Mitsubishi Electric Melservo-J5 MR-J5 Series User Manual
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Mitsubishi Electric Melservo-J5 MR-J5 Series User Manual

Troubleshooting
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Mitsubishi Electric AC Servo System
MR-J5
User's Manual
(Troubleshooting)
-MR-J5-_G_
-MR-J5W_-_G
-MR-J5-_A_

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Summary of Contents for Mitsubishi Electric Melservo-J5 MR-J5 Series

  • Page 1 Mitsubishi Electric AC Servo System MR-J5 User's Manual (Troubleshooting) -MR-J5-_G_ -MR-J5W_-_G -MR-J5-_A_...

  • Page 3: About The Manual

    About the manual This manual covers the following servo amplifiers. These include servo amplifiers with optional units.  MR-J5-_G_/MR-J5W_-_G/MR-J5-_A_ In this manual, the servo amplifier names are abbreviated as shown below. Symbol Servo amplifier MR-J5-_G_ [WG] MR-J5W_-_G MR-J5-_A_ U.S. CUSTOMARY UNITS U.S.

  • Page 4: Table Of Contents

    CONTENTS About the manual ................1 U.S.
  • Page 5 [AL. 08E_Serial communication error]............61 [AL.
  • Page 6 The servo motor starts moving immediately after the power-on of the servo amplifier or servo-on ..105 The home position deviates at the homing ........... . 106 The position deviates during operation after the homing.

  • Page 7: Chapter 1 Servo Amplifier Troubleshooting

    SERVO AMPLIFIER TROUBLESHOOTING Precautions • MR-J5-_G_-RJ and -MR-J5-_A_-RJ will be available in the future. • In MR-J5, the alarm No. and warning No. are changed to be shown with three digits followed by one digit indicating the detailed No., which were shown with two digits and one detailed No. in MR-J4 series. Outline When an error occurs in the servo system, the corresponding alarm and warning is displayed.
  • Page 8 • When [AL. 0E6 Servo forced stop warning], [AL. 0E9 Main circuit off warning], [AL. 0EA ABS servo-on warning], or [AL. 0EB The other axis error warning] occurs, the servo amplifier is changed to servo-off status. If any other warning occurs, the operation can still be continued, but an alarm may occur.

  • Page 9: The List Of Alarm No./Warning No

    The list of alarm No./warning No. Explanation of the lists Motor stop method For the alarms and warnings in which "SD" is written in the stop method column, the servo motor stops with the dynamic brake after forced stop deceleration. For the alarms and warnings in which "DB" or "EDB" is written in the stop method column, the servo motor stops with the dynamic brake.
  • Page 10 Detail No. Alarm/Warning Motor stop Stop Alarm deactivation Motor stop method system warning Safety Alarm Communic Power reset reset ation reset cycling 010.1 Alarm All axes           010.2 Alarm All axes ...
  • Page 11 Detail No. Alarm/Warning Motor stop Stop Alarm deactivation Motor stop method system warning Safety Alarm Communic Power reset reset ation reset cycling      01F.1 Alarm Each axis 020.1 Alarm Each axis      ...
  • Page 12 Detail No. Alarm/Warning Motor stop Stop Alarm deactivation Motor stop method system warning Safety Alarm Communic Power reset reset ation reset cycling      042.1 Alarm Each axis      042.2 Alarm Each axis 042.3 Alarm Each axis...
  • Page 13 Detail No. Alarm/Warning Motor stop Stop Alarm deactivation Motor stop method system warning Safety Alarm Communic Power reset reset ation reset cycling      08E.1 Alarm All axes 08E.2 Alarm All axes      ...
  • Page 14 Detail No. Alarm/Warning Motor stop Stop Alarm deactivation Motor stop method system warning Safety Alarm Communic Power reset reset ation reset cycling        0E5.1 Warning        0E5.2 Warning 0E5.3 Warning ...

  • Page 15: Handling Methods For Alarms/Warnings

    Handling methods for alarms/warnings Remove the cause of the alarm and warning in accordance with this section. MR Configurator2 can be used as reference for the cause of a warning. [AL. 010_Undervoltage] • The voltage of the control circuit power supply has dropped. •...

  • Page 16: [Al. 011_Switch Setting Error]

    [AL. 011_Switch setting error] • The setting of the DIP switch is incorrect. • The setting of the rotary switch is incorrect. [AL. 011.1_Rotary switch setting error] Cause Check/action method Model Each selected network has its settable range, Check the settings of the rotary switches (SW1/SW2). When the value set with the rotary switch and the actual value do not match, [WG] and the values set with the rotary switches...

  • Page 17: [Al. 012_Memory Error 1 (Ram)]

    [AL. 012_Memory error 1 (RAM)] • The internal parts of the servo amplifier (RAM) have malfunctioned. [AL. 012.1_RAM error 1] Cause Check/action method Model The internal parts of the servo amplifier has Noise from the power supply may have caused the failure. Disconnect the cables except for the control circuit power supply, and then check the malfunctioned.

