Efden 002 Management

1502, EFDEN-002-007, 001

FD CONTROLLER INSTRUCTION MANUAL

CONTROL AND MAINTENANCE FUNCTION

7th edition

・Before attempting to operate the robot, please read through this operating manual carefully, and comply with all the safety-related items and instructions in the text. ・The installation, operation and maintenance of this robot should be undertaken only by those individuals who have attended one of our robot course. ・When using this robot, observe the low related with industrial robot and with safety issues in each country. ・This operating manual must be given without fail to the individual who will be actually operating the robot. ・Please direct any queries about parts of this operating manual which may not be completely clear or any inquiries concerning the after-sale service of this robot to any of the service centers listed on the back cover.

Table of Contents

Table of Contents Chapter 1 User Management 1.1 User management ..................................................................................................................... 1-1 1.1.1 Enabling user management .............................................................................................. 1-2 1.1.2 Automatic log-out setting ................................................................................................... 1-3 1.1.3 Registering the users allowed to perform the editing operations ...................................... 1-3 1.1.4 Setting the user operation limitations ................................................................................ 1-5 1.1.5 Copying user registration information ............................................................................... 1-6 1.1.6 User information editing .................................................................................................... 1-8 1.2 Using the user management function........................................................................................ 1-9 1.2.1 Log-in operation................................................................................................................. 1-9 1.2.2 Log-out operation ............................................................................................................ 1-10 1.2.3 User information at log-in ................................................................................................ 1-11

Chapter 2 Edit logging 2.1 Concerning edit logging............................................................................................................. 2-1 2.2 Referencing the edit logging...................................................................................................... 2-2 2.2.1 Editor logging monitor displays ......................................................................................... 2-2 2.2.2 Editor logging monitor functions ........................................................................................ 2-7

Chapter 3 User Check 3.1 User Check ................................................................................................................................ 3-1 3.2 Setting the user check ............................................................................................................... 3-2 3.2.1 Setting up the check item .................................................................................................. 3-2 3.2.2 Allocating input/output signals ........................................................................................... 3-6 3.2.3 When reaching the inspection timing ................................................................................ 3-6 3.2.4 When check and part replacement are completed............................................................ 3-7

Chapter 4 Troubleshooting 4.1 When failure has occurred......................................................................................................... 4-1 4.2 Concerning the failure details .................................................................................................... 4-2 4.2.1 Failure category................................................................................................................. 4-2 4.2.2 Concerning criticality codes and failure codes .................................................................. 4-3 4.3 Concerning “System Failure”..................................................................................................... 4-4 4.3.1 Outline of “System Failure”................................................................................................ 4-4 4.3.2 How to recover and response to the failures..................................................................... 4-4 4.4 Recovery after failing of power down detection......................................................................... 4-5 4.4.1 Recovery after failing of power down detection ................................................................ 4-5 4.4.2 Setting of start operation permission................................................................................. 4-5 4.5 Troubleshooting ......................................................................................................................... 4-7 4.5.1 Assumed cause of each error code................................................................................... 4-7 4.5.2 Assumed cause of each phenomenon ............................................................................ 4-11 4.6 Displaying the failure log ......................................................................................................... 4-14 1

Table of Contents

4.6.1 Function of the failure log monitor ................................................................................... 4-15 4.6.2 Settings regarding the failure log..................................................................................... 4-16 4.6.3 Failure filtering function ................................................................................................... 4-20 4.6.4 Displaying the system failure log..................................................................................... 4-23 4.6.5 Frequency of the failure occurrence................................................................................ 4-24 4.7 Failure list ................................................................................................................................ 4-27

Chapter 5 Robot Diagnosis 5.1 Robot Diagnosis ........................................................................................................................ 5-1 5.1.1 Program Diagnosis ............................................................................................................ 5-1 5.1.2 OverHaul Time................................................................................................................... 5-3

2

Chapter 1 User Management

This chapter describes the user management function. 1.1 User management ......................................................................................1-1 1.1.1 Enabling user management .................................................................1-2 1.1.2 Automatic log-out setting ......................................................................1-3 1.1.3 Registering the users allowed to perform the editing operations..........1-3 1.1.4 Setting the user operation limitations ...................................................1-5 1.1.5 Copying user registration information...................................................1-6 1.1.6 User information editing .......................................................................1-8 1.2 Using the user management function .........................................................1-9 1.2.1 Log-in operation ...................................................................................1-9 1.2.2 Log-out operation ...............................................................................1-10 1.2.3 User information at log-in ................................................................... 1-11

1.1 User management

1.1 User management The user management function is a maintenance function designed to enable the robot to be operated safely in an operating environment in which a multiple number of users will be operating one robot controller. The function places limits on the editing operations performed by users for the robot, and allows only registered users to perform the allowed editing operations. Even with the registered users, it limits the operations they can perform by their level of experience: For instance, beginners may perform only simple setting operations whereas experienced operators may perform sophisticated setting operations. In this way, the function prevents mistakes that would be made if all editing operations were allowed for all users, and it does this by establishing a number of user levels. When the function is enabled, registered users must log in if they wish to perform editing operations. When users log in, they can perform only those editing operations within the range allowed for their particular user level. If no users have logged in, the protection level will be set to the BEGINNER status so no editing operations can be performed. Furthermore, when this function is enabled, the following operations for the protection level change (R314) function are restricted. (1) The protection level cannot be changed while a user has logged in. (2) The protection level cannot be changed even when there is no logged-in user. However, in order to manage this function, the level can be changed by an operator having the qualification as SPECIALIST. (3) When this controller starts up, it will always start up in the BEGINNER status regardless of the - [1 Control Constants] - [8 Protecting level select ion] setting.

IMPORTANT

• “Editing operations” to be restricted by this function refers to operations to change

the constants of the robot system and to edit the task programs or condition files. There are no restrictions on other operations without editing, such as check operation, playback operation and monitor startup. • The qualification of operator can be switched to SPECIALIST, even when this function is enabled. It is therefore recommended to change the default SPECIALIST password. For details on the steps taken to change the password, see Section 4.7.3 “How to change the passwords” in the “SETUP MANUAL”. • When the user management function is set to “enabled,” the following operations are restricted for BEGINNER operators. • Task program copying operations • Copying operations using ＜Service＞- [7 File Manager] • Step speed change operations • Step accuracy change operations • Step pass-through/positioning change operations

1-1

1.1 User management

1.1.1 Enabling user management The factory default setting of the user management function has been “Disabled.” But can be turned to “Enabled” by the following operating. The qualifications level of SPECIALIST is required to carry out the functions described in this section.

Enabling the user management function

＋

1-2

1

Press - [1 Control Constants] - [17 User Management] [1 User Management function]. ≫ The screen on which to set user management is displayed.

2

Bring the cursor to “User management function,” and press [ENABLE] +[right] to select the “Enabled” setting.

3

After the setting has been established, press f12 . ≫ The previous screen is restored.

1.1 User management

1.1.2 Automatic log-out setting The log-out operation will be automatically performed, after a certain period of time has elapsed without any operation. Even if user forgot to log out, this function serves to secure the user management function by preventing another user from operating the robot without permission.

POINT

＋

The automatic log-out function is executed only in the teach mode. Log-out is not implemented automatically in the playback mode.

1

Press - [1 Control Constants] - [17 User Management] [1 User Management Function]. ≫ When the user management function is set to “enabled,” the setting items for the automatic log-out function are displayed as shown below.

2

Bring the cursor to “Automatic log out function,” and press [ENABLE] +[right] to select the “Enabled” setting.

3

Bring the cursor to “Automatic log out time,” and set the non-operation time.

4

After the setting has been established, press f12 . ≫ The previous screen is restored.

1.1.3 Registering the users allowed to perform the editing operations The first step which must be taken is to register the users who are allowed to perform the robot editing operations. Users can be registered by following the steps described below. Up to 999 users can be registered. To set the function, the operator must have the qualifications level of SPECIALIST.

Registering the users 1

Press - [1 Control Constants] - [17 User Management] [2 User Registration]. ≫The screen on which to register the users is displayed.

1-3

1.1 User management

Table 1.1.1 User registration setting items Data registered User ID (*)

Input range

Description

3-digit number

This is the ID for identifying the users. With user management,

from 001 to 999

users are controlled using these IDs. The same ID cannot be set for more than one user.

Password

User name (*)

A number

This is the numerical value data for authenticating users when

consisting of 0

they log in.

to 8 digits

If no data is input, there will be no password for users to enter.

1 to 14

Input the name of the user to be registered here.

characters BEGINNER USER EXPERT SPECIALIST

Protect level (*)

Comment

Max. 20

Enter the protection level of the user to be registered here.

Comments on users may be entered in this field.

characters □Change program □Change arc condition setting ON/OFF □Change arc constant setting □Change sensor condition setting □Change sensor constant setting □Conversion program □File manager Input is required for all the items indicated by an asterisk (*). For details on the operation limitations, refer to “Operation Limitations” in chapter 2.

Limited operation

Check box

2

Press f8 . ≫The lowest ID among the currently unregistered user IDs is displayed in the “User ID” field.

3

Press f9 . ≫A list of the currently registered users is displayed.

This key is used to switch the user listing method between ascending order and descending order. This key is used to delete the information of the selected user.

4

1-4

After the setting has been established, press f12 . ≫The user information is registered, and the previous screen is restored.

1.1 User management

1.1.4 Setting the user operation limitations This function serves to place limitations on some operations carried out by the registered users, as shown in Table 1.1.1. Table 1.1.1 Setting items of operation limitation function and descriptions of limitations imposed Setting item

Change arc condition setting

Description of limitation imposed Limitations are imposed on the file operations (creating new files and copying, deleting and renaming existing files) for task programs and on the editing operations (step recording, insertion, deletion and overwriting). Limitations are imposed on the selection operations for the [21 Arc Welding Application] menu.

Change arc constant setting

Limitations are imposed on the selection operations for the - [14 Arc Welding Application] menu.

Change sensor condition setting

Limitations are imposed on the selection operations for the [29 Sensor Application] menu.

Change sensor condition setting

Limitations are imposed on the selection operations for the - [19 Sensor Application] menu. Limitations are imposed on the selection operations for the [9 Program Conversion] menu. Limitations are imposed on the selection operations for the [7 File Manager] menu.

Change program

Program conversion File manager

Shown below is an example of a menu which appears when limitations have been imposed on operation. The menus which cannot be selected are shown in gray.

Fig. 1.1.1 Example of menu display when operations have been limited

Setting the operation limitations 1

2

Press - [1 Control Constants] - [17 User Management] [2 User Registration]. ≫ The screen on which to register the users is displayed.

For details of the limitations imposed on each item, refer to Table 1.1.1. Using [up/down], bring the cursor to the “Limited operation” check boxes which correspond to the items to be set. For the settings on items other than the operation limitations, refer to Chapter 1 User Management.

1-5

1.1 User management

＋

3

To set an operation limitation, press [1] while holding down [ENABLE]. ≫A check mark (limitation) is now set in the box for the item specified.

＋

4

To release an operation limitation, press [2] while holding down [ENABLE]. ≫The check mark (limitation) set in the box for the item specified is now removed.

5

After performing the settings, press f12 . ≫ The settings are recorded.

1.1.5 Copying user registration information The user registration information is stored in the “USERID.CON” filename. By copying this file between robots, it is possible to transfer the user information from one robot to another. When the same user information is used for managing two or more robots, it is more convenient to copy the user registration information by the operations described below. To perform this operation, the operator must have the qualifications level of SPECIALIST or above.

Writing the user registration information

1-6

1

Press - [1 Control Constants] - [17 User Management] [2 User Registration]. ≫ User registration screen appears.

2

Press f10 on the user registration screen in section 1.2.3. ≫The folder and file in which the information is to be written are displayed.

3

Specify the folder in which the information is to be written, and press f12 . ≫This complete the writing process.

1.1 User management

Reading the user registration information 1

Press - [1 Control Constants] - [17 User Management] [2 User Registration]. ≫ User registration screen appears.

2

Press f11 on the user registration screen in section 1.2.3. ≫The folder and file from which the information is to be read are displayed.

3

Specify the file from which the information is to be read, and press f12 . ≫ If there are no problems in the file which is read, the file is read, the user information is then updated, and the previous screen is restored. ≫ If you try to read in the same user ID as the registered one, a message confirming whether or not to overwrite the existing data appears as shown below. Select “Yes” only for the ID to be updated.

1-7

1.1 User management

1.1.6 User information editing Registered user information can be edited by taking the steps below. To perform this operation, the operator must have the qualifications level of SPECIALIST or above.

Editing the user information

1-8

1

Press - [1 Control Constants] - [17 User Management] [3 Edit a registered user]. ≫The registered user list screen is displayed.

2

Select the user whose information is to be edited, and press [Enter]. ≫The information of the selected user is displayed.

3

After editing the user information, press f12 . ≫After the edited data has been registered, the previous screen is restored.

1.2 Using the user management function

1.2 Using the user management function 1.2.1 Log-in operation User must log into the robot controller to perform editing operations. There are the following three ways to log in. (1) Select R503 (Log-in) from the short-cut functions. (2) Select -[33 User management]-[1.Log in] (3) Allocate the function (code 1503) to an f key and press the f key.

f key for log-in

INFO.

When there is already any logged-in user, the user will be automatically logged out.

Logging in 1

Perform one of the above three operations. ≫ The log-in input screen is displayed.

USER NAME Enter the user ID, and the registered user name will be displayed in the user name field. 2

IMPORTANT

Input the user ID and password in this order. ≫ If there are no problems with the authentication of the password, log-in is completed, and the previous screen is restored.

If a user has forgotten the password, the password must be changed. For details on how to change the password, refer to “User information editing” in section 1.1.6 on page 1-8.

1-9

1.2 Using the user management function

3

If the user ID is not recognized in step 1 above, move the cursor to the [USER NAME] button, and press [Enter]. ≫ The screen which lists the registered users is displayed.

4

After selecting the user, press [Enter]. ≫ The previous screen is restored, and the designated user is now selected.

1.2.2 Log-out operation After finishing the editing operation, user must perform the log-out operation to leave the logged-in status. As with log-in, log-out can be performed in one of the following three ways. (1) Select R504 (Log-out) from the short-cut functions. (2) Select -[33 User management]-[2.Log out] (3) Allocate the function (code 1503) to an f key and press f key under the logged-in status. f key

INFO.

The f key for is indicated as a key for log out under the logged-in status. Automatic log-out If the automatic log-out function is set to “enabled,” a user will automatically be logged out when the non-operation time has reached the selected period of time.

Logging out

POINT

1-10

1

Perform one of the above three operations. ≫The log-out screen is displayed.

2

Select [OK], and press [Enter]. ≫After log-out, the previous screen is restored.

When log-out is initiated, the protection level returns to BEGINNER, thus limiting the subsequent editing operations. To proceed with editing again, the user needs to log in again.

1.2 Using the user management function

1.2.3 User information at log-in If the user is logged in, an icon indicating ‘logged-in’ appears in the changeable status display area. The user ID is displayed on the icon so that the logged-in user can be identified. When the user logs out, the icon is cleared. In the example given below, the user with the “001” user ID has logged in.

This section describes the steps for checking the user information at log-in and the steps for changing the user information of a logged-in user.

Checking the information of the logged-in user 1

While the user is logged in, execute the System Environment short-cut (R286). ≫The information of the currently logged-in user is now displayed.

286

User ID Log-in time User name Comment Operator class 2

Press [Reset]. ≫The previous screen is restored.

Changing the user information of the user who is logged in 1

While the user is logged in, execute the short-cut (R505) Edit own user information. ≫ The user information now appears in gray.

505

1-11

1.2 Using the user management function

Password

1-12

2

To edit the information, press f12 . ≫ The password confirmation screen now appears for authenticating the user.

3

Input the password. ≫ The previous user information screen is displayed, and status in which the user information can be edited is established.

4

Move the cursor to the item to be edited, and after editing, press f12 . ≫The edited data is stored, and the previous screen is restored.

Chapter 2 Edit logging

This chapter describes the edit logging function. 2.1 Concerning edit logging ..............................................................................2-1 2.2 Referencing the edit logging .......................................................................2-2 2.2.1 Editor logging monitor displays ............................................................2-2 2.2.2 Editor logging monitor functions ...........................................................2-7

2.1 Concerning edit logging

2.1 Concerning edit logging The edit logging function, which is designed for maintenance purposes, makes it possible to initiate a speedy recovery from logged information when an editing error has caused trouble in operation. It achieves this by leaving a log of the changes made to the files and setting items edited by the users--that is to say, who made the changes, when they were made, what changes were made and in what way they were made. Only task programs and arc welding conditions are logged in the edit logging. With the arc welding conditions, the editing of the arc welding conditions and arc welding constants are logged.

IMPORTANT

• If edit logging data is to be returned to previous values, this must be done manually. • The edit logging function logs changes made by the editing operation of user.

Automatically changed data, e.g. deviation when using a sensor, is not to be logged in the history..

Set the maximum numbers which can be acquired for the task program edit log and the edit log for the arc welding conditions. The edit logging function can be disabled by setting the edit logging numbers to zero. To set the function, the operator must have the qualifications level of EXPERT or above. The edit logging function is normally disabled. The function can be set to “Enabled” by operating as follows.

Enabling the edit logging function 1

Press - [24 Logging Data] - [5 Edit Logging Item]. ≫ The edit logging setting screen is displayed.

2

Enter the maximum number of the edit operations to be logged. A figure selected from 0-10 can be entered in the hundreds digit field. When 0 is input, the function is disabled.

Numerical value

IMPORTANT

If the entered maximum number of the edit operations to be logged is smaller than the actual number of the edit operations already logged, older log data beyond the confines of the maximum number will be deleted. 3

After the setting has been established, press f12 . ≫ After setting the maximum edit logging number, the previous screen is restored.

2-1

2.2 Referencing the edit logging

2.2 Referencing the edit logging The edit logging data can be referenced using the monitors. There are two editor logging monitors, each for a different type of logging data. “61 Program editor logging” is used for task programs whereas “62 Arc welding editor logging” is used for the arc welding conditions.

2.2.1 Editor logging monitor displays Displaying the task program editor logging monitor 1

Press - [Monitor 1-4] - [61 Program editor logging]. ≫ The task program editor logging monitor is displayed.

Operation date/time

Task program, Step number

Editing type

Editing type: Displayed in this column are the general descriptions which enable the editing operations to be identified.(See Table 2.2.1.)

2-2

2.2 Referencing the edit logging

Table 2.2.1 Editing types Operation location Program editor

Program screen editor

File manager

Program converter

Welding condition editor

Welding constants

Welding constants (welding condition databases)

Display message

Description of operation

Recorded step

Operation for teaching movement command

Inserted step

Operation for adding movement command

Overwritten step

Operation for overwriting movement command

Modified position of step Deleted step

Operation for modifying position of movement command Operation for deleting movement command or function command

Teached func step

Operation for teaching function command

Modified step

Operation for changing parameter of movement command

Undo

Undo operation after performing editing operation

Redo

Redo operation after performing undo operation

Screen Editor(Insert) Screen Editor (Modify) Screen Editor (Delete) Copy file Delete file Rename file Condition/Speed Copy step Angle XYZ shift Tool Mirror image 3D shift Language Point Shift Expansion/reduction External axis shift Format Conversion Unit Conversion Pitch Copy & Shift Multi Welding Create welding file Delete welding file Edit welding file Online modification of welding condition Edit welding constant data Create file Copy file Delete file Inserted record Deleted record Modified record

Insertion operation using screen editor Editing operation using screen editor Step deletion using screen editor Copying operation for program files Deletion operation for program files Renaming operation for program files Program conversion menu no.1 Program conversion menu no.2 Program conversion menu no.3 Program conversion menu no.4 Program conversion menu no.5 Program conversion menu no.6 Program conversion menu no.7 Program conversion menu no.8 Program conversion menu no.9 Program conversion menu no.10 Program conversion menu no.11 Program conversion menu no.12 Program conversion menu no.13 Program conversion menu no.16 Program conversion menu no.17 Creation operation for welding-related (welding, weaving, etc.) condition files Deletion operation for welding-related (welding, weaving, etc.) condition files Editing operation for existing welding-related condition data On-line modification operation for welding condition data Changing operation for welding-related constant settings File creation operation for welding characteristic, welding condition databases, etc. File copying operation for welding characteristic, welding condition databases, etc. File deletion operation for welding characteristic, welding condition databases, etc. Record addition operation for welding condition databases Record deletion operation for welding condition databases Record modification operation for welding condition databases

2-3

2.2 Referencing the edit logging 2

Using [up/down], bring the cursor to the log whose detailed information is to be displayed, and press [Enter]. ≫ The detailed information is displayed in the bottom half of the screen.

Line 1: Detailed listing description The items are displayed in the following sequence. Editing type

Filename

Step no.

[User information]

• The user information is displayed only when the user management function has been enabled.

Line 2: Guide message The guide messages are displayed when the position data has been displayed. In the example shown above, a guide message is not displayed, and a blank line is shown. Lines 3, 4: Pre-change and post-change values When, as shown above, the system has a multiple number of mechanisms, all the mechanism data is displayed when movement commands have been modified. 3

2-4

Press [Enter] again. ≫ The detailed information screen is closed.

2.2 Referencing the edit logging

Displaying the arc welding editor logging monitor 1

Press - [Monitor 1-4] - [62 Arc welding editor logging]. ≫ The arc welding editor logging monitor is displayed.

Editing type Refer to Table 2.2.1

Operation date/time Data type

Editing location • Condition filenames in the case of condition files • Task program names and step numbers in the case of direct values • Menu names in the case of constant settings Table 2.2.2 List of data types

Data type

Description

PRG

Program

AS/AE

Arc start condition, Arc end condition

WS

Weaving condition

RT

Arc retry condition

MOV

Robot operation condition

MOF

Multi-offset condition

RRS

Robot RS condition

ASM/AEM

Arc start condition in multipass welding Arc end condition in multipass welding

ASMV/AEMV

Arc start in multipass welding Arc end in multipass welding (variables)

RS

RS condition

CON

Welding constants

2-5

2.2 Referencing the edit logging 2

Using [up/down], bring the cursor to the log whose detailed information is to be displayed, and press [Enter]. ≫ The detailed information is displayed in the bottom half of the screen.

Detailed listing description Title of edited data Pre-change value Post-change value

Line 1: Detailed listing description The items are displayed in the following sequence. Editd4 • The step numbers are displayed only when the edited data are direct values rather than condition files. • The user information is displayed only when the user management function has been enabled.

Line 2: Title of edited data The names of the items displayed during editing are displayed. Line 3: Pre-edited and post-edited values The settings before and after editing are displayed. However, in the case of radio buttons and combo boxes, the numbers starting from the first of the items selected are displayed on the left as numerical values (counted from zero). On the right, a message for the data selected at the time is displayed. An example is shown on the left below. However, “-” is displayed if the message is of a type which can be changed. The example shown below on the right is a case in point.

3

2-6

Press [Enter] again. ≫ The detailed information screen is closed.

2.2 Referencing the edit logging

2.2.2 Editor logging monitor functions A number of different display methods are available for the editor logging monitors to make it easier to analyze the edit logging concerned. Before proceeding, change to the operator qualifications level of USER or above.

Using the display selection function of the editor logging monitors Select the editor logging monitor (task program or welding conditions), and press [EDIT]. ≫ The title bar of the editor logging monitor turns red, and a number of soft keys used for the editor logging monitor are displayed.

1

5

6 1

2

3

4

1

For changing the items sorted Use this key to change the items sorted in the edit logging. As the initial value, the items are sorted in the date/time sequence. Each time the key is pressed, the sorted items change as follows: Date/time sequence

POINT 2

Program number sequence

User ID sequence

The user ID sequence can be selected only when the user management function has been enabled.

For changing the sorting sequence Use this key to switch the sorting between ascending and descending order. The sorting reference is based on the items which were set using key 1 .

3

For splitting the screen Use this key to split the screen into the top half and bottom half.

2-7

2.2 Referencing the edit logging

4

For moving up/down Use this key to move up or down when the screen has been split using key 4.

5

For selecting the display This f key is displayed only when the arc welding editor logging monitor is used. Use it to change the items whose edit logging is to be displayed. As the initial value, all items are displayed. Each time this key is pressed, the items to be displayed change as follows: All items

6

2

2-8

Welding conditions

Welding constants

Clearing the edit logging Use this key to clear all the edit logging information. (For this, the operator must have the qualifications level of EXPERT or above.)

Press [RESET/R]. ≫ The title bar and soft keys are restored to the original statuses.

Chapter 3 User Check

This section describes the user check function for notifying operators of the robot inspection timing, parts replacement timing and other inspection-related information. 3.1 User Check .................................................................................................3-1 3.2 Setting the user check ................................................................................3-2 3.2.1 Setting up the check item......................................................................3-2 3.2.2 Allocating input/output signals...............................................................3-6 3.2.3 When reaching the inspection timing ....................................................3-6 3.2.4 When check and part replacement are completed ................................3-7

3.1 User Check

3.1 User Check User check function is used to notify the operators of the inspection timing of the robot and the exchange timing of the parts. The check Items and the setting values to be checked can be freely set up to 8 types in each mechanism or arc welding power supply. For example, the setting such as “giving notice of the tip replacement when the time taken for the arc welding reaches 100 min.” is possible. When reaching the specified inspection timing, the message which prompts the operator to check is displayed on the teach pendant, and, at the same time, the user maintenance signal is output to notify the operators of the inspection timing.

INFO.

 

This function corresponds to “System Maintenance Function” of conventional EX-C series robot controller. Change the operator qualification to EXPERT or higher in advance.



To output the user maintenance signal, the signal-allocation setting is required. As for the set signal in this function, refer to “3.2.2 Allocating input/output signals”.



Checking for the check item is performed in 5 min-periods. For this reason, the notice of the inspection requirement cannot be given at the time of reaching the inspection timing. (refer to e.g.1)



The check time is updated at the timing of checking the check item. For this reason, when the robot controller is powered off, the time during off-state of the controller cannot be counted as the check time. Powered OFF (refer to e.g.2) Inspection period (5 min.)

IMPORTANT Checking items

E.g.1) Even if the arc time reaches the inspection timing at this point, the notice cannot be given. The notice of the inspection can be given at the timing of “Checking items”.

Checking items

E.g.2) Even if the arc welding is performed during this time, the arc time cannot be counted. The time to be checked such as the arc time is updated at the timing of “Checking items”.

3-1

3.2 Setting the user check

3.2 Setting the user check 3.2.1 Setting up the check item Follow the procedure below to configure the check item. (1) Select the target of the check (“Mechanism” / “Arc welding”). (2) Select the mechanism to be set, when the target of the check is “Mechanism”. (In the case of one-mechanical configuration, no selection is required.) (3) Select the arc welding power supply to be set, when the target of the check is “Arc welding power supply”. (In the case of one-arc welding power supply configuration, no selection is required.) (4) Select the check item number. (Up to 8 types can be set) (5) Set the message of the inspection timing. (E.g. Tip replacement) (6) Select the suitable time category for the content of the inspection from the table below. (7) Configure the setting value to be checked. (Inspection timing) Table 3.2.1

Kind of check available when the target of the check is “Mechanism”

Kind of check Calendar Energizing Servo ON

Operation

Table 3.2.2

Kind of check available when the target of the check is “Arc welding power supply”

Kind of check Calendar

Arc ON Welding counts

Consumption of wire

INFO.

3-2

Contents The target number of months from the current date can be set. For example, in the case of giving notice of the inspection timing in a year from today. The accumulated time of the activated this controller can be set. The value shall be set by the hour. The accumulated time from the servo power-on to the servo power-off can be set. The value shall be set by the hour. The accumulated value of time taken for the automatic operation can be set. The value shall be set by the hour.

Contents The target number of months from the current date can be set. For example, in the case of giving notice of the inspection timing in a year from today. The total hours of the accumulated welding time taken for the automatic operation and the welding time during the check welding can be set. The value shall be set by the minute. The accumulated number of welding can be set in units of from the arc start to the arc end. The accumulated consumption of wire used in the welding can be set. The value shall be set in units of Kg. Note; this function can be set when the D-series welding power supply without DA is selected.

If the setting value to be checked is set to 0, the notice of the inspection cannot be given.

3.2 Setting the user check

Setting up the check item for the mechanism 1

Open - [25.Robot Diagnosis] - [5.User Check]. ≫ The list screen of the user check items is displayed.

2

Select “Mechanism” in the Check object field. Then, select the mechanism to be checked in [Unit / Mechanism]. ≫ The selected mechanism No. is displayed on the f7 key.

3

Move the cursor to the content field and press [Enter]. ≫ The setting screen of the user check items is displayed.

The setting items and the display contents are as follows.

3-3

3.2 Setting the user check Table 3.2.3 Items Mechanism No. No Content

Details The selected mechanism No. is displayed. The check item No. is displayed. The check content is set as comment. The set-up contents at this point are used for the message to prompt the operator to check. For example, in the case where the check content is set to “annual inspection”, as shown below, the message is set in the beginning of the check message and displayed on the teach pendant, when reaching the inspection timing. (Check message) 【annual inspection】Exchange the axis. After that 0 clearing of “Consumtion time until present”

Check day Last Modified Kind at time Set time (Remainder)

Calendar

3-4

Note that press [ENABLE] + [Edit] to configure the settings. Edit the check contents on the soft keyboard. The date when the check complete procedure is performed is displayed. The date when the check content is modified is displayed. Select the kind of time to be checked. For details, refer to Table 3.2.1. Set the setting value to be checked. (inspection timing) The items other than “Calendar” in Kind of check field are set in this process. The parenthetic value indicates the rest of hours for the inspection timing. Set the setting value to be checked. (inspection timing) The item, “Calendar”, in the Kind of check field is set in this process. The parenthetic value indicates the date to be checked. When this key is pressed, the inspection timing is reset. In addition, this key is also used after the check is completed. For details, refer to “3.2.4 When check and part replacement are completed”.

4

Press f9 or f10 , when changing to the different check item No., and change the check item No.

5

Set the check content and press f12 . ≫ The previous setting screen is returned. The set check content is displayed in the content field.

3.2 Setting the user check

Setting up the check item for the arc welding 1

Open - [25.Robot Diagnosis] - [5.User Check]. ≫ The list screen of the user check items is displayed.

2

Select “Welder” for Check object. Then, move the cursor to the welder field to select the welding power supply to be checked.

3

Move the cursor to the content field and press [Enter]. ≫ The setting screen of the user check items is displayed.

Setting items are as follows. Table 3.2.4 Details of the items Items Welder Kind at time

Details A selected arc welding power supply is displayed. Select the kind of time to be checked. For details, refer to Table 3.2.2.

4

Press f9 or f10 , when changing to the different check item No.

5

Set the check content and press f12 . ≫ The previous setting screen is returned. The set check content is displayed in the content field.

3-5

3.2 Setting the user check

3.2.2 Allocating input/output signals The basic I/O signals used in the user check function are as follows. The I/O signals are used for the mechanism check and the arc welding power supply. “M1 to M9” shown in the table below denotes the mechanism No. and “W1 to W4” denotes the arc welding power supply No. Those I/O signals are not allocated before shipment. If necessary to use them, refer to the instruction manuals “SET UP” to allocate the signals. Table 3.2.5 Input signal name

Input signal

Application

Function.

User chk complete 1 to 8 （M1 to M9）

Mechanism

User chk complete 1 to 8 （W1 to W4）

Arc welding power supply

The inspection timing is reset for the next checkup. The number from 1 to 8 defined as the check item No. can be set in each check item.

Table 3.2.6 Input signal name

Output signal

Application

Function.

User maintenance 1 to 8 （M1 to M9）

Mechanism

User maintenance 1 to 8 （W1 to W4）

Arc welding power supply

The signal of the check item that reaches the inspection timing is output. The number from 1 to 8 defined as the check item No. can be set in each check item.

3.2.3 When reaching the inspection timing When the inspection items specified in advance have reached the inspection timing, the message will appear on the Teach pendant. Also, the signals shown in the Table 3.2.6 are output. The check item that reaches the inspection timing is highlighted in red on the list screen of user check items.

Display of the check message

The set check contents are displayed.

Display of the check items that reach the inspection timing

The items are highlighted in red.

3-6

3.2 Setting the user check

3.2.4 When check and part replacement are completed After completing the inspection operation, the corresponding user inspection signals for check are to be reset, and the upcoming inspection timing is reconfigured. Completing the inspection and the replacement of components, be sure to implement the completion of inspection. For the check complete procedure, there are two methods as follows. (1) Manual operation Perform the check complete procedure with the teach pendant on the setting screen of the user check item. (2) Input signal Change the user chk complete signal set in each check item to ON.

User complete operation on the setting screen of user check item 1

Open [5.User Check] in - [25.Robot Diagnosis]. ≫ The list screen of the user check items is displayed.

2

Select the check item to perform the complete procedure from the check items of 1 to 8, and press [Enter]. ≫ The setting screen of the user check items is displayed.

3

Press f8 . ≫ The following confirmation screen is displayed.

4

Select “YES” and press [Enter]. ≫ The selected check item is completed. If “NO” is selected, the selected check item cannot be completed.

3-7

3.2 Setting the user check

NOTE

3-8

Chapter 4 Troubleshooting

This chapter describes the symptom and its measures on the failure code of robot controller. 4.1 When failure has occurred.........................................................................4-1 4.2 Concerning the failure details ....................................................................4-2 4.2.1 Failure category ....................................................................................4-2 4.2.2 Concerning criticality codes and failure codes ......................................4-3 4.3 Concerning “System Failure”.....................................................................4-4 4.3.1 Outline of “System Failure” ...................................................................4-4 4.3.2 How to recover and response to the failures.........................................4-4 4.4 Recovery after failing of power down detection .........................................4-5 4.4.1 Recovery after failing of power down detection.....................................4-5 4.4.2 Setting of start operation permission.....................................................4-5 4.5 Troubleshooting.........................................................................................4-7 4.5.1 Assumed cause of each error code.......................................................4-7 4.5.2 Assumed cause of each phenomenon ................................................ 4-11 4.6 Displaying the failure log .........................................................................4-14 4.6.1 Function of the failure log monitor.......................................................4-15 4.6.2 Settings regarding the failure log ........................................................4-16 4.6.3 Failure filtering function .......................................................................4-20 4.6.4 Displaying the system failure log.........................................................4-23 4.6.5 Frequency of the failure occurrence....................................................4-24 4.7 Failure list ................................................................................................4-27

These white letters will not be printed. Do not delete these letters.

4.1 When failure has occurred

4.1 When failure has occurred When a failure has occurred in the robot, the failure monitor starts, and the details of the failure (name of its category, date/time of its occurrence, description and remedial action) are displayed on the teach pendant.

(1) (5) (2) (6) (3) (7) (4)

(1)

Failure category

The name of the failure category appears here.

(2)

Failure code and cause

The failure code and cause appear here. The failure code is alphanumerically expressed. In the example of the screen shown above, “A2101” is the failure code.

(3)

Details and remedial action

The details of the failure and the remedial action to be taken appear here. Use the remedial action displayed here as a reference, and eliminate the cause of the failure.

(4)

Release method

The method used to release the failure display appears here. When all the contents of (3) and (4) do not appear in the display area, scroll the screen using [up or down].

(5)

Number of failure incidents

The figure on the right indicates the number of failure incidents which have occurred simultaneously. Only one failure incident is displayed on the screen at one time. To view other types of trouble, press [ENABLE] and [up or down].

(6)

Date/time of occurrence

The date and time of the failure occurrence appear here.

(7)

F11

When a failure that requires e.g. parts inspection or parts replacement occurs, this will show up here. (Not all of the errors support this) When this key is pressed, the inspection/part replacement procedure will be displayed.(Visual Maintenance Support Function)

(8)

f12

Press this to release the failure display. The failure display can also be released by pressing [RESET/R] twice.

4-1

4.2 Concerning the failure details

4.2 Concerning the failure details 4.2.1 Failure category The failure categories which are displayed at (1) on the previous page are established to enable where the failure has occurred to be pinpointed to some extent. Table 4.2.1

Failure category

Failure category

4-2

Main failure

Emergency stop failure

Emergency stop triggered by input from overrun, shock sensor, etc.

Control sequence failure

Failure detected by monitoring of control systems such as magnet switches and circuit protectors, etc.

CPU board failure

Watchdog timer detection or other CPU board-related failure occurrence.

Servo failure

Failure detected by IPM drive unit software.

Amplifier unit failure

Failure detected by IPM drive unit hardware.

Encoder failure

Failure detected by internal of encoder.

Teach pendant failure

Failure detected by teach pendant.

PLC failure

Failure detected by PLC.

User failure

Failure defined by the operator

Operation failure

Failure caused by an operation error made by operator.

Spot welding failure

Failure inherent to “spot welding function” (but not included above)

Arc welding failure

Failure inherent to “arc welding function” (but not included above)

FieldBus failure

Failure inherent to "FieldBus function" (but not included above)

Shift failure

Failure inherent to "Shift function" (but not included above)

Auto Calibration failure

Failure inherent to "Automatic Calibration function" (but not included above)

Sealing failure

Failure inherent to "Sealing function" (but not included above)

Vision sensor failure

Failure inherent to "Vision sensor function" (but not included above)

FLEXhand failure

Failure inherent to "FLEXhand function" (but not included above)

Preventive maintenance message

Failure inherent to "Preventive maintenance function" (but not included above)

Request maintenance

Message to require the inspection (but not included above)

4.2 Concerning the failure details

4.2.2 Concerning criticality codes and failure codes The failure codes displayed at (2) on the previous page are expressed using the following format. [Example] Control sequence failure code E1103 E

1

1

0

3

(A) (B) (A) Criticality codes The failure detected by the robot is classified into three types by their level of criticality. Table 4.2.2 Type of failure

Criticality codes Details

E (errors)

Failure caused by parts failure or internal data failure which prohibits continued operation until the cause of the failure is eliminated, and failure which may potentially injure the operator or damage the robot system if operation is continued are classified as E (errors). If E (error) occurs during the auto operation, the robot system servo is turned off.

A (alarms)

Failure which may lead to an error at a future point in time, failure which must be remedied now or failure requiring simple operations, checks and/or remedial action before robot operation or movements are continued even though it may not potentially injure the operator or damage the robot system are classified as A (alarms). If A (alarm) occurs during the auto operation, the robot system servo remains on, stopping temporarily.

I (Information)

Failure requiring that the operator and ambient devices be informed of the occurrence of irregularities even though they will not interfere with continued robot operations or movements is classified as I (information). Information may sometimes be conveyed not when a failure has occurred but when the robot is operating normally. If I (information) occurs during the auto operation, robot system displays the message on the teach pendant, operating continuously.

(B) Failure codes These are 4-digit numbers used to identify a failure. (See the following pages.)

4-3

4.3 Concerning “System Failure”

4.3 Concerning “System Failure” 4.3.1 Outline of “System Failure” The function “System Failure” is to stop the system safely when the software has detected unrecoverable errors. The errors may stem from the hardware failures such as CPU or memory defects and software failures.

Display example of teach pendant when “System Failure” occurred

4.3.2 How to recover and response to the failures When this error happens, the robot makes an emergency stop, which will disable all the following operation. Therefore, the recovering measures needs to be taken as follows. 【How to recover the failures】

Shut off the robot controller, and turn on the power again. 【How to response to the failures】

Please make a contact to our service engineers with the details of errors such as; “Operation you have done”, “Operating situation”, and “Error Code”, “Flag”, “Address”, “Stack” indicated on Teach pendant.

4-4

4.4 Recovery after failing of power down detection

4.4 Recovery after failing of power down detection 4.4.1 Recovery after failing of power down detection If power down detection failed, alarm A0004 ”Data was not saved correctly when power down.” is detected at the timing of power on, and program / step number is cleared (not selected). In case that “Motors/ON/Start sel. source” is set to “Controller”, program or step number must be selected by teach pendant before initiating playback operation for safety. On software version FDV03.28 or later, this safety function is enabled even when “Motors/ON/Start sel. source” is set to “External”. If playback operation is tried without selecting step, error E2518“Step number not designated” is detected and playback operation is denied. This error detection is functioning from shipment, so it is unnecessary to change this setting by following to the procedure written here. In case of multi-unit specification, program selection or step selection is necessary for each unit. As an exception, in case that unit is started by CALL or FORK functions, this operation is unnecessary because started unit program is initiated from step 0.

4.4.2 Setting of start operation permission When power down detection is failed, it is selectable to permit or not to permit start operation. This error detection is functioning from shipment, so it is unnecessary to change this setting. 1

Select TEACH mode.

2

Set the operator qualification to EXPERT or higher.

3

Press - [5 Operation Constants] - [1 Operation Condition] and press [Enter]. ≫ Following menu will appear.

＋

4-5

4.4 Recovery after failing of power down detection 4

Align cursor on [37 Start permission after A004] and select one by [Enable] + [Left/Right] key.

＋ Candidates

After step set

No need

5

4-6

Explanation When power down detection is failed, Step number must be selected (step set operation) before initiating playback operation for safety. If playback operation is tried without selecting step, error E2518“Step number not designated” is detected and playback operation is denied. When power down detection is failed, playback operation is permitted without selecting step.

Press F12 . ≫ Setting is stored to memory.

4.5 Troubleshooting

4.5 Troubleshooting Perform inspection and part replacement safely, observing the following instructions.

4.5.1 Assumed cause of each error code When an error occurs, you can estimate the part which causes the error from the error code. In case of an error, please investigate the cause in decreasing order of the possibility, using this table. Table 4.5.1

Assumed cause of each error code

○ ◎

○

○

Abnormal servo tracking

○

◎

○

○

22

Position Deviation error

○

◎

○

○

24

Servo CPU stop

25

Encoder Bit jump

●

●

26

Interference detected

○

○

27

Encoder data change after stop

●

●

28

Low voltage of motor power

◎

△

29

Encoder absolute data error

◎

30

Encoder absolute data failure

◎

31

Motor rotation too fast when turning the motors ON

◎

32

Over current

○

○

◎

38

Over load

○

○

◎

39

Over rotation

○

40

The abnormalities in CPU in a T/P

42

Over temperature of motor

43

Over speed

44

Over voltage of motor power

46

Over temperature of regenerative discharge resister Encoder counter overflow/underflow

50

◎ △

◎

○

Primary power supply & ambient temp.

◎

Jig controller

◎

◎

Operation panel / box

◎

Teach pendant

21

4

Reduction gear

12

The automatic saving function at the timing of the power failure detection (or controller power OFF operation) failed. The robot cannot reach the recorded point.

Motor & encoder

No TP indication

Manipulator & load

None

Control cable (robot wiring)

Riser board ○

Regenerative resistor

Sequence board ◎

IPM drive unit

CPU board ◎

I/O board

Multi power Supply unit ◎

Arc I/F board

Power unit ○

Error code

◎

◎

◎

● ○

○ ● ◎

○

○

○ ◎

○

○ ○

◎ ◎

◎ ○

○

◎

○

◎ ◎

○

◎ ◎

◎：Big possibility, ●：Big possibility or external noise, ○：Moderate possibility, △：Small possibility

4-7

4.5 Troubleshooting

Encoder battery charge low

57

Encoder count status failure Emergency stop was shortly input or Magnetic SW was cut off.

62

○

◎

◎

○

◎

○

△

○

Primary power supply & ambient temp.

55

○

Jig controller

Positional deviation

◎

Operation panel / box

54

●

Teach pendant

Encoder battery error

●

Reduction gear

52

●

Motor & encoder

Encoder data transmission failure

Manipulator & load

51

Control cable (robot wiring)

Regenerative resistor

IPM drive unit

I/O board

Arc I/F board

Riser board

Sequence board

CPU board

Multi power Supply unit

Power unit

Error code

◎ ○

○

○

○

64

Drive unit power failure

◎

65

Over travel limit switch activated

○

66

Low voltage of brake power

◎

72

Drive unit IPM failure

◎

74

Motor regeneration circuit fault

○

78

CPU board power fault.

