Tag Archives: Alarms & Faults

FANUC Controls Alarms

Fanuc Power Supply Alarm Codes – Alpha Series

Recently we had a customer who was working on troubleshooting a FANUC CNC Power Supply alarm that he had on a machine. He was wondering what the different codes stood for, so we wanted to go ahead and list the different alarm codes for this series. These codes apply to power supplies that start with the following prefixes. The “X”s after the H will be numbered, so an example part number is A06B-6087-H130.

A06B-6081-HXXX
A06B-6083-HXXX
A06B-6077-HXXX
A06B-6091-HXXX
A06B-6120-HXXX
A06B-6140-HXXX
A06B-6110-HXXX

Here is a list of the alarm codes for these series of Power Supply Modules.

AL01: The main circuit power module (IPM) has detected am Error (PSM-5.5,-11)
Overcurrent flows into the input of the main circuit (PSM-15 to –30).

AL02: A cooling fan for the control circuit has stopped.

AL03: The Temperature of the main circuit heat sink has risen abnormally.

AL04: In the main circuit the DC voltage (DC Link) has dropped.

AL05: The main circuit capacitor was not recharged within the specified time.

AL06: The Input Power Supply is abnormal (open phase).

AL07: In the main circuit the DC Voltage at the DC link is abnormally high.

Be sure to check out our article covering FANUC CNC Troubleshooting Frequently Asked Questions here.

A06B-6087-H130 alarm codes

For more information or to get a quote on a FANUC power supply, please call 800-691-8511 or email sales@mroelectric.com.

We also provide repair services for FANUC Power Supplies.

MagneTek GPD503 Fault Codes

Below is a chart with fault codes regarding the MagneTek G3 GPD503 series drives. MRO Electric and Supply offers free evaluations on units. You can find our RMA form on our repair page. Follow us on Twitter @MROElectric for updates on new products and find any deals we may have.

bbExternal Base Block command
Base Block command at multi-function terminal is active, shutting off GPD 503 output (motor coasting). Temporary condition, cleared when input command is removed.
bUSTransmission error
Control data cannot be received normally for longer than 2 seconds.
CALLCommunication ready
Drive is waiting for the PLC to establish communication.
CPF00Transmission error or control function hardware fault (including internal RAM, external RAM or PROM)
Transmission between GPD 503 and remote operator is not established within 5 seconds after the power supply is turned on. (Displayed on the remote operator.)
CPF01Transmission error
Transmission error occurs 2 seconds or more after transmission has first been established.
CPF02Base block circuit failure
GPD 503 failure.
CPF03NV-RAM (S-RAM) fault
GPD 503 failure.
CPF04NV-RAM (BCC, Access Code)
fault
GPD 503 failure. This fault may be caused after changing EPROM chips. Perform a Sn-03 Reset operation to attempt to clear this fault.
CPF05A/D converter failure in CPU
GPD 503 failure.
CPF06Optional connection failure
Improper installation or wiring of option card.
CPF20A/D converter failure
Defective option card.
CPF21Transmission interface card (option) self-analysis function fault
Defective option card. Check option card connector for proper installation.
CPF22Model code fault
Defective option card. Check option card connector for proper installation.
CPF23Mutual-analysis function fault
Defective option card. Check option card connector for proper installation.
EF (blinking)Simultaneous forward and reverse operation commands
Fwd Run and Rev Run commands are both closed for more than 500 ms. Removing one command will allow drive operation.
EF0External fault
GPD 503 is in Stop mode.
EF3Ext. fault signal at term. 3
A fault condition has occurred in the external circuit(s) monitored by the contact providing input to the indicated terminal. If display is steady, GPD 503 is in Stop mode; if display is blinking, the terminal is programmed to allow continued operation after receiving fault input.
EF5Ext. fault signal at term. 5
A fault condition has occurred in the external circuit(s) monitored by the contact providing input to the indicated terminal. If display is steady, GPD 503 is in Stop mode; if display is blinking, the terminal is programmed to allow continued operation after receiving fault input.
EF6Ext. fault signal at term. 6
A fault condition has occurred in the external circuit(s) monitored by the contact providing input to the indicated terminal. If display is steady, GPD 503 is in Stop mode; if display is blinking, the terminal is programmed to allow continued operation after receiving fault input.
EF7Ext. fault signal at term. 7
A fault condition has occurred in the external circuit(s) monitored by the contact providing input to the indicated terminal. If display is steady, GPD 503 is in Stop mode; if display is blinking, the terminal is programmed to allow continued operation after receiving fault input.
EF8Ext. fault signal at term. 8
A fault condition has occurred in the external circuit(s) monitored by the contact providing input to the indicated terminal. If display is steady, GPD 503 is in Stop mode; if display is blinking, the terminal is programmed to allow continued operation after receiving fault input.
ErrConstant write-in fault
Temporary display, in Program mode, indicating that constant setting was not written into EPROM memory.
FAnCooling fan failure
GPD 503 is in Stop mode.
FUFuse blown
DC Bus fuse has cleared. Check for short circuit in output, and check main circuit transistors.
GFGround fault protection
Ground current > approx. 50% of the GPD 503 rated current.
oCOvercurrent
GPD 503 output current exceeds 200% of GPD 503 rated current, or ground fault has occurred, with ground current exceeding 50% of GPD 503 rated current.
oHHeat sink overheated
Fin temperature exceeds 90° C (194° F)
oH2 (blinking)External overheat
External temperature monitoring circuit(s) detected an overtemperature condition and produced an input signal.
oL1Overload
Thermal motor overload protection has tripped.
oL2Overload
GPD 503 overload protection has tripped.
oL3 (blinking)Overload
GPD 503 output torque exceeds the set Overtorque Detection level, but GPD 503 is programmed for continued operation at overtorque detection.
oL3Overload
GPD 503 output torque exceeds the set Overtorque Detection level, and GPD 503 is programmed for coast to stop at overtorque detection.
oPE01kVA constant setting fault
Sn-01 setting is incorrect.
oPE02Constant setting range fault
An-XX, bn-XX, Cn-XX, or Sn-XX setting range fault.
oPE03Constant set value fault
Sn-15 to -18 (multi-function input) set value fault.
oPE04Constant set value fault
PG constant, number of poles, or PG division rate set incorrectly.
oPE10Constant set value fault
Cn-02 to -08 (V/f data) set incorrectly.
oPE11Constant set value fault
One of the following conditions was detected: • Cn-23 > 5 KHz and Cn-24 5 KHz or • Cn-25 > 6 and Cn-24 > Cn-23
ou (blinking)Overvoltage
Internal monitor of DC Bus voltage indicates that input AC power is excessively high, while GPD 503 is in stopped condition.
ouOvervoltage (OV)
Detection level: Approx. 400V for 230V; Approx. 800V for 460V; Approx. 1000V for 575V.
rrRegenerative transistor Failure
Dynamic Braking resistor has failed.
rHBraking resistor unit overheated
Dynamic Braking resistor has overheated.
Uu (blinking)Low voltage (Power UV)
Internal monitor of DC Bus voltage indicates that input AC power is below Undervoltage detection level, while the GPD 503 is in stopped condition.
Uu1 Low voltage (Power UV)Occurs two seconds after detection of low voltage.
Uu2 Low voltage UVControl circuit voltage levels drop below acceptable levels during operation.
Uu3 Low voltage (MC-ANS fault)Main circuit magnetic contactor does not operate correctly.

