Kawasak

A/AD CONTROLLERS
ERROR CODES
MPVADERV30E-2

Kawasak
Kawasaki Robotics (USA), Inc.
This publication contains proprietary information of Kawasaki Robotics (USA), Inc. and
is furnished solely for customer use only. No other uses are authorized or permitted
without the express written permission of Kawasaki Robotics (USA), Inc. The contents
of this manual cannot be reproduced, nor transmitted by any means, e.g., mechanical,
electrical, photocopy, facsimile, or electronic data media, without the express written
permission of Kawasaki Robotics (USA), Inc.

All Rights Reserved.

Copyright © 2002, Kawasaki Robotics (USA), Inc.

Wixom, Michigan 48393

The descriptions and specifications in this manual were in effect when it was submitted
for publishing. Kawasaki Robotics (USA), Inc. reserves the right to change or discon-
tinue specific robot models and associated hardware and software, designs, descrip-
tions, specifications, or performance parameters at any time and without notice, without
incurring any obligation whatsoever.

This manual presents information specific to the robot model listed on the title page of
this document. Before performing maintenance, operation, or programming procedures,
all personnel are recommended to attend an approved Kawasaki Robotics (USA), Inc.
training course.

KAWASAKI ROBOTICS (USA), INC. TRAINING

Training courses covering operation, programming, electrical maintenance, and me-

chanical maintenance are available from Kawasaki Robotics (USA), Inc. These courses
are conducted at our training facility in Wixom, Michigan, or on-site at the customer’s
location.

For additional information contact:

Kawasaki Robotics (USA), Inc.

Training and Documentation Dept.
28059 Center Oaks Court
Wixom, Michigan 48393
 A/AD SERIES CONTROLLERS
Kawasak ERROR CODES

REVISION HISTORY

Revision Release
Description of Change Initials
Number Date

-0 03/10/00 Initial PDF release KR

-1 02/06/02 Changes to error code 1513 – MCR-115 JES

-2 11/22/02 Changes to error codes per MCR-149 CB/CB

 Kawasak A/AD CONTROLLERS
ERROR CODES

ERROR CONDITIONS

1.0 ERROR CONDITIONS .......................................................................................... 1-2

1.1 Error Conditions .................................................................................................... 1-3

1-1 February 6, 2002

 A/AD CONTROLLERS
Kawasak ERROR CODES

ERROR CONDITIONS

1.0 ERROR CONDITIONS

Information provided in this unit describes the causes of error conditions, and the steps that
need to be taken to eliminate the errors.For complete troubleshooting information, refer to
unit 10, Troubleshooting.

The errors are listed in numeric order by error code. The error code information is also
available on the A/AD Help/Troubleshooting/Error Codes floppy disk, and can be accessed
through Auxiliary Function 126 on the function menu keypad.

1-2 February 6, 2002

 Kawasak A/AD CONTROLLERS
ERROR CODES

ERROR CONDITIONS

1.1 ERROR CONDITIONS

The following section contains descriptions of error conditions that may occur on the A Series and
AD Series controllers. Following the description of most error Codes in this section is a list of prob-
able solutions to correct the errors.

ERROR CODE -50: Warning! Cannot move along straight line in this
configuration
Warning! Joints must be driven too fast to achieve Cartesian motion.
Warning! Joints must be driven beyond robot’s ability to achieve
Cartesian motion.

The joint speed may exceed its capacity depending on the wrist position, if manual operation is executed in
Tool or Base mode during Teach mode.

Linear motion is prohibited at this time.

=> Change the wrist position.

=> Slow down the jog speed.
=> Operate in the respective joint mode.
___________________________________________________________________________________

ERROR CODE-51: Warning! Cannot keep current configuration. Use slower speed.
Warning! Cannot achieve Cartesian motion.

There are two ranges used to monitor the “sudden change error” of the command values. The range depends
on the mode of operation, Teach or Repeat. This error occurs when the command value exceeds the range at
the time the command value is checked.

(This function is not available with all software versions.)

=> Change the wrist position.

=> Slow down the repeat speed .
=> Change each move to joint interpolation.
___________________________________________________________________________________

ERROR CODE -52: Warning!

Unused.
___________________________________________________________________________________

ERROR CODE -53: Warning! Error logging buffer is near capacity.

___________________________________________________________________________________

ERROR CODE -54: Warning! Error logging buffer is full.

___________________________________________________________________________________

1-3 March 31, 1997

 Kawasak A/AD CONTROLLERS
ERROR CODES

ERROR CONDITIONS

ERROR CODE -200: Cannot execute a program because motor power is OFF.
Can’t run because MOTOR POWER is off.
Because MOTOR POWER is off, can’t run.

The program cannot be executed because power source for the motor is OFF.

=> Execute again after switching the motor power ON.

=> Defective switch or defective 9ZA board for “Motor power” .
___________________________________________________________________________________

ERROR CODE -201: Can’t execute a program in TEACH mode.

Can’t run because of TEACH mode.
Because of TEACH mode, can’t run.

The program cannot be executed in Teach mode.

=> Execute again in Repeat mode by releasing teach lock.

=> Defective switch or 9ZA board for “Teach/Repeat” changeover function.
___________________________________________________________________________________

ERROR CODE -202: Cannot execute a program because teach lock is ON.
Can’t run because TEACH LOCK is ON.
Because of TEACH LOCK ON, can’t run.

The program cannot be executed with the Teach Lock ON.

=> Execute again after turning OFF the “Teach Lock” switch on Teach Pendant.
=> Defective Teach Pendant or 9ZA board.
___________________________________________________________________________________

ERROR CODE -203: Cannot use Teach Pendant because teach lock is OFF.
Can’t drive from Teach pendant, because Teach Lock is OFF.
Because of TEACH LOCK OFF, can’t move in teach run.

Manual operation is not possible because the “Teach Lock” switch on the Teach Pendant is OFF.

=> Switch ON the “Teach Lock” switch on Teach Pendant, to execute manual operation.
=> Defective Teach Pendant or 9ZA board.
___________________________________________________________________________________

ERROR CODE -204: Turn teach lock ON.

Teach Lock is currently off, wait until it is on.

=> Turn Teach Lock switch ON before executing a TEACH command.

___________________________________________________________________________________

ERROR CODE -205: Teach Pendant is in operation now.

Teach pendant is currently in use.
The Teach Pendant is currently executing a task. Please wait
until the task is complete.

Unused.
___________________________________________________________________________________
1-4 September 26, 2002
 Kawasak A/AD CONTROLLERS
ERROR CODES

ERROR CONDITIONS

ERROR CODE -206: Turn Teach Mode ON.

Please wait until the robot is in the Teach mode.

A TEACH command cannot be executed in the Repeat mode.

___________________________________________________________________________________

ERROR CODE -207: Turn to HOLD at HOLD/RUN switch.

This occurs when an attempt is made to execute any of the operations below
with the HOLD/RUN switch on the panel being in the RUN position.
a. EXECUTE or CONTINUE command
b. STEP or MSTEP command
c. DO command.

Only applicable if “CHECK. HOLD” system switch is ON (enabled) position.

=> Execute the above AS command again after turning the “HOLD/RUN” switch to HOLD position.
___________________________________________________________________________________

ERROR CODE -300: The program is already running.

This occurs when an attempt is made to edit or execute a program currently running.

=> Stop and cancel the program currently executing to execute it again.
___________________________________________________________________________________

ERROR CODE -301: Robot control program is already running.

This occurs when an attempt is made to execute the DO command when the robot
operation program is already running, or to execute the TOOL or BASE commands
while the robot program is under execution.

=> Wait until completion of the program under operation.

=> Terminate the program under operation.
___________________________________________________________________________________

ERROR CODE -302: Can’t continue. Use EXECUTE.

This occurs when an attempt is made to execute the CONTINUE command where
execution of the program is not permitted.

=> Execute the CONTINUE command after making a selection of a program again.
=> Execute by the EXECUTE command.
___________________________________________________________________________________

1-5 September 26, 2002

 Kawasak A/AD CONTROLLERS
ERROR CODES

ERROR CONDITIONS

ERROR CODE -303: Robot is moving now.

Can’t perform, because robot is moving.
Can’t be executed (Robot is moving.)

This occurs when an attempt is made to execute any of the commands below:
a. Cycle start
b. EXECUTE or CONTINUE command
c. TOOL or BASE command
d. DO command
e. SYSINIT command.
___________________________________________________________________________________

ERROR CODE -304: Cannot execute because of error . Reset error.

Can’t perform, because of error state. Reset error.
Currently in error state. Reset error and execute.

This occurs when an attempt is made to execute any of the operations below:
a. Cycle start
b. EXECUTE or CONTINUE command
c. DO command

=> Execute again after resetting error.

___________________________________________________________________________________

ERROR CODE -305: In error state. Reset error and then turn motor power ON.
Can’t turn on motor power, because of error state.
Because of error status, can’t turn motor power on.

This occurs when an attempt is made to switch the motor power ON in an error state.

=> Switch ON the motor power again after resetting error.

___________________________________________________________________________________

ERROR CODE -306: Cannot execute with the DO command.

Can’t DO this instruction.
Cannot DO command.

This occurs when an attempt is made to execute a command which is not allowed
to execute by the DO command.

=> Refer to AS LANGUAGE MANUAL to make sure whether the intended

command can be executed by the DO command or not.
___________________________________________________________________________________

ERROR CODE -307: Cannot reset this error. (Code xxxx)

Cannot error reset. (Code xxxx)

Unused.
___________________________________________________________________________________

1-6 September 26, 2002

 Kawasak A/AD CONTROLLERS
ERROR CODES

ERROR CONDITIONS

ERROR CODE -308: PC program is running.

Stepper 2 running

This occurs when an attempt is made to execute the following command while
executing a PC program:
a. SYSINIT command.

=> Execute the command again after stopping and finishing the PC program.
___________________________________________________________________________________

ERROR CODE -309: DO command argument is missing.

This occurs if an argument is omitted when executing the DO command after

initializing the system.

=> Please select the correct arguments.

___________________________________________________________________________________

ERROR CODE -310: Cannot delete the program because it is running.

Can’t delete program, because it is used by another.
Because selected program is executing, it can’t be deleted.

This occurs when an attempt is made to KILL a program which is being used
or has been reserved by the PRIME command.

=> Stop the program in Cycle Operation, and delete the execution file
by either the KILL command or Program Cancel.
___________________________________________________________________________________

ERROR CODE -311: Variable (or program) does not exist.

Program (or variable) not found
Element (or variable) not found

This occurs when a program or variable does not exist due to deletion,
either by the DELETE command or Program Cancel.
Or, a program which does not exist in the memory is specified either by the SAVE
command or Program Retention (Memory>Floppy Disk).

=> Check the specified program or variable in the directory.

___________________________________________________________________________________

ERROR CODE -312: Variable (or program) of this type does not exist.
Data (or program) of this type is not found
Element of this type (program) not found

Unused.
___________________________________________________________________________________

1-7 September 26, 2002

 Kawasak A/AD CONTROLLERS
ERROR CODES

ERROR CONDITIONS

ERROR CODE -313: Unknown element type.

Data type is not defined
Element type not defined

Unused.
___________________________________________________________________________________

ERROR CODE -314: Cannot execute because the program is already used.
Can’t perform because program is called by another program.
Because the program is running, it can’t be executed.

This occurs when a program called by the CALL, ON or ONI command is being
edited, or, an attempt is made to execute the same program by another
program or the PC program.

=> Stop editing, and continue the program.

=> Cancel the program intended to use, and execute it again.
___________________________________________________________________________________

ERROR CODE -315: Can’t execute because setting aux.data is being set.

Unused.
___________________________________________________________________________________

ERROR CODE -316: Waiting for weld completion.

Changing the step is prohibited while spot weld sequence is in process (wait
until weld completion signal and Large/Small “opening” detect signals are
on, and after power application signal is on).

=> Changing the step can be made after finishing the welding sequence either
by cancelling the ‘standby’ or by inputting weld-completion and
Large/Small detect signals.
___________________________________________________________________________________

ERROR CODE -317: Envelope error at last emergency stop jt xx.

(This error is not covered depending on the software version).

This occurs when the difference exceeds the set value (setting can be made
by data setting 42), by comparing the current value after restart (cycle start
etc.) with the specified value at the time of emergency stop.

This is intended to send an alarm to draw the operator’s attention at the time
of restart if amount of overrun at the time of an emergency stop exceeded a
specified value.
___________________________________________________________________________________

1-8 September 26, 2002

 Kawasak A/AD CONTROLLERS
ERROR CODES

ERROR CONDITIONS

ERROR CODE -320: Cannot operate while teach pendant is in operation.

Can’t perform, because of current Teach Pendant procedure
Can’t perform on Teach Pendant

You cannot perform functions on the operator interface panel while the Teach
Pendant is in use.

=> Perform functions on the operator panel after Teach Pendant operation is complete.
___________________________________________________________________________________

ERROR CODE -321: Cannot operate while panel is in operation.

Can’t perform, because of current panel procedure.
Can’t perform on Panel

You cannot Teach or select programs with the Teach Pendant while using the edit
mode on the operation interface panel.

=> Perform the operation on the Teach Pendant after completing the operation
on the operator interface panel.
___________________________________________________________________________________

ERROR CODE -322: Can’t perform on Teach Pendant or panel.

Unused.
___________________________________________________________________________________

ERROR CODE -323: The number of I/O signals entered is greater than what is installed.
___________________________________________________________________________________

ERROR CODE -350: Illegal input data.

Input data for monitor command or data setting is illegal.

=> Input correct data again.

___________________________________________________________________________________

ERROR CODE -351: Too many arguments.

Too much data.

Input data for monitor commands, etc. entered exceeds the

permitted number of input items.

=> Verify input data and input again.

___________________________________________________________________________________

ERROR CODE -352: Invalid data or too many arguments.

Invalid argument or excessive data.

Entered data is invalid or too many arguments.

Too much data or other than numeric characters have been entered.

=> Check and input correct data again.

___________________________________________________________________________________
1-9 September 26, 2002
 Kawasak A/AD CONTROLLERS
ERROR CODES

ERROR CONDITIONS

ERROR CODE: -353: Input data is too large.

Too big of a value.

Value of input data by the POINT or HERE command exceeds the allowable range.

=> Check the input data, and input correct data again.
___________________________________________________________________________________

ERROR CODE -354: Too many transfer steps entered.

When using the data transfer function (XFER command, Ref: AUX. 3: Data Transfer)
to transfer steps within the same program, the number of transfer steps entered
is greater than the number of steps in the program.

(The source step number and number of steps) >= (The number of steps in the
source program).

=> Execute again by specifying a correct step number or step count.

___________________________________________________________________________________

ERROR CODE -355: Source step does not exist.

When using the Data Transfer Function (XFER command, Ref. Aux. 3: Data Transfer)
the specified step number of the transfer source does not exist in the program
specified as the source program.

=> Execute again by specifying a correct step number or step count.

___________________________________________________________________________________

ERROR CODE -360: Illegal WHERE parameter.

A numeric character other than the one permitted in the system is specified.

=> Execute again with correct numeric character.

___________________________________________________________________________________

ERROR CODE -361: Illegal PC number.

Unused.
___________________________________________________________________________________

ERROR CODE -370: Lower limit is greater than upper limit.

Unused.
___________________________________________________________________________________

1-10 September 26, 2002

 Kawasak A/AD CONTROLLERS
ERROR CODES

ERROR CONDITIONS

ERROR CODE -371: External-axis type and Gun type data mismatch.

(For servo specifications only)

Setting of servo gun does not match in setting of types for the extension
joints (Ref. Aux. 160) and guns (Ref. data setting 114). (Number of setting
for either one of servo guns exceeds that of the other, or, setting of servo
guns for the clamp number does not match each other).
This error is detected at the time of cycle start start-up, such as when
starting reproduction operation of the robot.

=> Set types of the extension joint and guns again so that relevant data
may match each other.
___________________________________________________________________________________

ERROR CODE -400: Syntax error

Initial letter of command (instruction, switch name), name of variable or

location is illegal.

=> Retype the command or variable name correctly and input again.
___________________________________________________________________________________

ERROR CODE -401: Invalid statement

Invalid statement (Illegal instruction or switch name).

Spelling of the command (instruction, switch name) is wrong.

=> Input correct command (instruction, switch name) again.

___________________________________________________________________________________

ERROR CODE -402 : Ambiguous statement

(Missing characters or wrong abbreviation).

When typing commands (instructions, switch names) you must use the correct
abbreviation or type the entire command name.

=> Type the command correctly and input again.

___________________________________________________________________________________

ERROR CODE -403: Cannot use this command or instruction here.

Can’t accept this command (inst.) now.
Missing Statement Type.

An attempt has been made to execute a program instruction or

a monitor command which cannot be executed while a program is in operation.

=> Execute the instruction or command after the program has been executed.
___________________________________________________________________________________

1-11 September 26, 2002

 Kawasak A/AD CONTROLLERS
ERROR CODES

ERROR CONDITIONS

ERROR CODE -404: Cannot execute with DO command.

Cannot use DO with this instruction.
Can’t execute in DO command.

Unused.
___________________________________________________________________________________

ERROR CODE -405: Statement cannot be executed.

Can’t execute this instruction.

Execution command/instruction does not match the current instructions

to execute (monitor command, switch, etc.)

=> Execute again after making correct input.

___________________________________________________________________________________

ERROR CODE -406: Not a program instruction.

Not a program instruction.

Unused.
___________________________________________________________________________________

ERROR CODE -407: Unexpected text at end of line.

Expected the End of statement.
Expected the End of Command.

Unused.
___________________________________________________________________________________

ERROR CODE -408: Missing argument.

Can’t find string data.
Unexpected End of Command.

No argument is specified in executing DO command etc.

=> Type correct argument and input again.

___________________________________________________________________________________

ERROR CODE -409: Missing a comma.

Expected a Comma.

Unused.
___________________________________________________________________________________

ERROR CODE -410: Illegal expression.

No real number expression is present or an expression specified by an

argument is illegal for the DECOMPOSE command.

=> Input a correct expression again.

___________________________________________________________________________________

1-12 September 26, 2002

 Kawasak A/AD CONTROLLERS
ERROR CODES

ERROR CONDITIONS

ERROR CODE -411: Illegal function.

Mismatched function type.

When assigning values to variables using functions, the data that the function
returns must be compatible with the variable type.

(Example): POINT #A=SHIFT(b BY 10,0,0)

Can’t assign XYZ data to a precision point.

=> Check the variable type and the data returned by the function.
___________________________________________________________________________________

ERROR CODE -412: Illegal argument of function.

Illegal function parameters.

Type or number of function parameters is different when editing programs and/or

inputting a monitor command.

(Example): POINT #a=#POINT(0,0,0,0,0,0,0,0)

Excessive number of parameters.

=> Check and correct the parameter.

___________________________________________________________________________________

ERROR CODE -413: Invalid variable (or program) name.

Invalid Value.

Illegal variable or program name used when editing a program or inputting a monitor command.

(Example): JMOVE ##a Too many precision symbols.

CALL#a Program name is wrong.

=> Check and correct the variable (or Program) name.

___________________________________________________________________________________

ERROR CODE -414: Illegal variable type.

Mismatch variable type.
Missing Variable Tag.

Illegal variable is specified when editing a program and/or inputting a monitor command.

(Example): a==b = is excessive by one.

b=#a+b You cannot combine location & rel=al variables using arithmetic operators.

=> Specify correct variable.

___________________________________________________________________________________

1-13 September 26, 2002

 Kawasak A/AD CONTROLLERS
ERROR CODES

ERROR CONDITIONS

ERROR CODE -415: Illegal array index.

Missing Subscript of Variable array.

This occurs when an attempt is made to use a variable already defined as

a new array, or to reverse the array order when editing a program or inputting
a monitor command.

(Example): HERE a or HERE a[1]

HERE a[1] or HERE a

=> Correct the variable and input the data again.

___________________________________________________________________________________

ERROR CODE -416: Missing parenthesis.

When editing a program function or inputting a monitor command that uses

parentheses, each pair of parentheses must contain a left and right parenthesis
to be a valid function or command.

(Example): POINT a=FRAME(a,b,(c,d)

v=(v+1)+w/2)

=> Retype the function or command with the correct number of parentheses.
___________________________________________________________________________________

ERROR CODE -417 : Expected a binary operator.

___________________________________________________________________________________

ERROR CODE -418 : Illegal constant.

A variable, or non constant has been used where a constant or integer should
have been used in a monitor command.

(Example): WHERE a (Should be WHERE1 or WHERE2 )

=> Use the proper constant or integer with this command. See AS Language Manual for details.
___________________________________________________________________________________

ERROR CODE -419: Illegal qualifier.

When using monitor commands (LIST, DIRECTORY, DELETE, etc.) or program

instructions (POINT, PRINT, etc.), you must specify the correct qualifier such
as IP, IL, IR, etc.

(Example): LIST/K

=> Retype the command or instruction using the correct qualifier. See AS Language Manual for details.
___________________________________________________________________________________

1-14 September 26, 2002

 Kawasak A/AD CONTROLLERS
ERROR CODES

ERROR CONDITIONS

ERROR CODE -420: Invalid label.

You cannot use reserved characters for labels when editing or creating a program.

(Example): GOTO #a

=> Retype the label name using valid characters. See AS Language Manual for details.
___________________________________________________________________________________

ERROR CODE -421: Invalid name.

The specified name of a variable, program, file, etc., is invalid.

An invalid name has been specified when executing a program command or
instruction input through the panel.

=> Use the DIRECTORY commands to verify program, file, and variable names.
___________________________________________________________________________________

ERROR CODE -422 : Missing expected character.

Missing key character (or word).
Missing Specified String.

A command or instruction has been typed incorrectly when editing a program

or inputting a monitor command.

(Example): TOOL a=b (Should be TOOL a)

=> Retype the command or instruction correctly and input again.

___________________________________________________________________________________

ERROR CODE -423: Illegal switch name.

Bad switch name.

The name of the system switch specified using the SWITCH command is illegal or invalid.

=> Retype the system switch name and input again. See AS Language Manual for details.
___________________________________________________________________________________

ERROR CODE -424: Ambiguous switch name.

When using the SWITCH command, you can only define a system switch that
is available with the current software.

=> Specify the correct system switch name and input data again.
___________________________________________________________________________________

ERROR CODE -425: Illegal format qualifier

Illegal format indicator

The format qualifier specified with the PRINT/TYPE command or instruction is illegal.

