Motion Controller Data Sequence Number Error

When error [5.7025] occurs, the robot decelerates and stops in SS1 stop mode, then switches to STO (servo off).

• The error appears intermittently — sometimes right after start-up, sometimes after one or two hours of operation — and a reboot clears it for a while.
• It can occur while running a program, while jogging, or while standing still waiting for a signal.
• It often occurs more on hot days, or after the control box cover has been closed.
• It may come together with 5.7134 (over temperature in board) or 2.1908 (an invalid control command was generated).

[5.7025] Safety controller category

Motion Controller data sequence number error occurred
Param 1: CPU Number

Inside the control box, the motion controller sends data to the safety controller in numbered packets. This error means a packet arrived late or was skipped, so the safety controller stops the robot.

• Controller overheating — the most common cause. When the control box gets too hot, its processor slows down and data is no longer sent on time. Typical conditions are a clogged fan filter, a stopped fan, a control box in a hot or enclosed place, or extra devices mounted inside the control box.
• Software issue fixed in a later version — several cases were resolved by a software update.
• Cable, connector or noise — a loose power or robot arm cable, a missing ferrite core, or a strong noise source near the controller.
• A part in the controller — less common. This needs service.

• Check that the control box fan is turning, and clean the fan filter.
• Check the ambient temperature around the control box, and whether it is installed in an enclosed space or next to a heat source. Keep it within the specified operating temperature.
• If other devices are mounted inside the control box, check that they are not heating it up.
• As a test, run the robot for a while with the control box cover open. If the error stops, the cause is heat. Do not leave the cover open as a permanent fix — improve the cooling of the installation instead.
• Update the controller software to the latest version of the line you use. Software causes of 5.7025 were fixed across V2.12.1 to V2.12.3 on the legacy controller and in V3.4 on the integrated controller.
• Check that the power cable and robot arm cable are firmly connected, and that ferrite cores are fitted on the robot arm cable and teach pendant cable.
• To rule out external equipment, test with only the robot arm, the controller and the teach pendant connected.

If the error continues, contact your distributor.

• Robot model and serial number
• Software version of the controller
• All error codes shown with 5.7025, and the date and time
• The ambient temperature and where the control box is installed
• The controller log exported right after the error

• 5.7134 Over temperature in board occurred — check cooling first
• 2.1908 An invalid control command was generated — see Invalid Control Command Generated
• 2.1903 Currently not permitted event is attempted
• 4.1001 Unknown error occurred
• 5.7021 Raw data sequence number error occurred on Inverter board — see Raw Data Sequence Number Error on Inverter Board
• 5.7023 Joint torque sensor data sequence number error occurred on Inverter board — see Joint Torque Sensor Data Sequence Error