90206-1045DEG E Troubleshooting Manual

Kawasaki Robot Controller
E Series
Troubleshooting
Manual
Kawasaki Heavy Industries, Ltd.
90206-1045DEG
E Series Controller
Kawasaki Robot Troubleshooting Manual
PREFACE
This manual is for troubleshooting the E Series Controllers (standard spec.).
This manual describes controller composition and the information necessary for troubleshooting
including: parts layout inside controller, power supply circuit, system diagram, switch settings for
printed board, etc. This information is given assuming the conditions below are met:
 Kawasaki Maintenance course and safety education have been completed before starting
operation.
 Robot and Controller are installed and connected per “Installation and Connection Manual”.
 Controller and peripheral devices are connected per “External I/O Manual”.
 Robot is being operated per “Operation Manual”.
This manual describes troubleshooting procedures in as much detail as possible. However,

because it is not possible to predict every possible trouble that can occur with the robot, only the
most important troubleshooting measures are presented here. Therefore, should any
unexplained questions or problems arise, please contact Kawasaki. Refer to the contact
information listed on the rear cover of this manual for the nearest Kawasaki.
Read and understand this manual and other related documents thoroughly, and keep the manual
for future reference to prepare for trouble.
This manual describes the following controller models.
E10, E12, E13, E14 (Japan Spec., 9-axis controller)
E20, E22, E23, E24, E73, E74, E94 (Japan Spec.)
E30, E32, E33, E34 , E76, E77, E97 (North America Spec.)
E40, E42, E43, E44, E70, E71, E91 (Europe Spec.)
1. This manual does not describe troubleshooting for the systems in which the robot is utilized.
Accordingly, Kawasaki is not responsible for any accidents, damages, and/or problems
relating to industrial property rights as a result of using the system.
2. It is recommended that all personnel assigned for activation of operation, teaching,
maintenance or inspection of the robot attend the necessary education/training course(s)
prepared by Kawasaki, before assuming their responsibilities.
3. Kawasaki reserves the rights to change, revise, or update this manual without prior notice.
4. This manual may not, in whole or in part, be reprinted or copied without the prior written
consent of Kawasaki.
5. Store this manual with care and keep it available for use at any time. If the robot is
reinstalled or moved to a different site or sold off to a different user, attach this manual to the
robot without fail. In the event the manual is lost or damaged severely, contact Kawasaki.
Copyright © 2012 Kawasaki Heavy Industries Ltd. All rights reserved.
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E Series Controller
SYMBOLS
The items that require special attention in this manual are designated with the following symbols.
Ensure proper and safe operation of the robot and prevent physical injury or property damage by
complying with the safety matters given in the boxes with these symbols.
！ DANGER
Failure to comply with indicated matters can result in

imminent injury or death.
！ WARNING
Failure to comply with indicated matters may possibly lead
to injury or death.
！ CAUTION
Failure to comply with indicated matters may lead to
physical injury and/or mechanical damage.
[ NOTE ]
Denotes precautions regarding robot specification,
handling, teaching, operation and maintenance.
！ WARNING
1. The accuracy and effectiveness of the diagrams, procedures, and detail

explanations given in this manual cannot be confirmed with absolute
certainty. Accordingly, it is necessary to give one’s fullest attention when
using this manual to perform any work. Should any unexplained
questions or problems arise, please contact Kawasaki.
2. Safety related contents described in this manual apply to each individual
work and not to all robot work. In order to perform every work in safety,
read and fully understand the safety manual, all pertinent laws, regulations
and related materials as well as all the safety explanation described in each
chapter, and prepare safety measures suitable for actual work.
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E Series Controller
INTRODUCTORY NOTES
1. HARDWARE KEYS AND SWITCHES (BUTTON)
E series controller provides hardware keys and switches on the operation panel and the teach
pendant for various kinds of operations. In this manual the names of the hardware keys and
switches are enclosed with a square as follows. The terms “key” or “switch” which should
follow the relevant names are sometimes omitted for simpler expression. When pressing two or
more keys at the same time, the keys are indicated by “+” as shown in the example below.
EXAMPLES
ENTER: expresses the hardware key “ENTER”.
TEACH/REPEAT: indicates the mode switch “TEACH/REPEAT” on the operation panel.
A+MENU: indicates pressing and holding down A then pressing MENU.
2. SOFTWARE KEYS AND SWITCHES
E series controller provides software keys and switches which appear on the screen of the teach
pendant for various kinds of operations depending on specifications and situations. In this
manual, the names of software keys and switches are enclosed by “< >” parentheses. The terms
“key” or “switch” which should follow the relevant names are sometimes omitted for simpler
expression.
EXAMPLES
<ENTER>: expresses an “ENTER” key that appears on the teach pendant screen.
<NEXT PAGE>: expresses a “NEXT PAGE” key on the teach pendant screen.
3. SELECTION ITEMS
Very often an item must be selected from a menu or pull-down menu on the teach pendant screen.
In this manual the names of these menu items are enclosed in brackets [XXX].
EXAMPLES
[Auxiliary Function]: expresses the item “Auxiliary Function” in a menu. To select it, move the
cursor to the relevant item by the arrow keys, and press the  key. For
detailed description, this procedure should be described every time, but
“select [XXX] item” will be used instead for simpler expression.
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E Series Controller
CONTENTS
1.0 Composition of E Series Controller ······················································· 1-1

1.1 External View of Controller ································································ 1-2
1.1.1 Controller Main Body ······································································· 1-2
1.1.2 Teach Pendant ·············································································· 1-27
1.2 Controller Device and Its Arrangement ················································· 1-29
1.2.1 Controller Front ············································································ 1-29
1.2.1.1 Operation Panel ············································································ 1-33
1.2.2 Inside of Controller ········································································ 1-36
1.2.2.1 E1x/E2x/E3x/E4x Controller ····························································· 1-36
1.2.2.2 E7x Controller ·············································································· 1-42
1.2.2.3 E9x Controller ·············································································· 1-44
1.2.3 Schematic Diagram ········································································ 1-46
2.0 Description of Controller···································································· 2-1

2.1 Teach Pendant ················································································ 2-6
2.1.1 Functions of Teach Pendant ································································ 2-6
2.1.2 Overview of Teach Pendant ································································ 2-6
2.1.3 System Configuration of Teach Pendant ·················································· 2-8
2.2 1TA/1VA Board (Main CPU Board) ······················································ 2-9
2.2.1 Main Functions ··············································································· 2-9
2.2.2 Connectors, LEDs, Check Pins and DIP Switches ···································· 2-10
2.2.2.1 Layout ······················································································· 2-10
2.2.2.2 Connectors ·················································································· 2-12
2.2.2.3 LEDs ························································································· 2-12
2.2.2.4 Check Pins ·················································································· 2-13
2.2.2.5 DIP Switches ··············································································· 2-14
2.3 1TR Board (Power Sequence Board) ··················································· 2-16
2.3.1 Main Functions ············································································· 2-16
2.3.2 Switches, Connectors, Jumpers, LEDs, Check Pins and Fuses ······················ 2-17
2.3.2.1 Layout ······················································································· 2-17
2.3.2.2 Switch Function and Settings····························································· 2-18
2.3.2.3 Connectors ·················································································· 2-18
2.3.2.4 Jumper Settings············································································· 2-18
2.3.2.5 LEDs ························································································· 2-19
2.3.2.6 Check Pins ·················································································· 2-19
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E Series Controller
2.3.2.7 Fuse ·························································································· 2-19

2.3.3 Connection with External Circuits (Safety Circuit, etc.)······························ 2-20
2.4 1TX Board (Mother Board for E1x/E2x/E3x/E4x Controller) ······················ 2-21
2.4.1 Connectors and Jumpers ·································································· 2-21
2.4.1.1 Layout ······················································································· 2-21
2.4.1.2 Connectors ·················································································· 2-22
2.4.1.3 Jumper Settings············································································· 2-22
2.5 1TW Board (IO Board) (Option) ························································ 2-23
2.5.1 Specifications ··············································································· 2-23
2.5.2 Connectors, LEDs, Check Pins and Switches ·········································· 2-24
2.5.2.1 Layout ······················································································· 2-24
2.5.2.2 Connectors ·················································································· 2-24
2.5.2.3 LEDs ························································································· 2-25
2.5.2.4 Check Pins ·················································································· 2-25
2.5.2.5 Switches ····················································································· 2-25
2.5.2.6 Pin Assignment ············································································· 2-27
2.6 1FG/1HG Boards (Battery Backup Board for Encoder) ······························ 2-28
2.6.1 1FG Board ·················································································· 2-28
2.6.1.1 Main Functions ············································································· 2-28
2.6.1.2 Layout ······················································································· 2-28
2.6.1.3 Check Pins ·················································································· 2-29
2.6.1.4 Connectors ·················································································· 2-29
2.6.2 1HG Board ·················································································· 2-30
2.6.2.1 Main Functions ············································································· 2-30
2.6.2.2 Layout ······················································································· 2-30
2.6.2.3 Check Pins ·················································································· 2-30
2.6.2.4 Connectors ·················································································· 2-31
2.7 1PV/1TK Boards (Arm ID Board) (Option) ··········································· 2-31
2.7.1 1PV Board ·················································································· 2-31
2.7.1.1 Layout ······················································································· 2-31
2.7.1.2 1PV Board Connectors ···································································· 2-32
2.7.1.3 LEDs ························································································· 2-32
2.7.1.4 Check Pins ·················································································· 2-32
2.7.1.5 Switches ····················································································· 2-32
2.7.1.6 1JD/1JE Board Connectors ······························································· 2-32
2.7.2 1TK Board ·················································································· 2-33
2.7.2.1 Layout ······················································································· 2-33
2.7.2.2 1TK Board Connectors ···································································· 2-33
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E Series Controller
2.7.2.3 LEDs ························································································· 2-33

2.7.2.4 Check Pins ·················································································· 2-34
2.7.2.5 Switches ····················································································· 2-34
2.7.2.6 1TY Board Connectors ···································································· 2-34
2.8 Encoder ······················································································ 2-35
2.8.1 Main Functions ············································································· 2-35
2.9 Servo Amplifier Unit for 6 Axes ························································· 2-37
2.9.1 1TB Board (Servo Board for E1x/E2x/E3x/E4x Controller) ························ 2-37
2.9.1.1 Main Functions ············································································· 2-37
2.9.1.2 Connectors, Jumpers, LEDs, Check Pins and Switches ······························ 2-38
2.9.1.2.1 Layout ······················································································· 2-38
2.9.1.2.2 Connectors ·················································································· 2-39
2.9.1.2.3 Jumpers ······················································································ 2-40
2.9.1.2.4 LEDs ························································································· 2-41
2.9.1.2.5 Check Pins ·················································································· 2-42
2.9.1.2.6 Switches ····················································································· 2-42
2.9.1.3 1TB Board Software ······································································· 2-42
2.9.2 1TC/1VE/1TD/1VD Boards
(Power Block Board for E1x/E2x/E3x/E4x Controller) ······························ 2-43
2.9.2.1 Main Functions ············································································· 2-43
2.9.2.2 Connectors and Check Pins ······························································· 2-44
2.9.2.2.1 Layout ······················································································· 2-44
2.9.2.2.2 Connectors (For 1TC/1VE/1TD/1VD Board) ········································· 2-45
2.9.2.2.3 Check Pins ·················································································· 2-45
2.10 Amplifier Unit for Single Axis ··························································· 2-46
2.10.1 Specifications ··············································································· 2-46
2.10.2 Main Functions ············································································· 2-46
2.10.3 Connectors ·················································································· 2-46
2.11 DC Power Supply for Control (AVR) ··················································· 2-47
2.11.1 Specifications ··············································································· 2-47
2.11.2 Main Functions ············································································· 2-47
2.11.3 Connectors and Output Voltage Adjustment ··········································· 2-48
2.11.3.1 Layout ······················································································· 2-48
2.11.3.2 Connectors ·················································································· 2-48
2.11.3.3 Output Voltage Adjusting Knob ·························································· 2-48
2.12 MC Unit ····················································································· 2-49
2.12.1 1TU Board (MC Power Board for E1x/E2x/E3x/E4x Controller) ·················· 2-49
2.12.1.1 Main Function ·············································································· 2-49
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E Series Controller
2.12.1.2 Connectors, LEDs and Check Pins ······················································ 2-50

2.12.1.2.1 Layout ······················································································· 2-50
2.12.1.2.2 Connectors ·················································································· 2-50
2.12.1.2.3 LEDs ························································································· 2-51
2.12.1.2.4 Check Pins ·················································································· 2-51
2.12.2 1TQ/1TV Boards (MC Control Board) ················································· 2-52
2.12.2.1 Main Functions ············································································· 2-52
2.12.2.2 Connectors, Jumpers, LEDs, Check Pins and Switch ································· 2-53
2.12.2.2.1 Layout ······················································································· 2-53
2.12.2.2.2 Connectors ·················································································· 2-54
2.12.2.2.3 Jumper Settings············································································· 2-55
2.12.2.2.4 LEDs ························································································· 2-55
2.12.2.2.5 Check Pins ·················································································· 2-57
2.12.2.2.6 Switch························································································ 2-57
2.13 Manual Brake Release Switch (Option) ················································ 2-58
2.14 Additional Regenerative Register Unit·················································· 2-58
2.15 1UX Board (Mother Board for E7x Controller) ······································· 2-60
2.15.1 Connectors and Jumpers ·································································· 2-60
2.15.1.1 Layout ······················································································· 2-60
2.15.1.2 Connectors ·················································································· 2-61
2.15.1.3 Jumper Settings············································································· 2-61
2.16 Servo Amplifier Section for E7x Controller ············································ 2-62
2.16.1 1TB Board (Servo Board for E7x Controller)·········································· 2-62
2.16.2 1UY Board (Servo Relay Board) ························································ 2-63
2.16.2.1 Main Functions ············································································· 2-63
2.16.2.2.1 Layout ······················································································· 2-64
2.16.2.2.2 Connectors ·················································································· 2-65
2.16.3 1UZ Board (Power Block Board for E7x Controller) ································· 2-65
2.16.3.1 Main Functions ············································································· 2-66
2.16.3.2.1 Layout ······················································································· 2-67
2.16.3.2.2 Connectors ·················································································· 2-67
2.17 Power Supply Unit for E7x Controller ·················································· 2-68
2.17.1 1UE Board (MC Power Board for E7x Controller) ··································· 2-69
2.17.1.1 Main Functions ············································································· 2-69
2.17.1.2 Connectors ·················································································· 2-69
2.17.1.2.1 Layout ······················································································· 2-69
vii
E Series Controller
2.17.1.2.2 Connectors ·················································································· 2-70

2.18 Power Unit ·················································································· 2-71
2.18.1 1VJ Board (Power Unit Power Board for E9x Controller) ··························· 2-71
2.18.1.1 Main Functions ············································································· 2-71
2.18.1.2 Connectors, LEDs and Check Pins ······················································ 2-72
2.18.1.2.1 Layout ······················································································· 2-72
2.18.1.2.2 Connectors ·················································································· 2-73
2.18.1.2.3 LEDs ························································································· 2-73
2.18.1.2.4 Check Pins ·················································································· 2-73
2.18.2 1VH Boards (Power Unit Control Board for E9x Controller) ······················· 2-74
2.18.2.1 Main Functions ············································································· 2-74
2.18.2.2 Connectors, Jumpers, LEDs, Check Pins and Switch································· 2-75
2.18.2.2.1 Layout ······················································································· 2-75
2.18.2.2.2 Connectors ·················································································· 2-76
2.18.2.2.3 Jumper Settings············································································· 2-77
2.18.2.2.4 LEDs ························································································· 2-77
2.18.2.2.5 Check Pins ·················································································· 2-78
2.18.2.2.6 Switch ······················································································· 2-78
2.18.3 1VF/1WF Boards (PFC Board) ·························································· 2-79
2.18.3.1 Main Functions ············································································· 2-79
2.18.3.2 Connectors and Check Pins······························································· 2-79
2.18.3.2.1 Layout ······················································································· 2-79
2.18.3.2.2 Connectors ·················································································· 2-80
2.18.3.2.3 Check Pins ·················································································· 2-80
2.19 1VZ Board (Mother Board for E9x Controller) ······································· 2-81
2.19.1 Connectors and Jumper ··································································· 2-81
2.19.1.1 Layout ······················································································· 2-81
2.19.1.2 Connectors ·················································································· 2-82
2.19.1.3 Jumper Settings············································································· 2-82
3.0 Troubleshooting ·············································································· 3-1

3.1 Initial Troubles and Countermeasures ····················································· 3-2
3.1.1 Initial Trouble 1: Controller Power Does Not Turn ON ································ 3-2
3.1.2 Initial Trouble 2: Teach Pendant Is Not Operable ······································· 3-5
3.1.3 Initial Trouble 3: Motor Power Does Not Turn ON ····································· 3-8
3.1.4 Initial Trouble 4: Robot Does Not Move ················································· 3-9
3.2 Steady-State Troubles and Countermeasures ··········································· 3-10
viii
E Series Controller
3.3 Error Classification ········································································ 3-10

3.4 Error Handling by Robot ···································································3-11
3.5 Further Error Classification and Error Numbers ······································· 3-12
3.6 Error Display ··············································································· 3-13
3.7 Error List ···················································································· 3-13
3.8 Common Error Examples ································································· 3-14
4.0 Procedures for Replacement ································································ 4-1

4.1 General Safety Precautions on Replacement ············································· 4-3
4.2 Parts in Card Rack ··········································································· 4-6
4.2.1 1TA/1VA Boards (Main CPU Board) ····················································· 4-6
4.2.2 CF Card on 1TA/1VA Boards (Main CPU Board) ······································ 4-7
4.2.3 1TR Board (Power Sequence Board) ····················································· 4-9
4.2.4 1TW Board (IO Board)······································································ 4-9
4.2.5 AVR ·························································································· 4-10
4.3 Servo Amplifier Unit for 6 Axes Part (E1x/E2x/E3x/E4x/E9x Controller) ········ 4-12
4.3.1 Servo Amplifier Unit for 6 Axes ························································· 4-12
4.3.2 1TB Board (Servo Board) ································································ 4-14
4.3.3 Amplifier Unit for Single Axis ··························································· 4-16
4.4 MC Unit Part (E1x/E2x/E3x/E4x Controller)·········································· 4-17
4.4.1 MC Unit ····················································································· 4-17
4.5 Fans (E1x/E2x/E3x/E4x Controller) ···················································· 4-21
4.5.1 Fans for Card Rack ········································································ 4-21
4.5.2 Fans for Servo Amp. Unit for 6 Axes ··················································· 4-21
4.5.3 Fan for Amp. Unit for Single Axis ······················································· 4-22
4.5.4 Fan inside MC Unit ········································································ 4-22
4.6 Batteries ····················································································· 4-25
4.6.1 Coin Battery on 1TA/1VA Boards ······················································· 4-25
4.6.2 Battery on 1FG/1HG Boards ····························································· 4-26
4.7 Fuses ························································································· 4-27
4.7.1 Fuses on 1TR Board ······································································· 4-27
4.8 Removing the Top Cover of Controller (E7x Controller) ···························· 4-28
4.9 Replacing the Power Supply Unit Part (E7x Controller) ····························· 4-30
4.9.1 Power Supply Unit ········································································· 4-30
4.9.2 1UE Board (MC Power Board) ·························································· 4-31
4.10 Replacing Servo Amplifier Section (E7x Controller) ································· 4-32
ix
E Series Controller
4.10.1 1UZ Board (Power Block Board)························································ 4-32

4.10.2 1UY Board (Servo Relay Board) ························································ 4-33
4.10.3 1TB Board (Servo Board) ································································ 4-35
4.11 Replacing Fan (E7x Controller) ·························································· 4-36
4.11.1 Fans for Card Rack ········································································ 4-36
4.11.2 Fan at Servo Amplifier Section ·························································· 4-37
4.11.3 Fan on Controller Upper Side ···························································· 4-37
4.11.4 Heat Exchange Fan ········································································ 4-39
4.12 Replacing Mother Board ·································································· 4-41
4.12.1 E1x/E2x/E3x/E4x Controller ····························································· 4-41
4.12.2 E7x Controller ·············································································· 4-43
4.12.3 E9x Controller ·············································································· 4-44
4.13 Replacing Regenerative Resistor ························································ 4-45
4.13.1 E1x/E2x/E3x/E4x Controller ····························································· 4-45
4.13.2 E7x Controller ·············································································· 4-46
4.13.3 E9x Controller ·············································································· 4-47
4.14 Replacing Additional Regenerative Resistor Unit ····································· 4-48
4.15 Replacing Magnetic Contactor (K1, K2) (E7x Controller)··························· 4-49
4.16 Replacing Power Unit Section (E9x Controller)······································· 4-50
4.16.1 Replacing Power Unit ····································································· 4-50
4.16.2 Replacing 1VH Board (Power Unit Control Board) ·································· 4-51
4.17 Replacing Fans (E9x Controller) ························································ 4-53
4.17.1 Replacing Fan of Card Rack Section ···················································· 4-53
4.17.2 Replacing Fan of Power Unit Section ··················································· 4-54
4.17.3 Replacing Power Unit Section (Outside Air Side)····································· 4-55
4.17.4 Replacing Servo Amplifier Fin (Outside Air Side) ···································· 4-56
5.0 Schematic Diagrams of Separate and Machine Harnesses ····························· 5-1

5.1 Separate Harness ············································································· 5-2
5.1.1 E10/E20/E30/E40/E71/E74/E77/E91/E94/E97-R Series (06L/10L/10N/20N)/
YF003N Separate Harness Wire Distribution List ······································ 5-2
5.1.2 E22/E23/E32/E33/E42/E43 Separate Harness Wire Distribution List ················ 5-4
5.1.3 E24/E34/E44 Separate Harness Wire Distribution List ······························· 5-6
5.1.4 E70/E73/E76-RS03N, E71/E74/E77-R Series (05L/05N) Separate Harness Wire
Distribution List ·············································································· 5-8
5.2 Machine Harness ··········································································· 5-10
5.2.1 R Series ······················································································ 5-10
5.2.2 Y Series (YF003N) ········································································ 5-33
x
E Series Controller
5.2.3 Z Series (ZX, ZT Series, ZH Series, ZD Series) ······································· 5-38

5.2.4 M Series (MX Series, MD Series, MT Series) ········································· 5-50
5.2.5 B Series ······················································································ 5-62
Appendix Error Message List ·········································································· A-1
xi
E Series Controller
xii
E Series Controller 1. Composition of E Series Controller
1.0 COMPOSITION OF E SERIES CONTROLLER
There are two types of controllers in E series; standard type (E1x/E2x/E3x/E4x) and small type
(E7x/E9x). Every type of controller is composed of a controller body and a teach pendant.
1.1 External View of Controller ··································································· 1-2

1.1.1 Controller Main Body ·········································································· 1-2
1.1.2 Teach Pendant ·················································································· 1-27
1.2 Controller Device and Its Arrangement ····················································· 1-29
1.2.1 Controller Front ················································································ 1-29
1.2.1.1 Operation Panel ················································································ 1-33
1.2.2 Inside of Controller ············································································ 1-36
1.2.2.1 E1x/E2x/E3x/E4x Controller ································································· 1-36
1.2.2.2 E7x Controller ·················································································· 1-42
1.2.2.3 E9x Controller ·················································································· 1-44
1.2.3 Schematic Diagram ············································································ 1-46
1-1
1.1 EXTERNAL VIEW OF CONTROLLER
The figures below show the exterior of the controller and the teach pendant.
1.1.1 CONTROLLER MAIN BODY
The E Series Controller is shown below.
Left view Front view
Right view Rear view

E10 controller
1-2
E12 controller
1-3
E13 controller
1-4
E14 (MX) controller
1-5
E14 (MD) controller
1-6
550 450
950
E20 Controller
1-7
550 450
950
E22 Controller
1-8
550 450 180

950
E23 Controller
1-9
550 450
950
E24 Controller (MX)
1-10
550 450 180

950
E24 Controller (MD)
1-11

E30 Controller
1-12
E32 Controller
1-13
E33 Controller
1-14
E34 Controller (MX)
1-15
E34 Controller (MD)
1-16

E40 Controller
1-17

E42 Controller
1-18

E43 Controller
1-19

E44 Controller (MX)
1-20

E44 Controller (MD)
1-21
E70/E71 controller
1-22
E73/E74 controller
1-23
E76/E77 controller
1-24
580 500
250
18
E91 controller
1-25
580 500
250

18
E94/97 controller
1-26
1.1.2 TEACH PENDANT
The small sized teach pendant (option for E73/E74) are mainly composed of the following parts.
1. LCD (Liquid crystal display) with touch panel (Small sized teach pendant does not have the
touch panel function.)
2. Hardware operation keys
3. Emergency stop switch
4. Teach lock switch
5. Deadman switches (Two on the back)
1. LCD with touch panel
3. Emergency stop switch
4. Teach lock switch

(In the dashed line)
Front view
5. Deadman switches
(3 position)
Rear view
Teach pendant
1-27
4. Teach lock switch 3. Emergency stop switch
1. LCD

(In the dashed line)
Front view
5. Deadman switches
(3 position)
Rear view
Small sized teach pendant

(Option for E73/E74)
1-28
1.2 CONTROLLER DEVICE AND ITS ARRANGEMENT
In the E series controller, operation switches and connectors are provided on the outer surface of
the controller, and control devices are located inside the controller.
1.2.1 CONTROLLER FRONT
The following parts are arranged on the front part of the controller.
E1x/E2x/E4x controller
1. Operation panel
2. Hook (for hanging Teach pendant/Cable)
3. Teach pendant connector: Connects teach pendant cables.
4. Teach pendant (TP)
5. Accessory panel: USB port, RS-232C port are provided under the cover of the accessory panel.
Press the cover to open. (See figure on page 1-32.)
6. Controller power switch: Turns ON/OFF the controller power. At power ON, controller door
cannot be opened.
7. Coin lock
5. Accessory panel
1. Operation panel
2. Hook (for hanging teach

6. Controller power switch pendant/Cable)
3. Teach pendant connector:

7. Coin lock Connects teach pendant cables.
Controller front (e.g. E20 controller)
1-29
E3x controller
1. Operation panel
2. Hook (for hanging Teach pendant/Cable)
Press the cover to open. (See figure on page 1-32.)
6. Controller power switch: Turns ON/OFF the controller power. At power ON, controller door
cannot be opened.
7. Coin lock
8. Brake release switch panel: Manual brake release switches for 9 axes are provided inside the
cover.
9. AC outlet (option): AC115 V 1  inlet is provided inside the cover.
5. Accessory panel
1. Operation panel
2. Hook (for hanging cable)
6. Controller power switch
2. Hook (for hanging teach

pendant)
8. Brake release switch
7. Coin lock 3. Teach pendant connector:

Connects teach pendant cables.
9. AC outlet (option)
4. Teach pendant
1-30
E7x/E9x controller
1. Operation panel
Press the cover to open. (E7x) (See figure on page 1-32.)
USB port, Ethernet port, RS-232C port and brake release box connecting
port are provided. (E9x) (See figure on page 1-32.)
5. Brake release switch panel: Connects brake release switch. (E7x)
6. Controller power switch: Turns ON/OFF the controller power.
3. Teach pendant
1. Operation panel
4. Accessory panel
5. Brake release
switch panel
2. Teach pendant
connector
4. Accessory panel
(Including brake 1. Operation panel
release box
connecting port.)
2. Teach pendant
connector
1-31
Bake release box

connecting port USB port
USB port
RS-232C port Ethernet port

RS-232C port
Internal layout of Accessory Panel Layout of Accessory Panel

(E1x/E2x/E3x/E4x/E7x) (E9x)
Connector for separate harness
Rear side (e.g.: E20 controller)
1-32
1.2.1.1 OPERATION PANEL
The following buttons, switches, and display lamps are built into the operation panel to perform
the functions below.
E1x/E2x/E73/E74/E94, E3x/E76/E77/E97 controller

1. Switches
(1) TEACH/REPEAT switch : Selects TEACH/REPEAT mode.
(2) EMERGENCY STOP switch : Emergency stop
2. Lamp
CONTROLLER POWER lamp
Teach/Repeat
switch
Controller power lamp Emergency stop switch
(Operation panel for E1x/E2x/E73/E74 controller)
Teach/Repeat
switch

(Operation panel for E3x controller)
Teach/Repeat
switch
(Operation panel for E76/E77/E94/E97 controller)

1-33
E4x/E70/E71/E91 controller (Option for E1x/E2x/E73/E74/E94 controller)

1. Switches
(1) FAST CHECK/TEACH/REPEAT switch : Selects FAST CHECK/TEACH/REPEAT
mode.
(2) EMERGENCY STOP switch : Brings the robot to an emergency stop.
2. Lamp
CONTROLLER POWER lamp
Fast Check/
Teach/Repeat switch
1-34
Optional operation panel

The following optional operation panels are available (excluding E9x controller). For E73/E74
controller, the optional operation panel is required to be used with small sized TP.
1. Buttons/Switches
(1) MOTOR POWER button : Motor power ON
(2) CYCLE START button : Cycle start
(3) ERROR RESET button : Error reset
(4) HOLD/RUN switch : Switches RUN/HOLD.
2. Lamps
MOTOR POWER lamp, CYCLE START lamp, ERROR lamp
Hold/Run switch Error reset button Error lamp
Cycle start
button/lamp
Motor power
button/lamp
Optional operation panel for E1x/E2x/E4x controller (except E3x and E7x)
Error lamp Hold/Run switch
Motor power Cycle start Error reset

button/lamp button/lamp button
Optional operation panel for E7x controller (required when using small sized TP)
1-35
1.2.2 INSIDE OF CONTROLLER
1.2.2.1 E1X/E2X/E3X/E4X CONTROLLER
Inside of the E1x/E2x/E3x/E4x controller houses main three units: Card rack unit, MC unit, and
servo amplifier unit.
1. Card rack unit

Printed boards and DC power supply (AVR) are housed in this rack. Main CPU board, power
sequence board, and mother board are the standard boards common to all controller models,
and four optional IO boards can also be housed.
(1) Mother board (1TX board)

(2) Main CPU board (1TA/1VA board)
(3) Power sequence board (1TR board)
(4) DC power supply for control (AVR)
(5) IO board (1TW board)
2. MC unit
(1) Magnetic contactors

(2) Fan
(3) MC control board (1TQ/1TV board)
(4) MC power board (1TU board)
(5) Power supply for power module
The whole MC unit can be replaced after disconnecting the connectors. (Refer to chapter 4
for more details.)
3. Servo amplifier unit
Each servo amplifier unit of E controller is composed of the following parts:

(1) Power block + Case (Six 1TC/1TD/1VE/1VD boards included.)*
(2) Servo board (1TB board)
(3) Plastic cover
NOTE* How to combine the 1TC/1TD/1VE/1VD boards depends on the motor capacity used
for the robot arm.
1-36
If any replacements are needed, the replacement of whole (1) or (2) is necessary. (Refer to
chapter 4 for more details.)
！ WARNING
1. The MC unit and servo amplifier unit have their own power
chargers (P-N voltage). Prior to performing any work on the
units, turn OFF the controller power, wait at least 7 minutes, and
confirm that the P-N voltage is 0 V.
2. When replacing servo amplifier unit, check over the part number
to avoid mistake in replacement.
3. When connecting cables, make sure that all the cable markings
correspond with markings of the terminal block and the
connector numbers.
1-37
E10/E12/E13/E14 Layout of Internal Parts
DC power supply for

control (AVR)
Card rack unit
Controller power
switch
Brake release switch*

IO board
(1TW board)*
Power sequence board
(1TR board)
Amplifier unit for Main CPU board
single axis* (1TA/1VA board)
MC unit Servo amplifier unit for 6

axes
Servo board (1TB board)
(Mounted under the cover.)
NOTE* Option
1-38
DC power supply
for control (AVR)
Card rack unit
Controller power
switch
IO board
Amplifier unit for (1TW board)*
single axis*
(1TR board)
Main CPU board
Brake release switch* (1TA/1VA board)
Servo amplifier unit for 6

axes
MC unit Servo board (1TB board)
NOTE* Option
1-39
DC power supply for

control (AVR)
Card rack unit
Controller power
switch
IO board
(1TW board)*
Amplifier unit for (1TR board)
single axis*
Main CPU board
(1TA/1VA board)
Servo amplifier unit for 6

axes
MC unit
NOTE* Option
1-40
DC power supply for

control (AVR)
Card rack unit
Controller power
switch
AC outlet (230VAC)
IO board
(1TW board)*
Amplifier unit for Power sequence board
single axis* (1TR board)
Main CPU board
Brake release switch (1TA/1VA board)
MC unit
Servo amplifier unit
for 6 axes
NOTE* Option
1-41
1.2.2.2 E7X CONTROLLER
Inside of the E7x Controller houses main three units: Card rack unit, Power supply unit, Servo
amplifier section.
1. Card rack unit

and three optional IO boards can also be housed.
(1) Mother board (1UX board)

(2) Main CPU board (1TA/1VA board)
2. Power supply unit
(1) MC control board (1TQ/1TV board)

(2) MC power board (1UE board)
3. Servo amplifier section
Servo amplifier section is composed of the following parts:

(2) Servo relay board (1TY board)
(3) Six power block boards (1UZ board)
1-42
！ WARNING
1. The power supply unit and servo amplifier section have their own
power chargers (P-N voltage). Prior to performing any work on
the units, turn OFF the controller power, wait at least 7 minutes,
and confirm that the P-N voltage is 0 V.
2. When replacing servo amplifier section, check over the part
number to avoid mistake in replacement.
3. When connecting cables, make sure that all the cable markings
correspond with markings of the terminal block and the connector
numbers.
E70/E71/E73/E74/E76/E77 Layout of Internal Parts
Power supply unit
MC power board
(1UE board)
MC
Servo amplifier
section
Power block board

(1UZ board)
Upper view
Card rack unit
IO board
(1TW board)*
(1TR board)
DC power supply for Main CPU board
control (AVR) (1TA/1VA board)
Left side view
NOTE* Option
1-43
1.2.2.3 E9X CONTROLLER
Inside of the E9x controller houses main three units: Card rack unit, Power unit, Servo amplifier
section.
1. Card rack unit

and three optional IO boards can also be housed.
(1) Mother board (1VZ board)

(2) Main CPU board (1VA board)
2. Power unit
(1) Power unit control board (1VH board)

(2) Power unit power board (1VJ board)
(3) PFC board (1VF/1WF board)
3. Servo amplifier section
Servo amplifier section is composed of the following parts:

(1) Power block + case (including total 4 to 6 1VE/1VD boards)*
(3) Plastic cover
NOTE* Combination and number of 1VE/1VD boards to be used differ depending on the
motor configuration of the connected arm model.
1-44
！ WARNING
1. The power unit and servo amplifier section have their own power
chargers (P-N voltage). Prior to performing any work on the
units, turn OFF the controller power, wait at least 7 minutes, and
confirm that the P-N voltage is 0 V.
2. When replacing servo amplifier section, check over the part
number to avoid mistake in replacement.
3. When connecting cables with connectors, make sure that all the
cable markings correspond with markings of the terminal block
and the connector numbers.
E91/E94/E97 Layout of Internal Parts

(1TR board)
IO board
Main CPU board (1TW board)*
(1VA board)
DC power supply
for control (AVR)
Card rack unit Servo amplifier unit
Power unit
PFC board Servo board (1TB board)

(1VF/1WF board) (Provided on rear of cover)
Power unit power

board
(1VJ board)
Controller power switch

Power unit
control board
(1VH board)
NOTE* Option
1-45
1.2.3 SCHEMATIC DIAGRAM

1. E10/E20 controller
for RA series only.

NOTE
1-46
1-47
prevent. resistor
Inrush current
1-48
4. E14/E24 controller (MX)
1-49
5. E14/E24 controller (MD)
1-50
6. E30 controller
for RA series only.

NOTE
1-51
7. E32 controller
prevent. resistor
Inrush current
1-52
8. E33 controller
prevent. resistor
Inrush current
1-53
9. E34 controller (MX)
Regenerative
resistor
prevent. resistor
Inrush current
1-54
10. E34 controller (MD)
X320 X306
prevent. resistor
Inrush current
1-55
11. E40 controller
for RA series only.

NOTE
1-56
12. E42 controller
1-57
13. E43 controller
prevent. resistor
Inrush current
1-58
14. E44 controller (MX)
prevent. resistor
Inrush current
1-59
15. E44 controller (MD)
prevent. resistor
Inrush current
1-60
Power supply unit
Controller top
Fan
Card rack
Fan
Heat ex- Power Block

Changer Fan Fanx2
Thermal switch
Brake
Brake
Brake release panel
E Series Controller
(connect option brake

release box)
Power
MC communication(RS485),Power supply,Safety circuit
Brake control,MC control To External Axis Motor
Power
Servo amp.
16. E70/E71/E76/E77 controller
section
(JT8) (JT7)
(Option) (Option) Power
Regenerative
resistor
phase input (Servo relay board)

Main breaker Noise filter PN power supply
CN4 CN8
To Robot Arm
CN1 CN7
Brake power supply
1-61
(Servo board) Encoder
(Mother board)
Encoder ,Battery Alarm,12V,I/O24V,LS
DC power supply
Arm ID
Accessory panel
Servo communication(RS422),Safety circuit,Power supply abnormal
Main CPU board
Control power lamp Teach/Repeat

(Power sequence
board)
Teach/Repeat
Emergency stop Emergency stop TFT Image signal
To Teach Pendant
Emergency stop/Deadman signal
Optional Input
operation panel
(Option) Output
(IO board)
1. Composition of E Series Controller
Power supply unit
Controller top
Fan
Card rack
Fan
Heat ex- Power block

Changer Fan Fanx2
Thermal switch
Brake
Brake
Brake release panel
E Series Controller
(connect option brake

release box)
Power
MC communication(RS485),Power supply,Safety circuit
Brake control,MC control To External Axis Motor
Power
Servo amp.
section
(JT8) (JT7)
(Option) (Option) Power
Regenerative
resistor
phase input (Servo relay board)

Main breaker Noise filter PN power supply
CN4 CN8
To Robot Arm
CN1 CN7
Brake power supply
1-62
(Servo board) Encoder
(Mother board)
Encoder ,Battery Alarm,12V,I/O24V,LS
DC power
Arm ID
Accessory panel
Main CPU board Servo communication(RS422),Safety circuit,Power supply abnormal
Teach/Repeat (Power sequence

Control power
board)
lamp
Teach/Repeat Emergency stop TFT Image signal To Teach Pendant
Emergency stop
Emergency stop/Deadman signal
Optional Input
operation panel
(Option) Output
(IO board)
1. Composition of E Series Controller
18. E91 controller
1-63
1-64
E Series Controller 2. Description of Controller
2.0 DESCRIPTION OF CONTROLLER
This chapter describes in detail each of the printed boards and units that make up the E Series
Controller.
2.1 Teach Pendant ················································································ 2-6

2.1.1 Functions of Teach Pendant································································· 2-6
2.1.2 Overview of Teach Pendant································································· 2-6
2.1.3 System Configuration of Teach Pendant ·················································· 2-8
2.2 1TA/1VA Board (Main CPU Board) ······················································ 2-9
2.2.1 Main Functions ··············································································· 2-9
2.2.2 Connectors, LEDs, Check Pins and DIP Switches······································ 2-10
2.2.2.1 Layout ························································································· 2-10
2.2.2.2 Connectors···················································································· 2-12
2.2.2.3 LEDs ·························································································· 2-12
2.2.2.4 Check Pins···················································································· 2-13
2.2.2.5 DIP Switches ················································································· 2-14
2.3 1TR Board (Power Sequence Board) ····················································· 2-16
2.3.1 Main Functions ·············································································· 2-16
2.3.2 Switches, Connectors, Jumpers, LEDs, Check Pins and Fuses ······················· 2-17
2.3.2.1 Layout ························································································· 2-17
2.3.2.2 Switch Function and Settings ······························································ 2-18
2.3.2.3 Connectors···················································································· 2-18
2.3.2.4 Jumper Settings ·············································································· 2-18
2.3.2.5 LEDs ·························································································· 2-19
2.3.2.6 Check Pins···················································································· 2-19
2.3.2.7 Fuse···························································································· 2-19
2.3.3 Connection with External Circuits (Safety Circuit, etc.) ······························· 2-20
2.4 1TX Board (Mother Board for E1x/E2x/E3x/E4x Controller) ························ 2-21
2.4.1 Connectors and Jumpers ···································································· 2-21
2.4.1.1 Layout ························································································· 2-21
2.4.1.2 Connectors···················································································· 2-22
2.4.1.3 Jumper Settings ·············································································· 2-22
2.5 1TW Board (IO Board) (Option) ·························································· 2-23
2.5.1 Specifications ················································································ 2-23
2.5.2 Connectors, LEDs, Check Pins and Switches ··········································· 2-24
2.5.2.1 Layout ························································································· 2-24
2.5.2.2 Connectors···················································································· 2-24
2.5.2.3 LEDs ·························································································· 2-25
2-1
2.5.2.4 Check Pins···················································································· 2-25

2.5.2.5 Switches ······················································································ 2-25
2.5.2.6 Pin Assignment ·············································································· 2-27
2.6 1FG/1HG Boards (Battery Backup Board for Encoder) ······························· 2-28
2.6.1 1FG Board ···················································································· 2-28
2.6.1.1 Main Functions ·············································································· 2-28
2.6.1.2 Layout ························································································· 2-28
2.6.1.3 Check Pins···················································································· 2-29
2.6.1.4 Connectors···················································································· 2-29
2.6.2 1HG Board ··················································································· 2-30
2.6.2.1 Main Functions ·············································································· 2-30
2.6.2.2 Layout ························································································· 2-30
2.6.2.3 Check Pins···················································································· 2-30
2.6.2.4 Connectors···················································································· 2-31
2.7 1PV/1TK Boards (Arm ID Board) (Option) ············································· 2-31
2.7.1 1PV Board ···················································································· 2-31
2.7.1.1 Layout ························································································· 2-31
2.7.1.2 1PV Board Connectors ····································································· 2-32
2.7.1.3 LEDs ·························································································· 2-32
2.7.1.4 Check Pins···················································································· 2-32
2.7.1.5 Switches ······················································································ 2-32
2.7.1.6 1JD/1JE Board Connectors ································································ 2-32
2.7.2 1TK Board···················································································· 2-33
2.7.2.1 Layout ························································································· 2-33
2.7.2.2 1TK Board Connectors ····································································· 2-33
2.7.2.3 LEDs ·························································································· 2-33
2.7.2.4 Check Pins···················································································· 2-34
2.7.2.5 Switches ······················································································ 2-34
2.7.2.6 1TY Board Connectors ····································································· 2-34
2.8 Encoder ······················································································· 2-35
2.8.1 Main Functions ·············································································· 2-35
2.9 Servo Amplifier Unit for 6 Axes ·························································· 2-37
2.9.1 1TB Board (Servo Board for E1x/E2x/E3x/E4x Controller) ·························· 2-37
2.9.1.1 Main Functions ·············································································· 2-37
2.9.1.2 Connectors, Jumpers, LEDs, Check Pins and Switches································ 2-38
2.9.1.2.1 Layout ························································································· 2-38
2.9.1.2.2 Connectors···················································································· 2-39
2.9.1.2.3 Jumpers ······················································································· 2-40
2.9.1.2.4 LEDs ·························································································· 2-41
2-2
2.9.1.2.5 Check Pins···················································································· 2-42

2.9.1.2.6 Switches ······················································································ 2-42
2.9.1.3 1TB Board Software ········································································ 2-42
2.9.2 1TC/1VE/1TD/1VD Boards
(Power Block Board for E1x/E2x/E3x/E4x Controller) ······························· 2-43
2.9.2.1 Main Functions ·············································································· 2-43
2.9.2.2 Connectors and Check Pins ································································ 2-44
2.9.2.2.1 Layout ························································································· 2-44
2.9.2.2.2 Connectors (For 1TC/1VE/1TD/1VD Board) ··········································· 2-45
2.9.2.2.3 Check Pins···················································································· 2-45
2.10 Amplifier Unit for Single Axis ···························································· 2-46
2.10.1 Specifications ················································································ 2-46
2.10.2 Main Functions ·············································································· 2-46
2.10.3 Connectors···················································································· 2-46
2.11 DC Power Supply for Control (AVR) ···················································· 2-47
2.11.1 Specifications ················································································ 2-47
2.11.2 Main Functions ·············································································· 2-47
2.11.3 Connectors and Output Voltage Adjustment ············································ 2-48
2.11.3.1 Layout ························································································· 2-48
2.11.3.2 Connectors···················································································· 2-48
2.11.3.3 Output Voltage Adjusting Knob··························································· 2-48
2.12 MC Unit ······················································································ 2-49
2.12.1 1TU Board (MC Power Board for E1x/E2x/E3x/E4x Controller) ··················· 2-49
2.12.1.1 Main Function ··············································································· 2-49
2.12.1.2 Connectors, LEDs and Check Pins························································ 2-50
2.12.1.2.1 Layout ························································································· 2-50
2.12.1.2.2 Connectors···················································································· 2-50
2.12.1.2.3 LEDs ·························································································· 2-51
2.12.1.2.4 Check Pins···················································································· 2-51
2.12.2 1TQ/1TV Boards (MC Control Board)··················································· 2-52
2.12.2.1 Main Functions ·············································································· 2-52
2.12.2.2 Connectors, Jumpers, LEDs, Check Pins and Switch ·································· 2-53
2.12.2.2.1 Layout ························································································· 2-53
2.12.2.2.2 Connectors···················································································· 2-54
2.12.2.2.3 Jumper Settings ·············································································· 2-55
2.12.2.2.4 LEDs ·························································································· 2-55
2.12.2.2.5 Check Pins···················································································· 2-57
2.12.2.2.6 Switch ························································································· 2-57
2.13 Manual Brake Release Switch (Option) ·················································· 2-58
2-3
2.14 Additional Regenerative Register Unit ··················································· 2-58

2.15 1UX Board (Mother Board for E7x Controller)········································· 2-60
2.15.1 Connectors and Jumpers ···································································· 2-60
2.15.1.1 Layout ························································································· 2-60
2.15.1.2 Connectors···················································································· 2-61
2.15.1.3 Jumper Settings ·············································································· 2-61
2.16 Servo Amplifier Section for E7x Controller ············································· 2-62
2.16.1 1TB Board (Servo Board for E7x Controller) ··········································· 2-62
2.16.2 1UY Board (Servo Relay Board)·························································· 2-63
2.16.2.1 Main Functions ·············································································· 2-63
2.16.2.2.1 Layout ························································································· 2-64
2.16.2.2.2 Connectors···················································································· 2-65
2.16.3 1UZ Board (Power Block Board for E7x Controller) ·································· 2-65
2.16.3.1 Main Functions ·············································································· 2-66
2.16.3.2.1 Layout ························································································· 2-67
2.16.3.2.2 Connectors···················································································· 2-67
2.17 Power Supply Unit for E7x Controller ··················································· 2-68
2.17.1 1UE Board (MC Power Board for E7x Controller)····································· 2-69
2.17.1.1 Main Functions ·············································································· 2-69
2.17.1.2 Connectors···················································································· 2-69
2.17.1.2.1 Layout ························································································· 2-69
2.17.1.2.2 Connectors···················································································· 2-70
2.17.2 1TQ/1TV Boards (MC Control Board)··················································· 2-70
2.18 Power Unit ··················································································· 2-71
2.18.1 1VJ Board (Power Unit Power Board for E9x Controller) ···························· 2-71
2.18.1.1 Main Functions ·············································································· 2-71
2.18.1.2 Connectors, LEDs and Check Pins························································ 2-72
2.18.1.2.1 Layout ························································································· 2-72
2.18.1.2.2 Connectors···················································································· 2-73
2.18.1.2.3 LEDs ·························································································· 2-73
2.18.1.2.4 Check Pins···················································································· 2-73
2.18.2 1VH Boards (Power Unit Control Board for E9x Controller)························· 2-74
2.18.2.1 Main Functions ·············································································· 2-74
2.18.2.2 Connectors, Jumpers, LEDs, Check Pins and Switch ·································· 2-75
2.18.2.2.1 Layout ························································································· 2-75
2.18.2.2.2 Connectors···················································································· 2-76
2.18.2.2.3 Jumper Settings ·············································································· 2-77
2-4
2.18.2.2.4 LEDs ·························································································· 2-77

2.18.2.2.5 Check Pins···················································································· 2-78
2.18.2.2.6 Switch ························································································· 2-78
2.18.3 1VF/1WF Boards (PFC Board) ··························································· 2-79
2.18.3.1 Main Functions ·············································································· 2-79
2.18.3.2.1 Layout ························································································· 2-79
2.18.3.2.2 Connectors···················································································· 2-80
2.18.3.2.3 Check Pins···················································································· 2-80
2.19 1VZ Board (Mother Board for E9x Controller) ········································· 2-81
2.19.1 Connectors and Jumper ····································································· 2-81
2.19.1.1 Layout ························································································· 2-81
2.19.1.2 Connectors···················································································· 2-82
2.19.1.3 Jumper Settings ·············································································· 2-82
2-5
2.1 TEACH PENDANT
The teach pendant can be used by connecting the teach pendant cable to the X1 connector on the
front of the controller.
2.1.1 FUNCTIONS OF TEACH PENDANT
1. Display of various kinds of information and conditions by LCD

2. Input function by the touch panel on LCD (Small sized TP does not have this function.)
3. Input function by the hardware keys
4. Function of emergency stop, teach lock, and deadman by various dedicated switches
2.1.2 OVERVIEW OF TEACH PENDANT
LCD with
Touch Panel
Emergency Stop
Switch
Teach Lock Switch

Hardware Operation
Keys
(in the dashed line)
Deadman Switches
(3 positions)
Front view Rear view
Teach pendant
2-6
Emergency Stop Switch

Teach Lock Switch
LCD
Deadman Switches
(3 positions)
Hardware Operation Keys

(in the dashed line)
Front view Rear view
Small sized teach pendant
2-7
2.1.3 SYSTEM CONFIGURATION OF TEACH PENDANT
The following block diagram shows a configuration of the teach pendant.
Power
sequence
board
Deadman signal
Emergency stop
Teach RS-422 Main CPU
pendant board
Image signal (digital RGB)
！ CAUTION
意
1. Prior to using the touch panel, attach the protection sheet. (Three sheets are
included with shipment.) Use only the dedicated touch pen or a PDA touch
pen. Do not operate the touch panel with sharp tools, such as a screw driver,
etc. Doing so may damage the panel.
2. Protect the teach pendant and its LCD from strong impact (Do not drop, etc.).
3. Teach pendant is not explosion proof type. Do not use it in an explosive
environment or work cell.
4. Teach pendant is not waterproof and should be kept out of water, oil, etc.
5. Do not pull the teach pendant cable forcibly or push it into the gap between the
safety fence rails, etc.
2-8
2.2 1TA/1VA BOARD (MAIN CPU BOARD)
This board is the main CPU board of the E Series Controller. (1TA board: before 2011, 1VA
board: after 2011)
The 1TA/1VA board executes AS language commands/instructions, processes basic robot motion
planning and communication with internal/external I/O equipment and devices, and conducts
interface controls with these devices.
2.2.1 MAIN FUNCTIONS
The 1TA board performs the following functions:
1. Stores AS group software and servo group software (in the CF card).
2. Controls AS software system.
3. Stores user programs and data in the CF card.
4. Performs servo data communication with servo board.
5. Performs digital RGB parallel communication and serial communication via RS-422 with
teach pendant.
6. Functions as an optional slot bus interface. (Communicates with the IO and other optional
boards.)
7. Houses two RS-232C ports. (One is connected to that in accessory panel.)
8. Houses two USB ports. (One is connected to that in accessory panel.)
9. Houses two Ethernet ports.
10. Functions as a clock. (Backed up by a coin battery.)
The 1VA board performs the following functions besides the functions above.
11. Communicates with the second servo board.