○

◎

79

CPU board temperature fault.

○

◎

◎

80

CPU board power fault.

◎

◎

○

81

CPU board battery failure

106

The motors are not ON.

116

TP connect failure

119

The T/P connection is abnormal.

177

Primary power supply fault.

379

Safety plug is not inserted or the state of safety plug signal has changed in teach mode.

659

Teach pendant touch panel error.

777

Robot moved during Motors-ON sequence.

783

Motion stop.

○

787

Watchdog Timeout Error.

◎

902

servo clock halted

○

○

903

Servo communication stop Sequence board connect failure.

○

○

904

◎

◎

◎

○

◎

◎ ○ ○

◎

◎

◎

◎

○

◎

○

○

◎

○

◎

◎

○ ◎

○

○

◎

◎

◎

○

○

○

○

○

◎：Big possibility, ●：Big possibility or external noise, ○：Moderate possibility, △：Small possibility

4-8

4.5 Troubleshooting

Operation panel / box

Jig controller

◎

○

◎

○

○

Abnormal setting of the I/O board.

967

975

T/P selector switch is set to MANUAL. Playback unavailable because Enable SW is not released position. Magnetic switch is not active.

○

◎

976

Confirm magnet-ON (Fixed input IN28) is OFF.

○

○

1001

PWM was cut off.

◎

1016

1051

Manipulator battery warning The magnetic switch contacts were welded and stick each other. T/P SELECTOR SWITCH

1052

EXT EMG STOP

○

○

SFP

○

○

G-STOP (G_EMG)

○

○

TEACH / PLAYBACK SEL

○

○

MAT SW

○

○

HI-SPEED TEACH

○

○

EMERGENCY STOP

○

1063

T/P EMERGENCY STOP

○

1064

CRON

◎

973

1048

1053 1054 1059 1060 1061 1062

The inconsistency was detected in the sequence circuit.

905

◎ ○ ○

◎

◎ ◎

◎

○

2006

T/P selector switch is set to AUTO.

○

2101

Stop or External stop signal being given.

○

2103

The emergency stop button or the external emergency stop is inputted.

○

2104

External Motors-OFF is inputted.

○

2111

◎

◎

○

Playback unavailable because Motors-OFF sequence is being executed.

2106

○ ◎

2002

Playback unavailable because servo system has not been turned on yet. The internal operation signal was inputted in the state of external selection.

Primary power supply & ambient temp.

Teach pendant

Reduction gear

Motor & encoder

Manipulator & load

Control cable (robot wiring)

Regenerative resistor

IPM drive unit

I/O board

Arc I/F board

Riser board

Sequence board

CPU board

Multi power Supply unit

Power unit

Error code

◎

○

◎

◎

○ ◎ ○ ◎

◎

◎

◎

◎ ◎

◎

○

◎

◎

○

○

◎：Big possibility, ●：Big possibility or external noise, ○：Moderate possibility, △：Small possibility

4-9

4.5 Troubleshooting

Safety signal input line failure(Safety plug)

○

2402

Safety signal input line failure (Enable / Mat SW) Playback unavailable because the enable switch is not in the release position.

○

◎

○

◎

2973

◎

◎

○

◎ ◎

2974

Pause or External pause signal being given.

4002

Can't communicate with the welding power supply.

◎

4003

Can't communicate with the welding power supply.

◎

4016

The Arc-I/F is not found.

○

○

◎

◎

4920 9208

Servo communication initialization failure

9209

Brake fuse off

◎

9213

Drive unit power failure (15V)

◎

9216

Low voltage of sequence control power supply An inconsistency was detected in the servo failure.

9220

◎ ○

○

It was not possible to communicate with the arc welding power supply. Shock sensor detected the collision.

4099

◎

Primary power supply & ambient temp.

2401

Jig controller

2400

The external operation signal was inputted in the state of internal selection. Emergency stop signal input line failure.

2112

Operation panel / box

Teach pendant

Reduction gear

Motor & encoder

Manipulator & load

Control cable (robot wiring)

Regenerative resistor

IPM drive unit

I/O board

Arc I/F board

Riser board

Sequence board

CPU board

Multi power Supply unit

Power unit

Error code

◎ ○ ◎

○

◎

○

◎

◎

◎ ○

○

○

○ ○

○

9229

Brake fuse off.(F1)

○

○

9240

Drive unit power failure (24V)

○

○

9241

Drive unit precharge failure

◎

9242

Drive unit phase lack.

○

◎

○

◎

◎：Big possibility, ●：Big possibility or external noise, ○：Moderate possibility, △：Small possibility

4-10

4.5 Troubleshooting

4.5.2 Assumed cause of each phenomenon Possible causes of failures are summarized below. We have prepared a table respectively for three patterns of failure occurrence. Refer to the corresponding table to estimate the part causing the failure.

In case of a failure occurring right after program start-up If any of the following phenomena or errors occurs right after the control power ON and program start-up, the problem may lie in the connection between the corresponding connector and the printed circuit board, or connection of the related cable. In case of following problem, check whether the corresponding connector is correctly connected. Table 4.5.2 No.

Assumed cause of each phenomenon 1 Error code

Phenomenon / Error message

None

1

Power is not turned on.

None None None

2

None None None

Teach pendant screen is black.

None error

is

Part estimated to have caused the error Connector name Name of the unit (board) Primary power Circuit breaker U and W Customer’s plant CNPW Multi power supply unit CNRSTIN Power unit TP cable CNTP Sequence board CNPW Multi power supply unit Sequence board (connection) CNP24V１ CNNLX CPU board (connection) Multi power supply unit CNPS (connection) TP cable Teach pendant CNLAN2 CPU board TP cable CNLAN2 Teach pendant CPU board

3

“TPE0002” communication displayed on teach pendant

4

Key operation is impossible on teach pendant

None

5

Cooling fan does not function (discharge resistor / IPM drive unit).

None

CNFAN

6

Cooling fan does not function (CPU rack).

None

CNFAN

7

Over travel LS is detected

E0065 E0065 E0065

CNEC1 CN78E

8

Error in regeneration discharge resistor temperature rise

E0046

CNR

9

Error in servo communication start

E9208 E9208 E9208 E9208

10

Drive unit lacking of power phase

E9242

11

Detection of power failure

E0177

CNCOM CNVP CNP24V CNLAN3 Primary power V CNPW

TPE0002

Cooling fan

Over travel LS

IPM drive unit Multi power supply unit

Cooling fan Multi power supply unit IPM drive unit IPM drive unit Manipulator IPM drive unit IPM drive unit IPM drive unit Multi power supply unit CPU board Circuit breaker Customer’s plant Multi power supply unit

4-11

4.5 Troubleshooting

In case of a failure occurring at the time of servo power ON If any of the following phenomena or errors occurs before or at the time of turning on of the servo power, the problem may lie in the connection between the corresponding connector and the printed circuit board, or connection of the related cable. In case of a following problem, check whether the corresponding connector is correctly connected. Table 4.5.3 No.

Assumed cause of each phenomenon 2 Error code

Phenomenon / Error message

None 1

Power is not turned on.

None None None

2

None None None

Teach pendant screen is black

None 3

Teach pendant screen is white.

4

“TPE0002” communication displayed on teach pendant

5

Cooling fan does not function (discharge resistor / IPM drive unit).

None

CNFAN

6

Cooling fan does not function (CPU rack).

None

CNFAN

7

Over travel LS is detected

E0065 E0065 E0065

CNEC1 CN78E

Over travel LS

Multi power supply unit IPM drive unit IPM drive unit Manipulator

8

Error in regeneration discharge resistor temperature rise

E0046

CNR

IPM drive unit

CNLAN3 CNCOM CNRST CNVP CNP24V CNPW CNMS

error

is

TPE0002

Cooling fan IPM drive unit Multi power supply unit

Cooling fan

9

Servo communication stopped

10

Magnet switch contact does not open

E0903 E0903 E0903 E0903 E0903 E0903 E1048

11

Servo error not coincident

E9220

CNSV

12

Shock sensor is detected

13 14 15 16 17

Detection of power failure Announcement of “data not saved” Brake power supply voltage drop Motion stopped Motor power down Error in regeneration discharge resistor temperature rise

A4920 A4920 E0177 A0004 E0066 E0783 E0028

CNMCH CNEC1 CNPW CNPW CNRST CNPW CNRST

CPU board IPM drive unit IPM drive unit IPM drive unit Multi power supply unit Multi power supply unit IPM drive unit IPM drive unit Sequence board IPM drive unit IPM drive unit Multi power supply unit Multi power supply unit IPM drive unit Multi power supply unit IPM drive unit

E0046

CNR

IPM drive unit

18

4-12

None

Part estimated to have caused the error Connector name Name of the unit (board) Primary power Circuit breaker U and W Customer’s plant CNPW Multi power supply unit CNRSTIN Power unit TP cable CNTP Sequence board CNPW Multi power supply unit Sequence board (connection) CNP24V１ CPU board (connection) CNNLX Multi power supply unit CNPS (connection) CNTP Sequence board TP cable CNLAN2 Teach pendant CPU board

4.5 Troubleshooting

In case of a failure occurring during servo operation If any of the following phenomena or errors occurs after turning on of the servo power, the problem may lie in the connection between the corresponding connector and the printed circuit board, or connection of the related cable. In case of a following problem, check whether the corresponding connector is correctly connected. Table 4.5.4 No.

Assumed cause of each phenomenon 3 Error code

Phenomenon / Error message

None 1

Power is not turned on.

None None None None None None None

Part estimated to have caused the error Connector name Name of the unit (board) Primary power Circuit breaker U and W Customer’s plant CNPW Multi power supply unit Power unit CNRSTIN TP cable CNTP Sequence board Multi power supply unit CNPW Sequence board (connection) CNP24V１ CPU board (connection) CNNLX CNTP Sequence board TP cable Teach pendant CNLAN2 CPU board

2

Teach pendant screen is black

3

Teach pendant screen is white.

4

“TPE0002” communication displayed on teach pendant

5

Cooling fan does not function (discharge resistor / IPM drive unit).

None

CNFAN

6

Cooling fan does not function (CPU rack).

None

CNFAN

7

Power failure of the servo

8

Over travel LS is detected

None E0065 E0065 E0065 E0903 E0903 E0903 E0903 E0903 E0903

CNMS CNEC1 CN78E

E9220

CNSV CNMCH CNEC1 CNPW CNPW CNRST CNVP CNBK2 CNSW

Multi power supply unit IPM drive unit IPM drive unit IPM drive unit Manipulator CPU board IPM drive unit IPM drive unit IPM drive unit Multi power supply unit Multi power supply unit IPM drive unit Sequence board IPM drive unit IPM drive unit Multi power supply unit Multi power supply unit IPM drive unit IPM drive unit IPM drive unit IPM drive unit

E0074

CNR

IPM drive unit

E0028

CNRST

IPM drive unit

E0046

CNSR

IPM drive unit

error

is

TPE0002

Cooling fan

9

Servo communication stopped

10

Servo error not coincident

11

Shock sensor is detected

12 13 14 15

Detection of power failure Announcement of “data not saved” Brake power supply voltage drop Motion stopped

A4920 A4920 E0177 A0004 E0066 E0783

16

Error in motor temperature rise

E0042

17 18 19

Error in motor power supply / regeneration discharge circuit Motor power supply voltage drop Error in regeneration discharge resistor temperature rise

Over travel LS CNLAN3 CNCOM CNRST CNVP CNP24V CNPW

IPM drive unit Multi power supply unit

Cooling fan

4-13

4.6 Displaying the failure log

4.6 Displaying the failure log This function enables to display the failure log occurred in the past.

Displaying the failure log 1

Proceed to - [Monitor 1-4] – [Failure Log]. ≫ The “Failure Logging Monitor” appears.

Date of failure occurrence 2

Failure code

Details

Move a cursor to a specific failure to display its details using [Up/Down] key, and press [Enter]. ≫The lower half of the screen shows detailed information.

Date of failure occurrence

Category of failure cause

Failure code Details Location of error Details and measures How to release the failure 3

4-14

Again, press [Enter]. ≫ The details screen closes.

4.6 Displaying the failure log

4.6.1 Function of the failure log monitor On the failure log monitor, various functions are provided to analyze the failures in particular.

Using the display function of failure log monitor 1

Activate the “Failure Logging Monitor”, and press [Edit]. ≫ A title bar on the monitor turns red, and its dedicated soft keys appear.

6

1

7

2

8

3

9

4

5

1

Filter Enables to pick up a particular failure to display. (The operator qualification of EXPERT or higher is required.) Page 4-20, “4.6.3 Failure filtering function”.

2

Sort Changes a sorting factor of the failure log. Since the default is set at “Date”, the items change in sequence as shown below by pressing this key every time. Date

3

Code

Prog.

Step

Sort Switches ascending/descending sort. The sorting factor is as specified in [2].

4

Move Moves up and down when the screen separation is set ON in [5].

5

Screen Separation The screen is split into two sections.

6

Filter Changes a level of importance to display the failure log. Since the default is set to display the logs of all levels of importance, the items change in sequence as shown below by pressing this key every time. All

Error

Alarm

Information

4-15

4.6 Displaying the failure log

7

Failure Log Clear Clears the failure log. (The operator qualification of EXPERT or higher is required.)

8

Fail Freq. The frequency of failure occurrence is graphically indicated and analyzed. (The operator qualification of EXPERT or higher is required.) Page 4-24, 4.6.5 “Frequency of the failure occurrence”.

9

System Failure The frequency of failure occurrence is graphically indicated and analyzed. (The operator qualification of EXPERT or higher is required.) Page 4-23, 4.6.4 “Displaying the system failure log”.

2

Press [Reset/R] key. ≫ The title bar and soft keys are restored.

4.6.2 Settings regarding the failure log The constants regarding the failure log are given in the table below. Table 4.6.1 Constant name

4-16

Constants regarding the failure log Details

Setting item/ range

Default

Error

Specifies Save/Not save for the failure of which level of importance is “Error”.

Save/ Not save

Save

Alarm

Specifies Save/Not save for the failure of which level of importance is “Alarm”.

Save/ Not save

Save

Information

Specifies Save/Not save for the failure of which level of importance is “Information”.

Save/ Not save

Not save

Separate save

Set this constant to “Enable” to save failure logs of the specified failure code separately from the other normal failures. When setting to “Enable”, an appropriate failure code shall be designated in advance.

Disable/Enable

Disable

Info. by failure logs

Specifies Not occur/Occur whether or not to output the information by the number of failure logs. If setting to “Occur”, Information (I2412) is output when the remaining of failure logs reaches the specified number of “Remainder of logs”.

Not occur/ Occur

Not occur

Remainder of logs

When setting “Info. by failure logs” to “Occur”, the remainder of logs shall be specified to output the Information.

0～99

0

Info. by separate logs

Specifies Not occur/Occur whether or not to output the information by the number of logs to save separately. If setting to “Occur”, Information (I2413) is output when the remaining of failure logs reaches the specified number of “Remainder of separate logs”.

Not occur/ Occur

Not occur

Remainder of separate logs

When setting “Info. by separate logs” to “Occur”, the remainder of logs shall be specified to output the Information.

0～999

0

4.6 Displaying the failure log

POINT

Usually, the maximum of 200 failure logs can be stored. Exceeding this number, the logs are to be deleted in the chronological sequence, the oldest one first. When the “Separate save” has been set to “Enable”, the failure logs even exceeding 200 will not be deleted but moved and saved in a different area as long as those are specified by the failure code. Note that the different area can store the maximum of 1000 failure logs. Exceeding this number, the logs are to be deleted in the chronological sequence, the oldest one first.

Set the operator qualification to EXPERT or higher in advance.

Configuring the failure log 1

Open - [24 Logging Data] – [1 Error Logger Item]. ≫ The “Error Logger Item” screen appears.

2

Configure the log by the following operation. To select the constant for setting: Use [Up/Down] key. To enter the value: Enter a value using the numerical key, and press [Enter].

Entering a value

To change the choice: Press [Right/Left] with holding [ENABLE].

＋ 3

IMPORTANT

Upon completion of the setting, press f12. ≫ The setting is saved to restore the original screen.

To set the Separate save to “Enable”, an appropriate failure code shall be designated in advance.

4-17

4.6 Displaying the failure log

Specifying the failure code to save separately 1

Set the Separate save to “Enable”. ≫ The f8 soft key appears.

2

Press f8 key. ≫ The “Select Failure Log” screen appears.

3

Specify the failure code to save separately by the following operation. To change the failure code input field to configure: Use [Up/Down] key. To scroll the page: Press f9 and f10 key.

Entering a value

4-18

To directly enter the value with numerical keys: Enter a value using the numerical key, and press [Enter].

4.6 Displaying the failure log To enter the value referring to the registered failure code: Press f8 key. ≫The “Failure code” screen appears.

Align a cursor on a specific failure code to select using [Up/Down] key, and press [Enter]. ≫The “Select Failure Log” screen is restored with the desired code selected. 4

Upon completion of the setting, press f12. ≫ The failure code to save separately is set, and the “Error Logger Item” screen is restored.

4-19

4.6 Displaying the failure log

4.6.3 Failure filtering function The Failure Logging Monitor enables to filter a specified failure to display. Table 4.6.2 Item

POINT

Type of failure Details

Failure code

Failures of the specified failure code are filtered.

0～9999

Classification code

Failures categorized in the specified classification code are filtered. For details, Page 4-2, “4.2.1 Failure category”.

－

Mode

The failures occurred in the specified mode are filtered. There are two alternatives of mode; Teach mode and Playback mode.

Teach mode/ Playback mode

Unit

Only the failures of the specified unit number are filtered.

1～9

Mechanism

Failures occurred in the mechanism of the specified mechanism number are filtered.

1～9

Axis

Only servo-related failures occurred in the axis of the specified axis number are filtered.

1～9

Welder

Only failures occurred in the welder of the specified welder number are filtered.

1～4

Sensor

Only failures occurred in the sensor of the specified sensor number are filtered.

1～12

Program

Only failures occurred in the specified program number are filtered.

0～9999

Step

Only failures occurred in the specified step number are filtered.

0～9999

It is available to select two or more filtering items by AND condition. Set the operator qualification to EXPERT or higher in advance.

4-20

Setting range in filtering

4.6 Displaying the failure log

Filtering and displaying the failure 1

Activate the “Failure Logging Monitor”, and press [Edit]. ≫A title bar on the monitor turns red, and its dedicated soft keys appear.

2

Press f2 key. ≫The “Failure Filtering Setting” screen appears.

3

Move a cursor to the desired filtering item using [Up/Down] key.

Press [Enable] + [1]. ≫ The selected item is check-marked. To uncheck the item, press [Enable] + [2].

＋

4

Entering a value

Align a cursor on the value input field or the desired field using [Up/Down/Right/Left] key, and set the conditions.

To enter the value: Enter a value using the numerical key, and press [Enter]. To choose from the list: Press [Enter] to select the desired item from the pull-down list, and press [Enter] again.

4-21

4.6 Displaying the failure log To select the failure code (available only when the filtering item is set at “Failure code”): Align a cursor on the value input field of failure code. ≫ Then, f8 key appears. Press f8 key. ≫The “Failure code” screen appears.

Align a cursor on a specific failure code to select using [Up/Down] key, and press [Enter]. ≫ The “Failure Filtering Setting” screen is restored with the failure code entered. 5

4-22

Upon completion of the setting, press f12. ≫ The Failure Logging Monitor is restored, which displays only a specified failure.

4.6 Displaying the failure log

4.6.4 Displaying the system failure log It is available to display the system failure log. To use this function, specify the operator qualification to EXPERT or higher in advance.

Displaying the system failure log 1

Activate the “Failure Logging Monitor”, and press [Edit]. ≫ A title bar on the monitor turns red, and its dedicated soft keys appear.

2

Press f10 key. ≫The system failure log appear.

3

Press f10 key. ≫ The screen returns to 1.

4

Press [Reset/R] key. ≫ The title bar and soft keys are restored.

4-23

4.6 Displaying the failure log

4.6.5 Frequency of the failure occurrence Graphically displaying the frequency of failure occurrence, failure analysis is available. Monitoring items on the graph can be selected from the ones given in the table below. Table 4.6.3

Monitoring item

Item

Details

Failure code

Graphically displays the frequency of failure occurrence.

Program

Graphically displays the frequency of failure occurrence by every program.

Program - Step

Graphically displays the frequency of failure occurrence by every step.

Time

Graphically displays the frequency of failure occurrence by the time. It is indicated hour-by-hour between 0 and 23.

User Check

Graphically displays the frequency of failure occurrence by the time of user check. “Chapter For details of the time of user check, see 4．User Check”.

Set the operator qualification to EXPERT or higher in advance.

Graphically displaying the frequency of failure occurrence 1

Activate the “Failure Logging Monitor”, and press [Edit]. ≫ A title bar on the monitor turns red, and its dedicated soft keys appear.

2

Press f9 key. ≫ The frequency of failure occurrence is graphically displayed.

1

6

2

7

3

8

4

5

Monitoring item

4-24

Frequency of failure in each item

Graphical indication of the frequency of failure in each item

4.6 Displaying the failure log

1

Monitor Item Setting Specifies the monitoring item for the graph. Page 4-25, ”Specifies the monitoring item for frequency”.

2

Filter Filters and displays a specific failure. Page 4-20, “4.6.3 Failure filtering function”.

3

Sort Changes the sorting factor either to "Val." or “Item”. The default is set at “Val”.

4

Move Moves up and down when the screen separation is set by [5].

5

Screen Separation The screen is split into two sections.

6

Cause Classification Graphically displays the frequency of classification of failure cause. Pressing this key again, the screen is restored. For details of the cause classification, see category”.

7

Page 4-2, “4.2.1 Failure

Failure Log Clear Clears the failure log.

8

Fail Log The screen returns to 1.

3

Press [Reset/R] key. ≫ The title bar and soft keys are restored.

Specifies the monitoring item for frequency 1

Press f1 key. ≫ The “Setting of the Failure Frequency Monitor” screen appears.

4-25

4.6 Displaying the failure log

＋

2

Press [Enable] + [Right/Left] key to select the item for graphic display.

3

The following settings are required if you have selected “User Check”. ≫The setting items “User Check Object”, “User Check Content”, and “Division unit of user check” become available.

The setting item and its details are as follows. Item

Details

User Check Object

Selects Mechanism/Arc welding and its corresponding number.

User Check Content

Selects the inspection details specified by “User Check”.

Division unit of user check

Specifies the unit for each user check time. Note that the inspection item determines the unit to be used as shown below. Check item Mechanism

Category of time Calendar Current-conducting time

Arc welding

Servo ON time

H H

Calendar

Month

Arcing time

Minute

Number of welding times

4-26

H

Operating hours

Amount of wire consumption

4

Unit Month

Time Kg

Upon completion of the setting, press f12. ≫ The Failure Logging Monitor is restored, which displays a graph of the specified items.

4.7 Failure list

4.7 Failure list All the failure codes are listed from the next page.

4-27

Error code list No.

Condition

Contents

CPU board failure CPU board failure

Program check-sum fault. The automatic saving function at the timing of the power failure detection (or controller power OFF operation) failed.

12

Servo failure

The robot cannot reach the recorded point.

Error occurs when abnormality is found in the work program. When the primary power is turned OFF or when the primary power voltage dropped abnormally, the current status of the controller (e.g. step number etc.) will be automatically saved to the internal memory. This error will be displayed if the automatic saving process failed. This error occurs when the robot does not reach the position even if ten seconds have passed since the command position was output to the robot.

20

Servo failure

Abnormal velocity command. Modify abnormal axis motion.

Abnormal velocity command data is calculated.

21

Servo failure

Abnormal servo tracking

This failure occurs when the robot does not follow to the command position.

22

Servo failure

Position Deviation error

This failure occurs when the deviation between the command and encoder data position exceeds the set permissible deviation.

24

Amplifier unit failure

Servo CPU stop

This failure occurs when the servo CPU on servo substrate stops.

25

Servo failure

Encoder Bit jump

This failure occurs when the amount of the encoder current position exceeds the borderline for the encoder bit jump detection.

26

Servo failure

Interference detected

This failure occurs when the robot manipulator collides with something.

27

Servo failure

Encoder data change after stop

This failure occurs when the encoder data continues to change while the command position value is stopping.

28

Amplifier unit failure

Low voltage of motor power

This failure occurs when the Motor power supply voltage(P-N) are lower than regular setting level.

29

Encoder failure

Encoder incremental data error

Error occurs when fault is detected in the encoder.

2 4

4-28

Class

Please copy the file by the file restore.

Error reset.

Severity Teach Auto Alarm Alarm

(1)Check the output voltage of the power supply unit (5V). (2)Replace the power supply unit. (3)Replace the sequence board.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

(1)Please confirm whether the robot manipulator interferes in something. (2)Please confirm that the Pay-load is within the nominal rating. (3)Check if the concerned axis is hard to move by using brake release function. (4)Replace the drive unit. (5)Replace the motor. (6)Check the internal wiring of the robot or the control cable between the robot and the controller by referring to the instruction manual "MANIPULATOR". Modify abnormal axis motion to be minimized. Contact our service department in case axis motion is not so big.

Please do error reset or turn on the drive preparation.

Error

Error

Error

Error

on

on

After removal of failure, please carry out "failure-reset". After removal of failure, please carry out "failure-reset".

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

After removal of failure, please carry out "failure-reset".

Error

Error

Error

Error

on

on

After removal of failure, please turn on power supply of the controller again. After removal of failure, please carry out "failure-reset".

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

After removal of failure, please carry out "failure-reset".

Error

Error

Error

Error

on

on

After removal of failure, please carry out "failure-reset".

Error

Error

Error

Error

on

on

After removal of failure, please carry out "failure-reset".

Error

Error

Error

Error

on

on

After removal of failure, please turn on power supply of the controller again.

Error

Error

Error

Error

on

on

Measure

(1)Check the primary power voltage. (2)Check whether the actual load exceeds the maximum payload value or not. (3)Check whether the ambient temperature is not below 0 degree. (4)Check if the concerned axis is hard to move by using brake release function. (5)Replace the drive unit. (6)Replace the motor. (7)Check the internal wiring of the robot or the control cables between the robot and the controller by referring to the instruction manual "MANIPULATOR". (1)Check whether the robot manipulator interferes with something. (2)Check whether the actual load exceeds the maximum payload value or not. (3)Check if the concerned axis is hard to move by using brake release function. (4)Replace the drive unit. (5)Replace the motor. (6)Check the internal wiring of the robot or the control cables between the robot and the controller by referring to the instruction manual "MANIPULATOR". (1)Power ON again. (2)Please check the voltage of the 24V power supply on servo substrate (UM351(L21700X00)). (3)Please replace the drive unit.

(1)Please confirm whether connectors CNEC1/CNEC2/CN78E on the servo board UM351 (L21700x00) are correctly connected. And, check the damages on them. (2)Please confirm connector CNR4/CN2 between the controller and the robot. (3)Please confirm the power supply voltage of the encoder. For details, refer to the instruction manual "CONTROLLER MAINTENANCE MANUAL". (4)Please replace the drive unit. (5)Please replace the power supply unit. (6)Please replace the motor or the encoder. (7)Please confirm the wiring in the robot manipulator referring to the instruction manual "MANIPULATOR". (1)Please confirm whether the robot manipulator interferes with something. (2)Please confirm that the weight, center of gravity, moment of inertia of the tool match with the actual load. (3)Please lower the detection level or invalidate the problem part by using FN230. (4)Check if the concerned axis is hard to move by using brake release function. (5)Please confirm the cable between the controller and the robot.(U,V,W and brake control line) (6)Please replace the drive unit. (1)Please check whether the connectors CNEC1/CNEC2/CN78E on the servo board UM351(L21700X00) are correctly connected. And, check the damages on them. (2)Please check whether CNR4/CN2 is correctly connected. (3)Please check the power supply voltage of the encoder. (4)Please check that the Pay-load is within the nominal rating. (5)Please check if the manipulator interferes with something or not. (If this error occurs when the robot stops) (6)Please replace the drive unit. (7)Please replace the power supply unit. (8)Please replace the power supply unit. (9)Please replace the motor or the encoder. (10)Please check the wiring in the robot manipulator or the control cables (wire harness) by referring to "MANIPULATOR MANUAL". (1)Please check the connection of CNRST on the front of drive unit correctly. (2)Please check that a primary voltage of the controller is within the specification. (3) Please confirm that a power supply to CNRST is around AC200V. If the supply voltage is low, please replace a power unit. If the supply voltage is within the specification, please replace the drive unit. (1)Check if the encoder power supply voltage is normal or not (Refer to "CONTROLLER MAINTENANCE MANUAL"). (2)Please reset the encoder. (3)Check encoder wiring. (4)Replace the motor or the encoder.

Release

Output Teach Auto Alarm Alarm

Logger Teach Auto on on

Error code list 30

Encoder failure

Encoder absolute data failure

This failure occurs when an absolote data fault is detected inside the encoder.

(1)Please turn OFF the controller power. (2)Please replace the motor or the encoder. (3)Please check the power supply voltage of the encoder refering to "CONTROLLER MAINTENANCE MANUAL". (4)Please check the wiring of the encoder.

31

Encoder failure

Motor rotation too fast when turning the motors ON

This failure occurs if at the time of turning Motors ON, the encoder speed is too fast.

(1)Please check the power supply voltage of the encoder refering to "CONTROLLER MAINTENANCE MANUAL". (2)Please check the wiring of the encoder. (3)Please reset the encoder.

32

Servo failure

Over current

This failure occurs when the current in the drive unit exceeds the rated value.

33

Servo failure

Synchronous failure of servo command.

36

Encoder failure

Encoder Initialize error

Synchronous failure of servo command occurred in servo system. Error occurs when fault is detected in the encoder.

(1)Please check whether the robot manipulator interferes with something. (2)Please check that the Pay-load is within the nominal rating. (3)Check if the concerned axis is hard to move by using brake release function. (4)Please check the connectors CNP1-8, CNBK1, CNBK2,and CNSW. (5)Please replace the drive unit. (6)Please replace the motorof the concerned axis. (7)Please check the internal wiring of the robot. (motor current U,V,W and brake control line) (8) Please check the control cables (wire-harnesses) between the controller and the robot manipulator. (9)Please adjust the over current detection level ("Peak Amps error")(external axis). If error persists, Contact our service department.

37

Encoder failure

Over temperature of encoder

This failure occurs when the encoder temperature rises abnormally.

38

Servo failure

Over load

This failure occurs when the current in the motor or drive unit exceeds the rated value.

39

Servo failure

Over rotation

This failure occurs when the number of rotations of motors exceeds a maximum rotation speed limit.

40

TP failure

The abnormalities in CPU in a T/P

CPU built in the teach pendant stopped.

41

Encoder failure

Encoder Memory Access error

Error occurs when fault is detected in the encoder.

42

Amplifier unit failure

Over temperature of motor

This failure occurs when the motor temperature rises abnormally.

43

Amplifier unit failure

Over speed

This failure occurs when the rotation speed of motors is abnormal.

44

Amplifier unit failure

Over voltage of motor power

This failure occurs when the Motor power supply voltage(P-N) are higher than regular setting level.

46

Amplifier unit failure

Over temperature of regenerative discharge resister

This failure occurs when the temperature of the regenerative discharge resister rises abnormally.

(1)Please turn OFF the controller power. (2)Please replace the motor or the encoder. (3)Please check the power supply voltage of the encoder refering to "CONTROLLER MAINTENANCE MANUAL". (4)Please check the wiring of the encoder.

(1)Please confirm that the Pay-load is within the nominal rating. (2)Please stop the robot in order to lowering the motor temperature, and restart. (3)If failure persists, please lower the operation speed of the robot. (4) Please exchange motor and encoder. (1)Please check whether the robot manipulator interferes with something. (2)Please check that the Pay-load is within the nominal rating. (3)Check if the concerned axis is hard to move by using brake release function. (4)Please check the connectors CNP1-8, CNBK1,CNBK2, or CNSW on the drive unit. (5)Please replace the drive unit. (6)Please replace the concerned motor. (7)Please check the internal wiring of the robot. (motor current U,V,W and brake control line). (8)Please check the control cables (wire-harnesses) between the controller and the robot manipulator. (9)Please adjust the over load detection level ("Overload error") (external axis). (1)Please check whether the robot manipulator interferes with something. (2)Please check whether the setting of the Pay-load and center of gravity are correct. (3)Check if the concerned axis is hard to move by using brake release function. (4)Please replace the motor or the encoder. (5)Please replace the drive unit. (6)Please replace the manipulator wirings. Please check whether there are any abnormalities in the T/P and the connection cable. Please turn OFF and ON the main power supply. Please replace the T/P, when an error still comes out. (1)Please turn OFF the controller power. (2)Please replace the motor or the encoder. (3)Please check the power supply voltage of the encoder refering to "CONTROLLER MAINTENANCE MANUAL". (4)Please check the wiring of the encoder.

(1)Please check that the Pay-load is within the nominal rating. (2)Please check the wiring of the motor thermostat refering to "CONTROLLER MAINTENANCE MANUAL". (3)Please check the connector CNBK2 on the drive unit. (4)Please stop the robot in order to lowering the motor temperature, and restart. (5)If the failure persists, please lower the operation speed of the robot or add a DELAY function (FN50) in the program to lower the duty. (1)Please check whether the connector CNEC1/CNEC2/CN78E on the servo board UM351 (L21700X00) are correctly connected. (2)Please replace the drive unit. (3)Please replace the motor or the encoder. (4)Please check the manipulator wirings and the control cables (wire-harness) between the controller and the manipulator referring to "MANIPULATOR MANUAL". (1)Please check whether CNR is correctly connected. (2)Please check the discharge register(5-ohm or 30-ohm) (3)Please replace the drive unit.

(1)Check if the fans are operating. (2)Please check the wiring of the sensor. (3)Please replace the discharge register. (4)Please replace the drive unit. (5)Please check the voltage of the 24V power supply. (6)Please replace the multi power supply unit. (7)If the failure persists, please lower the operation speed of the robot or add a DELAY function (FN50) in the program to lower the duty.

After removal of failure, please turn on power supply of the controller again. After removal of failure, please turn on power supply of the controller again. After removal of failure, please carry out "failure-reset".

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Error reset.

Error

Error

Error

Error

on

on

After removal of failure, please turn on power supply of the controller again. After removal of failure, please carry out "failure-reset". After removal of failure, please carry out "failure-reset".

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

After removal of failure, please carry out "failure-reset".

Error

Error

Error

Error

on

on

Turn on the power again.

Error

Error

Error

Error

on

on

After removal of failure, please turn on power supply of the controller again. After removal of failure, please carry out "failure-reset".

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

After removal of failure, please carry out "failure-reset".

Error

Error

Error

Error

on

on

After removal of failure, please carry out "failure-reset". After removal of failure, please carry out "failure-reset".

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

4-29

Error code list 50

Encoder failure

Encoder counter overflow/underflow

This failure occurs when the counter overflow/underflow occured inside the encoder unit.

(1)Please turn ON the power supply of the controller again. (2)Please replace the motor or the encoder. (3)Please check the power supply voltage of the encoder refering to "CONTROLLER MAINTENANCE MANUAL". (4)Please check the wiring of the encoder.

51

Servo failure

Encoder data transmission failure

This failure occurs when the communication data with the encoder is abnormal or the encoder has been disconnected.

52

Encoder failure

Encoder battery charge low

This failure occurs when the voltage of the battery in the encoder has decreased.

(1)Please check whether the connectors CNEC1/CNEC2/CN78E on the servo board UM351 (L21700X) are correctly connected. (2)Please check whether the CNR4 or CN2 is correctly connected. And check the damages on them. (3)Please confirm the power supply voltage of the encoder. (4)Please replace the drive unit. (5)Please replace the motor or the encoder. (6)Please check the manipulator wirings and the control cables (wire-harness) between the controller and the manipulator referring to "MANIPULATOR MANUAL". (1)Please reset the encoder and turn on power supply of the controller again.(2)Please confirm battery of abnormal axis. (3)Please confirm battery voltage(up to 3.6V). (4)Please replace motor and encoder. (5)Please confirm wiring of battery and encoder. (6)Please replace drive unit.

53

Servo failure

Invalid encoder type

This failure occurs when the invalid encoder type is selected.

Please check [Mechine Constants] [Motor and Encoder][Encoder type].

54

Servo failure

Encoder data abnormal

This failure occurs when the change of the encoder data is abnormal.

(1)Please check the supply voltage of the encoder refering to "CONTROLLER MAINTENANCE MANUAL". (2)Please check the wiring of the encoder.

55

Encoder failure

Motor rotation too fast when power off

(1)Please reset the encoder and turn on power supply of the controller again.(2)Please replace motor and encoder. (3)Please check the wiring of the encoder. (4)Please check the supply voltage of the encoder refering to "CONTROLLER MAINTENANCE MANUAL". (5)Please replace the drive unit. (6)Please replace the multi power supply unit.

56

Servo failure

Encoder pre-load failure

Because the motor had been rotated at high speed when the power off, it became impossible to detect the the absolute amount of the encoder rotation correctly. (This detection is done inside the encoder unit and the error status is sent to the controller.) This failure occurs if the pre-load operation of the encoder was not correctly done.

57

Encoder failure

Encoder count status failure

This failure occurs when the Encoder data(absolute) is abnormal.

59

Control failure

Can't follow conveyer speed.

62

Control failure

Emergency stop was shortly input or Magnetic SW was cut off.

63

CPU board failure

Controller temperature fault.

Error occurs when the robot system can not perform its task at the current conveyer speed. This error occurs when it has a condition that communication cable, connection of Emergency stop, Mode select signals(Teach/Play) or Safety plug is open or poor connection. Error occurs when the temperature of the core of the controller becomes abnormality high.

64

Amplifier unit failure

Drive unit power failure

This failure occurs when drive unit power VP15(+15V) was not supplied.

(1)Please check the wiring of drive unit. (2)Please replace the drive unit.

65

Amplifier unit failure

Over travel limit switch activated

This failure occurs when an axis reaches the end of its travel and actuates an Over travel limit switch (LS).

66

Amplifier unit failure

Low voltage of brake power

This failure occurs when brake power supply PB decreases.

(1) If there is no LS that is being pushed phisically, the wirings for the LS may be broken. (2) If the LS is physically being actuated, then move the manipulator towards the normal motion range by the teach pendant operation in the setting screen of "software-limit". (3) Replace the drive unit. (1)Please confirm the cables of CNBKP-CNPB(drive unit). (2)Please replace the drive unit.

72

Amplifier unit failure

Drive unit IPM failure

This failure occurs when current of power module (IPM) in the drive unit flows more than permitted range.

(1)Please confirm internal wirings and the cable between the controller and the robot manipulator.(2)Please replace the drive unit.(3)Please replace the abnormal motor.

74

Amplifier unit failure

Motor regeneration circuit fault

This failure occurs when the regenerative discharge circuit is disconnected (broken) by large current or heat.

(1)Please check whether the CNR connector of the drive unit is connected or not. (2)Please check the wiring of the discharge resistor. (3)Please check the resistance of the discharge resistor 5 ohm / 3 ohm.

4-30

After removal of failure, please turn on power supply of the controller again. After removal of failure, please turn on power supply of the controller again.

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

After removal of failure, please turn ON power supply of the controller again. For details, refer to "SETUP MANUAL" and "MANIPULAT OR MANUAL". After removal of failure, please turn on power supply of the controller again. After removal of failure, please carry out "failure-reset". After removal of failure, please turn on power supply of the controller again.

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Error

Error

Error

Error

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on

(1)Please confirm the supply voltage of the encoder refering to "AX controller maintenance manual".(2)Please confirm whether the robot manipulator interferes in something.(3)Please confirm the wiring of the encoder. (1)Please reset the encoder and turn on power supply of the controller again. (2)Please replace the motor or the encoder. (3)Please check the wiring of the encoder. (4)Please check the supply voltage of the encoder refering to "CONTROLLER MAINTENANCE MANUAL". (5)Please replace the drive unit. (6)Please replace the multi power supply unit. Reduce the speed of the conveyer, or check the connection of conveyer pulse line.

After removal of failure, please carry out "failure-reset". After removal of failure, please turn on power supply of the controller again. Error reset.

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

(1)Please check the wiring of the emergency-stop, the mode selector switch, and the safety plug. (2)Please replace the sequence board (UM352(L21700F00)).

After removal of failure, please carry out "failure-reset".

Error

Error

Error

Error

on

on

Check the fans are operating, or clean up the heat exchanger.

After removal of failure, please carry out "failure-reset". After removal of failure, please carry out "failure-reset". After removal of failure, please carry out "failure-reset".

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

After removal of failure, please carry out "failure-reset". After removal of failure, please carry out "failure-reset". After removal of failure, please carry out "failure-reset".

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Error

Error

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Error

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on

Error code list 75

Amplifier unit failure

Error of brake control circuit

The breakdown was detected in brake control circuit (relay, diode),or break release switches was used just after the motor-off sequence. Please do not release the brake, so that there is danger to which the arm falls. This error occurs when the power supply for the CPU is out of the range of 3.3V +/- 10%.

Please replace the Drive Unit.

78

CPU board failure

CPU bord power fault.

79

CPU board failure

80

CPU bord temperature fault.

This error occurs when the temperature of the CPU becomes 65 degree or more.

(1)Check the cooling fans on the rack unit are operating. (2)Clean up the cooling fans.

CPU board failure

CPU bord power fault.

This error occurs when the power supply voltage for the CPU becomes +10% (higher) or -6%(lower) from the rated voltage.

(1)Check the 5V supply voltage of multi power supply unit. For details, refer to "CONTROLLER MAINTENANCE MANUAL". (2)Please replace the multi power supply unit. (3)Please replace the CPU board.

81

CPU board failure

CPU board battery failure

This error occurs when the voltage of battery on the CPU bord has decreased.

(1)Please exchange the battery. Then, (2)Please set up the date correctly.

99

Operational failure

5th axis operating range exceeded.

Select [Constants][Machine constants] and use the correct axis operation keys to move back into the 5th-axis Operating range. Warning! damage can occur if 5th-axis hits arm 1.

105

Control failure

Ext. Motors-off' signal is being given or Motors-OFF button being held.

106

Operational failure

The motors are not ON.

Error occurs when 5th-axis moves out of its Operating range. Operating range can be exceeded when the 5th-axis(and 6th-axis) is moved via the rotation of the 4th-axis. Error occurs when Motors-ON button is pressed while the Motors-OFF button is held or external motors-OFF signal is being given. The motors are not ON.

116

TP failure

TP connect failure

It becomes this failure when TP isn't connected and a cable is out.

Connect TP properly. Exchange TP when it is out.

117

TP failure

TP connect failure

Connect TP properly. Exchange TP when it is out.

118

TP failure

The teach pendant reception is abnormal.

119

TP failure

The T/P connection is abnormal.

120

TP failure

The T/P connection is abnormal.

121

Operational failure

122

Servo failure

The robot's joint angle exceeded the software stroke range. The robot's joint angle exceeded the software stroke range.(Current position)

This error occurs when TP is connected after the control power supply is turned on. Abnormality was detected by the key notification reception from teach pendant. Abnormality was detected by the sending and receiving processing from the T/P. The version of wireless TP by which the connection demand was carried out differs from the version to which this control device corresponds. It will become this error if a robot joint angle reaches the software stroke range. It will become this error if a robot joint angle reaches the software stroke range.(Current position)

129

Operational failure Operational failure Control failure

The angle which an arm makes is too large. The angle which an arm makes is too small. Collision sensor actuated.

