Conexiones Robot

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Part Number: 150133-1

Release Date: October 20, 2004
Document Version: 1
Document Status: Final
Motoman, Incorporated
805 Liberty Lane
West Carrollton, OH 45449
TEL: (937) 847-6200
FAX: (937) 847-6277
24-Hour Service Hotline: (937) 847-3200
The information contained within this document is the proprietary property of Motoman, Inc., and may not be
copied, reproduced or transmitted to other parties without the expressed written authorization of Motoman,
Inc.
©2003 by MOTOMAN
All Rights Reserved
Because we are constantly improving our products, we reserve the right to change specifications without
notice. MOTOMAN is a registered trademark of YASKAWA Electric Manufacturing.
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This manual provides maintenance information for the NX100 controller and contains the
following sections:
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Provides general information about the structure of this manual, a list of reference documents,
and customer service information.
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This section provides information regarding the safe use and operation of Motoman products.
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Provides detailed maintnenance information for the NX100 controller.
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For additional information refer to the following:
• NX100 Controller Manual (P/N 149201-1)
• Concurrent I/O Manual (P/N 149230-1)
• Operator’s Manual for your application
• Vendor manuals for system components not manufactured by Motoman
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If you are in need of technical assistance, contact the Motoman service staff at (937) 847-3200.
Please have the following information ready before you call:
• Robot Type (EA1400, HP20, etc.)
• Application Type (arcwelding, spot welding, handling)
• Robot Serial Number (located on back side of robot arm)
• Robot Sales Order Number (located on back of controller)
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YASKAWA
NX100
MAINTENANCE MANUAL
Upon receipt of the product and prior to initial operation, read these instructions thoroughly, and retain
for future reference.
MOTOMAN INSTRUCTIONS
MOTOMAN- INSTRUCTIONS
NX100 INSTRUCTIONS
NX100 OPERATOR’S MANUAL
NX100 MAINTENANCE MANUAL
The NX100 operator’s manuals above correspond to specific usage.
Be sure to use the appropriate manual.
YASKAWA MANUAL NO. RE-CHO-A104

MANDATORY
• This manual explains maintenance procedures of the NX100 system.
Read this manual carefully and be sure to understand its contents
before handling the NX100.
• General items related to safety are listed in Section 1: Safety of the

NX100 Instructions. To ensure correct and safe operation, carefully
read the NX100 Instructions before reading this manual.
CAUTION
• Some drawings in this manual are shown with the protective covers or
shields removed for clarity. Be sure all covers and shields are replaced
before operating this product.
• The drawings and photos in this manual are representative examples

and differences may exist between them and the delivered product.
• YASKAWA may modify this model without notice when necessary due to
product improvements, modifications, or changes in specifications. If
such modification is made, the manual number will also be revised.
• If your copy of the manual is damaged or lost, contact a YASKAWA rep-

resentative to order a new copy. The representatives are listed on the
back cover. Be sure to tell the representative the manual number listed
on the front cover.
• YASKAWA is not responsible for incidents arising from unauthorized

modification of its products. Unauthorized modification voids your prod-
uct’s warranty.
ii
Notes for Safe Operation
Read this manual carefully before maintenance or inspection of the NX100.
In this manual, the Notes for Safe Operation are classified as “WARNING,” “CAUTION,”
“MANDATORY,” or ”PROHIBITED.”
Indicates a potentially hazardous situation which, if not avoided,

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

CAUTION could result in minor or moderate injury to personnel and dam-
age to equipment. It may also be used to alert against unsafe
practices.
Always be sure to follow explicitly the items listed under this

MANDATORY heading.
PROHIBITED Must never be performed.
Even items described as “CAUTION” may result in a serious accident in some situations. At
any rate, be sure to follow these important items.
NOTE To ensure safe and efficient operation at all times, be sure to follow all instructions, even if
not designated as “CAUTION” and “WARNING.”
iii
WARNING
• Before maintenance, inspection, and wiring, check that servo power is
turned OFF when the emergency stop buttons on the front door of the
NX100 and programming pendant are pressed.
When the servo power is turned OFF, the SERVO ON LED on the program-
ming pendant is turned OFF.
Injury or damage to machinery may result if the emergency stop circuit cannot stop the
manipulator during an emergency. The manipulator should not be used if the emergency
stop buttons do not function.
Emergency Stop Button
• Once the emergency stop button is released, clear the cell of all items
which could interfere with the operation of the manipulator. Then turn
the servo power ON.
Injury may result from unintentional or unexpected manipulator motion.

TURN
Release of Emergency Stop
• Observe the following precautions when performing teaching operations

within the P-point maximum envelope of the manipulator :
- View the manipulator from the front whenever possible.
- Always follow the predetermined operating procedure.
- Ensure that you have a safe place to retreat in case of emergency.
Improper or unintended manipulator operation may result in injury.
• Confirm that no persons are present in the P-point maximum envelope of

the manipulator and that you are in a safe location before:
- Turning ON the NX100 power
- Moving the manipulator with the programming pendant
- Running the system in the check mode
- Performing automatic operations
Injury may result if anyone enters the P-point maximum envelope of the manipulator dur-
ing operation. Always press an emergency stop button immediately if there are prob-
lems.The emergency stop buttons are located on the right of the front door of the NX100
and the programming pendant.
iv
CAUTION
• Perform the following inspection procedures prior to conducting manip-
ulator teaching. If problems are found, repair them immediately, and be
sure that all other necessary processing has been performed.
-Check for problems in manipulator movement.
-Check for damage to insulation and sheathing of external wires.
• Always return the programming pendant to the hook on the NX100 cabi-
net after use.
The programming pendant can be damaged if it is left in the P-point maximum envelope
of the manipulator, on the floor, or near fixtures.
• Read and understand the Explanation of Warning Labels in the NX100

Instructions before operating the manipulator.
Definition of Terms Used Often in This Manual

The MOTOMAN manipulator is the YASKAWA industrial robot product.
The manipulator usually consists of the controller, the programming pendant, and supply
cables.
In this manual, the equipment is designated as follows.
Equipment Manual Designation
NX100 Controller NX100
NX100 Programming Pendant Programming Pendant
Cable between the manipulator and the controller Manipulator cable
v
Descriptions of the programming pendant keys, buttons, and displays are shown as follows:
Equipment Manual Designation
Programming Character Keys The keys which have characters printed on them are
Pendant denoted with [ ].
ex. [ENTER]
Symbol Keys The keys which have a symbol printed on them are
not denoted with [ ] but depicted with a small picture.
ex. page key
GO BACK
PAGE
The cursor key is an exception, and a picture is not

shown.
Axis Keys “Axis Keys” and “Numeric Keys” are generic names
Numeric Keys for the keys for axis operation and number input.
Keys pressed When two keys are to be pressed simultaneously,

simultaneously the keys are shown with a “+” sign between them,
ex. [SHIFT]+[COORD]
Displays The menu displayed in the programming pendant is

denoted with { }.
ex. {JOB}
Description of the Operation Procedure

In the explanation of the operation procedure, the expression "Select • • • " means that the
cursor is moved to the object item and the SELECT key is pressed, or that the item is directly
selected by touching the screen.
vi
1 Equipment Configuration
1.1 Arrangement of Units and Circuit Boards . . . . . . . . . . 1-1
1.2 Power Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.3 Signal Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
2 Security System
2.1 Protection Through Security Mode Settings . . . . . . . . 2-1
2.1.1 Security Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
Changing the Security Mode . . . . . . . . . . . . . . . . . . . . . . . . .2-5
2.1.2 User ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6
Changing a User ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6
3 Inspections
3.1 Regular Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.2 NX100 Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3.2.1 Checking if the Doors are Firmly Closed . . . . . . . . . . . . . . . . . .3-2
3.2.2 Checking for Gaps or Damage in the Sealed Construction
Section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2
3.3 Cooling Fan Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.4 Emergency Stop Button Inspections . . . . . . . . . . . . . . . 3-5
3.5 Enable Switch Inspections . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3.6 Battery Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
3.7 Power Supply Voltage Confirmation . . . . . . . . . . . . . . . 3-6
3.8 Open Phase Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
4 Preparation before Replacing Parts

4.1 Creating a Check Program . . . . . . . . . . . . . . . . . . . . . . . . 4-3
5 Replacing Parts
5.1 Replacing NX100 Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.1.1 Replacing Parts of the CPU Unit . . . . . . . . . . . . . . . . . . . . . . . .5-2
Replacing the Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3
Replacing the Control Circuit Board (JANCD-NCP01) . . . . .5-3
Replacing the Control Power Supply (CPS-420F). . . . . . . . .5-4
vii
Replacing the Servo Control Circuit Board
(SGDR-AXA01A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Replacing the Robot I/F Unit (JZNC-NIF01) . . . . . . . . . . . . . 5-6
Replacing the I/O Circuit Board (JANCD-NIO01) . . . . . . . . . 5-7
Replacing the Robot I/F Circuit Board (JANCD-NIF01) . . . . 5-7
5.1.2 Replacing the SERVOPACK . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
5.1.3 Checking and Replacing Fuses . . . . . . . . . . . . . . . . . . . . . . . 5-11
Power Supply Contactor Unit . . . . . . . . . . . . . . . . . . . . . . . 5-11
Robot I/F Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
5.2 NX100 Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
5.3 Supplied Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
5.4 Recommended Spare Parts . . . . . . . . . . . . . . . . . . . . . . . 5-15
6 Operations after Replacing Parts

6.1 Home Position Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6.1.1 Calibrating Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Registering All Axes at One Time. . . . . . . . . . . . . . . . . . . . . 6-3
Registering Individual Axes . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Changing the Absolute Data. . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Clearing Absolute Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
6.1.2 Manipulator Home Position. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
6.2 Position Deviation Check Using the Check
Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
6.3 Home Position Data Correction . . . . . . . . . . . . . . . . . . . . 6-11
6.4 Setting the Second Home Position (Check Point) . . 6-13
6.4.1 Purpose of Position Check Operation. . . . . . . . . . . . . . . . . . . 6-15
6.4.2 Procedure for the Second Home Position Setting
(Check Point) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
6.4.3 Procedure After an Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
7 System Diagnosis
7.1 System Version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7.2 Manipulator Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
7.3 Input/Output Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
7.3.1 User Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
User Input Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
User Input Detailed Window . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
7.3.2 User Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
User Output Window. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
User Output Detailed Window . . . . . . . . . . . . . . . . . . . . . . . 7-4
Modifying the Output Status . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
viii
7.3.3 System Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-6
System Input Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-6
System Input Detailed Window . . . . . . . . . . . . . . . . . . . . . . .7-6
7.3.4 System Output. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-7
System Output Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-7
System Output Detailed Window. . . . . . . . . . . . . . . . . . . . . .7-7
7.3.5 RIN Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-8
RIN Input Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-8
7.3.6 Modification of the Signal Name . . . . . . . . . . . . . . . . . . . . . . . .7-9
Direct Modification on the Detailed Window . . . . . . . . . . . .7-10
Modification from the Menu . . . . . . . . . . . . . . . . . . . . . . . . .7-11
7.3.7 Signal Number Search . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-12
Direct Search on the Detailed Window . . . . . . . . . . . . . . . .7-13
Search from the Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-14
7.3.8 Relay Number Search . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-15
Direct Search on the Detail Window . . . . . . . . . . . . . . . . . .7-16
Search from the Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-17
7.4 Cumulative Time Display . . . . . . . . . . . . . . . . . . . . . . . . . 7-18
7.4.1 Cumulative Time Display Window . . . . . . . . . . . . . . . . . . . . . .7-18
7.4.2 Individual Window of the Cumulative Time Display. . . . . . . . .7-19
7.4.3 Clearing the Cumulative Time Display . . . . . . . . . . . . . . . . . .7-20
7.5 Alarm History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21
7.5.1 Alarm History Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-21
7.5.2 Clearing the Alarm History. . . . . . . . . . . . . . . . . . . . . . . . . . . .7-22
7.6 I/O Message History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23
7.6.1 I/O Message History Window . . . . . . . . . . . . . . . . . . . . . . . . .7-23
Search . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-23
7.6.2 Clearing the I/O Message History . . . . . . . . . . . . . . . . . . . . . .7-24
7.7 Position Data When Power is Turned ON/OFF . . . . 7-25
7.8 Current Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-26
7.9 Servo Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27
7.9.1 Servo Monitor Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-27
7.9.2 Changing the Monitor Items . . . . . . . . . . . . . . . . . . . . . . . . . .7-28
7.9.3 Clearing Maximum Torque Data . . . . . . . . . . . . . . . . . . . . . . .7-29
8 Alarm
8.1 Outline of Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
8.2 Alarm Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
8.2.1 Displaying and Releasing Alarm . . . . . . . . . . . . . . . . . . . . . . . .8-2
8.2.2 Special Alarm Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-3
Sub Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-3
Multiple SERVOPACK System . . . . . . . . . . . . . . . . . . . . . . .8-4
Independent Control Function (Optional) . . . . . . . . . . . . . . .8-4
8.3 Alarm Message List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
ix
9 Error
9.1 Error Message List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
9.1.1 System and General Operation . . . . . . . . . . . . . . . . . . . . . . . . 9-2
9.1.2 Editing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
9.1.3 Job Defined Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
9.1.4 External Memory Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9
9.1.5 Concurrent I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-15
9.1.6 Maintenance Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-16
x
1.1 Arrangement of Units and Circuit Boards
1 Equipment Configuration
The NX100 is comprised of individual units and modules (circuit boards). Malfunctioning com-
ponents can generally be easily repaired after a failure by replacing a unit or a module. This
section explains the configuration of the NX100 equipment.
The arrangements of units and circuit boards in small-capacity, medium-capacity, and large-
capacity NX100s are shown.
Small Capacity
Robot I/F unit:
A JZNC-NIF01
Emergency stop button:
Major axes control
Breaker: AR22V2R-04R
circuit board:
Refer to the
SGDR-AXA01A
following table.
Backside duct fan: Control power supply:

4715MS-22T-B50-B00 CPS-420F
(For air inlet) CPU unit:
JZNC-NRK01
Welding circuit board:

Power supply
JANCD-XEW02
contactor unit:
Refer to the
following table SERVOPACK:
Refer to the
following table.
Regenerative resistor:
MRC22-125K-220W-12.5
(220W,12.5 ) Interior circulation fan:
4715MS-22T-B50-B00
(Air flows up)
(MXT)
Robot system input
terminal block
Back View A' Sectional View A-A'

(with removed cover)
Model SERVOPACK Power Supply
NX100 Breaker Contactor Unit
Type (Converter Integrated)
EA1400N
ERCR-EA1400N-AA00 SGDR-EA1400N NF30SW 3P 10A JZRCR-NTU01-1
HP6
Configuration 1 for Small-Capacity NX100
1-1
A Emergency stop button:

Robot I/F unit: AR22V2R-04R
Breaker: JZNC-NIF01
Refer to the Major axes control
following table. circuit board:
SGDR-AXA01A
Control power supply:
Backside duct fan: CPS-420F
4715MS-22T-B50-B00 CPU unit:
(For air inlet) JZNC-NRK01
Power supply
Converter:
contactor unit:
Refer to the
Refer to the
following table.
following table
SERVOPACK:
Regenerative resistor: Refer to the
MRC22-125K-220W-12.5 following table.
(220W,12.5 ) Interior circulation fan:
4715MS-22T-B50-B00
(Air flows up)
(MXT)
Robot system input
terminal block

Model Power Supply
NX100 SERVOPACK Converter Breaker
Type Contactor Unit
HP20 ERCR-HP20-AA00 SGDR-HP20 SGDR-COA080A01B NF30SW 3P 15A JZRCR-NTU01-1
Configuration 2 for Small-Capacity NX100
Medium or Large Capacity

Robot I/F unit:
A JZNC-NIF01
Major axes control Emergency stop button:
Breaker: circuit board: AR22V2R-04R
Refer to the SGDR-AXA01A
following table Control power
supply:
CPS-420F
Backside duct fan: CPU unit:
5915PS-22T-B30-B00 JZNC-NRK01
(For air inlet)
Power supply Converter:

contactor unit: Refer to the
Refer to the following table.
following table
SERVOPACK:
Refer to the
Regenerative resistor: following table.
RDC50N2R0JI200X3S
(1500W,6 ) Interior
circulation fan:
4715MS-22T-B50-B00
(MXT) (Air flows up)
Robot system input
terminal block

Model Power Supply

NX100 SERVOPACK Converter Breaker Contactor Unit
Type
EH50 ERCR-EH50-AA00 SGDR-EH50 SGDR-COA250A01B NF30SW 3P 20A JZRCR-NTU02-1
ES165N
ERCR-ES165N-AA00 SGDR-ES165N SGDR-COA250A01B NF30SW 3P 30A JZRCR-NTU02-1
HP165
Configuration for Medium- or Large-Capacity NX100
1-2
1.2 Power Flow
1.2 Power Flow

Power supply contactor unit JZRCR-NTU
PE
QF1 4X 1KM 2KM 1X
1 2 1 1 2 1 2 1
Three-phase, L1(R)
200VAC, 50/60Hz L2(S) 3 4 2 3 4 3 4 2
220VAC, 60Hz L3(T) 5 6 3 5 6 5 6 3
1FU 2FU
CPU unit (5A) (5A)
JZNC-NRK01
JANCD-NBB01 CPS-5P2EF
CN01
(200VAC input) 3X
4 B1 3 1Z 1
CNP CNP 3 B2 250VAC
2X 6XT
1 A1 4 10A 2 B1 Servo cooling fan
1
A2
E A1 2 EV1
JANCD-NTU01 3 Backside duct fan

CN03
(+24V2, 24VDC CN02 CN09 EV3
+24V3 output) 4
(+24V2, CN10
CN05 24VDC (Contactor control)
+24V3 input) EV4
(+24V1) 1 1KM
2
3 2KM
JANCD-NCP01
4
CN08
(Output for brake)
CNAS CNAS
24VDC (Brake)
JANCD-NIF01
CNAT3 CNAP3
CN06
CNC CNC (+24V1)
CND
CND Programming pendant

JANCD-NIO01 X81
24VDC
CN12
(External power input
+24V2/+24VU)
SGDR-AXA01A
1CV
CNK CNK (Converter) CNP1
CNP11
CN101 1 2 1 2 3
CNJS CNJS
(+24V1)
CNP4
(P,N)
1SV Manipulator
(SERVOPACK) S-axis motor
Power
Brake
CNP4
1AMP L-axis motor
CNP6
Power
CNP4 Brake
2AMP
CNP6
U-axis motor
CNP4 Power
3AMP
CNP6 Brake
CNP4 R-axis motor
4AMP
CNP6 Power
CNP4 Brake
5AMP
CNP6 B-axis motor
CNP4 Power
6AMP Brake
CNP6
T-axis motor
Power
Brake
1-3
1.3 Signal Flow
1.3 Signal Flow

Power supply contactor unit
QF1 JZRCR-NTU
Three-phase, Circuit 4X 1X
1KM 2KM
200VAC, 50/60Hz breaker
220VAC, 60Hz
CPU unit
JZNC-NRK01
JANCD-NBB01 CPS-NX1
JANCD-NTU01
CN09
2XT (Contactor control)
(External output for CNP CNP
emergency stop signal) NKC002 CN03/04
(Control signal of
contactor unit)
PBESP CN01 CN05
Emergency stop switch (Serial
communications) (Individual control
CNESP1 Terminator signal for external axis overrun)
(Emergency stop (R-IN) CN02 CN06 (Overrun, shock sensor lamp)
signal input) (R-OUT)
MXT
CNM
(System I/O)
CNTU NXC001
JANCD-NCP01
CNAS CNAS
2XT
(External output for
LAN1
(PP) emergency stop signal)
Programming
JANCD-NIF01 pendant
CNAT3 CNAP3 X81
NXC010
CN06
CNC CNC (+24V1,
CND emergency stop signal
of the programming pendant,
CND Enable switch signal)
JANCD-NIO01 (User I/O)
CN10 I/O=12/12
CN09 I/O=12/12
CN08 I/O=8/8
CN07 I/O=8/8
CN02/
CN01
SGDR-AXA01A
CN03 1CV
Terminator
CNK CNK CN04 (Converter)
CNJS CNJS NXC004

CN08 CN1
CN102 Manipulator
(+17V3,+5V)
S-axis motor
PG
1SV
L-axis motor
(SERVOPACK)
PG
CN102 U-axis motor
NXC005-1 1AMP
CN11 CN1
PG
CN102
2AMP
CN1 R-axis motor
CN102 PG
NXC005-2 3AMP
CN12 CN1
CN102 B-axis motor
4AMP
CN1 PG
CN102
NXC005-3 5AMP T-axis motor
CN13 CN1
CN102 PG
6AMP
CN1
SGDR-FBA01A
5V(output)
CN02 24V(input)
OT
SHOCK
Option
LAMP
1-4
2.1 Protection Through Security Mode Settings
2 Security System
The NX100 modes setting are protected by a security system. The system allows operation
and modification of settings according to operator clearance. Be sure operators have the cor-
rect level of training for each level to which they are granted access.
2.1.1 Security Mode

There are three security modes. Editing mode and managememt mode require a user ID. The
user ID consists of numbers and letters, and contains no less than 4 and no more than 8 char-
acters. (Significant numbers and signs: ”0 to 9”, “-”, “.”.
Security Mode Descriptions
Security Mode Explanation
This mode allows basic operation of the robot (stopping,

Operation Mode
starting, etc.) for people operating the robot work on the line.
This mode allows the operator to teach and edit jobs and
Editing Mode
robot settings.
This mode allows those authorized to set up and maintain

Managememt
robot system: parameters, system time and modifying user
Mode
IDs.
2-1
Menu & Security Mode
Allowed Security Mode

Main Menu Sub Menu
DISPLAY EDIT
JOB JOB Operation Edit
SELECT JOB Operation Operation
CREATE NEW JOB Edit Edit
MASTER JOB Operation Edit
JOB CAPACITY Operation -
RESERVED START (JOB) Edit Edit
RESERVATION STATUS Operation -
VARIABLE BYTE Operation Edit
INTEGER Operation Edit
DOUBLE PRECITION Operation Edit
REAL Operation Edit
STRING Operation Edit
POSITION (ROBOT) Operation Edit
POSITION (BASE) Operation Edit
POSITION (ST) Operation Edit
IN/OUT EXTERNAL INPUT Operation -
EXTERNAL OUTPUT Operation -
USER INPUT Operation -
USER OUTPUT Operation -
SYSTEM INPUT Edit -
SYSTEM OUTPUT Edit -
RIN Edit -
REGISTER Edit -
AUXILIARY RELAY Edit -
CONTROL INPUT Edit -
PSEUDO INPUT SIGNAL Edit Management
NETWORK INPUT Edit -
ANALOG OUTPUT Edit -
SV POWER STATUS Edit -
LADDER PROGRAM Management Management
I/O ALARM Management Management
I/O MESSAGE Management Management
2-2

Main Menu Sub Menu
DISPLAY EDIT
ROBOT CURRENT POSITION Operation -
COMMAND POSITION Operation -
SERVO MONITOR Management -
SECOND HOME POS Operation Edit
WORK HOME POSITION Operation Edit
DROP AMOUNT Management Management
POWER ON/OFF POS Operation -
TOOL Edit Edit
INTERFERENCE Management Management
SHOCK SENS LEVEL Operation Management
USER COORDINATE Edit Edit
HOME POSITION Management Management
MANIPULATOR TYPE Management -
ROBOT CALIBRATION Edit Edit
ANALOG MONITOR Management Management
OVERRUN&S-SENSOR Edit Edit
LIMIT RELEASE Edit Management
ARM CONTROL Management Management
SHIFT VALUE Operation -
SYSTEM INFO MONITORING TIME Operation Management
ALARM HISTORY Operation Management
I/O MSG HISTORY Operation Management
VERSION Operation -
FD/PC CARD LOAD Edit -
SAVE Operation -
VERIFY Operation -
DELETE Operation -
DEVICE Operation Operation
2-3

Main Menu Sub Menu
DISPLAY EDIT
PARAMETER S1CxG Management Management
S2C Management Management
A1P Management Management
RS Management Management
S1E Management Management
SETUP TEACHING COND Edit Edit
OPERATE COND Management Management
DATE/TIME Management Management
GRP COMBINATION Management Management
SET WORD Edit Edit
RESERVE JOB NAME Edit Edit
USER ID Edit Edit
SET SPEED Management Management
KEY ALLOCATION Management Management
RESERVED START (CONNECT) Management Management
ARC WELDING ARC START CONDITION Operation Edit
ARC END CONDITION Operation Edit
ARC AUXILIARY CONDITION Operation Edit
WELDER CONDITION Operation Edit
ARC WELD DIAGNOSIS Operation Edit
WEAVING Operation Edit
HANDLING HANDLING DIAGNOSIS Operation Edit
SPOT WELDING WELD DIAGNOSIS Operation Edit
I/O ALLOCATION Management Management
GUN CONDITION Management Management
WELDER CONDITION Management Management
SPOT WELDING WELD DIAGNOSIS Operation Edit
(MOTOR GUN)
GUN PRESSURE Edit Edit
PRESSURE Edit Edit
I/O ALLOCATION Management Management
GUN CONDITION Management Management
2-4

Main Menu Sub Menu
DISPLAY EDIT
GUN CONDITION AUX Management Management
WELDER CONDITION Management Management
GENERAL GENERAL DIAGNOSIS Operation Edit
PAINT PAINT SYSTEM Management Management
PAINT DEVICE Management Management
CCV-PAINT TABLE Management Management
PAINT CONDITION Operation Edit
Changing the Security Mode

Operation Explanation
1 Select {SYSTEM INFO} under The sub menu appears.

the main menu.
DATA EDIT DISPLAY UTILITY
FD/PC CARD
FLOPPY DISK/Compact Flash
JOB
DOUT
MOVE
END CF
ARC WELDING PARAMETER DEVICE FC1

FC2
PC CARD
VARIABLE SETUP
B001
MONITORING TIME
IN/OUT
In Out
ALARM HISTORY
ROBOT
I/O MSG HISTORY
SYSTEM INFO
VERSION
Main Menu SECURITY Turn on servo power
Note: Icons for the main menu such as arc welding system differ
depending on the system being used.
2 Select {SECURITY}. The selection window of security mode appears.

JOB FD/PC CARD SECURITY MODE

DOUT
MOVE
END CF
ARC WELDING PARAMETER

MODE EDITING MODE
VARIABLE SETUP
B001
IN/OUT
In Out
ROBOT
SYSTEM INFO
Main Menu ShortCut Turn on servo power
2-5
3 Press [SELECT] and select

"SECURITY MODE."
DOUT
MOVE
END CF
ARC WELDING PARAMETER

MODE OPERATING MODE
EDITING MODE
VARIABLE SETUP MANAGEMENT MODE
B001
IN/OUT
In Out
ROBOT
SYSTEM INFO
4 Select "SECURITY MODE." The user ID input window appears.


DOUT
MOVE
END CF
ARC WELDING PARAMETER PASSWORD=

MODE
VARIABLE SETUP
B001
IN/OUT
In Out
ROBOT
SYSTEM INFO
At the factory, the following below user ID number is

SUPPLE
-MENT
preset.
• Editing Mode:[00000000]
• Managememt Mode:[99999999]
5 Input the user ID.
6 Press [ENTER]. The input user ID is compared with the user ID of the selected
security mode. When the correct user ID is entered, the security
mode is changed.
2.1.2 User ID
User ID is requested when Editing Mode or Managememt Mode is operated.
User ID must be between 4 characters and 8, and they must be numbers and symbols (“0 to
9”,“-” and “.”).
Changing a User ID
In order to change the user ID, the NX100 must be in Editing Mode or Managememt Mode.
Higher security modes can make changes the user ID of to lower security modes.
2-6
1 Select {SETUP} under the

main menu.
2 Select {USER ID}. The USER ID window appears.
USER ID
EDITING MODE
MANAGEMENT MODE
3 Select the desired ID. The character input line appears, and the message "Input current
ID no. (4 to 8 digits)" is shown.
USER ID
EDITING MODE
MANAGEMENT MODE
Main Menu ShortCut Input new ID no. (4 to 8 digits)
4 Input current ID and press When the correct user ID is entered, a new user ID is requested
[ENTER]. to be input. "Input new user ID no.(4 to 8 digits)" appears.
USER ID
EDITING MODE
MANAGEMENT MODE
Main Menu ShortCut Input new ID no. (4 to 8 digits)
5 Input new ID and press User ID is changed.

[ENTER].
2-7
3.1 Regular Inspections
3 Inspections
3.1 Regular Inspections
CAUTION
• Do not touch the cooling fan or other equipment while the power is
turned ON.
Failure to observe this caution may result in electric shock or injury.
Carry out the following inspections.
Inspection
Inspection Equipment Inspection Item Comments
Frequency
Check that the doors are Daily

completely closed.
NX100 Controller
Check for gaps or dam- Monthly
age to the sealed con-
struction.
Interior circulation fan Check operation As required While power ON

and backside duct fan
Emergency stop Check operation As required While servo ON

button
Enable switch Check operation As required In teach mode
Confirm battery alarm or As required

Battery message is displayed or
not
3-1
3.2 NX100 Inspections
3.2 NX100 Inspections
3.2.1 Checking if the Doors are Firmly Closed

• The NX100 has a fully sealed construction, designed to keep external air containing oil
mist out of the NX100.
Be sure to keep the NX100 doors fully closed at all times, even when the controller is not
operating.
• Open or close the two locks in each door with the screwdriver when opening or closing
the doors for maintenance after the main power is turned OFF. (CW:Open, CCW:Close)
Make sure push the door closed and turn the door lock with the driver. When the door is
closed, turn the door lock until the door clicks.
Main power switch
Door lock
Door lock
NX100 Front View
3.2.2 Checking for Gaps or Damage in the Sealed Con-

struction Section
• Open the door and check that the seal around the door is undamaged.
• Check that the inside of the NX100 is not excessively dirty. If it is dirty, determine the
cause, take measures to correct the problem and immediately clean up the dirt.
• Fully close each door lock and check that no excessive gaps exist around the edge of the
door.
3-2
3.3 Cooling Fan Inspections
Inspect the cooling fans as required. A defective fan can cause the NX100 to malfunction
because of excessive high temperatures inside.
The interior circulation fan and backside duct fan normally operate while the power is turned
ON. Check if the fans are operating correctly by visual inspection and by feeling air moving
into the air inlet and from the outlet.
When the message of the "Cooling fan in control box stopped" is displayed, it may be
NOTE caused by the error occurrance at the cooling fan (JZNC-NZU01) inside the control power
supply (CPS-420F) of the CPU unit.
The playback operation (execution of the JOB) cannot be performed when the error occurs
at the cooling fan. In this case, the alarm 4119 "FAN ERROR (IN CONTROL BOX)" occurs
8 hours later.
When the messege of the "Cooling fan in control box stopped" is displayed, carry out an
inspection and the replacement of the cooling fan on the CPU rack as soon as possible.
Interior circulation fan Backside duct fan
Air intake
Air outlet
Cooling Fan Construction (Small-capacity NX100)
3-3
Interior circulation fan Backside duct fan
Air intake
Air outlet
Cooling Fan Construction (Medium- or large-capacity NX100)
3-4
3.4 Emergency Stop Button Inspections
3.4 Emergency Stop Button Inspections
The emergency stop buttons are located on both the front door of the NX100 and the
programming pendant. Confirm the servo power is OFF by pressing the emergency stop
button on the the front door of the NX100 after the servo ON, before the manipulator is
operated.
3.5 Enable Switch Inspections
The programing pendant is equipped with a three-position enable switch. Perform the follow-
ing operation to confirm the enable switch operates.
1. Set the mode switch on the programming pendant to "TEACH."
REMOTE TEACH
PLAY
2. Press [SERVO ON READY] on the programming pendant. The [SERVO ON] lamp
blinks.
SERVO
ON
READY
Blinking SERVO ON
3. When the enable switch is grasped lightly, the servo power is turned ON.
When the enable switch is grasped firmly or released, the servo power is turned OFF.
If the [SERVO ON] lamp does not light in previous operation (2), check the following:
NOTE • The emergency stop button on the front door of the NX100 is pressed.
• The emergency stop button on the programming pendant is pressed.
• The emergency stop signal is input from external.
If the servo is not turned ON in a previous operation (3), check the following:
• The overrun LS is operating.
• If a major alarm is occurring.
3-5
3.6 Battery Inspections
3.6 Battery Inspections
The NX100 has a battery that backs up the important program files for user data in the CMOS
memory.
A battery alarm indicates when a battery has expired and must be replaced. The programming
pendant display and the message "Memory battery weak" appears at the bottom of the dis-
play.
The way to replace the battery is described in “5.1.1 Replacing Parts of the CPU Unit.”
3.7 Power Supply Voltage Confirmation
Check the voltage of 1, 3, 5 terminal of the circuit breaker (QF1) with an electric tester.
Power Supply Voltage Confirmation
Measuring Items Terminals Correct Value
Correlate voltage Between 1 and 3, 3 200 to 220V (+10%, -15%)

and 5, 5 and 1
Voltage between earth Between 1 and E, 5 200 to 220V (+10%, -15%)

(phase-S ground) and E
Between 3 and E About 0V
Breaker
Circuit Breaker (QF1)
3-6
3.8 Open Phase Check
3.8 Open Phase Check
Open Phase Check List
Check Item Contents
Lead Cable Check Confirm if the lead cable for the power supply is wired as shown
in the following. If the wiring is wrong or broken, repair it.
Input Power Supply Check the open phase voltage of input power supply with an
Check electric tester.
(Normal value: 200-220VAC (+10%, -15%))
Circuit Breaker (QF1) Turn ON the breaker and check the open phase voltage of “2, 4,
Check 6” of the circuit breaker (QF1) with an electric tester. If abnormal,
replace the circuit breaker (QF1).
200/220VAC input
R S T
1 3 5
Breaker
(QF1)
2 4 6 Power supply contactor unit
Converter
Contactor Contactor
(1KM) (2KM)
4X 1X CNP1
1 1 2 1 2 1 1
2 3 4 3 4 2 2
3 5 6 5 6 3 3
3-7
4 Preparation before Replacing Parts
WARNING
• Before operating the manipulator, check that the SERVO ON lamp turns
OFF when the emergency stop buttons on the front door of the NX100
and the programming pendant are pressed.
Injury or damage to machinery may result if the manipulator cannot be stopped in case of
an emergency.



- Turning ON the NX100 power.

ing operation.
• Always press the emergency stop button immediately if there are prob-
lems.
Emergency stop buttons are located at the upper right corner of the front door of the
NX100 and on the upper right of the programming pendant.
4-1
CAUTION
- Check for problems in manipulator movement.

- Check for damage to insulation and sheathing of external wires.
net after use.
The following flowchart shows the operations for replacing parts.

Start
Creating a check program : Chapter 4
Replacing parts : Chapter 5
Home position : Chapter 6

calibration
Position deviation check

using the check program
OK?
No
Yes
End
This chapter describes how to create a check program as a preparation for replacing parts.
The check program is a program to check the position deviation. If positions are deviated,
home position calibration is required. For the calibration, this program data is used to correct
the home position data. In the following cases particularly, the home position calibration using
the check program is needed. Be sure to create a check program referring to "4.1 Creating a
Check Program."
• Change in the combination of the manipulator and NX100
• Replacement of the motor or absolute encoder
• Clearing stored memory (by replacement of NCP01 circuit board, weak battery, etc.)
• Home position deviation caused by hitting the manipulator against a workpiece, etc.
4-2
4.1 Creating a Check Program
4.1 Creating a Check Program
To check position deviation whenever necessary, create a program in which a check point is
taught (the job for the check point). In the job for the check point, teach two points; one as a
check point and the other as the point to approach the check point. This program checks for
any deviation between the tool tip position and the check point.
Enlarged View
4-3
5.1 Replacing NX100 Parts
5 Replacing Parts
WARNING
• Turn OFF the power supply before opening the NX100 doors.
Failure to observe this warning may result in electric shock.
• After turning OFF the power supply, wait at least 5 minutes before
replacing a SREVOPACK (including the converter) or control power sup-
ply unit. Do not touch any terminals during this period.
CAUTION
• To prevent anyone inadvertently turning ON the power supply during
maintenance, put up a warning sign such as "DO NOT TURN ON THE
POWER" at the primary power supply (knife switch, wiring circuit
breaker, etc.) and at the NX100 and related controllers and use
accepted lockout/tagout procedures.
• Do not touch the regeneration resistors. They are very hot.
Failure to observe this caution may result in burn injuries.
• After maintenance is completed, carefully check that no tools are left

inside the NX100 and that the doors are securely closed.
5-1
5.1.1 Replacing Parts of the CPU Unit

CPU unit (JZNC-NRK01) is comprised of the control power supply (CPS-420F), the rack for
the various circuit boards, control circuit board (JANCD-NCP01), servo control circuit board
(SGDR-AXA01A), and robot I/F unit (JZNC-NIF01).
Monitor, alarm display LED
Robot I/F unit Control circuit board Servo control circuit board Control power supply
JZNC-NIF01 JANCD-NCP01 SGDR-AXA01A CPS-420F
Monitor, alarm display LED Monitor, alarm display LED

(F1,F2)
24V fuse for I/O
(CN05)
(CNSP1) 24VDC output connector
Emergency stop connector
(CN04)
(CNTU) 24VDC output connector
TU hotline I/O connector
(CNM) (CN03)
System input connector for robot 24VDC output connector
(CN02)
Remote control connector
Battery
(CN01)
200VAC input connector
(CN12)
Connector for external power supply (CN07) Cover
Compact flash Connector for encoder signal
(CN11)
24VDC output connector (CN06)
PWM signal connector
(CN07,CN08,CN09,CN10) (CN05)
User I/O connector PWM signal connector
Front View (without Cover) (CN04)

PWM signal connector
Front View (with Cover)
(CN06)
Hotline connector for (LAN1)
programming pendant Programming pendant connector
(CN03)
(CN04) I/O communications connector
I/F connector between robots
(CN03)
(CN02)
I/O I/F connector RIF communications connector
(CN02)
Drive I/F(2) connector (CN01)
(CN01) Converter signal connector
Drive I/F(1) connector
Bottom View
CPU Unit Configuration (JZNC-NRK01)
5-2
Replacing the Battery

Replace the battery immediately if a battery alarm occurs. Replace the battery within two
hours after the breaker turns OFF.
(The battery alarms appear on the programing pendant display.)
Replacement Procedure
1. Remove the left cover of the CPU unit.
2. Remove the battery connector (BAT) on the back board on the left of the CPU unit.
3. Remove the battery from the rack frame.
4. Mount a new battery on the rack frame and connect the battery connector (BAT) on the
back board.
Although the CMOS memory is backed up by super capacitor, the battery must be
NOTE replaced as soon as the battery alarm occurs. The job data and other data may be lost if
the battery alarm occurs and the breaker is turned OFF for more than 2 hours.
Replacing the Control Circuit Board (JANCD-NCP01)

Turn OFF the power before replacing a circuit board.
NOTE The JANCD-NCP01 circuit board contains important file data for the user programs, which
is backed up by the battery. Incorrect operations can cause this stored file data to be lost.
1. Disconnect all cables connected to the circuit board. (Be sure to remove the connec-
tors at the bottom of the circuit board.)
2. Remove 2 screws fixing the circuit board and rack.
3. Pull out the circuit board from the rack.
4. Remove the Compact Flash from the removed circuit board and insert the Compact
Flash into a new circuit board.
5. Mount the new circuit board to the rack.
6. Tighten upper and lower screws.
7. Connect all disconnected cables.
Cover
Control circuit board

JANCD-NCP01 Compact flash
Bottom connector view

Front side
LAN1 LAN0 COM
CN1
Option PCI Slot #CPU2
Option PCI Slot #AXIS
CN3
CN3
CN2
CN2
CN1
CN6
CN1
EXT
NIF PCI PCI CPU PCI AXIS CPS-420
Rear side
5-3
Replacing the Control Power Supply (CPS-420F)
CAUTION
replacing a control power supply. Do not touch any terminals during this
period. Confirm all monitor lights are turned OFF.
1. Disconnect all cables connected to the control power supply.
2. Loosen four upper and lower screws attaching the control power supply and the rack.
(two screws on each side).
3. Pull out the control power supply from the rack holding the grips which are attached at
the upper and lower side.
4. Insert the new control power supply into the slot of the rack.
5. Push the new control power supply until it is placed in the same position of other
boards.
Control power supply

CPS-420F
POWERSUPPLY
CPS-NX1
No.
DATE
Fuji Electric Co.,Ltd. JAPAN
01 02 03 04 05 06 07 08 09 10
SOURCE 11 12 13 14 15 16 17 18 19 20
21 22 23 24 25 26 27 28 29 30
A B CDE F GHJ K
+5VSB L MN P QR S T U V
PON
+5V
+24V
OTHER
FAN
OHT
CN05
(+24V1)
CN04
(+24V2)

CN03
Front side (TU)
LAN0 COM
CN1
CN3
CN3
CN2
LAN1
CN02
CN2
CN01
(REMOTE) (AC IN)
CN1
CN6
CN1
EXT
INPUT
200-240V AC
NIF PCI PCI CPU PCI AXIS CPS-420 50/60Hz
3A
Rear side
5-4
Replacing the Servo Control Circuit Board (SGDR-AXA01A)

Turn OFF the power before replacing a servo control circuit board.
1. Disconnect all cables connected to the servo control circuit board. (Be sure to remove
the connectors at the bottom of the board.)
2. Remove 2 screws fixing the servo control circuit board and rack.
3. Pull out the servo control circuit board from the rack.
4. Insert a new board into the slot of the rack.
7. Set the rotary switch to the same value as the removed board’s rotary switch.
Servo control circuit board

SGDR-AXA01A
Rotary switch
POWERSUPPLY
CPS-NX1
No.
DATE
01 02 03 04 05 06 07 08 09 10
SOURCE 11 12 13 14 15 16 17 18 19 20
21 22 23 24 25 26 27 28 29 30
A B CDE F GHJ K
PON
+5V
+24V
OTHER
FAN
OHT
CN05
(+24V1)
CN04
(+24V2)
Bottom connector view CN03