12. Houses two RS-485 ports.
2-9
2.2.2 CONNECTORS, LEDS, CHECK PINS AND DIP SWITCHES
2.2.2.1 LAYOUT
CN2 CN8
CN13
CN11
DIP SW CN6 CN7 Check pins, LEDs

1 2 34 5 6 78 CN3 CN4 CN10
Outline view of 1TA board
TP3 LD1 LD2 LD3 LD4 LD5 LD7
TP4 TP6 TP8 TP10 TP12
TP5 TP7 TP9 TP11
2-10
CN2 CN8
CN13
CN11
DIP SW CN6 CN7 Check pins, LED

CN CN
1 2 34 5 6 7 8 CN3 CN4 10A 10B
CN16
Outline view of 1VA board
LED4 LED5 LED1 LED2 LED3 LED14
TP7 TP8 TP9 TP6 TP5
TP1 TP1 TP1 TP1
TP1 TP3 TP4
2-11
2.2.2.2 CONNECTORS
No. Contents Destination

Communication with servo board Mother board S2
CN2
and TP
CN3 RS-232C Accessory panel
CN4 RS-232C –
CN6 USB Accessory panel
CN7 USB –
CN8 System bus Mother board S3
CN10 (1TA board) Ethernet –
CN10A/10B (1VA
board)
CN11 For compact flash CF card
CN13 Connector for additional board Additional servo communication
board
CN16 Servo communication
(Ch2, only 1VA board)
2.2.2.3 LEDS
1TA board
No. Contents Color Lighting Condition
LD1 Blink at normal state,
System RUN Green
(SYSRUN) ON at abnormal state
LD2 OFF at normal state,
System error Red
(ERROR) ON at abnormal state
LD3 ON at controller power ON,
Power supply Green
(PWR) OFF at controller power OFF
ON when CF card inserted,
LD4 For CF card
Green OFF when no CF card inserted,
(PR.CF_ACT) (Primary)
Blink when accessing the CF
LD7 OFF at normal state,
CPU overheat Red
(PROC) Blink at CPU overheating
2-12
1VA board
No. Contents Color Lighting Condition
LED1 ON at controller power ON,
Power supply Green
(PWR) OFF at controller power OFF
ON when CF card inserted,
LED2
For CF card Green OFF when no CF card inserted,
(CF-ACT)
Blink when accessing the CF
LED3 OFF at normal state,
CPU overheat 1 Red
(PROC.H) ON at CPU overheating
LED4 Blink at normal state,
System RUN Green
(SYS.RUN) ON at abnormal state
System error Red
(ERROR) ON at abnormal state
CPU overheat 2 Red
(THERM) Blink at CPU overheating (System is shut down.)
2.2.2.4 CHECK PINS
1TA board
No. Function Normal range
TP3 +1.8 V power voltage +1.71 - +1.89 V
TP5 GND -
TP7 CPU CORE +1.29 - +1.42 V
TP9 +5 V power voltage +5.05 - +5.15 V
2-13
1VA board
No. Function Normal range
TP1 GND -
TP3 +5 V (input) +5.05 - +5.15 V
TP4 +3.3 V (input) +3.25 - +3.35 V
TP5 +3.3 V +3.14 - +3.46 V
TP6 +2.5 V +2.38 - +2.62 V
TP7 +1.5 V +1.43 - +1.57 V
TP8 +1.8 V +1.71 - +1.89 V
TP9 +1.8 V (memory) +1.71 - +1.89 V
TP10 +1.2 V +1.14 - +1.26 V
TP11 +1.05 V +1.00 - +1.10 V
TP12 +1.05 V (graphic) +1.00 - +1.10 V
TP13 VCPU core +0.75 - +1.22 V
2.2.2.5 DIP SWITCHES
DIPSW
Default (Factory settings) Function
No.
1 OFF Reset (only 1TA board)*
2 OFF
3 OFF
4 OFF Used for the system
5 OFF (Not to be used)
6 OFF
7 OFF
Confirmation query for
8 OFF
initialization at ON
NOTE* Reset (only 1TA board)

Use this switch when the controller does not restart even after power is re-supplied at occurrence
of overheating, etc. The restart procedure is shown below:
1. Turn OFF the controller power.

2. Turn ON the DIP switch 1.
3. Turn ON the controller power.
4. Turn OFF the DIP switch 1 in approx. two seconds.
2-14
！ CAUTION
Leaving DIP switch 1 ON after procedure 3 makes the
switch OFF forcibly and stop moving. When this state
occurs, execute 1 to 3 again.
[ NOTE ]
DIPSW1 has no reset function for 1VA board. When the system
stops due to abnormal overheating, etc., LED14 (THERM) blinks.
In this case, the system can be restarted by turning controller
power OFF/ON.
2-15
2.3 1TR BOARD (POWER SEQUENCE BOARD)
This is the power sequence board of the E Series Controller. 1TR board monitors conditions of
the power circuits and safety circuits of the E Series Controller, communicates with the 1TA/1VA
board (main CPU board), and controls the safety circuits.
The 1TR board performs the following functions:
1. Connects the external safety circuits. (Refer to External I/O Manual for more details.)
2. Detects condition of the safety circuits.
3. Checks if the safety circuits are normal, and notifies the 1TA/1VA board of the result.
4. Notifies the 1TA/1VA board of primary power failure in AVR, and monitors DC power
supply that AVR generates.
5. Cuts OFF output of AVR when abnormality is detected in the primary and DC power
supply.
6. Sets the number of safety circuits (double circuit as standard). To change the setting,
jumper settings on the MC unit is also necessary.*
7. Sets the delay time before cutting OFF the motor power (backup time by hardware) after
switching HOLD/RUN optional switch from RUN to HOLD.
8. Detects fuse blowouts for the safety circuit (F1).
9. Monitors temperature inside the controller and detects error when the temperature becomes
high.
10. Notifies the 1TA/1VA board of the switch input state of the optional operation panel. Also,
lights ON the lamps on optional operation panel.
11. Enables mounting up to two optional daughter boards.
12. Houses the LS override switch.
NOTE* Changing the number of safety circuits is enabled only for the E2x/E73/E74 controllers.
In other controllers, the number of the circuit is set to two and cannot be changed.
2-16
2.3.2 SWITCHES, CONNECTORS, JUMPERS, LEDS, CHECK PINS AND FUSES

2.3.2.1 LAYOUT
TP3 TP2
FUSE F1
X9 X8 X7
TP6 TP5 TP4 TP1
JP1
A1 B1 SW
CN1
JP1
A6 B6 SW2
JP2
JP2
A1 B1
ON
A6 B6 1 2 3 4
P2 P1
Outline view of 1TR board (front)
CN10
LD1 LD2 LD3 LD4 LD5
LD6 LD7 LD8 LD10 LD9
CN3 CN4
CN2
Outline view of 1TR board (rear)

2-17
2.3.2.2 SWITCH FUNCTION AND SETTINGS
1. SW1 (LS Override Switch)

The LS Override Switch, yellow press-button switch, is located on the upper front side of the
1TR board. The LS is not effective while pressing the switch.
2. SW2
No. Function Default
SW2-1 Sets the number of the safety circuits. OFF: Double circuit
(ON: Single circuit, OFF: Double
circuit)
SW2-2 Sets backup time for HOLD ON: 2 seconds
(ON: 2 seconds, OFF: No setting)
SW2-3 Unused OFF (modification prohibited)
SW2-4 Unused OFF (modification prohibited)
2.3.2.3 CONNECTORS

X7 External emergency stop input External wiring
X8 Safety fence, External trigger input, Teaching state External wiring
output
X9 External control power ON, External motor ON, External wiring
External HOLD input, I/O24 V output
P1 System bus Mother board S4
P2 Emergency stop, Safety circuit input/output for Mother board S9
Teach/Repeat, etc.
CN2 Option – Connector for -12 V power supply –
CN3, CN4 Connector for optional board –
CN10 Emergency stop output for Mitsubishi SSC-NET 1LP board CN4
2.3.2.4 JUMPER SETTINGS
No. Contents Settings

CN1 For debug Unconnected.
(modification prohibited)
JP1, JP2 Switches emergency stop monitor. Jumper JP1
Jumper JP1: Monitors operation panel/emergency
stop in teach pendant.
Jumper JP2: Not monitor operation panel/emergency
stop in teach pendant.
2-18
2.3.2.5 LEDS
No. Contents Color Lighting state

LD1 (OPEMG) EMERGENCY STOP is ON in Red OFF at normal state,
operation panel. ON at emergency stop
LD2 (TPMEG) EMERGENCY STOP is ON in teach Red OFF at normal state,
pendant. ON at emergency stop
LD3 (EXEMG) External EMERGENCY STOP is ON. Red OFF at normal state,
ON at emergency stop
LD4 (PSERR) Power sequence error is occurring. Red OFF at normal state,
ON at abnormal state
LD5 (WDERR) Bus access watch dog error is occurring. Red OFF at normal state,
LD6 (+3.3V) Supplying +3.3 V power. Green ON when supplying the
power normally
LD7 (+5V) Supplying +5 V power. Green ON when supplying the
power normally
power normally
power normally
LD10 Accessing system bus. Green ON at normal state
(ACCESS)
2.3.2.6 CHECK PINS
No. Contents Normal range

TP1 +5 V power supply +5.05 - +5.15 V
TP2 +3.3 V power supply +3.25 - +3.35 V
TP4 GND -
TP6 24 V GND -
2.3.2.7 FUSE
No. Contents
F1 Fuse for emergency stop line (1A)
2-19
2.3.3 CONNECTION WITH EXTERNAL CIRCUITS (SAFETY CIRCUIT, ETC.)
External circuits are connected via the terminal block connector on the front of the 1TR board.
Note that the connection method differs depending on either single or double circuit in the safety
circuit. In the case of double circuit, two input contacts, each one per circuit, needs to be
activated simultaneously. Three connectors X7, X8 and X9 are used for terminal blocks.
Refer to External I/O Manual for more details.
2-20
2.4 1TX BOARD (MOTHER BOARD FOR E1X/E2X/E3X/E4X CONTROLLER)
This is the mother board for E1x/E2x/E3x/E4x controllers. The 1TA/1VA board (main CPU
board), the 1TR board (power sequence board), the 1TW board (IO board), other optional boards
and the AVR unit are all connected to the 1TX board.
For the mother board of E7x controller, refer to 2.15.
2.4.1 CONNECTORS AND JUMPERS
2.4.1.1 LAYOUT
S2 S4 S5 S6 S7 S8
S1 J1
1
S3 2
S9 3
J2 J1
1
2 J2
3
X207 X214 X213 X212 X206 X205 X204 X203 X202 X211 X210
Outline view of 1TX board
2-21
2.4.1.2 CONNECTORS
No. Contents and destination Connection at default

S1 AVR Connected
S2 1TA/1VA board (main CPU board) CN2 Connected
S4 1TR board (Power sequence board) P1 Connected
S5 Optional slot 1 Unconnected
X202 Operation panel (Emergency stop switch) Connected
X203 Operation panel (Teach/Repeat switch) Connected
X204 Teach pendant Connected
X206 Input/Output of 1TB board (Servo board) Connected
signal
X207 Power supply to 1TB board (Servo board) Connected
X210 Optional operation panel (Optional Connected (Jumper connector
switches) is connected as default.)
X211 Optional operation panel (Optional lamps) Unconnected
X212 Additional optional signals Unconnected
X213 Optional power supply connector 1 Unconnected
No. Contents Standard settings

Switches GND-FG
J1 1-2 connected. (GND-FG unconnected.)
connection
Switches 24VG-FG
J2 2-3 connected. (24VG-FG connected.)
connection
2-22
2.5 1TW BOARD (IO BOARD) (OPTION)
This board is an optional parallel IO board which provides 32 input and 32 output channels, and
is mounted to the optional slot of the mother board. 1TW board has two types, SINK/NPN spec.
and SOURCE/PNP spec.
2.5.1 SPECIFICATIONS
Input Specifications Output Specifications

Number of input 32 Number of output 32
channels channels
Input type Photo coupler Output type Photo coupler insulated
transistor array
Input voltage DC24 V Output voltage DC24 V
rating rating
Input voltage DC24 V  10 % Load voltage range DC24 V  10 %
range
Input current 10 mA Maximum load 0.1 A/channel
rating current (1.6 A/common)
Maximum surge 0.4 A/channel
current
Maximum 100 % ON Maximum 100 % ON
simultaneous (16 channels/common) simultaneous (16 channels/common)
input channels simultaneously output channels simultaneously
Common system 16 channels/common Common system 16 channels/common
(+ common) (- common)
Up to four 1TW boards can be used. But since there are four slots available for optional boards
in the card rack, the number of the 1TW boards is limited depending on the number of other
optional boards to be mounted.
The DC24 V for external equipment is not supplied from the controller; thus, be sure to prepare
DC24 V power when IO board is connected.
For connection with the external equipment, refer to Installation and Connection Manual and
External I/O Manual.
2-23
2.5.2 CONNECTORS, LEDS, CHECK PINS AND SWITCHES
2.5.2.1 LAYOUT
CN4 CN3 CN2 CN1
TP2
CN5
LD2 LD1 SW5 SW3
SW4 SW2
4 3 2 1
ON
CN6
CN7
4 3 2 1
SW1 TP1
ON
P1
Outline view of 1TW board
2.5.2.2 CONNECTORS

CN1* Connector for analog output External wiring
CN2 Output connector External wiring
CN3* Arc IO connector XSOL
CN4 Input connector External wiring
CN5* Connector for connecting arc IO optional board Arc IO optional board
CN6* Connector for connecting arc IO optional board Arc IO optional board
CN7 For debug –
NOTE* CN1, 3, 5, 6 are mounted when optional analog output is used.
2-24
2.5.2.3 LEDS
No. Contents Color Lighting condition

LD1 (ACCESS) Accessing system bus. Green ON at normal state
Bus access watch dog error is OFF at normal state,
LD2 (WDERR) Red
occurring. ON at abnormal state
2.5.2.4 CHECK PINS
No. Contents
TP1 Ground (GND)
TP2 Analog ground (AGND)
2.5.2.5 SWITCHES
No. Functions Standard setting

SW1-1 Address settings on boards Settings as in the left cell.
SW1-2 1st board 2nd board
3rd board 4th board
SW1-3 Optional reset function settings* OFF: Disabled

ON: Optional reset enabled
OFF: Optional reset disabled
SW1-4 Unused OFF(Modification prohibited)
2-25
SW2-5 Output voltage range settings of:

SW2- Analog output CH1
SW4- Analog output CH3 Output voltage 0 - 10 V
Settings are as follows:
1. 0 - +10 V 2. 0 - +15 V
3. minus 10V - +10 V
NOTE* By optional reset function, all the outputs become OFF when an access to the 1TW board
via bus is not made for a certain period of time.
2-26
2.5.2.6 PIN ASSIGNMENT
CN2 CN4
1 19 COM2
20 OUT 1 37 (IN1732)
OUT17 2 NC 18 COM1
21 OUT 2 36 (IN116)
OUT18 3 NC 17
22 OUT 3 35 NC
OUT19 4 IN32 16
23 OUT 4 34 IN16
OUT20 5 IN31 15
24 OUT 5 33 IN15
OUT21 6 IN30 14
25 OUT 6 32 IN14
OUT22 7 IN29 13
26 OUT 7 31 IN13
OUT23 8 IN28 12
27 OUT 8 30 IN12
OUT24 9 IN27 11
28 OUT 9 29 IN11
OUT25 10 IN26 10
29 OUT10 28 IN10
OUT26 11 IN25 9
30 OUT11 27 IN 9
OUT27 12 IN24 8
31 OUT12 26 IN 8
OUT28 13 IN23 7
32 OUT13 25 IN 7
OUT29 14 IN22 6
33 OUT14 24 IN 6
OUT30 15 IN21 5
34 OUT15 23 IN 5
OUT31 16 IN20 4
35 OUT16 22 IN 4
OUT32 17 IN19 3
36 COM1 NC 21 IN 3
(OUT116) 18 VIN1 IN18 2
37 COM2 (OUT116) 20 IN 2
(OUT1732) 19 VIN2 IN17 1
(OUT1732) IN 1
The figure above depicts pin arrangements of the connectors on the printed board side. Types of
connectors for the harness are as follows.
Connector body : for CN2 17JE-13370-02(D1)A (DDK) or equivalent
for CN4 17JE-23370-02(D1) (DDK) or equivalent
2-27
2.6 1FG/1HG BOARDS (BATTERY BACKUP BOARD FOR ENCODER)
2.6.1 1FG BOARD
2.6.1.1 MAIN FUNCTIONS
This printed board is built inside the base of large-sized robots, and it performs the following
functions:
1. Supplies power to the encoder by converting the +12 V supplied from the controller to +5 V
while the controller power is ON.
2. Supplies power from the battery to keep the position data stored in the encoder while the
controller power is OFF.
3. Detects the battery voltage drop, and alerts the controller.
4. Relays signals (axis restriction limit switch, etc.) detected in the robot arm.
2.6.1.2 LAYOUT
CN
13
CN
Battery 12
TPG TP1 TP2
CN
CN8 11
TP4
CN
TPG2 TP5 10
TP3
CN CN
9 7
CN1 CN2 CN3 CN4 CN5 CN6
2-28
2.6.1.3 CHECK PINS
No. Function
TP1 Checks +12 V voltage supplied from the controller.
TP2 Checks +5 V voltage supplied to the encoder.
TP3 Checks voltage supplied to the encoder. +5 V (ON)/Battery (OFF)
TP4 Checks battery voltage.
TP5 Checks +24 V voltage.
TPG Grounds for +5 V, +12 V and battery.
TPG2 Ground for +24 V.
2.6.1.4 CONNECTORS
No. Destination
CN1 JT1 encoder
CN2 JT2 encoder
CN3 JT3 encoder
CN4 JT4 encoder
CN5 JT5 encoder
CN6 JT6 encoder
CN7 JT7 encoder
CN8 Controller
Arm ID board (DC24 V for IO signals and data
CN9
communication)
CN10 Battery
CN11 Axis restriction limit switch*
NOTE* See the following figure for the connection.
Short circuit
CN11 CN12 CN13 connector
1 2 3 4 1 2 3 4 1 2 3 4
LS1+ LS2+ LS1- LS2-
2-29
2.6.2 1HG BOARD
This printed board is built inside the base of small-sized robots (for RA04BN/RA06VN robot,
mounted in the rear part of the controller) and it performs the following functions:
1. Supplies power to the encoder by converting the +12 V supplied from the controller to +5 V
while the controller power is ON.
*
2 . Supplies power from the battery to keep the pose data stored in the encoder while the
controller power is OFF.
*
3 . Detects the battery voltage drop, and alerts to the controller.
NOTE* The 1HG board for RA04BN/RA06VN robot does not have the functions 2 and 3.
RA04BN/RA06VN robot uses the battery in the robot arm to keep the pose data stored
in the encoder.
2.6.2.2 LAYOUT
TP2
TP1
CN4
CN5
TP5 TP4
TP3
CN1 CN2
2.6.2.3 CHECK PINS
No. Function
TP1 Checks +12 V voltage supplied from the controller.
TP2 Checks +5 V voltage supplied to the encoder.
TP3 Checks voltage to the encoder. +5 V (ON)/Battery (OFF)
TP4 Checks battery voltage.
TP5 Grounds for +5 V, +12 V and battery
2-30
2.6.2.4 CONNECTORS
No. Destination Contents

CN1 Controller +12 V, JT7 encoder signal, Battery alarm
**
CN2 JT7 encoder JT7 encoder signal, Power supply
**
CN3 Battery Battery power supply
CN4 JT1- JT6 encoder Encoder power supply
NOTE** Not installed on the 1HG board for RA04BN/RA06VN robot.
2.7 1PV/1TK BOARDS (ARM ID BOARD) (OPTION)
The Arm ID board is of two kinds: 1PV board for Z/M series robot, and 1TK board for R series
robot. Each board needs a daughter board, 1JD/1JE board for the 1PV and 1TY board for the
1TK board, to send/receive arm IO signals. Each board performs the following functions:
1. 1PV/1TK boards
Reads/writes data on the built-in flash memory via serial communication with the controller.
2. 1JD/1JE/1TY boards (Machine IO board, option)

Sends/Receives the IO signals via serial/parallel communication with the controller. 1JD
board is for SINK/NPN spec. and 1JE board is for SOURCE/PNP spec. 1TY board has two
types, SINK/NPN spec. and SOURCE/PNP spec.
2.7.1 1PV BOARD
2.7.1.1 LAYOUT
1PV board
CN2
TP3
TP4
SW1 LD1LD2
TP9 1PV: CN3

1JD/1JE: CN1
CPU
TP1
TP2
CN1
CN2 CN3
1JD/1JE board
Outline view of 1PV board with 1JD/1JE board connected
2-31
2.7.1.2 1PV BOARD CONNECTORS

CN1 For machine wiring Customer’s device
CN2 Communication on controller side 1FG board
CN3 1JD/1JE board connection 1JD/1JE board
2.7.1.3 LEDS
No. Color Contents Lighting condition

LD1 (RUN) Green CPU in run state. Blink at normal state,
OFF or ON at abnormal state
LD2 (ERR) Red Error OFF at normal state,
2.7.1.4 CHECK PINS
No. Function
TP1 +24 V
TP2 24G
TP3 VCC (+5 V)
TP4 GND
TP9 VDD (+3.3 V)
2.7.1.5 SWITCHES
Switch No. Default Function

SW1 1-5 OFF Software switch for application
6 OFF (Writing prohibited ) Writing prohibited/permitted
7-8 OFF For system check (Operation
prohibited)
2.7.1.6 1JD/1JE BOARD CONNECTORS
1JD (NPN, SINK)/ 1JE (PNP, SOURCE) board connectors

CN1 1PV board connection 1PV board
CN2 Input, Power supply Customer’s device
CN3 Input/output, Power supply Customer’s device
2-32
2.7.2 1TK BOARD
2.7.2.1 LAYOUT
1TK board CN2 TP4

TP3
CN3 TP5
SW1
LD2
1TK board: CN3
LD1 1TY board: CN1
CPU
CN2
CN1 TP2 TP1
1TY board
Outline view of 1TK board with 1TY board connected
2.7.2.2 1TK BOARD CONNECTORS

CN1 For machine wiring Customer’s device
CN2 Communication on the 1HG board
controller side
CN3 1TY board connection 1TY board
2.7.2.3 LEDS
No. Color Contents Lighting condition

LD1 (RUN) Green CPU in run state Blink at normal state,
OFF or ON at abnormal state
LD2 (ERR) Red Error OFF at normal state,
2-33
2.7.2.4 CHECK PINS
No. Function
TP1 +24 V
TP2 24G
TP3 VCC (+5 V)
TP4 GND
TP5 VDD (+3.3 V)
2.7.2.5 SWITCHES
Switch No. Default Function

SW1 1-5 OFF Software switch for application
6 OFF (Writing prohibited) Writing prohibited/permitted
7-8 OFF For system check (Operation
prohibited)
2.7.2.6 1TY BOARD CONNECTORS
1TY board (NPN, SINK/ PNP, SOURCE) connectors

CN1 1TK board connection 1TK board
CN2 Output Customer’s device
CN3 Input, Power supply Customer’s device
2-34
2.8 ENCODER
There are three encoder models for the E Controller, MK32, M35 and M40, which differ by
installation method to the motor but share the same basic specifications. These electronic
multi-turn absolute encoders output 33 bits of data via serial communication. The 33 bits is the
sum of 17 bits of absolute angle position within one rotation by an optical encoder and 16 bits of
the number of rotations data read via counter counting magnetic pulse/rotation. The counter
data is backed up by a battery.
The encoder performs the following functions:
1. Motor rotation angle detection

One rotation: 131072 (217) pulses
Number of rotations: 65536 (216) counts
When the motor rotates in the direction of CCW (seen from motor output axis side), the value
counts up.
Response speed is 6000 rpm
2. Communication
Position data is transmitted synchronizing with the data request signal from the servo board.
(Half duplex serial communications and baud rate: 4 Mbps)
3. Operational state per power supply voltage

Encoder operation changes per power supply voltage. There are three types of operations as
follows:
(1) Non-operating state: All operation stops when power supply is +3.0 V or less.
(2) Backup state: Rotation counter remains functional at +3.6 V to +5 V of power
supply.
(3) Normal operation state: Detects absolute position within one rotation, counts number of
rotations, and communicates with the controller at +5 V of power
supply.
4. Backup
By the backup of a built-in super capacitor, the rotation counter functions properly for 30
minutes after the 1FG/1HG board (encoder battery backup board) is disconnected.
2-35
5. Motor CS signal detection

Detects the magnetic pole position of the motor by installing the encoder at the position where
the rotation origin overlaps with the zero cross point of the motor’s voltage inducing U-phase.
6. Differences between MK32, M35 and M40

Installation method differs depending on the motor. MK32 is for large motors and separation
from the motor is possible. M35 and M40 are for small motors, and separation from the
motor is not possible.
2-36
2.9 SERVO AMPLIFIER UNIT FOR 6 AXES
The servo amplifier unit for 6 axes of E1x/E2x/E3x/E4x controller consists of servo board, power
block boards, and case. The servo board is mounted under the cover, and the power block
boards are mounted on the back of the servo board.
For details about the servo amplifier section of E7x controller, refer to 2.16. The information on
1TB board is described in this chapter.
Case
A
1TB board
(Servo board)
Heatsink
Servo board fixing plate
Cover
Power block board

(Total: 6 boards)
A
View A-A Front view
2.9.1 1TB BOARD (SERVO BOARD FOR E1X/E2X/E3X/E4X CONTROLLER)
The 1TB board is the servo board for E1x/E2x/E3x/E4x controller and mounted on the power
block by connectors.
The 1TB board performs the following functions:
1. Interface function for communication with encoders of 9 axes. (Encoder types: MK32, M35
and M40)
2. Servo data communication with 1TA/1VA board (main CPU board):
Calculates interpolation command receiving the motion plan from the 1TA/1VA board, and
processes calculations on the position loop, speed loop and motor current loop of up to 9
axes.
2-37
3. Outputs PWM signals to the power block.

4. Controls brakes for up to 9 axes.
5. Communicates with up to three MC units.
6. Cuts OFF the motor power ON signal to the MC unit when the servo-related hardware error
occurs, an error is detected by servo software (encoder-related errors, etc.), or a
communication error is detected by the 1TB board.
7. Detects and corrects errors in hardware.
8. Monitors the axis restriction LS state.
9. Communicates with the arm ID board.
2.9.1.2 CONNECTORS, JUMPERS, LEDS, CHECK PINS AND SWITCHES
2.9.1.2.1 LAYOUT
X513
X501
X511
X512
567
X506 4 0
3 21
J2
X508 SW7
12 9
J9
X509
8 5
4 1
X510
PUSH PUSH PUSH
J3
J6
J4
X520 X514
J5
J7
X502
J3 X519
JTAG_CPU
CN3
J1 X518
X503
X503
X517
CN2
X515
TP24 X504 X505 X507 SW2
TP23 TP25
Outline view of 1TB board (Front)
TP12 ON
1 2 3 4 5 6 7 8
TP14
TP13
LD1 LD4
LD5
TP10
LD3
LD11 LD13
TP11
TP15
LD10 LD2
LD14 LD16
LD15 LD12
TP26 LD8 LD9 2-38

X516-2 X516-4 X516-6
X516-1 X516-3 X516-5
Outline view of 1TB board (Rear)
2.9.1.2.2 CONNECTORS
No. Contents Destination Destination (E7x)

(E1x/E2x/E3x/E4x)
X501 DC power supply input 1TX board X207 1UX board X207
X502 Input/Output to/from boards in 1TX board X206 1UX board X206
the card rack
X503 Input/Output to/from MC unit 1 MC unit 1 X304 1TV board X304
X504 Input/Output to/from MC unit 2 MC unit 2 X304 –
(Used for two MC units spec.)
X505 Input/Output to/from MC unit 3 MC unit 3 X304 –
(Used for three MC units spec.)
X506 Optional communication – –
connector
X507 Optional communication – –
connector
X508 Debug communication connector – –
X509 Communication with encoder of X3 X3
JT1 - JT6,
Battery alarm input
X510 Safety circuit, IO24 V output X3 X3
2-39
X511 Communication with encoder of X3 (Or JT7 signal X3 (Or JT7 signal
JT7, Battery alarm input connector on the rear side) connector on the
rear side)
X512 Communication with encoder of JT8 signal connector on the JT8 signal
JT8, Battery alarm input (Used rear side (Option) connector on the
when JT8 is connected.) rear side (Option)
X513 Communication with encoder of JT9 signal connector on the –
JT9, Battery alarm input (Used rear side (Option)*
when JT9 is connected.)
X514 Communication with Arm ID X3 X3
board
X515 Optional LS override switch – –
connector
X516-1 to For power block connection Power block X516-1 to 6 1UZ board CN1- 6
6
X517 For JT7 power block connection JT7 amp. unit for 1 axis 1UY board CN9
X553 (Option)
X518 For JT8 power block connection JT8 amp. unit for 1 axis 1UY board CN10
X553 (Option)
X519 For JT9 power block connection JT9 amp. unit for 1 axis –
X553 (Option)*
X520 Optional connector – –
CN2 For optional board – –
CN3 For optional board – –
NOTE* For E3x/E4x controller only
2.9.1.2.3 JUMPERS

J1 For debug 2-3 connected (modification prohibited)
J2 For switching encoder type 1-5 connected (modification prohibited)
J5 For debug Unconnected (modification prohibited)
JTAG_CPU For debug Unconnected (modification prohibited)
2-40
2.9.1.2.4 LEDS

LD1 Monitor software on servo board in run Green Blinks until servo software
(MON_RUN) state. starts running after power
is supplied, then becomes
OFF.
LD2 (ERR_DC) Power supply on servo board is Red OFF at normal state,
abnormal. ON at abnormal state
LD3 (Tx_STA1) Sending state 1 in servo data Green Blink at normal state,
communication (with main CPU board). OFF at abnormal state
LD4 Error “Error reset disable” detected by Red OFF at normal state,
(ERR_NRST) servo board is occurring. ON at abnormal state
LD5 (Tx_STA2) Sending state 2 in servo data Green Blink at normal state,
communication (with main CPU board). OFF at abnormal state
LD8 (+24V) +24 V power supply on servo board Green ON at normal state,
OFF at abnormal state
LD9 (I/O24V) IO24 V power supply on servo board Green ON at normal state,
OFF at abnormal state
LD10 Servo FPGA in run state Green Blink at run state
(I LOOP HW) (OFF right after power is
supplied.)
LD11 Receiving state in servo data Green Blink at normal state,
(Rx_STA) communication (with main CPU board). OFF at abnormal state
LD12 Servo error is occurring. Red OFF at normal state,
(SV_ERR) ON at abnormal state
LD13 Servo software in run state Green Blink at run state
(SV_RUN) (OFF right after power is
supplied.)
LD14 Servo control is ON. Green ON at servo control ON
(RGSO_STA)
LD15 Motor brake control enabled. Green ON when motor brake
(BRK_STA) control accepted.
LD16 Watch dog timer error is occurring. Red OFF at normal state,
(ERR_WDT) ON at abnormal state
2-41
2.9.1.2.5 CHECK PINS
No. Contents
TP10 3.3 V power supply
TP12 12 V power supply
TP23 +24 V power supply
TP24 IO24 V power supply
TP25 24 VG
TP26 GND
NOTE Check pins other than those above are for debug/measurement.
2.9.1.2.6 SWITCHES
Location Contents Settings

SW2 For debug OFF for all (modification prohibited)
SW7 Servo board number Standard: 0 (The number changes
settings depending on the number of servo
boards.)
2.9.1.3 1TB BOARD SOFTWARE
The 1TB board has a CPU, but servo software is installed in the CF card on the 1TA/1VA board
(main CPU board). Thus, the data is transmitted from the 1TA/1VA board to the 1TB board
when the controller power is turned ON.
2-42
2.9.2 1TC/1VE/1TD/1VD BOARDS (POWER BLOCK BOARD FOR

E1X/E2X/E3X/E4X CONTROLLER)
The 1TC/1VE and 1TD/1VD boards are power block boards of E1x/E2x/E3x/E4x controller: the
1TC/1VE board is for large-sized motor and the 1TD/1VD board is for small-sized motor. One
power block board is used in each axis, and 6 boards are used for the standard 6 axes spec. in the
E series controller.
For optional 7, 8 and 9 axes specifications, the 1TC/1VE board (for large motor) and the
1TD/1VD board (for small motors) are used in the amplifier unit for one axis. The board
controls the power and drives the AC servomotors receiving the commands from the 1TB board
(servo board).
After 2011, boards with current capacities of 50 A/30 A/15 A changed as shown in the table
below. Functions are compatible between the boards.
Before 2011 After 2011

100 A 1TC board (100 A) -
50 A 1TC board (50 A) 1VE board (50 A)
30 A 1TD board (30 A) 1VD board (30 A)
15 A 1TD board (15 A) 1VD board (15 A)
For details about power block boards for E7x controller, refer to 2.16.3.
The 1TC/1VE/1TD/1VD board performs the following functions:
1. Receives PN voltage from the MC unit and uses it as a power.

2. Receives the PWM (Pulse Width Modulation) commands from the 1TB board (servo board),
and controls the current for the motor by switching the IPM (Intelligent Power Modules).
3. Detects the current flowing in the motor by the current detection circuit, and feeds back to
the 1TB board.
4. Sends alarm signals of abnormal power module to the 1TB board when the IPM detects
overcurrent, overheat, etc.
5. Sets power block code by mounting the 0  resistors RJ1 - RJ4. If the model setting in the
software and this code do not match, an error occurs.
2-43
2.9.2.2 CONNECTORS AND CHECK PINS
2.9.2.2.1 LAYOUT
X516 X516
TP8 TP1 TP2 TP3 TP4 TP5 TP6

TP7
TP6
TP3 TP1 TP7 TP8
TP5
TP4 TP2 X552

X552
P N P N
X551 X551
Outline view of 1TC board Outline view of 1VE board
X516 X516
TP5
TP7 TP1 TP3

TP6 TP4
X552 TP6
TP5 TP8
TP4 TP3 TP2 TP1

TP8 TP7
TP2
X552
P N P N
X551 X551
Outline view of 1TD board Outline view of 1VD board
2-44
2.9.2.2.2 CONNECTORS (FOR 1TC/1VE/1TD/1VD BOARD)
No. Function Remarks

X516 PWM signal, current feedback, error signal
X551 Motor output (U, V, W)
X552 IPM control power input (DC20 V)
P PN voltage input (P) in main circuit Threaded terminal
N PN voltage input (N) in main circuit Threaded terminal
For 1TC, 1TD boards

TP1 IPM control power supply (W phase, +)
TP2 IPM control power supply (W phase, -)
TP3 IPM control power supply (V phase, +)
TP4 IPM control power supply (V phase, -)
TP5 IPM control power supply (U phase, +)
TP6 IPM control power supply (U phase, -)
TP7 IPM control power supply (N phase, +)
TP8 IPM control power supply (N phase, -)
For 1VE, 1VD boards

TP1 IPM control power supply (U phase, +)
TP2 IPM control power supply (U phase, -)
TP3 IPM control power supply (V phase, +)
TP4 IPM control power supply (V phase, -)
TP5 IPM control power supply (W phase, +)
TP6 IPM control power supply (W phase, -)
TP7 IPM control power supply (N phase, +)
TP8 IPM control power supply (N phase, -)
2-45
2.10 AMPLIFIER UNIT FOR SINGLE AXIS
This unit is single axis power block for the external axis and can additionally be mounted inside
the controller. There are four kinds of units: two for large motors (1TC/1VE board built-in), and
two for small motors (1TD/1VD board built-in). The unit is composed of power block unit
(1TC/1VE/1TD/1VD board), connector board (1TL board) and case.
1TL board
1TC/1VE/1TD/1VD board Case

A
View A-A A Front view
Specification
Item
For large motor For small motor
Built-in board 1TC board, 1VE board 1TD board, 1VD board
Number of axis Single axis Single axis
Power block rated output 100 A (only 1TC board) 50 A 30 A 15 A
Refer to 1TC/1VE/1TD/1VD board of Servo amplifier unit for 6 axes for the functions.
2.10.3 CONNECTORS
No. Function
X551 Power supply to motor (connected to separate harness)
X562 PN voltage input
X563 PN voltage/power distribution
X564 20 V control power supply/power distribution
X565 20 V control power supply input
X566 Signal connector of PWM, etc. (connected to either X517 (JT7), X518 (JT8), or
X519 (JT9) of servo board)
2-46
2.11 DC POWER SUPPLY FOR CONTROL (AVR)
The AVR (Auto Voltage Regulator) unit is housed in the left part of the card rack, and supplies
control power to each board via the 1TX board (mother board).
Input Output
Rated voltage 200 - 240 VAC +3.3 VDC 4.0 A
Rated current 1.25 A +5 VDC 11 A
Rated frequency 50/60 Hz +12 VDC 3.0 A
Allowable voltage 160 - 265 VAC +24 VDC 3.5 A
Momentary maximum voltage 280 VAC
The DC power supply for control (AVR) performs the following functions:
1. Converts input AC power into AC/DC power, and supplies +3.3 V, +5 V, +12 V, +24 V
necessary for each board.
2. Detects AC input power errors, and alerts the 1TR board. There are three types of detection
as follows.
(1) Detection of instant power failure

Detection level is 130 to 145 VAC or less. When this state continues for 25 to 35 msec,
an error signal is output to the 1TR board.
(2) Detection of over-voltage
Detection level is 267 to 283 VAC or more. When this state continues for 1 to 2 sec. or
more, an error signal is output to the 1TR board.
(3) Detection of low voltage
Detection level is 148 to 158 VAC or less. When this state continues for 1 to 2 sec. or
more, an error signal is output to the 1TR board.
3. Shuts down when the DC voltage on the output side is overloaded (outputs 105 % or more of
the rated capacity continuously for 5 sec. or more) or over-voltage state occurs (115 % - 130 %
of the rated capacity). It can be restored by re-inputting the power in 10 sec. or more after
shutdown.
4. Turns ON/OFF the DC output by the remote signal from the 1TR board.
2-47
2.11.3 CONNECTORS AND OUTPUT VOLTAGE ADJUSTMENT

2.11.3.1 LAYOUT
CN1
AVR
+5 V adjustment
+3.3 V adjustment
AVR front
2.11.3.2 CONNECTORS
CN1(X201): AC210 V input
2.11.3.3 OUTPUT VOLTAGE ADJUSTING KNOB
The +5 V and +3.3 V adjusting knobs are provided on the front of the AVR.
(For the +12 V and +24 V, output voltage is not adjustable.)
！ CAUTION
1. Normally, avoid touching these adjusting knobs.

2. When checking the output voltage, use the check pins on the following
boards.
Voltage Board Check pin Normal range
+5 V 1TR board TP4(GND)-TP1 +5.05 - +5.15 V
+3.3 V 1TR board TP4(GND)-TP2 +3.25 - +3.35 V
3. When adjusting the voltage, rotate the adjusting knob slowly. Rapid
rotating may damage the AVR.
！ DANGER
Before removing the AVR unit from the card rack, cut OFF the external
power supply and wait at least 7 minutes so that the output voltage
becomes 0.
2-48
2.12 MC UNIT
The MC unit for E1x/E2x/E3x/E4x controller consists of 1TU board (MC power module),
1TQ/1TV boards (MC control board), magnetic contactor (MC), inrush current preventing
resistor, power supply for power module, MC unit fan, and case, etc.
For details of the power supply unit for E7x controller, refer to 2.17.
Power supply for power module

1TV board
Case Fan Magnetic contactor
1TQ board 1TU board
A (MC)
A
Capacitor
MC unit front View A-A
2.12.1 1TU BOARD (MC POWER BOARD FOR E1X/E2X/E3X/E4X CONTROLLER)
For E1x/E2x/E3x/E4x controller, this board is mounted in the rear part of the MC unit, and
generates PN voltage from the AC210 V, controls regeneration, and generates brake power, etc.
For the MC power board of E7x controller, refer to 2.17.1.
2.12.1.1 MAIN FUNCTION
1. Sends/receives signals to/from the 1TQ/1TV boards (MC control board).

2. Outputs PN voltage generated from the AC210 V to the servo amplifier unit.
3. Controls inrush current by receiving the commands from the 1TQ/1TV boards (MC control
board).
4. Monitors the PN voltage and notifies the 1TQ/1TV boards of the abnormal state.
5. Connects the AC40 V input from power transformer to the diode bridge on the 1TU board,
and generates DC24 V for brake power supply.
6. Performs regenerative control. Also, notifies the 1TQ/1TV boards of the abnormal state in
the thermal switch of the regenerative resistor.
2-49
7. Monitors 20 V voltage for the power module and notifies the 1TQ/1TV boards of the
abnormal state.
8. Monitors thyristor module temperature for PN voltage generation and notifies the 1TQ/1TV
boards of the abnormal state.
2.12.1.2 CONNECTORS, LEDS AND CHECK PINS
2.12.1.2.1 LAYOUT
LD1
X354
TP2
X356
X353
X352
X351
TP1
X357
TP4
TP5
X355 X359
X362
TP3
X358
X361
TP7 X360
TP6
TP8
TP9
Outline view of 1TU board

X351 AC210 V 3  input Magnetic contactor in MC unit
X352 P-N voltage output for 6 axes amp. P-N terminal in servo amp. unit for 6 axes
X353 P-N voltage output for single axis Amp. unit for single axis X562
amp.
X354 Regenerative resistor, thermal Regenerative resistor (XRS connector)
switch connection
X355 Inrush current preventing resistor Inrush current preventing resistor in MC
2-50
connection unit
X356 P-N voltage smoothing capacitor Smoothing capacitor in MC unit
connection
X357 DC20 V input 20 V power supply in MC unit
X358 DC20 V output for 6 axes amplifier Power block board in servo amplifier unit
for 6 axes
X359 DC20 V output for single axis Amplifier unit for single axis X565
amplifier
X360 AC40 V 1  input Transformer for brake power supply
X361 Brake power supply output 1TV board X320 in MC unit
X362 MC unit internal signal 1TV board X306 in MC unit
2.12.1.2.3 LEDS

LD1 P-N voltage Orange ON when supplying P-N
voltage
No. Contents
TP1 P
TP2 N (GND for P-N voltage)
TP3 10 V
TP4 20 V
TP5 15 V
TP6 BR24 V
TP7 BR24G
TP8 BR15 V
TP9 BR15G
2-51
2.12.2 1TQ/1TV BOARDS (MC CONTROL BOARD)
The boards are MC control boards of the E series controller and mounted in the front part inside
the MC unit of E1x/E2x/E3x/E4x controller. The 1TQ and 1TV boards are connected directly
by a board-to-board connector and are used as a pair. The 1TQ board mounts a CPU, and
communicates with the 1TB board (servo board) via RS485.
1. Sends/receives signals to/from the 1TB board (servo board) via serial communication.
2. Controls safety relay and MC (Magnetic contactor), and monitors safety circuits and detects
abnormalities.
3. Sets the number of safety circuits (double circuit as standard). To change the setting, switch
settings on the 1TR board (power sequence board) is also necessary.
4. Controls ON/OFF for the inrush current control relay on the 1TU board (MC power board).
5. Monitors brake power supply voltage and detects abnormalities.
6. Detects abnormal signals from the 1TU board (regenerative thermal switch, thyristor thermal
switch, abnormal 20 V power supply, etc.). Also, receives regenerative state signals from
the 1TU board and detects abnormalities if any.
7. Monitors PN voltage values from the 1TU board. Also, detects any abnormalities in the PN
voltage.
8. Distributes power for fan. Also, monitors signals of the number of fan rotations and detects
the number of rotations.
9. Controls ON/OFF of the fan power for the servo amplifier.
10. Controls motor brake for up to 9 axes by receiving signals from the 1TB board.
11. Notifies AS software of the abnormal state, such as disconnection/short-circuit, of the brake
line.
12. Detects abnormalities in the motor thermal line (disconnection of separate harness).
13. Allows connections of manual brake release switches (option) for up to 9 axes.
14. Allows connections of hour meter (option).
15. Allows to output servo ON lamp contact signals.
2-52
2.12.2.2 CONNECTORS, JUMPERS, LEDS, CHECK PINS AND SWITCH
2.12.2.2.1 LAYOUT
1TQ board
TP6 TP7
TP8
X302
TP19
TP18
X309
X303
TP2
TP1 TP14
JP4
1
2
TP13 3
X304
TP12
JP4
X305
X308
SW1
JP1
X301 X307
ISP1
TP5 TP4 TP17

TP3 TP15 TP16
Front Rear
LD17
LD13
LD14
LD16
LD15
LD12
LD10
LD11
LD6
LD8
LD7
LD9
LD5
LD4
LD3
LD2
LD1
2-53
1TV board
X316 X320
X315
X309
X317
X318
X319
TP9
TP10
X312
X313 X311
TP11
X314
JP3
JP2 X306
Front Rear

X301 Contact input for external control of MC External circuit (Jumper connector
unit is connected as default.)
X302 Fan connection Fan1 - 6 in controller
(Card rack, servo amp., MC unit)
X303 Optional fan connection Optional fan
X304 Servo board input/output signal 1TB board: X503
X305 Debug communication –
X306 Internal signal of MC unit 1TU board: X362
X307 Servo ON lamp connection External servo ON lamp (option)
X308 Hour meter connection Hour meter (option)
X309U 1TQ-1TV boards connection X309L
X309L 1TQ-1TV boards connection X309U
X311 MC(magnetic contactor) connection MC (magnetic contactor)
X312 Brake release signal distribution for JT7, 8 Separation operation unit (option)
and 9
2-54
X313 MC off check line output Jumper connector for standard.

