ZUEP5796X

ZUEP5799X
Main CPU Card

Welding Control Card

Backplane card

ZUEP5791X
Servo CPU Card
ZUEP5796X
Main CPU Card
Backplane card
ZUEP5806X ZUEP5806X

Power card
ZUEP5803X

R6
R7
Welding Welding Servo amp
power IF card Sub IF card Servo
Power Supply AEDXXXXX
ZUEP5779XA1 ZUEP5755XA1
AED01283

Resolver card
ZUEP5764XXX
Inverter card
ZUEP5805X

Inverter card
ZUEP5805X
Motor

This manual is made for Panasonic authorized system partners service engineer to understand alarm detection more logically. Since this manual
contain detail technical information, please do not pass this to any 3rd party nor 3rd person. Even for authorized system partner, the manual will
be given with hard copy only.

SE11-0174E07
 Page 1

A3020 Weld IF card DSP error A3021 Filler IF card DSP error

Detection logic… Detection logic…

Error in DSP (Digital Signal Processor) on the Welding control card. The DSP sends error Error in DSP (Digital Signal Processor) on the Filler control card. The DSP sends error to
to IF-CPU on the Welding control card. And this information will be transferred to Main IF-CPU on the Welding control card. And this information will be transferred to Main CPU
CPU card. card.

Backplane card Backplane card

ZUEP5799XA1
ZUEP5796X
Main CPU Card

Filler Control Card

ZUEP5796X

ZUEP5799X
Main CPU Card

Welding Control Card

ZUEP5806X ZUEP5806X
CPU BUS CPU BUS
connector IFCPU connector IFCPU

DSP DSP

CPU BUS CPU BUS

communication communication
Detected by here Detected by here

Action should be taken… Action should be taken…

• Check connection between Backplane card and Welding control card • Check connection between Backplane card and Filler control card
• Eliminate electrical noise source what is coming to Welding control card • Eliminate electrical noise source what is coming to Filler control card
• Try to replace Welding control card • Try to replace Filler control card
• Try to replace Backplane card or Main CPU card • Try to replace Backplane card or Main CPU card
 Page 2

A3030 Weld IF card DSP communication error ** A3031 Filler IF card DSP communication error **

Detection logic… Detection logic…

<01> The undefined command was sent from IF-CPU to DSP <01> The undefined command was sent from IF-CPU to DSP
<02> Sum check value from DSP to IF-CPU was not correct <02> Sum check value from DSP to IF-CPU was not correct

Backplane card Backplane card

ZUEP5799XA1
ZUEP5796X
Main CPU Card

Filler Control Card

ZUEP5796X

ZUEP5799X
Main CPU Card

Welding Control Card

ZUEP5806X ZUEP5806X
CPU BUS CPU BUS
connector IFCPU connector IFCPU

DSP DSP

CPU BUS CPU BUS

communication communication
Detected by here Detected by here

Action should be taken… Action should be taken…

• Try to download latest software to all PC board to keep version matching • Try to download latest software to all PC board to keep version matching
• Check connection between Backplane card and Welding control card • Check connection between Backplane card and Filler control card
• Eliminate electrical noise source what is coming to Welding control card • Eliminate electrical noise source what is coming to Filler control card
• Try to replace Welding control card (or replace Backplane card or Main CPU card) • Try to replace Filler control card (or replace Backplane card or Main CPU card)
 Page 3

A3100 Weld IF card comm. Error **

Detection logic…

If the communication between Main CPU card and Welding control card is having problem,
this error will be shown.

01 Sum check error from IF-CPU to Main CPU card

02 Time out for sending command from Main CPU card to IF-CPU
(50msec)

05 Time out for sending command from IF-CPU to Main CPU card
Detected by here (3.0sec)

06 Initialization error for FPGA

Backplane card
ZUEP5796X

ZUEP5799X
Main CPU Card

Welding Control Card

ZUEP5806X
CPU BUS 07 Initialization error for DSP
connector
IFCPU
08 Transferring error of DPS program to DSP-RAM

09

DSP 10 Ready signal receiving time out after Main CPU card sent ready
signal to IF-CPU at robot controller power on

11 Initialization completed signal receiving time out after Main CPU

CPU BUS
communication card sent servo fix parameter to IF-CPU at robot controller power on

Action should be taken…

• Check connection between Backplane card, Welding control card and Main CPU card
• Check software matching between Main CPU card and Welding control card
• Try to replace Welding control card
• Try to replace Main CPU card or Backplane card
 Page 4

A3101 Filler IF card comm. Error

Detection logic…

If the communication between Main CPU card and Filler control card is having problem,
this error will be shown.

01 Sum check error from IF-CPU to Main CPU card

02 Time out for sending command from Main CPU card to IF-CPU
(50msec)

05 Time out for sending command from IF-CPU to Main CPU card
Detected by here (3.0sec)

06 Initialization error for FPGA

Backplane card
ZUEP5799XA1
ZUEP5796X
Main CPU Card

Filler Control Card

ZUEP5806X
CPU BUS
IFCPU 07 Initialization error for DSP
connector
08 Transferring error of DPS program to DSP-RAM

09

DSP 10 Ready signal receiving time out after Main CPU card sent ready
signal to IF-CPU at robot controller power on

CPU BUS
11 Initialization completed signal receiving time out after Main CPU
communication card sent servo fix parameter to IF-CPU at robot controller power on

Action should be taken…

• Check connection between Backplane card, Filler control card and Main CPU card
• Check software matching between Main CPU card and Filler control card
• Try to replace Filler control card
• Try to replace Main CPU card or Backplane card
 Page 5

A3200 Weld Alarm : P-side over voltage A3210 Weld Alarm : Lack of Phase

Detection logic… Detection logic…

The primary input voltage became more than rated input voltage +10% (If AC200V, The one of phase for primary input voltage is missing. This error will be detected by
AC225V is detection voltage for this alarm). This error will be detected by Welding Sub IF Welding control card by monitoring AC200V on connector X9 (KS200). This error check
card by using AC15V coming from transformer. always works 3 second after switching on the Magnet switch.

Backplane card Backplane card

ZUEP5796X

ZUEP5799X
Main CPU Card

Welding Control Card

ZUEP5796X

ZUEP5799X
Main CPU Card

Welding Control Card

ZUEP5806X ZUEP5806X

X3 (WLD-IF) X3 (WLD-IF)

X11 (WELD_IN) X11 (WELD_IN) X9 (KS200)

Error signal Error signal
Welding Welding Welding Welding
power IF card Sub IF card power IF card Sub IF card
Detected by here Detected by
ZUEP5779XA1 ZUEP5755XA1 ZUEP5779XA1 ZUEP5755XA1
(by AC15V) here
X9 (WLD-IF) X9 (WLD-IF)

X16 (WLD-IN) X16 (AC15V) X16 (WLD-IN) X17 (MS-CTRL)

Error signal Error signal

MS control signal
AC200V Transformer AC15V AC200V Magnet switch

AC200V

Action should be taken… Action should be taken…

• Check input voltage AC200V. And check AC15V from transformer • Check input voltage AC200V and AC200V after Magnet switch
• Check all of above connections • Check contact of Magnet switch
• Try to replace Welding sub IF card • Check all of above connections
• Try to replace Welding power IF card • Try to replace Welding sub IF card
• Try to replace Welding control card • Try to replace Welding power IF card
• Try to replace Welding control card
 Page 6

A3220 Weld Alarm : S-side main circuit error A3230 Weld Alarm : S-side over voltage error

Detection logic… Detection logic…

The error on 2ndry switch (IGBT) circuit. In case more than 4V is measured between C Abnormal voltage on 2ndry side. In case more than DC150V (or DC120V more than 500
and E on 2ndry IGBT more than 30 second, this error will be detected. There is possibility micro second) is measured by Welding Sub IF card, this error will be detected.
that IGBT has been broken with open circuit.

Backplane card Backplane card

Welding Control Card

Main CPU Card
ZUEP5796X

ZUEP5799X

ZUEP5796X

ZUEP5799X
Main CPU Card

Welding Control Card

ZUEP5806X ZUEP5806X

X3 (WLD-IF) X3 (WLD-IF)

X15 (DRV) X1(W_VOLT)

Voltage X7 (AMP/VOLT) Voltage
X11 (WELD_IN) R6 feedback (+)
Error signal feedback EX_V1
Welding Welding Welding Welding R7
on IGBT
power IF card Sub IF card power IF card Sub IF card
ZUEP5779XA1 ZUEP5755XA1 ZUEP5779XA1 ZUEP5755XA1
X9 (WLD-IF) Detected by X9 (WLD-IF)
here
Voltage
X15 Detected by feedback (-)
X16 W Volt
Error signal Inverter card (AMP / VOLT) here Torch(+)
Inverter card (WLD-IN) Torch(+)
2ndry switch ZUEP5805X
ZUEP5805X
IGBT

Inverter card Inverter card

ZUEP5805X ZUEP5805X

AC200V Base(-) AC200V Base(-)

Action should be taken… Action should be taken…

• Check all of above connection for IGBT • Check voltage on 2ndry side (Touch sensor voltage, feeder motor voltage leaking)
• Check IGBT switching function, and try to replace if IGBT is not working • Check all of connection for above line
• Try to replace Welding sub IF card • Try to replace Welding sub IF card
• Try to replace Welding power IF card • Try to replace Welding power IF card
• Try to replace Welding control card • Try to replace Welding control card
 Page 7

A3240 Weld Alarm:Inverter unbalance A3500 Wire feeder Amp ready error

Detection logic… Detection logic…

The servo ready signal from feeder amplifier did not come within 500m second after
This alarm is only for 450A WG power source. In case CT2 has less or more than 1/2 of sending SV ON command. This error will be detected by Welding control card.
CT1 current, this alarm will be detected.

Backplane card

ZUEP5796X

ZUEP5799X
Main CPU Card

Welding Control Card

ZUEP5806X

X3 Detected
(WLD-IF) by here

Backplane card

ZUEP5796X

ZUEP5799X
Main CPU Card

Welding Control Card

ZUEP5806X
X1 (DRV)

X12
(AMP/VOLT)
X7
(AMP/VOLT)
Welding Welding X4
power IF card Sub IF card (AMP_CT)
ZUEP5779XA1 ZUEP5755XA1
Measured current DC280V
by CT1 (Total current)
X4 (DC2) SV Ready
X1 (DRV)
Inverter card X13
ZUEP5805X (EX_IN)
CT1 Torch(+)
Servo Servo amp
Power Supply AED01291 X2 (AMPB)
Inverter card AED01283
X9
ZUEP5805X X10 (APOW2) SV ON
(AMP2)
Base(-)
Inverter card
AC200V ZUEP5805X X3 (AMPA)
VN1
Measured current
by CT2 (1/2 of CT1)
DC+/-15V

Inverter card
ZUEP5805X
CT2

Action should be taken… Action should be taken…

• Check connection for above circuit, especially connection for CT • Check connection for DC+/-15V, VN1 and DRV signal for the feeder amplifier
• Check Inverter card (MOS-FET) and 2ndry diode whether they are damaged or not • Check voltage for DC+/-15V, VN1 to the feeder amplifier
• Try to replace Welding sub IF card, power IF card or Welding control card • Try to replace feeder amplifier or Welding control card
• Try to replace Inverter card
 Page 8

A3510 Wire feeder IPM error A3520 Weld IF card receive data error

Detection logic… Detection logic…

The IPM (Intelligent Power Module), which controls motor power, on the feeder amplifier <01> Communication error. The command from Main to Weld IF-CPU is abnormal.
has error condition. There are two possibility with this error. 1) Over current on wire <02> Communication error. Error code from DSP to IF-CPU is unknown.
feeder motor (more than 5.1A), 2) Control voltage became less than DC10V (Normally
DC15V).

Backplane card
ZUEP5796X

ZUEP5799X
Main CPU Card

Welding Control Card

ZUEP5806X
X1 (DRV)

Detected
by here

Backplane card

ZUEP5796X

ZUEP5799X
Main CPU Card

Welding Control Card

ZUEP5806X
CPU BUS
connector IFCPU

Detected IPM Error

by here X1 (DRV)

X3 (M-OUT)
Servo Servo amp DSP
Power Supply AED01291 X2 (AMPB)
AED01283
X9 IPM
X10 (APOW2)
(AMP2) Feeder motor CPU BUS
communication

X3 (AMPA)
VN1
DC+/-15V
Motor power UVW

Action should be taken… Action should be taken…

• Check connection for DC+/-15V, VN1 and DRV signal for the feeder amplifier • Check connection between Backplane card, Welding control card and Main CPU card
• Check voltage for DC+/-15V, VN1 to the feeder amplifier • Check software matching between Main CPU card and Welding control card
• Check coil resistance of feeder motor including cable line (U-V, V-W, U-W) • Try to replace Welding control card
• Check resistance between motor power line and earth grounding (U-E, V-E, W-E) • Try to replace Main CPU card or Backplane card
• Try to replacing feeder amplifier or Welding control card
 Page 9

A3521 Filler IF card receive data error A3530 Wire feeder Amp low-voltage

Detection logic… Detection logic…

<01> Communication error. The command from Main to Filler IF-CPU is abnormal. The voltage for feeder amplifier is dropped. In case servo amplifier control voltage
<02> Communication error. Error code from DSP to IF-CPU is unknown. DC15V became less than DC10V, this error will be detected.

Backplane card

ZUEP5796X

ZUEP5799X
Main CPU Card

Welding Control Card

ZUEP5806X
X1 (DRV)
Detected
by here

Backplane card
ZUEP5799XA1
ZUEP5796X
Main CPU Card

Filler Control Card

ZUEP5806X
CPU BUS
connector IFCPU

Detected LOW VOLT

by here X1 (DRV) Error

DSP X3 (M-OUT)
Servo Servo amp
Power Supply AED01291 X2 (AMPB)
AED01283
CPU BUS X9 IPM
X10 (APOW2)
communication
(AMP2) Feeder motor

X3 (AMPA)
VN1
DC+/-15V
Motor power UVW

Action should be taken… Action should be taken…

• Check connection between Backplane card, Filler control card and Main CPU card • Check connection for DC+/-15V, VN1 for the feeder amplifier
• Check software matching between Main CPU card and Filler control card • Check voltage for DC+/-15V, VN1 to the feeder amplifier
• Try to replace Filler control card • Try to replacing feeder amplifier or Welding control card
• Try to replace Main CPU card or Backplane card
 Page 10

A3540 Wire feeder motor speed over A3550 Wire feeder current detect error

Detection logic… Detection logic…

The speed of motor became more than 120% of motor maximum speed. The feeder motor current just after switching on the servo power had more than 12.5%
Detected by Welding control card by measuring pulse signal from Welding power IF card of maximum value of A/D converter.
(The speed feed back data is originally from feeder motor as resolver signal, and the
resolver signal is converted to pulse signal by Welding power IF card).

