COPYRIGHTED DOCUMENT - INTENDED FOR CUSTOMER REFERENCE ONLY

D SERIES CONTROLLER
TROUBLESHOOTING AND
COMPONENT REPLACEMENT
MRVDCONTV113E-4

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 per-
mission of Kawasaki Robotics (USA), Inc.

All Rights Reserved.

Copyright © 2007, Kawasaki Robotics (USA), Inc.

Wixom, Michigan 48393 90206-1034DEF
 COPYRIGHTED DOCUMENT - INTENDED FOR CUSTOMER REFERENCE ONLY
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.
28140 Lakeview Drive
Wixom, Michigan 48393
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TROUBLESHOOTING AND COMPONENT REPLACEMENT

TROUBLESHOOTING

1.0 TROUBLESHOOTING ................................................................................... 1-2

1.1 Error Recovery ............................................................................................... 1-2
1.2 Preliminary Troubleshooting ........................................................................... 1-5
1.2.1 Troubleshooting Common Failures ................................................................. 1-5
1.2.1.1 Controller Power Cannot Be Set to ON .......................................................... 1-6
1.2.1.2 Teach Pendant Is Inoperable .......................................................................... 1-8
1.2.1.3 Motor Power Cannot Be Enabled ................................................................. 1-10
1.2.1.4 Robot Does Not Move .................................................................................. 1-11
1.3 Error Codes.................................................................................................. 1-12
1.3.1 Error Display ................................................................................................ 1-13
1.3.2 Error List ...................................................................................................... 1-13
1.3.2.1 DXXXX Fatal Error Codes ............................................................................ 1-14
1.3.2.2 EXXXX Non-Fatal Error Codes .................................................................... 1-58
1.3.2.3 PXXXX Operation Error Codes .................................................................. 1-158
1.3.2.4 WXXXX Mechanical/Control Warning Error Codes .................................... 1-199
1.3.2.5 Additional Error Codes List ........................................................................ 1-210
1.4 Troubleshooting Flowcharts ....................................................................... 1-230

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1.0 TROUBLESHOOTING

This unit provides error recovery flowcharts, error code information, and error code
troubleshooting flow charts. In addition, typical causes and remedies for the errors are
also provided.

1.1 ERROR RECOVERY

Figures 1-1 and 1-2 show troubleshooting processes that may be helpful if the controller
becomes unresponsive to commands or an error code has been encountered that can-
not be cleared. Troubleshooting should begin with confirmation of basic integrity of the
system: ensure that the power supply is on and meeting supply requirements, all cables
are correctly attached, all circuit boards are properly installed and fully seated, all pe-
ripheral equipment is wired correctly, software is properly configured, etc.

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Locate error on the error

Source of error known Troubleshoot
table and determine the Run Program
characteristics and possible and correct and continue
causes of the error source of to monitor
error

Source of error unknown

Error cleared and robot Run Program

Press the yellow
runs normally and continue
reset button on the
controller panel to monitor

Error will not clear or

machine is in a “locked” mode

Have any changes been

made to system? New Error clears and robot
Ensure the robot Run Program
internal parts, interface Yes runs normally
system data, all and continue
components added or components, signals, to monitor
removed, signal interface and programs are
agrees with program, etc. compatible

No

Error or “locked” Run Program

Cycle the condition cleared
controller power and continue
OFF and ON to monitor

Error still present

Create Error or “locked” Reset Run program

backup information condition cleared system settings not and continue
files and initialize the set to defaults after to monitor
system initialization

Continued on next page

Figure 1-1 Troubleshooting Process

August 9, 2005 1-3

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Continued from previous pg

Error still present

Remove the
1KA/1RA board from
the rack and allow
RAM memory to
deplete

Reinstall Error clears and robot

1KA/1RA runs normally Run program
board, initialize the and continue
system, zero to monitor

Begin electrical
troubleshooting and repair if
qualified; call service
technician for further
assistance

Figure 1-2 Troubleshooting Process (Continued)

1-4 July 31, 2007

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1.2 PRELIMINARY TROUBLESHOOTING

Prior to following error code troubleshooting procedures, ensure preliminary trouble-

shooting steps are completed.

1. Ensure proper 460 VAC three-phase power is available at the input and output side
of the controller main disconnect (circuit breaker F1).

2. Ensure circuit breakers F2, F3, F4, and F5 are not tripped.

3. Ensure proper +5 VDC, +12 VDC, -12 VDC and +24 VDC are available from the
AVR power supply.

4. Observe the state of LEDs and refer to the appropriate section of the D Series
Controller Electrical Maintenance Manual for conditions indicated by the LEDs. If
these conditions are not normal, correct the cause of abnormal LED indications.

5. Check for loose connection at circuits boards and cable connections.

6. Ensure all circuit boards are properly seated in the card rack (where applicable).

7. Ensure the F1 and F2 fuses on the 1KP board are not open.

1.2.1 TROUBLESHOOTING COMMON FAILURES

This section describes some common failures, possible causes, and corrective actions.

1.2.1.1 Controller Power Cannot Be Set ON

1.2.1.2 Teach Pendant is Inoperable

1.2.1.3 Motor Power Cannot Be Set ON

1.2.1.4 Robot Does Not Move

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1.2.1.1 CONTROLLER POWER CANNOT BE SET TO ON

This failure occurs when the controller does not power-up when the controller main
disconnect is set to ON.

Failure 1: When the controller main disconnect is set to ON, circuit breaker F1 is tripped
immediately.

Main causes include:

1. The AC power line is short-circuited in the controller, and circuit breaker F1 detects
overcurrent and is tripped.

2. Defective F1 circuit breaker.

⇒ Interrupt the 460 VAC to the main disconnect (circuit breaker F1) set the controller
main disconnect to ON. Using an ohm meter check for a short circuit between these
points:

R and S, S and T, T and R, R and FG, S and FG, T and FG (FG=frame ground)

If a short circuit is detected replace components as necessary (wiring, transformer

T1, circuit breaker F1, etc.).

Failure 2: When the main disconnect is set to ON, the control power lamp does not
illuminate (circuit breaker F1 does not trip).

This failure occurs when the controller does not activate properly because of an abnor-
mality in the external power supplied to the controller or in the power supply circuit in the
controller.

Main causes include:

1. The external power voltage supplied to the controller is not within specifications, the
primary power cable is disconnected or damaged, or the external power is not
supplied.

2. Power is not supplied to the 1KQ/1NR board, or the 1KQ/1NR board is defective.

3. Power is not supplied to the AVR power supply.

4. Power is not supplied to the control power lamp due to a defective AVR power
supply, 1KX/1NR board, 1LS/1NS board or control power lamp.

5. Disconnected or short-circuited wiring in the controller.

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⇒ Ensure external power supply is within specifications. Ensure external power supply
cable is properly connected and is not damaged.
⇒ Ensure connectors at the 1KQ/1NR board are properly installed and not damaged.
⇒ Ensure the 1KP board fuses F1 and F2 are not open.
⇒ Replace the 1KQ/1NR board.
⇒ Ensure the power supplied to the AVR power supply is within specifications. Ensure
the power connector at the AVR power supply is properly connected and not dam-
aged.
⇒ Ensure to output voltages from the AVR power supply are within specifications.
⇒ Ensure the control power lamp is properly installed and is not defective.
⇒ Repair or replace disconnected or short-circuited wiring in the controller.

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1.2.1.2 TEACH PENDANT IS INOPERABLE

The teach pendant is in operable with the controller main disconnect set to ON and the
control power lamp is illuminated.

Failure 1: The control power lamp is illuminated and the teach pendant is inoperable
(the back light is not illuminated).

DC power is supplied to the controller, but power is not supplied to the teach pendant to
illuminate the display or back light.

Main causes include:

1. +12 VDC is not supplied to the teach pendant.

2. Defective LCD panel, circuit board, or other internal teach pendant components.

3. Disconnected or short-circuited teach pendant cable.

⇒ Ensure the teach pendant cable is properly connected to the controller.

⇒ Replace the teach pendant.
⇒ Replace the teach pendant cable.

Failure 2: The back light is illuminated, but the screen is not displayed.

When the teach pendant back light is illuminated this indicates power is supplied to the
teach pendant. If the teach pendant is operating normally the initial screen is displayed
regardless of the 1KA/1RA board condition.

Main causes include:

1. Defective LCD panel, circuit board, or other internal teach pendant components.

⇒ Replace the teach pendant.

Failure 3: The teach pendant screen is displayed and the back light is illuminated, but
key input and AS Language commands are not possible.

This condition occurs when key input and AS Language commands do not reach the
1KA/1RA board or data from the 1KA/1RA board does not reach the teach pendant.

Data is transmitted between the 1KA/1RA board and the teach pendant as shown in
figure 1-3.

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1KX/1NX Mother Board

Display Device

Input
Keys
1KA/1RA Main CPU Board

Teach Pendant

Figure 1-3 1KA/1RA/Teach Pendant Communication

Main causes include:

1. Interruption in data communication between the teach pendant and the 1KA/1RA
board.

2. Defective LCD panel, circuit board, or other internal teach pendant components.

3. Defective 1KA/1RA or 1KX/1NX boards.

4. Disconnected or short-circuited teach pendant cable.

⇒ Ensure the teach pendant cable is properly connected to the controller.

⇒ Replace the teach pendant cable.
⇒ Replace the teach pendant.
⇒ Replace the 1KA/1RA or 1KX/1NX boards.

July 31, 2007 1-9

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1.2.1.3 MOTOR POWER CANNOT BE ENABLED

This condition exists when motor power does not engage when the MOTOR POWER
switch is pressed.

Main causes include:

1. An error condition exists.

2. K1, K2, or K3 are not engaged due to a defective 1KQ/1NR board, MC unit, teach
pendant, software, eternal signals etc.

3. Emergency stop condition exists.

4. Defective power block.

5. Disconnected or short-circuited motor power supply harness.

6. Motor temperature or controller internal temperature exceeds limits

⇒ If the operation panel error lamp is illuminated or an error message is displayed on

the teach pendant LCD, take appropriate measures to release the error condition
according to the error message.
⇒ Check and repair any abnormalities in the motor power supply circuit.
⇒ Ensure all EMERGENCY STOP switches are released.
⇒ Replace the power block.
⇒ Replace the motor power supply harness.
⇒ Ensure motor temperature and controller internal temperature does not exceed limits.

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1.2.1.4 ROBOT DOES NOT MOVE

This condition exists when the robot does not move when conditions are set for teach or
repeat mode.

Main causes include:

1. External hold condition exists.

2. An error condition exists.

3. Operation panel switches set incorrectly.

4. Motor brakes are not released.

5. If the check mode is selected, ensure an enabling device is engaged and the GO
(step forward) key is pressed.

6. Robot is waiting for input signals in repeat mode (cycle start, step forward, program
change, WX, JUMP, etc.)

⇒ Release external hold condition.

⇒ If the operation panel error lamp is illuminated or an error message is displayed on
the teach pendant LCD, take appropriate measures to release the error condition
according to the error message.
⇒ Ensure the operation panel switches are set correctly for robot operation.
⇒ Ensure proper brake voltage is available to the brake release circuit. Check and
repair poor connections, disconnected connectors, open wiring, short circuited wiring,
or any abnormalities in the brake circuits. Ensure the 1KP board, 1KQ/1NR board,
AVR power supply, MC unit, 1KQ/1NR board, servo motor, and controller internal
brake harnesses are in serviceable condition.
⇒ When check mode is selected, ensure an enabling device is engaged and the GO
(step forward) key is pressed.
⇒ In repeat mode, ensure input signals are received to release a wait condition.

! WARNING
The robot may move suddenly when a wait condition is
released. Do not approach the robot when it appears to
be stopped.

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1.3 ERROR CODES

This unit provides information about the error codes that are displayed on the teach
pendant or other user interfaces that provide display screen information. The error
codes are listed in numerical order by prefix and code number with the message that is
displayed on the teach pendant. An expanded explanation of the message is provided
along with possible methods to clear or prevent the specific error. Troubleshooting
information is preceded by an ⇒ symbol.

Table 1-1 provides an explanation of the error code prefixes.

Table 1-1 Error Code Prefix Descriptions

Error Log Code Description Comment

D Fatal error Hardware, software, or peripheral device error.
When error is corrected control power must be
cycled OFF and ON.
E Non-fatal error When error is corrected, press error reset.
P Operation error Does not affect robot motion.
W Mechanical/control warning May cause an error if not corrected.

Table 1-2 describes the controller state for each type of error.

Table 1-2 Controller Error State

Error Type Error Lamp Cycle Start Lamp Motor Power

P OFF ON ON
1 1 1
W ON or OFF ON or OFF ON or OFF
1
E ON OFF ON or OFF
D ON OFF OFF
1
Depending on the error content

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1.3.1 ERROR DISPLAY

Error messages are displayed on the teach pendant LCD screen and/or a PC interfaced
with the controller using KRterm/KCWIN32 terminal software.

The teach pendant LCD screen displays operation errors (P errors) in the system mes-
sage area and other error messages are shown in a pop-up screen display (Figure 1-4).

Program [Comment ] Step PC Status 03-01-31 11:55

1 pcprg1 T JOINT
pg6 1
C
[ ] [ ] R 90%

Program aborted. No = 1
System Message Area
RPS

! Error
(E0100) 02-11-08(Fri) 16:33:20
Abnormal comment statement exists.

Error Pop-up Screen

Reset Close

JT 1 JT 2 JT 3 JT 4 JT 5 JT 6

0.000 0.000 0.000 0.000 0.000 0.000

Figure 1-4 Teach Pendant Error Screen Display

1.3.2 ERROR LIST

Refer to the following sections for errors and descriptions:

1.3.2.1 DXXXX Fatal Error Codes

1.3.2.2 EXXXX Non-Fatal Error Codes

1.3.2.3 PXXXX Operation Error Codes

1.3.2.4 WXXXX Mechanical/Control Warning Error Codes

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1.3.2.1 DXXXX FATAL ERROR CODES

ERROR CODE D0001 CPU Error. (PC=%08X)

The 1KA/1RA board CPU has stopped (detected by the AS software). This error is
caused by defective AS or servo software, defective hardware, or noise related malfunc-
tion.
PC Error Display Example:

Error (D0001) CPU error Code=1

Task (Pc01) Stop SIG=00070004 [FAULT (PARALLEL)] PC=*****

Indicates the place the error occurred

⇒ Refer to the error message displayed on a PC interfaced with the controller.

⇒ Cycle controller power OFF and ON. Do not initialize the controller. If a message for
initialization is displayed, select “NO”.
⇒ If the error does not reset when power is cycled, initialize the system and reload
program data.
⇒ Replace the 1KA/1RA board.
⇒ If the above steps do not correct the error, contact KRI customer service.
_____________________________________________________________________

ERROR CODE D0002 Main CPU BUS error. (PC=%08X)

A 1KA/1RA board bus error occurs (in the VME bus line, detected by AS software); data
processing is not completed normally. This error is caused by defective AS software,
defective 1KA/1RA board, or noise related malfunction.
PC Error Display Example:

Error (D0002) CPU BUS error Code=1

Task (Pc01) Stop SIG=00070004 [NMI(VME BUS ERROR)] PC=*****

Indicates the place the error occurred

⇒ Refer to the error message displayed on a PC interfaced with the controller.

⇒ Cycle controller power OFF and ON. Do not initialize the controller. If a message for
initialization is displayed, select “NO”.
⇒ If the error does not reset when power is cycled, initialize the system and reload
program data.
⇒ Replace the 1KA/1RA board.
⇒ If the above steps do not correct the error, contact KRI customer service.
_____________________________________________________________________

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ERROR CODE D0003 VME BUS error. (PC=%08X)

This error occurs when the CPU does not receive a response from one of the I/O bus
devices within a specific time. This error is caused by defective AS software, defective
1KA/1RA board, or noise related malfunction.
PC Error Display Example:

Error (D0003) VME bus error Code=1

Task (Pc01) Stop SIG=00070004 [NMI(VME BUS ERROR)] PC=*****
bus-read=******** bus-write=*********

Indicates the place the error occurred

⇒ Refer to the error message displayed on a PC interfaced with the controller.

⇒ Cycle controller power OFF and ON. Do not initialize the controller. If a message for
initialization is displayed, select “NO”.
⇒ If the error does not reset when power is cycled, initialize the system and reload
program data.
⇒ Replace the 1KA/1RA board.
⇒ If the above steps do not correct the error, contact KRI customer service.
_____________________________________________________________________

ERROR CODE D0004 [ARM CONTROL BOARD] CPU error. (PC=%08X)

The 1KB/1RB board CPU is stopped (detected by the AS software). This error is caused
by defective AS or servo software, defective hardware, or noise related malfunction.
PC Error Display Example:

Error (D0004) [ARM CONTROL BOARD] CPU error Code=1

Task (Pc01) Stop SIG=00070004 [FAULT (PARALLEL)] PC=*****

Indicates the place the error occurred

⇒ Refer to the error message displayed on a PC interfaced with the controller.

⇒ Cycle controller power OFF and ON. Do not initialize the controller. If a message for
initialization is displayed, select “NO”.
⇒ Ensure the correct 1KB/1RB board software is loaded into the 1KA/1RA board.
⇒ Replace the 1KB/1RB board.
⇒ If the above steps do not correct the error, contact KRI customer service.
_____________________________________________________________________

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ERROR CODE D0005 [ARM CONTROL BOARD] CPU BUS error. (PC=%08X)

On the 1KB/1RB board, a bus error occurs (in the VME bus line, detected by AS soft-
ware); data processing is not completed normally. This error is caused by defective AS
software, defective 1KB/1RB board, or noise related malfunction.
PC Error Display Example:

Error (D0005) [ARM CONTROL BOARD] CPU BUS error Code=1

Task (Pc01) Stop SIG=00070004 [NMI(VME BUS ERROR)] PC=*****

Indicates the place the error occurred

⇒ Refer to the error message displayed on a PC interfaced with the controller.

⇒ Cycle controller power OFF and ON. Do not initialize the controller. If a message for
initialization is displayed, select “NO”.
⇒ Ensure the correct 1KB/1RB board software is loaded into the 1KA/1RA board.
⇒ Replace the 1KB/1RB board.
⇒ If the above steps do not correct the error, contact KRI customer service.
_____________________________________________________________________

ERROR CODE D0900Teach data is broken.

The program storage area of the system memory is damaged and is not linking data
correctly.

Main causes include:

1. Loss of memory battery back-up.
2. Noise related malfunction.
3. Defective 1KA/1RA board.

⇒ Set the 1KA board switch SW2-8 to ON and initialize the memory, do not use AUX
0805 or SYSINIT command. Reload the robot program data.
⇒ Check the memory backup battery. Replace if necessary (3.3 VDC or less). When
battery voltage drops to 3.3 VDC, or less, error W1010 is displayed.
⇒ Replace the 1KA/1RA board if the error recurs.
_____________________________________________________________________

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ERROR CODE D0901 AS Flash memory sum check error.

A check sum error occurrs in AS software, in flash memory on the 1KA/1RA board,
when the controller is powered-up. The check sum data is created when the FCHK
command is executed and is recorded in flash memory during AS software download.

Main causes include:

1. When the AS software is downloaded, the FCHK command is not executed.
2. The addressing of the FCHK command is wrong.
3. The flash memory and 1KA/1RA board are defective.
4. The system data in the flash memory is corrupt.

⇒ Confirm the content of the command as_load.cmd file on the PC card. If error occurs
immediately after downloading the AS software, download AS software again. If error
continues after download, replace the 1KA/1RA board.
_____________________________________________________________________

ERROR CODE D0902 Servo flash memory sum check error.

A check sum error of the servo software in flash memory on the 1KA/1RA board occurrs
when the controller is powered-up. The check sum data is created when the FCHK
command is executed and is recorded in flash memory during software download.

Main causes include:

1. When the servo software is downloaded, the FCHK command is not executed.
2. The addressing of the FCHK command is wrong.
3. The flash memory and 1KA/1RA board are defective.
4. The system data in flash memory is corrupt.

⇒ If the error occurs immediately after servo software download, confirm the content of
sv_load.cmd on the PC card and download servo software again. If the error reoc-
curs, replace the 1KA/1RA board.
_____________________________________________________________________

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ERROR CODE D0903 IP board memory error. (Code)

This error occurs when the flash ROM on the 1GS board is corrupt (check sum error).

Code 2: flash ROM SAM error.

Code 3: DPRAM write and read error.
Code 4: SRAM write and read error.

⇒ Replace the 1GS board.

_____________________________________________________________________

ERROR CODE D0904 Memory is locked due to AC_FAIL.

The memory is accessed during the controller shut down due to a power supply abnor-
mality (ACFAIL) (AVR +5 V, +12 V, -12 V, +24 V).

⇒ Cycle the controller power OFF and ON.

⇒ Check for proper AVR voltage supply (+5 V, +12 V, -12 V, +24 V) and related circuitry.
_____________________________________________________________________

ERROR CODE D1000 Read error of servo control software.

Main causes include:

1. Servo control software (armsc.mb) not found at controller power-up or software is
corrupt.
2. Defective 1KJ/1QJ board.

⇒ Download servo control software (armsc.mb).

⇒ Replace 1KJ/1QJ board.
_____________________________________________________________________

ERROR CODE D1001 Download error of servo control software.

Servo control software (armsc.mb) download failure at controller power-up.

Main causes include:

1. Incorrect servo control software.
2. Defective 1KJ/1QJ board.
2. Defective 1KA/1RA and or 1KB/1RB board.

⇒ Ensure the correct servo software is loaded into the 1KA/1RA board.
⇒ Replace the 1KJ/1QJ board.
⇒ Replace the 1KA/1RA and or 1KB/1RB board.
_____________________________________________________________________

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ERROR CODE D1002 Init. error of servo software.

Servo software (armsc.mb) initialization failure at controller power-up.

Main causes include:

1. Servo software is not installed correctly or is corrupt.
2. Incompatibility between the AS and servo software.
3. Defective 1KA/1RA and or 1KB/1RB board.

⇒ Reinstall servo software.

⇒ Check compatibility of AS and servo software and reinstall software as needed.
⇒ Replace the 1KA/1RA and or 1KB/1RB boards.
_____________________________________________________________________

ERROR CODE D1003 Init. error of servo control software.

Servo software (armsv.abs) initialization failure at controller power-up.

Main causes include:

1. Servo software is not installed correctly or is corrupt.
2. Incompatibility between the AS and servo software.
3. Defective 1KA/1RA and or 1KB/1RB board.

⇒ Reinstall servo software.

⇒ Check compatibility of AS and servo software and reinstall software as needed.
⇒ Replace the 1KA/1RA and or 1KB/1RB boards.
_____________________________________________________________________

July 31, 2007 1-19

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TROUBLESHOOTING

ERROR CODE D1004 [ARM CTRL BOARD] watch dog error of servo control
software.

The watch dog circuit on the 1KA/1RA board or 1KB/1RB board has detected a software
problem. This is caused by a defective 1KA/1RA main CPU board or 1KB/1RB servo
CPU board or a problem with the servo software.

Interface
1KX (Mother Board) ELPD
CPU
Watch Dog
Error Signal
Servo
1KA/1RA (Main CPU Board) Control Gate Array
CPU
1KB/1RB (Servo CPU Board)

⇒ Replace the AS or servo software.

⇒ Replace the 1KA/1RA or 1KB/1RB board.
_____________________________________________________________________

ERROR CODE D1005 Servo board command error. (%d)

Servo software returned an error code, other than a servo system error, to the AS soft-
ware after receiving an unrecognized command from the 1KA/1RA board.

Interface
1KX (Mother Board) ELPD
CPU

Servo
1KA/1RA (Main CPU Board) Control Gate Array
CPU
1KB/1RB (Servo CPU Board)

Main causes include:

1. Corrupt servo or AS software.
2. Noise malfunction.
3. Defective 1KB/1RB servo board or 1KA/1RA main CPU board.
4. Versions of servo and AS software incompatible.

⇒ Install correct versions of servo and AS software.

⇒ Replace the 1KA/1RA or 1KB/1RB board.
_____________________________________________________________________

1-20 July 31, 2007

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TROUBLESHOOTING

ERROR CODE D1006 AMP power unit error.

General servo system error. This error indicates that a servo system error has occurred.
Refer to any other servo system errors which occurred at the same time.

When a servo error signal (SVER) is sent from the 1KB board (servo CPU board) to the
1KP board (power sequence board) motor power is shut down. The error notification is
sent to the AS software via the EPLD. The error information from the 1KB/1RB board is
sent through the command line and the corresponding error code(s) is/are displayed
after D1006.

1KP (Power Sequence Board)

Interface
1KX (Mother Board) ELPD
CPU

Servo
1KA/1RA (Main CPU Board) Control Gate Array
CPU
1KB/1RB (Servo CPU Board)

⇒ Check the servo error codes that follow this error for additional information. Ensure
that the 1KP board and 1KB/1RB board are properly seated.
_____________________________________________________________________

July 31, 2007 1-21

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TROUBLESHOOTING

ERROR CODE D1007 Regenerative time over [%X].

This error occurs when current is sent to regenerative resistors for six or more consecu-
tive seconds.

When the robot decelerates, the motors enter the power generation state to absorb the
inertia energy from the arm. When the P-N power voltage exceeds the rated value (390
VDC), the current is split from the power block to the regenerative resistor. When the
voltage drops to a safe level (365 VDC) the resistor is removed from the circuit.

Motor power
Motor power circuit

Interface P-N power

CPU
Motor power voltage
Drive circuit
(P-N power monitoring
1KC: IGBT
voltage) circuit/
Servo 1KD: IGBT
CPU Regeneration
1KL/1KR: FET
controlling
circuit

Gate Array Regenerative

Regenerative
signal
resistor

1KB/1RB board Power block

Controller

Main causes include:

1. Abrupt direction changes at high speed.
2. Burned out regenerative resistors in the power block.
3. Defective power block.
4. Defective servo board (1KB/1RB board).
5. Loose or disconnected harness between 1KX board (mother board) connector X211
or X212 and the 1KB/1RB board (servo CPU board) connector X501 or X502.
6. Defective/incorrect optional second regenerative resistance unit (when used).

⇒ Avoid abrupt high speed direction changes. Change accuracy, speed, add points.
⇒ Replace defective regenerative resistor.
⇒ Install/replace optional second regenerative resistance unit.
⇒ Replace defective 1KB/1RB board.
⇒ Replace defective power block.
⇒ Check connections described in item 5 and repair as necessary.
_____________________________________________________________________

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TROUBLESHOOTING

ERROR CODE D1008 P-N low voltage [%X].

The voltage between P-N supplied to the power block is 60 VDC or less at servo on.

! WARNING
Because motor power is not supplied, when low voltage
occurs, the arm will fall until the error is detected. As a
result, other errors may be generated (abnormal speed,
deviation error, etc.).

External power Main MC unit Motor power

disconnect (1KQ/1NQ board)

K3 STATUS

Interface
CPU

P-N power
Servo P-N power low
voltage
CPU voltage error EPLD
monitoring
circuit

Gate Array

1KB/1RB board 1KP board Power block

Main causes include:

1. Motor power circuit connector detached or loose.
2. Three phase (U, V, W) control power circuit breaker set to OFF.
3. Defective 1KB/1RB/1KP/1KQ/1NQ boards.
4. Defective power block.
5. Defective MC unit or harness.

⇒ Ensure the motor power circuit connector is properly attached.

⇒ Ensure control power circuit breaker is set to ON.
⇒ Replace the 1KB/1RB/1KP/1KQ /1NQ boards.
⇒ Replace the power block.
⇒ Replace the MC unit or harness.
_____________________________________________________________________

July 31, 2007 1-23

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TROUBLESHOOTING

ERROR CODE D1009 P-N- high voltage [%X].

The voltage between P-N supplied to the power block exceeded 410 VDC.

External power Main MC unit

disconnect (1KQ/1NQ board)

Motor power

Interface
CPU
Regenerative Additional
P-N power resistor regenerative
Servo P-N power high resistor
voltage
CPU voltage error
monitoring Thermal Thermal
circuit (140° C) (140° C)

Gate Array

1KB/1RB board Power block Additional regenerative

resistor (option)

Main causes include:

1. High inertia loads due to excessive tool weight or incorrect program data.
2. Defective regenerative resistance control circuit, overheat failure of regenerative
resistance unit, defective voltage monitoring circuit, or defective power block.
3. Defective servo board (1KB/1RB board) or harness.
4. Defective additional regenerative resistance unit.

⇒ Reteach program steps to eliminate sudden high speed direction changes (dynamic
shock).
⇒ Replace the regenerative unit.
⇒ Replace the 1KB/1RB board, power block or harness.
⇒ Replace the additional regenerative resistor unit.
_____________________________________________________________________

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TROUBLESHOOTING

ERROR CODE D1010 Regenerative resistor over-heat [%X].

The thermal switch for the power block regenerative resistor unit, or the optional regen-
erative resistor unit reached 140° C (284°F), or the heat sink thermal switch reached
90° C (194°F), or the controller cabinet thermal switch reached 70° C (158° F). The
thermal switches are wired in series and the AS software cannot distinguish which
thermal switch is activated. For D7X controller, if the heat exchange fan is inoperative
(X207 disconnected) this error is generated.

External power Main MC unit

disconnect (1KQ/1NQ board)

Motor power

Interface
CPU
Regenerative Additional
P-N power resistor regenerative
Servo P-N power high resistor
voltage
CPU voltage error
monitoring Thermal Thermal
circuit (140° C) (140° C)

Gate Array

1KB/1RB board Power block Additional regenerative

resistor (option)

Main causes include:

1. High inertia loads due to excessive tool weight or incorrect program data.
2. Defective cooling fans.
3. Insufficient clearance for air circulation.
4. High ambient controller temperature.
5. Defective power block.
6. Disconnected or defective harness between the 1KC/1KD board and the additional
regenerative resistor unit.
7. Defective regenerative resistor unit.
8. Defective additional regenerative resistor unit.
9. Defective 1KB/1RB board.
10. Disconnected or defective harness between X211 or X212 on the 1KX/1NX board
and X501 or X502 on the power block.

July 31, 2007 1-25

 D SERIES CONTROLLER
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⇒ Reteach program steps to eliminate sudden high speed direction changes (dynamic
shock).
⇒ Ensure cooling fans are in proper working condition.
⇒ Reduce controller ambient temperature.
⇒ Replace defective thermal switch(es).
⇒ Repair or replace disconnected or defective harness(es).
⇒ Replace the regenerative unit.
⇒ Replace the 1KB/1RB board, power block or harness.
⇒ Replace the additional regenerative resistor unit.
⇒ Connect or repair D7X power supply connection for heat exchange fan (X207).
_____________________________________________________________________

ERROR CODE D1011 AS or servo software is not compatible with the robot
model.

This error occurs when the servo software does not match the robot specifications.

⇒ Load the correct AS and servo software.

_____________________________________________________________________

ERROR CODE D1012 Servo type mismatch. Check the settings.

Servo type set for the robot and servo software do not match.

⇒ Change the robot servo type setting.

⇒ Install servo software that matches the robot setting.
_____________________________________________________________________

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ERROR CODE D1013 P-N capacitor is not discharged.

This error occurs when motor power is OFF for a period of time and the P-N power
voltage does not decrease to 60 VDC or less.

External power Main MC unit Motor power

disconnect (1KQ/1NQ board)

K3 STATUS

Interface
CPU

P-N power
Servo P-N capacitor
voltage
CPU discharge error EPLD
monitoring
circuit

Gate Array

1KB/1RB board 1KP board Power block

Main causes include:

1. Defective 1KB/1RB/1KP/1KQ/1NQ boards.
2. Defective power block.
3. Defective MC unit or harness between the MC unit and the power block.

⇒ Replace the 1KB/1RB/1KP/1KQ/1NQ boards.

⇒ Replace the power block.
⇒ Replace the MC unit or harness between the MC unit and the power block.
_____________________________________________________________________

July 31, 2007 1-27

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TROUBLESHOOTING

ERROR CODE D1014 Servo system error. (Code=%08X)

An unrecognized error occurred in the 1KB/1RB board.

⇒ Contact KRI customer service (include operating conditions/settings at the time the
error occurred).
_____________________________________________________________________

ERROR CODE D1015 The servo data file does not exist.

This error occurs when the servo data file is not found.

⇒ Contact KRI customer service (include operating conditions/settings at the time the
error occurred).
_____________________________________________________________________

ERROR CODE D1016 Data applicable to the robot model not in servo servo data
file.

This error occurs when the installed robot model file is not found in the servo data file.

⇒ Contact KRI customer service (include operating conditions/settings at the time the
error occurred).
_____________________________________________________________________

ERROR CODE D1017 Error of download of servo data.

Servo data could not be downloaded from the servo software at controller power-up.

⇒ Ensure the correct servo software is installed.

⇒ Ensure the 1KA/1RA and 1KB/1RB boards are properly installed.
_____________________________________________________________________

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ERROR CODE D1500 Encoder misread error Jt%-M.

Immediately after controller power on, steady encoder data is not able to be read. This
error is caused by a disconnected encoder signal line or a short circuit, or a defect in the
main body of the encoder.

Encoder Encoder

Encoder I/F

Power circuit Battery

1KB/1RB board
1FG/1HG board
Encoder power supply +12 V

Controller Robot

Main causes include:

1. Defective encoder or encoder harness.
2. Defective servo weld gun encoder (detected at controller power-up/power-down with
gun connected.
3. Servo weld gun is not connected.
4. Defective 1KB/1RB board.
5. Defective 1FG/1HG board.

⇒ Check for disconnection or short circuit in encoder signal line.

⇒ Replace the encoder or encoder harness.
⇒ Replace the 1KB/1RB servo board.
⇒ Replace the 1FG/1HG board.
⇒ Release the servo weld gun axis in teach mode and cycle controller power OFF and
ON.
_____________________________________________________________________

July 31, 2007 1-29

 D SERIES CONTROLLER
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TROUBLESHOOTING

ERROR CODE D1501 Defective gun changer connection or encoder comm. error.

This error occurs when the servo weld gun is connected and encoder data is not read
normally within the specified time.

Main causes include:

1. Improper connection at the tool changer.
2. Defective encoder or encoder communication line.

⇒ Check tool changer connection and repair as necessary.

⇒ Check encoder and encoder harness and replace as necessary.
_____________________________________________________________________

ERROR CODE D1502 Amp over current Jt%-M.

The feedback current from a current sensor in the power block exceeded 150% of the
maximum instantaneous motor current rating.

HIC 1GM board

(Over current I/V
detection) converter
Over current
error signal
Current
Gate feedback
Array

1KB/1RB Board

PWM
Current U, V, W
sensor earth
IPM Motors

Power block Robot

Controller

Main causes include:

1. Short in the U, V, W from the power block to motor and ground wire.
2. Defective motor.
3. Defective power block.
4. Defective 1KB/1RB servo board, harness, etc.

⇒ Check the connection for the U, V, W and ground line to the power block. Replace the
separation harness if necessary.
⇒ Replace the motor, 1KB/1RB board, power block, or harness.
_____________________________________________________________________
1-30 July 31, 2007
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ERROR CODE D1503 Current detector type (%X) mismatch!

When the controller power supply is turned ON, the ID code data of the 1GM (1KV)
board and the AS software installed on the 1KB/1RB board do not correspond. The unit
name of the servo board displayed at (%X) in the error message corresponds to the CH
column in the table below.

Relay to Power Sequence

CH To Communication Board (1KP PC Board)
A First 1KB/1RB PC Board A Master
Unit
B First 1KB/1RB PC Board B Master
Unit
C First 1KB/1RB PC Board C Slave
Unit
or
Second 1KB/1RB PC Board
A Unit
or
One Axis Amplifier
D Second 1KB/1RB PC Board Slave
B Unit
or
One Axis Amplifier

Main causes include:

1. 1GM (1KV) board is not suitable for the AS software (robot model).
2. The AS software does not correspond to the 1GM (1KV) board.

⇒ Ensure the correct AS software is loaded.

⇒ Replace the 1GM (1KV) board.
_____________________________________________________________________

July 31, 2007 1-31

 D SERIES CONTROLLER
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TROUBLESHOOTING

ERROR CODE D1504 Abn. curr. feedback Jt %-M. (Amp fail, pwr harness discon-
nect).

This error occurs if the current feedback value is near 0 from the time the servo is turned
ON until the brake is released, even if the commanded current value meets or exceeds
the expected current.

1GM board
Servo CPU I/V
converter

Current
feedback

1KB/1RB Board

Current U, V, W
sensor earth
IPM Motors

Power block Robot

Controller

Main causes:
1. Motor power line U, V, and/or W phase are disconnected.
2. Improper power harness line connection.
3. Defective power block

⇒ Check the power line wiring and repair or replace as necessary.

⇒ Replace the power block.
_____________________________________________________________________

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ERROR CODE D1505 Motor harness disconnected or amplifier over heat. (%X)

Motor thermal circuit is open due to motor overheat or harness problem. Not all robot
models utilize thermal switches in the motors. Some robot models may have multiple
thermal switches connected in series (see diagram below). The FS03/06/10/20 robot
models have the thermal switch mounted near JT1 motor. The FS03 model is calibrated
to 55° C and FS06/10/20 models are calibrated to 65° C

Upper arm

Thermal switch

Interface Rotor trunk

Thermal line
CPU (TH)
Photo coupler Thermal switch

Servo
CPU
Robot

Gate Array

1KB/1RB board 1KQ/1NR board

Controller

Main causes include:

1. Disconnected thermal line.
2. Defective connection in the separation harness.
3. Defective 1KB/1RB servo board.
4. Defective 1KQ/1NR board.
5. When the motor thermal switch is used:
– The robot rated weight capacity is exceeded.
– The ambient temperature exceeds limits for use.
– Excessive execution of abrupt high speed direction changes.
– Defective controller cooling fan or cooling air purge system.
– Servo system holding the robot arm in high load position for extended periods.
– Defective thermal switch.

⇒ When the thermal switch opens, error cannot be reset until cooling is complete.
⇒ Confirm continuity of thermal line.
⇒ Replace the harness or the 1KB/1RB servo board as necessary.
⇒ Replace the 1KQ/1NR board.
⇒ Use the auto servo off function, AUX 0808, to prevent the servo system holding a high
load arm position for extended periods.
_____________________________________________________________________

July 31, 2007 1-33

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ERROR CODE D1506 Power module error Jt%-M.

An error signal from the IPM module in the power block is detected by the 1KB/1RB
board.

Motor Robot

Interface
CPU
PWM signal

Servo
CPU IPM error signal
HIC IPM

Gate Array

1KB/1RB board Power block

Controller

Main causes include:

1. U, V, and W phase short-circuited or short-circuited to ground wire.
2. Payload weight exceeds rating.
3. Defective cooling fan in the power block.
4. Ambient temperature above normal operating limits.
5. Constant execution of abrupt high speed direction changes.
6. Defective 1KB/1RB board.
7. Disconnected or defective harness between the 1KB/1RB board and the power
block.
8. Disconnection or poor connection in the thermal line at the separate harness and/or
controller harness.
9. Defective thermal switch in the controller or servo motors (if used).
10. Defective power block.

⇒ Check and repair cause of U, V, and W phase short-circuited or short-circuited to

ground wire.
⇒ Ensure payload does not exceed rating.
⇒ Reduce ambient temperature.
⇒ Ensure cooling fans are in proper working condition.
⇒ Correct abrupt high speed direction changes in the robot program.
⇒ Replace the 1KB/1RB board.
⇒ Repair or replace the harness between the 1KB/1RB board and the power block.
⇒ Check the thermal line in the separate harness and controller harness, and repair or
replace as necessary.
⇒ Replace the power block.
_____________________________________________________________________
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ERROR CODE D1507 AC primary power OFF.

This error occurs when there is an instantaneous decrease in the external power to the
AVR for controller power supply (130–145 VAC or less for 20–30 msec).

Main Circuit Controller

External disconnect breaker power AVR for
power 210 VAC controller
F1 T1 F3 power
Transformer REMOTE
AC error
signal
1KQ/1NQ board

AVR
output
cut

EPLD

Mother Board
Local 1KP board
bus

1KX board 1KB/1RB board

Main causes include:

1. The external power is below the specified rating, or an instantaneous power decrease
occurred.
2. The non-fuseable breaker (NFB) F1 for the control power supply is turned OFF or
tripped due to a short-circuit.
3. An instantaneous decrease in the 210 VAC supply to AVR for the control power sup-
ply.
4. Circuit breaker F3 is OFF or tripped due to a short circuit.
5. Defective AVR.
6. Defect in the external power supply.
7. Defective 1KP board.
8. Defective 1KQ/1NQ board.

⇒ It is normal for this error to occur when NFB F1 is set OFF and back ON.
⇒ Check power supply circuit through NFB F1 and repair as necessary.
⇒ Check power supply circuit to the AVR through the circuit breaker F3 and repair as
necessary.
⇒ Confirm that external power is supplied according to specifications.
⇒ Replace the 1KP board.
⇒ Replace the 1KQ/1NQ board.
⇒ Replace the AVR.
_____________________________________________________________________

July 31, 2007 1-35

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ERROR CODE D1508 24VDC power source is too low.

24 VDC to the power sequence board has dropped to +21.6 VDC or less.

Main Circuit Controller

power AVR for
External disconnect breaker
power 210 VAC controller
F1 T1 F3 power
Transformer

1KQ/1NQ board

24 VDC
monitor

EPLD
DC error
signal
Mother Board
Local 1KP board
bus

1KX board 1KB/1RB board

Main causes include:

1. Defective AVR for control power supply.
2. Defective 1KP board.
3. Defective 1KQ/1NQ board.
4. Short circuit in the motor power on circuitry, the EMERGENCY STOP switch, or axis
restriction limit switch circuits.
5. Short in machine valve and sensor circuits.

⇒ Check the power supply, machine valve, and the sensor circuits for short circuits.
⇒ Ensure the 24 VDC load does not exceed the power supply capacity.
⇒ Check the AVR, the 1KP power sequence board, and the 1KQ/1NQ relay board and
replace as necessary.
_____________________________________________________________________

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ERROR CODE D1509 Primary power source is too high.

Voltage level of the AVR for the controller power supply is too high (267-277 VAC or
more for 1-2 sec.).

Main Circuit Controller

External breaker power AVR for
disconnect
power 210 VAC controller
F1 T1 F3 power
REMOTE
Transformer AC error
signal
1KQ/1NQ board

AVR
output
cut

EPLD

Mother Board
Local 1KP board
bus

1KX board

Main causes include:

1. Primary power exceeds the specified rating.
2. Defective AVR.
3. Defective 1KP power sequence board.
4. Defective 1KQ/1NQ relay board.
5. Power supply circuit problem.