Common UNI1405 Fault Codes

Below is a table of common Unidrive faults found within the Control Techniques Unidrive series, more specifically, the UNI1405. MRO Electric offers core credit on exchanges for new and refurbished units, and have a wide selection of option cards such as the UD51, UD73, and UD77. We also repair Unidrives in-house. Contact us if you are interested in finding a new machine so we can keep your downtime to a minimum!

HF81Software Error (odd address word)
HF82Large option module removed
HF83Power Board Code Failure
HF84Current Offset Trim Failure
HF85A to D failure (ES-CC step)
HF86Interrupt Watchdog failure
HF87Internal ROM check error
HF88Watchdog Failure
HF89Unused Interrupts (nmi as source)
HF90Stack Overflow
HF91Stack Underflow
HF92Software Error (undefined op code)
HF93Software Error (protection fault)
HF94Software Error (odd address word)
HF95Software Error (odd address inst.)
HF96Software Error (illegal ext bus)
HF97Level 1 Noise
HF98Interrupt Crash
HF99Level 1 Crash

Yaskawa P1000 Fault Codes

Below is a table of common fault codes found on Yaskawa P1000 units. If problems continue to occur, it may be worth replacing your unit. MRO Electric specializes in Yaskawa repair, as well as unit distribution, if you are interested in obtaining a new or refurbished P1000 unit.

