CODE
(2) SRVO–002 SVAL1 Teach pendant E–stop
(Explanation) The emergency stop button on the operator’s Teach Pendant was pressed.
(Action 1) Release the emergency stop button on the teach pendant.
(Action 2) Replace Teach Pendant.
Emergency stop button
Fig.3.5 (2) SRVO–002 SVAL1 Teach pendant E–stop
(3) SRVO–003 SVAL1 Deadman switch released
(Explanation) The teach pendant is enabled, but the deadman switch is not pressed.
(Action 1) Press the deadman switch to run the robot.
(Action 2) Replace the teach pendant.
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(4) SRVO–004 SVAL1 Fence open
(Explanation) In AUTO mode, there is no short circuit between FENCE11 and FENCE12 and between FENCE21 and FENCE22 on the terminal block TBEB5 of the emergency stop board.
If the safety fence is connected between FENCE11 and FENCE12 and between FENCE21 and FENCE22, the door of the safety fence is open.
(Action 1) When the safety fence is connected, close the door.
(Action 2) Check the cables and switches connected to FENCE11, FENCE12, FENCE21 and FENCE22.
(Action 3) When this signal is not used, short–circuit between FENCE11 and FENCE12 and between FENCE21 and FENCE22.
NOTE
In the system that uses the fence signal, do not short–circuit this signal to disable it because the operation is dangerous.
When this signal must be temporarily short–circuited, make safety provisions separately.
(Action 4) When AUTO mode is not entered even though the mode switch is set to AUTO, the mode switch may be faulty. Replace the operator panel.
(Action 5) Replace the emergency stop unit.
Before taking (Action 6), make a backup copy of all the programs and settings of the control unit.
(Action 6) Replace the robot control board.
Emergency stop unit
Short connection boards:
two positions (terminal blocks located on the right when viewing from the front)
Fig.3.5 (4) SRVO–004 SVAL1 Fence open
(5) SRVO–005 SVAL1 Robot overtravel
(Explanation) This alarm should not occur because no overtravel input signal is provided. However, this alarm can be caused by an abnormal overtravel input signal across the robot interconnection cable and robot control board.
(Action 1) Check the robot interconnection cable (RMP) for the following.
1) The male and female connection pins are not twisted or are not loose.
2) The connector is securely connected.
3) The cable is free from a break and ground fault.
Next, check that the connector CRM82 of the robot control board is securely connected. In addition, check that the RMP cable is sound and free from a break or visible twist.
Before taking (Action 2), make a backup copy of all the programs and settings of the control unit.
(Action 2) Replace the robot control board.
Robot control board
Fig.3.5 (5) SRVO–005 SVAL1 Robot overtravel
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(6) SRVO–006 SVAL1 Hand broken
(Explanation) The safety joint, if any, is broken. If no joint is broken, the HBK signal line of the robot interconnection cable has a break or ground fault.
(Action 1) Holding down the shift key, press the alarm release button. This releases the alarm. Keeping on holding down the shift key, carry out jog feed to move the tool to the work area.
1) Replace the safety joint.
2) Examine the cable.
(Action 2) Check the robot interconnection cable (RMP) for the following.
1) The male and female connection pins are not twisted or are not loose.
2) The connector is securely connected.
3) The cable is free from a break and ground fault.
Next, check that the connector CRM82 of the robot control board is securely connected. In addition, check that the RMP cable is sound and free from a break or visible twist.
Before taking (Action 3), make a backup copy of all the programs and settings of the control unit.
(Action 3) Replace the robot control board.
Robot control board
Fig.3.5 (6) SRVO–006 SVAL1 Hand broken
(7) SRVO–007 SVAL1 External E–stop
(Explanation) EMGIN11 and EMGIN12/EMGIN21 and EMGIN22 on the terminal block TBEB5 of the emergency stop board are not short–circuited. If an external emergency stop switch is connected across EMGIN11 and EMGIN12/EMGIN21 and EMGIN22, the switch has been pressed.
(Action 1) If an external emergency stop switch is connected, releases the switch.
(Action 2) Check the switch and cable connected to EMGIN11 and EMGIN12 and to EMGIN21 and EMGIN22.
