Chapter 8

Troubleshooting
8-1 Error Processing ................................................ 8-1
Preliminary Checks When a Problem Occurs .......................8-1
Precautions When Troubleshooting......................................8-2
Replacing the Servomotor and Servo Drive..........................8-2
8-2 Alarm Table........................................................ 8-3
8-3 Troubleshooting ................................................. 8-7
Error Diagnosis Using the Displayed Alarm Codes ..............8-7
Error Diagnosis Using the Displayed Warning Codes ..........8-14
Error Diagnosis Using the Operating Status .........................8-15
8-4 Overload Characteristics
(Electronic Thermal Function) ............................ 8-20
Overload Characteristics Graphs ..........................................8-20
8-5 Periodic Maintenance......................................... 8-21
Servomotor Service Life........................................................8-21
Servo Drive Service Life .......................................................8-22
Replacing the Absolute Encoder Battery ..............................8-23
 8-1 Error Processing

8-1 Error Processing

Preliminary Checks When a Problem Occurs

This section explains the preliminary checks and analytical tools required to determine the cause of
a problem.

„ Checking the Power Supply Voltage

ΠCheck the voltage at the power supply input terminals.
Main Circuit Power Supply Input Terminals (L1, L3)
R88D-GN@L-ML2 (50 W to 400 W): Single-phase, 100 to 115 VAC (85 to 127 V), 50/60 Hz
R88D-GN@H-ML2 (100 W to 1.5 kW): Single-phase, 200 to 240 VAC (170 to 264 V), 50/60 Hz
Main Circuit Power Supply Input Terminals (L1, L2, L3)
R88D-GN@H-ML2 (750 W to 7.5 kW): Three-phase, 200 to 240 VAC (170 to 264 V), 50/60 Hz
Control Circuit Power Supply Input Terminals (L1C, L2C)
R88D-GN@L-ML2: Single-phase, 100 to 115 VAC (85 to 127 V), 50/60 Hz
R88D-GN@H-ML2: Single-phase, 200 to 240 VAC (170 to 264 V), 50/60 Hz
If the voltage is outside of this range, there is a risk of operation failure, so be sure that the power
supply is correct.

ΠCheck the voltage of the sequence input power supply. (+24 VIN Terminal (CN1 pin 1))
8 Within the range of 11 to 25 VDC
If the voltage is outside of this range, there is a risk of operation failure, so be sure that the power
supply is correct.
Troubleshooting

„ Checking Whether an Alarm Has Occurred

ΠEvaluate the problem using the 7-segment LED display on the front panel.
You can also evaluate the problem by using the R88A-PR02G Parameter Unit.
ΠCX-Drive can also be used for the display. The operation status can also be monitored.
Check the load status, including data trace.
ΠWhen an alarm has occurred:
Check the alarm code that is displayed (@@) and evaluate the problem based on the alarm that is
indicated.
ΠWhen an alarm has not occurred:
Make an analysis according to the problem.

8-1
 8-1 Error Processing

Precautions When Troubleshooting

When checking and verifying I/O after a problem has occurred, the Servo Drive may suddenly start
to operate or suddenly stop, so always take the following precautions.
You should assume that anything not described in this manual is not possible with this product.

„ Precautions
ΠDisconnect the cable before checking for wire breakage. Even if you test conduction with the cable
connected, test results may not be accurate due to conduction via bypassing circuit.
ΠIf the encoder signal is lost, the Servomotor may run away, or an error may occur. Be sure to
disconnect the Servomotor from the mechanical system before checking the encoder signal.
ΠWhen performing tests, first check that there are no persons in the vicinity of the equipment, and
that the equipment will not be damaged even if the Servomotor runs away. Before performing the
tests, verify that you can immediately stop the machine using an emergency stop even if the
Servomotor runs away.

Replacing the Servomotor and Servo Drive

Use the following procedure to replace the Servomotor or Servo Drive.

„ Replacing the Servomotor

1. Replace the Servomotor.
8
2. Perform origin position alignment (for position control).
Œ When the Servomotor is replaced, the Servomotor’s origin position (phase Z) may deviate, so
origin alignment must be performed.

Troubleshooting
Œ Refer to the Position Controller’s manual for details on performing origin alignment.
3. Set up the absolute encoder.
ΠIf a Servomotor with an absolute encoder is used, the absolute value data in the absolute encoder
will be cleared when the Servomotor is replaced, so setup is again required. The rotation data will
be different from before the Servomotor was replaced, so reset the initial Motion Control Unit
parameters.
ΠFor details, refer to Absolute Encoder Setup on page 6-6.

„ Replacing the Servo Drive

1. Copy the parameters.
Use the Parameter Unit or CX-Drive to write down all the parameter settings or save them.
2. Replace the Servo Drive.
3. Set the parameters.
Use the Parameter Unit or CX-Drive to set all the parameters.
4. Set up the absolute encoder.
ΠIf a Servomotor with an absolute encoder is used, the absolute value data in the absolute encoder
will be cleared when the Servo Drive is replaced, so setup is again required. The rotation data will
be different from before the Servo Drive was replaced, so reset the initial Motion Control Unit
parameters.
ΠFor details, refer to Absolute Encoder Setup on page 6-6.

8-2
 8-2 Alarm Table

8-2 Alarm Table

„ Protective Functions
The Servo Drive has built-in protective functions. When a protective function is activated, the
Servo Drive turns OFF the alarm output signal (ALM) and switches to the Servo OFF status.
The alarm code will be displayed on the front panel.

Alarm type Description

Protective function that allows the alarm to be reset, and leaves record in the
---
alarm history.
Protective function that does not allow the alarm to be reset, and requires the
PR control power supply to be turned OFF and turned ON again after resolving the
problem.
X Protective function that does not leave record in the alarm history.

ΠAlarms can be reset via the network, CX-Drive or the Parameter Unit.
Precautions
for Correct Use ΠOverload (alarm code 16) cannot be reset for approximately 10 s after its
occurrence.
ΠIf "HH", "hh", or "yy" is displayed on the Alarm Number display, the built-in
MPU is malfunctioning. Turn OFF the power supply.

