Servo Related Errors

NOTE: Email support_preciseflex@brooksautomation.com for help resolving error codes.

 

Code Text Description

-3000

NULL pointer detected

 

-3001

Too many arguments

 

-3002

Too few arguments

 

-3003

Illegal value

 

-3004

Servo not initialized

 

-3005

Servo mode transition failed

 

-3006

Servo mode locked

 

-3007

Servo hash table not found

 

-3008

Servo hash entry collision

 

-3009

No hash entry found

 

-3010

Servo hash table full

 

-3011

Illegal parameter access

 

-3012

One or more servo tasks stopped

A software watchdog timer has not been updated in the required time. This normally indicates a controller hardware failure or a system software bug.

-3013

Servo task submission failed

 

-3014

Cal parameters not set correctly

This error is generated if a homing operation is initiated and one or more parameters that affect homing are not set properly.  For example, this error is generated in the following circumstances:

  1. The "Hardstop envelope limit, mcnt" (DataID 10122) is less thanor equal to zero or it is greater than either the "Soft envelope error limit, mcnt" (DataID 10302) or the "Hard envelope error limit, mcnt" (DataID 10303).  If you are not using DataID 10122 for your homing method, set it to a small non-zero value to avoid this error.

-3015

Cal position not ready

If your robot is equipped with the Precise Absolute encoders, e.g. you have a PrecisePlace 2300/2400 robot, this indicates that the robot does not have its factory encoder calibration data defined. Most likely, one of the "Index code for calibration" (DataID 16241) values is zero.  To correct the problem, run the factory encoder calibration program.

For 3rd party absolute encoders, this error indicates that the full precision absolute encoder position could not be read from the encoder during the homing operation.  In some cases, this indicates an error in reading the multiple turn counter for the encoder.  If this problem persists, it probably indicates an encoder or controller hardware failure.

For incremental encoders, this error indicates that a signal required for the selected homing method was not found (e.g. a missing homing or limit or index signal) or a signal was corrupted (e.g. incorrect index due to excessive skew).

-3016

Illegal cal seek command

This error should never be generated.  It indicates that the homing operation sent an illegal command to the servo code.  Please report this message along with the process that generated this problem to Precise.

-3017

No axis selected

A debug control panel operation has been requested for an axis that does not exist on a particular servo network node. Reselect the axis and try again. Verify that the node mapped to the axis is active on the network.

-3100

Hard envelope error

This error is generated if the value of the "Position tracking error, mcnt" (DataID 12320) for an axis exceeds its "Hard envelope error limit, mcnt" (DataID 10303) for a sufficient period of time.  This error indicates that there was a significant difference between an axis' commanded position and its actual position.  This can occur if:

  • The axis is being driven too fast for the load that it is carrying.
  • The axis hits an obstacle and cannot advance.
  • The axis is oscillating due to a servo tuning instability.
  • There is a hardware failure of some type.

Normally, this error can be avoided by reducing the speed and/or acceleration of a motion.

-3101

PID output saturated too long

This error indicates that the sum of the servo feedback terms ("Compensator output torque" (DataID 12304) minus the sum of the "Dynamic feedforward torque" (DataID 12337) and the "Filtered feedforward torque" (DataID 12331)) has either saturated the maximum specified torque for an axis or the "Max positive/negative torque limit for PID feedback" (10351,10352) for more than the time specified the "PID output saturation duration limit" (DataID 10369), which is set to 200 msec by default.

This error is generated if the limits are set too low or the axis has been over-driven or the axis has collided with an obstacle or some other unexpected error has occurred.

This check reduces the time that an axis is over-driven or that it drives into an obstacle.

-3102

Illegal zero index

An encoder zero index pulse was detected when none is expected.  The axis is marked as "not calibrated" and the robot must be re-homed.  Verify that parameters "Encoder counts for resolution calc, ecnt" (DataID 10203) and "Encoder revs for resolution calc, rev" (DataID 10204) are correct.  If the unexpected pulse is due to noise, the parameter "Index noise spikes limit" (DataID 10222) may be adjusted.  If the unexpected pulse is due to encoder slippage, parameter "Index skew count limit, mcnt" (DataID 10221) may be adjusted.