Detected
by here
Detected
Backplane card
ZUEP5796X

ZUEP5799X by here
Main CPU Card

Welding Control Card

ZUEP5806X
X1(DRV) Backplane card

ZUEP5796X

ZUEP5799X
Main CPU Card

Welding Control Card

ZUEP5806X
X1 (DRV)

Speed feedback
(PLS)
X2(PLS)

X7(FDR-IF) R/D convert A/D

DRV signal
X1 (DRV) Welding
power IF card Motor current
X3 (M-OUT) ZUEP5779XA1 (Measured by CT)
Servo Servo amp X1 (DRV)
Power Supply AED01291
X3 (M-OUT)
AED01283 Servo amp
Servo
X10(RSLV) Power Supply AED01291
Feeder motor AED01283
CT
Feeder motor

Speed feedback
(RSLV)
Motor power UVW

Action should be taken… Action should be taken…

• Check connection for DRV signal for the feeder amplifier • Check connection for DRV signal for the feeder amplifier
• Check connection for Resolver signal and Pulse signal line • Check coil resistance of feeder motor including cable line (U-V, V-W, U-W)
• Try to replace Welding control card or Welding power IF card • Check resistance between motor power line and earth grounding (U-E, V-E, W-E)
• Try to replace feeder motor • Try to replace feeder amplifier or Welding control card
• Try to replace feeder motor
 Page 11

A3560 Wire feeder regenerative register over duty error A3570 Wire feeder IPM over current error

Detection logic… Detection logic…

The voltage for the motor power became more than DC430V. High side of IPM output got over current (Motor power line is leaked or shorted).
The voltage for the motor power is provided to IPM. Normally, this voltage has DC290V,
but if this became more than DC430V, this error will be detected.

Backplane card Backplane card

ZUEP5796X

ZUEP5799X

ZUEP5796X

ZUEP5799X
Main CPU Card

Welding Control Card

Main CPU Card

Welding Control Card

ZUEP5806X ZUEP5806X
X1 (DRV) X1 (DRV)

Detected Detected IPM over

by here Over duty by here
X1 (DRV) X1 (DRV) current

X3 (M-OUT) X3 (M-OUT)
Servo Servo amp Servo Servo amp
Power Supply AED01291 Power Supply AED01291 X2 (AMPB)
AED01283 X9 VN1 AED01283
X10 (APOW2) X9 IPM
(AMP2) X10 (APOW2)
Feeder motor (AMP2) Feeder motor

X3 (AMPA)
VN1
DC+/-15V DC+/-15V
Motor power UVW Motor power UVW

Action should be taken… Action should be taken…

• Check voltage for +/-15V, VN1 to the feeder amplifier • Check coil resistance of feeder motor including cable line (U-V, V-W, U-W)
• Check coil resistance of feeder motor including cable line (U-V, V-W, U-W) • Check resistance between motor power line and earth grounding (U-E, V-E, W-E)
• Check resistance between motor power line and earth grounding (U-E, V-E, W-E) • Check voltage for +/-15V, VN1 to the feeder amplifier
• Try to replace feeder amplifier or Welding control card • Try to replace feeder motor after checking there is no problem for motor line
• Try to replace feeder amplifier or Welding control card
 Page 12

A3590 Wire feeder IPM over temperature A3600 Weld Alarm: AC Unit S-side over voltage error

Detection logic… Detection logic…

Thermal switch on the servo amplifier detected over temperature. Secondly side Over voltage was detected by AC unit. The over voltage information was
came to DSP on Welding Control Card. The information will be forwarded to IF-CPU to
Main CPU card from DSP.

Backplane card

ZUEP5796X

ZUEP5799X
Main CPU Card

Welding Control Card

ZUEP5806X
CPU BUS
connector IFCPU
Backplane card
ZUEP5796X

ZUEP5799X
Main CPU Card

Welding Control Card

ZUEP5806X X3
X1 (DRV) (WLD-IF)

DSP

CPU BUS
communication

Over Over voltage

Detected
temperature
by here X1 (DRV)
Detected
X3 (M-OUT) CN4 by here
Servo Servo amp SPC PCB
I/O card
Power Supply AED01291 ZUEP1497XA6
ZUEP1505X
AED01283 X9 VN1 IF PCB
X10 (APOW2) THERMAL
ZUEP1504X
(AMP2) CN6
Feeder motor CN6
CN5
CN5
Over voltage
Over voltage

DC+/-15V
Motor power UVW

Action should be taken… Action should be taken…

• Check coil resistance of feeder motor including cable line (U-V, V-W, U-W) • Check possibility to make over voltage (too much long length of welding power cable or
• Check resistance between motor power line and earth grounding (U-E, V-E, W-E) the welding cable is coiled) and improve the condition. See SR10-0110E02.
• Check cooling fan is running or not, clean the cooling fan and amplifier • Check welding condition eliminate short arc transfer (bring voltage up 0.5 to 1.0V)
• Try to replace feeder amplifier, Try to replace Welding control card • SPC PCB might be damaged, try to replace SPC PCB
 Page 13

A4000 Over temperature A4010 – A4132 Contact welded : *******************

Detection logic… Detection logic…

The temperature goes up more than rated specification. All of safety input are monitored by double circuit due to safety for the operator. In case
This error will be detected thermal switch on the Sequencer card. one of double circuit contact shows opposite condition, this alarm will be detected. There
are many types of safety input like Emergency stop, Door stop and so on. The part of
message where has ********** shows which circuit has wrong status.

Error information
(CAN BUS)

Error information Detected

(CAN BUS) by here

Backplane card Safety card

ZUEP5796X
Main CPU Card
ZUEP5806X
CPU BUS
ZUEP5808X
connector X3
(CAN0)
Backplane card Sequencer card X1
ZUEP5796X
Main CPU Card

ZUEP5806X (CAN0)
CPU BUS
ZUEP5789X
connector

X4 X31
(CAN1) (CAN1) CPU BUS
THERMAL communication

Detected
CPU BUS

SPEMG
by here

1
communication
Double contact
Check whether they are having same status
(Open & Open or Close & Close) or not

EMG-IN
EMG
8
Action should be taken… Action should be taken…

• Check temperature inside of robot controller whether extremely high or not • Check external circuit and connections which was indicated on the message
• Check cooling fan is running or not, clean cooling fan and Sequencer card • Try to make short circuit for the indicated circuit on the message
• Try to replace Sequencer card • Try to replace safety card or Sequencer card
 Page 14

A4140 Over run release input is detected A4150 Safety circuit 24V error

Detection logic… Detection logic…

The status of overrun release switch on the safety card is changed while normal operation. DC24V on the Safety card is not available. The DC24V come from Power card and
The robot power should be switched off in case this switch status needed to be changed. will be converted to S24V on Safety card after passing Fuse1. The Safety card checks
this S24V is available or not.

Error information
(CAN BUS)

Detected
by here

Error information X23

Backplane card Safety card

ZUEP5796X
Main CPU Card
(CAN BUS) (EMD)
ZUEP5806X
CPU BUS
ZUEP5808X
connector X3
(CAN0) X16
F1 (3A) (SV1)

Backplane card Safety card

ZUEP5796X
Main CPU Card

ZUEP5806X
CPU BUS X1
ZUEP5808X
connector X3 (CAN0)
(CAN0) Overrun
Release SW CPU BUS
communication

DC24V
X1 Power card
(CAN0) ZUEP5803X
X12
CPU BUS (24-1)
communication
Detected DC24V
by here AC200V

DC power supply
ZWS150AF-24/J
X10
(EMG-SQ)

Action should be taken… Action should be taken…

• Check overrun release switch and set to normal operation position • Check fuse on Safety card, and check LED2 on Safety card (S24V available -> LED2 ON)
• Check stability of overrun release switch • Check connector on Safety card including X23 (EMD) connector
• Try to replace Safety card • Check connection between Safety card, Power card and DC power supply
• Try to replace safety card or Power card
 Page 15

A4160 Sequencer PWR 24V error A4900 Contact welded: Independent E-axis servo Off input(**)

Detection logic… Detection logic…

DC24V on the Sequencer card is not available. The DC24V come from Power card and Independent external axis has possibility to switch off servo power independently. And
will be provided to X22(24-1) connector on Sequencer card. The Sequencer card checks the servo off input are monitored by double circuit due to safety for the operator. In case
this DC24V is available or not. one of double circuit contact shows opposite condition, this alarm will be detected. The
information will be sent from External axis Power card to Backplane card by RS422 signal.

Error information
(CAN BUS)

Double contact
X22 Check whether they are having same status
(24-1) (Open & Open or Close & Close) or not
Backplane card

ZUEP5796X
Main CPU Card
Backplane card Sequencer card
ZUEP5796X
Main CPU Card

ZUEP5806X
ZUEP5806X CPU BUS
CPU BUS
ZUEP5789X connector
connector

X4 X31
(CAN1) (CAN1)

Detected CPU BUS 1 EMG-IN 12

CPU BUS by here communication
communication
AXIS 1 AXIS 2 AXIS 3
X9
(RS422-5) Detected
DC24V
Power card by here Status of
ZUEP5803X External axis Power card EMG
X1
X12 ZUEP5821X (EMG-IF)
(24-1)
RS422 External axis EMG card
Digital signal
DC24V ZUEP5749X
AC200V X20
(SIO) X11
DC power supply (EMG-IF)
ZWS150AF-24/J
X10
(EMG-SQ)

Action should be taken… Action should be taken…

• Check connector on Sequencer card especially X22 (24-1) connector • Check external circuit and connections which was indicated on the message
• Check connection between Sequencer card, Power card and DC power supply • Try to make short circuit for the indicated circuit on the message
• Try to replace Sequencer card or Power card • Check connection between EMG card, Power card and Backplane card
• Try to put clamp filter on the RS422 cable near by Backplane card
• Try to replace External axis Power card
 Page 16

A5000 System alarm (***) <Sub code> A5010 Abort

Detection logic… Detection logic…

When the robot software goes abnormal state that there is no possibility to execute Abnormal condition was found by Main CPU card.
further software command, this error message will be shown.

Detected
by here

Backplane card

ZUEP5796X
Main CPU Card
ZUEP5806X

Detected
by here

Backplane card IOP

ZUEP5796X
Main CPU Card

ZUEP5806X
CPU

IOP

CPU

00001000 Parameter error at calling Kernel

00001010 Timer module was called twice
00001020 Not used
00001030 Error No. with DPR ERR was not existing
00001040 CPU ERR was detected, but no ERR board was found
00001050 Parameter ERR for System data reading function
00003000 FIFO writing ERR to CTRL-ID
00003001 FIFO writing ERR to INF-ID

Action should be taken… Action should be taken…

• Check electrical noise source near by Main CPU card and other cards, and remove those • Check electrical noise source near by Main CPU card and other cards, and remove those
• Try to make all memory clear and check whether same problem happens or not • Try to make all memory clear and check whether same problem happens or not
• This alarm can be generated by software bug, try to check whether there is any • This alarm can be generated by software bug, try to check whether there is any
particular way to get this alarm or not particular way to get this alarm or not
• Try to replace Main CPU card • Try to replace Main CPU card
 Page 17

A5020 IOP CPU error A5021 Sequencer card comm. error

Detection logic… Detection logic…

The IOP-CPU on the Backplane card got error condition. Communication error for Sequencer card. The Backplane card and Sequencer card uses
Main CPU card checks status of IOP-CPU. CAN BUS for transferring data. There is no signal coming back from Sequencer card.

Communication
(CAN BUS)
Detected
by here
Detected
Backplane card by here
ZUEP5796X
Main CPU Card

ZUEP5806X
CPU BUS
Backplane card Sequencer card

ZUEP5796X
Main CPU Card
connector
ZUEP5806X
CPU BUS
ZUEP5789X
connector
IOP
X4 X31
(CAN1) (CAN1)

CPU BUS
communication
CPU BUS
communication

Action should be taken… Action should be taken…

• Check connection between Backplane card and Main CPU card • Check connection between Sequencer card and Backplane card
• Check electrical noise source near by Backplane card and remove those • Check damage of CAN BUS communication cable
• Try to download latest software to all of PC board • Check electrical noise source near by CAN BUS cable and remove those
• Try to replace Backplane card • Try to replace Sequencer card or Backplane card
 Page 18

A5022 Safety card comm. error A5030 Servo CPU error

Detection logic… Detection logic…

Communication error for Safety card. The Backplane card and Safety card uses CAN BUS The CPU on the Servo CPU card got error condition. Main CPU card checks status of Servo
for transferring data. There is no signal coming back from Safety card. CPU card. A5040 and A5050 are standing for the External axis Servo CPU card. The
contents of alarm is same as A5030.

Detected
Communication by here
(CAN BUS)

Backplane card

ZUEP5791X
Servo CPU Card
ZUEP5796X
Main CPU Card
Detected
by here ZUEP5806X
CPU BUS
connector CPU
Backplane card Safety card
ZUEP5796X
Main CPU Card

ZUEP5806X
CPU BUS
ZUEP5808X
connector X3
(CAN0)
X1
(CAN0)

CPU BUS
CPU BUS communication
communication

Action should be taken… Action should be taken…

• Check connection between Safety card and Backplane card • Check connection between Backplane card, Servo CPU card and Main CPU card
• Check damage of CAN BUS communication cable • Check electrical noise source near by Servo CPU card and remove those
• Check electrical noise source near by CAN BUS cable and remove those • Try to download latest software to all of PC board
• Try to replace Safety card or Backplane card • Try to replace Servo CPU card
 Page 19

A5060 Weld IF card CPU error A5070 Filler IF card CPU error

Detection logic… Detection logic…

The CPU on the Welding control card got error condition. The CPU on the Filler control card got error condition.
Main CPU card checks status of CPU on the Welding control card. Main CPU card checks status of CPU on the Filler control card.

Detected Detected
by here by here

Backplane card Backplane card

ZUEP5799XA1
ZUEP5796X
Main CPU Card

Filler Control Card

ZUEP5796X

ZUEP5799X
Main CPU Card

Welding Control Card

ZUEP5806X ZUEP5806X
CPU BUS CPU BUS
connector CPU connector CPU

CPU BUS CPU BUS

communication communication

Action should be taken… Action should be taken…

• Check connection between Backplane card, Welding control card and Main CPU card • Check connection between Backplane card, Filler control card and Main CPU card
• Check electrical noise source near by Welding control card and remove those • Check electrical noise source near by Filler control card and remove those
• Try to download latest software to all of PC board • Try to download latest software to all of PC board
• Try to replace Welding control card • Try to replace Filler control card
 Page 20

A5200 Robot Comm. Error <Sub code> A5210 Cooperative Robot Servo Comm. error

Detection logic… Detection logic…

The communication error with twin harmonizer system. No acknowledge command from cooperative Robot (Fanuc robot) was fed back after
sending point stop command (0F00) or touch sensing stop command (0F03).