  • Page 18: [Al. 013_Clock Error]

    [AL. 013_Clock error] • The internal parts of the servo amplifier have malfunctioned. • A clock transmitted from the controller has an error. [AL. 013.1_CPU error 1] Cause Check/action method Model The internal parts of the servo amplifier have Noise from the power supply may have caused the failure. Disconnect the cables except for the control circuit power supply, and then check the malfunctioned.

  • Page 19: [Al. 014_Control Process Error]

    [AL. 014_Control process error] • The process did not complete within the specified time. • The internal parts of the servo amplifier (communication IC) have malfunctioned. [G] [AL. 014.1_Control process error 1] Cause Check/action method Model The servo parameter setting is incorrect. Set the servo parameter to a value before the alarm occurrence, and then check the repeatability.

  • Page 20: [Al. 016_Encoder Initial Communication Error 1]

    [AL. 016_Encoder initial communication error 1] • An error has occurred in the communication between an encoder and servo amplifier. [AL. 016.1_Encoder initial communication - Receive data error 1] Cause Check/action method Model There is an error in the encoder cable. Check if the encoder cable is disconnected, shorted, or incorrectly wired.
  • Page 21 [AL. 016.5_Encoder initial communication - Transmission data error 1] Page 18 [AL. 016.1_Encoder initial communication - Receive data error 1] [AL. 016.6_Encoder initial communication - Transmission data error 2] Page 18 [AL. 016.1_Encoder initial communication - Receive data error 1] [AL.

  • Page 22: [Al. 017_Board Error]

    [AL. 017_Board error] • A part in the servo amplifier is malfunctioning. [AL. 017.1_Board error 1] Cause Check/action method Model The current detection circuit is malfunctioning. Check that this alarm occurs in the servo-on status. If the alarm occurs, the servo amplifier may have malfunctioned.
  • Page 23 [AL. 017.9_Board error 8] Cause Check/action method Model There is an abnormality in the surrounding Check the noise, ambient temperature, and others, and implement appropriate countermeasures for the cause. environment. If there is noise, take countermeasures to reduce the noise. Refer to "Noise reduction techniques"...

  • Page 24: [Al. 019_Memory Error 3]

    [AL. 019_Memory error 3] • The internal parts of the servo amplifier (Flash-ROM) have malfunctioned. [AL. 019.1_Flash-ROM error 1] Cause Check/action method Model The Flash-ROM is malfunctioning. Noise from the power supply may have caused the failure. Disconnect the cables except for the control circuit power supply, and then check the repeatability.

  • Page 25: [Al. 01A_Servo Motor Combination Error]

    [AL. 01A_Servo motor combination error] • The combination of the servo amplifier and servo motor is incorrect. • The combination of the servo amplifier and servo motor constant file is incorrect. [AL. 01A.1_Servo motor combination error 1] Cause Check/action method Model The servo amplifier and the servo motor have Refer to "Specifications"...

  • Page 26: [Al. 01E_Encoder Initial Communication Error 2]

    [AL. 01E_Encoder initial communication error 2] • The encoder is malfunctioning. [AL. 01E.1_Encoder malfunction] Cause Check/action method Model The encoder is malfunctioning. Replace the servo motor. There is an abnormality in the surrounding Check the noise, ambient temperature, and others, and implement appropriate [WG] countermeasures for the cause.

  • Page 27: [Al. 01F_Encoder Initial Communication Error 3]

    [AL. 01F_Encoder initial communication error 3] • The connected encoder is not compatible with the servo amplifier. [AL. 01F.1_Incompatible encoder] Cause Check/action method Model Incompatible servo motor or linear encoder Refer to "Specifications" in the following manual. MR-J5-A User's Manual (Introduction) was connected to the servo amplifier.

  • Page 28: [Al. 020_Encoder Normal Communication Error 1]

    [AL. 020_Encoder normal communication error 1] • An error has occurred in the communication between an encoder and servo amplifier. [AL. 020.1_Encoder normal communication - Receive data error 1] Cause Check/action method Model There is an error in the encoder cable. Check if the encoder cable is disconnected or shorted.
  • Page 29 [AL. 020.6_Encoder normal communication - Transmission data error 2] Cause Check/action method Model When an A/B/Z-phase differential output linear Check if the Z-phase pulse signals (PZ and PZR) of the encoder cable are disconnected or shorted. encoder is used, the wiring of the linear Refer to "A/B/Z-phase differential output linear encode"...

  • Page 30: [Al. 021_Encoder Normal Communication Error 2]

    [AL. 021_Encoder normal communication error 2] • The encoder detected an error signal. [AL. 021.1_Encoder data error 1] Cause Check/action method Model An excessive speed or acceleration was Decrease the control gain, and then check the repeatability. If the error does not repeat, use the encoder with a lower gain.

  • Page 31: [Al. 024_Main Circuit Error]

    [AL. 024_Main circuit error] • A ground fault occurred on the servo motor power lines. • A ground fault occurred on the servo motor. [AL. 024.1_Ground fault detected at hardware detection circuit] Cause Check/action method Model A ground fault or short occurred in the servo Check if the servo motor power cable has been shorted.

