1502, EFDEN-002-007, 001

FD CONTROLLER
INSTRUCTION MANUAL

CONTROL AND MAINTENANCE FUNCTION

7th edition

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

Table of Contents

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

Chapter 2 Edit logging

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

Chapter 3 User Check

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

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

Table of Contents

4.6.1 Function of the failure log monitor ................................................................................... 4-15

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

Chapter 5 Robot Diagnosis

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

Chapter 1 User Management

This chapter describes the user management function.

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

1.1 User management

1.1 User management

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

IMPORTANT

Editing operations to be restricted by this function refers to operations to change

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

1-1

1.1 User management

1.1.1 Enabling user management

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

Enabling the user management function

1-2

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

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

After the setting has been established, press f12 <Complete>.

The previous screen is restored.

1.1 User management

1.1.2 Automatic log-out setting

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

POINT

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

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

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

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

After the setting has been established, press f12 <Complete>.

The previous screen is restored.

1.1.3 Registering the users allowed to perform the editing operations

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

Registering the users

1

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

1-3

1.1 User management

Table 1.1.1 User registration setting items

Data registered
User ID (*)

Input range

Description

3-digit number

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

from 001 to 999

users are controlled using these IDs.

The same ID cannot be set for more than one user.

Password

User name (*)

A number

This is the numerical value data for authenticating users when

consisting of 0

they log in.

to 8 digits

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

1 to 14

Input the name of the user to be registered here.

characters
BEGINNER
USER
EXPERT
SPECIALIST

Protect level (*)

Comment

Max. 20

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

Comments on users may be entered in this field.

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

Limited operation

Check box

Press f8 <Next User>.

The lowest ID among the currently unregistered user IDs is displayed in the User
ID field.

Press f9 <User List>.

A list of the currently registered users is displayed.

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

1-4

After the setting has been established, press f12 <Complete>.

The user information is registered, and the previous screen is restored.

1.1 User management

1.1.4 Setting the user operation limitations

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

Change arc condition

setting

Description of limitation imposed

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

Change arc constant

setting

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

Change sensor
condition setting

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

Change sensor
condition setting

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

Change program

Program conversion
File manager

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

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

Setting the operation limitations

1

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

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

1-5

1.1 User management

To set an operation limitation, press [1] while holding down [ENABLE].

A check mark (limitation) is now set in the box for the item specified.

To release an operation limitation, press [2] while holding down [ENABLE].

The check mark (limitation) set in the box for the item specified is now removed.

After performing the settings, press f12 <Complete>.

The settings are recorded.

1.1.5 Copying user registration information

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

Writing the user registration information

1-6

Press <Constant Setting> - [1 Control Constants] - [17 User Management] [2 User Registration].
User registration screen appears.

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

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

1.1 User management

Reading the user registration information

1

Press <Constant Setting> - [1 Control Constants] - [17 User Management] [2 User Registration].
User registration screen appears.

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

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

1-7

1.1 User management

1.1.6 User information editing

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

Editing the user information

1-8

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

Select the user whose information is to be edited, and press [Enter].

The information of the selected user is displayed.

After editing the user information, press f12 <Complete>.

After the edited data has been registered, the previous screen is restored.

1.2 Using the user management function

1.2 Using the user management function

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

f key
for log-in

INFO.

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

Logging in
1

Perform one of the above three operations.

The log-in input screen is displayed.

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

IMPORTANT

Input the user ID and password in this order.

If there are no problems with the authentication of the password, log-in is
completed, and the previous screen is restored.

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

1-9

1.2 Using the user management function

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

After selecting the user, press [Enter].

The previous screen is restored, and the designated user is now selected.

1.2.2 Log-out operation

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

INFO.

The f key for <User log in> is indicated as

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

Logging out

POINT

1-10

Perform one of the above three operations.

The log-out screen is displayed.

Select [OK], and press [Enter].

After log-out, the previous screen is restored.

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

1.2 Using the user management function

1.2.3 User information at log-in

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

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

Checking the information of the logged-in user

1

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

286

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

Press [Reset].
The previous screen is restored.

Changing the user information of the user who is logged in

1

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

505

1-11

1.2 Using the user management function

Password

1-12

To edit the information, press f12 <Edit>.

The password confirmation screen now appears for authenticating the user.

Input the password.

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

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

Chapter 2 Edit logging

This chapter describes the edit logging function.

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

2.1 Concerning edit logging

2.1 Concerning edit logging

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

IMPORTANT

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

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

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

Enabling the edit logging function

1

Press <Constant Setting> - [24 Logging Data] - [5 Edit Logging Item].

The edit logging setting screen is displayed.

Enter the maximum number of the edit operations to be logged. A figure

selected from 0-10 can be entered in the hundreds digit field. When 0 is
input, the function is disabled.

Numerical
value

IMPORTANT

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

After the setting has been established, press f12 <Complete>.

After setting the maximum edit logging number, the previous screen is restored.

2-1

2.2 Referencing the edit logging

2.2 Referencing the edit logging

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

2.2.1 Editor logging monitor displays

Displaying the task program editor logging monitor
1

Press <Service Utilities> - [Monitor 1-4] - [61 Program editor logging].

The task program editor logging monitor is displayed.

Operation date/time

Task program,
Step number

Editing type

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

2-2

2.2 Referencing the edit logging

Table 2.2.1 Editing types

Operation location
Program editor

Program screen
editor

File manager

Program converter

Welding condition
editor

Welding constants

Welding constants
(welding condition
databases)

Display message

Description of operation

Recorded step

Operation for teaching movement command

Inserted step

Operation for adding movement command

Overwritten step

Operation for overwriting movement command

Modified position of
step
Deleted step

Operation for modifying position of movement command

Operation for deleting movement command or function command

Teached func step

Operation for teaching function command

Modified step

Operation for changing parameter of movement command

Undo

Undo operation after performing editing operation

Redo

Redo operation after performing undo operation

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

Insertion operation using screen editor

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

2-3

2.2 Referencing the edit logging

2

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

Line 1: Detailed listing description

The items are displayed in the following sequence.
Editing type

Filename

Step no.

[User information]

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

Line 2: Guide message

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

2-4

Press [Enter] again.

The detailed information screen is closed.

2.2 Referencing the edit logging

Displaying the arc welding editor logging monitor

1

Press <Service Utilities> - [Monitor 1-4] - [62 Arc welding editor logging].
The arc welding editor logging monitor is displayed.

Editing type
Refer to Table 2.2.1

Operation date/time
Data type

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

Data type

Description

PRG

Program

AS/AE

Arc start condition, Arc end condition

WS

Weaving condition

RT

Arc retry condition

MOV

Robot operation condition

MOF

Multi-offset condition

RRS

Robot RS condition

ASM/AEM

Arc start condition in multipass welding

Arc end condition in multipass welding

ASMV/AEMV

Arc start in multipass welding

Arc end in multipass welding
(variables)

RS

RS condition

CON

Welding constants

2-5

2.2 Referencing the edit logging

2

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

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

Line 1: Detailed listing description

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

Line 2: Title of edited data

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

2-6

Press [Enter] again.

The detailed information screen is closed.

2.2 Referencing the edit logging

2.2.2 Editor logging monitor functions

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

Using the display selection function of the editor logging monitors

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

6
1

For changing the items sorted

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

POINT
2

Program number sequence

User ID sequence

The user ID sequence can be selected only when the user

management function has been enabled.

For changing the sorting sequence

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

For splitting the screen

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

2-7

2.2 Referencing the edit logging

For moving up/down

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

For selecting the display

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

2-8

Welding conditions

Welding constants

Clearing the edit logging

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

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

Chapter 3 User Check

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

3.1 User Check

3.1 User Check

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

INFO.




This function corresponds to System Maintenance Function of conventional EX-C

series robot controller.
Change the operator qualification to EXPERT or higher in advance.

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

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

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

IMPORTANT
Checking items

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

Checking items

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

3-1

3.2 Setting the user check

3.2 Setting the user check

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

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

Kind of check
Calendar
Energizing
Servo ON

Operation

Table 3.2.2

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

Kind of check
Calendar

Arc ON
Welding counts

Consumption of wire

INFO.

3-2

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

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

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

3.2 Setting the user check

Setting up the check item for the mechanism

1

Open <Service> - [25.Robot Diagnosis] - [5.User Check].

The list screen of the user check items is displayed.

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

Move the cursor to the content field and press [Enter].

The setting screen of the user check items is displayed.

The setting items and the display contents are as follows.

3-3

3.2 Setting the user check

Table 3.2.3
Items
Mechanism No.
No
Content

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

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

Calendar

3-4

Note that press [ENABLE] + [Edit] to configure the settings. Edit

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

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

Set the check content and press f12 <Complete>.

The previous setting screen is returned.
The set check content is displayed in the content field.

3.2 Setting the user check

Setting up the check item for the arc welding

1

Open <Service> - [25.Robot Diagnosis] - [5.User Check].

The list screen of the user check items is displayed.

Select Welder for Check object.

Then, move the cursor to the welder field to select the welding power supply to be
checked.

Move the cursor to the content field and press [Enter].

The setting screen of the user check items is displayed.

Setting items are as follows.

Table 3.2.4 Details of the items
Items
Welder
Kind at time

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

Press f9 <Prev No> or f10 <Next No>, when changing to the different check item
No.

Set the check content and press f12 <Complete>.

The previous setting screen is returned.
The set check content is displayed in the content field.

3-5

3.2 Setting the user check

3.2.2 Allocating input/output signals

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

Input signal

Application

Function.

User chk complete 1 to 8

M1 to M9

Mechanism

User chk complete 1 to 8

W1 to W4

Arc welding power

supply

The inspection timing is reset for the next

checkup. The number from 1 to 8 defined
as the check item No. can be set in each
check item.

Table 3.2.6
Input signal name

Output signal

Application

Function.

User maintenance 1 to 8
M1 to M9

Mechanism

User maintenance 1 to 8
W1 to W4

Arc welding power

supply

The signal of the check item that reaches

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

3.2.3 When reaching the inspection timing

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

Display of the check message

The set check contents

are displayed.

Display of the check items that reach the inspection timing

The items are

highlighted in red.

3-6

3.2 Setting the user check

3.2.4 When check and part replacement are completed

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

User complete operation on the setting screen of user check item

1

Open [5.User Check] in <Service> - [25.Robot Diagnosis].

The list screen of the user check items is displayed.

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

Press f8 <Check Complete>.

The following confirmation screen is displayed.

Select YES and press [Enter].

The selected check item is completed.
If NO is selected, the selected check item cannot be completed.

3-7

3.2 Setting the user check

NOTE

3-8

Chapter 4 Troubleshooting

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

<FLYLEAF>
These white letters will not be printed. Do not delete these letters.

4.1 When failure has occurred

4.1 When failure has occurred

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

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

(1)

Failure category

The name of the failure category appears here.

(2)

Failure code and cause

The failure code and cause appear here.

The failure code is alphanumerically expressed. In the example of
the screen shown above, A2101 is the failure code.

(3)

Details and remedial action

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

(4)

Release method

The method used to release the failure display appears here.

When all the contents of (3) and (4) do not appear in the display
area, scroll the screen using [up or down].

(5)

Number of failure incidents

The figure on the right indicates the number of failure incidents

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

(6)

Date/time of occurrence

The date and time of the failure occurrence appear here.

(7)

F11<Trouble Shooting>

When a failure that requires e.g. parts inspection or parts

replacement occurs, this <Trouble Shooting> will show up here.
(Not all of the errors support this) When this key is pressed, the
inspection/part replacement procedure will be displayed.(Visual
Maintenance Support Function)

(8)

f12 <Failure Reset>

Press this to release the failure display.

The failure display can also be released by pressing [RESET/R]
twice.

4-1

4.2 Concerning the failure details

4.2 Concerning the failure details

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

Failure category

Failure category

4-2

Main failure

Emergency stop failure

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

Control sequence
failure

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

CPU board failure

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

Servo failure

Failure detected by IPM drive unit software.

Amplifier unit failure

Failure detected by IPM drive unit hardware.

Encoder failure

Failure detected by internal of encoder.

Teach pendant failure

Failure detected by teach pendant.

PLC failure

Failure detected by PLC.

User failure

Failure defined by the operator

Operation failure

Failure caused by an operation error made by operator.

Spot welding failure

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

Arc welding failure

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

FieldBus failure

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

Shift failure

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

Auto Calibration failure

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

Sealing failure

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

Vision sensor failure

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

FLEXhand failure

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

Preventive
maintenance message

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

Request maintenance

Message to require the inspection (but not included above)

4.2 Concerning the failure details

4.2.2 Concerning criticality codes and failure codes

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

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

Criticality codes
Details

E (errors)

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

A (alarms)

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

I (Information)

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

(B) Failure codes

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

4-3

4.3 Concerning System Failure

4.3 Concerning System Failure

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

Display example of teach pendant when System Failure occurred

4.3.2 How to recover and response to the failures

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

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

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

4-4

4.4 Recovery after failing of power down detection

4.4 Recovery after failing of power down detection

4.4.1 Recovery after failing of power down detection
If power down detection failed, alarm A0004 Data was not saved correctly when power down. is detected at
the timing of power on, and program / step number is cleared (not selected). In case that Motors/ON/Start sel.
source is set to Controller, program or step number must be selected by teach pendant before initiating
playback operation for safety.
On software version FDV03.28 or later, this safety function is enabled even when Motors/ON/Start sel. source
is set to External. If playback operation is tried without selecting step, error E2518Step number not
designated is detected and playback operation is denied. This error detection is functioning from shipment, so it
is unnecessary to change this setting by following to the procedure written here.
In case of multi-unit specification, program selection or step selection is necessary for each unit.
As an exception, in case that unit is started by CALL or FORK functions, this operation is unnecessary because
started unit program is initiated from step 0.

4.4.2 Setting of start operation permission

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

Select TEACH mode.

Set the operator qualification to EXPERT or higher.

Press <Constant setting> - [5 Operation Constants] - [1 Operation Condition] and

press [Enter].
Following menu will appear.

4-5

4.4 Recovery after failing of power down detection

4

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

Candidates

After step set

No need

4-6

Explanation
When power down detection is failed,
Step number must be selected (step set operation)
before initiating playback operation for safety.
If playback operation is tried without selecting step,
error E2518Step number not designated is detected
and playback operation is denied.
When power down detection is failed,
playback operation is permitted without selecting step.

Press F12 <Complete>.

Setting is stored to memory.

4.5 Troubleshooting

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

4.5.1 Assumed cause of each error code

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

Assumed cause of each error code

Abnormal servo tracking

22

Position Deviation error

24

Servo CPU stop

25

Encoder Bit jump

26

Interference detected

27

Encoder data change after stop

28

Low voltage of motor power

29

Encoder absolute data error

30

Encoder absolute data failure

31

Motor rotation too fast when

turning the motors ON

32

Over current

38

Over load

39

Over rotation

40

The abnormalities in CPU in a T/P

42

Over temperature of motor

43

Over speed

44

Over voltage of motor power

46

Over temperature of regenerative

discharge resister
Encoder counter
overflow/underflow

50

Primary power supply &

ambient temp.

Jig controller

Operation panel / box

Teach pendant

21

Reduction gear

12

The automatic saving function at

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

Motor & encoder

No TP indication

Manipulator & load

None

Control cable (robot wiring)

Riser board

Regenerative resistor

Sequence board

IPM drive unit

CPU board

I/O board

Multi power Supply unit

Arc I/F board

Power unit

Error code

Big possibility, Big possibility or external noise, Moderate possibility, Small possibility

4-7

4.5 Troubleshooting

Encoder battery charge

low

57

Encoder count status

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

62

Primary power supply &

ambient temp.

55

Jig controller

Positional deviation

Operation panel / box

54

Teach pendant

Encoder battery error

Reduction gear

52

Motor & encoder

Encoder data
transmission failure

Manipulator & load

51

Control cable (robot wiring)

Regenerative resistor

IPM drive unit

I/O board

Arc I/F board

Riser board

Sequence board

CPU board

Multi power Supply unit

Power unit

Error code

64

Drive unit power failure

65

Over travel limit switch

activated

66

Low voltage of brake

power

72

Drive unit IPM failure

74

Motor regeneration circuit

fault

78

CPU board power fault.

79

CPU board temperature

fault.

80

CPU board power fault.

81

CPU board battery failure

106

The motors are not ON.

116

TP connect failure

119

The T/P connection is

abnormal.

177

Primary power supply

fault.

379

Safety plug is not inserted or the

state of safety plug signal has
changed in teach mode.

659

Teach pendant touch

panel error.

777

Robot moved during

Motors-ON sequence.

783

Motion stop.

787

Watchdog Timeout Error.

902

servo clock halted

903

Servo communication
stop
Sequence board connect
failure.

904

Big possibility, Big possibility or external noise, Moderate possibility, Small possibility

4-8

4.5 Troubleshooting

Operation panel / box

Jig controller

Abnormal setting of the

I/O board.

967

975

T/P selector switch is set

to MANUAL.
Playback unavailable
because Enable SW is
not released position.
Magnetic switch is not
active.

976

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

1001

PWM was cut off.

1016

1051

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

1052

EXT EMG STOP

SFP

G-STOP
(G_EMG)

TEACH /
PLAYBACK SEL

MAT SW

HI-SPEED
TEACH

EMERGENCY
STOP

1063

T/P EMERGENCY
STOP

1064

CRON

973

1048

1053
1054
1059
1060
1061
1062

The inconsistency was detected in the sequence circuit.

905

2006

T/P selector switch is set

to AUTO.

2101

Stop or External stop

signal being given.

2103

The emergency stop button or the

external emergency stop is
inputted.

2104

External Motors-OFF is
inputted.

2111

Playback unavailable because

Motors-OFF sequence is being
executed.

2106

2002

Playback unavailable because

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

Primary power supply &

ambient temp.

Teach pendant

Reduction gear

Motor & encoder

Manipulator & load

Control cable (robot wiring)

Regenerative resistor

IPM drive unit

I/O board

Arc I/F board

Riser board

Sequence board

CPU board

Multi power Supply unit

Power unit

Error code

Big possibility, Big possibility or external noise, Moderate possibility, Small possibility

4-9

4.5 Troubleshooting

Safety signal input line

failure(Safety plug)

2402

Safety signal input line

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

2973

2974

Pause or External
pause signal being
given.

4002

Can't communicate with

the welding power supply.

4003

Can't communicate with

the welding power supply.

4016

The Arc-I/F is not found.

4920
9208

Servo communication
initialization failure

9209

Brake fuse off

9213

Drive unit power failure

(15V)

9216

Low voltage of sequence

control power supply
An inconsistency was
detected in the servo
failure.

9220

It was not possible to

communicate with the arc
welding power supply.
Shock sensor detected
the collision.

4099

Primary power supply &

ambient temp.

2401

Jig controller

2400

The external operation

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

2112

Operation panel / box

Teach pendant

Reduction gear

Motor & encoder

Manipulator & load

Control cable (robot wiring)

Regenerative resistor

IPM drive unit

I/O board

Arc I/F board

Riser board

Sequence board

CPU board

Multi power Supply unit

Power unit

Error code

9229

Brake fuse off.(F1)

9240

Drive unit power failure

(24V)

9241

Drive unit precharge

failure

9242

Drive unit phase lack.

Big possibility, Big possibility or external noise, Moderate possibility, Small possibility

4-10

4.5 Troubleshooting

4.5.2 Assumed cause of each phenomenon

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

In case of a failure occurring right after program start-up

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

Assumed cause of each phenomenon 1

Error
code

Phenomenon / Error message

None

Power is not turned on.

None
None
None

None
None
None

Teach pendant screen is black.

None
error

is

Part estimated to have caused the error

Connector name
Name of the unit (board)
Primary power
Circuit breaker
U and W
Customers plant
CNPW
Multi power supply unit
CNRSTIN
Power unit
TP cable
CNTP
Sequence board
CNPW
Multi power supply unit
Sequence board (connection)
CNP24V
CNNLX
CPU board (connection)
Multi power supply unit
CNPS
(connection)
TP cable
Teach pendant
CNLAN2
CPU board
TP cable
CNLAN2
Teach pendant
CPU board

TPE0002 communication
displayed on teach pendant

Key operation is impossible on teach

pendant

None

Cooling fan does not function (discharge

resistor / IPM drive unit).

None

CNFAN

Cooling fan does not function (CPU rack).

None

CNFAN

Over travel LS is detected

E0065
E0065
E0065

CNEC1
CN78E

Error in regeneration discharge resistor

temperature rise

E0046

CNR

Error in servo communication start

E9208
E9208
E9208
E9208

10

Drive unit lacking of power phase

E9242

11

Detection of power failure

E0177

CNCOM
CNVP
CNP24V
CNLAN3
Primary power
V
CNPW

TPE0002

Cooling fan

Over travel LS

IPM drive unit

Multi power supply unit

Cooling fan
Multi power supply unit
IPM drive unit
IPM drive unit
Manipulator
IPM drive unit
IPM drive unit
IPM drive unit
Multi power supply unit
CPU board
Circuit breaker
Customers plant
Multi power supply unit

4-11

4.5 Troubleshooting

In case of a failure occurring at the time of servo power ON

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

Assumed cause of each phenomenon 2

Error
code

Phenomenon / Error message

None
1

Power is not turned on.

None
None
None

None
None
None

Teach pendant screen is black

None
3

Teach pendant screen is white.

TPE0002 communication
displayed on teach pendant

Cooling fan does not function (discharge

resistor / IPM drive unit).

None

CNFAN

Cooling fan does not function (CPU rack).

None

CNFAN

Over travel LS is detected

E0065
E0065
E0065

CNEC1
CN78E

Over travel LS

Multi power supply unit

IPM drive unit
IPM drive unit
Manipulator

Error in regeneration discharge resistor

temperature rise

E0046

CNR

IPM drive unit

CNLAN3
CNCOM
CNRST
CNVP
CNP24V
CNPW
CNMS

error

is

TPE0002

Cooling fan
IPM drive unit
Multi power supply unit

Cooling fan

Servo communication stopped

10

Magnet switch contact does not open

E0903
E0903
E0903
E0903
E0903
E0903
E1048

11

Servo error not coincident

E9220

CNSV

12

Shock sensor is detected

13
14
15
16
17

Detection of power failure

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

A4920
A4920
E0177
A0004
E0066
E0783
E0028

CNMCH
CNEC1
CNPW
CNPW
CNRST
CNPW
CNRST

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

E0046

CNR

IPM drive unit

18

4-12

None

Part estimated to have caused the error

Connector name
Name of the unit (board)
Primary power
Circuit breaker
U and W
Customers plant
CNPW
Multi power supply unit
CNRSTIN
Power unit
TP cable
CNTP
Sequence board
CNPW
Multi power supply unit
Sequence board (connection)
CNP24V
CPU board (connection)
CNNLX
Multi power supply unit
CNPS
(connection)
CNTP
Sequence board
TP cable
CNLAN2
Teach pendant
CPU board

4.5 Troubleshooting

In case of a failure occurring during servo operation

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

Assumed cause of each phenomenon 3

Error
code

Phenomenon / Error message

None
1

Power is not turned on.

None
None
None
None
None
None
None

Part estimated to have caused the error

Connector name
Name of the unit (board)
Primary power
Circuit breaker
U and W
Customers plant
CNPW
Multi power supply unit
Power unit
CNRSTIN
TP cable
CNTP
Sequence board
Multi power supply unit
CNPW
Sequence board (connection)
CNP24V
CPU board (connection)
CNNLX
CNTP
Sequence board
TP cable
Teach pendant
CNLAN2
CPU board

Teach pendant screen is black

Teach pendant screen is white.

TPE0002 communication
displayed on teach pendant

Cooling fan does not function (discharge

resistor / IPM drive unit).

None

CNFAN

Cooling fan does not function (CPU rack).

None

CNFAN

Power failure of the servo

Over travel LS is detected

None
E0065
E0065
E0065
E0903
E0903
E0903
E0903
E0903
E0903

CNMS
CNEC1
CN78E

E9220

CNSV
CNMCH
CNEC1
CNPW
CNPW
CNRST
CNVP
CNBK2
CNSW

Multi power supply unit

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

E0074

CNR

IPM drive unit

E0028

CNRST

IPM drive unit

E0046

CNSR

IPM drive unit

error

is

TPE0002

Cooling fan

Servo communication stopped

10

Servo error not coincident

11

Shock sensor is detected

12
13
14
15

Detection of power failure

Announcement of data not saved
Brake power supply voltage drop
Motion stopped

A4920
A4920
E0177
A0004
E0066
E0783

16

Error in motor temperature rise

E0042

17
18
19

Error in motor power supply / regeneration

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

Over travel LS
CNLAN3
CNCOM
CNRST
CNVP
CNP24V
CNPW

IPM drive unit

Multi power supply unit

Cooling fan

4-13

4.6 Displaying the failure log

4.6 Displaying the failure log

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

Displaying the failure log

1

Proceed to <Service Utilities> - [Monitor 1-4] [Failure Log].

The Failure Logging Monitor appears.

Date of failure
occurrence
2

Failure code

Details

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

Date of failure
occurrence

Category of
failure cause

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

4-14

Again, press [Enter].

The details screen closes.

4.6 Displaying the failure log

4.6.1 Function of the failure log monitor

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

Using the display function of failure log monitor

1

Activate the Failure Logging Monitor, and press [Edit].

A title bar on the monitor turns red, and its dedicated soft keys appear.

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

Sort <Date/Code/Prog./Step>
Changes a sorting factor of the failure log.
Since the default is set at Date, the items change in sequence as shown
below by pressing this key every time.
Date

Code

Prog.

Step

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

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

Screen Separation
The screen is split into two sections.

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

Error

Alarm

Information

4-15

4.6 Displaying the failure log

Failure Log Clear

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

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

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

Press [Reset/R] key.

The title bar and soft keys are restored.

4.6.2 Settings regarding the failure log

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

4-16

Constants regarding the failure log

Details

Setting item/
range

Default

Error

Specifies Save/Not save for the failure of

which level of importance is Error.

Save/
Not save

Save

Alarm

Specifies Save/Not save for the failure of

which level of importance is Alarm.

Save/
Not save

Save

Information

Specifies Save/Not save for the failure of

which level of importance is Information.

Save/
Not save

Not save

Separate save

Set this constant to Enable to save failure

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

Disable/Enable

Disable

Info. by failure logs

Specifies Not occur/Occur whether or not to

output the information by the number of
failure logs.
If setting to Occur, Information (I2412) is
output when the remaining of failure logs
reaches the specified number of Remainder
of logs.

Not occur/
Occur

Not occur

Remainder of logs

When setting Info. by failure logs to Occur,

the remainder of logs shall be specified to
output the Information.

099

Info. by separate logs

Specifies Not occur/Occur whether or not to

output the information by the number of logs
to save separately.
If setting to Occur, Information (I2413) is
output when the remaining of failure logs
reaches the specified number of Remainder
of separate logs.

Not occur/
Occur

Not occur

Remainder of separate logs

When setting Info. by separate logs to

Occur, the remainder of logs shall be
specified to output the Information.

0999

4.6 Displaying the failure log

POINT

<Number of failure logs to store>

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

Set the operator qualification to EXPERT or higher in advance.

Configuring the failure log

1

Open <Constant Setting> - [24 Logging Data] [1 Error Logger Item].

The Error Logger Item screen appears.

Configure the log by the following operation.

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

Entering
a value

To change the choice:

Press [Right/Left] with holding [ENABLE].

IMPORTANT

Upon completion of the setting, press f12<Complete>.

The setting is saved to restore the original screen.

To set the Separate save to Enable, an appropriate failure code shall be

designated in advance.

4-17

4.6 Displaying the failure log

Specifying the failure code to save separately

1

Set the Separate save to Enable.

The f8 <Select> soft key appears.

Press f8 <Select> key.

The Select Failure Log screen appears.

Specify the failure code to save separately by the following operation.

To change the failure code input field to configure:
Use [Up/Down] key.
To scroll the page:
Press f9 and f10 <Scroll page> key.

Entering
a value

4-18

To directly enter the value with numerical keys:

Enter a value using the numerical key, and press [Enter].

4.6 Displaying the failure log

To enter the value referring to the registered failure code:
Press f8 <Refer> key.
The Failure code screen appears.

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

Upon completion of the setting, press f12<Complete>.

The failure code to save separately is set, and the Error Logger Item screen is
restored.

4-19

4.6 Displaying the failure log

4.6.3 Failure filtering function

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

POINT

Type of failure
Details

Failure code

Failures of the specified failure code are filtered.

09999

Classification
code

Failures categorized in the specified classification code

are filtered.
For details,
Page 4-2, 4.2.1 Failure category.

Mode

The failures occurred in the specified mode are filtered.

There are two alternatives of mode; Teach mode and
Playback mode.

Teach mode/
Playback mode

Unit

Only the failures of the specified unit number are filtered.

19

Mechanism

Failures occurred in the mechanism of the specified

mechanism number are filtered.

19

Axis

Only servo-related failures occurred in the axis of the

specified axis number are filtered.

19

Welder

Only failures occurred in the welder of the specified

welder number are filtered.

14

Sensor

Only failures occurred in the sensor of the specified

sensor number are filtered.

112

Program

Only failures occurred in the specified program number

are filtered.

09999

Step

Only failures occurred in the specified step number are

filtered.

09999

<Multiple choices of the filtering items>

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

4-20

Setting range in
filtering

4.6 Displaying the failure log

Filtering and displaying the failure

1

Activate the Failure Logging Monitor, and press [Edit].

A title bar on the monitor turns red, and its dedicated soft keys appear.

Press f2 <Filter> key.

The Failure Filtering Setting screen appears.

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

Press [Enable] + [1].

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

Entering a
value

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

To enter the value:

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

4-21

4.6 Displaying the failure log

To select the failure code (available only when the filtering item is set at Failure
code):
Align a cursor on the value input field of failure code.
Then, f8 <Refer> key appears.
Press f8 <Refer> key.
The Failure code screen appears.

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

4-22

Upon completion of the setting, press f12<Complete>.

The Failure Logging Monitor is restored, which displays only a specified failure.

4.6 Displaying the failure log

4.6.4 Displaying the system failure log

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

Displaying the system failure log

1

Activate the Failure Logging Monitor, and press [Edit].

A title bar on the monitor turns red, and its dedicated soft keys appear.

Press f10 <System Failure> key.

The system failure log appear.

Press f10 <Fail Log> key.

The screen returns to 1.

Press [Reset/R] key.

The title bar and soft keys are restored.

4-23

4.6 Displaying the failure log

4.6.5 Frequency of the failure occurrence

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

Monitoring item

Item

Details

Failure code

Graphically displays the frequency of failure occurrence.

Program

Graphically displays the frequency of failure occurrence

by every program.

Program - Step

Graphically displays the frequency of failure occurrence

by every step.

Time

Graphically displays the frequency of failure occurrence

by the time.
It is indicated hour-by-hour between 0 and 23.

User Check

Graphically displays the frequency of failure occurrence

by the time of user check.
Chapter
For details of the time of user check, see
4User Check.

Set the operator qualification to EXPERT or higher in advance.

Graphically displaying the frequency of failure occurrence

1

Activate the Failure Logging Monitor, and press [Edit].

A title bar on the monitor turns red, and its dedicated soft keys appear.

Press f9 <Fail Freq.> key.

The frequency of failure occurrence is graphically displayed.

Monitoring item

4-24

Frequency of failure in
each item

Graphical indication of
the frequency of failure
in each item

4.6 Displaying the failure log

Monitor Item Setting

Specifies the monitoring item for the graph.
Page 4-25, Specifies the monitoring item for frequency.

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

Sort <Val./Item>
Changes the sorting factor either to "Val." or Item.
The default is set at Val.

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

Screen Separation
The screen is split into two sections.

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

Page 4-2, 4.2.1 Failure

Failure Log Clear

Clears the failure log.

Fail Log
The screen returns to 1.

Press [Reset/R] key.

The title bar and soft keys are restored.

Specifies the monitoring item for frequency

1

Press f1 <Monitor Item Setting> key.

The Setting of the Failure Frequency Monitor screen appears.

4-25

4.6 Displaying the failure log

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

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

The setting item and its details are as follows.

Item

Details

User Check Object

Selects Mechanism/Arc welding and its corresponding

number.

User Check Content

Selects the inspection details specified by User Check.

Division unit of user

check

Specifies the unit for each user check time.

Note that the inspection item determines the unit to be used
as shown below.
Check item
Mechanism

Category of time
Calendar
Current-conducting time

Arc welding

Servo ON time

H
H

Calendar

Month

Arcing time

Minute

Number of welding times

4-26

Operating hours

Amount of wire
consumption

Unit
Month

Time
Kg

Upon completion of the setting, press f12<Complete>.

The Failure Logging Monitor is restored, which displays a graph of the specified
items.

4.7 Failure list

4.7 Failure list

All the failure codes are listed from the next page.

4-27

Error code list

No.

Condition

Contents

CPU board
failure
CPU board
failure

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

12

Servo failure

The robot cannot reach

the recorded point.

Error occurs when abnormality is

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

20

Servo failure

Abnormal velocity
command. Modify
abnormal axis motion.

Abnormal velocity command data

is calculated.

21

Servo failure

Abnormal servo
tracking

This failure occurs when the

robot does not follow to the
command position.

22

Servo failure

Position Deviation error

This failure occurs when the

deviation between the command
and encoder data position exceeds
the set permissible deviation.

24

Amplifier
unit failure

Servo CPU stop

This failure occurs when the servo

CPU on servo substrate stops.

25

Servo failure

Encoder Bit jump

This failure occurs when the

amount of the encoder current
position exceeds the borderline for
the encoder bit jump detection.

26

Servo failure

Interference detected

This failure occurs when the robot

manipulator collides with
something.

27

Servo failure

Encoder data change

after stop

This failure occurs when the

encoder data continues to change
while the command position value
is stopping.

28

Amplifier
unit failure

Low voltage of motor

power

This failure occurs when the Motor

power supply voltage(P-N) are
lower than regular setting level.

29

Encoder
failure

Encoder incremental
data error

Error occurs when fault is detected

in the encoder.

2
4

4-28

Class

Please copy the file by the file restore.

Error reset.

Severity
Teach
Auto
Alarm
Alarm

(1)Check the output voltage of the power supply unit

(5V). (2)Replace the power supply unit. (3)Replace the
sequence board.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

(1)Please confirm whether the robot manipulator

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

Please do
error reset or
turn on the
drive
preparation.

