Trouble Shooting Manual for MRC

YASNAC MRC ver. 3.144B

Trouble Shooting Guide, YASNAC MRC

MOTOMAN ROBOTICS AB a subsidiary of YASKAWA Electric Corporation

Notes

MOTOMAN ROBOTICS AB

Alarm 0010

Trouble Shooting YASNAC MRC Page: 1

CPU Board Insertion Error Alarm Occurrence Turn power OFF, and then ON again.

NO

Alarm re-occurs?

YES

Remove the SV board corresponding to the display, and then re-install it

Resume use

Alarm re-occurs?

YES

NO Resume use

Remove the MCP01 board, and then re-install it NO Resume use

Alarm re-occurs?

YES

Replace the ROM of the board corresponding to the display NO

Alarm re-occurs?

YES Replace the board corresponding to the display

ROM failure

YES

Alarm re-occurs?

Board failure

Replace all boards

NO Board failure

Skapad: 98-10-09

Ändrad: 98-11-26

Alarm re-occurs?

NO

YES Contact MOTOMAN-service

Filnamn: T:\M-ROBOT\ENGELSK\TROUBLE_SHOOTING.FM

Trouble Shooting YASNAC MRC

MOTOMAN ROBOTICS AB

Page: 2

Alarm 0020

CPU Communication Error Alarm Occurrence Turn power OFF, and then ON again.

NO Resume use

Alarm re-occurs?

YES

Remove the SV board corresponding to the display, and then re-install it Alarm re-occurs?

YES

NO Resume use

Remove all boards, and then re-install them

NO

Alarm re-occurs?

Resume use

YES

Replace the ROM of the board corresponding to the display NO

Alarm re-occurs?


ROM failure

YES

Alarm re-occurs?

Board failure

Replace all boards

NO Board failure

Skapad: 98-10-09

Ändrad: 98-11-26

Alarm re-occurs?

NO



MOTOMAN ROBOTICS AB

Alarm 0030


ROM Error Alarm Occurrence Turn power OFF, and then ON again.

NO Resume use

Alarm re-occurs?

YES

Replace the ROM of the board corresponding to the display NO ROM failure

Alarm re-occurs?



Skapad: 98-10-09

Ändrad: 98-11-26

Alarm re-occurs?

NO Board failure



MOTOMAN ROBOTICS AB

Page: 4

Alarm 0040

RAM Error (local) Alarm Occurrence Turn power OFF, and then ON again.

NO

Alarm re-occurs?

Resume use

YES

Remove the board corresponding to the display, and then re-install it NO Resume use

Alarm re-occurs?


YES

Contact MOTOMAN-service

Skapad: 98-10-09

Ändrad: 98-11-26

Alarm re-occurs?

NO Board failure


MOTOMAN ROBOTICS AB

Alarm 0050


RTC Error) Alarm Occurrence Turn power OFF, and then ON again.

NO Resume use

Alarm re-occurs?

YES

Remove the board corresponding to the display, and then re-install it NO Resume use

Alarm re-occurs?


YES


Skapad: 98-10-09

Ändrad: 98-11-26

Alarm re-occurs?

NO Board failure



MOTOMAN ROBOTICS AB

Page: 6

Alarm 0060

RAM Error (A-bus Common) Alarm Occurrence Turn power OFF, and then ON again.

NO

Alarm re-occurs?

Resume use

YES

Remove the board corresponding to the display, and then re-install it YES

Alarm re-occurs?

NO

Remove all boards and re-install again

NO

Alarm re-occurs?

Resume use


Resume use

YES

Alarm re-occurs?

Board failure

Replace all boards NO

Alarm re-occurs?

Board failure

Skapad: 98-10-09

NO


Ändrad: 98-11-26


MOTOMAN ROBOTICS AB

Alarm 0070


RAM Error (D-Bus 2-Port) Alarm Occurrence Turn power OFF, and then ON again.

NO Resume use

Alarm re-occurs?

YES

Remove the SV board corresponding to the display, and then re-install it YES

Alarm re-occurs?

NO

Remove all boards and re-install again NO Resume use

Alarm re-occurs?

Resume use

YES

Replace the SV board corresponding to the display NO

Alarm re-occurs?

SV board failure

YES Replace the MCP02 board

YES

Alarm re-occurs?

Replace all boards NO Board failure

Skapad: 98-10-09

Ändrad: 98-11-26

Alarm re-occurs?

NO

Board failure YES




MOTOMAN ROBOTICS AB

Page: 8

Alarm 0080

RAM Error (S-Bus 2-Port) Alarm Occurrence Turn power OFF, and then ON again. Alarm re-occurs?

NO Resume use

YES

Remove the board corresponding to the display, and then re-install it Alarm re-occurs?

YES

NO

Remove MCP01 and re-install again Alarm re-occurs?

NO Resume use

Resume use

YES Replace the board corresponding to the display Alarm re-occurs?

YES Replace the MCP01 board Alarm re-occurs?

NO MCP01 board failure

Skapad: 98-10-09

Ändrad: 98-11-26

NO Board failure

YES



MOTOMAN ROBOTICS AB

Alarm 0090


I/O Module Communication Error Alarm Occurrence Turn power OFF, and then ON again.

NO

Alarm re-occurs?

YES Confirm the setting of the I/O module

Resume use

Alarm re-occurs?

YES

NO Resume use

Check the wiring of the cable between MIF01 and MBB02 NO Resume use

Alarm re-occurs?

YES

Remove the I/O module corresponding to the display, and then re-install it Alarm re-occurs?

YES

NO Resume use

Replace the I/O module NO

Alarm re-occurs?

YES Replace MIF01 board

I/O module failure YES


Skapad: 98-10-09

Ändrad: 98-11-26

Alarm re-occurs?

NO MIF01 board failure



MOTOMAN ROBOTICS AB

Page: 10

Alarm 0100

IAMP Communication Error Alarm Occurrence Turn power OFF, and then ON again. Alarm re-occurs?

NO Resume use

YES

Remove the cable connector between the MSV board and IAMP Alarm re-occurs?

YES Check the wiring of the cable between MSV board and IAMP Alarm re-occurs?

NO

Resume use

YES

Resume use

Confirm the setting of the servopack Alarm re-occurs?

YES Replace the servopack NO

Alarm re-occurs?

NO Resume use

YES Replace the MSV board

Servopack failure YES


Skapad: 98-10-09

NO

Ändrad: 98-11-26

Alarm re-occurs?

NO MSV board failure


MOTOMAN ROBOTICS AB

Alarm 0110


IAMP Parameter Modification Error Alarm Occurrence Turn power OFF, and then ON again.

NO Resume use

Alarm re-occurs?

YES

Remove the cable connector between the MSV board and IAMP and re-install Alarm re-occurs?

YES

NO

Check the wiring of the cable between MSV board and IAMP

NO

Alarm re-occurs?

Resume use

YES Replace the servopack

Resume use NO

Alarm re-occurs?

YES Replace the MSV board



Skapad: 98-10-09

Ändrad: 98-11-26

Alarm re-occurs?

NO

MSV Board failure



MOTOMAN ROBOTICS AB

Page: 12

Alarm 0120

Encoder communication error Alarm Occurrence Turn power OFF, and then ON again.

Resume use

NO

Alarm re-occurs?

YES

Remove the cable connector between encoder and IAMP, and then re-install it

Remove the cable connector between the MSV board and IAMP and re-install Alarm re-occurs?

YES

NO

Resume use Resume use

NO

Alarm re-occurs?

YES

Check the cable ground between encoder and IAMP Cable failure

NO

Remove the cable connector between encoder and IAMP, and then install to another axis

YES

Alarm re-occurs?

Replace the servopack

Alarm re-occurs? YES

NO

Check the wiring of the cable between MSV board and IAMP

Cable failure

NO

YES

Alarm re-occurs?

YES

Alarm re-occurs?

Alarm re-occurs? YES Replace the MSV board


Reset the absolute encoder YES

Servopack failure


Replace the motor

NO

NO

Resume use

Alarm re-occurs? NO BSV Board failure


NO Motor failure Skapad: 98-10-09

Ändrad: 98-11-26


MOTOMAN ROBOTICS AB

Alarm 0130


Encoder Overspeed Alarm Occurrence Turn power OFF, and then ON again.

NO

Alarm re-occurs?

Resume use

YES After the motor stops, control power ON.

YES

Alarm re-occurs?

Reset the absolute encoder

NO

Alarm re-occurs?

Resume use

Resume use

YES Replace servo motor

YES


Skapad: 98-10-09

NO

Ändrad: 98-11-26

Alarm re-occurs?

NO Motor failure



MOTOMAN ROBOTICS AB

Page: 14

Alarm 0131

Encoder Data Error Alarm Occurrence Turn power OFF, and then ON again.

NO

Alarm re-occurs?

Resume use

YES Reset the absolute encoder

NO

Alarm re-occurs?

YES Replace the motor

Resume use YES

Alarm re-occurs?

Motor failure


Alarm 0132

NO

Encoder Back-up Error Alarm Occurrence

Change the battery, reset the alarm and then set home position NO

Alarm re-occurs?

Resume use

YES Reset the absolute encoder

NO

Alarm re-occurs?

Replace the motor

Resume use YES Contact MOTOMAN-service Skapad: 98-10-09

Ändrad: 98-11-26

YES

Alarm re-occurs?

NO Motor failure


MOTOMAN ROBOTICS AB

Alarm 0133


Encoder Checksum Error Alarm Occurrence

Change the battery, reset the alarm and then set home position. NO

Alarm re-occurs?

Resume use

YES

Reset the absolute encoder NO

Alarm re-occurs?

Resume use

Replace servo motor


Skapad: 98-10-09

Ändrad: 98-11-26

YES

Alarm re-occurs?

NO Motor failure



MOTOMAN ROBOTICS AB

Page: 16

Alarm 0134

Encoder Battery Error Alarm Occurrence

Change the battery

NO

Alarm re-occurs?

Resume use

YES

Check Internal wiring YES

Alarm re-occurs?

Resume use

Reset the absolute encoder

NO

Alarm re-occurs?

Resume use

YES Replace the motor

YES

Alarm re-occurs?

NO Motor failure


Alarm 0135

NO

Encoder Overheat Alarm Occurrence After cooling, turn the power ON again

NO

Alarm re-occurs?

Resume use

Check Internal wiring

YES Contact MOTOMAN-service Skapad: 98-10-09

YES

Ändrad: 98-11-26

Alarm re-occurs?

NO Internal wire failure


MOTOMAN ROBOTICS AB

Alarm 0200


Fault (Parameter) Alarm Occurrence Turn power OFF, and then ON again.

NO

Alarm re-occurs?

YES

Resume use

Contact MOTOMANservice before initializing the parameter file

Alarm 0210

Fault (System Config-Data) Alarm Occurrence

Contact MOTOMANservice before initializing the parameter file

Alarm 0220

Fault (Job Management Data) Alarm Occurrence Turn power OFF, and then ON agian.

NO

Alarm re-occurs?

Resume use

Initialize the job file YES Contact MOTOMAN-service

Skapad: 98-10-09

YES

Ändrad: 98-11-26

Alarm re-occurs?

NO Job file destroyed



Alarm 0230

MOTOMAN ROBOTICS AB

Fault (CIO Ladder) Alarm Occurrence Initialize the CIO Ladder Alarm re-occurs?

NO

YES


CIO Ladder destroyed

Alarm 0300

Verify Error (System Config-Data) Alarm Occurrence

Contact MOTOMANservice before initializing the system config.

Alarm 0310

Verify Error (CMOS Memory Size) Alarm Occurrence Confirm the extension CMOS board NO

Alarm re-occurs?

The extension CMOS board is not mounted

Skapad: 98-10-09

Ändrad: 98-11-26

YES Contact MOTOMANservice before initializing the system config.


MOTOMAN ROBOTICS AB

Alarm 0320


Verify Error (I/O module) Alarm Occurrence

Remove the I/O-module that corresponds to the display, then re-install the module Alarm re-occurs?

NO

YES

Resume use

Confirm the setting of the I/O module Alarm re-occurs?

YES Replace the I/O module corresponding to the display

NO

Alarm re-occurs?

I/O module failure

Alarm 0330

NO Resume use

YES


Illegal Parameter Alarm Occurrence Reset original parameter value

NO

Alarm re-occurs?

Resume use

Skapad: 98-10-09

YES


Ändrad: 98-11-26



Alarm 0340

MOTOMAN ROBOTICS AB

Verify Error (Servopack Type) Alarm Occurrence

Set the parameter to match the mounted servopack type NO

Alarm re-occurs?

YES

Resume use


Alarm 0350

Verify Error (Encoder Type) Alarm Occurrence

Set the parameter to match the mounted encoder type NO

Alarm re-occurs?

Resume use

Alarm 0360

YES


Verify Error (Application) Alarm Occurrence

Contact MOTOMAN-service before initializing the system config.

Alarm 0370

Verify Error (Sensor Function) Alarm Occurrence

Contact MOTOMAN-service before initializing the system config.

Skapad: 98-10-09

Ändrad: 98-11-26


MOTOMAN ROBOTICS AB

Alarm 0400


Parameter Transmission Error Alarm Occurrence Turn power OFF, and then ON agian.

NO

Alarm re-occurs?

Resume use

YES

Replace the board corresponding to the display

NO

Alarm re-occurs?

Board failure

Replace all boards YES Contact MOTOMAN-service

Alarm 0410

YES

Alarm re-occurs?

NO

Board failure

Mode Change Error Alarm Occurrence Turn power OFF, and then ON again.

NO

Alarm re-occurs?

Resume use

Skapad: 98-10-09


Ändrad: 98-11-26



MOTOMAN ROBOTICS AB

Alarm 0900 - 0920 Watch Dog Timer Error Turn power OFF, and then ON agian.

Alarm Occurrence

Alarm re-occurs? NO

YES Remove the board corresponding to the display, then re-install it

Resume use Remove all boards, then re-install them

Alarm re-occurs?

YES

NO

Alarm re-occurs? NO

Resume use YES

Resume use

Replace the EPROM of the board corresponding to the display Replace board corresponding to the display

YES

Alarm re-occurs? NO


NO

Replace all boards

Board failure Alarm re-occurs?

EPROM failure

YES

NO Contact MOTOMAN-service

Board failure

AL-0900

MCP02

AL-0901

Skapad: 98-10-09

AL-0906

MCP01

AL-0914

MSV#5

AL-0907

MIF01

AL-0915

MSV#6 MSV#7

AL-0902

MSL#1

AL-0910

MSV#1

AL-0916

AL-0903

MSL#2

AL-0911

MSV#2

AL-0917

AL-0904

AL-0912

MSV#3

AL-0920

AL-0905

AL-0913

MSV#3

Ändrad: 98-11-26

MIF02



MOTOMAN ROBOTICS AB

Page: 23

Alarm 0930 - 0937 Access Error Turn power OFF, and then ON agian.

Alarm Occurrence

Alarm re-occurs? NO



Alarm re-occurs?

YES

NO

Alarm re-occurs? NO

Resume use YES

Resume use


YES

Alarm re-occurs? NO


NO

Replace all boards


EPROM failure

YES


Board failure

AL-0930

MIF02

AL-0931 AL-0932

Skapad: 98-10-09

AL-0933 AL-0934

MSL#1

Ändrad: 98-11-26

MSL#2

AL-0936

MCP01

AL-0937

MIF01

AL-0935



MOTOMAN ROBOTICS AB

Alarm 0940 - 0947 A-Bus Error Turn power OFF, and then ON agian.

Alarm Occurrence

Alarm re-occurs? NO



Alarm re-occurs?

YES

NO

Alarm re-occurs? NO

Resume use YES

Resume use


YES

Alarm re-occurs? NO


NO

Replace all boards


EPROM failure

YES


Board failure

AL-0940

MIF02

AL-0941 AL-0942

Skapad: 98-10-09

AL-0943 AL-0944

MSL#1

Ändrad: 98-11-26

MSL#2

AL-0946

MCP01

AL-0947

MIF01

AL-0945


MOTOMAN ROBOTICS AB

Alarm 0999


NMI Error Alarm Occurrence Turn power OFF, and then ON agian. Alarm re-occurs? YES

NO Resume use

Remove all boards and then re-install them Alarm re-occurs? YES

NO

Replace EPROM of all boards

Resume use

Alarm re-occurs? NO

EPROM failure

Replace all boards Alarm re-occurs?

Skapad: 98-10-09

YES

NO


Board failure

Ändrad: 98-11-26



Alarm 1010

MOTOMAN ROBOTICS AB

ROM Error (Syscon) Alarm Occurrence Turn power OFF, and then ON agian. Alarm re-occurs?

NO

YES

Resume use

Remove the EPROM board on the MCP01 board and then re-install them Alarm re-occurs? YES

NO

Replace EPROM board on the MCP01 board

Make sure connector has no loose connections, and then resume use

Alarm re-occurs? NO

MMM02 failure

Replace MCP01 board Alarm re-occurs?

Skapad: 98-10-09

YES

NO


Board failure

Ändrad: 98-11-26


MOTOMAN ROBOTICS AB

Alarm 1020


ROM Error (Motion) Alarm Occurrence Turn power OFF, and then ON agian. Alarm re-occurs?

NO

YES

Resume use

Remove the EPROM board on the MCP02 board and then re-install them Alarm re-occurs? YES

NO



Alarm re-occurs? NO

MMM04 failure


Skapad: 98-10-09

YES

NO


Board failure

Ändrad: 98-11-26



MOTOMAN ROBOTICS AB

Page: 28

Alarm 1030

ROM Error (CIO) Alarm Occurrence Turn power OFF, and then ON agian. Alarm re-occurs? YES

NO Resume use

Remove the EPROM board on the MIF01 board and then re-install them Alarm re-occurs? YES

NO



Alarm re-occurs? NO

EPROM failure

Replace MIF01 board Alarm re-occurs?

Skapad: 98-10-09

YES

NO


Board failure

Ändrad: 98-11-26



MOTOMAN ROBOTICS AB

Alarm 1040

Page: 29

System Error (Syscon) Alarm Occurrence Turn power OFF, and then ON agian. Alarm re-occurs?

NO

YES

Resume use

Replace MCP01 board Alarm re-occurs? YES

NO


Board failure

1

Skapad: 98-10-09

6

Multi Task Specification Error

2

Motion Interrupt Not Done

7

Lack of Command Saving Area

3

Syscon Error

8

EMS Error

4

Command Processing

9

5

Undefined Interrupt

10

Ändrad: 98-11-26

SL Interrupt Not Done



MOTOMAN ROBOTICS AB

Page: 30

Alarm 1050

ROM Error (Sensor) Alarm Occurrence Turn power OFF, and then ON agian. Alarm re-occurs?

NO

YES

Resume use

Remove the EPROM board on the MSL board and then re-install it Alarm re-occurs? YES

NO

Replace EPROM board on the MSL board


Alarm re-occurs? NO

YES

EPROM failure

Replace MSL board corresponding to the display Alarm re-occurs?

Skapad: 98-10-09

YES

NO


Board failure

Ändrad: 98-11-26


MOTOMAN ROBOTICS AB

Alarm 1060


System Error (CIO) Alarm Occurrence Turn power OFF, and then ON agian. Alarm re-occurs?

NO

YES

Resume use

Replace MIF01 board Alarm re-occurs? NO


Board failure

01

05

Command Error SYSCONCIO

02

06

System Error

04

Skapad: 98-10-09

YES

FA Communication Bus Error

Ändrad: 98-11-26



Alarm 1070

MOTOMAN ROBOTICS AB

Fault (Parameter) Alarm Occurrence Turn power OFF, and then ON agian. Alarm re-occurs? YES

NO Resume use

Initialize

the parameter file Alarm re-occurs?

Skapad: 98-10-09

YES

NO


Board failure

0

RC parameters

8

AP parameters

1

RO parameters

9

RS parameters

2

SV paramerters

10

SP parameters

3

SVM parameters

11

CM parameters

4

SC parameters

12

SE parameters

5

SD parameters

13

VC parameters

6

CIO parameters

14

RSM parameters

7

FD parameters

Ändrad: 98-11-26


MOTOMAN ROBOTICS AB

Alarm 1080


Fault (Job data) Alarm Occurrence Turn power OFF, and then ON agian. Alarm re-occurs? YES

NO Resume use

Initialize

the job file Alarm re-occurs?

Alarm 1090

YES

NO


Job file destroyed

File Failure (Motion) Alarm Occurrence Turn power OFF, and then ON agian. Alarm re-occurs?

NO

YES

Resume use


Skapad: 98-10-09

Ändrad: 98-11-26



MOTOMAN ROBOTICS AB

Page: 34

Alarm 1100

File Total Checksum Error (Motion) Turn power OFF, and then ON agian.

Alarm Occurrence

Alarm re-occurs? NO

YES

Resume use


Alarm 1110

YES

NO


Board failure

Set-up Process Error (Syscon) Turn power OFF, and then ON agian.

Alarm Occurrence

Alarm re-occurs? NO

YES

Resume use


1

Skapad: 98-10-09

YES

NO


Board failure

Motion Section Set-up incomplete

Ändrad: 98-11-26


MOTOMAN ROBOTICS AB

Alarm 1120


Wrong Segment Clock Value Turn power OFF, and then ON agian.

Alarm Occurrence

Alarm re-occurs? NO

YES

Resume use

Reset phase offset data file Alarm re-occurs?

Alarm 1130

YES

NO


CMOS file breakdown

MMM Error Turn power OFF, and then ON agian.

Alarm Occurrence

Alarm re-occurs? NO

YES

Resume use


0 1

Process Definition Table Not Set

2

Entry Table Overflow

Skapad: 98-10-09

Ändrad: 98-11-26

3

Process Not Set

4

Process Control Code Not Set



Alarm 1140

MOTOMAN ROBOTICS AB

MMM Error Alarm Occurrence Turn power OFF, and then ON agian. Alarm re-occurs?

NO

YES

Resume use


Alarm 1150

Fault Alarm Occurrence Turn power OFF, and then ON agian. Alarm re-occurs?

NO

YES

Resume use


Skapad: 98-10-09

Ändrad: 98-11-26


MOTOMAN ROBOTICS AB

Alarm 1160


High Temperature (in Control Box) Alarm Occurrence Turn power OFF, and then ON agian. Alarm re-occurs?

NO

YES

Resume use

Turn the power off, let the controller cool inside, and then turn power on again Alarm re-occurs? YES

NO

Check movement of cooling fan

Resume use


NO

Check wiring cooling fan Faulty? YES

NO Replace fan Replace power unit (CPS-18F)


Alarm re-occurs?

YES

NO Alarm re-occurs?

Fan failure NO Power unit failure


Skapad: 98-10-09

Ändrad: 98-11-26



MOTOMAN ROBOTICS AB

Page: 38

Alarm 1170

Overrun Limit Switch Released Alarm Occurrence Turn power OFF, and then ON agian. Alarm re-occurs?

NO

YES

Resume use

Check the OVERRUN RECOVERY switch Alarm re-occurs?

Skapad: 98-10-09

YES

NO


Switch failure

Ändrad: 98-11-26


MOTOMAN ROBOTICS AB


Alarm 1180 - 1186 Servo Monitor System Error Alarm Occurrence Turn power OFF, and then ON agian. Alarm re-occurs? NO

YES

Resume use

Replace MSV board corresponding to the display Alarm re-occurs? YES

NO

Board failure

Replace MCP01 board Alarm re-occurs? NO

YES

Board failure


Skapad: 98-10-09

YES

NO


Board failure

AL-1180

MSV#1

AL-1183

MSV#4

AL-1181

MSV#2

AL-1184

MSV#5

AL-1182

MSV#3

AL-1185

MSV#6

Ändrad: 98-11-26

AL-1186

MSV#7



MOTOMAN ROBOTICS AB

Page: 40

Alarm 1190 - 1196 Servo System Error Alarm Occurrence Turn power OFF, and then ON agian. Alarm re-occurs? NO

YES

Resume use

Replace MSV board corresponding to the display Alarm re-occurs? YES

NO

Board failure

Replace MCP01 board Alarm re-occurs? NO

YES

Board failure


Skapad: 98-10-09

YES

NO


Board failure

AL-1190

MSV#1

AL-1193

MSV#4

AL-1191

MSV#2

AL-1194

MSV#5

AL-1192

MSV#3

AL-1195

MSV#6

Ändrad: 98-11-26

AL-1196

MSV#7



MOTOMAN ROBOTICS AB

Page: 41

Alarm 1200 - 1206 Overcurrent Alarm Occurrence

Condition at the time of alarm?

At control power ON

Replace servopack corresponding to the display

Running

Alarm re-occurs?

Check first grounding terminal

Go to point A

NO YES Contact MOTOMAN-service

At servo power ON

Servopack failure

Faulty grounding YES

NO


B Check second ground terminal

Alarm re-occurs? NO


NO

Check internal wiring

NO

Servopack failure

Replace motor corresponding to the display


YES


Alarm re-occurs? NO YES

Internal wiring failure

Servomotor failure Contact MOTOMAN-service

Skapad: 98-10-09

Ändrad: 98-11-26



MOTOMAN ROBOTICS AB

Alarm 1200 - 1206 Overcurrent (...continued) A Check movement of servopack cooling fan Abnormal? YES

NO

Replace cooling fan

Check robot load

Alarm re-occurs?

Fan failure

NO

Load condition? OK

YES

Overload Alarm occurs at a specific point?


Decrease weight

NO YES Check first grounding terminal

YES

Faulty grounding

NO

NO

Servopack failure

Go to point B

Replace servopack corresponding to the display Alarm re-occurs?

YES

Skapad: 98-10-09


AL-1200

MSV#1

AL-1203

MSV#4

AL-1201

MSV#2

AL-1204

MSV#5

AL-1202

MSV#3

AL-1205

MSV#6

Ändrad: 98-11-26

AL-1206

MSV#7



MOTOMAN ROBOTICS AB

Page: 43

Alarm 1210 - 1216 MCCB Tripped Alarm Occurrence At control power ON


Turn ON the MCCB Alarm re-occurs? YES

NO

At servo power ON

Running


Resume use Go to point A


Servopack failure

NO

Faulty grounding


YES B Contact MOTOMAN service

YES

NO

Check second ground terminal

Alarm re-occurs? NO


NO

Replace internal wiring

YES

NO

Servopack failure


Alarm re-occurs?

YES


Alarm re-occurs? NO


YES

Motor failure Contact MOTOMAN-service

Skapad: 98-10-09

Ändrad: 98-11-26



MOTOMAN ROBOTICS AB

Alarm 1210 - 1216 MCCB Tripped (...continued) A

Check robot load Load condition? OK Overload Alarm occurs at a specific point?

Decrease weight

NO YES Check first grounding terminal

YES

Faulty grounding

NO

NO

Servopack failure

Go to point B


YES

Skapad: 98-10-09


AL-1210

MSV#1

AL-1213

MSV#4

AL-1211

MSV#2

AL-1214

MSV#5

AL-1212

MSV#3

AL-1215

MSV#6

Ändrad: 98-11-26

AL-1216

MSV#7



MOTOMAN ROBOTICS AB

Page: 45

Alarm 1220 - 1226 Ground Fault Alarm Occurrence


At control power ON


Running

Alarm re-occurs?


Go to point A

NO YES Contact MOTOMAN-service

At servo power ON

Servopack failure


NO

Replace servopack corresponding to the display Check second ground terminal

Alarm re-occurs? NO


NO

Check internal wiring

NO

Servopack failure



YES


Alarm re-occurs? NO YES


Servo motor failure Contact MOTOMAN-service

Skapad: 98-10-09

Ändrad: 98-11-26



MOTOMAN ROBOTICS AB

Page: 46

Alarm 1220 - 1226 Ground Fault (...continued) A

Alarm occurs at a specific point?

NO

YES

Check first grounding terminal Faulty grounding

Check second ground terminal

NO

YES



NO

Check internal wiring Alarm re-occurs? NO YES Internal wiring failure



Alarm re-occurs?

Alarm re-occurs?

YES

NO


Skapad: 98-10-09

Servopack failure

NO

YES

Motor failure


AL-1220

MSV#1

AL-1223

MSV#4

AL-1221

MSV#2

AL-1224

MSV#5

AL-1222

MSV#3

AL-1225

MSV#6

Ändrad: 98-11-26

AL-1226

MSV#7



MOTOMAN ROBOTICS AB

Page: 47

Alarm 1230 - 1236 Defective Current Offset Alarm Occurrence


Alarm re-occurs?

Skapad: 98-10-09

NO

YES

Servopack failure


AL-1230

MSV#1

AL-1233

MSV#4

AL-1231

MSV#2

AL-1234

MSV#5

AL-1232

MSV#3

AL-1235

MSV#6

Ändrad: 98-11-26

AL-1236

MSV#7



MOTOMAN ROBOTICS AB

Page: 48

Alarm 1240- 1246 Encoder Transmission Error Turn power OFF, and then ON again.

Alarm Occurrence

Alarm re-occurs?

Remove the cable between MSV board and IAMP, then re-install it

YES

NO Resume use

Remove the cable between encoder and IAMP, then re-install it

Resume use

NO

Alarm re-occurs?

YES

NO


Resume use

Check the cable ground between encoder and IAMP

Remove the cable between the encoder and IAMP, then install connector from another axis


NO

Alarm re-occurs?

YES

Check the cable between encoder and IAMP Alarm re-occurs?

NO

NO

Servopack failure

Reset absolute encoder


Cable failure NO


Alarm re-occurs?

YES

NO

Replace the servomotor

Replace MSV board

Alarm re-occurs?

NO

YES

Board failure

Alarm re-occurs?

NO

Resume use

YES

Motor failure Contact MOTOMAN-service

Skapad: 98-10-09

AL-1240

MSV#1

AL-1243

MSV#4

AL-1241

MSV#2

AL-1244

MSV#5

AL-1242

MSV#3

AL-1245

MSV#6

Ändrad: 98-11-26

AL-1246

MSV#7


MOTOMAN ROBOTICS AB


Alarm 1250 - 1256 Defective Encoder Internal Data Alarm Occurrence Turn power OFF, and then ON again. Alarm re-occurs? NO

YES

Resume use

Reset absolute encoder corresponding to the displayed axis Alarm re-occurs? YES

NO

Replace motor corresponding to the displayed axis

Resume use

Alarm re-occurs? NO

YES

Motor failure


Skapad: 98-10-09

AL-1250

MSV#1

AL-1253

MSV#4

AL-1251

MSV#2

AL-1254

MSV#5

AL-1252

MSV#3

AL-1255

MSV#6

Ändrad: 98-11-26

AL-1256

MSV#7



MOTOMAN ROBOTICS AB

Page: 50

Alarm 1260 - 1266 Defective Encoder Absolute Data Alarm Occurrence Turn power OFF, and then ON again. Alarm re-occurs? NO

YES

Resume use

Reset absolute encoder corresponding to the displayed axis Alarm re-occurs? YES

NO

Replace motor corresponding to the displayed axis

Resume use

Alarm re-occurs? NO

YES

Motor failure


Skapad: 98-10-09

AL-1260

MSV#1

AL-1263

MSV#4

AL-1261

MSV#2

AL-1264

MSV#5

AL-1262

MSV#3

AL-1265

MSV#6

Ändrad: 98-11-26

AL-1266

MSV#7



MOTOMAN ROBOTICS AB

Page: 51

Alarm 1270 - 1276 Encoder Overheat Alarm Occurrence


At control power ON

Running

If motor has cooling fan check if fan is working

A Check Robot load Reset absolute encoder corresponding to the displayed axis

NO

YES

Load condition?

Check wiring

Overload


NO

Abnormal?

Decrease weight

Resume use

Faulty wiring? NO

Replace internal wiring

Replace motor Alarm re-occurs?

Replace cooling fan

YES

NO

YES

Alarm re-occurs? NO


Motor failure

Fan failure


Skapad: 98-10-09

Go to point A

AL-1270

MSV#1

AL-1273

MSV#4

AL-1271

MSV#2

AL-1274

MSV#5

AL-1272

MSV#3

AL-1275

MSV#6

Ändrad: 98-11-26


NO

AL-1276

MSV#7



MOTOMAN ROBOTICS AB

Page: 52

Alarm 1280- 1286 Servo Monitor Transmission Error Alarm Occurrence Turn power OFF, and then ON again. Alarm re-occurs? NO

YES

Resume use

Remove the cable between MSV board and IAMP, then re-install it Alarm re-occurs? YES

NO

Check the cable wiring between MSV board and IAMP

Resume use

Faulty wiring YES

NO

Replace cable


Alarm re-occurs?

YES Alarm re-occurs?

NO

YES

NO Cable failure

Replace MSV board Servopack failure

Skapad: 98-10-09


NO


Board failure

AL-1280

MSV#1

AL-1283

MSV#4

AL-1281

MSV#2

AL-1284

MSV#5

AL-1282

MSV#3

AL-1285

MSV#6

Ändrad: 98-11-26

AL-1286

MSV#7


MOTOMAN ROBOTICS AB


Alarm 1290 -1296 Servo CPU Synchronizing Error Alarm Occurrence Replace MSV board Alarm re-occurs? NO

YES

Board failure


AL-1290

MSV#1

AL-1293

MSV#4

AL-1291

MSV#2

AL-1294

MSV#5

AL-1292

MSV#3

AL-1295

MSV#6

AL-1296

MSV#7

AL-1306

MSV#7

Alarm 1300 -1306 DSP Program Checksum Error Alarm Occurrence Replace MSV board Alarm re-occurs? NO

YES

Board failure


Skapad: 98-10-09

AL-1300

MSV#1

AL-1303

MSV#4

AL-1301

MSV#2

AL-1304

MSV#5

AL-1302

MSV#3

AL-1305

MSV#6

Ändrad: 98-11-26



MOTOMAN ROBOTICS AB

Alarm 1310 -1316 Mon Pgrm Total Checksum Error Alarm Occurrence Replace MSV board Alarm re-occurs? NO

YES

Board failure


Skapad: 98-10-09

AL-1310

MSV#1

AL-1313

MSV#4

AL-1311

MSV#2

AL-1314

MSV#5

AL-1312

MSV#3

AL-1315

MSV#6

Ändrad: 98-11-26

AL-1316

MSV#7



MOTOMAN ROBOTICS AB

Page: 55

Alarm 1320- 1326 Servopack Failure Alarm Occurrence Turn power OFF, and then ON again. Alarm re-occurs? NO

YES

Resume use

Remove the cable between MSV board and IAMP, then re-install it Alarm re-occurs? YES

NO

Check the cable wiring between MSV board and IAMP

Resume use

Faulty wiring YES

NO

Replace cable


Alarm re-occurs?


NO

YES

NO Cable failure

Replace MSV board Servopack failure

Skapad: 98-10-09


NO


Board failure

AL-1320

MSV#1

AL-1323

MSV#4

AL-1321

MSV#2

AL-1324

MSV#5

AL-1322

MSV#3

AL-1325

MSV#6

Ändrad: 98-11-26

AL-1326

MSV#7



MOTOMAN ROBOTICS AB

Page: 56

Alarm 1330- 1336 Position Error Alarm Occurrence


At control power ON

Go to point A

Running

At servo power ON Replace the cable between encoder and IAMP with a cable from another axis Moved to another axis?

NO Replace MSV board


Check wiring

YES

NO Board failure Faulty wiring YES

NO

Replace cable Alarm re-occurs?

YES

NO

Replace the servo motor Alarm re-occurs?

YES


Cable failure NO Motor failure

Skapad: 98-10-09

Ändrad: 98-11-26



MOTOMAN ROBOTICS AB

Page: 57

Alarm 1330- 1336 Position Error (... continued)

A

Is there a noise source around?

NO

YES Remove the noise source Alarm re-occurs?

YES

NO Resume use

Check wiring Faulty wiring YES Replace cable Replace the servo motor

YES

Alarm re-occurs?

NO NO

Alarm re-occurs?

Motor failure

Cable failure YES Replace MSV board Alarm re-occurs?

YES


NO Board failure

Skapad: 98-10-09

AL-1330

MSV#1

AL-1333

MSV#4

AL-1331

MSV#2

AL-1334

MSV#5

AL-1332

MSV#3

AL-1335

MSV#6

Ändrad: 98-11-26

AL-1336

MSV#7



MOTOMAN ROBOTICS AB

Page: 58

Alarm 1340- 1346 Overload 1 Alarm Occurrence


At control power ON

Replace MSV board Right away

Running

How long after Servo ON does alarm occur?

After several minutes

Check for interference

Check Robot load Load condition?

Interference? YES NO

Overload

OK

Modify teaching Alarm re-occurs?

Reduce load YES

NO

Check motor wiring Faulty wiring

NO

Teaching error YES Alarm re-occurs?

Go to point A

Replace wiring NO

YES

Alarm re-occurs?

Board failure

YES

NO


Cable failure

Skapad: 98-10-09

AL-1340

MSV#1

AL-1343

MSV#4

AL-1341

MSV#2

AL-1344

MSV#5

AL-1342

MSV#3

AL-1345

MSV#6

Ändrad: 98-11-26

AL-1346

MSV#7



MOTOMAN ROBOTICS AB

Page: 59

Alarm 1340- 1346 Overload 1 (...continued) Is brake release audiable?

NO

A

Check brake circuit YES Input voltage abnormal

Abnormal condition?

NO

Input voltage normal

Check brake lead wiring

Replace SVM

Faulty wiring

Replace MTU board

NO

Alarm re-occurs?

YES

NO

Check motor brake

Replace wiring

YES Resume use

Alarm re-occurs?

Alarm re-occurs?

NO YES

YES

NO

Resume use Contact MOTOMAN-service

Resume use

NO Check if mechanically locked

YES Replace the servo motor

Movable?

NO

Defective?

Alarm re-occurs?

Fix mechanical problem

YES

YES NO

Alarm re-occurs?

YES


Resume use

NO Resume use

Skapad: 98-10-09

Ändrad: 98-11-26



MOTOMAN ROBOTICS AB

Page: 60

Alarm 1350- 1356 Overload 2 Alarm Occurrence


At control power ON

Replace MSV board Right away

Running

How long after Servo ON does alarm occur?

After several minutes

Check for interference

Check robot load

Interference?

Load condition?

YES NO

Overload

OK

Modify teaching Alarm re-occurs?

Reduce load YES

NO

Check motor wiring Faulty wiring

NO

Teaching error YES Alarm re-occurs?

Go to point A

Replace wiring NO

YES

Alarm re-occurs?

Board failure

YES

NO


Cable failure

Skapad: 98-10-09

AL-1350

MSV#1

AL-1353

MSV#4

AL-1351

MSV#2

AL-1354

MSV#5

AL-1352

MSV#3

AL-1355

MSV#6

Ändrad: 98-11-26

AL-1356

MSV#7



MOTOMAN ROBOTICS AB

Page: 61

Alarm 1350- 1356 Overload 2 (...continued) Is brake release audiable?

NO

A

Check brake circuit YES Input voltage abnormal

Abnormal condition?

Replace MTU board

NO

Output voltage abnormal

Check brake lead wiring

Replace SVM

Faulty wiring NO

Alarm re-occurs?

YES

NO

Check motor brake

Replace wiring

YES Resume use

Alarm re-occurs?

Alarm re-occurs?

NO YES

YES

NO

Resume use Contact MOTOMAN-service

Resume use

NO Check if mechanically locked

YES Replace the servo motor

Movable?

NO

Defective?

Alarm re-occurs?


YES

YES NO

Alarm re-occurs?

YES


Resume use

NO Resume use

Skapad: 98-10-09

Ändrad: 98-11-26



MOTOMAN ROBOTICS AB

Page: 62

Alarm 1360-1366

Broken PG Line Alarm Occurrence

At control power on


Replace cable between encoder & IAMP with cable from another axis

At servo power on

Move to other axis?

Replace MSV board

NO

YES

Alarm re-occurs?

Running

1

YES

Check wiring NO MSV board failure Faulty wiring?

YES

Replace servopack Alarm re-occurs?

Replace cable YES

NO Replace motor

YES

NO

Alarm re-occurs?

Servopack failure

Replace cable between IAMP and MSV Alarm re-occurs?

NO

NO YES

Cable failure

Cable failure Replace motor Alarm re-occurs?

NO Motor failure

Alarm re-occurs?

NO

YES YES Contact MOTOMAN-service

Skapad: 98-10-09

Ändrad: 98-11-26

Motor failure




MOTOMAN ROBOTICS AB

Alarm 1360-1366

Page: 63

Broken PG Line (...continued)

1 Is there a noise source around?

YES

Remove noise source

YES

Alarm re-occurs?

NO Check wiring Faulty wiring?

YES

NO

Resume use

NO

Cable failure

Replace cable

NO Alarm re-occurs?

YES

Replace motor Alarm re-occurs?

YES

NO

MSV board failure Alarm re-occurs?

NO

YES

Motor failure Replace servopack

MSV board failure

Alarm re-occurs?

YES

NO Servopack failure

Replace cable between IAMP and MSV NO

Alarm re-occurs?

Cable failure

YES

Replace motor

YES

Alarm re-occurs?


Skapad: 98-10-09

AL-1360

MSV#1

AL-1363

MSV#4

AL-1361

MSV#2

AL-1364

MSV#5

AL-1362

MSV#3

AL-1365

MSV#6

Ändrad: 98-11-26

AL-1366

NO Motor failure

MSV#7



MOTOMAN ROBOTICS AB

Page: 64

Alarm 1370-1376

Over Speed Alarm Occurrence Is there a noise source around?

NO

Check wiring

YES

Faulty wiring?

NO

YES

Alarm re-occurs?

Condition at the time of alarm


NO Resume use

At servo power on

1

Remove noise source

YES

Running

At servo power on NO

Cable failure 1

NO

Alarm occurs at specific point?

YES YES 1 NO

Replace MSV board Alarm re-occurs?

YES

MSV board failure

NO

YES

Point of alarm taught by MOVJ?

Reduce speed

YES

Multiple axes moving at the same time?

Replace motor NO Alarm re-occurs?

NO

Motor failure

Alarm re-occurs?

YES

1

YES NO Contact MOTOMAN-service

Skapad: 98-10-09

Resume use

AL-1370

MSV#1

AL-1373

MSV#4

AL-1371

MSV#2

AL-1374

MSV#5

AL-1372

MSV#3

AL-1375

MSV#6

Ändrad: 98-11-26

AL-1376

MSV#7



MOTOMAN ROBOTICS AB

Alarm 1380-1386

Page: 65

Servo Tracking Error

Alarm Occurrence


Running Check if robot interferes with work or fixture

At control power on Modify teaching

YES

Interference?

NO

Alarm re-occurs?

YES

Check motor wiring

OK

Check load Load condition?

NO

Overload

Teaching error Decrease weight Replace MSV board Alarm re-occurs?

Faulty wiring?

NO

NO

1

YES

1

YES YES

MSV board failure Replace wiring harness


Alarm re-occurs? NO Wiring failure

Skapad: 98-10-09

AL-1380

MSV#1

AL-1383

MSV#4

AL-1381

MSV#2

AL-1384

MSV#5

AL-1382

MSV#3

AL-1385

MSV#6

Ändrad: 98-11-26

AL-1386

MSV#7



MOTOMAN ROBOTICS AB

Page: 66

Alarm 1380-1386

Servo Tracking Error (...continued) 1 Is brake release audible?

NO

YES

Check brake circuit Abnormal condition?

Input voltage abnormal Replace MTU board

Output voltage abnormal Replace SVM Alarm re-occurs?

NO Resume use Alarm re-occurs?

YES

Check brake lead wiring Faulty wiring?

NO

NO

YES


Resume use

NO Resume use

Contact MOTOMAN-service Check if mechanically locked NO

Alarm re-occurs?

NO

Defective? YES

Movable?

Replace motor


Skapad: 98-10-09

Check motor brake

Replace wiring harness

Contact MOTOMAN service

YES

NO

YES YES


YES

Alarm re-occurs?

NO

NO

Resume use

Resume use

Ändrad: 98-11-26



MOTOMAN ROBOTICS AB

Page: 67

Alarm 1390-1396 Speed (Monitor) Alarm Occurrence

Is there a noise source around?

NO

Check wiring

YES

Remove noise source Alarm re-occurs?

YES

Faulty wiring?

Resume use

NO At control power on

1

YES



NO

Running

At servo power on NO

Cable failure 1

NO

Alarm occurs at specific point?

YES YES 1 NO

Replace MSV board

Point of alarm taught by MOVJ YES

Alarm re-occurs?

NO

MSV board failure

YES

Multiple axes moving at the same time?

Replace motor

NO

Reduce speed

Alarm re-occurs?

NO

Alarm re-occurs?

Motor failure

YES

NO


Resume use

Skapad: 98-10-09

AL-1390

MSV#1

AL-1393

MSV#4

AL-1391

MSV#2

AL-1394

MSV#5

AL-1392

MSV#3

AL-1395

MSV#6

Ändrad: 98-11-26

YES

YES

AL-1396

1

MSV#7



MOTOMAN ROBOTICS AB

Page: 68

Alarm 3000-3006

Not Ready For Servo System Alarm Occurrence Turn the power off and then on again

Resume use

Alarm re-occurs?

NO

YES Check MTU board

NO

Defective?

NO

Is SVM working?

Defective?

Alarm re-occurs?

Replace MTU board

YES

Check primary power voltage

Replace SVM

YES

Alarm re-occurs?

YES

YES

YES Primary power failure

1

NO

NO

Resume use

Check cable between servopack and MSV board YES

1

Defective?

NO

1

Replace cable

NO Resume use

Alarm re-occurs?

YES

1

NO Cable failure

Skapad: 98-10-09

AL-3000

MSV#1

AL-3003

MSV#4

AL-3001

MSV#2

AL-3004

MSV#5

AL-3002

MSV#3

AL-3005

MSV#6

Ändrad: 98-11-26

AL-3006

MSV#7



MOTOMAN ROBOTICS AB

Alarm 3000-3006

Page: 69

Not Ready For Servo System (...continued)

1

Check cable between servopack and SVM Defective?

YES

Replace cable

NO Replace servopack

YES

Alarm re-occurs?

Alarm re-occurs?

YES



NO

Cable failure

YES



Skapad: 98-10-09

Ändrad: 98-11-26



MOTOMAN ROBOTICS AB

Page: 70

Alarm 3010-3016

Servo Defective Speed

Alarm Occurrence

Are you trying to turn power on while axis is moving

YES

Try power on while axis is stopped

NO Replace MSV board

YES

Alarm re-occurs?

Alarm re-occurs?

NO

MSV board failure

NO

Resume use

YES Contact MOTOMAN service

Skapad: 98-10-09

AL-3010

MSV#1

AL-3013

MSV#4

AL-3011

MSV#2

AL-3014

MSV#5

AL-3012

MSV#3

AL-3015

MSV#6

Ändrad: 98-11-26

AL-3016

MSV#7



MOTOMAN ROBOTICS AB

Alarm 3020-3026

Page: 71

Servo Defective DB

Alarm Occurrence Turn the power off and then on again Alarm re-occurs?

YES


NO

NO

Servopack failure

NO

MSV board failure

Resume use YES Replace MSV board Alarm re-occurs? YES Contact MOTOMAN service

Skapad: 98-10-09

AL-3020

MSV#1

AL-3023

MSV#4

AL-3021

MSV#2

AL-3024

MSV#5

AL-3022

MSV#3

AL-3025

MSV#6

Ändrad: 98-11-26

AL-3026

MSV#7



MOTOMAN ROBOTICS AB

Page: 72

Alarm 3030-3036

Regenerative Trouble

Alarm Occurrence At servo power on

Condition at the time of alarm? At control power on Replace servopack Alarm re-occurs?

Check regeneration resistor NO

YES

Defective? Contact MOTOMAN-service

Replace regeneration resistor

YES

YES

Alarm re-occurs?

NO

NO

Servopack failure

Regeneration resistor failure

Skapad: 98-10-09

AL-3030

MSV#1

AL-3033

MSV#4

AL-3031

MSV#2

AL-3034

MSV#5

AL-3032

MSV#3

AL-3035

MSV#6

Ändrad: 98-11-26

AL-3036

MSV#7



MOTOMAN ROBOTICS AB

Alarm 3040-3046

Page: 73

Overvoltage

Alarm Occurrence


At servo power on

At control power on

Check primary power voltage Abnormal?

Primary power failure

YES

NO Check regeneration resistor Replace servopack

NO

Alarm re-occurs?

YES

Defective?

Replace regeneration resistor

YES


YES

Alarm re-occurs?

NO

NO

Servopack failure

Regeneration resistor failure

Skapad: 98-10-09

AL-3040

MSV#1

AL-3043

MSV#4

AL-3041

MSV#2

AL-3044

MSV#5

AL-3042

MSV#3

AL-3045

MSV#6

Ändrad: 98-11-26

AL-3046

MSV#7



MOTOMAN ROBOTICS AB

Page: 74

Alarm 3050-3056

Voltage Drop


Condition at the time of alarm? At control power on


Replace servopack

NO

Alarm re-occurs?

YES

Abnormal?

YES




Skapad: 98-10-09

AL-3050

MSV#1

AL-3053

MSV#4

AL-3051

MSV#2

AL-3054

MSV#5

AL-3052

MSV#3

AL-3055

MSV#6

Ändrad: 98-11-26

AL-3056

MSV#7



MOTOMAN ROBOTICS AB

Alarm 3060-3066

Page: 75

Heat sink overheat


Condition at the time of alarm? At control power on


Replace servopack

NO

Alarm re-occurs?

YES

Abnormal?

YES




Skapad: 98-10-09

AL-3060

MSV#1

AL-3063

MSV#4

AL-3061

MSV#2

AL-3064

MSV#5

AL-3062

MSV#3

AL-3065

MSV#6

Ändrad: 98-11-26

AL-3066

MSV#7



MOTOMAN ROBOTICS AB

Page: 76

Alarm 3070-3076

Servo Blown Fuse


Condition at the time of alarm? At control power on Replace servopack Alarm re-occurs?

Check motor cable NO

YES

Abnormal? Contact MOTOMAN-service

YES

Replace wiring harness Alarm re-occurs?

YES

NO

NO

Servopack failure

Wiring failure

Skapad: 98-10-09

AL-3070

MSV#1

AL-3073

MSV#4

AL-3071

MSV#2

AL-3074

MSV#5

AL-3072

MSV#3

AL-3075

MSV#6

Ändrad: 98-11-26

AL-3076

MSV#7


MOTOMAN ROBOTICS AB


Alarm 3080-3086 Broken Current Ref Cable Alarm Occurrence Check cable between servopack and MSV board Defective?

YES

Replace cable

Replace servopack

YES

Alarm re-occurs?

Alarm re-occurs?

YES

Replace MSV board

NO

NO

Alarm re-occurs?

Servopack failure

NO

Cable failure

YES



Skapad: 98-10-09

AL-3080

MSV#1

AL-3083

MSV#4

AL-3081

MSV#2

AL-3084

MSV#5

AL-3082

MSV#3

AL-3085

MSV#6

Ändrad: 98-11-26

AL-3086

MSV#7



Alarm 3090-3096

MOTOMAN ROBOTICS AB

Open Phase

Alarm Occurrence Check primary power voltage Abnormal?

YES

NO

Check if contactor is stuck or not Abnormal?


Replace contactor

YES

Alarm re-occurs?

NO Check cable for SVM contactor

Replace cable

YES

YES

NO

Abnormal?

Contactor failure

NO Alarm re-occurs?

YES


NO

YES

Replace MSV board

Cable failure NO

Abnormal?


NO

MSV board failure


Skapad: 98-10-09

AL-3090

MSV#1

AL-3093

MSV#4

AL-3091

MSV#2

AL-3094

MSV#5

AL-3092

MSV#3

AL-3095

MSV#6

Ändrad: 98-11-26

AL-3096

MSV#7



MOTOMAN ROBOTICS AB

Alarm 4000

Page: 79

Not Ready Alarm Occurrence Reset alarm, and then execute the operation again Alarm re-occurs?

NO Resume use

Alarm 4010


Current Position Set Program Error Alarm Occurrence Reset alarm, and then execute the operation again Alarm re-occurs?

NO Resume use

Alarm 4020


Servo Power On Sequence Error Alarm Occurrence Reset alarm, and then execute the operation again NO Resume use

Skapad: 98-10-09

Ändrad: 98-11-26

Alarm re-occurs?




MOTOMAN ROBOTICS AB

Page: 80

Alarm 4030

Servo Power Off Sequence Error Alarm Occurrence Reset alarm, and then execute the operation again NO

Alarm re-occurs?

Resume use

Alarm 4040


Home Calibration Error Alarm Occurrence Reset alarm, and then execute the operation again NO

Alarm re-occurs?

Resume use

Alarm 4050


Absolute Data Change Error Alarm Occurrence Reset alarm, and then execute the operation again NO Resume use

Skapad: 98-10-09

Ändrad: 98-11-26

Alarm re-occurs?




MOTOMAN ROBOTICS AB

Alarm 4060

Page: 81

Segment Data Output Error Alarm Occurrence Reset alarm, and then execute the operation again NO

Alarm re-occurs?

Resume use

Alarm 4070


Axis Parameter Error Alarm Occurrence Initialize parameter setting NO

Alarm re-occurs?

Resume use

Alarm 4080


Table Parameter Error For Actual Axis Alarm Occurrence Initialize parameter setting NO Resume use

Skapad: 98-10-09

Ändrad: 98-11-26

Alarm re-occurs?




MOTOMAN ROBOTICS AB

Page: 82

Alarm 4090

Sequence Task Control Error Alarm Occurrence Reset alarm, and then execute the operation again NO

Alarm re-occurs?

Resume use

Alarm 4100


Data Refresh Error Alarm Occurrence Reset alarm, and then execute the operation again NO

Alarm re-occurs?

Resume use

Alarm 4110


Undefined Command (Arith) Alarm Occurrence Reset alarm, and then execute the operation again NO Resume use

Skapad: 98-10-09

Ändrad: 98-11-26

Alarm re-occurs?




MOTOMAN ROBOTICS AB

Alarm 4120

Page: 83

System Error (Arith) Alarm Occurrence Reset alarm, and then execute the operation again Alarm re-occurs?

NO Resume use

Alarm 4130


Arithmetic Error Alarm Occurrence Reset alarm, and then execute the operation again Alarm re-occurs?

NO Resume use

Alarm 4140


Select Error (Parameter) Alarm Occurrence Reset alarm, and then execute the operation again NO Resume use

Skapad: 98-10-09

Ändrad: 98-11-26

Alarm re-occurs?




MOTOMAN ROBOTICS AB

Page: 84

Alarm 4150

Group Axis Control Error Alarm Occurrence Reset alarm, and then execute the operation again NO

Alarm re-occurs?

Resume use

Alarm 4160


Two Steps Same Position (Circle) Alarm Occurrence

Confirm the taught program, and then input three different points NO

Alarm re-occurs?

Resume use

Alarm 4170


Two Steps Same Position (Spline) Alarm Occurrence

Confirm the taught program, and then input three different points NO Resume use

Skapad: 98-10-09

Ändrad: 98-11-26

Alarm re-occurs?




MOTOMAN ROBOTICS AB

Alarm 4180

Page: 85

Two Steps Same Position (3 steps) Alarm Occurrence


Alarm re-occurs?

YES

Resume use

Alarm 4190


Two Steps Same Position (weave) Alarm Occurrence


Alarm re-occurs?

YES

Resume use

Alarm 4200


Teach Error (Spline) Alarm Occurrence Confirm the taught program, and then provide instructions to position taught points correctly

NO Resume use

Skapad: 98-10-09

Ändrad: 98-11-26

Alarm re-occurs?




MOTOMAN ROBOTICS AB

Page: 86

Alarm 4210

Impossible Linear Motion (L/U) Alarm Occurrence

Confirm the taught program so the pattern of L and U axes is the same

NO

Alarm re-occurs?

Resume use

Alarm 4220


Impossible Linear Motion (S/L) Alarm Occurrence

Confirm the taught program so the pattern of S and L axes is the same

NO Resume use

Skapad: 98-10-09

Ändrad: 98-11-26

Alarm re-occurs?



MOTOMAN ROBOTICS AB

Alarm 4230


Excessive Segment (Low speed) Alarm Occurrence Decrease the speed of the step where the alarm occured NO

Alarm re-occurs?

YES

Set form of axes S and L, and provide a new instruction

Resume use

Alarm re-occurs?

NO Resume use

Alarm 4240


Excessive Segment (High speed) Alarm Occurrence Decrease the speed of the step where the alarm occured NO

Alarm re-occurs?

YES Set form of axes S and L, and provide a new instruction

Resume use

NO Resume use

Skapad: 98-10-09

Ändrad: 98-11-26

Alarm re-occurs?




MOTOMAN ROBOTICS AB

Page: 88

Alarm 4250-4300

Soft Limit Over Alarm Occurrence

Reset alarm using soft-limit-over reset method, and then provide another instruction Alarm re-occurs?

NO

YES

Resume use


AL-4250

Pulse limit over: minimum

AL-4280

Cube limit over: maximum

AL-4260

Pulse limit over: maximum

AL-4290

Special soft limit over: minimum

AL-4270

Cube limit over: minimum

AL-4300

Special soft limit over: maximum

Alarm 4310-4340

Mechanical Interference Alarm Occurrence

Reset alarm using soft-limit-over reset method, and then provide another instruction.

NO

Alarm re-occurs?


Resume use

AL-4310

Mechanical interference: minimum

AL-4330

Special mechanical interference: maximum

AL-4320

Mechanical interference: maximum

AL-4340

Special mechanical interference: minimum

Skapad: 98-10-09

Ändrad: 98-11-26



MOTOMAN ROBOTICS AB

Alarm 4350-4360

Page: 89

Pulse Mechanical limit Alarm Occurrence

Reset alarm using soft-limit-over reset method, and then provide another instruction.

Alarm re-occurs?

NO

YES

Resume use

AL-4350


Pulse mechanical limit: minimum

Alarm 4370

AL-4360

Pulse mechanical limit: maximum

Station Axis Data Input Error Alarm Occurrence

Reset alarm, and then execute the operation again

NO Resume use

Skapad: 98-10-09

Ändrad: 98-11-26

Alarm re-occurs?




MOTOMAN ROBOTICS AB

Page: 90

Alarm 4380

Segment Control Error Alarm Occurrence Reset alarm, and then execute the operation again

NO

Alarm re-occurs?

Resume use

Alarm 4390


Sub-segment Control Error Alarm Occurrence Reset alarm, and then execute the operation again

NO

Alarm re-occurs?

Resume use

Alarm 4400


Wrong Specified Control Group Alarm Occurrence

Reset alarm, and then execute the operation again NO Resume use

Skapad: 98-10-09

Ändrad: 98-11-26

Alarm re-occurs?




MOTOMAN ROBOTICS AB

Alarm 4410

Page: 91

CPU Communication Error Alarm Occurrence

Reset alarm, and then execute the operation again Alarm re-occurs?

NO

YES

Resume use

Alarm 4420


Failed To Select Over SP Level Alarm Occurrence

Reset alarm, and then execute the operation again NO

Alarm re-occurs?

YES

Resume use

Turn the power off, and then on again YES

Alarm re-occurs?

Replace MSV board NO MSV board failure

Skapad: 98-10-09

Ändrad: 98-11-26

Alarm re-occurs?

NO Resume use




MOTOMAN ROBOTICS AB

Page: 92

Alarm 4430

Averaging Number Change Error Alarm Occurrence


Alarm re-occurs?

YES

Resume use

Turn the power off, and then on again Alarm re-occurs?

YES

Replace MSV board NO

Alarm re-occurs?

Resume use YES

MSV board failure

Alarm 4440

NO


Torque Limit Change Error Alarm Occurrence


Alarm re-occurs?

YES

Resume use

Turn the power off, and then on again YES

Alarm re-occurs?

Replace MSV board NO MSV board failure

Skapad: 98-10-09

Ändrad: 98-11-26

Alarm re-occurs?

NO Resume use




MOTOMAN ROBOTICS AB

Alarm 4450

Page: 93

JMS Error Alarm Occurrence


NO Resume use


1/255

Parameter

11/245

Sequence number error

2/254

Access time over

12/244

Step numer error

3/253

Access error

13/243

4/252

Job name error

14/242

5/251

Existing job open

15/241

6/250

Memory over

16/240

Lack of handle

7/249

Not existing

17/239

Write Protected

8/248

Acess not permitted

18/238

Maximum instruction

9/247

Handling number error

19/237

Maximum step

10/246

System error

99/157

Job failure

Alarm 4460

Code error

JHM Error Alarm Occurrence Turn the power off, and then on again NO Resume use

Skapad: 98-10-09

Ändrad: 98-11-26

Alarm re-occurs?




MOTOMAN ROBOTICS AB

Page: 94

Alarm 4470

Instruction Interpreter Error Alarm Occurrence Turn the power off, and then on again NO

Alarm re-occurs?

Resume use

Alarm 4480


Undefined Global Variable Alarm Occurrence

Reset the parameter, and then execute the operation again NO

Alarm re-occurs?

Resume use

Alarm 4490


Var-Scoreboard Control Error Alarm Occurrence


Skapad: 98-10-09

Ändrad: 98-11-26

Alarm re-occurs?




MOTOMAN ROBOTICS AB

Alarm 4500

Page: 95

Undefined Local Variable Alarm Occurrence

Set the local variable to the job heade and then execute the operation again NO

Alarm re-occurs?

Resume use

Alarm 4510


Less Than 3 Steps (circular) Alarm Occurrence

Confirm the taught program, and then input instructions to provide more than three steps continuously

NO

Alarm re-occurs?

Resume use

Alarm 4520


Cannot Interpolate Circular Motion Alarm Occurrence

Confirm the taught program, and then input instructions to provide more than three steps continuously

NO Resume use

Skapad: 98-10-09

Ändrad: 98-11-26

Alarm re-occurs?




MOTOMAN ROBOTICS AB

Page: 96

Alarm 4530

Undefined Job Alarm Occurrence

Reset alarm, end then execute the operation again Alarm re-occurs?

NO

YES

Resume use

Alarm 4540


Undefined Label Alarm Occurrence Check the taught point, and then teach the point again NO

Alarm re-occurs?

YES

Resume use

Alarm 4550


Undefined Return Job Alarm Occurrence Start from the original job NO Resume use

Alarm re-occurs?

YES Check the taught point, and then teach the point again NO

Resume use

Skapad: 98-10-09

Ändrad: 98-11-26

Alarm re-occurs?

YES




MOTOMAN ROBOTICS AB

Alarm 4560

Page: 97

Lack Of Local-Variable Area Alarm Occurrence

Decrease the use of local variables Alarm re-occurs?

NO Resume use

Alarm 4570


Local-Variable Control Error Alarm Occurrence


NO Resume use

Alarm 4580


Job Call Stack Error Alarm Occurrence


Skapad: 98-10-09

Ändrad: 98-11-26

Alarm re-occurs?




MOTOMAN ROBOTICS AB

Page: 98

Alarm 4590

Feedback Pulse Making Error Alarm Occurrence


NO Resume use

Alarm 4600


Unsuccessful Fine Positioning Alarm Occurrence Reset alarm, and then execute the operation again NO

Alarm re-occurs?

YES

Resume use

Turn the power off, and then on again Alarm re-occurs?

YES Replace MSV board NO

Alarm re-occurs?

MSV board failure

Skapad: 98-10-09

Ändrad: 98-11-26

NO Resume use




MOTOMAN ROBOTICS AB

Alarm 4610

Page: 99

Pending Block-End Error Alarm Occurrence


NO Resume use

Alarm 4620


Data Preset Error Alarm Occurrence


NO Resume use

Alarm 4630


Variable Data Type Error Alarm Occurrence


Skapad: 98-10-09

Ändrad: 98-11-26

Alarm re-occurs?




MOTOMAN ROBOTICS AB

Page: 100

Alarm 4640

Over Variable Limit Alarm Occurrence Change value of variable type that exceeds numerical range limits. NO

Alarm re-occurs?

Resume use

Alarm 4650

(B**) ‘0-255 (I**) -32768~32767 (D**) -2147483648 ~214748 (R**) -1.70141E+38 ~1.70141E


Defective Taught Point (circular) Alarm Occurrence Check taught point, and then teach three points not in a straight line NO

Alarm re-occurs?

Resume use

Alarm 4660


Weaving Control Error Alarm Occurrence

Reset alarm, and then check weave file and REFP points NO Resume use

Skapad: 98-10-09

Ändrad: 98-11-26

Alarm re-occurs?




MOTOMAN ROBOTICS AB

Alarm 4670-4671

Page: 101

Overrun In Axis

Alarm Occurrence Recover from overtravel then try again Alarm re-occurs?

NO Resume use

YES

Set the swith again

Check short switch on MBB02

YES

Abnormal? NO

Alarm re-occurs?

NO Swith setting failure

Check the over run limit switch

YES

Replace switch

YES

Defective? NO

Alarm re-occurs?

NO

YES

Check the wiring of the overrun limit switch Alarm re-occurs?

Switch failure

YES

Replace wiring harness

NO Replace MTU board Replace MBB02 (IOBB) board

YES

Alarm re-occurs?

Alarm re-occurs?

YES

NO Lead failure

NO

Alarm re-occurs?

NO

YES

Board failure MBB02 (IOBB) failure

AL-4670

At robot axes occurrence

Skapad: 98-10-09

Ändrad: 98-11-26


AL-4671

At external axes occurrence



MOTOMAN ROBOTICS AB

Page: 102

Alarm 4680-4730

File Fault Alarm Occurrence


NO Resume use

YES

Load the file corresponding to the screen, and then try again Alarm re-occurs?

NO


Resume use

AL-4680

Tool file

AL-4710

Weaving file

AL-4690

User frame file

AL-4720

Home position absolute data file

AL-4700

Servo monitor signal file

AL-4730

Second home position data file

Alarm 4740

Posn File Data Read-Out Error Alarm Occurrence


Skapad: 98-10-09

Ändrad: 98-11-26

Alarm re-occurs?




MOTOMAN ROBOTICS AB

Alarm 4750

Page: 103

Unmatched Posn Var Data Type Alarm Occurrence Change position variable data type (pulse - XYZ). Alarm re-occurs?

NO Resume use

Alarm 4760


File No. Error Alarm Occurrence


NO Resume use

Alarm 4770


Undefined Reference Point Alarm Occurrence

Register the reference point

NO Resume use

Skapad: 98-10-09

Ändrad: 98-11-26

Alarm re-occurs?




MOTOMAN ROBOTICS AB

Page: 104

Alarm 4780

Stack More Than 8 (job call) Alarm Occurrence

Check program, and modify so that stack does not exceed 8 calls NO

Alarm re-occurs?

Resume use

Alarm 4790


Arithmetic Section Request Error Alarm Occurrence


Alarm re-occurs?

Resume use

Alarm 4800


Request-To-Send Error Alarm Occurrence


Skapad: 98-10-09

Ändrad: 98-11-26

Alarm re-occurs?




MOTOMAN ROBOTICS AB

Alarm 4810

Page: 105

Over Variable No. (B000~B039) (I000~I039) D000~D039) R000~R039) P000~P127) BP000~BP127) EX000~EX127)

Alarm Occurrence Check program, and change variable number within limit Alarm re-occurs?

NO

YES

Resume use

Alarm 4820


Position Data Management Error Alarm Occurrence


Alarm re-occurs?

Resume use


1

Not enough area

9

Control information destroyed

2

Number of axis zero

10

Irregular position number

3

Position not kept

11

Position data not set

4

Number of position over

12

Undefined position

5

Area not specified

13

Undefined control group

6

File destroyed

14

Initialization not done

7

Memory over

15

Number of axis over

8

Position data destroyed

Skapad: 98-10-09

Ändrad: 98-11-26



MOTOMAN ROBOTICS AB

Page: 106

Alarm 4830-4850

Undefined Condition File Alarm Occurrence Complete the setting of the file NO

Alarm re-occurs?

YES

Resume use


AL-4830

Welder condition file

AL-4840

Arc start condition file

Alarm 4860

AL-4850

Arc end condition file

Wrong Welder Selection Alarm Occurrence

Match unit of voltage selection to welder type NO Resume use

Skapad: 98-10-09

Ändrad: 98-11-26

Alarm re-occurs?




MOTOMAN ROBOTICS AB

Alarm 4870-4900

Page: 107

Condition File Fault Alarm Occurrence


NO

YES Load file, and the try again

Resume use NO

Alarm re-occurs?

Resume use


AL-4870

Welder condition file

AL-4890

Arc end condition file

AL-4880

Arc start condition file

AL-4900

Arc condition supp. file

Alarm 4910

AX-CPU Command Area Error Alarm Occurrence


Skapad: 98-10-09

Ändrad: 98-11-26

Alarm re-occurs?




MOTOMAN ROBOTICS AB

Page: 108

Alarm 4920-4950

File Fault Alarm Occurrence


NO

YES

Resume use

Load file, and then try again NO

Alarm re-occurs?

Resume use


AL-4920

COM-ARC 3 Condition file

AL-4940

Correction condition file

AL-4930

COM-ARC 3 Data file

AL-4950

Phase offset data file

Alarm 4960

System Change Alarm Occurrence Turn the power off, and then on again

NO Resume use

Skapad: 98-10-09

Ändrad: 98-11-26

Alarm re-occurs?




MOTOMAN ROBOTICS AB

Alarm 4970

Page: 109

Equation Exception Error Alarm Occurrence


NO

YES

Resume use

Alarm 4980


Excessive Instruction Equation Alarm Occurrence

Check the program, and make the expression short Alarm re-occurs?

NO

YES

Resume use

Alarm 4990


Encoder Battery Error Alarm Occurrence


Alarm re-occurs?

Battery failure

YES

Replace battery board for encoder

NO MFC board failure

Skapad: 98-10-09

Ändrad: 98-11-26

Alarm re-occurs?

YES




MOTOMAN ROBOTICS AB

Page: 110

Alarm 5000

Encoder Overheat

Alarm Occurrence Turn the power off, let encoder cool, and then turn the power on Alarm re-occurs? YES If motor has cooling fan, check if fan is working properly Is fan working?

YES

NO Check the wiring of fan Defective?

NO

YES Replace fan wiring Alarm re-occurs?

Check load YES

NO

Load condition?

Replace fan Alarm re-occurs?

Lead failure

OK

Overload

YES

Decrease weight NO Replace motor

Fan failure Contact MOTOMAN-service

YES

Alarm re-occurs? NO Motor failure

Skapad: 98-10-09

Ändrad: 98-11-26



MOTOMAN ROBOTICS AB

Alarm 5010

Page: 111

Illegal Parameter Alarm Occurrence

Change the parameter back to original Alarm re-occurs?

NO

YES

Resume use

Load parameter file, and then try again NO

Alarm re-occurs?


Resume use

Alarm 5020

YES

Zero Divisor Occurrence Alarm Occurrence

Change the program so that the number will not be divided by zero NO Resume use

Skapad: 98-10-09

Ändrad: 98-11-26

Alarm re-occurs?




Alarm 5030

MOTOMAN ROBOTICS AB

Global-Variable Area Parameter Error Alarm Occurrence

Change the parameter back to original value Alarm re-occurs?

NO

YES

Resume use

Load parameter file, and then try again NO

Alarm re-occurs?


Resume use

Alarm 5040

YES

Out Of Range (abso data)

Alarm Occurrence

Reset alarm by checking second home position Alarm re-occurs?

YES

NO

Check battery wiring to encodeers Defective?

YES

Replace battery

Resume use NO Replace motor Motor failure

NO


YES

Alarm re-occurs? NO Battery failure


Skapad: 98-10-09

Ändrad: 98-11-26



MOTOMAN ROBOTICS AB

Alarm 5060

Page: 113

Undefined Auto-Weld Release Cond Alarm Occurrence

Set welding release condition time, and then try again Alarm re-occurs?

NO Resume use

Alarm 5070


Undefined Position For Arc Retry Alarm Occurrence

Add step, and then try again

NO

Alarm re-occurs?

Resume use

Alarm 5080


Overspeed Limit Alarm Occurrence

Check setting for MFC04 board, and then try again NO Resume use

Skapad: 98-10-09

Ändrad: 98-11-26

Alarm re-occurs?




MOTOMAN ROBOTICS AB

Page: 114

Alarm 5090

DC 24V Power Supply Failure

Alarm Occurrence

Check 24V power voltage supplied to IOBB Defective?

YES

Replace DC 24V power supply

NO Check fuse on IOBB

YES

Alarm re-occurs?

YES

Replace fuse

Replace IOBB

YES

Alarm re-occurs?

Alarm re-occurs?

NO

Board failure

Defective?

NO

Power supply failure

NO

Fuse failure

NO


Skapad: 98-10-09

Ändrad: 98-11-26



MOTOMAN ROBOTICS AB

Alarm 5100

Page: 115

Shock Sensor Action Alarm Occurrence Remove interference between the tool and the fixture, etc

Remove interference, and then try again

YES

Interference? NO

Alarm re-occurs?

Check the shock sensor cable

YES

NO

Defective?

YES

Replace cable

YES

Alarm re-occurs?

Resume use NO Check the shock sensor operation Check the setting of IOBB short pin switch Abnormal?

NO

Abnormal? Set the short pin switch

YES

Replace MTU board

MTU board failure

YES

NO Sensor failure


Setting failure

Replace MRY board Alarm re-occurs?

Skapad: 98-10-09

Replace shock sensor

Alarm re-occurs?

YES

NO Alarm re-occurs?

Cable failure

YES

Alarm re-occurs?

NO

NO

Replace IOBB YES

Alarm re-occurs?

NO

YES

MRY board failure


Ändrad: 98-11-26

NO

IOBB failure



Alarm 5110

MOTOMAN ROBOTICS AB

Brake Fuse Blown Alarm Occurrence Check the brake lead wiring for short to ground Short? Check the brake fuse

Replace the brake fuse

YES

YES

Replace lead wire for brake

YES

Alarm re-occurs? NO

Fuse blown?

Lead wire failure NO Alarm re-occurs?

YES

Replace the MTU board Alarm re-occurs?

NO

NO

Board failure

Fuse failure YES Contact MOTOMAN-service

Skapad: 98-10-09

Ändrad: 98-11-26



MOTOMAN ROBOTICS AB

Alarm 5120

Page: 117

Parity Error Alarm Occurrence Check the parameter for parity check function Invalid parameter?

YES

Set the parameter correctly

NO Check input Check the input program

YES

NO

Abnormal?

YES

Parameter setting failure

NO Alarm re-occurs?

YES

Alarm re-occurs?

Replace the MTU board Alarm re-occurs?

NO

NO

Board failure

Abnormal input YES Contact MOTOMAN-service

Skapad: 98-10-09

Ändrad: 98-11-26



Alarm 5130

MOTOMAN ROBOTICS AB

Over BCD Range Alarm Occurrence

Check the BCD function parameter Invalid parameter?

YES


NO Check input/output Check the input/ output program

YES

YES

NO

Abnormal?


NO Alarm re-occurs?

YES

Replace IO module board Alarm re-occurs?

NO Input/output failure

Alarm re-occurs?

NO

Board failure


Skapad: 98-10-09

Ändrad: 98-11-26



MOTOMAN ROBOTICS AB

Alarm 5140

Page: 119

Over Binary Range (parity check) Alarm Occurrence Check parity check - BCD function parameter Invalid parameter?

YES


NO Check output Check the output program

NO

Abnormal?

YES


NO Alarm re-occurs?

Alarm re-occurs?

YES

Replace IO module board

YES

Alarm re-occurs?

NO Output failure

NO

Board failure


Alarm 5150

Offline Undefined Command (Arith) Alarm Occurrence Reset alarm, and then execute the operation again NO Resume use

Skapad: 98-10-09

Ändrad: 98-11-26

Alarm re-occurs?




MOTOMAN ROBOTICS AB

Page: 120

Alarm 5160

Offline System Error (Arith) Alarm Occurrence Reset alarm, and then execute the operation again NO

Alarm re-occurs?

YES

Resume use

Alarm 5170


Robot Calibration Data Error Alarm Occurrence Reset alarm, and then execute the operation again NO

Alarm re-occurs?

Resume use

Alarm 5180


Robot Calibration Frame Error Alarm Occurrence Reset alarm, and then execute the operation again NO Resume use

Skapad: 98-10-09

Ändrad: 98-11-26

Alarm re-occurs?




MOTOMAN ROBOTICS AB

Alarm 5190

Page: 121

Arithmetic Section Init Error Alarm Occurrence Reset alarm, and then execute the operation again Alarm re-occurs?

NO Resume use

Alarm 5200


Set-Up Process Error (motion) Alarm Occurrence Reset alarm, and then execute the operation again Alarm re-occurs?

NO Resume use

Alarm 5210


System Error (motion) Alarm Occurrence Reset alarm, and then execute the operation again NO Resume use

Skapad: 98-10-09

Ändrad: 98-11-26

Alarm re-occurs?




MOTOMAN ROBOTICS AB

Page: 122

Alarm 5220

Servo Ready Monitoring Error Alarm Occurrence Reset alarm, and then execute the operation again NO

Alarm re-occurs?

Resume use

Alarm 5230


Calibration Data Error Alarm Occurrence Reset alarm, and then execute the operation again NO

Alarm re-occurs?

Resume use

Alarm 5240


Tool Calibration Data Error Alarm Occurrence Reset alarm, and then execute the operation again NO Resume use

Skapad: 98-10-09

Ändrad: 98-11-26

Alarm re-occurs?




MOTOMAN ROBOTICS AB

Alarm 5250-5300

Page: 123

File Fault Alarm Occurrence Reset alarm, and then execute the operation again Alarm re-occurs?

NO Resume use

YES

Load the file corresponding to the display, and then try again

NO

Alarm re-occurs?


Resume use

AL-5250

Robot calibration file

AL-5280

Arc end cond guide file

AL-5260

Tool calibration file

AL-5290

Welder user-defined file

AL-5270

Arc start cond guide file

AL-5300

Ladder program file

Alarm 5310

Arithmetic Alarm Reset Error Alarm Occurrence Reset alarm, and then execute the operation again NO Resume use

Skapad: 98-10-09

Ändrad: 98-11-26

Alarm re-occurs?




MOTOMAN ROBOTICS AB

Page: 124

Alarm 5320

Wrong Control Group Axis Alarm Occurrence Check program and modify it (include control group to the original job). NO

Alarm re-occurs?

Resume use

Alarm 5330


Cannot Execute Job (no robot) Alarm Occurrence Check program and modify it (include control group to the original job). NO

Alarm re-occurs?

Resume use

Alarm 5340


Sensing Data Request Error Alarm Occurrence Reset alarm, and then execute the operation again NO Resume use

Skapad: 98-10-09

Ändrad: 98-11-26

Alarm re-occurs?




MOTOMAN ROBOTICS AB

Alarm 5350

Page: 125

Main Contactor On Reply Error Alarm Occurrence Reset alarm, and then execute the operation again NO

Alarm re-occurs?

Resume use

YES Check if main contactor is working or not

NO

Working?

YES

Check voltage for main contactor coil NO

Abnormal?

YES

Replace main contactor Alarm re-occurs?

YES

Check MTU board Defective?

NO

YES

Replace MTU board

NO

Contactor failure


YES

Alarm re-occurs? NO MTU board failure

Skapad: 98-10-09

Ändrad: 98-11-26



MOTOMAN ROBOTICS AB

Page: 126

Alarm 5360

Main Contactor Off Reply Error Alarm Occurrence Reset alarm, and then execute the operation again NO

Alarm re-occurs?

Resume use


NO

Working?

YES


Abnormal?

YES


YES


NO Contactor failure

YES

Replace MTU board


YES


Skapad: 98-10-09

Ändrad: 98-11-26



MOTOMAN ROBOTICS AB

Alarm 5370

Page: 127

Braking Lock Reply Error Alarm Occurrence Reset alarm, and then execute the operation again NO

Alarm re-occurs?

Resume use


NO

Working?

YES


Abnormal?

YES


YES


NO

YES

Replace MTU board

NO

Contactor failure


YES


Skapad: 98-10-09

Ändrad: 98-11-26



MOTOMAN ROBOTICS AB

Page: 128

Alarm 5380

Braking Release Reply Error Alarm Occurrence Reset alarm, and then execute the operation again NO

Alarm re-occurs?

Resume use


NO

Working?

YES


Abnormal?

YES


YES


NO Contactor failure

YES

Replace MTU board


YES


Skapad: 98-10-09

Ändrad: 98-11-26



MOTOMAN ROBOTICS AB

Alarm 5390

Page: 129

Servo-Ready On Error Alarm Occurrence Reset alarm, and then execute the operation again NO

Alarm re-occurs?

Resume use


NO

Working?

YES

1

YES

Replace MTU board


Abnormal?

YES


YES


NO

NO

Contactor failure


YES


Skapad: 98-10-09

Ändrad: 98-11-26



Alarm 5390

MOTOMAN ROBOTICS AB

Servo-Ready On Error (...continued) 1

Check change LED on servopack YES

Lit? NO Turn off power, and then turn it on again Alarm re-occurs?

NO

Resume use

YES Check wiring between contactor and servopack

Defective?

Replace wiring between contactor and servopack

YES

NO Check wiring between MSV board and servopack Defective?

YES

YES

Alarm re-occurs?

NO

Wiring failure

Replace wiring between MSV board and servopack

NO Replace servopack Alarm re-occurs? NO

YES YES

Alarm re-occurs?

NO

Wiring failure

NO

MSV board failure


Servopack failure YES Contact MOTOMAN-service Skapad: 98-10-09

Ändrad: 98-11-26



MOTOMAN ROBOTICS AB

Alarm 5400

Page: 131

Servo-Ready Off Error Alarm Occurrence Reset alarm, and then execute the operation again NO

Alarm re-occurs?

Resume use


NO

Working?

YES

1

YES

Replace MTU board


Abnormal?

YES


YES


NO

NO

Contactor failure


YES


Skapad: 98-10-09

Ändrad: 98-11-26



Alarm 5400

MOTOMAN ROBOTICS AB

Servo-Ready Off Error (...continued) 1

Check change LED on servopack YES

Lit? NO Turn off power, and then turn it on again Alarm re-occurs?

NO

Resume use

YES Check wiring between contactor and servopack

Defective?

Replace wiring between contactor and servopack

YES

NO Check wiring between MSV board and servopack Defective?

YES

YES

Alarm re-occurs?

NO

Wiring failure



YES YES

Alarm re-occurs?

NO

Wiring failure

NO

MSV board failure


Servopack failure YES Contact MOTOMAN-service Skapad: 98-10-09

Ändrad: 98-11-26



MOTOMAN ROBOTICS AB

Alarm 5410

Page: 133

Base-Block On Error Alarm Occurrence Reset alarm, and then execute the operation again Alarm re-occurs?

NO

Resume use

NO

Resume use

YES Turn off power, and then turn it on again Alarm re-occurs? YES Check wiring between MSV board and servopack Defective?

YES



YES YES

Alarm re-occurs?

NO

Wiring failure

NO

MSV board failure


Servopack failure YES Contact MOTOMAN-service

Skapad: 98-10-09

Ändrad: 98-11-26



Alarm 5420

MOTOMAN ROBOTICS AB

Base-Block Off Error Alarm Occurrence Reset alarm, and then execute the operation again Alarm re-occurs?

NO

Resume use

NO

Resume use


YES



YES YES

Alarm re-occurs?

NO

Wiring failure

NO

MSV board failure



Skapad: 98-10-09

Ändrad: 98-11-26



MOTOMAN ROBOTICS AB

Alarm 5430

Page: 135

Dynamic Brake On Error Alarm Occurrence Reset alarm, and then execute the operation again Alarm re-occurs?

NO

Resume use

NO

Resume use


YES



YES YES

Alarm re-occurs?

NO

Wiring failure

NO

MSV board failure



Skapad: 98-10-09

Ändrad: 98-11-26



Alarm 5440

MOTOMAN ROBOTICS AB

Dynamic Brake Off Error Alarm Occurrence Reset alarm, and then execute the operation again Alarm re-occurs?

NO

Resume use

NO

Resume use


YES



YES YES

Alarm re-occurs?

NO

Wiring failure

NO

MSV board failure



Skapad: 98-10-09

Ändrad: 98-11-26


MOTOMAN ROBOTICS AB

Alarm 5450


Unused (on) Alarm Occurrence Reset alarm, and then execute the operation again NO

Alarm re-occurs?

Resume use


Alarm 5460

Unused (off) Alarm Occurrence Reset alarm, and then execute the operation again NO

Alarm re-occurs?

Resume use


Alarm 5470

Cannot Edit (edit lock job) Alarm Occurrence

Release Edit-lock, and then execute the operation again NO

Alarm re-occurs?

Resume use

Skapad: 98-10-09


Ändrad: 98-11-26



Alarm 5480

MOTOMAN ROBOTICS AB

Select Error (application 1) Alarm Occurrence Reset alarm, and then execute the operation again NO

Alarm re-occurs?

YES

Resume use


Alarm 5490

Select Error (application 2) Alarm Occurrence Reset alarm, and then execute the operation again NO

Alarm re-occurs?

YES

Resume use


Alarm 5500

Select Error (sensor 1) Alarm Occurrence Reset alarm, and then execute the operation again NO

Alarm re-occurs?

Resume use

Skapad: 98-10-09

Ändrad: 98-11-26



MOTOMAN ROBOTICS AB

Alarm 5510


Select Error (sensor 2) Alarm Occurrence Reset alarm, and then execute the operation again Alarm re-occurs?

NO Resume use


Alarm 5520

Wrong Port Out (analog output) Alarm Occurrence Reset alarm, and then execute the operation again Alarm re-occurs?

NO Resume use

Data 1


Application 1

Skapad: 98-10-09

YES

Ändrad: 98-11-26

Data 2

Application 2



MOTOMAN ROBOTICS AB

Page: 140

Alarm 5530

Pass Over

Alarm Occurrence Is COM-ARC III’s function normal?

Check workpiece deviation

YES

NO Check the cable between the current detection unit and the sensor board

Defective?

Deviation?

Small

Large

Position a workpiece

Check the current detection unit

NO

YES

Defective?

YES

Replace the current detection unit

Change the cable NO Replace the sensor board Sensor board failure

Alarm re-occurs?

NO

YES

YES

Alarm re-occurs? NO Current detection unit failure


Alarm 5540

Wrong Selection (sensor) Alarm Occurrence Reset alarm, and then execute the operation again NO

Alarm re-occurs?

Resume use

Skapad: 98-10-09

Ändrad: 98-11-26



MOTOMAN ROBOTICS AB

Alarm 5550


Wrong Mech Parameter File Alarm Occurrence Reset alarm, and then execute the operation again NO

Alarm re-occurs?

Resume use


Alarm 5560

Incompleted PT Frame Alarm Occurrence Reset alarm, and then execute the operation again NO

Alarm re-occurs?

Resume use


Alarm 5570

Defective Taught Point (cutting) Alarm Occurrence Reset alarm, and then execute the operation again NO

Alarm re-occurs?

Resume use

Data 1


CW axis position is not 0.

Skapad: 98-10-09

YES

Ändrad: 98-11-26

Data 2

Cutting radius is 0.



Alarm 5580

MOTOMAN ROBOTICS AB

Defective Taught Point (endless) Alarm Occurrence Reset alarm, and then execute the operation again NO

Alarm re-occurs?

YES

Resume use

Data 1 Data 2


Linear motion error (MRESET not executed. Endless on base axes

Alarm 5590

Data 3

Endless not selected on T-axis.

Data 4

Command position exceeds limit (214748367 pulse).

Correctional Direction Data Alarm Occurrence Reset alarm, and then execute the operation again NO

Alarm re-occurs?

YES

Resume use


Alarm 5600

Position Correction Data Alarm Occurrence Reset alarm, and then execute the operation again NO

Alarm re-occurs?

Resume use

Skapad: 98-10-09

Ändrad: 98-11-26

YES Contact MOTOMAN-service Filnamn: T:\M-ROBOT\ENGELSK\TROUBLE_SHOOTING.FM

MOTOMAN ROBOTICS AB

Alarm 5610


Over Tool File No. Alarm Occurrence Reset alarm, and then execute the operation again NO

Alarm re-occurs?

Resume use


Alarm 5620

Defective Taught Point (weav) Alarm Occurrence

Check the REFP, and then teach the REFP again NO

Alarm re-occurs?

Resume use

Data 1


Weaving atart point and end point is the same

Alarm 5630

Data 2

Weaving REFP 1 or 2 is on the path

Undefined Robot Calibration Alarm Occurrence

Execute robot calibration

NO

Alarm re-occurs

Resume use

Skapad: 98-10-09


Ändrad: 98-11-26



MOTOMAN ROBOTICS AB

Page: 144

Alarm 5640

Parameter Error Alarm Occurrence Reset the parameter with the original data NO

Alarm re-occurs?

Resume use

YES

Load the parameter file and then try again Alarm re-occurs?

NO

YES

Resume use

Alarm 5650


Defective Taught Point (Calib) Alarm Occurrence

Check the taught point, and then teach the point again NO

Alarm re-occurs?

Resume use

Data 3 Data 4

Skapad: 98-10-09


Data for station 2nd axis is not same 3, 4, 5 points. Data for station 1st axis is not same 1, 2, 3 points.

Ändrad: 98-11-26

Data 5 Data 6

Data for station 2nd axis is not same 1, 2, 3 points. Data for station 1st axis is not same 3, 4, 5 points.


MOTOMAN ROBOTICS AB

Alarm 5660


DM-Bank Transmission Error Alarm Occurrence Reset alarm, and then execute the operation again NO

Alarm re-occurs?

Resume use


Alarm 5670

Cannot Execute Job (no grp axis) Alarm Occurrence

Set group axes

NO

Alarm re-occurs?

Resume use


Alarm 5680

Univ Data Preset Request Error Alarm Occurrence Reset alarm, and then execute the operation again NO

Alarm re-occurs?

Resume use

Skapad: 98-10-09


Ändrad: 98-11-26



MOTOMAN ROBOTICS AB

Page: 146

Alarm 5690

Braking Sequence Error Alarm Occurrence Reset alarm, and then execute the operation again NO

Alarm re-occurs?

YES

Resume use


Alarm 5700

Process Error (Syscon - axis) Alarm Occurrence Reset alarm, and then execute the operation again NO

Alarm re-occurs?

YES

Resume use

Alarm 5710


Illegal Sv Parameter (online) Alarm Occurrence

Reset the parameter with the original data. NO

Alarm re-occurs?

Resume use

Load the parameter file and then try again

NO Resume use

Skapad: 98-10-09

YES

Ändrad: 98-11-26

Alarm re-occurs?



MOTOMAN ROBOTICS AB

Alarm 5720


Illegal Sv Parameter (online) Alarm Occurrence Reset alarm, and then execute the operation again NO

Alarm re-occurs?

YES

Resume use

Replace the MSV board, and then try again Alarm re-occurs?

NO Resume use

Alarm 5730


Sv Parameter Change Error (online) Alarm Occurrence Reset alarm, and then execute the operation again NO

Alarm re-occurs?

Resume use

Replace the MSV board, and then try again NO Resume use

Skapad: 98-10-09

YES

Ändrad: 98-11-26

Alarm re-occurs?




MOTOMAN ROBOTICS AB

Page: 148

Alarm 5740

Illegal Max Speed Parameter Alarm Occurrence Reset the parameter with the original data NO

Alarm re-occurs?

Resume use

YES

Load the parameter file and then try again Alarm re-occurs?

NO Resume use

Alarm 5750


Undefined Position Variable Alarm Occurrence

Set the position variable

NO

Alarm re-occurs?

YES

Resume use

Alarm 5760


Undefined User Frame Alarm Occurrence

Set the user frame

NO

Alarm re-occurs?

Resume use

Skapad: 98-10-09

Ändrad: 98-11-26



MOTOMAN ROBOTICS AB

Alarm 5770


Out Of Range (parallel process) Alarm Occurrence Reset alarm, and then execute the operation again NO

Alarm re-occurs?

Resume use


Alarm 5780

SL Board On-Line Error Alarm Occurrence Reset alarm, and then execute the operation again NO

Alarm re-occurs?

Resume use


Alarm 5790

Interrupt Error (sensor) Alarm Occurrence Reset alarm, and then execute the operation again NO

Alarm re-occurs?

Resume use

Skapad: 98-10-09


Ändrad: 98-11-26



Alarm 5800

MOTOMAN ROBOTICS AB

Out Of Current Detector Range Alarm Occurrence Reset alarm, and then execute the operation again NO

Alarm re-occurs?

YES

Resume use


Alarm 5810

Command Error (sensor) Alarm Occurrence Reset alarm, and then execute the operation again NO

Alarm re-occurs?

YES

Resume use


Alarm 5820

Process Error (sensor) Alarm Occurrence Reset alarm, and then execute the operation again NO

Alarm re-occurs?

Resume use

Skapad: 98-10-09

Ändrad: 98-11-26



MOTOMAN ROBOTICS AB

Alarm 5830


Parallel Start Instruction Error Alarm Occurrence Check the program, and then modify it. NO

Alarm re-occurs?

Resume use


Alarm 5840

Cannot Execute Job (grp axis) Alarm Occurrence

Set group axes

NO

Alarm re-occurs?

Resume use


Alarm 5850

Measure Inst Execute Error Alarm Occurrence Reset alarm, and then execute the operation again NO

Alarm re-occurs?

Resume use

Skapad: 98-10-09


Ändrad: 98-11-26


Headquarters: MOTOMAN ROBOTICS AB Box 504 l 385 25 Torsås l Sweden Tel: +46-486-48800l Fax: +46-486-41410

Subsidiary: MOTOMAN ROBOTICS UK LTD 1 Swan Industrial Estate l Banbury l OXON OX16 8DJ l England Tel: +44-1295-272755 l Fax: +44-1295-267127

MOTOMAN ROBOTICS ITALIA SRL Via Emilia 1420/16 l I-41100 Modena l ITALY Tel: +39-59280496 l Fax: +39-59280602

MOTOMAN ROBOTICS FRANCE S.A. Rue Nungesser et Coli l D2A Nantes-Atlantique l F-44860 Saint-Aignan-de-Grand-Lieu l France Tel: +33-2-40131919 l Fax: +33-40754147

MOTOMAN ROBOTICS ESPAÑA S.L. Avenida Marina 56 l Parcela 90 l ES-08830 ST. Boi de Llobregat l Spain Tel: +34-36303478 l Fax: +34-36543459

Distributors: ELECTRO-ARCO S.A. Rua Vice Almirante Azevedo Coutinho, 4 l Venda Nova l PT-2700 Amadora l Portugal Tel: +351-14968160 l Fax: +351-14990696

HN AUTOMATIC A/S Hjulmagervej 4 l DK-7100 Vejle l Denmark Tel: +45-79428000 l Fax: +45-79428001

LINCOLN-KD S.A. Ctra, Laureà Miró 396-398 l E-08980 Sant Feliu de Llobregat l Spain Tel: +34-36859600 l Fax: +34-36859633

MOTOMAN ROBOTIT OY Kärsämäentie 8 l SF-20300 Turku l Finland Tel: +358-22145600 l Fax: +358-22145660

ROBOT-TEKNIKK AS Øvre Eikervei 177 l N-3048 Drammen l Norway Tel: +47-32217830 l Fax: +47-32217840

SIAD S.p.a. Via S. Bernardino, 92 l I-24126 Bergamo l Italy Tel: +39-35-328111 l Fax: +39-35-320183

MOTOMAN ROBOTICS AB a subsidiary of YASKAWA Electric Corporation

Trouble Shooting Manual for MRC

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