bATDigital Operator Battery Voltage Low - The digital operator battery is low Replace the digital operator battery.
boLBraking Transistor Overload Fault - The wrong braking resistor is installed Select the correct braking resistor.
bUSOption Communication Error - No signal was received from the PLC. Check for faulty wiring.
CE MEMOBUS/Modbus Communication Error - Faulty communications wiring or an existing short circuit.
CEMEMOBUS/Modbus Communication Error - Faulty communications wiring or an existing short circuit.
CPF02A/D Conversion Error - Control circuit is damaged. Replace the control board or the entire drive.
CPF03Control Board Connection Error - Turn off the power and check the connection between the control board and the drive.
CPF06EEPROM Memory Data Error - Turn off the power and check the connection between the control board and the drive.
CPF07Terminal Board Connection Error - Faulty connection between the terminal board and the control board. Turn off the power and reconnect the terminal board.
CPF08Terminal Board Connection Error - Faulty connection between the terminal board and the control board. Turn off the power and reconnect the terminal board.
CPF11Control Circuit Error - Hardware is damaged. Cycle Power. Replace hardware.
CPF12Control Circuit Error - Hardware is damaged. Cycle Power. Replace hardware.
CPF13Control Circuit Error - Hardware is damaged. Cycle Power. Replace hardware.
CPF14Control Circuit Error - Hardware is damaged. Cycle Power. Replace hardware.
CPF15Control Circuit Error - Hardware is damaged. Cycle Power. Replace hardware.
CPF16Control Circuit Error - Hardware is damaged. Cycle Power. Replace hardware.
CPF17Control Circuit Error - Hardware is damaged. Cycle Power. Replace hardware.Control Circuit Error - Hardware is damaged. Cycle Power. Replace hardware.
CPF18Control Circuit Error - Hardware is damaged. Cycle Power. Replace hardware.
CPF19Control Circuit Error - Hardware is damaged. Cycle Power. Replace hardware.
CPF20Control Circuit Error - Hardware is damaged. Cycle Power. Replace hardware.
CPF21Control Circuit Error - Hardware is damaged. Cycle Power. Replace hardware.
CPF22Hybrid IC Error - Hardware is damaged. Cycle Power. Replace hardware.
CPF23Control Board Connection Error - Hardware is damaged. Cycle Power. Replace hardware.
CPF24Drive Unit Signal Fault - The drive capacity cannot be detected correctly. Cycle Power. Replace hardware.
CPF25Terminal Board Not Connected - Hardware is damaged. Cycle Power. Replace hardware.
CPF26Control Circuit Error - Hardware is damaged. Cycle Power. Replace hardware.
CPF27Control Circuit Error - Hardware is damaged. Cycle Power. Replace hardware.
CPF28Control Circuit Error - Hardware is damaged. Cycle Power. Replace hardware.
CPF29Control Circuit Error - Hardware is damaged. Cycle Power. Replace hardware.
CPF30Control Circuit Error - Hardware is damaged. Cycle Power. Replace hardware.
CPF31Control Circuit Error - Hardware is damaged. Cycle Power. Replace hardware.
CPF32Control Circuit Error - Hardware is damaged. Cycle Power. Replace hardware.
CPF33Control Circuit Error - Hardware is damaged. Cycle Power. Replace hardware.
CPF34Control Circuit Error - Hardware is damaged. Cycle Power. Replace hardware.
CPF35Control Circuit Error - Hardware is damaged. Cycle Power. Replace hardware.
CPF40Control Circuit Error - Hardware is damaged. Cycle Power. Replace hardware.
CPF41Control Circuit Error - Hardware is damaged. Cycle Power. Replace hardware.
CPF42Control Circuit Error - Hardware is damaged. Cycle Power. Replace hardware.
CPF43Control Circuit Error - Hardware is damaged. Cycle Power. Replace hardware.
E5SI-T3 Watchdog Timer Error - Data has not been received from the PLC Execute DISCONNECT or ALM_CLR, then issue a CONNECT command or SYNC_SET command.
EF0Option Card External Fault - An external fault condition is present. Check external causes.
EF1External Fault Terminal S1 - An external fault condition is present. Check external causes. Bad S1 Terminal.
EF2External Fault Terminal S1 - An external fault condition is present. Check external causes. Bad S1 Terminal.
EF3External Fault Terminal S1 - An external fault condition is present. Check external causes. Bad S1 Terminal.
EF4External Fault Terminal S1 - An external fault condition is present. Check external causes. Bad S1 Terminal.
EF5External Fault Terminal S1 - An external fault condition is present. Check external causes. Bad S1 Terminal.
EF6External Fault Terminal S1 - An external fault condition is present. Check external causes. Bad S1 Terminal.
EF7External Fault Terminal S1 - An external fault condition is present. Check external causes. Bad S1 Terminal.
EF8External Fault Terminal S1 - An external fault condition is present. Check external causes. Bad S1 Terminal.
ErrEEPROM Write Error - Noise has corrupted data. Cycle power. Correct the parameter.
FAnInternal Fan Fault - Internal cooling fan has malfunctioned. Check for fan operation.
FbHExcessive PID Feedback - PID feedback input is greater than the level set to. Check parameter.
FbLPID Feedback Loss - Check parameter. There is a problem with the feedback sensor.
GFGround Fault - A current short to ground exceeded 50% of rated current on the output side of the drive. Check motor/cables.
LFOutput Phase Loss - Phase loss on the output side of the drive. Check motor/cables.
LF3Power Unit Output Phase Loss 3 - Phase loss on the output side of the drive. Check motor/cables.
nSENode Setup Error - A terminal assigned to the node setup function closed during run.
oCOvercurrent - Output current greater than the specified overcurrent level. Check parameter. Check motor.
oFA01Option Card Fault - The option card connection is faulty. Check connection. Replace hardware.
oFA03Option Card Fault - The option card connection is faulty. Check connection. Replace hardware.
oFA04Option Card Fault - The option card connection is faulty. Check connection. Replace hardware.
oFA05Option Card Fault - The option card connection is faulty. Check connection. Replace hardware.
oFA06Option Card Fault - The option card connection is faulty. Check connection. Replace hardware.
oFA10Option Card Fault - The option card connection is faulty. Check connection. Replace hardware.
oFA11Option Card Fault - The option card connection is faulty. Check connection. Replace hardware.
oFA12Option Card Connection Error - The option card connection is faulty. Check connection. Replace hardware.
oFA13Option Card Connection Error - The option card connection is faulty. Check connection. Replace hardware.
oFA14Option Card Connection Error - The option card connection is faulty. Check connection. Replace hardware.
oFA15Option Card Connection Error - The option card connection is faulty. Check connection. Replace hardware.
oFA16Option Card Connection Error - The option card connection is faulty. Check connection. Replace hardware.
oFA17Option Card Connection Error - The option card connection is faulty. Check connection. Replace hardware.
oFA30Option Card Connection Error - The option card connection is faulty. Check connection. Replace hardware.
oFA31Option Card Connection Error - The option card connection is faulty. Check connection. Replace hardware.