Error

Error

Error

Error

on

on

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

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

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

Error

Error

Error

Error

on

on

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

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

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

Error

Error

Error

Error

on

on

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

Error

Error

Error

Error

on

on

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

Error

Error

Error

Error

on

on

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

Error

Error

Error

Error

on

on

Measure

(1)Check the primary power voltage. (2)Check whether

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

(1)Please confirm whether connectors

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

Release

Output
Teach
Auto
Alarm
Alarm

Logger
Teach Auto
on
on

Error code list

30

Encoder
failure

Encoder absolute data

failure

This failure occurs when an

absolote data fault is detected
inside the encoder.

(1)Please turn OFF the controller power. (2)Please

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

31

Encoder
failure

Motor rotation too fast

when turning the
motors ON

This failure occurs if at the time of

turning Motors ON, the encoder
speed is too fast.

(1)Please check the power supply voltage of the

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

32

Servo failure

Over current

This failure occurs when the

current in the drive unit exceeds
the rated value.

33

Servo failure

Synchronous failure of
servo command.

36

Encoder
failure

Encoder Initialize error

Synchronous failure of servo

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

(1)Please check whether the robot manipulator

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

37

Encoder
failure

Over temperature of
encoder

This failure occurs when the

encoder temperature rises
abnormally.

38

Servo failure

Over load

This failure occurs when the

current in the motor or drive unit
exceeds the rated value.

39

Servo failure

Over rotation

This failure occurs when the

number of rotations of motors
exceeds a maximum rotation
speed limit.

40

TP failure

The abnormalities in
CPU in a T/P

CPU built in the teach pendant

stopped.

41

Encoder
failure

Encoder Memory
Access error

Error occurs when fault is detected

in the encoder.

42

Amplifier
unit failure

Over temperature of
motor

This failure occurs when the motor

temperature rises abnormally.

43

Amplifier
unit failure

Over speed

This failure occurs when the

rotation speed of motors is
abnormal.

44

Amplifier
unit failure

Over voltage of motor

power

This failure occurs when the Motor

power supply voltage(P-N) are
higher than regular setting level.

46

Amplifier
unit failure

Over temperature of
regenerative discharge
resister

This failure occurs when the

temperature of the regenerative
discharge resister rises
abnormally.

(1)Please turn OFF the controller power. (2)Please

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

(1)Please confirm that the Pay-load is within the

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

(1)Please check that the Pay-load is within the nominal

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

(1)Check if the fans are operating. (2)Please check the

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

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

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Error reset.

Error

Error

Error

Error

on

on

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

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

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

Error

Error

Error

Error

on

on

Turn on the
power again.

Error

Error

Error

Error

on

on

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

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

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

Error

Error

Error

Error

on

on

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

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

4-29

Error code list

50

Encoder
failure

Encoder counter
overflow/underflow

This failure occurs when the

counter overflow/underflow
occured inside the encoder unit.

(1)Please turn ON the power supply of the controller

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

51

Servo failure

Encoder data
transmission failure

This failure occurs when the

communication data with the
encoder is abnormal or the
encoder has been disconnected.

52

Encoder
failure

Encoder battery charge

low

This failure occurs when the

voltage of the battery in the
encoder has decreased.

(1)Please check whether the connectors

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

53

Servo failure

Invalid encoder type

This failure occurs when the invalid

encoder type is selected.

Please check [Mechine Constants] [Motor and

Encoder][Encoder type].

54

Servo failure

Encoder data abnormal

This failure occurs when the

change of the encoder data is
abnormal.

(1)Please check the supply voltage of the encoder

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

55

Encoder
failure

Motor rotation too fast

when power off

(1)Please reset the encoder and turn on power supply

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

56

Servo failure

Encoder pre-load
failure

Because the motor had been

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

57

Encoder
failure

Encoder count status

failure

This failure occurs when the

Encoder data(absolute) is
abnormal.

59

Control
failure

Can't follow conveyer

speed.

62

Control
failure

Emergency stop was

shortly input or
Magnetic SW was cut
off.

63

CPU board
failure

Controller temperature
fault.

Error occurs when the robot

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

64

Amplifier
unit failure

Drive unit power failure

This failure occurs when drive unit

power VP15(+15V) was not
supplied.

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

replace the drive unit.

65

Amplifier
unit failure

Over travel limit switch

activated

This failure occurs when an axis

reaches the end of its travel and
actuates an Over travel limit switch
(LS).

66

Amplifier
unit failure

Low voltage of brake

power

This failure occurs when brake

power supply PB decreases.

(1) If there is no LS that is being pushed phisically, the

wirings for the LS may be broken. (2) If the LS is
physically being actuated, then move the manipulator
towards the normal motion range by the teach pendant
operation in the setting screen of "software-limit". (3)
Replace the drive unit.
(1)Please confirm the cables of CNBKP-CNPB(drive
unit). (2)Please replace the drive unit.

72

Amplifier
unit failure

Drive unit IPM failure

This failure occurs when current of

power module (IPM) in the drive
unit flows more than permitted
range.

(1)Please confirm internal wirings and the cable

between the controller and the robot
manipulator.(2)Please replace the drive unit.(3)Please
replace the abnormal motor.

74

Amplifier
unit failure

Motor regeneration
circuit fault

This failure occurs when the

regenerative discharge circuit is
disconnected (broken) by large
current or heat.

(1)Please check whether the CNR connector of the

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

4-30

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

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

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

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

(1)Please confirm the supply voltage of the encoder

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

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

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

(1)Please check the wiring of the emergency-stop, the

mode selector switch, and the safety plug. (2)Please
replace the sequence board (UM352(L21700F00)).

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

Error

Error

Error

Error

on

on

Check the fans are operating, or clean up the heat

exchanger.

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

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

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

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Error code list

75

Amplifier
unit failure

Error of brake control

circuit

The breakdown was detected in

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

Please replace the Drive Unit.

78

CPU board
failure

CPU bord power fault.

79

CPU board
failure

80

CPU bord temperature

fault.

This error occurs when the

temperature of the CPU becomes
65 degree or more.

(1)Check the cooling fans on the rack unit are

operating. (2)Clean up the cooling fans.

CPU board
failure

CPU bord power fault.

This error occurs when the power

supply voltage for the CPU
becomes +10% (higher) or
-6%(lower) from the rated voltage.

(1)Check the 5V supply voltage of multi power supply

unit. For details, refer to "CONTROLLER
MAINTENANCE MANUAL". (2)Please replace the multi
power supply unit. (3)Please replace the CPU board.

81

CPU board
failure

CPU board battery

failure

This error occurs when the voltage

of battery on the CPU bord has
decreased.

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

the date correctly.

99

Operational
failure

5th axis operating

range exceeded.

Select [Constants][Machine constants] and use the

correct axis operation keys to move back into the
5th-axis Operating range. Warning! damage can occur
if 5th-axis hits arm 1.

105

Control
failure

Ext. Motors-off' signal

is being given or
Motors-OFF button
being held.

106

Operational
failure

The motors are not ON.

Error occurs when 5th-axis moves

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

116

TP failure

TP connect failure

It becomes this failure when TP

isn't connected and a cable is out.

Connect TP properly. Exchange TP when it is out.

117

TP failure

TP connect failure

Connect TP properly. Exchange TP when it is out.

118

TP failure

The teach pendant

reception is abnormal.

119

TP failure

The T/P connection is

abnormal.

120

TP failure

The T/P connection is

abnormal.

121

Operational
failure

122

Servo failure

The robot's joint angle

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

This error occurs when TP is

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

129

Operational
failure
Operational
failure
Control
failure

The angle which an

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

The 1st arm and the 2nd arm may

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

132

Operational
failure
TP failure

It will become this error if a robot

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

Please move to link software stroke within the limits by

manual operation (each axis).

136

The robot's joint angle

exceeded the link
software stroke range.
TP connect failure

139

TP failure

The T/P connection is

abnormal.

140

TP failure

The abnormalities in
CPU in a T/P

Abnormality was detected by the

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

Please confirm whether there is something that it is

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

177

Emergency
stop failure

Primary power supply

fault.

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

243

Operational
failure

244

Operational
failure

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

Error occurs when the Power

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

130
131

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

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Alarm

Error

Alarm

Error

on

on

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

Error

Error

Error

Error

on

on

Inform
ation

Alarm

Inform
ation

Alarm

on

on

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Please move to software stroke within the limits by

manual operation (each axis).

Error reset.

Alarm

Error

Alarm

Error

on

on

Please motor power on in machine constant/software

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

Error reset.

Error

Error

Error

Error

on

on

Error reset.

Alarm

Error

Alarm

Error

on

on

Error reset.

Alarm

Error

Alarm

Error

on

on

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

Error

Error

Error

Error

on

on

Alarm

Error

Alarm

Error

on

on

Error

Inform
ation

Inform
ation

Inform
ation

on

on

Alarm

Inform
ation

Alarm

Inform
ation

on

on

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

Error

Error

Error

Error

on

on

Alarm

Error

Alarm

Error

on

on

Alarm

Error

Alarm

Error

on

on

(1)Check the 5V supply voltage of multi power supply

unit. For details, refer to "CONTROLLER
MAINTENANCE MANUAL". (2)Please replace the multi
power supply unit. (3)Please replace the CPU board.

Ensure that Motors-OFF is not being given when

pressing Motors-ON button.

Turn motors ON by pressing the Motor-ON button.

Please confirm whether there is something that it is

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

Connect TP properly. Exchange TP when it is out.

Correct the program.

Correct the program.

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

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

No reset
operations
neccesary.
No reset
operations
neccesary.

4-31

Error code list

245

Operational
failure

The bend direction of

J3 axis is different,
interpolation cannot be
continued.

The bend direction of J3 axis is

different at the starting point and
the terminal point.

Please correct the angle of J3 axis to the same

direction.

246

Operational
failure

247

Operational
failure

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

When the posture is calculated,

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

248

Control
failure

250

Operational
failure

The gravity bend

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

251

Operational
failure

The bend direction of

J4 axis is different,
interpolation cannot be
continued.

The flexion it tried to revise, but the

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

Please insert the step in the middle so that the change

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

257

Operational
failure

Pose calculation failed.

270

Control
failure

Conveyer motion
during test .

271

Control
failure
PLC failure

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

379

Control
failure

Safety plug is not

inserted or the state of
safety plug signal has
changed in teach
mode.

493

Operational
failure

Compound motion limit

over.

494

Operational
failure

Over movable area of

ATRAC4 flat type.

550

PLC failure

It is scan time over of

Built-in PLC.

Compound motion J5 and J6 of

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

582

Vision
sensor
failure

Vision sensor not

connected.

It detects, when the vision sensor

is not connected.

Correct vision sensor connection line.

659

TP failure

Teach pendant touch

panel error.

Error occurs if at the time of turning

power ON, the touch panel of teach
pendant is pushed.

Touch panel is not touched for turn power ON again. If

error persists change the Teach pendant.

674

Spot weld
failure

Welder communication
fault(No reply).

675

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

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

(1)Check power supply of the welder and

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

695

Spot weld
failure

LCA EPROM
checksum error.

696

Spot weld
failure

Application EPROM
checksum error.

697

Spot weld
failure
Control
failure

DPR error.

Operational
failure

The angle between 3rd

axis and ground is
over.

Error occurs when the welder

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

367

676
677
694

704

705

4-32

Executive EPROM
checksum error.

Invalid Conveyer
register value.

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

Alarm

Error

Alarm

Error

on

on

Alarm

Error

Alarm

Error

on

on

No reset
operations
neccesary.

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

No reset
operations
neccesary.
No reset
operations
neccesary.

Alarm

Error

Alarm

Error

on

on

Alarm

Error

Alarm

Error

on

on

Alarm

Error

Alarm

Error

on

on

Error

Error

Error

Error

on

on

Stop the conveyer, reset, and restart test.

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

Error

Error

Error

Error

on

on

Check that the pulse generator is functioning correctly.

Error reset.

Error

Error

Error

Error

on

on

Check the environment of Built-in PLC of operation.

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

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

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

Alarm

Error

Alarm

Error

on

on

Alarm

Error

Alarm

Error

on

on

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Error

Error

Error

Error

on

on

Install the system software once more.

Turn on the
power again.

Error

Error

Error

Error

on

on

Install the system software once more.

Turn on the
power again.

Error

Error

Error

Error

on

on

Install the system software once more.

Turn on the
power again.

Error

Error

Error

Error

on

on

Install the system software once more.

Turn on the
power again.
Error reset.

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Error reset.

Alarm

Error

Alarm

Error

on

on

This error occurs when all axis

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

Check pose data.

This error occurs when a Motors

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

Insert the Safety plug in Auto mode.

Please move to the limit by manual operation (each

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

Check a conveyer pulse input circuit.

Please move in the direction where 3rd angle incline

does not take place by manual operation.

Error code list

706

Operational
failure

727

Servo failure

749

Spot weld
failure

Spot Welder SCR1

thermal switch
actuated.

This failure occurs when the

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

750

Spot weld
failure

Spot Welder SCR2

thermal switch
actuated.

Failure occurs when the Thermo.

Temp. fault signal is received by
the controller.

Check the Thermo. Temp. fault signal and the spot

welding unit.

759

Spot weld
failure

Isolation contact failed

to pull in.

Failure occurs when the isolation

contact of the welder fails to
actuate correctly.

Refer to the Welder timing Manual.

760

Spot weld
failure

Isolation contact stuck

close.

Failure occurs when the isolation

contact of the welder fails to
actuate correctly.

Refer to the Welder timing Manual.

762

Spot weld
failure

Welder board not

installed.

Install the welder board.

777

Control
failure

Robot moved during

Motors-ON sequence.

Error occurs if the welding timer

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

783

CPU board
failure

Motion stop.

This error occurs when the main

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

785

CPU board
failure
CPU board
failure

I/O timeout.

It becomes this error when main

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

788

CPU board
failure

Movement too large in

Compliance control.

Error occurs when movement by

an external force is too large while
in Compliance control.

789

CPU board
failure

CPU error.

It becomes this error when an CPU

error occurs in CPU board.

895

Control
failure

Conveyer not running.

897

Control
failure

Too little conveyer

pulse counted.

898

Servo failure

Servo command stop

Error occurs when conveyer pulse

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

902

Amplifier
unit failure

serveo clock halted

This failure occurs when the clock

of servo board
UM351(L21700X00) halted.

(1)Please confirm the supply voltage of the servo board

UM351(L21700X00). (2)Please replace the drive unit.

903

Amplifier
unit failure

Servo communication
stop

This failure occurs when the

communication between CPU
board and the servo board stops.

(1)Please confirm whether connector CNCOM of servo

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

904

CPU board
failure

Sequence board
connect failure.

Please check whether the sequence board is correctly

connected or not.

905

CPU board
failure

Abnormal setting of the

I/O board.

910

Amplifier
unit failure

Abnormal output of the

servo gun pressure
sensor.

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

787

The angle between

flange and ground is
over.
Robot over
temperature

Watchdog Timeout
Error.

The flange tended to operate

exceeding flange incline.

Please move the manipulator towards the normal

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

Error reset.

Alarm

Error

Alarm

Error

on

on

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

Error

Error

Error

Error

on

on

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

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

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

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

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

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

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

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Error reset.

Error

Error

Error

Error

on

on

Separate input timing of a starting command from

conveyer start LS signal.

Error reset.

Error

Error

Error

Error

on

on

Please refer to the troubleshooting of the controller

maintenance manual.

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

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

(1)Please check the connectors CNP1-CNP5 on the

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

(1)Turn on the power again. Please confirm the error is

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

Check DIP-SW on the I/O board.

Turn on the
power again.

Error

Error

Error

Error

on

on

Please check 1) connector on the analog sensor board,

2) the conection between pressure sensor and robot
controller, 3) exchange new pressure sensor.

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

Error

Error

Error

Error

on

on

4-33

Error code list

911

Amplifier
unit failure

Autozero failure of
analog input.

Beause analog input signal has the

offset value, autozero cannot be
executed.

Please check 1) connection of analog input line 2)

analog input signal by its manual.

919

Operational
failure

The allowed
unbalanced torque is
exceeded.

This failure is detected when

moving to the position in which the
allowed unbalanced torque is
exceeded.

920

Operational
failure

Robot tended to
operate exceeding Y
asix motion limit.

Robot tended to operate exceeding

the operating area determined by
the mechanism.

921

Operational
failure

Robot tended to
operate exceeding rear
motion limit.

Robot tended to operate exceeding

the operating area determined by
the mechanism.

956

FieldBus
failure

The communication
error occurred.

The details of a communication

error should check a sub code.

(1)Please move the robot to the position in a

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

957

FieldBus
failure

The system error was

detected.

The details of a communication

error should check a sub code.

On the fieldbus hardware setting screen, check whether

the settings are correct.

958

FieldBus
failure

The error was detected

with the self check of a
communication board.

The defect of a communication board is considered.

959

FieldBus
failure

A communication
board is not found.

They are the abnormalities of a

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

960

FieldBus
failure

A part or all I/O links

are stopping.

Since the between title has

occurred in the I/O device, a robot
cannot be started.

Please check the device which the problem has

generated by the field bus monitor.

967

Control
failure

T/P selector switch is

set to MANUAL.

Playback operation is impossible

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

(1)Set the T/P selector switch to AUTO. (2)Please

replace the T/P. (3)Please replace the sequence board
(UM352(L21700F)).

975

Control
failure

Magnetic switch is not

active.

This error occurs when a signal

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

(1)Please check the cable of the power unit and the

drive unit. (2)Please replace the sequence board
UM352/L21700F00. (3)Please replace the multi power
supply unit.

976

Control
failure

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

This error occurs when the

Confirm magnet-ON (Fixed input
IN28) is unexpectedly cut OFF
during motor power ON condition.

(1)Please replace the power unit. (2)Please replace the

sequence board (UM352/L21700F00).

977

Control
failure

Both teach and

playback mode signal
is not fixed.

Neither teach mode nor playback

mode signal is turned ON.

Please confirm the operation mode signals connection.

1001

Control
failure

PWM was cut off.

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

1003

Control
failure

1012

Control
failure

Analog input board is

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

Error occurs when software can't

be selected the cause which a
PWM signal was cut off.
Although analog input (output)
board is not installed, analog input
(output) function is executed.

1016

Encoder
failure

1024

Servo failure

4-34

Error

Error

Error

Error

on

on

Alarm

Error

Alarm

Error

on

on

No reset
operations
neccesary.

Alarm

Error

Alarm

Error

on

on

No reset
operations
neccesary.

Alarm

Error

Alarm

Error

on

on

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

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Turn off the power and connect analog Input (output)

board correctly.

Error reset.

Error

Error

Error

Error

on

on

This error occurs when PWM is not

turned off even if a certain time
passes after the mechanism
diconnection.

There are some problems in the brake and the PWM

control circuit of sequence PCB. Please replace the
sequence PCB or the drive unit.

Error

Error

Error

Error

on

on

Manipulator battery
warning

This warning occurs when the

voltage of the battery in the robot
manipulator decreases.

(1)Please exchange the battery referring to Instruction

Manual "Manipulator". (2) Please perform the Encoder
Reset and Encoder Correction.

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

Robot over
temperature

This failure occurs when the

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

(1)Please confirm that the Pay-load is within the

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

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

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

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

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

Error code list

1046

Control
failure

Master-ON circuit is
inconsistent.

1048

Control
failure

The magnetic switch

contacts were welded
and stick each other.

(1)This error occurs when the

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

1049

Spot weld
failure

This IWB does not

support MFDC

Error occurs when the IWB version

is old.

1051

Control
failure

The inconsistency was

detected with the
sequence circuit.(TP
enable switch)

This failure occurs when the

inconsistency or abnormal was
detected in duplicated signal at the
TP enable switch.

(1)Please check whether only one of signals is input or

only one contact is weld at the TP enable switch.
(2)Please replace the sequence board
UM352/L21700F00.

1052

Control
failure

Control
failure

This failure occurs when the

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

(1)Please check whether only one of the signals is input

or only one contact is weld at the external emergency
stop. (2)Please replace the sequence board
UM352/L21700F00.

1053

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

1054

Control
failure

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

This failure occurs when an

inconsistency or abnormality was
detected in the duplicated signal
circuit for the G-STOP input.

(1)Please check whether only one of the signals is input

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

1055

Spot weld
failure

The welder board failed

in initialization.

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

circuit board.

1056

Spot weld
failure

1058

Spot weld
failure
Control
failure

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

Error occurs when the initialization

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

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

This failure occurs when an

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

(1)Please check whether only one of the signals is input

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

1059

1060

Control
failure

1061

Control
failure

1062

Control
failure

1063

Control
failure

1064

Control
failure

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

This failure occurs when an

inconsistency or abnormality was
detected in the duplicated signal
circuit for the CRON input.

1065

Spot weld
failure

The welder is not

initialized.

Error occurs when the initialization

of the welder is not complete.

1068

Spot weld
failure
Arc try
condition file

The contents of a VSF

file are not correctly.
Robot monitoring unit
Encoder failure.

It generates, when the contents of

a VSF file have a error.
This failure occurs when the
Encoder data(absolute) is
abnormal.

1101

Arc try
condition file

The robot's joint angle

exceeded the software
stroke range.

It will become this error if a robot

joint angle reaches the software
stroke range.

1102

Arc try
condition file

Position exceeded the

limit area.

The position of a limit object

exceeded the limit area.

1103

Arc try
condition file

Robot monitoring unit

Speed failure.

This failure occurs when the

Encoder data(absolute) is
abnormal.

1100

This failure occurs when an

inconsistency or abnormality was
detected in the duplicated signal
circuit for the T/P emergency stop.

(1)Replace the sequence board UM352/L21700F00.

(2)Replace the power unit.

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

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

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

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Power ON again after executing R930, and confirm

each parameter of the timer.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Replace the timer PCB (PMU).

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

(1)Please check whether only one of the signals is input

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

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

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

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

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Failure reset.

Error

Error

Error

Error

on

on

Failure reset.

Error

Error

Error

Error

on

on

(1)Please check the cables (from the power unit to the

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

(1)Please check whether only one of the signals is input

or only one contact is weld at the safety plug. (2)Please
replace the sequence board UM352/L21700F00.

(1) Check power supply of the welder and

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

After pressing LS release button, press master ON

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

4-35

Error code list

1104

Arc try
condition file

Robot monitoring unit

over current.

Over current detected.

Removal failure.

1105

Arc try
condition file
Arc try
condition file

Robot monitoring unit

disparity failure.
Robot monitoring unit
internal failure.

This failure occurs when the safety

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

Removal failure.

1107

Arc try
condition file

Robot monitoring unit

does not be approved.

Please approve the parameter of the robot monitoring

unit.

1108

Arc try
condition file

Robot monitoring unit

communication stop.

This failure occurs when the

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

1109

Arc try
condition file

Robot monitoring unit

Stop monitor failure.

1110

Arc try
condition file

1111

Arc try
condition file

1112

Arc try
condition file

1113

Arc try
condition file

Robot monitoring unit

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

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

1114

Arc try
condition file

Robot monitoring unit

Tool monitor failure.

Please confirm the input sigal "Tool number".

1115

Arc try
condition file

Robot monitoring unit

tool postere failure.

1116

Arc try
condition file

Robot monitoring unit

safety communication
failure.

This failure occurs when there is

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

1120

Operational
failure

Outside tool posture

limit range

1121

Operational
failure

1155

Spot weld
failure

The robot's joint angle

exceeded the zone
limit range.
The welder board failed
in initialization.

After pressing LS release button, press master ON

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

1156

Spot weld
failure

Memory error is
detected by the welder
board.

The tool operated by posture

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

1158

Spot weld
failure
Operational
failure

Nothing acknowledge from timer

controller CPU.
The command position of a limit
object tried to exceed the limit
range.
The current position of a limit
object exceeded the limit area.

Replace the timer PCB (RE-01).

1106

1171

Operational
failure

1174

Operational
failure

Timer controller CPU is

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

1175

Request
maintenance

Number of servo-off
exceeds the threshold.

1176

Request
maintenance

Number of servo error

exceeds the threshold.

1820

Sealing
failure
Sealing
failure

The gun nozzle is

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

1170

1821

1822

Sealing
failure

1823

Operational
failure

1824

Operational
failure

1825

Operational
failure

4-36

Controller cannot make

trajectory at the
singular area.

Please exchange Robot monitoring unit.

(1)Please confirm whether connector (CNCOM) of robot

monitoring unit is correctly connected. (2)Please
confirm power supply to the robot monitoring unit.
(3)Please replace the robot monitoring unit.

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

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Please input "Stop Monitor Signal".

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

Error

Error

Error

Error

on

on

Please check motors cable and encoder cable.

Failure reset.

Error

Error

Error

Error

on

on

Please check parameters "Pos. Con.".

Failure reset.

Error

Error

Error

Error

on

on

Please check parameters "Vel. Con.".

Failure reset.

Error

Error

Error

Error

on

on

(1)Please confirm the robot monitoring unit connection

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

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

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Failure reset.

Error

Error

Error

Error

on

on

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

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Error

Alarm

Error

on

on

Error reset.

Alarm

Error

Alarm

Error

on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

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

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Failure reset.

Alarm

Error

Alarm

Error

on

on

After pressing LS release button, press master ON

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

Power ON again. If error occurs again, replace the

welder board.

Please confirm setting by [constant:machine

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

Failure reset.

Error

Error

Error

Error

on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Please check the brake.

Error reset.

Error

Error

Error

Error

on

on

Please check the brake.

Error reset.

Error

Error

Error

Error

on

on

Please clean the gun nozzle.

Error reset.

Error

Error

Error

Error

on

on

Please clean the gun nozzle.

Error reset.

Error

Error

Error

Error

on

on

The flow pressure exceeded a set

value.

Please clean the gun nozzle.

Error reset.

Error

Error

Error

Error

on

on

The function which cannot be used

during Adaptive Motion was used.

Please record this function on the step which is not

Adaptive Motion.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Error occurs when movement by

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

Check Adaptive Motion conditions.

Error reset.

Error

Error

Error

Error

on

on

Please modify the teach point.

Error reset.

Error

Error

Error

Error

on

on

Error occurs when a CALL is made

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

Error code list

1826

Sensor
failure

Force sensor input

changed too much.

It is detected when the amount of

change of the force sensor input in
each scanning exceeds error
detection level set in constants.

(1)Please don't give the force sensor much power.

(2)Please confirm whether the the force sensor is
correct. (3)Modify the error detection level.

1827

Sensor
failure

No reaction from force

sensor.

It is detected when the force

sensor input stays in maximum or
minimum value longer than error
detection time set in constants. .

(1)Please confirm whether the the force sensor is

correct. (2)Modify the error detection time.

1828

Welder error
code W2

The shift value or the

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

(1)Modify motion to minimize force(torque). (2)Modify

motion to minimize shift value. (3)Modify the error
detection value.

1829

Welder error
code W2

Abnormal velocity of
axis is calculated by
force control.

It is detected when the shift value

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

1830

Welder error
code W2

The mechanism for

force control cannot be
selected.

(1)Check mechanism number of function parameter.

(2)Modify the program so that there is only one
mechanism under force control condition.

1831

Welder error
code W2

The coordinate for

force control cannot be
selected.

1832

Welder error
code W2

Froce Control function

can not be carried out.

(1)Force control dose not support

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

1833

Welder error
code W2

GETFORCE2 function
can not be carried out.

GETFORCE2 function is already

carried out.

GETFORCE2 function is started after GETFORCE2

function is ended.

1834

Welder error
code W2

Route Coordinata can

not be created under
force control condition.

Modify the robot program.

1835

Welder error
code W2

1836

Sensor
failure

The Tool No. was

changed during force
control motion.
Abnormal zero position
value of force sensor is
detected.

The follows occured under force

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

(1)Please confirm whether the the force sensor is

correct. (2)Modify the error detection level.

1837

Operational
failure

The mechanism not existing

cannot be specified or any
mechanisms other than a
manipulator cannot be specified.

Please correct a program to specify the existing

mechanism number or to specify a manipulator type
mechanism number.

1838

Operational
failure

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

Please re-specify the tool number that is not being

used.

1839

Operational
failure

Tool constant change

amount limit over.

The specified tool number is used

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

2002

Control
failure

Playback unavailable
because Motors-OFF
sequence is being
executed.

This error occurs when an

Motors-ON command is input while
the Motors-OFF sequence is being
executed.

2003

Spot weld
failure

Spot welding function

can not be carried out.

The mistake of the method of

recording the welding function is
found.

2006

Control
failure

T/P selector switch is

set to AUTO.

In Teach mode, Motors are not

able to be ON while T/P selector
switch is set to AUTO.

(1)Please push the Motors-ON button after the

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

2007

Control
failure

Can not turn on the

mortors.

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

2010

Operational
failure

It was going to start

while the work program
was edited on the
screen.

It connects by the normal mode by

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

2021

Operational
failure

WI cancel operation is
disabled. (Servo gun)

This error occurs when WI cancel

is operated during a servo gun
motor power off.

Please operate WI cancel after a motor power on.

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

sensor.

(1)Check the coordinate number of selected contition

as function parameter. (2)Modify the program so that
same coordinate is used under force control condition.

Please record force controlfunction after step 1 or move

step.

Modify the robot program.

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

Please start after ending the editor on the screen.

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

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

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

Error

Error

Error

Error

on

on

Alarm

Alarm

Alarm

Alarm

on

on

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

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Error

Error

Alarm

Alarm

on

on

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

Alarm

Alarm

Alarm

Alarm

on

on

Error

Error

Error

Error

on

on

Error

Error

Alarm

Alarm

on

on

Error

Error

Error

Error

on

on

Error

Error

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

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

4-37

Error code list

2022

Operational
failure

Variable which gives

speed parameter is
invalid.

This error occurs when speed

parameter of Moving command
made by Robot Language is given
by variable and its value is invalid.

Please set value to the variable or change speed

parameter to numerical value.

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

Alarm

Alarm

Alarm

Alarm

on

on

2027

Spot weld
failure

The change in the tip

consumption detected
by search 3 is
abnormal.

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

search 1.

2030

Operational
failure

Designated command
position exceeds Robot
operating area.

The difference between the

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

Alarm

Alarm

Alarm

Alarm

on

on

(1)Please move the robot to the position in a

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

Error reset.

Alarm

Error

Alarm

Error

on

on

2038

Spot weld
failure

2044

Spot weld
failure

The function can not be

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

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Please reconsider the recorded position. If the position

has no problem, replace the Drive Unit

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

2048

Spot weld
failure

2049

Spot weld
failure

2050

Operational
failure

2055

Spot weld
failure

2059

Operational
failure

2060

Operational
failure

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

Use pressures adequate for the Servo gun being used.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Check the peripheral system or welder.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

This error occurs if robot does not

keep the basic position between
multi driven axises.

Return robot to the basic position by manual operation

without Multi Drive Conrtol. If this error occurs again,
check the basic position or the level of error detection.

Error reset.

Error

Error

Error

Error

on

on

Servo Gun Pressure already

achieved to the designated value
for manual operation.

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

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Setting rectangular coordinate

system is different registering the
tool and now.

Please set the tool constant (length and center of

gravity) again by present rectangular coordinate
system. Or, please change setting rectangular
coordinate system.

The error is not

released until
measures are
executed.

Alarm

Alarm

Alarm

Alarm

on

on

Error occurs when 4th-axis moves

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

Select [Constants][Machine constants] and use the

correct axis operation keys to move back into the
4th-axis Operating range. Warning! damage can occur
if 4th-axis hits arm 1.

No reset
operations
neccesary.

Alarm

Error

Alarm

Error

on

on

2062

Spot weld
failure

Weld condition dose

not exist.

Check the desired condition number and retry.

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

The memory medium is

read-only.

When it is going to copy a file to a

write-protected memory cards etc.,
this error sets.

Please prepare the memory medium to which writing is

made and perform a copy from the beginning once
again.

Alarm

Alarm

Alarm

Alarm

on

on

Operational
failure

It cannot process in the

same device.

It was going to copy to the same

device by the same file name.

Please change a file name or a device and redo copy

operation again.

Alarm

Alarm

Alarm

Alarm

on

on

2090

Control
failure

Max. follow angle over.

Check the press syncronize parameters.

Error

Error

Error

Error

on

on

2091

Control
failure

Confirm record point of press synchronous step.

Error reset.

Error

Error

Error

Error

on

on

2092

CPU board
failure
Control
failure

Record point of press

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

Error occurs when the robot was

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

The error is not

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

2063

Spot weld
failure

Weld condition group

number is not set.

2082

Operational
failure

The memory medium is

not prepared.

2083

Operational
failure

2089

Please do playback start from steps other than press

synchronous step.
Set Conveyer shape in Press.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Error

Error

Error

Error

on

on

Please confirm channel number or the slave node

number.

Error reset.

Error

Error

Error

Error

on

on

Release Stop button or External stop signal(if External

stop signal cable is cut the external stop signal is
considered as being given.

Error reset.

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

Please cancel an emergency stop button and an

external emergency stop signal.

Error reset.

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

2093

2100

FieldBus
failure

2101

Operational
failure

2103

Operational
failure

4-38

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

The emergency stop

button or the external
emergency stop is
inputted.

The function was attempted that is

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

Please record weld condition with group

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

Error code list

2104

Operational
failure

External Motors-OFF is
inputted.

2105

Operational
failure

The emergency hold is

inputted.

2106

Operational
failure

2108

Operational
failure

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

2109

Operational
failure

2110

PLC failure

2111

Operational
failure

The internal operation

signal was inputted in
the state of external
selection.

2112

Operational
failure

The external operation

signal was inputted in
the state of internal
selection.

2113

Operational
failure

2118

Shift failure

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

2119

Shift failure

2138

Operational
failure

The command buffer of

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

2141

Operational
failure

2142

Operational
failure

2144

Operational
failure

2145

Request
maintenance

There are signs of

abnormality in the J2
axis

2150

Operational
failure

Program is too large.

Error occurs when number of bytes

of a program is too large.

2151

Operational
failure

The program or the file

does not exist.

This error occurs when the

program number is specified which
does not exist in the program jump
call instruction.

Please correct the program number to a correct value

the jump call ahead.

2152

Operational
failure

The step does not

exist.

This error is detected when the

step number which does not exist
in the step jump call instruction is
specified.

Please correct the step number to a correct value at the

jump destination.

It is not possible to start

by selecting this
function step.
Toyopuc I/F:The
sequence program has
stopped.

In the state where the external

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

Please cancel the external Motors-OFF signal.

Error reset.

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

Please cancel the external emergency hold signal.

Error reset.

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

Please start after turning on MSHP.

Error reset.

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

This It is prohibited to start

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

Please start after specifying the move step.

Error reset.

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

Please select the move step or the function step that

can be executed from, and start.

Error reset.

Alarm

Alarm

Inform
ation

Inform
ation

on

on

Toyopuc I/F:The sequence

program has stopped.