The 1st arm and the 2nd arm may cause interference with a position. The 1st arm and the 2nd arm may cause interference with a position. Error occurs when a signal is received from the collision sensor.

132

Operational failure TP failure

It will become this error if a robot joint angle reaches the link software stroke range. It becomes this failure when TP isn't connected and a cable is out.

Please move to link software stroke within the limits by manual operation (each axis).

136

The robot's joint angle exceeded the link software stroke range. TP connect failure

139

TP failure

The T/P connection is abnormal.

140

TP failure

The abnormalities in CPU in a T/P

Abnormality was detected by the sending and receiving processing from the T/P. CPU built in the teach pendant stopped.

Please confirm whether there is something that it is possible to become a noise source in the vicinity of the T/P and the cable. Please check whether there are any abnormalities in the T/P and the connection cable. Please turn OFF and ON the main power supply. Please replace the T/P, when an error still comes out.

177

Emergency stop failure

Primary power supply fault.

Check the status of the Primary(mains) power supply.

243

Operational failure

244

Operational failure

Designated command position exceeds Robot operating area. Danger of Robot interference.

Error occurs when the Power supply unit detects that primary power is below nominal level. Error occurs when a shift function, etc. tries to send the robot out of the robot operating area. Robot wrist may interfere with under the part of manipulator body.

130 131

After removal of failure, please turn on power supply of the controller again. After removal of failure, please carry out "failure-reset". After removal of failure, please carry out "failure-reset". After removal of failure, please carry out "failure-reset". After removal of failure, please carry out "failure-reset". No reset operations neccesary.

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Alarm

Error

Alarm

Error

on

on

After removal of failure, please carry out "failure-reset". No reset operations neccesary. After removal of failure, please carry out "failure-reset". Turn on the power again.

Error

Error

Error

Error

on

on

Inform ation

Alarm

Inform ation

Alarm

on

on

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Please move to software stroke within the limits by manual operation (each axis).

Error reset.

Alarm

Error

Alarm

Error

on

on

Please motor power on in machine constant/software limit at the EXPERT level and move to software stroke within the limit by manual operation. Please turn on the motor as it is, when error occurred only with the axis without brakes. Please move in the direction where interference does not take place by manual operation. Please move in the direction where interference does not take place by manual operation. Remove obstruction, check condition of the tool, reset the collision sensor, and restart robot.

Error reset.

Error

Error

Error

Error

on

on

Error reset.

Alarm

Error

Alarm

Error

on

on

Error reset.

Alarm

Error

Alarm

Error

on

on

After removal of failure, please carry out "failure-reset". Error reset.

Error

Error

Error

Error

on

on

Alarm

Error

Alarm

Error

on

on

Error

Inform ation

Inform ation

Inform ation

on

on

Alarm

Inform ation

Alarm

Inform ation

on

on

Inform ation

Inform ation

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Inform ation

on

on

Error

Error

Error

Error

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on

Alarm

Error

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on

Alarm

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on

(1)Check the 5V supply voltage of multi power supply unit. For details, refer to "CONTROLLER MAINTENANCE MANUAL". (2)Please replace the multi power supply unit. (3)Please replace the CPU board.

Ensure that Motors-OFF is not being given when pressing Motors-ON button.

Turn motors ON by pressing the Motor-ON button.

Please confirm whether there is something that it is possible to become a noise source in the vicinity of teach pendant and the cable. Please confirm whether there is something that it is possible to become a noise source in the vicinity of the T/P and the cable. Please change into the right version.

Connect TP properly. Exchange TP when it is out.

Correct the program.

Correct the program.

After removal of failure, please carry out "failure-reset". Error reset.

After removal of failure, please carry out "failure-reset". Error reset.

No reset operations neccesary. No reset operations neccesary.

4-31

Error code list 245

Operational failure

The bend direction of J3 axis is different, interpolation cannot be continued.

The bend direction of J3 axis is different at the starting point and the terminal point.

Please correct the angle of J3 axis to the same direction.

246

Operational failure

247

Operational failure

Wrist posture calculation fault. Please insert the middle step. There is a tool which exceeds rating.

When the posture is calculated, this error occurs when the wrist goes the inverse direction from teaching position. Because tool center of gravity or tool weight has exceeded rating, it becomes medium speed playback.

248

Control failure

250

Operational failure

The gravity bend revision quantity is too big. Controller cannot make trajectory at the J1 singular area.

251

Operational failure

The bend direction of J4 axis is different, interpolation cannot be continued.

The flexion it tried to revise, but the revision quantity exceeded error inspection angle. When the robot moves by the linear/circle interpolation, the robot's wrist center point cannot pass the J1 singular area. The direction of J5 arm is different more than 180 degrees at the starting point and the terminal point.

Please insert the step in the middle so that the change amount of the wrist axis in one step may become small. Please reduce the accuracy in the step before and after the error's occurring. (1)Please execute automatic tool center of gravity setting.(2)Please verify whether the tool has not exceeded rating.(3)When the tool has exceeded rating, please make sure to be settled inside rating. Please take a second look tool setting. Center of gravity of the tool or mass of the tool, occur when it is large. Please execute Automatic COG setting. At the teach mode, the robot's wrist center point moves from the J1 singular area by joint jog operation. At the playback mode, please modify the teach point and/or change for the joint interpolation. Please correct the angle of J4 axis so that the direction of J5 arm becomes less than 180 degrees.

257

Operational failure

Pose calculation failed.

270

Control failure

Conveyer motion during test .

271

Control failure PLC failure

Conveyer pulses exceeded limit. The error was detected by Built-in PLC.

379

Control failure

Safety plug is not inserted or the state of safety plug signal has changed in teach mode.

493

Operational failure

Compound motion limit over.

494

Operational failure

Over movable area of ATRAC4 flat type.

550

PLC failure

It is scan time over of Built-in PLC.

Compound motion J5 and J6 of ATRAC4 flat type over movable area. It detects, when the scanning time of Built-in PLC is too long.

582

Vision sensor failure

Vision sensor not connected.

It detects, when the vision sensor is not connected.

Correct vision sensor connection line.

659

TP failure

Teach pendant touch panel error.

Error occurs if at the time of turning power ON, the touch panel of teach pendant is pushed.

Touch panel is not touched for turn power ON again. If error persists change the Teach pendant.

674

Spot weld failure

Welder communication fault(No reply).

675

Spot weld failure Spot weld failure Spot weld failure Spot weld failure

Welder communication fault(Check sum). Welder communication fault(Message wrong). Major Welder fault.

(1)Check power supply of the welder and communication cables, and power ON again. (2)Initialize welder data. Check power supply of the welder and communication cables, and power ON again. Check power supply of the welder and communication cables, and power ON again. Remove the cause of weld fault.

695

Spot weld failure

LCA EPROM checksum error.

696

Spot weld failure

Application EPROM checksum error.

697

Spot weld failure Control failure

DPR error.

Operational failure

The angle between 3rd axis and ground is over.

Error occurs when the welder board is not correctly connected, or backup files are incorrect. Error occurs when received data from the welder board is abnormal. Error occurs when received data from the welder board is abnormal. Error occurs when the welder board generate the weld fault. Error occurs when a system software checksum error of welder timer substrate is detected. Error occurs when a system software checksum error of welder timer substrate is detected. Error occurs when an application EPROM checksum error of welder timer substrate is detected. Error occurs when a DPR error of welder timer substrate is detected. Error occurs when a conveyer register value exceeded value of . The 3rd axis tended to operate exceeding 3rd angle incline.

367

676 677 694

704

705

4-32

Executive EPROM checksum error.

Invalid Conveyer register value.

After removal of failure, please carry out "failure-reset". No reset operations neccesary.

Alarm

Error

Alarm

Error

on

on

Alarm

Error

Alarm

Error

on

on

No reset operations neccesary.

Inform ation

Inform ation

Inform ation

Inform ation

on

on

No reset operations neccesary. No reset operations neccesary.

Alarm

Error

Alarm

Error

on

on

Alarm

Error

Alarm

Error

on

on

Alarm

Error

Alarm

Error

on

on

Error

Error

Error

Error

on

on

Stop the conveyer, reset, and restart test.

After removal of failure, please carry out "failure-reset". No reset operations neccesary. Error reset.

Error

Error

Error

Error

on

on

Check that the pulse generator is functioning correctly.

Error reset.

Error

Error

Error

Error

on

on

Check the environment of Built-in PLC of operation.

Unusual reset is carried out after changing Built-in PLC into a starting state. After removal of failure, please carry out "failure-reset".

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

No reset operations neccesary. No reset operations neccesary. Please change the PLC state setting to "start" after correct Ladder program or change the "PLC scan time". After removal of failure, please turn on power supply of the controller again. After removal of failure, please turn on power supply of the controller again. Error reset.

Alarm

Error

Alarm

Error

on

on

Alarm

Error

Alarm

Error

on

on

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Error

Error

Error

Error

on

on

Install the system software once more.

Turn on the power again.

Error

Error

Error

Error

on

on

Install the system software once more.

Turn on the power again.

Error

Error

Error

Error

on

on

Install the system software once more.

Turn on the power again.

Error

Error

Error

Error

on

on

Install the system software once more.

Turn on the power again. Error reset.

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Error reset.

Alarm

Error

Alarm

Error

on

on

This error occurs when all axis angles can not be calculated in robot language file. Error occurs when the conveyer running signal is detected during executing a program in Conveyer simulation or test mode. Error occurs when the number of conveyer pulses exceeds 10KHz. It becomes this error when Built-in PLC detects an error.

Check pose data.

This error occurs when a Motors ON command(button) is given in Auto mode when the Safety plug is not inserted or the state of safety plug signal has changed in teach mode. | J5 axis | + | J6 axis | exceeded limit value.

Insert the Safety plug in Auto mode.

Please move to the limit by manual operation (each axis).When it cannot move, at the [Constants][Machine constants][Software limit] please try again. Please move to the limit by manual operation (each axis).When it cannot move, at the [Constants][Machine constants][Software limit] please try again. Change the "PLC scan time" or correct Ladder program. There is a possibility to be detected scan time over, when the "E177 Primary power supply fault." occurs,

Check a conveyer pulse input circuit.

Please move in the direction where 3rd angle incline does not take place by manual operation.

Error code list 706

Operational failure

727

Servo failure

749

Spot weld failure

Spot Welder SCR1 thermal switch actuated.

This failure occurs when the temperature of the motor, the encoder, the harness, and the connector guessed from the motor current and the motor speed is abnormal. Failure occurs when the Thermo. Temp. fault signal is received by the controller.

750

Spot weld failure

Spot Welder SCR2 thermal switch actuated.

Failure occurs when the Thermo. Temp. fault signal is received by the controller.

Check the Thermo. Temp. fault signal and the spot welding unit.

759

Spot weld failure

Isolation contact failed to pull in.

Failure occurs when the isolation contact of the welder fails to actuate correctly.

Refer to the Welder timing Manual.

760

Spot weld failure

Isolation contact stuck close.

Failure occurs when the isolation contact of the welder fails to actuate correctly.

Refer to the Welder timing Manual.

762

Spot weld failure

Welder board not installed.

Install the welder board.

777

Control failure

Robot moved during Motors-ON sequence.

Error occurs if the welding timer PCB does not exists in the controller when welding is attempted. This error occurs when the robot moved during Motors-ON sequence.

783

CPU board failure

Motion stop.

This error occurs when the main CPU detects a motion stop. (This error is detected in the CPU board and the sequence board.)

785

CPU board failure CPU board failure

I/O timeout.

It becomes this error when main CPU detects a I/O system stop. This error occurs when the Watchdog Circuit detects a motion stop.

788

CPU board failure

Movement too large in Compliance control.

Error occurs when movement by an external force is too large while in Compliance control.

789

CPU board failure

CPU error.

It becomes this error when an CPU error occurs in CPU board.

895

Control failure

Conveyer not running.

897

Control failure

Too little conveyer pulse counted.

898

Servo failure

Servo command stop

Error occurs when conveyer pulse never changes more than 1 second, after start LS is given. Error occurs when a After conveyer start LS is input, though it was passed , when it is short of value of value. This failure occurs when the update of the command value transmitted to the servo stops during a certain time.

902

Amplifier unit failure

serveo clock halted

This failure occurs when the clock of servo board UM351(L21700X00) halted.

(1)Please confirm the supply voltage of the servo board UM351(L21700X00). (2)Please replace the drive unit.

903

Amplifier unit failure

Servo communication stop

This failure occurs when the communication between CPU board and the servo board stops.

(1)Please confirm whether connector CNCOM of servo board UM351(L21730X) on the drive unit is correctly connected.(2)Please confirm whether connector CNLAN3 of CPU board is correctly connected.(3)Please replace the drive unit.(4)Please replace the CPU board.(5)Please replace the cable between the drive unit and te CPU board.

904

CPU board failure

Sequence board connect failure.

Please check whether the sequence board is correctly connected or not.

905

CPU board failure

Abnormal setting of the I/O board.

910

Amplifier unit failure

Abnormal output of the servo gun pressure sensor.

Sequence board(UM352(L21700F00)) is not recognized. I/O board is not recognized. DIP-SW on the I/O board is incorrect. Error occurs when 1) disconnect between pressure sensor and robot controller, 2) pressure sensor troubles, 3) troubles of the analog sensor board in robot controller.

787

The angle between flange and ground is over. Robot over temperature

Watchdog Timeout Error.

The flange tended to operate exceeding flange incline.

Please move the manipulator towards the normal motion range by the teach pendant operation in the setting screen of "software-limit". (1)Please check that the Pay-load is within the nominal rating. (2)Please check the wiring of the motor brake refering to "MANIPULATOR MANUAL". (3)Please lower the temperature of the abnormal location, and lower the outside temperature. (4)If failure persists, please lower the operation speed of the robot. Check the Thermo. Temp. fault signal and the spot welding unit.

Error reset.

Alarm

Error

Alarm

Error

on

on

After removal of failure, please carry out "failure-reset".

Error

Error

Error

Error

on

on

After removal of failure, please carry out "failure-reset". After removal of failure, please carry out "failure-reset". After removal of failure, please carry out "failure-reset". After removal of failure, please carry out "failure-reset". Error reset.

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

After removal of failure, please carry out "failure-reset". Turn on the power again.

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Turn on the power again. Turn on the power again.

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Check the constants of the Compliance control function. Turn on the power again.

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Error reset.

Error

Error

Error

Error

on

on

Separate input timing of a starting command from conveyer start LS signal.

Error reset.

Error

Error

Error

Error

on

on

Please refer to the troubleshooting of the controller maintenance manual.

After removal of failure, please carry out "failure-reset". After removal of failure, please turn on power supply of the controller again. After removal of failure, please carry out "failure-reset". Wait more than 5 seconds for next motor power on. Turn on the power again.

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Error

Error

Error

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Error

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on

on

(1)Please check the connectors CNP1-CNP5 on the drive unit. (2)Please check whether the robot manipulator interferes with something. (3)Please replace the drive unit. (4)Please replace the power unit. (5)Please replace the motor. (1)Please remove the CPU board and the sequence board, and insert them again. (2)If this failure persists, replace the sequence board. (3)Please replace the CPU board. (4)Please replace the system-CF for re-installing the system. Turn on the power again. If the error is not released, reinstall the system. (1)Turn ON the power again. Please confirm the error is released. (2)Please enlarge "Interpolation Cycle Time". (3)Please remove the CPU board or the sequence board (UM352(L21700F00)) and install them again. Check the condition of the Compliance control performance.

(1)Turn on the power again. Please confirm the error is released.(2)Please insert a CPU board firmly again.(3)When the phenomenon recurs, please inform our service section. Check the conveyor is functioning. Or check the wiring between Pulse Generator and robot controller.

Check DIP-SW on the I/O board.

Turn on the power again.

Error

Error

Error

Error

on

on

Please check 1) connector on the analog sensor board, 2) the conection between pressure sensor and robot controller, 3) exchange new pressure sensor.

After removal of failure, please turn on power supply of the controller again.

Error

Error

Error

Error

on

on

4-33

Error code list 911

Amplifier unit failure

Autozero failure of analog input.

Beause analog input signal has the offset value, autozero cannot be executed.

Please check 1) connection of analog input line 2) analog input signal by its manual.

919

Operational failure

The allowed unbalanced torque is exceeded.

This failure is detected when moving to the position in which the allowed unbalanced torque is exceeded.

920

Operational failure

Robot tended to operate exceeding Y asix motion limit.

Robot tended to operate exceeding the operating area determined by the mechanism.

921

Operational failure

Robot tended to operate exceeding rear motion limit.

Robot tended to operate exceeding the operating area determined by the mechanism.

956

FieldBus failure

The communication error occurred.

The details of a communication error should check a sub code.

(1)Please move the robot to the position in a permissible torque in the constant setting mode. (2)Please correct the teaching so as not to exceed the position in a permissible torque. (3)Please confirm installed posture. (4)Please confirm the tool load. Please move to the operating area within the Y axis motion limit by manual operation. Please correct the teaching so as not to exceed the position within the Y axis motion limit in the constant setting mode. Please move to the operating area within the rear motion limit by manual operation. Please correct the teaching so as not to exceed the position within the rear motion limit in the constant setting mode. An unusual cause is removed based on a sub code.

957

FieldBus failure

The system error was detected.

The details of a communication error should check a sub code.

On the fieldbus hardware setting screen, check whether the settings are correct.

958

FieldBus failure

The error was detected with the self check of a communication board.

The defect of a communication board is considered.

959

FieldBus failure

A communication board is not found.

They are the abnormalities of a communication board. Please check the details of abnormalities to system service. The communication board specified on the constant setting screen is not found.

960

FieldBus failure

A part or all I/O links are stopping.

Since the between title has occurred in the I/O device, a robot cannot be started.

Please check the device which the problem has generated by the field bus monitor.

967

Control failure

T/P selector switch is set to MANUAL.

Playback operation is impossible while the T/P selector switch is set to MANUAL.

(1)Set the T/P selector switch to AUTO. (2)Please replace the T/P. (3)Please replace the sequence board (UM352(L21700F)).

975

Control failure

Magnetic switch is not active.

This error occurs when a signal from a magnetic switch is not received within the specified time after the Motors ON signal is given.

(1)Please check the cable of the power unit and the drive unit. (2)Please replace the sequence board UM352/L21700F00. (3)Please replace the multi power supply unit.

976

Control failure

Confirm magnet-ON (Fixed input IN28) is OFF.

This error occurs when the Confirm magnet-ON (Fixed input IN28) is unexpectedly cut OFF during motor power ON condition.

(1)Please replace the power unit. (2)Please replace the sequence board (UM352/L21700F00).

977

Control failure

Both teach and playback mode signal is not fixed.

Neither teach mode nor playback mode signal is turned ON.

Please confirm the operation mode signals connection.

1001

Control failure

PWM was cut off.

(1)Replace power unit. (2)Replace drive unit.

1003

Control failure

1012

Control failure

Analog input board is not installed. Or analog output board is not installed. PWM of the disconnected mechanism has been turned on.

Error occurs when software can't be selected the cause which a PWM signal was cut off. Although analog input (output) board is not installed, analog input (output) function is executed.

1016

Encoder failure

1024

Servo failure

4-34

Error

Error

Error

Error

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on

Alarm

Error

Alarm

Error

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on

No reset operations neccesary.

Alarm

Error

Alarm

Error

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on

No reset operations neccesary.

Alarm

Error

Alarm

Error

on

on

After removal of failure, please carry out "failure-reset". After removal of failure, please carry out "failure-reset". A communication board is exchanged. The setting value of a field bus hardware setup is changed. If a problem is solved, it will restore automatically. (In order to solve a problem, the re-injection of a power supply may be required) After removal of failure, please carry out "failure-reset". After removal of failure, please carry out "failure-reset". After removal of failure, please turn on power supply of the controller again. After removal of failure, please carry out "failure-reset". Error reset.

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Error

Error

Error

Error

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on

Error

Error

Error

Error

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Error

Error

Error

Error

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on

Error

Error

Error

Error

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on

Error

Error

Error

Error

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on

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Error

Error

Error

Error

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on

Turn off the power and connect analog Input (output) board correctly.

Error reset.

Error

Error

Error

Error

on

on

This error occurs when PWM is not turned off even if a certain time passes after the mechanism diconnection.

There are some problems in the brake and the PWM control circuit of sequence PCB. Please replace the sequence PCB or the drive unit.

Error

Error

Error

Error

on

on

Manipulator battery warning

This warning occurs when the voltage of the battery in the robot manipulator decreases.

(1)Please exchange the battery referring to Instruction Manual "Manipulator". (2) Please perform the Encoder Reset and Encoder Correction.

Inform ation

Inform ation

Inform ation

Inform ation

on

on

Robot over temperature

This failure occurs when the temperature of the motor, the encoder, the harness, and the connector guessed from the motor current and the motor speed is abnormal.

(1)Please confirm that the Pay-load is within the nominal rating. (2)Please confirm the wiring of the motor brake refering to "Manipulator Maintenance Manual". (3)Please lowering the temperature of an abnormal location, and lowering the outside temperature. (4)If failure persists, please lower the operation speed of the robot.

After removal of failure, please carry out "failure-reset". After the battery is exchanged, please carry out "failure-reset" and then turn on the power supply of the controller again. After removal of failure, please carry out "failure-reset".

Inform ation

Inform ation

Inform ation

Inform ation

on

on

Please check the slot ID of a field bus hardware setup.

After removal of failure, please turn on power supply of the controller again. Error reset.

Error code list 1046

Control failure

Master-ON circuit is inconsistent.

1048

Control failure

The magnetic switch contacts were welded and stick each other.

(1)This error occurs when the magnet on confirming input signal (fixed input IN28) is not turned ON within the designated time after consist of conditions. This error occurs when the contacts of the magnetic switch were welded and stick each other.

1049

Spot weld failure

This IWB does not support MFDC

Error occurs when the IWB version is old.

1051

Control failure

The inconsistency was detected with the sequence circuit.(TP enable switch)

This failure occurs when the inconsistency or abnormal was detected in duplicated signal at the TP enable switch.

(1)Please check whether only one of signals is input or only one contact is weld at the TP enable switch. (2)Please replace the sequence board UM352/L21700F00.

1052

Control failure

Control failure

This failure occurs when the inconsistency or abnormality was detected in the duplicated signal circuit for the externel emergency stop. This failure occurs when an inconsistency or abnormality was detected in the duplicated signal circuit for the safety plug.

(1)Please check whether only one of the signals is input or only one contact is weld at the external emergency stop. (2)Please replace the sequence board UM352/L21700F00.

1053

An inconsistency was detected in the sequence circuit.(Ext.emergency stop) An inconsistency was detected with the sequence circuit.(safety plug)

1054

Control failure

An inconsistency was detected in the sequence circuit.(G-STOP)

This failure occurs when an inconsistency or abnormality was detected in the duplicated signal circuit for the G-STOP input.

(1)Please check whether only one of the signals is input or only one contact is weld at the G-STOP input. (2)Please replace the sequence board UM352/L21700F00.

1055

Spot weld failure

The welder board failed in initialization.

Power ON again. If error persists replace the I/F printed circuit board.

1056

Spot weld failure

1058

Spot weld failure Control failure

Memory error is detected by the welder board. Timer controller CPU is not ready. An inconsistency was detected in the sequence circuit.(Teach/Playback select) An inconsistency was detected in the sequence circuit.(Mat switch)

Error occurs when the initialization of the welder board is not complete. Error occurs when an internal memory of the welder board is destroyed. Nothing acknowledge from timer controller CPU. This failure occurs when an inconsistency or abnormality was detected in the duplicated signal circuit for the Teach/Playback select input. This failure occurs when an inconsistency or abnormality was detected in the duplicated signal circuit for the Mat switch input.

An inconsistency was detected in the sequence circuit.(High-speed teach) An inconsistency was detected in the sequence circuit.(emergency stop) An inconsistency was detected in the sequence circuit.(T/P emergency stop)

This failure occurs when an inconsistency or abnormality was detected in the duplicated signal circuit for the High-speed teach input. This failure occurs when an inconsistency or abnormality was detected in the duplicated signal circuit for the emergency stop.

(1)Please check whether only one of the signals is input or only one contact is welded at the High-speed teach input. (2)Please replace the sequence board UM352/L21700F00.(3)Please replace the operation box or operation panel. (1)Please check whether only one of the signals is input or only one contact is welded at the emergency stop. (2)Please replace the sequence board UM352/L21700F00. (3)Please replace the operation box or the operation panel. (1)Please check whether only one of the signals is input or only one contact is welded at the T/P emergency stop. (2)Please replace the sequence board UM352/L21700F00.(3)Please replace the teach pendant. (1)Please check whether only one of the signals is input or only one contact is welded at the CRON input. (2)Please replace the sequence board UM352/L21700F00.

1059

1060

Control failure

1061

Control failure

1062

Control failure

1063

Control failure

1064

Control failure

An inconsistency was detected in the sequence circuit.(CRON)

This failure occurs when an inconsistency or abnormality was detected in the duplicated signal circuit for the CRON input.

1065

Spot weld failure

The welder is not initialized.

Error occurs when the initialization of the welder is not complete.

1068

Spot weld failure Arc try condition file

The contents of a VSF file are not correctly. Robot monitoring unit Encoder failure.

It generates, when the contents of a VSF file have a error. This failure occurs when the Encoder data(absolute) is abnormal.

1101

Arc try condition file

The robot's joint angle exceeded the software stroke range.

It will become this error if a robot joint angle reaches the software stroke range.

1102

Arc try condition file

Position exceeded the limit area.

The position of a limit object exceeded the limit area.

1103

Arc try condition file

Robot monitoring unit Speed failure.

This failure occurs when the Encoder data(absolute) is abnormal.

1100

This failure occurs when an inconsistency or abnormality was detected in the duplicated signal circuit for the T/P emergency stop.

(1)Replace the sequence board UM352/L21700F00. (2)Replace the power unit.

After removal of failure, please carry out "failure-reset". After removal of failure, please carry out "failure-reset".

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

After removal of failure, please carry out "failure-reset". After removal of failure, please carry out "failure-reset". After removal of failure, please carry out "failure-reset". After removal of failure, please carry out "failure-reset". After removal of failure, please carry out "failure-reset". Error reset.

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Error

Error

Error

Error

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on

Error

Error

Error

Error

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on

Error

Error

Error

Error

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Power ON again after executing R930, and confirm each parameter of the timer.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Replace the timer PCB (PMU).

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

(1)Please check whether only one of the signals is input or only one contact is welded at the Teach/Playback select input. (2)Please replace the sequence board UM352/L21700F00. (3)Please replace the operation box or operation panel. (1)Please check whether only one of the signals is input or only one contact is welded at the Mat switch input. (2)Please replace the sequence board UM352/L21700F00.

After removal of failure, please carry out "failure-reset". After removal of failure, please carry out "failure-reset". After removal of failure, please carry out "failure-reset". After removal of failure, please carry out "failure-reset". After removal of failure, please carry out "failure-reset". After removal of failure, please carry out "failure-reset". Error reset.

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

After removal of failure, please turn on power supply of the controller again. Failure reset.

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Failure reset.

Error

Error

Error

Error

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Failure reset.

Error

Error

Error

Error

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(1)Please check the cables (from the power unit to the drive unit(CNMS) / from the drive unit to the sequence board (CNSV) ). (2)Please replace the power unit. (3)Please replace the sequence board UM352/L21700F00. (4)Please replace the multi power supply unit. (5)Please replace the drive unit. Replace new version.

(1)Please check whether only one of the signals is input or only one contact is weld at the safety plug. (2)Please replace the sequence board UM352/L21700F00.

(1) Check power supply of the welder and communication cables, and power ON again. (2)Initialize welder data. (3) If error persists replace the welder. Check the contents of a VSF file. (1)Please re-correct connections of wire harness. (2)Please exchange drive unit. (3)Please exchange encoders (motors).

After pressing LS release button, press master ON button in machine constant/software limit at the EXPERT level. And move robot within software stroke on manual operation during pressing LS release button. After pressing LS release button, press master ON button in machine constant/virtual safety fence/range setting at the EXPERT level. And move robot within limit area on manual operation during pressing LS release button. (1)Please exchange drive unit. (2)Please exchange encoders (motors).

4-35

Error code list 1104

Arc try condition file

Robot monitoring unit over current.

Over current detected.

Removal failure.

1105

Arc try condition file Arc try condition file

Robot monitoring unit disparity failure. Robot monitoring unit internal failure.

This failure occurs when the safety input signal is abnormal. This failure occurs when the Robot monitoring unit is abnormal.

Removal failure.

1107

Arc try condition file

Robot monitoring unit does not be approved.

Please approve the parameter of the robot monitoring unit.

1108

Arc try condition file

Robot monitoring unit communication stop.

This failure occurs when the parameter of the robot monitoring unit does not be approved. This failure occurs when the communication between CPU board and the robot monitoring unit stops.

1109

Arc try condition file

Robot monitoring unit Stop monitor failure.

1110

Arc try condition file

1111

Arc try condition file

1112

Arc try condition file

1113

Arc try condition file

Robot monitoring unit Position monitor failure. Robot monitoring unit Position disparity failure. Robot monitoring unit Velocity disparity failure. Robot monitoring unit connection failure.

When the "StopMonitorInputSignal" isn't input, the robot move. This failure occurs when there is disparity between "Encoder postion" and "Motor position". This failure occurs when there is position disparity between CPU1 and CPU2. This failure occurs when there is velocity disparity between CPU1 and CPU2. The robot monitoring unit is not correctly connected.

1114

Arc try condition file

Robot monitoring unit Tool monitor failure.

Please confirm the input sigal "Tool number".

1115

Arc try condition file

Robot monitoring unit tool postere failure.

1116

Arc try condition file

Robot monitoring unit safety communication failure.

This failure occurs when there is disparity between "Tool input" and "robot motion tool". It will become this error if a robot tool posture reaches the limit angle. This failure occurs when the Robot monitoring unit detect the error in safety network communication.

1120

Operational failure

Outside tool posture limit range

1121

Operational failure

1155

Spot weld failure

The robot's joint angle exceeded the zone limit range. The welder board failed in initialization.

After pressing LS release button, press master ON button. And move robot within zone limit on manual operation during pressing LS release button. After pressing LS release button, press master ON button. And move robot within zone limit on manual operation during pressing LS release button. Power ON again. If error persists replace the welder board (RE-01).

1156

Spot weld failure

Memory error is detected by the welder board.

The tool operated by posture beyond the limits of the posture limit setting. It will become this error if a robot joint angle reaches the zone limit range. Error occurs when the initialization of the RE-01 welder board is not complete. Error occurs when an internal memory of the welder board is destroyed.

1158

Spot weld failure Operational failure

Nothing acknowledge from timer controller CPU. The command position of a limit object tried to exceed the limit range. The current position of a limit object exceeded the limit area.

Replace the timer PCB (RE-01).

1106

1171

Operational failure

1174

Operational failure

Timer controller CPU is not ready. The command position tried to exceed the limit range. The current position exceeded the limit area. Invalid relative program call command found.

1175

Request maintenance

Number of servo-off exceeds the threshold.

1176

Request maintenance

Number of servo error exceeds the threshold.

1820

Sealing failure Sealing failure

The gun nozzle is choked up. The pressure exceeded the upper bound. The pressure exceeded the lower bound. This function cannot be available during Adaptive Motion. Movement too large in Adaptive Motion.

1170

1821

1822

Sealing failure

1823

Operational failure

1824

Operational failure

1825

Operational failure

4-36

Controller cannot make trajectory at the singular area.

Please exchange Robot monitoring unit.

(1)Please confirm whether connector (CNCOM) of robot monitoring unit is correctly connected. (2)Please confirm power supply to the robot monitoring unit. (3)Please replace the robot monitoring unit.

After removal of failure, please turn on power supply of the controller again. Failure reset. Pplease turn on power supply of the controller again. Failure reset.

Error

Error

Error

Error

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on

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Please input "Stop Monitor Signal".

After removal of failure, please turn on power supply of the controller again. Failure reset.

Error

Error

Error

Error

on

on

Please check motors cable and encoder cable.

Failure reset.

Error

Error

Error

Error

on

on

Please check parameters "Pos. Con.".

Failure reset.

Error

Error

Error

Error

on

on

Please check parameters "Vel. Con.".

Failure reset.

Error

Error

Error

Error

on

on

(1)Please confirm the robot monitoring unit connection setting in the "Servo amplifier unit"menu. (2)Please confirm the communication line to the robot monitoring unit. (3)Please confirm the power-supply voltage of the robot monitoring unit.

After removal of failure, please turn on power supply of the controller again. Failure reset.

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Failure reset.

Error

Error

Error

Error

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on

Failure reset after removing the causes of the failure. Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Error

Alarm

Error

on

on

Error reset.

Alarm

Error

Alarm

Error

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Error reset.

Alarm

Alarm

Alarm

Alarm

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on

After removal of failure, please turn on power supply of the controller again. Error reset.

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Failure reset.

Alarm

Error

Alarm

Error

on

on

After pressing LS release button, press master ON button. And move robot within limit angle on manual operation during pressing LS release button. Check the master device and the connection of the communication cable.

Power ON again. If error occurs again, replace the welder board.

Please confirm setting by [constant:machine constant:virtual safety fence] and confirm teaching program. Select [constant:machine constant:virtual safety fence:range setting] and move a limit object to the limit range by the manual. Alter relative program call functions in the program.

Failure reset.

Error

Error

Error

Error

on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Please check the brake.

Error reset.

Error

Error

Error

Error

on

on

Please check the brake.

Error reset.

Error

Error

Error

Error

on

on

Please clean the gun nozzle.

Error reset.

Error

Error

Error

Error

on

on

Please clean the gun nozzle.

Error reset.

Error

Error

Error

Error

on

on

The flow pressure exceeded a set value.

Please clean the gun nozzle.

Error reset.

Error

Error

Error

Error

on

on

The function which cannot be used during Adaptive Motion was used.

Please record this function on the step which is not Adaptive Motion.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Error occurs when movement by an external force is too large while in Adaptive Motion. Robot cannot pass the singular area during Adaptive Motion 'Follow' type.

Check Adaptive Motion conditions.

Error reset.

Error

Error

Error

Error

on

on

Please modify the teach point.

Error reset.

Error

Error

Error

Error

on

on

Error occurs when a CALL is made within a relative program call function more than 2 times. The number of times the servo-off during playback exceeds the threshold. The number of times the servo error has occurred during playback exceeds the threshold. The flow pressure exceeded a set value. The flow pressure exceeded a set value.

Error code list 1826

Sensor failure

Force sensor input changed too much.

It is detected when the amount of change of the force sensor input in each scanning exceeds error detection level set in constants.

(1)Please don't give the force sensor much power. (2)Please confirm whether the the force sensor is correct. (3)Modify the error detection level.

1827

Sensor failure

No reaction from force sensor.

It is detected when the force sensor input stays in maximum or minimum value longer than error detection time set in constants. .

(1)Please confirm whether the the force sensor is correct. (2)Modify the error detection time.

1828

Welder error code W2

The shift value or the force(torque) value of force control exceeded the error detection value.

(1)Modify motion to minimize force(torque). (2)Modify motion to minimize shift value. (3)Modify the error detection value.

1829

Welder error code W2

Abnormal velocity of axis is calculated by force control.

It is detected when the shift value or the force(torque) value of force control exceeded error detection value set in constants.[1]:force,[2]:torque,[3]:sh ift(X/Y/Z),[4]:shift(RX/RY/RZ) It is detected when velocity of axis exceeded maximun value is calculated by force control.

1830

Welder error code W2

The mechanism for force control cannot be selected.

(1)Check mechanism number of function parameter. (2)Modify the program so that there is only one mechanism under force control condition.

1831

Welder error code W2

The coordinate for force control cannot be selected.

1832

Welder error code W2

Froce Control function can not be carried out.

(1)Force control dose not support mechanism except manipulator mechanism. Or Specified mechanism is not in the unit.(2)There is another mechanism under force control condition. The force control cannot be executed at the same time for two or more mechanisms. Another coordinate is used by force control condition. The coordinate for force control can not be changed under force control condition. The mistake of the method of recording the force control function is found.

1833

Welder error code W2

GETFORCE2 function can not be carried out.

GETFORCE2 function is already carried out.

GETFORCE2 function is started after GETFORCE2 function is ended.

1834

Welder error code W2

Route Coordinata can not be created under force control condition.

Modify the robot program.

1835

Welder error code W2

1836

Sensor failure

The Tool No. was changed during force control motion. Abnormal zero position value of force sensor is detected.

The follows occured under force control condition. (1)"Interpolation Off" Step was carried out. (2)Touch founction was carried out. (3) Robot moved to the direction of Z axis of tool coordinate. (4) The robot passed discontinuous track. The Tool No. can not be changed during force control motion. It is detected when zero position value of force sensor exceeds error detection level set in constants.

(1)Please confirm whether the the force sensor is correct. (2)Modify the error detection level.

1837

Operational failure

The mechanism not existing cannot be specified or any mechanisms other than a manipulator cannot be specified.

Please correct a program to specify the existing mechanism number or to specify a manipulator type mechanism number.

1838

Operational failure

The specified mechanism number does not exist or mechanism type is not proper. The specified tool number is used.

Please re-specify the tool number that is not being used.

1839

Operational failure

Tool constant change amount limit over.

The specified tool number is used at the step under present operation. Rewriting the tool number of the step under operation is forbidden. Amount of change in the tool constant for newly specified has exceeded the limit value.

2002

Control failure

Playback unavailable because Motors-OFF sequence is being executed.

This error occurs when an Motors-ON command is input while the Motors-OFF sequence is being executed.

2003

Spot weld failure

Spot welding function can not be carried out.

The mistake of the method of recording the welding function is found.

2006

Control failure

T/P selector switch is set to AUTO.

In Teach mode, Motors are not able to be ON while T/P selector switch is set to AUTO.

(1)Please push the Motors-ON button after the Motors-OFF sequence has been finished. (2)Please input the Motors-ON command after the Motors-OFF sequence has been finished. (3)Replace the sequence board UM352/L21700F00. (1)Please confirm the welding number. (2)Please record spot welding function after step 1. (3)You tried to drive the GUN mechanism which was not able to be driven with this unit. Set the T/P selector switch to MANUAL side.

2007

Control failure

Can not turn on the mortors.

Please set up the manual operation in "shortcut" menu.

2010

Operational failure

It was going to start while the work program was edited on the screen.

It connects by the normal mode by wireless TP, and where the operation mode is made teach-mode, it will become this error if the motors turn ON. This error occurs if it starts while the work program was edited on the screen.

2021

Operational failure

WI cancel operation is disabled. (Servo gun)

This error occurs when WI cancel is operated during a servo gun motor power off.

Please operate WI cancel after a motor power on.

(1)Check the force control condition. (2)Check the force sensor.

(1)Check the coordinate number of selected contition as function parameter. (2)Modify the program so that same coordinate is used under force control condition.

Please record force controlfunction after step 1 or move step.

Modify the robot program.

Please check the value of the new tool length of the real variable register. Or, please check the tool constant value to be assigned.

Please start after ending the editor on the screen.

After removal of failure, please carry out "failure-reset". After removal of failure, please carry out "failure-reset". After removal of failure, please carry out "failure-reset".

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

After removal of failure, please carry out "failure-reset". After removal of failure, please carry out "failure-reset".

Error

Error

Error

Error

on

on

Alarm

Alarm

Alarm

Alarm

on

on

After removal of failure, please carry out "failure-reset". After recording the move step, Please Check Go. This error will be canceled if a program is corrected and restarted. No reset operations neccesary.

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Error

Error

Alarm

Alarm

on

on

No reset operations neccesary. After removal of failure, please carry out "failure-reset". After removal of failure, please carry out "failure-reset". After removal of failure, please carry out "failure-reset". After removal of failure, please carry out "failure-reset". After removal of failure, please carry out "failure-reset". After recording the move step, Please Check Go. After removal of failure, please carry out "failure-reset". Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Error

Error

Error

Error

on

on

Error

Error

Alarm

Alarm

on

on

Error

Error

Error

Error

on

on

Error

Error

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Inform ation

Inform ation

Inform ation

Inform ation

on

on

This error is released if it starts again after ending the editor on the screen. No reset operations neccesary.

4-37

Error code list 2022

Operational failure

Variable which gives speed parameter is invalid.

This error occurs when speed parameter of Moving command made by Robot Language is given by variable and its value is invalid.

Please set value to the variable or change speed parameter to numerical value.

Please set value to the variable or change speed parameter to numerical value. Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

2027

Spot weld failure

The change in the tip consumption detected by search 3 is abnormal.

Check the lack of gun tip. If it is no trouble, execute gun search 1.

2030

Operational failure

Designated command position exceeds Robot operating area.

The difference between the consumption detected by search 3 and the consumption detected by search 1 exceeded the search 3 abnormal tip change. This failure occurs when the operation radius exceeds the limitation.

Alarm

Alarm

Alarm

Alarm

on

on

(1)Please move the robot to the position in a permissible torque in the constant setting mode. (2)Please correct the teaching so as not to exceed the position in a permissible torque. (3)Please confirm installed posture. (4)Please confirm the tool load. Please execute the function after releasing the separation.

Error reset.

Alarm

Error

Alarm

Error

on

on

2038

Spot weld failure

2044

Spot weld failure

The function can not be used while servo gun is separating. The encoder data of gun axis is not steady.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Please reconsider the recorded position. If the position has no problem, replace the Drive Unit

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

2048

Spot weld failure

2049

Spot weld failure

2050

Operational failure

2055

Spot weld failure

2059

Operational failure

2060

Operational failure

The command pressure is out of range. Ready to weld status from welder board isn't completed, or a weld-enabled signal isn't input. Robot does not keep the basic position between multi driven axises. Pressure already achieved to the designated value for manual operation. There is a possibility that the interpolation operation and the de-and acceleration control are not correctly done due to a set disagreement of rectangular coordinate system. 4th axis operating range exceeded.

Use pressures adequate for the Servo gun being used.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Check the peripheral system or welder.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

This error occurs if robot does not keep the basic position between multi driven axises.

Return robot to the basic position by manual operation without Multi Drive Conrtol. If this error occurs again, check the basic position or the level of error detection.

Error reset.

Error

Error

Error

Error

on

on

Servo Gun Pressure already achieved to the designated value for manual operation.

Pressure value is too low when servo gun axis does not move. Review pressure data.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Setting rectangular coordinate system is different registering the tool and now.

Please set the tool constant (length and center of gravity) again by present rectangular coordinate system. Or, please change setting rectangular coordinate system.

The error is not released until measures are executed.

Alarm

Alarm

Alarm

Alarm

on

on

Error occurs when 4th-axis moves out of its Operating range. Though 4th axis is within the software motion range, the 4th axis occasionally exceeds the range of motion by receiving axis interference from other axes. Weld condition setting with group, the weld condition is 1-16(Group16 is 1-15).Weld condition number is out of range. Spot weld function(Fn119 or Fn303) was executed without recording weld condition with group function(Fn282). The detection reason is that the specified device was not detected when the file operation is done.

Select [Constants][Machine constants] and use the correct axis operation keys to move back into the 4th-axis Operating range. Warning! damage can occur if 4th-axis hits arm 1.

No reset operations neccesary.

Alarm

Error

Alarm

Error

on

on

2062

Spot weld failure

Weld condition dose not exist.

Check the desired condition number and retry.

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Inform ation

Inform ation

Inform ation

Inform ation

on

on

The memory medium is read-only.

When it is going to copy a file to a write-protected memory cards etc., this error sets.

