electronic gear ratio is not too large,
and the acceleration/deceleration
is not too small.
2 Do not actuate the network while
executing normal mode autotuning
and jog operation.
3 Alarm code 27 is issued when
clearing the multi-turn data on the
absolute encoder via RS-232
communications. This is for safety
purposes, not an error. When
executing the multi-turn clear
command via the network, an
alarm will not be issued, but be sure
to reset the control power supply.
The value of the internal deviation
counter (internal control unit) exceeded
227 (134217728).
Check that the speed monitor and
torque monitor values are indicated as
commanded by the Servo Drive. Check
that torque is not saturated. Check that
the No. 1 Torque Limit (Pn05E) and the
No. 2 Torque Limit (Pn05F) are not too
small.
Check by readjusting the gain,
increasing the acceleration / deceleration times, and lowering the speed with
the reduced load.
Internal deviation
counter overflow
Overrun limit error
Parameter error
The Servomotor exceeded the
allowable operating range set by the
Overrun Limit Setting (Pn026) with
respect to the position command input.
1 The gain is not appropriate for the
load.
2 The setting for Pn026 is too small.
Data in the parameter save area was
corrupted when the data was read from
the EEPROM at power-ON.
1 Check the position loop gain,
speed loop gain, integration time
constant, and inertia ratio.
2 Increase the setting for Pn026.
Set Pn026 to 0 to disable the
protective function.
If the warning continues to occur even
after retransferring all parameters, the
Servo Drive may have failed.
Replace the Servo Drive.
8-10
8
Troubleshooting
Alarm
code
8-3 Troubleshooting
Alarm
code
37
38
Alarm Name
Parameter corruption
Drive prohibit input
error
Troubleshooting
8
40
Absolute encoder
system down error
Cause
Countermeasure
The EEPROM write verification data
was corrupted when the data was read
from the EEPROM at power-ON.
If the warning continues to occur even
after retransferring all parameters, the
Servo Drive may have failed.
Replace the Servo Drive.
1 The Drive Prohibit Input Selection
(Pn004) is set to 0, and both
Forward and Reverse Drive
Prohibit Inputs (POT and NOT)
became OPEN.
2 The Drive Prohibit Input Selection
(Pn004) is set to 2, and either
Forward or Reverse Drive Prohibit
Input (POT or NOT) became
OPEN.
3 With the Drive Prohibit Input
Selection (Pn004) set to 0,
MECHATROLINK-II
communications interrupted, and
either Forward or Reverse Drive
Prohibit Input (POT or NOT) turned
ON, an operation command (jog
operation or normal mode
autotuning) was received via
RS232. Or, either POT or NOT
turned ON while operating on an
operation command received via
RS232.
Check the sensors, power supply, and
wiring for the Forward and Reverse
Drive Prohibit Inputs.
Also check that the response of the
power supply (12 to 24 VDC) is not too
slow.
Check that there is no command input
in the direction of the Drive Prohibit Input.
The power supply and battery voltage
to the encoder dropped, and the
capacitor voltage dropped below the
specified value. (3.0 V or less)
Connect the power supply for the
battery, and clear the absolute encoder. Refer to Absolute Encoder Setup on
page 6-6.
Initial setup of the absolute encoder
must be performed to clear the alarm.
The multi-turn counter of the encoder
exceeded the specified value.
Check the setting for the Operation
Switch When Using Absolute Encoder
(Pn00B).
Set the travel distance from the mechanical origin within 32767 rotations.
Initial setup of the absolute encoder
must be performed to clear the alarm.
The Servomotor rotation speed exceeded the specified value when
power to the absolute encoder is
supplied by the battery only during a
power outage.
Check the power supply voltage on the
encoder side (5 V ± 5%).
Check the connection of the CN2
connector.
Initial setup of the absolute encoder
must be performed to clear the alarm.
An error was detected in the one-turn
counter for the encoder.
Replace the Servomotor.
Check for malfunction due to noise.