Please confirm Toyopuc I/F.

Error

Error

Error

Error

on

on

It detects, when starting selection

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

Please operate it after setting starting selection or

program selection as an inside.

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

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

Please perform external operation after setting up

starting selection or program selection outside.

Error reset.

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

Please cycle the primary power to initialize the state.

Error reset.

Error

Error

Error

Error

off

off

Setting data in shift register.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Please modify robot program.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

This error occurs when the number

of step call and return instruction is
match or the multiple call exceeds
eight times.

Please correct the program so that the number of call

return instructions is corresponding, and a multiple call
should not exceed eight times.

Alarm

Alarm

Alarm

Alarm

on

on

The unit composition is

a different program.

This error occurs when the

program jump or call instruction
directly jumps or calls the program
that the unit is different.

Please correct the called program number value.

Alarm

Alarm

Alarm

Alarm

on

on

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

This error occurs when the

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

Check the desired program number and retry.

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

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

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

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

Please record the end instruction.

1. Check tool set and in-kind tool number that is

specified by the program. 2. Check the gas pressure of
the gas balancer. 3. Check with the brake release
function J2 axis moves smoothly. 4.Replace the drive
unit 5.Replace the motor.
Edit program in order to reduce its size.

4-39

Error code list

2155

Operational
failure

The usage of the flow

control instruction is
improper..

This error is detected when the

usage of the flow control instruction
is wrong.

Please correct the program so that the usage of the flow

control instruction may become proper.

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

Alarm

Alarm

Alarm

Alarm

on

on

2161

Operational
failure

Change of a coordinate
system cannot be
performed during
circular.

This error occurs if a coordinate

system is changed during circular.

Please teach by the same coordinate system during

circular.

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

2164

Operational
failure

Change of a tool
cannot be performed
during circular.

This error occurs if a tool is

changed during circular.

Please teach by the same tool during circular.

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

2165

Operational
failure

The file is protected.

All protected files or files partially

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

Because the specified file (program or constant)

contains important data, protecting is put so that the
content is not carelessly changed.

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

2166

Operational
failure

The reproduction
protection of the
program is carried out.

The specified work program is not a program which

should be used for operation operation.

2167

Operational
failure

2169

Operational
failure

The amount of the

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

It detects, when it is going to carry

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

Alarm

Alarm

Alarm

Alarm

on

on

Recreate the 10 point program (4 point under tool

constant setting only) ensuring the recorded points are
exactly the same point in space.

Error reset.

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

It is displayed, when the specified

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

Please specify a move function.

Error reset.

Alarm

Alarm

Alarm

Alarm

off

off

2170

Operational
failure

Tool postures differ.

Please make a tool posture the same.

Error reset.

Alarm

Alarm

Alarm

Alarm

off

off

2171

Operational
failure

Tool number do not

match.

Please make a tool number the same.

Error reset.

Alarm

Alarm

Alarm

Alarm

off

off

2173

Shift failure

Shift value limit

exceeded.

Reset the limit value[Constants][Shift limit & evaluation

value] and retry program.

Alarm

Alarm

Alarm

Alarm

on

on

The function which cannot be used

during conveyor synchronization
was used.

Please record this function on the step which is not

conveyor synchronization.

Alarm

Alarm

Alarm

Alarm

on

on

Operational
failure

This function cannot be

available during
conveyor
synchronization.
The file path is not
found.

No reset
operations
neccesary.
Error reset.

2174

Control
failure

2175

The system cannot find the path

specified.

Please check whether a file path is right.

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

2176

Operational
failure

The file access is

denied.

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

on the controller.

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

2177

Shift failure

Move limit during shift

execution exceeded
between steps.

The process cannot access the file

because it is being used by another
process.
This error occurs if the allowable
distance between steps during shift
execution is too large.

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

Alarm

Alarm

Alarm

Alarm

on

on

2181

Control
failure

Conveyer running
signal was not
received.

Conveyer running signal was not

received in conveyer normal mode.

No reset
operations
neccesary.

Alarm

Alarm

Alarm

Alarm

on

on

2185

Operational
failure

Step number selected

is not available.

This error occurs when designated

step number does not exist.

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

2194

Operational
failure

The program is not

recorded nor selected.

This error occurs when the

program which is not recorded is
selclted and start playback.

Please start after recording the program or selecting

other programs.

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

2201

Shift failure

Alarm

Alarm

Alarm

Alarm

on

on

Shift failure

Alarm

Alarm

Alarm

Alarm

on

on

2203

Shift failure

This error occurs when a

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

Correct the sequence of Palletize and Palletize end

functions in the program.

2202

Palletize-end does not

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

Alarm

Alarm

Alarm

Alarm

on

on

2204

Shift failure

Multiplex palletize over.

This error occurs when multiplex

palletize beyond 8 is carried out.

Please confirm a robot program.

Alarm

Alarm

Alarm

Alarm

on

on

2230

Control
failure

Conveyer sync. is not

available.

Enable Conveyer synchronization

Alarm

Alarm

Alarm

Alarm

on

on

2240

Operational
failure

PUBLIC.INC file is
wrong.

Please confirm the definition of variables.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

2241

Operational
failure

COSNT.INC file is
wrong.

Failure occurs if execution of a

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

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

Please confirm the definition of names.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

4-40

1. Please reteach as don't pass wrist dead zone. 2.

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

Terminate the unnecessary palletize.(by using R55 or

R377)
Please refer to palletize data.

Error code list

2242

Operational
failure

Module file is wrong.

2243

Operational
failure

The variable Data file is

wrong.

2244

Operational
failure
Operational
failure
Operational
failure
Operational
failure
Operational
failure

The variable data is an

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

2250

Operational
failure

The step data is

abnormal.

2251

Operational
failure

Incorrect Register or
variable number.

2252

Operational
failure
Operational
failure

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

2254

Operational
failure

2255

Operational
failure
Operational
failure

2245
2246
2247
2248

2253

2256

This failure occurs when the

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

Please confirm the method of the function.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Please set the initial data of variables, after to select

program.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Please set the initial data of variable.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Please review the variable.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Please review the variable.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Error occurs when incorrect

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

Enter the correct register or variable number.

The Dynalog function

command exceeds the
normal range.

This error occurs when an illegal

function command is found while
playback operation, and the robot
stops.

Please set a correct function command again.

Division by 0.

This error occurs when a value is

divided by 0 in robot language file.
Error occurs when input playback
command while it is executing the
compilation process.
The wrist operated by posture
beyond the limits of the posture
limit setting.
Step of the tool where 0 is set to
limit angle the when regulation
effective of wrist posture limit was
played back.
This error occurs when the number
of program reservations exceeds
ten.
Error occurs when a Conveyer
running signal is inputed when
conveyer simulation or test mode.
Error occurs when analog input
override (FN169) and digital input
override (FN277) are played at the
same time.
The specified interruption signal
was not input whiel executing
FN227.
This error occurs when the
program on which the move
command is not recorded before or
after the circle middle point (C1) is
started.
This error occurs when the
program on which the move
command is not recorded before
the circle middle end (C2) is
started.
Error occurs when number of bytes
of a step is too big.
This error occurs when Search
write function is attempted when
not in <1 cycle> mode.
This error occurs when the robot
moves beyond search range

Check the program.

This error occurs if a Search is

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

The Search base step position(s) will be automatically

written into the functions.

2258

Operational
failure

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

2259

Operational
failure

It is the tool which does

not appoint limit angle

2268

Operational
failure

The program can not

reserve any more.

2272

Control
failure

Conveyer running
signal is ON.

2277

Spot weld
failure

2300

Spot weld
failure

Analog input override

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

2301

Operational
failure

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

2302

Operational
failure

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

2303

Step is too big.

2356

Operational
failure
Shift failure

2357

Shift failure

2358

Shift failure

Search base step

position is not defined.

2359

Shift failure

2360

Operational
failure

Search Start not

followed by Search
End.
The setting of a case
jump function is
unsuitable.

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

Please review the variable.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Please confirm the method of the function.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Please set a correct parameter again.

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

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Please confirm the number of variables which are read

or written.
Please correct the parameter.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

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

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

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

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

The number of program reservation should cope with it

by the sequence etc. not to accumulate too much.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Turn off the conveyer running input signal OFF.

Error reset.

Error

Error

Error

Error

on

on

Check the program, and delete function.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Please confirm the state of the sensor, the connection

with the controller and the number of the signal.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Please start after recording a move command before or

after the circle middle point (C1).

This error will

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

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

Please start after the compilation processing ends.

Please operate the robot so that the wrist posture may

operate within the range of the limit.

Please start after recording a move command before

the circle end point (C2).

Modify or delete the step.

Select <1 cycle> mode.

Modify(enlarge) the search range or program to rectify

error.

Alter program to give correct Search start/end

sequence.
Please check a case jump and correspondence of a
case jump end.

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

4-41

Error code list

2361

Operational
failure

It was going to jump

beyond the case jump
range.

This failure occurs when the

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

Please set a correct parameter again.

2367

PLC failure

Scan of Built-in PLC

has stopped.

Although Built-in PLC status is

except <Disabled>, when scan of
Built-in PLC has stopped, it
becomes this error at the time of
robot operation.

Built-in PLC status is set as <RUN> by constant mode,

and scan is started.

2368

PLC failure

Connection with
Built-in PLC cannot be
performed.

It becomes this error when

connection with Built-in PLC
cannot be performed.

Please check the environment of Built-in PLC of

operation.

2369

PLC failure

Built-in PLC cannot be

started.

It becomes this error when Built-in

PLC cannot be started.

Please check the environment of Built-in PLC of

operation.

2370

PLC failure

Built-in PLC cannot be

stopped.

It becomes this error when Built-in

PLC cannot be stopped.

Please check the environment of Built-in PLC of

operation.

2371

PLC failure

There is no resource
performed by Built-in
PLC.

It will become this error if a starting

demand is performed in the state
where there is no resource
performed by Built-in PLC.

Download a PLC ladder program.

2372

PLC failure

PLC-Engine has not

been started.

It becomes this error when it is not

able to start by the starting demand
of PLC-Engine.

Please check the environment of Built-in PLC of

operation.

2373

PLC failure

It becomes this error when an error

is detected by Program check at
the time of PLC-Engine starting.

Please carry out program check by [3 PLC program

check] of [14 PLC program Edit] of Service.

2383

Operational
failure

The error was detected

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

This error occurs when the function

instruction which is not permitted is
setted while playback executing,
and the robot stops.

Please set the function again.

2387

Shift failure

3 of the step points for

On-transfer are in line.

Error occurs when 3 step points

are situated along the same line for
the On-line Transfer(M53,M54).

Designate step positions not in the same line for the

On-line transfer function.

2390

Operational
failure

There is no user
function definition data.

Error occurs when there is no data

which defined the specified user
function.

Create a user function definition file.

2391

Operational
failure

There is no user
function definition data.

Error occurs when there is no data

which defined the specified user
function.

Create a user function definition file.

2400

Emergency
stop failure

Emergency stop signal

input line failure.

This Error occurs when

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

First, release all emergency stop switches, and perform

operation again. If the error recurs, check whether the
emergency stop SW line is correctly wired.

2401

Emergency
stop failure

Safety signal input line

failure(Safety plug)

This Error occurs when

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

First, release sefety plugs, and perform operation

again. If the error recurs, check whether the safety
plug line is correctly wired.

4-42

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

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

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Error code list

2402

Emergency
stop failure

Safety signal input line

failure(Enable/Mat SW)

This error occurs when

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

First, release enable switches, and perform the

operation again. If the error recurs, check whether the
enable switch line is correctly wired.

2410

Operational
failure
Request
maintenance

User failure is not

defined.
It became a check time
limit.

The error file was not found.

Please define Failure by [Service][25 Robot

Diagnosis][6 User Error].
Please do the check completion processing after it
checks.

2412

Request
maintenance

Information by number
of failure log

The number of remainder failure

log reached a set value.

2413

Request
maintenance

Information by number
of another preservation
failure log

The number of remainder another

preservation failure log reached a
set value.

2435

Spot weld
failure

2436

Spot weld
failure

The specified welder

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

2437

Spot weld
failure

Abnormal panel
thickness detected.

2497

FieldBus
failure
FieldBus
failure
Operational
failure

RIO detected the

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

The servo gun connected with the

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

2519

Operational
failure

Please recover the

statement of the
Interface panel.

2527

Operational
failure

File read or write fault.

2528

Operational
failure

The memory medium is

not discriminable.

2530

Operational
failure
Spot weld
failure

Bad program file.

2536

Spot weld
failure

Welder fault.

2537

Spot weld
failure

Welding time exceeded

limit.

2538

Spot weld
failure

The gun not open.

Error occurs if the Gun closed

signal is received after the welding
sequence ends.

Check the GUN or welding unit.

2539

Spot weld
failure

The gun is not half

open.

Check the GUN or welding unit.

2540

Spot weld
failure

The gun is not fully

open.

2541

Spot weld
failure

Stuck Weld GUN

detected.

Error occurs if the Gun half-open

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

2411

2498
2518

2535

File operation of FTP

client is canceled.

check

It failed to save data when the

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

Error occurs when the welding

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

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Inform
ation

Inform
ation

Error

Error

on

on

Inform
ation

Inform
ation

Error

Error

on

on

Error reset.

Inform
ation

Inform
ation

Error

Error

on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Modify the program.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Check the weld condition data and real work piece

thickness.

This error is
released if
restart
playback.
Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

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

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Please try once again, after delete the file.

No reset
operations
neccesary.

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

By Service / File Manager / Format memory

card/Floppy disk, please use it after initializing a
memory medium.

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

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

Alarm

Alarm

Alarm

Alarm

on

on

No reset
operations
neccesary.

Alarm

Alarm

Alarm

Alarm

on

on

This error is
released if
restart
playback.

Alarm

Alarm

Alarm

Alarm

on

on

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

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

The failure log file is backing up preserved if necessary.

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

Please check the connection and the RIO scanner of

the communication cable.
Please exchange the RIO interface.
Please designate a step number and retry.

(1)Please execute "State return" in the Interface Panel

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

Delete the program file.

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

Check the welder is operating normally.

Check the GUN or welding unit.

Error occurs if the Weld stuck signal is received when

the welding sequence ends.

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

4-43

Error code list

2542

Spot weld
failure

Coolant fault #1.

Error occurs if the Water flow

switch #1 signal is detected after
completion of a welding sequence.

Check the GUN or welding unit.

2543

Spot weld
failure

Coolant fault #2.

Error occurs if the Water flow

switch #2 signal is detected after
completion of a welding sequence.

Check the GUN or welding unit.

2544

Spot weld
failure

Air pressure fault.

Error occurs if the Air pressure

switch signal is detected after
completion of a welding sequence.

Check the GUN or welding unit.

2545

Spot weld
failure

Transformer
temperature fault.

Error occurs if the Thermo. temp.

fault signal is detected after
completion of a welding sequence.

Check the GUN or welding unit.

2546

Spot weld
failure

Peripheral system fault.

Error occurs if the System fault

signal is detected after completion
of a welding sequence.

Check the GUN or welding unit.

2552

Spot weld
failure

Both of half-open and

full-open signals are
given.

Check the GUN or welding unit to determine the cause

of the two simultaneous signals.

2555

Spot weld
failure

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

Error occurs if both the Gun

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

2556

Spot weld
failure
Shift failure

2570

Vision
sensor
failure

Vision sensor
communication data
error.

The function was attempted that is

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

Please execute the function after releasing the grip.

2569

The function can not be

used while servo gun is
gripping.
The amount of circle
locus compensation is
unusual.

2571

Vision
sensor
failure

Vision sensor
command/reply buffer
overflow.

Too many commands to vision

sensor or replies from vision
sensor at the same time.

Please modify timing of function execution.

2572

Vision
sensor
failure

Vision sensor
recognition error.

Vision sensor could not recognize

the measure object.

Please check the measure object is within measure

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

2573

Vision
sensor
failure

Vision sensor shift

error.

The measure object isn't within

shift area or vision sensor could not
recognize the measure object.

Please check the measure object is within shift area. If

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

2574

Vision
sensor
failure

Error about frame

grabber.

Frame grabber is out of order.

Please replace the frame grabber board.

2575

Vision
sensor
failure

Image acquire error.

Acquiring image timeout detected.

Or Camera cable is cut / camera is
out of order.

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

camera cable / camera.

2576

Vision
sensor
failure

Vision sensor socket

error.

Fail to create the socket which

connect to vision sensor unit.

Please check setting of connection to vision sensor unit.

2577

Vision
sensor
failure

Vision sensor type

error.

Vision sensor function recorded by

another vision sensor type is done.

Please remove the vision sensor function and record

again.

2578

Vision
sensor
failure

Measure of Vision
sensor is not complete.

Vision measure wait function was

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

Please measure again, or record Vision measure wait

function before Vision shift function.

2579

Vision
sensor
failure

The measurement time

is over.

The measurement processing time

too much or the trigger signal line
has been disconnected.

Please modify the method of measuring the vision

sensor, and check the trigger signal line.

4-44

Please confirm to the sequence of weld-timer.

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

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

This error is
released if
restart
playback.
Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Please modify teaching position.

No reset
operations
neccesary.

Alarm

Alarm

Alarm

Alarm

on

on

Please check hardware of vision sensor.

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

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Error code list

2582

Vision
sensor
failure

Vision sensor
communication data
error.

Error was detected in the data

format which had been sent from
the vision sensor.

Please confirm whether there is loosening of connector.

2583

Vision
sensor
failure

Vision sensor returns

no answer.

It takes time to process the vision

sensor too much.

Please modify setting of the vision sensor.

2584

Vision
sensor
failure

Vision sensor error.

Error was detected in the vision

sensor.

Please refer to the manual of the vision sensor.

2585

Vision
sensor
failure
Vision
sensor
failure

Vision sensor function

can not be carried out.

The function execution by the

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

Please cancel the vision mode, and do the check

go/back.

2586

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

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

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Please slow down the conveyer speed.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

The visual teaching correction

function is set as enable.

Please set the visual teaching correction function to

disable.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

The distance between the

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

Please measure these points again.

Error reset.

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

Please modify the measurement execution timing.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Please check the position of the work.

Error reset.

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

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

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

Alarm

Alarm

Alarm

Alarm

on

on

2587

Spot weld
failure

2588

Vision
sensor
failure

2589

Vision
sensor
failure
Vision
sensor
failure
Vision
sensor
failure

A multiple
measurement
happened.
Shift range over.

Vision sensor error.

Error was detected in the vision

sensor.

Please refer to the manual of the vision sensor.

2592

Operational
failure

Multiple shift failure.

Modify program to rectify error.

2593

Vision
sensor
failure
Spot weld
failure

The measurement time

is over.

2595

Spot weld
failure

2596

Vision
sensor
failure
Vision
sensor
failure

It was going to execute

the function which is
not permitted during
seam welding.
No base position data
set.

A shift, an online transformation,

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

2590

2591

2594

2597

2598

2599

Vision
sensor
failure
Shift failure

Seam welding function

can not be carried out.

Measure point datas is

abnormal.

The measurement type

is abnormal.
Shift register contains
no data.

2601

Operational
failure

Servo gun auto-setting

gets abnormal data.

2605

Operational
failure

User coordinate does

not exist.

2606

Operational
failure

User coordinate is
indefinite.

2607

Operational
failure

2608

Operational
failure

2609

Operational
failure

The user coordinate

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

Please modify the method of measuring the vision

sensor, and check the trigger signal line.

Error reset.

Inform
ation

Inform
ation

Inform
ation

Inform
ation

off

off

Please modify program or constant data.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Please modify program.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

There is no base position before

doing the shift function.

Please register base position.

Error reset.

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

This failure occurs when the

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

(1)Please measure these points again. (2)Please

confirm base positional data.

Error reset.

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

(1)Please confirm the measurement type. (2)Please

use the 'SHIFTR' function at 2D measurement.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Setting data in shift register.

Error reset.

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

(1)Please make the servo gun position more wildly

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

No reset
operations
neccesary.
No reset
operations
neccesary.

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Define User coordinate system(s) in [Service][10 User

Coord. Definition]before attempting to use it.

No reset
operations
neccesary.

Alarm

Alarm

Alarm

Alarm

on

on

Please select stationary tool defined by the world

coordinate using FN67.

No reset
operations
neccesary.

Alarm

Alarm

Alarm

Alarm

on

on

This function is not permitted for

using user coordinate on TCF
coordinate system.
Work coordinate or user coordinate
on TCF coordinate was used for
the manipulator set as the
operation standard mechanism.

Please define user coordinate defined by the world

coordinate.

No reset
operations
neccesary.
No reset
operations
neccesary.

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Please change coordinate.

4-45

Error code list

2610

Operational
failure

Pause substitution
overlaps.

2611

Operational
failure

Modifying user
coordinate failed.

2612

Operational
failure

2613

Operational
failure

2614

Operational
failure

2615

Operational
failure

Multiple execution of
the SEAMANG function
was carried out.
The SEAMANG
function was performed
under permitted
condition.
Tool number has been
changed during
SEAMANG function.
Wrist posture under
using FN289 Wrist
singularity control
function is invalid.

2620

PLC failure

2621

PLC failure

2622

PLC failure

SHARP I/F: CPU error

detected.

2623

PLC failure

SHARP I/F: I/O error

detected.

2624

PLC failure

SHARP I/F: Special I/O

error detected.

2625

PLC failure

SHARP I/F: Option

error detected.

2626

PLC failure

SHARP I/F: Power

error detected.

2627

PLC failure

SHARP I/F: Extend

Power error detected.

2628

PLC failure

2651

PLC failure

SHARP I/F: Sequence

program is stopping.
Toyopuc I/F is a
uninstallation.

2652

PLC failure

Toyopuc I/F:I/O
refreshing has
stopped.

There is no response from

Toyopuc I/F.

Please confirm Toyopuc I/F.

2653

PLC failure

Toyopuc I/F detected the dual port

memory malfunction.

Please refer to the manual of Toyopuc I/F.

2654

PLC failure

Toyopuc
I/F:Abnormality is
found in the dual port
memory.
Error occurred by
toyopuc I/F.

Toyopuc I/F detected the error.

Please refer to the manual of toyopuc I/F.

2655

PLC failure

The communication
with Toyopuc I/F got
the suspension.

The communication with Toyopuc

I/F did the time-out.

The bad electrical contact of Toyopuc I/F or bad

functionality of UM237 is thought.

2656

Spot weld
failure

Current of tip dresser

abnormaled.

This error occurs when the servo

dresser is exceeded beyond
current range.

(1)Please confirm the tip dress condition.(2)Please

confirm the cable between the controller and the servo
tip dresser.(3)Please replace the motor.(4)Please
replace the drive unit.

2657

Spot weld
failure

Tip dresser abnormal.

This error occurs when normal

input signal from tip dresser is lost
during tip dress function.

Please check the normal input signal from the tip

dresser.

2658

Operational
failure

The user window has

not been opened.

The user window has not been

opened.

The user window has not been opened.

2659

Operational
failure

Other user tasks use

the user window.

Other user tasks use the user

window.

Other user tasks use the user window.

4-46

SHARP I/F: JW32CV

module cannot be
recognized.
SHARP I/F: Memory
error detected.

Without executing move command,

pause substitution to the same
mechanism was performed.
Modifying user coordinate failed for
one reason of the followings.
(1)[OZX order] is chosen though it
is instruction of two or less points.
(2)The points are less than three
points. (3)Three points are on the
same line. (4)Position data is not
encoder. (5)User coordinates
register file does not exist.
While performing the SEAMANG
function, the SEAMANG function
was performed again.
The function which uses the analog
input function except SEAMANG
can't be used when SEAMANG
function is used.
The Tool No. can not be changed
during SEAMANG function.

Please teach move command after LETCOORDP

function and execute.

No reset
operations
neccesary.
No reset
operations
neccesary.

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

No reset
operations
neccesary.
No reset
operations
neccesary.

Error

Error

Error

Error

off

on

Error

Error

Error

Error

off

on

Error

Error

Error

Error

off

on

Alarm

Alarm

Alarm

Alarm

on

on

Please confirm setting of JW32CV module.

No reset
operations
neccesary.
This error will
be canceled if
a program is
corrected and
restarted.
Error reset.

FN289 Wrist singularity control

function is execured, wrist posture
must be a level in the robot
coordinate and J4 axis must be
less than +-2 degrees.
When the data exchange with the
module cannot be processed, this
error is detected.
Error occurs when Memory failure
in the JW32CV module self-check
is detected.
Error occurs when CPU failure in
the JW32CV module self-check is
detected.
Error occurs when I/O failure in the
JW32CV module self-check is
detected.
Error occurs when Special I/O
failure in the JW32CV module
self-check is detected.
Error occurs when Option failure in
the JW32CV module self-check is
detected.
Error occurs when Power failure in
the JW32CV module self-check is
detected.
Error occurs when Extend Power
failure in the JW32CV module
self-check is detected.
A sequence program of JW32CV
module is stopping.
Toyopuc I/F is not found.

Before move step execution, (1)Please level the wrist

posture in the robot cooddinate. (2)Please make J4 axis
into less than +-2 degrees.

Alarm

Alarm

Alarm

Alarm

on

on

Refer to the Self-check section of the JW32CV Manual.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Refer to the Self-check section of the JW32CV Manual.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Refer to the Self-check section of the JW32CV Manual.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Refer to the Self-check section of the JW32CV Manual.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Refer to the Self-check section of the JW32CV Manual.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Refer to the Self-check section of the JW32CV Manual.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Refer to the Self-check section of the JW32CV Manual.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Please start a sequence program of JW32CV module.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Please confirm whether Toyopuc I/F is installed.

Please turn on
the power
supply again
after Toyopuc
I/F installs.
Automatically
restores,
when the
problem is
solved.
Automatically
restores, when
the problem is
solved.
Automatically
restores,
when the
problem is
solved.
Please reenter
the power
supply after
removing a
wrong cause.
After removal
of failure,
please turn on
power supply
of the
controller
again.
This error is
released if
restart
playback.
This error will
be canceled if
a program is
corrected and
restarted.
This error will
be canceled if
a program is
corrected and
restarted.

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

Please correct instruction points.

Please modify the program as SEAMANG function will

not be performed again when you use the function.
Please modify the program if you use the SEAMANG
and the function which uses analog input at the same
time.
Modify the robot program as same tool number is used
during SEAMANG function.

Error code list

2660

Spot weld
failure

length of tip dressed

abnormaled.

This error occurs when the dress

length of tip is exceeded beyond
dress length range.

(1)Please confirm the tip dress condition.(2)Please

confirm the tip consumption.

2661

Spot weld
failure

Tip dress cannot be

executed that is servo
gun search write is
enabled.

Servo gun tip cannot be dressing

during of search write.

(1)If tip dress control "servo" then set the tip dress
search write "Enabled", else set the servo gun search
write "Disabled".

2662

PLC failure

2port ram is abnormal.

Abnormality of 2port ram occurred.

Please confirm the contact failure of Toyopuc I/F,

confirm the stop of PC, and confirm reset of PC.

2663

PLC failure

The interface is
abnormal with PC.

Failed in the data reading from PC.

Please confirm the contact failure of Toyopuc I/F,

confirm the stop of PC, and confirm reset of PC.

2669

Shift failure

For glass handling, X bending shift

is calculated too big.

2670

Shift failure

2671

Control
failure

X Bending shift volume

is bigger than the error
limit.
Y Bending shift volume
is bigger than the error
limit.
Conveyer
synchronization not ON

2672

Shift failure

2673

Shift failure

2674

Shift failure

Sensors don't turn

on.(ALIGMNENT)

2675

Shift failure

2676

Shift failure

Bending shift volume is

bigger than the error
limit.
No support function for
SJ type manipulator.

2677

Spot weld
failure
Spot weld
failure

Major Welder
error(Fault).
Welding command is
not execute.

2679

Shift failure

2680

Operational
failure

2681

Operational
failure

2682

Shift failure

2683

Shift failure

Torsion shift volume is

bigger than the error
limit.
The position of X1
exceeded the amount
of the compulsion
return.
The position of X1
exceeded the record
position tolerable
quantity.
Sensors don't turn
on.(MAPPING)
Glass Handling : The
SJ type manipulator's
1st and 2nd arms are
unbalanced.

2684

Shift failure

2685

Shift failure

2686

Shift failure

2687

Spot weld
failure
Spot weld
failure

2678

2688

Usage of MAPPING
function is wrong.
Usage of ALIGNMENT
function is wrong.

Glass Handling :
Dynamic twisted
correction value
over.(Accelerating
revision)
Glass Handling :
Dynamic twisted
correction value
over.(Teach point
revision)
Glass Handling :
Dynamic twisted
correction value
over.(Position)
Major Welder error.
Welding command is
not execute.

2698

Operational
failure

Data level too low for

Auto tool load center
setting.

2699

Operational
failure

2701

Spot weld
failure

The measurement
result of the automatic
setting of tool moment
of inertia is abnormal.
Servo gun pressure is
not achieved.

Modify XY bending table to correct value.

After removal
of failure,
please turn on
power supply
of the
controller
again.
After removal
of failure,
please turn on
power supply
of the
controller
again.
Please reenter
the power
supply after
removing a
wrong cause.
Please reenter
the power
supply after
removing a
wrong cause.
Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

For glass handling, Y bending shift

is calculated too big.

Modify XY bending table to correct value.

Error reset.

Error

Error

Error

Error

on

on

Error occurs if a command or

function is attempted requiring
Conveyer synchronization ON.
MAPPING function is re-executed
while MAPPING execution.
ALIGNMENT function is
re-executed while ALIGNMENT
execution.
There was no input of alignment
sensors while ALIGNMENT
searching.
For glass handling, bending shift is
calculated too big.

Turn Conveyer synchronization ON

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Modify program to rectify error.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Modify program to rectify error.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Confirm that the work passes on the alignmnet sensors.

Adjust sensor sensitivity. Confirm connection from
sensors.
Modify bending table to correct value.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Error

Error

Error

Error

on

on

This error occurs if no support

function for SJ is executed.

No support function is not used.

Alarm

Alarm

Alarm

Alarm

on

on

Remove the cause of the error.

No reset
operations
neccesary.
Error reset.

Error occurs when the welder

board generate the error(Fault).
Error occurs when the welder
board abort welding command
sequence.
For glass handling, torsion shift is
calculated too big.

Alarm

Alarm

Alarm

Alarm

on

on

Remove the cause of weld error.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Modify twist table to correct value.

Error reset.

Error

Error

Error

Error

on

on

The position of X1 of the robot

exceeds the amount of the
compulsion return.

Please correct the position of X1 by use of Adjust

Position key.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

The value of X1 in the set step

exceeds the record position
tolerable quantity.

Please set X1 below the record position tolerable

quantity.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

There was no input of alignment

sensors while MAPPING.
For glass handling, the J1 angle of
the earth does not equal to the J2
angle of the earth.

Confirm connection from sensors.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

1) On [Constant Setting]-[Machine
Parameters]-[Encoder Correct], the J1 angle of the
earth equals to the J2 angle of the earth. 2) After the
memory format of the controller, this error occurs. The
encoder correct is exactly executed.
Please take a second look accelerating twisted revision
parameter.

Error reset.

Error

Error

on

on

Error reset.

Alarm

Error

on

on

For glass handling, dynamic

twisted correction value exceeded
error inspection level.

Please take a second look teach point twisted revision

parameter.

Error reset.

Alarm

Error

on

on

For glass handling, dynamic

twisted correction value exceeded
error inspection level.

Please take a second look position twisted revision

parameter.

Error reset.

Alarm

Error

on

on

Error occurs when the welder

board generate the weld error.
Error occurs when the welder
board abort welding command
sequence.
In the automatic tool center of
gravity set function, it is not
possible to calculate by the
gathered current value.
This failure occurs when gathered
speed or current data are
abnormal.

Remove the cause of weld error.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Remove the cause of weld error.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

(1)Teach points that enough unbalanced torque is

exerted on J3,J5 and J6 axis. (2)Make the wrist posture
vary greatly between step 1 and step 2 positions.

No reset
operations
neccesary.

Alarm

Alarm

Alarm

Alarm

on

on

(1)Please correct the teaching so that move range is

wide as much as possible. (2)Please correct the
teaching so that the move axis is not influenced by
gravity.
Error occurs when the set gun pressure is not achieved
within the time period set in [Constant][General
characteristic of Servo Gun].

No reset
operations
neccesary.

Alarm

Alarm

Alarm

Alarm

on

on

This error is
released if
restart
playback.

Alarm

Alarm

Alarm

Alarm

on

on

For glass handling, dynamic

twisted correction value exceeded
error inspection level.

Error occurs when the set gun

pressure is not achieved within the
time period set in
[Constant][General characteristic
of Servo Gun].

4-47

Error code list

2703

Spot weld
failure

GUN SEARCH not

complete.

2710

Spot weld
failure

WI signal does not

become off.

2757

Spot weld
failure

2763

Spot weld
failure

Weld control is not

supported by MEDLAN
command.
Different spot welding
gun mounted.

2781

Spot weld
failure

2782

Spot weld
failure

2783

Spot weld
failure

2784

Spot weld
failure

2785

Spot weld
failure

Welding point is far

from a recorded point.

2786

Spot weld
failure

2790

Operational
failure

It was going to start

while waiting for WI of
manual or external
welding.
Pose calculation failed.

2791

Operational
failure

Error signal detected

during form cutting.

2792

Operational
failure

No current detection
signal turn on.

2793

Operational
failure

Form cutting error.

2800

Operational
failure

Mechanism is not
mounted.

2801

Operational
failure

Sub-mechanism
cannot be selected.

2802

Operational
failure

Mechanism number is
wrong.

2803

Operational
failure

Different mechanism
mounted.

2804

Operational
failure

Conflict of mechanism
change.

2805

Operational
failure

Mechanism number is
wrong.

2806

Operational
failure

The state of the master

mechanism and the
slave mechanism is the
disagreements.

2823

Sealing
failure

2824

Sealing
failure

2825

Sealing
failure

The temperature of the

material exceeded the
upper bound.
The temperature of the
material exceeded the
lower bound.
Flow ready fault.

2826

Sealing
failure

The material is lack.

2827

Sealing
failure

The sealing
incomplete.

4-48

Servo Gun Move-tip

consumption exceeded
maximum limit.
Servo Gun Settle-tip
consumption exceeded
maximum limit.
The difference of tip
consumption is too
large. The
synchronous welding
was not executed.
The synchronous
welding cannot be
executed.