-3103

Missing zero index

No encoder zero index pulse was detected when one is expected.  The axis is marked as "not calibrated" and the robot must be re-homed.  Verify that parameters "Encoder counts for resolution calc, ecnt" (DataID 10203) and "Encoder revs for resolution calc, rev" (DataID 10204) are correct.  If the missing pulse is due to encoder slippage, parameter "Index skew count limit, mcnt" (DataID 10221) may be adjusted. 

-3104

Motor duty cycle exceeded

Duty cycle testing is intended to prevent a motor from being damaged due to overheating.  The overheating estimate is computed based upon the average power that is supplied to a motor by an amplifier over a period of time.

The duty cycle criteria is defined by the "RMS rated motor current, A(rms)" (DataID 10611), "Duty cycle limit in terms of rated torque" (DataID 10623), "Duty cycle exceeded duration" (DataID 10622) and "Duty cycle SPR filter pole" (DataID 10621).

If the dynamically computed "Duty cycle value, tcnt^2" (DataID 12606) exceeds the "Duty cycle limit, tcnt^2" (DataID 10624), which is defined from the criteria above, the "Motor duty cycle exceeded" error is generated and motor power is disabled.

If this error is generated, but the motor is still very cool, try changing the "Duty cycle SPR filter pole" (DataID 10621) to average the power over a longer period of time.  This will reduce the effect of short periods of high power utilization.

-3105

Motor stalled

This error indicates that the torque/current for a motor has been saturated at the peak value as defined by the "RMS rated motor current, A(rms)" (DataID 10611) * "AUTO mode motor PEAK(non-RMS)/(RMS rated) current, %" (DataID 10613) for "Motor stalled check duration" (DataID 10617) seconds.

This is different than the conventional definition of having a motor not moving for a period of time with the torque/current continuously above a specified level.

-3106

Axis over-speed

This error is generated when power is enabled or during normal running if the system detects that an axis has violated a speed limit.

If this occurs when power is enabled, it indicates that the axis has violated the speed limit defined by "Special power-up speed limit" (DataID 10210).  The possible causes for this error are as follows:

  1. The motor torque sign is negated and the axis is attempting to run away at high speed.
  2. For 3rd party amplifiers, there is an excessive DAC offset.
  3. For gravity loaded axes, the axis might be dropping very quickly after the brake is released.
  4. A somewhat large offset between the amplifier/motor phase currents might be causing the axis to move excessively when the system attempts to automatically compensate for the phase offset.  The "Disable auto phase offset adjustment" (DataID 10695) can be used to turn off this adjustment if desired.
  5. The "Special power-up speed limit" (DataID 10210) may be set too low.

If this error occurs when the system is running, it indicates that either the "Run-time speed limit" (DataID 10208) or the "Manual mode speed limit" (DataID 10209) has been violated.   When this runtime error occurs, do the following:

  1. Reduce the speed of your motions to avoid damaging the motor or its gear train or violating manual control safety regulations.
  2. Review the values of 10208 and 10209 and ensure that they are set properly.
  3. If possible, reduce the gear ratio of the motor to reduce the maximum motor rotational speed.
  4. If the error is triggered by intermittent noise in the velocity signal, reduce the "Motor velocity SPR filter pole" (10207).  This value will not affect the PID loop tuning, but it does affect other functions of the system. Review the documentation for 10207 before you change its value.

-3107

Amplifier over-current This error is generated if the FPGA firmware detects that the output motor current has exceeded the specified current limits for too long a time.

-3108

Amplifier over-voltage

This error is generated by the FPGA firmware when it detects that the DC bus voltage is too high.  The limit on the bus voltage is a function of the controller model being utilized.  For the G1xxxA/B controllers, the maximum voltage is approximately 59.5 VDC.  For the G3xxx and G2xxxB/C series controllers, the maximum voltage was approximately 445 VDC, but in May 2014 was adjusted down to 436 VDC.  Whenever a motor decelerates, it typically pumps power back into the motor power supply and the voltage will rise above its nominal value.  For example, if the nominal bus voltage is 330V, it is not unusual to see the voltage rise into the high 300's when a large motor is decelerating.  To monitor the DC bus voltage, see "Raw DC bus voltage, volt" (DataID 12684). If this problem persists, it may indicate that the motor power supply must be changed or augmented to include more capacity to dump or absorb more power when the robot is decelerating.

