Yaskawa Error Code A910 Exclusive Today

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

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: yaskawa error code a910 exclusive

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. Yaskawa Error Code A

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

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 Excessive Load: The mechanical load on the motor

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

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."

1. The "Zombie Capacitor" Issue (Exclusive Insight)

Yaskawa drives built between 2015-2020 have a known, unpublished sensitivity on the +5V rail that powers the digital operator. As electrolytic capacitors on the control board age, the +5V line can develop high-frequency ripple. The digital operator requires a clean DC signal. Ripple above 50mV peak-to-peak will corrupt the handshake, triggering A910. A standard multimeter will show "5V" and pass the fault, but an oscilloscope reveals the truth.

2. Corrupted Firmware in the Digital Operator (Not the Drive)

Most technicians reflash the drive. That rarely works for A910. The issue is often the operator’s own EEPROM. The JVOP-180 operators have a habit of losing their bootloader handshake string after repeated power cycles, especially if the drive is powered off via a main disconnect rather than a soft shutdown.

2. Common Causes

• Excessive Load: The mechanical load on the motor shaft exceeds the rated torque of the motor for too long (e.g., a jammed conveyor, a pump with high viscosity fluid, or a seized bearing).
• Incorrect Parameter Settings:
  • E2-01 (Motor Rated FLA): Set lower than the actual motor nameplate current.
  • L1-01 (Motor Protection Selection): Set incorrectly for the motor type (Standard vs. Inverter Duty).
• Acceleration/Deceleration Issues: The accel/decel times (C1-xx parameters) are too short, causing high current spikes during starting/stopping that trigger the thermal calculation.
• Voltage Issues: Low input voltage causing the motor to draw higher current to maintain power.
• Motor Overheating: The motor itself is running hot due to ambient temperature or blocked cooling fins, lowering its tolerance for current.

When to escalate to Yaskawa support

• You cannot identify the owning device or clear the exclusivity.
• The error persists after controlled power-cycle and network checks.
• Repeated A910 occurrences without clear cause.
• If firmware reflash or hardware replacement seems required.

Have the following ready for Yaskawa support:

• Model and serial number of the affected device.
• Firmware version and network topology.
• Exact error message and timestamps.
• Steps already taken and logs/screenshots of diagnostics.

Common Symptoms Preceding A910

Before the drive locks out with A910, operators often report:

• Intermittent flickering of the digital operator’s backlight.
• The display showing garbled characters for a split second.
• The drive functioning normally for hours, then faulting A910 without a load change.
• A buzzing or clicking sound from the operator’s connection port.

How to Clear / Reset A910

• Auto-reset: Set L5-01 (Number of Auto Restart Attempts) to 1 or 2. The drive will attempt to resume after power returns.
• Manual reset: Cycle input power off → wait for charge light to die → power on. OR send a reset signal via terminal (set H1-oo = 7E).
• Digital Operator: Press STOP/RESET key (if fault is active and drive is stopped).

Affected equipment

• Yaskawa AC drives (VFDs), motion controllers (Sigma, MPiec), servo drives, and networked I/O modules that support exclusive sessions or ownership controls.