Error occurs when a GUN search

function is abnormally interrupted
by a Spot welding function. Or, the
order of executing the tip
consumption detection is wrong.
Error occurs when a WI signal,
from the last weld sequence,
remains on more than 5s after a
GUN or WELD signal is output by
the controller.
Error occurs when the weld control
software is too old.

Please modify the execution timing of the tip

consumption detection.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Check the welder is operating normally.

This error is
released if
restart
playback.

Alarm

Alarm

Alarm

Alarm

on

on

Install the latest software version.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Error occurs when a gun different

from the gun specified in a Spot
welding function is detected.
Servo Gun Move-tip consumption
exceeded the maximum limit.

Correct the program, otherwise attach the correct gun

before using Spot welding function.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Replace the worn Move-tip and detect tip consumption

again.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Servo Gun Settle-tip consumption

exceeded the maximum limit.

Replace the worn Settle-tip and detect tip consumption

again.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

When the synchronous welding

was executed, the difference of tip
consumption of master gun and
slave gun exceeded the alarm
detection level.
(1)Specified cancer is not
connected. (2)The same welder is
specified. (3)Specified gun is not in
the unit. (4) Guns with different
installation has been selected.
(5)The servo gun exists together to
the air gun. (6)MEDbus welding I/F
is specified in
SYNCSPOT(FN303). (7)MEDbus
welding I/F is not specified in
SYNCSPOTIWB(FN316).
This error occurs when the welding
point is far from a recorded point.

Please execute synchronous welding again after

exchanging the tip, and detecting the tip consumption.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Please reconsider gun/welder number.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Please check not to collide from other equipment.

Please check settings as below, servo gun contact
detect, tool constant parameters, servo gun tip
consumption, servo gun bend characters.
Please start after releasing WI.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

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

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Please input the submechanism input signal correctly,

and using a mount mechanism function.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Please set the mechanism number correctly.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Please correct the program.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Please correct the program.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Please set the mechanism number correctly.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Please connect the mechanism again after separating

the mechanism once.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Please check the temperature adjuster.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Please check the temperature adjuster.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Please check whether the specified pressure is

appropriate.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Please modify the timing of reload.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Please cancel the cause of stopping or modify the

timing to flow after the reload operation is done.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

It will generate, if it starts while

waiting for WI of manual or external
welding.
This error occurs when any axis
angles can not be calculated with
the form parameters.
This error occurs when the error
signal of form cutting is ON during
form cutting..
This error occurs when the current
detection signal isn't turn on at
cutting start.
This error occurs when any trouble
are happen during the form cutting.

Check form parameters.

Error occurs when a mount

mechanism function is attempted
without a mechanism being
attached. Or, the sub-mechanism
input signal line has been
disconnected.
Because two or more
submechanism input signal has
been turned on, the connected
mechanism cannot be selected.
The mechanism number that was
not able to change the mechanism
or was being registered with the
Connection simultaneously mech.
table by the slave was selected. .
Error occurs when a mechanism
different from the mechanism
specified in a step is detected.
Error occurs when the change
function was executed for the
mechanism using other units.
The mechanism number which was
not able to change the mechanism
was selected.
The connection of the mechanism
registered in Connection
simultaneously mech. table of the
mechanism change is a
disagreement.
The temperature of the seal
material exceeded the set upper
bound value.
The temperature of the seal
material exceeded the set lower
bound value.
Error occurs when the set pressure
is not achieved within the time
period set in constant.
The seal material in the pump does
not suffice for the specified
amount.
The robot stopped while flowing or
the pump position reached flow
limit.

Attach a mechanism before using a mount mechanism

function.

Check the cutting controller. Check the connection with

the cutting contorller.
Check the cutting controller. Check the connection with
the cutting contorller.
Check form cutting parameters. And Check the cutting
controller and the connection with the cutting contorller.

Error code list

2828

Sealing
failure
Sealing
failure

The sealing operation

cannnot be executed.
The reload operation is
incomplete.

Sealing
failure
Sealing
failure

Dispense incomplete.

Sealing
failure
Operational
failure

The dispense function

can not be carried out.
The command which is
not permitted was
executed in the
controller with the
force/Torque sensor.

2851

Operational
failure

2852

FLEXhand
failure

The force/torque
sensor function can not
be carried out.
Clamp position limit
over.

2853

FLEXhand
failure

The air assist

mechanism is
abnormal.

2854

FLEXhand
failure

FLEXhand clamping
motion time over.

2855

FLEXhand
failure

Air assist mechanism

does not work.

2856

FLEXhand
failure

Clamp function usage

is wrong.

2857

FLEXhand
failure

Unclamp function
usage is wrong.

2858

FLEXhand
failure

Unclamp direction is
not correct.

2859

Operational
failure

A fetched signal status

has changed.

2860

Operational
failure

Effective steps which

FETCH result is
available was
exceeded.

2861

Shift failure

The designated
palletize No. is not
registered.

2862

Shift failure

The designated
palletize number has
never been executed
yet.

2863

Shift failure

Designate a palletize
number under
execution.

2864

Shift failure

2865

Shift failure

This function is not

supported to the unit
without manipulator.
palletize function can
not be carried out.

2866

Spot weld
failure

Welder fault.

2867

Spot weld
failure

Coolant fault #1.

Error occurs when the Water flow

switch #1 signal is detected in a
welding sequence.

Check the GUN or welding unit.

2868

Spot weld
failure

Coolant fault #2.

Error occurs when the Water flow

switch #2 signal is detected in a
welding sequence.

Check the GUN or welding unit.

2829

2830
2831

2832
2850

The analog input board

is a uninstallation.

Other sealing operation is

executing.
Because Motor's on is turn off
while reloading, reload operation is
not able to be completed.
Reached flow limit.

Please modify the timing of operation.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Please modify the timing of operation.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Please modify the timing to flow after the reload

operation is done.
Please modify setting whether to install the analog input
board.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Please modify program.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Please correct not to use the analog input use function

of a force/torque sensor and others with the same
controller.

No reset
operations
neccesary.

Alarm

Alarm

Alarm

Alarm

on

on

Please modify parameter.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

It detects when clamping motion

quantity exceeds 'Clamp position
limit' setting.
It detects when the air assist
mechanism is located on the
clamping end during the clamp
function is executed.
It detects when clamping motion
time exceeds the setting 'Wait time
for clamp action'.
It detects when input signal from
the air assist mechanism is not
change even if its activation signal
is output.
It detests when FN362 clamp
function is executed again while
FLEXhand is clamping.
It detests when FN363 unclamp
function is executed while
FLEXhand is not clamping.
It detests when FLEXhand tries to
move to clamping direction when
unclamp function is executed.
I-signal status fetched by 'FN528
FETCH' function must not change
before a function referring the
I-signal is executed.
Executed position step number
exceed the setting number of
Effective span of a fetched signal
before reaching the step which is
checked by the signal set by fetch
function.
The palletize pattern of designated
number is not defined.

(1)Confirm a place of the work piece. (2)Confirm the

recorded position of the clamping start step.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

(1)Confirm whether FLEXhand grips the work

correctly.(2)Confirm whether FLEXhand is dropping the
work.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

(1)Confirm FLEXhand clamps the work piece well. if it

doesn't, correct its position or recorded step position.
(2)Correct setting 'Clamping pressure' higher.
Confirm whether the air assist mechanism works
correctly. (2)Confirm whether the signal from the air
assist mechanism is input correctly.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Confirm and correct the program.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Confirm and correct the program.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

(1)Confirm setting of 'Opened finger position'. (2)If the

parameter is 0, the setting 'Standard unclamp distance'
in service menu is used. Confirm the setting.
(1)Control the I-signal status so as not to change until a
function referring the signal is executed. (2)Modify
'FN528 FETCH' recorded step.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

This failure is
released if
restart
playback.
This failure is
released if
restart
playback.

Error

Error

Alarm

Alarm

on

on

Error

Error

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Palletize status is registered in

palletize register when executing it
once, and maintained until
resetting it. This operation cannot
be done to palletize number
unregistered in the palletize
register.
This operation is possible only the
palletize number under execution.

(1)Please designated an executed palletize number.

(2)Please execute palletize of the designated number
even once before doing this operation.

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

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

This error occurs if this function is

executed in the unit without
manipulator.
A move step is needed just after
FN388(PALLET3_SELZ)/FN394(P
ALLET3_SELZJMP) step.
Error occurs when the Welder fault
signal is detected in a welding
sequence.

Do not use this function in the unit without manipulator.

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

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

It is setting which uses the thermo

sensor and the pressure sensor
though the analog input board is
not installed.
Specified gun is not defined in the
unit.
In a controller with the force/torque
sensor, the commands
(SPDDOWNA etc.) which use the
analog input's of those other than a
force/torque sensor cannot be
used.
Force/torque sensor function is
disabled.

(1)Modify 'FN528 FETCH' recorded step. (2)Effective

span of fetched signal can be modified at "Constant
Setting:6 Signals:1 Signal Condition".

(1)Please designated a defined palletize number.

(2)Please define palletize pattern of the designated
number.

(1)Please designated a palletize number under

execution. (2)Please execute palletize of the
designated number before doing this operation.

Please record move step just after

FN388(PALLET3_SELZ)/FN394(PALLET3_SELZJMP).
Check the welder unit.

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

4-49

Error code list

2869

Spot weld
failure

Air pressure fault.

Error occurs when the Air pressure

switch signal is detected in a
welding sequence.

Check the GUN or welding unit.

2870

Spot weld
failure

Transformer
temperature fault.

Error occurs when the Thermo.

temp. fault signal is detected in a
welding sequence.

Check the GUN or welding unit.

2871

Spot weld
failure

Peripheral system fault.

Error occurs when the System fault

signal is detected in a welding
sequence.

Check the System.

2872

Spot weld
failure

The move-electrode
diameter is less than
the minimum diameter.

Replace the worn move-electrode and detect electrode

consumption again.

2873

Spot weld
failure

The settle-electrode
diameter is less than
the minimum diameter.

2880

Spot weld
failure

Corrected value of spot

position is abnormal.

2881

Spot weld
failure

Spot position
correction can not be
carried out.

The move-electrode diameter is

less than the minimum diameter
set by the seam welding
parameters.
The settle-electrode diameter is
less than the minimum diameter
set by the seam welding
parameters.
Corrected value is over to setting
permit value by spot position
correction.
It is in condition which spot position
correction can not be carried out.

2882

Spot weld
failure

2883

Spot weld
failure
Spot weld
failure

The search of spot

position correction
went wrong.
Spot position correct
function fails.
The specified welder is
not effective.

2908

2923

Spot weld
failure

Spot welding gun is not

mechanically
connected

2937

Operational
failure

Speed type endless

cannot be executed.

2938

Operational
failure

The change in an
endless control cannot
be executed.

2939

Operational
failure

The function can not be

used in velocity control.

2945

Operational
failure

Signals of multi input

are not designated.

2946

Shift failure

User coordinate
number is not selected.

2961

FieldBus
failure

Setted area of common

memory is overlapped.

2971

Operational
failure

Stationary tool is not

selected.

2973

Control
failure

Playback unavailable
because the enable
switch is not in the
release position.

2974

Operational
failure

Pause or External
pause signal being
given.

2975

Control
failure
Preventive
maintenance
message

It cannot be started
under G-STOP.
System Memory
Protection disabled

Preventive
maintenance
message

System Memory
Protection disabled

2976

2977

4-50

A work was not able to be detected

by spot position correction.
Internal failure of spot position
correction is detected.
The specified welder is not
effectively set by the spot welding
constant.
It was judged that spot welding gun
was not mechanically connected
because the connection signal was
not input.
Error occurs when speed type
endless was not able to be
executed.

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

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Replace the worn settle-electrode and detect electrode

consumption again.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Please confirm the position of spot welding function.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

(1)Please confirm the not squeeze off. (2)Please

confirm the machine lock and mechanism disconnect
are off. (3)Please confirm the "servo gun teach check"
and "press adjust" are disabled. (4)Spot position
correction with other welder machine be carried out at
ones.
(1)Please confirm parameters of the spot position
correction. (2)Please confirm the recorded position of
spot welding function.
There is no countermeasure in particular.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Modify the welder number.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Connect gun mechanically. When gun is connected,

check the disconnection of the signal line.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Please set the mechanism number again.

The error is not

released until
measures are
executed.
Error reset

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

off

off

Please execute the function after change control type of

change type endless axis to position control.

Error reset

Alarm

Alarm

Alarm

Alarm

off

off

Create the multi input conditions, or replace the function

to normal input.

Error reset.

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

Execute [FN113 Change coordinate for shift] before

shift functions.

No reset
operations
neccesary.
No reset
operations
neccesary.

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Because the endless control

method is not set to "Change", the
specified mechanism cannot be
executed.
The function was attempted that is
not allowable while change type
endless axis is controlled by
velocity control.
Error occurs when a multi input
function was attempted playback
with no condition number.
It is necessary to select user
coordinate number before shift
function at user coordinate.
1.Area of common memory setted
by robot controller is already used
by other node. 2.Since
communication was not able to be
established at the time of power
activation, it was not able to
participate in a network.
Failure occurs when Stationary tool
is not selected although step is
Stationary tool interpolation.
This error occurs when a playback
command was input while the
enable switch is being grasped.

1. Please confirm the endless control method. 2. Please

confirm the mechanism number.

Error occurs when a Start

command is given while the pause
signal is being held or External
pause signal is being given.
Error occurs when a start
command is given under G-STOP.
System Memory Protection is
disabled. You must not turn off the
controller.

Release Pause or External pause signal(if External

pause signal cable is cut the external pause signal is
considered as being given.

System Memory Protection is

disabled. You must not turn off the
controller.

Please change System Memory Protection enable.

1.After change setting into correct one, perform

re-initialization of Fieldbus. 2.Check the connection of a
LAN cable. Turn off the power and replace a LAN cable.

Please select stationary tool using FN67.

(1)Please input the playback command after releasing

the enable switch. (2)Replace the teach pendant.
(3)Replace the sequence board UM352/L21700F00.

Please release G-STOP by turning on G-STOP signal

(TBEX1).
Please change System Memory Protection enable.

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

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Please change
System
Memory
Protection
enable and
restart the
controller.
Please change
System
Memory
Protection
enable and
restart the
controller.

Alarm

Alarm

Alarm

Alarm

on

on

Inform
ation

Inform
ation

Inform
ation

Inform
ation

off

off

Error code list

2978

Preventive
maintenance
message

System Memory
Protection disabled

System Memory Protection is

disabled. You may lost the data of
system memory at power off.

Please change System Memory Protection enable.

Error

Error

Error

Error

on

on

Check the user application.

Please change
System
Memory
Protection
enable and
restart the
controller.
Error reset.

2990

Spot weld
failure
Spot weld
failure
Operational
failure

The user application is

not ready.
No response form the
user application.
Duplicate output signal
attribute.

3010

Control
failure

Far distance between a

current position and a
position at putting
servo-power off.

3018

Spot weld
failure

Weld tip may be worn.

3021

Control
failure

Too far distance

between a current
position and a position
at putting servo-power
off.

3022

Operational
failure

Take care of not

recovering position at
the next servo on.

3037

Spot weld
failure

3051

Control
failure

The external operation

of servo gun is not
permitted while running
program.
Please release both of
the enable swiches.

The user application is not ready or

it stopped.
No response to the specified user
application to the command.
FN35 was going to carried out or
set on output signal which
assigned attribute already.
Since stopping during high-speed
playback and so on, robot couldn't
normally stop on the trajectry.
Since the distance is over the limit
for error detection value, robot
can't recovery.
This warning occurs when the
Weld counter exceeds the limit
value.
Since stopping during high-speed
playback and so on, robot couldn't
normally stop on the trajectry.
Since the distance is over the limit
for error detection value, robot
can't recovery.
Since the position for recovery
couldn't recorded, never recover
the position at the next servo on
without related to distance. This
might be occured at servo off
during recovery position.
The external operation of servo
gun was executed while running
program.

Alarm

Alarm

Alarm

Alarm

on

on

Check the user application.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Please clear attribute assignment in order not to

attribute is duplicate.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

If a limit for error detection is too small, change the

value in constant setting. Position Recovery is
invalidated setting both recovery limit values to zero.

Robot can
restart from
there without
reset
operation.

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

Check the Gun tip and reset the counter.

No reset
operations
neccesary.
Error reset.
Robot can't
playback, untill
step is set.

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

Alarm

Alarm

Alarm

Alarm

on

on

There is no way.

No reset
operations
neccesary.

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

Please execute of external operation while program is

stopping or servo gun is separating.

No reset
operations
neccesary.

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

This failure occurs when grasping

the enable swich after detecting
inconsistency without releasing
both of them.
When the startup is input during
the processing execution by text
read/write screen, this error is
output.
At the teach-mode, Enable switch
was not released position and
robot master ON operation was
carried into effect.
This error occurs when detecting
the temperature alarm on the CPU
board.
It was not a connection to the FTP
server that was backing up of an
automatic backup ahead. Or,
neither an initial folder nor the
folder of this name existed on the
home directory of the FTP server.
The thing backed up automatically
cannot be done. The storage
medium is not prepared, and
read-only and memory capacity
shortage, etc. are thought.
When it is going to copy a file to a
write-protected memory cards etc.,
this error sets.

Please release both of the enable swiches.

No reset
operations
neccesary.

Inform
ation

Inform
ation

Inform
ation

Inform
ation

off

off

3057

Spot weld
failure

Cannot startup while

read/write text
executing.

Please input the startup instruction after text read/write

operation ends.

No reset
operations
neccesary.

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

3062

Spot weld
failure

Enable switch is not

released position.

Release Enalbe switch and please perform robot

master ON operation.

No reset
operations
neccesary.

Inform
ation

Inform
ation

Inform
ation

Inform
ation

off

off

3079

CPU board
failure

CPU bord temperature

warning.

(1)Check the fans on the rack unit are operating, or

clean up them. (2)Replace the rack-unit fan. (3)Replace
the CPU board.
Please confirm host name, user ID, password, and
initial folder of ftp client.

Error reset.

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

3081

Operational
failure

Auto backup can't

connect to FTP server
for auto backup.

No reset
operations
neccesary.

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

3082

Operational
failure

Abnormality occurred
while backing up
automatically.

Please confirm the state of the storage medium.

No reset
operations
neccesary.

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

3083

Operational
failure

The memory medium is

read-only.

Please prepare the memory medium to which writing is

made and perform a copy from the beginning once
again.

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

Failure occurs if there is no

memory space left when
attempting to copy to external
device or internal memory.",
The detection reason is that the
specified device was not detected
when the file operation is done.

Create space in current media device or use another.

It will be
canceled if
some keys are
pushed.
No reset
operations
neccesary.

3084

Operational
failure

Media device is full.

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

3085

Operational
failure

The memory media is

not prepared.

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

Because T/P was not connected, it

was not able to access the T/P
external memory.

Please connect T/P.

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

Operational
failure

Auto backup can't

connect to the T/P
external memory for
auto backup.
It failed in the
attestation with TP.

It will be
canceled if
some keys are
pushed.
No reset
operations
neccesary.

3086

Operational
failure

3087

The attestation to TP external

memory went wrong.

Please check connection of TP external memory.

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

3089

Operational
failure

It cannot process in the

same device.

It was going to copy to the same

device by the same file name.

Please change a file name or a device and redo copy

operation again.

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

3097

Spot weld
failure

Cannot startup while

read/write text
executing.

Please input the startup instruction after text read/write

operation ends.

Inform
ation

Inform
ation

Inform
ation

Inform
ation

off

off

3103

Control
failure

In OFF-mode, motors
are not able to be ON.

When the startup is input during

the processing execution by text
read/write screen, this error is
output.
Both of play and teach signal are
OFF.

No reset
operations
neccesary.
It will be
canceled if
some keys are
pushed.
No reset
operations
neccesary.

Inform
ation

Inform
ation

Inform
ation

Inform
ation

off

off

3110

Operational
failure

Number of axes
miss-matched.

Check the program file type is comptible with the

constants currently in use.

Inform
ation

Alarm

Inform
ation

Alarm

on

on

3111

PLC failure

The alarm was

generated by Toyopuc
I/F.

Failure occurs when the number of

axes used in a program is not
compatible with the unit constant
files.
Toyopuc I/F detected the alarm.

No reset
operations
neccesary.
No reset
operations
neccesary.
Automatically
restores, when
the problem is
solved.

Alarm

Alarm

Alarm

Alarm

on

on

2991
2999

If a limit for error detection is too small, change the

value in constant setting.

Whether the device such as memory cards specified by

the file operation menu is correctly installed is
confirmed.

Please confirm play and teach signals are connected

exactly.

Please refer to the manual of Toyopuc I/F.

4-51

Error code list

3112

PLC failure

SHARP I/F: Battery

error occurred.

Warning occurs when the battery

for the memory backup is nothing
or discharged.
It exists together to fieldbus
functions.

Replace the battery for the memory backup.

No reset
operations.

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

3113

PLC failure

3134

Operational
failure

SHARP I/F: It exists

together to fieldbus
functions.
Data given is incorrect.

Disable fieldbus functions, and reenter the power

supply.

Error reset.

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

Data keyed-in is out of range or not

defined.

Input suitable data.

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

Warning is given when the set

warning limit for gun tip
consumption is exceeded. Tip
consumption warning signal is
outputted.
Welder version is unmatched.

Check the lack of gun tip.

No reset
operations
neccesary.
No reset
operations
neccesary.

3137

Spot weld
failure

Servo Gun Dramatic tip

consumption change
detected.

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

3138

Spot weld
failure

Welder version is
unmatched.

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

Welder backup file is

not found.

Welder backup file is not found.

Initialize welder data.

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

Spot weld
failure
Preventive
maintenance
message

Welder error occurred.

Welder detects ALERT or FAULT.

Refer to the Welder Manual.

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

3141

Spot weld
failure

3142

(1)Please execute the grease exchange. (2)Please

refer to the robot maintenance manual for the exchange
method and the exchange part.

Inform
ation
Inform
ation

Inform
ation
Inform
ation

on

The decelerator of the displayed

axis reached at the grease
exchange time.

Inform
ation
Inform
ation

on

It seems to reach at the

grease exchange time.

Inform
ation
Inform
ation

on

on

3147

Preventive
maintenance
message

It seems to reach at the

grease replenishment
time.

The decelerator, the bearing or

balancer of the displayed axis
reached at the grease
replenishment time.

(1)Please execute the grease replenishment. (2)Please

refer to the robot maintenance manual for the
replenishment method and the replenishment part.

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

3148

Preventive
maintenance
message

There is an axis which

exceeds the allowance
and maximum torque.

The presumption generation torque

exceeded a permissible value by
displayed program step and axis.

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

3149

Preventive
maintenance
message

It is a program which
remarkably shortens
longevity.

In the displayed program, longevity

is within at 5000 hours.There is a
possibility which is the program of
call/jump origin when the call/jump
are used.

Error reset.

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

3150

Preventive
maintenance
message

There is a possibility
that the setting of the
load weight and center
of gravity is inapposite.

IIt is detected when there is a big

difference between the longevities
calculated from longevity and the
motor speed calculated from the
current.

Error reset.

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

3151

Operational
failure

The program or the file

does not exist.

This error occurs when the

program number is specified which
does not exist in the program jump
call instruction.

(1)Change to ratings or less when the robot load

condition is investigated, and weight and the wrist
torque exceed it to ratings.(Gravity setting is used)
(2)There is a possibility to exceed the acceleration
which can be used. (Check the step before and after)
(3)There is a possibility with a large interference torque,
too. (Drop the acceleration of the displayed step.)
(1)Change to ratings or less when the robot load
condition is investigated, and weight and the wrist
torque exceed it to ratings. (Gravity setting is used)
(2)The amount of operation is, and the average speed
and the average torque greatly exceed ratings because
of largeness or high speed, and there is a possibility
that longevity has shortened. Reduce the amount of
operation of the object axis or slow down the speed if
there is no obstacle in work. (program diagnosis)
(3)There is a possibility to be generated because the
cycle time is remarkably short. Slow down the speed
overall.
(1)Please confirm whether the setting of the load weight
and center of gravity is correct. (2)Please change to
ratings or less when the robot load condition is
investigated, and weight and the wrist torque exceed it
to ratings. (3)There is a possibility that the trouble
occurs in the robot when not corresponding to the
above-mentioned.
Please correct the program number to a correct value
the jump call ahead.

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

3155

Operational
failure

This robot type is

different.

Please select a suitable program.

Alarm

Alarm

Alarm

Alarm

on

on

3156

Spot weld
failure

Servo Gun Move-tip

consumption
approaching limit.

3157

Spot weld
failure

Servo Gun Settle-tip

consumption
approaching limit.

3158

Spot weld
failure

3159

Spot weld
failure

3160

Spot weld
failure

Servo Gun Move-tip

consumption exceeded
maximum limit.
Servo Gun Settle-tip
consumption exceeded
maximum limit.
The change in the tip
consumption detected
by search 3 is
abnormal.

Error occurs when a program

created for different robot type is
read.
Warning is given when the set
warning for Move-tip consumption
limit is exceeded. Tip consumption
warning signal is outputted.
Warning is given when the set
warning for Settle-tip consumption
limit is exceeded. Tip consumption
warning signal is outputted.
Servo Gun Move-tip consumption
exceeded the maximum limit.

This failure is
released if a
correct
program is
setted and
restart
playback.
Error reset.

3161

Spot weld
failure
Spot weld
failure
Operational
failure

3146

3162
3165

4-52

Servo gun pressure is

not achieved.
GUN SEARCH not
complete.
The file is protected.

Initialize welder data.

After
exchanging
grease, Please
reset at the
[Service][Robo
t
Diagnosis][Gre
ase Exchange
Cycle] menu.
After
replenishing
grease, Please
reset at the
[Service][Robo
t
Diagnosis][Gre
ase Exchange
Cycle] menu.
Error reset.

Check the Gun tip. If tips are good check the setting
otherwise change the tip to the new one, and detect tip
consumption again.

Error reset.

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

Check the Gun tip. If tips are good check the setting
otherwise change the tip to the new one, and detect tip
consumption again.

Error reset.

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

Replace the worn Move-tip and detect tip consumption

again.

Error reset.

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

Servo Gun Settle-tip consumption

exceeded the maximum limit.

Replace the worn Settle-tip and detect tip consumption

again.

Error reset.

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

The difference between the

consumption detected by search 3
and the consumption detected by
search 1 exceeded the search 3
abnormal tip change.
Error occurs when the set gun
pressure is not achieved.
The order of executing the tip
consumption detection is wrong.
All protected files or files partially
protected (program or constant)
tried to be corrected and deleted.

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

search 1.

Error reset.

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

Check the external pressure value.

Error reset.

Inform
ation
Inform
ation
Inform
ation

Inform
ation
Inform
ation
Inform
ation

on

Error reset.

Inform
ation
Inform
ation
Inform
ation

on

Please modify the execution timing of the tip

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

Inform
ation
Inform
ation
Inform
ation

on

on

on

on

Please release
protecting the
file (program or
constant).

Error code list

3168

Preventive
maintenance
message

There is the axis in

1000 hours for
overhaul.

The life time of the axis displayed

with present operated (time to
reaching to longevity) became
1,000 hours or less.
The life time of the axis displayed
with present operated (time to
reaching to longevity) became 0
hour or less.
This error occurs if it starts when
unit is not ready.

Exchange the axis early. After that 0 clearing of

"Consumption time until present".

Error reset.

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

3169

Preventive
maintenance
message

There is the axis in 0

hours for overhaul.

Exchange the axis. After that 0 clearing of

"Consumption time until present".

Error reset.

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

3170

Operational
failure

It was going to start,

when unit was not
ready.

Please check unit ready signal output conditions, and

start after making it the unit ready.

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

Dramatic difference of panel

thickness exists between recorded
value in weld condition and
detected value.
Information occurs when the
temperature of the core of the
controller exceeds 60 . If this state
lasts 10 min, motor power will be
automatically shutdown and E0063
displayed.,
You did re-weld except for the time
of abnormal welding.

Check the weld condition data and real work piece

thickness.

This error is
released if it
starts again
after making it
the unit ready.
No reset
operations
neccesary.

3175

Spot weld
failure

Abnormal panel
thickness detected.

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

3177

CPU board
failure

Controller temperature
fault.

Check the fans are operating, or clean up the heat

exchanger.

No reset
operations
neccesary.

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

3178

Spot weld
failure

Re-weld is not allowed.

Please restart after set a step in auto mode, or do

manual weld.

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

Conveyer running signal was not

received in conveyer normal mode.

In conveyer normal mode, turn on conveyer running

signal.

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

Operational
failure

Conveyer running
signal was not
received.
The program is not
recorded nor selected.

This error occurs when the

program which is not recorded is
selclted and reserve playback.

Please reserve after recording the program or selecting

other programs.

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

3218

Operational
failure

Command not possible

while running program.

Stop the program and retry the command.

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

3353

Operational
failure

It is protected with the

record-disable-switch
or the password.

This command is not able to be

used during the execution of a
program.
It detects, when it is going to
correct or delete the file (a
program, constant) protected with
the password.

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

3354

Servo failure

Rising of motor torque

is observed.

Check whether there is any cause of raising motor

torque, about motors, reduction gears or cables etc.

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

3355

Spot weld
failure

Current feedback of
servo gun is abnormal.

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

3528

Operational
failure

The memory medium is

not discriminable.

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

3536

Spot weld
failure

Welder fault.

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

3537

Spot weld
failure

Welding time exceeded

limit.

Inform
ation

Inform
ation

Inform
ation

on

on

Spot weld
failure

The gun not open.

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

3539

Spot weld
failure

The gun is not half

open.

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

Inform
ation

3538

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

3540

Spot weld
failure

The gun is not fully

open.

Check the GUN or welding unit.

No reset
operations
neccesary.

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

3541

Spot weld
failure

Stuck Weld GUN

detected.

Error occurs if the Weld stuck signal is received when

the welding sequence ends.

Inform
ation

Inform
ation

Inform
ation

on

on

Spot weld
failure

Coolant fault #1.

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

3543

Spot weld
failure

Coolant fault #2.

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

3544

Spot weld
failure

Air pressure fault.

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

3545

Spot weld
failure

Transformer
temperature fault.

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

3546

Spot weld
failure

Peripheral system fault.

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

3552

Spot weld
failure

Both of half-open and

full-open signals are
given.

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

Inform
ation

3542

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

3553

Spot weld
failure

Manual axis moving

cannot be operated
during waiting for WI.

The motor torque in a cycle went

up as compared with the average
value the 10 cycles past.
In the servo gun with pressure
sensor, the axis current to
pressurizing power is abnormal.
When memory media, such as a
FIROPPI disk and an memory
card, are not initialized, this error
occurs.
Error occurs when the welding
timer detected some errors.
Standard welding timer generates
this error when the controller
received the welder fault signal
from welding timer after the end of
welding sequence. Regarding
except standard welding timer,
refer the each operation manual.
Error occurs if a Weld competed
signal is not input before the
designated time period.
Error occurs if the Gun closed
signal is received after the welding
sequence ends.
Error occurs if the Gun half-open
signal is not received after Open
gun half signal is output by the
controller.
Error occurs if the Gun full-open
signal is not received after Open
gun fully signal is output by the
controller.
Error occurs if the System fault
signal is detected after completion
of a welding sequence.
Error occurs if the Water flow
switch #1 signal is detected after
completion of a welding sequence.
Error occurs if the Water flow
switch #2 signal is detected after
completion of a welding sequence.
Error occurs if the Air pressure
switch signal is detected after
completion of a welding sequence.
Error occurs if the Thermo. temp.
fault signal is detected after
completion of a welding sequence.
Error occurs if the System fault
signal is detected after completion
of a welding sequence.
Error occurs if both the Gun
half-open signal and Gun full-open
signal are received simultaneously
after Open gun half signal is output
by the controller.
Error occurs if manual axis moving
during waiting for WI.

No reset
operations
neccesary.
No reset
operations
neccesary.
This error is
released if it
sets a correct
program and
reserve
playback.
No reset
operations
neccesary.
Set the
record-disableswitch to OFF
or release
password
protecting.
No reset
operations
neccesary.
No reset
operations
neccesary.
It will be
canceled if
some keys are
pushed.
No reset
operations
neccesary.

3181

Control
failure

3194

Please release
the WI.

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

Since the specified file (program or constant) contains

important data, protection is applied

Please check the pressure sensor, the axis motor of

servo gun, or those cables connected.
By Service / File Manager / Format memory
card/Floppy disk, please use it after initializing a
memory medium.
Check the welder unit.

Check the welder is operating normally.

Check the GUN or welding unit.

Check the GUN or welding unit.

Check the GUN or welding unit.

Check the GUN or welding unit.

Check the GUN or welding unit.

Check the GUN or welding unit.

Check the GUN or welding unit.

Check the GUN or welding unit to determine the cause

of the two simultaneous signals.

Please releasing WI.

4-53

Error code list

3555

Spot weld
failure
Spot weld
failure

Servo-gun is not
executed to obey the
welder sequence.
Current of tip dresser
abnormaled.

Error occurs when the servo-gun is

not achieved to command
pressure.
This error occurs when the servo
dresser is exceeded beyond
current range.

3656

3660

Spot weld
failure

Current of tip dresser

abnormaled.

3666

Request
maintenance

Cooler fans stopped.

This error occurs when the dress

length of tip is exceeded beyond
dress length range.
Error occurs when cooler fans
stopped.

3667

Request
maintenance

Brake power supply

cooling fan of the drive
unit in has stopped.

Error occurs when Brake power

supply cooling fan of the drive unit
stopped.

3668

Request
maintenance

Brake power supply

cooling fan of the drive
unit in has stopped.

Error occurs when Brake power

supply cooling fan of the drive unit
stopped.

(1)Please check the cable connector CNMCH.

(2)Please confirm internal wirings and the cable
between the controller and the robot manipulator.
(3)Please replace cooler fans. (4)Please replace the
drive unit.

3677

Spot weld
failure

Minor Welder
warning(Alarm).

3678

Spot weld
failure

Weld error reset is not

execute.

3687

Spot weld
failure
Spot weld
failure

Minor Welder error.

3689

Spot weld
failure

RE-01 battery error

Error occurs when the welder

board generate the
warning(Alarm).
Error occurs when welder
command execute without reset
the error.
Error occurs when the welder
board generate the weld error.
Error occurs when welder
command execute without reset
the error.
Lithem battery cannot be used if it
does.

3690

Spot weld
failure

RE-01 battery charge

low

Error occurs when the voltage of

lithium battery on RE-01 bord has
decreased.

Please exchange the lithem batteries referring to the

"RE-01 maintenance manual".

3700

Operational
failure

It stopped in the home

stop position.

Please carry out manual operation again.