=> Select the correct qualifier and input again. See AS Language Manual for details.
___________________________________________________________________________________
1-15 September 26, 2002
 Kawasak A/AD CONTROLLERS
ERROR CODES

ERROR CONDITIONS

ERROR CODE -426 : Duplicate statement label.

Duplicate label.

A specific label can only be used once in the same program.

=> Select a different label name or number and enter the data again.
___________________________________________________________________________________

ERROR CODE -450: Control structure error.

An illegal structure has been found using the following control structure commands:
IF-THEN-ELSE-END, WHILE-END, DO-UNTIL, CASE-VALUE-ANY-END, FOR-END.

=> Retype the control flow structure using the correct syntax. See AS Language Manual for details.
___________________________________________________________________________________

ERROR CODE -451: Step:xxx Wrong END statement.

Step:xxx Bad END statement.

An illegal END statement has been found in a program that is being edited or loaded.

=> Check and correct the control structure statement.

[Reference] Control structure command:

IF-THEN-ELSE-END, WHILE-END, DO-UNTIL, CASE-VALUE-ANY-END, FOR-END, etc.
___________________________________________________________________________________

ERROR CODE -452: Step:xxx Extra END statement.

In editing or loading a program, although an END command is present, no

corresponding structure command exists in the previous step.

=> Check and correct the control structure statement.

___________________________________________________________________________________

ERROR CODE -453: Step:xxx Cannot terminate DO with END.

When editing or loading a program, an END statement was used to terminate the DO
STRUCTURE. The DO control structure must be used with the UNTIL statement.
(Example): DO
CALL get.part
UNTIL SIG(buffer.full)

=> Check and correct the control structure statement.

(The last part of the DO control structure must be UNTIL, not END.
___________________________________________________________________________________

1-16 September 26, 2002

 Kawasak A/AD CONTROLLERS
ERROR CODES

ERROR CONDITIONS

ERROR CODE -454: Step:xxx No VALUE statement after CASE.

Step:xxx No VALUE statement.

In editing or loading a program, although a CASE command is present,

no VALUE command exists in the next step.

=> Check and correct the control structure statement properly.

(Make sure to input VALUE command after CASE command.)
See AS Language Manual for details.
___________________________________________________________________________________

ERROR CODE -455: Step:xxxPreceding IF missing.

In editing or loading a program, although there is present a structure command

which should be preceded by IF (namely, ELSE command), no corresponding
structure command exists in the previous step, or although the corresponding
structure command is present, it is not the IF command.

=> Check and correct the control structure statement and input data again.
See AS Language Manual for details.
___________________________________________________________________________________

ERROR CODE -456 : Step:xxx Preceding CASE missing.

In editing or loading a program, although there is present a structure command

which should have been preceded by CASE command (namely, VALUE and ANY command),
no corresponding structure command exists in the previous step, or although
a relevant structure command is present, it is not the CASE command.

=> Check and correct the control structure statement. See AS Language Manual for details.
___________________________________________________________________________________

ERROR CODE -457: Step:xxx Preceding DO missing.

In editing or loading a program, although there is present a structure command

which should have been preceded by a DO command (namely, UNTIL command),
no corresponding structure command exists in the previous step, or although
a corresponding structure command is present, it is not the DO command.

=> Check and correct the control structure statement properly. See AS Language Manual for details.
___________________________________________________________________________________

ERROR CODE -458: Step:xxx Can’t find END of xxx.

In editing or loading a program, a control flow structure was found missing an

END statement.

=> Locate the missing END statement in the program and try again.
___________________________________________________________________________________

1-17 September 26, 2002

 Kawasak A/AD CONTROLLERS
ERROR CODES

ERROR CONDITIONS

ERROR CODE -459: Step:xxx Too many control structures.

Step:xxx Control structure is too nested.

In editing or loading a program, more than 11 layers of control structure are present.

=> Check the program and correct the control structure statement.
___________________________________________________________________________________

ERROR CODE -460: Variable (or program) already exists.

Element already exists.

When loading a program from disk to RAM using the LOAD command or Floppy-Memory
function, a program of the same name currently resides in RAM.
(Depending on the software version, this error may stop the load process or
automatically overwrite the program).

=> Delete the program from memory first, then execute the LOAD command.
___________________________________________________________________________________

ERROR CODE -461: Variable of different type already exists.

Same name but different type variable exists.
Element of different type exists.

Unused.
___________________________________________________________________________________

ERROR CODE -462: Name matches exactly, but type doesn’t.

Unused.
___________________________________________________________________________________

ERROR CODE -480 : One of the strings is too long. (Max. 15)
Name (or string) length is too long. ( Max. 15)
One of the strings is longer than MAXSTRLENGTH.

Unused.
___________________________________________________________________________________

ERROR CODE -490 : Program name not specified.

No program specified.
Default program name does not exist.

When editing a program, you must specify a program name or use the current program.

=> Properly specify a program name.

___________________________________________________________________________________

ERROR CODE -491: Illegal parameter of editor command.

Extra-End of editor instruction.

Unused.
___________________________________________________________________________________

1-18 September 26, 2002

 Kawasak A/AD CONTROLLERS
ERROR CODES

ERROR CONDITIONS

ERROR CODE -492: Illegal step number.

Bad step number.

Unused.
___________________________________________________________________________________

ERROR CODE -493: Comma (or space) is missing after the R command.
No comma after the R editor command.
Bad parameter of editor instruction.

Unused.
___________________________________________________________________________________

ERROR CODE -494: Program is interlocked by another procedure.

Unused.
___________________________________________________________________________________

ERROR CODE -495:

___________________________________________________________________________________

ERROR CODE -496:

___________________________________________________________________________________

ERROR CODE -497:

___________________________________________________________________________________

ERROR CODE -498: Program is not specified.

Unused.
___________________________________________________________________________________

ERROR CODE -499: Invalid statement.

Invalid tokenized statement.

In editing the program, steps were encountered that couldn’t be read.

=> Check the program and correct the step causing the problem.
___________________________________________________________________________________

ERROR CODE -500: Input data is not ready in non request mode.
Input data is not ready on non request mode.

Unused.
___________________________________________________________________________________

ERROR CODE -501 : Deleted ^C.

^C input.

Unused.
___________________________________________________________________________________

1-19 September 26, 2002

 Kawasak A/AD CONTROLLERS
ERROR CODES

ERROR CONDITIONS

ERROR CODE -502 : Detected ^Z or end of file.

Unused.
___________________________________________________________________________________

ERROR CODE -503: I/O buffer full.

No buffer space.
No I/O buffer space.

Unused.
___________________________________________________________________________________

ERROR CODE -504: Data is lost because of too many I/O requests.
Because of too many I/O requests, there is no I/O buffer.

Unused.
___________________________________________________________________________________

ERROR CODE -505:

___________________________________________________________________________________

ERROR CODE -506: Data receiver over run.

Unused.
___________________________________________________________________________________

ERROR CODE -507: Communication error.

This occurs in one of the following cases, when receiving data through the vision sensor:
a. Time out (Reception time-out)
b. Reception stopped due to HOLD, ABORT or PCABORT.
c. Reception suspended due to CTRL/C or carriage return.

=> Check condition of the communication line, and start again.

___________________________________________________________________________________

ERROR CODE -508: Communication sum check error.

Unused.
___________________________________________________________________________________

ERROR CODE -510: I/O logical unit is not attached.

I/O is not attached now.
Right for using I/O unattached.

Unused.
___________________________________________________________________________________

ERROR CODE -511: Illegal command for this I/O.

Illegal I/O command for this I/O.

Unused.
___________________________________________________________________________________
1-20 September 26, 2002
 Kawasak A/AD CONTROLLERS
ERROR CODES

ERROR CONDITIONS

ERROR CODE -512 : Illegal I/O logical unit number.

I/O logical device number is wrong.
Illegal I/O logical number.

Unused.
___________________________________________________________________________________

ERROR CODE -513: Attempted to access system I/O.

Tried to access system I/O.

Unused.
___________________________________________________________________________________

ERROR CODE -514: Device is not ready.

Unused.
___________________________________________________________________________________

ERROR CODE -515: Device is in use by other process.

Unused.
___________________________________________________________________________________

ERROR CODE -516: xxx cannot find.

Unused.
___________________________________________________________________________________

ERROR CODE -517: *** File load Error ***

Unused.
___________________________________________________________________________________

ERROR CODE -518: xxx is executing, can’t load it.

Unused.
___________________________________________________________________________________

ERROR CODE -519 : Device is not ready.

Unused.
___________________________________________________________________________________

ERROR CODE -520: Record length is too long.

Record size is too large.

Unused.
___________________________________________________________________________________

ERROR CODE -521: File is already opened.

Unused.
___________________________________________________________________________________
1-21 September 26, 2002
 Kawasak A/AD CONTROLLERS
ERROR CODES

ERROR CONDITIONS

ERROR CODE -522: File is not opened.

Unused.
___________________________________________________________________________________

ERROR CODE -523: Illegal file name.

File name error.

Unused.
___________________________________________________________________________________

ERROR CODE -524: Illegal record length.

Unused.
___________________________________________________________________________________

ERROR CODE -525: File already exists in floppy.

File already exists.

Unused.
___________________________________________________________________________________

ERROR CODE -526: File does not exist in floppy.

File does not exist.

Specified file did not exist at the time of file reading or deletion.

=> Check the file name, and input correct file name again.
___________________________________________________________________________________

ERROR CODE -527: Attempted to open too many files.

Too many files open.

Unused.
___________________________________________________________________________________

ERROR CODE -530: Floppy not connected.

Floppy does not connect.
Disk drive is not connected.

In executing commands related to floppy disk, there is no hardware signal

response to indicate proper connection of disk device.

Check the following:

=> Connection of disk device.
=> Disk device, 1BF board, 9ZA board.
=> Local bus harness.
___________________________________________________________________________________

1-22 September 26, 2002

 Kawasak A/AD CONTROLLERS
ERROR CODES

ERROR CONDITIONS

ERROR CODE -531: Disk is not ready.

An error output signal is sent from disk device unless a floppy disk is
properly located in the disk unit when executing commands related to the
floppy disk.

=> Make sure the floppy disk is installed correctly in the drive unit.
=> Disk device, 1BF board, 9ZA board.
=> Local bus harness.
___________________________________________________________________________________

ERROR CODE -532: Wrong disk is located.

In executing commands related to floppy disk, the disk unit checks the located
floppy and outputs an error signal unless it is 2HD with MS-DOS format.

=> Floppy diskette must be 2HD type.

=> Floppy diskette must use MS-DOS format.
=> Local bus harness.
___________________________________________________________________________________

ERROR CODE -533: Invalid disk format.

Unused.
___________________________________________________________________________________

ERROR CODE -534: File contents format error.

In executing commands related to floppy disk, the last characters of a file

on the floppy diskette were not EOF (END OF FILE).
(File format is not MS-DOS type)
(Data on the floppy disk has been damaged).

=> Replace the floppy diskette.

___________________________________________________________________________________

ERROR CODE -535: Disk is write-protected.

Disk is protected.

When executing floppy disk commands, the located diskette was found to be write-protected.

Check the following:

=> Write-protection of floppy diskette.
=> Disk device, 1BF board, 9ZA board
=> Local bus harness.
___________________________________________________________________________________

1-23 September 26, 2002

 Kawasak A/AD CONTROLLERS
ERROR CODES

ERROR CONDITIONS

ERROR CODE -536: Disk full.

The current floppy disk is full and has no available free space.

Check the following:

=> Write-protection of floppy diskette.
=> Disk device, 1BF board, 9ZA board
=> Local bus harness.
___________________________________________________________________________________

ERROR CODE -537: Too many files.

In executing commands related to the floppy disk, the number of files

on the located floppy diskette exceeds the limit (192 files).

=> Prepare another floppy diskette.

=> Disk device, 1BF board, 9ZA board
=> Local bus harness.
___________________________________________________________________________________

ERROR CODE -538: Can’t write on read-only file.

Can’t write, protected.
Can’t write onto protected file.

Unused.
___________________________________________________________________________________

ERROR CODE -540: Initialization error.

Disk initialization error.

Unused.
___________________________________________________________________________________

ERROR CODE -541: Error on header sector in initialization.

Disk initialization error at header sector.

Unused.
___________________________________________________________________________________

ERROR CODE -542: Directory read error.

Unused.
___________________________________________________________________________________

ERROR CODE -543: Data read error.

Data read in error.

Unused.
___________________________________________________________________________________

1-24 September 26, 2002

 Kawasak A/AD CONTROLLERS
ERROR CODES

ERROR CONDITIONS

ERROR CODE -544: Floppy disk data transfer error.

Floppy transfer error.
Data write transfer error.

Unused.
___________________________________________________________________________________

ERROR CODE -545 : Record inhibited. Set “record accept” and operate again.

An operation such as editing auxiliary data, positional data, or recording a

step was attempted with the Record Inhibit on (Aux. Function 71).

=> Execute again after setting RECORD ACCEPT/INHIBIT to ACCEPT

(Aux. Function 71). See A/AD Operations and Programming Manual for details.
___________________________________________________________________________________

ERROR CODE -546: Unexpected error in disk access.

Unexpected error on disk.

Unused.
___________________________________________________________________________________

ERROR CODE -547: No response from floppy disk.

No response from disk.

No response from the disk drive within 100ms when trying to read or write to
the disk.

Check the following:

=> FDD connector, local bus harness.

=> FDD (1BF board, disk drive).
=> 9ZA board.
___________________________________________________________________________________

ERROR CODE -550: Too many characters in a line.

Too many characters in line.
Too many line characters.

The number of characters in a line exceeds the maximum number, when reading
data from a floppy disk. This occurs in reading a program which has been
made on a personal computer.

=> Correct the number of characters per line, and execute data reading again.
___________________________________________________________________________________

ERROR CODE -551:

___________________________________________________________________________________

ERROR CODE -552:

___________________________________________________________________________________

1-25 September 26, 2002

 Kawasak A/AD CONTROLLERS
ERROR CODES

ERROR CONDITIONS

ERROR CODE -553:

___________________________________________________________________________________

ERROR CODE -554: Output data error.

Data output error.

In executing the SAVE command, there is a problem with the data being saved
to disk.
___________________________________________________________________________________

ERROR CODE -555: No data space in Floppy Control Board area.

There is no free space for data on the 1BF board for MS-DOS management (No possibility to occur).

=> Defective 1BF software.

___________________________________________________________________________________

ERROR CODE -556: Mode error.

No read or write mode available for the floppy disk drive.

=> 1BF board.

=> Defective 9ZA board software(AS).
___________________________________________________________________________________

ERROR CODE -557: Disk drive error.

A FAULT signal has been sent from the floppy disk drive.

=> Floppy disk drive.

=> 1BF board.
___________________________________________________________________________________

ERROR CODE -560: ADC not installed.

A/D converter error.
A/D error.
___________________________________________________________________________________

ERROR CODE -561: A/D channel error.

Illegal A/D channel number.
___________________________________________________________________________________

ERROR CODE -562: A/D input range error.

Illegal A/D input error.
___________________________________________________________________________________

ERROR CODE -563:

___________________________________________________________________________________

ERROR CODE -564:

___________________________________________________________________________________

1-26 September 26, 2002

 Kawasak A/AD CONTROLLERS
ERROR CODES

ERROR CONDITIONS

ERROR CODE -565: 1AS board not installed.

___________________________________________________________________________________

ERROR CODE -570: Cannot write data to PLC while it is running.

(Option : 1CC board correspondence)

An attempt was made to load data from a floppy disk while the built-in sequence
was running.

=> Execute again after resetting the 1CC board or stopping the sequencer.
___________________________________________________________________________________

ERROR CODE -571: PLC interface error.

(Option : 1CC board correspondence)

Signal communication is not available between 9ZA and 1CC boards.
(Data communication between the two boards should occur regularly within a fixed period of time),
a. No response from 1CC board
b. Abnormal 1CC board.

=> 1CC board.

=> 9ZA board.
___________________________________________________________________________________

ERROR CODE -572: PLC DPRAM error.

(Option : 1CC board correspondence).

Occurs when a 9ZA or 1CC board is reset (including power-on reset).
The 9ZA board checks read/write of Dual Port Memory (DPRAM) on the 1CC board,
but is unable to read the data written at that time.

=> 1CC board.

=> 9ZA board.
___________________________________________________________________________________

ERROR CODE -573 : Built-in PLC is not installed.

(Option: 1CC correspondence)

Installation of the 1CC board is checked when the power is switched ON.
An error is detected unless the 1CC board is installed and executing commands.

=> 1CC board.

=> 9ZA board.
___________________________________________________________________________________

ERROR CODE -580: Retry error.

(Option: Host communication I correspondent)

Please refer to the HOST COMMUNICATION I MANUAL.
___________________________________________________________________________________

1-27 September 26, 2002

 Kawasak A/AD CONTROLLERS
ERROR CODES

ERROR CONDITIONS

ERROR CODE -581: Stop of process.

(Option: Host communication I correspondent)

Please refer to the HOST COMMUNICATION I MANUAL.
___________________________________________________________________________________

ERROR CODE -582: Serial port is being used. OR cannot use.

(Option: Host communication I correspondent)

Please refer to the HOST COMMUNICATION I MANUAL.
___________________________________________________________________________________

ERROR CODE -583: Data was not received after request.

(Option: Host communication I correspondent)

Please refer to the HOST COMMUNICATION I MANUAL.
___________________________________________________________________________________

ERROR CODE -584: Too much data received (MAX=255 character).

(Option: Host communication I correspondent)

Please refer to the HOST COMMUNICATION I MANUAL.
___________________________________________________________________________________

ERROR CODE -585: Abnormal data (EOT) received in communicating.

(Option: Host communication I correspondent)

Please refer to the HOST COMMUNICATION I MANUAL.
___________________________________________________________________________________

ERROR CODE -586: Time out

(Option: Host communication I correspondent)

Please refer to the HOST COMMUNICATION I MANUAL.
___________________________________________________________________________________

ERROR CODE -587: Receive error.

(Option: Host communication I correspondent)

Please refer to the HOST COMMUNICATION I MANUAL.
___________________________________________________________________________________

ERROR CODE -588: Check sum error.

(Option: Host communication I correspondent)

Please refer to the HOST COMMUNICATION I MANUAL.
___________________________________________________________________________________

1-28 September 26, 2002

 Kawasak A/AD CONTROLLERS
ERROR CODES

ERROR CONDITIONS

ERROR CODE -589: Parity error.

Please refer to the HOST COMMUNICATION I MANUAL.

Unused.
___________________________________________________________________________________

ERROR CODE -590 : Remote operation panel I/F error. Code is xxx.
Operation panel I/F error. Code is xxx.

(Option: Remote operation panel correspondent)

CODE 1 :Watch dog 2 : ROM
4 : RAM 8 : DPRAM
10 : Breaking of wire 20 : Parity
40 : Time-over 80 : Sumcheck

=> Remote operation panel.

=> Communication harness.
=> I/F board for remote operation panel (1AA or 1AB board).
___________________________________________________________________________________

ERROR CODE -591: Illegal device number.

(Option: Host communication I, II correspondent).

Refer to the manual [HOST COMMUNICATION I]
Refer to the manual [HOST COMMUNICATION II]
___________________________________________________________________________________

ERROR CODE -592: Cannot use in the remote terminal.

(Option: Host communication II correspondent)

Refer to the manual [HOST COMMUNICATION II]
___________________________________________________________________________________

ERROR CODE -600: Motor power OFF.

Push EMERGENCY STOP button.

To be displayed when any of the Emergency Stops below are inputted:

> Emergency stop switch on the operation panel.
> Emergency stop switch on the teach pendant.
> External emergency stop switch (Motor power OFF signal <Open>

=> Emergency stop switch, connection of teach pendant or external emergency stop signal.
=> 9ZR or 1BP board, 1BP board connector, wiring on the panel.

For additional information on error code -600, see troubleshooting flow chart in unit 10.
___________________________________________________________________________________

1-29 September 26, 2002

 Kawasak A/AD CONTROLLERS
ERROR CODES

ERROR CONDITIONS

ERROR CODE -610: Weld completion time-over.

(Spot weld specifications type A)

No weld completion signal has been received in a prescribed period of time
after sending a weld start signal.
(See Data Set Functions 114-11 in the A/AD Operations Manual)

=> Gun or welder.

=> 9ZR board.
=> (Interface/Interlock panel).
___________________________________________________________________________________

ERROR CODE -611: Illegal extend (retract) output signal.

(Spot weld specifications type A)

In using a retractable type gun, the output signals for both Extend and Retract
have not been properly set. See Data Set Function 114, clamp specifications in the
A/AD Operations Manual.

=> Select an output signal for either “Extend” or “Retract” in accordance with Data Setting 114-10.
=> Set the gun type to “Non ret” using Data Set 114-12.
___________________________________________________________________________________

ERROR CODE -612: Weld fault input.

(Spot weld specifications type A)

The weld fault input signal specified by the Data Set Function 114-11 has been
received by the robot controller.

=> Check the weld controller and verify SLOGIC program to correct weld error.
=> 9ZR board.
___________________________________________________________________________________

ERROR CODE -613: Retract position monitor error.

(Spot weld specifications type A)

In using a retractable type gun, the retract input signal has not been received
by the robot controller when the gun is in the retract position. See Data Set Function 114-10.

=> Check the mechanical operation of the gun and the input sensor used for monitoring Retract position.
=> 9ZR board.
___________________________________________________________________________________

ERROR CODE -614: Extend position monitor error.

(Spot weld specifications type A)

In using a retractable type gun, the Extend input signal has not been received
by the robot controller even though the Extend output has been turned ON.
See Data Set Function 114-10.

=> Check the mechanical operation of the gun and the input sensor used to monitor the Extend position.
=> 9ZR board.
___________________________________________________________________________________
1-30 September 26, 2002
 Kawasak A/AD CONTROLLERS
ERROR CODES

ERROR CONDITIONS

ERROR CODE -615: Weld completion signal is already received.

(Spot weld specifications type A)

At the time the weld initiate output was issued, a weld complete input signal
had already been received. Data Set Function 114-11.

=> Check the gun or the weld controller.

=> 9ZR board.
=> Adjust the timing value of the motion start delay after weld completion.
Setting found in the Data Set Menu 114-2.
___________________________________________________________________________________

ERROR CODE -616: Gun retract position mismatch.

(Spot weld specifications type A)

In the check mode, the retractable gun output signals are monitored and compared
with the open/close gun data for a specific step. If the data does not compare
(for example, the gun is open when it should be closed), an error is detected.
This error is only detected when the robot begins to move in the check mode.

