5 Troubleshooting

This chapter explains troubleshooting of the robot.

Contents

5.1 Diagnostics................................................................................................................................ 5-2

5.2 Determining cause of malfunction.......................................................................................... 5-4
5.3 Diagnostic and resolution for major part failures ................................................................. 5-5
5.3.1 Fulcrum bearing ................................................................................................................. 5-5
5.3.2 Reduction gear ................................................................................................................... 5-5
5.3.3 Brakes ................................................................................................................................. 5-6
5.3.4 Motor ................................................................................................................................... 5-7
5.3.5 Encoder ............................................................................................................................... 5-7
5.4 Motor replacement.................................................................................................................... 5-8
5.4.1 Main axes motor replacement......................................................................................... 5-10
5.4.2 Wrist axes motor replacement ....................................................................................... 5-13
5.5 Encoder zero adjustment ....................................................................................................... 5-15
5.5.1 Encoder zero adjustment of the main axes ................................................................... 5-15
5.5.2 Encoder zero adjustment of the wrist axes ................................................................... 5-18
5.5.3 Encoder reset ................................................................................................................... 5-20
5.5.4 Encoder compensation.................................................................................................... 5-22

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5.1 Diagnostics
Robot failure

The robot system is of such design that the robot stops immediately when abnormality is detected.
However, if a an abnormality is observed the robot should be immediately emergency stopped.

◇
! WARNING
Abnormalities(errors) of the robot include:

1. Abnormalities disabling the robot from operation until abnormality is corrected.

2. Abnormalities leaving robot operation enabled for a while after the abnormality occurs.
3. Abnormalities leaving robot operation enabled if controller power is cycled(off/on).
4. Abnormalities leaving robot operation enabled even though abnormality is present.
5. Abnormalities causing abnormal robot behavior due to errors in a factory system (not robot).
6. Abnormalities causing abnormal system behavior due to errors in a robot system.

There are numerous other abnormalities in addition to those above. Abnormality will be expected to
repeat in the case of 2, 3 and 4. Root cause of abnormalities many be very difficult to determine, even
by a skillful engineer, particularly in complicated systems.

◎ MANDATORY
Stop robot operation if any abnormality is observed and immediately report the
problem to a supervisor or maintenance department with the required
training(skills) to troubleshoot and repair NACHI robots. Shutdown and
reporting procedure should be specified in a work code, and a system to
ensure implementation of this procedure should be established.

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 In order to quickly restore a robot to a normal operating condition, it is necessary to diagnose the
problem and determine if the cause is electrical or mechanical. After determination of the problem type
it is necessary to determine the part, or parts, responsible for the malfunction and replace them.

Step 1: Locate the problem

In most cases an error code will be generated and displayed on the LCD that will indicate the
cause of a malfunction. In the event that the Troubleshooting guide given for a particular error does
not resolve a problem, check the following possible mechanical faults..

∗ Abnormal sound generated from a given robot manipulator section or component.

∗ Abnormal temperature of a given robot manipulator section or component.
∗ Abnormal play or backlash in a given axis.

Step 2: Evaluate correction method

After location of a problem it will be necessary to determine the part or parts required to effect
repairs. Refer to table 5.2 for a list of potential malfunctions and probable major components that
may be related to the problem. It is important to note that additional components associated with a
malfunction may need replacement when some major mechanical components are replaced.
Example: In some cases failed bearings may cause the failure of a larger component. If the failed
bearing is not replaced when the major component is replaced, the major component may fail again
soon after replacement.

Step 3: Repair the problem

After determining and acquiring necessary parts and tools required, refer to Table 5.2,
determine then conduct the relevant repair procedure. It is recommended that NACHI engineering
department be contacted if a user is not experienced or confident replacing a robot part. NACHI
may be able to either provide a procedure for replacement or provide skilled NACHI technicians for
repair work.

Note: Follow procedures given in chapter 3 “Troubleshooting” in the AW

Controller maintenance manual prior to checking for mechanical
problems.
The majority of failures can be resolved by following the simple steps
given by an error code.