oFA32Option Card Connection Error - The option card connection is faulty. Check connection. Replace hardware.
oFA33Option Card Connection Error - The option card connection is faulty. Check connection. Replace hardware.
oFA34Option Card Connection Error - The option card connection is faulty. Check connection. Replace hardware.
oFA35Option Card Connection Error - The option card connection is faulty. Check connection. Replace hardware.
oFA36Option Card Connection Error - The option card connection is faulty. Check connection. Replace hardware.
oFA37Option Card Connection Error - The option card connection is faulty. Check connection. Replace hardware.
oFA38Option Card Connection Error - The option card connection is faulty. Check connection. Replace hardware.
oFA39Option Card Connection Error - The option card connection is faulty. Check connection. Replace hardware.
oFA40Option Card Connection Error - The option card connection is faulty. Check connection. Replace hardware.
oFA41Option Card Connection Error - The option card connection is faulty. Check connection. Replace hardware.
oFA42Option Card Connection Error - The option card connection is faulty. Check connection. Replace hardware.
oFA43Option Card Connection Error - The option card connection is faulty. Check connection. Replace hardware.
oFb00Option Card Connection Error - The option card connection is faulty. Check connection. Replace hardware.
oFb01Option Card Error - The option card connection is faulty. Check connection. Replace hardware.
oFb02Option Card Error - The option card connection is faulty. Check connection. Replace hardware.
oFb03Option Card Error - The option card connection is faulty. Check connection. Replace hardware.
oFb11Option Card Error - The option card connection is faulty. Check connection. Replace hardware.
oFb12Option Card Connection Error - The option card connection is faulty. Check connection. Replace hardware.
oFb13Option Card Connection Error - The option card connection is faulty. Check connection. Replace hardware.
oFb14Option Card Connection Error - The option card connection is faulty. Check connection. Replace hardware.
oFb15Option Card Connection Error - The option card connection is faulty. Check connection. Replace hardware.
oFb16Option Card Connection Error - The option card connection is faulty. Check connection. Replace hardware.
oFb17Option Card Connection Error - The option card connection is faulty. Check connection. Replace hardware.
oFC00Option Card Connection Error - The option card connection is faulty. Check connection. Replace hardware.
oFC01Option Card Error - The option card connection is faulty. Check connection. Replace hardware.
oFC02Option Card Error - The option card connection is faulty. Check connection. Replace hardware.
oFC03Option Card Error - The option card connection is faulty. Check connection. Replace hardware.
oFC11Option Card Error - The option card connection is faulty. Check connection. Replace hardware.
oFC12Option Card Connection Error - The option card connection is faulty. Check connection. Replace hardware.
oFC13Option Card Connection Error - The option card connection is faulty. Check connection. Replace hardware.
oFC14Option Card Connection Error - The option card connection is faulty. Check connection. Replace hardware.
oFC15Option Card Connection Error - The option card connection is faulty. Check connection. Replace hardware.
oFC16Option Card Connection Error - The option card connection is faulty. Check connection. Replace hardware.
oFC17Option Card Connection Error - The option card connection is faulty. Check connection. Replace hardware.
oFC50Option Card Error - The option card connection is faulty. Check connection. Replace hardware.
oFC51Option Card Error - The option card connection is faulty. Check connection. Replace hardware.
oFC52Option Card Error - The option card connection is faulty. Check connection. Replace hardware.
oFC53Option Card Error - The option card connection is faulty. Check connection. Replace hardware.
oFC54Option Card Error - The option card connection is faulty. Check connection. Replace hardware.
oFC55Option Card Error - The option card connection is faulty. Check connection. Replace hardware.
oHHeatsink Overheat - Check ambient temperature. Check parameter setting.
oH1Heatsink Overheat - Check ambient temperature. Check parameter setting.
oH4Motor Overheat Fault (PTC input) - Check ambient temperature. Check parameter setting.
oH5Motor Overheat Fault (NTC input) - Check ambient temperature. Check parameter setting.
oL1Motor Overload - Load heavy. Increase accel or decel time.
oL2Drive Overload - Load heavy. Increase accel or decel time.
oL3Overtorque Detection 1 - current has exceeded the value set for torque detection. Check parameter setting.
oL4Overtorque Detection 2 - current has exceeded the value set for torque detection. Check parameter setting.
oL7High Slip Braking oL - Use braking resistor. Reduce decel time.
oPrOperator Connection Fault - The external operator has been disconnected from the drive.
ovOvervoltage - Deceleration time is too short and regenerative energy is flowing from the motor into the drive. Increase decel time.
PFInput Phase Loss - Drive input power has an open phase or has a large imbalance.
rFBraking Resistor Fault - The resistance of the braking resistor is too low.
rHDynamic Braking Resistor - Deceleration time is too short and excessive regenerative energy is flowing back into the drive.
rrDynamic Braking Transistor - The braking transistor is damaged. Cycle power to the drive and check for reoccurrence of the fault.
SCIGBT Short Circuit or Ground Fault - IGBT failure. Cycle power to the drive and check for reoccurrence of the fault.
SErToo Many Speed Search Restarts - Parameters related to Speed Search are set to the wrong values.
TdETime Data Error - An error has occurred in the real-time clock. Replace digital operator.
THoThermistor Disconnect - The thermistor that detects motor temperature has become disconnected.
TIETime Interval Error - An error has occurred in the real-time clock. Replace digital operator.
TIMTime Not Set - Set time in parameter o4-17.
UL3Undertorque Detection 1 - Current is below the minimum set value. Check parameter setting.
UL4Undertorque Detection 2 - Current is below the minimum set value. Check parameter setting.
UL6Motor Underload - Current is below the minimum set value. Check parameter setting.
UnbCCurrent Unbalance - Current flow has become unbalanced. Check for damaged transistors.
Uv1Undervoltage - DC Bus Undervoltage. Check parameter setting. Input phase loss.
Uv2Control Power Supply Undervoltage - Voltage is too low for the control drive input power. Ride-through power loss.
Uv3Soft Charge Circuit Fault - Precharge relay or resistor fault. Bad precharge.
Uv4Gate Drive Board Undervoltage - Voltage drop in the gate drive board circuit. Cycle power to see if fault reoccurs.
voFOutput Voltage Detection Fault - Problem detected with the voltage on the output side of the drive.
vToLVT Overload - The output current of the drive has been elevated for a set length of time.