=> When gun retract position is wrong, do the following to recover:

> Reset the error.
> Adjust “CC” Code “O/C” data in Teach mode.
> Press “CLAMP” key to clamp the gun.
> Move the robot in check mode again.
=> When gun retract position is not wrong, simply reset the error and then move the
robot in check mode again.
___________________________________________________________________________________

ERROR CODE -620: Weld schedule data is abnormal.

(Spot weld specifications type B)
___________________________________________________________________________________

ERROR CODE -621: No response from RWC x.

(Spot weld specifications type B)

The robot controller has sent weld conditions to the Remote Weld Controller
(RWC), and expects a response back. However, no response has been received.

Check the following:

=> Welder or communication cables.
=> 9ZM board.
___________________________________________________________________________________

1-31 September 26, 2002

 Kawasak A/AD CONTROLLERS
ERROR CODES

ERROR CONDITIONS

ERROR CODE -622: RWC response error x.

(Spot weld specifications type B)

After transmitting the welding conditions to the specified welder (RWC), the response data back from the
welder is abnormal.
(x : represents the number of the welder)

Check the following:

=> Spot welder.
=> 9ZM board, communication cable.
___________________________________________________________________________________

ERROR CODE -623: Weld fault x.

(Spot weld specifications type B) - (x : represents the welder’s number)

A weld complete signal has not been received by the robot from the Robot Weld
Controller (RWC) or there is an electrical malfunction with the RWC. Typical
electrical problems include the following: fluctuation in current, faulty SCR or
SCR circuit, SCR has not fired, abnormal line voltage.

Check the following:

=> Welder or gun.
=> 9ZM board, communication cables.
___________________________________________________________________________________

ERROR CODE -624: RWC error x

(Spot weld specifications type B) - (x: represents the number of the welder)
The current flow from the specified welder (RWC) is abnormal. Typical causes:
insufficient cooling of the SCR, a memory data error, weld current is not
synchronized with gun clamp conditions, a system error, gun control valves
malfunction.

Check the following:

=> Welder or gun.
=> 9ZM board or communication cables.
___________________________________________________________________________________

ERROR CODE -625: Cable disconnection error x.

(Spot weld specifications type B) - (x: represents the number of the welder)
The robot controller has detected a drop in current flow from the RWC to the weld gun.

Check the following:

=> Welder or gun.
=> 9ZM board or communication cables.
___________________________________________________________________________________

1-32 September 26, 2002

 Kawasak A/AD CONTROLLERS
ERROR CODES

ERROR CONDITIONS

ERROR CODE -626: Weld current short or leak x.

(Spot weld specifications type B)

Weld current data from the specified weld controller (RWC) is abnormal.
(x: represents the number of the welder).
Short in secondary cable or internal leak in secondary cable or gun.

=> Weld cable.

=> Weld controller or gun.
=> 9ZM board or communication cable.
___________________________________________________________________________________

ERROR CODE -627: Main cable exchange alarm x.

(Spot weld specifications type B) - (x: represents the number of the welder).
The present value of the counter for the specified gun has exceeded the set
value for initiating an alarm to replace the weld main cable.

=> Reset the value of the alarm counter again.

=> Replace the main cable.
=> Select a greater value for the counter.
___________________________________________________________________________________

ERROR CODE -628: Gun-clamp mismatch.

(Spot weld specifications type B)

The data for the current gun and clamp does not match the data for gun and clamp
at the current weld step.

=> Check for correct application of the gun and clamp numbers.
___________________________________________________________________________________

ERROR CODE -629: No connection with RWC x.

(Spot weld specifications type B) - (x: represents the number of the welder)
The start-up sequence for communication with the RWC during power up has failed
or cannot be executed.

Check the following:

=> Welder, communication cables.
=> 9ZM board.
___________________________________________________________________________________

ERROR CODE -630: Robot has stopped during welding.

(Spot weld specifications type C)

This error is for servo controlled weld guns only. This error is produced
when the robot is placed in the HOLD or E-STOP condition after the clamp
output is energized, and before the weld complete signal is received.
___________________________________________________________________________________

1-33 September 26, 2002

 Kawasak A/AD CONTROLLERS
ERROR CODES

ERROR CONDITIONS

ERROR CODE -631: Can’t achieve desired pressure.

(Spot weld specifications type C)

(For servo controlled guns only)
The gun has not achieved the correct pressure within 5 seconds.

=> Gun tips worn.

=> Metal is too thin.
=> Pressure is set too high.
___________________________________________________________________________________

ERROR CODE -632: Gun Tip Stick.

(Spot weld specifications type C)

(For servo controlled guns only)

An over current condition has occurred in the servo gun circuit. This generally
occurs when the gun tips become welded to the part and do not release.

=> Weld controller.

=> 9ZM board, communication cable.
___________________________________________________________________________________

ERROR CODE -700: No free memory.

No free memory is available to Teach or Edit programs.

=> Check for usable memory capacity, and delete unnecessary programs.
=> Increase the memory capacity of 9ZA board.
___________________________________________________________________________________

ERROR CODE -800: Program does not exist.

No program has been selected at the time of program execution, or the selected
program does not exist.

=> Select a program before pressing cycle start.

=> Check the directory to make sure the program exists.
___________________________________________________________________________________

ERROR CODE -801: No program step.

This step does not exist in the program, or cannot be executed.

=> Select a program before pressing cycle start.

=> Make sure the program currently resides in memory.
=> Check the program using the LIST command to verify step.
___________________________________________________________________________________

1-34 September 26, 2002

 Kawasak A/AD CONTROLLERS
ERROR CODES

ERROR CONDITIONS

ERROR CODE -802: Nonexistent label.

Nonexistent label, cannot transfer control.

In executing the GOTO command, the label of the destination step is not defined.

=> Check to be sure that there is a label at the destination step.

=> Correct the program by inserting a label at the destination step.
___________________________________________________________________________________

ERROR CODE -803: Undefined variable.

Undefined variable encountered.

Variable data for the argument in the command or instruction is not defined.

=> Redefine the variable data.

=> Correct the program.
___________________________________________________________________________________

ERROR CODE -804: Undefined location data.

Location data is not defined.

The location variable data for the TOOL, BASE, or POINT command/instruction
is not defined.

=> Define the variable for the undefined location data.

=> Modify the name of variable for the location data.
___________________________________________________________________________________

ERROR CODE -805: Undefined string variable.

End of list in EVAL.

The string variable data for the ASC or LEN functions is not defined.

=> Define the undefined string variable data.

=> Modify the name of string variable.
___________________________________________________________________________________

ERROR CODE -806: Format specifier missing.

There is no format.

Unused.
___________________________________________________________________________________

ERROR CODE -807: Undefined program or label.

Nonexistent program or label.

The program name or label associated with the ON or ONI command is not defined.

=> Define the undefined program name or label.

=> Modify the program name or label.
___________________________________________________________________________________

1-35 September 26, 2002

 Kawasak A/AD CONTROLLERS
ERROR CODES

ERROR CONDITIONS

ERROR CODE -808: Illegal value.

Value out of range.

Numeric data exceeds the upper and lower limits of the range.

=> Correct the value of the numeric data.

=> Modify the program.
___________________________________________________________________________________

ERROR CODE -810: Divided by zero.

The system has encountered an illegal division by “0” process. This typically
occurs in calculations used for the FRAME function and circular interpolation.

=>Check and correct the source data for the frame or circular interpolation calculation.
___________________________________________________________________________________

ERROR CODE -811: Floating point overflow.

Floating point operation overflow.

The system has encountered a numeric floating point overflow in using arithmetic
(+,–,*,/) or logical (AND, OR, etc.) operators. This also occurs when converting
a numeric argument to an integer value.

=> Correct the program. Integer values with full precision ranges are from –16,777,216 to
16,777,216. See AS Language Manual.
___________________________________________________________________________________

ERROR CODE -812: Character string is too long.

The character string used with the following operators is too long.
a. Arithmetic operator +
b. Comparison operator ==, <>, <, >=
c. LEN function.

=> Modify the program.

___________________________________________________________________________________

ERROR CODE -813: Illegal exponential operation.

Negative exponent in EVAL.
Negative x in x^y is not allowed.

In using the exponential operator “^”, the numeric constant in the expression
must be greater than zero (x>0) to achieve the correct result.
(Example): a= (–3) ^ 2 results in error.
a= –3^2 results in –9
a= –1*–3^2 results in 9.

=> Correct the program.

___________________________________________________________________________________

1-36 September 26, 2002

 Kawasak A/AD CONTROLLERS
ERROR CODES

ERROR CONDITIONS

ERROR CODE -814: Expression is too complicated.

Stack over in evaluation.
Stack overflow in expression evaluation.

A numeric argument found in an expression is too complex to calculate.

=> Modify the program.

___________________________________________________________________________________

ERROR CODE -815: No expressions to evaluate.

The type of data in the argument is not correct for the operation being performed.

=> Correct the program.

___________________________________________________________________________________

ERROR CODE -816: Unexpected error while evaluating expression.

Unexpected error while evaluating expression.

This error occurs when the system is evaluating the argument in an expression and
the argument data is found to be abnormal or missing. Typical causes are:

a. No argument or function found in the expression.

b. Required data and argument type do not match.
c. The type of data in the argument is undefined.

=> Modify the program.

=> Memory failure on the 9ZA board.
=> Replace the 9ZA board.
___________________________________________________________________________________

ERROR CODE -817: SQRT parameter is negative.

Negative SQRT parameter.
SQRT parameter is missing.

In the SQRT function, a negative value has been placed in the argument.
(Example): a=SQRT (–4)

=> Correct the program.

___________________________________________________________________________________

ERROR CODE -820: Illegal array index.

Array index out of range.
Invalid array index.

In specifying an array, the array subscript number exceeds the value of the
range 0 – 9999.

=> Correct the program.

___________________________________________________________________________________

1-37 September 26, 2002

 Kawasak A/AD CONTROLLERS
ERROR CODES

ERROR CONDITIONS

ERROR CODE -821: Illegal argument value.

Invalid argument value.

The parameter specified for the command or instruction is illegal.

(Example):
TOOL parameter
The parameter specified is not the NULL TOOL or a defined transformation value.

=> Correct the program.

___________________________________________________________________________________

ERROR CODE -822 : Illegal joint number.

Unused.
___________________________________________________________________________________

ERROR CODE -823: Illegal signal number.

Signal number does not match system configuration.

In SIG or BITS command/instruction, the specified signal number exceeds the

range permitted for the system.

=> Correct the program.

=> Check the signal number and verify that it is within the max. allowed number.
=> Defective 9ZR board.
___________________________________________________________________________________

ERROR CODE -824: Illegal timer number.

Timer number over in FUNC.

The timer number defined in the TIMER function exceeds the range of 0 –10.

=> Correct the program.

___________________________________________________________________________________

ERROR CODE -825: Illegal signal number.

Signal number is too large.
Signal number exceeds the maximum.

In executing RUNMASK, SIGNAL, BITS, PULSE or SWAIT signal commands, the signal
number exceeds the range permitted by the system.

=> Correct the program

=> Check the signal number and verify that it is within the maximum number
permitted for the system.
=> Defective 9ZR board.
___________________________________________________________________________________

1-38 September 26, 2002

 Kawasak A/AD CONTROLLERS
ERROR CODES

ERROR CONDITIONS

ERROR CODE -826: Illegal clamp number.

The clamp number exceeds the maximum permitted by the system.

=> Correct the program.

=> Check the maximum clamp number.
___________________________________________________________________________________

ERROR CODE -827: Illegal time value.

Invalid time value.

In the TIMER or DELAY command, a negative number is specified for time.

=> Correct the program.

___________________________________________________________________________________

ERROR CODE -828: No value set.

No set value.

No set value exists in the BITS command, etc.

=> Correct the program.

___________________________________________________________________________________

ERROR CODE -829: Illegal signal number.

In using the following: RUNMASK, SIGNAL, BITS, PULSE or SWAIT. The signal number exceeds a range
permitted by the system.

=>Correct the program.

___________________________________________________________________________________

ERROR CODE -830: Illegal time input code.

Illegal TIME data.

The TIME command, data for setting the date and time is too long or exceeds the permitted range of numbers.

=> Input the date and time correctly.

___________________________________________________________________________________

ERROR CODE -831: Illegal month input.

Illegal TIME input month.

Unused.
___________________________________________________________________________________

1-39 September 26, 2002

 Kawasak A/AD CONTROLLERS
ERROR CODES

ERROR CONDITIONS

ERROR CODE -832: Illegal time input data.

In TIME command, erroneous data has been entered.

a. Negative numeric number
b. Data is out of the permitted range.
c. Date does not exist (Example: February 30, etc.)

=> Input the time and date correctly.

___________________________________________________________________________________

ERROR CODE -833: Illegal qualifier.

Illegal decorative.

The point command has an illegal qualifier.

=> Correct the program by specifying the correct qualifier.

___________________________________________________________________________________

ERROR CODE -834: Program name already exists.

Program name is already in existence.

When using the RENAME command, you must specify a program name that does not currently exist.

=> Check and correct the program name.

___________________________________________________________________________________

ERROR CODE -835: Cannot use KILL command because the program is running.
Can’t KILL.

An attempt has been made to cancel a registered program using the KILL command
when the program is currently executing.

=> Execute the KILL command again after ending the current program.
___________________________________________________________________________________

ERROR CODE -836: Cannot use KILL command because the program is running.
Can’t KILL.

An attempt has been made to cancel a registered program using the PCKILL command while the program is
currently executing.

=> Execute the command again after ending the program you want to cancel.
___________________________________________________________________________________

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 Kawasak A/AD CONTROLLERS
ERROR CODES

ERROR CONDITIONS

ERROR CODE -837: Cannot use dedicated signal.

Cannot use specialized signal.
Can’t use because of special signal.

An attempt has been made to use a general signal which has already been defined
as a dedicated signal.

=> Check the allocation of dedicated signals. If the signal is dedicated but not in use,
release it or use a signal that is not dedicated.
=> Correct the program. See A/AD Operations Manual.
___________________________________________________________________________________

ERROR CODE -838: RPS mode is not configured.

The following dedicated signals have not been defined for use with the RPS
(external program select) mode:

a. When the RPS mode resets the external program, neither the RPS ON or external
program input is dedicated.
b. The external program input signal is not dedicated at the time the EXTCALL is issued.
c. The external program input signal is not dedicated at the time the jump command is set.
d. The RPS ON signal is not dedicated at the time the end command is set.
___________________________________________________________________________________

ERROR CODE -839: Cannot use negative number.

Negative number.
Negative value is not allowed.

Cannot use a negative number with the PULSE and ACCURACY commands.

=> Correct the program. See AS Language Manual for details.

___________________________________________________________________________________

ERROR CODE -840: Too many subroutines.

Too many subroutine nests.

In the CALL or EXTCALL command, nesting exceeded 20. (Nesting of subroutine must be less than 20).

=> Correct the program.

___________________________________________________________________________________

ERROR CODE -841: Cannot use PULSE because the signal is already ON.
Can’t use this signal in PULSE, because it is already ON.
Signal is already ON, cannot use PULSE.

In execution of the PULSE command or instruction, the specified signal is

already ON. You cannot PULSE an output that is already ON.

=> Correct the program.

___________________________________________________________________________________

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ERROR CODES

ERROR CONDITIONS

ERROR CODE -842: Non-existent subroutine.

Non-existent subroutine to CALL.
Calling non-existent subroutine.

The program called by the CALL or ON command does not exist.

=> Create the program.

=> Correct the program.
___________________________________________________________________________________

ERROR CODE -843: Nonexistent label.

Unused (Refer to ERROR CODE -802).

___________________________________________________________________________________

ERROR CODE -844: Cannot execute.

Can’t execute because there is no program.

An attempt has been made to execute a command which cannot be executed by the DO command.
(Example: CALL, RETURN, GOTO, WAIT, etc.)

=> These commands cannot be executed by the DO command. If it is necessary to execute them,
first create a program using these commands, then execute the program using the EXECUTE
command.
___________________________________________________________________________________

ERROR CODE -845: Non-existent program.

___________________________________________________________________________________

ERROR CODE -846: No program exists.

No program found.

The program specified using the DIRECTORY or LIST command does not exist.
___________________________________________________________________________________

ERROR CODE -847: No location values exist.

No location value found.
No location found.

No location variables were found using the LIST/L command.

___________________________________________________________________________________

ERROR CODE -848: No real values exist.

No real_variable found.

No real variable values were found using the LIST/R command.

___________________________________________________________________________________

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 Kawasak A/AD CONTROLLERS
ERROR CODES

ERROR CONDITIONS

ERROR CODE -849: No string value exists.

No string variable found.
No string value found.

No string variable values found using the LIST/S command.

___________________________________________________________________________________

ERROR CODE -850: Out of absolute lower limit.

Absolute motion exceeds the lower limit.
Lower software limit is out of range.

An attempt has been made to set the software lower limit to a value outside the allowable range.

=> Verify the allowable working envelope of the robot, then set the lower software limit correctly.

___________________________________________________________________________________

ERROR CODE -851: Out of absolute upper limit.

Absolute motion exceeds the upper limit.
Upper software limit is out of range.

An attempt has been made to set the software upper limit to a value outside the allowable range.

=> Verify the allowable working envelope of the robot, then set the upper software limit correctly.
___________________________________________________________________________________

ERROR CODE -852: Out of user lower limit.

Motion exceeds user lower limit.
User motion limit is out of range.

An attempt has been made to set the software lower limit to a value outside the allowable range.

=> Verify the allowable working envelope of the robot, then set the lower software limit correctly.
___________________________________________________________________________________

ERROR CODE -853: Out of user upper limit.

Out of upper user motion limit.
Higher motion out of user limit.

An attempt has been made to set the software upper limit to a value outside the allowable range.

=> Verify the allowable working envelope of the robot, then set the upper software limit correctly.
___________________________________________________________________________________

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 Kawasak A/AD CONTROLLERS
ERROR CODES

ERROR CONDITIONS

ERROR CODE -854: Current position of jt x is out of range.

Current position of jt x is out of limit.
Out of motion limit!! Current JT x.

Current position of the relative joint exceeds the upper or lower limit of motion range.
In REPEAT or CHECK mode, the joint value of the current robot position exceeds the motion range set under
‘software limit’.

=> Check and reset the ‘software limit’.

=> Correct the taught point or position data.
___________________________________________________________________________________

ERROR CODE -855: Motion start location of jt x is out of range.

Motion start location of jt x is out of limit.
Out of limit! Motion start position of JT x.

Prior to executing a program or step, the path planning system has found the starting step to be outside the
allowable lower or upper software limit range.

=> Check and reset the ‘software limit’.

=> Correct the taught point or position data.
=> Correct the program.
___________________________________________________________________________________

ERROR CODE -856: Motion end location of jt x is out of range.

Motion end location of jt x is out of limit.
Out of limit! Motion end position of JT x.

The program path planning system has determined that the destination or end location of the current step will
cause the specified axis to be out of range with respect to the upper and lower software limits.

=> Check and reset the ‘software limit’.

=> Correct the teaching point or position data.
=> Correct the program.
___________________________________________________________________________________

ERROR CODE -857: Destination is out of range.

Destination is out of motion range.
Out of range.

The system has determined from the current position and tool posture that the current destination places all
axes outside the allowable software limit range.

=> Correct the taught point or location data.

=> Correct the program.
___________________________________________________________________________________

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 Kawasak A/AD CONTROLLERS
ERROR CODES

ERROR CONDITIONS

ERROR CODE -858: Illegal configuration for linear motion.

Illegal configuration, cannot use linear motion.
Can’t move along straight line, use JOINT interpolation motion.

The system has determined that the start and end points for the linear or circular interpolation moves are
illegal.

=> Correct the taught point or location data.

=> Correct the program.
___________________________________________________________________________________

ERROR CODE -859: Out of user upper/lower limit.

In setting a motion range (Software Limit), the set value is out of upper/lower limit of motion range.

=> Correct the upper and lower set value of motion range.
___________________________________________________________________________________

ERROR CODE -870: Cannot set values smaller than xxx in ACCURACY.
Can’t accept smaller values than xxx as ACCURACY data.
ACCURACY Command can’t have a value smaller than xxx.

Unused.
___________________________________________________________________________________

ERROR CODE -871 : Illegal joint number.

Illegal JT number.

In using the DRIVE command, the specified number of joints exceeds the actual number of joints in the
system (Joint numbers are expressed as integers from 1–6 or 1–7 depending on the robot configuration).

=> Check the number of joints allowed in the system, and correct the program.
___________________________________________________________________________________

ERROR CODE -872: Cannot execute a motion instruction in the PC program.

PC program can’t execute motion instructions.
Motion related commands executed by PC program.

A motion command/instruction has been found in the PC (Process Control) program (programs executed by
the PCEXECUTE command).
Motion commands such as JMOVE, LMOVE, and/or DELAY cannot be executed by the PC program.

=> Correct the PC program.

=> Instead of using the PCEXECUTE command, execute the motion command by using the EXECUTE
command (Cycle start).
___________________________________________________________________________________

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 Kawasak A/AD CONTROLLERS
ERROR CODES

ERROR CONDITIONS

ERROR CODE -873: Illegal auxiliary data number.

Illegal aux. data number.

The value selected for auxiliary data (speed, timer, tool, etc.) has exceeded the allowable range.

=> Correct the value of the auxiliary data.

=> Replace the 9ZA board.
___________________________________________________________________________________

ERROR CODE -874: No circular location.

No C1MOVE or C2MOVE after current step.

The current circular interpolation move does not start with a C1MOVE command and end with a C2MOVE
command. The C1MOVE command must be followed by a C1MOVE or a C2MOVE command.

=> Correct the program.

=> Reteach the location with a C1MOVE or C2MOVE command.
___________________________________________________________________________________

ERROR CODE -875: No C1MOVE (CIR1) instruction.

No C1MOVE instruction preceded.

The current circular interpolation move does not start with a C1MOVE command and end with C2MOVE
command. The C2MOVE must be preceded by a C1MOVE command.

=> Correct the program.

=> Reteach the location using the correct circular interpolation command.
___________________________________________________________________________________

ERROR CODE -876: Cannot create circle.

Cannot create circle, because 3 points are too narrow or on the straight line.

In order to execute circular interpolated motion, the robot requires 3 points to calculate the radius and center of
the circle or arc. However, the 3 points specified in the current program cannot be used.

=> Correct the program.

=> Correct the taught locations.
___________________________________________________________________________________

ERROR CODE -877: Cannot execute, because of sealing type.

(Only for special sealing and painting type software)

An attempt has been made to execute a command that is reserved for special sealing and painting type
software.

=> Correct the program.