Front side (TU)
LAN1 LAN0 COM
CN1
CN3
CN3
CN2
CN02
CN2
CN01
(REMOTE) (AC IN)
CN1
CN6
CN1
EXT
INPUT
200-240V AC
3A
Back side
5-5
Replacing the Robot I/F Unit (JZNC-NIF01)

Turn OFF the power before replacing a robot I/F unit.
The robot I/F unit contains important data such as robot job data and parameter data. Be
NOTE sure to back up these data before replacing. (Back-up procedure: In the maintenance
mode, select {FD/PC CARD} under the main menu, select {SAVE}, and then save CMOS.)
1. Disconnect all cables connected to the robot I/F unit. (Be sure to remove the connec-
tors at the bottom of the unit.)
2. Remove 2 screws fixing the robot I/F unit and rack.
3. Pull out the robot I/F unit from the rack.
4. Insert a new robot I/F unit into the slot of the rack.
7. Set the rotary switch to the same value as the removed unit’s rotary switch.
8. Turn ON the breaker and load the back-up data.
(1) In the maintenance mode, select {FD/PC CARD} under the main menu.
(2) Select {LOAD} to load the CMOS.
Robot I/F unit

JZNC-NIF01
Rotaty switch
POWERSUPPLY
CPS-NX1
No.
DATE
01 02 03 04 05 06 07 08 09 10
SOURCE 11 12 13 14 15 16 17 18 19 20
21 22 23 24 25 26 27 28 29 30
A B CDE F GHJ K
PON
+5V
+24V
OTHER
FAN
OHT
CN05
(+24V1)
CN04
(+24V2)
Bottom connector view CN03

Front side (TU)
LAN1 LAN0 COM
CN1
CN3
CN3
CN2
CN02
CN2
CN01
(REMOTE) (AC IN)
CN1
CN6
CN1
EXT
INPUT
200-240V AC
3A
Back side
Do not leave the robot I/F unit (JZNC-NIF01) out of the rack. A fully-charged capacitor
NOTE inside the unit will be discharged in 16 hours after removal. If the capacitor is discharged,
the CMOS data will be cleared and then all the system settings and user settings will be
lost.
5-6
Replacing the I/O Circuit Board (JANCD-NIO01)

Turn OFF the power before replacing an I/O circuit board.
NOTE sure to back up these data before replacing. (Data is saved in the robot I/F circuit board
(JANCD-NIF01).)
1. Following the replacement procedure for the robot I/F unit, remove the robot I/F unit
from the CPU unit.
2. Remove 5 screws fixing the I/O circuit board (JANCD-NIO01) and the robot I/F circuit
board (JANCD-NIF01).
3. Carefully remove a connector connected with the robot I/F circuit board (JANCD-
NIF01).
4. Connect a new I/O circuit board (JANCD-NIO01) to the robot I/F circuit board (JANCD-
NIF01) with the connector.
5. Tighen the 5 screws to fix the I/O circuit board (JANCD-NIO01).
6. Insert the robot I/F unit into the slot of the CPU unit.
Replacing the Robot I/F Circuit Board (JANCD-NIF01)

Turn OFF the power before replacing a robot I/F circuit board.
NOTE sure to back up these data before replacing. (Back-up procedure: In the maintenance
mode, select {FD/PC CARD} under the main menu, select {SAVE}, and then save CMOS.)
1. Following the replacement procedure for the robot I/F unit, remove the robot I/F unit
from the CPU unit.
2. Remove 5 screws fixing the I/O circuit board (JANCD-NIO01) and the robot I/F circuit
board (JANCD-NIF01).
3. Carefully remove a connector connected with the I/O circuit board (JANCD-NIO01).
4. Remove 5 studs fixing the robot I/F circuit board (JANCD-NIF01) on the base plate.
5. Fix a new robot I/F circuit board (JANCD-NIF01) with the 5 studs on the base plate.
6. Connect the I/O circuit board (JANCD-NIO01) to the new robot I/F circuit board
(JANCD-NIF01) with the connector.
7. Tighen the 5 screws to fix the robot I/F circuit board (JANCD-NIF01).
8. Insert the robot I/F unit into the slot of the CPU unit.
10. Set the rotary switch to the same value as the removed board’s rotary switch.
11. Turn ON the breaker and load the back-up data.
(1) In the maintenance mode, select {FD/PC CARD} under the main menu.
(2) Select {LOAD} to load the CMOS.
5-7
5.1.2 Replacing the SERVOPACK
WARNING
replacing a SERVOPACK. Do not touch any terminals during this period.
There are two kinds of SERVOPACKs.
Type Manipulator
Integrated Type HP6, EA1400N
Separated Type HP20, EH50, ES165N, HP165
Replacement Procedure (Integrated Type)

1. Turn OFF the breaker and the primary power supply and wait at least 5 minutes before
replacing. Do not touch any terminals during this period.
2. Verify that the SERVOPACK CHARGE lamp (red LED) is unlit.
3. Disconnect all the cables connected externally to the SERVOPACK.
Three-phase AC power supply connector (CNP1)
Regenerative resistor connector (CNP3)
AC control power supply connector (CNP11)
DC control power supply connector (CN101)
Converter control signal connector (CN1)
PWM signal connectors (AMP1 to AMP6-CN1)
Motor power connectors (AMP1 to AMP6-CNP6)
4. Remove the ground wiring connected to the SERVOPACK.
5. Remove the two screws at the top on each side of the SERVOPACK.
6. Hold the top and bottom grips and lift them to pull out the SERVOPACK.
7. Install the new SERVOPACK and reconnect the connectors in the reverse order of the
removing procedure.
5-8
(AMP4 to AMP6-CNP6)
Converter Output connectors for motor power
Upper grip
(CN102) Charge lamp
PWM amplifier control power
supply connector (AMP4 to AMP6-CN1)
(CN101) PWM signal connectors
DC control power supply connector
(CN1)
Converter control signal connector PWM amplifiers
(6 amplifiers)
(CN101)
(CNP11)
AC control power supply connector (AMP1 to AMP3-CN1)
PWM signal connectors
(CNP1)
Three-phase AC power suply
connector
(AMP1 to AMP3-CNP6)
Gronud terminal Output connectors for motor power
Lower grip
(CNP3)
Connector for regenerative resistance
Configuration of Integrated Type SERVOPACK
Replacement Procedure (Separated Type)
• How to Replace Converter

2. Verify that the converter CHARGE lamp (red LED) is unlit.
3. Disconnect all the cables connected externally to the converter.
Three-phase AC power supply connector (CNP1)
Regenerative resistor connector (CNP3)
AC control power supply connector (CNP11)
DC control power supply connector (CN101)
Converter control signal connector (CN1)
PWM amplifier control power supply connector (CN102)
PN power supply connector (CNP4)
4. Remove the ground wiring connected to the converter.
5. Remove the two screws at the top on each side of the converter.
6. Hold the top grip and lift it to pull out the converter.
7. Install the new converter and reconnect the connectors in the reverse order of the
removing procedure.
5-9
• How to Replace SERVOPACK

2. Verify that the converter CHARGE lamp (red LED) is unlit.
3. Disconnect all the cables connected externally to the SERVOPACK.
PWM signal connectors (AMP1 to AMP6-CN1)
PWM amplifier control power supply connector (CN102) (at converter side)
PN power supply connector (CNP4) (at converter side)
Motor power connectors (AMP1 to AMP6-CNP6)
4. Remove the ground wiring connected to the SERVOPACK.
5. Remove the two screws at the top on each side of the SERVOPACK.
6. Hold the top and bottom grips and lift them to pull out the SERVOPACK.
7. Install the new PWM amplifier and reconnect the connectors in the reverse order of the
removing procedure.
Converter Charge lamp SERVOPACK (AMP4 to AMP6-CNP6)
Upper grip Output connectors for motor power
Upper grip
(CN102)
PWM amplifier control power
(AMP4 to AMP6-CN1)
supply connector PWM signal connectors
(CN1)
Converter control signal connector
PWM amplifiers
(CNP4) (6 amplifiers)
PN power connector
(CNP11)
AC control power supply
connector (AMP1 to AMP3-CN1)
Ground terminal PWM signal connectors
(CNP1) (AMP1 to AMP3-CNP6)

Three-phase AC power Output connectors for motor power
supply connector Ground terminal
(CNP3) Lower grip
Connector for regenerative resistance
Configuration of Separated Type SERVOPACK
5-10
5.1.3 Checking and Replacing Fuses

Power Supply Contactor Unit
The types of fuses on power supply contactor unit (JZRCR-NTU ) are as follows.
Parts No. Fuse Name Specification
1FU, 2FU Control Power Supply Fuse 250V,10A, Time Lag Fuse
(326010, 250V, 10A (Littelfuse))
3FU Brake Fuse SMP50, 5A, 125V

(Daito Communication Apparatus
Co., Ltd.)
4X
(3FU)
Brake fuse
CN08
5A 125V
F F
3FU
US
US
(1FU) (2FU)
E E
1FU 2FU
Fuse for AC control 10A 250V 10A 250V
power supply
CN07
CN06
NJ2096-
YASKAWA ELECTRIC CORPORATION
DATE
JAPAN
CN05
CN04
SER NO.
TYPE
CN03
3X
CN02
2X
SW1
1X
CN01
Fuse Position
If a fuse appears to be blown (see "8.3 Alarm Message List"), remove each fuse shown
above and check the continuity with an electric tester. If the fuse is blown, replace it with the
same type of fuse (supplied).
NOTE Determine and correct the cause of the blown fuse. If the problem is uncorrected, the fuse
may blow again.
5-11
Robot I/F Unit

The types of fuses on the robot I/F unit (JZNC-NIF01) are as follows.
Parts No. Fuse Name Specification
F1, F2 24VDC Fuse for I/O 250V, 3A, Rapid Cut Fuse
(312003, 250V, 3A (Littelfuse))
Robot I/F unit

JZNC-NIF01
(F1) (F2)
24VDC fuse for I/O POWERSUPPLY
CPS-NX1
No.
DATE
01 02 03 04 05 06 07 08 09 10
SOURCE 11 12 13 14 15 16 17 18 19 20
21 22 23 24 25 26 27 28 29 30
A B CDE F GHJ K
PON
+5V
+24V
OTHER
FAN
OHT
CN05
(+24V1)
CN04
(+24V2)

CN03
(TU)
Front side
LAN1 LAN0 COM
CN1
CN3
CN3
CN2
CN02
CN2
CN01
(REMOTE) (AC IN)
CN1
CN6
CN1
EXT
INPUT
200-240V AC
3A
Back side
If a fuse appears to be blown (see "8.3 Alarm Message List"), remove each fuse shown
above and check the continuity with an electric tester. If the fuse is blown, replace it with the
same type of fuse (supplied).
NOTE Determine and correct the cause of the blown fuse. If the problem is uncorrected, the fuse
may blow again.
5-12
5.2 NX100 Parts List
NX100 Parts List
No. Name Model Comment
1 SERVOPACK *1 6 axes type
2 CPU unit JZNC-NRK01
Backboard JANCD-NBB01
Control circuit board JANCD-NCP01
Servo control circuit board SGDR-AXA01A Not included in CPU unit

(JZNC-NRK01)
Control power supply CPS-420F Not included in CPU unit

(JZNC-NRK01)
Robot I/F unit JZNC-NIF01 Not included in CPU unit

(JZNC-NRK01)
Robot I/F circuit board JANCD-NIF01
I/O circuit board JANCD-NIO01
3 Power supply contactor unit *2
4 Interior circulation fan 4715MS-22T-B50-B00
5 Backside duct fan 4715MS-22T-B50-B00 HP06, EA1400N, HP20
5915PC-22T-B30-B00 EH50, ES165N, HP165
6 Power supply contactor unit fuse 326010, 10A, 250V Time lag fuse
SMP50, 5A, 125V Alarm fuse
Robot I/F unit fuse 312003, 3A, 250V Rapid cut fuse
7 Battery ER6VC3N 3.6V
*1 The type of the SERVOPACK depends on the manipulator model. For details, see the
table "SERVOPACK List."
*2 The type of the power supply contactor unit depends on the manipulator model. For
details, see the table "Power Supply Contactor Unit List."
5-13
SERVOPACK List
HP6, EA1400N
Component
Type
SERVOPACK SGDR-EA1400N
Converter SGDR-COA040A01B
Amplifier S SGDR-SDA140A01BY22
L SGDR-SDA140A01BY22
U SGDR-SDA140A01BY22
R SGDR-SDA060A01B
B SGDR-SDA060A01B
T SGDR-SDA060A01B
SERVOPACK List
HP20 EH50 ES165N, HP165

Component
Type Type Type
SERVOPACK SGDR-HP20 SGDR-EH50 SGDR-ES165N
Amplifier S SGDR-SDA140A01B SGDR-SDA710A01B SGDR-SDA710A01B
L SGDR-SDA350A01BY23 SGDR-SDA710A01B SGDR-SDA710A01B
U SGDR-SDA140A01BY22 SGDR-SDA350A01B SGDR-SDA710A01B
R SGDR-SDA060A01B SGDR-SDA140A01B SGDR-SDA350A01B
B SGDR-SDA060A01B SGDR-SDA140A01B SGDR-SDA350A01B
T SGDR-SDA060A01B SGDR-SDA140A01B SGDR-SDA350A01B
Converter SGDR-COA080A01B SGDR-COA250A01B SGDR-COA250A01B
Power Supply Contactor Unit List
Type Manipulator Type
JZRCR-NTU01- HP6, EA1400N, HP20
JZRCR-NTU02- EH50, ES165N, HP165
5-14
5.3 Supplied Parts List
5.3 Supplied Parts List
The supplied parts of NX100 is as follows.

Parts No.1 to 3 are used for fuse for replacement and No.4 and 5 are used as a tool for con-
necting the I/O.
No Parts Name Dimensions Pcs Model Application
326010
10A 6 dia. JZRCR-NTU
1 2 10A 250V
Ceramic fuse 1FU, 2FU
3.0 (Littelfuse)
312003
3A 6 dia. JZNC-NIF01
2 2 3A 250V
Glass-Tube fuse F1, F2
3.0 (Littelfuse)
17 SMP50
5 5A 125V
5A JZRCR-NTU
3 2 (Daito Commu-
Alarm fuse 18 3FU
nication Appa-
ratus Co., Ltd.)
2 231-131 JZRCR-NTU -
WAGO (WAGO Com- CN06, 07
4 Connector wiring pany of Japan, CPS-420F-CN02
tool Ltd.) JZNC-NIF01-CN12
1 210-119SB
WAGO
(WAGO Com-
5 Terminal block MXT
pany of Japan,
wiring tool
Ltd.)
5.4 Recommended Spare Parts
It is recommended that the following parts and components be kept in stock as spare parts for
the NX100. The spare parts list for the NX100 is shown below. Product performance can not
be guaranteed when using spare parts from any company other than Yaskawa. To buy the
spare parts which are ranked B or C, inform the manufacturing number (or order number ) of
NX100 to Yaskawa representative. The spare parts are ranked as follows:
• Rank A: Expendable and frequently replaced parts

• Rank B: Parts for which replacement may be necessary as a result of frequent operation
• Rank C: Drive unit
NOTE For replacing parts in Rank B or Rank C, contact your Yaskawa representative.
5-15
Recommended Spare Parts of NX100 for HP6 and EA1400N
Qty
Manufac-
No Rank Name Type Qty per Remark
turer
Unit
1 A Battery ER6VC3N 3.6V TOSHIBA 1 1
BATTERY
CO., LTD.
2 A Control Power Supply Fan JZNC-NZU01 Yaskawa 1 1
3 A Backside Duct Fan 4715MS-22T-B50- Minebea Co., 2 2
B00 Ltd.
4 A Interior Circulation Fan 4715MS-22T-B50- Minebea Co., 2 2
B00 Ltd.
5 A Control Power Supply Fuse 326010 10A 250V Littelfuse 10 2
6 A Brake Fuse SMP50 5A 125V Daito Commu- 10 1
nication Appa-
ratus Co., Ltd.
7 A 24VDC Fuse for I/O 312003 3A 250V Littelfuse 10 2
8 B Control Power Supply CPS-420F Yaskawa 1 1
9 B Servo Control Circuit Board SGDR-AXA01A Yaskawa 1 1
10 B Control Circuit Board JANCD-NCP01 Yaskawa 1 1
11 B Robot I/F Circuit Board JANCD-NIF01-1 Yaskawa 1 1
12 B I/O Circuit Board JANCD-NIO01-1 Yaskawa 1 1
13 B Power-ON Sequence Circuit JANCD-NTU01-1 Yaskawa 1 1
Board
14 C Robot I/F Unit JZNC-NIF01-1 Yaskawa 1 1
15 C SERVOPACK SGDR-EA1400N Yaskawa 1 1
16 C Power Supply Contactor JZRCR-NTU01-1 Yaskawa 1 1
Unit
17 C CPU Unit*1 JZNC-NRK01-1 Yaskawa 1 1
18 C Programming Pendant *2 JZRCR-NPP01-1 Yaskawa 1 1 With 8m
cable
*1 The CPU unit (JZNC-NRK01-1) does not include the control power supply (CPS-420F),
servo control circuit board (SGDR-AXA01A), and robot I/F unit (JZNC-NIF01). Must be
ordered separately if required.
*2 Specify application (Arc, General, Spot, Handling) of key sheet when No.18 "Program-
ming Pendant" is ordered.
5-16
Recommended Spare Parts of NX100 for HP20
Qty
Manufac-
turer
Unit
BATTERY
CO., LTD.
B00 Ltd.
4 A Interior Circulation Fan 4715MS-22T-B50- Minebea Co., 2 2
B00 Ltd.
nication Appa-
ratus Co., Ltd.
8 B Converter SGDR- Yaskawa 1 1
COA080A01B
Board
16 C SERVOPACK SGDR-HP20 Yaskawa 1 1
Unit
cable
5-17
Recommended Spare Parts of NX100 for EH50
Qty
Manufac-
turer
Unit
BATTERY
CO., LTD.
B00 Ltd.
4 A Interior Circulation Fan 5915PC-22T-B30- Minebea Co., 2 2
B00 Ltd.
nication Appa-
ratus Co., Ltd.
COA250A01B
Board
16 C SERVOPACK SGDR-EH50 Yaskawa 1 1
Unit
cable
5-18
Recommended Spare Parts of NX100 for ES165N and HP165
Qty
Manufac-
turer
Unit
BATTERY
CO., LTD.
B00 Ltd.
4 A Interior Circulation Fan 5915PC-22T-B30- Minebea Co., 2 2
B00 Ltd.
nication Appa-
ratus Co., Ltd.
COA250A01B
Board
16 C SERVOPACK SGDR-ES165N Yaskawa 1 1
Unit
cable
5-19
6 Operations after Replacing Parts
WARNING
• Before operating the manipulator, check that the SERVO ON lamp turns
OFF when the emergency stop buttons on the front door of the NX100
and the programming pendant are pressed.
Injury or damage to machinery may result if the manipulator cannot be stopped in case of
an emergency.



- Turning ON the NX100 power.

ing operation.
• Always press the emergency stop button immediately if there are prob-
lems.
Emergency stop buttons are located at the upper right corner of the front door of the
NX100 and on the upper right of the programming pendant.
6-1
6.1 Home Position Calibration
CAUTION

- Check for damage to insulation and sheathing of external wires.
net after use.
Teaching and playback are not possible before home position calibration is complete.
NOTE In a system with two or more manipulators, the home position of all the manipulators must
be calibrated before starting teaching or playback.
Home position calibration is an operation in which the home position and absolute encoder
position coincide. Although this operation is performed prior to shipment at the factory, the fol-
lowing cases require this operation to be performed again.
• Change in the combination of the manipulator and NX100

• Replacement of the motor or absolute encoder
• Clearing stored memory (by replacement of NCP01 circuit board, weak battery, etc.)
• Home position deviation caused by hitting the manipulator against a workpiece, etc.
To calibrate the home position, use the axis keys to calibrate the mark for the home position
on each axis so that the manipulator can take its posture for the home position. There are two
operations for home position calibration:
• All the axes can be moved at the same time

• Axes can be moved individually
6-2
If the absolute data of the home position is already known, set the absolute data again after
completing home position registration.
Home Position
SUPPLE
-MENT
The home position is the position with the pulse value "0" for each axis. The deviation val-
ues between the home position and the control reference position are set to parameters.
The deviation values are specified as an angle in units of 1/1000°, and vary depending on
manipulator types. See "6.1.2 Manipulator Home Position."
6.1.1 Calibrating Operation

Registering All Axes at One Time
1 Select {ROBOT} under the

main menu.
2 Select {HOME POSITION}. The HOME POSITIONING window appears.

HOME POSITIONING
SELECT ABSOLUTE DATA
R1:S {
L {
U {
R {
B {
T {
Main Menu ShortCut
3 Select {DISPLAY} under the The pull-down menu appears.

menu. DATA EDIT DISPLAY UTILITY
HOME POSITIONING ROBOT1

SELECT ABSOLUTE
STATION1 DATA
R1:S {
L {
U {
R {
B {
T {
Main Menu ShortCut
4 Select the desired control

group.
6-3
5 Select {EDIT} under the The pull-down menu appears.

SELECT ALL AXIS

HOME POSITIONING
R1:S {
L {
U {
R {
B {
T {
Main Menu ShortCut
6 Select {SELECT ALL AXES}. The confirmation dialog box appears.

HOME POSITIONING
R1:S {
L {
U {
R {
B {
T { Create home position?
YES NO
Main Menu ShortCut
7 Select “YES.” Displayed position data of all axes are registered as home posi-
tion.
When “NO” is selected, the registration will be canceled.
6-4
Registering Individual Axes

main menu.

HOME POSITIONING
R1:S {
L {
U {
R {
B {
T {
Main Menu ShortCut


SELECT ABSOLUTE
STATION1 DATA
R1:S {
L {
U {
R {
B {
T {
Main Menu ShortCut

group.
HOME POSITIOING
R1:S { -278
L { 30154
U {
R { -217
B {
T {
Main Menu ShortCut
6-5
5 Select the axis to be regis- The confirmation dialog box appears.

tered.
HOME POSITIONING
R1:S { -278
L { 30154
U {
R { -217
B {
Create home position?
T {
YES NO
Main Menu ShortCut
6 Select “YES.” Displayed position data of the axis are registered as home posi-
tion.
When “NO” is selected, the registration will be canceled.
Changing the Absolute Data

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

main menu.

HOME POSITIONING
R1:S {
L {
U {
R {
B {
T {
Main Menu ShortCut
6-6

menu.

SELECT ABSOLUTE
STATION1 DATA
R1:S {
L {
U {
R {
B {
T {
Main Menu ShortCut

group.
5 Select the absolute data to The number can now be entered.

be registered. DATA EDIT DISPLAY UTILITY
HOME POSITIONING
R1:S { -278
L { 3000
U { -29912
R { -217
B { 7745
T { 15881
Main Menu ShortCut
6 Enter the absolute data using

the numeric keys.
7 Press [ENTER]. Absolute data are modified.
6-7
Clearing Absolute Data

main menu.

HOME POSITIONING
R1:S {
L {
U {
R {
B {
T {
Main Menu ShortCut
3 Select {DATA} under the

menu.
4 Select {CLEAR ALL DATA}. The all absolute data are cleared.
HOME POSITIONING
R1:S {
L {
U {
R {
B {
T {
Main Menu ShortCut
6-8
6.1.2 Manipulator Home Position

With the MOTOMAN-HP6, the home position is as follows.
U-axis angle against horizontal

line on the ground (-0°) B-axis center line angle against
U-axis center line (-90°)
L-axis angle against vertical

line to the ground (-0°)
NOTE Other manipulator models have different positions. Always consult the documentation for
the correct manipulator model.
6-9
6.2 Position Deviation Check Using the Check Program
6.2 Position Deviation Check Using the Check Pro-

gram
Use the check program to check if positions are deviated with the following procedure.
1. Call up the check program in which the check point is taught (the job for the check
point) and operate the manipulator at low speed.
2. Check the tool tip position.

If it points the check point exactly as shown in the following figure, there is no deviation
from the positions. Proceed to "6.4 Setting the Second Home Position (Check Point)."
If not, there is a deviation. When the motor or encoder, etc. was replaced, move the
corresponding axis only, when the stored memory was cleared or the manipulator was
hit against a workpiece, move all axes, to the check point by joint motion. Then, pro-
ceed to "6.3 Home Position Data Correction."
Enlarged View
6-10
6.3 Home Position Data Correction
When there is a deviation from the positions, correct the home position data with the following
procedure.
1. Check the values of the following pulses. (If there is no deviation, the following two val-
ues coincide.)
• Command position pulse of the check point which was taught in advance
• Current position pulse where the manipulator (tool tip) was moved to the check
point after performing the check program
Displaying the Command Position Pulse

main menu.
2 Select {COMMAND POSI- The command position pulse values appear.

TION}. Note the values.
Displaying the Current Position Pulse

main menu.
2 Select {CURRENT POSI- The current position pulse values appear.

TION}. Note the values.
2. Calculate the difference between the command position pulse and the current position
pulse.
The difference pulse = Command position pulse − Current position pulse
6-11
3. On the HOME POSITIONING window, add the difference pulse value to the absolute
data of the axis whose motor or encoder, etc. was replaced.

main menu.
2 Select {HOME POSITION}.

HOME POSITIONING
R1:S {
L {
U {
R {
B {
T {
Main Menu ShortCut
3 Select {DISPLAY} under the

menu.

group.
5 Select the absolute data to

be registered.
6 Enter the numeric data for

the absolute data.
7 Press [ENTER].
4. Confirm that the command position pulse and the current position pulse coincide.
The home position data have been corrected. Proceed to "6.4 Setting the Second Home
Position (Check Point)."
6-12
6.4 Setting the Second Home Position (Check Point)
WARNING
• Be aware of safety hazards when performing the position confirma-
tion of the second home position (check point).
Abnormality of the PG system may be a cause for alarm. The manipulator may
operate in an unexpected manner, and there is a risk of damage to equipment or
injury to personnel.
• Before operating the manipulator, check that the SERVO ON lamp

goes out when the emergency stop buttons on the front door of
NX100 and the programming pendant are pressed.
Injury or damage to machinery may result if the manipulator cannot be stopped in

case of an emergency.
• Observe the following precautions when performing teaching oper-

ations within the P-point maximum envelope of the manipulator :

• Prior to performing the following operations, be sure that no one is

in the P-point maximum envelope of the manipulator, and be sure
that you are in a safe place when:
- Turning ON the NX100 power

- Running the system in the check mode
- Performing automatic operations
Injury may result from contact with the manipulator if persons enter the P-point max-
imum envelope of the manipulator.
• Always press the emergency stop button immediately if there are

problems.
Emergency stop buttons are attached on the right of the front door of the NX100
and the programming pendant.
6-13
CAUTION
• Perform the following inspection procedures prior to teaching the
manipulator. If problems are found, correct them immediately, and
be sure that all other necessary tasks have been performed.

- Check for damage to the insulation and sheathing of external
wires.
- Always return the programming pendant to its hook on the NX100
cabinet after use.
If the programming pendant is inadvertently left on the manipulator, a fixture, or on

the floor, the manipulator or a tool could collide with it during manipulator move-
ment, possibly causing injury or equipment damage.
6-14
6.4.1 Purpose of Position Check Operation

If the absolute number of rotation detected at power supply ON does not match the data
stored in the absolute encoder the last time the power supply was turned off, an alarm is
issued when the controller power is turned ON.
There are two possible causes of this alarm:
• Error in the PG system

• The manipulator was moved after the power supply was turned OFF.
If there is an error with the PG system, the manipulator may stall when playback is started. If
the absolute data allowable range error alarm has occurred, playback and test runs will not
function and the position must be checked.
After absolute data allowable range alarm occurs
Reset alarm
Turn ON servo power
Procedure After Alarm Occurs
Position confirmation
operation
Compare second home

NG
position (check point)
pulses with current
position pulses
Alarm occurs again
OK
Correct defective axis
• Replace PG system
• Home position calibration
∗ Position checking point
Playback possible
Position Check
After the absolute data allowable range alarm occurs, move to the second home position
using the axis keys and check the position. To prevent the position from changing, playback,
test runs, and FWD operation will not function.
6-15
Pulse Difference Check

The pulse number at the second home position is compared with that at the current posi-
tion. If the difference is within the allowable range, playback is enabled. If not, the error
alarm occurs again.
• The allowable range pulse is the number of pulses per rotation of the motor (PPR data).
• The initial value of the second home position is the home position (where all axes are at
pulse 0). The second home position can be changed. For details, refer to "6.4.2 Proce-
dure for the Second Home Position Setting (Check Point)."
Alarm Occurence
If the error alarm occurs again, there may be an error in the PG system. Check the system.
After adjusting the erroneous axis, calibrate the home position of the axis, then check the
position again.
• Home position calibration of all the axes at the same time enables playback operations
NOTE without having to check the position.
• Sometimes in a system with a manipulator that has no brake, it is possible to enable

playback without position checking after the absolute data allowable range error alarm
occurs. However, as a rule, always check the position.
Under the above special conditions, the manipulator moves as follows:
After starting, the manipulator moves at low speed (1/10 of the maximum speed) to the
step indicated by the cursor. If it is stopped and restarted during this motion, the low
speed setting is retained until the step at cursor is reached. Regardless of cycle setting,
the manipulator stops after the cursor step is reached. Starting the manipulator again
then moves it at the programmed speed and cycle of the job.
6-16
6.4.2 Procedure for the Second Home Position Setting

(Check Point)
Apart from the normal home position of the manipulator, the second home position can be set
up as a check point for absolute data. Use the following steps to set the specified point.
If two or more manipulators or stations are controlled by one controller, the second home posi-
tion must be set for each manipulator or station.

main menu.
2 Select {SECOND HOME The SECOND HOME POSITION window appears.
POS}. The message “Available to move to any modify second home
position” is shown.
SECOND HOME POSITION

HOME POSITION CURRENT DIFFERENCE
R1:S 0 0 0
L 0 0 0
U 0 0 0
R 0 0 0
B 0 0 0
T 0 0 0
Main Menu ShortCut
3 GO BACK The group axes by which the second home position is set is
Press the page key . selected when there are two or more group axes.
PAGE
4 Press the axis keys. Move the manipulator to the new second home position.
5 Press [MODIFY] and The second home position is chaged.
[ENTER].
6-17
6.4.3 Procedure After an Alarm
WARNING
• Be aware of safety hazards when performing the position confirma-
tion of the specified point.
Abnormality of the PG system may be cause for alarm. The manipulator may oper-
ate in an unexpected manner, and there is a risk of damage to equipment or injury
to personnel.
If the absolute data allowable range alarm occurs, perform the followings
• Reset the alarm
• Turn Servo power ON
and confirm the second home position. After the confirmation, if the PG system is found to be
the cause of the alarm, perform the necessary operation, such as replacing the PG, etc.
The robot current position data when turning main power supply OFF and ON can be con-
firmed in “Power ON/OFF Position Window”.
SUPPLE
Refer to " 7.7 Position Data When Power is Turned ON/OFF " for details on the
-MENT “Power ON/OFF Position Window.”

main menu.
2 Select {SECOND HOME The SECOND HOME POSITION window appears.
POS}.
3 GO BACK The group axes by which the second home position is set is
Press the page key . selected when there are two or more group axes.
PAGE
4 Press [FWD]. TCP moves to the second home position. The robot moving
speed is set as selected manual operation speed.
menu.
6 Select {CONFIRM The message “Home position checked” is shown.
POSITION}. Pulse data of the second home position and current pulse data
are compared. If the compared error is in allowed range, playback
operation can be done.
If the error is beyond the allowed range, the alarm occurs again.
6-18
7.1 System Version
7 System Diagnosis
7.1 System Version
It is possible to check the system CPU version information as follows.
1 Select {SYSTEM INFO}

under the main menu.
2 Select {VERSION}. The VERSION window appears.
VERSION
SYSTEM : NS1.00A(US)-00
PARAM : 1.00A
MODEL : UP130-A*
APPLI : SPOT WELD
CPU SYSTEM ROM BOOT ROM

NCP01 1.00 1.00
NPP01 1.00 1.00
AX∗#0 1.00-00 1.00
Main Menu ShortCut
7-1
7.2 Manipulator Model
7.2 Manipulator Model

main menu.
2 Select {MANIPULATOR The ROBOT AXIS CONFIG window appears.

TYPE}.
ROBOT AXIS CONFIG

AXIS CONFIGURATION
R1 : UP130-A* 0011_1111 B1 : 0000_00001

S1 : TURN-1
Main Menu ShortCut
7-2
7.3 Input/Output Status
7.3.1 User Input

The status of input signal from the external can be confirmed.
User Input Window
1 Select {IN/OUT} under the

main menu.
2 Select {USER INPUT}. The USER INPUT window appears.
USER INPUT
NO. 7654_3210
#0001X 0111_1011
#0002X 0000_0000
#0003X 0000_0000
#0004X 1111_0000
#0005X 0000_0000
#0006X 0000_1010
#0007X 0000_0000
#0008X 0000_0000
Main Menu ShortCut
User Input Detailed Window

menu.
2 Select {DETAIL}. The USER INPUT detailed window appears.

USER INPUT
GROUP IG#01 123 : DEC. 7b : HEX.
IN#0001 #00010
IN#0002 #00011
IN#0003 #00012 {
IN#0004 #00013
IN#0005 #00014
IN#0006 #00015
IN#0007 #00016
IN#0008 #00017 {
Main Menu ShortCut
7-3
7.3.2 User Output

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

main menu.
2 Select {USER OUTPUT}. The USER OUTPUT window appears.

USER OUTPUT
NO. 7654_3210
#1001X 0111_1011
#1002X 0000_0000
#1003X 0000_0000
#1004X 1111_0000
#1005X 0000_0000
#1006X 0000_1010
#1007X 0000_0000
#1008X 0000_0000
Main Menu ShortCut
User Output Detailed Window

menu.
2 Select {DETAIL}. The USER OUTPUT detailed window appears.

USER OUTPUT
GROUP 0G#01 123 : DEC. 7b : HEX.
OUT#0001 #10010 {
OUT#0002 #10011 {
OUT#0003 #10012 {
OUT#0004 #10013 {
OUT#0005 #10014 {
OUT#0006 #10015 {
OUT#0007 #10016 {
OUT#0008 #10017 {
Main Menu ShortCut
7-4
Modifying the Output Status
1 Select the desired output sig- Select the status of the desired output signal, “ ” or “ ,” in
nal number. the user output detailed window.
2 Press [INTER LOCK] + The status is changed. ( :ON status, :OFF status)
[SELECT].
USER OUTPUT
GROUP OG#01 122 : DEC. 7a : HEX.
OUT#0001 #10010 {
OUT#0002 #10011 {
OUT#0003 #10012 {
OUT#0004 #10013 {
OUT#0005 #10014 {
OUT#0006 #10015 {
OUT#0007 #10016 {
OUT#0008 #10017 {
Main Menu ShortCut
7-5
7.3.3 System Input
System Input Window

main menu.
2 Select {SYSTEM INPUT}. The SYSTEM INPUT window appears.

SYSTEM INPUT
NO. 7654_3210
#4001X 0111_1011
#4002X 0000_0000
#4003X 0000_0000
#4004X 1111_0000
#4005X 0000_0000
#4006X 0000_1010
#4007X 0000_0000
#4008X 0000_0000
Main Menu ShortCut
System Input Detailed Window

menu.
2 Select {DETAIL}. The SYSTEM INPUT detailed window appears.

SYSTEM INPUT
GROUP 123 : DEC. 7b : HEX.
SIN#0001 #40010 { SYSTEM ALM REQ
SIN#0002 #40011 { SYSTEM MSG REQ
SIN#0003 #40012 { USER ALM REQ
SIN#0004 #40013 { USER MSG REQ
SIN#0005 #40014 { ALM/ERR RESET
SIN#0006 #40015 {
SIN#0007 #40016 { SPEED LIMIT
SIN#0008 #40017 {
Main Menu ShortCut
7-6
7.3.4 System Output
System Output Window

main menu.
2 Select {SYSTEM OUTPUT}. The SYSTEM OUTPUT window appears.

SYSTEM OUTPUT
NO. 7654_3210
#5001X 0111_1011
#5002X 0000_0000
#5003X 0000_0000
#5004X 1111_0000
#5005X 0000_0000
#5006X 0000_1010
#5007X 0000_0000
#5008X 0000_0000
Main Menu ShortCut
System Output Detailed Window

menu.
2 Select {DETAIL}. The SYSTEM OUTPUT detailed window appears.

SYSTEM OUTPUT
GROUP 123 : DEC. 7b : HEX.
SOUT#0001 #50010 MAJOR ALM OCCUR
SOUT#0002 #50011 MINOR ALM OCCUR
SOUT#0003 #50012 { SYSTEM ALM OCCUR
SOUT#0004 #50013 USER ALM OCCUR
SOUT#0005 #50014 ERROR OCCUR
SOUT#0006 #50015 MEMORY BTRY WEAK
SOUT#0007 #50016 ENCDR BTRY WEAK
SOUT#0008 #50017 {
Main Menu ShortCut
7-7
7.3.5 RIN Input
RIN Input Window

main menu.
2 Select {RIN}. The RIN window appears.

RIN
RIN#001 { DIRECT IN1

Main Menu ShortCut
7-8
7.3.6 Modification of the Signal Name

The name of the user input or output signal can be modified.
USER INPUT
IN#0001 #00010 {
IN#0002 #00011 {
IN#0003 #00012 {
IN#0004 #00013 { Signal name
IN#0005 #00014 {
IN#0006 #00015 {
IN#0007 #00016 {
IN#0008 #00017 {
Main Menu ShortCut
The name can be modified in the following two ways.

• Direct modification on the detailed window
• Modification from the menu
7-9
Direct Modification on the Detailed Window
1 Move the cursor to the signal The window for character input appears.
name to be modified in the
detailed window, and press
[SELECT].
2 Enter the signal name.
3 Press [ENTER]. New signal name is registered.

USER INPUT
IN#0001 #00010 TEST SIGNAL

IN#0002 #00011
IN#0003 #00012 {
IN#0004 #00013
IN#0005 #00014
IN#0006 #00015
IN#0007 #00016
IN#0008 #00017 {
Main Menu ShortCut
7-10
Modification from the Menu
1 Move the cursor to the signal

name to be modified in the
detailed window.

menu.
SEARCH SIGNAL NO.

USER INPUT
GROUP SEARCH RELAY NO. 123 : DEC. 7b : HEX.
IN#0001 #00010
RENAME
IN#0002 #00011
IN#0003 #00012 {
IN#0004 #00013
IN#0005 #00014
IN#0006 #00015
IN#0007 #00016 {
IN#0008 #00017 {
Main Menu ShortCut
3 Select {RENAME}. The window for character input appears.
4 Enter the signal name.
5 Press [ENTER]. New signal name is registered.

USER INPUT
IN#0001 #00010 TEST SIGNAL

IN#0002 #00011
IN#0003 #00012 {
IN#0004 #00013
IN#0005 #00014
IN#0006 #00015
IN#0007 #00016
IN#0008 #00017 {
Main Menu ShortCut
7-11
7.3.7 Signal Number Search

A search can be made for a signal number of a user input, user output, system input, or sys-
tem output.
USER INPUT
IN#0001 #00010 {
IN#0002 #00011 {
IN#0003 #00012 {
Signal No. IN#0004 #00013 {
IN#0005 #00014 {
IN#0006 #00015 {
IN#0007 #00016 {
IN#0008 #00017 {
Main Menu ShortCut
A search for the signal number can be made in the following two ways.
• Direct search on the detailed window
• Search from the menu
7-12
Direct Search on the Detailed Window
1 Move the cursor to a signal The number input line appears.

number in the detail window,
JOB EDIT
and press [SELECT]. DISPLAY UTILITY
USER INPUT
IN#0001 #00010 {=
Signal no. input TEST SIGNAL
IN#0002 #00011 {
IN#0003 #00012 {
IN#0004 #00013 {
IN#0005 #00014 {
IN#0006 #00015 {
IN#0007 #00016 {
IN#0008 #00017 {
Main Menu ShortCut
2 Enter the number of the sig- Type the signal number in the number input line.
nal. Signal no. input = 41
3 Press [ENTER] to start the The page where the signal number exists appears.
search.
USER INPUT
GROUP IG#06 128 : DEC. 80 : HEX.
IN#0041 #00060 {
IN#0042 #00061 {
IN#0043 #00062 {
IN#0044 #00063 {
IN#0045 #00064 {
IN#0046 #00065 {
IN#0047 #00066 {
IN#0048 #00067
Main Menu ShortCut
7-13
Search from the Menu

menu in the detail window.
SEARCH SIGNAL NO.

USER INPUT
IN#0001 #00010
RENAME {
IN#0002 #00011 {
IN#0003 #00012 {
IN#0004 #00013 {
IN#0005 #00014 {
IN#0006 #00015 {
IN#0007 #00016 {
IN#0008 #00017 {
Main Menu ShortCut
2 Select {SEARCH SIGNAL The number input line appears.

NO.}.
3 Enter the number of the sig-

nal.
4 Press [ENTER] to start the The page where the signal number exists appears.
search.
7-14
7.3.8 Relay Number Search

A search can be made for a relay number of a user input or output signal or a system input or
output signal.
USER INPUT
IN#0001 #00010 {
IN#0002 #00011 {
IN#0003 #00012 {
Relay No. IN#0004 #00013 {
IN#0005 #00014 {
IN#0006 #00015 {
IN#0007 #00016 {
IN#0008 #00017 {
Main Menu ShortCut
A search for the relay number can be made in the following two ways.
• Direct search on the detailed window
• Search from the menu
7-15
Direct Search on the Detail Window
1 Move the cursor to a relay The number input line appears.

number in the detail window,
JOB
and press [SELECT]. EDIT DISPLAY UTILITY
USER INPUT
IN#0001 #00010 {=
Relay no. input TEST SIGNAL
IN#0002 #00011 {
IN#0003 #00012 {
IN#0004 #00013 {
IN#0005 #00014 {
IN#0006 #00015 {
IN#0007 #00016 {
IN#0008 #00017 {
Main Menu ShortCut
2 Enter the number of the Type the relay number in the number input line.
relay.
Relay no. input =
3 Press [ENTER] to start the The page where the input relay number exists appears.
search.
USER INPUT
GROUP IG#06 128 : DEC. 80 : HEX.
IN#0041 #00060 {
IN#0042 #00061 {
IN#0043 #00062 {
IN#0044 #00063 {
IN#0045 #00064 {
IN#0046 #00065 {
IN#0047 #00066 {
IN#0048 #00067 {
Main Menu ShortCut
7-16
Search from the Menu

menu in the detail window.
SEARCH SIGNAL NO.

