Page 1 Upon receipt of the product and prior to initial operation, read these instructions thoroughly, and retain for future reference. MOTOMAN INSTRUCTIONS MOTOMAN- INSTRUCTIONS NX100 INSTRUCTIONS NX100 OPERATOR’S MANUAL NX100 MAINTENANCE MANUAL The NX100 operator’s manuals above correspond to specific usage. Be sure to use the appropriate manual. YASKAWA ELECTRIC CORPORATION MANUAL NO. RE-CHO-A104 8...
Page 2 If such modification is made, the manual number will also be revised. • If your copy of the manual is damaged or lost, contact a YASKAWA rep- resentative to order a new copy. The representatives are listed on the back cover.
Page 3 Notes for Safe Operation Read this manual carefully before maintenance or inspection of the NX100. In this manual, the Notes for Safe Operation are classified as “WARNING,” “CAUTION,” “MANDATORY,” or ”PROHIBITED.” Indicates a potentially hazardous situation which, if not avoided, WARNING could result in death or serious injury to personnel.
Page 4 Injury may result if anyone enters the P-point maximum envelope of the manipulator dur- ing operation. Always press an emergency stop button immediately if there are prob- lems.The emergency stop buttons are located on the right of the front door of the NX100 and the programming pendant.
Page 5 -Check for problems in manipulator movement. -Check for damage to insulation and sheathing of external wires. • Always return the programming pendant to the hook on the NX100 cabi- net after use. The programming pendant can be damaged if it is left in the P-point maximum envelope of the manipulator, on the floor, or near fixtures.
Page 6 Descriptions of the programming pendant keys, buttons, and displays are shown as follows: Equipment Manual Designation Programming Character Keys The keys which have characters printed on them are Pendant denoted with [ ]. ex. [ENTER] Symbol Keys The keys which have a symbol printed on them are not denoted with [ ] but depicted with a small picture.
Page 7 ......4 Replacing Parts 5.1 Replacing NX100 Parts ......5 5.1.1 Replacing Parts of the CPU Unit .
Page 8: Table Of Contents
Robot I/F Unit ........5-14 5.2 NX100 Parts List .
Page 9 Modifying the Output Status ......7-5 7.3.3 Specific Input ........7-6 Specific Input Window .
Page 10 Alarm 8.1 Outline of Alarm ........8 8.2 Alarm Display .
Page 11 1.1 Arrangement of Units and Circuit Boards 1 Equipment Configuration The NX100 is comprised of individual units and modules (circuit boards). Malfunctioning com- ponents can generally be easily repaired after a failure by replacing a unit or a module. This section explains the configuration of the NX100 equipment.
Page 12 Power Supply NX100 SERVOPACK Converter Breaker Contactor Unit Type ERCR-UP20MN-AA00 UP20MN SGDR-EH50Y27 NF30SW 3P 20A SGDR-EH50Y24 ERCR-UP50N-AA00 UP50N ES165N JZRCR-NTU02 -1 ERCR-ES165N-AA00 SGDR-ES165N NF30SW 3P 30A HP165 SGDR-COA250A01B ERCR-ES200N-AA00 ES200N ERCR-ES165RN-AA00 ES165RN SGDR-ES165NY28 ES200RN ERCR-ES200RN-AA00 Configuration for Medium- or Large-Capacity NX100...
Page 13 1.2 Power Flow Power Flow Power supply contactor unit (JZRCR-NTU L1(R) Three-phase, 200VAC, 50/60Hz L2(S) 220VAC, 60Hz L3(T) CPU unit (5A) (5A) NZNC-NRK01 JANCD-NBB01 CPS-5P2EF CN01 Filter (200VAC input) AC250V Servo cooling fan CN03 Backside duct fan (+24V2, 24VDC CN02 +24V3 output) (+24V2, CN9 A1...
Page 14 1.3 Signal Flow Signal Flow Power supply contactor unit JZRCR-NTU Three-phase, Circuit 200VAC, 50/60Hz breaker 220VAC, 60Hz CPU unit JZNC-NRK01 JANCD-NBB01 CPS-NX1 JANCD-NTU01 CN09 (Contactor control) (External output for CBL- CN03/04 emergency stop signal) NKC002 (Control signal of contactor unit) PBESP CN01 CN05...
Page 15 2 Security System Protection Through Security Mode Settings The NX100 modes setting are protected by a security system. The system allows operation and modification of settings according to operator clearance. Be sure operators have the cor- rect level of training for each level to which they are granted access.
Page 16 2.1 Protection Through Security Mode Settings Menu & Security Mode Allowed Security Mode Main Menu Sub Menu DISPLAY EDIT Operation Edit SELECT JOB Operation Operation Edit Edit CREATE NEW JOB MASTER JOB Operation Edit JOB CAPACITY Operation Edit Edit RES. START (JOB) Operation RES.
Page 17 2.1 Protection Through Security Mode Settings Menu & Security Mode Allowed Security Mode Main Menu Sub Menu DISPLAY EDIT ROBOT CURRENT POSITION Operation COMMAND POSITION Operation SERVO MONITOR Management WORK HOME POS Operation Edit SECOND HOME POS Operation Edit DROP AMOUNT Management Management POWER ON/OFF POS...
Page 18 2.1 Protection Through Security Mode Settings Menu & Security Mode Allowed Security Mode Main Menu Sub Menu DISPLAY EDIT PARAMETER S1CxG Management Management Management Management Management Management Management Management Management Management Management Management Management Management Management Management Management Management Management Management Management Management...
Page 19 2.1 Protection Through Security Mode Settings Menu & Security Mode Allowed Security Mode Main Menu Sub Menu DISPLAY EDIT SPOT WELDING WELD DIAGNOSIS Operation Edit (MOTOR GUN) GUN PRESSURE Edit Edit PRESSURE Edit Edit I/O ALLOCATION Management Management GUN CONDITION Management Management CLEARANCE SETTING...
Page 20 2.1 Protection Through Security Mode Settings Changing the Security Mode Operation Explanation 1 Select {SYSTEM INFO} under The sub menu appears. the main menu. FD/CF DOUT MOVE SETUP ARC WELDING VERSION VARIABLE B001 MONITORING TIME IN/OUT ALARM HISTORY ROBOT I/O MSG HISTORY SYSTEM INFO SECURITY Main Menu...
Page 21 2.1 Protection Through Security Mode Settings Operation Explanation 4 Input the user ID. The user ID input window appears. DATA EDIT DISPLAY UTILITY SECURITY FD/CF DOUT MOVE Password= DISPLAY SETUP ARC WELDING MODE VARIABLE B001 IN/OUT ROBOT SYSTEM INFO Input current ID no. (4 to 8 digits) Main Menu Short Cut At the factory, the following below user ID number is...
Page 22 User ID must be between 4 characters and 8, and they must be numbers and symbols (“0 to 9”,“-” and “.”). Changing a User ID In order to change the user ID, the NX100 must be in Editing Mode or Management Mode. Higher security modes can make changes the user ID of to lower security modes. Operation...
Page 23 2.1 Protection Through Security Mode Settings Operation Explanation 3 Select the desired ID. The character input line appears, and the message "Input current ID no. (4 to 8 digits)" is shown. DATA EDIT DISPLAY UTILITY USER ID FD/CF DOUT MOVE Password= PARAMETER ARC WELDING...
Page 24 Carry out the following inspections. Inspection Inspection Equipment Inspection Item Comments Frequency Check that the doors are Daily completely closed. NX100 Controller Check for gaps or dam- Monthly age to the sealed con- struction. Interior circulation fan Check operation As required While power ON...
Page 25 • The NX100 has a fully sealed construction, designed to keep external air containing oil mist out of the NX100. Be sure to keep the NX100 doors fully closed at all times, even when the controller is not operating. • Open or close the two locks in each door with the screwdriver when opening or closing the doors for maintenance after the main power is turned OFF.
Page 26 3.3 Cooling Fan Inspections Cooling Fan Inspections Inspect the cooling fans a . A defective fan can cause the NX100 to malfunction s required because of excessive high temperatures inside. The interior circulation fan and backside duct fan normally operate while the power is turned ON.
Page 27 3.3 Cooling Fan Inspections Backside duct fan Interior circulation fan Air intake Air outlet Cooling Fan Construction (Medium- or large-capacity NX100)
Page 28 The emergency stop buttons are located on both the front door of the NX100 and the programming pendant. Confirm the servo power is OFF by pressing the emergency stop button on the the front door of the NX100 after the servo ON, before the manipulator is operated.
Page 29 3.6 Battery Inspections Battery Inspections The NX100 has a battery that backs up the important program files for user data in the CMOS memory. A battery alarm indicates when a battery has expired and must be replaced. The programming pendant display and the message "Memory battery weak" appears at the bottom of the dis- play.
Page 30 3.8 Open Phase Check Open Phase Check Open Phase Check List Check Item Contents Lead Cable Check Confirm if the lead cable for the power supply is wired as shown in the following. If the wiring is wrong or broken, repair it. Input Power Supply Check the open phase voltage of input power supply with an Check...
Page 31 WARNING • Before operating the manipulator, check that the SERVO ON lamp turns OFF when the emergency stop buttons on the front door of the NX100 and the programming pendant are pressed. Injury or damage to machinery may result if the manipulator cannot be stopped in case of an emergency.
Page 32 - Check for problems in manipulator movement. - Check for damage to insulation and sheathing of external wires. • Always return the programming pendant to the hook on the NX100 cabi- net after use. The programming pendant can be damaged if it is left in the P-point maximum envelope of the manipulator, on the floor, or near fixtures.