⇒ Ensure the power supply to the controller is within ratings.

⇒ Check power supply circuit to the AVR.
⇒ Confirm the supply power is within specifications.
⇒ Replace the 1KP board.
⇒ Replace the 1KQ/1NQ board.
⇒ Replace the AVR.
_____________________________________________________________________

July 31, 2007 1-37

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ERROR CODE D1510 Primary power source is too low.

Voltage level of the AVR primary power supply is too low (150-158 VAC or less for 1-2
sec.).

Main Circuit Controller

External power AVR for
disconnect breaker
power 210 VAC controller
F1 T1 F3 power
Transformer AC error
signal
1KQ/1NQ board

EPLD

Mother Board
Local 1KP board
bus

1KX board 1KB/1RB board

Main causes include:

1. Drop in the external power supply voltage.
2. Defective AVR.
3. Defective NFB F1.
4. Defective 1KP power sequence board.
5. Defective 1KQ/1NQ relay board.
6. Power supply circuit problem.

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

⇒ Check the AVR and NFB F1 and replace as necessary.
⇒ Confirm supply power is within specifications.
⇒ Replace the 1KP board.
⇒ Replace the 1KQ/1NQ board.
_____________________________________________________________________

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ERROR CODE D1511 +12VDC or -12VDC is abnormal.

+/-12 VDC supplied to the 1KA/1RA board is out of specifications.

+12 VDC: +10.75 VDC or less.
-12 VDC: -10.4 VDC or more.

Main causes include:

1. Defective AVR.
2. Defective 1KA/1RA, 1KB/1RB, or 1KP board.
3. Power supply contacts in the motherboard are damaged.
5. Defective power block.
6. Defective 1FG/1HG board.
7. Short in the harness between the servo unit and the 1FG board.
8. Short in the optional circuit boards, i.e., vision, etc.
9. Insufficient DC power supply capacity to support optional boards.

⇒ Adjust the AVR output voltage.

⇒ Replace the AVR and each board for the controller power supply.
⇒ Check for short circuits in the operation panel and separation harness and replace as
necessary.
_____________________________________________________________________

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ERROR CODE D1512 Brake line error for Jt%-M.

This error occurs when the 1KB/1RB board detects an error signal sent from the brake
release control MOSFET on the 1KQ/1NR board.

Motor Robot
Controller

1KP board Brake power supply D7X

Brake power supply D3X
+24 VDC

Motor brake line

Transformer Circuit breaker

Safety circuit

Brake power supply error signal Voltage

monitoring
Brake release signal
Brake line error signal MOSFET

1KB/1RB board 1KQ/1NR board

Brake line errors are not detected during motor power OFF. Brake line disconnection is
not detected during automatic operation. Brake line error detection timing is shown in
the diagram below.

ON

Motor power
START

Servo control
RELEASE

Brake release

Disconnection Short-circuit
detected detected

Main causes include:

1. Disconnection/short-circuit/ground fault/poor connection at the brake line axis motor
harness.
2. Defective connection for the brake power line.
3. Defective connection or harness between the 1KB/1RB and 1KQ/1NR boards.
4. Defective connection or harness between the 1KB/1RB and 1KX/1NX boards.
5. Defective connection or harness between the 1NR and 1NX boards.
6. Incorrect 1KP board safety circuit setting.
7. Defective 1KB/1RB or 1KQ/1NR board.

⇒ Check for disconnection or short-circuit in the motor harness, and repair or replace as

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necessary.
⇒ Check and repair brake power line and connections as necessary.
⇒ Check and repair connections between 1KB/1RB and 1KQ/1NR, 1KB/1RB and 1KX/
1NX, and 1NR and 1NX as necessary.
⇒ Ensure the 1KB/1RB board is properly seated in the card rack.
⇒ Ensure the 1KP board safety circuit setting is correct.
⇒ Replace the 1KB/1RB and or the 1KQ/1NR.
_____________________________________________________________________

ERROR CODE D1513 Brake power is abnormal. (%X)

This error occurs when the 1KB/1RB board detects an error signal sent from the brake
power supply, voltage monitoring circuit, on the 1KQ/1NR board.

Motor Robot
Controller

1KP board Brake power supply D7X

Brake power supply D3X
+24 VDC

Motor brake line

Transformer Circuit breaker

Safety circuit

Brake power supply error signal Voltage

monitoring
Brake release signal
Brake line error signal MOSFET

1KB/1RB board 1KQ/1NR board

Main causes include:

1. Defective transformer winding for brake power supply.
2. Short or open in wiring from transformer to brake power supply circuit.
3. Disconnected or defective harness between the 1KB/1RB board and the 1KQ/1NR
board.
4. 1KB/1RB board not properly seated in the 1KX/1NX board.
5. 1NR board not properly seated in the 1NX board.
6. Defective circuit breaker F4 or F4 tripped.
7. Defective MC unit (1KQ board).
8. Defective 1NR board.

⇒ Check transformer winding and wiring and repair or replace as necessary.

⇒ Repair or replace harness between the 1KB/1RB and 1KQ/1NR board.
⇒ Ensure the 1NR and or the 1KB/1RB boards are properly seated in the 1KX/1NX
board.
⇒ Replace MC unit.
⇒ Reset or replace circuit protector F4 as necessary.
⇒ Replace the 1KB/1RB and or 1KQ/1NR boards as necessary.
_____________________________________________________________________
July 31, 2007 1-41
 D SERIES CONTROLLER
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ERROR CODE D1514 I/O 24V fuse is open.

Fuse F2 on the 1KP board is open.

Main causes include:

1. Solenoid valve or diode polarity reversed.
2. Current load on the 24 VDC I/O circuit exceeds rating.
3. Short-circuit or ground fault in the 24 VDC I/O harness.
4. Defective 1KP board.

⇒ Check components for proper polarity and repair as necessary.

⇒ Ensure the load on the 24 VDC I/O circuit is within rating.
⇒ Check the I/O harness and replace as necessary.
⇒ Replace fuse F2 on the 1KP board (after cheching for short-circuit).
⇒ If the above steps do not correct the problem, replace the 1KP board.
_____________________________________________________________________

ERROR CODE D1515 Mismatch in setting of safety circuit as single/double.

Main causes include:

1. Safety circuit setting between the software and hardware do not match.
2. Defective 1KP board.

⇒ Set SW-2 on the 1KP board to ON for a double circuit or OFF for a single circuit.
⇒ In AUX 2021-2 set [2 Line] ON or [1 Line] OFF.
⇒ Replace 1KP board.
_____________________________________________________________________

ERROR CODE D1516 Mismatch betw hard/software settings for HOLD backup
time.

Main causes include:

1. The setting that specifies a two second delay before motor power is set OFF when
the RUN/HOLD switch is switched from RUN to HOLD, is not matched between the
software and hardware.
2. Defective 1KP board.

⇒ Set SW-1 on the 1KP board to ON for two second delay or OFF no delay.
⇒ In AUX 2021-2 set the delay parameter to [standard] (delay) or [Off] (no delay).
⇒ Replace 1KP board.
_____________________________________________________________________

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ERROR CODE D1517 Blown fuse on safety circuit emergency line.

Fuse F1 on the 1KP board is open.

Main causes include:

1. Incorrect wiring in the emergency line (wiring harness, emergency stop, safety fence,
external trigger, teach pendant, limit switches).
2. Short-circuit in the emergency line (wiring harness, emergency stop, safety fence,
external trigger, teach pendant, limit switches).
3. Defective 1KP board.

⇒ Check wiring and components in the safety circuit emergency line and repair/replace
as necessary.
⇒ Replace 1KP board.
⇒ Ensure the controller power is set OFF, when wiring safety circuits. The fuse F1 will
blow if wiring is shorted.
_____________________________________________________________________

ERROR CODE D1518 Mismatch in the Emer. Stop condition safety circuit.

Main causes include:

1. When the system is set for double safety circuits, and the circuits at the operation
panel, teach pendant, and/or the external emergency stop switch are wired as single
circuits.
2. Disconnection or ground fault in the emergency stop circuit.
3. Defective 1KP board.

⇒ With the E-STOP switch(es) engaged, check wiring harness and switches in the
circuit and repair or replace as necessary.
⇒ Ensure all contacts in the external emergency stop circuit are wired correctly (double
circuits).
⇒ If the above steps do not correct the problem, replace the 1KP board.
_____________________________________________________________________

August 9, 2005 1-43

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ERROR CODE D1519 Mismatch of the safety circuit LS condition.

In a double safety circuit system, conditions set for contacts in the limit switch (LS) circuit
do not match.

Main causes include:

1. Defective harness connection or harness (short-circuit or ground fault in harness).
2. Defective LS override switch.
3. Defective 1KP board

⇒ Replace the controller/separate/machine harness(es).

⇒ Replace the LS override switch.
⇒ Replace the 1KP board.
_____________________________________________________________________

ERROR CODE D1520 Mismatch of the safety circuit TEACH/REPEAT condition.

Main causes include:

1. TEACH/REPEAT switch setting and relay conditions for switching teach/repeat modes
do not match.
2. Contact condition at the TEACH/REPEAT switch does not match between the first and
second safety circuits.
3. Defective 1KP board.

⇒ Check the TEACH/REPEAT switch and relays (RY5 and RY6 on the 1KP board), and
replace as necessary.
⇒ Replace the 1KP board.
_____________________________________________________________________

ERROR CODE D1521 Mismatch in safety circuit safety-fence condition.

In a double safety circuit system, conditions set for contact at the safety fence circuit do
not match.

Main causes include:

1. Incorrect circuit or wiring for safety fence circuit (single circuit wired).
2. Disconnection or ground fault in the safety fence circuit wiring.
3. Defective safety fence switch.
4. Defective 1KP board.

⇒ Inspect contact points at the safety fence circuit and repair or replace as necessary.
⇒ Replace the 1KP board.
_____________________________________________________________________

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ERROR CODE D1522 Mismatch in cond. of safety circuit enabling device.

In a double safety circuit system, conditions set for contacts at the TRIGGER switch
circuit do not match.
NOTE
If the trigger switch is not pressed firmly, only one con-
tact may engage resulting in this error. The trigger
switch has three positions and pressing too firmly may
disengage the trigger circuit.

⇒ Replace the teach pendant, teach pendant harness or controller harness to the teach
pendant connector.
⇒ Replace the 1KP board.
_____________________________________________________________________

ERROR CODE D1523 Mismatch in cond. of safety circuit enabling device.

In a double safety circuit system, conditions set for contacts at the EXTERNAL TRIG-
GER switch circuit do not match.

⇒ Inspect contacts on the EXT.TRIGGER switch and replace as necessary.

⇒ Check for disconnection or short-circuit in external trigger wiring and repair as neces-
sary.
⇒ Replace the 1KP board.
_____________________________________________________________________

ERROR CODE D1524 Incorrect operation of the safety relay.

Safety relay on the 1KQ board did not operate correctly.

Main causes include:

1. Defective controller harness.
2. Defective 1KQ board
3. Defective MC unit.
4. Defective 1KP board.

⇒ Replace controller harness.

⇒ Replace the 1KQ board.
⇒ Replace the MC unit.
⇒ Replace the 1KP board.
_____________________________________________________________________

August 9, 2005 1-45

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ERROR CODE D1525 Incorrect operation of MC(K1).

Main causes include:

1. Defective controller harness.
2. Defective magnetic contactor K1.
3. Defective MC unit (1KQ/1NQ board).
4. Defective 1KP board.

⇒ Replace controller harness.

⇒ Replace magnetic contactor K1.
⇒ Replace MC unit (1KQ/1NQ board).
⇒ Replace 1KP board.
_____________________________________________________________________

ERROR CODE D1526 Incorrect operation of MC(K2).

Main causes include:

1. Defective controller harness.
2. Defective magnetic contactor K2.
3. Defective MC unit (1KQ/1NQ board).
4. Defective 1KP board.

⇒ Replace controller harness.

⇒ Replace magnetic contactor K2.
⇒ Replace MC unit (1KQ/1NQ board).
⇒ Replace 1KP board.
_____________________________________________________________________

ERROR CODE D1527 Incorrect operation of MC(K3).

Main causes include:

1. Defective controller harness.
2. Defective magnetic contactor K3.
3. Defective MC unit (1KQ/1NQ board).
4. Defective 1KP board.

⇒ Replace controller harness.

⇒ Replace magnetic contactor K3.
⇒ Replace MC unit (1KQ/1NQ board).
⇒ Replace 1KP board.
_____________________________________________________________________

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ERROR CODE D1528 Controller temperature is out of range.

Temperature inside the controller exceeds specification.

Main causes include:

1. Defective cooling fan(s). For D7X controller, defective heat exchange fan on the left
side of the controller.
2. Ambient temperature above specified rating.
3. Defective 1KP board.

⇒ Inspect cooling fans for proper operation and replace fans and/or fan harness(es) as
necessary.
⇒ Ensure air inlet filter is not restricted.
⇒ Lower ambient temperature within specifications.
⇒ Replace the 1KP board.
_____________________________________________________________________

ERROR CODE D1529 Signal harness is disconnected or encoder power error.

This error is caused when a communication error occurs for all axes.

Main causes include:

1. Separate harness disconnected or poor connection.
2. Abnormality in encoder power supply.
3. Low battery voltage on the encoder battery board (1FG/1HG).
4. Defective encoder battery board (1FG/1HG).

⇒ Ensure proper connections at the separate harness.

⇒ Ensure proper encoder power is supplied.
⇒ Replace batteries on the encoder battery board (1FG/1HG).
⇒ Replace the encoder battery board (1FG/1HG).
_____________________________________________________________________

ERROR CODE D1530 Abnormal current limit of Jt%-M.

Main causes include:

1. Ground fault in the motor power line U/V/W.
2. Unavailable program data.

⇒ Check motor power line and replace as necessary.

⇒ Modify program data.
_____________________________________________________________________

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ERROR CODE D1531 Heat sink on power block overheated.

Main causes include:

1. Temperature inside the controller above specification because of air inlet or outlet
blockage.
2. Defective cooling fan.
3. Defective power block.

⇒ Ensure air inlet and outlet ports are clear.

⇒ Ensure cooling fans are in proper working order.
⇒ Replace the power block.
_____________________________________________________________________

ERROR CODE D2000 No response from Comm. board for laser sensor.

Laser sensor communication board program stopped.

⇒ Set robot controller and laser sensor power OFF. Set laser sensor power ON then set
robot controller power ON.
_____________________________________________________________________

ERROR CODE D2001 RI/O or C-NET board initialize error.

Initial data processing between the 1KA/1RA and 1FS/1HS boards is not correctly com-
pleted at controller power-up.

Main causes include:

1. Defective 1KA/1RA board.
2. Defective 1FS/1HS board.
3. Noise related malfunction.

⇒ Ensure the 1KA/1RA and 1FS/1HS boards are properly seated into the 1KX/1NX
board.
⇒ Ensure harnesses are properly connected at the 1KA/1RA and 1FS/1HS boards.
⇒ Check for noise malfunction and shield integrity.
⇒ Replace the 1KA/1RA board.
⇒ Replace the 1FS/1HS board.
_____________________________________________________________________

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ERROR CODE D2002 No response from the arm ID board.

Main causes include.

1. Defective 1KB/1RB board.
2. Defective 1KP board.
3. Defective 1GV arm ID board.
4. Defective harness.
5. Noise related malfunction.

⇒ Replace 1KB/1RB board.

⇒ Replace 1KP board.
⇒ Replace 1GV board.
⇒ Replace harness.
⇒ Check for noise malfunction and shield integrity.
_____________________________________________________________________

ERROR CODE D2003 No data in the arm ID board.

This error occurs when data is not present in the arm ID board (1GV) memory. This
error cannot be reset.

⇒ Execute the ZROBOT.ZZERO instruction and transfer the data to the arm ID board
(1GV).
⇒ Replace the arm ID board (1GV).
_____________________________________________________________________

ERROR CODE D2004 Mismatch data in the arm ID board.

This error occurs when robot data, other than the serial number, is different between the
arm ID board (1GV) and in the processor board (1KA/1RA). This error cannot be reset.

⇒ Robot data in the controller 1KA/1RA board and robot data in the arm ID 1GV board
do not match, confirm correct data is used.
⇒ Execute the ZBLTARM_ALLSET instruction and transfer the data from the controller
1KA/1RA board to the arm ID 1GV board.
_____________________________________________________________________

ERROR CODE D2005 CC-LINK software version mismatch.

Software versions installed in the 1HS board and AS software are incompatible.

⇒ Check 1HS board and AS software versions and reload software as necessary.
_____________________________________________________________________

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ERROR CODE D2006 Watch dog error on communication board for Explosion
proof TP.

This error occurs when the CPU on the communication board (1GS board) for the explo-
sion-proof teach pendant is suspended.

Main causes include:

1. Defective communication board (1GS board).
2. Defective main CPU board (1KA/1RA board).

⇒ Replace defective 1GS board.

⇒ Replace defective 1KA/1RA board.
_____________________________________________________________________

ERROR CODE D2007 No response from the built-in sequence board.

This error occurs when the built-in PLC is in an error condition or the program mode.

⇒ Cycle the controller power OFF and ON after the cause of the built-in PLC error is
corrected.
⇒ Set the built-in PLC to the operating mode.
_____________________________________________________________________

ERROR CODE D2008 Magnet is Contactor of group %d is stuck.

This error occurs when a communication error exists between the arm ID board interface
board (1KP) and the arm ID board (1GV) (abnormal ROM, RAM, DPRAM, etc.).

⇒ Replace the arm ID board (1GV).

⇒ Replace the arm ID interface board (1KP).
⇒ Check and repair or replace harnesses and connections as necessary.
_____________________________________________________________________

ERROR CODE D2010 Sync. error between user I/F and arm control board.

1KA/1RA and 1KB/1RB board synchronization failed for 1 second or more.

⇒ Replace 1KA/1RA board.

⇒ Replace 1KB/1RB board.
_____________________________________________________________________

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ERROR CODE D2011 Parameter download error between user I/F & arm ctrl
boards.

1KA/1RA and 1KB/1RB boards parameter exchange cannot be downloaded.

⇒ Replace the 1KA/1RA board.

⇒ Replace the 1KB/1RB board.
_____________________________________________________________________

ERROR CODE D2012 SOFT ABSORBER error. Turn OFF & ON the control
power.
(Software absorber function)

Main causes include:

1. Abnormality during soft absorber sequence.
2. 1KB/1RB board upload/download is requested, but not executed.

⇒ Cycle controller power OFF and ON.

⇒ Replace the 1KB/1RB board.
⇒ If the error recurs, contact KRI Customer Service.
_____________________________________________________________________

ERROR CODE D2013 CHANGE GAIN Error. Turn OFF & ON the control power.
(Change gain function)

Main causes include:

1. Abnormality during change gain sequence.
2. 1KB/1RB board upload/download is requested, but not executed.

⇒ Cycle the controller power OFF and ON.

_____________________________________________________________________

ERROR CODE D2014 Robot network initialize error.

This error occurs when initialization of the Ethernet board is not successful during
power-up.

Main causes include:

1. 1KA/1RA board components do not correspond to Ethernet option.
2. Ethernet MAC address is not set.
3. Defective 1KA/1RA board.

⇒ Install the appropriate 1KA/1RA board and optional 1KN/1QN Ethernet board and set
the MAC address.
_____________________________________________________________________

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ERROR CODE D2016 No response from the arm control board.

Request is sent to the 1KB/1RB board from the 1KA/1RA board and there is no
response.

⇒ Reset error and if error recurs, replace the 1KA/1RA or 1KB/1RB boards.
_____________________________________________________________________

ERROR CODE D2017 No response from User I/F board.

1KA/1RA board software stopped.

Main causes include:

1. AS software is not installed correctly or is corrupt.
2. Defective 1KA/1RA board.

⇒ Reinstall correct AS software.

⇒ Replace 1KA/1RA board.
_____________________________________________________________________

ERROR CODE D2018 [ARM CTRL BOARD] no response.

1KB/1RB board software stopped.

Main causes include:

1. AS software is not installed correctly or is corrupt.
2. Defective 1KB/1RB board.

⇒ Reinstall correct AS software.

⇒ Replace 1KB/1RB board.
_____________________________________________________________________

ERROR CODE D2019 [ARM CTRL BOARD] servo software no response.

1KB/1RB board software stopped.

Main causes include:

1. Servo software is not installed correctly or is corrupt.
2. Defective 1KB/1RB board.

⇒ Reinstall correct 1KB/1RB board servo software to the 1KA/1RA board.

⇒ Replace 1KB/1RB board.
_____________________________________________________________________

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ERROR CODE D2020 [ARM CTRL BOARD] servo control software no response.

1KB/1RB board software stopped.

Main causes include:

1. Servo software is not installed correctly or is corrupt.
2. Defective 1KB/1RB board.

⇒ Reinstall correct 1KB/1RB board servo software to the 1KA/1RA board.

⇒ Replace 1KB/1RB board.
_____________________________________________________________________

ERROR CODE D2021 Arm data file is not found.

When robot model is selected, data file corresponding to the installed arm is not found in
the system file.

⇒ Contact KRI customer service (include operating conditions/settings at the time the
error occurred).
_____________________________________________________________________

ERROR CODE D2022 Arm data is not found.

When robot model is selected, the arm data in the arm data file did not match the se-
lected robot.

⇒ Ensure the correct model setting is used.

⇒ Ensure the correct software version is installed.
_____________________________________________________________________

ERROR CODE D2023 Failed to load arm data.

When robot model is selected, the arm data file for the selected robot model is incom-
patible with the AS software.

⇒ Ensure the correct model setting is used.

⇒ Ensure the correct software version is installed.
_____________________________________________________________________

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ERROR CODE D2024 [ARM CTRL BOARD] robot type setting failed.

System software is not compatible with the robot model set in the AS software.

⇒ Ensure the correct model setting is used.

⇒ Ensure the correct software version is installed.
_____________________________________________________________________

ERROR CODE D2025 Robot codes set in software and Arm ctrl board do not
match.

Robot model hardware and software settings do not match.

⇒ Ensure 1KB/1RB board dip switch S2 setting is correct.

⇒ Use AUX 0804 or AS Language ID monitor command to ensure correct software
version is installed.
_____________________________________________________________________

ERROR CODE D2026 Code set in software & curr. sensor I/F b’d do not match.

1GM daughter board on the 1KB/1RB board does not match hardware or software
settings.

⇒ Ensure correct 1GM board is installed.

⇒ Ensure 1KB/1RB board dip switch S2 setting is correct.
⇒ Use AUX 0804 or AS Language ID monitor command to ensure correct software
version is installed.
_____________________________________________________________________

ERROR CODE D2027 Codes set in software and power block do not match.

Power block settings and hardware or software settings do not match.

⇒ Ensure correct power block is installed.

⇒ Ensure power block jumper settings are correct.
⇒ Use AUX 0804 or AS Language ID monitor command to ensure correct software
version is installed.
_____________________________________________________________________

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ERROR CODE D2028 (SSCNET) initialization error. (code 0x%4x).

The Mitsubishi single axis amplifier failed to initialize at controller power-up. A 2 byte
code follows the error message. The higher byte indicates axis number and the lower
byte indices the error code.

Higher byte:
0: system error.
Any other number: axis number that caused error.

Lower byte:
1: 1LP daughter board not installed to 1KB/1RB board.
3: Mitsubishi amplifier/motor not connected to the specified axis.
2, 4, 5: Other problems.

⇒ Lower byte 1: install 1LP board.

⇒ Lower byte 3: connect amplifier or motor.
⇒ Lower byte 2, 4, 5: replace the 1LP board, amplifier or motor.
_____________________________________________________________________

ERROR CODE D2029 Motor codes in software & Arm control b’d mismatch. (Jt-A)

Software and hardware motor code settings, of axis assigned to channel 7 (seventh
axis), do not match.

⇒ Ensure 1KB/1RB board dip switch S8 setting is correct.

⇒ Ensure correct AS and servo software are installed.
_____________________________________________________________________

ERROR CODE D2030 Codes set in software and curr. sensor I/F b’d mismatch.
(Jt-A)

Software and hardware settings, for the axis assigned to channel 7 (seventh axis), do
not match 1KV board settings.

⇒ Ensure 1KB/1RB board dip switch S8 setting is correct.

⇒ Ensure correct AS and servo software are installed.
_____________________________________________________________________

July 31, 2007 1-55

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ERROR CODE D2031 Codes set in software and on add’l pwr block mismatch.
(Jt-A)

Software and hardware settings, for the axis assigned to channel 7 (seventh axis), do
not match power block settings.

⇒ Ensure correct power block is installed.

⇒ Ensure power block jumper settings are correct.
⇒ Use AUX 0804 or AS Language ID monitor command to ensure correct software
version is installed.
_____________________________________________________________________

ERROR CODE D2032 Motor codes set in software and Arm ctrl b’d. (Jt-B)

Software and hardware motor code settings, for the axis assigned to channel 8 (eight
axis), do not match.

⇒ Ensure 1KB/1RB board dip switch S8 setting is correct.

⇒ Ensure correct AS and servo software are installed.
_____________________________________________________________________

ERROR CODE D2033 Codes set in software & curr. sensor I/F b’d mismatch.
(Jt-B)

Software and hardware settings for the axis assigned to channel 8 (eight axis) do not
match 1KV board settings.

⇒ Ensure 1KB/1RB board dip switch S8 setting is correct.

⇒ Ensure correct AS and servo software are installed.
_____________________________________________________________________

ERROR CODE D2034 Codes set in software and on add’l pwr block mismatch.
(Jt-B)

Software and hardware settings for the axis assigned to channel 8 (eight axis) do not
match power block settings.

⇒ Ensure power block jumper settings are correct.

⇒ Ensure correct AS and servo software are installed.
_____________________________________________________________________

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ERROR CODE D2035 Program execution error.

Program failed to start when cycle start command was issued.

⇒ Reset the error, and restart the program.

⇒ If the error recurs, contact KRI Customer Service.
_____________________________________________________________________

ERROR CODE D2036 (SSCNET) system error occurred in 1LP I/F board. (code
%4X)

Main causes include:

1. Defective 1LP board (1KB daughter board)
2. 5 VDC power supply voltage dropped to 4.5 VDC or less.

⇒ Replace 1LP board.

⇒ Adjust 5 VDC power supply to specifications then cycle controller power OFF and ON.
_____________________________________________________________________

ERROR CODE D4500 Fieldbus interface board is not detected.

The I/F board specified in AUX 0608-2 is not installed.

⇒ Set controller power OFF and install the specified I/F board.
⇒ If specified I/F board is installed, verify proper installation.
⇒ Ensure settings in AUX 0608-2 are correct.
⇒ Ensure I/F board LED indicator displays proper operation.
⇒ Ensure 1JF board jumper settings are correct.
_____________________________________________________________________

ERROR CODE D4501 ABMA-PDP) I/F module error. %s %08X

Improperly installed or defective ABMA-PDP module

⇒ Check error code.

⇒ Ensure 1JF board and I/F board are properly installed and cycle controller power OFF
and ON.
⇒ If error recurs, check LED1 on the I/F card.
If the LED is ON, execute configuration.
If the LED is OFF, contact I/F card manufacturer.
_____________________________________________________________________

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ERROR CODE D4502 FIELD-BUS-INIT) Error Reply. %x

At fieldbus start-up, a mismatch in length of I/O data with the node at the end of the
connection is detected when a message is sent to the fieldbus I/F card, or maximum
I/O data length is exceeded.

⇒ Check the I/F card LED display. Match the I/O data length with the master.
⇒ Ensure I/O data length is within length specified for the fieldbus I/F card.
⇒ Cycle controller power OFF and ON.
⇒ Replace fieldbus cable.
⇒ If this error recurs, contact KRI Customer Service (include sub-code %x).
_____________________________________________________________________

ERROR CODE D4503 FIELD-BUS-INIT) Reply timeout. %x

At fieldbus start-up, no response is detected due to defective hardware or incorrect

settings during I/F board initialization.

⇒ Check the I/F card LED display.

⇒ Ensure the master and slave I/O data length match.
⇒ Cycle controller power OFF and ON.
⇒ Replace the fieldbus cable.
⇒ If this error recurs, contact KRI Customer Service (include sub-code %x).
_____________________________________________________________________

ERROR CODE D4504 ANYBUS) OUT/FB.CTRL request timeout. %x

Reading input signal area access is requested but denied due to hardware problem.

⇒ Check the I/F card LED display and reset the error.
⇒ If this error cannot be reset, contact KRI Customer Service (include sub-code %x).
_____________________________________________________________________

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1.3.2.2 EXXXX NON-FATAL ERROR CODES

ERROR CODE E0001 Unknown error.

Unregistered error occurred.

⇒ Contact KRI customer service (include operating conditions/settings and operation log
at the time the error occurred).
_____________________________________________________________________

ERROR CODE E0100 Abnormal comment statement exists.

Statements containing incorrect AS Language syntax can be included in a program as

comments. If the comment is not preceded with a semicolon (;) the step is executed as
a step and an error is generated.

⇒ Correct program comment syntax (add preceding semicolon).

⇒ Delete incorrect program step.
_____________________________________________________________________

ERROR CODE E0101 Nonexistent label.

Occurs when executing a GOTO command and the destination label is not defined.
Example: “IF x>0 GOTO 10” is specified, but the label “10” is not included in a program
step an error is generated.

⇒ Ensure valid labels are used within the program.

⇒ Delete the reference to the nonexistent label.
_____________________________________________________________________

ERROR CODE E0102 Variable is not defined.

Main causes include:

1. Variable data for a specific command/instruction is not defined.
Example: “x=SIN(y)” is specified and “y” is not defined.

2. Command/instruction contains incorrect AS Language syntax.

Example: “PCEND pcprog1” should be “PCEND 1”.

⇒ Ensure variables are properly defined.

⇒ Ensure correct AS Language command/instruction syntax is used.
_____________________________________________________________________

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ERROR CODE E0103 Location data is not defined.

Main causes include:

1. The location variable for the BASE, TOOL or POINT command is not specified.
Example: “TOOL a” is specified and “a” is not defined.

2. DEST or #DEST function is used and the destination data is not defined.

⇒ Ensure all locations used in programs and functions are defined.

_____________________________________________________________________

ERROR CODE E0104 String variable is not defined.

String variables evaluated by ASC and LEN functions are not defined.
Example: “ASC(“$sample”)” is specified and “$sample” is not defined.

⇒ Define the string variables to be evaluated or correct the name of the string variable
used for evaluation.
_____________________________________________________________________

ERROR CODE E0105 program or label is not defined.

The program name or label associated with an ON or ONI command does not exist.

⇒ Define the program or label used with the ON or ONI command.

_____________________________________________________________________

ERROR CODE E0106 Value is out of range.

The numeric value entered exceeds the upper or lower limits of the acceptable range.
Example: “SPEED 10000” exceeds maximum value of 100.

⇒ Enter data that is within acceptable range.

_____________________________________________________________________

ERROR CODE E0107 No array suffix.

Attempt to process an array variable with undefined suffixes, i.e., attempting to process
A=B[C,D,E], but C, D, E have no values.

⇒ Rewrite the program to define the array suffix before attempting to process the array.
_____________________________________________________________________

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ERROR CODE E0108 Divided by zero.

Occurs when the system encounters a mathematical evaluation that involves division by
“0”. Typically associated with the FRAME function and circular interpolation.

⇒ Check data source for calculations.

_____________________________________________________________________

ERROR CODE E0109 Floating point overflow.

Occurs when the system encounters 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. For more information refer to the D Series Controller AS Language
Reference Manual.
_____________________________________________________________________

ERROR CODE E0110 String too long.

Character strings associated with arithmetic or comparative operators or the LEN func-
tion are too long (255 character maximum).

⇒ Correct the character string.

_____________________________________________________________________

ERROR CODE E0111 Attempted operation with neg. exponent.

Numeric values that have exponents must be positive in value.

⇒ Correct equations in program.

_____________________________________________________________________

ERROR CODE E0112 Too complicated expression.

Encountered numeric calculation too complex to be evaluated.

⇒ Simplify mathematical equations.

_____________________________________________________________________

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ERROR CODE E0113 No expressions to evaluate.

The type of data in an argument is incompatible with the operation being performed.

⇒ Correct the program to evaluate compatible expressions.

_____________________________________________________________________

ERROR CODE E0114 SQRT parameter is negative.

In the argument of a SQRT function, a negative number is entered for evaluation.

Example: “x=SQRT(-2)” causes an error. “x=SQRT(2)” is acceptable.

⇒ Do not enter negative numbers for SQRT function evaluation.

_____________________________________________________________________

ERROR CODE E0115 Array suffix value outside range.

Occurs when the array suffix number exceeds the acceptable range from 0 to 9999.
Example: “DECOMPOSE x[10000]=a” causes an error. “DECOMPOSE x[1]=a” is ac-
ceptable.

⇒ Ensure the range of array suffixes are acceptable.

_____________________________________________________________________

ERROR CODE E0116 Faulty or missing argument value.

Displayed when the parameter specified for a command or an instruction is illegal.

Example: “TOOL 2112” (after the TOOL command a defined transformation location or
null is expected, 2112 causes an error).

⇒ Use correct argument values.

_____________________________________________________________________

ERROR CODE E0117 Incorrect joint number.

The joint number entered does not exist or is in the wrong format.

⇒ Retype the command using the correct joint number and format.
_____________________________________________________________________

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ERROR CODE E0118 Too many subroutine calls.

Occurs when more than 20 subroutines are nested with EXTCALL or CALL instructions.

⇒ Do not exceed 20 nested subroutines.

_____________________________________________________________________

ERROR CODE E0119 Nonexistent subroutine.

Displayed when the program specified by a CALL, ON, or ONI instruction does not exist.

⇒ Select only existing programs to be run as subroutines.

_____________________________________________________________________

ERROR CODE E0903 Check sum error of system data.

The check sum of the system data of the AS software is changed when the system
information such as model number, number of axes, and option setting is downloaded.
When the error occurs in situations other than software download, the error is caused by
defective memory battery back-up, defective 1KA board, or memory error from noise.

⇒ Use AUX 0803 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 0803 to clear
the error.
⇒ Check the memory backup battery. Replace if necessary.
⇒ Replace the 1KA board if the error recurs.

NOTE
A robot data sheet is supplied with each robot. The ro-
bot data sheet contains a list of factory settings and can
be used to reenter orignal factory settings. If system
data or options change the robot data sheet should be
updated to provide correct robot information when
needed.

_____________________________________________________________________

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ERROR CODE E1000 ADC channel error.

This error occurs when an A/D converter channel number other than 1–8 is used.

⇒ Ensure the correct A/D converter channel number is used (1–8).

_____________________________________________________________________

ERROR CODE E1001 ADC input range error.

This error occurs when an A/D converter input voltage is incorrect.

The correct analog input voltage ranges are:

1. 0– +10 V
2. ±5 V
3. ±10 V

⇒ Ensure the correct analog input voltage range is used.

_____________________________________________________________________

ERROR CODE E1002 PLC interface error.

This error occurs when signal communication is not available between the 1KA/1RA
board and the PC3JB board (TOYOPUC PLC).
NOTE
When this error occurs, set motor power to OFF to pre-
vent external signal input.

⇒ Replace PC3JB (TOYOPUC PLC).

⇒ Replace 1KA/1RA board.
_____________________________________________________________________

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ERROR CODE E1003 Built-in PLC is not installed.

[Option: PC3JB (PLC) correspondence]

Main causes include:

1. The system checks for proper installation and operation of the PC3JB board
(TOYOPUC PLC) on power-up.
2. This error occurs if PLCSAVE or PLCLOAD is executed and the PC3JB board
(TOYOPUC PLC) is not installed.
3. This error occurs if the PC3JB board (TOYOPUC PLC) is not installed and operating
properly.

⇒ Replace PC3JB (TOYOPUC PLC).

⇒ Replace 1KA/1RA board.
_____________________________________________________________________

ERROR CODE E1004 Interbus board is not ready.

At 1JF board start-up, the board did not achieve the ready state within the required time.

⇒ Cycle controller power OFF and ON.

⇒ Ensure the 1JF board is correctly installed.
⇒ Replace the 1JF board.
_____________________________________________________________________

ERROR CODE E1005 Spin axis encoder difference error.

At controller power-up or RTSET execution, the current value is substantially different

than the calculated encoder value for the spin axis.

⇒ Perform the spin axis zeroing procedure (zeroing data is not set). Refer to the Spin
Control Function (Option) Manual for the spin axis zeroing procedure.
_____________________________________________________________________

ERROR CODE E1006 Touch panel switch is short-circuited.

This error occurs if a touch panel key is pressed or the TEACH/REPEAT switch position
is changed during controller power-up.

⇒ Do not touch any touch panel keys or change the position of the TEACH/REPEAT
switch during controller power-up.
⇒ Replace the teach pendant.
_____________________________________________________________________

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ERROR CODE E1007 Power sequence board is not installed.

The first address of the No.1 1KP power sequence board cannot be read at controller
power-up.

Main causes include:

1. The 1KP power sequence board is not installed in the correct card slot.
2. Jumper or dip switch settings of the 1KP power sequence board are incorrect.
3. Defective 1KP power sequence board.

⇒ Ensure the 1KP board DSW1 setting is configured as power sequence board No. 1
and is installed in the 1KP card rack slot. Check and replace the board if necessary.
_____________________________________________________________________

ERROR CODE E1008 No.2 power sequence board is not installed.

The first address of the No.2 1KP power sequence board cannot be read at controller
power-up.

Main causes include:

1. The 1KP power sequence board is not installed in the correct card slot.
2. Jumper or dip switch settings of the 1KP power sequence board are incorrect.
3. Defective 1KP power sequence board.

⇒ Ensure the 1KP board DSW1 setting is configured as power sequence board No. 2
and is installed in the No. 2 1KP card rack slot. Check and replace the board if neces-
sary.
_____________________________________________________________________

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ERROR CODE E1009 No. %-M I/O board is not installed.

Cannot read the first addresses of I/O boards (1GW/1HW) based on the number of
signals that have been set in AUX 0611 or with DO (output point), or DI (input point) of
the ZSIGSPEC command, at controller power-up. This error is not used when a 1FS
board is installed.

Main causes include:

1. Incorrect value set in AUX 0611 or with the ZSIGSPEC command.
2. Error in board address of I/O board (1GW/1HW).
3. Defective I/O board or I/O board not installed (1GW/1HW board, etc.).

⇒ Set the correct number of signals in AUX 0611 or with the ZSIGSPEC command. I/O
cards are typically mounted in the card rack from right to left in ascending order.
Because of VME buss communication, this is not critical. The robot can run without
I/O boards. The maximum number of signals in the software set in AUX 0611, or with
the ZIGSPEC command, is DO, DI=256, INT=512, but DO and DI are restricted by
hardware and other options.
⇒ Set board address jumpers correctly.
⇒ Replace the 1GW/1HW board.
_____________________________________________________________________

ERROR CODE E1010 Power sequence board detects error.

An error signal, not classified through the error summary, is generated by the 1KP board
and is sent to the 1KB/1RB board. This error occurs when the error signal sent from the
1KP board is not recognized by the AS software.

Main causes include:

1. The error detection function of the 1KP power sequence board does not correspond
to the error processing function of the AS software.
2. AS software is not installed correctly or is corrupt.
3. Defective 1KP power sequence board.
4. Defective 1KB/1RB board.

⇒ Ensure the correct version of AS software is installed.

⇒ Replace the 1KP power sequence board.
⇒ Replace the 1KB/1RB board.
_____________________________________________________________________

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ERROR CODE E1011 Built-in sequence board is not installed.

Installation of the built-in (Sharp) sequence board is checked at controller power-up.

⇒ Install the built-in (Sharp) sequence board.

⇒ Ensure the built-in (Sharp) sequence board is properly installed.
⇒ If the built-in (Sharp) sequence board is not used, change the settings so the control-
ler does not check for the built-in (Sharp) sequence board.
NOTE
The PC3JB board (TOYOPUC PLC) is not recognized
as a built-in sequence board.

_____________________________________________________________________

ERROR CODE E1012 RI/O board or C-NET board is not installed.

This error occurs at controller power-up and the first address of the RI/O board is not
read (1GW/1HW, 1FS etc.).
1. The RI/O or C-Net board is not installed.
2. Defective RI/O or C-Net board.

⇒ Ensure the RI/O or C-Net board is installed.

⇒ Replace the RI/O or C-Net board.
_____________________________________________________________________

ERROR CODE E1013 InterBus board is not installed.

The 1JF board is not installed.

⇒ Ensure the 1JF board is properly installed.

⇒ Replace the 1JF board.
_____________________________________________________________________

ERROR CODE E1016 No. %-M CC-LINK board is not installed.

The specified number 1HS board is not installed.

⇒ Installed the specified number 1HS board.

⇒ Ensure the specified number 1HS board is properly installed.
⇒ Replace the specified number 1HS board.
_____________________________________________________________________

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ERROR CODE E1017 PLC error. Error code is Hex. %x.

This error occurs when a PC3JB (TOYOPUC) internal error is present (program memory
check sum error, parameter setting error, etc.).

⇒ Refer to the PC3JB (TOYOPUC) manual for the code (Hex. %x).
⇒ Replace the PC3JB (TOYOPUC).
_____________________________________________________________________

ERROR CODE E1018 INTER-BUS status error.

A processing error such as cable disconnection is detected at the 1JF board during
communication.

⇒ Refer to the 1JF board manual for information for checking error state displayed by
the front LED.
⇒ Replace the 1JF board.
_____________________________________________________________________

ERROR CODE E1020 External equipment is abnormal.

An abnormality in peripheral equipment is detected by the PC3JB board (TOYOPUC).

⇒ Check PC3JB board (TOYOPUC) peripheral equipment connections.

⇒ Ensure proper installation and connection of peripheral equipment.
_____________________________________________________________________

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ERROR CODE E1021 Arm ID board error. (code %x).

Code Description
4AH Arm ID board data is not normal or is corrupt
4FH Writing error to arm ID board memor y1
C1H Communication check sum error2
C5H Communication protocol error2
C6H Communication response time-out error2
FFH Other errors (unknown error)3
1
Cannot write to arm ID board memor y. Replace arm ID board.
2
Damaged or disconnected communication cable.
3
F*H cycle controller power ON and OFF. If error does not
clear, fur ther diagnosis is needed (possible damaged arm ID
board or power sequence board).

