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FANUC Robotics SYSTEM R-J3 i-size, B-size, and Paint Controller Electrical Connection and Maintenance Manual MARM3CONM10801E

REV. A

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3.5 TROUBLESHOOTING USING THE ERROR CODE

(1) SRVO-001 SVAL1 Operator panel E-stop o (Explanation) The emergency stop button on the operation box or operator's panel or is pressed. o (Action 1) Release the emergency stop button pressed on the operator's box. o (Action 2) Check the wires connecting the emergency stop switch connector CRT8 for continuity. If an open wire is found replace the entire harness. o (Action 3) With the emergency stop in the released position, check for continuity across the terminals of the switch. If continuity is not found, replace the switch. If continuity is found replace the operator panel PCB. o (Action 4) Replace the Main Board.

(2) SRVO-002 SVAL1 Teach pendant E-stop o (Explanation) The emergency stop button on the operator's Teach Pendant was pressed. o (Action 1) Release the emergency stop button on the teach pendant.

(Action 2) Replace Teach Pendant.

(3) SRVO-003 SVAL1 Deadman switch released o (Explanation) The teach pendant is enabled, but the deadman's switch is not pressed. o (Action 1) Press the deadman switch to run the robot. o (Action 4) Replace the teach pendant.

(4) SRVO-004 SVAL1 Fence open o (Explanation) On the terminal block TBOP1of the panel board, no connection is made between 3 (FENCE1) and 4 (FENCE2). If a safety fence is connected between 3 (FENCE1) and 4 (FENCE2), the door of the safety fence is open. o (Action 1) If a safety fence is connected, close the door. o (Action 2) Check the switch and cable connected to 3 (FENCE1) and 4 (FENCE2). o (Action 3) When this signal is not used, make a connection between 3 (FENCE1) and 4 (FENCE2). o (Action 4) Replace the panel PC board.

WARNING Do NOT short-circuit, or disable, this signal in a system in which the Fence signal is in use, as it is very dangerous. If it is necessary to run the robot by short-circuiting the signal even temporarily, an additional safety provision must be provided.

(5) SRVO-005 SVAL1 Robot overtravel o (Explanation) The robot has moved beyond a hardware limit switch on the axes. It is factory-placed in the overtravel state for packing purposes. If the Overtravel signal is not in use, it may have been disabled by short-circuiting CRM37B on the servo amplifier. o (Action 1) 1) Select [System OT release] on the overtravel release screen to release each robot axis from the overtravel state. 2) Hold down the shift key, and press the alarm release button to reset the alarm condition. 3) Still hold down the shift key, and jog to bring all axes into the movable range. o (Action 2) Check the overtravel connection cable (one-piece i -cabinet/robot type) and robot connection cable (RP1) for a ground fault. If no limit switch is in use, a jumper connector must be attached to the CRM37B connector of the servo amplifier. Check for the jumper connector. o (Action 3) Replace the servo amplifier.

(6) SRVO-006 SVAL1 Hand broken o (Explanation) The safety joint (if in use) might have been broken. Alternatively, the HBK signal on the robot connection cable might be a ground fault or a cable disconnection. If the Hand broken signal is not in use, it may have been disabled by shortcircuiting CRM37A on the servo amplifier. o (Action 1) Hold down the shift key, and press the alarm release button to reset the alarm condition. Still hold down the shift key, and jog the tool to the work area. 1) Replace the safety joint. 2) Check the safety joint cable. o (Action 2) Check the robot connection cable (RP1) for a ground fault or a cable disconnection. o (Action 3) Replace the servo amplifier.

(7) SRVO-007 SVAL1 External E-stop o (Explanation) On the terminal block TBOP1 of the panel board, no connection is made between 1 (EMGIN1) and 2 (EMGIN2). If an external emergency stop switch is connected between 1 (EMGIN1) and 2 (EMGIN2), the switch is pressed. o (Action 1) If an external emergency stop switch is connected, releases the switch. o (Action 2) Check the switch and cable connected to 1(EMGIN1) and 2 (EMGIN2). o (Action 3) When this signal is not used, make a connection between 1 (EMGIN1) and 2 (EMGIN2). o (Action 4) Replace the PC board.

WARNING Do NOT short-circuit, or disable, this signal in a system in which the External emergency stop input signal is in use, as it is very dangerous. If it is necessary to run the robot by short-circuiting the signal even temporarily, an additional safety provision must be provided.

(8) SRVO-009 SVAL1 Pneumatic pressure alarm o (Explanation) An abnormal air pressure was detected. o (Action 1) If an abnormal air pressure is detected, check the cause. If the peripheral device are normal, check the robot cable and if the peripheral device are abnormal, replace the device. o (Action 2) Replace the servo amplifier.