Page 33 4.1 Creating a Check Program Creating a Check Program To check position deviation whenever necessary, create a program in which a check point is taught (the job for the check point). In the job for the check point, teach two points; one as a check point and the other as the point to approach the check point.
Page 34 5 Replacing Parts Replacing NX100 Parts WARNING • Turn OFF the power supply before opening the NX100 doors. Failure to observe this warning may result in electric shock. • After turning OFF the power supply, wait at least 5 minutes before replacing a SREVOPACK (including the converter) or control power sup- ply unit.
Page 35 5.1 Replacing NX100 Parts 5.1.1 Replacing Parts of the CPU Unit CPU unit (JZNC-NRK01) is comprised of the control power supply (CPS-420F), the rack for the various circuit boards, control circuit board (JANCD-NCP01), servo control circuit board (SGDR-AXA01A), and robot I/F unit (JZNC-NIF01 ).
Page 36 5.1 Replacing NX100 Parts Replacing the Battery Replace the battery immediately if a battery alarm occurs. Replace the battery within two hours after the breaker turns OFF. (The battery alarms appear on the programing pendant display.) Replacement Procedure 1. Remove the left cover of the CPU unit.
Page 37 5.1 Replacing NX100 Parts Replacing the Control Power Supply (CPS-420F) CAUTION • After turning OFF the power supply, wait at least 5 minutes before replacing a control power supply. Do not touch any terminals during this period. Confirm all monitor lights are turned OFF.
Page 38: Replacing The Servo Control Circuit Board
5.1 Replacing NX100 Parts Replacing the Servo Control Circuit Board (SGDR-AXA01A) Turn OFF the power before replacing a servo control circuit board. Replacement Procedure 1. Disconnect all cables connected to the servo control circuit board. (Be sure to remove the connectors at the bottom of the board.) 2.
Page 39: Replacing The Robot I/F Unit (Jznc-Nif01 )
• There are some versions which require maker mode operations after replacing the robot I/F unit. Contact your Yaskawa representative for maker mode operations. • Before removing the robot I/F unit from the CPU rack temporarily, turn ON the system power and charge the onboard capacitor for one hour.
Page 40 5.1 Replacing NX100 Parts Robot I/F unit JZNC-NIF01 Rotaty switch POWER SUPPLY CPS-NX1 DATE Fuji Electric Co.,Ltd. JAPAN 03 04 05 06 08 09 10 SOURCE 13 14 15 16 18 19 20 23 24 25 26 28 29 30...
Page 41: Replacing The Robot I/F Circuit Board (Jancd-Nif01)
• There are some versions which require maker mode operations after replacing the robot I/F circuit board. Contact your Yaskawa representative for maker mode operations. • Before removing the robot I/F unit from the CPU rack temporarily, turn ON the system power and charge the onboard capacitor for one hour.
Page 42: Replacing The I/O Circuit Board (Jancd-Nio01 )
5.1 Replacing NX100 Parts Replacing the I/O Circuit Board (JANCD-NIO01 ) • Turn OFF the power before replacing the I/O circuit board (JANCD-NIO01 ). NOTE • Be sure to back up robot data before replacing the robot I/F unit since the robot I/F unit contains important data such as robot jobs and parameters.
Page 43: Replacing The Servopack
5.1 Replacing NX100 Parts 5.1.2 Replacing the SERVOPACK WARNING • After turning OFF the power supply, wait at least 5 minutes before replacing a SERVOPACK. Do not touch any terminals during this period. Failure to observe this warning may result in electric shock.
Page 44 5.1 Replacing NX100 Parts (AMP4 to AMP6-CNP6) Converter Output connectors for motor power Upper grip Charge lamp (CN102) PWM amplifier control power (AMP4 to AMP6-CN1) supply connector PWM signal connectors (CN101) DC control power supply connector Monitor, alarm display LED...
Page 45 5.1 Replacing NX100 Parts • How to Replace SERVOPACK 1. Turn OFF the breaker and the primary power supply and wait at least 5 minutes before replacing. Do not touch any terminals during this period. 2. Verify that the converter CHARGE lamp (red LED) is unlit.
Page 46: Checking And Replacing Fuses
5.1 Replacing NX100 Parts 5.1.3 Checking and Replacing Fuses Power Supply Contactor Unit The types of fuses on power supply contactor unit (JZRCR-NTU ) are as follows Parts No. Fuse Name Specification 1FU, 2FU Control Power Supply Fuse 250V,10A, Time Lag Fuse...
Page 47: Robot I/F Unit
5.1 Replacing NX100 Parts Robot I/F Unit The types of fuses on the robot I/F unit (JZNC-NIF01 ) are as follows. Parts No. Fuse Name Specification F1, F2 24VDC Fuse for I/O 250V, 3.15A, Rapid Cut Fuse (2173.15P, 3.15A, 250V...
Page 48: Nx100 Parts List
5.2 NX100 Parts List NX100 Parts List NX100 Parts List Name Model Comment SERVOPACK 6 axes type CPU unit JZNC-NRK01 Backboard JANCD-NBB01 Control circuit board JANCD-NCP01 Servo control circuit board SGDR-AXA01A Not included in CPU unit (JZNC-NRK01) Control power supply...
Page 49 5.2 NX100 Parts List SERVOPACK List HP6, EA1400N Component Model Model SERVOPACK SGDR-EA1400NY26 SGDR-EA1400N Converter SGDR-COA040A01B SGDR-COA040A01B Amplifier SGDR-SDA060A01B SGDR-SDA140A01BY22 SGDR-SDA060A01B SGDR-SDA140A01BY22 SGDR-SDA060A01B SGDR-SDA140A01BY22 SGDR-SDA060A01B SGDR-SDA060A01B SGDR-SDA060A01B SGDR-SDA060A01B SGDR-SDA060A01B SGDR-SDA060A01B SERVOPACK List HP20, EA1900N UP50N UP20MN Component Model Model Model...
Page 50 5.2 NX100 Parts List SERVOPACK List ES165N, HP165, ES200N ES165RN, ES200RN Component Model Model SERVOPACK SGDR-ES165N SGDR-ES165NY28 Amplifier SGDR-SDA710A01B SGDR-SDA710A01B SGDR-SDA710A01BY29 SGDR-SDA710A01BY29 SGDR-SDA710A01B SGDR-SDA710A01BY25 SGDR-SDA350A01B SGDR-SDA350A01B SGDR-SDA350A01B SGDR-SDA350A01B SGDR-SDA350A01B SGDR-SDA350A01B Converter SGDR-COA250A01B SGDR-COA250A01B Power Supply Contactor Unit List Type Manipulator Type...
Page 51: Supplied Parts List
It is recommended that the following parts and components be kept in stock as spare parts for the NX100. The spare parts list for the NX100 is shown below. Product performance can not be guaranteed when using spare parts from any company other than Yaskawa. To buy the spare parts which are ranked B or C, inform the manufacturing number (or order number) of NX100 to Yaskawa representative.
Page 52 5.4 Recommended Spare Parts Recommended Spare Parts of NX100 for HP3 Parts Rank Name Type Manufacturer Remarks Unit Battery ER6VC3N 3.6V TOSHIBA BAT- TERY CO., LTD. Control Power Sup- JZNC-NZU01 Yaskawa Electric ply Fan Corporation Backside Duct Fan 4715MS-22T-B50- Minebea Co., Ltd.
Page 53 5.4 Recommended Spare Parts Recommended Spare Parts of NX100 for HP6 and EA1400N Parts Rank Name Type Manufacturer Remarks Unit Battery ER6VC3N 3.6V TOSHIBA BAT- TERY CO., LTD. Control Power Sup- JZNC-NZU01 Yaskawa Electric ply Fan Corporation Backside Duct Fan 4715MS-22T-B50- Minebea Co., Ltd.
Page 54 5.4 Recommended Spare Parts Recommended Spare Parts of NX100 for HP20 and EA1900N Parts Rank Name Type Manufacturer Remarks Unit Battery ER6VC3N 3.6V TOSHIBA BAT- TERY CO., LTD. Control Power Sup- JZNC-NZU01 Yaskawa Electric ply Fan Corporation Backside Duct Fan 4715MS-22T-B50- Minebea Co., Ltd.
Page 55 5.4 Recommended Spare Parts Recommended Spare Parts of NX100 for UP20MN Parts Rank Name Type Manufacturer Remarks Unit Battery ER6VC3N 3.6V TOSHIBA BAT- TERY CO., LTD. Control Power Sup- JZNC-NZU01 Yaskawa Electric ply Fan Corporation Backside Duct Fan 5915MS-22T-B50- Minebea Co., Ltd.
Page 56 5.4 Recommended Spare Parts Recommended Spare Parts of NX100 for UP50N Parts Rank Name Type Manufacturer Remarks Unit Battery ER6VC3N 3.6V TOSHIBA BAT- TERY CO., LTD. Control Power Sup- JZNC-NZU01 Yaskawa Electric ply Fan Corporation Backside Duct Fan 5915MS-22T-B50- Minebea Co., Ltd.
Page 57 5.4 Recommended Spare Parts Recommended Spare Parts of NX100 for ES165N, HP165, and ES200N Parts Rank Name Type Manufacturer Remarks Unit Battery ER6VC3N 3.6V TOSHIBA BAT- TERY CO., LTD. Control Power Sup- JZNC-NZU01 Yaskawa Electric ply Fan Corporation Backside Duct Fan 5915MS-22T-B50- Minebea Co., Ltd.