Also take EMC measures.
Initial setup of the absolute encoder
must be performed to clear the alarm.
An absolute encoder multi-turn counter
or incremental encoder phase AB signal error was detected.
Replace the Servomotor.
Check for malfunction due to noise.
Also take EMC measures.
Initial setup of the absolute encoder
must be performed to clear the alarm.
ABS
41
Absolute encoder
counter overflow error
ABS
42
Absolute encoder
overspeed error
ABS
44
Absolute encoder
one-turn counter error
45
Absolute encoder
multi-turn counter
error
8-11
8-3 Troubleshooting
47
Alarm Name
Absolute encoder
status error
ABS
48
49
82
83
84
86
Cause
The encoder’s detection values were
higher than the specified value at
power-ON.
A phase-Z pulse of the 2500 p/r 5-line
serial encoder was not detected
Encoder phase Z error
regularly.
The encoder has failed.
Encoder PS signal
error
Node address setting
error
Watchdog data error
Do not rotate the Servomotor when the
power is turned ON.
Replace the Servomotor.
Check for malfunction due to noise.
Also take EMC measures.
Logic error was detected in the PS
signal (magnetic pole) of the 2500 p/r
5-line serial encoder.
The encoder has failed.
Replace the Servomotor.
The rotary switch for setting the node
address of the Servo Drive was set out
of range. (Value is read at power-ON)
Check the value of the rotary switch for
setting the node address.
Set the rotary switch correctly (set to 1
to 31), and then turn OFF the control
power supply for the Servo Drive and
turn it ON again.
Data received during each
MECHATROLINK-II communications
cycle repeatedly failed, exceeding the
number of times set by the Communications Control (Pn005).
Check that commands are being sent
from the master node to the slave
node.
Check the MECHATROLINK-II
communications cable for disconnection or wiring problem.
Check the connection of the terminator
(termination resistor).
Check the MECHATROLINK-II
communications cable for excessive
noise, and that the cable is laid properly. Also check the FG wiring for the Servo Drive.
Increase the consecutive communications error detection count in the Communications Control (Pn005).
Communications error
Transmission cycle
error
Countermeasure
While actuating MECHATROLINK-II
communications, synchronization
frames (SYNC) were
not received according to the transmission cycle.
ΠThe synchronization frames
themselves were faulty.
ΠThe transmission cycle of the
synchronization frames was not as
specified. (Includes dropped frames).
ΠCheck the transmission cycle of the
synchronization frames sent from the
master node, and ensure that it does
not fluctuate and is as specified.
ΠCheck the communications cable for
disconnection or wiring problem.
ΠCheck for excessive noise on the
communications cable.
ΠCheck the connection of the
terminator (termination resistor).
ΠCheck the laying of the
communications cable and the FG
wiring.
Synchronization data exchanged
between the master and slave nodes
during each MECHATROLINK-II communications cycle resulted in an error.
ΠCheck the update process for the
watchdog data (MN) on the master
node.
8-12
8
Troubleshooting
Alarm
code
8-3 Troubleshooting
Alarm
code
Alarm Name
87
Emergency stop input
error
90
Transmission cycle
setting error
91
Parameter setting
error
95
Servomotor
non-conformity
8
Troubleshooting
8-13
Other errors
Countermeasure
ΠThe emergency stop input became
OPEN.
ΠCheck the power supply and wiring
connected to the emergency stop
input. Check that the emergency stop
input is ON.
ΠCheck that the response of the
control signal power supply (12 to 24
VDC) at power-ON is not too slow in
comparison to the startup of the
Servo Drive.
ΠThe transmission cycle setting for
receiving the MECHATROLINK-II
CONNECT command is incorrect.
ΠCheck the transmission cycle
settings, and resend the CONNECT
command.
ΠA SYNC-related command was
issued while MECHATROLINK-II was
SYNC command error
in asynchronous communications
mode.
93
Others
Cause
ΠCheck the command sent from the
master node.