Please prepare the memory medium to which writing is made and perform a copy from the beginning once again.

Alarm

Alarm

Alarm

Alarm

on

on

Operational failure

It cannot process in the same device.

It was going to copy to the same device by the same file name.

Please change a file name or a device and redo copy operation again.

Alarm

Alarm

Alarm

Alarm

on

on

2090

Control failure

Max. follow angle over.

Check the press syncronize parameters.

Error

Error

Error

Error

on

on

2091

Control failure

Confirm record point of press synchronous step.

Error reset.

Error

Error

Error

Error

on

on

2092

CPU board failure Control failure

Record point of press synchronous step is not available. It is not possible to start from a current step. Press brake sync. is not available.

Error occurs when the robot was about to follow more than the max. follow angle. Error occurs when the position of press interlock waiting step and a synchronous step is different. Error occurs when playback start is done from press synchronous step. Error occurs if execution of a function related to the press brake is attempted when Press is not selected with Conveyer type. Channel number or the slave node number specified with FN312 or R502 is not used. Error occurs when a Start command is given while the Stop button is being held or External stop signal is being given. Where an emergency stop button or an external emergency stop signal is inputted, it detects, when the Motors-ON signal or the External Motors-ON signal is inputted.

The error is not released until measures are executed. The error is not released until measures are executed. It will be canceled if some keys are pushed. It will be canceled if some keys are pushed. It will be canceled if some keys are pushed. Error reset.

2063

Spot weld failure

Weld condition group number is not set.

2082

Operational failure

The memory medium is not prepared.

2083

Operational failure

2089

Please do playback start from steps other than press synchronous step. Set Conveyer shape in Press.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Error

Error

Error

Error

on

on

Please confirm channel number or the slave node number.

Error reset.

Error

Error

Error

Error

on

on

Release Stop button or External stop signal(if External stop signal cable is cut the external stop signal is considered as being given.

Error reset.

Inform ation

Inform ation

Inform ation

Inform ation

on

on

Please cancel an emergency stop button and an external emergency stop signal.

Error reset.

Inform ation

Inform ation

Inform ation

Inform ation

on

on

2093

2100

FieldBus failure

2101

Operational failure

2103

Operational failure

4-38

Specified channel number or slave node number is not used. Stop or External stop signal being given.

The emergency stop button or the external emergency stop is inputted.

The function was attempted that is not allowable while servo gun is separationg. The servo gun axis did not stop while waiting to reach the specified pressure. Error occurs when a pressure too great or too small for the Servo gun is designated. Welder power turned off or welder error occurred, a weld-enabled signal not given.

Please record weld condition with group function(Fn282) before executing spot welding function(Fn119 or Fn303). Whether the device such as memory cards specified by the file operation menu is correctly installed is confirmed.

Error code list 2104

Operational failure

External Motors-OFF is inputted.

2105

Operational failure

The emergency hold is inputted.

2106

Operational failure

2108

Operational failure

Playback unavailable because servo system has not been turned on yet. It is not possible to start by specifying the function step

2109

Operational failure

2110

PLC failure

2111

Operational failure

The internal operation signal was inputted in the state of external selection.

2112

Operational failure

The external operation signal was inputted in the state of internal selection.

2113

Operational failure

2118

Shift failure

Settings were changed. To initialize the ststus, please cycle the primary power. Shift register contains no data.

2119

Shift failure

2138

Operational failure

The command buffer of serial communication is full. The communication command failed. Setting the call instruction is improper.

2141

Operational failure

2142

Operational failure

2144

Operational failure

2145

Request maintenance

There are signs of abnormality in the J2 axis

2150

Operational failure

Program is too large.

Error occurs when number of bytes of a program is too large.

2151

Operational failure

The program or the file does not exist.

This error occurs when the program number is specified which does not exist in the program jump call instruction.

Please correct the program number to a correct value the jump call ahead.

2152

Operational failure

The step does not exist.

This error is detected when the step number which does not exist in the step jump call instruction is specified.

Please correct the step number to a correct value at the jump destination.

It is not possible to start by selecting this function step. Toyopuc I/F:The sequence program has stopped.

In the state where the external Motors-OFF signal is inputted, when the Motors-ON signal or the external Motors-ON signal is inputted, it detects. In the state where the external emergency hold signal is inputted, when the Motors-ON signal or the external Motors-ON signal is inputted, it detects. The start is impossible, because the start operation is done before MSHP is turned on.

Please cancel the external Motors-OFF signal.

Error reset.

Inform ation

Inform ation

Inform ation

Inform ation

on

on

Please cancel the external emergency hold signal.

Error reset.

Inform ation

Inform ation

Inform ation

Inform ation

on

on

Please start after turning on MSHP.

Error reset.

Inform ation

Inform ation

Inform ation

Inform ation

on

on

This It is prohibited to start specifying the function because there is the position where the function is executed is not an original position but a possibility. It is not possible to start by selecting this function step.

Please start after specifying the move step.

Error reset.

Inform ation

Inform ation

Inform ation

Inform ation

on

on

Please select the move step or the function step that can be executed from, and start.

Error reset.

Alarm

Alarm

Inform ation

Inform ation

on

on

Toyopuc I/F:The sequence program has stopped.

Please confirm Toyopuc I/F.

Error

Error

Error

Error

on

on

It detects, when starting selection tends to push the Motors-ON button or a starting button in the state of the exterior or it is going to choose a program from TP in the state of the program selection exterior. It detects, when the Motors-ON or the start signals are inputted from the exterior in the state of an inside of start selection or a program selection signal is inputted from the exterior in the state of the inside of program selection. This error is detected when Motors-ON command is inputted in a state where some settings were changeed. Error occurs when data aren't established in specified shift register. Too many command of serial communication requested at the same time.

Please operate it after setting starting selection or program selection as an inside.

Automatically restores, when the problem is solved. Error reset.

Inform ation

Inform ation

Inform ation

Inform ation

on

on

Please perform external operation after setting up starting selection or program selection outside.

Error reset.

Inform ation

Inform ation

Inform ation

Inform ation

on

on

Please cycle the primary power to initialize the state.

Error reset.

Error

Error

Error

Error

off

off

Setting data in shift register.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Please modify robot program.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

This error occurs when the number of step call and return instruction is match or the multiple call exceeds eight times.

Please correct the program so that the number of call return instructions is corresponding, and a multiple call should not exceed eight times.

Alarm

Alarm

Alarm

Alarm

on

on

The unit composition is a different program.

This error occurs when the program jump or call instruction directly jumps or calls the program that the unit is different.

Please correct the called program number value.

Alarm

Alarm

Alarm

Alarm

on

on

Program number selected is not available. There is no end.

This error occurs when the program number designated is more than 9999. If there is no end mark when playback executing, this error is detected after the last step is executed. There is a possibility of error in the drive system such as a motor / reducer / gas balancer.

Check the desired program number and retry.

This error is released if the step set do over again and restart playback. This failure is released if a correct program is setted and restart playback. No reset operations neccesary. This error is released if restart playback. No reset operations neccesary.

Inform ation

Inform ation

Inform ation

Inform ation

on

on

Inform ation

Inform ation

Inform ation

Inform ation

on

on

Inform ation

Inform ation

Inform ation

Inform ation

on

on

No reset operations neccesary. This failure is released if a correct program is setted and restart playback. This error is released if the correct step set do over again and restart playback.

Inform ation

Inform ation

Inform ation

Inform ation

on

on

Inform ation

Inform ation

Inform ation

Inform ation

on

on

Inform ation

Inform ation

Inform ation

Inform ation

on

on

Please record the end instruction.

1. Check tool set and in-kind tool number that is specified by the program. 2. Check the gas pressure of the gas balancer. 3. Check with the brake release function J2 axis moves smoothly. 4.Replace the drive unit 5.Replace the motor. Edit program in order to reduce its size.

4-39

Error code list 2155

Operational failure

The usage of the flow control instruction is improper..

This error is detected when the usage of the flow control instruction is wrong.

Please correct the program so that the usage of the flow control instruction may become proper.

his error is released if it reactivates after the program is corrected so that the usage of the flow control instruction may become proper. This error will be canceled if a program is corrected and restarted. This error will be canceled if a program is corrected and restarted. Please release protecting the file (program or constant). When you start, please choose Step 1 from T/P.

Alarm

Alarm

Alarm

Alarm

on

on

2161

Operational failure

Change of a coordinate system cannot be performed during circular.

This error occurs if a coordinate system is changed during circular.

Please teach by the same coordinate system during circular.

Inform ation

Inform ation

Inform ation

Inform ation

on

on

2164

Operational failure

Change of a tool cannot be performed during circular.

This error occurs if a tool is changed during circular.

Please teach by the same tool during circular.

Inform ation

Inform ation

Inform ation

Inform ation

on

on

2165

Operational failure

The file is protected.

All protected files or files partially protected (program or constant) tried to be corrected and deleted.

Because the specified file (program or constant) contains important data, protecting is put so that the content is not carelessly changed.

Inform ation

Inform ation

Inform ation

Inform ation

on

on

2166

Operational failure

The reproduction protection of the program is carried out.

The specified work program is not a program which should be used for operation operation.

2167

Operational failure

2169

Operational failure

The amount of the movement of each axis is too small in the automatic tool constant setting. Or, the number of record steps does not suffice. A step number is unsuitable..

It detects, when it is going to carry out reproduction or check GO of the work program which required reproduction protection from a head step (Step 0). When there is no point or less 10 point data effective to the calculation, and the program is not clearly recorded the same point excluding the error by the teaching.

Alarm

Alarm

Alarm

Alarm

on

on

Recreate the 10 point program (4 point under tool constant setting only) ensuring the recorded points are exactly the same point in space.

Error reset.

Inform ation

Inform ation

Inform ation

Inform ation

on

on

It is displayed, when the specified step does not exist, or when the step of a reference program is the function step. It is displayed when the tool posture in two specified points is not the same. The tool number recorded on the specified step differs from the selected tool number. This error occurs if the allowable shift distance is too large.

Please specify a move function.

Error reset.

Alarm

Alarm

Alarm

Alarm

off

off

2170

Operational failure

Tool postures differ.

Please make a tool posture the same.

Error reset.

Alarm

Alarm

Alarm

Alarm

off

off

2171

Operational failure

Tool number do not match.

Please make a tool number the same.

Error reset.

Alarm

Alarm

Alarm

Alarm

off

off

2173

Shift failure

Shift value limit exceeded.

Reset the limit value[Constants][Shift limit & evaluation value] and retry program.

Alarm

Alarm

Alarm

Alarm

on

on

The function which cannot be used during conveyor synchronization was used.

Please record this function on the step which is not conveyor synchronization.

Alarm

Alarm

Alarm

Alarm

on

on

Operational failure

This function cannot be available during conveyor synchronization. The file path is not found.

No reset operations neccesary. Error reset.

2174

Control failure

2175

The system cannot find the path specified.

Please check whether a file path is right.

Inform ation

Inform ation

Inform ation

Inform ation

on

on

2176

Operational failure

The file access is denied.

Please try once again. If it still recurs, please re-switch on the controller.

Inform ation

Inform ation

Inform ation

Inform ation

on

on

2177

Shift failure

Move limit during shift execution exceeded between steps.

The process cannot access the file because it is being used by another process. This error occurs if the allowable distance between steps during shift execution is too large.

No reset operations neccesary. No reset operations neccesary. No reset operations neccesary.

Alarm

Alarm

Alarm

Alarm

on

on

2181

Control failure

Conveyer running signal was not received.

Conveyer running signal was not received in conveyer normal mode.

No reset operations neccesary.

Alarm

Alarm

Alarm

Alarm

on

on

2185

Operational failure

Step number selected is not available.

This error occurs when designated step number does not exist.

Inform ation

Inform ation

Inform ation

Inform ation

on

on

2194

Operational failure

The program is not recorded nor selected.

This error occurs when the program which is not recorded is selclted and start playback.

Please start after recording the program or selecting other programs.

Inform ation

Inform ation

Inform ation

Inform ation

on

on

2201

Shift failure

Alarm

Alarm

Alarm

Alarm

on

on

Shift failure

Alarm

Alarm

Alarm

Alarm

on

on

2203

Shift failure

This error occurs when a palletize-end function(M47) does not follow Palletize function(M48). When palletizing of 32 or more is executed at the same time, this error is detected. This error occurred calculate shift value is failed from palletize data.

Correct the sequence of Palletize and Palletize end functions in the program.

2202

Palletize-end does not follow Palletize function. More than 32 Palletizing routines not allowed. Palletize data is abnormal.

Alarm

Alarm

Alarm

Alarm

on

on

2204

Shift failure

Multiplex palletize over.

This error occurs when multiplex palletize beyond 8 is carried out.

Please confirm a robot program.

Alarm

Alarm

Alarm

Alarm

on

on

2230

Control failure

Conveyer sync. is not available.

Enable Conveyer synchronization

Alarm

Alarm

Alarm

Alarm

on

on

2240

Operational failure

PUBLIC.INC file is wrong.

Please confirm the definition of variables.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

2241

Operational failure

COSNT.INC file is wrong.

Failure occurs if execution of a function related to the Conveyer is attempted when Conveyer synchronization has not been enabled. This failure occurs when the mistake is found in the method of defining the variable. This failure occurs when the mistake is found in the method of defining the name.

No reset operations neccesary. This error is released if it sets a correct program and restart playback. No reset operations neccesary. No reset operations neccesary. No reset operations neccesary. No reset operations neccesary. Error reset.

Please confirm the definition of names.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

4-40

1. Please reteach as don't pass wrist dead zone. 2. Please consider to use form specified commands. 3. Reset the limit value[Constants][Shift Amount limit][Move limit between steps] and retry program. In conveyer normal mode, turn on conveyer running signal. If the signal is not used, set [When turning off conveyor running signal. = Ignore] in [Constant: 20 Conveyor constant: 4 Conveyor added function] menu. Check the desired step number and retry.

Terminate the unnecessary palletize.(by using R55 or R377) Please refer to palletize data.

Error code list 2242

Operational failure

Module file is wrong.

2243

Operational failure

The variable Data file is wrong.

2244

Operational failure Operational failure Operational failure Operational failure Operational failure

The variable data is an irregular value. The variable cannot be rewritten. The variable doesn't exist. The variable has already existed. The mistake is found in the method of recording the function.

2250

Operational failure

The step data is abnormal.

2251

Operational failure

Incorrect Register or variable number.

2252

Operational failure Operational failure

Failed in reading or writing variable. The parameter for the function command exceeds the normal range.

2254

Operational failure

2255

Operational failure Operational failure

2245 2246 2247 2248

2253

2256

This failure occurs when the mistake is found in the method of recording the function. This failure occurs when it failed in the preservation of the variable data file. The variable of irregular data cannot be used. The variable data of an other unit cannot be rewritten. The variable that doesn't exist cannot be used. The existing variable cannot be redefined. The function command that cannot be used is recorded. whether to find the mistake in the method of recording the function. This error occurs when the value which is not permitted as a parameter of the function instruction is setted while playback executing, and the robot stops.

Please confirm the method of the function.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Please set the initial data of variables, after to select program.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Please set the initial data of variable.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Please review the variable.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Please review the variable.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Error occurs when incorrect Register or variable number is used in a program. This error occurs when the variable is continuously read or written. This error occurs when an illegal parameter is found in the function command while playback operation, and the robot stops.

Enter the correct register or variable number.

The Dynalog function command exceeds the normal range.

This error occurs when an illegal function command is found while playback operation, and the robot stops.

Please set a correct function command again.

Division by 0.

This error occurs when a value is divided by 0 in robot language file. Error occurs when input playback command while it is executing the compilation process. The wrist operated by posture beyond the limits of the posture limit setting. Step of the tool where 0 is set to limit angle the when regulation effective of wrist posture limit was played back. This error occurs when the number of program reservations exceeds ten. Error occurs when a Conveyer running signal is inputed when conveyer simulation or test mode. Error occurs when analog input override (FN169) and digital input override (FN277) are played at the same time. The specified interruption signal was not input whiel executing FN227. This error occurs when the program on which the move command is not recorded before or after the circle middle point (C1) is started. This error occurs when the program on which the move command is not recorded before the circle middle end (C2) is started. Error occurs when number of bytes of a step is too big. This error occurs when Search write function is attempted when not in mode. This error occurs when the robot moves beyond search range

Check the program.

This error occurs if a Search is attempted without the existence of the Search base step position. This error occurs when a Search start does not follow a Search End function. This failure occurs when a case jump and a case jump end do not correspond while playback executing, and the robot will stop.

The Search base step position(s) will be automatically written into the functions.

2258

Operational failure

Playback unavailable because compilation process is executing. Outside wrist posture limit range

2259

Operational failure

It is the tool which does not appoint limit angle

2268

Operational failure

The program can not reserve any more.

2272

Control failure

Conveyer running signal is ON.

2277

Spot weld failure

2300

Spot weld failure

Analog input override and digital input override can not be used at same time. No signal input while executing FN227

2301

Operational failure

There is no referring to point for the circle middle point (C1).

2302

Operational failure

There is no referring to point for the circle end point (C2).

2303

Step is too big.

2356

Operational failure Shift failure

2357

Shift failure

2358

Shift failure

Search base step position is not defined.

2359

Shift failure

2360

Operational failure

Search Start not followed by Search End. The setting of a case jump function is unsuitable.

Playback mode of Search write function is not corrected. Search range exceeded.

Please review the variable.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Please confirm the method of the function.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Please set a correct parameter again.

This error is released if a correct program or step is setted and restart playback. Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Please confirm the number of variables which are read or written. Please correct the parameter.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Althogh re-start operation is possible, please correct the teaching program. This error is released if a correct program or step is setted and restart playback. Check the program. No reset operations neccesary. Error reset.

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When step of the tool which does not use wrist posture limit is played back, please set wrist posture limit to invalidity.

Error reset.

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The number of program reservation should cope with it by the sequence etc. not to accumulate too much.

Error reset.

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Turn off the conveyer running input signal OFF.

Error reset.

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Check the program, and delete function.

Error reset.

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Please confirm the state of the sensor, the connection with the controller and the number of the signal.

Error reset.

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Please start after recording a move command before or after the circle middle point (C1).

This error will be canceled if a program is corrected and restarted. This error will be canceled if a program is corrected and restarted. Error reset.

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Please start after the compilation processing ends.

Please operate the robot so that the wrist posture may operate within the range of the limit.

Please start after recording a move command before the circle end point (C2).

Modify or delete the step. Select mode.

Modify(enlarge) the search range or program to rectify error.

Alter program to give correct Search start/end sequence. Please check a case jump and correspondence of a case jump end.

No reset operations neccesary. No reset operations neccesary. No reset operations neccesary. No reset operations neccesary. This failure is released if a correct program is setted and restart playback.

4-41

Error code list 2361

Operational failure

It was going to jump beyond the case jump range.

This failure occurs when the condition value of a case jump is too large and there is no jump step in the program while playback executing, this abnormality is detected, and the robot will stop.

Please set a correct parameter again.

2367

PLC failure

Scan of Built-in PLC has stopped.

Although Built-in PLC status is except , when scan of Built-in PLC has stopped, it becomes this error at the time of robot operation.

Built-in PLC status is set as by constant mode, and scan is started.

2368

PLC failure

Connection with Built-in PLC cannot be performed.

It becomes this error when connection with Built-in PLC cannot be performed.

Please check the environment of Built-in PLC of operation.

2369

PLC failure

Built-in PLC cannot be started.

It becomes this error when Built-in PLC cannot be started.

Please check the environment of Built-in PLC of operation.

2370

PLC failure

Built-in PLC cannot be stopped.

It becomes this error when Built-in PLC cannot be stopped.

Please check the environment of Built-in PLC of operation.

2371

PLC failure

There is no resource performed by Built-in PLC.

It will become this error if a starting demand is performed in the state where there is no resource performed by Built-in PLC.

Download a PLC ladder program.

2372

PLC failure

PLC-Engine has not been started.

It becomes this error when it is not able to start by the starting demand of PLC-Engine.

Please check the environment of Built-in PLC of operation.

2373

PLC failure

It becomes this error when an error is detected by Program check at the time of PLC-Engine starting.

Please carry out program check by [3 PLC program check] of [14 PLC program Edit] of Service.

2383

Operational failure

The error was detected by Program check at the time of PLC-Engine starting. The function data is abnormal.

This error occurs when the function instruction which is not permitted is setted while playback executing, and the robot stops.

Please set the function again.

2387

Shift failure

3 of the step points for On-transfer are in line.

Error occurs when 3 step points are situated along the same line for the On-line Transfer(M53,M54).

Designate step positions not in the same line for the On-line transfer function.

2390

Operational failure

There is no user function definition data.

Error occurs when there is no data which defined the specified user function.

Create a user function definition file.

2391

Operational failure

There is no user function definition data.

Error occurs when there is no data which defined the specified user function.

Create a user function definition file.

2400

Emergency stop failure

Emergency stop signal input line failure.

This Error occurs when disagreement has happened between dual emergency stop signal input lines. (1) Cable failure(contact failure, broken wire) (2)Emergency stop switch troubles.

First, release all emergency stop switches, and perform operation again. If the error recurs, check whether the emergency stop SW line is correctly wired.

2401

Emergency stop failure

Safety signal input line failure(Safety plug)

This Error occurs when disagreement has happened between dual safety signal input lines. (1) Cable failure(contact failure, broken wire) (2)Safety plug troubles.

First, release sefety plugs, and perform operation again. If the error recurs, check whether the safety plug line is correctly wired.

4-42

This failure is released if a correct program is setted and restart playback. Unusual reset is carried out after changing Built-in PLC into a starting state. Unusual reset is carried out after changing Built-in PLC into a starting state. Unusual reset is carried out after changing Built-in PLC into a starting state. Unusual reset is carried out after changing Built-in PLC into a starting state. After download, it changes into a starting state and unusual reset is carried out. Again, a starting setup is carried out, it changes into a starting state, and unusual reset is carried out. Error reset.

This error is released if a correct program or step is setted and restart playback. Designate step positions not in the same line for the On-line transfer function. A power supply is re-switched on after creating a user function definition file. A power supply is re-switched on after creating a user function definition file. First, release all emergency stop switches, and perform operation again. If impossible, remove the cause of the error, and turn on the power again. First, release safety plugs, and perform operation again. If impossible, remove the cause of the error, and turn on the power again.

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Error code list 2402

Emergency stop failure

Safety signal input line failure(Enable/Mat SW)

This error occurs when disagreement has happened between dual safety signal input lines. (1) Cable failure(contact failure, broken wire) (2)Enable/Mat SW troubles.

First, release enable switches, and perform the operation again. If the error recurs, check whether the enable switch line is correctly wired.

2410

Operational failure Request maintenance

User failure is not defined. It became a check time limit.

The error file was not found.

Please define Failure by [Service]→[25 Robot Diagnosis]→[6 User Error]. Please do the check completion processing after it checks.

2412

Request maintenance

Information by number of failure log

The number of remainder failure log reached a set value.

2413

Request maintenance

Information by number of another preservation failure log

The number of remainder another preservation failure log reached a set value.

2435

Spot weld failure

2436

Spot weld failure

The specified welder cannot be used with this unit. The servo gun is not connected with the specified welder.

2437

Spot weld failure

Abnormal panel thickness detected.

2497

FieldBus failure FieldBus failure Operational failure

RIO detected the communications error. The RIO interface is abnormal. Step number not designated.

The servo gun connected with the specified welder is not defined as a mechanism of this unit. The welder with which the servo gun was not connected when the servo gun function was used was specified. Dramatic difference of panel thickness exists between recorded value in weld condition and detected value. An abnormal communication was generated by the RIO link. There is no answer from the RIO interface. This error occurs when a command only valid after designating a step number is attempted without step designation.

2519

Operational failure

Please recover the statement of the Interface panel.

2527

Operational failure

File read or write fault.

2528

Operational failure

The memory medium is not discriminable.

2530

Operational failure Spot weld failure

Bad program file.

2536

Spot weld failure

Welder fault.

2537

Spot weld failure

Welding time exceeded limit.

2538

Spot weld failure

The gun not open.

Error occurs if the Gun closed signal is received after the welding sequence ends.

Check the GUN or welding unit.

2539

Spot weld failure

The gun is not half open.

Check the GUN or welding unit.

2540

Spot weld failure

The gun is not fully open.

2541

Spot weld failure

Stuck Weld GUN detected.

Error occurs if the Gun half-open signal is not received after Open gun half signal is output by the controller. Error occurs if the Gun full-open signal is not received after Open gun fully signal is output by the controller. Error occurs if the System fault signal is detected after completion of a welding sequence.

2411

2498 2518

2535

File operation of FTP client is canceled.

check

It failed to save data when the primary power is turned OFF or when the primary power voltage dropped abnormally.Because "Recovery at power failure" of the interface panel is set the "necessary" , it needs to return the interface panel statement. This failure occurs when the media format does not match the format selected in the controller or the file has been corrupted.", When memory media, such as a FIROPPI disk and an memory card, are not initialized, this error occurs. Error occurs when data header of program file is crashed. FTP client menu is closed, when upload or download executed.

Error occurs when the welding timer detected some errors. Standard welding timer generates this error when the controller received the welder fault signal from welding timer after the end of welding sequence. Regarding except standard welding timer, refer the each operation manual. Error occurs if a Weld competed signal is not input before the designated time period.

Error

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on

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Error reset.

Inform ation

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Error

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on

Error reset.

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Modify the program.

Error reset.

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Check the weld condition data and real work piece thickness.

This error is released if restart playback. Error reset.

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Error reset.

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This error is released if a correct program or step is setted and restart playback. After removal of failure, please carry out "failure-reset".

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Please try once again, after delete the file.

No reset operations neccesary.

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on

By Service / File Manager / Format memory card/Floppy disk, please use it after initializing a memory medium.

It will be canceled if some keys are pushed. Error reset.

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on

Alarm

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on

No reset operations neccesary.

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on

This error is released if restart playback.

Alarm

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on

This error is released if restart playback. This error is released if restart playback. This error is released if restart playback. This error is released if restart playback. This error is released if restart playback.

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The failure log file is backing up preserved if necessary. Afterwards, "Failure log clear" is executed by the failure logging monitor. Or, information on the number of failure log is set to "Not Occur" by the error logger item. The failure log file is backing up preserved if necessary. Afterwards, "Failure log clear" is executed by the failure logging monitor. Or, information on the number of another preservation failure log is set to "Not Occur" by the error logger item. Modify the program.

Please check the connection and the RIO scanner of the communication cable. Please exchange the RIO interface. Please designate a step number and retry.

(1)Please execute "State return" in the Interface Panel Design. (2)If recovery is not required, please set "Recovery at power failure" to "Unnecessary" in the "Touch Panel Conditions".

Delete the program file. The file under writing might been damaged. Please confirm the file that is uploaded or downloaded. Please delete and execute download or upload again when the file has been damaged. Check the welder unit.

Check the welder is operating normally.

Check the GUN or welding unit.

Error occurs if the Weld stuck signal is received when the welding sequence ends.

First, release enable switches, and perform the operation again. If it is impossible, remove the cause of the error, and turn ON the power again. Error reset. The check completion processing is done. Error reset.

4-43

Error code list 2542

Spot weld failure

Coolant fault #1.

Error occurs if the Water flow switch #1 signal is detected after completion of a welding sequence.

Check the GUN or welding unit.

2543

Spot weld failure

Coolant fault #2.

Error occurs if the Water flow switch #2 signal is detected after completion of a welding sequence.

Check the GUN or welding unit.

2544

Spot weld failure

Air pressure fault.

Error occurs if the Air pressure switch signal is detected after completion of a welding sequence.

Check the GUN or welding unit.

2545

Spot weld failure

Transformer temperature fault.

Error occurs if the Thermo. temp. fault signal is detected after completion of a welding sequence.

Check the GUN or welding unit.

2546

Spot weld failure

Peripheral system fault.

Error occurs if the System fault signal is detected after completion of a welding sequence.

Check the GUN or welding unit.

2552

Spot weld failure

Both of half-open and full-open signals are given.

Check the GUN or welding unit to determine the cause of the two simultaneous signals.

2555

Spot weld failure

Servo-gun is not executed to obey the welder sequence.

Error occurs if both the Gun half-open signal and Gun full-open signal are received simultaneously after Open gun half signal is output by the controller. Error occurs when the servo gun is not achieved to command pressure.

2556

Spot weld failure Shift failure

2570

Vision sensor failure

Vision sensor communication data error.

The function was attempted that is not allowable while servo gun is gripping. This error occurs if the amount of compensation of each axis becomes excessive as a result of compensation calculation. Internal error in the vision sensor system was detected.

Please execute the function after releasing the grip.

2569

The function can not be used while servo gun is gripping. The amount of circle locus compensation is unusual.

2571

Vision sensor failure

Vision sensor command/reply buffer overflow.

Too many commands to vision sensor or replies from vision sensor at the same time.

Please modify timing of function execution.

2572

Vision sensor failure

Vision sensor recognition error.

Vision sensor could not recognize the measure object.

Please check the measure object is within measure area. If the object is within measure area, please modify measure condition parameters or adjust lighting environment.

2573

Vision sensor failure

Vision sensor shift error.

The measure object isn't within shift area or vision sensor could not recognize the measure object.

Please check the measure object is within shift area. If the object is within shift area, please modify measure condition parameters or adjust lighting environment.

2574

Vision sensor failure

Error about frame grabber.

Frame grabber is out of order.

Please replace the frame grabber board.

2575

Vision sensor failure

Image acquire error.

Acquiring image timeout detected. Or Camera cable is cut / camera is out of order.

Please check camera setting. If this is right, replace the camera cable / camera.

2576

Vision sensor failure

Vision sensor socket error.

Fail to create the socket which connect to vision sensor unit.

Please check setting of connection to vision sensor unit.

2577

Vision sensor failure

Vision sensor type error.

Vision sensor function recorded by another vision sensor type is done.

Please remove the vision sensor function and record again.

2578

Vision sensor failure

Measure of Vision sensor is not complete.

Vision measure wait function was done without measuring, or Vision shift function was done before measure completed.

Please measure again, or record Vision measure wait function before Vision shift function.

2579

Vision sensor failure

The measurement time is over.

The measurement processing time too much or the trigger signal line has been disconnected.

Please modify the method of measuring the vision sensor, and check the trigger signal line.

4-44

Please confirm to the sequence of weld-timer.

This error is released if restart playback. This error is released if restart playback. This error is released if restart playback. This error is released if restart playback. This error is released if restart playback. This error is released if restart playback.

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This error is released if restart playback. Error reset.

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on

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Please modify teaching position.

No reset operations neccesary.

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on

Please check hardware of vision sensor.

After removal of failure, please turn on power supply of the controller again. After removal of failure, please carry out "failure-reset". After removal of failure, please turn on power supply of the controller again. After removal of failure, please turn on power supply of the controller again. After removal of failure, please turn on power supply of the controller again. After removal of failure, please turn on power supply of the controller again. After removal of failure, please turn on power supply of the controller again. After removal of failure, please turn on power supply of the controller again. After removal of failure, please turn on power supply of the controller again. After removal of failure, please turn on power supply of the controller again.

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Error code list 2582

Vision sensor failure

Vision sensor communication data error.

Error was detected in the data format which had been sent from the vision sensor.

Please confirm whether there is loosening of connector.

2583

Vision sensor failure

Vision sensor returns no answer.

It takes time to process the vision sensor too much.

Please modify setting of the vision sensor.

2584

Vision sensor failure

Vision sensor error.

Error was detected in the vision sensor.

Please refer to the manual of the vision sensor.

2585

Vision sensor failure Vision sensor failure

Vision sensor function can not be carried out.

The function execution by the check go/back is not permitted in the vision mode. The vision sensor was not able to complete processing while the conveyer moved at trigger intervals.

Please cancel the vision mode, and do the check go/back.

2586

A synchronous gap was occered by a vision correction conveyer synchronous function. Playback unavailable because visual teaching correction is valid. The measurement point exceeded the distance limit.

After removal of failure, please turn on power supply of the controller again. After removal of failure, please turn on power supply of the controller again. After removal of failure, please turn on power supply of the controller again. Error reset.

Alarm

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on

on

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on

on

Alarm

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on

on

Alarm

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on

on

Please slow down the conveyer speed.

Error reset.

Alarm

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Alarm

Alarm

on

on

The visual teaching correction function is set as enable.

Please set the visual teaching correction function to disable.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

The distance between the measurement points is abnormal or the shape of the measurement point is abnormal. The measurement had been executed again before the measurement was completed. The measurement result is out of shift range.

Please measure these points again.

Error reset.

Inform ation

Inform ation

Inform ation

Inform ation

on

on

Please modify the measurement execution timing.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Please check the position of the work.

Error reset.

Inform ation

Inform ation

Inform ation

Inform ation

on

on

After removal of failure, please carry out "failure-reset". Error reset.

Inform ation

Inform ation

Inform ation

Inform ation

on

on

Alarm

Alarm

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Alarm

on

on

2587

Spot weld failure

2588

Vision sensor failure

2589

Vision sensor failure Vision sensor failure Vision sensor failure

A multiple measurement happened. Shift range over.

Vision sensor error.

Error was detected in the vision sensor.

Please refer to the manual of the vision sensor.

2592

Operational failure

Multiple shift failure.

Modify program to rectify error.

2593

Vision sensor failure Spot weld failure

The measurement time is over.

2595

Spot weld failure

2596

Vision sensor failure Vision sensor failure

It was going to execute the function which is not permitted during seam welding. No base position data set.

A shift, an online transformation, and the base coordinate shift with the vision sensor were executed in the multiple. The measurement processing time too much or the trigger signal line has been disconnected. Carrying out this function is not permitted during seam welding. Or errors are in constant data. The function about another units, such as CALLFAR, is not permitted during seam welding.

2590

2591

2594

2597

2598

2599

Vision sensor failure Shift failure

Seam welding function can not be carried out.

Measure point datas is abnormal.

The measurement type is abnormal. Shift register contains no data.

2601

Operational failure

Servo gun auto-setting gets abnormal data.

2605

Operational failure

User coordinate does not exist.

2606

Operational failure

User coordinate is indefinite.

2607

Operational failure

2608

Operational failure

2609

Operational failure

The user coordinate number which cannot be used as the Stationary tool coordinate was chosen. The user coordinate number which cannot be used was chosen. The coordinate which cannot be used was chosen.

Please modify the method of measuring the vision sensor, and check the trigger signal line.

Error reset.

Inform ation

Inform ation

Inform ation

Inform ation

off

off

Please modify program or constant data.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Please modify program.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

There is no base position before doing the shift function.

Please register base position.

Error reset.

Inform ation

Inform ation

Inform ation

Inform ation

on

on

This failure occurs when the measurement point data is insufficient or the measurement position contradicts the data of a base position when the shift amount is calculated. When the measurement type was a setting of 2D, it tried to execute 'VLOCCVT' function. Error occurs when data aren't established in specified shift register. It is not possible to compute the servo gun inertia using current gathered by parametor auto-setting Failure occurs when use of User coordinate is attempted without the coordinate system being pre-defined. This error is detected when the base of specified user coordinates is not in agreement with the operation standard mechanism of the current unit. Failure occurs although step is Stationary tool interpolation, the operation standard mechanism is chosen as the base of Stationary tool coordinate.

(1)Please measure these points again. (2)Please confirm base positional data.

Error reset.

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on

(1)Please confirm the measurement type. (2)Please use the 'SHIFTR' function at 2D measurement.

Error reset.

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on

on

Setting data in shift register.

Error reset.

Inform ation

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on

on

(1)Please make the servo gun position more wildly between pose 1 and pose 2. (2)Please confirm the servo parameters of target servo gun mechanism. Define User coordinate system(s) in [Service][10 User Coord. Definition]before attempting to use it.

No reset operations neccesary. No reset operations neccesary.

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on

on

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on

on

Define User coordinate system(s) in [Service][10 User Coord. Definition]before attempting to use it.

No reset operations neccesary.

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on

on

Please select stationary tool defined by the world coordinate using FN67.

No reset operations neccesary.

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on

This function is not permitted for using user coordinate on TCF coordinate system. Work coordinate or user coordinate on TCF coordinate was used for the manipulator set as the operation standard mechanism.

Please define user coordinate defined by the world coordinate.

No reset operations neccesary. No reset operations neccesary.

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on

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Please change coordinate.

4-45

Error code list 2610

Operational failure

Pause substitution overlaps.

2611

Operational failure

Modifying user coordinate failed.

2612

Operational failure

2613

Operational failure

2614

Operational failure

2615

Operational failure

Multiple execution of the SEAMANG function was carried out. The SEAMANG function was performed under permitted condition. Tool number has been changed during SEAMANG function. Wrist posture under using FN289 Wrist singularity control function is invalid.

2620

PLC failure

2621

PLC failure

2622

PLC failure

SHARP I/F: CPU error detected.

2623

PLC failure

SHARP I/F: I/O error detected.

2624

PLC failure

SHARP I/F: Special I/O error detected.

2625

PLC failure

SHARP I/F: Option error detected.

2626

PLC failure

SHARP I/F: Power error detected.

2627

PLC failure

SHARP I/F: Extend Power error detected.

2628

PLC failure

2651

PLC failure

SHARP I/F: Sequence program is stopping. Toyopuc I/F is a uninstallation.

2652

PLC failure

Toyopuc I/F:I/O refreshing has stopped.

There is no response from Toyopuc I/F.

Please confirm Toyopuc I/F.

2653

PLC failure

Toyopuc I/F detected the dual port memory malfunction.

Please refer to the manual of Toyopuc I/F.

2654

PLC failure

Toyopuc I/F:Abnormality is found in the dual port memory. Error occurred by toyopuc I/F.

Toyopuc I/F detected the error.

Please refer to the manual of toyopuc I/F.

2655

PLC failure

The communication with Toyopuc I/F got the suspension.

The communication with Toyopuc I/F did the time-out.

The bad electrical contact of Toyopuc I/F or bad functionality of UM237 is thought.

2656

Spot weld failure

Current of tip dresser abnormaled.

This error occurs when the servo dresser is exceeded beyond current range.

(1)Please confirm the tip dress condition.(2)Please confirm the cable between the controller and the servo tip dresser.(3)Please replace the motor.(4)Please replace the drive unit.

2657

Spot weld failure

Tip dresser abnormal.

This error occurs when normal input signal from tip dresser is lost during tip dress function.

Please check the normal input signal from the tip dresser.

2658

Operational failure

The user window has not been opened.

The user window has not been opened.

The user window has not been opened.

2659

Operational failure

Other user tasks use the user window.

Other user tasks use the user window.

Other user tasks use the user window.

4-46

SHARP I/F: JW32CV module cannot be recognized. SHARP I/F: Memory error detected.

Without executing move command, pause substitution to the same mechanism was performed. Modifying user coordinate failed for one reason of the followings. (1)[OZX order] is chosen though it is instruction of two or less points. (2)The points are less than three points. (3)Three points are on the same line. (4)Position data is not encoder. (5)User coordinates register file does not exist. While performing the SEAMANG function, the SEAMANG function was performed again. The function which uses the analog input function except SEAMANG can't be used when SEAMANG function is used. The Tool No. can not be changed during SEAMANG function.

Please teach move command after LETCOORDP function and execute.

No reset operations neccesary. No reset operations neccesary.

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

No reset operations neccesary. No reset operations neccesary.

Error

Error

Error

Error

off

on

Error

Error

Error

Error

off

on

Error

Error

Error

Error

off

on

Alarm

Alarm

Alarm

Alarm

on

on

Please confirm setting of JW32CV module.

No reset operations neccesary. This error will be canceled if a program is corrected and restarted. Error reset.

FN289 Wrist singularity control function is execured, wrist posture must be a level in the robot coordinate and J4 axis must be less than +-2 degrees. When the data exchange with the module cannot be processed, this error is detected. Error occurs when Memory failure in the JW32CV module self-check is detected. Error occurs when CPU failure in the JW32CV module self-check is detected. Error occurs when I/O failure in the JW32CV module self-check is detected. Error occurs when Special I/O failure in the JW32CV module self-check is detected. Error occurs when Option failure in the JW32CV module self-check is detected. Error occurs when Power failure in the JW32CV module self-check is detected. Error occurs when Extend Power failure in the JW32CV module self-check is detected. A sequence program of JW32CV module is stopping. Toyopuc I/F is not found.

Before move step execution, (1)Please level the wrist posture in the robot cooddinate. (2)Please make J4 axis into less than +-2 degrees.

Alarm

Alarm

Alarm

Alarm

on

on

Refer to the Self-check section of the JW32CV Manual.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Refer to the Self-check section of the JW32CV Manual.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Refer to the Self-check section of the JW32CV Manual.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Refer to the Self-check section of the JW32CV Manual.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Refer to the Self-check section of the JW32CV Manual.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Refer to the Self-check section of the JW32CV Manual.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Refer to the Self-check section of the JW32CV Manual.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Please start a sequence program of JW32CV module.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Please confirm whether Toyopuc I/F is installed.

Please turn on the power supply again after Toyopuc I/F installs. Automatically restores, when the problem is solved. Automatically restores, when the problem is solved. Automatically restores, when the problem is solved. Please reenter the power supply after removing a wrong cause. After removal of failure, please turn on power supply of the controller again. This error is released if restart playback. This error will be canceled if a program is corrected and restarted. This error will be canceled if a program is corrected and restarted.

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Inform ation

Inform ation

Inform ation

Inform ation

on

on

Inform ation

Inform ation

Inform ation

Inform ation

on

on

Please correct instruction points.

Please modify the program as SEAMANG function will not be performed again when you use the function. Please modify the program if you use the SEAMANG and the function which uses analog input at the same time. Modify the robot program as same tool number is used during SEAMANG function.

Error code list 2660

Spot weld failure

length of tip dressed abnormaled.

This error occurs when the dress length of tip is exceeded beyond dress length range.

(1)Please confirm the tip dress condition.(2)Please confirm the tip consumption.

2661

Spot weld failure

Tip dress cannot be executed that is servo gun search write is enabled.

Servo gun tip cannot be dressing during of search write.

(1)If tip dress control "servo" then set the tip dress search write "Enabled", else set the servo gun search write "Disabled".

2662

PLC failure

2port ram is abnormal.

Abnormality of 2port ram occurred.

Please confirm the contact failure of Toyopuc I/F, confirm the stop of PC, and confirm reset of PC.

2663

PLC failure

The interface is abnormal with PC.

Failed in the data reading from PC.

Please confirm the contact failure of Toyopuc I/F, confirm the stop of PC, and confirm reset of PC.

2669

Shift failure

For glass handling, X bending shift is calculated too big.

2670

Shift failure

2671

Control failure

X Bending shift volume is bigger than the error limit. Y Bending shift volume is bigger than the error limit. Conveyer synchronization not ON

2672

Shift failure

2673

Shift failure

2674

Shift failure

Sensors don't turn on.(ALIGMNENT)

2675

Shift failure

2676

Shift failure

Bending shift volume is bigger than the error limit. No support function for SJ type manipulator.

2677

Spot weld failure Spot weld failure

Major Welder error(Fault). Welding command is not execute.

2679

Shift failure

2680

Operational failure

2681

Operational failure

2682

Shift failure

2683

Shift failure

Torsion shift volume is bigger than the error limit. The position of X1 exceeded the amount of the compulsion return. The position of X1 exceeded the record position tolerable quantity. Sensors don't turn on.(MAPPING) Glass Handling : The SJ type manipulator's 1st and 2nd arms are unbalanced.

2684

Shift failure

2685

Shift failure

2686

Shift failure

2687

Spot weld failure Spot weld failure

2678

2688

Usage of MAPPING function is wrong. Usage of ALIGNMENT function is wrong.