Connected to the separation
operation unit for option.
X314 Thermal switch connection in robot arm Separate motor harness connector
X315 Brake release switch connection Brake release switch (option)
X316 JT1 - 6 brake connection Separate motor harness connector
X317 JT7 brake connection, confirmation of JT7 Separate motor harness connector
connection or rear side connector for JT7
(option)
X318 JT8 brake connection, confirmation of JT8 Rear side connector for JT8
connection (option)
X319 JT9 brake connection, confirmation of JT9 Rear side connector for JT9
connection (option)*
X320 Brake power supply input 1TU board: X361
NOTE* For E3x/E4x controller only
2.12.2.2.3 JUMPER SETTINGS

JP1 For debug Unconnected (modification
prohibited)
JP2 For switching the number of safety circuits Double circuit when JP2 is
JP3 connected.
Single circuit when JP3 is
connected.
JP4 Software writing setting 1-2 connected (modification
prohibited)
ISP1 For debug Unconnected (modification
prohibited)
2.12.2.2.4 LEDS

LD1(RUN) CPU on 1TQ board in run state Green Blink at run state
LD2(ERR_CPU) Abnormal state in 1TQ board Red OFF at normal state,
LD3(KS1) Safety relay (KS1) on 1TV board in Green ON at run state
run state
2-55

run state
run state
LD6(STG) Requesting motor power supply ON Green ON when requested.
LD7(KS_EX1) Safety relay (KS_EX1) for Green ON at run state
explosion-proof on 1TV board in run
state
LD8(KS_EX2) Safety relay (KS_EX2) for Green ON at run state
explosion-proof on 1TV board in run
state
LD9(K1) MC (magnetic contactor: K1) in run Green ON at run state
state
LD10(K2) MC (magnetic contactor: K2) in run Green ON at run state
state
LD11(K3) MC (inrush current preventing relay: Green ON at run state
K3) in run state
LD12(PN_STS) P-N voltage Green ON at rated value (150
V) or above
LD13(ERR_PS) Safety circuit in abnormal state Red OFF at normal state,
LD14(ERR_SYS) Supplying power to board Red OFF at normal state,
LD15(RDY_PWR) Motor power supply ON state Green ON at motor power ON
LD16(EN_PWR) Safety circuit state Green ON at normal state
LD17(ERR_WDT) CPU watch dog error state Red OFF at normal state,
2-56
No. Contents
TP5 GND
TP6 Brake power supply
TP8 Brake power supply GND
TP9 Power supply for brake control
TP16 +24 V
TP17 24 VG
NOTE Check pins other than those above are for debug/measurement.
2.12.2.2.6 SWITCH
No. Contents Setting

SW1 For debug OFF for all (modification prohibited)
2-57
2.13 MANUAL BRAKE RELEASE SWITCH (OPTION)
This switch manually releases the electromagnetic brake mounted in the motor for robot. Refer
to the Installation and Connection Manual for details.
2.14 ADDITIONAL REGENERATIVE REGISTER UNIT
Additional regenerative register units are provided on the side of E23, E24 (MD spec.), E33, E34
(MD spec.), E43 and E44 (MD spec.) controllers as standard, and are required when regenerative
energy, which is regenerated by robot motion, is large. The following parts are built in the units.
1. Regenerative registers
2. FAN x 2 pcs.
External view of additional regenerative register unit
2-58
Layout of additional regenerative register unit
2-59
2.15 1UX BOARD (MOTHER BOARD FOR E7X CONTROLLER)
This is the mother board for E7x controller. The 1TA/1VA board (main CPU board), the 1TR
board (power sequence board), the 1TW board (IO board), other optional boards and the AVR
unit are all connected to the 1UX board.
For the mother board for E1x/E2x/E3x/E4x controllers, refer to 2.4.
2.15.1 CONNECTORS AND JUMPERS
2.15.1.1 LAYOUT
J1 J2
S7
X210
X207 S6 12 3 12 3
J1 J2
X201
S5
X202
X215
S4 S9 X203
X214
X213
S2 S3
X204
X212
X206 X205
S1
Outline view of 1UX board
2-60
2.15.1.2 CONNECTORS

S1 AVR Connected
X206 Input/Output of 1TB board (Servo board) signal Connected
X207 Power supply to 1TB board (Servo board) Connected
X210 Optional operation panel (Optional switches) Connected (standard: jumper
connector)

Switches GND-FG connection 1-2 connected. (GND-FG
J1
unconnected.)
Switches 24VG-FG connection 2-3 connected. (24VG-FG
J2
connected.)
2-61
2.16 SERVO AMPLIFIER SECTION FOR E7X CONTROLLER
The servo amplifier section of E7x controller consists of servo board, servo relay board and 6
power block boards. From the top of the controller, power block board, servo relay board, servo
board are installed.
Servo amplifier section
Power block board (1UZ board)
Top view
Power block board (1UZ board)
Servo relay board (1UY board)
Front view
2.16.1 1TB BOARD (SERVO BOARD FOR E7X CONTROLLER)
The 1TB board is the servo board of E series controller and mounted on the servo relay board by
connectors for E7x controller.
For details, refer to 2.9.1.
2-62
2.16.2 1UY BOARD (SERVO RELAY BOARD)
1UY board is mounted between the servo board and the power block. This board sends PN
voltage generated in the power supply unit and the PWM (Pulse Width Modulation) command
signals from the 1TB board to the 1UZ board (power block board). This board also sends motor
current signals from the 1UZ board and alarm signals to the 1TB board.
1UY board performs the following functions.
1. Receives PN voltage from the 1UE board (MC power board) and outputs it to the 1UZ board
(power block board).
2. Receives the PWM (Pulse Width Modulation) commands from the 1TB board (servo board)
and outputs it to the 1UZ board.
3. Outputs the motor current feedback signal detected by the 1UZ board to the 1TB board.
4. Sends alarm signals from the 1UZ board to the 1TB board when the IPM detects overcurrent,
overheat, etc.
2-63
2.16.2.2.1 LAYOUT
CNAMP4S CNAMP4P CNAMP1S CNAMP1P
CNAMP5S CNAMP5P CNAMP2S CNAMP2P
CNAMP6S CNAMP6S
P CNAMP3S CNAMP3P
CN7
CN8
CNAMP7S CNAMP7P
CNAMP8S CNAMP8P
CN10
CN9
Outline view of 1UY board (front)
CN5 CN3 CN1
CN6 CN4 CN2
Outline view of 1UY board (rear)
2-64
No. Function Destination Remarks

CNAMP1S - Input/Output of signal 1UZ board (power block board) CN1 * of
6S CNAMP*S,
CNAMP7S Input/Output of JT7 signal 1UZ board (power block board) CN1 CNAMP*P,
(option) CN*
CNAMP8S Input/Output of JT8 signal 1UZ board (power block board) CN1 indicates
(option) the axis
CNAMP1P - Output for PN voltage 1UZ board (power block board) CN2 number.
6P
CNAMP7P JT7 Output for PN voltage 1UZ board (power block board) CN2
CNAMP8P JT8 Output for PN voltage 1UZ board (power block board) CN2
CN1 - 6 Input signal (PWM signal, 1TB board (servo board) X516-1 - 6
error signal)
CN7 DC18V input for servo 1UE board (MC power board) CN1
amplifier
CN8 P-N voltage input for servo 1UE board (MC power board) CN4
amplifier
CN9 JT7 Input signal (option) 1TB board (servo board) X517
CN10 JT8 Input signal (option) 1TB board (servo board) X518
2.16.3 1UZ BOARD (POWER BLOCK BOARD FOR E7X CONTROLLER)
This board is power block board of E7x controller, one power block board is used in each axis,
and 6 boards are used for the standard 6 axes spec. This board is also used for optional 7, 8 and
9 axes spec. The board controls the power and drives the AC servomotors receiving the
commands from the 1TB board (servo board).
2-65
1UZ board performs the following functions.
1. Receives PN voltage from the 1UY board (servo relay board) and uses it as a power.
2. Receives the PWM (Pulse Width Modulation) commands from the 1TB board (servo board)
via the 1UY board, and controls the current for the motor by switching the IPM (Intelligent
Power Modules).
3. Detects the current flowing in the motor by the current detection circuit, and feeds back to the
1TB board.
4. Sends alarm signals of abnormal power module to the 1TB board via the 1UY board when
the IPM detects overcurrent, overheat, etc.
2-66
2.16.3.2.1 LAYOUT
CN3
CN2
CN1
Outline view of 1UZ board
No. Function Destination

CN1 PWM signal, current feedback, 1UY board (servo relay board) CNAMP1S - 8S
error signal CNAMP7S, 8S are options.
CN2 PN voltage input in main 1UY board (servo relay board) CNAMP1P - 8P
circuit CNAMP7P, 8P are options.
CN3 Motor output (U,V,W) Motor
2-67
2.17 POWER SUPPLY UNIT FOR E7X CONTROLLER
The power supply unit for E7x controller consists of 1UE board (MC power board) and 1TQ/1TV
board (MC control board). 1TQ/1TV board is mounted in the rear part of 1UE board.
Power supply unit
MC power board
(1UE board)
Top view
2-68
2.17.1 1UE BOARD (MC POWER BOARD FOR E7X CONTROLLER)
For E7x controller, this board is mounted in the upper part of the power supply unit, and
generates PN voltage from the AC210 V, controls regeneration, and generates brake power, etc.
1. Sends/receives signals to/from the 1TQ/1TV boards (MC control board).

2. Outputs PN voltage generated from the AC210 V to the 1UY board (servo relay board).
3. Controls inrush current by receiving the commands from the 1TQ/1TV boards.
4. Monitors the PN voltage and notifies the 1TQ/1TV boards of the abnormal state.
5. Performs regenerative control. Also, notifies the 1TQ/1TV boards of the abnormal state in
the thermal switch of the regenerative resistor.
6. Generates and monitors 18 V voltage for the power module and notifies the 1TQ/1TV boards
of the abnormal state.
7. Monitors thyristor module temperature for PN voltage generation and notifies the 1TQ/1TV
boards of the abnormal state.
2.17.1.2 CONNECTORS
2.17.1.2.1 LAYOUT
CN4
CN8
CN2
CN1
CN3
CN6
Outline view of 1UE board
2-69

CN1 DC18V output for servo amplifier 1UY board (servo relay board) CN7
CN2 Regenerative resistor, thermal switch connection Regenerative resistor
CN3 AC210V input Magnetic connector
CN4 P-N voltage output for servo amplifier 1UY board (servo relay board) CN8
CN6 AC210V input AC power supply
CN8 Power supply unit internal signal 1TV board (MC control board) X306
The boards are MC control boards of the E series controller and mounted on the rear side of 1UE
board (MC power board) in the power supply unit of E7x controller. 1TQ board and 1TV board
are connected directly by a board-to-board connector and are used as a pair. For details, refer to
2.12.2. For E7x controller, connector X306 is connected to CN8 of 1UE board.
2-70
2.18 POWER UNIT
The power unit for E9x controller consists of 1VJ board (power unit power board), 1VH board
(power unit control board), 1VF/1WF board (PFC board), inrush current preventing resistor,
power supply for power module, power unit fan, and case, etc.
1VJ board
1VF/1WF board 1VF/1WF board
1VJ board
1VH
board
1VH
board
Fan Fan
Top of power unit A-A cross-section view
2.18.1 1VJ BOARD (POWER UNIT POWER BOARD FOR E9X CONTROLLER)
For E9x controller, this board is mounted inside the power unit and is used as a pair with 1VH
board. The board is located in the rear part of the power unit, and generates PN voltage from the
AC210 V and controls regeneration, etc.
1. Sends/receives signals to/from 1VH board (power unit control board).

2. Outputs PN voltage generated from AC210 V to the servo amplifier unit.
3. Controls inrush current by receiving commands from 1VH board (power unit control board).
4. Monitors PN voltage and notifies 1VH board of the state.
5. Performs regeneration control. Also, notifies 1VH board of the abnormal state in the
thermal switch of the regenerative resistor.
2-71
6. Monitors 20 V voltage for the power module and notifies 1VH board of the abnormal state.
7. Monitors thyristor module temperature for PN voltage generation and notifies 1VH board of
the abnormal state.
8. Monitors internal 6.9 V power-supply voltage and notifies 1VH board of the abnormal state.
2.18.1.2 CONNECTORS, LEDS AND CHECK PINS
2.18.1.2.1 LAYOUT
LD1
TP2 X354
X356
X353
X352
X351
X363
X357 TP1
TP4 TP5
X364
TP3
X355 X359
TP10
X362
X358
Outline view of 1VJ board
2-72

X351 AC210 V input Power unit relay X323 connector
X352 P-N voltage output for 6 axes P-N terminal in servo amplifier unit for 6
amplifier axes
X353 P-N voltage External P-N capacitor of power unit
X354 Regenerative resistor, thermal Regenerative resistor (XRS connector)
switch connection
X355 Inrush current preventing resistor Inrush current preventing resistor in power
connection unit
X356 1VF board connection 1VF board X391 connector
X357 DC20 V input 1VF board X393 connector
X358 DC20 V output for 6 axes amplifier Power block board in servo amplifier unit
for 6 axes
X359 DC20 V output for single axis Not used (used when connecting external
amplifier axes)
X362 Power unit internal signal 1VH board X306 connector
X363 AC power distribution to 20 V XPS1 connector in power unit
power supply
X364 Input/output of IPM gate drive 1VH board X309 connector
power supply
2.18.1.2.3 LEDS

LD1 P-N voltage Orange ON when supplying P-N
voltage
No. Contents
TP1 P
TP3 10 V
TP4 20 V
TP5 15 V
TP10 6.9 V
2-73
2.18.2 1VH BOARDS (POWER UNIT CONTROL BOARD FOR E9X CONTROLLER)
This is a power unit control board of the E9x controller and mounted on the top surface of power
unit. The board is used as a pair with 1VJ board (power unit power board). The 1VH board
sends/receives signals to/from 1TB board via serial communication.
1. Sends/receives signals to/from 1TB board (servo board) via serial communication.
2. Controls and monitors safety circuits, and detects abnormalities.
3. Sets the number of safety circuits (double circuit as standard). To change the setting, switch
setting changes on 1TR board (power sequence board) is also necessary.
4. Controls ON/OFF for the inrush current control circuit on 1VJ board (power unit power
board).
5. Monitors brake power supply voltage and detects abnormalities.
6. Detects abnormal signals from 1VJ board (regenerative thermal switch, thyristor thermal
switch, abnormal 20 V power supply, etc.). Also, receives regenerative state signals from
1VJ board and detects abnormalities if any.
7. Monitors PN voltage values from 1VJ board. Also, detects any abnormalities in the PN
voltage.
8. Distributes power for fan. Also, monitors fan rotation speed signals and detects the rotation
speed.
9. Controls ON/OFF of the fan power for the servo amplifier.
10. Controls motor brake for up to 9 axes by receiving signals from 1TB board.
11. Notifies AS software of the abnormal state, such as disconnection and short-circuit, of the
brake line.
12. Detects abnormalities in the motor thermal line (disconnection of separate harness).
13. Allows connections of manual brake release switches (option) for up to 9 axes.
14. Allows connections of hour meter (option). (The hour meter option is not available for E9x
controller.)
15. Allows to output servo ON lamp contact signals.
2-74
2.18.2.2 CONNECTORS, JUMPERS, LEDS, CHECK PINS AND SWITCH
2.18.2.2.1 LAYOUT
X316 X315 X317 X318 X319 X312 X313 X314
TP11
X302 X303 X304

X307
LD10
X308
X301
LD12
JP2
LD16 SW3
TP5
LD15
LD18 TP4
LD14
JP3
LD13 SW2
TP12 TP3
LD11
LD8
TP20 LD5 TP1
LD4 SW1
LD2
TP21
LD1
TP14 TP22 TP6 TP7
TP10
CN1 LD9 TP8
TP9
JP1 X305
Front
TP13
X306 X309 X320
Rear
2-75

X301 Contact input for external control Not used
*Jumper connector is connected for
standard.
X302 Fan connection Fan in controller
X303 Optional fan connection Optional fan
standard.
X304 Servo board input/output signal 1TB board: X503
X305 Debug communication –
X306 Power unit internal signal 1VJ board: X362
1VF board: X394
X307 Servo ON lamp connection External servo ON lamp
X308 Hour meter connection Not used
X309 IPM gate power input/output 1VJ board: X364
X312 Brake release signal distribution for JT7, 8 Not used
and 9
X313 Off check line output Not used
standard.
X314 Thermal switch connection in robot arm Separate motor harness connector
X315 Brake release switch connection Brake release switch
X316 JT1-6 brake connection Separate motor harness connector
X317 JT7 brake connection, confirmation of JT7 Not used for standard (connected
connection when using JT7)
X320 Brake power supply input Power unit relay X325 connector
2-76
2.18.2.2.3 JUMPER SETTINGS

JP1 For debug Unconnected (modification prohibited)
JP2 For switching the number of safety Double circuit when JP2 is connected.
JP3 circuits Single circuit when JP3 is connected.
CN1 For debug Unconnected (modification prohibited)
2.18.2.2.4 LEDS

LD1 (RUN) CPU in run state Green Blink at run state
LD2 (ERR) CPU abnormality detection state Red OFF at normal state,
ON when abnormality is
detected
LD4 (SCR ON) Rectifier circuit ON Green ON at rectifier circuit on
1VJ board
LD5 (INRSH ON) Inrush control circuit ON Green ON at inrush control
circuit on 1VJ board
LD8 (BRPWR) Brake 24 V power supply state Green ON at normal state
LD9 (STO) IPM gate power in run state Orange ON in run state
LD10 (SBC) Motor brake power in run state Orange ON in run state
LD11 (PN-STS) P-N voltage state Orange ON when exceeding
specified value (150 V)
LD12 (RDYp) Motor power ON state Red ON at motor power ON
LD13 (STG) Requesting motor power ON Green ON when requested.
LD14 (ENPWR) Safety circuit state Green ON at normal state
LD15 (ERRps) 1VH board hardware abnormality Red OFF at normal state,
detection state ON at abnormal state
LD16 (WDT) CPU watch dog error state Red OFF at normal state,
LD18 (GATE_EN) Requesting IPM gate power ON Green ON when requested.
2-77
No. Contents
TP1 5 V power supply (via the fuse in 1VH board)
TP5 GND
TP6 +24 V
TP7 24 VG
TP8 20 V input
TP9 20 V output
TP10 20 VG
TP11 24 V power supply for brake
TP12 Motor brake drive power supply
TP13 GND
TP20 For debug
TP21 For debug
TP22 For debug
2.18.2.2.6 SWITCH
No. Contents Setting

SW1 Brake power supply OFF delay (a pair with SW2) OFF for all
SW2 Brake power supply OFF delay (a pair with SW1) OFF for all
SW3 For debug OFF for all
2-78
2.18.3 1VF/1WF BOARDS (PFC BOARD)
This is a PFC (power factor correction) board of E9x controller and mounted inside the power
unit of E9x controller. 1VF and 1WF boards are connected by a board-to-board connector
directly and used as a pair.
1. Boosts the primary voltage rectified by full-wave bridge rectifier on 1VJ board, and controls
so that the PN voltage becomes 370 V.
2. Controls so that the phase of primary current matches the phase of primary voltage by power
factor correction (PFC) control.
3. Distribute 20 V power supply to 1VJ board. (The 20 V power supply is also used inside
1VF board.)
4. Sends error signals to 1VH board if abnormality, such as broken switching element and over
current, is observed.
5. Starts PFC control by a command from 1VH board.
2.18.3.2.1 LAYOUT
X391
X390F X390M
TP1
TP2
TP4
TP6 TP5 TP3
X394 X393 X392
Outline view of 1VF board Outline view of 1WF board
2-79

X390F 1VF-1WF board connection X390M
X390M 1VF-1WF board connection X390F
X391 PN voltage generation 1VJ board: X356
X392 DC20 V input 20 V power supply in the power unit
X393 DC20 V distribution 1VJ board: X357
X394 PFC error signal, PFC start signal 1VH board: X306
No. Contents
TP1 P
TP3 20 V
TP4 15 V
TP5 15G
TP6 5V
2-80
2.19 1VZ BOARD (MOTHER BOARD FOR E9X CONTROLLER)
This is the mother board for E9x controller. 1VA board (main CPU board), 1TR board (power
sequence board), 1TW board (IO board), other optional boards and AVR unit are connected to the
1VZ board.
2.19.1 CONNECTORS AND JUMPER
2.19.1.1 LAYOUT
J1 J2
S7
X207
S6 12 3 12 3 X210
J1 J2
X201
X215 S5
X202
X214
S4 S9 X203
X213
X216
S2 S3
X212 X204
X206 X205
S1
Outline view of 1VZ board
2-81
2.19.1.2 CONNECTORS

S1 AVR Connected
S2 1VA board (main CPU board) CN2 Connected
S3 1VA board (main CPU board) CN8 Connected
X206 1TB board (Servo board) signal input/output Connected
X207 1TB board (Servo board) power supply Connected
X210 Optional operation panel (Optional switches) Connected (standard: jumper
connector)
X215 +24 V output for brake power supply Connected
X216 +24 V power supply output for fan Connected

J1 Switches GND-FG connection 1-2 connected. (GND-FG
unconnected.)
J2 Switches 24VG-FG connection 2-3 connected. (24VG-FG
connected.)
2-82
E Series Controller 3. Troubleshooting
3.0 TROUBLESHOOTING
When troubles occur, they are normally solved based on the error messages that are displayed.
However, for some troubles, messages cannot be displayed due to initial troubles such as
controller power failure or teach pendant screen malfunction, etc.
This chapter divides the errors into two types: initial troubles which can/do not display error
messages, and steady-state troubles which output an error message, and describes the causes and
countermeasures for each type of errors.
3.1 Initial Troubles and Countermeasures························································ 3-2

3.1.1 Initial Trouble 1: Controller Power Does Not Turn ON ··································· 3-2
3.1.2 Initial Trouble 2: Teach Pendant Is Not Operable ·········································· 3-5
3.1.3 Initial Trouble 3: Motor Power Does Not Turn ON ········································ 3-8
3.1.4 Initial Trouble 4: Robot Does Not Move ···················································· 3-9
3.2 Steady-State Troubles and Countermeasures ·············································· 3-10
3.3 Error Classification ············································································ 3-10
3.4 Error Handling by Robot ······································································ 3-11
3.5 Further Error Classification and Error Numbers ··········································· 3-12
3.6 Error Display ··················································································· 3-13
3.7 Error List ························································································ 3-13
3.8 Common Error Examples ····································································· 3-14
3-1
3.1 INITIAL TROUBLES AND COUNTERMEASURES
This section describes the following most common initial troubles.
3.1.1 Initial Trouble 1: Controller power Does Not Turn ON

3.1.2 Initial Trouble 2: Teach Pendant Is Not Operable
3.1.3 Initial Trouble 3: Motor Power Does Not Turn ON
3.1.4 Initial Trouble 4: Robot Does Not Move
3.1.1 INITIAL TROUBLE 1: CONTROLLER POWER DOES NOT TURN ON
This occurs when the system does not activate even if the CONTROLLER POWER (NFB
(No-Fuse Breaker)) of the controller is turned ON. In the examples below, the controller power
switch is referred to as the CONTROLLER POWER.
1. When turning ON the CONTROLLER POWER of the controller, the NFB has immediately
tripped.
2. The CONTROLLER POWER in the controller can be turned ON, but the control power lamp
on the operation panel does not light up.
Details of each case are described below.
Case1: When turning ON the CONTROLLER POWER of the controller, the NFB is
immediately tripped.
This occurs when controller power is not supplied to the controller because the NFB in the
controller has immediately tripped (turned OFF), even though CONTROLLER POWER was
turned ON.
Main cause:
1. The AC power line is short-circuited in the controller, and the controller power switch detects
overcurrent and then it has tripped.
2. Failure of the controller power switch.
3-2
Countermeasure:
！ DANGER
1. Before operation, be sure to intercept the external power switch so that the
external power supplied to the controller is shut OFF.
2. Display signs stating clearly “POWER CUT-OFF IN PROGRESS” or
“TROUBLESHOOTING IN PROGRESS”, and take measures to prevent
personnel from accidentally turning ON the power (tag or lock out power
switches, etc.).
1. Cut OFF the CONTROLLER POWER and then check the followings for short-circuit with a
tester (voltmeter).
R: S R: FG
S: T S: FG
T: R T: FG
If there is any short-circuit after checking, replace the parts, such as controller harness,
transformer, etc.
2. Replace the controller power switch.
Case2: CONTROLLER POWER in the controller can be turned ON, but the control
power lamp on the operation panel does not light up.
This occurs when the system does not activate properly because of an abnormality in the external
power supplied to the controller or in the power supply circuit of the controller.
Main cause:
1. The external power voltage supplied to the controller deviates from the specified value, the
external power supply/input cable is disconnected, or the external power is not supplied.
2. Power is not supplied to the AVR.
3. The power is not supplied to the control power lamp due to a failure of the AVR, mother board,
or the lamp itself.
4. Failure in the external control power control wiring for the power sequence board.
5. Failure such as disconnection, short-circuit, etc. of the wiring in the controller.
6. Immediately prior to the trouble occurrence, AVR security function for overcurrent/
overvoltage has been activated.
3-3
Countermeasure:
1. Check the specification of the external power voltage, and then check the external power
supply/input cable and the external power voltage.
2. Check the connection of the power connector to the AVR.
3. Check the output power voltage of the AVR, and check for failure of the control power lamp.
Replace them if necessary.
4. Check for faults in the external control power control wiring.
5. Check the wirings between NFB and AVR, and between mother board and control power lamp
in the controller. Also, check for any abnormality in the +12 V power supply with check pins
on the power sequence board.
3-4
3.1.2 INITIAL TROUBLE 2: TEACH PENDANT IS NOT OPERABLE
This is the state where the teach pendant is not operable even if the CONTROLLER POWER of
the controller is turned ON and the control power is ON. The following three cases can be
considered.
1. The control power lamp lights ON, but the teach pendant screen is not displayed. (Back light
does not turn ON.)
2. The back light of the teach pendant turns ON, but the screen is not displayed.
3. The screen of the teach pendant is displayed, but operations such as key input or AS command
are not possible.
Details of each case are described below.
Case1: The control power lamp lights ON, but the teach pendant screen is not displayed.
(Back light does not turn ON.)
DC power supply is normal in the controller, but if no power is supplied to the teach pendant, the
screen is not displayed and the back light does not turn ON.
Main cause:
1. +12V power is not supplied to the teach pendant.
2. Faulty parts in the teach pendant, such as LCD, printed board, etc.
3. Disconnection or short-circuit in the cable between the teach pendant and the controller.
Countermeasure:
1. Check whether the cable of the teach pendant is properly connected to the connector.
2. Replace the teach pendant.
3. Replace the cable of the teach pendant.
3-5
Case2: The back light of the teach pendant turns ON, but the screen is not displayed.
When the backlight is ON, the power is supplied to the teach pendant, but the teach pendant
screen does not display any characters.
Main cause:
1. Incorrect setting of the DIP switch on the main CPU board.
2. Failure of the teach pendant.
3. Disconnection of the harness to the teach pendant.
4. Improper mounting of DRAM on the main CPU board.
5. Failure of the main CPU board.
Countermeasure:
1. Adjust the setting of the DIP switch and restart the controller. Refer to 2.2.2.5 for more details.
3. Check the harness to the teach pendant.
4. Check the mounting condition of the DRAM on the main CPU board.
5. Replace the main CPU board.
Case3: “Operating System not found (1TA board)/Boot Device (Compact Flash) not
found (1VA board)” is displayed on the screen of the teach pendant.
Main cause:
1. Improper mounting of the compact flash.
2. Failure of the compact flash.
Countermeasure:
1. Check the mounting condition of the compact flash.
2. Replace the compact flash.
Case4: The background color of the teach pendant becomes red, and “load drivers: fail
check kernel and driver version” is displayed.
Main cause:
1. Wrong software has been installed.
2. Failure of the compact flash.
3-6
Countermeasure:
1. Update the OS driver.
2. Replace the compact flash.
Case5: The screen of the teach pendant is displayed, but operations such as key input or
AS command are not possible.
This occurs when the key information that was input does not reach the main CPU board, or data
from the main CPU does not reach the teach pendant.
The key information input by the teach pendant is transmitted to the main CPU board via the path
described below.
Mother board
Display device
1KX/1NX board
Main
MainCPU board
CPU Input
keys
1KA board
Teach pendant
Main cause:
1. Failure of the teach pendant.
2. Disconnection of the harness to the teach pendant.
Countermeasure:
2. Check the harness to the teach pendant.
3-7
3.1.3 INITIAL TROUBLE 3: MOTOR POWER DOES NOT TURN ON
This occurs when the motor power cannot be turned ON even after pressing the MOTOR ON
button on the teach pendant.
Main cause:
1. An error has occurred.
2. Emergency Stop is in effect.
Countermeasure:
1. When the error message is displayed, check the content of the error and take appropriate
measures to fix the error.
2. Confirm that all Emergency Stop switches are released.
Reference:
The state of the safety circuit can be checked by selecting <Monitor1>  <DIAG Monitor> 
<Safe_Cir Monitor1(safety circuit input monitor1)> on the teach pendant screen. For the
operation of the safety circuit input monitor, refer to Operation Manual.
3-8
3.1.4 INITIAL TROUBLE 4: ROBOT DOES NOT MOVE
This is the state when the robot does not move even though motor power is ON.
Main cause:
1. External hold is in effect.
2. An error has occurred.
3. X210 connector of the mother board is not connected.
4. The brake of the motor is not released.
5. CHECK GO (step forward key) on the teach pendant was not pressed in check mode, or the
TRIGGER switch was released.
6. Robot is waiting for signals to be input in repeat mode, such as signals for cycle start, step
forward, program change, WX, jump, etc.
Countermeasure:
1. Release the external hold.
2. When the error message is displayed, check the content of the error and take appropriate
measures to fix the error.
3. Check the connection of the X210 connector of the mother board.
4. Replace the servo amplifier unit or MC unit/power unit. Also, check the harness between the
servo board and MC unit/power unit. (E1x/E2x/E3x/E4x/E9x)
Replace the servo amplifier section or power supply unit. Also, check the harness between
the servo board and power supply unit. (E7x)
5. If the robot is in check mode, press CHECK GO (step forward key), the TRIGGER switch, etc.
on the teach pendant.
6. If in repeat mode, input the signal and break the waiting state.
！ DANGER
Robot may move suddenly when stop conditions are released.

Do not approach robot even when it appears to be stopped.
3-9
3.2 STEADY-STATE TROUBLES AND COUNTERMEASURES
Once a robot starts to move, error messages will be displayed for most assumable troubles. To
solve these troubles, follow the messages. If a trouble occurs under conditions which cannot be
assumed, no error messages will be displayed. In this case, please contact the nearest KHI
service center or branch office with the details of this trouble.
3.3 ERROR CLASSIFICATION
When an assumable error occurs, the code and message for that error is displayed and error is
classified into the following four types depending on its condition and seriousness. Error codes
are displayed with the letter, P, W, E or D in front (representing the error type) followed by a
four-digit number.
1. P: Operation error
Errors caused by operation mistakes. This type of error does not affect robot motion.
Example: “P0126 Illegal switch name.”
2. W: Warning
This is not yet an error but may cause an error if left unfixed.
Example: “W1013 Encoder battery low voltage.”
3. E: Minor failure
This is a minor failure which essentially can be recovered by the error reset function
without turning OFF/ON the controller power after the cause of error is removed.
Example: “E1082 Out of absolute lower limit.”
4. D: Major failure
This is a serious error involving hardware, software or peripheral devices which essentially
cannot be recovered by the error reset function, and its recovery requires turning OFF/ON
the controller power.
Example: “D1528 Controller temperature is out of range.”
3-10
3.4 ERROR HANDLING BY ROBOT
The following table shows how the robot processes each error type.
Error Error lamp Cycle start Motor power

type ON* OFF OFF
P X X X
W   
E O O 
D O O O
Processing of each error type
Symbols indicating measures to be performed are as follows.

X: not executed O: executed : depending on the error content
NOTE* For the controller with optional operational panel only.
3-11
3.5 FURTHER ERROR CLASSIFICATION AND ERROR NUMBERS
Errors are further subdivided into the items shown in the table below, and each is assigned with
four-digit error numbers. The following classification commonly applies to all the error types of
P, W, E and D.
Error Category Error No.

Serious error 0001 - 0099
Grammatical error 0100 - 0899
Memory 0900 - 0999
Common error 1000 - 3999
Communication 4000 - 4999
Spot 5000 - 5499
Vision 5500 - 5999
Painting 6000 - 6499
Arc 6500 - 6999
Others 500 items
Error category and error No.
Also, common errors are divided as shown in the table below per P/W/E/D.
Program execution operation 1000 - 1999

P
Others 2000 - 3999
W Standard 1000 - 3999
E Standard 1000 - 3999
Servo related 1000 - 1499
D Encoder, amplifier related 1500 - 1999
Others 2000 - 3999
Details of common error
3-12
3.6 ERROR DISPLAY
Error messages are displayed on the LCD of the teach pendant and the screen of the PC via the
terminal software (KRterm/Kcwin32). (Small sized TP only displays error codes.)
On the teach pendant, operation errors (P) are displayed in the system message area, and other
errors are shown by the pop-up screen. The figure below is a sample error pop-up screen
displayed on the LCD of the teach pendant.
Error pop-up screen
3.7 ERROR LIST
Refer to Error Message List attached as appendix.
3-13
3.8 COMMON ERROR EXAMPLES
This section describes the contents, main causes, and countermeasures for the most typical errors
requiring explanation in order of their code number.
Items listed below in the left column are given under “Error message” on the following pages.
Item Description Classification

Error processing Robot process at time Display Displays error message only.
the error occurred. Cycle stop Cycle start stops.
Motor power Turns motor power OFF.
OFF
Control power Turns control power OFF
OFF internally.
Error reset Is recovery possible Acceptable Remove the error cause, press the
by pressing error reset <Reset> on the teach pendant or
button? optional operation panel (and
MOTOR ON/A+CYCLE START
buttons on the teach pendant if
necessary), then operation can be
continued.
Non-acceptable Remove the error cause, then turn
the CONTROLLER POWER OFF
 ON.
[ NOTE ]
XX of [Servo boardXX] in error messages indicates the servo board
number. In the system where 2 servo boards are used such as a multi-axis
controller, [Servo board2] is displayed when an error is detected in the
multi-axis controller.
3-14
Error code : D0001

Error message : CPU error. (PC=XX)
Error processing : Motor power OFF Error reset : Non-acceptable
Content:
The CPU of the main CPU board stopped functioning. (Detected by AS software)
Main cause:
Failure of the main CPU board.
Countermeasure:
1. Turn the controller power OFF and then ON. If a message for initialization appears, select
<NO>.
2. If this error occurs only when a certain step of a program or a special operation are executed,
report all details to KHI, including information of all messages, robot model, controller model,
machine number, AS/servo software versions, operation at the time of error occurrence, the
contents of program lists, equipped options, etc.
3. If the program does not return to normal, execute initialization and reload the teach data.
Take note that if the teach pendant or the terminal software on the PC is not running at this
time, initialization cannot be done.
4. Replace the main CPU board if the error does not constantly recur or the error cannot be
resolved.
3-15
Error code : D0007

Error message : [Servo boardXX]CPU error. (CodeXX)
Content:
An exceptional process was performed in the servo board CPU.
Failure of the servo board.
Countermeasure:
<NO>.
3. Replace the servo board if the error does not constantly recur or the error cannot be resolved.
3-16
Error code : D0008

Error message : [Servo boardXX]Floating point exception. (CodeXX)
Content:
Floating-point calculations which result in indefinite value are performed in the servo software.
Main cause:
Failure of the servo software.
Countermeasure:
<NO>.
2. Replace the servo board if the error cannot be resolved.
3-17
Error code : D0009

Error message : [Servo boardXX]CPU exception. (PC=XX)
Content:
This error occurs at the same time as when [Servo board] CPU error (D0007) or [Servo boardXX]
Floating point exception (D0008) occurs.
Main cause:
Countermeasure:
1. Refer to countermeasures for D0007 or D0008 which is occurring at the same time as this
error.
2. Inform KHI which error is occurring, D0007 Servo board] CPU error or D0008 [Servo
boardXX] Floating point exception, and of the value of PC.
3-18
Error code : D0900

Error message : Teach data is broken.
Error processing : Motor power OFF Error reset : Acceptable
Content:
The data base (link list) information controlling teach data in user memory is damaged (after
accessing teach data in the editor, for example).
Main cause:
1. Broken file system in the CF card.
3. Failure of the power sequence board.
4. Failure of the AVR.
Countermeasure:
1. Promptly turn ON the DIP SW-8 on the main CPU board when this error occurs. Then,
execute initialization and reload the teach data.
[ NOTE ]
The system memory cannot be completely initialized by
SYSINT command or Aux. function 0805 Initialize System
since a part of the system data is maintained.
2. Replace the CF card if the error recurs.

3. Replace the main CPU board if the error recurs.
4. Replace the power sequence board if the error recurs.
5. Replace the AVR if the error recurs.
3-19
Error code : D0904

Error message : Memory is locked due to AC_FAIL.
Error processing : Display Error reset : Non-acceptable
Content:
This error occurs when the external power supply decreases and saving or loading are executed
after power supply abnormality (AC FAIL) is detected in the AVR.
Countermeasure:
This error may occur when the controller power is turned OFF. This error can be fixed by
turning the controller power ON again. If the error is still not fixed, check for any abnormalities
in items relating to the power supply circuit including the AVR, or replace the power sequence
board.
3-20
Error code : D1021

Error message : Servo FPGA configuration data not found.
Content:
Configuration data in servo FPGA software (armsf.cnf) cannot be read properly.
Main cause:
Servo FPGA configuration data whose name is arms.cnf does not exist in the CF card on the main
CPU board.
Countermeasure:
1. Check the version of servo group software, and reinstall the servo group software.
2. Replace the CF card on the main CPU board.
4. If the error cannot be resolved, report all details to KHI, including information of all messages,
robot model, controller model, machine number, AS/servo software versions.
3-21
Error code : D1025

Error message : [Servo boardXX]Detected Watch dog error.(Servo FPGA)
Content:
The bus access from the CPU on the servo board to the servo FPGA stopped for a certain period
of time.
Main cause:
Countermeasure:
1. Turn the controller power OFF and then ON, and check if the same error occurs.
2. Replace the servo board if the same error occurs.
3-22
Error code : D1026

Error message : [Servo boardXX]Abnormal signal input from power sequence board.
Content:
When the power sequence board detects AC primary power supply failure for AVR for control
power, DC power supply failure, or abnormal watch dog in main CPU board, it transmits the
error signals to the servo board, and the servo board detects the abnormalities.
Main cause:
1. Failure of the wiring between the mother board and servo board.
3. Failure of the servo board.
4. Failure of the mother board.
Countermeasure:
1. Check the wiring between the mother board (X206) and servo board (X502).
2. Replace the power sequence board.
3. Replace the servo board.
4. Replace the mother board.
3-23
Error code : D1027

Error message : [MCXX]Detected Watch dog error. (Servo boardXX)
Content:
The bus access from CPU to CPLD has stopped for a certain period of time in the MC control
board.
Main cause:
Failure of the MC control board.
Countermeasure:
1. Turn the controller power OFF and then ON.
2. If the same error occurs, replace the MC unit or the MC control board.
3-24
Error code : D1028

Error message : [Servo boardXX]DC power is abnormal.(Servo FPGA)
Content:
Each DC power supply voltage deviated from the rated value in the servo board.
Main cause:
1. Inappropriate voltage adjustment for the AVR for control power.
2. Failure of the AVR for control power.
Countermeasure:
1. Check the 5 V between test pins on the power sequence board, then adjust the voltage so that it
becomes within 5.05 – 5.15 V.
2. Replace the AVR.
3-25
Error code : D1029

Error message : [Servo boardXX]AC primary power is abnormal.(Servo FPGA)
Content:
An abnormal state occurred in the AC primary power supply of the slave controller (multi-axis
controller).
Main cause:
1. Abnormal AC primary power supply of the slave controller (multi-axis controller).
2. Failure of the AVR in the slave controller (multi-axis controller).
4. Disconnection of the signal harness between the mother board and servo board in the slave
controller (multi-axis controller).
Countermeasure:
1. Turn the slave controller (multi-axis controller) power OFF and then ON.
2. Replace the AVR of the slave controller (multi-axis controller).
4. Check the connection of the signal harness between the mother board and servo board in the
slave controller (multi-axis controller).
3-26
Error code : D1030

Error message : Cannot start communication with the servo boardXX.
Content:
Communication with the servo board cannot be started at controller power ON.
Main cause:
1. Unconnected servo board, or disconnection of the harness between the main CPU board and
servo board.
5. Controller power of the master controller (robot controller) was turned ON with the controller
power of the slave controller (multi-axis controller) turned OFF when using a slave controller
(multi-axis controller). (In this case, “servo boardXX” in the error message is displayed as
“servo board2”.)
Countermeasure:
1. Check the connection with the servo board.
2. When using a slave controller (multi-axis controller), turn ON the controller power of the
master controller (robot controller) after turning ON the controller power of the slave controller
(multi-axis controller).
<NO>.
4. If the error does not constantly recur or the program does not return to normal, replace the main
CPU board, servo board and mother board.
3-27
Error code : D1031

Error message : Read error of servo software.
Content:
Failed in reading servo software (armsv.mb).
Main cause:
1. Servo group software is not installed correctly.
2. Failure of the CF card in the main CPU board.
Countermeasure:
1. Check the servo group software version, then reinstall the software.
2. Replace the CF card of the main CPU board.
3-28
Error code : D1032

Error message : [Servo boardXX]Download error of servo software.(CodeXX)
Content:
Servo software was not downloaded correctly at controller power ON.
Main cause:
2. Failure of the CF card in the main CPU board.
Countermeasure:
CPU board, the servo board, or the mother board.
3-29
Error code : D1033

Error message : Connection Port No(XX) and Servo board No(XX) mismatch.
Content:
Communication port channel for the servo board on the main CPU board does not correspond to
the rotary switch number set on the servo board.
Main cause:
1. Incorrect setting on the rotary switch (SW7) on the servo board.
2. Improper wiring when two or more servo boards are used.
5. Failure of the additional servo communication board on the main CPU board.
Countermeasure:
1. Check the setting on the rotary switch in the servo board. (In proper setting, “0” is set when one
servo board is used. When two or more boards are used, number is set from “0” for the first
board, “1” for the second board, and so on.)
2. Check the each harness state from the main CPU board or additional servo communication
board.
5. Replace the additional servo communication board.
3-30
Error code : D1034

Error message : The servo data file is missing or not acceptable.(CodeXX)
Content:
This error occurs when servo data file for the specified arm model was not found when turning
ON the controller power. When the servo software does not contain the data of the arm model,
code 101 is displayed.
Main cause:
1. Improper servo software version.
2. Servo group software is not installed properly.
3. Failure of the CF card of the main CPU board.
Countermeasure:
2. Replace the CF card in the main CPU board.
CPU board, servo board or mother board.
3-31
Error code : D1035

Error message : [Servo boardXX]Init. error of servo software.(CodeXX)
Content:
Failed in initialization of servo software at controller power ON.
Main cause:
1. The servo group software is not installed correctly.
2. The servo group software which is incompatible with the AS group software is installed.
Countermeasure:
2. Install servo group software which is compatible with the AS group software.
3-32
Error code : D1036

Error message : [Servo boardXX]Download error of servo data.(CodeXX)
Content:
Failed in download of servo data at controller power ON.
Main cause:
Countermeasure:
3-33
Error code : D1037

Error message : [Servo boardXX]Configuration error in servo FPGA.(CodeXX)
Content:
Error occurred during processing the servo FPGA configuration data (armsf.cnf).
Main cause:
1. Servo group software was not installed properly.
2. Failure of the CF card on the main CPU board.
Countermeasure:
1. Check the version of servo group software, and reinstall the servo group software.
2. Replace the CF card on the main CPU board.
CPU board, servo board, or mother board.
3-34
Error code : D1038

Error message : [Servo boardXX]Upload error of servo software initial data.(CodeXX)
Content:
An error occurred while processing initialization data upload in the servo board at controller
power ON.
Main cause:
2. Servo group software is incompatible with the AS group software.
Countermeasure:
3-35
Error code : D1039

Error message : [Servo boardXX] Download error of servo software initial data.(CodeXX)
Content:
An error occurred while processing initialization data download in the servo board at controller
power ON.
Main cause:
2. Servo group software is incompatible with the AS group software.
Countermeasure:
3-36
Error code : D1040

Error message : [Servo boardXX]Device check error. (CodeXX)
Content:
An error was detected when checking the memory device on the servo board.
Main cause:
Countermeasure:
<NO>.
2. If the error does not constantly recur or the program does not return to normal, replace the
servo board.
3-37
Error code : D1041

Error message : JtXX axis brake release circuit is abnormal.
Content:
At motor power ON, brake is released before servo control starts.
Main cause:
1. Failure of the brake release circuit in the MC control board/power unit control board.
Countermeasure:
1. Replace the MC control board/power unit control board.
3-38
Error code : D1044

Error message : [MCXX]Detected Watch dog error.(Servo board XX)(codeXX)
Content:
Bus access from CPU of the power unit control board (1VH) to CPLD stopped for a certain
period of time.
Main cause:
Failure of the power unit control board.
Countermeasure:
1. Turn the controller power OFF and then ON
2. If the error recurs, replace the power unit control board.
3-39
Error code : D1500

Error message : Encoder misread error JtXX.
Content:
When the encoder data is read immediately after the controller power is turned ON, stable
data could not be read. This is detected by the servo software.
Encoder
Encoder
Servo board
Encoder
I/F
Encoder power Power supply
supply +12 V circuit Battery
Encoder battery backup board
Controller Robot main body
Main cause:
1. Disconnection or short-circuit in the encoder harness.
2. Failure of the encoder.
Countermeasure:
1. Check for disconnection or short-circuit in the encoder harness, and replace the encoder.
3-40
Error code : D1502

Error message : Amp overcurrent JtXX.
Content:
During servoing, the feedback current from the current detection circuit on the power block
exceeds 1.5 times of the maximum instantaneous current limit to the motor.
A current threshold value for each joint is set into and detected by the servo FPGA mounted on
the servo board.
Servo FPGA
Current feedback
Servo board
PWM
Current
detection
circuit
IPM Each motor
Power block Robot main body
Controller
Main cause:
1. Failure of the power block.
3. U, V, or W-phase and the ground line are short-circuited between the power block and the
motor.
4. Improper connection of separate harness connector.
5. Failure of the motor.
Countermeasure:
1. Replace the servo amplifier unit. (E1x/E2x/E3x/E4x/E9x)
Replace the 1UZ board, servo board and servo relay board for JtXX. (E7x)
2. Check for short-circuit, ground fault and disconnection of U, V, or W-phase of the motor and
improper connection, and replace the separate harness/machine harness if necessary.
3. Replace the motor.
3-41
Error code : D1504

Error message : Abn. curr feedback JtXX. (Amp fail, pwr harness disconnect)
Content:
In the period from servo ON to brake release, the feedback current is almost 0 despite the current
command is constantly sent.
1GM board
Servo Servo FPGA
I/V
CPU
converter
Current
feedback
1KBboard
Servo board
Current
Current U, V, W
detection
sensor earth
circuit Each
IPM
m otor
Power block Robot m ain body
Controller
Main cause:
1. U-phase, V-phase or W-phase of the motor power line is disconnected. (Normally,
disconnection is not checked.)
2. Improper connection in the power line for controller harness, separate harness or machine
harness.
Countermeasure:
1. Check for improper wiring or disconnection, and replace the harness if necessary.
3-42
Error code : D1512

Error message : Brake line error for JtXX.
Content:
The CPU on the MC control board (1TQ/1TV) or power unit control board (1VH) detected error
signals from MOSFET for brake release.
Robot
Motor main body
Motor brake line

Controller
DC24-26 V
Brake power supply>>
Safety circuit
Brake power supply error signal
Voltage detect.
CPU Brake release signal MOSFET
Brake line error signal
MC control board/
Power unit control board
Servo board
Timing for detecting brake line error

The brake line error is detected at the time shown below. This error is not detected at motor
power OFF.
ON
Brake power supply
Start
Servo control
Release
Brake release
Disconnection Short-circuit
detection detection
The error cause depends on the timing of the error occurrence: if the error occurs before servo
control starts, the cause may be a disconnection, and if after servo control starts, the cause may be
a short-circuit. During automatic operation, disconnection is not detected.
3-43
Main cause:
1. Short-circuit, disconnection or ground fault (contact with earth) of the motor brake line.
2. Failure of the MC control board/power unit control board.
3. Attempted to turn ON motor power and operate robot while pressing the brake release switch.
Countermeasure:
1. Check for disconnection or short-circuit in the motor harness.
2. Check for wiring failure or disconnection in the motor harness.
3. Replace the MC control board/power unit control board or the MC unit/power unit.
4. Do not press the brake release switch when attempting to operate robot.
3-44
Error code : D1516

Error message : Mismatch betw hard/software settings for HOLD backup time.
Content:
The settings that cut OFF the motor power of hardware in 2 seconds after switching HOLD/RUN
from RUN to HOLD does not match between software and hardware.
Main cause:
1. Although 2 sec. of backup time is set in the software, no backup time is set in the
hardware.
2. Although no backup time is set in the software, 2 sec. of backup time is set in the
hardware.
Countermeasure:
1. To set 2 sec. of backup time, set SW2-2 on the power sequence board to ON, then set
[Hold Backup Time] to [Standard] in Aux. 2021-2.
2. To set no backup time, set SW2-2 on the power sequence board to OFF, then set [Hold
Backup Time] to [OFF] in Aux. 2021-2.
3-45
Error code : D1517