Main causes include:

1. Defective harness.
2. Defective serial flash memory on the 1GV board.
3. Defective 1GV board.
4. Defective 1KP board.

⇒ Replace harness.
⇒ Replace serial flash memory on the 1GV board.
⇒ Replace 1GV board.
⇒ Replace 1KP board.
_____________________________________________________________________

ERROR CODE E1022 Power sequence board error. (code %x)

Main causes include:

1. Defective harness.
2. Defective 1KP board.

⇒ Replace harness.
⇒ Replace 1KP board.
_____________________________________________________________________

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ERROR CODE E1023 Communication error in robot network.

Main causes include:

1. Communication between robots is not normal during cooperative motion operation.
2. Power to one of the controllers connected to the network is not set ON.

⇒ Ensure network cables and connections are correct.

⇒ Ensure robot network settings are correct.
⇒ Ensure power for all controller connected to the network is set ON.
_____________________________________________________________________

ERROR CODE E1024 EXT.AXIS release sequence error. (code %4X)

Occurs when a gun disconnect is not normally completed.

Code Description
0 No response from servo software.
EF** Could not be executed because RGSO is ON.
FF** Could not be executed because RGSO is ON.
EE** Code pertaining to other than release/connection.
FE** Code pertaining to other than release/connection.
ED** Release/connection operation did not complete normally.
FD** Release/connection operation did not complete normally.
200 Gun did not return within motion range after calibration.

Main causes include:

1. No response from servo software at external axis release.
2. Defective 1KB/1RB board.
3. Defective 1KP board.

⇒ Check cables and replace as necessary.

⇒ Replace the 1KB/1RB board.
⇒ Replace the 1KP board.
⇒ Reinstall servo software.
_____________________________________________________________________

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ERROR CODE E1025 EXT AXIS connecting error. (code %4X)

Occurs when the gun axis connection is not normally completed.

Code Description
0 No response from servo software.
EF** Could not be executed because RGSO is ON.
FF** Could not be executed because RGSO is ON.
EE** Code pertaining to other than release/connection.
FE** Code pertaining to other than release/connection.
ED** Release/connection operation did not complete normally.
FD** Release/connection operation did not complete normally.
200 Gun did not return within motion range after calibration.

Main causes include:

1. Motion range for gun or the limit value for clamping force is not set correctly.
2. Defective gun or gun brake circuit.
3. No response from servo software.
4. Defective 1KB/1RB board.
5. Defective 1KP board.

⇒ Verify that the servo gun’s upper and lower limits are correctly set in AUX 1011.
⇒ Use the gun brake release switch, release the gun’s brake. Manually move the gun to
check for mechanical binding.
⇒ Adjust the clamping force in AUX 1021.
⇒ Reinstall the servo software.
⇒ Check brake circuit and repair as necessary.
⇒ Replace the 1KB/1RB board.
⇒ Replace the 1KP board.
_____________________________________________________________________

ERROR CODE E1026 Main CPU mismatch.

This error occurs when the are conflicting CPU cache settings.

⇒ Change the CPU cache setting to “No” and cycle controller power OFF and ON.
⇒ Use the ZCPUCACH instruction to set the CPU cache setting to “OFF”.
_____________________________________________________________________

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ERROR CODE E1027 Safety circuit was cut OFF.

The safety gate branch of the safety circuit is open due to a missing safety plug or defec-
tive circuit.

⇒ Reinsert the safety plug.

⇒ Repair open circuit.
_____________________________________________________________________

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ERROR CODE E1028 Jt %-M Motor overload.

The current feedback from the power block exceeded maximum continuous ratings
longer than the time allowed.

1GM board
Servo
Time I/V
CPU
converter

ABNORMAL Current
feedback

1KB/1RB board

Continuous Motor current Current

current rating sensor U, V, W earth
Overload Curve IPM Motors

Power block Robot

Main causes include:

Mechanical-
1. The robot arm has contacted an external item hindering movement.
2. The harness is caught in the robot arm.
3. The cyclo reduction unit, the gear, or the bearing(s) are damaged.
4. Gear cyclo reduction unit backlash is too narrow.
5. Payload weight exceeds robot specifications for capacity.
6. Robot motion pattern exceeds ratings of the motor.
7. Motor brake is not released.

Electrical-
1. Motor power line U, V, and W phase are disconnected.
2. The brake line is disconnected or brake drive circuit is damaged.
3. The power block is damaged.
4. Defect in the 1KQ/1NR board.
5. Defect in the 1KB/1RB servo board.
6. Malfunction of the motor.
7. Servo spot weld gun:
–Clamping pressure and/or clamping time is excessive.
–Distance between weld points is short; the motor does not have time to cool suffi-
ciently between welds.
–Clamping pressure setting exceeds the servo gun motor power capacity.

⇒ Check the cyclo reduction unit, the gear, or the bearing(s) for mechanical failure.
Replace as necessary.

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⇒ Re-teach the robot motion as necessary.

⇒ Check the harness and servo unit for electrical malfunctions and replace if necessary.
⇒ Replace the 1KB/1RB board.
⇒ Replace the 1KQ/1NR board.

Servo Spot Weld Gun

⇒ If the weld points are close to each other, set a time delay. This provides a cool-down
period for the servo gun motor.
⇒ Set the clamping force lower (see servo gun manufacturer’s specifications).
_____________________________________________________________________

ERROR CODE E1029 Encoder rotation data is abnormal. (Jt %-M)

Occurs when there is a difference (+2 rotations or more) between the rotation data in the
serial encoder data and the rotation data calculated using the incremental technique.

Encoder Encoder

Servo
Encoder I/F
CPU

1KB/1RB board Power

Battery
circuit

Encoder +12 VDC power supply

1FG/1HG board
Controller Robot

⇒ Check connections at encoder, 1FG/1HG board, and separation harness.

⇒ Check for noise and shield integrity.
⇒ Ensure the 1KB/1RB board is properly seated into the card rack.
⇒ Check for continuity in the machine harness and separation harness.
⇒ Replace 1FG/1HG board.
⇒ Replace the 1KB/1RB board.
⇒ Replace the encoder.

For additional information on error code E1029, see section 1.4.

_____________________________________________________________________

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ERROR CODE E1030 Encoder data abnormal. (Jt %-M)

When control power is switched ON, the current encoder value is compared to the
stored encoder value when the power is turned OFF. If the difference is more than the
value set in AUX 0504 Encoder Error Range, or by the ENCCHK_DATA command, this
error occurs.

Encoder Encoder

Servo
Encoder I/F
CPU

1KB/1RB board Power

Battery
circuit

Encoder +12 VDC power supply

1FG/1HG board
Controller Robot

Main causes include:

1. Value set in AUX 0504 is to small.
2. Back up battery failure due to disconnection or discharged battery (+3.3 VDC or less).
3. Control power is turned off during robot motion by an abnormal power supply, etc.,
causing the robot to stop in a position other than the last position stored in the AS
software.
4. Motor replacement/encoder replacement (zeroing must be performed).
5. Robot arm or motor operated by force when control power is off.
6. Controller was initialized (this error occurs for all axes).
7. Servo spot weld gun.
–Loose connection at tool changer.
–Defective tool changer harness.

⇒ Ensure the value set in AUX 0504 is correct.

⇒ Data may have been lost due to backup battery. See error W1013. Replace the
battery. There is a possibility that internal encoder data may be lost. Check the robot
zeroing.
⇒ Check connections at tool changer, clean connections, replace harness as necessary.
⇒ Check each harness for short circuit and repair, or replace, as necessary.
⇒ Replace the encoder, the 1KB/1RB board or the 1FG/1HG encoder battery backup
board as necessary.
⇒ After repair is complete, confirm correct program playback in check mode before
running program in repeat mode.
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ERROR CODE E1031 Miscount of encoder data (Jt %-M).

The servo gun or tool changer harness is defective.

⇒ Inspect the servo gun and tool changer harnesses; replace if necessary.
_____________________________________________________________________

ERROR CODE E1032 Mismatch ABS and INC encoder data (Jt %-M).

Occurs when there is a large difference between the value in the serial encoder data
and the calculated data using the incremental technique.

Encoder Encoder

Servo
Encoder I/F
CPU

1KB/1RB board Power

Battery
circuit

Encoder +12 VDC power supply

1FG/1HG board
Controller Robot

Main causes include:

1. Defective encoder or encoder harness.
2. Defective 1KB/1RB board.
3. Noise related malfunction.
4. Defective 1FG/1HG board.
5. Servo spot weld gun.
–Loose connection at tool changer.
–Defective tool changer harness.

⇒ Replace encoder, replace 1KB/1RB board.

⇒ Check connections at encoder, 1FG/1HG board, and separation harness.
⇒ Ensure the 1KB/1RB board is properly seated into the card rack.
⇒ Check for continuity in the machine harness and separation harness.
⇒ Check for noise and shield integrity.
⇒ Replace 1FG/1HG board.

For additional information on error code E1032, see section 1.4.

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ERROR CODE E1034 Encoder initialize error (Jt %-M).

The encoder is not able to read the absolute position at control power on. The scanning
of absolute data begins immediately after a shift from the state of non-operation, or
back-up operation, to normal encoder operation. BUSY=1 is output until the absolute
position has been determined.

Encoder Encoder

Servo
Encoder I/F
CPU

1KB/1RB board Power

Battery
circuit

Encoder +12 VDC power supply

1FG/1HG board
Controller Robot

Main causes include:

1. Encoder rotated at 300 RPM or more at controller power-up (including conveyor
encoder).
2. Defective encoder or encoder harness.
3. Defective 1KB/1RB, 1KQ/1NR, or 1GF/1HG board.
4. Defective manual brake release.

⇒ In the case of a conveyor encoder, ensure power-up speed is below 300 RPM.
⇒ Check connections at encoder, 1FG/1HG board.
⇒ Ensure the 1KB/1RB board is properly seated into the card rack.
⇒ Replace encoder, replace 1KB/1RB, 1KQ/1NR, or 1FG/1HG board.
⇒ Check for continuity in the machine harness, separation and signal harness repair or
replace as necessary.

For additional information on error code E1034, see section 1.4.

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ERROR CODE E1035 Encoder response error (Jt %-M).

Occurs when the encoder does not respond, or response is slow, to data request signal
from the 1KB/1RB board.

Encoder Encoder

Servo
Encoder I/F
CPU

1KB/1RB board Power

Battery
circuit

Encoder +12 VDC power supply

1FG/1HG board
Controller Robot

Main causes include:

1. Defective encoder or encoder harness.
2. Defective 1KB/1RB or 1FG/1HG board.
3. Noise related malfunction.
4. Servo spot weld gun.
–Loose connection at tool changer.
–Defective tool changer harness.

⇒ Check connections at encoder, 1FG/1HG board, and separation harness.

⇒ Ensure the 1KB/1RB board is properly seated into the card rack.
⇒ Replace encoder, replace 1KB/1RB board.
⇒ Check for continuity in the machine harness and separation harness.
⇒ Replace 1FG/1HG board.
⇒ Check for noise malfunction and shield integrity.
⇒ Inspect the servo gun and tool changer harnesses; replace as necessary.
⇒ After repair is complete, confirm correct program playback in check mode before
running program in repeat mode.

For additional information on error code E1035, see section 1.4.

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ERROR CODE E1036 Encoder communication error. (Jt %-M)

Cyclic redundancy check (CRC) fault or framing error is detected in communication with
the encoder.

Encoder Encoder

Servo
Encoder I/F
CPU

1KB/1RB board Power

Battery
circuit

Encoder +12 VDC power supply

1FG/1HG board
Controller Robot

Main causes include:

1. Noise related malfunction.
2. Defective encoder or encoder harness.
3. Defective 1KB/1RB or 1FG/1HG board.
4. Servo spot weld gun.
–Loose connection at tool changer.
–Defective tool changer harness.

⇒ Check for noise malfunction and shield integrity.

⇒ Check connections at encoder, 1FG/1HG board, and separation harness.
⇒ Ensure the 1KB/1RB board is properly seated into the card rack.
⇒ Replace encoder, replace 1KB/1RB board.
⇒ Check for continuity in the machine harness, separation harness and signal harness.
⇒ Replace 1FG/1HG board.
⇒ Inspect the servo gun and tool changer harnesses; replace as necessary.
⇒ After repair is complete, confirm correct program playback in check mode before
running program in repeat mode.

For additional information on error code E1036, see section 1.4.

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ERROR CODE E1037 Encoder data conversion error. (Jt %-M).

This error is caused by abnormal encoder absolute position data.

Encoder Encoder

Servo
Encoder I/F
CPU

1KB/1RB board Power

Battery
circuit

Encoder +12 VDC power supply

1FG/1HG board
Controller Robot

Main causes include:

1. Noise related malfunction.
2. Defective encoder or encoder harness.
3. Defective 1KB/1RB or 1FG/1HG board.
4. Servo spot weld gun.
–Loose connection at tool changer.
–Defective tool changer harness.

⇒ Check for noise malfunction and shield integrity.

⇒ Replace encoder, replace 1KB/1RB board.
⇒ Check connections at encoder, 1FG/1HG board, and separation harness.
⇒ Ensure the 1KB/1RB board is properly seated into the card rack.
⇒ Check for continuity in the machine harness and separation harness.
⇒ Replace 1FG/1HG board.
⇒ Inspect the servo gun and tool changer harnesses; replace as necessary.
⇒ After repair is complete, confirm correct program playback in check mode before
running program in repeat mode.

For additional information on error code E1037, see section 1.4.

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ERROR CODE E1038 Encoder ABS-track error. (Jt %-M)

The absolute data and the incremental data in the encoder are different. ABSALM=1 is
output from the encoder when this error occurs.

Encoder Encoder

Servo
Encoder I/F
CPU

1KB/1RB board Power

Battery
circuit

Encoder +12 VDC power supply

1FG/1HG board
Controller Robot

Main causes include:

1. Noise related malfunction.
2. Defective encoder or encoder harness.
3. Defective 1KB/1RB or 1FG/1HG board.
4. Servo spot weld gun.
–Loose connection at tool changer.
–Defective tool changer harness.

⇒ Check for noise malfunction and shield integrity.

⇒ Replace encoder, replace 1KB/1RB board.
⇒ Check connections at encoder, 1FG/1HG board, and separation harness.
⇒ Ensure the 1KB/1RB board is properly seated into the card rack.
⇒ Check for continuity in the machine harness and separation harness.
⇒ Replace 1FG/1HG board.
⇒ Inspect the servo gun and tool changer harnesses; replace as necessary.

For additional information on error code E1038, see section 1.4.

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ERROR CODE E1039 Encoder INC-pulse error. (Jt %-M)

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

Encoder Encoder

Servo
Encoder I/F
CPU

1KB/1RB board Power

Battery
circuit

Encoder +12 VDC power supply

1FG/1HG board
Controller Robot

Main causes include:

1. Noise related malfunction.
2. Defective encoder or encoder harness.
3. Defective 1KB/1RB or 1FG/1HG board.
4. Servo spot weld gun.
–Loose connection at tool changer.
–Defective tool changer harness.

⇒ Replace encoder, replace 1KB/1RB board.

⇒ Check connections at encoder, 1FG/1HG board, and separation harness.
⇒ Ensure the 1KB/1RB board is properly seated into the card rack.
⇒ Check for continuity in the machine harness and separation harness.
⇒ Replace 1FG/1HG board.
⇒ Inspect the servo gun and tool changer harnesses; replace as necessary.

For additional information on error code E1039, see section 1.4.

_____________________________________________________________________

ERROR CODE E1040 Encoder MR-sensor error. (Jt %-M)

The state of the MR sensor in the encoder does not match with JT ENCODER in one
rotation.

⇒ Replace the encoder or encoder harness.

⇒ Replace signal harness.
⇒ Replace 1KB/1RB board.
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ERROR CODE E1041 Limit switch (JT %d) is ON.

This error occurs when the robot moves beyond the set working range (restricted space)
and activates the axis restriction limit switch.

The mechanical stopper and the axis restriction limit switch are optional and the axis
they are installed on varies with machine type and configuration.

1KB/1RB board

Axis Axis
restriction restriction
LS LS
Local bus

EPLD

1KX board 1KP board 1FG/1HG board

Controller Robot

Main causes include:

1. Software limits are set incorrectly in AUX 0507.
2. Axis is moved using the manual brake release and the limit switch is turned ON.
3. The limit switch is turned ON by overshoot from inertia.
4. Incorrect zeroing data.
5. Defective axis restriction limit switch or signal harness.
6. Defective 1KP board.

⇒ Check the limit switch and limit switch harness; replace as necessary.
⇒ Set the software limits in AUX 0507 to an appropriate value.
⇒ Change the installation angle of the axis restriction limit switch to an appropriate
value.
⇒ Replace the 1KP power sequence board.
⇒ Return robot within the motion range using the manual brake release or press and
hold the overtravel override switch on the 1KP board, reset the error, set motor power
ON in teach mode and jog the robot off of the axis restriction limit switch.
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ERROR CODE E1042 Limit switch signal line is disconnected.

This error occurs when the axis restriction limit switch is activated and the robot did not
move beyond the set working range (restricted space).

The mechanical stopper and the axis restriction limit switch are optional and the axis
they are installed on varies with machine type and configuration.

1KB/1RB board

Axis Axis
restriction restriction
LS LS
Local bus

EPLD

1KX board 1KP board 1FG/1HG board

Controller Robot

Main causes include:

1. Axis restriction limit switch activated by brake release or unexpected robot motion.
2. Axis restriction limit switch installed inside motion range set in AUX 0507.
3. Incorrect zeroing data.
4. Defective axis restriction limit switch.
5. Defective signal harness.
6. Defective 1KP board.

⇒ Set the software limits in AUX 0507 to an appropriate value.

⇒ Change the installation angle of the axis restriction limit switch to an appropriate
value.
⇒ Check harness and limit switch and replace as necessary.
⇒ Replace the 1KP power sequence board.
⇒ Return robot within the motion range using the manual brake release or press and
hold the overtravel override switch on the 1KP board, reset the error, set motor power
ON in teach mode and jog the robot off of the axis restriction limit switch.
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ERROR CODE E1043 Teach-plug is abnormal.

This error occurs in teach mode if the teach plug is not installed or in repeat mode if the
teach plug is connected.

⇒ Ensure the teach-plug is in the proper state for the mode used.
⇒ Check and repair the teach-plug circuit as necessary.
_____________________________________________________________________

ERROR CODE E1045 Gun-clamp Mismatch.

(Spot weld specifications type B)

Spot weld is not selected in AUX 0605-1 when a servo spot weld gun is used.

⇒ Ensure spot weld is selected in AUX 0605-1.

_____________________________________________________________________

ERROR CODE E1046 Too short distance between start point and end point.
(sensing function)

In a work sensing step, the final end point determined by overrun distance could not be
defined because the end point and start point are too close together.

⇒ Teach the start point far enough from the end point so the final end point can be
defined.
_____________________________________________________________________

ERROR CODE E1047 Axis number is not for conveyor follow mode.

Main causes include:

1. Setting the conveyor to the same axis number that is assigned to the traverse axis.
2. Changing settings in a specific conveyor tracking mode while in conveyor follow mode.

⇒ Set the correct axis number for the conveyor ais using the ZCVAXIS command.
⇒ Change to the conveyor tracking mode if the robot does have a traverse unit.
_____________________________________________________________________

ERROR CODE E1048 Offset data of zeroing is illegal value.

When robot data is loaded the default value of zeroing offset for all axes is 0.

⇒ Confirm the loaded data is correct.

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ERROR CODE E1049 Current position is out of specified area.

(Option)

Current values of the robot are not in the specified area at the start of repeat operation.

⇒ Set CHGMOVE to OFF.

⇒ Move the robot inside of the specified area in teach mode.
_____________________________________________________________________

ERROR CODE E1050 Encoder and brake power off signal not dedicated.

A gun change is executed on a servo spot weld gun without setting [Encoder and brake
power (7)] dedicated signal in AUX 0602.

⇒ From AUX 0602 Dedicated output Signals, set the [Encoder and brake power (7)]
signal to dedicated and enter the signal number.
_____________________________________________________________________

ERROR CODE E1051 Incorrect double OX output.

When double type signals are used, if either output in the pair is turned ON, the other
turns OFF. An instruction to turn both outputs ON, or turn both outputs OFF (OX=1,2 or
OX=-1,-2), causes this error.

⇒ Change the OX signal setting.

⇒ Modify program data.
_____________________________________________________________________

ERROR CODE E1052 Work sensing signal is not dedicated.

(sensing function)

This error occurs when the X-linear step is executed and the dedicated work sensing
signal is not detected. When the sensing function is used, a dedicated work sensing
signal must be set in AUX 1103.

⇒ Ensure the work sensing dedicated signal is set properly.

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ERROR CODE E1053 Work sensing signal already input.

(sensing function)

Main causes include:

1. The X-linear step is executed and the work sensing signal is already on.
2. The sensing start-point is too close to the workpiece.
3. The sensing device or sensing device harness fails.

⇒ Reteach the start point further away from the workpiece.

⇒ Repair or replace sensing device or sensing device harness.
_____________________________________________________________________

ERROR CODE E1054 Cannot execute motion instruction.

Main causes include:

1. A motion instruction is executed for the slave robot during cooperative motion.
2. A motion instruction is executed in soft absorber mode (from SASTART to SAEND).

⇒ Correct the slave robot program. Only non-motion instructions can be used for the
slave robot in the cooperative motion program.
⇒ Do not use program motion instructions while in soft absorber mode. Only motion
instructions specific to the soft absorber function can be used in soft absorber mode.
_____________________________________________________________________

ERROR CODE E1055 Start point position error for circle.

The robot is stopped after it began executing a circular motion and moved 4 mm or more
away from its calculated path (jogging or brake slippage, etc.). Attempting to continue
execution of the path from this position results in this error.

⇒ Move the robot closer to the calculated path or restart the program a step prior to the
circular path.
_____________________________________________________________________

ERROR CODE E1056 MASTER robot already exists.

This error occurs when MASTER instructions are executed for both robots during coop-
erative motion.

⇒ One robot must be configured as the MASTER robot and the other robot must be
configured as the SLAVE robot.
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ERROR CODE E1057 Check to which robot MASTER/ALONE were instructed.

This error occurs when a robot other than the MASTER robot executes the ALONE,
MJMOVE, or MLMOVE instructions.

⇒ Make program corrections as required.

_____________________________________________________________________

ERROR CODE E1058 SLAVE robot already exists.

This error occurs when SLAVE instructions are executed for both connected robots
during cooperative motion in repeat mode.

⇒ Do not execute SLAVE instructions for both robots at the same time.
_____________________________________________________________________

ERROR CODE E1059 Not an instruction for cooperative motion.

This error occurs when attempting to execute a non-cooperative motion instruction in the
MASTER robot program during cooperative motion.

⇒ Ensure only cooperative motion instructions are used in the MASTER robot program
during cooperative motion.
_____________________________________________________________________

ERROR CODE E1060 Cannot execute in check back mode.

The program reached an instruction which cannot be executed in check back mode.
Example:
Executing SHIFT instructions in reverse order results in a different path and cannot be
done.

⇒ Execute after selecting a step that can be checked backward. If possible, check
forward.
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ERROR CODE E1061 Cannot execute in ONE program.

A motion instruction is specified in the ONE program.

⇒ Do not program motion instructions in the ONE program.

⇒ Refer to the D Series Controller AS Language Reference Manual for proper use of the
AS Language commands.
_____________________________________________________________________

ERROR CODE E1062 JT2 and JT3 interfere during motion to start pose.

Movement from the current position to the start pose would cause JT2 and JT3 to move
beyond their limits.

⇒ Modify the position of the start pose of the program.

_____________________________________________________________________

ERROR CODE E1063 JT2 and JT3 interfere during motion to end pose.

Movement from the current position to the end pose would cause JT2 and JT3 to move
beyond their limits.

⇒ Modify the position of the end pose of the program.

_____________________________________________________________________

ERROR CODE E1064 Illegal pallet number.

This error occurs when a pallet number other than 1-9 is used with the PALUP instruc-
tion, or the PALLET function.

⇒ Ensure pallet number 1–9 is used.

_____________________________________________________________________

ERROR CODE E1065 Illegal material number.

This error occurs when the work (part) number in a block step program instruction or the
pallet function is other than 1–999.

⇒ Ensure the work number is 1–999.

_____________________________________________________________________

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ERROR CODE E1066 Illegal pattern number.

Main causes include:

1. Program step does not comply with AS Language syntax.
2. Pattern number for work specified, using block step instructions or the PALLET func-
tion, is not between 1 and 5.

⇒ Refer to the D Series Controller AS Language Reference Manual for proper use of the
AS Language commands.
⇒ Ensure the work pattern number specified is correct.
_____________________________________________________________________

ERROR CODE E1067 Illegal pattern type.

Main causes include:

1. Program step does not comply with AS Language syntax.
2. Pattern type for work specified using block step instructions or the PALLET function is
not between 1 and 5.

⇒ Refer to the D Series Controller AS Language Reference Manual for proper use of the
AS Language commands.
⇒ Ensure the work pattern number specified is correct.
_____________________________________________________________________

ERROR CODE E1068 Illegal work data.

Main causes include:

1. Program step does not comply with AS Language syntax.
2. Work data specified using block step instructions or the PALLET function is incorrect
or not registered.

⇒ Refer to the D Series Controller AS Language Reference Manual for proper use of the
AS Language commands.
⇒ Ensure the work data specified is correct.
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ERROR CODE E1069 Illegal pallet data.

Main caused include:

1. Program step does not comply with AS Language syntax.
2. Pallet data in a block step program, the PALUP instruction or the PALLET function, is
incorrect or not registered.

⇒ Refer to the D Series Controller AS Language Reference Manual for proper use of the
AS Language commands.
⇒ Ensure the pallet data specified is correct.
_____________________________________________________________________

ERROR CODE E1070 ON/ONI signal is already input.

An ON/ONI instruction mode “/ERR” is specified and the signal condition to monitor is
already attained when monitoring starts.

⇒ Delete the “/ERR” mode from the ON/ONI instruction or specify “/LVL” mode.
⇒ Modify the program so the signal condition is not attained until monitoring starts.
_____________________________________________________________________

ERROR CODE E1071 XMOVE signal is already input.

An XMOVE instruction mode “/ERR” is specified and the signal condition to monitor is
already attained when monitoring starts.

⇒ Delete the “/ERR” mode from the XMOVE instruction or specify “/LVL” mode.
⇒ Modify the program so the signal condition is not attained until monitoring starts.
_____________________________________________________________________

ERROR CODE E1072 Home position data is not defined.

This error occurs when the home position data in AUX 0402 is set to all zeros and the
HOME command is executed.

⇒ Ensure the data for home position is other than all zeros in AUX 0402.
⇒ If a home position of all zeros is required, set the ZCHECKHOME switch to OFF.
_____________________________________________________________________

ERROR CODE E1073 Illegal timer number.

Displayed when a timer is specified other than 1–10.

⇒ Specify timers 1–10.

_____________________________________________________________________

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ERROR CODE E1074 Over maximum signal number.

When the RUNMASK, SIGNAL, BITS, PULSE, or SWAIT commands are used with a
signal number that exceeds the range permitted by system configuration, this error is
displayed.

⇒ Check signal number specified in instruction and ensure it is within system configura-
tion.
_____________________________________________________________________

ERROR CODE E1075 Illegal clamp number.

Displayed when the clamp number entered exceeds the maximum permitted by system
configuration.

⇒ Use only clamp numbers that are supported by system configuration.

_____________________________________________________________________

ERROR CODE E1076 Cannot use negative time value.

Displayed when a negative number is entered as part of a DELAY or TIMER command.

⇒ Correct the time setting to a positive number.

_____________________________________________________________________

ERROR CODE E1077 No value set.

Occurs when an instruction like the BITS command is evaluated and there is no corre-
sponding value set.

⇒ Correct program code to evaluate existing values.

_____________________________________________________________________

ERROR CODE E1078 Illegal signal number.

This error is displayed when the RUNMASK, SIGNAL, BITS, PULSE, or SWAIT com-
mands are used with a signal number that exceeds the range permitted by system
configuration.

⇒ Check signal number specified in the instruction and ensure it is within system con-
figuration.
_____________________________________________________________________

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ERROR CODE E1079 Cannot use dedicated signal.

Occurs when a previously dedicated signal is used as a general purpose signal.

⇒ Use signals that have not been dedicated for specific functions.
_____________________________________________________________________

ERROR CODE E1080 Not RPS mode.

Main causes include:

1. External program reset signal is received, but RPS ON signal, or external program
input signal is not dedicated.
2. JUMP is taught in a block step program, but external program input signal is not
dedicated.
3. END is taught in a block step program, but the RPS ON signal is not dedicated.
4. EXTCALL is executed, but the signal for external program input is not dedicated.

⇒ Correct the program data.

⇒ If RPS is to be used the necessary signals must be dedicated.
_____________________________________________________________________

ERROR CODE E1081 Cannot use negative value.

Displayed when a negative number is used in conjunction with the PULSE or

ACCURACY commands/instructions.

⇒ Use only positive numbers in the acceptable range for the PULSE and ACCURACY
commands/instructions.
_____________________________________________________________________

ERROR CODE E1082 Out of absolute lower motion range limit.

Displayed when an attempt is made to set the software lower limits of robot travel to a
value that is beyond the robots lower limit (LLIMIT command).

⇒ Set lower software travel limits to an acceptable value.

_____________________________________________________________________

ERROR CODE E1083 Out of absolute upper motion range limit.

Displayed when an attempt is made to set the software upper limits of robot travel to a
value that is beyond the robots upper limit (ULIMIT command).

⇒ Set upper software travel limits to an acceptable value.

_____________________________________________________________________

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ERROR CODE E1084 Out of set lower motion range limit.

Data used is beyond the lower limit set in AUX 0507.

Example:
Data used for the SETHOME command is beyond the lower limit set in AUX 0507.

⇒ Set motion range within the motion range limits set in AUX 0507.
⇒ Set lower software travel limits to an acceptable range (confirm safe operation).
_____________________________________________________________________

ERROR CODE E1085 Out of user upper limit.

Data used is beyond the upper limit set in AUX 0507.

Example:
Data used for the SETHOME command is beyond the upper limit set in AUX 0507.

⇒ Set motion range within the motion range limits set in AUX 0507.
⇒ Set upper software travel limits to an acceptable range (confirm safe operation).
_____________________________________________________________________

ERROR CODE E1086 Start point for Jt %ld beyond motion range.

Robot pose at motion start is beyond the range set in AUX 0507.
Example:
DO HOME is executed at a point that is out of motion range set in AUX 0507.

⇒ Correct pose to within working envelope or expand software limits to accept pose.
_____________________________________________________________________

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ERROR CODE E1087 End location point for Jt %ld beyond motion range.

Main causes include:

1. Jt %ld at a taught point is beyond the motion range set in AUX 0507.
2. With a servo spot weld gun installed, if a taught point is near the motion range limit for
an axis, the robot motion that results from performing tip wear compensation in re-
peat/check mode causes the robot to exceed the motion range limit.
3. Taught data for the gun axis is out of motion range.
Example:
Taught data is changed from a gun released to a gun connected state without any
corresponding change in pose data.

⇒ Correct pose to within motion range or expand software limits in AUX 0507 to accept
pose.
⇒ Correct the correct data so that the robot motion is within motion range with the gun
connected.
_____________________________________________________________________

ERROR CODE E1088 Destination is out of motion range.

While executing a motion to a step, the software calculated the pose destination of all
joints to be outside of the allowable upper or lower software limits.

⇒ Correct pose to within motion range or expand software limits to accept pose.
_____________________________________________________________________

ERROR CODE E1089 Cannot do linear motion in current configuration.

System software determined that the start and end points of a linear or circular move will
cause the robot to exceed the acceptable motion parameters.

⇒ Change motion interpolation to a joint move; move the pose to avoid configuration
conflict.
_____________________________________________________________________

ERROR CODE E1090 External modulation data is not input.

(Option)

External modulation data is not received.

⇒ Check for abnormality in the external modulation data line and repair as necessary.
_____________________________________________________________________

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ERROR CODE E1091 External modulation data is abnormal.

(Option)

Modulation data is too large.

⇒ Check for abnormality in the external modulation data line and repair as necessary.
_____________________________________________________________________

ERROR CODE E1092 Modulation data is over limit.

(Option)

Modulation data exceeds the set allowable capacity.

⇒ Check for abnormality in the external modulation data line and repair as necessary.
_____________________________________________________________________

ERROR CODE E1093 Incorrect motion instruction to execute modulate motion.

(Option)

A non-modulation instruction is specified.

⇒ Specify appropriate modulation instruction.

_____________________________________________________________________

ERROR CODE E1094 Illegal joint number.

Occurs when the DRIVE or other similar command is used and a joint number is speci-
fied that is not part of the robot configuration.

⇒ Confirm robot configuration before using the DRIVE or other similar command.
_____________________________________________________________________

ERROR CODE E1095 Cannot execute motion instruction in PC program.

A PC program cannot contain instructions that initiate robot motion.

⇒ Correct the PC program by removing motion instructions.

_____________________________________________________________________

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ERROR CODE E1096 Incorrect auxiliary data settings.

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

⇒ Correct the value of auxiliary data.

⇒ Perform system initialization.
⇒ If correct value is entered and this error recurs, contact KRI customer service.
_____________________________________________________________________

ERROR CODE E1097 Missing C1MOVE or C2MOVE instruction.

Program circular motion instructions must have a C1MOVE followed by either a

C1MOVE or C2MOVE and end with a C2MOVE.

⇒ Correct program instructions.

_____________________________________________________________________

ERROR CODE E1098 C1MOVE (CIR1) instruction required before C2MOVE.

Program circular motion instructions must have C2MOVE move preceded by a

C1MOVE.

⇒ Correct program instructions.

_____________________________________________________________________

ERROR CODE E1099 Unable to create arc path, check positions of the 3 points.

Circular interpolation moves cannot be processed because the points identified are too
close together or are on a straight path.

⇒ Correct program instructions.

_____________________________________________________________________

ERROR CODE E1100 Cannot execute in sealing specification.

Occurs when a CLOSE(I), OPEN(I), or RELAX(I) command is executed in a program

and clamp specifications in AUX 0605-1 are set for sealing.

⇒ Correct program instructions to match software configuration.

_____________________________________________________________________

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ERROR CODE E1101 Can only execute in sealing specification.

Occurs when a GUNON, GUNOFF, GUNONTIME or GUNOFFTIME command is ex-

ecuted in a program and clamp specifications in AUX 0605-1 are not set for sealing.

⇒ Correct program instructions to match software configuration.

_____________________________________________________________________

ERROR CODE E1102 Option is not set, cannot execute.

(Option)

A command/instruction is executed for an option that is not installed and/or set up.
Example:
An attempt to save/load data to/from a floppy disk is made, but a floppy disk drive is not
installed and/or set up.

⇒ Ensure the option is installed and software is set up properly.

⇒ To install an option that is not included in the original controller specifications contact
KRI customer service.
_____________________________________________________________________

ERROR CODE E1103 Over conveyor position

(Option)

The value of the conveyor axis exceeds the set motion area limit.

⇒ Set the conveyor axis value to a value less than the maximum value.
_____________________________________________________________________

ERROR CODE E1104 Too many SPINMOVE instructions.

This error occurs when the SPINMOVE instruction is used in 17 or more consecutive
steps.

⇒ Correct the SPINMOVE program instruction to 16 or less consecutive steps in the

program between spin start and spin stop.
_____________________________________________________________________

ERROR CODE E1106 Cannot execute in this robot.

This error occurs when a request is executed on a robot arm that does not support the
function.

⇒ Contact KRI customer service to have the function installed or delete the request.
_____________________________________________________________________

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ERROR CODE E1108 Duplicate robot network IDs.

With the robot network installed and operational, the same ID number is assigned to two
different robots connected to the network.

⇒ Change the robot ID using the ROBNETID command.

_____________________________________________________________________

ERROR CODE E1109 Conveyor I/F board is not installed.

1JS board is not installed for interface with an incremental-type conveyor encoder.

1. 1JS board not installed to the 1GW/1HW board.

2. Defective 1JS board.
3. The 1JS board is installed onto a defective 1GW/1HW board.

⇒ Ensure the 1JS board is properly installed.

⇒ Replace the 1JS board.
⇒ Replace the 1JS board and the 1GW/1HW board.
_____________________________________________________________________

ERROR CODE E1110 GROUP is not primed.

The GROUP instruction is not programmed before a motion instruction, with external
axis system.

⇒ This error occurs if the program is interrupted after a GROUP instruction and before
the motion commands pertaining to the GROUP instruction are complete. When
restarting the program prime the program before the GROUP instruction.
⇒ In check mode, if the GROUP instruction is used, start checking before the GROUP
instruction.
_____________________________________________________________________

ERROR CODE E1113 Work sensing signal is not detected.

(sensing function)

This error occurs when the X-linear step is executed and the workpiece is not detected
before the robot axes reach coincidence of the taught point.
The sensing device or sensing device harness may be defective.

⇒ Set the accuracy range to a smaller value.

⇒ Repair or replace sensing device or sensing device harness.
_____________________________________________________________________

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ERROR CODE E1114 Interruption in cooperative control.

This error occurs when an error condition is generated for one robot during cooperative
motion in repeat mode operation.

⇒ Repair the cause of the interruption and reset the error.

_____________________________________________________________________

ERROR CODE E1115 Force termination of cooperative control.

The program ended without executing the ALONE instruction in either the MASTER or
the SLAVE robot program. Both robots are stopped and cooperative motion is released.

⇒ Insert the ALONE instruction in either the MASTER or the SLAVE robot program.
_____________________________________________________________________

ERROR CODE E1116 Spin axis is not stopped on every 360 degrees.

During spin, the robot or spin axis is stopped and the current pose is taught with the JT6
spin axis stopped at a position other than 0 degrees.

Main causes include:

1. EMERGENCY STOP switch is pressed.
2. HOLD/RUN switch is set to HOLD.
3. TEACH/REPEAT switch is set to TEACH.

⇒ Execute SPINRESET to correct the rotation angle of the JT6 spin axis to stop in 360
degree units.
_____________________________________________________________________

ERROR CODE E1117 Process time over.

Lack of system processing time

⇒ Contact KRI customer service (include operating conditions/settings and operation log
at the time the error occurred).
_____________________________________________________________________

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ERROR CODE E1118 Command value for Jt %ld suddenly changed.

Spot Welding and Material Handling

In the repeat mode, the commanded position of the joint identified exceeds the limit
value. In the check mode, the commanded position of the joint identified exceeds the
speed limit value.

⇒ Check for singularity condition during robot motion and reteach to correct.
⇒ Check for loose or defective servo system encoders, harnesses, and circuit boards.
⇒ Replace 1KB/1RB board.
⇒ Replace power block.

Servo Spot Weld Gun

Occurs when corrections for deflection cause movement of the robot to exceed the
range of motion of one or more axes. This condition is not limited to the gun axis; any
axis, including the gun axis, can cause this error.

⇒ Change the posture of the robot.

⇒ Decrease the speed in the step.
⇒ Reduce the amount of the deflection correction in the step by using AS Language
SGREFLEX command (check conditions during pressurizing).
⇒ Reteach the point and change the configuration of the posture of the robot if needed.
_____________________________________________________________________

ERROR CODE E1119 Commanded value for Jt %ld beyond motion range.

Spot Welding and Material Handling

The commanded position for the joint identified exceeds the software limits. Condition is
monitored in both the check and repeat modes.

⇒ Correct taught positions to avoid the software limits.

⇒ Adjust the software limits in AUX 0507 to provide the necessary motion range.

Servo Spot Weld Gun

If a taught point is near a servo gun or arm axis range of motion limit, the combination of
tip wear and deflection correction can prevent the robot from reaching the taught point.

⇒ Do not teach points that are near axes range of motion limits.
_____________________________________________________________________

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ERROR CODE E1120 Current command causes interference betw Jt2 and Jt3.

A posture is attempted which causes Jt2 and Jt3 to interfere with each other.

⇒ Change the taught poses.

_____________________________________________________________________

ERROR CODE E1121 Other robot is in the interference area.

This error occurs when the zone interference signal is not received.

⇒ Ensure the zone interference signal is set-up correctly and the program is written
correctly.
_____________________________________________________________________

ERROR CODE E1122 Unexpected motor power OFF.

Occurs when software turns motor power ON (K1 or K2 contactors ON) but there is no
signal feedback (MCON) indicating motor power is ON.

Main causes include:

1. Defect in the 1KP power sequence board.
2. Defect in the 1KQ/1NQ relay board.
3. Malfunction in the error detection circuit and error processing of 1KP/1KQ board.
4. Auxiliary contact of magnet contactor (K1, K2) for motor power is defective.
5. Malfunction with the servo software or the AS software.
6. Defect in the harnesses between 1KQ-CN3 and KI/K2.

⇒ Reinstall AS/servo software.

⇒ Replace the 1KP power sequence board.
⇒ Replace the 1KQ/1NQ relay board.
⇒ Replace the magnetic contactor (K1, K2).
⇒ Repair or replace the harnesses between 1KQ-CN3 and K1/K2.
⇒ Replace the MC unit.
_____________________________________________________________________

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ERROR CODE E1123 Speed error Jt %-M.

Joint speed (motor speed) calculated using encoder values exceeds the rated value.

Main causes include:

1. Disconnected motor power line U, V, and/or W phase, or defective power block.
2. Wiring error in motor power line and/or encoder line.
3. Disconnected encoder signal line, short circuit in encoder or encoder wiring, and/or
defective main body of the encoder.
4. Robot motion program causes a singularity.
5. Defective 1KB/1RB servo board and/or power block.
6. Moment of inertia exceeded the motor torque.

⇒ Reduce payload to the specified ratings.

⇒ Check for disconnection, short circuit, and proper wiring for the U, V, and W motor
power line.
⇒ Replace the encoder and/or encoder harness as necessary.
⇒ Replace the 1KB/1RB board.
⇒ Replace the power block.
⇒ Rewrite program data such as speed and pose in the case of singularity motion.
_____________________________________________________________________

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ERROR CODE E1124 Deviation error of Jt %-M.

Spot Welding and Material Handling

The difference between the current value from the encoder and the command value in
the AS software exceeds the regulated value (varies by robot model).