Page 58 5.4 Recommended Spare Parts Recommended Spare Parts of NX100 for ES165RN and ES200RN Parts Rank Name Type Manufacturer Remarks Unit Battery ER6VC3N 3.6V TOSHIBA BAT- TERY CO., LTD. Control Power Sup- JZNC-NZU01 Yaskawa Electric ply Fan Corporation Backside Duct Fan 5915MS-22T-B50- Minebea Co., Ltd.
Page 59: Operations After Replacing Parts
WARNING • Before operating the manipulator, check that the SERVO ON lamp turns OFF when the emergency stop buttons on the front door of the NX100 and the programming pendant are pressed. Injury or damage to machinery may result if the manipulator cannot be stopped in case of an emergency.
Page 60: Home Position Calibration
- Check for problems in manipulator movement. - Check for damage to insulation and sheathing of external wires. • Always return the programming pendant to the hook on the NX100 cabi- net after use. The programming pendant can be damaged if it is left in the P-point maximum envelope of the manipulator, on the floor, or near fixtures.
Page 61: Calibrating Operation
6.1 Home Position Calibration If the absolute data of the home position is already known, set the absolute data again after completing home position registration. Home Position SUPPLE -MENT The home position is the position with the pulse value "0" for each axis. See "6.1.3 Manipulator Home Position."...
Page 62 6.1 Home Position Calibration Operation Explanation Select {DISPLAY} under the The pull-down menu appears. menu, DATA EDIT DISPLAY UTILITY or select "PAGE" to display ROBOT 1 HOME POSITIONING FD/CF the selection window for the SELECT ABSOLUTE DATA DOUT MOVE STATION 1 R1:S control group, PARAMETER...
Page 63 6.1 Home Position Calibration Operation Explanation Select {SELECT ALL AXES}. The confirmation dialog box appears. DATA EDIT DISPLAY UTILITY HOME POSITIONING FD/CF SELECT ABSOLUTE DATA DOUT MOVE R1:S PARAMETER ARC WELDING VARIABLE SETUP ¡ B001 Create home position? ¡ IN/OUT DISPLAY SETUP ROBOT SYSTEM INFO...
Page 64: Registering Individual Axes
6.1 Home Position Calibration Registering Individual Axes Operation Explanation Select {ROBOT} under the main menu. Select {HOME POSITION}. Select the desired control Perform steps 3 and 4 which have been described in " Register- group. ing All Axes at One Time " to select the desired control group. Select the axis to be regis- tered.
Page 65: Changing The Absolute Data
6.1 Home Position Calibration Changing the Absolute Data To change the absolute data of the axis when home position calibration is completed, perform the following: Operation Explanation Select {ROBOT} under the main menu. Select {HOME POSITION}. Select the desired control Perform steps 3 and 4 which have been described in "...
Page 66: Clearing Absolute Data
6.1 Home Position Calibration Clearing Absolute Data Operation Explanation Select {ROBOT} under the main menu. Select {HOME POSITION}. Perform steps 2, 3, and 4 which have been described in " Regis- tering All Axes at One Time " to display the HOME POSITION- ING window and select the desired control group.
Page 67: Manipulator Home Position
6.1 Home Position Calibration 6.1.3 Manipulator Home Position With the MOTOMAN-HP6, the home position is as follows. U-axis angle against horizontal line on the ground (-0°) B-axis center line angle against U-axis center line (-0°) L-axis angle against vertical line to the ground (-0°) NOTE Other manipulator models have different positions.
Page 68: Position Deviation Check Using The Check Program
6.2 Position Deviation Check Using the Check Program Position Deviation Check Using the Check Pro- gram Use the check program to check if positions are deviated with the following procedure. 1. Call up the check program in which the check point is taught (the job for the check point) and operate the manipulator at low speed.
Page 69: Home Position Data Correction
6.3 Home Position Data Correction Home Position Data Correction When there is a deviation from the positions, correct the home position data with the following procedure. 1. Check the values of the following pulses. (If there is no deviation, the following two val- ues coincide.) •...
Page 70: Setting The Second Home Position (Check Point)
Injury may result from contact with the manipulator if persons enter the P-point max- imum envelope of the manipulator. • Always press the emergency stop button immediately if there are problems. Emergency stop buttons are attached on the right of the front door of the NX100 and the programming pendant. 6-12...
Page 71 - Check for damage to the insulation and sheathing of external wires. - Always return the programming pendant to its hook on the NX100 cabinet after use. If the programming pendant is inadvertently left on the manipulator, a fixture, or on the floor, the manipulator or a tool could collide with it during manipulator move- ment, possibly causing injury or equipment damage.
Page 72: Purpose Of Position Check Operation
6.4 Setting the Second Home Position (Check Point) 6.4.1 Purpose of Position Check Operation If the absolute number of rotation detected at power supply ON does not match the data stored in the absolute encoder the last time the power supply was turned off, an alarm is issued when the controller power is turned ON.
Page 73 6.4 Setting the Second Home Position (Check Point) Pulse Difference Check The pulse number at the second home position is compared with that at the current posi- tion. If the difference is within the allowable range, playback is enabled. If not, the alarm occurs again.
Page 74: Procedure For The Second Home Position Setting
6.4 Setting the Second Home Position (Check Point) 6.4.2 Procedure for the Second Home Position Setting (Check Point) Apart from the "home position" of the manipulator, the second home position can be set up as a check point for absolute data. Use the following steps to set the specified point. If two or more manipulators or stations are controlled by one controller, the second home posi- tion must be set for each manipulator or station.
Page 75: Procedure After The Alarm
6.4 Setting the Second Home Position (Check Point) 6.4.3 Procedure after the Alarm WARNING • Be aware of safety hazards when performing the position confirma- tion of the specified point. Abnormality of the PG system may be cause for alarm. The manipulator may oper- ate in an unexpected manner, and there is a risk of damage to equipment or injury to personnel.
Page 76 6.4 Setting the Second Home Position (Check Point) Operation Explanation The group axes by which the second home position is set is Press the page key selected when there are two or more group axes. or select "PAGE" to display the DATA EDIT DISPLAY...
Page 77: System Diagnosis
7.1 System Version 7 System Diagnosis System Version It is possible to check the system CPU version information as follows. Operation Explanation Select {SYSTEM INFO} under the main menu. Select {VERSION}. The VERSION window appears. DATA EDIT DISPLAY UTILITY VERSION SYSTEM NS3.12.00A(US)-00 PARAM...
Page 78: Manipulator Model
7.2 Manipulator Model Manipulator Model Operation Explanation Select {ROBOT} under the main menu. Select {MANIPULATOR The ROBOT AXIS CONFIG window appears. TYPE}. DATA EDIT DISPLAY UTILITY ROBOT AXIS CONFIG AXIS CONFIGURATION R1: EA1400-A0* 0011-1111 S1: TURN-1 0000-0001 PAGE Main Menu Short Cut...
Page 79: Input/Output Status
7.3 Input/Output Status Input/Output Status 7.3.1 Universal Input The status of input signal which is referred to by input instruction of a job can be confirmed. Universal Input Window Operation Explanation Select {IN/OUT} under the main menu. Select {UNIVERSAL INPUT}. The UNIVERSAL INPUT window appears.
Page 80: Universal Output
7.3 Input/Output Status 7.3.2 Universal Output The status of the output signal set by the output instruction can be confirmed and modified. Universal Output Window Operation Explanation Select {IN/OUT} under the main menu. Select {UNIVERSAL OUT- The UNIVERSAL OUTPUT window appears. PUT}.
Page 81: Modifying The Output Status
7.3 Input/Output Status Modifying the Output Status The status of universal output signal can be changed by the operation below. Operation Explanation Select the desired output sig- the desired output signal, “ Select the status of ” or “ ,” in nal number.
Page 82: Specific Input
7.3 Input/Output Status 7.3.3 Specific Input Specific Input Window Operation Explanation Select {IN/OUT} under the main menu. Select {SPECIFIC INPUT}. The SPECIFIED INPUT window appears. DATA EDIT DISPLAY UTILITY SPECIFIED INPUT GROUP 0:DEC. 00:HEX. SIN#0001 #40010 SYSTEM ALM REQ SIN#0002 #40011 SYSTEM MSG REQ SIN#0003...
Page 83: Specific Output
7.3 Input/Output Status 7.3.4 Specific Output Specific Output Window Operation Explanation Select {IN/OUT} under the main menu. Select {SPECIFIC OUTPUT}. The SPECIFIED OUTPUT window appears. DATA EDIT DISPLAY UTILITY SPECIFIED OUTPUT GROUP 0:DEC. 00:HEX. SOUT#0001 #50010 MAJOR ALM OCCUR SOUT#0002 #50011 MINOR ALM OCCUR SOUT#0003...
Page 84: Rin Input
7.3 Input/Output Status 7.3.5 RIN Input RIN Input Window Operation Explanation Select {IN/OUT} under the main menu. Select {RIN}. The RIN window appears. EDIT DATA DISPLAY UTILITY RIN INPUT 1 RIN#001 DIRECT IN1 (SERVO) RIN#002 DIRECT IN2 (SERVO) RIN#003 DIRECT IN3 (SERVO) RIN#004 DIRECT IN4 (SERVO) RIN#005...
