Motoman MRC Troubleshooting

YASNAC MRC ver. 3.
144B
Trouble Shooting Guide, YASNAC MRC
MOTOMAN ROBOTICS AB
a subsidiary of YASKAWA Electric Corporation
MOTOMAN
ROBOTICS
Trouble Shooting YASNAC MRC
AB Page: 1
Alarm 0010 CPU Board Insertion Error
Alarm Occurrence
Turn power OFF,

and then ON again.
Alarm
NO re-occurs? YES
Resume use Remove the SV board corresponding

to the display, and then re-install it
Alarm
YES re-occurs? NO
Remove the MCP01 Resume use

board, and then re-install it
Alarm
NO re-occurs? YES
Resume use Replace the ROM of the board

corresponding to the display
Alarm
NO re-occurs? YES
ROM failure Replace the board

Alarm
YES re-occurs? NO
Board failure
Replace all boards
Alarm
NO re-occurs? YES
Board failure Contact

MOTOMAN-service
Skapad: 98-10-09 Ändrad: 98-11-26 Filnamn: T:\M-ROBOT\ENGELSK\TROUBLE_SHOOTING.FM

Trouble Shooting YASNAC MRC MOTOMAN
ROBOTICS
Page: 2 AB
Alarm 0020 CPU Communication Error
Alarm Occurrence
Turn power OFF,

and then ON again.
Alarm
NO re-occurs? YES

Alarm
YES re-occurs? NO
Remove all boards, Resume use

and then re-install them
Alarm
NO re-occurs? YES

Alarm
NO re-occurs? YES

Alarm
YES re-occurs? NO
Board failure
Replace all boards
Alarm
NO re-occurs? YES

MOTOMAN-service

MOTOMAN
ROBOTICS
AB Page: 3
Alarm 0030 ROM Error
Alarm Occurrence
Turn power OFF,

and then ON again.
Alarm
NO re-occurs? YES

Alarm
NO re-occurs? YES

Alarm
YES re-occurs? NO
Contact Board failure

MOTOMAN-service

ROBOTICS
Page: 4 AB
Alarm 0040 RAM Error (local)
Alarm Occurrence
Turn power OFF,

and then ON again.
Alarm
NO re-occurs? YES
Resume use Remove the board corresponding

Alarm
NO re-occurs? YES
Resume use Replace the board

Alarm
YES re-occurs? NO

MOTOMAN-service

MOTOMAN
ROBOTICS
AB Page: 5
Alarm 0050 RTC Error)
Alarm Occurrence
Turn power OFF,

and then ON again.
Alarm
NO re-occurs? YES

Alarm
NO re-occurs? YES

Alarm
YES re-occurs? NO

MOTOMAN-service

ROBOTICS
Page: 6 AB
Alarm 0060 RAM Error (A-bus Common)
Alarm Occurrence
Turn power OFF,

and then ON again.
Alarm
NO re-occurs? YES

Alarm
YES re-occurs? NO
Remove all boards Resume use

and re-install again
Alarm
NO re-occurs? YES

Alarm
YES re-occurs? NO
Replace all boards Board failure
Alarm
NO re-occurs? YES

MOTOMAN-service

MOTOMAN
ROBOTICS
AB Page: 7
Alarm 0070 RAM Error (D-Bus 2-Port)
Alarm Occurrence
Turn power OFF,

and then ON again.
Alarm
NO re-occurs? YES

Alarm
YES re-occurs? NO
Remove all boards Resume use

Alarm
NO re-occurs? YES
Resume use Replace the SV board

Alarm
NO re-occurs? YES
SV board failure Replace the MCP02 board
Alarm
YES re-occurs? NO
Replace all boards Board failure
Alarm
NO re-occurs? YES

MOTOMAN-service

ROBOTICS
Page: 8 AB
Alarm 0080 RAM Error (S-Bus 2-Port)
Alarm Occurrence
Turn power OFF,

and then ON again.
Alarm
NO re-occurs? YES

Alarm
YES re-occurs? NO
Remove MCP01 Resume use

Alarm
NO re-occurs? YES

YES Alarm
re-occurs? NO
Replace the MCP01 board Board failure
Alarm
NO re-occurs? YES
MCP01 board failure Contact

MOTOMAN-service

MOTOMAN
ROBOTICS
AB Page: 9
Alarm 0090 I/O Module Communication Error
Alarm Occurrence
Turn power OFF,

and then ON again.
Alarm
NO re-occurs? YES
Resume use Confirm the setting

of the I/O module
Alarm
YES re-occurs? NO
Check the wiring of the cable Resume use

between MIF01 and MBB02
Alarm
NO re-occurs? YES
Resume use Remove the I/O module corresponding

Alarm
YES re-occurs? NO
Replace the I/O module Resume use
Alarm
NO re-occurs? YES
I/O module Replace MIF01 board

failure
Alarm
YES re-occurs? NO
Contact MIF01 board failure

MOTOMAN-service

ROBOTICS
Page: 10 AB
Alarm 0100 IAMP Communication Error
Alarm Occurrence
Turn power OFF,

and then ON again.
Alarm
NO re-occurs? YES
Resume use Remove the cable connector

between the MSV board and IAMP
Alarm
YES re-occurs? NO

between MSV board and IAMP
Alarm
NO re-occurs? YES

of the servopack
Alarm NO
YES re-occurs?
Replace the servopack Resume use
Alarm
NO re-occurs? YES
Servopack failure Replace the MSV board
Alarm
YES re-occurs? NO
Contact MSV board failure

MOTOMAN-service

MOTOMAN
ROBOTICS
AB Page: 11
Alarm 0110 IAMP Parameter Modification Error
Alarm Occurrence
Turn power OFF,

and then ON again.
Alarm
NO re-occurs? YES
Resume use Remove the cable connector between

the MSV board and IAMP and re-install
Alarm
YES re-occurs? NO

Alarm
NO re-occurs? YES
Resume use Replace the servopack
Alarm
NO re-occurs? YES
Servopack failure Replace the MSV board
Alarm
YES re-occurs? NO
Contact MSV Board

MOTOMAN-service failure

ROBOTICS
Page: 12 AB
Alarm 0120 Encoder communication error
Alarm Occurrence
Turn power OFF,

and then ON again.
Alarm Remove the cable connector between

Resume use NO re-occurs? YES
the MSV board and IAMP and re-install
Remove the cable connector Alarm

between encoder and IAMP, YES re-occurs? NO
and then re-install it
Resume use
Alarm
Resume use NO re-occurs? YES
Remove the cable connector
between encoder and IAMP,
and then install to another axis
Check the cable ground Alarm

YES re-occurs? NO
between encoder and IAMP
Alarm Replace the

Cable failure NO re-occurs? servopack
YES Alarm
NO re-occurs?
Check the wiring of the cable Servopack
between MSV board and IAMP failure YES
Alarm Replace the

Cable failure NO re-occurs? MSV board
YES YES Alarm

re-occurs?
Reset the absolute Contact
encoder MOTOMAN-service NO
Replace the Alarm BSV Board

YES re-occurs? NO Resume use
motor failure
Alarm Contact
YES MOTOMAN-service
re-occurs?
NO
Motor failure

MOTOMAN
ROBOTICS
AB Page: 13
Alarm 0130 Encoder Overspeed
Alarm Occurrence
Turn power OFF,

and then ON again.
Alarm
NO re-occurs? YES
Resume use After the motor stops,

control power ON.
Alarm
YES re-occurs? NO
Reset the Resume use

absolute encoder
Alarm
NO re-occurs? YES
Resume use Replace

servo motor
Alarm
YES re-occurs? NO
Contact Motor failure

MOTOMAN-service

ROBOTICS
Page: 14 AB
Alarm 0131 Encoder Data Error
Alarm Occurrence
Turn power OFF,

and then ON again.
Alarm
NO re-occurs? YES
Resume use Reset the

absolute encoder
Alarm
NO re-occurs? YES
Resume use Replace the motor
Alarm
YES re-occurs? NO

MOTOMAN-service
Alarm 0132 Encoder Back-up Error
Alarm Occurrence
Change the battery, reset the alarm

and then set home position
Alarm
NO re-occurs? YES

absolute encoder
Alarm
NO re-occurs? YES
Alarm
YES re-occurs? NO

MOTOMAN-service

MOTOMAN
ROBOTICS
AB Page: 15
Alarm 0133 Encoder Checksum Error
Alarm Occurrence
Change the battery, reset the alarm

and then set home position.
Alarm
NO re-occurs? YES

absolute encoder
Alarm
NO re-occurs? YES
Resume use Replace

servo motor
Alarm
YES re-occurs? NO

MOTOMAN-service

ROBOTICS
Page: 16 AB
Alarm 0134 Encoder Battery Error
Alarm Occurrence
Change the battery
Alarm
NO re-occurs? YES
Resume use Check

Internal wiring
Alarm
YES re-occurs? NO
Reset the Resume use

absolute encoder
Alarm
NO re-occurs? YES
Alarm
YES re-occurs? NO

MOTOMAN-service
Alarm 0135 Encoder Overheat

Alarm Occurrence
After cooling, turn the

power ON again
Alarm
NO re-occurs? YES
Resume use Check

Internal wiring
Alarm
YES re-occurs? NO
Contact Internal wire


MOTOMAN
ROBOTICS
AB Page: 17
Alarm 0200 Fault (Parameter)
Alarm Occurrence
Turn power OFF,

and then ON again.
Alarm
NO re-occurs? YES
Resume use Contact MOTOMAN-

service before
initializing the parameter file
Alarm 0210 Fault (System Config-Data)
Alarm Occurrence
Contact MOTOMAN-
service before
initializing the parameter file
Alarm 0220 Fault (Job Management Data)
Alarm Occurrence
Turn power OFF,

and then ON agian.
Alarm
NO re-occurs? YES
Resume use Initialize the job file
Alarm
YES re-occurs? NO
Contact Job file destroyed

MOTOMAN-service

ROBOTICS
Page: 18 AB
Alarm 0230 Fault (CIO Ladder)
Alarm Occurrence
Initialize the
CIO Ladder
Alarm
NO YES
re-occurs?
CIO Ladder Contact

destroyed MOTOMAN-service
Alarm 0300 Verify Error (System Config-Data)
Alarm Occurrence
Contact MOTOMAN-
service before
initializing the system config.
Alarm 0310 Verify Error (CMOS Memory Size)
Alarm Occurrence
Confirm the
extension CMOS board
Alarm
NO re-occurs? YES
The extension CMOS Contact MOTOMAN-

board is not mounted service before

MOTOMAN
ROBOTICS
AB Page: 19
Alarm 0320 Verify Error (I/O module)
Alarm Occurrence
Remove the I/O-module that corresponds

to the display, then re-install the module
Alarm
NO re-occurs? YES

of the I/O module
Alarm
YES re-occurs? NO
Replace the I/O module Resume use

Alarm
NO re-occurs? YES
I/O module failure Contact

MOTOMAN-service
Alarm 0330 Illegal Parameter
Alarm Occurrence
Reset original
parameter value
Alarm
NO re-occurs? YES
Resume use Contact

MOTOMAN-service

ROBOTICS
Page: 20 AB
Alarm 0340 Verify Error (Servopack Type)
Alarm Occurrence
Set the parameter to match the

mounted servopack type
Alarm
NO re-occurs? YES

service before
Alarm 0350 Verify Error (Encoder Type)
Alarm Occurrence
Set the parameter to match the

mounted encoder type
Alarm
NO re-occurs? YES

service before
Alarm 0360 Verify Error (Application)
Alarm Occurrence
Contact MOTOMAN-service
before initializing the system config.
Alarm 0370 Verify Error (Sensor Function)
Alarm Occurrence
Contact MOTOMAN-service
before initializing the system config.