  • Page 32: [Al. 025_Absolute Position Erased]

    [AL. 025_Absolute position erased] • The absolute position data have errors. • Power was switched on for the first time in the absolute position detection system. [AL. 025.1_Servo motor encoder - Absolute position erased] Cause Check/action method Model Power was switched on for the first time in the When the power was switched on for the first time after the absolute position detection system is set, check that the battery is mounted correctly before absolute position detection system.

  • Page 33: [Al. 027_Initial Magnetic Pole Detection Error]

    [AL. 027_Initial magnetic pole detection error] • The initial magnetic pole detection cannot be performed properly. [AL. 027.1_Initial magnetic pole detection - Abnormal termination] Cause Check/action method Model A moving part collided against the machine. If the moving part collides, move the start position of the magnetic pole detection.
  • Page 34 [AL. 027.3_Initial magnetic pole detection - Limit switch error] Cause Check/action method Model In the magnetic pole detection, both limit Check the limit switch status. If both of the limit switches are turned off, turn on the limit switches. switches are turned off. When using a direct drive motor, see also 2.

  • Page 35: [Al. 028_Linear Encoder Error 2]

    [AL. 028_Linear encoder error 2] • There is an abnormality in the using environment of the linear encoder. [AL. 028.1_Linear encoder environmental error] Cause Check/action method Model The ambient temperature of the linear encoder Check the ambient temperature and the specifications of the linear encoder. is outside of specifications.

  • Page 36: [Al. 02A_Linear Encoder Error 1]

    [AL. 02A_Linear encoder error 1] • An error of the linear encoder was detected. The content of the errors varies depending on each encoder manufacturer. [AL. 02A.1_Linear encoder error 1-1] Cause Check/action method Model Mounting condition of the linear encoder and Adjust the positions of the linear encoder and head.

  • Page 37: [Al. 02B_Encoder Counter Error]

    [AL. 02B_Encoder counter error] • There is an error in the data created by the encoder. [AL. 02B.1_Encoder counter error 1] Cause Check/action method Model There is an error in the encoder cable. Check if the encoder cable is disconnected or shorted. The external conductor of the encoder cable is Check if the external conductor of the encoder cable is connected to the [WG]...

  • Page 38: [Al. 030_Regenerative Error]

    [AL. 030_Regenerative error] • The permissible regenerative power of the built-in regenerative resistor or regenerative option was exceeded. • A regenerative transistor in the servo amplifier is malfunctioning. [AL. 030.1_Regenerative heat error] Cause Check/action method Model The setting of the regenerative resistor Check the regenerative resistor (regenerative option) in use and the setting value of [Pr.

  • Page 39: [Al. 031_Overspeed]

    [AL. 031_Overspeed] • The servo motor speed exceeded the maximum speed. [AL. 031.1_Servo motor speed error] Cause Check/action method Model The command pulse frequency is high. Check the command pulse frequency. If the command pulse frequency exceeds the maximum input pulse frequency, review the operation pattern. The setting of the electronic gear is incorrect.

  • Page 40: [Al. 032_Overcurrent]

    [AL. 032_Overcurrent] • A higher than the permissible current was applied to the servo amplifier. [AL. 032.1_Overcurrent detected at hardware detection circuit (during operation)] Cause Check/action method Model The servo amplifier is malfunctioning. Check that this alarm occurs as the servo motor power cables (U / V / W) are disconnected.

  • Page 41: [Al. 033_Overvoltage]

    [AL. 033_Overvoltage] • The value of the bus voltage exceeded the specified value. 200 V class: 400 V DC [AL. 033.1_Main circuit voltage error] Cause Check/action method Model The setting of the regenerative resistor Check the regenerative resistor (regenerative option) in use and the setting value of [Pr.

  • Page 42: [Al. 035_Command Frequency Error]

    [AL. 035_Command frequency error] • The input command pulse frequency is high. [AL. 035.1_Command frequency error] Cause Check/action method Model The command pulse frequency is high. Check the command pulse frequency, and if the command pulse frequency exceeds the maximum input pulse frequency, review the operation pattern. The setting of [Pr.

  • Page 43: [Al. 037_Parameter Error]

    [AL. 037_Parameter error] • Servo parameter setting value is incorrect. [AL. 037.1_Parameter setting range error] Cause Check/action method Model The servo parameter was set outside of the [A]: Check the servo parameter error No. display screen of the servo amplifier display section, the MR Configurator2 alarm display screen, and other relevant setting range.

  • Page 44: [Al. 03A_Inrush Current Suppression Circuit Error]

    [AL. 03A_Inrush current suppression circuit error] • The inrush current suppression circuit error was detected. [AL. 03A.1_Inrush current suppression circuit error] Cause Check/action method Model The inrush current suppressor circuit is Replace the servo amplifier. malfunctioning. [WG] 1 SERVO AMPLIFIER TROUBLESHOOTING 1.3 Handling methods for alarms/warnings...