(9) SRVO-014 WARN Fan motor abnormal o (Explanation) A fan motor in the backplane unit is abnormal. o (Action) Check the fan motor and its cables. Replace them if necessary.

(10) SRVO-015 SVAL1 SYSTEM OVER HEAT (Group : i Axis : j) o (Explanation) The temperature in the control unit exceeds the specified value. o (Action 1) If the ambient temperature is higher than specified (45 C), cool down ambient temperature using the air conditioning unit. o (Action 2) If the fan motor is not running, check it and its cables. Replace them if necessary. o (Action 3) If the thermostat on the main board is defective, replace the backplane unit.

(11) SRVO-018 SVAL1 Brake abnormal o (Explanation) An excessive brake current is detected. The seven-segment LED on the servo amplifier indicates 1. o (Action 1) Check the robot connection cable (RM1) and cables internal to the mechanical section for a short-circuit and connection to the ground. o (Action 2) Replace the servo amplifier.

(12) SRVO-019 SVAL1 SVON input o (Explanation) On the terminal block TBOP1 of the panel board, no connection is made between 5 (SVOFF1) and 6 (SVOFF2). If a switch is connected between 5 (SVOFF1) and 6 (SVOFF2), the switch is pressed. o (Action 1) If a switch is connected, releases the switch. o (Action 2) Check the switch and cable connected to 5 (SVOFF1) and 6 (SVOFF2). o (Action 3) When this signal is not used, make a connection between 5 (SVOFF1) and 6 (SVOFF2). o (Action 4) Replace the panel board.

WARNING Do NOT short-circuit, or disable, this signal in a system in which the Servo off emergency stop signal input is in use, as it is very dangerous. If it is necessary to run the robot by short-circuiting the signal even temporarily, an additional safety provision must be provided.

(13) SRVO-021 SVAL1 SRDY off (Group : i Axis : j) o (Explanation) The HRDY is on and the SRDY is off, although there is no other cause of an alarm. (HRDY is a signal with which the host directs the servo system whether to turn on or off the servo amplifier magnetic contactor. SRDY is a signal with which the servo system informs the host whether the magnetic contactor is

o o o o o o

turned on.) If the servo amplifier magnetic contactor cannot be turned on when directed so, it is most likely that a servo amplifier alarm has occurred. If a servo amplifier alarm has been detected, the host will not issue this alarm (SRDY off). Therefore, this alarm indicates that the magnetic contactor cannot be turned on for an unknown reason. (Action 1) Check whether an outage has occurred on an emergency stop line (teach pendant emergency stop, teach pendant enable/disable switch, teach pendant deadman switch, operator box emergency stop, external emergency stop input, fence input, servo-off input, or door switch). This alarm occurs if the alarm cause cannot be detected by software because of a short break and magnetic contactor off. (Action 2) Check the magnetic contactor for continuity. If it is bad replace it. (Action 3) Replace the cable between the emergency stop board and the magnetic contactor. (Action 4) Replace the emergency stop control PCB. (Action 5) Replace axis control card on the main board. (Action 6) Replace the servo amplifier. (Action 7) Replace the main board.

(14) SRVO-022 SVAL1 SRDY on (Group : i Axis : j) o (Explanation) When the HRDY is about to go on, the SRDY is already on. (HRDY is a signal with which the host directs the servo system whether to turn on or off the servo amplifier magnetic contactor. SRDY is a signal with which the servo system informs the host whether the magnetic contactor is turned on. o (Action 1) Replace the axis control board on the main board. o (Action 2) Replace the servo amplifier.

(Action 3) Replace the main board.

(15) SRVO-023 SVAL1 Stop error excess (Group : i Axis : j) o (Explanation) When the servo is at stop, the position error is abnormally large. o (Action 1) Check whether the motor brake has been released. o (Action 2) Check to see if the load is greater than the rating. If greater, reduce it to within the rating. (If the load is too greater, the torque required for acceleration / deceleration becomes higher than the capacity of the motor. As a result, the motor becomes unable to follow the command, and an alarm is issued.) o (Action 3) Check each phase voltage of the three-phase power (200 VAC) input to the servo amplifier. If it is 170 VAC or lower, check the line voltage. (If the voltage input to the servo amplifier becomes low, the torque output also becomes low. As a result the motor may become unable to follow the command, hence possibly an alarm.) o (Action 4) If the line voltage is 170 VAC or higher, replace the servo amplifier. o (Action 5) Check disconnection of motor power cable (RM1, RM2, RM3). o (Action 6) Replace the motor.