FANUC Alarm Codes – A06B-6066 Drives – Alarm 5

The following is a list of procedures to fix the Alarm 5 status on your drive:

  • If you are receiving the alarm after a fresh install of the drive, check to make sure all jumpers and wires are set in their correct position. You can find the location for these inside your user manual.
  • Make sure the drive is off. Check the resistances on the drive, and then test the voltage. If it has been powered up recently, you can then turn it on to check the voltage again. However, do not immediately turn it back off to check the resistances again. You must give it at least 30 minutes for the voltage to return to safe levels so that you can check again.
  • To check the voltage, you can test the DC voltage of the jumper attached between screws 17/18 and 19.
  • Using your ground on screw 19 and and the red lead on the other two screws, your reader should say anywhere from .003 to .006 volts.
  • To check the resistance, remove the jumper from screws 15/16 and then tighten the screws. Use an ohm reader to make sure the resistance isn’t OPEN.
  • Check the resistance between screws 17 and 18. If it is 16 ohms that is where you want it to be.

fanuc cnc

Sometimes you may not have the necessary equipment to make a diagnosis on your motor, but we do. MRO Electric and Supply offers high quality repair services on all motors and spindle drives so you don’t have to worry about it. Please take a look at our website to see all available brands and parts we can service for you. Our rebuilds for these size drives usually only take 2-3 days, which includes rebuilding the part, painting the part, and fully testing the part to ensure top quality. By getting your part back to you as soon as possible, you are able to minimize downtime, and by doing the job right you can have peace of mind knowing that your FANUC drive will now work properly and not be the reason for downtime in the future.