=> Correct the taught location.
___________________________________________________________________________________

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ERROR CODES

ERROR CONDITIONS

ERROR CODE -878: Cannot execute, because direction of 7th axis has changed.

(Only for special paint and sealing software)

An attempt has been made to reverse the direction of the transverse axis counter
to the correct direction. (If the robot first stops due to a WX, CL1, etc,
then the direction is considered legal and the error is not generated).

=> Correct the program.

=> Correct taught locations.
___________________________________________________________________________________

ERROR CODE -879: Cannot execute; not sealing type.

(Only for sealing specifications)

Attempts have been made to execute the following commands: GUNON, GUNOFF, GUNONTIME or
GUNOFFTIMER. These commands are only applicable with the optional sealing software.

=> Modify the program.

=> Set the clamp specifications again.
___________________________________________________________________________________

ERROR CODE -1000: Tags don’t match.

Free memory management tags don’t match.

At the time of initialization/execution of the FREE command (free area display),

the management marks applied to memory are damaged.

=> Initialize and execute loading again from the auxiliary storage.
=> Replace the 9ZA board.
___________________________________________________________________________________

ERROR CODE -1001: Bad block size.

Bad free block size.

In changing a used memory location to a free area by the DELETE command (delation), the management
marks controlling the memory are damaged.

(Reference):
a. The last address of the block intended to be freed-up is out of memory size.
b. The management marks being applied to the top and bottom of a block are damaged.

=> Initialize once, and load again from the auxiliary storage.
=> Replace the 9ZA board.
___________________________________________________________________________________

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 Kawasak A/AD CONTROLLERS
ERROR CODES

ERROR CONDITIONS

ERROR CODE -1002: Address out of memory limits.

Return address out of memory limits.

In using the DELETE command to free-up memory, the memory management system has determined that the
first address of the block intended to be changed is out of the memory limit.

=> Initialize once, and load again from the auxiliary storage.
=> Replace 9ZA board.
___________________________________________________________________________________

ERROR CODE -1003: Data base error.

Data base error=system error.
Teach data is damaged. (system error).

The data base for the user memory (link list) is damaged.

=> Initialize once, and load again from the auxiliary storage.
=> Replace 9ZA board.
___________________________________________________________________________________

ERROR CODE -1010: No response from RTC.

RTC is not responding.

The real time clock on the 9ZA board (for calendar) is out of order and does not respond.

=> Replace the 9ZA board (Defective real time clock).

___________________________________________________________________________________

ERROR CODE -1011: Interpolation calculation time exceeded.

The amount of time (16 to 32 ms) required by the system software to calculate an interpolated motion has
been exceeded. Therefore, the location command signal is not sent to the 1AE/1GE board (servo software).

=> When using circle interpolation, a 16MHz 9ZA board is required.

=> Replace either 9ZA or 1AE/1GE board.
=> May be due to defective AS software. Inform our Service dept.

For additional information on error code -1011, see troubleshooting flow chart in unit 10.
___________________________________________________________________________________

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ERROR CODES

ERROR CONDITIONS

ERROR CODE -1012: Commanded position of jt x has suddenly changed.

Commanded position of jt x has suddenly changed.

In the Repeat mode, the commanded value of each axis is greater than 1.3 times the max. arm speed. In
Check mode, the commanded value has exceeded 200mm/s.

=> Replace the servo-amp.

=> Replace the specified servo assembly (motor and encoder).
=> Replace 9ZA or 1AE/1GE board.
=> May be due to defective AS software.Inform our Service dept.
___________________________________________________________________________________

ERROR CODE -1013: 9ZB board detected that command position

of jt x has suddenly changed.

Unused.
___________________________________________________________________________________

ERROR CODE -1014: Commanded position of jt x is out of range.

Commanded position of jt x is out of motion limit.
In commanded position, Jt. x is out of motion limit.

The commanded value for each joint sent to the 9ZB or 1AE/1GE board (Servo Board) has exceeded the
motion range during a fixed period of time. (Condition is monitored during Check and Repeat modes).

=> Correct taught location.

=> Correct the program.
___________________________________________________________________________________

ERROR CODE -1015: Commanded speed of jt x is too large.

Commanded position of JT x is over maximum speed.
Speed of commanded position of Jt. x is too high.

Unused.
___________________________________________________________________________________

ERROR CODE -1019 Check sum error of system data. The check sum data
of the system data of the AS software was rewritten.

When downloading the system information such as model number, number of axis was changed. This check
sum data should not change and the error will occur. When the error occurs in situations other than download-
ing, the error is caused by defective memory back-up, defective 9ZA board, or memory error from noise.

=> Use AUX 78 CLEAR CHECK SUM ERROR or CHSUM command to reset the data.
When the error cannot be reset using the check sum commands, the command with the abnormality is
shown. Rewrite the command and use CHSUM or AUX 78 to clear the error.
___________________________________________________________________________________

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 Kawasak A/AD CONTROLLERS
ERROR CODES

ERROR CONDITIONS

ERROR CODE -1020: EPROM Data trouble.

EPROM Data error.

When switching control power ON, an EPROM checksum error has been detected on the 9ZA board.

=> Replace 9ZA board (damaged ROM data, ROM not installed correctly).
(Reference) IC numbers: U80, U88, U96, U103

For additional information on error code -1020, see troubleshooting flow chart in unit 10.
___________________________________________________________________________________

ERROR CODE -1021: RAM memory trouble:address xxxx.

RAM memory error. Address xxxx.

Normal Read/Write of RAM on the 9ZA board cannot be executed when the control power is switched ON.
(Only executed at the time of initialization).

=> Replace the 9ZA board (RAM trouble).

(Reference) IC No. U78, U79, U86, U87, U94, U95, U101 and U102.

For additional information on error code -1021, see troubleshooting flow chart in unit 10.
___________________________________________________________________________________

ERROR CODE -1022: RAM battery low voltage. (9ZA board)

This error is detected if battery voltage of 9ZA board is low when the control power is switched ON.
< Software >

=> Replace the battery on the 9ZA board.

=> Replace the 9ZA board.

Make sure to save the data before replacing the battery!

For additional information on error code -1022, see troubleshooting flow chart in unit 10.
___________________________________________________________________________________

ERROR CODE -1023: RAM battery low voltage. (9ZM board)

This error is detected if battery voltage on the 9ZM board is low when the control power is switched ON.

=> Replace the battery on the 9ZM board.

=> Replace the 9ZM board.

Make sure to save before replacing the battery!

___________________________________________________________________________________

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ERROR CODES

ERROR CONDITIONS

ERROR CODE -1100 : *** CPU Error ***

This error is caused by various interruptions detected by the CPU on the 9ZA board. Generally, this occurs
due to defective software or when an element of the CPU or memory is abnormal.

=> Note the condition when the error occurred, and execute the operation again after switching OFF the
control power.
=> Replace the 9ZA board.
=> May be due to defective software. Record the conditions when the error occurred, and report them to our
Service dept. accordingly.

For additional information on error code -1100, see troubleshooting flow chart in unit 10.
___________________________________________________________________________________

ERROR CODE -1102: *** I/O Bus error ***

* Bus Error exception *

This error occurs when the CPU does not receive a response from one of the I/O Bus devices within a period
of time. I/O devices include the 9ZR, 9ZW, function panel, keyboard, etc.

=> Take note of the condition when the error occurred, and execute the
operation again after cycling power once.
=> Replace 9ZA board or the above mentioned boards related to the I/O register.
=> Report the conditions when the error occurred to our Service dept. since the
trouble may be due to defective AS software.

For additional information on error code -1102, see troubleshooting flow chart in unit 10.
___________________________________________________________________________________

ERROR CODE -1103: *** Address error ***

* Address Error exception *

This error occurs when the CPU attempted to prefetch a command from an old address.
The cause is similar to ERROR CODE -1102 Bus error.

=> Take note of the condition when the error occurred, and execute the
operation again after cycling the control power once.
=> Replace 9ZA board or the above mentioned boards related to I/O register.
=> Report the conditions when the error occurred to our Service dept. since the
trouble may be due to defective AS software.
___________________________________________________________________________________

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ERROR CODES

ERROR CONDITIONS

ERROR CODE -1104: *** Illegal instruction error ***

* Illegal instruction exception *
*** Instruction not defined execute error ***

Processing command illegal or defective CPU.

The cause maybe due to a defective CPU on the 9ZA board or an abnormal bus memory device.

=> Take note of the condition when the error occurred, and execute the operation
again after cycling the control power.
=> Replace 9ZA board or I/O Bus related boards.
=> Report the conditions when the error occurred to our Service dept. since the
trouble may be due to defective AS software.
___________________________________________________________________________________

ERROR CODE -1105: *** Divided by zero error***

* Zero divide exception *

This error occurs when the 9ZA CPU attempts to execute an arithmetic divide
calculation with an illegal divisor of zero.

=> Take note of the condition when the error occurred, and execute the operation
again after cycling the control power.
=> Replace 9ZA board or I/O Bus related boards.
=> Report the conditions when the error occurred to our Service dept. since the
trouble may be due to defective AS software.
___________________________________________________________________________________

ERROR CODE -1106:

___________________________________________________________________________________

ERROR CODE -1107:

___________________________________________________________________________________

ERROR CODE -1108: *** Privilege violation error ***

*** Supervisor exception error ***
* Privilege violation exception *

An attempt has been made to execute a command which is generally unusable (a privilege command) with the
AS software. The cause may be due to defective AS software, abnormal memory or element related to bus on
the 9ZA board.

=> Take note of the condition when the error occurred, and execute the operation
again after cycling the control power.
=> Replace 9ZA board or I/O Bus related devices.
=> Report the conditions when the error occurred to our Service dept. since the
trouble may be due to defective AS software.
___________________________________________________________________________________

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ERROR CODES

ERROR CONDITIONS

ERROR CODE -1109: *** Trace exception ***

*** Trace exception ***

This error occurs when the CPU on the 9ZA board has detected an interrupt trace exception. However, the
trace exception is currently not used. Therefore, if the error should occur, the cause may be due to abnormal
element(s) or abnormal memory on the CPU of the 9ZA board.

=> Take note of the conditions when the error occurred, and execute the operation
again after cycling the control power.
=> Replace 9ZA board or I/O Bus related devices.
=> Report the conditions when the error occurred to our Service dept. since the
trouble may be due to defective AS software.
___________________________________________________________________________________

ERROR CODE -1110: *** Line 1010 emulator ***

* Line 1010 emulator exception *

Illegal CPU processing command. The cause may be due to a defective CPU on the 9ZA board or an abnor-
mal bus or memory device.

=> Take note of the condition when the error occurred, and execute the
operation again after cycling the control power.
=> Replace the 9ZA board.
___________________________________________________________________________________

ERROR CODE -1111: *** Line 1111 emulator ***

* Line 1111 emulator *

Illegal CPU processing command. The cause may be due to a defective CPU on the
9ZA board or an abnormal bus or memory device.

=> Take note of the condition when the error occurred, and execute the
operation again after cycling the control power.
=> Replace the 9ZA board.
___________________________________________________________________________________

ERROR CODE -1112:

___________________________________________________________________________________

ERROR CODE -1113 : *** Coprocessor protocol violation ***

The CPU on the 9ZA board has detected mismatched data between the CPU and coprocessor in executing
floating-point arithmetic.

=> Take note of the conditions when the error occurred, and execute the
operation again after cycling the control power.
=> Replace the 9ZA board or I/O Bus related boards.
=> Report the conditions when the error occurred to our Service dept. since the
error may be due to defective AS software.
___________________________________________________________________________________

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ERROR CODES

ERROR CONDITIONS

ERROR CODE -1114: *** CPU command format error ***

*** CPU instruction format error ***

The CPU on the 9ZA board has detected abnormal or corrupt data in memory. The
cause may be due to a defective CPU, memory device, bus signal, or software problem.

=> Take note of the conditions when the error occurred, and execute the
operation again after cycling the control power.
=> Replace the 9ZA board or I/O Bus related boards.
___________________________________________________________________________________

ERROR CODE -1115: *** Interruption before I/O initialize ***

** Uninitialized Interrupt **

The initialization of the SIO (serial I/O) communication has failed due to a 9ZA board interrupt.
The cause may be due to a defective SIO or memory device on the 9ZA board.

=> Take note of the condition when the error occurred, and execute the operation
again after cycling OFF the control power once.
=> Replace the 9ZA board or the boards related to the above mentioned I/O device.
___________________________________________________________________________________

ERROR CODE -1116: Vector offset=xxx PC=xxxx

Exception vector offset=xxx PC=xxx

This message displays additional information and specific codes for ERROR CODES 1110–1115.
Note the code that is displayed and report it to our Service Dept.
(No further explanation of the codes is provided).
___________________________________________________________________________________

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ERROR CODES

ERROR CONDITIONS

ERROR CODE -1308: Motor power OFF.

This error typically indicates that even though the software recognizes motor power ON, there is no signal or
feedback from the hardware indicating motor power. Refer to the following ERROR CODES for more
information: 1501, 1601, 1602, 1400~1409, 1511.

Check the following hardware items:

=> CP4 off.
=> Encoder.
=> 1AE and 1BP boards.
=> Power circuit relays CR3 and CR4.

Error code -1308 detection:

1. When motor power is requested by the AS software signal (/STG), SSR17 (solid state relay 17) on the
1BP board is energized via the 1AE/1GE board. The MPWR LED on the 1AE/1GE board is ON.
2. When SSR17 is energized relay CR3, on the power supply assembly, is energized through hardware
safety interlocks (Figure 9-1 2 ).
3. When relay CR3 is energized contactor MC1 (repeat mode) or MC2 (teach mode), on the power supply
assembly, is energized and motor power is applied (Figure 9-1 3 ).
4. When contactor MC1 (repeat mode) or MC2 (teach mode) is energized motor power is applied, MC1 or
MC2 auxiliary contacts close, relay RY10, on the 1BP board, is energized, LD4 on the 1BP board lights
(Figure 9-2 4 ).
5. The 1AE/1GE board sends a motor power ON confirmation signal to the AS software on the 9ZA board.
If the AS software does not receive the motor power ON confirmation signal after the fixed time expires,
the SSR on the 1AE/1GE board is de-energized, motor power is turned off and error code "-1308 motor
power off" is displayed (Figure 9-2 1 ).

Error code -1308 can be temporarily masked by setting 1AE SW2 bit 2 to the ON position.

The table below shows related software signals, errors generated and the 1BP board SW2 error mask bit
where applicable. If multiple errors are displayed refer to the appropriate error code fro each error. Temporarily
mask errors with the 1BP board SW2 where applicable to aid in diagnosing the area of the fault.

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ERROR CODES

ERROR CONDITIONS

Signal Description Error Code 1PB SW2 Error Mask Bit

EMGST Motor power OFF -600

BRKERR BRAKE Signal disconnected or shor ted -1522

ACERR AC primary power OFF -1800

Limit switch of JTx is ON

AXSLS -1601/-1602 SW2-8
Limit switch signal line disconnnected

MTH Motor overheat -1501 SW2-7

RTH Regenerative resisror overheat or disconnected -1413 SW2-5

ENCBAT Encoder battery voltage low -1511

RTFL Power source (100 V) to power block A(B) is low -1410 SW2-4

HV (P) Power unit alarm -1414 SW2-3

SVDERA Servo power block A error, Code is XXX -1411

SVDERB Servo power block A error, Code is XXX -1412

The possible areas of the fault are:

• Hardware related to the motor power ON circuit.

1. Defective 1BP board (relays; SSR, RY2, RY3, RY4, RY5 and RY6).
2. Damaged connector or poor connection at 1BP board connector(s).
3. Defective CR3 relay.
4. Defective +24 VDC power supply (power supply, CP2, and wiring for the power supply circuit).
5. Defective RUN/HOLD switch (RUN/HOLD switch is monitored by the AS software).
6. Defective separate operation panel harness or poor connection at the harness connector).
7. Defective 1AE/1GE board.

• Hardware related to motor power ON confirmation circuit.

1. Defective 1BP board (relay; RY10).

2. Damaged connector or poor connection at 1BP board connector(s).
3. Defective MC1 or MC2 auxiliary contacts.
4. Defective +24 VDC power supply (power supply, CP2, and wiring for the power supply circuit).
5. Defective 1AE/1GE board.

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ERROR CODES

ERROR CONDITIONS

Motor power
RY6 RY5
Motor power request (MON)
RY2
LS EMG LS: Axis restriction LS
RY2 EMG: Emergency stop PB

1BP Board 2

SSR RY2 Run / Hold RY3 RY12

Hold processing (RUN)
CR3
STG MON EX.HOLD EX.HOLD: External HOLD
TRIG: TP trigger switch
REPEAT: TEACH/REPEAT switch
RY4
When software
signals STG and
MON are present TRIG REPEAT
CR3 is energized

3
CR3
For motor power
MC magnetic contactor
(MC1, MC2)
RUN

Figure 9-1 Motor Power ON/OFF Circuit

4 +24 VDC +5 VDC 1AE/1GE Board

MC
RY10 LD4 Motor Power ON
1
The 1AE/1GE board sends
a motor power ON confirmation
signal to the AS software on the
+24 VDC GND
9ZA board using the VME bus.
SW2-2

SW2-2: Error code -1308

can be temporarily masked
1BP Board by setting 1AE SW2 bit 2 to
the ON position.
MC: Magnetic contactor MC1 or MC2

Figure 9-2 Motor Power ON Confirmation

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ERROR CODES

ERROR CONDITIONS

Additional causes of error -1308

• Corrupt AS software; The software does not recognize the motor power ON confirmation signal. The
software mis-detects an emergency stop or an abnormal stop (envelope error) as error code -1308.
• 1BP board is defective; Motor power is not engaged due to SSR relay failure.
• Defective MC1 and/or MC2 contactor spike diode; Relay SSR fails due to voltage spike created by the
MC1 and/or MC2 pull-in coil.
• Defective MC1 and/or MC2 auxiliary contacts or terminal connections; The motor power ON confirma-
tion signal is not generated and sent to the AS software.
• Defective encoder power circuit; The encoder battery error is not generated because the 1BP board
power-up sequence is interrupted and error code -1308 is generated.
• Defective 9ZG board; The encoder battery circuit is interrupted due to the defective 9ZG board and error
code -1308 is generated as stated above.
• Defective or unstable +24 VDC power supply; One element of circuit protector CP2 opens causing the
output of the +24 VDC power supply to become unstable. The relays on the 1BP board, CR3, MC1 and
MC2 do not operate properly and the motor power ON confirmation signal is not sent to the AS software
and error code -1308 is generated.
• Deflective machine solenoid harness; If the machine solenoid harness is defective it causes the +24
VDC supply to become unstable and MC1 and MC2 do not function properly.
___________________________________________________________________________________

ERROR CODE -1309: Watch dog error (Digital Servo board CPU-A (B).

(For the AD controller only)

Servo CPU on 1AE board is not operating normally.

=> Replace the 1AE board.

=> Replace the 9ZA board.

For additional information on error code -1309, see troubleshooting flow chart in unit 10.
___________________________________________________________________________________

ERROR CODE -1310: Watch dog error -Voltage monitor board CPU1(2)

(Only for AD controller).

The watch dog circuit has detected a problem on the 1BP board. The 1BP board monitors the +5 VDC,
+12 VDC, –12 VDC, and 24 VDC power supply voltages.

=> Replace the 1BP board.

=> Replace either mother board or 9ZA board.
___________________________________________________________________________________

ERROR CODE -1311: Watch dog error -Remote operation panel board CPU1(2).

(Only for AD controller).

The watch dog circuit has detected a problem with the interface board (IBR) for the remote operation panel.

=> Replace the 1BF board.

=> Replace either mother board or 9ZA board.
___________________________________________________________________________________

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ERROR CODES

ERROR CONDITIONS

ERROR CODE -1312: Calculation time over -Digital servo board CPUA (B).

(Only for AD controller)

Normal transmitting and receiving of data between the 9ZA and 1AE board has not
occurred within the specified time period (16ms or 32ms).

=> Replace the 1AE board.

=> Replace either mother board or 9ZA board.

For additional information on error code -1312, see troubleshooting flow chart in unit 10.
___________________________________________________________________________________

ERROR CODE -1313: CPU-A DUAL PORT RAM abnormal, Address: xx

(Only for AD controller)

During initialization of the servo CPU on the 1AE board, data cannot be read or written to the CPU-A dual port
RAM located on the 1AE board.

=> Replace the 1AE board.

=> Replace either mother board or 9ZA board.
___________________________________________________________________________________

ERROR CODE -1314: CPU-B DUAL PORT RAM abnormal.Address: xx

(Only for AD controller)

During initialization of the servo CPU on the 1AE board, data cannot be accessed from the CPU-B dual port
RAM located on the 1AE board.

=> Replace the 1AE board.

=> Replace either mother board or 9ZA board.
___________________________________________________________________________________

ERROR CODE -1314: CPU-A RAM program abnormal. Address: xx

(Only for AD controller)

During initialization of the servo CPU on the 1AE board, data cannot be accessed from the CPU-A dual port
RAM located on the 1AE board.

=> Replace the 1AE board.

=> Replace either mother board or 9ZA board.
___________________________________________________________________________________

ERROR CODE -1316: CPU-B RAM program abnormal.Address xx

(Only for AD controller)

During initialization of the servo CPU on the 1AE board, data cannot be accessed
from the CPU-B dual port RAM located on the 1AE board.

=> Replace the 1AE board.

=> Replace either mother board or 9ZA board.
___________________________________________________________________________________

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ERROR CODES

ERROR CONDITIONS

ERROR CODE -1317: CPU-A RAM Data abnormal.Address* xx

(Only for AD controller)

During initialization of the servo CPU on the 1AE board, data cannot be accessed from the CPU-A dual port
RAM located on the 1AE board.

=> Replace 1AE board.

=> Replace either mother board or 9ZA board.
___________________________________________________________________________________

ERROR CODE -1318: CPU-B RAM data abnormal. Address: xx

(Only for AD controller)

During initialization of the servo CPU on the 1AE board, data cannot be accessed from the CPU-B dual port
RAM located on the 1AE board.

=> Replace 1AE board.

=> Replace either mother board or 9ZA board.
___________________________________________________________________________________

ERROR CODE -1319: Digit. servo board CPU-A(B) monitor command error.

(Only for AD controller)

The servo CPU (on 1AE board) is not operating normally.
(No response from 1AE board when a monitor command is transmitted to the 9ZA board).

=> Replace 1AE board.

=> Replace 9ZA board.
___________________________________________________________________________________

ERROR CODE -1350: 9ZM board error.

Unused.
___________________________________________________________________________________

ERROR CODE -1400: Amp alarmjt x.