(16) SRVO-024 SVAL1 Move error excess (Group : i Axis : j) o (Explanation) When the robot is running, its position error is greater than a specified value ($PARAM _ GROOP. $MOVER _ OFFST or $PARAM _ GROUP. $TRKERRLIM). It is likely that the robot cannot follow the speed specified by program. o (Action) Take the same actions as described for the above alarm. (17) SRVO-025 SVAL1 Motn dt overflow (Group : i Axis : j) o (Explanation) The specified value is too great. (18) SRVO-026 WARN2 Motor speed limit (Group : i Axis : j) o (Explanation) A value higher than the maximum motor speed ($PARAM_GROUP.$MOT_SPD_LIM) was specified. The actual motor speed is clamped to the maximum speed. (19) SRVO-027 WARN Robot not mastered (Group : i) o (Explanation) An attempt was made to calibrate the robot, but the necessary adjustment had not been completed. o (Action) Make the adjustment on the positioning menu select System positioning. (20) SRVO-030 SVAL1 Brake on hold (Group : i) o (Explanation) This alarm occurs when the robot pauses, if the brake on hold function has been enabled ($SCR. $BRKHOLD _ ENB = 1). Disable the function if it is not necessary. o (Action) Disable [Servo-off during pause] on the general setting menu (Select Setting general). (21) SRVO-031 SVAL1 User servo alarm (Group : i) o (Explanation) An user servo alarm occurred. (22) SRVO-033 WARN Robot not calibrated (Group : i) o (Explanation) An attempt was made to set up a reference point for simplified adjustment, but the robot had not been calibrated. o (Action) Calibrate the robot. 1. Supply power. 2. Set up a simplified adjustment reference point using [Positioning] on the positioning menu. (23) SRVO-034 WARN Ref pos not set (Group : i)

(Explanation) An attempt was made to perform simplified adjustment, but the reference point had not been set up. o (Action) Set up a simplified adjustment reference point on the positioning menu. (24) SRVO-035 WARN2 Joint speed limit (Group : i Axis : j) o (Explanation) A value higher than the maximum axis speed ($PARAM_GROUP.$JNTVELLIM) was specified. Each actual axis speed is clamped to the maximum speed. (25) SRVO-036 SVAL1 Inpos time over (Group : i Axis : j) o (Explanation) The robot did not get to the effective area ($PARAM _ GROUP.$ STOPTOL) even after the position check monitoring time ($PARAM _ GROUP. $INPOS _ TIME) elapsed. o (Action) Take the same actions as for SRVO-23 (large position error at a stop). (26) SRVO-037 SVAL1 Imstp input (Group : i) o (Explanation) The *IMSTP signal for a peripheral device interface was input. o (Action) Turn on the *IMSTP signal. (27) SRVO-038 SVAL2 Pulse mismatch (Group : i Axis : j) o (Explanation) The pulse count obtained when power is turned off does not match the pulse count obtained when power is applied. o (Action) Perform APC reset and remaster robot (RES-PCA) 1. Press MENUS. 2. Select SYSTEM. 3. Press F1 [TYPE]. 4. Select MASTER/CAL. 5. Press F3, PES-PCA. 6. Press RESET. The fault condition should reset. If the controller is still faulted with additional servo-related errors, cold start the controller. It might be necessary to remaster the robot. (28) SRVO-041 SVAL2 MOFAL alarm (Group : i Axis : j) o (Explanation) The servo value was too high. o (Action) Cold start the controller. 1. Turn off the controller. 2. Cold start the controller. (29) SRVO-042 MCAL alarm (Group : i Axis : j) o (Explanation) This alarm means that the contacts of the magnetic contactor have stuck to each other. The alarm condition occurs if the magnetic contactor turns out to be already on when an attempt is made to turn it on. The alarm condition is detected between the time contact sticking occurs and the time an attempt is made to turn on the magnetic contactor. This alarm is represented by "2" on the 7segment LED indicator of the servo amplifier. o (Action 1) Check the magnetic contactor, and replace it if necessary. If the contacts of the magnetic contactor have stuck to each other, turn off the circuit breaker. If the power is switched off without turning off the circuit breaker, the servo amplifier may get damaged, because the stuck contacts keep three-phase 200 V applied to the servo amplifier. o (Action 2) Replace the emergency stop board.

(Action 3) Replace the servo amplifier.