MRO Electric and Supply has new and refurbished FANUC CNC parts available. For more information, please call 800-691-8511 or email sales@mroelectric.com.

Diagnosing your FANUC Current Alarm

If you are getting a high current alarm on your FANUC motor, it is going to be caused by either the motor itself, the drive, or a cable. To begin the process of figuring out which alarm you are receiving you must disconnect the leads from the motor. Try powering it up and look to see if the alarm LED is lit. Fanuc alarms include the HC LED, alarm 8/9/A/B for Servo motors, and alarm 12 for Spindle motors.

  • If you no longer are seeing an alarm, the motor is most likely bad.
  • If you have powered the motor and are receiving the alarm, the issue is most likely with the drive.

Because you have disconnected the leads from the motor, you are able to use an ohm meter/megger to monitor the power levels of the cable and motor, and make sure they are working as intended. Using a megger will help you decide if your motor is grounded correctly where an ohm reader will let you know if your motor has shorted.

Using your ohm meter check for shorts both leg-to-leg and leg-to-ground on each of the legs. The leg-to-leg readings should be consistently low between every leg while the leg-to-ground readings will stay open. The megger is used to check between the leg and ground to see if the problem could be with the terminal box on the motor or any cables connected to it.

Sometimes you may not have the necessary equipment to make a diagnosis on your motor, but we do. MRO Electric and Supply offers high quality repair services on all motors so you don’t have to worry about it. Check out our website to see all available brands and parts we can service for you.

MRO Electric and Supply has new and refurbished FANUC CNC parts available. We also offer repair pricing. For more information, please call 800-691-8511 or email sales@mroelectric.com.

KUKA Controllers lineup

KUKA Error Codes

The list below contains common KUKA Error Codes. These codes are applicable to all KUKA controllers, including the KRC1, KRC2, KRC3, and the KRC4.

Common KUKA Error Codes

  • Error Code 14 – SOFTPLC: @P1@
  • Error Code 284 – Accu–voltage at <kps number> below <voltage level> during last buffering
    • Cause
      • The accu voltage was too low at the last switch off to buffer the
        shutdown.
      • The accu is not charged correctly anymore.
      • The accu is to old or broken.
    • Effect
      • Eventually loss of reference.
      • Cold boot.
      • Active commands inhibited
    • Remedy
      • Exchange accu.
  • Error Code 310 – Safety Circuit for drives not ready
    • Cause
      • Safety circuit is telling drives not to move.
      • Faulty X11
      • Faulty ESC board
      • Faulty KPS 600
    • Remedy
      • Check ESC monitor and other messages to narrow down the root cause with the safety circuit
      • Replace faulty components
  • Error Code 364 – Unknown operation mode
    • Possible Cause
      • Faulty KPS 600 Drive
    • Remedy
      • Replace KPS 600
  • Error Code 420 – Local protective stop (QE)
    • Possible Cause
      • Faulty KPS600 Drive
    • Remedy
      • Replace KPS600
  • Error Code 1033 – ERROR ON READING, DRIVER: ** **
  • Error Code 1034 – ERROR ON WRITING, DRIVER: ** **
  • Error Code 1133 – GEAR TORQUE EXCEEDED AXIS
    • Cause
      • The calculated gear torque is larger than the maximum permissible gear torque.
    • Monitor
      • Cyclic in interpolation cycle.
    • Effect
      • Motion and program are stopped.
    • Remedy
      • Reteach points.
  • Error Code 1239 – ACKN. SYNCHRONISATION ERROR DRIVE
  • Error Code 1376 – ACTIVE COMMANDS INHIBITED
    • Cause
      • A message which causes the active commands to be inhibited has been set.
    • Monitor
      • In command processing.
    • Effect
      • Command is not executed.
    • Remedy
      • Acknowledge active messages in the message window.
  • Error Code 2029 – SYNTAX ERROR IN KUKA MODULE
  • Error Code 2135 – NAME NOT DECLARED AS SUBROUTINE
  • Error Code 6502 – Error during reading INI file init/iosys.ini 1
    • Remedy
      • Check iosys.ini file
      • Ensure correct DeviceNET driver is installed
      • Check data cable between robot / cabinet
  • Error Code 10053
    • Remedy
      • Check fan to ensure it isn’t vibrating. This could be causing the Mfc card to move into the motherboard’s slot.