MOTOMAN
ROBOTICS
AB Page: 21
Alarm 0400 Parameter Transmission Error
Alarm Occurrence
Turn power OFF,

and then ON agian.
Alarm
NO re-occurs? YES

Alarm
NO re-occurs? YES
Board failure Replace

all boards
Alarm
YES re-occurs? NO

MOTOMAN-service
Alarm 0410 Mode Change Error
Alarm Occurrence
Turn power OFF,

and then ON again.
Alarm
NO re-occurs? YES
Resume use Contact

MOTOMAN-service

ROBOTICS
Page: 22 AB
Alarm 0900 - 0920 Watch Dog Timer Error
Turn power OFF,

and then ON agian. Alarm Occurrence
Alarm
re-occurs?
NO YES
Remove the board corresponding to
Resume use the display, then re-install it
Remove all boards, Alarm

then re-install them YES re-occurs?
Alarm NO
re-occurs?
NO Resume use
YES
Resume use Replace the EPROM of the board
Replace board Alarm

corresponding to the display YES re-occurs?
Alarm NO
re-occurs?
YES NO EPROM failure
Replace all Board failure

boards
Alarm
re-occurs? YES
NO
Contact
Board failure MOTOMAN-service
AL-0900 MCP02 AL-0906 MCP01 AL-0914 MSV#5

AL-0901 AL-0907 MIF01 AL-0915 MSV#6
AL-0902 MSL#1 AL-0910 MSV#1 AL-0916 MSV#7
AL-0903 MSL#2 AL-0911 MSV#2 AL-0917
AL-0904 AL-0912 MSV#3 AL-0920 MIF02
AL-0905 AL-0913 MSV#3

MOTOMAN
ROBOTICS
AB Page: 23
Alarm 0930 - 0937 Access Error
Turn power OFF,

Alarm
re-occurs?
NO YES

Alarm NO
re-occurs?
NO Resume use
YES
Replace board Alarm

Alarm NO
re-occurs?

boards
Alarm
re-occurs? YES
NO
Contact
AL-0930 MIF02 AL-0933 MSL#2 AL-0936 MCP01

AL-0931 AL-0934 AL-0937 MIF01
AL-0932 MSL#1 AL-0935

ROBOTICS
Page: 24 AB
Alarm 0940 - 0947 A-Bus Error
Turn power OFF,

Alarm
re-occurs?
NO YES

Alarm NO
re-occurs?
NO Resume use
YES
Replace board Alarm

Alarm NO
re-occurs?

boards
Alarm
re-occurs? YES
NO
Contact
AL-0940 MIF02 AL-0943 MSL#2 AL-0946 MCP01

AL-0941 AL-0944 AL-0947 MIF01
AL-0942 MSL#1 AL-0945

MOTOMAN
ROBOTICS
AB Page: 25
Alarm 0999 NMI Error
Alarm Occurrence
Turn power OFF,

and then ON agian.
Alarm
re-occurs?
NO YES
Resume use Remove all boards

and then re-install them
Alarm
re-occurs?
YES NO
Replace EPROM Resume use

of all boards
Alarm
re-occurs?
NO
EPROM failure Replace

all boards
Alarm
re-occurs?
YES NO

MOTOMAN-service

ROBOTICS
Page: 26 AB
Alarm 1010 ROM Error (Syscon)
Alarm Occurrence
Turn power OFF,

and then ON agian.
Alarm
re-occurs?
NO YES
Resume use Remove the EPROM board on the

MCP01 board and then re-install them
Alarm
re-occurs?
YES NO
Replace EPROM board Make sure connector has

on the MCP01 board no loose connections,
and then resume use
Alarm
re-occurs?
NO
MMM02 failure Replace MCP01

board
Alarm
re-occurs?
YES NO

MOTOMAN-service

MOTOMAN
ROBOTICS
AB Page: 27
Alarm 1020 ROM Error (Motion)
Alarm Occurrence
Turn power OFF,

and then ON agian.
Alarm
re-occurs?
NO YES

MCP02 board and then re-install them
Alarm
re-occurs?
YES NO

and then resume use
Alarm
re-occurs?
NO
MMM04 failure Replace MCP02

board
Alarm
re-occurs?
YES NO

MOTOMAN-service

ROBOTICS
Page: 28 AB
Alarm 1030 ROM Error (CIO)
Alarm Occurrence
Turn power OFF,

and then ON agian.
Alarm
re-occurs?
NO YES

MIF01 board and then re-install them
Alarm
re-occurs?
YES NO

and then resume use
Alarm
re-occurs?
NO
EPROM failure Replace MIF01

board
Alarm
re-occurs?
YES NO

MOTOMAN-service

MOTOMAN
ROBOTICS
AB Page: 29
Alarm 1040 System Error (Syscon)
Alarm Occurrence
Turn power OFF,

and then ON agian.
Alarm
re-occurs?
NO YES
Resume use Replace MCP01

board
Alarm
re-occurs?
YES NO

MOTOMAN-service
1 6 Multi Task Specification Error

2 Motion Interrupt Not Done 7 Lack of Command Saving Area
3 Syscon Error 8 EMS Error
4 Command Processing 9
5 Undefined Interrupt 10 SL Interrupt Not Done

ROBOTICS
Page: 30 AB
Alarm 1050 ROM Error (Sensor)
Alarm Occurrence
Turn power OFF,

and then ON agian.
Alarm
re-occurs?
NO YES

MSL board and then re-install it
Alarm
re-occurs?
YES NO

on the MSL board no loose connections,
and then resume use
Alarm
re-occurs?
NO YES
EPROM failure Replace MSL board

Alarm
re-occurs?
YES NO

MOTOMAN-service

MOTOMAN
ROBOTICS
AB Page: 31
Alarm 1060 System Error (CIO)
Alarm Occurrence
Turn power OFF,

and then ON agian.
Alarm
re-occurs?
NO YES
Resume use Replace MIF01

board
Alarm
re-occurs?
YES NO

MOTOMAN-service
01 05 Command Error SYSCONCIO

02 06 System Error
04 FA Communication Bus Error

ROBOTICS
Page: 32 AB
Alarm 1070 Fault (Parameter)
Alarm Occurrence
Turn power OFF,

and then ON agian.
Alarm
re-occurs?
NO YES
Resume use Initialize

the parameter file
Alarm
re-occurs?
YES NO
Contact MOTOMAN- Board failure

service before
0 RC parameters 8 AP parameters
1 RO parameters 9 RS parameters
2 SV paramerters 10 SP parameters
3 SVM parameters 11 CM parameters
4 SC parameters 12 SE parameters
5 SD parameters 13 VC parameters
6 CIO parameters 14 RSM parameters
7 FD parameters

MOTOMAN
ROBOTICS
AB Page: 33
Alarm 1080 Fault (Job data)
Alarm Occurrence
Turn power OFF,

and then ON agian.
Alarm
re-occurs?
NO YES
Resume use Initialize

the job file
Alarm
re-occurs?
YES NO
Contact MOTOMAN- Job file destroyed

service before
Alarm 1090 File Failure (Motion)
Alarm Occurrence
Turn power OFF,

and then ON agian.
Alarm
re-occurs?
NO YES

service before

ROBOTICS
Page: 34 AB
Alarm 1100 File Total Checksum Error (Motion)
Turn power OFF,

Alarm
re-occurs?
NO YES

board
Alarm
re-occurs?
YES NO

MOTOMAN-service
Alarm 1110 Set-up Process Error (Syscon)
Turn power OFF,

Alarm
re-occurs?
NO YES

board
Alarm
re-occurs?
YES NO

MOTOMAN-service
1 Motion Section Set-up incomplete

MOTOMAN
ROBOTICS
AB Page: 35
Alarm 1120 Wrong Segment Clock Value
Turn power OFF,

Alarm
re-occurs?
NO YES
Resume use Reset phase offset

data file
Alarm
re-occurs?
YES NO
Contact CMOS file breakdown

MOTOMAN-service
Alarm 1130 MMM Error
Turn power OFF,

Alarm
re-occurs?
NO YES
Resume use Contact

MOTOMAN-service
0 3 Process Not Set

1 Process Definition Table Not Set 4 Process Control Code Not Set
2 Entry Table Overflow

ROBOTICS
Page: 36 AB
Alarm 1140 MMM Error
Alarm Occurrence
Turn power OFF,

and then ON agian.
Alarm
re-occurs?
NO YES
Resume use Contact

MOTOMAN-service
Alarm 1150 Fault
Alarm Occurrence
Turn power OFF,

and then ON agian.
Alarm
re-occurs?
NO YES
Resume use Contact

MOTOMAN-service

MOTOMAN
ROBOTICS
AB Page: 37
Alarm 1160 High Temperature (in Control Box)
Alarm Occurrence
Turn power OFF,

and then ON agian.
Alarm
re-occurs?
NO YES
Resume use Turn the power off, let the controller

cool inside, and then turn power on again
Alarm
re-occurs?
YES NO
Check movement of cooling fan Resume use
Alarm
re-occurs?
NO YES
Check wiring cooling fan
Faulty?
NO YES
Replace fan Contact

MOTOMAN-service
Replace power unit Alarm
YES re-occurs?
(CPS-18F)
NO
Alarm
re-occurs? Fan failure
NO
YES Power unit failure
Contact
MOTOMAN-service

ROBOTICS
Page: 38 AB
Alarm 1170 Overrun Limit Switch Released
Alarm Occurrence
Turn power OFF,

and then ON agian.
Alarm
re-occurs?
NO YES
Resume use Check the

OVERRUN RECOVERY
switch
Alarm
re-occurs?
YES NO
Contact Switch failure

MOTOMAN-service

MOTOMAN
ROBOTICS
AB Page: 39
Alarm 1180 - 1186 Servo Monitor System Error
Alarm Occurrence
Turn power OFF,

and then ON agian.
Alarm
re-occurs?
NO YES
Resume use Replace MSV board

Alarm
re-occurs?
YES NO
Board failure
Replace MCP01 board
Alarm
re-occurs?
NO YES
Board failure
Replace MCP02 board
Alarm
re-occurs?
YES NO

MOTOMAN-service
AL-1180 MSV#1 AL-1183 MSV#4 AL-1186 MSV#7

AL-1181 MSV#2 AL-1184 MSV#5
AL-1182 MSV#3 AL-1185 MSV#6

ROBOTICS
Page: 40 AB
Alarm 1190 - 1196 Servo System Error
Alarm Occurrence
Turn power OFF,

and then ON agian.
Alarm
re-occurs?
NO YES
Resume use Replace MSV board

Alarm
re-occurs?
YES NO
Board failure
Replace MCP01 board
Alarm
re-occurs?
NO YES
Board failure
Replace MCP02 board
Alarm
re-occurs?
YES NO

MOTOMAN-service

AL-1191 MSV#2 AL-1194 MSV#5
AL-1192 MSV#3 AL-1195 MSV#6

MOTOMAN
ROBOTICS
AB Page: 41
Alarm 1200 - 1206 Overcurrent
Alarm Occurrence
Condition
At control at the time At servo
power ON power ON
of alarm?
Replace servopack
corresponding to the display Running
Check first
grounding terminal
Alarm
re-occurs?
Go to
NO point Faulty
YES A grounding
Contact Servopack NO YES

Replace servopack
corresponding
to the display
B
Check second Alarm

ground terminal re-occurs?
Faulty NO YES
grounding
YES NO Servopack
failure
Check
internal wiring Replace motor Contact
corresponding MOTOMAN-service
Alarm to the display
re-occurs?
Alarm
NO YES re-occurs?
NO
Internal wiring YES
failure Servomotor
failure
Contact
MOTOMAN-service