-3109

Amplifier under-voltage

This indicates that the DC motor bus has dropped too low.  This can occur if:

  1. The bus voltage does not rise above 10V the first time that motor power is enabled.
  2. The bus voltage falls too far (typically 30%) below its nominal value at any time after power has been enabled.  
  3. The bus voltage falls below 10V while motor power and the motor amplifiers are enabled.

If this error is generated at the same time as a "Hard E-STOP" error (-1028), it is possible that the "E-stop delay" (DataID 267) is set too short and the DC motor bus voltage is dropping before the amplifiers are disabled.

If this error persists, it could be due to a fuse on the Motor Power Supply being blown.  To monitor the DC bus voltage, see "Raw DC bus voltage, volt" (DataID 12684).  To see the current setting of the nominal voltage look at "Nominal DC bus voltage, volt" (DataID 12683).

-3110

Amplifier fault

This is a generic message indicating that the amplifier hardware has detected a significant problem and has shut down.  For example, the output motor current has exceeded the rated limits of the hardware, or the input power to the amplifier has failed while the amplifier was enabled.   Frequently, a separate amplifier-related error message is also displayed that provides details about the specific problem.

  1. Verify that the amplifiers are configured properly.
  2. Verify the motors are wired correctly.
  3. Verify the current loop tuning is correct.  Unstable current loop tuning can trigger an amplifier fault.
  4. Verify the motor and motor harness are not shorted. This can be done by disconnecting the motor and measuring the resistance between the UVW phases.  The resistance should be the same for each pair and low, but not zero.
  5. If this error occurs when an E-STOP is asserted, verify that the "Delay after setting brakes" (DataID 260) is longer than or equal to the "E-Stop delay" (DataID 267).  Normally, DataID 260 should be at least 0.1 seconds shorter than DataID 267.

-3111

Brake fault This error indicates that the FPGA has detected a fault condition in the hardware motor brake driver circuit.  This test is not currently enabled, so this error message should never be generated.

-3112

Excessive dual encoder slippage If an axis has been configured for dual encoder loop control (i.e. two encoders are used to control a single motor), this error is generated if there is an excessive position or speed differential between the readings of the two encoders.  The slippage limits are defined by "Dual loop position slippage limit" (DataID 10212) and "Dual loop speed slippage limit" (DataID 10216).

If the axis is driven by a traction drive, some amount of slippage occurs every time that the axis is accelerated or decelerated.  This normal slippage is automatically corrected for by the system software.  If excessive speed slippage occurs, it could indicate that one of the two encoders has failed and the system was shutdown to prevent a run-away condition.

-3113

Motor commutation setup failed

The procedure for determining the commutation reference angle for the motor failed and the reference angle was not established. This error normally occurs the first time that motor power is enabled after the controller is restarted or during the homing process.

The followings are the common causes for the failure:

  1.     Motor power was disabled. The motor power was manually disabled or was automatically disabled due to another error occurring before the end of the search process.
  2.    Lose motor cable. Some commutation reference search processes move the motor a short distance. During this small motion, the motor cable became disconnected. Encoder feedback lost.
  3. TEhnec ofdeeedback device (encoder) is not working properly or the "Encoder type" (DataID 10027) was incorrectly set.
  4.    Incorrect configuration parameters. Any of the following parameters may have been incorrect set. The Precise Configuration Utility (PCU) contains tools that can be used to verify the correct settings.
    • DataID 10108, Dedicated DIN's selection
    • DataID 10650, Commutation sign
    • DataID 10651, # of pole pairs per motor revolution
    • DataID 10652, Commutation counts per electrical cycle
  5. Poor current loop tuning. The motor current loop may not be properly tuned.
  6. Improper configuration parameters for selected commutation search method. While the default parameter values will work for a wide variety of axis configurations, there are cases which require parameter adjustment in order to properly perform commutation reference finding. Refer to the selected commutation method parameter description for details.

If the problem persists after checking the above items, please contact Precise support for further assistance.

-3114

Servo tasks overrun The servo tasks are not able to complete their servo computations within the specified servo period.  Too many axes are being servoed by a single board, the parameter "Servo update period in sec" (DataID 603) is too small, or a CPU failure has occurred.  This error is fatal and prevents robot power from being turned on until the controller is rebooted.