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5.2 Determining Cause of Malfunction
There are cases where a malfunction may be caused by one(or more) of a number of parts.
Refer to Table 5.2.
Refer to section 5.3 to determine a major defective component. Contact NACHI Engineering
department for recommendations on associated parts which should also be replaced.
Table 5.2 Trouble phenomena and causes
Defect parts Reduction Fulcrum
Brake Motor Encoder
Trouble phenomenon gear bearing
Overload [note 1] ○ ○ ○ ○
Displacement ○ ○ ○
Abnormal sound occurrence ○ ○ ○ ○
Shuddering in operation [note 2] ○ ○
Staggering at stop [note 3] ○ ○ ○
Irregular twitching [note 4] ○ ○ ○
Abnormal deviation ○ ○
Free fall of an axis ○ ○
Overheating ○ ○ ○
Incorrect action and out-of-control movement ○ ○

Note 1: Phenomenon which occurs when a load exceeds rated motor load. Thermal relay or circuit
protector are tripped.
Note 2: Phenomenon which gives vibration in one or more axis.
Note 3: Phenomenon which gives oscillating motion when the robot stops.
Note 4: Phenomenon which gives sporadic twitching when the robot is not in motion.

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5.3 Diagnostics and Resolution for Major Part Failures
5.3.1 Fulcrum Bearing

Vibration, abnormal sound, and overloads are observed when a fulcrum bearing is damaged. Note
that when bolts holding bearings become loose bearing play occurs. That play may damage the
bearings.

1. Diagnostics
∗ Shake the forearm and the upperarm back and forth by hand to check if bearings exhibit any
play. (If possible use a chain hoist to hold the forearm and upperarm off the reduction gears to
check for play in the bearings. )
∗ Check to see if the robot collided with surrounding equipment.

2. Resolution
∗ Replace the bearing(s). A chain hoist or similar type of equipment is necessary to lift the
robot arm. Contact NACHI service section in the case of difficulties.

5.3.2 Reduction gear

Vibration and abnormal sound will be observed when a reduction gear is damaged. Normal
operation is inhibited and an overload or abnormal deviation error occurs. In addition overheating
may result.
(The robot may also become completely inoperable or a position offset error may occur.)

(a) Main Axes (S, H, V)

Ensure arms are supported before switching on the H or V axis brake

△
! CAUTION
release switches.
The robot arm will fall due to gravity if unsupported..

1. Diagnostics
∗ Check to see if vibration, abnormal sound or overheating of the reduction gear occurs when
the robot is in operation.
∗ Check to see if there is play or looseness in the reduction gear by switching on the S axis
brake release switch and shaking the robot forearm back and forth by hand to see if any
abnormalities can be felt.
∗ Check if the robot has hit any of the surrounding equipment, before problems occur.
(Damage can occur to the reduction gear due to shock of crashes. )

2. Resolution
∗ Replace the reduction gear. A chain hoist or similar type of equipment is necessary to
support/carry the robot arm. Contact NACHI service section in the case of difficulties.

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(b) Wrist Axes (R2, B, R1)

Use extreme caution when switching on the wrist axes brake release

△
! CAUTION
switches. Arm will fall under gravity when brake is released.
Support arm before switching brake release switches.

1. Diagnostics
∗ Check to see if vibration, abnormal sound or overheating of the reduction gear is present when
the robot is in operation.
∗ Shake the end-effector (tool, spot gun, gripper hand, etc.) back and forth to see if there is play
in any reduction gear.
∗ Turn Motors OFF and switch a wrist axis brake release switch and check that the axis can be
rotated by hand. If it doesn't the reduction gear is possibly faulty.
(Use extreme caution when switching on the H or V axis brake release switches. Note that the
arm will drop under gravity if not supported.)
∗ Check if the robot has hit any of the surrounding equipment, before problems occur.
(Damage can occur to the reduction gear due to shock of crashes. )

2. Resolution
∗ Replace the reduction gear. A chain hoist or similar type of equipment may be necessary to
support/carry the robot wrist. Contact NACHI service section in the case of difficulties.
∗ or Replace the entire wrist section.
(System recovery will be resumed much quicker by changing the entire wrist assembly. The
wrist can be overhauled and become backup stock.)

5.3.3 Brakes

Two main fault modes exist for the brakes. (a) an axis moves(drops) in the MOTORS OFF state and
(b) the brake does not disengage during the MOTORS ON (motion) state. The latter causes overloads
and noise.