USER INPUT
IN#0001 #00100
RENAME {
IN#0002 #00011 {
IN#0003 #00012 {
IN#0004 #00013 {
IN#0005 #00014 {
IN#0006 #00015 {
IN#0007 #00016 {
IN#0008 #00017 {
Main Menu ShortCut
2 Select {SEARCH RELAY The number input line appears.

NO.}.
3 Enter the number of the

relay.
4 Press [ENTER] to start the The page where the relay number exists appears.
search.
7-17
7.4 Cumulative Time Display
7.4.1 Cumulative Time Display Window

The status of system operation, e.g. power ON time, can be checked.
1 Select {SYSTEM INFO}.
2 Select {MONITORING The window for cumulative time display appears.

TIME}.
SYS MONITORING TIME
1 CONTROL POWER TIME (1998/07/06 10:00 )

2385:42'02
2 SERVO POWER TIME (1998/07/06 10:30 )
2380:10'12
3 PLAYBACK TIME (1998/10/22 11:12 )
2210:00'20
4 MOVING TIME (1998/10/22 15:30 )
1875:15'30
5 OPERATING TIME (1998/10/22 16:12 )
0:0'0
Main Menu ShortCut
CONTROL POWER TIME

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

Displays the cumulative time that the servo power sup-
ply has been ON.
PLAYBACK TIME
Displays the cumulative time during which playback was
executed.
MOVING TIME
Displays the cumulative time that the manipulator was in
motion.
OPERATING TIME
Displays the cumulative time spent in operation. For
example, if the manipulator is used for spot welding, it
displays the amount of time spent in spot welding; if the
manipulator is used for handling, it displays the time
spent in handling.
7-18
7.4.2 Individual Window of the Cumulative Time Display

GO BACK
If the page key PAGEis pressed, servo power ON time by each robot axis, playback time,
motion time and operating time by each application, is individually displayed.
SERVO POWER TIME
ROBOT1 (1998/07/06 10:00 )

2385:42'02
STATION1 (1998/08/03 10:00 )
262:37'02
PLAYBACK TIME
ROBOT1 (1998/07/06 10:00 )

2385:42'02
STATION1 (1998/08/03 10:00 )
262:37'02
OPERATING TIME
APPLI1 (1998/07/06 10:00 )

2385:42'02
APPLI2 (1998/08/03 10:00 )
262:37'02
MOVING TIME
ROBOT1 (1998/07/06 10:00 )

2385:42'02
STATION1 (1998/08/03 10:00 )
262:37'02
NOTE The total axes times here are not always the same as the time in the cumulative time dis-
play window because these windows show time as seen from the individual axis.
7-19
7.4.3 Clearing the Cumulative Time Display

Cumulative time displays can be cleared and set back to 0 by following procedure. These
operations can be performed in the cumulative time display window, or in the individual win-
dows.
1 Select the time to be cleared. The confirmation dialog box appears.

SYS MONITORING TIME
CONTROL POWER TIME (1998/07/06 10:00 )

2385:42'02
SERVO POWER TIME (1998/07/06 10:30 )
2380:10'12
PLAYBACK TIME (FROM 10/22/1998 11:12)
2210:00'20 Initialize?
MOVING TIME MOVING
(FROM TIME
10/22/1998 15:30)
1875:15'30
OPERATING TIME YES NO16:12)
(FROM 10/22/1998
Main Menu ShortCut
2 Select “YES.” The cumulative time value at the cursor line is reset to 0, and a
new time measurement begins.
SYS MONITORING TIME
CONTROL POWER TIME (1998/07/06 10:00 )

2385:42'02
SERVO POWER TIME (1998/07/06 10:30 )
2380:10'12
PLAYBACK TIME (1998/10/22 11:12 )
2210:00'20
MOVING TIME (1998/10/22 15:30 )
0:00'00
OPERATING TIME (1998/10/22 16:12 )
Main Menu ShortCut
7-20
7.5 Alarm History
7.5 Alarm History
7.5.1 Alarm History Window

There are five types of alarm list windows: the "MAJOR ALARM" window, the "MINOR
ALARM" window, the "USER ALARM (SYSTEM)" window, the "USER ALARM (USER)" win-
dow, and the "OFF-LINE" window. Each window shows the alarm code and the date and time.

2 Select {ALARM HISTORY}. The window for alarm history appears.

MAJOR ALARM
CODE DATE CLOCK
01 1030 05/12/1998 12:00

02 0060 06/15/1998 15:25
03
04
05
MEMORY ERROR (PARAMETER FILE)

[5]
JOB: TEST0001 LINE: 0010 STEP: 010
Main Menu ShortCut
3 GO BACK GO BACK
Press the page key PAGE to Each time the page key is pressed, the window changes
PAGE
change the window. "MAJOR ALARM" "MINOR ALARM" "USER ALARM(SYS-

TEM)” "USER ALARM(USER)" "OFF-LINE."
7-21
7.5 Alarm History
7.5.2 Clearing the Alarm History

The history of the minor alarms and the user alarms (system and user ) can be cleared.
1 Display the alarm history win-

dow to be cleared.

menu.
3 Select {CLEAR HISTORY}. The confirmation dialog box appears.

MAJOR ALARM
CODE DATE CLOCK
01 1030 1998/05/12 12:00

02 0060 1998/06/15 15:25
03
04
05
Clear data?
YES NO
MEMORY ERROR (PARAMETER FILE)

[5]
JOB: TEST0001 LINE: 0010 STEP: 010
Main Menu ShortCut
4 Select “YES.” The alarm history displayed is reset.
7-22
7.6 I/O Message History
7.6.1 I/O Message History Window

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

2 Select {I/O MSG HISTORY}. The I/O MESSAGE HISTORY window appears.
I/O MESSAGE HISTORY
0001 GAS SHORTAGE

0002 WIRE SHORTAGE
0003
0004
0005
0006
0007
DATE/TIME: 1999/06/1612:00
JOB NAME: ARCON LINE: 0006 STEP: 004
Main Menu ShortCut
Press [SELECT], and numeric values can now be entered.

Input the history number, and press [ENTER]. The search for
the input history number begins, and the I/O message that
appeared on the window is displayed.
Search
Use the following operation to search for the I/O message history.
1 Select {EDIT} under the

menu.
2 Select {SEARCH}. The character input line appears.
3 Enter the history No.
4 Press [ENTER]. The search for the input history number begins, and the I/O
message is displayed.
7-23
7.6.2 Clearing the I/O Message History

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

menu.
2 Select {CLEAR HISTORY}. The confirmation dialog box appears.

I/O MESSAGE HISTORY
0001 GAS SHORTAGE

0002 WIRE SHORTAGE
0003
0004
0005 Clear data?
0006
0007
YES NO
DATE/TIME: 1999/06/1612:00
JOB NAME: ARCON LINE: 0006 STEP: 004
Main Menu ShortCut
3 Select “YES.” The displayed I/O message history is cleared.
7-24
7.7 Position Data When Power is Turned ON/OFF
7.7 Position Data When Power is Turned ON/OFF
Power ON/OFF Position Window

The Power ON/OFF position window shows the position of the manipulator when power was
turned OFF the last time, the current position of the manipulator when power was later turned
ON, and the amount of difference between the two positions. When alarm 4107, "OUT OF
RANGE (ABSO DATA)" occurs, the error value of the faulty axes can be verified in this win-
dow.

main menu.
2 Select {POWER ON/OFF The POWER ON/OFF POSITION window appears.

POS}.
POWER ON/OFF POSITION

OFF POS ON POS DIFFERENCE
R1:S 4775 4120 665

L 8225 8225 0
U 960 960 0
R -336 -336 0
B -202 -203 1
T -10 -11 1
Main Menu ShortCut
7-25
7.8 Current Position
7.8 Current Position
Current Position Window


main menu.
2 Select {CURRENT POSI- The CURRENT POSITION window appears.

TION} under the sub menu.
CURRENT POSITION
COORDINATE: PULSE TOOL:00
R1:S 0
L 0
U 0
R 0
B 0
T 0
Main Menu ShortCut
3 Select the types of coordi- The pull-down menu appears.

nates to be displayed.
CURRENT POSITION
COORDINATE: PULSE TOOL: 00
R1:S 0
PULSE
L 0
BASE
U 0
ROBOT
R 0
USER
B 0
T 0
Main Menu ShortCut
4 Select the desired coordinate The type of coordinates being displayed is changed.
system.
CURRENT POSITION
COORDINATE: BASE TOOL: 00
R1:X 915.000 mm Rx 180.00 deg.

Y 0.000 mm Ry 0.00 deg.
Z 765.000 mm Rz 0.00 deg.
<ROBOT TYPE>
FRONT S< 180
UP R< 180
FLIP T< 180
Main Menu ShortCut
7-26
7.9 Servo Monitoring
7.9.1 Servo Monitor Window

The servo monitor window shows the servo-related data of each axis.
Monitor Items Description
FEEDBACK PULSE Feedback position (actual position) of each axis

“0” at the home position.
ERROR PULSE Difference between the command position and

the feedback position of each axis.
SPEED DEVIATION Difference between the command speed and the

feedback speed of each axis.
SPEED INST Speed reference of each axis.
FEEDBACK SPEED Feedback speed (actual speed) of each axis.
TORQUE SPEC Torque reference of each axis.
MAX. TORQUE Keeps the maximum value of the torque refer-

ence of each axis.
“0” when the maximum torque is cleared or the
control power supply is turned ON or OFF.
ENCODER ROTATE SUM Position after one rotation of the encoder when
the control power supply of each axis is turned
ON.
MOTOR ABSOLUTE Absolute value of the motor is calculated by add-

ing the position in one rotation to the sum of the
accumulated rotations when the control power
supply of each axis is turned ON.
7-27
7.9.2 Changing the Monitor Items
1 Set the security mode to the

management mode.

main menu.
3 Select {SERVO MONITOR}. The SERVO MONITOR window appears.

SERVO MONITOR
FEEDBACK PULSE ERROR PULSE
R1:S 1805 300

L 234 0
U 995 0
R 123 0
B 237 0
T 2432 0

menu. MONITOR ITEM 1 is the data on the left, and MONITOR ITEM 2
is the data on the right.
MONITOR ITEM1>
SERVO MONITOR
MONITOR ITEM2> ERROR PULSE
FEEDBACK PULSE
R1:S 1805 300

L 234 0
U 995 0
R 123 0
B 237 0
T 2432 0
5 Select MONITOR ITEM 1 or The sub-menu choices appear.

2, and view the sub-menu
choices by pressing the right DATA EDIT DISPLAY UTILITY
arrow key [→]. SERVO MONITOR

FEEDBACK PULSE
FEEDBACK PULSE
ERROR PULSE ERROR PULSE
R1:S 1805
SPEED DEVIATION 300
L 234 0
U SPEED
995INST 0
R 123 0
B 237 0
T 2432 0
6 Select a menu. The type of monitor-related information is changed.

SERVO MONITOR
SPEED INST ERROR PULSE
R1:S 4000 300

L 0 0
U 0 0
R 0 0
B 0 0
T 0 0
7-28
7.9.3 Clearing Maximum Torque Data

The data for the maximum torque can be cleared when the maximum torque-related informa-
tion is being displayed.
1 Select {DATA} under the The clear max torque window appears.
menu.
CLEAR MAX TORQUE

MAX TORQUE ERROR PULSE
R1:S 30 0
L 70 0
U 80 0
R 20 0
B 40 0
T 30 0
2 Select {MAX. TORQUE}. The maximum torque data is cleared.

SERVO MONITOR
MAX TORQUE FEEDBACK PULSE
R1:S 0 0
L 0 0
U 0 0
R 0 0
B 0 0
T 0 0
7-29
8.1 Outline of Alarm
8 Alarm
8.1 Outline of Alarm
When an alarm of level 0 to 3 (major alarm) occurs, the servo power supply is turned OFF.
Alarm Code Classification
Alarm Code Alarm Level Alarm Reset Method
Level 0 (Major alarm) It is not possible to reset by "RESET" under

(Off line alarm : Initial diagnosis/ the ALARM window or the system input signal
0 Hardware diagnosis alarm) (Alarm reset). Turn OFF the main power sup-
ply and correct the cause of the alarm. Then
turn ON the main power supply again.
Level 1 to 3 (Major alarm) It is not possible to reset by "RESET" under

1 the ALARM window or the system input signal
to (Alarm reset). Turn OFF the main power sup-
3 ply and correct the cause of the alarm. Then
turn ON the main power supply again.
4 Level 4 to 8 (Minor alarm) After correcting the cause, it is possible to

to reset by "RESET" under the ALARM window
8 or the system input signal (Alarm reset).
Level 9 (Minor alarm) After correcting the cause for which the sys-
(I/O alarm) tem input signal for the system or user alarm
9 request turns ON, it is possible to reset by
"RESET" under the ALARM window or the
system input signal (Alarm reset).
8-1
8.2 Alarm Display
8.2 Alarm Display
8.2.1 Displaying and Releasing Alarm

If an alarm occurs during operation, the manipulator stops immediately and the ALARM win-
dow appears on the programming pendant indicating that the machine was stopped by an
alarm.
ALARM
Alarm No. ALARM 4100 1 Sub-data

OVERRUN (ROBOT)
ALARM 4321 SLURBT
Alarm OVERLOAD (MOMENT)
ALARM 4315 SLURBT
message COLLISION DETECT
OCCUR TIMES: 1
RESET
Main Menu ShortCut
If more than one alarm occurs simultaneously, all the alarms are displayed. Scroll the viewing
area with the cursor key to view the alarm that is not currently displayed on the viewing area.
To view details of the alarm contents, move the cursor to the alarm and press [ASSIST].
ALARM
ALARM 4100 1
OVERRUN (ROBOT)
[Cause]
One of the manipulator overrun limit switches activated.
[Remedy]
Move back the manipulator out of the overrun limit switch range.
OCCUR TIMES: 1
RESET
Main Menu ShortCut
The following operations are available in the alarm status: window change, mode change,
alarm reset, and emergency stop. If the window is changed to another window during alarm
occurrence, the ALARM window can be shown again by selecting {SYSTEM INFO} under the
main menu and then selecting {ALARM}.
Releasing Alarms
Alarms are classified by minor and major alarms.
• Minor Alarms
Select "RESET" on the ALARM window or turn ON the "ALARM RESET" setting when
using an external input signal.
8-2
8.2 Alarm Display
• Major Alarms
Turn OFF the main power suply, remove the cause of the alarm, and then turn ON the
power supply again.
If a severe alarm such as hardware failure occurs, servo power is automatically shut OFF
and the manipulator stops. If releasing does not work, turn OFF the main power and cor-
rect the cause of the alarm.
8.2.2 Special Alarm Display

Sub Data
Sub data such as data for the axis where the alarm occurred, may also be displayed for
some alarms.
• Decimal data
Without signs: 0 to 65535
With signs: -32768 to 32767
• Binary data
The alarm occurrence data becomes “1.”
With 8 bits: 0000_0001
With 16 bits: 00000001_00000001
• Axis data
The axis where the alarm occurred is highlighted.
With robot axis: Robots 1 to 4 [SLURBT]
With base axis: Robots 1 to 4 [123]
With station axis: Stations 1 to 6 [ 1 2 3 ]
• XYZ coordinate data

The coordinates where the alarm occurred are highlighted.
[XYZ]
[ X Y Z Tx Ty Tz ]
• 123 data
The data for which the alarm occurred is highlighted.
[123]
• Control group data

The control group where the alarm occurred is highlighted.
[ R1 R2 S1 S2 S3 ]
8-3
8.2 Alarm Display
Multiple SERVOPACK System

In a system using more than one SERVOPACK, the number of the SERVOPACK where
the alarm occurred is also displayed. The S1 switch of the AXA01 circuit board shows the
SERVOPACK number.
SV#1: SERVOPACK 1 (AXA01 circuit board S1 switch: 0)
Independent Control Function (Optional)

In the independent control function (multi-task job), the tasks that were being done when
the alarm occurred are also displayed.
TASK#0: Master-task job
TASK#1: Sub-task1 job (SUB1)
8-4
8.3 Alarm Message List
CAUTION
Before handling the system control circuit board “JANCD-NCP01” for any remedies, con-
sult YASKAWA representative. To handle the JANCD-NCP01, personnel must be appro-
priately skilled in maintenance mode operation.
JANCD-NCP01 backs up very important file data for the user program with a battery.
Careless operation may delete registered data.
Alarm Message List

Alarm Sub
Message Cause Remedy
Number Code
0020 10 CPU COMMUNI- An error occurred in communica- • Turn the power OFF then back ON.
CATION ERROR tions between boards when the • Check that the optional board #1 is correctly
control power turned ON. inserted.
• No response was sent from the If the error occurs again, contact your
optional board #1. Yaskawa representative.
CATION ERROR tions between boards when the • Check that the optional board #2 is correctly
control power turned ON. inserted.
• No response was sent from the If the error occurs again, contact your
optional board #2. Yaskawa representative.
CATION ERROR tions between boards when the • Check the connections of communications
control power turned ON. cable, terminator terminal, and the station
• No response was sent from the number settings.
servo board #1. If the error occurs again, contact your
Yaskawa representative.
0021 50 COMMUNICA- An error occurred in communica- • Turn the power OFF then back ON.
TION ERROR tions with the servo board #1. • Check the connections of communications
(SERVO) • The communications CPU for the cable, terminator terminal, and the station
servo board #1 detected an error number settings.
when the control power turned If the error occurs again, contact your
ON. Yaskawa representative.
8-5
Alarm Message List

Alarm Sub
Number Code
0030 1 ROM ERROR The system program file is dam- If the error occurs again, contact your
aged. Yaskawa representative.
• The NCP01 system program is
damaged.
• The system program of optional
board #1 is damaged.
• The system program of optional
• The system program of servo
0060 1 to COMMUNICA- An error was detected in communi- • Turn the power OFF then back ON.
15 TION ERROR cations with an I/O module board • Check the connections of communications
(I/O MODULE) when the control power turned ON. cable, terminator terminal, and the station
number settings.
If the error occurs again, contact your
0100 1 COMMUNICA- An error was detected in communi- • Turn the power OFF then back ON.
TION ERROR cations with the servo board #1. If the error occurs again, contact your
8-6
Alarm Message List

Alarm Sub
Number Code
0200 DMS MEMORY The parameter file is damaged. Initialize the parameter file.
file ERROR If the error occurs again, contact your
No. (PARAMETER Yaskawa representative.
FILE)
0210 0 MEMORY The system configuration informa- Initialize the system.
ERROR tion data are damaged. If the error occurs again, contact your
(SYSTEM CON- Yaskawa representative.
FIG-DATA)
0220 0 MEMORY The management data of job files Initialize the job files.
ERROR are damaged. If the error occurs again, contact your
(JOB MNG DATA) Yaskawa representative.
0220 1 MEMORY The job files are damaged. Initialize the job files.
ERROR If the error occurs again, contact your
0220 2 MEMORY The management data of position Initialize the position data files.
ERROR data files are damaged. If the error occurs again, contact your
0220 3 MEMORY The memory play file is damaged. Initialize the memory play file.
0230 0 MEMORY The concurrent I/O ladder program Initialize the concurrent I/O ladder program.
ERROR is damaged. If the error occurs again, contact your
(LADDER PRG Yaskawa representative.
FILE)
0300 2 VERIFY ERROR The setting of concurrent I/O Set a correct value for the concurrent I/O
(SYSTEM CON- parameter is incorrect. parameter.
FIG-DATA)
0300 3 VERIFY ERROR An invalid value is set for the seg- Set a correct value for the segment clock.
(SYSTEM CON- ment clock.
FIG-DATA)
0300 4 VERIFY ERROR Inconsistency was detected in axis- Correctly set the axis-related parameters.
(SYSTEM CON- related parameters.
FIG-DATA)
0300 5 VERIFY ERROR Inconsistency was detected in sen- Correctly set the sensor parameters.
(SYSTEM CON- sor parameters.
FIG-DATA)
0300 6 VERIFY ERROR A system configuration data verifi- Needs investigation. Contact your Yaskawa
(SYSTEM CON- cation error occurred. representative.
FIG-DATA) A parameter verification error Perform configuration of the I/O Module.
occurred.
8-7
Alarm Message List

Alarm Sub
Number Code
0300 7 VERIFY ERROR Inconsistency was detected in Use the functions of the mounted optional
(SYSTEM CON- optional functions. board.
FIG-DATA) • The set optional functions are dif-
ferent from those of the mounted
optional board.
0300 8 VERIFY ERROR The function designation for the Set the correct function for the concurrent
(SYSTEM CON- concurrent I/O parameter is incor- I/O parameter.
FIG-DATA) rect.
0310 0 VERIFY ERROR The CMOS memory capacity is dif- Initialize the system or use a RIF board with
(CMOS MEM- ferent from its initial setting. correct CMOS capacity.
ORY SIZE)
0320 1 to VERIFY ERROR The function of the connected I/O Connect a correct I/O module.
15 (I/O MODULE) module is different from the set
function.
0330 0 VERIFY ERROR Inconsistency was detected in the Correctly set the application setting parame-
(SENSOR FUNC- application setting parameters. ters.
TION)
0370 0 VERIFY ERROR The designation in the parameter is Set a correct value for the welding timer des-
(SPOT POWER different from the connected weld- ignation.
SOURCE I/F) ing timer.
0400 50 to PARAMETER An error occurred during the • Turn the power OFF then back ON.
53 TRANSMISSION parameter/file transfer to the servo If the error occurs again, contact your
ERROR board. Yaskawa representative.
0410 MODE CHANGE An error occurred during startup Restart the system.
ERROR sequence processing with the If the error occurs again, contact your
servo CPU, and the system did not Yaskawa representative.
startup normally.
0500 SEGMENT Motion command processing was Restart the system.
PROC NOT not completed within the specified If the error occurs again, contact your
READY time. Yaskawa representative.
0510 SOFTWARE Inconsistency was detected in the Correct the combination.
VERSION system program.
UNMATCH • The combination of the main sys-
tem program and the servo sys-
tem program are incorrect.
0900 WATCHDOG A system operation error occurred. Restart the system. If the error occurs again,
TIMER ERROR contact your Yaskawa representative.
(NIF BOARD)
0950 100 CPU ERROR The servo board #1 is defective. Replace the servo board.
• An error was detected in the CPU
of servo board #1.
of servo board #2.
of servo board #3.
of servo board #4.
1000 1 ROM ERROR An error occurred in the board or Replace the main CPU board.
system software (ROM).
• A checksum error occurred in the
main ROM.
1001 10 ROM ERROR A checksum error occurred in the • Turn the power OFF then back ON.
board or the EEPROM. If the error occurs again, contact your
8-8
Alarm Message List

Alarm Sub
Number Code
1001 20 ROM ERROR The SRDY signal did not turn ON • Turn the power OFF then back ON.
after the WRITE ENABLE com- If the error occurs again, contact your
mand was written. (EEPROM Yaskawa representative.
WRITE ENABLE error)
after the WRITE PROTECT com- If the error occurs again, contact your
mand was written. (EEPROM Yaskawa representative.
WRITE PROTECT error)
after the ERASE command was If the error occurs again, contact your
written. (EEPROM ERASE error) Yaskawa representative.
after the CLEAR command was If the error occurs again, contact your
written. (EEPROM CLEAR error) Yaskawa representative.
after data were written. (EEPROM If the error occurs again, contact your
writing error) Yaskawa representative.
after data were read. (EEPROM If the error occurs again, contact your
reading error) Yaskawa representative.
1001 26 ROM ERROR The written data were rejected at • Turn the power OFF then back ON.
verification. (EEPROM verify error) If the error occurs again, contact your
1030 0 MEMORY An error was detected at memory Initialize the RC parameter file in mainte-
ERROR check. nance mode, and then load the RC parame-
(PARAMETER • The memory for RC parameter file ter file saved in the external memory device.
FILE) is damaged.
1030 1 MEMORY An error was detected at memory Initialize the RO parameter file in mainte-
ERROR check. nance mode, and then load the RO parame-
(PARAMETER • The memory for RO parameter file ter file saved in the external memory device.
FILE) is damaged.
1030 2 MEMORY An error was detected at memory Initialize the SV parameter file in mainte-
ERROR check. nance mode, and then load the SV parame-
(PARAMETER • The memory for SV parameter file ter file saved in the external memory device.
FILE) is damaged.
1030 3 MEMORY An error was detected at memory Initialize the SVM parameter file in mainte-
ERROR check. nance mode, and then load the SVM param-
(PARAMETER • The memory for SVM parameter eter file saved in the external memory device.
FILE) file is damaged.
1030 4 MEMORY An error was detected at memory Initialize the SC parameter file in mainte-
ERROR check. nance mode, and then load the SC parame-
(PARAMETER • The memory for SC parameter file ter file saved in the external memory device.
FILE) is damaged.
1030 5 MEMORY An error was detected at memory Initialize the SD parameter file in mainte-
ERROR check. nance mode, and then load the SD parame-
(PARAMETER • The memory for SD parameter file ter file saved in the external memory device.
FILE) is damaged.
1030 6 MEMORY An error was detected at memory Initialize the CIO parameter file in mainte-
ERROR check. nance mode, and then load the CIO parame-
(PARAMETER • The memory for CIO parameter ter file saved in the external memory device.
1030 7 MEMORY An error was detected at memory Initialize the FD parameter file in mainte-
ERROR check. nance mode, and then load the FD parame-
(PARAMETER • The memory for FD parameter file ter file saved in the external memory device.
FILE) is damaged.
1030 8 MEMORY An error was detected at memory Initialize the AP parameter file in mainte-
ERROR check. nance mode, and then load the AP parame-
(PARAMETER • The memory for AP parameter file ter file saved in the external memory device.
FILE) is damaged.
8-9
Alarm Message List

Alarm Sub
Number Code
1030 9 MEMORY An error was detected at memory Initialize the RS parameter file in mainte-
ERROR check. nance mode, and then load the RS parame-
(PARAMETER • The memory for RS parameter file ter file saved in the external memory device.
FILE) is damaged.
1030 10 MEMORY An error was detected at memory Initialize the SE parameter file in mainte-
ERROR check. nance mode, and then load the SE parame-
(PARAMETER • The memory for SE parameter file ter file saved in the external memory device.
FILE) is damaged.
1030 11 MEMORY An error was detected at memory Initialize the SVC parameter file in mainte-
ERROR check. nance mode, and then load the SVC parame-
(PARAMETER • The memory for SVC parameter ter file saved in the external memory device.
1030 12 MEMORY An error was detected at memory Initialize the AMC parameter file in mainte-
ERROR check. nance mode, and then load the AMC param-
(PARAMETER • The memory for AMC parameter eter file saved in the external memory device.
1030 13 MEMORY An error was detected at memory Initialize the SVP parameter file in mainte-
ERROR check. nance mode, and then load the SVP parame-
(PARAMETER • The memory for SVP parameter ter file saved in the external memory device.
1030 14 MEMORY An error was detected at memory Initialize the MF parameter file in mainte-
ERROR check. nance mode, and then load the MF parame-
(PARAMETER • The memory for MF parameter file ter file saved in the external memory device.
FILE) is damaged.
1030 15 MEMORY An error was detected at memory Initialize the SVS parameter file in mainte-
ERROR check. nance mode, and then load the SVS parame-
(PARAMETER • The memory for SVS parameter ter file saved in the external memory device.
1031 1 MEMORY The file data used by MOTION are Initialize the damaged file in the maintenance
ERROR damaged. mode. Then, load the saved file and restore.
(MOTION1) • The home position calibration file
is damaged.
(MOTION1) • The tool file is damaged.
(MOTION1) • The user coordinates file is dam-
aged.
(MOTION1) • The robot calibration file is dam-
aged.
(MOTION1) • The tool calibration file is dam-
aged.
(MOTION1) • The weaving amplitude condition
file is damaged.
(MOTION1) • The home position correction data
file is damaged.
(MOTION1) • The conveyor calibration file is
damaged.
8-10
Alarm Message List

Alarm Sub
Number Code
(MOTION1) • The arm and tool interference pre-
vention file is damaged.
(MOTION1) • The weaving file is damaged.
(MOTION1) • The Power Source condition data
file is damaged.
(MOTION1) • The welding condition auxiliary file
is damaged.
(MOTION1) • The arc start condition file is dam-
aged.
(MOTION1) • The arc end condition file is dam-
aged.
(MOTION1) • The COMARC condition file is
damaged.
(MOTION1) • The COMARC data file is dam-
aged.
(MOTION1) • The path correction condition file
is damaged.
(MOTION1) • The painting characteristics file is
damaged.
(MOTION1) • The painting condition file is dam-
aged.
(MOTION1) • The multi-layer index file is dam-
aged.
(MOTION1) • The multi-layer condition file is
damaged.
(MOTION1) • The sensor monitoring condition
file is damaged.
(MOTION1) • The name position file is dam-
aged.
8-11
Alarm Message List

Alarm Sub
Number Code
(MOTION1) • The conveyor condition file is
damaged.
(MOTION1) • The Press characteristics file is
damaged.
(MOTION1) • The servo float condition file is
damaged.
(MOTION1) • The spot welding Power Source
condition data file is damaged.
(MOTION1) • The air-gun condition file is dam-
aged.
(MOTION1) • The motor-gun condition file is
damaged.
(MOTION1) • The gun pressure file is damaged.
(MOTION1) • The dry-spotting gun pressure file
is damaged.
(MOTION1) • The anticipation OT# output file is
damaged.
(MOTION1) • The anticipation OG# output file is
damaged.
(MOTION1) • The handling condition file is dam-
aged.
(MOTION1) • The form cut file is damaged.
(MOTION1) • The spot (user) I/O allocation file
is damaged.
(MOTION1) • The linear servo float condition file
is damaged.
(MOTION1) • The macro definition file is dam-
aged.
8-12
Alarm Message List

Alarm Sub
Number Code
(MOTION1) • The seal amount correction condi-
tion file (spray) is damaged.
(MOTION1) • The seal amount correction condi-
tion file (undercoating) is dam-
aged.
(MOTION1) • The arc monitor file is damaged.
(MOTION1) • The motor-gun condition auxiliary
file is damaged.
(MOTION1) • The job registration table is dam-
aged.
(MOTION1) • The painting device condition file
is damaged.
(MOTION1) • The painting system file is dam-
aged.
(MOTION1) • The painting condition file is dam-
aged.
(MOTION1) • The paint characteristics file is
damaged.
(MOTION1) • The EVB gun file is damaged.
(MOTION1) • The paint filling file is damaged.
(MOTION1) • The welding pulse condition file is
damaged.
(MOTION1) • The clearance file is damaged.
(MOTION1) • The linear scale condition file is
damaged.
(MOTION1) • The gauging sensor file is dam-
aged.
8-13
Alarm Message List

Alarm Sub
Number Code
(MOTION1) • The conveyor condition auxiliary
file is damaged.
1050 1 SET-UP The motion instruction did not start • Turn the power OFF then back ON.
PROCESS up. (motion instruction setup incom- If the error occurs again, contact your
ERROR plete.) Yaskawa representative.
(SYSCON)
1050 2 SET-UP The motion instruction did not start • Turn the power OFF then back ON.
PROCESS up. (Setup of the servo control cir- If the error occurs again, contact your
ERROR cuit board and NCP02 circuit board Yaskawa representative.
(SYSCON) incomplete, parameter setting value
error)
1051 1 SET-UP PRO- An error occurred in the setup pro- • Turn the power OFF then back ON.
CESS ERROR cess of MOTION when the control If the error occurs again, contact your
(MOTION) power turned ON. Yaskawa representative.
• The servo control section was not
started up.
• The position data of when the
power supply had turned OFF
could not be transmitted to the
servo control section.
• The servo control section could
not receive the position data of
when the power supply had
turned OFF.
• The request to turn ON the PG
power supply for the mounted
axis could not be sent.
• The PG power supply for the
mounted axis could not turn ON.
• The request to prepare a feed-
back pulse could not be sent.
• The feedback pulse could not be
prepared.
• The request to initialize the arith-
metic section could not be sent.
8-14
Alarm Message List

Alarm Sub
Number Code
• The arithmetic section could not
be initialized.
• The request to prepare the current
value could not be sent.
• The current value could not be
prepared.
1100 SYSTEM An unknown alarm was detected • Turn the power OFF then back ON.
ERROR because of noise or control error. If the error occurs again, contact your
1101 SYSTEM An error occurred during the sytem • Turn the power OFF then back ON.
ERROR control check. If the error occurs again, contact your
(SYSTEM 1) Yaskawa representative.
1102 SYSTEM An error occurred during the sytem • Turn the power OFF then back ON.
ERROR control check. If the error occurs again, contact your
(SYSTEM 2) Yaskawa representative.
1103 SYSTEM An error occurred during the sys- • Turn the power OFF then back ON.
ERROR tem event data control check. If the error occurs again, contact your
(EVENT) Yaskawa representative.
1104 SYSTEM An error occurred during the sys- • Check the I/O signal line connectors and
ERROR tem I/O control check. (I/O circuit cables.
(CIO) board communications error, C I/O • Reset the I/O module in maintenance mode.
parameter setting value error etc.) • Replace the NIF01, I/O contactor unit, and/
or I/O module.
1105 0 SYSTEM No processing corresponds to the • Turn the power OFF then back ON.
ERROR command code sent from MOTION. If the error occurs again, contact your
(SERVO) Yaskawa representative.
1105 1 SYSTEM Illegal command data (parameter) • Turn the power OFF then back ON.
ERROR is received from MOTION. If the error occurs again, contact your
1105 2 SYSTEM An error occurred in the file transfer • Turn the power OFF then back ON.
ERROR sequence at execution of motion If the error occurs again, contact your
(SERVO) command. Yaskawa representative.
1105 3 SYSTEM The data size for the file transfer • Turn the power OFF then back ON.
ERROR was over housing size at executing If the error occurs again, contact your
(SERVO) a motion command. Yaskawa representative.
1105 4 SYSTEM An optional function was com- • Turn the power OFF then back ON.
ERROR manded to be executed while If the error occurs again, contact your
(SERVO) another optional function was in Yaskawa representative.
execution.
1105 5 SYSTEM The request to change standardiza- • Turn the power OFF then back ON.
ERROR tion time was sent without permis- If the error occurs again, contact your
(SERVO) sion. Yaskawa representative.
1105 6 SYSTEM The motor instruction standardiza- • Turn the power OFF then back ON.
ERROR tion time is out of the allowable If the error occurs again, contact your
(SERVO) range. Yaskawa representative.
1105 7 SYSTEM The KP parameter input value is • Turn the power OFF then back ON.
ERROR out of the allowable range. If the error occurs again, contact your
8-15
Alarm Message List

Alarm Sub
Number Code
1105 8 SYSTEM The KP parameter input value for • Turn the power OFF then back ON.
ERROR two degrees of freedom control is If the error occurs again, contact your
(SERVO) out of the allowable range. Yaskawa representative.
1105 9 SYSTEM No processing corrensponds to the • Turn the power OFF then back ON.
ERROR command code sent from MOTION. If the error occurs again, contact your
1105 10 SYSTEM An uncontrollable axis was desig- • Turn the power OFF then back ON.
ERROR nated. If the error occurs again, contact your
1105 11 SYSTEM An attempt was made to apply the • Turn the power OFF then back ON.
ERROR brake to the motor while the power If the error occurs again, contact your
(SERVO) was being supplied. Yaskawa representative.
1105 12 SYSTEM An attempt was made to supply • Turn the power OFF then back ON.
ERROR power to the motor while the brake If the error occurs again, contact your
(SERVO) was applied to the motor. Yaskawa representative.
1105 14 SYSTEM An error occurred in the encoder • Turn the power OFF then back ON.
ERROR power supply control process. If the error occurs again, contact your
1105 15 SYSTEM The segment clock was not the • Turn the power OFF then back ON.
ERROR specified value. If the error occurs again, contact your
1105 17 SYSTEM An attempt was made to turn ON • Turn the power OFF then back ON.
ERROR the servo while the encoder was If the error occurs again, contact your
(SERVO) not ready. Yaskawa representative.
1105 18 SYSTEM The request to turn ON the servo • Turn the power OFF then back ON.
ERROR power supply again was sent to an If the error occurs again, contact your
(SERVO) axis where the servo’s power was Yaskawa representative.
already ON.
1105 30 SYSTEM The linear servo float does not sup- • Turn the power OFF then back ON.
ERROR port the manipulator type specified If the error occurs again, contact your
(SERVO) in the RC parameter at calculation Yaskawa representative.
for servo-float-related parameters.
1105 37 SYSTEM The manipulator (B-axis) passed Check the job so that the manipulator (B-
ERROR the singular point while the linear axis) does not pass the singular point while
(SERVO) servo float was ON. the linear servo float is ON.
1105 40 SYSTEM The axes for which the servo were Check the wiring to the contactor.
ERROR attempted to be turned ON were If the error occurs again, contact your
(SERVO) not connected to the contactor. Yaskawa representative.
1105 43 SYSTEM The servo ON command was exe- • Turn the power OFF then back ON.
ERROR cuted while the encoder was in If the error occurs again, contact your
(SERVO) alarm status. Yaskawa representative.
1105 47 SYSTEM The alarm number is illegal. • Turn the power OFF then back ON.
1105 60 SYSTEM The axis endless function is set Disable the axis endless function of motor
ERROR enabled for motor guns. guns axis.
(SERVO)
1105 61 SYSTEM The axis endless function is set Disable the axis endless function for the
ERROR enabled for the encoder for which encoder.
(SERVO) this function cannot be used.
The axis endless function cannot
be used for the encoders manufac-
tured by Tamagawa Seiki Co., Ltd.
1105 63 SYSTEM An error occurred while the axis • Turn the power OFF then back ON.
ERROR endless function was being used. If the error occurs again, contact your
8-16
Alarm Message List

Alarm Sub
Number Code
1105 68 SYSTEM The home position detecting func- Disable either the axis endless function or the
ERROR tion was used for the axis for which home position detection function.
(SERVO) the axis endless function was
enabled.
1105 69 SYSTEM The servo float function was used Disable the axis endless function, or do not
ERROR for the axis for which the axis end- use the servo float function.
(SERVO) less function was enabled.
1105 80 SYSTEM An axis number that is not for gun • Turn the power OFF then back ON.
ERROR change was specified. If the error occurs again, contact your
1105 81 SYSTEM An axis number that is not for gun • Turn the power OFF then back ON.
ERROR change was specified. If the error occurs again, contact your
1105 82 SYSTEM The PG power supply of the axis for • Turn the power OFF then back ON.
ERROR gun change is ON. If the error occurs again, contact your
1105 83 SYSTEM The servo power supply of the axis • Turn the power OFF then back ON.
ERROR for gun change is ON. If the error occurs again, contact your
1105 90 SYSTEM The gun number allocated to the • Turn the power OFF then back ON.
ERROR specified physical axis is different If the error occurs again, contact your
(SERVO) from the specified gun condition file Yaskawa representative.
number.
1105 91 SYSTEM The gun pressure file number is • Turn the power OFF then back ON.
ERROR incorrect. If the error occurs again, contact your
1105 92 SYSTEM The axis specified for gun pressure • Turn the power OFF then back ON.
ERROR is not a gun axis. If the error occurs again, contact your
1105 100 SYSTEM The sequence was untimely exe- • Turn the power OFF then back ON.
ERROR cuted in the general-purpose 10ms If the error occurs again, contact your
(SERVO) process although it was not the Yaskawa representative.
execution timing.
ERROR cuted in the segment_G process If the error occurs again, contact your
(SERVO) although it was not the execution Yaskawa representative.
timing.
execution timing.
execution timing.
ERROR cuted in the dynamics calculation If the error occurs again, contact your
execution timing.
ERROR cuted in the dynamics compensa- If the error occurs again, contact your
(SERVO) tion process although it was not the Yaskawa representative.
execution timing.
ERROR cuted in the servo communications If the error occurs again, contact your
(SERVO) CERF sending process although it Yaskawa representative.
was not the execution timing.
8-17
Alarm Message List

Alarm Sub
Number Code
ERROR cuted in the servo communications If the error occurs again, contact your
(SERVO) CERF receiving process although it Yaskawa representative.
was not the execution timing.
ERROR cuted in the segment_R process If the error occurs again, contact your
timing.
ERROR cuted in the segment_E process If the error occurs again, contact your
timing.
ERROR cuted in the segment_OPT1 pro- If the error occurs again, contact your
(SERVO) cess although it was not the Yaskawa representative.
execution timing.
execution timing.
execution timing.
1105 120 SYSTEM A general-purpose 10ms process • Turn the power OFF then back ON.
ERROR did not complete within the time set If the error occurs again, contact your
(SERVO) on the scheduling table. Yaskawa representative.
1105 121 SYSTEM The segment_G process did not • Turn the power OFF then back ON.
ERROR complete within the time set on the If the error occurs again, contact your
(SERVO) scheduling table. Yaskawa representative.
1105 122 SYSTEM The general-purpose 4ms process • Turn the power OFF then back ON.
(SERVO) on the scheduling table. (Emer- Yaskawa representative.
gency stop detected.)
1105 125 SYSTEM The dynamics calculation process • Turn the power OFF then back ON.
1105 126 SYSTEM The dynamics compensation pro- • Turn the power OFF then back ON.
ERROR cess did not complete within the If the error occurs again, contact your
(SERVO) time set on the scheduling table. Yaskawa representative.
1105 127 SYSTEM The CERF transmission process • Turn the power OFF then back ON.
1105 128 SYSTEM The dynamics calculation process • Turn the power OFF then back ON.
1105 129 SYSTEM The CERF receiving process did • Turn the power OFF then back ON.
ERROR not complete within the time set on If the error occurs again, contact your
(SERVO) the scheduling table. Yaskawa representative.
1105 130 SYSTEM The segment_R process did not • Turn the power OFF then back ON.
8-18
Alarm Message List

