20. Appendix

20.1. Appendix 1: Motion controller errors and handling methods

Main Fault Code	Sub Fault Code	Description
0-No Fault	0	No fault
1-Command Point Error	1	Joint command point error, resettable
1-Command Point Error	2	Linear target point error (including tool mismatch), resettable
1-Command Point Error	3	Arc intermediate point error (including tool mismatch), resettable
1-Command Point Error	4	Arc target point error (including tool mismatch), resettable
1-Command Point Error	5	Arc command points too close, resettable
1-Command Point Error	6	Full circle/helix intermediate point 1 error (including tool mismatch), resettable
1-Command Point Error	7	Full circle/helix intermediate point 2 error (including tool mismatch), resettable
1-Command Point Error	8	Full circle/helix intermediate point 3 error (including tool mismatch), resettable
1-Command Point Error	9	Full circle/helix command points too close, resettable
1-Command Point Error	10	TPD command point error, resettable
1-Command Point Error	11	TPD command tool does not match current tool, resettable
1-Command Point Error	12	TPD current command and next command start point deviation too large, resettable
1-Command Point Error	13	Internal/external tool switching error, resettable
1-Command Point Error	14	New helix start point error, resettable
1-Command Point Error	15	New spline command point error, resettable
1-Command Point Error	17	PTP joint command limit exceeded, resettable
1-Command Point Error	18	TPD joint command limit exceeded, resettable
1-Command Point Error	19	LIN/ARC joint command limit exceeded, resettable
1-Command Point Error	20	Cartesian space command overspeed, not resettable
1-Command Point Error	21	Joint space torque command limit exceeded, resettable
1-Command Point Error	22	JOG joint command limit exceeded, resettable
1-Command Point Error	23	Axis 1 joint space command speed limit exceeded, resettable
1-Command Point Error	24	Axis 2 joint space command speed limit exceeded, resettable
1-Command Point Error	25	Axis 3 joint space command speed limit exceeded, resettable
1-Command Point Error	26	Axis 4 joint space command speed limit exceeded, resettable
1-Command Point Error	27	Axis 5 joint space command speed limit exceeded, resettable
1-Command Point Error	28	Axis 6 joint space command speed limit exceeded, resettable
1-Command Point Error	29	Joint feedback speed limit exceeded, not resettable
1-Command Point Error	30	Joint command and feedback deviation too large, not resettable, requires restart
1-Command Point Error	31	DMP target point error (including tool mismatch), resettable
1-Command Point Error	33	Next command joint configuration changed (next command has singular pose, use PTP command or change next point), resettable
1-Command Point Error	34	Current command joint configuration changed (next command has singular pose, use PTP command or change next point), resettable
1-Command Point Error	35	LIN command joint speed limit exceeded, resettable
1-Command Point Error	36	LIN command adaptive speed exceeds threshold, resettable
1-Command Point Error	37	Unreachable point in trajectory, resettable
1-Command Point Error	38	Unreachable point in trajectory - singular pose, resettable
1-Command Point Error	49	Command error, only LIN and ARC commands allowed between ARCSTART and ARCEND, resettable
1-Command Point Error	50	Command error, only LIN and ARC commands allowed between WEAVESTART and WEAVEEND, resettable
1-Command Point Error	51	Weaving parameter error, resettable
1-Command Point Error	52	Weaving command points too close, resettable
1-Command Point Error	53	Unreachable point in weaving trajectory - singular pose, resettable
1-Command Point Error	54	Unreachable point in weaving trajectory - joint command limit exceeded, resettable
1-Command Point Error	55	Unreachable point in weaving trajectory - planning anomaly (tool z coincides with forward direction x angle), resettable
1-Command Point Error	56	Unreachable point in weaving trajectory - planning anomaly (arc waypoint error), resettable
1-Command Point Error	65	Laser sensor command deviation too large, resettable
1-Command Point Error	66	Laser sensor command interrupted, seam tracking ended early, resettable
1-Command Point Error	81	External axis command speed limit exceeded, resettable
1-Command Point Error	82	External axis command and feedback deviation too large, not resettable, requires homing or restart
1-Command Point Error	83	Extended peripheral (external axis/IO) communication error, resettable
1-Command Point Error	84	Extended peripheral (external axis/IO) communication packet loss error, resettable
1-Command Point Error	97	Conveyor tracking - start point and reference point pose change too large, resettable
1-Command Point Error	113	Constant force control - X direction exceeds max adjustment distance, resettable
1-Command Point Error	114	Constant force control - Y direction exceeds max adjustment distance, resettable
1-Command Point Error	115	Constant force control - Z direction exceeds max adjustment distance, resettable
1-Command Point Error	116	Constant force control - RX direction exceeds max adjustment angle, resettable
1-Command Point Error	117	Constant force control - RY direction exceeds max adjustment angle, resettable
1-Command Point Error	118	Constant force control - RZ direction exceeds max adjustment angle, resettable
1-Command Point Error	119	External sensor data error, resettable
1-Command Point Error	120	Helix exploration motion failed, resettable
1-Command Point Error	121	Rotational insertion motion failed, resettable
1-Command Point Error	122	Linear insertion motion failed, resettable
1-Command Point Error	123	Surface positioning motion failed, resettable