(Action 3) When this signal is not used, make a connection between EMGIN11 and EMGIN12 and a connection between EMGIN21 and EMGIN22. (WARNING) (Action 4) Replace the emergency stop unit.
WARNING
Do NOT short–circuit, or disable, this signal in a system in which the External emergency stop input signal is in use, as it is very dangerous. If it is necessary to run the robot by short–circuiting the signal even temporarily, an additional safety provision must be provided.
Emergency stop unit
Short connection boards:
two positions (terminal blocks located on the left when viewing from the front)
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(8) SRVO–009 SVAL1 Pneumatic pressure alarm
(Explanation) An abnormal air pressure was detected. The input signal is located on the end effector of the robot.
Refer to the manual of your robot.
(Action 1) If an abnormal air pressure is detected, check the cause.
If the peripheral device are normal, check the robot connection cable.
Before taking (Action 2), make a backup copy of all the programs and settings of the control unit.
(Action 2) Replace the robot control board.
Robot control board
Fig.3.5 (8) SRVO–009 SVAL1 Pneumatic pressure alarm
(9) SRVO–014 WARN Fan motor abnormal
(Explanation) A fan motor in the backplane unit is abnormal.
(Action) Check the fan motor and its cables. Replace them if necessary.
Fan motor
Fig.3.5 (9) SRVO–014 WARN Fan motor abnormal
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(10) SRVO–015 SVAL1 SYSTEM OVER HEAT (Group : i Axis : j) (Explanation) The temperature in the control unit exceeds the
specified value.
(Action 1) If the ambient temperature is higher than specified (45°C), cool down ambient temperature.
(Action 2) If the fan motor is not running, check it and its cables.
Replace them if necessary.
(Action 3) If the thermostat on the robot control board is defective, replace the robot control board.
Fan motor
(on the heat exchange)
Fan motor (door face) Robot control board
Fig.3.5 (10) SRVO–015 SVAL1 SYSTEM OVER HEAT
(11) SRVO–021 SVAL1 SRDY off (Group : i Axis : j)
(Explanation) The HRDY is on and the SRDY is off, although there is no other cause of an alarm. (HRDY is a signal with which the host detects the servo system whether to turn on or off the servo amplifier magnetic contactor.
SRDY is a signal with which the servo system informs the host whether the magnetic contactor is turned on.)
If the servo amplifier magnetic contactor cannot be turned on when directed so, it is most likely that a servo amplifier alarm has occurred. If a servo amplifier alarm has been detected, the host will not issue this alarm (SRDY off). Therefore, this alarm indicates that the magnetic contactor cannot be turned on for an unknown reason.
(Action 1) Measure the voltage of the 200–VAC input to the power supply module. If the voltage is 170 VAC or lower, adjust the input voltage.
(Action 2) Check that CRR78 of the emergency stop board and CX3 and CX4 of the power supply module are securely connected. Check the cables of the emergency stop board and power supply module for a break.
(Action 3) Check the EMERGENCY STOP line (teach pendant emergency stop, teach pendant enable/disable switch, teach pendant deadman switch, operator panel emergency stop, external emergency stop input, fence input) for a possibility of an instantaneous interruption. If the software cannot judge the cause of the alarm at an instantaneous interruption of the EMERGENCY STOP line, this alarm occurs.
(Action 4) Replace the emergency stop unit.
(Action 5) If an alarm occurs on all axes, the power supply module may be faulty. Replace the power supply module.
(Action 6) If an alarm occurs on a particular axis, the servo amplifier module may be faulty. Replace the servo amplifier module controlling the axis.
(Action 7) Replace the axis control card on the robot control board.
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Robot control board Servo amplifier module Power supply module Emergency stop unit
Axis control card
Fig.3.5 (11) SRVO–021 SVAL1 SRDY off
(12) SRVO–022 SVAL1 SRDY on (Group : i Axis : j)
(Explanation) When the HRDY is about to go on, the SRDY is already on. (HRDY is a signal with which the host directs the servo system whether to turn on or off the servo amplifier magnetic contactor. SRDY is a signal with which the servo system informs the host whether the magnetic contactor is turned on.