Main causes include or the following abnormalities:

Mechanical -
1. Singularity motion.
2. The robot arm has contacted an external item hindering movement.
3. The harness is caught in the robot arm.
4. The cyclo reduction unit, the gear, or the bearing are damaged.
5. Cyclo reduction unit gear backlash is too narrow.
6. Payload weight exceeds robot specifications for capacity.
7. Robot motion pattern exceeds ratings of the motor.
8. Motor brake is not released.

Electrical-
1. Motor power line U, V, and W phase are disconnected.
2. The brake line is disconnected or brake drive circuit is damaged.
3. Defective 1KQ/1NR board.
4. The power block is damaged.
5. Defective 1KB/1RB servo board.
6. Malfunction of the motor.

⇒ Check the cyclo reduction unit, etc. for mechanical failure. Replace as necessary.
⇒ Re-teach robot motion as necessary.
⇒ Check the harnesses and power block unit for electrical malfunctions and replace as
necessary.
⇒ Replace the 1KB/1RB board.
⇒ Replace the 1KQ/1NR board.
⇒ Correct the teach data in case of singularity motion.

Servo Spot Weld Gun

The thickness of the workpiece at the weld point is greater than the thickness when the
point is taught. The thickness difference required to set this error is approximately 10
mm, depending on the gun type.

⇒ Inspect the workpiece; replace it if necessary.

_____________________________________________________________________

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ERROR CODE E1126 Commanded speed error Jt %-M.

This error occurs when the positional command value sent to the 1KB/1RB board from
the 1KA/1RA board exceeds the value range.

Main causes include:

1. A sudden change in robot motion.
2. Defective 1KA/1RA/1KB/1RB board.
3. Corrupt AS software caused the commanded speed value to exceed motor capacity
rating.

⇒ Modify program data to eliminate sudden changes in robot motion.

⇒ Replace the 1KB/1RB board.
⇒ Replace the 1KA/1RA board.
⇒ Replace the 1KX board (motherboard).
⇒ Reload software for the 1KB/1RB board and/or 1KA/1RA board.
_____________________________________________________________________

ERROR CODE E1127 Command acceleration error Jt %-M.

This error occurs when the amount of change in the speed value, sent to the 1KB/1RB
board from the 1KA/1RA board, exceeds the value range.

Main causes include:

1. Sudden change in robot motion.
2. Defective 1KA/1RA/1KB/1RB board.
3. Corrupt AS software caused the commanded acceleration value to exceed motor
capacity rating.

⇒ Modify program data to eliminate sudden changes in robot motion.

⇒ Replace the 1KB/1RB board.
⇒ Replace the 1KA/1RA board.
⇒ Replace the 1KX board (motherboard).
⇒ Reload software for the 1KB/1RB board and/or 1KA/1RA board.
_____________________________________________________________________

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ERROR CODE E1128 Uncoincidence error betw destination and current Jt %ld
pos.

This error occurs during program execution, if all joints do not reach total coincidence
within the commanded accuracy and time.

Main causes include.

Mechanical-
1. Damaged bearings.
2. Insufficient gear backlash.
3. Motor brake not released.
4. Arm movement restricted by harnesses or peripheral devices.

Electrical-
1. Motor power line U, V, and W phase are disconnected.
2. Defective 1KB/1RB servo board.
3. Defective 1KQ/1NR board (malfunction in the brake circuit).
3. Defective power block.
4. Disconnected motor power or brake lines.
5. Defective encoder or encoder harness.

Program data-
1. The difference in the angle of the wrist at the start and end steps is too great.
Example: 180 degrees at the start step and -180 degrees at the end step.

⇒ Repair mechanical or electrical failures as necessary.

⇒ Check interference from external devices.
⇒ Modify taught wrist positions as required.
_____________________________________________________________________

ERROR CODE E1129 External axis Jt %ld moved while holding them.
(External axis restriction function)

This error occurs when an attempt is made to move the robot in teach or repeat mode
while the external axis restriction signal is present.

⇒ Ensure the internal interlock circuit is operating normally.

⇒ Ensure the robot program is written correctly.
_____________________________________________________________________

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ERROR CODE E1130 Jt %-M collision was detected.

Motor current command value exceeds the threshold value set in AUX 0510.

⇒ Remove obstacles in the robot motion path area.

⇒ Ensure tool settings are correct.
⇒ If an obstacle was not encountered, increase the threshold value set in AUX 0510.
_____________________________________________________________________

ERROR CODE E1131 Jt %-M Unexpected shock is detected.

Change in motor current command value, per unit of time, exceeds the threshold value
set in AUX 0510.

⇒ Remove obstacles in the robot motion path area.

⇒ Ensure tool settings are correct.
⇒ If an obstacle was not encountered, increase the threshold value set in AUX 0510.
_____________________________________________________________________

ERROR CODE E1132 Motor power OFF. Measurement stopped.

This error occurs when motor power is interrupted during auto load measurement.

Main causes include:

1. External HOLD/RUN switch is set to HOLD.
2. TEACH/REPEAT switch is set to TEACH.
3. External EMERGENCY STOP switch is pressed.

⇒ Reset switches to allow repeat operation. Repeat the auto load measurement.
⇒ Ensure the motor power is not interrupted during auto load measurement. Repeat the
auto load measurement.
_____________________________________________________________________

ERROR CODE E1133 Conveyor has reached max. value position.

The conveyor exceeded the maximum value set for the conveyor during program execu-
tion.

⇒ Ensure conveyor maximum value is set correctly.

⇒ Modify program data as necessary.
_____________________________________________________________________

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ERROR CODE E1134 Abnormal work transfer pitch of conveyor.

The signal for resetting the conveyor value is received before the conveyor reached the
position specified by the work transfer pitch.

⇒ Ensure the work transfer pitch is set correctly.

⇒ Modify program data as necessary.
_____________________________________________________________________

ERROR CODE E1135 Motor power OFF.

Displayed whenever an emergency stop is encountered.

Main causes include:

1. External EMERGENCY STOP switch is pressed.
2. Teach pendant or operation panel EMERGENCY STOP switch is pressed.
3. Emergency stop line is disconnected.

⇒ Reset emergency stop button and reapply motor power.

⇒ Repair emergency stop line as necessary.
_____________________________________________________________________

ERROR CODE E1136 Standard terminal is not connected.

A PRINT, TYPE, or PROMPT command is specified for display on a PC that is not con-
nected.

⇒ Verify the PC connections and set-up, or modify, the commands for display on the
teach pendant.
_____________________________________________________________________

ERROR CODE E1137 Cannot input/output to teach pendant.

Main causes include:

1. A PRINT, TYPE, or PROMPT command is specified for display on the teach pendant,
and a teach pendant connection is not present.
2. Incorrect setting for teach pendant connection.
3. Controller is unable to switch to the teach pendant keyboard screen in its current
state.

⇒ Verify the teach pendant connections and set-up, or modify, the commands for display
on the PC.
⇒ Reset the teach pendant so switching to the keyboard screen is possible.
_____________________________________________________________________

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ERROR CODE E1138 Aux. terminal is not connected.

External monitoring device is not connected.

⇒ Ensure the external monitoring device is properly connected.

_____________________________________________________________________

ERROR CODE E1139 DA board is not installed.

(Option, analog voltage output)

Main causes include:

1. The optional I/O board for analog output is not installed or is defective (1GW/1HW
with analog output option).
2. The signal number used is not in the range of usable signal numbers set using the
SETOUTSIG command/instruction.

⇒ Install or replace the optional I/O board for analog output (1GW/1HW with analog
output option).
⇒ Ensure the signal number used is in the range of usable signal numbers set using the
SETOUTSIG command/instruction.
_____________________________________________________________________

ERROR CODE E1140 No conveyor axis.

Conveyor synchronous function is set-up but a conveyor axis is not installed.

⇒ Change the settings or install the conveyor axis.

_____________________________________________________________________

ERROR CODE E1141 Conveyor transfers beyond sync. zone.

During synchronous motion the conveyor transferred beyond the synchronous zone set
using the CVWAIT instruction.

⇒ Ensure the synchronous zone set using the CVWAIT instruction is correct.
_____________________________________________________________________

ERROR CODE E1142 No traverse axis.

Conveyor follow mode is set-up but a traverse axis is not installed.

⇒ Ensure conveyor tracking mode is properly set-up.

⇒ Install a traverse axis.
_____________________________________________________________________

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ERROR CODE E1143 Conveyor axis number is not set.

Conveyor axis number is not set at execution of conveyor synchronous motion.

⇒ Set the conveyor axis number using the ZCVAXIS instruction.

_____________________________________________________________________

ERROR CODE E1144 No Arm control board.

⇒ Ensure the 1KB/1RB arm control board is properly installed.

⇒ Replace the 1KB/1RB board.
⇒ Replace the 1KA/1RA board.
_____________________________________________________________________

ERROR CODE E1145 Cannot use specified channel, already in use.

Several “WHERE” commands were executed at the same time.

⇒ Do not execute unnecessary “WHERE” commands.

_____________________________________________________________________

ERROR CODE E1146 [LESQ] Aborted by process time over.

KLogic program did not complete execution within the specified time.

⇒ Contact KRI customer service (include operating conditions/settings and operation log
at the time the error occurred).
_____________________________________________________________________

ERROR CODE E1147 Cannot open setting file, so cannot set to shipment state.

When “2: Setting to shipment state” is selected from the initialization screen, there is no
setting file (ini_load.cmd) in the 1KA/1RA board memory.

⇒ Load the setting file (ini_load.cmd) into the 1KA/1RA board memory.
_____________________________________________________________________

ERROR CODE E1148 Cannot read setting file, so cannot set to shipment state.

When “2: Setting to shipment state” is selected from the initialization screen, the setting
file (ini_load.cmd) in the 1KA/1RA board memory could not be decoded.

⇒ Ensure the proper setting file (ini_load.cmd) is loaded into the 1KA/1RA board
memory.
_____________________________________________________________________

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ERROR CODE E1149 Cannot open setting data, so cannot set to shipment state.

When “2: Setting to shipment state” is selected from the initialization screen, a data file
in the setting file (ini_load.cmd) in the 1KA/1RA board memory could not be opened.

⇒ Ensure the proper setting file (ini_load.cmd) is loaded into the 1KA/1RA board
memory.
_____________________________________________________________________

ERROR CODE E1150 Cannot read setting data, so cannot set to shipment state.

When “2: Setting to shipment state” is selected from the initialization screen, a data file
in the setting file (ini_load.cmd) in the 1KA/1RA board memory could not be decoded.

⇒ Ensure the proper setting file (ini_load.cmd) is loaded into the 1KA/1RA board
memory.
⇒ If the proper setting file (ini_load.cmd) is loaded replace the 1KA/1RA board.
_____________________________________________________________________

ERROR CODE E1151 Too much data for setting to the shipment state.

When “2: Setting to shipment state” is selected from the initialization screen, more than
10 data files are in the setting file (ini_load.cmd) in the 1KA/1RA board memory.

⇒ Ensure 10 or less data files are in the setting file (ini_load.cmd) loaded into the 1KA/
1RA board memory.
_____________________________________________________________________

ERROR CODE E1152 Name of setting data for shipment state is too long.

When “2: Setting to shipment state” is selected from the initialization screen, the name of
a data file in the setting file (ini_load.cmd) in the 1KA/1RA board memory exceeds eight
characters, or the file extension exceeds four characters.

⇒ Ensure the file name and extension contains the proper number of characters.
_____________________________________________________________________

ERROR CODE E1153 Power sequence board detects error. (Code=%08X)

An error is detected by the 1KP board but the code (Code=%08X) could not be inter-
preted by the AS software.

⇒ Replace the 1KP board.

⇒ If this error recurs after replacing the 1KP board contact KRI customer service.
_____________________________________________________________________

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ERROR CODE E1154 Option SIO port is not installed.

Main causes include:

1. Optional communication port (1GS board) is not installed to the 1KA/1RA board.
2. Optional communication port (1GS board) is not recognized by the 1KA/1RA board.

⇒ Install the optional communication port (1GS board) onto the 1KA/1RA board.
⇒ Replace the 1KA/1RA board.
_____________________________________________________________________

ERROR CODE E1155 A/D converter is not installed.

A/D converter board (1FH) is not installed to the 1KA/1RA board.

⇒ Install the A/D converter board (1FH).

_____________________________________________________________________

ERROR CODE E1156 [ARM CONTROL BOARD] Processing time over.

AS software processing did not complete within normal time.

⇒ Reset the error.

⇒ If this error recurs, contact KRI customer service.
_____________________________________________________________________

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ERROR CODE E1157 Arm ID I/F board error. (code %X)

Code Description
C1H Communication check sum error1
C5H Communication protocol error1
C6H Communication response time-out error1
FFH Other errors (unknown error)2
1
Damaged or disconnected communication cable.
2
F*H cycle controller power ON and OFF. If error does not clear
further diagnosis is needed (possible damaged arm ID board
or power sequence board).

Main causes include:

1. Defective 1GV/1KA/1RA/1KB/1RB/1KP boards.
2. Defective controller harness, separate harness, and/or machine harness.

⇒ Replace 1GV/1KA/1RA/1KB/1RB/1KP boards.

⇒ Replace controller harness, separate harness, and/or machine harness.
_____________________________________________________________________

ERROR CODE E1158 (SSCNET) Servo error of Jt %-M.

Alarm or warning detected in the Mitsubishi servo amplifier or servo motor.

⇒ Refer to the message displayed after the error message.

_____________________________________________________________________

ERROR CODE E1159 (SSCNET) Error code for servo is (%2x).

Alarm or warning detected in the Mitsubishi servo amplifier or servo motor.

⇒ Refer to the Mitsubishi servo amplifier instruction manual for troubleshooting.

_____________________________________________________________________

ERROR CODE E1160 (SSCNET) Servo error and monitor setting error of Jt %-M.

Alarm or warning detected in the Mitsubishi servo amplifier or servo motor, but alarm
and warning is not set to be monitored and displayed.

⇒ Set the alarm and warning to be monitored, and refer to the messaged displayed for
troubleshooting.
_____________________________________________________________________

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ERROR CODE E1162 Buffer overflow occurred gravity comp. value channel %-M.

Gravity compensation value overflow due to mismatch of load weight and the set value.

⇒ Contact KRI customer service (include operating conditions/settings and operation log
at the time the error occurred).
_____________________________________________________________________

ERROR CODE E1163 Robot stopped in checking operational area.

The robot stopped during auto load measurement and is unable to continue the opera-
tion.

⇒ Repair the cause of the robot stopping and re-execute auto load measurement.
_____________________________________________________________________

ERROR CODE E1164 [LSEQ] Program execution error in at control power ON.
(code %d)

Controller power is set OFF during KLogic program execution and the program did not
re-execute automatically at the next controller power-up.

⇒ Display the contents of the error message number displayed after the code (sub-code
%d) using the $ERROR function.
Example: TYPE $ERROR (-11038)
_____________________________________________________________________

ERROR CODE E1165 Unable to download ext. axis parameter. (Jt-A)

Download failed due to channel 7 parameter being downloaded by another process.

⇒ Re-execute parameter download.

⇒ If this error recurs, contact KRI customer service.
_____________________________________________________________________

ERROR CODE E1166 Num. not assigned to specified channel. (Jt-A)

Channel is not assigned an axis number.

⇒ Assign an axis number to channel 7.

_____________________________________________________________________

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TROUBLESHOOTING

ERROR CODE E1167 Unable to download ext. axis parameter. (Jt-B)

Download failed due to channel 8 parameter is being downloaded by another process.

⇒ Re-execute parameter download.

⇒ If this error recurs, contact KRI customer service.
_____________________________________________________________________

ERROR CODE E1168 Num. not assigned to specified channel. (Jt-B)

Channel is not assigned an axis number.

⇒ Assign an axis number to channel 8.

_____________________________________________________________________

ERROR CODE E1169 Error in servo parameter change sequence. (code %4x)

Servo parameters upload/download requested but completion is not confirmed.

Code Description
A Unit number normally 0.
B Channel number. 0 is the first channel on the 1KB board and is normally JT1.
C Group number. Servo parameters are in two parts.
D Sequence status
Initialize:0, normal:, 1 upload request: 2, waiting upload:3, download request:4,
F waiting download:5, end process: 6.

⇒ Reset error.
⇒ If error cannot be reset, cycle controller power OFF and ON.
_____________________________________________________________________

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ERROR CODE E4000 Data communication error.

Main causes include:

1. When receiving data from vision sensor:
–Time out occurred, data is not received within the specified time.
–Robot is stopped by HOLD, ABORT or PCABORT during data communication.
–Robot stopped by the CONTROL key or ENTER key from a PC keyboard during
data communication
2. During Host Communication I, data is not received within the specified time after ENQ
code is sent.
3. Communication error occurred during PC terminal, floppy disk, or PC card interaction
with the AS software.

⇒ Check communication line, and re-execute.

⇒ Ensure communication protocol used for Host Communication I is correct.
⇒ Check the communication cable, and replace as necessary.
_____________________________________________________________________

ERROR CODE E4001 Data reading error.

Discrepency in data between when it is written to a PC terminal, floppy disk or PC card

and when it is read back from the storage media for verification.

⇒ Re-execute data reading.

⇒ If this error recurs, replace the storage media, 1KA/1RA/1KF boards, harness, etc.
_____________________________________________________________________

ERROR CODE E4002 Data transfer error.

Error occurred during data writing to a PC terminal, floppy disk or PC card.

⇒ Re-execute data writing.

⇒ If this error recurs, replace the storage media, 1KA/1RA/1KF boards, harness, etc.
_____________________________________________________________________

ERROR CODE E4003 Unexpected error in file access.

During floppy disk or PC card interaction with the AS software, an undefined communi-
cation error occurred.

⇒ Re-execute file access.

⇒ If this error recurs, replace the storage media, 1KA/1RA/1KF boards, harness, etc.
_____________________________________________________________________

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TROUBLESHOOTING

ERROR CODE E4004 Communication retry error.

Communication retry error during Host Communication I.

Main causes include:

1. No response after sending text.
2. After text is sent, NAK (resend request) exceeded the allowed number of retries.

⇒ Ensure communication protocol used for Host Communication I is correct.

⇒ Check the communication cable and replace as necessary.
_____________________________________________________________________

ERROR CODE E4005 Communication process was stopped.

During Host Communication I, a stop monitor command (ABORT, PCABORT, etc.) is

executed during execution of SEND/RECEIVE.

⇒ Re-execute the EXECUTE, PCEXECUTE, etc. command.

_____________________________________________________________________

ERROR CODE E4006 Receive no data after request.

During Host Communication I, text data is not received within the allowed time after the
data request is sent.

⇒ Ensure communication protocol used for Host Communication I is correct.

⇒ Check the communication cable and replace as necessary.
_____________________________________________________________________

ERROR CODE E4007 Receiving data is too long (MAX=255 character).

During Host Communication I, an attempt to receive a string with more than 255 charac-
ters is made.

⇒ Ensure communication protocol used for Host Communication I is correct.

_____________________________________________________________________

ERROR CODE E4008 Abnormal data (EOT) received in communication.

During Host Communication I, abnormal code (EOT) is received and the communication
process is stopped.

⇒ Ensure communication protocol used for Host Communication I is correct.

_____________________________________________________________________

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ERROR CODE E4009 Communication time out error.

During Host Communication I or TCP/IP interface, data is not received within the allowed
time after executing the RECEIVE instruction.

⇒ Ensure communication protocol used for Host Communication I is correct.

⇒ Reserve the communication line.
_____________________________________________________________________

ERROR CODE E4010 Terminal already in use.

The prompt instruction is executed by two or more programs at the same time.

⇒ Do not execute the prompt instruction from two or more programs at the same time.
_____________________________________________________________________

ERROR CODE E4011 Communication port already in use.

During Host Communication I, TERMON is executed from the teach pendant keyboard
screen while the PC terminal port is in use.

⇒ Ensure the PC terminal port is not in use before execution of TERMON from the teach
pendant keyboard screen.
_____________________________________________________________________

ERROR CODE E4012 Waiting for input of PROMPT. Connect input device.

The input device specified by a prompt command, i.e., PC or teach pendant, is not
connected.

⇒ Ensure the specified device is connected.

_____________________________________________________________________

ERROR CODE E4013 TELNET) SEND error. CODE=%d.

This error occurs when data is transmitted by TCP/IP, and an abnormality occurs in the
communication line or the connection is aborted or closed.

⇒ Check the communication line to the target end node and repair as necessary.
⇒ Check for problems at the target end node and repair as necessary.
⇒ The sub-error code (CODE=%d) is generated by the TCP/IP package. Refer to the
TCP/IP package manual.
_____________________________________________________________________

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ERROR CODE E4014 TELNET) RECV error. CODE=%d.

During TCP/IP communication, data is not received due to a RECV (receive) error.

⇒ Check the communication line to the target end node and repair as necessary.
⇒ Check for problems at the target end node and repair as necessary.
⇒ The sub-error code (CODE=%d) is generated by the TCP/IP package. Refer to the
TCP/IP package manual.
_____________________________________________________________________

ERROR CODE E4015 TELNET) IAC receive error. CODE=%d.

During TCP/IP communication, an error occurred when receiving data.

⇒ Check the communication line to the target end node and repair as necessary.
⇒ Check for problems at the target end node and repair as necessary.
⇒ Ensure the PC at the target end is using KCWIN TCP software.
⇒ The sub-error code (CODE=%d) is generated by the TCP/IP package. Refer to the
TCP/IP package manual.
_____________________________________________________________________

ERROR CODE E4016 TELNET) Close failure. CODE =%d.

An error occurred in the LISTEN/ACCEPT function during an attempt to close the

socket. TCP/IP resources (queue or buffer) may be full. May be a problem with the
communication line or at the target end node.

⇒ Stop any other TCP/IP functions operating at the same time.

⇒ Cycle robot controller power OFF and ON.
⇒ The sub-error code (CODE=%d) is generated by the TCP/IP package. Refer to the
TCP/IP package manual.
_____________________________________________________________________

ERROR CODE E4017 TELNET) Main socket close failure. CODE=%d.

An error occurred in the LISTEN/ACCEPT function during an attempt to close the main
socket. TCP/IP resources (queue or buffer) may be full. May be a problem with the
communication line or at the target end node.

⇒ Stop any other TCP/IP functions operating at the same time.

⇒ Cycle robot controller power OFF and ON.
⇒ The sub-error code (CODE=%d) is generated by the TCP/IP package. Refer to the
TCP/IP package manual.
_____________________________________________________________________

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ERROR CODE E4018 TELNET) System error. CODE=%d.

Parameter settings entered using the NETCONF command does not comply with AS
Language syntax.

The code (CODE=%d) indicates a detailed SUB error code for the TCP/IP package.

⇒ Refer to the TCP/IP package manual.

⇒ Ensure the parameter settings are entered in compliance with AS Language syntax.
_____________________________________________________________________

ERROR CODE E4019 TCP/IP) Socket open failure. CODE=%d

Dst.IP=%d.%d.%d.%d.

This error occurs when execution of a socket open instruction (TCP_LISTEN/

TCP_CONNECT/UPD_SENDTO/UPD_RECVFROM) fails. If multiple socket numbers
are used, the number of sockets may exceed the limit. Possible IP address parameter
error.

⇒ Ensure during multiple socket openings do not exceed limits.

⇒ Ensure the IP address parameters are correct.
⇒ The sub-error code (CODE=%d) is generated by the TCP/IP package. Refer to the
TCP/IP package manual.
_____________________________________________________________________

ERROR CODE E4020 TCP/IP) Socket close failure. CODE=%d

Dst.IP=%d.%d.%d.%d.

This error occurs when socket closing instruction (TCP_CLOSE/TCP_END_LISTEN/

UDP_SENDTO/UDP_RECVFREOM) fails. May be a problem with the communication
line or at the target end node.

⇒ Check the communication line to the target end node and repair as necessary.
⇒ Check for problems at the target end node and repair as necessary.
⇒ The sub-error code (CODE=%d) is generated by the TCP/IP package. Refer to the
TCP/IP package manual.
_____________________________________________________________________

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ERROR CODE E4021 TCP/IP) Communication Error. CODE=%d

Dst.IP=%d.%d.%d.%d.

A communication error occurred during execution of the UDP_SENDTO/

UDP_RECVFROM/TCP_SEND/TCP_RECV instruction. May be a problem with the
Ethernet line or at the target end.

⇒ Check the communication line to the target end node and repair as necessary.
⇒ Check for problems at the target end node and repair as necessary.
⇒ The sub-error code (CODE=%d) is generated by the TCP/IP package. Refer to the
TCP/IP package manual.
_____________________________________________________________________

ERROR CODE E4022 TCP/IP) Message is too long.

Data sent exceeds the allowed size limit using the TCP_SEND/UDP_SENDTO/
UDP_RECVFROM instruction.

⇒ Edit the data to within allowed size limit (TCP: 4096 bytes or less, UPD: 1472 bytes or
less).
_____________________________________________________________________

ERROR CODE E4023 TCP/IP) Cannot reach the Host.

Failed to connect with the target end node when executing the UDP_SENDTO/
UDP_RECVFROM/TCP_CONNECT instruction. The host of the corresponding IP
address does not exist on the network. Designated port number or IP address may be
wrong. May be a problem with the communication line or at the target end node.

⇒ Ensure the port number and the IP address are correct.

⇒ Ensure the parameter settings comply with AS Language syntax.
⇒ Check the communication line to the target end node and repair as necessary.
_____________________________________________________________________

ERROR CODE E4024 TCP/IP) Communication Time Out.

Dst.IP=%d.%d.%d.%d.

Communication time-out occurred during instruction execution. May be a problem with

the Ethernet line or at the target end node.

⇒ Check the communication line to the target end node and repair as necessary.
_____________________________________________________________________

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ERROR CODE E4025 TCP/IP) Connection aborted.

Communication is disconnected during execution of the UDP_SENDTO/

UDP_RECVFROM/TCP_CONNECT/TCP_SEND/TCP_RECV/TCP_ACCEPT instruc-
tion. May be a problem with the Ethernet line or at the target end node.

⇒ Check the communication line to the target end node and repair as necessary.
_____________________________________________________________________

ERROR CODE E4026 TCP/IP) No Buffer Space.

A communication error occurred during execution of the UDP_SENDTO/

UDP_RECVFROM/TCP_SEND/TCP_RECV instruction. TCP/IP resources (queue or
buffer) may be full.

⇒ Stop any other TCP/IP functions operating at the same time.

⇒ Cycle robot controller power OFF and ON.
⇒ Check the communication line to the target end node and repair as necessary.
_____________________________________________________________________

ERROR CODE E4027 TCP/IP) Bad Socket.

Failed to connect with the target end node when executing the UDP_SENDTO/
UDP_RECVFROM/TCP_CONNECT instruction. Designated port number or IP address
may be wrong. May be a problem with the Ethernet line or at the target end node.

⇒ Ensure the port number and the IP address are correct.

⇒ Ensure the parameter settings comply with AS Language syntax.
⇒ Check the communication line to the target end node and repair as necessary.
_____________________________________________________________________

ERROR CODE E4028 FTP) Data receive error. (code=%d)

Failure to receive the teach data via LAN→Memory (Manual LOAD), or the LAN file
directory information list. May be a communication cable connection problem.

⇒ Ensure the communication cable connections are correct and re-execute.

_____________________________________________________________________

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ERROR CODE E4029 FTP) Data send error. (code=%d).

Failure to transmit the teach data via Memory→LAN (Manual SAVE). May be a commu-
nication cable connection problem.

⇒ Ensure the communication cable connections are correct and re-execute.

_____________________________________________________________________

ERROR CODE E4031 FTP) Failed to disconnect with FTP server. (code=%d)

Failure to terminate when completing communication with the FTP server.

Probable causes:
1. Communication cable is not properly connected.
2. The remote host FTP server is OFF or is in an abnormal condition.

⇒ Ensure the communication cable is properly connected and re-execute.

⇒ Reboot the remote host FTP server.
_____________________________________________________________________

ERROR CODE E4032 FTP) Unregistered OS detected.

An unregistered OS is detected.

⇒ Register the detected OS.

_____________________________________________________________________

ERROR CODE E4033 FTP) Failed to connect with server. (code=%d)

The connection failed when communication is started with the FTP server.

Main causes include:

1. The designated address does not exist on the network.
2. Communication cable is not properly connected.
3. Failed to login to FTP server.

⇒ Ensure the IP address is correct in Set Remote Host Information.

⇒ Ensure the communication cable is properly connected, and re-execute.
⇒ Ensure the user name and password for the LAN remote host save/load settings are
correct.
_____________________________________________________________________

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ERROR CODE E4034 FTP) failed to receive HOST OS information. (code=%d)

Error occurred during receiving OS information from the server.

⇒ Ensure the communication cable is properly connected, and re-execute.

⇒ Reboot the FTP server.
_____________________________________________________________________

ERROR CODE E4036 FTP) FTP service busy now.

A command is being executed by the server.

⇒ Allow the current command to complete execution, and re-execute.

⇒ If this error recurs contact KRI customer service.
_____________________________________________________________________

ERROR CODE E4037 FTP) Failed AUTO-SAVing.

An error occurred during auto save; an additional error code is displayed after the error
message.

⇒ Follow the procedures for the error displayed after the error message.
_____________________________________________________________________

ERROR CODE E4050 No response from the FDD/PC_CARD driver board.

A SAVE/LOAD etc. command is requested by the 1KA/1RA board, but no response is

received from the 1KF board.

⇒ Check harness and connections to the 1KF board and repair as necessary.
⇒ Replace the 1KA/1RA/1KF boards.
_____________________________________________________________________

ERROR CODE E4051 No communication with FDD/PC_CARD driver board.

No communication between the 1KA/1RA and 1KF boards.

⇒ Check harness and connections to the 1KF board and repair as necessary.
⇒ Replace the 1KA/1RA/1KF boards.
_____________________________________________________________________

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ERROR CODE E4052 [FDD/PC_CARD] Failed to set verify function. Please set
again.

Failure to set condition for verify function for the 1KF board.

⇒ Re-set condition for verify function in AUX 0208.

_____________________________________________________________________

ERROR CODE E4053 Channel error.

A monitor or program instruction is executed on an unavailable channel.

Example: Port number is not set within 8192–65535 for UPD_SENDTO.

⇒ Specify an available channel.

_____________________________________________________________________

ERROR CODE E4054 TCP/IP) Cannot execute because Ethernet board not
installed.

Main causes include:

1. 1KN/1QN board (daughter board on the 1KA/1RA board) is not installed.
2. Defective 1KN/1QN/1KA/1RA boards.

⇒ Ensure the 1KN/1QN board is properly installed.

⇒ Replace the 1KA/1RA/1KN/1QN boards.
_____________________________________________________________________

ERROR CODE E4055 TCP) Cannot create a socket.

Failure to open a socket when TCP_LISTEN/TCP_CONNECT is executed.

Main causes include:

1. Too many sockets open.
2. Same port is used too many times.

⇒ Close opened sockets using TCP_CLOSE and re-execute TCP_LISTEN/

TCP_CONNECT.
⇒ Avoid executing too many instructions at a time.
⇒ Ensure parameters are correct.

_____________________________________________________________________

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ERROR CODE E4056 TCP) This port is not in LISTEN (SOCK).

Main causes include:

1. Failure to open the socket when executing TCP_ACCEPT.
2. Failure to close the socket when executing TCP_END_LISTEN.

⇒ Ensure correct port number is used.

⇒ Ensure the parameter settings are entered in compliance with AS Language syntax.
_____________________________________________________________________

ERROR CODE E4057 TCP) Illegal Socket ID.

Communication error occurred when executing TCP_SEND/TCP_RECV, or failure to

close socket when executing TCP_CLOSE/TCP_END_LISTEN.

Main causes include:

1. The socket ID number or port number is not created.
2. Incorrect program execution order.

⇒ Ensure the correct socket ID number or port number is used.

⇒ Ensure the program execution order is correct
_____________________________________________________________________

ERROR CODE E4058 Failed download to FDD/PC_CARD driver board.

Failed to download software to the floppy disk driver board or the PC card driver board
(1KF board).

⇒ Ensure proper 1KF board software download settings are used.

⇒ It the error recurs, replace the 1KF board.
_____________________________________________________________________

ERROR CODE E4500 ANYBUS) IN-AREA request timeout. %X

Main causes include:

1. Error lamp ON:
Request for access to the output signal writing area is rejected due to hardware
abnormality.
2. Error lamp OFF:
Access to the output signal writing area is not released due to hardware abnormality.

⇒ Check LED indicator on the interface card, and reset the error.
⇒ If the error message is still displayed, contact KRI customer service, include the sub-
code %X.
_____________________________________________________________________

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ERROR CODE E4501 ANYBUS) OUT/FB.CTRL release timeout. %X

Access to the input signal reading area is not released due to defective hardware.

⇒ Check LED indicator on the interface card, and reset the error.
⇒ If the error message is still displayed contact KRI customer service, include the sub-
code %X.
_____________________________________________________________________

ERROR CODE E4510 DN) Master status. %X

The status of the master port changed due to faulty communication, caused by cable
disconnection during DeviceNet communication. %X indicates the status code.

⇒ Check the status sub-code %X and reset the error.

_____________________________________________________________________

ERROR CODE E4511 DN) Node status. %X

The status of the slave node changed due to faulty I/O communication, caused by
DeviceNet slave node cable disconnection.

⇒ Use the status sub-code %X as a troubleshooting aid.

⇒ Check the DeviceNet slave node cable and connections, and repair as necessary.
_____________________________________________________________________

ERROR CODE E4512 ABM-DN) Mailbox error.

An error is returned because data sent the mailbox is not accepted due to incorrect
DeviceNet parameter setting.

⇒ Ensure the MAC_ID specified for the slave node and the parameter settings are
correct, and re-execute DEVNET command.
_____________________________________________________________________

ERROR CODE E4520 ABMA-PDP) Status STOP. %08X

During I/O communication in auto clear mode, an error occurred in the slave node and
the status of AnyBus PROFIBUS-DP master changed to STOP.

⇒ Check the connections of the fieldbus cable and repair as necessary.

⇒ Use the sub-code %08X as a troubleshooting aid, clear the cause of the error and
reset the error.
_____________________________________________________________________

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ERROR CODE E4521 ABMA-PDP) Status OFFLINE. %08X

An error occurred in the ABMA-PDP module, and the status of AnyBus PROFIBUS-DP
master changed to OFFLINE.

⇒ Use the sub-sub-code %08X as a troubleshooting aid, clear the cause of the error
and reset the error.
⇒ If the error recurs, cycle the controller power OFF and ON.
_____________________________________________________________________

ERROR CODE E4522 ABMA-PDP) I/O data communication error. %08X

During I/O communication, configuration data is downloaded to the interface card, then
communication is disconnected.

⇒ Use the sub-code %08X as a troubleshooting aid, clear the cause of the error and
reset the error.
_____________________________________________________________________

ERROR CODE E4523 ABMA-PDP) sending of timed out I/O data. %08X

The ABMA-PDP module is overloaded and output signals from the AS system cannot be
processed within the allowed time.

⇒ Check the fieldbus cable connections and repair as necessary.

⇒ Use the sub-code %08X as a troubleshooting aid, clear the cause of the error and
reset the error.
_____________________________________________________________________

ERROR CODE E4524 ABMA-PDP) Timeout of receiving I/O data. %08X

ABMA-PDP module overload, input signals from the slave cannot be processed within
the allowed time.

⇒ Check the fieldbus cable and connections, repair/replace as necessary.

⇒ Use the sub-code %08X as a troubleshooting aid, clear the cause of the error and
reset the error.
_____________________________________________________________________

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ERROR CODE E4525 ABMA-PDP) Timeout of sending message. %08X

ABMA-PDP module overload, sending message cannot be processed within the allowed
time.

⇒ Check the fieldbus cable and connections, repair/replace as necessary.

⇒ Use the sub-code %08X as a troubleshooting aid, clear the cause of the error and
reset the error.
_____________________________________________________________________

ERROR CODE E4526 ABMA-PDP) Timeout of receiving message. %08X

ABMA-PDP module overload, receiving message cannot be processed within the al-
lowed time.

⇒ Check the fieldbus cable and connections, repair/replace as necessary.

⇒ Use the sub-code %08X as a troubleshooting aid, clear the cause of the error and
reset the error.
_____________________________________________________________________

ERROR CODE E4527 ABMA-PDP) Check configuration data. %08X

Incorrect configuration data or bus parameter is downloaded. Download cannot be

completed after error reset.

⇒ Use the sub-code %08X as a troubleshooting aid, ensure correct configuration data
and bus parameters are used and re-execute download.
⇒ If the number of external I/O signals is changed, cycle controller power OFF and ON.
_____________________________________________________________________

ERROR CODE E4528 PROFIBUS) Slave Diag-error response detected. %08X

Incorrect slave diagnosis command parameter is entered. If sub-code %08X=A1 (hexa-

decimal notation), the node address used is out of range.

⇒ Ensure the correct parameters and node address are used.

⇒ Check the fieldbus cable and connections, repair/replace as necessary.
_____________________________________________________________________

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ERROR CODE E4529 PROFIBUS) Statistic counter-error response detected. %X

Incorrect slave diagnosis command parameter is entered.

⇒ Use the sub-code %X as a troubleshooting aid, clear the cause of the error and reset
the error.
⇒ Ensure the correct parameters and node address are used.
_____________________________________________________________________

ERROR CODE E4530 DN) DeviceNet cable is disconnected.

DeviceNet cable connected to the slave device is disconnected while system switch
DN_DISCON_ERR is ON.

⇒ Reset the error in teach mode, and move the robot to a pose to enable access for
troubleshooting.
⇒ Check the DeviceNet cable and connections, repair/replace as necessary.
_____________________________________________________________________

ERROR CODE E5000 Connected permission signal has not been turned ON.

Dedicated gun connection “OK” signal is OFF when gun connection is executed.

⇒ Ensure gun connection “OK” signal is ON, re-execute gun connection.

_____________________________________________________________________

ERROR CODE E5001 RWC type is not process control type.

This error occurs when welder type setting is set to adaptive control and the weld con-
troller connected to the system is not an adaptive control type.

⇒ Ensure welder type setting is correctly set to adaptive control or constant current
control.
_____________________________________________________________________

ERROR CODE E5002 1GS board is not process control type.

This error occurs when welder type setting is set to adaptive control and the 1GS board
and 1GS board software are not compatible with adaptive control.

⇒ Replace the 1GS board and 1GS board software with adaptive control components.
_____________________________________________________________________

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ERROR CODE E5003 Illegal extend (retract) output signal.

Occurs when the output signals for the extend and retract operation of a spot welding
application are not properly set.

⇒ Check the setting in AUX 0605.

_____________________________________________________________________

ERROR CODE E5004 Weld completion signal already input.

Displayed when the weld completion signal is received before the weld initiate output.

Main causes include:

1. Weld completion signal is not set OFF, after the last welding step.
2. Before the weld completion signal is set OFF, the robot started execution of the next
welding step.

⇒ Check operation of welding equipment (gun and weld controller/timer), check the
signal number setting in AUX 0605-11, repair/modify as necessary.
⇒ Check the 1KA/1RA/1GW (1HW) boards and replace as necessary.
⇒ Check the interlock circuit and repair as necessary.
⇒ Check program data, weld timing, and welding data settings, modify as necessary
_____________________________________________________________________

ERROR CODE E5005 Welding schedule setting data is abnormal.

(Spot weld specifications type B)

The weld conditions set for the program welding point are out of range or not set for
clamp 1.

⇒ Ensure the correct weld conditions are set for the program weld point.
_____________________________________________________________________

ERROR CODE E5006 CLAMP SPEC is not set PULSE.

The error occurs when the spot weld clamp signal specification in the system (robot
system switch RWC=ON) is set to level instead of pulse.

⇒ Ensure the spot weld clamping signal specification is set to pulse using the
SETCLAMP AS Language command.
_____________________________________________________________________

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ERROR CODE E5007 Servo weld gun not connected or wrong gun connected.
(Servo spot weld gun only)

Main causes include:

1. The robot executes a step when a gun is not attached to the tool changer.
2. The gun number in the tool changer is different than the gun number specified for the
program step.
3. Incorrect gun number is read due to damaged gun harness.

⇒ Execute the step in manual mode or manually install the correct gun. In the teach or
check mode, verify connection of the gun by pressing the connect/separate button.
⇒ If the correct gun is attached to the tool changer, confirm that the gun signal number
(AUX 0605-41, GUN CONNECTION SIGNAL) is correct. From the MONITOR (IN-
PUT SIGNAL) screen, confirm that the signal number is received.
⇒ Inspect the connections between the gun and the 1FG board and repair as neces-
sary.
⇒ Check gun harness and connections and repair/replace as necessary.
⇒ Temporarily set the gun connect signal number (AUX 0605-41, GUN CONNECTION
SIGNAL) to 0 (when the gun connect number is set to 0, the error is not detected);
ensure that the correct gun is in the tool changer. Repair the gun connection and set
the gun connect signal number as soon as possible.
_____________________________________________________________________

ERROR CODE E5008 Tip wear measurement (stage 1) was not executed.
(Servo spot weld gun only)

The tip wear measurement program stage 2 (reference plate) is attempted, without first
performing stage 1.

⇒ Execute tip wear measurement program stage 1 prior to executing stage 2.

_____________________________________________________________________

ERROR CODE E5009 Work sensing signal (gun_tip touch signal) is not set.
(Servo spot weld gun only)

A workpiece thickness measurement is attempted, when the gun tip touch signal (set in
AUX 1021) has not been received.

⇒ Set the gun tip touch signal number (AUX 1021).

_____________________________________________________________________

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ERROR CODE E5010 Servo weld gun mechanical parameter is not set.
(Servo spot weld gun only)

A new gun is connected and the mechanical parameters are not defined in AUX 1021.

⇒ Define the parameters in AUX 1021.

_____________________________________________________________________

ERROR CODE E5011 This clamp number already set for servo weld gun axis.
(Servo spot weld gun only)

This error occurs when a servo spot weld gun number is duplicated using the ZAXIS AS
Language command or AUX 2002.

⇒ Ensure the servo spot weld gun numbers are not duplicated using the ZAXIS AS
Language command or AUX 2002.
_____________________________________________________________________

ERROR CODE E5012 Cannot change the gun because offset data is abnormal.

The encoder offset data set for the gun is different at time of gun change.

⇒ Ensure encoder offset data for all guns is the same.

_____________________________________________________________________

ERROR CODE E5013 Cannot change multiple guns at the same step.
(Servo spot weld gun only)

The operator is attempting to execute a step with more than one gun change.

⇒ Edit the program so that there is only one gun change per step.
_____________________________________________________________________

ERROR CODE E5014 Gun is connected other.