ΠThe electronic gear ratio parameter is
set outside the allowable setting
range. (Less than 1/100 or greater
than 100/1)
ΠCheck the parameter setting.
ΠThe combination of the Servomotor
and Servo Drive is not appropriate.
ΠUse the Servomotor and Servo Drive
in the correct combination.
The control circuit malfunctioned due
to excessive noise.
An error occurred within the Servo
Drive due to the activation of its
self-diagnosis function.
Turn OFF the power supply, and then
turn it back ON.
If the error continues to occur, there
may be a failure.
Stop the operation, and replace the
Servomotor and Servo Drive.
8-3 Troubleshooting
Error Diagnosis Using the Displayed Warning Codes
94h
Error
Cause
Countermeasure
Data setting warning
ΠCommand argument setting is out of
the range.
ΠParameter write failure.
ΠCommand settings are wrong, and
others.
ΠCheck the setting range.
ΠCheck the control power supply
voltage.
ΠCheck the command settings.
ΠCommand output conditions are not
satisfied.
ΠReceived unsupported command.
ΠSubcommand output conditions are
not satisfied.
ΠOperation command in the drive
prohibited direction was issued after
being stopped by a POT/NOT input.
ΠSend the command after the
command output conditions are
satisfied.
ΠDo not send unsupported
commands.
ΠFollow the subcommand output
conditions and send.
ΠCheck the status of POT/NOT input
and operation command.
ΠOne or more MECHATROLINK-II
communications error occurred.
ΠRefer to the countermeasures for
Communications error on page 8-12
(alarm code 83).
95h
Command warning
96h
ML-II communications
warning
90h
Overload warning
Π85% of the overload alarm trigger
level has been exceeded.
Refer to Overload on page 8-8.
91h
Regeneration
overload
Π85% of the regeneration overload
alarm trigger level has been
exceeded.
Refer to Regeneration overload on
page 8-9.
92h
Battery warning
93h
Fan lock warning
8
ΠVoltage of absolute encoder battery
has dropped below 3.2 V.
Replace the absolute encoder battery
while the control power supply is being
input.
ΠThe built-in cooling fan stopped, or
rotated abnormally.
ΠModels with a built-in fan
R88D- GN10H-ML2/ GN20H-ML2/
GN30H-ML2/-GN40H-ML2/-GN50HML2/-GN75H-ML2
If the warning continues to occur,
the fan may have failed.
If so, the internal temperature of the
Servo Drive will rise, causing a failure.
Replace the fan.
8-14
Troubleshooting
Warning
Code
8-3 Troubleshooting
Error Diagnosis Using the Operating Status
Symptom
7-segment
LED is not lit.
Troubleshooting
8
Probable cause
No control power supply.
Items to check
Countermeasure
Check that the control power supply
voltage is within the specified
range.
Ensure that power is
supplied properly.
Check that the power supply input
is wired correctly.
Wire correctly.
Check that the network cable
is connected correctly.
Check that the host
controller is running.
Check that the terminator is
connected.
Check the connector and
connection.
LED (COM)
is not lit.
MECHATROLINK-II
communications not
actuated.
LED (COM)
is flashing in
green.
Asynchronous communications on the
Can be controlled from the host
MECHATROLINK-II
controller (Normal status).
communications actuated.
LED (COM)
is lit in green.
Synchronous communications on the
MECHATROLINK-II
communications actuated.
Controllable status (Normal status). Normal status.
LED (COM)
is flashing in red.
Recoverable alarm related
to MECHATROLINK-II
communications.
ΠReset and actuate the network
again from the host controller.
ΠCheck the network wiring.
Check the wiring and noise.
LED (COM)
is lit in red.
Irrecoverable alarm related
to MECHATROLINK-II
communications.
Check that there is no overlap of
node address on the network, and
that the number of connected
Servo Drives is less than 17.
Correct the network
address.
An alarm has
occurred.
Read the alarm code and
the alarm history.