MRO Electric carries replacement KUKA Robotics parts such as teach pendants, drives, motors, and more. To request a quote, please call 800-691-8511 or email sales@mroelectric.com.

sinumerik 840d sl

Siemens SINUMERIK 840D SL: Product Spotlight & Alarms

The Siemens SINUMERIK 840D sl is a popular open CNC for modular and premium machining concepts with powerful and dynamic system functions that can be used for a wide range of applications. The CNC system is drive based, and can handle up to 93 axes or spindles and any number of PLC axes. The 840D sl can be used in combination with SINAMICS S120 drives and SIMATIC S7-300 PLCs. The system’s powerful hardware architecture and intelligent control systems ensure machining with the highest level of performance and precision. Additionally, there are a number of solutions that allow for easy IT integration.

The SINUMERIK 840D sl can be used for a wide range of applications including:

  • Turning
  • Milling
  • Gear Machining
  • Grinding
  • Machining Composites
  • Handles and CNC Machining using Robots
  • Nibbling, Waterjet Cutting, Laser Machining, & Plasma Machining
  • Multitasking

The SINUMERIK 840D sl has extremely high precision and performance with accuracy up to 80-bits nano. Its dynamic feed forward control ensures that following error is completely compensated for. With its superb algorithms such as Look Ahead, this system can perform at maximum speed with the same level of performance. The SINUMERIK system also minimizes idle time to keep your production levels at maximum capacity. It can handle kinematic transformations with ease, and sets the standard in energy efficiency. The SINUMERIK 840D sl has a number of integrated safety functions to protect personnel and other machines.

Below is the Siemens SINUMERIK Alarm List:

400000PLC STOP %1 Definitions: PLC not in cyclic mode. Travel with the machine is not possible. %1: 1 Ready(User program has not been started) 2 Break (User program has been interrupted) 3 Error (Other PLC alarm with PLC Stop active) Reaction: Alarm display. Remedy: Rectify other PLC alarm; Switch on menu in PLC stop position or test user program. Program Continuation: Alarm display showing cause of alarm disappears. No further operator action necessary.
400001System error %2 Definitions: %1 :Type number With this alarm, internal alarm states are displayed that, in conjunction with the transferred error number, provide information on the cause and location of the error. Reaction: PLC Stop Remedy: Notify Siemens of this error together with the error message. Program Continuation: Switch control OFF – ON.
400002System error %1 Definitions: %1 :Type number Internal error states are displayed with this alarm. An error number is also specified to provide further details about the cause and location of the error. Reaction: PLC Stop Remedy: Report this error to Siemens along with the type number. Program Continuation: Switch control OFF – ON.
400003Faulty connection to the operator panel Definitions: %1 :Type number This alarm displays that the connection to the machine control panel via the MCPA module has been interrupted. Reaction: Mode group not ready for operation Remedy: Check connection to the MCPA module. Program Continuation: Clear alarm with the Delete key or NC START.
400004Code error: %2 network %1 Definitions: %1 :Network number %2 :Internal error code, module type The user program contains an operation which is not supported by the control. Reaction: PLC Stop Remedy: Modify and reload user program. Program Continuation: Switch control OFF – ON.
400006Loss of remanent PLC data Definitions: The following causes are possible: Control handling (e.g. standard PLC deletion, power up with default values) Control handling of power up with backed up data without backing up data in advance Support time exceeded Reaction: Alarm display. Remedy: Update the data required. Program Continuation: Clear alarm with the Delete key or NC START.
400007Operand error: %2 network %1 Definitions: %1 :Network number %2 :Module type Reaction: PLC Stop Remedy: The variable displayed must be checked in the user program for violation of the address range, impermissible data type and alignment errors. Program Continuation: Switch control OFF – ON.
400008Programming tool – version is not compatible %1 %2 Definitions: %1 :Programming tool version This version is not compatible with the product version of the control system. Reaction: PLC Stop Remedy: Translate the user program using a suitable programming tool version and load in the control. Program Continuation: Switch control OFF – ON.
400009Computing time overrun at PLC level: %2 network %1 Definitions: %1 :Network number %2 :Module type Check user program of the corresponding network displayed. Reaction: PLC Stop Remedy: Change user program Program Continuation: Switch control OFF – ON.
400010Arithmetic error in user program: Type %2 network %1 Definitions: Check user program in the specified network. %1Network number, module ID %2 = 1:Division by zero using fixed-point arithmetic 2:Floating-point arithmetic Reaction: PLC Stop Remedy: Change user program. Program Continuation: Switch control OFF – ON.
400011Maximum number of subroutine levels exceeded: %2 network %1 Definitions: %1Network number %2Module ID Check user program in the specified network. Reaction: PLC Stop Remedy: Change user program. Program Continuation: Switch control OFF – ON.
400013PLC user program is incorrect Definitions: The PLC user program in the control is incorrect or is not available. Reaction: PLC Stop Remedy: Reload PLC user program. Program Continuation: Switch control OFF – ON.
400014PROFIBUS DP: power up interrupted, type: %1 Definitions: %1: 1PROFIBUS DP power up interrupted 2Software versions of NC and PLC do not match 3Number of slots per function exceeded 4PROFIBUS DP server not ready Reaction: PLC Stop Remedy: Types 1 to 3:Report error to Siemens Type 4:802D sl – Check and/or replace PCU hardware and/or check MD 11240 Program Continuation: Switch control OFF – ON.
400015PROFIBUS DP: I/O defect: log adr. %1 bus/station: %2 Definitions: The PLC-AWP is using I/O addresses which are not available. %1Logical I/O address %2Bus number/station number Causes of error: Bus peripheral has no voltage Bus address set incorrectly Bus connection faulty Active MD 11240 (SDB configuration) is set incorrectly Reaction: PLC Stop Remedy: Rectify the error using the error cause Program Continuation: Switch control OFF – ON.