Robot No.1 Robot No.2 Panasonic robot

controller controller controller

Detected Detected
by here by here
ZUEP5796X
Main CPU Card

ZUEP5796X
Main CPU Card
ZUEP5796X
Main CPU Card

Fanuc robot
ZUEP5825X
Hi SPD
Comm. Card
ZUEP5825X
Comm. Card
Hi SPD

CPU CPU
CPU controller

Ethernet cable

Action should be taken… Action should be taken…

• Check connection between No.1 robot and No.2 robot (Optical fiber) • Check error status on Fanuc robot
• Try to download latest software to all of PC board for both robot • Check connection of Ethernet cable and any damage on Ethernet cable
• Check electrical noise source near by Main CPU card and other cards, and remove those • This alarm can be generated by software bug, try to check whether there is any
• Check another robot whether it has any specific error or not particular way to get this alarm or not
• This alarm can be generated by software bug, try to check whether there is any
particular way to get this alarm or not
• Try to replace High speed comm. Card or Main CPU card
 Page 21

A5300 TP Communication error A5310 IOP CPU Comm. Error

Detection logic… Detection logic…

This error will be shown in case communication between Main CPU card and TP CPU 0001 : No communication fed back from IOP CPU on Backplane card
card has error condition. This error will be detected by Main CPU card. Main CPU card 0002 : Command area from Main CPU card to IOP CPU got transfer busy
retried communication 50 times x 100msec.

Communication

Detected
Detected by here
TP CPU card
by here
ZUEP
X2 X13 Backplane card

ZUEP5796X
Main CPU Card
(TCOM) (COM)
Backplane card ZUEP5806X
ZUEP5796X
Main CPU Card

CPU BUS
ZUEP5806X
CPU BUS connector
connector

CPU BUS
CPU BUS communication
communication

Action should be taken… Action should be taken…

• Check connection between Main CPU card, Backplane card and TP • Check connection between Backplane card and Main CPU card
• Check damage on the teaching pendant cable • Check electrical noise source near by Backplane card and remove those
• Check electrical noise source near by Teaching pendant and cable, and remove those • Try to download latest software to all of PC board
• Try to replace teaching pendant cable, TP unit or Backplane card • Try to replace Backplane card
 Page 22

A6010 Servo comm. timeout A6011 Servo comm. Time out (Position ACK)

Detection logic… Detection logic…

No acknowledge command coming back from Servo CPU card (within 3sec). No position reached acknowledge command coming back from Servo CPU card (within
3sec).

Detected Detected
by here by here

Backplane card Backplane card

ZUEP5791X
Main CPU Card
ZUEP5796X

Servo CPU Card

ZUEP5791X
Servo CPU Card
ZUEP5796X
Main CPU Card

ZUEP5806X ZUEP5806X
CPU BUS CPU BUS
connector CPU connector CPU

CPU BUS CPU BUS

communication communication

Action should be taken… Action should be taken…

• Check connection between Backplane card, Servo CPU card and Main CPU card • Check connection between Backplane card, Servo CPU card and Main CPU card
• Check electrical noise source near by Servo CPU card and remove those • Check electrical noise source near by Servo CPU card and remove those
• Try to download latest software to all of PC board • Try to download latest software to all of PC board
• Try to replace Servo CPU card • Try to replace Servo CPU card
 Page 23

A6012 Servo comm. Timeout (Position demand) A6020 Servo comm. Error <Sub code>

Detection logic… Detection logic…

No command for requesting position coming from Servo CPU card. <01> Sum check value received by Main CPU card was abnormal
<02> Normal command area from Main CPU card to Servo CPU card was busy
<03> Priority command area from Main CPU card to Servo CPU card was busy
<04> Sum check value for position counter red by Main CPU card was abnormal

Detected Detected
by here by here

Backplane card Backplane card

ZUEP5791X
Main CPU Card
ZUEP5796X

Servo CPU Card

ZUEP5791X
Servo CPU Card
ZUEP5796X
Main CPU Card

ZUEP5806X ZUEP5806X
CPU BUS CPU BUS
connector CPU connector CPU

CPU BUS CPU BUS

communication communication

Action should be taken… Action should be taken…

• Check connection between Backplane card, Servo CPU card and Main CPU card • Check connection between Backplane card, Servo CPU card and Main CPU card
• Check electrical noise source near by Servo CPU card and remove those • Check electrical noise source near by Servo CPU card and remove those
• Try to download latest software to all of PC board • Try to download latest software to all of PC board
• Try to replace Servo CPU card • Try to replace Servo CPU card
 Page 24

A6030 Servo ON/OFF response error A6040 Servo position command error ****

Detection logic… Detection logic…

・Optional data for acknowledge command of Servo OFF was not correct (Not NULL) Position command reading time out detected by Main CPU card.
・Axis pattern for Servo ON/OFF command was not correct First 2 digits (**) of sub code shows area number where problem was detected (0 to 5)
Next 2 digits (**) of sub code shows the board number which has no problem
(E.g.) Robot S,CPU OK -> 01 / External S,CPU1 OK -> 02 / External S,CPU2 OK -> 04
Note : OK Board number will be shown by binary code

Detected Detected
by here by here

Backplane card Backplane card

ZUEP5791X
Main CPU Card
ZUEP5796X

Servo CPU Card

ZUEP5791X
Servo CPU Card
ZUEP5796X
Main CPU Card

ZUEP5806X ZUEP5806X
CPU BUS CPU BUS
connector CPU connector CPU

CPU BUS CPU BUS

communication communication

Action should be taken… Action should be taken…

• Check connection between Backplane card, Servo CPU card and Main CPU card • Check connection between Backplane card, Servo CPU card and Main CPU card
• Check electrical noise source near by Servo CPU card and remove those • Check electrical noise source near by Servo CPU card and remove those
• Try to download latest software to all of PC board • Try to download latest software to all of PC board
• Try to replace Servo CPU card • Try to replace Servo CPU card
 Page 25

A7000 Interpolation data error A7001 Servo control error

Detection logic… Detection logic…

In case interpolation time on position control command from Main CPU card has over If DSP on the Servo CPU card cannot transact position feedback 2 times to Main CPU card
specification of robot, this error will be detected. 01: Sum check error, 02: Undefined due to Serial data was not fed back from Resolver card, this error will be shown.
command, 03: Wrong command

Detected
by here

Backplane card

ZUEP5791X
Servo CPU Card
ZUEP5796X
Main CPU Card
ZUEP5806X
IFCPU

Interpolation Detected
data by here Power card
ZUEP5803X

Backplane card ZUEP5791X DSP

Servo CPU Card
ZUEP5796X
Main CPU Card

ZUEP5806X
CPU BUS
connector IFCPU X21
Serial
X7 X22 (RE-IN)
data
(RE-IN) (RE-OUT)
X1 (DRV)

Data X3 (M-OUT)
Servo amp
Servo
Power Supply AEDXXXXX
DSP Serial
data
AED01283

Resolver card
CPU BUS ZUEP5764XXX R/D
conversion
communication

Motor
power UVW
Resolver
signal
Motor

Note: This picture shows case of RT axis

Action should be taken… Action should be taken…

• Try to download latest software to all of PC board • Check connection between Servo CPU card, Power card and Resolver card
• Check connection between Backplane card, Servo CPU card and Main CPU card • Check +/- S phase cable damage for shown axis by voltage meter
• Check electrical noise source near by Servo CPU card and remove those • Try to replace Servo CPU card or Resolver card
• Check whether there is any particular way to get this alarm or not • Try to replace cable or harness which include S phase
• Try to replace Main CPU card or Servo CPU card
• Make full back up and report to Panasonic Japan with back up data
 Page 26

A7002 Servo CPU Comm. Error (IF) A7003 Skew error

Detection logic… Detection logic…

This error will be shown in case communication between Main CPU card and Servo CPU In case the position difference between gantry master axis and Slave axis is more than
card has error condition. This error will be detected by Servo CPU card. specified limit on system setting, this Skew error will be shown. There are several
01: Sum check error, 02：Unknown command, 03：Wrong command possibility for this. 1) Overload on gantry pair system, 2) Backlash on gantry pair system,
and 3) Emergency stop while high speed movement of gantry pair system.

Detected
by here

Backplane card

ZUEP5796X
Main CPU Card

External axis

ZUEP5791X
Servo CPU Card
ZUEP5806X
CPU BUS
connector
Detected
by here X7
(RE-IN)

Backplane card
ZUEP5791X
Servo CPU Card
ZUEP5796X
Main CPU Card

ZUEP5806X
CPU BUS
connector IF

CPU BUS
communication
External axis Power card
ZUEP5821X

X17
(RE-OUT) Encoder
Encoder feed back
feed back

CPU BUS
communication

Synchronized motion

Master Slave
motor motor

Action should be taken… Action should be taken…

• Check connection between Backplane card, Servo CPU card and Main CPU card • Release skew error condition with skew error release mode
• Check electrical noise source near by Servo CPU card and remove those • Check situation of system, when this alarm occurred based on followings info.
• Try to download latest software to all of PC board Overload on gantry pair system, Backlash on gantry pair system, and Emergency stop
• Try to replace Servo CPU card while high speed movement of gantry pair system
 Page 27

A7004 Drift error A7005 Pre-set count over

Detection logic… Detection logic…

Robot did not stop at teach point precisely. Servo CPU card checks deviation counter data The deviation counter over was occurred while preset movement.
becomes within certain range or not at stop point. If the data did not come within certain The present motion will be operated only one time, when servo power is switched on
range Servo CPU card sends error status to Main CPU card. after switching on the robot power. In case deviation gets more than 400 pulse, this error
will be detected by Servo CPU card.

Backplane card Backplane card

ZUEP5791X
Servo CPU Card
ZUEP5796X

ZUEP5791X
Main CPU Card

Servo CPU Card

ZUEP5796X
Main CPU Card
ZUEP5806X ZUEP5806X

Power card Power card

ZUEP5803X ZUEP5803X
DEV DEV

Detected Detected
by here X21 by here X21
(RE-IN) (RE-IN) Pulse
X7 X22 X7 X22 data
(RE-IN) (RE-OUT) (RE-IN) (RE-OUT)
X1 (DRV) X1 (DRV)

X3 (M-OUT) X3 (M-OUT)
Servo Servo amp Pulse
Servo Servo amp
AEDXXXXX data AEDXXXXX
Power Supply Pulse Power Supply Pulse
AED01283 data AED01283 data

Resolver card Resolver card

ZUEP5764XXX R/D ZUEP5764XXX R/D
conversion conversion

Motor Motor
power UVW power UVW
Resolver Resolver
signal signal
Motor Motor

Note: This picture shows case of RT axis Note: This picture shows case of RT axis

Action should be taken… Action should be taken…

• Check robot motion whether it has over shooting or not • Check there is collision or not, and check brake release condition
• Check weight on the robot whether there is weight more than specification or not • Check all connection between Servo CPU card, Power card and Servo amplifier
• Check coil resistance of motor including cable line (U-V, V-W, U-W) • Check connection between Servo amplifier and Servo motor (Motor power)
• Check resistance between motor power line and earth grounding (U-E, V-E, W-E) • Check coil resistance of motor including cable line (U-V, V-W, U-W)
• Try to set default servo parameter again on maintenance mode • Check resistance between motor power line and earth grounding (U-E, V-E, W-E)
• Try to replace Servo CPU card, Servo amplifier or Servo motor • Try to replace Servo CPU card, Servo amplifier or Servo motor
 Page 28

A7006 R/D error A7007 Absolute encoder error

Detection logic… Detection logic…

In case the cable between Resolver card and resolver is disconnected while robot power In case the serial data from Resolver card was not readable 2 times continuously, this
is switch on, this error will be detected by Resolver card. After switching off and on the alarm will be shown. The Servo CPU card checks this always, when robot servo power is
robot power, the TP will show Encoder reset message. ON state.
* Servo CPU card checks status signal ST5 (RE) what is included on serial data from
Resolver card is ON. Status signal will be checked 1) Just before servo on, 2) At
Collision detect, 3) At Lock detected

Backplane card Backplane card

ZUEP5791X
Servo CPU Card
ZUEP5796X

ZUEP5791X
Main CPU Card

Servo CPU Card

ZUEP5796X
Main CPU Card
ZUEP5806X ZUEP5806X

Power card Power card

ZUEP5803X ZUEP5803X

Detected
X21 by here X21
(RE-IN) (RE-IN) Serial
X7 X22 X7 X22 data
(RE-IN) (RE-OUT) (RE-IN) (RE-OUT)
X1 (DRV) X1 (DRV)

X3 (M-OUT) X3 (M-OUT)
Servo Servo amp Serial
Servo Servo amp
AEDXXXXX data AEDXXXXX
Power Supply Serial Power Supply Serial
AED01283 data AED01283 data

Resolver card Resolver card

Detected
ZUEP5764XXX R/D ZUEP5764XXX R/D
conversion conversion
by here

Motor Motor
power UVW power UVW
Resolver Resolver
signal signal
Motor Motor

Note: This picture shows case of RT axis Resolver Note: This picture shows case of RT axis

Action should be taken… Action should be taken…

• Check connection between Resolver card and resolver on the Servo motor • Check connection between Resolver card, Power card and Servo CPU card
• Make revolution counter reset (Encoder reset) and adjust origin position by REV or 1/4 • Check damage on the cable between Resolver card, Power card and Servo CPU card
REV (512 pulse) • Try to replace Resolver card or Servo CPU card
• Try to replace Resolver card in case same problem occurred again
 Page 29

A7008 Absolute data speed error A7009 Position count over

Detection logic… Detection logic…

In case the difference between position counter and serial data from Resolver card has Deviation counter over. In case the deviation counter which will keep pulse data (for next
more than 16384 pulse, this alarm will be detected. movement) gets over flow, this error will be shown. The deviation counter is on the Servo
CPU card. The maximum range for deviation counter is +/- 4096.

Backplane card Backplane card

ZUEP5791X
Servo CPU Card
ZUEP5796X

ZUEP5791X
Main CPU Card

Servo CPU Card

ZUEP5796X
Main CPU Card
ZUEP5806X ZUEP5806X

Power card Power card

ZUEP5803X ZUEP5803X
DEV

Detected
X21 by here X21
Detected Pulse
X7 X22 (RE-IN) X7 X22 (RE-IN)
by here data
(RE-IN) (RE-OUT) (RE-IN) (RE-OUT)
X1 (DRV) X1 (DRV)
Serial
X3 (M-OUT) data X3 (M-OUT)
Servo Servo amp Servo Servo amp
&
Power Supply AEDXXXXX Serial Pulse Power Supply AEDXXXXX Pulse
AED01283 data AED01283 data
&
Pulse
Resolver card Resolver card
ZUEP5764XXX R/D ZUEP5764XXX R/D
conversion conversion

Motor Motor
power UVW power UVW
Resolver Resolver
signal signal
Motor Motor

Note: This picture shows case of RT axis Resolver Note: This picture shows case of RT axis

Action should be taken… Action should be taken…

• Check connection between Servo CPU card, Power card and Resolver card • Check there is collision or not, and check brake release condition
• Check damage on Serial data feed back cable (encoder cable) • Check all connection between Servo CPU card, Power card and Servo amplifier
• Try to replace Servo CPU card or Resolver card • Check connection between Servo amplifier and Servo motor (Motor power)
• Check coil resistance of motor including cable line (U-V, V-W, U-W)
• Check resistance between motor power line and earth grounding (U-E, V-E, W-E)
• Try to replace Servo CPU card, Servo amplifier or Servo motor
 Page 30

A7010 Amp ready error A7011 IPM error

Detection logic… Detection logic…

The servo ready signal from indicated axis’s amplifier did not come within 500m second The IPM (Intelligent Power Module), which controls motor power, on the indicated axis’s
after sending SV ON command. This error will be detected by Servo CPU card. amplifier has error condition. There are two possibility with this error. 1) Over current on
the motor, 2) Control voltage became less than DC10V (Normally DC15V).