(Action 1) Replace the axis control card on the robot control board.
(Action 2) If an alarm occurs on all axes, the power supply module may be faulty. Replace the power supply module.
(Action 3) If an alarm occurs on a particular axis, the servo amplifier module may be faulty. Replace the servo amplifier module controlling the axis.
Robot control board Servo amplifier module Power supply module Axis control card
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(13) SRVO–023 SVAL1 Stop error excess (Group : i Axis : j)
(Explanation) When the servo is at stop, the position error is abnormally large.
(Action 1) Check whether the motor brake has been released.
(Action 2) Make sure that the servo amplifier CZ2L to N are connected tightly.
(Action 3) Check to see if the load is greater than the rating. If greater, reduce it to within the rating. (If the load is too greater, the torque required for acceleration / deceleration becomes higher than the capacity of the motor. As a result, the motor becomes unable to follow the command, and an alarm is issued.)
(Action 4) Check each phase voltage of the CZ1 connector of the three–phase power (200 VAC) input to the servo amplifier. If it is 170 VAC or lower, check the line voltage. (If the voltage input to the servo amplifier becomes low, the torque output also becomes low. As a result the motor may become unable to follow the command, hence possibly an alarm.)
(Action 5) If the line voltage is 170 VAC or higher, replace the power supply module or servo amplifier module.
(Action 6) Check disconnection of robot connection cable (RMP).
(Action 7) Replace the motor.
Servo amplifier module Power supply module
Fig.3.5 (13) SRVO–023 SVAL1 Stop error excess
(14) SRVO–024 SVAL1 Move error excess (Group : i Axis : j)
(Explanation) When the robot is running, its position error is greater than a specified value ($PARAM _ GROUP.
$MOVER _ OFFST or $PARAM _ GROUP.
$TRKERRLIM). It is likely that the robot cannot follow the speed specified by program.
(Action 1) Check the robot for binding axis.
(Action 2) Take the same actions as described for the above alarm.
(15) SRVO–025 SVAL1 Motn dt overflow (Group : i Axis : j) (Explanation) The specified value is too great.
(16) SRVO–026 WARN2 Motor speed limit (Group : i Axis : j)
(Explanation) A value higher than the maximum motor speed ($PARAM_GROUP.$MOT_SPD_LIM) was specified. The actual motor speed is clamped to the maximum speed.
(17) SRVO–027 WARN Robot not mastered (Group : i)
(Explanation) An attempt was made to calibrate the robot, but the necessary adjustment had not been completed.
(Action) Master the robot.
(18) SRVO–030 SVAL1 Brake on hold (Group : i)
(Explanation) This alarm occurs when the robot pauses, if the brake on hold function has been enabled ($SCR.
$BRKHOLD _ ENB = 1). Disable the function if it is not necessary.
(Action) Disable [Servo–off during pause] on the general setting menu (Select Setting general).
(19) SRVO–031 SVAL1 User servo alarm (Group : i) (Explanation) An user servo alarm occurred.
(20) SRVO–033 WARN Robot not calibrated (Group : i)
(Explanation) An attempt was made to set up a reference point for simplified adjustment, but the robot had not been calibrated.
(Action) Calibrate the robot.
1.Supply power.
2.Set up a simplified adjustment reference point using [Positioning] on the positioning menu.
(21) SRVO–034 WARN Ref pos not set (Group : i)
(Explanation) An attempt was made to perform simplified adjustment, but the reference point had not been set up.
(Action) Set up a simplified adjustment reference point on the positioning menu.
(22) SRVO–035 WARN2 Joint speed limit (Group : i Axis : j)
(Explanation) A value higher than the maximum axis speed
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(25) SRVO–038 SVAL2 Pulse mismatch (Group : i Axis : j)
(Explanation) The pulse count obtained when power is turned off does not match the pulse count obtained when power is applied. This alarm is asserted after exchange the pulsecoder or battery for back up of the pulsecoder data or loading back up data to the Robot control board.
(Action) Perform Absolute Pulse Coder reset and remaster robot (RES–PCA)
1. Press MENUS.
2. Select SYSTEM.
3. Press F1 [TYPE].
4. Select MASTER/CAL.
5. Press F3, PES–PCA and YES.
6. Execute mastering.
7. Press RESET.
The fault condition should reset. If the controller is still faulted with additional servo–related errors, cold start the controller.