Page 85: Signal Number Search
7.3 Input/Output Status 7.3.6 Signal Number Search A search can be made for a signal number of a universal input, universal output, specific input, and specific output. DATA EDIT DISPLAY UTILITY UNIVERSAL INPUT GROUP IG#001 IG#01 0:DEC. 00:HEX. 123 : 10 7b : 16 IN#0001 #00010...
Page 86: Input/Output Window
7.3 Input/Output Status Direct Search on the Universal/Specified Input/Output Window Operation Explanation Move the cursor to a signal Numeric values can now be entered. number in the UNIVERSAL/ DISPLAY DATA EDIT UTILITY SPECIFIED INPUT/OUT- PUT window, and press UNIVERSAL INPUT GROUP IG#001 0:DEC.
Page 87: Search From The Menu
7.3 Input/Output Status Search from the Menu Operation Explanation Select {EDIT} under the The pull-down menu appears. menu in the UNIVERSAL/ DATA EDIT DISPLAY UTILITY SPECIFIED INPUT/OUT- SEARCH SIGNAL PUT window. UNIVERSAL INPUT GROUP 0:DEC. 00:HEX. 123 : 10 7b : 16 SEARCH RELAY IG#001 IG#01...
Page 88: Relay Number Search
7.3 Input/Output Status 7.3.7 Relay Number Search A search can be made for a relay number of a universal input, universal output, specific input, and specific output. EDIT DATA DISPLAY UTILITY UNIVERSAL INPUT GROUP IG#001 IG#01 123 : 10 7b : 16 0:DEC.
Page 89: Input/Output Window
7.3 Input/Output Status Direct Search on the Universal/Specified Input/Output Window Operation Explanation Move the cursor to a relay Numeric values can now be entered. number in the UNIVERSAL/ DATA EDIT DISPLAY UTILITY SPECIFIED INPUT/OUT- PUT window, and press UNIVERSAL INPUT GROUP 0:DEC.
Page 90: Search From The Menu
7.3 Input/Output Status Search from the Menu Operation Explanation Select {EDIT} under the The pull-down menu appears. menu in the UNIVERSAL/ DATA EDIT DISPLAY UTILITY SPECIFIED INPUT/OUT- SEARCH SIGNAL PUT window. UNIVERSAL INPUT GROUP 0:DEC. 00:HEX. 123 : 10 7b : 16 SEARCH RELAY IG#001 IG#01...
Page 91: Modification Of The Signal Name
7.3 Input/Output Status 7.3.8 Modification of the Signal Name The name of the universal input or output signal can be modified. DATA EDIT DISPLAY UTILITY UNIVERSAL INPUT GROUP 0:DEC. 00:HEX. 123 : 10 7b : 16 IG#001 IG#01 IN#0001 #00010 IN#0002 #00011 IN#0003...
Page 92: Modification From The Menu
7.3 Input/Output Status Modification from the Menu Operation Explanation Move the cursor to the signal name to be modified in the UNIVERSAL/SPECIFIED INPUT/OUTPUT window. Select {EDIT} under the The pull-down menu appears. menu. EDIT DATA DISPLAY UTILITY SEARCH SIGNAL UNIVERSAL INPUT GROUP SEARCH RELAY IG#001...
Page 93: System Monitoring Time Display
7.4 System Monitoring Time Display System Monitoring Time Display 7.4.1 System Monitoring Time Display Window The status of system operation, e.g. power ON time, can be checked. Operation Explanation Select {SYSTEM INFO}. Select {MONITORING The SYS MONITORING TIME window appears. TIME}.
Page 94: Individual Window Of The System Monitoring Time Display
7.4 System Monitoring Time Display 7.4.2 Individual Window of the System Monitoring Time Display If the page key is pressed, or "PAGE" is selected to display the selection window for the system monitoring time display, the servo power time, playback time, moving time, and each- application operating time by each control group are individually displayed.
Page 95: Clearing The System Monitoring Time Display
7.4 System Monitoring Time Display 7.4.3 Clearing the System Monitoring Time Display The moving time and operating time can be cleared and set back to 0 by following procedure. These operations can be performed in the SYS MONITORING TIME window, or in the individ- ual windows.
Page 96: Alarm History
7.5 Alarm History Alarm History 7.5.1 Alarm History Window The alarm history can be confirmed in the alarm history window. There are five types of alarm history windows: the "MAJOR ALARM" window, the "MINOR ALARM" window, the "USER ALARM (SYSTEM)" window, the "USER ALARM (USER)" window, and the "OFF-LINE ALARM"...
Page 97: Clearing The Alarm History
7.5 Alarm History 7.5.2 Clearing the Alarm History The history of the minor alarms and the user alarms (system and user) can be cleared. Operation Explanation Display the alarm history win- dow to be cleared. Select {DATA} under the The pull-down menu "CLEAR HISTORY" appears. menu.
Page 98: I/O Message History
7.6 I/O Message History I/O Message History 7.6.1 I/O Message History Window The I/O message history can be confirmed in the I/O MESSAGE HISTORY window. The I/O MESSAGE HISTORY window shows the date and time, job name, line number, and step number of the I/O message that appeared on the window.
Page 99: Clearing The I/O Message History
7.6 I/O Message History 7.6.2 Clearing the I/O Message History Use the following operation to clear the I/O message history. Operation Explanation Select {DATA} under the menu. Select {CLEAR HISTORY}. The confirmation dialog box appears. DATA EDIT UTILITY DISPLAY I/O MESSAGE HISTORY 0001 GAS SHORTAGE 0002...
Page 100: Position Data When Power Is Turned On/Off
7.7 Position Data When Power is Turned ON/OFF Position Data When Power is Turned ON/OFF 7.7.1 Power ON/OFF Position Window The Power ON/OFF position window shows the position of the manipulator when power was turned OFF the last time, the current position of the manipulator when power was later turned ON, and the amount of difference between the two positions.
Page 101: Current Position
7.8 Current Position Current Position 7.8.1 Current Position Window Operation Explanation Select {ROBOT} under the main menu. Select {CURRENT POSI- The CURRENT POSITION window appears. TION} under the sub menu. EDIT UTILITY DATA DISPLAY CURRENT POSITION COORDINATE PULSE TOOL 00 PAGE Short Cut Main Menu...
Page 102: Servo Monitoring
7.9 Servo Monitoring Servo Monitoring 7.9.1 Servo Monitor Window The servo monitor window shows the servo-related data of each axis. Monitor Items Description FEEDBACK PULSE Feedback position (actual position) of each axis “0” at the home position ERROR PULSE Difference between the command position and the feedback position of each axis SPEED DEVIATION Difference between the command speed and the...
Page 103: Changing The Monitor Items
7.9 Servo Monitoring 7.9.2 Changing the Monitor Items Operation Explanation Set the security mode to the management mode. Select {ROBOT} under the main menu. Select {SERVO MONITOR}. The SERVO MONITOR window appears. DATA EDIT DISPLAY UTILITY SERVO MONITOR FEEDBACK PULSE ERROR PULSE 1805 2432...
Page 104: Clearing Maximum Torque Data
7.9 Servo Monitoring 7.9.3 Clearing Maximum Torque Data The data for the maximum torque can be cleared when the maximum torque-related informa- tion is being displayed. Operation Explanation Select {DATA} under the The clear max torque window appears. menu. DATA EDIT DISPLAY UTILITY...
Page 105: Alarm
8.1 Outline of Alarm 8 Alarm Outline of Alarm When an alarm of level 0 to 3 (major alarm) occurs, the servo power supply is turned OFF. Alarm Code Classification Alarm Code Alarm Level Alarm Reset Method Level 0 (Major alarm) It is not possible to reset by "RESET"...
Page 106: Alarm Display
8.2 Alarm Display Alarm Display 8.2.1 Displaying and Releasing Alarm If an alarm occurs during operation, the manipulator stops immediately and the win- ALARM dow appears on the programming pendant indicating that the machine was stopped by an alarm. DATA EDIT DISPLAY UTILITY...
Page 107: Special Alarm Display
8.2 Alarm Display 8.2.2 Special Alarm Display Sub Data Sub data such as data for the axis where the alarm occurred, may also be displayed for some alarms. • Decimal data Without signs: 0 to 65535 With signs: -32768 to 32767 •...
Page 108: Independent Control Function (Optional)
8.2 Alarm Display Independent Control Function (Optional) In the independent control function (multi-task job), the tasks that were being done when the alarm occurred are also displayed. TASK#0: Master-task job TASK#1: Sub-task1 job (SUB1) TASK#2: Sub-task2 job (SUB2) TASK#3: Sub-task3 job (SUB3) TASK#4: Sub-task4 job (SUB4) TASK#5: Sub-task5 job (SUB5) TASK#6: Sub-task6 job (SUB6)
Page 109: Alarm Message List
CAUTION ∗∗−∗ Before handling the system control circuit board “JANCD-NIF ” for any remedies, con- ∗∗−∗ sult YASKAWA representative. To handle the JANCD-NIF , personnel must be appro- priately skilled in maintenance mode operation. ∗∗−∗ JANCD-NIF backs up very important file data for the user program with a battery.
Page 110 #2 is damaged. If the error occurs again, contact your 0030 ROM ERROR • The system program of servo Yaskawa representative. board #1 is damaged. • The system program of servo board #2 is damaged. • The system program of servo board #3 is damaged.
Page 111 0103 TION ERROR • The error was detected during the If the error occurs again, contact your (AXA#4) check of the number of the CERF Yaskawa representative. communications. The parameter file is damaged. RC parameter RO parameter SV parameter SVM parameter...