  • Page 45: [Al. 042_Servo Control Error]

    [AL. 042_Servo control error] • A servo control error occurred. [AL. 042.1_Servo control error by position deviation] Cause Check/action method Model The setting of the encoder resolution differs Check the setting of [Pr. PL02 Linear encoder resolution setting - Numerator] and [Pr.
  • Page 46 [AL. 042.3_Servo control error by torque/thrust deviation] Cause Check/action method Model The setting of the encoder resolution differs Check the setting of [Pr. PL02 Linear encoder resolution setting - Numerator] and [Pr. PL03 Linear encoder resolution setting - Denominator]. from the actual value. Refer to "Linear encoder resolution setting"...

  • Page 47: [Al. 045_Main Circuit Device Overheat]

    [AL. 045_Main circuit device overheat] • The inside of the servo amplifier overheated. [AL. 045.1_Main circuit device overheat error 1] Cause Check/action method Model Ambient temperature exceeded the specified Check the ambient temperature, and if the temperature exceeds the specified value, lower the ambient temperature.

  • Page 48: [Al. 046_Servo Motor Overheat]

    [AL. 046_Servo motor overheat] • The servo motor overheated. [AL. 046.1_Abnormal temperature of servo motor 1] Cause Check/action method Model Ambient temperature of the servo motor has Check the ambient temperature of the servo motor, and if the temperature exceeds the specified value, lower the ambient temperature. exceeded the specified value.

  • Page 49: [Al. 047_Cooling Fan Error]

    [AL. 047_Cooling fan error] • The speed of the servo amplifier cooling fan decreased. • The fan speed decreased to 30 % or less of the rated speed of the alarm occurrence level. [AL. 047.1_Cooling fan stop error] Cause Check/action method Model A foreign object was caught in the cooling fan.

  • Page 50: [Al. 050_Overload 1]

    [AL. 050_Overload 1] • The load exceeded the overload protection characteristics of the servo amplifier. [AL. 050.1_Thermal overload error 1 during operation] Cause Check/action method Model The servo motor power cable was Check the servo motor power cable, and then repair or replace the cable. disconnected.
  • Page 51 [AL. 050.5_Thermal overload error 2 during a stop] Page 48 [AL. 050.4_Thermal overload error 1 during a stop] [AL. 050.6_Thermal overload error 4 during a stop] Page 48 [AL. 050.4_Thermal overload error 1 during a stop] 1 SERVO AMPLIFIER TROUBLESHOOTING 1.3 Handling methods for alarms/warnings...

  • Page 52: [Al. 051_Overload 2]

    [AL. 051_Overload 2] • Maximum output current continuously flowed due to machine collision or other causes. [AL. 051.1_Thermal overload error 3 during operation] Cause Check/action method Model The servo motor power cable was Repair or replace the servo motor power cable. disconnected.

  • Page 53: [Al. 052_Excessive Error]

    [AL. 052_Excessive error] • Droop pulses exceeded the alarm occurrence level. [AL. 052.1_Excessive droop pulse 1] Cause Check/action method Model The servo motor power cable was Repair or replace the servo motor power cable. disconnected. [WG] The connection of the servo motor is incorrect. Check the U/V/W wiring for forgotten screws, loose screws, and incorrect wiring.
  • Page 54 [AL. 052.6_Excessive droop pulse at servo-off] Cause Check/action method Model The servo motor shaft was rotated by external Make sure that the servo motor is not rotated (moved) by external force. force. The moving part of the linear servo [WG] motor was moved by external force.

  • Page 55: [Al. 054_Oscillation Detection]

    [AL. 054_Oscillation detection] • An oscillation was detected on the servo motor. [AL. 054.1_Oscillation detection error] Cause Check/action method Model The servo system is unstable and oscillating. Check the torque ripple with MR Configurator2. If the torque ripple is vibrating, adjust the servo gain with the auto tuning. Set the machine resonance suppression filter.

  • Page 56: [Al. 056_Forced Stop Error]

    [AL. 056_Forced stop error] • The servo motor failed to decelerate normally during a forced stop deceleration. [AL. 056.2_Over speed during forced stop] Cause Check/action method Model The forced stop deceleration time constant is Set a larger value in "Deceleration time constant at forced stop", and then check the repeatability.

  • Page 57: [Al. 063_Sto Timing Error]

    [AL. 063_STO timing error] • STO signal turned off when the servo motor is rotating. [AL. 063.1_STO1 off] Cause Check/action method Model STO1 was turned off (enabled) under the After the servo motor stops, turn off (enable) STO1. following speed conditions. •...

  • Page 58: [Al. 068_Sto Diagnosis Error]

    [AL. 068_STO diagnosis error] • An error was detected in the STO input signal. [AL. 068.1_Mismatched STO signal error] Cause Check/action method Model STO1 or STO2 is inputted incorrectly. Check that STO1 and STO2 of the CN8 connector are wired correctly. Refer to "When using STO function"...

  • Page 59: [Al. 069_Command Error]

    [AL. 069_Command error] • When the software limit is activated, the command position exceeded 32 bits (-2147483648 to 2147483647). • When the software limit is activated, the command position exceeded 30 bits (-536870912 to 536870911) from the value that was set. •...
  • Page 60 [AL. 069.4_Reverse rotation stroke end detection - Command excess error] Cause Check/action method Model The command position exceeded 30 bits from Review the operation pattern so that the command does not exceed 30 bits. [WG] the position which was detected after detecting LSN (Reverse rotation stroke end).