8
„ Warning Function
The Servo Drive issues a warning before a protective function is activated, allowing you to check
overload and other status in advance. A warning is also issued for a network error, allowing you
Troubleshooting

to check the network status.

8-3
 8-2 Alarm Table

„ Alarms
Alarm Alarm
Error Detection Function Detection Details and Cause of Error
Display Type
The DC voltage of the main circuit has
11 X Control power supply undervoltage
dropped below the specified value.
The DC voltage of the main circuit is
12 --- Overvoltage
abnormally high.
13 X Main power supply undervoltage The DC voltage of the main circuit is low.
Overcurrent flowed to the IGBT. Servomotor
14 PR Overcurrent
power line ground fault or short circuit.
The temperature of the Servo Drive radiator
15 PR Servo Drive overheat
exceeded the specified value.
Operation was performed with torque
16 --- Overload significantly exceeding the rating for several
seconds to several tens of seconds.
The regenerative energy exceeded the
18 PR Regeneration overload processing capacity of the regeneration
resistor.
Communications between the encoder and
the Servo Drive failed for a specified number
21 PR Encoder communications error
of times, thereby activating the error detection
function.
Communications error occurred for the data
23 PR Encoder communications data error
from the encoder.
The number of position deviation pulses
24 --- Deviation counter overflow exceeded the Deviation Counter Overflow
Level (Pn209). 8
The rotation speed of the Servomotor
26 --- Overspeed exceeded the setting of the Overspeed
Detection Level Setting (Pn073).

Troubleshooting
27 PR Command error The operation command resulted in an error.
The value of the internal deviation counter
29 --- Internal deviation counter overflow (internal control unit) exceeded 227
(134217728).
The Servomotor exceeded the allowable
operating range set in the Overrun Limit
34 --- Overrun limit error
Setting (Pn026) with respect to the position
command input.
Data in the parameter save area was
PR
36 Parameter error corrupted when the data was read from the
X
EEPROM at power-ON.
The EEPROM write verification data was
PR
37 Parameter corruption corrupted when the data was read from the
X
EEPROM at power-ON.
Forward and Reverse Drive Prohibit Inputs
38 X Drive prohibit input error
(NOT and POT) both became OPEN.
Absolute encoder The voltage supplied to the absolute encoder
40 PR
system down error
ABS dropped below the specified value.
Absolute encoder counter The multi-turn counter of the absolute
41 PR
overflow error
ABS encoder exceeded the specified value.
The Servomotor rotation speed exceeded the
Absolute encoder
42 PR ABS specified value when power to the absolute
overspeed error
encoder is supplied by the battery only.
Absolute encoder
44 PR A one-turn counter error was detected.
one-turn counter error
An absolute encoder multi-turn counter or in-
Absolute encoder
45 PR cremental encoder phase AB signal error was
multi-turn counter error
detected.
Absolute encoder The rotation of the absolute encoder is higher
47 --- ABS than the specified value.
status error

8-4
 8-2 Alarm Table

Alarm Alarm
Error Detection Function Detection Details and Cause of Error
Display Type
A phase-Z pulse was not detected
48 R Encoder phase Z error
regularly.
49 R Encoder PS signal error A logic error was detected in the PS signal.
The rotary switch for setting the node address
82 R Node address setting error
of the Servo Drive was set out of range.
Data received during each MECHATROLINK-
II communications cycle repeatedly failed,
83 --- Communications error
exceeding the number of times set in the
Communications Control (Pn005).
While actuating MECHATROLINK-II
communications, synchronization frames
84 --- Transmission cycle error
(SYNC) were not received according to the
transmission cycle.
Synchronization data exchanged
between the master and slave nodes
86 --- Watchdog data error during each MECHATROLINK-II
communications cycle resulted in an
error.
87 X Emergency stop input error The emergency stop input became OPEN.
The transmission cycle setting error when
90 --- Transmission cycle setting error the MECHATROLINK-II
CONNECT command is received.
A SYNC-related command was issued while
91 --- SYNC command error MECHATROLINK-II was in asynchronous
8 communications mode.
Parameter setting exceeded the allowable
93 R Parameter setting error
range.
R The combination of the Servomotor and
95 Servomotor non-conformity
X Servo Drive is not appropriate.
Troubleshooting

The control circuit malfunctioned due to

excessive noise.
Others R Other errors
An error occurred within the Servo Drive due
to the activation of its self-diagnosis function.

Note The alarm display is in decimal.

For example, if a SYNC command error occurs, "91" will flash on the front panel of the G-
series Servo Drive. The warning code read from the host Position Control Unit (CJ1W-
NC@71 or CS1W-NC@71) would be 405B.

8-5
 8-2 Alarm Table

„ Warnings

Warning Warning Detection

Priority Warning Details
Code Function
· Command argument setting is out of the range.
94h Data setting warning · Parameter write failure.
High · Command settings are wrong, and others.
· Command output conditions are not satisfied.
95h Command warning · Received unsupported command.
· Subcommand output conditions are not satisfied.
ML-II
One or more MECHATROLINK-II communications error
96h communications
occurred.
warning
85% of the overload alarm trigger level has been
90h Overload warning
exceeded.
Regeneration 85% of the regeneration overload alarm trigger level has
91h
overload warning been exceeded.
Voltage of absolute encoder battery has dropped below
92h Battery warning
3.2 V.
Low
93h Fan lock warning The built-in cooling fan stopped, or rotated abnormally.

Note 1. All warnings are retained. After resolving the problem, clear the alarms and the warnings.
Note 2. When multiple warnings occur, the warning codes are displayed on the front panel in the
8
order of their priority (shown above).
Note 3. The alarm display is in hexadecimal.
For example, if a regenerative load warning occurs, "91" and "00" will alternately flash on

Troubleshooting
the front panel of the G-series Servo Drive. The warning code read from the host Position
Control Unit (CJ1W-NC@71 or CS1W-NC@71) would be 4091.

8-6
 8-3 Troubleshooting

8-3 Troubleshooting
If an error occurs in the machine, determine the error conditions from the alarm indicator and
operating status, identify the cause of the error, and take appropriate countermeasures.