1-Command Point Error	129	Exceeded max torque record points, resettable
1-Command Point Error	130	Speed switching error, resettable
1-Command Point Error	147	Focus following error, resettable
1-Command Point Error	148	Attitude speed limit exceeded, resettable
1-Command Point Error	149	Joint status word feedback abnormal, resettable
2-Drive Fault	1	Axis 1 drive fault, not resettable
2-Drive Fault	2	Axis 2 drive fault, not resettable
2-Drive Fault	3	Axis 3 drive fault, not resettable
2-Drive Fault	4	Axis 4 drive fault, not resettable
2-Drive Fault	5	Axis 5 drive fault, not resettable
2-Drive Fault	6	Axis 6 drive fault, not resettable
3-Soft Limit Exceeded	1	Axis 1 soft limit exceeded, resettable
3-Soft Limit Exceeded	2	Axis 2 soft limit exceeded, resettable
3-Soft Limit Exceeded	3	Axis 3 soft limit exceeded, resettable
3-Soft Limit Exceeded	4	Axis 4 soft limit exceeded, resettable
3-Soft Limit Exceeded	5	Axis 5 soft limit exceeded, resettable
3-Soft Limit Exceeded	6	Axis 6 soft limit exceeded, resettable
4-Collision Fault	1	Axis 1 collision fault, resettable
4-Collision Fault	2	Axis 2 collision fault, resettable
4-Collision Fault	3	Axis 3 collision fault, resettable
4-Collision Fault	4	Axis 4 collision fault, resettable
4-Collision Fault	5	Axis 5 collision fault, resettable
4-Collision Fault	6	Axis 6 collision fault, resettable
4-Collision Fault	7	End effector collision fault, resettable
5-Active Slave Count Error	1	Active slave count error, not resettable
6-Slave Error	1	Slave offline, not resettable
6-Slave Error	2	Slave status does not match set value, not resettable
6-Slave Error	3	Slave not configured, not resettable
6-Slave Error	4	Slave configuration error, not resettable
6-Slave Error	5	Slave initialization error, not resettable
6-Slave Error	6	Slave mailbox communication initialization error, not resettable
7-IO Error	1	Channel error, resettable
7-IO Error	2	Value error, resettable
7-IO Error	3	WaitDI timeout, resettable
7-IO Error	4	WaitAI timeout, resettable
7-IO Error	5	WaitAxleDI timeout, resettable
7-IO Error	6	WaitAxleAI timeout, resettable
7-IO Error	7	Channel configured function error, resettable
7-IO Error	8	Arc start timeout, resettable
7-IO Error	9	Arc end timeout, resettable
7-IO Error	10	Search positioning timeout, resettable
7-IO Error	11	Conveyor IO detection timeout, resettable
7-IO Error	12	WaitAuxDI timeout, resettable
7-IO Error	13	WaitAuxAI timeout, resettable
7-IO Error	14	Wire search positioning timeout, resettable
8-Gripper Error	1	Gripper motion timeout error, resettable
9-File Error	1	zbt config file version error, initialization error - not resettable
9-File Error	2	zbt config file load failed, initialization error - not resettable
9-File Error	3	user config file version error, initialization error - not resettable
9-File Error	4	user config file load failed, initialization error - not resettable
9-File Error	5	exaxis config file version error, initialization error - not resettable
9-File Error	6	exaxis config file load failed, initialization error - not resettable
9-File Error	7	Robot model inconsistent, requires reconfiguration - not resettable
9-File Error	8	dhpara config file version error, initialization error - not resettable
9-File Error	9	dhpara config file load failed, initialization error - not resettable
9-File Error	10	Robot model not set - not resettable
9-File Error	11	load config file version error, initialization error - not resettable
9-File Error	12	load config file load failed, initialization error - not resettable
9-File Error	13	speed config file version error, initialization error - not resettable
9-File Error	14	speed config file load failed, initialization error - not resettable
10-Singular Pose	1	Singular pose
11-Drive Communication Error	1	Axis 1 drive communication error, not resettable
11-Drive Communication Error	2	Axis 2 drive communication error, not resettable
11-Drive Communication Error	3	Axis 3 drive communication error, not resettable
11-Drive Communication Error	4	Axis 4 drive communication error, not resettable
11-Drive Communication Error	5	Axis 5 drive communication error, not resettable
11-Drive Communication Error	6	Axis 6 drive communication error, not resettable
12-External Axis Soft Limit	1	External axis 1 soft limit exceeded, resettable
12-External Axis Soft Limit	2	External axis 2 soft limit exceeded, resettable
12-External Axis Soft Limit	3	External axis 3 soft limit exceeded, resettable
12-External Axis Soft Limit	4	External axis 4 soft limit exceeded, resettable
13-Parameter Setting Error	1	Tool number out of range, resettable
13-Parameter Setting Error	2	Positioning completion threshold error, resettable
13-Parameter Setting Error	3	Collision level error, resettable
13-Parameter Setting Error	4	Load weight error, resettable
13-Parameter Setting Error	5	Load center of mass X error, resettable
13-Parameter Setting Error	6	Load center of mass Y error, resettable
13-Parameter Setting Error	7	Load center of mass Z error, resettable
13-Parameter Setting Error	8	DI filter time error, resettable
13-Parameter Setting Error	9	AxleDI filter time error, resettable
13-Parameter Setting Error	10	AI filter time error, resettable
13-Parameter Setting Error	11	AxleAI filter time error, resettable
13-Parameter Setting Error	12	DI high/low level range error, resettable
13-Parameter Setting Error	13	DO high/low level range error, resettable
13-Parameter Setting Error	14	Workpiece number out of range, resettable
13-Parameter Setting Error	15	External axis number out of range, resettable
13-Parameter Setting Error	16	Conveyor encoder channel error, resettable
13-Parameter Setting Error	17	Conveyor workpiece axis number error, resettable