Page 112 • Reset the I/O module in maintenance mode. FIG-DATA) sistent. If the error occurs again, contact your Yaskawa representative. The parameter is inconsistent. The set optional functions are dif- Use the functions of the mounted optional ferent from those of the mounted board.
Page 113 • Set a correct value for the segment clock. out of allowable range is set. If the error occurs again, contact your Yaskawa representative. VERIFY ERROR The set value of segment clock is • Set a correct value, which is larger than the...
Page 114 LADDER PRO- 0720 due to excessive machine codes. If the error occurs again, contact your GRAM ERROR Yaskawa representative. The last instruction is not the END instruction. An error was found in the PART instruction. An error was found in the GOUT instruction.
Page 115 8.3 Alarm Message List Alarm Message List Alarm Message Cause Remedy Number Code An error occurred during the Upgrade to the same version and rewrite the 0803 FILE ERROR parameter of Manipulator Model parameter. (mecha.rom) loading. The TOYOPUC board cannot be Verify that the TOYOPUC board is normally identified installed.
Page 116 A system operation error occurred. • Turn the power OFF then back ON. 0900 TIMER ERROR If the error occurs again, contact your (NIF BOARD) Yaskawa representative. Vec- An error was detected in the CPU. Replace the NCP01 board. CPU ERROR 0910...
Page 117 ERASE command was 1001 If the error occurs again, contact your (AXA01) written. (EEPROM ERASE error) Yaskawa representative. The SRDY signal did not turn ON after the CLEAR command was written. (EEPROM CLEAR error) The SRDY signal did not turn ON after data were written.
Page 118 8.3 Alarm Message List Alarm Message List Alarm Message Cause Remedy Number Code • The memory for SVC parameter file is damaged. • The memory for AMC parameter Initialize the appropriate parameter file in the file is damaged. MEMORY maintenance mode, and then load the appro- ERROR •...
Page 119 8.3 Alarm Message List Alarm Message List Alarm Message Cause Remedy Number Code The file data used by MOTION are damaged. • The name position file is dam- aged. • The conveyor condition file is damaged. • The Press characteristics file is damaged.
Page 120 • The request to prepare the current value could not be sent. • The current value could not be prepared. SYSTEM An unknown alarm was detected Contact your Yaskawa representative. 1100 ERROR because of noise or control error. SYSTEM An error occurred during the sys- •...
Page 121 • Turn the power OFF then back ON. 1102 ERROR tem control check. If the error occurs again, contact your (SYSTEM 2) Yaskawa representative. SYSTEM An error occurred during the sys- • Turn the power OFF then back ON. 1103 ERROR tem event data control check.
Page 122 Cause Remedy Number Code The linear servo float does not sup- Contact your Yaskawa representative. port the manipulator type specified in the RC parameter at calculation for servo-float-related parameters. The manipulator (B-axis) passed Correct the job so that the manipulator (B-...
Page 123 ERROR If the error occurs again, contact your The sequence was untimely exe- (SERVO) cuted in the segment_E process Yaskawa representative. although it was not the execution timing. The sequence was untimely exe- cuted in the segment_OPT1 pro- cess although it was not the execution timing.
Page 124 1105 ERROR If the error occurs again, contact your the scheduling table. (SERVO) Yaskawa representative. The segment_OPT3 process did not complete within the time set on the scheduling table. The segment clock in the ROM for spot welding is different from the specified value.
Page 125 1105 ERROR If the error occurs again, contact your group change is ON. (SERVO) Yaskawa representative. The servo power supply of the axis for group change is ON. An error occurred in motor control mode switching process. The observer and collision detec-...
Page 126 • Turn the power OFF then back ON. nal reading from micro program. If the error occurs again, contact your ∗ : axis No.) Yaskawa representative. SYSTEM ∗ 1105 ERROR The mechanical brake remains...
Page 127 8.3 Alarm Message List Alarm Message List Alarm Message Cause Remedy Number Code 1209 EXTERNAL WDT 0000_ Defective watchdog timer circuit Replace the NIF circuit board. ∗∗ BROKEN that checks the safety circuit (NIF01) 0000_0001: 1 signal (PLD1) error 0000_0010: 2 signal (PLD1) error 1210 SERIAL COM- 0000_...
Page 128 0000_ The emergency stop button PBESP • Confirm that the cable is not short-circuited. ∗∗ STICKING of the NX100 front door is melted • Replace if necessary. and stuck. 0000_0001: 1 signal (PLD1) error 0000_0010: 2 signal (PLD2) error 1215...
Page 129 An error occurred in the FTP server 1221 If the error occurs again, contact your RESET ERROR task creating process of the Ehter- Yaskawa representative. net function. An error occurred in the FTP client task creating process of the Ehter- net function.
Page 130 • Turn the power OFF then back ON. cess of the Ethernet function. If the error occurs again, contact your An error occurred in the DNS Yaskawa representative. resolver initialization process of the Ethernet function. An error occurred in the DNS...
Page 131 COMMUNICA- cooling the power supply unit. nected unit) 1302 TION ERROR If the error occurs again, contact your ∗∗ The received buffer of JL080 is (SERVO I/O) Yaskawa representative. incorrect. ∗∗ : station number of the con- nected unit) 8-27...
Page 132 • Turn the power OFF then back ON. ERROR metic process or parameter arith- If the error occurs again, contact your (SERVO) metic process. Yaskawa representative. The data [X ] indicates the gen- eration process. 10000: Observer control 20000: High-precision path...
Page 133 • Turn the power OFF then back ON after ∗ 1343 TION ERROR Command timeout cooling the power supply unit. ∗ (CONVERTER) : converter No.) If the error occurs again, contact your Yaskawa representative. ∗ Sent buffer FULL ∗ : converter No.) 8-29...
Page 134 TION ERROR Error code received cooling the power supply unit. ∗ (CONVERTER) : converter No.) If the error occurs again, contact your Yaskawa representative. ∗ Received command error ∗ : converter No.) 1345 SAFETY CIR- Unmatched signal was detected in •...
Page 135 An error was detected in bit shifting • Turn the power OFF then back ON. RECTION compensation. If the error occurs again, contact your FAILED Yaskawa representative. 1355 SERIAL ENC Encoder multi-turn limit quantity • Turn the power OFF then back ON. MULTITURN...
Page 136 Amplifier overheated. • Turn the power OFF then back ON after (AMPLIFIER) cooling the amplifier. If the error occurs again, contact your Yaskawa representative. 1515 SON_OUT SON_OUT relay sticking is sent • Turn the power OFF then back ON. RELAY STICK- from the TU circuit board.
Page 137 8.3 Alarm Message List Alarm Message List Alarm Message Cause Remedy Number Code 1538 INCR ENCODER Initial pulse of incremental encod- • Turn the power OFF then back ON. INIT PULSE ERR ers is incorrect. • Correct the encoder connection. (SV2) •...
Page 138 8.3 Alarm Message List Alarm Message List Alarm Message Cause Remedy Number Code 1554 OVER CUR- A ground fault along the motor • Turn the power OFF then back ON. RENT (SERVO2) power line, interphase short-circuit- • Check if a ground fault has not occurred in ing, motor error, or SERVOPACK the U-, V-, and W-phase of motor power error is suspected.
Page 139 8.3 Alarm Message List Alarm Message List Alarm Message Cause Remedy Number Code 1566 ENCODER Communication with the encoder is • Turn the power OFF then back ON. ECHO BACK incorrect. • Correct the encoder connection. ERROR • Check for noise. (SERVO2) •...
Page 140 8.3 Alarm Message List Alarm Message List Alarm Message Cause Remedy Number Code 1594 MONITOR PLD Error between WDTs was detected • Turn the power OFF then back ON. ERROR 3 in TU. If the error occurs again, replace the TU cir- (SERVO I/O) cuit board.
Page 141 8.3 Alarm Message List Alarm Message List Alarm Message Cause Remedy Number Code 4014 MEMORY An error was detected at memory Initialize the file for calibration between ERROR (ROBOT check. manipulators in the maintenance mode, and CARIB FILE) • The memory for the file for calibra- then load the file for calibration between tion between manipulators is manipulators saved in the external memory...
Page 142 8.3 Alarm Message List Alarm Message List Alarm Message Cause Remedy Number Code 4036 MEMORY An error was detected at memory Initialize the wear amount file in the mainte- ERROR check. nance mode, and then load the wear amount (WEARING FILE) •...
Page 143 8.3 Alarm Message List Alarm Message List Alarm Message Cause Remedy Number Code 4049 MEMORY An error was detected at memory Initialize the painting amount correction file in ERROR check. the maintenance mode, and then load the (PASTE QUAN • The memory for the painting painting amount correction file saved in the COMPENSA- amount correction file is dam-...
Page 144 8.3 Alarm Message List Alarm Message List Alarm Message Cause Remedy Number Code 4063 MEMORY An error was detected at memory Initialize the conveyor condition auxiliary file ERROR check. in the maintenance mode, and then load the (CONVEYOR • The memory for the conveyor con- conveyor condition auxiliary file saved in the COND SUPP.) dition auxiliary file is damaged.
Page 145 • Check the communications cable for the I/O 0000_0011: External 24 V power module supply error If the error occurs again, contact your Yaskawa representative. 4110 SHOCK SEN- The shock sensor activated. Remove the cause of shock sensor activa- SOR ACTIVA- tion.