ROBOTICS
Page: 42 AB
Alarm 1200 - 1206 Overcurrent (...continued)
Check movement of
servopack cooling fan
Abnormal?
YES NO
Replace Check
cooling fan robot load
Alarm Fan Load

re-occurs? NO failure condition?
OK
YES Overload
Alarm
Contact occurs at a Decrease
MOTOMAN-service specific point? weight
NO
YES
Check first
grounding terminal
Faulty Go to
YES grounding NO point
B
Replace servopack
corresponding
to the display
Alarm Servopack
re-occurs? NO failure
YES Contact
MOTOMAN-service

AL-1201 MSV#2 AL-1204 MSV#5
AL-1202 MSV#3 AL-1205 MSV#6

MOTOMAN
ROBOTICS
AB Page: 43
Alarm 1210 - 1216 MCCB Tripped
Alarm Occurrence
At control
power ON
Condition
At servo
at the time power ON
Turn ON the of alarm?
MCCB
Alarm
re-occurs? NO Running
Check first
grounding terminal
YES Resume use
Go to
Replace servopack point Faulty
corresponding to the display A grounding
Alarm Servopack NO YES

Replace servopack
YES corresponding
to the display
B
Contact
MOTOMAN Check second Alarm
service ground terminal re-occurs?
Faulty NO YES
grounding
YES NO Servopack
failure
Replace
re-occurs?
Alarm
NO YES re-occurs?
NO
Internal wiring YES
failure Motor failure
Contact
MOTOMAN-service

ROBOTICS
Page: 44 AB
Alarm 1210 - 1216 MCCB Tripped (...continued)
Check
robot load
Load
condition?
OK
Overload
Alarm
occurs at a Decrease
specific point? weight
NO
YES
Check first
grounding terminal
Faulty Go to
YES grounding NO point
B
Replace servopack
corresponding
to the display
Alarm Servopack
YES Contact
MOTOMAN-service

AL-1211 MSV#2 AL-1214 MSV#5
AL-1212 MSV#3 AL-1215 MSV#6

MOTOMAN
ROBOTICS
AB Page: 45
Alarm 1220 - 1226 Ground Fault
Alarm Occurrence
Condition
At control at the time At servo
power ON power ON
of alarm?
Replace servopack
corresponding to the display Running
Check first
grounding terminal
Alarm
re-occurs?
Go to
NO point Faulty
YES A grounding
Contact Servopack NO YES

Replace servopack
corresponding
to the display
Check second Alarm

ground terminal re-occurs?
Faulty NO YES
grounding
YES NO Servopack
failure
Check
re-occurs?
Alarm
NO YES re-occurs?
NO
Internal wiring YES
failure Servo motor
failure
Contact
MOTOMAN-service

ROBOTICS
Page: 46 AB
Alarm 1220 - 1226 Ground Fault (...continued)
Alarm
occurs at a
NO
specific point?
Check first YES
grounding terminal
Faulty Check second

grounding NO ground terminal
YES Faulty
grounding
Replace servopack YES NO
corresponding
to the display Check
internal wiring
Alarm
re-occurs?
NO
YES
Internal wiring Replace motor
failure Contact corresponding
MOTOMAN-service to the display
Alarm
re-occurs? Alarm
re-occurs?
YES NO
NO YES
Contact Servopack Motor Contact

MOTOMAN-service failure failure MOTOMAN-service

AL-1221 MSV#2 AL-1224 MSV#5
AL-1222 MSV#3 AL-1225 MSV#6

MOTOMAN
ROBOTICS
AB Page: 47
Alarm 1230 - 1236 Defective Current Offset
Alarm Occurrence
Replace servopack
Alarm
re-occurs?
NO YES
Servopack Contact
failure MOTOMAN-service

AL-1231 MSV#2 AL-1234 MSV#5
AL-1232 MSV#3 AL-1235 MSV#6

ROBOTICS
Page: 48 AB
Alarm 1240- 1246 Encoder Transmission Error
Turn power OFF,

and then ON again. Alarm Occurrence
Alarm Remove the cable between MSV

re-occurs? YES
board and IAMP, then re-install it
NO
Remove the cable between Alarm
YES re-occurs?
Resume use encoder and IAMP, then re-install it
Alarm NO
Resume use NO re-occurs?
YES Resume use
Check the cable ground
between encoder and IAMP Remove the cable between the
encoder and IAMP, then
Alarm install connector from another axis
re-occurs?
YES NO Alarm
YES re-occurs?
Check the cable
between encoder and IAMP NO
Alarm Cable failure Replace the servopack

re-occurs? NO
Alarm
Servopack failure NO re-occurs?
Reset absolute
encoder
YES
Alarm Replace the
re-occurs? YES servomotor Replace MSV board
NO Alarm Alarm
re-occurs? NO re-occurs?
Resume use NO
YES Board failure YES
Motor failure
Contact
MOTOMAN-service

AL-1241 MSV#2 AL-1244 MSV#5
AL-1242 MSV#3 AL-1245 MSV#6

MOTOMAN
ROBOTICS
AB Page: 49
Alarm 1250 - 1256 Defective Encoder Internal Data
Alarm Occurrence
Turn power OFF,

and then ON again.
Alarm
re-occurs?
NO YES
Resume use Reset absolute encoder

corresponding to the displayed axis
Alarm
re-occurs?
YES NO
Replace motor corresponding Resume use

to the displayed axis
Alarm
re-occurs?
NO YES
Motor failure Contact

MOTOMAN-service

AL-1251 MSV#2 AL-1254 MSV#5
AL-1252 MSV#3 AL-1255 MSV#6

ROBOTICS
Page: 50 AB
Alarm 1260 - 1266 Defective Encoder Absolute Data
Alarm Occurrence
Turn power OFF,

and then ON again.
Alarm
re-occurs?
NO YES
Resume use Reset absolute encoder

corresponding to the displayed axis
Alarm
re-occurs?
YES NO
Replace motor corresponding Resume use

to the displayed axis
Alarm
re-occurs?
NO YES
Motor failure Contact

MOTOMAN-service

AL-1261 MSV#2 AL-1264 MSV#5
AL-1262 MSV#3 AL-1265 MSV#6

MOTOMAN
ROBOTICS
AB Page: 51
Alarm 1270 - 1276 Encoder Overheat
Alarm Occurrence
Condition
At control at the time Running
power ON
of alarm?
If motor has cooling

fan check if fan is
A working
Check
NO Abnormal?
Robot load
Reset absolute encoder
corresponding to the Load YES
displayed axis condition?
Check
Alarm Overload wiring
re-occurs?
Decrease
YES NO weight
Resume use Faulty

wiring?
NO
Replace internal
Replace motor wiring
Alarm Replace Alarm

re-occurs? cooling fan YES re-occurs?
YES NO Alarm NO
re-occurs?
YES Internal wiring
Motor failure NO failure
Go to
Contact Fan point
MOTOMAN-service failure A

AL-1271 MSV#2 AL-1274 MSV#5
AL-1272 MSV#3 AL-1275 MSV#6

ROBOTICS
Page: 52 AB
Alarm 1280- 1286 Servo Monitor Transmission Error
Alarm Occurrence
Turn power OFF,

and then ON again.
Alarm
re-occurs?
NO YES
Resume use Remove the cable between MSV

Alarm
re-occurs?
YES NO
Check the cable wiring Resume use

Faulty
wiring
YES NO
Replace cable Replace the

servopack
Alarm
re-occurs? YES
Alarm
re-occurs? YES
NO
NO
Cable failure Replace MSV board
Servopack failure Alarm

re-occurs?
YES NO

MOTOMAN-service

AL-1281 MSV#2 AL-1284 MSV#5
AL-1282 MSV#3 AL-1285 MSV#6

MOTOMAN
ROBOTICS
AB Page: 53
Alarm 1290 -1296 Servo CPU Synchronizing Error
Alarm Occurrence
Replace MSV board
Alarm
re-occurs?
NO YES

MOTOMAN-service

AL-1291 MSV#2 AL-1294 MSV#5
AL-1292 MSV#3 AL-1295 MSV#6
Alarm 1300 -1306 DSP Program Checksum Error
Alarm Occurrence
Replace MSV board
Alarm
re-occurs?
NO YES

MOTOMAN-service

AL-1301 MSV#2 AL-1304 MSV#5
AL-1302 MSV#3 AL-1305 MSV#6

ROBOTICS
Page: 54 AB
Alarm 1310 -1316 Mon Pgrm Total Checksum Error
Alarm Occurrence
Replace MSV board
Alarm
re-occurs?
NO YES

MOTOMAN-service

AL-1311 MSV#2 AL-1314 MSV#5
AL-1312 MSV#3 AL-1315 MSV#6

MOTOMAN
ROBOTICS
AB Page: 55
Alarm 1320- 1326 Servopack Failure
Alarm Occurrence
Turn power OFF,

and then ON again.
Alarm
re-occurs?
NO YES
Resume use Remove the cable between MSV

Alarm
re-occurs?
YES NO
Check the cable wiring Resume use

Faulty
wiring
YES NO
Replace cable Replace the

servopack
Alarm
re-occurs? YES
Alarm
re-occurs? YES
NO
NO
Cable failure Replace MSV board
Servopack failure Alarm

re-occurs?
YES NO

MOTOMAN-service

AL-1321 MSV#2 AL-1324 MSV#5
AL-1322 MSV#3 AL-1325 MSV#6

ROBOTICS
Page: 56 AB
Alarm 1330- 1336 Position Error
Alarm Occurrence
Condition
At control Go to
at the time Running point
power ON
of alarm? A
At servo
power ON
Replace the cable between
encoder and IAMP with a
cable from another axis
Moved to
another axis? NO
Replace MSV board
YES
Alarm
Check wiring re-occurs?
NO YES
Board failure
Faulty
wiring
YES NO
Replace cable
Alarm Replace the

re-occurs? YES servo motor
NO Alarm Contact
re-occurs? YES MOTOMAN-service
Cable failure
NO
Motor failure

MOTOMAN
ROBOTICS
AB Page: 57
Alarm 1330- 1336 Position Error (... continued)
Is there a
A noise source NO
around?
YES
Remove the
noise source
Alarm
re-occurs? YES
NO
Resume use Check wiring
Faulty
wiring
YES
Replace cable
Replace the Alarm

servo motor YES re-occurs?
NO
Alarm NO
Motor failure re-occurs?
Cable failure
YES
Replace MSV board
Alarm Contact
NO
Board failure

AL-1331 MSV#2 AL-1334 MSV#5
AL-1332 MSV#3 AL-1335 MSV#6

ROBOTICS
Page: 58 AB
Alarm 1340- 1346 Overload 1
Alarm Occurrence
Condition
power ON
of alarm?
Replace MSV board How long

Right away after Servo ON After several
does alarm minutes
occur?
Check for Check
interference Robot load
Load
Interference? condition?
YES
NO OK Overload
Modify
teaching Reduce
load
Alarm Check
re-occurs? YES motor wiring
NO Faulty
wiring NO
Teaching error
YES Go to
Alarm point
re-occurs? Replace wiring A
NO
Alarm
re-occurs? YES
YES Board failure
Contact NO
MOTOMAN-service
Cable failure

AL-1341 MSV#2 AL-1344 MSV#5
AL-1342 MSV#3 AL-1345 MSV#6

MOTOMAN
ROBOTICS
AB Page: 59
Alarm 1340- 1346 Overload 1 (...continued)
Is brake
NO release A
audiable?
Check
brake circuit
YES
Input voltage Abnormal NO
abnormal condition?
Input voltage Check brake

Replace MTU board normal lead wiring
Replace SVM Faulty

wiring
Alarm NO
re-occurs? YES
NO Check
YES Replace wiring motor brake
Resume use
Alarm
Alarm re-occurs?
re-occurs? NO
YES YES
NO Resume use
Contact
Resume use MOTOMAN-service
NO Defective?
Check if YES
mechanically locked
Replace the
servo motor
NO Movable?
Alarm
Fix mechanical re-occurs?
problem YES YES
NO
Alarm Contact
re-occurs? YES MOTOMAN-service Resume use
NO
Resume use