To move robot arm in MOTORS OFF state switch on brake release

△
! CAUTION
switch to release the motor brake.
Use extreme caution when switching on the wrist axes brake release
switches. Arm will fall under gravity when brake is released.
Support arm before switching brake release switches.

1. Diagnostics
∗ Check if the brake can be heard operating by switching the brake release switch on and off
while in MOTORS OFF state. If brake operation can not be heard, the brake cable may be
broken. (Brake release switches are located on the right side of the UM837 circuit board on
controller door.)(Use extreme caution when switching on the H or V axis brake release
switches. Note that the arm will drop under gravity if not supported.)

2. Resolution
∗ If motor cables are found to be good, replace respective motor. Refer to Section 5.4, “Motor
Replacement.”

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5.3.4 Motor
Motor problems cause abnormal robot actions (such as staggering at stop, irregular twitching, and
shuddering in operation). Motor problems may also cause overheating or abnormal sounds. Because
motor problem and damaged reduction gear characteristics are similar, it is difficult to easily tell which
is component is causing the problem. Check also the related reduction gear and fulcrum bearing while
investigation motor problems.

1. Diagnostics
∗ Check for overheating and abnormal sounds.

2. Resolution
∗ Replace the motor Refer to Section 5.4, “Motor Replacement.”

5.3.5 Encoder

Position offset, incorrect action and out of-control movement may occur when an encoder is faulty.
Staggering at stop and irregular twitching may also occur. Encoder problems rarely cause abnormal
mechanical sounds, overheating or vibrations.

1. Diagnostics
∗ Check for problems with the encoder data.
∗ Use positioning pins and blocks to check that positional data is correct at pin position.
∗ Check that no irregular variations are present in encoder data (bits) when moving each robot
axis.
∗ When possible transfer servo amp RBX1100 into a similar type robot, if problem follows board
then RBX1100 is faulty. Refer to AW controller Maintenance manual, Sect. 3.2, for RBX1100
exchange.

2. Resolution
∗ Check for broken or damaged cabling. If cabling is found to be good, replace the motor.
Refer to Section 5.4, “Motor Replacement.”
∗ If the problems followed the servo amp RBX1100, replace the board. Refer to Sect
Replacement of a drive unit (Servo Amp Replacement) in the AW Controller Maintenance
manual.

3. Caution on the encoders

When an encoder has not received a 5V DC (±5%) for more than 1 hour, due to flat
encoder batteries or disconnection, encoder data is lost and the encoder will not work correctly.
An abnormal encoder circuit condition is detected when turning controller power on. When
abnormal encoder circuit condition has been detected, encoders must be reset.

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5.4 Motor Replacement

Robot motors have built-in brakes to hold the robot arm in position

△
! CAUTION
when motors are OFF. Therefore, when a motor is removed a robot
arm will drop. Support the arm with positioning pins or a crane before
removing a motor to prevent the arm from dropping.
Ensure the motors are not hot before touching and handling them.
Motors may be very hot just after stopping robot.
Take care when lifting a motor . Motor weights are listed below.

Mass of motor
Robot model
S and V axes H axis R2, B and R1
axes

【SH133-01】 【SH166-01】
24.3 kg 24.3 kg 11.0 kg
【SH133T-01】【SH166T-01】

【SH200-01】【SH200T-01】 24.3 kg 27.0 kg 11.0 kg

Moving robot to pin(reference) position requires close contact with

△
! CAUTION
robot with MOTORS ON. Therefore, perform pinning in pairs. An
observer must always be ready to give an emergency stop. The person
pinning the robot must work within the robot operating area carefully
but swiftly.
An escape route should be determined before starting pinning work.
Ensure the positioning pins have been removed before operating the
robot after replacing a motor. Pin or the reference hole may be
damaged if pin is forgotten. If the reference hole is damaged future
reference alignment will not be possible.

1. Necessary tools
Table 5.4-1 Necessary tools
Robot
Parts name Axis name Parts no. (Model) Note
mode
Torque wrench S, H and V axes M12 torque wrench (long type L = more than 280) All model ∗1,∗2
(Prepared by User) R2, B and R1 axes M8 torque wrench (long type L = more than 280) All model ∗1,∗3

∗1 Use long wrench or extension. (Refer to Fig. 5.4. )

∗2 Main axes motor replacement.
∗3 Wrist axes motor replacement and attachment of
positioning blocks.