Alarm Sub
Number Code
1105 131 SYSTEM The segment_E process did not • Turn the power OFF then back ON.
1105 132 SYSTEM The segment_OPT1 process did • Turn the power OFF then back ON.
1105 150 SYSTEM The segment clock in the ROM for • Turn the power OFF then back ON.
ERROR spot welding is different from the If the error occurs again, contact your
(SERVO) specified value. Yaskawa representative.
1105 151 SYSTEM The averaging time is not an even • Turn the power OFF then back ON.
ERROR number. (times) If the error occurs again, contact your
1105 152 SYSTEM An attempt to use a function that is • Turn the power OFF then back ON.
ERROR not allowed in the current ROM was If the error occurs again, contact your
(SERVO) made. Yaskawa representative.
1105 154 SYSTEM An error occurred in real-time data • Turn the power OFF then back ON.
ERROR transmission of SVSPOT Executing If the error occurs again, contact your
(SERVO) bit sent from MOTION. Yaskawa representative.
1105 160 SYSTEM The illegal data are stored in the • Turn the power OFF then back ON.
ERROR averaging buffer. If the error occurs again, contact your
1105 170 SYSTEM The sum value in the averaging • Turn the power OFF then back ON.
ERROR buffer is incorrect. If the error occurs again, contact your
1105 180 SYSTEM The “empty” status of averaging • Turn the power OFF then back ON.
ERROR buffer is incorrect. If the error occurs again, contact your
1105 201 SYSTEM The transfer of servo float condition • Turn the power OFF then back ON.
ERROR file was not successfully completed. If the error occurs again, contact your
1105 202 SYSTEM The transfer of gun condition file • Turn the power OFF then back ON.
ERROR was not successfully completed. If the error occurs again, contact your
1105 203 SYSTEM The transfer of gun pressure file • Turn the power OFF then back ON.
ERROR was not successfully completed. If the error occurs again, contact your
1105 204 SYSTEM The transfer of dry-spotting gun • Turn the power OFF then back ON.
ERROR pressure file was not successfully If the error occurs again, contact your
(SERVO) completed. Yaskawa representative.
1105 205 SYSTEM The transfer of servo hand charac- • Turn the power OFF then back ON.
ERROR teristics file was not successfully If the error occurs again, contact your
1105 206 SYSTEM The transfer of collision detecting • Turn the power OFF then back ON.
ERROR sencitivity setting file was not suc- If the error occurs again, contact your
(SERVO) cessfully completed. Yaskawa representative.
1105 207 SYSTEM The tool file transfer was not suc- • Turn the power OFF then back ON.
ERROR cessfully completed. If the error occurs again, contact your
1105 208 SYSTEM The transfer of linear servo float • Turn the power OFF then back ON.
ERROR condition file was not successfully If the error occurs again, contact your
8-19
Alarm Message List

Alarm Sub
Number Code
1105 209 SYSTEM The transfer of gun condition auxil- • Turn the power OFF then back ON.
ERROR iary file was not successfully com- If the error occurs again, contact your
(SERVO) pleted. Yaskawa representative.
1105 300 SYSTEM A logical error occurred in the • Turn the power OFF then back ON.
ERROR parameter for modification of reso- If the error occurs again, contact your
(SERVO) lution which was calculated by the Yaskawa representative.
parameter specified by CMOS.
1105 302 SYSTEM A logical error occurred in the • Turn the power OFF then back ON.
ERROR parameter. If the error occurs again, contact your
1105 500 SYSTEM Inconsistency of FP register. • Turn the power OFF then back ON.
1105 600 SYSTEM An uncontrolled axis was specified • Turn the power OFF then back ON.
ERROR when the instruction for group If the error occurs again, contact your
(SERVO) change was executed. Yaskawa representative.
1105 602 SYSTEM The PG power supply of the axis for • Turn the power OFF then back ON.
ERROR group change is ON. If the error occurs again, contact your
1105 603 SYSTEM The servo power supply of the axis • Turn the power OFF then back ON.
ERROR for group change is ON. If the error occurs again, contact your
1105 700 SYSTEM An error occurred in motor control • Turn the power OFF then back ON.
ERROR mode switching process. If the error occurs again, contact your
1105 800 SYSTEM The observer and collision detec- • Turn the power OFF then back ON.
ERROR tion function are set disabled If the error occurs again, contact your
(SERVO) although the broken belt detection Yaskawa representative.
function is set enabled.
1105 901 SYSTEM Vibration was detected in the serial • Turn the power OFF then back ON.
ERROR encoder. If the error occurs again, contact your
8-20
Alarm Message List

Alarm Sub
Number Code
1105 1000 SYSTEM The check item number of SVD • Turn the power OFF then back ON after
ERROR parameter is unmatched. cooling the power supply unit.
(SERVO) If the error occurs again, contact your
1105 1001 SYSTEM The check item number of SV • Turn the power OFF then back ON after
1105 1002 SYSTEM The check item number of SVM • Turn the power OFF then back ON after
1105 1003 SYSTEM The check item number of SVP • Turn the power OFF then back ON after
1105 1004 SYSTEM The check item number of AMC • Turn the power OFF then back ON after
1105 1005 SYSTEM The check item number of MFG • Turn the power OFF then back ON after
1105 1006 SYSTEM The check item number of MFA • Turn the power OFF then back ON after
1105 1007 SYSTEM The check item number of SVC • Turn the power OFF then back ON after
1105 1008 SYSTEM The check item number of SVS • Turn the power OFF then back ON after
1105 2000 SYSTEM The status setting to base block is • Turn the power OFF then back ON after
ERROR different from that of base block sig- cooling the power supply unit.
(SERVO) nal reading from JL056. If the error occurs again, contact your
(SERVO) nal writing to JL056. If the error occurs again, contact your
(SERVO) nal reading from micro program. If the error occurs again, contact your
1105 2100 SYSTEM The motioning software is not used • Turn the power OFF then back ON after
ERROR with circuit board as target. cooling the power supply unit.
1105 32807 SYSTEM An error occurred in the first • Turn the power OFF then back ON after
ERROR encoder communications. cooling the power supply unit.
1200 HIGH The temperature inside the control- Check if the in-panel cooling fan correctly
TEMPERATURE ler (CPS power supply unit) is too operates.
high.
8-21
Alarm Message List

Alarm Sub
Number Code
1202 0 FAULT An error occurred in the main CPU • Turn the power OFF then back ON.
board due to: If the error occurs again, contact your
- Defective board Yaskawa representative.
- Incorrect connection
- software control error
1204 0000_ COMMUNICA- Communications and power supply Check the noise source and take counter-
0000_ TION ERROR (IO error occurred in the I/O circuit measures to reduce the noise.
0000_ MODULE) board. (standard I/O of NIF01 unit) Reset the I/O module in maintenance mode.
0001 Replace the NIF01 circuit board.
1204 ****_ COMMUNICA- Communications and power supply Check the I/O signal line (NIF01-I/O circuit
****_ TION ERROR error occurred in the I/O circuit board) connectors and cables.
****_ (IO MODULE) board. (standard I/O of NIF01 unit) Check the connection of the I/O circuit board
***0 *: 0 is correct. 1 is incorrect. Bit and the external device. Check the noise
position of 1 shows the station source and take countermeasures to reduce
number of incorrect I/O circuit the noise.
board. Reset the I/O module in maintenance mode.
Replace the NIF01 circuit board.
1207 BROKEN B_ON The brake relay fuse was blown. Replace the brake relay fuse.
RELAY FUSE
(NIF01)
1208 BROKEN S_ON The servo-ON relay fuse was Replace the servo-ON relay fuse.
RELAY FUSE blown.
(NIF01)
1209 0000_ EXTERNAL WDT Defective watchdog timer circuit Replace the NIF01 circuit board.
00** BROKEN that checks the safety circuit
(NIF01) 0000_0001: 1 signal (PLD1) error
0000_0010: 2 signal (PLD1) error
1210 0000_ SERIAL COM- Checking error of toggle that Replace the NIF01 circuit board.
00** MUNICATION switches double checking safety
TOGGLE CHECK circuits in cycle of 1 ms
ERROR (NIF01) 0000_0001: 1 signal (PLD1) error
8-22
Alarm Message List

Alarm Sub
Number Code
1211 ****_ INPUT The signal does not have a match Check the signal.
****_ COMPARISON signal as a result the mutual check
****_ ERROR of a dual signal.
****_ (NIF01) 0000_0000_0000_0001: Panel sig-
nal emergency stop signal
(PBESP) unmatched error
0000_0000_0000_0010: Program-
ming pendant emergency stop sig-
nal (PPESP) unmatched error
0000_0000_0000_0100: External
emergency stop signal (EXESP)
unmatched error
0000_0000_0000_1000: System
CPU error (ERRCPU) unmatched
error
0000_0000_0001_0000: Servo ON
condition signal (SYSRDY)
unmatched error
0000_0000_0010_0000: Safety
plug signal (SAF) unmatched error
0000_0000_0100_0000: Servo ON
signal (SVON) unmatched error
0000_0000_1000_0000: External
servo ON signal (EXSVON)
unmatched error
0000_0001_0000_0000: Unused
0000_0010_0000_0000: Mainte-
nance signal (MAINTE) unmatched
error
0000_0100_0000_0001: Unused
0000_1000_0000_0001: Unused
0001_0000_0000_0000: Unused
0010_0000_0000_0000: Unused
0100_0000_0000_0000: Safety
speed mode selection (SSP)
unmatched error
1000_0000_0000_0000: Full speed
test (FST) unmatched error
1212 0000_ PLD MUTUAL The input comparison error Check the one of PPESP ,PBESP, EXESP,
00** MONITOR occurred. and SAF signals.
ERROR 0000_0001: 1 signal (PLD1) error
1213 0000_ MUTUAL WDT The input comparison error Check the one of PPESP ,PBESP, EXESP,
00** ERROR occurred. and SAF signals.
1214 0000_ PBESP RELAY The emergency stop button PBESP • Confirm that the cable is not short-circuited.
00** STICKING of the NX100 front door is melted • Replace if necessary.
and stuck.
1215 0000_ PPESP RELAY The emergency stop button of pro- • Confirm that the cable is not short-circuited.
00** STICKING gramming pendant PPESP is • Replace if necessary.
melted and stuck.
1216 0000_ EXESP RELAY The external emergency stop but- • Confirm that the cable is not short-circuited.
00** STICKING ton EXESP is melted and stuck. • Replace if necessary.
8-23
Alarm Message List

Alarm Sub
Number Code
1217 0000_ S_ON RELAY The servo-ON relay is melted and Replace the servo-ON relay.
00** STICKING stuck.
1218 0000_ B_ON RELAY The brake relay is melted and Replace the brake relay.
00** STICKING stuck.
1219 ANOTHER PLD The watchdog timer checking the • Turn the power OFF then back ON.
EXT WDT safety circuit is incorrect. If the error occurs again, replace the NIF unit.
ERROR (NIF
BOARD)
1300 SERVO CPU A synchronization error occurred • Correct the cable connection or replace the
SYNCHRONIZ- between CPUs. cable.
ING ERROR • Erroneous communications • Replace the main CPU board and/or servo
occurred between the main CPU control board.
board and the servo control circuit
board due to:
- Defective board
1301 0 COMMUNICA- • Erroneous communications • Correct the cable connection or replace the
TION ERROR occurred between main CPU cable.
(SERVO) board and servo control circuit • Replace the main CPU board and/or servo
board due to: control board.
- Defective board
(Communication status error)
board due to: control circuit board.
- Defective board
(Watchdog timer error)
- Defective board
(JL040 alarm)
- Defective board
(Communication status error)
1301 4 COMMUNICA- • Erroneous communications • Check the cable connection or replace the
- Defective board
(Data consistency error)
8-24
Alarm Message List

Alarm Sub
Number Code
TION ERROR occurred between the contactor cable.
(SERVO I/O) unit (for I/Os, manipulators, and • Replace the contactor unit and/or servo
external axes) and servo control control circuit board.
circuit board due to:
- Defective board
No interrupt from servo I/O com-
munications (JL080) occurred.
(Communication loop back)
- Defective board
The servo I/O communications
(JL080) received status is incor-
rect.
(No interrupt)
(SERVO I/O) unit (for I/Os, manipulators, and • Replace the contactor unit and/or control
external axes) and control circuit circuit board.
board due to:
- Defective board
(JL080) buffer switch status is
incorrect.
(Watchdog timer error)
- Defective board
(JL080) receiving status is incor-
rect.
(Command timeout)
(SERVO I/O) unit (for I/Os, manipulators, and • Replace the contactor unit and/or the servo
- Defective board
The communications loop back
value of servo I/O communications
(JL080) is incorrect.
(Communication loop back)
1302 11 COMMUNICA- The received address of JL080 is • Turn the power OFF then back ON after
TION ERROR unmatched with the sent address. cooling the power supply unit.
(SERVO I/O) If the error occurs again, contact your
1302 12 COMMUNICA- The received buffer of JL080 is • Turn the power OFF then back ON after
TION ERROR incorrect. cooling the power supply unit.
(SERVO I/O) If the error occurs again, contact your
8-25
Alarm Message List

Alarm Sub
Number Code
1303 Deci- ARITHMETIC An error occurred in control arith- • Turn the power OFF then back ON.
mal ERROR metic process or parameter arith- If the error occurs again, contact your
data (SERVO) metic process. Yaskawa representative.
1304 EX-AXIS BOARD • The external board is not mounted Mount an external board or correct the exter-
NOT INSTALLED although an external axis is speci- nal axis selection parameter.
fied.
• "With external axes" is specified
for the system without external
axes.
1306 Phy- AMPLIFIER The amplifier type setting is incor- Set the installed amplifier type in the system
sical TYPE MIS- rect. configuration.
axis MATCH
bit
1307 Phy- ENCODER TYPE The encoder type (motor model) Set the installed motor type in the system
sical MISMATCH setting is incorrect. configuration.
axis
bit
1308 CONVERTER The converter model set in the sys- Set the mounted converter model in system
TYPE tem configuration is different from configuration.
MISMATCH that of the one mounted.
1309 HARDWARE Converter hardware is incorrect. • Turn the power OFF then back ON after
ERROR cooling the power supply unit.
(CONVERTER) If the error occurs again, contact your
1310 CHARGE Converter hardware is incorrect. • Turn the power OFF then back ON.
ERROR If the error occurs again, replace the con-
(CONVERTER) verter.
1311 A/D DETECTION Converter hardware is incorrect. • Turn the power OFF then back ON after
ERROR cooling the power supply unit.
1312 ID ERROR Converter hardware is incorrect. • Turn the power OFF then back ON.
(CONVERTER) If the error occurs again, replace the con-
verter.
1325 COMMUNICA- Communication error occurred • Correct the encoder connection.
TION ERROR between the encoder and the servo • Check for noise.
(ENCODER) control circuit board due to: • Confirm the motor type.
- Misconnection of encoder If the error occurs again, replace the servo
- Noise from external devices control circuit board.
- Incorrect motor type
- Defective servo control circuit
board or encoder
1326 DEFECTIVE An error occurred in the encoder Turn the power OFF then back ON.
ENCODER position detecting circuit. If the error occurs again, replace the motor of
ABSOLUTE the corresponding axis.
DATA
1327 ENCODER The control power supply turned Stop the manipulator motion and then turn
OVER SPEED ON while the encoder was rotating ON the control power supply to check if the
(at more than 400min-1). error occurs. If the error occurs, the encoder
- The axis was in free-fall state. is defective. Replace the motor for the axis.
- Defective encoder
1328 DEFECTIVE Internal parameter error of the Turn the power OFF then back ON.
SERIAL serial encoder If the error occurs again, replace the motor of
ENCODER • The encoder fault may be the the corresponding axis.
cause.
1329 DEFECTIVE No response of encoder reset com- Turn the power OFF then back ON.
SERIAL pletion at the occurrnce of encoder If the error occurs again, replace the motor
ENCODER COM- backup error. (encoder) of the corresponding axis.
MAND The encoder fault may be the
cause.
8-26
Alarm Message List

Alarm Sub
Number Code
1330 MICRO PRO- Defective servo control circuit Turn the power OFF then back ON.
GRAM TRANS- board (Occurred only when the If the error occurs again, replace the servo
MIT ERROR control power supply turned ON.) control circuit board.
1335 INCOMPLETE The encoder resetting did not com- Connect a battery to the encoder.
ENCODER plete. No battery may be con- If the error still occurs after having connected
RESET nected. a battery, the encoder fault may be the
cause.
1343 1 COMMUNICA- No response from the converter. • Turn the power OFF then back ON after
TION ERROR (communications status error) cooling the power supply unit.
TION ERROR (command timeout) cooling the power supply unit.
TION ERROR (sent buffer FULL) cooling the power supply unit.
TION ERROR (CRC-16 error) cooling the power supply unit.
TION ERROR (error code received) cooling the power supply unit.
TION ERROR (received command error) cooling the power supply unit.
1349 POWER LOST The power to the motor became • Turn the power OFF then back ON.
DETECTION unstable. If the error occurs again, contact your
1350 CONTACTOR The mounted board type is Check the board type and replace if neces-
UNIT TYPE unmatched. The safety settings sary.
UNMATCH have been set for a controller that
does not meet the specifications
outlined in the safety standards.
1352 SERIAL COR- An error was detected in bit shifting • Turn the power OFF then back ON.
RECTION compensation. If the error occurs again, contact your
FAILED Yaskawa representative.
1355 SERIAL ENC Encoder multi-turn limit quantity Turn the power OFF then back ON. If the
MULTITURN error error occurs again, replace the motor
LIMIT ERR (encode) for axis.
1356 INVALID AXIS A task request was sent to an axis • Turn the power OFF then back ON.
SPECIFICATION of the group that was disabled by If the error occurs again, contact your
ERROR the group separation function. Yaskawa representative.
1357 PRESS ERROR The position or speed value Check the job.
exceeded the limit value during
presurring after gun electrode hit
the welded target. The motion after
gun electrode hits the welded target
is incorrect.
1360 PA NOT The prealigner is not mounted Check the prealigner connection.
INSTALLED although use of the prealigner has
been selected.
8-27
Alarm Message List

Alarm Sub
Number Code
1500 PLD INTERNAL PLD internal mutual monitoring Replace the TU circuit board.
MUTUAL MONI- error is sent from the TU circuit
TOR ERROR board.
(SERVO I/O)
1501 SVMX RELAY PLD internal mutual monitoring Replace the TU circuit board.
STICKING error is sent from the TU circuit
(SERVO I/O) board.
1502 TACTOR PLD internal mutual monitoring Replace the TU circuit board.
STICKING error is sent from the TU circuit
(SERVO I/O) board.
1503 INPUT COMPAR- PLD internal mutual monitoring Replace the TU circuit board.
ISON ERROR error is sent from the TU circuit
(SERVO I/O) board.
1504 TUSON RELAY PLD internal mutual monitoring Replace the TU circuit board.
BREAKDOWN error is sent from the TU circuit
(SERVO I/O) board.
1505 B_ON RELAY PLD internal mutual monitoring Replace the TU circuit board.
FUSE BREAK- error is sent from the TU circuit
DOWN (SERVO board.
I/O)
1506 MAIN TACTOR PLD internal mutual monitoring Replace the TU circuit board.
RELAY FUSE error is sent from the TU circuit
BREAKDOWN board.
(SERVO I/O)
1507 S_ON RELAY PLD internal mutual monitoring Replace the TU circuit board.
FUSE BREAK- error is sent from the TU circuit
DOWN (SERVO board.
I/O)
1508 MUTUAL WDT PLD internal mutual monitoring Replace the TU circuit board.
ERROR error is sent from the TU circuit
(SERVO I/O) board.
1509 EXTERNAL WDT PLD internal mutual monitoring Replace the TU circuit board.
OVER error is sent from the TU circuit
(SERVO I/O) board.
1510 EXTERNAL WDT PLD internal mutual monitoring Replace the TU circuit board.
BREAKDOWN error is sent from the TU circuit
(SERVO I/O) board.
1511 SERIAL COM- PLD internal mutual monitoring Replace the TU circuit board.
MUNICATION error is sent from the TU circuit
TOGGLE CHECK board.
ERROR
(SERVO I/O)
1512 POWER SUP- The fan of the power supply unit is • Turn the power OFF then back ON.
PLY FAN ALARM incorrect. If the error occurs again, contact your
1513 POWER The power supply unit overheated. • Turn the power OFF then back ON after
SUPPLY cooling the power supply unit.
OVERHEAT If the error occurs again, contact your
1514 OVERHEAT Amplifier overheated. • Turn the power OFF then back ON after
(AMPLIFIER) cooling the amplifier.
4000 MEMORY An error was detected at memory Initialize the tool file in maintenance mode,
ERROR check. and then load the tool file saved in the exter-
(TOOL FILE) • The memory for the tool file is nal memory device.
damaged.
8-28
Alarm Message List

Alarm Sub
Number Code
4001 MEMORY An error was detected at memory Initialize the user coordinates file in mainte-
ERROR check. nance mode, and then load the user coordi-
(USER COORD • The memory for the user coordinates file saved in the external memory
FILE) nates file is damaged. device.
4002 MEMORY An error was detected at memory Initialize the servo monitor signal file in main-
ERROR check. tenance mode, and then load the servo moni-
(SV MON • The memory for the servo monitor signal file saved in the external memory
SIGNAL FILE) tor signal file is damaged. device.
4003 MEMORY An error was detected at memory Initialize the weaving condition file in mainte-
ERROR check. nance mode, and then load the weaving con-
(WEAVING FILE) • The memory for the weaving condition file saved in the external memory
dition file is damaged. device.
4004 MEMORY An error was detected at memory • Reset the alarm, and set the home position-
ERROR check. ing data (absolute data) again.
(HOME POS • The memory for the home posi- • Load the home positioning file saved in the
FILE) tioning file is damaged. external memory device.
4005 MEMORY An error was detected at memory Load the second home position file saved in
ERROR check. the external memory device.
(SECOND HOME • The memory for the second home
POS) position file is damaged.
4006 MEMORY An error was detected at memory Initialize the arc welding Power Source condi-
ERROR check. tion file in the maintenance mode, and then
(POWER • The memory for the arc welding load the arc welding Power Source condition
SOURCE COND) Power Source condition file is file saved in the external memory device.
damaged.
4007 MEMORY An error was detected at memory Initialize the arc start condition file in the
ERROR check. maintenance mode, and then load the arc
(ARC START • The memory for the arc start con- start condition file saved in the external mem-
COND FILE) dition file is damaged. ory device.
4008 MEMORY An error was detected at memory Initialize the arc end condition file in the main-
ERROR check. tenance mode, and then load the arc end
(ARC END • The memory for the arc end con- condition file saved in the external memory
COND FILE) dition file is damaged. device.
4009 MEMORY An error was detected at memory Initialize the arc auxiliary condition file in the
ERROR check. maintenance mode, and then load the arc
(ARC AUX COND • The memory for the arc auxiliary auxiliary condition file saved in the external
FILE) condition file is damaged. memory device.
4010 MEMORY An error was detected at memory Initialize the COM-ARC condition file in the
ERROR check. maintenance mode, and then load the COM-
(COM-ARC • The memory for the COM-ARC ARC condition file saved in the external
COND FILE) condition file is damaged. memory device.
4012 MEMORY An error was detected at memory Initialize the link servo float condition file in
ERROR check. the maintenance mode, and then load the
(LINK • The memory for the link servo link servo float condition file saved in the
SERVOFLOAT) float condition file is damaged. external memory device.
4013 MEMORY An error was detected at memory Initialize the linear servo float condition file in
ERROR check. the maintenance mode, and then load the lin-
(LINEAR • The memory for the linear servo ear servo float condition file saved in the
SERVOFLOAT) float condition file is damaged. external memory device.
4014 MEMORY An error was detected at memory Initialize the file for calibration between
ERROR (ROBOT check. manipulators in the maintenance mode, and
CARIB FILE) • The memory for the file for calibra- then load the file for calibration between
tion between manipulators is manipulators saved in the external memory
damaged. device.
4017 MEMORY An error was detected at memory Initialize the Power Source characteristics
ERROR check. user definition file in the maintenance mode,
(POWER SRC • The memory for the Power Source and then load the Power Source charactris-
USER DEF) characteristics user definition file tics user definition file saved in the external
is damaged. memory device.
8-29
Alarm Message List

Alarm Sub
Number Code
4018 MEMORY An error was detected at memory Initialize the ladder program file in the main-
ERROR check. tenance mode, and then load the ladder pro-
(LADDER PRG • The memory for the ladder program file saved in the external memory
FILE) gram file is damaged. device.
4019 MEMORY An error was detected at memory Initialize the user coordinates file in the main-
ERROR check. tenance mode, and then load the user coodi-
(CUTTING • The memory for the user coordinates file saved in the external memory
COND FILE) nates file is damaged. device.
4020 MEMORY An error was detected at memory Initialize the work home position file.
ERROR check.
(WORK HOME • The memory for the work home
POS FILE) position file is damaged.
4021 MEMORY An error was detected at memory Initialize the conveyor condition file in the
ERROR check. maintenance mode, and then load the con-
(CONVEYOR • The memory for the conveyor conveyor condition file saved in the external
COND FILE) dition file is damaged. memory device.
4025 MEMORY An error was detected at memory Initialize the interrupt job file in the mainte-
ERROR check. nance mode, and then load the interrupt job
(INTERRUPT • The memory for the interrupt job file saved in the external memory device.
JOB FILE) file is damaged.
4028 MEMORY An error was detected at memory Initialize the sensor monitoring condition file
ERROR check. in the maintenance mode, and then load the
(SENSOR MON • The memory for the sensor moni- sensor monitoring condition file saved in the
COND FILE) toring condition file is damaged. external memory device.
4031 MEMORY An error was detected at memory Initialize the spot welding gun condition file in
(GUN COND • The memory for the spot welding spot welding gun condition file saved in the
FILE) gun condition file is damaged. external memory device.
4032 MEMORY An error was detected at memory Initialize the spot welding SPOT WELD con-
ERROR check. dition file in the maintenance mode, and then
(SPOT WELD • The memory for the spot welding load the spot welding Power Source condi-
COND) Power Source condition file is tion file saved in the external memory device.
damaged.
4033 MEMORY An error was detected at memory Initialize the gun pressure file in the mainte-
ERROR check. nance mode, and then load the gun pressure
(GUN PRES- • The memory for the gun pressure file saved in the external memory device.
SURE FILE) file is damaged.
4034 MEMORY An error was detected at memory Initialize the anticipation outputs file in the
ERROR check. maintenance mode, and then load the antici-
(ANTICIPATION • The memory for the anticipation pation outputs file saved in the external mem-
OT FILE) outputs (OT) file is damaged. ory device.
4035 MEMORY An error was detected at memory Initialize the anticipation outputs file in the
ERROR check. maintenance mode, and then load the antici-
(ANTICIPATION • The memory for the anticipation pation outputs file saved in the external mem-
OG FILE) outputs (OG) file is damaged. ory device.
4036 MEMORY An error was detected at memory Initialize the wear amount file in the mainte-
ERROR check. nance mode, and then load the wear amount
(WEARING FILE) • The memory for the wear amount file saved in the external memory device.
file is damaged.
4037 MEMORY An error was detected at memory Initialize the FULL/SHORT OPEN position
ERROR check. setting file in the maintenance mode, and
(STROKE • The memory for the FULL/SHORT then load the FULL/SHORT OPEN position
POSITION) OPEN position setting file is dam- setting file saved in the external memory
aged. device.
4038 MEMORY An error was detected at memory Initialize the dry-spotting pressure file in the
ERROR check. maintenance mode, and then load the dry-
(PRESSURE • The memory for the dry-spotting spotting pressure file saved in the external
FILE) pressure file is damaged. memory device.
8-30
Alarm Message List

Alarm Sub
Number Code
4039 MEMORY An error was detected at memory Initialize the form cut file in the maintenance
ERROR check. mode, and then load the form cut file saved in
(FORM CUT • The memory for the form cut file is the external memory device.
FILE) damaged.
4040 MEMORY An error was detected at memory Initialize the shock level file in the mainte-
ERROR (SHOCK check. nance mode, and then load the shock level
LEVEL FILE) • The memory for the shock level file saved in the external memory device.
file is damaged.
4041 MEMORY An error was detected at memory Initialize the spot I/O allocation file in the
ERROR check. maintenance mode, and then load the spot
(SPOT IO • The memory for the spot I/O allo- I/O allocation file saved in the external mem-
ALLOCATE FL) cation file is damaged. ory device.
4042 MEMORY An error was detected at memory Initialize the vision condition file in the main-
ERROR check. tenance mode, and then load the vision con-
(VISION FILE) • The memory for the vision condi- dition file saved in the external memory
tion file is damaged. device.
4043 MEMORY An error was detected at memory Initialize the vision calibration file in the main-
ERROR check. tenance mode, and then load the vision cali-
(VISION • The memory for the vision calibra- bration file saved in the external memory
CALIBRATION) tion file is damaged. device.
4044 MEMORY An error was detected at memory Initialize the welding pulse condition file in the
ERROR check. maintenance mode, and then load the weld-
(WELDING • The memory for the welding pulse ing pulse condition file saved in the external
PULSE COND condition file is damaged. memory device.
FILE)
4045 MEMORY An error was detected at memory Initialize the welding pulse selection file in the
ERROR check. maintenance mode, and then load the weld-
(WELDING • The memory for the welding pulse ing pulse selection file saved in the external
PULSE selection file is damaged. memory device.
SELECTION
FILE)
4046 MEMORY An error was detected at memory Initialize the conveyor calibration file in the
ERROR check. maintenance mode, and then load the con-
(CONVEYOR • The memory for the conveyor cali- veyor calibration file saved in the external
CALIBRATION) bration file is damaged. memory device.
4047 MEMORY An error was detected at memory Initialize the macro definition file in the main-
ERROR (MACRO check. tenance mode, and then load the macro defi-
DEFINITION • The memory for the macro defini- nition file saved in the external memory
FILE) tion file is damaged. device.
4048 MEMORY An error was detected at memory Initialize the sealer gun characteristics file in
(SERVO S-GUN • The memory for the sealer gun sealer gun characteristics file saved in the
FILE) characteristics file is damaged. external memory device.
4049 MEMORY An error was detected at memory Initialize the painting amount correction file in
(PASTE QUAN • The memory for the painting painting amount correction file saved in the
COMPENSA- amount correction file is dam- external memory device.
TION FILE) aged.
4050 MEMORY An error was detected at memory Initialize the axis motion I/O allocation file in
(AXIS I/O ALLO- • The memory for the axis motion I/ axis motion I/O allocation file saved in the
CATION FILE) O allocation file is damaged. external memory device.
4051 MEMORY An error was detected at memory Initialize the gun characteristics auxiliary file
(GUN COND • The memory for the gun charac- gun characteristics auxiliary file saved in the
AUX FILE) teristics auxiliary file is damaged. external memory device.
4052 MEMORY An error was detected at memory Initialize the tool interference file in the main-
ERROR check. tenance mode, and then load the tool inter-
(TOOL INTER- • The memory for the tool interfer- ference file saved in the external memory
FERENCE FILE) ence file is damaged. device.
8-31
Alarm Message List

Alarm Sub
Number Code
4053 MEMORY An error was detected at memory Initialize the painting system setting file in the
ERROR check. maintenance mode, and then load the paint-
(PAINTING SYS- • The memory for the painting sys- ing system setting file saved in the external
TEM CONFIGU- tem setting file is damaged. memory device.
RATION)
4054 MEMORY An error was detected at memory Initialize the painting device characteristics
ERROR check. file in the maintenance mode, and then load
(PAINTING • The memory for the painting the painting device characteristics file saved
SPECIAL) device characteristics file is dam- in the external memory device.
aged.
4055 MEMORY An error was detected at memory Initialize the painting CCV file in the mainte-
ERROR check. nance mode, and then load the painting CCV
(CCV-PAINT • The memory for the painting CCV file saved in the external memory device.
TABLE) file is damaged.
4056 MEMORY An error was detected at memory Initialize the paint filling file in the mainte-
ERROR check. nance mode, and then load the paint filling
(PLUG VOLUME • The memory for the paint filling file file saved in the external memory device.
FILE) is damaged.
4057 MEMORY An error was detected at memory Initialize the EVB gun file in the maintenance
ERROR check. mode, and then load the EVB gun file saved
(EVB GUN • The memory for the EVB gun file in the external memory device.
COND) is damaged.
4058 MEMORY An error was detected at memory Initialize the EVB turbine file in the mainte-
ERROR check. nance mode, and then load the EVB turbine
(EVB TURBINE • The memory for the EVB turbine file saved in the external memory device.
COND) file is damaged.
4059 MEMORY An error was detected at memory Initialize the EVB paint file in the mainte-
ERROR check. nance mode, and then load the EVB paint file
(EVB PAINT • The memory for the EVB paint file saved in the external memory device.
COND) is damaged.
4060 MEMORY An error was detected at memory Initialize the clearance file in the maintenance
ERROR (CLEAR- check. mode, and then load the clearance file saved
ANCE FILE) • The memory for the clearance file in the external memory device.
is damaged.
4061 MEMORY An error was detected at memory Initialize the gaging sensor file in the mainte-
ERROR check. nance mode, and then load the gaging sen-
(GAGING SEN- • The memory for the gaging sensor sor file saved in the external memory device.
SOR FILE) file is damaged.
4062 MEMORY An error was detected at memory Initialize the linear scale condition file in the
ERROR check. maintenance mode, and then load the linear
(LINEAR SCALE • The memory for the linear scale scale condition file saved in the external
FILE) condition file is damaged. memory device.
4063 MEMORY An error was detected at memory Initialize the conveyor condition auxiliary file
(CONVEYOR • The memory for the conveyor con- conveyor condition auxiliary file saved in the
COND SUPP.) dition auxiliary file is damaged. external memory device.
4064 MEMORY An error was detected at memory Initialize the weaving synchronizing welding
ERROR check. condition file in the maintenance mode, and
(WEAVING SYN- • The memory for the weaving syn- then load the weaving synchronizing welding
CHRONIZING chronizing welding condition file is condition file saved in the external memory
WELD FILE) damaged. device.
4100 OVERRUN One of the manipulator overrun limit Move back the manipulator out of the overrun
(ROBOT AXIS) switches activated. limit switch range. (Refer to the INSTRUC-
TIONS.)
4101 OVERRUN One of the external-axis overrun Move back the external axis out of the over-
(EXTERNAL limit switches activated. run limit switch range. (Refer to the
AXIS) INSTRUCTIONS.)
8-32
Alarm Message List

Alarm Sub
Number Code
4102 SYSTEM DATA The system parameters are modi- Turn the power OFF then back ON.
HAS BEEN fied.
CHANGED • An attempt was made to turn ON
the servo power supply after hav-
ing modified the system parame-
ters.
The data indicates the cause of
alarm.
1: System parameter modified
4103 1 PARALLEL An error occurred in the indepen- Complete the sub task by PWAIT command.
START dent control startup operation.
INSTRUCTION • Sub task being executed:
ERROR Although a job is being executed
by instructed sub task, an attempt
was made to execute another job
by the sub task.
4103 2 PARALLEL An error occurred in the indepen- Check the job to be started and the execution
START dent control startup operation. timing for start command again.
INSTRUCTION • Group axis being used:
ERROR The job operated by another sub
task uses the same group axis.
INSTRUCTION • Multiple start of same job:
ERROR The job that was tried to be
started was executed by another
sub task.
4103 4 PARALLEL An error occurred in the indepen- Register the master job for sub task.
INSTRUCTION • Master job unregistration:
ERROR Although the master job was not
registered, an attempt was made
to execute PSTART SUB (job
name omitted).
INSTRUCTION • Synchronization instruction error:
ERROR When restarted by PSTART, syn-
chronization instruction status of
the sub task under interruption
was different from the status to
restart.
4103 6 PARALLEL An error occurred in the indepen- Reset the alarm, and then start the sub task.
INSTRUCTION • Stopped by an alarm:
ERROR An attempt was made to start the
sub task which is stopped by an
alarm.
4104 WRONG An error occurred when an instruc- Reset the alarm, and then remove the cause
EXECUTION OF tion was executed by the data according to the alarm data.
LOAD INST transmission DCI function. The
data indicates the cause of alarm.
(Refer to the manual for Data
Transmission Function for details.)
SAVE INST transmission DCI function. The
8-33
Alarm Message List

Alarm Sub
Number Code
DELETE INST transmission DCI function. The
4107 OUT OF RANGE The position difference between Move the manipulator or station to the zero
(ABSO DATA) when the power was turned OFF position by the axis operation and check the
and when the power was turned home position alignment marks (the arrow).
ON again exceeded the tolerance If the zero position does not match the home
for the manipulator or a station. position, check if there is no error in the PG
system of the axis for which the alarm
occurred.
4109 0000_ DC24V POWER The external 24V power for I/Os is • Check if the fuse of robot I/F unit (NIF01) is
00** SUPPLY not output. not blown.
FAILURE (I/O) 0000_0001: Fuse blown (NIF01 • Check the 24V external power supply.
unit) • Check the communications cable for the I/O
0000_0011: External 24 V power module
supply error If the error occurs again, contact your
4110 SHOCK SEN- The shock sensor activated. Remove the cause of shock sensor activa-
SOR ACTIVA- tion.
TION
4111 BRAKE FUSE The brake fuse blew out. Replace the fuse.
BREAKDOWN
4112 1 DATA SENDING An error occurred during data trans- Reset the alarm, and then remove the cause.
ERROR mission.
• Retry over of NAK
ERROR mission.
• Retry over for timeout in timer A
ERROR mission.
• Retry over for mutual response
error
4113 1 DATA RECEIV- An error occurred during data trans- Reset the alarm, and then remove the cause.
ING ERROR mission.
• Reception timeout (timer A)
ING ERROR mission.
• Reception timeout (timer B)
ING ERROR mission.
• Heading length is too short.
ING ERROR mission.
• Heading length is too long.
ING ERROR mission.
• The header No. error
ING ERROR mission.
• The text length exceeded 256
characters.
8-34
Alarm Message List

Alarm Sub
Number Code
4114 1 TRANSMISSION An error occurred during data trans- Reset the alarm, and then remove the cause.
HARDWARE mission.
ERROR • Overrun error
HARDWARE mission.
ERROR • Parity error
HARDWARE mission.
ERROR • Framing error
HARDWARE mission.
ERROR • Transmission timeout (timer A)
HARDWARE mission.
ERROR • Transmission timeout (timer B)
SYSTEM BLOCK mission.
(This alarm occurs when received
data cause inconsistency on the
system although the transmission
protocol is correct. Mainly, this
alarm occurs due to an illegal trans-
mission or erronous report at the
data sending side.)
• Received EOT while waiting ACK.
data sending side.)
• Received EOT while waiting ENQ.
data sending side.)
• Received EOT before last block
reception.
data sending station.)
• Received codes other than EOT
after last block reception.
4116 TRANSMISSION An error occurred during data trans- • Turn the power OFF then back ON.
SYSTEM mission. If the error occurs again, contact your
ERROR Yaskawa representative.
8-35
Alarm Message List

Alarm Sub
Number Code
4119 FAN ERROR The rotation speed of in-panel cool- Reset the alarm, and then move the manipu-
(IN CONTROL ing fan decreased. lator to the safe position in the teach mode.
BOX) The in-panel cooling fan needs to be
replaced. Contact your Yaskawa representa-
tive.
4121 COOLING FAN 1 The rotation speed of the cooling Reset the alarm, and then move the manipu-
ERROR fan 1 with alarm sensor connected lator to the safe position in the teach mode.
to the contactor unit decreased. The cooling fan 1 needs to be replaced.
Contact your Yaskawa representative.
4200 SYSTEM An error occurred during the access • Reset the alarm, and then try again.
ERROR to file data (during file edition or • Turn the power OFF then back ON.
(FILE DATA) external memory device operation). If the error occurs again, contact your
4201 -1 SYSTEM An error occurred during the access • Reset the alarm, and then try again.
ERROR (JOB) to a job in parameter specifications. • Turn the power OFF then back ON.
4201 -2 SYSTEM Access time exceeded the limit dur- • Reset the alarm, and then try again.
ERROR (JOB) ing the access to a job. • Turn the power OFF then back ON.
4201 -3 SYSTEM The access to a job could not be • Reset the alarm, and then try again.
ERROR (JOB) performed with the specified job • Turn the power OFF then back ON.
name. This occurred when access- If the error occurs again, contact your
ing a job. Yaskawa representative.
4201 -4 SYSTEM The character not allowed was • Reset the alarm, and then try again.
ERROR (JOB) used as a job name. This occurred • Turn the power OFF then back ON.
when accessing a job. If the error occurs again, contact your
4201 -5 SYSTEM A job was newly created with the • Reset the alarm, and then try again.
ERROR (JOB) same name of the job already spec- • Turn the power OFF then back ON.
ified in the memory. This occurred If the error occurs again, contact your
when accessing a job. Yaskawa representative.
4201 -6 SYSTEM The allowable job registration area Delete unused jobs and/or expand CMOS.
ERROR (JOB) (memory) was exceeded. This
occurred when accessing a job.
4201 -7 SYSTEM A job that did not exist in the mem- • Reset the alarm, and then try again.
ERROR (JOB) ory was specified. This occurred • Turn the power OFF then back ON.
4201 -8 SYSTEM An attempt was made to change Release the prohibition and change it.
ERROR (JOB) the contents for the job prohibited
from being edited. This occurred
when accessing a job.
ERROR (JOB) to a job in handle value. • Turn the power OFF then back ON.
8-36
Alarm Message List

