YASKAWA MOTOMAN FS100 Maintenance Manual

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FS100

MAINTENANCE MANUAL

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

MOTOMAN INSTRUCTIONS

MOTOMAN-



INSTRUCTIONS

FS100 INSTRUCTIONS

FS100 OPERATOR’S MANUAL

FS100 MAINTENANCE MANUAL

YASKAWA ELECTRIC CORPORATION

MANUAL NO. RE-CHO-A111 5

FS100

MANDATORY

• This manual explains maintenance procedures of the FS100 system. Read this manual carefully and be sure to understand its contents before handling the FS100.

• General items related to safety are listed in Chapter 1: Safety of the

FS100 INSTRUCTIONS. To ensure correct and safe operation, carefully read the FS100 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 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 is not responsible for incidents arising from unauthorized modification of its products. Unauthorized modification voids your product’s warranty.

FS100

Notes for Safe Operation

Read this manual carefully before installation, operation, maintenance, or inspection of the FS100 .

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

“WARNING”, “CAUTION”, “MANDATORY”, or “PROHIBITED”.

DANGER

WARNING

CAUTION

Indicates an imminent 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 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 “DAN-

GER”, “WARNING” and “CAUTION” . iii

FS100

WARNING

• Before operating the manipulator, check that servo power is turned

OFF when the emergency stop button on the programming pendant is pressed.

When the servo power is turned OFF, the SERVO ON LED on the programing 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 button does not function.

Fig. : Emergency Stop Button

• In the case of not using the programming pendant, be sure to supply the emergency stop button on the equipment. Then before operating the manipulator, check to be sure that the servo power is turned OFF by pressing the emergency stop button.

Connect the external emergency stop button to the 5-6 pin and 16-

17 pin of the robot system signal connector (CN2).

• Upon shipment of the FS100, this signal is connected by a jumper cable in the dummy connector. To use the signal, make sure to supply a new connector, and then input it.

If the signal is input with the jumper cable connected, it does not function, which may result in personal injury or equipment damage.

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

Then turn the servo power ON.

Injury may result from unintentional or unexpected manipulator motion.

Fig. : Release of Emergency Stop Button

TURN

• Observe the following precautions when performing teaching operations within the manipulator’s operating range:

– Be sure to use a lockout device to the safeguarding when going inside. Also, display the sign that the operation is being performed inside the safeguarding and make sure no one closes the safeguarding.

– 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.

FS100

WARNING

• Confirm that no person is present in the manipulator’s operating range and that you are in a safe location before:

– Turning ON the power for the FS100.

– Moving the manipulator with the programming pendant.

– Running the system in the check mode.

– Performing automatic operations.

Injury may result if anyone enters the manipulator’s operating range during operation. Always press an emergency stop button immediately if there are problems.

The emergency stop button is located on the programing pendant.

CAUTION

• Perform the following inspection procedures prior to teaching the manipulator. If problems are found, correct them immediately, and be sure that all other necessary tasks have been performed.

– Check for problems in manipulator movement.

– Check for damage to the insulation and sheathing of external wires.

• Return the programming pendant to a safe place after use.

If the programming pendant is inadvertently left on the manipulator, on a fixture, or on the floor, the manipulator or a tool may collide with the programming pendant during manipulator movement, which may result in personal injury or equipment damage.

• Read and understand the Explanation of Warning Labels in the

FS100 Instructions before operating the manipulator.

Definition of Terms Used Often in This Manual

The MOTOMAN is the YASKAWA industrial robot product.

The MOTOMAN usually consists of the manipulator, the FS100 controller, manipulator cables, the FS100 programming pendant (optional), and the

FS100 programming pendant dummy connector (optional).

In this manual, the equipment is designated as follows:

Equipment

FS100 controller

FS100 programming pendant

Cable between the manipulator and the controller

FS100 programming pendant dummy connector

Manual Designation

FS100

Programming pendant

Manipulator Cable

Programming pendant dummy connector v

FS100

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

Equipment

Programming

Pendant

PC Keyboard

Manual Designation

Character Keys The keys which have characters printed on them are denoted with [ ]. ex. [ENTER]

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

Axis Keys

Numeric Keys

Keys pressed simultaneously ex. PAGE key

GO BACK

PAGE

The Cursor 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 key SHIFT +COORD key

TOOL SEL

COORD

Mode Key

Button

Displays

Three kinds of modes that can be selected by the mode key are denoted as follows:

REMOTE, PLAY, or TEACH

Three buttons on the upper side of the programming pendant are denoted as follows:

HOLD button

START button

EMERGENCY STOP button

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

The name of the key is denoted ex. Ctrl key on the keyboard

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.

Registered Trademark

In this manual, names of companies, corporations, or products are trademarks, registered trademarks, or brand names for each company or corporation. The indications of (R) and

are omitted.

FS100

Explanation of Warning Labels

DANGER

• The label described below is attached to the manipulator.

Observe the precautions on the warning labels.

Failure to observe this caution may result in injury or damage to equipment.

Fig. : Warning Labels

WARNING Label A:

WARNING

Moving parts may cause injury

WARNING Label B:

WARNING

Do not enter robot work area.

• The following warning labels are attached to FS100.

Observe the precautions on the warning labels.

Failure to observe this warning may result in injury or damage to equipment.

Fig. : Location of Warning Labels

Heavy Object Warning NP

Top View

Front View

Electric Shock Warning NP

Electric Shock Warning NP vii

FS100

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

1.1 Arrangement of Units and Circuit Boards .......................................................................... 1-1

1.2 Power Flow

...................................................................................................................................... 1-2

1.3 Signal Flow

...................................................................................................................................... 1-3

2 Security System .............................................................................................................................. 2-1

2.1 Protection Through Security Mode Settings ...................................................................... 2-1

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

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

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

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

3 Maintenance and Inspections ......................................................................................................... 3-1

3.1 Daily Inspections................................................................................................................ 3-1

3.2 Cooling Fan Inspections .................................................................................................... 3-3

3.3 Emergency Stop Button Inspections.................................................................................. 3-4

3.4 Enable Switch Inspections ................................................................................................. 3-4

3.5 Battery Inspections ............................................................................................................ 3-5

4 Preparation before Replacing Parts ................................................................................................ 4-1

4.1 Creating a Check Program ................................................................................................ 4-3

5 Replacing Parts............................................................................................................................... 5-1

5.1 Fuse Replacement............................................................................................................. 5-1

5.2 Interior Circulation Fan Replacement ................................................................................ 5-3

5.3 Battery Replacement ......................................................................................................... 5-4

6.1 List of Accessories ............................................................................................................. 6-1

7 Operations After Replacing Parts.................................................................................................... 7-1

7.1 Home Position Calibration ................................................................................................. 7-2

7.1.1 Home Position Calibration .................................................................................... 7-2

7.1.2 Calibrating Operation............................................................................................ 7-4

7.1.2.1 Registering All Axes at One Time............................................................ 7-4

7.1.2.2 Registering Individual Axes ..................................................................... 7-6

7.1.2.3 Changing the Absolute Data ................................................................... 7-7

7.1.2.4 Clearing Absolute Data............................................................................ 7-8

viii

FS100

7.1.3 Manipulator Home Position ................................................................................ 7-10

7.2 Position Deviation Check Using the Check Program....................................................... 7-11

7.3 Checking of the Check Program...................................................................................... 7-12

7.3.1 Motion of the Check Program............................................................................. 7-12

7.3.2 Checking of the Check Program......................................................................... 7-12

7.3.3 Home Position Data Correction .......................................................................... 7-13

7.4 Setting the Second Home Position (Check Point) ........................................................... 7-14

7.4.1 Purpose of Position Check Operation ................................................................ 7-16

7.4.2 Procedure for the Second Home Position Setting (Check Point) ....................... 7-18

7.4.3 Procedure after the Alarm .................................................................................. 7-19

8 System Diagnosis ........................................................................................................................... 8-1

8.1 System Version.................................................................................................................. 8-1

8.2 Manipulator Model ............................................................................................................. 8-1

8.3 Input/Output Status............................................................................................................ 8-2

8.3.1 Universal Input ..................................................................................................... 8-2

8.3.1.1 Universal Input Window........................................................................... 8-2

8.3.1.2 Universal Input Simple Window............................................................... 8-2

8.3.2 Universal Output................................................................................................... 8-3

8.3.2.1 Universal Output Window........................................................................ 8-3

8.3.2.2 Universal Output Simple Window............................................................ 8-3

8.3.2.3 Modifying the Output Status .................................................................... 8-4

8.3.3 Specific Input ........................................................................................................ 8-5

8.3.3.1 Specified Input Window........................................................................... 8-5

8.3.3.2 Specific Input Simple Window ................................................................. 8-5

8.3.4 Specific Output ..................................................................................................... 8-6

8.3.4.1 Specified Output Window ........................................................................ 8-6

8.3.4.2 Specific Output Simple Window .............................................................. 8-6

8.3.5 RIN Input .............................................................................................................. 8-7

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

8.3.6 Signal Number Search ......................................................................................... 8-8

8.3.6.1 Direct Search on the Universal/Specified Input/Output Window ............. 8-9

8.3.6.2 Search from the Menu........................................................................... 8-10

8.3.7 Relay Number Search ........................................................................................ 8-11

8.3.7.1 Direct Search on the Universal/Specified Input/Output Window ........... 8-12

8.3.7.2 Search from the Menu........................................................................... 8-13

8.3.8 Modification of the Signal Name......................................................................... 8-14

8.3.8.1 Direct Modification on the Universal/Specified Input/Output Window ... 8-14

8.3.8.2 Modification from the Menu ................................................................... 8-15

FS100

8.4 System Monitoring Time Display ..................................................................................... 8-16

8.4.1 System Monitoring Time Display Window .......................................................... 8-16

8.4.2 Individual Window of the System Monitoring Time Display ................................ 8-17

8.4.3 Clearing the System Monitoring Time Display.................................................... 8-18

8.5 Alarm History ................................................................................................................... 8-19

8.5.1 Alarm History Window ........................................................................................ 8-19

8.5.2 Clearing the Alarm History.................................................................................. 8-20

8.6 I/O Message History ........................................................................................................ 8-21

8.6.1 I/O Message History Window ............................................................................. 8-21

8.6.1.1 Search ................................................................................................... 8-21

8.6.2 Clearing the I/O Message History....................................................................... 8-22

8.7 Position Data When Power is Turned ON/OFF ............................................................... 8-23

8.7.1 Power ON/OFF Position Window ....................................................................... 8-23

8.8 Current Position ............................................................................................................... 8-24

8.8.1 Current Position Window .................................................................................... 8-24

8.9 Servo Monitoring.............................................................................................................. 8-25

8.9.1 Servo Monitor Window........................................................................................ 8-25

8.9.1.1 Changing the Monitor Items .................................................................. 8-26

8.9.1.2 Clearing Maximum Torque Data............................................................ 8-28

9 Alarm............................................................................................................................................... 9-1

9.1 Outline of Alarm ................................................................................................................. 9-1

9.2 Alarm Display..................................................................................................................... 9-2

9.2.1 Displaying and Releasing Alarm........................................................................... 9-2

9.2.1.1 Releasing Alarms .................................................................................... 9-2

9.2.2 Special Alarm Display........................................................................................... 9-3

9.3 Display of Alarm Details..................................................................................................... 9-5

9.3.1 Parameter ............................................................................................................. 9-5

9.3.2 Display of Alarm Detail Window........................................................................... 9-5

9.3.3 Transition of Alarm Detail Window........................................................................ 9-7

9.4 Alarm Message List ........................................................................................................... 9-8

10 Error ........................................................................................................................................... 10-1

10.1 Error Message ............................................................................................................... 10-1

10.1.1 System and General Operation ........................................................................ 10-2

10.1.2 Editing............................................................................................................... 10-5

FS100

10.1.3 Job Defined Data.............................................................................................. 10-6

10.1.4 External Memory Equipment ............................................................................ 10-9

10.1.5 Concurrent I/O ................................................................................................ 10-14

10.1.6 Maintenance Mode ......................................................................................... 10-15

10.2 Particular Error Message ............................................................................................. 10-16

10.2.1 Message ......................................................................................................... 10-16

10.2.1.1 Fatal Error ......................................................................................... 10-16

10.2.1.2 Application Transaction Error ............................................................ 10-17

10.2.1.3 Other Errors ...................................................................................... 10-17

10.2.2 When the Error is Indicated ............................................................................ 10-18

10.2.2.1 Fatal Error ......................................................................................... 10-18

10.2.2.2 Application Transaction Error ............................................................ 10-18

10.2.2.3 Other Errors ...................................................................................... 10-18

11 LED Indicator on Each Circuit Board ......................................................................................... 11-1

11.1 6 LED-Spot Indicator on the Main CPU Circuit Board (CPU201R)................................ 11-2

11.2 7-Segment LED Indicator on the Main CPU Circuit Board (CPU201R)......................... 11-3

11.2.1 Status of 7-Segment LED Indicator at Error Occurrence ................................. 11-4

11.2.2 Status of 7-Segment LED Indicator at Control Power Start-up (one digit) ....... 11-5

11.2.3 Status of 7-Segment LED Indicator at Hardware Error Occurrence................. 11-5

11.2.4 Status of 7-Segment LED Indicator at Alarm Occurrence ................................ 11-6

11.3 7 SEG-LED Indicator on Machine Safety Board (SF2300)............................................ 11-7

11.4 7 SEG-LED Indicator on SERVO Control Board (IFM).................................................. 11-8

11.4.1 LED Indicator at Alarm Occurrence in the Main CPU and SERVO Control Board

Communication System ..................................................................................... 11-8

11.4.2 LED Indicator During the Start-up Process ...................................................... 11-9

FS100

1 Equipment Configuration

1.1

Arrangement of Units and Circuit Boards

1 Equipment Configuration

Converter unit

CSTR-COB02AA

1.1 Arrangement of Units and Circuit Boards

Fig. 1-1: Arrangement of Units and Circuit Boards

Mounting base unit

CSTR-MBB08AAA

PWM amplifier module

CSTR-SDB AAA ***

Major axes control circuit board

CSTR-IFBM3LA

I/O relay circuit board

CSTRFBBCA8R03CAA

Power relay circuit board

JEPMC-PSD3007R-E

Control circuit board

JEPMC-CP3201R-E

(abbreviated as CPU-201R)

Top view

(without top cover)

User I/O circuit board for Japan and North America: JAPMC-IO2308R-E

(abbreviated as LIO-08R) for Europe: JAPMC-IO2309R-E

(abbreviated as LIO-09R)

Machine safety circuit board

JAPMC-SF2300R-E

(abbreviated as SF2300R)

1-1

FS100

1 Equipment Configuration

1.2

Power Flow

1.2 Power Flow

Three phase

220/200VAC

50Hz/60Hz

CN1

QF1

CIRCUIT

PROTECTOR

Noise filter

COOLING

FAN

COOLING

FAN

MC1

POWER

RELAY

CV1

CN304

(Control power supply)

CN303

(Main circuit)

CAPACITOR

UNIT (CRBCC)

CN203

DC280V

CN302

(CSTR-COB02AA)

(Condensor input)

(5V output)

CN308

CONVERTER

CN306

(24V4 output)

REGENERATIVE

RESISTOR

CN301

(PN)

(24V output)

CN307

CN310

(24V3 output)

CN305 CN309

P.P(OPTION)

X81

F1 (250V 0.6A)

24V (to PP)

(Power supply for control unit)

CN3

JAPMC-CP3201-E

CN4(USB)

CN1(RS232C)

CN6(MIII)

CPU201

CN10(BAT)

CN3(Ethernet)

CN2(Ethernet)

(MIII)CN5

CN3 LIO08

IO for the user (1)

IO for the user (2)

Safety

CN5(OT1,OT2)

(+24V3)CN6

CN2(PPESP,DSW)

CN1(PBESP) (HWBB,EDM)CN4

CN3

(SAFF,ONEN,EXESP)

(ESPOUT,DSWOUT)

CNTR-01

217IF-02

+24V4

(Brake power supply)

DC280V

16.5V

CN54

(PN)

CSTR-MBB

CN53

(Gate power supply)

CN55

CN52 CN120

(Control (FBB control) power supply)

CN56 (Safety) CN8

CN110

CN101

CN111

CN101

CN112

CN101

AMP1

CN102

CN51

AMP2

CN102

CN51

AMP3

CN102

CN51

CN100

Motor power

CN101

CN102

FBB

(Brake release) CN210

CN209 (Relay IO)

CN211

(External IO)

CN201

(Control power supply)

CN206 (Manipulator IO)

CN208 (PP IO)

CN202

CN203

CN207

(PG signal)

(Brake output (24V))

CN204

(External axis PG signal)

CN205

(Brake power supply)

CN200 (FBB control)

(External axis PG signal)

MANIPULATOR

S-AXIS MOTOR

POWER

L-AXIS MOTOR

Brake

POWER

U-AXIS MOTOR

Brake

POWER

CN115

CN101

AMP6

CN102

CN51

CN105

X21 Brake output

Motor power

T-AXIS MOTOR

Brake

POWER

CN6A

IFM

CN50 CN51

Main circuit board

CSTR-MBBCB

Mounting base board

CSTR-MBBCA

1-2

FS100

1 Equipment Configuration

1.3

Signal Flow

1.3 Signal Flow

MC1

POWER

RELAY

Feed back signal

Control signal

Power supply turning

ON signal

P.P(OPTION)