Error Diagnosis Using the Displayed Alarm Codes

Alarm
Alarm Name Cause Countermeasure
code
The voltage between P and N in the Measure the line voltage between
control voltage converter has dropped control power supply L1C and L2C.
below the specified value. 1 Resolve the cause of the power
1 The power supply voltage is low. A supply voltage drop and/or
Control power supply momentary power failure occurred. momentary power failure.
11
undervoltage 2 The power supply capacity is 2 Increase the power supply
insufficient. The inrush current at capacity.
power-ON caused the power 3 Replace the Servo Drive.
supply voltage to drop.
3 The Servo Drive has failed.
The voltage between P and N in the Measure and check the line voltages
main circuit has exceeded the speci- between L1, L2, and L3 of the main
fied value. The power supply voltage is power supply. Input a correct voltage.
too high. Phase advance capacitor Remove the phase advance capacitor.
8 and/or UPS (uninterruptible power 1 Measure the resistance for the
supply) is causing a jump in voltage. external regeneration resistor
1 Regenerative energy cannot be between terminals B1 and B2 of the
12 Overvoltage
absorbed due to a disconnection of Servo Drive, and check that the
Troubleshooting

the regeneration resistor. reading is normal. Replace it if

2 Regenerative energy cannot be disconnected.
absorbed due to the use of an 2 Provide the necessary
inappropriate external regeneration regeneration resistance and
resistor. wattage.
3 The Servo Drive has failed. 3 Replace the Servo Drive.
With the Undervoltage Alarm Selection Measure and check the line voltages
(Pn065) set to 1, the main power between L1, L2, and L3 of the main
supply between L1 and L3 was power supply.
interrupted for longer than the time set 1 Resolve the cause of the power
by Momentary Hold Time (Pn06D). supply voltage drop and/or
Alternatively, the voltage between P momentary power failure.
and N in the main circuit dropped 2 Check the setting for the
below the specified value while the Momentary Hold Time (Pn06D).
Servo Drive was ON. 3 Increase the power supply
Main power supply 1 The power supply voltage is low. capacity. Refer to the Servo Drive
13
undervoltage 2 A momentary power failure specifications for the power supply
occurred. capacity.
3 The power supply capacity is insuf- 4 Correctly connect the phases (L1,
ficient - The inrush current at L2, and L3) of the power supply.
power-ON caused the power Connect single-phase 100 V and
supply voltage to drop. single-phase 200 V to L1 and L3.
4 Missing phase - A single-phase 5 Replace the Servo Drive.
power supply was used for a three-
phase Servo Drive.
5 The Servo Drive has failed.

8-7
 8-3 Troubleshooting

Alarm
Alarm Name Cause Countermeasure
code
The current on the inverter circuit 1 If the alarm is triggered
exceeded the specified value. immediately when the Servo Drive
1 The Servo Drive has failed. is turned ON with the Servomotor
(Failure of circuit, IGBT parts, etc.) lines disconnected, replace the
2 Short circuit on Servomotor lines U, Servo Drive.
V, and W. 2 Check for short circuit in the
3 Ground fault on the Servomotor Servomotor lines U, V, and W.
lines. Connect the Servomotor lines
4 Servomotor burnout. correctly.
5 Contact failure on the Servomotor 3 Check the insulation resistance
lines. between Servomotor lines U, V, W
6 The dynamic brake relay has been and the ground line. If there is
consequently welded. insulation failure, replace the
7 The Servomotor is not compatible Servomotor.
14 Overcurrent with the Servo Drive. 4 Measure the interphase
8 The operation command input is resistances of the Servomotor. If
received simultaneously with or they are unbalanced, replace the
before Servo-ON. Servomotor.
5 Check the connector pins for
connections U, V, and W of the
Servomotor. If they are loose or
have come off, securely fix them.
6 Replace the Servo Drive.
7 Check and match the capacity of
the Servomotor and the Servo
Drive.
8 After the Servo ON, wait for at least
100 ms before inputting an 8
operation command.

The temperature of the Servo Drive 1 Reduce the Servo Drive's ambient
radiator or power elements exceeded temperature, and improve the

Troubleshooting
the specified value. cooling conditions.
1 The Servo Drive's ambient 2 Increase the capacity of the Servo-
15 Servo Drive overheat
temperature has exceeded the motor. Reduce the effective load
specified value. Radiation ratio, for example with a longer
performance has dropped. acceleration / deceleration time.
2 There is excessive load.
The effective values of the torque Check that the torque (current) wave-
commands have exceeded the over- form is not oscillating, and that it is not
load level set by the Overload Detec- fluctuating significantly in the vertical
tion Level Setting (Pn072). Operation direction. Check the overload warning
is performed with reverse time charac- display and the load ratio.
teristics. 1 Increase the capacity of the Servo
1 The load is excessive, and the Drive and Servomotor, or reduce
effective torque has exceeded the the load. Or increase the
set level and operation has been acceleration / deceleration time to
performed for a long time. reduce the effective torque.
2 Oscillation, hunching, and vibration 2 Readjust the gain to stop oscillation
16 Overload
are occurring due to improper gain and hunching.
adjustment. 3 Connect the Servomotor lines as
3 Servomotor phases are incorrectly specified in the wiring diagram.
wired and/or are disconnected. Replace the cables.
4 The mechanical load is increasing. 4 Check that the mechanics operate
There is a problem with the smoothly.
mechanics. 5 Measure the voltage at the brake
5 The holding brake is ON. terminal. Turn OFF the brake.
6 The Servomotor lines are Note You cannot reset the warning
incorrectly wired between multiple for at least 10 seconds after it
axes. occurred.