Fig. 5.4 Torque wrench

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 2. Necessary parts
Robot model: [1]…
…【SH133-01】 】【SH133T-01】
】【SH166-01】 】【SH166T-01】
】
[2]… 】【SH200T-01】
…【SH200-01】 】
Table 5.4-2 Necessary parts
Robot
Parts name Axis name Punch letter Parts no. (Model) Note
model
017-0153-000
S, H and V axes All model
Positioning pin Hex. socket head cap screw M10×200
(Option) Parallel pin(female screw)φ13h7×50
R2, B and R1 axes All model
Hex. socket head cap screw M8×120
R2-axis fixed sideSF133 R2 029-0212-000 All model
SH133 R2 529-0027-001 [1]
R2-axis moving side
SH200 R2 529-0030-001 [2]
Positioning block
B-axis moving side SF133 B 029-0214-000 All model
(Option)
R1-axis fixed side SF133 R1 029-0215-000 All model
SF133 R1 029-0216-000 [1]
R1-axis moving side
SH200 R1 529-0031-001 [2]
R2-axis fixed side Hex. socket head cap screw M8×40(2 bolts) All model
Hex. socket head cap screw M8×80(2 bolts) [1]
R2-axis moving side
Bolt Hex. socket head cap screw M8×70(2 bolts) [2]
[strength class11T] Hex. socket head cap screw M8×40(2 bolts)
& B-axis moving side
Plain washer M8[class 1] (2 washers)
All model ∗1
Washer
(Option) R1-axis fixed side Hex. socket head cap screw M8×45(2 bolts) All model
Hex. socket head cap screw M8×55(2 bolts) [1]
R1-axis moving side
Hex. socket head cap screw M8×35(2 bolts) [2]
∗1 Recommended fastening torque 33.3 N⋅m

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5.4.1 Main Axes Motor Replacement

1) Put the controller into TEACH mode and select MOTORS ON.
When MOTORS ON status can not be obtained due an abnormality, support the
respective arm so it can not fall and begin at step no. 3.
2) Move axis requiring motor replacement to the reference position and insert positioning
pins. (Refer to Fig. 5.5.1-1 or Fig. 5.5.1-2)
(NOTE: If the robot is not in pin position the stored energy in the counterbalance may
violently move the robot arm when a H-axis motor is removed)
3) Turn controller power OFF. Turn mains power off.
4) Disconnect the cannon connector from the motor(s).
5) Remove the motor attachment bolts (4-M12×30) and pull out the motor from the robot.
Refer to Fig 5.4.1-1 or Fig. 5.4.1-2for bolt location.
Take care not to damage the lip of the motor shaft oil seal when removing a motor.
(NOTE: If the robot is not in pin position the stored energy in the counterbalance may
violently move the robot arm when a H-axis motor is removed)
6) Remove the spur gear from the motor shaft. Do not to apply excessive impact to the motor
shaft. Refer to Fig 5.4.1-3.
7) Fit the gear on the replacement motor after lightly applying grease. (Optimal Longtime
PD2) to the shaft. Then tighten the 6-M5x25 bolts gradually & uniformly to 9.8 N･m using a
torque wrench.
8) (NOTE: Move axes to pin position if it was not performed above.)
9) Apply (Optimal Longtime PD2) between the gear teeth and mount the motor on the robot.
Fasten the 4-M12×30 bolts to 116 N･m using a torque wrench.
Take care that the motor shaft gear oil seal is not damaged when mounting main motors.
10) Connect the cannon connector to the motor.
11) During the replacement of V and H axis motors grease can be lost. Estimate amount of
grease lost during replacement procedure and replenishment. Refer to sect. 4.1
12) Perform Encoder reset procedure in Section 5.5.3, “Encoder Reset”.
Check motor connections before moving robot to perform Encoder
correction. Select teach mode, turn MOTORS ON and grasp deadman
ATTENTION switch for 2-3 seconds. Check that MOTORS ON lamp was continuously
lit while the deadman was held in. Correct any poor connections.