ROBOTICS
Page: 60 AB
Alarm 1350- 1356 Overload 2
Alarm Occurrence
Condition
power ON
of alarm?
Replace MSV board How long

Right away after Servo ON After several
does alarm minutes
occur?
Check for Check
interference robot load
Load
Interference? condition?
YES
NO OK Overload
Modify
teaching Reduce
load
Alarm Check
re-occurs? YES motor wiring
NO Faulty
wiring NO
Teaching error
YES Go to
Alarm point
re-occurs? Replace wiring A
NO
Alarm
re-occurs? YES
YES Board failure
Contact NO
MOTOMAN-service
Cable failure

AL-1351 MSV#2 AL-1354 MSV#5
AL-1352 MSV#3 AL-1355 MSV#6

MOTOMAN
ROBOTICS
AB Page: 61
Alarm 1350- 1356 Overload 2 (...continued)
Is brake
NO release A
audiable?
Check
brake circuit
YES
Input voltage Abnormal NO
abnormal condition?
Output voltage Check brake

Replace MTU board abnormal lead wiring
Replace SVM Faulty

wiring
Alarm NO
re-occurs? YES
NO Check
YES Replace wiring motor brake
Resume use
Alarm
Alarm re-occurs?
re-occurs? NO
YES YES
NO Resume use
Contact
Resume use MOTOMAN-service
NO Defective?
Check if YES
mechanically locked
Replace the
servo motor
NO Movable?
Alarm
Fix mechanical re-occurs?
problem YES YES
NO
Alarm Contact
re-occurs? YES MOTOMAN-service Resume use
NO
Resume use

ROBOTICS
Page: 62 AB
Alarm 1360-1366 Broken PG Line
Alarm Occurrence
Condition
power on 1
of alarm?
Replace cable between encoder & At servo

IAMP with cable from another axis power on
Move to NO Replace MSV

other axis? board
YES Alarm
re-occurs? YES
Check wiring
NO Replace servopack
MSV board failure Alarm

re-occurs? NO
Faulty
wiring? YES Replace cable
YES Servopack failure
NO Replace cable between

IAMP and MSV
Alarm
Replace motor YES re-occurs?
Alarm
re-occurs? NO
NO
YES Cable failure
Cable failure
Replace motor
Alarm
re-occurs? NO
Alarm
re-occurs? NO
Motor failure
YES
YES Motor failure
Contact
MOTOMAN-service Contact
MOTOMAN-service

MOTOMAN
ROBOTICS
AB Page: 63
Alarm 1360-1366 Broken PG Line (...continued)
Is there a noise Remove noise

YES
source around? source
NO
Alarm
Check wiring YES re-occurs? NO Resume use
Faulty
wiring? YES Replace cable
NO
Alarm
Replace motor YES re-occurs? NO Cable failure
Alarm
re-occurs? YES MSV board failure
NO Alarm
NO re-occurs? YES
Motor failure
MSV board failure Replace servopack
Alarm
YES re-occurs? NO
Replace cable between Servopack failure

IAMP and MSV
Alarm
NO re-occurs? YES Replace motor
Cable failure Alarm

YES re-occurs? NO

MOTOMAN-service

AL-1361 MSV#2 AL-1364 MSV#5
AL-1362 MSV#3 AL-1365 MSV#6

ROBOTICS
Page: 64 AB
Alarm 1370-1376 Over Speed
Alarm Occurrence
Is there a noise Remove noise

NO source around? YES source
Alarm
Check wiring YES re-occurs? NO
Faulty Resume use

wiring? NO
At servo Condition at the

1 Running
YES power on time of alarm
Replace cable At servo

power on
Alarm
re-occurs? NO Cable failure
Alarm occurs
1 NO
at specific point?
YES
YES
1
Point of alarm
NO taught by MOVJ?
Replace MSV board
Alarm YES
re-occurs? NO MSV board failure
Multiple axes
YES Reduce speed YES moving at the
same time?
Replace motor
NO
Alarm
re-occurs? NO Motor failure
Alarm
re-occurs? YES 1
YES
NO
Contact
MOTOMAN-service Resume use

AL-1371 MSV#2 AL-1374 MSV#5
AL-1372 MSV#3 AL-1375 MSV#6

MOTOMAN
ROBOTICS
AB Page: 65
Alarm 1380-1386 Servo Tracking Error
Alarm Occurrence
Condition at the Running

time of alarm?
Check if robot interferes
At control with work or fixture
power on
Modify teaching YES Interference? NO Check load
Alarm Check motor Load

re-occurs? YES OK
wiring condition?
NO
Overload
Teaching error
Decrease weight
Replace MSV board
Faulty
wiring? NO 1
Alarm
re-occurs? NO
YES
YES MSV board failure
Replace wiring
Contact harness
MOTOMAN-service
Alarm
re-occurs? YES 1
NO
Wiring failure

AL-1381 MSV#2 AL-1384 MSV#5
AL-1382 MSV#3 AL-1385 MSV#6

ROBOTICS
Page: 66 AB
Alarm 1380-1386 Servo Tracking Error (...continued)
Is brake
NO release audible? YES
Check brake
circuit
Input voltage Abnormal

NO
abnormal condition?
Replace Output voltage Check brake

MTU board abnormal lead wiring
Replace SVM Faulty Check motor

wiring? NO brake
Alarm
NO re-occurs? YES
Resume use YES Replace wiring

harness
Alarm Contact
re-occurs? YES MOTOMAN Alarm
re-occurs? NO
service
NO
YES Resume use
Resume use
Contact
MOTOMAN-service
Check if mechanically NO Defective?

locked
YES
NO Movable?
Fix mechanical Replace motor

problem YES
Alarm Contact Alarm

re-occurs? YES MOTOMAN-service YES re-occurs?
NO NO
Resume use Resume use

MOTOMAN
ROBOTICS
AB Page: 67
Alarm 1390-1396 Speed (Monitor)
Alarm Occurrence
NO Is there a noise YES Remove noise

source around? source
Alarm
Check wiring YES re-occurs? NO
Faulty Resume use

NO
wiring?
At control Condition at the Running
1 power on time of alarm?
YES
Replace cable At servo

power on
Alarm
re-occurs? NO Cable failure
Alarm occurs
1 NO at specific point?
YES
YES
1
Point of alarm
NO taught by MOVJ
Replace
MSV board
YES
Alarm MSV board
re-occurs? NO
failure Multiple axes
Reduce speed YES moving at the
YES same time?
Replace motor NO
Alarm Alarm
re-occurs? NO Motor failure re-occurs? YES 1
YES NO
Contact Resume use

MOTOMAN
service

AL-1391 MSV#2 AL-1394 MSV#5
AL-1392 MSV#3 AL-1395 MSV#6

ROBOTICS
Page: 68 AB
Alarm 3000-3006 Not Ready For Servo System
Alarm Occurrence
Turn the power off

and then on again
Alarm
Resume use NO re-occurs?
YES
Check Is SVM Check primary

NO YES
MTU board working? power voltage
Defective? NO Replace SVM Defective? YES
YES Alarm Primary power

re-occurs? YES 1
failure
Replace
MTU board NO NO
Resume use Check cable between

servopack and MSV board
Alarm
re-occurs? YES 1 YES Defective? NO 1
NO Replace cable
Resume use Alarm

re-occurs? YES 1
NO
Cable failure

AL-3001 MSV#2 AL-3004 MSV#5
AL-3002 MSV#3 AL-3005 MSV#6

MOTOMAN
ROBOTICS
AB Page: 69
Alarm 3000-3006 Not Ready For Servo System (...continued)
Check cable between

servopack and SVM
Defective? YES Replace cable
NO
Replace Alarm
servopack YES re-occurs? NO Cable failure
Alarm Replace
re-occurs? YES MSV board
NO Alarm Contact
re-occurs? YES MOTOMAN
service
Servopack
failure NO
MSV board
failure

ROBOTICS
Page: 70 AB
Alarm 3010-3016 Servo Defective Speed
Alarm Occurrence
Are you trying to Try power on while

turn power on while YES
axis is moving axis is stopped
NO
Replace Alarm
MSV board YES re-occurs? NO Resume use
Alarm MSV board

re-occurs? NO
failure
YES
Contact
MOTOMAN
service

AL-3011 MSV#2 AL-3014 MSV#5
AL-3012 MSV#3 AL-3015 MSV#6

MOTOMAN
ROBOTICS
AB Page: 71
Alarm 3020-3026 Servo Defective DB
Alarm Occurrence
Turn the power off

and then on again
Alarm
re-occurs? YES Replace servopack
NO Alarm Servopack
Resume use
YES
Replace
MSV board
Alarm MSV board

re-occurs? NO
failure
YES
Contact
MOTOMAN
service

AL-3021 MSV#2 AL-3024 MSV#5
AL-3022 MSV#3 AL-3025 MSV#6

ROBOTICS
Page: 72 AB
Alarm 3030-3036 Regenerative Trouble
Alarm Occurrence
Condition at the At servo

time of alarm? power on
At control Check regeneration

power on resistor
Replace Replace regeneration

NO Defective? YES
servopack resistor
Alarm Contact Alarm

re-occurs? YES YES re-occurs?
MOTOMAN-service
NO NO
Servopack Regeneration
failure resistor failure

AL-3031 MSV#2 AL-3034 MSV#5
AL-3032 MSV#3 AL-3035 MSV#6

MOTOMAN
ROBOTICS
AB Page: 73
Alarm 3040-3046 Overvoltage
Alarm Occurrence

At control Check primary

power on power voltage
Primary power
Abnormal? YES
failure
NO
Check regeneration
resistor
Replace Replace regeneration

NO Defective? YES
servopack resistor
Alarm Contact Alarm

MOTOMAN-service
NO NO
Servopack Regeneration
failure resistor failure

AL-3041 MSV#2 AL-3044 MSV#5
AL-3042 MSV#3 AL-3045 MSV#6

ROBOTICS
Page: 74 AB
Alarm 3050-3056 Voltage Drop
Alarm Occurrence


Replace Primary power

NO Abnormal? YES
servopack failure
Alarm Contact
NO
Servopack
failure

AL-3051 MSV#2 AL-3054 MSV#5
AL-3052 MSV#3 AL-3055 MSV#6

MOTOMAN
ROBOTICS
AB Page: 75
Alarm 3060-3066 Heat sink overheat
Alarm Occurrence


Replace Primary power

NO Abnormal? YES
servopack failure
Alarm Contact
NO
Servopack
failure

AL-3061 MSV#2 AL-3064 MSV#5
AL-3062 MSV#3 AL-3065 MSV#6

ROBOTICS
Page: 76 AB
Alarm 3070-3076 Servo Blown Fuse
Alarm Occurrence

At control Check motor

power on cable
Replace Replace wiring

NO Abnormal? YES
servopack harness
Alarm Contact Alarm

MOTOMAN-service
NO NO
Servopack Wiring failure

failure

AL-3071 MSV#2 AL-3074 MSV#5
AL-3072 MSV#3 AL-3075 MSV#6

MOTOMAN
ROBOTICS
AB Page: 77
Alarm 3080-3086 Broken Current Ref Cable
Alarm Occurrence
Check cable between

servopack and MSV board
NO
Replace Alarm
YES re-occurs? NO Cable failure
servopack
Alarm Replace
re-occurs? YES
MSV board
NO Alarm Contact
Servopack
failure NO
MSV board
failure

AL-3081 MSV#2 AL-3084 MSV#5
AL-3082 MSV#3 AL-3085 MSV#6

ROBOTICS
Page: 78 AB
Alarm 3090-3096 Open Phase
Alarm Occurrence
Check primary
power voltage
Abnormal? Check if contactor

YES
is stuck or not
NO Replace
Abnormal? YES
contactor
Primary power
failure NO
Check cable for Alarm