Detected X1 (DRV)
by here
X1 (DRV)
Backplane card

ZUEP5796X
Main CPU Card

ZUEP5791X
Servo CPU Card
Backplane card ZUEP5806X

ZUEP5791X
Servo CPU Card
ZUEP5796X
Main CPU Card

ZUEP5806X

DC280V Detected IPM Error

X3 (DC1) by here X1 (DRV)
SV Ready
X3 (DC1)
X1 (DRV)
X3 (M-OUT)
Servo Servo amp
Servo amp Power Supply AEDXXXXX X2 (AMPB)
Servo
AEDXXXXX AED01283 X7
Power Supply
X7
X2 (AMPB) X8 (APOW1) IPM
X8 AED01283 (AMP1)
(APOW1) Motor
(AMP1)
SV ON

VN1 X3 (AMPA)

VN1 X3 (AMPA) DC+/-15V

DC+/-15V Motor power UVW

Note: This picture shows case of RT axis Note: This picture shows case of RT axis

Action should be taken… Action should be taken…

• Check connection for DC+/-15V, VN1 and DRV signal for the indicated axis’s amplifier • Check connection for DC+/-15V, VN1 and DRV signal for the indicated axis’s amplifier
• Check voltage for DC+/-15V, VN1 to the indicated axis’s amplifier • Check voltage for DC+/-15V, VN1 to the indicated axis’s amplifier
• Try to replace amplifier or Servo CPU card • Check coil resistance of motor including cable line (U-V, V-W, U-W)
• Check resistance between motor power line and earth grounding (U-E, V-E, W-E)
• Try to replacing amplifier or Servo CPU card
 Page 31

A7012 Servo Power error A7013 IPM over current

Detection logic… Detection logic…

Indicated axis’s Servo amplifier detected Servo power error (SVERR), but detail of SVERR High side of IPM output got over current (Motor power line is leaked or shorted).
was not sent to Servo CPU card from Servo power supply via RS422 signal.

X1 (DRV) X1 (DRV)

Backplane card Backplane card

ZUEP5796X

ZUEP5796X
Main CPU Card

Main CPU Card

ZUEP5791X

ZUEP5791X
Servo CPU Card

Servo CPU Card

ZUEP5806X ZUEP5806X

X20 IPM over

Detected (422) Detected
current
X3 (DC1) by here X1 (DRV) X3 (DC1) by here X1 (DRV)

X3 (M-OUT)
Servo Servo amp Servo Servo amp
Power Supply AEDXXXXX X2 (AMPB) Power Supply AEDXXXXX X2 (AMPB)
X7
AED01283 AED01283(APOW1)
X8 SVERR X8 IPM
(AMP1) (AMP1)
VN1 Motor

X3 (AMPA)
No detail
SVERR
X6
DC+/-15V
(422)
Motor power
UVW
Note: This picture shows case of RT axis

Action should be taken… Action should be taken…

• Check connection between Servo CPU card, Servo power supply and Servo amplifier • Check coil resistance of indicated axis’s motor including cable line (U-V, V-W, U-W)
• Try to replace Servo power supply • Check resistance between motor power line and earth grounding (U-E, V-E, W-E)
• Try to replace Servo amplifier or Servo CPU card • Check voltage for +/-15V, VN1 to the indicated axis’s amplifier
• Try to replace indicated axis’s motor after checking there is no problem for motor line
• Try to replace indicated axis’s amplifier or Servo CPU card
 Page 32

A7014 IPM over temperature A7015 Regenerative register over duty

Detection logic… Detection logic…

Thermal switch on the servo amplifier detected over temperature. Over duty of Regenerative resister (PN power line). If regenerative circuit IGBT was
switched on more than 168msec, this alarm will be detected. The time can be different
depending on robot type.

X1 (DRV) X1 (DRV)

Backplane card Backplane card

ZUEP5796X

ZUEP5796X
Main CPU Card

Main CPU Card

ZUEP5791X

ZUEP5791X
Servo CPU Card

Servo CPU Card

ZUEP5806X ZUEP5806X

Over X20
Detected (422)
temperature
X3 (DC1) by here X1 (DRV) X3 (DC1) X1 (DRV)

X3 (M-OUT)
Servo Servo amp Servo Servo amp
Power Supply AEDXXXXX X2 (AMPB) Power Supply AEDXXXXX X2 (AMPB)
X7
AED01283(APOW1) AED01283 Detected
X8 THERMAL X8 by here SVERR
(AMP1) (AMP1)
VN1 Motor

Over duty
X3 (AMPA) (RS422)
SVERR
DC+/-15V
X6
(422)
Motor power
UVW
Note: This picture shows case of RT axis

Action should be taken… Action should be taken…

• Check coil resistance of indicated axis’s motor including cable line (U-V, V-W, U-W) • Check input voltage AC200V (3 phase) to Servo power supply
• Check resistance between motor power line and earth grounding (U-E, V-E, W-E) • Check output voltage DC300V from Servo power supply
• Check cooling fan is running or not, clean the cooling fan and amplifier • Check regenerative resister’s resistance (33 ohm)
• Try to replace indicated axis’s amplifier, Try to replace Servo CPU card • Try to replace Servo power supply
 Page 33

A7016 Regenerative register over voltage A7017 Regenerative register over temperature

Detection logic… Detection logic…

Over voltage for PN power line on the Servo power supply. If this line got DC450V more Over temperature (detected by thermal1). Currently this circuit is not used (shorted)
than 15msec, this alarm will be detected. The detection voltage can be different by short circuit connector on Servo power unit.
depending on robot type.

X1 (DRV) X1 (DRV)

Backplane card Backplane card

ZUEP5796X
Main CPU Card
ZUEP5796X
Main CPU Card

ZUEP5791X
Servo CPU Card
ZUEP5791X
Servo CPU Card
ZUEP5806X ZUEP5806X

X20 X20
(422) (422)
X3 (DC1) X1 (DRV) X3 (DC1) X1 (DRV)

Servo Servo amp Servo Servo amp

Power Supply AEDXXXXX X2 (AMPB) Power Supply AEDXXXXX X2 (AMPB)
AED01283 Detected AED01283 Detected
X8 by here SVERR X8 by here SVERR
(AMP1) (AMP1)

X4

Over voltage Over temperature

(RS422) (RS422)
SVERR SVERR
Servo
X6 X6
protection card
(422) (422)
ZUEP5802X

Action should be taken… Action should be taken…

• Check input voltage AC200V (3 phase) to Servo power supply • Check connection of short circuit connector X4 on Servo protection card.
• Check output voltage DC300V from Servo power supply
• Check regenerative resister’s resistance (33 ohm)
• Try to replace Servo power supply
 Page 34

A7018 Servo Power over temperature A7019 Regenerative register over duty

Detection logic… Detection logic…

Over temperature (detected by thermal2). Currently this circuit is not used (shorted) Over duty of Regenerative resister (PN power line) was detected just after booting up
by short circuit connector on Servo power unit. robot controller power. If regenerative circuit IGBT was switched on more than 168msec,
this alarm will be detected. The time can be different depending on robot type.

X1 (DRV) X1 (DRV)

Backplane card Backplane card

ZUEP5796X
Main CPU Card

ZUEP5796X
Main CPU Card
ZUEP5791X
Servo CPU Card

ZUEP5791X
Servo CPU Card
ZUEP5806X ZUEP5806X

X20 X20
(422) (422)
X3 (DC1) X1 (DRV) X3 (DC1) X1 (DRV)

Servo Servo amp Servo Servo amp

Power Supply AEDXXXXX X2 (AMPB) Power Supply AEDXXXXX X2 (AMPB)
AED01283 Detected AED01283 Detected
X8 by here SVERR X8 by here SVERR
(AMP1) (AMP1)

X4

Over temperature Over duty

(RS422) (RS422)
SVERR SVERR
Servo
X6 X6
protection card
(422) (422)
ZUEP5802X

Action should be taken… Action should be taken…

• Check connection of short circuit connector X4 on Servo protection card. • Check input voltage AC200V (3 phase) to Servo power supply
• Check output voltage DC300V from Servo power supply
• Check regenerative resister’s resistance (33 ohm)
• Try to replace Servo power supply
 Page 35

A7020 Regenerative register over voltage A7021 Regenerative register over temperature

Detection logic… Detection logic…

Over voltage for PN power line on the Servo power supply was detected just after booting Over temperature (detected by thermal1) was detected just after booting up robot
up robot controller power. If this line got DC450V more than 15msec, this alarm will be controller power. Currently this circuit is not used (shorted) by short circuit connector on
detected. The detection voltage can be different depending on robot type. Servo power unit.

X1 (DRV) X1 (DRV)

Backplane card Backplane card

ZUEP5796X
Main CPU Card
ZUEP5796X
Main CPU Card

ZUEP5791X
Servo CPU Card
ZUEP5791X
Servo CPU Card
ZUEP5806X ZUEP5806X

X20 X20
(422) (422)
X3 (DC1) X1 (DRV) X3 (DC1) X1 (DRV)

Servo Servo amp Servo Servo amp

Power Supply AEDXXXXX X2 (AMPB) Power Supply AEDXXXXX X2 (AMPB)
AED01283 Detected AED01283 Detected
X8 by here SVERR X8 by here SVERR
(AMP1) (AMP1)

X4

Over voltage Over temperature

(RS422) (RS422)
SVERR SVERR
Servo
X6 X6
protection card
(422) (422)
ZUEP5802X

Action should be taken… Action should be taken…

• Check input voltage AC200V (3 phase) to Servo power supply • Check connection of short circuit connector X4 on Servo protection card.
• Check output voltage DC300V from Servo power supply
• Check regenerative resister’s resistance (33 ohm)
• Try to replace Servo power supply
 Page 36

A7022 Servo Power over temperature A7023 Lack of Phase

Detection logic… Detection logic…

Over temperature (detected by thermal2) was detected just after booting up robot One of phase on AC200V (3 phase) coming to Servo power supply is missing (lacked).
controller power. Currently this circuit is not used (shorted) by short circuit connector on
Servo power unit.

X1 (DRV) X1 (DRV)

Backplane card Backplane card

ZUEP5796X
Main CPU Card

ZUEP5791X
Servo CPU Card

ZUEP5796X
Main CPU Card

ZUEP5791X
Servo CPU Card
ZUEP5806X ZUEP5806X

X20 X20
(422) (422)
X3 (DC1) X1 (DRV) X3 (DC1) X1 (DRV)

Servo Servo amp Servo amp

Servo Detected
Power Supply AEDXXXXX X2 (AMPB) AEDXXXXX
Power Supply by here X2 (AMPB)
AED01283 Detected AED01283
X8 by here SVERR X8 SVERR
(AMP1) (AMP1)

X4

Over temperature Lack of phase

(RS422) (RS422)
SVERR SVERR
Servo
X6 X6
protection card
(422) (422)
ZUEP5802X

Action should be taken… Action should be taken…

• Check connection of short circuit connector X4 on Servo protection card. • Check input voltage AC200V (3 phase) to Servo power supply
• Check all connections related to AC200V input (Magnet switch, Circuit breaker and etc)
• Try to replace Servo power supply
 Page 37

A7024 Servo protect card initialize error A7025 Servo protect card comm. error

Detection logic… Detection logic…

Initial communication error between Servo CPU card and Servo protection card. Communication error between Servo CPU card and Servo protection card.

Detected Detected
by here by here
X1 (DRV) X1 (DRV)

Backplane card Backplane card

ZUEP5796X
Main CPU Card
ZUEP5796X
Main CPU Card

ZUEP5791X
Servo CPU Card
ZUEP5791X
Servo CPU Card
ZUEP5806X ZUEP5806X

X20 X20
(422) (422)
X3 (DC1) X1 (DRV) X3 (DC1) X1 (DRV)

Servo Servo amp Servo Servo amp

Power Supply AEDXXXXX X2 (AMPB) Power Supply AEDXXXXX X2 (AMPB)
AED01283 AED01283
X8 X8
(AMP1) (AMP1)

X4 X4

No communication No communication
Servo Servo
X6 X6
protection card protection card
(422) (422)
ZUEP5802X ZUEP5802X

Action should be taken… Action should be taken…

• Check connection between Servo CPU card and Servo power supply(RS422). • Check connection between Servo CPU card and Servo power supply(RS422).
• Try to replace Servo power supply • Try to replace Servo power supply
 Page 38

A7026 Servo protect card comm. error A7027 Encoder cable error

Detection logic… Detection logic…

CPU error on Servo protection card. The encoder signal coming from Resolver card has +A / -A , +B / -B. In case +A and –A
(or +B and -B) has same status (H/H or L/L), this alarm will be detected.