8-8
 8-3 Troubleshooting

Alarm
Alarm Name Cause Countermeasure
code
The regenerative energy exceeded the Check the regeneration resistance
capacity of the regeneration resistor. load ratio. Continuous regenerative
1 The converter voltage was braking is not acceptable.
increased by regenerative energy 1 Check the operation pattern (speed
during deceleration due to a large monitor). Check the regeneration
load inertia. The voltage was resistance load ratio and the over-
further increased due to insufficient regeneration warning display.
energy absorption of the Increase the capacity of the
regeneration resistance. Servomotor and the Servo Drive to
2 Because the Servomotor’s rotation slow down the deceleration time.
speed is too high, regenerative Use an External Regeneration
Regeneration
18 energy cannot be fully absorbed Resistor.
overload
within the specified deceleration 2 Check the operation pattern (speed
time. monitor). Check the regeneration
3 The operating limit of the External resistance load ratio and the over-
Regeneration Resistor is limited to regeneration warning display.
10%. Increase the capacity of the
Servomotor and the Servo Drive to
slow down the deceleration time.
Lower the Servomotor rotation
speed. Use an External
Regeneration Resistor.
3 Set Pn06C to 2.
Communications between the encoder Check that the encoder line is properly
and the Servo Drive failed for a connected.
Encoder specified number of times, thereby Check that there is no damage to the
21
8 communications error activating the error detection function. encoder due to incorrect connections.
(No response to request from the Replace the Servomotor and check
Servo Drive.) again.
Communications error occurred for the ΠCheck that the encoder power supply
Troubleshooting

data from the encoder. Mainly a data voltage is within the range of 4.75 to
error due to noise. The encoder line is 5.25 VDC. (If the encoder line is
connected, but the communications long.)
data is erroneous. ΠIf the Servomotor line and the
Encoder encoder line are bound together,
23 communications data separate them.
error ΠCheck that the shield is connected to
FG (frame ground), and that FG is
grounded.
ΠAttach a ferrite core to the encoder
cable. Attach a radio noise filter to the
power cable.
The number of position deviation 1 Use the speed monitor and torque
pulses exceeded the Deviation monitor to check that the
Counter Overflow Level (Pn209). Servomotor is operating as
1 The Servomotor operation is not commanded. Check that torque is
following the commands. not saturated. Check that the No. 1
2 The Deviation Counter Overflow Torque Limit (Pn05E) and the No. 2
Deviation counter Level (Pn209) is set too low. Torque Limit (Pn05F) are not too
24
overflow Calculate the deviation counter small.
value based on the command Check by readjusting the gain,
speed and the position loop gain. increasing the acceleration /
deceleration times, and lowering
the speed with the reduced load.
2 Increase the setting for Pn209.

8-9
 8-3 Troubleshooting

Alarm
Alarm Name Cause Countermeasure
code
The rotation speed of the Servomotor ΠCheck that excessive speed
exceeded the setting of the Overspeed commands have not been issued.
Detection Level Setting (Pn073). ΠIf overshoot is occurring due to
26 Overspeed
improper gain adjustment, adjust the
gain for the position loop and the
speed loop.
The operation command resulted in an ΠCheck that the operation commands
error. are correct.
1 Incorrect value in position 1 Review the operation commands
command. and settings.
· The amount of change in the Check the settings. For example,
position command (value calculat- check that the amount of change
ed with the electronic gear ratio) for the position command is not too
exceeded the specified value. large (i.e. interpolation function),
· The travel distance required for the backlash compensation
acceleration / deceleration, amount is not too large, the
calculated when starting backlash compensation time
positioning, exceeded the constant is not too small, the
specified value. electronic gear ratio is not too large,
2 A MECHATROLINK-II link was and the acceleration/deceleration
27 Command error
established with the host while is not too small.
executing a standalone operation 2 Do not actuate the network while
(normal mode autotuning, and jog executing normal mode autotuning
operation). and jog operation.
Note If the alarms are cleared 3 Alarm code 27 is issued when
immediately after actuating clearing the multi-turn data on the
communications, this alarm absolute encoder via RS-232 8
may be cleared immediately communications. This is for safety
after it has been issued, and purposes, not an error. When
cannot be read. executing the multi-turn clear
3 Multi-turn data on the absolute command via the network, an

Troubleshooting
encoder was cleared via RS-232 alarm will not be issued, but be sure
communications after actuating the to reset the control power supply.
MECHATROLINK-II link.
The value of the internal deviation Check that the speed monitor and
counter (internal control unit) exceeded torque monitor values are indicated as
227 (134217728). commanded by the Servo Drive. Check
that torque is not saturated. Check that
the No. 1 Torque Limit (Pn05E) and the
Internal deviation
29 No. 2 Torque Limit (Pn05F) are not too
counter overflow
small.
Check by readjusting the gain,
increasing the acceleration / decelera-
tion times, and lowering the speed with
the reduced load.
The Servomotor exceeded the 1 Check the position loop gain,
allowable operating range set by the speed loop gain, integration time
Overrun Limit Setting (Pn026) with constant, and inertia ratio.
34 Overrun limit error respect to the position command input. 2 Increase the setting for Pn026.
1 The gain is not appropriate for the Set Pn026 to 0 to disable the
load. protective function.
2 The setting for Pn026 is too small.
Data in the parameter save area was If the warning continues to occur even
corrupted when the data was read from after retransferring all parameters, the
36 Parameter error
the EEPROM at power-ON. Servo Drive may have failed.
Replace the Servo Drive.

8-10
 8-3 Troubleshooting

Alarm
Alarm Name Cause Countermeasure
code
The EEPROM write verification data If the warning continues to occur even
was corrupted when the data was read after retransferring all parameters, the
37 Parameter corruption
from the EEPROM at power-ON. Servo Drive may have failed.
Replace the Servo Drive.
1 The Drive Prohibit Input Selection Check the sensors, power supply, and
(Pn004) is set to 0, and both wiring for the Forward and Reverse
Forward and Reverse Drive Drive Prohibit Inputs.
Prohibit Inputs (POT and NOT) Also check that the response of the
became OPEN. power supply (12 to 24 VDC) is not too
2 The Drive Prohibit Input Selection slow.
(Pn004) is set to 2, and either Check that there is no command input
Forward or Reverse Drive Prohibit in the direction of the Drive Prohibit In-
Input (POT or NOT) became put.
OPEN.
3 With the Drive Prohibit Input
Drive prohibit input Selection (Pn004) set to 0,
38 MECHATROLINK-II
error
communications interrupted, and
either Forward or Reverse Drive
Prohibit Input (POT or NOT) turned
ON, an operation command (jog
operation or normal mode
autotuning) was received via
RS232. Or, either POT or NOT
turned ON while operating on an
operation command received via
8 RS232.