X81

Ethernet (to PP)

Safety signal

CN3

JAPMC-CP3201-E

CN4(USB)

CN1(RS232C)

CN6(MIII)

CPU201

CN10(BAT)

CN3(Ethernet)

CN2(Ethernet)

(MIII)CN5

CN3 LIO08

IO for the user (1)

IO for the user (2)

Safety

CN5(OT1,OT2) (+24V3)CN6

CN2(PPESP,DSW)

CN1(PBESP) (HWBB,EDM)CN4

CN3

(SAFF,ONEN,EXESP)

(ESPOUT,DSWOUT)

CNTR-01

CV1

(Control

CN304 CN303 power supply) (Main circuit)

CN301

(PN)

(24V output)

CN307

CN310

(24V3 output)

CONVERTER

CN302

(CSTR-COB02AA)

(Condensor input)

CN308

(5V output)

CN306

(Control power supply)(Servo control)

(24V4 output)

CN305 CN309

FBB

CN209 (Relay IO)

CN211

(External IO)

CN201

(Control power supply)

(ManipulatorIO) CN206

(PG signal) CN203

CN207

CN208 (PP IO)

CN202

CN204

(External axis PG signal)

CN205

(Break power supply)

CN200 (FBB control)

(External axis PG signal)

Encoder signal

FBA control signal

(Encoder signal)

217IF-02

Movement block signal (redundant)

CN54

(PN)

CN53 CN52 CN120

CSTR-MBB

CN55 CN56 (Safety) CN8

CN101

AMP1

CN102

CN51

AMP2

CN102

CN51

AMP3

CN102

CN51

CN100

CN101

CN102

MANIPULATOR

S-AXIS MOTOR

ENCODER

L-AXIS MOTOR

ENCODER

U-AXIS MOTOR

ENCODER

CN115

CN101

AMP6

CN102

CN51

CN105

T-AXIS MOTOR

ENCODER

Encoder sigal

X11 Overtravel sigal

MechatroLink III

CN6A

IFM

CN50 CN51

(Main circuit board)

CSTR-MBBCB

(Mounting base board)

CSTR-MBBCA

(Overtravel sigal)

5V (OUT)

SHOCK.LAMP

(OPTION)

24V (IN)

1-3

FS100

2 Security System

2.1

Protection Through Security Mode Settings

2 Security System

2.1.1

Security Mode

2.1 Protection Through Security Mode Settings

The FS100 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.

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”, “-”, “.”.

Table 2-1: Security Mode Descriptions

Security Mode

Operation Mode

Explanation

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

Editing Mode

Management

Mode

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.

2-1

FS100

2 Security System

2.1

Protection Through Security Mode Settings

Table 2-2: Menu & Security Mode (Sheet 1 of 3)

Main Menu Sub Menu

JOB

VARIABLE

JOB

SELECT JOB

CREATE NEW JOB

MASTER JOB

JOB CAPACITY

CYCLE

BYTE

INTEGER

DOUBLE

REAL

STRING

POSITION (ROBOT)

POSITION (BASE)

POSITION (ST)

LOCAL VARIABLE

IN/OUT EXTERNAL INPUT

EXTERNAL OUTPUT

UNIVERSAL INPUT

UNIVERSAL OUTPUT

SPECIFIC INPUT

SPECIFIC OUTPUT

RIN

CPRIN

AUXILIARY RELAY

CONTROL INPUT

PSEUDO INPUT SIG

NETWORK INPUT

NETWORK OUTPUT

ANALOG OUTPUT

SV POWER STATUS

TERMIMAL

LADDER PROGRAM

I/O ALARM

I/O MESSAGE

1) Displayed in the teach mode only.

Operation

Allowed Security Mode

DISPLAY EDIT

Operation Edit

Operation

Edit

Operation

Operation -

Operation

Edit

Operation

Edit

Operation

Operation -

Management Management

Edit

Operation

Management

2-2

FS100

2 Security System

2.1

Protection Through Security Mode Settings

Table 2-2: Menu & Security Mode (Sheet 2 of 3)

Main Menu

ROBOT

Sub Menu Allowed Security Mode

DISPLAY EDIT

Operation CURRENT POSITION

COMMAND POSITION

SERVO MONITOR

WORK HOME POS

SECOND HOME POS

DROP AMOUNT

POWER ON/OFF POS

Operation

Management -

Operation

Edit

Management Management

Operation -

Edit Edit

Management Management

TOOL

INTERFERENCE

SHOCK SENS LEVEL

USER COORDINATE

HOME POSITION

Operation

Edit

Management Management

MANIPULATOR TYPE

ANALOG MONITOR

OVERRUN&S-SENSOR

LIMIT RELEASE

ARM CONTROL

Management

Edit

Management

Edit

Edit Edit

Management Management

SHIFT VALUE Operation

HAND VIBRATION CONTROL Operation

Management

SYSTEM INFO VERSION

MONITORING TIME

ALARM HISTORY

I/O MSG HISTORY

NETWORK SERVICE

FD/CF

USER DEFINITION MENU

SECURITY

LOAD

SAVE

VERIFY

DELETE

DEVICE

FOLDER

1) Displayed in the teach mode only.

Operation

Management -

Operation

Edit

Operation

Edit

Management

Operation

Management

2-3

FS100

2 Security System

2.1

Protection Through Security Mode Settings

Table 2-2: Menu & Security Mode (Sheet 3 of 3)

Main Menu

PARAMETER

SETUP

DISPLAY

SETUP

GENERAL

Sub Menu

S1E

S2E

S3E

S4E

S5E

S1CxG

S2C

S3C

S4C

A1P

A2P

S6E

S7E

S8E

TEACHING COND.

Allowed Security Mode

DISPLAY EDIT

Management Management

Management

Management Management

Edit Edit

OPERATE COND.

OPERATE ENABLE

FUNCTION ENABLE

JOG COND.

Management Management

PLAYBACK COND.

FUNCTION COND.

Management Management

DISPLAYING COLOR COND.

Management Management

DATE/TIME Management Management

GRP COMBINATION

RESERVE JOB NAME

USER ID

SET SPEED

KEY ALLOCATION

JOG KEY ALLOC.

RES. START (CNCT)

AUTO BACK SET

Management Management

Edit Edit

Management Management

Edit Management

Management Management

WRONG DATA LOG Edit

ENERGY SAVING FUNCTION Edit

ENCODER MAINTENANE

CHANGE FONT

Edit

Operation

CHANGE BUTTON

INITIALIZE LAYOUT

Operation

CHANGE WINDOW PATTERN Operation

GENERAL DIAG.

Operation

Management

Operation

Edit

2-4

FS100

2 Security System

2.1

Protection Through Security Mode Settings

2.1.1.1

Changing the Security Mode

1. Select {SYSTEM INFO} under the main menu.

– The sub menu appears.

2. Select {SECURITY}.

– The selection window of security mode appears.

3. Press [SELECT] and select "SECURITY MODE".

2-5

FS100

2 Security System

2.1

Protection Through Security Mode Settings

4. Input the user ID.

– The user ID input window appears.

SUPPLE

-MENT

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

• Editing Mode:[00000000]

Management Mode:[99999999]

5. Press [ENTER].

– The input user ID is compared with the user ID of the selected security mode. When the correct user ID is entered, the security mode is changed.

2-6

FS100

2 Security System

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 “.”)

2.1.2.1

Changing a User ID

In order to change the user ID, the FS100 must be in Editing Mode or

Management Mode. Higher security modes can make changes the user

ID of to lower security modes.

1. Select {SETUP} under the main menu.

– The sub menu appears.

2. Select {USER ID}.

– The USER ID window appears.

2-7

FS100

2 Security System

2.1

Protection Through Security Mode Settings

3. Select the desired ID.

– The character input line appears, and the message "Input current ID no. (4 to 8 digits)" is shown.

4. Input current ID and press [ENTER].

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

5. Input new ID and press [ENTER].

– User ID is changed.

2-8

FS100

3 Maintenance and Inspections

3.1

Daily Inspections

3 Maintenance and Inspections

Operator’s manual for daily inspection and parts replacement are explained in this section. Be sure to read and understand this instruction before operating the FS100.

To ensure correct and safe operation, carefully read the FS100

INSTRUCTIONS (RE-CTO-A218).

WARNING

• Maintenance and inspections should be carried out by the qualified worker.

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

3.1 Daily Inspections

WARNING

• Do not touch the cooling fan or other equipment while the power is turned ON.

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

3-1

FS100

3 Maintenance and Inspections

3.1

Daily Inspections

Carry out the following inspections.

Inspection

Equipment

Inspection Item Method Inspection

Interval

As required

Comments

FS100 Controller exterior

Power supply cable

Check for damages and cracks

Check for damages or connections.

Check visually

Check visually As required

Check for damages and loose connectors

Manipulator cable

(between the FS100 and the manipulator)

Cover mounting screws

Cooling fan

Check for damages or connections.

Check for defect or loose of the screws

Check the operation

Check visually

Use screw driver

Check visually

As required

Check for damages and loose connectors

Tighten loose screws

When the power is turned ON

When the SERVO is turned ON

Emergency stop button

(programming pendant)

Enable switch

(programming pendant)

Check the operation

By activating the button

By activating the switch

Before the manipulator operation

During the teach mode

Battery

(for the system)

Message indication

Check LED lights

Check visually As required Before blocking the power supply

1 Be sure to confirm that the SERVO can be turned OFF by pressing the external emergency button when the programming pendant is not used.

The external emergency button is prepared by the user.

3-2

FS100

3 Maintenance and Inspections

3.2

Cooling Fan Inspections

3.2 Cooling Fan Inspections

Inspect the cooling fans as required. A defective fan can cause the FS100 to malfunction because of excessive high temperatures inside.

The interior circulation fan and cooling fan normally operate while the power is turned ON. Check if the fans are operating correctly by visual inspection and by feeling air moving into the air inlet and from the outlet.

Air intake

Air outlet

(Backside View)

Cooling fan installing direction

Air outlet Air intake Air intake

Air outlet

(Top View)

Cooling wind direction

3-3

FS100

3 Maintenance and Inspections

3.3

Emergency Stop Button Inspections

3.3 Emergency Stop Button Inspections

The emergency stop button is located on the programming pendant.

Before operating the manipulator, confirm that the SERVO power is ON/

OFF by pressing the emergency stop button after the SERVO is ON.

• Be sure to confirm that the SERVO can be turned OFF by pressing the external emergency button when the programming pendant is not used.

The external emergency button is prepared by the user.

3.4 Enable Switch Inspections

The programing pendant is equipped with a three-position enable switch.

Perform the following operations to confirm that the enable switch is firmly operated.

(1) Set the Mode key on the programming pendant to "TEACH".

Mode key with a switch

REMOTE

PLAY

TEACH

(2) Press [SERVO ON READY] on the programming pendant. Then

[SERVO ON] lamp blinks.

SERVO ON

(3) When the enable switch is grasped lightly, the servo power is turned ON.

When the enable switch is grasped firmly or released, the servo power is turned OFF.

NOTE

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

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

• The emergency stop signal is externally input.

If the [SERVO ON] lamp does not blink in previous operation (3), check the following:

• If a major alarm is occurring.

3-4

FS100

3 Maintenance and Inspections

3.5

Battery Inspections

3.5 Battery Inspections

The FS100 has a battery that backs up the important program files for user data in the CMOS memory.

A battery alarm is indicated when a battery is weakened to be replaced.

Also, a message "Memory battery weak" appears on the programming pendant display.

Refer to chapter 5.3 “Battery Replacement” at page 5-4

for the battery replacement.

When the programming pendant is not used, be sure to confirm, from the

LED audit window on the FS100 front door, that the battery alarm LED of the CPU unit (CPU-201R) is not lit up.

Also, the battery alarm status can be confirmed by “battery alarm” of a system input.

3-5

4 Preparation before Replacing Parts

FS100

4 Preparation before Replacing Parts

WARNING

• Before operating the manipulator, check that servo power is turned

OFF when the emergency stop button on the programming pendant is pressed.

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

Connect the external emergency stop button to the 5-6 pin and 16-

17 pin of the robot system signal connector (CN2).

• Upon shipment of the FS100, this signal is connected by a jumper cable in the dummy connector. To use the signal, make sure to supply a new connector, and then input it.

If the signal is input with the jumper cable connected, it does not function, which may result in personal injury or equipment damage.

• Observe the following precautions when performing teaching operations within the manipulator’s operating range:

– 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 person is present in the manipulator’s operating range and that you are in a safe location before:

– Turning ON the power for the FS100.

– Moving the manipulator with the programming pendant.

Injury may result if anyone enters the manipulator’s operating range during operation. Always press an emergency stop button immediately if there are problems.

The emergency stop button is located on the programing pendant.

4-1

FS100

4 Preparation before Replacing Parts

CAUTION

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

– Check for problems in manipulator movement.

– Check for damage to the insulation and sheathing of external wires.

• Return the programming pendant to a safe place after use.

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

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 chapter 4.1 “Creating a Check Program” at page 4-3

• Change in the combination of the manipulator and FS100

• Replacement of the motor or absolute encoder

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

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

4-2

FS100

4 Preparation before Replacing Parts

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.

Fig. 4-1: <Enlarged View>

4-3

FS100

5 Replacing Parts

5.1

Fuse Replacement

WARNING

• To prevent anyone inadvertently turning ON the power supply

(including a pressurized air), put up a warning sign such as "DO

NOT TURN ON THE POWER" before the maintenance, inspection, or wiring operation.

WARNING

• Maintenance and inspections should be carried out by the qualified worker.

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

5.1 Fuse Replacement

Following fuses

are mounted in the FS100.

Fuse name Where to mount Type Manufacturer

I/O power supply fuse

(F1: left side of the following figure)

Front side of the FS100 0312.600, 250V, 0.6A

6.3 dia. x 32 mm, fast-blow type

Littel Fuse Ltd.

Fuse for regenerative resistor fan protection

(F2: right side of the following figure)

Front side of the FS100 250V, 1A

5 dia. x 20 mm

1 A fuse is delivered with the FS100 before shipment for replacement.

2 Fuse for regenerative resistor fan protection is mounted on the FS100 for HP20Fonlly.

Littel Fuse Ltd.

5-1

FS100

5 Replacing Parts

5.1

Fuse Replacement

F1 F2

Locations of the fuse

If the fuse seems to be blown, check its conduction. If it is blown, replace it with the same type of fuse (supplied).

NOTE If the fuse seems to be blown, be sure to investigate its cause, or blown again after the replacement.

5-2

FS100

5 Replacing Parts

5.2

Interior Circulation Fan Replacement

5.2 Interior Circulation Fan Replacement

Only interior cooling fan EV2 and EV3 can be replaced.

NOTE

Turn OFF the power before replacing the fan.

 Replacement Procedures

1. Disconnect plug codes connected to the fan.

(Remove the ground wirings screwed to the fan, too)

2. Remove the screws (3 places) fixing the fan and the fan guard.

3. Uninstall the fan from the FS100.

4. Install the new fan to the FS100.

(When installing the fan, be carefull to its installing direction so that the air is drewn inside the FS100.)

5. Tighten the screws (3 places) to fix the fan and the fan guard.

6. Connect all the disconnected plug codes and the ground wirings.

(Connect the plug code securely so that there is no space between the plug code and the fan. Also, connect the ground wirings firmly.)

Cooling fan (EV3)

Cooling fan (EV2)

Air outlet

Interior Circulation Fan for Replacement

5-3

FS100

5 Replacing Parts

5.3

Battery Replacement

5.3 Battery Replacement

The battery must be replaced as soon as the battery alarm occurred.

Please be sure to replace it within 1 hour after the power is turned OFF.

(When the programming pendant is used, a message to ask battery replacement appears on its window.

Also, the timing can be confirmed by the lighting-up of the battery alarm

LED on the CPU unit (CPU-201R) or the battery alarm of the specified output.)

WARNING

• To perform this operation, it is required to open the top plate of the

FS100 while the power is turned ON.

Do NOT open the plate to perform the operation within five minutes after turning OFF the FS100 power supply and primary power source.

• Do NOT touch units or terminal parts within five minutes after turning OFF the FS100 power supply.

Failure to observe this warning may result in electric shocks.

• Close the top plate as soon as the maintenance work such as the inspection or maintenance, etc. is completed.

Failure to observe this warning may result in electric shocks.

WARNING

• To prevent anyone inadvertently turning ON the power supply during maintenace operation, put up a warning sign such as “DO

NOT TURN ON THE POWER” at the primary power supply (knife switch, wiring circuit breaker, etc.) .

Failure to observe this warning may result in electric shocks or injury.

