Yaskawa Error Code - A910 Exclusive [top]

The Yaskawa error code A.910 is a warning that signals an overload condition in a servo drive. Specifically, this code indicates that the motor or drive is operating near its capacity and is at risk of triggering a full "Overload" alarm—either A.710 (instantaneous maximum load) or A.720 (continuous maximum load). What Does the A.910 Error Mean?

Unlike a hard "Fault" that stops the motor immediately, A.910 is technically a warning. It serves as a preemptive notification that the current load on the servomotor is exceeding normal operating parameters. If the condition causing the overload is not addressed, the drive will eventually shut down with a hard fault to protect the hardware from permanent damage. Common Causes of the A.910 Warning

Mechanical Overload: The most common cause is a physical bind or excessive weight/friction in the machine’s mechanics that forces the motor to draw more current than its rated limit.

Rapid Acceleration/Deceleration: Extremely aggressive speed changes can cause current spikes that trigger the overload warning.

Drive/Motor Capacity Mismatch: If the SERVOPACK capacity is significantly lower than the servomotor it is trying to drive, the system may struggle to maintain the required torque.

Incorrect Parameter Settings: Errors in parameters related to torque limits or current levels can cause the drive to report an overload prematurely. Troubleshooting and Solutions

To resolve the A.910 error and prevent it from becoming a critical A.710 or A.720 fault, follow these steps:

Inspect Mechanical Components: Check for any obstructions, broken bearings, or lack of lubrication in the system that could be increasing mechanical resistance.

Review Motion Profiles: If the warning occurs during specific movements, try reducing the acceleration or deceleration rates in the host controller or drive parameters.

Check Parameter Settings: Verify that parameters such as Pn520 (Position Error Pulse Overflow) or others related to motor current are set correctly for your specific application.

Verify Sizing: Ensure the motor and SERVOPACK are properly matched. Yaskawa generally recommends a capacity ratio between 1/4 and 4 for stable operation.

Monitor with Software: Use Yaskawa’s SigmaWin+ software to monitor real-time torque and current usage to pinpoint exactly when the overload occurs.

Yaskawa Servopack Fault Codes Guide | PDF | Power Supply - Scribd

4. How to Clear the Fault

Once the physical cause is resolved or parameters are corrected:

The A910 warning may persist until the drive's internal thermal model cools down.
If the drive did not trip (stop), the warning light may turn off automatically after current returns to normal.
If the drive tripped, cycle the power or press the RESET button (assuming the fault has cleared).

Summary Checklist:

Check for mechanical jams.
Match E2-01 to Motor Nameplate FLA.
Ensure motor is not overheating physically.

Yaskawa Error Code A.910 Overload Warning typically found on Yaskawa Sigma-7 (and occasionally Sigma-5) servo drives. Unlike hard faults that immediately shut down the system, this code acts as an early warning alert. It notifies operators that the motor has been operating continuously at a torque level exceeding its rating, putting it on the verge of a critical overload trip (such as an A.710 or A.720 overload alarm).

Resolving this code promptly is essential to avoid forced machine downtime. This feature guide breaks down the causes, diagnostic steps, and remedies for the A.910 error. 🔍 Quick Reference: A.910 Overview Alarm Name Overload Warning Yaskawa Sigma-5 / Sigma-7 Series SERVOPACKs Primary Meaning yaskawa error code a910 exclusive

The motor is operating dangerously close to its thermal or torque limits. System Behavior

The drive will generally continue running but issues a warning. If unaddressed, it will escalate to a full shutdown alarm. ⚠️ Top 5 Causes of Error A.910

The A.910 warning is triggered by one of these common system stresses: Mechanical Binding or Jamming:

Debris, lack of lubrication, or worn-out bearings create physical resistance, forcing the motor to draw more torque than necessary. Exceeded Operation Profiles:

High-cycle rates, overly aggressive acceleration/deceleration curves, or continuous peak-torque demands that exceed the motor's rated capacity. Incorrect Parameter Thresholds: The overload warning level parameter (

) is set too low or inappropriately for the specific application. Wiring or Contact Faults:

Poor physical connections or damaged encoder/power cables providing inconsistent feedback or power drops. Hardware Failure: Internal damage within the SERVOPACK itself. 🛠️ Step-by-Step Diagnostic & Remedy Feature

When an A.910 code appears on your digital operator, follow this sequential troubleshooting pipeline: 1. Inspect the Mechanical System

Check the machinery driven by the servomotor for physical obstructions, misalignments, or excessive friction.

Clear any jams, realign mechanical actuators, and lubricate guide rails or gearboxes to minimize drag. 2. Evaluate Operating Conditions

Review the motion profile (speed, acceleration, and duty cycle) at the host controller.

If the motor is running at peak torque for too long, reduce the acceleration rates, lengthen the cycle times, or decrease the overall payload. If the load cannot be reduced, consider upgrading to a motor with a higher capacity. 3. Adjust Parameter Pn52B (Overload Warning Level) Check the value of parameter

, which dictates at what percentage of the rated load the A.910 warning triggers.

If the load is safely within the continuous capability of the motor but simply riding high, adjust to a more suitable threshold to prevent nuisance warnings. 4. Verify Wiring and Connections

Inspect the main circuit power cables and the encoder cables linking the motor to the SERVOPACK.

Ensure all terminals are tightly secured and free of corrosion. Look for cracked or frayed shielding on cables that could be inducing electronic noise. 5. Address Potential SERVOPACK Failure The Yaskawa error code A

If mechanical loads are verified as normal and parameters are correct but the code persists.