(30) SRVO-043 SVAL1 DCAL alarm (Group : i Axis : j) o (Explanation) The regenerative discharge energy was too high to be dissipated as heat. (To run the robot, the servo amplifier supplies energy to the robot. When going down the vertical axis, the robot operates from the potential energy. If a reduction in the potential energy is higher than the energy needed for acceleration, the servo amplifier receives energy from the motor. A similar phenomenon occurs even when no gravity is applied, for example, at deceleration on a horizontal axis. The energy that the servo amplifier receives from the motor is called the regenerative energy. The servo amplifier dissipates this energy as heat. If the regenerative energy is higher than the energy dissipated as heat, the difference is stored in the servo amplifier, causing an alarm.) "8" is display on the servo segment LED of the servo amplifier. o (Action 1) This alarm may occur if the axis is subjected to frequent acceleration/deceleration or if the axis is vertical and generates a large amount of regenerative energy. If this alarm has occurred, relax the service conditions. o (Action 2) Check fuse FU1 in the servo amplifier. If it has blown, remove the cause, and replace the fuse. One of the probable causes of a blown fuse is a ground fault in the end effecter (RDI/RDO), ROT, or HBK signal. o (Action 3) Detach the cable from CRR43A on the emergency stop board, and check for continuity between pins 1 and 2 of the cable-end connector. If there is no continuity between the pins, replace the regenerative resistance. o (Action 4) Detach the cables from CRR45A, CRR45B, and CRR45C on the servo amplifier, and check the resistance between pins 1 and 2 of each cable-end connector. If the resistance is not 9 , replace the regenerative resistance. o (Action 5) Replace the servo amplifier.

(31) SRVO-044 SVAL1 HVAL alarm (Group : i Axis : j) o (Explanation) The DC voltage (DC link voltage) of the main circuit power supply is abnormally high. The servo amplifier LED indicates 7. o (Action 1) Check the three-phase input voltage at the servo amplifier. If it is 253 VAC or higher, check the line voltage. (If the three-phase input voltage is higher than 253 VAC, high acceleration/deceleration can result in this alarm.) o (Action 2) Check that the load weight is within the rating. If it is higher than the rating, reduce it to within the rating. (If the machine load is higher than the rating, the accumulation of regenerative energy might result in the HVAL alarm even when the three-phase input voltage is within the rating. o (Action 3) Replace the servo amplifier.

(32) SRVO-045 SVAL1 HCAL alarm (Group : i Axis : j) o (Explanation) Abnormally high current flowed in the main circuit of the servo amplifier. The servo amplifier 7-segment LED indicates -. At the same time, a red LED (HC1 to HC6) corresponding to the HCAL alarm on the side of 7-segment LED. o (Action 1) Disconnect the motor power lines from the servo amplifier terminals, supply power, and see if the alarm occurs again. If the alarm occurs, replace the servo amplifier. o (Action 2) Disconnect the motor power lines from the servo amplifier terminals, and check the insulation of each motor power line (U, V, or W) and the GND line. If there is a short-circuit, the motor, robot interconnection cable, or intra-robot cable is defective. Check them and replace them if necessary. o (Action 3) Disconnect the motor power lines from the servo amplifier terminals, and measure the resistance between the U and V, V and W, and W and U with a ohmmeter with a very low resistance range. If the resistances at these three places are different from each other, the motor, robot interconnection cable, or intrarobot cable is defective. Check each item in detail and replace it if necessary.

(33) SRVO-046 SVAL2 OVC alarm (Group : i Axis : j) o (Explanation) This alarm is issued to prevent the motor from thermal damage that might occur when the root meant square current calculated within the servo system is out of the allowable range. o (Action 1) Check the operating conditions for the robot. If the technical data of the robot such as duty cycle or load weight is higher than the rating, reduce it to within the rating. o (Action 2) Check each phase voltage of the three-phase input power (200 VAC for the servo amplifier. If it is 170 VAC or lower, check the line voltage. o (Action 3) Replace the servo amplifier. o (Action 4) Replace the motor.

Reference

Relationships among the OVC, OVL, and HC alarms

Overview This section points out the differences among the OVC, OVL, and HC alarms and describes the purpose of each alarm. Alarm detection section Abbreviation OVC OVL Designation Overcurrent alarm Servo software Overload alarm High current alarm Thermal relay in the motor OHAL2 Thermal relay in the servo amplifier OHAL1 Thermal relay in the separate regenerative dis charge unit DCAL Servo amplifier Detection section

HC

Purpose of each alarm

1) HC alarm (high current alarm) If high current flow in a power transistor momentarily due to abnormality or noise in the control circuit, the power transistor and rectifier diodes might be damaged, or the magnet of the motor might be degaussed. The HC alarm is intended to prevent such failures.

2) OVC and OVL alarms (overcurrent and overload alarms) The OVC and OVL alarms are intended to prevent overheat that may lead to the burnout of the motor winding, the breakdown of the servo amplifier transistor, and the separate regenerative resistor. The OVL alarm occurs when each built-in thermal relay detects a temperature higher than the rated value. However, this method is not necessarily perfect to prevent these failures. For example, if the motor frequently repeats to start and stop, the thermal time constant of the motor, which has a large mass, becomes higher than the time constant of the thermal relay, because these two components are different in material, structure, and dimension. Therefore, if the motor repeats to start and stop within a short time as shown in Fig. 1, the temperature rise in the motor is steeper than that in the thermal relay, thus causing the motor to burn before the thermal relay detects an abnormally high temperature.