-3115

Encoder quadrature error For incremental encoders, the encoder count and direction of change is derived from two square waves (channels A & B) that are 90 degrees out of phase.  If at any time, the FPGA detects that the phase angle between the channels is too small, a quadrature error is generated.  Normally, this error is caused by noise in the encoder lines.  To correct this problem, please see the recommendations on wiring encoders and motors in the Installation Section of the Controller Hardware Manual.  The motor wiring is as important as the encoder wiring since the motors are often generating the noise that is cause the erroneous reading on the encoder channels.

When this error occurs, the motor must be commutated again and should be re-homed since this error indicates that the position of the motor/encoder is not longer exactly known.

For robots with gravity loaded axes (e.g. Z-axes), the "Severe error power off mode" (DataID 142) should be set to mode 1.  If the robot's incremental encoders suffer a quadrature error, the robot's brakes will be set immediately and minimize dropping due to gravity loading.

-3116

Precise encoder index error  

-3117

Amplifier RMS current exceeded

This error indicates that the rated RMS current for an integrated amplifier has been exceeded and the software has disabled motor power to protect the amplifier from being damaged.  This is an internal test that is automatically performed and cannot be disabled.  See the specifications for your controller for the RMS rating of the amplifiers.  If this error occurs, consider doing the following:

  1. Reduce the accelerations, decelerations and speeds for your motions.
  2. Verify that the rated RMS current for the motor is equal to or below that of the amplifier.  If the motor needs to operate at a higher average current level (due to gravity loading, constantly working against friction, etc.), consider purchasing a controller with amplifiers that have a higher rated RMS current.

This error is different than a "Motor duty cycle exceeded" (-3104) error.  The duty cycle testing is intended to protect a motor from being damaged due to over-heating.  There are a number of parameters for configuring the duty cycle testing to match a motor's operating specifications.

-3118

Dedicated DINs not config'ed for Hall If the "Commutation reference setup config" (DataID 10700) specifies that the "Hall-effect" method is to be used for commutating a motor, then the "Dedicated DIN's selection" (DataID 10108) must be set to configure the single-ended inputs in the corresponding encoder connector for use as hall sensor inputs.  If DataID 10108 is not set properly, this error is generated.  Normally, DataID 10108 is automatically configured if DataID 10700 specifies the "Hall-effect" method.

-3119

Illegal 6-step number If the "Commutation reference setup config" (DataID 10700) specifies that the "Hall-effect" method is to be used for commutating a motor, the single-ended inputs in the corresponding encoder connector are read to determine the hall sensor 6-step value.  The only permitted hall readings are values from 1 to 6.  If the single-ended digital inputs are set to some other value, this error is generated.

-3120

Illegal commutation angle

This is a general error message that indicates a problem has been detected with the commutation reference angle.  Some possible problems that would generate this error message include:

  1. The "Commutation counts per electrical cycle" (DataID 10652) may be set to zero or some other invalid number.
  2. For a motor with an absolute encoder, the "Commutation offset" (DataID 10775) may be un-initialized so the commutation reference angle cannot be set based upon the encoders single turn data reading.
  3. For a motor with a serial incremental encoder that outputs hall sensor readings during startup, the hall sensor reading may have been unavailable or invalid.
  4. For a motor with hall sensors, the commutation angle specified for a hall sensor reading (DataIDs 10744-10756) may be un-initialized.
  5. For a motor with an analog encoder, the "Analog hall commutation phase angle" (DataID 10756) may not yield a valid commutation reference angle.

-3121

Encoder fault

This code is generated when an error occurs in communication with a serial encoder such as a Panasonic or Yaskawa serial encoder.  This error indicates one of several possible problems.

  1. For the Yaskawa Sigma II/III serial absolute encoder, this error is generated when the encoder signals a "Runtime Error" due to an error in the encoder's memory. When this occurs, bit 1 in the "Encoder alarm" field (DataID 12251) is set. Check the encoder cable and cycle the power to see if the error goes away. See the Yaskawa encoder alarm documentation for more details.
  2. For the Panasonic serial incremental encoder (type 41), this error is generated when the encoder signals a Preload error after the encoder has been initialized. When this occurs, bit 7 is set in the "Encoder alarm" field (DataID 12251). See the Panasonic encoder alarm documentation for more details.