Glass Handling : Dynamic twisted correction value over.(Accelerating revision) Glass Handling : Dynamic twisted correction value over.(Teach point revision) Glass Handling : Dynamic twisted correction value over.(Position) Major Welder error. Welding command is not execute.

2698

Operational failure

Data level too low for Auto tool load center setting.

2699

Operational failure

2701

Spot weld failure

The measurement result of the automatic setting of tool moment of inertia is abnormal. Servo gun pressure is not achieved.

Modify XY bending table to correct value.

After removal of failure, please turn on power supply of the controller again. After removal of failure, please turn on power supply of the controller again. Please reenter the power supply after removing a wrong cause. Please reenter the power supply after removing a wrong cause. Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

For glass handling, Y bending shift is calculated too big.

Modify XY bending table to correct value.

Error reset.

Error

Error

Error

Error

on

on

Error occurs if a command or function is attempted requiring Conveyer synchronization ON. MAPPING function is re-executed while MAPPING execution. ALIGNMENT function is re-executed while ALIGNMENT execution. There was no input of alignment sensors while ALIGNMENT searching. For glass handling, bending shift is calculated too big.

Turn Conveyer synchronization ON

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Modify program to rectify error.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Modify program to rectify error.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Confirm that the work passes on the alignmnet sensors. Adjust sensor sensitivity. Confirm connection from sensors. Modify bending table to correct value.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Error

Error

Error

Error

on

on

This error occurs if no support function for SJ is executed.

No support function is not used.

Alarm

Alarm

Alarm

Alarm

on

on

Remove the cause of the error.

No reset operations neccesary. Error reset.

Error occurs when the welder board generate the error(Fault). Error occurs when the welder board abort welding command sequence. For glass handling, torsion shift is calculated too big.

Alarm

Alarm

Alarm

Alarm

on

on

Remove the cause of weld error.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Modify twist table to correct value.

Error reset.

Error

Error

Error

Error

on

on

The position of X1 of the robot exceeds the amount of the compulsion return.

Please correct the position of X1 by use of Adjust Position key.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

The value of X1 in the set step exceeds the record position tolerable quantity.

Please set X1 below the record position tolerable quantity.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

There was no input of alignment sensors while MAPPING. For glass handling, the J1 angle of the earth does not equal to the J2 angle of the earth.

Confirm connection from sensors.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

1) On [Constant Setting]-[Machine Parameters]-[Encoder Correct], the J1 angle of the earth equals to the J2 angle of the earth. 2) After the memory format of the controller, this error occurs. The encoder correct is exactly executed. Please take a second look accelerating twisted revision parameter.

Error reset.

Error

Error

on

on

Error reset.

Alarm

Error

on

on

For glass handling, dynamic twisted correction value exceeded error inspection level.

Please take a second look teach point twisted revision parameter.

Error reset.

Alarm

Error

on

on

For glass handling, dynamic twisted correction value exceeded error inspection level.

Please take a second look position twisted revision parameter.

Error reset.

Alarm

Error

on

on

Error occurs when the welder board generate the weld error. Error occurs when the welder board abort welding command sequence. In the automatic tool center of gravity set function, it is not possible to calculate by the gathered current value. This failure occurs when gathered speed or current data are abnormal.

Remove the cause of weld error.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Remove the cause of weld error.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

(1)Teach points that enough unbalanced torque is exerted on J3,J5 and J6 axis. (2)Make the wrist posture vary greatly between step 1 and step 2 positions.

No reset operations neccesary.

Alarm

Alarm

Alarm

Alarm

on

on

(1)Please correct the teaching so that move range is wide as much as possible. (2)Please correct the teaching so that the move axis is not influenced by gravity. Error occurs when the set gun pressure is not achieved within the time period set in [Constant][General characteristic of Servo Gun].

No reset operations neccesary.

Alarm

Alarm

Alarm

Alarm

on

on

This error is released if restart playback.

Alarm

Alarm

Alarm

Alarm

on

on

For glass handling, dynamic twisted correction value exceeded error inspection level.

Error occurs when the set gun pressure is not achieved within the time period set in [Constant][General characteristic of Servo Gun].

4-47

Error code list 2703

Spot weld failure

GUN SEARCH not complete.

2710

Spot weld failure

WI signal does not become off.

2757

Spot weld failure

2763

Spot weld failure

Weld control is not supported by MEDLAN command. Different spot welding gun mounted.

2781

Spot weld failure

2782

Spot weld failure

2783

Spot weld failure

2784

Spot weld failure

2785

Spot weld failure

Welding point is far from a recorded point.

2786

Spot weld failure

2790

Operational failure

It was going to start while waiting for WI of manual or external welding. Pose calculation failed.

2791

Operational failure

Error signal detected during form cutting.

2792

Operational failure

No current detection signal turn on.

2793

Operational failure

Form cutting error.

2800

Operational failure

Mechanism is not mounted.

2801

Operational failure

Sub-mechanism cannot be selected.

2802

Operational failure

Mechanism number is wrong.

2803

Operational failure

Different mechanism mounted.

2804

Operational failure

Conflict of mechanism change.

2805

Operational failure

Mechanism number is wrong.

2806

Operational failure

The state of the master mechanism and the slave mechanism is the disagreements.

2823

Sealing failure

2824

Sealing failure

2825

Sealing failure

The temperature of the material exceeded the upper bound. The temperature of the material exceeded the lower bound. Flow ready fault.

2826

Sealing failure

The material is lack.

2827

Sealing failure

The sealing incomplete.

4-48

Servo Gun Move-tip consumption exceeded maximum limit. Servo Gun Settle-tip consumption exceeded maximum limit. The difference of tip consumption is too large. The synchronous welding was not executed. The synchronous welding cannot be executed.

Error occurs when a GUN search function is abnormally interrupted by a Spot welding function. Or, the order of executing the tip consumption detection is wrong. Error occurs when a WI signal, from the last weld sequence, remains on more than 5s after a GUN or WELD signal is output by the controller. Error occurs when the weld control software is too old.

Please modify the execution timing of the tip consumption detection.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Check the welder is operating normally.

This error is released if restart playback.

Alarm

Alarm

Alarm

Alarm

on

on

Install the latest software version.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Error occurs when a gun different from the gun specified in a Spot welding function is detected. Servo Gun Move-tip consumption exceeded the maximum limit.

Correct the program, otherwise attach the correct gun before using Spot welding function.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Replace the worn Move-tip and detect tip consumption again.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Servo Gun Settle-tip consumption exceeded the maximum limit.

Replace the worn Settle-tip and detect tip consumption again.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

When the synchronous welding was executed, the difference of tip consumption of master gun and slave gun exceeded the alarm detection level. (1)Specified cancer is not connected. (2)The same welder is specified. (3)Specified gun is not in the unit. (4) Guns with different installation has been selected. (5)The servo gun exists together to the air gun. (6)MEDbus welding I/F is specified in SYNCSPOT(FN303). (7)MEDbus welding I/F is not specified in SYNCSPOTIWB(FN316). This error occurs when the welding point is far from a recorded point.

Please execute synchronous welding again after exchanging the tip, and detecting the tip consumption.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Please reconsider gun/welder number.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Please check not to collide from other equipment. Please check settings as below, servo gun contact detect, tool constant parameters, servo gun tip consumption, servo gun bend characters. Please start after releasing WI.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

No reset operations neccesary. No reset operations neccesary. No reset operations neccesary. No reset operations neccesary. Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Please input the submechanism input signal correctly, and using a mount mechanism function.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Please set the mechanism number correctly.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Please correct the program.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Please correct the program.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Please set the mechanism number correctly.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Please connect the mechanism again after separating the mechanism once.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Please check the temperature adjuster.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Please check the temperature adjuster.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Please check whether the specified pressure is appropriate.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Please modify the timing of reload.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Please cancel the cause of stopping or modify the timing to flow after the reload operation is done.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

It will generate, if it starts while waiting for WI of manual or external welding. This error occurs when any axis angles can not be calculated with the form parameters. This error occurs when the error signal of form cutting is ON during form cutting.. This error occurs when the current detection signal isn't turn on at cutting start. This error occurs when any trouble are happen during the form cutting.

Check form parameters.

Error occurs when a mount mechanism function is attempted without a mechanism being attached. Or, the sub-mechanism input signal line has been disconnected. Because two or more submechanism input signal has been turned on, the connected mechanism cannot be selected. The mechanism number that was not able to change the mechanism or was being registered with the Connection simultaneously mech. table by the slave was selected. . Error occurs when a mechanism different from the mechanism specified in a step is detected. Error occurs when the change function was executed for the mechanism using other units. The mechanism number which was not able to change the mechanism was selected. The connection of the mechanism registered in “Connection simultaneously mech. table” of the mechanism change is a disagreement. The temperature of the seal material exceeded the set upper bound value. The temperature of the seal material exceeded the set lower bound value. Error occurs when the set pressure is not achieved within the time period set in constant. The seal material in the pump does not suffice for the specified amount. The robot stopped while flowing or the pump position reached flow limit.

Attach a mechanism before using a mount mechanism function.

Check the cutting controller. Check the connection with the cutting contorller. Check the cutting controller. Check the connection with the cutting contorller. Check form cutting parameters. And Check the cutting controller and the connection with the cutting contorller.

Error code list 2828

Sealing failure Sealing failure

The sealing operation cannnot be executed. The reload operation is incomplete.

Sealing failure Sealing failure

Dispense incomplete.

Sealing failure Operational failure

The dispense function can not be carried out. The command which is not permitted was executed in the controller with the force/Torque sensor.

2851

Operational failure

2852

FLEXhand failure

The force/torque sensor function can not be carried out. Clamp position limit over.

2853

FLEXhand failure

The air assist mechanism is abnormal.

2854

FLEXhand failure

FLEXhand clamping motion time over.

2855

FLEXhand failure

Air assist mechanism does not work.

2856

FLEXhand failure

Clamp function usage is wrong.

2857

FLEXhand failure

Unclamp function usage is wrong.

2858

FLEXhand failure

Unclamp direction is not correct.

2859

Operational failure

A fetched signal status has changed.

2860

Operational failure

Effective steps which FETCH result is available was exceeded.

2861

Shift failure

The designated palletize No. is not registered.

2862

Shift failure

The designated palletize number has never been executed yet.

2863

Shift failure

Designate a palletize number under execution.

2864

Shift failure

2865

Shift failure

This function is not supported to the unit without manipulator. palletize function can not be carried out.

2866

Spot weld failure

Welder fault.

2867

Spot weld failure

Coolant fault #1.

Error occurs when the Water flow switch #1 signal is detected in a welding sequence.

Check the GUN or welding unit.

2868

Spot weld failure

Coolant fault #2.

Error occurs when the Water flow switch #2 signal is detected in a welding sequence.

Check the GUN or welding unit.

2829

2830 2831

2832 2850

The analog input board is a uninstallation.

Other sealing operation is executing. Because Motor's on is turn off while reloading, reload operation is not able to be completed. Reached flow limit.

Please modify the timing of operation.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Please modify the timing of operation.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Please modify the timing to flow after the reload operation is done. Please modify setting whether to install the analog input board.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Please modify program.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Please correct not to use the analog input use function of a force/torque sensor and others with the same controller.

No reset operations neccesary.

Alarm

Alarm

Alarm

Alarm

on

on

Please modify parameter.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

It detects when clamping motion quantity exceeds 'Clamp position limit' setting. It detects when the air assist mechanism is located on the clamping end during the clamp function is executed. It detects when clamping motion time exceeds the setting 'Wait time for clamp action'. It detects when input signal from the air assist mechanism is not change even if its activation signal is output. It detests when FN362 clamp function is executed again while FLEXhand is clamping. It detests when FN363 unclamp function is executed while FLEXhand is not clamping. It detests when FLEXhand tries to move to clamping direction when unclamp function is executed. I-signal status fetched by 'FN528 FETCH' function must not change before a function referring the I-signal is executed. Executed position step number exceed the setting number of Effective span of a fetched signal before reaching the step which is checked by the signal set by fetch function. The palletize pattern of designated number is not defined.

(1)Confirm a place of the work piece. (2)Confirm the recorded position of the clamping start step.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

(1)Confirm whether FLEXhand grips the work correctly.(2)Confirm whether FLEXhand is dropping the work.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

(1)Confirm FLEXhand clamps the work piece well. if it doesn't, correct its position or recorded step position. (2)Correct setting 'Clamping pressure' higher. Confirm whether the air assist mechanism works correctly. (2)Confirm whether the signal from the air assist mechanism is input correctly.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Confirm and correct the program.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Confirm and correct the program.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

(1)Confirm setting of 'Opened finger position'. (2)If the parameter is 0, the setting 'Standard unclamp distance' in service menu is used. Confirm the setting. (1)Control the I-signal status so as not to change until a function referring the signal is executed. (2)Modify 'FN528 FETCH' recorded step.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

This failure is released if restart playback. This failure is released if restart playback.

Error

Error

Alarm

Alarm

on

on

Error

Error

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Palletize status is registered in palletize register when executing it once, and maintained until resetting it. This operation cannot be done to palletize number unregistered in the palletize register. This operation is possible only the palletize number under execution.

(1)Please designated an executed palletize number. (2)Please execute palletize of the designated number even once before doing this operation.

After removal of failure, please carry out "failure-reset". After removal of failure, please carry out "failure-reset".

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

This error occurs if this function is executed in the unit without manipulator. A move step is needed just after FN388(PALLET3_SELZ)/FN394(P ALLET3_SELZJMP) step. Error occurs when the Welder fault signal is detected in a welding sequence.

Do not use this function in the unit without manipulator.

After removal of failure, please carry out "failure-reset". No reset operations neccesary. Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

It is setting which uses the thermo sensor and the pressure sensor though the analog input board is not installed. Specified gun is not defined in the unit. In a controller with the force/torque sensor, the commands (SPDDOWNA etc.) which use the analog input's of those other than a force/torque sensor cannot be used. Force/torque sensor function is disabled.

(1)Modify 'FN528 FETCH' recorded step. (2)Effective span of fetched signal can be modified at "Constant Setting:6 Signals:1 Signal Condition".

(1)Please designated a defined palletize number. (2)Please define palletize pattern of the designated number.

(1)Please designated a palletize number under execution. (2)Please execute palletize of the designated number before doing this operation.

Please record move step just after FN388(PALLET3_SELZ)/FN394(PALLET3_SELZJMP). Check the welder unit.

After removal of failure, please turn on power supply of the controller again. After removal of failure, please turn on power supply of the controller again. After removal of failure, please turn on power supply of the controller again.

4-49

Error code list 2869

Spot weld failure

Air pressure fault.

Error occurs when the Air pressure switch signal is detected in a welding sequence.

Check the GUN or welding unit.

2870

Spot weld failure

Transformer temperature fault.

Error occurs when the Thermo. temp. fault signal is detected in a welding sequence.

Check the GUN or welding unit.

2871

Spot weld failure

Peripheral system fault.

Error occurs when the System fault signal is detected in a welding sequence.

Check the System.

2872

Spot weld failure

The move-electrode diameter is less than the minimum diameter.

Replace the worn move-electrode and detect electrode consumption again.

2873

Spot weld failure

The settle-electrode diameter is less than the minimum diameter.

2880

Spot weld failure

Corrected value of spot position is abnormal.

2881

Spot weld failure

Spot position correction can not be carried out.

The move-electrode diameter is less than the minimum diameter set by the seam welding parameters. The settle-electrode diameter is less than the minimum diameter set by the seam welding parameters. Corrected value is over to setting permit value by spot position correction. It is in condition which spot position correction can not be carried out.

2882

Spot weld failure

2883

Spot weld failure Spot weld failure

The search of spot position correction went wrong. Spot position correct function fails. The specified welder is not effective.

2908

2923

Spot weld failure

Spot welding gun is not mechanically connected

2937

Operational failure

Speed type endless cannot be executed.

2938

Operational failure

The change in an endless control cannot be executed.

2939

Operational failure

The function can not be used in velocity control.

2945

Operational failure

Signals of multi input are not designated.

2946

Shift failure

User coordinate number is not selected.

2961

FieldBus failure

Setted area of common memory is overlapped.

2971

Operational failure

Stationary tool is not selected.

2973

Control failure

Playback unavailable because the enable switch is not in the release position.

2974

Operational failure

Pause or External pause signal being given.

2975

Control failure Preventive maintenance message

It cannot be started under G-STOP. System Memory Protection disabled

Preventive maintenance message

System Memory Protection disabled

2976

2977

4-50

A work was not able to be detected by spot position correction. Internal failure of spot position correction is detected. The specified welder is not effectively set by the spot welding constant. It was judged that spot welding gun was not mechanically connected because the connection signal was not input. Error occurs when speed type endless was not able to be executed.

After removal of failure, please turn on power supply of the controller again. After removal of failure, please turn on power supply of the controller again. After removal of failure, please turn on power supply of the controller again. Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Replace the worn settle-electrode and detect electrode consumption again.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Please confirm the position of spot welding function.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

(1)Please confirm the not squeeze off. (2)Please confirm the machine lock and mechanism disconnect are off. (3)Please confirm the "servo gun teach check" and "press adjust" are disabled. (4)Spot position correction with other welder machine be carried out at ones. (1)Please confirm parameters of the spot position correction. (2)Please confirm the recorded position of spot welding function. There is no countermeasure in particular.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Modify the welder number.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Connect gun mechanically. When gun is connected, check the disconnection of the signal line.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Please set the mechanism number again.

The error is not released until measures are executed. Error reset

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

off

off

Please execute the function after change control type of change type endless axis to position control.

Error reset

Alarm

Alarm

Alarm

Alarm

off

off

Create the multi input conditions, or replace the function to normal input.

Error reset.

Inform ation

Inform ation

Inform ation

Inform ation

on

on

Execute [FN113 Change coordinate for shift] before shift functions.

No reset operations neccesary. No reset operations neccesary.

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Because the endless control method is not set to "Change", the specified mechanism cannot be executed. The function was attempted that is not allowable while change type endless axis is controlled by velocity control. Error occurs when a multi input function was attempted playback with no condition number. It is necessary to select user coordinate number before shift function at user coordinate. 1.Area of common memory setted by robot controller is already used by other node. 2.Since communication was not able to be established at the time of power activation, it was not able to participate in a network. Failure occurs when Stationary tool is not selected although step is Stationary tool interpolation. This error occurs when a playback command was input while the enable switch is being grasped.

1. Please confirm the endless control method. 2. Please confirm the mechanism number.

Error occurs when a Start command is given while the pause signal is being held or External pause signal is being given. Error occurs when a start command is given under G-STOP. System Memory Protection is disabled. You must not turn off the controller.

Release Pause or External pause signal(if External pause signal cable is cut the external pause signal is considered as being given.

System Memory Protection is disabled. You must not turn off the controller.

Please change System Memory Protection enable.

1.After change setting into correct one, perform re-initialization of Fieldbus. 2.Check the connection of a LAN cable. Turn off the power and replace a LAN cable.

Please select stationary tool using FN67.

(1)Please input the playback command after releasing the enable switch. (2)Replace the teach pendant. (3)Replace the sequence board UM352/L21700F00.

Please release G-STOP by turning on G-STOP signal (TBEX1). Please change System Memory Protection enable.

No reset operations neccesary. After removal of failure, please carry out "failure-reset". Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Please change System Memory Protection enable and restart the controller. Please change System Memory Protection enable and restart the controller.

Alarm

Alarm

Alarm

Alarm

on

on

Inform ation

Inform ation

Inform ation

Inform ation

off

off

Error code list 2978

Preventive maintenance message

System Memory Protection disabled

System Memory Protection is disabled. You may lost the data of system memory at power off.

Please change System Memory Protection enable.

Error

Error

Error

Error

on

on

Check the user application.

Please change System Memory Protection enable and restart the controller. Error reset.

2990

Spot weld failure Spot weld failure Operational failure

The user application is not ready. No response form the user application. Duplicate output signal attribute.

3010

Control failure

Far distance between a current position and a position at putting servo-power off.

3018

Spot weld failure

Weld tip may be worn.

3021

Control failure

Too far distance between a current position and a position at putting servo-power off.

3022

Operational failure

Take care of not recovering position at the next servo on.

3037

Spot weld failure

3051

Control failure

The external operation of servo gun is not permitted while running program. Please release both of the enable swiches.

The user application is not ready or it stopped. No response to the specified user application to the command. FN35 was going to carried out or set on output signal which assigned attribute already. Since stopping during high-speed playback and so on, robot couldn't normally stop on the trajectry. Since the distance is over the limit for error detection value, robot can't recovery. This warning occurs when the Weld counter exceeds the limit value. Since stopping during high-speed playback and so on, robot couldn't normally stop on the trajectry. Since the distance is over the limit for error detection value, robot can't recovery. Since the position for recovery couldn't recorded, never recover the position at the next servo on without related to distance. This might be occured at servo off during recovery position. The external operation of servo gun was executed while running program.

Alarm

Alarm

Alarm

Alarm

on

on

Check the user application.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Please clear attribute assignment in order not to attribute is duplicate.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

If a limit for error detection is too small, change the value in constant setting. Position Recovery is invalidated setting both recovery limit values to zero.

Robot can restart from there without reset operation.

Inform ation

Inform ation

Inform ation

Inform ation

on

on

Check the Gun tip and reset the counter.

No reset operations neccesary. Error reset. Robot can't playback, untill step is set.

Inform ation

Inform ation

Inform ation

Inform ation

on

on

Alarm

Alarm

Alarm

Alarm

on

on

There is no way.

No reset operations neccesary.

Inform ation

Inform ation

Inform ation

Inform ation

on

on

Please execute of external operation while program is stopping or servo gun is separating.

No reset operations neccesary.

Inform ation

Inform ation

Inform ation

Inform ation

on

on

This failure occurs when grasping the enable swich after detecting inconsistency without releasing both of them. When the startup is input during the processing execution by text read/write screen, this error is output. At the teach-mode, Enable switch was not released position and robot master ON operation was carried into effect. This error occurs when detecting the temperature alarm on the CPU board. It was not a connection to the FTP server that was backing up of an automatic backup ahead. Or, neither an initial folder nor the folder of this name existed on the home directory of the FTP server. The thing backed up automatically cannot be done. The storage medium is not prepared, and read-only and memory capacity shortage, etc. are thought. When it is going to copy a file to a write-protected memory cards etc., this error sets.

Please release both of the enable swiches.

No reset operations neccesary.

Inform ation

Inform ation

Inform ation

Inform ation

off

off

3057

Spot weld failure

Cannot startup while read/write text executing.

Please input the startup instruction after text read/write operation ends.

No reset operations neccesary.

Inform ation

Inform ation

Inform ation

Inform ation

on

on

3062

Spot weld failure

Enable switch is not released position.

Release Enalbe switch and please perform robot master ON operation.

No reset operations neccesary.

Inform ation

Inform ation

Inform ation

Inform ation

off

off

3079

CPU board failure

CPU bord temperature warning.

(1)Check the fans on the rack unit are operating, or clean up them. (2)Replace the rack-unit fan. (3)Replace the CPU board. Please confirm host name, user ID, password, and initial folder of ftp client.

Error reset.

Inform ation

Inform ation

Inform ation

Inform ation

on

on

3081

Operational failure

Auto backup can't connect to FTP server for auto backup.

No reset operations neccesary.

Inform ation

Inform ation

Inform ation

Inform ation

on

on

3082

Operational failure

Abnormality occurred while backing up automatically.

Please confirm the state of the storage medium.

No reset operations neccesary.

Inform ation

Inform ation

Inform ation

Inform ation

on

on

3083

Operational failure

The memory medium is read-only.

Please prepare the memory medium to which writing is made and perform a copy from the beginning once again.

Inform ation

Inform ation

Inform ation

Inform ation

on

on

Failure occurs if there is no memory space left when attempting to copy to external device or internal memory.", The detection reason is that the specified device was not detected when the file operation is done.

Create space in current media device or use another.

It will be canceled if some keys are pushed. No reset operations neccesary.

3084

Operational failure

Media device is full.

Inform ation

Inform ation

Inform ation

Inform ation

on

on

3085

Operational failure

The memory media is not prepared.

Inform ation

Inform ation

Inform ation

Inform ation

on

on

Because T/P was not connected, it was not able to access the T/P external memory.

Please connect T/P.

Inform ation

Inform ation

Inform ation

Inform ation

on

on

Operational failure

Auto backup can't connect to the T/P external memory for auto backup. It failed in the attestation with TP.

It will be canceled if some keys are pushed. No reset operations neccesary.

3086

Operational failure

3087

The attestation to TP external memory went wrong.

Please check connection of TP external memory.

Inform ation

Inform ation

Inform ation

Inform ation

on

on

3089

Operational failure

It cannot process in the same device.

It was going to copy to the same device by the same file name.

Please change a file name or a device and redo copy operation again.

Inform ation

Inform ation

Inform ation

Inform ation

on

on

3097

Spot weld failure

Cannot startup while read/write text executing.

Please input the startup instruction after text read/write operation ends.

Inform ation

Inform ation

Inform ation

Inform ation

off

off

3103

Control failure

In OFF-mode, motors are not able to be ON.

When the startup is input during the processing execution by text read/write screen, this error is output. Both of play and teach signal are OFF.

No reset operations neccesary. It will be canceled if some keys are pushed. No reset operations neccesary.

Inform ation

Inform ation

Inform ation

Inform ation

off

off

3110

Operational failure

Number of axes miss-matched.

Check the program file type is comptible with the constants currently in use.

Inform ation

Alarm

Inform ation

Alarm

on

on

3111

PLC failure

The alarm was generated by Toyopuc I/F.

Failure occurs when the number of axes used in a program is not compatible with the unit constant files. Toyopuc I/F detected the alarm.

No reset operations neccesary. No reset operations neccesary. Automatically restores, when the problem is solved.

Alarm

Alarm

Alarm

Alarm

on

on

2991 2999

If a limit for error detection is too small, change the value in constant setting.

Whether the device such as memory cards specified by the file operation menu is correctly installed is confirmed.

Please confirm play and teach signals are connected exactly.

Please refer to the manual of Toyopuc I/F.

4-51

Error code list 3112

PLC failure

SHARP I/F: Battery error occurred.

Warning occurs when the battery for the memory backup is nothing or discharged. It exists together to fieldbus functions.

Replace the battery for the memory backup.

No reset operations.

Inform ation

Inform ation

Inform ation

Inform ation

on

on

3113

PLC failure

3134

Operational failure

SHARP I/F: It exists together to fieldbus functions. Data given is incorrect.

Disable fieldbus functions, and reenter the power supply.

Error reset.

Inform ation

Inform ation

Inform ation

Inform ation

on

on

Data keyed-in is out of range or not defined.

Input suitable data.

Inform ation

Inform ation

Inform ation

Inform ation

on

on

Warning is given when the set warning limit for gun tip consumption is exceeded. Tip consumption warning signal is outputted. Welder version is unmatched.

Check the lack of gun tip.

No reset operations neccesary. No reset operations neccesary.

3137

Spot weld failure

Servo Gun Dramatic tip consumption change detected.

Inform ation

Inform ation

Inform ation

Inform ation

on

on

3138

Spot weld failure

Welder version is unmatched.

Inform ation

Inform ation

Inform ation

Inform ation

on

on

Welder backup file is not found.

Welder backup file is not found.

Initialize welder data.

Inform ation

Inform ation

Inform ation

Inform ation

on

on

Spot weld failure Preventive maintenance message

Welder error occurred.

Welder detects ALERT or FAULT.

Refer to the Welder Manual.

No reset operations neccesary. No reset operations neccesary. Error reset.

3141

Spot weld failure

3142

(1)Please execute the grease exchange. (2)Please refer to the robot maintenance manual for the exchange method and the exchange part.

Inform ation Inform ation

Inform ation Inform ation

on

The decelerator of the displayed axis reached at the grease exchange time.

Inform ation Inform ation

on

It seems to reach at the grease exchange time.

Inform ation Inform ation

on

on

3147

Preventive maintenance message

It seems to reach at the grease replenishment time.

The decelerator, the bearing or balancer of the displayed axis reached at the grease replenishment time.

(1)Please execute the grease replenishment. (2)Please refer to the robot maintenance manual for the replenishment method and the replenishment part.

Inform ation

Inform ation

Inform ation

Inform ation

on

on

3148

Preventive maintenance message

There is an axis which exceeds the allowance and maximum torque.

The presumption generation torque exceeded a permissible value by displayed program step and axis.

Inform ation

Inform ation

Inform ation

Inform ation

on

on

3149

Preventive maintenance message

It is a program which remarkably shortens longevity.

In the displayed program, longevity is within at 5000 hours.There is a possibility which is the program of call/jump origin when the call/jump are used.

Error reset.

Inform ation

Inform ation

Inform ation

Inform ation

on

on

3150

Preventive maintenance message

There is a possibility that the setting of the load weight and center of gravity is inapposite.

IIt is detected when there is a big difference between the longevities calculated from longevity and the motor speed calculated from the current.

Error reset.

Inform ation

Inform ation

Inform ation

Inform ation

on

on

3151

Operational failure

The program or the file does not exist.

This error occurs when the program number is specified which does not exist in the program jump call instruction.

(1)Change to ratings or less when the robot load condition is investigated, and weight and the wrist torque exceed it to ratings.(Gravity setting is used) (2)There is a possibility to exceed the acceleration which can be used. (Check the step before and after) (3)There is a possibility with a large interference torque, too. (Drop the acceleration of the displayed step.) (1)Change to ratings or less when the robot load condition is investigated, and weight and the wrist torque exceed it to ratings. (Gravity setting is used) (2)The amount of operation is, and the average speed and the average torque greatly exceed ratings because of largeness or high speed, and there is a possibility that longevity has shortened. Reduce the amount of operation of the object axis or slow down the speed if there is no obstacle in work. (program diagnosis) (3)There is a possibility to be generated because the cycle time is remarkably short. Slow down the speed overall. (1)Please confirm whether the setting of the load weight and center of gravity is correct. (2)Please change to ratings or less when the robot load condition is investigated, and weight and the wrist torque exceed it to ratings. (3)There is a possibility that the trouble occurs in the robot when not corresponding to the above-mentioned. Please correct the program number to a correct value the jump call ahead.

Inform ation

Inform ation

Inform ation

Inform ation

on

on

3155

Operational failure

This robot type is different.

Please select a suitable program.

Alarm

Alarm

Alarm

Alarm

on

on

3156

Spot weld failure

Servo Gun Move-tip consumption approaching limit.

3157

Spot weld failure

Servo Gun Settle-tip consumption approaching limit.

3158

Spot weld failure

3159

Spot weld failure

3160

Spot weld failure

Servo Gun Move-tip consumption exceeded maximum limit. Servo Gun Settle-tip consumption exceeded maximum limit. The change in the tip consumption detected by search 3 is abnormal.

Error occurs when a program created for different robot type is read. Warning is given when the set warning for Move-tip consumption limit is exceeded. Tip consumption warning signal is outputted. Warning is given when the set warning for Settle-tip consumption limit is exceeded. Tip consumption warning signal is outputted. Servo Gun Move-tip consumption exceeded the maximum limit.

This failure is released if a correct program is setted and restart playback. Error reset.

3161

Spot weld failure Spot weld failure Operational failure

3146

3162 3165

4-52

Servo gun pressure is not achieved. GUN SEARCH not complete. The file is protected.

Initialize welder data.

After exchanging grease, Please reset at the [Service][Robo t Diagnosis][Gre ase Exchange Cycle] menu. After replenishing grease, Please reset at the [Service][Robo t Diagnosis][Gre ase Exchange Cycle] menu. Error reset.

Check the Gun tip. If tips are good check the setting otherwise change the tip to the new one, and detect tip consumption again.

Error reset.

Inform ation

Inform ation

Inform ation

Inform ation

on

on

Check the Gun tip. If tips are good check the setting otherwise change the tip to the new one, and detect tip consumption again.

Error reset.

Inform ation

Inform ation

Inform ation

Inform ation

on

on

Replace the worn Move-tip and detect tip consumption again.

Error reset.

Inform ation

Inform ation

Inform ation

Inform ation

on

on

Servo Gun Settle-tip consumption exceeded the maximum limit.

Replace the worn Settle-tip and detect tip consumption again.

Error reset.

Inform ation

Inform ation

Inform ation

Inform ation

on

on

The difference between the consumption detected by search 3 and the consumption detected by search 1 exceeded the search 3 abnormal tip change. Error occurs when the set gun pressure is not achieved. The order of executing the tip consumption detection is wrong. All protected files or files partially protected (program or constant) tried to be corrected and deleted.

Check the lack of gun tip. If it is no trouble, execute gun search 1.

Error reset.

Inform ation

Inform ation

Inform ation

Inform ation

on

on

Check the external pressure value.

Error reset.

Inform ation Inform ation Inform ation

Inform ation Inform ation Inform ation

on

Error reset.

Inform ation Inform ation Inform ation

on

Please modify the execution timing of the tip consumption detection. Because the specified file (program or constant) contains important data, protecting is put so that the content is not carelessly changed.

Inform ation Inform ation Inform ation

on

on

on

on

Please release protecting the file (program or constant).

Error code list 3168

Preventive maintenance message

There is the axis in 1000 hours for overhaul.

The life time of the axis displayed with present operated (time to reaching to longevity) became 1,000 hours or less. The life time of the axis displayed with present operated (time to reaching to longevity) became 0 hour or less. This error occurs if it starts when unit is not ready.

Exchange the axis early. After that 0 clearing of "Consumption time until present".

Error reset.

Inform ation

Inform ation

Inform ation

Inform ation

on

on

3169

Preventive maintenance message

There is the axis in 0 hours for overhaul.

Exchange the axis. After that 0 clearing of "Consumption time until present".

Error reset.

Inform ation

Inform ation

Inform ation

Inform ation

on

on

3170

Operational failure

It was going to start, when unit was not ready.

Please check unit ready signal output conditions, and start after making it the unit ready.

Inform ation

Inform ation

Inform ation

Inform ation

on

on

Dramatic difference of panel thickness exists between recorded value in weld condition and detected value. Information occurs when the temperature of the core of the controller exceeds 60 . If this state lasts 10 min, motor power will be automatically shutdown and E0063 displayed., You did re-weld except for the time of abnormal welding.

Check the weld condition data and real work piece thickness.

This error is released if it starts again after making it the unit ready. No reset operations neccesary.

3175

Spot weld failure

Abnormal panel thickness detected.

Inform ation

Inform ation

Inform ation

Inform ation

on

on

3177

CPU board failure

Controller temperature fault.

Check the fans are operating, or clean up the heat exchanger.

No reset operations neccesary.

Inform ation

Inform ation

Inform ation

Inform ation

on

on

3178

Spot weld failure

Re-weld is not allowed.

Please restart after set a step in auto mode, or do manual weld.

Inform ation

Inform ation

Inform ation

Inform ation

on

on

Conveyer running signal was not received in conveyer normal mode.

In conveyer normal mode, turn on conveyer running signal.

Inform ation

Inform ation

Inform ation

Inform ation

on

on

Operational failure

Conveyer running signal was not received. The program is not recorded nor selected.

This error occurs when the program which is not recorded is selclted and reserve playback.

Please reserve after recording the program or selecting other programs.

Inform ation

Inform ation

Inform ation

Inform ation

on

on

3218

Operational failure

Command not possible while running program.

Stop the program and retry the command.

Inform ation

Inform ation

Inform ation

Inform ation

on

on

3353

Operational failure

It is protected with the record-disable-switch or the password.

This command is not able to be used during the execution of a program. It detects, when it is going to correct or delete the file (a program, constant) protected with the password.

Inform ation

Inform ation

Inform ation

Inform ation

on

on

3354

Servo failure

Rising of motor torque is observed.

Check whether there is any cause of raising motor torque, about motors, reduction gears or cables etc.

Inform ation

Inform ation

Inform ation

Inform ation

on

on

3355

Spot weld failure

Current feedback of servo gun is abnormal.

Inform ation

Inform ation

Inform ation

Inform ation

on

on

3528

Operational failure

The memory medium is not discriminable.

Inform ation

Inform ation

Inform ation

Inform ation

on

on

3536

Spot weld failure

Welder fault.

Inform ation

Inform ation

Inform ation

Inform ation

on

on

3537

Spot weld failure

Welding time exceeded limit.

Inform ation

Inform ation

Inform ation

on

on

Spot weld failure

The gun not open.

Inform ation

Inform ation

Inform ation

Inform ation

on

on

3539

Spot weld failure

The gun is not half open.

No reset operations neccesary. No reset operations neccesary. No reset operations neccesary.

Inform ation

3538

Inform ation

Inform ation

Inform ation

Inform ation

on

on

3540

Spot weld failure

The gun is not fully open.

Check the GUN or welding unit.

No reset operations neccesary.

Inform ation

Inform ation

Inform ation

Inform ation

on

on

3541

Spot weld failure

Stuck Weld GUN detected.

Error occurs if the Weld stuck signal is received when the welding sequence ends.

Inform ation

Inform ation

Inform ation

on

on

Spot weld failure

Coolant fault #1.

Inform ation

Inform ation

Inform ation

Inform ation

on

on

3543

Spot weld failure

Coolant fault #2.

Inform ation

Inform ation

Inform ation

Inform ation

on

on

3544

Spot weld failure

Air pressure fault.

Inform ation

Inform ation

Inform ation

Inform ation

on

on

3545

Spot weld failure

Transformer temperature fault.

Inform ation

Inform ation

Inform ation

Inform ation

on

on

3546

Spot weld failure

Peripheral system fault.

Inform ation

Inform ation

Inform ation

Inform ation

on

on

3552

Spot weld failure

Both of half-open and full-open signals are given.

No reset operations neccesary. No reset operations neccesary. No reset operations neccesary. No reset operations neccesary. No reset operations neccesary. No reset operations neccesary. No reset operations neccesary.

Inform ation

3542

Inform ation

Inform ation

Inform ation

Inform ation

on

on

3553

Spot weld failure

Manual axis moving cannot be operated during waiting for WI.

The motor torque in a cycle went up as compared with the average value the 10 cycles past. In the servo gun with pressure sensor, the axis current to pressurizing power is abnormal. When memory media, such as a FIROPPI disk and an memory card, are not initialized, this error occurs. Error occurs when the welding timer detected some errors. Standard welding timer generates this error when the controller received the welder fault signal from welding timer after the end of welding sequence. Regarding except standard welding timer, refer the each operation manual. Error occurs if a Weld competed signal is not input before the designated time period. Error occurs if the Gun closed signal is received after the welding sequence ends. Error occurs if the Gun half-open signal is not received after Open gun half signal is output by the controller. Error occurs if the Gun full-open signal is not received after Open gun fully signal is output by the controller. Error occurs if the System fault signal is detected after completion of a welding sequence. Error occurs if the Water flow switch #1 signal is detected after completion of a welding sequence. Error occurs if the Water flow switch #2 signal is detected after completion of a welding sequence. Error occurs if the Air pressure switch signal is detected after completion of a welding sequence. Error occurs if the Thermo. temp. fault signal is detected after completion of a welding sequence. Error occurs if the System fault signal is detected after completion of a welding sequence. Error occurs if both the Gun half-open signal and Gun full-open signal are received simultaneously after Open gun half signal is output by the controller. Error occurs if manual axis moving during waiting for WI.

No reset operations neccesary. No reset operations neccesary. This error is released if it sets a correct program and reserve playback. No reset operations neccesary. Set the record-disableswitch to OFF or release password protecting. No reset operations neccesary. No reset operations neccesary. It will be canceled if some keys are pushed. No reset operations neccesary.

3181

Control failure

3194

Please release the WI.

Inform ation

Inform ation

Inform ation

Inform ation

on

on

Since the specified file (program or constant) contains important data, protection is applied

Please check the pressure sensor, the axis motor of servo gun, or those cables connected. By Service / File Manager / Format memory card/Floppy disk, please use it after initializing a memory medium. Check the welder unit.

Check the welder is operating normally.

Check the GUN or welding unit.

Check the GUN or welding unit.

Check the GUN or welding unit.

Check the GUN or welding unit.

Check the GUN or welding unit.

Check the GUN or welding unit.

Check the GUN or welding unit.

Check the GUN or welding unit to determine the cause of the two simultaneous signals.

Please releasing WI.

4-53

Error code list 3555

Spot weld failure Spot weld failure

Servo-gun is not executed to obey the welder sequence. Current of tip dresser abnormaled.

Error occurs when the servo-gun is not achieved to command pressure. This error occurs when the servo dresser is exceeded beyond current range.

3656

3660

Spot weld failure

Current of tip dresser abnormaled.

3666

Request maintenance

Cooler fans stopped.

This error occurs when the dress length of tip is exceeded beyond dress length range. Error occurs when cooler fans stopped.

3667

Request maintenance

Brake power supply cooling fan of the drive unit in has stopped.

Error occurs when Brake power supply cooling fan of the drive unit stopped.

3668

Request maintenance

Brake power supply cooling fan of the drive unit in has stopped.

Error occurs when Brake power supply cooling fan of the drive unit stopped.

(1)Please check the cable connector CNMCH. (2)Please confirm internal wirings and the cable between the controller and the robot manipulator. (3)Please replace cooler fans. (4)Please replace the drive unit.

3677

Spot weld failure

Minor Welder warning(Alarm).

3678

Spot weld failure

Weld error reset is not execute.

3687

Spot weld failure Spot weld failure

Minor Welder error.

3689

Spot weld failure

RE-01 battery error

Error occurs when the welder board generate the warning(Alarm). Error occurs when welder command execute without reset the error. Error occurs when the welder board generate the weld error. Error occurs when welder command execute without reset the error. Lithem battery cannot be used if it does.

3690

Spot weld failure

RE-01 battery charge low

Error occurs when the voltage of lithium battery on RE-01 bord has decreased.

Please exchange the lithem batteries referring to the "RE-01 maintenance manual".

3700

Operational failure

It stopped in the home stop position.

Please carry out manual operation again.

3701

Operational failure

Option un-setting up.

3702

Vision sensor failure

Illigal request of conveyor sync.

3703

Vision sensor failure Vision sensor failure

The measurement number is a unsetting.

It will generate, if it comes to the position registered by setup of a home stop position function. It generates, when it is going to use the option function which is not set up. Conveyor sync. request method is different from vision sensor constant setting. Or, it was requested when edit mode of vision sensor. When conveyor sync. is requested, the measurement number is a unsetting. The conveyer speed is too fast.

3688

3704

Weld error reset is not execute.

The buffer is full. The measurement result was not able to be stored. The pose search shift data cannot be acquired.

3782

Vision sensor failure

3790

Encoder failure

3800

User failure

3810

Spot weld failure Operational failure

Welder communication fault(No reply). Welder option isn't set up.

3812

Spot weld failure

Welder version is unmatched.

3813

Spot weld failure Spot weld failure Spot weld failure

3811

3814 3872

4-54

Please confirm to the sequence of weld-timer.

Inform ation

Inform ation

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Inform ation

on

on

Inform ation

Inform ation

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on

on

Error reset.

Inform ation

Inform ation

Inform ation

Inform ation

on

on

Inform ation

Inform ation

Inform ation

Inform ation

on

on

Error

Error

Error

Error

on

on

Inform ation

Inform ation

Inform ation

Inform ation

on

on

Remove the cause of the warning.

After removal of failure, please carry out "failure-reset". After removal of failure, please turn on power supply of the controller again. After removal of failure, please turn on power supply of the controller again. Error reset.

Inform ation

Inform ation

Alarm

Alarm

on

on

Error reset.

Error reset.

Inform ation

Inform ation

Alarm

Alarm

on

on

Remove the cause of weld error.

Error reset.