X1 (DRV)
Backplane card

ZUEP5791X
Servo CPU Card
ZUEP5796X
Main CPU Card
Backplane card ZUEP5806X
ZUEP5796X
Main CPU Card

ZUEP5791X
Servo CPU Card
ZUEP5806X

Power card
ZUEP5803X

Detected
by here X21
X7 X22 (RE-IN) Pulse
X20 (RE-IN) (RE-OUT) data
(422) X1 (DRV)
X3 (DC1) X1 (DRV)
X3 (M-OUT)
Servo Servo amp
Servo amp Power Supply AEDXXXXX Pulse
Servo
Power Supply AEDXXXXX X2 (AMPB) AED01283 data

AED01283
X8
(AMP1) Resolver card
ZUEP5764XXX R/D
X4 conversion
Detected CPU
by here

Motor
CPU error power UVW
Resolver
Servo signal
X6
protection card Motor
(422)
ZUEP5802X

Note: This picture shows case of RT axis

Action should be taken… Action should be taken…

• Check connection between Servo CPU card and Servo power supply(RS422). • Check connection between Servo CPU card, Power card and Resolver card
• Try to replace Servo power supply • Check damage on pulse feed back cable (encoder cable)
• Try to replace Servo CPU card, Resolver card
• See technical document SR11-0135E02 (Counter measurement for cable error)
 Page 39

A7028 Main Servo comm. Error (DPRAM FIFO full) A7030 Counter error ** (Axis name)

Detection logic… Detection logic…

FIFO area for interpolation command reading complete and point reaching completed A counter was not revised specified cycle continuously.
command where Servo CPU reads is full. - This alarm is especially for Smart absolute encoder
- Detected any time, alarm will be shown immediately
One of below Sub code will be shown
01: Rotor position counter (125us x 10 cycle -> NG)
02: Speed counter (250us x 5 cycle -> NG)
03: Position counter (2msec x 4 cycle -> NG)

Detected
by here

Backplane card

ZUEP5845X
Servo CPU Card
ZUEP5796X
Main CPU Card
ZUEP5806X

Detected
by here
Power card
ZUEP5850X
Backplane card
ZUEP5791X
Main CPU Card
ZUEP5796X

Servo CPU Card

ZUEP5806X
CPU BUS
connector CPU
X20
X7 X17 (RE-IN)
(RE-IN) (RE-OUT)

FIFO Servo Servo amp

Power Supply AEDXXXXX
Serial data
AED01283

RE PWR card
ZUEP5847X Serial data
CPU BUS
communication

Problem
Happened
here

Motor

Note: This picture shows case of RT axis

Action should be taken… Action should be taken…

• Try to download latest software to all of PC board • Check connection between Backplane card, Servo CPU card and Main CPU card
• Check connection between Backplane card, Servo CPU card and Main CPU card • Check connection from the encoder to S,CPU card, also connection related encoder
• Check electrical noise source near by Servo CPU card and remove those • Check electrical noise source related encoder line and remove those
• Check whether there is any particular way to get this alarm or not • Try to download latest software to all of PC board
• Try to replace Main CPU card or Servo CPU card • Try to replace Servo CPU card, Servo motor (Encoder)
• Make full back up and report to Panasonic Japan with back up data
 Page 40

A7031 Thermal reference setting error ** (Axis name) A7032 Status reset error ** (Axis name)

Detection logic… Detection logic…

The access to set standard value of encoder over heat (EEPROM access) was not The resetting of encoder status was not successfully done.
successfully completed. - This alarm is especially for Smart absolute encoder
- This alarm is especially for Smart absolute encoder - Detected at servo power on, alarm will be shown at this moment
- Detected at controller power on, alarm will be shown at this moment

Detected Detected
by here by here

Backplane card Backplane card

Main CPU Card

Main CPU Card

ZUEP5796X

ZUEP5796X
ZUEP5845X

ZUEP5845X
Servo CPU Card

Servo CPU Card

ZUEP5806X ZUEP5806X

Power card Power card

ZUEP5850X ZUEP5850X

X20 X20
X7 X17 (RE-IN) X7 X17 (RE-IN)
(RE-IN) (RE-OUT) (RE-IN) (RE-OUT)

Servo Servo amp Servo Servo amp

Power Supply AEDXXXXX Power Supply AEDXXXXX
Serial data Serial data
AED01283 AED01283

RE PWR card RE PWR card

ZUEP5847X Serial data ZUEP5847X Serial data

Problem Problem
Happened Happened
here here

Motor Motor

Note: This picture shows case of RT axis Note: This picture shows case of RT axis

Action should be taken… Action should be taken…

• Check connection between Backplane card, Servo CPU card and Main CPU card • Check connection between Backplane card, Servo CPU card and Main CPU card
• Check connection from the encoder to S,CPU card, also connection related encoder • Check connection from the encoder to S,CPU card, also connection related encoder
• Check electrical noise source related encoder line and remove those • Check electrical noise source related encoder line and remove those
• Try to download latest software to all of PC board • Try to download latest software to all of PC board
• Try to replace Servo CPU card, Servo motor (Encoder) • Try to replace Servo CPU card, Servo motor (Encoder)
 Page 41

A7033 Encoder status error ** (Axis name) A7034 Absolute data status error ** (Axis name)

Detection logic… Detection logic…

When S,CPU card tried to reset encoder over heat status, the S,CPU card found that the The motor was not at same position (=rotated) during switching on the encoder power.
error bit other than over heat was ON. (It was rotated more than 100rpm speed)
- This alarm is especially for Smart absolute encoder - This alarm is especially for Smart absolute encoder
- Detected at servo power on, alarm will be shown at this moment - Detected any time, alarm will be shown immediately

Detected Detected
by here by here
Main CPU Card

Main CPU Card

ZUEP5796X

ZUEP5796X
ZUEP5845X

ZUEP5845X
Servo CPU Card

Servo CPU Card

Backplane card Backplane card
ZUEP5806X ZUEP5806X

Power card Power card

ZUEP5850X ZUEP5850X

X20 X20
X7 X17 (RE-IN) X7 X17 (RE-IN)
(RE-IN) (RE-OUT) (RE-IN) (RE-OUT)

Servo Servo amp Servo Servo amp

Power Supply AEDXXXXX Power Supply AEDXXXXX
Serial data Serial data
AED01283 AED01283

RE PWR card RE PWR card

ZUEP5847X Serial data ZUEP5847X Serial data

Problem Problem
Happened Happened
here here

Motor Motor

Note: This picture shows case of RT axis Note: This picture shows case of RT axis

Action should be taken… Action should be taken…

• Check connection between Backplane card, Servo CPU card and Main CPU card • Check connection between Backplane card, Servo CPU card and Main CPU card
• Check connection from the encoder to S,CPU card, also connection related encoder • Check connection from the encoder to S,CPU card, also connection related encoder
• Check electrical noise source related encoder line and remove those • Check electrical noise source related encoder line and remove those
• Try to download latest software to all of PC board • Try to download latest software to all of PC board
• Try to replace Servo CPU card, Servo motor (Encoder) • Try to replace Servo CPU card, Servo motor (Encoder)
 Page 42

A7035 Encoder single turn count error ** (Axis name) A7036 Encoder multi turn count error ** (Axis name)

Detection logic… Detection logic…

The resolution (in one rotation) became lower than specification. There was abnormal condition on revolution counter.
(Encoder status bit 5 is ON) (Encoder status bit 6 is ON)
- This alarm is especially for Smart absolute encoder - This alarm is especially for Smart absolute encoder
- Detected any time, alarm will be shown immediately - Detected any time, alarm will be shown immediately

Detected Detected
by here by here
Main CPU Card

Main CPU Card

ZUEP5796X

ZUEP5796X
ZUEP5845X

ZUEP5845X
Servo CPU Card

Servo CPU Card

Backplane card Backplane card
ZUEP5806X ZUEP5806X

Power card Power card

ZUEP5850X ZUEP5850X

X20 X20
X7 X17 (RE-IN) X7 X17 (RE-IN)
(RE-IN) (RE-OUT) (RE-IN) (RE-OUT)

Servo Servo amp Servo Servo amp

Power Supply AEDXXXXX Power Supply AEDXXXXX
Serial data Serial data
AED01283 AED01283

RE PWR card RE PWR card

ZUEP5847X Serial data ZUEP5847X Serial data

Problem Problem
Happened Happened
here here

Motor Motor

Note: This picture shows case of RT axis Note: This picture shows case of RT axis

Action should be taken… Action should be taken…

• Check connection between Backplane card, Servo CPU card and Main CPU card • Check connection between Backplane card, Servo CPU card and Main CPU card
• Check connection from the encoder to S,CPU card, also connection related encoder • Check connection from the encoder to S,CPU card, also connection related encoder
• Check electrical noise source related encoder line and remove those • Check electrical noise source related encoder line and remove those
• Try to download latest software to all of PC board • Try to download latest software to all of PC board
• Try to replace Servo CPU card, Servo motor (Encoder) • Try to replace Servo CPU card, Servo motor (Encoder)
 Page 43

A7040 Servo CPU Comm. Error (DSP) A7041 Servo memory error

Detection logic… Detection logic…

This error will be shown in case communication between Main CPU card and Servo CPU An error occurred for the RAM on DSP. The Servo CPU card software does DSP RAM read
card has error condition. This error will be detected by Servo CPU card. / Write check. And in case there is error condition, this error will be detected.
01: Sum check error, 02：Unknown command, 03：Wrong command

Detected Detected
by here by here

ZUEP5791X
Servo CPU Card
ZUEP5796X
Main CPU Card

Backplane card

ZUEP5791X
Servo CPU Card
ZUEP5796X
Main CPU Card
ZUEP5806X Backplane card
CPU BUS ZUEP5806X
connector IF CPU BUS
connector

DSP DSP
RAM

CPU BUS
communication CPU BUS
communication

Action should be taken… Action should be taken…

• Check connection between Backplane card, Servo CPU card and Main CPU card • Check connection between Backplane card, Servo CPU card and Main CPU card
• Check electrical noise source near by Servo CPU card and remove those • Check electrical noise source near by Servo CPU card and remove those
• Try to download latest software to all of PC board • Try to download latest software to all of PC board
• Try to replace Servo CPU card • Try to replace Servo CPU card
 Page 44

A7042 Current detect error A7050 Servo power off ( PRST off)

Detection logic… Detection logic…

A/D error detection. In case the motor current detection on Servo CPU card has abnormal Main CPU card checks PRST status. When PRST is OFF more than 1 sec, Main CPU card
condition, this error will be detected. If motor current offset is more than 12.5% of understand that servo power was switched off and it checks reason of this. However in
maximum value just after switching on the servo power, this error will be detected. case Main CPU card could not find the reason of servo power off, this alarm will be shown.

Detected
X1 (DRV)
by here
ZUEP5796X
Main CPU Card

Backplane card

ZUEP5791X
Servo CPU Card

ZUEP5791X
Servo CPU Card
ZUEP5796X
Main CPU Card
ZUEP5806X Backplane card
ZUEP5806X

Power card
ZUEP5803X
A/D
Detected
by here

Motor current
PRST X7 X22
X3 (DC1) X1 (DRV) information
status (RE-IN) (RE-OUT)

X3 (M-OUT)
Servo Servo amp
AEDXXXXX Servo Servo amp
Power Supply X2 (AMPB)
Power Supply AEDXXXXX
AED01283 X7
X8 (APOW1) CT AED01283
(AMP1)
Motor
PRST
status

VN1 X3 (AMPA)
DC+/-15V

Motor power UVW

Note: This picture shows case of RT axis

Action should be taken… Action should be taken…

• Check coil resistance of indicated axis’s motor including cable line (U-V, V-W, U-W) • Check error history whether there is error or alarm which occur often or not
• Check resistance between motor power line and earth grounding (U-E, V-E, W-E) If some error which switch off servo power occurred, that line may have chattering
• Try to replace Servo CPU card or Servo amplifier • Check whether there is any electrical noise source or not, like high frequency noise from
TIG power source. If there is so, avoid electrical noise. The error must be happened at
arc start in case of TIG high frequency noise
 Page 45

A7080 Servo torque free error A7090 Servo undefined code error

Detection logic… Detection logic…

The servo torque free axis information from Servo CPU card is not same as what Main In case Servo CPU has sent undefined alarm code to Main CPU card, this error will be
CPU card sent with torque free command. Or no acknowledge from Servo CPU card to detected. The sub code beside of this message shows the undefined alarm code number
Main CPU card. from Servo CPU card.

ZUEP5791X
Servo CPU Card
ZUEP5796X
Main CPU Card

Backplane card
ZUEP5806X

Detected
Power card by here
ZUEP5803X

ZUEP5791X
Servo CPU Card
ZUEP5796X
Main CPU Card
Backplane card
ZUEP5806X
CPU BUS
Detected connector
by here

Servo Servo amp

Power Supply AEDXXXXX
AED01283
Torque free
control
Resolver card
ZUEP5764XXX CPU BUS Not defined
communication alarm code

Motor

Note: This picture shows case of RT axis

Action should be taken… Action should be taken…

• Check software matching between Main CPU card and Servo CPU card • Try to download latest software to all of PC board
• Try to replace Main CPU card or Servo CPU card • Try to replace Main CPU card or Servo CPU card
• Make full back up and report to Panasonic Japan with back up data • Make full back up and report to Panasonic Japan with back up data
 Page 46

A8000 Encoder battery error A8001 Encoder over speed

Detection logic… Detection logic…

The battery voltage for revolution counter on Resolver card become less than DC3.0V. If the motor is rotated with rated or acceleration speed while robot power is off condition,
This error status will be sent from the encoder or Resolver card with +/- S phase (Serial this alarm will be detected. (The speed monitoring error under battery operation). The TP
data). The TP will not show this alarm and show just Encoder reset message. But this will not show this alarm and show just Encoder reset message. But this alarm will be
alarm will be stored on error / alarm history. stored on error / alarm history.

ZUEP5791X
Servo CPU Card
ZUEP5791X

ZUEP5796X
Servo CPU Card

Main CPU Card

ZUEP5796X

Backplane card
Main CPU Card

Backplane card
ZUEP5806X ZUEP5806X

Power card Power card

ZUEP5803X ZUEP5803X

X21 X21
X7 X22 (RE-IN) X7 X22 (RE-IN)
(RE-IN) (RE-OUT) (RE-IN) (RE-OUT)

Servo Servo amp Servo Servo amp

Power Supply AEDXXXXX Serial data Power Supply AEDXXXXX Serial data
AED01283 (BAT ERR) AED01283 (SPD ERR)
Serial data Serial da
(BAT ERR) (SPD ER
Resolver card Resolver card
Detected
ZUEP5764XXX Detected
ZUEP5764XXX
by here by here

Battery Battery
ER6VCT ER6VCT

Motor Motor

Rotated
Note: This picture shows case of RT axis Note: This picture shows case of RT axis by high speed

Action should be taken… Action should be taken…

• Check voltage of Resolver card battery and replace them • Check voltage of Resolver card battery just in case
• Make revolution counter reset (Encoder reset) and adjust origin position by 1/4 REV • Make revolution counter reset (Encoder reset) and adjust origin position by REV or 1/4
(512 pulse) REV (512 pulse)
• Check whether there was any external big force onto robot manipulator while robot
power is off or not, to avoid same problem again
 Page 47

A8002 Encoder counter over A8003 Resolver cable disconnected.

Detection logic… Detection logic…

In case the revolution counter on the Resolver card got data over flow, this alarm will be In case the cable between Resolver card and resolver is disconnected while robot power
detected. The TP will not show this alarm and show just Encoder reset message. But this is off state, this error will be detected on Resolver card. And this error status will be sent
alarm will be stored on error / alarm history. to Servo CPU card, when robot power is switched on. The TP will not show this alarm and
show just Encoder reset message. But this alarm will be stored on error / alarm history.