  • Page 61: [Al. 086_Network Communication Error]

    [AL. 086_Network communication error] • An error occurred in the network communication. [AL. 086.1_Network communication error 1] Cause Check/action method Model A network cable was disconnected. Check if the network cable is connected correctly. Turn off the control circuit power supply of the servo amplifier, and then [WG] connect the network cable correctly.

  • Page 62: [Al. 088_Watchdog 1]/[Al. 888_Watchdog 1]/[Al. 88888_Watchdog 1]

    [AL. 088_Watchdog 1]/[AL. 888_Watchdog 1]/[AL. 88888_Watchdog 1] • CPU or other component parts are malfunctioning. [AL. 088.1_Watchdog 1]/[AL. 088_Watchdog 1]/[AL. 888_Watchdog 1]/[AL. 88888_Watchdog 1] Cause Check/action method Model The internal parts of the servo amplifier have Replace the servo amplifier. malfunctioned.

  • Page 63: [Al. 08E_Serial Communication Error]

    [AL. 08E_Serial communication error] • A communication error occurred between the servo amplifier and a personal computer or controller. • An error occurred in Mitsubishi Electric serial communication (USB communication). [AL. 08E.1_Serial communication receive error] Cause Check/action method Model The setting of the personal computer or other Check the setting of the personal computer and others.

  • Page 64: [Al. 090_Homing Incomplete Warning]

    [AL. 090_Homing incomplete warning] • Homing did not complete properly with the positioning function. [AL. 090.1_Homing incomplete] Cause Check/action method Model An automatic operation was executed while Check if homing was not executed. If homing was not executed, execute homing. [WG] homing was incomplete.

  • Page 65: [Al. 091_Servo Amplifier Overheat Warning]

    [AL. 091_Servo amplifier overheat warning] • The temperature inside of the servo amplifier has reached a warning level. [AL. 091.1_Main circuit device overheat warning] Cause Check/action method Model Ambient temperature of the servo amplifier Lower the ambient temperature. exceeded the specified value. [WG] The close mounting does not meet Check the specifications of close mounting.

  • Page 66: [Al. 092_Battery Cable Disconnection Warning]

    [AL. 092_Battery cable disconnection warning] • The battery voltage for the absolute position detection system decreased. [AL. 092.1_Encoder battery cable disconnection warning] Cause Check/action method Model When a MR-BAT6V1SET(-A) battery or MR- Check if the battery is connected correctly. BT6VCASE battery case is used, the battery is [WG] not connected to CN4.

  • Page 67: [Al. 093_Abs Data Transfer Warning]

    [AL. 093_ABS data transfer warning] • ABS data were not transferred. [AL. 093.1_Magnetic pole detection incomplete warning at ABS data transfer request] Cause Check/action method Model The Z-phase was not turned on at servo-on. Check if the position within one-revolution is "0". If the position within one- revolution is "0"...

  • Page 68: [Al. 095_Sto Warning]

    [AL. 095_STO warning] • STO input signal turned off during servo motor stop. [AL. 095.1_STO1 off detection] Cause Check/action method Model STO1 is not inputted correctly. Refer to the wiring diagram and correct the wiring. When the STO function is not used, install the short-circuit connector attached to the servo amplifier on CN8.

  • Page 69: [Al. 096_Home Position Setting Warning]

    [AL. 096_Home position setting warning] • Homing failed. [AL. 096.1_In-position warning at homing] Cause Check/action method Model At the time of homing, INP (In-position) did not Adjust gains so that the droop pulses are set within the In-position range. Remove the cause of droop pulse occurrence, and then perform homing. turn on within the specified time.

  • Page 70: [Al. 098_Software Position Limit Warning]

    [AL. 098_Software position limit warning] • A software position limit, which is set with a servo parameter, is reached. [AL. 098.1_Forward rotation-side software stroke limit reached] Cause Check/action method Model A software position limit was set within the Check if [Pr. PT15] and [Pr. PT17] are set correctly. [WG] actual operation range.

  • Page 71: [Al. 099_Stroke Limit Warning]

    [AL. 099_Stroke limit warning] • The stroke limit signal is off. [AL. 099.1_Forward rotation stroke end off] Cause Check/action method Model The forward rotation stroke limit switch is not Check if the limit switch is connected correctly. The status of the input signal can be confirmed on the I/O monitor screen of connected to LSP.

  • Page 72: [Al. 09B_Excessive Error Warning]

    [AL. 09B_Excessive error warning] • Droop pulses exceeded the warning occurrence level. [AL. 09B.1_Excessive droop pulse 1 warning] Cause Check/action method Model The servo motor power cable was Repair or replace the servo motor power cable. disconnected. [WG] The connection of the servo motor is incorrect. Check the U/V/W wiring.

  • Page 73: [Al. 09E_Network Warning]

    [AL. 09E_Network warning] • Error exists in the network data reception. • An error exists in the network setting. [AL. 09E.2_Communication cycle setting warning] Cause Check/action method Model The communication cycle was set to 31.25 μs. [G]: Set [Pr. PA01.7 High speed mode] to "1". [WG]: Set the communication cycle to 62.5 μs or longer.