Page 146 4116 TRANSMISSION An error occurred during data trans- If the error occurs again, contact your SYSTEM mission. Yaskawa representative. ERROR 4117 BRAKE POWER The power for brake is not output. • Verify the brake wiring. If the fuse is blown,...
Page 147 X Servo board • The cooling fan 1 needs to be replaced. 1: Servo board1 (SV#1) Contact your Yaskawa representative. 2: Servo board2 (SV#2) 3: Servo board3 (SV#3) 4: Servo board4 (SV#4) Y Power-ON unit...
Page 148 ON. An error occurred in the data size If the error occurs again, contact your written to PCI of the Ethernet funci- Yaskawa representative. ton. An error occurred when the request to write PCI data was received in the Ethernet function.
Page 149 Ether- back ON. net function. If the error occurs again, contact your Yaskawa representative. An error occurred in the creation of receiving socket during the UDP process of the Ethernet function. An error occurred in the creation of...
Page 150 TOYOPUC is in stopped state. Use the PCwin, etc. to run the TOYOPUC, TOYOPUC RUN 4135 then reset the alarm for the NX100, or turn STOP ON the power supply again. The PCI bus state of the TOYO- PUC turns to "ER".
Page 151 • Verify the SNTP related settings. tion. If the error occurs again, contact your The SNTP process of the Ethernet Yaskawa representative. function was not successfully com- pleted. The name resolution error occurred • Set a correct IP address for the SNTP in the SNTP process of the Ether- server.
Page 152 • Turn the power OFF then back ON. number of the accessed job. If the error occurs again, contact your • An error occurred in step number Yaskawa representative. of the accessed job. • A job specified at job search did not exist in the memory.
Page 153 • Turn the power OFF then back ON. If the error occurs again, contact your • A job specified at job search did Yaskawa representative. not exist in the memory. • There was an instruction that did Check the NCP01 and NCP02 software ver- not exist in a job because of sions before/after updating.
Page 154 SYSTEM If the error occurs again, contact your • Position data control is not initial- 4203 ERROR (POSI- Yaskawa representative. ized. TION DATA) • The number of axes for the control groups exceeded the limit. • An error occurred in exclusive control.
Page 155 SYSTEM If the error occurs again, contact your • The number of axes for the control 4204 ERROR (POSI- Yaskawa representative. groups exceeded the limit. TION DATA) • An error occurred in exclusive control. • An error occurred in exceptional control.
Page 156 If the error occurs again, contact your (MOTION) • Error in the parameter to prepare Yaskawa representative. the speed data table • Error in the parameter to prepare the global-variable control table • Error in the parameter to prepare the axis control table •...
Page 157 • No data link added to the com- If the error occurs again, contact your (MOTION) mand Yaskawa representative. • Setting status error of the user coordinates file • Previous path data reference error • Target position preparation error in arc-retry shift motion mode •...
Page 158 4207 ERROR If the error occurs again, contact your setting parameter error (MOTION) Yaskawa representative. • Job argument over • Job argument stack overflow • Job argument stack underflow • Designation error of the fetched feedback pulse area at prepara- tion of current value •...
Page 159 4207 ERROR If the error occurs again, contact your (MOTION) • Queue operation error for WORK Yaskawa representative. ID conveyor (data length too long) • Queue operation error for WORK IN/OUT checking conveyor (at ENQUE) • Queue operation error for WORK...
Page 160 • Turn the power OFF then back ON. 4207 ERROR instruction If the error occurs again, contact your (MOTION) Yaskawa representative. • No xth-line move instruction exists where the master control group belongs. • Marking error for WORK ID con- veyor queue (empty queue) •...
Page 161 • Turn the power OFF then back ON. 4207 ERROR executed. If the error occurs again, contact your (MOTION) Yaskawa representative. • Null pointer assignment detected • Function or other processing parameter error 1000 • System clock (RTC) setting error 1001 •...
Page 162 • Reset the alarm, and then try again. SYSTEM 4208 If the error occurs again, contact your ERROR (ARITH) • Zero division occurred at observer Yaskawa representative. operation. • Processing error in optimized acceleration/deceleration control • Dynamic model arithmetic error • Speed limit control error (exces- sive moment of gravity) •...
Page 163 • Reset the alarm, and then try again. • No master-group is designated at If the error occurs again, contact your preparation of master-tool user Yaskawa representative. coordinates. • Gauging function error (command designation error) • A coordinated motion was...
Page 164 4210 ERROR If the error occurs again, contact your ified local variable. (Local variable) Yaskawa representative. • An error occurred when memory area for local variable was released. • An error occurred when memory area for local variable was regis- tered.
Page 165 For the factor , register the position of the JOB DATA SIMPLIFIED RESTO- corresponding file again. RATION FUNCTION • If it fails in restoration, refer to "NX100 (HW0483260)". OPTIONS INSTRUCTIONS FOR JOB DATA SIMPLIFIED RESTORATION FUNC- TION (HW0483260)", and restore the file system.
Page 166 An error occurred in the conversion ERROR If the error occurs again, contact your process of DNS server address Yaskawa representative. during the network service data cre- ation process of the Ethernet func- tion. An error occurred in the acquisition...
Page 167 8.3 Alarm Message List Alarm Message List Alarm Message Cause Remedy Number Code 4230 REDUCER MON- Failed to stop the operation under • Reset the alarm, and then turn ON the ITOR OVER the HOLD STOP command. servo again. • Check the HOLD STOP. If the error occurs again, replace the servo control circuit board.
Page 168 8.3 Alarm Message List Alarm Message List Alarm Message Cause Remedy Number Code 4305 CONVERTER • No response (READY 2 signal) of • Check the wiring for the primary power sup- CIRCUIT charge completion was sent from ply of the SERVOPACK. CHARGE the converter when the servo •...
Page 169 • Turn the power OFF then back ON. ENCODER COR- serial encoder exceeded the allow- If the error occurs again, contact your RECT LIMITA- able limit. Yaskawa representative. TION OVER 4320 OVER LOAD The motor torque continuously Check the motor, board, manipulator motion...
Page 170 8.3 Alarm Message List Alarm Message List Alarm Message Cause Remedy Number Code 4323 AMPLIFIER The torque a several times as much • Check the wiring and connection for the OVER LOAD as the motor rated torque has con- motor power line, motor type, manipulator (INSTANT) tinuously been applied for a certain interference, SERVOPACK, and circuit...
Page 171 8.3 Alarm Message List Alarm Message List Alarm Message Cause Remedy Number Code 4335 EARTH FAULT Ground fault of the motor power • Check the motion connection. line occurred due to: • Remove the motor connector to check the - Motor failure conduction.
Page 172 • Turn the power OFF then back ON. POSE CONTROL of the linear servo float. If the error occurs again, contact your SPECIFICATION Yaskawa representative. ERROR 4350 LINEAR SERVO While the servo float was in execu- Check the job.
Page 173 GUN BENDING Cntrl The function of gun bending correc- • Invalidate the bending correction function. CORRECTION grp bit tion was performed to the model • Contact your Yaskawa representative. ERROR desig- which was not supported for the nation function. 4367...
Page 174 4401 TASK CONTROL (job) in SYNC specification. If the error occurs again, contact your ERROR Yaskawa representative. • An attempt was made to execute an instruction that could not be executed at line sequence execu- tion. • An exceptional error occurred in job execution process.
Page 175 ON. • Selection error of motion system If the error occurs again, contact your parameter Yaskawa representative. An internal control error occurred in a coordi- nated motion. • Designation error for master and slave • Slave designation error •...
Page 176 • Designation error of occupation 4406 CONTROL If the error occurs again, contact your control for Bank position ERROR Yaskawa representative. • Designation error of occupation control group for tracking motion • No master and slave designated for tracking motion 4407...
Page 177 4428 • The value of bank_refresh_flag(x) TROL ERROR If the error occurs again, contact your exceeded its limit. Yaskawa representative. • Bank refreshing timing error • RT-buffer setting timing error • RT-buffer tracking option error • The segment was received although the previous segment had not been sent.
Page 178 • Turn the power OFF then back ON. 4429 FIED CONTROL If the error occurs again, contact your • Control-group error for the con- GROUP Yaskawa representative. veyor prereading-calculation start point • Occupation control-group error • Control-group error for multi-layer sampling •...
Page 179 • Turn the power OFF then back ON. 4431 JHM ERROR • No job handle was found. If the error occurs again, contact your Yaskawa representative. • Job control proprietary is incor- rect. • Job control proprietary could not be changed.
Page 180 • The set data for double-precision integer-type variable (S1D param- eter) area is incorrect. • The set data for real type variable UNDEFINED (S1D parameter) area is incorrect. Needs investigation. Contact your Yaskawa 4433 GLOBAL representative. • The set data for character-string VARIABLE type variable (S1D parameter) area is incorrect.
Page 181 • If the error occurs again although no exter- nal force is applied to the manipulator, re- insert the system CPU board correctly. If the error occurs again, contact your Yaskawa representative. Data error occurred at job prereading reinter- pretation. • The token for prereading process- ing could not be obtained.
Page 182 4445 ERROR If the error occurs again, contact your • A_BANK conversion has not been Yaskawa representative. completed. • An exceptional error occurred in job execution process. The variable value exceeded the limit. The variable value exceeded the limit.
Page 183 • The coordinate control axis desig- Internal control error. If the error occurs nation for the reference point is again, contact your Yaskawa representative. WEAVING CON- 4448 different from actual control axis. TROL ERROR • The distance between the point P and the TCP could not be calcu- lated in wrist weaving.