Inform ation Inform ation

Alarm

on

on

Error reset.

Inform ation Inform ation

Alarm

Error reset.

Alarm

Alarm

on

on

Please exchange the lithem batteries referring to the "RE-01 maintenance manual".

After removal of failure, please turn on power supply of the controller again. After removal of failure, please turn on power supply of the controller again. No reset operations neccesary. No reset operations neccesary. No reset operations neccesary.

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Inform ation

Inform ation

Inform ation

Inform ation

on

on

Inform ation

Inform ation

Inform ation

Inform ation

on

on

Inform ation

Inform ation

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Inform ation

on

on

No reset operations neccesary. No reset operations neccesary.

Inform ation

Inform ation

Inform ation

Inform ation

on

on

Inform ation

Inform ation

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on

(1)Please confirm the tip dress condition.(2)Please confirm the cable between the controller and the servo tip dresser.(3)Please replace the motor.(4)Please replace the drive unit. (1)Please confirm the tip dress condition.(2)Please confirm the tip consumption. (1)Please check the cable connector CNMCH. (2)Please confirm internal wirings and the cable between the controller and the robot manipulator. (3)Please replace cooler fans. (4)Please replace the drive unit. (1)Please check the cable connector CNMCH. (2)Please confirm internal wirings and the cable between the controller and the robot manipulator. (3)Please replace cooler fans. (4)Please replace the drive unit.

Please set up an option.

Please modify constant setting. Or, cancel edit mode.

Please modify parameters. Or, check input signals.

Please slow down the conveyer speed.

No reset operations neccesary. Error reset.

The shift data corresponding to the master data number that has been sent from the vision sensor is not registered. The error counter of the encoder exceeded the setting value.

Please check master data for pose search.

No reset operations neccesary.

Inform ation

Inform ation

Inform ation

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on

on

Please check the encoder.

Error reset.

Inform ation

Inform ation

Inform ation

Inform ation

on

on

The received shift data contains the status that notifies abnormality.

Please confirm the state of PC that transmits the shift data.

Inform ation

Inform ation

Inform ation

Inform ation

on

on

Error occurs when the welder is not correctly connected. It generates, when it is going to use the welder option function which is not set up. Welder version is unmatched.

(1)Check power supply of the welder and communication cables. (2)Initialize welder data. Please set up an welder option.

No reset operations neccesary. Error reset.

Inform ation Inform ation

Inform ation Inform ation

Inform ation Inform ation

off

off

on

on

Inform ation

Inform ation

Inform ation

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on

on

Welder error occurred.

Welder detects FAULT.

Refer to the Welder Manual.

No reset operations neccesary. No reset operations neccesary. Error reset.

Inform ation Inform ation

Welder detects ALERT.

Refer to the Welder Manual.

Error reset.

The move-electrode diameter is less than the warning diameter set by the seam welding parameters.

Please check the electrode. The electrode is not worn out, and correct the seam welding parameters. The electrode is worn out, and replace the worn move-electrode and detect electrode consumption again..

Error reset.

Inform ation Inform ation Inform ation

Inform ation Inform ation Inform ation

on

The move-electrode diameter is less than the warning diameter.

Inform ation Inform ation Inform ation

on

Welder error occurred.

Inform ation Inform ation Inform ation

The error counter of the encoder exceeded the setting value. Abnormal shift data received.

Cannot restore a welding parameter using the backup data of a welder different in a version.

on

on

on

on

Error code list 3873

Spot weld failure

The settle-electrode diameter is less than the warning diameter.

The settle-electrode diameter is less than the warning diameter set by the seam welding parameters.

3960

FieldBus failure

A part or all I/O links are stopping.

Since the between title has occurred in the I/O device, a robot cannot be started.

3992

Operational failure Arc weld failure

The function was attempted that is not allowable while mode is external application. The welding power supply didn't respond.

Please execute the function after releasing the external application mode.

4000

4001

Arc weld failure

The function can not be used in external application mode. Communication timeout occurred between the controller and the welding power supply. Received data failure.

The data which are received from the welding power supply are incorrect.

Check the connection of the welding power supply to the controller.

4002

Arc weld failure

Can't communicate with the welding power supply.

The communication between the controller and the welding power supply is shutdown.

Check the connection of the welding power supply to (L21700S00/UM355).

4003

Arc weld failure

Can't communicate with the welding power supply.

The communication driver detected the failure.

Check the connection of the welding power supply to the controller. And check the connection of UM355(L21700S00) board.

4004

Arc weld failure

The registration of the welding power supply is incorrect.

The kind of registered WPS and actual WPS are not same, or the Dip switch setting of Robot I/F board inside the welding power supply is wrong.

Register WPS correctly, or set Dip switch of Robot I/F board correctly.

4005

Arc weld failure

The welding power supply of old version is connected.

The controll software of the welding power supply is old.

Please update the welding power supply.

4006

Arc weld failure

Arc weld failure

The servo of the wire feed control unit does not turn on/off because the software of the welding power supply is old. The welding power supply doesn't correspond to the stitch pulse welding function.

Please update the welding power supply.

4007

The welding power supply version is wrong for the servo wire feed control. The control software is abnormal in the welding power supply.

4008

Arc weld failure

Arc weld failure

4010

Arc weld failure

4011

Arc weld failure

The arc welding cannot be done.

4012

Arc weld failure

4013

Arc weld failure

The gas mass flow control function cannot be used. The control software is abnormal in the welding power supply.

The Synchro-welding is not executed because the software of the welding power supply does not support the Synchro-welding by CAN communication. The Synchro-welding is not executed because the welding power supply does not support the Synchro-welding by CAN communication. The arc welding power supply doesn't correspond to the welding condition slope function. The arc welding power supply doesn't correspond to the welding characteristic data self adjustment function. The arc welding power supply doesn't correspond to the gas mass flow control function. The welding power supply doesn't correspond to the cycle pulsed welding function.

Please update the welding power supply.

4009

The welding power supply version does not support the Synchro-welding by CAN communication. The welding power supply does not support the Synchro-welding by CAN communication. The arc welding cannot be done.

4014

Arc weld failure

Abnormality occurred by the communication with the robot controller or peripherals on the welding power supply.

4015

Arc weld failure

The failure occurs in the controller of the welding power supply.

It was not possible to communicate with the robot controller or the peripherals on the arc welding power supply. Microcomputer control failure occurred in the welding power supply.

Please check the electrode. The electrode is not worn out, and correct the seam welding parameters. The electrode is worn out, and replace the worn settle-electrode and detect electrode consumption again.. Please check the device which the problem has generated by the field bus monitor.

Error reset.

Inform ation

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on

on

If a problem is solved, it will restore automatically. (In order to solve a problem, the re-injection of a power supply may be required) Error reset

Inform ation

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on

on

Inform ation

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off

off

Turn on the controller and the welding power supply again. Turn on the controller and the welding power supply again. Turn on the controller and the welding power supply again. Turn on the controller and the welding power supply again. After registeration/s etting, turn on the controller and the welding power supply again. After updating, turn on the controller and the welding power supply again. After updating, turn on the welding power supply again. The control software of the welding power supply improves in the version, and the power supply in the robot controller and the welding power supply is turned on again. After updating, turn on the welding power supply again.

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Please setup the Synchro-welding by RS-422 communication.

Error reset.

Error

Error

Error

Error

on

on

The upgrade should do the software of the arc welding power supply.

Error reset.

Error

Error

Error

Error

on

on

The upgrade should do the software of the arc welding power supply.

Error reset.

Error

Error

Error

Error

on

on

The upgrade should do the software of the arc welding power supply.

Error reset.

Error

Error

Error

Error

on

on

Please update the welding power supply.

Error

Error

Error

Error

on

on

Confirm the connection with the welding power supply or the peripherals. Or, in the function of the welding power supply, confirm the the setting of the transmission rate of the CAN communication .

After updating, turn on the welding power supply again. Turn the welding power supply on again.

Error

Error

Error

Error

on

on

Turn the welding power supply on again. Confirm an abnormal display of the arc welding power supply, and contact our service when abnormality relapses. Back up files to external CF memory.

Failure reset, and turn on the welding power supply again.

Error

Error

Error

Error

on

on

Check the connection of the welding power supply to the controller.

The control software of the welding power supply must improve in the version.

4-55

Error code list 4016

Arc weld failure

The Arc-I/F is not found.

Check the connection of the Arc-I/F(L21700S) to the sequence board(L21700F).

Turn on the power again.

Error

Error

Error

Error

off

off

Set CAN baudrate 500Kbps. And turn on the power again. Please check the connection between the Arc-I/F board(L21700S) and the sequence board(L21700F). You might exchange their boards. Please contact our service department. Please check the connection between the Arc-I/F board(L21700S) and the sequence board(L21700F). You might exchange their boards. Please contact our service department. Please update the welding power supply.

Turn on the power again. Error reset.

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Error reset.

Error

Error

Error

Error

on

on

The cold tandem welding function cannot be used.

The Arc-I/F board(L21700S) doesn't connect with the sequence board(L21700F). CAN baudrate of the Arc-I/F board(L21700S) couldn't set. The communication error has occurred between the Arc-I/F board(L21700S) and the sequence board(L21700F). The communication error has occurred between the Arc-I/F board(L21700S) and the sequence board(L21700F). The welding power supply doesn't correspond to the cold tandem welding function.

4017

Arc weld failure Arc weld failure

CAN baudrate setting is failure. The communication error has occurred.

4019

Arc weld failure

The communication test has failed.

4020

Arc weld failure

Error

Error

Error

Error

on

on

Arc weld failure

The wire touch detection cannot be used.

The welding power supply doesn't correspond to the wire touch detection.

Please update the welding power supply.

Error

Error

Error

Error

on

on

4022

Arc weld failure

The supported function information of welding power supply cannot be read.

Confirm the connection with the welding power supply.

Error

Error

Error

Error

on

on

4085

Arc weld failure

Error

Error

Error

on

on

Arc weld failure

There is no response from the arc welding power supply.

Check the connection of the welding power supply to (L21700S00/UM355).

Error

Error

Error

Error

on

on

4102

Operational failure Operational failure

In simultaneous weaing, weaving conditions are not in agreement. The mechanism number specified in the 1st parameter is not belong to current unit.

Please make weaving conditions in agreement.

Turn the welding power supply on again. Turn the welding power supply on again. Error reset.

Error

4099

Communication timeout occurred inside the welding power supply. It was not possible to communicate with the arc welding power supply. It is weaving condition disagreement. Mechanism Error in External axis relative move function (FN407). Axis Error in External axis relative move function (FN407:RELMOV) Mechanism type error.

The robot controller does not receive a information of the supported function from the welding power supply when turning on the power. The contollor of the welding power supply didn't respond.

After updating, turn on the welding power supply again. After updating, turn on the welding power supply again. Failure reset, and turn on the welding power supply again.

4021

Alarm

Error

Alarm

Error

on

on

Specify correct mechanism number which belongs to current unit.

Error reset.

Error

Error

Error

Error

on

on

The axis number specified in the 2nd parameter is not defined in a mechanism of 1st parameter.

Check the axis number of 2nd parameter taught in the function command, and teach again.

Error reset.

Error

Error

Error

Error

on

on

The mechanism specified in 1st paramter is neither positioner nor slider. This error is detected when the G-STOP input value in two systems is not corresponding.

Select a unit which has positioner or slider, and then specify a positioner or a slider in 1st parameter.

Error reset.

Error

Error

Error

Error

on

on

Please confirm the G-STOP input value.

Error

Error

Error

Error

on

on

Since the data when power failure did not be saved correctly, the position data of endless rotation axis has not been resumed to the data before power failure. The basic position of endless rotation axis was not able to be restored correctly by the mechanism change. The manual operation, check operation or playback operation has been performed for a mechanism whose servo power has been individually set to OFF. Mechanisms other than the ones targeted for operation have been specified in the servo ON command (SPN). Mechanisms other than the ones targeted for operation have been specified in the servo OFF command (SPF). Because robot doesn't reach the command position, servo OFF cannot be executed.

Please perform the Encoder Correction (with position record method) to the axis in which abnormalities have generated.

After removal of failure, please turn on power supply of the controller again. Error reset.

Alarm

Alarm

Error

Error

on

on

Please perform the Encoder reset and Correction (with position record method) to the axis in which abnormalities have generated.

Error reset.

Error

Error

Error

Error

on

on

Check the mechanism whose servo power is OFF, and turn it ON.

Error reset.

Alarm

Error

Alarm

Error

on

on

Review the mechanisms which have been specified by the servo ON command (SPN).

Error reset.

Alarm

Error

Alarm

Error

on

on

Review the mechanisms which have been specified by the servo OFF command (SPF).

Error reset.

Alarm

Error

Alarm

Error

on

on

(1)Please confirm whether the robot manipulator interferes in something.(2)Please confirm that the Pay-load is within the nominal rating.(3)If failure persists, the problem may be a mechanical defect in the manipulator, contact our service department. Please confirm followings to the mechansim to which servo off is set. (1)Instruction angle is not changed. (2)Current angle is not changed, by the external force.

After removal of failure, please carry out "failure-reset". After removal of failure, please carry out "failure-reset".

Error

Error

Error

Error

on

on

Alarm

Error

Alarm

Error

on

on

Cancel shock sensor by manual operation.

Error reset.

Alarm

Error

Alarm

Error

on

on

Please change a interporation type to [joint] or make the same the wrist axis angle of a starting point and an ending point. Please improve registration of the Spray machine, and a setup of a connection mechanism.

Error reset.

Alarm

Error

Alarm

Error

on

on

Error reset.

Error

Error

Error

Error

off

off

Please record by the Spray machine number belonging to the present unit.

Error reset.

Error

Error

Error

Error

off

off

4018

4900

4901

Operational failure

4902

Operational failure

4903

Operational failure

G-STOP input value is not corresponding.

4905

Operational failure

Playback was started in the state that the basic posture of any axes is not setup.

4906

Operational failure

The position of the endless rotation axis is abnormal.

4910

Operational failure

Mechanism* is servo off.

4911

Operational failure

SPN parameter error.

4912

Operational failure

SPF parameter error.

4914

Servo failure

Mechanism servo OFF cannot be executed.

4915

Operational failure

The instruction value of the mechanism to which servo OFF is set has changed.

4920

Emergency stop failure

Shock sensor detected the collision.

4921

Operational failure

Module mechanism interpolation failure.

4930

Operational failure

The connection mechanism of the Spray machine does not exist.

4931

Operational failure

The Spray machine does not belong to a current unit.

4-56

This error detected when the difference between the instruction position and the current position exceeds a regulated value in the mechanism to which servo OFF is set. Since the shock sensor detected the collision, the robot was stopped for safety. This failure occurs when a module mechanism cannot reach the position and the posture. This error is detected, when the Spray machine set as the first parameter is not registered or the connection mechanism is not set up. This error is detected when the mechanism connected to the Spray machine set as the first parameter does not belong to the present unit.

Turn off the power supply in the welding power supply, and contact our service.

Error code list 4932

Operational failure

Rotation shaft information is unusual.

4940

Emergency stop failure Emergency stop failure

The abnormalities in file access. Alarm carried out number-of-times generating of regulation, and was breaking down. The weaving trajectory exceeded regulation speed.

4999

By the case of extension synchronization control, the rotation shaft information over the shaft number set as Thermal spraying start conditions is not set up, or this error is detected when the interval of a start position-end position is less than 300mm. The abnormalities occurred in file access processing. Alarm carried out number-of-times generating of regulation, and was breaking down.

Please reset up correctly the rotation shaft information corresponding to the shaft number set as the Thermal spraying start conditions.

Error reset.

Error

Error

Error

Error

off

off

Contact our service department. Back up files to external CF memory. Please fix failure from the cause of alarm.

Error reset.

Error

Error

Error

Error

on

on

Error reset.

Error

Error

Error

Error

on

on

The speed of weaving trajectory has been exceeded the regulation speed, since the move distance between weaving points is too long, or the frequency (speed) is too high. The amount of posture change between weaving points is too large.

Correct the distance between weaving points, frequency, or speed.

After removal of failure, please carry out "failure-reset".

Alarm

Alarm

Alarm

Alarm

on

on

Please correct posture change of taught weaving pattern data.

After removal of failure, please carry out "failure-reset". After removal of failure, please carry out "failure-reset". Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

5005

Arc weld failure

5006

Arc weld failure

The amount of posture change of taught weaving exceeded the restriction value.

5007

Arc weld failure

Pose calculation failed.

Each axis angle can't be calculated. The posture data specified in the weaving condition is incorrect.

Check the posture data in weaving condition.

5008

Operational failure

Permission speed over occurred.

Stop time is made small or frequency is dropped. Or please change into not carrying out welding time maintenance.

5010

Arc weld failure

The welding current value has exceeded the allowable limit.

5011

Arc weld failure

The welding voltage value has exceeded the allowable limit.

5013

Arc weld failure

The welding power supply has been turned off.

The stop time of weaving conditions was too large at maintenance of welding time, or frequency was too high, and permission speed over occurred. The difference between the welding current value measured by the welding power supply and the taught one has exceeded the allowable limit set by the arc constants. The difference between the welding voltage value measured by the welding power supply and the taught one has exceeded the allowable limit set by the arc constants. The controller couldn't communicate with the welding power supply.

5014

Arc weld failure

Arc start failure.

No arc has been generated in spite of retrying the arc start.

5015

Arc weld failure

Arc outage was detected.

Arc outage occurred during welding.

Eliminate all causes of arc outage, for instance by adjusting the wedling conditions, fixing wire feed failure, and so on.

5016

Arc weld failure

Wire stick has been detected.

Wire has stuck.

Cut stuck wire.

5017

Arc weld failure Arc weld failure Arc weld failure Arc weld failure

Low gas pressure.

Low gas pressure signal is inputted. Wire not fed signal is inputted.

Supply gas.

This failure is released if restart playback. This failure is released if restart playback. This failure is released if restart playback. Error reset.

Supply wire.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Cooling water signal is inputted.

Supply water.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

The registered welding characteristic data isn't for the connected welding power supply. Welding voltage adjustment method has been changed from the synergetic control to the individual control, and vise versa while welding. W.P.S failure signal is inputted, or failure of the welding power supply occurs. The primary input voltage of the welding power supply has decreased. The average current used for the inner control of the welding power supply exceeds the limit. An internal temperature of the welding power supply rises.

Register the welding characteristic data for the using one.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Modify the task program.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Read through the welding power supply instruction manual and eliminate all causes.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Refer to the instruction manual of the welding power supply(Failure Name: Input voltage shortage) and eliminate all causes. Refer to the instruction manual of the welding power supply (Failure Name: Output overcurrent) and eliminate all causes. Refer to the instruction manual of the welding power supply (Failure Name: Thermal overload) and eliminate all causes. Refer to the instruction manual of the welding power supply (Failure Name: Input overvoltage) and eliminate all causes. Refer to the instruction manual of the welding power supply (Failure Name: Loss of phase) and eliminate all causes. Refer to the instruction manual of the welding power supply (Failure Name: Inverter drive circuit error) and eliminate all causes. Refer to the instruction manual of the welding power supply (Failure Name: Arc voltage detecting line error/detection error) and eliminate all causes.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

5018 5020 5021

Lack of wire was detected. Lack of water was detected. Arc welding characteristic data failure. Welding voltage adjustment method can't be changed while welding.

5022

Arc weld failure

5023

Arc weld failure

Failure of the welding power supply occurred.

5024

Arc weld failure

5025

Arc weld failure

5026

Arc weld failure

5027

Arc weld failure

5028

Arc weld failure

5029

Arc weld failure

5030

Arc weld failure

Input voltage shortage failure ocurred in the welding power supply. Output overcurrent occurred in the welding power supply. Thermal overload occurred in the welding power supply. Input overvoltage occurred in the welding power supply. Loss of phase occurred in the welding power supply. Inverter drive circuit failure occurred in the welding power supply. Arc voltage detection failure occurred in the welding power supply.

The primary input voltage of the welding power supply exceeds the threshold. Loss of phase in the primary input of the welding power supply. The failure occurs around the inverter drive circuit of the welding power supply. Arc voltage detection failure or arc voltage detecting line failure occurred.

Check the welding conditions(wire extension etc). There is possibility of missmatch the welding characteristic data to your environment if this failure occurs over and over again. In such case, adjust the welding characteristic data by the adjudstment of welding condition function etc. Check the welding conditions(wire extension etc). There is possibility of missmatch the welding characteristic data to your environment if this failure occurs over and over again. In such case, adjust the welding characteristic data by the adjudstment of welding condition function etc. Turn on the welding power supply. In case the welding power supply has been already turned on, check the connection of the welding power supply to the controller. Check the workpiece's condition, wire's condition, and connection of the cable.

4-57

Error code list 5031

Arc weld failure

5032

Arc weld failure

5033

Arc weld failure

5034

Arc weld failure

Gas check failure occurred in the welding power supply.

5035

Arc weld failure

5036

Arc weld failure

5037

Arc weld failure

5038

Arc weld failure

5039

Arc weld failure

5040

Arc weld failure

5041

Arc weld failure

5042

Arc weld failure

5043

Arc weld failure

5045

Arc weld failure

5046

Arc weld failure

5047

Arc weld failure

5048

Arc weld failure

Secondaly transistor failure occurred in the welding power supply. Water pressure failure occurred in the welding power supply. Secondaly transistor failure occurred in the welding power supply. The specified welding power supply can't use in this unit. A control power supply failure occurred in the welding power supply. An electric detection vessel failure occurred in welding power supply. The excess failure of the use rate occurred in welding power supply. A temperature failure occurred in the wire feed control circuit ing the welding power supply. The load of wire feed exceeded allowable value. The control power supply of the welding power supply was reset. The welding characteristic data are not installed. The arc characteristic can't be changed while arc welding. The incorrect welding method is specified.

5049

Arc weld failure Arc weld failure

5050

5051

Arc weld failure

5052

Arc weld failure Arc weld failure

5053

Microcomputer failure occurred in the welding power supply. Encoder failure was detected by the welding power supply. Current detection line failure occurred in the welding power supply.

The arc characteristic file can't be read. The wire feed characteristic file can't be read. The arc welding wave control file can't be read. The arc constant file can't be read. Welding voltage adjustment method differs.

The failure occurs in the welding power supply.

Refer to the instruction manual of the welding power supply (Failure Name: Microcomputer failure) and eliminate all causes. Refer to the instruction manual of the welding power supply (Failure Name: Encoder error) and eliminate all causes. Refer to the instruction manual of the welding power supply (Failure Name: 9. Current detection error).

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Turn OFF the gas check switch of the welding power supply.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Refer to the instruction manual of the welding power supply (Failure Name: Secondaly transistor failure) and eliminate all causes. Refer to the instruction manual of the welding power supply (Failure Name: Water pressure error) and eliminate all causes. Refer to the instruction manual of the welding power supply (Failure Name: Secondaly transistor failure) and eliminate all causes. Register the welding power supply which is specified by the task program, or modify the task program.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Refer to the instruction manual of the welding power supply (Failure Name: (The wire feed control board)Control power supply) and eliminate all causes. Refer to the instruction manual of the welding power supply (Failure Name: The first･second electric current error) and eliminate all causes.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Refer to the instruction manual of the welding power supply (Failure Name: The excess of the use rate) and eliminate all causes. Refer to the instruction manual of the welding power supply (Failure Name: The temperature wrong point of the wire feed control circuit) and eliminate all causes.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

The wire feed load has exceeded the allowable value set in the arc constant. The control power supply of the welding power supply was reset.

A load is on the wire feeder by wear of the liner, the chip defect, and so on. Remove the factors.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

The voltage of primary power may decrease in an instance. Check the voltage of primary power.

Alarm

Alarm

Alarm

Alarm

on

on

If the welding characteristic data are not installed, Arc function commands can't be execute. The arc function attempted changing the arc characteristic into the incorrect one. The welding method of the arc function and the welding method of the arc characteristic aren't the same. Read file failure occurs while reading the arc characteristic file. Read file failure occurs while reading the wire feed characteristic file. Read file failure occurs while reading the arc welding wave control file. Read file failure occurs while reading the arc constant file. The voltage adjusting method currently taught differs from the voltage adjusting method of characteristic data. WCR of W-I/F had short-circuited at the time of arc start.

Turn on the welding power supply again.

Failure reset, and turn on the welding power supply again. Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Please modify the task program.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Please modify the task program.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Please initialize the arc characteristic file.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Please initialize the wire feed characteristic file.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Please initialize the arc welding wave data file.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Please initialize the arc constant file.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Modify the task program.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Please check the state of W-I/F or a welding power supply.

This failure is released if restart playback. Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

This failure is released if restart playback. This failure is released if restart playback.

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

This failure is released if restart playback. Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Please create the arc condition file or edit the task program.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Please create the offset condition file or the multi offset file, or edit the task program.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Failure exists in the encoder of a wire feed unit or encoder cables are not connected. The failure(the connector is disconnected etc) exists in the current detecting cable of the welding power supply. The gas check switch of the welding power supply is ON for more than two minutes without a break. The surge power of the second transistor for the welding power supply is abnormally high. Cooling water flow is not sufficient when using a water cooled torch. The surge power of the second transistor for the robot welding power supply is abnormally high. The specified welding power supply isn't defined in this unit. A control power supply failure occurred in welding power supply. A connector inside the welding power supply may be miss-connected. Inside temperature of the welding power supply rises. An unusual fever appears on the wire feed control circuit of the welding power supply.

5054

Arc weld failure

WCR Short-circuit Error

5056

Arc weld failure Arc weld failure

The electrode short-circuited failure. The Filler Wire heating failure.

The electrode and the work are short-circuited while arc welding. During Filler Wire heating, inside the electric supply tip, a wire melts and was cut.

Please modify the task program.

5058

Arc weld failure

The Filler Wire heating Defect.

Please check the wire inside an electric supply tip, and the heating cable failure (contact failure, broken wire).

5059

Arc weld failure

The wire short-circuited failure.

It can consider that there was no wire in an electric supply tip, or a wire melts and was cut inside the electric supply tip at the time of heating. The wire and the work are short-circuited while arc welding.

5060

Arc weld failure Arc weld failure

5062

Arc weld failure

Read file failure occurs while reading the heating characteristic file. The arc condition file which is specified by the arc welding function doesn't exist. The offset condition file or the multi offset file which is specified by the multi offset function doesn't exist.

Please initialize the heating characteristic file.

5061

The heating characteristic file can't be read. The arc condition file doesn't exist.

5057

4-58

The offset condition file or the multi offset file doesn't exist.

Please check the wire inside an electric supply tip, and the heating cable failure (contact failure, broken wire).

Please check the state of W-I/F, and a welding power supply.

Error code list 5063

Arc weld failure

The weaving synchronization went wrong.

A communication failure has been detected between the welding power supply and the extension serial board.

Please check connection between an extension serial board and a welding power supply.

Turn on the controller and the welding power supply again. Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

5064

Arc weld failure

The weaving condition file doesn't exist.

Please create the weaving condition file or edit the task program.

5065

Arc weld failure

5066

Arc weld failure

5067

Arc weld failure

The power supply of a feed control device is not on. Pump failure occurred in the welding power supply. The arc retry condition file doesn't exist.

The weaving condition file which is specified by the weaving function doesn't exist. Communication with a feed control device was not completed.

Alarm

Alarm

Alarm

Alarm

on

on

When you turn on a feed control device or the power supply is already on, please check connection with a feed control device. Refer to the instruction manual of the welding power supply (Failure Name: Pump error) and eliminate all causes. Please create the arc retry condition file or edit the task program.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

5068

Arc weld failure

5069

Arc weld failure

5070

Arc weld failure

The arc robotrs condition file doesn't exist. The robot move condition file doesn't exist. The arc rs condition file doesn't exist.

Please create the robotrs condition file or edit the task program.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Please create the robot move condition file or edit the task program.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Please create the rs condition file or edit the task program.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

5071

Arc weld failure

The module error in WPS.

Refer to the instruction manual of the welding power supply and eliminate all causes.(An abnormal number of the welding power supply has been described in the above-mentioned parentheses.) Refer to the instruction manual of the welding power supply and eliminate all causes.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

5072

Arc weld failure

5073

Arc weld failure

5074

Arc weld failure

5075

Arc weld failure

5076

Arc weld failure

5077

Arc weld failure

The speed failure of the wire feed control circuit occurred in the welding power supply. Input voltage shortage failure ocurred in the welding power supply. The cooler fan failure ocurred in the welding power supply. A control power supply abnormal temperature occurred in the welding power supply. The arc welding power supply detected abnormality of the servo feeder unit. The controller couldn't communicate with the servo feeder unit.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Refer to the instruction manual of the welding power supply(Failure Name: The primary input driver) and eliminate all causes. Refer to the instruction manual of the welding power supply(Failure Name: The cooler fan failure) and eliminate all causes. Refer to the instruction manual of the welding power supply(Failure Name: A control power supply abnormal temperature) and eliminate all causes.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Refer to the instruction manual of the servo feeder unit and eliminate all causes.(An abnormal number of the servo feeder unit has been described in the above-mentioned parentheses.) Please confirm the connection of the arc welding power supply and the servo feeder unit.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

5078

Arc weld failure

When you turn on a gas mass flow control unit or the power supply is already on, please check connection with a gas mass flow control unit. Please create the gas equipment file or edit the gas mass flow control data.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

5079

Arc weld failure

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

5080

Operational failure

5081

Operational failure

5082

Operational failure

5083

Operational failure

5084

Operational failure

5085

Arc weld failure

5086

Arc weld failure

5087

Arc weld failure

5088

Arc weld failure

Resources were not securable at the time of starting. The appointed program cannot be edited / playback. Operation or command for Multi-unit cannot be executed. The unit-branch commands cannot be executed. The unit-branch commands cannot be executed. Communication timeout occurred inside the welding power supply. There is a illegal section of melt down control within a arc welding section. There is a illegal section of melt down control within a arc welding section. Back bead has detected.

Modify the wait time specified in FORK or CALLFAR command.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

The same number program exists.

Delete the program not to overlap with file operation.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

The option of Multi-unit is not set up.

Please set up the option of Multi-unit.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Some unit-branch commands were tried to execute at the same time.

Please correct the program so that the unit-branch commands does not be executed at the same time.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

A unit-branch commands FORK were tried to execute in the already forked program. The contollor of the welding power supply didn't respond.

Please correct the program so that the unit-branch commands does not be executed in the already forked program. Check the route of cable and ground connection.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Condition changing from Melt Down Control to Normal Control or from Normal Control to Melt Down Control, is not acceptable. Condition changing from Melt Down Control to Normal Control or from Normal Control to Melt Down Control, is not acceptable. Arc welder has changed the welding condtion.

Please correct the taught program.

Turn the welding power supply on again. No reset operations neccesary.

Alarm

Alarm

Alarm

Alarm

on

on

Please correct the taught program.

No reset operations neccesary.

Alarm

Alarm

Alarm

Alarm

on

on

Please re-designe the welding condition or the taught path.

Inform ation

Inform ation

Inform ation

Inform ation

on

on

Deviation of welding path has detected.

Deviation of welding path toward upper plate has occured.

Please re-designe the taught path.

Inform ation

Inform ation

Inform ation

Inform ation

on

on

Tandem-Arc-Start-com mand is incorrect.(Fe-wire) Tandem-Arc-Start-com mand is incorrect.(Al-wire)

A move command must be inserted between preceding and trailing arc-start-command. Trailing-arc-start-command must follow preceding-arc-start-command continually. Trailing-arc-start-command is taught before preceding-arc-start-command.

Modify the task program.

No reset operations neccesary. No reset operations neccesary. Error reset.

5089

Arc weld failure

5090

Arc weld failure

Alarm

Alarm

Alarm

Alarm

on

on

5091

Arc weld failure

Modify the task program.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

5092

Arc weld failure

Modify the task program.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

The power supply of a gas mass flow control unit is not on. The gas equipment file doesn't exist.

The Electrode type is incorrect.

Cooling water flow is not sufficient when using a water cooled torch. The arc retry condition file which is specified by the arc welding function doesn't exist. The arc robotrs condition file which is specified by the arc welding function doesn't exist. The robot move condition file which is specified by the arc welding function doesn't exist. The arc rs condition file which is specified by the arc welding function doesn't exist. Abnormality occurs by the module in the welding power supply.

The speed failure of the wire feed control circuit occurred in the welding power supply. The primary input driver of the welding power supply has decreased. The cooler fan's rotation has fallen or it stops. The temperature rises in the control power supply.

The failure occurs in servo feeder unit.

Abnormality occurred by the communication between the arc welding power supply and the servo feeder unit. Communication with a gas mass flow control unit was not completed. The gas equipment file which is specified by the gas mass flow control file doesn't exist. The wait time of resource reservation was over.

4-59

Error code list 5093

Arc weld failure

5094

Arc weld failure

5095

Arc weld failure

5096

Arc weld failure

5097

Arc weld failure

Arc voltage cannot be detected while RS control.

Arc start faiulre using RS control or arc voltage detection failure occurred in the welding power supply.

5098

Arc weld failure

EP start failure.

5099

Arc weld failure

The arc welding power supply was operated during playback.

The arc welding characteristic data of EP mode isn't registered. Or the welding voltage adjustment method of EP mode is different from EN mode. The arc welding power supply cannot be operated during playback.

5100

Arc weld failure Arc weld failure

EP start failure.

5102

Arc weld failure

An adjustment program choice is unusual.

An start program is different from the adjustment program.

Start by the specified adjustment program.

5103

Arc weld failure

Adjustment welding mode wrong point.

Check the welding mode to adjust.

5104

Arc weld failure

Pilot arc start failure.

The welding mode of the AS function is different from the welding mode of the adjustment object. The pilot arc was not turned on.

5105

Arc weld failure

A plasma unit/WPS is abnormal.

5106

Arc weld failure

The pilot arc outage is abnormal.

5107

Arc weld failure Arc weld failure

Pilot arc OFF error.

5109

Arc weld failure

5110

Arc weld failure

5111

Arc weld failure

The error occurs in servo wire feed control unit. Retract operation was executed over 10 seconds. Stitch pulse welding control error.

5112

Arc weld failure

Stitch pulse welding unit setting error.

5113

Arc weld failure Arc weld failure

WCR input signal unsetting. Arc welding unit setting abnormality.

5115

Arc weld failure

The WCR OFF time-out is abnormal.

5118

Arc weld failure

5119

Arc weld failure Arc weld failure

There is a wrong arc start command in the tool change setting welding power supply. There is a wrong AS command. The arc welding power supply detected abnormality of the gas mass flow control unit. The gas mass flow value has exceeded the allowable limit.

5101

5108

5114

5120

5121

Arc weld failure

5122

Arc weld failure

4-60

The current execution pass is in another multipass section The arc welding power supply is installed.

Motor overcurrent occurred in the welding power supply. The emergency is stopping or the welding power supply is stopping.

An adjustment movement start is unusual.

Pilot arc ON error.

The gas pressure value has exceeded the allowable limit.

It is prohibited to start since the different offset might be applied. During installation of an arc welding power supply, neither operation of the arc welding power supply nor execution of playback command can be performed. Short circuit in the power line to the motor or motor overload happens. The emergency stop is input or the wiring of the STOP terminals in the welding power supply is disconnected.

EP start condition of AS function is wrong. Arc-Monitor isn't indicated.

Abnormality occurs by a plasma fine unit or Plasma Welding Power Supply. The pilot arc outage occurred.

Please set the step which the multipass section suitable for the current execution pass or change the current execution pass. Please perform again after the completion of installation of an arc welding power supply.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Refer to the instruction manual of the welding power supply (Failure Name: Motor overcurrent) and eliminate all causes. (1)Please cancel an emergency stop button and an external emergency stop signal, and check the connection of the welding power supply to the controller. (2)When the check welding is ON, you have to grasp the enable switch to cancel the emergency stop. Check the workpiece's condition, wire's condition, connection of the cable, and RS control condition. Or refer to the instruction manual of the welding power supply (Failure Name: Arc voltage detection error) and eliminate all causes. Register the correct welding characteristic data. Or Correct EP start condition.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Please do not operate the welding power supply during playback.

Failure reset, and turn on the welding power supply again. Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Correct EP start condition. Indicate Arc-Monitor, and confirm an adjustment condition.

Check the connection condition of the cable.

Please see the manual of a plasma fine unit or Plasma Welding Power Supply.

This failure is released if restart playback. Error reset.

The pilot arc was not able to be turned off. Since the purge was turned on, the pilot arc was not able to be turned on. The error occurs in servo wire feed control unit.

Check the connection condition of the cable.

This failure is released if restart playback. Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Turn off the purge.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Refer to the instruction manual of the servo wire feed control unit and eliminate all causes.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Stop retract for the protection of Assist Feeder.

If you operate retract more, execute 90 seconds later.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

The synchronized control, the FC control, the slope control or the adjustment of the WCD cannot be executed by the stitch pulse welding. The stitch pulse cannot weld with the unit to which two or more welding machines are registered. The WCR input signal is not allocated. For the unit to which two or more welding machines are registered, it is not possible to weld. WCR was not turned off in the time limit.

Please change the welding condition.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Please change the registration of the weld power supply in the unit.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Please allocate the WCR input signal.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Please change the registration of the welding machine in the unit.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Please check the WCR signal from "WCR OFF waiting time" of the welding constant and the welding power supply. Please modify the task program.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Please teach again after deleteing the AS command.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Refer to the instruction manual of the gas mass flow control unit and eliminate all causes.(An abnormal number of the gas mass flow control unit has been described in the above-mentioned parentheses.) Please confirm [The remainder pressure of gas cylinder, the piping of the gas, and the setting of the gas mass flow control unit.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Please confirm the remainder pressure of gas cylinder, the piping of the gas, and the setting of the gas mass flow control unit.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

The AS command more than two passing is recorded by one mechanism. The Synchro or FC welding is taught to the AS command. The failure occurs in gas mass flow control unit.

The difference between the gas mass flow value measured by the welding power supply and the taught one has exceeded the allowable limit set by the contloler. The gas pressure measured in the arc welding power supply exceeded the limiting value set with the controller.

Check the connection condition of the cable.

This failure is released if restart playback. This failure is released if restart playback. Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Error code list 5123

Arc weld failure

The set gas mass flow is not output.

The set gas mass flow was not output in specified time.

5124

Arc weld failure Arc weld failure

The gas flow control unit was reset. The data to the gas flow control unit cannot be set. Zero deviation error on the gas flow control unit was detected.

The control data in the gas flow control unit was reset. The data set to the gas flow control unit is abnormal.

5125

5126

Arc weld failure

5127

Arc weld failure

5128

Arc weld failure

The analog output board is a uninstallation. Filler wire stick has been detected.

5129

Arc weld failure

5130

Please confirm the residual quantity of the gas cylinder, the piping of the gas, and the setting of the gas mass flow control unit. Please confirm the power cable of the gas flow control unit. Please confirm the data of the gas flow control unit.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Even if passing the specified time after Gas OFF, the actual gas flow could not restore 0 on the gas flow control unit. It is setting which uses the Plasma welder though the analog output board is not installed. Filler wire has stuck.

1.Check the error judgment delay time. 2.Check the gas type and the gas pressure at main cock. 3.The gas flow control unit may be damaged or broken down. Please contact our customer service center. Please modify setting whether to install the analog output board.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Cut stuck wire.

Alarm

Alarm

Alarm

Alarm

on

on

Filler touch detection failure

It was not able to detect that a filler wire touched welding base metal.

Please check the state of a filler wire, a welding constant, and wiring.

Alarm

Alarm

Alarm

Alarm

on

on

Operational failure

Welding mode option un-setting up.

Welding mode option which is not set up was used.

Please set up a welding mode option.

Alarm

Alarm

Alarm

Alarm

on

on

5131

Operational failure

Welding mode option can't use.

Since the welding mode option is not set up correctly, it can't use.

Alarm

Alarm

Alarm

Alarm

on

on

5132

Arc weld failure

Specified mode can't use.

Alarm

Alarm

Alarm

Alarm

on

on

5133

Operational failure

Welding mode option can't use.

Since the welding unit is not supporting specified mode, it can't use. Since the welding mode option is not set up correctly, it can't use.

Since system memory protection was effective, an option was not able to be written in a system memory.Please once repeal a system memory protection function and start a system again. Please use a welding unit with specified mode.

After removal of failure, please carry out "failure-reset". After removal of failure, please carry out "failure-reset". No reset operations neccesary. No reset operations neccesary.

Alarm

Alarm

Alarm

Alarm

on

on

5134

Arc weld failure

Cycle pulsed welding control error.

Alarm

Alarm

Alarm

Alarm

on

on

5135

Arc weld failure

Cycle pulsed welding control error.

5136

Arc weld failure

The multipass section is abnormal.

5137

Arc weld failure

5138

Arc weld failure

5139

Arc weld failure

The welding power supply secondaly electric characteristic file can't be read. The first･second main circuit failure occurred in the welding power supply. It is necessary to turn the welding power supply on again.

5140

Arc weld failure

The speed of the wire speed has exceeded the allowable limit.

5143

Arc weld failure

Threshold trigger

5146

Arc weld failure

The arc try condition file doesn't exist.

5147

Arc weld failure

5148

Arc weld failure

The load of filler feed exceeded allowable value. The abnormalities of arc voltage direct detection

5190

Arc weld failure

5200

In the arc condition file of the cycle pulsed welding, the welding control must be "Cycle pulse" and the slope condition must be specified by "Distance". The condition of Cycle pulsed welding is specified by 'AS' function. It must be specified by 'ASS' function. The 'ASM' function, the 'AEM' function, the 'OFFSET' function, and the 'EP' function cannot be executed outside the multipass section. Read file failure occurs while reading the welding power supply secondaly electric characteristic file. The failure exists in the first･ second main circuit of the welding power supply.

Please change the welding condition.

No reset operations neccesary. No reset operations neccesary. Error reset.

Please modify the task program.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Please teach the 'MPS' function and the 'MPE' function.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Please initialize the welding power supply secondaly electric characteristic file.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Refer to the instruction manual of the welding power supply (Failure Name: The first･second main circuit failure).

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

The arc welding power supply cannot be operated if it doesn't turn on again.

Turn the welding power supply on again.

Alarm

Alarm

Alarm

Alarm

on

on

Please confirm whether an excessive load contracts the wire feeder. Please contact our customer service center when the permissible value is large.

Alarm

Alarm

Alarm

Alarm

on

on

Please confirm the arc welding construction condition.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Please create the arc try condition file or edit the task program.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

A load is on the filler feeder by wear of the liner, the chip defect, and so on. Remove the factors.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Please set up ON "Direct arc voltage detection" of a welding constant, and please check connection of the arc voltage detection line by the side of a base material.

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Sensor failure

Sensor Function cannot be executed.

Wrong usage of sensor function is detected in teaching program

Please record sensor search function after move step.

Alarm

Alarm

Alarm

Alarm

on

on

5201

Sensor failure

Search range exceeded.

This error occurs when the robot moves beyond search range

Modify(enlarge) the search range or program to rectify error.

Alarm

Alarm

Alarm

Alarm

on

on

5202

Sensor failure

Search range is short

Modify(shorten) the search range or program to rectify error.

Alarm

Alarm

Alarm

Alarm

on

on

5203

Sensor failure

Deviation range exceeded.

This error occurs when the robot detect the touch status within minimum search range. This error occurs when the robot moves beyond deviation range

After removal of failure, please carry out "failure-reset". After removal of failure, please carry out "failure-reset". After recording the move step, Please Check Go. No reset operations neccesary. No reset operations neccesary. No reset operations neccesary.