Check details of alarm by referring
to Error Diagnosis Using the Displayed Alarm Codes on page 8-7.
Take countermeasures by
referring to Error Diagnosis
Using the Displayed Alarm
Codes on page 8-7.
8-15
Normal status.
8-3 Troubleshooting
Does not
Servo lock.
Servo lock is ON,
but Servomotor
does not rotate.
The Servomotor
operates
momentarily, but
it does not operate after that.
Probable cause
Items to check
Countermeasure
Not Servo locked.
Check the response of
the NCF71 Servo lock bit.
Set the Servo lock command
bit on the host controller
again.
The power cable is
not properly connected.
Check the wiring of the Servomotor
power cable.
Wire the Servomotor power
cable correctly.
Servomotor power is not
ON.
Check the wiring of the main circuit,
and the voltage of the power
supply.
Input the main circuit power
supply and voltage correctly.
The Forward and Reverse
Drive Prohibit Inputs (POT
and NOT) are OFF.
ΠCheck that the inputs for POT and
NOT are not OFF.
ΠCheck the +24 VIN input for CN1.
Turn ON POT and NOT, and
input +24 VIN correctly.
Torque limit is 0.
Check that torque limits Pn05E and
Pn05F are not set to 0.
Set the maximum torque to
be used for each.
Torque control is used for
the control from the host
controller, and the torque
command value is set to 0.
Check the control mode and the
torque command value for the host
controller.
Set the control mode for the
host controller to position
control mode, and check
Servo lock.
Servo Drive failure.
---
Replace the Servo Drive.
No command is sent
from the host controller.
For position commands, check that
speed and position are not set to 0.
Input the position and speed
data to start the Servomotor.
8
Cannot tell whether the
Servomotor is rotating.
Check that the speed command
from the host controller is not too
slow.
Check the speed command
from the host controller.
The holding brake is
working.
Check the brake interlock (BKIR)
signal and the +24 VDC power
supply.
For a Servomotor with brake,
check that its holding brake
is released by Servo lock.
The No.1 and No. 2 Torque
Limits (Pn05E, Pn05F) are
too small.
Check that the torque limits Pn05E
and Pn05F are not set to a value
close to 0.
Set the maximum torque to
be used for each.
Troubleshooting
Symptom
Torque control is used for
the control from the host
controller, and the torque
command value is too
small.
Check the control mode and the
torque command value for the host
controller.
Set the control mode for the
host controller to position
control mode, and check
Servo lock.
The Speed Limit (Pn053) is
set to 0 for torque control
mode.
Check the Speed Limit (Pn053)
value.
Increase the value for the
Speed Limit (Pn053).
Servo Drive failure.
---
Replace the Servo Drive.
The Servomotor Power
Cable is wired incorrectly.
Check the wiring of the Servomotor
Power Cable phases U, V, and W.
Correctly wire the Servomotor Power Cable phases U,
V, and W.
Not enough position command data.
Check the position data, electronic
gear, and others for NCF71.
Set the correct data.
8-16
8-3 Troubleshooting
Symptom
The Servomotor
rotates
without a
command.
The Servomotor
rotates in the
direction opposite
to the command.
The holding
brake does not
work.
8
Troubleshooting
The Servomotor
is overheating.
The Servomotor
rotation is
unstable.
8-17
Probable cause
Items to check
Countermeasure
There is a small input for
speed command mode.
Check that there is no input
for speed command mode.
Set the speed command to
0, or switch to position control mode.
There is a small input for
torque command mode.
Check that there is no input for
torque command mode.
Switch from torque control
mode to position control
mode.
The Operating Direction
Setting (Pn043) setting is
incorrect.
Check the Operating Direction
Setting (Pn043) value.
Change the Operating
Direction Setting (Pn043)
value.
NCF71 command is
incorrect.
ΠSet values are inappropriate for
an absolute command.
ΠThe polarity is incorrect for an
incremental command.
ΠCheck the current and
target values.