YES re-occurs?
SVM contactor
NO
Replace cable YES Abnormal?
Contactor
NO failure
Alarm Replace
re-occurs? YES
servopack
NO Alarm Replace
re-occurs? YES
MSV board
Cable failure
NO
Abnormal? NO
Servopack
failure MSV board
YES failure
Contact
MOTOMAN-service

AL-3091 MSV#2 AL-3094 MSV#5
AL-3092 MSV#3 AL-3095 MSV#6

MOTOMAN
ROBOTICS
AB Page: 79
Alarm 4000 Not Ready
Alarm Occurrence
Reset alarm, and then

execute the operation again
Alarm
NO re-occurs? YES
Resume use Contact

MOTOMAN-service
Alarm 4010 Current Position Set Program Error
Alarm Occurrence

Alarm
NO re-occurs? YES
Resume use Contact

MOTOMAN-service
Alarm 4020 Servo Power On Sequence Error
Alarm Occurrence

Alarm
NO re-occurs? YES
Resume use Contact

MOTOMAN-service

ROBOTICS
Page: 80 AB
Alarm 4030 Servo Power Off Sequence Error
Alarm Occurrence

Alarm
NO re-occurs? YES
Resume use Contact

MOTOMAN-service
Alarm 4040 Home Calibration Error
Alarm Occurrence

Alarm
NO re-occurs? YES
Resume use Contact

MOTOMAN-service
Alarm 4050 Absolute Data Change Error
Alarm Occurrence

Alarm
NO re-occurs? YES
Resume use Contact

MOTOMAN-service

MOTOMAN
ROBOTICS
AB Page: 81
Alarm 4060 Segment Data Output Error
Alarm Occurrence

Alarm
NO re-occurs? YES
Resume use Contact

MOTOMAN-service
Alarm 4070 Axis Parameter Error
Alarm Occurrence
Initialize parameter
setting
Alarm
NO re-occurs? YES
Resume use Contact

MOTOMAN-service
Alarm 4080 Table Parameter Error For Actual Axis
Alarm Occurrence
Initialize parameter
setting
Alarm
NO re-occurs? YES
Resume use Contact

MOTOMAN-service

ROBOTICS
Page: 82 AB
Alarm 4090 Sequence Task Control Error
Alarm Occurrence

Alarm
NO re-occurs? YES
Resume use Contact

MOTOMAN-service
Alarm 4100 Data Refresh Error
Alarm Occurrence

Alarm
NO re-occurs? YES
Resume use Contact

MOTOMAN-service
Alarm 4110 Undefined Command (Arith)
Alarm Occurrence

Alarm
NO re-occurs? YES
Resume use Contact

MOTOMAN-service

MOTOMAN
ROBOTICS
AB Page: 83
Alarm 4120 System Error (Arith)
Alarm Occurrence

Alarm
NO re-occurs? YES
Resume use Contact

MOTOMAN-service
Alarm 4130 Arithmetic Error
Alarm Occurrence

Alarm
NO re-occurs? YES
Resume use Contact

MOTOMAN-service
Alarm 4140 Select Error (Parameter)
Alarm Occurrence

Alarm
NO re-occurs? YES
Resume use Contact

MOTOMAN-service

ROBOTICS
Page: 84 AB
Alarm 4150 Group Axis Control Error
Alarm Occurrence

Alarm
NO re-occurs? YES
Resume use Contact

MOTOMAN-service
Alarm 4160 Two Steps Same Position (Circle)
Alarm Occurrence
Confirm the taught program, and

then input three different points
Alarm
NO re-occurs? YES
Resume use Contact

MOTOMAN-service
Alarm 4170 Two Steps Same Position (Spline)
Alarm Occurrence

Alarm
NO re-occurs? YES
Resume use Contact

MOTOMAN-service

MOTOMAN
ROBOTICS
AB Page: 85
Alarm 4180 Two Steps Same Position (3 steps)
Alarm Occurrence

Alarm
NO re-occurs? YES
Resume use Contact

MOTOMAN-service
Alarm 4190 Two Steps Same Position (weave)
Alarm Occurrence

Alarm
NO re-occurs? YES
Resume use Contact

MOTOMAN-service
Alarm 4200 Teach Error (Spline)
Alarm Occurrence
Confirm the taught program,

and then provide instructions to
position taught points correctly
Alarm
NO re-occurs? YES
Resume use Contact

MOTOMAN-service

ROBOTICS
Page: 86 AB
Alarm 4210 Impossible Linear Motion (L/U)
Alarm Occurrence
Confirm the taught

program so the pattern
of L and U axes is the same
Alarm
NO re-occurs? YES
Resume use Contact

MOTOMAN-service
Alarm 4220 Impossible Linear Motion (S/L)
Alarm Occurrence
Confirm the taught

program so the pattern
of S and L axes is the same
Alarm
NO re-occurs? YES
Resume use Contact

MOTOMAN-service

MOTOMAN
ROBOTICS
AB Page: 87
Alarm 4230 Excessive Segment (Low speed)
Alarm Occurrence
Decrease the speed of the step

where the alarm occured
Alarm
NO re-occurs? YES
Resume use Set form of axes S and L,

and provide a new instruction
Alarm
NO re-occurs? YES
Resume use Contact

MOTOMAN-service
Alarm 4240 Excessive Segment (High speed)
Alarm Occurrence
Decrease the speed of the step

where the alarm occured
Alarm
NO re-occurs? YES
Resume use Set form of axes S and L,

and provide a new instruction
Alarm
NO re-occurs? YES
Resume use Contact

MOTOMAN-service

ROBOTICS
Page: 88 AB
Alarm 4250-4300 Soft Limit Over
Alarm Occurrence
Reset alarm using soft-limit-over

reset method, and then provide
another instruction
Alarm
NO re-occurs? YES
Resume use Contact

MOTOMAN-service
AL-4250 Pulse limit over: minimum AL-4280 Cube limit over: maximum
AL-4260 Pulse limit over: maximum AL-4290 Special soft limit over: minimum
AL-4270 Cube limit over: minimum AL-4300 Special soft limit over: maximum
Alarm 4310-4340 Mechanical Interference
Alarm Occurrence

another instruction.
Alarm
NO re-occurs? YES
Resume use Contact

MOTOMAN-service
AL-4310 Mechanical interference: AL-4330 Special mechanical interference:

minimum maximum
AL-4320 Mechanical interference: AL-4340 Special mechanical interference:
maximum minimum

MOTOMAN
ROBOTICS
AB Page: 89
Alarm 4350-4360 Pulse Mechanical limit
Alarm Occurrence

another instruction.
Alarm
NO re-occurs? YES
Resume use Contact

MOTOMAN-service
AL-4350 Pulse mechanical limit: minimum AL-4360 Pulse mechanical limit: maximum
Alarm 4370 Station Axis Data Input Error
Alarm Occurrence

Alarm
NO re-occurs? YES
Resume use Contact

MOTOMAN-service

ROBOTICS
Page: 90 AB
Alarm 4380 Segment Control Error
Alarm Occurrence

Alarm
NO re-occurs? YES
Resume use Contact

MOTOMAN-service
Alarm 4390 Sub-segment Control Error
Alarm Occurrence

Alarm
NO re-occurs? YES
Resume use Contact

MOTOMAN-service
Alarm 4400 Wrong Specified Control Group
Alarm Occurrence

Alarm
NO re-occurs? YES
Resume use Contact

MOTOMAN-service

MOTOMAN
ROBOTICS
AB Page: 91
Alarm 4410 CPU Communication Error
Alarm Occurrence

Alarm
NO re-occurs? YES
Resume use Contact

MOTOMAN-service
Alarm 4420 Failed To Select Over SP Level
Alarm Occurrence

Alarm
NO re-occurs? YES
Resume use Turn the power off,

and then on again
Alarm
YES re-occurs? NO
Replace MSV board Resume use
Alarm
NO re-occurs? YES
MSV board failure Contact

MOTOMAN-service

ROBOTICS
Page: 92 AB
Alarm 4430 Averaging Number Change Error
Alarm Occurrence

Alarm
NO re-occurs? YES

and then on again
Alarm
YES re-occurs? NO
Alarm
NO re-occurs? YES

MOTOMAN-service
Alarm 4440 Torque Limit Change Error
Alarm Occurrence

Alarm
NO re-occurs? YES

and then on again
Alarm
YES re-occurs? NO
Alarm
NO re-occurs? YES

MOTOMAN-service

MOTOMAN
ROBOTICS
AB Page: 93
Alarm 4450 JMS Error
Alarm Occurrence

Alarm
NO re-occurs? YES
Resume use Contact

MOTOMAN-service
1/255 Parameter 11/245 Sequence number error

2/254 Access time over 12/244 Step numer error
3/253 Access error 13/243
4/252 Job name error 14/242 Code error
5/251 Existing job open 15/241
6/250 Memory over 16/240 Lack of handle
7/249 Not existing 17/239 Write Protected
8/248 Acess not permitted 18/238 Maximum instruction
9/247 Handling number error 19/237 Maximum step
10/246 System error 99/157 Job failure
Alarm 4460 JHM Error
Alarm Occurrence
Turn the power off,

and then on again
Alarm
NO re-occurs? YES
Resume use Contact

MOTOMAN-service

ROBOTICS
Page: 94 AB
Alarm 4470 Instruction Interpreter Error
Alarm Occurrence
Turn the power off,

and then on again
Alarm
NO re-occurs? YES
Resume use Contact

MOTOMAN-service
Alarm 4480 Undefined Global Variable
Alarm Occurrence
Reset the parameter, and then

Alarm
NO re-occurs? YES
Resume use Contact

MOTOMAN-service
Alarm 4490 Var-Scoreboard Control Error
Alarm Occurrence

Alarm
NO re-occurs? YES
Resume use Contact

MOTOMAN-service

MOTOMAN
ROBOTICS
AB Page: 95
Alarm 4500 Undefined Local Variable
Alarm Occurrence
Set the local variable to the job heade

and then execute the operation again
Alarm
NO re-occurs? YES
Resume use Contact

MOTOMAN-service
Alarm 4510 Less Than 3 Steps (circular)
Alarm Occurrence

then input instructions to provide
more than three steps continuously
Alarm
NO re-occurs? YES
Resume use Contact

MOTOMAN-service
Alarm 4520 Cannot Interpolate Circular Motion
Alarm Occurrence

then input instructions to provide
more than three steps continuously
Alarm
NO re-occurs? YES
Resume use Contact

MOTOMAN-service

ROBOTICS
Page: 96 AB
Alarm 4530 Undefined Job
Alarm Occurrence
Reset alarm, end then

Alarm
NO re-occurs? YES
Resume use Contact

MOTOMAN-service
Alarm 4540 Undefined Label
Alarm Occurrence
Check the taught point, and

then teach the point again
Alarm
NO re-occurs? YES
Resume use Contact

MOTOMAN-service
Alarm 4550 Undefined Return Job
Alarm Occurrence
Start from the original job
Alarm
NO re-occurs? YES
Resume use Check the taught point, and
Alarm
NO re-occurs? YES
Resume use Contact