Fig.1 Relationship between the temperatures of the motor and thermal relay on start/stop cycles To prevent the above defects, software is used to monitor the current in the motor constantly in order to estimate the temperature of the motor. The OVC alarm is issued based on this estimated temperature. This method estimates the motor temperature with substantial accuracy, so it can prevent the failures described above. To sum up, a double protection method is used; the OVC alarm is used for protection from a short-time overcurrent, and the OVL alarm is used for protection from long-term overload. The relationship between the OVC and OVL alarms is shown in Fig 2.

Fig.2 Relationship between the OVC and OVL alarms NOTE The relationship shown in Fig. 2 is taken into consideration for the OVC alarm. The motor might not be hot even if the OVC alarm has occurred. In this case, do not change the parameters to relax protection.

(34) SRVO-047 SVAL1 LVAL alarm (Group : i Axis : j)

o o o

(Explanation) The control power supply voltage (+5 V, etc.) is abnormally low. The servo amplifier seven segment LED indicates "6". (Action 1) Replace the servo amplifier. (Action 2) Replace the power supply unit.

(35) SRVO-049 SVAL1 OHAL1 alarm (Group : i Axis : j) o (Explanation) The thermostat in the transformer worked. Alternatively, fuse F1 or F2 in the servo amplifier has blown. The servo amplifier LED indicates "3". o (Action 1) Check the operating conditions for the robot. If the technical data of the robot such as duty cycle or load weight is higher than the rating, reduce it to within the rating. o (Action 2) If fuses F1 and F2 have blown, replace the servo amplifier. o (Action 3) Replace the transformer.

(36) SRVO-050 SVAL1 CLALM alarm (Group : i Axis : j) o (Explanation) The disturbance torque estimated by the servo software is abnormally high. (A collision has been detected.) o (Action 1) Check that the robot has collided with anything. If it has, reset the robot and jog-feed it to recover from the collision. o (Action 2) Check that the load weight is within the rating. If it is higher than the rating, reduce it to within the rating. (If the robot is used out of its usable range, the estimated disturbance torque becomes abnormally high, possibly resulting in this alarm being detected.) o (Action 3) Check the phase voltage of the three-phase input power (200 VAC) to the servo amplifier. If it is 170 VAC or lower, check the line voltage. o (Action 4) Replace the servo amplifier.

(37) SRVO-051 SVAL2 CUER alarm (Group : i Axis : j) o (Explanation) The offset of the current feedback value is abnormally high. o (Action) Replace the servo amplifier.

(38) SRVO-054 DSM Memory Error o (Explanation) An access to the servo module memory fails. o (Action) Replace the axis control card.

(39) SRVO-055 SVAL2 FSSB com error 1 (Group : i Axis : j) o (Explanation) A communication error has occurred between the main board and servo amplifier. o (Action 1) Check the communication cable (optical fiber) between the main board and servo amplifier. Replace it if it is faulty. o (Action 2) Replace the axis control card on the main board. o (Action 3) Replace the servo amplifier. o (Action 4) Replace the main board.

(40) SRVO-056 SVAL2 FSSB com error 2 (Group : i Axis : j) o (Explanation) A communication error has occurred between the main board and servo amplifier. o (Action 1) Check the communication cable (optical fiber) between the main board and servo amplifier. Replace it if it is faulty. o (Action 2) Replace the axis control card on the main board. o (Action 3) Replace the servo amplifier. o (Action 4) Replace the main board.

(41) SRVO-057 SVAL2 FSSB disconnect (Group : i Axis : j) o (Explanation) Communication was interrupted between the main board and servo amplifier. o (Action 1) Check whether fuse F3 in the power supply unit has blown. If it has, take a measure according to the explanation in Section 3.5. o (Action 2) Check the communication cable (optical fiber) between the main board and servo amplifier. Replace it if it is faulty. o (Action 3) Replace the axis control card on the main board. o (Action 4) Replace the servo amplifier. o (Action 5) Replace the main board.

(42) SRVO-058 SVAL2 FSSB init error (Group : i Axis : j) o (Explanation) Communication was interrupted between the main board and servo amplifier. o (Action 1) Check whether fuse F3 in the power supply unit has blown. If it has, take a measure according to the explanation in Section 3.5. o (Action 2) Check the communication cable (optical fiber) between the main board and servo amplifier. Replace it if it is faulty. o (Action 3) Replace the axis control card on the main board. o (Action 4) Replace the servo amplifier. o (Action 5) Replace the main board.