This is a severe error and requires the encoder to be re-initialization and/or power cycled.

-3122

Soft envelope error

The position error of an axis has exceeded the value set in the "Soft envelope error limit" (DataID 10302).  This is a safety precaution to ensure that each axis does not deviate too far from its intended position.  This error may indicate that the following has occurred:

  1. An axis has been commanded to accelerate too quickly or move too fast and does not have the power to perform the operation.  If necessary, this can be confirmed by datalogging the "Compensator output torque" (DataID 12304) and the "Position tracking error" (DataID 12320) for the axis in question.  If this is the source of the envelope error, the position error will increase significantly when the motor torque saturates at its maximum value for several tens of milliseconds.
  2. The axis has gone unstable due to a hardware failure or some other error.  This can be confirmed by listening for an audible noise or by datalogging the "Velocity tracking error" (DataID 12321) for the axis in question and looking for high frequency oscillations.
  3. An axis may have crashed into an obstacle and is unable to move to the specified position.
  4. The "Software envelope error limit" (DataID 10302) may be set to too small of a value.

-3123

Cannot switch serial encoder mode When an absolute or incremental serial encoder is employed, it can operate in either sync or async mode.  In order to switch between the two modes the axis motor power must be turned OFF.   If it's not then this error is issued.

-3124

Serial encoder busy During communication with a serial absolute or incremental encoder, if the encoder takes too long to process a command, this error is issued. When the encoder is in its normal synchronous mode, this error can be generated when the encoder is periodically returning position data.  During asynchronous mode , this error can be generated when the host controller issues a specific encoder command to perform a diagnostic function.

If this error persists, please check the encoder connections and power cycle the encoder.

-3125

Illegal encoder command The serial command issued from the controller is not supported by the encoder. Normally, this error should never occur.  However, if it is generated, it indicates that there is an internal implementation error. Please inform Precise.

-3126

Encoder operation error

This indicates that a serial encoder is rotating at too high a speed before motor power is turned on or an error has been detected in the encoder position data. This error is generated when the encoder signals the following alarms conditions:

  1. For Panasonic and Tamagawa serial encoders, this error is generated when "Over-speed" (bit 0) and/or "Counter Error" (bit 2) is set in the "Encoder alarm" field (DataID 12251).
  2. For Yaskawa serial encoders, this error is generated when "Absolute Error" (bit 3), "Over-speed" (bit 4) and/or "Reset Complete" (bit 6) is set in the "Encoder alarm" field (DataID 12251).

This is a standard error and requires the encoder to be re-initialization and/or power cycled.

See the Panasonic, Tamagawa and Yaskawa encoder alarm documentation for more details.

-3127

Encoder battery low Many serial absolute encoders require a connection to an external battery. If the battery voltage is too low, this error is issued.  When this error is generated, the encoder is still operational and its internal data, e.g. multi-turn value, will still be valid. However, the battery should be replaced as soon as possible before the internal data is lost.

-3128

Encoder battery down

Many serial absolute encoders require a connection to an external battery. If the battery is dead or this backup power is disconnected (even momentarily), this error is issued and will be latched until cleared. When this error occurs, the encoder's internal multi-turn data is no longer valid and the encoder position must be re-calibrated.  The battery must be replaced or reconnected and the factory setup for the encoder must be executed again.

If this error occurs, verify that the battery voltage is adequate (typically 3.6V or above) and is connected to the encoder via the controller.  Once the battery power has been restored, execute the factory calibration program to clear this latched error and reset the encoder's multiple turn counter.

-3129

Invalid encoder multi-turn data

During run-time, this error is triggered when an encoder's multi-turn counter either over-flows or under-flows or the encoder itself detects a read error of the multi-turn data.

The over-flow or under-flow error should not occur so long as the encoder is not continuously turned in a single direction and the homing setup is done properly.

If the error is generated when the controller is restarted or during homing, the error is most likely due to a read error and the encoder should be power cycled to clear this condition.

For Panasonic and Tamagawa serial absolute encoders, this error is generated when the "Multi-turn Counter Overflow" bit (bit 3) and/or "Multi-turn read error" bit (bit 5) is set in the "Encoder alarm" field (DataID 12251). See the Panasonic/Tamagawa encoder alarm documentation for more details.

