Yaskawa Error Code A910 ((exclusive))

The Yaskawa A.910 error code is a common Overload Warning typically found on Sigma-series servo drives, such as the Sigma-7, Sigma-5, and Sigma-3. It serves as a pre-alarm notification that the motor or drive is operating near its thermal limit, allowing operators to intervene before a full shutdown (like an A.710 or A.720 fault) occurs. Understanding the A.910 Alarm

Unlike a hard "Fault," the A.910 is classified as a Warning. This means the motor will generally continue to run, but the drive’s digital operator will flash the code to indicate that the operation has exceeded the overload protection characteristics. Primary Causes and Remedies Potential Cause Recommended Remedy Mechanical Obstruction

Check the machine for jams, excessive friction, or worn bearings that increase the physical load on the motor. Wiring Issues

Verify that the servomotor and encoder cables are correctly wired and that there are no faulty contacts or loose connections. Operational Overload

Reduce the operation speed, lower the cycle frequency, or decrease the overall load applied to the motor. High Ambient Temp

Ensure the SERVOPACK panel temperature is below 55°C. Check cooling fans and ventilation filters for clogs. Parameter Settings

Check parameter Pn52B (Overload Warning Level). If it is set too low for your application, it may trigger the warning prematurely. Troubleshooting Steps

Monitor Current Consumption: Use the drive's monitor mode (e.g., Un002 for torque reference) to see if the motor is consistently drawing current near its rated limit.

Clear the Warning: If the cause is temporary, you can often clear the warning by cycling the power or using a "Warning Reset" command via the digital operator or SigmaWin+ software.

Check Hardware Integrity: If the warning persists even with no load, the internal current detection circuit of the SERVOPACK may be faulty, requiring a replacement of the drive unit.

For robotic applications specifically using the FS100 controller, a similar code (0910) may indicate a CPU Error, typically requiring a controller restart or hardware inspection.

The monotone whine of the Yaskawa Sigma-7 servo amplifier was the only sound in the entire packaging line. It was a sound that Elias, the lead robotics technician, usually found comforting—a mechanical heartbeat. But today, the heartbeat had flatlined.

Elias stared at the HMI screen. The conveyor belt was frozen. The robotic arm, usually a blur of yellow metal and precision, hung limp over a pallet of boxed goods. The operators stood back, arms crossed, looking at Elias with the weary expectation of people who knew the shift was about to get much longer.

In the center of the control panel, the tiny seven-segment LED display on the drive blinked a steady, accusing red.

A910.

Elias felt a knot tighten in his stomach. He didn't even need to pull out his phone to check the manual; he knew this one. It was the bogeyman of Yaskawa error codes. The white whale.

"Overload," Elias muttered, wiping grease from his hands with a rag.

"Overload?" asked Sarah, the shift supervisor. "But the arm isn't moving. How can it be overloaded if it’s standing still?"

"That’s the tricky part, Sarah," Elias said, popping the cover off the servo drive cabinet. "A910 isn't just 'I'm carrying too much weight.' It’s 'I'm working too hard to do absolutely nothing.'"

He connected his laptop to the drive’s USB port, firing up the SigmaWin+ software. He needed to see the trace data. The code A910 meant the motor was drawing excessive current for a prolonged period, or the drive estimated that the thermal capacity of the motor was exceeded.

But Elias knew the robot. It was a load-and-unload bot. It barely lifted fifty pounds. It shouldn't be overheating.

He looked at the status monitor. The command speed was zero. The torque reference, however, was spiking at 140%.

"It's fighting a ghost," Elias whispered.

"What?" Sarah leaned in.

"Look at this," Elias pointed to the digital waveform on his screen. "The motor is trying to move, but something is physically locking it in place. The drive is dumping current into the windings to try and overcome the resistance, but it can't, so it trips the overload protection before the motor burns out."

"Brakes?" Sarah suggested. "Maybe the brake didn't release?"

"That was my first guess," Elias said. "But if the brake was stuck, we’d hear it groan or smell burning friction material. This is silent."

Elias walked over to the robot base. The mechanical brake unit was encased in a housing behind the motor. He put his ear close. Nothing. He reached out to nudge the arm manually—it was rock solid. The servo lock was engaged, holding the position with an iron grip.

He went back to the laptop. He disabled the servo lock (Servo Off) and switched the drive to JOG mode. "I'm going to try to jog it forward, one millimeter. Just a tick. Stand clear."