Also called “Servo amp CPU error”. Occurs due to the following abnormal cases:
1. Servo amplifier CPU watch dog error.
2. Faulty reading of the encoder value when the control power is switched ON.
3. Detection of encoder annunciator signal.

Check the following if error occurred at power up:

Single joints => Servo motor (encoder), servo-amp. internal harness, panel harness.
Multiple joints => 1AE board, internal harness (9ZG or 9TK board).
During operation => Servo amp, 1AE board, defective connection between servo-amp and 1AE.
___________________________________________________________________________________

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ERROR CODES

ERROR CONDITIONS

ERROR CODE -1401: Amp overcurrentJt xx.

This error is detected when the current flow through the power transistors
in the servo amp exceeds the rated value (90% of the maximum current).

Error occurs when control power is switched ON => Servo amp.

Error occurs when motor power is switched ON => Servo amp.
Error occurs when servo power is switched ON => Harness between amp and motor.

During operation => Servo amp, motor and between servo amp and motor.
* When replacing the motor, also replace the servo amp to make sure.

For additional information on error code -1401, see troubleshooting flow chart in unit 10.
___________________________________________________________________________________

ERROR CODE -1402: Amp overheatJt xx.

Over heat in JT x amp.
Amp of jt x over heat.

The thermostat installed on the heat sink of the servo amp is open (90°C, 194°F).

Error occurs when control power is switched ON

=> Servo amp.
Error occurs during operation
=> Servo amp, motor, excessive payload, illegal posture instruction, mechanical problem (friction).
___________________________________________________________________________________

ERROR CODE -1403: Amp main circuit overvoltagejt x.

Over voltage in JT x amp. main circuit.
Amp main circuit voltage of jt x is high.

This error is detected when the voltage in the main power circuit (between P-N) is abnormally high
(415 VDC approx.).

Error occurs when control power is switched ON => Servo amp.

Error occurs when motor power is switched ON => Servo amp and primary voltage.
During operation => Regenerative resistance/wiring, wiring (P,N),
amp power unit and servo amp.
___________________________________________________________________________________

ERROR CODE -1404: Amp main circuit has low voltage in jt x.

Low voltage in amp main circuit of JT x.
Amp main circuit voltage of jt x is low.

This error is detected when voltage in the main circuit of the servo amp is
abnormally low (below 60 VDC approx. for U and EX series, 100 VDC for J series).
Error occurs when control power is switched ON => Servo amp.
Error occurs when motor power is switched ON => Servo amp, transformer or primary voltage
(voltage drop or open phase).

During operation => Servo amp, (P,N) wiring or amp power unit.
Others => 9ZB board, power circuit.
___________________________________________________________________________________
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ERROR CODES

ERROR CONDITIONS

ERROR CODE -1405: Low amp control power in jt x.

Alarm in amp control power of JT x
Amp control power of jt x is low

The control power for the specified servo amp is out of tolerance (<80>132.5 VAC <±13.5> 16.5 VDC).
Error occurs when switching the control power ON =>Servo amp, primary power voltage, control transformer
and power circuit.

During operation => Primary power voltage, control transformer and power circuit.
___________________________________________________________________________________

ERROR CODE -1406: Motor speed of jt x exceeds the limit.

Motor speed over limit in JT x
Motor speed of jt x is out of limit

The servo amp detected an excessive motor speed of 1.2 times the rated speed.

Occurs at start of operation => Servo amp, 9ZG (9TH) boards, Internal harness,
separation harness, servo motor (including encoder).
During operation => Internal harness, mechanical unit, teach problem (abrupt change
in posture), load conditions, amp power unit, transformer, primary
power, servo amp, 9ZG/9TK boards and separation harness.
Others => Servo amp.
___________________________________________________________________________________

ERROR CODE -1407: Amp power unit error.

This error is detected due to one of the following conditions: Temperature of the regenerative
resistor exceeds 130°C (266°F), power unit fuse is open, excess voltage in the P-N circuit
(>395 V) or 350 VDC for more than 6 seconds, or loss of the primary power phases R-T.

Check the following:

=> Breaker in the power unit and RST terminals of the power unit.
=> Regenerative/Dynamic break resistors.
=> Primary power (voltage drop, open-phase), transformer, power circuit or
main circuit PN wiring.
=> Excessive payload.
___________________________________________________________________________________

ERROR CODE -1408: Amp fuse blown in jt x.

JT x amp. has blown fused.
AMP fuse of jt x is open.

Servo amp fuse has blown (EX 30/40 only).

=> Refer to servo amp (Error Code -1401 : Amp overcurrent jt x)

___________________________________________________________________________________

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ERROR CODES

ERROR CONDITIONS

ERROR CODE -1409: Amp A/D converter abnormal jt x.

Alarm in amp. A/D converter of JT x
AMP A/D converter of jt x abnormal

The A/D (analog to digital) converter located in the servo amp has failed or is operating abnormally
(EX 30/40 only).

=> Replace servo amp.

___________________________________________________________________________________

ERROR CODE -1410: The 100 VAC power source for servo power blocks A and B is low.

(Only for AD controller).

This error indicates that the power source for the base drivers is under 25% of 100 VAC.

Check the following:

At the time of ‘switching the control power ON’ => Power block, primary power voltage,
control transformer and power circuit.
During operation => Primary power voltage, control
transformer and power circuit
Others => 1AE/1GE board.

For additional information on error code -1410, see troubleshooting flow chart in unit 10.
___________________________________________________________________________________

ERROR CODE -1411: Servo A error. Code is xxxx.

(Only for AD controller).

This error indicates that the unknown error Code is reported by the servo A
software. The code listed with the error message is sent by the servo software.

This error occurs when AS detects servo CPU error or AS does not have any
proper message about error codes from servo CPU.

xxxx = 1 Servo CPU does not work at power-up process.

xxxx = 7 Servo CPU has failed in the program download process from FLASH to SRAM.
xxxx = 90 Servo CPU has failed in the servo program initializing process.
xxxx = 91 Servo CPU has failed in the servo main program start process.
xxxx = FF98 Illegal interrupt occurs at the servo CPU. Please refer to error -1555.

Note: If servo software version SOO–SOC is installed, Code (FF98) is displayed instead
of Error Code -1555 (Encoder data conversion error). Software newer than version
SOC will display the proper error message (-1555).

=> Treat according to error Code from servo software.

=> Replace 1AE/1GE board.
=> Replace 9ZA board or mother board.
=> Replace encoder.

For additional information on error code -1411, see troubleshooting flow chart in unit 10.
___________________________________________________________________________________

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ERROR CODES

ERROR CONDITIONS

ERROR CODE -1412: Servo B error. Code is xxxx.

(Only for AD controller).

This error indicates that the unknown error Code is reported by the servo B
software. The code listed with the error message is sent by the servo software.

xxxx = 1 Servo CPU does not work at power-up process.

xxxx = 7 Servo CPU has failed in the program download process from FLASH to SRAM.
xxxx = 90 Servo CPU has failed in the servo program initializing process.
xxxx = 91 Servo CPU has failed in the servo main program start process.
xxxx = FF98 Illegal interrupt occurs at the servo CPU.

Note: If servo software version SOO–SOC is installed, Code (FF98) is displayed instead
of Error Code -1555 (Encoder data conversion error). Software newer than version
SOC will display the proper error message (-1555).

=> Treat according to error Code from servo software.

=> Replace 1AE/1GE board.
=> Replace 9ZA board or mother board.

For additional information on error code -1412, see troubleshooting flow chart in unit 10.
___________________________________________________________________________________

ERROR CODE -1413: Regenerative resister overheat or disconnect.

(Only for AD controller).

For additional information on error code -1413, see troubleshooting flow chart in unit 10.
___________________________________________________________________________________

ERROR CODE -1414: Not implemented.

___________________________________________________________________________________

ERROR CODE -1415: Power source (±12VDC) for A and B power block is low.

(Only for AD controller).

This error is detected when the ±12VDC supply for the A and B power blocks is out of tolerance by ±2VDC.

Check the following:

At the time of ‘switching the control power ON’ => Power block, AVR.
During operation => Primary power voltage,
control transformer and power circuit.
Other => 1AE/1GE board.

For additional information on error code -1415, see troubleshooting flow chart in unit 10.
___________________________________________________________________________________

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ERROR CODES

ERROR CONDITIONS

ERROR CODE -1416: Overheat condition detected at A and B power blocks.

(Only for AD controller).

This error indicates that the thermostat on the heat sink of the servo amp power block is open.
(90°C, 194°F).

Check the following:

At the time of ‘switching the control power ON’ => Power block.
During operation => Power block, motor, overload, incorrect arm posture,
mechanical problem, 1AE/1GE board.

For additional information on error code -1416, see troubleshooting flow chart in unit 10.
___________________________________________________________________________________

ERROR CODE -1417: Overcurrent in P-N circuit of power blocks A and B.

(Only for AD controller).

This error indicates that the electrical current in the P-N circuit is over 100% of normal
value of power device. When this error occurs, the servo system is immediately shut down.

Check the following:

=> Power block.
=> 1AE/1GE board.

For additional information on error code -1417, see troubleshooting flow chart in unit 10.
___________________________________________________________________________________

ERROR CODE -1418: Amp main circuit voltage of power block A(B) is abnormal.

(Only for AD controller).

This error indicates that the servo amp main circuit voltage is out of range. The normal range is from 50 to 400
VDC. The abnormal voltage range must be continuous for one second to generate an error.

At the time of ‘switching the control power ON’ => Power block.
At the time of ‘switching the motor power ON’ => Power block and primary power voltage.
During operation => Regenerative resistance/wiring, high-voltage wiring
(P,N), amp power unit and power block.
Others => 1AE/1GE board.

For additional information on error code -1418, see troubleshooting flow chart in unit 10.
___________________________________________________________________________________

ERROR CODE -1419: 3-phase power source is abnormal.

(Only for AD controller).

___________________________________________________________________________________

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ERROR CODES

ERROR CONDITIONS

ERROR CODE -1420: Different current sensor I/F board A (B).

(Only for AD controller).

Wrong current sensor interface board installed.

=> Replace current sensor I/F board.

=> Match power block and AS software.
___________________________________________________________________________________

ERROR CODE -1422: Error of servo C, Code is xxxx.

(Only for AD controller).

This error occurs when AS detects servo CPU error or AS does not have any proper message about error
code from servo CPU.

xxxx = 1 Servo CPU does not work at power-up process.

xxxx = 7 Servo CPU has failed in the program download process from FLASH to SRAM.
xxxx = 90 Servo CPU has failed in the servo program initializing process.
xxxx = 91 Servo CPU has failed in the servo main program start process.
xxxx = FF98 Illegal interrupt occurs at the servo CPU.

Note: If servo software version SOO–SOC is installed, Code (FF98) is displayed instead of error
Code -1555 (Encoder data conversion error). Software newer than version SOC will display
the proper error message (-1555).

= > Treat according to error code from servo software.

= > Replace 1AE/1GE board.
= > Replace 9ZA board or mother board.

For additional information on error code -1422, see troubleshooting flow chart in unit 10.
___________________________________________________________________________________

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ERROR CODES

ERROR CONDITIONS

ERROR CODE -1423: Error of servo D, Code is xxxx.

(Only for AD controller).

This error occurs when AS detects servo CPU error or AS does not have any proper message about error
code from servo CPU.

xxxx = 1 Servo CPU does not work at power-up process.

xxxx = 7 Servo CPU has failed in the program download process from FLASH to SRAM.
xxxx = 90 Servo CPU has failed in the servo program initializing process.
xxxx = 91 Servo CPU has failed in the servo main program start process.
xxxx = FF98 Illegal interrupt occurs at the servo CPU.

Note:If servo software version SOO–SOC is installed, Code (FF98) is displayed instead of
error Code -1555 (Encoder data conversion error). Software newer than version SOC
will display the proper error message (-1555).

= > Treat according to error code from servo software.

= > Replace 1AE/1GE board.
= > Replace 9ZA board or mother board.

For additional information on error code -1423, see troubleshooting flow chart in unit 10.
___________________________________________________________________________________

ERROR CODE -1500: Motor overload in jt x

Motor overload in JT x
Jt x of motor overload

This error occurs when a servo amplifier detects a high command signal when the servo is OFF.

During operation (No) => 1AE/1GE for AD controllers board or servo amp.
During operation (Yes) => Interference of robot arm, payload exceeded, operating pattern, mechanical unit,
servo motor (brake), servo amp, machine harness (brake wiring)

For additional information on error code -1500, see troubleshooting flow chart in unit 10.
___________________________________________________________________________________

ERROR CODE -1501: Motor hot.

To prevent the motor from overheating, a thermo-switch in the motor opens when the temperature of the stater
windings reach 130°C (266°F).

During operation (No) => Machine harness (open thermal wiring), separation harness, 9ZP (or 1BP)
or 1AE/1GE board.
During operation (Yes) => Interference of robot arm, load conditions, operating pattern, mechanical failure,
servo motor (brake), servo amp, machine harness (brake wiring) or 1BP board
(brake control).

For additional information on error code -1501, see troubleshooting flow chart in unit 10.
___________________________________________________________________________________

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ERROR CODES

ERROR CONDITIONS

ERROR CODE -1502: Brake signal line failure.

BRAKE signal line is open or shorted, or Power error
BRAKE signal line error, short or Power error

The 1BP board has detected an open brake line circuit or an abnormal brake line voltage. For joint number,
see the indication lamp on 1BP board.

=> Machine harness (brake line) or separation harness (brake line)

=> Harness in the panel, 1BP board or 1AE board.
=> Servo motor (Brake).
=> Transformer, power circuit or primary power (drop in current/voltage).
___________________________________________________________________________________

ERROR CODE -1503: Speed error jt x.

The 1AE/1GE board has detected an overspeed condition in the Teach or Repeat mode.

In TEACH => Error occurs depending on the motion or arm posture when in Base or
Tool mode; reduce the speed.
During operation => Error occurs after error reset and switching motor power ON.
=> Servo amp, 1AE/1GE, 9ZG/9TK, machine or separation harness.
(Refer to Error Code: -1518)
=> Occurs at specific points.
=> Teach (linear or circle interpolation during sudden change in motion).
=> Load condition, mechanical problem, servo amp, power unit or
primary power source.

For additional information on error code -1503, see troubleshooting flow chart in unit 10.
___________________________________________________________________________________

ERROR CODE -1504: Position envelope error in jt x.

Position envelope of jt x error.

During operation, the commanded position and current position are constantly monitored. If the robot is
unable to move to the commanded position within a set time and speed, this error occurs.

=> Interference of robot arm.

=> Servo amp, servo motor.
=> Internal/separation harness (including 9ZG/9TK board).
=> Load conditions, teach (Sudden change in posture or speed) or primary
power (open-phase, etc).
=> Servo power unit, servo motor (brake).
=> (Refer to Error Code -1518: Miscount of encoder data jt x).

For additional information on error code -1504 see troubleshooting flow chart in unit 10.
___________________________________________________________________________________

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ERROR CODES

ERROR CONDITIONS

ERROR CODE -1505: Velocity envelope error in jt x.

Velocity envelope of jt x error.

The robot’s current velocity is unable to keep up with the velocity command signal.

=> Refer to Error Code: -1504 : Position envelope error.

___________________________________________________________________________________

ERROR CODE -1506: Velocity error Jt x.

Unused.
___________________________________________________________________________________

ERROR CODE -1507: Acceleration error jt x.

Unused.
___________________________________________________________________________________

ERROR CODE -1510: Encoder harness broken jt x.

Encoder alarm JT x.
Jt x of encoder harness is cut.

This error is detected when the encoder signal is lost, due to an open encoder signal harness or defective
encoder.

=> Machine/separation harness (encoder signals), trunk connector or

9ZG or 9TK board (including the connectors).
=> Check +12 VDC and 5 VDC at 9TK/9TL or 9ZG board.
=> Servo amp or servo motor (encoder).
=> 9ZB or 1AE board.

For additional information on error code -1510 see troubleshooting flow chart in unit 10.
___________________________________________________________________________________

ERROR CODE -1511: Encoder battery low voltage.

Encoder battery voltage low.

This error occurs when the encoder battery voltage is below critical voltage (2.5 V approx.)
Does not apply to EX 30/40.

=> Replace battery.

=> 9ZG board, servo motor (encoder) or internal harness (battery cable).
=> Internal/separation harness, panel harness or 9ZH board.
=> 1BP, 9ZG or 1AE/1GE board.
=> Internal/separation harness (Shielding).

For additional information on error code -1511 see troubleshooting flow chart in unit 10.
___________________________________________________________________________________

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ERROR CODES

ERROR CONDITIONS

ERROR CODE -1512: Encoder LED broken jt x.

Encoder LED OFF: JT x.
Jt x of encoder LED off.

Error is detected by the servo system when an encoder annunciator signal is low.
Refer to Servo amp CPU error =>Error Code -1400 Amp alarm

=> Harness between amp CN1 and 1AE/1GE board.

=> Harness between 9ZG(9TK) board and encoder.
=> Servo-amp or servo motor (encoder).
=> Machine/separation harness (encoder ABS signal).
=> 1AE/1GE board.

For additional information on error code -1512, see troubleshooting flow chart in unit 10.
___________________________________________________________________________________

ERROR CODE -1513: Encoder rotation data abnormal jt x.

Rotation data error at JT x.
Jt x of data abnormal.

Occurs when there is a difference between the rotation data in the serial encoder data and the calculated
rotation data by incremental technique.

=> Check connections at encoder, 1FG board and separation harness.

=> Check for noise and shield integrity.
=> Check connections, jumpers and switches on 1GE board.
=> Check for continuity in the machine harness and separation harness.
=> Replace the 1FG board.
=> Replace the 1GE board.
=> Replace the encoder.

For additional information on error code -1513, see troubleshooting flow chart in unit 10.
___________________________________________________________________________________

ERROR CODE -1514: Miscount of encoder data in jt x.

Position of JT x is unmatched.
Miscount of jt x encoder data.

The servo amp has detected a miscount of encoder data for the specified joint. (EX 30/40 models only)

=> Servo motor (encoder) or servo amp.

=> Machine/separation harness (encoder signal).
=> Machine/separation harness (shielded wire).
___________________________________________________________________________________

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ERROR CODES

ERROR CONDITIONS

ERROR CODE -1515: Encoder or motor wiring abnormal on jt x.

Circuit alarm on encoder or motor of jt x abnormal.
Encoder or wiring of motor on jt x abnormal.

The servo amp has detected an open circuit . (EX 30/40 models only).

=> Servo motor (encoder) or servo amp.

=> Machine/separation harness (encoder signal).
=> Machine/separation harness (shielded wire).
___________________________________________________________________________________

ERROR CODE -1516: Encoder data abnormal on jt x.

Abnormal encoder data on JT x.
Encoder data of jt x abnormal.

When control power is switched ON, the current encoder value is compared to a reference value at the time
the control power was turned OFF. If the values do not match, this error occurs. Normal occurrence is due to
the following: power failure during operation of the robot, motor replacement, initialization of the 9ZA board.

=> 9ZG/9TK board (Preset switch of battery).

=> Servo motor (encoder), machine/separation harness, 9ZG/9TK or 1AE/1GE board,
servo-amp, panel harness (grounding).
___________________________________________________________________________________

ERROR CODE -1517: Can’t read initial encoder data jt x.

Can’t read initial data from encoder.
Can’t read initial data of jt x encoder.

This error occurs if the initial encoder data cannot be read during power up. Check the following:

=> Motor (encoder), internal/separation harness (shielded wire), panel harness.

=> Machine/separation harness, 9ZG/9TK or 1AE/1GE board.
=> 9ZG(9TK) board, AVR (+12V) or machine/separation harness (encoder power source).

For additional information on error code -1517, see troubleshooting flow chart in unit 10.
___________________________________________________________________________________

ERROR CODE -1518: Miscount of encoder data in jt x.

Miscount of jt x encoder data.

This error occurs when the command value at the time the control power is switched ON is different from the
one before the power was switched OFF.

=> Axes have been moved after switching off control power.
=> Defective encoder.

For additional information on error code -1518, see troubleshooting flow chart in unit 10.
___________________________________________________________________________________

ERROR CODE -1519: Abnormal conveyor encoder data.

(For systems with conveyor encoders only)

___________________________________________________________________________________
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ERROR CODES

ERROR CONDITIONS

ERROR CODE -1520: Conveyer of encoder LED or harness is cut

(Only the unit correspondent to the conveyor encoder)

___________________________________________________________________________________

ERROR CODE -1521: Mismatched ABS and INC encoder of jt x

(Only for AD controller).

This error indicates that the difference between absolute encoder value and incremental value is not within the
correct range.

=> 1AE board.

=> Servo motor and encoder assembly.
=> Machine/separation harness (encoder signal).
=> Machine/separation harness (shield wire).

For additional information on error code -1521, see troubleshooting flow chart in unit 10.
___________________________________________________________________________________

ERROR CODE -1522: Jt BRAKE signal disconnected or shorted.

(Only for AD controller).

This error indicates that break line is disconnected, short circuited or power source of brake is abnormal.

=> Machine/separation harness (brake wire).

=> Internal harness, 1BP board and 1AE/1GE board.
=> Servo motor (brake).
=> Transformer, power circuit and primary power voltage (low).

For additional information on error code -1522, see troubleshooting flow chart in unit 10.
___________________________________________________________________________________

ERROR CODE -1523: Power monitor board (1PB) error. Code is xxxx.

(Only for AD controller).

This message indicates that an error code is reported by the power monitor software.
___________________________________________________________________________________

ERROR CODE -1524: Encoder line error of JT x.

(Only for AD controller).

This error indicates a problem with the incremental encoder value when the Z-phase is detected during power
up.

Check or replace the following:

=> Servo motor (encoder)

=> 1AE/1GE board.
=> Machine/separation harness (include shield wire).
=> Power source of encoder.

For additional information on error code -1524, see troubleshooting flow chart in unit 10.
___________________________________________________________________________________
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ERROR CODES

ERROR CONDITIONS

ERROR CODE -1550 Encoder initialize error jt-x.

Occurs when encoder continuously outputs busy signal during controller reads of encoder data at initial
power-up.

=> In the case of a conveyor encoder, ensure power-up speed is below 300 RPM. Check connections at
encoder, 1FG board, jumpers, and switches on 1GE/1GB board. Replace encoder, replace 1GE/1GB
board, replace 1FG board. Check for continuity in the machine harness and separation harness.

For additional information on error code -1550, see troubleshooting flow chart in unit 10.
___________________________________________________________________________________

ERROR CODE -1553 Encoder response error jt-x.