(43) SRVO-061 SVAL2 CKAL alarm (Group : i Axis : j) o (Explanation) This alarm occurs if the rotation speed count in the pulse coder is abnormal (abnormal count clock). o (Action) Replace the pulse coder. NOTE This alarm might accompany the DTERR, CRCERR, or STBERR alarm. In this case, however, there is no actual condition for this alarm.

(44) SRVO-062 SVAL2 BZAL alarm (Group : i Axis : j) o (Explanation) This alarm occurs if no battery for pulse coder absolute-position backup is connected. A probable cause is a broken battery cable in the robot. o (Action) Remove the cause of the alarm, and set the system variable $MCR.$SPC_RESET to TRUE, then supply power again. After this, mastering is required. (45) SRVO-063 SVAL2 RCAL alarm (Group : i Axis : j) o (Explanation) This alarm occurs if the rotation speed count in the pulse coder is abnormal (abnormal counter). o (Action) Replace the pulse coder. NOTE This alarm might accompany the DTERR, CRCERR, or STBERR alarm. In this case, however, there is no actual condition for this alarm.

(46) SRVO-064 SVAL2 PHAL alarm (Group : i Axis : j) o (Explanation) This alarm occurs if the phase of the pulses generated in the pulse coder is abnormal. o (Action) Replace the pulse coder. NOTE This alarm might accompany the DTERR, CRCERR, or STBERR alarm. In this case, however, there is no actual condition for this alarm.

(47) SRVO-065 WARN BLAL alarm (Group : i Axis : j) o (Explanation) The battery voltage for the pulse coder is lower than the rating. o (Action) Replace the battery. (If this alarm occurs, turn on the AC power and replace the battery as soon as possible. A delay in battery replacement may result in the BZAL alarm being detected. In this case, the position data will be lost. Once the position data is lost, mastering will become necessary. (48) SRVO-066 SVAL2 CSAL alarm (Group : i Axis : j) o (Explanation) The ROM in the pulse coder is abnormal. o (Action) Replace the pulse coder. NOTE This alarm might accompany the DTERR, CRCERR, or STBERR alarm. In this case, however, there is no actual condition for this alarm.

(49) SRVO-067 SVAL2 OHAL2 alarm (Group : i Axis : j) o (Explanation) The temperature inside the pulse coder or motor is abnormally high, and the built-in thermostat has operated. o (Action 1) Check the operating conditions for the robot. If the technical data of the robot such as duty cycle or load weight is higher than the rating, reduce it to within the rating. o (Action 2) When power is supplied to the motor after it has become sufficiently cool, if the alarm still occurs, replace the motor. (50) SRVO-068 SVAL2 DTERR alarm (Group : i Axis : j) o (Explanation) The serial pulse coder does not return serial data in response to a request signal. - See actions on SRVO-070 (51) SRVO-069 SVAL2 CRCERR alarm (Group : i Axis : j) o (Explanation) The serial data has disturbed during communication. - See actions on SRVO-070 (52) SRVO-070 SVAL2 STBERR alarm (Group : i Axis : j) o (Explanation) The start and stop bits of the serial data are abnormal. o (Action 1) Check that the shielding of the robot interconnection cable (for the pulse coder) and the peripheral equipment cable is connected securely to the grounding plate.

o o o o

(Action 2) Check that each unit is grounded securely. (Action 3) Replace the servo amplifier. (Action 4) Replace the pulse coder. (Action 5) Replace the robot interconnection cable (for the pulse coder).

(53) SRVO-071 SVAL2 SPHAL alarm (Group : i Axis : j) o (Explanation) The feedback speed is abnormally high. o (Action 1) If this alarm occurs together with the PHAL alarm (No. 064), this alarm does not correspond to the major cause of the failure. o (Action 2) Replace the pulse coder. (54) SRVO-072 SVAL2 PMAL alarm (Group : i Axis : j) o (Explanation) It is likely that the pulse coder is abnormal. o (Action) Replace the pulse coder and remaster the robot. (55) SRVO-073 SVAL2 CMAL alarm (Group : i Axis : j) o (Explanation) It is likely that the pulse coder is abnormal or the pulse coder has malfunctioned due to noise. o (Action) Make a simplified adjustment and enhance the shielding. (56) SRVO-074 SVAL2 LDAL alarm (Group : i Axis : j) o (Explanation) The LED in the pulse coder is broken. o (Action) Replace the pulse coder, and remaster the robot. (57) SRVO-075 WARN Pulse not established (Group : i Axis : j) o (Explanation) The absolute position of the pulse coder cannot be established. o (Action) Reset the alarm, and jog-feed the robot along the axis on which the alarm has occurred until the same alarm will not occur again. (Jog one motor revolution) (58) SRVO-081 WARN EROFL alarm (Track enc : i) o (Explanation) The pulse counter for line tracking has overflowed. o (Action) Contact the FANUC service center. (59) SRVO-082 WARN DAL alarm (Track ebc : i) o (Explanation) The line tracking pulse coder has not been connected. o (Action 1) Check the pulse coder connection cable, and replace it if necessary. o (Action 2) Replace the pulse coder.