ZUEP5791X
Servo CPU Card
ZUEP5791X

ZUEP5796X
Servo CPU Card

Main CPU Card

ZUEP5796X

Backplane card
Main CPU Card

Backplane card
ZUEP5806X ZUEP5806X

Power card Power card

ZUEP5803X ZUEP5803X

X21 X21
X7 X22 (RE-IN) X7 X22 (RE-IN)
(RE-IN) (RE-OUT) (RE-IN) (RE-OUT)

Servo Servo amp Servo Servo amp

Power Supply AEDXXXXX Serial data Power Supply AEDXXXXX
Serial data
AED01283 (CNT OVER) AED01283 (CABLE ERR)
Serial data
(CNT OVER)
Resolver card Resolver card
ZUEP5764XXX Serial data
Detected
ZUEP5764XXX Detected (CABLE ERR)
by here Counter for by here
CNT revolution

Battery Battery
ER6VCT ER6VCT
A8003 Resolver cable disconnected.
Motor Motor
Sensor cable disconnected.
Check sensor cable. And reset encoder.
Note: This picture shows case of RT axis Note: This picture shows case of RT axis
This cable is
disconnected

Action should be taken… Action should be taken…

• Check voltage of Resolver card battery just in case • Check voltage of Resolver card battery just in case
• Make revolution counter reset (Encoder reset) and adjust origin position by REV or 1/4 • Check connection between Resolver card and resolver on the Servo motor
REV (512 pulse) • Make revolution counter reset (Encoder reset) and adjust origin position by REV or 1/4
• Replace Resolver card (Servo motor, if VR robot) in case same problem occurred again REV (512 pulse)
• Try to replace Resolver card in case same problem occurred again
 Page 48

A8004 R/D error. A8005 Encoder single turn count error ** (Axis name)

Detection logic… Detection logic…

In case the cable between Resolver card and resolver is disconnected while robot power The resolution (in one rotation) became lower than specification.
is on state, this error will be detected on Resolver card. After switching off and on the (Encoder status bit 5 is ON)
robot power, the TP will show Encoder reset message. - This alarm is especially for Smart absolute encoder
- Detected at controller power on, will be leaded to encoder reset mode
- The alarm will be recorded on error history

Detected
by here

ZUEP5791X
Servo CPU Card
ZUEP5796X
Main CPU Card

Backplane card

ZUEP5845X
Servo CPU Card
ZUEP5796X
Main CPU Card
Backplane card
ZUEP5806X ZUEP5806X

Power card Power card

ZUEP5803X ZUEP5850X

X21 X20
X7 X22 (RE-IN) X7 X17 (RE-IN)
(RE-IN) (RE-OUT) (RE-IN) (RE-OUT)

Servo Servo amp Servo amp

Servo
Power Supply AEDXXXXX AEDXXXXX
Serial data Power Supply Serial data
AED01283 (CABLE ERR) AED01283

Resolver card RE PWR card

ZUEP5764XXX Serial data Serial data
Detected ZUEP5847X
(CABLE ERR)
by here

Problem
Battery Happened
A8004 R/D error. ER6VCT here
R/D error. Motor Motor
Check sensor cable and R/D.
And reset encoder.
Note: This picture shows case of RT axis Note: This picture shows case of RT axis
This cable is
disconnected

Action should be taken… Action should be taken…

• Check connection between Resolver card and resolver on the Servo motor • Check connection between Backplane card, Servo CPU card and Main CPU card
• Make revolution counter reset (Encoder reset) and adjust origin position by REV or 1/4 • Check connection from the encoder to S,CPU card, also connection related encoder
REV (512 pulse) • Check electrical noise source related encoder line and remove those
• Try to replace Resolver card in case same problem occurred again • Try to download latest software to all of PC board
• Try to replace Servo CPU card, Servo motor (Encoder)
 Page 49

A8006 Encoder multi turn count error ** (Axis name) A8010 Encoder data error

Detection logic… Detection logic…

There was abnormal condition on revolution counter. When robot power is switched on, serial data what has motor current position data will be
(Encoder status bit 6 is ON) sent from Resolver card to Servo CPU card. In case data what was received by Servo CPU
- This alarm is especially for Smart absolute encoder card 1st time and 2nd time has difference, this alarm will be shown. Main CPU card
- Detected at controller power on, will be leaded to encoder reset mode judges this alarm.
- The alarm will be recorded on error history

Detected Detected
by here by here

ZUEP5791X
Servo CPU Card
ZUEP5796X
Main CPU Card
ZUEP5845X
Backplane card

Servo CPU Card

ZUEP5796X
Main CPU Card

Backplane card
ZUEP5806X ZUEP5806X

Power card Power card

ZUEP5850X ZUEP5803X

X20 X21
X7 X17 (RE-IN) X7 X22 (RE-IN)
(RE-IN) (RE-OUT) (RE-IN) (RE-OUT)

Servo Servo amp Servo Servo amp

Power Supply AEDXXXXX Power Supply AEDXXXXX
Serial data Serial data
AED01283 AED01283 (POSITION DATA)

RE PWR card Resolver card

Serial data ZUEP5764XXX Serial data
ZUEP5847X
(POSITION DATA)

Problem
Happened
here

Motor Motor

Note: This picture shows case of RT axis Note: This picture shows case of RT axis

Action should be taken… Action should be taken…

• Check connection between Backplane card, Servo CPU card and Main CPU card • Check connection between Resolver card, Power card and Servo CPU card
• Check connection from the encoder to S,CPU card, also connection related encoder • Check damage on the cable between Resolver card, Power card and Servo CPU card
• Check electrical noise source related encoder line and remove those • Try to replace Resolver card, Servo CPU card or motor
• Try to download latest software to all of PC board
• Try to replace Servo CPU card, Servo motor (Encoder)
 Page 50

E7001 Collision detected E7002 Collision detect hold limit error

Detection logic… Detection logic…

Robot arm collision is detected by checking motor current. The robot controller is After collision detected, the robot arm will be flex mode. But in case the robot arm is
monitoring motor current while robot arm has servo power. In case motor current is moved too much more than limited degrees, this error will be detected. Original error
exceeded more than normal current, this error will be detected. status of robot shall be E7001 Collision detected. So, same check as E7001 is needed.
Note: There was case that error was detected by the welding noise. Check whether
the error will be detected during welding or not.

Detected by here Detected by here

X1 (DRV) X1 (DRV)

ZUEP5796X
Main CPU Card
ZUEP5796X

Backplane card
Main CPU Card

ZUEP5791X
Backplane card

Servo CPU Card

ZUEP5791X
Servo CPU Card
ZUEP5806X ZUEP5806X

A/D A/D

Motor current Motor current

X1 (DRV) information X1 (DRV) information

X3 (M-OUT) X3 (M-OUT)
Servo amp Servo amp
AEDXXXXX AEDXXXXX

CT CT
Motor Motor

Motor power UVW Motor power UVW

Note: This picture shows case of RT axis Note: This picture shows case of RT axis

Action should be taken… Action should be taken…

• Check there is any crash or load on the robot arm or accessories • Check there is any crash or load on the robot arm or accessories
• Check load parameter setting whether the parameter value is right or not • Check load parameter setting whether the parameter value is right or not
• Check load percentage value on the teaching pendant whether any strange data or not • Check load percentage value on the teaching pendant whether any strange data or not
• Check detected axis load by brake release whether there is mechanical load or not • Check detected axis load by brake release whether there is mechanical load or not
• Try to replace Servo CPU card, Servo amplifier or Servo motor • Try to replace Servo CPU card, Servo amplifier or Servo motor
 Page 51

E7041 Motor over load error E7042 Lock detected

Detection logic… Detection logic…

This error will be detected in case motor current goes 110 to 300% of rated current. This error will be detected in case torque command from Servo CPU card exceed more
The detection will be motor current percentage * time (E.g. 120%-> 57sec = Error, than 75% of maximum value. The detection will be done by software side. The error will
300%-> 1.9sec = Error) . be detected in case torque command is high even there is no flow of motor current.
This mean that damage (open cut) of motor harness also detected with this error.

Detected by here Detected by here

X1 (DRV) X1 (DRV)

ZUEP5796X
Main CPU Card
ZUEP5796X

Backplane card
Main CPU Card

ZUEP5791X
Backplane card

Servo CPU Card

ZUEP5791X
Servo CPU Card
ZUEP5806X ZUEP5806X

A/D

Torque
Motor current command
X1 (DRV) information X1 (DRV)

X3 (M-OUT) X3 (M-OUT)
Servo amp Servo amp
AEDXXXXX AEDXXXXX

CT CT
Motor Motor

Motor power UVW Motor power UVW

Note: This picture shows case of RT axis Note: This picture shows case of RT axis

Action should be taken… Action should be taken…

• Check there is any crash or load on the robot arm or accessories • Check there is any crash or load on the robot arm or accessories
• Check load percentage value on the teaching pendant whether any strange data or not • Check load percentage value on the teaching pendant whether any strange data or not
• Check coil resistance of feeder motor including cable line (U-V, V-W, U-W) • Check coil resistance of feeder motor including cable line (U-V, V-W, U-W)
• Check resistance between motor power line and earth grounding (U-E, V-E, W-E) • Check resistance between motor power line and earth grounding (U-E, V-E, W-E)
• Check detected axis load by brake release whether there is mechanical load or not • Check detected axis load by brake release whether there is mechanical load or not
• Try to replace Servo CPU card, Servo amplifier or Servo motor • Try to replace Servo CPU card, Servo amplifier or Servo motor
 Page 52

E7043 Encoder over heat

Detection logic…

The encoder PC board got more than specified temperature (90deg C).
(The encoder status bit 7 is ON)
- This alarm is especially for Smart absolute encoder
- Detected any time, alarm will be shown immediately

Detected
by here

ZUEP5845X
Servo CPU Card
ZUEP5796X
Main CPU Card

Backplane card
ZUEP5806X

Power card
ZUEP5850X

X20
X7 X17 (RE-IN)
(RE-IN) (RE-OUT)

Servo Servo amp

Power Supply AEDXXXXX
Serial data
AED01283

RE PWR card
ZUEP5847X Serial data

Problem
Happened
here

Motor

Note: This picture shows case of RT axis

Action should be taken…

• Check temperature of motor
• Check load of motor by brake release
• Reduce speed
• Check whether the setting related servo control is right or not (E.g. Robot type)
• Set all parameter (E.g. Servo parameter) default
• Try to replace servo amplifier. If not improved, try to replace motor
 Page 53

Display of CC-LINK card with several situations

(1) Normal operation (4) Not right Nord number is set

CC-LINK cable connected, PLC runs with normal state
One LED ON state
One other LED BLINK state
Three LED ON state (2sec OFF / 0.1sec ON)

E4220 CC-LINK : OFF LINE

WILL BE SHOWN
Blinking by Blinking by
0.5sec / 0.5sec 0.5sec / 0.5sec

(2) CC-LINK cable is not connected (5) Not right communication speed is set

One LED ON state

One other LED BLINK state
All LED OFF state (2sec OFF / 0.1sec ON)

E4220 CC-LINK : OFF LINE E4220 CC-LINK : OFF LINE

WILL BE SHOWN WILL BE SHOWN
Blinking by Blinking by
0.5sec / 0.5sec 0.5sec / 0.5sec

(3) PLC (CPU) is stopped (6) Not correct rotary switch setting is set
Note: rotary switch setting is not needed for G3
One LED ON state
One other LED BLINK state Case of CARD ERROR
(2sec OFF / 0.1sec ON) One LED get RED color

E4220 CC-LINK : CARD ERROR (0103) or

E4220 CC-LINK : OFF LINE E4220 CC-LINK : OFF LINE
WILL BE SHOWN WILL BE SHOWN
Blinking by
0.5sec / 0.5sec Case of CARD ERROR
Blinking by 0.25sec / 0.25sec
 Page 54

Display of DeviceNet card with several situations

(1) Normal operation (4) Not right Nord number is set

DeviceNet cable connected, PLC runs with normal state
One LED ON state
One other LED BLINK state
Two LED ON state (0.5sec OFF / 0.5sec ON)

E4201 DEVICENET: OFFLINE

WILL BE SHOWN

Blinking by Blinking by
0.5sec / 0.5sec 0.5sec / 0.5sec

(2) DeviceNet cable is not connected (5) Not right communication speed is set

One LED ON state

One other LED RED state
One LED ON state
(0.5sec OFF / 0.5sec ON)

E4201 DEVICENET: COMM ERROR E4201 DEVICENET: OFFLINE

WILL BE SHOWN WILL BE SHOWN

Blinking by Blinking by
0.5sec / 0.5sec 0.5sec / 0.5sec

(3) PLC (CPU) power is OFF

One LED ON state

E4201 DEVICENET: COMM ERROR

WILL BE SHOWN

Blinking by
0.5sec / 0.5sec
 Page 55

Display of Ethernet/IP card with several situations

(1) Normal operation (4) Not right Nord number is set

CC-LINK cable connected, PLC runs with normal state
One LED ON state
One other LED BLINK state
Three LED ON state (2sec OFF / 0.1sec ON)

E4220 CC-LINK : OFF LINE

WILL BE SHOWN
Blinking by Blinking by
0.5sec / 0.5sec 0.5sec / 0.5sec

(2) CC-LINK cable is not connected (5) Not right communication speed is set

One LED ON state

One other LED BLINK state
All LED OFF state (2sec OFF / 0.1sec ON)

E4220 CC-LINK : OFF LINE E4220 CC-LINK : OFF LINE

WILL BE SHOWN WILL BE SHOWN
Blinking by Blinking by
0.5sec / 0.5sec 0.5sec / 0.5sec

(3) PLC (CPU) is stopped (6) Not correct rotary switch setting is set
Note: rotary switch setting is not needed for G3
One LED ON state
One other LED BLINK state Case of CARD ERROR
(2sec OFF / 0.1sec ON) One LED get RED color

E4220 CC-LINK : CARD ERROR (0103) or

E4220 CC-LINK : OFF LINE E4220 CC-LINK : OFF LINE
WILL BE SHOWN WILL BE SHOWN
Blinking by
0.5sec / 0.5sec Case of CARD ERROR
Blinking by 0.25sec / 0.25sec
 Page 56

W0010 Weld Error : No current W0020 Weld Error : No arc

Detection logic… Detection logic…

After executing torch switch on, the welding current was not flowed from welding wire to
The robot received no arc command from the welding machine during welding.
base metal within specified time. The time of this check can be set on the robot setting
This detection is done by welding machine (digital com. type) and no arc error status
menu and default is 3.0sec (Menu : Arc welding machine -> No arc detection time ->
was sent from welding machine to the robot via digital communication cable.
“Before arc on”).
Note : This error is standing for digital welding machine (E.g. GR3/GB2/GE2/GZ4)
Note : This error is standing for both of TAWERS and digital welding machine

Wire feeder Wire feeder

No current flowing

Welding machine Welding machine Arc start

Welding arc
gone off
was okay

Action should be taken… Action should be taken…

• Check work piece surface (slag/oil), consumable (welding tip) • Check work piece surface (slag/oil), consumable (welding tip)
• Check rotation of wire feeder at welding start without wire clamp on wire feeder • Check wire feeding by inching mode whether force is enough or not
• Check wire feeding by inching mode whether force is enough or not • Check flexible conduit whether it is too long and the curve diameter is small or not
• Do continuity check from plus terminal to welding tip, minus terminal to base metal • Check damage of welding power cable line (plus/minus), voltage feed back line
• Check off load voltage (voltage after switching torch switch on) of welding machine • Change consumable torch cable liner / torch body inner tube etc
Offload voltage WG: DC15V with lift arc on / DC65V with off / Digital welder DC65V Checking of welding parameter also needed, if the welding condition is not good
 Page 57