Error message : Blown fuse on safety circuit emergency line.
Content:
Blown fuse on Emergency Stop line. (Fuse F1 on the upper side of the power sequence board.)
Main cause:
1. Improper wiring for Emergency Stop, safety fence, external trigger, etc.
2. Short-circuit or ground fault in other safety circuit harnesses (for Emergency Stop line, limit
switch, or teach pendant).
Countermeasure:
1. Check for the wirings for Emergency Stop, safety fence, external trigger, etc., and correct the
wiring if improper.
2. Replace the faulty harness.
！ CAUTION
Before wiring safety circuits, be sure to turn the controller
power OFF. Doing the wiring at controller power ON, the
Emergency Stop line fuse may blow when the lines touch the
chassis.
3-46
Error code : D1518

Error message : Mismatch in the Emer. Stop condition on safety circuit.
Content:
Contacts state for Emergency Stop switches on operation panel, teach pendant and external panel
does not match between the first and second safety circuits.
Main cause:
1. Failure of the circuit or wiring for External Emergency Stop input, or only single circuit
connected.
2. Disconnection or ground fault in the wiring of Emergency Stop line.
3. Failure of the Emergency Stop switch in the operation panel or teach pendant.
Countermeasure:
1. Check the circuit and wiring for the External Emergency Stop switch(es), and correct it if
improper.
2. Press each E-STOP so that the faulty switch can be identified.
3. Replace the faulty E-STOP switch in the operation panel or teach pendant, or its harness if
faulty.
Reference:
！ CAUTION
Before wiring safety circuits, be sure to turn the controller power
OFF. Doing the wiring at controller power ON, the Emergency
Stop line fuse may blow when the lines touch the chassis.
[ NOTE ]
1. This error does not occur when single circuit is set for safety circuit.
2. Error reset is possible only when the safety circuits are OFF state (open state) in
both first and second circuits. When they are ON, error reset cannot be executed.
3-47
Error code : D1520

Error message : Mismatch in safety circuit TEACH/REPEAT condition.
Content:
Contacts state for TEACH/REPEAT switch does not match between the first and second safety
circuits.
Main cause:
1. Failure of the TEACH/REPEAT switch.
2. Disconnection, etc. between the mother board and TEACH/REPEAT switch.
Countermeasure:
1. Replace the TEACH/REPEAT switch.
2. Check the wiring between the mother board and TEACH/REPEAT switch.
Reference:
[ NOTE ]
3-48
Error code : D1521

Error message : Mismatch in safety circuit safety-fence condition.
Content:
Contacts state for safety fence does not match between the first and second safety circuits.
Main cause:
1. Failure of the circuit or wiring in safety fence input. Or only the first circuit is input.
2. Disconnection or ground fault in wiring of safety fence input.
3. Failure of the safety fence switch.
Countermeasure:
1. Check the circuit and wiring in the safety fence input and modify it if necessary.
2. Replace the switch.
Reference:
！ CAUTION
[ NOTE ]
2. Error reset is possible only when the safety circuits are OFF state (open state) in both
first and second circuits. When they are ON, error reset cannot be executed.
3-49
Error code : D1522

Error message : Mismatch in cond. of safety circuit enabling device.
Content:
Contacts state for teach trigger switch of the teach pendant does not match between the first and
second safety circuits.
Main cause:
1. Disconnection, short-circuit, ground fault, etc. in the wiring of teach trigger switch.
2. Failure of the teach trigger switch.
Countermeasure:
1. Check the teach pendant harness or controller harness.
Reference:
[ NOTE ]
1. Two contacts are built into the teach trigger switches. If the trigger switch is not
pressed firmly enough, only one contact may become ON, which may result in this
error. Also, in the 3-position trigger switches, pressing them too firmly may cause
trigger OFF. In these cases, lose hold of the switch and try to press the switch again.
3-50
Error code : D1523

Error message : Mismatch in cond. of safety circuit ext. enabling device.
Content:
Contacts state for external trigger switches does not match between the first and second safety
circuits.
Main cause:
1. Disconnection, short-circuit, ground fault, etc. in the wiring of external trigger.
2. Failure of the external trigger switch.
Countermeasure:
1. Check the circuit and wiring in the external trigger, and modify it if necessary.
2. Replace the external trigger switch.
Reference:
！ CAUTION
[ NOTE ]
3-51
Error code : D1529

Error message : Signal harness disconnected or Encoder power error.
Content:
Communication error occurred in the encoders of all axes.
Main cause:
1. Disconnection, short-circuit, or no connection in the separate (signal) harness, or machine
harness.
2. Disconnection, or short-circuit, etc. in the 12 V wiring in the controller.
3. Abnormal encoder battery backup board.
Countermeasure:
1. Check the connection of the separate (signal) harness, or machine harness.
2. Check the 12 V wiring in the controller.
3. Replace the encoder battery backup board.
3-52
Error code : D1543

Error message : [Servo boardXX]DC 5V is abnormal.
Content:
The 5 V supplied to the servo board from the AVR for control power deviated from the rated
value.
Main cause:
4. Failure of the power block board.
5. Failure of the MC unit (MC control board)/power unit (power unit control board).
6. Ground fault or short-circuit in the 5 V wiring.
Countermeasure:
2. Replace the AVR.
Replace the servo amplifier section. (E7x)
6. Check for the ground fault or short-circuit in the 5 V wiring.
3-53
Error code : D1544

Error message : [Servo boardXX]DC 3.3V is abnormal.
Content:
The 3.3 V deviated from the rated value in the servo board.
Main cause:
Countermeasure:
Replace the servo board.
3-54
Error code : D1545

Content:
The 12 V supplied to the servo board from the AVR for control power deviated from the rated
value.
Main cause:
Countermeasure:
1. Replace the AVR.
3-55
Error code : D1546

Content:
Main cause:
Countermeasure:
3-56
Error code : D1547

Content:
Main cause:
Countermeasure:
3-57
Error code : D1548

Content:
Main cause:
Countermeasure:
3-58
Error code : D1549

Error message : [Servo boardXX]Primary power source is too low.
The AC primary power supply voltage has become less than -20 % of the rated value and the
state continues for 1 - 2 sec. in the slave controller (multi-axis controller).
Main cause:
1. Abnormal AC primary power supply in the slave controller (multi-axis controller).
Countermeasure:
3-59
Error code : D1550

Error message : [Servo boardXX]Primary power source is too high.
The AC primary power supply voltage has become -20% or more of the rated value and the state
continues for 1 - 2 sec. in the slave controller (multi-axis controller).
Main cause:
Countermeasure:
3-60
Error code : D1551

Error message : [Servo boardXX]AC primary power OFF.
The AC primary power supply voltage has become less than -30% of the rated value and the state
continues for 1/50 - 1/30 sec. in the slave controller (multi-axis controller).
Main cause:
Countermeasure:
3-61
Error code : D1552

Error message : [MCXX]DC 3.3V is abnormal. (Servo boardXX)
Content:
The power supply detection circuit for 3.3 V detected the value which deviated from the rated
value in the MC control board.
Main cause:
1. Failure of the MC control board.
2. Failure of the 3.3 V system (wiring, MC power board) in the MC unit. (E1x/E2x/E3x/E4x)
Failure of the 3.3 V system (wiring, MC power board) in the power supply unit. (E7x)
Countermeasure:
1. Replace the MC control board.
2. Replace the MC unit. (E1x/E2x/E3x/E4x)
Replace the power supply unit. (E7x)
3-62
Error code : D1553

Error message : [MCXX]DC 5V is abnormal. (Servo boardXX)
Content:
The power supply detection circuit for 5 V detected the value which deviated from the rated value
in the MC control board.
Main cause:
Countermeasure:
becomes within 5.05 - 5.15 V.
2. Replace the AVR.
3-63
Error code : D1557

Error message : [Power sequence board]DC 3.3V is abnormal.
Error processing : Control power OFF Error reset : Non-acceptable
Content:
The 3.3 V supplied to the power sequence board from the AVR for control power deviated from
the rated value.
Main cause:
Countermeasure:
1. Check the 3.3 V between test pins on the power sequence board, then adjust the voltage so that
it becomes within 3.25 - 3.35 V.
2. Replace the AVR.
3-64
Error code : D1558

Error message : [Power sequence board]DC 5V is abnormal.
Content:
The 5 V supplied to the power sequence board from the AVR for control power deviated from the
rated value.
Main cause:
Countermeasure:
2. Replace the AVR.
3-65
Error code : D1559

Content:
The 12 V supplied to the power sequence board from the AVR for control power deviated from
the rated value.
Main cause:
Countermeasure:
1. Replace the AVR.
3-66
Error code : D1560

Error processing : Control power OFF Error reset : Acceptable
Content:
The DC24 V power supplied to the power sequence board from the AVR for control power
deviated from the rated value.
Main cause:
1. Control power was turned OFF by using external control power OFF function.
4. The 24 V was ground-faulted or short-circuited in the controller wiring.
Countermeasure:
1. Check if the control power was turned OFF by using external control power OFF function*.
2. Replace the AVR.
4. Check for ground fault or short-circuit in the 24 V controller wiring.
NOTE*: This error occurs when control power is turned OFF by using external control power
OFF function, however, it is not abnormal.
3-67
Error code : D1561

Error message : [Power sequence board]AC primary power OFF.
Content:
This error occurs when AC primary power voltage is less than -30 % of the rated value and the
state continues for 1/50 to 1/30 sec.
External
power supply AC200 V AVR for
NFB control power
REMOTE
AC error signal
AVR
output cut
Main CPU
board
CPLD
Main cause:
1. Abnormal AC primary power supply.
2. Failure of the wiring or connector connection in the controller.
Countermeasure:
1. Check the primary power supply voltage.
2. Check the wiring or connector connection in the controller.
3. Replace the AVR.
[ NOTE ]
The error occurrence after turning OFF the controller power switch is not abnormal state.
3-68
Error code : D1562

Error message : [Power sequence board]AC primary power voltage is too high.
Content:
This error occurs when AC primary power voltage became +20 % or more of the rated value and
the state continues for 1 to 2 sec.
External
NFB control power
REMOTE
AC error signal
AVR
output cut
Main CPU
board
CPLD
Main cause:
2. Failure of wiring or connector connection in the controller.
Countermeasure:
3. Replace the AVR.
3-69
Error code : D1563

Error message : [Power sequence board]AC primary power voltage is too low.
Content:
This error occurs when AC primary power voltage became less than -20 % of the rated value and
the state continues for 1 to 2 sec.
External
NFB control power
REMOTE
AC error signal
AVR
output cut
Main CPU
board
CPLD
Main cause:
2. Failure of the wiring or connector connection in the controller.
Countermeasure:
3. Replace the AVR.
3-70
Error code : D1564

Error message : [Power sequence board]Remote power off signal was detected.
Content:
Remote power supply OFF signal was input in the power sequence board.
Main cause:
1. Remote power supply OFF signal was input, which is not normally input in the AS software.
In case of the error occurrence when using software exchange function from the AS software,
it is not actually an error.
Countermeasure:
<NO>.
2. The problem is likely to be in the AS system if this error occurs only when a certain step of a
program or a special operation are executed. In this case, report all details to KHI, including
information of all messages, robot model, controller model, machine number, AS/servo
software versions, operation at the time of error occurrence, the contents of program lists,
equipped options, etc.
CPU board.
3-71
Error code : D1565

Error message : Cannot access power sequence board.(CodeXX)
Content:
An error occurred when accessing to the power sequence board.
Main cause:
Failure of the main CPU board.
Countermeasure:
1. Reset the error. If it cannot be reset, turn the controller power OFF and then ON. If a
message for initialization appears, select <NO>.
CPU board.
3-72
Error code : D1566

Error message : P-N capacitor has not discharged.(Servo boardXX)(MCXX)
Content:
When the controller power is ON, the P-N voltage detection circuit detected 60 V or more.
Main cause:
1. Failure of the MC power board/power unit power board.
2. Disconnection or improper connection in the harness between the MC power board/power unit
power board and regenerative resistor.
4. Disconnection or improper connection in the harness between the MC control board/power unit
control board and MC power board/power unit power board.
Countermeasure:
Replace the power unit. (E9x)
2. Check for unconnected connector or disconnection of the harness between the MC power
board/power unit power board (X354) and regenerative resistor (XRS).
(E1x/E2x/E3x/E4x/E9x)
Check for unconnected connector or disconnection of the harness between 1UE board (CN2)
and regenerative resistor (XRS). (E7x)
3-73
Error code : D1567

Error message : [Servo boardXX]Primary Power source is error.
Content:
Abnormal voltage of AC primary power supply is detected instantaneously in the slave controller
(multi-axis controller), but the code from the AVR could not be read normally.
Main cause:
Countermeasure:
3-74
Error code : D1568

Error message : [Servo boardXX]Power supply circuit for PWM signal output malfunctioned.
Content:
An abnormality is found in the PWM power supply output circuit on the servo board.
Main cause:
Countermeasure:
3-75
Error code : D1572

Error message : [MCXX]MC control board error[clock](Servo board XX) (CodeXX)
Content:
Clock error was detected on the power unit control board (1VH).
Main cause:
1. Failure of the power unit control board.
Countermeasure:
1. Replace the power unit control board.
3-76
Error code : D1573

Error message : [MCXX]MC control board error[reset IC] (Servo board XX) (CodeXX)
Content:
Power-ON reset error was detected on the power unit control board (1VH) at the time of power
ON.
Main cause:
Countermeasure:
3-77
Error code : D1575

Error message : [MCXX]Setting error of Dip-SW for Off-delay setting(Servo board
XX)(CodeXX)
Content:
There is a discrepancy in the settings between SW1 and SW2 which are DIP switches on the
power unit control board (1VH).
Main cause:
1. Discrepancy in settings between SW1 and SW2 on the power unit control board.
Countermeasure:
1. Check the settings of SW1 and SW2 on the power unit control board and make all the settings
to OFF.
3-78
Error code : D1576

Error message : [MCXX]Error reset for MC control board is input over the fixed time(Servo
board XX)(CodeXX)
Content:
Error reset signal input to the power unit board (1VH) via SV software from AS software
exceeded 500 ms.
Main cause:
Countermeasure:
<NO>.
3-79
Error code : D1577

Error message : [MCXX]Error of gate power output in MC control board[detected ON during
OFF condition](Servo board XX)(CodeXX)
Content:
An error was detected on the IPM 20 V power supply output section on the power unit control
board (1VH) while the gate power supply output is OFF.
Main cause:
2. Failure of the power unit power board.
3. Abnormality in the 20 V system in the power unit.
Countermeasure:
2. Replace the power unit.
3-80
Error code : D1578

Error message : [MCXX]Error of brake power output in MC control board[detected ON
during OFF condition](Servo board XX)(CodeXX)
Content:
An error was detected on the brake power supply output section on the power unit control board
(1VH) while the brake power supply output is OFF.
Main cause:
2. Abnormality in the motor brake 24 V power supply output system.
Countermeasure:
2. Check for any abnormality (short-circuit and disconnection, etc.) in the motor brake 24 V
power supply output system from the power unit.
3-81
Error code : D1579

Error message : [MCXX]P-N Capacitor is not connected.(Servo boardXX)
Content:
Rapid rise of PN voltage was detected while motor power is ON.
Main cause:
1. PN capacitor is not connected.
2. Failure of the PN capacitor.
3. Failure of the power unit.
Countermeasure:
1. Check if the PN capacitor is connected to the power unit.
2. Replace the PN capacitor.
3-82
Error code : D2055

Error message : [Power sequence board]Watchdog error was detected.
Content:
The bus access from the main CPU board to the power sequence board was not made for a certain
period of time (16 ms) or more.
Main cause:
Countermeasure:
1. Turn the AC primary power OFF and then ON, and check if the same error occurs.
3-83
Error code : D2056

Error message : [I/O board(No.XX)]Several boards have same ID address.
Content:
The same address is set in two or more IO boards.
Main cause:
1. Incorrect setting in the DIP switch (SW1) for setting address in the IO board.
2. Failure of the IO board.
Countermeasure:
1. Check the DIP switch (SW1) setting in the IO board.
2. Replace the IO board.
3-84
Error code : D2057

Error message : [Servo boardXX]No response from Servo FPGA device.
Content:
No regular response is received from the servo FPGA software in the servo board.
Main cause:
Countermeasure:
1. Check if the correct servo FPGA software (ARMSF) is downloaded to the servo board
(Software version check).
3-85
Error code : D2058

Error message : [Main CPU board]DC power supply is abnormal.(XX mV)
Content:
Power supply voltage is abnormal in any one of the power supplies including those generated in
the main CPU board.
Main cause:
1. Old version of the driver is installed in 1VA board.
2. Abnormal main CPU board.
3. Abnormal AVR.
Countermeasure:
At first, turn the controller power OFF and then ON. If the error still occurs:
1. Check the version of the OS driver and update the OS driver if old.
3. Replace the AVR.
3-86
Error code : D2068

Error message : [IO board No. XX]Device check failure.(CodeXX)
Content:
The boot process for the IO board failed after turning ON the controller power due to the causes
excluding the following errors:
E1009 No.XX I/O board is not installed.

D2056 [I/O board(No.XX)]Several boards have same ID address.
Main cause:
1. AS group software is not installed correctly.
Countermeasure:
<NO>.
3. If the error does not constantly recur or the program does not return to normal, replace the CF
card, or main CPU board.
4. Reinstall the AS group software.
3-87
Error code : D2069

Error message : [ANYBUS interface board(No.XX)]Several boards have the same ID address.
Content:
The same address was set in two or more ANYBUS interface boards.
Main cause:
1. Incorrect setting in the DIP switch (SW1) for setting address in the ANYBUS interface board.
2. Failure of the ANYBUS interface board.
Countermeasure:
1. Check the DIP switch (SW1) setting in the ANYBUS interface board.
2. Replace the ANYBUS interface board.
3-88
Error code : D2072

Error message : Unexpected termination of main CPU board. Check program and data in teach
mode.
Error processing : Motor power OFF Error reset : Acceptable in teach mode only
Content:
Main CPU board abended due to a hardware failure, etc., and the set data, etc. were not saved
properly.
Main cause:
1. File system on the CF card is broken.
Countermeasure:
Change the mode to Teach and check if program data, set data, etc. are not broken. If this error
occurs even though the data are not broken, the hardware may be in failure. Contact Kawasaki.
3-89
Error code : E0002

Error message : [Servo boardXX]CPU BUS error.
Content:
The bus access from the CPU on the servo board is abnormal.
Main cause:
Countermeasure:
<NO>.
3. Replace the servo board if the error does not constantly recur or the error cannot be resolved.
3-90
Error code : E0903

Error message : Check sum error of system data.
Content:
The check sum data for the AS software system data (machine model, number of axes, option
setting, etc.) has been rewritten for some reason.
Main cause:
1. Failure of the CF card.
The error occurrence is not abnormal when files with system or robot data (model, options, etc.)
have been loaded and data settings have been changed at AS software replacement, etc.
Countermeasure:
1. Set “Enable” in Aux. function 0803 Reset Check Sum Error, and reset the error. This setting
is automatically reset to “Disable” when turning OFF  ON the controller power again.
2. If the step 1 above does not solve the error, the instruction for faulty data will be displayed.
Modify the data first and then fix errors by Aux. function 0803 Reset Check Sum Error again.
3. When the error cannot be fixed or the same error occurs other than the causes above, replace
the main CPU board or CF card.
[ NOTE ]
An initial listing of set values is enclosed with the controller of each machine or
with the manuals at factory shipment. Confirm the value settings with this list.
Keep this list for future use. When changing any setting, record the new
values. (E.g.: changing of options, operating range settings, etc.)
3-91
Error code : E1009

Error message : No. XX I/O board is not installed.
Error processing : Display Error reset : Acceptable
Content:
The first address of the IO board, etc. based on the IO signal numbers set in Aux. function 0611
Number of IO Signals cannot be read at controller power ON. This error typically occurs in the
following condition.
Number of IO signals set in Aux. function 0611 > Number of mounted IO boards  32
However, when the sequencer board is used, this error does not occur. Also, INT (Number of
Internal Signals) in Aux. function 0611 is a virtual signal of memory and is not related to the IO
board.
Main cause:
1. Incorrect setting in Aux. function 0611 Number of IO Signals.
2. IO board, etc. is not mounted.
3. Incorrect address settings on DIP switch (SW1) for a board address in the IO board.
Countermeasure:
1. Set the correct number of signals in Aux. function 0611 Number of IO Signals.
2. Correctly set the DIP switch (SW1) for a board address in the IO board and then mount it in the
card rack. IO board(s) is usually mounted in the vacant slots starting from the leftmost, but
the board works properly wherever it is mounted.
[ NOTE ]
1. After resetting this error, automatic operation is possible without the IO board.
In this case, the input is fixed to OFF, but the output can be switched between
ON and OFF in the AS software as a normal operation.
2. Maximum number of signals which can be set in Aux. function 0611 Number
of IO Signals is 960 for DO and DI, and 960 for INT. However, the number
of signals for DO and DI is restricted by hardware or other options. Usually,
the number of signals can be increased/decreased in units of 32 by
mounting/dismounting IO board, etc.
3-92
Error code : E1028

Error message : JtXX motor overloaded.
Content:
The feedback current from the power block has exceeded the continuous current rating of the
motor longer than the time allowed. The servo software detects this error based on the following
data (overload curve).
Servo board
Motor current Servo Servo

CPU FPGA
Abnormal
Current
feedback
Continuous
rating current
Time
Current
detection
circuit U,V,W earth Each
Overload curve IPM
motor
Robot main body

Power block
Main cause:
1. Mechanical factors:
(1) The robot arm comes in contact with the jig, etc.
(2) The cables etc. are caught by the robot arm.
(3) Failure of the reducer, gear, bearing, etc.
(4) Too small backlash in the gear reduction part.
(5) The payload exceeds robot rated weight.
(6) A robot motion pattern repeated which results in exceeding the rated motor capacity (due to
shuttle movement, etc.).
(7) The motor brake is not released.
(8) Gas pressure in the gas spring is below the specified value( in the arm with the gas spring).
2. Electric factors:
(1) Disconnection of the motor power line of U, V, or W phases. (No disconnection check is
performed.)
(3) Failure of the power block.
(4) Failure of the servo board.
(5) Failure of the motor.
3-93
Countermeasure:
1. If the robot arm interfered with something, move it away from the interference in teach mode.
Then, check for failures in the drive parts, reducers, etc., and for positioning deviation caused
by arm deformation.
2. When any parts (reducers, etc.) are damaged, check and replace them if necessary.
3. If the payload or the motion pattern causes the error, modify them.
4. When an electrical factor causes the error, check the servo amp. unit, MC unit, power unit,
motor, etc., and replace them if necessary. (E1x/E2x/E3x/E4x/E9x)
When an electrical factor causes the error, check the servo amp. section, power supply unit,
motor, etc., and replace them if necessary. (E7x)
5. Check gas pressure and state of the gas spring and replenish gas or replace the gas spring, if
necessary.
[ NOTE ]
Repeating this error may burn out the motor. Be sure to
remove the causes before restarting the robot.
3-94
Error code : E1029

Error message : Encoder rotation data is abnormal. (JtXX)
Content:
Encoder detected a difference of one or more rotations between the data of number of rotations
obtained by counting the magnetic pulses and the number of encoder rotations obtained by
converting encoder value change to encoder rotations.
Encoder
Encoder
Servo Encoder
CPU I/F

Servo board supply +12 V circuit Battery
Main cause:
Countermeasure:
1. Replace the encoder.
[ NOTE ]
1. This error may occur immediately after error occurrences of E1035,
E1036 and E1037 due to a discrepancy between the encoder value
and the current value in the servo software.
2. When this error occurs, the discrepancy of encoder value is in
multiples of 8192, which is the value of one rotation.
3-95
Error code : E1030

Error message : Encoder data is abnormal. (JtXX)
Content:
The difference between encoder values right before turning OFF the controller power and at the
next controller power ON exceeds the value set in Aux. function 0504 Encoder Value Error
Range at Power-ON. This is detected by the AS software.
This value is usually set to 2.0 degrees for each rotation axis. When set as 0.0 degrees, this error
is not detected. Setting too small value may cause this error when turning ON the controller
power, even though there is no abnormality.
Encoder
Encoder
Servo Encoder
CPU I/F

[ NOTE ]
The error occurrence right after executing initialization does
not mean abnormality. Because at initialization, the last
encoder value right before turning OFF the controller power is
also reset, this error occurs in all axes.
3-96
Main cause:
1. The internal data of the encoder is not maintained due to a deterioration of the encoder backup
battery voltage, disconnection of the encoder harness, failure of the encoders, etc.
2. When the controller power is turned OFF due to abnormal power supply, etc. during the robot
motion, the arm cannot stop its motion immediately. Because of this, a discrepancy may be
caused between the last encoder value recorded by AS software and the current value at the
actual position of stoppage.
3. Initializing is executed. (This error occurs in all axes.)
4. The motor or the encoder is replaced.
5. The arm (motor) is moved forcibly during the controller power OFF.
Countermeasure:
1. Perform zeroing of the encoder promptly after replacing the motor or the encoder.
！ WARNING
There is a possibility that the internal data of the encoder is not

maintained when this error occurs. Therefore, confirm without fail that
angle value for each axis becomes 0 after setting all axes to their scribe
marks (mechanical origin) in teach mode. If the angle values do not
become 0, execute zeroing without fail.
！ CAUTION
After the error reset, automatic operation is possible.
However, beware there is a high possibility of causing
malposition of the robot as the current value goes out of
order. Do not fail to confirm the above-mentioned zeroing
and the playback of steps in check mode.
2. Check the battery for the encoder backup, and when it decreases to +3.3 V or less, replace the
battery promptly. Replace the encoder batteries used in all axes, including conveyor, at the
same time.
3. Check for disconnection or short-circuit in the encoder harness.
4. Replace the encoder, encoder battery backup board, etc.
3-97
Error code : E1032

Error message : Mismatch ABS and INC encoder data (JtXX).
Content:
A large difference was detected between the number of encoder rotations from the servo board
and the number of rotations calculated in the servo software. This is detected by the servo
software.
Encoder
Encoder
Servo Encoder
CPU I/F

Main cause:
Countermeasure:
3-98
Error code : E1034

Error message : Encoder initialize error (jtXX).
Content:
This error occurs when the encoder is rotating at 300 rpm or more at controller power ON, the
absolute position data cannot be fixed.
Encoder
Encoder
Servo Encoder
CPU I/F

Main cause:
1. The motor (encoder) was rotating at 300 rpm or more at controller power ON. (This also
applies to the conveyer encoder, etc.)
Countermeasure:
1. Set the motor (encoder) to rotate less than 300 rpm at controller power ON.
3-99
Error code : E1035

Error message : Encoder response error (JtXX).
Content:
The encoder does not respond to the servo board or the response is slow.
Encoder
Encoder
Servo Encoder
CPU I/F

Main cause:
1. Disconnection or short-circuit of the encoder harness.
Countermeasure:
1. Check for disconnection or short-circuit in the encoder harness.
[ NOTE ]
After error reset, execute the robot program slowly in repeat
mode or move the robot carefully in teach mode.
3-100
Error code : E1036

Error message : Encoder communication error. (JtXX)
Content:
Abnormality in the CRC or framing error is detected in the communication with the encoder.
CRC abnormal : Abnormality is detected by processing the data where the CRC data is
added to the communicated encoder data.
Framing abnormal : The stop bit is not detected in the encoder data.
Encoder
Encoder
Servo Encoder
CPU I/F

Main cause:
Countermeasure:
[ NOTE ]
After error reset, execute the robot program slowly in repeat
mode or move the robot carefully in teach mode.
3-101
Error code : E1038

Error message : Encoder ABS-track error. (JtXX)
Content:
There is a discrepancy between the absolute data and the incremental data in the encoder.
Encoder
Encoder
Servo Encoder
CPU I/F

Main cause:
Countermeasure:
3-102
Error code : E1039

Error message : Encoder INC-pulse error. (JtXX)
Content:
An abnormal pattern is detected in the output signal of the incremental pulse from the encoder.
Encoder
Encoder
Servo Encoder
CPU I/F

Main cause:
Countermeasure:
3-103
Error code : E1041

Error message : Limit switch (JtXX) is ON.
Content:
Robot went beyond the set motion range (restricted space) and activated the axis restriction limit
switch.
Set the motion range of each axis in Aux. function 0507 Motion Limits. Normally, the
maximum motion range of the robot is set at factory shipment.
To change the setting of the motion range, take into consideration the following conditions.
Maximum Mechanical Axis restriction Set motion

operating > stopper > limit switch > range
range (restricted space)
The mechanical stopper and the axis restriction limit switch are options, and the axis in which
they are installed varies with arm model and configuration. Typically, the AS software restricts
robot motion so as not to exceed the set motion range.
Axis Axis
restriction restriction
LS LS
FPGA

Servo board
Controller Robot arm
3-104
Main cause:
1. Due to an incorrect setting of the zeroing data, manual brake release, etc., the robot was moved
out of the set motion range (restricted space), and the axis restriction limit switch was turned
ON.
2. With the axis restriction limit switch ON, the motion range was set larger than the current
values.
3. The axis restriction limit switch harness was disconnected when the robot was outside of the
set motion range.
4. If the set motion range was close to the set angle of the axis restriction limit switch, the limit
switch may have been turned ON due to overshoot of the robot.
5. Disconnection, etc. in the axis restriction limit switch harness.
Countermeasure:
1. When this error occurs, the motor power can be turned ON while pressing and holding down
the override switch on the power sequence board. Move the arm by teach mode into the
motion range.
2. Or, use the (optional) manual brake release switch and release the brake manually to move the
arm into the motion range when the power cannot be turned ON. At this time, turn OFF the
motor power and release all Emergency Stops without fail.
3. Set the motion range to an appropriate value.
4. Change placement of the axis restriction limit switches appropriately.
5. Check the harness or the axis restriction limit switch, and replace them if necessary.
3-105
Error code : E1109

Error message : Conveyor I/F board is not installed.
Content:
Although an incremental type encoder is set to be used as a conveyor encoder, the conveyor I/F
board (1SQ board) which is to be used as the I/F board for the encoder is not mounted.
Main cause:
1. The conveyor I/F board is not mounted.
2. Failure of the conveyor I/F board.
3. Failure of the power sequence board on which the conveyor I/F board is mounted.
Countermeasure:
1. Mount the conveyor I/F board.
2. If the same error occurs after mounting the conveyor I/F board, replace the power sequence
board.
3-106
Error code : E1118

Error message : Command value for JtXX suddenly changed.
Content:
[Command value - Current value] calculated for each axis in repeat mode exceeded the following
value.
Rated axis max. speed 1.3 (Rated axis max. speed varies depending on the robot model and
axis.)
Main cause:
1. During a robot motion, a sudden motion change occurred.
2. Improper connection of the harness, etc.
3. Failure of the servo board, the power block, etc.
Countermeasure:
1. Modify the teach data so that no sudden changes occur.
2. Check each harness and board since improper connection of the harness, servo abnormalities,
etc., may be possible causes of the malfunction.
3-107
Error code : E1119

Error message : Command value for JtXX beyond motion range.
Content:
The command value for each axis has exceeded the set motion range (restricted space) in teach
mode, check mode or repeat mode.
Main cause:
1. Incorrect setting of the motion range.
2. Poses near the motion limits were taught in the program.
Countermeasure:
1. Modify motion range to appropriate one.
2. Change the teaching point(s) in the program.
Maximum Mechanical Axis restriction Set motion range

operating > stopper > limit switch > (restricted space)
range
they are installed varies with arm model and configuration.
[ NOTE ]
An initial listing of set values is enclosed with the controller of each machine or
with the manuals at factory shipment. Confirm the value settings with this list.
Keep this list for future use. When changing any setting, record the new
values. (E.g.: changing of options, motion range settings, etc.)
3-108
Error code : E1120

Error message : Current command causes interference betw Jt2 and Jt3.
Content:
Command values of the second and third axes are interfering with each other, for robots whose
second and third axes are a link mechanism, such as Z series, etc.
(For robots whose second and third axes are not a link mechanism, such as R series, this error is
not detected.)
Main cause:
Inappropriate teaching data, including the pose while moving.
Countermeasure:
Modify the teaching data.
3-109
Error code : E1123

Error message : Speed error JtXX.
Content:
Each axis speed (motor speed) calculated from the encoder value exceeded the rated value. This
is detected by the servo software.
Main cause:
1. The arm fell: due to disconnection of the motor power line U, V, or W phases, or a failure of
the power block.
2. Malfunction due to wiring failure in the motor power line or the encoder line.
3. Disconnection or short-circuit in the encoder harness, or failure of the encoder.
4. A sudden change in the robot motion.
6. The required inertia moment exceeded the motor torque limit while moving at maximum speed
because load exceeded the rated load.
Countermeasure:
1. Check for disconnection or short-circuit in the harness.
4. If sudden changes in robot motion occur, modify the teach data so that the poses are corrected,
the speed becomes lower, etc.
3-110
Error code : E1124

Error message : Deviation error of JtXX.
Content:
The difference between the present value of the encoder and the command value of the AS
software exceeded a rated value. This is detected by the servo software. The rated value
differs depending on robot models, axes, etc.
Main cause:
(1) Robot arm came in contact with the jig, etc.
(2) Cables, etc. were caught by the robot arm.
(3) The reducer, gear, bearing, etc. are damaged.
(4) The backlash is too small in the gear reduction part.
(8) Gas pressure in the gas spring is below the specified value (in the arm with the gas spring).
(1) Motor power line U, V, and W phases are disconnected. (No disconnection check is
performed.)
(4) Failure of the MC unit/power unit.
(5) Disconnection between the servo board (X503, X504, X505) and MC control board
(X304).
(6) Disconnection, etc. in the PN voltage wiring between the MC unit/power unit (X352,
X353) and servo amp. unit. (E1x/E2x/E3x/E4x/E9x)
Disconnection, etc. in the PN voltage wiring between the MC power board (CN4) and
servo relay boar (CN8). (E7x)
3. A sudden change motion occurred.
3-111
Countermeasure:
1. When the robot arm interfered with something, move it away from the interference in teach
mode. Then, check for failures in the drive parts, reducers, etc., and for positioning deviation
caused by arm deformation.
2. When parts (reducers, etc.) are damaged, check and replace them if necessary.
4. If an electrical factor is causing the error, check the harness, servo amp. unit, MC unit/power
unit, motor, etc., and replace them if necessary. (E1x/E2x/E3x/E4x/E9x)
If an electrical factor is causing the error, check the harness, servo amp. section, power supply
unit, motor, etc., and replace them if necessary. (E7x)
5. If there are sudden changes in robot motion, modify the teach data.
6. Check gas pressure and state of the gas spring and replenish gas or replace the gas spring, if
necessary.
3-112
Error code : E1128

Error message : Uncoincidence error betw destination and current JtXX pos.
Content:
The command value arrived at the destination but the current value does not arrive at the accuracy
setting range after a certain period of time elapsed This is detected by the AS software.
Main cause:
(1) Robot arm made contact with the jig, etc., or the cables, etc. are caught by the robot arm.
(2) The axis load has become too large due to breakage of the reducer, bearing, etc.
performed.)
(2) Failure of the servo amp. unit.
(3) Failure of the MC unit/power unit.
(4) Disconnection between the servo board (X503, X504, X505) and MC control board
(X304).
(5) Disconnection, etc. in the PN voltage wiring between the MC unit/power unit (X352,
X353) and servo amp. unit. (E1x/E2x/E3x/E4x/E9x)
Disconnection, etc. in the PN voltage wiring between the MC power board (CN4) and
servo relay boar (CN8). (E7x)
(6) Failure of the encoder or disconnection of the encoder.
3. Problem in the teach data:

During linear interpolation motion, after being calculated to maintain the orientation of the tool
on the XYZ coordinates system, the command values are usually converted into joint
command values and then used for operating. However, this error might occur when the
angle of the wrist axis between the start and the end steps differs largely (such as opposite
direction for JT6, etc.) even if the tool orientation taught at the start and end points of robot
motion are the same in OAT values of the orientation.
3-113
Countermeasure:
1. In the case of mechanical failures, modify teaching and positions of jig and cable, replace
the reducers, etc. or adjust the backlash, etc.
2. If an electrical factor is causing the error, check the harness, encoder, servo amp. unit, MC
unit, power unit (E1x/E2x/E3x/E4x/E9x), power supply unit (E7x), etc., and replace them
if necessary.
3. Modify the teach data if the error occurs in a specific program step.
3-114
Error code : E1262

Error message : Encoder rotation speed exceeded limit (JtXX)
Content:
An error was detected because encoder rotation speed exceeded the 7700 rpm limit value.
Main cause:
Inappropriate teach data to exceed the limit value in encoder rotation.
Countermeasure:
1. Modify the teach data by repositioning the taught point, etc. so that the speed reduces in the
area where error occurred.
3. If error cannot be solved after taking countermeasures above, report all details to Kawasaki,
including information of all messages, robot model, controller model, machine number,
AS/servo software versions, operation at time of error, the contents of program lists, equipped
options, etc.
3-115
Error code : E1263

Error message : Encoder temperature exceeded limit (JtXX)
Content:
An error was detected because encoder temperature exceeded the limit value.
Main cause:
Inappropriate teach data to apply overload while moving.
Countermeasure:
1. Modify the teach data by reducing the speed of acceleration/deceleration or by extending
waiting time, etc. so that load is reduced on the axis where error occurred.
options, etc.
3-116
Error code : E1267

Error message : The initial setting of encoder is abnormal. (JtXX)
Content:
Settings that are made during encoder initialization did not complete successfully.
Initialization settings:
The abnormal detection value for encoder rotation speed is set at 7700 rpm.
The abnormal detection value for encoder temperature is set at 95 C
Main cause:
Failed to write to the encoder memory or failure of the encoder line.
Countermeasure:
<NO>.
3. Check for disconnection in the encoder line.
options, etc.
3-117
Error code : E1268

Error message : Breakage in the encoder line or faulty setting of encoder baud rate. (JtXX)
Content:
When turning ON the controller power, encoder baud rate did not switch to 4 Mbps, or the baud
rate switched to 4 Mbps but the state was not recognized as having been switched.
Main cause:
Disconnected or unconnected encoder line, or failed to write to the encoder memory.
Countermeasure:
<NO>.
2. Confirm the encoder is formatted in A.
4. Check for disconnection in the encoder line.
options, etc.
3-118
Error code : E1287

Error message : Power module error JtXX (UPPER).
Content:
The power module has detected an error signal in the power block.
Motor
Robot
m ain body
PW M signal
HIC IPM
IPM error signal
1KB board
Servo board Power block
Controller
Main cause:
1. Improper power block connection with the servo board.
2. Disconnection of motor power line (U, V, W), unconnected connector, improper connection.
3. Short-circuit current flowed.
4. IPM control power voltage (+15 V, upper side) decreased.
5. IGBT chip temperature increased in the IPM.
6. Failure of the IPM or the short current detection circuit of power block board.
7. Failure of the power unit control board or power unit power board.
8. Damage of the DC power supply in the MC unit/power unit.
Countermeasure:
1. Check if the servo board is mounted correctly.
2. Check if motor power line is connected.
3. Check if the U-phase, V-phase, or W-phase in the motor is short-circuited or grounded.
4. Check for the wiring, and connection of the connectors in the servo amplifier unit.
Check the wiring, and connection of the connectors in the servo amplifier section. (E7x)
5. Check the cooling devices such as cooling fan, etc., or fan running time setting.
3-119

7. Replace the MC unit/power unit. (E1x/E2x/E3x/E4x/E9x)
3-120
Error code : E1288

Error message : Power module error JtXX (LOWER).
Content:
The power module has detected an error signal in the power block.
Motor
Robot
m ain body
PW M signal
HIC IPM
IPM error signal
1KB board Power block

Servo board Controller
Main cause:
1. Improper power block connection with the servo board.
2. IPM control power voltage (+15 V, lower side) decreased.
3. Short-circuit current flowed.
4. IGBT chip temperature increased in the IPM.
5. Failure of the IPM.
6. Failure of the power unit control board (1VH) or power unit power board (1VJ).
7. Damage of DC power supply in the MC unit/power unit.
Countermeasure:
1. Check if the servo board is mounted correctly.
2. Check for the wiring, and connection of the connectors in the servo amplifier unit.
Check for the wiring, and connection of the connectors in the servo amplifier section. (E7x)
3. Check if the U-phase, V-phase, or W-phase in the motor is short-circuited or grounded.
4. Check the cooling devices such as cooling fan, etc., or fan running time setting.
3-121
Error code : E1289

Error message : [Servo boardXX]Synchronous error.(Servo FPGA)
Content:
Synchronous operation failed between the servo board CPU and servo FPGA.
Main cause:
Countermeasure:
2. Replace the servo board if the same error occurs.
3-122
Error code : E1290

Error message : JtXX Voltage of the current sensor exceeded the upper limit.
Content:
The motor current detected by the motor current detection circuit in the power block board
exceeded the upper limit.
Servo FPGA
Current feedback
Servo board
PMW
Current
detection
circuit Each
IPM
motor
Controller
Main cause:
3. Ground fault or short-circuit in the motor power line.
4. Failure of the motor.
Countermeasure:
2. Check for ground fault or short-circuit in the motor power line.
3-123
Error code : E1291

Error message : JtXX Current sensor is disconnected or out of order.(U)
Content:
The U-phase motor current detection circuit is in failure in the power block board, or the signal
line to the servo board is abnormal.
Servo FPGA
Current feedback
Servo board
PMW
Current
detection
circuit Each
IPM
motor
Controller
Main cause:
3. Improper connection of connectors between the power block and servo board.
4. Improper connection of separate harness connector.
5. Failure of the motor, improper connection of motor connectors.
Countermeasure:
Replace the 1UZ board and servo board of JT XX. (E7x)
3. Check the connection of connectors between the power block and servo board.
4. Replace the separate harness and the machine harness.
3-124
Error code : E1292

Error message : [Servo boardXX]Abnormal signal input from MCXX.
Content:
Power supply abnormal signal is input from the MC control board (1TQ/1TV)/power unit control
board (1VH).
Main cause:
1. Inappropriate voltage adjustment in the AVR for control power.
6. Disconnection in the harness between the servo board (X503, X504, X505) and MC control
board (X304).
Countermeasure:
2. Replace the AVR.
6. Check the harness between the servo board (X503, X504, X505) and MC control board/power
unit control board (X304).
3-125
Error code : E1293

Error message : [Servo boardXX]Current feedback gain is abnormal.
Content:
In the servo board, the current setting value that is set in the CPU for servo FPGA is different
between the write and read values.
Main cause:
Countermeasure:
3-126
Error code : E1294

Error message : [Servo boardXX]I/O 24V is low.
Content:
Decrease of the IO24 V which is generated in the servo board is detected.
Main cause:
1. Ground fault or short-circuit in the IO24 V line.
2. Decrease of 24 V power supply in the AVR for control power.
3. Disconnection, etc. in the 24 V wiring.
Countermeasure:
1. Check for any ground fault or short-circuit in the IO24 V line, such as machine harness, X3
signal harness, or harness connected from X9 connector of power sequence board.
2. Check the 24 V power supply voltage in the AVR, replace it if it has a problem.
3. Check the 24 V wiring.
3-127
Error code : E1295

Error message : [Servo boardXX]24V for internal valve is low.
Content:
Decrease of the 24 V power supply for machine valve is detected. The 24 V is generated in the
optional machine valve/sensor board which is mounted on the servo board.
Main cause:
1. Ground fault or short-circuit in the 24 V line for the machine valve.
2. Failure of the optional machine valve/sensor board.
Countermeasure:
1. Check for ground fault or short-circuit in the 24 V line for machine valve, such as machine
harness, or separate harness.
2. Replace the optional machine valve/sensor board on the servo board.
3-128
Error code : E1296

Error message : [Servo boardXX]Mismatch in safety circuit LS conditions.
Content:
Contacts state for axis restriction limit switch (LS) does not match between the first and second
safety circuits.
Main cause:
1. Improper input circuit or wiring in the axis restriction LS input in the robot arm. Or only the
first circuit is input.
2. Disconnection or ground fault in the wiring of the axis restriction LS.
3. Failure of the axis restriction LS.
Countermeasure:
1. Check the wiring of the axis restriction LS in the robot arm.
2. Replace the axis restriction LS.
Reference:
[ NOTE ]
3-129
Error code : E1297

Error message : [Servo boardXX]Mismatch in jumper wiring for detecting internal pressure.
Content:
In the X510 wiring connected to the servo board, connection state of the safety circuit jumper
harness does not match between the first and second circuits.
Main cause:
1. Disconnection in the X510 connector part.
Countermeasure:
1. Check theX510 connector part.
Reference:
[ NOTE ]
3-130
Error code : E1298

Error message : [Servo boardXX]Mismatch in contact condition of LS override switches.
Content:
The limit switch override switch state does not match between the first and second switches.
Main cause:
1. Disconnection or short-circuit in the limit switch override switch lines.
2. Failure of the limit switch override switch (on the power sequence board).
Countermeasure:
1. Check for the disconnection or short-circuit in the wiring between the mother board (X206)
and servo board (X502).
Reference:
[ NOTE ]
3-131
Error code : E1299

Error message : [Servo boardXX]Jumper wiring for detecting internal pressure is
disconnected.
Content:
The jumper line (X510) is not connected in the safety circuit on the servo board.
Main cause:
1. Improper connection in the jumper line (X510) connected to the servo board.
Countermeasure:
1. Check the X510 connector line connected to the servo board.
Reference:
3-132
Error code : E1300

Content:
The 24 V voltage supplied to the servo board from the AVR for control power became deviated
from the rated value.
Main cause:
3. Failure of the MC unit/power unit. (E1x/E2x/E3x/E4x/E9x)
Failure of the power supply unit. (E7x)
5. Ground fault, short-circuit, or disconnection in the 24 V wiring.
Countermeasure:
1. Replace the AVR.
5. Check the 24 V wiring for any abnormality.
3-133
Error code : E1301

Error message : [Servo b’dXX]Encoder type mismatch between software and servo board.
Content:
The servo software setting does not match the jumper switch setting in the servo board.
Main cause:
1. Incorrect setting of the jumper connector (J2) on the servo board.
2. Incorrect servo software version.
Countermeasure:
1. Check the setting of the jumper connector (J2) on the servo board.
2. Check the servo software version.
3-134
Error code : E1302

Error message : [MCXX]OFF check is abnormal.(Servo boardXX)
Content:
The OFF state of the magnetic contactor (K1 or K2) is not detected before motor power ON.
Main cause:
1. Failure of the magnetic contactor (K1 or K2).
2. Disconnection or improper connection in the harness inside the MC unit. (E1x/E2x/E3x/E4x)
Disconnection or improper connection in the harness inside the power supply unit. (E7x)
4. Unconnected X313 jumper harness of MC control board.
Countermeasure:
Replace the magnetic contactor and power supply unit. (E7x)
2. Check if X313 jumper harness is connected.
3-135
Error code : E1303

Error message : [MCXX]OFF check of safety relay is abnormal.(Servo boardXX)
Content:
The OFF state of the safety relay (KS1 or KS2) in the MC control board is not detected before
motor power ON.
Main cause:
Countermeasure:
Replace the MC control board.
3-136
Error code : E1304

Error message : [MCXX]Incorrect operation of K1.(Servo boardXX)
Content:
The magnetic contactor (MC) K1 does not operate properly.
Main cause:
1. Failure of the MC (K1).
2. Disconnection or improper wiring in the harness of the MC unit. (E1x/E2x/E3x/E4x)
Countermeasure:
Replace the MC unit. (E1x/E2x/E3x/E4x)
Replace the magnetic contactor (K1) and power supply unit. (E7x)
3-137
Error code : E1305

Error message : [MCXX]Incorrect operation of K2.(Servo boardXX)
Content:
The magnetic contactor (MC) K2 does not operate properly.
Main cause:
1. Failure of the MC (K2).
2. Disconnection or improper wiring in the harness of the MC unit. (E1x/E2x/E3x/E4x)
Countermeasure:
Replace the magnetic contactor (K2) and power supply unit. (E7x)
3-138
Error code : E1306

Error message : [MCXX]Incorrect operation of inrush current control relay.(Servo boardXX)
Content:
The inrush current control relay on the MC board does not operate properly.
Main cause:
1. Failure of the MC power board of the MC unit.
3. Disconnection or improper wiring in the harness of the MC unit.
Countermeasure:
3-139
Error code : E1307

Error message : [MCXX]Incorrect operation of safety relay KS1.(Servo boardXX)
Content:
The safety relay (KS1) in the MC control board does not operate properly.
Main cause:
Countermeasure:
3-140
Error code : E1308

Content:
Main cause:
Countermeasure:
3-141
Error code : E1309

Content:
Main cause:
Countermeasure:
3-142
Error code : E1310

Error message : [MCXX]Incorrect operation of motor ON relay.(Servo boardXX)
Content:
The motor ON relay in the MC control board does not operate properly.
Main cause:
Countermeasure:
3-143
Error code : E1311

Error message : [MCXX]Incorrect operation of safety circuit motor OFF relay.(Servo
boardXX)
Content:
The motor OFF relay in the MC control board does not operate properly.
Main cause:
Countermeasure:
Reference:
3-144
Error code : E1312

Error message : [MCXX]Mismatch in safety circuit motor OFF relay.(Servo boardXX)
Content:
The contact state of the motor OFF relay in the MC control board does not match between the
first and second contacts.
Main cause:
Countermeasure:
Reference:
[ NOTE ]
3-145
Error code : E1313

Error message : [MCXX]Mismatch in individual MC control of safety circuit.(Servo
boardXX)
Content:
The contact state for individual power cut OFF connected to X301 connector of the MC control
board does not match between the first and second contacts.
Main cause:
1. Improper wiring connected to X301 connector of the MC control board (only the first contact is
connected, etc.) or failure of the contact.
Countermeasure:
1. Check if the wiring to X301 is proper, or the contact has no failures.
Reference:
[ NOTE ]
3-146
Error code : E1314

Error message : [MCXX]Thyristor Thermal is abnormal.(Servo boardXX)
Content:
Overheat or thermal signal of the three-phase rectification module on the MC power board/power
unit power board is detected in the MC control board/power unit control board.
Main cause:
1. Abnormal cooling fan on top of the amplifier unit for single axis.
3. Disconnection or improper connection in the harness inside the MC unit/power unit.
Countermeasure:
1. Check if the fan on top of the amplifier unit for single axis operates properly.
3-147
Error code : E1315

Error message : Watchdog error in NoXX I/O board.
Content:
The bus access from the main CPU board to the IO board was not made for a certain period of
time (250 ms) or more.
Main cause:
Countermeasure:
3. Replace the IO board.
3-148
Error code : E1316

Error message : [I/O board(No.XX)]Access Error.[Address:XX][Code:XX]
Content:
Abnormal access with IO board occurs.
Main cause:
Abnormal device driver.
- The address represents that in which process the error occurred.
- The code represents return value from the IO board device driver at error occurrence.
Countermeasure:
CPU board.
3-149
Error code : E1318

Error message : [MCXX]DC 20V is abnormal.(Servo boardXX)
Content:
The 20 V power supply voltage for IPM deviated from the rated value.
Main cause:
1. Disconnection or improper connection of AC power harness to MC unit/power unit
(E1x/E2x/E3x/E4x/E9x) or power supply unit (E7x).
2. Open-phase in the R-phase or S-phase.
3. Failure of the power supply for IPM.
4. Failure of the MC power board/power unit power board inside the MC unit.
5. Disconnection or improper connection in the harness inside the MC unit/power unit.
8. Failure of the PFC control board. (E9x)
Countermeasure:
1. Check the AC power harness line to the MC unit/power unit (E1x/E2x/E3x/E4x/E9x) or the
power supply unit (E7x).
2. Check for open-phase in the R-phase or S-phase.
3-150
Error code : E1321

Error message : [Main CPU board]Servo board(XX) communication error. (CodeXX)
Content:
An abnormal communication occurred continuously, exceeding the rated communication cycle
between the main CPU board and the servo board.
Main cause:
The cause of the error is displayed in the last 8 numbers of the code. The code shows the error
details of the last two communication cycles. The first four numbers shows the latest cycle error,
while the last four numbers shows the error of one cycle before the latest cycle.
There are following codes for the error:

1) 0001 Error when processing sending data from the main CPU board.
2) 0002 Error when processing receiving data by the main CPU board. (Data from the servo
board could not be received.)
3) 0004 The two counters values for communication control do not match among the data
received from the servo board.
4) 0008 The counter value for communication control is the same as the previous value
among the data received from the servo board.
5) 0010 The counter value for communication control is not consecutive among the data
received from the servo board.
Countermeasure:
If the same error occurs after executing error reset, process the followings for each code.
1) 0001 Replace the main CPU board.