(60) SRVO-083 WARN CKAL alarm (Track ebc : i) o (Explanation) This alarm occurs if the rotation speed count in the pulse coder is abnormal (abnormal count clock). o (Action) See the description about the SRVO-061 CKAL alarm. (61) SRVO-084 WARN BZAL alarm (Track enc : i) o (Explanation) This alarm occurs if the backup battery for the absolute position of the pulse coder has not been connected. See the description about the BZAL alarm (SRVO-062). (62) SRVO-085 WARN RCAL alarm (Track ebc : i) o (Explanation) This alarm occurs if the rotation speed count in the pulse coder is abnormal (abnormal counter). o (Action) See the description about the SRVO-063 RCAL alarm. (63) SRVO-086 WARN PHAL alarm (Track enc : i) o (Explanation) This alarm occurs if the phase of pulses generated in the pulse coder is abnormal. See the description about the PHAL alarm (SRVO-064). (64) SRVO-087 WARN BLAL alarm (Track enc : i) o (Explanation) This alarm occurs if the voltage of the backup battery for the absolute position of the pulse coder is low. See the description about the BLAL alarm (SRVO-065). (65) SRVO-088 WARN CSAL alarm (Track ebc : i) o (Explanation) The ROM in the pulse coder is abnormal. o (Action) See the description about the SRVO-066 CSAL alarm. (66) SRVO-089 WARN OHAL2 alarm (Track enc : i) o (Explanation) The motor has overheated. See the description about the OHAL2 alarm (SRVO-067). (67) SRVO-090 WARN DTERR alarm (Track enc : i) o (Explanation) Communication between the pulse coder and line tracking interface board is abnormal. See the description about the DTERR alarm (SRVO068). (68) SRVO-091 WARN CRCERR alarm (Track enc : i) o (Explanation) Communication between the pulse coder and line tracking interface board is abnormal. See the description about the CRCERR alarm (SRVO-069). (69) SRVO-092 WARN STBERR alarm (Track enc : i) o (Explanation) Communication between the pulse coder and line tracking interface board is abnormal. See the description about the STBERR alarm (SRVO-070). (70) SRVO-093 WARN SPMAL alarm (Track enc : i) o (Explanation) This alarm occurs if the current position data from the pulse coder is higher than the previous position data. See the description about the SPHAL alarm (SRVO-071). (71) SRVO-094 WARN PMAL alarm (Track enc : i) o (Explanation) It is likely that the pulse coder is abnormal. See the description about the PMAL alarm (SRVO-072). (72) SRVO-095 WARN CMAL alarm (Track enc : i)

(Explanation) It is likely that the pulse coder is abnormal or the pulse coder has malfunctioned due to noise. See the description about the CMAL alarm (SRVO073). (73) SRVO-096 WARN LDAL alarm (Track enc : i) o (Explanation) The LED in the pulse coder is broken. See the description about the LDAL alarm (SRVO-074). (74) SRVO-097 WARN Pulse not established (enc : i) o (Explanation) The absolute position of the pulse coder cannot be established. See the description about (SRVO-075). Pulse not established. (75) SRVO-105 SVAL1 Door open or E. Stop o (Explanation) The door of the i -cabinet is open. o (Action 1) Close the door if open. o (Action 2) Check the door switch and door switch contact cable. Replace any abnormal component. o (Action 3) This alarm occurs also if the emergency stop line was broken, but the software failed to identify the cause. Check whether the emergency stop line is abnormal, by referencing the general connection diagram in the appendix. o (Action 4) Replace the servo amplifier.

(76) SRVO-136 SVAL1 DCLVAL alarm (Group : i Axis : j) o (Explanation) The servo the DC current of amplifier (DC link voltage) of the main power supply is abnormally low. the servo amplifier LED indicates "4". o -This alarm occured in the robot operation. o (Action 1) Check the phase voltage of the three-phase input power (200 VAC) to the servo amplifier. If it is 170 VAC or lower, check the line voltage. o (Action 2) Replace the servo amplifier. o -If this alarm occurs before the magnetic contactor is turned on: o (Action 1) Check each phase-to-phase voltage of the three-phase input (200 VAC) on the primary side of the magnetic contactor. If the input is not higher than 170 VAC, check the input power supply voltage. o (Action 2) Replace the emergency stop board. o (Action 3) Replace the servo amplifier.