3701

Operational
failure

Option un-setting up.

3702

Vision
sensor
failure

Illigal request of
conveyor sync.

3703

Vision
sensor
failure
Vision
sensor
failure

The measurement
number is a unsetting.

It will generate, if it comes to the

position registered by setup of a
home stop position function.
It generates, when it is going to use
the option function which is not set
up.
Conveyor sync. request method is
different from vision sensor
constant setting. Or, it was
requested when edit mode of
vision sensor.
When conveyor sync. is requested,
the measurement number is a
unsetting.
The conveyer speed is too fast.

3688

3704

Weld error reset is not

execute.

The buffer is full. The

measurement result
was not able to be
stored.
The pose search shift
data cannot be
acquired.

3782

Vision
sensor
failure

3790

Encoder
failure

3800

User failure

3810

Spot weld
failure
Operational
failure

Welder communication
fault(No reply).
Welder option isn't set
up.

3812

Spot weld
failure

Welder version is
unmatched.

3813

Spot weld
failure
Spot weld
failure
Spot weld
failure

3811

3814
3872

4-54

Please confirm to the sequence of weld-timer.

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

Error reset.

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

Error

Error

Error

Error

on

on

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

Remove the cause of the warning.

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

Inform
ation

Inform
ation

Alarm

Alarm

on

on

Error reset.

Error reset.

Inform
ation

Inform
ation

Alarm

Alarm

on

on

Remove the cause of weld error.

Error reset.

Inform
ation
Inform
ation

Alarm

on

on

Error reset.

Inform
ation
Inform
ation

Alarm

Error reset.

Alarm

Alarm

on

on

Please exchange the lithem batteries referring to the

"RE-01 maintenance manual".

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

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

No reset
operations
neccesary.
No reset
operations
neccesary.

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

(1)Please confirm the tip dress condition.(2)Please

confirm the cable between the controller and the servo
tip dresser.(3)Please replace the motor.(4)Please
replace the drive unit.
(1)Please confirm the tip dress condition.(2)Please
confirm the tip consumption.
(1)Please check the cable connector CNMCH.
(2)Please confirm internal wirings and the cable
between the controller and the robot manipulator.
(3)Please replace cooler fans. (4)Please replace the
drive unit.
(1)Please check the cable connector CNMCH.
(2)Please confirm internal wirings and the cable
between the controller and the robot manipulator.
(3)Please replace cooler fans. (4)Please replace the
drive unit.

Please set up an option.

Please modify constant setting. Or, cancel edit mode.

Please modify parameters. Or, check input signals.

Please slow down the conveyer speed.

No reset
operations
neccesary.
Error reset.

The shift data corresponding to the

master data number that has been
sent from the vision sensor is not
registered.
The error counter of the encoder
exceeded the setting value.

Please check master data for pose search.

No reset
operations
neccesary.

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

Please check the encoder.

Error reset.

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

The received shift data contains

the status that notifies abnormality.

Please confirm the state of PC that transmits the shift

data.

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

Error occurs when the welder is not

correctly connected.
It generates, when it is going to use
the welder option function which is
not set up.
Welder version is unmatched.

(1)Check power supply of the welder and

communication cables. (2)Initialize welder data.
Please set up an welder option.

No reset
operations
neccesary.
Error reset.

Inform
ation
Inform
ation

Inform
ation
Inform
ation

Inform
ation
Inform
ation

off

off

on

on

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

Welder error occurred.

Welder detects FAULT.

Refer to the Welder Manual.

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

Inform
ation
Inform
ation

Welder detects ALERT.

Refer to the Welder Manual.

Error reset.

The move-electrode diameter is

less than the warning diameter set
by the seam welding parameters.

Please check the electrode. The electrode is not worn

out, and correct the seam welding parameters. The
electrode is worn out, and replace the worn
move-electrode and detect electrode consumption
again..

Error reset.

Inform
ation
Inform
ation
Inform
ation

Inform
ation
Inform
ation
Inform
ation

on

The move-electrode
diameter is less than
the warning diameter.

Inform
ation
Inform
ation
Inform
ation

on

Welder error occurred.

Inform
ation
Inform
ation
Inform
ation

The error counter of the

encoder exceeded the
setting value.
Abnormal shift data
received.

Cannot restore a welding parameter using the backup

data of a welder different in a version.

on

on

on

on

Error code list

3873

Spot weld
failure

The settle-electrode
diameter is less than
the warning diameter.

The settle-electrode diameter is

less than the warning diameter set
by the seam welding parameters.

3960

FieldBus
failure

A part or all I/O links

are stopping.

Since the between title has

occurred in the I/O device, a robot
cannot be started.

3992

Operational
failure
Arc weld
failure

The function was attempted that is

not allowable while mode is
external application.
The welding power supply didn't
respond.

Please execute the function after releasing the external

application mode.

4000

4001

Arc weld
failure

The function can not be

used in external
application mode.
Communication
timeout occurred
between the controller
and the welding power
supply.
Received data failure.

The data which are received from

the welding power supply are
incorrect.

Check the connection of the welding power supply to

the controller.

4002

Arc weld
failure

Can't communicate
with the welding power
supply.

The communication between the

controller and the welding power
supply is shutdown.

Check the connection of the welding power supply to

(L21700S00/UM355).

4003

Arc weld
failure

Can't communicate
with the welding power
supply.

The communication driver detected

the failure.

Check the connection of the welding power supply to

the controller. And check the connection of
UM355(L21700S00) board.

4004

Arc weld
failure

The registration of the

welding power supply
is incorrect.

The kind of registered WPS and

actual WPS are not same, or the
Dip switch setting of Robot I/F
board inside the welding power
supply is wrong.

Register WPS correctly, or set Dip switch of Robot I/F

board correctly.

4005

Arc weld
failure

The welding power

supply of old version is
connected.

The controll software of the

welding power supply is old.

Please update the welding power supply.

4006

Arc weld
failure

Arc weld
failure

The servo of the wire feed control

unit does not turn on/off because
the software of the welding power
supply is old.
The welding power supply doesn't
correspond to the stitch pulse
welding function.

Please update the welding power supply.

4007

The welding power

supply version is wrong
for the servo wire feed
control.
The control software is
abnormal in the
welding power supply.

4008

Arc weld
failure

Arc weld
failure

4010

Arc weld
failure

4011

Arc weld
failure

The arc welding cannot

be done.

4012

Arc weld
failure

4013

Arc weld
failure

The gas mass flow

control function cannot
be used.
The control software is
abnormal in the
welding power supply.

The Synchro-welding is not

executed because the software of
the welding power supply does not
support the Synchro-welding by
CAN communication.
The Synchro-welding is not
executed because the welding
power supply does not support the
Synchro-welding by CAN
communication.
The arc welding power supply
doesn't correspond to the welding
condition slope function.
The arc welding power supply
doesn't correspond to the welding
characteristic data self adjustment
function.
The arc welding power supply
doesn't correspond to the gas
mass flow control function.
The welding power supply doesn't
correspond to the cycle pulsed
welding function.

Please update the welding power supply.

4009

The welding power

supply version does
not support the
Synchro-welding by
CAN communication.
The welding power
supply does not
support the
Synchro-welding by
CAN communication.
The arc welding cannot
be done.

4014

Arc weld
failure

Abnormality occurred by the

communication with the robot
controller or peripherals on the
welding power supply.

4015

Arc weld
failure

The failure occurs in the controller

of the welding power supply.

It was not possible to

communicate with the
robot controller or the
peripherals on the arc
welding power supply.
Microcomputer control
failure occurred in the
welding power supply.

Please check the electrode. The electrode is not worn

out, and correct the seam welding parameters. The
electrode is worn out, and replace the worn
settle-electrode and detect electrode consumption
again..
Please check the device which the problem has
generated by the field bus monitor.

Error reset.

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

If a problem is
solved, it will
restore
automatically.
(In order to
solve a
problem, the
re-injection of
a power supply
may be
required)
Error reset

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

Inform
ation

Inform
ation

Inform
ation

Inform
ation

off

off

Turn on the
controller and
the welding
power supply
again.
Turn on the
controller and
the welding
power supply
again.
Turn on the
controller and
the welding
power supply
again.
Turn on the
controller and
the welding
power supply
again.
After
registeration/s
etting, turn on
the controller
and the
welding power
supply again.
After updating,
turn on the
controller and
the welding
power supply
again.
After updating,
turn on the
welding power
supply again.
The control
software of the
welding power
supply
improves in the
version, and
the power
supply in the
robot controller
and the
welding power
supply is
turned on
again.
After updating,
turn on the
welding power
supply again.

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Please setup the Synchro-welding by RS-422

communication.

Error reset.

Error

Error

Error

Error

on

on

The upgrade should do the software of the arc welding

power supply.

Error reset.

Error

Error

Error

Error

on

on

The upgrade should do the software of the arc welding

power supply.

Error reset.

Error

Error

Error

Error

on

on

The upgrade should do the software of the arc welding

power supply.

Error reset.

Error

Error

Error

Error

on

on

Please update the welding power supply.

Error

Error

Error

Error

on

on

Confirm the connection with the welding power supply

or the peripherals. Or, in the function of the welding
power supply, confirm the the setting of the
transmission rate of the CAN communication .

After updating,
turn on the
welding power
supply again.
Turn the
welding power
supply on
again.

Error

Error

Error

Error

on

on

Turn the welding power supply on again. Confirm an

abnormal display of the arc welding power supply, and
contact our service when abnormality relapses. Back up
files to external CF memory.

Failure reset,
and turn on the
welding power
supply again.

Error

Error

Error

Error

on

on

Check the connection of the welding power supply to

the controller.

The control software of the welding power supply must

improve in the version.

4-55

Error code list

4016

Arc weld
failure

The Arc-I/F is not

found.

Check the connection of the Arc-I/F(L21700S) to the

sequence board(L21700F).

Turn on the
power again.

Error

Error

Error

Error

off

off

Set CAN baudrate 500Kbps. And turn on the power

again.
Please check the connection between the Arc-I/F
board(L21700S) and the sequence board(L21700F).
You might exchange their boards. Please contact our
service department.
Please check the connection between the Arc-I/F
board(L21700S) and the sequence board(L21700F).
You might exchange their boards. Please contact our
service department.
Please update the welding power supply.

Turn on the
power again.
Error reset.

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Error reset.

Error

Error

Error

Error

on

on

The cold tandem

welding function
cannot be used.

The Arc-I/F board(L21700S)

doesn't connect with the sequence
board(L21700F).
CAN baudrate of the Arc-I/F
board(L21700S) couldn't set.
The communication error has
occurred between the Arc-I/F
board(L21700S) and the sequence
board(L21700F).
The communication error has
occurred between the Arc-I/F
board(L21700S) and the sequence
board(L21700F).
The welding power supply doesn't
correspond to the cold tandem
welding function.

4017

Arc weld
failure
Arc weld
failure

CAN baudrate setting

is failure.
The communication
error has occurred.

4019

Arc weld
failure

The communication
test has failed.

4020

Arc weld
failure

Error

Error

Error

Error

on

on

Arc weld
failure

The wire touch

detection cannot be
used.

The welding power supply doesn't

correspond to the wire touch
detection.

Please update the welding power supply.

Error

Error

Error

Error

on

on

4022

Arc weld
failure

The supported function

information of welding
power supply cannot
be read.

Confirm the connection with the welding power supply.

Error

Error

Error

Error

on

on

4085

Arc weld
failure

Error

Error

Error

on

on

Arc weld
failure

There is no response from the arc

welding power supply.

Check the connection of the welding power supply to

(L21700S00/UM355).

Error

Error

Error

Error

on

on

4102

Operational
failure
Operational
failure

In simultaneous weaing, weaving

conditions are not in agreement.
The mechanism number specified
in the 1st parameter is not belong
to current unit.

Please make weaving conditions in agreement.

Turn the
welding power
supply on
again.
Turn the
welding power
supply on
again.
Error reset.

Error

4099

Communication
timeout occurred inside
the welding power
supply.
It was not possible to
communicate with the
arc welding power
supply.
It is weaving condition
disagreement.
Mechanism Error in
External axis relative
move function
(FN407).
Axis Error in External
axis relative move
function
(FN407:RELMOV)
Mechanism type error.

The robot controller does not

receive a information of the
supported function from the
welding power supply when turning
on the power.
The contollor of the welding power
supply didn't respond.

After updating,
turn on the
welding power
supply again.
After updating,
turn on the
welding power
supply again.
Failure reset,
and turn on the
welding power
supply again.

4021

Alarm

Error

Alarm

Error

on

on

Specify correct mechanism number which belongs to

current unit.

Error reset.

Error

Error

Error

Error

on

on

The axis number specified in the

2nd parameter is not defined in a
mechanism of 1st parameter.

Check the axis number of 2nd parameter taught in the

function command, and teach again.

Error reset.

Error

Error

Error

Error

on

on

The mechanism specified in 1st

paramter is neither positioner nor
slider.
This error is detected when the
G-STOP input value in two
systems is not corresponding.

Select a unit which has positioner or slider, and then

specify a positioner or a slider in 1st parameter.

Error reset.

Error

Error

Error

Error

on

on

Please confirm the G-STOP input value.

Error

Error

Error

Error

on

on

Since the data when power failure

did not be saved correctly, the
position data of endless rotation
axis has not been resumed to the
data before power failure.
The basic position of endless
rotation axis was not able to be
restored correctly by the
mechanism change.
The manual operation, check
operation or playback operation
has been performed for a
mechanism whose servo power
has been individually set to OFF.
Mechanisms other than the ones
targeted for operation have been
specified in the servo ON
command (SPN).
Mechanisms other than the ones
targeted for operation have been
specified in the servo OFF
command (SPF).
Because robot doesn't reach the
command position, servo OFF
cannot be executed.

Please perform the Encoder Correction (with position

record method) to the axis in which abnormalities have
generated.

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

Alarm

Alarm

Error

Error

on

on

Please perform the Encoder reset and Correction (with

position record method) to the axis in which
abnormalities have generated.

Error reset.

Error

Error

Error

Error

on

on

Check the mechanism whose servo power is OFF, and

turn it ON.

Error reset.

Alarm

Error

Alarm

Error

on

on

Review the mechanisms which have been specified by

the servo ON command (SPN).

Error reset.

Alarm

Error

Alarm

Error

on

on

Review the mechanisms which have been specified by

the servo OFF command (SPF).

Error reset.

Alarm

Error

Alarm

Error

on

on

(1)Please confirm whether the robot manipulator

interferes in something.(2)Please confirm that the
Pay-load is within the nominal rating.(3)If failure
persists, the problem may be a mechanical defect in the
manipulator, contact our service department.
Please confirm followings to the mechansim to which
servo off is set. (1)Instruction angle is not changed.
(2)Current angle is not changed, by the external force.

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

Error

Error

Error

Error

on

on

Alarm

Error

Alarm

Error

on

on

Cancel shock sensor by manual operation.

Error reset.

Alarm

Error

Alarm

Error

on

on

Please change a interporation type to [joint] or make the

same the wrist axis angle of a starting point and an
ending point.
Please improve registration of the Spray machine, and
a setup of a connection mechanism.

Error reset.

Alarm

Error

Alarm

Error

on

on

Error reset.

Error

Error

Error

Error

off

off

Please record by the Spray machine number belonging

to the present unit.

Error reset.

Error

Error

Error

Error

off

off

4018

4900

4901

Operational
failure

4902

Operational
failure

4903

Operational
failure

G-STOP input value is

not corresponding.

4905

Operational
failure

Playback was started

in the state that the
basic posture of any
axes is not setup.

4906

Operational
failure

The position of the

endless rotation axis is
abnormal.

4910

Operational
failure

Mechanism* is servo
off.

4911

Operational
failure

SPN parameter error.

4912

Operational
failure

SPF parameter error.

4914

Servo failure

Mechanism servo OFF

cannot be executed.

4915

Operational
failure

The instruction value of

the mechanism to
which servo OFF is set
has changed.

4920

Emergency
stop failure

Shock sensor detected

the collision.

4921

Operational
failure

Module mechanism
interpolation failure.

4930

Operational
failure

The connection
mechanism of the
Spray machine does
not exist.

4931

Operational
failure

The Spray machine

does not belong to a
current unit.

4-56

This error detected when the

difference between the instruction
position and the current position
exceeds a regulated value in the
mechanism to which servo OFF is
set.
Since the shock sensor detected
the collision, the robot was stopped
for safety.
This failure occurs when a module
mechanism cannot reach the
position and the posture.
This error is detected, when the
Spray machine set as the first
parameter is not registered or the
connection mechanism is not set
up.
This error is detected when the
mechanism connected to the Spray
machine set as the first parameter
does not belong to the present unit.

Turn off the power supply in the welding power supply,

and contact our service.

Error code list

4932

Operational
failure

Rotation shaft
information is unusual.

4940

Emergency
stop failure
Emergency
stop failure

The abnormalities in
file access.
Alarm carried out
number-of-times
generating of
regulation, and was
breaking down.
The weaving trajectory
exceeded regulation
speed.

4999

By the case of extension

synchronization control, the
rotation shaft information over the
shaft number set as Thermal
spraying start conditions is not set
up, or this error is detected when
the interval of a start position-end
position is less than 300mm.
The abnormalities occurred in file
access processing.
Alarm carried out number-of-times
generating of regulation, and was
breaking down.

Please reset up correctly the rotation shaft information

corresponding to the shaft number set as the Thermal
spraying start conditions.

Error reset.

Error

Error

Error

Error

off

off

Contact our service department. Back up files to

external CF memory.
Please fix failure from the cause of alarm.

Error reset.

Error

Error

Error

Error

on

on

Error reset.

Error

Error

Error

Error

on

on

The speed of weaving trajectory

has been exceeded the regulation
speed, since the move distance
between weaving points is too
long, or the frequency (speed) is
too high.
The amount of posture change
between weaving points is too
large.

Correct the distance between weaving points,

frequency, or speed.

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

Alarm

Alarm

Alarm

Alarm

on

on

Please correct posture change of taught weaving

pattern data.

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

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

5005

Arc weld
failure

5006

Arc weld
failure

The amount of posture

change of taught
weaving exceeded the
restriction value.

5007

Arc weld
failure

Pose calculation failed.

Each axis angle can't be

calculated. The posture data
specified in the weaving condition
is incorrect.

Check the posture data in weaving condition.

5008

Operational
failure

Permission speed over

occurred.

Stop time is made small or frequency is dropped. Or

please change into not carrying out welding time
maintenance.

5010

Arc weld
failure

The welding current

value has exceeded
the allowable limit.

5011

Arc weld
failure

The welding voltage

value has exceeded
the allowable limit.

5013

Arc weld
failure

The welding power

supply has been turned
off.

The stop time of weaving

conditions was too large at
maintenance of welding time, or
frequency was too high, and
permission speed over occurred.
The difference between the
welding current value measured by
the welding power supply and the
taught one has exceeded the
allowable limit set by the arc
constants.
The difference between the
welding voltage value measured by
the welding power supply and the
taught one has exceeded the
allowable limit set by the arc
constants.
The controller couldn't
communicate with the welding
power supply.

5014

Arc weld
failure

Arc start failure.

No arc has been generated in spite

of retrying the arc start.

5015

Arc weld
failure

Arc outage was

detected.

Arc outage occurred during

welding.

Eliminate all causes of arc outage, for instance by

adjusting the wedling conditions, fixing wire feed failure,
and so on.

5016

Arc weld
failure

Wire stick has been

detected.

Wire has stuck.

Cut stuck wire.

5017

Arc weld
failure
Arc weld
failure
Arc weld
failure
Arc weld
failure

Low gas pressure.

Low gas pressure signal is

inputted.
Wire not fed signal is inputted.

Supply gas.

This failure is
released if
restart
playback.
This failure is
released if
restart
playback.
This failure is
released if
restart
playback.
Error reset.

Supply wire.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Cooling water signal is inputted.

Supply water.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

The registered welding

characteristic data isn't for the
connected welding power supply.
Welding voltage adjustment
method has been changed from
the synergetic control to the
individual control, and vise versa
while welding.
W.P.S failure signal is inputted, or
failure of the welding power supply
occurs.
The primary input voltage of the
welding power supply has
decreased.
The average current used for the
inner control of the welding power
supply exceeds the limit.
An internal temperature of the
welding power supply rises.

Register the welding characteristic data for the using

one.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Modify the task program.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Read through the welding power supply instruction

manual and eliminate all causes.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Refer to the instruction manual of the welding power

supply(Failure Name: Input voltage shortage) and
eliminate all causes.
Refer to the instruction manual of the welding power
supply (Failure Name: Output overcurrent) and
eliminate all causes.
Refer to the instruction manual of the welding power
supply (Failure Name: Thermal overload) and eliminate
all causes.
Refer to the instruction manual of the welding power
supply (Failure Name: Input overvoltage) and eliminate
all causes.
Refer to the instruction manual of the welding power
supply (Failure Name: Loss of phase) and eliminate all
causes.
Refer to the instruction manual of the welding power
supply (Failure Name: Inverter drive circuit error) and
eliminate all causes.
Refer to the instruction manual of the welding power
supply (Failure Name: Arc voltage detecting line
error/detection error) and eliminate all causes.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

5018
5020
5021

Lack of wire was

detected.
Lack of water was
detected.
Arc welding
characteristic data
failure.
Welding voltage
adjustment method
can't be changed while
welding.

5022

Arc weld
failure

5023

Arc weld
failure

Failure of the welding

power supply occurred.

5024

Arc weld
failure

5025

Arc weld
failure

5026

Arc weld
failure

5027

Arc weld
failure

5028

Arc weld
failure

5029

Arc weld
failure

5030

Arc weld
failure

Input voltage shortage

failure ocurred in the
welding power supply.
Output overcurrent
occurred in the welding
power supply.
Thermal overload
occurred in the welding
power supply.
Input overvoltage
occurred in the welding
power supply.
Loss of phase occurred
in the welding power
supply.
Inverter drive circuit
failure occurred in the
welding power supply.
Arc voltage detection
failure occurred in the
welding power supply.

The primary input voltage of the

welding power supply exceeds the
threshold.
Loss of phase in the primary input
of the welding power supply.
The failure occurs around the
inverter drive circuit of the welding
power supply.
Arc voltage detection failure or arc
voltage detecting line failure
occurred.

Check the welding conditions(wire extension etc).

There is possibility of missmatch the welding
characteristic data to your environment if this failure
occurs over and over again. In such case, adjust the
welding characteristic data by the adjudstment of
welding condition function etc.
Check the welding conditions(wire extension etc).
There is possibility of missmatch the welding
characteristic data to your environment if this failure
occurs over and over again. In such case, adjust the
welding characteristic data by the adjudstment of
welding condition function etc.
Turn on the welding power supply. In case the welding
power supply has been already turned on, check the
connection of the welding power supply to the
controller.
Check the workpiece's condition, wire's condition, and
connection of the cable.

4-57

Error code list

5031

Arc weld
failure

5032

Arc weld
failure

5033

Arc weld
failure

5034

Arc weld
failure

Gas check failure

occurred in the welding
power supply.

5035

Arc weld
failure

5036

Arc weld
failure

5037

Arc weld
failure

5038

Arc weld
failure

5039

Arc weld
failure

5040

Arc weld
failure

5041

Arc weld
failure

5042

Arc weld
failure

5043

Arc weld
failure

5045

Arc weld
failure

5046

Arc weld
failure

5047

Arc weld
failure

5048

Arc weld
failure

Secondaly transistor
failure occurred in the
welding power supply.
Water pressure failure
occurred in the welding
power supply.
Secondaly transistor
failure occurred in the
welding power supply.
The specified welding
power supply can't use
in this unit.
A control power supply
failure occurred in the
welding power supply.
An electric detection
vessel failure occurred
in welding power
supply.
The excess failure of
the use rate occurred in
welding power supply.
A temperature failure
occurred in the wire
feed control circuit ing
the welding power
supply.
The load of wire feed
exceeded allowable
value.
The control power
supply of the welding
power supply was
reset.
The welding
characteristic data are
not installed.
The arc characteristic
can't be changed while
arc welding.
The incorrect welding
method is specified.

5049

Arc weld
failure
Arc weld
failure

5050

5051

Arc weld
failure

5052

Arc weld
failure
Arc weld
failure

5053

Microcomputer failure
occurred in the welding
power supply.
Encoder failure was
detected by the
welding power supply.
Current detection line
failure occurred in the
welding power supply.

The arc characteristic

file can't be read.
The wire feed
characteristic file can't
be read.
The arc welding wave
control file can't be
read.
The arc constant file
can't be read.
Welding voltage
adjustment method
differs.

The failure occurs in the welding

power supply.

Refer to the instruction manual of the welding power

supply (Failure Name: Microcomputer failure) and
eliminate all causes.
Refer to the instruction manual of the welding power
supply (Failure Name: Encoder error) and eliminate all
causes.
Refer to the instruction manual of the welding power
supply (Failure Name: 9. Current detection error).

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Turn OFF the gas check switch of the welding power

supply.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Refer to the instruction manual of the welding power

supply (Failure Name: Secondaly transistor failure) and
eliminate all causes.
Refer to the instruction manual of the welding power
supply (Failure Name: Water pressure error) and
eliminate all causes.
Refer to the instruction manual of the welding power
supply (Failure Name: Secondaly transistor failure) and
eliminate all causes.
Register the welding power supply which is specified by
the task program, or modify the task program.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Refer to the instruction manual of the welding power

supply (Failure Name: (The wire feed control
board)Control power supply) and eliminate all causes.
Refer to the instruction manual of the welding power
supply (Failure Name: The firstsecond electric current
error) and eliminate all causes.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Refer to the instruction manual of the welding power

supply (Failure Name: The excess of the use rate) and
eliminate all causes.
Refer to the instruction manual of the welding power
supply (Failure Name: The temperature wrong point of
the wire feed control circuit) and eliminate all causes.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

The wire feed load has exceeded

the allowable value set in the arc
constant.
The control power supply of the
welding power supply was reset.

A load is on the wire feeder by wear of the liner, the chip

defect, and so on. Remove the factors.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

The voltage of primary power may decrease in an

instance. Check the voltage of primary power.

Alarm

Alarm

Alarm

Alarm

on

on

If the welding characteristic data

are not installed, Arc function
commands can't be execute.
The arc function attempted
changing the arc characteristic into
the incorrect one.
The welding method of the arc
function and the welding method of
the arc characteristic aren't the
same.
Read file failure occurs while
reading the arc characteristic file.
Read file failure occurs while
reading the wire feed characteristic
file.
Read file failure occurs while
reading the arc welding wave
control file.
Read file failure occurs while
reading the arc constant file.
The voltage adjusting method
currently taught differs from the
voltage adjusting method of
characteristic data.
WCR of W-I/F had short-circuited
at the time of arc start.

Turn on the welding power supply again.

Failure reset,
and turn on the
welding power
supply again.
Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Please modify the task program.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Please modify the task program.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Please initialize the arc characteristic file.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Please initialize the wire feed characteristic file.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Please initialize the arc welding wave data file.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Please initialize the arc constant file.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Modify the task program.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Please check the state of W-I/F or a welding power

supply.

This failure is
released if
restart
playback.
Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

This failure is
released if
restart
playback.
This failure is
released if
restart
playback.

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

This failure is
released if
restart
playback.
Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Please create the arc condition file or edit the task

program.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Please create the offset condition file or the multi offset

file, or edit the task program.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Failure exists in the encoder of a

wire feed unit or encoder cables
are not connected.
The failure(the connector is
disconnected etc) exists in the
current detecting cable of the
welding power supply.
The gas check switch of the
welding power supply is ON for
more than two minutes without a
break.
The surge power of the second
transistor for the welding power
supply is abnormally high.
Cooling water flow is not sufficient
when using a water cooled torch.
The surge power of the second
transistor for the robot welding
power supply is abnormally high.
The specified welding power
supply isn't defined in this unit.
A control power supply failure
occurred in welding power supply.
A connector inside the welding
power supply may be
miss-connected.
Inside temperature of the welding
power supply rises.
An unusual fever appears on the
wire feed control circuit of the
welding power supply.

5054

Arc weld
failure

WCR Short-circuit
Error

5056

Arc weld
failure
Arc weld
failure

The electrode
short-circuited failure.
The Filler Wire heating
failure.

The electrode and the work are

short-circuited while arc welding.
During Filler Wire heating, inside
the electric supply tip, a wire melts
and was cut.

Please modify the task program.

5058

Arc weld
failure

The Filler Wire heating

Defect.

Please check the wire inside an electric supply tip, and

the heating cable failure (contact failure, broken wire).

5059

Arc weld
failure

The wire short-circuited

failure.

It can consider that there was no

wire in an electric supply tip, or a
wire melts and was cut inside the
electric supply tip at the time of
heating.
The wire and the work are
short-circuited while arc welding.

5060

Arc weld
failure
Arc weld
failure

5062

Arc weld
failure

Read file failure occurs while

reading the heating characteristic
file.
The arc condition file which is
specified by the arc welding
function doesn't exist.
The offset condition file or the multi
offset file which is specified by the
multi offset function doesn't exist.

Please initialize the heating characteristic file.

5061

The heating
characteristic file can't
be read.
The arc condition file
doesn't exist.

5057

4-58

The offset condition file

or the multi offset file
doesn't exist.

Please check the wire inside an electric supply tip, and

the heating cable failure (contact failure, broken wire).

Please check the state of W-I/F, and a welding power

supply.

Error code list

5063

Arc weld
failure

The weaving
synchronization went
wrong.

A communication failure has been

detected between the welding
power supply and the extension
serial board.

Please check connection between an extension serial

board and a welding power supply.

Turn on the
controller and
the welding
power supply
again.
Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

5064

Arc weld
failure

The weaving condition

file doesn't exist.

Please create the weaving condition file or edit the task

program.

5065

Arc weld
failure

5066

Arc weld
failure

5067

Arc weld
failure

The power supply of a

feed control device is
not on.
Pump failure occurred
in the welding power
supply.
The arc retry condition
file doesn't exist.

The weaving condition file which is

specified by the weaving function
doesn't exist.
Communication with a feed control
device was not completed.

Alarm

Alarm

Alarm

Alarm

on

on

When you turn on a feed control device or the power

supply is already on, please check connection with a
feed control device.
Refer to the instruction manual of the welding power
supply (Failure Name: Pump error) and eliminate all
causes.
Please create the arc retry condition file or edit the task
program.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

5068

Arc weld
failure

5069

Arc weld
failure

5070

Arc weld
failure

The arc robotrs

condition file doesn't
exist.
The robot move
condition file doesn't
exist.
The arc rs condition file
doesn't exist.

Please create the robotrs condition file or edit the task

program.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Please create the robot move condition file or edit the

task program.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Please create the rs condition file or edit the task

program.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

5071

Arc weld
failure

The module error in

WPS.

Refer to the instruction manual of the welding power

supply and eliminate all causes.(An abnormal number
of the welding power supply has been described in the
above-mentioned parentheses.)
Refer to the instruction manual of the welding power
supply and eliminate all causes.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

5072

Arc weld
failure

5073

Arc weld
failure

5074

Arc weld
failure

5075

Arc weld
failure

5076

Arc weld
failure

5077

Arc weld
failure

The speed failure of the

wire feed control circuit
occurred in the welding
power supply.
Input voltage shortage
failure ocurred in the
welding power supply.
The cooler fan failure
ocurred in the welding
power supply.
A control power supply
abnormal temperature
occurred in the welding
power supply.
The arc welding power
supply detected
abnormality of the
servo feeder unit.
The controller couldn't
communicate with the
servo feeder unit.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Refer to the instruction manual of the welding power

supply(Failure Name: The primary input driver) and
eliminate all causes.
Refer to the instruction manual of the welding power
supply(Failure Name: The cooler fan failure) and
eliminate all causes.
Refer to the instruction manual of the welding power
supply(Failure Name: A control power supply abnormal
temperature) and eliminate all causes.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Refer to the instruction manual of the servo feeder unit

and eliminate all causes.(An abnormal number of the
servo feeder unit has been described in the
above-mentioned parentheses.)
Please confirm the connection of the arc welding power
supply and the servo feeder unit.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

5078

Arc weld
failure

When you turn on a gas mass flow control unit or the

power supply is already on, please check connection
with a gas mass flow control unit.
Please create the gas equipment file or edit the gas
mass flow control data.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

5079

Arc weld
failure

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

5080

Operational
failure

5081

Operational
failure

5082

Operational
failure

5083

Operational
failure

5084

Operational
failure

5085

Arc weld
failure

5086

Arc weld
failure

5087

Arc weld
failure

5088

Arc weld
failure

Resources were not

securable at the time of
starting.
The appointed program
cannot be edited /
playback.
Operation or command
for Multi-unit cannot be
executed.
The unit-branch
commands cannot be
executed.
The unit-branch
commands cannot be
executed.
Communication
timeout occurred inside
the welding power
supply.
There is a illegal
section of melt down
control within a arc
welding section.
There is a illegal
section of melt down
control within a arc
welding section.
Back bead has
detected.

Modify the wait time specified in FORK or CALLFAR

command.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

The same number program exists.

Delete the program not to overlap with file operation.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

The option of Multi-unit is not set

up.

Please set up the option of Multi-unit.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Some unit-branch commands were

tried to execute at the same time.

Please correct the program so that the unit-branch

commands does not be executed at the same time.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

A unit-branch commands FORK

were tried to execute in the already
forked program.
The contollor of the welding power
supply didn't respond.

Please correct the program so that the unit-branch

commands does not be executed in the already forked
program.
Check the route of cable and ground connection.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Condition changing from Melt

Down Control to Normal Control or
from Normal Control to Melt Down
Control, is not acceptable.
Condition changing from Melt
Down Control to Normal Control or
from Normal Control to Melt Down
Control, is not acceptable.
Arc welder has changed the
welding condtion.

Please correct the taught program.

Turn the
welding power
supply on
again.
No reset
operations
neccesary.

Alarm

Alarm

Alarm

Alarm

on

on

Please correct the taught program.

No reset
operations
neccesary.

Alarm

Alarm

Alarm

Alarm

on

on

Please re-designe the welding condition or the taught

path.

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

Deviation of welding
path has detected.

Deviation of welding path toward

upper plate has occured.

Please re-designe the taught path.

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

Tandem-Arc-Start-com
mand is
incorrect.(Fe-wire)
Tandem-Arc-Start-com
mand is
incorrect.(Al-wire)

A move command must be

inserted between preceding and
trailing arc-start-command.
Trailing-arc-start-command must
follow
preceding-arc-start-command
continually.
Trailing-arc-start-command is
taught before
preceding-arc-start-command.

Modify the task program.