  • Page 74: [Al. 09F_Battery Warning]

    [AL. 09F_Battery warning] • The battery voltage for the absolute position detection system decreased. [AL. 09F.1_Low battery] Cause Check/action method Model The battery cable is not connected to CN4. Check if the battery is connected correctly. The battery voltage is low. The battery is Check the voltage of the battery with a tester, and if the voltage is lower than [WG] 4.9 V DC, replace the battery.

  • Page 75: [Al. 0E0_Excessive Regenerative Error]

    [AL. 0E0_Excessive regenerative error] • [AL. 030.1 Regenerative heat error] may occur. [AL. 0E0.1_Excessive regenerative warning] Cause Check/action method Model The regenerative load ratio exceeded 85 %. Page 36 [AL. 030.1_Regenerative heat error] [WG] 1 SERVO AMPLIFIER TROUBLESHOOTING 1.3 Handling methods for alarms/warnings...

  • Page 76: [Al. 0E1_Overload Warning 1]

    [AL. 0E1_Overload warning 1] • [AL. 050 Overload 1] or [AL. 051 Overload 2] may occur. [AL. 0E1.1_Thermal overload warning 1 during operation] Cause Check/action method Model The load was over 85 % of the alarm level of Page 48 [AL. 050.1_Thermal overload error 1 during operation] [AL.
  • Page 77 [AL. 0E1.8_Thermal overload warning 4 during a stop] Cause Check/action method Model The load was over 85 % of the alarm level of Page 49 [AL. 050.6_Thermal overload error 4 during a stop] [AL. 050.6 Thermal overload error 4 during a [WG] stop].

  • Page 78: [Al. 0E2_Servo Motor Overheat Warning]

    [AL. 0E2_Servo motor overheat warning] • [AL. 046.2 Abnormal temperature of servo motor 2] may occur. [AL. 0E2.1_Servo motor temperature warning] Cause Check/action method Model The temperature of the servo motor reached Page 46 [AL. 046.2_Abnormal temperature of servo motor 2] 85 % of the occurrence level of [AL.

  • Page 79: [Al. 0E3_Absolute Position Counter Warning]

    [AL. 0E3_Absolute position counter warning] • The multi-revolution counter of the absolute position encoder exceeded the maximum range. • There is an error in the absolute position encoder pulses. [AL. 0E3.1_Multi-revolution counter travel distance excess warning] Cause Check/action method Model In the absolute position system, the travel Review the operation range.

  • Page 80: [Al. 0E5_Abs Time-Out Warning]

    [AL. 0E5_ABS time-out warning] • When transferring the absolute position data, it took more than 5 s for the programmable controllers to respond. • During absolute position erased data transfer, ABSM (ABS transfer mode) turned off. • SON (Servo-on), RES (Reset), EM2 (Forced stop 2), or EM1 (Forced stop 1) turned off during absolute position erased data transfer.

  • Page 81: [Al. 0E6_Servo Forced Stop Warning]

    [AL. 0E6_Servo forced stop warning] • EM2 (Forced stop 2) or EM1 (Forced stop 1) was turned off. [AL. 0E6.1_Forced stop warning] Cause Check/action method Model EM2/EM1 was turned off. After ensuring safety, turn EM2/EM1 on. An external 24 V DC power supply has not Input the external 24 V DC power supply.

  • Page 82: [Al. 0E8_Cooling Fan Speed Reduction Warning]

    [AL. 0E8_Cooling fan speed reduction warning] • The cooling fan speed decreased to a warning level or lower. [AL. 0E8.1_Decreased cooling fan speed warning] Cause Check/action method Model A foreign object was caught in the cooling fan. Remove the foreign matter. The cooling fan has reached its life.

  • Page 83: [Al. 0E9_Main Circuit Off Warning]

    [AL. 0E9_Main circuit off warning] • The servo-on command was inputted with main circuit power supply off. • The bus voltage dropped when the servo motor was rotating at 50 r/min or lower. [AL. 0E9.1_Servo-on signal on during main circuit off] Cause Check/action method Model...

  • Page 84: [Al. 0Ea_Abs Servo-On Warning]

    [AL. 0EA_ABS servo-on warning] • The servo amplifier did not go to the servo-on status within 1 s after ABSM (ABS transfer mode) was turned on. [AL. 0EA.1_ABS servo-on warning] Cause Check/action method Model The wiring of input/output signals is incorrect. Check for disconnection or loose connection in the I/O signal wire.

  • Page 85: [Al. 0Eb_The Other Axis Error Warning]

    [AL. 0EB_The other axis error warning] • An alarm, which stops all axes, such as [AL. 024 Main circuit error] or [AL. 032 Overcurrent] occurred on a different axis. • [Pr. PF02.0 Target alarm selection of the other axis error warning] is set to "1" (All alarms). [AL.