ΠCheck the rotation
direction.
Power is supplied to the
holding brake.
Check whether power is supplied to
the holding brake.
ΠCheck the brake interlock
(BKIR) signal and the relay
circuit.
ΠCheck that the holding
brake is not worn down.
The load is too large.
Measure the torque using the front
panel IM or a tool.
ΠSlow down the
acceleration/deceleration.
ΠLower the speed and
measure the load.
The heat radiation conditions for the Servomotor
have worsened.
ΠCheck that the specified heat
radiation conditions are satisfied.
ΠFor a Servomotor with a brake,
check the load ratio.
ΠImprove the heat radiation
conditions.
ΠReduce the load.
ΠImprove ventilation.
The ambient temperature is
too high.
Check that the ambient temperature has not exceeded 40 °C.
Load and gain do not
match.
Check the response waveforms for
speed and torque.
Adjust the speed loop gain
so that the rotation is
stabilized.
Load inertia exceeds the
specified range.
Calculate the load inertia.
ΠCheck if the adjustments
can be made via manual
tuning.
ΠIncrease the capacity of the
Servomotor.
Low rigidity is resulting in
vibration.
Measure the vibration frequency of
the load.
Enable damping control, and
set the vibration filter frequencies.
Loose coupling with the
machine, and/or large
gaps.
Check coupling with the machine.
Tighten the coupling with the
machine.
ΠRadiate heat and cool.
ΠReduce the load ratio.
8-3 Troubleshooting
Symptom
Probable cause
Items to check
Countermeasure
Problem with the coupling
between the Servomotor
axis and the machine.
Check that the coupling of the Servomotor and the machine is not
misaligned.
Deceleration stop
command is received from
the host controller.
Check the control ladder on the
host controller.
Review the control on the
host controller.
ΠCheck the load inertia.
ΠDynamic brake resistor is
disconnected.
ΠReview the load inertia.
ΠReplace the Servomotor
and Servo Drive with
appropriate models.
ΠRe-tighten the coupling.
ΠReplace with a tight
coupling.
Machine position
is misaligned.
Overshoots when
starting or
stopping.
Load inertia is too large.
Dynamic brake is disabled.
Check if the dynamic brake
is disabled or has failed.
ΠIf disabled, enable it.
ΠIf there is a failure, or
disconnection of the
resistor, replace the
Servomotor.
The Position Loop Gain
(Pn010) is too large.
Review the Position Loop Gain
(Pn010).
Adjust the gain to avoid
overshooting.
Poor balance between the
Speed Loop Integration
Time Constant (Pn012)
and the Speed Loop Gain
(Pn011).
Review the Speed Loop Integration
Time Constant (Pn012) and the
Speed Loop Gain (Pn011).
Use CX-Drive and analog
monitors (SP, IM) to measure the response and adjust
the gain.
Inappropriate machine
rigidity setting by realtime
autotuning.
Review the machine rigidity setting.
Match the machine rigidity
setting to the load rigidity.
Inertial ratio setting differs
from the load.
Review the Inertial Ratio (Pn020).
Match the Inertia Ratio
(Pn020) to the load.
8-18
8
Troubleshooting
The Servomotor
is slow to stop
even if the RUN
command is
turned OFF while
the Servomotor is
rotating.
8-3 Troubleshooting
Symptom
Probable cause
Items to check
Countermeasure
Review the Torque Command Filter
Time Constant (Pn014).
Increase the Torque Command Filter Time Constant
(Pn014) to stop the vibration.
Vibration occurs due to
machine resonance.
Check if the resonance frequency is
high or low.
If the resonance frequency is
high, set an adaptive filter to
stop the resonance, or measure the resonance frequency and set Notch
Filters 1 and 2.
ΠThe Position Loop Gain
(Pn010) is too large.
ΠPoor balance between
the Speed Loop
Integration Time Constant
(Pn012) and the Speed
Loop Gain (Pn011).