(77) SRVO-156 SVAL1 IPMAL alarm (Group : i Axis : j) o (Explanation) Abnormally high current flowed through the main circuit of the servo amplifier. The hyphen "-" appears in the servo amplifier 7-segment LED indicator. At the same time, the LED (red) corresponding to the axis (IPM1 to IPM6) for which the IPMAL alarm has occurred lights. This LED is beside the 7-segment LED indicator. o (Action 1) Detach the motor power lines from the respective terminals on the servo amplifier, and switch on the power, then check to see if the alarm occurs again. If the alarm occurs, replace the servo amplifier. o (Action 2) Detach the motor power lines from the respective terminals on the servo amplifier, and check for isolation between each motor power line (U, V, or W) and a ground potential (GND). If a motor power line is short-circuited to a ground, the motor, robot connection cable, or robot internal cable is likely to be defective. Check each of them, and replace it if necessary. o (Action 3) Detach the motor power lines from the respective terminals on the servo amplifier, and check the resistance between each motor power line pair (U and V, V and W, or W and U) using a meter that is capable of measuring a very low resistance. If the measured three resistances are different, the motor, robot connection cable, or robot internal cable is likely be defective. Check each of them, and replace it if necessary.

(78) SRVO-200 WARN Control box fan abnormal o (Explanation) The fan motor (option) in the operation box is abnormal. o (Action) Check the fan motor and fan motor connection cable. If they turn out to be defective, replace them.

(79) SRVO-201 SVAL1 Panel E-stop or SVEMG abnormal o (Explanation) The EMERGENCY STOP button on the operation panel was pressed, but the EMERGENCY STOP line was not disconnected. o (Action 1) Check the EMERGENCY STOP button on the operation panel, and replace it if necessary. o (Action 2) Replace the panel board. o (Action 3) Replace the servo amplifier. NOTE This alarm might occur if the EMERGENCY STOP button is pressed slowly.

(80) SRVO-202 SVAL1 TP E-stop or SVEMG abnormal o (Explanation) The EMERGENCY STOP button on the operation box was pressed, but the EMERGENCY STOP line was not disconnected. o (Action 1) Check the teach pendant connection cable, and replace it if necessary. o (Action 2) Replace the teach pendant. o (Action 3) Replace the panel board. o (Action 4) Replace the servo amplifier. NOTE This alarm might occur if the EMERGENCY STOP button is pressed slowly.

(81) SRVO-203 SVAL1 SVON input (SVEMG abnormal) o (Explanation) The switch connected across SVOFF1 and SVOFF2 on the TBOP1 terminal board on the panel board was pressed, but the emergency stop line was not disconnected. o (Action 1) Replace the panel board. o (Action 2) Replace the servo amplifier.

(82) SRVO-204 SVAL1 External (SVEMG abnormal) E-stop o (Explanation) The switch connected across EMGIN1 and EMGIN2 on the TBOP1 terminal board on the panel board was pressed, but the EMERGENCY STOP line was not disconnected. o (Action 1) Replace the panel board. o (Action 2) Replace the servo amplifier.

(83) SRVO-205 SVAL1 Fence open (SVEMG abnormal) o (Explanation) The switch connected across FENCE1 and FENCE2 on the TBOP1 terminal board on the panel board was pressed, but the EMERGENCY STOP line was not disconnected. o (Action 1) Replace the panel board. o (Action 2) Replace the servo amplifier.

(84) SRVO-206 SVAL1 Deadman switch (SVEMG abnormal) o (Explanation) The DEADMAN switch was released when the teach pendant was operable, but the EMERGENCY STOP line was not disconnected. o (Action 1) Check the teach pendant connection cable. Replace it if necessary. o (Action 2) Replace the teach pendant. o (Action 3) Replace the panel board. o (Action 4) Replace the servo amplifier.

(85) SRVO-207 SVAL1 TP switch abnormal or door open o (Explanation) The teach pendant is operable, and the deadman switch has been grasped, but the EMERGENCY STOP line is kept disconnected. Alternatively, the control unit door is open. (In case of i -cabinet) o (Action 1) Close the control unit door, if open. (In case of i -cabinet) o (Action 2) Check the door switch, and replace it if necessary. (In case of i cabinet) o (Action 3) Check the teach pendant connection cable, and replace it if necessary. o (Action 4) Replace the teach pendant. o (Action 5) Replace the panel board. o (Action 6) Replace the servo amplifier.

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Copyright 1998 by FANUC Robotics North America, Inc.