  • Page 86: [Al. 0Ec_Overload Warning 2]

    [AL. 0EC_Overload warning 2] • Operation was repeated with a high load ratio while the servo motor shaft was not rotating. [AL. 0EC.1_Overload warning 2] Cause Check/action method Model The load is excessive or the capacity is Reduce the load. Otherwise, replace the servo motor with a larger-capacity servo motor.

  • Page 87: [Al. 0Ed_Output Watt Excess Warning]

    [AL. 0ED_Output watt excess warning] • The output wattage (speed × torque) of the servo motor exceeded the rated output, and that status continued steadily. [AL. 0ED.1_Output watt excess warning] Cause Check/action method Model The output wattage of the servo motor (speed Reduce the servo motor speed.

  • Page 88: [Al. 0F0_Tough Drive Warning]

    [AL. 0F0_Tough drive warning] • The tough drive function was activated. [AL. 0F0.1_Instantaneous power failure tough drive warning] Cause Check/action method Model The voltage of the control circuit power supply Page 13 [AL. 010.1_Voltage drop in the control circuit power] has dropped.

  • Page 89: [Al. 0F2_Drive Recorder Warning]

    [AL. 0F2_Drive recorder warning] • Writing/reading/clearing of the drive recorder data failed. [AL. 0F2.1_Drive recorder warning 1] Cause Check/action method Model There is an error in the drive recorder data. Check if clearing the alarm history of the drive recorder with MR Configurator2 disables the warning.

  • Page 90: [Al. 0F3_Oscillation Detection Warning]

    [AL. 0F3_Oscillation detection warning] • An oscillation was detected on the servo motor. [AL. 0F3.1_Oscillation detection warning] Page 53 [AL. 054.1_Oscillation detection error] 1 SERVO AMPLIFIER TROUBLESHOOTING 1.3 Handling methods for alarms/warnings...

  • Page 91: [Al. 0F7_Machine Diagnosis Warning]

    [AL. 0F7_Machine diagnosis warning] • The equipment on which the servo motor is installed may be malfunctioning. [AL. 0F7.1_Vibration failure prediction warning] Cause Check/action method Model Due to degradation of components in the When the increase in the vibration level during motor operation is less than 5 % of the rated torque from the initial operation, set a larger value for vibration equipment, the vibration became larger.
  • Page 92 [AL. 0F7.5_Static friction failure prediction warning] Cause Check/action method Model As the surrounding environment changed, the If the operating environment was changed from the initial operation, reset the threshold, and then re-create a threshold. If the operating environment is friction of the equipment was also changed. unchanged, refer to 2 and examine the equipment.

  • Page 93: [Al. 118_Encoder Diagnosis]

    [AL. 118_Encoder diagnosis] • The servo amplifier is in the test operation mode. [AL. 118.1_Encoder communication circuit diagnosing] Cause Check/action method Model The servo amplifier is in the encoder Cancel the encoder communication circuit diagnosis mode. Refer to "Encoder communication diagnosis function" in the following manual. communication circuit diagnosis mode.

  • Page 94: [Al. 119_Memory Error 4]

    [AL. 119_Memory error 4] • There is an error in memory. [AL. 119.1_Memory error 4-1] Cause Check/action method Model There is an abnormality in the surrounding Check the power supply for noise. If there is noise, take countermeasures to reduce the noise. environment.

  • Page 95: [Al. 11A_Servo Motor Constant Error]

    [AL. 11A_Servo motor constant error] • The servo motor constant file is damaged. [AL. 11A.1_Servo motor constant file error] Cause Check/action method Model Writing of the servo motor constant file failed. During the servo motor constant file writing, due to noise mixing and the like, there is a possibility that the servo motor constant file is damaged.

  • Page 96: [Al. 130_Regenerative Error 2]

    [AL. 130_Regenerative error 2] • The regenerative power exceeds the permissible regenerative power of the built-in regenerative resistor or regenerative option. • A regenerative transistor in the servo amplifier is malfunctioning. [AL. 130.1_Regenerative heat error] Cause Check/action method Model The setting of the regenerative resistor Refer to "Regenerative option"...

  • Page 97: [Al. 139_Open Phase Error]

    [AL. 139_Open phase error] • An open phase occurred in the main circuit power supply of the servo amplifier. • An open phase occurred in the servo motor power line. [AL. 139.1_Input open phase error] Cause Check/action method Model An open phase occurred in the main circuit Check that the main circuit power line is connected with the servo amplifier.

  • Page 98: [Al. 168_Sto Function Error]

    [AL. 168_STO function error] • There is an error in the STO function. [AL. 168.1_STO function error] Cause Check/action method Model A servo amplifier that is not compatible with Install the short-circuit connector attached to the servo amplifier in the CN8. the STO function does not have a short-circuit [WG] connector connected to its CN8 connector.

  • Page 99: [Al. 188_Watchdog 2]

    [AL. 188_Watchdog 2] • CPU or other components are malfunctioning. [AL. 188_Watchdog 2] Cause Check/action method Model The internal parts of the servo amplifier have Replace the servo amplifier. malfunctioned. [WG] 1 SERVO AMPLIFIER TROUBLESHOOTING 1.3 Handling methods for alarms/warnings...