2) 0002 1. Check if the communication harness between the main CPU board and servo board
is connected properly.
2. Replace the communication harness  servo board  main CPU board.
3) 0004 Replace the communication harness  servo board  main CPU board.
3-151
Error code : E1322

Error message : Setting num. of safety circuits differs betw. powerseq.b'd and MCXX. (Servo
b'dXX)
Content:
The DIP switch (SW2-1) setting for specifying the number of safety circuits on the power
sequence board does not match the jumper setting (JP2 or JP3) in the MC control board
(1TQ/1TV)/power unit control board (1VH).
Main cause:
1. Incorrect switch settings on the power sequence board or MC control board/power unit control
board.
Countermeasure:
1. Check if the jumper setting is correct between the DIP switch (SW2-1) in the power sequence
board and the jumper (JP2 or JP3) in the MC control board/power unit control board.
If the jumper setting is correct,
3-152
Error code : E1323

Error message : Setting num. of safety circuits differs betw. servo b'dXX and MCXX.
Content:
The state of jumper (JP2 or JP3) setting for specifying the number of safety circuits on the MC
control board (1TQ/1TV)/power unit control board (1VH) is not transmitted to the servo board
properly.
Main cause:
1. Disconnection in the harness between the servo board (X503, X504, X505) and the MC control
board/power unit control board (X304).
Countermeasure:
1. Check the harness between the servo board (X503, X504, X505) and the MC control board/
power unit control board (X304).
3-153
Error code : E1324

Error message : Safe circuit disconnected between power sequence board and servo boardXX.
Content:
The wiring of the safety circuit is disconnected between the power sequence board and servo
board.
Main cause:
1. Disconnection or improper connection in the harness between the mother board and servo
board.
Countermeasure:
1. Check the harness between the mother board and servo board.
Reference:
3-154
Error code : E1325

Error message : Safe circuit disconnected between servo boardXX and MCXX.
Content:
The wiring of the safety circuit is disconnected between the servo board and MC unit/power unit.
The wiring of the safety circuit is disconnected between the servo board and power supply unit.
(E7x)
Main cause:
1. Disconnection or improper connection in the harness between the servo board and MC unit/
power unit. (E1x/E2x/E3x/E4x/E9x)
Disconnection or improper connection in the harness between the servo board and power
supply unit. (E7x)
Countermeasure:
1. Check the harness between the servo board and MC unit/power unit. (E1x/E2x/E3x/E4x/E9x)
Check the harness between the servo board and power supply unit. (E7x)
Reference:
3-155
Error code : E1326

Error message : Safety fence is open.
Content:
The signal which shows that the safety fence is open input from outside. When the system switch
SF_OPEN_ERROR is OFF, this error does not occur but instead a message appears in the
message display area on the TP. When the system switch SF_OPEN_ERROR is ON, or when
your version of the software does not come with the SF_OPEN_ERROR switch, an error occurs.
Main cause:
1. The external contact connected to X8 connector (1-2 pin, 3-4pin) on the power sequence board
is open.
Countermeasure:
1. Check the signal which shows that the safety fence is open input from outside.
2. When that signal is not input, replace the power sequence board.
Reference:
3-156
Error code : E1327

Error message : [Power sequence board]Miscompare in motor off relay condition on safety
circuit.
Content:
The contacts of the motor OFF relay on the power sequence board do not match between the first
and second contacts.
Main cause:
Failure of the power sequence board.
Countermeasure:
Replace the power sequence board.
Reference:
[ NOTE ]
3-157
Error code : E1328

Error message : [Power sequence board]Error of motor off relay on safety circuit.
Content:
The motor OFF relay in the power sequence board does not operate properly.
Main cause:
Failure of the power sequence board.
Countermeasure:
Replace the power sequence board.
Reference:
3-158
Error code : E1329

Error message : [Power sequence board]Error in TEACH/REPEAT switch on safety circuit.
Content:
The signal state that is not identified as either TEACH or REPEAT continued for
TEACH/REPEAT switch.
Main cause:
2. Failure of the harness or unconnected harness connector between the TEACH/REPEAT switch
and mother board (X203).
Countermeasure:
2. Check for unconnected harness connector, improper connection, or disconnection in the
harness between the TEACH/REPEAT switch and mother board (X203).
Reference:
3-159
Error code : E1330

Error message : [Power sequence board]IO 24V is low.
Content:
The IO24 V voltage supplied to the power sequence board from the servo board has decreased.
Or, the 24 V for the AVR for control power has decreased.
Main cause:
1. The IO 24 V was ground-faulted or short-circuited in the external wiring.
5. Disconnection of the harness between the servo board (X501) and mother board (X207).
Countermeasure:
1. Check for ground fault or short-circuit of the IO24 V in the external wiring when the IO24 V is
used as an external wiring. (Ground fault or short-circuit may also occur in the wiring inside
the robot arm.)
2. When the error occurs at the same time as “D1560 DC 24V is abnormal.”, refer to
countermeasure for D1560.
5. Check for unconnected connector or disconnection in the harness between the servo board
(X501) and mother board (X207).
3-160
Error code : E1331

Error message : [Power sequence board]Thermal error.
Content:
The thermal switch (70 C) for monitoring controller temperature activated in the power sequence
board.
Main cause:
1. Rotation speed of the cooling fan decreased in the controller.
2. The ambient temperature of the controller increased up to 45 C or more.
3. Defect in the power sequence board.
Countermeasure:
1. When the error “W1053: Rotational speed of fan is below the limit” is occurring, refer to the
countermeasure for W1053.
2. Check if the ambient temperature of the controller is 45 C or below.
3-161
Error code : E1332

Error message : [Power sequence board]Power error signal was input from servo boardXX.
Content:
The DC voltage in the servo board has decreased.
Main cause:
1. Inappropriate voltage adjustment in the AVR for control power.
5. Disconnection or unconnected connector in the harness between the servo board (X501) and
mother board (X207).
Countermeasure:
2. Replace the AVR for control power.
5. Check for unconnected connector or disconnection in the harness between the servo board
(X501) and mother board (X207).
3-162
Error code : E1333

Error message : Motor power ON signal has turned off.(Servo boardXX)(MCXX)
Content:
Although the motor power is ON in the AS software, other errors are not detected and motor ON
state signal transmitted to the servo board from the MC unit/power unit does not become ON or
the signal stopped.
Main cause:
1. Failure of the MC unit control board/power unit control board.
3. Disconnection between the MC unit/power unit and servo board. (E1x/E2x/E3x/E4x/E9x)
Disconnection between the power supply unit and servo board. (E7x)
4. Unconnected X301 connector of MC unit control board/power unit control board.
Countermeasure:
3. Check the harness between the MC control board/power unit control board (X304) and servo
board (X503 for MC unit/power unit 1, X504 for MC unit/power unit 2, X505 for MC
unit/power unit 3). (E1x/E2x/E3x/E4x/E9x)
Check the harness between the MC control board/power unit control board (X304) and servo
board (X503). (E7x)
4. Check if the X301 connector is connected.
3-163
Error code : E1334

Error message : TEACH/REPEAT switch is abnormal.(Mode differs betw. safety circuit and
monitor.)
Content:
There is a discrepancy in the state signals for TEACH/REPEAT switch (between the safety
circuit and control monitor signal).
Main cause:
2. Failure of the harness between the TEACH/REPEAT switch and mother board (X203).
Countermeasure:
2. Check for improper connection or disconnection in the harness between the TEACH/REPEAT
switch and mother board (X203).
Reference:
3-164
Error code : E1335

Error message : Unexpected motor power OFF.(Servo boardXX)(MCXX)
Content:
Although the motor power is ON in the AS software, other errors than this is not detected and the
motor power of MC unit/power unit or power supply unit is not activated, or they stopped.
Main cause:
4. Disconnection between the mother board and servo board.
5. Disconnection between the MC unit/power unit and servo board. (E1x/E2x/E3x/E4x/E9x)
Disconnection between the power supply unit and servo board. (E7x)
6. Unconnected connector X301 in the MC control board/power unit control board.
Countermeasure:
5. Check the wiring between the MC control board/power unit control board (X304) and servo
board (X503, X504, X505).
6. Check the connector X301 in the MC control board/power unit control board.
Reference
1. For the MC unit and power supply unit which use 1TQ/1TV board.
 The code at the end of the message shows conditions of MC and safety relay in hexadecimal
code when this error is detected. “X” indicates conditions of K1, K2, K3, KS1, KS2 and
KS3 from high bit, showing “0” when they are ON and “1” when they are OFF, when
changed to the 6-bit binary-coded form.
(Example) When K1, K3 and KS3 are OFF and K2, KS1 and KS2 are ON, it will be Code
29 (101001).
3-165
2. For the power unit which uses 1VH board

The power unit does not have MC and safety relay, and the code indicates the condition in the
1VH board.
 If the error reoccur after taking the countermeasures, contact Kawasaki Service and inform
the details including the above code.
3-166
Error code : E1336

Error message : [Servo boardXX]Communication error with Main CPU board.
Content:
An error is detected by the servo board in communication between the main CPU board and servo
CPU board.
Main cause:
1. Failure of the wiring between the mother board and servo board. (When two or more servo
boards are used, in the wiring between the additional servo communication board and servo
board.)
3. Failure of the main CPU board or additional servo communication board.
Countermeasure:
1. Check if the error is resolved by executing error reset.
4. Replace the main CPU board or additional servo communication board.
3-167
Error code : E1337

Error message : [MCXX]Brake power is abnormal.(Servo boardXX)
Content:
The brake power supply voltage (DC24 V to DC26 V) generated in the MC unit/power unit or
power supply unit deviated from the rated value.
Robot
Motor main body
Motor brake line

Controller
DC24-26 V
Brake power supply>>
Safety circuit
Brake power supply error signal
Voltage detect.
CPU Brake release signal MOSFET
Brake line error signal
MC control board/
Power unit control board
Servo board
Main cause:
1. Circuit protector (CP) activated due to short-circuit or ground fault in the brake power
supply lines.
2. Failure of the wiring for input to transformer for the brake power supply or in the wiring
from the transformer to the MC power board/power unit power board.
Disconnection of brake power supply line (X320) to the MC control board/power unit
control board.
4. Failure of the MC control board/power unit power board.
5. Short-circuit or ground fault of the harness inside the MC unit/power unit.
Short-circuit or ground fault of the harness inside the power supply unit. (E7x)
6. Short-circuit or ground fault of the fan wiring. (Fan for servo amp. unit excluded.)
Failure of the mother board or the AVR. (E7x/E9x)
3-168
Countermeasure:
1. Restore the circuit protector to a normal state if it activated.
3. Check the input/output wiring lines in the transformer for brake power supply.
Check the brake power supply line.
4. Check the fan wiring lines.
Replace the mother board or the AVR. (E7x/E9x)
3-169
Error code : E1338

Error message : [MCXX]P-N low voltage.(Servo boardXX)
Content:
The motor power voltage (P-N voltage) is at the rated value (DC150 V) or less when the motor
power is turned ON or while it is ON.
[ NOTE ]
Beware when low voltage occurs, the arm will fall until the error is detected
because the motor power is not supplied during servoing. As a result, other
errors such as abnormal speed, abnormal deviation, etc. might be detected.
Main cause:
1. Disconnection or improper connection in the harness inside the MC unit. (E1x/E2x/E3x/E4x)
2. Failure of the MC power board.
3. Failure of the MC control block.
4. Disconnection or improper connection in the harness between the MC power board (X352,
X353) and power block board.
Countermeasure:
2. Check for any abnormality in the harness between the MC power board (X352, X353) and
power block board.
3. Replace the servo amplifier unit. (E1x/E2x/E3x/E4x)
3-170
Error code : E1339

Error message : [MCXX]P-N high voltage.(Servo boardXX)
Content:
The motor power voltage (P-N voltage) is at the rated value (DC410 V) (*DC450 V or more for
E9x controller) or more when the motor power is turned ON or while it is ON.
Main cause:
1. Inappropriate teaching causing excessive regeneration was executed.
3. Disconnection of the regenerative resistor harness or failure of the regenerative resistor.
5. Failure of the additional regenerative resistor (option).
Countermeasure:
1. When the regenerating current is excessive, modify the teaching, or reduce the repeat speed.
2. When the motion requires greater resistance capacity, install another additional regenerative
resistor.
4. Replace the regenerative resistor.
5. Replace the additional regenerative resistor.
3-171
Error code : E1340

Error message : [MCXX]Regenerative time over.(Servo boardXX)
Content:
Regeneration time continued for 6 seconds or more in the MC power board/power unit power
board.
The term “regeneration” here means as follows: When the robot decelerates, the motor
generates power by absorbing the inertia energy of the robot arm, and the power may cause
overvoltage between P-N of the motor. To prevent the overvoltage, current is set to distribute to
regenerative resistor from the MC unit/power unit/power supply unit when the P-N voltage
exceeds a rated value.
MC unit/power unit
Control board Power board
Regeneration
state signal Regenerative
CPU Regenerative
circuit resistor
Main cause:
3. Improper harness connection between the MC control board/power unit control board and MC
power board/power unit power board.
4. If the error occurs during connection with the additional regenerative resistor (option), the
resistor itself may be in failure.
5. Inappropriate teaching causing regeneration for 6 sec. in a row was executed.
Countermeasure:
2. Check the model and connection of the additional regenerative resistor. When it is connected
properly, replace the additional regenerative resistor.
3. Modify the teach data.
3-172
Error code : E1341

Error message : [MCXX]Regenerative resistor overheat.(Servo boardXX)
Content:
Either or all of the thermal switches are disconnected in the regenerative resistor (140 C) or in
the regenerative resistor of the optional additional regenerative resistor (140 C). Because each
thermal switch is serially connected, the AS software cannot detect which thermal switch is
disconnected.
MC unit/power unit
Control board Power board

Additional
Regenerative regenerative
Regeneration
resistor resistor
overheat error Regenerative
CPU circuit
Thermal Thermal
(140 C) (140 C)
Additional
regeneration unit
(option)
Main cause:
1. Insufficient cooling activated the thermal switch, caused by halt or failure of the regenerative
resistor cooling fan, cooling fan for additional regenerative resistor(option).
2. Inappropriate teaching exceeding regenerative capacity was executed.
3. Ambient temperature of the controller is high.
4. Disconnection or improper connection in the harness between X354 and XRS in the MC power
board/power unit power board.
5. Disconnection or improper connection in the harness between the MC power board/power unit
power board and additional regenerative resistor.
8. Failure of the regenerative resistor or in the additional regenerative resistor.
3-173
Countermeasure:
1. Check if the cooling fans are functioning properly.
2. Modify the teach data, or reduce repeat speed.
3. Reduce the ambient temperature of the controller.
4. Check for disconnection or short-circuit in each harness.
6. Replace the regenerative resistor, or additional regenerative resistor (option).
！ CAUTION
Do not turn OFF the controller power immediately after ending the
operation. Especially, for the controller applied with regenerative
resistor, set fan control for more than 60 minutes and leave the
controller power ON until the resistor is cooled-down enough.
3-174
Error code : E1342

Error message : Motor harness disconnected or robot temperature exceeded limit.(MCXX)
(Servo boardXX)
Content:
The thermal contact in the arm connected to the motor harness activated or the harness was
disconnected.
Upper arm
Thermal
switch
MC unit/power unit
Rotor trunk
MC control board/ Thermal line
(TH) Thermal
power unit control
switch
board
Robot arm
Controller
Main cause:
1. Disconnection of thermal line in the arm.
2. Disconnection or improper connection in the separate harness.
3. Disconnection of the X314 harness in the MC control board/power unit control board.
4. Abnormal brake power supply (DC26 V).
6. When the thermal switch is built-in:
(1) An error such as overload has just occurred.
(2) The robot load has exceeded the payload.
(3) The ambient temperature of the robot exceeded the allowable range for the robot operation.
(4) Excessive robot motion such as repeated shuttle motion (counter teach) was executed.
(5) Servoing was continued for a long time at a posture applying force load on the arm.
(6) Failure of the thermal switch.
Countermeasure:
1. Check the thermal line between X314 connector in the MC control board/power unit control
board and the arm.
3. Refer to “E1337” if the brake power supply has any abnormalities.
4. Check the operation conditions and use the robot within its specified ratings.
5. When the servoing continues for a long time at a posture applying force load on the arm, which
results in a line stop, set the robot to HOLD by interlock, etc. or set an Auto servo OFF time in
Aux. function 0808 Environment Data.
3-175
Error code : E1343

Error message : Mismatch betw connected place of brake harness and software setting. (JtXX)
Content:
The external axis setting in the software (which specifies that in which MC unit/power unit is
used for each brake for 7, 8, 9 axes) and the connection place of brake harness for external axis do
not match.
Main cause:
1. Incorrect setting for external axis in the software.
2. Disconnection or improper connection in the harness of X317, X318, or X319 in the MC
control board/power unit control board.
Countermeasure:
1. Check the software setting in Aux. function <2002 External axis setting>.
2. Check the connection in the harness of X317, X318, and X319 in the MC control board/power
unit control board.
3-176
Error code : E1344

Error message : JtXX Current sendor is disconnected or out of order.(V)
Content:
The V-phase motor current detection circuit is in failure in the power block board, or the signal
line to the servo board is abnormal.
Main cause:
3. Improper connection in the harness between the power block board and servo board.
4. Improper connection in the separate harness connector.
5. Failure of the motor, improper connection of the motor connectors.
Countermeasure:
3. Check the connector connection in the harness between the power block board and servo
board.
Servo FPGA
Current feedback
Servo board
PWM
Current
detection
circuit
IPM Each motor
Controller
4. Replace the separate harness and machine harness.

3-177
Error code : E1345

Error message : [Servo boardXX]Limit switch signal line is disconnected.
Content:
The axis restriction limit switch was activated although the robot did not move beyond the set
motion range (restricted space).
Maximum Mechanical Axis restriction Set motion range

operating > stopper > limit switch > (restricted space)
range
they are installed varies with machine model and configuration. Typically, the AS software
restricts robot motion so as not to exceed the set motion range.
Axis Axis
restriction restriction
LS LS
FPGA

Servo board
Controller Robot arm
3-178
Main cause:
1. The axis restriction limit switch was activated because the motion range of the robot is set
wider than the placement of the axis restriction limit switches.
2. Due to an incorrect setting of the zeroing data causing unexpected motion of the robot, etc., the
axis restriction limit switch was activated.
3. Disconnection or failure of the axis restriction limit switch harness.
4. Failure of the axis restriction limit switch.
Countermeasure:
1. When this error occurs, the motor power can be turned ON while pressing and holding down
the override switch on the power sequence board. Move the arm in teach mode into the
motion range.
2. Or, use the manual brake release switch (option) and release the brake manually to move the
arm into the motion range when power cannot be turned ON. At this time, turn OFF motor
power and release all Emergency Stops without fail.
3. Set the motion range to an appropriate value.
4. Change placement of the axis restriction limit switches appropriately.
5. Check the harness or the axis restriction limit switch, and replace them if necessary.
Reference:
3-179
Error code : E1347

Error message : [MCXX]Destination spec is incorrect.(Servo boardXX)
Content:
MC unit or power supply unit for Japan spec. is used for Europe/North America spec. controllers.
Main cause:
1. Incorrect part number of the MC unit is used. (E1x/E2x/E3x/E4x)
Incorrect part number of the power supply unit is used. (E7x)
2. Failure of the MC unit. (E1x/E2x/E3x/E4x)
3. Disconnection in the harness (X206-X502) between the mother board and servo board.
Countermeasure:
1. Check the part number for the MC unit. (E1x/E2x/E3x/E4x)
Check the part number for the power supply unit. (E7x)
3. Check the harness (X206-X502) between the mother board and servo board.
3-180
Error code : E1348

Error message : [MCXX]Robot arm spec/separate control spec is incorrect. (Servo boardXX)
Content:
Incorrect MC unit is used. The first MC unit should be used for robot main body, and the
second or later should be used for separation operation.
Main cause:
1. The MC unit for robot main body is connected as a MC unit for separation operation. Or the
MC unit for separation operation is connected as a MC unit for robot main body.
Countermeasure:
1. Check if the MC unit part number and the destination of the connection are correct.
2. Replace the MC unit.
3-181
Error code : E1349

Error message : [MCXX]Explosion proof setting is mismatch.(Servo boardXX)
Content:
Specifications of AS software and MC unit do not match in point of non-explosion-proof or
explosion-proof specification.
Main cause:
1. The AS software version does not correspond to the MC unit.
Countermeasure:
1. Check if the AS software version which is in use is correct.
2. Check the MC unit part number and replace the MC unit if incorrect.
3-182
Error code : E1350

Error message : [MCXX]MC specification error.[CodeXX](Servo boardXX)
Content:
The MC unit/power unit ID does not correspond to any specifications of the MC unit/power unit.
Main cause:
Failure of the MC unit/power unit.
Countermeasure:
Replace the MC unit/power unit.
3-183
Error code : E1352

Error message : JtXX Codes set in software and power block do not match.
Content:
The power block setting does not match between the hardware and software.
Main cause:
1. Incorrect servo amp. unit (servo amp. section) part number is used in the software model and
motor settings.
Countermeasure:
1. Check the servo amp. unit (servo amp. section) part number for the software model and motor
settings in Aux. <804 Software version>, <2002 External axis setting>.
2. Replace the servo amp. unit. (E1x/E2x/E3x/E4x/E9x)
3-184
Error code : E1353

Error message : [Main CPU board]CPU temperature is abnormal.
Content:
The CPU temperature exceeded the motion limit temperature in the main CPU board.
Main cause:
1. High ambient temperature.
2. Malfunction of the cooling fan.
Countermeasure:
1. Lower the ambient temperature.
2. Check the cooling devices such as cooling fan, etc.
3-185
Error code : E1355

Error message : Error in servo I/F command communication.(Code:XX)
Content:
An error occurred in the communication (command communication) with the servo board. The
every two digits of the code starting from the left stands for unit number, command number,
channel number, and error code.
Main cause:
1. Servo group software that does not correspond to AS group software is installed.
Countermeasure:
CPU board, servo board, mother board.
3-186
Error code : E1359

Error message : JtXX axis U phase overcurrent.
Content:
A large direct current may flow into one phase out of three phases in the motors depending on
robot arm posture. If the state continues, electric lines may be burned out even though the motor
overload does not occur.
Servo board
Motor current
Servo Servo
Abnormal FPGA
CPU
Current
feedback
Continuous
rating current
Time
Current
Overload curve detection
circuit U,V,W earth Each
IPM
motor
Robot main body

Power block
Main cause:
The period during which the robot maintains the robot arm posture with servo ON is too long.
Countermeasure:
1. Modify the teaching so that the load on the axis where the error occurred decreases. (Avoid a
teaching that causes large load, such as one applied by maintaining the arm posture horizontally
holding a workpiece.)
2. If the posture maintaining period becomes long, execute servo OFF or enable auto servo OFF
function.
3-187
Error code : E1360

Error message : JtXX axis V phase overcurrent.
Content:
A large direct current may flow into one phase out of three phases in the motors depending on the
Servo board
Motor current
Servo Servo
Abnormal CPU FPGA
Current
feedback
Continuous
rating current
Time
Current
detection
Overload curve circuit U,V,W earth
IPM Each
motor
Robot main body

Power block
Main cause:
Countermeasure:
function.
3-188
Error code : E1361

Error message : JtXX axis W phase overcurrent.
Content:
A large direct current may flow into one phase out of three phases in the motors depending on the
Servo board
Motor current
Servo Servo
Abnormal CPU FPGA
Current
feedback
Continuous
rating current
Time
Current
detection
Overload curve circuit U,V,W earth
IPM Each
motor
Robot main body

Power block
Main cause:
Countermeasure:
function.
3-189
Error code : E1362

Error message : [Servo boardXX]Speed of tool center point exceeded safety speed.
Content:
The servo software detected that the tool point speed exceeded the safety speed (250 mm/s)
during operation in teach mode or in check mode.
Main cause:
1. The tool point speed exceeded the safety speed due to speed overshoot caused by excessive
acceleration/deceleration.
2. The tool point speed error was detected prior to each axis speed error (E1123) or together with
E1123.
Countermeasure:
1. For each axis speed error, refer to countermeasure for E1123.
2. Execute error reset.
3. If the same error occurs, lessen manual speed setting. Or modify the data to smaller value in
speed in Aux. <401 Teach/Check Speed>.
4. When operating with peripheral equipment cooperatively such as conveyor synchronization
option, decrease the speed for the peripheral equipment.
3-190
Error code : E1363

Error message : [Servo boardXX]Speed of flange center point exceeded safety speed.
Content:
The servo software detected that the flange center speed exceeded the safety speed (250 mm/s)
Main cause:
1. The flange center speed exceeded the safety speed due to speed overshoot caused by excessive
E1123.
Countermeasure:
3-191
Error code : E1366

Error message : Watchdog error in NoXX ANYBUS interface board.
Content:
The bus access from the main CPU board to ANYBUS interface was not made for a certain
period of time (250 ms) or more.
Main cause:
2. Failure of the ANYBUS interface board.
Countermeasure:
3. Replace the ANYBUS interface board.
3-192
Error code : E1377

Error message : [Main CPU board]Speed of tool center point exceeded safety speed.
Content:
The AS software detected that the tool point speed exceeded the safety speed (250 mm/s) during
operation in teach mode or in check mode.
Main cause:
1. The tool point speed exceeded the safety speed due to speed overshoot caused by excessive
E1123.
Countermeasure:
3-193
Error code : E1378

Error message : [Main CPU board]Speed of flange center point exceeded safety speed.
Content:
The AS software detected that the flange center speed exceeded the safety speed (250 mm/s)
Main cause:
1. The flange center speed exceeded the safety speed due to speed overshoot caused by excessive
E1123.
Countermeasure:
3-194
Error code : E1379

Error message : [Main CPU board]Deviation error of JtXX.
Content:
software exceeded a rated value. This is detected by the AS software. The rated value
differs depending on robot models, axes, etc.
Main cause:
(1) Robot arm came in contact with the jig, etc.
(2) Cables, etc. were caught by the robot arm.
(3) The reducer, gear, bearing, etc. are damaged.
performed.)
(4) Failure of the MC unit/power unit. (E1x/E2x/E3x/E4x/E9x)
(5) Disconnection between the servo board (X503, X504, X505) and MC control board/power
unit control board (X304).
(6) Disconnection, etc. in the PN voltage wiring between the MC power board/power unit
power board (X352, X353) and servo amp. unit.
3. A sudden change motion occurred.
3-195
Countermeasure:
1. When the robot arm interfered with something, move it away from the interference in teach
mode. Then, check for failures in the drive parts, reducers, etc., and for positioning deviation
caused by arm deformation.
2. When parts (reducers, etc.) are damaged, check and replace them if necessary.
4. When an electrical factor causes the error, check the harness, servo amp. unit (servo amp.
section), MC unit (power supply unit)/ power unit, motor, etc., and replace them if necessary.
5. If there are sudden changes in robot motion, modify the teach data.
3-196
Error code : E1382

Error message : [Servo board XX] valve, sensor I/F board missing.
Content:
The built-in valve/sensor interface board (1UU board) for RS03 robot cannot be used. This
built-in valve/sensor interface board is used in RS03 robot only.
Main cause:
1. The built-in valve/sensor interface board (1UU board) is not installed, although [User Sensor
Input]or [Built-in Valve Output] is set to [Enable] in Aux.0610 Input/Output Signals in Robot
Arm.
2. Failure of the 1UU board.
3. The 1UU board with incorrect part number is used. (The board without JP1/JP2 installed
cannot be used.)
Countermeasure:
1. Check if the built-in valve/sensor interface board (1UU board) is installed. When using robot
other than RS03, set [User Sensor Input] and [Built-in Valve Output] to [Disable] in Aux. 0610
Input/Output Signals in Robot Arm.
2. Replace the built-in valve/sensor interface board (1UU board) if the error occurs even when it
is installed.
3. Replace the 1UU board with the correct one.
3-197
Error code : E1392

Error message : Servo software does not support deviation alarm function.
Content:
Deviation alarm function (optional) is enabled, however, servo software does not support it.
Main cause:
Servo software version is not appropriate.
Countermeasure:
1. Disable the deviation alarm function if the function is not used.
2. Replace the servo software with a new one whose version is SVE_080000019 or subsequent
versions.
3-198
Error code : E1409

Error message : [MCXX]Error of gate power output in MC control board[Diagnostic
pulse](Servo board XX)(CodeXX)
Content:
The diagnosis pulse error was detected at the IPM 20 V power supply output section on the power
unit control board (1VH).
Main cause:
Countermeasure:
3-199
Error code : E1411

Error message : [MCXX]Error of gate power output in MC control board[mismatch between
output and feedback](Servo board XX)(CodeXX)
Content:
The discrepancy between the output condition and the feedback was detected at the IPM 20 V
power supply output section on the power unit control board (1VH).
Main cause:
4. Abnormality in the 20 V system in the power block.
Countermeasure:
3. Replace the power block.
3-200
Error code : E1412

Error message : [MCXX]Error of brake power output in MC control board[Diagnostic
Content:
The diagnosis pulse error was detected at the brake power supply output section on the power unit
control board (1VH).
Main cause:
2. Abnormality in the motor brake power supply output system from the power unit.
Countermeasure:
2. Check for any abnormality (short-circuit, disconnection, etc.) in the motor brake power supply
output system from the power unit.
3-201
Error code : E1414

Error message : [MCXX]Brake release switch was pushed during motor power ON, or error
of break power output(Servo board XX)(CodeXX)
Content:
The discrepancy error between the output condition and the feedback was detected at the gate
power supply output section on the power unit control board (1VH).
Main cause:
1. Brake release switch was pressed while the motor power was ON.
3. Abnormality in the wiring of X320 connector (brake 24 V power supply system) (unconnected
connector, disconnection, etc.) among the mother board (X215), whole surface of the power
unit (X325) and the power unit control board.
4. Failure of the mother board (1VZ).
5. Abnormality in the motor brake 24 V power supply output system from the power unit.
Countermeasure:
1. Check if the brake release switch is not pressed while the motor power is ON.
3. Check the wiring from X315 to X320.
5. Check for any abnormality (short-circuit, disconnection, etc.) in the motor brake power supply
output system from the power unit.
3-202
Error code : E1415

Error message : [MCXX]Error of motor ON output in MC control board[Diagnostic
Content:
The diagnosis pulse error was detected at the motor ON output section on the power unit control
board (1VH).
Main cause:
2. Abnormality in the motor ON output system (X313 connector section) from the power unit.
(*Jumper line is connected between A1 and B1 as a default.)
Countermeasure:
2. Check for any abnormality (short-circuit, disconnection, etc.) in the motor ON output system
(X313 connector section) from the power unit.
3-203
Error code : E1416

Error message : [MCXX]Error of motor ON output in MC control board[mismatch between
outputs](Servo board XX)(CodeXX)
Content:
An abnormality was detected at the motor ON output section on the power unit control board
(1VH).
Main cause:
Countermeasure:
3-204
Error code : E1417

Error message : [MCXX]Error of motor ON output in MC control board[mismatch between
Content:
The discrepancy error between the output condition and the feedback was detected on the motor
ON output section on the power unit control board (1VH).
Main cause:
2. Abnormality in the wiring of X320 connector (brake 24 V power supply system) (unconnected
3. Failure of the mother board (1VZ).
4. Abnormality in the motor ON output system (X313 connector section) from the power unit.
(*Jumper line is connected between A1 and B1 as a default.)
Countermeasure:
2. Check the wiring to the X320.
4. Check for any abnormality (short-circuit, disconnection, etc.) in the motor ON output system
(X313 connector section) form the power unit.
3-205
Error code : E1418

Error message : [MCXX]Error of MC shutoff output in MC control board[Diagnostic
Content:
An abnormality was found in the power unit control board (1VH).
Main cause:
Countermeasure:
3-206
Error code : E1419

Error message : [MCXX]Error of MC shutoff output in MC control board[mismatch between
Content:
Main cause:
Countermeasure:
3-207
Error code : E1420

Error message : [MCXX]Error of MC shutoff output in MC control board[mismatch between
Content:
Main cause:
Countermeasure:
3-208
Error code : E1421

Error message : [MCXX]Mismatch in safety circuit inputs (Servo board XX)(CodeXX)
Content:
The power unit control board (1VH) detects this error when the discrepancy arises for 10 seconds
or more on the safety circuits of the controller.
Main cause:
1. Discrepancy between first and second circuits.
Countermeasure:
1. Take countermeasures following the error contents if a discrepancy error of other safety circuit
has arisen before this error (example: D1518 Mismatch in the Emer. Stop condition on safety
circuit., etc.).
Reference:
[ NOTE ]
2. Error reset is possible only when the safety circuits are OFF state
(open state) in both first and second circuits. When they are ON,
error reset cannot be executed.
3-209
Error code : E1422

Error message : [MCXX]Short circuit in safety circuit inputs or 24V power drop (Servo board
XX) (CodeXX)
Content:
The voltage condition of the safety circuit monitored by the power unit control board (1VH) was
abnormal.
Main cause:
1. The short-circuit between first and second circuits, the short-circuit to the different power
supply, etc. occurs on the safety circuit, and the voltage of the safety circuit became in
abnormal state.
3. Decline of 24 V (X304 connector, voltage between A1 and A2) to the power unit control
board.
Countermeasure:
1. Check if any abnormality is observed in the safety circuit, referring to the safety circuit monitor
function, etc.
3. Check if 24 V is supplied to the power unit control board.
3-210
Error code : E1423

Error message : [MCXX]MC control board error[Diagnostic pulse of safety circuit
input](Servo board XX)
Content:
An abnormality was observed in the condition of safety circuit terminal monitored by the power
unit control board (1VH).
Main cause:
Countermeasure:
3-211
Error code : E1424

Error message : [MCXX]Mismatch in MC shutoff inputs (Servo board XX) (CodeXX)
Content:
Main cause:
Countermeasure:
3-212
Error code : E1425

Error message : [MCXX]Short circuit in MC shutoff inputs or 12V power drop (Servo board
XX) (CodeXX)
Content:
Main cause:
Countermeasure:
3-213
Error code : E1426

Error message : [MCXX]MC control board error[Diagnostic pulse of MC shutoff input](Servo
board XX)(CodeXX)
Content:
Main cause:
Countermeasure:
3-214
Error code : E1427

Error message : [MCXX]Relay connected to motor ON output is welded or error of weld
diagnostic circuit(Servo board XX)(CodeXX)
Content:
The OFF condition of external relay connected to X313 connector on the power unit control
board (1VH) could not be detected while the motor power was OFF.
Main cause:
1. Unconnected X313 jumper (between A1 and B1) connector. Or, welding of the relay
connected to X313.
2 Abnormality in the wiring of X320 connector (brake 24 V power supply system) (unconnected
Countermeasure:
1. Check if there is a connection between A1 and B1 of the X313 connector.
2. Check the wiring from X215 to X320.
3-215
Error code : E1428

Error message : [MCXX]MC connected to MC shutoff output is welded or error of weld
Content:
Main cause:
Countermeasure:
3-216
Error code : E1429

Error message : [MCXX]Failure of MC in MC unit (Servo board XX)(CodeXX)
Content:
Main cause:
Countermeasure:
3-217
Error code : E1430

Error message : [MCXX]Error of PFC board(Servo board XX)
Content:
An abnormality such as over current, abnormal motion of switching element and decline of
controller power was detected on the PFC boards (1VF/1WF).
Main cause:
1. Failure of the PFC boards.
2. Abnormality in the connector connected to the PFC boards or power unit control board and
wiring.
3. Abnormality in AC200 V line to DC20 V power in the power unit (disconnection, etc.).
Countermeasure:
1. Check for any abnormality such as disconnection in the wiring connected to the PFC boards
(X392, X393, X394) and the wiring connected to the power unit control board (X306).
2. Check for any abnormality such as disconnection is observed in the AC200 V system in the
power unit.
3-218
Error code : E1431

Error message : [MCXX]Voltage drop of power for power module in MC power board(Servo
board XX)
Content:
The power decline of 6.9 V was detected in the power unit power board (1VJ).
Main cause:
2. Disconnection of the signal line between the power unit power board and the power unit
control board.
Countermeasure:
1. Check for any abnormality such as disconnection in the wiring between the power unit power
board in the power unit (X362) and the power unit control board (X306).
3-219
Error code : E1432

Error message : [MCXX]Communication error for PN voltage sensor(Servo board XX)
Content:
The power unit control board (1VH) detected an abnormality in communication with PN voltage
sensor in the power unit power board (1VJ).
Main cause:
2. Disconnection of signal line between the power unit power board and the power unit control
board.
Countermeasure:
board in the power unit (X362) and the power unit control board (X306).
3-220
Error code : E1433

Error message : [MCXX]Mismatch between software setting and Off-delay DIP-SW setting
on MC control board (Servo board XX)
Content:
The AS software detected the setting error of DIP switches (SW1,2) on the power unit control
board (1VH).
Main cause:
1. Abnormality in the settings of DIP switches (SW1,2) on the power unit control board.
Countermeasure:
1. Make all the settings of SW1 and SW2 on the power unit control board to OFF.
3-221
Error code : E1434

Error message : [MCXX]MC power board is wrong(Servo board XX)
Content:
The ID of the power unit power board (1VJ) differs.
Main cause:
1. Wrong type of the power unit power board or failure.
2. Failure of the PFC control boards.
3. Disconnection of the signal line between the power unit power board or the PFC control boards
and the power unit control board.
Countermeasure:
board inside the power unit (X362) or the PFC control board (X394) and the power unit
control board (X306).
3-222
Error code : E1436

Error message : [MCXX]P-N low voltage.(Servo board XX)(CodeXX)
Content:
This is the error detected by the power unit control board (1VH) based on the value of PN voltage
sensor on the power unit power board. The motor power voltage (P-N voltage) is at the rated
value (DC150 V) or less when the motor power is turned ON or while it is ON.
[ NOTE ]
Beware when low voltage occurs, the arm will fall until the error is detected
because the motor power is not supplied during servoing. As a result, other
errors such as abnormal speed, abnormal deviation, etc. might be detected.
Main cause:
1. Disconnection of harness in the power unit, improper connection.
3. Failure of the PFC board.
5. Disconnection or short of harness between the power unit power board (X352, X353) and the
power block board. Or, failure of the PN capacitor.
Countermeasure:
2. Check for any abnormality in the harness between the power unit power board (X352, X353)
and the power block board. Or, replace the PN capacitor.
3. Replace the servo amplifier unit.
3-223
Error code : E1437

Error message : [MCXX]Mismatch in state of ind, shutoff contacts of safety
circuits.(SrvB'dXX)(CodeXX)
Content:
Contact conditions for individual power cutting off connected to X301 of the power unit control
board (1VH) differ between first and second systems.
Main cause:
1. Wrong wiring connected to the X301 connector of the power unit control board (e.g. connected
only in the first system), or failure of the contact points.
Countermeasure:
1. Check if the wiring to the X301 is appropriate or the connected contact point has no problem.
Reference:
[ NOTE ]
2. Error reset is possible only when the safety circuits are OFF state
(open state) in both first and second circuits. When they are ON,
error reset cannot be executed.
3-224
Error code : E1438

Error message : [MCXX] PFC board does not working.(Servo board XX)(PN voltage =
XXXV)
Content:
This is the error detected when the PFC boards are mounted. PN voltage was monitored at the
time of motor power ON and the PN voltage in servoing was 345 V or less.
Main cause:
1. Failure of the PFC boards.
4. Abnormality in the connector and wiring connected to the PFC boards or the power unit
control board.
5. Abnormality in the AC primary power supply voltage.
Countermeasure:
1. Check for any abnormality such as disconnection in the wiring connected to the PFC boards
(X392, X393, X394) and the wiring of the power unit control board (X306).
4. Confirm that the AC primary power source voltage is within the specification of the controller.
3-225
Error code : E4074

Error message : [Servo boardXX]No response from MCXX.(Code:XX)
Content:
This error occurs when no response is received from the MC unit/power unit or power supply
unit.
Main cause:
1. Disconnection or improper connection in the harness between the MC control board/power unit
control board (X304) and servo board (X503, X504, X505).
Countermeasure:
1. Check the harness between the MC unit/power unit and servo board. (E1x/E2x/E3x/E4x/E9x)
Check the harness between the power supply unit and servo board. (E7x)
3-226
Error code : E4075

Error message : [Servo boardXX]Error in communication with MCXX.(Code:XX)
Content:
An abnormality is detected on the servo board side in the communication between the servo
board and MC control board (1TQ/1TV) or power unit control board (1VH).
Main cause:
3. Failure of the wiring between the servo board and MC control board/power unit control board.
Countermeasure:
1. Check if the error is resolved by executing error reset.
4. Check the wiring between servo board (X503 for MC unit or power unit 1, X504 for MC unit
or power unit 2, X505 for MC unit or power unit 3) and MC control board/power unit control
board (X304).
3-227
Error code : E4076

Error message : [MCXX]Servo boardXX communication error.(Code:XX)
Content:
Communication between the servo board and MC control board (1TQ/1TV) or power unit control
board (1VH) is not performed properly.
Main cause:
2. Failure of the MC control board or the power unit control board.
3. Disconnection or improper connection in the harness between the servo board and MC control
board or the power unit control board.
Countermeasure:
1. Check the connection between the servo board and MC control board or the power unit control
board.
3-228
Error code : E4077

Error message : [Servo boardXX]Error in communication with main CPU board.(Code:XX)
Content:
Data communication between the main CPU board and servo board failed three times or more in
a row.
Main cause:
<Code>
0,1,8,9,A: Data processing is abnormal in the servo board due to a failure of the servo board.
2 : Communication data is not received from the main CPU board due to disconnection of
the communication line.
3 : Bit error in the communication data from the main CPU board due to improper
connection of the communication line.
4,5,6,7 : Abnormal data due to a failure of the main CPU board or servo board.
Countermeasure:
Execute error reset. If the error cannot be solved after executing error reset, the cause is possibly
in the servo board, main CPU board, or communication line between boards. In this case, report
the error code to KHI.
<Code>
0,1,8,9,A: Replace the servo board.
2 : Check for unconnected connector or disconnection in the communication line
between the main CPU board and servo board.
3 : Check if the communication line between the main CPU board and servo board is
connected properly.
4,5,6,7 : Replace the main CPU board or servo board.
3-229
Error code : E4078

Error message : [Servo boardXX]Error in command communication with the main CPU
board.(Code:XX)
Content:
In command communication between the main CPU board and servo board, the number that the
same data is sent from the servo board became five times or more.
Main cause:
<Code>
0 : The number of data resendings is abnormal due to no response from the main CPU board.
The cause may be in the abnormal communication check that is not performed constantly
between the main CPU board and servo board.
1 : The number of data resendings is abnormal in the main CPU board because the data that
sent from the servo board is not read normally. The cause may be a failure of the servo
board.
Countermeasure:
2. If the error occurs frequently, replace the main CPU board or servo board.
3-230
Error code : E6506

Error message : Torch interference.
Content:
The limit switch built in the torch holder of the arc welding specification robot detected torch
interference.
Main cause:
1. The torch interfered with an object, and the limit switch in the torch bracket functioned.
2. Disconnection in the harness of the limit switch.
Countermeasure:
1. After error reset, move the robot in teach mode and return the torch to its original state.
2. Check the harness for the limit switch, and replace it if necessary.
After error reset, the robot can be moved in teach mode. In repeat mode, the torch cannot be
returned to its original state.
3-231
Error code : W1012

Error message : Servo parameter changed. Turn OFF & ON the control power.
Content:
In the following cases, turning controller power OFF then ON is required for writing new data in
the servo board:
- loading of robot/system data that enables use of optional axes (Jt7+)
- setting of the servo parameter data or model for external axes
- changing the number of corresponding axes.
Countermeasure:
Turn the controller power OFF, and then ON.
[ NOTE ]
When the model is changed, the servo group software must
also be replaced with the correct one so that normal
operations can be supported.
3-232
Error code : W1013

Error message : Encoder battery low voltage. [Servo(XX)]
Content:
The battery voltage which is built-in the base part of the robot arm and is connected to the
encoder battery backup board, etc. has decreased to +3.3 V or less. Or, the encoder battery
alarm harness has been disconnected. This error is only detected when controller power and
motor power are turned ON.
Encoder
Encoder
Servo Encoder
CPU I/F Battery alarm signal
Power supply
circuit/
Battery voltage Battery
Encoder power detect. circuit
Servo board supply +12 V
Main cause:
1. Deterioration of the battery.
2. Failure of the encoder battery backup board.
3. Battery consumption increased due to a failure of the encoder, or a short-circuit in the harness
between the encoder battery backup board and encoder, thereby the battery discharged.
4. Battery alarm signal line from the encoder battery backup board is disconnected.
5. Failure of the servo board, etc.
3-233
Countermeasure:
1. The internal data of the encoder may not be maintained when this error occurs. Therefore,
confirm without fail that the angle values are at 0 after matching all axes to their scribe marks
(mechanical zero point) in teach mode. If angle values are not 0, do not fail to execute
zeroing.
！ WARNING
1. After the error reset, automatic operation is possible. However,

beware there is a high possibility of causing malposition of the robot
as the current value goes out of order. Do not fail to confirm the
above-mentioned zeroing and the playback of steps in check mode.
2. When this error occurs, beware that the internal data of the encoder
may not be maintained if turning OFF the controller power.
2. When the battery for the encoder backup decreases to +3.3 V or less, replace the battery
promptly. Replace the encoder batteries used in all axes, including conveyor, at the same
time.
3. Check for disconnection or short-circuit in each harness.
4. Replace the encoder, servo board, or encoder battery backup board.
3-234
Error code : W1017