He hit the button. Click. The drive faulted out immediately. A910 reappeared instantly.

"Instant overload," Elias scratched his chin. "That’s not a mechanical jam. A mechanical jam would let it build up torque for a second or two before tripping. This is happening instantly." yaskawa error code a910

He looked back at the motor cables. They were thick, black, industrial things, running from the drive to the motor. He traced the line with his eyes. It looked fine. No cuts, no burns.

But then, he saw it. A faint shimmer in the air near the cable tray.

"Elias, what are you looking at?" Sarah asked, seeing him squint.

"Sparks," Elias said. "Or... the memory of sparks."

He knelt down by the cable tray. During the last maintenance cycle, a zip tie had been pulled too tight around the main power cable (the UVW phases). Over months of the robot's repetitive twisting motion, that sharp plastic edge had slowly sawed its way through the insulation.

Elias gently touched the cable. It was hot. Not warm—hot.

He pulled out his multimeter. He checked the resistance between the U and V phases at the motor disconnect.

Zero.

"A dead short," Elias sighed. "Sarah, we found the ghost."

The cable had worn through, shorting two of the three power phases together

A very specific question!

The Yaskawa error code A910 is a fault code that appears on Yaskawa servo drives, particularly on the Σ5 (Sigma 5) series. After conducting research, I found that:

Error Code A910: Servo Motor Overheating

The A910 error code indicates that the servo motor has overheated. This can occur due to various reasons such as:

  1. Overload: The motor is subjected to an excessive load, causing it to overheat.
  2. Poor ventilation: Inadequate cooling or ventilation around the motor, leading to heat buildup.
  3. High ambient temperature: Operating the motor in an environment with a high temperature.
  4. Faulty motor or driver: A malfunctioning motor or driver can cause overheating.

Symptoms:

Troubleshooting steps:

  1. Check the motor load: Verify that the motor is not overloaded. Check the load and adjust it if necessary.
  2. Inspect ventilation: Ensure proper ventilation around the motor. Check for any obstructions or blockages that may be restricting airflow.
  3. Monitor ambient temperature: Verify that the operating environment temperature is within the recommended range.
  4. Check for motor or driver issues: Inspect the motor and driver for any signs of malfunction or damage.

Recommendations:

Rating:

Based on the information provided, I'd rate this error code review as follows:

In Yaskawa systems, the code A.910 is an Overload Warning. This minor fault or alarm typically indicates that the motor is drawing current near its rated capacity and is on the verge of a critical overload trip (such as A.710 or A.720). Report for Yaskawa Error Code A.910 Description Alarm Name Overload Warning Status Minor Fault/Warning (ALM LED usually flashes) Primary Meaning

The drive has detected a load that exceeds the motor's continuous rating for a specific duration, but has not yet reached the trip point. Common Causes

Mechanical Issues: Excessive load due to mechanical friction, binding, or a sudden obstruction in the machine.

Operating Conditions: The starting torque exceeds the maximum allowed torque, or the motor is operating at peak capacity for too long.

Wiring Faults: Incorrect or loose contact in the servomotor or encoder wiring.

Environmental Factors: High ambient temperature inside the SERVOPACK panel (exceeding 55∘C55 raised to the composed with power C

Parameter Settings: The overload warning level (parameter Pn52B) is set too low for the current application. Recommended Corrective Actions

Check Mechanical Load: Inspect the connected machinery for jams, lack of lubrication, or increased friction.

Verify Wiring: Ensure all motor and encoder cable connections are secure and correctly pinned.

Adjust Parameters: If the load is normal but the warning is premature, verify the setting of Pn52B (Overload Warning Level).

Cooling Check: Ensure panel fans are operational and the temperature is within the specified range ( 55∘C55 raised to the composed with power C The Yaskawa A

Monitor Operation: Use the monitor function (e.g., Un006 for motor load ratio) to see how close the system is to a full overload alarm. Note on Robot Controllers DX100 ALARM CODE 0910 CPU ERROR (YCP01)

DX100 ALARM CODE 0910 CPU ERROR (YCP01) – Yaskawa Motoman. Yaskawa Knowledge Center NX100 ALARM CODE 0910 CPU ERROR (NCP01)

The Yaskawa error code A.910 is an Overload Warning that indicates a drive is nearing its physical limits. Unlike a hard "fault" that immediately stops the motor, this is a preemptive warning issued before critical overload alarms like A.710 (instantaneous overload) or A.720 (continuous overload) occur. Root Causes and Solutions

When this code appears on a Yaskawa Sigma-3 or Sigma-7 series drive, it is usually triggered by one of the following factors: Mechanical Overload & Load Conditions

Cause: The motor is physically struggling with a load that exceeds its rated torque, or there is mechanical friction (e.g., worn bearings, misalignment).