Alarm

The abnormalities in the filler wire feeding

The speed of the wire measured in the arc welding power supply has exceeded the allowable limit at the speed of the wire that the arc welding power supply output. The threshold specified under the welding record condition was detected in the arc welding power supply. The arc try condition file which is specified by the arc welding function doesn't exist. The filler feed load has exceeded the allowable value set in the arc constant. The arc voltage detection procedure by the side of a base material is wrong. The arc voltage detection is needed for this welding mode. The filler wire is not sent or it is incomplete penetration.

Turn the welding power supply on again. Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Please restore the welding mode option on the welding mode option screen.

Please check the feeding state and welding conditions of the filler wire.

Modify(enlarge) the deviation range or program to rectify error.

4-61

Error code list 5204

Sensor failure

Sensor number is mismatched.

5205

Sensor failure

The input-and-output signal is not assigned.

5206

Sensor failure Sensor failure

A deviation file is wrong. A deviation file is not found.

5208

Sensor failure

Mechanism type is mismatched.

5209

Sensor failure

A detecting wire extension file is wrong.

5210

Sensor failure

5211

Sensor failure

A detecting wire extension file is not found. Coordinate systems are mismatched.

5212

Sensor failure

Cannot search.

5213

Sensor failure Sensor failure Sensor failure

Gap Over

5216

Sensor failure

Groove depth short

5217

Sensor failure Sensor failure Sensor failure Sensor failure Sensor failure

Angle1 over

Sensor failure Sensor failure

Seaching time over

Sensor failure Sensor failure Sensor failure Sensor failure

Unstable detection

Sensor failure Sensor failure Sensor failure Sensor failure Sensor failure

Gap file error

5233

Sensor failure

5234

Sensor failure Sensor failure Sensor failure Sensor failure

Communication timeout occurred between the controller and the sensor unit Sensor condition file error Sensor condition file is not exist. Sensor Failure

5207

5214 5215

5218 5219 5220 5221

5222 5223

5224 5225 5226 5227

5228 5229 5230 5231 5232

5235 5236 5237

5238

4-62

Sensor failure

Gap short Groove depth over

Angle1 short Angle2 over Angle2 short Groove un-detected

Sensor mounting error

Out of measurement distance Reference point error ZG1 workpiece undetected

No gap file Gff file error No gff file Sensor disconnected (Laser search)

Start Point un-detected

Cannot restart during seam tracking.

This error occures when the sensor number in the sensor step does not meet that of the connected sensor. This error occurs when the input-and-output signal required for search operation is not assigned. This error occurs when read-out of a deviation file goes wrong. This error occurs when the specified deviation file cannot be found. This error occurs when the mechanism type in specified deviation file is mismatched. This error occurs when read-out of a detecting wire extension file goes wrong. This error occurs when the specified detecting wire extension file cannot be found. This error occurs when the coordenate systems are not matched between selected deviation files. Search direction cannot be specified because the search vector is not taught, or calculating search vector was failed. Detected gap is exceeded beyond maximum allowable value. Detected gap becomes lower than minimum allowable value. Detected groove depth is exceeded beyond maximum allowable value. Detected groove depth becomes lower than minimum allowable value. Detected angle1 is exceeded beyond maximum allowable value. Detected angle1 becomes lower than minimum allowable value. Detected angle2 is exceeded beyond maximum allowable value. Detected angle2 becomes lower than minimum allowable value. Groove position cannot be detected

This error occurs when searching time is too long. This error occurs when sensor mounting is not set.

This error occurs when measured data is unstable. This error occurs when measured distance is out of range. This error occurs when reference point is not stored. This error occurs when the laser reflection beam is not sufficiently received in ZG1 starting.

This error occurs when wrong data is detected in gap file. This error occurs when the specified gap file is not exist. This error occurs when wrong data is detected in GFF file. This error occurs when the specified GFF file is not exist. This error occurs when there is no communication between laser sensor and RC. This error occurs when there is no response from Laser Sensor Unit.

This error occurs when wrong data is detected in LSF or LSR file. This error occurs when specified LSF or LSR file is not exist. This failure occurs when the error is issued from the sensor controller This failure occurs when the start point is not detected during ZF search. Cannot restart during seam tracking.

Check that sensor settings and /or teaching programs.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Set up an input-and-output signal.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Check a deviation file.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Correct the file number.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Correct the file number.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Check a detecting wire extension file.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Correct the file number.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Correct the file number.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

(1)Specify the search vector. (2)When the search vector was already specified, modify the search vector.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Check that gap amount and modify allowable value if needed. Check that gap amount and modify allowable value if needed. Check that groove depth amount and modify allowable value if needed.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Check that groove depth amount and modify allowable value if needed.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Check that angle1 amount and modify allowable value if needed. Check that angle1 amount and modify allowable value if needed. Check that angle2 amount and modify allowable value if needed. Check that angle2 amount and modify allowable value if needed. (1)Check setting parameters in GFF file. (2)If you are provided with the optional data terminal, use Groove Data function in RD/AD tab menu, and modify the teaching program so that laser data are properly obtained. To short the searching time less than 2s or modify sample rate in GFF file. (1)Specify sensor mounting direction. (2)Execute the sensor calibration before executing the ZJLETP command.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Check that target surface condition and/or measurement angle. Check that target piece is located at desired position.

After removal of failure, please carry out "failure-reset". Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Execute trial motion to get reference point.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

(1)At the ZG1 start point, the workpiece must be taught within the measurement range. (2)When the workpiece is placed within the measurement range, adjust the angle of laser against the workpiece, and constantly light the distance LED on laser head. (3)If you are provided with the optional data terminal, use RD/AD tab menu, and check that always 206 or higher laser beam in the LEVEL display is received. Check the contents in gap file.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Check the gap file number.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Check that contents in GFF file.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Check that GFF file number.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Turn on the sensor unit. In case the sensor unit has been already turned on, check the connection of the sensor unit to the controller. Check the connection of the sensor unit to the controller.

Error reset.

Error

Error

Error

Error

on

on

Turn on the controller and the sensor unit again. Error reset.

Error

Error

Error

Error

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Check that contents in LSF or LSR file. Check that LSF or LSR file number.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Check the sensor status by WinUser.

Error reset.

Error

Error

Error

Error

on

on

(1)Check the groove recognization by WinUser. (2)Enlarge the ZF maximum search range.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Do not modify the position and posture of the robot when the robot is stopped in ZT period if the restarting is required.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Error code list 5239

Sensor failure

ZF Deviation range exceeded

5240

Sensor failure Sensor failure

ZF search range exceeded ZT Position Deviation range exceeded

Sensor failure Sensor failure

ZN offset range exceeded ZN Search range exeeced.

Sensor failure Sensor failure

End point un-detected

Sensor failure Sensor failure Sensor failure

Laser ON Failed

5249

Sensor failure

ZT Posture Deviation range exceeded

5250

Sensor failure

Sensor disconnected

5251

Sensor failure

Correction amount by arc-sensor exceeds specified value.

5252

Sensor failure

5253

Sensor failure

Calculation turns to unstable during arc-sensing process. Welding position cannot be detected

5254

Sensor failure

Unstable wire-feeding.

5255

Sensor failure Sensor failure

ST parameter error.

5241

5242 5243

5244 5245

5246 5247 5248

5256

5257

Sensor failure

5258

Sensor failure Sensor failure

5259

Deviation range exceeded.

Laser is not ready. Error in instruction of ZN command.

The ET command less program was performed. Abnormalities were found in the parameter of basic data. Error in instruction of ZG1 command. At the start-point detection or in the tracking section, the move command with no Synchromotion teaching (without "H") was found. Sensor stop signal input.

This error occurs when the distance between the detected start point and ZF taught point exceeded the deviation range. This error occurs when the robot moves beyond search range This error occurs when the robot moves beyond Position deviation range This error occurs when the setting offset is beyond the range This error occurs when the robot moves beyond search range during ZN. End point of workpiece is not detected. This error occurs when the distance between the detected end point and taught point before ZE exceeded the deviation range. Laser is not activated.

Check detected position. If no problems exist, moodify(enlarge) the ZF deviation range parameter or program to rectify error.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Modify(enlarge) the search range or program to rectify error. Check the target position If no problems exist, moodify(enlarge) the ZT parameters or program to rectify error. Modify(enlarge) the ZN offset to rectify error.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Modify(enlarge) the ZN search range or program to rectify error.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Modify(enlarge) ZN search range or program to rectify error. Check the detected point. If no problems exist, Modify(enlarge) the deviation range or program to rectify error.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Turn on the Laser by ZON or manual operation.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Wait 3 seconds or longer after ZON was performed before ZF/ZT/ZJ. Please improve instruction.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Check the target posture If no problems exist, moodify(enlarge) the ZT parameters or program to rectify error. Turn on the sensor unit. In case the sensor unit has been already turned on, check the connection of the sensor unit to the controller. Check that currect torch position. If it is OK, extend the value CHASING RANGE in teaching parameter. If it is NG, try to adjust sensor parameters.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Check that welding condition to be stable.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Try to re-adjust sensing parameters.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Check that equipments for wire feeding.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

It improves whether each parameter is setting within the limits. Please teaching ET command.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

An appointed basic data file does not exist or a file cannot be read.

Please check a basic data file with a service menu.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

ZG1 command in the weaving section cannot be executed. In the start-point detection section or the tracking section in Synchromotion system, the move command is not taught as Synchromotion teaching ("H").

Please improve instruction.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Specify all the move commands, right before ZF command, in ST~ET section and in ZT~ZE section to Synchromotion teaching ("H").

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Stop signal is input into the laser sensor unit.

(1)Release Emergency Stop Button on the Laser Sensor Unit. (2)Close the Emergency Stop Alarm Input loop connected to CN2 on the laser sensor unit.

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

ZF/ZT/ZJ will be performed before 3 seconds after ZON is carried out. There is no move command immediately after ZN command to which a move command or ZT command does not exist before ZN command, or it is [ that two or more move commands are taught between ZN - ZE, etc. and ] a factor. This error occurs when the robot moves beyond Posture deviation range The controller couldn't communicate with the sensor unit. Error is activated when the case that correction amount by the sensor exceeds the specified value in teaching parameter. This error is activated when stability of welding arc decreased significantly. This error is activated when the deviation detection cannot be calculated during arc-sensing process. Note that position correction is not executed. Wire-feeding status turn to unstable. Deviation is lager than specified value. The instruction parameter of ST command is over the setting range. ET command is not taught after ST command.

5260

Sensor failure

5261

Sensor failure

Groove un-detected.

Groove cannot be detected.

(1)Check that LASER power is ON. (2)Check the cable between Laser Sensor Unit and Sensor Head is connected properly. (3)Check the cable between Robot Controller and Laser Sensor Unit is connected properly.

5262

Sensor failure

Torch moving distance over.

The distance corrected by the sensor within 1 interpolation time was exceeded over the internal distance.

(1)Adjust the stability of groove detection by WinUser. (2)Check the cable between Robot Controller and Laser Sensor Unit is connected properly. In addition, also check the sensor head cable.

5263

Sensor failure Sensor failure Sensor failure

No SFM file

Check SFM file number.

Alarm

Alarm

Alarm

Alarm

on

on

Check that contents in SFM file.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Please improve instruction.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

5266

Sensor failure

DE Corrected point failure

Alarm

Alarm

Alarm

Alarm

on

on

Sensor failure

JOINT command exists in tracking section.

(1)Modify the AS speed so that it is close to the proper one.(2)Modify DE taught point so that the distance between DE and ET taught point is longer. Modify JOINT command in the teaching section (ST～ ET, ZF～ZT～ZN～ZE) of tracking sensor to LIN command or CIR1/CIR2 command.

Error reset.

5267

This error occurs when specified SFM file is not exist. This error occurs when wrong data is detected in SFM file. There is no move command immediately after DE command to which a move command or ST command does not exist before DE command, or it is [ that two or more move commands are taught between DE - ET, etc. and ] a factor. This error occurs when the order of DE corrected point and ET taught point are exchanged by tracking. JOINT command cannot be executed in the tracking sensor section.

After removal of failure, please carry out "failure-reset". After removal of failure, please carry out "failure-reset". After removal of failure, please carry out "failure-reset". Error reset.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

5264 5265

SFM file error Error in instruction of DE command.

4-63

Error code list 5268

Sensor failure

Sensor Function cannot be executed.

An error is in a connection setup of a sensor and a mechanism.

Please check a constant setup and instruction of a sensor.

5269

Sensor failure

5270

Sensor failure

ZN Search destination point is exceeded range. The tracking speed is a negative value.

This error occurs when the robot moves beyond Software Limit range by ZN search. This error occurs when the tracking speed is set to a negative value by speed change of Adaptive Control.

5271

Sensor failure

5272

Sensor failure

5273

Sensor failure

5274

Sensor failure

5275

Sensor failure

Error in instruction of ZE command outside tracking section Continuous ZT commands have same sensor number. Continuous ZN commands have same sensor number. Continuous ZE commands have same sensor number. ZN command according to ZT does not exist.

5276

Sensor failure

5277

Sensor failure

5278

Sensor failure

5279

Sensor failure

This error occurs when ZT command according to ZE does not exist. This error occurs when continuous ZT commands have same sensor number. This error occurs when continuous ZN commands have same sensor number. This error occurs when continuous ZE commands have same sensor number. This error occurs in case that ZN commands for all laser sensors is not instructed when the tracking by the plural laser sensors are performed. This error occurs when ZE command according to ZT is not instructed. This error occurs when ZT command according to ZN is not instructed. This error occurs when ZT command according to ZE is not instructed. This error occurs when ZT command is instructed just after ZN or ZE command.

Modify () the ZN mamimum distance so that the point extended ZN maximum distance from the previous point of ZE is within the robot working range. (1)Specify the AS speed properly so that it will not become negative by Adaptive Control. (2)Connect WinUser to the sensor, and review the setting "gap speed" in the spread sheet. Modify ZT or ZE command.

5280

Sensor failure

5281

Sensor failure

5282

Sensor failure

5283

Sensor failure

5284

Sensor failure

Abnormal setting of "Maximum distance" in ZN commands.

5285

Sensor failure

A reference position has not been taught.

5286

Sensor failure

An undefined dummy point is being referred.

5287

Sensor failure

A vector is not taught.

5288

Sensor failure

5289

Sensor failure

An undefined temporary buffer point is being referred. A vector cannot be defined or identified when executing SF2/ZF2.

5290

Sensor failure

Logic error of the patterned search macro.

5291

Sensor failure

An operation error occurred when executing SF2/ZF2.

5292

Sensor failure

DE Search range exeeced.

5293

Sensor failure

5294

Sensor failure

The command of teaching prohibition in ZF and after Adaptive welding current over

5295

Sensor failure

Adaptive welding current short

4-64

ZE command according to ZT does not exist. ZT command according to ZN does not exist. ZT command according to ZE does not exist. ZT command exists in the section of continuous ZN or ZE commands. ZN command exists in the section of continuous ZT or ZE commands. ZE command exists in the section of continuous ZT or ZN commands. Abnormal setting of ON/OFF of External I/O detection in ZN commands. Abnormal setting of input port number of External I/O detection in ZN commands.

No reset operations neccesary. Error reset.

Alarm

Alarm

Alarm

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on

on

Alarm

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Alarm

on

on

Error reset.

Alarm

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on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Check each sensor number of ZT command.

Error reset.

Alarm

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on

on

Check each sensor number of ZN command.

Error reset.

Alarm

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Alarm

Alarm

on

on

Check each sensor number of ZE command.

Error reset.

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on

on

Modify ZN commands.

Error reset.

Alarm

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Alarm

on

on

Modify ZT or ZE command.

Error reset.

Alarm

Alarm

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Alarm

on

on

Modify ZT or ZN command.

Error reset.

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on

on

Modify ZT or ZE command.

Error reset.

Alarm

Alarm

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on

on

Modify ZT, ZN or ZE command.

Error reset.

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on

on

This error occurs when ZN command is instructed just after ZT or ZE command.

Modify ZT, ZN or ZE command.

Error reset.

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Alarm

on

on

This error occurs when ZE command is instructed just after ZT or ZN command.

Modify ZT, ZN or ZE command.

Error reset.

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Alarm

on

on

This error occurs when both settings of External I/O detection in the continuous ZN instructions are not same. This error occurs when both settings of input port number of External I/O detection in the continuous ZN instructions are not same. This error occurs when both parameters of "Maximum distance" in the continuous ZN instructions are not same. This error occurs if a reference position is not taught when executing SF2/ZF2. When executing SF2/ZF2, an undefined dummy point was attempted to be referred. Since a vector is not taught, the motion direction of patterned search cannot be operated. When executing SF2/ZF2, an undefined temporary buffer point was attempted to be referred. (1)The motion start/end point of S (search) command or M (move) command are the same. (2)When executing the vector intersection operation mode (a=1) by L (vector calcuation) command, two kinds of vector are identical. Parameter settings for the patterned search macro are fault, which causes a SF2/ZF2 execution failure. A search target point of S (search) command or a motion target point of M (move) command were not able to be obtained.

Modify the setting of External I/O detection in each ZN command.

Error reset.

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Alarm

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Alarm

on

on

Modify the setting of input port number of External I/O detection in each ZN command.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Modify "Maximum distance" in each ZN command.

Error reset.

Alarm

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on

on

Teach a reference position by executing manual operation, macro-execution or trial operation.

Error reset.

Alarm

Alarm

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Alarm

on

on

To make a reference to the dummy point, modify the patterned search macro so that the dummy point can be referred after defined. Teach a vector (both its start point and end point).

Error reset.

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on

on

Error reset.

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on

on

To make a reference to a temporary buffer point, modify the patterned search macro so that the temporary buffer point can be referred after defined. (3)Check the vector specified by the temporary buffer point in each command, and remove the errors.

Error reset.

Alarm

Alarm

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Alarm

on

on

Error reset.

Alarm

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on

on

Review the contents of the patterned search macro and parameter settings for the patterned search (including the set point).

Error reset.

Alarm

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on

on

Review the contents of the patterned search macro and parameter settings for the patterned search (including the set point) so that the search target point and the motion target point can be got within the robot motion range. Modify(enlarge) the DE search range or program to rectify error.

Error reset.

Alarm

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Alarm

on

on

Error reset.

Alarm

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on

on

Review the teaching in ZF-ZT and ZF-ZE section.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Check the lists of the specified spreadsheet in the sensor controller by WinUser. If the spreadsheet is OK, increase maximum current watch value of adaptive control. Check the lists of the specified spreadsheet in the sensor controller by WinUser. If the spreadsheet is OK, decrease minimum current watch value of adaptive control.

Error reset.

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on

on

Error reset.

Alarm

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on

on

This error occurs when the robot moves beyond search range during DE. This error occurs when the command not permitted has been taught in ZF-ZT and ZF-ZE section. Welding current specified by adaptive control exceeds maximum current watch value of adaptive control. Welding current specified by adaptive control becomes lower than minimum current watch value of adaptive control.

Error code list 5296

Sensor failure

Adaptive welding voltage over

5297

Sensor failure

Adaptive welding voltage short

5298

Sensor failure

Adaptive travel speed over

5299

Sensor failure

Adaptive travel speed short

5300

Auto Calibration failure

Auto Calibration function can not be carried out.

5301

Auto Calibration failure Auto Calibration failure

Other units are running program.

Auto Calibration failure Auto Calibration failure Auto Calibration failure Auto Calibration failure

The maximum search distance error.

5302

5303

5304

5305

5306

5307

5308

5309

5310

5311

5312

5313

5314

5315

5316

5317

5318

5319

5320

Auto Calibration failure Auto Calibration failure Auto Calibration failure Auto Calibration failure Auto Calibration failure Auto Calibration failure

Auto Calibration failure Auto Calibration failure Auto Calibration failure Auto Calibration failure Auto Calibration failure Auto Calibration failure Auto Calibration failure Auto Calibration failure

5321

Auto Calibration failure

5322

Auto Calibration failure Auto Calibration failure Auto Calibration failure

5323

5330

Welding voltage specified by adaptive control exceeds maximum voltage watch value of adaptive control. Welding voltage specified by adaptive control becomes lower than minimum voltage watch value of adaptive control. Travel speed specified by adaptive control exceeds maximum speed watch value of adaptive control. Travel speed specified by adaptive control becomes lower than minimum speed watch value of adaptive control. An error is in the record method of an automatic calibration related function.

Check the lists of the specified spreadsheet in the sensor controller by WinUser. If the spreadsheet is OK, increase maximum voltage watch value of adaptive control. Check the lists of the specified spreadsheet in the sensor controller by WinUser. If the spreadsheet is OK, decrease minimum voltage watch value of adaptive control. Check the lists of the specified spreadsheet in the sensor controller by WinUser. If the spreadsheet is OK, increase maximum speed watch value of adaptive control. Check the lists of the specified spreadsheet in the sensor controller by WinUser. If the spreadsheet is OK, decrease minimum speed watch value of adaptive control. Please record an automatic calibration function behind a move command.Or please choose a mechanism correctly.

CALIBROB(FN702) cannot be performed while running the program of other units. The amount of compensation of joint offset or a tool parameter is over the maximum set up by the constant. This error occurs when the robot moves beyond search range

Please perform CALIBROB (FN702) again after stopping all units.

This error occurs when reference points are not acquired.

Please acquired reference points.

This error occurs when the "A" and "B" points have different orientation. It becomes this error when the orientation of the reference point at the time of the direction search of Z differs from A1, B1 or A2, and B-2. This error occurs when the auto calibration sensor required for search operation is not set up. This error occurs when the input-and-output signal required for search operation is not set up. A condition file cannot be read.

Please make "A" and "B" points into the same orientation.

The abnormalities in an automatic calibration parameter. Automatic calibration measurement file error. The abnormalities in automatic calibration correct.

The maximum compensation value error.

Error reset.

Alarm

Alarm

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Alarm

on

on

Error reset.

Alarm

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Alarm

Alarm

on

on

Error reset.

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on

on

Error reset.

Alarm

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Alarm

on

on

After recording the move step, Please Check Go. Error reset.

Alarm

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on

on

Alarm

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Alarm

on

on

Please acquire a measuring point again after correcting a gap of a robot using a torch gauge or a point mark.

Error reset.

Inform ation

Inform ation

Alarm

Alarm

on

on

Modify(enlarge) the search range or program to rectify error.

No reset operations neccesary. No reset operations neccesary. No reset operations neccesary. No reset operations neccesary.

Alarm

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on

on

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on

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on

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on

Please register an automatic calibration sensor by constant setup.

Error reset.

Alarm

Alarm

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Alarm

on

on

Set up an input-and-output signal.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Please set up constant data again or perform initialization.

Error reset.

Alarm

Alarm

Alarm

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on

on

The parameter in an automatic calibration constant file is unusual.

Please set up a constant file correctly.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

It has not accessed whether a measurement file could be created.

Please enable it to create a measurement file.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Reliability is not in the measured data. There is a possibility that the sensor might incorrect-detect or a totter may be in attachment of a tool. Abnormalities occurred at the time of work program compensation.

Please perform reference point acquisition again.

Error reset.

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on

on

Please perform reference point acquisition again.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Abnormalities occurred at the time of work program compensation.

It is not especially.

Inform ation

Inform ation

Inform ation

Inform ation

on

on

Since a robot's position is shifted greatly, measurement is uncontinuable. The gap of a robot was detected in the state where all measuring points have not measured. Datum point acquisition mode CALIBROB (FN702) was performed. It becomes this error when the inputted search operation distance is too large. This error occurs when the robot moves beyond search range

Please acquire a measuring point again after correcting a gap of a robot to the range which can be measured using a torch gauge or a point mark. Please measure all measuring points.

No reset operations neccesary. Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

It is not especially.

Error reset.

Inform ation

Inform ation

Alarm

Alarm

on

on

Modify(enlarge) the search range or program to rectify error.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Modify(enlarge) the search range or program to rectify error.

Alarm

Alarm

Alarm

Alarm

on

on

Reliability is not in the measured data. There is a possibility that the sensor might incorrect-detect or a totter may be in attachment of a tool. Although the all-points measurement of the quick checki point is not carried out, MESPOS (FN700) was performed. Reference point was not taken from point 1Q.

Please perform measuring point acquisition again.

No reset operations neccesary. Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Please measure the quick checki point again.

Error reset.

Alarm

Alarm

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Alarm

on

on

Please perform taking reference point from point 1Q.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Reference point error.

Reference point was not taken from point 1A.

Please perform taking reference point from point 1A.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Measuring point Orientation error.

This error occurs when the "A" and "B" points have different orientation. There is a possibility that the sensor might incorrect-detect or a totter may be in attachment of a tool.

Please perform measuring point acquisition again.

No reset operations neccesary.

Alarm

Alarm

Alarm

Alarm

on

on

The reference point for automatic calibrations is not acquired. Reference point Orientation error. Reference point orientation error(At the time of the direction search of Z). The auto calibration sensor is not registered. The input-and-output signal is not set up. File reading error.

The abnormalities in work program compensation. The abnormalities in work program compensation. A robot's position is shifted greatly. All measuring points are not acquired. CALIBROB (FN702) cannot be performed. Cannot search.

The minimum search distance error. The abnormalities in calibration compensation at the time of remeasurement. The quick checki point is not measured.

Reference point error.

Please make the same the orientation of B points of A1, B1 point, A points of the direction search of Z or A2, B-2 point, and the direction search of Z.

4-65

Error code list 5331

Auto Calibration failure

Measuring point orientation error(At the time of the direction search of Z).

5332

Auto Calibration failure

The abnormalities in automatic calibration correct.

5333

Auto Calibration failure Auto Calibration failure Auto Calibration failure Sensor failure

The abnormalities in work program compensation. Measuring point error.

5401

Sensor failure

Abnormal setting of the current monitoring range

5402

Sensor failure

Abnormal setting of the voltage monitoring range

5403

Sensor failure

Adaptive condition setting error

5404

Sensor failure

Adaptive weaving amplitude over

5406

Sensor failure

ZF Posture Deviation range exceeded.

5408

Sensor failure

Maximum distance in ZN command is too long.

5410

Sensor failure

Stability waiting time over

5411

Sensor failure

ZJ Deviation range exceeded

5412

Sensor failure

Adaptive Wire Speed Over

5413

Sensor failure

Adaptive Wire Speed Short

5414

Sensor failure Sensor failure Sensor failure Sensor failure Sensor failure

Area Over

5419

Sensor failure

5420

Sensor failure

5421

Sensor failure

SF8 Max. Compensative-Surveila nce val. Over SF8 Min. Compensative-Surveila nce val. Short The touch detection point is abnormal.

5422

Sensor failure

Adaptive EN Ratio Over

5334

5335

5400

5415 5416 5417 5418

4-66

It becomes this error when the orientation of the measuring point at the time of the direction search of Z differs from A1, B1 or A2, and B-2.There is a possibility that the sensor might incorrect-detect or a totter may be in attachment of a tool. Reliability is not in the measured data. There is a possibility that the sensor might incorrect-detect or a totter may be in attachment of a tool. Abnormalities occurred at the time of work program compensation.

Please perform measuring point acquisition again.

No reset operations neccesary.

Alarm

Alarm

Alarm

Alarm

on

on

Please perform measuring point acquisition again.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Please perform measuring point acquisition again.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Measuring point was not taken from point 1Q.

Please perform taking measuring point from point 1Q.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Measuring point error.

Measuring point was not taken from point 1A.

Please perform taking measuring point from point 1A.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Abnormal setting of the speed monitoring range

This error occurs when the minimum value of speed monitoring value exceeds the maximum value in the condition settings for the adaptive control. This error occurs when the minimum value of current monitoring value exceeds the maximum value in the condition settings for the adaptive control. This error occurs when the minimum value of voltage monitoring value exceeds the maximum value in the condition settings for the adaptive control. An illegal setting change of an adaptive condition was done in the tracking section. Effective and the invalidity of an adaptive control cannot be switched in the tracking section, and the number of samples of moving averages be changed. Weaving amplitude specified by adaptive control exceeds maximum amplitude watch value of adaptive control. This error occurs when the difference between the target posture calculated by ZF instruction and the taught posture exceeds Posture deviation range. Target position calculated by ZN command is out of the movable area because Maximum distance in ZN command is too long. The stability waiting time was exceeded.

Review the minimum and maximum value of the speed monitoring value.

Error reset.

Alarm

Alarm

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on

on

Review the minimum and maximum value of the current monitoring value.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Review the minimum and maximum value of the voltage monitoring value.

Error reset.

Alarm

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Alarm

on

on

Please confirm the specified LSR file number. Please confirm the content of the LSR file set when the specified number is correct.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Check the lists of the specified spreadsheet in the sensor controller by WinUser. If the spreadsheet is OK, increase maximum amplitude watch value of adaptive control. Check the target posture If no problems exist, moodify(enlarge) the ZF parameters or program to rectify error.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Alarm

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on

on

Decrease the maximum distance in ZN command.

Error reset.

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on

(1)Modify(enlarge) stable waiting time to rectify error. (2)Modify the teaching point so that the groove is within the field of view of laser. (3)When the groove is within the field of view, modify the parameters by the software attached to the sensor so that the groove is detected normally. Check detected position. If no problems exist, modify(enlarge) the ZJ deviation range parameter or program to rectify error.

Error reset.

Alarm

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on

on

Error reset.

Alarm

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on

on

Check the lists of the specified spreadsheet in the sensor controller by WinUser. If the spreadsheet is OK, increase maximum wire speed watch value of adaptive control. Check the lists of the specified spreadsheet in the sensor controller by WinUser. If the spreadsheet is OK, decrease minimum wire speed watch value of adaptive control. Check the area watch value(maximum) and enlarge if needed. Check the area watch value(minimum) and decrease if needed. Check the mismatch watch value(maximum) and enlarge if needed. Check the mismatch watch value(minimum) and decrease if needed. Please execute the trial movement or the edit, and get reference position again.

Error reset.

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on

on

Error reset.

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on

on

Error reset.

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on

on

Error reset.

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on

on

Error reset.

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on

on

Error reset.

Alarm

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on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Check contents of the register specified in SF8. If there is no problem, increase Max. Compensative-Surveilance val. in SF8. Check contents of the register specified in SF8. If there is no problem, decrease Min. Compensative-Surveilance val. in SF8. Contact our service department. Back up files to external CF memory. Because the robot stop step is different to the execute step, step-set must be needed for restart. Check the lists of the specified spreadsheet in the sensor controller by WinUser. If the spreadsheet is OK, increase maximum EN ratio watch value of adaptive control.

Error reset.

Alarm

Alarm

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Alarm

on

on

Error reset.

Alarm

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on

on

Turn on the power again.

Alarm

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Alarm

on

on

Error reset.

Alarm

Alarm

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on

on

Area Short Mismatch Over Mismatch Short Search position was changed.

This error occurs when the distance between the detected point and ZJ reference point exceeded the deviation range. Wire Speed specified by adaptive control exceeds maximum wire speed watch value of adaptive control. Wire speed specified by adaptive control becomes lower than minimum wire speed watch value of adaptive control. Detected area is exceeded beyond maximum allowable value. Detected area becomes lower than minimum allowable value. Detected mismatch is exceeded beyond maximum allowable value. Detected mismatch becomes lower than minimum allowable value. It differs from the position in which search position obtained reference position. Contents of the register specified in SF8 exceeded beyond Max. Compensative-Surveilance val. Contents of the register specified in SF8 becomes lower than Min. Compensative-Surveilance val. It leaves the final instruction position too much the position in which the touch signal was detected. EN ratio specified by adaptive control exceeds maximum EN ratio watch value of adaptive control.

Error code list 5423

Sensor failure

Adaptive EN Ratio Short

5424

Sensor failure

Abnormal setting of the EN Ratio monitoring range

5425

Sensor failure

Abnormal setting of the Wire speed monitoring range

5426

Sensor failure

Normal Angle Over

5427

Sensor failure

Normal Angle Short

5428

Sensor failure

Sensor kind is mismatched.

5429

Sensor failure

The target position and posture cannot be calculated.

5430

Operational failure

5439

Sensor failure Sensor failure

Playback unavailable user task program because it is being used all user task. Tracking condition file doesn't exist. Tracking direction cannot be defined.

EN ratio specified by adaptive control becomes lower than minimum EN ratio watch value of adaptive control. This error occurs when the minimum value of EN ratio monitoring value exceeds the maximum value in the condition settings for the adaptive control. This error occurs when the minimum value of Wire speed monitoring value exceeds the maximum value in the condition settings for the adaptive control. Detected Normal angle is exceeded beyond maximum allowable value. Detected Normal angle becomes lower than minimum allowable value. This error occurs when the sensor kind in the sensor step does not meet that of the connected sensor. The target position and posture were not able to be calculated according to the detection value of the sensor, taught aim angle and the lag angle.

Check the lists of the specified spreadsheet in the sensor controller by WinUser. If the spreadsheet is OK, decrease minimum EN ratio watch value of adaptive control. Review the minimum and maximum value of the EN ratio monitoring value.

Error reset.

Alarm

Alarm

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on

on

Error reset.

Alarm

Alarm

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on

on

Review the minimum and maximum value of the Wire speed monitoring value.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Check that Normal angle amount and modify allowable value if needed.

Error reset.

Alarm

Alarm

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on

on

Check that Normal angle amount and modify allowable value if needed.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Check that sensor settings and /or teaching programs.

Reset failure.

Alarm

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on

on

(1) Please correct specified Aim Angle and Lad Angle. (2) Please confirm whether detected Joint Normal Angle is an expected angle with the GAP file. It is likely to become Joint Normal not anticipated according to the state of Groove. (3) It is likely to become this abnormality when the absolute amount of the offset is too large at two point search. Please reduce it in that case. Please confirm the starting condition of user task.

Error reset.

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on

on

Error reset.

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on

on

Please create the tracking condition file or edit the program. Please change tracking coordinates.

Error reset.

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on

on

Error reset.

Alarm

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on

on

No reset operations neccesary.

Alarm

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off

on

No reset operations neccesary. Turn on the power again.

Alarm

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off

on

Alarm

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on

on

Error reset.

Alarm

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on

on

After removal of failure, please carry out "failure-reset". After removal of failure, please carry out "failure-reset". After removal of failure, please carry out "failure-reset". Reboot robot controller and sensor unit. Error reset.

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on

on

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on

on

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Error

Error

Error

Error

on

on

Alarm

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on

on

Reset failure.

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on

on

Reset failure.

Alarm

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on

on

Reset failure.

Alarm

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on

on

Reset failure.

Alarm

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on

on

Reset failure.

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on

on

5441

Sensor failure

The welding length of Test Tracking is insufficient.

Error occurs when it is not able to start user task program ,because used all user task or not exist user task program. The condition file specified by the tracking function doesn't exist. For the traveling direction of the torch is parallel to the direction of gravity, tracking direction cannot be defined. Test Trackinig was not able to be completed normally, because the welding length was insufficient

5442

Sensor failure

Test Tracking is stopped.

Test Tracking is discontinued for sensor OFF or weaving OFF.

5443

Sensor failure

Data Sending Error.

Data was not able to be sent to the sensor.

5444

Sensor failure

Sensor Receive Data Error.

NAK frame was received from the sensor.

5445

Sensor failure

Sensor Send Data Error.

An abnormal frame was received from the sensor.

5446

Sensor failure

No Sensor Response.

Response command from the sensor was not able to be received.

(1)Please confirm the connection of the cable between the robot controller system and the arc sensor unit. (2)Still, when it is not released, Control power supply is re-switched on.

5447

Sensor failure

Sensor ID error.

Illegal Sensor ID.

Please confirm the sensor setting.

5448

Sensor failure

The controller could not communicate with the sensor unit.

5449

Sensor failure

Reboot robot controller and sensor unit. In case that the error still occurs after rebooting, check the connection of the sensor unit to the controller. Please set 0 to current response after executing the test tracking. If TIG-AVC, set 0 to arc standard voltage.

5450

Sensor failure

The controller could not communicate with the Sensor unit. ST instruction or the sample data file is wrong. Extended Ethernet Error

5451

Sensor failure

Sensor Lens Error

5452

Sensor failure

Sensor Interface Error

Abnormality concerning the lens was detected with the sensor camera. The sensor detected the error concerning the telecommunication control.

5453

Sensor failure

Sensor Hot Alarm

5454

Sensor failure

Laser OFF

5440

The result of an online modification cannot be applied to the sample data. It failed in the start of extended Ethernet.

An internal abnormal temperature was detected with the sensor camera. The Laser is disabled.

Please correspond whether to lengthen the welding length or to slow down the speed or to raise the weaving frequency or to reduce one section measurement frequency of the Test Tracking setting. Please OFF both sensor and weaving.

Reboot robot controller. Still, there is a possibility that the increase serial board has been damaged when not released. (1)Please confirm the connection of the cable between the robot controller system and the arc sensor unit. (2)Still, when it is not released, Control power supply is re-switched on. (1)Please confirm the connection of the cable between the robot controller system and the arc sensor unit. (2)Still, when it is not released, Control power supply is re-switched on.

Please confirm whether the extended Ethernet card is correctly installed. Or, please confirm whether the MAC address is correctly set. Still, there is a possibility that the version of OS is old when this abnormality occurs. Please contact our service department after confirming the version number of OS etc. Back up files to external CF memory. Please confirm whether the protective lens is correctly installed. Please wipe dirt off when the protective lens is dirty or exchange it for a new lens. Please treat it according to the instruction of the manual when abnormality is displayed on the display of the sensor.Please put the power supply of the sensor and the controller again when abnormality is not displayed. Please contact our service after confirming the version of the sensor and the controller when same abnormality is displayed afterward. Please drop the power supply of the sensor, and put time for a while at once. Please turn on the power supply again after falling the temperature of the camera. Please execute it after turning on the laser light. Please check whether cables are correctly connected when it doesn't turn on the laser light. Or, please put the power supply of the sensor and the controller again.

4-67

Error code list 5455

Sensor failure

The task number is wrong.

The specified task number doesn't exist in the sensor.

5456

Sensor failure

The posture change amount is excessive.

The calculated target posture has greatly changed into the posture when groove is detected. And, when the amount of the change exceeds the posture change over watch value, this alarm is detected.

5500

User failure

Installation Angle is updated.

Installation Angle is updated by request from OLP.

(1)Please specify the task number made with WeldCom. (2)Please make the task library of the specified task number with WeldCom. (3)Please load the task library file where the specified task number exists into the sensor by using WeldCom. (1) Please correct specified Aim Angle and Lead Angle. (2) Please confirm whether detected Joint Normal Angle is an expected angle with the GAP file. It is likely to become Joint Normal not anticipated according to the state of Groove. (3) Check that actual posture change amount and modify the posture change over watch value if needed. Check [Constant Setting]->[12 Format and Configuration]->[5 Installation Angle].

5501

User failure

Tool Constants are updated.

Tool Constants are updated by request from OLP.

Check [Constant Setting]->[3 Machine Constants]->[1 Tool Constants].

5510

Operational failure

Operational failure

5702

Operational failure

It cannot re-start.

Error occurs when it is not able to start user task program ,because used all user task or not exist user task program. It generates, when it is going to use the option function which is not set up. Movement in a return position or a section state cannot be resumed.

Please confirm the starting condition of user task.

5701

Playback unavailable user task program because it is being used all user task. Option un-setting up.

5703

Shift failure

The input-and-output signal is not set up.

Set up an input-and-output signal.

5704

Shift failure

5705

Shift failure

Abnormality occurred by the parity check of the shift input signal. Other units are running program.

This error occurs when the input-and-output signal is not set up. The value of the shift input signal is not steady.

No reset operations neccesary. No reset operations neccesary. Error reset.

Please the parity bit of the shift input signal must normally input or confirm whether the noise has gotten on the signal. Please perform again after stopping all units.

No reset operations neccesary. Error reset.

5706

Operational failure

Application isn't set up.

Please set up the correct Application.

6005

Arc weld failure

The weaving trajectory exceeded regulation speed.

6006

Arc weld failure

6010

Arc weld failure

The amount of posture change of taught weaving exceeded the restriction value. The welding current value has exceeded the allowable limit.

6011

Arc weld failure

The welding voltage value has exceeded the allowable limit.

6014

Arc weld failure

6015

This function command cannot be performed while running the program of other units. It generates when it is going to use the application function which is not set up. The amount of movements of weaving pattern data large, or frequency (speed) was large, the speed of a weaving trajectory exceeded regulation speed. The amount of change of the posture of weaving pattern data is too large.

Please set up an option.

Please re-start after a step-set out of the section.

Please correct the amount of movements of weaving, or frequency (speed).

Please correct posture change of taught weaving pattern data.

Arc start failure.

The difference between the welding current value measured by the welding power supply and the taught one has exceeded the allowable limit set by the arc constants. The difference between the welding voltage value measured by the welding power supply and the taught one has exceeded the allowable limit set by the arc constants. No arc is generated after retrying.

Check the welding conditions(wire extension etc). There is possibility of missmatch the welding characteristic data to your environment if this failure occurs over and over again. In such case, adjust the welding characteristic data by the adjudstment of welding condition function etc. Check the welding conditions(wire extension etc). There is possibility of missmatch the welding characteristic data to your environment if this failure occurs over and over again. In such case, adjust the welding characteristic data by the adjudstment of welding condition function etc. Check the workpiece's condition, wire's condition, and connection of the cable.

Arc weld failure

Arc outage was detected.

Arc outage occurred during welding.

6016

Arc weld failure

Wire stick was detected.

Wire is stuck.

Eliminate all causes of arc outage, for instance by adjusting the wedling conditions, fixing wire feed failure, and so on. Cut stuck wire.

6019

Arc weld failure

Wire shortage was detected.

Not enough wire signal is inputted.

Supply wire.

6024

Arc weld failure

6043

Arc weld failure Arc weld failure

The primary input voltage of the welding power supply has decreased. It exceeded the allowable value which the load of wire feed was set up to by the welding fixed number. The battery of welding power supply is exhausted.

Refer to the instruction manual of the welding power supply(Failure Name: Input voltage shortage) and eliminate all causes. A load is on the wire feed department by wear of the liner, the chip defect, and so on. Get rid of load factors.

6044

6054

Arc weld failure

Input voltage shortage failure ocurred in the welding power supply. The load of wire feed exceeded allowable value. The battery of welding power supply is exhausted. WCR Short-circuit Error

WCR of W-I/F had connected too hastily at the time of an arc start.

Please check the state of W-I/F, and a welding power supply.

6074

Arc weld failure

The cooler fan's rotation has fallen or it stops.

6080

Operational failure

Refer to the instruction manual of the welding power supply(Failure Name: The cooler fan failure) and eliminate all causes. Please start after waiting for the completion of starting.

6085

Arc weld failure

6106

Arc weld failure

The cooler fan failure ocurred in the welding power supply. It was going to start the unit containing the resources under starting. Communication timeout occurred inside the welding power supply. The pilot arc outage is abnormal.

6107

Arc weld failure

Setting error of the failure limit type.

4-68

It will generate, if the unit containing the resources under starting is started.

Exchange a battery because it can't be connected any more with the welding power supply.

Reset failure.

Alarm

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on

Reset failure.

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on

No reset operations neccesary. No reset operations neccesary. Error reset.

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on

Alarm

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on

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Alarm

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on

Alarm

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Alarm

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on

No reset operations neccesary. No reset operations neccesary.

Alarm

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on

on

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Move posture change restriction-withi n the limits. No reset operations neccesary.

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No reset operations neccesary.

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on

No reset operations neccesary. No reset operations neccesary. No reset operations neccesary. No reset operations neccesary. No reset operations neccesary. No reset operations neccesary. No reset operations neccesary. No reset operations neccesary. No reset operations neccesary. No reset operations neccesary.

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The contollor of the welding power supply didn't respond.

Check the route of cable and ground connection.

No reset operations neccesary.

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on

The pilot arc outage occurred.