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

5089

Arc weld
failure

5090

Arc weld
failure

Alarm

Alarm

Alarm

Alarm

on

on

5091

Arc weld
failure

Modify the task program.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

5092

Arc weld
failure

Modify the task program.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

The power supply of a

gas mass flow control
unit is not on.
The gas equipment file
doesn't exist.

The Electrode type is

incorrect.

Cooling water flow is not sufficient

when using a water cooled torch.
The arc retry condition file which is
specified by the arc welding
function doesn't exist.
The arc robotrs condition file which
is specified by the arc welding
function doesn't exist.
The robot move condition file which
is specified by the arc welding
function doesn't exist.
The arc rs condition file which is
specified by the arc welding
function doesn't exist.
Abnormality occurs by the module
in the welding power supply.

The speed failure of the wire feed

control circuit occurred in the
welding power supply.
The primary input driver of the
welding power supply has
decreased.
The cooler fan's rotation has fallen
or it stops.
The temperature rises in the
control power supply.

The failure occurs in servo feeder

unit.

Abnormality occurred by the

communication between the arc
welding power supply and the
servo feeder unit.
Communication with a gas mass
flow control unit was not
completed.
The gas equipment file which is
specified by the gas mass flow
control file doesn't exist.
The wait time of resource
reservation was over.

4-59

Error code list

5093

Arc weld
failure

5094

Arc weld
failure

5095

Arc weld
failure

5096

Arc weld
failure

5097

Arc weld
failure

Arc voltage cannot be

detected while RS
control.

Arc start faiulre using RS control or

arc voltage detection failure
occurred in the welding power
supply.

5098

Arc weld
failure

EP start failure.

5099

Arc weld
failure

The arc welding power

supply was operated
during playback.

The arc welding characteristic data

of EP mode isn't registered. Or the
welding voltage adjustment
method of EP mode is different
from EN mode.
The arc welding power supply
cannot be operated during
playback.

5100

Arc weld
failure
Arc weld
failure

EP start failure.

5102

Arc weld
failure

An adjustment program
choice is unusual.

An start program is different from

the adjustment program.

Start by the specified adjustment program.

5103

Arc weld
failure

Adjustment welding
mode wrong point.

Check the welding mode to adjust.

5104

Arc weld
failure

Pilot arc start failure.

The welding mode of the AS

function is different from the
welding mode of the adjustment
object.
The pilot arc was not turned on.

5105

Arc weld
failure

A plasma unit/WPS is
abnormal.

5106

Arc weld
failure

The pilot arc outage is

abnormal.

5107

Arc weld
failure
Arc weld
failure

Pilot arc OFF error.

5109

Arc weld
failure

5110

Arc weld
failure

5111

Arc weld
failure

The error occurs in

servo wire feed control
unit.
Retract operation was
executed over 10
seconds.
Stitch pulse welding
control error.

5112

Arc weld
failure

Stitch pulse welding

unit setting error.

5113

Arc weld
failure
Arc weld
failure

WCR input signal

unsetting.
Arc welding unit setting
abnormality.

5115

Arc weld
failure

The WCR OFF

time-out is abnormal.

5118

Arc weld
failure

5119

Arc weld
failure
Arc weld
failure

There is a wrong arc

start command in the
tool change setting
welding power supply.
There is a wrong AS
command.
The arc welding power
supply detected
abnormality of the gas
mass flow control unit.
The gas mass flow
value has exceeded
the allowable limit.

5101

5108

5114

5120

5121

Arc weld
failure

5122

Arc weld
failure

4-60

The current execution

pass is in another
multipass section
The arc welding power
supply is installed.

Motor overcurrent
occurred in the welding
power supply.
The emergency is
stopping or the welding
power supply is
stopping.

An adjustment
movement start is
unusual.

Pilot arc ON error.

The gas pressure value

has exceeded the
allowable limit.

It is prohibited to start since the

different offset might be applied.
During installation of an arc
welding power supply, neither
operation of the arc welding power
supply nor execution of playback
command can be performed.
Short circuit in the power line to the
motor or motor overload happens.
The emergency stop is input or the
wiring of the STOP terminals in the
welding power supply is
disconnected.

EP start condition of AS function is

wrong.
Arc-Monitor isn't indicated.

Abnormality occurs by a plasma

fine unit or Plasma Welding Power
Supply.
The pilot arc outage occurred.

Please set the step which the multipass section suitable

for the current execution pass or change the current
execution pass.
Please perform again after the completion of installation
of an arc welding power supply.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Refer to the instruction manual of the welding power

supply (Failure Name: Motor overcurrent) and eliminate
all causes.
(1)Please cancel an emergency stop button and an
external emergency stop signal, and check the
connection of the welding power supply to the
controller. (2)When the check welding is ON, you have
to grasp the enable switch to cancel the emergency
stop.
Check the workpiece's condition, wire's condition,
connection of the cable, and RS control condition. Or
refer to the instruction manual of the welding power
supply (Failure Name: Arc voltage detection error) and
eliminate all causes.
Register the correct welding characteristic data. Or
Correct EP start condition.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Please do not operate the welding power supply during

playback.

Failure reset,
and turn on the
welding power
supply again.
Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Correct EP start condition.

Indicate Arc-Monitor, and confirm an adjustment
condition.

Check the connection condition of the cable.

Please see the manual of a plasma fine unit or Plasma

Welding Power Supply.

This failure is
released if
restart
playback.
Error reset.

The pilot arc was not able to be

turned off.
Since the purge was turned on, the
pilot arc was not able to be turned
on.
The error occurs in servo wire feed
control unit.

Check the connection condition of the cable.

This failure is
released if
restart
playback.
Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Turn off the purge.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Refer to the instruction manual of the servo wire feed

control unit and eliminate all causes.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Stop retract for the protection of

Assist Feeder.

If you operate retract more, execute 90 seconds later.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

The synchronized control, the FC

control, the slope control or the
adjustment of the WCD cannot be
executed by the stitch pulse
welding.
The stitch pulse cannot weld with
the unit to which two or more
welding machines are registered.
The WCR input signal is not
allocated.
For the unit to which two or more
welding machines are registered, it
is not possible to weld.
WCR was not turned off in the time
limit.

Please change the welding condition.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Please change the registration of the weld power supply

in the unit.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Please allocate the WCR input signal.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Please change the registration of the welding machine

in the unit.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Please check the WCR signal from "WCR OFF waiting

time" of the welding constant and the welding power
supply.
Please modify the task program.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Please teach again after deleteing the AS command.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Refer to the instruction manual of the gas mass flow

control unit and eliminate all causes.(An abnormal
number of the gas mass flow control unit has been
described in the above-mentioned parentheses.)
Please confirm [The remainder pressure of gas
cylinder, the piping of the gas, and the setting of the gas
mass flow control unit.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Please confirm the remainder pressure of gas cylinder,

the piping of the gas, and the setting of the gas mass
flow control unit.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

The AS command more than two

passing is recorded by one
mechanism.
The Synchro or FC welding is
taught to the AS command.
The failure occurs in gas mass flow
control unit.

The difference between the gas

mass flow value measured by the
welding power supply and the
taught one has exceeded the
allowable limit set by the
contloler.
The gas pressure measured in the
arc welding power supply
exceeded the limiting value set
with the controller.

Check the connection condition of the cable.

This failure is
released if
restart
playback.
This failure is
released if
restart
playback.
Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Error code list

5123

Arc weld
failure

The set gas mass flow

is not output.

The set gas mass flow was not

output in specified time.

5124

Arc weld
failure
Arc weld
failure

The gas flow control

unit was reset.
The data to the gas
flow control unit cannot
be set.
Zero deviation error on
the gas flow control unit
was detected.

The control data in the gas flow

control unit was reset.
The data set to the gas flow control
unit is abnormal.

5125

5126

Arc weld
failure

5127

Arc weld
failure

5128

Arc weld
failure

The analog output

board is a
uninstallation.
Filler wire stick has
been detected.

5129

Arc weld
failure

5130

Please confirm the residual quantity of the gas cylinder,

the piping of the gas, and the setting of the gas mass
flow control unit.
Please confirm the power cable of the gas flow control
unit.
Please confirm the data of the gas flow control unit.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Even if passing the specified time

after Gas OFF, the actual gas flow
could not restore 0 on the gas flow
control unit.
It is setting which uses the Plasma
welder though the analog output
board is not installed.
Filler wire has stuck.

1.Check the error judgment delay time. 2.Check the gas

type and the gas pressure at main cock. 3.The gas flow
control unit may be damaged or broken down. Please
contact our customer service center.
Please modify setting whether to install the analog
output board.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Cut stuck wire.

Alarm

Alarm

Alarm

Alarm

on

on

Filler touch detection

failure

It was not able to detect that a filler

wire touched welding base metal.

Please check the state of a filler wire, a welding

constant, and wiring.

Alarm

Alarm

Alarm

Alarm

on

on

Operational
failure

Welding mode option

un-setting up.

Welding mode option which is not

set up was used.

Please set up a welding mode option.

Alarm

Alarm

Alarm

Alarm

on

on

5131

Operational
failure

Welding mode option

can't use.

Since the welding mode option is

not set up correctly, it can't use.

Alarm

Alarm

Alarm

Alarm

on

on

5132

Arc weld
failure

Specified mode can't

use.

Alarm

Alarm

Alarm

Alarm

on

on

5133

Operational
failure

Welding mode option

can't use.

Since the welding unit is not

supporting specified mode, it can't
use.
Since the welding mode option is
not set up correctly, it can't use.

Since system memory protection was effective, an

option was not able to be written in a system
memory.Please once repeal a system memory
protection function and start a system again.
Please use a welding unit with specified mode.

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

Alarm

Alarm

Alarm

Alarm

on

on

5134

Arc weld
failure

Cycle pulsed welding

control error.

Alarm

Alarm

Alarm

Alarm

on

on

5135

Arc weld
failure

Cycle pulsed welding

control error.

5136

Arc weld
failure

The multipass section

is abnormal.

5137

Arc weld
failure

5138

Arc weld
failure

5139

Arc weld
failure

The welding power

supply secondaly
electric characteristic
file can't be read.
The firstsecond main
circuit failure occurred
in the welding power
supply.
It is necessary to turn
the welding power
supply on again.

5140

Arc weld
failure

The speed of the wire

speed has exceeded
the allowable limit.

5143

Arc weld
failure

Threshold trigger

5146

Arc weld
failure

The arc try condition

file doesn't exist.

5147

Arc weld
failure

5148

Arc weld
failure

The load of filler feed

exceeded allowable
value.
The abnormalities of
arc voltage direct
detection

5190

Arc weld
failure

5200

In the arc condition file of the cycle

pulsed welding, the welding control
must be "Cycle pulse" and the
slope condition must be specified
by "Distance".
The condition of Cycle pulsed
welding is specified by 'AS'
function. It must be specified by
'ASS' function.
The 'ASM' function, the 'AEM'
function, the 'OFFSET' function,
and the 'EP' function cannot be
executed outside the multipass
section.
Read file failure occurs while
reading the welding power supply
secondaly electric characteristic
file.
The failure exists in the first
second main circuit of the welding
power supply.

Please change the welding condition.

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

Please modify the task program.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Please teach the 'MPS' function and the 'MPE' function.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Please initialize the welding power supply secondaly

electric characteristic file.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Refer to the instruction manual of the welding power

supply (Failure Name: The firstsecond main circuit
failure).

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

The arc welding power supply

cannot be operated if it doesn't turn
on again.

Turn the welding power supply on again.

Alarm

Alarm

Alarm

Alarm

on

on

Please confirm whether an excessive load contracts the

wire feeder. Please contact our customer service center
when the permissible value is large.

Alarm

Alarm

Alarm

Alarm

on

on

Please confirm the arc welding construction condition.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Please create the arc try condition file or edit the task
program.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

A load is on the filler feeder by wear of the liner, the chip

defect, and so on. Remove the factors.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Please set up ON "Direct arc voltage detection" of a

welding constant, and please check connection of the
arc voltage detection line by the side of a base material.

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Sensor
failure

Sensor Function
cannot be executed.

Wrong usage of sensor function is

detected in teaching program

Please record sensor search function after move step.

Alarm

Alarm

Alarm

Alarm

on

on

5201

Sensor
failure

Search range
exceeded.

This error occurs when the robot

moves beyond search range

Modify(enlarge) the search range or program to rectify

error.

Alarm

Alarm

Alarm

Alarm

on

on

5202

Sensor
failure

Search range is short

Modify(shorten) the search range or program to rectify

error.

Alarm

Alarm

Alarm

Alarm

on

on

5203

Sensor
failure

Deviation range
exceeded.

This error occurs when the robot

detect the touch status within
minimum search range.
This error occurs when the robot
moves beyond deviation range

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

Alarm

The abnormalities in
the filler wire feeding

The speed of the wire measured in

the arc welding power supply has
exceeded the allowable limit at the
speed of the wire that the arc
welding power supply output.
The threshold specified under the
welding record condition was
detected in the arc welding power
supply.
The arc try condition file which is
specified by the arc welding
function doesn't exist.
The filler feed load has exceeded
the allowable value set in the arc
constant.
The arc voltage detection
procedure by the side of a base
material is wrong. The arc voltage
detection is needed for this welding
mode.
The filler wire is not sent or it is
incomplete penetration.

Turn the
welding power
supply on
again.
Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Please restore the welding mode option on the welding

mode option screen.

Please check the feeding state and welding conditions

of the filler wire.

Modify(enlarge) the deviation range or program to

rectify error.

4-61

Error code list

5204

Sensor
failure

Sensor number is
mismatched.

5205

Sensor
failure

The input-and-output
signal is not assigned.

5206

Sensor
failure
Sensor
failure

A deviation file is
wrong.
A deviation file is not
found.

5208

Sensor
failure

Mechanism type is
mismatched.

5209

Sensor
failure

A detecting wire
extension file is wrong.

5210

Sensor
failure

5211

Sensor
failure

A detecting wire
extension file is not
found.
Coordinate systems
are mismatched.

5212

Sensor
failure

Cannot search.

5213

Sensor
failure
Sensor
failure
Sensor
failure

Gap Over

5216

Sensor
failure

Groove depth short

5217

Sensor
failure
Sensor
failure
Sensor
failure
Sensor
failure
Sensor
failure

Angle1 over

Sensor
failure
Sensor
failure

Seaching time over

Sensor
failure
Sensor
failure
Sensor
failure
Sensor
failure

Unstable detection

Sensor
failure
Sensor
failure
Sensor
failure
Sensor
failure
Sensor
failure

Gap file error

5233

Sensor
failure

5234

Sensor
failure
Sensor
failure
Sensor
failure
Sensor
failure

Communication
timeout occurred
between the controller
and the sensor unit
Sensor condition file
error
Sensor condition file is
not exist.
Sensor Failure

5207

5214
5215

5218
5219
5220
5221

5222
5223

5224
5225
5226
5227

5228
5229
5230
5231
5232

5235
5236
5237

5238

4-62

Sensor
failure

Gap short
Groove depth over

Angle1 short
Angle2 over
Angle2 short
Groove un-detected

Sensor mounting error

Out of measurement
distance
Reference point error
ZG1 workpiece
undetected

No gap file
Gff file error
No gff file
Sensor disconnected
(Laser search)

Start Point un-detected

Cannot restart during

seam tracking.

This error occures when the sensor

number in the sensor step does not
meet that of the connected sensor.
This error occurs when the
input-and-output signal required for
search operation is not assigned.
This error occurs when read-out of
a deviation file goes wrong.
This error occurs when the
specified deviation file cannot be
found.
This error occurs when the
mechanism type in specified
deviation file is mismatched.
This error occurs when read-out of
a detecting wire extension file goes
wrong.
This error occurs when the
specified detecting wire extension
file cannot be found.
This error occurs when the
coordenate systems are not
matched between selected
deviation files.
Search direction cannot be
specified because the search
vector is not taught, or calculating
search vector was failed.
Detected gap is exceeded beyond
maximum allowable value.
Detected gap becomes lower than
minimum allowable value.
Detected groove depth is
exceeded beyond maximum
allowable value.
Detected groove depth becomes
lower than minimum allowable
value.
Detected angle1 is exceeded
beyond maximum allowable value.
Detected angle1 becomes lower
than minimum allowable value.
Detected angle2 is exceeded
beyond maximum allowable value.
Detected angle2 becomes lower
than minimum allowable value.
Groove position cannot be
detected

This error occurs when searching

time is too long.
This error occurs when sensor
mounting is not set.

This error occurs when measured

data is unstable.
This error occurs when measured
distance is out of range.
This error occurs when reference
point is not stored.
This error occurs when the laser
reflection beam is not sufficiently
received in ZG1 starting.

This error occurs when wrong data

is detected in gap file.
This error occurs when the
specified gap file is not exist.
This error occurs when wrong data
is detected in GFF file.
This error occurs when the
specified GFF file is not exist.
This error occurs when there is no
communication between laser
sensor and RC.
This error occurs when there is no
response from Laser Sensor Unit.

This error occurs when wrong data

is detected in LSF or LSR file.
This error occurs when specified
LSF or LSR file is not exist.
This failure occurs when the error
is issued from the sensor controller
This failure occurs when the start
point is not detected during ZF
search.
Cannot restart during seam
tracking.

Check that sensor settings and /or teaching programs.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Set up an input-and-output signal.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Check a deviation file.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Correct the file number.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Correct the file number.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Check a detecting wire extension file.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Correct the file number.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Correct the file number.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

(1)Specify the search vector. (2)When the search

vector was already specified, modify the search vector.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Check that gap amount and modify allowable value if

needed.
Check that gap amount and modify allowable value if
needed.
Check that groove depth amount and modify allowable
value if needed.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Check that groove depth amount and modify allowable

value if needed.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Check that angle1 amount and modify allowable value if

needed.
Check that angle1 amount and modify allowable value if
needed.
Check that angle2 amount and modify allowable value if
needed.
Check that angle2 amount and modify allowable value if
needed.
(1)Check setting parameters in GFF file. (2)If you are
provided with the optional data terminal, use Groove
Data function in RD/AD tab menu, and modify the
teaching program so that laser data are properly
obtained.
To short the searching time less than 2s or modify
sample rate in GFF file.
(1)Specify sensor mounting direction. (2)Execute the
sensor calibration before executing the ZJLETP
command.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Check that target surface condition and/or

measurement angle.
Check that target piece is located at desired position.

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

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Execute trial motion to get reference point.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

(1)At the ZG1 start point, the workpiece must be taught

within the measurement range. (2)When the workpiece
is placed within the measurement range, adjust the
angle of laser against the workpiece, and constantly
light the distance LED on laser head. (3)If you are
provided with the optional data terminal, use RD/AD tab
menu, and check that always 206 or higher laser beam
in the LEVEL display is received.
Check the contents in gap file.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Check the gap file number.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Check that contents in GFF file.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Check that GFF file number.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Turn on the sensor unit. In case the sensor unit has

been already turned on, check the connection of the
sensor unit to the controller.
Check the connection of the sensor unit to the
controller.

Error reset.

Error

Error

Error

Error

on

on

Turn on the
controller and
the sensor unit
again.
Error reset.

Error

Error

Error

Error

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Check that contents in LSF or LSR file.

Check that LSF or LSR file number.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Check the sensor status by WinUser.

Error reset.

Error

Error

Error

Error

on

on

(1)Check the groove recognization by WinUser.

(2)Enlarge the ZF maximum search range.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Do not modify the position and posture of the robot

when the robot is stopped in ZT period if the restarting
is required.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Error code list

5239

Sensor
failure

ZF Deviation range
exceeded

5240

Sensor
failure
Sensor
failure

ZF search range
exceeded
ZT Position Deviation
range exceeded

Sensor
failure
Sensor
failure

ZN offset range
exceeded
ZN Search range
exeeced.

Sensor
failure
Sensor
failure

End point un-detected

Sensor
failure
Sensor
failure
Sensor
failure

Laser ON Failed

5249

Sensor
failure

ZT Posture Deviation
range exceeded

5250

Sensor
failure

Sensor disconnected

5251

Sensor
failure

Correction amount by
arc-sensor exceeds
specified value.

5252

Sensor
failure

5253

Sensor
failure

Calculation turns to
unstable during
arc-sensing process.
Welding position
cannot be detected

5254

Sensor
failure

Unstable wire-feeding.

5255

Sensor
failure
Sensor
failure

ST parameter error.

5241

5242
5243

5244
5245

5246
5247
5248

5256

5257

Sensor
failure

5258

Sensor
failure
Sensor
failure

5259

Deviation range
exceeded.

Laser is not ready.

Error in instruction of
ZN command.

The ET command less

program was
performed.
Abnormalities were
found in the parameter
of basic data.
Error in instruction of
ZG1 command.
At the start-point
detection or in the
tracking section, the
move command with
no Synchromotion
teaching (without "H")
was found.
Sensor stop signal
input.

This error occurs when the

distance between the detected
start point and ZF taught point
exceeded the deviation range.
This error occurs when the robot
moves beyond search range
This error occurs when the robot
moves beyond Position deviation
range
This error occurs when the setting
offset is beyond the range
This error occurs when the robot
moves beyond search range during
ZN.
End point of workpiece is not
detected.
This error occurs when the
distance between the detected end
point and taught point before ZE
exceeded the deviation range.
Laser is not activated.

Check detected position. If no problems exist,

moodify(enlarge) the ZF deviation range parameter or
program to rectify error.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Modify(enlarge) the search range or program to rectify

error.
Check the target position If no problems exist,
moodify(enlarge) the ZT parameters or program to
rectify error.
Modify(enlarge) the ZN offset to rectify error.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Modify(enlarge) the ZN search range or program to

rectify error.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Modify(enlarge) ZN search range or program to rectify

error.
Check the detected point. If no problems exist,
Modify(enlarge) the deviation range or program to
rectify error.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Turn on the Laser by ZON or manual operation.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Wait 3 seconds or longer after ZON was performed

before ZF/ZT/ZJ.
Please improve instruction.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Check the target posture If no problems exist,

moodify(enlarge) the ZT parameters or program to
rectify error.
Turn on the sensor unit. In case the sensor unit has
been already turned on, check the connection of the
sensor unit to the controller.
Check that currect torch position. If it is OK, extend the
value CHASING RANGE in teaching parameter. If it is
NG, try to adjust sensor parameters.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Check that welding condition to be stable.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Try to re-adjust sensing parameters.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Check that equipments for wire feeding.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

It improves whether each parameter is setting within the

limits.
Please teaching ET command.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

An appointed basic data file does

not exist or a file cannot be read.

Please check a basic data file with a service menu.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

ZG1 command in the weaving

section cannot be executed.
In the start-point detection section
or the tracking section in
Synchromotion system, the move
command is not taught as
Synchromotion teaching ("H").

Please improve instruction.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Specify all the move commands, right before ZF

command, in ST~ET section and in ZT~ZE section to
Synchromotion teaching ("H").

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Stop signal is input into the laser

sensor unit.

(1)Release Emergency Stop Button on the Laser

Sensor Unit. (2)Close the Emergency Stop Alarm Input
loop connected to CN2 on the laser sensor unit.

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

ZF/ZT/ZJ will be performed before

3 seconds after ZON is carried out.
There is no move command
immediately after ZN command to
which a move command or ZT
command does not exist before ZN
command, or it is [ that two or more
move commands are taught
between ZN - ZE, etc. and ] a
factor.
This error occurs when the robot
moves beyond Posture deviation
range
The controller couldn't
communicate with the sensor unit.
Error is activated when the case
that correction amount by the
sensor exceeds the specified value
in teaching parameter.
This error is activated when
stability of welding arc decreased
significantly.
This error is activated when the
deviation detection cannot be
calculated during arc-sensing
process. Note that position
correction is not executed.
Wire-feeding status turn to
unstable. Deviation is lager than
specified value.
The instruction parameter of ST
command is over the setting range.
ET command is not taught after ST
command.

5260

Sensor
failure

5261

Sensor
failure

Groove un-detected.

Groove cannot be detected.

(1)Check that LASER power is ON. (2)Check the cable

between Laser Sensor Unit and Sensor Head is
connected properly. (3)Check the cable between Robot
Controller and Laser Sensor Unit is connected properly.

5262

Sensor
failure

Torch moving distance

over.

The distance corrected by the

sensor within 1 interpolation time
was exceeded over the internal
distance.

(1)Adjust the stability of groove detection by WinUser.

(2)Check the cable between Robot Controller and Laser
Sensor Unit is connected properly. In addition, also
check the sensor head cable.

5263

Sensor
failure
Sensor
failure
Sensor
failure

No SFM file

Check SFM file number.

Alarm

Alarm

Alarm

Alarm

on

on

Check that contents in SFM file.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Please improve instruction.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

5266

Sensor
failure

DE Corrected point
failure

Alarm

Alarm

Alarm

Alarm

on

on

Sensor
failure

JOINT command exists

in tracking section.

(1)Modify the AS speed so that it is close to the proper

one.(2)Modify DE taught point so that the distance
between DE and ET taught point is longer.
Modify JOINT command in the teaching section (ST
ET, ZFZTZNZE) of tracking sensor to LIN
command or CIR1/CIR2 command.

Error reset.

5267

This error occurs when specified

SFM file is not exist.
This error occurs when wrong data
is detected in SFM file.
There is no move command
immediately after DE command to
which a move command or ST
command does not exist before DE
command, or it is [ that two or more
move commands are taught
between DE - ET, etc. and ] a
factor.
This error occurs when the order of
DE corrected point and ET taught
point are exchanged by tracking.
JOINT command cannot be
executed in the tracking sensor
section.

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

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

5264
5265

SFM file error

Error in instruction of
DE command.

4-63

Error code list

5268

Sensor
failure

Sensor Function
cannot be executed.

An error is in a connection setup of

a sensor and a mechanism.

Please check a constant setup and instruction of a

sensor.

5269

Sensor
failure

5270

Sensor
failure

ZN Search destination
point is exceeded
range.
The tracking speed is a
negative value.

This error occurs when the robot

moves beyond Software Limit
range by ZN search.
This error occurs when the tracking
speed is set to a negative value by
speed change of Adaptive Control.

5271

Sensor
failure

5272

Sensor
failure

5273

Sensor
failure

5274

Sensor
failure

5275

Sensor
failure

Error in instruction of
ZE command outside
tracking section
Continuous ZT
commands have same
sensor number.
Continuous ZN
commands have same
sensor number.
Continuous ZE
commands have same
sensor number.
ZN command
according to ZT does
not exist.

5276

Sensor
failure

5277

Sensor
failure

5278

Sensor
failure

5279

Sensor
failure

This error occurs when ZT

command according to ZE does
not exist.
This error occurs when continuous
ZT commands have same sensor
number.
This error occurs when continuous
ZN commands have same sensor
number.
This error occurs when continuous
ZE commands have same sensor
number.
This error occurs in case that ZN
commands for all laser sensors is
not instructed when the tracking by
the plural laser sensors are
performed.
This error occurs when ZE
command according to ZT is not
instructed.
This error occurs when ZT
command according to ZN is not
instructed.
This error occurs when ZT
command according to ZE is not
instructed.
This error occurs when ZT
command is instructed just after
ZN or ZE command.

Modify () the ZN mamimum distance so that the point

extended ZN maximum distance from the previous
point of ZE is within the robot working range.
(1)Specify the AS speed properly so that it will not
become negative by Adaptive Control. (2)Connect
WinUser to the sensor, and review the setting "gap speed" in the spread sheet.
Modify ZT or ZE command.

5280

Sensor
failure

5281

Sensor
failure

5282

Sensor
failure

5283

Sensor
failure

5284

Sensor
failure

Abnormal setting of
"Maximum distance" in
ZN commands.

5285

Sensor
failure

A reference position
has not been taught.

5286

Sensor
failure

An undefined dummy
point is being referred.

5287

Sensor
failure

A vector is not taught.

5288

Sensor
failure

5289

Sensor
failure

An undefined
temporary buffer point
is being referred.
A vector cannot be
defined or identified
when executing
SF2/ZF2.

5290

Sensor
failure

Logic error of the

patterned search
macro.

5291

Sensor
failure

An operation error
occurred when
executing SF2/ZF2.

5292

Sensor
failure

DE Search range
exeeced.

5293

Sensor
failure

5294

Sensor
failure

The command of
teaching prohibition in
ZF and after
Adaptive welding
current over

5295

Sensor
failure

Adaptive welding
current short

4-64

ZE command
according to ZT does
not exist.
ZT command
according to ZN does
not exist.
ZT command
according to ZE does
not exist.
ZT command exists in
the section of
continuous ZN or ZE
commands.
ZN command exists in
the section of
continuous ZT or ZE
commands.
ZE command exists in
the section of
continuous ZT or ZN
commands.
Abnormal setting of
ON/OFF of External I/O
detection in ZN
commands.
Abnormal setting of
input port number of
External I/O detection
in ZN commands.

No reset
operations
neccesary.
Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Check each sensor number of ZT command.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Check each sensor number of ZN command.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Check each sensor number of ZE command.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Modify ZN commands.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Modify ZT or ZE command.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Modify ZT or ZN command.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Modify ZT or ZE command.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Modify ZT, ZN or ZE command.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

This error occurs when ZN

command is instructed just after ZT
or ZE command.

Modify ZT, ZN or ZE command.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

This error occurs when ZE

command is instructed just after ZT
or ZN command.

Modify ZT, ZN or ZE command.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

This error occurs when both

settings of External I/O detection in
the continuous ZN instructions are
not same.
This error occurs when both
settings of input port number of
External I/O detection in the
continuous ZN instructions are not
same.
This error occurs when both
parameters of "Maximum distance"
in the continuous ZN instructions
are not same.
This error occurs if a reference
position is not taught when
executing SF2/ZF2.
When executing SF2/ZF2, an
undefined dummy point was
attempted to be referred.
Since a vector is not taught, the
motion direction of patterned
search cannot be operated.
When executing SF2/ZF2, an
undefined temporary buffer point
was attempted to be referred.
(1)The motion start/end point of S
(search) command or M (move)
command are the same. (2)When
executing the vector intersection
operation mode (a=1) by L (vector
calcuation) command, two kinds of
vector are identical.
Parameter settings for the
patterned search macro are fault,
which causes a SF2/ZF2 execution
failure.
A search target point of S (search)
command or a motion target point
of M (move) command were not
able to be obtained.

Modify the setting of External I/O detection in each ZN

command.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Modify the setting of input port number of External I/O

detection in each ZN command.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Modify "Maximum distance" in each ZN command.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Teach a reference position by executing manual

operation, macro-execution or trial operation.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

To make a reference to the dummy point, modify the

patterned search macro so that the dummy point can be
referred after defined.
Teach a vector (both its start point and end point).

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

To make a reference to a temporary buffer point, modify

the patterned search macro so that the temporary buffer
point can be referred after defined.
(3)Check the vector specified by the temporary buffer
point in each command, and remove the errors.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Review the contents of the patterned search macro and

parameter settings for the patterned search (including
the set point).

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Review the contents of the patterned search macro and

parameter settings for the patterned search (including
the set point) so that the search target point and the
motion target point can be got within the robot motion
range.
Modify(enlarge) the DE search range or program to
rectify error.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Review the teaching in ZF-ZT and ZF-ZE section.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Check the lists of the specified spreadsheet in the

sensor controller by WinUser. If the spreadsheet is OK,
increase maximum current watch value of adaptive
control.
Check the lists of the specified spreadsheet in the
sensor controller by WinUser. If the spreadsheet is OK,
decrease minimum current watch value of adaptive
control.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

This error occurs when the robot

moves beyond search range during
DE.
This error occurs when the
command not permitted has been
taught in ZF-ZT and ZF-ZE section.
Welding current specified by
adaptive control exceeds
maximum current watch value of
adaptive control.
Welding current specified by
adaptive control becomes lower
than minimum current watch value
of adaptive control.

Error code list

5296

Sensor
failure

Adaptive welding
voltage over

5297

Sensor
failure

Adaptive welding
voltage short

5298

Sensor
failure

Adaptive travel speed

over

5299

Sensor
failure

Adaptive travel speed

short

5300

Auto
Calibration
failure

Auto Calibration
function can not be
carried out.

5301

Auto
Calibration
failure
Auto
Calibration
failure

Other units are running

program.

Auto
Calibration
failure
Auto
Calibration
failure
Auto
Calibration
failure
Auto
Calibration
failure

The maximum search

distance error.

5302

5303

5304

5305

5306

5307

5308

5309

5310

5311

5312

5313

5314

5315

5316

5317

5318

5319

5320

Auto
Calibration
failure
Auto
Calibration
failure
Auto
Calibration
failure
Auto
Calibration
failure
Auto
Calibration
failure
Auto
Calibration
failure

Auto
Calibration
failure
Auto
Calibration
failure
Auto
Calibration
failure
Auto
Calibration
failure
Auto
Calibration
failure
Auto
Calibration
failure
Auto
Calibration
failure
Auto
Calibration
failure

5321

Auto
Calibration
failure

5322

Auto
Calibration
failure
Auto
Calibration
failure
Auto
Calibration
failure

5323

5330

Welding voltage specified by

adaptive control exceeds
maximum voltage watch value of
adaptive control.
Welding voltage specified by
adaptive control becomes lower
than minimum voltage watch value
of adaptive control.
Travel speed specified by adaptive
control exceeds maximum speed
watch value of adaptive control.
Travel speed specified by adaptive
control becomes lower than
minimum speed watch value of
adaptive control.
An error is in the record method of
an automatic calibration related
function.

Check the lists of the specified spreadsheet in the

sensor controller by WinUser. If the spreadsheet is OK,
increase maximum voltage watch value of adaptive
control.
Check the lists of the specified spreadsheet in the
sensor controller by WinUser. If the spreadsheet is OK,
decrease minimum voltage watch value of adaptive
control.
Check the lists of the specified spreadsheet in the
sensor controller by WinUser. If the spreadsheet is OK,
increase maximum speed watch value of adaptive
control.
Check the lists of the specified spreadsheet in the
sensor controller by WinUser. If the spreadsheet is OK,
decrease minimum speed watch value of adaptive
control.
Please record an automatic calibration function behind
a move command.Or please choose a mechanism
correctly.

CALIBROB(FN702) cannot be
performed while running the
program of other units.
The amount of compensation of
joint offset or a tool parameter is
over the maximum set up by the
constant.
This error occurs when the robot
moves beyond search range

Please perform CALIBROB (FN702) again after

stopping all units.

This error occurs when reference

points are not acquired.

Please acquired reference points.

This error occurs when the "A" and

"B" points have different
orientation.
It becomes this error when the
orientation of the reference point at
the time of the direction search of Z
differs from A1, B1 or A2, and B-2.
This error occurs when the auto
calibration sensor required for
search operation is not set up.
This error occurs when the
input-and-output signal required for
search operation is not set up.
A condition file cannot be read.