Occurs when the encoder does not respond to data request signal from the 1GB/1GE board.

=> Check connections at encoder, 1FG board, and separation harness. Check connections, jumpers, and
switches on 1GE/1GB board. Replace encoder, replace 1GE/1GB board. Check for continuity in the
machine harness and separation harness. Replace 1FG board.

For additional information on error code -1553, see troubleshooting flow chart in unit 10.
___________________________________________________________________________________

ERROR CODE -1554 Encoder communication error jt-x.

Occurs when the encoder serial data is not correctly transmitted according to communication protocol.

=> Check connections at encoder, 1FG board, and separation harness. Check connections, jumpers, and
switches on 1GE/1GB board. Replace encoder, replace 1GE/1GB board. Check for continuity in the
machine harness and separation harness. Replace 1FG board.

For additional information on error code -1554, see troubleshooting flow chart in unit 10.
___________________________________________________________________________________

ERROR CODE -1555 Encoder data conversion error jt-x.

Occurs when the M-code data from the encoder has error pattern.

=> Replace encoder, replace 1GE/1GB board. Check connections at encoder, 1FG board, and separation
harness. Check connections, jumpers and switches on 1GE/1GB board. Check for continuity in the
machine harness and separation harness. Replace 1FG board.

For additional information on error code -1555, see troubleshooting flow chart in unit 10.
___________________________________________________________________________________

1-73 September 26, 2002

 Kawasak A/AD CONTROLLERS
ERROR CODES

ERROR CONDITIONS

ERROR CODE -1556 Encoder ABS-track error jt-x.

The absolute data and the incremental data in the encoder are different.

=>Defective encoder
=>Defective 1GB or 1FG boards
=>Open or short-circuited encoder harness

For additional information on error code -1556, see troubleshooting flow chart in unit 10.
___________________________________________________________________________________

ERROR CODE -1557 Encoder INC-pulse error jt-x.

Occurs when the encoder A and B incremental pulses are abnormal. The encoder INPALM bit sent with the
serial data=1.

=>Replace encoder, replace 1GE/1GB board. Check connections at encoder, 1FG board, and separation
harness. Check connections, jumpers, and switches on 1GE/1GB board. Check for continuity in the
machine harness and separation harness. Replace 1FG board.

For additional information on error code -1557, see troubleshooting flow chart in unit 10.
___________________________________________________________________________________

ERROR CODE -1600: Uncoincidence error on jt x.

Uncoincidence of JT x error.

During the execution of a program, all joints must reach total coincidence within a given accuracy and time (5
sec. approx.) . If the difference between the designated value and current value exceeds the established
accuracy, this error occurs.

=> Load condition, teaching points, position of mechanical stopper.

=> Setting of ACCURACY, change of wrist position (at the time of linear or circle interpolation motion).

=> Interference, friction or brake.

=> 1AE/1GE board (Illegal setting or defective dip switch).
___________________________________________________________________________________

ERROR CODE -1601: Limit switch of jt x is ON

This error occurs when the software can specify the axis that has caused the over travel condition. If the joint
number cannot be specified, ERROR CODE 1602 “limit switch signal line is broken” is displayed.

=> Determine the cause of actuating the control limit switch and correct the problem.
=> If the actual joint number does not match the displayed joint number, refer to the Error Code -1602
“Limit switch signal line is broken”

For additional information on error code -1601, see troubleshooting flow chart in unit 10.
___________________________________________________________________________________

1-74 September 26, 2002

 Kawasak A/AD CONTROLLERS
ERROR CODES

ERROR CONDITIONS

ERROR CODE -1602: Limit switch signal line is open.

This error occurs when the software cannot specify the axis that has caused the over travel condition. If the
joint number can be identified, the ERROR CODE 1601 “Limit switch of Jt x is ON” will be displayed.

Check the following:

=> Installing position of the limit switch or limit value set incorrectly.

=> Machine/separation harness (LS signal), limit switch or panel harness.

=> Positional slippage, zeroing data or taught data.
=> 1BP or 1AE/1GE board.

For additional information on error code -1602, see troubleshooting flow chart in unit 10.
___________________________________________________________________________________

ERROR CODE -1800: AC primary power OFF

AC line power off

This error is detected when there is a fluctuation or loss of power to the 9ZA board (5 VDC, 12 VDC, –12
VDC).

=> Primary power (Standard, instantaneous failure, power failure, fluctuation).

=> AVR (defective power supply or incorrect adjustment), power circuit, 1BP or 9ZA board.
=> 1BP, 1AE/1GE or 9ZA board.

For additional information on error code -1800, see troubleshooting flow chart in unit 10.
___________________________________________________________________________________

ERROR CODE -1801: DC 24V power voltage is too low.

For additional information on error code -1801, see troubleshooting flow chart in unit 10.
___________________________________________________________________________________

ERROR CODE -1802: Primary power source is high.

Primary power source voltage level is too high. The main causes of this error include a defect in the power
sequence board (1BP), relay CR2 or a shorted diode bridge.

⇒ Verify the power supply voltage to the controller is within ratings.

⇒ Check 1BX board connector BX-CN5A for proper connection.
⇒ Confirm the supply power is within specifications.
⇒ Confirm CP3 is ON.
⇒ Confirm transformer tap settings are correct.
⇒ Replace 1BP board.
⇒ Confirm relay CR2 is properly seated in it's socket.
⇒ Replace relay CR2.
⇒ Replace 1BP board.
⇒ Replace shorted diode bridge.

For additional information on error code -1802, see troubleshooting flow chart in unit 10.
___________________________________________________________________________________

1-75 September 26, 2002

 Kawasak A/AD CONTROLLERS
ERROR CODES

ERROR CONDITIONS

ERROR CODE -1803: Primary power source is low.

Primary power source voltage level is too low. The main causes of this error include a defect in the power
sequence board (1BP), relay CR2 or shorted diode bridge.

⇒ Verify the power supply voltage to the controller is within ratings.

⇒ Check 1BX board connector BX-CN5A for proper connection.
⇒ Confirm the supply power is within specifications.
⇒ Confirm CP3 is ON.
⇒ Confirm transformer tap settings are correct.
⇒ Replace 1BP board.
⇒ Confirm relay CR2 is properly seated in its socket.
⇒ Replace relay CR2.
⇒ Replace 1BP board.
⇒ Replace shorted diode bridge.

For additional information on error code -1803, see troubleshooting flow chart in unit 10.
___________________________________________________________________________________

ERROR CODE -1804: 5 VDC or ± 12 VDC is abnormal.

5 VDC or +/-12 VDC supplied to the 9ZA board is out of specifications.

Main causes include:
1. Defective DC power supply.
2. Defective 9ZA board.
3. Power supply contacts in the mother board are bad.
4. Poor connections, incorrect jumper settings, and/or incorrect switch settings on the 9ZA board.
5. AVR voltage adjustment out of specifications (adjust AVR voltages to specifications).
6. Defective 9ZG board.
7. Short or open in the power block harnesses, signal harness, and the 1BX board.

⇒ Replace the AVR1.

⇒ Replace the 9ZA board.
⇒ Check for short circuits in the teach pendant, power block harnesses, signal harness and replace as
necessary.

For additional information on error code -1804, see troubleshooting flow chart in unit 10.
___________________________________________________________________________________

ERROR CODE -1900: Unexpected hardware error.

Unused.
___________________________________________________________________________________

ERROR CODE -1901: Unexpected error.

Unused.
___________________________________________________________________________________

1-76 September 26, 2002

 A/AD CONTROLLERS
Kawasak ERROR CODES

TROUBLESHOOTING

2.0 TROUBLESHOOTING .......................................................................................... 2-2

2.1 General Troubleshooting Flow Charts ................................................................... 2-3
2.2 Error Code Troubleshooting Flow Charts ............................................................ 2-15

2-1 March 31, 1997

 A/AD CONTROLLERS
Kawasak ERROR CODES

TROUBLESHOOTING

2.0 TROUBLESHOOTING

This unit is divided into two (2) sections: flow charts for general troubleshooting and flow
charts for error code troubleshooting.

The General Troubleshooting Flow Charts (section 10.1) provide the individual steps
necessary to locate problems that may not generate an error message, such as control
power problems, plasma display unit problems, or motor power problems.

The Error Code Troubleshooting Flow Charts (section 10.2) provide the step-by-step
procedures required to locate the problems associated with error code messages.

2-2 March 31, 1997

 A/AD CONTROLLERS
Kawasak ERROR CODES

TROUBLESHOOTING

2.1 GENERAL TROUBLESHOOTING FLOW CHARTS

For use when primary power is switched ON at the NFB, but the controller will not
power up. (1 of 8)

START

Is relay CR3 No
Is primary No E
Fix it energized?
power OK?

Y es
Y es

Is
No
protector A
CP 1 ON? Are +5, +12,
No Adjust to
& -12 VDC correctly
specifications
adjusted?
Yes

Is
No
protector CP 2 B Yes
ON?

Yes

Is relay CR2 No
G
Is energized?
No
protector CP 3 C
ON?

Yes
Yes

SERVICE CALL

Is LED on
No
AVR (+24 VDC) D
illuminated?
Is problem No
F
solv ed?

Yes
Yes

Is AVR
No Adjust to
output at 24.0 END
24.0 VDC
VDC?

Yes

2-3 March 31, 1997

 A/AD CONTROLLERS
Kawasak ERROR CODES

TROUBLESHOOTING

(2 of 8)
A

Turn CP1
and the
NFB ON

Did CP1 trip No Observe

OFF again? for a while

Yes

Turn OFF
the NFB

Are transformer Yes Set them

taps set wrong? correctly

No

Replace
CP1

Did CP1 trip No

END
OFF again?

Yes

SERVICE CALL

2-4 March 31, 1997

 A/AD CONTROLLERS
Kawasak ERROR CODES

TROUBLESHOOTING

(3 of 8)
B

Did CP2 trip No Observe

OFF again? for a while

Yes

Is relay CR1 No Replace AVR(+24VDC) or

energized? CR1

Yes

Is 115 VAC
Yes
outlet being Do not use outlet
used?

No Does
Yes
problem still
exist?

Check for short-circuit in

100VAC line No

SERVICE CALL
END

2-5 March 31, 1997

 A/AD CONTROLLERS
Kawasak ERROR CODES

TROUBLESHOOTING

(4 of 8)

Turn CP3
and the
NFB ON

Did CP3 trip No Observe

OFF again? for a while

Yes

Switch the
NFB OFF

Replace the
diode bridge

Switch the
NFB ON

Does the
No
problem END
re-occur?

Yes

SERVICE CALL

2-6 March 31, 1997

 A/AD CONTROLLERS
Kawasak ERROR CODES

TROUBLESHOOTING

(5 of 8)
D

Is input Are trans.

No No Set them
voltage at 100 taps set
correctly
VAC? correctly?

Yes
Yes

SERV ICE CALL

Switch the
NFB OFF

Switch the
NFB ON
after 5 min.

Does AVR
No Replace AVR
(+24 VDC) LED
(+24 VDC)
illuminate?

Yes
Does
Switch NFB OFF, & No
problem still END
remove 9ZR board
exist?

Yes
Switch the
NFB ON
after 5 min. SERVICE CALL

Does No
Yes External loading of +24 VDC
problem still
is too large. Reduce loading
exist?

2-7 March 31, 1997

 A/AD CONTROLLERS
Kawasak ERROR CODES

TROUBLESHOOTING

(6 of 8)
E

Are external Are

Yes EPCOM-EPON or Close the
power control Yes
EPCOM-EPOFF applicable
terminals being
opened? circuits
used?

No
No

Is connector
Yes
BX-CN5A Re-connect it
disconnected?

No

Is relay CR2
Yes
disconnected from
its socket?

No

Replace relay CR2

Is there Yes Replace

24VDC at DB1, P20
and N20? DB1

Does Yes
problem still
exist? No

Replace 1BP

No

No Does
END problem still
exist?

Yes

SERVICE CALL

2-8 March 31, 1997

 A/AD CONTROLLERS
Kawasak ERROR CODES

TROUBLESHOOTING

F (7 of 8)

Is connector
No
AVR-CN1 Connect it
firmly connected?

Yes

Is AVR1
firmly inserted No Fully Insert the
into the card board
file?

Yes

Is AVR1
Yes Replace 1BX
shorted at
board
1BX connection?

No

Replace AVR1

Does
No
problem still END
exist?

Yes

SERVICE CALL

2-9 March 31, 1997

 A/AD CONTROLLERS
Kawasak ERROR CODES

TROUBLESHOOTING

G (8 of 8)

Is connec tor Yes Connect it

BX-CN 5A loos e? firmly

No

Check 1BP board

connections, jumpers, and
sw itches

Is relay C R3 Yes
disconnected from its Re-connect it
socket?

No

Measure ac ross
term inal 1 & 0 on
CR3. Does it equal Replace 1B P board
24V DC ?

Replace relay C R3

Does No
problem still END
exist?

Yes

SER VICE C ALL

2-10 March 31, 1997

 A/AD CONTROLLERS
Kawasak ERROR CODES

TROUBLESHOOTING

For use when the plasma display unit does not function properly. (1 of 1)
START

Check 9ZA board

connections, jumpers, &
switches

Check all connections of

SOP harness

Check PDU AVR Fuse

Is PDU AVR No Adjust PDU AVR to

properly adjusted? proper specs.

Yes
Replace
9ZA board

Does
problem still No
exist?

Yes

Replace
PDU

Does
No
problem still END
exist?

Yes

SERVICE CALL

2-11 March 31, 1997

 A/AD CONTROLLERS
Kawasak ERROR CODES

TROUBLESHOOTING

For use when motor power can not be turned ON. (1 of 2)

START

Is an error Yes Refer to error

displayed? code unit

No

Press the
MOTOR POWER
button

Is LE D Is
No No
(MPWR) on 1 AE/1GE motor power Replace switch
boa rd illuminated? switch OK?

Yes
Yes

Is
Yes Isolate break in circuit
Is MC1 (or MC2) No E-stop circuit
A and restore continuity
energized? open?

No

Yes
Is
Yes Isolate break in circuit
HOLD circuit
and restore continuity
open?

No
No
Is MS energized? B
Are
connectors
No
BX-CN5A and Connect firmly
Yes BX-CN5B seated
properly?

Does No Yes
problem still END
exist?
Is relay
CR4 energized in No
Yes REP EAT A
No
mode?

Does
Yes
SERVICE CALL problem still Yes
exist?

2-12 March 31, 1997

 A/AD CONTROLLERS
Kawasak ERROR CODES

TROUBLESHOOTING

(2 of 2)

Is relay
Yes Replace
coil receiving
relay
+24 VDC?

No

Is Is AVR
No No Is CP2 Yes Locate break in
AVR suppling input at 100
ON? 100 VAC line.
+24 VDC? VAC?

No
Yes Yes
Locate break in
+24 VDC line. Replace
Reset CP2
Check AVR
connector
BX-CN5A

Is relay
Yes Replace
B coil receiving
relay
100 VAC?

No

Is relay No
A
CR2 energized?

Yes

Is CP2 Yes Locate break in

ON? 100 VAC line.

No

Reset CP2

2-13 March 31, 1997

 A/AD CONTROLLERS
Kawasak ERROR CODES

TROUBLESHOOTING

For use when the robot does not move. (1 of 1)

START

Is an error Yes Refer to error

displayed? code unit

No

Are
Teach/Repeat No Set switches
& Hold/Run Switches correctly
set correctly?

Yes

Is robot in No Reset External

External Hold? Hold

Yes

If in
Repeat mode, is Yes Override wait condition
program waiting if applicable
for input?

No

Does
No
problem still END
exist

Yes

SERVICE CALL

2-14 March 31, 1997

 A/AD CONTROLLERS
Kawasak ERROR CODES

TROUBLESHOOTING

2.2 ERROR CODE TROUBLESHOOTING FLOW CHARTS

Error 600 - Motor Power OFF

For use when the E-STOP button was pressed or there is a break in the E-STOP circuit.
(1 of 3)
Error 600

Is
(EMG) LED No
A
on 1BP board
illuminated?

Yes

Is E-STOP
Yes
button on S.O.P Release switch
pressed?

No

Is
E-STOP button on Yes
Release switch
teach pendant
pressed?

No

Is
Yes Connect Teach
teach pendant
Pendant
disconnected?

No

Is
No
External E-STOP B
being used?

Yes

Check continuity of entire

E-STOP circuit and locate
break point

2-15 March 31, 1997

 A/AD CONTROLLERS
Kawasak ERROR CODES

TROUBLESHOOTING

(2 of 3)
A

Check connections,
jumpers, and switches
on 1BP board

Check connections,
jumpers, and switches
on 1AE/1GE board

Does
No
problem still END
exist?

Yes

Replace 1BP board

Does No
problem still END
exist?

Yes

Replace 1AE board

Does No
problem still END
exist?

Yes

SERVICE CALL

2-16 March 31, 1997

 A/AD CONTROLLERS
Kawasak ERROR CODES

TROUBLESHOOTING

(3 of 3)

B Replace 1AE
board

Check connections,
jumpers, and switches
on 9ZR board Does
No
problem still END
exist?

Check connections, Yes

jumpers, and switches
on 1BP board
Replace 9ZR
board

Check all connections on

1BX board
Does No
problem still END
exist?
Check connections on
S.O.P and 1CL board Yes

Replace Teach
Check Teach Pendant
Pendant
harness for breaks and
proper connection

Does
Does No
No problem still END
problem still END exist?
exist?
Yes
Yes
Replace 1CL &
1BF boards
Replace 1BP
board

Does
problem still No END
Does
No exist?
problem still END
exist?
Yes
Yes
SERVICE CALL

2-17 March 31, 1997

 A/AD CONTROLLERS
Kawasak ERROR CODES

TROUBLESHOOTING

Error 1011 - Interpolation calculation time over

If the 9ZA board interpolation process has not terminated within a specified period of
time, this error will be produced. (1 of 1)

Error 1011

Check connections,
jumpers, and switches
on 9ZA board

Check connections,
jumpers, and switches
on 1AE/1GE board

Does
No
problem still
exist?

Yes

Replace
9ZA board

Does
No
problem still END
exist?

Yes

Replace
1AE/1GE
board

Does
No
problem still
exist?

Yes

SERVICE CALL

2-18 March 31, 1997

 A/AD CONTROLLERS
Kawasak ERROR CODES

TROUBLESHOOTING

Error 1020 - EPROM Data trouble

This error is produced if any error is found in the EPROM data stored on the 9ZA board.
(1 of 1)

Error 1020

Cycle controller
power

Does problem No
re-occur?

Yes

Make sure all PCB's are fully

inserted into card file

Does problem No
END
still exist?

Yes

Replace
9ZA board

Does problem No
still exist?

Yes

SERVICE CALL

2-19 March 31, 1997

 A/AD CONTROLLERS
Kawasak ERROR CODES

TROUBLESHOOTING

Error 1021 - RAM memory trouble address **** (1 of 1)

This error occurs if a failure of RAM memory is detected.

Error 1021

Cycle controller
power

Does problem No
re-occur?

Yes

Make sure all PCB's are fully

inserted into card file

Does problem No
END
still exist?

Yes

Replace
9ZA board

Does problem No
still exist?

Yes

SERVICE CALL

2-20 March 31, 1997

 A/AD CONTROLLERS
Kawasak ERROR CODES

TROUBLESHOOTING

Error 1022 - RAM battery low voltage

This error occurs when the back-up batteries on the 9ZA board drop to a critical voltage
level.
(1 of 1)

Error 1022

Make sure that the 9ZA

board is correctly placed in
the card file

Yes Is 9ZA battery

voltage above
3.0 VDC?

No

Replace batteries

Does problem No
END
still exist?

Yes

Replace
9ZA board

2-21 March 31, 1997

 A/AD CONTROLLERS
Kawasak ERROR CODES

TROUBLESHOOTING

Error 1100 - CPU error

The error occur when the CPU on the 9ZA board stops functioning. (1 of 1)

Error 1100

Was the
This error is normal,
white CPU abort Yes
restart CPU by pressing
switch on the 9ZA board
the red CPU rest button
pressed?

No

Make sure that all PCB's

are fully inserted into the
card file

Initialize the
controller

Does No
the problem still
exist?

Yes

Replace the
9ZA board

Does No
the problem still END
exist?

Yes

SERVICE CALL

2-22 March 31, 1997

 A/AD CONTROLLERS
Kawasak ERROR CODES

TROUBLESHOOTING

Error 1102 - Bus Error

Is error occurs when the 9ZA CPU stops processing information. (1 of 1)

Error 1102

Make sure that all PCB's

are fully inserted into the
card file

Initialize the
controller

Does No
the problem still
exist?

Yes

Replace the
9ZA board

Does No
the problem still END
exist?

Yes

SERVICE CALL

2-23 March 31, 1997

 A/AD CONTROLLERS
Kawasak ERROR CODES

TROUBLESHOOTING

Error 1309 - Watch dog error of CPU-A(B) on digital servo board

This error occurs when the 1AE/1GE board detects a watch dog error. (1 of 1)

Error 1309

Check all connections,

jumpers, and switches on
the 1AE/1GE board

Check all connections,

jumpers, and switches on
the 9ZA board

Does No
problem still
exist?

Yes
Replace the
1AE/1GE
board

Does
problem still No END
exist?

Yes

Replace the
9ZA board

Does No
problem still
exist?

Yes

SERVICE CALL

2-24 March 31, 1997

 A/AD CONTROLLERS
Kawasak ERROR CODES

TROUBLESHOOTING

Error 1312 - Digital servo board CPU-A(B) calculation time over

ThIs error occurs when the 1AE/1GE board processing is not terminated within the specified
period of time. (1 of 1)

Error 1312

Check all connections,

jumpers, and switches on
the 1AE/1GE board

Check all connections,

jumpers, and switches on
the 9ZA board

Does No
problem still
exist?

Yes

Replace the
1AE/1GE board

Does
problem still No END
exist?

Yes

Replace the
9ZA board

Does No
problem still
exist?

Yes

SERVICE CALL

2-25 March 31, 1997

 Kawasak A/AD CONTROLLERS
ERROR CODES

TROUBLESHOOTING

Error 1401 - Amp overcurrent jt x

This error occurs when current flow through the power blocks exceeds the maximun limit.
(1 of 3)
Error 1401

Does
No
the problem END
still exist?
Cycle controller power

Yes

Yes Is an error
Replace the appropriate
produced?
power block and servo motor

No

Cycle start program

Does No
the problem END
still exist?
Was
an error produced No
A
immediately when motor Yes
power was ON?
SERVICE CALL

Yes

Check all connections,

jumpers, and switches on
the 1AE/1GE board

Check all connections on

the power blocks

Does
No
the problem END
still exist?