The tool changer is attempting to connect to a gun that is already connected to another
axis tool changer or is missing.

⇒ Select a different gun or disconnect the gun from the other tool changer.
_____________________________________________________________________

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ERROR CODE E5015 Gun status data disagrees with clamp condition.
(Servo spot weld gun only)

Incorrect program data is used.

Main causes include:

1. Clamp ON is taught in a step that includes a gun change.
2. Clamp OFF is taught in a step that includes a point for “wear measurement using
automatic clamping”, “wear measurement reference plate”, or “work position deviation
measurement”.

⇒ Ensure clamp OFF is taught in a step that includes a gun change.

⇒ Ensure clamp ON is taught in a step that includes a point for “wear measurement
using automatic clamping”, “wear measurement reference plate”, or “work position
deviation measurement”.
_____________________________________________________________________

ERROR CODE E5016 Data of SRVPRESS is wrong.

This error occurs when the welding clamp pressure change cycle ratio number for the
servo gun is other than SRV3PRESS, SRV4PRESS, SRV5PRESS, or SRV6PRESS.

⇒ Ensure the cycle ratio number is set correctly.

_____________________________________________________________________

ERROR CODE E5017 Wear base data is not registered.

This error occurs when the tip wear base data entry was not made and the tip wear
measurement operation is performed.

⇒ Ensure tip wear base data entry is performed before tip wear measurement operation
is performed.
_____________________________________________________________________

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ERROR CODE E5018 Weld completion signal has not been detected.

Occurs when a weld complete signal is not received in the allowed time period.

Main causes include:

1. Defective weld gun, weld controller/timer, cable, etc.
2. Defective 1KA/1RA/1GW (1HW) boards, or harness, etc.
3. Defective interlock circuit.
4. Noise related malfunction.

⇒ Check gun, weld controller/timer, cable, etc. and repair/replace as necessary.

⇒ Check 1KA/1RA/1GW (1HW) boards and harness and replace as necessary.
⇒ Check for noise malfunction and shield integrity.
_____________________________________________________________________

ERROR CODE E5019 Weld fault signal is detected.

Main causes include:

1. Defective weld gun, weld controller/timer, cable, etc.
2. Defective 1KA/1RA/1GW (1HW) boards, harness, etc.
3. Defective interlock circuit.
4. Noise related malfunction.

⇒ Check gun, weld controller/timer, cable, etc. and repair/replace as necessary.

⇒ Check 1KA/1RA/1GW (1HW) boards and harness and replace as necessary.
⇒ Check for noise malfunction and shield integrity.
_____________________________________________________________________

ERROR CODE E5020 Retract pos. monitor error.

Occurs when the input signal for the retract operation of a 2-stroke retractable gun is not
received.

Main causes include:

1. Defective weld gun, weld controller/timer, cable, etc.
2. Defective 1KA/1RA/1GW (1HW) boards, harness, etc.
3. Defective interlock circuit.
4. Incorrect retract position input signal setting.
5. Noise related malfunction.

⇒ Check gun, weld controller/timer, cable, etc. and repair/replace as necessary.

⇒ Check 1KA/1RA/1GW (1HW) boards and harness and replace as necessary.
⇒ Ensure the retract position input signal setting is correct.
⇒ Check for noise malfunction and shield integrity.
_____________________________________________________________________

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ERROR CODE E5021 Extend pos. monitor error.

Occurs when the input signal for the extend operation of a 2-stroke retractable gun is not
received.

Main causes include:

1. Defective weld gun, weld controller/timer, cable, etc.
2. Defective 1KA/1RA/1GW (1HW) boards, harness, etc.
3. Defective interlock circuit.
4. Incorrect extend position input signal setting.
5. Noise related malfunction.

⇒ Check gun, weld controller/timer, cable, etc. and repair/replace as necessary.

⇒ Check 1KA/1RA/1GW (1HW) boards and harness and replace as necessary.
⇒ Ensure the extend position input signal setting is correct.
⇒ Check for noise malfunction and shield integrity.
_____________________________________________________________________

ERROR CODE E5022 Current gun retract position differs from a destination.

In the check mode, retractable gun output signals are monitored and compared to clamp
condition code and open/close data for a specific step. If the data does not match, this
error is displayed.

⇒ Ensure settings in clamp condition code and open/close data match output signal
settings, check operation of gun with the clamp key.
_____________________________________________________________________

ERROR CODE E5023 Wear is abnormal, cannot take measurement.

When executing tip wear measurement, the moving or fixed tip wear exceeds the al-
lowed value.

⇒ Replace the worn gun tip.

⇒ Ensure tip wear measurement data is correct.
_____________________________________________________________________

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ERROR CODE E5024 Pressurization comp. signal has not been detected.

Pressurization completion signal is not received from the weld controller/timer.

Main causes include:

1. Defective weld controller/timer.
2. Defective servo spot weld gun.
3. Defective harness, cable, etc.

⇒ Check weld controller/timer, servo spot weld gun, harnesses, and cables and repair/
replace as necessary.
_____________________________________________________________________

ERROR CODE E5025 Gun opening comp. signal has not been detected.

Gun opening completion signal is not received from the servo weld gun.

Main causes include:

1. Defective servo spot weld gun.
2. Defective servo spot weld gun cable, cable connections, tool changer, etc.

⇒ Check the servo spot weld gun, servo spot weld gun cable, cable connections, and
tool changer contacts and connections and repair/replace as necessary.
_____________________________________________________________________

ERROR CODE E5026 RWC error. -%d.

(Spot weld specifications type B)
(-%d: represents the welder number)

The current flow from the specified remote weld controller (RWC) Is abnormal.

Main causes:
20: SCR overheat 21: Memory abnormal
22: Power failure 23: System error
24: Defective electro-valve (gun control valve)

Main causes include:

Insufficient SCR cooling, a memory data error, weld current is not synchronized with gun
clamp conditions, system error, or gun control valves malfunction.

⇒ Check welder and weld gun repair/replace as necessary.

⇒ Check 1GS board, and communication cables repair/replace as necessary.
_____________________________________________________________________

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ERROR CODE E5027 Robot stopped during weld.

(Spot weld specifications type C)
(Servo spot weld gun only)

This error occurs when the robot is placed in a HOLD or an E-STOP condition after the
clamp output signal is sent, and before the weld complete signal is received.

⇒ Return the system to normal operation and re-execute weld.

_____________________________________________________________________

ERROR CODE E5028 Cannot achieve set force.

The gun does not obtain the set closing pressure within 5 seconds after the gun starts
closing.

Main causes include:

1. Tip wear measurement is not executed.
2. Incorrect taught point (closing pressure is not defined for the recorded position).
3. Closing pressure is set too high.
4. Workpiece is too thin.
5. Incorrect lower limit motion setting (LLIMIT command).

⇒ Perform the tip wear measurement.

⇒ Reteach the point.
⇒ Decrease the closing pressure.
⇒ Ensure the workpiece specifications are correct and the workpiece is in the correct
position.
⇒ Ensure lower limit motion is set correctly (LLIMIT command).
_____________________________________________________________________

ERROR CODE E5029 Gun tip stuck.

Indicates that the tips are stuck. More power is required to open the gun, following a
weld, than the stuck detection value, set in AUX 1021 Force for Stuck Detection [kgf].

If the stuck detection value is set below the power level required for normal operation,
the gun cannot operate properly and the error is set.

⇒ If the gun is stuck, release it manually.

⇒ If the gun is not stuck, verify that the stuck detection value (AUX 1021, Force for Stuck
Detection [kgf]) is set correctly. This setting may need to be increased.
_____________________________________________________________________

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ERROR CODE E5030 Copper plate wear exceeds limit. step=%d.

(Servo spot weld gun only)

The copper backing plate wear exceeds the copper plate wear limit (AUX 1029). The
error is detected when the gun executes a weld.

⇒ Replace the copper backing plate.

_____________________________________________________________________

ERROR CODE E5031 Weld completion signal is not turned off.

This error occurs when the weld completion and weld initiate signals are high (ON) at
the same time for three seconds.

⇒ Change the weld complete signal to a pulsed signal with a duration of less than three
seconds.
⇒ Set the weld complete signal OFF using the rising-edge-trigger in the welding instruc-
tion.
_____________________________________________________________________

ERROR CODE E5032 Calibration did not end normally.

(Servo spot weld gun only)

During calibration operation after a gun change calibration is aborted.

Main causes include:

1. E-stop condition.
2. Changing modes during calibration.

⇒ Reset the error and perform a manual gun change.

_____________________________________________________________________

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ERROR CODE E5033 Cannot weld because of abnormal thickness.

(Servo spot weld gun only)

The thickness of the workpiece is out of tolerance.

Main causes include:

1. Defective workpiece.
2. Incorrect positioning of the workpiece.
3. A gap between the two panels being welded.
4. Current tip wear (AUX 1029) and actual tip wear are different.

⇒ Inspect the workpiece. Measure the thickness and positioning; replace workpiece
and/or correct abnormal positioning.
⇒ Execute the tip wear measurement program. Manually measure the tip wear; com-
pare these measurements to the current tip wear data (AUX 1029).
_____________________________________________________________________

ERROR CODE E5034 Tip wear limit. (MOVING SIDE)

Moving tip wear exceeds the set maximum wear limit during wear measurement.

⇒ Replace the moving tip.

_____________________________________________________________________

ERROR CODE E5035 Tip wear exceeds limit. (FIXED SIDE)

Fixed tip wear exceeds the set maximum wear limit during wear measurement.

⇒ Replace the fixed tip.

_____________________________________________________________________

ERROR CODE E6001 Step after XD(2)START must be LMOVE or HMOVE.

Incorrect motion instruction is taught. The step following XD(2)START requires an

LMOVE or HMOVE motion instruction for touch sensing.

⇒ Ensure the step following XD(2)START is an LMOVE or HMOVE.

_____________________________________________________________________

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ERROR CODE E6002 Signal condition already input.

The signal condition is already met when an XDMOVE or XD(2)START move is executed
and the signal monitoring starts.

⇒ Check input signal timing for the door open detection signal and the monitored sig-
nals, and correct interlock data or program data as necessary.
_____________________________________________________________________

ERROR CODE E6003 Door open detect signal is not dedicated.

During XD(2)START execution, the input signal for door open state is not set as a dedi-
cated input signal.

⇒ Set the input signal from the sensor for detecting door open/close state as a dedi-
cated input signal.
_____________________________________________________________________

ERROR CODE E6004 Location data was not detected.

An attempt to acquire compensation value from the door open state sensor is made, but
the pose data that incorporates the compensation value could not be acquired because
the door detecting instruction was not executed.

⇒ Check the program data and add XDMOVE or XD(2)START before executing XDGET
instruction.
_____________________________________________________________________

ERROR CODE E6006 Signal not detected.

Main causes include:

1. As the robot moves the specified distance per XDMOVE or XD(2)START with sensing
enabled, the monitored signal condition is not met.
2. Signal condition is not met within the time specified by DIN_WAIT instruction.

⇒ Check the timing of the door open detection input signal and the signals monitored by
XDMOVE or XD(2)START, and correct the interlock data or program data as neces-
sary.
_____________________________________________________________________

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ERROR CODE E6007 Wrist can’t be straightened any more (Singular point 1).

The posture of JT5 is set too close to 0 degrees (or a multiple of 360 degrees) on a
robot equipped with a 3S type wrist.
NOTE
This does not normally occur in joint mode, but may oc-
cur with conveyor synchronous function enabled.

⇒ Change wrist posture.

⇒ Move the robot in joint interpolation.
⇒ Change the wrist posture before enabling conveyor synchronous function, to prevent
this error.
_____________________________________________________________________

ERROR CODE E6008 Wrist can’t be bent any more. (Singular point 2).

The posture of JT5 is set too close to 180 degrees (or multiple of ±360 degrees) on a
robot equipped with a 3S wrist.
NOTE
This does not normally occur in joint mode, but may oc-
cur with conveyor synchronous function enabled.

⇒ Change wrist posture.

⇒ Move the robot in joint interpolation.
⇒ Change the wrist posture before enabling conveyor synchronous function, to prevent
this error.
_____________________________________________________________________

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ERROR CODE E6012 Relative distance between guns is too near.

The gun tips of two networked robots is less than the minimum specified distance for the
application.

⇒ If this error occurs in teach mode, drive the axes so the distance between gun tips is
within specified value.
⇒ If this error occurs in check/repeat mode, modify the program data, and change the
motion timing and relative distance.
NOTE
If this error does not occur in a near-miss condition,
check the distance (and home position) set for error de-
tection for the robot pair.

_____________________________________________________________________

ERROR CODE E6500 No welding interface board.

The welding interface (1GN) board is not detected at control power ON.

⇒ Turn control power off and confirm that the welding interface (1GN) board is mounted
to the 1GW (1HW) board.
⇒ Confirm that the welding interface (1GN) board is not loose. Insert the board firmly.
⇒ Replace the 1GW/1GN (1HW/1GN) board.
_____________________________________________________________________

ERROR CODE E6501 No. 2 welding interface board not found.

The polarity ratio function is set for analog output, or an additional 1GW (1HW) board is
required for 3, or more, analog output channels.

⇒ Install additional 1GW (1HW) board as required.

⇒ Ensure 1GW (1HW) boards are properly installed.
_____________________________________________________________________

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ERROR CODE E6502 Arc failure.

The signal (current detection: WCR) that indicates the robot is executing the weld was
not returned from the weld controller/timer within 1 second, or less, after welding started.

Main causes include:

1. Arc is not generated when welding starts.
2. Arc generation is interrupted for 1, or more, seconds during welding.

⇒ Check for insulating debris that prevents welding, clear debris as necessary.
⇒ Confirm that adequate supply of wire is available.
⇒ Confirm that wire is not stuck to the welding tip.
⇒ Check weld controller/timer and cables, repair/replace as necessary.
_____________________________________________________________________

ERROR CODE E6503 Wire stuck.

Main causes include:

1. Welding and crater fill are completed and the arc is set OFF, but a weld stuck detec-
tion signal is received. The weld stuck detection signal does not clear after the es-
cape process is executed.
2. The wire is stuck to the base metal at weld completion.

⇒ Cut the wire and re-execute weld.

⇒ Change weld conditions if problem occurs frequently.
_____________________________________________________________________

ERROR CODE E6504 Arc start failure.

The signal (current detection: WCR), that indicates the robot is executing the weld, is not
return from the weld controller/timer at welding start.

Main causes include:

1. Insulating debris that prevents welding.
2. Welding wire feed supply ran out, or wire is stuck to welding tip.

⇒ Check for insulating debris that prevents welding, clear debris as necessary.
⇒ Confirm that adequate supply of wire is available.
⇒ Confirm that wire is not stuck to the welding tip.
_____________________________________________________________________

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ERROR CODE E6505 Arc weld insulation defect.

This error occurs when robot movement causes insulation failure.

⇒ Ensure the welder, torch, and robot insulation are in good working condition.
_____________________________________________________________________

ERROR CODE E6506 Torch interference.

The limit switch for torch interference detection is tripped or damaged.

After the error is reset the robot can be moved in teach mode. The robot cannot be
moved in repeat mode until the limit switch is reset.

⇒ Move the robot away from the interference to close the limit switch. Inspect the torch
for damage.
⇒ Determine the cause of the interference before continuing operation.
⇒ Replace damaged limit switch and/or harness, as necessary.
_____________________________________________________________________

ERROR CODE E6507 Illegal interpolation data.

A welding step is taught as joint interpolation with arc welding specification software.

⇒ Welding steps must use linear or circular interpolation for arc welding specification
software. Ensure the interpolation is correct.
_____________________________________________________________________

ERROR CODE E6509 No work detected.

(Touch sensing)

Occurs when touch sensing does not detect the workpiece within the range of the touch
sensing distance set in system data, or no workpiece is present.

⇒ Reset the workpiece in the proper position.

⇒ Increase the range of touch sensing distance in system data (increases touch sensing
time).
_____________________________________________________________________

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ERROR CODE E6510 Undefined sensing direction.

(Touch sensing)

Occurs when the step proceeding the WORK_DETECT instruction is not an air_cut
point.

⇒ Insert an air_cut point in the program before the WORK_DETECT instruction.

⇒ When using step select to chose the start step, select the air_cut point before the
WORK_DETECT instruction in the program.
_____________________________________________________________________

ERROR CODE E6511 Insufficient num. of sensing points.

(Touch sensing)

The number of steps taught with the work deviation compensation function is insufficient
for the number of sensing points, or an air_cut point is not taught immediately following
the sensing point.

Example:
1. AC JOINT SPEED9 ACCU4 TIMER0 MOTHER_RESET
2. AC LINEAR SPEED9 ACCU4 TIMER0 MOTHER_WORK2 (error occurs at this step)
3. WS LINEAR SPEED9 TIMER0

Step set two pattern 2 (with 2 sensing points) and step 3 is a weld start point instead of
an air_cut point.

⇒ Add the required air_cut sensing points (two points in this example).

Example:
2. AC LINEAR SPEED9 ACCU4 TIMER0 MOTHER_WORK2
3. AC JOINT SPEED9 ACCU4 TIMER0
4. AC LINEAR SPEED9 ACCU4 TIMER0 MOTHER_WORK2
5. WS LINEAR SPEED9 TIMER0
_____________________________________________________________________

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ERROR CODE E6512 Undefined mother or daughter work.

(Touch sensing)

Main causes include:

1. A previous work instruction is not completed before another work instruction is ex-
ecuted.
2. Program execution is started at a step in that does not allow completion of a previous
work instruction.

Example:
1. AC JOINT SPEED9 ACCU4 TIMER0 MOTHER_RESET
2. AC LINEAR SPEED9 ACCU4 TIMER0 DAUGHTER_WORK2 (error occurs at this
step)

⇒ Add the required steps in the program to complete the first work instruction before
another work instruction is executed (in this example a step is inserted before step 2).

Example:
1. AC JOINT SPEED9 ACCU4 TIMER0 MOTHER_RESET
2. AC LINEAR SPEED9 ACCU4 TIMER0 MOTHER_WORK1
3. AC LINEAR SPEED9 ACCU4 TIMER0 DAUGHTER_WORK2
_____________________________________________________________________

ERROR CODE E6513 Too many sensing points.

(Touch sensing)

Occurs when a work instruction is completed and another work instruction is executed
without a reset instruction.

Example:
1. AC JOINT SPEED9 ACCU4 TIMER0 MOTHER_RESET
2. AC LINEAR SPEED9 ACCU4 TIMER0 MOTHER_WORK1
3. AC LINEAR SPEED9 ACCU4 TIMER0
4. WS LINEAR SPEED9 TIMER0
5. WE LINEAR WELD_COND0
6. AC LINEAR SPEED9 ACCU4 TIMER0
7. WS LINEAR SPEED9 ACCU4 TIMER0 MOTHER_WORK1 (error occurs at this step)

⇒ Add a reset instruction before the next work instruction.

Example:
6. AC LINEAR SPEED9 ACCU4 TIMER0 MOTHER_RESET
7. WS LINEAR SPEED9 ACCU4 TIMER0 MOTHER_WORK1
_____________________________________________________________________

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ERROR CODE E6514 Work specification incorrect.

(Touch sensing)

Occurs when a previous work instruction is not completed before another work instruc-
tion is executed.

Example:
1. AC JOINT SPEED9 ACCU4 TIMER0 MOTHER_RESET
2. AC LINEAR SPEED9 ACCU4 TIMER0 MOTHER_WORK2
3. AC LINEAR SPEED9 ACCU4 TIMER0
4. AC LINEAR SPEED9 ACCU4 TIMER0 MOTHER_WORK1 (error occurs at this step)

⇒ Add the required steps in the program to complete the first work instruction before
another work instruction is executed.

Example:
4. AC LINEAR SPEED9 ACCU4 TIMER0 MOTHER_WORK2
_____________________________________________________________________

ERROR CODE E6515 Incorrect sensing point specified.

(Touch sensing)

Occurs when points are taught in incorrect order.

Example:
points should be taught in order A1, B1, A2, B2, A3, B3.

Occurs when the distance between two points taught on the same check plane is
10 mm, or less, or the angle, between the two sensing surfaces, is out of range (30 to
150 degrees).

⇒ Reteach points to comply with parameters described above.

_____________________________________________________________________

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ERROR CODE E6516 Wire check failure.

(Touch sensing)

Main causes include:

1. The position of a taught point is recorded too far from the workpiece, and the wire tip
did not touch the work within the allowed time.
2. The weld wire is not sent due to the welding unit power off etc.

⇒ Reteach point at the correct distance.

⇒ Ensure workpiece is within specifications and is properly placed.
⇒ Check the welding machine for power and press CYCLE START to manually feed wire
for five seconds.
⇒ Check the wire supply, wire feeder, and welding equipment and repair/replace as
necessary.
_____________________________________________________________________

ERROR CODE E6517 incorrect weld condition number.

The weld condition number, is not within the acceptable range (1–20).
Example: W1SET 100=60, 250, 28, 2, 3 Weld condition 100 is out of range (1–20).

⇒ Set weld condition within range.

Example: W1SET 1=60, 250, 28, 2, 3
_____________________________________________________________________

ERROR CODE E6518 No weld condition data set.

Weld data is not set in the weld condition number specified.

Example: Weld condition 1 is not set for LWC #a1, 1

⇒ Ensure weld data is set in the specified weld condition number used.
Example: W1SET 1=60, 250, 28, 2, 3
_____________________________________________________________________

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ERROR CODE E6519 Weld condition data out of range.

Ensure data is within range as shown below.

Current: 0–999 Amp

Voltage: 0–99.9 Volt
Speed: 0–999 cm/min
Time: 0–9.9 second
Weaving width: 0–40.0 mm
Weaving frequency: 0–4.0 Hz
Weaving pattern: 0–9

⇒ Correct weld condition data as necessary.

_____________________________________________________________________

ERROR CODE E6520 Laser sensor tracking value exceeded.

Tracking deviation exceeds the allowed threshold value to permit welding, and continues
to exceed the value longer than time allowed for normal operation.

Main causes include:

1. Workpiece is improperly placed.
2. Error check value is set too low.

⇒ Ensure the workpiece is properly placed.

⇒ Ensure the error check value is set correctly.
_____________________________________________________________________

ERROR CODE E6521 Beyond laser sensor tracking ability.

The difference between the over-tracking ability detection start value and the current
over-tracking value, exceeds the threshold value set.

Main causes include:

1. Workpiece is improperly placed.
2. Error check value is set too low.

⇒ Ensure the workpiece is properly placed.

⇒ Ensure the error check value is set correctly.
_____________________________________________________________________

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ERROR CODE E6522 Laser sensor cannot detect welding joint.

Main causes include:

1. The laser sensor unable to find a groove.
2. The laser sensor detects a groove that does not match the specified groove number
data.
3. The laser sensor controller EMERGENCY STOP switch is pressed.
4. Incorrect laser sensor settings or defective laser sensor.

⇒ Re-teach the groove data.

⇒ Ensure the correct groove number is specified.
⇒ Release the laser sensor controller EMERGENCY STOP switch.
⇒ Refer to the laser sensor operation manual and ensure correct set-up and operation
procedures are used.
_____________________________________________________________________

ERROR CODE E6523 Calibration data between torch and camera is not ready.

Calibration data is not set (LTCALIB command).

⇒ Set the calibration data using the LTCALIB command.

_____________________________________________________________________

ERROR CODE E6524 Error in data calculated using laser sensor.

Processing based on laser sensor data could not be calculated.

⇒ Readjust the laser sensor so 80 percent or more of grooves are correctly detected.
⇒ If the error cannot be reset after laser sensor readjustment, contact KRI customer
service.
_____________________________________________________________________

ERROR CODE E6525 Cannot detect weld joint, laser sensor tracking set already.

Main causes include:

1. A PC program executes a function, such as LSEN, during execution of a program
using a laser sensor.

2. During execution of a function, such as the LSEN, a program using a laser sensor is
executed.

⇒ Correct program data so the laser sensor is not used by two instructions at the same
time.
_____________________________________________________________________

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ERROR CODE E6526 No response from laser sensor controller.

Main causes include:

1. Disconnected or defective laser sensor harness.
2. Incorrect laser sensor settings or defective laser sensor.

⇒ Check laser sensor, laser sensor harness and connections and repair/replace as
necessary.
⇒ Refer to the laser sensor operation manual and ensure correct set-up and operation
procedures are used.
_____________________________________________________________________

ERROR CODE E6527 Laser sensor communication error. Code is %c.

Incorrect laser sensor settings or defective laser sensor.

⇒ Refer to the laser sensor operation manual for sub-code %c and ensure correct set-
up and operation procedures are used.
_____________________________________________________________________

ERROR CODE E6528 Start point not found by laser sensor.

Main causes include:

1. The laser sensor unable to find a groove.
2. The laser sensor detected a groove that does not match the specified groove number
data.
3. The laser sensor controller EMERGENCY STOP switch is pressed.
4. Incorrect laser sensor settings or defective laser sensor.

⇒ Re-teach the groove data.

⇒ Ensure the correct groove number is specified.
⇒ Release the laser sensor controller EMERGENCY STOP switch.
⇒ Refer to the laser sensor operation manual and ensure correct set-up and operation
procedures are used.
_____________________________________________________________________

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ERROR CODE E6529 Finish point not found by laser sensor.

Main causes include:

1. The laser sensor unable to find a groove.
2. Auto tracking function is enabled with no data present, and finish point detection
failed.

⇒ Re-teach data, or readjust the detection range for the finish point.
⇒ Disable auto tracking function ID because there is no data, and re-execute finish point
detection.
_____________________________________________________________________

ERROR CODE E6530 Cannot use circular interp. with laser sensor function.

Laser sensor tracking function is used with circular interpolation.

⇒ Do not use circular or linear interpolation with laser sensor tracking function.
_____________________________________________________________________

ERROR CODE E6531 Cannot turn laser ON because motor power is OFF.

Attempt to use laser sensor when motor power is OFF.

⇒ Set motor power ON and re-execute.

_____________________________________________________________________

ERROR CODE E6532 No communication board to laser sensor.

The laser sensor 1HA communication board is not installed.

⇒ Ensure the laser sensor 1HA communication board is properly installed.

_____________________________________________________________________

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ERROR CODE E6533 No RTPM board.

Main causes include:

1. The software for RTPM option is installed, but the hardware (1FH board) is not in-
stalled properly.
2. Hardware for RTPM (1FH board) is installed, but the software for RTPM option is not
installed.
2. The software and hardware (1FH board) are installed, but controller power was not
cycled OFF and ON after RTPM option is set-up.

⇒ Ensure the 1FH board is properly installed.

⇒ Reseat the 1FH board and connectors.
⇒ Perform RTPM option set-up procedure and cycle controller power OFF and ON.
_____________________________________________________________________

ERROR CODE E6534 Too many taught points for RTPM.

Occurs when the number of taught points, between the weld start point and the weld
end point, exceeds 127 points

⇒ Reteach program points, not to exceed 127 RTPM points.

_____________________________________________________________________

ERROR CODE E6535 RTPM arc sensor error.

Exceeded the number of weaves set for arc sensor fault detection, and the lateral (+)
and (-) values for current are less than 10 A, more than 490 A, or the difference is
0.2 A, or less.

Main causes include:

1. Weld start-point is too far from the groove.
2. Defective weld controller/timer, or weld controller/timer set OFF.

⇒ Ensure the wiring for the current sensor for RTPM is not loose or disconnected.
⇒ Ensure the weld start-point is taught in the welding groove.
⇒ Ensure the welder is powered-up and in normal operating condition.
⇒ Weld with RTPM disabled, check for problems with the weld controller/timer and
repair/replace as necessary.
_____________________________________________________________________

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ERROR CODE E6536 RTPM current deviation error.

Occurs when actual current exceeds commanded current (feedback current) for a time
period exceeding the current deviation error time-out value.

Main causes include:

1. Weld start-point is too far from the groove.
2. Defective weld controller/timer, or weld controller/timer set OFF.
3. Incorrect linearization or offset/gain.

⇒ Ensure the weld start point is taught in the welding groove.

⇒ Set controller power to OFF and reseat the 1FH board and the 1FH board connectors.
⇒ Ensure the welding unit power is ON and in proper operating condition.
⇒ Ensure the RTPM function is activated.
⇒ Ensure the welding unit metered current, during a continuous bead, is the same as
the commanded current.
⇒ Ensure values set for linearization or offset/gain are correct.
⇒ Weld with RTPM disabled, and check for problems with the weld controller/timer and
repair/replace as necessary.
_____________________________________________________________________

ERROR CODE E6537 RTPM tracking value is out of range.

Occurs when the deviation detection value exceeds the error check value set in RTPM,
continuously, exceeding the number of times allowed.

Main causes include:

1. Weld start-point is too far from the groove.
2. Defective weld controller/timer, or weld controller/timer set OFF.
3. The deviation error detection value is set too low.

⇒ Ensure the weld start point is taught in the welding groove.

⇒ Weld with RTPM disabled, and check for problems with the weld controller/timer and
repair/replace as necessary.
⇒ If the welding groove is being tracked normally, the deviation error detection value
may be set too low. Increase the value.
_____________________________________________________________________

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ERROR CODE E6538 Beyond RTPM tracking ability.

Occurs when the current tracking value exceeds the threshold value and the number of
times value set for RTPM tracking ability errors.

Example:
If the threshold is set at 9 mm, and the number of times is set at 30, the error occurs
after 30 weave cycles and the path deviates more than 9 mm from the original welding
path.

Main causes include:

1. Weld start-point is too far from the groove.
2. Defective weld controller/timer, or weld controller/timer set OFF.
3. The deviation error detection value is set too low.

⇒ Ensure the welding start point is taught in the groove. Starting outside the groove will
cause this error.
⇒ Execute a weld, without the RTPM function, to ensure the weld controller/timer is
operating properly.
⇒ Modify fixturing and/or part to minimize the required correction.
⇒ Verify the linearization table is correct by comparing the current reading indicated on
the weld controller/timer to the current value set in the weld condition number.
⇒ If the welding groove is being tracked normally, the deviation error detection value
may be set too low. Increase the value.
_____________________________________________________________________

ERROR CODE E6539 AVC tracking value is out of range.

The tracking deviation value, used as the threshold for error detection, is exceeded
continuously.

Main causes include:

1. Weld start-point is too far from the groove.
2. Defective weld controller/timer, or weld controller/timer set OFF.
3. The deviation error detection value is set too low.

⇒ Ensure the welding start point is taught in the groove. Starting outside the groove will
cause this error.
⇒ Execute a weld with AVC disabled, to ensure the weld controller/timer is operating
properly.
⇒ If the welding groove is being tracked normally, the deviation error detection value
may be set too low. Increase the value.
_____________________________________________________________________

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ERROR CODE E6540 Beyond AVC tracking ability.

Occurs when the current tracking value exceeds the threshold value and the number of
times value set for RTPM tracking ability errors.

Main causes include:

1. Weld start-point is too far from the groove.
2. Defective weld controller/timer, or weld controller/timer set OFF.
3. The deviation error detection value is set too low.

⇒ Ensure the welding start point is taught in the grove. Starting outside the grove
causes this error.
⇒ Execute a weld with AVC disabled, to ensure the weld controller/timer is operating
properly.
⇒ If the welding groove is being tracked normally, the deviation error detection value
may be set too low. Increase the value.
_____________________________________________________________________

ERROR CODE E6541 No AVC board.

Main causes include:

1. AVC (1FH) board is not installed onto the 1KA/1RA board.
2. Controller power is not cycled OFF and ON after setting specifications.

⇒ Ensure the AVC (1FH) board is properly installed.

⇒ Replace the AVC board.
⇒ Cycle controller power OFF and ON after setting specifications.
_____________________________________________________________________

ERROR CODE E6542 AVC voltage deviation error.

During AVC function execution, the reference voltage and/or feedback voltage exceeds
the threshold value specified for over-voltage detection.

Main causes include:

1. Defective weld controller/timer, or weld controller/timer set OFF.
2. Defective harness or harness connections.

⇒ Execute a weld with AVC disabled to ensure the weld controller/timer is operating
properly.
⇒ Check the voltage sensing device and harness, and repair/replace as necessary.
_____________________________________________________________________

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ERROR CODE E6543 Too many taught points for AVC.

Occurs when the number of taught points between the weld start point and the weld end
point exceeds 127 points.

⇒ Reteach program points, not to exceed 127 RTPM points.

_____________________________________________________________________

ERROR CODE E6562 Electric pole stuck.

The electrode is stuck to the base metal during TIG welding.

⇒ Cut the electrode.

⇒ Change weld conditions if problem occurs frequently.
_____________________________________________________________________

ERROR CODE E7000 Servo weld gun disconnected.

When a welding step is executed the servo spot weld gun is not connected.

⇒ Connect the servo spot weld gun and re-execute.

_____________________________________________________________________

ERROR CODE E7001 Location data includes released gun status data.

The servo weld gun axis position value data indicates the gun is disconnected.

⇒ Use the correct gun disconnect procedure.

_____________________________________________________________________

ERROR CODE E7002 Destination is far from target point.

Program point is too far from the taught point.

⇒ Contact KRI customer service (include operating conditions/settings at the time the
error occurred).
_____________________________________________________________________

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ERROR CODE E8200 Not in cooperative mode.

Cooperative motion instruction is taught before MASTER/SLAVE instruction or after

ALONE instruction.

⇒ Use cooperative motion instructions between MASTER/SLAVE instruction and

ALONE instruction.
_____________________________________________________________________

1.3.2.3 PXXXX OPERATION ERROR CODES

ERROR CODE P0100 Illegal input data.

AS Language command/instruction does not comply with AS Language syntax.

⇒ Enter AS Language command/instruction in correct AS Language syntax.

_____________________________________________________________________

ERROR CODE P0101 Too many arguments.

AS Language command/instruction exceeds the number of user specified items allowed

by the format.

⇒ Enter AS Language command/instruction in correct AS Language syntax and format

for the command/instruction used.
_____________________________________________________________________

ERROR CODE P0102 Input data is too big.

AS Language command/instruction data exceeds the allowable range.

⇒ Enter data that is within acceptable range.

_____________________________________________________________________

ERROR CODE P0103 Illegal PC number.

PCEND command/instruction specified a PC program number that is out of the allow-

able range.

⇒ PC program number must be -1 or 1–5.

Example: PCEND 2
_____________________________________________________________________

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ERROR CODE P0104 Illegal robot number.

A robot number is specified that exceeds the number of robots connected to the control-
ler.
Example: “LLIMIT 3” is entered when 2 robots are connected to the controller.

⇒ Ensure robot number does not exceed the number of robots connected to controller.
Example: “LLIMIT 2” can be used when 2 robots are connected to the controller.
_____________________________________________________________________

ERROR CODE P0106 Illegal priority.

Priority level designation is out of the allowable range (1–127).

Example: LOCK 128

⇒ Ensure the correct priority level number is entered (1–127).

Example: LOCK 2
_____________________________________________________________________

ERROR CODE P0107 Invalid coordinate value.

Upper limit value is less than lower limit value for work space output data.

⇒ Enter the correct upper limit coordinates.

_____________________________________________________________________

ERROR CODE P0108 Syntax error.

Occurs when an AS Language command is entered that does not follow the correct
syntax.

⇒ Correct the syntax, format or spelling of the command/instruction.

_____________________________________________________________________

ERROR CODE P0109 Invalid statement.

Main causes include:

1. An AS Language command is entered that has typing errors, incorrect spelling or is in
the wrong format.
2. An existing variable name, that is already used for a variable of a different type, is
used.

⇒ Correct the syntax, format or spelling of the command/instruction.

⇒ Do not use existing variable names.
_____________________________________________________________________

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ERROR CODE P0110 Specify full spelling of command.

Displayed when an abbreviation is entered incorrectly or has missing letters.

⇒ Enter the correct abbreviation or use the full spelling of the command.
_____________________________________________________________________

ERROR CODE P0111 Cannot use this command/instruction in current mode.

The command/instruction entered could not be executed in the selected mode.

Example: “EDIT” is entered in the program edit mode (used in monitor mode).
Example: “TERMOFF” is entered from the teach pendant keyboard (used from a PC
terminal).

⇒ Ensure correct mode is selected.

_____________________________________________________________________

ERROR CODE P0114 Illegal expression.

A command/instruction is entered that does not comply with AS Language syntax or

format.
Example: “DO HERE” the DO command cannot be used with the HERE command/
instruction.

⇒ Ensure correct syntax and format are used.

Example: “HERE point1” is correct and does not return an error.
_____________________________________________________________________

ERROR CODE P0115 Illegal function.

Occurs when functions are used to assign values to variables, but the data is incompat-
ible.
Example: “POINT #a=SQRT(y)” returns an error.

⇒ Ensure function is compatible with variables.

Example: “x=SQRT (y)” is correct and does not return an error.
_____________________________________________________________________

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ERROR CODE P0116 Illegal argument of function.

Function parameter does not comply with AS Language syntax.

Example: “x=SQRT” returns and error.

⇒ Use correct syntax and format for functions and arguments.

Example: “x=SQRT(3)” is correct and does not return and error.
_____________________________________________________________________

ERROR CODE P0117 Invalid variable (or program) name.

Displayed when illegal variable or program name is entered from the editor or monitor
modes.
Example: “JM ##a” too many precision point symbols.
Example: “CALL #a” is not an acceptable program name.

⇒ Ensure program names and variables are defined correctly.

_____________________________________________________________________

ERROR CODE P0118 Illegal variable type.

Displayed when illegal variable is entered from editor or monitor modes.

Example: “b = #a + b” cannot combine location and real variables using an arithmetic
operator.

⇒ Use compatible variable type for commands or instructions.

_____________________________________________________________________

ERROR CODE P0119 Incorrect array suffix.

Main causes include:

1. An array is entered that does not comply with AS Language syntax or array format.
Example: “point[1.2.]=1” returns an error.
2. A previously defined variable or array name is used to define a new array name.
Example: “HERE a” is entered then “HERE a[1]” is entered. An error is returned
because location variable “a” is already used.

⇒ Enter the array in compliance with AS Language syntax and array format.
Example: “point[1.2]=1” is correct and does not return an error.
⇒ Change the previously defined variable name.
_____________________________________________________________________

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ERROR CODE P0120 Incongruent num. parenthesis.

Occurs when parentheses are not entered as a pair, containing both a left and right
parenthesis.

⇒ Enter parentheses in left and right pairs.

_____________________________________________________________________

ERROR CODE P0121 Expected to be a binary operator.

A non-binary operator has been entered where a command expected a binary operator.

⇒ Enter a binary operator.

_____________________________________________________________________

ERROR CODE P0122 Illegal constant.

A variable, or a non-constant, is used where a constant or integer should be used with a

monitor command.
Example: “WHERE a” Should be WHERE 1 … WHERE 6.

⇒ Use the proper constant or integer with the command. See the D Series Controller
AS Language Reference Manual for more information.
_____________________________________________________________________

ERROR CODE P0123 Illegal qualifier.

Displayed when monitor commands are followed by unexpected qualifiers.

Example: “LIST W” expected characters include P, L, and R for program, location, and
real variables; “W” causes error.

⇒ Enter qualifiers in compliance with AS Language syntax and format.

_____________________________________________________________________

ERROR CODE P0124 Invalid label.

Occurs in the editor mode when a GOTO instruction is combined with a reserved char-
acter.
Example: “GOTO #a” returns an error because “#” is a reserved character.

⇒ Do not use reserved characters in label identification.

_____________________________________________________________________

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ERROR CODE P0125 Missing expected character.

Occurs when commands or instructions are entered with an incorrect format.

Example: “TOOL a=b”, “=b” causes an error, “TOOL a” would be correct.

⇒ Use correct syntax and format for commands and instructions.

_____________________________________________________________________

ERROR CODE P0126 Illegal switch name.

Displayed when a system switch is incorrectly identified.

Example: “SWITCH light” there is no system switch named “light”.

⇒ Use valid switch names.

_____________________________________________________________________

ERROR CODE P0127 Specified switch name needs full spelling.

System switch name entered does not comply with AS Language syntax.
Example: “SWITCH ERR” returns an error.

⇒ Use system switch names in compliance with AS Language syntax.

Example: “SWITCH ERROR” is correct and does not return an error.
_____________________________________________________________________

ERROR CODE P0128 Illegal format specifier.

Occurs when the TYPE or PRINT command is not used with an acceptable format
portion of the instruction.
Example: “PRINT/A” returns an error

⇒ Use only specified format instructions with TYPE and PRINT commands.
Example: “PRINT/D” is correct and does not return an error
_____________________________________________________________________

ERROR CODE P0129 Duplicate statement label.

Main causes include:

1. A previously used label is used the second time in the same program.
2. When transferring or copying a program, the same label name is used in the source
and destination programs.

⇒ Use label names only once per program.

_____________________________________________________________________

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ERROR CODE P0130 Cannot define as array.

A program name is assigned as an array variable.

Example: “EDIT test[1]” returns an error.

⇒ Enter program names in compliance with AS Language syntax and format.

Example: “EDIT test1” is correct and does not return an error.
_____________________________________________________________________

ERROR CODE P0131 No. of dimension in array exceeds 3.

Attempted to create an array variable with more than 3 dimensions.

Example: “point[3,5,7,9]=1” returns an error.

⇒ Use 3 or less dimensions (elements) in an array.

Example: “point[1,2,3]=1” is correct and does not return an error.
_____________________________________________________________________

ERROR CODE P0132 Array variable already exists.

Attempted to create an array variable with a different number of dimensions (elements)

with the same name as an existing array variable .
Example: If array variable “test[1]” exists, an array variable “test[1,2]” cannot be defined.

⇒ Confirm array variable exists. Select new name for the array variable with a different
number of dimensions (elements).
Example: “sample[1,2]”
_____________________________________________________________________

ERROR CODE P0133 Non array variable exists.

Attempted to create an array variable with the same name as an existing real variable.
Example: “x=1” is entered, then “y=x[1]” is entered and an error is returned because
real variable “x” already exists.

⇒ Confirm real variable exists. Select new name for array variable.
_____________________________________________________________________

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ERROR CODE P0134 Array variable expected.

A real value array name is not used as the array variable for a DECOMPOSE
instruction.
Example: “DECOMPOSE x=point” returns an error.

⇒ Enter real value array name in compliance with AS Language syntax and format.
Example: “DECOMPOSE x[1]=point” is correct and an error is not returned.
_____________________________________________________________________

ERROR CODE P0135 Local variable expected.

A global variable is used when defining a temporary argument for a subroutine.