5-4

FS100

5 Replacing Parts

5.3

Battery Replacement

 Replacement Procedure

1. Uninstall the top plate and loosen the strap which is fixing the battery.

Battery fixing strap

2. Disconnect the connector from the battery extension lead wire and remove the battery.

Extension lead wire connector

3. Connect the new battery to the battery extension lead wire.

5-5

FS100

5 Replacing Parts

5.3

Battery Replacement

4. Fix the battery with the strap.

Fasten the strap till the third hole of it.

When fixing the battery, put the black lead wire toward inner side of the

FS100.

Inner side of the controller

Black lead wire

5-6

Fasten the strap till the third hole

FS100

5 Replacing Parts

5.3

Battery Replacement

Inner side of the controller

Wrong example

Do not fix the battery lead parallel to the inner side of the controller.

Fix the battery lead wire to the inner side of the controller.

The battery might fall off due to the vivration, etc., if the lead wire is fixed parallel to the controller.

NOTE

Although the CMOS memory is backed up by super capacitor, the battery must be replaced as soon as the message

"Memory battery weak" appears.

The job data and other data may be lost if the message

"Memory battery weak" appears and the breaker is turned

OFF for more than 1 hours.

5-7

FS100

6 Recommended Spare Parts

6.1

List of Accessories

6 Recommended Spare Parts

6.1 List of Accessories

Accessories of FS100 are as follows.

No.

Name Type Manufacturer

Power supply connector

Waterproof cable clamp

Dummy connector for safety signal short circuit

I/O power supply protection fuse

CE05-6A18-10SD-

D-BSS

DDK

CE3057-10A-1-D DDK

HB1370101-1

0312.600MXP

Yaskawa Electric

Corporation

Littel

Qty.

Qty. per unit

1 1

Accessory No.1

Accessory No.3

Accessory No.2

6-1

FS100

6 Recommended Spare Parts

6.2

Recommended Spare Parts

6.2 Recommended Spare Parts

The spare parts are ranked as follows.

CAUTION

• It is recommended to use the parts and components in the following table as spare parts for the FS100.

Product performance cannot be guaranteed when using spare parts from any company other than Yaskawa.

• 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.

Table 6-1: Spare Parts for the FS100

Rank

Parts

No.

Name

Battery

Type

BR-1/2AA 3.0V

Manufacturer

Qty.

Qty. per unit

Remark

Panasonic 1 1 When the battery alarm occurred

I/O power supply protection fuse

Cooling fan

(EV2, EV3)

0312.600MXP

Littel 1

3610PS-23T-B30-A00 MINEBEA 2

2 After 6 years or

36000h, whichever is earlier.

6-2

7 Operations After Replacing Parts

FS100

7 Operations After Replacing Parts

WARNING

• Before operating the manipulator, check that servo power is turned

OFF when the emergency stop button on the programming pendant is pressed.

Connect the external emergency stop button to the 5-6 pin and 16-

17 pin of the robot system signal connector (CN2).

• Upon shipment of the FS100, this signal is connected by a jumper cable in the dummy connector. To use the signal, make sure to supply a new connector, and then input it.

If the signal is input with the jumper cable connected, it does not function, which may result in personal injury or equipment damage.

• Observe the following precautions when performing teaching operations within the manipulator’s operating range:

– 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 person is present in the manipulator’s operating range and that you are in a safe location before:

– Turning ON the power for the FS100.

– Moving the manipulator with the programming pendant.

Injury may result if anyone enters the working envelope of the manipulator during operation. Always press an emergency stop button immediately if there are problems.

Emergency stop buttons is located at the upper right of the programming pendant.

7-1

FS100

7 Operations After Replacing Parts

7.1

Home Position Calibration

CAUTION

– Check for problems in manipulator movement.

– Check for damage to the insulation and sheathing of external wires.

• Return the programming pendant to a safe place after use.

7.1 Home Position Calibration

7.1.1

Home Position Calibration

NOTE

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

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 FS100

• Replacement of the motor or absolute encoder

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

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

7-2

FS100

7 Operations After Replacing Parts

7.1

Home Position Calibration

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 completing home position registration.

SUPPLE

-MENT

Home Position

The home position is the position with the pulse value "0" for

each axis. See chapter 7.1.3

“Manipulator Home Position” at page 7-10 .

7-3

FS100

7 Operations After Replacing Parts

7.1

Home Position Calibration

7.1.2

Calibrating Operation

7.1.2.1

Registering All Axes at One Time

1. Select {ROBOT} under the main menu.

2. Select {HOME POSITION}.

– The HOME POSITIONING window appears.

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

GO BACK

PAGE or press page key .

– The pull-down menu appears.

4. Select the desired control group.

7-4

FS100

7 Operations After Replacing Parts

7.1

Home Position Calibration

5. Select {EDIT} under the menu.

– The pull-down menu appears.

6. Select {SELECT ALL AXES}.

– The confirmation dialog box appears.

7. Select “YES”.

– Displayed position data of all axes are registered as home position.

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

7-5

FS100

7 Operations After Replacing Parts

7.1

Home Position Calibration

7.1.2.2

Registering Individual Axes

1. Select {ROBOT} under the main menu.

2. Select {HOME POSITION}.

3. Select the desired control group.

– Perform steps 3 and 4 which have been described in

chapter 7.1.2.1

“Registering All Axes at One Time” at page 7-4 to

select the desired control group.

4. Select the axis to be registered.

– The confirmation dialog box appears.

5. Select "YES".

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

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

7-6

FS100

7 Operations After Replacing Parts

7.1

Home Position Calibration

7.1.2.3

Changing the Absolute Data

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

1. Select {ROBOT} under the main menu.

2. Select {HOME POSITION}.

3. Select the desired control group.

– Perform steps 3 and 4 which have been described in "Registering All

Axes at One Time" to select the desired control group

4. Select the absolute data to be registered.

– The number can now be entered.

5. Enter the absolute data using the numeric keys.

6. Press [ENTER].

– Absolute data are modified.

7-7

FS100

7 Operations After Replacing Parts

7.1

Home Position Calibration

7.1.2.4

Clearing Absolute Data

1. Select {ROBOT} under the main menu.

2. Select {HOME POSITION}.

– Perform steps 2, 3, and 4 which have been described in "Registering

All Axes at One Time" to display the HOME POSITIONING window and select the desired control group.

3. Select {DATA} under the menu.

– The pull-down menu appears.

4. Select {CLEAR ALL DATA}.

– The confirmation dialog box appears.

7-8

FS100

7 Operations After Replacing Parts

7.1

Home Position Calibration

5. Select "YES".

– The all absolute data are cleared. When "NO" is selected, the operation will be canceled.

7-9

FS100

7 Operations After Replacing Parts

7.1

Home Position Calibration

7.1.3

Manipulator Home Position

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

B-axis center line angle against

U-axis center line (-90

)

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

°)

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

)

NOTE

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

7-10

FS100

7 Operations After Replacing Parts

7.2

Position Deviation Check Using the Check Program

7.2 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) 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 chapter 7.4

“Setting the Second Home Position (Check Point)” at page 7-14 .

– 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

chapter 7.3.3

“Home Position Data Correction” at page 7-13 .

7-11

FS100

7 Operations After Replacing Parts

7.3

Checking of the Check Program

7.3 Checking of the Check Program

7.3.1

Motion of the Check Program

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

7.3.2

Checking of the Check Program

Check the deviation in to the check point. If the tool tip position is deviated, there is a deviation.

When the motor or encoder, etc. was replaced, move the corresponding axis only, when the stored memory was cleared or the manipulator was hit against a workpiece, move all axes, to the check point by joint motion.

7-12

FS100

7 Operations After Replacing Parts

7.3

Checking of the Check Program

7.3.3

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. Then, proceed to chapter 7.4 “Setting the Second Home Position (Check

Point)” at page 7-14 .

– If there is a deviation, execute the following procedures to correct it.

(1) Command position pulse of the check point which was taught in advance

Displaying the Command Position Pulse

I) Select {ROBOT} under the main menu.

II) Select {COMMAND POSITION}.

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

Displaying the Current Position Pulse

I) Select {ROBOT} under the main menu.

II) Select {CURRENT POSITION}.

2. Calculate the difference between the command position pulse and the current position pulse.

The difference pulse = Command position pulse − Current position

pulse

3. On 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

chapter 7.1.2.3

“Changing the Absolute Data” at page 7-7 in

chapter 6.1.2.

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

– The home position data have been corrected.

– Proceed to chapter 7.4 “Setting the Second Home Position (Check

Point)” at page 7-14 .

7-13

FS100

7 Operations After Replacing Parts

7.4

Setting the Second Home Position (Check Point)

7.4 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 button on the programming pendant is pressed.

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

Connect the external emergency stop button to the 5-6 pin and 16-

17 pin of the robot system signal connector (CN2).

• Upon shipment of the FS100, this signal is connected by a jumper cable in the dummy connector. To use the signal, make sure to supply a new connector, and then input it.

If the signal is input with the jumper cable connected, it does not function, which may result in personal injury or equipment damage.

• Observe the following precautions when performing teaching operations within the manipulator’s operating range:

– 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 manipulator’s operating range, and be sure that you are in a safe place when:

– Turning ON the FS100 power.

– Moving the manipulator with the programming pendant.

Injury may result from contact with the manipulator if persons enter the manipulator’s operating range.

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

Emergency stop button is attached on the programming pendant.

7-14

FS100

7 Operations After Replacing Parts

7.4

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.

• Return the programming pendant to a safe place after use.

7-15

FS100

7 Operations After Replacing Parts

7.4

Setting the Second Home Position (Check Point)

7.4.1

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 FS100 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

1, Position confirmation operation

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

Alarm occurs again

3, Correct defective axis

Replace PG system

Home position calibration

Position checking point

Playback possible

7-16

FS100

7 Operations After Replacing Parts

7.4

Setting the Second Home Position (Check Point)

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.

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 chapter 7.4.2

“Procedure for the Second Home Position Setting (Check Point)” at page 7-18 .

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.

• S ometimes 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

“COMFIRM 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.

7-17

FS100

7 Operations After Replacing Parts

7.4

Setting the Second Home Position (Check Point)

7.4.2

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 FS100, the second home position must be set for each manipulator or station.

1. Select {ROBOT} under the main menu.

2. Select {SECOND HOME POS}.

– The SECOND HOME POS window appears.

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

3. Press the page key

GO BACK

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.

4. Press the axis keys.

– Move the manipulator to the new second home position.

5. Press [MODIFY] and [ENTER].

– The second home position is changed.

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FS100

7.4.3

Procedure after the Alarm

Operations After Replacing Parts

7.4

Setting the Second Home Position (Check Point)

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

chapter 8.7 “Position Data When Power is

Turned ON/OFF” at page 8-23

for details on the

“POWER ON/OFF POS" window.

1. Select {ROBOT} under the main menu.

2. Select {SECOND HOME POS}.

– The SECOND HOME POS window appears.

7-19

FS100

7 Operations After Replacing Parts

7.4

Setting the Second Home Position (Check Point)

3. Press the page key

GO BACK

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.

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.

7-20

FS100

8 System Diagnosis

8.1

System Version

8 System Diagnosis

8.1 System Version

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

1. Select {SYSTEM INFO} under the main menu.

2. Select {VERSION}.

– The VERSION window appears.

8.2 Manipulator Model

1. Select {ROBOT} under the main menu.

2. Select {MANIPULATOR TYPE}.

– The ROBOT AXIS CONFIG window appears.

8-1

FS100

8 System Diagnosis

8.3

Input/Output Status

8.3 Input/Output Status

8.3.1

Universal Input

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

8.3.1.1

Universal Input Window

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

2. Select {UNIVERSAL INPUT}.

– The UNIVERSAL INPUT window appears.

8.3.1.2

Universal Input Simple Window

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

2. Select {UNIVERSAL INPUT}.

– The UNIVERSAL INPUT window appears.

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

– The UNIVERSAL INPUT simple window appears.

8-2

FS100

8 System Diagnosis

8.3

Input/Output Status

8.3.2

Universal Output

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

8.3.2.1

Universal Output Window

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

2. Select {UNIVERSAL OUTPUT}.

– The UNIVERSAL OUTPUT window appears.

8.3.2.2

Universal Output Simple Window

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

2. Select {UNIVERSAL OUTPUT}.

– The UNIVERSAL OUTPUT window appears.

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

– The UNIVERSAL OUTPUT simple window appears.

8-3

FS100

8 System Diagnosis

8.3

Input/Output Status

8.3.2.3

Modifying the Output Status

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

1. Select the desired output signal number.

– Select the status of the desired output signal, “  ” or “  ” in the

UNIVERSAL OUTPUT window.

2. Press INTER LOCK key

INTER

LOCK + [SELECT].

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

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

8-4

FS100

8 System Diagnosis

8.3

Input/Output Status

8.3.3

Specific Input

8.3.3.1

Specified Input Window

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

2. Select {SPECIFIED INPUT}.

– The SPECIFIED INPUT window appears.

8.3.3.2

Specific Input Simple Window

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

2. Select {SPECIFIED INPUT}.

– The SPECIFIED INPUT window appears.

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

– The SPECIFIC INPUT simple window appears.

8-5

FS100

8 System Diagnosis

8.3

Input/Output Status

8.3.4

Specific Output

8.3.4.1

Specified Output Window

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

2. Select {SPECIFIED OUTPUT}.

– The SPECIFIED OUTPUT window appears.

8.3.4.2

Specific Output Simple Window

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

2. Select {SPECIFIED OUTPUT}.

– The SPECIFIED OUTPUT window appears.

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

– The SPECIFIC OUTPUT simple window appears.

8-6

FS100

8 System Diagnosis

8.3

Input/Output Status

8.3.5

RIN Input

8.3.5.1

RIN Input Window

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

2. Select {RIN}.

– The RIN window appears.

8-7

FS100

8 System Diagnosis

8.3

Input/Output Status

8.3.6

Signal Number Search

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

Signal number

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

8-8

FS100

8 System Diagnosis

8.3

Input/Output Status

8.3.6.1

Direct Search on the Universal/Specified Input/Output Window

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

INPUT/OUTPUT window, and press [SELECT].

– Numeric values can now be entered.

2. Enter the signal number to be searched.

– Type the signal number in the number input line.

3. Press [ENTER] to start the search.

– The page where the signal number exists appears.

8-9

FS100

8 System Diagnosis

8.3

Input/Output Status

8.3.6.2

Search from the Menu

1. Select {EDIT} under the menu in the UNIVERSAL/SPECIFIED INPUT/

OUTPUT window.

– The pull-down menu appears.

2. Select {SEARCH SIGNAL NO.}.

– Numeric values can now be entered.

3. Enter the signal number to be searched.

– Type the signal number in the number input line.

4. Press [ENTER] to start the search.

– The page where the signal number exists appears.

8-10

FS100

8 System Diagnosis

8.3

Input/Output Status

8.3.7

Relay Number Search

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

Relay number

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

8-11

FS100

8 System Diagnosis

8.3

Input/Output Status

8.3.7.1

Direct Search on the Universal/Specified Input/Output Window

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

INPUT/OUTPUT window, and press [SELECT].

– Numeric values can now be entered.

2. Enter the relay number to be searched.

– Type the relay number in the number input line.

3. Press [ENTER] to start the search.

– The page where the relay number exists appears.

8-12

FS100

8 System Diagnosis

8.3

Input/Output Status

8.3.7.2

Search from the Menu

1. Select {EDIT} under the menu in the UNIVERSAL/SPECIFIED INPUT/

OUTPUT window.

– The pull-down menu appears.

2. Select {SEARCH RELAY SIGNAL NO.}.

– Numeric values can now be entered.

3. Enter the relay number to be searched.

– Type the relay number in the number input line.

4. Press [ENTER] to start the search.

– The page where the relay number exists appears.

8-13

FS100

8 System Diagnosis

8.3

Input/Output Status

8.3.8

Modification of the Signal Name

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

Signal name

The name can be modified in the following two ways.

• Direct modification on the UNIVERSAL/SPECIFIED INPUT/OUTPUT window.

• Modification from the menu

8.3.8.1

Direct Modification on the Universal/Specified Input/Output Window

1. Move the cursor to the signal name to be modified in the UNIVERSAL/

SPECIFIED INPUT/OUTPUT window, and press [SELECT].

– The window for character input appears.

2. Enter the signal name.

3. Press [ENTER].

– New signal name is registered.

8-14

FS100

8.3

System Diagnosis

Input/Output Status

8.3.8.2

Modification from the Menu

1. Move the cursor to the signal name to be modified in the UNIVERSAL/

SPECIFIED INPUT/OUTPUT window.

2. Select {EDIT} under the menu.

– The pull-down menu appears.

3. Select {RENAME}.

– The window for character input appears.

4. Enter the signal name.

5. Press [ENTER].

– New signal name is registered.

8-15

FS100

8 System Diagnosis

8.4

System Monitoring Time Display

8.4 System Monitoring Time Display

8.4.1

System Monitoring Time Display Window

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

1. Select {SYSTEM INFO}.

2. Select {MONITORING TIME}.

– The SYS MONITORING TIME window appears.

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.

8-16

FS100

8 System Diagnosis

8.4

System Monitoring Time Display

8.4.2

Individual Window of the System Monitoring Time Display

If the page key

GO BACK

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 each-application operating time by each control group are individually displayed.