The power supply and battery voltage Connect the power supply for the
Absolute encoder to the encoder dropped, and the battery, and clear the absolute encod-
Troubleshooting

system down error capacitor voltage dropped below the er. Refer to Absolute Encoder Setup on
40
specified value. (3.0 V or less) page 6-6.
ABS Initial setup of the absolute encoder
must be performed to clear the alarm.
The multi-turn counter of the encoder Check the setting for the Operation
exceeded the specified value. Switch When Using Absolute Encoder
Absolute encoder (Pn00B).
41 counter overflow error Set the travel distance from the me-
ABS chanical origin within 32767 rotations.
Initial setup of the absolute encoder
must be performed to clear the alarm.
The Servomotor rotation speed ex- Check the power supply voltage on the
Absolute encoder ceeded the specified value when encoder side (5 V ± 5%).
overspeed error power to the absolute encoder is Check the connection of the CN2
42
supplied by the battery only during a connector.
ABS power outage. Initial setup of the absolute encoder
must be performed to clear the alarm.
An error was detected in the one-turn Replace the Servomotor.
counter for the encoder. Check for malfunction due to noise.
Absolute encoder
44 Also take EMC measures.
one-turn counter error
Initial setup of the absolute encoder
must be performed to clear the alarm.
An absolute encoder multi-turn counter Replace the Servomotor.
Absolute encoder or incremental encoder phase AB sig- Check for malfunction due to noise.
45 multi-turn counter nal error was detected. Also take EMC measures.
error Initial setup of the absolute encoder
must be performed to clear the alarm.

8-11
 8-3 Troubleshooting

Alarm
Alarm Name Cause Countermeasure
code
Absolute encoder The encoder’s detection values were Do not rotate the Servomotor when the
47 status error higher than the specified value at power is turned ON.
power-ON.
ABS
A phase-Z pulse of the 2500 p/r 5-line Replace the Servomotor.
serial encoder was not detected Check for malfunction due to noise.
48 Encoder phase Z error
regularly. Also take EMC measures.
The encoder has failed.
Logic error was detected in the PS Replace the Servomotor.
Encoder PS signal signal (magnetic pole) of the 2500 p/r
49
error 5-line serial encoder.
The encoder has failed.
The rotary switch for setting the node Check the value of the rotary switch for
address of the Servo Drive was set out setting the node address.
Node address setting of range. (Value is read at power-ON) Set the rotary switch correctly (set to 1
82
error to 31), and then turn OFF the control
power supply for the Servo Drive and
turn it ON again.
Data received during each Check that commands are being sent
MECHATROLINK-II communications from the master node to the slave
cycle repeatedly failed, exceeding the node.
number of times set by the Communi- Check the MECHATROLINK-II
cations Control (Pn005). communications cable for disconnec-
tion or wiring problem.
Check the connection of the terminator
(termination resistor). 8
83 Communications error
Check the MECHATROLINK-II
communications cable for excessive
noise, and that the cable is laid proper-
ly. Also check the FG wiring for the Ser-

Troubleshooting
vo Drive.
Increase the consecutive communica-
tions error detection count in the Com-
munications Control (Pn005).
While actuating MECHATROLINK-II ΠCheck the transmission cycle of the
communications, synchronization synchronization frames sent from the
frames (SYNC) were master node, and ensure that it does
not received according to the transmis- not fluctuate and is as specified.
sion cycle. ΠCheck the communications cable for
ΠThe synchronization frames disconnection or wiring problem.
Transmission cycle themselves were faulty. ΠCheck for excessive noise on the
84
error ΠThe transmission cycle of the communications cable.
synchronization frames was not as ΠCheck the connection of the
specified. (Includes dropped frames). terminator (termination resistor).
ΠCheck the laying of the
communications cable and the FG
wiring.
Synchronization data exchanged ΠCheck the update process for the
between the master and slave nodes watchdog data (MN) on the master
86 Watchdog data error
during each MECHATROLINK-II com- node.
munications cycle resulted in an error.

8-12
 8-3 Troubleshooting

Alarm
Alarm Name Cause Countermeasure
code
ΠThe emergency stop input became ΠCheck the power supply and wiring
OPEN. connected to the emergency stop
input. Check that the emergency stop
input is ON.
Emergency stop input
87 ΠCheck that the response of the
error
control signal power supply (12 to 24
VDC) at power-ON is not too slow in
comparison to the startup of the
Servo Drive.
ΠThe transmission cycle setting for ΠCheck the transmission cycle
Transmission cycle receiving the MECHATROLINK-II settings, and resend the CONNECT
90
setting error CONNECT command is incorrect. command.

ΠA SYNC-related command was ΠCheck the command sent from the

issued while MECHATROLINK-II was master node.
91 SYNC command error in asynchronous communications
mode.
ΠThe electronic gear ratio parameter is ΠCheck the parameter setting.
Parameter setting set outside the allowable setting
93 range. (Less than 1/100 or greater
error
than 100/1)

Servomotor ΠThe combination of the Servomotor ΠUse the Servomotor and Servo Drive
95 and Servo Drive is not appropriate. in the correct combination.
non-conformity
The control circuit malfunctioned due Turn OFF the power supply, and then
to excessive noise. turn it back ON.
8 An error occurred within the Servo If the error continues to occur, there
Others Other errors
Drive due to the activation of its may be a failure.
self-diagnosis function. Stop the operation, and replace the
Servomotor and Servo Drive.
Troubleshooting

8-13
 8-3 Troubleshooting

Error Diagnosis Using the Displayed Warning Codes

Warning
Error Cause Countermeasure
Code
ΠCommand argument setting is out of ΠCheck the setting range.
the range. ΠCheck the control power supply
94h Data setting warning ΠParameter write failure. voltage.
ΠCommand settings are wrong, and ΠCheck the command settings.
others.
ΠCommand output conditions are not ΠSend the command after the
satisfied. command output conditions are
ΠReceived unsupported command. satisfied.
ΠSubcommand output conditions are ΠDo not send unsupported
95h Command warning not satisfied. commands.
ΠOperation command in the drive ΠFollow the subcommand output
prohibited direction was issued after conditions and send.
being stopped by a POT/NOT input. ΠCheck the status of POT/NOT input
and operation command.
ΠOne or more MECHATROLINK-II ΠRefer to the countermeasures for
ML-II communications communications error occurred. Communications error on page 8-12
96h
warning (alarm code 83).
Π85% of the overload alarm trigger
90h Overload warning level has been exceeded. Refer to Overload on page 8-8.