Yes

Replace the
1AE/1GE board

2-26 September 26, 2002

Kawasak A/AD CONTROLLERS
ERROR CODES

TROUBLESHOOTING

(2 of 3)
A

Check for short-circuit

between U, V, & W at
power block

Check for short circuit in

machine harness inside
the robot arm

Check connections and

continuity of motor
harnesses

Can
resistance be No
measured between Replace servo motor
each phase of the
servo motor?

Yes
Check connections, Does
Yes No
jumpers, and switches on the problem END
the 1AE /1GE board still exist?

Does No
the problem END
still exist?

Yes

2-27 September 26, 2002

Kawasak A/AD CONTROLLERS
ERROR CODES

TROUBLESHOOTING

(3 of 3)

Check all connections on

the power blocks

Does
No
the problem END
still exist?

Yes

Replace 1AE/1GE board

Does No
the problem END
still exist?

Yes

Replace the appropriate power block

and servo motor

Does
No
the problem END
still exist?

Yes

SERVICE CALL

2-28 September 26, 2002

 A/AD CONTROLLERS
Kawasak ERROR CODES

TROUBLESHOOTING

Error 1410 - Power source (100 VAC) of power block A(B) is low (1 of 1)
This error occurs when 100 VAC is not fed to the power blocks.

Error 1410

Does
connector CN7 on the No Locate break in
power blocks have 100VAC line
100VAC?

Yes

Check connections,
jumpers, and switches on
the 1AE/1GE board

Check connection and

continuity of harness from
1AE/1GE board to power block

Does No
problem still END
exist?

Yes

Replace
power block

Does
No
problem still END
exist?

Yes

Replace the
1AE/1GE board

Does
problem still No END
exist?

Yes

SERVICE CALL

2-29 March 31, 1997

 Kawasak A/AD CONTROLLERS
ERROR CODES

TROUBLESHOOTING

Error 1411- Servo A error. Code is xxxx.

This error indicates that the unknown error code is reported by servo A software.

Error 1411

Yes
Code is FF98? 1

No

No
Code is 1,7,90, or 91? Service Call

Yes
2
Reinstall the
servo software

Does No
problem still END
exist?

Yes

Replace 1GE
board

Does No
problem still END
exist?

Yes

Replace 9ZA
board

2-30 March 18, 1999

 A/AD CONTROLLERS
Kawasak ERROR CODES

TROUBLESHOOTING

Does No
problem still END
exist?

Yes

Replace 9ZA board

Does No
problem still END
exist?

Yes

Replace the mother

board (1BX)

Does No
problem still END
exist?

Yes

Service call

2-31 March 18, 1999

Kawasak A/AD CONTROLLERS
ERROR CODES

TROUBLESHOOTING

1 C ode is F F98

D isc o n n ec t 1 G E -C N 3
(E n c o d e r s i g n a l l in e )

Did error No
m e s sa ge ch a ng e 2
to 1 5 5 3 ?

Yes

Reconnect 1G E-C N3
bo a rd
T he c a u se o f th is e rro r
is e n c o d e r t r o u b le
S e a rch a b n orm al enco d e r
b y d is c o n n e c t in g e n c o d e r
co n n e cto r. If abn o rm a l
e n c o d e r e x is t s , e r r o r
m e s s a g e c h a n g e s to
15 53 w h e n th e e n co der
c o n n e c t o r is
discon n e cted .

Did y ou
No
fi n d a b n o r m a l S e r v i c e c a ll
en c o d e r?

Yes

R e p la c e th e e n c o d e r

Does
No
p r o b l e m s t il l END
exist?

Yes

S e r v i c e c a ll

2-32 March 18, 1999

 A/AD CONTROLLERS
Kawasak ERROR CODES

TROUBLESHOOTING

Error 1412 - Servo B error. Code is xxxx.

This error indicates that the unknown error code is reported by servo B software.

Error 1412

Yes
Code is F F98? 1

No

No
Code is 1,7,90, or 91? Servic e Call

Yes
2
Reinstall the
servo software

Does No
problem still END
exist?

Yes

Replace 1GE
board

Does No
problem still END
ex ist?

Yes

Replace 9Z A
board

2-33 March 18, 1999

Kawasak A/AD CONTROLLERS
ERROR CODES

TROUBLESHOOTING

Does No
problem still END
exist?

Yes

Replace 9ZA board

Does No
problem still END
exist?

Yes

Replace the mother

board (1BX)

Does No
problem still END
exist?

Yes

Service call

2-34 March 18, 1999

 A/AD CONTROLLERS
Kawasak ERROR CODES

TROUBLESHOOTING

1 Code is F F98

D i sc o n n ec t 1 G E -C N 3
(E n co d e r si g n a l l in e )

D i d e rr o r No
m e s s a ge c h a ng e 2
to 1 5 5 3 ?

Yes

R e c on n e c t 1 G E - C N 3
bo a rd
T he c a u se o f th i s e r ro r
is e n c o d e r t ro u b le
S e a r ch a b n orm a l e nc o d e r
by d is c on n e c tin g e nc o d e r
co n n e cto r . I f a bn o r m a l
en c o d e r e x is t s , e rr o r
m e s s a ge c h a ng e s to
15 5 3 w h e n th e e n c o de r
co n n e cto r is
dis co n n e cte d .

Did you
No
fin d a b n o r m a l S e rvi c e c a ll
en c o d e r?

Yes

R e p la c e th e e n co d e r

Does
No
pr o b l e m s til l END
ex i st?

Yes

S e r vi c e c a ll

2-35 March 18, 1999

 A/AD CONTROLLERS
Kawasak ERROR CODES

TROUBLESHOOTING

Error 1413 - Regenerative resistor overheat (1 of 3)

This error occurs when the regenerative resistors overheat.

Erro r 1413

Is Is
(R TH ) LE D on No con nector No Connect it
1B P boa rd BX-C N5B s eated firm ly
illuminated? correctly?

Yes Yes

Check c onnectio ns,

Are jum pers, and sw itches
regenerativ e No on 1BP board
resistance A
cooling fans Yes
wo rking?

Does No
Yes problem still END
ex ist?

Yes

Does No
problem still END
ex ist?

Yes

Is there
continuity
acros s pins B
of connec tor
J3?

Yes

Is
connector No Connect it
BX-C N5 B
firm ly
seated
correctly?

Yes

2-36 March 31, 1997

 A/AD CONTROLLERS
Kawasak ERROR CODES

TROUBLESHOOTING

(2 of 3)
A

Are fans Yes Replace

receiving
fans
100 VAC?

No

Is
No Replace
connector J10
connector
conducting?

Yes
B

Locate break in
100 VAC line
Are the
Replace
regenerative No
regenerative
resistors
resistors
hot?

Yes

Is
load within No Reduce
allowable load
range?

Yes

Modify
program

Does
No
problem still END
exist?

Yes

Replace power
block B

2-37 March 31, 1997

 A/AD CONTROLLERS
Kawasak ERROR CODES

TROUBLESHOOTING

(3 of 3)
C

Check all connections, jumpers,

and switches on the 1BP board

Does
No
problem still END
exist?

Yes

Replace 1BP
board

Does No
problem still END
exist?

Yes

SERVICE CALL

2-38 March 31, 1997

 A/AD CONTROLLERS
Kawasak ERROR CODES

TROUBLESHOOTING

Error 1415 - Power source (+/- 12 VDC) of power block A(B) is low (1 of 1)
This error occurs when DC power to the power block has dropped.

Error 1415

Is
No
AVR1 output voltage Re-adjust
correct?

Yes

Check connections on
power blocks
Replace the
1AE/1GE board
Check connections, jumpers, and
switches on the 1AE/1GE board

Does No
problem still END
Does No exist?
problem still END
exist?
Yes
Yes
Replace 1AE/1GE board-power
Check connections and continuity block harness
of the harness from the 1AE/1GE
board to the power block

Does
No
problem still END
Does No exist?
problem still END
exist?

Yes
Yes

Replace the SERVICE CALL

appropriate
power block

Does
problem still No END
exist?

Yes

2-39 March 31, 1997

 A/AD CONTROLLERS
Kawasak ERROR CODES

TROUBLESHOOTING

Error 1416 - Heat sink of power block A(B) overheat (1 of 4)

This error occurs when power block heat sink is excessively overheated.

Error 1416

Push error reset

button

Does Yes
Re-run
error reset?

No Does
No
problem still END
exist?

Yes

Turn Motor Power OFF

Make sure the voltage

across P & N is 0 VDC

Is
power block Yes
A
heat sink
hot?

No
Check connections,
jumpers, and switches
on the 1AE/1GE board

Check all power block

connections

Check 1AE/1GE-power block

harness for continuity

Does
No
problem still END
exist?

Yes

2-40 March 31, 1997

 A/AD CONTROLLERS
Kawasak ERROR CODES

TROUBLESHOOTING

(2 of 4)
B

Replace 1AE/1GE
board

Does
No
problem still END
exist?

Yes

Replace power block

Does
No
problem still END
exist?

Yes

Replace 1AE/1GE-power
block harness

Does
problem still No END
exist?

Yes

SERVICE CALL

2-41 March 31, 1997

 A/AD CONTROLLERS
Kawasak ERROR CODES

TROUBLESHOOTING

(3 of 4)
A

Is
power block fan No C
working?

Yes

Is payload No
within allowable Reduce load
range?

Yes

Is any abnormal
Yes
noise generated from
the robot?

No

Check motor connections

and coil resistance

Does
No
problem still END
exist?

Yes

Replace power block

Does
No
problem still END
exist?

Yes

SERVICE CALL

2-42 March 31, 1997

 A/AD CONTROLLERS
Kawasak ERROR CODES

TROUBLESHOOTING

(4 of 4)
C

Are fans Yes

receiving 100 Replace fans
VAC?

No

Is connector J10 No
Connect firmly
firmly connected?

Y es

Is there a
Yes
break in the 100 Replace wires
VAC line?

No

SERVICE CALL

2-43 March 31, 1997

 A/AD CONTROLLERS
Kawasak ERROR CODES

TROUBLESHOOTING

Error 1417 - P-N of power block A or B overcurrent (1 of 1)

This error occurs when a short-circuit is detected in the power block section.

Error 1417

Check connections,
jumpers, and switches
on the 1AE/1GE board

Check connections
and continuity of
1AE/1GE-power block
harness

Check all power block

connections

Does
No
problem still END
exist?

Yes

Replace 1AE/1GE board

Does
No END
problem still
exist?

Yes

Replace power block

Does
problem still No
END
exist?

Yes

SERVICE CALL

2-44 March 31, 1997

 A/AD CONTROLLERS
Kawasak ERROR CODES

TROUBLESHOOTING

Error 1418 - Main circuit voltage of power block A(B) is abnormal (1 of 2)

This error occurs when the P-N voltage of the power block is abnormal.

Error 1418

Press error reset button

Did
error occur as
Yes
soon as motor power
was turned
ON?
Is
Correct
No primary voltage No
primary
within allowable
voltage
range?
Is
Fix No
power block Yes
wiring
wiring OK?

Yes Is
appropriate No
B
MC contactor being
Replace 1DD board energized?

Yes
Does Check power block
No
problem still END connections
exist?

Yes

Does
SERVICE CALL No
problem still END
exist?

Yes

Replace power block

Does
problem still No
END
exist?

Yes

SERVICE CALL

2-45 March 31, 1997

 A/AD CONTROLLERS
Kawasak ERROR CODES

TROUBLESHOOTING

(2 of 2)
B

Is
contactor coil Y es Replace magnetic
receiving contactor
+24 VDC?

No

Is AVR
Y es Locate break in
producing
+24 VDC line
+24 VDC?

No

Is
No
AVR input at Replace AVR
100 VAC?

Y es

Locate break in
100VAC line

2-46 March 31, 1997

 A/AD CONTROLLERS
Kawasak ERROR CODES

TROUBLESHOOTING

Error 1422 - Error of servo C, code is xxxx.

This error occurs when AS detects servo CPU error or AS does not have any proper mes-
sage about error code from servo CPU.

Error 1422

Yes
Code is FF98? 1

No

No
Code is 1,7,90, or 91? Service Call

Yes
2
Reinstall the
servo software

Does No
problem still END
exist?

Yes

Replace 1GE
board

Does No
problem still END
exist?

Yes

Replace 9ZA
board

2-47 March 18, 1999

Kawasak A/AD CONTROLLERS
ERROR CODES

TROUBLESHOOTING

Does No
problem still END
exist?

Yes

Replace 9ZA board

Does No
problem still END
exist?

Yes

Replace the mother

board (1BX)

Does No
problem still END
exist?

Yes

Service call

2-48 March 18, 1999

 A/AD CONTROLLERS
Kawasak ERROR CODES

TROUBLESHOOTING

1 Code is F F 98

Disco n n ect 1 G E -C N 3
(E n c o d e r s i g n a l l in e )

D id error No
m e ssa ge ch ang e 2
to 1 5 5 3 ?

Yes

Reconnect 1G E-C N 3
board
T he c a use o f th is e rror
is e n c o d e r t r o u b le
S e a rch a b norm a l e nc od e r
b y d is c o n n e c t in g e n c o d e r
co n ne cto r. If a bn o rm a l
e n c o d e r e x is t s , e r r o r
m e s s a ge c h a ng e s to
15 5 3 w h en th e en c o der
c o n n e c t o r is
dis co n ne cte d .

D id you
No
fi n d a b n o r m a l S e r v i c e c a ll
enc oder?

Yes

R e p la c e th e e n c o d e r

Does
No
p r o b l e m s t il l END
ex ist?

Yes

S e r v i c e c a ll

2-49 March 18, 1999

 Kawasak A/AD CONTROLLERS
ERROR CODES

TROUBLESHOOTING

Error 1423 - Error of servo D, code is xxxx.

This error occurs when AS detects servo CPU error or AS does not have any proper mes-
sage about error code from servo CPU.

Error 1423

Yes
Code is FF98? 1

No

No
Code is 1,7,90, or 91? Service Call

Yes
2
Reinstall the
servo software

Does No
problem still END
exist?

Yes

Replace 1GE
board

Does No
problem still END
exist?

Yes

Replace 9ZA
board

2-50 March 18, 1999

 A/AD CONTROLLERS
Kawasak ERROR CODES

TROUBLESHOOTING

Does No
problem still END
exist?

Yes

Replace 9ZA board

Does No
problem still END
exist?

Yes

Replace the mother

board (1BX)

Does No
problem still END
exist?

Yes

Service call

2-51 March 18, 1999

Kawasak A/AD CONTROLLERS
ERROR CODES

TROUBLESHOOTING

1 Code is FF98

Disconnect 1GE-CN3
(Encoder signal line)

Did error No
message change 2
to 1553?

Yes

Reconnect 1GE-CN3
board
The cause of this error
is encoder trouble
Search abnormal encoder
by disconnecting encoder
connector. If abnormal
encoder exists, error
message changes to
1553 when the encoder
connector is
disconnected.

Did you
No
find abnormal Service call
encoder?

Yes

Replace the encoder

Does
No
problem still END
exist?

Yes

Service call

2-52 March 18, 1999

 A/AD CONTROLLERS
Kawasak ERROR CODES

TROUBLESHOOTING

Error 1500 - Motor overload jt * (1 of 2)

This error occurs when current in the servo motor has exceeded the specified value.

Error 1500

Is there
Yes
interference with Remove interference
the robot?

No

Check connections and

continuity of inside
machine harness

Does
No
problem still END
exist?

Yes

Check continuity of motor

lines in the separation cables

Does
problem still No END
exist?

Yes

Check connections,
jumpers, and switches on
the 1AE /1GE board

Does
No
problem still END
exist?

Yes

2-53 March 31, 1997

 A/AD CONTROLLERS
Kawasak ERROR CODES

TROUBLESHOOTING

(2 of 2)
A

Check all connections

on the power block Replace servo motor

Does Does
No
problem still END No
problem still END
exist? exist?

Yes Yes

Check connections & continuity

of 1AE/1GE-power block harness SERVICE CALL

Does No
problem still END
exist?

Yes

Replace 1AE/1GE board

Does
problem still No END
exist?

Yes

Replace power block

Does
No END
problem still
exist?

Yes

2-54 March 31, 1997

 A/AD CONTROLLERS
Kawasak ERROR CODES

TROUBLESHOOTING

Error 1501 - Motor hot

This error occurs when the motor is overheated or the thermal line has been disconnected.
(1 of 3)
Error 1501

Is(MTH)
No
LED on 1BP board
illuminated?

Yes

Is servo
motor hotter than No A
other motors?

Yes

Is motor type No
Replace servo motor
correct?

Yes

Does
an overload Yes
Refer to Overload error
error occur
first?

No

Replace servo motor

Does No
problem still END
exist?

Yes

SERVICE CALL

2-55 March 31, 1997

 A/AD CONTROLLERS
Kawasak ERROR CODES

TROUBLESHOOTING

(2 of 3)

Check connections, jumpers, &

switches on the 1BP board

Switch DIP switch SW1 bit

TH1 on the 1BP board ON

Press ERROR RESET

button

Does Yes
B
error reset?

No

Switch DIP switch SW1 bit TH1

on the 1BP board OFF

Check continuity of
separation cables

Does
No
problem still END
exist?

Yes

SERVICE CALL

2-56 March 31, 1997

 A/AD CONTROLLERS
Kawasak ERROR CODES

TROUBLESHOOTING

B (3 of 3)

Check connections, jumpers, and

switches on the 1BP board

Does
No
problem still END
exist?

Yes

Check connections, jumpers, and

switches on the 1AE/1GE board

Does
No
problem still END
exist?

Yes

Replace 1BP board

Does
No
problem still END
exist?

Yes

Replace 1AE/1GE board

Does
No
problem still END
exist?

Yes

SERVICE CALL

2-57 March 31, 1997

 A/AD CONTROLLERS
Kawasak ERROR CODES

TROUBLESHOOTING

Error 1503 - Speed error jt * (1 of 3)

This error occurs when the robot exceeds the maximum specified speed.

Error 1503

Was
Was robot
robot in CHECK Yes Yes
in a linear Reduce speed
MODE when error
move?
occured?

No No

Press ERROR RESET

push-button and re-run

Did error No
END
re-occur?

Yes

Does No
error occur at A
same step?

Yes

Is there
No Replace inside
a sudden change in
machine harness
motion?

Yes Does
problem still No END
Modify program exist?

Yes

SERVICE CALL
END

2-58 March 31, 1997

 A/AD CONTROLLERS
Kawasak ERROR CODES

TROUBLESHOOTING

(2 of 3)
A

Is
robot load within No
Reduce loading
acceptable
range?

Yes

Is
Yes
P-N voltage B
normal?

No

Is power Yes Replace Power block

block B input
B
voltage normal?

No

Are
transformer taps set No Set taps correctly
correctly?

Yes

SERVICE CALL

2-59 March 31, 1997

 A/AD CONTROLLERS
Kawasak ERROR CODES

TROUBLESHOOTING

(3 of 3)
B

Check continuity of inside Replace servo motor

machine harness

Does Does
No No
problem still END problem still END
exist? exist?

Yes
Yes

Replace 1DD board

SERVICE CALL

Does
No
problem still END
exist?

Yes

Replace power block

Does
No
problem still END
exist?

Yes

Replace 1AE /1GE board

Does No
problem still END
exist?

Yes

2-60 March 31, 1997

 A/AD CONTROLLERS
Kawasak ERROR CODES

TROUBLESHOOTING

Error 1504 - Position envelope error jt *

This error occurs when a difference between the command values which move the robot
and the encoder values is detected.
(1 of 2)

Error 1504

Is there Yes
interference with Remove interference
the robot?

No

Press ERROR RESET Does

problem still No END
push-button & re-run
exist?

Yes
Does problem No
A
re-occur? Replace 1AE /1GE board

B Yes

Check continuity of inside Does

problem still No END
machine harness
exist?

Yes
Does
No
problem still END Replace servo motor &
exist? encoder

Yes

Replace 1DD board

Does No
problem still END
exist?
Does
No Yes
problem still END
exist?

Yes SERVICE CALL

Replace power block

2-61 March 31, 1997

 A/AD CONTROLLERS
Kawasak ERROR CODES

TROUBLESHOOTING

(2 of 2)
A

Was error
Yes If the E-STOP push-button is pressed while
produced when
the robot is moving at high speed, an error
E-STOP button was
may be produced. This is normal
pressed?

No

Was Was a
robot in TEACH Yes linear move Yes Reduce speed
mode? performed?

No
No

Is payload
No
within acceptable Reduce payload
range?

Yes

Are motor
brakes working No B
properly?

Yes

SERVICE CALL

2-62 March 31, 1997

 A/AD CONTROLLERS
Kawasak ERROR CODES

TROUBLESHOOTING

Error 1510 - Encoder harness broken jt * (1 of 2)

This error occurs when the encoder signal line is disconnected or broken.

Error 1510

Push ERROR RESET

push-button

Does Yes Observe conditions for

error reset? a while

No

Check connections, jumpers,

and switches on the
1AE/1GE board

Check continuity of separation

cables containing encoder
signal lines

Check connections &

switches on the 9ZG board

Check continuity of inside

machine harness containing
encoder signal lines

Does
No
problem still END
exist?

Yes

2-63 March 31, 1997

 A/AD CONTROLLERS
Kawasak ERROR CODES

TROUBLESHOOTING

(2 of 2)

Replace 1AE/1GE board

Does No
problem still END
exist?

Yes

Replace encoder

Does No
problem still END
exist?

Yes

Replace 9ZG board

Does No
problem still END
exist?

Yes

SERVICE CALL

2-64 March 31, 1997

 A/AD CONTROLLERS
Kawasak ERROR CODES

TROUBLESHOOTING

Error 1511 - Encoder battery low voltage (1 of 2)

This error occurs when the battery for encoder back-up has reached critical voltage.

Error 1511

Press the ER ROR R ESE T

push-button

Does Does Observe

Yes Re-cycle No
the error problem conditions for
pow er
reset? re-occur? a w hile

No
Yes
Measure battery
voltage on 9ZG board
Check connections on
the 9ZG board

Check connections, jumpers, Is battery

Yes
and switches on the voltage greater
1A E/1GE board than 3V?

No
Check continuity of BATA L+ & Replace
BATAL- signal lines battery

Yes Does
problem still
exist?
Does No
problem still END No
exist?