Alarm Sub
Number Code
ERROR (JOB) to a job in job data control system. • Turn the power OFF then back ON.
ERROR (JOB) to a job in sequence number of the • Turn the power OFF then back ON.
accessed job. If the error occurs again, contact your
ERROR (JOB) to a job in step number of the • Turn the power OFF then back ON.
accessed job. If the error occurs again, contact your
4201 -13 SYSTEM A job specified at job search did not • Reset the alarm, and then try again.
ERROR (JOB) exist in the memory. This occurred • Turn the power OFF then back ON.
4201 -14 SYSTEM There was an instruction that did Check the NCP01 and NCP02 software ver-
ERROR (JOB) not exist in a job because of incon- sions before/after updating.
sistency of the system software.
This occurred when accessing a
job.
4201 -16 SYSTEM Unused handles were lacking when • Reset the alarm, and then try again.
ERROR (JOB) an attempt was made to open a job. • Turn the power OFF then back ON.
4201 -18 SYSTEM The number of instructions added Delete unnecessary instructions and add
ERROR (JOB) to a job exceeded 9999. This new instructions.
occurred when accessing a job.
4201 -19 SYSTEM The number of steps added to a job Delete unnecessary steps and add new
ERROR (JOB) exceeded 9999. This occurred steps.
when accessing a job.
4201 -20 SYSTEM A job was newly created with the • Reset the alarm, and then try again.
ERROR (JOB) same name of the undefined job • Turn the power OFF then back ON.
already specified in the memory. If the error occurs again, contact your
This occurred when accessing a Yaskawa representative.
job.
4201 -99 SYSTEM A job data in the memory was • Reset the alarm, and then try again.
ERROR (JOB) destroyed. This occurred when • Turn the power OFF then back ON.
accessing a job. If the error occurs again, contact your
ERROR to a job (during job edition or exter- • Turn the power OFF then back ON.
(JOB) nal memory device operation). If the error occurs again, contact your
4203 -1 SYSTEM An error occurred in position data Initialize the job in the maintenance mode.
ERROR (POSI- control process.
TION DATA) • The memory area for position data
is lacking at the initialization of the
position data control process.
TION DATA) • The number of axes for all the
control groups is zero at the ini-
tialization of the position data con-
trol process
8-37
Alarm Message List

Alarm Sub
Number Code
4203 -3 SYSTEM An error occurred in position data • When the data is loaded from the external
ERROR (POSI- control process. memory, the control axis for external mem-
TION DATA) • The number of axes for position ory is different from that for system. Initial-
data is zero. ize the job.
• When a point is added, the job is not initial-
ized after the control axis for system was
changed to a different control group by sys-
tem configuration. Initialize the job.
TION DATA) • The number of stored position
data exceeded the maximum
stored data at the initialization of
the position data control process.
TION DATA) • The memory size of the position
data exceeded the maximum
memory size at the initialization of
the position data control process.
TION DATA) • Unused position data file is
destroyed.
4203 -7 SYSTEM An error occurred in position data Delete unnecessary steps (position data) and
ERROR (POSI- control process. add position data.
TION DATA) • Unused position data file does not
exist.
TION DATA) • Position data file is destroyed.
TION DATA) • Position data control information is
destroyed.
TION DATA) • An error occurred in specified
position data number.
4203 -11 SYSTEM An error occurred in position data If the error occurs again, contact your
ERROR (POSI- control process. Yaskawa representative.
TION DATA) • Position data is not registered.
TION DATA) • An attempt was made to access
the undefined position data.
TION DATA) • An attempt was made to access
the position data for the undefined
control group.
TION DATA) • Position data control is not initial-
ized.
TION DATA) • The number of axes for the control
groups exceeded the limit.
8-38
Alarm Message List

Alarm Sub
Number Code
TION DATA) • An error occurred in exclusive
control.
TION DATA) • An error occurred in exceptional
control.
ERROR to position data (in playback opera- • Turn the power OFF then back ON.
(POSITION tion or in motion). If the error occurs again, contact your
DATA) Yaskawa representative.
4206 SYSTEM An error occurred in data transmis- • Turn the power OFF then back ON.
ERROR sion. If the error occurs again, contact your
(TRANSMIS- Yaskawa representative.
SION)
4207 1 SYSTEM A system error occurred in • Reset the alarm, and then try again.
ERROR MOTION. • Turn the power OFF then back ON.
(MOTION) <Command-related processsing If the error occurs again, contact your
FATAL error> Yaskawa representative.
• An interrupt undefined in the main
command from the system control
section occurred.
(MOTION) <Command-related processsing If the error occurs again, contact your
• An interrupt undefined in the sub
command from the system control
section occurred.
(MOTION) <Command-related processing If the error occurs again, contact your
• The interrupt command that was
sent previously from the system
control section is being pro-
cessed.
• An error was detected in the inter-
rupt command data from the sys-
tem control section.
• An undefined command was
detected in the sub segment task
of MOTION.
detected in the servo-related pro-
cessing of MOTION.
8-39
Alarm Message List

Alarm Sub
Number Code
detected in the offline processing
task of MOTION.
detected in the utility task of
MOTION.
(MOTION) <Object Token not generated> If the error occurs again, contact your
• Task Token is not generated. Yaskawa representative.
• Mail-box Token is not generated. Yaskawa representative.
• Semaphore Token is not gener- Yaskawa representative.
ated.
• Memory-pool Token is not gener- Yaskawa representative.
ated.
(MOTION) <RMS960 system call error> If the error occurs again, contact your
• RMS receiving data error Yaskawa representative.
(MOTION) <RMS960 system calll error> If the error occurs again, contact your
• RMS sending data error Yaskawa representative.
• RMS receiving unit error Yaskawa representative.
• RMS sending unit error Yaskawa representative.
• Task generation error Yaskawa representative.
• Mail-box generation error Yaskawa representative.
• Semaphore generation error Yaskawa representative.
8-40
Alarm Message List

Alarm Sub
Number Code
• Token pointer error Yaskawa representative.
(MOTION) <Object Token work area overflow> If the error occurs again, contact your
• TCB area overflow Yaskawa representative.
• Stack area overflow Yaskawa representative.
• Mail-box area overflow Yaskawa representative.
• Semaphore area overflow Yaskawa representative.
(MOTION) <Application-processing-related If the error occurs again, contact your
• Main command error
• MSS system - ID number error
• HA-MSS system number error
• Incorrect control group designa-
tion
• Offline bank semaphore reception
error
• m_gen_area semaphore recep-
tion error
• Offline HA processing timeout
8-41
Alarm Message List

Alarm Sub
Number Code
• DM_BANK flag error (DM_BANK
conversion processing)
• S → M offline processing com-
mand type error
• SL data transmission request
function error
• Error in designation of application
in the request of general-purpose
data preset for each application.
• Error in the parameter to prepare
the speed data table
the global-variable control table
the axis control table
the online servo-constant modifi-
cation table
• Mail-box of sequence task is not
ready.
• Control-group usage undefined
8-42
Alarm Message List

Alarm Sub
Number Code
• Segment task polling command
error
• Physical axis number error
• The control group impossible to
release the brake
• Sub-segment request FULL
• Sub-segment process timeout
• Data latch request FULL
• Data latch process timeout
• AXIS command request FULL
• AXIS command process timeout
4207 56 SYSTEM A system error occurred in Reset the alarm, and then try again. Turn the
ERROR MOTION. power OFF then back ON. If the error occurs
(MOTION) <Application-processing-related again, contact your Yaskawa representative.
FATAL error>
• Positioning monitor request FULL
• Positioning monitor process time-
out
8-43
Alarm Message List

Alarm Sub
Number Code
• Failed AXIS servo OFF command
request during emergency stop
• Memory pool area overflow
• Conversion primary expression for
Power Source command ↔ EW
command not prepared
• Duplicated request error during
master control-group tracking
• GVM shared resource sema-
phore error
• Job queue DEQUE error
• Convertion primary expression for
painting device command ↔ EW
command not prepared
• Execution system decision table
not set
• Unknown mode data (Without
TEACH/PLAY mode data)
• Shift-value output timeout of the
general-purpose sensor
8-44
Alarm Message List

Alarm Sub
Number Code
• Interrupt main status set
• System number error at the mas-
ter side in twin synchronous sys-
tem
• No data link added to the com-
mand
• Setting status error of the user
coordinates file
• Previous path data reference error
• Target position preparation error in
arc-retry shift motion mode
• Request to compensate position
error of the axis that is not end-
less axis
• Inner track zone status error
• Instruction queue and instruction
system data area overflow
• Offline answer bank flag error
8-45
Alarm Message List

Alarm Sub
Number Code
• Path and trace queue ENQUE
BANK error
• Pending and block end request
FULL
• Base axis file type error
• Output buffer SYSCON for auto-
matic test data in use
• Conversion completion status for
AXIS section feedback latch data
not established
• Sensor number (SL#) error
• File C1 through C3 for calibtaion
between manipulators not set
• File C1 through C3 for conveyor
calibration not set
• HA function error
(conv_pos_data())
(conv_shift_data())
8-46
Alarm Message List

Alarm Sub
Number Code
(trans_angle_to_pulse())
(trans_pulse_to_angle())
(conv_pulse_to_angle())
(pr_atinf_pos_make())
(make_pos_data())
• Control-group axis configuration
information parameter error
• Error in the parameter for the table
for physical axes
• Error in the parameter for the table
for physical TU
• Excessive number of control
group axes in use
• JOG and PLAY maximum speed
setting parameter error
8-47
Alarm Message List

Alarm Sub
Number Code
• Job argument over
• Job argument stack overflow
• Job argument stack underflow
• Designation error of the fetched
feedback pulse area at prepara-
tion of current value
• Timeout for waiting permission to
modify the number of averaging
times
• Object undefined for CLEAR
instruction
• No space in RT_BANK setting
area for correction-amount data
• Queue operation error for vari-
able write-in history at prereading
(at ENQUE)
(at DEQUE)
(undefined operation)
8-48
Alarm Message List

Alarm Sub
Number Code
(data length too long)
• Queue operation error for score-
board setting history (at ENQUE)
board setting history (at DEQUE)
board setting history (undefined
operation)
board setting history (data length
too long)
• Queue operation error for instruc-
tion execution (at ENQUE)
tion execution (at DEQUE)
tion execution (undefined opera-
tion)
tion execution (data length too
long)
8-49
Alarm Message List

Alarm Sub
Number Code
• Queue operation error for WORK
ID conveyor (at ENQUE)
ID conveyor (at DEQUE)
ID conveyor (undefined opera-
tion)
ID conveyor (data length too long)
IN/OUT checking conveyor (at
ENQUE)
IN/OUT checking conveyor (at
DEQUE)
IN/OUT checking conveyor
(undefined operation)
IN/OUT checking conveyor (deta
length too long)
• Queue operation error for waiting
for semaphore for LOCK instruc-
tion (at ENQUE)
8-50
Alarm Message List

Alarm Sub
Number Code
tion (at DEQUE)
tion (undefined operation)
tion (data length too long)
• Impossible to execute system
exclusive for system job
• Event queue number range
exceeded
• No motor-gun control group for
ESRCH instruction
• The number of WORK ID data and
the MAX. WORK FIND COUNT
unmatched (MOTION ≠ CV)
• The number of WORK IN/OUT
data and the MAX. WORK FIND
COUNT unmatched (MOTION ≠
CV)
• Excessive number of schedulings
for execution of instructions
8-51
Alarm Message List

Alarm Sub
Number Code
• Instruction execution scheduling
impossible
• Illegal 1st-line move instruction at
execution of +SMOV instruction
• Impossible to execute the slave
circular interpolation and the mas-
ter circular interpolation at the
same time
• Impossible to execute the slave
spline interpolation and the mas-
ter spline interpolation at the
same time
• Illegal index value for a +MOVx
instruction
• No xth-line move instruction exists
where the master control group
belongs.
• Marking error for WORK ID con-
veyor queue (empty queue)
• Marking error for WORK IN/OUT
conveyor queue (empty queue)
• Data error 1 at restarting after an
emergency stop (actual status
and the data status unmatched)
8-52
Alarm Message List

Alarm Sub
Number Code
• Timeout for receiving segment
data output request
• The number which designates the
setting area of correction amount
in RT_BANK exceeded the limit
value.
• Task error of the function calling
source (cv_sync_intr ( ))
• No control group for motor gun for
clearance move instruction
• Motor gun conditon file number
error (including gun pressure file)
• GETTOOLW manipulator desig-
nation error
• Overflow of entry number for
instruction execution
8-53
Alarm Message List

Alarm Sub
Number Code
• Data latch processing (function
number overflow)
• Data latch processing (real-time
status number overflow)
• Failed to set a timer unit. (No allo-
cation space for timer unit setting)
• Segment data missing (seg_t_req
was not received in time.)
• GETS instruction internal error
• SETFILE undefined file
• GETFILE undefined file
• The parameter was destroyed
when a GETPRM instruction was
executed.
• Null pointer assignment detected
• Function or other processing
parameter error
8-54
Alarm Message List

Alarm Sub
Number Code
• System clock (RTC) setting error
• System task priority arrangement
error
• VxWorks primitive error
(msgQCreate)
(msgQSend)
(msgQReceive)
(semBCreate)
(semGive)
(semTake)
• Failed system job environment
configuration
4208 1 SYSTEM A system error occurred in the path Reset the alarm, and then try again.
ERROR (ARITH) control section. If the error occurs again, contact your
• Prereading task is not completed. Yaskawa representative.
• The answer bank flag is already Yaskawa representative.
set.
8-55
Alarm Message List

Alarm Sub
Number Code
• Inner path motion is impossible. Yaskawa representative.
• Error in the number of position Yaskawa representative.
data
• The averaging buffer in the arith- Yaskawa representative.
metic section is destroyed.
• No previous bank exists. Yaskawa representative.
• The answer bank flag is ON. Yaskawa representative.
• An error occurred in preparation of Yaskawa representative.
current position.
• Mails could not correctly be Yaskawa representative.
received in the current task.
• Spline-curve path designation Yaskawa representative.
error
• The previous bank’s prereading Yaskawa representative.
conversion could not correctly be
completed.
• A manipulator designation error Yaskawa representative.
occurred at JOG operation using
the external reference point.
• Designation error of cubic interfer- Yaskawa representative.
ence coordinates
• Path control position data error of Yaskawa representative.
prereading bank
• Weaving control position data Yaskawa representative.
error of prereading bank
• Station/base axis motion com- Yaskawa representative.
mand error
• User coordinates number error Yaskawa representative.
8-56
Alarm Message List

Alarm Sub
Number Code
• Processing error in re-preparation Yaskawa representative.
of segment control data
• Prereading task not completed at Yaskawa representative.
master in twin synchronous sys-
tem
• Zero division occurred at observer Yaskawa representative.
operation.
• Processing error in optimized Yaskawa representative.
acceleration/deceleration control
• Dynamic model arithmetic error Yaskawa representative.
• Speed limit control error (exces- Yaskawa representative.
sive moment of gravity)
• Square root of a negative number Yaskawa representative.
• The system number is not set at Yaskawa representative.
master in twin synchronous sys-
tem.
• Designation error of control group Yaskawa representative.
for servo sealer gun
• Designation error of control condi- Yaskawa representative.
tion for servo sealer gun
• FORMCUT internal control error Yaskawa representative.
• Arm interference check error Yaskawa representative.
(radius data referencing mistake)
• Arm interference check error (mis- Yaskawa representative.
calculation using direct kinemat-
ics)
• Arm interference check error (L- Yaskawa representative.
axis expansion flag setting error)
• Arm interference check error Yaskawa representative.
(check-point re-setting error)
8-57
Alarm Message List

Alarm Sub
Number Code
• Impossible to edit the averaging Yaskawa representative.
buffer (zero division)
• No master-group is designated at Yaskawa representative.
preparation of master-tool user
coordinates.
• Gauging function error (command Yaskawa representative.
designation error)
4208 38 SYSTEM A system error occurred in the path The coordinated motion cannot be performed
ERROR (ARITH) control section. by the Following function. Change the setting
• A coordinated motion was so that only the manipulator moves.
attempted using the Following
function.
4208 39 SYSTEM A system error occurred in the path Set a positive value for the bending speed.
ERROR (ARITH) control section.
• Zero or a negative value is set for
the bending speed of the Follow-
ing function.
4208 40 SYSTEM A system error occurred in the path Set a positive value for the bending stroke.
ERROR (ARITH) control section.
the bending stroke of the Follow-
ing function.
• Pulse linked JOG function error Yaskawa representative.
• Special JOG operation error Yaskawa representative.
• Following function error (The used Yaskawa representative.
manipulator model does not sup-
port 7-axis Following Control.)
4209 100 OFFLINE A system error occurred in the Reset the alarm, and then try again.
SYSTEM offline position-data preparation If the error occurs again, contact your
ERROR (ARITH) section. Yaskawa representative.
• Data setting error in offline data
bank
• Data setting error in offline answer
bank
• OFF_USER_POS occupation
control error
• OFF_USER_POS valid control
error
8-58
Alarm Message List

Alarm Sub
Number Code
• Mail-receiving error of offline task
• Offline occupation control error
• Designation error for offline cubic
interference coordinates
• OFF_USER_ROT_POS occupa-
tion control error
• OFF_USER_ROT_POS valid
control error
• OFF_CV_CALIB_POS occupation
control error
• OFF_CV_CALIB_POS valid con-
trol error
• Incorrect teaching for offline con-
veyor tracking turntable function
• No manipulator is designated for
offline conveyor tracking turnta-
ble function.
4210 -1 SYSTEM An error occurred in local variable • Reset the alarm, and then try again.
ERROR control process. • Turn the power OFF then back ON.
(Local variable) • Local variable is not used. If the error occurs again, contact your
(Local variable) • Memory area for local variable If the error occurs again, contact your
could not be obtained. Yaskawa representative.
(Local variable) • No unused handle value exists If the error occurs again, contact your
when local variable area is cre- Yaskawa representative.
ated.
8-59
Alarm Message List

Alarm Sub
Number Code
(Local variable) • An error occurred in exclusive If the error occurs again, contact your
control. Yaskawa representative.
(Local variable) • Handle value is invalid for speci- If the error occurs again, contact your
fied local variable. Yaskawa representative.
(Local variable) • Handle value is incorrect for spec- If the error occurs again, contact your
ified local variable. Yaskawa representative.
(Local variable) • An error occurred when memory If the error occurs again, contact your
area for local variable was Yaskawa representative.
released.
(Local variable) • An error occurred when memory If the error occurs again, contact your
area for local variable was regis- Yaskawa representative.
tered.
(Local variable) • Local variable control process is If the error occurs again, contact your
not initialized. Yaskawa representative.
(Local variable) • Local variable area shared heap If the error occurs again, contact your
area. Yaskawa representative.
(Local variable) • An error occurred in exclusive If the error occurs again, contact your
4220 SERVO POWER The servo power is not supplied to Turn OFF the servo power supply, and then
OFF FOR JOB the job control group axis (control turn ON the servo power supply for the group
group for subcode) to be operated. axis to be operated.
4221 SERVO POWER The servo power is not supplied to Turn OFF the servo power supply, and then
OFF FOR JOB the job control group axis (control turn ON the servo power supply for the group
group for subcode) to be operated. axis to be operated.
4223 INPUT A dual signal is mutually checking Check the enable switch (DSW and EXDSW)
COMPARISON with the result that Enable switch I/O signal.
ERROR (DSW and EXDSW) I/O signal does
(DSW) not have a match signal as a result
the mutual check of a dual signal.
4223 1 SAFE CIRCUIT A safety circuit signal error Check the wiring of the safety circuit signal
SIGNAL DIS- occurred in I/O unit. cables connected to the I/O contactor unit.
AGREEMENT
(SERVO)
AGREEMENT
(SERVO)
AGREEMENT
(SERVO)
8-60
Alarm Message List

Alarm Sub
Number Code
4224 -1 MEMORY PLAY An error occurred in control process • Reset the alarm, and then try again.
FILE ERROR for memory play file. • Turn the power OFF then back ON.
4224 -2 MEMORY PLAY An error occurred in memory play Needs investigation. Contact your Yaskawa
FILE ERROR file. representative.
• The arrangement address infor-
mation is destroyed for memory
play file system.
• The fixed control information is
destroyed for memory play file
system.
4224 -4 MEMORY PLAY The memory play file number is Needs investigation. Contact your Yaskawa
FILE ERROR incorrect. representative.
• An attempt was made to newly
register the memory play file
under use.
• An error occurred in checking writ-
ten sampling data when the data
was written to CMOS.
• An attempt was made to access
an unused memory play file data.
4224 -8 MEMORY PLAY The memory play file is destroyed. Needs investigation. Contact your Yaskawa
FILE ERROR representative.
• The memory area for sampling
data is full.
• The sampling data is destroyed.
4224 -11 MEMORY PLAY Data in control process for memory Needs investigation. Contact your Yaskawa
FILE ERROR play file is incorrect. representative.
• The sampling data is scanned
only at top or end position.
• The memory play file system is
not initialized.
• The offset value is out of range at
sampling data scanning.
4300 SERVO PARAM- The parameter input value is out of Reset the value within the allowable range.
ETER ERROR the allowable range.
8-61
Alarm Message List

Alarm Sub
Number Code
4301 CONTACTOR An error occurred in the contactor • Reset the alarm, and then turn ON the
ERROR due to a defective contactor unit or servo again.
circuit board. • Check the 24-V power supply for I/O.
• The contactor of contactor unit did
not turn ON at servo ON.
• The signal from the contactor
turned OFF while the servo was
ON.
• The signal from the contactor
remains ON when the servo
turned OFF at emergency stop.
• The contactor turned ON while the
servo was OFF for emergency
stop.
4302 BRAKE CIRCUIT • The brake relay signal did not turn Reset the alarm, and then turn ON the servo
ERROR ON when the servo turned ON. again. If the error occurs again, replace the
• The brake relay signal turned OFF contactor unit and/or servo control circuit
while the servo was ON. board.
• The brake signal remains ON
when the servo turned OFF at
emergency stop.
• The brake signal turned ON while
the servo was OFF for emergency
stop.
4303 CONVERTER • No response of charge completion • Reset the alarm, and then turn ON the
READY SIGNAL was sent from the converter when servo again.
ERROR the servo turned ON. • Check the primary power supply voltage.
• The SERVO READY signal turned If the error occurs again, replace the servo
OFF while the servo was ON. control circuit board and/or converter.
• The SERVO READY signal
• The SERVO READY signal turned
ON while the servo was OFF for
emergency stop.
• The primary power supply voltage
is too low.
• The voltage dropped.
• Defective servo control and/or
converter
4304 CONVERTER • No response of primary power • Check the wiring for the primary power sup-
INPUT POWER supply input was sent from the ply of the SERVOPACK.
ERROR converter when the servo turned • Confirm that the power supply voltage is
ON. 170V or more.
• The READY 1 signal remains ON If the error occurs again, replace the servo
when the servo turned OFF at control circuit board and/or converter.
emergency stop.
• The READY 1 signal turned ON
while the servo was OFF for
emergency stop.
• Incorrect wiring or voltage drop of
primary power supply
• Defective servo control and/or
converter
8-62
Alarm Message List

Alarm Sub
Number Code
4305 CONVERTER • No response (READY 2 signal) of • Check the wiring for the primary power sup-
CIRCUIT charge completion was sent from ply of the SERVOPACK.
CHARGE the converter when the servo • Confirm that the power supply voltage is
ERROR turned ON. 170V or more.
• The READY 2 signal turned OFF If the error occurs again, replace the servo
while the servo was ON. control circuit board and/or converter.
• The READY 2 signal remains ON
when the servo turned OFF at
emergency stop.
• The READY 2 signal turned ON
while the servo was OFF for
emergency stop.
• Incorrect wiring and/or voltage
drop of primary power supply
• Defective servo control circuit
board, converter, and/or amplifier
4306 AMPLIFIER • No response "Power ON" was • Check the wiring for the primary power sup-
READY SIGNAL sent from the amplifier when the ply of the SERVOPACK.
ERROR servo turned ON. • Confirm that the power supply voltage is
• The amplifier READY signal 170V or more.
turned OFF while the servo was If the error occurs again, replace the
ON. WRCA01 circuit board, servo control circuit
• The amplifier READY signal board, converter, and/or amplifier.
• The amplifier READY signal
turned ON while the servo was
OFF for emergency stop.
• Defective servo control circuit
board, converter, and/or amplifier
4307 SERVO ON The motion speed of the encoder The control power supply cannot be turned
SPEED ERROR before the dynamic brake turns ON while the manipulator is moving.
OFF in servo ON sequence Stop the manipulator motion, and then turn
exceeded the threshold for a cer- ON the servo power supply.
tain period.
• The servo power supply turned
ON while the manipulator (motor
and encoder) was moving.
4308 VOLTAGE DROP The DC power voltage supplied to • Check the wiring for the primary power sup-
(CONVERTER) the SERVOPACK amplifier dropped ply of the SERVOPACK.
below 143V due to: • Confirm that the power supply voltage is
- Low voltage of the primary 170V or more.
power supply If the error occurs again, replace the servo
- Open phase control circuit board, servo control circuit
- Defective converter board, and/or converter.
- Defective servo control
circuit board
4309 DEFECTIVE Serial encoder internal parameter Reset the alarm, and then perform the home
ENCODER error occurred. positioning again. Turn the power OFF then
INTERNAL DATA back ON.
If the error occurs again, replace the motor of
the corresponding axis.
4310 ENCODER The temperature of the encoder • Review the load condition and ambient
OVERHEAT exceeded 100 °C. operating temperature.
• Encoder thermister failure • Confirm that the primary power supply volt-
age is 200V + 10%.
If the error occurs again, replace the servo
control circuit board or the motor.
4311 ENCODER • Encoder resetting (initialization) Reset the alarm, and then perform the home
BACK-UP not completed positioning again. Confirm that the encoder
ERROR • The position data in the encoder backup battery voltage is 2.8V or more.
was lost due to the voltage drop If the error occurs again, replace the encoder
of encoder backup battery. (motor).
8-63
Alarm Message List

Alarm Sub
Number Code
4312 ENCODER BAT- Encoder backup battery voltage is Confirm that the encoder backup battery volt-
TERY ERROR too low. age is 2.8V or more. If not, replace the bat-
• The voltage of the encoder tery.
backup battery is below 2.8V.
The position data may be lost.
4313 SERIAL The temperature of the encoder • Review the load condition and ambient
ENCODER exceeded 100 °C. operating temperature.
OVER HEAT • Encoder thermister failure • Confirm that the primary power supply volt-
age is 200V + 10%.
If the error occurs again, replace the servo
control circuit board or the motor.
4314 SERIAL Encoder backup battery voltage is Confirm that the encoder backup battery volt-
ENCODER too low. age is 2.8V or more. If not, replace the bat-
BATTERY • The voltage of the encoder tery.
ERROR backup battery is below 2.8V.
The position data may be lost.
4315 COLLISION • A collision was detected because Reset the alarm, and then remove the object
DETECT of the interference between the or move the manipulator back to a safe posi-
manipulator and a peripheral tion. If the alarm cannot be reset, invalidate
device. the collision detection level setting file or set
• The external force applied to the the detection level higher.
robot exceeded the threshold.
4316 PRESSURE The pressure set in the gun pres- Reset the pressure value in the gun pressure
DATA LIMIT sure file or dry spotting pressure file file or dry spotting pressure file below the
exceeded the maximum pressure maximum pressure value.
set in the gun condition file.
4317 PRE-LOAD The motor does not operate in the Adjust the gun opening.
ERROR pre-load process.
4318 SERIAL The speed feedback value of the • Turn the power OFF then back ON.
ENCODER COR- serial encoder exceeded the allow- If the error occurs again, contact your
RECT LIMITA- able limit. Yaskawa representative.
TION OVER
4320 OVER LOAD The motor torque continuously Check the motor, board, manipulator motion
(CONTINUE) exceeded the rated torque for a (influence by external force), and taught ori-
certain period due to: entation.
- Motor cable disconnection
- Motor failure
- Defective board
- External force applied to manipu-
lator, etc.
4321 OVER LOAD The torque a several times as much Check the motor, board, manipulator motion
(INSTANT) as the rated torque has been (influence by external force), and taught ori-
applied to the motor due to: entation.
- Motor cable disconnection
- Motor failure
- Defective board
lator, etc.
4322 AMPLIFIER The current a several times as Check the wiring and connection for the
OVER LOAD much as the rated current has con- motor power line, board, cable disconnection,
(CONTINUE) tinuously flown in the amplifier for a motor type, manipulator interferences,
certain period. SERVOPACK, and board, etc.
Replace if necessary.
4323 AMPLIFIER The torque a several times as much Check the wiring and connection for the
OVER LOAD as the motor rated torque has con- motor power line, motor type, manipulator
(INSTANT) tinuously been applied for a certain interference, SERVOPACK, and circuit
period. boards. Replace if necessary.
8-64
Alarm Message List

Alarm Sub
Number Code
4324 CONVERTER The total load value of all the Review the manipulator operating condition
OVER LOAD motors connected to the converter such as reducing the teaching speed, etc.
exceeded the converter rating.
4326 SPEED ERROR The speed exceeded the limit due Check the motor, board, manipulator motion
to: (influence by external force), and taught ori-
- Motor cable disconnection entation.
- Motor failure
- Defective board
lator, etc.
4327 MOTOR ROTA- While the motor is accelerating, the Check the wiring and connection for the
TION ERROR direction of the torque and the encoder and the motor power line.
speed was detected as being the
opposite of what it was supposed to
be.
4328 SERVO TRACK- The axis deviated from the speci- Check the manipulator interferences and
ING ERROR fied position and motion path motor power line.
beyond the allowable range. If the error occurs again, replace the servo
control circuit board, and/or the amplifier or
motor of the corresponding axis.
4329 POSITION The number of pulses generated by Check for the external noise.
ERROR one motor rotation does not agree Provide noise protection such as installing a
with the specified value due to: ferrite core if required.
- Noise from external devices If the error occurs again, replace the servo
- Defective board control circuit board, external axis servo con-
- Motor failure trol circuit board, and/or motor.
4330 SPEED MONI- The read speed monitoring level Check the connection cables for speed moni-
TORING signal is disconnected. toring unit.
INSTRUCTION
CABLE DISCON-
NECTION
4332 POSITION The number of pulses generated by Check for the external noise.
ERROR (SERIAL one motor rotation does not agree Provide noise protection such as installing a
ENCODER) with the specified value due to: ferrite core if required.
- Noise from external devices If the error occurs again, replace the servo
- Defective board control circuit board, external servo control
- Motor failure circuit board, and/or motor.
4334 OVER VOLTAGE The DC voltage supplied to the Check the primary power supply voltage.
(CONVERTER) amplifier exceeded 420V due to: Reduce the teaching speed and check if the
- Overloaded error occurs. If the error does not occur with
- Converter failure the reduced speed, review the load condition.
- Defective servo control circuit If the error occurs again, replace the servo
board control circuit board and/or the converter.
4335 EARTH FAULT Ground fault of the motor power Check the motion connection.
line occurred due to: Remove the motor connector to check the
- Motor failure conduction. If there is conduction, replace the
- Ground fault of motor line or lead lead cable; if there is no conduction,replace
cables the servo control circuit board.
board
- Defective SERVOPACK
4336 OPEN PHASE The SERVOPACK primary power Correct the SERVOPACK primary power
(Converter) supply is open-phase due to: supply connection,
- Misconnection of primary power Confirm that the power supply voltage is
supply more than 170V.
- Lowered primary power supply If the error occurs again, replace the servo
voltage control circuit board.
board
- Defective converter
8-65
Alarm Message List

Alarm Sub
Number Code
4337 OVER Ground fault of the motor power Check the motion connection.
CURRENT line occurred due to: Remove the motor connector to check the
(AMPLIFIER) - Motor failure conduction. If there is conduction, replace the
- Ground fault of motor line or lead lead cable; if there is no conduction, replace
cables the servo control circuit board.
- Defective servo control circuit If no fault is found, turn OFF the power sup-
board ply to cool down the motor. If this natural
- Defective amplifier cooling solves the problem, the load condi-
tion and ambient operating temperature must
be reviewed and corrected.
4338 REGENERA- The regenerative energy at motor Review the load condition and teaching
TION ERROR deceleration is too large. speed.
(CONVERTER) - The primary power supply voltage Confirm that the power supply voltage is
is too high (above 242V) 220V ±10%.
- Converter failure If the error occurs again, replace the servo
- Defective servo control circuit control circuit board.
board
4339 INPUT POWER The SERVOPACK primary power Confirm that the power supply voltage is
OVER VOLTAGE supply voltage exceeded 242V. 220V ±10%.
(CONV) If the error occurs again, replace the servo
control circuit board or the converter.
4340 TEMPERATURE SERVOPACK(converter) overheat Confirm that the power supply voltage is
ERROR 220V ±10%.
(CONVERTER) If the error occurs again, replace the servo
control circuit board or the converter.
4344 LINEAR SERVO The deviation of X, Y, and Z-axis Check the job.
FLOAT TRACK- exceeded the allowable limit while
ING ERROR the linear servo float was in execu-
tion.
4345 LINK SERVO The link servo float can not be exe- Check the job.
FLOAT ERROR cuted while the linear servo float is
in execution.
4346 LINK SERVO The limit torque of the link servo Set the limit torque of the link servo float con-
FLOAT LIMITA- float condition file is outside the dition file again.
TION TORQUE specified range.
RANGE ERROR
4347 LINEAR SERVO The limit torque of the linear servo Set the limit torque of the linear servo float
FLOAT LIMITA- float condition file is outside the condition file again.
TION TORQUE specified range.
RANGE ERROR
4348 LINEAR SERVO While the linear servo float was in Check the job.
FLOAT COORDI- execution, another request of linear
NATES TYPE servo float execution was sent with
UNMATCH a different coordinates specified.
4349 LINEAR SERVO A logical error occurred in the des- • Reset the alarm, and then try again.
FLOAT TOOL ignation for tool orientation control • Turn the power OFF then back ON.
POSE CONTROL of the linear servo float. If the error occurs again, contact your
SPECIFICATION Yaskawa representative.
ERROR
4350 LINEAR SERVO While the servo float was in execu- Check the job.
FLOAT EXECU- tion, the linear servo float can not
TION ERROR be executed.
4351 BELT DISCON- The driving belt may be discon- Check the belt, and replace it if necessary.
NECTION nected because the torque
DETECTION decreased below the normal value.
4352 TWIN DRIVE The deviation of the position error Check the load.
OVER pulse from the twin drive axis
DEVIATION exceeded the allowable limit with
twin drive function.
8-66
Alarm Message List

Alarm Sub
Number Code
4353 DEFECTIVE Endless motion impossible Reset the alarm.

TAUGHT POINT • The feedback pulse value
(ENDLESS) exceeded the maximum value
(maximum number of pulses ±
536870912)
4354 FILE NO. The collision detection file for exclu- Do not use the collision detection file for
ERROR sive use for the SVSPOT is used exclusive use for the SVSPOT with the
(SHOCK LEVEL) with the SHCKSET instruction. SHCKSET instruction.
4355 EXTERNAL An external force above the thresh- Check the job.
PRES DETECT old was detected on the servo-float
(SERVOFLOAT) executing axis.
4356 ARM CTRL The search of motor-gun equalizing If the error occurs again, contact your
PARAMETER function cannot be executed Yaskawa representative.
ERR because no observer (including col-
(OBSERVER) lision detection) is specified.
4357 IMPOSSIBLE The manipulator orientation at the Check the job.
SRCH execution of search of the motor-
(EQUALIZE gun equalizing function is the orien-
TEACH) tation for the singular point.
4358 DUPLICATE The pressuring instruction was exe- Do not execute the pressuring instruction
PRESS ERROR cuted with manual pressurization with manual pressurization during pressuring.
during pressuring.
4359 CONVERTER An error occurred in the converter. Turn the power OFF then back ON. If the
ERROR error occurs again, replace the servo control
circuit board or the converter.
4360 WAFER ALIGN- An error occurred in communica- Check the connection of prealigner.
MENT ERROR tions with the prealigner.
(SERVO)
4400 1 NOT READY The arithmetic process for motion • Reset the alarm, and then try again.
(ARITH) control did not complete within reg- • Turn the power OFF then back ON.
ulated time. If the error occurs again, contact your
• No motion command was pre- Yaskawa representative.
pared.
• The arithmetic processing section Yaskawa representative.
is not ready for JOG operation.
is not ready for the playback oper-
ation.
• The prereading processing in the Yaskawa representative.
arithmetic processing section has
not completed.
is not ready for the timer follow-up
of the conveyor tracking function.
8-67
Alarm Message List

Alarm Sub
Number Code
• The prereading processing in the Yaskawa representative.
arithmetic processing section has
not completed when specifying
the target position.
4401 1 SEQUENCE An error occurred in job execution • Reset the alarm, and then try again.
TASK CONTROL process. • Turn the power OFF then back ON.
ERROR • Unused A_BANK does not exist in If the error occurs again, contact your
the prereading processing of Yaskawa representative.
move instruction.
ERROR • Unused bank priority does not If the error occurs again, contact your
exist in the prereading process- Yaskawa representative.
ing of move instruction.
ERROR • A_BANK pointer is not set. If the error occurs again, contact your
ERROR • A_BANK conversion could not be If the error occurs again, contact your
performed. Yaskawa representative.
ERROR • The specified A_BANK number If the error occurs again, contact your
does not exist. Yaskawa representative.
ERROR • An error occurred when system If the error occurs again, contact your
number (MSS) was obtained. Yaskawa representative.
ERROR • An error occurred in RMS960 sys- If the error occurs again, contact your
tem call. Yaskawa representative.
ERROR • Undefined interrupt command was If the error occurs again, contact your
received. Yaskawa representative.
ERROR • Job start condition is not defined. If the error occurs again, contact your
ERROR • An error occurred in instruction If the error occurs again, contact your
prefetch queue operation. Yaskawa representative.
ERROR • Intermediate code is not defined. If the error occurs again, contact your
ERROR • Instruction prereading processing If the error occurs again, contact your
has not been completed normally. Yaskawa representative.
8-68
Alarm Message List

Alarm Sub
Number Code
ERROR • An error occurred in job data If the error occurs again, contact your
change. Yaskawa representative.
ERROR • The specified sequence number If the error occurs again, contact your
at job execution start is incorrect. Yaskawa representative.
ERROR • The added area for interruption If the error occurs again, contact your
command is incorrect. Yaskawa representative.
ERROR • System number (MSS) for inter- If the error occurs again, contact your
ruption command is incorrect. Yaskawa representative.
ERROR • An error occurred at start of twin If the error occurs again, contact your
synchronous operation. Yaskawa representative.
ERROR • An error occurred when SYNC If the error occurs again, contact your
specification was reset. Yaskawa representative.
ERROR • An error occurred in occupation If the error occurs again, contact your
control group setting in MOTION. Yaskawa representative.
ERROR • An error occurred in path/trace If the error occurs again, contact your
ERROR • An error occurred when waiting for If the error occurs again, contact your
a completion of main system task Yaskawa representative.
(job) in SYNC specification.
ERROR • An attempt was made to execute If the error occurs again, contact your
an instruction that could not be Yaskawa representative.
executed at line sequence execu-
tion.
4401 80 SEQUENCE An exceptional error occurred in job • Reset the alarm, and then try again.
TASK CONTROL execution process. • Turn the power OFF then back ON.
ERROR • Main processing command is If the error occurs again, contact your
incorrect in prereading process- Yaskawa representative.
ing.
ERROR • Subprocessing command is incor- If the error occurs again, contact your
rect in prereading processing. Yaskawa representative.
ERROR • Prereading processing has not If the error occurs again, contact your
been completed at job execution. Yaskawa representative.
8-69
Alarm Message List

Alarm Sub
Number Code
ERROR • A_BANK conversion has not been If the error occurs again, contact your
completed. Yaskawa representative.
ERROR • System number (MSS) is incorrect If the error occurs again, contact your
in prereading processing. Yaskawa representative.
ERROR • An error occurred in instruction If the error occurs again, contact your
prefetch queue operation in pre- Yaskawa representative.
reading processing.
ERROR • An error occurred at IES switching If the error occurs again, contact your
in prereading processing. Yaskawa representative.
4402 UNDEFINED An undefined command was issued Reset the alarm, and then try again.
COMMAND to the path control section. If the error occurs again, contact your
(ARITH) Yaskawa representative.
4404 1 ARITHMETIC An error occurred in the arithmetic • Change the positions so that two arms are
ERROR process for coordinates. not aligned in a straight line.
(MOTION) • The S-arm and L-arm of a scalar • Change the step (move instruction), where
type manipulator are aligned in a the alarm occurred, to MOVJ.
straight line. Interpolation such
as linear and circular interpola-
tion is impossible in such orienta-
tion.
4404 2 ARITHMETIC An error occurred in the arithmetic Change the position in the step (move
ERROR process for coordinates. instruction) where the alarm occurred.
(MOTION) • When a vertically-articulated
manipulator was moved by a spe-
cial linear interpolation, the R-axis
angle could not correctly be cal-
culated.
4404 3 ARITHMETIC An error occurred in the arithmetic Change the position in the step (move
ERROR process for coordinates. instruction) where the alarm occurred.
(MOTION) • When a vertically-articulated
manipulator was moved by a spe-
cial linear interpolation, the L-axis
angle could not correctly be cal-
culated.
(MOTION) • The L-arm and U-arm of a verti- • Change the step (move instruction), where
cally-articulated manipulator are the alarm occurred, to MOVJ.
aligned in a straight line. Interpo-
lation such as linear and circular
interpolation is impossible in such
orientation.
(MOTION) • The L-arm and U-arm of a verti- • Change the step (move instruction), where
cally-articulated manipulator are the alarm occurred, to MOVJ.
aligned in a straight line. Interpo-
lation such as linear and circular
interpolation is impossible in such
orientation.
8-70
Alarm Message List