13) Perform Encoder correction. Refer to “Encoder Correction” in the AW Controller

Reference manual.
(NOTE: Axis must be moved to pin position if the robot was not at pin position when
changing the motor.)
14) Remove the positioning pin. Move the axis slightly in Low speed 2 or 3 free pin if it is stuck.
S-axis: Remove the positioning block and reattach slot cover.
15) Confirm that the robot operates as it should and that no errors are observed.

Note) 1 [ N･m ] = 1 / 9.8 [ kgf･m ]

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 Robot model:【
【SH133-01】 】【SH200-01】
】【SH166-01】 】

Fig. 5.4.1-1 Main axes motor attachment bolt

Robot model:【
【SH133T-01】 】【SH200T-01】
】【SH166T-01】 】

Fig. 5.4.1-2 Main axes motor attachment bolt

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 Robot model:【
【SH133-01】 】【SH200-01】
】【SH166-01】 】
Robot model:【
【SH133T-01】 】【SH200T-01】
】【SH166T-01】 】

Fig. 5.4.1-3 Section of gear assembly (main axes motor)

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5.4.2 Wrist Axes Motor Replacement

Wrist axes(R1, B, R2) are mechanically linked due to the wrist design and the position of one
affects another(position of R2 & B affects R1 and position of R2 affects B). Therefore, place all wrist
axes at reference position when exchanging a wrist axis motor.

1) Remove covers covering positioning block attachment points. (Refer to Fig.5.5.2-1 and
Fig.5.5.2-2)
2) Mount the wrist positioning blocks with two M8 bolts.
(Length of bolt differs between robots and axes: Refer to Table 5.4-2)
3) Put the controller into TEACH mode and select MOTORS ON.
When MOTORS ON status can not be obtained due an abnormality, support the
respective axis (tool) so it can not fall and begin at step no. 5.
4) Move all wrist axes to reference position and insert positioning pins.
(Refer to Fig.5.5.2-1and Fig.5.5.2-2)
5) Turn controller power OFF. Turn mains power off.
6) Disconnect the cannon connector from the motor(s).
7) Unbolt motor 3- M8×40mm bolts and pull out the motor/gear from the robot.
Refer to Fig 5.4.2-1 for location of wrist motor bolts.
8) Remove the gear-assy from the motor shaft. Do not to apply excessive impact to the
motor shaft. (Refer to Fig.5.4.2-2 and Fig.5.4.2-3)
a) Remove gear (4-M5x20 bolts) and tap off the motor case.
b) Remove circlip(snap ring), tap off bearing and remove second circlip.
(unless short allen-key is available for the next step)
c) Unbolt the 6-M5x25 bolts and remove ring from the motor shaft.
9) Lightly apply grease(Optimal Longtime PD2) to new motor shaft and fit gear assembly.
a) Fit power lock onto shaft. (6-M4x25 bolts: 4.9 Nm).
b) Attach circlip, fit bearing and attach second circlip.
c) Slide on Motor case housing. (Ensure O-ring is fitted)
d) Bolt gear to gear shaft (6-M5x20 bolts: 9.8Nm)
10) (NOTE: Move axes to pin position if it was not performed above.)
11) Apply grease(Optimal Longtime PD2) between the gear teeth and mount motor to the
robot taking care not to damage the gear teeth.
Fasten the 3-M8×40 bolts to 33.3 N･m using a torque wrench.
12) Connect the cannon connector to the motor.
13) Perform Encoder reset procedure in Section 5.5.3, “Encoder Reset”.

Check motor connections before moving robot to perform Encoder

correction. Select teach mode, turn MOTORS ON and grasp deadman
ATTENTION switch for 2-3 seconds. Check that MOTORS ON lamp was continuously
lit while the deadman was held in. Correct any poor connections.

14) Perform Encoder correction. Refer to “Encoder Correction” in the AW Controller

Reference manual. (NOTE: Axis must be moved to pin position if the robot was not at pin
position when changing the motor.
15) Remove the positioning pin. Move the axis slightly in Low speed 2 or 3 free pin if it is
stuck.
16) Remove positioning block(s) from wrist and attach cover(s).
17) Confirm that the robot operates as it should and that no errors are observed.