Example: “SUB(a)” returns an error.

⇒ Use a local variable when defining a temporary argument for a subroutine.

Example: “SUB(.a)” is correct and does not return an error.
_____________________________________________________________________

ERROR CODE P0136 Unexpected suffix.

An array with a suffix is used when defining a temporary argument for a subroutine.
Example: “sub(.a[3])” returns an error.

⇒ Enter the temporary argument in compliance with AS Language syntax and format.
Example: “sub.a” is correct and does not return an error.
_____________________________________________________________________

ERROR CODE P0137 Mismatch of arguments at subroutine call.

The number of arguments between the source program and the destination program do
not match.
Example: Source: “SUB(.a)”; Destination: “SUB(.a,b)” returns an error.

⇒ Ensure the number of arguments between the source program and the destination
program match.
_____________________________________________________________________

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ERROR CODE P0138 Mismatch of argument type at subroutine call.

At a subroutine call, the type of real value argument is different than the type of tempo-
rary argument defined.
Example: “CALL sub(1)” returns an error.

⇒ Correct the type of the argument in the called program or origin program.
Example: “CALL sub1” is correct and does not return an error.
_____________________________________________________________________

ERROR CODE P0139 Illegal control structure.

Main causes include:

1. In a control structure CASE is the last step, or VALUE, END, or ANY are missing after
CASE.
2. Destination step for structure instruction is missing.

⇒ Use correct syntax and components in control flow structures.

_____________________________________________________________________

ERROR CODE P0140 Step:%ld Wrong END statement.

Occurs when an illegal END statement is entered during editing.

⇒ Use correct syntax and components in control flow structures.

_____________________________________________________________________

ERROR CODE P0141 Step:%ld Extra END statement.

Occurs when an extra END statement is present and there is no corresponding struc-
ture.

⇒ Use correct syntax and components in control flow structures, check structure of END
statements.
_____________________________________________________________________

ERROR CODE P0142 Step:%ld Cannot terminate DO with END.

This error is displayed when the control flow structure DO….UNTIL is entered with an
END statement.

⇒ Use correct syntax and components in control flow structures.

_____________________________________________________________________

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ERROR CODE P0143 Step:%ld No VALUE statement after CASE.

Occurs when the control flow structure CASE OF….END is entered without a value to
evaluate.

⇒ Use correct syntax and components in control flow structures.

_____________________________________________________________________

ERROR CODE P0144 Step:%ld Preceding IF missing.

Displayed when control flow structure does not contain the correct structure for
IF…THEN… ELSE…END commands.

⇒ Use correct syntax and components in control flow structures.

_____________________________________________________________________

ERROR CODE P0145 Step:%ld Preceding CASE missing.

Displayed when control flow structure does not contain the correct structure for
CASE…OF… VALUE…ANY…END commands.

⇒ Use correct syntax and components in control flow structures.

_____________________________________________________________________

ERROR CODE P0146 Step:%ld Preceding DO missing.

Displayed when control flow structure does not contain the correct structure for
DO…UNTIL.

⇒ Use correct syntax and components in control flow structures.

_____________________________________________________________________

ERROR CODE P0147 Step:%ld Cannot find END of %ld.

Occurs when control flow structure that requires an END statement does not contain the
necessary END.

⇒ Use correct syntax and components in control flow structures.

_____________________________________________________________________

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ERROR CODE P0148 Step:%ld Too many control structures.

Occurs when 10 layers of control flow structure are exceeded.

⇒ Limit control flow structure to 10 layers.

_____________________________________________________________________

ERROR CODE P0149 Variable (or program) already exists.

The name of a program, loaded from floppy disk or PC card using the LOAD command,
already exists in the system memory. This error is not used in the spot welding applica-
tion.

⇒ Change the name of the program currently in system memory.

⇒ Delete the program in system memory, if not needed.
_____________________________________________________________________

ERROR CODE P0150 Variable of different type already exists.

Displayed when a variable is entered that is already in the system memory.

Example: A location named “weld1” is entered when a program named “weld1” is al-
ready in the memory.

⇒ Do not use variable names for more than one item.

_____________________________________________________________________

ERROR CODE P0151 Internal buffer over due to complicated expression.

Main causes include:

1. An expression is entered that is too complicated.
2. Too many arguments for a command/instruction.
Example: “LIST/PPPPPP” returns an error.
3. More than twenty six arguments are specified in one subroutine.

⇒ Rewrite to reduce the complexity of the expression.

⇒ Ensure the argument for the command/instruction is correct.
Example: “LIST/P” is correct and does not return an error.
⇒ Do not use more than twenty six arguments in a subroutine.
_____________________________________________________________________

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ERROR CODE P0152 Undefined Variable (or program).

Attempt to call a subroutine, or process a variable, that does not exist.

Example: “LIST/P test” is entered, but program test does not exist.

⇒ Verify the variable or program exists.

_____________________________________________________________________

ERROR CODE P0153 Illegal clock value.

Time or date is entered in the wrong format.

⇒ Re-enter the values correctly; time—military, date—yy/mm/dd.

_____________________________________________________________________

ERROR CODE P0154 Missing “=”.

The argument is missing the necessary “=”.

Example: “XFER test sub” returns an error.

⇒ Ensure command/instruction complies with AS Language syntax and format.

Example: “XFER test=sub” is correct and does not return an error.
_____________________________________________________________________

ERROR CODE P0155 Missing “)”.

The argument is missing the necessary “)”.

Example: “(.a” returns an error.

⇒ Ensure command/instruction complies with AS Language syntax and format.

Example: “(.a)” is correct and does not return an error.
_____________________________________________________________________

ERROR CODE P0156 Missing “]”.

The argument is missing the necessary “]”.

Example: “$line[2” returns and error.

⇒ Ensure command/instruction complies with AS Language syntax and format.

Example: “$line[2]” is correct and does not return an error.
_____________________________________________________________________

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ERROR CODE P0157 Missing “TO”.

The argument is missing the necessary “TO”.

Example: “FOR test = 1 max.test” returns an error.

⇒ Ensure command/instruction complies with AS Language syntax and format.

Example: “FOR test = 1 TO max.test” is correct and does not return an error.
_____________________________________________________________________

ERROR CODE P0158 Missing “BY”.

The argument is missing the necessary “BY”.

Example: “POINT y = SHIFT (x 5,5,5)

⇒ Ensure command/instruction complies with AS Language syntax and format.

Example: “POINT y = SHIFT (x BY 5,5,5)
_____________________________________________________________________

ERROR CODE P0159 Missing “:”.

The argument is missing the necessary “:”.

Example: “SEND 1 $out,err” returns an error.

⇒ Ensure command/instruction complies with AS Language syntax and format.

Example: “SEND 1: $out,err” is correct and does not return an error.
_____________________________________________________________________

ERROR CODE P0160 Specify ”ON” or “OFF”.

The command/instruction does not comply with AS Language syntax or format.

Example: “TRACE 1 ON” returns an error.

⇒ Ensure command/instruction complies with AS Language syntax and format.

Example: “TRACE 1:ON” is correct and does not return an error.
_____________________________________________________________________

ERROR CODE P0161 Robot num. must be specified.

This error occurs when the robot number is omitted from the syntax of an AS Language
command which requires the robot number as an argument.
Example: “HERE P” returns an error.

⇒ Include the robot number as an argument as required.

Example: “HERE 1: P” is correct and does not return an error.
_____________________________________________________________________

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ERROR CODE P0162 Cannot modify position data in this instruction.

During modifying an AS Language program from the teach screen, pose data is modi-
fied at a step with a non-positional command/instruction.
Example: Trying to modify pose data, at a step with “DELAY 1” recorded, returns an
error.

⇒ Pose data can only be modified for AS Language program steps containing move
instructions (JMOVE, LMOVE, etc.).
_____________________________________________________________________

ERROR CODE P1000 Cannot execute program because motor power is OFF.

Program will not start because motor power is not ON.

⇒ Set motor power ON.

⇒ Select repeat mode.
⇒ Set teach lock OFF.
⇒ Re-execute program.
_____________________________________________________________________

ERROR CODE P1001 Cannot execute program in TEACH mode.

Programs cannot run in teach mode.

⇒ Ensure that the controller is in REPEAT mode.

⇒ Defective TEACH/REPEAT switch.
⇒ Defective 1KA/1RA board.
_____________________________________________________________________

ERROR CODE P1002 Cannot execute program because teach lock is ON.

Programs cannot run with the teach lock in the ON position.

⇒ Set the TEACH LOCK switch OFF and execute the program again in repeat mode.
⇒ Defective teach pendant or 1KA/1RA board.
_____________________________________________________________________

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ERROR CODE P1003 Cannot execute a program because of EXT.HOLD input.

An attempt to cycle start a program is made while external hold signal is ON.

⇒ Release the external hold and re-execute cycle start.

⇒ Verify dedicated input signals in AUX 0601 match signals programed from the PLC in
the Slogic program.
⇒ If the external hold signal is not needed, change the signal setting in AUX 0601 from
set to reset.
NOTE
With cycle start switch set OFF in AUX 0502, cycle start
is kept ON if external hold is applied; program execution
resumes once external hold is released.

_____________________________________________________________________

ERROR CODE P1004 Cannot execute program being reset.

This error occurs when a cycle start signal is received during a program reset.

⇒ Adjust the timing of the program reset and the cycle start signals.
_____________________________________________________________________

ERROR CODE P1006 Cannot execute program because of EXT.START DIS-

ABLE.

This error occurs when the external cycle start signal is received with the EXT.START
dedicated signal OFF.

⇒ Release the EXT.START dedicated signal in AUX. 0601 Dedicated Input Signal.
⇒ The EXT.START dedicated signal must be ON when the external cycle start signal is
received.
⇒ Use the external cycle start dedicated input signal to execute the robot program.
_____________________________________________________________________

ERROR CODE P1009 Program is already running.

Main causes include:

1. An attempt is made to edit or execute a program that is running.
2. SYSINIT command is executed while a program is running.

⇒ Stop the robot control program prior to editing or checking.

⇒ Stop the robot control program prior to executing the SYSINIT command.
_____________________________________________________________________

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ERROR CODE P1010 Robot control program is already running.

Occurs when an attempt is made to execute a DO, TOOL, or BASE command when a
robot control program is running.

⇒ Wait for the robot control program to complete execution.

⇒ Stop the robot control program.
_____________________________________________________________________

ERROR CODE P1011 Cannot continue this program. Use EXECUTE.

After a program is executed the specified number of times in repeat mode, the CON-
TINUE command is entered or the CYCLE START switch is pressed.

⇒ The CONTINUE command or CYCLE START switch cannot be used at this time, use
the EXECUTE command to start the program.
⇒ Re-select the program and press the CYCLE START switch.
_____________________________________________________________________

ERROR CODE P1012 Robot is moving now.

Displayed if any of the following commands are entered while a program is running:
EXECUTE, CONTINUE, TOOL, BASE, DO. SYSINIT or CYCLE START.

⇒ Stop the program or confirm the operation to be performed.

_____________________________________________________________________

ERROR CODE P1013 Cannot execute because in error now. Reset error.

Occurs when attempt is made to start robot motion before an error has been cleared.

⇒ Clear any errors and re-enter the command.

_____________________________________________________________________

ERROR CODE P1014 Cannot execute because program already in use.

An attempt to execute the same program using the EXECUTE and PCEXECUTE is
made.

⇒ Allow the program to complete executing and re-execute.

_____________________________________________________________________

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ERROR CODE P1015 Cannot delete, in use by another command.

Cannot COPY, DELETE or XFER command because program is being edited or ex-
ecuted.

⇒ Complete program editing before using COPY, DELETE or XFER commands.

⇒ Allow program execution to complete before using COPY, DELETE or XFER com-
mands.
_____________________________________________________________________

ERROR CODE P1016 Cannot delete, used in program.

An attempt is made to delete a variable that is used in a program.

⇒ Deletion of variables used in programs is not allowed by the AS system.

_____________________________________________________________________

ERROR CODE P1017 Cannot delete a program in Editor.

Attempting to delete a program that is open in editor mode.

⇒ Exit editor mode, and then delete the selected program.

_____________________________________________________________________

ERROR CODE P1018 KILL or PCKILL to delete program.

Occurs when an attempting to delete a program that is still on the stack (selected).

⇒ Select another program or KILL/PC KILL the program, then delete.

_____________________________________________________________________

ERROR CODE P1019 PC program is running.

Occurs when a PC program is running and instructions are entered that are not allowed.

⇒ Allow the PC program to complete execution and re-enter the instructions.

⇒ Stop the PC program and re-enter the instruction.
_____________________________________________________________________

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ERROR CODE P1020 Cannot operate because teach pendant in operation.

Functions cannot be performed on the personal computer while the teach pendant is in
use.

⇒ Perform functions on the PC after the teach pendant operation is completed.

_____________________________________________________________________

ERROR CODE P1021 Cannot execute with DO command.

Displayed when the DO command is entered with an instruction that does not comply
with AS Language syntax.

⇒ Ensure command/instruction is in compliance with AS Language syntax and format.

_____________________________________________________________________

ERROR CODE P1022 Cannot execute with MC instruction.

An improper MC instruction is entered.

Example: MC DO HOME.

⇒ The MC instruction is used with ABORT, CONTINUE, ERESET, EXECUTE, HOLD,

and SPEED only.
_____________________________________________________________________

ERROR CODE P1023 Cannot execute in Robot program.

MC or PCSCAN instruction is used in a robot program.

⇒ MC or PCSCAN instructions are used in a PC programs only.

_____________________________________________________________________

ERROR CODE P1024 Statement cannot be executed.

Occurs when the AS Language instruction entered is not acceptable for the mode of
operation.
Example: DO HOME is executed with TEACH LOCK ON.

⇒ Use instructions and commands that are compatible with the selected mode.
_____________________________________________________________________

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ERROR CODE P1025 Cannot be executed, function not set.

An attempt is made to use a function that is not installed or set-up.

Example: Communication with 1GV board with data communication or I/O communica-
tion disabled.

⇒ To add a function that is not set-up or installed contact KRI customer service.
Example: For the above example, enable data communication or I/O communication.
_____________________________________________________________________

ERROR CODE P1026 Can’t KILL program that is running.

Displayed when an attempt is made to KILL a program that is executing.

⇒ Stop program execution with HOLD or ABORT commands before program is removed
from the stack with a KILL command.
_____________________________________________________________________

ERROR CODE P1027 Cannot edit program, TEACH LOCK is ON.

Programs cannot be edited if the TEACH LOCK switch is ON.

⇒ Turn TEACH LOCK switch OFF.

_____________________________________________________________________

ERROR CODE P1028 Cannot paste.

Occurs when the operator is executing the paste function and no data is stored in the
paste buffer or the step(s) cannot be overwritten.

⇒ Ensure steps are copied before paste operation is executed.

⇒ Ensure insertion point is correct or steps can be overwritten.
_____________________________________________________________________

ERROR CODE P1029 Program name not specified.

Displayed when no program is on the stack and the EDIT command is entered without
specifying a program name.

⇒ Specify the name of the program to edited.

_____________________________________________________________________

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ERROR CODE P1030 Program interlocked by other procedure.

The selected program is not recognized as a robot program or a PC program and is

used by another part of the software.

⇒ Initialize the system and reload the program.

_____________________________________________________________________

ERROR CODE P1031 No free memory.

Main causes include:

1. Not enough free memory to edit or teach a program.
2. Too many paths registered for arc welding (900 paths allowed in database).

⇒ Delete unused programs and variables, or, expand system memory to maintain the
required capacity.
⇒ Store 900 or less arc welding paths in database.
_____________________________________________________________________

ERROR CODE P1032 No program step.

The step specified for execution or copying does not exist in program.

⇒ Select valid steps for execution.

⇒ Create step(s) in the program.
_____________________________________________________________________

ERROR CODE P1033 Program name already exists.

When using the RENAME or COPY command a new program name must be specified.
If an existing name is used this error is displayed.

⇒ Specify unused program names when renaming or copying programs.

⇒ If not needed, delete the existing program with the name used.
_____________________________________________________________________

ERROR CODE P1034 This program is not editable.

The auto load measurement program cannot be edited.

⇒ Use a program name that does not include the auto load measurement program
name.
_____________________________________________________________________

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ERROR CODE P1035 Record inhibited. Set [record accept] and operate again.

Displayed when an attempt is made to enter data, but Inhibit Record in auxiliary function
0802 is set to inhibit.

⇒ Change the setting of the Inhibit Record in AUX 0802.

_____________________________________________________________________

ERROR CODE P1036 Program change inhibited. Set [Accept] and operate again.

Displayed when an attempt is made to enter data, but Program Change in auxiliary
function 0802 is set to inhibit.

⇒ Change the setting of the Program Change in AUX 0802.

_____________________________________________________________________

ERROR CODE P1037 Program name cannot be called “calib_load_”.

⇒ Use a program name that does not include “calib_load_“.

_____________________________________________________________________

ERROR CODE P1038 Program does not exist.

Main causes include:

1. Non-existing program is selected.
2. Program check operation or cycle start is executed without a program selected.

⇒ Select an existing program before executing program check or cycle start.

_____________________________________________________________________

ERROR CODE P1039 Teach pendant is not connected.

The “T” command is executed without the teach pendant connected.

⇒ Install teach pendant and re-execute the “T” command.

_____________________________________________________________________

ERROR CODE P1040 Cannot execute this command in I/F panel.

A monitor-command button is set-up on the I/F panel to execute a command that is not
permitted from the I/F panel. When the monitor-command button is pressed this error is
displayed.

⇒ Use commands permitted for I/F panel use.

_____________________________________________________________________

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ERROR CODE P1041 Auto monitor command failure.

An error occurrs when a command specified for the auto monitor command function is
executed.

⇒ Use the error cause stored in the error log as a troubleshooting aid.
_____________________________________________________________________

ERROR CODE P1042 NUM program is running.

This error occurs when the NUM program is executed and the NUM program is already
running.

⇒ Allow the current program execution to complete before re-executing.

_____________________________________________________________________

ERROR CODE P1043 Cannot execute in REPEAT mode.

Teach mode function is attempted in repeat mode.

⇒ Ensure teach mode is selected when executing teach mode functions.

_____________________________________________________________________

ERROR CODE P1044 Cannot execute on because motor power is ON.

An attempt is made to enable motion verification mode while motor power is ON.

⇒ Set motor power OFF and re-execute.

_____________________________________________________________________

ERROR CODE P2000 Turn OFF motor power.

An attempt is made to execute an operation or command which is not permitted with

motor power ON.
Example: ZZERO command.

⇒ Turn motor power OFF and re-execute operation or command.

_____________________________________________________________________

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ERROR CODE P2001 Turn HOLD/RUN sw. to HOLD.

Occurs when an attempt to execute DO, STEP, MSTEP, CONTINUE, or EXECUTE

command is made with the RUN/HOLD switch in the RUN position. Only applies if the
CHECK.HOLD system switch is ON (AUX 0502).

⇒ Turn the RUN/HOLD switch to HOLD position.

_____________________________________________________________________

ERROR CODE P2002 There is no external axis.

External axis cooperative motion command is executed and external axis equipment is
not installed.

⇒ Enable option or contact customer service to install external axis option.

_____________________________________________________________________

ERROR CODE P2003 Illegal positioner type.

An out of range value is used to specify the type of positioner for an external axis.

⇒ Specify the positioner type with a value that is in range.

_____________________________________________________________________

ERROR CODE P2004 Cannot change, user data already exist.

An attempt is made to change system data (number of axes, etc.) without deleting exist-
ing user data.

⇒ Save user data to PC card or floppy disk and delete user data from system memory.
Change system data and reload user data from PC card or floppy disk.
_____________________________________________________________________

ERROR CODE P2006 Option is OFF.

Selected option is set OFF (disabled) or is not installed.

⇒ Enable option or contact KRI customer service to install option.

_____________________________________________________________________

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ERROR CODE P2007 Cannot execute because executed by other device.

Occurs when the operator attempts to execute the same command from the KCWIN
terminal and the teach pendant at the same time.

⇒ Cannot execute commands from two devices at the same time.

_____________________________________________________________________

ERROR CODE P2008 Device is not ready.

This error occurs when the RS232C communication port is configured to be used with a
PC and Host Communication (I) communication is attempted.

⇒ Use the AS Language TERMOFF command to reconfigure the communication proto-

col.
_____________________________________________________________________

ERROR CODE P2009 Illegal file name.

This error occurs when a file name does not follow to the proper syntax during file save
or load.

⇒ The first character in a file name must be alphabetic.

⇒ File names are limited to eight characters (excluding three character extension).
⇒ File names cannot contain spaces.
_____________________________________________________________________

ERROR CODE P2010 Disk is not ready.

This error occurs when a floppy disk is not installed or is not readable.

⇒ Ensure the floppy disk is properly installed in the drive unit.

⇒ Ensure the floppy disk is not write protected.
⇒ Defective floppy drive unit or defective 1KA/1RA board.
⇒ Defective local bus harness.
_____________________________________________________________________

ERROR CODE P2011 Invalid disk format.

Incorrect disk format.

⇒ Ensure the disk format is: 2HD, 1.44 MB or 1.25 MB.

_____________________________________________________________________

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ERROR CODE P2012 Disk is write protected.

This error occurs when attempting to write to a disk that is write protected.

⇒ Disable the write protection on the floppy disk card.

⇒ Defective floppy disk, floppy disk drive unit, or defective 1KA/1RA board.
⇒ Defective local bus harness.
_____________________________________________________________________

ERROR CODE P2013 Disk full.

This error occurs when attempting to write to a floppy disk that does not have enough
free space to complete a save.

⇒ Disable the write protection on the floppy disk.

⇒ Use a floppy disk with free space available.
⇒ Defective floppy disk, floppy disk drive unit, or defective 1KA/1RA board.
_____________________________________________________________________

ERROR CODE P2014 Too many files.

This error occurs when the number of files on the floppy disk, or PC card, exceeds the
maximum.

⇒ Use a floppy disk with available free space.

⇒ Defective floppy disk, floppy disk drive unit, or defective 1KA/1RA board.
⇒ Defective local bus harness.
_____________________________________________________________________

ERROR CODE P2015 Cannot write on read-only file.

An attempt is made to overwrite or delete a read-only file on a floppy disk or PC card.

⇒ Change the file properties.

_____________________________________________________________________

ERROR CODE P2016 Cannot open the file.

The file cannot be opened with the SAVE or LOAD commands.

⇒ Ensure the floppy disk is properly inserted into the floppy disk drive.
⇒ Ensure an existing file name is used.
⇒ Defective local bus harness.
⇒ Defective floppy disk, floppy disk drive unit, or 1KA/1RA board.
_____________________________________________________________________

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ERROR CODE P2017 Cannot close the file.

A file opened by the SAVE or LOAD command cannot be closed.

⇒ If the file is opened using a PC, ensure proper connection with the controller.
⇒ Defective local bus harness.
⇒ Defective floppy disk, floppy disk drive unit, or 1KA/1RA board.
_____________________________________________________________________

ERROR CODE P2019 ADC function already in use.

This error occurs when a monitor command and a program command are executed for
an ADC function at the same time.

⇒ Do not execute a monitor command for an ADC function while a robot or process
control program is executing an ADC function command.
_____________________________________________________________________

ERROR CODE P2020 Illegal device number.

For Host Communication I, the sensor port is specified as logical device number 1 or 7.
The PC terminal port is specified as logical device number 2 or 8. This error occurs
when a SEND command/instruction specifies an illegal device number.
Example: SEND 3:$out,err.

⇒ Ensure an available device number is specified.

Example: SEND 1:$out,err.
_____________________________________________________________________

ERROR CODE P2022 Cannot use DOUBLE OX.

When DOUBLE type signals are used, if either output signal in the pair is set ON, the
other is set to OFF. An instruction (BITS, PULSE, DLYSIG, etc.) to change the state of
either output signal causes this error to occur.

⇒ Ensure signals used with the BITS, PULSE, DLYSIG, etc. commands/instructions are
not designated as DOUBLE OX.
_____________________________________________________________________

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ERROR CODE P2023 In cooperative mode.

Main causes include:

1. An EXECUTE, DO, PRIME, or PRESET command, or, a program selection, step
selection, or external program reset command is executed during cooperative motion.
2. MASTER or SLAVE instruction is executed between MASTER and ALONE instruc-
tions in the MASTER robot program, or between SLAVE and ALONE instructions in
the SLAVE robot program.

⇒ Do not use EXECUTE, DO, PRIME or PRESET commands or program select, step
select, or external program reset command during cooperative motion.
⇒ Correct the MASTER or SLAVE robot program as needed.
_____________________________________________________________________

ERROR CODE P2024 Invalid coordinate value X.

This error occurs when the work space output signal lower X value is greater than the
upper value in AUX 0403.

⇒ Ensure upper and lower values are set correctly in AUX 0403.
_____________________________________________________________________

ERROR CODE P2025 Invalid coordinate value Y.

This error occurs when the work space output signal lower Y value is greater than the
upper value in AUX 0403.

⇒ Ensure upper and lower values are set correctly in AUX 0403.
_____________________________________________________________________

ERROR CODE P2026 Invalid coordinate value Z.

This error occurs when the work space output signal lower Z value is greater than the
upper value in AUX 0403.

⇒ Ensure upper and lower values are set correctly in AUX 0403.
_____________________________________________________________________

ERROR CODE P2027 Cannot use signal, already used in I/F panel.

This error occurs when a signal allocated for the I/F panel is used as an OX signal.

⇒ Use a signal that is not allocated for the I/F panel.

_____________________________________________________________________

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ERROR CODE P2028 Arm ID board is busy.

This error occurs when the 1GV arm ID board is processing data when a flash memory
access command is executed (MNTREC, MNTLOG, etc.).

⇒ Execute the flash memory access command after the 1GV arm ID board completes
processing the data.
⇒ Defective 1GV arm ID board.
_____________________________________________________________________

ERROR CODE P2029 Axis setting data is incorrect.

The channel number for the external axis is set to a channel number already assigned to
another axis in AUX 2001, External Axis Set.

⇒ Ensure the correct channel number is set in AUX 2001 using the values from the
original factory specification sheet.
_____________________________________________________________________

ERROR CODE P2031 Deleted step was destination of Jump, Call instruction.

This error occurs when the destination step for a JUMP or CALL instruction specified by
FN20, FN23, or FN26 is deleted.

⇒ Teach a step at the JUMP destination.

⇒ Ensure the correct step is designated in FN20, FN23, or FN26.
_____________________________________________________________________

ERROR CODE P2032 Incorrect number input as WHERE parameter.

Occurs if a numeric value entered with the WHERE command is not in the acceptable
range.
Example: WHERE 100.

⇒ Ensure that data is within acceptable range.

Example: WHERE 1.
_____________________________________________________________________

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ERROR CODE P2033 Logging is running.

This error occurs when a robot program or a PC program executes the SETTRACE or
RESTRACE commands during LSTRACE command execution.

⇒ Execute SETTRACE or RESTRACE after logging is completed.

⇒ Turn off trace functions in all robot and PC programs.
_____________________________________________________________________

ERROR CODE P2034 Undefined memory.

This error occurs when the TRACE ON command is executed before securing the
memory address with the SETTRACE command.

⇒ Secure the memory address with the SETTRACE command.

_____________________________________________________________________

ERROR CODE P2035 Non data.

This error occurs when the ZMNTCLEAR instruction is executed for a number of mainte-
nance log entries greater than the number of entries in the maintenance log.

⇒ Use the MNTLOG command or AUX 123-2 to display and confirm the number of
maintenance log entries.
_____________________________________________________________________

ERROR CODE P2038 Matrix Calculation Error.

An error occurred in a software calculation.

Example: The three points for creating an arc path are on the same line in the CSHIFT
function.

⇒ Make necessary corrections and recalculate value.

_____________________________________________________________________

ERROR CODE P2039 Cannot start cycle from FN instruction.

This error occurs when an FN instruction is the first step at cycle start.

⇒ Do not execute cycle start at a step containing an FN instruction.

_____________________________________________________________________

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ERROR CODE P2040 Card is not ready.

The controller tried to read the PC card, but the PC card is not inserted.

⇒ Insert PC card and re-execute.

_____________________________________________________________________

ERROR CODE P2041 Wrong card loaded.

The PC card inserted in the controller cannot be used or is defective.

⇒ Insert a usable PC card.

_____________________________________________________________________

ERROR CODE P2042 Card is write-protected.

An attempt is made to overwrite or delete data on a PC card that is write-protected.

⇒ Remove write-protection and re-execute.

_____________________________________________________________________

ERROR CODE P2043 Card battery is low voltage.

An attempt is made to access a PC card with low battery voltage.

⇒ Replace card battery and re-execute.

_____________________________________________________________________

ERROR CODE P2044 Card is not formatted.

An attempt is made to access a PC card that is not formatted.

⇒ Insert a formatted PC card.

⇒ Use AUX 0204 to format the SRAM PC card.
_____________________________________________________________________

ERROR CODE P2045 Cannot format this card.

An attempt is made to format a non-SRAM PC card.

⇒ Use a PC to format a non-SRAM card.

_____________________________________________________________________

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ERROR CODE P2046 Card initialization error.

PC card format failed.

⇒ Re-execute PC card format.

⇒ If the error recurs, use another PC card.
_____________________________________________________________________

ERROR CODE P2047 File is already open.

An attempt is made to open a file that is already open.

⇒ Cycle controller power OFF and ON and re-execute.

⇒ If this error recurs, replace the 1KA/1RA/1KF boards or harness.
_____________________________________________________________________

ERROR CODE P2048 File does not exist in card.

Non-existing file is specified for loading or deleting from a PC card.

⇒ Ensure an existing file name is used.

_____________________________________________________________________

ERROR CODE P2049 Attempted to open too many files.

An attempt is made to open a file while another file is open.

⇒ Cycle controller power OFF and ON and re-execute.

⇒ If this error recurs, replace the 1KA/1RA/1KF boards or harness.
_____________________________________________________________________

ERROR CODE P2050 Unexpected error during card access.

An unregistered error occurred.

⇒ Cycle controller power OFF and ON and re-execute.

⇒ If this error recurs, replace the PC card, 1KA/1RA/1KF boards, or harness.
_____________________________________________________________________

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ERROR CODE P2051 Illegal sequence numbers for file I/O data.

During data transfer between the 1KA/1RA and 1KF boards, the response from the 1KF
board does not conform to the request from the 1KA/1RA board.

⇒ Replace the 1KA/1RA/1KF boards.

⇒ Replace the harness between the 1KA/1RA and 1KF boards.
⇒ Check for noise malfunction and shield integrity.
_____________________________________________________________________

ERROR CODE P2052 [LSEQ] Program includes unavailable instructions.

An unavailable instruction is included in basic operation part of the KLogic program

(lsqpg).
Example: JMOVE.

⇒ Delete unavailable instruction form the KLogic program (lsqpg).

_____________________________________________________________________

ERROR CODE P2053 [LSEQ] Too many steps exist.

An excessive number of steps exist in the basic operation part of the KLogic program
(lsqpg).

⇒ Correct the KLogic program so the number of steps does not exceed the maximum
number of steps allowed (10,000 steps maximum).
_____________________________________________________________________

ERROR CODE P2054 [LSEQ] Invalid type of signal variable.

An instruction that specifies an invalid signal variable as an argument is used in the

basic operation part of the KLogic program.
Example: LSQ OUT,&X0000.

⇒ Ensure a valid signal variable is used in the KLogic program.

Example: LSQ OUT,&Y0000.
_____________________________________________________________________

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ERROR CODE P2055 [LSEQ] Program is already running.

During execution of the basic operation part of the sequence function of the KLogic
program, the program is executed again by the LSQEXECUTE command/instruction.

⇒ Place the basic operation part of the sequence function in HOLD and re-execute.
⇒ Correct the currently running program using the LSQREWRITE command.
_____________________________________________________________________

ERROR CODE P2056 [LSEQ] No. of signal is outside specifiable range.

The basic operation part of the KLogic program includes an instruction that specifies an
invalid signal number as an argument.
Example: LSQ STR, &X0800.

⇒ Ensure valid signal numbers are used in the KLogic program.

Example: LSQ STR,&X07FF.
_____________________________________________________________________

ERROR CODE P2057 [SerialFlash] cannot open file.

A file stored on the 1KA/1RA board cannot be opened.

Main cases include:

1. The file is corrupt.
2. An attempt to save is made, but the 1KA/1RA board serial flash memory is set to
write-protect.

⇒ Ensure the 1KA/1RA board serial flash memory is not set to write-protect.
⇒ Replace the 1KA/1RA board serial flash memory.
_____________________________________________________________________

ERROR CODE P2058 [SerialFlash] data read error.

A file on the 1KA/1RA board cannot be read because the file is corrupt.

⇒ Replace the 1KA/1RA board serial flash memory.

_____________________________________________________________________

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ERROR CODE P2059 [SerialFlash] data write error.

The specified file cannot be written to the 1KA/1RA board.

Main causes include:

1. The file is corrupt.
2. The serial flash memory on the 1KA/1RA board is set to write-protect.

⇒ Ensure the 1KA/1RA board serial flash memory is not set to write-protect.
⇒ Replace the 1KA/1RA board serial flash memory.
_____________________________________________________________________

ERROR CODE P2060 [SerialFlash] File or directory doesn’t exist.

The specified file or directory does not exist in the serial flash memory on the 1KA/1RA
board.

⇒ Ensure the file or directory exists in the serial flash memory.

⇒ Create a new file or directory.
_____________________________________________________________________

ERROR CODE P2061 File does not exist in floppy.

When accessing the floppy disk, the specified file cannot be found on the floppy disk.

⇒ Ensure an existing file name is specified.

_____________________________________________________________________

ERROR CODE P2062 [FDD/PC_CARD] Failure in writing data per verify function.

When the verify function is enabled in AUX 0208, the destination and source data are
compared when writing data to a floppy disk or PC card. This error occurs if the data
does not match.

⇒ Replace the floppy disk/PC card.

⇒ If this error recurs, replace the 1KA/1RA/1KF boards or harness.
_____________________________________________________________________

ERROR CODE P2063 [FDD/PC_CARD] Faulty response from verify function.

Setting enable or disable for the verify function in AUX 0208 failed.

⇒ Re-execute.
⇒ If this error recurs, replace the 1KF board.
_____________________________________________________________________

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ERROR CODE P2064 [FDD] No space available.

Floppy disk has less than 12 KB of free space and the data cannot be saved.

⇒ Insert a floppy disk with sufficient free space and re-execute.

⇒ Delete unnecessary data from the floppy disk and re-execute.
_____________________________________________________________________

ERROR CODE P2065 [Multi Disks] Invalid disk was loaded.

When loading data that is saved to several floppy disks, the data on the currently in-
serted floppy disk does not follow the data previously loaded.

⇒ Use a PC to verify data on disk.

⇒ Ensure data is loaded in the order it is saved.
_____________________________________________________________________

ERROR CODE P2066 Boot flash state is write-disenable.

Attempting to rewrite the contents of the boot flash memory.

Example: Rewriting the MAC address.

⇒ Boot flash memory is write-protected.

_____________________________________________________________________

ERROR CODE P2067 [Serial Flash] File directory error.

Specified directory exists, but cannot be read due to abnormality.

Example: Error when accessing the serial flash memory.

⇒ Replace the serial flash memory on the 1KA/1RA board.

_____________________________________________________________________

ERROR CODE P2068 Cannot execute program being edited now.

An attempt is made, from another monitor, to edit the file currently being edited, or to
CALL the program from another program.

⇒ Complete the program edit and re-execute.

_____________________________________________________________________

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ERROR CODE P2069 [FDD/PC_CARD] Device already in use.

Attempting to perform several processes at the same time to/from the floppy disk/PC
card. The next task is commanded while the previously commanded task is in progress.

⇒ Allow each task to be completed before initiating another task to/from the floppy disk/
PC card.
_____________________________________________________________________

ERROR CODE P2070 No more data can be registered.

An attempt is made to set additional signal names or comments beyond the maximum
number allowed in the KLogic program.

⇒ Delete unnecessary signal names and comments.

⇒ Initialize all data.
_____________________________________________________________________

ERROR CODE P2071 C/S switch set to disable.

The CYCLE START switch is pressed while the cycle start switch invalid option set ON.

⇒ Set the cycle start switch invalid option OFF and re-execute.
_____________________________________________________________________

ERROR CODE P2072 [LSEQ] Maximum cycles of execution.

While executing the basic operation part of the KLogic program, execution cycle time is
calculated as longer than the cycle time set using the LSQ_CYCMAX (maximum length
of execution cycle) command/instruction. In this case, the program is not executed.

⇒ Reduce the number of steps in the program.

⇒ Increase the maximum execution cycle time (if possible).
_____________________________________________________________________

ERROR CODE P2073 [LSEQ] Other program is waiting execution.

During execution of the basic operation part of the KLogic program, an attempt is made
to execute LSQREWRITE. Overwriting program data using the LSQREWRITE com-
mand/instruction is executed after completing the last step of the currently running
program.

⇒ Allow the current program execution to complete before executing the LSQREWRITE
command/instruction.
_____________________________________________________________________

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ERROR CODE P2074 Floppy disk is broken.

This error occurs when ten or more defective sectors are detected on a floppy disk.

⇒ Use a new or known good floppy disk.

_____________________________________________________________________

ERROR CODE P2075 Channel number of Jt%d is incorrect.

Main causes include:

1. Non-existing channel number is allocated.
2. Board for driving Mitsubishi motor is not installed or incorrect board is installed on the
1KB/1RB board.

⇒ Ensure the external axis channel number set in AUX 2002 is correct.
⇒ Ensure the correct Mitsubishi motor driving board is installed to the 1KB/1RB board.
_____________________________________________________________________

ERROR CODE P4500 FIELD-BUS) Interface not enabled.

Main causes include:

1. An attempt is made to execute the PROFIBUS (/DEVNET) command without register-
ing the appropriate fieldbus interface.
2. The PROFIBUS (/DEVNET) interface card is not installed.

⇒ Ensure the fieldbus interface is registered.

⇒ Ensure the fieldbus interface card is properly installed.
_____________________________________________________________________

ERROR CODE P4501 DEVNET) Node %d not in the scanlist.

An attempt is made to execute the DEVNET command to a slave that is not in the
scanlist.

⇒ Ensure the MAC_ID, settings and parameters for the device to receive the monitor
command are correct and re-execute the DEVNET command.
_____________________________________________________________________

ERROR CODE P4502 DEVNET) Already in that mode.

An attempt is made to change the operation mode setting, using the DEVNET com-
mand, to the mode that is currently set.

⇒ Ensure the correct parameter is set and re-execute the DEVNET command.
_____________________________________________________________________

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ERROR CODE P4503 Duplicate signal number.

The specified signal number cannot be used because the same signal number is cur-
rently set.

⇒ Specify a different signal number.

_____________________________________________________________________

ERROR CODE P5000 Waiting weld completion.

Displayed when a command to change the step is entered while a welding sequence is
in progress (weld complete or retract/extend signal not received).

⇒ Reset the error, and release the wait condition.

⇒ Manually input weld complete or retract/extend signal.
_____________________________________________________________________

ERROR CODE P5001 Waiting retract or extend pos. input signal.

One of the following operations is attempted when the robot is processing a spot weld
sequence (waiting for the Retract/Extend signal after the weld complete signal is re-
ceived).
1. Cycle start (including EXECUTE, CONTINUE command).
2. Program selection or step change.
3. Record.

⇒ Input the Retract/Extend detection signal to the robot or access the wait override
screen on the teach pendant. Refer to the D Series Controller Operations and Pro-
gramming Manual for the wait override procedure.
_____________________________________________________________________

ERROR CODE P5002 Spot sequence is running.

Step change, program change, or program execution attempted while the spot weld
sequence is executing (after Retract/Extend input signal and weld complete signal are
received).
Example: The robot is executing motion start delay time after weld complete.

⇒ Perform step change, program registration or program execution after the spot weld-
ing sequence is complete.
⇒ Reset the error, and release the wait condition.
_____________________________________________________________________

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ERROR CODE P5003 External axis type and gun data mismatch.

The servo gun setting does not correspond to the type of external axis (set in AUX 2002)
and type of gun (set in AUX 0605-12). This error is detected when motion begins for a
step with a clamp signal set.

⇒ Confirm that the external axis and gun type data settings are correct.
_____________________________________________________________________

ERROR CODE P6000 Shifted location of STEP %4d is out of range.

After the shift function is executed, an axis (axes) exceeds motion range.

⇒ Ensure the new pose data after the shift is within motion range.
_____________________________________________________________________

ERROR CODE P6001 Step %4d in source program is out of motion range.

Source program pose data is out of motion range in the shift function.

⇒ Ensure the pose data in the source program is within motion range.
_____________________________________________________________________

ERROR CODE P6003 Cannot execute program because of suspend playback.

An attempt is made to cycle start when the dedicated input signal for forced termination
of repeat operation is set OFF.

⇒ Manually input the dedicated signal for forced termination of repeat operation.
_____________________________________________________________________

ERROR CODE P6500 Cannot generate working line direction.

This error occurs when weld start and end points are the same, and motion direction
cannot be determined.

⇒ Ensure the start and end points are not the same.
_____________________________________________________________________

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ERROR CODE P6501 Illegal tool posture.

The tool angle (angle between torch and welding line; also called torch angle) is 0 de-
grees and the welding cannot be executed.

⇒ Teach a third point besides the weld start and end points above the line between the
start and end points so that the torch assumes an appropriate angle.
_____________________________________________________________________

ERROR CODE P6502 No weld database.

The arc weld condition database specified by the source program does not exist.

⇒ Create arc weld condition database specified by the program.

_____________________________________________________________________

ERROR CODE P6503 Cannot change weld condition.

An attempt is made to change weld conditions using the real time weld condition modifi-
cation function without selecting check mode and WELD ON.

⇒ To change weld conditions using the real time weld condition modification function.
1. Select check mode.
2. Set WELD ON.
3. Change weld conditions.
_____________________________________________________________________

ERROR CODE P6504 Step:%ld Preceding L.START missing.

This error occurs when an L.START instruction does not proceed an L.END instruction.

⇒ Add a step containing an L.START instruction before the step containing the L.END
instruction.
_____________________________________________________________________

ERROR CODE P7000 Cannot program reset, because not at home position 1.

The robot is not at the registered home 1 position, and the program reset signal is ig-
nored.

⇒ Ensure the robot is at the home 1 position, and re-execute.