20.2. Appendix 2: Wide Voltage Control Box Fault Table

Fault Code	Fault Name	Troubleshooting Method
3	Auxiliary MCU Offline	1. Re-flash the auxiliary MCU firmware 2. Repair the auxiliary MCU or replace the control box
4	Main and Auxiliary MCU Emergency Stop Input Mismatch	1. Check the emergency stop wiring harness of the button box or replace the button box assembly 2. Check the two emergency stop shorting wiring harnesses on the control box terminals 3. If the fault persists, repair or replace the control box
5	Main and Auxiliary MCU Safety Input Mismatch	1. Check the two safety shorting wiring harnesses on the control box terminals 2. If the fault persists, repair or replace the control box
6	Main and Auxiliary MCU 3-Position Enable and Emergency Stop Input Mismatch	1. Check the 3-position enable switch on the teach pendant and the teach pendant wiring harness 2. Replace the teach pendant assembly 3. Check whether the Web is in teach pendant mode and whether the teach pendant is connected 4. If the fault persists, repair or replace the control box
7	Main STO Input/Output Mismatch	1. Check whether the control box heavy-load connector and STO wiring harness are securely plugged in 2. Check whether the drive supports the STO function 3. For wide-voltage certified control box + non-certified robot configuration, check whether functional safety mode is enabled 4. The wide-voltage certified control box in certification mode enables STO fault detection; the non-certified robot does not support functional safety mode 5. If the fault persists, repair or replace the control box
8	Auxiliary STO Input/Output Mismatch	1. Check whether the control box heavy-load connector and STO wiring harness are securely plugged in 2. Check whether the drive supports the STO function 3. For wide-voltage certified control box + non-certified robot configuration, check whether functional safety mode is enabled 4. The wide-voltage certified control box in certification mode enables STO fault detection; the non-certified robot does not support functional safety mode 5. If the fault persists, repair or replace the control box
9	Main MCU Detects 48V Relay Input/Output Mismatch	1. Check the input and feedback of the forced-guided relay in the control box 2. Check whether the 48V relay in the control box is stuck 3. Check whether the 48V relay feedback circuit in the control box is functioning properly 4. If the fault persists, repair or replace the control box
10	Auxiliary MCU Detects 48V Relay Input/Output Mismatch	1. Check the input and feedback of the forced-guided relay in the control box 2. Check whether the 48V relay in the control box is stuck 3. Check whether the 48V relay feedback circuit in the control box is functioning properly 4. If the fault persists, repair or replace the control box
	Control Box Power Off, No 48V Output	1. Check the 24V short-circuit protection chip related circuit and check for any short circuits on the 24V 2. Check the emergency stop input & safety input terminal shorting wiring harnesses 3. Check whether the 24V power supply daughter board in the control box outputs 24V 4. If the fault persists, repair or replace the control box