Note) 1 [ N･m ] = 1 / 9.8 [ kgf･m ]

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 Fig. 5.4.2-1 Wrist axes motor attachment bolt

Fig. 5.4.2-2 Section of gear assembly (R2 and B axes motor)

Fig. 5.4.2-3 Section of gear assembly (R1 axis motor)

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5.5 Encoder Zero Adjustment
When encoder data has been corrupted due to some problem or motor replacement it is necessary
to reset an encoder and compensate for any offset between actual encoder position and pin(reference)
position.
Positioning pins and blocks must be used to obtain pin position.
Wrist axes(R1, B, R2) are mechanically linked due to the wrist design and the position of one
affects another(position of R2 & B affects R1 and position of R2 affects B). Therefore, place all wrist
axes at reference position when performing wrist encoder zero adjustment.

Moving robot to pin(reference) position requires close contact with

△
! CAUTION
robot with MOTORS ON. Therefore, perform pinning in pairs. An
observer must always be ready to give an emergency stop. The person
pinning the robot must work within the robot operating area carefully
but swiftly.
An escape route should be determined before starting pinning work.
Ensure the positioning pins have been removed before operating the
robot after replacing a motor. Pin or the reference hole may be
damaged if pin is forgotten. If the reference hole is damaged future
reference alignment will not be possible.

5.5.1 Encoder Zero Adjustment of the Main Axes

1. Obtain the reference (pin) positions.
a) Put the controller into TEACH mode and select MOTORS ON
b) Remove cap.(S-axis)
c) Move axis requiring encoder zero adjustment to the reference position.
Use low speed 2 for fine adjustment.
Insert positioning pin. (Refer to Fig. 5.5.1-1or Fig. 5.5.1-2)
(Note: Never attempt to move robot with a positioning pin in place.)

2. Encoder reset
Refer to Section 5.5.3, “Encoder Reset,” to reset encoders.

3. Software Encoder value correction

To compensate for the offset between pin position and actual encoder reset position the
Encoder Correction facility is available in robot software.
Refer to “Encoder Correction,” in the AW Controller Reference manual.

4. Confirm adjustment is correct

a) Remove positioning pins. Move an axis slightly in Low speed 2 or 3 to free the pin if it is stuck.
b) Reattach cap. (S-axis)
c) Confirm that the robot operates as it should and that no errors are observed.

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 Robot model:【
【SH133-01】 】【SH200-01】
】【SH166-01】 】

Fig 5.5.1-1 Locations for the main axis positioning pin holes

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 Robot model:【
【SH133T-01】 】【SH200T-01】
】【SH166T-01】 】

Fig 5.5.1-2 Locations for the main axis positioning pin holes

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5.5.2 Encoder Zero Adjustment of the Wrist Axes

1. Obtain the reference (pin) positions.

a) Remove covers covering positioning block attachment points.
(Refer to Fig. 5.5.2-1 and Fig. 5.5.2-2)
b) Mount the wrist positioning blocks with two M8 bolts.
(Length of bolt differs between robots and axes: Refer to Table 5.4-2)
c) Put the controller into TEACH mode and select MOTORS ON.
d) Move all wrist axes to reference position and insert positioning pins.
(Note: Never attempt to move robot with a positioning pin in place.)

2. Encoder reset
Refer to Section 5.5.3, “Encoder Reset,” to reset encoders.

3. Software Encoder value correction

To compensate for the offset between pin position and actual encoder reset position the
Encoder Correction facility is available in robot software.
Refer to “Encoder Correction,” in the AW Controller Reference manual.

4. Confirm adjustment is correct

a) Remove positioning pins. Move an axis slightly in Low speed 2 or 3 to free the pin if it is
stuck.
b) Remove any positioning blocks and reattach covers.
c) Confirm that the robot operates as it should and that no errors are observed.