W0025 No arc detected by robot W0030 Weld Error : Wire stick

Detection logic… Detection logic…

After getting current detection (arc on), the current detect signal did not come more than
The welding wire is stuck to the base metal at end of welding. The welding machine
specified time from welding machine. The time of this check can be set on the robot
detects the wire stick condition by execution of stick check on the robot. And send error
setting menu and default is 0.5sec (Menu : Arc welding machine -> No arc detection time
status to the robot via digital communication cable.
-> “After arc on”).
Note : This error is standing for digital welding machine (E.g. GR3/GB2/GE2/GZ4)
Note : This error is standing for digital welding machine (E.g. GR3/GB2/GE2/GZ4)

Wire feeder Wire feeder

Welding machine Arc start

Welding arc Welding machine Arc start Wire was stuck
gone off to base metal
was okay was okay

Action should be taken… Action should be taken…

• Check work piece surface (slag/oil), consumable (welding tip) • Check whether the welding wire is really stuck to the base metal or not
• Check wire feeding by inching mode whether force is enough or not • If wire stuck to base, cut wire & restart. Need to check torch angle & crater parameter
• Check flexible conduit whether it is too long and the curve diameter is small or not • If wire not stuck to base, check resistance between welding tip and base
• Check damage of welding power cable line (plus/minus), voltage feed back line • If the resistance between tip and base is 0 ohm for both direction, the plus side power
• Change consumable torch cable liner / torch body inner tube etc line might be leaked to minus base line. Check all the line isolations
Checking of welding parameter also needed, if the welding condition is not good
Also check the “No arc detection time” whether the setting is suitable or not
 Page 58

W0031 Stick check time out W0090 Weld Error : S-side ov/curr

Detection logic… Detection logic…

The welding machine detected more than rated current was flowed. The welding current
The robot requested stick check to the welding machine, but no reply comes back from
is checked by CT (Current transformer) in the welding machine and Welding machine CPU
the welding machine side within 2.0 sec.
card detects this error condition (Welder Error display E-2). After welding machine detects
error, the error status will be sent to robot via digital communication cable.
Note : This error is standing for digital welding machine (E.g. GR3/GB2/GE2/GZ4)
Note : This error is standing for digital welding machine (E.g. GR3/GB2/GE2/GZ4)

Stick check command

Wire feeder

RS422 serial
communication

Too much current was

Flowed (E.g. 450A)

No reply within 2.0 sec

Welding machine

Action should be taken… Action should be taken…

• Check all cable connection related welding machine (serial communication cable / • Check distance between welding tip and base metal. If short (E.g.5mm), this happens
control cable between welding machine to robot / wire feeder motor and encoder cable) • Check the welding parameter whether the high welding amperage is used or not
• Try to replace above cable one by one (1: Feeder motor & encoder cable / 2: Serial • Monitor wire feeding speed whether it is constant during welding or not, because the
communication cable / 3: Control cable ) wire feeder encoder signal might not coming correct, and feeding speed gets fast
• Try to replace conversion card which is inside of robot manipulator below wire feeder • Try to replace wire feeder cable / wire feeder one by one
• Try to replace welding machine PC board one by one
 Page 59

W0200 Weld Error : Wire feed motor W0260 Weld Error : Wire feed governor

Detection logic… Detection logic…

Even the welding machine CPU did not give order to rotate the wire feeder motor, In case more than 180rpm (= 22.6 m/min) of rotation for the wire feeder is detected,
there was encoder signal back from wire feeder what seems like the feeder was rotated. the welding machine detects this error (Welder Error display E-15). The error status will
Error will be detected by welding machine (Welder Error display E-14). The error status be sent to robot via digital communication cable.
will be sent to robot via digital communication cable.
Note : This error is standing for digital welding machine (E.g. GR3/GB2/GE2/GZ4)
Note : This error is standing for digital welding machine (E.g. GR3/GB2/GE2/GZ4)

Encoder signal back Encoder signal back

So much faster
Encoder feed back

Wire feeder Wire feeder

No motor power sending Normal operation

from welding machine Voltage for the motor

Welding machine Welding machine

Action should be taken… Action should be taken…

• Check whether the customer rotated feed roller by his hand or not • Check whether the customer rotated feed roller by his hand or not
• Check whether the capacitor unit is on the wire feeder or not, if it might needed • Check the welding parameter which is specified in the section where error occurred
• Check all cable connection related welding machine (serial communication cable / • Check whether the capacitor unit is on the wire feeder or not, if it might needed
control cable between welding machine to robot / wire feeder motor and encoder cable) • Check all cable connection related welding machine (serial communication cable /
• Try to replace cable one by one. If not succeeded, replace related PC board one by one control cable between welding machine to robot / wire feeder motor and encoder cable)
• Try to replace cable one by one. If not succeeded, replace related PC board one by one
 Page 60

W0270 Weld Error : Wire feed encoder W1010 Weld Error : No arc

Detection logic… Detection logic…

The TAWERS welding control CPU card detected no arc during welding. The time of this
In case there is no encoder feed back from wire feeder even welding CPU tried to rotate
check can be set on the robot setting menu and default is 0.5sec (Menu : Arc welding
wire feeder, this error will be detected (Welder Error display E-13). The error status will
machine -> No arc detection time -> “After arc on”).
be sent to robot via digital communication cable.
Note : This error is standing for TAWERS WG type welding machine
Note : This error is standing for digital welding machine (E.g. GR3/GB2/GE2/GZ4)

No encoder signal back

Wire feeder Wire feeder

Normal operation
Voltage for the motor

Welding machine Welding machine Arc start

Welding arc
gone off
was okay

Action should be taken… Action should be taken…

• Check cable connection and visible damage near by wire feeder • Check work piece surface (slag/oil), consumable (welding tip)
• Check control cable connection and visible damage between robot and welding machine • Check wire feeding by inching mode whether force is enough or not
• Check damage of conversion PC board in robot manipulator located near by wire feeder • Check flexible conduit whether it is too long and the curve diameter is small or not
• Try to replace wire feeder cable / conversion PC board • Check damage of welding power cable line (plus/minus), voltage feed back line
• Change consumable torch cable liner / torch body inner tube etc
Note: If conversion PC board is damaged due to encoder cable damage, the board will be
Checking of welding parameter also needed, if the welding condition is not good
damaged again in case you do not repair the damage of cable and change just PC board
 Page 61

W1020 Weld Error : Wire stick W1110 Weld Error : S-side over current

Detection logic… Detection logic…

The TAWERS welding control CPU card detected wire stick at end of welding. The welding The TAWERS welding control CPU card detected over current during welding.
machine outputs around DC10V at stick check and check this voltage by voltage feed back The welding current is checked by CT (current transformer). If there is information more
circuit. If the feed back circuit detects there is less than DC5V, error will be detected. than 450A current x more than 0.1sec flowed, this error will be detected.

Note : This error is standing for TAWERS WG type welding machine Note : This error is standing for TAWERS WG type welding machine

Wire feeder
Wire feeder

+FB 200 ohm parallel

(=100ohm)

Voltage information
to welding control CPU

DC10V
CT (Approx.) Too much current was
Flowed (450A x 0.1sec)
Welding sub IF card
ZUEP5755X

Welding machine - FB Wire was stuck

to base metal
Welding machine

Action should be taken… Action should be taken…

• Check whether the welding wire is really stuck to the base metal or not • Check distance between welding tip and base metal. If short (E.g.5mm), this happens
• If wire stuck to base, cut wire & restart. Need to check torch angle & crater parameter • Check the welding parameter whether the high welding amperage is used or not
• If wire not stuck to base, check resistance between welding tip and base
• If the resistance between tip and base is 0 ohm for both direction, the plus side power
line might be leaked to minus base line. Check all the line isolations
• If the resistance is infinity, FB line might be damaged. Check damage point
 Page 62

W1120 Weld Error : S-side voltage output no detect W1210 Weld Error : P-side unit temperature error

Detection logic… Detection logic…

The TAWERS welding control CPU card detected no voltage. 1) If there is no voltage The TAWERS welding control CPU card detected primary unit temperature error.
feed back within 1.0sec after torch switch ON, this error will be detected at welding start. This will be detected by thermal switch near by MOSFET. And detect temperature level
2) If voltage goes down less than 5V x 0.5sec during welding, this will be detected. is 80 degrees C.

Note : This error is standing for TAWERS WG type welding machine Note : This error is standing for TAWERS WG type welding machine

ZUEP5796X

ZUEP5799X
Main CPU Card

Welding Control Card

Backplane card
ZUEP5806X

Wire feeder

+FB 200 ohm parallel

(=100ohm)
R6
Voltage information Welding Welding R7

to welding control CPU power IF card Sub IF card

ZUEP5779XA1 ZUEP5755XA1
Thermal
switch
No voltage
CT detected
X13
Inverter card (THRMAL)
ZUEP5805X

Welding machine - FB Inverter card

ZUEP5805X

Thermal
switch

Action should be taken… Action should be taken…

• Check resistance between welding tip and base metal (Normally 100ohm) • Check environment temperature whether it is high or not
• Disconnect power cable from welding machine, and check resistance between plus and • Check X13 connector (pin 1-2) on welding sub card really thermal is working or not
minus. Infinity or 0ohm both direction = secondary diode damage, check welder inside (pin 1-2 Normal condition close circuit / Over temp -> Open circuit )
• Check connection of voltage feed back line to be 100 ohm • Check cooling fan whether working or not, cleaning of dust for cooling pass also needed
Note : Do not start welding until finding problem cause. If try, MOSFET will be damaged
 Page 63

W1220 Weld Error : S-side unit temperature error

Detection logic…

The TAWERS welding control CPU card detected secondary unit temperature error.
This will be detected by thermal switch near by secondary diode and secondary switch
(IGBT). And detect temperature level is 90 degrees C.

Note : This error is standing for TAWERS WG type welding machine

ZUEP5796X

ZUEP5799X
Main CPU Card

Welding Control Card

Backplane card
ZUEP5806X

R6
Welding Welding R7
power IF card Sub IF card
ZUEP5779XA1 ZUEP5755XA1

X13
(THRMAL)

Inverter card
ZUEP5805X

Inverter card
ZUEP5805X

Thermal Thermal
switch switch

Action should be taken…

• Check environment temperature whether it is high or not
• Check X13 connector (pin 4-5) on welding sub card really thermal is working or not
(pin 1-2 Normal condition close circuit / Over temp -> Open circuit )
• Check cooling fan whether working or not, cleaning of dust for cooling pass also needed
 Page 64

Case study 1: Please grasp dead man switch again (1/3)

Symptom when problem happened Logic of this detection

When the servo power is switched on in teaching mode, The robot is checking servo power status with SVBRK_B circuit
the message ”Please grasp dead man switch” is shown. before switching on the servo power. This message will be
This message change to “Press and release emergency stop shown in case SVBRK_B has open circuit before switching on the
switch” in case you try to switch on the servo in auto mode. servo power (Servo OFF=CLOSE / Servo ON=OPEN).

Error information
(CAN BUS)

Teach mode Detected

by here

Safety card

ZUEP5796X
Main CPU Card
Backplane card
ZUEP5806X
CPU BUS
ZUEP5808X
connector X3
(CAN0) X16
F1 (3A) (SV1)

CPU BUS X1
communication (CAN0)

SVBRK_B
Power card
Factor 1 ZUEP5803X
SVBRK_B open SVBRK_B circuit by
signal from MS Using status contact
X16
of MGSW
(MS)
X7
(SV3)

MS1 Servo
Power Supply
AED01283
X5 X10
(SV2) (EMG-SQ)

Auto mode
Power card
<Exterior>
MS2 ZUEP5821X Factor 3
X3
<Built-in> SVBRK_B open signal
(SVFD) from External axis?
ZUEP5819X

Factor 2 X16
SVBRK_B open signal Welding (SV2)
from WG welder harness? power IF card
ZUEP5779XA1 The connection can
X12 be SV2 or SV3
(SV3)
 Page 65

Case study 1: Please grasp dead man switch again (2/3)

Detection schematic External axis
controller side
X4
(EMGPWR1)
X15 Power card
Safety card (SV1) ZUEP5803X X5
Power card <Exterior> 7
(SV2)

X4
ZUEP5808X ZUEP5821X
5 5B 8
SVBRK_B+ 5 X16

X5
(SV2)
5 Pin 7,8 are Shorted
SVBRK_B-
6 6B or Magnet switch
K7

X6
6
Status contact
BRK
X10 6

X7
(EMG-SQ)
SVBRK_B+ and – has
to have close circuit 5 5
K8

X8
X16
(MS)
BRK
3 6

X9
6
Robot
controller side 4 X12 X9
(SV3) (EMGPWR6)
7
MS1
X7
(SV3)
8 WG welding
machine side

MS2

Welding power IF card

ZUEP5779XA1
SVBRK_B signal is not
wired to welding power IF
Magnet switch status card. Shorted at SV3
contact on robot side
(two magnet switch before
servo power unit)
X3
(SVFD)
 Page 66

Case study 1: Please grasp dead man switch again (3/3)

Action must be taken… (3) Resistance coming to SV2 on Power card (pin 5-6)

Open circuit (Infinity or some resistance)

The SVBRK_B signal circuit has to be checked. Check component
Since the open or close status (resistance) has to be checked, signal giving to SV2
make sure you switch off the robot controller power. Pin1
Pin11

(1) Resistance coming to SV1 on Safety card (pin 5-6)

Close circuit (Zero ohm)

Replace Safety card

Pin11
Open circuit (Infinity)

Pin1 Symbol
(4) Resistance coming to SV3 on power card (pin 5-6) for pin1

Open circuit (Infinity or some resistance)

Check component
Symbol
for pin1
signal giving to SV3

Pin11 Pin1
(2) Resistance coming to MS on power card (pin 3-4, pin 7-8)
Open circuit (Infinity or some resistance)
Check Magnet switch
Close circuit (Zero ohm)

Pin8

(5) Replace power card Symbol

Pin1 for pin1
 Page 67

Case study 2: Connecting… (1/4)

Symptom when problem happened Logic of this detection

The message of “Connecting…” is shown There will be initial communication between robot Main COU
and there is no progress, when power is switched on. card and Teaching pendant CPU card, when the robot controller
power is switched on. This error will be detected in case Main
CPU card has no response to teaching pendant.