Check the connection condition of the cable.

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on

The failure limit by the rate cannot be set by the version of this welder.

In the welding constant, please set a relative value.

No reset operations neccesary. No reset operations neccesary.

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Error code list 6108

Arc weld failure

Pilot arc ON error.

The pilot arc was not able to be turned on.

6109

Arc weld failure

Purge(Cleaning gas) ON error.

The purge(cleaning gas) was not able to be turned on.

6116

Arc weld failure

The arc welding power supply doesn't correspond to the management of the consumption of the wire.

6117

Arc weld failure

6121

Arc weld failure

The management of the consumption of the wire of the user maintenance function cannot be used. The Gas OFF Delay function cannot be used. The gas mass flow value has exceeded the allowable limit.

6122

Arc weld failure

The gas pressure value has exceeded the allowable limit.

6123

Arc weld failure

The set gas mass flow is not output.

6140

Arc weld failure

The speed of the wire speed has exceeded the allowable limit.

6141

Arc weld failure

6142

Arc weld failure

The welding redorder function cannot be used. The welding record file cannot be made.

6143

Arc weld failure

Threshold trigger

6144

Arc weld failure

Welding recorder cannot connect to FTP server.

6145

Arc weld failure

Abnormality occurred while saving the welding record file.

6147

Arc weld failure

6237

Sensor failure

The load of filler feed exceeded allowable value. Start Point un-detected

6238

Sensor failure

Cannot restart during seam tracking.

6239

Sensor failure

ZF Deviation range exceeded

6240

Sensor failure Sensor failure

ZF search range exceeded ZT Position Deviation range exceeded

6243

Sensor failure

ZN Search range exeeced.

6245

Sensor failure

Deviation range exceeded.

6249

Sensor failure

ZT Posture Deviation range exceeded

6261

Sensor failure

Groove un-detected.

6294

Sensor failure

Adaptive welding current over

6295

Sensor failure

Adaptive welding current short

6296

Sensor failure

Adaptive welding voltage over

6297

Sensor failure

Adaptive welding voltage short

6241

The arc welding power supply doesn't correspond to the Gas Off Delay function. The difference between the gas mass flow value measured by the welding power supply and the taught one has exceeded the allowable limit set with the controller. The gas pressure measured in the arc welding power supply exceeded the limiting value set with the controller. The set gas mass flow was not output in specified time. The speed of the wire measured in the arc welding power supply has exceeded the allowable limit at the speed of the wire that the arc welding power supply output. There is not becoming empty in the memory that memorizes the welding record data. The file cannot be made because there is no free space of the device. The threshold specified under the welding record condition was detected in the arc welding power supply. It was not a connection to the FTP server that was saving device for a welding recorder. Or, neither an initial folder nor the folder of this name existed on the home directory of the FTP server. The welding recorder cannot save record file. The storage medium is not prepared, and read-only and memory capacity shortage, etc. are thought. The filler feed load has exceeded the allowable value set in the arc constant. This failure occurs when the start point is not detected during ZF search. Cannot restart during seam tracking. This error occurs when the distance between the detected start point and ZF taught point exceeded the deviation range. This error occurs when the robot moves beyond search range This error occurs when the robot moves beyond Position deviation range This error occurs when the robot moves beyond search range during ZN. This error occurs when the distance between the detected end point and taught point before ZE exceeded the deviation range. This error occurs when the robot moves beyond Posture deviation range Groove cannot be detected.

Welding current specified by adaptive control exceeds maximum current watch value of adaptive control. Welding current specified by adaptive control becomes lower than minimum current watch value of adaptive control. Welding voltage specified by adaptive control exceeds maximum voltage watch value of adaptive control. Welding voltage specified by adaptive control becomes lower than minimum voltage watch value of adaptive control.

Please check follows. (1)Turn off the purge(cleaning gas). (2)Release the emergency stop. (3)Reset plasma unit/WPS error. (4)Set weld ON. (5)Set the registration of welder "PlasmaDA" or "PlasmaWPS". Please check follows. (1)Turn off the pilot arc. (2)Release the emergency stop. (3)Reset plasma unit error. The upgrade should do the software of the arc welding power supply.

No reset operations neccesary.

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on

No reset operations neccesary. No reset operations neccesary.

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The upgrade should do the software of the arc welding power supply. Or, please set the Gas OFF Delay time to 0. Please confirm the remainder pressure of gas cylinder, the piping of the gas, and the setting of the gas mass flow control unit.

No reset operations neccesary. No reset operations neccesary.

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Please confirm the remainder pressure of gas cylinder, the piping of the gas, and the setting of the gas mass flow control unit.

No reset operations neccesary.

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on

Please confirm the residual quantity of the gas cylinder, the piping of the gas, and the setting of the gas mass flow control unit. Please confirm whether an excessive load contracts the wire feeder. Please contact our customer service center when the permissible value is large.

No reset operations neccesary. No reset operations neccesary.

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Please reduce the number of record data.

No reset operations neccesary. No reset operations neccesary. No reset operations neccesary.

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on

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Please confirm host name, user ID, password, and initial folder of ftp client.

No reset operations neccesary.

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on

on

Please confirm the state of the storage medium.

No reset operations neccesary.

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on

A load is on the filler feeder by wear of the liner, the chip defect, and so on. Remove the factors.

No reset operations neccesary. Error reset.

Inform ation

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on

on

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Please secure the free space of the device.

Please confirm the arc welding construction condition.

(1)Check the groove recognization by WinUser. (2)Enlarge the ZF maximum search range. Do not modify the position and posture of the robot when the robot is stopped in ZT period if the restarting is required. Check detected position. If no problems exist, moodify(enlarge) the ZF deviation range parameter or program to rectify error.

Error reset.

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on

Error reset.

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Modify(enlarge) the search range or program to rectify error. Check the target position If no problems exist, moodify(enlarge) the ZT parameters or program to rectify error. Modify(enlarge) the ZN search range or program to rectify error.

Error reset.

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Error reset.

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Check the detected point. If no problems exist, Modify(enlarge) the deviation range or program to rectify error.

Error reset.

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Check the target posture If no problems exist, moodify(enlarge) the ZT parameters or program to rectify error. (1)Check that LASER power is ON.(2)Check the cable between Laser Sensor Unit and Sensor Head is connected properly.(3)Check the cable between Robot Controller and Laser Sensor Unit is connected properly. Check the lists of the specified spreadsheet in the sensor controller by WinUser. If the spreadsheet is OK, increase maximum current watch value of adaptive control. Check the lists of the specified spreadsheet in the sensor controller by WinUser. If the spreadsheet is OK, decrease minimum current watch value of adaptive control. Check the lists of the specified spreadsheet in the sensor controller by WinUser. If the spreadsheet is OK, increase maximum voltage watch value of adaptive control. Check the lists of the specified spreadsheet in the sensor controller by WinUser. If the spreadsheet is OK, decrease minimum voltage watch value of adaptive control.

Error reset.

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Take countermeasur es and reset failure. Error reset.

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Error reset.

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Error reset.

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Error reset.

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Error reset.

4-69

Error code list 6298

Sensor failure

Adaptive travel speed over

Travel speed specified by adaptive control exceeds maximum speed watch value of adaptive control.

6299

Sensor failure

Adaptive travel speed short

6300

Sensor failure

Search range exceeded.

Travel speed specified by adaptive control becomes lower than minimum speed watch value of adaptive control. This error occurs when the robot moves beyond search range

6301

Sensor failure

Search range is short

6302

Sensor failure

Deviation range exceeded.

6303

Sensor failure Sensor failure Sensor failure

Gap Over

6306

Sensor failure

Groove depth short

6307

Sensor failure Sensor failure Sensor failure Sensor failure Sensor failure Sensor failure Sensor failure

Angle1 over

6330

Sensor failure

Correction amount by arc-sensor exceeds specified value.

6331

Sensor failure

6332

Sensor failure

Calculation turns to unstable during arc-sensing process. Welding position cannot be detected

6333

Sensor failure

Unstable wire-feeding.

6334

Sensor failure Sensor failure

ST parameter error.

6336

Sensor failure

Adaptive Wire Speed Over

6337

Sensor failure

Adaptive Wire Speed Short

6338

Sensor failure Sensor failure Sensor failure Sensor failure Sensor failure

Area Over

6343

Sensor failure

Adaptive EN Ratio Short

6344

Sensor failure

Normal Angle Over

6345

Sensor failure

Normal Angle Short

6404

Sensor failure

Adaptive weaving amplitude over

6304 6305

6308 6309 6310 6311 6312 6329

6335

6339 6340 6341 6342

4-70

Gap short Groove depth over

Angle1 short Angle2 over Angle2 short Groove un-detected Unstable detection The target position and posture cannot be calculated.

ZJ Deviation range exceeded

Area Short Mismatch Over Mismatch Short Adaptive EN Ratio Over

Check the lists of the specified spreadsheet in the sensor controller by WinUser. If the spreadsheet is OK, increase maximum speed watch value of adaptive control. Check the lists of the specified spreadsheet in the sensor controller by WinUser. If the spreadsheet is OK, decrease minimum speed watch value of adaptive control. Modify(enlarge) the search range or program to rectify error.

This error occurs when the robot detect the touch status within minimum search range. This error occurs when the robot moves beyond deviation range

Modify(shorten) the search range or program to rectify error.

Detected gap is exceeded beyond maximum allowable value. Detected gap becomes lower than minimum allowable value. Detected groove depth is exceeded beyond maximum allowable value. Detected groove depth becomes lower than minimum allowable value. Detected angle1 is exceeded beyond maximum allowable value. Detected angle1 becomes lower than minimum allowable value. Detected angle2 is exceeded beyond maximum allowable value. Detected angle2 becomes lower than minimum allowable value. Groove position cannot be detected This error occurs when measured data is unstable. The target position and posture were not able to be calculated according to the detection value of the sensor, taught aim angle and the lag angle.

Check that gap amount and modify allowable value if needed. Check that gap amount and modify allowable value if needed. Check that groove depth amount and modify allowable value if needed.

Error is activated when the case that correction amount by the sensor exceeds the specified value in teaching parameter. This error is activated when stability of welding arc decreased significantly. This error is activated when the deviation detection cannot be calculated during arc-sensing process. Note that position correction is not executed. Wire-feeding status turn to unstable. Deviation is lager than specified value. The instruction parameter of ST command is over the setting range. This error occurs when the distance between the detected point and ZJ reference point exceeded the deviation range. Wire Speed specified by adaptive control exceeds maximum wire speed watch value of adaptive control. Wire speed specified by adaptive control becomes lower than minimum wire speed watch value of adaptive control. Detected area is exceeded beyond maximum allowable value. Detected area becomes lower than minimum allowable value. Detected mismatch is exceeded beyond maximum allowable value. Detected mismatch becomes lower than minimum allowable value. EN ratio specified by adaptive control exceeds maximum EN ratio watch value of adaptive control. EN ratio specified by adaptive control becomes lower than minimum EN ratio watch value of adaptive control. Detected Normal angle is exceeded beyond maximum allowable value. Detected Normal angle becomes lower than minimum allowable value. Weaving amplitude specified by adaptive control exceeds maximum amplitude watch value of adaptive control.

Modify(enlarge) the deviation range or program to rectify error.

Error reset.

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Error reset.

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No reset operations neccesary. No reset operations neccesary. No reset operations neccesary. Error reset.

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Error reset. Error reset.

Check that groove depth amount and modify allowable value if needed.

Error reset.

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Check that angle1 amount and modify allowable value if needed. Check that angle1 amount and modify allowable value if needed. Check that angle2 amount and modify allowable value if needed. Check that angle2 amount and modify allowable value if needed. Check setting parameters in GFF file.

Error reset.

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Error reset. Error reset. Error reset. Error reset.

Check that target surface condition and/or measurement angle. (1) Please correct specified Aim Angle and Lad Angle. (2) Please confirm whether detected Joint Normal Angle is an expected angle with the GAP file. It is likely to become Joint Normal not anticipated according to the state of Groove. (3) It is likely to become this abnormality when the absolute amount of the offset is too large at two point search. Please reduce it in that case. Check that currect torch position. If it is OK, extend the value CHASING RANGE in teaching parameter. If it is NG, try to adjust sensor parameters.

Error reset.

Error reset.

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Check that welding condition to be stable.

Error reset.

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Try to re-adjust sensing parameters.

Error reset.

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Check that equipments for wire feeding.

Error reset.

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on

It improves whether each parameter is setting within the limits. Check detected position. If no problems exist, modify(enlarge) the ZJ deviation range parameter or program to rectify error.

Error reset.

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on

on

Check the lists of the specified spreadsheet in the sensor controller by WinUser. If the spreadsheet is OK, increase maximum wire speed watch value of adaptive control. Check the lists of the specified spreadsheet in the sensor controller by WinUser. If the spreadsheet is OK, decrease minimum wire speed watch value of adaptive control. Check the area watch value(maximum) and enlarge if needed. Check the area watch value(minimum) and decrease if needed. Check the mismatch watch value(maximum) and enlarge if needed. Check the mismatch watch value(minimum) and decrease if needed. Check the lists of the specified spreadsheet in the sensor controller by WinUser. If the spreadsheet is OK, increase maximum EN ratio watch value of adaptive control. Check the lists of the specified spreadsheet in the sensor controller by WinUser. If the spreadsheet is OK, decrease minimum EN ratio watch value of adaptive control. Check that Normal angle amount and modify allowable value if needed.

Error reset.

Inform ation

Inform ation

Inform ation

Inform ation

on

on

Error reset.

Inform ation

Inform ation

Inform ation

Inform ation

on

on

Error reset.

Inform ation Inform ation Inform ation Inform ation Inform ation

Inform ation Inform ation Inform ation Inform ation Inform ation

Inform ation Inform ation Inform ation Inform ation Inform ation

Inform ation Inform ation Inform ation Inform ation Inform ation

on

on

on

on

on

on

on

on

on

on

Error reset.

Inform ation

Inform ation

Inform ation

Inform ation

on

on

Error reset.

Inform ation

Inform ation

Inform ation

Inform ation

on

on

Check that Normal angle amount and modify allowable value if needed.

Error reset.

Inform ation

Inform ation

Inform ation

Inform ation

on

on

Check the lists of the specified spreadsheet in the sensor controller by WinUser. If the spreadsheet is OK, increase maximum amplitude watch value of adaptive control.

Error reset.

Inform ation

Inform ation

Inform ation

Inform ation

on

on

No reset operations neccesary.

Error reset.

Error reset. Error reset. Error reset. Error reset.

Error code list 6448

TP failure

6449

TP failure

7000 9001

User failure Emergency stop failure

9002

Emergency stop failure

9003

Operational failure

Abnormal velocity command. Modify abnormal axis motion.

9005

Servo failure

Position Deviation error

This failure occurs when the deviation between the command and encoder data position exceeds the set permissible deviation.

9011

Emergency stop failure

9012

Emergency stop failure

The robot's joint angle before and behind a record point was not in agreement. The amount of step movements is abnormal.

9020

CPU board failure

Error of Interpolation Stop.

The robot joint angle of this step starting point and the robot joint angle of the last step target point is different. The result which added the amount of step movements to the robot's joint angle in a starting point is not in agreement with the robot joint angle in a target point. Motion control section detected the Time-out Error of Interpolation Stop.

9021

CPU board failure

Error of Waiting for arriving of target position.

Robot has not arrived at target position.

9022

CPU board failure

Error of Waiting for arriving of accuracy position.

Robot has not arrived at target position accurately.

9023

CPU board failure

Error of interruption of Position Command.

Position Command interrupted.

9024

CPU board failure CPU board failure

Error of mechanism resource acquisition. Safety slow speed error

Motion control section didn't acquire mechanism resource. Robot speed does not become safety level.

9026

CPU board failure

Stop Release error

Stop command of Motion control section was not released.

9027

CPU board failure

System freezing

It became impossible to continue the playback of a program.

9028

CPU board failure

Motion Calculation error

Motion control section detected Calculation error.

9030

Emergency stop failure

Error of brake delay in interference detection.

The axis that the brake doesn't lock even if prescribed time has passed since interference was detected exists..

Turn motors ON by pressing the Motor-ON button..

9031

Control failure

Frequent input-signal caused system busy.

Check input-signal.

9032

Emergency stop failure

Extremely frequent input-signal was detected. Reducer modeling reverse amends error.

9033

CPU board failure

Motion synchronous error

When reversely making amends by the reducer modeling, the amount of amends exceeded a specified value. Synchronous processing inside a motion was not performed normally.

9034

CPU board failure

Waiting timeout for robot starting

9100

Emergency stop failure

Stop interpolation

Contact our service department. Back up files to external CF memory. Because the robot stop step is different to the execute step, step-set must be needed for restart. Contact our service department. Back up files to external CF memory. Because the robot stop step is different to the execute step, step-set must be needed for restart. Contact our service department. Back up files to external CF memory. Because the robot stop step is different to the execute step, step-set must be needed for restart. Contact our service department. Back up files to external CF memory. Because the robot stop step is different to the execute step, step-set must be needed for restart.

9025

Battery remainder amount shortage of the wireless T/P. Wireless strength shortage of th wireless T/P User failure. The robot's joint angle before and behind a record point was not in agreement. The amount of step movements is abnormal.

The capacity of the battery of the wireless T/P has decreased.

Please connect with the cradle, and charge with the battery.

Wireless strength of the wireless T/P has weakened.

Please bring the wireless T/P close to the controller.

User failure. The robot's joint angle was not in agreement at the starting point of this step and the target point of this step. The result which added the amount of step movements to the robot's joint angle in a starting point is not in agreement with the robot joint angle in a target point. Abnormal velocity command data is calculated.

Please carry out "failure-reset". Contact our service department. Back up files to external CF memory. Because the robot stop step is different to the execute step, step-set must be needed for restart. Contact our service department. Back up files to external CF memory. Because the robot stop step is different to the execute step, step-set must be needed for restart.

In spite of having canceled the synchronous waiting within a motion, a robot did not start for a definite period of time. Motion control section stopped the calculation of interpolation.

No reset operations neccesary. No reset operations neccesary. Error reset. Error reset.

Inform ation

Inform ation

Inform ation

Inform ation

off

off

Inform ation

Inform ation

Inform ation

Inform ation

off

off

Error Alarm

Error Error

Error Alarm

Error Error

on on

on on

Error reset.

Alarm

Error

Alarm

Error

on

on

Modify abnormal axis motion to be minimized. Contact our service department in case axis motion is not so big. Back up files to external CF memory. Because the robot stop step is different to the execute step, step-set must be needed for restart. (1)Please confirm whether the robot manipulator interferes in something.(2)Please confirm that the Pay-load is within the nominal rating.(3)If failure persists, the problem may be a mechanical defect in the manipulator, contact our service department. Contact our service department. Back up files to external CF memory. Because the robot stop step is different to the execute step, step-set must be needed for restart. Contact our service department. Back up files to external CF memory. Because the robot stop step is different to the execute step, step-set must be needed for restart.

After removal of failure, please carry out "failure-reset". After removal of failure, please carry out "failure-reset". Turn on the power again.

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Turn on the power again.

Error

Error

Error

Error

on

on

Contact our service department. Back up files to external CF memory. Because the robot stop step is different to the execute step, step-set must be needed for restart. Contact our service department. Back up files to external CF memory. Because the robot stop step is different to the execute step, step-set must be needed for restart. Contact our service department. Back up files to external CF memory. Because the robot stop step is different to the execute step, step-set must be needed for restart. Contact our service department. Back up files to external CF memory. Because the robot stop step is different to the execute step, step-set must be needed for restart. Contact our service department. Back up files to external CF memory. Contact our service department. Back up files to external CF memory. Because the robot stop step is different to the execute step, step-set must be needed for restart. Contact our service department. Back up files to external CF memory. Because the robot stop step is different to the execute step, step-set must be needed for restart. This error may be avoidable by changing program. Ex. (1)A Delay command (Fn50) is inserted before the step which the error generated, (2)Movement command of the same point is inserted, (3)Movement command is changed into the in-position check(with P). When this error occurs, a stop step differs from an execution step. Please play back carefully enough after checking operation in teach mode. When this error recurs, please back up a file and contact to our service. Contact our service department. Back up files to external CF memory. Because the robot stop step is different to the execute step, step-set must be needed for restart.

Error reset.

Error

Error

Error

Error

on

on

Error reset.

Error

Error

Error

Error

on

on

Error reset.

Error

Error

Error

Error

on

on

Error reset.

Error

Error

Error

Error

on

on

Error reset.

Error

Error

Error

Error

on

on

Error reset.

Error

Error

Error

Error

on

on

Error reset.

Error

Error

Error

Error

on

on

Error reset.

Error

Error

Error

Error

on

on

Because the robot stop step is different to the execute step, step-set must be needed for restart. Error reset. Please do error reset or turn on the drive preparation. Turn on the power again.

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Error reset.

Error

Error

Error

Error

on

on

Error reset.

Error

Error

Error

Error

on

on

Error reset.

Error

Error

Error

Error

on

on

Turn on the power again.

Error

Error

Error

Error

on

on

4-71

Error code list 9101

Emergency stop failure Emergency stop failure CPU board failure CPU board failure

Exceed operation time

9113

CPU board failure

System Error (RT_FLT_DENORMAL _OPERAND).

9114

CPU board failure

9115

CPU board failure

9116

CPU board failure

9117

CPU board failure

System Error (RT_FLT_DIVIDE_BY_ ZERO). System Error (RT_FLT_INEXACT_R ESULT). System Error (RT_FLT_INVALID_O PERATION). System Error (RT_FLT_OVERFLOW ).

9119

CPU board failure

System Error (RT_FLT_UNDERFLO W).

9120

CPU board failure

9129

CPU board failure

9140

CPU board failure

System Error (RT_INT_DIVIDE_BY_ ZERO). System Error (RT_ILLEGAL_INSTR UCTION). System Error (Mutex Timeout).

9144

CPU board failure

System Error (MailBox Timeout Error).

System Error. MailBox Timeout.

9151

Emergency stop failure CPU board failure

Stop interpolation by system busy The Hibernation is not enabled.

9153

CPU board failure

An internal memory is not nomally allocated.

9200

CPU board failure CPU board failure CPU board failure

Motion process is not recognized. I/O system is not recognized. Servo communication initialization failure

Motion control section stopped the calculation of interpolation. Because abnormality occurred when Hibernation file is made, the Hibernation is not enabled. (Details) (1)Device opening abnormality of D drive. (2)Hibernationfile cannot be made. (3)Can not lock D drive. (4)Can not dismount D drive.(5)Can not unlock D drive. When initialize robot controller,an internal memory is not nomally allocated. Can't recongnize Motion process.

9209

Amplifier unit failure

Brake fuse off

This failure occurs when the fuse F1 on the brake control board UM351/L21700X00 was cut.

(1)Please exchange the brake fuse. (2)Replace the drive unit.

9210

Amplifier unit failure

Brake fuse off.(additional axis)

This failure occurs when the fuse F1-1 or F1-2 on brake control substrate UM226(L9172Y) was cut.

Please exchange the brake fuse.

9213

Amplifier unit failure

Drive unit power failure

This failure occurs when the drive unit power PG15(+15V) was not supplied.

Please replace the drive unit.

9216

Control failure

Low voltage of sequence control power supply

This failure occurs when the voltage of sequence control power supply P1(24V) is decreases.

(1)Please check the voltage of sequence control power supply P1(24V). (2)Please remove the sequence board and insert it again. (3)Please check the external signal wire of I/O is correctly connected. (4)Please exchange the multi power supply unit. (5)Please exchange the sequence board.

9217

Amplifier unit failure

Servo shared memory abnormal

This failure occurs when reading or wrinting data to the shared memory between servo communication CPU and servo CPU was not successfully finished.

Please replace the drive unit.

9218

CPU board failure CPU board failure

Servo CPU(#2) DP memory error. Servo CPU(#3) DP memory error.

Servo CPU(#2) D.P.memory error

Replace the Drive Unit.

Servo CPU(#3) D.P.memory error

Replace the Drive Unit.

9102 9103 9105

9152

9204 9208

9219

4-72

Playback cannot be continued. System Error (RT_BREAKPOINT). System Error (RT_ACCESS_VIOLA TION).

The robot dose not work continuously. I/O signal was not able to be processed. A breakpoint was encountered. The thread attempted to read from or write to a virtual address for which it does not have the appropriate access. One of the operands in a floating-point operation is denormal. A denormal value is one that is too small to represent as a standard floating-point value. The thread attempted to divide a floating-point value by a floating-point divisor of zero. The result of a floating-point operation cannot be represented exactly as a decimal fraction. This exception represents any floating-point exception not included in this list. The exponent of a floating-point operation is greater than the magnitude allowed by the corresponding type. The exponent of a floating-point operation is less than the magnitude allowed by the corresponding type. The thread attempted to divide an integer value by an integer divisor of zero. The method has terminated due to invalid parameters or property values. System Error. Mutex Timeout.

Can't recognize I/O system. This failure occurs when the communication between the CPU board and the drive unit (the servo board) cannot begin.

Contact our service department. Back up files to external CF memory. Contact our service department. Back up files to external CF memory. Turn on the power again. If the error is not released, reinstall the system. Turn on the power again. If the error is not released, reinstall the system.

Turn on the power again. Turn on the power again. Turn on the power again. Turn on the power again.

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Turn on the power again. If the error is not released, reinstall the system.

Turn on the power again.

Error

Error

Error

Error

on

on

Turn on the power again. If the error is not released, reinstall the system.

Turn on the power again.

Error

Error

Error

Error

on

on

Turn on the power again. If the error is not released, reinstall the system.

Turn on the power again.

Error

Error

Error

Error

on

on

Turn on the power again. If the error is not released, reinstall the system.

Turn on the power again.

Error

Error

Error

Error

on

on

Turn on the power again. If the error is not released, reinstall the system.

Turn on the power again.

Error

Error

Error

Error

on

on

Turn on the power again. If the error is not released, reinstall the system.

Turn on the power again.

Error

Error

Error

Error

on

on

Turn on the power again. If the error is not released, reinstall the system.

Turn on the power again.

Error

Error

Error

Error

on

on

Turn on the power again. If the error is not released, reinstall the system.

Turn on the power again.

Error

Error

Error

Error

on

on

(1)Please turn on the power again.(2)Please connect and disconnect CPU board or system CF.(3)Please reinstall the system.(4)Please replace the CPU board. (1)Please turn on the power again.(2)Please connect and disconnect CPU board or system CF.(3)Please reinstall the system.(4)Please replace the CPU board. Contact our service department. Back up files to external CF memory. Turn on the power again. If the error is not released, contact our service department. Back up files to external CF memory.

Turn on the power again.

Error

Error

Error

Error

on

on

Turn on the power again.

Error

Error

Error

Error

on

on

Error reset.

Error

Error

Error

Error

on

on

Error reset.

Error

Error

Error

Error

on

on

(1)Turn on the power again. If the error is not released, contact our service department.(2)Please replace system CF. Turn on the power again. If the error is not released, reinstall the system. Turn on the power again. If the error is not released, reinstall the system. (1)Please check whether the connector of the drive unit (CNCOM) is correctly connected. (2)Please check whether the connector of the CPU board (CNLAN3) is correctly connected. (3)Please replace the drive unit. (4)Please replace the CPU board. (5)Please replace the cable between the drive unit and te CPU board.

Turn on the power again.

Error

Error

Error

Error

on

on

Turn on the power again. Turn on the power again. After removal of failure, please turn on power supply of the controller again. After removal of failure, please carry out "failure-reset". After removal of failure, please carry out "failure-reset". After removal of failure, please carry out "failure-reset". After removal of failure, please turn on power supply of the controller again. After removal of failure, please turn on power supply of the controller again. No reset operations. No reset operations.

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

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Error code list 9220

Servo failure

An inconsistency was detected in the servo failure.

This failure occurs when an inconsistency was detected in servo failure.

9225

CPU board failure CPU board failure CPU board failure CPU board failure Amplifier unit failure

Servo CPU(#1 axis) is not ready. Servo CPU(#2 axis) is not ready. Servo CPU(#3 axis) is not ready. Servo CPU(#4 axis) is not ready. Brake fuse off.(F1)

Nothing acknowledge form servo CPU(#1 axis) Nothing acknowledge form servo CPU(#2 axis) Nothing acknowledge form servo CPU(#3 axis) Nothing acknowledge form servo CPU(#4 axis) This failure occurs when the fuse F1 on servo board UM351/L21700X00 was cut.

CPU board failure Operational failure

Servo CPU(#9 axis) is not ready. Operational failure.

Nothing acknowledge form servo CPU(#9 axis) insertion external memory during playback.

Replace the Drive Unit.

9240

Amplifier unit failure

Drive unit power failure

This failure occurs when drive unit power (+24V) was not supplied.

9241

Amplifier unit failure

Drive unit precharge failure

This failure occurs when drive unit precharge was not executed.

(1)Please check fuse(F3) on servo board UM351/L21700X00. Replace fuse(F3) when it is out. (2)Please check the cable connector CNMCH,CNSV,CNMS,CNEC1. (3)Please replace the drive unit. (1)Please check supply voltage(+24V) for drive unit. (2)Please replace the drive unit.

9242

Amplifier unit failure

Drive unit phase lack.

This failure occurs when drive unit lacked a phase of power supply.

(1)Please check primary power source. (2)Please check supply voltage. (3)Please replace the power unit. (4)Please replace the drive unit.

9243

Amplifier unit failure

Drive unit power failure

This failure occurs when drive unit power P10V(+10V) was not supplied.

Please replace the drive unit.

9244

Amplifier unit failure

Current sensor failure

Error occurs if the current sensor is abnormal.

Please replace the Drive Unit.

9226 9227 9228 9229

9233 9234

(1)Please check whether the cable connected with CNSV has been disconnected. (2)Please turn OFF and ON the primary power and restart the controller. (3)Please replace the drive unit. (4)Please replace the sequence board. UM352/L21700F00. Replace the Drive Unit. Replace the Drive Unit. Replace the Drive Unit. Replace the Drive Unit. (1)Please check brake fuse(F1) on servo board. (2)Please check the manipulator wirings and the control cables between the robot and the controller. (3)Please replace the drive unit.

restart playback.

After removal of failure, please carry out "failure-reset". No reset operations. No reset operations. No reset operations. No reset operations. After removal of failure, please carry out "failure-reset". No reset operations. No reset operations neccesary. After removal of failure, please carry out "failure-reset". After removal of failure, please carry out "failure-reset". After removal of failure, please carry out "failure-reset". After removal of failure, please carry out "failure-reset". After removal of failure, please turn on power supply of the controller again.

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

4-73

Error code list

NOTE

4-74

Chapter 5 Robot Diagnosis

This section describes the user check function for notifying operators of the robot inspection timing, parts replacement timing and other inspection-related information. 5.1 Robot Diagnosis .........................................................................................5-1 5.1.1 Program Diagnosis ...............................................................................5-1 5.1.2 OverHaul Time ......................................................................................5-3

5.1 Robot Diagnosis

5.1 Robot Diagnosis In this controller, functions that can be used for robot diagnosis and preventional maintenance are provided. This chapter explains those functions. The data for robot diagnosis are recorded automatically all the time. There are no special operations to record the diagnosis data.

POINT

The menu that is not described in this chapter can not be used. Those menus are not supported or only for our service engineers. And, axes of which the diagnosis data is not displayed are not supported.

5.1.1 Program Diagnosis The load torque for each axis etc. can be analyzed for every program. When opening this screen, the diagnosis data of the last playback operation will be displayed. (Except for partial accumulated data) The diagnosis data is updated for every playback operation. The past history is not stored. 1 Open - [25 Robot Diagnosis] – [1 Program Diagnosis]. >> The diagnosis data for the last playback operation of the current program. If the program has not played back even 1 time, the data that was displayed at last time will be displayed again. 1st page (main data) Program number can be changed.

Page number can be changed.

Diagnosi data can be cleared.

2

Press keys to change the page. 2nd page (Spot welding related data)

3rd page (Velocity and toque)

3

Press [Reset / R] key to exit.

5-1

5.1 Robot Diagnosis

1st page Item UNIT

Description The present program No.and the present UNIT No.

Program START TIME

This is the time when the cycle time measurement was started.

CYCLE TIME

The newest cycle time is displayed here. This is the total number of the cycles from when the controller power was turned ON. The time used for I signal waiting functions e.g. FN525 WAITI etc. and percentage. The time used for timer waiting functions e.g. FN50 DELAY etc. and percentage. This is the reason why the cycle time measurement was terminated. If "Cycle was ended" is not displayed here, the measurement was terminated in half way. In that case, the data does not show the correct information for the whole program. If there are some axes that exceeded the allowable peak torque, the step is displayed up to 10. If some data are displayed here, please check if the tool mass and COG are set correctly. And, it is recommended to slow down the recorded speed for the step.

TOTAL CYCLE I WAITING TIMER

ENDING TIME

Torque over

2nd page Item SPOT TIME CYCLE TIME (The number of spot welding)

Description This is the total time of spot welding execution. This is displayed for every welding machine. (W1～W6) Number of spot welding. This is displayed for every welding machine. (W1～W6)

3rd page Item AV. SPEED [rpm] (Average speed) MAX. SPEED [rpm] (Maximum speed)

AV. TORQ [Nm] [%] (Average torque) MAX. TORQ [Nm] [%] (Maximum torque)

LIFE SPAN [Hr] X100[Tm]

Description The average and the maximum value of the motor rotation velocity of each axis. The average torque of each axis is displayed as the ratio [%] for the rated torque. The maximum torque of each axis is displayed as the ratio [%] for the allowable peak torque. If the operator class is EXPERT or higher, the torque value [Nm] is displayed also. If there is an axis whose maximum torque exceeds 100%, please check if the tool mass and the center of gravity are set correctly. And, it is recommended to slow down the recorded speed in the step in which the concerned axis moves fast. The remaining life [Hour] of reduction gear of each axis is displayed in a premise that this program is continued to be played back. The life is also in the number of playback cycles also. Please be sure that this value is calculated in a premise that the robot is very new. Therefore, this value has nothing to do with the present condition of the robot mechanism. And, this is an estimated value that is calculated using a life span equation under a condition that the torque larger than the allowable limit will not occur. Please regard this value just a reference. When the calcullated value is smaller than 5,000 [Hours], an information "I3149" will be displayed.

5-2

5.1 Robot Diagnosis

5.1.2 OverHaul Time The "LIFE SPAN" described in "5.1.1 Program Diagnosis" is just a result that was calculated after 1 time playback. On the other hand, this "OverHaul Time" menu can forecast the over haul time (= reduction gear's life) by gathering the torque information accumulated in the memory. This value is calculated by analyzing/accumulating the all motion of the robot in the actual playback operation. And, this is an estimated value that is calculated using a life span equation under a condition that the torque larger than the allowable limit will not occur. Please regard this value just a reference. 1

Open - [25 Robot Diagnosis] [2 OverHaul Time]. >>A screen like the following will be displayed.

2

Press [Reset/R] key to exit without saving. Press to save the data.

Item Remainder of life Ratio Mechanism

Description For a new reduction gear, "100.0%" should be displayed. And this value will decrease while the robot is moving. And, when the value reaches "0%", it is necessary to replace the reduction gear. If the value is getting small, please contact our service department. (The tentative limit is 10% or 1000[Hr].) The name of the mechanism and the axis is displayed for a mechanism of which the "Remainder of life Ratio" is the smallest.

Axis Overhaul CycleConv. Base Cycle Time Start Time

This is the remaining time [Hours] until the overhaul (reduction gear replacement). If the time for 1 cycle is set to the "Base Cycle Time" in [sec], the "CycleConv." (Number of cycles) is also displayed. This is the time when the measurement was started.

When the reduction gear is replaced with new one

to open this screen and input Press "0" for the concerned axis and then press to save the data. Then the "Remainder of life Ratio" for the axis will return to 100.0%. When "Remainder of life Ratio" is initialized in case of memory format operation etc.. Please enter the total moving time so far of the reduction gear to "Consumption time until present".

POINT

Because these values will be changed to wrong values when executing format operation or backup restore operation, please memorize these values before doing those operations and after finishing those operation, input the memorized values again.

5-3

5.1 Robot Diagnosis

Settings of "Torque over display" and "Torque calculation method In case of operator class SPECIALIST, the following setting can be changed. Item

Current Torque calculation method can be selected.

Analyze (Torque analization method)

Default setting: "Current"

Position

Description The torque is estimated by referring to the actual motor current. The estimated torque includes the influence of the waste of the mechanism. But it also includes the calculation error due to the actuator system. By referring to the robot's mass model and the angles (positions) of each axis, each axis's torque is calculated based on motion equation. Because this calculation is done based on the logical mass model only, it does not include the influence of the waste of the mechanism. But the calculation is more accurate than the setting of . (CAUTION)

To calculate the torque accurately, the tool setting (weight, COG, and inertia) and user load setting must be set correctly. If a robot is used with the setting of "Analyze" = "Position", the robot controller cannnot detect the change of the torque due to the mechanical waste. As a result, there may be possibility that unexpected malfunction of the robot occurs in the future. After confirming the motion of the program with the setting of "Position", do not forget to change the setting to "Current".

CAUTION How to use

1

Set the "Analyze" to "Position".

2

Playback the all programs for the production.

3 4

If "I3148" occurs, please try to take counter measure e.g. slow down the motion speed, change the tool to light one, etc. If "I3148" is not detected, change the setting of "Analyze" to "Current".

5

Playback the all programs for the production.

6

If "I3148" occurs again, please try to take counter measure e.g. slow down the motion speed, change the tool to light one, etc. If "I3148" is not detected, start the production.

7

5-4

5.1 Robot Diagnosis

Related errors for the "Program Diagnosis" and the "OverHaul Time" No. Message Cause Counter measure

No. Message Cause

Counter measure

No. Message Cause Counter measure

No. Message Cause Counter measure No. Message Cause Counter measure

I 3148 There is an axis which exceeds the allowance and maximum torque. The presumption generation torque exceeded a permissible value by displayed program step and axis. (1)Change to ratings or less when the robot load condition is investigated, and weight and the wrist torque exceed it to ratings.(Gravity setting is used) (2)There is a possibility to exceed the acceleration which can be used. (Check the step before and after) (3)There is a possibility with a large interference torque, too. (Drop the acceleration of the displayed step.) I 3149 It is a program which remarkably shortens longevity. In the displayed program, longevity is within at 5000 hours.There is a possibility which is the program of call/jump origin when the call/jump are used. (1)Change to ratings or less when the robot load condition is investigated, and weight and the wrist torque exceed it to ratings. (Gravity setting is used) (2)The amount of operation is, and the average speed and the average torque greatly exceed ratings because of largeness or high speed, and there is a possibility that longevity has shortened. Reduce the amount of operation of the object axis or slow down the speed if there is no obstacle in work. (program diagnosis) (3)There is a possibility to be generated because the cycle time is remarkably short. Slow down the speed overall. I 3150 There is a possibility that the setting of the load weight and center of gravity is inapposite. It is detected when there is a big difference between the longevities calculated from longevity and the motor speed calculated from the current. (1)Please confirm whether the setting of the load weight and center of gravity is correct. (2)Please change to ratings or less when the robot load condition is investigated, and weight and the wrist torque exceed it to ratings. (3)There is a possibility that the trouble occurs in the robot when not corresponding to the above-mentioned. I 3168 There is the axis in 1000 hours for overhaul. The life time of the axis displayed with present operated (time to reaching to longevity) became 1,000 hours or less. Exchange the reduction gear of the axis as early as possible. After that, set “0” for the “Consumption time until present” in the “Over Haul Time” screen. (For this setting, EXPERT or more is necessary) I 3169 There is the axis in 0 hours for overhaul. The life time of the axis displayed with present operated (time to reaching to longevity) became 0 hour or less. Exchange the reduction gear of the axis immediately. After that, set “0” for the “Consumption time until present” in the “Over Haul Time” screen. (For this setting, EXPERT or more is necessary)

5-5

5.1 Robot Diagnosis

NOTE

5-6

http://www.nachi-fujikoshi.co.jp/ Japan Main Office

Phone: +81-3-5568-5245

Fax: +81-3-5568-5236

Nachi Robotic Systems Inc. (NRS) North America Headquarters

Shiodome Sumitomo Bldg. 17F, 1-9-2 Higashi-Shinbashi Minato-ku, TOKYO, 105-0021 JAPAN

http://www.nachirobotics.com/

Phone: 248-305-6545

Fax: 248-305-6542

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Phone: 502-517-1553

Fax: 317-535-3659

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South Caroline Service Center Phone: 864-458-8000

Fax: 864-458-8256

1310 Garlington Road, Suite L, Greenville, SC 29615, U.S.A.

Canada Branch Office

Phone: 905-760-9542

Fax: 905-760-9477

89 Courtland Ave., Unit No.2, Concord, Ontario, L4K 3T4, CANADA

Mexico Branch Office

Phone :+52-555312-6556

Fax:+52-55-5312-7248

Urbina No.54, Parque Industrial Naucalpan, Naucalpan de Juarez, Estado de Mexico C.P. 53489, MEXICO

Indiana Service Center

NACHI EUROPE GmbH

http://www.nachi.de/

Central Office Germany

Phone: +49-2151-65046-0

Fax: +49-2151-65046-90

Bischofstrasse 99, 47809, Krefeld, GERMANY

U.K. branch

Phone: +44-0121-423-5000

Fax: +44-0121-421-7520

Unit 3, 92, Kettles Wood Drive, Woodgate Business Park, Birmingham B32 3DB, U.K.

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Phone: + 420-255-734-000

Fax: +420-255-734-001

Obchodni 132, 251 01 Cestlice, PRAGUE-EAST CZECH REPUBLIC

NACHI AUSTRALIA PTY. LTD.

http://www.nachi.com.au/

Robotic Division & Victoria office

Phone: +61-(0)3-9796-4144

Fax: +61-(0)3-9796-3899

38, Melverton Drive, Hallam, Victoria 3803, , AUSTRALIA

Sydney office

Phone: +61-(0)2-9898-1511

Fax: +61-(0)2-9898-1678

Unit 1, 23-29 South Street, Rydalmere, N.S.W, 2116, AUSTRALIA

Brisbane office

Phone: +61-(0)7-3272-4714

Fax: +61-(0)7-3272-5324

7/96 Gardens Dr,Willawong,QLD 4110, , AUSTRALIA

NACHI SHANGHAI CO., LTD. Shanghai office

Phone: +86-(0)21-6915-2200

http://www.nachi.com.cn/ Fax: +86-(0)21-6915-2200

NACHI KOREA Seoul office

11F Royal Wealth Centre, No.7 Lane 98 Danba Road Putuo District, Shanghai 200062, China

http://www.nachi-korea.co.kr/ Phone: +82-(0)2-469-2254

Fax: +82-(0)2-469-2264

2F Dongsan Bldg. 276-4, Sungsu 2GA-3DONG, Sungdong-ku, Seoul 133-123, KOREA

Copyright NACHI-FUJIKOSHI CORP. Robot Division

1-1-1, FUJIKOSHIHONMACHI, TOYAMA CITY, JAPAN 930-8511 Phone +81-76-423-5137 Fax +81-76-493-5252

NACHI-FUJIKOSHI CORP. holds all rights of this document. No part of this manual may be photocopied or reproduced in any from without prior written consent from NACHI-FUJIKOSHI CORP. Contents of this document may be modified without notice. Any missing page or erratic pagination in this document will be replaced. In case that an end user uses this product for military purpose or production of weapon, this product may be liable for the subject of export restriction stipulated in the Foreign Exchange and Foreign Trade Control Law. Please go through careful investigation and necessary formalities for export. Original manual is written in Japanese.

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