Robot Model：
：【SH133-01】
】【SH166-01】
】【SH133T-01】
】【SH166T-01】
】

Fig 5.5.2-1 Insertion locations for the wrist axis positioning pins

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Robot Model：
：【SH200-01】
】【SH200T-01】
】

Fig 5.5.2-2 Insertion locations for the wrist axis positioning pins

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5.5.3 Encoder Reset
1. Reset Procedure (For encoder zero adjustment. Assuming pin position.)
1) Turn controller on, and wait for more than 3 minutes.
If error occurs see Notes 1 on next page.
2) With MOTORS OFF state actuate Emergency stop to ensure safety.
3) Remove the battery unit attachment bolts(4-M6x15), and pull out battery unit in BJ1 BOX.
(Refer to Fig. 5.5.3-1)
4) Check the batteries are all well connected.
5) Turn reset switch of axes requiring encoder reset on.(Refer to Table.5.5.3-1 and Fig.5.5.3-2)
Wait 10 to 15 seconds and turn off reset switch. Repeat for other axes if necessary.
(Note: Turn off reset switch certainly after encoder reset.)
6) Turn off controller.
7) After check all reset switches to keep Normal Position shown in Fig.5.5.3-2, confirm the
encoder reset data as explained in “2. Confirming the reset” below.
8) Mount battery unit on BJ1 BOX. (4-M6x15 bolts)
9) Check motor connections before moving robot to perform Encoder correction. Select teach
mode, turn MOTORS ON and grasp deadman switch for 2-3 seconds. Check that MOTORS
ON lamp was continuously lit while the deadman was held in. Correct any poor connections.
10)Return to “Software Encoder value correction” in “5.5 Encoder zero adjusting procedure.”
Table 5.5.3-1 Reset switch numbers corresponding to axes
Axis Reset switch number
S 1
H 2
V 3
R2 4
B 5
R1 6

Fig. 5.5.3-1 Buttery unit

Fig. 5.5.3-2 Buttery connect P.C.B

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 Note 1: E0050 --- Occurrence of an encoder counter overflow or underflow
E0052 --- Encoder batteries abnormal condition and possibility of abnormal
encoder data

The above errors occur if the motor encoder capacitors have not been charged.
Leave controller power on for 5min or more.
Turn controller off then turn controller on again. If error continues check wiring.

2. Confirming the reset

This operation is used to verify an encoder reset was performed

△
! CAUTION
correctly.
Note this procedure is not “Encoder Correction” that compensates for
the difference between reset position and pin(reference) position.

The “Present Encoder Value” displayed on the LCD screen(below) is the raw(actual) encoder
data value plus the “Encoder Compensation Value”.
Raw encoder data values should be less than one revolution from the absolute zero position
of the encoder immediately after the resetting an encoder. Follow the procedure below to
confirm that the encoder has indeed been reset. Note that the number of pulses per one
encoder revolution depends on robot model.

1) Controller should be off. All positioning pins must be out.

2) Confirm that the all reset switches on the battery connect P.C.D have kept Normal Position
shown in Fig.5.5.3-2.
3) Turn controller power on.

Check motor connections before moving robot to perform Encoder

correction. Select teach mode, turn MOTORS ON and grasp deadman
ATTENTION switch for 2-3 seconds. Check that MOTORS ON lamp was
continuously lit while the deadman was held in. Correct any poor
connections.

4) Turn motors OFF and select [Constant] [Machine constants] [Encoder correction].
The encoder compensation value for each axis is displayed in most left-hand column and the
present encoder value in the center column. Refer to Fig 5.5.3-3
5) Move the cursor to the encoder compensation value of the axes that were Reset and press
“0”(zero) then “SET”. (Encoder value is now corrected)
6) Select [Complete] with “f12” key. (corrections are saved)
7) Check that the present encoder value is now within the “data range after reset” shown
in Table 5.5.3-2. If the present encoder value is not within that range the encoder has not
been reset, then reset the encoder again.

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 ↑ ↑
Encoder Present Encoder Value
Compensation Value

Fig. 5.5.3-3 Encoder Compensation

Table 5.5.3-2 Data range after resetting

Axis Data range after reset No. of pulses per encoder one evolution
All axes 0 to 2047 2048

5.5.4 Encoder Compensation

Check motor connections before moving robot to perform Encoder

correction. Select teach mode, turn MOTORS ON and grasp deadman
ATTENTION switch for 2-3 seconds. Check that MOTORS ON lamp was
continuously lit while the deadman was held in. Correct any poor
connections.

Encoder Correction compensates for the offset between the actual encoder position and pin
position (position when positioning pins are inserted).
Refer to “Encoder Correction” in the AW Controller Reference manual for details.

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