Yes

2-65 March 31, 1997

 A/AD CONTROLLERS
Kawasak ERROR CODES

TROUBLESHOOTING

(2 of 2)
A

Is connector No
BX-CN7 firmly Connect it firmly
connected?

Yes

Replace 1AE/1GE board

Does No
problem still END
exist?

Yes

Replace 9ZG board

Does No
problem still END
exist?

Yes

SERVICE CALL

2-66 March 31, 1997

 A/AD CONTROLLERS
Kawasak ERROR CODES

TROUBLESHOOTING

Error 1512 - Encoder LED is broken in jt * (1 of 2)

This error occurs when the LED inside the encoder is not transmitting.

Error 1512

Press the ERROR RESET

push-button

Does Yes Does

No Observe conditions
the error Re-run problem
for a while
reset? re-occur?

No
Yes

Check connections, jumpers, and

switches on the 1AE/1GE board

Check continuity of
separation harness

Check connections on
the 9ZG board

Does
No
problem still END
exist?

Yes

2-67 March 31, 1997

 A/AD CONTROLLERS
Kawasak ERROR CODES

TROUBLESHOOTING

A (2 of 2)

Is connector No
BX-CN7 firmly Connect it firmly
connected?

Yes

Replace 1AE/1GE board

Does No
problem still END
exist?

Yes

Replace encoder

Does No
problem still END
exist?

Yes

Replace 9ZG board

Does No
problem still END
exist?

Yes

SERVICE CALL

2-68 March 31, 1997

 A/AD CONTROLLERS
Kawasak ERROR CODES

TROUBLESHOOTING

Error 1513 - Encoder rotation data abnormal jtx.

Rotation data error at jtx.

E rro r 1 5 13

D oe s th is
erro r o c cu r ju s t F ollow
Ye s tro ub les ho o tin g
afte r res e tting error
155 3, 155 4, or flow ch art fo r ea ch
15 55 ? error

No

Re plac e en c o de r

Y es

D oe s No
pro blem still END
ex ist?

Y es

Re p la c e 1G E b oa rd

D oe s
No
pro blem still EN D
ex ist?

Y es

Ch e ck c onn ec tion s a t the

en c od er c o nn e cto r

C he ck c onn ec tion s o n the

1F G bo ard

Ch e ck c onn ec tion s in the

sep aratio n harne s s

C he ck c on ne c tio ns , ju m pers , an d
sw itch es o n the 1GE bo ard

2-69 March 18, 1999

Kawasak A/AD CONTROLLERS
ERROR CODES

TROUBLESHOOTING

Does No
problem still END
exist?

Yes

Check inside
machine harness
and separation
harness

Does No
problem still END
exist?

Yes

Replace 1FG board

Does No
problem still END
exist?

Yes

Service call

2-70 March 18, 1999

 A/AD CONTROLLERS
Kawasak ERROR CODES

TROUBLESHOOTING

Error 1517 - Can not read initial encoder data (1 of 2)

This error occurs when the encoder can't read the initial data at power-up.

Error 1517

Cycle controller power

Does
No
problem still END
exist?

Yes
Check connections, jumpers, and
switches on the 1AE/1GE board

Check continuity of ABS &

SYNC signals in the separation
harness

Does No
problem still END
exist?

Yes

Check connections on
the 9ZG board

Check inside machine

harness for breaks

Does No
problem still END
exist?

Yes

2-71 March 31, 1997

 A/AD CONTROLLERS
Kawasak ERROR CODES

TROUBLESHOOTING

A (2 of 2)

Is connector No
BX-CN7 firmly Connect it firmly
connected?

Yes

Replace 1AE/1GE board

Does No
problem still END
exist?

Yes

Replace encoder

Does No
problem still END
exist?

Yes

Replace 9ZG board

Does No
problem still END
exist?

Yes

SERVICE CALL

2-72 March 31, 1997

 A/AD CONTROLLERS
Kawasak ERROR CODES

TROUBLESHOOTING

Error 1518 - Miscount of encoder data jt * (1 of 2)

This error occurs when the encoder detects a data counting error.

Error 1518

Press the ERROR RESET

push-button

Does Yes Does

No Observe conditions
the error Re-run problem
for a while
reset? re-occur?

No
Yes

Check connections, jumpers, and

switches on the 1AE/1GE board

Check continuity of
separation harness

Check connections on
the 9ZG board

Does
No
problem still END
exist?

Yes

2-73 March 31, 1997

 A/AD CONTROLLERS
Kawasak ERROR CODES

TROUBLESHOOTING

A (2 of 2)

Is connector No
BX-CN7 firmly Connect it firmly
connected?

Yes

Replace 1AE/1GE board

Does No
problem still END
exist?

Yes

Replace encoder

Does No
problem still END
exist?

Yes

Replace 9ZG board

Does No
problem still END
exist?

Yes

SERVICE CALL

2-74 March 31, 1997

 A/AD CONTROLLERS
Kawasak ERROR CODES

TROUBLESHOOTING

Error 1521 - Mis-match ABS and INC encoder jt *

This error occurs when the encoder detects a mis-match in the absoulute and incremental
data.
(1 of 2)

Error 1521

Press the ERROR RESET

push-button

Does Yes Does

No Observe conditions
the error Re-run problem
for a while
reset? re-occur?

No
Yes

Check connections, jumpers, and

switches on the 1AE/1GE board

Check continuity of
separation harness

Check connections on
the 9ZG board

Does No
problem still END
exist?

Yes

2-75 March 31, 1997

 A/AD CONTROLLERS
Kawasak ERROR CODES

TROUBLESHOOTING

A (2 of 2)

Is connector No
BX-CN7 firmly Connect it firmly
connected?

Yes

Replace 1AE/1GE board

Does No
problem still END
exist?

Yes

Replace encoder

Does No
problem still END
exist?

Yes

Replace 9ZG board

Does No
problem still END
exist?

Yes

SERVICE CALL

2-76 March 31, 1997

 A/AD CONTROLLERS
Kawasak ERROR CODES

TROUBLESHOOTING

Error 1522 - Jt * brake signal disconnected or short (1 of 2)

This error occurs when a brake line has been disconnected.

Error 1522

Check 1BP board LED's and

determine axis number

Can error be No Short circuit error

reset?

Replace 1BP board

Yes
Check connections, jumpers, and
switches on the 1BP board
Check continuity of inside
machine harness
Check continuity of inside
machine harness
Check continuity of brake signals
in the separation harness
Check continuity of brake signals
in the separation harness

Does No Does
problem still END No problem still
exist? exist?

Yes Yes

Check servo motor Check servo motor

Does No Does
No
problem still END problem still
exist? exist?

Yes Yes

SERVICE CALL
A

2-77 March 31, 1997

 A/AD CONTROLLERS
Kawasak ERROR CODES

TROUBLESHOOTING

(2 of 2)

Is
Is relay CR2 No Yes
relay firmly in Replace relay CR2
energized?
socket?

Yes No

Is connector No Set
BX-CN5A firmly correctly in
connected? socket

Yes

Is
transformer No Replace transformer
output voltage at
26 VAC?

Yes

Replace diode bridge

Does
problem still No END
exist?

Yes

SERVICE CALL

2-78 March 31, 1997

 A/AD CONTROLLERS
Kawasak ERROR CODES

TROUBLESHOOTING

Error 1524 - Encoder line error of jt * (1 of 3)

This error occurs when an encoder signal line has been disconnected or broken.

Error 1524

Press ERROR RESET

push-button

Does No
A
error reset?

Yes

Move the applicable

axis in TEACH mode`

Is an error No Observe conditions for

produced? a while

Yes

Cycle controller power

Is an error No
produced?

Yes

Check connections, jumpers, and

switches on the 1AE/1GE board

Does
No
problem still END
exist?

Yes

2-79 March 31, 1997

 A/AD CONTROLLERS
Kawasak ERROR CODES

TROUBLESHOOTING

(2 of 3)
A

Replace 1AE/1GE board

Does
No
problem still END
exist?

Yes

Check continuity of encoder signals in

the separation harness

Does
problem still No END
exist?

Yes

Check connections of
9ZG board

Does
No
problem still END
exist?

Yes

Check continuity of encoder signals in

the inside machine harness

Does
problem still No END
exist?

Yes

2-80 March 31, 1997

 A/AD CONTROLLERS
Kawasak ERROR CODES

TROUBLESHOOTING

(3 of 3)

Check continuity of inside

machine harness

Replace 1AE/1GE board

Does No
problem still END
exist?

Yes

Replace encoder

Does No
problem still END
exist?

Yes

Replace 9ZG/1FG board

Does No
problem still END
exist?

Yes

SERVICE CA LL

2-81 March 31, 1997

 Kawasak A/AD CONTROLLERS
ERROR CODES

TROUBLESHOOTING

Error 1550 - Encoder initialize error jtx.

Occurs when encoder continuously outputs busy signal during controller reads of encoder
data at initial power-up.
Error 1550

Does the
Reduce conveyor
encoder revolve over
Yes encoder revolution
300 RPM?
speed under 300
(Case of conveyor
RPM at power-up
encoder)

No END
Check connections at the
encoder connector

Check connections on the

1FG board

Check connections in the

separation harness

Check connections, jumpers, and

switches on the 1GE board

Does No
problem still END
exist?

Yes

Replace encoder

Does No
problem still END
exist?

Yes

2-82 March 18, 1999

 A/AD CONTROLLERS
Kawasak ERROR CODES

TROUBLESHOOTING

Replace 1GE board

Does No
problem still END
exist?

Yes

Replace 1FG board

Does No
problem still END
exist?

Yes

Check machine
harness and
separation harness

Does No
problem still END
exist?

Yes

Service call

2-83 March 18, 1999

 Kawasak A/AD CONTROLLERS
ERROR CODES

TROUBLESHOOTING

Error 1553 - Encoder response error jtx.

Occurs when the encoder does not respond to data request signal from the 1GB/1GE
board.

Error 1553

Retry robot
Can you reset Yes program execution
the error? or manual
operation carefully

No

Check connections at the Yes Does the error

encoder connector reoccur?

No
Check connections on the
1FG board
END

Check connections in the

separation harness

Check connections, jumpers, and

switches on the 1GE board

Does No
problem still END
exist?

Yes

Replace encoder

Does No
problem still END
exist?

Yes

2-84 March 18, 1999

 A/AD CONTROLLERS
Kawasak ERROR CODES

TROUBLESHOOTING

Replace 1GE board

Does No
problem still END
exist?

Yes

Check machine
harness and
separation harness

Does No
problem still END
exist?

Yes

Replace 1FG board

Does No
problem still END
exist?

Yes

Service call

2-85 March 18, 1999

 Kawasak A/AD CONTROLLERS
ERROR CODES

TROUBLESHOOTING

Error 1554 - Encoder communication error jtx.

Occurs when the encoder serial data is not correctly transmitted according to communica-
tion protocol.

Error 1554

Retry robot
Can you reset Yes program execution
the error? or manual
operation carefully

No

Check connections at the Yes Does the error

encoder connector reoccur?

No
Check connections on the
1FG board
END

Check connections in the

separation harness

Check connections, jumpers, and

switches on the 1GE board

Does No
problem still END
exist?

Yes

Replace encoder

Does No
problem still END
exist?

Yes

2-86 March 18, 1999

 A/AD CONTROLLERS
Kawasak ERROR CODES

TROUBLESHOOTING

Replace 1GE board

Does No
problem still END
exist?

Yes

Check machine
harness and
separation harness

Does No
problem still END
exist?

Yes

Replace 1FG board

Does No
problem still END
exist?

Yes

Service call

2-87 March 18, 1999

 Kawasak A/AD CONTROLLERS
ERROR CODES

TROUBLESHOOTING

Error 1555 - Encoder data conversion error jtx.

Occurs when the M-code data from the encoder has error pattern.

Error 1555

Retry robot
Can you reset Yes program execution
the error? or manual
operation carefully

No

Replace encoder Yes Does the error

reoccur?
Yes
No
Does No
problem still END
exist?

Yes

Replace 1G E board

Does
No
problem still END
exist?

Yes

Check connections at the

encoder connector

Check connections on the

1FG board

Check connections in the

separation harness

Check connections, jumpers, and

sw itches on the 1GE board

A
2-88 March 18, 1999
 A/AD CONTROLLERS
Kawasak ERROR CODES

TROUBLESHOOTING

Does No
problem still END
exist?

Yes

Check inside
machine harness
and separation
harness

Does No
problem still END
exist?

Yes

Replace 1FG board

Does No
problem still END
exist?

Yes

Service call

2-89 March 18, 1999

 Kawasak A/AD CONTROLLERS
ERROR CODES

TROUBLESHOOTING

Error 1556 - Error ABS-track error jtx.

The absolute data and the incremental data in the encoder are different.

Error 1556

Replace encoder

Does No
problem still END
exist?

Yes

Replace 1G E board

Does
No
problem still END
ex ist?

Yes
Check connections at the
enc oder connector

Check connections on the

1FG board

Check connections in the

separation harness

Check connections , jumpers, and

sw itches on the 1GE board

Does
No
problem s till END
exist?

Yes

2-90 March 18, 1999

 A/AD CONTROLLERS
Kawasak ERROR CODES

TROUBLESHOOTING

Check inside
machine harness
and separation
harness

Does No
problem still END
exist?

Yes

Replace 1FG board

Does No
problem still END
exist?

Yes

Service call

2-91 March 18, 1999

 Kawasak A/AD CONTROLLERS
ERROR CODES

TROUBLESHOOTING

Error 1557 - Encoder INC-pulse error jtx.

Occurs when the encoder A and B incremental pulses are abnormal. The encoder INPALM
bit sent with the serial data = 1.

E rror 1 55 7

R e p la c e en c o d e r

Do e s No
pro b le m s t ill END
ex ist?

Yes

Re p la c e 1G E b o a rd

Does
No
pro b l e m s till END
ex i st?

Yes
Ch e ck c on n e c tio n s a t th e
en c o d e r c o n n e cto r

Ch e ck c on n e c t io n s o n t h e
1F G b o a rd

C h e ck c on n e c t io n s in th e
se p a r a tio n ha rn e s s

C h e ck c on n e c tio n s , ju m pe rs , a n d
sw itc h es o n th e 1 G E b o a rd

Does
No
pro b le m s t ill END
ex ist ?

Yes

2-92 March 18, 1999

 A/AD CONTROLLERS
Kawasak ERROR CODES

TROUBLESHOOTING

Does No
problem still END
exist?

Yes

Check inside
machine harness
and separation
harness

Does No
problem still END
exist?

Yes

Replace 1FG board

Does No
problem still END
exist?

Yes

Service call

2-93 March 18, 1999

 A/AD CONTROLLERS
Kawasak ERROR CODES

TROUBLESHOOTING

Error 1601 - Limit switch of jt * is ON

This error occurs when the robot is beyond the software limit and the limit switch is ON.
(1 of 3)

Error 1601

Is (LS)
No Is limit
LED on the 1BP No
switch installed Fix it
board
correctly?
illuminated?

Yes Yes

Re-run
Press & hold LS
OVER-RIDE switch on
the accessory panel

Does No
problem still Observe for a while
exist?
Is (LS)
No
A LED on the 1BP
board OFF Yes

Yes

Is limit Yes
switch energized Move robot arm
by robot? OFF the limit switch

No

Check connections, jumpers,

& switches on the 1BP board

Does No
problem still END
exist?

Yes

2-94 March 31, 1997

 A/AD CONTROLLERS
Kawasak ERROR CODES

TROUBLESHOOTING

(2 of 3)
B

Check continuity of Replace 1AE/1GE board

separation harness

Does
Does No No
problem still END
problem still END
exist?
exist?

Yes Yes

Replace 1BP board

SERVICE CALL

Does
problem still No END
exist?

Yes

Replace inside
machine harness

Does No
problem still END
exist?

Yes
Replace separation
harness

Does No
problem still END
exist?

Yes

2-95 March 31, 1997

 A/AD CONTROLLERS
Kawasak ERROR CODES

TROUBLESHOOTING

(3 of 3)
A

Is connector Yes
BX-CN7 disconnected Re-connect it
from the 1BX
board?

No

Replace 1BP board

Does
No
problem still END
exist?

Yes

SERVICE CALL

2-96 March 31, 1997

 A/AD CONTROLLERS
Kawasak ERROR CODES

TROUBLESHOOTING

Error 1602 - Limit switch signal line is broken (1 of 3)

This error occurs when the limit switch is ON.

Error 1602

Is (LS)
No Is limit
LED on the 1BP No
switch installed Fix it
board
correctly?
illuminated?

Yes Yes

Re-run
Press and hold LS
OVER-RIDE switch on
the accessory panel

Does No
problem still Observe for a while
exist?
Is (LS)
No
A LED on the 1BP
board OFF Yes

Yes

Is limit Yes
switch energized Move robot arm
by robot? OFF the limit switch

No

Check connections, jumpers,

& switches on the 1BP board

Does No
problem still END
exist?

Yes

2-97 March 31, 1997

 A/AD CONTROLLERS
Kawasak ERROR CODES

TROUBLESHOOTING

(2 of 3)
B

Check continuity of Replace 1AE/1GE board

separation harness

Does
Does No No
problem still END
problem still END
exist?
exist?

Yes Yes

Replace 1BP board

SERVICE CALL

Does
problem still No END
exist?

Yes

Replace inside
machine harness

Does No
problem still END
exist?

Yes
Replace separation
harness

Does No
problem still END
exist?

Yes

2-98 March 31, 1997

 A/AD CONTROLLERS
Kawasak ERROR CODES

TROUBLESHOOTING

(3 of 3)
A

Is connector Yes
BX-CN7 disconnected Re-connect it
from the 1BX
board?

No

Replace 1BP board

Does
No
problem still END
exist?

Yes

SERVICE CALL

2-99 March 31, 1997

 A/AD CONTROLLERS
Kawasak ERROR CODES

TROUBLESHOOTING

Error 1800 - AC primary power OFF (1 of 2)

This error occurs when primary power is interrupted.

Error 1800

Was
primary power Yes
This is normal
turned
OFF?

No

Is primary No
Fix it
power OK?

Yes

Is protector No
A
CP3 ON?

Yes

Is
connector
BX-CN5A disconnected Yes Re-connect it
from the 1BX
board?

No

Is relay CR2 No B
energized?

Yes

Replace 1BP board

Does
No
problem still END
exist?

Yes

SERVICE CALL

2-100 March 31, 1997

 A/AD CONTROLLERS
Kawasak ERROR CODES

TROUBLESHOOTING

(2 of 2)
A

Turn protector CP3 ON,

then switch NFB ON

Did
protector CP3 No
Observe for a while
trip OFF
again?

Yes

Replace diode bridge

Does
No
problem still END
exist?

Yes

SERVICE CALL

Is
relay CR2 Yes Set it
disconnected from correctly
socket?

No

Replace relay CR2

Does
No
problem still END
exist?

Yes

SERVICE CALL

2-101 March 31, 1997

 A/AD CONTROLLERS
Kawasak ERROR CODES

TROUBLESHOOTING

Error 1801 - 24 VDC power source is low (1 of 1)

This error occurs when the output of AVR (+24VDC) is too low.

Error 1801

Is AVR output No
Adjust output voltage
at +24.0 VDC?

Yes

Switch OFF NFB

Pull out 9ZR board

Switch ON NFB

Does
problem still No END
exist?

Yes

Is
connector
No Connect it firmly
BX-CN5A connected
to the 1BX
board?

Yes

Check connections, jumpers, and

switches on the 1BP board

Does
Yes Check connections, jumpers, and
problem still
switches on the 1AE board
exist?

No

Does
No Yes
END problem still SERVICE CALL
exist?

2-102 March 31, 1997

 A/AD CONTROLLERS
Kawasak ERROR CODES

TROUBLESHOOTING

Error 1802 - Primary power source is high (1 of 2)

This error occurs when primary power is too high.

Error 1802

Was
primary power Yes
This is normal
turned
OFF?

No

Is primary No
Fix it
power OK?

Yes

Is protector No
A
CP3 ON?

Yes

Is
connector
BX-CN5A disconnected Yes Re-connect it
from the 1BX
board?

No

Is relay CR2 No B
energized?

Yes

Replace 1BP board

Does
No
problem still END
exist?

Yes

SERVICE CALL

2-103 March 31, 1997

 A/AD CONTROLLERS
Kawasak ERROR CODES

TROUBLESHOOTING

(2 of 2)
A

Turn protector CP3 ON,

then switch NFB ON

Did
protector CP3 No
Observe for a while
trip OFF
again?

Yes

Replace diode bridge

Does
No
problem still END
exist?

Yes

SERVICE CALL

Is
relay CR2 Yes Set it
disconnected from correctly
socket?

No

Replace relay CR2

Does
No
problem still END
exist?

Yes

SERVICE CALL

2-104 March 31, 1997

 A/AD CONTROLLERS
Kawasak ERROR CODES

TROUBLESHOOTING

Error 1803 - Primary power source is too low (1 of 2)

This error occurs when primary power is too low.

Error 1803

Was
primary power Yes
This is normal
turned
OFF?

No

Is primary No
Fix it
power OK?

Yes

Is protector No
A
CP3 ON?

Yes

Is
connector
BX-CN5A disconnected Yes Re-connect it
from the 1BX
board?

No

Is relay CR2 No B
energized?

Yes

Replace 1BP board

Does
No
problem still END
exist?

Yes

SERVICE CALL

2-105 March 31, 1997

 A/AD CONTROLLERS
Kawasak ERROR CODES

TROUBLESHOOTING

(2 of 2)
A

Turn protector CP3 ON,

then switch NFB ON

Did
protector CP3 No
Observe for a while
trip OFF
again?

Yes

Replace diode bridge

Does
No
problem still END
exist?

Yes

SERVICE CALL

Is
relay CR2 Yes Set it
disconnected from correctly
socket?

No

Replace relay CR2

Does
No
problem still END
exist?

Yes

SERVICE CALL

2-106 March 31, 1997

 A/AD CONTROLLERS
Kawasak ERROR CODES

TROUBLESHOOTING

Error 1804 - +5 VDC or +/-12 VDC is abnormal

This error occurs when system line voltage (+5 VDC & +/-12 VDC) has become abnormal.

Error 1804 (1 of 1)

Are No
AVR1 outputs set Adjust outputs correctly
correctly?

Yes

Check connections, jumpers,

and switches on the 9ZA board

Check continuity of power block harnesses,

signal harness, and 1BX board

Does
No
problem still END
exist?

Yes

Replace AVR1 power

supply board

Does
problem still No END
exist?

Yes

Replace 9ZA board

Does
problem still No END
exist?

Yes

SERVICE CALL

2-107 March 31, 1997