20.3. Appendix 3: Servo Drive Fault Code Table

Fault Code	Fault Name	Troubleshooting Method
1	Software overcurrent fault	1. Check whether the joint load or resistance has increased or is abnormal. 2. If the fault persists, repair or replace the drive board.
2	Overvoltage fault	Reduce robot operating speed or acceleration.
3	Undervoltage fault	1. Check whether the 48V power supply output from the control box is abnormal. 2. Check for short circuits between the drive board and the joint housing. 3. If the fault persists, repair or replace the drive board.
4	Overtemperature fault	Reduce robot load or reduce robot operating speed.
5	Overload fault	Reduce robot load or reduce robot operating speed.
6	Overspeed fault	1. Check whether the set screw securing the magnetic encoder assembly to the motor shaft is loose. 2. Re-perform encoder zeroing. 3. If the fault persists, repair or replace the magnetic encoder assembly.
7	Parameter abnormal fault	Repair or replace the drive board.
8	Runaway fault	1. Check whether the set screw securing the magnetic encoder assembly to the motor shaft is loose. 2. Re-perform encoder zeroing. 3. If the fault persists, repair or replace the magnetic encoder assembly.
9	Position error fault	1. Check whether the joint load or resistance has increased or is abnormal. 2. If the fault persists, repair or replace the drive board.
10	Position overflow fault	1. Check whether the hard limit stop is loose. 2. Re-perform robot zeroing.
11	Hardware overcurrent fault	Repair or replace the drive board.
12	Drive inhibit fault	Not enabled.
13	Motor stall fault	1. Check whether the brake solenoid is engaged. 2. Check whether the hard limit stop has been hit. 3. If the fault persists, repair or replace the drive board.
14	Power supply fault	Not enabled.
15	STO fault	Not enabled.
16	Phase current AD zeroing fault	Repair or replace the drive board.
17	EEPROM fault	Repair or replace the drive board.
18	Hall sensor fault	1. Check whether the Hall sensor harness is securely connected, and check for short circuits or open circuits. 2. If the fault persists, repair or replace the joint.
19	Encoder fault	Repair or replace the magnetic encoder assembly.
20	Encoder zeroing fault	1. Re-perform encoder zeroing. 2. If the fault persists, repair or replace the magnetic encoder assembly.
21	Encoder Z-phase signal loss fault	Not enabled.
22	Encoder count fault	Not enabled.
23	Encoder multi-turn data overflow fault	Not enabled.
24	External clock fault	Repair or replace the drive board.
25	UVW phase sequence fault	Not enabled.
26	FPGA fault	Not enabled.
27	Homing fault	Not enabled.
28	Magnetic encoder fault	1. Check whether the set screw securing the magnetic encoder assembly to the motor shaft is loose. 2. If the fault persists, repair or replace the magnetic encoder assembly.
29	Motor power cable disconnection fault	1. Check whether the motor power cable is securely connected, and check for short circuits or open circuits. 2. If the fault persists, repair or replace the drive board.
30	EtherCAT fault	1. Check whether the Ethernet cable is securely connected, and check for short circuits or open circuits. 2. If the fault persists, repair or replace the drive board.
31	EtherCAT_SM_DOG fault	1. Check whether the Ethernet cable is securely connected, and check for short circuits or open circuits. 2. If the fault persists, repair or replace the drive board.
32	EtherCAT_FATALSYNC fault	1. Check whether the Ethernet cable is securely connected, and check for short circuits or open circuits. 2. If the fault persists, repair or replace the drive board.
33	EtherCAT_SYNC fault	1. Check whether the Ethernet cable is securely connected, and check for short circuits or open circuits. 2. If the fault persists, repair or replace the drive board.
34	EtherCAT_RFT fault	1. Check whether the Ethernet cable is securely connected, and check for short circuits or open circuits. 2. If the fault persists, repair or replace the drive board.
35	Drive axis address fault	1. Re-configure the drive axis address. 2. If the fault persists, repair or replace the drive board.
36	Robot zeroing fault	1. Re-perform robot zeroing. 2. First use JLINK to erase the FLASH, then re-download the program and perform zeroing. 3. If the fault persists, repair or replace the drive board.
37	Encoder communication fault	1. Check whether the encoder cable is securely connected, and check for short circuits or open circuits. 2. If the fault persists, repair or replace the magnetic encoder assembly.
40	Magnetic encoder module fault - zeroing fault	1. Re-perform magnetic encoder assembly zeroing. 2. If the fault persists, repair or replace the magnetic encoder assembly.
41	Magnetic encoder module fault - multi-turn fault	1. Check whether the set screw securing the magnetic encoder assembly to the motor shaft is loose. 2. If the fault persists, repair or replace the magnetic encoder assembly.
42	Magnetic encoder module fault - multi-turn small magnetic encoder fault	1. Check whether the multi-turn small magnetic encoder chip is abnormal. 2. If the fault persists, repair or replace the magnetic encoder assembly.
43	Magnetic encoder module fault - multi-turn large magnetic encoder fault	1. Check whether the multi-turn large magnetic encoder chip is abnormal. 2. If the fault persists, repair or replace the magnetic encoder assembly.
44	Magnetic encoder module fault - single-turn magnetic encoder fault	1. Check whether the single-turn magnetic encoder chip is abnormal. 2. If the fault persists, repair or replace the magnetic encoder assembly.
45	Magnetic encoder module fault - optical encoder fault	1. Check whether the optical encoder disc is contaminated or not securely adhered. 2. If the fault persists, repair or replace the magnetic encoder assembly.
46	Robot type setting abnormal fault	1. Without powering off, check the firmware version number of the faulty drive. 2. Re-configure the robot type. 3. If the fault persists, repair or replace the drive board.
47	Brake voltage detection fault	1. Check whether the brake wiring is abnormal. 2. Check whether the brake circuit is abnormal.
50	Position command abnormal fault	1. Check whether the position command sent by the host computer (controller) is abnormal (or if the position command changes abruptly).
51	Magnetic encoder module fault - optical encoder fault	1. Check whether the torque sensor wiring is abnormal. 2. If the fault persists, repair or replace the torque sensor.