_____________________________________________________________________

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1.3.2.4 WXXXX MECHANICAL/CONTROL WARNING ERROR CODES

ERROR CODE W1000 Cannot move along straight line JT%ld in this configura-
tion.

When operating manually in teach mode and in base or tool mode, axis (JT%ld) speed
exceeds capability with the wrist in this posture.

⇒ Change the wrist posture.

⇒ Reduce teach speed.
⇒ Reduce repeat speed.
⇒ Change the interpolation mode to joint.
_____________________________________________________________________

ERROR CODE W1001 Over maximum joint speed in check. Set low speed.

Commanded speed for each joint exceeds the allowable value during check operation.

⇒ Reduce check speed, re-execute.

_____________________________________________________________________

ERROR CODE W1002 Operation information was cleared.

The memory area used to store operational information is corrupt.

⇒ Cycle the controller power OFF and ON.

⇒ If this error recurs, replace the 1KA/1RA board.
_____________________________________________________________________

ERROR CODE W1003 Calibration failed. Retry after changing posture.

Auto load measurement failed.

⇒ Change the posture of the robot to allow sufficient torque load to be applied to JT3, 5,
and 6 for auto load measurement.
_____________________________________________________________________

ERROR CODE W1004 JT%-M out of motion range. Check operational area.

The robot motion exceeds the operational area set during auto load measurement.

⇒ Increase the range of motion set for auto load measurement.

⇒ Ensure the robot posture is configured as described in the auto load measurement
procedure.
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ERROR CODE W1005 Illegal center of gravity, default parameter is set.

Load mass value is set to a value other than zero, but the center of gravity is set to all
zeroes.

⇒ Enter the correct center of gravity value.

_____________________________________________________________________

ERROR CODE W1006 Incorrect load moment. Default parameter is set.

Load mass value and center of gravity are set, but the load moment of inertia is set to all
zeroes.

⇒ Set correct values for the load moment of inertia.

_____________________________________________________________________

ERROR CODE W1007 Application setting changed. Turn OFF & ON the control
power.

When application setting is changed, controller power must be cycled OFF and ON.

⇒ Cycle controller power OFF and ON.

_____________________________________________________________________

ERROR CODE W1008 Parameter changed. Turn OFF & ON the control power.

When parameters are changed, controller power must be cycled OFF and ON.

⇒ Cycle controller power OFF and ON.

_____________________________________________________________________

ERROR CODE W1009 Position envelope error of jt%-M at last E-stop.

The error message is generated when an E-stop is applied and the position of the robot
is not within a range of the commanded position. The error deviation range is specified
in AUX 0503.

⇒ Before the error is reset, the operator must be aware of the robot’s position within the
work envelope.
_____________________________________________________________________

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ERROR CODE W1010 RAM battery low voltage.

Main causes include:

1. Backup battery voltage below minimum value (3.3 VDC or less).
2. Defective battery harness.
3. Defective 1KA/1RA board.

⇒ Back up system and program data. Check and replace batteries as required.
⇒ Check batteries for defective connections. Repair as required.
⇒ Defective battery voltage monitoring circuit. Replace the 1KA/1RA board.
_____________________________________________________________________

ERROR CODE W1011 PLC alarm. (%04X)

This error occurs when a PC3JB (TOYOPUC) internal error (alarm) is present (battery
voltage low error, etc.).

⇒ Refer to the PC3JB (TOYOPUC) manual for the alarm code (%04X).
⇒ Replace the PC3JB (TOYOPUC).
_____________________________________________________________________

ERROR CODE W1012 Servo parameter Changed. Turn OFF & ON the control
power.

When robot model, number of axes, servo parameters for external axes, or the 1KB/1RB
board are changed, controller power must be cycled OFF and ON.

⇒ When model is changed, the servo software must also be changed.

⇒ Cycle controller power OFF and ON.
_____________________________________________________________________

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ERROR CODE W1013 Encoder battery low voltage [Servo (%X)].

Voltage of the encoder back up battery on the 1FG/1HG board decreased to 3.3 volts or
less, or the encoder battery alarm signal (BAL_AL) is disconnected. This error is only
detected at control power on or motor power on.

Encoder Encoder

Servo
Encoder I/F
CPU
Battery alarm
error
Power circuit/
1KB/1RB board battery power Battery
monitor circuit
Encoder +12 VDC power supply
1FG/1HG board
Controller Robot

Main causes include:

1. Discharged batteries.
2. Defective encoder battery board (1FG/1HG board).
3. Defective encoder.
4. Short in the harness from the encoder battery backup board to the encoder.
5. Short in the harness or defective encoder causing increased battery discharge.
6. Battery alarm signal line from the 1FG/1HG board is disconnected.
7. Defective servo board (1KB/1RB board).

⇒ Replace the battery. There is a possibility that internal encoder data may be lost.
Check the robot zeroing.
⇒ Check each harness for short circuit.
⇒ Replace the encoder, the 1KB/1RB servo board, or the 1FG/1HG encoder battery
backup board, if necessary.
_____________________________________________________________________

ERROR CODE W1014 Number of Axis Changed. Reinitialize.

The number of axis assigned to the robot has changed.

⇒ Change the number of axes and initialize the system.

_____________________________________________________________________

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ERROR CODE W1015 Possibility of failure.

The monitored value of I2 (current squared) exceeds the normal value for the monitored
program and indicates excessive wear in the cyclo reduction unit or a servo motor/brake
problem.

Current increase may be caused by program modifications.

⇒ If the robot control program is modified, the monitored value of I2 may need to be re-
evaluated and changed.
⇒ Check and replace the worn cyclo reduction unit.
⇒ Check and replace the defective servo motor/brake assembly.
_____________________________________________________________________

ERROR CODE W1016 Torque of motor is over limit. JT%ld

This error occurs when the current value exceeds the permitted set value. This error
may also occur if the overspeed load torque or inertia force is too high.

⇒ Ensure the robot program moves do not cause excessive load torque or inertia force.
⇒ Reduce the robot program speed or accel/decel parameters.
⇒ Ensure the load on the robot arm does not exceed the robot’s capacity.
_____________________________________________________________________

ERROR CODE W1017 Encoder battery low voltage. [External axis (%ld)]

Main causes include:

1. Discharged batteries.
2. Defective encoder battery board (1FG/1HG board).
3. Defective encoder.
4. Short in the harness from the encoder battery backup board to the encoder.
5. Battery discharge.
6. Defective servo board (1KB/1RB board).

⇒ Exchange the battery. There is a possibility that internal encoder data may be lost.
Check the robot zeroing.
⇒ Check each harness for short circuit.
⇒ Replace the encoder, the 1KB/1RB servo board, or the 1FG/1HG encoder battery
backup board, if necessary.
_____________________________________________________________________

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ERROR CODE W1018 Network parameter is changed. Turn OFF & ON the control
power.

When network setting data is changed, the controller power must be cycled OFF and
ON.

⇒ Cycle controller power OFF and ON.

_____________________________________________________________________

ERROR CODE W1019 The registered value is beyond rated load.

The moment of inertia of the tool exceeds the permitted value when the auto load mea-
surement is executed.

⇒ Ensure the tool and payload do not exceed the capacity of the robot.
⇒ Re-execute the auto load measurement.
_____________________________________________________________________

ERROR CODE W1020 Error sector was found.

This error occurs when a defective sector is detected on a floppy disk.

⇒ The disk may be used, but it is recommend to transfer the data to a new floppy disk.
_____________________________________________________________________

ERROR CODE W1021 The optimal posture can’t be found at present location.

When optimal configuration mode is selected, position and optimal tool posture, for
changing to linear motion, is not obtained in the current position and tool posture.

⇒ Select a different mode.

⇒ Change the robot position and tool posture and re-execute.
_____________________________________________________________________

ERROR CODE W4500 FIELD-BUS) Slave port OFFLINE.

Slave port is offline due to master power or communication line termination.

⇒ Check the master power and communication line and repair as necessary.
When repairs are completed wait for on-line status to return (1JF board LED 1 ON).
_____________________________________________________________________

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ERROR CODE W4501 FIELD-BUS) Master port OFFLINE.

Master port is offline due to communication line termination.

⇒ Check the slave and communication line and repair as necessary.

When repairs are completed wait for on-line status to return (1JF board LED 1 ON).
_____________________________________________________________________

ERROR CODE W5001 PLC communication error.

During PLC communication through the remote I/O function, an error occurred.

Main causes include:

1. The PLC is not in run mode.
2. After the NAC (communication processor) is initialized the INIT_COMPLETE BIT is
not set ON.

⇒ Ensure the PLC is in run mode.

⇒ Ensure the NAC configuration is correct.
⇒ Ensure the PLC connection is established.
⇒ Check for noise malfunction and shield integrity.
_____________________________________________________________________

ERROR CODE W5002 Weld controller #%d not connected.

During execution of the connection check sequence to the weld controller no response is
returned from the weld controller.

⇒ Ensure the welder connection is established. Repair or replace weld controller and
interface cable as necessary.
⇒ Ensure the welder is operational.
⇒ Check for noise malfunction and shield integrity.
_____________________________________________________________________

ERROR CODE W5003 Weld controller #%d no response.

During communication with the weld controller, no response is returned.

⇒ Ensure the welder connection is established. Repair or replace weld controller and
interface cable as necessary.
⇒ Ensure the welder is operational.
⇒ Check for noise malfunction and shield integrity.
_____________________________________________________________________

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ERROR CODE W5004 Weld controller #%d response error.

During communication with the weld controller, data received from the weld controller
does not conform to the specified protocol.

⇒ Ensure the welder connection is established. Repair or replace weld controller and
interface cable as necessary.
⇒ Ensure the welder is operational.
⇒ Check for noise malfunction and shield integrity.
_____________________________________________________________________

ERROR CODE W5005 (Spot welding) No response from RWC %d.

This error occurs when the robot controller sends weld conditions to the remote weld
controller (RWC), and does not receive a response (%d indicates the weld controller
number).

⇒ Defective welder or welder communication cables.

⇒ Defective 1KA/1RA/1GS board.
⇒ Check for noise malfunction and shield integrity.
_____________________________________________________________________

ERROR CODE W5006 (Spot welding) RWC response error %d.

This error occurs after weld conditions are sent to the specified remote weld controller
(RWC), and the response is abnormal (%d indicates the weld controller number).

⇒ Defective welder or welder communication cables.

⇒ Defective 1KA/1RA/1GS board.
⇒ Check for noise malfunction and shield integrity.
_____________________________________________________________________

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ERROR CODE W5007 (Spot welding) Weld fault %d.

This error occurs when a weld complete signal is not received by the robot controller
from the remote weld controller (RWC), or there is an electrical malfunction with the
RWC.

Code %d:
10: Under current 11: Over current
12: Short in SCR circuit 13: SCR did not fire
14: Data error 26: No weld

Typical electrical problems include:

Fluctuation in current, faulty SCR or SCR circuit, SCR has not fired, or abnormal line
voltage.

⇒ Defective welder or weld gun.

⇒ Defective 1KA/1RA/1GS board, or interface cables.
⇒ Check for noise malfunction and shield integrity.
_____________________________________________________________________

ERROR CODE W5008 (Spot welding) Cable disconnection error %d.

This error occurs when the robot controller detects a drop in current flow from the re-
mote weld controller (RWC) to the weld gun (%d indicates the weld controller number).

⇒ Defective welder or weld gun.

⇒ Defective 1KA/1RA/1GS board, or interface cables.
⇒ Check for noise malfunction and shield integrity.
_____________________________________________________________________

ERROR CODE W5009 (Spot welding) Internal leak %d.

Weld current data from the specified remote weld controller (RWC) is abnormal.
Short in secondary cable, or internal leak in secondary cable or weld gun.

⇒ Defective weld cable.

⇒ Defective weld controller or gun.
⇒ Defective 1KA/1RA/1GS board or interface cable.
⇒ Check for noise malfunction and shield integrity.
_____________________________________________________________________

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ERROR CODE W5010 (Spot welding) Main cable exchange alarm %d.

The present value of the counter for the specified weld gun exceeds the set value for
initiating an alarm to replace the main cable (%d indicates gun number).

⇒ Reset the alarm counter value.

⇒ Replace the main cable.
⇒ Select a higher counter value.
_____________________________________________________________________

ERROR CODE W5011 (Spot welding) No connection with RWC %d.

The start-up sequence, for communication with the remote weld controller (RWC) during
power up, failed or cannot be executed.

⇒ Defective welder or welder interface cables.

⇒ Defective 1KA/1RA/1GS board.
_____________________________________________________________________

ERROR CODE W5012 Cannot achieve set force.

Set force is not achieved within five seconds of pressurization start for servo spot weld
gun.

Main causes include:

1. Excessive tip wear.
2. Wear measurement failure.
3. Incorrect program data in step where error occurs.
4. Clamping force value set too high.
5. Workpiece is too thin.
6. Incorrect lower limit setting (LLIMIT command).

⇒ Re-execute tip wear measurement.

⇒ Re-teach program step.
⇒ Set appropriate clamping force value.
⇒ Ensure workpiece is placed correctly
⇒ Ensure lower limit setting is correct (LLIMIT command).
_____________________________________________________________________

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1.3.2.5 ADDITIONAL ERROR CODES LIST

Table 1-3 lists additional error codes that can occur in the robot arm and controller.

Table 1-3 Additional Error Code List

Code Old Code Error Message

P0105 -366 Illegal program.
P0163 -421 Name of program, variable, file, etc. misspecified.
P0164 Illegal Robot network ID.
P0165 -448 Step:%ld No SVALUE statement after SCASE.
P0166 -449 Step:%ld Preceding SCASE missing.
P1005 -218 Cannot execute program because of EXT. START ENABLE.
P1007 -220 Start signal was not input at a RPS_END step.
P1008 -221 Cannot execute program, HOLD sw. engaged.
P1045 -214 Set TEACH mode and teach lock ON.
P1046 -215 Turn on trigger switch.
P1047 The disconnected robot can not select the program/step.
P1048 -254 Cannot operate during execution of brake check.
P1049 -230 Program is locked.
P1050 Exist protected program.
P1051 -231 Cannot unlock protection while program running.
P1052 Because the memory was full, could not copy the program.
P1053 Because the memory was full, the copy of program was suspended.
P1054 Turn off trigger switch.
P2005 -106 Graphic area error.
P2021 -598 Cannot execute on this terminal.
P2030 -444 Unknown Aux. function number.
P2036 -393 Memory verify error.
P2037 -463 Real time path modulation is already running.
P2076 -2227 SAVE/LOAD in progress.
P2077 [Serial Flash] Access error occurred.
P2078 [Serial Flash] Upload or Download was aborted.
P2079 Card full.
P2080 Can not execute because of the channel assigned joint No.
P2083 -3200 User log is not created.

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Table 1-3 Additional Error Code List (Cont.)

Code Old Code Error Message

P2084 -3201 The number of registration of a user log was changed.
P2085 -3202 Cannot regist user log, no free memory.
P2086 -3217 User log data is not registered.
P2087 -3218 The kind of user log data and specified data is different.
P2088 Can not load the improper compensation parameter.
P2090 No servo data of the servo spec.
P2091 [Serial Flash] The file or directory already exists.
P2092 [Serial Flash] The directory is not yet empty.
P2093 [Serial Flash] There is no space to write.
P2094 [Serial Flash] Cannot access the file for read only.
P2095 No response from option CPU board.
P2096 Cannot execute cycle start after palletizing motion aborted.
P2097 Cannot change steps during palletizing motion.
P2098 The axis type is not set as the endless.
P4504 -3110 FIELD-BUS)signals limit over.（max. %03d)
P4505 CC-LINK)Version mismatch.
P4506 EN/IP-M)Already in specified mode.
P4507 FIELD-BUS)Cannot execute with old ANYBUS card firmware.
P4508 -3105 FIELD-BUS)Cannot communicate with interface card.
P4509 -3103 FIELD-BUS)Wrong interface card type error.
P4510 FIELD-BUS)Initialization of the card is not complete.
P6002 -2106 Specified painting data bank does not exist.
P6004 -2118 Cannot execute because of the Air Purge sequence.
P6505 -930 The axis type is not set as the servo torch
P6506 Shift function can not be used in CIR interp.
P7001 In force meas. mode, only NOP Interp. avail.
P7002 Cannot change stroke because clamp on now.
P7003 Servo parameter file is not found.
P7500 -110 Turn motor power on.
P7501 -206 Because of repeat mode,wait to teach mode.
P7502 -255 Over the number which can be registered in interruption.
P7503 -331 Cannot execute program in error masking.
P7504 -369 ONC/ONCI channel has already received.
P7505 -553 Cannot execute in saving.

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Table 1-3 Additional Error Code List (Cont.)

Code Old Code Error Message

P7506 -3072 Cannot accept a record because robot is moving.
P8400 Cannot execute program because of CLAMP MODE sig. inputting.
P8800 The controller number is the same.
P8801 The IL robot number is the same.
P8802 It is processing it by the IL server.
P8803 The connection with the IL server has not been permitted.
P8804 IL server IP address is a unsetting.
P8805 It is not teach mode.
P8806 Please do servo OFF.
P8807 ILL)Communication time out error.
P8808 ILL)PC server processing completion waiting is time out error.

P8809 ILL)PC server processing demand completion waiting is time out error.

P8810 ILL)Inter lock less function system error.

W1022 Not execute ZRPAADSET command.
W1023 Teach Plug Position wrong or P-N low voltage.[%x]
W1024 Deviation from last stop position exceeds the limit set.
W1025 (SSCNET) Excessive regenerative warning of Jt %-M.(code %.2X)
W1026 (SSCNET) Motor overload warning of Jt %-M.(code %.2X)
W1027 While lifter is locked, it can not move.
The center of gravity for payload is over limit. Reduction gears could be
W1028
broken.
The center of gravity for payload is over limit. Use the JT5 at zero
W1029
degree only.
W1030 -1540 Braking torque of Jt%-M has decreased.
W1031 Cannot move along straight line unless JT%ld value is 0 degree.
W1032 Cannot move straight - the flange faces direction of upper sphere.
W1033 Cannot change orientation.
W1034 Encoder power voltage is low . jt%-M
W1035 Encoder battery voltage is low. Check zeroing. Jt%-M
W1036 Step data is different.
W2901 SLOGIC ERROR MESSAGE #1
W2902 SLOGIC ERROR MESSAGE #2
W2903 SLOGIC ERROR MESSAGE #3
W2904 SLOGIC ERROR MESSAGE #4

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Table 1-3 Additional Error Code List (Cont.)

Code Old Code Error Message

W2905 SLOGIC ERROR MESSAGE #5
W2906 SLOGIC ERROR MESSAGE #6
W2907 SLOGIC ERROR MESSAGE #7
W2908 SLOGIC ERROR MESSAGE #8
W2909 SLOGIC ERROR MESSAGE #9
W2910 SLOGIC ERROR MESSAGE #10
W2911 SLOGIC ERROR MESSAGE #11
W2912 SLOGIC ERROR MESSAGE #12
W2913 SLOGIC ERROR MESSAGE #13
W2914 SLOGIC ERROR MESSAGE #14
W2915 SLOGIC ERROR MESSAGE #15
W2916 SLOGIC ERROR MESSAGE #16
W2917 SLOGIC ERROR MESSAGE #17
W2918 SLOGIC ERROR MESSAGE #18
W2919 SLOGIC ERROR MESSAGE #19
W2920 SLOGIC ERROR MESSAGE #20
W2921 SLOGIC ERROR MESSAGE #21
W2922 SLOGIC ERROR MESSAGE #22
W2923 SLOGIC ERROR MESSAGE #23
W2924 SLOGIC ERROR MESSAGE #24
W2925 SLOGIC ERROR MESSAGE #25
W2926 SLOGIC ERROR MESSAGE #26
W2927 SLOGIC ERROR MESSAGE #27
W2928 SLOGIC ERROR MESSAGE #28
W2929 SLOGIC ERROR MESSAGE #29
W2930 SLOGIC ERROR MESSAGE #30
W2931 SLOGIC ERROR MESSAGE #31
W2932 SLOGIC ERROR MESSAGE #32
W2933 SLOGIC ERROR MESSAGE #33
W2934 SLOGIC ERROR MESSAGE #34
W2935 SLOGIC ERROR MESSAGE #35
W2936 SLOGIC ERROR MESSAGE #36
W2937 SLOGIC ERROR MESSAGE #37
W2938 SLOGIC ERROR MESSAGE #38

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Table 1-3 Additional Error Code List (Cont.)

Code Old Code Error Message

W2939 SLOGIC ERROR MESSAGE #39
W2940 SLOGIC ERROR MESSAGE #40
W2941 SLOGIC ERROR MESSAGE #41
W2942 SLOGIC ERROR MESSAGE #42
W2943 SLOGIC ERROR MESSAGE #43
W2944 SLOGIC ERROR MESSAGE #44
W2945 SLOGIC ERROR MESSAGE #45
W2946 SLOGIC ERROR MESSAGE #46
W2947 SLOGIC ERROR MESSAGE #47
W2948 SLOGIC ERROR MESSAGE #48
W2949 SLOGIC ERROR MESSAGE #49
W2950 SLOGIC ERROR MESSAGE #50
W2951 SLOGIC ERROR MESSAGE #51
W2952 SLOGIC ERROR MESSAGE #52
W2953 SLOGIC ERROR MESSAGE #53
W2954 SLOGIC ERROR MESSAGE #54
W2955 SLOGIC ERROR MESSAGE #55
W2956 SLOGIC ERROR MESSAGE #56
W2957 SLOGIC ERROR MESSAGE #57
W2958 SLOGIC ERROR MESSAGE #58
W2959 SLOGIC ERROR MESSAGE #59
W2960 SLOGIC ERROR MESSAGE #60
W2961 SLOGIC ERROR MESSAGE #61
W2962 SLOGIC ERROR MESSAGE #62
W2963 SLOGIC ERROR MESSAGE #63
W2964 SLOGIC ERROR MESSAGE #64
W2965 -92 The max load is %d%% of a permissible torque.
W2966 -95 Load exceeded permissible torque.
W2967 -91 Load exceeded max torque.
W2968 Please set a group number as %-M.
W3800 -1482 Encoder battery voltage decrease
W3801 -1495 Because the brake has been released, it is not possible to move.
W3802 Maint. period elapsed, maint. is required.
W3803 Total power ON time exceeded limit, maint. is required.

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Table 1-3 Additional Error Code List (Cont.)

Code Old Code Error Message

W3804 Total robot connection time exceeded limit, maint. is required.
W3805 Total servo ON time exceeded limit, maint. is required.
W3806 Total Jt%-M the total travel dist. exceeded limit, maint. is required.
W3807 Total times of MC ON exceeded limit, maint. is required.
W3808 Total times of servo ON exceeded limit, maint. is required.
W3809 Total times of E-stop exceeded limit, maint. is required.
W3810 Jt%-M total (curr)^3-motion dist. exceeded limit, maint. is required.
W3811 Jt%-M RMS value of current exceeded limit, maint. is required.
W4502 CC-LINK）Data link error on Master board. %x
W5000 -609 Release wait cond., in force measurement mode.
W5013 Tip wear over the limit. (MOVING SIDE)
W5014 Tip wear over the limit. (FIXED SIDE)
W6000 -2109 Grease reduction gears and motor bearings.
W6001 -2110 Replace the robot main cable.
W6002 -2111 Replace the cooling fans in the controller.
W6003 -2112 Replace the DC power supply in the controller.
W6004 -2113 Replace the servo power unit.
W6005 -2114 Replace the power amplifier for the robot arm.
W6006 -2115 Replace the power amplifier for the robot wrist.
W6007 -2116 Replace the power amplifier for the traveler.
W6008 Internal pressure interlock is jumped.
W6009 Not selected Internal pressure Explosion-proof.
Cannot operate excluding the servo welding gun axis. Because the
W7000
pressure measurement mode.
W7500 -340 Can't continue check motion because separated from last pos.
W7501 -3070 Cannot execute a program because of LOW voltage.
W8400 Cannot achieve set force of Jt %d.
Command value almost exceeds virtual safety fence.(Sphere%2d,
W8800 -1034
Line%d)
Command value almost exceeds virtual safety fence.(Sphere%2d,
W8801 -1034
ZUpper)
Command value almost exceeds virtual safety fence.(Sphere%2d,
W8802 -1034
ZLower)
Command value almost invades restricted space.(Sphere%2d, Part.%d
W8803 -1034
Line%d)

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Table 1-3 Additional Error Code List (Cont.)

Code Old Code Error Message

Command value almost invades restricted space.(Sphere%2d, Part.%d
W8804 -1034
ZUpper)
Command value almost invades restricted space.(Sphere%2d, Part.%d
W8805 -1034
ZLower)
Command value almost exceeds virtual safety fence.(ToolBox,
W8806 -1034
Line%d)
Command value almost exceeds virtual safety fence.(ToolBox,
W8807 -1034
ZUpper)
Command value almost exceeds virtual safety fence.(ToolBox,
W8808 -1034
ZUpper)

W8809 -1034 Command value almost invades restricted space.(ToolBox, Part.%d)

W8810 -1034 Command value almost exceeds virtual safety fence.(Link%d, Line%d)

W8811 -1034 Command value almost exceeds virtual safety fence.(Link%d, ZUpper)

W8812 -1034 Command value almost exceeds virtual safety fence.(Link%d, ZLower)

Command value almost invades restricted space.(Link%d, Part.%d

W8813 -1034
Line%d)
Command value almost invades restricted space.(Link%d, Part.%d
W8814 -1034
ZUpper)
Command value almost invades restricted space.(Link%d, Part.%d
W8815 -1034
ZLower)
W8851 Detected area interference.
W8852 Detected arm interference.(%s%d, %s%d %s%d)
W8853 ILL)Detected arm interference.(%s%d, %s %s%d)
W8854 ILL)Communication time out error.

W8855 ILL)Sequence processing demand completion waiting is time out error.

W8856 ILL)Sequence processing completion waiting is time out error.

W8857 ILL)Sequence processing system error.
W8858 ILL)Create/Set processing completion waiting is time out error.
W8859 ILL)Inter lock less function system error.
W8900 Can not operate because motion limitation signal was input.
E0120 No destination program.
E0121 Cannot specify the jump source program as jump destination.
E0900 -427 Block step instruction check sum error.

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Table 1-3 Additional Error Code List (Cont.)

Code Old Code Error Message

E0901 -499 Step data is broken.
E0902 -816 Expression data is broken.
E1014 -1211 Dual port memory for communication is not installed.
E1015 -1212 Amp Interface board is not installed.(code=%XH)
E1033 -1524 Encoder line error of (jt %-M).
E1040 -1558 Encoder MR-sensor error. (jt %-M)
E1105 -1032 Start/Destination point is in protected space.
E1107 -1219 Cannot use SEPARATE CONTROL.
E1111 -2018 Due to motion restriction, JT%ld cannot move.
E1125 -1505 Velocity envelope error jt %-M.
E1161 Automatic Tool Registration not supported by robot model.
E1170 Slave is not ready.
E1171 CC-LINK communication board is not installed.
E1172 -636 Weld communication board is not installed.
E1173 Servo communication error Jt %-M.
E1174 AD board No.0 is not installed.
E1175 Offset data of zeroing is illegal value.(Robot%d)
E1176 (SSCNET) Download error of external axis parameter.
E1177 (SSCNET) Joint number is not assigned to the channel.
E1178 Communication error between Arm Control and Arm I/F board.
E1179 The current under bending compensation is too large.(jt %-M)
E1180 Download error of external axis parameter.(Jt-%d)
E1181 -1511 Encoder battery low voltage.[Servo(%X)]
E1182 Encoder battery low voltage.[External axis(%d)]
E1183 Because JT5 is not zero degree, cannot move along straight line.
E1184 Illegal configuration for motion.
E1185 JT1 and JT2 is interfered at start location.
E1186 JT1 and JT2 is interfered at end location.
E1187 Current command between Jt1 and Jt2 is interfered.
E1188 (SSCNET) Error in servo parameter change sequence.(code %.4x)
E1189 (SSCNET) Regenerative error of Jt %-M.(code %.2X)
E1190 (SSCNET) Speed error of Jt %-M.(code %.2X)
E1191 (SSCNET) Motor overload of Jt %-M.(code %.2X)
E1192 (SSCNET) Deviation error of Jt %-M.(code %.2X)

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Table 1-3 Additional Error Code List (Cont.)

Code Old Code Error Message

E1193 (SSCNET) Encoder battery of Jt %-M is low voltage.(code %.2X)
E1194 (SSCNET) Paratmeter warning of Jt %-M.(code %.2X)
E1195 (Dual servo) Deviation error between master joint and slave joint.
E1196 While lifter is locked, it can not move.
E1197 Compensation LS signal is not dedicated.
E1198 Brake check sequence error.
E1199 -1914 Brake check function is not supported by servo software ver.
E1200 (Dual servo) Cannot compensate current error (deviation %d).
E1201 Interference check board is not installed.
E1202 Voice recorder cannot stop.
E1203 LS location is not registered.
E1204 Current stretch over the limit.
E1205 Total stretch over the limit.
E1207 The type of I/O board on arm ID board is wrong.
E1208 Download error of servo parameter.(Jt-%d)
E1209 Upload error of servo parameter.(Jt-%d)
E1210 -1080 Cannot execute program because unprotected.
E1211 Because the memory was full, could not copy the program.
E1212 Because the memory was full, the copy of program was suspended.
E1213 JT4 and robot arm interfere during motion to start pose.
E1214 JT4 and robot arm interfere during motion to end pose.
E1215 Current command causes interference between JT4 and robot arm.
E1216 JT5 and JT6 interfere during motion to start pose.
E1217 JT5 and JT6 interfere during motion to end pose.
E1218 Current command causes interference between JT5 and JT6.
E1219 Exceeds allowable No. of output instructions for the path.
E1220 Signal output point is out of the path.
E1221 Too many signal numbers are specified.
E1222 Motion instruction to start/end point of path not set.
E1223 No pose data in last/next motion instruction.
E1224 Several signal output points detected at the same point.
E1225 Correction end instruction is missing.
E1228 JT4 value in the start point is not 0 degree.
E1229 JT4 value in the target point is not 0 degree.

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Table 1-3 Additional Error Code List (Cont.)

Code Old Code Error Message

E1230 Flange faces direction of upper sphere in start point.
E1231 Flange faces direction of upper sphere in target point.
E1232 Option CPU board is not installed.
E1233 IJoint/ILinear signal not specified.
E1234 IJoint/ILinear signal not detected.
E1235 -1265 Separate control I/O board is not installed.
E1236 Distance is too long to correct.
E1237 Vision recognition error.
E1238 Vision communication error.
E1239 Cannot use this instruction in frame correction mode.
E1240 BASE FRAME is not sent from vision unit.
E1241 Improper parameter for FN481.
E1242 Cannot create more than 99 BASE FRAME.
E1243 Cannot execute because camera%d is disconnected.
E1244 JT1 and JT2 and floor interfere during motion to start pose.
E1245 JT1 and JT2 and floor interfere during motion to end pose.
E1246 Current command causes interference between JT1, JT2 and floor.
E1247 Calculation of encoder absolute data is not completed.(jt %-M)
E1248 EEPROM access flag in encoder is busy.(jt %-M)
E1249 Temperature in encoder is over the limit.(jt %-M)
E1250 Rotation speed of encoder is over the limit.(jt %-M)
E1251 EEPROM access error occurred in encoder.(jt %-M)
E1252 Encoder rotation data ( internal ) is abnormal.(jt %-M)
Uncoincidence error between request and response in encoder. (jt %-
E1253
M)
E1254 MC of a group%-M is OFF, it cannot operate.
E1255 The motor power of unchosen robot was turned on.
E1256 Internal valve, sensor and error reset I/F board missing.
E1257 MC of group%-M turned off during individual repeat operation.
E1258 MC turned off during operation.
E1259 Invalid Structure of palletizing instruction.
E1260 Cannot execute instruction during palletizing motion.
E1261 Palletizing motion aborted.
E1262 Encoder rotation speed exceeded limit (jt %-M)

July 31, 2007 1-219

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Table 1-3 Additional Error Code List (Cont.)

Code Old Code Error Message

E1263 Encoder temperature exceeded limit (jt %-M)
E1264 Endless axis velocity envelope error.(jt %-M)
E1267 The initial setting of Encoder is abnormal. (jt %-M)
Breakage in the encoder line or faulty setting of encoder baud rate. (jt
E1268
%-M)
E3800 -1453 JT%-M axis amp servo amp heating
E3801 -1457 JT%-M axis amp main circuit power supply decrease
E3802 -1510 Encoder harness disconnected jt%-M
E3803 -1455 JT%-M axis amp speed control error
E3804 JT%-M axis amp velocity feedback error
E3805 -1456 jt%-M axis amp position envelope error
E3806 -1484 JT%-M axis amp servo ready does not turn on
E3807 JT%-M axis amp IPM overheated.
E3808 Motor power OFF (EXT_EMG).
E3809 -1472 Brake release signal error
E3810 -1481 Power sequence ready off
E3811 JT%-M axis amp command value suddenly changed.
E3900 Mismatch moving tool data and selected tool data.
E4030 -2218 FTP)Server does not recognize command.(code=%d)
E4035 -2224 FTP)TCP/IP not initialized.
E4059 ASCYCLE communication receive error(CODE: %X)
[ARM CONTROL BOARD] ASCYCLE communication receive error
E4060
(CODE: %X)
E4061 -882 Received gauge hole data exceeds allowable range.
E4062 -883 Master/slave data is not registered.
E4063 -884 Reference point data is not registered.
E4064 -887 3D calibration/measurement modes are both ON.
E4065 -889 Unregistered variable specified to receive data.
E4066 -890 Variable specified to receive data is broken.
E4067 -891 Received data is broken.
E4068 -892 Start code is not correct.
E4069 -893 End code is not correct.
E4070 -894 3D camera group No. not specified.
E4071 -895 Incorrect 3D camera group No.

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Table 1-3 Additional Error Code List (Cont.)

Code Old Code Error Message

E4072 Communication beginning wait time out error.
E4073 No servo off signal from ARM I/F board.
E4531 CC-LINK)Communication has been disconnected. %x
E4532 CC-LINK)Initial condition setting is incorrect.
E4533 CC-LINK)Watch dog timeout error.
E4534 CC-LINK)Parameter setting error. %x
E4535 CC-LINK)Time out on setting parameter.
E4536 CC-LINK)Master board is abnormal. %x
E4537 CC-LINK)Initialization error on master board . %x
E5036 -602 Incorrect gun status data.
E5037 -660 Tip wear exceeds limit. %s:
E5038 -973 Arc detection signal did not turn OFF.
E5039 -1273 No response from RWC communication I/F board.
E5040 Cannot connect gun because gun is already connected.
E5041 Cannot disconnect gun because gun is already disconnected.
E5042 Gun No is not defined or Gun type is not servo gun.
E5043 Communication error in welder. (code %d)
E5044 Failed to get weld data. (timer %d)
E5045 Failed to change weld data. (timer %d)
E5046 Weld error has arisen.
E5047 Receiving weld items now, wait till completion.
Weld controller is unconnected or weld items are not received. (timer
E5048
%d)
E5049 Serial number signal error.
E5050 This welder is without Traceability.
E5051 Cannot calibrate because tool change axis is disconnected.
E5052 The pressurizing power measurement value is abnormal.
E5053 The pressurizing power sensor is disconnected or it breaks down.
E5500 -1750 Vision board is not installed.
E5501 -2751 (Vision) Camera not connected.
E5502 -2710 (Vision) Incorrect parameter.
E5503 -2711 (Vision) Incorrect Symbol.
E5504 -2712 (Vision) Incorrect name.
E5505 -2713 (Vision) Incorrect image memory.

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Table 1-3 Additional Error Code List (Cont.)

Code Old Code Error Message

E5506 -2715 (Vision) Incorrect histogram data.
E5507 -2716 (Vision) Incorrect mode.
E5508 -2717 (Vision) Incorrect density(/color).
E5509 -2718 (Vision) Incorrect camera input assignment.
E5510 -2719 (Vision) Incorrect camera ch. number.
E5511 -2720 (Vision) Incorrect Window No.
E5512 -2722 (Vision) Incorrect coordinates data.
E5513 -2723 (Vision) Incorrect number.
E5514 -2726 (Vision) Incorrect image code(binary/multi).
E5515 -2728 (Vision) Incorrect threshold.
E5516 -2729 (Vision)PROTO(/TEMPLATE) not registered or already exists.
E5517 -2745 (Vision) Cal. data not registered.
E5518 -2746 (Vision) Graphic cursor is not initialized.
E5519 -2747 (Vision) Too many samples from PROTO object.
E5520 -2748 (Vision) Too many targets detected.
E5521 -2754 (Vision)Vision command not initiated.
E5522 -2768 (Vision) System registered with abnormal data.
E5523 -2770 (Vision) Error in processing image(s).
E5524 -2771 (Vision) Sound port assigned another function.
E5525 -2749 (Vision) Lack of data storage area.
E5526 -2752 (Vision) Incorrect synch. mode.
E5527 -2753 (Vision)Vision processing now.
E5528 -2766 (Vision) Image capture error.
E5529 -2767 (Vision) Time out or Buffer overflow.
E5530 -2769 (Vision) Failed to write on flash memory.
E5531 -2772 (Vision) Proto data abnormal, so initialized.
E5532 -2774 (Vision) Work detection failure.
E5533 -2797 (Vision) Initialization error. Code = %d
E5534 -2799 (Vision) Vision system error.
E5535 -2744 (Vision) Specified motion mode is incorrect.
E5536 -2732 (Vision) Inappropriate camera/projector parameters.
E5537 -2721 (Vision) Incorrect camera switch assignment.
E5538 -2727 (Vision) This plane is assigned to another camera.
E5539 -2755 (Vision) Edge was not found.

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Table 1-3 Additional Error Code List (Cont.)

Code Old Code Error Message

E5540 -2761 (Vision) Inappropriate HSI data.
E5541 -2762 (Vision) H data range width is over 128.
E5542 -2731 (Vision) Distance image input unit not set for camera.
E5543 -2758 (Vision) Cannot calculate the set edge points.
E5544 -2760 (Vision) Check color conversion table type in set config.
E5545 -2725 (Vision) Incorrect area size.
E5546 -2756 (Vision) Slit image does not exist.
E5547 -2724 (Vision) Incorrect no. of correlation vectors.
E5548 -2759 (Vision) Inappropriate vector data.
E5549 -2775 (Vision) X-Fit environment was not set.
E5550 -2776 (Vision) Mouse is not initialized.
E5551 -2777 (Vision)Camera switcher board is not installed.
E6009 -2171 Purge air flow is insufficient.
E6010 -2105 Out of motion area XYZ.
E6011 -2172 Internal air pressure low.
E6013 -2147 No free memory in program queue.
E6014 -2148 No free memory in delayed start queue.
E6015 -1074 Special signal is not specialized.
E6016 -2120 Robot arm stretching out (Singular Point 3).
E6017 -2121 Out of mechanical XYZ motion limits.
E6018 Painting equipment control board error. (code %d)
E6019 Painting equipment control board is not installed.
E6508 -949 No D/A board for polarity ratio control.
E6544 -990 Hyper Arc tracking value is out of range.
E6545 -991 Beyond Hyper Arc tracking ability.
E6546 -993 Bead end is not found.
E6547 -994 Finish end is not found.
E6548 -995 Hyper Arc revolution beyond normal deviation.
E6549 -996 Hyper Arc torch calibration error.
E6550 -997 Hyper Arc Z phase index error.
E6551 -985 No Hyper Arc board.
E6552 -986 Hyper Arc board error. Code is %d.
E6553 -987 Hyper Arc current sensor error.
E6554 -988 Hyper Arc voltage sensor error.

July 31, 2007 1-223

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Table 1-3 Additional Error Code List (Cont.)

Code Old Code Error Message

E6555 -989 Hyper Arc current deviation error.
E6556 -992 Hyper Arc amplifier error. Code is %d.
E6557 -945 No Wire feeding Control board.
E6558 -946 Wire feeding control error, code is %d.
E6559 -947 Wire feeding speed deviation error.
E6560 -965 Cannot re-calibrate weld in progress.
E6561 -966 Cannot weld, re-calibration in progress.
E6563 KHITS tracking system error. (code = %x)
E6564 -977 The arc weld instruction sequence is incorrect.
E6565 Arc welding Interface board(1LN) is not installed.(robot %d)
E6566 -2800 FN instructions not executed in the correct order.
E6567 -2801 KLS tracking system error.(code=%08x)
E6568 -2802 Failed in executing command to tracking system.(cmd=%d)
E6569 -2803 Taught data exceeds inclination limit for compensation.
E6570 -906 Can not execute because welding now.
E6571 -906 Can not execute because wire inching/retracting now.
E6572 Teach point for circular motion is missing.
E7003 The clearance distance of gun%d is set to 0mm.
E7004 Gun tip wear change over the limit. (MOVING SIDE)
E7005 Gun tip wear change over the limit. (FIXED SIDE)
E7006 Clamp number or gun number is not servo weld gun.

E7007 1267 Cannot change tip base data in 1 Stg. because tip wear rate is not set.

E7008 Independent Gun control is not completed.

E7500 -1496 Jt%-M Collision is detected.
E7501 -1497 Jt%-M Unexpected shock is detected.
E7502 -1806 AC Fail Process Error = %08x
E7503 -1485 POWER SEQUENCE setting data incorrect.
E7504 -673 Angle between JT%-M is out of range at start location.
E7505 -674 Angle between JT%-M is out of range at end location.
E7506 -1017 Angle between JT%-M is out of range.
E7507 -3219 SC1MOVE or SC2MOVE instruction is required after SC1MOVE.
E7508 -3220 SC1MOVE instruction is required before SC2MOVE.
E7509 -3221 Cannot execute, interpolation conditions are not fulfilled.

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Table 1-3 Additional Error Code List (Cont.)