Π85% of the regeneration overload

8
Regeneration alarm trigger level has been Refer to Regeneration overload on
91h
overload exceeded. page 8-9.

ΠVoltage of absolute encoder battery Replace the absolute encoder battery

Troubleshooting
92h Battery warning has dropped below 3.2 V. while the control power supply is being
input.
ΠThe built-in cooling fan stopped, or If the warning continues to occur,
rotated abnormally. the fan may have failed.
ΠModels with a built-in fan If so, the internal temperature of the
93h Fan lock warning
R88D- GN10H-ML2/ GN20H-ML2/ Servo Drive will rise, causing a failure.
GN30H-ML2/-GN40H-ML2/-GN50H- Replace the fan.
ML2/-GN75H-ML2

8-14
 8-3 Troubleshooting

Error Diagnosis Using the Operating Status

Symptom Probable cause Items to check Countermeasure

Check that the control power supply
Ensure that power is
voltage is within the specified
7-segment supplied properly.
No control power supply. range.
LED is not lit.
Check that the power supply input
Wire correctly.
is wired correctly.
Check that the network cable Check that the host
MECHATROLINK-II is connected correctly. controller is running.
LED (COM)
communications not
is not lit. Check that the terminator is Check the connector and
actuated.
connected. connection.
Asynchronous communica-
LED (COM)
tions on the Can be controlled from the host
is flashing in Normal status.
MECHATROLINK-II controller (Normal status).
green.
communications actuated.
Synchronous communica-
LED (COM) tions on the
Controllable status (Normal status). Normal status.
is lit in green. MECHATROLINK-II
communications actuated.
Recoverable alarm related ΠReset and actuate the network
LED (COM) again from the host controller.
to MECHATROLINK-II Check the wiring and noise.
8 is flashing in red.
communications. ΠCheck the network wiring.

Check that there is no overlap of

Irrecoverable alarm related
LED (COM) node address on the network, and Correct the network
to MECHATROLINK-II
is lit in red. that the number of connected address.
Troubleshooting

communications.
Servo Drives is less than 17.
Take countermeasures by
Check details of alarm by referring
An alarm has Read the alarm code and referring to Error Diagnosis
to Error Diagnosis Using the Dis-
occurred. the alarm history. Using the Displayed Alarm
played Alarm Codes on page 8-7.
Codes on page 8-7.

8-15
 8-3 Troubleshooting

Symptom Probable cause Items to check Countermeasure

Set the Servo lock command
Check the response of
Not Servo locked. bit on the host controller
the NCF71 Servo lock bit.
again.

The power cable is Check the wiring of the Servomotor Wire the Servomotor power
not properly connected. power cable. cable correctly.

Check the wiring of the main circuit,

Servomotor power is not Input the main circuit power
and the voltage of the power
ON. supply and voltage correctly.
supply.
ΠCheck that the inputs for POT and
Does not The Forward and Reverse NOT are not OFF.
Turn ON POT and NOT, and
Servo lock. Drive Prohibit Inputs (POT ΠCheck the +24 VIN input for CN1.
input +24 VIN correctly.
and NOT) are OFF.

Check that torque limits Pn05E and Set the maximum torque to
Torque limit is 0.
Pn05F are not set to 0. be used for each.

Torque control is used for Set the control mode for the
Check the control mode and the
the control from the host host controller to position
torque command value for the host
controller, and the torque control mode, and check
controller.
command value is set to 0. Servo lock.

Servo Drive failure. --- Replace the Servo Drive.

No command is sent For position commands, check that Input the position and speed 8
from the host controller. speed and position are not set to 0. data to start the Servomotor.

Check that the speed command

Cannot tell whether the Check the speed command

Troubleshooting
from the host controller is not too
Servomotor is rotating. from the host controller.
slow.

Check the brake interlock (BKIR) For a Servomotor with brake,

The holding brake is
signal and the +24 VDC power check that its holding brake
working.
supply. is released by Servo lock.

Servo lock is ON,

but Servomotor The No.1 and No. 2 Torque Check that the torque limits Pn05E
Set the maximum torque to
does not rotate. Limits (Pn05E, Pn05F) are and Pn05F are not set to a value
be used for each.
too small. close to 0.

Torque control is used for

Set the control mode for the
the control from the host Check the control mode and the
host controller to position
controller, and the torque torque command value for the host
control mode, and check
command value is too controller.
Servo lock.
small.
The Speed Limit (Pn053) is
Check the Speed Limit (Pn053) Increase the value for the
set to 0 for torque control
value. Speed Limit (Pn053).
mode.

Servo Drive failure. --- Replace the Servo Drive.

Correctly wire the Servomo-

The Servomotor The Servomotor Power Check the wiring of the Servomotor
tor Power Cable phases U,
operates Cable is wired incorrectly. Power Cable phases U, V, and W.
V, and W.
momentarily, but
it does not oper- Not enough position com- Check the position data, electronic
ate after that. Set the correct data.
mand data. gear, and others for NCF71.

8-16
 8-3 Troubleshooting

Symptom Probable cause Items to check Countermeasure

Set the speed command to

There is a small input for Check that there is no input
0, or switch to position con-
The Servomotor speed command mode. for speed command mode.
trol mode.
rotates
without a
Switch from torque control
command. There is a small input for Check that there is no input for
mode to position control
torque command mode. torque command mode.
mode.