Review the Position Loop Gain
(Pn010), Speed Loop Integration
Time Constant (Pn012), and the
Speed Loop Gain (Pn011).
Use CX-Drive and
analog monitors (SP, IM) to
measure the response and
adjust the gain.
The Speed Feedback Filter
Time Constant (Pn013)
does not match the load.
Check the Speed Feedback Filter
Time Constant (Pn013). The
parameter is usually set to 0.
Increase the Speed Feedback Filter Time Constant
(Pn013) and operate.
Check whether the vibration frequency is 100 Hz or below.
If the vibration frequency is
100 Hz or below, stop the
vibration by setting the vibration frequency for the vibration filter.
Check whether the coupling with
the load is unbalanced.
Make adjustments to
balance the rotation.
Check for eccentricity of the load.
Eliminate eccentricity.
Eccentricity of the load
results in noise due to
fluctuation of torque.
Check for noise from within the
decelerator.
Check the decelerator specifications and perform an
inspection.
The Torque Command
Filter Time Constant
(Pn014) does not match
the load.
Unusual noise
and vibration
occurs from
the Servomotor
or the load.
Vibration occurs due to low
mechanical rigidity.
Troubleshooting
8
Vibration occurs due to
mechanical installation.
8-19
8-4 Overload Characteristics (Electronic Thermal Function)
8-4 Overload Characteristics
(Electronic Thermal Function)
An overload protection (electronic thermal) function is built into the Servo Drive to protect the Servo
Drive and Servomotor from overloading.
If an overload does occur, first eliminate the cause of the error and then wait at least one minute for
the Servomotor temperature to drop before turning on the power again.
If the power is turned ON again repeatedly at short intervals, the Servomotor windings may burn out.
Overload Characteristics Graphs
The following graphs show the characteristics of the load ratio and the electronic thermal function's
operation time.
Time (s)
100
50 W
100 W (100 V)
100 W (200 V)
200 W
400 W
750 W
10
8
0.1
115
100
150
200
250
Troubleshooting
1
300 Torque (%)
Time (s)
100
R88M-G@10T
R88M-G@20T
R88M-G@15T
R88M-G@30T
R88M-GP@
10
900 W to 6 kW
1 kW to 5 kW
7.5 kW
1 kW to 5 kW
100 W to 400 W
1
0.1
115
100
150
200
250
300 Torque (%)
When the torque command = 0, and a constant torque command is continuously applied after three
or more times the overload time constant has elapsed, the overload time t [s] will be:
t [s] = − Overload time constant [s] × loge (1 − Overload level [%] / Torque command [%]) 2
(The overload time constant [s] depends on the Servomotor. The standard overload level is 115%.)
Precautions
for Correct Use
ΠOverload (alarm code 16) cannot be reset for approximately 10 seconds
after its occurrence.
8-20
8-5 Periodic Maintenance
8-5 Periodic Maintenance
Caution
Resume operation only after transferring to the new Unit the
contents of the data required for operation.
Not doing so may result in equipment damage.
Do not attempt to disassemble or repair any of the products.
Any attempt to do so may result in electric shock or injury.
Servomotors and Servo Drives contain many components and will operate properly only when each
of the individual components is operating properly.
Some of the electrical and mechanical components require maintenance depending on application
conditions. Periodic inspection and part replacement are necessary to ensure proper long-term
operation of Servomotors and Servo Drives. (quotes from “The Recommendation for Periodic
Maintenance of a General-purpose Inverter” published by JEMA)
The periodic maintenance cycle depends on the installation environment and application conditions
of the Servomotor or Servo Drive.
Recommended maintenance times are listed below for Servomotors and Servo Drives. Use these
for reference in determining actual maintenance schedules.
Troubleshooting
8
Servomotor Service Life
ΠThe service life for components is listed below.
Bearings: 20,000 hours
Decelerator: 20,000 hours
Oil seal: 5,000 hours
Encoder: 30,000 hours
These values presume an ambient Servomotor operating temperature of 40°C, shaft loads within
the allowable range, rated operation (rated torque and rated r/min), and proper installation as
described in this manual.