Error message : Encoder battery low voltage.[External axis(XX)]
Content:
The battery voltage which is built-in the encoder relay box for external axis, etc. and is connected
to the encoder battery backup board, etc. has decreased to +3.3 V or less. Or, the encoder
battery alarm harness has been disconnected. Take note that this error is only detected when
controller power and motor power are turned ON.
Encoder
Encoder
Servo Encoder
CPU I/F Battery alarm signal
Power supply
circuit/
Battery voltage Battery
Encoder power detect. circuit
Servo board supply +12 V
Controller Encoder box for external axis
Main cause:
1. Deterioration of the battery.
2. Failure of the encoder battery backup board.
3. Battery consumption increased due to a failure of the encoder, or a short-circuit in the harness
between the encoder battery backup board and encoder, thereby discharging the battery.
4. Battery alarm signal line from the encoder battery backup board is disconnected.
5. Failure of the servo board, etc.
3-235
Countermeasure:
1. The internal data of the encoder may not be maintained when this error occurs. Therefore,
confirm without fail that the angle values are at 0 after matching all axes to the mechanical zero
points in teach mode. If angle values are not 0, do not fail to execute zeroing.
！ WARNING
1. After the error reset, automatic operation is possible. However,

beware there is a high possibility of causing malposition of the robot
as the current value goes out of order. Do not fail to confirm the
above-mentioned zeroing and the playback of steps in check mode.
2. When this error occurs, beware that the internal data of the encoder
may not be maintained if turning OFF the controller power.
2. When the battery for the encoder backup decreases to +3.3 V or less, replace the battery
promptly. Replace the encoder batteries used in all axes, including conveyor, at the same
time.
3. Check for disconnection or short-circuit of each harness.
4. Replace the encoder, encoder battery backup board.
3-236
Error code : W1034

Error message : Encoder power voltage is low. JtXX
Content:
The battery voltage of encoder has decreased.
Main cause:
It has reached the encoder battery replacement time.
Countermeasure:
1. Replace the encoder battery.
robot model, controller model, machine number, AS/servo software versions, operation at the
time of error occurrence, the contents of program lists, equipped options, etc.
3-237
Error code : W1053

Error message : (FANXX-XX)Rotational speed of fan is below the limit. (ServoBoardXX)
Content:
Rotation speed of fan inside the controller has decreased.
Main cause:
1. Deterioration of the fan.
2. Disconnection or improper connection in the harness between the fan and MC control
board/power unit control board.
4. Abnormal brake power supply inside the MC unit/power unit.
5. Failure of the mother board. (E9x)
Countermeasure:
1. Check if the harness between the fan and MC control board/power unit control board. is
connected properly.
2. Replace the fan.
4. Replace the mother board. (E9x)
NOTE “XX-XX” of (FANXX-XX) in the error message stands for MC unit (power supply unit,
power unit) and fan numbers, and abnormal fan can be specified from these numbers.
As for the place where the fan of E1x/E2x/E3x/E4x is mounted, refer to drawings of
“Locations and numbers of fans” in 4.5.4. For the fan of E7x, refer to 4.11. For the
fan of E9x, refer to 4.17.
3-238
Error code : W1054

Error message : AVR reaches the expected lifetime soon.
Content:
The residual lifetime of the AVR has become short, which is predicted by the function that
detects temperature and residual life time of the AVR.
Main cause:
1. The residual lifetime of the AVR has become less than 1/8 of the expected lifetime.
2. Abnormality occurred in the power sequence board.
Countermeasure:
1. Replace the AVR.
3-239
Error code : W1056

Error message : [Main CPU board]CPU temperature exceeded the limit. (XX 1/1000 deg C)
Content:
In the main CPU board, CPU temperature has increased and reached the point that may damage
the CPU if it kept operating.
Main cause:
1. High ambient temperature.
2. Malfunction of the cooling fan.
Countermeasure:
1. Lower the ambient temperature.
2. Check the cooling devices such as cooling fan, etc.
3-240
Error code : W1072

Error message : Deviation of JtXX is too large.
Content:
software exceeded a limit of deviation error detection. This is detected by the servo software.
The detection limit value differs depending on robot models, axes, etc.
Main cause:
See (E1124) Deviation error of JtXX.
Countermeasure:
See (E1124) Deviation error of JtXX.
3-241
3-242
E Series Controller 4. Procedures for Replacement
4.0 PROCEDURES FOR REPLACEMENT
This chapter describes procedures for replacement of parts inside the controller: printed boards,
servo amplifiers, hardware including AVR, etc., and, units.
4.1 General Safety Precautions on Replacement ·················································4-3

4.2 Parts in Card Rack ···············································································4-6
4.2.1 1TA/1VA Boards (Main CPU Board) ·························································4-6
4.2.2 CF Card on 1TA/1VA Boards (Main CPU Board)···········································4-7
4.2.3 1TR Board (Power Sequence Board) ··························································4-9
4.2.4 1TW Board (IO Board) ··········································································4-9
4.2.5 AVR ······························································································ 4-10
4.3 Servo Amplifier Unit for 6 Axes Part (E1x/E2x/E3x/E4x/E9x Controller) ············ 4-12
4.3.1 Servo Amplifier Unit for 6 Axes ····························································· 4-12
4.3.2 1TB Board (Servo Board) ····································································· 4-14
4.3.3 Amplifier Unit for Single Axis ······························································· 4-16
4.4 MC Unit Part (E1x/E2x/E3x/E4x/E9x Controller) ········································ 4-17
4.4.1 MC Unit ························································································· 4-17
4.4.2 1TQ/1TV Boards (MC Control Board) ····················································· 4-19
4.5 Fans (E1x/E2x/E3x/E4x Controller)························································· 4-21
4.5.1 Fans for Card Rack············································································· 4-21
4.5.2 Fans for Servo Amp. Unit for 6 Axes························································ 4-21
4.5.3 Fan for Amp. Unit for Single Axis ··························································· 4-22
4.5.4 Fan inside MC Unit ············································································ 4-22
4.6 Batteries ························································································· 4-25
4.6.1 Coin Battery on 1TA/1VA Boards ··························································· 4-25
4.6.2 Battery on 1FG/1HG Boards ································································· 4-26
4.7 Fuses ····························································································· 4-27
4.7.1 Fuses on 1TR Board ··········································································· 4-27
4.8 Removing the Top Cover of Controller (E7x Controller)································· 4-28
4.9 Replacing the Power Supply Unit Part (E7x Controller) ································· 4-30
4.9.1 Power Supply Unit ············································································· 4-30
4.9.2 1UE Board (MC Power Board) ······························································ 4-31
4.9.3 1TQ/1TV Boards (MC Control Board) ····················································· 4-31
4.10 Replacing Servo Amplifier Section (E7x Controller) ····································· 4-32
4.10.1 1UZ Board (Power Block Board) ···························································· 4-32
4.10.2 1UY Board (Servo Relay Board) ···························································· 4-33
4.10.3 1TB Board (Servo Board) ····································································· 4-35
4.11 Replacing Fan (E7x Controller) ······························································ 4-36
4-1
4.11.1 Fans for Card Rack············································································· 4-36

4.11.2 Fan at Servo Amplifier Section ······························································· 4-37
4.11.3 Fan on Controller Upper Side ································································ 4-37
4.11.4 Heat Exchange Fan ············································································ 4-39
4.12 Replacing Mother Board ······································································ 4-41
4.12.1 E1x/E2x/E3x/E4x Controller ································································· 4-41
4.12.2 E7x Controller ·················································································· 4-43
4.12.3 E9x Controller ·················································································· 4-44
4.13 Replacing Regenerative Resistor ····························································· 4-45
4.13.1 E1x/E2x/E3x/E4x Controller ································································· 4-45
4.13.2 E7x Controller ·················································································· 4-46
4.13.3 E9x Controller ·················································································· 4-47
4.14 Replacing Additional Regenerative Resistor Unit ········································· 4-48
4.15 Replacing Magnetic Contactor (K1, K2) (E7x Controller) ······························· 4-49
4.16 Replacing Power Unit Section (E9x Controller) ··········································· 4-50
4.16.1 Replacing Power Unit ········································································· 4-50
4.16.2 Replacing 1VH Board (Power Unit Control Board) ······································ 4-51
4.17 Replacing Fans (E9x Controller) ····························································· 4-53
4.17.1 Replacing Fan of Card Rack Section ························································ 4-53
4.17.2 Replacing Fan of Power Unit Section ······················································· 4-54
4.17.3 Replacing Power Unit Section (Outside Air Side) ········································· 4-55
4.17.4 Replacing Servo Amplifier Fin (Outside Air Side) ········································ 4-56
4-2
4.1 GENERAL SAFETY PRECAUTIONS ON REPLACEMENT
This section describes the precautions to be taken when replacing parts due to trouble, etc.
This information is presented here for use as general precautions. In addition to these, adhere
the safety measures required for each replacement procedure.
！ CAUTION
Parts replacement duties are limited to personnel who have

completed special training and education for the installed
robot or for an equivalent model.
1. Read and understand thoroughly all manuals, specifications and related documents provided
by Kawasaki before operation.
2. Before entering the safety fence (safeguarded space), make sure all necessary safety
measures are prepared and functioning well.
3. Before starting replacement work, shut OFF controller power up to the external power
switch. Display signs indicating clearly “POWER CUT-OFF IN PROGRESS” or
“REPLACEMENT IN PROGRESS”, and lock out/tag out the external power switch to
prevent personnel from accidentally turning ON the power.
4. Before starting replacement work, secure enough space around the robot so there is no
danger of interference with peripheral systems. Shut down the peripheral systems
completely so they will not make any sudden motion.
5. Disable automatic operation functions when entering the safety fence. If the robot makes
any abnormal motion, press EMERGENCY STOP switch immediately, and evacuate on a
planned path of retreat.
6. In addition to the EMERGENCY STOP switch operated by the technician, install another
EMERGENCY STOP switch for the supervisor outside the safety fence, in a place where the
robot’s entire motion range can be monitored and the switch is accessible and easy for the
supervisor to press. If the robot moves abnormally during observation of the replacement,
press the EMERGENCY STOP switch immediately. After an emergency stop, reset and
restart robot operations from outside the fence. Moreover, monitoring duties are limited to
personnel who are trained and qualified.
4-3
7. Use only Kawasaki approved parts during replacement.
8. When replacing printed boards, do not fail to turn OFF controller power. To replace servo
amplifier, MC unit/power unit, or AVR, wait at least seven minutes after controller power
OFF before disconnecting connectors. then confirm that output voltage from the DC power
supply and the P-N voltage are 0 V.
9. During operation, both technician and supervisor must always watch out for abnormal
motion and possible pinch points in and around the robot.
10. Semiconductors are often used in printed boards. Note that these semiconductors are
sensitive to static electricity, be sure to discharge any electrostatic on the body before
handling the printed boards.
11. Directly touching the parts containing semiconductors may cause electrostatic discharge
damage. When handling printed boards, do not touch the semiconductors directly but hold
the periphery of the printed boards. If parts must be touched directly, confirm that
electrostatic on the body has been discharged.
12. Putting printed boards directly onto the controller, etc. may cause electrostatic discharge
damage. Be sure to put them on an electrostatic-proof mat board or sheet, or enclose
printed boards in an electrostatic-proof bag.
13. Avoid removing printed boards at controller power ON, or turning the controller power ON
without any printed boards mounted.
14. Take a record of all data set currently on controller, printed boards, etc. so the system can be
restored to its normal operating condition.
15. To prevent position deviation of the robot, take a record of the robot’s pose before starting the
replacement procedure.
16. Be sure to connect connectors and cables correctly. When using connectors equipped with
locks, do not fail to lock after insertion. Do not touch connector pins.
17. Immediately after robot motion stop, the heat sink, the regenerative resistor, etc. may be very
hot. Do not touch the servo amplifier unit directly, there is a danger of burn.
4-4
18. Printed boards and servo amplifiers are designed differently for each robot model. Be sure
to replace the correct type.
19. When air or water is supplied, shut OFF the supply source and release any remaining
pressure from the lines before starting any replacement procedure.
20. Use lighting of 1500 lux or more to avoid mistakes when reading data or replacing defective
parts.
21. After completion of replacement, confirm that the controller functions with no abnormality.
22. When mounting a part by screws, tighten them to the torque shown in the table below unless
specified in the manual.
Nominal diameter Tightening torque (N·m)

M2.6 0.5
M3 0.8
M4 1.5
M5 2.5
4-5
4.2 PARTS IN CARD RACK
In the card rack of E1x/E2x/E3x/E4x controller, AVR, 1TA/1VA board (main CPU board), 1TR
board (power sequence board), and 1TW board (IO board, option) are housed from the left as
shown left below and, in the card rack of E9x controller, as shown right below. In the card rack
of E7x controller, AVR and the three boards above are housed in the same order from the bottom
as shown in center below.
This section describes the replacement procedure for the parts inside the card rack.
1TR board
1TA/1VA board 1TR board 1VA board
1TW board (option)
1TW board (option)
1TW board (option)
1TR board
AVR AVR
AVR 1TA/1VA board
Card rack front Card rack front Card rack front

(E2x/E3x/E4x controller) (E7x controller) (E9x controller)
4.2.1 1TA/1VA BOARDS (MAIN CPU BOARD)
1. This is the main CPU board used for storing taught pose data, user program data, etc. in the
CF card. Before replacing the board, save all data to storage media such as USB memory,
etc. just in case. For more details about data saving procedure, refer to the Operation
Manual, a separate volume.
2. After completion of data saving, turn OFF the controller power.
3. Update the OS driver when replacing 1TA board with 1VA board. In other cases, go to 6.
4-6
4. Insert the USB flash drive in which the update data of the OS driver is stored into the USB
port of the accessary panel, turn ON the DIPSW 3, 5 and 8 of 1TA board, and turn ON the
controller power.
5. Update is executed automatically. Turn OFF the controller power after the completion of
the update.
6. Disconnect all the connectors with cables connected to the board.
7. Loosen the screws at both ends of ejectors of the 1TA/1VA board, and pull out the board from
the card rack by holding the ejectors at both ends of the board.
8. When replacing only the 1TA/1VA board, demount the CF card. (Demount the CF card
without touching any other electronic parts on the 1TA/1VA board.)
9. Confirm that settings for DIP SW on the new 1TA/1VA board are the same as settings before
board replacement. For the CF card demounted in step 5, insert it to the new 1TA/1VA
board.
10. Remount the new 1TA/1VA board into the card rack and set it in the mother board securely.
11. Tighten the screws at both ends of ejectors of the 1TA/1VA board.
12. Reconnect all the connectors with cables.
4.2.2 CF CARD ON 1TA/1VA BOARDS (MAIN CPU BOARD)
1. The CF card on the 1TA/1VA board stores each software and taught program data, etc.
Before replacing the CF card, be sure to save all data to storage media such as USB memory,
etc. For more details about data saving procedures, refer to the Operation Manual.
2. After completion of data saving, turn OFF the controller power.
3. Dismount the 1TA/1VA board from the card rack by following the procedure described in
4.2.1 1TA1VA board.
4. Remove the CF card from the 1TA/1VA board without touching any other electronic parts on
the 1TA/1VA board.
4-7
5. Insert a new CF card in the right direction into the 1TA/1VA board.
6. Remount the 1TA/1VA board into the card rack and set it in the mother board securely.
7. Reconnect all the harnesses, then tighten the screws at both ends of the 1TA/1VA board.
8. Insert a USB memory containing new software into the USB port in the accessory panel, and
supply controller power by switching the DIP SW 3, 5, 8 on the 1TA/1VA board to ON.
9. Software download automatically starts. When the download is complete, cut OFF the
controller power, then switch the DIP SW 8 on the 1TA/1VA board to ON.
10. Supply controller power and when the confirmation query for initialization is displayed, select
<999: Initialization of all data>.
11. When the confirmation query for initialization is displayed again, select <1: YES>.
12. After completion of initialization, load all data saved before board replacement into the
1TA/1VA board. For more details about data loading procedure, refer to the Operation
Manual.
14. Switch the DIP SW 8 on the 1TA/1VA board to OFF.
Ejector Ejector
Screw Screw
DIP SW
CF card
Outline view of 1TA/1VA board
4-8
4.2.3 1TR BOARD (POWER SEQUENCE BOARD)
2. Loosen the screws at both ends of the 1TR board, and pull out the 1TR board from the card
rack by holding the ejectors at both ends of the board. If cables are connected to the front
connector, disconnect them first.
3. Confirm that settings for SW2, JP1 and JP2 on the new 1TR board are the same as settings
before board replacement. then, remount the new 1TR board to the card rack and set it in the
mother board securely.
4. Tighten the screws at both ends of the 1TR board. When cables are disconnected from the
front connector in step 2, reconnect them.
Ejector Ejector
Screw Screw
JP1
JP2 SW2
Outline view of 1TR board
4.2.4 1TW BOARD (IO BOARD)
2. Loosen the screws at the top and bottom of the 1TW board, and pull out the 1TW board from
the card rack by holding the ejectors at both ends of the board. If cables are connected to the
front connector, disconnect them first.
4-9
3. Confirm that settings for SW1 on the new 1TW board are the same as settings before board
replacement. Then, remount the new 1TW board to the card rack and set it in the mother
board securely.
4. Tighten the screws at the top and bottom of the 1TW board. When cables are disconnected
from the front connector in step 2, reconnect them.
4.2.5 AVR
2. Disconnect the connectors connected to the AVR.
3. Loosen the two screws fixing the AVR, and remove the AVR.
4. Insert a new AVR to the card rack, and tighten it with two screws securely.
5. Reconnect the connectors disconnected in step 2 and turn ON the controller power.
6. Confirm that the voltage between respective check pins on the 1TR board is within the range
shown in the table below.
If the voltage is out of

No. Color Standard Allowable range GND
allowable range
adjust the voltage with
TP1 Red +5.0 V +5.05 V - +5.15 V TP4 (black)
adjusting knob on the AVR.
adjust the voltage with
TP2 Yellow +3.3 V +3.25 V - +3.35 V TP4 (black)
adjusting knob on the AVR.
TP3 Orange +12.0 V +12.25 V - +12.75 V replace the AVR. TP4 (black)
TP5 White +24 V +23.9 V - +24.7 V replace the AVR. TP6 (brown)
4-10
7. If there is no abnormality in the controller after checking voltage, paint-lock each adjusting
knob of the AVR.
Screw
Connector
AVR
Voltage
adjusting
knob
Screw Screw
AVR
Screw Voltage adjusting
Connector
knob
Outline view of AVR Outline view of AVR

(E1x/E2x/E3x/E4x controller) (E7x controller)
+5 V adjust.
+3.3 V adjust.
Adjusting knob
(Enlarged view)
4-11
4.3 SERVO AMPLIFIER UNIT FOR 6 AXES PART (E1X/E2X/E3X/E4X/E9X

CONTROLLER)
This section describes the procedure for replacement of the servo amplifier unit mounted in the
controller. Since there are several kinds of servo amplifier unit for 6 axes depending on robot
models, be sure to use appropriate unit for the robot when replacing it.
！ DANGER
Do not touch any connector pins during replacement because

high voltage may be applied in the power block unit.
4.3.1 SERVO AMPLIFIER UNIT FOR 6 AXES
！ DANGER
Before starting replacement work, turn OFF the controller power,

wait at least seven minutes and confirm that PN voltage is 0 V.
！ CAUTION
Power block unit weighs approx. 10 kg. Be careful not to

incur back injury, etc. when removing the power block unit.
1. Disconnect all connectors connected to the servo amplifier unit. (Also disconnect connectors
connected to the servo board, and connectors X352, X358 in the right back of the MC unit/
power unit.)
2. Loosen the two upper screws fixing the servo amplifier unit to the controller until the unit can
become free from the controller. (These screws are not removed from the servo amplifier unit.)
3. Unscrew the ground line fixing screw at the upper left of the servo amplifier unit for 6 axes and
disconnect the line. (Be careful of the fall of the screw as it is removable.)
4. Unlock the two bottom levers fixing the servo amplifier unit to the controller. (Slide both levers
inward to unlock.)
5. Remove the servo amplifier unit by pulling it out sliding on the support platform. To be safe,
hold the handle on top the unit with one hand.
4-12
6. Place a new unit on the support platform, and set it to the controller by holding the handle on
top with one hand, then mount it by tightening the two upper screws and locking two bottom
levers securely. (Slide both levers outward to lock.) Fix the ground line with fixing screw at
the upper left of the unit too.
7. Reconnect all the connectors disconnected in step 1.

Servo amp. unit fixing screws (two at upper)
Ground line
fixing screw
Servo amp. unit fixing levers (two at bottom)
(e.g.: E2x controller)

4-13
4.3.2 1TB BOARD (SERVO BOARD)
This section describes the procedure for replacement of the 1TB board (servo board) mounted in
the servo amplifier unit for 6 axes.
1. Dismount the servo amp. unit for 6 axes from the controller by following the procedure shown
in 4.3.1, and place it on the horizontal table.
2. Uncover the servo amp. front cover (plastic) that is hooked at right, left and bottom of the unit.
Push here.
Push here.
1. Unhook the hooked
parts at right
and left.
2. Unhook the two

hooked parts to
remove the cover.
Servo amp. unit for 6 axes front Left side view
3. When replacing the 1TB board, take out it together with fixing plates that is connected with the
board. Unscrew 6 plate fixing screws shown in the figure below.*
NOTE* Do not remove only the 1TB board from the servo amplifier unit. Doing so applies
excessive load on the board and may damage it, causing bend, etc.
4. Pull out the plate with 1TB board and dismount it from the power block unit by holding the
handle hole at the bottom and the plate edge at the top of the plate. (1TB board is connected
with the power block unit via rear connectors.)
4-14
Screw
Plate edge
1TB board
Connector
Screw
Connector
Screw
Connector
1TB board
1TB board Power block
Screw Handle hole fixing plate
Right view
5. Unscrew the nine screws fixing the 1TB board and
Screw
its plate, and remove the 1TB board. (See the Screw
right figure.)
6. Fix the plate fixing the 1TB board removed in step

3 with six screws to the power block unit Screw
Screw
temporarily.
7. Mount a new 1TB board to the power block unit.

Position the plate and connect the six rear
connectors to the power block securely. (The Screw
Screw
connectors can be easily connected by pressing
the place where PUSH is printed on the 1TB
board.)
！ CAUTION
When connecting the 1TB board to the power block unit, keep
the 1TB board horizontal as much as possible. If the 1TB board
is tilted 5 or more, or is rotated, the connectors connected with
the power block unit may be damaged.
8. Fix the 1TB board with the nine screws unscrewed in step 5.
4-15
9. Fully tighten the six screws tightened temporarily in step 6, which fix the plate and power
block unit.
10. Re-cover the servo amp. front cover. (Hook from the bottom side to mount.)
11. Remount the servo amp. unit for 6 axes in accordance with the procedure of 4.3.1.
4.3.3 AMPLIFIER UNIT FOR SINGLE AXIS
There are several kinds of amplifier unit for single axis depending on robot models. Be sure to
use appropriate unit for the robot when replacing it.
！ DANGER

1. Disconnect all connectors connected to the amplifier unit.
2. Loosen the four screws (1 to 4 in figure below) fixing the amplifier unit to the controller by
supporting the unit* until the amplifier unit can become free from the controller. (These screws
are not removed from the amplifier unit.)
NOTE* The unit may fall if it is not supported.
3. Remove the amplifier unit.
4. Mount a new unit to the controller with the four screws loosened in step 2 securely.
5. Reconnect the connectors disconnected in step 1.
4-16
1 2
X566
X563 X564
X562 X565
X551
3 4
Amplifier unit for single axis
4.4 MC UNIT PART (E1X/E2X/E3X/E4X CONTROLLER)
This section describes the procedure for replacement of the MC unit which is a power supply unit
and the 1TQ/1TV boards (MC control boards) which are mounted in the MC unit.
4.4.1 MC UNIT
！ DANGER

1. Disconnect all connectors connected to the MC unit. Disconnection of jumper harness and
dummy connectors is not necessary.
2. Loosen the two bottom front screws fixing the MC unit to the controller (See figure below.),
then remove the MC unit from the controller by sliding forward then upward a little. (The MC
unit is hooked at the back.)
3. Mount a new MC unit to the controller in the reverse order of step 2 with the two screws
unscrewed in step 2 securely.
4-17
MC unit
Two screws (at bottom)
！ CAUTION
MC unit weighs approx. 7 kg. Be careful not to jam your

fingers when replacing the MC unit.
！ CAUTION
When replacing the MC unit of revision R00 or R01 of

P/N50632-1066 with the MC unit of revision after R02 having the
jumper harness connected to the X313 connector section (1TQ/1TV
board section), do not disconnect the jumper harness. (The harness
is not connected for the MC units of R00 and R01.) Error E1302
occurs at the motor power ON, if the harness is disconnected.
4-18
！ DANGER

1. Dismount the MC unit. Refer to 4.4.1 for the procedure.
2. Unscrew the two screws fixing the MC unit front cover and remove the cover, the 1TQ/1TV
boards can be seen. (1TQ board is the front board and 1TV board is the back board, and the
two boards are mounted as a pair.)
Screws
Front cover
Top view
1TQ board
1TV board
Right side view
3. Unscrew the four screws fixing the 1TV board (back board) to the MC unit.
4-19
4. Pull out the 1TQ/1TV boards and disconnect all connectors mounted on the back of the 1TV
board. Screws
Front view
1TV board
Right side view
1TQ board
5. Reconnect all connectors disconnected in step 4 to a new 1TQ/1TV boards, and fix the boards
to the MC unit with the four screws unscrewed in step 3. Be careful not to damage the wiring
at the time.
6. Remount the front cover removed in step 2 by fixing the two screws unscrewed in step 2.
7. Remount the MC unit to the controller. Refer to 4.4.1.
！ CAUTION
When replacing the 1TQ/1TV board (P/N: 50999-2941)where a jumper
harness is not connected to the X313 section with the 1TQ/1TV board
(P/N: 50999-0009) where a jumper harness is connected, do not
disconnect the X313 jumper harness. Disconnecting the jumper harness
causes the error 1302 at the motor power ON.
4-20
4.5 FANS (E1X/E2X/E3X/E4X CONTROLLER)
Fans are mounted in the card rack, on top of the servo amplifier unit for six axes and amplifier
unit for single axis, and in the MC unit. This section describes the procedure for replacement of
these fans.
！ CAUTION
Fans may not be clean depending on the environment. In

that case, prevent dust falling from the fan onto the boards of
the controller by placing a sheet, etc. under the fan during the
replacement work.
4.5.1 FANS FOR CARD RACK
1. Turn OFF the controller power, and wait until the fan stops.
2. Disconnect the two connectors on the plastic fan unit (two fans built-in) on top of the card rack.
then, pull the two handles to remove the fan unit.
3. Mount a new fan unit in the reverse order of step 2.
Connectors
Handles
4.5.2 FANS FOR SERVO AMP. UNIT FOR 6 AXES
The same parts are used here as the fan unit for card rack. the replacement procedure is also the
same. For the place where the fans are mounted, refer to the drawings shown in 4.5.4.
4-21
4.5.3 FAN FOR AMP. UNIT FOR SINGLE AXIS
Different parts are used here from the fan unit for card rack (single fan built-in), but the
replacement procedure is the same as the fan unit for card rack. For the place where the fan is
mounted, refer to the drawings shown in 4.5.4.
Connector
Handle
4.5.4 FAN INSIDE MC UNIT
2. Disconnect the “XFAN” connector on upper right of the MC unit front. Unscrew the two
screws on top of the MC unit (See figure below.) and dismount the fan unit.
Screws
Fan unit
XFAN
connector
Fan unit
MC unit front view Top view
3. Unscrew the four screws fixing the fan (harness set) and remove the fan.
Screws
Bottom view
4-22
4. Mount a new fan (harness set) to the plate with the four screws securely. Be sure to correctly
mount the fan in the same direction as the old fan.
5. Remount the fan unit with the two screws to top of the MC unit, and reconnect the connector
disconnected in step 2.
For warning of W1053, see the note below.
[ NOTE ]
In the E series controller, the rotation speed of the fan for the 1TQ board in the
MC unit is monitored. If the rotation speed decreases, a message such as
“(W1053) (FAN1-6) Rotational speed of fan is below the limit.” is displayed.
“FAN1-6” in the message stands for the number of fan and means “Fan number
6” of “MC unit 1”.
Locations and numbers of fans for each controller and additional regenerative resistor unit are
shown below.
1-1 1-2 1-1 1-2
1-3 1-3
1-4 1-4
1-5
1-5
1-6 1-6
E2x controller E3x controller
4-23
1-1 1-2
1-3
1-4
1-5
1-6
E4x controller
1-8
1-7
Additional regenerative resistor unit
4-24
4.6 BATTERIES
This section describes the replacement procedure for the battery provided to backup time, etc.
4.6.1 COIN BATTERY ON 1TA/1VA BOARDS
As backup power supply for RTC (Real Time Clock) and BIOS setting, the 1TA/1VA board is
equipped with a coin battery.
When on-board coin battery is removed, RTC and BIOS setting are initialized. Restore them by
following the procedure below.
1. Before replacing the coin battery, confirm that the new battery is one specified by KHI for 3 V
supply. (See 1.6 in installation and connection manual for model No.)
3. Pull out the 1TA/1VA board and remove the coin battery from its holder. For procedure for
pulling out the board, refer to 4.2.1.
4. After setting a new battery to the holder, put back the 1TA/1VA board to the original place.
5. When a sticker is put on the old battery, the initialization value in the BIOS setting is modified.
For the initialization value and modification procedure, contact Kawasaki.
6. Turn ON the controller power.
7. Set time referring to time setting in Operation Manual, etc.
Coin battery
1TA/1VA board
[ NOTE ]
1. In the 1TA/1VA board, user data is stored in the CF card. Thus,
user program is not deleted when the coin battery is replaced.
2. The coin battery has a life of approx. 10 years.
4-25
4.6.2 BATTERY ON 1FG/1HG BOARDS
1. Record the encoder value for all axes before replacing a battery.
2. Before replacing the battery, confirm that the new battery has +3.6 V or more voltage.
4. For the 1HG board, pull out the connector box located on the base of the robot main body.
For the 1FG board, dismount the plate that the battery is mounted.
5. Disconnect the battery connector (CN10 for 1FG, CN4 for 1HG), cut two tying bands fixing
the battery, and remove the battery.
6. Fix a new battery with two tying bands, and reconnect the connector disconnected in step 4.
7. For the 1HG board, set the connector box to the original place. For the 1FG board, set the
plate that the battery is mounted to the original place.
8. Mount the cover to the robot arm. Turn ON the controller power and check if the encoder
value has not changed.
！ CAUTION
1. Battery life is about two years (assuming controller power is continuously
OFF), but the lifetime differs depending on ambient temperature, etc.
2. While replacing a battery, the built-in super capacitor maintains encoder
values for approximately 30 minutes on a full charge. So, replace a battery
within 30 minutes. (Note that if the super capacitor is not fully charged, the
data retention time is less than 30 minutes.)
4-26
4.7 FUSES
This section describes the procedure for replacement of the fuses.
4.7.1 FUSES ON 1TR BOARD
One type of fuse (Fuse1) is mounted on the 1TR board.
2. Push the fuse on front of the 1TR board and turn it 90 degrees to the left. then pull it out to
remove it from the board.
3. Push a new fuse, and turn it 90 degrees to the right to mount.
Fuse 1
1KP ボ
Outline view of 1TR board
4-27
4.8 REMOVING THE TOP COVER OF CONTROLLER (E7X CONTROLLER)
1. Unscrew the two screws fixing the meshed cover and dismount the cover by sliding forward
then upward a little. (The cover is caught on the metal plate by two cathes on the back part.)
Screw Screw
(1)
Left side view Front view
2. Unscrew the six screws fixing the left side cover (1) of the controller, and then dismount the
cover.
3. Unscrew the screws＊ fixing the top cover (2) of the controller. For the screws，refer to the
note below.
4. Lift the top cover (2) of the controller a little and dismount the connectors of the fan and
regenerative resistor, and then dismount the cover.
NOTE＊ Screw type

Three kinds of screws are used on the top cover (2) of the controller. Unscrew Yellow
M4 and Silver M3 screws to dismount the top cover of the controller.
Yellow M4: fixing the top cover of the controller and internal parts (Heat sink on 1UZ
board and power supply unit, etc.)
Silver M3: fixing the top cover of the controller and controller
Silver M4: fixing the top cover of the controller and external parts (Fan and
regenerative resistor, etc.)
4-28
Yel.M4 Sil.M3 Sil.M3 Sil.M3
Yel.M4
Yel.M4
(2)
(2)
Yel.M4 Yel.M4 Sil.M3 Sil.M3

(when using JT7 and 8)
4-29
4.9 REPLACING THE POWER SUPPLY UNIT PART (E7X CONTROLLER)
This section describes the procedure for replacement of the power supply unit, 1UE board (MC
power board) and 1TQ/1TV boards (MC control board) in the power unit.
4.9.1 POWER SUPPLY UNIT
！ DANGER

1. Dismount the top cover (2) of the controller. For the procedure, refer to 4.8.
2. Disconnect all the connectors connected to the power supply unit. First disconnect the front
connectors connected to 1UE and 1TV boards, then disconnect connectors connected to the
sides of 1TQ/1TV boards by lifting the power supply unit slightly.
3. Dismount the power supply unit.
4. Connect all the connectors properly to a new power supply unit in the reverse order of step 2,
and then mount the power supply unit to the controller. Be careful not to misconnect all the
connectors.
5. Remount the controller cover.
Power supply unit
MC power board (1UE board)
Top view 4-30

4.9.2 1UE BOARD (MC POWER BOARD)
！ DANGER

1. Dismount the power supply unit. For the procedure, refer to 4.9.1.
2. Unscrew the six screws fixing the 1UE board to the unit, and then dismount the 1UE board.
3. Fix a new 1UY board with the six screws to the unit.
4. Mount the power supply unit to the controller. For the procedure, refer to 4.9.1.
！ DANGER

2. Lay the power supply unit on its front side and unscrew the four screws fixing the 1TQ/1TV
boards to the unit, and then dismount the 1TQ/1TV boards.
3. Fix new 1TQ/1TV boards with the four screws to the unit.
4. Mount the power unit to the controller. For the procedure, refer to 4.9.1.
4-31
4.10 REPLACING SERVO AMPLIFIER SECTION (E7X CONTROLLER)
This section describes the procedure for replacement of the servo amplifier section mounted in
the E7x controller. The servo amplifier section consists of 1UZ board (power block board),
1UY board (servo relay board), 1TB board (servo board).
！ DANGER
Do not touch any connector pins during replacement because

high voltage may be applied in the power block unit.
4.10.1 1UZ BOARD (POWER BLOCK BOARD)
！ DANGER

2. Disconnect the connectors on the 1UZ board to be replaced.
3. Dismount the 1UZ board.
4. Mount a new 1UZ board properly.
4-32
JT1
JT2
JT3
Servo amplifier section
Power block board (1UZ

board)
JT4 JT5 JT6 JT7 JT8
Top view
4.10.2 1UY BOARD (SERVO RELAY BOARD)
！ DANGER

2. Disconnect all connectors connected to the power supply unit, 1UZ board and fan.
4. Dismount all 1UZ boards.
5. Dismount the fan.
4-33
Screw
Fan
Screw
Top view
6. Unscrew the six screws from the metal board where the 1UZ board was mounted, and then
dismount the metal board.
7. Disconnect all connectors connected to the 1UY board.
8. Unscrew the seven screws fixing the 1UY board to the controller, and then dismount the 1UY
board.
9. Fix a new 1UY board with the seven screws to the controller.
11. Remount the metal board in the reverse order of step 6, and fix it with the six screws to the
controller.
12. Remount the fan.
13. Remount all the 1UZ board properly.
14. Remount the power supply unit. For the procedure, refer to 4.9.1.
15. Remount the connectors disconnected in step 2.

4-34
4.10.3 1TB BOARD (SERVO BOARD)
1. Place the controller lengthwise as shown below.
(4)
Screw
Screw
Lengthwise Bottom view

2. Unscrew the five screws fixing the bottom cover of the controller, and then dismount the cover.
See the figure above.
3. Disconnect all connectors connected to the 1TB board.
4. Unscrew the eight screws fixing the 1TB board to the controller, and dismount the 1TB board
from the 1UY board.
5. Mount a new 1TB board on the 1UY board, and then fix the 1UY board with the eight screws
to the controller.
！ CAUTION
When connecting the 1TB board to the 1UY board, keep the 1TB board
horizontal as much as possible. If the 1TB board is tilted 5 or more, or
is rotated, the connectors connected with the 1UY board may be damaged.
6. Reconnect all the connectors disconnected step 3.
7. Remount the bottom cover (4) on the controller, and fix it with the five screws.
8. Arrange the controller sideways.

4-35
4.11 REPLACING FAN (E7X CONTROLLER)
For E7x controller, fans are mounted in the card rack, servo amplifier section, and on top and rear
side of the controller. This section describes the procedure for replacement of these fans.
！ CAUTION
Fans may not be clean depending on the environment. In that case,

prevent dust falling from the fan onto the boards of the controller by
placing a sheet, etc. under the fan during the replacement work.
4.11.1 FANS FOR CARD RACK
(5) Screw
Lengthwise Bottom view
2. Place the controller lengthwise as shown above.
3. Unscrew the two screws fixing the bottom cover (5) of the controller.
4. Dismount the fan, and then disconnect the connector connected to the fan.
5. Unscrew the two screws fixing the fan to the cover (5).
6. Fix a new fan with the two screws to the cover (5), and then reconnect the connector
disconnected in step 4.
7. Mount the fan on the controller and fix it with the two screws.
4-36
8. Arrange the controller sideways.
4.11.2 FAN AT SERVO AMPLIFIER SECTION
3. Disconnect all connectors connected to the fan.
Fan
Top view
4. Dismount the fan, and then unscrew the two screws fixing the fan to the metal board.
5. Fix a new fan with the two screws to the metal board, and then mount the fan on the
controller.
6. Reconnect all the connectors discnnected in step 3.
4.11.3 FAN ON CONTROLLER UPPER SIDE
2. Unscrew the two screws fixing the meshed cover and dismount the cover by sliding forward
and upward a little. (The cover is caught on the metal plate by two cathes on the back part.)
4-37
Fan Heat sink
Screw
Front view
Screw
Top view
3. Dismount the the balck cover connected to the fan with the harness.
4. Disconnect the connector inside the balck cover.
5. Unscrew the four screws fixing the fan to the heat sink.
6. Fix a new fan on the controller and fix it with the four screws.
7. Reconnect the connector disconnected in step and remount the black cover.
4-38
4.11.4 HEAT EXCHANGE FAN
Heat exchange fan is located on the controller rear side.
Screw
Screw
Rear view
2. Unscrew the four screws fixing the fan to the controller .
3. Dismount the fan, and then disconnect the connector connected to the fan.
4. Reconnect the connector disconnected in step 3 to a new fan.
5. Mount the fan and fix it with the four screws.
4-39
NOTE For the error W1053, refer to below.

For E7x controller, 1TQ board in the power unit monitors the rotation speed. If the fan
speed is below the limit, the error “(W1053)(FAN3) Rotational speed of fan is below the
limit. (Servo boardXX)” is displayed. “FAN3” means the fan number, means “Fan
no.3” of “MC unit 1”. FAN1-2 are not detected.
Fan position and its number inside the controller are shown below.
1-1
1-3
1-4 1-5
Top view Top inside view
1-2
Rear view
4-40
4.12 REPLACING MOTHER BOARD
This section describes the procedure for replacement of the mother board.
4.12.1 E1X/E2X/E3X/E4X CONTROLLER
！ DANGER
Before starting replacement work, turn OFF the
controller power and wait at least seven minutes.
1. Disconnect all connectors connected to the mother board.
2. Dismount the AVR and all the printed circuit boards inserted into the card rack.
3. Unscrew the two bottom screws fixing the card rack to the controller (See figure below.), then
dismount the card rack from the controller by taking it up. (The card rack is hooked at the
upper part of the back side.)
5. Mount the card rack to the controller in the reverse order of step 3 with the two screws
unscrewed in step 3 securely.
6. Remount the AVR and all the printed circuit boards dismounted in step 2.
4-41
Card rack
Mother board
Two screws (at bottom)
4-42
4.12.2 E7X CONTROLLER
！ DANGER
1. Dismount the left cover (1) and top cover (2) of the controller. For the procedure, refer to 4.8.
2. Disconnect all the connectors connected to the mother board.
4. Unscrew the screws fixing the card rack to the controller (See the figure below.) and dismount
the card rack.
6. Fix the card rack using the screws unscrewed in step 4.
8. Connect all the connectors disconnected in step 2,
Screw Screw
Screw
Screw
Top surface Front surface of card rack
4-43
！ DANGER
2. Disconnect connectors of FAN 1 and FAN 2. (See the figure below.)
3. Unscrew the four screws fixing the card rack to the controller (See the figure below.), and
dismount the card rack.
4. Disconnect all the connectors connected to the mother board.
5. Replace the mother board. When mounting the mother board, fix it aligning to 2 positioning
guides.
6. Reconnect all the connectors dismounted in step 4.
7. Mount the card rack on the controller in reverse order of step 3, and tighten it firmly with the
four screws unscrewed in step 3.
8. Reconnect all the connectors dismounted in step 2.
Connector for FAN2 Card rack
Connector for FAN1
4 screws Mother board
Positioning guide
4-44
4.13 REPLACING REGENERATIVE RESISTOR
4.13.1 E1X/E2X/E3X/E4X CONTROLLER
2. Dismount the servo amplifier unit.
3. Ensure that the regenerative resistor is not too hot to touch.
4. Disconnect the connector from the back.
5. Unscrew the screws and hexagonal spacers using a driver, spanner (7 mm), etc. and remove the
regenerative resistor.
6. Mount a new regenerative resistor and reconnect the connector.
7. Remount the servo amplifier unit.
Regenerative
resistor
Screw, hexagonal spacer
Connector without servo amp. unit

(Figure shows E22 controller)
4-45
2. Dismount the top cover (2) of the controller. For the procedure, refer to 4.8. The connector
of the regenerative resistor is dismounted at this time.
3. Disconnect the connector of the regenerative resistor through the through hole.
4. Unscrew the two screws and dismount the regenerative resistor.
5. Mount a new regenerative resistor.
6. Put the connector of the regenerative resistor through the through hole. If the membrane is
torn, repair it with vinyl tape, etc. to fill the gap.
7. Remount the cover.
Regenerative resistor
Screw
(2) (2)
Connector
4-46
2. Dismount the servo amplifier unit.
3. Confirm that the regenerative resistor is not hot.
4. Disconnect the connector.
5. Unscrew screws and hexagonal spaces with a driver, a spanner (7 mm), etc., and remove the
6. Mount a new regenerative resistor, and connect the connector.
7. Mount the servo amplifier unit.
Screw, hexagonal spacer
Connector
(Figure shows E94 controller.)
4-47
4.14 REPLACING ADDITIONAL REGENERATIVE RESISTOR UNIT
2. Open the door, and disconnect all connectors at the end of line connected to the additional
3. Loosen two bottom screws fixing the additional regenerative resistor unit and unscrew two top
screws. When the two screws are unscrewed, the unit will tilt and come off. Accordingly,
push the unit so that it does not tilt.
4. Remove the additional regenerative resistor unit.
5. Mount a new additional regenerative resistor unit. Be careful not to catch the line at this time.
6. Fix the additional regenerative resistor unit with bolts.
7. Reconnect all connectors.
Bolts
Additional regenerative
Front resistor unit Right side

E23 controller
4-48
4.15 REPLACING MAGNETIC CONTACTOR (K1, K2) (E7X CONTROLLER)
This section describes the procedure for replacement of the magnetic contactor.
！ DANGER
2. Disconnect all connectors connected to the magnetic contactor.
3. Unscrew the bolts fixing the plate on which the magnetic contactor is mounted from the right
side. The bolts are the M4 hexlobe bolts and a star screwdriver T20 is necessary.
4. Remove the magnetic contactor with the plate.
5. Replace the magnetic contactor.
6. Mount a new magnetic contactor with the bolts unscrewed in step 3.
7. Reconnect the connector disconnected in step 2.
8. Mount the cover of the controller.
Magnetic contactor
(K1, K2)
M4 hexlobe bolt
(Applicable tool: star screwdriver T20)
Top Right
4-49
4.16 REPLACING POWER UNIT SECTION (E9X CONTROLLER)
This section describes the procedure for replacement of the power unit and the 1VH board (power
unit control board) mounted in the power unit.
4.16.1 REPLACING POWER UNIT
！ DANGER

1. Disconnect all the connectors connected to the power unit. It is not necessary to disconnect
jumper harness and dummy connectors.
2. Remove the power unit by unscrewing two left screws fixing the power unit to the controller
(See the figure below.) and two right screws (See the figure below. With a feature to prevent
from coming off) and holding up.
3. Mount a new power unit to the controller in reverse order of step 2, and tighten the two left
screws and the two right screws removed in step 2 firmly.
Power unit
2 screws (left side)
2 screws (right side)

(with feature to
prevent coming off)
4-50
！ CAUTION
Power unit weighs approx. 5 kg. Be careful not to jam

your fingers when replacing the power unit.
4.16.2 REPLACING 1VH BOARD (POWER UNIT CONTROL BOARD)
！ DANGER

1. The 1VH can be seen by unscrewing two screws mounting the top cover of the power unit and
holding up the top cover. It is not necessary to disconnect the connector mounted on the
cover.
2. Disconnect all the connectors connected to top and right sides of the 1VH board. (It is not
necessary to disconnect X313 and X301 jumper connectors.)
2 screws
4 screws
Connector mounted
on the top cover
Top cover
1VH board
Top side of power unit
Top cover
Connector
1VH board
Front side of power unit

4-51
3. Unscrew 4 screws fixing the 1VH board on the unit.
4. Pull out the 1VH board to the front, and disconnect all the connectors connected to the rear of
the 1VH board.
Screw
1VH board
1VH board
rear side connector
Front side of power unit
5. Connect all the connectors removed in step 4 to a new 1VH board and fix them to the unit with
the 4 screws unscrewed in step 4. At this time, be careful not to damage the wiring.
(Confirm that the X313 and X301 jumper connectors are connected to the new 1VH board.)
6. Connect all the connectors disconnected in step 2.
7. Fix the top cover dismounted in step 1 with the 2 screws unscrewed in step 2 as it was.
4-52
4.17 REPLACING FANS (E9X CONTROLLER)
Fans are mounted on the card rack section, the power unit section, the power unit section (outside
air side) and servo amplifier unit (outside air side). This section describes the procedure for
replacement of the fans.
4.17.1 REPLACING FAN OF CARD RACK SECTION
1. Turn OFF the controller power and wait until the fan stops.
2. The card rack can be seen by dismounting the rear plate. Remove the connectors for fan.
3. Dismount the fan unit on which two fans are mounted.
4. Replace the fan using a spanner (5.5 mm), etc. and a driver. At this time, note that the
mounting direction of the fan should be the same as it was.
5. Restore to its former state in reverse order of steps 3 and 2.

Rear plate Connector
Card rack fan unit

M3 flange nut
Wind-direction
M3 screws
4-53
4.17.2 REPLACING FAN OF POWER UNIT SECTION
2. Dismount the top cover of the controller, disconnect X323 and X325 connectors, unscrew 2
screws shown in the figure below (with a feature to prevent coming off), then dismount the fan
unit.
3. Replace the fan using a spanner (5.5 mm), etc. and a driver. At this time, note that the
mounting direction of the fan should be the same as it was.
4. Restore to its former state in reverse order of step 2.
Fan unit
M3 nut
Wind-direction
2 screws
M3 screw
(with feature to prevent
coming off)
4-54
4.17.3 REPLACING POWER UNIT SECTION (OUTSIDE AIR SIDE)
2. Arrange the controller lengthwise and dismount the plate on the bottom. (See the figure
below.)
3. Disconnect the connector connected to the fan, unscrew two screws and remove the fan
(harness set).
4. Mount a new fan (harness set) with the two screws unscrewed in step 3. If it is tightened up
to the position where the frame of the fan deforms, do not tighten any more. In addition, note
that the mounting direction of the fan should be the same as it was.
5. Connect the connector dismounted in step 3 and mount the plate on the bottom dismounted in
step 2.
Fan
2 screws
Wind-direction
Plate Connector
4-55
4.17.4 REPLACING SERVO AMPLIFIER FIN (OUTSIDE AIR SIDE)
2. Arrange the controller lengthwise and dismount the plate on the bottom. (See the figure
below.)
3. Disconnect the connector connected to the fan, unscrew four screws and remove the fan
(harness set).
Fan
Wind-direction
2 screws Connector
Plate
4. Mount a new fan (harness set) with the four screws. At this time, note that the mounting
direction of the fan should be the same as it was.
5. Connect the connector disconnected in step 3 and mount the plate dismounted in step 2 as it
was.
4-56
NOTE For the error W1053, refer to below.

