Robotersysteme AG K5 Troubleshooting Guide V1.8 54 pages 4. September 2008 RTI control software version as of 1.45.032 © Copyright by igm Robotersysteme AG This material is the sole property of igm Robotersysteme AG and is confidential. It may not be copied or given to a third party or appropriated in any other way without our written consent. The control system may feature additional undocumented functions. igm Robotersysteme AG is not under obligation to provide these functions with new shipment or in case of service. Information contained in this document is subject to change without notice. Robotersysteme AG Version 1.0 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 Author OLB REM STI STI VO STI Vo Vo Vo K5 Errormessages Date 27.4.05 13.06.05 07.03.06 10.03.06 14.3.06 11.04.06 18.5.07 4.3.08 4.9.08 Remark creation Updated Missing messages Several texts added Document renamed to “K5 Troubleshooting Guide” Non-Error messages removed, missing message added Messages at DSE-, KPS- and HEDA errors removed. minor changes A lot of error texts added Texts added K5 Troubleshooting Guide Introduction Robotersysteme AG 1. Introduction 1.1. Texts All message texts described in the following were taken from the file "k5master.txt". There could be minor differences in the text contents. 1.2. Abbreviations Following texts in an error message will be replaced by their real values: Text Remark M.S.T Stepnumber in the format: Main.Sub.TempStepnumber XXX.PRG Stepprogram name XXX.LIB Library name AxNr substitute for the axis number Nr substitute for a general number NUMB substitute for a general number NAME General naming (e.g. labelname, reference, …) 1.3. Table The Errortext Number to the left of the errormessage is unique in the K5 system and will be shown with each errormessage on the K5 (refer also to K5 Introduction.pdf): Errortext Number 1 Call target of step M.S.T in program 'XXX.prg' not found! Reason When does the error occur? Solution How can this error be fixed? ! There may be gaps in the sequence of errormessage numbers! Once used, later removed message numbers, will never be used anymore! K5 Troubleshooting Guide (en).doc / 08-09-04 igm Robotersysteme AG 1 Robotersysteme AG Error messages K5 Troubleshooting Guide 2. Error messages 1 Reason The called sub program has not been found. Solution Check the step in the main program and the name of the sub program. 2 Root reference name 'Name''Name' not found in program 'XXX.prg'! In the main program an undefined root reference name for a split multilayer Reason has been used Check the used name and the name used for the root reference in the Solution multilayer root. 3 Process definition name 'Name''Name' not found in program 'XXX.prg'! In the main program a welding definition is requested from the library which Reason does not exist there Check the requested name Solution 4 FillGroup name 'Name''Name' defined more than once in program 'XXX.prg'! 5 Reason In the main program a name of a fill group has been used more than once. Solution Modify the names so they are unique. Multiple jump target name 'Name' to Nr detected more than once in program 'XXX.prg'! Reason In the program a name of a jump target has been used more than once. Solution Modify the names so they are unique. 6 Root reference name 'Name''Name' defined more then once in program 'XXX.prg'! In the main program a root reference name has been used for a split Reason multilayer more than once Modify the names so they are unique. Solution 7 Process definition name 'Name' Name' defined more than once in prog 'XXX.prg'! 8 9 10 2 Call target of step M.S.T in program 'XXX.prg' not found! Reason A name for a welding definition has been used more than once in the library. Solution Modify the welding definition names so that they are unique. Step name with step 'M.S.T' defined more than once in program 'XXX.prg'! Reason In the program a step name has been used more than once. Solution Modify the step names so they are unique. Subroutine name to step 'M.S.T' defined more than once in progrem 'XXX.prg'! Reason In the program a name of a subroutine has been used more than once. Solution Modify the subroutine names so they are unique. External axis nmb: 'AxNr' Kinematic type mismatch. Prog is 'XXX.prg'! Reason The axis type of an external axis in the program does not match with the settings in the parameter file. Solution Check the axis settings in the station dialog (axis type). Load the right parameter file or correct the program. igm Robotersysteme AG 08-09-04 / K5 Troubleshooting Guide (en).doc K5 Troubleshooting Guide 11 12 Error messages Robotersysteme AG FillGroup name 'Name''Name'not found in program 'XXX.prg'! Reason The called fill group