This is a standard error and requires the encoder to be re-initialization and/or power cycled

-3130

Illegal encoder operation mode During normal run-time operation, serial absolute and serial incremental encoders should be in synchronous communication mode. If an encoder is not in this mode when motor power is enabled, this error is issued. Normally, this error should not be generated.

If this error persists, use the Absolute Encoder Diagnostics page in the web interface to re-initialize the serial encoder or power cycle the encoder.

-3131

Encoder not supported or mis-matched

The parameter "Encoder type" (DataID 10027) is set to a value not supported by the servos or that is inconsistent with the ID code returned by a serial encoder.  This can occur if:

  • The Encode type is not set to the proper value
  • When the controller first communicates with the encoder, the encoder communication is corrupted and the wrong encoder ID is received
  • For bus line absolute encoders, one or more of the encoders did not properly boot and the encoder message received by the controller did not include the response from all of the expected encoders


This error is fatal and prevents robot power from being turned on until the controller is rebooted.

-3132

Trajectory extrapolation limit exceeded

This error occurs in systems with slave controllers or GSB boards that are networked to a master controller via Ethernet or RS485.  If a set point transmission is lost, the servo code on the slave controller or GSB extrapolates from the previous trajectory set points.  If the number of sequential missed set points exceeds the "Number of consecutive extrapolations allowed" (DataID 10424), the servo generates this severe level error and disables motor power.

If this error occurs, verify that the value of DataID 10424 is not set too low.  Typically, this value should be set to 8. 

If this error is generated by an Ethernet slave controller, there is probably noise in the Ethernet network.  Ensure that shielded twisted pair Ethernet cables are used to interconnect the master and slave controllers and in any other part of the network that could inject noise.

If this error is generated by a GSB slave, there is probably noise on the RS485 bus.  Verify that the termination jumpers are installed correctly and that the RS485 connectors are firmly seated on all boards, and ensure that shielded twisted pair wire is used for all of the RS485 signals.  View the GSB error statistics to identify what GSB board is experiencing noise.

To minimize noise generation in a custom high voltage robot mechanism, verify that the recommended ferrite beads are installed on all motor power wires and that the communication cables are not routed next to the high voltage signal lines.

If this error is generated by servos on the master controller, or in systems that are not part of a servo network, it indicates that the controller's CPU is overloaded.  If the problem persists, please contact Precise technical support.

-3133

Amplifier fault, DC bus stuck This error is generated if an amplifier is in a fault state and the user tries to re-enable motor power while the DC bus voltage is still not below 18VDC.  If an amplifier fault has occurred, the high power relay to the motor power supply must be disengaged before motor power is re-enabled.

-3134

Encoder data or accel/decel limit error

This error indicates that either invalid position data has been received from a serial encoder or a serial encoder's position reading changed by too large of a value in a very short period of time.  Most often, this means that six or more consecutive "Absolute encoder bad readings" (DataID 12269) or "Absolute encoder communication errors" (DataID 12259) have occurred.  If the controller detects a single error of these types, it will usually automatically correct the error and continue normal operation.

When this error code is generated, the robot must be homed again to re-sample the encoder's full absolute position information.  Also, the encoder may be disabled.  To restart the encoder's operation, use the "Reset" function in the "Absolute Encoder Diagnostics" page of the web interface.

If the mechanism is expected to operate at very high accelerations and decelerations, increase the limit used to detect bad encoder readings by reducing the value defined by the "Min. accel time to 5000 RPM, msec" DataID 10252.

If DataID 10252 is properly set for the expected operation of the axis and the axis is not moving exceeding fast and this problem persists, it typically indicates that there is a hardware problem.  The possible hardware defects (starting with the most likely cause) are:  a poor connection in an encoder cable (please ensure all contacts are high compression with gold plating); a damaged encoder cable; electronic noise in the encoder cable; a defective encoder; a defective controller.

-3135

Phase offset too large The detected amplifier phase offset is too large to be corrected automatically. To perform phase offset correction manually, disable the automatic phase offset adjustment using DataID 10695.

-3136

Excessive movement during phase offset adjustment

Automatic amplifier phase offset correction (DataID 10695) can only be performed on Precise integrated amplifiers and when the motor is not in motion. If this error continues to persist even when the motor is stopped and you have Precise amplifiers, disable this adjustment by setting DataID 10695 to 1 and contact Precise support.