It might be necessary to remaster the robot.
(26) SRVO–041 SVAL2 MOFAL alarm (Group : i Axis : j) (Explanation) The servo value was too high.
(Action) Cold start the controller.
(27) SRVO–044 SVAL1 HVAL alarm (Group : i Axis : j)
(Explanation) The DC voltage (DC link voltage) of the main circuit power supply is abnormally high.
The LED indication on the power supply module is
“7” (HVAL).
(Action 1) Check the three–phase input voltage at the power supply module. If it is 253 VAC or higher, check the line voltage. (If the three–phase input voltage is higher than 253 VAC, high acceleration/deceleration can result in this alarm.)
(Action 2) Check that the load weight is within the rating. If it is higher than the rating, reduce it to within the rating.
(If the machine load is higher than the rating, the accumulation of regenerative energy might result in the HVAL alarm even when the three–phase input voltage is within the rating.
(Action 3) Replace the power supply module.
Power supply module
Fig.3.5 (27) SRVO–044 SVAL1 HVAL alarm
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(28) SRVO–045 SVAL1 HCAL alarm (Group : i Axis : j)
(Explanation) Abnormally high current flowed in the main circuit of the servo amplifier module.
The LED indications on the servo amplifier modules are “b”, “C”, and “d”.
(Action 1) Disconnect the Robot connection cable (Motor power) from the connector CZ2 of the servo amplifier module. If error occurs, replace the servo amplifier.
(Action 2) Disconnect the Robot connection cable (Motor power) from the servo amplifier module connector (CZ2), and check the insulation of each Robot connection cable (Motor power) (U, V, or W) and the GND line.
If there is a short–circuit, the motor, robot interconnection cable, or intra–robot cable is defective. Check them and replace them if necessary.
(Action 3) Disconnect the Robot connection cable (Motor power) from the servo amplifier module connector (CZ2), and measure the resistance between the U and V, V and W, and W and U with a ohmmeter with a very low resistance range. If the resistances at these three places are different from each other, the motor, robot interconnection cable, or intra–robot cable is defective. Check each item in detail.
Before taking (Action 4), make a backup copy of all the programs and settings of the control unit.
(Action 4) Replace the robot control board.
Robot control board Servo amplifier module
Fig.3.5 (28) SRVO–045 SVAL1 HCAL alarm
(29) SRVO–046 SVAL2 OVC alarm (Group : i Axis : j)
(Explanation) This alarm is issued to prevent the motor from thermal damage that might occur when the root meant square current calculated within the servo system is out of the allowable range.
(Action 1) Check the operating conditions for the robot and relax the service conditions.
(Action 2) Check each phase voltage of the three–phase input power (200 VAC for the power supply module. If it is 170 VAC or lower, check the line voltage.
(Action 3) Replace the power supply module and servo amplifier module.
(Action 4) Check the robot connection cable (RMP).
(Action 5) Replace the motor.
Servo amplifier module Power supply module
Fig.3.5 (29) SRVO–046 SVAL2 OVC alarm
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Relationships among the OVC, OVL, and HC alarms Overview
This section points out the differences among the OVC, OVL, and HC alarms and describes the purpose of each alarm.
Alarm detection section
Abbreviation Designation Detection section OVC Overcurrent alarm Servo software
OVL Overload alarm Thermal relay in the motor OHAL2 Thermal relay in the servo amplifier OHAL1 Thermal relay in the separate regenerative dis-charge unit DCAL
HC High current alarm Servo amplifier
Purpose of each alarm 1) HC alarm (high current alarm)
If high current flow in a power transistor momentarily due to abnormality or noise in the control circuit, the power transistor and rectifier diodes might be damaged, or the magnet of the motor might be degaussed. The HC alarm is intended to prevent such failures.
2) OVC and OVL alarms (overcurrent and overload alarms)
The OVC and OVL alarms are intended to prevent overheat that may lead to the burnout of the motor winding, the breakdown of the servo amplifier transistor, and the separate regenerative resistor.
