liminfoABB Fault Code Reference
ABB robot controller & drive fault code reference with causes and solutions
About ABB Fault Code Reference
The ABB Fault Code Reference is a free online lookup tool for automation engineers working with ABB IRC5 robot controllers and ACS series variable frequency drives. It covers over 40 fault codes across five categories: Robot Controller errors (10036, 10050, 10064, 10220, 10254), Motion faults (20001-20030), Communication errors (30001-30009), I/O and Sensor diagnostics (40001-40030), and ACS drive faults (2001-2014). Each entry includes the fault number, description, root cause analysis, and numbered resolution steps.
This reference is designed for field engineers, maintenance technicians, and system integrators who need to quickly diagnose and resolve ABB robot and drive faults during production downtime. Common scenarios include collision detection (10220), wrist singularity path errors (10254), emergency stop activation (10208), encoder communication failures (20025), EtherNet/IP and PROFINET communication loss (30001-30006), and ACS drive overcurrent or overvoltage conditions (2001-2002).
All fault data is loaded client-side with instant search and category filtering. The reference supports both Korean and English, making it ideal for international manufacturing teams. No login, installation, or internet connection is required after initial page load — the entire database works offline in your browser.
Key Features
- ABB IRC5 robot controller fault codes with root cause analysis and resolution steps
- ACS580/ACS880 drive fault codes including OVERCURRENT, OVERVOLT, OVERTEMP, and EARTH_FAULT
- Five-category filtering: Robot Controller, Motion, Communication, I/O & Sensor, Drive (ACS)
- Instant search by fault code number (e.g. 10220), name, or keyword
- Detailed step-by-step troubleshooting procedures for each fault
- Bilingual Korean and English support for global manufacturing teams
- Fully offline-capable after page load — no server processing required
- Mobile-responsive design for use on the factory floor with phones or tablets
Frequently Asked Questions
What does ABB error 10036 mean?
ABB error 10036 indicates that a joint position is outside the configured working range (Upper/Lower Joint Bound). This typically occurs when a taught position has been modified or when the robot approaches mechanical stops. To resolve it, check the affected axis position on the FlexPendant, verify the Joint Bound values in Configuration > Motion > Axis, jog the robot within range in manual mode, and re-teach the position if necessary.
How do I clear a fault on an ABB IRC5 robot?
To clear an IRC5 fault: (1) Read the detailed fault message in the FlexPendant event log, (2) Address the root cause (mechanical obstruction, wiring issue, parameter error, etc.), (3) Press the "Motors On" button on the controller, (4) If the fault persists, try a warm restart from the FlexPendant menu. For persistent hardware faults, a full power cycle (OFF/ON) of the controller may be required.
How do I reset an ABB robot after collision detection (10220)?
After collision detection fault 10220: (1) Check for and remove any obstacles around the robot, (2) Jog each axis carefully in manual mode to verify free movement, (3) Inspect the tool and workpiece for damage, (4) Acknowledge the fault on the FlexPendant, (5) Press "Motors On" and restart the program at reduced speed. If collisions recur, adjust the Motion Supervision TuneValue parameter to tune sensitivity.
What causes ABB error 10254 (wrist singularity)?
Error 10254 occurs when the robot approaches a wrist singularity where axis 4 and axis 6 align on the same rotation axis (axis 5 angle near 0 degrees). The inverse kinematics calculation becomes impossible. Solutions include using the SingArea \Wrist instruction for singularity interpolation, modifying the path to avoid the singularity zone, or using MoveJ (joint movement) to pass through the singularity region.
Where can I find ACS880/ACS580 drive fault codes?
This reference includes the most common ACS series drive faults: OVERCURRENT (2001), DC_OVERVOLT (2002), DEV_OVERTEMP (2003), MOT_OVERTEMP (2005), DC_UNDERVOLT (2007), MOT_STALL (2009), EARTH_FAULT (2010), SHORT_CIRC (2013), and SUPPLY_PHASE (2014). Each entry includes the fault code, description, probable causes, and step-by-step corrective actions including reset procedures.
How do I troubleshoot ABB PROFINET communication errors?
For PROFINET errors (30002, 30006): (1) Inspect PROFINET cables and RJ45 connectors for damage, (2) Verify the device Station Name matches the controller configuration, (3) Confirm the PLC program is running, (4) Use PROFINET diagnostics to monitor real-time communication status, (5) Check network switch port status and GSDML file version compatibility. For persistent issues, check EMI shielding on cables.
What does ABB motor overtemperature error 20030 mean?
Error 20030 indicates the servo motor temperature sensor (PTC or KTY type) has detected a temperature exceeding the allowable limit. Common causes include continuous high-load operation, insufficient cooling, or a faulty sensor. Check the motor surface temperature with an infrared thermometer, verify the ambient temperature is below 45 degrees C, check cooling fan operation, and review the duty cycle to reduce continuous operation ratio.
How do I fix ABB ACS drive earth fault (2010)?
ACS drive earth fault 2010 indicates ground leakage current from the motor or output cable. To diagnose: (1) Disconnect the drive output, (2) Measure motor cable insulation resistance with a 500V megger (normal: greater than 1 megaohm), (3) Measure motor winding-to-case insulation, (4) Inspect cable routing for damage, pinching, or moisture, (5) Check inside the motor terminal box for water ingress. Replace the cable or motor if insulation has degraded.