The oil seal can be replaced.
ΠThe radial loads during operation (rotation) on timing pulleys and other components contacting
belts is twice the still load. Consult with the belt and pulley manufacturers and adjust designs and
system settings so that the allowable shaft load is not exceeded even during operation. If a
Servomotor is used under a shaft load exceeding the allowable limit, the Servomotor shaft can
break, the bearings can burn out, and other problems can occur.
8-21
8-5 Periodic Maintenance
Servo Drive Service Life
8
Troubleshooting
ΠDetails on the service life of the Servo Drive are provided below.
Aluminum electrolytic capacitors: 28,000 hours
(at an ambient Servo Drive operating temperature of 55°C, the rated operation output (rated
torque), installed as described in this manual.)
Axial fan: 10,000 to 30,000 hours
Inrush current prevention relay: Approx. 20,000 operations (The service life depends on the
operating conditions.)
ΠWhen using the Servo Drive in continuous operation, use fans or air conditioners to maintain an
ambient operating temperature below 40°C.
ΠWe recommend that ambient operating temperature and the power ON time be reduced as much
as possible to lengthen the service life of the Servo Drive.
ΠThe life of aluminum electrolytic capacitors is greatly affected by the ambient operating
temperature. Generally speaking, an increase of 10°C in the ambient operating temperature will
reduce capacitor life by 50%.
ΠThe aluminum electrolytic capacitors deteriorate even when the Servo Drive is stored with no
power supplied. If the Servo Drive is not used for a long time, we recommend a periodic inspection
and part replacement schedule of five years.
ΠIf the Servomotor or Servo Drive is not to be used for a long time, or if they are to be used under
conditions worse than those described above, a periodic inspection schedule of five years is
recommended.
ΠUpon request, OMRON will examine the Servo Drive and Servomotor and determine if a
replacement is required.
8-22
8-5 Periodic Maintenance
Replacing the Absolute Encoder Battery
ABS
Replace the Absolute Encoder Backup Battery if it has been used for more than three years or if an
absolute encoder system down error (alarm code 40) has occurred.
„ Replacement Battery Model and Specifications
Item
Specifications
Name
Absolute Encoder Backup Battery
Model
R88A-BAT01G
Battery model
ER6V (Toshiba)
Battery voltage
3.6 V
Current capacity
2000 mA·h
„ Mounting the Backup Battery
Mounting the Battery for the First Time
Connect the absolute encoder battery to the Servomotor, and then set up the absolute encoder.
Refer to Absolute Encoder Setup on page 6-6.
Once the absolute encoder battery is attached, it is recommended that the control power supply be
turned ON and OFF once a day to refresh the battery.
If you neglect to refresh the battery, battery errors may occur due to voltage delay in the battery.
8
Troubleshooting
Replacing the Battery
If a battery alarm occurs, the absolute encoder battery must be replaced.
Replace the battery with the control power supply to the Servo Drive ON. If the battery is replaced
with the control power supply to the Servo Drive OFF, data held in the encoder will be lost.
Once the absolute encoder battery has been replaced, clear the battery alarm. For details on
clearing the alarm, refer to Alarm Reset on page 6-25.
Note If the absolute encoder is cleared, or the absolute values are cleared using communications,
all error and rotation data will be lost and the absolute encoder must be set up again. For
details, refer to Absolute Encoder Setup on page 6-6.
8-23
8-5 Periodic Maintenance
Battery Mounting Procedure
1. Prepare the R88A-BAT01G replacement battery.
R88A-BAT01G
2. Remove the battery box cover.
8
Troubleshooting
Raise the hooks to remove the cover.
3. Put the battery into the battery box.
Insert the battery.
Attach the connector.
4. Close the cover to the battery box.
Make sure that the connector
wiring does not get caught when
closing the cover to the battery
box.
8-24
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