For E9x controller, 1VH board in the power unit monitors the rotation speed. If the fan
speed is below the limit, the error “(W1053)(FAN1-6) Rotational speed of fan is below
the limit. (Servo boardXX)” is displayed. “FAN1-6” in the message indicates the fan
number, and indicates “Fan no.6” of “power unit 1” in the above example.
Fan position and its number inside the E9x controller are shown below.
1-1 1-2
1-6 1-4 1-3 1-5
4-57
4-58
E Series Controller 5. Schematic Diagrams of Separate and Machine Harnesses
5.0 SCHEMATIC DIAGRAMS OF SEPARATE AND MACHINE HARNESSES
This chapter compiles a listing of the electrical schematic diagrams for the separate and
machine harnesses and the wire distribution lists for the E Series Controller. Please note that
this information is provided for reference purposes only and should not be applied as the basis
of maintenance or repair operations.
5.1 Separate Harness ·············································································· 5-2

5.1.1 E10/E20/E30/E40/E71/E74/E77/E91/E94/E97-R Series (06L/10L/10N/20N)/
YF003N Separate Harness Wire Distribution List ········································ 5-2
5.1.2 E22/E23/E32/E33/E42/E43 Separate Harness Wire Distribution List ················· 5-4
5.1.3 E24/E34/E44 Separate Harness Wire Distribution List ·································· 5-6
5.1.4 E70/E73/E76-RS03N, E71/E74/E77-R Series (05L/05N) Separate Harness Wire
Distribution List ··············································································· 5-8
5.2 Machine Harness ············································································· 5-10
5.2.1 R Series ························································································ 5-10
5.2.2 Y Series (YF003N) ··········································································· 5-33
5.2.3 Z Series (ZX, ZT Series, ZH Series, ZD Series) ········································· 5-38
5.2.4 M Series (MX Series, MD Series, MT Series) ··········································· 5-50
5.2.5 B Series ························································································ 5-62
5-1
5.1 SEPARATE HARNESS
5.1.1 E10/E20/E30/E40/E71/E74/E77/E91/E94/E97-R SERIES (06L/10L/10N/20N)/

YF003N SEPARATE HARNESS WIRE DISTRIBUTION LIST
1. Signal Harness
X3
Signal name No. Destination
JT1-ENCP 1 X3A-1
JT1-ENCN 8 X3A-8
JT2-ENCP 2 X3A-2
JT2-ENCN 9 X3A-9
JT3-ENCP 3 X3A-3
JT3-ENCN 10 X3A-10
JT4-ENCP 4 X3A-4
JT4-ENCN 11 X3A-11
JT5-ENCP 5 X3A-5
JT5-ENCN 12 X3A-12
JT6-ENCP 6 X3A-6
JT6-ENCN 13 X3A-13
JT7-ENCP 7 X3A-7
JT7-ENCN 14 X3A-14
EPVP 22 X3A-22
EPVN 23 X3A-23
LS1P 27 X3A-27
LS1N 34 X3A-34
LS2P 28 X3A-28
LS2N 35 X3A-35
+12V 36 X3A-36
GND 29 X3A-29
GND 30 X3A-30
BAT ALP 20 X3A-20
BAT ALN 21 X3A-21
+12V 31 X3A-31
GND 37 X3A-37
GND 38 X3A-38
+12V 32 X3A-32
GND 24 X3A-24
GND 25 X3A-25
SIG-1 15 X3A-15
SIG-2 16 X3A-16
SIG-3 17 X3A-17
SIG-4 18 X3A-18
I/O 24V 39 X3A-39
I/O 24G 40 X3A-40
I/O 24V 33 X3A-33
I/O 24G 26 X3A-26
SPARE 41 X3A-41
SPARE 42 X3A-42
SHIELD L X3A- L
5-2
2. Motor Harness
X4
Signal Name No. Destination Signal Name No. Destination
JT1-MOTOR U 1 X4A-1 EARTH U X4A- U
JT1-MOTOR V 13 X4A-13 JT1-BRAKE P 37 X4A-37
JT1-MOTOR W 25 X4A-25 JT1-BRAKE N 49 X4A-49
JT2-MOTOR U 2 X4A-2 JT2-BRAKE P 38 X4A-38
JT2-MOTOR V 14 X4A-14 JT2-BRAKE N 50 X4A-50
JT2-MOTOR W 26 X4A-26 JT3-BRAKE P 39 X4A-39
JT3-MOTOR U 3 X4A-3 JT3-BRAKE N 51 X4A-51
JT6-MOTOR U 6 X4A-6 SIGO-1 61 X4A-61
JT6-MOTOR V 18 X4A-18 SIGO-2 62 X4A-62
JT6-MOTOR W 30 X4A-30 SIGO-3 63 X4A-63
TH P 69 X4A-69 SIGO-7 67 X4A-67
TH N 70 X4A-70 SIGO-8 68 X4A-68
SHIELD L X4A- L EARTH 58 X4A-58
EARTH 59 X4A-59 EARTH 33 X4A-33
BASE-LS P 9 X4A-9
Connection between controller and robot BASE-LS N 21 X4A-21
Controller side
控制器側 Robot side X4A
X3A
Motor harness (X4)
Signal harness (X3)
Rear view of E20 controller
Motor harness (X4)
Signal harness (X3)

Rear view of E7x controller
5-3
5.1.2 E22/E23/E32/E33/E42/E43 SEPARATE HARNESS WIRE DISTRIBUTION

LIST
1. Signal Harness 2. Base Axis Motor Harness
X3 X4
JT1-ENCP 1 X3A-1 JT1-MOTOR U 1 X4A-1
JT1-ENCN 8 X3A-8 JT1-MOTOR V 2 X4A-2
JT3-ENCP 3 X3A-3 JT1-MOTOR W 3 X4A-3
JT3-ENCN 10 X3A-10 JT2-MOTOR U 4 X4A-4
JT2-MOTOR V 5 X4A-5
JT4-ENCP 4 X3A-4
JT2-MOTOR W 6 X4A-6
JT4-ENCN 11 X3A-11
JT3-MOTOR U 7 X4A-7
JT6-ENCP 6 X3A-6 JT3-MOTOR V 8 X4A-8
JT6-ENCN 13 X3A-13 JT3-MOTOR W 9 X4A-9
JT2-ENCP 2 X3A-2  10
JT2-ENCN 9 X3A-9  11
JT7-ENCP 7 X3A-7  12
JT7-ENCN 14 X3A-14 TH P a X4A-a
JT5-ENCP 5 X3A-5 TH N b X4A-b
JT5-ENCN 12 X3A-12 EARTH U X4A- U
EPVP 22 X3A-22 SHIELD L X4A- L
EPVN 23 X3A-23
LS1P 27 X3A-27
LS1N 34 X3A-34
LS2P 28 X3A-28
LS2N 35 X3A-35
+12V 36 X3A-36
GND 29 X3A-29
GND 30 X3A-30
BAT-ALP 20 X3A-20
BAT-ALN 21 X3A-21
+12V 31 X3A-31
GND 37 X3A-37
GND 38 X3A-38
+12V 32 X3A-32
GND 24 X3A-24
GND 25 X3A-25
SIG-1 15 X3A-15
SIG-2 16 X3A-16
SIG-3 17 X3A-17
SIG-4 18 X3A-18
I/O 24V 39 X3A-39
I/O 24G 40 X3A-40
I/O 24V 33 X3A-33
I/O 24G 26 X3A-26
SHIELD L X3A- L
5-4
X5
JT7-MOTOR W 37 X5A-37 X5A-27
SIGO-4 27
SHIELD L X5A- L
SIGO-5 33 X5A-33
JT1-BRAKE P 3 X5A-3
SIGO-6 34 X5A-34
JT1-BRAKE N 4 X5A-4
JT2-BRAKE P 10 X5A-10 SIGO-7 40 X5A-40
JT2-BRAKE N 11 X5A-11 SIGO-8 41 X5A-41
JT3-BRKAE P 17 X5A-17  7
JT3-BRAKE N 18 X5A-18  14
EARTH 38 X5A-38  21
U X5A- U  28
 35
 42
Connection between controller and robot
Controller side Robot side

X4A X5A X3A
Base axis motor harness (X4)
Wrist axis motor harness (X5)
Signal harness (X3)
E22 コントローラ背
Rear
面view of E22 controller
5-5
5.1.3 E24/E34/E44 SEPARATE HARNESS WIRE DISTRIBUTION LIST
1. Signal Harness 2-1. Base Axis Motor Harness (JT1-JT3)
X3 X4-1
JT1-ENCP 1 X3A-1 JT1-MOTOR U 1 X4A-1-1
JT1-ENCN 8 X3A-8 JT1-MOTOR V 2 X4A-1-2
JT2-ENCP 2 X3A-2 JT1-MOTOR W 3 X4A-1-3
JT2-ENCN 9 X3A-9 JT2-MOTOR U 4 X4A-1-4
JT3-ENCP 3 X3A-3 JT2-MOTOR V 5 X4A-1-5
JT3-ENCN 10 X3A-10 JT2-MOTOR W 6 X4A-1-6
JT4-ENCP 4 X3A-4 JT3-MOTOR U 7 X4A-1-7
JT4-ENCN 11 X3A-11 JT3-MOTOR V 8 X4A-1-8
JT5-ENCP 5 X3A-5 JT3-MOTOR W 9 X4A-1-9
JT5-ENCN 12 X3A-12 TH P a X4A-1-a
JT6-ENCP 6 X3A-6 TH N b X4A-1-b
JT6-ENCN 13 X3A-13 EARTH U X4A-1- U
JT7-ENCP 7 X3A-7 SHIELD L X4A-1- L
JT7-ENCN 14 X3A-14
EPVP 22 X3A-22 2-2. Wrist Axis Motor Harness (JT4-JT6)
EPVN 23 X3A-23
LS1P 27 X3A-27 X4-2
LS1N 34 X3A-34 Signal Name No. Destination
LS2P 28 X3A-28 JT4-MOTOR U 1 X4A-2-1
LS2N 35 X3A-35 JT4-MOTOR V 2 X4A-2-2
+12V 36 X3A-36 JT4-MOTOR W 3 X4A-2-3
GND 29 X3A-29 JT5-MOTOR U 4 X4A-2-4
GND 30 X3A-30 JT5-MOTOR V 5 X4A-2-5
BAT-ALP 20 X3A-20 JT5-MOTOR W 6 X4A-2-6
BAT-ALN 21 X3A-21 JT6-MOTOR U 7 X4A-2-7
+12V 31 X3A-31 JT6-MOTOR V 8 X4A-2-8
GND 37 X3A-37 JT6-MOTOR W 9 X4A-2-9
GND 38 X3A-38 TH P a X4A-2-a
+12V 32 X3A-32 TH N b X4A-2-b
GND 24 X3A-24 EARTH U X4A-2- U
GND 25 X3A-25 SHIELD L X4A-2- L
SIG-1 15 X3A-15
SIG-2 16 X3A-16
SIG-3 17 X3A-17
SIG-4 18 X3A-18
I/O 24V 39 X3A-39
I/O 24G 40 X3A-40
I/O 24V 33 X3A-33
I/O 24G 26 X3A-26
SHIELD L L
5-6
3. Motor Harness
X5
SHIELD L X5A- L SIGO-5 33 X5A-33
JT1-BRAKE N 4 X5A-4 SIGO-7 40 X5A-40
JT2-BRAKE N 11 X5A-11  7
JT3-BRAKE P 17 X5A-17  14
JT3-BRAKE N 18 X5A-18  21
EARTH 38 X5A-38  28
U X5A- U  35
 42
Connection between controller and robot
Robot side
Controller side
X5A
X4A-2
X4A-1 X3A
Motor harness (X4-2)
Base axis motor harness (X4-1)
Wrist axis motor harness (X5)
Signal harness (X3)
Rear view of E24 controller
5-7
5.1.4 E70/E73/E76-RS03N, E71/E74/E77-R SERIES (05L/05N) SEPARATE

HARNESS WIRE DISTRIBUTION LIST
1. Signal Harness
X3
Signal Name No. Destination
JT1-ENCP 1 X401-13
JT1-ENCN 8 X401-14
JT2-ENCP 2 X401-15
JT2-ENCN 9 X401-16
JT3-ENCP 3 X401-25
JT3-ENCN 10 X401-26
JT4-ENCP 4 X401-27
JT4-ENCN 11 X401-28
+12V 31 X401-65
GND(+12V) 37 X401-49
GND(+12V) 38 X401-49
+12V 32 X401-50
GND(+12V) 24 X401-51
GND(+12V) 25 X401-51
+12V 36 X401-52
GND(+12V) 29 X401-53
GND(+12V) 30 X401-53
EPVP 22 -
EPVN 23 -
JT5-ENCP 5 X401-37
JT5-ENCN 12 X401-38
JT6-ENCP 6 X401-39
JT6-ENCN 13 X401-40
JT7-ENCP 7 X401-61
JT7-ENCN 14 X401-62
LS1P 27 X401-1
LS1N 34 X401-2
LS2P 28 X401-3
LS2N 35 X401-4
BAT-AL+ 20 X401-63
BAT-AL- 21 X401-64
I/O 24V 39 X401-68
I/O 24G 40 X401-56
I/O 24V 33 X401-68
I/O 24G 26 X401-56
SIG-1 15 X401-66
SIG-2 16 X401-67
SIG-3 17 X401-54
SIG-4 18 X401-55
5-8
2. Motor Harness
X4
Signal Name No. Destination JT1-BRAKE P 37 X401-17
JT1-MOTOR U 1 X401-21 JT1-BRAKE N 49 X401-30
JT1-MOTOR V 13 X401-22 JT2-BRAKE P 38 X401-18
JT1-MOTOR W 25 X401-23 JT2-BRAKE N 50 X401-30
JT3-MOTOR U 3 X401-72 JT3-BRAKE P 39 X401-7
JT3-MOTOR V 15 X401-60 JT3-BRAKE N 51 X401-31
JT3-MOTOR W 27 X401-48 JT4-BRAKE P 40 X401-8
JT5-MOTOR U 5 X401-70 JT4-BRAKE N 52 X401-31
JT5-MOTOR W 29 X401-46 JT5-BRAKE N 53 -
EARTH 59 X401-24 JT6-BRAKE P 42 X401-20
JT2-MOTOR U 2 X401-34 JT6-BRAKE N 54 -
JT2-MOTOR W 26 X401-36 JT7-BRAKE N 55 X401-6
JT4-MOTOR U 4 X401-71 SIGO-1 61 X401-41
JT4-MOTOR V 16 X401-59 SIGO-2 62 X401-42
JT4-MOTOR W 28 X401-47 SIGO-3 63 X401-43
JT6-MOTOR U 6 X401-69 SIGO-4 64 X401-44
JT6-MOTOR V 18 X401-57 SIGO-5 65 -
JT6-MOTOR W 30 X401-45 SIGO-6 66 -
MTH P 69 X401-32 SIGO-7 67 -
MTH N 70 X401-33 SIGO-8 68 X401-29
JT7-MOTOR U 7 X401-9 EARTH 33
JT7-MOTOR V 19 X401-10 EARTH 58 X401- L
JT7-MOTOR W 31 X401-11 EARTH U
BASE-LS P 9 -
BASE-LS N 21 -
Controller side Robot side
X401
Signal harness (X3)
Motor harness (X4)
5-9
5.2 MACHINE HARNESS

5.2.1 R SERIES
RS/RA/RC/RF Series, 10L/20N Machine Harness Schematic Diagram

Motor
Motor
Motor
Motor
ID board
Motor
Motor
OUTSIDE ROBOT
5-10
RS/RA/RC/RF Series, 10L/20N Machine Harness Connection Diagram (1/2)
Battery voltage
decline
detection circuit
Voltage
decline
detection
circuit
ID board
5-11
5-12
Motor
Motor
Motor
Motor
ID board
Motor
Motor
OUTSIDE ROBOT
5-13
5-14
Battery voltage
decline
detection circuit
Voltage
decline
detection
circuit
ID board
5-15
RS/RA/RC/RF Series, 30N/50N/80N Machine Harness Schematic Diagram
Motor
Motor
Motor
Motor
ID board
Motor
Motor
OUTSIDE ROBOT
5-16
RS/RA/RC/RF Series, 30N/50N/80N Machine Harness Connection Diagram (1/2)
5-17
RS/RA/RC/RF Series, 30N/50N/80N Machine Harness Connection Diagram (2/2)
Battery voltage
decline
detection circuit
Voltage
decline
detection
circuit
ID board
5-18
RD80N Machine Harness Schematic Diagram
Motor
Motor
Motor
board
Motor
Motor
OUTSIDE ROBOT
5-19
RD80N Machine Harness Connection Diagram (1/2)
board
detection
Voltage
decline
circuit
detection circuit
Battery voltage
decline
5-20
RD80N Machine Harness Connection Diagram (2/2)
5-21
RS/RA/RC/RF Series, 015X Machine Harness Connection Diagram (1/2)
IO board
detection
Voltage
decline
circuit
detection circuit
Battery voltage
decline
5-22
RS/RA/RC/RF Series, 015X Machine Harness Connection Diagram (2/2)
5-23
Motor
Motor
Motor
Motor
board
(Option)
Motor
Motor
Battery
board
Motor
signal
5-24
5-25
5-26
5-27
5-28
RS03N Machine Harness Connection Diagram
Solenoid valve
Solenoid valve
Encoder
Encoder
Encoder
Encoder
Brake
Brake
Motor
Motor
Brake
Brake
Motor
Motor
Encoder
Brake
Motor
Encoder
Brake
Motor
Battery
board
signal
Motor
5-29
RS03N Machine Harness Connection Diagram (1/2)
Cable
shield
Cable
shield
5-30
RS03N Machine Harness Connection Diagram (2/2)
5-31
RS03N Machine Harness Connection Diagram (2/2) (continued)
5-32
5.2.2 Y SERIES (YF003N)
YF003N Machine Harness Schematic Diagram
ID board
5-33
YF003N Machine Harness Connection Diagram (1/4)
5-34
5-35
Battery voltage
decline
detection circuit
Voltage
decline
detection
circuit
ID board
5-36
5-37
5.2.3 Z SERIES (ZX, ZT SERIES, ZH SERIES, ZD SERIES)

ZX, ZT Series Machine Harness Schematic Diagram
5-38
ZX, ZT Series Machine Harness Connection Diagram (1/3)
BRAKE
BRAKE
BRAKE
BRAKE
BRAKE
BRAKE
BRAKE
5-39
5-40
5-41
ZH Series Machine Harness Schematic Diagram

plate
5-42
ZH Series Machine Harness Connection Diagram (1/3)
5-43
5-44
5-45
ZD Series Machine Harness Schematic Diagram
5-46
ZD Series Machine Harness Connection Diagram (1/3)
5-47
5-48
5-49
5.2.4 M SERIES (MX SERIES, MD SERIES, MT SERIES)

MX Series Machine Harness Schematic Diagram
Option BOX
5-50
MX Series Machine Harness Connection Diagram (1/3)
5-51
5-52
5-53
MD Series Machine Harness Schematic Diagram
(3.1KW or less)
5-54
MD Series Machine Harness Connection Diagram (1/3)
5-55
5-56
5-57
MT Series Machine Harness Schematic Diagram
Option BOX
5-58
MT Series Machine Harness Connection Diagram (1/3)
5-59
5-60
5-61
5.2.5 B SERIES
B Series (100N) Machine Harness Schematic Diagram
5-62
B Series (100N) Machine Harness Connection Diagram (1/2)
5-63
B Series (100N) Machine Harness Connection Diagram (2/2)
5-64
B Series (100L/100X/130X/165N/165L/200L) Machine Harness Schematic Diagram
5-65
B Series (100L/100X/130X/165N/165L/200L) Machine Harness Connection Diagram

(1/2)
5-66
B Series (100L/100X/130X/165N/165L/200L) Machine Harness Connection Diagram

(2/2)
5-67
5-68
E Series Controller Appendix. Error Message List
APPENDIX ERROR MESSAGE LIST
Code Error Message

P0100 Illegal input data.
P0101 Too many arguments.
P0102 Input data is too big.
P0103 Illegal PC number.
P0104 Illegal Robot number.
P0105 Illegal program.
P0106 Illegal priority.
P0107 Invalid coordinate value.
P0108 Syntax error.
P0109 Invalid statement.
P0110 Specify full spelling of command.
P0111 Cannot use this command/instruction in current mode.
P0112 Cannot execute with DO command.
P0113 Not a program instruction.
P0114 Illegal expression.
P0115 Illegal function.
P0116 Illegal argument of function.
P0117 Invalid variable (or program) name.
P0118 Illegal variable type.
P0119 Incorrect array suffix.
P0120 Incongruent num. of parenthesis.
P0121 Expected to be a binary operator.
P0122 Illegal constant.
P0123 Illegal qualifier.
P0124 Invalid label.
P0125 Missing expected character.
P0126 Illegal switch name.
P0127 Specified switch name needs full spelling.
P0128 Illegal format specifier.
P0129 Duplicate statement label.
P0130 Cannot define as array.
P0131 No. of dimensions in array exceeds 3.
P0132 Array variable already exists.
P0133 Non array variable exists.
P0134 Array variable expected.
A-1
Code Error Message

P0135 Local variable expected.
P0136 Unexpected suffix.
P0137 Mismatch of arguments at subroutine call.
P0138 Mismatch of argument type at subroutine call.
P0139 Illegal control structure.
P0140 Step:XX Wrong END statement.
P0141 Step:XX Extra END statement.
P0142 Step:XX Cannot terminate DO with END.
P0143 Step:XX No VALUE statement after CASE.
P0144 Step:XX Preceding IF missing.
P0145 Step:XX Preceding CASE missing.
P0146 Step:XX Preceding DO missing.
P0147 Step:XX Cannot find END of XX.
P0148 Step:XX Too many control structures.
P0149 Variable (or program) already exists.
P0150 Variable of different type already exists.
P0151 Internal buffer over due to complicated expression.
P0152 Undefined variable (or program).
P0153 Illegal clock value.
P0154 Missing '='.
P0155 Missing ')'.
P0156 Missing ']'.
P0157 Missing "TO".
P0158 Missing "BY".
P0159 Missing ':'.
P0160 Specify "ON" or "OFF".
P0161 Robot Num. must be specified.
P0162 Cannot modify position data in this instruction.
P0163 Name of program, variable, file, etc. misspecified.
P0164 Illegal Robot network ID.
P0165 Step:XX No SVALUE statement after SCASE.
P0166 Step:XX Preceding SCASE missing.
P1000 Cannot execute program because motor power is OFF.
P1001 Cannot execute program in TEACH mode.
P1002 Cannot execute program because teach lock is ON.
P1003 Cannot execute program because of EXT. HOLD input.
P1004 Cannot execute program being reset.
A-2
Code Error Message

P1005 Cannot execute program because of EXT. START ENABLE.
P1006 Cannot execute program because of EXT. START DISABLE.
P1007 Start signal was not input at a RPS_END step.
P1008 Cannot execute program, HOLD sw. engaged.
P1009 Program is already running.
P1010 Robot control program is already running.
P1011 Cannot continue this program. Use EXECUTE.
P1012 Robot is moving now.
P1013 Cannot execute because in error now. Reset error.
P1014 Cannot execute because program already in use.
P1015 Cannot delete, in use by another command.
P1016 Cannot delete, used in program.
P1017 Cannot delete a program in Editor.
P1018 KILL or PCKILL to delete program.
P1019 PC program is running.
P1020 Cannot operate, teach pendant in operation.
P1021 Cannot execute with DO command.
P1022 Cannot execute with MC instruction.
P1023 Cannot execute in Robot program.
P1024 Statement cannot be executed.
P1025 Cannot be executed, function not set.
P1026 Cannot KILL program that is running.
P1027 Cannot edit program, teach lock is ON.
P1028 Cannot paste.
P1029 Program name not specified.
P1030 Program interlocked by other procedure.
P1031 No free memory.
P1032 No program step.
P1033 Program name already exists.
P1034 This program is not editable.
P1035 Record inhibited. Set [Record Accept] and operate again.
P1036 Program change inhibited. Set [Accept] and operate again.
P1037 Program name cannot be called "calib_load_".
P1038 Program does not exist.
P1039 Teach pendant is not connected.
P1040 Cannot execute this command in I/F panel.
P1041 Auto monitor command failure.
A-3
Code Error Message

P1042 NUM program is running.
P1043 Cannot execute in REPEAT mode.
P1044 Cannot execute on because motor power is ON.
P1045 Set TEACH mode and teach lock ON.
P1046 Turn on trigger switch.
P1047 The disconnected robot cannot select the program/step.
P1048 Cannot operate during execution of brake check.
P1049 Program is locked.
P1050 Exist protected program.
P1051 Cannot unlock protection while program running.
P1052 Because the memory was full, could not copy the program.
P1053 Because the memory was full, the copy of program was suspended.
P1054 Turn off trigger switch.
P1055 Teach the axis lock instruction at the step of clamp ON.
P1056 Teach the axis unlocking instruction at the step of clamp ON.
P2000 Turn OFF motor power.
P2001 Turn HOLD/RUN sw. to HOLD.
P2002 There is no external axis.
P2003 Illegal positioner type.
P2004 Cannot change, user data already exists.
P2005 Graphic area error.
P2006 Option is OFF.
P2007 Cannot execute because executed by other device.
P2008 Device is not ready.
P2009 Illegal file name.
P2010 Disk is not ready.
P2011 Invalid disk format.
P2012 Disk is write-protected.
P2013 Disk full.
P2014 Too many files.
P2015 Cannot write on read-only file.
P2016 Cannot open the file.
P2017 Cannot close the file.
P2018 Storage data logging now.
P2019 ADC function already in use.
P2020 Illegal device number.
P2021 Cannot execute on this terminal.
A-4
Code Error Message

P2022 Cannot use DOUBLE OX.
P2023 In cooperative mode.
P2024 Invalid coordinate value X.
P2025 Invalid coordinate value Y.
P2026 Invalid coordinate value Z.
P2027 Cannot use signal, already used in I/F panel.
P2028 Arm ID board is busy.
P2029 Axis setting data is incorrect.
P2030 Unknown Aux. function number.
P2031 Deleted step was destination step of Jump, Call instruction.
P2032 Incorrect number input as WHERE parameter.
P2033 Logging is running.
P2034 Undefined memory.
P2035 Non data.
P2036 Memory verify error.
P2037 Real time path modulation is already running.
P2038 Matrix calculation error.
P2039 Cannot start cycle from FN instruction.
P2040 Card is not ready.
P2041 Wrong card loaded.
P2042 Card is write-protected.
P2043 Card battery is low voltage.
P2044 Card is not formatted.
P2045 Cannot format this card.
P2046 Card initialization error.
P2047 File is already open.
P2048 File does not exist in card.
P2049 Attempted to open too many files.
P2050 Unexpected error during card access.
P2051 Illegal sequence numbers for file I/O data.
P2052 [LSEQ]Program includes unavailable instruction.
P2053 [LSEQ]Too many steps exist.
P2054 [LSEQ]Invalid type of signal variable.
P2055 [LSEQ]Program is already running.
P2056 [LSEQ]No.of signal is outside specifiable range.
P2057 [SerialFlash]Cannot open file.
P2058 [SerialFlash]Data read error.
A-5
Code Error Message

P2059 [SerialFlash]Data write error.
P2060 [SerialFlash]File or directory doesn't exist.
P2061 File does not exist in floppy.
P2062 [FDD/PC_CARD]Failure in writing data per verify function.
P2063 [FDD/PC_CARD]Faulty response from verify function.
P2064 [FDD]No space available.
P2065 [Multi Disks]Invalid disk was loaded.
P2066 Boot flash state is write-disenable.
P2067 [Serial Flash]File directory error.
P2068 Cannot execute program being edited now.
P2069 [FDD/PC_CARD]Device already in use.
P2070 No more data can be registered.
P2071 C/S switch set to disable.
P2072 [LSEQ]Maximum cycles of execution.
P2073 [LSEQ]Other program is waiting execution.
P2074 Floppy disk is broken.
P2075 Channel number for JtXX is incorrect.
P2076 SAVE/LOAD in progress.
P2077 [Serial Flash]Access error occurred.
P2078 [Serial Flash]Upload or Download was aborted.
P2079 Card full.
P2080 Can not execute because of the channel assigned joint No.
P2083 User log is not created.
P2084 The number of registration of a user log was changed.
P2085 Cannot register user log, no free memory.
P2086 User log data is not registered.
P2087 The kind of user log data and specified data is different.
P2088 Cannot load the improper compensation parameter.
P2090 No servo data of the servo spec.
P2091 [Serial Flash]The file or directory already exists.
P2092 [Serial Flash]The directory is not yet empty.
P2093 [Serial Flash]There is no space to write.
P2094 [Serial Flash]Cannot access the file for read only.
P2095 No response from option CPU board.
P2096 Cannot execute cycle start after palletizing motion aborted.
P2097 Cannot change steps during palletizing motion.
P2098 The axis is not for endless rotation.
A-6
Code Error Message

P2099 Cannot change palletizing state into ON.
P2100 Macro error.
P2101 Nesting is too deep in include file.
P2102 File or folder is missing.
P2103 USB memory is not inserted.
P2104 Failed to download softwares.
P2105 Available USB memory is low.
P2106 Available compact flash memory is low.
P2107 System is now downloading the software.
P2108 There is no software in the USB memory.
P2109 Cannot execute program because of simultaneously operation sig. inputting.
P2110 [USB/CF]File write error.
P2111 Please return spin-axis to the original position.
P2112 File name is too long.
P2113 Cannot start cycle from KI instruction.
P4500 FIELD-BUS)Interface not enabled.
P4501 DEVNET)Node XX not in the scanlist.
P4502 DEVNET)Already in that mode.
P4503 Duplicate signal number.
P4504 FIELD-BUS)signals limit over.(max. XX)
P4505 CC-LINK)Version mismatch.
P4506 EN/IP-M)Already in specified mode.
P4507 FIELD-BUS)Cannot execute with old ANYBUS card firmware.
P4508 FIELD-BUS)Cannot communicate with interface card.
P4509 FIELD-BUS)Wrong interface card type error.
P4510 FIELD-BUS)Initialization of the card is not complete.
P5000 Waiting weld completion.
P5001 Waiting retract or extend pos. input signal.
P5002 Spot sequence is running.
P5003 External-axis type and Gun type data mismatch.
P6000 Shifted location of STEPXX is out of range.
P6001 STEPXX in source program is out of motion range.
P6002 Specified painting data bank does not exist.
P6003 Cannot execute program because of suspend playback.
P6004 Cannot execute because of the Air Purge sequence.
P6005 Cannot execute because robot is disconnected.
P6006 Cannot specify circular move to end point of spraying path.
A-7
Code Error Message

P6007 Number of taught points for spraying path exceeds the limit.
P6008 Number of instructions between points exceeds the limit.
P6009 Shortage in number of taught points for spraying path.
P6010 Selected program other than pgxxx.
P6011 Cannot move, change to joint interpolation or add points.
P6012 Cannot edit program, TEACH LOCK is OFF.
P6500 Cannot generate working line direction.
P6501 Illegal tool posture.
P6502 No weld database.
P6503 Cannot change weld condition.
P6504 Step:XX Preceding L.START missing.
P6505 The axis type is not set as the servo torch.
P6506 Shift function can not be used in CIR interp.
P7000 Cannot program reset, because not at home position 1.
P7001 In force meas. mode, only NOP Interp. avail.
P7002 Cannot change stroke because clamp on now.
P7003 Servo parameter file is not found.
P7500 Turn motor power on.
P7501 Because of repeat mode,wait to teach mode.
P7502 Over the number which can be registered in interruption.
P7503 Cannot execute program in error masking.
P7504 ONC/ONCI channel has already received.
P7505 Cannot execute in saving.
P7506 Cannot accept a record because robot is moving.
P7507 Amount of the data change is too large in repeat operation.
P8400 Cannot execute program because of CLAMP MODE sig. inputting.
P8800 The controller number is duplicated.
P8801 The IL robot number is duplicated.
P8802 The IL server is processing.
P8803 The connection with the IL server is disabled.
P8804 IL server IP address is not yet set.
P8805 Set the mode to Teach.
P8806 Turn off servo.
P8807 ILL)Communication time out error.
P8808 ILL)Time out error for PC server processing.
P8809 ILL)PC server processing demand completion waiting is time out error.
P8810 ILL)Error in auto interlock setting system.
A-8
Code Error Message

P8811 ILL)Could not release operation lock for slave controller.
P8812 ILL)Could not communicate with the PC server.
P8813 The IL robot number is unregistered.
P9000 Unacceptable control-direction.
P9001 Unacceptable control-distance.
P9002 Same data are specified for some reference points.
P9003 Reference points1,2,3 are on a straight line.
P9004 Reference point 4 is out of allowed range.
P9005 Cannot manipulate because teach lock is ON.
W1000 Cannot move along straight line JtXX in this configuration.
W1001 Over maximum joint speed in check. Set low speed.
W1002 Operation log information was cleared.
W1003 Calibration failed. Retry after changing posture.
W1004 JtXX out of motion range. Check operational area.
W1005 Illegal center of gravity, default parameter is set.
W1006 Incorrect load moment. Default parameter is set.
W1007 Application setting changed. Turn OFF & ON the control power.
W1008 Parameter changed. Turn OFF & ON the control power.
W1009 Position envelope error of JtXX at last E-stop.
W1010 RAM battery low voltage.
W1011 PLC alarm. (XX)
W1012 Servo parameter changed. Turn OFF & ON the control power.
W1013 Encoder battery low voltage. [Servo(XX)]
W1014 Number of axes changed. Reinitialize.
W1015 Possibility of failure.
W1016 Torque of motor is over limit. JtXX
W1017 Encoder battery low voltage.[External axis(XX)]
W1018 Network parameter is changed. Turn OFF & ON the control power.
W1019 The registered value is beyond rated load.
W1020 Error sector was found.
W1021 The optimal posture can't be found at present location.
W1022 Not execute ZRPAADSET command.
W1023 Teach Plug Position wrong or P-N low voltage.[XX]
W1024 Deviation from last stop position exceeds the limit set.
W1025 (SSCNET)Excessive regenerative warning of JtXX.(CodeXX)
W1026 (SSCNET)Motor overload warning of JtXX.(CodeXX)
W1027 While lifter is locked, it cannot move.
A-9
Code Error Message

W1028 The center of gravity for payload is over limit. Reduction gears could be broken.
W1029 The center of gravity for payload is over limit. Use the Jt5 at zero degree only.
W1030 Braking torque of JtXX has decreased.
W1031 Cannot move along straight line unless JtXX value is 0 degree.
W1032 Cannot move straight - the flange faces direction of upper sphere.
W1033 Cannot change orientation.
W1034 Encoder power voltage is low. JtXX
W1035 Encoder battery voltage is low. Check zeroing. JtXX
W1036 Step data is different.
W1037 The axis is not for endless rotation.
W1048 No. of encoder errors exceeded limit JtXX.
W1053 (FANXX-XX)Rotational speed of fan is below the limit. (ServoBoardXX)
W1054 AVR reaches the expected lifetime soon.
W1055 Vision cycle timer over.
W1056 [Main CPU board]CPU temperature exceeded the limit. (XX 1/1000 deg C)
W1057 Cannot move along straight line tool in this configuration.
W1058 Link3 interferes in ground.
W1059 Link5 interferes in base.
W1060 Link6 interferes in base.
W1061 TP changed. Confirm current pose, and operate the robot.
W1062 The TP backlight lighting time exceeded the limit.
W1063 The number of ON/OFF operations of MC relay exceeded the
limit.(SrvB'dXX)(MCXX)
W1064 Exceeded the limit.(Parts:XX)
W1072 Deviation of JtXX is too large.
W2901 SLOGIC ERROR MESSAGE #1
A-10
Code Error Message

A-11
Code Error Message

W2965 The max load is XX of a permissible torque.
W2966 Load exceeded permissible torque.
W2967 Load exceeded max torque.
W2968 Please set a group number as XX.
W3801 Because the brake has been released, it is not possible to move.
W3802 Maint. period elapsed, maint. is required.
W3803 Total power ON time exceeded limit, maint. is required.
W3804 Total robot connection time exceeded limit, maint. is required.
W3805 Total servo ON time exceeded limit, maint. is required.
W3806 Total JtXX the total travel dist. exceeded limit, maint. is required.
W3807 Total times of MC ON exceeded limit, maint. is required.
W3808 Total times of servo ON exceeded limit, maint. is required.
W3809 Total times of E-stop exceeded limit, maint. is required.
W3810 JtXX total (curr)^3-motion dist. exceeded limit, maint. is required.
W3811 JtXX RMS value of current exceeded limit, maint. is required.
W3812 Power supply(1) for input to NO.XX I/O board is abnormal.
W3813 Power supply(2) for input to NO.XX I/O board is abnormal.
W3814 Power for output from NO.XX I/O board is abnormal or Fuse blown.
W4000 No response from PLC to Break down info writing.
W4001 Break down info cannot write on PLC[EC = XX].
W4002 Break down info writing cannot receive correct answer.
W4500 FIELD-BUS)Slave port OFFLINE.
A-12
Code Error Message

W4501 FIELD-BUS)Master port OFFLINE.
W4502 CC-LINK)Data link error on Master board. XX
W5000 Release wait cond., in force measurement mode.
W5001 PLC communication error.
W5002 Weld controller XX not connected.
W5003 Weld controller XX no response.
W5004 Weld controller XX response error.
W5005 (Spot welding)No response from RWC XX.
W5006 (Spot welding)RWC response error XX.
W5007 (Spot welding)Weld fault XX.
W5008 (Spot welding)Cable disconnection error XX.
W5009 (Spot welding)Internal leak XX.
W5010 (Spot welding)Main cable exchange alarm XX.
W5011 (Spot welding)No connection with RWC XX.
W5012 Cannot achieve set force.
W5013 Tip wear over the limit. (MOVING SIDE)
W5014 Tip wear over the limit. (FIXED SIDE)
W5015 (Spot welding) Welding current has decreased.
W5016 Weld warning has arisen. (CodeXX)
W6000 Grease reduction gears and motor bearings.
W6001 Replace the robot main cable.
W6002 Replace the cooling fans in the controller.
W6003 Replace the DC power supply in the controller.
W6004 Replace the servo power unit.
W6005 Replace the power amplifier for the robot arm.
W6006 Replace the power amplifier for the robot wrist.
W6007 Replace the power amplifier for the traveller.
W6008 Exp interlock is disabled by jumper wiring.
W6009 Not selected Internal pressure Explosion-proof.
W6010 Disable Gun Relative Distance Check (ID:XX).
W6011 Shutter release signal variable logging error.
W7000 Cannot operate excluding the servo welding gun axis. Because the pressure
measurement mode.
W7001 Detected board gap quantity error.
W7002 Detected board gap quantity error.
W7003 The foreign body was detected in the Tip Dress.
W7004 Value of auto collect exceeds work abnormality level.
A-13
Code Error Message

W7500 Can't continue check motion because separated from last pos.
W7501 Cannot execute a program because of LOW voltage.
W8400 Cannot achieve set force of JtXX.
W8800 Command value almost exceeds virtual safety fence.(SphereXX, LineXX)
W8801 Command value almost exceeds virtual safety fence.(SphereXX, ZUpper)
W8802 Command value almost exceeds virtual safety fence.(SphereXX, ZLower)
W8803 Command value almost invades restricted space.(SphereXX, Part.XX LineXX)
W8804 Command value almost invades restricted space.(SphereXX, Part.XX ZUpper)
W8805 Command value almost invades restricted space.(SphereXX, Part.XX ZLower)
W8806 Command value almost exceeds virtual safety fence.(ToolBox, LineXX)
W8807 Command value almost exceeds virtual safety fence.(ToolBox, ZUpper)
W8808 Command value almost exceeds virtual safety fence.(ToolBox, ZUpper)
W8809 Command value almost invades restricted space.(ToolBox, Part.XX)
W8810 Command value almost exceeds virtual safety fence.(LinkXX, LineXX)
W8811 Command value almost exceeds virtual safety fence.(LinkXX, ZUpper)
W8812 Command value almost exceeds virtual safety fence.(LinkXX, ZLower)
W8813 Command value almost invades restricted space.(LinkXX, Part.XX LineXX)
W8814 Command value almost invades restricted space.(LinkXX, Part.XX ZUpper)
W8815 Command value almost invades restricted space.(LinkXX, Part.XX ZLower)
W8851 Detected area interference.
W8852 Detected arm interference.(XX, XX)
W8853 ILL)Detected arm interference.(XX, XX)
W8854 ILL)Communication time out error.
W8855 ILL)Sequence processing demand completion waiting is time out error.
W8856 ILL)Sequence processing completion waiting is time out error.
W8857 ILL)Sequence processing system error.
W8858 ILL)Create/Set processing completion waiting is time out error.
W8859 ILL)Inter lock less function system error.
W8860 [ARM CONTROL b'd]Data received from IL server is invalid.
W8900 Can not operate because motion limitation signal was input.
E0001 Unknown error.
E0002 [Servo boardXX]CPU BUS error.
E0100 Abnormal comment statement exists.
E0101 Nonexistent label.
E0102 Variable is not defined.
E0103 Location data is not defined.
E0104 String variable is not defined.
A-14
Code Error Message

E0105 Program or label is not defined.
E0106 Value is out of range.
E0107 No array suffix.
E0108 Divided by zero.
E0109 Floating point overflow.
E0110 String too long.
E0111 Attempted operation with neg. exponent.
E0112 Too complicated expression.
E0113 No expressions to evaluate.
E0114 SQRT parameter is negative.
E0115 Array suffix value outside range.
E0116 Faulty or missing argument value.
E0117 Incorrect joint number.
E0118 Too many subroutine calls.
E0119 Nonexistent subroutine.
E0120 No destination program.
E0121 Cannot specify the jump source program as jump destination.
E0900 Block step instruction check sum error.
E0901 Step data is broken.
E0902 Expression data is broken.
E0903 Check sum error of system data.
E1000 ADC channel error.
E1001 ADC input range error.
E1002 PLC interface error.
E1003 Built-in PLC is not installed.
E1004 INTER-bus board is not ready.
E1005 Spin axis encoder difference error.
E1006 Touch panel switch is short-circuited.
E1007 Power sequence board is not installed.
E1008 Second Power sequence board is not installed.
E1009 No.XX I/O board is not installed.
E1010 Power sequence detects error.
E1011 Built-in sequence board is not installed.
E1012 RI/O board or C-NET board is not installed.
E1013 INTER-BUS board is not installed.
E1014 Dual port memory for communication is not installed.
E1015 Amp Interface board is not installed.(Code=XX)
A-15
Code Error Message

E1016 No.XX CC-LINK board is not installed.
E1017 PLC error.Error code is Hex.XX.
E1018 INTER-BUS status error.
E1019 Power sequence board for safety unit is not installed.
E1020 External equipment is abnormal.
E1021 Arm ID board error. (CodeXX)
E1022 Power sequence board error. (CodeXX)
E1023 Communication error in robot network.
E1024 EXT.AXIS release sequence error.(CodeXX)
E1025 EXT.AXIS connect sequence error.(CodeXX)
E1026 Main CPU ID mismatch.
E1027 Safety circuit was cut OFF.
E1028 JtXX motor overloaded.
E1029 Encoder rotation data is abnormal.(JtXX)
E1030 Encoder data is abnormal.(JtXX)
E1031 Miscount of encoder data.(JtXX)
E1032 Mismatch ABS and INC encoder data(JtXX).
E1033 Encoder line error of (JtXX).
E1034 Encoder initialize error (JtXX).
E1035 Encoder response error(JtXX).
E1036 Encoder communication error.(JtXX)
E1037 Encoder data conversion error.(JtXX)
E1038 Encoder ABS-track error.(JtXX)
E1039 Encoder INC-pulse error.(JtXX)
E1040 Encoder MR-sensor error. (JtXX)
E1041 Limit switch (JtXX) is ON.
E1044 Destination position is out of the specified area.
E1045 (Spot welding)Gun-clamp mismatch.
E1046 Too short distance between start point and end point.
E1047 Axis number is not for conveyor follow mode.
E1048 Offset data of zeroing is illegal value.
E1049 Current position is out of the specified area.
E1050 Encoder and brake power off signal not dedicated.
E1051 Incorrect double OX output.
E1052 Work sensing signal is not dedicated.
E1053 Work sensing signal already input.
E1054 Cannot execute motion instruction.
A-16
Code Error Message

E1055 Start point position error for circle.
E1056 MASTER robot already exists.
E1057 Check to which robot MASTER/ALONE were instructed.
E1058 SLAVE robot already exists.
E1059 Not an instruction for cooperative motion.
E1060 Cannot execute in check back mode.
E1061 Cannot execute in ONE program.
E1062 Jt2 and Jt3 interfere during motion to start pose.
E1063 Jt2 and Jt3 interfere during motion to end pose.
E1064 Illegal pallet number.
E1065 Illegal work number.
E1066 Illegal pattern number.
E1067 Illegal pattern type.
E1068 Illegal work data.
E1069 Illegal pallet data.
E1070 ON/ONI signal is already input.
E1071 XMOVE signal is already input.
E1072 Home position data is not defined.
E1073 Illegal timer number.
E1074 Over maximum signal number.
E1075 Illegal clamp number.
E1076 Cannot use negative time value.
E1077 No value set.
E1078 Illegal signal number.
E1079 Cannot use dedicated signal.
E1080 Not RPS mode.
E1081 Cannot use negative value.
E1082 Out of absolute lower motion range limit.
E1083 Out of absolute upper motion range limit.
E1084 Out of set lower motion range limit.
E1085 Out of set upper motion range limit.
E1086 Start point for JtXX beyond motion range.
E1087 End point for JtXX beyond motion range.
E1088 Destination is out of motion range.
E1089 Cannot do linear motion in current configuration.
E1090 External modulation data is not input.
E1091 External modulation data is abnormal.
A-17
Code Error Message

E1092 Modulation data is over limit.
E1093 Incorrect motion instruction to execute modulate motion.
E1094 Illegal joint number.
E1095 Cannot execute motion instruction in PC program.
E1096 Incorrect auxiliary data settings.
E1097 Missing C1MOVE or C2MOVE instruction.
E1098 C1MOVE(CIR1)instruction required before C2MOVE.
E1099 Unable to create arc path, check positions of the 3 points.
E1100 Cannot execute in sealing specification.
E1101 Can only execute in sealing specification.
E1102 Option is not set, cannot execute.
E1103 Over conveyer position.
E1104 Too many SPINMOVE instructions.
E1105 Start/Destination point is in protected space.
E1106 Cannot execute in this robot.
E1107 Cannot use SEPARATE CONTROL.
E1108 Duplicate robot network IDs.
E1109 Conveyor I/F board is not installed.
E1110 GROUP is not primed.
E1111 Due to motion restriction, JtXX cannot move.
E1113 Work sensing signal is not detected.
E1114 Interruption in cooperative control.
E1115 Forced termination of cooperative control.
E1116 Spin axis is not stopped on every 360 degrees.
E1117 Process time over.
E1118 Command value for JtXX suddenly changed.
E1119 Command value for JtXX beyond motion range.
E1120 Current command causes interference betw Jt2 and Jt3.
E1121 Other robot is already in the interference area.
E1122 Unexpected motor power OFF.
E1123 Speed error JtXX.
E1124 Deviation error of JtXX.
E1125 Velocity envelope error JtXX.
E1126 Command speed error of JtXX.
E1127 Command acceleration error of JtXX.
E1128 Uncoincidence error betw destination and current JtXX pos.
E1129 External axis JtXX moved while holding them.
A-18
Code Error Message

E1130 JtXX collision was detected.
E1131 JtXX unexpected shock is detected.
E1132 Motor power OFF. Measurement stopped.
E1133 Conveyor has reached max. value position.
E1134 Abnormal work transfer pitch of conveyor.
E1135 Motor power OFF.
E1136 Standard terminal is not connected.
E1137 Cannot input/output to teach pendant.
E1138 Aux. terminal is not connected.
E1139 DA board is not installed.
E1140 No conveyor axis.
E1141 Conveyor transfers beyond sync. zone.
E1142 No traverse axis.
E1143 Conveyor axis number is not set.
E1144 No Arm control board.
E1145 Cannot use specified channel, already in use.
E1146 [LSEQ]Aborted by processing time over.
E1147 Cannot open setting file, so cannot set to shipment state.
E1148 Cannot read setting file, so cannot set to shipment state.
E1149 Cannot open setting data, so cannot set to shipment state.
E1150 Cannot read setting data, so cannot set to shipment state.
E1151 Too much data for setting to the shipment state.
E1152 Name of setting data for shipment state is too long.
E1153 Power sequence board detected error.(Code=XX)
E1154 Option SIO port not installed.
E1155 A/D converter is not installed.
E1156 [ARM CONTROL BOARD]Processing time over.
E1157 Arm ID I/F board error. (CodeXX)
E1158 (SSCNET)Servo error in JtXX.
E1159 (SSCNET)Error code for servo is (XX).
E1160 (SSCNET)Servo error and monitor setting error of JtXX.
E1161 Automatic Tool Registration not supported by robot model.
E1162 Buffer overflow occurred in the gravity comp. value channel XX.
E1163 Robot stopped in checking operational area.
E1164 [LSEQ]Program execution error at control power ON.(CodeXX)
E1165 Unable to download ext. axis parameter.(Jt-A)
E1166 Num. not assigned to specified channel.(Jt-A)
A-19
Code Error Message