  • Page 100: [Al. 1E9_Open Phase Warning]

    [AL. 1E9_Open phase warning] • An open phase occurred in the main circuit power supply of the servo amplifier. [AL. 1E9.1_Input open phase warning] Cause Check/action method Model An open phase occurred in the main circuit Page 95 [AL. 139.1_Input open phase error] power line of the servo amplifier.

  • Page 101: [Al. 1F8_Memory Warning 1]

    [AL. 1F8_Memory warning 1] • There is an error in a memory. [AL. 1F8.1_Memory writing frequency warning] Cause Check/action method Model The frequency of writing to the memory Prepare for replacing the servo amplifier, by making a backup of necessary data, or by other means.

  • Page 102: Trouble Which Does Not Trigger An Alarm/Warning

    Trouble which does not trigger an alarm/warning This section shows the examples of possible causes of trouble which does not trigger an alarm or warning. Refer to this section and remove each cause of trouble. Precautions • When the servo amplifier, servo motor, controller, or encoder malfunctions, the cases shown in this section may occur. The display shows "A"...

  • Page 103: The Display Shows "Off

    The display shows "off" • The display shows "off". Possible cause Check/action method Model Operation mode for manufacturer setting is Do not turn on all the DIP switches (SW3). Set SW3 correctly. Refer to "Switch setting and display of the servo amplifier" in the following [WG] enabled.

  • Page 104: The Increase In The Servo Motor Speed Is Insufficient Or Excessive

    Possible cause Check/action method Model RES (Reset) is switched on. Switch off RES. The setting of the control mode is incorrect. Check the setting of [Pr. PA01.0 Control mode selection]. In the position control mode, the command Check if the pulse train is outputted from the controller. pulse is not inputted.

  • Page 105: The Servo Motor Vibrates With Low Frequency

    Possible cause Check/action method Model In the speed control mode and the torque Review the settings of SP1, SP2, SP3, and setting of internal speed. control mode, the selection of SP1 (Speed selection 1), SP2 (Speed selection 2), or SP3 (Speed selection 3) is incorrect.

  • Page 106: The Servo Motor Vibrates

    The servo motor vibrates • The servo motor vibrates. Possible cause Check/action method Model The servo gain is high. Or the response of the Decrease the servo gain, and then check if the trouble is solved. Or, decrease the value of [Pr. PA09 Auto tuning response]. auto tuning is high.

  • Page 107: The Machine Vibrates Unsteadily When It Stops

    The machine vibrates unsteadily when it stops • The machine vibrates unsteadily when it stops. Possible cause Check/action method Model The servo gain is low. Or the response of the Increase the servo gain. Or, increase the value of [Pr. PA09 Auto tuning response].

  • Page 108: The Home Position Deviates At The Homing

    The home position deviates at the homing • The home position deviates at the homing. Possible cause Check/action method Model When performing the dog type homing, the Check if a fixed amount (in one revolution) deviates. Adjust the position of the proximity dog.

  • Page 109: In The Absolute Position Detection System, A Position Mismatch Occurs At Power Restoration

    In the absolute position detection system, a position mismatch occurs at power restoration • In the absolute position detection system, a position mismatch occurs at power restoration. Possible cause Check/action method Model At power-off status of the servo amplifier, an Extend the acceleration time.

  • Page 110: Coasting Distance Of The Servo Motor Became Longer

    Coasting distance of the servo motor became longer • The coasting distance of the servo motor became longer. Possible cause Check/action method Model The load increased and exceeded the Reduce the load. permissible load to motor inertia. [WG] The electromagnetic brake was malfunctioning Remove the servo motor and all the wiring from the machine, and check if the servo motor shaft can be rotated by the hands.
  • Page 111 MEMO 1 SERVO AMPLIFIER TROUBLESHOOTING 1.4 Trouble which does not trigger an alarm/warning...

  • Page 112: Revisions

    First edition This manual confers no industrial property rights of any other kind, nor does it confer any patent licenses. Mitsubishi Electric Corporation cannot be held responsible for any problems involving industrial property rights which may occur as a result of using the contents noted in this manual.

  • Page 113: Warranty

    WARRANTY Warranty 1. Warranty period and coverage We will repair any failure or defect hereinafter referred to as "failure" in our FA equipment hereinafter referred to as the "Product" arisen during warranty period at no charge due to causes for which we are responsible through the distributor from which you purchased the Product or our service provider.

  • Page 114: Trademarks

    TRADEMARKS MELSERVO is a trademark or registered trademark of Mitsubishi Electric Corporation in Japan and/or other countries. All other product names and company names are trademarks or registered trademarks of their respective companies. SH(NA)-030312ENG-A...
  • Page 116 SH(NA)-030312ENG-A(1906)MEE MODEL: MODEL CODE: HEAD OFFICE : TOKYO BUILDING, 2-7-3 MARUNOUCHI, CHIYODA-KU, TOKYO 100-8310, JAPAN NAGOYA WORKS : 1-14 , YADA-MINAMI 5-CHOME , HIGASHI-KU, NAGOYA , JAPAN When exported from Japan, this manual does not require application to the Ministry of Economy, Trade and Industry for service transaction permission. Specifications are subject to change without notice.

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