Alarm Sub
Number Code
4404 7 ARITHMETIC An error occurred in the arithmetic • Perform the teaching again so that the TCP
ERROR process for coordinates. of the manipulator is always within the
(MOTION) • The TCP of the manipulator is out working envelope.
of working envelope. • Change the shift value so that the TCP of
the manipulator is always within the work-
ing envelope.
4404 8 ARITHMETIC An error occurred in the arithmetic Change the step (move instruction), where
ERROR process for coordinates. the alarm occurred, to MOVJ.
(MOTION) • Interpolation such as linear and
circular interpolation cannot be
performed with this manipulator.
4404 9 ARITHMETIC An error occurred in the arithmetic Correct the taught point.
ERROR process for coordinates.
(MOTION) • Specified motion cannot be per-
formed with this manipulator.
4405 1 SELECT ERROR A parameter error occurred in the • Reset the alarm, and turn the power OFF
(PARAMETER) path control section. then back ON.
• Selection error of motion system If the error occurs again, contact your
parameter Yaskawa representative.
4406 1 GROUP AXIS An internal control error occurred in • Reset the alarm, and then try again.
CONTROL a coordinated motion. If the error occurs again, contact your
ERROR • Designation error for master and Yaskawa representative.
slave
ERROR • Slave designation error Yaskawa representative.
ERROR • Slave interpolation error Yaskawa representative.
ERROR • No designation of master axis Yaskawa representative.
ERROR • No designation of slave axis Yaskawa representative.
ERROR • Master-axis designation error for Yaskawa representative.
JOG motion
ERROR • Slave-axis designation error for Yaskawa representative.
JOG motion
ERROR • Occupation control error Yaskawa representative.
ERROR • Designation error of occupation Yaskawa representative.
control for JOG motion
control for Bank position
control group for tracking motion
8-71
Alarm Message List

Alarm Sub
Number Code
ERROR • No master and slave designated Yaskawa representative.
for tracking motion
4407 TWO STEPS Among three taught points in a cir- Teach the different 3 points again.
SAME POSI- cular interpolation step, two or three
TION (CIRC) points are on the same point.
4408 TWO STEPS Among three taught points in a Teach the different 3 points again.
SAME POSI- spline interpolation step, two or
TION (SPLINE) three points are on the same point.
4409 TWO STEPS Among three taught points to create Teach the different 3 points again.
SAME POSI- an user coordinate system, two or
TION (3 POINTS) three points are on the same point.
4410 TWO STEPS Among three taught points (start, Teach the different 3 points again.
SAME POSI- end, and reference points) to create
TION (WEAV) a weaving coordinate system, two
or three points are on the same
point.
4411 TEACH ERROR The spline interpolation could not Teach the positions so that the distance
(SPLINE) correctly be performed. between the teaching points is even.
• The distance between the teach-
ing points in the spline interpola-
tion section is not equidistant.
4412 IMPOSSIBLE Interpolation motion could not be • Perform the teaching again to make the
LINEAR MOTION performed because of different form of L- and U-axes same at start point
(L/U) form of L- and U-axes. and end point.
• In case the form (folded direction) • Use a MOVJ instruction.
of L- and U-axes at start point and
end point are different except for
MOVJ instructions, the manipula-
tor cannot move.
4413 IMPOSSIBLE Interpolation motion could not be • Perform the teaching again to make the
LINEAR MOTION performed because of different form of S- and L-axes same at start point
(S/L) form of S- and L-axes. and end point.
• In case the form (folded direction) • Use a MOVJ instruction.
of S- and L-axes at start point and
end point are different except for
MOVJ instructions, the manipula-
tor cannot move.
4414 EXCESSIVE The manipulator motion speed • Reduce the speed in the step (move
SEGMENT exceeded the limit (LOW level). instruction) where the alarm occurred.
(LOW SPEED) • The manipulator may be near the singular
point. Change the position and orientation
of the manipulator.
4415 EXCESSIVE The manipulator motion speed • Reduce the speed in the step (move
SEGMENT exceeded the limit (HIGH level). instruction) where the alarm occurred.
(HIGH SPEED) • The manipulator may be near the singular
point. Change the position and orientation
of the manipulator.
4416 PULSE LIMIT The manipulator exceeded its Change the manipulator position in the step
(MIN.) motion limit (pulse limit) in the neg- (move instruction) where the alarm occurred.
ative (−) direction.
4417 PULSE LIMIT The manipulator exceeded its Change the manipulator position in the step
(MAX.) motion limit (pulse limit) in the posi- (move instruction) where the alarm occurred.
tive (+) direction.
4418 CUBE LIMIT The manipulator TCP exceeded its Change the position in the step (move
(MIN.) motion limit (cube limit) in the nega- instruction) where the alarm occurred.
tive (−) direction.
8-72
Alarm Message List

Alarm Sub
Number Code
4419 CUBE LIMIT The manipulator TCP exceeded its Change the position in the step (move
(MAX.) motion limit (cube limit) in the posi- instruction) where the alarm occurred.
tive (+) direction.
4420 SPECIAL SOFT- The manipulator exceeded its Change the position in the step (move
LIMIT (MIN.) motion limit (special software limit) instruction) where the alarm occurred.
in the negative (−) direction.
4421 SPECIAL SOFT- The manipulator exceeded its Change the position in the step (move
LIMIT (MAX.) motion limit (special software limit) instruction) where the alarm occurred.
in the positive (+) direction.
4422 MECHANICAL The manipulator exceeded its mini- Change the position in the step (move
INTERFER- mum-angle motion limit. (Mechani- instruction) where the alarm occurred.
ENCE (MIN.) cal interference)
4423 MECHANICAL The manipulator exceeded its maxi- Change the position in the step (move
INTERFER- mum-angle motion limit. (Mechani- instruction) where the alarm occurred.
ENCE (MAX.) cal interference)
4424 SPECIAL The manipulator exceeded its mini- Change the position in the step (move
MECHANICAL mum-angle motion limit. (Special instruction) where the alarm occurred.
INTRF (MIN.) mechanical interference)
4425 SPECIAL The manipulator exceeded its maxi- Change the position in the step (move
MECHANICAL mum-angle motion limit. (Special instruction) where the alarm occurred.
INTRF (MAX.) mechanical interference)
4426 PULSE The manipulator exceeded its Change the position in the step (move
MECHANICAL motion limit (mechanical limit) in the instruction) where the alarm occurred.
LIMIT (MIN.) negative (−) direction.
4427 PULSE The manipulator exceeded its Change the position in the step (move
MECHANICAL motion limit (mechanical limit) in the instruction) where the alarm occurred.
LIMIT (MAX.) positive (+) direction.
4428 1 SEGMENT CON- An error occurred in the real-time • Reset the alarm, and then try again.
TROL ERROR processing section that controls the • Turn the power OFF then back ON.
arithmetic section. If the error occurs again, contact your
<System error> Yaskawa representative.
• RT-buffer control command error
calculation section. If the error occurs again, contact your
• Segment-receiving control com-
mand error
• No bank priority
• Answer error at MOVE simulating
• The value of bank_refresh_flag(x)
exceeded its limit.
• Bank refreshing timing error
8-73
Alarm Message List

Alarm Sub
Number Code
• RT-buffer setting timing error
• RT-buffer tracking option error
• The segment was received
although the previous segment
had not been sent.
4429 1 WRONG SPECI- An error occurred in the manipula- • Reset the alarm, and then try again.
FIED CONTROL tor information at job execution. • Turn the power OFF then back ON.
GROUP <System error> If the error occurs again, contact your
• Control group not designated Yaskawa representative.
GROUP <Systm error> If the error occurs again, contact your
• Slave control-group error Yaskawa representative.
• Master control-group error Yaskawa representative.
• Master and Slave control-group Yaskawa representative.
error
• Control-group error for a job file Yaskawa representative.
• Control-group error for a user Yaskawa representative.
coordinate file
• Control-group error for a calibra- Yaskawa representative.
tion file between manipulators
• Control-group error for a tool cali- Yaskawa representative.
bration file
• Control-group error for a refer- Yaskawa representative.
ence point
8-74
Alarm Message List

Alarm Sub
Number Code
• Control-group error for preread- Yaskawa representative.
ing-calculation start point (for
adv_st_pos)
• Control-group error for the cur- Yaskawa representative.
rent-value preset position
• Control-group error for the con- Yaskawa representative.
veyor prereading-calculation start
point
• Occupation control-group error Yaskawa representative.
• Control-group error for multi-layer Yaskawa representative.
sampling
• Control-group error for servo hand Yaskawa representative.
• MRESET control-group error Yaskawa representative.
• Control-group error for general- Yaskawa representative.
purpose area of path correction
amount
• Control-group error for a con- Yaskawa representative.
veyor calibration file
• Control-group error for the pre- Yaskawa representative.
reading-calculation start point (for
dm_st_pos)
4430 1 CPU COMMUNI- An error occurred in interrupt pro- • Reset the alarm, and then try again.
CATION ERROR cess between CPUs. • Turn the power OFF then back ON.
<System error> If the error occurs again, contact your
• Interrupt processing error Yaskawa representative.
between MOTION and system
control section
8-75
Alarm Message List

Alarm Sub
Number Code
between MOTION and SL#1
between MOTION and CV#1
between MOTION and CV#2
between MOTION and PS#1
between MOTION and PS#2
4431 1 JHM ERROR Data error occurred in job control • Reset the alarm, and then try again.
process. • Turn the power OFF then back ON.
• An error occurred in JMS system If the error occurs again, contact your
call when an attempt was made to Yaskawa representative.
open a job.
• No space was found in job handle If the error occurs again, contact your
value storage area when an Yaskawa representative.
attempt was made to open a job.
• No job handle was found. If the error occurs again, contact your
• Job control proprietary is incor- If the error occurs again, contact your
rect. Yaskawa representative.
8-76
Alarm Message List

Alarm Sub
Number Code
• Job control proprietary could not If the error occurs again, contact your
be changed. Yaskawa representative.
• An error occurred in exclusive If the error occurs again, contact your
4432 1 INSTRUCTION An error occurred in instruction • Reset the alarm, reselect the job, and then
INTERPRETER interpretation/execution process. try again.
ERROR • The intermediate code of the • Delete the instruction where an alarm
instruction that is to be executed occurred, and then reregister and execute
is incorrect. the instruction.
• Delete the job where an alarm occurred,
and then reregister and execute the job.
ERROR • Destination (variable) tag arrange- • Delete the instruction where an alarm
ment is incorrect. occurred, and then reregister and execute
the instruction.
ERROR • Tag data type is incorrect. • Delete the instruction where an alarm
occurred, and then reregister and execute
the instruction.
ERROR • Box number is incorrect. • Delete the instruction where an alarm
the instruction.
ERROR • An error occurred in block separa- • Delete the instruction where an alarm
tion processing of intermediate occurred, and then reregister and execute
code. the instruction.
ERROR • Box number definition is dupli- • Delete the instruction where an alarm
cated. occurred, and then reregister and execute
the instruction.
8-77
Alarm Message List

Alarm Sub
Number Code
ERROR • Undefined instruction was found • Delete the instruction where an alarm
at block separation of intermedi- occurred, and then reregister and execute
ate code. the instruction.
ERROR • IPRM is not set. • Delete the instruction where an alarm
the instruction.
ERROR • An error occurred in tag data • Delete the instruction where an alarm
search process. occurred, and then reregister and execute
the instruction.
ERROR • An error occurred move instruc- • Delete the instruction where an alarm
tion search process. occurred, and then reregister and execute
the instruction.
ERROR • An error occurred reference point • Delete the instruction where an alarm
search process. occurred, and then reregister and execute
the instruction.
ERROR • Variable information does not • Delete the instruction where an alarm
exist. occurred, and then reregister and execute
the instruction.
ERROR • An error occurred at position file • Delete the instruction where an alarm
data reading. occurred, and then reregister and execute
the instruction.
8-78
Alarm Message List

Alarm Sub
Number Code
ERROR • Variable data type is not defined. • Delete the instruction where an alarm
the instruction.
ERROR • An instruction is included with • Delete the instruction where an alarm
incorrect intermediate code in occurred, and then reregister and execute
expression instruction. the instruction.
ERROR • The syntax in expression instruc- • Delete the instruction where an alarm
tion is incorrect. occurred, and then reregister and execute
the instruction.
ERROR • The tag data length is zero when • Delete the instruction where an alarm
tag data is read. occurred, and then reregister and execute
the instruction.
ERROR • The necessary tag data is not set. • Delete the instruction where an alarm
the instruction.
ERROR • The object to be processed was • Delete the instruction where an alarm
secret variable in position file con- occurred, and then reregister and execute
trol process, so it could not be the instruction.
processed. • Delete the job where an alarm occurred,
ERROR • The object to be processed was • Delete the instruction where an alarm
position type variable in position occurred, and then reregister and execute
file control process, so it could not the instruction.
be processed. • Delete the job where an alarm occurred,
8-79
Alarm Message List

Alarm Sub
Number Code
ERROR • Job argument settings do not • Delete the instruction where an alarm
match when a variable is given occurred, and then reregister and execute
and/or taken between jobs. the instruction.
ERROR • An attempt was made to perform • Delete the instruction where an alarm
undefined operation at four-rule occurred, and then reregister and execute
operation instruction. the instruction.
ERROR • Arithmetic stack used for expres- • Delete the instruction where an alarm
sion operation exceeded. occurred, and then reregister and execute
the instruction.
ERROR • Arithmetic stack used for expres- • Delete the instruction where an alarm
sion operation is empty. occurred, and then reregister and execute
the instruction.
ERROR • Operation items are lacking in • Delete the instruction where an alarm
expression operation and opera- occurred, and then reregister and execute
tion processing cannot be per- the instruction.
formed. • Delete the job where an alarm occurred,
ERROR • Access mechanism for old param- • Delete the instruction where an alarm
eters is used. occurred, and then reregister and execute
the instruction.
ERROR • An exceptional error occurred. • Delete the instruction where an alarm
the instruction.
8-80
Alarm Message List

Alarm Sub
Number Code
4433 0 UNDEFINED The global variable is not defined. Needs investigation. Contact your Yaskawa
GLOBAL • The set data for byte type vari- representative.
VARIABLE able (S1D parameter) area is
incorrect.
GLOBAL • The set data for integer type vari- representative.
VARIABLE able (S1D parameter) area is
incorrect.
GLOBAL • The set data for double-precision representative.
VARIABLE integer-type variable (S1D param-
eter) area is incorrect.
GLOBAL • The set data for real type variable representative.
VARIABLE (S1D parameter) area is incorrect.
GLOBAL • The set data for character-string representative.
VARIABLE type variable (S1D parameter)
area is incorrect.
GLOBAL • The set data for robot-axis posi- representative.
VARIABLE tion-type variable (S1D parame-
ter) area is incorrect.
GLOBAL • The set data for base-axis posi- representative.
GLOBAL • The set data for station-axis posi- representative.
4435 0 UNDEFINED The local variable is not defined. Set the number of local variables to be used
LOCAL • The byte type variable is not in the job header.
VARIABLE defined.
LOCAL • The integer type variable is not in the job header.
VARIABLE defined.
LOCAL • The double-precision integer-type in the job header.
VARIABLE variable is not defined.
LOCAL • The real-number type variable is in the job header.
VARIABLE not defined.
LOCAL • The character-string type variable in the job header.
VARIABLE is not defined.
LOCAL • The robot-axis position-type vari- in the job header.
VARIABLE able is not defined.
LOCAL • The base-axis position-type vari- in the job header.
LOCAL • The station-axis position-type vari- in the job header.
8-81
Alarm Message List

Alarm Sub
Number Code
4436 LESS THAN 3 An error occurred in circular inter- Reset the alarm, and then perform teaching
STEP polation instruction execution. so that circulation interpolation steps are con-
(CIRCULAR) • There is no continuous three tinuous three points or more.
points or more for circular interpo-
lation step.
4437 LESS THAN 3 An error occurred in spline interpo- Reset the alarm, and then perform teaching
STEP (SPLINE) lation instruction execution. so that spline interpolation steps are continu-
• There is no continuous three ous three points or more.
points or more for spline interpola-
tion step.
4438 UNDEFINED The job to be executed is not regis- • Reset the alarm, and then register the job.
JOB tered in the memory. • Delete the CALL/JUMP instruction where
an alarm occurred.
4439 UNDEFINED An error occurred in label jump exe- • Reset the alarm, and then register the label.
LAVEL cution. • Delete the JUMP instruction where an alarm
• The label for jump destination occurred.
does not exist in the job.
4440 UNDEFINED Call source job does not exist in the • Reset the alarm, and then execute the mas-
RETURN JOB job call stack. ter (start) job.
• Delete the RET instruction.
4441 LACK OF LOCAL An error occurred when memory Reset the alarm, and then reduce the number
VARIABLE AREA area for local variable was of local variables to be used.
obtained.
• Memory area is lacking because
too many local variables in the job
are used.
4444 UNSUCCESS- When PL = 0 or an external servo • Reset the alarm, and then check if external
FUL FINE POSI- turned OFF, the number of the force is applied to the manipulator. If exter-
TIONING servo error pulses did not fall in the nal force is applied to the manipulator,
limit range that had been set in a move the manipulator by the axis operation,
parameter, within the specified etc. to remove the external force. Then, try
time. again.
• If the error occurs again although no exter-
nal force is applied to the manipulator, re-
insert the system CPU board correctly.
4445 1 DATA PRESET Data error occurred at job preread- • Reset the alarm, reselect the job, and then
ERROR ing reinterpretation. try again.
• The token for prereading process- If the error occurs again, contact your
ing could not be obtained. Yaskawa representative.
• The prereading processing has If the error occurs again, contact your
not been completed within the Yaskawa representative.
time, and the waiting time for
completion exceeded the limit.
• The prereading operation pro- If the error occurs again, contact your
cessing has not been completed Yaskawa representative.
within the time, and the waiting
time for completion exceeded the
limit.
• An error occurred in prereading If the error occurs again, contact your
operation process. Yaskawa representative.
8-82
Alarm Message List

Alarm Sub
Number Code
• A_BANK conversion has not been If the error occurs again, contact your
completed. Yaskawa representative.
• An exceptional error occurred in If the error occurs again, contact your
job execution process. Yaskawa representative.
4446 0 OVER VARI- The variable value exceeded the Change the variable data type for storage or
ABLE LIMIT limit. correct the job, so that the variable value is
within the limit.
4446 1 OVER VARI- The value for the binary (0/1) data Change the variable data type for storage or
ABLE LIMIT type variable exceeded the limit. correct the job, so that the variable value is
within the limit.
4446 2 OVER VARI- The value for the signed 1-byte Change the variable data type for storage or
ABLE LIMIT data type variable is less than the correct the job, so that the variable value is
minimum value. within the limit.
4446 8 OVER VARI- The value for the real-number 4- Change the variable data type for storage or
ABLE LIMIT byte data type variable is less than correct the job, so that the variable value is
the minimum value. within the limit.
ABLE LIMIT data type variable exceeded the correct the job, so that the variable value is
maximum value. within the limit.
4446 32771 OVER VARI- The value for the unsigned 1-byte Change the variable data type for storage or
4446 32776 OVER VARI- The value for the real-number 4- Change the variable data type for storage or
ABLE LIMIT byte data type variable exceeded correct the job, so that the variable value is
the maximum value. within the limit.
4446 32780 OVER VARI- The value for the label-name type Change the variable data type for storage or
ABLE LIMIT variable exceeded the maximum correct the job, so that the variable value is
value. within the limit.
4446 32781 OVER VARI- The value for the job-name type Change the variable data type for storage or
ABLE LIMIT variable exceeded the maximum correct the job, so that the variable value is
value. within the limit.
4446 32782 OVER VARI- The value for the character-string Change the variable data type for storage or
ABLE LIMIT type variable exceeded the maxi- correct the job, so that the variable value is
mum value. within the limit.
8-83
Alarm Message List

Alarm Sub
Number Code
4446 32783 OVER VARI- The value for comment type vari- Change the variable data type for storage or
ABLE LIMIT able exceeded the maximum value. correct the job, so that the variable value is
within the limit.
4447 0 DEFECTIVE Incorrect teaching of circular inter- Teach the 3 points again so that they do not
TAUGHT POINT polation steps lie in a straight line.
(CIRC) • The three points taught for the cir-
cular interpolation step lie in a
straight line.
4448 1 WEAVING CON- An error occurred in weaving con- Reset the alarm, and then try again.
TROL ERROR trol. If the error occurs again, contact your
• Weaving control-group designa- Yaskawa representative.
tion error
4448 4 WEAVING CON- An error occurred in weaving con- Reset the value 0.1 seconds or more.
TROL ERROR trol.
• When the speed is specified by
weaving time in the weaving file,
zero or the negative value is set
for the weaving time.
4448 5 WEAVING CON- An error occurred in weaving con- Reset the value 0.1 Hz or more.
TROL ERROR trol.
• When the speed is specified by
frequency in the weaving file, zero
or the negative value is set for the
frequency.
4448 6 WEAVING CON- An error occurred in weaving con- Set a positive value for the timer value.
TROL ERROR trol.
• When the timer mode is specified
in the weaving file, a negative
value is set for the timer value.
4448 7 WEAVING CON- An error occurred in weaving con- Set a positive value for the vertical and hori-
TROL ERROR trol. zontal distance.
• For triangle or L-type weaving,
zero is set for the vertical or hori-
zondal distance.
4448 8 WEAVING CON- An error occurred in weaving con- Internal control error. If the error occurs
TROL ERROR trol. again, contact your Yaskawa representative.
• The coordinate control axis desig-
nation for the reference point is
different from actual control axis.
4448 9 WEAVING CON- An error occurred in weaving con- Set the correct dimensions in the tool data.
TROL ERROR trol.
• The distance between the point P
and the TCP could not be calcu-
lated in wrist weaving.
4448 10 WEAVING CON- An error occurred in weaving con- Set the correct dimensions in the tool data.
TROL ERROR trol.
• The distance between the point P
and the TCP could not be calcu-
lated in circular wrist weaving.
4448 11 WEAVING CON- An error occurred in weaving con- Internal control error.
TROL ERROR trol. Contact your Yaskawa representative.
• The Y-direction element of circu-
lar coordinate system for circular
wrist weaving could not be calcu-
lated.
4448 12 WEAVING CON- An error occurred in weaving con- Internal control error.
TROL ERROR trol. Contact your Yaskawa representative.
• The X-direction element of circular
coordinate system for circular
wrist weaving could not be calcu-
lated.
8-84
Alarm Message List

Alarm Sub
Number Code
• Weaving basic-orientation calcula- Yaskawa representative.
tion error
• Calculation error of horizontal- Yaskawa representative.
and wall-direction vector for
weaving
4449 UNMATCHED The storage destination data Match the position type variable data type for
POSNVAR DATA (pulse/Cartesian) is different from the storage source/destination.
ERROR the storage source data.
4450 1 FILE NO. An error occurred in tool file num- • Reset the alarm, reselect the job, and then
ERROR ber check. try again.
4450 2 FILE NO. An error occurred in user coordi- • Reset the alarm, reselect the job, and then
ERROR nate file number check. try again.
4450 3 FILE NO. An error occurred in calibration file • Reset the alarm, reselect the job, and then
ERROR number check between the manip- try again.
ulators. If the error occurs again, contact your
4450 4 FILE NO. An error occurred in tool calibration • Reset the alarm, reselect the job, and then
ERROR file number check. try again.
4450 5 FILE NO. An error occurred in reference point • Reset the alarm, reselect the job, and then
ERROR number check. try again.
4450 6 FILE NO. An error occurred in weaving file • Reset the alarm, reselect the job, and then
ERROR number check. try again.
4450 7 FILE NO. An error occurred in check for weld- • Reset the alarm, reselect the job, and then
ERROR ing start condition file number. try again.
4450 8 FILE NO. An error occurred in check for weld- • Reset the alarm, reselect the job, and then
ERROR ing end condition file number. try again.
4450 9 FILE NO. An error occurred in conveyor char- • Reset the alarm, reselect the job, and then
ERROR acteristic file number check. try again.
4450 10 FILE NO. An error occurred in press charac- • Reset the alarm, reselect the job, and then
ERROR teristic file number check. try again.
4450 11 FILE NO. An error occurred in gun character- • Reset the alarm, reselect the job, and then
ERROR istic file number check. try again.
4450 12 FILE NO. An error occurred in conveyor cali- • Reset the alarm, reselect the job, and then
ERROR bration file number check. try again.
8-85
Alarm Message List

Alarm Sub
Number Code
4450 13 FILE NO. An error occurred in argument num- • Reset the alarm, reselect the job, and then
ERROR ber check. try again.
4450 14 FILE NO. An error occurred in check for • Reset the alarm, reselect the job, and then
ERROR motor gun characteristic file num- try again.
ber. If the error occurs again, contact your
4451 UNDEFINED The reference point (reference Register the reference point.
REFERENCE point number in binary for subcode)
is not registered or is insufficient.
4452 STACK MORE An attempt was made to add more Reset the alarm, and then correct the job so
THAN 8 (JOB than eight stacks in the job call that the number of nests for CALL instruction
CALL) stack. is eight or less.
4453 OVER VARI- The variable number (the variable Correct the job using the variable number
ABLE NO. number which an attempt was within the range.
made to use for subcode) is out of
range.
4454 UNDEFINED The arc welding characteristic file Complete the settings for the arc welding
WELDER CON- cannot be accessed. characteristic file.
DITION FILE • The arc welding characteristic file
is not set.
4455 UNDEFINED The welding start condition file can- Complete the settings for the welding start
ARC START not be accessed. condition file.
COND FILE • The welding start condition file is
not set.
4456 UNDEFINED The welding end condition file can- Complete the settings for the welding end
ARC END COND not be accessed. condition file.
FILE • The welding end condition file is
not set.
4457 WRONG An error occurred in welder type Correct the reference unit for the welding
WELDER check. voltage.
SELECTION • The reference unit for the welding
voltage and the welder type (inde-
pendent/unified) do not match.
4459 EXCESSIVE An error occurred in expression Separate the operation expression, shorten
INSTRUCTION operation. the expression, and then register it to a job.
EQUATION • The operation is impossible
because the expression is too
long.
4460 ZERO DEVIDED An error occurred in operation Do not divide by zero.
OCCURRENCE instruction.
• Zero division occurred.
4461 UNDEFINED An error occurred in automatic Set the number of times of welding release
AUTO WELD welding release conditions. condition, and then try again.
RELEASE COND • The number of welding release
condition is zero for arc auxiliary
file.
4462 UNDEFINED An error occurred at arc retry exe- Set the move instruction following ARCON
POSITION FOR cution. instruction.
ARC RETRY • The arc retry has been set, but no
move instruction exists following
ARCON instruction.
4463 PARITY ERROR An error occurred in data for user I/ Check the parity data of the user I/O group.
O group.
• The parity check for user I/O
group detected the data error.
8-86
Alarm Message List

Alarm Sub
Number Code
4464 OVER BCD The BCD value exceeded the limit. • Correct the data.
RANGE • An attempt was made to output a • Correct the data designation (Binary or
value above the maximum value BCD) or parity check designation (with or
that can be expressed in Binary without.)
Coded Decimal: 99 (decimal)
when no parity check is specified,
and 79 (decimal) when parity
check is specified.
• An attempt was made to read a
data that cannot be expressed in
Binary Coded Decimal (a data
whose lower or upper 4 bits
exceeded 9 in decimal) in the
variable.
4465 OVER BINARY The binary data exceeded the limit. • Correct the data.
RANGE • An attempt was made to output a • Correct the parity check designation.
(PARITY) value that exceeded 127 (deci-
mal) to the user I/O when parity
check was specified.
4466 0 OFFLINE An undefined command was issued Reset the alarm, and then try again.
UNDEFINED to the offline position-data prepara- If the error occurs again, contact your
COMMAND tion section. Yaskawa representative.
(ARITH)
4467 0 USER COORDI- An error occurred at user coordi- Be sure that the number of steps will be three
NATES GENER- nate creation by a job. or more.
ATION STEP • The number of steps was lacking
SHORTAGE for a job for user coordinate cre-
ation.
4468 1 ROBOT The calibration data between The calibration function between manipula-
CALIBRATION manipulators could not correctly be tors cannot be used for this model.
DATA ERROR prepared.
• The calibration between manipu-
lators cannot be executed for this
model.
4468 2 ROBOT The calibration data between Set the different groups for the master group
CALIBRATION manipulators could not correctly be and the slave group.
• The master group and the slave
group are set to the same group.
4468 3 ROBOT The calibration data between Reset the alarm, and then try again.
CALIBRATION manipulators could not correctly be If the error occurs again, contact your
DATA ERROR prepared. Yaskawa representative.
• Incorrect designation of the con-
trol group for master group
trol group for slave group
• Incorrect designation of the occu-
pation control group for calibration
data
• Incorrect designation of the
enabling control group for calibra-
tion data
8-87
Alarm Message List

Alarm Sub
Number Code
4468 7 ROBOT The calibration data between Teach the different 3 points again.
CALIBRATION manipulators could not correctly be
• Among three points in the master-
group’s calibration data, two or
three points are on the same
point.
4468 8 ROBOT The calibration data between Teach the different 3 points again.
CALIBRATION manipulators could not correctly be
• Among three points in the slave-
group’s calibration data, two or
three points are on the same
point.
4468 9 ROBOT The calibration data between Teach the specified number of points for the
CALIBRATION manipulators could not correctly be calibration data.
• The number of the teaching points
for calibration data is insufficient.
4469 1 ROBOT The conversion coordinates for cali- The calibration function between manipula-
CALIBRATION bration between manipulators could tors cannot be used for this model.
FRAME ERROR not be prepared.
• The calibration between manipu-
lators cannot be executed for this
model.
4469 2 ROBOT The conversion coordinates for cali- Separate the master group and slave group.
CALIBRATION bration between manipulators could
FRAME ERROR not be prepared.
• The master group and the slave
group are in the same group.
4469 3 ROBOT The conversion coordinates for cali- Reset the alarm, and then try again.
CALIBRATION bration between manipulators could If the error occurs again, contact your
FRAME ERROR not be prepared. Yaskawa representative.
trol group for master group
trol group for slave group
• Calibration data setting error
4470 0 ROBOT CALI- An error occurred at calibration Correct the number of steps for a job.
BRATION STEP data creation between manipula-
SHORTAGE tors.
• The number of steps was lacking
for a job for calibration data cre-
ation between manipulators.
4471 1 CALIBRATION The tool calibration data could not Teach the specified number of points.
DATA ERROR correctly be prepared.
• Incorrect number of teaching
points for tool calibration
4471 2 CALIBRATION The tool calibration data could not Reset the alarm, and then try again.
DATA ERROR correctly be prepared. If the error occurs again, contact your
• Incorrect designation of the occu- Yaskawa representative.
pation control group for calibration
data
8-88
Alarm Message List

Alarm Sub
Number Code
• Incorrect designation of the Yaskawa representative.
enabling control group for calibra-
tion data
• Incorrect designation of the con- Yaskawa representative.
trol group for calibration data
Calibration could not be executed. Yaskawa representative.
4472 0 TOOL The tool calibration data could not Reset the alarm, and then try again.
CALIBRATION correctly be prepared. If the error occurs again, contact your
DATA ERROR Calibration could not be executed. Yaskawa representative.
4473 0 ARITHMETIC The alarm occurred in the calcula- Reset the alarm, and then try again.
ALARM RESET tion section could not be reset. If the error occurs again, contact your
ERROR Yaskawa representative.
4474 WRONG CON- The CALL/JUMP destination job • Make the setting in advance so that the con-
TROL GROUP could not be executed. trol group of the CALL/JUMP desgination
AXIS • An attempt was made to call or job is included in that of the CALL/JUMP
jump to a job whose control group source job.
cannot be controlled. (Sub code: • Use a PSTART instruction when the inde-
The related control-group) pendent control function is used.
4475 0 CANNOT EXE- An attempt was made to execute a Add the robot axis to the control-group of the
CUTE JOB job without robot axis. job.
(NO ROBOT) • The robot axis is not designated
for the control-group of the job at
execution of a work instruction
that uses a manipulator.
4476 0 CANNOT EDIT An attempt was made to change Release the prohibition.
(EDIT LOCKJOB) the tag data for the job prohibited
from being edited.
(EDIT LOCKJOB) the speed tag data for the job pro-
hibited from being edited.
(EDIT LOCKJOB) the board thickness tag data for the
job prohibited from being edited.
4477 SELECT ERROR Incorrect selection of application Needs investigation. Contact your Yaskawa
(APPLICATION) • When executing a work instruc- representative.
tion, the application selection
parameter (parameter exclusive
for manufacturer) is inconsistent
with the application parameter
(AP parameter). (Subcode: Appli-
cation number)
4480 SELECT ERROR Incorrect selection of sensor func- Needs investigation. Contact your Yaskawa
(SENSOR) tion representative.
• When executing a work instruc-
tion, the sensor application selec-
tion parameter (parameter
exclusive for manufacturer) is
inconsistent with the sensor
parameter (SE parameter). (Sub-
code: Sensor number)
8-89
Alarm Message List

Alarm Sub
Number Code
4484 WRONG PORT Incorrect analog output port selec- Correct the parameter value.
NO. (ANALOG tion parameter
OUTPUT) • The value of the parameter
AxP010 indicating the leading
number of analog output port
used for arc welding or sealing
application was incorrect. (Sub-
code: Application number)
4485 WRONG SELEC- When executing a sensor instruc- Needs investigation. Contact your Yaskawa
TION (SENSOR) tion, the robot specified to use the representative.
sensor (system parameter) and the
robot specified to use the applica-
tion (system parameter) are
unmatched.
4486 PASS OVER When executing COM-ARC func- • Remove the cause of the path-over.
tion, the path was beyond the spec- • Set the path over radius within the allowable
ified path-over monitor zone. range.
4487 0 WRONG MECH An error occurred in mechanical Reset the alarm, and then try again.
PARAMETER paramater for the path control sec- If the error occurs again, contact your
FILE tion. Yaskawa representative.
4489 1 DEFECTIVE The CUT instruction could not be Set zero pulse for the C-and W-axis position
TAUGHT POINT executed. at the cutting start position.
(CUTTING) • The C- and W-axis position at the
cutting start position is not zero
pulse.
4489 2 DEFECTIVE The CUT instruction could not be Set a value bigger than 0 for the radius.
TAUGHT POINT executed.
(CUTTING) • Zero is set for the cutting radius.
4489 3 DEFECTIVE The CUT instruction could not be The CUT instruction can be used for the
TAUGHT POINT executed. manipulator with small-circle cutting axis only.
(CUTTING) • The cutting machine axis is not
mounted.
4489 4 DEFECTIVE The CUT instruction could not be This robot cannot perform a hexagonal cut-
TAUGHT POINT executed. ting motion.
(CUTTING) • This manipulator cannot perform a Select an other cutting form.
hexagonal cutting motion.
4490 1 DEFECTIVE The Endless motion could not be To perform an interpolation motion such as
TAUGHT POINT performed. MOVL and MOVC after an Endless rotation,
(ENDLESS) • After the Endless rotation com- execute an MRESET instruction beforehand.
pleted, an attempt was made to
execute an interpolation instruc-
tion such as MOVL and MOVC
before executing an MRESET
instruction.
4490 2 DEFECTIVE The Endless motion could not be Change the parameter setting that desig-
TAUGHT POINT performed. nates the Endless rotation axis.
(ENDLESS) • The base axis is set as an End-
less rotation axis. The Endless
function cannot be used with the
base axis.
4490 3 DEFECTIVE The Endless motion could not be Set the parameter for designation of the End-
TAUGHT POINT performed. less rotation axis.
(ENDLESS) • An attempt was made to execute
the Endless function although the
endless axis was not designated.
4490 4 DEFECTIVE The Endless motion could not be Correct the rotation amount so that the End-
TAUGHT POINT performed. less axis does not exceed the maximum
(ENDLESS) • The Endless axis exceeded the pulse value.
maximum pulse value
(±536870911).
8-90
Alarm Message List

Alarm Sub
Number Code
4491 1 CORREC- An error occurred in the calculation Reset the alarm, and then try again.
TIONAL DIREC- section for the correcting direction If the error occurs again, contact your
TION ERROR at path correcting motion. Yaskawa representative.
• Control-group designation error
for correcting-direction prepara-
tion
• Designation error for the correct-
ing-direction coordinates
4491 3 CORREC- An error occurred in the calculation Teach the correcting direction with the refer-
TIONAL DIREC- section for the correcting direction ence point (REFP).
TION ERROR at path correcting motion.
• When “any direction” is set for the
correcting direction, the correction
coordinates is not prepared.
4491 4 CORREC- An error occurred in the calculation Teach the reference points (REFP) so that
TIONAL DIREC- section for the correcting direction each point is different.
TION ERROR at path correcting motion.
• When “any direction” is set for the
correcting direction, the refer-
ence points (REFP) are taught on
the same point.
• Designation error for the coordi-
nated motion control axis at the
reference point
4492 1 POSITION An error occurred in the calculation Reset the alarm, and then try again.
CORRECTION section for the correcting direction If the error occurs again, contact your
ERROR at path correcting motion. Yaskawa representative.
• Data unmatched between the cor-
rection amount data and the job
data:
The information about the control
groups designated for the series
of jobs, which is added to the cor-
rection amount data, does not
include the valid control-group for
the job.
4492 2 POSITION An error occurred in the calculation Reset the alarm, and then try again.
CORRECTION section for the correcting direction If the error occurs again, contact your
ERROR at path correcting motion. Yaskawa representative.
• Data unmatched between the cor-
rection amount data and the job
data:
The valid control-group infroma-
tion that is added to the correction
amount data disagrees with the
valid control-group for the job.
4493 OVER TOOL The tool fil number exceeded the Reset the alarm, and turn the power OFF
FILE NO. limit value. then back ON.
• The tool number for internal con- If the error occurs again, contact your
trol is 25 or more. Yaskawa representative.
4494 1 DEFECTIVE Incorrect teaching of weaving Change the positions so that the weaving
TAUGHT POINT motion positions start point and end point are different.
(WEAV) • The weaving start point and end
point are on the same point.
8-91
Alarm Message List

Alarm Sub
Number Code
4494 2 DEFECTIVE Incorrect teaching of weaving Change the positions so that the weaving
TAUGHT POINT motion positions start point, end point, and reference point are
(WEAV) • Among the weaving start point, different.
end point, and reference point,
two or three points are on the
same point.
4495 UNDEFINED Calibration between manipulators Before using the coordinated motion, execute
ROBOT has not executed. the calibration between manipulators.
CALIBRATION • A coordinated motion is impossi-
ble because no calibration
between manipulators has been
made.
4496 1 PARAMETER Setting error of motion control Set a correct value.
ERROR parameter If the error occurs again, contact your
• The setting of the manipulator Yaskawa representative.
number is incorrect.
• Zero is set for the resolution. Yaskawa representative.
• Zero is set in the feedback pulse Yaskawa representative.
parameter.
• The setting of L-axis ball-screw Yaskawa representative.
data is incorrect.
• The setting of U-axis ball-screw Yaskawa representative.
data is incorrect.
• Zero or a negative value is set for Yaskawa representative.
MAXPPS.
the maximum acceleration speed.
the maximum deceleration speed.
the play-mode servo averating
time.
• The setting of the manipulator Yaskawa representative.
number is incorrect. An unde-
fined type is designated.
4496 11 PARAMETER Setting error of motion control Set a correct coordinate system.
• The incorrect coordinate system is Yaskawa representative.
designated for the cubic interfer-
ence. An undefined coordinate
system is set.
8-92
Alarm Message List

Alarm Sub
Number Code
4496 12 PARAMETER Setting error of motion control Set a correct number.