-3137

Amplifier hardware failure or invalid configuration

This error will be reported in the following situations:

  1.    Amplifiers are being enabled and the controller does not have any integrated amplifiers but a Precise amplifier has been specified in the configuration database.   
  2. The motor DC bus voltage is too high or low for the configured Precise amplifiers.  Most likely, this indicates a software configuration error.

-3138

Encoder position not ready

The accuracy of the absolute encoder position data or the single turn position data of a serial encoder is reduced due to excessive rotational speed when the controller is turned on.

For Panasonic and Tamagawa serial encoders, this error is generated when the "Reduced encoder resolution" (bit 1) is set in the "Encoder alarm" field (DataID 12251). See the Panasonic/Tamagawa encoder alarm documentation for more details.

This alarm bit will be reset automatically by the encoder. However it is sometimes necessary to perform a re-initialization to clear the alarm condition.

-3139

Encoder not ready

A serial encoder is not ready to operate. This error is generated in the following situations:

  1. The configuration parameter specifies a serial encoder but the encoder is not physically connected to the controller.
  2. The servo code failed to initialize the serial encoder.
  3. The servo detects the serial encoder model (Panasonic and Tamagawa only), but the model is different from the specified "Encoder type" (DataID 10027).
  4. An attempt was made to enable motor power after a serial encoder communication error (-3140) occurred without re-initialize the encoder.

If a serial encoder is successfully initialized and is operated normally, the "Serial encoder ready" (bit 2) of "Encoder software status word" (DataID 12200) will be set to 1.

-3140

Encoder communication error

The controller hardware has failed to establish communication with a serial encoder or communication was lost after the encoder was initialized. This typically indicates that the FPGA firmware has timed out while waiting for a communication packet from the encoder.  The servo code may also issue an "Encoder not ready" error (-3139) depending upon the failure situation.

In addition to issuing this error, the "Serial encoder communication error" bit (bit 26) of the "Encoder software status word" (DataID 12200) will be set to 1. If the communication error is detected during the normal synchronized operation, the "Serial encoder ready" bit (bit 2) of the status word will be set to 0.

This is a severe error and requires the encoder to be re-initialization and/or power cycled.

-3141

Encoder overheated

A serial encoder has overheated. This error is generated in the following situations.

  1. For a Yaskawa serial encoder, this error is generated when the "Overheat" bit (bit 5) is set in the "Encoder alarm" field (DataID 12251). See the Yaskawa encoder alarm documentation for more details.


This is a severe error and requires the encoder to be re-initialization and/or power cycled.

-3142

Encoder hall sensor error

A serial incremental encoder has detected an error in its hall effect data.

  1. For a Panasonic serial incremental encoder (type 41), this error is generated when the "Count error between phase" bit (bit 4) and/or the "Illegal Hall Data bit (bit 6) is set in the "Encoder alarm" field (DataID 12251).

This is a severe error and requires the encoder to be re-initialization and/or power cycled.

-3143

General serial bus encoder error

This error is generated by some serial encoders that pass back a limited amount of status information while the robot is running.  When this error occurs, it means that an encoder has signaled an error, but no specific information about the nature of the error is known.

It may be possible to obtain more information on the error if you cycle the AC power on the controller.  For example, if this error was due to a low battery voltage condition, cycling AC power and re-homing the robot will generate an "Encoder battery low" (-3127) error.

To reset this error, go to the Absolute Encoder maintenance panel in the Settings section of the controller's web interface.  If the encoder error persists after the encoder is reset, the Operator Control Panel will display the detailed error information.


Currently, this error only occurs with the daisy-chained serial bus Panasonic encoders that are utilized in the Denso line of robots.

-3144

Amplifier overheating

The indicated power amplifier has exceeded its permitted operating temperature. Normally this error is followed by the generic error -1610 "Controller overheating". For amplifiers of the G3xxx or G1xxxA/B controllers (except for the G3x3xA 30A version), the limit is 80C.  For the amplifiers of the G3x3xA 30A version, the limit is 100C. See Amplifier temperature (DataID 12605) for the actual amplifier temperatures. The G2xxx controller power amplifier chips are equipped with internal temperature monitoring to protect the power modules, but they do not have temperature sensors that can be read.