NOTE

The total time of each control group here is not always the same as the time in the SYS MONITORING TIME window because these windows show time as seen from the individual control group.

8-17

FS100

8 System Diagnosis

8.4

System Monitoring Time Display

8.4.3

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.

1. Select the time to be cleared.

– The confirmation dialog box appears.

2. Select “YES”.

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

8-18

FS100

8 System Diagnosis

8.5

Alarm History

8.5 Alarm History

8.5.1

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.

1. Select {SYSTEM INFO} under the main menu.

2. Select {ALARM HISTORY}.

– The alarm history window appears.

3. Press the page key

GO BACK

PAGE to change the window, or select "PAGE" to display the selection window for the alarm windows.

– Each time the page key

GO BACK

PAGE is pressed, the window changes

"MAJOR ALARM"  "MINOR ALARM"  "USER

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

ALARM".

8-19

FS100

8 System Diagnosis

8.5

Alarm History

8.5.2

Clearing the Alarm History

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

1. Display the alarm history window to be cleared.

2. Select {DATA} under the menu.

– The pull-down menu "CLEAR HISTORY" appears.

3. Select {CLEAR HISTORY}.

– The confirmation dialog box appears.

4. Select “YES”.

– The alarm history displayed is reset.

8-20

FS100

8 System Diagnosis

8.6

I/O Message History

8.6 I/O Message History

8.6.1

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.

1. Select {SYSTEM INFO} under the main menu.

2. Select {I/O MSG HISTORY}

– The I/O MESSAGE HISTORY window appears.

8.6.1.1

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.

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

1. Select {EDIT} under the menu.

2. Select {SEARCH}.

– The character input line appears.

3. Enter the history No.

4. Press [ENTER].

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

8-21

FS100

8 System Diagnosis

8.6

I/O Message History

8.6.2

Clearing the I/O Message History

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

1. Select {DATA} under the menu.

2. Select {CLEAR HISTORY}.

– The confirmation dialog box appears.

3. Select “YES”.

– The displayed I/O message history is cleared.

8-22

FS100

8 System Diagnosis

8.7

Position Data When Power is Turned ON/OFF

8.7 Position Data When Power is Turned ON/OFF

8.7.1

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.

1. Select {ROBOT} under the main menu.

2. Select {POWER ON/OFF POS}.

– The POWER ON/OFF POSITION window appears.

8-23

FS100

8 System Diagnosis

8.8

Current Position

8.8 Current Position

8.8.1

Current Position Window

1. Select {ROBOT} under the main menu.

2. Select {CURRENT POSITION} under the sub menu.

– The CURRENT POSITION window appears.

3. Select the types of coordinates to be displayed.

– The pull-down menu appears.

4. Select the desired coordinate system.

– The type of coordinates being displayed is changed.

8-24

FS100

8 System Diagnosis

8.9

Servo Monitoring

8.9 Servo Monitoring

8.9.1

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

ENCODER TEMPERATURE

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.

Encoder tenperature of each axis

8-25

FS100

8.9

System Diagnosis

Servo Monitoring

8.9.1.1

Changing the Monitor Items

1. Set the security mode to the management mode.

2. Select {ROBOT} under the main menu.

3. Select {SERVO MONITOR}.

– The SERVO MONITOR window appears.

4. Select {DISPLAY} under the menu.

– The pull-down menu appears.

MONITOR ITEM 1 is the data on the left, and MONITOR ITEM 2 is the data on the right

8-26

FS100

8 System Diagnosis

8.9

Servo Monitoring

5. Select MONITOR ITEM 1 or 2, and view the sub-menu choices by the cursor key .

– The sub-menu choices appear.

6. Select a menu.

– The type of monitor-related information is changed.

8-27

FS100

8 System Diagnosis

8.9

Servo Monitoring

8.9.1.2

Clearing Maximum Torque Data

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

1. Select {DATA} under the menu.

– The clear max torque window appears

2. Select {MAX. TORQUE}.

– The maximum torque data is cleared.

8-28

FS100

9 Alarm

9.1

Outline of Alarm

9.1 Outline of Alarm

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

Table 9-1: Alarm Code Classification

Alarm Code Alarm Level

0 

1  to

3 

4  to

8 

9 

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).

9-1

FS100

9 Alarm

9.2

Alarm Display

9.2 Alarm Display

9.2.1

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 number

Alarm message

Sub data

If more than one alarm occurs simultaneously, all the alarms are displayed.

Scroll the viewing area with the cursor 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}.

9.2.1.1

Releasing Alarms

Alarms are classified by minor and major alarms.

• Minor Alarms

Select "RESET" on the ALARM window to release alarms.

Or, turn ON the system signal "ALARM RESET" when using an external input signal (system 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.

9-2

FS100

9 Alarm

9.2

Alarm Display

9.2.2

Special Alarm Display

(1) 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 2 [ S L U R B T ]

With base axis: Base 1 to 2

[ 1 2]

With station axis: Stations 1 to 3 [ 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 ]

(2) Multiple SERVO Control Board System

In a system using more than one SERVO control board, the number of

the SERVO control board where the alarm occurred is also displayed.

The SERVO control board number is determined by its S2 switch.

SV#1: SERVO control board 1

SV#2: SERVO control board 2

9-3

FS100

9 Alarm

9.2

Alarm Display

(3) 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)

9-4

FS100

9 Alarm

9.3

Display of Alarm Details

9.3 Display of Alarm Details

Alarm details displaying function indicates the alarm contents breakdown on the alarm window.

Press [Select] after moving the cursor to the subject alarm on the alarm window to display its “content”, “cause” and “measure”.

Skip displaying the alarm window to directly display this breakdown window is possible by specifying the parameter when an alarm occurs.

9.3.1

Parameter

S2C406 Alarm Details Direct Display 0: Invalid / 1: Valid

9.3.2

Display of Alarm Detail Window

Alarm No.

Page

Alarm explanation

Alarm title

Same as alarm

window data.

(Ordinary window)

Alarm content

{Right/Left} button

Cause

Measure

{Return} button {Retset} button {Page} button

 Page

Displays the page number of the alarm whose detail window is currently displayed

/ the total alarm number occurred coincidentally.

 Alarm No.

Displays the alarm number with decimal 4 digit.

 Sub data

Displays the sub code number defined to each alarm.

 Alarm content

Displays the content of the alarm.

9-5

FS100

9 Alarm

9.3

Display of Alarm Details

 {Right/Left} button

This button appears when there can be several “cause”s and “measure”s to one alarm. Press this to right/left ward to alternate the “cause” and the

“measure”.

 Cause

Displays the cause of an alarm.

 Measure

Displays the recovery method from the alarming state.

 {Reset}button

Press this button to reset the alarm.

 {Page} button

Press this button to display the page number inputting area.

This area appears when several alarms occur at a time.

9-6

FS100

9.3

Alarm

Display of Alarm Details

9.3.3

Transition of Alarm Detail Window

Alarm

Standard

ALARM DETAIL window

While direct display setting is set

(S2C406=1)

Move the Cursor (up and down) to select the alarm number to display each ALARM DETAIL window .

[Select]

{RETURN} button or [CANCEL]

When direct display is set, it would not return to the above window

SHIFT SHIFT key PAGE key

GO BACK

PAGE PAGE key

GO BACK

PAGE

{PAGE} button

 Press {Left} button

on the window or

 Move Cursor to the left

{RESET} button {RESET} button

 Press {Right} button

on the window or

 Move Cursor to the right

Window before alarm occurs

In case an unresettable alarm occured, the

ALARM window (or its ALARM DETAIL window) appears.

9-7

FS100

9 Alarm

9.4

Alarm Message List

9.4 Alarm Message List

CAUTION

• Before handling the main CPU board (CPU-201R) for any remedies, personnel must be appropriately skilled in maintenance mode operation.

• CPU-201R is saving important file data for the user program through its battery backup operation. Contact your Yaskawa representatives when measures for CPU-201R alarms are considered to be needed. Careless operation may delete registered data.

9-8

Alarm

Number

Alarm Name

ERROR

Sub

Code

Meaning

Cause

No response was sent from the

Main CPU board when the control power turned ON.

Software operation error occurred

Main CPU board failure

Remedy

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the controller. Save the CMOS.BIN before replacement to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the controller. Save the CMOS.BIN before replacement to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the controller. Save the CMOS.BIN before replacement to be safe.

No response was sent from the servo board #1 when the control power turned ON.

In this case, the FS100 may make wrong judgement that a signal such as external hold signal is input. However, it is caused by the communication error with Servo control board #1. Therefore, execute the following measure.

Setting error

Connection failure

No response was sent from the

Servo control board #2 when the control power turned ON.

Servo control board failure

Main CPU board failure

Setting error

Connection failure

Servo control board failure

(1)Turn the power OFF then back ON

(2)If the alarm occurs again, replace the controller. Save the CMOS.BIN before replacement to be safe.

(1) Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the controller. Save the CMOS.BIN before replacement to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the controller. Save the CMOS.BIN before replacement to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the controller. Save the CMOS.BIN before replacement to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the controller. Save the CMOS.BIN before replacement to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the controller. Save the CMOS.BIN before replacement to be safe.

Alarm

Number

Alarm Name

ERROR (SERVO)

30 ROM ERROR

Sub

Code

Meaning

Cause Remedy

The communications CPU for the

Servo control board #1 detected an error when the control power turned ON.

The communications CPU for the

Servo control board #2 detected an error when the control power turned ON.

The CPU-201R system program is damaged.

converter unit failure

Main CPU board failure

Setting error

Connection failure

Servo control board failure

Main CPU board failure

Setting error

Connection failure

Servo control board failure

Main CPU board failure

Software operation error occurred

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the controller. Save the CMOS.BIN before replacement to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the controller. Save the CMOS.BIN before replacement to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the controller. Save the CMOS.BIN before replacement to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the controller. Save the CMOS.BIN before replacement to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the controller. Save the CMOS.BIN before replacement to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the controller. Save the CMOS.BIN before replacement to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the controller. Save the CMOS.BIN before replacement to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the controller. Save the CMOS.BIN before replacement to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the controller. Save the CMOS.BIN before replacement to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the controller. Save the CMOS.BIN before replacement to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the controller. Save the CMOS.BIN before replacement to be safe.

Alarm

Number

Alarm Name

ERROR

(I/O MODULE)

Sub

Code

Meaning

The system program of Servo control board #1 is damaged.

The system program of Servo control board #2 is damaged.

The IO module board connected with 0th serial bus exists.

An error was detected in communications with the I/O module board connected with 1st serial bus when the control power turned ON.

Cause

Software operation error occurred

Servo control board failure

Software operation error occurred

Servo control board failure

Software operation error occurred

Main CPU board failure

Setting error

Connection failure

Board failure

(I/O module)

Main CPU board failure

Remedy

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the controller. Save the CMOS.BIN before replacement to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the controller. Save the CMOS.BIN before replacement to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the controller. Save the CMOS.BIN before replacement to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the controller. Save the CMOS.BIN before replacement to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the controller. Save the CMOS.BIN before replacement to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the controller. Save the CMOS.BIN before replacement to be safe.

1)Check the following settings.

·The rotary switch setting which specifies slot numbers of each I/O module

·I/O module settings in maintenance mode

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, check the connecting or inserting state of the following cables or connectors.

·IO module cable of the corresponding slot.

·Terminator

·24V power of the corresponding IO module.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the following board. Save the CMOS.BIN before replace the board to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the controller. Save the CMOS.BIN before replacement to be safe.

Alarm

Number

Alarm Name

Sub

Code

Meaning Cause

An error was detected in communications with the I/O module board connected with 2nd serial bus when the control power turned ON.

Setting error

Connection failure

Board failure

(I/O module)

Main CPU board failure

An error was detected in communications with the I/O module board connected with 3rd serial bus when the control power turned ON.

Setting error

Connection failure

Board failure

(I/O module)

Main CPU board failure

Remedy

(1)Check the following settings.

·The rotary switch setting which specifies slot numbers of each I/O module

·I/O module settings in maintenance mode

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, check the connecting or inserting state of the following cables or connectors.

·IO module cable of the corresponding slot.

·Terminator

·24V power of the corresponding IO module.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the following board. Save the CMOS.BIN before replace the board to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the controller. Save the CMOS.BIN before replacement to be safe.

(1)Check the following settings.

·The rotary switch setting which specifies slot numbers of each I/O module

·I/O module settings in maintenance mode

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, check the connecting or inserting state of the following cables or connectors.

·IO module cable of the corresponding slot.

·Terminator

·24V power of the corresponding IO module.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the following board. Save the CMOS.BIN before replace the board to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the controller. Save the CMOS.BIN before replacement to be safe.

Alarm

Number

Alarm Name

Sub

Code

Meaning Cause

An error was detected in communications with the I/O module board connected with 4th serial bus when the control power turned ON.

Setting error

Connection failure

Remedy

(1)Check the following settings.

·The rotary switch setting which specifies slot numbers of each I/O module

·I/O module settings in maintenance mode

Board failure (I/O module)

Main CPU board failure

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, check the connecting or inserting state of the following cables or connectors.

·IO module cable of the corresponding slot.

·Terminator

·24V power of the corresponding IO module.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the following board. Save the CMOS.BIN before replace the board to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the controller. Save the CMOS.BIN before replacement to be safe.

(1)Check the following settings.

·The rotary switch setting which specifies slot numbers of each I/O module

·I/O module settings in maintenance mode

An error was detected in communications with the I/O module board connected with 5th serial bus when the control power turned ON.

Setting error

Connection failure

Board failure (I/O module)

Main CPU board failure

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, check the connecting or inserting state of the following cables or connectors.

·IO module cable of the corresponding slot.

·Terminator

·24V power of the corresponding IO module.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the following board. Save the CMOS.BIN before replace the board to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the controller. Save the CMOS.BIN before replacement to be safe.

Alarm

Number

Alarm Name

Sub

Code

Meaning Cause

An error was detected in communications with the I/O module board connected with 6th serial bus when the control power turned ON.

Setting error

Connection failure

Remedy

(1)Check the following settings.

·The rotary switch setting which specifies slot numbers of each I/O module

·I/O module settings in maintenance mode

An error was detected in communications with the I/O module board connected with 7th serial bus when the control power turned ON.

Board failure (I/O module)

Main CPU board failure

Setting error

Connection failure

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, check the connecting or inserting state of the following cables or connectors.

·IO module cable of the corresponding slot.

·Terminator

·24V power of the corresponding IO module.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the following board. Save the CMOS.BIN before replace the board to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the controller. Save the CMOS.BIN before replacement to be safe.

(1)Check the following settings.

·The rotary switch setting which specifies slot numbers of each I/O module

·I/O module settings in maintenance mode

Board failure(I/O module)

Main CPU board failure

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, check the connecting or inserting state of the following cables or connectors.

·IO module cable of the corresponding slot.

·Terminator

·24V power of the corresponding IO module.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the following board. Save the CMOS.BIN before replace the board to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the controller. Save the CMOS.BIN before replacement to be safe.

Alarm

Number

Alarm Name

100 COMMUNICATION 1

ERROR (servo#1)

Sub

Code

Meaning Cause

An error was detected in communications with the I/O module board connected with 8th serial bus when the control power turned ON.

Setting error

Connection failure

Remedy

(1)Check the following settings.

·The rotary switch setting which specifies slot numbers of each I/O module

·I/O module settings in maintenance mode

Board failure (I/O module)

Main CPU board failure

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, check the connecting or inserting state of the following cables or connectors.

·IO module cable of the corresponding slot.

·Terminator

·24V power of the corresponding IO module.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the following board. Save the CMOS.BIN before replace the board to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the controller. Save the CMOS.BIN before replacement to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the controller. Save the CMOS.BIN before replacement to be safe.

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

Counter value received from

Servo control board is invalid.

Setting error

Connection failure

The error was detected during the check of the number of the serial communications.

Counter value received from

Servo control board is OFF by one cycle.

Servo control board failure

Main CPU board failure

Setting error

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the controller. Save the CMOS.BIN before replacement to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the controller. Save the CMOS.BIN before replacement to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the controller. Save the CMOS.BIN before replacement to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the controller. Save the CMOS.BIN before replacement to be safe.

Alarm

Number

Alarm Name

101 COMMUNICATION 1

ERROR (servo#2)

Sub

Code

Meaning

Cause Remedy

Connection failure

Servo control board failure

Main CPU board failure

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the controller. Save the CMOS.BIN before replacement to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the controller. Save the CMOS.BIN before replacement to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the controller. Save the CMOS.BIN before replacement to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the controller. Save the CMOS.BIN before replacement to be safe.

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

Counter value received from

Servo control board is invalid.

Setting error

Connection failure

Servo control board failure

Converter unit failure

Main CPU board failure

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the controller. Save the CMOS.BIN before replacement to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the controller. Save the CMOS.BIN before replacement to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the controller. Save the CMOS.BIN before replacement to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the controller. Save the CMOS.BIN before replacement to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the controller. Save the CMOS.BIN before replacement to be safe.

The error was detected during the check of the number of the serial communications.

Counter value received from

Servo control board is OFF by one cycle.