• The designation of the user coodi- Yaskawa representative.
nates number is incorrect. A
number out of the setting range is
set.
4496 13 PARAMETER Setting error of motion control Set a correct value for the resolution.
The reduction ratio ≤ 0 is output. Yaskawa representative.
4496 14 PARAMETER Setting error of motion control Set a correct value for the spring constant.
the spring constant.
4496 15 PARAMETER Setting error of motion control Set a correct value for the motor inertia.
the motor inertia.
4496 16 PARAMETER Setting error of motion control Set a correct value for the speed calculation
ERROR parameter constant.
• Zero or a negative value is set for If the error occurs again, contact your
the speed calculation constant. Yaskawa representative.
4496 17 PARAMETER Setting error of motion control If the error occurs again, contact your
ERROR parameter Yaskawa representative.
• Dividing number setting error
4496 18 PARAMETER Setting error of motion control Correct the parameter setting.
• The setting of allowable torque for Yaskawa representative.
the speed reducer is incorrect.
• The setting of allowable torque for Yaskawa representative.
the motor is incorrect.
4496 20 PARAMETER Setting error of motion control Do not use the torque acceleration/decelera-
ERROR parameter tion with this manipulator.
• The manipulator type is not appli-
cable for torque acceleration/
deceleration.
4496 21 PARAMETER Setting error of motion control Set a correct value for the balancer.
the balancer.
4496 22 PARAMETER Setting error of motion control Set a correct value for the angle of hexagon.
• The angle of hexagon set for the Yaskawa representative.
CUT instruction is out of the range
"0 degree < angle < 60 degrees."
• Encoder type designation error
• Observer sampling time error
• Two-degree-of-freedom system
Kp value error
8-93
Alarm Message List

Alarm Sub
Number Code
• The setting of torque acceleration/ Yaskawa representative.
deceleration designation parame-
ter is incorrect.
• Observer polarity setting error
• The inertia value error for the shift
value calculation
• Observer attenuation constant
error
• Torque estimation parameter error
• The segment clock error occurred
when the PV loop is 1 ms.
• Non-robot axis observer selection
error
• Zero is set for the response time Yaskawa representative.
constant.
• Effeciency data error
4496 35 PARAMETER Setting error of motion control The averaging time constant must be set for
ERROR parameter the optimized acceleration/deceleration con-
• Zero is set for the averaging time trol.
constant. Correct the parameter setting.
• Torque limit ratio data error
• Coulomb friction data error
• Kinematic friction coefficient data
error
• The setting in the optimized accel- Yaskawa representative.
eration/deceleration designation
parameter is incorrect.
• An uninstalled function is desig- Yaskawa representative.
nated.
8-94
Alarm Message List

Alarm Sub
Number Code
• The dynamics-model calculation
at the optimized acceleration/
deceleration is invalid.
• Zero is set for the inertia of Yaskawa representative.
dynamics fixed model.
• Designation error for dynamics-
model calculation type
• The optimized acceleration/decel-
eration control of speed limit func-
tion is disabled.
• The axis designation parameter Yaskawa representative.
for the speed limit function is not
set.
• The setting in the mode designa- Yaskawa representative.
tion parameter for the speed limit
function is incorrect.
• Zero or negative value is set in the Yaskawa representative.
allowable braking torque parame-
ter for the speed limit function.
• Zero or a negative value is set in Yaskawa representative.
the speed adjustment ratio
parameter for the speed limit
function.
the torque limit adjustment ratio
parameter for the acceleration/
deceleration tuning.
the parameter that sets the short-
est acceleration/deceleration time
for when the excessive torque is
applied at the optimized accelera-
tion/deceleration.
ERROR parameter
• Zero is set for the dimension infor-
mation "a3" for the SKR manipu-
lator.
8-95
Alarm Message List

Alarm Sub
Number Code
ERROR parameter
• The setting of sealer-gun control-
group parameter for the servo
sealer control is incorrect.
ERROR parameter
• The parameter setting for the Car-
tesian manipulator X-axis data is
incorrect.
ERROR parameter
• The parameter setting for the Car-
tesian manipulator Y-axis data is
incorrect.
• The setting for the Dual-arm
manipulator is incorrect.
ERROR parameter
• Zero or a negative value is set in
the FORMCUT maximum accel-
eration/deceleration time parame-
ter.
• The setting of expanded check-
point designating bits for the arm
interference check is incorrect.
ERROR parameter
the sphere at the arm interference
check point.
ERROR parameter
the cylinder at the arm interfer-
ence check point.
ERROR parameter
• The number of designated check
points for the arm interference
chek is insufficient.
ERROR parameter
• All of X, Y, and Z value of the
expanded check-point 1 for the
arm interference check are set to
zero.
ERROR parameter
• All of X, Y, and Z value of the
expanded check-point 2 for the
arm interference check are set to
zero.
8-96
Alarm Message List

Alarm Sub
Number Code
ERROR parameter
• The setting of wrist axis angle for
tube-incorporated wrist type
manipulators or three-roll wrist
type manipulators is incorrect.
4496 86 PARAMETER Setting error of motion control Change the parameter setting to disable the
ERROR parameter special link JOG operation for this manipula-
• The special link JOG operation tor.
cannot be used with this manipu-
lator.
ERROR parameter
• The setting in the parameter for
special angle limit check designa-
tion is incorrect.
• The setting of the deceleration
speed for the path-priority control
is less than zero.
ERROR parameter
• A negative value is set in the
roundness parameter for the
path-priority control.
ERROR parameter
• The link parameter for the cutting
device is not set.
4496 95 PARAMETER Setting error of motion control This function cannot be used for control
ERROR parameter groups other than the robot axis. Correct the
• The real-time bending correction parameter setting.
function is enabled for a control-
group other than robot axis.
ERROR parameter
• Zero is set for the dimension infor-
mation "a2" for the Arc Cell Torch
Arm type manipulators.
ERROR parameter
• Zero is set for the deceleration
ratio for double T-axis unit of the
V-shaped double T-axis manipu-
lator.
4497 1 DEFECTIVE Incorrect teaching points for cali- Perform the teaching again so that the teach-
TAUGHT POINT bration between manipulators ing points are different from one another.
(CALIB) • Some of the teaching points for
master-group are on the same
point.
4497 2 DEFECTIVE Incorrect teaching points for cali- Perform the teaching again so that the teach-
TAUGHT POINT bration between manipulators ing points are different from one another.
(CALIB) • Some of the teaching points for
slave-group are on the same
point.
4497 3 DEFECTIVE Incorrect teaching points for cali- Perform the teaching again so that the 2nd-
TAUGHT POINT bration between manipulators axis positions of C3, C4, and C5 of the sta-
(CALIB) • The 2nd-axis positions of C3, C4, tion axes are the same.
and C5 of station axes are not the
same.
8-97
Alarm Message List

Alarm Sub
Number Code
4497 4 DEFECTIVE Incorrect teaching points for cali- Perform the teaching again so that the 1st-
TAUGHT POINT bration between manipulators axis positions of C1, C2, and C3 of station
(CALIB) • The 1st-axis positions of C1, C2, axes are the same.
and C3 of station axes are not the
same.
4497 5 DEFECTIVE Incorrect teaching points for cali- Perform the teaching again so that the 2nd-
TAUGHT POINT bration between manipulators axis positions of C1, C2, and C3 of station
(CALIB) • The 2nd-axis positions of C1, C2, axes are not the same.
and C3 of station axes are the
same.
TAUGHT POINT bration between manipulators axis rotation direction of C3, C4, and C5 of
(CALIB) • The 1st-axis rotation direction of station axes are the same.
C3, C4, and C5 of station axes
are not the same.
TAUGHT POINT bration between manipulators axis (elevation axis) positions of C1, C2, and
(CALIB) • The 1st-axis (elevation axis) posi- C3 of station axes are the same.
tions of C1, C2, and C3 of station
axes are not the same.
TAUGHT POINT bration between manipulators axis (elevation axis) positions of C3, C4, and
(CALIB) • The 1st-axis (elevation axis) posi- C5 of station axes are the same.
tions of C3, C4, and C5 of station
axes are not the same.
4498 CANNOT An error occurred in a job without Register the instruction in a job with control
EXECUTE JOB control group. group.
(NO GRP AXIS) • An attempt was made to execute
an instruction that could not be
executed in a job without control
group.
4499 UNDEFINED The position type variable is not Set the position type variable.
POSITION registered.
VARIABLE • An attempt was made to use the
position type variable that was not
set. (Subcode: The variable num-
ber)
4500 UNDEFINED The user coordinate is not regis- Set the user coordinate.
USER FRAME tered.
• An attempt was made to use the
user coordinate that was not set.
(Subcode: User coordinate num-
ber)
4501 OUT OF RANGE The number of tasks exceeded the Reset the alarm, and then try again. If the
(PARALLEL limit. error occurs again, contact your Yaskawa
PROCESS) • An error occurred in the multi-task representative.
control process for the indepen-
dent control function. (Sub code:
Task number)
4502 SL BOARD ON- An error occurred in option board at • Remove the option board, and insert it prop-
LINE ERROR power ON. The option board was erly again.
detected not to operate normally at If the error occurs again, contact your
power ON. Yaskawa representative.
4505 UNDEFINED Arc retry could not be executed Register a step before the ARCON instruc-
POSITION FOR because there was no step before tion.
ARC ON the ARCON instruction.
8-98
Alarm Message List

Alarm Sub
Number Code
4506 UNDEFINED Arc-restart-return could not be exe- Reset the alarm, and then re-program the
POS FOR cuted because there was no job.
RESTART restart-return step in the job.
RETURN (Example: A retry request was
made while executing a step of the
called job.)
4507 REFP POS Incorrect teaching point for search • Perform the teaching again so that the
ERROR detection search start point and the motion target
(SEARCH • The search start point and the point are not the same.
MOTION) motion target point are the same, • Increase the distance between the search
or the distance between the two start point and the motion target point.
points is too short.
4508 0 SPECIFIED An invalid coordinate system was Reset the alarm, and then specify a valid
ERROR specified. coordinate system.
(COORDINATE) • The specified coordinate system
does not exist.
(COORDINATE) • Designation error of the master
tool coordinate system. This coor-
dinate system cannot be used.
(COORDINATE) • Designation error of the tool coor-
dinate system. This coordinate
system cannot be used.
(COORDINATE) • Designation error of the conveyor
coordinate system. This coordi-
nate system cannot be used.
(COORDINATE) • Designation error of the weaving
(COORDINATE) • Designation error of the COMARC
(COORDINATE) • Designation error of the cylindri-
cal coordinate system. This coor-
dinate system cannot be used.
(COORDINATE) • Designation error of the coordi-
nate system for the external refer-
ence point. This coordinate
system cannot be used.
nate system for 3D shifting. This
coordinate system cannot be
used.
8-99
Alarm Message List

Alarm Sub
Number Code
nate system at IMOV for 3D shift-
ing. This coordinate system
cannot be used.
4508 16 SPECIFIED An invalid coordinate system was Reset the alarm, and then specify the valid
(COORDINATE) • Designation error of the H-LINK
type cylindrical coordinate sys-
tem. This coordinate system can-
not be used.
4509 1 MFRAME An error occurred at MFRAME exe- The master or slave control group is incorrect
ERROR cution. when the master tool user coordinate is spec-
ified.
4510 CANNOT EXE- The SQRT instruction could not be Correct the job.
CUTE INSTRUC- executed.
TION (SQRT) • An attempt was made to calcu-
late the square root of negative
value. (The second argument was
negative.)
4511 OUT OF RANGE Incorrect robot position when the Reset the alarm, and then try again.
(DROP-VALUE) servo was turned ON
The pulse difference of the robot
position exceeded the allowable
value between when the servo was
OFF previously and when the servo
was ON this time.
The standard allowable number of
pulses is 100. (Subcode: Control
group exceeding the allowable
value.)
4512 TWO STEPS The teaching points are aligned in a Perform the teaching again so that the teach-
SAME LINE straight line. ing points are not aligned in a straight line.
(3 STEPS) • In the user coordinates for calibra-
tion between manipulators, three
or more teaching points are
aligned in a straight line.
4513 EXCESSIVE At the safety speed 1, the manipu- • Reduce the speed of the step (move
SEGMENT lator motion speed exceeded the instruction) where the alarm occurred.
(SAFETY: 1) speed limit value (LOW level). • The manipulator may be near the singular
: LOW point. Change the position and orientation
of the manipulator.
(SAFETY: 1) speed limit value (HIGH level). • The manipulator may be near the singular
: HIGH point. Change the position and orientation
of the manipulator.
(SAFETY: 2) speed limit value (LOW level). • The manipulator may be near the singular
: LOW point. Change the position and orientation
of the manipulator.
(SAFETY: 2) speed limit value (HIGH level). • The manipulator may be near the singular
: HIGH point. Change the position and orientation
of the manipulator.
8-100
Alarm Message List

Alarm Sub
Number Code
4517 SEARCH An error occurred in search/moni- Check the system versions for XCP01 and
MONITOR SET toring mode settings in servo sec- WRCA.
ERROR tion.
(SERVO) • An error occurred in interface with
servo section at search/monitor-
ing mode. (Subcode: The related
control-group)
4518 SEARCH MON An error occurred in search/moni- Check the system versions for XCP01 and
RELEASE toring mode releasing in servo sec- WRCA.
ERROR tion.
• An error occurred in interface with
servo section at search/monitor-
ing mode. (Subcode: The related
control-group)
4519 1 SPHERE INTRF An error occurred in sphere interfer- Perform the calibration between manipula-
ERR (ROBOT) ence between manipulators. tors.
CALCULATION • No calibration between manipula-
tors has been made.
4520 AXIS BLOCKING A motion was commanded for the Reset the alarm, and then try again. Turn ON
group axis during axis block at play the general-purpose input signal set in the
mode. (Subcode: The related con- parameter.
trol-group)
4521 0000_ WRONG JOB Job type is inconsistent. Check that what type of job will be started
0001 TYPE • A robot job was started from the before starting.
concurrent job at CALL/JUMP
instruction execution.
1001 TYPE • A concurrent job was started from before starting.
the robot job at CALL/JUMP
0001 TYPE • A system job was started from the before starting.
robot job at CALL/JUMP instruc-
tion execution.
4522 2 TAG DATA An error occurred at tag data • Correct the job file.
CHANGE PRO- change. If the error occurs again, contact your
CESS ERROR • An error occurred at instruction Yaskawa representative.
read-in.
CESS ERROR • The tag is not registered. Yaskawa representative.
CESS ERROR Yaskawa representative.
4524 CANNOT EXE- An error occurred at concurrent job Correct the job.
CUTE INST execution.
(CONCUR JOB) • There was an unexecutable
instruction such as move instruc-
tion in the concurrent job.
4525 SPECIFIED JOB An error occurred at startup of Needs investigation. Contact your Yaskawa
EXECUTION multi-system job. representative.
IMPOSSIBILITY • The specified job could not be
executed.
4527 UNDEFINED Incorrect analog output port num- Correct the specified analog output port num-
PORT NO. ber ber.
(AOUT) • The specified analog output port
number was not allowed.
8-101
Alarm Message List

Alarm Sub
Number Code
4528 SYNTAX ERROR An error occurred in the instruction • Needs investigation. Contact your Yaskawa
syntax. representative.
• The function and the correspond- • If replacement of the system software is
ing instruction data is inconsis- necessary, follow the instructions for
tent in the system software. replacement. After replacement, delete the
(Subcode: Box number) corresponding instructions, and then re-
register them.
4529 1 TWIN COORDI- An error occurred at twin synchroni- Specify a R □ +S □job for the job started by
NATED ERROR zation execution. SYNC instruction.
• A job without control group was
started by SYNC instruction.
4529 2 TWIN COORDI- An error occurred at twin synchroni- Specify a R □ +S □job fo the job started in
NATED ERROR zation execution. SYNC.
• A job only with robot axes was
started by SYNC instruction.
4529 3 TWIN COORDI- An error occurred at twin synchroni- Specify a R □ +S □job fo the job started in
NATED ERROR zation execution. SYNC.
• A job only with master control
group axes was started by SYNC
instruction.
4529 4 TWIN COORDI- An error occurred at twin synchroni- • Correct the job.
NATED ERROR zation execution. If the error occurs again, contact your
• At full synchronization, the com- Yaskawa representative.
pletion timings of move instruc-
tions for the master and the slave
disagreed.
• At full synchronization, no opera- Yaskawa representative.
tion request from the master was
sent.
• At full synchronization, the execu- Yaskawa representative.
tion timings of move instructions
for the master and the slave dis-
agreed.
4530 1 CONVEYOR An error occurred in conveyor syn- • Reset the alarm, and then try again.
SYNCHRONIZ- chronization execution. If the error occurs again, contact your
ING ERROR • The base axis specification is Yaskawa representative.
other than 1 or 2 for conveyor
characteristic file.
ING ERROR • No robot axis in the job for robot Yaskawa representative.
axis tracking
ING ERROR • No base axis in the job for base Yaskawa representative.
axis tracking
ING ERROR • The conveyor board number and Yaskawa representative.
conveyor characteristic file num-
ber used are incorrect.
ING ERROR • There was no conveyor start posi- Yaskawa representative.
tion data at prereading process-
ing.
8-102
Alarm Message List

Alarm Sub
Number Code
ING ERROR • No base axis in the job for arc Yaskawa representative.
tracking
4531 CONVEYOR Conveyor characteristic file is not Set "Use state" of conveyor characteristic file
CHARACTERIS- set. set for the job to "1: Use."
TIC FILE UNSET • "Use state" of the conveyor char-
acteristic file set for the job is not
set to "1: Use." (Subcode: Con-
veyor characteristic file number)
4532 CONVEYOR The conveyor speed decreased Correct the "Conveyor Lowest Speed" set in
SPEED DOWN below the "Conveyor Lowest the conveyor characteristic file.
Speed" set in the conveyor charac-
teristic file. (conveyor number for
subcode.)
4533 1 CONVEYOR An internal control error occurred at Reset the alarm, and then try again.
TRACKING conveyor tracking motion. If the error occurs again, contact your
CALCULATION • Designation error of the conveyor Yaskawa representative.
ERROR tracking control-group
CALCULATION • Designation error of the user coor- Yaskawa representative.
ERROR dinates for the conveyor tracking
CALCULATION • An attempt was made to use the Yaskawa representative.
ERROR conveyor tracking function with
the slave manipulator at coordi-
nate motion.
4533 4 CONVEYOR An internal control error occurred at Set a correct value for the resolution.
TRACKING conveyor tracking motion.
CALCULATION • Zero is set for the resolution for
ERROR the turn-table synchronization.
4534 TORQUE Excessive interference torque • Check if the weight information in the tool
INTERFERENCE • The load torque of an axis motor file is correctly set.
exceeded the allowable value • Reduce the speed in the step where the
when the manipulator is operat- alarm occurred.
ing at the specified speed. • Change the position and orientation in the
step where the alarm occurred.
4535 1 PSEND ERROR An error occurred at PSEND Check the destination address.
• An attempt was made to send a
mail to its own task.
4535 3 PSEND ERROR An error occurred at PSEND Check the destination address.
• The mail box number is incorrect.
4536 1 PRECV ERROR An error occurred at PRECV Check the destination address.
• An attempt was made to receive a
mail from its own task.
• The mail data type is inconsistent.
• The mail box number is incorrect.
4537 1 OFFLINEMAIL An error occurred in mail box con- • Reset the alarm, and then try again.
BOX PROCESS- trol in the offline processing section. If the error occurs again, contact your
ING ERROR • Mail box number error Yaskawa representative.
8-103
Alarm Message List

Alarm Sub
Number Code
ING ERROR • Undefined command for mail box Yaskawa representative.
operation
ING ERROR • OFF_MB_IFS pointer is incorrect. Yaskawa representative.
4538 ROBOT AXIS The robot axis tracking could not be Correct the job.
TRACKING executed.
IMPOSIBILITY • An attempt was made to execute
the SYMOVJ instruction at robot
tracking.
4539 1 CORNER R An internal control error occurred at Do not use the Corner-R motion for coordi-
CONTROL the Corner-R motion. nated motion.
ERROR • The Corner-R motion cannot be
used for coordinated motion.
4539 2 CORNER R An internal control error occurred at Perform the teaching again so that the start
CONTROL the Corner-R motion. step and end step are not on the same point.
ERROR • An attempt was made to execute
the Corner-R motion for the same
point.
4539 3 CORNER R An internal control error occurred at Perform the teaching again so that the Cor-
CONTROL the Corner-R motion. ner-R zone is not on a strait line.
ERROR • The Corner-R zone is taught on a
straight line.
4539 4 CORNER R An internal control error occurred at • Change the setting for the Corner-R radius.
CONTROL the Corner-R motion. • Perform the teaching again for the start step
ERROR • The start position or end position or end step for Corner-R.
for the Corner-R motion could not
be calculated inside the start zone
or the end zone.
4539 5 CORNER R An internal control error occurred at Do not use the Corner-R motion for master
CONTROL the Corner-R motion. manipulators at coordinated motion.
used for coordinated motion (with
master manipulators).
4539 6 CORNER R An internal control error occurred at Use a MOVL instruction when using the Cor-
CONTROL the Corner-R motion. ner-R motion.
used for MOVC, MOVS, and
EIMOVC instructions.
4539 7 CORNER R An internal control error occurred at Do not perform weaving when using the Cor-
CONTROL the Corner-R motion. ner-R motion.
ERROR • The Corner-R motion is disabled
during weaving.
4539 8 CORNER R An internal control error occurred at Use the same tool number in a Corner-R
CONTROL the Corner-R motion. zone.
ERROR • Different tool numbers are set in a
Corner-R zone (for the Corner-R
middle step and end step).
4539 9 CORNER R An internal control error occurred at Disable the higher-order acceleration/decel-
CONTROL the Corner-R motion. eration when using the Corner-R motion.
when the higher-order accelera-
tion/deceleration is specified.
4539 17 CORNER R An internal control error occurred at Do not perform the conveyor tracking when
CONTROL the Corner-R motion. using the Corner-R motion.
during conveyor tracking.
8-104
Alarm Message List

Alarm Sub
Number Code
4540 JOB QUE No job queue data Set a data to a job queue, and then call
EMPTY ERROR • "QUE" is used in CALL or JUMP "QUE."
instruction under the condition
that no job queue is used.
4541 INVALID INPUT An error occurred at VAL instruction Check the data of character string of conver-
STRING (VAL) execution. sion source.
• An attempt was made to convert a
character string that could not be
converted to a numerical value.
4542 1 MRESET An error occurred at MRESET • Reset the alarm, and then try again.
ERROR instruction execution. If the error occurs again, contact your
• An MRESET instruction was exe- Yaskawa representative.
cuted while no endless axis was
designated.
4543 JOB CALL An error occurred at job return. • Reset the alarm, and then try again.
STACK ERROR • At job return, an attempt was If the error occurs again, contact your
made to fetch a data from an Yaskawa representative.
empty job call stack or to stack a
data in the job call stack that is
full.
4544 1 MID$ ERROR An error occurred at MID$ instruc- Check the data of the caracter string to be
tion execution. extracted.
• The first character of character
string to be extracted is null at
MID$ instruction execution.
4544 2 MID$ ERROR An error occurred at MID$ instruc- Check the extraction start position or the data
tion execution. of the character string to be extracted.
• The extraction start position
exceeds the character string
length at MID$ instruction execu-
tion.
4545 COMMUNICA- An error occurred at OPEN/CLOSE • Reset the alarm, and then try again.
TION SERVICE instruction execution. If the error occurs again, contact your
ERROR • An error occurred in the communi- Yaskawa representative.
cation service at OPEN/CLOSE
4546 CANNOT The system job could not be exe- • Reset the alarm, and then try again.
EXECUTE cuted. If the error occurs again, contact your
SYSTEM JOB • An error in the system number of Yaskawa representative.
system job. (Subcode: System
number)
4547 PRIMITIVE A premitive error occurred in the • Reset the alarm, and then try again.
ERROR system software. (Subcode: Error If the error occurs again, contact your
code) Yaskawa representative.
4548 CANNOT An error occurred at INIEVNT • Reset the alarm, and then try again.
OPERATE instruction execution. If the error occurs again, contact your
SPECIFIED • The specified event could not be Yaskawa representative.
EVENT QUE operated at INIEVNT instruction
execution.
4549 INIEVNT NOT An error occurred at INIEVNT Execute an INIEVNT instruction.
EXECUTED instruction execution.
• INIEVNT instruction was not exe-
cuted before having executed the
event related process. (Subcode:
System number)
4550 CANNOT EXE- The specified instruction in the user Correct the job.
CUTE INST job could not be executed. (Sub-
(USER JOB) code: System number)
8-105
Alarm Message List

Alarm Sub
Number Code
4565 1 SOFTWARE The used function and the system • Reset the alarm, and then try again.
UNMATCH are inconsistent. If the error occurs again, contact your
• The multi-layer welding function is Yaskawa representative.
not used.
• The observer function is not used. Yaskawa representative.
• The TURBO function is not used. Yaskawa representative.
• The COMARC function is not Yaskawa representative.
used.
• The conveyor/press synchroniza- Yaskawa representative.
tion function is not used.
• The shared motion function is not Yaskawa representative.
used.
• The layer motion function is not Yaskawa representative.
used.
• The general sensor function is not Yaskawa representative.
used.
• The servo float function is not Yaskawa representative.
used.
• The laser cutting function (with Yaskawa representative.
small circle cutter) is not used.
• The motor gun function (for spot Yaskawa representative.
welding application) is not used.
• The speed control function Yaskawa representative.
(VCON/VCOF) is not used.
• The servo hand function (for han- Yaskawa representative.
dling application) is not used.
• The laser cutting function (for form Yaskawa representative.
cutting operation) is not used.
• The series communication func- Yaskawa representative.
tion between the systems
(PSEND/PRECV) is not used.
8-106
Alarm Message List

Alarm Sub
Number Code
• The motion extension function is Yaskawa representative.
not used.
• The bending function is not used. Yaskawa representative.
• The ME-NET function is not used. Yaskawa representative.
• An attempt was made to execute Yaskawa representative.
an undefined instruction.
4566 1 USER An internal control error occurred at Perform the teaching again for the user coor-
COORDINATES preparation of a user coordinates. dinates.
GENERATION • The teaching points are incorrect.
ERROR
4566 2 USER An internal control error occurred at Perform the teaching again for the user coor-
COORDINATES preparation of a user coordinates. dinates.
GENERATION • The teaching points for user-coor-
ERROR dinate turning are incorrect.
4566 3 USER An internal control error occurred at Reset the alarm, and then try again.
COORDINATES preparation of a user coordinates. If the error occurs again, contact your
GENERATION • The robot axis is not specified for Yaskawa representative.
ERROR the control group of the job to pre-
pare the user coordinates.
GENERATION • Position data error Yaskawa representative.
ERROR
GENERATION • Setting error of the slave group for Yaskawa representative.
ERROR user coordinate conversion
4567 CANNOT MONI- The distance could not be moni- Do not perform the arc retry or restart opera-
TOR DISTANCE tored when executing a move tion, or change the interpolation instruction to
instruction. MOVL/MOVC.
• An attempt was made to execute
MOVJ/MOVS instruction in arc
retry or restart operation.
4568 UNDEFINED No press characteristic file is set. Set the status of press characteristic file to be
PRESS CHAR- • An attempt was made to use the used in the job to "Used State."
ACTERISTIC unused press characteristic file in
FILE a job. (Subcode: Press charac-
teristic file number)
4569 PRESS RESO- No press resolution data is set. Set the data, and then press "Data Set" but-
LUTION DATA • The status of press resolution ton to set the status to "Completed."
UNSET data to be used in the job was set
to "Incomplete." (Subcode: Press
characteristic file)
4571 SERVO FLOAT The servo float mode could not be • Check the ROM version of servo board.
MODE RELEASE reset when executing a FLOATOF • Reset the alarm, and then try again.
ERROR instruction.
4572 UNDEFINED The control group for the motor gun Restart the setting of configuration in mainte-
MOTOR GUN is not set. nance mode, and correct the setting of motor
CONTROL GRP gun axis.
8-107
Alarm Message List

Alarm Sub
Number Code
4573 SPOT WELDER Incorrect spot welder number Correct the welder number set in the gun
NUMBER • The welder number set in the gun characteristic file.
ERROR characteristic file is incorrect.
(Subcode: Welder number)
4574 SPOT WELD The spot welding did not complete • Remove the cause such as disconnection of
COMPLETE within the specified time. power supply to the timer conductor, and
TIME LIMIT • Neither the welding completion
then try again.
signal nor the welding error sig-
• If the response from the timer takes too long
nal was received from the timer
conductor within the set time. time due to the system layout, increase the
(Subcode: Welder number) set time.
4575 ERROR IN Incorrect setting of spot welding Set the 2nd pressure, or change the start tim-
WELD START start timing ing.
TIMING SET • For motor gun, the welding timing
was set to "After First Pressure"
while no 2nd pressure was set.
4576 ERR IN MOTOR An error occurred when setting the • Check the ROM version of servo board.
GUN CONT motor gun control mode. • Reset the alarm, and then try again.
MODE • Though a motor gun control mode If the error occurs again, contact your
setting command was sent to the
servo section, no response was
received.
4577 ERR IN MOTOR An error occurred when resetting • Check the ROM version of servo board.
GUN MODE the motor gun control mode. • Reset the alarm, and then try again.
RLSE • Though a motor gun control mode
resetting command was sent to
the servo section, no response
was received.
4578 SPOT WELD An error occurred when executing Reset the timer conductor where the welding
ERROR spot welding. error occurred, and then try again.
• An error occurred when executing
welding using the specified sys-
tem timer conductor. (Subcode:
Welder number)
4579 1 ANTICIPATION An error occurred in the anticipation Register a move instruction between work
CONTROL control processing. instructions.
ERROR • No availability in anticipation con-
trol
4579 2 ANTICIPATION An error occurred in the anticipation Register a move instruction between work
CONTROL control processing. instructions.
ERROR • The anticipation data exceeded
the maximum length.
4580 ANTICIPATION Anticipation could not be executed • Reset the alarm, and then try again.
DISTANCE at re-painting. • Refer to Painting System Additional Func-
SHORTAGE • No return step in re-painting function Manual for details.
tion after emergency stop
4581 1 DEFECTIVE An error occurred in the anticipation Reset the alarm, and then correct the set
ANTICIPATION output file. number.
FILE • Incorrect setting of OT output
number for anticipation output file
4581 2 DEFECTIVE An error occurred in the anticipation Reset the alarm, and then correct the set
ANTICIPATION output file. number.
FILE • Incorrect setting of OG output
number for anticipation output file
4583 CANNOT EXE- An invalid gun type is set. Change the motion mode set to the gun.
CUTE GUN • The mode impossible to control is
TYPE set for the gun.
8-108
Alarm Message List

Alarm Sub
Number Code
4584 STRWAIT TIME An error occurred when executing a • Remove the cause such as defective limit
OUT STRWAIT instruction. switch, and then try again.
• No confirmation signal specified in
It the error occurs again, contact your
the stroke change confirmation Yaskawa representative.
instruction was input within the
set time.
4585 SERVO PART The PG power supply could not be Check the cable connection of motor gun
PG POWER ON turned ON. encoder.
ERROR • The encoder power supply could
not be turned ON when turning
ON the control power supply.
4587 1 MOTOR GUN An error occurred when changing Check the cable connection of motor gun
CHANGE the gun. encoder.
ERROR • A GUNCHG instruction was exe-
cuted in the system configuration
that did not allow the gun change
function.
4587 2 MOTOR GUN An error occurred when changing Execute GUNCHG/PICK instruction when the
CHANGE the gun. motor gun motor is servo OFF.
ERROR • A GUNCHG/PICK instruction was
executed while the motor gun
motor was servo ON.
4587 3 MOTOR GUN An error occurred when changing Execute GUNCHG/PICK instruction when the
CHANGE the gun. ATC is in chuck status.
ERROR • A GUNCHG/PICK instruction was
executed while the ATC was in
unchuck status.
4587 4 MOTOR GUN An error occurred when changing Execute GUNCHG/PLACE instruction when
CHANGE the gun. the ATC is in chuck status.
ERROR • A GUNCHG/PLACE instruction
was executed while the ATC was
in unchuck status.
ERROR • The encoder powr supply could
not be turned ON when executing
a GUNCHG/PICK instruction.
ERROR • The encoder powr supply could
not be turned OFF when execut-
ing a GUNCHG/PLACE instruc-
tion.
4587 7 MOTOR GUN An error occurred when changing • Check the gun characteristic file number
CHANGE the gun. specified by GUNCHG instruction.
ERROR • The gun number specified by the • Check the status of gun identification signal.
GUNCHG instruction did not
agree with the gun identification
signal.
4587 8 MOTOR GUN An error occurred when changing Check the 1st gun axis selection signal set-
CHANGE the gun. ting.
ERROR • The 1st gun axis selection signal
is not set when executing the
twin-wrist gun change.
4587 9 MOTOR GUN An error occurred when changing Check the setting for the gun axis selection
CHANGE the gun. signal.
ERROR • The right and left gun axis selec-
tion signals were duplicated when
executing the twin-wrist gun
change.
8-109
Alarm Message List

Alarm Sub
Number Code
4591 SERVO PART An error occurred at speed control • Check the ROM version of servo board.
SPEED CON- mode setting. • Reset the alarm, and then try again.
TROL MODE • Though a speed control mode set- If the error occurs again, contact your
SETTING ting command was sent to the Yaskawa representative.
ERROR servo section, but no response
was received.
4592 SERVO PART An error occurred at speed control • Check the ROM version of servo board.
SPEED CON- mode release. • Reset the alarm, and then try again.
TROL MODE • Though a speed control mode If the error occurs again, contact your
RELEASE release command was sent to the Yaskawa representative.
ERROR servo section, but no response
was received.
4593 SERVO HAND An error occurred at servo hand • Check the ROM version of servo board.
CONTROL control mode setting. • Reset the alarm, and then try again.
MODE SETTING • Though a servo hand control If the error occurs again, contact your
ERROR mode setting command was sent Yaskawa representative.
to the servo section, but no
response was received.
4594 SERVO HAND An error occurred at servo hand • Check the ROM version of servo board.
CONTROL control mode setting. • Reset the alarm, and then try again.
MODE RELEASE • Though a servo hand control If the error occurs again, contact your
ERROR mode release command was sent Yaskawa representative.
to the servo section, but no
response was received.
4595 1 FORM CUTTING An internal control error occurred in Correct the radius data.
MOTION IMPOS- the Form Cutting motion.
SIBILITY The setting for radius is incorrect.
• For a circle, it is incorrectly set as:
radius ≤ 0, radius < minimum
radius value, or radius > maxi-
mum radius value.
• For an ellipse, it is incorrectly set
as: radius ≤ 0, radius < minimum
radius value/2, or radius > (maxi-
mum radius/2 − width/2).
4595 2 FORM CUTTING An internal control error occurred in Correct the width data.
SIBILITY The setting for width is incorrect.
• For a rectangle, it is incorrectly set
as: width < 1.0, width > sqrt (maxi-
mum diameter2 − height2), or
width > maximum diameter.
• It is incorrectly set as: width < 0,
width > maximum diameter −2 ×
radius.
4595 3 FORM CUTTING An internal control error occurred in Correct the height data.
SIBILITY The setting for height is incorrect.
as: height > maximum diameter,
height < minimum diameter/2, or
height > sqrt (maximum diameter2
− width2).
4595 4 FORM CUTTING An internal control error occurred in Correct the corner radius data.
SIBILITY The setting for the corner radius is
incorrect.
as: corner radius > width/2 or cor-
ner radius > height/2.
8-110
Alarm Message List

Alarm Sub
Number Code
4595 5 FORM CUTTING An internal control error occurred in Correct the overlap data.
SIBILITY The setting for overlap is incorrect.
as overlap > width/2.
• For a circle, it is incorrectly set as
overlap > ABS (2π × radius).
• For an ellipse, it is incorrectly set
as overlap > π × radius +ABS
(width/2).
4595 6 FORM CUTTING An internal control error occurred in Correct the cutting speed data.
SIBILITY The setting for the cutting speed is
incorrect. It is set as the cutting
speed > maximum linear speed.
4595 7 FORM CUTTING An internal control error occurred in Do not use the coordinated motion.
SIBILITY • Coordinated motion cannot be
used with the Form Cutting
motion.
4595 8 FORM CUTTING An internal control error occurred in Correct the setting of the minimum diameter
MOTION IMPOS- the Form Cutting motion. parameter (S1CxG063) for the Form Cutting
SIBILITY • Zero or a negative value is set in motion.
the minimum diameter parameter
(S1CxG063) for the Form Cutting
motion.
4595 9 FORM CUTTING An internal control error occurred in Correct the setting of the maximum diameter
MOTION IMPOS- the Form Cutting motion. parameter (S1CxG064) for the Form Cutting
SIBILITY • Zero or a negative value is set in motion.
the maximum diameter parame-
ter (S1CxG064) for the Form Cut-
ting motion.
4595 10 FORM CUTTING An internal control error occurred in Execute the FORMAPR instruction.
SIBILITY • Although "PLACEMENT" or
"AUTO" is set for the start point
designation on the FORM CUT
SETTING window, the FOR-
MAPR instruction was not exe-
cuted.
4595 11 FORM CUTTING An internal control error occurred in The Cut file settings of FORMAPR and
MOTION IMPOS- the Form Cutting motion. FORMCUT instructions must be same.
SIBILITY • The Cut file setting of the FOR-
MAPR instruction is different from
that of the FORMCUT instruction.
4595 12 FORM CUTTING An internal control error occurred in The FORMAPR instruction cannot be used
MOTION IMPOS- the Form Cutting motion. for the conventional FORMCUT instruction.
SIBILITY • A FORMAPR instruction was • Change the instruction.
used for the conventional FORM- • Needs to validate the new FORMCUT
CUT instruction. instruction. Contact your Yaskawa repre-
sentative.
4595 13 FORM CUTTING An internal control error occurred in A form other than a circle, rectangle, and
MOTION IMPOS- the Form Cutting motion. ellipse cannot be designated for the conven-
SIBILITY • A form other than a circle, rectan- tional FORMCUT instruction.
gle, and ellipse was designated • Designate a circle, rectangle, or ellipse.
for the conventional FORMCUT • Needs to validate the new FORMCUT
instruction. instruction. Contact your Yaskawa repre-
sentative.
8-111
Alarm Message List

Alarm Sub
Number Code
4595 90 FORM CUTTING An internal control error occurred in Correct the radius data.
SIBILITY • The radius data setting for special
circular interpolation is incorrect.
It is incorrectly set as the radius ≤
0.
4595 91 FORM CUTTING An internal control error occurred in Perform the teaching again.
SIBILITY • The arc center coordinates could
not be calculated at special circu-
lar interpolation. Incorrect teach-
ing may be the cause.
4595 92 FORM CUTTING An internal control error occurred in Perform the teaching again.
SIBILITY • The arc center coordinates could
not be calculated at special circu-
lar interpolation. Incorrect teach-
ing may be the cause.
4595 93 FORM CUTTING An internal control error occurred in • Perform the teaching again so that the mov-
MOTION IMPOS- the Form Cutting motion. ing distance becomes longer.
SIBILITY • The averaging time at special cir- • Reduce the motion speed.
cular interpolation motion is too
short.
4595 94 FORM CUTTING An internal control error occurred in Perform the teaching again for the reference
MOTION IMPOS- the Form Cutting motion. point 2.
SIBILITY • Because the designated plane
included reference points at spe-
cial circular interpolation motion,
the arc center coordinates could
not be calculated. Incorrect teach-
ing of the reference point 2 may
be the cause.
4595 100 FORM CUTTING An internal control error occurred in Perform the teaching for the reference point 1
MOTION IMPOS- the Form Cutting motion. as the arc center position.
SIBILITY • The arc center position is not set
for the special circular interpola-
tion motion.
4597 1 OFFLINE An internal control error occurred at Reset the alarm, and then try again.
POSITION DATA offline position data conversion. If the error occurs again, contact your
CONVERSION • Incorrect information of reference Yaskawa representative.
ERROR position data for offline position
data conversion
CONVERSION • Incorrect user-coordinate number Yaskawa representative.
ERROR designation in the standard posi-
tion data for offline position data
conversion
CONVERSION • Incorrect reference-point data for Yaskawa representative.
ERROR offline position data conversion
CONVERSION • The standard position data for Yaskawa representative.
ERROR offline position data conversion
could not correctly be calculated.
8-112
Alarm Message List

Alarm Sub
Number Code
CONVERSION • Incorrect pulse incremental value Yaskawa representative.
ERROR for offline position data conver-
sion
CONVERSION • The position data could not cor- Yaskawa representative.
ERROR rectly be added by the pulse
incremental value at the offline
position data conversion.
CONVERSION • Incorrect Cartesian incremental Yaskawa representative.
ERROR value for offline position data con-
version
ERROR rectly be added by the Catesian
incremental value at the offline
CONVERSION • The position conversion could not Yaskawa representative.
ERROR be done in the designated coordi-
nate system at the offline position
data conversion.
CONVERSION • Incorrect incremental value of Yaskawa representative.
ERROR angle for offline position data con-
version
ERROR rectly be added by the incremen-
tal value of angle at the offline
CONVERSION • The reverse shift value for 3D Yaskawa representative.
ERROR shifting could not correctly be cal-
culated at the offline position data
conversion.
CONVERSION • The reverse shift value for 3D Yaskawa representative.
ERROR shifting could not correctly be
added at the offline position data
conversion.
CONVERSION • The reverse shift value could not Yaskawa representative.
ERROR correctly be calculated at the
offline position data conversion.
CONVERSION • The reverse shift value could not Yaskawa representative.
ERROR correctly be calculated at the
offline position data conversion.
8-113
Alarm Message List

Alarm Sub
Number Code
CONVERSION • The 3D shifting value could not Yaskawa representative.
ERROR correctly be added at the offline
CONVERSION • The shift value could not correctly Yaskawa representative.
ERROR be added at the offline position
data conversion.
CONVERSION • No reference point is specified for Yaskawa representative.
ERROR the offline position data conver-
sion.
CONVERSION • The positions for the mirror shift Yaskawa representative.
ERROR function could not correctly be
calculated at the offline position
data conversion.
CONVERSION • The positions could not correctly Yaskawa representative.
ERROR be converted for the mirror shift
function at the offline position data
conversion.
CONVERSION • The expansion positions for the Yaskawa representative.
ERROR mirror shift function could not cor-
rectly be converted at the offline
CONVERSION • Incorrect designation of coordi- Yaskawa representative.
ERROR nates for a new mirror-shift con-
version function at the offline
position data conversion
4599 0 SERVO An abnormal response was • Reset the alarm, and then try again.
COMMAND returned from the servo control sec- • Turn the power OFF then back ON.
ERROR tion. If the error occurs again, contact your
The servo control processing has Yaskawa representative.
not completed.
4601 UNDEFINED The motor gun characteristic file is Complete the settings for the motor gun char-
GUN COND FILE not set. (Subcode: Motor gun characteristic file.
acteristic file number)
4603 WIRE STICKING Wire stick occurred at spot welding. Remove the cause of wire stick.
• Wire stick was detected at the
welder. (Subcode: Welder num-
ber)
4604 DESIGNATED No home position correction data of • Reset the alarm, and then try again.
AXIS HOME specified axis If the error occurs again, contact your
POSITION COR- Yaskawa representative.
RECTION DATA
NON-EXISTING
8-114
Alarm Message List

Alarm Sub
Number Code
4605 SETTOOL An error occurred when executing a • Check if the tag set value is correct.
ERROR SETTOOL instruction. • Check if the parameter is set correctly.
• The difference between the cur-
rent tool constant and a new set
value exceeded the allowable
range (parameter set value).
4606 GLOBAL VARI- The memory area of global variable Correct the number of global (user) variables
ABLE AREA exceeded the limit value. to be used, or correct the parameter value.
OVERFLOW • An error occurred in the value of
parameter that defines the num-
ber of global (user) variables.
4607 1 MACRO COM- An error occurred when executing a Correct the registration of execution macro
MAND EXECU- macro instruction. job.
TION ERROR • The execution macro job is not
set.
4607 2 MACRO COM- An error occurred when executing a Correct the registration of interrupt macro job.
MAND EXECU- macro instruction.
TION ERROR • The interrupt macro job is not set.
4607 3 MACRO COM- An error occurred when executing a Correct the macro job.
MAND EXECU- macro instruction.
TION ERROR • An attempt was made to start the
job that could not be started by
the macro instruction.
4607 5 MACRO COM- An error occurred when executing a • Reset the alarm, and then try again.
MAND EXECU- macro instruction. • Turn the power OFF then back ON.
TION ERROR • An error occurred in the operation If the error occurs again, contact your
process of job call stack when the
execution of macro instruction
was cancelled.
4607 6 MACRO COM- An error occurred when executing a • Reset the alarm, and then try again.
MAND EXECU- macro instruction. • Turn the power OFF then back ON.
TION ERROR • Incorrect macro number
4608 1 JOB ARGUMENT An error occurred when executing a Correct the job.
GET ERROR GETARG instruction.
• The job argument is not set.
• No number of the specified job
argument
• The data types of job argument
disagreed.
4609 2 MEMORY PLAY An error occurred when executing Correct the job.
FILE ERROR the memo play operation.
• The memory play file was being
used in another system.
• The control group in the memory
play file did not agree with the
control group of execution job.
• An attempt was made to clear the
memory play file by a CLEAR
instruction before having exe-
cuted a MEMOF instruction.
8-115
Alarm Message List