The Operating Direction Change the Operating

Check the Operating Direction
Setting (Pn043) setting is Direction Setting (Pn043)
The Servomotor Setting (Pn043) value.
incorrect. value.
rotates in the
direction opposite ΠSet values are inappropriate for ΠCheck the current and
to the command. NCF71 command is an absolute command. target values.
incorrect. ΠThe polarity is incorrect for an ΠCheck the rotation
incremental command. direction.
ΠCheck the brake interlock
The holding (BKIR) signal and the relay
Power is supplied to the Check whether power is supplied to circuit.
brake does not
holding brake. the holding brake. ΠCheck that the holding
work.
brake is not worn down.
ΠSlow down the
Measure the torque using the front acceleration/deceleration.
The load is too large.
panel IM or a tool. ΠLower the speed and
measure the load.
8 ΠCheck that the specified heat ΠImprove the heat radiation
The heat radiation condi- radiation conditions are satisfied. conditions.
The Servomotor
tions for the Servomotor ΠFor a Servomotor with a brake, ΠReduce the load.
is overheating.
have worsened. check the load ratio. ΠImprove ventilation.
Troubleshooting

ΠRadiate heat and cool.

The ambient temperature is Check that the ambient tempera- ΠReduce the load ratio.
too high. ture has not exceeded 40 °C.

Adjust the speed loop gain

Load and gain do not Check the response waveforms for
so that the rotation is
match. speed and torque.
stabilized.
ΠCheck if the adjustments
can be made via manual
Load inertia exceeds the tuning.
Calculate the load inertia.
specified range.
The Servomotor ΠIncrease the capacity of the
rotation is Servomotor.
unstable.
Enable damping control, and
Low rigidity is resulting in Measure the vibration frequency of
set the vibration filter fre-
vibration. the load.
quencies.
Loose coupling with the
Tighten the coupling with the
machine, and/or large Check coupling with the machine.
machine.
gaps.

8-17
 8-3 Troubleshooting

Symptom Probable cause Items to check Countermeasure

ΠRe-tighten the coupling.
Problem with the coupling Check that the coupling of the Ser- ΠReplace with a tight
between the Servomotor vomotor and the machine is not coupling.
axis and the machine. misaligned.
Machine position
is misaligned.
Deceleration stop
Check the control ladder on the Review the control on the
command is received from
host controller. host controller.
the host controller.

ΠCheck the load inertia. ΠReview the load inertia.

The Servomotor ΠDynamic brake resistor is ΠReplace the Servomotor
Load inertia is too large.
is slow to stop disconnected. and Servo Drive with
even if the RUN appropriate models.
command is ΠIf disabled, enable it.
turned OFF while ΠIf there is a failure, or
the Servomotor is Check if the dynamic brake
Dynamic brake is disabled. disconnection of the
rotating. is disabled or has failed.
resistor, replace the
Servomotor.

The Position Loop Gain Review the Position Loop Gain Adjust the gain to avoid
(Pn010) is too large. (Pn010). overshooting.

Poor balance between the

Use CX-Drive and analog
Speed Loop Integration Review the Speed Loop Integration
monitors (SP, IM) to mea-
Overshoots when Time Constant (Pn012) Time Constant (Pn012) and the
starting or and the Speed Loop Gain Speed Loop Gain (Pn011).
sure the response and adjust 8
the gain.
stopping. (Pn011).
Inappropriate machine
Match the machine rigidity
rigidity setting by realtime Review the machine rigidity setting.

Troubleshooting
setting to the load rigidity.
autotuning.
Inertial ratio setting differs Match the Inertia Ratio
Review the Inertial Ratio (Pn020).
from the load. (Pn020) to the load.

8-18
 8-3 Troubleshooting

Symptom Probable cause Items to check Countermeasure

The Torque Command
Increase the Torque Com-
Filter Time Constant Review the Torque Command Filter
mand Filter Time Constant
(Pn014) does not match Time Constant (Pn014).
(Pn014) to stop the vibration.
the load.
If the resonance frequency is
high, set an adaptive filter to
Vibration occurs due to Check if the resonance frequency is stop the resonance, or mea-
machine resonance. high or low. sure the resonance frequen-
cy and set Notch
Filters 1 and 2.
ΠThe Position Loop Gain
(Pn010) is too large.
Review the Position Loop Gain Use CX-Drive and
ΠPoor balance between
(Pn010), Speed Loop Integration analog monitors (SP, IM) to
the Speed Loop
Time Constant (Pn012), and the measure the response and
Integration Time Constant
Speed Loop Gain (Pn011). adjust the gain.
(Pn012) and the Speed
Unusual noise Loop Gain (Pn011).
and vibration
occurs from The Speed Feedback Filter Check the Speed Feedback Filter Increase the Speed Feed-
the Servomotor Time Constant (Pn013) Time Constant (Pn013). The back Filter Time Constant
or the load. does not match the load. parameter is usually set to 0. (Pn013) and operate.

If the vibration frequency is

100 Hz or below, stop the
Vibration occurs due to low Check whether the vibration fre-
vibration by setting the vibra-
mechanical rigidity. quency is 100 Hz or below.
tion frequency for the vibra-
8 tion filter.
Check whether the coupling with Make adjustments to
the load is unbalanced. balance the rotation.
Troubleshooting

Eliminate eccentricity.
Eccentricity of the load
Vibration occurs due to Check for eccentricity of the load.
results in noise due to
mechanical installation.
fluctuation of torque.
Check the decelerator speci-
Check for noise from within the
fications and perform an
decelerator.
inspection.

8-19
 8-4 Overload Characteristics (Electronic Thermal Function)

8-4 Overload Characteristics

(Electronic Thermal Function)
An overload protection (electronic thermal) function is built into the Servo Drive to protect the Servo
Drive and Servomotor from overloading.
If an overload does occur, first eliminate the cause of the error and then wait at least one minute for
the Servomotor temperature to drop before turning on the power again.
If the power is turned ON again repeatedly at short intervals, the Servomotor windings may burn out.