The SINUMERIK 840D sl can be used in many different industries. Its customization solutions allow it to fulfill the requirements of even highly regulated industries. There are even support services and solutions provided for specific niches.
SINUMERIK 840D SL Applicatons

MRO Electric offers a variety of support services for the SINUMERIK 840D sl. These include providing new spares, refurbished components, and repair services. If you are in need of a replacement part or FANUC repairs, please call us at 800-691-8511 or email sales@mroelectric.com.
Siemens 6SN1145-1BA01-0DA1

Siemens 6SN1145-1BA01-0DA1: Beyond the User Manual

So what is the 6SN1145-1BA01-0DA1?

The Siemens 6SN1145-1BA01-0DA1 is a Simodrive Infeed/Regenerative Feedback Module with Closed-Loop control. This module is used to connect the drive group to the line supply. Specifically, it is used to input power into the DC link. It also provides the electronics power supply for the connected modules. The 6SN1145-1BA01-0DA1 does not have an comprehensive overload protection. This protection must be provided by the configuration and the correct setting of current values on the control boards.

The 6SN1145-1BA01-0DA1 forms the step-up converter for controlling the DC link voltage and allowing a regenerative feedback. This module can be used for a variety of applications, including the following:

  • Machines with high dynamic requirements placed on the drive.
  • Frequency braking cycles and high braking energy.
  • Control cabinet designs optimized for low operating costs.

This I/R module, the UI and monitoring module are located as the first module to the left of the drive group. The mounting surface of the infeed module and drive modules as well as the commutating reactors and line filter should be mounted to the mounting panels through a low resistance connector like  galvanized plates or panels.

The 6SN1145-1BA01-0DA1 has a total of 6 LEDs for local signaling as show below:

 6SN1145-1BA01-0DA1 Fault Codes
Here is what each LED indicates:

  • 1 LED red – Electronics power supply ± 15V faulted
  • 2 LED red – 5V voltage level faulted
  • 3 LED green – External enable signals not present (terminal 63 and/or terminal 64 missing)
  • 4 LED yellow – DC link charged (normal operation)
  • 5 LED red – Line supply fault
    • Commutating reactor not available, incorrectly installed or incorrectly selected.
    • System fault level of the line supply or transformer too low.
  • 6 LED red – DC link overvoltage
    • Possible Causes
      • Regnerative feedback off
      • Setting up operation
      • Line fault
      • PW either not operational or too small
      • Line supply voltage too high
      • Dynamic overload
      • Line filter inserted between I/R and the commutating reactor.

View the 6SN1145-1BA01-0DA1’s wiring diagram from the manual below:

6SN1145-1BA01-0DA1

MRO Electric has new and refurbished 6SN1145-1BA01-0DA1 Simodrives in stock. For more information or to request a price quote, email sales@mroelectric.com or call 800-691-8511.

Siemens 6SN1145-1BA01-0DA1
Siemens 6SN1145-1BA01-0DA1

Simodrive E/R Troubleshooting for 6SN1145-1BA02-0CA1

6SN1145-1BA02-0CA1
6SN1145-1BA02-0CA1

We often have people who are having issues with their current drive setup but can’t confirm that a specific drive in their system is the issue. They are all but sure, but understandably want to confirm the problem before buying a replacement from us, so we have a set of troubleshooting procedures issued from Siemens that we can send out so that people can confirm that they have a problem. Last week a customer was replacing a Siemens 6SN1145-1BA02-0CA1 module and wanted to troubleshoot their I/R module, so we’ve listed the troubleshooting procedures in the table below to help with  Simodrive E/R Troubleshooting.

For a full list of the Siemens Simodrives that we have available you can visit the section on our website here. To request a quote, please call us at 1-800-691-8511 or email sales@mroelectric.com

Continue reading Simodrive E/R Troubleshooting for 6SN1145-1BA02-0CA1