AC200V X23
(200IN)

AC200V
Power card
ZUEP5803X

X25 Transformer
(200)
AC18V

No
Communication

X10 TP CPU card

(AC18V) ZUEP5800X
X13
(COM)

ZUEP5796X
Main CPU Card
Backplane card
ZUEP5806X
CPU BUS
connector
Detected
X2 by here

No progress from this screen…

(TCOM)

CPU BUS
communication
 Page 68

Case study 2: Connecting… (2/4)

Detection schematic

Power fail
detection line

TP CPU card
AC200V ZUEP5800X
Power card
ZUEP5803X
L2
L3
1 1 AC18V
X13
F4 Transformer (COM)
F3
2 2 TP communication line
TP
AC200V
Communication
X23 X25 X10
If TP cable is damaged
(200IN) (200) 1 3 (=communication line damaged),
(AC18V)
“No connecting” will be shown.
Backplane card
ZUEP5806X LED1
Main CPU card
PFL

ZUEP5796X
Main CPU Card
If AC18V is not coming to backplane If Main CPU card is damaged or
card at booting up, the power fail will X2 CPU bus line has bad connection,
(TCOM)
be detected and no communication to “No connecting” will be shown.
TP will be happened
CPU BUS
connector

CPU BUS
communication
 Page 69

Case study 2: Connecting… (3/4)

TP cable diagram
 Page 70

Case study 2: Connecting… (4/4)

Action must be taken… (3) Check damage of TP cable line

The TP communication line has to be checked. Shorting to shield line

Also need to check whether there is any situation which or open circuit on comm. line.
makes stuck of communication like PFL and bad connection Replace teaching pendant cable
of CPU BUS connector.

(1) Check LED1 on Back plane card

LED1 is ON (RED color)
Check AC18V line

Check continuity
and isolation
LED1 is OFF

(See wiring diagram)

(4) Replace teaching TP unit (or TP CPU card) or Backplane card

(2) Check connection of TP communication line

Disconnect and connect

Connection is okay

Make sure that teaching pendant cable has no damage before this action.
You can damage the new board again in case there is shorting.
 Page 71

Case study 3: TCP movement is not good… (1/6)

Symptom when problem happened Logic of this problem

In case tool coordinate is used and torch angle is changed, The matching between virtual robot origin and tool offset (what
the location of tool end does not stay at same location. CPU is thinking) is not matching to physical robot origin and tool.
Normally, the location of tool end stays within +/- 1.5mm
even the torch angle is changed 90degrees.

80 degrees

E.g.3mm

Tool location is not good

(Red ideal tool location /
Origin position is not good actual tool location)
(Red ideal origin/ actual origin)
 Page 72

Case study 3: TCP movement is not good… (2/6)

Action must be taken…
(3) Check origin position with onsite calibration
The re-check of tool location / tool offset and origin position
is needed. Note that physical change of tool location and
Re-adjust origin
origin position will effect location of program. Deeply study Note: Program has to be modified,
how you solve this problem before change. but program can be converted precisely by DTPS.

(1) Check physical tool location with tool gauge

Setting surface
Re-adjust tool location Setting surface
Note: Program has to be modified

CAL pin
CAL pin

Right location
CAL pin
Setting surface
(2) Check tool offset data

Rotate TW axis 180 degrees and check

tool end is at same location or not. If not,
the tool offset has to be adjusted
CAL pin
Setting surface
CAL pin
Setting surface

TW axis 180 degrees Not same position?

 Page 73

Case study 3: TCP movement is not good… (3/6)

Precise tool offset data check method : L1 data

Put scale on the table and check Z data L1 = 502 – 112 + BW length
difference in case tool end is same height as scale
and in case TW end is same height as scale.

TA1400 series BW length

Tool end height is same as scale

200mm

TA1600 series BW length

TW axis flange height is same as scale

Move down

155mm

L1 = 390 + 200 = 590 (TA1400)

L1= 390 + 155 = 545 (TA1600)
 Page 74

Case study 3: TCP movement is not good… (4/6)

Precise tool offset data check method : L2, L4 data +X direction

0.5
TW: 0deg
Move tool end to be on the check pin

1.05

701.08-698.98=2.1
TW center

TW: 180deg
150.50-149.50=1.0
X1: 698.98 X2: 701.08
Y1: 149.50 Y2: 150.50

L2 = +1.05mm , L4 = +0.5mm

Rotate 180 degrees for TW axis Move tool end by only XY motion
(You will find the deviation) and get same location as pin
 Page 75

Case study 3: TCP movement is not good… (5/6)

Precise tool offset data check method : L3 data

If the data is showing less than 90 degrees,

need to adjust L3 value + direction. If it is more
than 90 degrees, adjust L3 value – direction.

If V shows 90 degrees,
the value of L3 is right !!!

15mm 15mm

90.00 degrees

87.20 degrees
Set torch angle horizontal to the ground floor.
And check the position display V data.
 Page 76

Case study 3: TCP movement is not good… (6/6)

Gear ratio
(Pulse/Deg.)
How to shift program in case onsite calibration is used…
Check difference Offset data
(New - Original) Diff / Ratio *-1
Original origin data
TA1400 series
Original New Pulse
Offset
Pulse Rev Total Pulse Rev Total Diff. /deg.
RT -416 0 -416 -426 0 -426 -10 798 0.013
UA -355 0 -355 -325 0 -325 30 688 -0.044
FA -410 0 -410 -420 0 -420 -10 688 0.015
RW -210 0 -210 -213 0 -213 -3 461 0.007
BW -115 0 -115 -113 0 -113 2 -455 0.004
TW -359 0 -359 -356 0 -356 3 -284 0.011

After onsite calibration

Shift all point according to
calculated offset data on DTPS
 Page 77

Case study 4: Encoder cable error… (1/6)

Symptom when problem happened Logic of this problem

When servo power is switched on or during welding The encoder signal coming from Resolver card has +A / -A , +B
A7027 Encoder cable error can be shown. / -B. In case +A and –A (or +B and -B) has same status (H/H or
L/L), this alarm will be detected.

Resolver card

Servo CPU Card

ZUEP5791X
Power card ZUEP5764XXX
ZUEP5803X

X21
(RE-IN)

X22
(RE-OUT)
X7
(RE-IN)

E.g. A7027 Encoder cable error TW

+5V +5V
+A +A
GND GND

+5V +5V
-A -A
GND GND

Normal condition Faulty condition

 Page 78

Case study 4: Encoder cable error… (2/6)

Action must be taken… (2) Check connection cable continuity and isolation
Shorting to shield line
The conductivity of encoder cable line has to be checked. or open circuit on encoder line.
Replace the connection cable
And the resistance of resolver card transmission line and
encoder receiver line shall be checked.
(3) Check resistance on Servo CPU card side

(1) Check connections (disconnect and connect)

Damage found Check whether there is any
noise source to damage
Connection cable Connection cable Servo CPU card or not.
And replace Servo CPU card.
Pin#1
See (6/6) for more detail.
Pin#2

Pin#23
Pin#24 See 3/6 to 6/6

(4) Check resistance on resolver card side

Damage found
Check whether there is any
noise source to damage
Resolver card or not.
And replace resolver card.
See (6/6) for more detail.

See 3/6 to 6/6

RE cable on Servo CPU card RE-IN and RE-OUT cable on Power card
(5) Check electrical noise
 Page 79

Case study 4: Encoder cable error… (3/6)

(1) Measurement for the encoder line
Measure encoder circuit resistance to Servo CPU card. Pin#1
Disconnect PG1, PG2 connector and check resistance. Pin#2

The below shows only PG1. But please check also PG2.

Pin#23
Pin#24

PG1

FA Phase S + to S - 222 ohm

FA Phase A + to A - 222 ohm

FA Phase B + to B - 222 ohm

UA Phase S + to S - 222 ohm

UA Phase A + to A - 222 ohm

UA Phase B + to B - 222 ohm

RT Phase S + to S - 222 ohm

RT Phase A + to A - 222 ohm

RT Phase B + to B - 222 ohm

Other combination 18.40 k ohm

Each phase to signal ground (pin#2) 9.20 k ohm

Each phase to earth ground Infinity

 Page 80

Case study 4: Encoder cable error… (4/6)

(2) Measurement for the encoder line
Measuring encoder circuit resistance to resolver card.
Check resistance for same connector, but for resolver card side (Do not connect PG1, PG2 connector).

FA Phase S + to S - 8.60 M ohm

FA Phase A + to A - 8.60 M ohm

FA Phase B + to B - 8.60 M ohm

UA Phase S + to S - 8.60 M ohm

UA Phase A + to A - 8.60 M ohm

UA Phase B + to B - 8.60 M ohm

RT Phase S + to S - 8.60 M ohm

RT Phase A + to A - 8.60 M ohm

RT Phase B + to B - 8.60 M ohm

 Page 81

Case study 4: Encoder cable error… (5/6)

(3) Measurement for the encoder power supply (PG2)

Disconnect PG2 connector and check voltage coming to black and red
cable. There should be DC16V. Please disconnect this cable before you
switch the robot power on, the voltage will be showed up after booting
up the windows CE.
 Page 82

Case study 4: Encoder cable error… (6/6)

<<Notice for Encoder cable error>>
In case Servo CPU card is damaged, please consider to check the reason of damage.
It can be below problem made the damage of Servo CPU card.
Servo CPU Card
ZUEP5791X

Power card
ZUEP5803X
Encoder receiver

Safety holder signal

circuit

Encoder signal

If they are near each other,

the electrical noise will be transferred
to encoder line.

Electrical noise
 Page 83

Case study 5: A4150 Safety circuit 24V error… (1/3)

Symptom when problem happened Logic of this problem

A4150 Safety circuit 24V error will be shown at robot This alarm will be detected by safety card. If there is no DC24V
controller power on. coming to safety card from power card (also from DC power
supply), this alarm will be shown.

Error information
(CAN BUS)

Detected
by here

X23
Safety card

ZUEP5796X
Main CPU Card
Backplane card (EMD)
ZUEP5806X
CPU BUS
ZUEP5808X
connector X3
(CAN0) X16
F1 (3A) (SV1)

X1
(CAN0)

CPU BUS
communication

DC24V
Power card
ZUEP5803X
X12
(24-1)

DC24V
AC200V

DC power supply
ZWS150AF-24/J
X10
(EMG-SQ)
 Page 84

Case study 5: A4150 Safety circuit 24V error… (2/3)

Action must be taken…
(3) Check input and output voltage on DC power supply
The DC24V line from DC power supply to Safety card shall be
checked. The LED on safety card and LED on power card No AC200V coming
Check input power connection from
gives quick check for this problem. power card (disconnect and connect).
Replace power card.

(1) Check LED2 and fuse on safety card

Input AC200V
Fuse blown
Replace Fuse, check external shorting
(torch power and safety holder)
Fuse not blown, LED2 OFF

AC200V coming, no DC24V output

(2) Check LED2 on Power card
LED2 ON
Check connection / harness between
Power card and Safety card. Disconnect
and connect.

Output DC24V
LED2 OFF

DC power supply may damaged, check

reason of damage according to (3/3)
 Page 85

Case study 5: A4150 Safety circuit 24V error… (3/3)

<<Notice for Encoder cable error>>
In case Servo CPU card is damaged, please consider to check the reason of damage.
It can be below problem made the damage of Servo CPU card.

Safety card
Power card
ZUEP5808X ZUEP5803X

Safety holder signal

F1 (3A)

Electrical noise
DC power supply
ZWS150AF-24/J

If they are near each other,

the electrical noise will be transferred
to encoder line.

Electrical noise
 Page 86

Case study 6: Applying latest servo parameter… (1/1)

Symptom when problem happened Action has to be taken…

When there is version up of robot software, the servo After loading back up data, switch off / on the robot controller
parameter can be revised to improve the movement of power and open Maintenance mode -> Servo parameter.
robot. But this will not be adapted with only version up And set default to apply the latest servo parameter.
and loading back up data.

Choose Each axis Parameter 1

(For Robot S,CPU card)

Vibration

Choose Default (Robot)

It will reset all servo parameter

Make sure you press OK and switch

controller power OFF/ON after this action
 Page 87

Case study 7: E7003 Over run / A4050 Contact welded over run… (1/3)

Symptom when problem happened Logic of this problem

In case over run signal from the robot manipulator is open The over run signal (double line) are coming to robot power
circuit, this error will be shown. There are double line for card first, and it is forwarded to safety card. In case both of two
this over run monitoring. Both line needs to be close circuit are open, the E7003 over run error will be detected.
circuit. In case only one of them is open, A4050 Contact welded : Over
run will be detected.

SV1

Safety card
Power card
ZUEP5808X

Overrun signal EMG-SQ

from manipulator

SV3
RE VCC
SV2 Over run
SW FA

Over run
SW UA
Safety card

Over run
SW RT
Power card
 Page 88

Case study 7: E7003 Over run / A4050 Contact welded over run… (2/3)
Action must be taken… Robot manipulator side

Check all wiring related to over run signal.

The signal flow for over run is as follows.

Robot controller side

Safety card

Check for over run or contact welded

4 3 2 1 SV1

Power card
DC24V
SV2 4B 3B 2B 1B EMG-SQ
1
K7
2 Relay
3 coil
4

SV3 REVCC
1 GND 9A
2 K8 DC24V
Relay 10A
3
coil 9B
4
GND 10B
 Page 89

Case study 7: E7003 Over run / A4050 Contact welded over run… (3/3)
Action must be taken… Robot manipulator side

Check all wiring related to over run signal.

The signal flow for over run is as follows.

Robot controller side

Safety card

Check point 3
Disconnect SV1 / EMG-SQ
Check for over run or connector
contactfrom
welded
PC board
and connect again

4 3 2 1 SV1

Power card
DC24V
Check point 1
SV2 4B 3B 2B 1B EMG-SQ Disconnect harness from
1
K7
REVCC connector and check
2 Relay conductivity between
3 coil 9A-10A and 9B to 10B.
4

SV3 REVCC
1 GND 9A
2 K8 DC24V
Relay 10A
3
coil 9B
4
GND 10B
Check point 2
Disconnect SV2 / SV3
connector from power card
and connect again
 Page 90

Revise history
00 This documentation was made and issued on Nov. 2011
01 Action must be taken (e.g. A7010) had information for feeder. This was corrected according to correct axis.
02 Error E7001 etc and W0010 etc are added June. 2013
03 Page 13, Alarm number of A4040 is replaced to A4010
04 The alarm and error for Smart absolute encoder were added A7030, 7031, 7032, 7033, 7034, 7035, 7036, 8005,
8006, E7043
05 Case study 1 to 6 are added June.2014
06 Correction of connector number for weld power IF card (ZUEP5779XA1) 「10(NG) -> X9」, 「X18(NG) -> X16」
Correction for the explanation of E7041 「E.g. 110%* 57sec = Error, 300%*1.9sec = Error（NG）」 ->
「E.g. 120%-> 57sec = Error, 300%-> 1.9sec = Error （Correct）」 . The explanation of 「TCP movement is not good…
(4/6) 」 is corrected (The calculation method of L2 / L4 information and data of L4 was not correct).
07 Case study 7: Over run is added