Please make "A" and "B" points into the same

orientation.

The abnormalities in an
automatic calibration
parameter.
Automatic calibration
measurement file error.
The abnormalities in
automatic calibration
correct.

The maximum
compensation value
error.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

After recording
the move step,
Please Check
Go.
Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Please acquire a measuring point again after correcting

a gap of a robot using a torch gauge or a point mark.

Error reset.

Inform
ation

Inform
ation

Alarm

Alarm

on

on

Modify(enlarge) the search range or program to rectify

error.

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

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Please register an automatic calibration sensor by

constant setup.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Set up an input-and-output signal.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Please set up constant data again or perform

initialization.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

The parameter in an automatic

calibration constant file is unusual.

Please set up a constant file correctly.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

It has not accessed whether a

measurement file could be created.

Please enable it to create a measurement file.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Reliability is not in the measured

data. There is a possibility that the
sensor might incorrect-detect or a
totter may be in attachment of a
tool.
Abnormalities occurred at the time
of work program compensation.

Please perform reference point acquisition again.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Please perform reference point acquisition again.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Abnormalities occurred at the time

of work program compensation.

It is not especially.

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

Since a robot's position is shifted

greatly, measurement is
uncontinuable.
The gap of a robot was detected in
the state where all measuring
points have not measured.
Datum point acquisition mode
CALIBROB (FN702) was
performed.
It becomes this error when the
inputted search operation distance
is too large.
This error occurs when the robot
moves beyond search range

Please acquire a measuring point again after correcting

a gap of a robot to the range which can be measured
using a torch gauge or a point mark.
Please measure all measuring points.

No reset
operations
neccesary.
Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

It is not especially.

Error reset.

Inform
ation

Inform
ation

Alarm

Alarm

on

on

Modify(enlarge) the search range or program to rectify

error.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Modify(enlarge) the search range or program to rectify

error.

Alarm

Alarm

Alarm

Alarm

on

on

Reliability is not in the measured

data. There is a possibility that the
sensor might incorrect-detect or a
totter may be in attachment of a
tool.
Although the all-points
measurement of the quick checki
point is not carried out, MESPOS
(FN700) was performed.
Reference point was not taken
from point 1Q.

Please perform measuring point acquisition again.

No reset
operations
neccesary.
Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Please measure the quick checki point again.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Please perform taking reference point from point 1Q.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Reference point error.

Reference point was not taken

from point 1A.

Please perform taking reference point from point 1A.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Measuring point
Orientation error.

This error occurs when the "A" and

"B" points have different
orientation. There is a possibility
that the sensor might
incorrect-detect or a totter may be
in attachment of a tool.

Please perform measuring point acquisition again.

No reset
operations
neccesary.

Alarm

Alarm

Alarm

Alarm

on

on

The reference point for

automatic calibrations
is not acquired.
Reference point
Orientation error.
Reference point
orientation error(At the
time of the direction
search of Z).
The auto calibration
sensor is not
registered.
The input-and-output
signal is not set up.
File reading error.

The abnormalities in
work program
compensation.
The abnormalities in
work program
compensation.
A robot's position is
shifted greatly.
All measuring points
are not acquired.
CALIBROB (FN702)
cannot be performed.
Cannot search.

The minimum search

distance error.
The abnormalities in
calibration
compensation at the
time of
remeasurement.
The quick checki point
is not measured.

Reference point error.

Please make the same the orientation of B points of A1,

B1 point, A points of the direction search of Z or A2, B-2
point, and the direction search of Z.

4-65

Error code list

5331

Auto
Calibration
failure

Measuring point
orientation error(At the
time of the direction
search of Z).

5332

Auto
Calibration
failure

The abnormalities in
automatic calibration
correct.

5333

Auto
Calibration
failure
Auto
Calibration
failure
Auto
Calibration
failure
Sensor
failure

The abnormalities in
work program
compensation.
Measuring point error.

5401

Sensor
failure

Abnormal setting of the

current monitoring
range

5402

Sensor
failure

Abnormal setting of the

voltage monitoring
range

5403

Sensor
failure

Adaptive condition
setting error

5404

Sensor
failure

Adaptive weaving
amplitude over

5406

Sensor
failure

ZF Posture Deviation
range exceeded.

5408

Sensor
failure

Maximum distance in
ZN command is too
long.

5410

Sensor
failure

Stability waiting time

over

5411

Sensor
failure

ZJ Deviation range
exceeded

5412

Sensor
failure

Adaptive Wire Speed

Over

5413

Sensor
failure

Adaptive Wire Speed

Short

5414

Sensor
failure
Sensor
failure
Sensor
failure
Sensor
failure
Sensor
failure

Area Over

5419

Sensor
failure

5420

Sensor
failure

5421

Sensor
failure

SF8 Max.
Compensative-Surveila
nce val. Over
SF8 Min.
Compensative-Surveila
nce val. Short
The touch detection
point is abnormal.

5422

Sensor
failure

Adaptive EN Ratio
Over

5334

5335

5400

5415
5416
5417
5418

4-66

It becomes this error when the

orientation of the measuring point
at the time of the direction search
of Z differs from A1, B1 or A2,
and B-2.There is a possibility that
the sensor might incorrect-detect
or a totter may be in attachment of
a tool.
Reliability is not in the measured
data. There is a possibility that the
sensor might incorrect-detect or a
totter may be in attachment of a
tool.
Abnormalities occurred at the time
of work program compensation.

Please perform measuring point acquisition again.

No reset
operations
neccesary.

Alarm

Alarm

Alarm

Alarm

on

on

Please perform measuring point acquisition again.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Please perform measuring point acquisition again.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Measuring point was not taken

from point 1Q.

Please perform taking measuring point from point 1Q.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Measuring point error.

Measuring point was not taken

from point 1A.

Please perform taking measuring point from point 1A.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Abnormal setting of the

speed monitoring
range

This error occurs when the

minimum value of speed
monitoring value exceeds the
maximum value in the condition
settings for the adaptive control.
This error occurs when the
minimum value of current
monitoring value exceeds the
maximum value in the condition
settings for the adaptive control.
This error occurs when the
minimum value of voltage
monitoring value exceeds the
maximum value in the condition
settings for the adaptive control.
An illegal setting change of an
adaptive condition was done in the
tracking section. Effective and the
invalidity of an adaptive control
cannot be switched in the tracking
section, and the number of
samples of moving averages be
changed.
Weaving amplitude specified by
adaptive control exceeds
maximum amplitude watch value of
adaptive control.
This error occurs when the
difference between the target
posture calculated by ZF
instruction and the taught posture
exceeds Posture deviation range.
Target position calculated by ZN
command is out of the movable
area because Maximum distance
in ZN command is too long.
The stability waiting time was
exceeded.

Review the minimum and maximum value of the speed

monitoring value.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Review the minimum and maximum value of the current

monitoring value.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Review the minimum and maximum value of the voltage

monitoring value.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Please confirm the specified LSR file number. Please

confirm the content of the LSR file set when the
specified number is correct.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Check the lists of the specified spreadsheet in the

sensor controller by WinUser. If the spreadsheet is OK,
increase maximum amplitude watch value of adaptive
control.
Check the target posture If no problems exist,
moodify(enlarge) the ZF parameters or program to
rectify error.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Decrease the maximum distance in ZN command.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

(1)Modify(enlarge) stable waiting time to rectify error.

(2)Modify the teaching point so that the groove is within
the field of view of laser. (3)When the groove is within
the field of view, modify the parameters by the software
attached to the sensor so that the groove is detected
normally.
Check detected position. If no problems exist,
modify(enlarge) the ZJ deviation range parameter or
program to rectify error.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Check the lists of the specified spreadsheet in the

sensor controller by WinUser. If the spreadsheet is OK,
increase maximum wire speed watch value of adaptive
control.
Check the lists of the specified spreadsheet in the
sensor controller by WinUser. If the spreadsheet is OK,
decrease minimum wire speed watch value of adaptive
control.
Check the area watch value(maximum) and enlarge if
needed.
Check the area watch value(minimum) and decrease if
needed.
Check the mismatch watch value(maximum) and
enlarge if needed.
Check the mismatch watch value(minimum) and
decrease if needed.
Please execute the trial movement or the edit, and get
reference position again.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Check contents of the register specified in SF8. If there

is no problem, increase Max.
Compensative-Surveilance val. in SF8.
Check contents of the register specified in SF8. If there
is no problem, decrease Min.
Compensative-Surveilance val. in SF8.
Contact our service department. Back up files to
external CF memory. Because the robot stop step is
different to the execute step, step-set must be needed
for restart.
Check the lists of the specified spreadsheet in the
sensor controller by WinUser. If the spreadsheet is OK,
increase maximum EN ratio watch value of adaptive
control.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Turn on the
power again.

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Area Short
Mismatch Over
Mismatch Short
Search position was
changed.

This error occurs when the

distance between the detected
point and ZJ reference point
exceeded the deviation range.
Wire Speed specified by adaptive
control exceeds maximum wire
speed watch value of adaptive
control.
Wire speed specified by adaptive
control becomes lower than
minimum wire speed watch value
of adaptive control.
Detected area is exceeded beyond
maximum allowable value.
Detected area becomes lower than
minimum allowable value.
Detected mismatch is exceeded
beyond maximum allowable value.
Detected mismatch becomes lower
than minimum allowable value.
It differs from the position in which
search position obtained reference
position.
Contents of the register specified in
SF8 exceeded beyond Max.
Compensative-Surveilance val.
Contents of the register specified in
SF8 becomes lower than Min.
Compensative-Surveilance val.
It leaves the final instruction
position too much the position in
which the touch signal was
detected.
EN ratio specified by adaptive
control exceeds maximum EN ratio
watch value of adaptive control.

Error code list

5423

Sensor
failure

Adaptive EN Ratio
Short

5424

Sensor
failure

Abnormal setting of the

EN Ratio monitoring
range

5425

Sensor
failure

Abnormal setting of the

Wire speed monitoring
range

5426

Sensor
failure

Normal Angle Over

5427

Sensor
failure

Normal Angle Short

5428

Sensor
failure

Sensor kind is
mismatched.

5429

Sensor
failure

The target position and

posture cannot be
calculated.

5430

Operational
failure

5439

Sensor
failure
Sensor
failure

Playback unavailable
user task program
because it is being
used all user task.
Tracking condition file
doesn't exist.
Tracking direction
cannot be defined.

EN ratio specified by adaptive

control becomes lower than
minimum EN ratio watch value of
adaptive control.
This error occurs when the
minimum value of EN ratio
monitoring value exceeds the
maximum value in the condition
settings for the adaptive control.
This error occurs when the
minimum value of Wire speed
monitoring value exceeds the
maximum value in the condition
settings for the adaptive control.
Detected Normal angle is
exceeded beyond maximum
allowable value.
Detected Normal angle becomes
lower than minimum allowable
value.
This error occurs when the sensor
kind in the sensor step does not
meet that of the connected sensor.
The target position and posture
were not able to be calculated
according to the detection value of
the sensor, taught aim angle and
the lag angle.

Check the lists of the specified spreadsheet in the

sensor controller by WinUser. If the spreadsheet is OK,
decrease minimum EN ratio watch value of adaptive
control.
Review the minimum and maximum value of the EN
ratio monitoring value.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Review the minimum and maximum value of the Wire

speed monitoring value.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Check that Normal angle amount and modify allowable

value if needed.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Check that Normal angle amount and modify allowable

value if needed.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Check that sensor settings and /or teaching programs.

Reset failure.

Alarm

Alarm

Alarm

Alarm

on

on

(1) Please correct specified Aim Angle and Lad Angle.

(2) Please confirm whether detected Joint Normal
Angle is an expected angle with the GAP file. It is likely
to become Joint Normal not anticipated according to the
state of Groove. (3) It is likely to become this
abnormality when the absolute amount of the offset is
too large at two point search. Please reduce it in that
case.
Please confirm the starting condition of user task.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Please create the tracking condition file or edit the

program.
Please change tracking coordinates.

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

No reset
operations
neccesary.

Alarm

Alarm

Alarm

Alarm

off

on

No reset
operations
neccesary.
Turn on the
power again.

Alarm

Alarm

Alarm

Alarm

off

on

Alarm

Alarm

Alarm

Alarm

on

on

Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

After removal
of failure,
please carry
out
"failure-reset".
After removal
of failure,
please carry
out
"failure-reset".
After removal
of failure,
please carry
out
"failure-reset".
Reboot robot
controller and
sensor unit.
Error reset.

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Error

Error

Error

Error

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Reset failure.

Alarm

Alarm

Alarm

Alarm

on

on

Reset failure.

Alarm

Alarm

Alarm

Alarm

on

on

Reset failure.

Alarm

Alarm

Alarm

Alarm

on

on

Reset failure.

Alarm

Alarm

Alarm

Alarm

on

on

Reset failure.

Alarm

Alarm

Alarm

Alarm

on

on

5441

Sensor
failure

The welding length of

Test Tracking is
insufficient.

Error occurs when it is not able to

start user task program ,because
used all user task or not exist user
task program.
The condition file specified by the
tracking function doesn't exist.
For the traveling direction of the
torch is parallel to the direction of
gravity, tracking direction cannot
be defined.
Test Trackinig was not able to be
completed normally, because the
welding length was insufficient

5442

Sensor
failure

Test Tracking is
stopped.

Test Tracking is discontinued for

sensor OFF or weaving OFF.

5443

Sensor
failure

Data Sending Error.

Data was not able to be sent to the

sensor.

5444

Sensor
failure

Sensor Receive Data

Error.

NAK frame was received from the

sensor.

5445

Sensor
failure

Sensor Send Data

Error.

An abnormal frame was received

from the sensor.

5446

Sensor
failure

No Sensor Response.

Response command from the

sensor was not able to be received.

(1)Please confirm the connection of the cable between

the robot controller system and the arc sensor unit.
(2)Still, when it is not released, Control power supply is
re-switched on.

5447

Sensor
failure

Sensor ID error.

Illegal Sensor ID.

Please confirm the sensor setting.

5448

Sensor
failure

The controller could not

communicate with the sensor unit.

5449

Sensor
failure

Reboot robot controller and sensor unit. In case that the

error still occurs after rebooting, check the connection
of the sensor unit to the controller.
Please set 0 to current response after executing the test
tracking. If TIG-AVC, set 0 to arc standard voltage.

5450

Sensor
failure

The controller could not

communicate with the
Sensor unit.
ST instruction or the
sample data file is
wrong.
Extended Ethernet
Error

5451

Sensor
failure

Sensor Lens Error

5452

Sensor
failure

Sensor Interface Error

Abnormality concerning the lens

was detected with the sensor
camera.
The sensor detected the error
concerning the telecommunication
control.

5453

Sensor
failure

Sensor Hot Alarm

5454

Sensor
failure

Laser OFF

5440

The result of an online modification

cannot be applied to the sample
data.
It failed in the start of extended
Ethernet.

An internal abnormal temperature

was detected with the sensor
camera.
The Laser is disabled.

Please correspond whether to lengthen the welding

length or to slow down the speed or to raise the
weaving frequency or to reduce one section
measurement frequency of the Test Tracking setting.
Please OFF both sensor and weaving.

Reboot robot controller. Still, there is a possibility that

the increase serial board has been damaged when not
released.
(1)Please confirm the connection of the cable between
the robot controller system and the arc sensor unit.
(2)Still, when it is not released, Control power supply is
re-switched on.
(1)Please confirm the connection of the cable between
the robot controller system and the arc sensor unit.
(2)Still, when it is not released, Control power supply is
re-switched on.

Please confirm whether the extended Ethernet card is

correctly installed. Or, please confirm whether the MAC
address is correctly set. Still, there is a possibility that
the version of OS is old when this abnormality occurs.
Please contact our service department after confirming
the version number of OS etc. Back up files to external
CF memory.
Please confirm whether the protective lens is correctly
installed. Please wipe dirt off when the protective lens is
dirty or exchange it for a new lens.
Please treat it according to the instruction of the manual
when abnormality is displayed on the display of the
sensor.Please put the power supply of the sensor and
the controller again when abnormality is not displayed.
Please contact our service after confirming the version
of the sensor and the controller when same abnormality
is displayed afterward.
Please drop the power supply of the sensor, and put
time for a while at once. Please turn on the power
supply again after falling the temperature of the camera.
Please execute it after turning on the laser light. Please
check whether cables are correctly connected when it
doesn't turn on the laser light. Or, please put the power
supply of the sensor and the controller again.

4-67

Error code list

5455

Sensor
failure

The task number is

wrong.

The specified task number doesn't

exist in the sensor.

5456

Sensor
failure

The posture change

amount is excessive.

The calculated target posture has

greatly changed into the posture
when groove is detected. And,
when the amount of the change
exceeds the posture change over
watch value, this alarm is detected.

5500

User failure

Installation Angle is
updated.

Installation Angle is updated by

request from OLP.

(1)Please specify the task number made with

WeldCom. (2)Please make the task library of the
specified task number with WeldCom. (3)Please load
the task library file where the specified task number
exists into the sensor by using WeldCom.
(1) Please correct specified Aim Angle and Lead Angle.
(2) Please confirm whether detected Joint Normal
Angle is an expected angle with the GAP file. It is likely
to become Joint Normal not anticipated according to the
state of Groove. (3) Check that actual posture change
amount and modify the posture change over watch
value if needed.
Check [Constant Setting]->[12 Format and
Configuration]->[5 Installation Angle].

5501

User failure

Tool Constants are

updated.

Tool Constants are updated by

request from OLP.

Check [Constant Setting]->[3 Machine Constants]->[1

Tool Constants].

5510

Operational
failure

Operational
failure

5702

Operational
failure

It cannot re-start.

Error occurs when it is not able to

start user task program ,because
used all user task or not exist user
task program.
It generates, when it is going to use
the option function which is not set
up.
Movement in a return position or a
section state cannot be resumed.

Please confirm the starting condition of user task.

5701

Playback unavailable
user task program
because it is being
used all user task.
Option un-setting up.

5703

Shift failure

The input-and-output
signal is not set up.

Set up an input-and-output signal.

5704

Shift failure

5705

Shift failure

Abnormality occurred
by the parity check of
the shift input signal.
Other units are running
program.

This error occurs when the

input-and-output signal is not set
up.
The value of the shift input signal is
not steady.

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

Please the parity bit of the shift input signal must

normally input or confirm whether the noise has gotten
on the signal.
Please perform again after stopping all units.

No reset
operations
neccesary.
Error reset.

5706

Operational
failure

Application isn't set up.

Please set up the correct Application.

6005

Arc weld
failure

The weaving trajectory

exceeded regulation
speed.

6006

Arc weld
failure

6010

Arc weld
failure

The amount of posture

change of taught
weaving exceeded the
restriction value.
The welding current
value has exceeded
the allowable limit.

6011

Arc weld
failure

The welding voltage

value has exceeded
the allowable limit.

6014

Arc weld
failure

6015

This function command cannot be

performed while running the
program of other units.
It generates when it is going to use
the application function which is
not set up.
The amount of movements of
weaving pattern data large, or
frequency (speed) was large, the
speed of a weaving trajectory
exceeded regulation speed.
The amount of change of the
posture of weaving pattern data is
too large.

Please set up an option.

Please re-start after a step-set out of the section.

Please correct the amount of movements of weaving, or

frequency (speed).

Please correct posture change of taught weaving

pattern data.

Arc start failure.

The difference between the

welding current value measured by
the welding power supply and the
taught one has exceeded the
allowable limit set by the arc
constants.
The difference between the
welding voltage value measured by
the welding power supply and the
taught one has exceeded the
allowable limit set by the arc
constants.
No arc is generated after retrying.

Check the welding conditions(wire extension etc).

There is possibility of missmatch the welding
characteristic data to your environment if this failure
occurs over and over again. In such case, adjust the
welding characteristic data by the adjudstment of
welding condition function etc.
Check the welding conditions(wire extension etc).
There is possibility of missmatch the welding
characteristic data to your environment if this failure
occurs over and over again. In such case, adjust the
welding characteristic data by the adjudstment of
welding condition function etc.
Check the workpiece's condition, wire's condition, and
connection of the cable.

Arc weld
failure

Arc outage was

detected.

Arc outage occurred during

welding.

6016

Arc weld
failure

Wire stick was

detected.

Wire is stuck.

Eliminate all causes of arc outage, for instance by

adjusting the wedling conditions, fixing wire feed failure,
and so on.
Cut stuck wire.

6019

Arc weld
failure

Wire shortage was

detected.

Not enough wire signal is inputted.

Supply wire.

6024

Arc weld
failure

6043

Arc weld
failure
Arc weld
failure

The primary input voltage of the

welding power supply has
decreased.
It exceeded the allowable value
which the load of wire feed was set
up to by the welding fixed number.
The battery of welding power
supply is exhausted.

Refer to the instruction manual of the welding power

supply(Failure Name: Input voltage shortage) and
eliminate all causes.
A load is on the wire feed department by wear of the
liner, the chip defect, and so on. Get rid of load factors.

6044

6054

Arc weld
failure

Input voltage shortage

failure ocurred in the
welding power supply.
The load of wire feed
exceeded allowable
value.
The battery of welding
power supply is
exhausted.
WCR Short-circuit
Error

WCR of W-I/F had connected too

hastily at the time of an arc start.

Please check the state of W-I/F, and a welding power

supply.

6074

Arc weld
failure

The cooler fan's rotation has fallen

or it stops.

6080

Operational
failure

Refer to the instruction manual of the welding power

supply(Failure Name: The cooler fan failure) and
eliminate all causes.
Please start after waiting for the completion of starting.

6085

Arc weld
failure

6106

Arc weld
failure

The cooler fan failure

ocurred in the welding
power supply.
It was going to start the
unit containing the
resources under
starting.
Communication
timeout occurred inside
the welding power
supply.
The pilot arc outage is
abnormal.

6107

Arc weld
failure

Setting error of the

failure limit type.

4-68

It will generate, if the unit

containing the resources under
starting is started.

Exchange a battery because it can't be connected any

more with the welding power supply.

Reset failure.

Alarm

Alarm

Alarm

Alarm

on

on

Reset failure.

Alarm

Alarm

Alarm

Alarm

on

on

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

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Alarm

Alarm

Alarm

Alarm

on

on

No reset
operations
neccesary.
No reset
operations
neccesary.

Alarm

Alarm

Alarm

Alarm

on

on

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

Move posture
change
restriction-withi
n the limits.
No reset
operations
neccesary.

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

No reset
operations
neccesary.

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

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

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

The contollor of the welding power

supply didn't respond.

Check the route of cable and ground connection.

No reset
operations
neccesary.

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

The pilot arc outage occurred.

Check the connection condition of the cable.

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

The failure limit by the rate cannot

be set by the version of this welder.

In the welding constant, please set a relative value.

No reset
operations
neccesary.
No reset
operations
neccesary.

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

Error code list

6108

Arc weld
failure

Pilot arc ON error.

The pilot arc was not able to be

turned on.

6109

Arc weld
failure

Purge(Cleaning gas)
ON error.

The purge(cleaning gas) was not

able to be turned on.

6116

Arc weld
failure

The arc welding power supply

doesn't correspond to the
management of the consumption of
the wire.

6117

Arc weld
failure

6121

Arc weld
failure

The management of
the consumption of the
wire of the user
maintenance function
cannot be used.
The Gas OFF Delay
function cannot be
used.
The gas mass flow
value has exceeded
the allowable limit.

6122

Arc weld
failure

The gas pressure value

has exceeded the
allowable limit.

6123

Arc weld
failure

The set gas mass flow

is not output.

6140

Arc weld
failure

The speed of the wire

speed has exceeded
the allowable limit.

6141

Arc weld
failure

6142

Arc weld
failure

The welding redorder

function cannot be
used.
The welding record file
cannot be made.

6143

Arc weld
failure

Threshold trigger

6144

Arc weld
failure

Welding recorder
cannot connect to FTP
server.

6145

Arc weld
failure

Abnormality occurred
while saving the
welding record file.

6147

Arc weld
failure

6237

Sensor
failure

The load of filler feed

exceeded allowable
value.
Start Point un-detected

6238

Sensor
failure

Cannot restart during

seam tracking.

6239

Sensor
failure

ZF Deviation range
exceeded

6240

Sensor
failure
Sensor
failure

ZF search range
exceeded
ZT Position Deviation
range exceeded

6243

Sensor
failure

ZN Search range
exeeced.

6245

Sensor
failure

Deviation range
exceeded.

6249

Sensor
failure

ZT Posture Deviation
range exceeded

6261

Sensor
failure

Groove un-detected.

6294

Sensor
failure

Adaptive welding
current over

6295

Sensor
failure

Adaptive welding
current short

6296

Sensor
failure

Adaptive welding
voltage over

6297

Sensor
failure

Adaptive welding
voltage short

6241

The arc welding power supply

doesn't correspond to the Gas Off
Delay function.
The difference between the gas
mass flow value measured by the
welding power supply and the
taught one has exceeded the
allowable limit set with the
controller.
The gas pressure measured in the
arc welding power supply
exceeded the limiting value set
with the controller.
The set gas mass flow was not
output in specified time.
The speed of the wire measured in
the arc welding power supply has
exceeded the allowable limit at the
speed of the wire that the arc
welding power supply output.
There is not becoming empty in the
memory that memorizes the
welding record data.
The file cannot be made because
there is no free space of the
device.
The threshold specified under the
welding record condition was
detected in the arc welding power
supply.
It was not a connection to the FTP
server that was saving device for a
welding recorder. Or, neither an
initial folder nor the folder of this
name existed on the home
directory of the FTP server.
The welding recorder cannot save
record file. The storage medium is
not prepared, and read-only and
memory capacity shortage, etc. are
thought.
The filler feed load has exceeded
the allowable value set in the arc
constant.
This failure occurs when the start
point is not detected during ZF
search.
Cannot restart during seam
tracking.
This error occurs when the
distance between the detected
start point and ZF taught point
exceeded the deviation range.
This error occurs when the robot
moves beyond search range
This error occurs when the robot
moves beyond Position deviation
range
This error occurs when the robot
moves beyond search range during
ZN.
This error occurs when the
distance between the detected end
point and taught point before ZE
exceeded the deviation range.
This error occurs when the robot
moves beyond Posture deviation
range
Groove cannot be detected.

Welding current specified by

adaptive control exceeds
maximum current watch value of
adaptive control.
Welding current specified by
adaptive control becomes lower
than minimum current watch value
of adaptive control.
Welding voltage specified by
adaptive control exceeds
maximum voltage watch value of
adaptive control.
Welding voltage specified by
adaptive control becomes lower
than minimum voltage watch value
of adaptive control.

Please check follows. (1)Turn off the purge(cleaning

gas). (2)Release the emergency stop. (3)Reset plasma
unit/WPS error. (4)Set weld ON. (5)Set the registration
of welder "PlasmaDA" or "PlasmaWPS".
Please check follows. (1)Turn off the pilot arc.
(2)Release the emergency stop. (3)Reset plasma unit
error.
The upgrade should do the software of the arc welding
power supply.

No reset
operations
neccesary.

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

No reset
operations
neccesary.
No reset
operations
neccesary.

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

The upgrade should do the software of the arc welding

power supply. Or, please set the Gas OFF Delay time to
0.
Please confirm the remainder pressure of gas cylinder,
the piping of the gas, and the setting of the gas mass
flow control unit.

No reset
operations
neccesary.
No reset
operations
neccesary.

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

Please confirm the remainder pressure of gas cylinder,

the piping of the gas, and the setting of the gas mass
flow control unit.

No reset
operations
neccesary.

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

Please confirm the residual quantity of the gas cylinder,

the piping of the gas, and the setting of the gas mass
flow control unit.
Please confirm whether an excessive load contracts the
wire feeder. Please contact our customer service center
when the permissible value is large.

No reset
operations
neccesary.
No reset
operations
neccesary.

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

Please reduce the number of record data.

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

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

Please confirm host name, user ID, password, and

initial folder of ftp client.

No reset
operations
neccesary.

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

Please confirm the state of the storage medium.

No reset
operations
neccesary.

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

A load is on the filler feeder by wear of the liner, the chip

defect, and so on. Remove the factors.

No reset
operations
neccesary.
Error reset.

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

Please secure the free space of the device.

Please confirm the arc welding construction condition.

(1)Check the groove recognization by WinUser.

(2)Enlarge the ZF maximum search range.
Do not modify the position and posture of the robot
when the robot is stopped in ZT period if the restarting
is required.
Check detected position. If no problems exist,
moodify(enlarge) the ZF deviation range parameter or
program to rectify error.

Error reset.

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

Error reset.

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

Modify(enlarge) the search range or program to rectify

error.
Check the target position If no problems exist,
moodify(enlarge) the ZT parameters or program to
rectify error.
Modify(enlarge) the ZN search range or program to
rectify error.

Error reset.

Inform
ation
Inform
ation

Inform
ation
Inform
ation

Inform
ation
Inform
ation

Inform
ation
Inform
ation

on

on

on

on

Error reset.

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

Check the detected point. If no problems exist,

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

Error reset.

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

Check the target posture If no problems exist,

moodify(enlarge) the ZT parameters or program to
rectify error.
(1)Check that LASER power is ON.(2)Check the cable
between Laser Sensor Unit and Sensor Head is
connected properly.(3)Check the cable between Robot
Controller and Laser Sensor Unit is connected properly.
Check the lists of the specified spreadsheet in the
sensor controller by WinUser. If the spreadsheet is OK,
increase maximum current watch value of adaptive
control.
Check the lists of the specified spreadsheet in the
sensor controller by WinUser. If the spreadsheet is OK,
decrease minimum current watch value of adaptive
control.
Check the lists of the specified spreadsheet in the
sensor controller by WinUser. If the spreadsheet is OK,
increase maximum voltage watch value of adaptive
control.
Check the lists of the specified spreadsheet in the
sensor controller by WinUser. If the spreadsheet is OK,
decrease minimum voltage watch value of adaptive
control.

Error reset.

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

Take
countermeasur
es and reset
failure.
Error reset.

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

Error reset.

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

Error reset.

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

Error reset.

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

Error reset.

4-69

Error code list

6298

Sensor
failure

Adaptive travel speed

over

Travel speed specified by adaptive

control exceeds maximum speed
watch value of adaptive control.

6299

Sensor
failure

Adaptive travel speed

short

6300

Sensor
failure

Search range
exceeded.

Travel speed specified by adaptive

control becomes lower than
minimum speed watch value of
adaptive control.
This error occurs when the robot
moves beyond search range

6301

Sensor
failure

Search range is short

6302

Sensor
failure

Deviation range
exceeded.

6303

Sensor
failure
Sensor
failure
Sensor
failure

Gap Over

6306

Sensor
failure

Groove depth short

6307

Sensor
failure
Sensor
failure
Sensor
failure
Sensor
failure
Sensor
failure
Sensor
failure
Sensor
failure

Angle1 over

6330

Sensor
failure

Correction amount by
arc-sensor exceeds
specified value.

6331

Sensor
failure

6332

Sensor
failure

Calculation turns to
unstable during
arc-sensing process.
Welding position
cannot be detected

6333

Sensor
failure

Unstable wire-feeding.

6334

Sensor
failure
Sensor
failure

ST parameter error.

6336

Sensor
failure

Adaptive Wire Speed

Over

6337

Sensor
failure

Adaptive Wire Speed

Short

6338

Sensor
failure
Sensor
failure
Sensor
failure
Sensor
failure
Sensor
failure

Area Over

6343

Sensor
failure

Adaptive EN Ratio
Short

6344

Sensor
failure

Normal Angle Over

6345

Sensor
failure

Normal Angle Short

6404

Sensor
failure

Adaptive weaving
amplitude over

6304
6305

6308
6309
6310
6311
6312
6329

6335

6339
6340
6341
6342

4-70

Gap short
Groove depth over

Angle1 short
Angle2 over
Angle2 short
Groove un-detected
Unstable detection
The target position and
posture cannot be
calculated.

ZJ Deviation range
exceeded

Area Short
Mismatch Over
Mismatch Short
Adaptive EN Ratio
Over

Check the lists of the specified spreadsheet in the

sensor controller by WinUser. If the spreadsheet is OK,
increase maximum speed watch value of adaptive
control.
Check the lists of the specified spreadsheet in the
sensor controller by WinUser. If the spreadsheet is OK,
decrease minimum speed watch value of adaptive
control.
Modify(enlarge) the search range or program to rectify
error.

This error occurs when the robot

detect the touch status within
minimum search range.
This error occurs when the robot
moves beyond deviation range

Modify(shorten) the search range or program to rectify

error.

Detected gap is exceeded beyond

maximum allowable value.
Detected gap becomes lower than
minimum allowable value.
Detected groove depth is
exceeded beyond maximum
allowable value.
Detected groove depth becomes
lower than minimum allowable
value.
Detected angle1 is exceeded
beyond maximum allowable value.
Detected angle1 becomes lower
than minimum allowable value.
Detected angle2 is exceeded
beyond maximum allowable value.
Detected angle2 becomes lower
than minimum allowable value.
Groove position cannot be
detected
This error occurs when measured
data is unstable.
The target position and posture
were not able to be calculated
according to the detection value of
the sensor, taught aim angle and
the lag angle.

Check that gap amount and modify allowable value if

needed.
Check that gap amount and modify allowable value if
needed.
Check that groove depth amount and modify allowable
value if needed.

Error is activated when the case

that correction amount by the
sensor exceeds the specified value
in teaching parameter.
This error is activated when
stability of welding arc decreased
significantly.
This error is activated when the
deviation detection cannot be
calculated during arc-sensing
process. Note that position
correction is not executed.
Wire-feeding status turn to
unstable. Deviation is lager than
specified value.
The instruction parameter of ST
command is over the setting range.
This error occurs when the
distance between the detected
point and ZJ reference point
exceeded the deviation range.
Wire Speed specified by adaptive
control exceeds maximum wire
speed watch value of adaptive
control.
Wire speed specified by adaptive
control becomes lower than
minimum wire speed watch value
of adaptive control.
Detected area is exceeded beyond
maximum allowable value.
Detected area becomes lower than
minimum allowable value.
Detected mismatch is exceeded
beyond maximum allowable value.
Detected mismatch becomes lower
than minimum allowable value.
EN ratio specified by adaptive
control exceeds maximum EN ratio
watch value of adaptive control.
EN ratio specified by adaptive
control becomes lower than
minimum EN ratio watch value of
adaptive control.
Detected Normal angle is
exceeded beyond maximum
allowable value.
Detected Normal angle becomes
lower than minimum allowable
value.
Weaving amplitude specified by
adaptive control exceeds
maximum amplitude watch value of
adaptive control.