-3145

Motor overheating

The indicated motor has exceeded its permitted operating temperature. Normally this error is followed by the generic error -1610 "Controller overheating". The parameter "Max motor temperature" (DataID 10110) determines the maximum allowed temperature. See "Motor temperature" (DataID 12110) for the actual motor temperature. Motor temperature monitoring is configurable and requires special temperature sensors in the motors and special signal conditioning electronics.

-3146

Earlier encoder error inhibiting power

An attempt to enable motor power failed because a severe encoder error previously occurred.  Consequently, the encoder is not operational and permitting motor power to be enabled could result in the motor being unstable.  Typically, the encoder in question is a serial absolute or incremental type and is either not communicating properly or must be reset.  Please go to the following web page to view the serial encoder status and to clear any error conditions:  Setup > Hardware Tuning and Diagnostics > Absolute Encoder.

-3147

Abnormal envelope error

This error indicates a more severe instance of the condition signaled by the "Hard envelope error" (-3100).  Like the "Hard" error, this error indicates that there was a significant difference betortween an axis' commanded position and its actual position.  And, like the "Hard" error, this error is generated when the value of the "Position tracking error, mcnt" (DataID 12320) for an axis exceeds its "Hard envelope error limit, mcnt" (DataID 10303) for a sufficient period of time.


However, the "Abnormal" error is generated in place of the "Hard" error when the command velocity is lower than 33% of the Manual mode speed limit (DataID 10209). So, the "Abnormal" error indicates that a significant position error occurred when an axis was not supposed to be moving fast.  This error normally indicates a collision occurred when the robot was moving at a slow speed or one of the following motor configuration parameters are incorrect.

  • Encoder sign (DataID 10202)
  • Torque sign (DataID 10609)
  • Commutation sign (DataID 10650)
  • Hard envelope error (DataID 10303)
  • Commutation offset (DataID 10775)
  • Commutation position at zero index (16653)

-3148

Encoder hardware related warning

This indicates that an internal encoder warning bit is ON. Currently this warning is only reported by BiSS encoders. Please consult the documentation for the specific encoder model to determine the nature of the error.

This is only a warning message. This error will not stop program execution or turn Off robot/motor power.

-3149

Velocity restrict limit exceeded

(CAT-3, GPL 4.2 or later) The low-level control that advances the commutation angle for a BLDC motor has detected that the motor is attempting to turn faster than the Run-time or Manual mode speed limits (DataIDs 10208/10209) permit. The motor is immediately shut down and an error is signaled.

Since a BLDC motor cannot generate torque if the commutation angle is not properly set and cannot rotate unless the commutation angle is properly advanced, this check provides a low level independent test to ensure that a motor is not rotating faster than permitted. This is sometimes referred to as an independent "Velocity Restrict" test.

This error will only be reported in controllers with FPGA firmware that supports CAT-3 safety capability, and the CAT-3 safety feature is enabled in software.

This error may indicate that:

  • DataIDs 10208/10209 are set too low
  • An application program is trying to drive the motor faster than allowed
  • An encoder read error has occurred due to noise on the encoder lines or bad data has been sent by an encoder. For non-CAT-3 systems, these types of errors typically generate "Encoder data or accel/decel limit errors" (-3134) or "Encoder operation errors" (-3126) or "Encoder communication errors" (-3140).
  • A system hardware failure or a system software error has occurred that attempted to drive the motor faster than allowed.

-3150

Position compare not enabled

 

-3151

Position compare memory allocation failed

 

-3152

Position compare buffer empty

 

-3153

Failed to start position compare task

 

-3154

Position compare buffer full

 

-3155

Invalid DOUT for position compare

 

-3156

Motor moving away from compare position

 

-3157

Position compare internal inconsistence error

 

-3160

Dump circuit duty cycle exceeded

The motor power dump circuit has been turn on too long. The dump circuit has been switched off to avoid overheating the dump resistor.

NOTE: If you load GPL versions 4.1J1 and later or 4.2E and later into a PreciseFlex™400 Rev B or earlier robot, this error may be erroneously generated. If this occurs, loading GPL 4.2H or later will properly detect the dump board in the robot and eliminate this error.

-3161

No position updated in Fpga