Setting error

Connection failure

Servo control board failure

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the controller. Save the CMOS.BIN before replacement to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the controller. Save the CMOS.BIN before replacement to be safe.

Alarm

Number

Alarm Name

(PARAMETER FILE)

Sub

Code

Meaning Cause

Converter unit failure

Main CPU board failure

The RC parameter is damaged.

Data error

Main CPU board failure

The RO parameter is damaged.

Data error

Main CPU board failure

The SV parameter is damaged.

Data error

Main CPU board failure

The SVM parameter is damaged.

Data error

Main CPU board failure

The SC parameter is damaged.

Data error

Main CPU board failure

Remedy

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the controller. Save the CMOS.BIN before replacement to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the controller. Save the CMOS.BIN before replacement to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, initialize the appropriate data in maintenance mode, and then load the data saved in the external memory device.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the controller. Save the CMOS.BIN before replacement to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, initialize the appropriate data in maintenance mode, and then load the data saved in the external memory device.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the controller. Save the CMOS.BIN before replacement to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, initialize the appropriate data in maintenance mode, and then load the data saved in the external memory device.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the controller. Save the CMOS.BIN before replacement to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, initialize the appropriate data in maintenance mode, and then load the data saved in the external memory device.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the controller. Save the CMOS.BIN before replacement to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, initialize the appropriate data in maintenance mode, and then load the data saved in the external memory device.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the controller. Save the CMOS.BIN before replacement to be safe.

Alarm

Number

Alarm Name

Sub

Code

Meaning

The SD parameter is damaged.

Cause

Data error

Main CPU board failure

The CIO parameter is damaged.

Data error

Main CPU board failure

The FD parameter is damaged.

Data error

Main CPU board failure

The AP parameter is damaged.

Data error

Main CPU board failure

The RS parameter is damaged.

Data error

Main CPU board failure

The SE parameter is damaged.

Data error

Main CPU board failure

Remedy

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, initialize the appropriate data in maintenance mode, and then load the data saved in the external memory device.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the controller. Save the CMOS.BIN before replacement to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, initialize the appropriate data in maintenance mode, and then load the data saved in the external memory device.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the controller. Save the CMOS.BIN before replacement to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, initialize the appropriate data in maintenance mode, and then load the data saved in the external memory device.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the controller. Save the CMOS.BIN before replacement to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, initialize the appropriate data in maintenance mode, and then load the data saved in the external memory device.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the controller. Save the CMOS.BIN before replacement to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, initialize the appropriate data in maintenance mode, and then load the data saved in the external memory device.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the controller. Save the CMOS.BIN before replacement to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, initialize the appropriate data in maintenance mode, and then load the data saved in the external memory device.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the controller. Save the CMOS.BIN before replacement to be safe.

Alarm

Number

Alarm Name

(SYSTEM CONFIG-

DATA)

(JOB MNG DATA)

Sub

Code

Meaning Cause

The SVC parameter is damaged.

Data error

Main CPU board failure

The AMC parameter is damaged.

Data error

Main CPU board failure

The SVP parameter is damaged.

Data error

Main CPU board failure

The MF parameter is damaged.

Data error

Main CPU board failure

The SVS parameter is damaged.

Data error

Main CPU board failure

The system configuration information data are damaged.

Main CPU board failure

The management data of job files are damaged.

Data error

Remedy

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, initialize the appropriate data in maintenance mode, and then load the data saved in the external memory device.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the controller. Save the CMOS.BIN before replacement to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, initialize the appropriate data in maintenance mode, and then load the data saved in the external memory device.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the controller. Save the CMOS.BIN before replacement to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, initialize the appropriate data in maintenance mode, and then load the data saved in the external memory device.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the controller. Save the CMOS.BIN before replacement to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, initialize the appropriate data in maintenance mode, and then load the data saved in the external memory device.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the controller. Save the CMOS.BIN before replacement to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, initialize the appropriate data in maintenance mode, and then load the data saved in the external memory device.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the controller. Save the CMOS.BIN before replacement to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the controller. Save the CMOS.BIN before replacement to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, initialize the job file in maintenance mode, and then load the data (job, variable data, Robot calibration data) saved in the external memory device.

Alarm

Number

Alarm Name

(LADDER PRG FILE)

(NETWORK SETUP)

Sub

Code

Meaning

The job files are damaged.

Cause

Main CPU board failure

Data error

Main CPU board failure

The management data of position data files are damaged.

Data error

Main CPU board failure

Memory and play back file is damaged.

Data error

Main CPU board failure

The CIO ladder file is damaged.

Data error

The network setting file is damaged.

Main CPU board failure

Data error

Main CPU board failure

Remedy

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the controller. Save the CMOS.BIN before replacement to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, initialize the job file in maintenance mode, and then load the data (job, variable data, Robot calibration data) saved in the external memory device.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the controller. Save the CMOS.BIN before replacement to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, initialize the job file in maintenance mode, and then load the data (job, variable data, Robot calibration data) saved in the external memory device.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the controller. Save the CMOS.BIN before replacement to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, initialize the appropriate data in maintenance mode, and then load the data saved in the external memory device.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the controller. Save the CMOS.BIN before replacement to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, initialize the appropriate data in maintenance mode, and then load the data saved in the external memory device.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the controller. Save the CMOS.BIN before replacement to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, initialize the appropriate data in maintenance mode, and then set the network again.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the controller. Save the CMOS.BIN before replacement to be safe.

Alarm

Number

Alarm Name

(SYSTEM CONFIG-

DATA)

(OVERRUN INPUT SET)

(CMOS MEMORY)

Sub

Code

Meaning

CIO parameter error.

Cause

Setting error

Main CPU board failure

Axis-related parameter error.

Setting error

Main CPU board failure

Sensor-use parameter error.

Setting error

Main CPU board failure

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

Setting error

Main CPU board failure

IO type error (combination impossible to coexist).

Setting error

Main CPU board failure

Sub Code: Control group

Parameter specification and OT signal information are wrong

The CMOS memory version is different from its initial setting.

Setting error

Main CPU board failure

Remedy

(1)Check the following settings.

·I/O module settings in maintenance mode

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the controller. Save the CMOS.BIN before replacement to be safe.

(1)Check the following settings.

·Control group settings in maintenance mode

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the controller. Save the CMOS.BIN before replacement to be safe.

(1)Check the following settings.

·The optional board setting in maintenance mode

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the controller. Save the CMOS.BIN before replacement to be safe.

(1)Check the following settings.

·The optional board setting in maintenance mode

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the controller. Save the CMOS.BIN before replacement to be safe.

(1)Check the following settings.

·I/O module settings in maintenance mode

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the controller. Save the CMOS.BIN before replacement to be safe.

(1)Check the following settings.

·Connection settings (OT) in maintenance mode

(1)Check the following settings.

·Set the security mode to MANAGEMENT MODE.

·Data rebuild in maintenance mode

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the controller. Save the CMOS.BIN before replacement to be safe.

Alarm

Number

Alarm Name

320 VERIFY ERROR

(I/O MODULE)

Sub

Code

Meaning Cause

The CRC data in CMOS memory and the CRC data calculated by the system software are inconsistent.

Setting error

Main CPU board failure

The I/O module connected to the serial bus #1 is different from the function of the set I/O module.

Setting error

Connection failure

Board failure (I/O module)

Main CPU board failure

The I/O module connected to the serial bus #2 is different from the function of the set I/O module.

Setting error

Connection failure

Board failure (I/O module)

Remedy

(1)Check the following settings.

·Set the security mode to MANAGEMENT MODE.

·Data rebuild in maintenance mode

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the controller. Save the CMOS.BIN before replacement to be safe.

(1)Check the following settings.

·The rotary switch setting which specifies slot numbers of each I/O module

·I/O module settings in maintenance mode

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, check the connecting or inserting state of the following cables or connectors.

·IO module cable of the corresponding slot.

·Terminator

·24V power of the corresponding IO module.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the following board. Save the CMOS.BIN before replace the board to be safe.

·Corresponding IO module

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the controller. Save the CMOS.BIN before replacement to be safe.

(1)Check the following settings.

·The rotary switch setting which specifies slot numbers of each I/O module

·I/O module settings in maintenance mode

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, check the connecting or inserting state of the following cables or connectors.

·IO module cable of the corresponding slot.

·Terminator

·24V power of the corresponding IO module.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the following board. Save the CMOS.BIN before replace the board to be safe.

·Corresponding IO module

Alarm

Number

Alarm Name

Sub

Code

Meaning

Cause Remedy

The I/O module connected to the serial bus #3 is different from the function of the set I/O module.

The I/O module connected to the serial bus #4 is different from the function of the set I/O module.

Main CPU board failure

Setting error

Connection failure

Board failure (I/O module)

Main CPU board failure

Setting error

Connection failure

Board failure (I/O module)

Main CPU board failure

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the controller. Save the CMOS.BIN before replacement to be safe.

(1)Check the following settings.

·The rotary switch setting which specifies slot numbers of each I/O module

·I/O module settings in maintenance mode

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, check the connecting or inserting state of the following cables or connectors.

·IO module cable of the corresponding slot.

·Terminator

·24V power of the corresponding IO module.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the following board. Save the CMOS.BIN before replace the board to be safe.

·Corresponding IO module

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the controller. Save the CMOS.BIN before replacement to be safe.

(1)Check the following settings.

·The rotary switch setting which specifies slot numbers of each I/O module

·I/O module settings in maintenance mode

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, check the connecting or inserting state of the following cables or connectors.

·IO module cable of the corresponding slot.

·Terminator

·24V power of the corresponding IO module.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the following board. Save the CMOS.BIN before replace the board to be safe.

·Corresponding IO module

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the controller. Save the CMOS.BIN before replacement to be safe.

Alarm

Number

Alarm Name

Sub

Code

Meaning

The I/O module connected to the serial bus #6 is different from the function of the set I/O module.

The I/O module connected to the serial bus #7 is different from the function of the set I/O module.

Cause

The I/O module connected to the serial bus #5 is different from the function of the set I/O module.

Setting error

Connection failure

Board failure (I/O module)

Main CPU board failure

Setting error

Connection failure

Board failure(I/O module)

Main CPU board failure

Setting error

Remedy

(1)Check the following settings.

·The rotary switch setting which specifies slot numbers of each I/O module

·I/O module settings in maintenance mode

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, check the connecting or inserting state of the following cables or connectors.

·IO module cable of the corresponding slot.

·Terminator

·24V power of the corresponding IO module.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the following board. Save the CMOS.BIN before replace the board to be safe.

·Corresponding IO module

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the controller. Save the CMOS.BIN before replacement to be safe.

(1)Check the following settings.

·The rotary switch setting which specifies slot numbers of each I/O module

·I/O module settings in maintenance mode

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, check the connecting or inserting state of the following cables or connectors.

·IO module cable of the corresponding slot.

·Terminator

·24V power of the corresponding IO module.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the following board. Save the CMOS.BIN before replace the board to be safe.

·Corresponding IO module

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the controller. Save the CMOS.BIN before replacement to be safe.

(1)Check the following settings.

·The rotary switch setting which specifies slot numbers of each I/O module

·I/O module settings in maintenance mode

Alarm

Number

Alarm Name

(APPLICATION)

(SEGMENT CLOCK)

Sub

Code

Meaning

Cause Remedy

The I/O module connected to the serial bus #8 is different from the function of the set I/O module.

Illegal instruction cycle is set.

Connection failure

Board failure(I/O module)

Main CPU board failure

Setting error

Connection failure

Board failure (I/O module)

Main CPU board failure

Setting error

Main CPU board failure

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, check the connecting or inserting state of the following cables or connectors.

·IO module cable of the corresponding slot.

·Terminator

·24V power of the corresponding IO module.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the following board. Save the CMOS.BIN before replace the board to be safe.

·Corresponding IO module

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the controller. Save the CMOS.BIN before replacement to be safe.

(1)Check the following settings.

·The rotary switch setting which specifies slot numbers of each I/O module

·I/O module settings in maintenance mode

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, check the connecting or inserting state of the following cables or connectors.

·IO module cable of the corresponding slot.

·Terminator

·24V power of the corresponding IO module.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the following board. Save the CMOS.BIN before replace the board to be safe.

·Corresponding IO module

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the controller. Save the CMOS.BIN before replacement to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the controller. Save the CMOS.BIN before replacement to be safe.

(1)Check the following settings.

·Instruction execution cycle

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the controller. Save the CMOS.BIN before replacement to be safe.

Alarm

Number

Alarm Name

400 PARAMETER

TRANSMISSION ERROR

Sub

Code

410

MODE CHANGE ERROR 50

Meaning

An error occurred during the parameter/file transfer to the 1st

Servo control board.

Setting error

An error occurred during the parameter/file transfer to the 2nd

Servo control board.

An error occurred during startup sequence processing with the servo CPU of 1st Servo control board, and the system did not startup normally.

Cause

Connection failure

Servo control board failure

Main CPU board failure

Setting error

Connection failure

Servo control board failure

Main CPU board failure

Setting error

Connection failure

Servo control board failure

Remedy

(1)Check the following settings.

·Control group settings in maintenance mode

·The Servo control board rotary switch setting (0) of the corresponding node number (SV#1)

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the controller. Save the CMOS.BIN before replacement to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the controller. Save the CMOS.BIN before replacement to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the controller. Save the CMOS.BIN before replacement to be safe.

(1)Check the following settings.

·Control group settings in maintenance mode

·The Servo control board rotary switch setting (1) of the corresponding node number (SV#2)

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the controller. Save the CMOS.BIN before replacement to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the controller. Save the CMOS.BIN before replacement to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the controller. Save the CMOS.BIN before replacement to be safe.

(1)Check the following settings.

·Control group settings in maintenance mode

·The Servo control board rotary switch setting (0) of the corresponding node number (SV#1)

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the controller. Save the CMOS.BIN before replacement to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the controller. Save the CMOS.BIN before replacement to be safe.

Alarm

Number

500

520

Alarm Name

SEGMENT PROC NOT

READY

UNMATCH

AXIS LIMIT OVER

Sub

Code

Meaning

Cause Remedy

An error occurred during startup sequence processing with the servo CPU of 2nd Servo control board, and the system did not startup normally.

Main CPU board failure

Setting error

Connection failure

Servo control board failure

Main CPU board failure

Setting error

Main CPU board failure

1st Servo control board's interface version is not corresponding to

Main CPU board

Main CPU board failure

2nd Servo control board's interface version is not corresponding to Main CPU board.

Main CPU board failure

Setting error

Main CPU board failure

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the controller. Save the CMOS.BIN before replacement to be safe.

(1)Check the following settings.

·Control group settings in maintenance mode

·The Servo control board rotary switch setting (1) of the corresponding node number (SV#2)

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the controller. Save the CMOS.BIN before replacement to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the controller. Save the CMOS.BIN before replacement to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the controller. Save the CMOS.BIN before replacement to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the controller. Save the CMOS.BIN before replacement to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the controller. Save the CMOS.BIN before replacement to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the controller. Save the CMOS.BIN before replacement to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the controller. Save the CMOS.BIN before replacement to be safe.

(1)Check the following settings.

·Control group settings in maintenance mode

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the controller. Save the CMOS.BIN before replacement to be safe.

Alarm

Number

Alarm Name

ERROR

Sub

Code

Meaning Cause

Data error

Main CPU board failure

An error was found in the relay

No. specification.

Data error

Main CPU board failure

An error was found in the register

No. specification.

Data error

Main CPU board failure

An incorrect instruction was set.

Data error

Main CPU board failure

Data error Output register is used redundantly.

Main CPU board failure

Output relay is used redundantly.

Data error

Main CPU board failure

Remedy

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, initialize the appropriate data in maintenance mode, and then load the data saved in the external memory device.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the controller. Save the CMOS.BIN before replacement to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, initialize the appropriate data in maintenance mode, and then load the data saved in the external memory device.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the controller. Save the CMOS.BIN before replacement to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, initialize the appropriate data in maintenance mode, and then load the data saved in the external memory device.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the controller. Save the CMOS.BIN before replacement to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, initialize the appropriate data in maintenance mode, and then load the data saved in the external memory device.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the controller. Save the CMOS.BIN before replacement to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, initialize the appropriate data in maintenance mode, and then load the data saved in the external memory device.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the controller. Save the CMOS.BIN before replacement to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, initialize the appropriate data in maintenance mode, and then load the data saved in the external memory device.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the controller. Save the CMOS.BIN before replacement to be safe.

Alarm

Number

Alarm Name

Sub

Code

Meaning

Unconnected relay exists.

Cause

Data error

Main CPU board failure

The STR instructions are overused.

Data error

Main CPU board failure

The AND-STR instructions are overused.

Data error

Main CPU board failure

A syntax error was found in the

CNT instruction.