The OVL alarm occurs when each built–in thermal relay detects a temperature higher than the rated value. However, this method is not necessarily perfect to prevent these failures. For example, if the motor frequently repeats to start and stop, the thermal time constant of the motor, which has a large mass, becomes higher than the time constant of the thermal relay, because these two components are different in material, structure, and dimension. Therefore, if the motor repeats to start and stop within a short time as shown in Fig.
1, the temperature rise in the motor is steeper than that in the thermal relay, thus causing the motor to burn before the thermal relay detects an abnormally high temperature.
Temperature
Start Stop Start Stop Start
Temperature at which the winding starts to burn
Thermal time constant of the motor is high.
Thermal time constant of the thermal relay is low.
Time Fig.1 Relationship between the temperatures of the motor and thermal relay on start/stop cycles
To prevent the above defects, software is used to monitor the current in the motor constantly in order to estimate the temperature of the motor. The OVC alarm is issued based on this estimated temperature.
This method estimates the motor temperature with substantial accuracy, so it can prevent the failures described above.
Reference
To sum up, a double protection method is used; the OVC alarm is used for protection from a short–time overcurrent, and the OVL alarm is used for protection from long–term overload. The relationship between the OVC and OVL alarms is shown in Fig 2.
Current
Protection area for the motor and servo amplifier
Protection by the OVL Limit current
Protection by the OVC
Rated continuous current
Time Fig.2 Relationship between the OVC and OVL alarms
NOTE
The relationship shown in Fig. 2 is taken into consideration for the OVC alarm. The motor might not be hot even if the OVC alarm has occurred. In this case, do not change the parameters to relax protection.
(30) SRVO–047 SVAL1 LVAL alarm (Group : i Axis : j)
(Explanation) The control power voltage (+5 V, etc.) on the servo amplifier module is too low. The LED indication on the servo amplifier module is “2” (LVAL).
(Action 1) Replace the servo amplifier module.
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(31) SRVO–049 SVAL1 OHAL1 alarm (Group : i Axis : j)
(Explanation) This alarm does not occur when the power supply module and serve amplifier modules used with the R–J3iB Mate are under normal conditions.
This alarm indicates that any of the power supply module and servo amplifier modules is faulty.
(Action 1) If this alarm occurs in relation to all axes, replace the power supply module.
(Action 2) If this alarm occurs in relation to a specific axis, replace the servo amplifier module that controls the axis.
Servo amplifier module Power supply module
Fig.3.5 (31) SRVO–049 SVAL1 OHAL1 alarm
(32) SRVO–050 SVAL1 CLALM alarm (Group : i Axis : j)
(Explanation) The disturbance torque estimated by the servo software is abnormally high. (A collision has been detected.) (Action 1) Check that the robot has collided with anything. If it
has, reset the robot and jog–feed it to recover from the collision.
(Action 2) Make sure that the load setting is correct.
(Action 3) Check that the load weight is within the rating. If it is higher than the rating, reduce it to within the rating.
(If the robot is used out of its usable range, the estimated disturbance torque becomes abnormally high, possibly resulting in this alarm being detected.) (Action 4) Check the phase voltage of the three–phase input power (200 VAC) to the power supply module. If it is 170 VAC or lower, check the line voltage.
(Action 5) Replace the power supply module and the servo amplifier module.
Servo amplifier module Power supply module
Fig.3.5 (32) SRVO–050 SVAL1 CLALM alarm
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(33) SRVO–051 SVAL2 CUER alarm (Group : i Axis : j)
(Explanation) The offset of the current feedback value is abnormally high.
(Action) Replace the servo amplifier module.
Servo amplifier module
Fig.3.5 (33) SRVO–051 SVAL2 CUER alarm
(34) SRVO–054 DSM Memory Error
(Explanation) An access to the axis control card on the robot control board memory fails.
(Action) Replace the axis control card.
Robot control board Servo amplifier module Axis control card
Fig.3.5 (34) SRVO–054 DSM Memory Error
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(35) SRVO–055 SVAL2 FSSB com error 1 (Group : i Axis : j)
(Explanation) A communication error has occurred between the
(Explanation) A communication error has occurred between the