20.4. Appendix 4: End plate 485 upgrade

During field use, it is possible to update the firmware to meet the new requirements. A new upgrade file (XX_XX_MAIN. bin) will be provided to upgrade the terminal board through the 485 interface (USB to 485 module is required). The upgrade steps are as follows:

Step1: 485 wiring. There is a 5Pin communication aviation connector at the end of the robot. The pin pin distribution and pin pin description of the aviation connector are shown in Fig. 1.Connect the 485 - A and 485 - B at the end of the robot with A and B of the USB to 485 tool using twisted pair cables.

Figure 18.3-1 Pin Pin Distribution of Aviation Connector

Step2: hardware connection. connect the USB end of the USB to 485 tool to the PC, and in the PC device manager, if the USB&485 tool is identified, the following interface will appear.

Figure 18.3-2 USB&485 Port Identification Description

Step3:Upgrade the tool. After the wiring is completed, open the “Fair Serial Port Debugging Assistant”, click the “Terminal Board” button, and select the above identified serial port in the “Serial Port Parameter Setting” function. The baud rate is 115200, the data bit is 8, the check bit is none, and the stop bit is 1. Then open the serial port. After success, the prompt “Serial port opened successfully” will appear.

Figure 18.3-3 Serial Port Parameter Settings

Step4:Firmware upgrade. Select “End plate” and click “Firmware upgrade”, as shown in the fig.

Figure 18.3-4 End Plate Firmware Upgrade

• First, click “Flash Erase”. After the erasure is successful, you will be prompted in the receiving data area that the erasure is successful.

• Open the file (the file to be upgraded), select the path to store it, as shown below. After the selection, the file name to be upgraded will appear in the file name display box.

Figure 18.3-5 Select Upgrade File

• Click “Send File”, and when the progress bar displays 100%, it means that the upgrade file has been sent.

Step5:Upgrade verification. The system is restarted and powered on. In the “Maintenance Information” column, select “Query terminal board firmware version information”, and the firmware version information will be displayed in the “Receive Data Area”. If it is consistent with the upgraded file version information, the upgrade is successful, otherwise the upgrade fails.

Figure 18.3-6 Querying Firmware Version Information

20.5. Appendix 5: Control Box 485 Upgrade

There is a “power communication” interface on the robot control box board, and USB&485 tools A and B are respectively connected to the “485-A” and “485-B” of its interface.

The upgrade process is the same as that of the terminal board, and the software can be selected accordingly, which will not be repeated here.

Figure 18.4-1 Power Communication Interface

20.6. Appendix 6: List of Spare Parts and Vulnerable Parts

Spare Part Name	Part No.	Quantity/piece(s)
M8 * 30 screw	4.0.08.2006185	4
Straight pin A type 8 * 20	4.5.00.2013076	2
Fuse 5x20 6A	/	1