Data error

Main CPU board failure

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

Data error

Main CPU board failure

Excessive machine codes Data error

Main CPU board failure

Remedy

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, initialize the appropriate data in maintenance mode, and then load the data saved in the external memory device.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the controller. Save the CMOS.BIN before replacement to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, initialize the appropriate data in maintenance mode, and then load the data saved in the external memory device.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the controller. Save the CMOS.BIN before replacement to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, initialize the appropriate data in maintenance mode, and then load the data saved in the external memory device.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the controller. Save the CMOS.BIN before replacement to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, initialize the appropriate data in maintenance mode, and then load the data saved in the external memory device.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the controller. Save the CMOS.BIN before replacement to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, initialize the appropriate data in maintenance mode, and then load the data saved in the external memory device.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the controller. Save the CMOS.BIN before replacement to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, initialize the appropriate data in maintenance mode, and then load the data saved in the external memory device.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the controller. Save the CMOS.BIN before replacement to be safe.

Alarm

Number

Alarm Name

Sub

Code

Meaning Cause

The last instruction is not the END instruction.

Data error

Main CPU board failure

An error was found in the PART instruction.

Data error

Main CPU board failure

An error was found in the GOUT instruction.

Data error

Main CPU board failure

The No. of operand is incorrect.

Data error

Main CPU board failure

The constant value is incorrect.

Data error

Main CPU board failure

The step capacity exceeds the memory capacity.

Data error

Main CPU board failure

Remedy

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, initialize the appropriate data in maintenance mode, and then load the data saved in the external memory device.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the controller. Save the CMOS.BIN before replacement to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, initialize the appropriate data in maintenance mode, and then load the data saved in the external memory device.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the controller. Save the CMOS.BIN before replacement to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, initialize the appropriate data in maintenance mode, and then load the data saved in the external memory device.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the controller. Save the CMOS.BIN before replacement to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, initialize the appropriate data in maintenance mode, and then load the data saved in the external memory device.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the controller. Save the CMOS.BIN before replacement to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, initialize the appropriate data in maintenance mode, and then load the data saved in the external memory device.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the controller. Save the CMOS.BIN before replacement to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, initialize the appropriate data in maintenance mode, and then load the data saved in the external memory device.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the controller. Save the CMOS.BIN before replacement to be safe.

Alarm

Number

Alarm Name

WEAK

ERROR

Sub

Code

Meaning

The number of operation instructions exceed the permissible value.

Cause

Data error

Main CPU board failure

A syntax error was found in the

CNT instruction or TMR instruction.

Data error

Main CPU board failure

A syntax error was found in the

JMP-LABEL instructions.

Data error

Main CPU board failure

The label of JMP destination does not exist.

Data error

Main CPU board failure

Main CPU board battery is weakening.

Connection failure

Sub Code: Option board. Number

× 100 factor

factor:

1 ROM ERR

2 RAM ERR

3 CPU ERR

4 SHARED MEMORY ERR

5 CNTR 　 ASIC ERR

CNTR01R board failure

Remedy

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, initialize the appropriate data in maintenance mode, and then load the data saved in the external memory device.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the controller. Save the CMOS.BIN before replacement to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, initialize the appropriate data in maintenance mode, and then load the data saved in the external memory device.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the controller. Save the CMOS.BIN before replacement to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, initialize the appropriate data in maintenance mode, and then load the data saved in the external memory device.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the controller. Save the CMOS.BIN before replacement to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, initialize the appropriate data in maintenance mode, and then load the data saved in the external memory device.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the controller. Save the CMOS.BIN before replacement to be safe.

(1)Confirm that the battery is appropriately connected to the main CPU board.

(1)Replace the battery in accordance with the instructions in FS100

MAINTENANCE MANUAL.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the CNTR01R board. Save the CMOS.BIN before replacing the board to be safe.

Alarm

Number

822

Alarm Name

ERROR

Sub

Code

Meaning

CNTR01R WDG ERROR 100

Cause

Sub Code: Option board.

Number×100 factor

factor:

1 WDG TIMEOVER

2 ADDRESS ERR(READ)

EXCEPTION

3 ADDRESS ERR(WRITE)

EXCEPTION

4 UNJUST INST

EXCEPTION

5 UNJUST SLOT

EXCEPTION

A Watchdog err was detected in the Option #1 board.

CNTR01R board failure

200

300

400

500

600

700

800

A Watchdog err was detected in the Option #2 board.

CNTR01R board failure

A Watchdog err was detected in the Option #3 board.

CNTR01R board failure

A Watchdog err was detected in the Option #4 board.

CNTR01R board failure

A Watchdog err was detected in the Option #5 board.

CNTR01R board failure

A Watchdog err was detected in the Option #6 board.

CNTR01R board failure

A Watchdog err was detected in the Option #7 board.

CNTR01R board failure

A Watchdog err was detected in the Option #8 board.

CNTR01R board failure

Remedy

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the CNTR01R board. Save the CMOS.BIN before replacing the board to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the CNTR01R board. Save the CMOS.BIN before replacing the board to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the CNTR01R board. Save the CMOS.BIN before replacing the board to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the CNTR01R board. Save the CMOS.BIN before replacing the board to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the CNTR01R board. Save the CMOS.BIN before replacing the board to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the CNTR01R board. Save the CMOS.BIN before replacing the board to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the CNTR01R board. Save the CMOS.BIN before replacing the board to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the CNTR01R board. Save the CMOS.BIN before replacing the board to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the CNTR01R board. Save the CMOS.BIN before replacing the board to be safe.

Alarm

Number

Alarm Name

(CPU-201R)

920 BUS ERROR

(CPU-201R)

(servo#1)

(servo#2)

1000

(Main CPU)

ROM ERROR

(Main CPU)

1001 ROM ERROR

(SERVO)

Sub

Code

Meaning Cause

An error was detected in the CPU. Main CPU board failure

Remedy

The JL chip does not operate normally.

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

Connection failure

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

Power Lost Signal Error

Main CPU board failure

Servo control board failure

Main CPU board failure

Connection failure

Servo control board failure

Main CPU board failure

Software operation error occurred

1*:A checksum error occurred in the board or the EEPROM.

(*: axis No.)

Servo control board failure

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the controller. Save the CMOS.BIN before replacement to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the controller. Save the CMOS.BIN before replacement to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the controller. Save the CMOS.BIN before replacement to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the controller. Save the CMOS.BIN before replacement to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the controller. Save the CMOS.BIN before replacement to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the controller. Save the CMOS.BIN before replacement to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the controller. Save the CMOS.BIN before replacement to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the controller. Save the CMOS.BIN before replacement to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the controller. Save the CMOS.BIN before replacement to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, save the CMOS.BIN in maintenance mode, and then contact your Yaskawa representative about occurrence status (operating procedure).

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace controller. Save the CMOS.BIN before replace controller to be safe.

Alarm

Number

1020

Alarm Name

MotoPlus application load error

Sub

Code

Meaning

Cause

The SRDY signal did not turn ON after the WRITE ENABLE command was written. (EEPROM

WRITE ENABLE error)

Servo control board failure

The SRDY signal did not turn ON after the WRITE PROTECT command was written. (EEPROM

WRITE PROTECT error)

Servo control board failure

The SRDY signal did not turn ON after the ERASE command was written. (EEPROM ERASE error)

Servo control board failure

The SRDY signal did not turn ON after the CLEAR command was written. (EEPROM CLEAR error)

Servo control board failure

The SRDY signal did not turn ON after data were written.

(EEPROM writing error)

Servo control board failure

The SRDY signal did not turn ON after data were read.

(EEPROM reading error)

Servo control board failure

The written data were rejected at verification.

(EEPROM verify error)

Servo control board failure

Num of the Application files is over the limit.

Insufficient memory space

Setting error

Remedy

MotoPlus application folder cannot be found.

Memory size required by

Application is over the limit

(2Mbyte).

Setting error

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace controller. Save the CMOS.BIN before replace controller to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace controller. Save the CMOS.BIN before replace controller to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace controller. Save the CMOS.BIN before replace controller to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace controller. Save the CMOS.BIN before replace controller to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace controller. Save the CMOS.BIN before replace controller to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace controller. Save the CMOS.BIN before replace controller to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace controller. Save the CMOS.BIN before replace controller to be safe.

Set the number of application file "*.OUT" to be within the defined value. (Delete unnecessary files from the MotoPlus menu of the maintenance mode.)

Memory to work MotoPlus application is insufficient under the combination of current system configuration and its optional function. IIf the alarm occurs again, save the CMOS.BIN in maintenance mode, and then contact your

Yaskawa representative about occurrence status (operating procedure).

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace controller and load the MotoPlus application which was loaded to the previous controller.

Check that if the object file name is too long or inappropriate letters are used.

Alarm

Number

Alarm Name

Sub

Code

Meaning Cause

Undefined symbols are included in the application.

Load failure (other)

Setting error

API library initialization failure Setting error

User root task not included

User root task generation failure

Setting error

10 RAM-Disk generation failure Setting error

1030 MEMORY ERROR

(PARAMETER FILE)

MotoPlus application process generation failure application file "*.VXE" in the controller exceeded the specified value

Failure to install the driver to communicate between MotoPlus application and the system.

Setting error

RCD, RCxG parameter error Data error

Main CPU board failure

Remedy

Check that symbols such as undefined functions or constants, which are provided from the system side, are included in the application program.

(1)Check the definition of static variable in the MotoPlus application program is correct or not.

(2)Check the MotoPlus application programs so that they are set within the specified values.

(3)Check that the object files are appropriately created.

Memory to work MotoPlus application is insufficient under the combination of current system configuration and its optional function. If the alarm occurs again, save the CMOS.BIN in maintenance mode, and then contact your Yaskawa representative about occurrence status (operating procedure).

Confirm that mpUsRoot() is described in the application program.

Yaskawa representative about occurrence status (operating procedure).

Check that the object file is appropriately created.

Set the number of application file "*.VXE" to be within the defined value. (Delete unnecessary files from the MotoPlus menu of the maintenance mode.)

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, initialize the appropriate parameter file in maintenance mode, and then load the parameter file saved in the external memory device.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace controller. Save the CMOS.BIN before replace controller to be safe.

Alarm

Number

Alarm Name

Sub

Code

Meaning

ROxG parameter error

SVD, SVxG parameter error

Main CPU board failure

Data error

SVMxG parameter error

Cause

Data error

Main CPU board failure

Data error

Main CPU board failure

Data error S1CxG, S2C, S3C, S4C parameter error

Main CPU board failure

S1D, S2D, S3D, S4D parameter error

Data error

Main CPU board failure

Remedy

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, initialize the appropriate parameter file in maintenance mode, and then load the parameter file saved in the external memory device.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace controller. Save the CMOS.BIN before replace controller to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, initialize the appropriate parameter file in maintenance mode, and then load the parameter file saved in the external memory device.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace controller. Save the CMOS.BIN before replace controller to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, initialize the appropriate parameter file in maintenance mode, and then load the parameter file saved in the external memory device.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace controller. Save the CMOS.BIN before replace controller to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, initialize the appropriate parameter file in maintenance mode, and then load the parameter file saved in the external memory device.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace controller. Save the CMOS.BIN before replace controller to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, initialize the appropriate parameter file in maintenance mode, and then load the parameter file saved in the external memory device.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace controller. Save the CMOS.BIN before replace controller to be safe.

Alarm

Number

Alarm Name

Sub

Code

Meaning

CIO parameter error

FD parameter error

Cause

Data error

Main CPU board failure

Data error

Main CPU board failure

A1P, A2P, …, A8P parameter error

Data error

RS parameter error

Main CPU board failure

Data error

Main CPU board failure

S1E, S2E, …, S8E parameter error

Data error

Main CPU board failure

Remedy

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, initialize the appropriate parameter file in maintenance mode, and then load the parameter file saved in the external memory device.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace controller. Save the CMOS.BIN before replace controller to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, initialize the appropriate parameter file in maintenance mode, and then load the parameter file saved in the external memory device.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace controller. Save the CMOS.BIN before replace controller to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, initialize the appropriate parameter file in maintenance mode, and then load the parameter file saved in the external memory device.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace controller. Save the CMOS.BIN before replace controller to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, initialize the appropriate parameter file in maintenance mode, and then load the parameter file saved in the external memory device.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace controller. Save the CMOS.BIN before replace controller to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, initialize the appropriate parameter file in maintenance mode, and then load the parameter file saved in the external memory device.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace controller. Save the CMOS.BIN before replace controller to be safe.

Alarm

Number

Alarm Name

Sub

Code

Meaning

SVCxB parameter error

12 AMCxG parameter error

13 SVPxG parameter error

14 MFxG parameter error

15 SVSxG parameter error

Cause

Data error

Main CPU board failure

Data error

Main CPU board failure

Data error

Main CPU board failure

Data error

Main CPU board failure

Data error

Main CPU board failure

Remedy

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, initialize the appropriate parameter file in maintenance mode, and then load the parameter file saved in the external memory device.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace controller. Save the CMOS.BIN before replace controller to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, initialize the appropriate parameter file in maintenance mode, and then load the parameter file saved in the external memory device.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace controller. Save the CMOS.BIN before replace controller to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, initialize the appropriate parameter file in maintenance mode, and then load the parameter file saved in the external memory device.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace controller. Save the CMOS.BIN before replace controller to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, initialize the appropriate parameter file in maintenance mode, and then load the parameter file saved in the external memory device.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace controller. Save the CMOS.BIN before replace controller to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, initialize the appropriate parameter file in maintenance mode, and then load the parameter file saved in the external memory device.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace controller. Save the CMOS.BIN before replace controller to be safe.

Alarm

Number

Alarm Name

1031 MEMORY ERROR

(MOTION1)

Sub

Code

Meaning

RExG parameter error

Cause

Data error

Main CPU board failure

"GET FILE" instruction, "SET

FILE" instruction execution target file

Home position calibration file

Data error

Tool file

User coordinates file

Robot calibration file

Data error

Tool calibration file Data error

Home position correction data file Data error

Conveyor calibration file

Arm and tool interference prevention file

Conveyor condition file

Data error

Remedy

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, initialize the appropriate parameter file in maintenance mode, and then load the parameter file saved in the external memory device.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace controller. Save the CMOS.BIN before replace controller to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, initialize the appropriate data in maintenance mode, and then load the data saved in the external memory device.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, initialize the appropriate data in maintenance mode, and then load the data saved in the external memory device.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, initialize the appropriate data in maintenance mode, and then load the data saved in the external memory device.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, initialize the appropriate data in maintenance mode, and then load the data saved in the external memory device.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, initialize the appropriate data in maintenance mode, and then load the data saved in the external memory device.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, initialize the appropriate data in maintenance mode, and then load the data saved in the external memory device.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, initialize the appropriate data in maintenance mode, and then load the data saved in the external memory device.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, initialize the appropriate data in maintenance mode, and then load the data saved in the external memory device.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, initialize the appropriate data in maintenance mode, and then load the data saved in the external memory device.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, initialize the appropriate data in maintenance mode, and then load the data saved in the external memory device.

Alarm

Number

Alarm Name

Sub

Code

Meaning

Press characteristics file

Cause

Data error

Servo float condition file

Anticipation OT# output file

Anticipation OG# output file

Form cut file

Data error

Linear servo float condition file Data error

Macro definition file

Job registration table

Data error

Linear scale condition file Data error

Conveyor condition auxiliary file Data error

Pelletizing condition file Data error

Mastering registration position Data error

Remedy

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, initialize the appropriate data in maintenance mode, and then load the data saved in the external memory device.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, initialize the appropriate data in maintenance mode, and then load the data saved in the external memory device.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, initialize the appropriate data in maintenance mode, and then load the data saved in the external memory device.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, initialize the appropriate data in maintenance mode, and then load the data saved in the external memory device.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, initialize the appropriate data in maintenance mode, and then load the data saved in the external memory device.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, initialize the appropriate data in maintenance mode, and then load the data saved in the external memory device.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, initialize the appropriate data in maintenance mode, and then load the data saved in the external memory device.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, initialize the appropriate data in maintenance mode, and then load the data saved in the external memory device.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, initialize the appropriate data in maintenance mode, and then load the data saved in the external memory device.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, initialize the appropriate data in maintenance mode, and then load the data saved in the external memory device.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, initialize the appropriate data in maintenance mode, and then load the data saved in the external memory device.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, initialize the appropriate data in maintenance mode, and then load the data saved in the external memory device.

Alarm

Number

1050

Alarm Name

SET-UP PROCESS

ERROR (SYSCON)

1051 SET-UP PROCESS

ERROR (MOTION)

Sub

Code

Meaning

Motion instruction setup incomplete

Online error

Cause

Main CPU board failure

Software operation error occurred

Main CPU board failure

Software operation error occurred

Unable to properly activate the servo control

Servo control board failure

Software operation error occurred

The position data of when the power supply was turned OFF cannot be transmitted to the servo control section

Servo control board failure

Software operation error occurred

The servo control section cannot receive the position data of when the power supply was turned OFF

Servo control board failure

Software operation error occurred

Remedy

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace controller. Save the CMOS.BIN before replace controller to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, save the CMOS.BIN in maintenance mode, and then contact your Yaskawa representative about occurrence status (operating procedure).

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace controller. Save the CMOS.BIN before replace controller to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, save the CMOS.BIN in maintenance mode, and then contact your Yaskawa representative about occurrence status (operating procedure).