Page 184 4450 ERROR If the error occurs again, contact your An error occurred in check for weld- Yaskawa representative. ing end condition file number. An error occurred in conveyor char- acteristic file number check. An error occurred in press charac- teristic file number check.
Page 185 • Reset the alarm, and then try again. UNDEFINED to the offline position-data prepara- If the error occurs again, contact your COMMAND tion section. Yaskawa representative. (ARITH) 4467 USER COORDI- An error occurred at user coordi- Be sure that the number of steps will be three NATES GENER- nate creation by a job.
Page 186 • Reset the alarm, and then try again. • Incorrect designation of the occu- If the error occurs again, contact your pation control group for calibration Yaskawa representative. data ROBOT • Incorrect designation of the 4468...
Page 187 • An attempt was made to change the board thickness tag data. 4477 SELECT ERROR Incorrect selection of application Needs investigation. Contact your Yaskawa (APPLICATION) • When executing a work instruc- representative. tion, the application selection parameter (parameter exclusive...
Page 188 • Reset the alarm, and then try again. PARAMETER parameter for the path control sec- If the error occurs again, contact your FILE tion. Yaskawa representative. 4488 PT frame not PT frame not completed • This alarm does not occur (No alarm data is completed used).
Page 189 CORRECTION rection amount data, does not If the error occurs again, contact your ERROR include the valid control-group for Yaskawa representative. the job. • Data unmatched between the cor- rection amount data and the job data: The valid control-group informa-...
Page 190 • Set a correct value. designated for the cubic interfer- If the error occurs again, contact your ence. An undefined coordinate Yaskawa representative. system is set. • The designation of the user coor- dinates number is incorrect. A number out of the setting range is set.
Page 191 Cause Remedy Number Code Setting error of motion control parameter If the error occurs again, contact your Yaskawa representative. • Non-robot axis observer selection error • Zero is set for the response time • Correct the parameter setting. constant. If the error occurs again, contact your Yaskawa representative.
Page 192 Y-axis data is incorrect. • The setting for the Dual-arm If the error occurs again, contact your manipulator is incorrect. Yaskawa representative. • Zero or a negative value is set in Correct the parameter setting. the FORMCUT maximum accel- eration/deceleration time parame- ter.
Page 193 8.3 Alarm Message List Alarm Message List Alarm Message Cause Remedy Number Code Setting error of motion control parameter This function cannot be used for control groups other than the robot axis. Correct the • The real-time bending correction parameter setting. function is enabled for a control- group other than robot axis.
Page 194 • Reset the alarm, and then try again. (PARALLEL limit. If the error occurs again, contact your PROCESS) • An error occurred in the multi-task Yaskawa representative. control process for the indepen- dent control function. (Sub code: Task number) 4502 SL BOARD ON- An error occurred in option board at •...
Page 195 8.3 Alarm Message List Alarm Message List Alarm Message Cause Remedy Number Code An invalid coordinate system was specified. SPECIFIED • Designation error of the H-LINK Reset the alarm, and then specify a valid 4508 ERROR type cylindrical coordinate sys- coordinate system.
Page 196 • The specified analog output port number was not allowed. 4528 SYNTAX ERROR An error occurred in the instruction • Needs investigation. Contact your Yaskawa syntax. representative. • The function and the correspond- • If replacement of the system software is...
Page 197 • Correct the job. 4529 NATED ERROR disagreed. If the error occurs again, contact your Yaskawa representative. • At full synchronization, no opera- tion request from the master was sent. • At full synchronization, the execu- • Correct the job.
Page 198 • Mail box number error 4537 BOX PROCESS- If the error occurs again, contact your • Undefined command for mail box ING ERROR Yaskawa representative. operation • OFF_MB_IFS pointer is incorrect. 4538 ROBOT AXIS The robot axis tracking could not be Correct the job.
Page 199 • Reset the alarm, and then try again. ERROR instruction execution. If the error occurs again, contact your • An MRESET instruction was exe- Yaskawa representative. cuted while no endless axis was designated. 4543 JOB CALL An error occurred at job return.
Page 200 4565 If the error occurs again, contact your • The laser cutting function (with UNMATCH Yaskawa representative. small circle cutter) is not used. • The motor gun function (for spot welding application) is not used. • The speed control function (VCON/VCOF) is not used.
Page 201 COORDINATES 4566 If the error occurs again, contact your pare the user coordinates. GENERATION Yaskawa representative. ERROR • Position data error • Setting error of the slave group for user coordinate conversion 4567...
Page 202 STRWAIT instruction. switch, and then try again. • No confirmation signal specified in It the error occurs again, contact your the stroke change confirmation Yaskawa representative. instruction was input within the set time. 4585 SERVO PART The PG power supply could not be...
Page 203 • Reset the alarm, and then try again. TROL MODE • Though a speed control mode set- If the error occurs again, contact your SETTING ting command was sent to the Yaskawa representative. ERROR servo section, but no response was received. 4592 SERVO PART An error occurred at speed control •...
Page 204 FORMCUT instruction. CUT instruction. • Change the instruction. • Needs to validate the new FORMCUT instruction. Contact your Yaskawa repre- sentative. • A form other than a circle, rectan- A form other than a circle, rectangle, and...
Page 205 POSITION DATA • The standard position data for 4597 If the error occurs again, contact your CONVERSION offline position data conversion Yaskawa representative. ERROR could not correctly be calculated. • Incorrect pulse incremental value for offline position data conver- sion •...
Page 206 POSITION DATA 4597 If the error occurs again, contact your CONVERSION • The reverse shift value could not Yaskawa representative. ERROR correctly be calculated at the offline position data conversion. • The 3D shifting value could not correctly be added at the offline position data conversion.
Page 207 • Turn the power OFF then back ON. ERROR tion. If the error occurs again, contact your The servo control processing has Yaskawa representative. not completed. 4601 UNDEFINED The motor gun characteristic file is Complete the settings for the motor gun char- GUN COND FILE not set.
Page 208 • Failed to read the memory play • Reset the alarm, and then try again. sampling data. If the error occurs again, contact your • Failed to write the memory play Yaskawa representative. sampling data. MEMORY PLAY 4610 SAMPLING • Failed to seek the memory play ERROR sampling data.
Page 209 • Set the function designation parameter. servo sealer gun motion. If the error occurs again, contact your • The function designation parame- Yaskawa representative. ter is not set. • No sealer gun axis exists at the job for which the sealer gun con- trol was attempted to be exe- •...
Page 210 8.3 Alarm Message List Alarm Message List Alarm Message Cause Remedy Number Code 4618 SHIFT INSTRUC- An internal control error occurred at Set the shift value for Y-axis only. TION EXECU- execution of the SHIFT instruction. TION ERROR • For the tool shift with Euler angle ±90 degrees, the shift value for axes other than Y-axis is set.
Page 211 • Reset the alarm, and then try again. 4625 EXECUTION OF If the error occurs again, contact your • The door is open. LOADDB INST Yaskawa representative. • The disk is write-protected. • Card controller access error • No card • Card drive information readout error •...
Page 212 8.3 Alarm Message List Alarm Message List Alarm Message Cause Remedy Number Code 4628 WRITE An error in the variable number set- Correct the written destination variable num- VARIABLE NO. ting. bers. MULTI SETTING • Duplicated usage of the written destination variable numbers.
Page 213 An internal control error occurred during the • Reset the alarm, and then try again. SYMOVJ motion. If the error occurs again, contact your Yaskawa representative. • The moving amount in the orienta- tion at the SYMOVJ motion posi- tion could not correctly be calculated.
Page 214 • Turn the power OFF then back ON after (CONVERTER) verter. cooling the power supply unit. No response from the converter. If the error occurs again, contact your Yaskawa representative. 4850 REGENERA- Disconnection of SERVOPACK • Turn the power OFF and back ON. TIVE TROUBLE regenerative resistor or failure of •...
Page 215 8.3 Alarm Message List Alarm Message List Alarm Message Cause Remedy Number Code 4855 OVERLOAD The motor is overloaded. • Turn the power OFF and back ON. (MOMENT) The motor torque has significantly • Check the settings for manipulator motion (SERVO2) exceeded the rated torque.
Page 216 4869 MECHA- The MECHATROLINK communica- • Turn the power OFF and back ON. TROLINK DATA tion data setting error. • Contact your Yaskawa representative. SET WARN- ING(SV2) 4870 MECHA- The MECHATROLINK communica- • Turn the power OFF and back ON.
Page 217 8.3 Alarm Message List Alarm Message List Alarm Message Cause Remedy Number Code 4903 CUBE/AXIS The manipulator has moved into • Check the position in the step (move INTERFER- the specified cube area 3 or the instruction) where the alarm occurred. ENCE 3 maximum or minimum value of the •...
Page 218 8.3 Alarm Message List Alarm Message List Alarm Message Cause Remedy Number Code 4915 CUBE/AXIS The manipulator has moved into • Check the position in the step (move INTERFER- the specified cube area 15 or the instruction) where the alarm occurred. ENCE 15 maximum or minimum value of the •...
Page 219 9.1 Error Message List 9 Error Error Message List Error warns the operator not to advance to the next operation caused by a wrong operation or the access method when using the programming pendant or an external equipment (com- puter, PLC, etc.). When an error occurs, confirm the content of the error then release the error.