Code Old Code Error Message

E8201 Unmatch the total of motion instruction in cooperative mode.
E8202 Unmatch step of motion instruction in cooperative mode.
E8203 Cannot use this instruction in cooperative mode.
E8204 Invalid cooperative group No.
E8205 No JMASTER robot.
E8206 TouchSensing in Cooperative mode is no supported.
E8207 JMASTER robot already exists.
E8208 WSLAVE robot already exists.
E8209 Fixed Point Motion in Cooperative mode is no supported.
E8210 No WSLAVE robot.
E8211 Out of sync.
E8212 Cannot continue non-cooperative instruction in cooperative mode.
E8400 Servohand opened in clamp ON step.(CLAMP=%d)
E8401 Clamping position of servo Hand is error.(CLAMP=%d)
E8402 Cannot achieve set force of Jt %d.
E8403 -2602 NC Joints lock signal not off.
E8404 -984 Interpolation other than joint int. is unavailable.
E8405 It tries to move the Matehan axis with the axis locked.
E8600 -1951 (FSJ)Processing condition error.%s
E8601 -1952 Gap was over the lower pos. limit.
E8602 -1953 Reached the Penetration depth within min. processing time.
It could not reach the setted Penetration depth within the appointed
E8603 -1954
period.
E8604 -1958 Pressure cable disconnected.
E8605 -382 Please input two set pressure or more.
E8606 -383 Please input data in ascending order.
E8607 -80 FSJ COUNTER ALARM.%d
E8608 -252 (FSJ) FSJ schedule setting data is abnormal.
E8609 -251 Setting tip force is over limit.
E8610 -253 Setting rotation speed is over limit.
Command value almost exceeds virtual safety fence.(Sphere%2d,
E8800 -1034
Line%d)
Command value almost exceeds virtual safety fence.(Sphere%2d,
E8801 -1034
ZUpper)

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Table 1-3 Additional Error Code List (Cont.)

Code Old Code Error Message

Command value almost exceeds virtual safety fence.(Sphere%2d,

E8802 -1034
ZLower)
Command value almost invades restricted space.(Sphere%2d, Part.%d
E8803 -1034
Line%d)
Command value almost invades restricted space.(Sphere%2d, Part.%d
E8804 -1034
ZUpper)
Command value almost invades restricted space.(Sphere%2d, Part.%d
E8805 -1034
ZLower)
Command value almost exceeds virtual safety fence.(ToolBox,
E8806 -1034
Line%d)
Command value almost exceeds virtual safety fence.(ToolBox,
E8807 -1034
ZUpper)
Command value almost exceeds virtual safety fence.(ToolBox,
E8808 -1034
ZUpper)

E8809 -1034 Command value almost invades restricted space.(ToolBox, Part.%d)

E8810 -1034 Command value almost exceeds virtual safety fence.(Link%d, Line%d)

E8811 -1034 Command value almost exceeds virtual safety fence.(Link%d, ZUpper)

E8812 -1034 Command value almost exceeds virtual safety fence.(Link%d, ZLower)

Command value almost invades restricted space.(Link%d, Part.%d

E8813 -1034
Line%d)
Command value almost invades restricted space.(Link%d, Part.%d
E8814 -1034
ZUpper)
Command value almost invades restricted space.(Link%d, Part.%d
E8815 -1034
ZLower)
E8820 -1035 Current value exceeded virtual safety fence.(Sphere%2d, Line%d)
E8821 -1035 Current value exceeded virtual safety fence.(Sphere%2d, ZUpper)
E8822 -1035 Current value exceeded virtual safety fence.(Sphere%2d, ZLower)

E8823 -1035 Current value invaded restricted space.(Sphere%2d, Part.%d Line%d)

E8824 -1035 Current value invaded restricted space.(Sphere%2d, Part.%d ZUpper)

E8825 -1035 Current value invaded restricted space.(Sphere%2d, Part.%d ZLower)

E8826 -1035 Current value exceeded virtual safety fence.(ToolBox, Line%d)

E8827 -1035 Current value exceeded virtual safety fence.(ToolBox, ZUpper)

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Table 1-3 Additional Error Code List (Cont.)

Code Old Code E rror M ess age

E 8828 -1035 Current v alue exc eeded v irtual s afety fence.(ToolB ox, ZLower)
E 8829 -1035 Current v alue invaded res tricted s pac e.(ToolB ox , Part.% d)
E 8830 -1035 Current v alue exc eeded v irtual s afety fence.(Link % d, Line% d)
E 8831 -1035 Current v alue exc eeded v irtual s afety fence.(Link % d, ZUpper)
E 8832 -1035 Current v alue exc eeded v irtual s afety fence.(Link % d, ZLower)
E 8833 -1035 Current v alue invaded res tricted s pac e.(Link% d, Part.% d Line% d)
E 8834 -1035 Current v alue invaded res tricted s pac e.(Link% d, Part.% d ZUpper)
E 8835 -1035 Current v alue invaded res tricted s pac e.(Link% d, Part.% d ZLower)
E 8850 Disabled robot m otion.
E 8851 Detec ted area interferenc e.
E 8852 Detec ted arm interferenc e.(% s% d, % s% d % s % d)
E 8853 Failed to predic t trajec tory .
E 8854 Detec ted deadlock .(% s % d, % s % d % s% d)
E 8855 No response from interferenc e c heck board.
Comm unic ation error between interferenc e check board and A RM
E 8856
CONTROL board.
E 8857 The num ber of robots is too m any.
E 8858 [INTE RFERE NCE CHECK B OA RD] P rocess ing tim e over.
[INTE RFERE NCE CHECK B OA RD] Can not rec eive data from ARM
E 8859
CTRL BOARD.
[A RM CTRL B OA RD] Can not rec eive data from INTERFE RENCE
E 8860
CHECK B OA RD.
E 8900 Detec ted torque for load pres enc e is abnorm al.
E 8901 Detec ted torque for load absence is abnorm al.
E 8902 S topped bec aus e m otion lim itation s ignal was input.
[A RM CONTROL B OA RD] Serv o control software CP U error.
D0006
(P C=% 8x , code % 4X )
D1018 S ervo s oftware vers ion m ism atc h.
[A RM CONTROL B OA RD] Watc hdog error in tim er built-in CPU for
D1019
s ervo c ontrol.
D1020 [A RM CONTROL B OA RD] Sy nc hronous error between CPUs.
D1021 S ervo FP GA configuration data not found.
D1022 Configuration error in serv o FPGA.(c ode % 4X )
D1023 Current m is m atch betw. m -plex er&s oftware J t% -M
[A RM CONTROL B OA RD] Serv o FPGA detected Watc h dog error
D1024
on ARM S C S oftware.

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Table 1-3 Additional Error Code List (Cont.)

Code Old Code Error Message

D1532 (SSCNET) Encoder communication error.(Jt %-M)(code %.2X)
D1533 (SSCNET) Absolute position of Jt %-M is erased.(code %.2X)
D1534 (SSCNET) Parameter error of Jt %-M.(code %.2X)
D1535 (SSCNET) Alarm of Jt %-M.(code %.2X)
D1536 Jt%-M does not move normally.
D1537 [Small Amp] Brake rectifier relay failure.
D1538 [Small Amp] DC 24V is abnormal.
D1539 Power supply circuit for PWM signal output malfunctioned.
D1540 -1501 Amplifier overheats.(%X)

D1541 Encoder type setting differs between software and Arm control board.

D2009 -2170 Internal pressure sensor error.

D2037 -1343 Safety unit circuit is abnormal.
D2038 (SSCNET) Interface board is not installed.
D2039 (SSCNET) Communication error of Jt %-M on initialization.
D2040 (SSCNET) Initialization error of Jt %-M.(code %.2X)
D2041 Connection of the signal harness is wrong.
D2042 Servo amp and robot arm are mismatched.
D2043 Arm I/F board detects AC-Fail.
D2044 [ARM CONTROL BOARD] No response from Servo FPGA software.
D2045 [ARM CONTROL BOARD] Device check error. (code %04X)
D2046 Relay OFF check error. (relay %-M)
D2047 Relay OFF check error. (external relay)
D2048 DC 12V Error of Internal pressure control board (1ST).
D2049 Over current Error of Internal pressure interlock relay(1).
D2050 Over current Error of Internal pressure interlock relay(2).
D2051 1ST board: Communication error.
D3800 -1076 Communication board memory error. (%d)
D3801 -1465 JT%-M axis amp interface error 1
D3802 -1466 JT%-M axis amp interface error 2
D3803 -1467 JT%-M axis amp interface error 3
D3804 -1450 JT%-M axis amp power element error
D3805 -1463 JT%-M axis amp current detector error
D3806 JT%-M axis amp main circuit voltage unmatch

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Table 1-3 Additional Error Code List (Cont.)

Code Old Code Error Message

D3807 -1461 JT%-M axis amp memory error(EEPROM error)
D3808 -1499 JT%-M axis amp inside RAM error
D3809 -1460 JT%-M axis amp servo processor error
D3810 -1462 JT%-M axis amp parameter error
D3811 -1498 JT%-M axis amp initial processing error
D3812 -1468 JT%-M axis amp undefinition error1
D3813 -1473 Amp communication I/F board initialed check error(%XH)
D3814 -1474 Amp communication I/F board undefinition error(%XH)
D3815 -1475 It is not possible to communicate with JT%-M axis amp
D3816 -1476 JT%-M axis amp communication frame reception error
D3817 -1477 JT%-M axis amp communication frame reception timeout
D3818 -1478 JT%-M axis amp communication bank data error
D3819 -1483 JT%-M axis amp init timeout
D3820 -1479 JT%-M axis amp communication undefinition error
D3821 -1494 Motor harness connection point is error.
D3822 -1599 Motor parameter is not consistent with controller. JT%-M
D3823 FAN NO. %-M in Controller is out of order.
D3824 Fuse NO.%-M on IO board NO.1 is open.
D3825 Fuse NO.%-M on IO board NO.2 is open.
D3826 Robot DC voltage error.
D3828 Controller type error.
D3829 -1338 K1 and/or K2 works wrong.
D3830 -1488 PN high voltage error
D3831 -1489 PN low voltage error
D3832 -1491 Register over time error
D3833 Discharge resistor overheated.
D3834 Power board switching circuit is abnormal.
D3835 Power board inrush current limiting circuit is abnormal.
D3836 DC Power voltage is abnormal.(code %X)
D3837 -1454 JT%-M axis amp control power supply error
D3838 Power board is abnormal.
D3839 -1334 Servo control line error.
D3840 FAN NO. %-M on power board is out of order.
D3841 Robot%d servo amp is not installed.

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Table 1-3 Additional Error Code List (Cont.)

Code Old Code Error Message

D3842 Control power supply of a power device is abnormal.
D6000 Barrier unit temperature is out of range.

1.4 TROUBLESHOOTING FLOWCHARTS

The following flowcharts are arranged by error code number. Refer also to the corre-
sponding error code information in section 1.3.2.2 during troubleshooting procedures.

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Error E1029

Does this
error occur just Follow
Yes troubleshooting
after resetting error
E1035, E1036, or flowchart for each
E1037? error

No

Replace encoder

Yes

Does No
problem still END
exist?

Yes

Replace 1KB/1RB board

Does
No
problem still END
exist?

Yes

Check connections at the

encoder connector

Check connections on the

1FG/1HG board

Check connections in the

separation harness

Check connections, jumpers, and

switches on the 1KB/1RB board

Figure 1-5 Error E1029 Flowchart (1)

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Does No
problem still END
exist?

Yes

Check inside
machine harness
and separation
harness

Does No
problem still END
exist?

Yes

Replace 1FG/1HG board

Does No
problem still END
exist?

Yes

Service call

Figure 1-6 Error E1029 Flowchart (2)

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Error E1032

Does this
error occur just Follow
Yes troubleshooting
after resetting error
E1035, E1036, or flowchart for each
E1037? error

No

No
Replace encoder END

Yes

Does
problem still
exist?

Yes

Replace 1KB/1RB board

Does
No
problem still END
exist?

Yes

Check connections at the

encoder connector

Check connections on the

1FG/1HG board

Check connections in the

separation harness

Check connections, jumpers, and

switches on the 1KB/RB board

Figure 1-7 Error E1032 Flowchart (1)

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Does No
problem still END
exist?

Yes

Check inside
machine harness
and separation
harness

Does No
problem still END
exist?

Yes

Replace 1FG/1HG board

Does No
problem still END
exist?

Yes

Service call

Figure 1-8 Error E1032 Flowchart (2)

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Error E1034

Does the
Reduce conveyor
encoder revolve over
Yes encoder revolution
300 RPM?
speed under 300
(For conveyor encoder)
RPM at power-up

No END
Check connections at the
encoder connector

Check connections on the

1FG/1HG board

Check connections in the

separation harness

Check connections, jumpers, and

switches on the 1KB/1RB board

Does No
problem still END
exist?

Yes

Replace encoder

Does No
problem still END
exist?

Yes

Figure 1-9 Error E1034 Flowchart (1)

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Replace 1KB/1RB board

Does No
problem still END
exist?

Yes

Replace 1FG/1HG board

Does No
problem still END
exist?

Yes

Check machine
harness and
separation harness

Does No
problem still END
exist?

Yes

Service call

Figure 1-10 Error E1034 Flowchart (2)

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Error E1035

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/1HG board
END

Check connections in the

separation harness

Check connections, jumpers, and

switches on the 1KB/1RB board

Does No
problem still END
exist?

Yes

Replace encoder

Does No
problem still END
exist?

Yes

Figure 1-11 Error E1035 Flowchart (1)

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Replace 1KB/1RB board

Does No
problem still END
exist?

Yes

Check machine
harness and
separation harness

Does No
problem still END
exist?

Yes

Replace 1FG/1HG board

Does No
problem still END
exist?

Yes

Service call

Figure 1-12 Error E1035 Flowchart (2)

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Error E1036

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/1HG board
END

Check connections in the

separation harness

Check connections, jumpers, and

switches on the 1KB/1RB board

Does No
problem still END
exist?

Yes

Replace encoder

Does No
problem still END
exist?

Yes

Figure 1-13 Error E1036 Flowchart (1)

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Replace 1KB/1RB board

Does No
problem still END
exist?

Yes

Check machine
harness and
separation harness

Does No
problem still END
exist?

Yes

Replace 1FG/1HG board

Does No
problem still END
exist?

Yes

Service call

Figure 1-14 Error E1036 Flowchart (2)

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Error E1037

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 1KB/1RB board

Does
No
problem still END
exist?

Yes

Check connections at the

encoder connector

Check connections on the

1FG/1HG board

Check connections in the

separation harness

Check connections, jumpers, and

switches on the 1KB/1RB board

Figure 1-15 Error E1037 Flowchart (1)

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Does No
problem still END
exist?

Yes

Check inside
machine harness
and separation
harness

Does No
problem still END
exist?

Yes

Replace 1FG/1HG board

Does No
problem still END
exist?

Yes

Service call

Figure 1-16 Error E1037 Flowchart (2)

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Error E1038

Replace encoder

Does No
problem still END
exist?

Yes

Replace 1KB/1RB board

Does
No
problem still END
exist?

Yes
Check connections at the
encoder connector

Check connections on the

1FG/1HG board

Check connections in the

separation harness

Check connections, jumpers, and

switches on the 1KB/1RB board

Does
No
problem still END
exist?

Yes

Figure 1-17 Error E1038 Flowchart (1)

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Check inside
machine harness
and separation
harness

Does No
problem still END
exist?

Yes

Replace 1FG/1HG board

Does No
problem still END
exist?

Yes

Service call

Figure 1-18 Error E1038 Flowchart (2)

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Error E1039

Replace encoder

Does No
problem still END
exist?

Yes

Replace 1KB/1RB board

Does
No
problem still END
exist?

Yes
Check connections at the
encoder connector

Check connections on the

1FG/1HG board

Check connections in the

separation harness

Check connections, jumpers, and

switches on the 1KB/1RB board

Does
No
problem still END
exist?

Yes

Figure 1-19 Error E1039 Flowchart (1)

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Does No
problem still END
exist?

Yes

Check inside
machine harness
and separation
harness

Does No
problem still END
exist?

Yes

Replace 1FG/1HG board

Does No
problem still END
exist?

Yes

Service call

Figure 1-20 Error E1039 Flowchart (2)

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2.0 COMPONENT REPLACEMENT

This chapter describes replacement procedure for parts inside the controller: printed boards,
power blocks, hardware including AVR, etc., and, units.

2.1 General Safety Precautions on Replacement··························································· 2-2

2.2 Replacement Procedure for Parts in Card Rack ······················································ 2-4
2.2.1 1KA/1RA Board (User I/F Board) ·········································································· 2-5
2.2.2 1KB/1RB Board (Arm Control Board) ··································································· 2-6
2.2.3 1KP Board (Power Sequence Board) ······································································ 2-7
2.2.4 AVR························································································································ 2-7
2.2.5 1NR Board (Brake Control Board) ········································································· 2-9
2.3 Replacement Procedure for Power Block Unit ····················································· 2-10
2.3.1 1KC Power Block Unit························································································· 2-10
2.3.2 1KD Power Block Unit (for D20/D30/D40 Controller) ········································ 2-11
2.3.3 1KD Power Block Unit (for D7x Controller)························································ 2-12
2.3.4 1KL Power Block Unit ························································································· 2-14
2.3.5 1KR Power Block Unit························································································· 2-14
2.4 Replacement Procedure for MC Unit Parts (for D2x/D3x/D4x Controller) ·········· 2-15
2.4.1 MC Unit················································································································ 2-15
2.4.2 1KQ Board (Power Circuit Board) ······································································· 2-16
2.5 Replacement Procedure for 1NQ Board (for D7x Controller)······························· 2-18
2.6 Replacement Procedure for Fan (for D2x/D3x/D4x Controller) ··························· 2-19
2.6.1 Fan for Card Rack································································································· 2-19
2.6.2 Fans on the back of Controller·············································································· 2-20
2.6.2.1 Upper Fan on back of Controller ·········································································· 2-20
2.6.2.2 Lower Fan on back of Controller·········································································· 2-21
2.6.3 MC Unit Fan········································································································· 2-22
2.7 Replacement Procedure for Fan (for D7x Controller)··········································· 2-23
2.7.1 Fan for Card Rack································································································· 2-23
2.7.2 Fan for Power Block Unit····················································································· 2-24
2.7.3 Heat Exchange Fan (for D71/74/77 Controller)···················································· 2-25
2.8 Replacement Procedure for Batteries···································································· 2-26
2.8.1 Battery on 1KA/1RA Board·················································································· 2-26
2.8.2 Battery on 1FG/1HG Board ·················································································· 2-27
2.9 Replacement Procedure for Fuses········································································· 2-28
2.9.1 Fuses on 1KP Board ····························································································· 2-28
2.9.2 Fuses on 1NQ Board (for D7x Controller)···························································· 2-29
2.10 Replacement Procedure for Filter ········································································· 2-30
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2.1 GENERAL SAFETY PRECAUTIONS ON REPLACEMENT

This section describes the precautions to be taken when replacing parts due to trouble, etc.

This information is presented here for use as general precautions. In addition to these,
adhere the safety measures required for each replacement procedure.

！ CAUTION

Parts replacement duties are limited to personnel who have

completed special training and education for the installed
robot or for an equivalent model.

1. Read and understand thoroughly all manuals, specifications and related documents
provided by Kawasaki before operation.

2. Before entering the safety fence (safeguarded space), make sure all necessary safety
measures are prepared and functioning well.

3. Before starting replacement work, shut OFF controller power up to the external power
switch. Display signs indicating clearly “POWER CUT-OFF IN PROGRESS” or
“REPLACEMENT IN PROGRESS”, and lock out/tag out the external power switch to
prevent personnel from accidentally turning ON the power.

4. Before starting replacement work, secure enough space around the robot so there is no
danger of interference with peripheral systems. Set the peripheral systems in a fixed
status so they will not make any sudden motion.

5. Disable automatic operation functions when entering the safety fence. If the robot
makes any abnormal motion, press EMERGENCY STOP switch immediately, and
evacuate on a planned path of retreat.

6. In addition to the EMERGENCY STOP switch held by the technician, install another
E-STOP switch for the supervisor outside the safety fence, in a place where the robot’s
entire motion range can be monitored. If the robot moves abnormally during
observation of the replacement, the E-STOP switch should be accessible and easy for the
supervisor to press. After an E-Stop, reset and restart robot operations from outside the
fence. Moreover, monitoring duties are limited to personnel who are trained and
qualified.
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7. Use only Kawasaki approved parts during replacement.

8. When replacing printed boards, do not fail to turn OFF controller power. To replace
power block, MC unit, or AVR, wait at least seven minutes after controller power OFF
before removing connectors. Then confirm that output voltage from the DC power
source and the P-N voltage are 0 V.

9. During operation, both technician and supervisor must always watch out for abnormal
motion and possible pinch points in and around the robot.

10. Semiconductors are often used in printed boards. Note that these semiconductors are
sensitive to static electricity, be sure to discharge any electrostatic on the body before
handling the printed boards.

11. Directly touching the parts containing semiconductors may cause electrostatic discharge
damage. When handling printed boards, do not touch the semiconductors directly but
hold the periphery of the printed boards. If parts must be touched directly, confirm that
electrostatic on the body has been discharged.

12. Putting printed boards directly onto the controller, etc. may cause electrostatic discharge
damage. Be sure to put them on an electrostatic-proof mat board or sheet, or enclose
printed boards in an electrostatic-proof bag.

13. Avoid removing printed boards at controller power ON, or turning the controller power
ON without any printed boards mounted.

14. Take a record of all data settings currently on controller, printed boards, etc. so the
system can be restored to its normal operating condition.

15. To prevent displacement of the robot, take a record of the robot’s pose before starting the
replacement procedure.

16. Be sure to connect connectors and cables correctly. When using connectors equipped
with locks, do not fail to lock after insertion. Do not touch connector pins.

17. Immediately after robot movement, the heat sink, the regenerative resistor, etc. may be
very hot. Do not touch the power block unit directly, there is a danger of burn.

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18. Printed boards and power blocks are designed differently for each robot model. Be sure
to replace the correct type.

19. When air or water is supplied, shut OFF the supply source and purge any remaining
pressure from the lines before starting any replacement procedure.

20. Use lighting of 1500 lux or more to avoid mistakes when reading data or replacing
defective parts.

21. After completion of replacement, confirm that the controller functions with no
abnormality.

2.2 REPLACEMENT PROCEDURE FOR PARTS IN CARD RACK

In the card rack of D2x/D3x/D4x controller, the 1KP board (power sequence board),
1KB/1RB board (arm control board), 1KA/1RA board (user I/F board), optional board, and
the AVR are housed from the left as shown below. For D7x controller, the 1NR board
(brake control board) is housed in the leftmost of the card rack.

This section describes the replacement procedure for the parts inside the card rack.

AVR

Optional board
1KA/1RA board
1KB/1RB board
1KP board

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2.2.1 1KA/1RA BOARD (USER I/F BOARD)

1. This is the user I/F board used for storing taught pose data, user program data, etc. in
memory. Before replacing the board, be sure to save all data to storage media such as
PC CARD, etc. For more details about data saving procedures, refer to the Operation
Manual, a separate volume.

2. After completion of data saving, turn OFF the controller power.

3. Press the button on the ejector of the 1KA/1RA board (red for 1KA board, yellow for
1RA board) to release the lock, and pull out the 1KA/1RA from the card rack by
extending the ejector up and down.

4. When replacing only the 1KA/1RA, disassemble daughter boards, 1KK, 1KN/1QN (for
1KA board only) and 1KJ/1QJ, by removing their connecting screws to the 1KA/1RA and
then the daughter boards.

5. Confirm that settings for SW1 and SW2 on the new 1KA/1RA are the same as before
board replacement. For the daughter boards disassembled in step 4, reassemble them to
the new 1KA/1RA.

6. Insert the new 1KA/1RA to the card rack and set it in the mother board.

7. Turn ON the SW2-8 on the 1KA/1RA.

8. Turn ON the controller power. When the initialization prompt is displayed on the teach
pendant display, select “999: Initialization of all data”.

9. When the confirmation query for initialization is displayed, select “1: YES”.

10. After completion of initialization, load all data saved before board replacement to the
1KA/1RA. For more details about data loading procedure, refer to the Operation
Manual, a separate volume.

11. Turn OFF the SW2-8 on the 1KA/1RA.

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Buttons of the ejector

Buttons of the ejector

CN8 SW2

Battery

Battery
SW1 SW1
CN203 CN8 CN11
CN11 CN6 CN6
Battery Battery
connector connector
CN7 CN7
1KN/1QN board

CN9

CN2 CN2
CN3 CN3
IP board 1KJ/1QJ IP board
1KJ/1QJ board
board

1KK board CN5 1KK board CN5

CN10 CN4 CN10 CN4 (P1)

Overview of the 1KA board Overview of the 1RA board

2.2.2 1KB/1RB BOARD (ARM CONTROL BOARD)

1. Turn OFF the controller power.

2. Press the button on the ejectorr of the 1KB/1RB board (red for 1KB board, yellow for 1RB
board) to release the lock, and pull out the 1KB/1RB from the card rack by extending the
ejector up and down.

3. Confirm that settings for SW1 to SW8 and SW10 on the new 1KB/1RB are the same as
before board replacement. Then, insert the new 1KB/1RB to the card rack and set it in the
mother board.
Buttons of the ejector Buttons of the ejector

S7 S2 S8
TP

CN10 CN9 CN8

S1

Add-in board on
Add-in board on
CN1 CN5 CN1
Servo control side
Servo control side CN5
1KV board 1KV board
JT7
1GM board 1KV board 1KV board 1GM board
JT8 JT7 JT8
Add-in board on Add-in board on
Arm control side CN3 CN2 CN4 CN3 CN2 CN4
Arm control side

S6 S5 S4 S3 S6 S5 S4 S3

S10
S10

Overview of the 1KB board 2-6 Overview of the 1RB board

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2.2.3 1KP BOARD (POWER SEQUENCE BOARD)

1. Turn OFF the controller power.

2. Loosen the screws on top and bottom of the 1KP board, and pull out the 1KP from the card
rack by holding the ejectors at both ends of the board. If wired to the front connector,
remove the connector first.

3. Confirm that settings for SW, J1 and J2 on the new 1KP are the same as before board
replacement. Then, insert the new 1KP to the card rack and set it in the mother board.

4. Fasten the screws on top and bottom of the 1KP.

Ejector Ejector

Screw
Screw

J1, J2

SW

Overview of the 1KP board

2.2.4 AVR

1. Turn OFF the controller power.

2. Remove the connectors connected to the AVR.

3. Loosen the two screws fixing the AVR, and remove the AVR.

4. Insert the new AVR to the card rack, and fasten it with the two screws.

5. Restore the connectors removed in step 2 and turn ON the controller power.

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6. Confirm the voltage at each check pin on the 1KA/1RA and 1KP as shown below.

1KA/1RA board
No. Color Standard Allowable range If the voltage is out of allowable range,
TP2 Yellow −12.0 V −11.95 V∼ −12.05 V Adjust the volume on the AVR.
TP3 Yellow +12.0 V +11.95 V∼ +12.05 V Adjust the volume on the AVR.
TP4 Yellow +5.0 V +4.95 V∼ +5.05 V Adjust the volume on the AVR.
TP6 Yellow +3.3 V +3.16 V∼ +3.44 V Replace the 1KA/1RA.

1KP board
No. Color Standard Allowable range If the voltage is out of allowable range,
TP1 White +24.0 V +23.9 V∼ +24.7 V Replace the AVR.

7. If there is no abnormality in the controller after checking voltage, paint lock each adjust
volume of the AVR.

Screw

Connector

Volume +5 V Adjust

Screw +12 V Adjust

−12 V Adjust

Volume
(enlarged view)
Overview of the AVR

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2.2.5 1NR BOARD (BRAKE CONTROL BOARD)

1. Turn OFF the controller power.

2. Loosen the screws on top and bottom of the 1NR board, and pull out the 1NR from the
card rack by holding the ejectors at both ends of the board. If wired to the front connector,
remove the connector first.

3. Confirm that settings for J1, J2 and J3 on the new 1NR are the same as before board
replacement. Then, insert the new 1NR to the card rack and set it in the mother board.

4. Fasten the screws on top and bottom of the 1NR.

Ejector Ejector

Screw Screw

J3

J2 J1

Overview of the 1NR board

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2.3 REPLACEMENT PROCEDURE FOR POWER BLOCK UNIT

This section describes the replacement procedure for the power block unit mounted in the
controller.

Four types of power block are available as described below.

1. 1KC: Power block for large robot (six axes)

2. 1KD: Power block for small robot (six axes)
3. 1KL: Optional power block for large motor (single axis)
4. 1KR: Optional power block for small motor (single axis)

Replacement procedures for the 1KC and 1KD are described in this section.

！ DANGER
High voltage is applied in the power block unit. Do
not touch any connector pin during replacement.

2.3.1 1KC POWER BLOCK UNIT

！ DANGER

Before starting replacement work, turn OFF the controller

power and wait at least seven minutes.

！ WARNING

Do not remove the screws or cover from the front of the

power block unit. This is a high voltage area and there is
a danger of electric shock.

！ CAUTION

Power block unit weighs approx. 20 kg. Be careful not to

incur back injury, etc. when removing the power block unit.

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1. Remove all connectors connected to the power block unit.

2. Loosen the four screws fixing the power block unit to the controller so that the power
block unit can be removed from the controller. (These screws are not removed from the
power block unit.)

3. To remove the power block unit, pull it out by sliding on the fulcrum. To be safe, hold the
handle on top with one hand.

4. Place the new unit on the fulcrum, and set it in by holding the handle on top with one hand.
Then, attach it to the controller by fastening the four screws correctly.

5. Restore the connectors removed in step 1.

Fixing screws (two in upper corners)

Fixing screws (two in lower corners)

Details for screws

: Screws on the front of power block unit

(Do not touch any of these screws.)

2.3.2 1KD POWER BLOCK UNIT (FOR D20/D30/D40 CONTROLLER)

The replacement procedure for the 1KD is same as that for the 1KC. However, the external
view of the power block unit is different between the 1KC and the 1KD.
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2.3.3 1KD POWER BLOCK UNIT (FOR D7X CONTROLLER)

！ DANGER

Before starting replacement work, turn OFF the controller

power and wait at least seven minutes.

1. Remove the controller cover.

2. Remove the connectors X506 and X507 connected to the power block unit.

3. Remove the screw fixing the earth wired from the power block unit.

4. Remove the four screws fixing the power block unit to the controller.

5. Pull out the power block unit by sliding backward on the fulcrum.

6. Remove the connectors X302 and X311.

7. Remove the connectors X211 and X212.

8. Remove the power block unit.

9. Attach the new unit to the controller in reverse order of removal.

Power block unit (1KD)

X212
X211

X506

X507

Earth

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X302

X311

Fixing screws (two in upper corners)

Fixing screws (two in lower corners)

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2.3.4 1KL POWER BLOCK UNIT

！ DANGER
Before starting replacement work, turn OFF the
controller power and wait at least seven minutes.

1. Remove all connectors connected to the power block unit.

2. Loosen the four screws fixing the power block unit to the controller (1 to 4 in figure
below) so that the power block unit can be removed from the controller. (These screws
are not removed from the power block unit.)

3. Remove the power block unit.

4. Attach the new unit to the controller by fastening the four screws removed in step 2
correctly.

5. Restore the connectors removed in step 1.

1 2

3 4

2.3.5 1KR POWER BLOCK UNIT

The replacement procedure for the 1KR is same as that for the 1KL.

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2.4 REPLACEMENT PROCEDURE FOR MC UNIT PARTS (FOR D2X/D3X/D4X

CONTROLLER)

This section describes the replacement procedure for the MC unit (power supply unit) and the
1KQ board (power circuit board) which flanks the MC unit.

2.4.1 MC UNIT
！ DANGER
Before starting replacement work, turn OFF the
controller power and wait at least seven minutes.

1. To facilitate the replacement process, remove all connectors and power block connectors
connected to the MC unit.

2. Loosen the four screws fixing the MC unit to the controller, then remove the MC unit from
the controller.* (See figure below.)

NOTE* Fully removing the screws may cause the MC unit to drop, or make the restoration
process unnecessarily difficult. Be sure to leave the screws on the controller side.

3. Attach the new MC unit to the controller, and fasten it with the four screws.**

NOTE** Be careful not to let the washers/screws fall under the MC unit.

4. Restore the connectors removed in step 1.

Fixing screws
(two in upper corners)

MC unit

Fixing screws
(two in lower corners)

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！ CAUTION

MC unit weighs approx. 6 kg. Be careful not to cut or

squeeze the tips of your fingers when replacing MC unit.

2.4.2 1KQ BOARD (POWER CIRCUIT BOARD)

！ DANGER
Before starting replacement work, turn OFF the
controller power and wait at least seven minutes.

1. Remove the MC unit. For details, refer to 4.4.1 MC Unit.

2. Remove the four screws fixing the 1KQ board assy to the MC unit (1 to 4 in figure below),
the one screw fixing the fan unit of the MC unit (5 in figure below), and the connector for
the fan. Then, pull out the 1KQ board assy.

1
2
3

1KQ board 4

MC unit
Connector

3. Remove the connector and the two wires of the 1KQ, then remove the 1KQ board assy
from the MC unit.

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4. Loosen the five nuts fixing the 1KQ to the plate (1 to 5 in figure below), and remove the
1KQ.

5. Attach the new 1KQ to the plate with the five nuts removed in step 4.

6. Restore the connector and two wires removed in step 3 to the assy assembled in step 5.

7. Refasten the screws and connect the connector removed in step 2.

8. Attach the MC unit to the controller. For details, refer to 4.4.1 MC Unit.

Connector to be
Plate 1KQ board 1 removed in step 3

5 4

Wires to be removed
in step 3

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2.5 REPLACEMENT PROCEDURE FOR 1NQ BOARD (FOR D7X

CONTROLLER)

This section describes the replacement procedure for the 1NQ board (power circuit board)

1. Turn OFF the controller power.

2. Remove the power block unit. (For the procedure, see 4.3.3 1KD Power Block Unit (for
D7x Controller).)

3. Remove the 1NR, 1KP, 1KB/1RB, and 1KA/1RA boards in the card rack.

4. Remove all connectors connected to the 1NQ board.

5. Remove the five screws fixing the 1NQ board.

6. Remove the 1NQ board from back side.

7. Attach the new 1NQ board by fastening the five screws.

8. Restore the connectors removed in step 4.

9. Restore the boards removed in step 3.

10. Restore the power block unit to the controller.

1NQ board

Screws for fixing

the 1NQ board

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2.6 REPLACEMENT PROCEDURE FOR FAN (FOR D2X/D3X/D4X

CONTROLLER)

Fans are installed for the card rack, the power block unit, and the MC unit. This section
describes the replacement procedure for these fans.

2.6.1 FAN FOR CARD RACK

1. Turn OFF the controller power.

2. Remove the connector connecting the fan to the card rack. Then, loosen and remove the
two screws fixing the fan unit.

3. Remove the power line and the earth wire connected to the fan. Loosen the four screws
fixing the fan, and then remove the fan.

4. Attach the new fan with the four screws, and restore the power line and earth wire removed
in step 3. Be sure to reattach the fan correctly; wind blows top to down.

5. Attach the fan unit to the top of the card rack, and fasten it with the two screws.

6. Restore the connector removed in step 2.

Screws for
fixing the fan

Connector

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2.6.2 FANS ON THE BACK OF CONTROLLER

This section describes the replacement procedures for the two fans mounted on the controller
back. The upper fan cannot be seen from outside.

2.6.2.1 UPPER FAN ON BACK OF CONTROLLER

1. Turn OFF the controller power.

2. Remove the six screws fixing the plate on the controller back (1 to 6 in figure below).

3. Pull out the plate, remove the connector connected to the controller, then remove the plate.

4. Remove the power line and the earth wire connected to the fan. Loosen and remove the
four screws fixing the fan, and then remove the fan.

5. Attach the new fan to the plate with the four screws, and restore the power line and earth
wire removed in step 4. Be sure to reattach the fan correctly; wind blows top to down.

6. Restore the connector removed in step 3, and reattach the plate with the six screws.

Fan (upper)

4
2

3 5

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2.6.2.2 LOWER FAN ON BACK OF CONTROLLER

1. Turn OFF the controller power.

2. Remove the six screws fixing the plate on the controller back.

3. Pull out the plate, remove the connector connected to the controller, and remove the plate.

4. Remove the power line and the earth wire connected to the fan. Loosen and remove the
four screws fixing the fan, and then remove the fan.

5. Attach the new fan to the plate with the four screws, and restore the power line and earth
wire removed in step 4. Be sure to reattach the fan correctly; wind blows from inside to
outside.

6. Restore the connector removed in step 3, and reattach the plate to the controller with the
six screws.

1
2
3
4 5
6 Fan (lower)

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2.6.3 MC UNIT FAN

1. Turn OFF the controller power.

2. Remove the two screws at the bottom of the MC unit (1 and 2 in figure below) and pull out
the plate. Remove the connecter connected to the 1KQ board and remove the fan unit.

3. Remove the four screws fixing the fan and remove the fan.

4. Attach the new fan to the plate with the four screws. Be sure to reattach the fan correctly;
wind blows top to down.

5. Restore the connector removed in step 2, and attach the plate to the MC unit with the two
screws.

1KQ board MC unit

Connector

1
2
Four screws for
fixing the fan

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2.7 REPLACEMENT PROCEDURE FOR FAN (FOR D7X CONTROLLER)

Fans are installed for the card rack, the power block unit, and the cover (only for D71/74/77
controller). This section describes the replacement procedure for these fans.

2.7.1 FAN FOR CARD RACK

1. Turn OFF the controller power.

2. Open the controller cover.

3. Remove the four screws fixing the fan.

4. Remove the power line and the earth wire connected to the fan, and then remove the fan.

5. Restore the power line and earth wire removed in step 4 to the new fan.

6. Fix the fan with the four screws. Be sure to reattach the fan correctly; wind blows top to
down.

Screws for fixing the fan

Screws for fixing the fan

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2.7.2 FAN FOR POWER BLOCK UNIT

1. Turn OFF the controller power.

2. Remove the four screws fixing the cover on the controller back, and then remove
ove the cover.

3. Remove the four screws fixing the fan.

4. Remove the power line and the earth wire connected to the fan, and then remove the fan.

5. Restore the power line and earth wire removed in step 4 to the new fan.

6. Fix the fan with the four screws. Be sure to reattach the fan correctly; wind blows from
outside to inside.

7. Restore the cover on the controller back with the four screws.

Fixing screws (two in upper corners)

Cover on the
controller back

Screws for
fixing the fan

Fixing screws (two in lower corners)

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2.7.3 HEAT EXCHANGE FAN (FOR D71/74/77 CONTROLLER)

Heat exchange fan is installed on the left side of the controller cover.

1. Turn OFF the controller power.

2. Remove the controller cover.

3. Remove the power harness from the bands which fix the harness.

4. Remove the four screws fixing the fan, and then remove the fan.

5. Attach the new fan with the four screws. Be sure to reattach the fan correctly.

6. Restore the power harness removed in step 3 with the bands.

7. Restore the controller cover.

Band Power harness Heat exchange fan

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2.8 REPLACEMENT PROCEDURE FOR BATTERIES

This section describes the replacement procedure for the battery provided to backup data.

2.8.1 BATTERY ON 1KA/1RA BOARD

As backup power supply for SRAM and RTC (Real Time Clock), the 1KA/1RA board is
equipped with a lithium battery and an emergency super capacitor for use during battery
replacement.

When on-board battery is removed, fully charged super capacitor can provide backup power
for only 15 minutes. Therefore, battery should be replaced immediately once the controller
power is cut OFF.

！ CAUTION
To prevent data erasion, be sure to save program data
as soon as it is completed.

1. Before replacing the battery, confirm that the new battery has +3.6V or more voltage.

2. Turn OFF the controller power.

3. Remove the battery connector of the 1KA/1RA and pull out the battery from the holder.
When it is hard to work on, pull out the 1KA/1RA. For more details about pulling out the
board, refer to 4.2.1 1KA/1RA Board (User I/F Board).

4. After installing the new battery to the holder, connect the battery connector. If the
1KA/1RA was pulled out, put it back to the original place.

CN SW2
Battery

SW1
CN11 CN6
Battery
connector
CN7

CN9
CN2
CN3

1KJ/1QJ IP board
CN5

CN10 CN4

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2.8.2 BATTERY ON 1FG/1HG BOARD

1. Record the encoder value for all axes before replacing a battery.

2. Before replacing the battery, confirm that the new battery has +3.6 V or more voltage.

3. Turn OFF the controller power.

4. For the 1HG board, pull out the connector box located on the base of the robot main body.
For the 1FG board, remove the plate that is installed with a battery.

5. Remove the battery connector (CN10 for 1FG, CN4 for 1HG), cut two bands fixing the
battery, and remove the battery.

6. Fix the new battery with two bands, and restore the connector removed in step 4.

7. For the 1HG, restore the connector box. For the 1FG, restore the plate that is installed
with a battery.

8. Reinstall the cover on the robot arm. Turn ON the controller power and check if the
encoder value has changed.

！ CAUTION
1. Battery life is about year and a half (assuming controller power is OFF
continuously), but longevity differs depending on ambient temperature, etc.
2. The encoder assembly contains a super capacitor that maintains memory
power for approximately 30 minutes. In order to maintain encoder data
when replacing the 1FG batteries or disconnecting the encoder from the
1FG board, the batteries must be replaced or the encoder reconnected
within the 30 minutes period. (Take note that if the super capacitor is not
fully charged, encoder data may not be maintained for the full 30 minutes.)

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2.9 REPLACEMENT PROCEDURE FOR FUSES

This section describes the replacement procedure for the fuses.

2.9.1 FUSES ON 1KP BOARD

Two types of fuses- Fuse1 and Fuse2- are mounted on the 1KP board.

1. Turn OFF the controller power.

2. Push the fuse on the front of the board and turn it 90 degrees to the left. Then pull it out
and remove the fuse from the board.

3. Push in the new fuse, and turn it 90 degrees to the right to install.

Fuse2 (Machine valves: 1 A) Fuse1 (E-Stop: 315 mA)

Overview of the 1KP board

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2.9.2 FUSES ON 1NQ BOARD (FOR D7X CONTROLLER)

1. Turn OFF the controller power.

2. Remove the controller cover.

3. Turn the fuse 90 degrees to the left. Then pull it out and remove the fuse from the board.

4. Push in the new fuse, and turn it 90 degrees to the right to install.

5. Restore the controller cover.

1NQ board F1 (1 A) F2 (1 A)

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2.10 REPLACEMENT PROCEDURE FOR FILTER

Wash filters periodically to keep them clean. For replacement, follow the replacement
procedure described below.

Filters are located on the side and back of the controller. Take the same procedure to replace
these filters.

1. In the center, bottom of the holder for the filter there is a notch. Insert something tube
shaped into the notch, and push up the filter. Be careful not to damage the controller face.

2. Pull up the raised filter.

3. Insert the replacement filter into the holder.

Filter (on back)

Notch
Filter (on side)

Notch

Side and back of the controller

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