MOTOMAN-service

MOTOMAN
ROBOTICS
AB Page: 97
Alarm 4560 Lack Of Local-Variable Area
Alarm Occurrence
Decrease the use

of local variables
Alarm
NO re-occurs? YES
Resume use Contact

MOTOMAN-service
Alarm 4570 Local-Variable Control Error
Alarm Occurrence

Alarm
NO re-occurs? YES
Resume use Contact

MOTOMAN-service
Alarm 4580 Job Call Stack Error
Alarm Occurrence

Alarm
NO re-occurs? YES
Resume use Contact

MOTOMAN-service

ROBOTICS
Page: 98 AB
Alarm 4590 Feedback Pulse Making Error
Alarm Occurrence

Alarm
NO re-occurs? YES
Resume use Contact

MOTOMAN-service
Alarm 4600 Unsuccessful Fine Positioning
Alarm Occurrence

Alarm
NO re-occurs? YES

and then on again
Alarm
YES re-occurs? NO
Alarm
NO re-occurs? YES

MOTOMAN-service

MOTOMAN
ROBOTICS
AB Page: 99
Alarm 4610 Pending Block-End Error
Alarm Occurrence

Alarm
NO re-occurs? YES
Resume use Contact

MOTOMAN-service
Alarm 4620 Data Preset Error
Alarm Occurrence

Alarm
NO re-occurs? YES
Resume use Contact

MOTOMAN-service
Alarm 4630 Variable Data Type Error
Alarm Occurrence

Alarm
NO re-occurs? YES
Resume use Contact

MOTOMAN-service

ROBOTICS
Page: 100 AB
Alarm 4640 Over Variable Limit

(B**) ‘0-255
Alarm Occurrence (I**) -32768~32767
(D**) -2147483648
~214748
Change value of variable type that (R**) -1.70141E+38
exceeds numerical range limits. ~1.70141E
Alarm
NO re-occurs? YES
Resume use Contact

MOTOMAN-service
Alarm 4650 Defective Taught Point (circular)
Alarm Occurrence
Check taught point, and then teach

three points not in a straight line
Alarm
NO re-occurs? YES
Resume use Contact

MOTOMAN-service
Alarm 4660 Weaving Control Error
Alarm Occurrence
Reset alarm, and then check

weave file and REFP points
Alarm
NO re-occurs? YES
Resume use Contact

MOTOMAN-service

MOTOMAN
ROBOTICS
AB Page: 101
Alarm 4670-4671 Overrun In Axis
Alarm Occurrence
Recover from overtravel

then try again
Alarm
NO re-occurs? YES Check short switch on MBB02
Resume use
Set the swith again YES Abnormal?
NO
Alarm Check the over

NO re-occurs? YES
run limit switch
Swith setting failure

Replace switch YES Defective?
NO
Alarm Check the wiring of the

NO re-occurs? YES
overrun limit switch
Switch failure Alarm Replace wiring

re-occurs? YES
harness
NO
Replace MTU Alarm

YES re-occurs?
board
Replace MBB02 Alarm NO

YES re-occurs?
(IOBB) board
Lead failure
Alarm NO
NO re-occurs? YES
Board failure
MBB02 (IOBB)
failure Contact
MOTOMAN-service
AL-4670 At robot axes occurrence AL-4671 At external axes occurrence

ROBOTICS
Page: 102 AB
Alarm 4680-4730 File Fault
Alarm Occurrence

Alarm Load the file corresponding to

NO re-occurs? YES
the screen, and then try again
Resume use Alarm

NO re-occurs? YES
Resume use Contact

MOTOMAN-service
AL-4680 Tool file AL-4710 Weaving file

AL-4690 User frame file AL-4720 Home position absolute data file
AL-4700 Servo monitor signal file AL-4730 Second home position data file
Alarm 4740 Posn File Data Read-Out Error
Alarm Occurrence

Alarm
NO re-occurs? YES
Resume use Contact

MOTOMAN-service

MOTOMAN
ROBOTICS
AB Page: 103
Alarm 4750 Unmatched Posn Var Data Type
Alarm Occurrence
Change position variable data

type (pulse - XYZ).
Alarm
NO re-occurs? YES
Resume use Contact

MOTOMAN-service
Alarm 4760 File No. Error
Alarm Occurrence

Alarm
NO re-occurs? YES
Resume use Contact

MOTOMAN-service
Alarm 4770 Undefined Reference Point
Alarm Occurrence
Register the reference point
Alarm
NO re-occurs? YES
Resume use Contact

MOTOMAN-service

ROBOTICS
Page: 104 AB
Alarm 4780 Stack More Than 8 (job call)
Alarm Occurrence
Check program, and modify so that

stack does not exceed 8 calls
Alarm
NO re-occurs? YES
Resume use Contact

MOTOMAN-service
Alarm 4790 Arithmetic Section Request Error
Alarm Occurrence

Alarm
NO re-occurs? YES
Resume use Contact

MOTOMAN-service
Alarm 4800 Request-To-Send Error
Alarm Occurrence

Alarm
NO re-occurs? YES
Resume use Contact

MOTOMAN-service

MOTOMAN
ROBOTICS
AB Page: 105
Alarm 4810 Over Variable No.

(B000~B039)
Alarm Occurrence (I000~I039)
D000~D039)
R000~R039)
Check program, and change P000~P127)
variable number within limit BP000~BP127)
EX000~EX127)
Alarm
NO re-occurs? YES
Resume use Contact

MOTOMAN-service
Alarm 4820 Position Data Management Error
Alarm Occurrence

Alarm
NO re-occurs? YES
Resume use Contact

MOTOMAN-service
1 Not enough area 9 Control information destroyed

2 Number of axis zero 10 Irregular position number
3 Position not kept 11 Position data not set
4 Number of position over 12 Undefined position
5 Area not specified 13 Undefined control group
6 File destroyed 14 Initialization not done
7 Memory over 15 Number of axis over
8 Position data destroyed

ROBOTICS
Page: 106 AB
Alarm 4830-4850 Undefined Condition File
Alarm Occurrence
Complete the
setting of the file
Alarm
NO re-occurs? YES
Resume use Contact

MOTOMAN-service
AL-4830 Welder condition file AL-4850 Arc end condition file

AL-4840 Arc start condition file
Alarm 4860 Wrong Welder Selection
Alarm Occurrence
Match unit of voltage

selection to welder type
Alarm
NO re-occurs? YES
Resume use Contact

MOTOMAN-service

MOTOMAN
ROBOTICS
AB Page: 107
Alarm 4870-4900 Condition File Fault
Alarm Occurrence

Alarm
NO re-occurs? YES
Resume use Load file, and the try again
Alarm
NO re-occurs? YES
Resume use Contact

MOTOMAN-service
AL-4870 Welder condition file AL-4890 Arc end condition file

AL-4880 Arc start condition file AL-4900 Arc condition supp. file
Alarm 4910 AX-CPU Command Area Error
Alarm Occurrence

Alarm
NO re-occurs? YES
Resume use Contact

MOTOMAN-service

ROBOTICS
Page: 108 AB
Alarm Occurrence

Alarm
NO re-occurs? YES
Resume use Load file, and then try again
Alarm
NO re-occurs? YES
Resume use Contact

MOTOMAN-service
AL-4920 COM-ARC 3 Condition file AL-4940 Correction condition file

AL-4930 COM-ARC 3 Data file AL-4950 Phase offset data file
Alarm 4960 System Change
Alarm Occurrence
Turn the power off,

and then on again
Alarm
NO re-occurs? YES
Resume use Contact

MOTOMAN-service

MOTOMAN
ROBOTICS
AB Page: 109
Alarm 4970 Equation Exception Error
Alarm Occurrence

Alarm
NO re-occurs? YES
Resume use Contact

MOTOMAN-service
Alarm 4980 Excessive Instruction Equation
Alarm Occurrence
Check the program, and

make the expression short
Alarm
NO re-occurs? YES
Resume use Contact

MOTOMAN-service
Alarm 4990 Encoder Battery Error
Alarm Occurrence

Alarm Replace battery

NO re-occurs? YES
board for encoder
Battery failure Alarm

NO re-occurs? YES
MFC board failure Contact

MOTOMAN-service

ROBOTICS
Page: 110 AB
Alarm 5000 Encoder Overheat
Alarm Occurrence
Turn the power off, let encoder

cool, and then turn the power on
Alarm
re-occurs?
YES
If motor has cooling fan, check

if fan is working properly
Is fan
YES
working?
NO
Check the wiring of fan
Defective? NO
YES
Replace fan wiring Check load
Alarm Load
re-occurs? YES Replace fan OK
condition?
NO Alarm Overload
re-occurs? YES
Lead failure Decrease weight
NO
Fan failure Replace motor
Contact Alarm
MOTOMAN-service YES re-occurs?
NO
Motor failure

MOTOMAN
ROBOTICS
AB Page: 111
Alarm 5010 Illegal Parameter
Alarm Occurrence
Change the parameter

back to original
Alarm
NO re-occurs? YES
Resume use Load parameter file,

and then try again
Alarm
NO re-occurs? YES
Resume use Contact

MOTOMAN-service
Alarm 5020 Zero Divisor Occurrence
Alarm Occurrence
Change the program so that the

number will not be divided by zero
Alarm
NO re-occurs? YES
Resume use Contact

MOTOMAN-service

ROBOTICS
Page: 112 AB
Alarm 5030 Global-Variable Area Parameter Error
Alarm Occurrence
Change the parameter

back to original value
Alarm
NO re-occurs? YES
Resume use Load parameter file,

and then try again
Alarm
NO re-occurs? YES
Resume use Contact

MOTOMAN-service
Alarm 5040 Out Of Range (abso data)
Alarm Occurrence
Reset alarm by checking

second home position
Alarm Check battery wiring

re-occurs? YES
to encodeers
NO
Defective? YES Replace battery
Resume use
NO
Alarm
Replace motor YES re-occurs?
Alarm
Motor failure NO re-occurs? NO
YES Battery failure
Contact
MOTOMAN-service

MOTOMAN
ROBOTICS
AB Page: 113
Alarm 5060 Undefined Auto-Weld Release Cond
Alarm Occurrence
Set welding release condition

time, and then try again
Alarm
NO re-occurs? YES
Resume use Contact

MOTOMAN-service
Alarm 5070 Undefined Position For Arc Retry
Alarm Occurrence
Add step, and then try again
Alarm
NO re-occurs? YES
Resume use Contact

MOTOMAN-service
Alarm 5080 Overspeed Limit
Alarm Occurrence
Check setting for MFC04

board, and then try again
Alarm
NO re-occurs? YES
Resume use Contact

MOTOMAN-service

ROBOTICS
Page: 114 AB
Alarm 5090 DC 24V Power Supply Failure
Alarm Occurrence
Check 24V power voltage

supplied to IOBB
Replace DC 24V
Defective? YES
power supply
NO
Alarm Power supply
Check fuse on IOBB YES re-occurs? NO failure
Defective? YES Replace fuse
NO
Alarm
Replace IOBB YES re-occurs? NO Fuse failure
Alarm
re-occurs? NO Board failure
YES
Contact
MOTOMAN-service

MOTOMAN
ROBOTICS
AB Page: 115
Alarm 5100 Shock Sensor Action
Alarm Occurrence
Remove interference between

the tool and the fixture, etc
Remove interference, YES Interference?

and then try again
NO
Alarm Check the shock

re-occurs? YES
sensor cable
NO
Resume use
NO
Check the shock Alarm

YES re-occurs? NO
sensor operation
Check the setting of Cable failure

NO Abnormal? YES
IOBB short pin switch
Set the short Replace shock sensor

Abnormal? YES
pin switch
Alarm
re-occurs? NO
NO
Replace MTU Alarm YES Sensor failure

YES re-occurs?
board
Contact
NO MOTOMAN-service
Alarm
re-occurs? YES
Setting failure
MTU board Replace MRY

failure board Replace IOBB
Alarm Alarm
YES re-occurs? NO IOBB failure
re-occurs?
NO YES
MRY board failure Contact