Page 220 9.1 Error Message List 9.1.1 System and General Operation Error No. Data Error Message Contents Turn off servo power and perform cor- It cannot be operated while servo rective action power supply is ON. Depress TEACH Out of specified operation mode Illegal setting for number of variables Parameter setting error Undefined robot position variables...
Page 221 9.1 Error Message List Error No. Data Error Message Contents Cannot operate Master JOB Cannot initialize Position not checked Second home position was not checked. Can specify servo off by safety relay Time could not be measured Time could not be measured for TRT function.
Page 222 9.1 Error Message List Error No. Data Error Message Contents The group axis of designation is not con- nection Servo power supply is limited Modification range over Undefined conveyor calibration data Forced pressure signal ON Negative correction distance I/O axis mode requesting ERRSVCPU signal error ERRCPU signal error...
Page 223 9.1 Error Message List 9.1.2 Editing Error No. Data Error Message Contents 1010 EDIT LOCK mode 1020 Enter correct value 1030 Unauthorized ID No. 1050 Enter correct date 1060 Enter correct clock 1070 Enter an ID number in 4-8 figures 1080 Negative value can’t be set 9.1.3...
Page 224 9.1 Error Message List Error No. Data Error Message Contents Unmatched number of parentheses in 2250 equation 2260 Wrong group axis selection Cannot insert any more instruction in 2270 ∗ JOB memory is full Lack of position file memories Lack of JOB registering memories 2280 Lack of instruction file memories Lack of memory pool...
Page 225 9.1 Error Message List Error No. Data Error Message Contents Cannot teach JOB without group-axis 2300 specification ∗ Same label exists 2310 Line No. 2340 Pasted data not found 2360 Cannot create editing area Cannot cut/copy NOP and END 2370 instructions 2390 Wrong group axis selection...
Page 226 9.1 Error Message List Error No. Data Error Message Contents 2640 Incorrect JOB name 2670 Undefined target JOB Relative job can’t be shifted with pulse 2710 type 2730 Cannot use robot macro JOB 2740 Cannot use concurrent macro JOB Cannot use JOB with group-axis speci- 2750 fication Cannot insert/modify/delete for group...
Page 227 9.1 Error Message List 9.1.4 External Memory Equipment Error No. Data Error Message Contents 3010 Floppy disk drive cable not connected Floppy disk not inserted into floppy 3020 disk drive 3030 Floppy disk protection is ON File not saved on floppy disk or Com- 3040 pact Flash File saved on floppy disk or Compact...
Page 228 9.1 Error Message List Error No. Data Error Message Contents 3140 Wrong pseudo instruction ∗ Concurrent I/O record error Format error Ladder program is too long. Exceed the range of the data 3150 Specification error of channel No. Specification error of relay No. Timer value error Specification error of timer No.
Page 229 9.1 Error Message List Error No. Data Error Message Contents ∗ Error in JOB data record Record on the number of position data (NPOS) is wrong for the for- mat. Record on the user coordinate No. (USER) is wrong for the format. Record on the tool No.
Page 230 9.1 Error Message List Error No. Data Error Message Contents No instruction Invalid instruction Invalid tag Invalid character Undefined intermediate code Intermediate code shortage Syntax stack overflow Syntax stack underflow Array type tag uncompleted Tag [ARRAY] Element type tag uncompleted Tag [ELEMENT] Macro JOB unregistered Input format error...
Page 231 9.1 Error Message List Error No. Data Error Message Contents BINARY/HEXADECIMAL WORD TYPE data error DOUBLE PRECISION INTEGER TYPE, DECIMAL DWORD TYPE data error BINARY/HEXADECIMAL WORD TYPE data error REAL TYPE data error LADDER SPECIAL TYPE data error 3220 JCL text Invalid text LABEL NAME data error JOB NAME data error...
Page 232 9.1 Error Message List Error No. Data Error Message Contents ∗ Cannot backup Compact Flash 3460 Insufficient Compact Flash memory. Not accessible to Compact Flash. 3470 Database not found 3480 Database access error 3490 Same database exists 3500 Check Compact Flash insertion Cannot delete folder.
Page 233 9.1 Error Message List 9.1.5 Concurrent I/O Error No. Data Error Message Contents ∗ Illegal relay No. 4010 Line No. ∗ Illegal instruction 4030 Line No. Relay/register No. duplicated in OUT/ Multiple outputs are instructed to ∗ GOUT or arithmetic instruction the relay or register.
Page 234 9.1 Error Message List 9.1.6 Maintenance Mode Error No. Data Error Message Contents 8010 Too many axes 8020 Too many I/O points 8030 Too many boards (XFB01B (MASTER)) 8031 Too many boards (MSC01B) Memory error (ControlNet output condi- 8040 tion) 8041 Memory error (UNIWIRE CONNECT DAT 8050...
Page 235 10.1 LED Indicator on NCP 01 Circuit Board 10 LED Indicator on Circuit Board 10.1 LED Indicator on NCP 01 Circuit Board The LED indicators: LED0/LED1 on the NCP01 circuit board show the statuses as in the fol- lowing table. The LED indicators show the operating statuses for the single NCP01 circuit board.
Page 236 10.2 LED Indicator on Robot I/F Unit 10.2 LED Indicator on Robot I/F Unit The 7-segment LED indicator and battery alarm LED lamp are located on the robot I/F unit (JZNC-NIF01 ). See " 10.3 7 SEG-LED Indicator " for details displayed by the 7-segment LED indicator. The battery alarm LED lamp is lit when the battery runs out.
Page 237 10.3 7 SEG-LED Indicator 10.3 7 SEG-LED Indicator The following tables show the operating statues for JANCD-NIF01/SGDR-AXA01/SGDR- AXA02/JANCD-NCP02. The operating statuses are indicated by 7 SEG-LED. [Normal Indication] NX100 Status NIF Circuit Board AXA Circuit Board NCP02 Circuit Board Right after applying All 7-SEG indicators light up.
Page 238 Waits for CERF communication synchronization. Sends the start-up request of on-line system. The on-line system has started. (Starts up the initialization task.) Processes the NX100 setup completion. (Servo ON enabled) Alarm occurs at the NX100 setup. The maintenance system is starting up.
Page 239 10.3 7 SEG-LED Indicator AXA01/AXA02 All Lit The power has been turned ON. The booting program has started. (ROM/RAM/FP register check) Starts the booting system. (Completes initializations of various kinds.) Completes the preparation for receiving the system program. The system program has been received. (Waits for the request of system change.) The system program has started.
Page 240 10.3 7 SEG-LED Indicator 7 SEG-LED Indicator Status (4 digit-indication) of Each Unit at Error Occurrence NIF01 0000 Arithmetic error 0001 Debug 0002 0003 Breakpoint 0004 Overflow 0005 Out of BOUND 0006 Invalid operation code 0007 Device disabled 0008 Double fault 0009 Coprocessor segment overrun 000A...
Page 241 10.3 7 SEG-LED Indicator AXA01/AXA02 0010 ROM error in the boot section 0020 RAM error 0030 FP register error 0040 On-line communications command error 0100 Reset exception 0200 Machine check exception 0210 WDT error 0300 Data access error 0400 Instruction access exception 0500 0600 Alignment exception...
Page 242 10.3 7 SEG-LED Indicator AXA01/AXA02 2800 Undefined exception 2900 Undefined exception 2A00 Undefined exception 2B00 Undefined exception 2C00 Undefined exception 2D00 Undefined exception 2E00 Undefined exception 2F00 Undefined exception 3010 Receiving data size error 3020 Receiving data sum error 3030 Receiving data write address error 3040 All receiving data sum error...
Page 243 10.3 7 SEG-LED Indicator NCP02 1500 Undefined exception 1600 Undefined exception 1700 Undefined exception 1800 Undefined exception 1900 Undefined exception 1A00 Undefined exception 1B00 Undefined exception 1C00 Undefined exception 1D00 Undefined exception 1E00 Undefined exception 1F00 Undefined exception 2000 Undefined exception 2100 Undefined exception 2200...
Page 244 5-13 ..hotline connector for programming pendant ............ converter 5-16 ......how to replace converter 5-11 ..converter control signal connector 5-10, 5-11 ......converter signal connector ......cooling fan (JZNC-NZU01) cooling fan construction (medium- or ........large-capacity NX100) Index-1...
Page 245 I/F circuit board 5-15 ....robot I/F unit (JZNC-NIF01 ) 5-2, 5-15 ......... robot I/F unit fuse 5-15 ........... NX100 controller .......... NX100 parts list 5-13 ..........security mode ..........security system servo control circuit board ........(SGDR-AXA01A) 5-2, 5-13 ........
Page 246 ......SPECIFIC OUTPUT window ..........Specific Input ....SPECIFIC INPUT simple window ......SPECIFIC INPUT window ..........Specific Output ....SPECIFIC OUTPUT simple window ......SPECIFIC OUTPUT window ........SPEED DEVIATION 7-26 ..........SPEED INST 7-26 ........supplied parts list 5-18 ............
Page 247 MAINTENANCE MANUAL HEAD OFFICE 2-1 Kurosaki-Shiroishi, Yahatanishi-ku, Kitakyusyu, Fukuoka, 806-0004, Japan Phone +81-93-645-7745 Fax +81-93-645-7746 YASKAWA America Inc. MOTOMAN Robotics Division 805 Liberty Lane, West Carrollton, OH 45449, U.S.A. Phone +1-937-847-6200 Fax +1-937-847-6277 YASKAWA Nordic AB Franska vagen 10, Box 4004, 390 04 Kalmar, Sweden...

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