Overload Characteristics Graphs

The following graphs show the characteristics of the load ratio and the electronic thermal function's
operation time.
Time (s)
100
50 W
100 W (100 V)
100 W (200 V)
200 W
400 W
10 750 W

1 8

Troubleshooting
0.1
115
100 150 200 250 300 Torque (%)
Time (s)
100
R88M-G@10T 900 W to 6 kW
R88M-G@20T 1 kW to 5 kW
R88M-G@15T 7.5 kW
R88M-G@30T 1 kW to 5 kW
10 R88M-GP@ 100 W to 400 W

0.1
115
100 150 200 250 300 Torque (%)

When the torque command = 0, and a constant torque command is continuously applied after three
or more times the overload time constant has elapsed, the overload time t [s] will be:
t [s] = − Overload time constant [s] × loge (1 − Overload level [%] / Torque command [%]) 2

(The overload time constant [s] depends on the Servomotor. The standard overload level is 115%.)

Precautions ΠOverload (alarm code 16) cannot be reset for approximately 10 seconds
for Correct Use after its occurrence.

8-20
 8-5 Periodic Maintenance

8-5 Periodic Maintenance

Caution
Resume operation only after transferring to the new Unit the
contents of the data required for operation.
Not doing so may result in equipment damage.

Do not attempt to disassemble or repair any of the products.

Any attempt to do so may result in electric shock or injury.

Servomotors and Servo Drives contain many components and will operate properly only when each
of the individual components is operating properly.
Some of the electrical and mechanical components require maintenance depending on application
conditions. Periodic inspection and part replacement are necessary to ensure proper long-term
operation of Servomotors and Servo Drives. (quotes from “The Recommendation for Periodic
Maintenance of a General-purpose Inverter” published by JEMA)
The periodic maintenance cycle depends on the installation environment and application conditions
of the Servomotor or Servo Drive.
8 Recommended maintenance times are listed below for Servomotors and Servo Drives. Use these
for reference in determining actual maintenance schedules.
Troubleshooting

Servomotor Service Life

ΠThe service life for components is listed below.
Bearings: 20,000 hours
Decelerator: 20,000 hours
Oil seal: 5,000 hours
Encoder: 30,000 hours
These values presume an ambient Servomotor operating temperature of 40°C, shaft loads within
the allowable range, rated operation (rated torque and rated r/min), and proper installation as
described in this manual.
The oil seal can be replaced.
ΠThe radial loads during operation (rotation) on timing pulleys and other components contacting
belts is twice the still load. Consult with the belt and pulley manufacturers and adjust designs and
system settings so that the allowable shaft load is not exceeded even during operation. If a
Servomotor is used under a shaft load exceeding the allowable limit, the Servomotor shaft can
break, the bearings can burn out, and other problems can occur.

8-21
 8-5 Periodic Maintenance

Servo Drive Service Life

ΠDetails on the service life of the Servo Drive are provided below.
Aluminum electrolytic capacitors: 28,000 hours
(at an ambient Servo Drive operating temperature of 55°C, the rated operation output (rated
torque), installed as described in this manual.)
Axial fan: 10,000 to 30,000 hours
Inrush current prevention relay: Approx. 20,000 operations (The service life depends on the
operating conditions.)
ΠWhen using the Servo Drive in continuous operation, use fans or air conditioners to maintain an
ambient operating temperature below 40°C.
ΠWe recommend that ambient operating temperature and the power ON time be reduced as much
as possible to lengthen the service life of the Servo Drive.
ΠThe life of aluminum electrolytic capacitors is greatly affected by the ambient operating
temperature. Generally speaking, an increase of 10°C in the ambient operating temperature will
reduce capacitor life by 50%.
ΠThe aluminum electrolytic capacitors deteriorate even when the Servo Drive is stored with no
power supplied. If the Servo Drive is not used for a long time, we recommend a periodic inspection
and part replacement schedule of five years.
ΠIf the Servomotor or Servo Drive is not to be used for a long time, or if they are to be used under
conditions worse than those described above, a periodic inspection schedule of five years is
recommended.
ΠUpon request, OMRON will examine the Servo Drive and Servomotor and determine if a
replacement is required.
8

Troubleshooting

8-22
 8-5 Periodic Maintenance

Replacing the Absolute Encoder Battery ABS

Replace the Absolute Encoder Backup Battery if it has been used for more than three years or if an
absolute encoder system down error (alarm code 40) has occurred.

„ Replacement Battery Model and Specifications

Item Specifications
Name Absolute Encoder Backup Battery
Model R88A-BAT01G
Battery model ER6V (Toshiba)
Battery voltage 3.6 V
Current capacity 2000 mA·h

„ Mounting the Backup Battery

Mounting the Battery for the First Time

Connect the absolute encoder battery to the Servomotor, and then set up the absolute encoder.
Refer to Absolute Encoder Setup on page 6-6.
Once the absolute encoder battery is attached, it is recommended that the control power supply be
8 turned ON and OFF once a day to refresh the battery.
If you neglect to refresh the battery, battery errors may occur due to voltage delay in the battery.

Replacing the Battery

Troubleshooting

If a battery alarm occurs, the absolute encoder battery must be replaced.

Replace the battery with the control power supply to the Servo Drive ON. If the battery is replaced
with the control power supply to the Servo Drive OFF, data held in the encoder will be lost.
Once the absolute encoder battery has been replaced, clear the battery alarm. For details on
clearing the alarm, refer to Alarm Reset on page 6-25.

Note If the absolute encoder is cleared, or the absolute values are cleared using communications,
all error and rotation data will be lost and the absolute encoder must be set up again. For
details, refer to Absolute Encoder Setup on page 6-6.

8-23
 8-5 Periodic Maintenance

Battery Mounting Procedure

1. Prepare the R88A-BAT01G replacement battery.

R88A-BAT01G

2. Remove the battery box cover.

8
Raise the hooks to remove the cover.

Troubleshooting
3. Put the battery into the battery box.

Insert the battery. Attach the connector.

4. Close the cover to the battery box.

Make sure that the connector

wiring does not get caught when
closing the cover to the battery
box.

8-24