Modify(enlarge) the deviation range or program to

rectify error.

Error reset.

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

Error reset.

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

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

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

Inform
ation
Inform
ation
Inform
ation

Inform
ation
Inform
ation
Inform
ation

Inform
ation
Inform
ation
Inform
ation

Inform
ation
Inform
ation
Inform
ation

on

on

on

on

on

on

Error reset.
Error reset.

Check that groove depth amount and modify allowable

value if needed.

Error reset.

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

Check that angle1 amount and modify allowable value if

needed.
Check that angle1 amount and modify allowable value if
needed.
Check that angle2 amount and modify allowable value if
needed.
Check that angle2 amount and modify allowable value if
needed.
Check setting parameters in GFF file.

Error reset.

Inform
ation
Inform
ation
Inform
ation
Inform
ation
Inform
ation
Inform
ation
Inform
ation

Inform
ation
Inform
ation
Inform
ation
Inform
ation
Inform
ation
Inform
ation
Inform
ation

Inform
ation
Inform
ation
Inform
ation
Inform
ation
Inform
ation
Inform
ation
Inform
ation

Inform
ation
Inform
ation
Inform
ation
Inform
ation
Inform
ation
Inform
ation
Inform
ation

on

on

on

on

on

on

on

on

on

on

on

on

on

on

Error reset.
Error reset.
Error reset.
Error reset.

Check that target surface condition and/or

measurement angle.
(1) Please correct specified Aim Angle and Lad Angle.
(2) Please confirm whether detected Joint Normal
Angle is an expected angle with the GAP file. It is likely
to become Joint Normal not anticipated according to the
state of Groove. (3) It is likely to become this
abnormality when the absolute amount of the offset is
too large at two point search. Please reduce it in that
case.
Check that currect torch position. If it is OK, extend the
value CHASING RANGE in teaching parameter. If it is
NG, try to adjust sensor parameters.

Error reset.

Error reset.

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

Check that welding condition to be stable.

Error reset.

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

Try to re-adjust sensing parameters.

Error reset.

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

Check that equipments for wire feeding.

Error reset.

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

It improves whether each parameter is setting within the

limits.
Check detected position. If no problems exist,
modify(enlarge) the ZJ deviation range parameter or
program to rectify error.

Error reset.

Inform
ation
Inform
ation

Inform
ation
Inform
ation

Inform
ation
Inform
ation

Inform
ation
Inform
ation

on

on

on

on

Check the lists of the specified spreadsheet in the

sensor controller by WinUser. If the spreadsheet is OK,
increase maximum wire speed watch value of adaptive
control.
Check the lists of the specified spreadsheet in the
sensor controller by WinUser. If the spreadsheet is OK,
decrease minimum wire speed watch value of adaptive
control.
Check the area watch value(maximum) and enlarge if
needed.
Check the area watch value(minimum) and decrease if
needed.
Check the mismatch watch value(maximum) and
enlarge if needed.
Check the mismatch watch value(minimum) and
decrease if needed.
Check the lists of the specified spreadsheet in the
sensor controller by WinUser. If the spreadsheet is OK,
increase maximum EN ratio watch value of adaptive
control.
Check the lists of the specified spreadsheet in the
sensor controller by WinUser. If the spreadsheet is OK,
decrease minimum EN ratio watch value of adaptive
control.
Check that Normal angle amount and modify allowable
value if needed.

Error reset.

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

Error reset.

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

Error reset.

Inform
ation
Inform
ation
Inform
ation
Inform
ation
Inform
ation

Inform
ation
Inform
ation
Inform
ation
Inform
ation
Inform
ation

Inform
ation
Inform
ation
Inform
ation
Inform
ation
Inform
ation

Inform
ation
Inform
ation
Inform
ation
Inform
ation
Inform
ation

on

on

on

on

on

on

on

on

on

on

Error reset.

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

Error reset.

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

Check that Normal angle amount and modify allowable

value if needed.

Error reset.

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

Check the lists of the specified spreadsheet in the

sensor controller by WinUser. If the spreadsheet is OK,
increase maximum amplitude watch value of adaptive
control.

Error reset.

Inform
ation

Inform
ation

Inform
ation

Inform
ation

on

on

No reset
operations
neccesary.

Error reset.

Error reset.
Error reset.
Error reset.
Error reset.

Error code list

6448

TP failure

6449

TP failure

7000
9001

User failure
Emergency
stop failure

9002

Emergency
stop failure

9003

Operational
failure

Abnormal velocity
command. Modify
abnormal axis motion.

9005

Servo failure

Position Deviation error

This failure occurs when the

deviation between the command
and encoder data position exceeds
the set permissible deviation.

9011

Emergency
stop failure

9012

Emergency
stop failure

The robot's joint angle

before and behind a
record point was not in
agreement.
The amount of step
movements is
abnormal.

9020

CPU board
failure

Error of Interpolation
Stop.

The robot joint angle of this step

starting point and the robot joint
angle of the last step target point is
different.
The result which added the amount
of step movements to the robot's
joint angle in a starting point is not
in agreement with the robot joint
angle in a target point.
Motion control section detected the
Time-out Error of Interpolation
Stop.

9021

CPU board
failure

Error of Waiting for

arriving of target
position.

Robot has not arrived at target

position.

9022

CPU board
failure

Error of Waiting for

arriving of accuracy
position.

Robot has not arrived at target

position accurately.

9023

CPU board
failure

Error of interruption of
Position Command.

Position Command interrupted.

9024

CPU board
failure
CPU board
failure

Error of mechanism
resource acquisition.
Safety slow speed
error

Motion control section didn't

acquire mechanism resource.
Robot speed does not become
safety level.

9026

CPU board
failure

Stop Release error

Stop command of Motion control

section was not released.

9027

CPU board
failure

System freezing

It became impossible to continue

the playback of a program.

9028

CPU board
failure

Motion Calculation
error

Motion control section detected

Calculation error.

9030

Emergency
stop failure

Error of brake delay in

interference detection.

The axis that the brake doesn't lock

even if prescribed time has passed
since interference was detected
exists..

Turn motors ON by pressing the Motor-ON button..

9031

Control
failure

Frequent input-signal caused

system busy.

Check input-signal.

9032

Emergency
stop failure

Extremely frequent
input-signal was
detected.
Reducer modeling
reverse amends error.

9033

CPU board
failure

Motion synchronous
error

When reversely making amends by

the reducer modeling, the amount
of amends exceeded a specified
value.
Synchronous processing inside a
motion was not performed
normally.

9034

CPU board
failure

Waiting timeout for

robot starting

9100

Emergency
stop failure

Stop interpolation

Contact our service department. Back up files to

external CF memory. Because the robot stop step is
different to the execute step, step-set must be needed
for restart.
Contact our service department. Back up files to
external CF memory. Because the robot stop step is
different to the execute step, step-set must be needed
for restart.
Contact our service department. Back up files to
external CF memory. Because the robot stop step is
different to the execute step, step-set must be needed
for restart.
Contact our service department. Back up files to
external CF memory. Because the robot stop step is
different to the execute step, step-set must be needed
for restart.

9025

Battery remainder
amount shortage of the
wireless T/P.
Wireless strength
shortage of th wireless
T/P
User failure.
The robot's joint angle
before and behind a
record point was not in
agreement.
The amount of step
movements is
abnormal.

The capacity of the battery of the

wireless T/P has decreased.

Please connect with the cradle, and charge with the

battery.

Wireless strength of the wireless

T/P has weakened.

Please bring the wireless T/P close to the controller.

User failure.
The robot's joint angle was not in
agreement at the starting point of
this step and the target point of this
step.
The result which added the amount
of step movements to the robot's
joint angle in a starting point is not
in agreement with the robot joint
angle in a target point.
Abnormal velocity command data
is calculated.

Please carry out "failure-reset".

Contact our service department. Back up files to
external CF memory. Because the robot stop step is
different to the execute step, step-set must be needed
for restart.
Contact our service department. Back up files to
external CF memory. Because the robot stop step is
different to the execute step, step-set must be needed
for restart.

In spite of having canceled the

synchronous waiting within a
motion, a robot did not start for a
definite period of time.
Motion control section stopped the
calculation of interpolation.

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

Inform
ation

Inform
ation

Inform
ation

Inform
ation

off

off

Inform
ation

Inform
ation

Inform
ation

Inform
ation

off

off

Error
Alarm

Error
Error

Error
Alarm

Error
Error

on
on

on
on

Error reset.

Alarm

Error

Alarm

Error

on

on

Modify abnormal axis motion to be minimized. Contact

our service department in case axis motion is not so
big. Back up files to external CF memory. Because the
robot stop step is different to the execute step, step-set
must be needed for restart.
(1)Please confirm whether the robot manipulator
interferes in something.(2)Please confirm that the
Pay-load is within the nominal rating.(3)If failure
persists, the problem may be a mechanical defect in the
manipulator, contact our service department.
Contact our service department. Back up files to
external CF memory. Because the robot stop step is
different to the execute step, step-set must be needed
for restart.
Contact our service department. Back up files to
external CF memory. Because the robot stop step is
different to the execute step, step-set must be needed
for restart.

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

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Turn on the
power again.

Error

Error

Error

Error

on

on

Contact our service department. Back up files to

external CF memory. Because the robot stop step is
different to the execute step, step-set must be needed
for restart.
Contact our service department. Back up files to
external CF memory. Because the robot stop step is
different to the execute step, step-set must be needed
for restart.
Contact our service department. Back up files to
external CF memory. Because the robot stop step is
different to the execute step, step-set must be needed
for restart.
Contact our service department. Back up files to
external CF memory. Because the robot stop step is
different to the execute step, step-set must be needed
for restart.
Contact our service department. Back up files to
external CF memory.
Contact our service department. Back up files to
external CF memory. Because the robot stop step is
different to the execute step, step-set must be needed
for restart.
Contact our service department. Back up files to
external CF memory. Because the robot stop step is
different to the execute step, step-set must be needed
for restart.
This error may be avoidable by changing program. Ex.
(1)A Delay command (Fn50) is inserted before the step
which the error generated, (2)Movement command of
the same point is inserted, (3)Movement command is
changed into the in-position check(with P). When this
error occurs, a stop step differs from an execution step.
Please play back carefully enough after checking
operation in teach mode. When this error recurs, please
back up a file and contact to our service.
Contact our service department. Back up files to
external CF memory. Because the robot stop step is
different to the execute step, step-set must be needed
for restart.

Error reset.

Error

Error

Error

Error

on

on

Error reset.

Error

Error

Error

Error

on

on

Error reset.

Error

Error

Error

Error

on

on

Error reset.

Error

Error

Error

Error

on

on

Error reset.

Error

Error

Error

Error

on

on

Error reset.

Error

Error

Error

Error

on

on

Error reset.

Error

Error

Error

Error

on

on

Error reset.

Error

Error

Error

Error

on

on

Because the
robot stop step
is different to
the execute
step, step-set
must be
needed for
restart. Error
reset.
Please do
error reset or
turn on the
drive
preparation.
Turn on the
power again.

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Error reset.

Error

Error

Error

Error

on

on

Error reset.

Error

Error

Error

Error

on

on

Error reset.

Error

Error

Error

Error

on

on

Turn on the
power again.

Error

Error

Error

Error

on

on

4-71

Error code list

9101

Emergency
stop failure
Emergency
stop failure
CPU board
failure
CPU board
failure

Exceed operation time

9113

CPU board
failure

System Error
(RT_FLT_DENORMAL
_OPERAND).

9114

CPU board
failure

9115

CPU board
failure

9116

CPU board
failure

9117

CPU board
failure

System Error
(RT_FLT_DIVIDE_BY_
ZERO).
System Error
(RT_FLT_INEXACT_R
ESULT).
System Error
(RT_FLT_INVALID_O
PERATION).
System Error
(RT_FLT_OVERFLOW
).

9119

CPU board
failure

System Error
(RT_FLT_UNDERFLO
W).

9120

CPU board
failure

9129

CPU board
failure

9140

CPU board
failure

System Error
(RT_INT_DIVIDE_BY_
ZERO).
System Error
(RT_ILLEGAL_INSTR
UCTION).
System Error (Mutex
Timeout).

9144

CPU board
failure

System Error (MailBox

Timeout Error).

System Error. MailBox Timeout.

9151

Emergency
stop failure
CPU board
failure

Stop interpolation by
system busy
The Hibernation is not
enabled.

9153

CPU board
failure

An internal memory is
not nomally allocated.

9200

CPU board
failure
CPU board
failure
CPU board
failure

Motion process is not

recognized.
I/O system is not
recognized.
Servo communication
initialization failure

Motion control section stopped the

calculation of interpolation.
Because abnormality occurred
when Hibernation file is made, the
Hibernation is not enabled.
(Details) (1)Device opening
abnormality of D drive.
(2)Hibernationfile cannot be made.
(3)Can not lock D drive. (4)Can not
dismount D drive.(5)Can not unlock
D drive.
When initialize robot controller,an
internal memory is not nomally
allocated.
Can't recongnize Motion process.

9209

Amplifier
unit failure

Brake fuse off

This failure occurs when the fuse

F1 on the brake control board
UM351/L21700X00 was cut.

(1)Please exchange the brake fuse. (2)Replace the

drive unit.

9210

Amplifier
unit failure

Brake fuse
off.(additional axis)

This failure occurs when the fuse

F1-1 or F1-2 on brake control
substrate UM226(L9172Y) was
cut.

Please exchange the brake fuse.

9213

Amplifier
unit failure

Drive unit power failure

This failure occurs when the drive

unit power PG15(+15V) was not
supplied.

Please replace the drive unit.

9216

Control
failure

Low voltage of
sequence control
power supply

This failure occurs when the

voltage of sequence control power
supply P1(24V) is decreases.

(1)Please check the voltage of sequence control power

supply P1(24V). (2)Please remove the sequence board
and insert it again. (3)Please check the external signal
wire of I/O is correctly connected. (4)Please exchange
the multi power supply unit. (5)Please exchange the
sequence board.

9217

Amplifier
unit failure

Servo shared memory

abnormal

This failure occurs when reading or

wrinting data to the shared memory
between servo communication
CPU and servo CPU was not
successfully finished.

Please replace the drive unit.

9218

CPU board
failure
CPU board
failure

Servo CPU(#2) DP
memory error.
Servo CPU(#3) DP
memory error.

Servo CPU(#2) D.P.memory error

Replace the Drive Unit.

Servo CPU(#3) D.P.memory error

Replace the Drive Unit.

9102
9103
9105

9152

9204
9208

9219

4-72

Playback cannot be
continued.
System Error
(RT_BREAKPOINT).
System Error
(RT_ACCESS_VIOLA
TION).

The robot dose not work

continuously.
I/O signal was not able to be
processed.
A breakpoint was encountered.
The thread attempted to read from
or write to a virtual address for
which it does not have the
appropriate access.
One of the operands in a
floating-point operation is
denormal. A denormal value is one
that is too small to represent as a
standard floating-point value.
The thread attempted to divide a
floating-point value by a
floating-point divisor of zero.
The result of a floating-point
operation cannot be represented
exactly as a decimal fraction.
This exception represents any
floating-point exception not
included in this list.
The exponent of a floating-point
operation is greater than the
magnitude allowed by the
corresponding type.
The exponent of a floating-point
operation is less than the
magnitude allowed by the
corresponding type.
The thread attempted to divide an
integer value by an integer divisor
of zero.
The method has terminated due to
invalid parameters or property
values.
System Error. Mutex Timeout.

Can't recognize I/O system.

This failure occurs when the
communication between the CPU
board and the drive unit (the servo
board) cannot begin.

Contact our service department. Back up files to

external CF memory.
Contact our service department. Back up files to
external CF memory.
Turn on the power again. If the error is not released,
reinstall the system.
Turn on the power again. If the error is not released,
reinstall the system.

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

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Turn on the power again. If the error is not released,

reinstall the system.

Turn on the
power again.

Error

Error

Error

Error

on

on

Turn on the power again. If the error is not released,

reinstall the system.

Turn on the
power again.

Error

Error

Error

Error

on

on

Turn on the power again. If the error is not released,

reinstall the system.

Turn on the
power again.

Error

Error

Error

Error

on

on

Turn on the power again. If the error is not released,

reinstall the system.

Turn on the
power again.

Error

Error

Error

Error

on

on

Turn on the power again. If the error is not released,

reinstall the system.

Turn on the
power again.

Error

Error

Error

Error

on

on

Turn on the power again. If the error is not released,

reinstall the system.

Turn on the
power again.

Error

Error

Error

Error

on

on

Turn on the power again. If the error is not released,

reinstall the system.

Turn on the
power again.

Error

Error

Error

Error

on

on

Turn on the power again. If the error is not released,

reinstall the system.

Turn on the
power again.

Error

Error

Error

Error

on

on

(1)Please turn on the power again.(2)Please connect

and disconnect CPU board or system CF.(3)Please
reinstall the system.(4)Please replace the CPU board.
(1)Please turn on the power again.(2)Please connect
and disconnect CPU board or system CF.(3)Please
reinstall the system.(4)Please replace the CPU board.
Contact our service department. Back up files to
external CF memory.
Turn on the power again. If the error is not released,
contact our service department. Back up files to
external CF memory.

Turn on the
power again.

Error

Error

Error

Error

on

on

Turn on the
power again.

Error

Error

Error

Error

on

on

Error reset.

Error

Error

Error

Error

on

on

Error reset.

Error

Error

Error

Error

on

on

(1)Turn on the power again. If the error is not released,

contact our service department.(2)Please replace
system CF.
Turn on the power again. If the error is not released,
reinstall the system.
Turn on the power again. If the error is not released,
reinstall the system.
(1)Please check whether the connector of the drive unit
(CNCOM) is correctly connected. (2)Please check
whether the connector of the CPU board (CNLAN3) is
correctly connected. (3)Please replace the drive unit.
(4)Please replace the CPU board. (5)Please replace
the cable between the drive unit and te CPU board.

Turn on the
power again.

Error

Error

Error

Error

on

on

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

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Error code list

9220

Servo failure

An inconsistency was
detected in the servo
failure.

This failure occurs when an

inconsistency was detected in
servo failure.

9225

CPU board
failure
CPU board
failure
CPU board
failure
CPU board
failure
Amplifier
unit failure

Servo CPU(#1 axis) is

not ready.
Servo CPU(#2 axis) is
not ready.
Servo CPU(#3 axis) is
not ready.
Servo CPU(#4 axis) is
not ready.
Brake fuse off.(F1)

Nothing acknowledge form servo

CPU(#1 axis)
Nothing acknowledge form servo
CPU(#2 axis)
Nothing acknowledge form servo
CPU(#3 axis)
Nothing acknowledge form servo
CPU(#4 axis)
This failure occurs when the fuse
F1 on servo board
UM351/L21700X00 was cut.

CPU board
failure
Operational
failure

Servo CPU(#9 axis) is

not ready.
Operational failure.

Nothing acknowledge form servo

CPU(#9 axis)
insertion external memory during
playback.

Replace the Drive Unit.

9240

Amplifier
unit failure

Drive unit power failure

This failure occurs when drive unit

power (+24V) was not supplied.

9241

Amplifier
unit failure

Drive unit precharge

failure

This failure occurs when drive unit

precharge was not executed.

(1)Please check fuse(F3) on servo board

UM351/L21700X00. Replace fuse(F3) when it is out.
(2)Please check the cable connector
CNMCH,CNSV,CNMS,CNEC1. (3)Please replace the
drive unit.
(1)Please check supply voltage(+24V) for drive unit.
(2)Please replace the drive unit.

9242

Amplifier
unit failure

Drive unit phase lack.

This failure occurs when drive unit

lacked a phase of power supply.

(1)Please check primary power source. (2)Please

check supply voltage. (3)Please replace the power unit.
(4)Please replace the drive unit.

9243

Amplifier
unit failure

Drive unit power failure

This failure occurs when drive unit

power P10V(+10V) was not
supplied.

Please replace the drive unit.

9244

Amplifier
unit failure

Current sensor failure

Error occurs if the current sensor is

abnormal.

Please replace the Drive Unit.

9226
9227
9228
9229

9233
9234

(1)Please check whether the cable connected with

CNSV has been disconnected. (2)Please turn OFF and
ON the primary power and restart the controller.
(3)Please replace the drive unit. (4)Please replace the
sequence board. UM352/L21700F00.
Replace the Drive Unit.
Replace the Drive Unit.
Replace the Drive Unit.
Replace the Drive Unit.
(1)Please check brake fuse(F1) on servo board.
(2)Please check the manipulator wirings and the control
cables between the robot and the controller. (3)Please
replace the drive unit.

restart playback.

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

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Alarm

Alarm

Alarm

Alarm

on

on

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

Error

Error

Error

Error

on

on

4-73

Error code list

NOTE

4-74

Chapter 5 Robot Diagnosis

This section describes the user check function for notifying operators of the robot
inspection timing, parts replacement timing and other inspection-related
information.
5.1 Robot Diagnosis .........................................................................................5-1
5.1.1 Program Diagnosis ...............................................................................5-1
5.1.2 OverHaul Time ......................................................................................5-3

5.1 Robot Diagnosis

5.1 Robot Diagnosis

In this controller, functions that can be used for robot diagnosis and preventional maintenance are provided.
This chapter explains those functions.
The data for robot diagnosis are recorded automatically all the time. There are no special operations to record
the diagnosis data.

POINT

The menu that is not described in this chapter can not be used. Those menus are not
supported or only for our service engineers. And, axes of which the diagnosis data is not
displayed are not supported.

5.1.1 Program Diagnosis

The load torque for each axis etc. can be analyzed for every program. When opening this screen, the
diagnosis data of the last playback operation will be displayed.
(Except for partial accumulated data) The diagnosis data is updated for every playback operation. The past
history is not stored.
1 Open <ServiceUtilities> - [25 Robot Diagnosis] [1 Program Diagnosis].
>> The diagnosis data for the last playback operation of the current program. If the
program has not played back even 1 time, the data that was displayed at last time will be
displayed again.
1st page (main data)
Program number
can be changed.

Page number
can be changed.

Diagnosi
data
can be cleared.

Press <Page up/down> keys to change the page.

2nd page (Spot welding related data)

3rd page (Velocity and toque)

Press [Reset / R] key to exit.

5-1

5.1 Robot Diagnosis

1st page
Item
UNIT

Description
The present program No.and the present UNIT No.

Program
START TIME

This is the time when the cycle time measurement was started.

CYCLE TIME

The newest cycle time is displayed here.

This is the total number of the cycles from when the controller power was turned
ON.
The time used for I signal waiting functions e.g. FN525 WAITI etc. and
percentage.
The time used for timer waiting functions e.g. FN50 DELAY etc. and
percentage.
This is the reason why the cycle time measurement was terminated.
If "Cycle was ended" is not displayed here, the measurement was terminated in
half way. In that case, the data does not show the correct information for the
whole program.
If there are some axes that exceeded the allowable peak torque, the step is
displayed up to 10.
If some data are displayed here, please check if the tool mass and COG are set
correctly. And, it is recommended to slow down the recorded speed for the step.

TOTAL CYCLE
I WAITING
TIMER

ENDING TIME

Torque over

2nd page
Item
SPOT TIME
CYCLE TIME
(The number of spot
welding)

Description
This is the total time of spot welding execution.
This is displayed for every welding machine. (W1W6)
Number of spot welding.
This is displayed for every welding machine. (W1W6)

3rd page
Item
AV. SPEED [rpm]
(Average speed)
MAX. SPEED [rpm]
(Maximum speed)

AV. TORQ [Nm] [%]

(Average torque)
MAX. TORQ [Nm] [%]
(Maximum torque)

LIFE SPAN [Hr]

X100[Tm]

Description
The average and the maximum value of the motor rotation velocity of each axis.
The average torque of each axis is displayed as the ratio [%] for the rated
torque.
The maximum torque of each axis is displayed as the ratio [%] for the allowable
peak torque.
If the operator class is EXPERT or higher, the torque value [Nm] is displayed
also.
If there is an axis whose maximum torque exceeds 100%, please check if the
tool mass and the center of gravity are set correctly. And, it is recommended to
slow down the recorded speed in the step in which the concerned axis moves
fast.
The remaining life [Hour] of reduction gear of each axis is displayed in a
premise that this program is continued to be played back. The life is also in the
number of playback cycles also.
Please be sure that this value is calculated in a premise that the robot is very
new. Therefore, this value has nothing to do with the present condition of the
robot mechanism. And, this is an estimated value that is calculated using a
life span equation under a condition that the torque larger than the allowable
limit will not occur. Please regard this value just a reference.
When the calcullated value is smaller than 5,000 [Hours], an information "I3149"
will be displayed.

5-2

5.1 Robot Diagnosis

5.1.2 OverHaul Time

The "LIFE SPAN" described in "5.1.1 Program Diagnosis" is just a result that was calculated after 1 time
playback. On the other hand, this "OverHaul Time" menu can forecast the over haul time (= reduction gear's
life) by gathering the torque information accumulated in the memory.
This value is calculated by analyzing/accumulating the all motion of the robot in the actual playback operation.
And, this is an estimated value that is calculated using a life span equation under a condition that the
torque larger than the allowable limit will not occur. Please regard this value just a reference.
1

Open <ServiceUtilities> - [25 Robot Diagnosis] [2 OverHaul Time].

>>A screen like the following will be displayed.

Press [Reset/R] key to exit without saving.

Press <Complete> to save the data.

Item
Remainder of life Ratio
Mechanism

Description
For a new reduction gear, "100.0%" should be displayed. And this value will
decrease while the robot is moving. And, when the value reaches "0%", it is
necessary to replace the reduction gear. If the value is getting small, please
contact our service department. (The tentative limit is 10% or 1000[Hr].)
The name of the mechanism and the axis is displayed for a mechanism of which
the "Remainder of life Ratio" is the smallest.

Axis
Overhaul
CycleConv.
Base Cycle Time
Start Time

This is the remaining time [Hours] until the overhaul (reduction gear
replacement). If the time for 1 cycle is set to the "Base Cycle Time" in [sec], the
"CycleConv." (Number of cycles) is also displayed.
This is the time when the measurement was started.

When the reduction gear is replaced with new one

to open this screen and input

Press
"0" for the concerned axis and then press
<Complete> to save the data. Then the
"Remainder of life Ratio" for the axis will
return to 100.0%.
When "Remainder of life Ratio" is initialized in case of memory format operation etc..
Please enter the total moving time so far of the reduction gear to "Consumption time until present".

POINT

Because these values will be changed to wrong values when executing format operation or
backup restore operation, please memorize these values before doing those operations and
after finishing those operation, input the memorized values again.

5-3

5.1 Robot Diagnosis

Settings of "Torque over display" and "Torque calculation method

In case of operator class SPECIALIST, the following setting can be changed.
Item

Current
Torque
calculation
method can be
selected.

Analyze
(Torque analization
method)

Default setting:
"Current"

Position

Description
The torque is estimated by referring to the actual
motor current. The estimated torque includes the
influence of the waste of the mechanism. But it also
includes the calculation error due to the actuator
system.
By referring to the robot's mass model and the angles
(positions) of each axis, each axis's torque is
calculated based on motion equation. Because this
calculation is done based on the logical mass model
only, it does not include the influence of the waste of
the mechanism. But the calculation is more accurate
than the setting of <Current>.
(CAUTION)

To calculate the torque accurately, the tool

setting (weight, COG, and inertia) and user load
setting must be set correctly.
If a robot is used with the setting of "Analyze" = "Position", the robot controller cannnot detect
the change of the torque due to the mechanical waste. As a result, there may be possibility
that unexpected malfunction of the robot occurs in the future. After confirming the motion of
the program with the setting of "Position", do not forget to change the setting to "Current".

CAUTION
How to use

Set the "Analyze" to "Position".

Playback the all programs for the production.

3
4

If "I3148" occurs, please try to take counter measure e.g. slow down the motion
speed, change the tool to light one, etc.
If "I3148" is not detected, change the setting of "Analyze" to "Current".

Playback the all programs for the production.

If "I3148" occurs again, please try to take counter measure e.g. slow down the
motion speed, change the tool to light one, etc.
If "I3148" is not detected, start the production.

5-4

5.1 Robot Diagnosis

Related errors for the "Program Diagnosis" and the "OverHaul Time"
No.
Message
Cause
Counter
measure

No.
Message
Cause

Counter
measure

No.
Message
Cause
Counter
measure

No.
Message
Cause
Counter
measure
No.
Message
Cause
Counter
measure

I 3148
There is an axis which exceeds the allowance and maximum torque.
The presumption generation torque exceeded a permissible value by displayed program step and
axis.
(1)Change to ratings or less when the robot load condition is investigated, and weight and the
wrist torque exceed it to ratings.(Gravity setting is used) (2)There is a possibility to exceed the
acceleration which can be used. (Check the step before and after) (3)There is a possibility with a
large interference torque, too. (Drop the acceleration of the displayed step.)
I 3149
It is a program which remarkably shortens longevity.
In the displayed program, longevity is within at 5000 hours.There is a possibility which is the
program of call/jump origin when the call/jump are used.
(1)Change to ratings or less when the robot load condition is investigated, and weight and the
wrist torque exceed it to ratings. (Gravity setting is used) (2)The amount of operation is, and the
average speed and the average torque greatly exceed ratings because of largeness or high
speed, and there is a possibility that longevity has shortened. Reduce the amount of operation of
the object axis or slow down the speed if there is no obstacle in work. (program diagnosis)
(3)There is a possibility to be generated because the cycle time is remarkably short. Slow down
the speed overall.
I 3150
There is a possibility that the setting of the load weight and center of gravity is inapposite.
It is detected when there is a big difference between the longevities calculated from longevity and
the motor speed calculated from the current.
(1)Please confirm whether the setting of the load weight and center of gravity is correct.
(2)Please change to ratings or less when the robot load condition is investigated, and weight and
the wrist torque exceed it to ratings. (3)There is a possibility that the trouble occurs in the robot
when not corresponding to the above-mentioned.
I 3168
There is the axis in 1000 hours for overhaul.
The life time of the axis displayed with present operated (time to reaching to longevity) became
1,000 hours or less.
Exchange the reduction gear of the axis as early as possible. After that, set 0 for the
Consumption time until present in the Over Haul Time screen. (For this setting, EXPERT or
more is necessary)
I 3169
There is the axis in 0 hours for overhaul.
The life time of the axis displayed with present operated (time to reaching to longevity) became 0
hour or less.
Exchange the reduction gear of the axis immediately. After that, set 0 for the Consumption time
until present in the Over Haul Time screen. (For this setting, EXPERT or more is necessary)

5-5

5.1 Robot Diagnosis

NOTE

5-6

http://www.nachi-fujikoshi.co.jp/
Japan Main Office

Phone:
+81-3-5568-5245

Fax:
+81-3-5568-5236

Nachi Robotic Systems Inc. (NRS)

North America Headquarters

Shiodome Sumitomo Bldg. 17F,

1-9-2 Higashi-Shinbashi
Minato-ku, TOKYO, 105-0021 JAPAN

http://www.nachirobotics.com/

Phone: 248-305-6545

Fax: 248-305-6542

42775 W. 9 Mile Rd. Novi, Michigan 48375, U.S.A

Phone: 502-517-1553

Fax: 317-535-3659

715 Pushville Road, Greenwood, Indiana, 46143, U.S.A.

South Caroline Service Center Phone: 864-458-8000

Fax: 864-458-8256

1310 Garlington Road, Suite L, Greenville, SC 29615, U.S.A.

Canada Branch Office

Phone: 905-760-9542

Fax: 905-760-9477

89 Courtland Ave., Unit No.2, Concord, Ontario, L4K 3T4, CANADA

Mexico Branch Office

Phone :+52-555312-6556

Fax:+52-55-5312-7248

Urbina No.54, Parque Industrial Naucalpan, Naucalpan de

Juarez, Estado de Mexico C.P. 53489, MEXICO

Indiana Service Center

NACHI EUROPE GmbH

http://www.nachi.de/

Central Office Germany

Phone:
+49-2151-65046-0

Fax:
+49-2151-65046-90

Bischofstrasse 99, 47809, Krefeld, GERMANY

U.K. branch

Phone:
+44-0121-423-5000

Fax:
+44-0121-421-7520

Unit 3, 92, Kettles Wood Drive, Woodgate Business Park,

Birmingham B32 3DB, U.K.

Czech branch

Phone:
+ 420-255-734-000

Fax:
+420-255-734-001

Obchodni 132, 251 01 Cestlice, PRAGUE-EAST

CZECH REPUBLIC

NACHI AUSTRALIA PTY. LTD.

http://www.nachi.com.au/

Robotic Division &

Victoria office

Phone:
+61-(0)3-9796-4144

Fax:
+61-(0)3-9796-3899

38, Melverton Drive, Hallam, Victoria 3803, , AUSTRALIA

Sydney office

Phone:
+61-(0)2-9898-1511

Fax:
+61-(0)2-9898-1678

Unit 1, 23-29 South Street, Rydalmere, N.S.W, 2116, AUSTRALIA

Brisbane office

Phone:
+61-(0)7-3272-4714

Fax:
+61-(0)7-3272-5324

7/96 Gardens Dr,Willawong,QLD 4110, , AUSTRALIA

NACHI SHANGHAI CO., LTD.

Shanghai office

Phone:
+86-(0)21-6915-2200

http://www.nachi.com.cn/
Fax:
+86-(0)21-6915-2200

NACHI KOREA
Seoul office

11F Royal Wealth Centre, No.7

Lane 98 Danba Road Putuo District, Shanghai 200062, China

http://www.nachi-korea.co.kr/
Phone:
+82-(0)2-469-2254

Fax:
+82-(0)2-469-2264

2F Dongsan Bldg.
276-4, Sungsu 2GA-3DONG, Sungdong-ku,
Seoul 133-123, KOREA

Copyright NACHI-FUJIKOSHI CORP.

Robot Division

1-1-1, FUJIKOSHIHONMACHI, TOYAMA CITY, JAPAN 930-8511

Phone +81-76-423-5137
Fax
+81-76-493-5252

NACHI-FUJIKOSHI CORP. holds all rights of this document. No part of this manual may be photocopied or
reproduced in any from without prior written consent from NACHI-FUJIKOSHI CORP. Contents of this document
may be modified without notice. Any missing page or erratic pagination in this document will be replaced.
In case that an end user uses this product for military purpose or production of weapon, this product may be liable
for the subject of export restriction stipulated in the Foreign Exchange and Foreign Trade Control Law. Please go
through careful investigation and necessary formalities for export.
Original manual is written in Japanese.