Solution: Check for mechanical blockages and verify that the load matches the motor's capacity. You may need to reconsider operating conditions or increase motor size. Wiring and Connectivity Issues

Cause: Incorrect or loose wiring in the servomotor or encoder cables can cause faulty feedback, making the drive "think" it is overloading.

Solution: Inspect and secure all connections for the servomotor main circuit and encoder cables. Parameter Settings

Cause: The Overload Warning Level (Pn52B) might be set too low, triggering the warning prematurely even if the motor is within safe operating limits.

Solution: Adjust parameter Pn52B to a more suitable percentage of the rated load according to Click2Electro. Environmental Factors Cause: High temperatures inside the SERVOPACK panel. Solution: Ensure the panel temperature stays below through improved ventilation or cooling fans. Next Steps for Troubleshooting

Monitor Torque: Use the drive’s monitoring tools (like SigmaWin+) to check the actual torque percentage during the operation that triggers the warning.

Verify Hardware: If wiring and load are correct but the error persists after power cycling, the SERVOPACK unit itself may be faulty and require replacement.

Check Previous Alarms: Check the alarm history to see if A.910 frequently leads to A.710 or A.720, which confirms a genuine physical overload.

Yaskawa error code A.910 Overload Warning commonly found in the Sigma-5 and Sigma-7 servo drive series. It acts as a preemptive alert, indicating that the system is approaching a full overload alarm (A.710 or A.720), which would shut down the drive. Core Meaning

This code signals that the motor is operating at a load or torque level that exceeds its continuous rating for a significant period. If ignored, the drive will eventually trip to protect the hardware. Yaskawa America Primary Causes and Solutions Mechanical Overload:

The most common cause is excessive physical load or a mechanical jam.

Inspect the machinery for friction, binding, or unexpected resistance. Incorrect Parameter Settings: The "Overload Warning Level" (Parameter ) might be set too low for your specific application. Verify and adjust Pn52B to a suitable level as per the Yaskawa Sigma-7 Product Manual Wiring Issues:

Poor contact or incorrect wiring between the servomotor and the encoder can trigger false or early warnings.

Ensure all motor and encoder cables are securely connected and correctly wired. Capacity Mismatch:

The motor may be undersized for the required operation/duty cycle.

Reconsider the operating conditions or increase the motor/drive capacity. Hardware Failure: In rare cases, internal failure of the itself can cause this error.

If mechanical and wiring checks pass, the SERVOPACK may need replacement. Summary Table for Quick Reference Alarm Name Overload Warning Related Alarms A.710 (Instantaneous Overload), A.720 (Continuous Overload) Critical Parameter Pn52B (Overload Warning Level) Typical Recovery

Inspect mechanics, verify wiring, or cycle power if intermittent

If the error persists after checking these areas, would you like to troubleshoot a specific Yaskawa drive model or look into parameter adjustment steps AI responses may include mistakes. Learn more Yaskawa Servo Drive Alarm Codes Guide | PDF - Scribd

The Yaskawa error code Overload Warning typically found on Sigma-7 series servo drives

. It acts as a preventative alert, signaling that the system is approaching a more severe (Instantaneous Maximum Load) or (Continuous Load) trip. Meaning and Impact Warning, Not a Hard Fault:

Unlike "Major Faults" that immediately coast the motor to a stop, the A.910 code is a warning. If you continue operation without addressing the cause, the drive will eventually trigger a full overload alarm and stop. Threshold:

It occurs when the motor operation exceeds the overload protection characteristics defined in the drive's parameters. Primary Causes Mechanical Load Issues:

Excessive physical load on the motor due to friction, a jammed mechanism, or an undersized motor for the application. Wiring Faults:

Incorrect wiring or faulty contacts between the servomotor and the encoder. Parameter Settings: The overload warning level (specifically parameter Overload : The motor is subjected to an

) may be set too low or is unsuitable for the current operating conditions. Hardware Failure: In rare cases, a failure within the unit itself can trigger false warnings. Recommended Solutions Check Mechanicals:

Verify the machine is moving freely and that there are no physical obstructions or excessive friction. Verify Wiring:

Ensure all encoder and motor power cables are securely connected and follow the Yaskawa Sigma-7 Wiring Diagrams Adjust Operating Cycle:

Reduce the speed, acceleration, or duty cycle to lower the average load on the motor. Parameter Adjustment:

If the load is within safe limits but the warning persists, adjust parameter to a more appropriate level using or the digital operator. Replace SERVOPACK:

If the warning occurs immediately at power-up without a load attached, the Yaskawa SERVOPACK may need professional repair or replacement. for adjusting the parameter on your drive? Σ-7C SERVOPACK - Troubleshooting Manual

Quick Reference Card

Yaskawa A910 – Output Phase Loss

✓ Check U, V, W connections
✓ Measure phase-to-phase resistance (should be balanced)
✓ Test motor directly on line power
✓ Inspect output contactor (if used)
✓ Disable detection ONLY for diagnosis

The Yaskawa error code A.910 is an Overload Warning. It is a proactive alert indicating that the servomotor is operating at a load level that will soon trigger a hard fault (A.710 or A.720) if the condition persists. 🛠️ Understanding A.910: Overload Warning

Unlike a "Fault" (which immediately stops the motor), a "Warning" allows the motor to continue running while notifying the operator of an impending issue. Primary Causes

Mechanical Binding: Excessive friction or a physical obstruction in the machinery.

Incorrect Sizing: The motor’s rated torque is too low for the current load inertia or application demands.

Rapid Acceleration: Aggressive acceleration/deceleration ramps are drawing excessive current.

Wiring Issues: Poor connections between the SERVOPACK and the motor. 🔍 Troubleshooting Steps

If your display shows A.910, follow these steps to prevent a full system shutdown: 1. Check the Mechanical Load

Inspect the hardware: Rotate the motor shaft manually (if safe) to check for physical resistance.

Lubrication: Ensure all bearings, gears, and slides are properly lubricated to reduce friction. 2. Verify Parameter Settings

Check Pn520: This parameter often controls the position error pulse overflow; if set too tight, it can mimic overload behavior.

Acceleration/Deceleration: Increase the "S-curve" or ramp times to reduce the instantaneous torque required from the motor. 3. Monitor Real-Time Data Use the SigmaWin+ software to monitor the Torque Reference.

If the torque reference is consistently above 100% of the motor's rated capacity, the load must be reduced. 4. Hardware Inspection

Cables: Ensure the motor and encoder cables are not damaged or experiencing interference.

Brakes: Verify that the motor's mechanical brake is fully releasing when the servo is turned ON. ⚠️ Impending Faults (The "Next Step")

If A.910 is ignored, the drive will eventually transition into one of these hard faults: A.710: Instantaneous Overload (High Load). A.720: Continuous Overload (Low Load). To help you resolve this faster, could you tell me:

What series of Yaskawa drive are you using (e.g., Sigma-5, Sigma-7, GA700)?

Is the error happening during a specific movement or while the motor is holding position?

Have there been any recent mechanical changes to the machine? Using Stall Prevention to Suppress Overloads - Yaskawa

Step 2: Check for Parameter Corruption

  1. Access the drive’s programming mode.
  2. Perform a Drive Initialize (parameter A1-03 in most Yaskawa drives). Set it to 2220 (2-wire initialization) or 3330 (3-wire) to restore factory defaults.
  3. Re-enter your motor parameters (voltage, current, RPM, etc.).
  4. If the fault disappears, the issue was corrupted calibration data.
  5. Warning: Initialization erases all configuration. Back up first using DriveWizard software if possible.

Introduction

In the high-stakes world of industrial automation, downtime is costly. When a Yaskawa drive—whether from the V1000, J1000, U1000, GA700, or A1000 series—halts production with Error Code A910, it signals a specific power-related fault. While this alarm can be alarming to operators, understanding its root causes is the first step toward rapid resolution.

Error A910 is officially defined by Yaskawa as Main Circuit Undervoltage. This alarm triggers when the DC bus voltage inside the drive drops below the specified threshold. For a 200V class drive, this typically occurs below approximately 190 VDC (or around 150 VDC for single-phase models). For a 400V class drive, the undervoltage threshold is roughly 380 VDC to 400 VDC, depending on the model and load conditions.

Unlike a fatal fault that requires a manual reset, A910 is often a temporary alarm. However, persistent occurrences indicate deeper electrical issues that can damage the drive’s capacitors and rectifier circuit over time.