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace controller. Save the CMOS.BIN before replace controller to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, save the CMOS.BIN in maintenance mode, and then contact your Yaskawa representative about occurrence status (operating procedure).

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace controller. Save the CMOS.BIN before replace controller to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, save the CMOS.BIN in maintenance mode, and then contact your Yaskawa representative about occurrence status (operating procedure).

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace controller. Save the CMOS.BIN before replace controller to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, save the CMOS.BIN in maintenance mode, and then contact your Yaskawa representative about occurrence status (operating procedure).

Alarm

Number

Alarm Name

Sub

Code

Meaning

Unable to send a request to prepare a feedback pulse

Unable to prepare a feedback pulse

Unable to send a request to initialize the arithmetic section

(ARITH)

Unable to initialize ARITH

Unable to send a request to prepare the current position

Cause

Servo control board failure

Software operation error occurred

Servo control board failure

Software operation error occurred

Main CPU board failure

Software operation error occurred

Main CPU board failure

Software operation error occurred

Main CPU board failure

Software operation error occurred

Remedy

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace controller. Save the CMOS.BIN before replace controller to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, save the CMOS.BIN in maintenance mode, and then contact your Yaskawa representative about occurrence status (operating procedure).

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace controller. Save the CMOS.BIN before replace controller to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, save the CMOS.BIN in maintenance mode, and then contact your Yaskawa representative about occurrence status (operating procedure).

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace controller. Save the CMOS.BIN before replace controller to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, save the CMOS.BIN in maintenance mode, and then contact your Yaskawa representative about occurrence status (operating procedure).

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace controller. Save the CMOS.BIN before replace controller to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, save the CMOS.BIN in maintenance mode, and then contact your Yaskawa representative about occurrence status (operating procedure).

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace controller. Save the CMOS.BIN before replace controller to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, save the CMOS.BIN in maintenance mode, and then contact your Yaskawa representative about occurrence status (operating procedure).

Alarm

Number

1053

1100

1101

1102

1103

1104

Alarm Name

SYSTEM ERROR

(EVENT)

SYSTEM ERROR

(MAN-MACHINE

MECHA)

SYSTEM ERROR

(MAN-MACHINE APPLI)

SYSTEM ERROR

(EVENT)

SYSTEM ERROR

(CIO)

Sub

Code

Meaning

Unable to prepare the current position

Cause

Main CPU board failure

Software operation error occurred

Sub Code

1 to 8: Signifies the internal software error at event process.

Software operation error occurred

Sub Code

C, B, F : Sub code of unknown alarm

Software operation error occurred

RAM software data error

Sub Code

0 to 6: Internal control error in software

Software operation error occurred

Sub Code

0 to 526: Internal control error in software

Software operation error occurred

Sub Code

1000_0000: I/O module setting error

Connection failure

Remedy

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace controller. Save the CMOS.BIN before replace controller to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, save the CMOS.BIN in maintenance mode, and then contact your Yaskawa representative about occurrence status (operating procedure).

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, save the CMOS.BIN in maintenance mode, and then contact your Yaskawa representative about occurrence status (operating procedure).

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, save the CMOS.BIN in maintenance mode, and then contact your Yaskawa representative about occurrence status (operating procedure).

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, save the CMOS.BIN in maintenance mode, and then contact your Yaskawa representative about occurrence status (operating procedure).

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, save the CMOS.BIN in maintenance mode, and then contact your Yaskawa representative about occurrence status (operating procedure).

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, save the CMOS.BIN in maintenance mode, and then contact your Yaskawa representative about occurrence status (operating procedure).

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, save the CMOS.BIN in maintenance mode, and then contact your Yaskawa representative about occurrence status (operating procedure).

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, check the connecting or inserting state of the following cables or connectors.

·IO module cable of the corresponding slot.

·24V power of the corresponding IO module.

Alarm

Number

Alarm Name

1105 SYSTEM ERROR

(SERVO)

Sub

Code

Meaning

Cause Remedy

Communication period with the motion part is inappropriate.

A task request was sent to an axis in the alarm status.

The linear servo float does not support the manipulator type specified in the RC parameter at calculation for servo-float-related parameters.

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

The alarm number is illegal.

Setting error

Main CPU board failure

Software operation error occurred

Servo control board failure

Software operation error occurred

Servo control board failure

Software operation error occurred

Setting error

Software operation error occurred

(1)Turn the power OFF then back ON.

(2)If the error occurs again, set the I/O module again in maintenance mode.

(3)If the alarm occurs again, save the CMOS.BIN in maintenance mode, and then contact your Yaskawa representative about occurrence status (operating procedure).

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the YCP01 board. Save the CMOS.BIN before replace the board to be safe. Replace the YCP01 board, and then remove the CF from the failure YCP01 board to insert it into the new YCP01.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, save the CMOS.BIN in maintenance mode, and then contact your Yaskawa representative about occurrence status (operating procedure).

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace controller. Save the CMOS.BIN before replace controller to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, save the CMOS.BIN in maintenance mode, and then contact your Yaskawa representative about occurrence status (operating procedure).

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace controller. Save the CMOS.BIN before replace controller to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, save the CMOS.BIN in maintenance mode, and then contact your Yaskawa representative about occurrence status (operating procedure).

(1)Check the following settings.

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

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, save the CMOS.BIN in maintenance mode, and then contact your Yaskawa representative about occurrence status (operating procedure).

Alarm

Number

Alarm Name

Sub

Code

115

128

135

136

137

Meaning

Parameter modified while the servo float is ON.

500

μ s non real process execution sequence error

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

General08ms process dose not complete within the time set by the scheduling table.

Dynamics arithmetic process dose not complete within the time set by the scheduling table.

500

μ s non real process dose not complete within the time set by the scheduling table.

Cause

Setting error

Software operation error occurred

Servo control board failure

Software operation error occurred

Servo control board failure

Software operation error occurred

Servo control board failure

Software operation error occurred

Servo control board failure

Software operation error occurred

Remedy

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, save the CMOS.BIN in maintenance mode, and then contact your Yaskawa representative about occurrence status (operating procedure).

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, save the CMOS.BIN in maintenance mode, and then contact your Yaskawa representative about occurrence status (operating procedure).

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace controller. Save the CMOS.BIN before replace controller to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, save the CMOS.BIN in maintenance mode, and then contact your Yaskawa representative about occurrence status (operating procedure).

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace controller. Save the CMOS.BIN before replace controller to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, save the CMOS.BIN in maintenance mode, and then contact your Yaskawa representative about occurrence status (operating procedure).

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace controller. Save the CMOS.BIN before replace controller to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, save the CMOS.BIN in maintenance mode, and then contact your Yaskawa representative about occurrence status (operating procedure).

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace controller. Save the CMOS.BIN before replace controller to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, save the CMOS.BIN in maintenance mode, and then contact your Yaskawa representative about occurrence status (operating procedure).

Alarm

Number

Alarm Name

Sub

Code

Meaning

138

140

151

160

200

303

Cause Remedy

Real time process dose not complete within the time set by the scheduling table.

External interruption occurred.

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

Software operation error occurred

Servo control board failure

The interface with the microprogram dose not complete within the time set by the scheduling table.

Software operation error occurred

Servo control board failure

The notch filter doesn't become effective after shifting to PLAY mode.

The difference between the base torque and the target torque exceeded the threshold in the jig robot bending correction.

Servo control board failure

Software operation error occurred

Servo control board failure

Software operation error occurred

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace controller. Save the CMOS.BIN before replace controller to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, save the CMOS.BIN in maintenance mode, and then contact your Yaskawa representative about occurrence status (operating procedure).

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace controller. Save the CMOS.BIN before replace controller to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, save the CMOS.BIN in maintenance mode, and then contact your Yaskawa representative about occurrence status (operating procedure).

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace controller. Save the CMOS.BIN before replace controller to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, save the CMOS.BIN in maintenance mode, and then contact your Yaskawa representative about occurrence status (operating procedure).

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, save the CMOS.BIN in maintenance mode, and then contact your Yaskawa representative about occurrence status (operating procedure).

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace controller. Save the CMOS.BIN before replace controller to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, save the CMOS.BIN in maintenance mode, and then contact your Yaskawa representative about occurrence status (operating procedure).

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, save the CMOS.BIN in maintenance mode, and then contact your Yaskawa representative about occurrence status (operating procedure).

Alarm

Number

Alarm Name

Sub

Code

500

Meaning

Inconsistency of FP register.

Cause Remedy

1000

1001

1002

1003

1004

1005

1006

The check item number of SVD parameter is unmatched.

The check item number of SV parameter is unmatched.

The check item number of SVM parameter is unmatched.

The check item number of SVP parameter is unmatched.

The check item number of AMC parameter is unmatched.

The check item number of MFG parameter is unmatched.

The check item number of MFA parameter is unmatched.

Servo control board failure

Software operation error occurred

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace controller. Save the CMOS.BIN before replace controller to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, save the CMOS.BIN in maintenance mode, and then contact your Yaskawa representative about occurrence status (operating procedure).

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, save the CMOS.BIN in maintenance mode, and then contact your Yaskawa representative about occurrence status (operating procedure).

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, save the CMOS.BIN in maintenance mode, and then contact your Yaskawa representative about occurrence status (operating procedure).

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, save the CMOS.BIN in maintenance mode, and then contact your Yaskawa representative about occurrence status (operating procedure).

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, save the CMOS.BIN in maintenance mode, and then contact your Yaskawa representative about occurrence status (operating procedure).

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, save the CMOS.BIN in maintenance mode, and then contact your Yaskawa representative about occurrence status (operating procedure).

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, save the CMOS.BIN in maintenance mode, and then contact your Yaskawa representative about occurrence status (operating procedure).

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, save the CMOS.BIN in maintenance mode, and then contact your Yaskawa representative about occurrence status (operating procedure).

Alarm

Number

1200

1204

1220

Alarm Name

HIGH TEMPERATURE

(IN CNTL BOX)

COMMUNICATION

ERROR

(OPTION MODULE)

LAN COMMUNICATION

PARAMETER ERROR

Sub

Code

1007

Meaning

4000

7200

7500

Cause Remedy

The check item number of SVC parameter is unmatched.

Software operation error occurred

Execution of the motion command does not complete within the specified time. (The last three digits expresses the command code.)

Software operation error occurred

Interpolation cycle is shorter than the set value.

(The last digit expresses the physical axis of the alarm occurrence.)

Setting error of the NSRCH instruction direct-in number.

Setting error

The temperature rises in the controller

Connection failure

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, save the CMOS.BIN in maintenance mode, and then contact your Yaskawa representative about occurrence status (operating procedure).

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, save the CMOS.BIN in maintenance mode, and then contact your Yaskawa representative about occurrence status (operating procedure).

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, save the CMOS.BIN in maintenance mode, and then contact your Yaskawa representative about occurrence status (operating procedure).

More than 4 direct in numbers are specified at time under the NSRCH instruction. Confirm its direct-in setting value.

Turn the power OFF then back ON after cooling down inside of the controller.

The communication error slot

(Serial-bus-connected Option module communication station

No.) is displayed by the bit.

0: correct / 1: incorrect

Module failure

(converter)

Connection failure

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, check the connecting state of the following cables.

·The power cables of the cooling fan inside of the converter unit.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace controller. Save the CMOS.BIN before replace controller to be safe.

Check the connecting or inserting state of the followings.

·Option modules of the corresponding slot.

·Option module cables of the corresponding slot.

Incorrect setting of the IP address which is used in the Ethernet function.

IO module failure

Power supply broken

Main CPU board broken

Setting error

Replace the I/O module of the corresponding station number.

Replace the 24V power supply supplied to the I/O module of the corresponding station number.

Save the CMOS.BIN file.

Replace the Main CPU board, and then load the saved CMOS.BIN file.

(1)Check the following settings.

·IP address setting of network in maintenance mode

Alarm

Number

1221

Alarm Name

ETHERNET INITIAL

PROCESS ERROR

Sub

Code

Meaning

Cause

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.

Incorrect setting of the host address which is used in the

Ethernet function.

Setting error

Incorrect setting of the host name which is used in the Ethernet function.

Setting error

Setting error Incorrect setting of the domain which is used in the Ethernet function.

An error occurred in the device initialization process of the

Ethernet function.

Software operation error occurred

Main CPU board failure

Setting error

An error occurred in the IP address setting process of the

Ethernet function.

Software operation error occurred

Main CPU board failure

An error occurred in the subnet mask setting process of the

Ethernet function.

Setting error

Software operation error occurred

Remedy

(1)Check the following settings.

·Subnet mask of network in maintenance mode

(1)Check the following settings.

·Default gateway of network in maintenance mode

(1)Check the following settings.

·Server (host) of network in maintenance mode

(1)Check the following settings.

·Host name of network in maintenance mode

(1)Check the following settings.

·Domain name of network in maintenance mode

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, save the CMOS.BIN in maintenance mode, and then contact your Yaskawa representative about occurrence status (operating procedure).

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace controller.

(1)Check the following settings.

·IP address setting of network in maintenance mode

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, save the CMOS.BIN in maintenance mode, and then contact your Yaskawa representative about occurrence status (operating procedure).

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace controller.

(1)Check the following settings.

·Subnet mask of network in maintenance mode

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, save the CMOS.BIN in maintenance mode, and then contact your Yaskawa representative about occurrence status (operating procedure).

Alarm

Number

Alarm Name

Sub

Code

Meaning

Cause

Main CPU board failure

An error occurred in the default gateway setting process of the

Ethernet function.

Setting error

Software operation error occurred

An error occurred in the host name setting process of the

Ethernet function.

Main CPU board failure

Setting error

Software operation error occurred

An error occurred in the MAC address getting process of the

Ethernet function.

Main CPU board failure

Software operation error occurred

An error occurred in the Web server task creating process of the Ethernet function.

Main CPU board failure

Software operation error occurred

An error occurred in the FTP server task creating process of the Ethernet function.

Main CPU board failure

Software operation error occurred

Remedy

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace controller.

(1)Check the following settings.

·Default gateway of network in maintenance mode

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, save the CMOS.BIN in maintenance mode, and then contact your Yaskawa representative about occurrence status (operating procedure).

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace controller.

(1)Check the following settings.

·Server (host) of network in maintenance mode

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, save the CMOS.BIN in maintenance mode, and then contact your Yaskawa representative about occurrence status (operating procedure).

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace controller.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, save the CMOS.BIN in maintenance mode, and then contact your Yaskawa representative about occurrence status (operating procedure).

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace controller.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, save the CMOS.BIN in maintenance mode, and then contact your Yaskawa representative about occurrence status (operating procedure).

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace controller.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, save the CMOS.BIN in maintenance mode, and then contact your Yaskawa representative about occurrence status (operating procedure).

Alarm

Number

Alarm Name

1301 COMMUNICATION

ERROR (SERVO)

Sub

Code

Meaning

Cause

Main CPU board failure

An error occurred in the FTP client task creating process of the

Ethernet function.

Software operation error occurred

Main CPU board failure

An error occurred in the semaphore generation process for access exclusion of the

Ethernet function.

Software operation error occurred

Main CPU board failure

An error occurred in the Web server task management ID getting process of the Ethernet function.

Software operation error occurred

Main CPU board failure

An error occurred in the FTP server task management ID getting process of the Ethernet function.

Software operation error occurred

Main CPU board failure

Communication status error Connection failure

Remedy

Module failure (converter)

Servo control board failure

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace controller.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, save the CMOS.BIN in maintenance mode, and then contact your Yaskawa representative about occurrence status (operating procedure).

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace controller.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, save the CMOS.BIN in maintenance mode, and then contact your Yaskawa representative about occurrence status (operating procedure).

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace controller.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, save the CMOS.BIN in maintenance mode, and then contact your Yaskawa representative about occurrence status (operating procedure).

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace controller.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, save the CMOS.BIN in maintenance mode, and then contact your Yaskawa representative about occurrence status (operating procedure).

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace controller.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace controller. Save the CMOS.BIN before replace controller to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace controller. Save the CMOS.BIN before replace controller to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace controller. Save the CMOS.BIN before replace controller to be safe.

Alarm

Number

Alarm Name

Sub

Code

Meaning

Watchdog timer error

JL0101 alarm

Communication status error

Cause Remedy

Main CPU board failure

Connection failure

Module failure (converter)

Servo control board failure

Main CPU board failure

Connection failure

Module failure (converter)

Servo control board failure

Main CPU board failure

Connection failure

Module failure (converter)

Servo control board failure

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace controller. Save the CMOS.BIN before replace controller to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace controller. Save the CMOS.BIN before replace controller to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace controller. Save the CMOS.BIN before replace controller to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace controller. Save the CMOS.BIN before replace controller to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace controller. Save the CMOS.BIN before replace controller to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace controller. Save the CMOS.BIN before replace controller to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace controller. Save the CMOS.BIN before replace controller to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace controller. Save the CMOS.BIN before replace controller to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace controller. Save the CMOS.BIN before replace controller to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace controller. Save the CMOS.BIN before replace controller to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace controller. Save the CMOS.BIN before replace controller to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace controller. Save the CMOS.BIN before replace controller to be safe.