The current detection or internal logic of the drive may be failing. Replace the SERVOPACK unit. 🛡️ Best Practices to Prevent A.910

To stop Overload Warnings from disrupting your facility's operations, implement these preventive habits: Perform Regular Audits:

Routinely monitor the drive's actual torque output using Yaskawa's

software to see how close the baseline operations are to the rated capacity. Scheduled Lubrication:

Keep automated tracks, ball screws, and bearings lubricated to ensure the motor does not overwork to combat dry friction. Enclosure Cooling:

Ensure your control cabinets have active cooling or filtered ventilation; high ambient heat lowers a servo drive's effective capacity. 6.3 Drive Alarms, Faults, and Errors

In Yaskawa servo drive systems, the code is classified as an Overload Warning

. Unlike a hard fault, a warning indicates that the system is approaching an operational limit but has not yet tripped a protective shutdown. Understanding the A.910 Warning

The A.910 warning specifically serves as a "pre-alarm" for more severe overload conditions. It is designed to alert operators before the drive triggers the following fatal alarms: : Overload – High Load. : Overload – Low Load. Yaskawa America

If the conditions causing A.910 are ignored and operation continues, the drive will eventually shut down with one of the above errors to protect the motor and internal circuitry. Common Causes Excessive Load

: The torque required by the application is consistently exceeding the motor's rated capacity. High Ambient Temperature : If the environment around the motor or drive exceeds

), the system's ability to dissipate heat is reduced, leading to premature overload detection. Mechanical Issues

: Increased friction in the mechanical system—such as worn bearings, jammed gears, or lack of lubrication—forces the motor to work harder than normal. Incorrect Gain Settings

: Aggressive servo gain settings can cause the motor to "hunt" or vibrate, drawing excessive current and triggering an overload warning. MachMotion Troubleshooting and Solutions Check Load Ratios : Use the monitor function (typically

for accumulated load ratio) to verify the actual percentage of the motor's capacity being used. If it is consistently near or above 100%, the application may require a larger motor or a change in duty cycle. Verify Environment The A910 warning may persist until the drive's

: Ensure that the cooling fans on the drive are functional and that there is adequate ventilation in the control cabinet. Inspect Mechanics

: Disconnect the motor from the load and check if the mechanical components move freely by hand. Tune the Servo : If vibration is present, use the Yaskawa SigmaWin+ software

to perform autotuning or manually adjust gains to stabilize the system.

For detailed technical specifications, you can refer to the official Yaskawa Sigma-5 Alarm Troubleshooting Guide MachMotion Drive Error List specific parameter settings for your drive model to adjust these warning thresholds?

Yaskawa A.910 error code is an "Overload Warning" commonly encountered in Yaskawa Sigma-series servo drives, such as the Sigma-3, Sigma-5, and Sigma-7.

While it doesn't always immediately stop the motor, it serves as a critical pre-emptive alert that the system is approaching a full overload alarm, which will halt production. Understanding the "Exclusive" Nature of A.910 The A.910 code is unique because it is a warning (Gr.2) rather than a hard fault (Gr.1)

. This means it often appears when the drive's internal thermal monitoring predicts an upcoming failure based on current load trends. Common Causes and Remedies Description Recommended Action Wiring Faults

Incorrect or loose contact in the servomotor or encoder wiring. Inspect and secure all motor and encoder connections. High Load Conditions

The starting or operating torque exceeds the motor's rated capacity. Reconsider load weight or increase motor capacity. Mechanical Issues

Excessive friction or mechanical jams in the driven equipment.

Check for physical obstructions or lubrication issues in the machinery. Environmental Heat

The temperature inside the SERVOPACK panel has exceeded safety limits. Ensure the panel temperature stays below Parameter Mismatch The overload warning level ( ) is set too low for the application. Adjust parameter to a suitable level for your specific duty cycle. Pro-Tip: The "Quick Fix" Experienced technicians often find that 90% of connectivity-related issues

in Yaskawa drives can be resolved by powering down, unplugging the 1CN and 2CN connectors , blowing them out with compressed air, and reseating them. For deeper diagnosis, connecting a laptop with Yaskawa SigmaWin+

can provide a detailed real-time trace of the torque and current levels causing the warning. Σ-7C SERVOPACK - Troubleshooting Manual - Yaskawa Europe

How to Prevent A910 from Recurring

Once you have cleared the error, use these exclusive preventive measures:

Soft power-downs: Never cut main power with the drive running. Use the STOP key to idle the drive, then disconnect.
Dielectric grease: Apply a microscopic amount of silicone dielectric grease to the operator pins. This prevents oxidation without impeding conductivity.
Parameter backup: Regularly back up all parameters via the USB port. A910 often corrupts the operator’s local memory, but the drive’s main EEPROM remains intact. Reload parameters after an A910 event.
Environmental control: If your panel runs above 50°C (122°F), the +5V regulator on the control board runs at 90% duty cycle, accelerating capacitor aging. Install a filtered fan blowing directly across the drive’s heatsink.

The "Exclusive" Nuance

Unlike a standard "CALL" or "BUS" error, A910 implies the drive sees the operator physically connected, but the data frame from the operator is corrupt or the timing is off by microseconds. It is an exclusive club of faults that straddle the line between "loose wire" and "imminent board failure."

Phase 3: The "Known Good" Swap

Do not swap the drive. Swap the digital operator with a brand new or known working unit from another machine of the exact same model.

If A910 moves with the operator: The operator is dead. Replace the JVOP.
If A910 stays on the original drive: The drive’s operator communication IC (UART transceiver) has failed.

Primary Causes of Yaskawa Error A910

To fix this exclusively, you must understand the root physics behind the error. Here are the four definitive causes: