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
Trouble Shooting YASNAC MRC

Page: 1
Alarm 0010
CPU Board Insertion 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 Remove the MCP01 board, and then re-install it NO Resume use Alarm re-occurs?
NO Resume use
YES
Replace the ROM of the board corresponding to the display NO ROM failure Alarm re-occurs? YES Replace the board corresponding to the display Alarm re-occurs?
YES
NO Board failure
Replace all boards Alarm re-occurs?
NO Board failure
YES Contact MOTOMAN-service
Skapad: 98-10-09
ndrad: 98-11-26
Filnamn: T:\M-ROBOT\ENGELSK\TROUBLE_SHOOTING.FM

Page: 2
MOTOMAN ROBOTICS AB
Alarm 0020
CPU Communication Error

NO Resume use
Alarm re-occurs?
YES
Remove the SV board corresponding to the display, and then re-install it Alarm re-occurs? NO Resume use
YES Remove all boards, and then re-install them Alarm re-occurs?
NO Resume use
YES
Replace the ROM of the board corresponding to the display NO ROM failure Alarm re-occurs? YES Replace the board corresponding to the display YES Alarm re-occurs?
NO Board failure
Replace all boards Alarm re-occurs?
NO Board failure
Skapad: 98-10-09
ndrad: 98-11-26
MOTOMAN ROBOTICS AB

Page: 3
Alarm 0030
ROM Error
NO Resume use
Alarm re-occurs?
YES
Replace the ROM of the board corresponding to the display NO ROM failure Alarm re-occurs? YES Replace the board corresponding to the display YES Contact MOTOMAN-service Alarm re-occurs?
NO Board failure
Skapad: 98-10-09
ndrad: 98-11-26

Page: 4
MOTOMAN ROBOTICS AB
Alarm 0040
RAM Error (local)

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 Replace the board corresponding to the display YES Alarm re-occurs? NO Board failure
Contact MOTOMAN-service
Skapad: 98-10-09
ndrad: 98-11-26
MOTOMAN ROBOTICS AB

Page: 5
Alarm 0050
RTC Error)
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 Replace the board corresponding to the display YES Alarm re-occurs? NO Board failure
Skapad: 98-10-09
ndrad: 98-11-26

Page: 6
MOTOMAN ROBOTICS AB
Alarm 0060
RAM Error (A-bus Common)

Alarm Occurrence Turn power OFF, and then ON again. Alarm re-occurs? YES
NO Resume use
Remove the board corresponding to the display, and then re-install it YES Remove all boards and re-install again Alarm re-occurs? YES Replace the board corresponding to the display YES Replace all boards Alarm re-occurs? NO Board failure YES Contact MOTOMAN-service Alarm re-occurs? NO Resume use
NO Resume use
NO Board failure
Alarm re-occurs?
Skapad: 98-10-09
ndrad: 98-11-26
MOTOMAN ROBOTICS AB

Page: 7
Alarm 0070
RAM Error (D-Bus 2-Port)

Alarm Occurrence Turn power OFF, and then ON again. Alarm re-occurs? YES
NO Resume use
Remove the SV board corresponding to the display, and then re-install it YES Remove all boards and re-install again Alarm re-occurs? NO Resume use
NO Resume use
Alarm re-occurs?
YES
Replace the SV board corresponding to the display NO SV board failure Alarm re-occurs? YES Replace the MCP02 board YES Replace all boards NO Board failure Alarm re-occurs? YES Alarm re-occurs?
NO
Board failure
Skapad: 98-10-09
ndrad: 98-11-26

Page: 8
MOTOMAN ROBOTICS AB
Alarm 0080
RAM Error (S-Bus 2-Port)

NO Resume use
Alarm re-occurs?
YES
Remove the board corresponding to the display, and then re-install it YES Remove MCP01 and re-install again Alarm re-occurs? Alarm re-occurs? NO Resume use
NO Resume use
YES Replace the board corresponding to the display
YES Replace the MCP01 board NO MCP01 board failure Alarm re-occurs?
Alarm re-occurs?
NO Board failure
YES
Skapad: 98-10-09
ndrad: 98-11-26
MOTOMAN ROBOTICS AB

Page: 9
Alarm 0090
I/O Module Communication Error

NO Resume use
Alarm re-occurs?
YES Confirm the setting of the I/O module Alarm re-occurs?
YES Check the wiring of the cable between MIF01 and MBB02 NO Resume use Alarm re-occurs?
NO Resume use
YES
Remove the I/O module corresponding to the display, and then re-install it YES Replace the I/O module Alarm re-occurs? NO Resume use YES Replace MIF01 board YES Contact MOTOMAN-service Alarm re-occurs? NO MIF01 board failure
NO
Alarm re-occurs?
I/O module failure
Skapad: 98-10-09
ndrad: 98-11-26

Page: 10
MOTOMAN ROBOTICS AB
Alarm 0100
IAMP Communication Error

NO Resume use
Alarm re-occurs?
YES
Remove the cable connector between the MSV board and IAMP YES Alarm re-occurs? NO Resume use
Check the wiring of the cable between MSV board and IAMP Alarm re-occurs?
NO Resume use
YES Confirm the setting of the servopack
YES Replace the servopack NO Servopack failure YES Contact MOTOMAN-service Alarm re-occurs?
Alarm re-occurs?
NO Resume use
YES Replace the MSV board Alarm re-occurs? NO MSV board failure
Skapad: 98-10-09
ndrad: 98-11-26
MOTOMAN ROBOTICS AB

Page: 11
Alarm 0110
IAMP Parameter Modification Error

NO Resume use
Alarm re-occurs?
YES
Remove the cable connector between the MSV board and IAMP and re-install YES Alarm re-occurs? NO Resume use
Check the wiring of the cable between MSV board and IAMP Alarm re-occurs?
NO Resume use
YES Replace the servopack
NO Servopack failure
Alarm re-occurs?
YES Replace the MSV board
Alarm re-occurs?
NO
MSV Board failure
Skapad: 98-10-09
ndrad: 98-11-26

Page: 12
MOTOMAN ROBOTICS AB
Alarm 0120
Encoder communication error

Resume use
NO
Alarm re-occurs?
YES
Remove the cable connector between the MSV board and IAMP and re-install Alarm re-occurs?
Remove the cable connector between encoder and IAMP, and then re-install it Resume use NO Alarm re-occurs? YES
YES
NO
Resume use Remove the cable connector between encoder and IAMP, and then install to another axis Alarm re-occurs?
Check the cable ground between encoder and IAMP Cable failure NO Alarm re-occurs? YES Check the wiring of the cable between MSV board and IAMP NO Alarm re-occurs? YES Reset the absolute encoder Replace the motor Alarm re-occurs? NO Motor failure
Skapad: 98-10-09 ndrad: 98-11-26
YES
NO Replace the servopack
NO Servopack failure
Alarm re-occurs? YES Replace the MSV board
Cable failure
YES Contact MOTOMAN-service NO Resume use
Alarm re-occurs? NO BSV Board failure
YES
Alarm re-occurs? Contact MOTOMAN-service
YES
MOTOMAN ROBOTICS AB

Page: 13
Alarm 0130
Encoder Overspeed
NO Resume use
Alarm re-occurs?
YES After the motor stops, control power ON.
YES Reset the absolute encoder Alarm re-occurs?
Alarm re-occurs?
NO Resume use
NO Resume use
YES Replace servo motor
YES
Alarm re-occurs?
NO Motor failure
Skapad: 98-10-09
ndrad: 98-11-26

Page: 14
MOTOMAN ROBOTICS AB
Alarm 0131
Encoder Data Error

Alarm Occurrence Turn power OFF, and then ON again. Alarm re-occurs?
NO Resume use
YES Reset the absolute encoder Alarm re-occurs? YES Replace the motor YES Contact MOTOMAN-service Alarm re-occurs? NO Motor failure
NO Resume use
Alarm 0132
Encoder Back-up Error

Alarm Occurrence
Change the battery, reset the alarm and then set home position NO Resume use Alarm re-occurs? YES Reset the absolute encoder Alarm re-occurs? YES Replace the motor YES Contact MOTOMAN-service
Skapad: 98-10-09 ndrad: 98-11-26
NO Resume use
Alarm re-occurs?
NO Motor failure
MOTOMAN ROBOTICS AB

Page: 15
Alarm 0133
Encoder Checksum Error

Alarm Occurrence
Change the battery, reset the alarm and then set home position. NO Resume use Alarm re-occurs? YES
Reset the absolute encoder NO Resume use Alarm re-occurs? YES Replace servo motor Alarm re-occurs?
NO Motor failure
Skapad: 98-10-09
ndrad: 98-11-26

Page: 16
MOTOMAN ROBOTICS AB
Alarm 0134
Encoder Battery Error

Alarm Occurrence
Change the battery Alarm re-occurs?
NO Resume use
YES
Check Internal wiring YES Reset the absolute encoder Alarm re-occurs? Alarm re-occurs? NO Resume use
NO Resume use
YES Replace the motor
Alarm re-occurs?
NO Motor failure
Alarm 0135
Encoder Overheat
Alarm Occurrence After cooling, turn the power ON again
NO Resume use
Alarm re-occurs?
YES Check Internal wiring Alarm re-occurs?

Skapad: 98-10-09 ndrad: 98-11-26
NO Internal wire failure
MOTOMAN ROBOTICS AB

Page: 17
Alarm 0200
Fault (Parameter)
NO Resume use
Alarm re-occurs?
YES 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 Resume use
Alarm re-occurs?
YES Initialize the job file
Alarm re-occurs?
NO Job file destroyed
Skapad: 98-10-09
ndrad: 98-11-26

Page: 18
MOTOMAN ROBOTICS AB
Alarm 0230
Fault (CIO Ladder)

Alarm Occurrence Initialize the CIO Ladder
NO
Alarm re-occurs?
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? YES Contact MOTOMANservice before initializing the system config.
The extension CMOS board is not mounted
Skapad: 98-10-09
ndrad: 98-11-26
MOTOMAN ROBOTICS AB

Page: 19
Alarm 0320
Verify Error (I/O module)

Alarm Occurrence
Remove the I/O-module that corresponds to the display, then re-install the module NO Resume use Alarm re-occurs? YES
Confirm the setting of the I/O module YES Replace the I/O module corresponding to the display Alarm re-occurs? YES Alarm re-occurs? NO Resume use
NO I/O module failure
Alarm 0330
Illegal Parameter
Alarm Occurrence Reset original parameter value
NO Resume use
Alarm re-occurs?
YES
Skapad: 98-10-09
ndrad: 98-11-26

Page: 20
MOTOMAN ROBOTICS AB
Alarm 0340
Verify Error (Servopack Type)

Alarm Occurrence
Set the parameter to match the mounted servopack type NO Resume use Alarm re-occurs? YES Contact MOTOMANservice before initializing the system config.
Alarm 0350
Verify Error (Encoder Type)

Alarm Occurrence
Set the parameter to match the mounted encoder type NO Resume use Alarm re-occurs? YES
Contact MOTOMANservice before initializing the system config.
Alarm 0360
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
ndrad: 98-11-26
MOTOMAN ROBOTICS AB

Page: 21
Alarm 0400
Parameter Transmission Error

Alarm Occurrence Turn power OFF, and then ON agian. Alarm re-occurs? YES
NO Resume use
Replace the board corresponding to the display Alarm re-occurs?
NO
YES Replace all boards
Board failure
Alarm re-occurs?
NO
Board failure
Alarm 0410
Mode Change Error

Alarm Occurrence Turn power OFF, and then ON again. Alarm re-occurs?
NO Resume use
Skapad: 98-10-09
ndrad: 98-11-26

Page: 22
MOTOMAN ROBOTICS AB
Alarm 0900 - 0920 Watch Dog Timer Error

Turn power OFF, and then ON agian. Alarm re-occurs? NO Resume use Remove all boards, then re-install them Alarm re-occurs? NO YES Resume use Replace the EPROM of the board corresponding to the display Replace board corresponding to the display Alarm re-occurs? YES Replace all boards Alarm re-occurs? NO Board failure Contact MOTOMAN-service NO Board failure YES YES Alarm re-occurs? NO EPROM failure YES YES Remove the board corresponding to the display, then re-install it Alarm re-occurs? NO Resume use Alarm Occurrence
AL-0900 AL-0901 AL-0902 AL-0903 AL-0904 AL-0905
MCP02 MSL#1 MSL#2
AL-0906 AL-0907 AL-0910 AL-0911 AL-0912 AL-0913
MCP01 MIF01 MSV#1 MSV#2 MSV#3 MSV#3
AL-0914 AL-0915 AL-0916 AL-0917 AL-0920
MSV#5 MSV#6 MSV#7 MIF02
Skapad: 98-10-09
ndrad: 98-11-26
MOTOMAN ROBOTICS AB

Page: 23
Alarm 0930 - 0937 Access Error

AL-0930 AL-0931 AL-0932
MIF02 MSL#1
AL-0933 AL-0934 AL-0935
MSL#2
AL-0936 AL-0937
MCP01 MIF01
Skapad: 98-10-09
ndrad: 98-11-26

Page: 24
MOTOMAN ROBOTICS AB
Alarm 0940 - 0947 A-Bus Error

AL-0940 AL-0941 AL-0942
MIF02 MSL#1
AL-0943 AL-0944 AL-0945
MSL#2
AL-0946 AL-0947
MCP01 MIF01
Skapad: 98-10-09
ndrad: 98-11-26
MOTOMAN ROBOTICS AB

Page: 25
Alarm 0999
NMI Error
Alarm Occurrence Turn power OFF, and then ON agian. Alarm re-occurs?
NO Resume use
YES Remove all boards and then re-install them Alarm re-occurs? YES Replace EPROM of all boards Alarm re-occurs? NO Resume use
NO
EPROM failure
Replace all boards Alarm re-occurs? YES Contact MOTOMAN-service NO
Board failure
Skapad: 98-10-09
ndrad: 98-11-26

Page: 26
MOTOMAN ROBOTICS AB
Alarm 1010
ROM Error (Syscon)

NO Resume use
YES Remove the EPROM board on the MCP01 board and then re-install them Alarm re-occurs? YES Replace EPROM board on the MCP01 board Alarm re-occurs? NO Make sure connector has no loose connections, and then resume use
NO
MMM02 failure
Replace MCP01 board Alarm re-occurs? YES Contact MOTOMAN-service NO
Board failure
Skapad: 98-10-09
ndrad: 98-11-26
MOTOMAN ROBOTICS AB

Page: 27
Alarm 1020
ROM Error (Motion)

NO Resume use
YES Remove the EPROM board on the MCP02 board and then re-install them Alarm re-occurs? YES Replace EPROM board on the MCP02 board Alarm re-occurs? NO Make sure connector has no loose connections, and then resume use
NO
MMM04 failure
Replace MCP02 board Alarm re-occurs? YES Contact MOTOMAN-service NO
Board failure
Skapad: 98-10-09
ndrad: 98-11-26

Page: 28
MOTOMAN ROBOTICS AB
Alarm 1030
ROM Error (CIO)

NO Resume use
YES Remove the EPROM board on the MIF01 board and then re-install them Alarm re-occurs? YES Replace EPROM board on the MCP01 board Alarm re-occurs? NO Make sure connector has no loose connections, and then resume use
NO
EPROM failure
Replace MIF01 board Alarm re-occurs? YES Contact MOTOMAN-service NO
Board failure
Skapad: 98-10-09
ndrad: 98-11-26
MOTOMAN ROBOTICS AB

Page: 29
Alarm 1040
System Error (Syscon)

NO Resume use
YES Replace MCP01 board Alarm re-occurs? YES Contact MOTOMAN-service NO
Board failure
1 2 3 4 5 Motion Interrupt Not Done Syscon Error Command Processing Undefined Interrupt
6 7 8 9 10
Multi Task Specification Error Lack of Command Saving Area EMS Error SL Interrupt Not Done
Skapad: 98-10-09
ndrad: 98-11-26

Page: 30
MOTOMAN ROBOTICS AB
Alarm 1050
ROM Error (Sensor)

NO Resume use
YES Remove the EPROM board on the MSL board and then re-install it Alarm re-occurs? YES Replace EPROM board on the MSL board Alarm re-occurs? NO Make sure connector has no loose connections, and then resume use
NO
YES Replace MSL board corresponding to the display Alarm re-occurs? YES Contact MOTOMAN-service NO
EPROM failure
Board failure
Skapad: 98-10-09
ndrad: 98-11-26
MOTOMAN ROBOTICS AB

Page: 31
Alarm 1060
System Error (CIO)

NO Resume use
YES Replace MIF01 board Alarm re-occurs? YES Contact MOTOMAN-service NO
Board failure
01 02 04 FA Communication Bus Error
05 06
Command Error SYSCONCIO System Error
Skapad: 98-10-09
ndrad: 98-11-26

Page: 32
MOTOMAN ROBOTICS AB
Alarm 1070
Fault (Parameter)
NO Resume use
YES
Initialize
the parameter file Alarm re-occurs? YES Contact MOTOMANservice before initializing the system config. NO
Board failure
0 1 2 3 4 5 6 7
RC parameters RO parameters SV paramerters SVM parameters SC parameters SD parameters CIO parameters FD parameters
8 9 10 11 12 13 14
AP parameters RS parameters SP parameters CM parameters SE parameters VC parameters RSM parameters
Skapad: 98-10-09
ndrad: 98-11-26
MOTOMAN ROBOTICS AB

Page: 33
Alarm 1080
Fault (Job data)

NO Resume use
YES
Initialize
the job file Alarm re-occurs? YES Contact MOTOMANservice before initializing the system config. NO
Job file destroyed
Alarm 1090
File Failure (Motion)

NO Resume use
YES Contact MOTOMANservice before initializing the system config.
Skapad: 98-10-09
ndrad: 98-11-26

Page: 34
MOTOMAN ROBOTICS AB
Alarm 1100
File Total Checksum Error (Motion)

Turn power OFF, and then ON agian. Alarm re-occurs?
Alarm Occurrence
NO Resume use
Board failure
Alarm 1110
Set-up Process Error (Syscon)

Alarm Occurrence
NO Resume use
Board failure
Motion Section Set-up incomplete
Skapad: 98-10-09
ndrad: 98-11-26
MOTOMAN ROBOTICS AB

Page: 35
Alarm 1120
Wrong Segment Clock Value

Alarm Occurrence
NO Resume use
YES Reset phase offset data file Alarm re-occurs? YES Contact MOTOMAN-service NO
CMOS file breakdown
Alarm 1130
MMM Error
Alarm Occurrence
NO Resume use
0 1 2 Process Definition Table Not Set Entry Table Overflow
3 4
Process Not Set Process Control Code Not Set
Skapad: 98-10-09
ndrad: 98-11-26

Page: 36
MOTOMAN ROBOTICS AB
Alarm 1140
MMM Error
NO Resume use
Alarm 1150
Fault
NO Resume use
Skapad: 98-10-09
ndrad: 98-11-26
MOTOMAN ROBOTICS AB

Page: 37
Alarm 1160
High Temperature (in Control Box)

NO Resume use
YES Turn the power off, let the controller cool inside, and then turn power on again Alarm re-occurs? YES Check movement of cooling fan Alarm re-occurs? NO Resume use
NO
YES Check wiring cooling fan Faulty? NO Replace fan YES Contact MOTOMAN-service
Replace power unit (CPS-18F) Alarm re-occurs?
YES
Alarm re-occurs? NO Fan failure NO
Power unit failure
Skapad: 98-10-09
ndrad: 98-11-26

Page: 38
MOTOMAN ROBOTICS AB
Alarm 1170
Overrun Limit Switch Released

NO Resume use
YES Check the OVERRUN RECOVERY switch Alarm re-occurs? YES Contact MOTOMAN-service NO
Switch failure
Skapad: 98-10-09
ndrad: 98-11-26
MOTOMAN ROBOTICS AB

Page: 39
Alarm 1180 - 1186 Servo Monitor System Error

Alarm Occurrence Turn power OFF, and then ON agian. Alarm re-occurs? NO Resume use YES Replace MSV board corresponding to the display Alarm re-occurs? YES Replace MCP01 board Alarm re-occurs? NO YES Replace MCP02 board Alarm re-occurs? YES Contact MOTOMAN-service NO NO
Board failure
Board failure
Board failure
AL-1180 AL-1181 AL-1182
MSV#1 MSV#2 MSV#3
AL-1183 AL-1184 AL-1185
MSV#4 MSV#5 MSV#6
AL-1186
MSV#7
Skapad: 98-10-09
ndrad: 98-11-26

Page: 40
MOTOMAN ROBOTICS AB
Alarm 1190 - 1196 Servo System Error

Alarm Occurrence Turn power OFF, and then ON agian. Alarm re-occurs? NO Resume use YES Replace MSV board corresponding to the display Alarm re-occurs? YES Replace MCP01 board Alarm re-occurs? NO YES Replace MCP02 board Alarm re-occurs? YES Contact MOTOMAN-service NO NO
Board failure
Board failure
Board failure
AL-1190 AL-1191 AL-1192
MSV#1 MSV#2 MSV#3
AL-1193 AL-1194 AL-1195
MSV#4 MSV#5 MSV#6
AL-1196
MSV#7
Skapad: 98-10-09
ndrad: 98-11-26
MOTOMAN ROBOTICS AB

Page: 41
Alarm 1200 - 1206 Overcurrent

Alarm Occurrence
At control power ON
Condition at the time of alarm?
At servo power ON
Replace servopack corresponding to the display Alarm re-occurs? NO YES Contact MOTOMAN-service
Running
Check first grounding terminal
Go to point A NO
Faulty grounding YES Replace servopack corresponding to the display Alarm re-occurs? NO YES
Servopack failure
B Check second ground terminal Faulty grounding YES Check internal wiring Alarm re-occurs? NO Internal wiring failure YES NO
Servopack failure
Replace motor corresponding to the display

Alarm re-occurs? NO YES
Servomotor failure
Skapad: 98-10-09
ndrad: 98-11-26

Page: 42
MOTOMAN ROBOTICS AB
Alarm 1200 - 1206 Overcurrent (...continued)

A Check movement of servopack cooling fan Abnormal? YES Replace cooling fan Alarm re-occurs? YES Contact MOTOMAN-service NO YES Check first grounding terminal Faulty grounding NO Go to point B Alarm occurs at a specific point? Fan failure OK Overload NO Check robot load NO Load condition?
Decrease weight
YES Replace servopack corresponding to the display Alarm re-occurs?
NO
Servopack failure
YES
AL-1200 AL-1201 AL-1202
MSV#1 MSV#2 MSV#3
AL-1203 AL-1204 AL-1205
MSV#4 MSV#5 MSV#6
AL-1206
MSV#7
Skapad: 98-10-09
ndrad: 98-11-26
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 Resume use
At servo power ON
Running
Replace servopack corresponding to the display Alarm re-occurs? YES B Contact MOTOMAN service Check second ground terminal Faulty grounding YES Replace internal wiring Alarm re-occurs? NO Internal wiring failure YES NO
Go to point A
Faulty grounding NO YES Replace servopack corresponding to the display Alarm re-occurs? NO YES
NO
Servopack failure
Servopack failure

Motor failure
Skapad: 98-10-09
ndrad: 98-11-26

Page: 44
MOTOMAN ROBOTICS AB
Alarm 1210 - 1216 MCCB Tripped (...continued)

A
Check robot load Load condition? OK Overload Alarm occurs at a specific point? NO YES Check first grounding terminal Faulty grounding NO Go to point B Decrease weight
YES Replace servopack corresponding to the display Alarm re-occurs?
NO
Servopack failure
YES
AL-1210 AL-1211 AL-1212
MSV#1 MSV#2 MSV#3
AL-1213 AL-1214 AL-1215
MSV#4 MSV#5 MSV#6
AL-1216
MSV#7
Skapad: 98-10-09
ndrad: 98-11-26
MOTOMAN ROBOTICS AB

Page: 45
Alarm 1220 - 1226 Ground Fault

Alarm Occurrence
At control power ON
At servo power ON
Replace servopack corresponding to the display Alarm re-occurs? NO YES Contact MOTOMAN-service
Running
Go to point A NO
Faulty grounding YES Replace servopack corresponding to the display
Servopack failure
Check second ground terminal Faulty grounding YES Check internal wiring Alarm re-occurs? NO Internal wiring failure YES NO NO
Alarm re-occurs? YES
Servopack failure

Servo motor failure

Skapad: 98-10-09
ndrad: 98-11-26

Page: 46
MOTOMAN ROBOTICS AB
Alarm 1220 - 1226 Ground Fault (...continued)

A
NO Check first grounding terminal Faulty grounding YES Replace servopack corresponding to the display NO
Alarm occurs at a specific point? YES
Check second ground terminal Faulty grounding YES Check internal wiring Alarm re-occurs? NO
NO YES Internal wiring failure Alarm re-occurs? YES NO NO Contact MOTOMAN-service YES Contact MOTOMAN-service Contact MOTOMAN-service Replace motor corresponding to the display Alarm re-occurs?
Servopack failure
Motor failure
AL-1220 AL-1221 AL-1222
MSV#1 MSV#2 MSV#3
AL-1223 AL-1224 AL-1225
MSV#4 MSV#5 MSV#6
AL-1226
MSV#7
Skapad: 98-10-09
ndrad: 98-11-26
MOTOMAN ROBOTICS AB

Page: 47
Alarm 1230 - 1236 Defective Current Offset

Alarm Occurrence
Replace servopack corresponding to the display
Servopack failure
AL-1230 AL-1231 AL-1232
MSV#1 MSV#2 MSV#3
AL-1233 AL-1234 AL-1235
MSV#4 MSV#5 MSV#6
AL-1236
MSV#7
Skapad: 98-10-09
ndrad: 98-11-26

Page: 48
MOTOMAN ROBOTICS AB
Alarm 1240- 1246 Encoder Transmission Error

Turn power OFF, and then ON again. Alarm re-occurs? NO Resume use Remove the cable between encoder and IAMP, then re-install it Alarm re-occurs? YES Check the cable ground between encoder and IAMP Alarm re-occurs? YES Check the cable between encoder and IAMP Alarm re-occurs? Reset absolute encoder Alarm re-occurs? NO Resume use NO YES Motor failure Contact MOTOMAN-service Board failure YES NO Cable failure Servopack failure NO NO YES Alarm re-occurs? NO Resume use Remove the cable between the encoder and IAMP, then install connector from another axis Alarm re-occurs? NO Replace the servopack Alarm re-occurs? YES YES Replace the servomotor Alarm re-occurs? Replace MSV board NO Alarm re-occurs? Alarm Occurrence Remove the cable between MSV board and IAMP, then re-install it
YES
Resume use
NO
YES
AL-1240 AL-1241 AL-1242
MSV#1 MSV#2 MSV#3
AL-1243 AL-1244 AL-1245
MSV#4 MSV#5 MSV#6
AL-1246
MSV#7
Skapad: 98-10-09
ndrad: 98-11-26
MOTOMAN ROBOTICS AB

Page: 49
Alarm 1250 - 1256 Defective Encoder Internal Data

Alarm Occurrence Turn power OFF, and then ON again. Alarm re-occurs? NO Resume use YES Reset absolute encoder corresponding to the displayed axis Alarm re-occurs? YES Replace motor corresponding to the displayed axis Alarm re-occurs? NO YES Contact MOTOMAN-service NO Resume use
Motor failure
AL-1250 AL-1251 AL-1252
MSV#1 MSV#2 MSV#3
AL-1253 AL-1254 AL-1255
MSV#4 MSV#5 MSV#6
AL-1256
MSV#7
Skapad: 98-10-09
ndrad: 98-11-26

Page: 50
MOTOMAN ROBOTICS AB
Alarm 1260 - 1266 Defective Encoder Absolute Data

Alarm Occurrence Turn power OFF, and then ON again. Alarm re-occurs? NO Resume use YES Reset absolute encoder corresponding to the displayed axis Alarm re-occurs? YES Replace motor corresponding to the displayed axis Alarm re-occurs? NO YES Contact MOTOMAN-service NO Resume use
Motor failure
AL-1260 AL-1261 AL-1262
MSV#1 MSV#2 MSV#3
AL-1263 AL-1264 AL-1265
MSV#4 MSV#5 MSV#6
AL-1266
MSV#7
Skapad: 98-10-09
ndrad: 98-11-26
MOTOMAN ROBOTICS AB

Page: 51
Alarm 1270 - 1276 Encoder Overheat

Alarm Occurrence
At control power ON
Running
A Check Robot load Reset absolute encoder corresponding to the displayed axis Alarm re-occurs? YES NO Resume use NO Replace motor Alarm re-occurs? YES NO Replace cooling fan Alarm re-occurs? YES Load condition? Overload NO
If motor has cooling fan check if fan is working

Abnormal? YES Check wiring
Decrease weight
Faulty wiring?
Replace internal wiring

Alarm re-occurs? NO YES Motor failure NO Fan failure Go to point A Internal wiring failure
AL-1270 AL-1271 AL-1272
MSV#1 MSV#2 MSV#3
AL-1273 AL-1274 AL-1275
MSV#4 MSV#5 MSV#6
AL-1276
MSV#7
Skapad: 98-10-09
ndrad: 98-11-26

Page: 52
MOTOMAN ROBOTICS AB
Alarm 1280- 1286 Servo Monitor Transmission Error

Alarm Occurrence Turn power OFF, and then ON again. Alarm re-occurs? NO Resume use YES Remove the cable between MSV board and IAMP, then re-install it Alarm re-occurs? YES Check the cable wiring between MSV board and IAMP Faulty wiring YES Replace cable Alarm re-occurs? NO NO Cable failure Servopack failure YES Contact MOTOMAN-service Replace MSV board Alarm re-occurs? NO Board failure YES Alarm re-occurs? YES NO Replace the servopack NO Resume use
AL-1280 AL-1281 AL-1282
MSV#1 MSV#2 MSV#3
AL-1283 AL-1284 AL-1285
MSV#4 MSV#5 MSV#6
AL-1286
MSV#7
Skapad: 98-10-09
ndrad: 98-11-26
MOTOMAN ROBOTICS AB

Page: 53
Alarm 1290 -1296 Servo CPU Synchronizing Error

Alarm Occurrence Replace MSV board Alarm re-occurs? NO Board failure YES Contact MOTOMAN-service
AL-1290 AL-1291 AL-1292
MSV#1 MSV#2 MSV#3
AL-1293 AL-1294 AL-1295
MSV#4 MSV#5 MSV#6
AL-1296
MSV#7
Alarm 1300 -1306 DSP Program Checksum Error

AL-1300 AL-1301 AL-1302
MSV#1 MSV#2 MSV#3
AL-1303 AL-1304 AL-1305
MSV#4 MSV#5 MSV#6
AL-1306
MSV#7
Skapad: 98-10-09
ndrad: 98-11-26

Page: 54
MOTOMAN ROBOTICS AB
Alarm 1310 -1316 Mon Pgrm Total Checksum Error

AL-1310 AL-1311 AL-1312
MSV#1 MSV#2 MSV#3
AL-1313 AL-1314 AL-1315
MSV#4 MSV#5 MSV#6
AL-1316
MSV#7
Skapad: 98-10-09
ndrad: 98-11-26
MOTOMAN ROBOTICS AB

Page: 55
Alarm 1320- 1326 Servopack Failure

Alarm Occurrence Turn power OFF, and then ON again. Alarm re-occurs? NO Resume use YES Remove the cable between MSV board and IAMP, then re-install it Alarm re-occurs? YES Check the cable wiring between MSV board and IAMP Faulty wiring YES Replace cable Alarm re-occurs? NO NO Cable failure Servopack failure YES Contact MOTOMAN-service Replace MSV board Alarm re-occurs? NO Board failure YES Alarm re-occurs? YES NO Replace the servopack NO Resume use
AL-1320 AL-1321 AL-1322
MSV#1 MSV#2 MSV#3
AL-1323 AL-1324 AL-1325
MSV#4 MSV#5 MSV#6
AL-1326
MSV#7
Skapad: 98-10-09
ndrad: 98-11-26

Page: 56
MOTOMAN ROBOTICS AB
Alarm 1330- 1336 Position Error

Alarm Occurrence
At control power ON
Running
Go to point A
At servo power ON Replace the cable between encoder and IAMP with a cable from another axis Moved to another axis? YES Check wiring NO Board failure Faulty wiring YES Replace cable Alarm re-occurs? NO Cable failure NO Motor failure YES Replace the servo motor Alarm re-occurs? Contact MOTOMAN-service NO Alarm re-occurs? YES
NO Replace MSV board
YES
Skapad: 98-10-09
ndrad: 98-11-26
MOTOMAN ROBOTICS AB

Page: 57
Alarm 1330- 1336 Position Error (... continued)

Is there a noise source around?
NO
YES Remove the noise source Alarm re-occurs? NO Resume use Check wiring Faulty wiring YES Replace cable Replace the servo motor NO Motor failure Alarm re-occurs? YES Replace MSV board Alarm re-occurs? NO Board failure YES Contact MOTOMAN-service NO Cable failure YES Alarm re-occurs?
YES
AL-1330 AL-1331 AL-1332
MSV#1 MSV#2 MSV#3
AL-1333 AL-1334 AL-1335
MSV#4 MSV#5 MSV#6
AL-1336
MSV#7
Skapad: 98-10-09
ndrad: 98-11-26

Page: 58
MOTOMAN ROBOTICS AB
Alarm 1340- 1346 Overload 1

Alarm Occurrence
At control power ON
Running
Replace MSV board Right away Check for interference
How long after Servo ON does alarm occur?
After several minutes Check Robot load Load condition?
Interference? YES NO OK
Overload
Modify teaching
Alarm re-occurs? NO Teaching error YES Alarm re-occurs? NO YES Board failure Alarm re-occurs? NO Cable failure YES Replace wiring Check motor wiring Faulty wiring
Reduce load
YES
NO
Go to point A
AL-1340 AL-1341 AL-1342
MSV#1 MSV#2 MSV#3
AL-1343 AL-1344 AL-1345
MSV#4 MSV#5 MSV#6
AL-1346
MSV#7
Skapad: 98-10-09
ndrad: 98-11-26
MOTOMAN ROBOTICS AB

Page: 59
Alarm 1340- 1346 Overload 1 (...continued)

NO Check brake circuit YES Input voltage abnormal Abnormal condition? Input voltage normal Replace SVM Alarm re-occurs? NO YES Resume use Alarm re-occurs? YES NO Resume use Contact MOTOMAN-service NO Check if mechanically locked NO Fix mechanical problem Alarm re-occurs? NO Resume use Movable? Defective? YES Replace the servo motor Alarm re-occurs? YES YES YES NO Contact MOTOMAN-service Resume use Alarm re-occurs? NO YES Resume use Replace wiring NO Is brake release audiable? A
Replace MTU board
Check brake lead wiring Faulty wiring NO YES Check motor brake
Skapad: 98-10-09
ndrad: 98-11-26

Page: 60
MOTOMAN ROBOTICS AB
Alarm 1350- 1356 Overload 2

Alarm Occurrence
At control power ON
Running
Replace MSV board Right away Check for interference
How long after Servo ON does alarm occur?
After several minutes Check robot load Load condition?
Interference? YES NO OK
Overload
Modify teaching
Alarm re-occurs? NO Teaching error YES Alarm re-occurs? NO YES Board failure Alarm re-occurs? NO Cable failure YES Replace wiring Check motor wiring Faulty wiring
Reduce load
YES
NO
Go to point A
AL-1350 AL-1351 AL-1352
MSV#1 MSV#2 MSV#3
AL-1353 AL-1354 AL-1355
MSV#4 MSV#5 MSV#6
AL-1356
MSV#7
Skapad: 98-10-09
ndrad: 98-11-26
MOTOMAN ROBOTICS AB

Page: 61
Alarm 1350- 1356 Overload 2 (...continued)

NO Check brake circuit YES Input voltage abnormal Abnormal condition? Output voltage abnormal Replace SVM Alarm re-occurs? NO YES Resume use Alarm re-occurs? YES NO Resume use Contact MOTOMAN-service NO Check if mechanically locked NO Fix mechanical problem Alarm re-occurs? NO Resume use Movable? Defective? YES Replace the servo motor Alarm re-occurs? YES YES YES NO Contact MOTOMAN-service Resume use Alarm re-occurs? NO YES Resume use Replace wiring NO Is brake release audiable? A
Replace MTU board
Check brake lead wiring Faulty wiring NO YES Check motor brake
Skapad: 98-10-09
ndrad: 98-11-26

Page: 62
MOTOMAN ROBOTICS AB
Alarm 1360-1366
Broken PG Line
Alarm Occurrence
At control power on
Running
Replace cable between encoder & IAMP with cable from another axis Move to other axis? YES Check wiring NO
At servo power on Replace MSV board Alarm re-occurs? NO MSV board failure YES Replace servopack Alarm re-occurs? YES NO Servopack failure
Faulty wiring?
YES
Replace cable
NO Replace motor YES Alarm re-occurs?
Replace cable between IAMP and MSV Alarm re-occurs? YES NO Cable failure
NO Cable failure Replace motor Alarm re-occurs? YES YES Contact MOTOMAN-service Contact MOTOMAN-service Motor failure NO Motor failure Alarm re-occurs? NO
Skapad: 98-10-09
ndrad: 98-11-26
MOTOMAN ROBOTICS AB

Page: 63
Alarm 1360-1366
1
Broken PG Line (...continued)
Is there a noise source around? NO Check wiring Faulty wiring? NO Replace motor Alarm re-occurs? NO Motor failure
YES
Remove noise source
YES YES
Alarm re-occurs? Replace cable
NO
Resume use
YES YES
Alarm re-occurs? MSV board failure Alarm re-occurs?
NO
Cable failure
NO
YES
MSV board failure YES
Replace servopack Alarm re-occurs? NO Servopack failure
Replace cable between IAMP and MSV NO Cable failure Alarm re-occurs? YES
Replace motor Alarm re-occurs?
NO Motor failure
AL-1360 AL-1361 AL-1362

Skapad: 98-10-09
MSV#1 MSV#2 MSV#3
AL-1363 AL-1364 AL-1365
MSV#4 MSV#5 MSV#6
AL-1366
MSV#7
ndrad: 98-11-26

Page: 64
MOTOMAN ROBOTICS AB
Alarm 1370-1376
Over Speed
Alarm Occurrence Is there a noise source around? YES Remove noise source Alarm re-occurs? NO Resume use Condition at the time of alarm At servo power on NO Cable failure 1 NO Alarm occurs at specific point? YES Running
NO
YES
Check wiring Faulty wiring? YES Replace cable Alarm re-occurs? YES 1 Replace MSV board Alarm re-occurs? YES Replace motor NO 1
NO At servo power on
NO
Point of alarm taught by MOVJ? YES Multiple axes moving at the same time? NO
MSV board failure Reduce speed YES
Alarm re-occurs? YES
NO
Motor failure
Alarm re-occurs? NO
YES
Resume use
AL-1370 AL-1371 AL-1372
MSV#1 MSV#2 MSV#3
AL-1373 AL-1374 AL-1375
MSV#4 MSV#5 MSV#6
AL-1376
MSV#7
Skapad: 98-10-09
ndrad: 98-11-26
MOTOMAN ROBOTICS AB

Page: 65
Alarm 1380-1386
Alarm Occurrence
Servo Tracking Error
Condition at the time of alarm? At control power on
Running Check if robot interferes with work or fixture YES Interference? Check load Load condition?
Modify teaching Alarm re-occurs? NO Teaching error
NO
YES
Check motor wiring
OK
Overload Decrease weight
Replace MSV board Alarm re-occurs? YES Contact MOTOMAN-service NO MSV board failure Replace wiring harness Alarm re-occurs? NO Wiring failure YES 1 Faulty wiring? YES NO 1
AL-1380 AL-1381 AL-1382
MSV#1 MSV#2 MSV#3
AL-1383 AL-1384 AL-1385
MSV#4 MSV#5 MSV#6
AL-1386
MSV#7
Skapad: 98-10-09
ndrad: 98-11-26

Page: 66
MOTOMAN ROBOTICS AB
Alarm 1380-1386
Servo Tracking Error (...continued)

1 Is brake release audible?
NO
YES
Check brake circuit Input voltage abnormal Replace MTU board Abnormal condition? Output voltage abnormal Replace SVM NO Resume use Alarm re-occurs? NO Resume use Alarm re-occurs? YES Contact MOTOMAN service
NO Check brake lead wiring Faulty wiring? YES Replace wiring harness Alarm re-occurs? YES NO Resume use NO Check motor brake
YES
Contact MOTOMAN-service Check if mechanically locked NO Fix mechanical problem Alarm re-occurs? NO Resume use YES Movable? YES Contact MOTOMAN-service YES Alarm re-occurs? NO Resume use Defective? YES Replace motor
NO
Skapad: 98-10-09
ndrad: 98-11-26
MOTOMAN ROBOTICS AB

Page: 67
Alarm 1390-1396 Speed (Monitor)

Alarm Occurrence
NO
Is there a noise source around? YES NO 1 At control power on
YES
Remove noise source Alarm re-occurs? NO Resume use Condition at the time of alarm? At servo power on Running
Check wiring Faulty wiring? YES Replace cable Alarm re-occurs? YES NO
Cable failure 1 NO
Alarm occurs at specific point? YES
1 Replace MSV board Alarm re-occurs? YES Replace motor Alarm re-occurs? YES Contact MOTOMAN service NO Motor failure Alarm re-occurs? NO Resume use YES NO NO
Point of alarm taught by MOVJ YES
MSV board failure

Reduce speed YES
Multiple axes moving at the same time? NO 1
AL-1390 AL-1391 AL-1392

Skapad: 98-10-09
MSV#1 MSV#2 MSV#3
AL-1393 AL-1394 AL-1395
MSV#4 MSV#5 MSV#6
AL-1396
MSV#7
ndrad: 98-11-26

Page: 68
MOTOMAN ROBOTICS AB
Alarm 3000-3006
Not Ready For Servo System

Alarm Occurrence Turn the power off and then on again Alarm re-occurs? YES
Resume use
NO
Check MTU board Defective? YES Replace MTU board
NO
Is SVM working? Replace SVM Alarm re-occurs? NO Resume use
YES
Check primary power voltage Defective?
NO
YES Primary power failure
YES
1 NO
Check cable between servopack and MSV board

YES Defective? NO
Alarm re-occurs? NO Resume use
YES
Replace cable Alarm re-occurs? NO Cable failure YES 1
AL-3000 AL-3001 AL-3002
MSV#1 MSV#2 MSV#3
AL-3003 AL-3004 AL-3005
MSV#4 MSV#5 MSV#6
AL-3006
MSV#7
Skapad: 98-10-09
ndrad: 98-11-26
MOTOMAN ROBOTICS AB

Page: 69
Alarm 3000-3006
1
Not Ready For Servo System (...continued)
Check cable between servopack and SVM

Defective? NO Replace servopack Alarm re-occurs? NO Servopack failure YES Alarm re-occurs? Replace MSV board Alarm re-occurs? NO MSV board failure Contact MOTOMAN service NO Cable failure YES Replace cable
YES
YES
Skapad: 98-10-09
ndrad: 98-11-26

Page: 70
MOTOMAN ROBOTICS AB
Alarm 3010-3016
Alarm Occurrence
Servo Defective Speed
Are you trying to turn power on while axis is moving NO Replace MSV board Alarm re-occurs? YES Contact MOTOMAN service
YES
Try power on while axis is stopped
YES
Alarm re-occurs? MSV board failure
NO
Resume use
NO
AL-3010 AL-3011 AL-3012
MSV#1 MSV#2 MSV#3
AL-3013 AL-3014 AL-3015
MSV#4 MSV#5 MSV#6
AL-3016
MSV#7
Skapad: 98-10-09
ndrad: 98-11-26
MOTOMAN ROBOTICS AB

Page: 71
Alarm 3020-3026
Alarm Occurrence Turn the power off and then on again Alarm re-occurs? NO Resume use
Servo Defective DB
YES
Replace servopack Alarm re-occurs? YES Replace MSV board Alarm re-occurs? YES Contact MOTOMAN service MSV board failure Servopack failure
NO
NO
AL-3020 AL-3021 AL-3022
MSV#1 MSV#2 MSV#3
AL-3023 AL-3024 AL-3025
MSV#4 MSV#5 MSV#6
AL-3026
MSV#7
Skapad: 98-10-09
ndrad: 98-11-26

Page: 72
MOTOMAN ROBOTICS AB
Alarm 3030-3036
Alarm Occurrence
Regenerative Trouble
Condition at the time of alarm? At control power on Replace servopack Alarm re-occurs? NO Servopack failure
At servo power on Check regeneration resistor NO Defective? Contact MOTOMAN-service YES Replace regeneration resistor Alarm re-occurs? NO Regeneration resistor failure
YES
YES
AL-3030 AL-3031 AL-3032
MSV#1 MSV#2 MSV#3
AL-3033 AL-3034 AL-3035
MSV#4 MSV#5 MSV#6
AL-3036
MSV#7
Skapad: 98-10-09
ndrad: 98-11-26
MOTOMAN ROBOTICS AB

Page: 73
Alarm 3040-3046
Alarm Occurrence
Overvoltage
Condition at the time of alarm? At control power on
At servo power on Check primary power voltage Abnormal? NO Check regeneration resistor Primary power failure
YES
Replace servopack Alarm re-occurs? NO Servopack failure
NO
Defective? Contact MOTOMAN-service
YES
Replace regeneration resistor Alarm re-occurs? NO Regeneration resistor failure
YES
YES
AL-3040 AL-3041 AL-3042
MSV#1 MSV#2 MSV#3
AL-3043 AL-3044 AL-3045
MSV#4 MSV#5 MSV#6
AL-3046
MSV#7
Skapad: 98-10-09
ndrad: 98-11-26

Page: 74
MOTOMAN ROBOTICS AB
Alarm 3050-3056
Alarm Occurrence
Voltage Drop
Condition at the time of alarm? At control power on Replace servopack Alarm re-occurs? NO Servopack failure NO
At servo power on Check primary power voltage Abnormal? Contact MOTOMAN-service Primary power failure
YES
YES
AL-3050 AL-3051 AL-3052
MSV#1 MSV#2 MSV#3
AL-3053 AL-3054 AL-3055
MSV#4 MSV#5 MSV#6
AL-3056
MSV#7
Skapad: 98-10-09
ndrad: 98-11-26
MOTOMAN ROBOTICS AB

Page: 75
Alarm 3060-3066
Alarm Occurrence
Heat sink overheat
At servo power on Check primary power voltage Abnormal? Contact MOTOMAN-service Primary power failure
YES
YES
AL-3060 AL-3061 AL-3062
MSV#1 MSV#2 MSV#3
AL-3063 AL-3064 AL-3065
MSV#4 MSV#5 MSV#6
AL-3066
MSV#7
Skapad: 98-10-09
ndrad: 98-11-26

Page: 76
MOTOMAN ROBOTICS AB
Alarm 3070-3076
Alarm Occurrence
Servo Blown Fuse
At servo power on Check motor cable Abnormal? Contact MOTOMAN-service YES Replace wiring harness Alarm re-occurs? NO Wiring failure
YES
YES
AL-3070 AL-3071 AL-3072
MSV#1 MSV#2 MSV#3
AL-3073 AL-3074 AL-3075
MSV#4 MSV#5 MSV#6
AL-3076
MSV#7
Skapad: 98-10-09
ndrad: 98-11-26
MOTOMAN ROBOTICS AB

Page: 77
Alarm 3080-3086 Broken Current Ref Cable

Alarm Occurrence Check cable between servopack and MSV board Defective? NO Replace servopack Alarm re-occurs? NO Servopack failure YES Alarm re-occurs? Replace MSV board Alarm re-occurs? NO MSV board failure YES Contact MOTOMAN-service NO Cable failure YES Replace cable
YES
AL-3080 AL-3081 AL-3082
MSV#1 MSV#2 MSV#3
AL-3083 AL-3084 AL-3085
MSV#4 MSV#5 MSV#6
AL-3086
MSV#7
Skapad: 98-10-09
ndrad: 98-11-26

Page: 78
MOTOMAN ROBOTICS AB
Alarm 3090-3096
Alarm Occurrence Check primary power voltage Abnormal? NO Primary power failure
Open Phase
YES
Check if contactor is stuck or not Abnormal? NO Check cable for SVM contactor YES Alarm re-occurs? NO Contactor failure YES Replace contactor
Replace cable
YES
Abnormal? NO
Alarm re-occurs? NO Cable failure
YES
Replace servopack Alarm re-occurs? NO Servopack failure YES YES Replace MSV board Abnormal? NO
MSV board failure
AL-3090 AL-3091 AL-3092
MSV#1 MSV#2 MSV#3
AL-3093 AL-3094 AL-3095
MSV#4 MSV#5 MSV#6
AL-3096
MSV#7
Skapad: 98-10-09
ndrad: 98-11-26
MOTOMAN ROBOTICS AB

Page: 79
Alarm 4000
Not Ready
Alarm Occurrence Reset alarm, and then execute the operation again NO Resume use Alarm re-occurs? YES Contact MOTOMAN-service
Alarm 4010
Current Position Set Program Error

Alarm 4020
Servo Power On Sequence Error

Skapad: 98-10-09
ndrad: 98-11-26

Page: 80
MOTOMAN ROBOTICS AB
Alarm 4030
Servo Power Off Sequence Error

Alarm 4040
Home Calibration Error

Alarm 4050
Absolute Data Change Error

Skapad: 98-10-09
ndrad: 98-11-26
MOTOMAN ROBOTICS AB

Page: 81
Alarm 4060
Segment Data Output Error

Alarm 4070
Axis Parameter Error

Alarm Occurrence Initialize parameter setting NO Resume use Alarm re-occurs? YES Contact MOTOMAN-service
Alarm 4080
Table Parameter Error For Actual Axis

Alarm Occurrence Initialize parameter setting NO Resume use Alarm re-occurs? YES Contact MOTOMAN-service
Skapad: 98-10-09
ndrad: 98-11-26

Page: 82
MOTOMAN ROBOTICS AB
Alarm 4090
Sequence Task Control Error

Alarm 4100
Data Refresh Error

Alarm 4110
Undefined Command (Arith)

Skapad: 98-10-09
ndrad: 98-11-26
MOTOMAN ROBOTICS AB

Page: 83
Alarm 4120
System Error (Arith)

Alarm 4130
Arithmetic Error
Alarm 4140
Select Error (Parameter)

Skapad: 98-10-09
ndrad: 98-11-26

Page: 84
MOTOMAN ROBOTICS AB
Alarm 4150
Group Axis Control Error

Alarm 4160
Two Steps Same Position (Circle)

Alarm Occurrence
Confirm the taught program, and then input three different points NO Resume use Alarm re-occurs? YES Contact MOTOMAN-service
Alarm 4170
Two Steps Same Position (Spline)

Alarm Occurrence
Skapad: 98-10-09
ndrad: 98-11-26
MOTOMAN ROBOTICS AB

Page: 85
Alarm 4180
Two Steps Same Position (3 steps)

Alarm Occurrence
Alarm 4190
Two Steps Same Position (weave)

Alarm Occurrence
Alarm 4200
Teach Error (Spline)

Alarm Occurrence Confirm the taught program, and then provide instructions to position taught points correctly
NO Resume use
Alarm re-occurs?
Skapad: 98-10-09
ndrad: 98-11-26

Page: 86
MOTOMAN ROBOTICS AB
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 Resume use
Alarm re-occurs?
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
Alarm re-occurs?
Skapad: 98-10-09
ndrad: 98-11-26
MOTOMAN ROBOTICS AB

Page: 87
Alarm 4230
Excessive Segment (Low speed)

Alarm Occurrence Decrease the speed of the step where the alarm occured NO Alarm re-occurs? YES
Resume use
Set form of axes S and L, and provide a new instruction NO Resume use Alarm re-occurs? YES Contact MOTOMAN-service
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 NO Resume use Alarm re-occurs? YES Contact MOTOMAN-service
Resume use
Skapad: 98-10-09
ndrad: 98-11-26

Page: 88
MOTOMAN ROBOTICS AB
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 Resume use
AL-4250 AL-4260 AL-4270
Pulse limit over: minimum Pulse limit over: maximum Cube limit over: minimum
AL-4280 AL-4290 AL-4300
Cube limit over: maximum Special soft limit over: minimum 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 Resume use
Alarm re-occurs?
AL-4310 AL-4320
Mechanical interference: minimum Mechanical interference: maximum
AL-4330 AL-4340
Special mechanical interference: maximum Special mechanical interference: minimum
Skapad: 98-10-09
ndrad: 98-11-26
MOTOMAN ROBOTICS AB

Page: 89
Alarm 4350-4360
Pulse Mechanical limit

Alarm Occurrence
Reset alarm using soft-limit-over reset method, and then provide another instruction.
NO Resume use
Alarm re-occurs?
AL-4350
Pulse mechanical limit: minimum
AL-4360
Pulse mechanical limit: maximum
Alarm 4370
Station Axis Data Input Error

Alarm Occurrence
Reset alarm, and then execute the operation again
NO Resume use
Alarm re-occurs?
Skapad: 98-10-09
ndrad: 98-11-26

Page: 90
MOTOMAN ROBOTICS AB
Alarm 4380
Segment Control Error

Alarm Occurrence Reset alarm, and then execute the operation again Alarm re-occurs?
NO Resume use
Alarm 4390
Sub-segment Control Error

Alarm Occurrence Reset alarm, and then execute the operation again Alarm re-occurs?
NO Resume use
Alarm 4400
Wrong Specified Control Group

Alarm Occurrence
Reset alarm, and then execute the operation again NO Resume use Alarm re-occurs? YES Contact MOTOMAN-service
Skapad: 98-10-09
ndrad: 98-11-26
MOTOMAN ROBOTICS AB

Page: 91
Alarm 4410
CPU Communication Error

Alarm Occurrence
Alarm 4420
Failed To Select Over SP Level

Alarm Occurrence
Reset alarm, and then execute the operation again NO Resume use Alarm re-occurs? YES
Turn the power off, and then on again YES Alarm re-occurs? NO Resume use YES Contact MOTOMAN-service
Replace MSV board NO MSV board failure Alarm re-occurs?
Skapad: 98-10-09
ndrad: 98-11-26

Page: 92
MOTOMAN ROBOTICS AB
Alarm 4430
Averaging Number Change Error

Alarm Occurrence
Reset alarm, and then execute the operation again NO Resume use Alarm re-occurs? YES Turn the power off, and then on again YES Alarm re-occurs? NO Resume use YES Contact MOTOMAN-service
Alarm 4440
Torque Limit Change Error

Alarm Occurrence
Reset alarm, and then execute the operation again NO Resume use Alarm re-occurs? YES Turn the power off, and then on again YES Alarm re-occurs? NO Resume use YES Contact MOTOMAN-service
Skapad: 98-10-09
ndrad: 98-11-26
MOTOMAN ROBOTICS AB

Page: 93
Alarm 4450
JMS Error
Alarm Occurrence
1/255 2/254 3/253 4/252 5/251 6/250 7/249 8/248 9/247 10/246
Parameter Access time over Access error Job name error Existing job open Memory over Not existing Acess not permitted Handling number error System error
11/245 12/244 13/243 14/242 15/241 16/240 17/239 18/238 19/237 99/157
Sequence number error Step numer error Code error Lack of handle Write Protected Maximum instruction Maximum step Job failure
Alarm 4460
JHM Error
Alarm Occurrence Turn the power off, and then on again NO Resume use Alarm re-occurs? YES Contact MOTOMAN-service
Skapad: 98-10-09
ndrad: 98-11-26

Page: 94
MOTOMAN ROBOTICS AB
Alarm 4470
Instruction Interpreter Error

Alarm Occurrence Turn the power off, and then on again NO Resume use Alarm re-occurs? YES Contact MOTOMAN-service
Alarm 4480
Undefined Global Variable

Alarm Occurrence
Reset the parameter, and then execute the operation again NO Resume use Alarm re-occurs? YES Contact MOTOMAN-service
Alarm 4490
Var-Scoreboard Control Error

Alarm Occurrence
Skapad: 98-10-09
ndrad: 98-11-26
MOTOMAN ROBOTICS AB

Page: 95
Alarm 4500
Undefined Local Variable

Alarm Occurrence
Set the local variable to the job heade and then execute the operation again NO Resume use Alarm re-occurs? YES Contact MOTOMAN-service
Alarm 4510
Less Than 3 Steps (circular)

Alarm Occurrence
Confirm the taught program, and then input instructions to provide more than three steps continuously Alarm re-occurs?
NO 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 Alarm re-occurs?
NO Resume use
Skapad: 98-10-09
ndrad: 98-11-26

Page: 96
MOTOMAN ROBOTICS AB
Alarm 4530
Undefined Job
Alarm Occurrence
Reset alarm, end then execute the operation again NO Resume use Alarm re-occurs? YES Contact MOTOMAN-service
Alarm 4540
Undefined Label
Alarm Occurrence Check the taught point, and then teach the point again NO Resume use Alarm re-occurs? YES Contact MOTOMAN-service
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 Alarm re-occurs? YES
Skapad: 98-10-09
ndrad: 98-11-26
MOTOMAN ROBOTICS AB

Page: 97
Alarm 4560
Lack Of Local-Variable Area

Alarm Occurrence
Decrease the use of local variables NO Resume use Alarm re-occurs? YES Contact MOTOMAN-service
Alarm 4570
Local-Variable Control Error

Alarm Occurrence
Alarm 4580
Job Call Stack Error

Alarm Occurrence
Skapad: 98-10-09
ndrad: 98-11-26

Page: 98
MOTOMAN ROBOTICS AB
Alarm 4590
Feedback Pulse Making Error

Alarm Occurrence
Alarm 4600
Unsuccessful Fine Positioning

Alarm Occurrence Reset alarm, and then execute the operation again NO Alarm re-occurs? YES Turn the power off, and then on again YES Replace MSV board NO Alarm re-occurs? YES Contact MOTOMAN-service Alarm re-occurs? NO Resume use
Resume use
MSV board failure
Skapad: 98-10-09
ndrad: 98-11-26
MOTOMAN ROBOTICS AB

Page: 99
Alarm 4610
Pending Block-End Error

Alarm Occurrence
Alarm 4620
Data Preset Error

Alarm Occurrence
Alarm 4630
Variable Data Type Error

Alarm Occurrence
Skapad: 98-10-09
ndrad: 98-11-26

Page: 100
MOTOMAN ROBOTICS AB
Alarm 4640
Over Variable Limit

Alarm Occurrence Change value of variable type that exceeds numerical range limits. NO Resume use Alarm re-occurs? YES Contact MOTOMAN-service
(B**) 0-255 (I**) -32768~32767 (D**) -2147483648 ~214748 (R**) -1.70141E+38 ~1.70141E
Alarm 4650
Defective Taught Point (circular)

Alarm Occurrence Check taught point, and then teach three points not in a straight line NO Resume use Alarm re-occurs? YES Contact MOTOMAN-service
Alarm 4660
Weaving Control Error

Alarm Occurrence
Reset alarm, and then check weave file and REFP points NO Resume use Alarm re-occurs? YES Contact MOTOMAN-service
Skapad: 98-10-09
ndrad: 98-11-26
MOTOMAN ROBOTICS AB

Page: 101
Alarm 4670-4671
Overrun In Axis
Alarm Occurrence Recover from overtravel then try again NO Resume use Alarm re-occurs? YES Check short switch on MBB02
Set the swith again
YES
Abnormal? NO
NO Swith setting failure
Alarm re-occurs?
YES
Check the over run limit switch Defective? NO
Replace switch
YES
NO Switch failure
Alarm re-occurs?
YES
Check the wiring of the overrun limit switch Alarm re-occurs? NO Replace MTU board YES Alarm re-occurs? NO Lead failure YES Replace wiring harness
Replace MBB02 (IOBB) board NO MBB02 (IOBB) failure Alarm re-occurs?
YES
Alarm re-occurs? NO Board failure
YES
AL-4670
At robot axes occurrence

ndrad: 98-11-26
AL-4671
At external axes occurrence
Skapad: 98-10-09

Page: 102
MOTOMAN ROBOTICS AB
Alarm 4680-4730
File Fault
Alarm Occurrence
Reset alarm, and then execute the operation again NO Resume use Alarm re-occurs? YES Load the file corresponding to the screen, and then try again NO Resume use Alarm re-occurs? YES Contact MOTOMAN-service
AL-4680 AL-4690 AL-4700
Tool file User frame file Servo monitor signal file
AL-4710 AL-4720 AL-4730
Weaving file Home position absolute data file Second home position data file
Alarm 4740
Posn File Data Read-Out Error

Alarm Occurrence
Skapad: 98-10-09
ndrad: 98-11-26
MOTOMAN ROBOTICS AB

Page: 103
Alarm 4750
Unmatched Posn Var Data Type

Alarm Occurrence Change position variable data type (pulse - XYZ). NO Resume use Alarm re-occurs? YES Contact MOTOMAN-service
Alarm 4760
File No. Error

Alarm Occurrence
Alarm 4770
Undefined Reference Point

Alarm Occurrence
Register the reference point Alarm re-occurs?
NO Resume use
Skapad: 98-10-09
ndrad: 98-11-26

Page: 104
MOTOMAN ROBOTICS AB
Alarm 4780
Stack More Than 8 (job call)

Alarm Occurrence
Check program, and modify so that stack does not exceed 8 calls NO Resume use Alarm re-occurs? YES Contact MOTOMAN-service
Alarm 4790
Arithmetic Section Request Error

Alarm Occurrence
Alarm 4800
Request-To-Send Error
Alarm Occurrence
Skapad: 98-10-09
ndrad: 98-11-26
MOTOMAN ROBOTICS AB

Page: 105
Alarm 4810
Over Variable No.

Alarm Occurrence Check program, and change variable number within limit NO Resume use Alarm re-occurs? YES Contact MOTOMAN-service
(B000~B039) (I000~I039) D000~D039) R000~R039) P000~P127) BP000~BP127) EX000~EX127)
Alarm 4820
Position Data Management Error

Alarm Occurrence
1 2 3 4 5 6 7 8
Not enough area Number of axis zero Position not kept Number of position over Area not specified File destroyed Memory over Position data destroyed
9 10 11 12 13 14 15
Control information destroyed Irregular position number Position data not set Undefined position Undefined control group Initialization not done Number of axis over
Skapad: 98-10-09
ndrad: 98-11-26

Page: 106
MOTOMAN ROBOTICS AB
Alarm 4830-4850
Undefined Condition File

Alarm Occurrence Complete the setting of the file NO Alarm re-occurs? YES Contact MOTOMAN-service
Resume use
AL-4830 AL-4840
Welder condition file Arc start condition file
AL-4850
Arc end condition file
Alarm 4860
Wrong Welder Selection

Alarm Occurrence
Match unit of voltage selection to welder type NO Resume use Alarm re-occurs? YES Contact MOTOMAN-service
Skapad: 98-10-09
ndrad: 98-11-26
MOTOMAN ROBOTICS AB

Page: 107
Alarm 4870-4900
Condition File Fault

Alarm Occurrence
Reset alarm, and then execute the operation again NO Resume use NO Resume use Alarm re-occurs? YES Load file, and the try again Alarm re-occurs? YES Contact MOTOMAN-service
AL-4870 AL-4880
Welder condition file Arc start condition file
AL-4890 AL-4900
Arc end condition file Arc condition supp. file
Alarm 4910
AX-CPU Command Area Error

Alarm Occurrence
Skapad: 98-10-09
ndrad: 98-11-26

Page: 108
MOTOMAN ROBOTICS AB
Alarm 4920-4950
File Fault
Alarm Occurrence
Reset alarm, and then execute the operation again Alarm re-occurs? YES Load file, and then try again NO Resume use Alarm re-occurs? YES Contact MOTOMAN-service
NO Resume use
AL-4920 AL-4930
COM-ARC 3 Condition file COM-ARC 3 Data file
AL-4940 AL-4950
Correction condition file Phase offset data file
Alarm 4960
System Change
Alarm Occurrence Turn the power off, and then on again Alarm re-occurs?
NO Resume use
Skapad: 98-10-09
ndrad: 98-11-26
MOTOMAN ROBOTICS AB

Page: 109
Alarm 4970
Equation Exception Error

Alarm Occurrence
Alarm 4980
Excessive Instruction Equation

Alarm Occurrence
Check the program, and make the expression short NO Resume use Alarm re-occurs? YES Contact MOTOMAN-service
Alarm 4990
Encoder Battery Error

Alarm Occurrence
Reset alarm, and then execute the operation again NO Battery failure Alarm re-occurs? Replace battery board for encoder Alarm re-occurs? YES
YES
NO MFC board failure
Skapad: 98-10-09
ndrad: 98-11-26

Page: 110
MOTOMAN ROBOTICS AB
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? NO Check the wiring of fan Defective? YES Replace fan wiring Alarm re-occurs? NO Lead failure NO Fan failure Contact MOTOMAN-service YES Replace motor Alarm re-occurs? NO Motor failure YES Replace fan Alarm re-occurs? Check load Load condition? YES Overload Decrease weight OK NO YES
Skapad: 98-10-09
ndrad: 98-11-26
MOTOMAN ROBOTICS AB

Page: 111
Alarm 5010
Illegal Parameter
Alarm Occurrence
Change the parameter back to original NO Resume use Alarm re-occurs? YES Load parameter file, and then try again NO Resume use Alarm re-occurs? YES Contact MOTOMAN-service
Alarm 5020
Zero Divisor Occurrence

Alarm Occurrence
Change the program so that the number will not be divided by zero NO Resume use Alarm re-occurs? YES Contact MOTOMAN-service
Skapad: 98-10-09
ndrad: 98-11-26

Page: 112
MOTOMAN ROBOTICS AB
Alarm 5030
Global-Variable Area Parameter Error

Alarm Occurrence
Change the parameter back to original value NO Resume use Alarm re-occurs? YES Load parameter file, and then try again NO Resume use Alarm re-occurs? YES Contact MOTOMAN-service
Alarm 5040
Out Of Range (abso data)
Alarm Occurrence
Reset alarm by checking second home position Alarm re-occurs? NO Resume use NO Replace motor Motor failure NO Alarm re-occurs? YES Contact MOTOMAN-service YES Alarm re-occurs? NO Battery failure YES Check battery wiring to encodeers Defective? YES Replace battery
Skapad: 98-10-09
ndrad: 98-11-26
MOTOMAN ROBOTICS AB

Page: 113
Alarm 5060
Undefined Auto-Weld Release Cond

Alarm Occurrence
Set welding release condition time, and then try again NO Resume use Alarm re-occurs? YES Contact MOTOMAN-service
Alarm 5070
Undefined Position For Arc Retry

Alarm Occurrence
Add step, and then try again
NO Resume use
Alarm re-occurs?
Alarm 5080
Overspeed Limit
Alarm Occurrence
Check setting for MFC04 board, and then try again NO Resume use Alarm re-occurs? YES Contact MOTOMAN-service
Skapad: 98-10-09
ndrad: 98-11-26

Page: 114
MOTOMAN ROBOTICS AB
Alarm 5090
DC 24V Power Supply Failure
Alarm Occurrence
Check 24V power voltage supplied to IOBB Defective? NO Check fuse on IOBB Defective? NO Replace IOBB Alarm re-occurs? YES Contact MOTOMAN-service YES NO Alarm re-occurs? Board failure NO Fuse failure YES YES Alarm re-occurs? Replace fuse NO Power supply failure YES Replace DC 24V power supply
Skapad: 98-10-09
ndrad: 98-11-26
MOTOMAN ROBOTICS AB

Page: 115
Alarm 5100
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? NO Resume use
YES
Check the shock sensor cable Defective? NO Check the shock sensor operation YES Alarm re-occurs? NO Cable failure YES Replace cable
Check the setting of IOBB short pin switch Abnormal? NO Replace MTU board
NO
Abnormal? Set the short pin switch
YES Replace shock sensor Alarm re-occurs?
YES
NO Sensor failure
YES
Alarm re-occurs? NO
Alarm re-occurs? MTU board failure
YES
Setting failure
Replace MRY board Alarm re-occurs? NO MRY board failure YES
Replace IOBB Alarm re-occurs? YES Contact MOTOMAN-service

NO
IOBB failure
Skapad: 98-10-09
ndrad: 98-11-26

Page: 116
MOTOMAN ROBOTICS AB
Alarm 5110
Brake Fuse Blown

Alarm Occurrence Check the brake lead wiring for short to ground Short? Check the brake fuse YES Replace lead wire for brake Alarm re-occurs? NO Lead wire failure NO
YES
Replace the brake fuse
YES
Fuse blown?
Alarm re-occurs? NO Fuse failure
YES
Replace the MTU board Alarm re-occurs? YES Contact MOTOMAN-service NO Board failure
Skapad: 98-10-09
ndrad: 98-11-26
MOTOMAN ROBOTICS AB

Page: 117
Alarm 5120
Parity Error
Alarm Occurrence Check the parameter for parity check function Invalid parameter? NO Check input YES Alarm re-occurs? NO Parameter setting failure YES Set the parameter correctly
Check the input program
YES
Abnormal? NO
Alarm re-occurs? NO Abnormal input
YES
Replace the MTU board Alarm re-occurs? YES Contact MOTOMAN-service NO Board failure
Skapad: 98-10-09
ndrad: 98-11-26

Page: 118
MOTOMAN ROBOTICS AB
Alarm 5130
Over BCD Range

Alarm Occurrence
Check the BCD function parameter Invalid parameter? NO Check input/output Check the input/ output program YES Abnormal? NO Alarm re-occurs? NO Input/output failure YES Replace IO module board Alarm re-occurs? YES Contact MOTOMAN-service NO Board failure YES Alarm re-occurs? NO Parameter setting failure YES Set the parameter correctly
Skapad: 98-10-09
ndrad: 98-11-26
MOTOMAN ROBOTICS AB

Page: 119
Alarm 5140
Over Binary Range (parity check)

Alarm Occurrence Check parity check - BCD function parameter Invalid parameter? NO Check output YES Alarm re-occurs? NO Parameter setting failure YES Set the parameter correctly
Check the output program
YES
Abnormal? NO
Alarm re-occurs? NO Output failure
YES
Replace IO module board Alarm re-occurs? YES Contact MOTOMAN-service NO Board failure
Alarm 5150
Offline Undefined Command (Arith)

Skapad: 98-10-09
ndrad: 98-11-26

Page: 120
MOTOMAN ROBOTICS AB
Alarm 5160
Offline System Error (Arith)

Alarm 5170
Robot Calibration Data Error

Alarm 5180
Robot Calibration Frame Error

Skapad: 98-10-09
ndrad: 98-11-26
MOTOMAN ROBOTICS AB

Page: 121
Alarm 5190
Arithmetic Section Init Error

Alarm 5200
Set-Up Process Error (motion)

Alarm 5210
System Error (motion)

Skapad: 98-10-09
ndrad: 98-11-26

Page: 122
MOTOMAN ROBOTICS AB
Alarm 5220
Servo Ready Monitoring Error

Alarm 5230
Calibration Data Error

Alarm 5240
Tool Calibration Data Error

Skapad: 98-10-09
ndrad: 98-11-26
MOTOMAN ROBOTICS AB

Page: 123
Alarm 5250-5300
File Fault
Alarm Occurrence Reset alarm, and then execute the operation again
NO Resume use
Alarm re-occurs?
YES
Load the file corresponding to the display, and then try again Alarm re-occurs?
NO Resume use
AL-5250 AL-5260 AL-5270
Robot calibration file Tool calibration file Arc start cond guide file
AL-5280 AL-5290 AL-5300
Arc end cond guide file Welder user-defined file Ladder program file
Alarm 5310
Arithmetic Alarm Reset Error

Skapad: 98-10-09
ndrad: 98-11-26

Page: 124
MOTOMAN ROBOTICS AB
Alarm 5320
Wrong Control Group Axis

Alarm Occurrence Check program and modify it (include control group to the original job). NO Resume use Alarm re-occurs? YES Contact MOTOMAN-service
Alarm 5330
Cannot Execute Job (no robot)

Alarm Occurrence Check program and modify it (include control group to the original job). NO Resume use Alarm re-occurs? YES Contact MOTOMAN-service
Alarm 5340
Sensing Data Request Error

Skapad: 98-10-09
ndrad: 98-11-26
MOTOMAN ROBOTICS AB

Page: 125
Alarm 5350
Main Contactor On Reply Error

Alarm Occurrence Reset alarm, and then execute the operation again NO Alarm re-occurs? YES Check if main contactor is working or not NO Check voltage for main contactor coil NO Abnormal? YES Working? YES
Resume use
Replace main contactor Alarm re-occurs? NO Contactor failure YES Check MTU board Defective? NO Contact MOTOMAN-service YES Alarm re-occurs? NO MTU board failure YES Replace MTU board
Skapad: 98-10-09
ndrad: 98-11-26

Page: 126
MOTOMAN ROBOTICS AB
Alarm 5360
Main Contactor Off Reply Error

Resume use
Skapad: 98-10-09
ndrad: 98-11-26
MOTOMAN ROBOTICS AB

Page: 127
Alarm 5370
Braking Lock Reply Error

Resume use
Skapad: 98-10-09
ndrad: 98-11-26

Page: 128
MOTOMAN ROBOTICS AB
Alarm 5380
Braking Release Reply Error

Resume use
Skapad: 98-10-09
ndrad: 98-11-26
MOTOMAN ROBOTICS AB

Page: 129
Alarm 5390
Servo-Ready On Error
Alarm Occurrence Reset alarm, and then execute the operation again NO Alarm re-occurs? YES Check if main contactor is working or not NO Check voltage for main contactor coil NO Abnormal? YES Working? YES 1
Resume use
Skapad: 98-10-09
ndrad: 98-11-26

Page: 130
MOTOMAN ROBOTICS AB
Alarm 5390
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? YES Check wiring between contactor and servopack Replace wiring between contactor and servopack
NO
Resume use
Defective? NO
YES
Check wiring between MSV board and servopack Defective? NO Replace servopack Alarm re-occurs? NO Servopack failure YES
YES
Alarm re-occurs?
NO
Wiring failure
YES
Replace wiring between MSV board and servopack
YES
Alarm re-occurs? Replace MSV board Alarm re-occurs? YES Contact MOTOMAN-service
NO
Wiring failure
NO
MSV board failure
Skapad: 98-10-09
ndrad: 98-11-26
MOTOMAN ROBOTICS AB

Page: 131
Alarm 5400
Servo-Ready Off Error

Alarm Occurrence Reset alarm, and then execute the operation again NO Alarm re-occurs? YES Check if main contactor is working or not NO Check voltage for main contactor coil NO Abnormal? YES Working? YES 1
Resume use
Skapad: 98-10-09
ndrad: 98-11-26

Page: 132
MOTOMAN ROBOTICS AB
Alarm 5400
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? YES Check wiring between contactor and servopack Replace wiring between contactor and servopack
NO
Resume use
Defective? NO
YES
Check wiring between MSV board and servopack Defective? NO Replace servopack Alarm re-occurs? NO Servopack failure YES
YES
Alarm re-occurs?
NO
Wiring failure
YES
Replace wiring between MSV board and servopack
YES
Alarm re-occurs? Replace MSV board Alarm re-occurs? YES Contact MOTOMAN-service
NO
Wiring failure
NO
MSV board failure
Skapad: 98-10-09
ndrad: 98-11-26
MOTOMAN ROBOTICS AB

Page: 133
Alarm 5410
Base-Block On Error
Alarm Occurrence Reset alarm, and then execute the operation again Alarm re-occurs? YES Turn off power, and then turn it on again Alarm re-occurs? YES Check wiring between MSV board and servopack Defective? NO Replace servopack Alarm re-occurs? NO Servopack failure YES Contact MOTOMAN-service YES YES Alarm re-occurs? Replace MSV board Alarm re-occurs? MSV board failure NO Wiring failure YES Replace wiring between MSV board and servopack NO Resume use
NO
Resume use
NO
Skapad: 98-10-09
ndrad: 98-11-26

Page: 134
MOTOMAN ROBOTICS AB
Alarm 5420
Base-Block Off Error

NO
Resume use
NO
Skapad: 98-10-09
ndrad: 98-11-26
MOTOMAN ROBOTICS AB

Page: 135
Alarm 5430
Dynamic Brake On Error

NO
Resume use
NO
Skapad: 98-10-09
ndrad: 98-11-26

Page: 136
MOTOMAN ROBOTICS AB
Alarm 5440
Dynamic Brake Off Error

NO
Resume use
NO
Skapad: 98-10-09
ndrad: 98-11-26
MOTOMAN ROBOTICS AB

Page: 137
Alarm 5450
Unused (on)
Alarm Occurrence Reset alarm, and then execute the operation again NO Alarm re-occurs? YES Contact MOTOMAN-service
Resume use
Alarm 5460
Unused (off)
Resume use
Alarm 5470
Cannot Edit (edit lock job)

Alarm Occurrence
Release Edit-lock, and then execute the operation again NO Resume use Alarm re-occurs? YES Contact MOTOMAN-service
Skapad: 98-10-09
ndrad: 98-11-26

Page: 138
MOTOMAN ROBOTICS AB
Alarm 5480
Select Error (application 1)

Resume use
Alarm 5490
Select Error (application 2)

Resume use
Alarm 5500
Select Error (sensor 1)

Resume use
Skapad: 98-10-09
ndrad: 98-11-26
MOTOMAN ROBOTICS AB

Page: 139
Alarm 5510
Select Error (sensor 2)

Resume use
Alarm 5520
Wrong Port Out (analog output)

Resume use
Data 1
Application 1
Data 2
Application 2
Skapad: 98-10-09
ndrad: 98-11-26

Page: 140
MOTOMAN ROBOTICS AB
Alarm 5530
Pass Over
Alarm Occurrence Is COM-ARC IIIs function normal? NO Check the cable between the current detection unit and the sensor board Check workpiece deviation
YES
Small
Deviation?
Large
Position a workpiece
Defective? YES Change the cable
NO
Check the current detection unit Defective? NO Replace the sensor board YES Alarm re-occurs? NO Current detection unit failure YES Replace the current detection unit
Sensor board failure
NO
Alarm re-occurs? YES Contact MOTOMAN-service
Alarm 5540
Wrong Selection (sensor)

Resume use
Skapad: 98-10-09
ndrad: 98-11-26
MOTOMAN ROBOTICS AB

Page: 141
Alarm 5550
Wrong Mech Parameter File

Resume use
Alarm 5560
Incompleted PT Frame
Resume use
Alarm 5570
Defective Taught Point (cutting)

Resume use
Data 1
CW axis position is not 0.
Data 2
Cutting radius is 0.
Skapad: 98-10-09
ndrad: 98-11-26

Page: 142
MOTOMAN ROBOTICS AB
Alarm 5580
Defective Taught Point (endless)

Resume use
Data 1 Data 2
Linear motion error (MRESET not executed. Endless on base axes
Data 3 Data 4
Endless not selected on T-axis. Command position exceeds limit (214748367 pulse).
Alarm 5590
Correctional Direction Data

Resume use
Alarm 5600
Position Correction Data

Resume use
Skapad: 98-10-09
ndrad: 98-11-26
MOTOMAN ROBOTICS AB

Page: 143
Alarm 5610
Over Tool File No.

Resume use
Alarm 5620
Defective Taught Point (weav)

Alarm Occurrence
Check the REFP, and then teach the REFP again NO Resume use Alarm re-occurs? YES Contact MOTOMAN-service
Data 1
Weaving atart point and end point is the same
Data 2
Weaving REFP 1 or 2 is on the path
Alarm 5630
Undefined Robot Calibration

Alarm Occurrence
Execute robot calibration Alarm re-occurs
NO Resume use
Skapad: 98-10-09
ndrad: 98-11-26

Page: 144
MOTOMAN ROBOTICS AB
Alarm 5640
Parameter Error
Alarm Occurrence Reset the parameter with the original data NO Alarm re-occurs? YES
Resume use
Load the parameter file and then try again NO Resume use Alarm re-occurs? YES Contact MOTOMAN-service
Alarm 5650
Defective Taught Point (Calib)

Alarm Occurrence
Check the taught point, and then teach the point again NO Resume use Alarm re-occurs? YES Contact MOTOMAN-service
Data 3 Data 4
Data for station 2nd axis is not same 3, 4, 5 points. Data for station 1st axis is not same 1, 2, 3 points.
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.
Skapad: 98-10-09
ndrad: 98-11-26
MOTOMAN ROBOTICS AB

Page: 145
Alarm 5660
DM-Bank Transmission Error

Resume use
Alarm 5670
Cannot Execute Job (no grp axis)

Alarm Occurrence
Set group axes Alarm re-occurs?
NO Resume use
Alarm 5680
Univ Data Preset Request Error

Resume use
Skapad: 98-10-09
ndrad: 98-11-26

Page: 146
MOTOMAN ROBOTICS AB
Alarm 5690
Braking Sequence Error

Resume use
Alarm 5700
Process Error (Syscon - axis)

Resume use
Alarm 5710
Illegal Sv Parameter (online)

Alarm Occurrence
Reset the parameter with the original data. NO Resume use Alarm re-occurs? YES Load the parameter file and then try again Alarm re-occurs?
NO Resume use
Skapad: 98-10-09
ndrad: 98-11-26
MOTOMAN ROBOTICS AB

Page: 147
Alarm 5720
Illegal Sv Parameter (online)

Alarm Occurrence Reset alarm, and then execute the operation again NO Alarm re-occurs? YES Replace the MSV board, and then try again NO Resume use Alarm re-occurs? YES Contact MOTOMAN-service
Resume use
Alarm 5730
Sv Parameter Change Error (online)

Alarm Occurrence Reset alarm, and then execute the operation again NO Alarm re-occurs? YES Replace the MSV board, and then try again NO Resume use Alarm re-occurs? YES Contact MOTOMAN-service
Resume use
Skapad: 98-10-09
ndrad: 98-11-26

Page: 148
MOTOMAN ROBOTICS AB
Alarm 5740
Illegal Max Speed Parameter

Alarm Occurrence Reset the parameter with the original data NO Alarm re-occurs? YES
Resume use
Load the parameter file and then try again NO Resume use Alarm re-occurs? YES Contact MOTOMAN-service
Alarm 5750
Undefined Position Variable

Alarm Occurrence
Set the position variable Alarm re-occurs?
NO Resume use
Alarm 5760
Undefined User Frame

Alarm Occurrence
Set the user frame Alarm re-occurs?
NO Resume use
Skapad: 98-10-09
ndrad: 98-11-26
MOTOMAN ROBOTICS AB

Page: 149
Alarm 5770
Out Of Range (parallel process)

Resume use
Alarm 5780
SL Board On-Line Error

Resume use
Alarm 5790
Interrupt Error (sensor)

Resume use
Skapad: 98-10-09
ndrad: 98-11-26

Page: 150
MOTOMAN ROBOTICS AB
Alarm 5800
Out Of Current Detector Range

Resume use
Alarm 5810
Command Error (sensor)

Resume use
Alarm 5820
Process Error (sensor)

Resume use
Skapad: 98-10-09
ndrad: 98-11-26
MOTOMAN ROBOTICS AB

Page: 151
Alarm 5830
Parallel Start Instruction Error

Alarm Occurrence Check the program, and then modify it. NO Alarm re-occurs? YES Contact MOTOMAN-service
Resume use
Alarm 5840
Cannot Execute Job (grp axis)

Alarm Occurrence
Set group axes Alarm re-occurs?
NO Resume use
Alarm 5850
Measure Inst Execute Error

Resume use
Skapad: 98-10-09
ndrad: 98-11-26
Headquarters:
MOTOMAN ROBOTICS AB
Box 504 l 385 25 Torss 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 ESPAA 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, Laure Mir 396-398 l E-08980 Sant Feliu de Llobregat l Spain Tel: +34-36859600 l Fax: +34-36859633
MOTOMAN ROBOTIT OY
Krsmentie 8 l SF-20300 Turku l Finland Tel: +358-22145600 l Fax: +358-22145660
ROBOT-TEKNIKK AS
vre 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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Trouble Shooting Manual For MRC

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YASNAC MRC ver. 3.

Trouble Shooting Guide, YASNAC MRC

MOTOMAN ROBOTICS AB a subsidiary of YASKAWA Electric Corporation

Trouble Shooting YASNAC MRC

CPU Board Insertion Error

Replace all boards Alarm re-occurs?

YES Contact MOTOMAN-service

Trouble Shooting YASNAC MRC

CPU Communication Error

Replace all boards Alarm re-occurs?

YES Contact MOTOMAN-service

Trouble Shooting YASNAC MRC

Trouble Shooting YASNAC MRC

RAM Error (local)

Trouble Shooting YASNAC MRC

Trouble Shooting YASNAC MRC

RAM Error (A-bus Common)

Trouble Shooting YASNAC MRC

RAM Error (D-Bus 2-Port)

Trouble Shooting YASNAC MRC

RAM Error (S-Bus 2-Port)

YES Replace the board corresponding to the display

Trouble Shooting YASNAC MRC

I/O Module Communication Error

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

I/O module failure

Trouble Shooting YASNAC MRC

IAMP Communication Error

YES Confirm the setting of the servopack

Trouble Shooting YASNAC MRC

IAMP Parameter Modification Error

YES Replace the servopack

YES Replace the MSV board

YES Contact MOTOMAN-service

MSV Board failure

Trouble Shooting YASNAC MRC

Encoder communication error

NO Replace the servopack

Alarm re-occurs? YES Replace the MSV board

YES Contact MOTOMAN-service NO Resume use

Alarm re-occurs? NO BSV Board failure

Alarm re-occurs? Contact MOTOMAN-service

Trouble Shooting YASNAC MRC

YES After the motor stops, control power ON.

YES Reset the absolute encoder Alarm re-occurs?

YES Replace servo motor

Trouble Shooting YASNAC MRC

Encoder Data Error

Encoder Back-up Error

Trouble Shooting YASNAC MRC

Encoder Checksum Error

YES Contact MOTOMAN-service

Trouble Shooting YASNAC MRC

Encoder Battery Error

Change the battery Alarm re-occurs?

YES Replace the motor

YES Contact MOTOMAN-service

YES Check Internal wiring Alarm re-occurs?

YES Contact MOTOMAN-service

NO Internal wire failure

Trouble Shooting YASNAC MRC

YES Contact MOTOMANservice before initializing the parameter file

Fault (System Config-Data)