E1167 Unable to download ext. axis parameter.(Jt-B)
E1168 Num. not assigned to specified channel.(Jt-B)
E1169 Error in servo parameter change sequence.(CodeXX)
E1170 Slave is not ready.
E1171 CC-LINK communication board is not installed.
E1172 Weld communication board is not installed.
E1173 Servo communication error JtXX.
E1174 AD board No.0 is not installed.
E1175 Offset data of zeroing is illegal value.(RobotXX)
E1176 (SSCNET)Download error of external axis parameter.
E1177 (SSCNET)Joint number is not assigned to the channel.
E1179 The current under bending compensation is too large.(JtXX)
E1180 Download error of external axis parameter.(JtXX)
E1181 Encoder battery low voltage.[Servo(XX)]
E1182 Encoder battery low voltage.[External axis(XX)]
E1183 Because Jt5 is not zero degree, cannot move along straight line.
E1184 Illegal configuration for motion.
E1185 Jt1 and Jt2 is interfered at start location.
E1186 Jt1 and Jt2 is interfered at end location.
E1187 Current command between Jt1 and Jt2 is interfered.
E1188 (SSCNET)Error in servo parameter change sequence.(CodeXX)
E1189 (SSCNET)Regenerative error of JtXX.(CodeXX)
E1190 (SSCNET)Speed error of JtXX.(CodeXX)
E1191 (SSCNET)Motor overload of JtXX.(CodeXX)
E1192 (SSCNET)Deviation error of JtXX.(CodeXX)
E1193 (SSCNET)Encoder battery of JtXX is low voltage.(CodeXX)
E1194 (SSCNET)Parameter warning of JtXX.(CodeXX)
E1195 (Dual servo)Deviation error between master joint and slave joint.
E1196 While lifter is locked, it cannot move.
E1197 Compensation LS signal is not dedicated.
E1198 Brake check sequence error.
E1199 Brake check function is not supported by servo software ver.
E1200 (Dual servo)Cannot compensate current error (deviation XX).
E1201 Interference check board is not installed.
E1202 Voice recorder cannot stop.
E1203 LS location is not registered.
E1204 Current stretch over the limit.
A-20
Code Error Message

E1205 Total stretch over the limit.
E1207 The type of I/O board on arm ID board is wrong.
E1208 Download error of servo parameter.(JtXX)
E1209 Upload error of servo parameter.(JtXX)
E1210 Cannot execute program because unprotected.
E1211 Because the memory was full, could not copy the program.
E1212 Because the memory was full, the copy of program was suspended.
E1213 Jt4 and robot arm interfere during motion to start pose.
E1214 Jt4 and robot arm interfere during motion to end pose.
E1215 Current command causes interference between Jt4 and robot arm.
E1216 Jt5 and Jt6 interfere during motion to start pose.
E1217 Jt5 and Jt6 interfere during motion to end pose.
E1218 Current command causes interference between Jt5 and Jt6.
E1219 Exceeds allowable No. of output instructions for the path.
E1220 Signal output point is out of the path.
E1221 Too many signal numbers are specified.
E1222 Motion instruction to start/end point of path not set.
E1223 No pose data in last/next motion instruction.
E1224 Several signal output points detected at the same point.
E1225 Correction end instruction is missing.
E1228 Jt4 value in the start point is not 0 degree.
E1229 Jt4 value in the target point is not 0 degree.
E1230 Flange faces direction of upper sphere in start point.
E1231 Flange faces direction of upper sphere in target point.
E1232 Option CPU board is not installed.
E1233 IJoint/ILinear signal not specified.
E1234 IJoint/ILinear signal not detected.
E1235 Separate control I/O board is not installed.
E1236 Distance is too long to correct.
E1237 Vision recognition error.
E1238 Vision communication error.
E1239 Cannot use this instruction in frame correction mode.
E1240 BASE FRAME is not sent from vision unit.
E1241 Improper parameter for FN481.
E1242 Cannot create more than 99 BASE FRAME.
E1243 Cannot execute because cameraXX is disconnected.
E1244 Jt1 and Jt2 and floor interfere during motion to start pose.
A-21
Code Error Message

E1245 Jt1 and Jt2 and floor interfere during motion to end pose.
E1246 Current command causes interference between Jt1, Jt2 and floor.
E1247 Calculation of encoder absolute data is not completed.(JtXX)
E1248 EEPROM access flag in encoder is busy.(JtXX)
E1249 Temperature in encoder is over the limit.(JtXX)
E1250 Rotation speed of encoder is over the limit.(JtXX)
E1251 EEPROM access error occurred in encoder.(JtXX)
E1252 Encoder rotation data (internal) is abnormal.(JtXX)
E1253 Uncoincidence error between request and response in encoder. (JtXX)
E1254 Cannot operate because a MC of a group XX is off.
E1255 The motor power of unchosen robot was turned on.
E1256 Internal valve , sensor and error reset I/F board missing.
E1257 MC of groupXX turned off during individual repeat operation.
E1258 MC turned off during operation.
E1259 Invalid Structure of palletizing instruction.
E1260 Cannot execute instruction during palletizing motion.
E1261 Palletising motion aborted.
E1262 Encoder rotation speed exceeded limit. (JtXX)
E1263 Encoder temperature exceeded limit. (JtXX)
E1264 Velocity envelope error in endless rotation axis.(JtXX)
E1267 The initial setting of Encoder is abnormal. (JtXX)
E1268 Breakage in the encoder line or faulty setting of encoder baud rate. (JtXX)
E1269 The program is for other robot.
E1270 The pose variable is for other robot.
E1271 Interference between arm and floor at start pose.
E1272 Interference between arm and floor at end pose.
E1273 Command causes interference between arm and floor.
E1274 JtXX Over speed in heavy load mode.
E1275 JtXX Beyond the motion range in heavy load mode.
E1276 Start point JtXX is beyond the motion range in heavy load mode.
E1277 End point JtXX is beyond the motion range in heavy load mode.
E1278 Can't slant wrist any more.
E1279 Wrist does not face vertically down at start point.
E1280 Wrist does not face vertically down at end point.
E1281 Command to Jt4 over limit.
E1282 Cannot operate because a MC of a groupXX(JtXX) is off.
E1283 analysis)The E1035 error occurs frequently.JtXX
A-22
Code Error Message

E1284 analysis)The E1035 and E1029 error occur at the same time.JtXX
E1287 Power module error JtXX (UPPER).
E1288 Power module error JtXX (LOWER).
E1289 [Servo boardXX]Synchronous error.(Servo FPGA)
E1290 JtXX Voltage of the current sensor exceeded the upper limit.
E1291 JtXX Current sensor is disconnected or out of order.(U)
E1292 [Servo boardXX]Abnormal signal input from MCXX.
E1293 [Servo boardXX]Current feedback gain is abnormal.
E1294 [Servo boardXX]I/O 24V is low.
E1295 [Servo boardXX]24V for internal valve is low.
E1296 [Servo boardXX]Mismatch in safety circuit LS conditions.
E1297 [Servo boardXX]Mismatch in jumper wiring for detecting internal pressure.
E1298 [Servo boardXX]Mismatch in contact condition of LS override switches.
E1299 [Servo boardXX]Jumper wiring for detecting internal pressure is disconnected.
E1300 [Servo boardXX]DC 24V is abnormal.
E1301 [Servo b’dXX]Encoder type mismatch between software and servo board.
E1302 [MCXX]OFF check is abnormal.(Servo boardXX)
E1303 [MCXX]OFF check of safety relay is abnormal.(Servo boardXX)
E1304 [MCXX]Incorrect operation of K1.(Servo boardXX)
E1305 [MCXX]Incorrect operation of K2.(Servo boardXX)
E1306 [MCXX]Incorrect operation of inrush current control relay.(Servo boardXX)
E1307 [MCXX]Incorrect operation of safety relay KS1.(Servo boardXX)
E1310 [MCXX]Incorrect operation of motor ON relay.(Servo boardXX)
E1311 [MCXX]Incorrect operation of safety circuit motor OFF relay.(Servo boardXX)
E1312 [MCXX]Mismatch in safety circuit motor OFF relay.(Servo boardXX)
E1313 [MCXX]Mismatch in individual MC control of safety circuit.(Servo boardXX)
E1314 [MCXX]Thyristor Thermal is abnormal.(Servo boardXX)
E1315 Watchdog error in NoXX I/O board.
E1316 [I/O board(No.XX)]Access Error.[Address:XX][Code:XX]
E1317 [Servo Board(NoXX)]Response from monitor is abnormal. [Code:XX]
E1318 [MCXX]DC 20V is abnormal.(Servo boardXX)
E1319 Internal valve, sensor and error reset I/F board No.2 is not installed.
E1321 [Main CPU board]Servo board(XX) communication error. (CodeXX)
A-23
Code Error Message

E1322 Setting num. of safety circuits differs betw. powerseq.b'd and MCXX. (Servo
b'dXX)
E1323 Setting num. of safety circuits differs betw. servo b'dXX and MCXX.
E1324 Safe circuit disconnected between power sequence board and servo boardXX.
E1325 Safe circuit disconnected between servo boardXX and MCXX.
E1326 Safety fence is open.
E1327 [Power sequence board]Miscompare in motor off relay condition on safety
circuit.
E1328 [Power sequence board]Error of motor off relay on safety circuit.
E1329 [Power sequence board]Error in TEACH/REPEAT switch on safety circuit.
E1330 [Power sequence board]IO 24V is low.
E1331 [Power sequence board]Thermal error.
E1332 [Power sequence board]Power error signal was input from servo boardXX.
E1333 Motor power ON signal has turned off.(Servo boardXX)(MCXX)
E1334 TEACH/REPEAT switch is abnormal.(Mode differs betw. safety circuit and
monitor.)
E1335 Unexpected motor powerOFF.(Servo boardXX)(MCXX)
E1336 [Servo boardXX]Communication error with Main CPU board.
E1337 [MCXX]Brake power is abnormal.(Servo boardXX)
E1338 [MCXX]P-N low voltage.(Servo boardXX)
E1339 [MCXX]P-N high voltage.(Servo boardXX)
E1340 [MCXX]Regenerative time over.(Servo boardXX)
E1341 [MCXX]Regenerative resistor overheat.(Servo boardXX)
E1342 Motor harness disconnected or robot temperature exceeded limit.(MCXX)
E1343 Mismatch betw connected place of brake harness and software setting. (JtXX)
E1344 JtXX Current sendor is disconnected or out of order.(V)
E1345 [Servo boardXX]Limit switch signal line is disconnected.
E1346 JtXX Failed to get encoder full data.
E1347 [MCXX]Destination spec is incorrect.(Servo boardXX)
E1348 [MCXX]Robot arm spec/separate control spec is incorrect. (Servo boardXX)
E1349 [MCXX]Explosion proof setting is mismatch.(Servo boardXX)
E1350 [MCXX]MC specification error.[CodeXX](Servo boardXX)
E1351 [MCXX]MC OFF delay specification is incorrect.(Servo boardXX)
E1352 JtXX Codes set in software and power block do not match.
E1353 [Main CPU board]CPU temperature is abnormal.
E1355 Error in servo I/F command communication.(Code:XX)
E1356 The tool shape is not set.
A-24
Code Error Message

E1357 Failed to download ext. axis parameter data.(Jt-C)
E1358 Axis No. is not assigned to the specified channel.(Jt-C)
E1359 JtXX axis U phase overcurrent.
E1360 JtXX axis V phase overcurrent.
E1361 JtXX axis W phase overcurrent.
E1362 [Servo boardXX]Speed of tool center point exceeded safety speed.
E1363 [Servo boardXX]Speed of flange center point exceeded safety speed.
E1365 TEACH KEY SWITCH is ON in two or more places.
E1366 Watchdog error in NoXX ANYBUS interface board.
E1367 Improper parameter for KI481.
E1377 [Main CPU board] Speed of tool center point exceeded safety speed.
E1378 [Main CPU board] Speed of flange center point exceeded safety speed.
E1379 [Main CPU board] Deviation error of JtXX.
E1382 [Servo boardXX] Internal valve/sensor interface board is not installed.
E1392 Servo software does not support deviation alarm function.
E1409 [MCXX]Error of gate power output in MC control board[Diagnostic pulse]
(Servo board XX)(CodeXX)
E1411 [MCXX]Error of gate power output in MC control board[mismatch between
E1412 [MCXX]Error of brake power output in MC control board[Diagnostic pulse]
E1414 [MCXX]Brake release switch was pushed during motor power ON, or error of
break power output(Servo board XX)(CodeXX)
E1415 [MCXX]Error of motor ON output in MC control board[Diagnostic pulse](Servo
board XX)(CodeXX)
E1416 [MCXX]Error of motor ON output in MC control board[mismatch between
E1417 [MCXX]Error of motor ON output in MC control board[mismatch between
E1418 [MCXX]Error of MC shutoff output in MC control board[Diagnostic pulse]
E1419 [MCXX]Error of MC shutoff output in MC control board[mismatch between
E1420 [MCXX]Error of MC shutoff output in MC control board[mismatch between
E1421 [MCXX]Mismatch in safety circuit inputs (Servo board XX)(CodeXX)
E1422 [MCXX]Short circuit in safety circuit inputs or 24V power drop (Servo board
A-25
Code Error Message

XX)(CodeXX)
E1423 [MCXX]MC control board error[Diagnostic pulse of safety circuit input](Servo
board XX)(CodeXX)
E1424 [MCXX]Mismatch in MC shutoff inputs (Servo board XX)(CodeXX)
E1425 [MCXX]Short circuit in MC shutoff inputs or 12V power drop (Servo board
XX)(CodeXX)
E1426 [MCXX]MC control board error[Diagnostic pulse of MC shutoff input](Servo
board XX)(CodeXX)
E1427 [MCXX]Relay connected to motor ON output is welded or error of weld
E1428 [MCXX]MC connected to MC shutoff output is welded or error of weld
E1429 [MCXX]Failure of MC in MC unit (Servo board XX)(CodeXX)
E1430 [MCXX]Error of PFC board(Servo board XX)
E1431 [MCXX]Voltage drop of power for power module in MC power board(Servo
board XX)
E1432 [MCXX]Communication error for PN voltage sensor(Servo board XX)
E1433 [MCXX]Mismatch between software setting and Off-delay DIP-SW setting on
MC control board (Servo board XX)
E1434 [MCXX]MC power board is wrong(Servo board XX)
E1436 [MCXX]P-N low voltage.(Servo boardXX)（CodeXX)
E1437 [MCXX]Mismatch in state of ind, shutoff contacts of safety circuits.(SrvB'dXX)
(CodeXX)
E1438 [MCXX] PFC board does not working.(Servo board XX)(PN voltage = XXV)
E3808 Motor power OFF (EXT_EMG).
E3809 Brake release signal error.
E3810 Power sequence ready off.
E3811 JtXX axis amp command value suddenly changed.
E3900 Mismatch moving tool data and selected tool data.
E4000 Data communication error.
E4001 Data reading error.
E4002 Data write error.
E4003 Unexpected error in file access.
E4004 Communication retry error.
E4005 Communication process was stopped.
E4006 Receive no data after request.
E4007 Receiving data is too long(MAX=255 characters).
A-26
Code Error Message

E4008 Abnormal data (EOT) received in communication.
E4009 Communication time out error.
E4010 Terminal already in use.
E4011 Communication port already in use.
E4012 Waiting for input of PROMPT. Connect input device.
E4013 TELNET)SEND error. Code=XX
E4014 TELNET)RECV error. Code=XX
E4015 TELNET)IAC receive error. Code=XX
E4016 TELNET)Close failure. Code=XX
E4017 TELNET)Main socket close failure. Code=XX
E4018 TELNET)System error. Code=XX
E4019 TCPIP)Socket open failure. Code=XX Dst.IP=XX.XX.XX.XX
E4020 TCPIP)Socket close failure. Code=XX Dst.IP=XX.XX.XX.XX
E4021 TCPIP)Communication Error. Code=XX Dst.IP=XX.XX.XX.XX
E4022 TCPIP)Message is too long.
E4023 TCPIP)Cannot reach the Host.
E4024 TCPIP)Communication Time Out. Dst.IP=XX.XX.XX.XX
E4025 TCPIP)Connection aborted.
E4026 TCPIP)No Buffer Space.
E4027 TCPIP)Bad Socket.
E4028 FTP)Data receive error.(Code=XX)
E4029 FTP)Data send error.(Code=XX)
E4030 FTP)Server does not recognize command.(Code=XX)
E4031 FTP)Failed to disconnect with FTP server.(Code=XX)
E4032 FTP)Unregistered OS detected.
E4033 FTP)Failed to connect with server.(Code=XX)
E4034 FTP)Failed to receive HOST OS information.(Code=XX)
E4035 FTP)TCP/IP not initialized.
E4036 FTP)FTP service busy now.
E4037 FTP)Failed AUTO-SAVing.
E4053 Channel error.
E4054 TCPIP)Cannot execute because Ethernet board not installed.
E4055 TCP)Cannot create a socket.
E4056 TCP)This port is not in LISTEN (SOCK).
E4057 TCP)Illegal Socket ID.
E4059 ASCYCLE communication receive error.(Code:XX)
E4060 [ARM CONTROL BOARD]ASCYCLE communication receive
A-27
Code Error Message

error.(Code:XX)
E4061 Received gauge hole data exceeds allowable range.
E4062 Master/slave data is not registered.
E4063 Reference point data is not registered.
E4064 3D calibration/measurement modes are both ON.
E4065 Unregistered variable specified to receive data.
E4066 Variable specified to receive data is broken.
E4067 Received data is broken.
E4068 Start code is not correct.
E4069 End code is not correct.
E4070 3D camera group No. not specified.
E4071 Incorrect 3D camera group No.
E4072 Communication beginning wait time out error.
E4073 No servo off signal from ARM I/F board.
E4074 [Servo boardXX]No response from MCXX.(Code:XX)
E4075 [Servo boardXX]Error in communication with MCXX.(Code:XX)
E4076 [MCXX]Servo boardXX communication error.(Code:XX)
E4077 [Servo boardXX]Error in communication with main CPU board.(Code:XX)
E4078 [Servo boardXX]Error in command communication with the main CPU
board.(Code:XX)
E4500 ANYBUS)IN-AREA request timeout.XX
E4501 ANYBUS)OUT/FB.CTRL release timeout.XX
E4510 DN)Master status.XX
E4511 DN)Node status.XX
E4512 ABM-DN)Mailbox error.
E4520 ABMA-PDP)Status STOP.XX
E4521 ABMA-PDP)Status OFFLINE. XX
E4522 ABMA-PDP)I/O data Communication error.XX
E4523 ABMA-PDP)Sending of timed out I/O data.XX
E4524 ABMA-PDP)Timeout of receiving I/O data.XX
E4525 ABMA-PDP)Timeout of sending message.XX
E4526 ABMA-PDP)Timeout of receiving message.XX
E4527 ABMA-PDP)Check configuration data.XX
E4528 PROFIBUS)Slave Diag-error response detected.XX
E4529 PROFIBUS)Statistic counter-error response detected.XX
E4530 DN)DeviceNet cable is disconnected.
E4531 CC-LINK)Communication has been disconnected. XX
A-28
Code Error Message

E4532 CC-LINK)Initial condition setting is incorrect.
E4533 CC-LINK)Watch dog timeout error.
E4534 CC-LINK)Parameter setting error. XX
E4535 CC-LINK)Time out on setting parameter.
E4536 CC-LINK)Master board is abnormal. XX
E4537 CC-LINK)Initialization error on master board . XX
E4538 CANopen)Network is disconnected.
E5000 Connected permission signal has not been turned ON.
E5001 RWC type is not process control type.
E5002 1GS board is not process control type.
E5003 Illegal extend (retract) output signal.
E5004 Weld completion signal already input.
E5005 (Spot weld)Weld schedule setting data is abnormal.
E5006 CLAMP SPEC is not set as PULSE.
E5007 Servo weld gun not connected or wrong gun connected.
E5008 Tip wear measurement (STAGE1) was not executed.
E5009 Work sensing signal(gun_tip touch signal) is not set.
E5010 Servo weld gun mechanical parameter is not set.
E5011 This clamp number already set for servo weld gun axis.
E5012 Cannot change the gun because offset data is abnormal.
E5013 Cannot change multiple guns at the same step.
E5014 Cannot execute, gun connected to another joint.
E5015 Gun status data disagrees with clamp condition.
E5016 Data of SRVPRESS is wrong.
E5017 Wear base data is not registered.
E5018 Weld completion signal has not been detected.
E5019 Weld fault signal is detected.
E5020 Retract pos. monitor error.
E5021 Extend pos. monitor error.
E5022 Current gun retract position differs from a destination.
E5023 Wear is abnormal, cannot take measurement.
E5024 Pressurization comp. signal has not been detected.
E5025 Gun opening comp. signal has not been detected.
E5026 (Spot welding)RWC error. XX
E5027 Robot stopped in welding.
E5028 Cannot achieve set force.
E5029 Gun tip stuck.
A-29
Code Error Message

E5030 Copper plate wear exceeds limit. step=XX
E5031 Weld completion signal is not turned OFF.
E5032 Calibration did not end normally.
E5033 Cannot weld because of abnormal thickness.
E5034 Tip wear exceeds limit. (MOVING SIDE)
E5035 Tip wear exceeds limit. (FIXED SIDE)
E5036 Incorrect gun status data.
E5037 Tip wear exceeds limit. XX
E5038 Arc detection signal did not turn OFF.
E5039 No response from RWC communication I/F board.
E5040 Cannot connect gun because gun is already connected.
E5041 Cannot disconnect gun because gun is already disconnected.
E5042 Gun No is not defined or Gun type is not servo gun.
E5043 Communication error in welder. (CodeXX)
E5044 Failed to get weld data. (timer XX)
E5045 Failed to change weld data. (timer XX)
E5046 Weld error has arisen.
E5047 Receiving weld items now, wait till completion.
E5048 Weld controller is unconnected or weld items are not received. (timer XX)
E5049 Serial number signal error.
E5050 This welder is without Traceability.
E5051 Cannot calibrate because tool change axis is disconnected.
E5052 The pressurizing power measurement value is abnormal.
E5053 The pressurizing power sensor is disconnected or it breaks down.
E5054 The selector switch on TP is set to manual operation.
E5055 The selector switch on TP is set to automatic operation.
E5056 No Initialization Weld board.
E5057 Initialization failure in Initialization Weld board.
E5058 Welder(DENGEN COMPANY) not connected. (welder XX)
E5059 Welder(DENGEN COMPANY) response error. (welder XX)
E5060 Initialization Weld board protected. (welder XX)
E5061 Welder(DENGEN COMPANY) data process not execute. (welder XX)
E5062 Welder(DENGEN COMPANY) data process error.(welder XX)
E5063 Weld error has arisen. (CodeXX)
E5064 Welder(DENGEN COMPANY) of weld was aborted. (welder XX)
E5065 Welder(DENGEN COMPANY) error has arisen. (welder XX)
E5066 Waiting weld completion time out.(welder XX)
A-30
Code Error Message

E5067 Magnet control is abnormal.(welder XX)
E5500 Vision board is not installed.
E5501 (Vision)Camera not connected.
E5502 (Vision)Incorrect parameter.
E5503 (Vision)Incorrect Symbol.
E5504 (Vision)Incorrect name.
E5505 (Vision)Incorrect image memory.
E5506 (Vision)Incorrect histogram data.
E5507 (Vision)Incorrect mode.
E5508 (Vision)Incorrect density(/color).
E5509 (Vision)Incorrect camera input assignment.
E5510 (Vision)Incorrect camera ch.number.
E5511 (Vision)Incorrect Window No.
E5512 (Vision)Incorrect coordinates data.
E5513 (Vision)Incorrect number.
E5514 (Vision)Incorrect image code(binary/multi).
E5515 (Vision)Incorrect threshold.
E5516 (Vision)PROTO(/TEMPLATE) not registered or already exists.
E5517 (Vision)Cal. data not registered.
E5518 (Vision)Graphic cursor is not initialized.
E5519 (Vision)Too many samples from PROTO object.
E5520 (Vision)Too many targets detected.
E5521 (Vision)Vision command not initiated.
E5522 (Vision)System registered with abnormal data.
E5523 (Vision)Error in processing image(s).
E5524 (Vision)Sound port assigned another function.
E5525 (Vision)Lack of data storage area.
E5526 (Vision)Incorrect synch. mode.
E5527 (Vision)Vision processing now.
E5528 (Vision)Image capture error.
E5529 (Vision)Time out or Buffer overflow.
E5530 (Vision)Failed to write on flash memory.
E5531 (Vision)Proto data abnormal, so initialized.
E5532 (Vision)Work detection failure.
E5533 (Vision)Initialization error. Code = XX
E5534 (Vision)Vision system error.
E5535 (Vision)Specified motion mode is incorrect.
A-31
Code Error Message

E5536 (Vision)Inappropriate camera/projector parameters.
E5537 (Vision)Incorrect camera switch assignment.
E5538 (Vision)This plane is assigned to another camera.
E5539 (Vision)Edge was not found.
E5540 (Vision)Inappropriate HSI data.
E5541 (Vision)H data range width is over 128.
E5542 (Vision)Distance image input unit not set for camera.
E5543 (Vision)Cannot calculate the set edge points.
E5544 (Vision)Check color conversion table type in set config.
E5545 (Vision)Incorrect area size.
E5546 (Vision)Slit image does not exist.
E5547 (Vision)Incorrect no. of correlation vectors.
E5548 (Vision)Inappropriate vector data.
E5549 (Vision)X-Fit environment was not set.
E5550 (Vision)Mouse is not initialized.
E5551 (Vision)Camera switcher board is not installed.
E6000 Explosion proof teach pendant is not connected.
E6001 Step after XD(2)START must be LMOVE or HMOVE.
E6002 Signal condition already input.
E6003 Door open detect signal is not dedicated.
E6004 Location data was not detected.
E6005 Incorrect setting of barrier unit.
E6006 Signal not detected.
E6007 Wrist can't be straightened any more (Singular point 1).
E6008 Wrist can't be bent any more (Singular point 2).
E6009 Purge air flow is insufficient.
E6010 Out of XYZ MOVING AREA LIMIT.
E6011 Pressure within enclosure is low.
E6012 Relative distance between guns is too near (ID:XX).
E6013 No free memory in program queue.
E6014 No free memory in delayed start queue.
E6015 Special signal is not specialized.
E6016 Robot arm stretching out (Singular Point 3).
E6017 Out of mechanical XYZ motion limits.
E6018 Painting equipment control board error. (CodeXX)
E6019 Painting equipment control board is not installed.
E6020 Monitoring Robot ID is duplicate.
A-32
Code Error Message

E6021 (Mutual-Wait)There is no response from the other party robot.
E6022 Duplicate Mutual-Wait IDs.
E6023 (Mutual-Wait)Communication error in Mutual-Wait.
E6024 Wrist can't bend any further left/right (Singular Point 1).
E6025 (Conveyer synchronous communications)It is a conveyer position reception
error.
E6026 Guns are too near in X direction. (ID:XX)
E6027 Guns are too near in Y direction. (ID:XX)
E6028 Guns are too near in Z direction. (ID:XX)
E6029 [Servo boardXX]Mismatch in internal pressure in safety circuit.
E6030 [Servo boardXX]Pressure within enclosure is low.
E6031 Monitoring Robot ID is invalid.
E6032 [Purge control board]Pressure within enclosure is low.
E6033 Painting equipment control process error. (CodeXX)
E6034 Cartridge table rotate command is abnormal.
E6500 No welding Interface board.
E6501 No.2 welding Interface board not found.
E6502 Arc failure.
E6503 Wire stuck.
E6504 Arc start failure.
E6505 Arc weld insulation defect.
E6506 Torch interference.
E6507 Illegal interpolation data.
E6508 No D/A board for polarity ratio control.
E6509 No work detected.
E6510 Undefined sensing direction.
E6511 Insufficient num. of sensing points.
E6512 Undefined mother or daughter work.
E6513 Too many sensing points.
E6514 Work specification incorrect.
E6515 Incorrect sensing point specified.
E6516 Wire check failure.
E6517 Incorrect weld condition number.
E6518 No weld condition data set.
E6519 Weld condition data is out of range.
E6520 Laser sensor tracking value exceeded.
E6521 Beyond Laser sensor tracking ability.
A-33
Code Error Message

E6522 Laser sensor cannot detect welding joint.
E6523 Calibration data between torch and camera is not ready.
E6524 Error in data calculated using Laser sensor.
E6525 Cannot detect weld joint, Laser sensor tracking set already.
E6526 No response from Laser sensor controller.
E6527 Laser sensor communication error. Code is XX.
E6528 Start point not found by Laser sensor.
E6529 Finish point not found by Laser sensor.
E6530 Cannot use circular interp. with Laser sensor function.
E6531 Cannot turn Laser ON because motor power is OFF.
E6532 No communication board to Laser sensor.
E6533 No RTPM board.
E6534 Too many taught points for RTPM.
E6535 RTPM arc sensor error.
E6536 RTPM current deviation error.
E6537 RTPM tracking value is out of range.
E6538 Beyond RTPM tracking ability.
E6539 AVC tracking value is out of range.
E6540 Beyond AVC tracking ability.
E6541 No AVC board.
E6542 AVC voltage deviation error.
E6543 Too many taught points for AVC.
E6544 Hyper Arc tracking value is out of range.
E6545 Beyond Hyper Arc tracking ability.
E6546 Bead end is not found.
E6547 Finish end is not found.
E6548 Hyper Arc revolution beyond normal deviation.
E6549 Hyper Arc torch calibration error.
E6550 Hyper Arc Z phase index error.
E6551 No Hyper Arc board.
E6552 Hyper Arc board error. Code is XX.
E6553 Hyper Arc current sensor error.
E6554 Hyper Arc voltage sensor error.
E6555 Hyper Arc current deviation error.
E6556 Hyper Arc amplifier error. Code is XX.
E6557 No Wire feeding Control board.
E6558 Wire feeding control error, code is XX.
A-34
Code Error Message

E6559 Wire feeding speed deviation error.
E6560 Cannot re-calibrate weld in progress.
E6561 Cannot weld, re-calibration in progress.
E6562 Electric pole stuck.
E6563 KHITS tracking system error. (Code = XX)
E6564 The arc weld instruction sequence is incorrect.
E6565 Arc welding Interface board(1LN) is not installed.(robot XX)
E6566 FN instructions not executed in the correct order.
E6567 KLS tracking system error.(Code=XX)
E6568 Failed in executing command to tracking system.(cmd=XX)
E6569 Taught data exceeds inclination limit for compensation.
E6570 Cannot execute because welding now.
E6571 Cannot execute because wire inching/retracting now.
E6572 Teach point for circular motion is missing.
E6573 The welding machine is abnormal.(Code=XX)
E6574 Sensing of groove: cannot detect edge.
E6575 Sensing of groove: gap error.
E6576 Welder is not ready for operation. (Code=XX)
E6577 Deviation is too large. Reset allows non-correction movement.
E6578 Sensing was interrupted due to power OFF. Restore step and retry.
E6579 KI instructions not executed in the correct order.
E7000 Servo weld gun disconnected.
E7001 Location data includes released gun status data.
E7002 Destination is far from target point.
E7003 The clearance distance of gunXX is set to 0mm.
E7004 Gun tip wear change over the limit. (MOVING SIDE)
E7005 Gun tip wear change over the limit. (FIXED SIDE)
E7006 Clamp number or gun number is not servo weld gun.
E7007 Cannot change tip base data in 1 Stg. because tip wear rate is not set.
E7008 Independent Gun control is not completed.
E7009 Current limit for servo welding gun is abnormal.
E7500 JtXX Collision is detected.
E7501 JtXX Unexpected shock is detected.
E7502 AC Fail Process Error = XX
E7503 POWER SEQUENCE setting data incorrect.
E7504 Angle between JtXX is out of range at start location.
E7505 Angle between JtXX is out of range at end location.
A-35
Code Error Message

E7506 Angle between JtXX is out of range.
E7507 SC1MOVE or SC2MOVE instruction is required after SC1MOVE.
E7508 SC1MOVE instruction is required before SC2MOVE.
E7509 Cannot execute, interpolation conditions are not fulfilled.
E7510 Cannot move with current posture.
E7511 Brake control bit number is duplicated.
E7512 L3C1MOVE or L3C2MOVE instruction is required after L3C1MOVE.
E7513 L3C1MOVE instruction is required before L3C2MOVE.
E7514 Specified parameter is not consistent.
E8200 Not in cooperative mode.
E8201 Unmatch the total of motion instruction in cooperative mode.
E8202 Unmatch step of motion instruction in cooperative mode.
E8203 Cannot use this instruction in cooperative mode.
E8204 Invalid cooperative group No.
E8205 No JMASTER robot.
E8206 TouchSensing in Cooperative mode is no supported.
E8207 JMASTER robot already exists.
E8208 WSLAVE robot already exists.
E8209 Fixed Point Motion in Cooperative mode is no supported.
E8210 No WSLAVE robot.
E8211 Out of sync.
E8212 Cannot continue non-cooperative instruction in cooperative mode.
E8213 No MASTER robot.
E8214 No SLAVE robot.
E8400 Servohand opened in clamp ON step.(CLAMP=XX)
E8401 Clamping position of servo Hand is error.(CLAMP=XX)
E8402 Cannot achieve set force of JtXX.
E8403 NC Joints lock signal not off.
E8404 Interpolation other than joint int. is unavailable.
E8405 It tries to move the Matehan axis with the axis locked.
E8600 （FSJ)Processing condition error.XX
E8601 Gap was over the lower pos. limit.
E8602 Reached the Penetration depth within min.processing time.
E8603 It could not reach the set Penetration depth within the appointed period.
E8604 Pressure cable disconnected.
E8605 Please input two set pressure or more.
E8606 Please input data in ascending order.
A-36
Code Error Message

E8607 FSJ COUNTER ALARM.XX
E8608 (FSJ)FSJ schedule setting data is abnormal.
E8609 Setting tip force is over limit.
E8610 Setting rotation speed is over limit.
E8611 FSW Logging buffer is full.
E8800 Command value almost exceeds virtual safety fence.(SphereXX, LineXX)
E8801 Command value almost exceeds virtual safety fence.(SphereXX, ZUpper)
E8802 Command value almost exceeds virtual safety fence.(SphereXX, ZLower)
E8803 Command value almost invades restricted space.(SphereXX, Part.XX LineXX)
E8804 Command value almost invades restricted space.(SphereXX, Part.XX ZUpper)
E8805 Command value almost invades restricted space.(SphereXX, Part.XX ZLower)
E8806 Command value almost exceeds virtual safety fence.(ToolBox, LineXX)
E8807 Command value almost exceeds virtual safety fence.(ToolBox, ZUpper)
E8808 Command value almost exceeds virtual safety fence.(ToolBox, ZUpper)
E8809 Command value almost invades restricted space.(ToolBox, Part.XX)
E8810 Command value almost exceeds virtual safety fence.(LinkXX, LineXX)
E8811 Command value almost exceeds virtual safety fence.(LinkXX, ZUpper)
E8812 Command value almost exceeds virtual safety fence.(LinkXX, ZLower)
E8813 Command value almost invades restricted space.(LinkXX, Part.XX LineXX)
E8814 Command value almost invades restricted space.(LinkXX, Part.XX ZUpper)
E8815 Command value almost invades restricted space.(LinkXX, Part.XX ZLower)
E8820 Current value exceeded virtual safety fence.(SphereXX, LineXX)
E8821 Current value exceeded virtual safety fence.(SphereXX, ZUpper)
E8822 Current value exceeded virtual safety fence.(SphereXX, ZLower)
E8823 Current value invaded restricted space.(SphereXX, Part.XX LineXX)
E8824 Current value invaded restricted space.(SphereXX, Part.XX ZUpper)
E8825 Current value invaded restricted space.(SphereXX, Part.XX ZLower)
E8826 Current value exceeded virtual safety fence.(ToolBox, LineXX)
E8827 Current value exceeded virtual safety fence.(ToolBox, ZUpper)
E8828 Current value exceeded virtual safety fence.(ToolBox, ZLower)
E8829 Current value invaded restricted space.(ToolBox, Part.XX)
E8830 Current value exceeded virtual safety fence.(LinkXX, LineXX)
E8831 Current value exceeded virtual safety fence.(LinkXX, ZUpper)
E8832 Current value exceeded virtual safety fence.(LinkXX, ZLower)
E8833 Current value invaded restricted space.(LinkXX, Part.XX LineXX)
E8834 Current value invaded restricted space.(LinkXX, Part.XX ZUpper)
E8835 Current value invaded restricted space.(LinkXX, Part.XX ZLower)
A-37
Code Error Message

E8850 Disabled robot motion.
E8851 Detected area interference.
E8852 Detected arm interference.(XX, XX)
E8853 Failed to predict trajectory.
E8854 Detected near miss.(XX, XX)
E8855 No response from interference check board.
E8856 Communication error between interference check board and ARM CONTROL
board.
E8857 The number of robots is too many.
E8860 [ARM CTRL BOARD]Cannot receive data from INTERFERENCE CHECK
BOARD.
E8861 Communication error between IL server and ARM CONTROL board.
E8862 Cable disconnected between IL server and ARM CONTROL board.
E8900 Detected torque for load presence is abnormal.
E8901 Detected torque for load absence is abnormal.
E8902 Stopped because motion limitation signal was input.
E9300 Cannot rotate JtXX. Because disconnected axis.
E9301 Cannot rotate JtXX. Because invalid axis.
E9302 Rotation speed setting for JtXX is abnormal.
D0001 CPU error.(PC=XX)
D0002 Main CPU BUS error.(PC=XX)
D0007 [Servo boardXX]CPU error. (CodeXX)
D0008 [Servo boardXX]Floating point exception. (CodeXX)
D0009 [Servo boardXX]CPU exception. (PC=XX)
D0900 Teach data is broken.
D0901 AS Flash memory sum check error.
D0902 Servo Flash memory sum check error.
D0903 IP board memory error. (XX)
D0904 Memory is locked due to AC_FAIL.
D1003 Init. error of servo control software.
D1011 As or servo software is not compatible with the robot model.
D1012 Servo type mismatch. Check the settings.
D1014 Servo system error.(Code=XX)
D1015 The servo data file does not exist.
D1016 Data applicable to the robot model not in servo data file.
D1017 Error of download of servo data.
D1018 Servo software version mismatch.
A-38
Code Error Message

D1020 [ARM CONTROL BOARD]Synchronous error between CPUs.
D1021 Servo FPGA configuration data not found.
D1022 Configuration error in servo FPGA.(CodeXX)
D1023 Current mismatch betw. m-plexer&software. JtXX
D1025 [Servo boardXX]Detected Watch dog error.(Servo FPGA)
D1026 [Servo boardXX]Abnormal signal input from power sequence board.
D1027 [MCXX]Detected Watch dog error.
D1028 [Servo boardXX]DC power is abnormal.(Servo FPGA)
D1029 [Servo boardXX]AC primary power is abnormal.(Servo FPGA)
D1030 Cannot start communication with the servo boardXX.
D1031 Read error of servo software.
D1032 [Servo boardXX]Download error of servo software.(CodeXX)
D1033 Connection Port No(XX) and Servo board No(XX) mismatch.
D1034 The servo data file is missing or not acceptable.(CodeXX)
D1035 [Servo boardXX]Init. error of servo software.(CodeXX)
D1036 [Servo boardXX]Download error of servo data.(CodeXX)
D1037 [Servo boardXX]Configuration error in servo FPGA.(CodeXX)
D1038 [Servo boardXX]Upload error of servo software initial data.(CodeXX)
D1039 [Servo boardXX]Download error of servo software initial data.(CodeXX)
D1040 [Servo boardXX]Device check error. (CodeXX)
D1041 JtXX axis brake release circuit is abnormal.
D1044 [MCXX] Detected Watch dog error.(Servo board XX)(codeXX)
D1500 Encoder misread error. JtXX
D1501 Defective gun changer connection or encoder comm. error.
D1502 Amp overcurrent. JtXX
D1504 Abn. curr feedback JtXX. (Amp fail, pwr harness disconnect)
D1507 AC primary power OFF.
D1512 Brake line error for JtXX.
D1516 Mismatch betw hard/software settings for HOLD backup time.
D1517 Blown fuse on safety circuit emergency line.
D1518 Mismatch in the Emer. Stop condition on safety circuit.
D1520 Mismatch in safety circuit TEACH/REPEAT condition.
D1521 Mismatch in safety circuit safety-fence condition.
D1522 Mismatch in cond. of safety circuit enabling device.
D1523 Mismatch in cond. of safety circuit ext.enabling device.
D1528 Controller temperature is out of range.
D1529 Signal harness disconnected or encoder power error.
A-39
Code Error Message

D1530 Abnormal current limit of JtXX.
D1532 (SSCNET)EnCoder communication error.(JtXX)(CodeXX)
D1533 (SSCNET)Absolute position of JtXX is erased.(CodeXX)
D1534 (SSCNET)Parameter error of JtXX.(CodeXX)
D1535 (SSCNET)Alarm of JtXX.(CodeXX)
D1536 JtXX does not move normally.
D1539 Power supply circuit for PWM signal output malfunctioned.
D1541 Encoder type set in software and arm control board mismatch.
D1542 No Rotation data from multidrop encoder at initialize.
D1543 [Servo boardXX]DC 5V is abnormal.
D1544 [Servo boardXX]DC 3.3V is abnormal.
D1545 [Servo boardXX]DC 12V is abnormal.
D1549 [Servo boardXX]Primary power source is too low.
D1550 [Servo boardXX]Primary power source is too high.
D1551 [Servo boardXX]AC primary power OFF.
D1552 [MCXX]DC 3.3V is abnormal.
D1553 [MCXX]DC 5V is abnormal.
D1557 [Power sequence board]DC 3.3V is abnormal.
D1558 [Power sequence board]DC 5V is abnormal.
D1561 [Power sequence board]AC primary power OFF.
D1562 [Power sequence board]AC primary power voltage is too high.
D1563 [Power sequence board]AC primary power voltage is too low.
D1564 [Power sequence board]Remote power off signal was detected.
D1565 Cannot access power sequence board.(CodeXX)
D1566 P-N capacitor has not discharged.(Servo board XX)(MCXX)
D1567 [Servo boardXX]Primary Power source is error.
D1568 [Servo boardXX]Power supply circuit for PWM signal output malfunctioned.
D1572 [MCXX]MC control board error[clock](Servo board XX)(CodeXX)
D1573 [MCXX]MC control board error[reset IC] (Servo board XX)(CodeXX)
D1575 [MCXX]Setting error of Dip-SW for Off-delay setting(Servo board
XX)(CodeXX)
D1576 [MCXX]Error reset for MC control board is input over the fixed time(Servo
A-40
Code Error Message

board XX)(CodeXX)
D1577 [MCXX]Error of gate power output in MC control board[detected ON during
D1578 [MCXX]Error of brake power output in MC control board[detected ON during
D1579 [MCXX]P-N Capacitor is not connected.(Servo board XX)
D2000 No response from Comm. board for Laser sensor.
D2001 RI/O or C-NET board initialize error.
D2002 No response from the Arm ID board.
D2003 No data in the Arm ID board.
D2004 Mismatch data in the Arm ID board.
D2005 CC-LINK software version mismatch.
D2006 Watch dog error on communication board for Explosion proof TP.
D2007 No response from the built-in sequence board.
D2008 Magnet is Contactor of groupXX is stuck.
D2009 Sensor for detecting pressure in enclosure is abnormal.
D2010 Sync. error between User I/F and Arm control board.
D2011 Parameter download error betw User I/F & Arm control boards.
D2012 Soft Absorber error. Turn OFF & ON the control power.
D2013 Change gain error. Turn OFF & ON the control power.
D2014 Robot network initialize error.
D2016 No response from the Arm control board.
D2021 Arm data file is not found.
D2022 Arm data is not found.
D2023 Failed to load arm data.
D2024 [ARM CTRL BOARD]Robot type setting failed.
D2025 Robot codes set in software and Arm ctrl board do not match.
D2026 Codes set in software & curr. sensor I/F b'd do not match.
D2027 Codes set in software and power block do not match.
D2028 (SSCNET) Initialization error. (CodeXX)
D2035 Program execution error.
D2036 (SSCNET)System error occurred in 1LP I/F board. (CodeXX)
D2037 Safety unit circuit is abnormal.
D2038 (SSCNET)Interface board is not installed.
D2039 (SSCNET)Communication error of JtXX on initialization.
D2040 (SSCNET)Initialization error of JtXX.(CodeXX)
D2041 Connection of the signal harness is wrong.
A-41
Code Error Message

D2042 Servo amp and robot arm are mismatched.
D2043 Arm I/F board detects AC-Fail.
D2044 [ARM CONTROL BOARD]No response from Servo FPGA software.
D2045 [ARM CONTROL BOARD]Device check error. (CodeXX)
D2046 Relay error on purge control board. (relay XX)
D2047 Jumper setting error or Safety relay failure on Servo CPU board.
D2048 DC 12V Voltage source error on purge control board.
D2049 Over current error in interlock relay drive circuit(1) for purge control board.
D2050 Over current error in interlock relay drive circuit(2) for purge control board.
D2051 Communication error on purge control board.
D2052 Hardware setting for the external axis amplifier has discrepancy. robot=n
D2053 (FANXX-XX)Rotational speed of fan is abnormal.(Servo boardXX)
D2054 Codes set in software and power block do not match.(Code:XX)
D2055 [Power sequence board]Watchdog error was detected.
D2056 [I/O board(No.XX)]Several boards have same ID address.
D2057 [Servo boardXX]No response from Servo FPGA device.
D2058 [Main CPU board]DC power supply is abnormal.(XX mV)
D2064 [Purge control board]Pressure within enclosure is low.(during purging)
D2065 Safety relay is abnormal which cut off brake power when inner pressure is low.
D2066 [Purge control board]DC is abnormal.(12V)
D2067 [Main CPU board]Communication with purge control board is abnormal.
D2068 [IO board No. XX]Device check failure.(CodeXX)
D2069 [ANYBUS interface board(No.XX)]Several boards have the same ID address.
D3800 Communication board memory error. (XX)
D3822 Motor parameter is not consistent with controller. JtXX
D3823 FAN NO. XX in Controller is out of order.
D3824 Fuse NO.XX on IO board NO.1 is open.
D3825 Fuse NO.XX on IO board NO.2 is open.
D3826 Robot DC voltage error.
D3828 Controller type error.
D4000 [DIAG]Error is detected in RS232C.(Code:XX)
D4001 [DIAG]Error is detected in Ethernet.(Code:XX)
D4500 Fieldbus interface board is not detected.
D4501 ABMA-PDP)I/F module error. XX
D4502 FIELD-BUS-INIT)Error reply. XX
D4503 FIELD-BUS-INIT)Reply timeout. XX
D4504 ANYBUS)OUT/FB.CTRL request timeout. XX
A-42
Code Error Message

D6000 Over temperature error in Barrier unit.
D6001 Mutual-Wait initialize error.
A-43
A-44
Kawasaki Robot Controller E Series
TROUBLESHOOTING MANUAL
February 27, 2009 : 1st Edition

October 19, 2012 : 7th Edition
Published by KAWASAKI HEAVY INDUSTRIES, LTD.
90206-1045DEG
Copyright  2012 KAWASAKI HEAVY INDUSTRIES, LTD. All rights reserved.

90206-1045DEG E Troubleshooting Manual

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90206-1045DEG E Troubleshooting Manual

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Kawasaki Robot Controller

Kawasaki Heavy Industries, Ltd.

This manual is for troubleshooting the E Series Controllers (standard spec.).

This manual describes troubleshooting procedures in as much detail as possible. However,

Failure to comply with indicated matters can result in

1. The accuracy and effectiveness of the diagrams, procedures, and detail

1. HARDWARE KEYS AND SWITCHES (BUTTON)

2. SOFTWARE KEYS AND SWITCHES

1.0 Composition of E Series Controller ······················································· 1-1

2.0 Description of Controller···································································· 2-1

2.3.2.7 Fuse ·························································································· 2-19

2.7.2.3 LEDs ························································································· 2-33

2.12.1.2 Connectors, LEDs and Check Pins ······················································ 2-50

2.17.1.2.2 Connectors ·················································································· 2-70

3.0 Troubleshooting ·············································································· 3-1

3.3 Error Classification ········································································ 3-10

4.0 Procedures for Replacement ································································ 4-1

4.10.1 1UZ Board (Power Block Board)························································ 4-32

5.0 Schematic Diagrams of Separate and Machine Harnesses ····························· 5-1

5.2.3 Z Series (ZX, ZT Series, ZH Series, ZD Series) ······································· 5-38

Appendix Error Message List ·········································································· A-1

1.0 COMPOSITION OF E SERIES CONTROLLER

1.1 External View of Controller ··································································· 1-2

1.1 EXTERNAL VIEW OF CONTROLLER

1.1.1 CONTROLLER MAIN BODY

The E Series Controller is shown below.

Left view Front view

Right view Rear view

Left view Front view

Right view Rear view

Left view Front view

Right view Rear view

Left view Front view

Right view Rear view

E14 (MX) controller

Left view Front view

Right view Rear view

E14 (MD) controller

Left view Front view

Right view Rear view

Left view Front view

Right view Rear view

550 450 180

Left view Front view

Right view Rear view

Left view Front view

Right view Rear view

E24 Controller (MX)

550 450 180

Left view Front view

Right view Rear view

E24 Controller (MD)

Left view Front view

Right view Rear view

Left view Front view

Right view Rear view

Left view Front view

Right view Rear view

Left view Front view

Right view Rear view

E34 Controller (MX)

Left view Front view

Right view Rear view

E34 Controller (MD)