Alarm

Number

1303

Alarm Name

ARITHMETIC ERROR

(SERVO)

Sub

Code

Meaning

Cause Remedy

Data consistency error

Main CPU board failure

Connection failure

Module failure

(converter)

Servo control board failure

Main CPU board failure

Software operation error occurred

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace controller. Save the CMOS.BIN before replace controller to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace controller. Save the CMOS.BIN before replace controller to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace controller. Save the CMOS.BIN before replace controller to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace controller. Save the CMOS.BIN before replace controller to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace controller. Save the CMOS.BIN before replace controller to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, save the CMOS.BIN in maintenance mode, and then contact your Yaskawa representative about occurrence status (operating procedure).

(1)Check the following settings.

Reexamine the tool file setting.

(Check the units of mass and center of gravity, positive/negative signs.)

The data [X____] indicates the generation process.

10000: Observer control

20000: High-precision path control

30000: Dynamics

40000: Disturbance observer control

50000: Dislocation detect

The data [_YYY_] indicates the alarm contents.

The data [____Z] indicates the physical axis number.

Tool file setting error

Software operation error occurred

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, save the CMOS.BIN in maintenance mode, and then contact your Yaskawa representative about occurrence status (operating procedure).

Alarm

Number

Alarm Name

1306 AMPLIFIER TYPE

MISMATCH

1307 ENCODER TYPE

MISMATCH

Sub

Code

Meaning Cause Remedy

Sub Code: Signifies the axis in which the alarm occurred

Motor load error

Setting error

Connection failure

Module failure (amplifier)

Servo control board failure

Setting error

Connection failure

Module failure (encoder)

Servo control board failure

Software operation error occurred

(1)Check the followings.

Overload is applied to the manipulator. Correct the tools, the work pieces, and the drive condition.

(1)Check the following settings.

·Check the current capacity of the amplifier before/after replacement by the model described in board.

·When the external axis is mounted, check if there is no difference between the amplifier selected at configuration and practically mounted one.

Reference parameter: from SVPxG232

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace controller. Save the CMOS.BIN before replace controller to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace controller. Save the CMOS.BIN before replace controller to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace controller. Save the CMOS.BIN before replace controller to be safe.

(1)Check the following settings.

·Check the motor type before and after the replacement.

·When the external axis is mounted, check if there is no difference between the motor selected at configuration and the motor that is actually mounted.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace controller. Save the CMOS.BIN before replace controller to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the encoder.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace controller. Save the CMOS.BIN before replace controller to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, save the CMOS.BIN in maintenance mode, and then contact your Yaskawa representative about occurrence status (operating procedure).

Alarm

Number

1308

1311

1325

Alarm Name

CONVERTER TYPE

MISMATCH

A/D DETECTION

ERROR (CONVERTER)

COMMUNICATION

ERROR (ENCODER)

Sub

Code

Meaning

Sub Code: Signifies the converter physical number in which the alarm occurred

Sub Code: Signifies the axis in which the alarm occurred

Cause

Sub Code: Signifies the converter in which the alarm occurred

Setting error

Connection failure

Module failure (converter)

Servo control board failure

Software operation error occurred

Module failure (converter)

Connection failure

Module failure (encoder)

Servo control board failure

Remedy

(1)Check the following settings.

·Check the current capacity of the amplifier before/after replacement by the model described in board.

·When the external axis is mounted, check if there is no difference between the amplifier selected at configuration and practically mounted one.

Reference parameter: from SVCxB025

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace controller. Save the CMOS.BIN before replace controller to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace controller. Save the CMOS.BIN before replace controller to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace controller. Save the CMOS.BIN before replace controller to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, save the CMOS.BIN in maintenance mode, and then contact your Yaskawa representative about occurrence status (operating procedure).

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace controller. Save the CMOS.BIN before replace controller to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, check the connecting or inserting state of the following cables.

{Robot axis}

·Cables between the controller and the encoder.

{External axis}

·Cables between the controller and the encoder.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the encoder.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace controller. Save the CMOS.BIN before replace controller to be safe.

Alarm

Number

1326

Alarm Name

DEFECTIVE ENCODER

ABSOLUTE DATA

Sub

Code

1327 ENCODER OVER

SPEED

Meaning

Sub Code: Signifies the axis in which the alarm occurred

Cause

Connection failure

Module failure (encoder)

Servo control board failure

External environment

Connection failure

Encoder failure

Servo control board failure

Remedy

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, check the connecting or inserting state of the following cables.

{Robot axis}

·Cables between the controller and the encoder.

{External axis}

·Cables between the controller and the encoder.

(1)Check the following settings.

Replace the defective motor (encoder).

·Check the position after the alarm.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace controller. Save the CMOS.BIN before replace controller to be safe.

(1)Check the following settings.

·Check the grounding condition of Manipulator.

·Check whether it is installed into the strong magnetic field.

·Check the position after the alarm.

(1)Turn the power OFF then back ON.

(2)Turn the servo OFF where the axis does not fall off while turning ON the servo.

(3)Replace the battery of the alarm occurring axis if the alarm and encoder back-up error occur again.

(4)If the alarm occurs again, check the connecting or inserting state of the following cables.

{Robot axis}

·Cables between the controller and the encoder.

{External axis}

·Cables between the controller and the encoder

Replace the defective motor (encoder).

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace controller. Save the CMOS.BIN before replace controller to be safe.

Alarm

Number

1328

Alarm Name

DEFECTIVE ENCODER

Sub

Code

1329

1330

1349

1352

DEFECTIVE SERIAL

ENCODER COMMAND

MICRO PROGRAM

TRANSMIT ERROR

POWER LOST

DETECTION

(SERVO)

SERIAL ENCODER

CORRECTION ERROR

Meaning

Sub Code: Signifies the axis in which the alarm occurred

Cause

Connection failure

Module failure (encoder)

Servo control board failure

Connection failure

Module failure (encoder)

Servo control board failure

Instant power failure

Sub Code: Signifies the axis in which the alarm occurred

Connection failure

Remedy

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, check the connecting or inserting state of the following cables.

{Robot axis}

·Cables between the controller and the encoder.

{External axis}

·Cables between the controller and the encoder

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the encoder.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace controller. Save the CMOS.BIN before replace controller to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, check the connecting or inserting state of the following cables.

{Robot axis}

·Cables between the controller and the encoder.

{External axis}

·Cables between the controller and the encoder.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the encoder.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace controller. Save the CMOS.BIN before replace controller to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace controller. Save the CMOS.BIN before replace controller to be safe.

Check if the primary power supply voltage is dropping.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, check the connecting or inserting state of the following cables.

{Robot axis}

·Cables between the controller and the encoder.

{External axis}

·Cables between the controller and the encoder.

Alarm

Number

Alarm Name

1355 SERIAL ENC

MULTITURN LIMIT

ERROR

1400 ENCODER ERROR

(CONVEYOR)

Sub

Code

Meaning

Cause Remedy

Sub Code: Signifies the axis in which the alarm occurred

An error occurred at conveyor encoder 1.

Connection failure

Module failure

(encoder)

Servo control board failure

Connection failure

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, check the connection and insertion of the following cables and connectors.

{Robot axis}

·Cable between encoders

·EAXA-CN508

{External axis}

·Cable between encoders

·EAXB-CN0534,535,536

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the encoder.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace controller. Save the CMOS.BIN before replace controller to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, check the connecting or inserting state of the following cables.

{Robot axis}

·Cables between the controller and the encoder.

{External axis}

·Cables between the controller and the encoder.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, check the connection and insertion of the following cables and connectors.

{Robot axis}

·Cable between encoders

·EAXA-CN508

{External axis}

·Cable between encoders

·EAXB-CN0534,535,536

Module failure

(encoder)

Servo control board failure

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the encoder.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace controller. Save the CMOS.BIN before replace controller to be safe.

Cable (defect), Module failure

(encoder)

Replace the encoder cable or encoder of the conveyor encoder 1.

1401

1402

1403

1404

1405

1406

1407

1512

Alarm

Number

1513

Alarm Name

CANNOT CHANGE

CONVEYOR MODE

WORK IN/NOT DATA

CNT. LMT. OVER

WORK IN/NOT SHIFT

DATA POS LMT.

WORK ID. DATA CNT.

LMT. OVER

WORK ID. SHIFT DATA

POS LMT.

START SHIFT DATA

CNT. LMT. OVER

START SHIFT DATA POS

LMT.

POWER SUPPLY FAN

ERROR

(SERVO)

POWER SUPPLY

OVERHEAT

(SERVO)

Sub

Code

Meaning

An error occurred at conveyor encoder 2.

An error occurred at conveyor encoder 3.

Cause Remedy

Cable (defect), Module failure

(encoder)

Replace the encoder cable or encoder of the conveyor encoder 2.

Cable (defect), Module failure

(encoder)

Replace the encoder cable or encoder of the conveyor encoder 3.

Input error

Work status error

Do not switch "Encoder / Virtual encoder" with the general signal while performing the conveyor synchronized function.

Check the work in/not shift data and actual the work status within the shift area.

Work status error

Check the work in/not shift data and actual the work status within the shift area.

Work status error

Check the work in/not shift data and actual the work status within the shift area.

Connection failure

Module failure

(converter)

Air inlet and exhaust

The temperature rises in the controller

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace controller. Save the CMOS.BIN before replace controller to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace controller. Save the CMOS.BIN before replace controller to be safe.

Check that the air inlet or outlet is not blocked.

Turn the power OFF then back ON after cooling the controller.

Connection failure

Module failure

(converter)

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace controller. Save the CMOS.BIN before replace controller to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace controller. Save the CMOS.BIN before replace controller to be safe.

Alarm

Number

1514

1547

1650

Alarm Name

OVERHEAT

(AMPLIFIER)

CURRENT FEEDBACK

ERROR

FILE TRANSFER DATA

ERROR (SV)

Sub

Code

Meaning Cause Remedy

•

The data [XXX_] indicates the

alarm contents.

•

2000:Error in current detection

value

•

The data [___Y] indicates the

physical axis number.

The temperature of amplifier rose.

Connection failure

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

Servo control board failure

Connection failure

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace controller. Save the CMOS.BIN before replace controller to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace controller. Save the CMOS.BIN before replace controller to be safe.

Check if a ground fault has not occurred in the U-, V-, and W-phase of motor power line, or short circuit has not occurred between these phases.

Connection failure

Module failure

(amplifier)

Module failure

(motor)

Servo control board failure

An error occurred when the last data was not received during the first data communication at execution of motion command.

Software operation error occurred

Servo control board failure

Main CPU board failure

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace controller. Save the CMOS.BIN before replace controller to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace controller. Save the CMOS.BIN before replace controller to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the motor.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace controller. Save the CMOS.BIN before replace controller to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, save the CMOS.BIN in maintenance mode, and then contact your Yaskawa representative about occurrence status (operating procedure).

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace controller. Save the CMOS.BIN before replace controller to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace controller. Save the CMOS.BIN before replace controller to be safe.

Alarm

Number

1651

1652

1653

Alarm Name

FILE TRANSFER DATA

SIZE ERRORERROR

(SV)

DB ON ERROR (SERVO)

BASE BLOCK SIGNAL

ERROR

(SERVO)

Sub

Code

Meaning

Cause Remedy

An error occurred when the first data was not received during on the way data communication at execution of motion command.

Main CPU board failure

Servo control board failure

An error occurred when the first data was not received during the last data communication at execution of motion command.

Servo control board failure

The data size for the file transfer does not agree with the received buffer size.

Buffer size over

Servo control board failure

Software operation error occurred

Servo control board failure

Software operation error occurred

Module failure (amplifier)

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace controller. Save the CMOS.BIN before replace controller to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace controller. Save the CMOS.BIN before replace controller to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace controller. Save the CMOS.BIN before replace controller to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace controller. Save the CMOS.BIN before replace controller to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace controller. Save the CMOS.BIN before replace controller to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace controller. Save the CMOS.BIN before replace controller to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, save the CMOS.BIN in maintenance mode, and then contact your Yaskawa representative about occurrence status (operating procedure).

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace controller. Save the CMOS.BIN before replace controller to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, save the CMOS.BIN in maintenance mode, and then contact your Yaskawa representative about occurrence status (operating procedure).

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace controller. Save the CMOS.BIN before replace controller to be safe.

Alarm

Number

1654

Alarm Name

PG POWER ON

MULTIPLE REQ (SV)

1655

1656

1657

CONVERTER

COMMAND ERROR (SV)

AXIS ENDLESS INFO

NOT GENERATED(SV)

AXIS ENDLESS

SPECIFIC. ERROR

(SV)

Sub

Code

Meaning Cause

Setting error

Software operation error occurred

Setting error

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

The home position detecting function cannot be used for the axis which the axis endless function was enabled.

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

The servo float function cannot be used for the axis which the axis endless function was enabled.

Setting error

The encoders manufactured by

Tamagawa Seiki Co., Ltd. was used for the axis for which the axis endless function was enabled.

The encoders manufactured by

Tamagawa Seiki Co., Ltd. cannot be used for the axis which the axis endless function was enabled.

Setting error

Remedy

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, save the CMOS.BIN in maintenance mode, and then contact your Yaskawa representative about occurrence status (operating procedure).

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, save the CMOS.BIN in maintenance mode, and then contact your Yaskawa representative about occurrence status (operating procedure).

Check the JOB.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace controller. Save the CMOS.BIN before replace controller to be safe.

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

Disable either the axis endless function or the servo float function of corresponding axis.

Disable the corresponding axis endless function.

Alarm

Number

1658

1664

Alarm Name

REDUCTION STOP

SPECIFIC. ERROR

(SV)

MICRO PRG EXECUTE

TIME OVER(SV)

Sub

Code

Meaning

Cause

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

The general servo function cannot be used for the axis which the axis endless function was enabled.

Setting error

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

The servo float function cannot be used for the axis which the deceleration stop function was enabled.

Setting error

The specified axis speed control function was executed for the axis which the deceleration stop function was enabled.

Specified axis speed control function cannot be used for the axis which the deceleration stop function was enabled.

Setting error

Sub code: specifies the axis that alarm occurred.

Servo control board failure

1665

1666

1667

MICRO PROGRAM

SYNC. ERROR (SV)

FILE RECEIVE

INCOMPLETE (SERVO)

RESOLUTION

CONVERSE CONST

ERROR

(SV)

Remedy

Disable the corresponding axis endless function.

Check the JOB.

Sub code: specifies the axis that alarm occurred.

Servo control board failure

Sub code: specifies the axis that alarm occurred.

Servo control board failure

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace controller. Save the CMOS.BIN before replace controller to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace controller. Save the CMOS.BIN before replace controller to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace controller. Save the CMOS.BIN before replace controller to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace controller. Save the CMOS.BIN before replace controller to be safe.

Alarm

Number

1674

Alarm Name

CTRL LAW SWITCHING

ORDER ERROR (SV)

Sub

Code

1684

1685

1686

1831

1832

INSTANT POWER

FAILURE

(TRQ)(SV)

INSTANT POWER

FAILURE

(TIME)(SV)

POS.DEVITATION

SATURATING ERROR

(SV)

HWBB FB ERROR

(PLD2)

ESP_OUT FB ERROR

(PLD1)

Meaning Cause

Sub code: specifies the axis that alarm occurred.

Servo control board failure

Remedy

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace controller. Save the CMOS.BIN before replace controller to be safe.

Check if the primary power supply voltage is dropping.

The instant power failure occurred and then the torque was saturated.

Voltage failure

The instant power failure occurred for longer than the certain time period.

Power failure

Voltage failure

Power failure

Setting error

Check if the instant power failure has occurred.

Check if the primary power supply voltage is dropping.

Check if the instant power failure has occurred.

Check the settings for manipulator motion condition (influence by external force, load condition).

Connection failure

Module failure (motor)

Servo control board failure

Check if a ground fault has not occurred in the U-, V-, and W-phase of motor power line, or short circuit has not occurred between these phases.

Check the connection of motor power line.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace the motor.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace controller. Save the CMOS.BIN before replace controller to be safe.

Module failure

(amplifier)

Machine safety board failure (1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace controller. Save the CMOS.BIN before replace controller to be safe.

Servo control board failure

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace controller. Save the CMOS.BIN before replace controller to be safe.

(1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace controller. Save the CMOS.BIN before replace controller to be safe.

Machine safety board failure (1)Turn the power OFF then back ON.

(2)If the alarm occurs again, replace controller. Save the CMOS.BIN before replace controller to be safe.

Alarm

Number

1833

Alarm Name

ESP_OUT FB ERROR

(PLD2)

Sub

Code

Meaning

1834

1835

1836

M-SAFETY WATCHDOG

ERROR (PLD1)

M-SAFETY WATCHDOG

ERROR (PLD2)

M-SAFETY WATCHDOG

ERROR (PLD3)

1837 M-SAFETY 24V POWER

SUPPLY ERROR

1838 M-SAFETY DC 24V

FUSE BROKEN