MOTOMAN-service

ROBOTICS
Page: 116 AB
Alarm 5110 Brake Fuse Blown
Alarm Occurrence
Check the brake lead wiring

for short to ground
YES Replace lead

Short? wire for brake
Check the Alarm

YES re-occurs?
brake fuse
Replace the NO
YES Fuse blown?
brake fuse
Lead wire failure
NO
Alarm Replace the

re-occurs? YES
MTU board
NO Alarm
Fuse failure
YES
Contact
MOTOMAN-service

MOTOMAN
ROBOTICS
AB Page: 117
Alarm 5120 Parity Error
Alarm Occurrence
Check the parameter for

parity check function
Invalid Set the parameter

YES
parameter? correctly
NO
Alarm
Check input YES re-occurs?
Check the NO
input program YES Abnormal?
Parameter setting
NO failure
Alarm Replace the MTU

re-occurs? YES
board
NO Alarm
Abnormal input
YES
Contact
MOTOMAN-service

ROBOTICS
Page: 118 AB
Alarm 5130 Over BCD Range
Alarm Occurrence
Check the BCD

function parameter

YES
NO
Check Alarm
input/output YES re-occurs?
Check the input/ NO

YES Abnormal?
output program
Parameter setting
NO failure
Alarm Replace IO
re-occurs? YES
module board
NO Alarm
Input/output
failure YES
Contact
MOTOMAN-service

MOTOMAN
ROBOTICS
AB Page: 119
Alarm 5140 Over Binary Range (parity check)
Alarm Occurrence
Check parity check - BCD

function parameter

YES
NO
Alarm
Check output YES re-occurs?
Check the NO
output program YES Abnormal?
Parameter setting
NO failure
Alarm Replace IO
re-occurs? YES
module board
NO Alarm
Output failure
YES
Contact
MOTOMAN-service
Alarm 5150 Offline Undefined Command (Arith)
Alarm Occurrence

Alarm
NO re-occurs? YES
Resume use Contact

MOTOMAN-service

ROBOTICS
Page: 120 AB
Alarm 5160 Offline System Error (Arith)
Alarm Occurrence

Alarm
NO re-occurs? YES
Resume use Contact

MOTOMAN-service
Alarm 5170 Robot Calibration Data Error
Alarm Occurrence

Alarm
NO re-occurs? YES
Resume use Contact

MOTOMAN-service
Alarm 5180 Robot Calibration Frame Error
Alarm Occurrence

Alarm
NO re-occurs? YES
Resume use Contact

MOTOMAN-service

MOTOMAN
ROBOTICS
AB Page: 121
Alarm 5190 Arithmetic Section Init Error
Alarm Occurrence

Alarm
NO re-occurs? YES
Resume use Contact

MOTOMAN-service
Alarm 5200 Set-Up Process Error (motion)
Alarm Occurrence

Alarm
NO re-occurs? YES
Resume use Contact

MOTOMAN-service
Alarm 5210 System Error (motion)
Alarm Occurrence

Alarm
NO re-occurs? YES
Resume use Contact

MOTOMAN-service

ROBOTICS
Page: 122 AB
Alarm 5220 Servo Ready Monitoring Error
Alarm Occurrence

Alarm
NO re-occurs? YES
Resume use Contact

MOTOMAN-service
Alarm 5230 Calibration Data Error
Alarm Occurrence

Alarm
NO re-occurs? YES
Resume use Contact

MOTOMAN-service
Alarm 5240 Tool Calibration Data Error
Alarm Occurrence

Alarm
NO re-occurs? YES
Resume use Contact

MOTOMAN-service

MOTOMAN
ROBOTICS
AB Page: 123
Alarm Occurrence

Alarm
NO re-occurs? YES
Resume use Load the file corresponding to

the display, and then try again
Alarm
NO re-occurs? YES
Resume use Contact

MOTOMAN-service
AL-5250 Robot calibration file AL-5280 Arc end cond guide file
AL-5260 Tool calibration file AL-5290 Welder user-defined file
AL-5270 Arc start cond guide file AL-5300 Ladder program file
Alarm 5310 Arithmetic Alarm Reset Error
Alarm Occurrence

Alarm
NO re-occurs? YES
Resume use Contact

MOTOMAN-service

ROBOTICS
Page: 124 AB
Alarm 5320 Wrong Control Group Axis
Alarm Occurrence
Check program and modify it (include

control group to the original job).
Alarm
NO re-occurs? YES
Resume use Contact

MOTOMAN-service
Alarm 5330 Cannot Execute Job (no robot)
Alarm Occurrence
Check program and modify it (include

control group to the original job).
Alarm
NO re-occurs? YES
Resume use Contact

MOTOMAN-service
Alarm 5340 Sensing Data Request Error
Alarm Occurrence

Alarm
NO re-occurs? YES
Resume use Contact

MOTOMAN-service

MOTOMAN
ROBOTICS
AB Page: 125
Alarm 5350 Main Contactor On Reply Error
Alarm Occurrence

Alarm
NO re-occurs? YES
Resume use Check if main contactor

is working or not
NO Working? YES
Check voltage for

main contactor coil
NO Abnormal? YES
Replace main
contactor
Alarm
re-occurs? YES Check MTU board
Defective? YES Replace MTU board

NO
Contactor failure NO
Contact Alarm
YES re-occurs?
MOTOMAN-service
NO
MTU board failure

ROBOTICS
Page: 126 AB
Alarm 5360 Main Contactor Off Reply Error
Alarm Occurrence

Alarm
NO re-occurs? YES

is working or not
NO Working? YES
Check voltage for

main contactor coil
NO Abnormal? YES
Replace main
contactor
Alarm

NO
Contact Alarm
YES re-occurs?
MOTOMAN-service
NO
MTU board failure

MOTOMAN
ROBOTICS
AB Page: 127
Alarm 5370 Braking Lock Reply Error
Alarm Occurrence

Alarm
NO re-occurs? YES

is working or not
NO Working? YES
Check voltage for

main contactor coil
NO Abnormal? YES
Replace main
contactor
Alarm

NO
Contact Alarm
YES re-occurs?
MOTOMAN-service
NO
MTU board failure

ROBOTICS
Page: 128 AB
Alarm 5380 Braking Release Reply Error
Alarm Occurrence

Alarm
NO re-occurs? YES

is working or not
NO Working? YES
Check voltage for

main contactor coil
NO Abnormal? YES
Replace main
contactor
Alarm

NO
Contact Alarm
YES re-occurs?
MOTOMAN-service
NO
MTU board failure

MOTOMAN
ROBOTICS
AB Page: 129
Alarm 5390 Servo-Ready On Error
Alarm Occurrence

Alarm
NO re-occurs? YES

is working or not
NO Working? YES 1
Check voltage for

main contactor coil
NO Abnormal? YES
Replace main
contactor
Alarm

NO
Contact Alarm
YES re-occurs?
MOTOMAN-service
NO
MTU board failure

ROBOTICS
Page: 130 AB
Alarm 5390 Servo-Ready On Error (...continued)
Check change LED

on servopack
YES Lit?
NO
Turn off power, and

then turn it on again
Alarm
re-occurs? NO Resume use
YES
Check wiring between

contactor and servopack
Replace wiring between

Defective? YES contactor and servopack
NO
Check wiring between MSV Alarm

YES re-occurs? NO Wiring failure
board and servopack

Defective? YES MSV board and servopack
NO
Alarm
Replace servopack YES re-occurs? NO Wiring failure
Alarm
re-occurs? YES Replace MSV board
NO Alarm MSV board

re-occurs? NO
failure
Servopack failure
YES
Contact
MOTOMAN-service

MOTOMAN
ROBOTICS
AB Page: 131
Alarm 5400 Servo-Ready Off Error
Alarm Occurrence

Alarm
NO re-occurs? YES

is working or not
NO Working? YES 1
Check voltage for

main contactor coil
NO Abnormal? YES
Replace main
contactor
Alarm

NO
Contact Alarm
YES re-occurs?
MOTOMAN-service
NO
MTU board failure

ROBOTICS
Page: 132 AB
Alarm 5400 Servo-Ready Off Error (...continued)
Check change LED

on servopack
YES Lit?
NO
Turn off power, and

Alarm
YES
Check wiring between

contactor and servopack

Defective? YES contactor and servopack
NO
Check wiring between MSV Alarm

YES re-occurs? NO Wiring failure
board and servopack

Defective? YES MSV board and servopack
NO
Alarm
Alarm
NO Alarm MSV board

re-occurs? NO
failure
Servopack failure
YES
Contact
MOTOMAN-service

MOTOMAN
ROBOTICS
AB Page: 133
Alarm 5410 Base-Block On Error
Alarm Occurrence

Alarm
YES
Turn off power, and

Alarm
YES
Check wiring between MSV

board and servopack

Defective? YES
MSV board and servopack
NO
Alarm
Alarm
NO Alarm MSV board

re-occurs? NO
failure
Servopack failure
YES
Contact
MOTOMAN-service

ROBOTICS
Page: 134 AB
Alarm 5420 Base-Block Off Error
Alarm Occurrence

Alarm
YES
Turn off power, and

Alarm
YES

board and servopack

Defective? YES
NO
Alarm
Alarm
NO Alarm MSV board

re-occurs? NO
failure
Servopack failure
YES
Contact
MOTOMAN-service

MOTOMAN
ROBOTICS
AB Page: 135
Alarm 5430 Dynamic Brake On Error
Alarm Occurrence

Alarm
YES
Turn off power, and

Alarm
YES

board and servopack

Defective? YES
NO
Alarm
Alarm
NO Alarm MSV board

re-occurs? NO
failure
Servopack failure
YES
Contact
MOTOMAN-service

ROBOTICS
Page: 136 AB
Alarm 5440 Dynamic Brake Off Error
Alarm Occurrence

Alarm
YES
Turn off power, and

Alarm
YES

board and servopack

Defective? YES
NO
Alarm
Alarm
NO Alarm MSV board

re-occurs? NO
failure
Servopack failure
YES
Contact
MOTOMAN-service

MOTOMAN
ROBOTICS
AB Page: 137
Alarm 5450 Unused (on)
Alarm Occurrence

Alarm
NO re-occurs? YES
Resume use Contact

MOTOMAN-service
Alarm 5460 Unused (off)
Alarm Occurrence

Alarm
NO re-occurs? YES
Resume use Contact

MOTOMAN-service
Alarm 5470 Cannot Edit (edit lock job)
Alarm Occurrence
Release Edit-lock, and then

Alarm
NO re-occurs? YES
Resume use Contact

MOTOMAN-service

ROBOTICS
Page: 138 AB
Alarm 5480 Select Error (application 1)
Alarm Occurrence

Alarm
NO re-occurs? YES
Resume use Contact

MOTOMAN-service
Alarm 5490 Select Error (application 2)
Alarm Occurrence

Alarm
NO re-occurs? YES
Resume use Contact

MOTOMAN-service
Alarm 5500 Select Error (sensor 1)
Alarm Occurrence

Alarm
NO re-occurs? YES
Resume use Contact

MOTOMAN-service

MOTOMAN
ROBOTICS
AB Page: 139
Alarm 5510 Select Error (sensor 2)
Alarm Occurrence

Alarm
NO re-occurs? YES
Resume use Contact

MOTOMAN-service
Alarm 5520 Wrong Port Out (analog output)
Alarm Occurrence

Alarm
NO re-occurs? YES
Resume use Contact

MOTOMAN-service
Data 1 Application 1 Data 2 Application 2

ROBOTICS
Page: 140 AB
Alarm 5530 Pass Over
Alarm Occurrence
Is COM-ARC III’s Check workpiece

YES
function normal? deviation
NO
Check the cable between

the current detection unit Small Deviation? Large Position a workpiece
and the sensor board
Defective? Check the current

NO detection unit
YES Replace the current

Defective? YES detection unit
Change the cable
NO
Replace the Alarm

YES re-occurs?
sensor board
Alarm NO
Sensor board failure NO re-occurs?
Current detection
YES unit failure
Contact
MOTOMAN-service
Alarm 5540 Wrong Selection (sensor)
Alarm Occurrence

Alarm
NO re-occurs? YES
Resume use Contact

MOTOMAN-service

MOTOMAN
ROBOTICS
AB Page: 141
Alarm 5550 Wrong Mech Parameter File
Alarm Occurrence

Alarm
NO re-occurs? YES
Resume use Contact

MOTOMAN-service
Alarm 5560 Incompleted PT Frame
Alarm Occurrence

Alarm
NO re-occurs? YES
Resume use Contact

MOTOMAN-service
Alarm 5570 Defective Taught Point (cutting)
Alarm Occurrence

Alarm
NO re-occurs? YES
Resume use Contact

MOTOMAN-service
Data 1 CW axis position is not 0. Data 2 Cutting radius is 0.