Alarm Sub
Number Code
4604 DESIGNATED No home position correction data

AXIS HOME for the designated axis
POSITION
CORRECTION
DATA
NON-EXISTING
4610 1 MEMORY PLAY An internal control error occurred at Reset the alarm, and then try again.
SAMPLING memory play sampling. If the error occurs again, contact your
ERROR • Failed to read the memory play Yaskawa representative.
sampling data.
ERROR • Failed to write the memory play Yaskawa representative.
sampling data.
ERROR • Failed to seek the memory play Yaskawa representative.
sampling data.
4610 4 MEMORY PLAY An internal control error occurred at Correctly set the memory play mode.
SAMPLING memory play sampling.
ERROR • Incorrect mode setting at memory
play sampling
ERROR • Incorrect designation of the con- Yaskawa representative.
trol group at memory play sam-
pling
ERROR • K/N < 0 in the memory play sam- Yaskawa representative.
pling section
ERROR • The memory play sampling data Yaskawa representative.
back-play mode could not be
detected.
ERROR • The memory play sampling data Yaskawa representative.
could not be initialized.
4611 OPTON An error occurred when executing a Correct the OPTON instruction.
INSTRUCTION OPTON instruction.
EXECUTION • The number of times that the
NUMBER OVER OPTON instruction was executed
exceeded the limit value.
4612 TSYNC ERROR An error occurred at the execution Set the same number of synchronizations of
of the TSYNC instruction. the TSYNC instruction.
• The number of synchronizations
(SNUM) specified by the TSYNC
instruction disagreed. (Sub code:
the number of synchronizations of
the first executed TSYNC)
4613 1 SERVO SEALER An internal control error occurred in Set the function designation parameter.
GUN CONTROL the servo sealer gun motion. If the error occurs again, contact your
ERROR • The function designation parame- Yaskawa representative.
ter is not set.
8-116
Alarm Message List

Alarm Sub
Number Code
4613 2 SERVO SEALER An internal control error occurred in Correct the job.
ERROR • No sealer gun axis exists at the Yaskawa representative.
job for which the sealer gun con-
trol was attempted to be exe-
cuted.
4613 3 SERVO SEALER An internal control error occurred in Correct the job.
ERROR • No robot axis exists at the job at Yaskawa representative.
which an attempt was made to
execute sealer gun control.
4613 4 SERVO SEALER An internal control error occurred in Set either "1" or "2" for PRM1 control method
GUN CONTROL the servo sealer gun motion. designation of the OPTON instruction.
ERROR • Incorrect designation of the con-
trol method for sealer gun control
4613 5 SERVO SEALER An internal control error occurred in If "1" is set for PRM1 of the OPTON instruc-
GUN CONTROL the servo sealer gun motion. tion, set the PRM2 needle position designa-
ERROR • Incorrect designation of the nee- tion to a value between 0 and 100.
dle position for sealer gun control
4613 6 SERVO SEALER An internal control error occurred in If "2" is set for PRM1 of the OPTON instruc-
GUN CONTROL the servo sealer gun motion. tion, set PRM2 sealing width designation to a
ERROR • Incorrect designation of the seal- value between 0 and 30.
ing width for sealer gun control
4614 0 SEALER GUN The servo sealer gun condition file Set the servo sealer gun condition file.
CHARACTERIS- is not set.
TIC FILE UNSET
4615 0 I/O AXIS I/O axis motion could not be per- • Stop the I/O axis motion.
MOTION IMPOS- formed. (in playback) • Correct the job.
SIBILITY (during • An attempt was made to com-
playback) mand a job whose control group
was in I/O axis motion.
4616 1 AXIS SHIFT An internal control error occurred Reset the alarm, and then try again.
ERROR when shifting the axis. If the error occurs again, contact your
• The file could not be switched Yaskawa representative.
because of incorrect start point
designation.
• The control group with which the Yaskawa representative.
axis shifting is performed dis-
agrees with the control group set
for the axis shifting function in the
calibration file.
• The calibration file number for axis Yaskawa representative.
shifting function is out of the appli-
cable range.
4617 1 SU AXIS SU-axes cannot move with the cur- • Reduce the speed of S- and U-axes.
MOTION DIS- rent L- and R-axes position. • Teach the positions of L- and R-axes again
ABLED For the CSL15D manipulator, the so that S- and U-axes can move.
(LR AXIS POSI- motion speed of S- and U-axes
TION ERROR) exceeded the upper limit.
4617 2 SU AXIS SU-axes cannot move with the cur- • Teach the positions of L- and R-axes again
MOTION DIS- rent L- and R-axes position. so that S- and U-axes can move.
ABLED For the CSL15D manipulator, S- • Correct the parameter for speed limit.
(LR AXIS POSI- and U-axes were going to move
TION ERROR) regardless of the limit speed "0"
when the positions of L- and R-
axes exceeded the upper limit.
8-117
Alarm Message List

Alarm Sub
Number Code
4618 1 SHIFT INSTRUC- An internal control error occurred at Set the shift value for Y-axis only.
TION EXECU- execution of the SHIFT instruction.
TION ERROR • For the tool shift with Euler angle
±90 degrees, the shift value for
axes other than Y-axis is set.
4619 UNDEFINED An error occurred in job registration Set the job registration table.
JOB ENTRY table.
TABLE • The job registration table is not
set. (Subcode: Designated regis-
tration number)
4620 0 ARM (TOOL) Arms or tools interfere between Perform the teaching again to correct posi-
INTERFERENCE manipulators. tions for manipulators.
• The arm interference check
between manipulators detected
that manipulator’s arms or tools
are interfered.
4621 WELD COM- An error occurred in welding com- Check the settings for welding completion
PLETE SIGNAL pletion signal. signal.
ERROR • The welding completion signal
was ON when starting the spot
welding instruction execution.
(Subcode: Welder number)
4622 0 SELF INTER- The manipulator’s arm interfers Perform the teaching again to correct posi-
FERENCE with a tool. tions for manipulators.
• The manipulator’s self interfer-
ence check detected that the
manipulator’s arm interferes with
a tool.
4623 1 GETPOS An error occurred when executing a Correct the GETPOS instruction.
COMMAND GETPOS instruction.
ERROR • An attempt was made to obtain
the step that used a local position
type variable. (The step with local
position type variable cannot be
fetched. Example: MOVJ LP000
VJ=25.00)
ERROR • An attempt was made to obtain
the step that used an array posi-
tion type variable. (The step with
array position type variable can-
not be fetched. Example: MOVJ
P[0] VJ=25.00)
ERROR • The specified step did not exist.
4624 PLUG VOLUME Incorrect setting of amount of fill- Review the setting for the amout of fillings.
SETTING ings
ERROR
4625 1 WRONG An error occurred when executing a • Reset the alarm, and then try again.
EXECUTION OF LOADDB instruction. If the error occurs again, contact your
LOADDB INST • No file Yaskawa representative.
LOADDB INST • No directory Yaskawa representative.
LOADDB INST • There was no directory entry after Yaskawa representative.
this point.
8-118
Alarm Message List

Alarm Sub
Number Code
4625 -1 WRONG An error occurred when executing a • Reset the alarm, and then try again.
LOADDB INST • No file name Yaskawa representative.
LOADDB INST • File presence error Yaskawa representative.
LOADDB INST • Incorrect file name Yaskawa representative.
LOADDB INST • The disk is full. Yaskawa representative.
LOADDB INST • The directory is full. Yaskawa representative.
LOADDB INST • I/O error Yaskawa representative.
LOADDB INST • Invalid handle Yaskawa representative.
LOADDB INST • Handle overflow Yaskawa representative.
LOADDB INST • File has already been opened. Yaskawa representative.
LOADDB INST • File attribute error Yaskawa representative.
LOADDB INST • Open mode error Yaskawa representative.
LOADDB INST • The hardware disk with large Yaskawa representative.
capacity is used.
LOADDB INST • The door is open. Yaskawa representative.
LOADDB INST • The disk is write-protected. Yaskawa representative.
LOADDB INST • Card controller access error Yaskawa representative.
LOADDB INST • No card Yaskawa representative.
LOADDB INST • Card drive information readout Yaskawa representative.
error
LOADDB INST • Partition table error Yaskawa representative.
8-119
Alarm Message List

Alarm Sub
Number Code
LOADDB INST • No drive number Yaskawa representative.
LOADDB INST • No specified partition number Yaskawa representative.
LOADDB INST • Cluster size error Yaskawa representative.
LOADDB INST • Incorrect number of sectors Yaskawa representative.
LOADDB INST • Sector/byte error Yaskawa representative.
LOADDB INST • Card not applicable for I/O Yaskawa representative.
LOADDB INST • Nonsupported version Yaskawa representative.
LOADDB INST • The setting register did not exist. Yaskawa representative.
LOADDB INST • Card not applicable for ATA Yaskawa representative.
LOADDB INST • Double chain error Yaskawa representative.
LOADDB INST • Media error (not fixed disk) Yaskawa representative.
LOADDB INST • Media error (not fixed disk) Yaskawa representative.
LOADDB INST • Sector read command error Yaskawa representative.
LOADDB INST • Sector write command error Yaskawa representative.
4626 IMPOSSIBLE An error occurred at S-axis high- Correct the limit distance for S-axis rotation
S-AXIS MOV speed rotation. center motion (S1CG067).
(IN SPHERE) • The S-axis rotation radius was
below the lower limit.
4627 GUN RECOGNI- The gun identification signal was Check the gun identification signal.
TION SIGNAL not received. (Subcode: Gun num-
OFF ber)
4628 WRITE An error in the variable number set- Correct the written destination variable num-
VARIABLE NO. ting. bers.
MULTI SETTING • Duplicated usage of the written
destination variable numbers.
(Subcode: Duplicated variable
number)
8-120
Alarm Message List

Alarm Sub
Number Code
4629 1 GROUP An error occurred when executing Validate the group change parameter.
CHANGE the group change function.
ERROR • The group change parameter was
invalid.
4629 2 GROUP An error occurred when executing Execute the GRPCHG instruction when the
CHANGE the group change function. external axis motor was servo OFF.
ERROR • The GRPCHG instruction was
executed while the external axis
motor was servo ON.
4629 3 GROUP An error occurred when executing Execute the GRPCHG instruction in chuck
CHANGE the group change function. status.
ERROR • The GRPCHG instruction was
executed in unchuck status.
4629 4 GROUP An error occurred when executing Check the group identification signal.
ERROR • The group identification signal
was not received.
4629 5 GROUP An error occurred when executing Check the specified control group number.
ERROR • The specified control group num-
ber and the group identification
number were unmatched.
4629 6 GROUP An error occurred when executing Turn ON the encoder PG power supply when
CHANGE the group change function. GRPCHG is ON.
ERROR • The encoder PG power supply
was OFF when the GRPCHG was
ON.
4629 7 GROUP An error occurred when executing Turn OFF the encoder PG power supply
CHANGE the group change function. when GRPCHG is OFF.
ERROR • The encoder PG power supply
was ON when the GRPCHG was
OFF.
4629 8 GROUP An error occurred when executing Check the group identification signal.
ERROR • The control group that corre-
sponded to the received group
identification signal did not exist.
4630 DUPLICATED The gun numbers were overlapped Check the gun numbers.
GUN NUMBER when executing a SVSPOT instruc-
tion. (Subcode: The overlapped
gun number)
4632 UNDEFINED The linear scale characteristic file is Set the linear scale characteristic file.
LNR SCALE FILE not set. (Subcode: Linear scale
characteristic file number)
4633 1 FOLLOWING An error occurred when executing a Re-execute the move instruction executed
ERROR FOLLOW instruction. before the FOLLOW instruction, and then re-
• An attempt was made to re-exe- execute the FOLLOW instruction.
cute the FOLLOW instruction
after interrupting it.
4634 0 FOLLOWING The manipulator motion speed • Reduce the bending speed.
SPEED OVER exceeded the limit during the Fol- • Perform the teaching again so that the
lowing motion. manipulator moving distance becomes
• With the specified bending speed, shorter.
the manipulator motion speed
exceeds the maximum speed.
4635 CANNOT The called job could not be exe- Correct the control group specified by the
EXECUTE cuted because the specified control CALL instruction.
COMMON JOB group was shared with the called
job. (Subcode: The related control-
group)
8-121
Alarm Message List

Alarm Sub
Number Code
4636 THICKNESS Incorrect workpiece thickness

ERROR (Sub code: Gun number)
4637 TRACK CHG No workpiece presence/absence Check the workpiece presence/absence data
WORK IN/NOT data at switching the synchroniza- for the synchronization section.
NOT FOUND tion section. (Subcode: Conveyor
characteristic file number)
4638 TRACKING CHG No workpiece type data at switch- Check the workpiece type data for the syn-
WORK ID NOT ing the synchronization section. chronization section.
FOUND (Subcode: Conveyor characteristic
file number)
4639 1 SYMOVJ INST An internal control error occurred Reset the alarm, and then try again.
EXECUTE during the SYMOVJ motion. If the error occurs again, contact your
ERROR • The moving amount in the orienta- Yaskawa representative.
tion at the SYMOVJ motion posi-
tion could not correctly be
calculated.
4639 2 SYMOVJ INST An internal control error occurred Set the conveyor moving amount for the
EXECUTE during the SYMOVJ motion. SYMOVJ motion.
ERROR • The conveyor moving amount is
not specified for the SYMOVJ
motion.
ERROR • An error occurred in the prepara- Yaskawa representative.
tion process of the manipulator
motion start position for the
SYMOVJ motion.
ERROR • An error occurred in the prepara- Yaskawa representative.
tion process of the manipulator
motion end position for the
SYMOVJ motion.
4640 1 WRONG An error occurred when executing a Correct the PSTART instruction.
EXECUTION OF PSTART instruction.
PSTART INST • No axis data of control group to be
disconnected
PSTART INST • An attempt was made to discon-
nect a control group other than
the occupation control group dur-
ing prereading processing.
PSTART INST • An attempt was made to discon-
nect a control group other than
the occupation control group
when executing a PSTART
instruction.
4641 CANNOT The disconnected control group Do not use the control group disconnected by
EXECUTE JOB could not be moved. itself for its own move instruction.
(SEPARATE • The control group disconnected
GROUP) by itself was used for its own
move instruction. (Subcode: The
disconnected control group used
by a move instruction)
4644 1 SPOT WELDER An error occurred between the con- • Reset the alarm, and then try again.
I/F ERROR troller and spot welder. • Turn the power OFF then back ON.
(ASW) • The controller could not access If the error ococurs again, contact your
the welder. Yaskawa representative.
8-122
Alarm Message List

Alarm Sub
Number Code
(ASW) • The controller could not send an If the error ococurs again, contact your
instruction to the welder because Yaskawa representative.
the welder was busy in process-
ing.
(ASW) • The welder could not receive the If the error ococurs again, contact your
instruction sent from the control- Yaskawa representative.
ler.
4644 102 SPOT WELDER An error occurred between the con- Check the specified welder number (system),
I/F ERROR troller and spot welder. and specify the correct welder number.
(ASW) • The specified welder number
(system) could not be found.
4645 NOT PERMIT Hover weaving could not be exe- • Correct the job.
FIXED-WEAV ON cuted. • Reset the alarm, and then try again.
SWVON • The hover weaving is disabled in • Turn the power OFF then back ON.
coordinated motion. If the error occurs again, contact your
4800 WDT ERROR Watchdog timer error in the con- • Turn the power OFF then back ON after
(CONVERTER) verter. cooling the power supply unit.
No response from the converter. If the error occurs again, contact your
8-123
9.1 Error Message List
9 Error
Error warns the operator not to advance to the next operation caused by a wrong operation or
the access method when using the programming pendant or an external equipment (compu-
tor, PLC, etc.).
When an error occurs, confirm the content of the error then release the error.
To release the error, perform either of the following operations:

• Press [CANCEL] on programming pendant.
• Input alarm/error reset signal (system input).
NOTE An error is different from an alarm because it does not stop the robot even if it occurred
while the robot was operated (during playback).
Main Menu ShortCut Cannot insert/modify/delete for axis detachment
When two or more errors occur, appears in the message display area. Activate the mes-
sage display area and press [SELECT] to view the list of current errors.
5/9
Cannot load macro job at current security mode
HELP
Cannot insert/modify/delete for group axis detachment
CLOSE
Cannot insert/modify/delete for axis detachment
To view details of the selected error contents, select "HELP." To close the error list, select
"CLOSE." To release all the errors, press [CANCEL].
9-1
9.1.1 System and General Operation
Error No. Data Error Message Contents
Turn off servo power and perform cor- It cannot be operated while servo
10 -
rective action power supply is ON.
20 - Depress TEACH Out of specified operation mode
30 - Illegal setting for number of variables Parameter setting error
40 - Undefined robot position variables Position variable cannot be used.
Undefined points (ORG, XX, XY) Not registered user coordinates

60 -
basic 3 points (ORG, XX, XY)
Program and current tool different The tool number registered with
teaching position data does not
70 - match the the tool number
selected at the programing pen-
dant.
80 - Same position in the 3 points
100 - On overrun recovery status
110 - Turn ON servo power
120 - Set to PLAY mode
130 - No start using external signal
140 - No start using P.P.
180 - TEACH mode select signal ON
190 - Set variable number
200 - Defined group axis
210 - Undefined coordinated robots
212 Cannot register group conbination
230 - While releasing soft limit
240 - Undefined robot
270 - Undefined gun condition file
280 - Lack of number of I/O points
290 - Cannot set same No.
300 - Undefined user frame
310 - Cannot register Master JOB
320 - Cannot operate CHECK-RUN
330 - Cannot operate MACHINE LOCK
9-2
340 - Cannot operate Master JOB
350 - Cannot initialize
Position not checked Second home position was not

380 -
checked.
390 - Can specify servo off by safety relay
Time could not be measured Time could not be measured for

410 -
TRT function.
Incorrect number of taught points The number of the taught points

420 -
for tool calibration is incorrect.
430 - Register start reserved JOB
460 - Excess time for measuring
500 - Undefined robot calibration data
510 - Undefined axis
Cannot select two coorditated combina-

520 -
tion
530 - Start reservation mode
Start reserved JOB change prohibit is

550 -
set
Cannot teach position while soft limit

560 -
released
Register group axis combination [SYNCHRO] was pressed for

590 - coordinated job which was not
registered as group.
600 - Out of setting data range
610 - Cannot use the user coordinate
620 - Select JOB (robot)
650 - Incorrect measured data
660 - Wrong data type of position variable
- Defined data
680
XXX File No.
700 - Wrong CMOS memory board type
760 - Error in start condition set
770 - During robot operation
800 - The gun of designation is not connected
9-3
The group axis of designation is not con-

801 -
nection
810 - Servo power supply is limited
820 - Modification range over
930 - Undefined conveyor calibration data
940 - Forced pressure signal ON
950 - Negative correction distance
960 - I/O axis mode requesting
970 - ERRSVCPU signal error
9-4
9.1.2 Editing
1010 - EDIT LOCK mode
1020 - Enter correct value
1030 - Unauthorized ID No.
1050 - Enter correct date
1060 - Enter correct clock
1070 - Enter an ID number in 4-8 figures
1080 - Negative value can’t be set
9.1.3 Job Defined Data
2010 - Incorrect character
2020 - Name not entered
2030 - Undefined JOB name
2040 - Defined JOB name
2050 - Address not found
2070 - Set robot exactly to taught position
2080 - Press INSERT or MODIFY
Only modifying move instruction possi-

2090 -
ble
2100 - JOB cannot be edited.
2110 - Over soft limit
2120 - Cannot insert/alter/delete with servo off
2150 - Inserting is not possible from this point
2160 - Cannot modify or delete this position
Press INSERT to record same step as

2170 -
previous step
2180 - Cannot insert data
2210 - Illegal data setting
2220 - Display edit instruction
2240 - Excessive instruction equation
9-5
Unmatched number of parentheses in

2250 -
equation
2260 - Wrong group axis selection
Cannot insert any more instruction in

2270 -
JOB
* JOB memory is full
1 Lack of position file memories
2 Lack of JOB registering memories

2280 3 Lack of instruction file memories
4 Lack of memory pool
Lack of pass condition file for multi-

5
layer
2290 - Undefined master JOB
* Undefined SUB Master JOB
1 Sub-master 1
2 Sub-master 2
3 Sub-master 3
2291 4 Sub-master 4
5 Sub-master 5
6 Sub-master 6
7 Sub-master 7
8 Sub-master 8
2292 - Undefined MASTER START JOB
* Undefined SUB START JOB
1 Sub-master 1
2 Sub-master 2
3 Sub-master 3
2293 4 Sub-master 4
5 Sub-master 5
6 Sub-master 6
7 Sub-master 7
8 Sub-master 8
9-6
Cannot teach JOB without group-axis

2300 -
specification
* Same label exists

2310
XXX Line No.
2340 - Pasted data not found
2360 - Cannot create editing area
Cannot cut/copy NOP and END

2370 -
instructions
2390 - Wrong group axis selection
2400 - Cannot move in cut & paste editing
2430 - Reverse data not found
2440 - Move C-and W-axis to basic position Lazer cutting
2450 - Relative JOB not permitted
2470 - Wrong JOB type
2480 - Wrong JOB coordinates setting
2500 - Cannot convert the JOB
2510 - Cannot correct position in the JOB
2520 - Enter JOB name
2530 - Illegal step number
2540 - Enter step number
2550 - Duplicated step number
2551 - Duplicated line number
Cannot correct steps of position vari-

2560 -
ables and REFP
2570 - The step does not contain speed
2580 - The step dose not contain PL/CONT
2590 - Soft limit range over
Cannot teach position in concurrent

2600 -
JOB
2610 - Wrong JOB kind
2620 - Cannot correct play speed in the JOB
2630 - Conveyor position not reset
9-7
2640 - Incorrect JOB name
2670 - Undefined target JOB
Relative job can’t be shifted with pulse

2710 -
type
2730 - Cannot use robot macro JOB
2740 - Cannot use concurrent macro JOB
Cannot use JOB with group-axis speci-

2750 -
fication
Cannot insert/modify/delete for group

2760 -
axis detachment
Axis is separated.
2761 -
Cannot add, modify, or delete.
Cannot reverse data of SVSPOTMOV

2770 -
instruction
2780 - Arithmetic error
9-8
9.1.4 External Memory Equipment
3010 - Floppy disk drive cable not connected
Floppy disk not inserted into floppy

3020 -
disk drive
3030 - Floppy disk protection is ON
File not saved on floppy disk or Com-

3040 -
pact Flash
File saved on floppy disk or Compact

3050 -
Flash
Out of memory on floppy disk or Com-

3060 -
pact Flash
Number of files on floppy disk or Com-

3070 -
pact Flash is full
I/O error on floppy disk or Compact

3080 -
Flash
Transmission error with floppy disk or

*
Compact Flash
1 Framing error
2 Overrun error
3 Parity error
4 Data code error

3090
5 Data read error
6 Data write error
7 Data time out
8 Serial I/O error
9 Error other than described above
3110 - Syntax error
* HEX code error
1 Specification error of data decord
3120 2 Specification error of EOF record
3 Record type error
4 Total check error of record
3130 - Verify error
9-9
3140 - Wrong pseudo instruction
* Concurrent I/O record error
1 Format error
2 Ladder program is too long.
3 Exceed the range of the data

3150
4 Specification error of channel No.
5 Specification error of relay No.
6 Timer value error
7 Specification error of timer No.
3160 - Cannot load illegal system data
* Condition file data error
1 Format error
3170 2 Specified file No. is omitted.
3 Specified tool No. is omitted.
4 User file is not registered.
9-10
* Error in JOB data record
Record on the number of position

1 data (NPOS) is wrong for the for-
mat.
Record on the user coordinate No.

2
(USER) is wrong for the format.
Record on the tool No. (TOOL) is

3
wrong for the format.
Record on the position data section

4
is wrong for the format.
Record on the robot type of XYZ

5 data (RCONF) is wrong for the for-
mat.
Date (DATE) record is wrong for the

6
format.
3190
Comment (COMM) record is wrong
7
for the format.
Record on the JOB attribute data

8
(ATTR) is wrong for the format.
Control group (GROUP)record is

9
Local variable (LVARS)record is

10
JOB argument (JARGS) record is

11
Record on the teaching coordinates

12 for relative job (FRAME) is wrong
for the format.
Position data corrdinates do not

13
match relative job coordinates.
3200 - NOP or END instruction not found
3210 - Position No. storage area not found
* Syntax error in instruction data
2 Interior control error
3 Undefined instruction/tag
3220
4 Instruction/tag shortage
5 Disuse instruction/tag
6 Sub instruction
9-11
7 No instruction
8 Invalid instruction
9 Invalid tag
10 Invalid character
11 Undefined intermediate code
12 Intermediate code shortage
13 Syntax stack overflow
14 Syntax stack underflow
Array type tag incompleted

15
Tag [ARRAY]
Element type tag incompleted

16
Tag [ELEMENT]
17 Macro JOB unregistered
18 Input format error
19 Data size over
20 MIN value over

3220 21 MAX value over
22 Operation expression error
23 Job call argument setting error
Macro job call argument setting

24
error
25 Position vector setting error
26 System error
27 Soft key designate error
28 Numerical input buffer overflow
29 Real type data precision error
30 Element format error
35 BOOL TYPE data error
36 CHAR data error
BYTETYPE, BINARY / HEXADECI-

37
MAL BYTE TYPE data error
INTEGER TYPE, DECIMAL WORD

38
TYPE data error
9-12
BINARY/HEXADECIMAL WORD
39
TYPE data error
DOUBLE PRECISION INTEGER

40 TYPE, DECIMAL DWORD TYPE
data error
BINARY/HEXADECIMAL WORD
41
TYPE data error
42 REAL TYPE data error
LADDER SPECIAL TYPE data

43
3220 error
44 JCL text
45 Invalid text
46 LABEL NAME data error
47 JOB NAME data error
48 STRING data error
49 COMMENT data error
58 Invalid instruction/tag detection
3230 - Syntax not matched
3240 - Undefined application
3250 - Cannot load this file
3260 - Excess input data
3270 - Cannot verify this file
Wrong welding condition (STANDARD/

3280 -
ENHANCED)
3290 - Serial port not defined
3300 - Serial port being used
3310 - Protocol being used
3350 - Not enough memory
3360 - Invalid folder
3370 - Incorrect folder name
Cannot load macro JOB at current Load in management mode.

3450 -
security mode
9-13
* Cannot backup Compact Flash
3460 1 Insufficient Compact Flash memory.
2 Not accessible to Compact Flash.
3470 - Database not found
3480 - Database access error
3490 - Same database exists
3500 - Check Compact Flash insertion
Cannot delete folder. Check attribute

3510 -
and inside file
3520 - Same folder exists
3530 - Cannot load at current security mode
9-14
9.1.5 Concurrent I/O
* Illegal relay No.

4010
XXX Line No.
* Illegal instruction
4030
XXX Line No.
Relay/register No. duplicated in OUT/ Multiple outputs are instructed to

*
GOUT or arithmetic instruction the relay or register.
4040
XXX Line No.
* The relay is not used

4050
XXX Line No.
* Excess STR-[-NOT] instructions

4060
XXX Line No.
* Excess AND [OR] STR instructions

4070
XXX Line No.
* Syntax error in CNT instructions

4080
XXX Line No.
* Enter STR [-NOT] at head of block Need STR [-NOT]

4090
XXX Line No.
Concurrent I/O memory is full Exceeds memory capacity

4120 -
(10000 steps)
4130 - END instruction not found END instruction not found
Wrong ladder program Position and number of PART

4140 -
instruction are wrong.
Wrong use of GSTR, GOUT commands GSTR and GOUT is not used
*
together.
4150
XXX Line No.
Excess TMR/CNT or arithmetic instruc- More than 100 TMR, CNT or

4220 -
tions arithmetic instruction used
4230 - Syntax error in TMR/CNT instructions
9-15
9.1.6 Maintenance Mode
8010 - Too many axes
8020 - Too many I/O points
8030 - Too many boards (XFB01B (MASTER))
8031 - Too many boards (MSC01B)
Memory error (ControlNet output condi-

8040 -
tion)
8041 - Memory error (UNIWIRE CONNECT DAT
8050 - Robot model is not registered
8060 - Cannot get UNIWIRE connection data
9-16
Numerics correlate voltage ........................................... 3-6
CPU unit (JZNC-NRK01) ....................... 5-2, 5-13
creating a check program .............................. 4-3
10A ceramic fuse ........................................ 5-15 cumulative time display ................................ 7-18
200VAC input connector ................................ 5-2 cumulative time display window ..................... 7-18
24V fuse for I/O ............................................ 5-2 current position ............................................ 7-26
24VDC fuse for I/O ...................................... 5-12 current position window ................................ 7-26
24VDC output connector................................ 5-2
3A glass-tube fuse ...................................... 5-15
5A alarm fuse ............................................. 5-15
A DC control power supply connector .......... 5-8, 5-9

decimal data ................................................. 8-3
displaying and releasing alarm ....................... 8-2
absolute data allowable range alarm occurs .. 6-15 door lock ...................................................... 3-2
AC control power supply connector ........... 5-8, 5-9 drive I/F(1) connector .................................... 5-2
alarm ........................................................... 8-1 drive I/F(2) connector .................................... 5-2
alarm history ............................................... 7-21
alarm history window ................................... 7-21
alarm level.................................................... 8-1
amplifier ..................................................... 5-14
axis data ...................................................... 8-3 E
editing mode ................................................ 2-1

emergency stop button .................................. 3-1
B emergency stop button inspections ................. 3-5
emergency stop connector ............................. 5-2
Enable switch ............................................... 3-1
backboard .................................................. 5-13 Enable switch inspections .............................. 3-5
backside duct fan ............................ 3-1, 3-3, 5-13 ENCODER ROTATE SUM............................ 7-27
battery ................................................. 3-1, 5-13 error message list ......................................... 9-1
battery inspections ........................................ 3-6 ERROR PULSE ........................................... 7-27
binary data ................................................... 8-3
brake fuse .................................................. 5-11
F
C
FEEDBACK PULSE ..................................... 7-27
FEEDBACK SPEED..................................... 7-27
changing the absolute data ............................ 6-6
changing the monitor items .......................... 7-28
checking and replacing fuses ....................... 5-11
circuit breaker (QF1) check ............................ 3-7
clearing absolute data ................................... 6-8 G
clearing the alarm history ............................. 7-22
clearing the cumulative time display .............. 7-20 ground wiring................................................ 5-8
clearing the I/O message history .................. 7-24
Compact Flash ............................................. 5-2
connector for encoder signal .......................... 5-2
connector for external power supply................ 5-2
control circuit board (JANCD-NCP01) ..... 5-2, 5-13 H
control group data ......................................... 8-3
control power supply (CPS-420F) ..... 3-3, 5-2, 5-13 home position ............................................... 6-3
control power supply fuse ............................ 5-11 home position calibration ............................... 6-2
converter .................................................... 5-14 hotline connector for programming pendant ..... 5-2
converter control signal connector ............ 5-8, 5-9 how to replace converter ............................... 5-9
converter signal connector ............................. 5-2
cooling fan (JZNC-NZU01) ............................. 3-3
cooling fan construction (medium- or large-capacity
NX100) ........................................................ 3-4
cooling fan construction (small-capacity NX100) 3-3
Index-1
I P
I/F connector between robots ......................... 5-2 PN power supply connector.................... 5-9, 5-10
I/O circuit board ........................................... 5-13 position data when power is turned
I/O communications connector........................ 5-2 ON/OFF ..................................................... 7-25
I/O I/F connector ........................................... 5-2 position deviation check using the check
I/O message history ..................................... 7-23 program ..................................................... 6-10
I/O message history window ......................... 7-23 power flow .................................................... 1-3
independent control function (optional) ............ 8-4 power ON/OFF position window ................... 7-25
individual window of the cumulative time power supply contactor unit .................. 5-11, 5-13
display........................................................ 7-19 power supply contactor unit fuse ................... 5-13
in-panel fan ........................................... 3-1, 5-13 power supply voltage confirmation .................. 3-6
in-panel ventilation fan ................................... 3-3 PWM amplifier control power supply
input power supply check ............................... 3-7 connector ............................................. 5-9, 5-10
input/output status ......................................... 7-3 PWM signal connector .................... 5-2, 5-8, 5-10
L R
lead cable check ........................................... 3-7 rack for the various circuit boards ................... 5-2
recommended spare parts ........................... 5-15
regenerative resistor connector ................ 5-8, 5-9
regular inspections ........................................ 3-1
relay number search .................................... 7-15
M
remote control connector ............................... 5-2
replacing parts .............................................. 5-1
main power switch ......................................... 3-2 replacing parts of the CPU unit ....................... 5-2
major alarm .................................................. 8-1 replacing the base-axis control circuit board
managememt mode ....................................... 2-1 (SGDR-AXA01A) .......................................... 5-5
manipulator home position ............................. 6-9 replacing the control circuit board
manipulator model ......................................... 7-2 (JANCD-NCP01) ........................................... 5-3
MAX. TORQUE ........................................... 7-27 replacing the control power supply
minor alarm .................................................. 8-1 (CPS-420F) .................................................. 5-4
mode switch.................................................. 3-5 replacing the I/O circuit board
modification of the signal name ....................... 7-9 (JANCD-NIO01) ............................................ 5-7
modifying the output status ............................. 7-5 replacing the robot I/F circuit board
MOTOR ABSOLUTE ................................... 7-27 (JANCD-NIF01) ............................................ 5-7
motor power connector .......................... 5-8, 5-10 replacing the robot I/F unit (JZNC-NIF01) ........ 5-6
multiple SERVOPACK system ........................ 8-4 replacing the SERVOPACK............................ 5-8
RIF communications connector ...................... 5-2
RIN input ...................................................... 7-8
RIN input window .......................................... 7-8
N robot I/F circuit board ................................... 5-13
robot I/F unit (JZNC-NIF01) .................... 5-2, 5-13
robot I/F unit fuse ........................................ 5-13
NX100 controller ........................................... 3-1
NX100 parts list ........................................... 5-13
S
O
security mode ............................................... 2-1
security system ............................................. 2-1
open phase check ......................................... 3-7 servo control circuit board
operation mode ............................................. 2-1 (SGDR-AXA01A) .................................. 5-2, 5-13
outline of alarm ............................................. 8-1 servo monitor window .................................. 7-27
servo monitoring ......................................... 7-27
SERVO ON .................................................. 3-5
SERVO ON READY ...................................... 3-5
SERVOPACK ............................... 5-8, 5-13, 5-14
SERVOPACK list ........................................ 5-14
Index-2
signal flow .................................................... 1-4
signal number search .................................. 7-12
SPEED DEVIATION .................................... 7-27
SPEED INST .............................................. 7-27
supplied parts list ........................................ 5-15
system diagnosis .......................................... 7-1
system input ................................................. 7-6
system input connector for robot ..................... 5-2
SYSTEM INPUT detailed window ................... 7-6
SYSTEM INPUT window ............................... 7-6
system output ............................................... 7-7
SYSTEM OUTPUT detailed window ............... 7-7
SYSTEM OUTPUT window ............................ 7-7
system version.............................................. 7-1
three-phase AC power supply connector ... 5-8, 5-9

TORQUE SPEC.......................................... 7-27
TU hotline I/O connector ................................ 5-2
user I/O connector ........................................ 5-2

user ID ......................................................... 2-6
user input ..................................................... 7-3
USER INPUT detailed window ....................... 7-3
USER INPUT window .................................... 7-3
user output ................................................... 7-4
USER OUTPUT detailed window .................... 7-4
USER OUTPUT window ................................ 7-4
voltage between earth (phase-S ground) ......... 3-6
WAGO connector wiring tool ........................ 5-15

WAGO terminal block wiring tool .................. 5-15
XYZ coordinate data...................................... 8-3
Index-3
NX100
MAINTENANCE MANUAL
HEAD OFFICE
2-1 Kurosaki-Shiroishi, Yahatanishi-ku, Kitakyusyu-shi, 806-0004, Japan
Phone 81-93-645-7745 Fax 81-93-645-7746
MOTOMAN INC. HEADQUARTERS
805 Liberty Lane West Carrollton, OH 45449, U.S.A.
Phone 1-937-847-6200 Fax 1-937-847-6277
YASKAWA MOTOMAN CANADA LTD.
2280 Argentia Road, Mississauga, Ontario, L5N 6H8, Canada
Phone 1-905-813-5900 Fax 1-905-813-5911
YASKAWA ELECTRIC AMERICA, INC.
2121 Norman Drive South Waukegan, IL 60085, U.S.A.
Phone 1-847-887-7000 Fax 1-847-887-7370
YASKAWA ELECTRIC EUROPE GmbH
Am Kronberger Hang 2, 65824 Schwalbach,Germany
Phone 49-6196-569-300 Fax 49-6196-888-301
MOTOMAN ROBOTICS EUROPE AB
Box 504 S38525 Torsas, Sweden
Phone 46-486-48800 Fax 46-486-41410
MOTOMAN ROBOTEC GmbH
Kammerfeldstr.1,D-85391 Allershausen, Germany
Phone 49-8166-90100 Fax 49-8166-90103
YASKAWA ELECTRIC KOREA CORPORATION
KFPA Bldg #1201, 35-4 Yeoido-dong, Youngdungpo-Ku, Seoul 150-010, Korea
Phone 82-2-784-7844 Fax 82-2-784-8495
YASKAWA ELECTRIC (SINGAPORE) PTE. LTD.
151 Lorong Chuan, #04-01, New Tech Park Singapore 556741, Singapore
Phone 65-6282-3003 Fax 65-6289-3003
YASKAWA ELECTRIC (SINGAPORE) PTE. LTD. MALAYSIA REPRESENTATIVE OFFICE
B615, 6th Floor, East Wing, Wisma Tractors, No.7, Jalan SS 16/1, Subang Jaya, 47500 Petaling Jaya, Selangor D.E. Malaysia
Phone 60-3-5031-5311 Fax 60-3-5031-5312
YASKAWA ELECTRIC (SHANGHAI) CO., LTD.
4F No Aona Road, Waigaoqiao Free Trade Zone, Pudong New Area, Shanghai 200131, China
Phone 86-21-5866-3470 Fax 86-21-5866-3869
YASKAWA ELECTRIC TAIWAN CORPORATION
9F, 16, Nanking E. RD., Sec. 3, Taipei, Taiwan
Phone 886-2-2502-5003 Fax 886-2-2505-1280
YASKAWA ELECTRIC (HK) COMPANY LIMITED
Rm. 2909-10, Hong Kong Plaza, 186-191 Connaught Road West, Hong Kong
Phone 852-2803-2385 Fax 852-2547-5773
BEIJING OFFICE
Room No. 301 Office Building Intemational Club, 21 Jianguomenwai Avenue, Beijing 100020, China
Phone 86-10-6532-1850 Fax 86-10-6532-1851
BEIJING YASKAWA BEIKE AUTOMATION ENGINEERING CO.,LTD.
30 Xue Yuan Road, Haidian, Beijing P.R. China Post Code: 100083, China
Phone 86-10-6234-5003 Fax 86-10-6234-5002
SHOUGANG MOTOMAN ROBOT CO., LTD.
7,Yongchang-North Road, Beijing Economic & Technological Development Area, Beijing 100076, China
Phone 86-10-6788-0541 Fax 86-10-6788-2878
YASKAWA ELECTRIC CORPORATION
YASKAWA
Specifications are subject to change without notice MANUAL NO. RE-CHO-A104

for ongoing product modifications and improvements. C Printed in Japan November 2003 03-11

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Part Number: 150133-1

YASKAWA MANUAL NO. RE-CHO-A104

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

• The drawings and photos in this manual are representative examples

• If your copy of the manual is damaged or lost, contact a YASKAWA rep-

• YASKAWA is not responsible for incidents arising from unauthorized

Indicates a potentially hazardous situation which, if not avoided,

Indicates a potentially hazardous situation which, if not avoided,

Always be sure to follow explicitly the items listed under this

PROHIBITED Must never be performed.

Emergency Stop Button

Injury may result from unintentional or unexpected manipulator motion.

Release of Emergency Stop

• Observe the following precautions when performing teaching operations

Improper or unintended manipulator operation may result in injury.

• Confirm that no persons are present in the P-point maximum envelope of

• Read and understand the Explanation of Warning Labels in the NX100

Definition of Terms Used Often in This Manual

Equipment Manual Designation

NX100 Controller NX100

NX100 Programming Pendant Programming Pendant

Cable between the manipulator and the controller Manipulator cable

Equipment Manual Designation

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

Keys pressed When two keys are to be pressed simultaneously,

Displays The menu displayed in the programming pendant is

Description of the Operation Procedure

4 Preparation before Replacing Parts

6 Operations after Replacing Parts

1.1 Arrangement of Units and Circuit Boards

Backside duct fan: Control power supply:

Welding circuit board:

Back View A' Sectional View A-A'

Configuration 1 for Small-Capacity NX100

A Emergency stop button:

Back View A' Sectional View A-A'

Configuration 2 for Small-Capacity NX100

Medium or Large Capacity

Power supply Converter:

Back View A' Sectional View A-A'

Model Power Supply

Configuration for Medium- or Large-Capacity NX100

1.2 Power Flow

JANCD-NTU01 3 Backside duct fan

CND Programming pendant

1.3 Signal Flow

CNJS CNJS NXC004

2.1 Protection Through Security Mode Settings

2.1.1 Security Mode

Security Mode Descriptions

Security Mode Explanation

This mode allows basic operation of the robot (stopping,

This mode allows those authorized to set up and maintain

Menu & Security Mode

Allowed Security Mode

Menu & Security Mode

Allowed Security Mode

Menu & Security Mode

Allowed Security Mode

Menu & Security Mode

Allowed Security Mode

Changing the Security Mode

1 Select {SYSTEM INFO} under The sub menu appears.

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