ROBOTICS
Page: 142 AB
Alarm 5580 Defective Taught Point (endless)
Alarm Occurrence

Alarm
NO re-occurs? YES
Resume use Contact

MOTOMAN-service
Data 1 Linear motion error (MRESET Data 3 Endless not selected on T-axis.
not executed.
Data 2 Endless on base axes Data 4 Command position exceeds limit
(214748367 pulse).
Alarm 5590 Correctional Direction Data
Alarm Occurrence

Alarm
NO re-occurs? YES
Resume use Contact

MOTOMAN-service
Alarm 5600 Position Correction Data
Alarm Occurrence

Alarm
NO re-occurs? YES
Resume use Contact

MOTOMAN-service

MOTOMAN
ROBOTICS
AB Page: 143
Alarm 5610 Over Tool File No.
Alarm Occurrence

Alarm
NO re-occurs? YES
Resume use Contact

MOTOMAN-service
Alarm 5620 Defective Taught Point (weav)
Alarm Occurrence
Check the REFP, and then

teach the REFP again
Alarm
NO re-occurs? YES
Resume use Contact

MOTOMAN-service
Data 1 Weaving atart point and end Data 2 Weaving REFP 1 or 2 is on the path
point is the same
Alarm 5630 Undefined Robot Calibration
Alarm Occurrence
Execute robot calibration
Alarm
NO re-occurs YES
Resume use Contact

MOTOMAN-service

ROBOTICS
Page: 144 AB
Alarm 5640 Parameter Error
Alarm Occurrence
Reset the parameter

with the original data
Alarm
NO re-occurs? YES
Resume use Load the parameter file

and then try again
Alarm
NO re-occurs? YES
Resume use Contact

MOTOMAN-service
Alarm 5650 Defective Taught Point (Calib)
Alarm Occurrence
Check the taught point, and

Alarm
NO re-occurs? YES
Resume use Contact

MOTOMAN-service
Data 3 Data for station 2nd axis is not Data 5 Data for station 2nd axis is not
same 3, 4, 5 points. same 1, 2, 3 points.
Data 4 Data for station 1st axis is not Data 6 Data for station 1st axis is not same
same 1, 2, 3 points. 3, 4, 5 points.

MOTOMAN
ROBOTICS
AB Page: 145
Alarm 5660 DM-Bank Transmission Error
Alarm Occurrence

Alarm
NO re-occurs? YES
Resume use Contact

MOTOMAN-service
Alarm 5670 Cannot Execute Job (no grp axis)
Alarm Occurrence
Set group axes
Alarm
NO re-occurs? YES
Resume use Contact

MOTOMAN-service
Alarm 5680 Univ Data Preset Request Error
Alarm Occurrence

Alarm
NO re-occurs? YES
Resume use Contact

MOTOMAN-service

ROBOTICS
Page: 146 AB
Alarm 5690 Braking Sequence Error
Alarm Occurrence

Alarm
NO re-occurs? YES
Resume use Contact

MOTOMAN-service
Alarm 5700 Process Error (Syscon - axis)
Alarm Occurrence

Alarm
NO re-occurs? YES
Resume use Contact

MOTOMAN-service
Alarm 5710 Illegal Sv Parameter (online)
Alarm Occurrence
Reset the parameter

with the original data.
Alarm
NO re-occurs? YES

and then try again
Alarm
NO re-occurs? YES
Resume use Contact

MOTOMAN-service

MOTOMAN
ROBOTICS
AB Page: 147
Alarm 5720 Illegal Sv Parameter (online)
Alarm Occurrence

Alarm
NO re-occurs? YES
Resume use Replace the MSV board,

and then try again
Alarm
NO re-occurs? YES
Resume use Contact

MOTOMAN-service
Alarm 5730 Sv Parameter Change Error (online)
Alarm Occurrence

Alarm
NO re-occurs? YES
Resume use Replace the MSV board,

and then try again
Alarm
NO re-occurs? YES
Resume use Contact

MOTOMAN-service

ROBOTICS
Page: 148 AB
Alarm 5740 Illegal Max Speed Parameter
Alarm Occurrence
Reset the parameter

with the original data
Alarm
NO re-occurs? YES

and then try again
Alarm
NO re-occurs? YES
Resume use Contact

MOTOMAN-service
Alarm 5750 Undefined Position Variable
Alarm Occurrence
Set the position variable
Alarm
NO re-occurs? YES
Resume use Contact

MOTOMAN-service
Alarm 5760 Undefined User Frame
Alarm Occurrence
Set the user frame
Alarm
NO re-occurs? YES
Resume use Contact

MOTOMAN-service

MOTOMAN
ROBOTICS
AB Page: 149
Alarm 5770 Out Of Range (parallel process)
Alarm Occurrence

Alarm
NO re-occurs? YES
Resume use Contact

MOTOMAN-service
Alarm 5780 SL Board On-Line Error
Alarm Occurrence

Alarm
NO re-occurs? YES
Resume use Contact

MOTOMAN-service
Alarm 5790 Interrupt Error (sensor)
Alarm Occurrence

Alarm
NO re-occurs? YES
Resume use Contact

MOTOMAN-service

ROBOTICS
Page: 150 AB
Alarm 5800 Out Of Current Detector Range
Alarm Occurrence

Alarm
NO re-occurs? YES
Resume use Contact

MOTOMAN-service
Alarm 5810 Command Error (sensor)
Alarm Occurrence

Alarm
NO re-occurs? YES
Resume use Contact

MOTOMAN-service
Alarm 5820 Process Error (sensor)
Alarm Occurrence

Alarm
NO re-occurs? YES
Resume use Contact

MOTOMAN-service

MOTOMAN
ROBOTICS
AB Page: 151
Alarm 5830 Parallel Start Instruction Error
Alarm Occurrence
Check the program,

and then modify it.
Alarm
NO re-occurs? YES
Resume use Contact

MOTOMAN-service
Alarm 5840 Cannot Execute Job (grp axis)
Alarm Occurrence
Set group axes
Alarm
NO re-occurs? YES
Resume use Contact

MOTOMAN-service
Alarm 5850 Measure Inst Execute Error
Alarm Occurrence

Alarm
NO re-occurs? YES
Resume use Contact

MOTOMAN-service

Headquarters:
MOTOMAN ROBOTICS AB
Box 504 l 385 25 Torsås l Sweden
Tel: +46-486-48800l Fax: +46-486-41410
Subsidiary:
MOTOMAN ROBOTICS UK LTD
1 Swan Industrial Estate l Banbury l OXON OX16 8DJ l England
Tel: +44-1295-272755 l Fax: +44-1295-267127
MOTOMAN ROBOTICS ITALIA SRL

Via Emilia 1420/16 l I-41100 Modena l ITALY
Tel: +39-59280496 l Fax: +39-59280602
MOTOMAN ROBOTICS FRANCE S.A.

Rue Nungesser et Coli l D2A Nantes-Atlantique l F-44860 Saint-Aignan-de-Grand-Lieu l France
Tel: +33-2-40131919 l Fax: +33-40754147
MOTOMAN ROBOTICS ESPAÑA S.L.

Avenida Marina 56 l Parcela 90 l ES-08830 ST. Boi de Llobregat l Spain
Tel: +34-36303478 l Fax: +34-36543459
Distributors:
ELECTRO-ARCO S.A.
Rua Vice Almirante Azevedo Coutinho, 4 l Venda Nova l PT-2700 Amadora l Portugal
Tel: +351-14968160 l Fax: +351-14990696
HN AUTOMATIC A/S
Hjulmagervej 4 l DK-7100 Vejle l Denmark
Tel: +45-79428000 l Fax: +45-79428001
LINCOLN-KD S.A.
Ctra, Laureà Miró 396-398 l E-08980 Sant Feliu de Llobregat l Spain
Tel: +34-36859600 l Fax: +34-36859633
MOTOMAN ROBOTIT OY
Kärsämäentie 8 l SF-20300 Turku l Finland
Tel: +358-22145600 l Fax: +358-22145660
ROBOT-TEKNIKK AS
Øvre Eikervei 177 l N-3048 Drammen l Norway
Tel: +47-32217830 l Fax: +47-32217840
SIAD S.p.a.
Via S. Bernardino, 92 l I-24126 Bergamo l Italy
Tel: +39-35-328111 l Fax: +39-35-320183
MOTOMAN ROBOTICS AB
a subsidiary of YASKAWA Electric Corporation

Motoman MRC Troubleshooting

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Motoman MRC Troubleshooting

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YASNAC MRC ver. 3.

Trouble Shooting Guide, YASNAC MRC

Alarm 0010 CPU Board Insertion Error

Turn power OFF,

Resume use Remove the SV board corresponding

Remove the MCP01 Resume use

Resume use Replace the ROM of the board

ROM failure Replace the board

Board failure Contact

Skapad: 98-10-09 Ändrad: 98-11-26 Filnamn: T:\M-ROBOT\ENGELSK\TROUBLE_SHOOTING.FM

Alarm 0020 CPU Communication Error

Turn power OFF,

Resume use Remove the SV board corresponding

Remove all boards, Resume use

Resume use Replace the ROM of the board

ROM failure Replace the board

Board failure Contact

Skapad: 98-10-09 Ändrad: 98-11-26 Filnamn: T:\M-ROBOT\ENGELSK\TROUBLE_SHOOTING.FM

Alarm 0030 ROM Error

Turn power OFF,

Resume use Replace the ROM of the board

ROM failure Replace the board

Contact Board failure

Skapad: 98-10-09 Ändrad: 98-11-26 Filnamn: T:\M-ROBOT\ENGELSK\TROUBLE_SHOOTING.FM

Alarm 0040 RAM Error (local)

Turn power OFF,

Resume use Remove the board corresponding

Resume use Replace the board

Contact Board failure

Skapad: 98-10-09 Ändrad: 98-11-26 Filnamn: T:\M-ROBOT\ENGELSK\TROUBLE_SHOOTING.FM

Alarm 0050 RTC Error)

Turn power OFF,

Resume use Remove the board corresponding

Resume use Replace the board

Contact Board failure

Skapad: 98-10-09 Ändrad: 98-11-26 Filnamn: T:\M-ROBOT\ENGELSK\TROUBLE_SHOOTING.FM

Alarm 0060 RAM Error (A-bus Common)

Turn power OFF,

Resume use Remove the board corresponding

Remove all boards Resume use

Resume use Replace the board

Replace all boards Board failure

Board failure Contact

Skapad: 98-10-09 Ändrad: 98-11-26 Filnamn: T:\M-ROBOT\ENGELSK\TROUBLE_SHOOTING.FM

Alarm 0070 RAM Error (D-Bus 2-Port)

Turn power OFF,

Resume use Remove the SV board corresponding

Remove all boards Resume use

Resume use Replace the SV board

SV board failure Replace the MCP02 board

Replace all boards Board failure

Board failure Contact

Skapad: 98-10-09 Ändrad: 98-11-26 Filnamn: T:\M-ROBOT\ENGELSK\TROUBLE_SHOOTING.FM

Alarm 0080 RAM Error (S-Bus 2-Port)

Turn power OFF,

Resume use Remove the board corresponding

Remove MCP01 Resume use

Resume use Replace the board

Replace the MCP01 board Board failure

MCP01 board failure Contact

Skapad: 98-10-09 Ändrad: 98-11-26 Filnamn: T:\M-ROBOT\ENGELSK\TROUBLE_SHOOTING.FM

Alarm 0090 I/O Module Communication Error

Turn power OFF,