has not been found. Solution Check the step in the main program and the name of the fill group. Invalid loop nesting M.S.T detected in prog 'XXX.prg'! Reason Loops not yet implemented. Solution 13 14 15 16 Invalid number of reference points found near or at step M.S.T in prog 'XXX.prg'! Reason An invalid number of reference points has been found. Solution Correct the step program accordingly. Invalid number of Weaving Points found near or at step M.S.T in program 'XXX.prg'! Reason An invalid number of weaving points has been found. Solution Correct the step program accordingly. Invalid Search Block nesting M.S.T found in prog 'XXX.prg'! Reason Search Begin or End was found at an incorrect location. Solution Correct the step program accordingly. Invalid Search sequence found near or at step M.S.T in prog 'XXX.prg'! Reason Solution 17 18 19 20 Invalid Mainstep M.S.T in Searchblock in program 'XXX.prg'! Reason Mainstep in searchblock is not allowed. Solution Correct the step program accordingly. Invalid Shift Block nesting M.S.T found in program 'XXX.prg'! Reason Shift Begin or End was found at an incorrect location. Solution Correct the step program accordingly. Invalid SinglePtShiftblock nesting M.S.T found in program 'XXX.prg'! Reason Single Point Shift Begin or End was found at an incorrect location Solution Correct the step program accordingly. Invalid step discovered: 'M.S.T'! Program: 'XXX.prg'. Reason Solution 21 Invalid step found before reference points near or at step M.S.T in prog 'XXX.prg'! Reason An invalid step before reference points has been found. Solution Correct the step program accordingly. See programming manual. K5 Troubleshooting Guide (en).doc / 08-09-04 igm Robotersysteme AG 3 Robotersysteme AG 22 Error messages K5 Troubleshooting Guide Step number 'M.S.T' invalid for ignition def.! Program is 'XXX.prg' Reason Solution 23 24 25 Invalid Subprog nesting M.S.T found in progrem 'XXX.prg'! Reason Subprogram Begin or End was found at an incorrect location. Solution Correct the step program accordingly. Invalid ToolExchange at 'M.S.T' in 'XXX.prg' without ToolExchange step! Reason During program execution a step has been detected requiring a tool exchange. However, this has not been explicitly Solution Check the step. IF you require a torch exchange, program a tool exchange step first. Invalid step type before Weaving Point near or at step M.S.T in program 'XXX.prg'! Reason Solution 26 Invalid step type after Weaving Point near or at step M.S.T in program 'XXX.prg'! Reason Solution 27 28 29 Jump target of step M.S.T in program 'XXX.prg' not found! Reason The called jump target has not been found. Solution Check the step in the main program and the name of the sub program. Referenced Library 'XXX.prg' not found (please load) ! Reason The requested library program (stored with the start step) has not been found in the system memory Solution Load the library program into the system memory (e.g., by pressing 2nd - L in the step menu) or modify the library name in the start step if it is incorrect 'AUX-Loop End' step M.S.T in program 'XXX.prg': Only valid in loops! Reason Loops not yet implemented. Solution 30 'AUX-Loop End' step not found at the end of program 'Name' 'XXX.prg'! Reason Loops not yet implemented. Solution 31 4 'Search End' step not found at the end of prog 'Name' 'XXX.prg'! Reason Search block has not been closed with ‘Search End’. Solution Add ‘Search End’ in the step program. igm Robotersysteme AG 08-09-04 / K5 Troubleshooting Guide (en).doc K5 Troubleshooting Guide 32 33 34 35 36 Error messages Robotersysteme AG 'Shift End' step not found at the end of program 'Name' 'XXX.prg'! Reason Shift block has not been closed with ‘Shift End’. Solution Add ‘Shift End’ in the step program. 'SinglePointShift End' step not found at the end of program 'Name' 'XXX.prg'! Reason SPS block has not been closed with ‘SPS End’. Solution Add ‘SPS End’ in the step program. 'AUX-Subprogram End' step not found at the end of program 'Name' 'XXX.prg'! Reason A sub program has not been closed with ‘Subprogram End’. Solution Add ‘Subprogram End’ in the sub program. No input function found on step M.S.T in program 'XXX.prg'! Reason At a conditional jump no input function has been defined. Solution Check the step. Add an input dfunction. Can't correct step M.S.T in program 'XXX.prg'! Reason Solution 37 Can't read step M.S.T in program 'XXX.prg'! Reason Solution 38 Insufficient memory capacity. Please retry! Reason Solution 39 Step M.S.T must be a PP-JOG step. Prog is 'XXX.prg'! Reason Solution 40 Axis 'AxNr' not found Reason Solution 41 Number of axes mismatch 'AxNr'! Reason Solution 42 Subsequent to step M.S.T, an unexpected EOP has been detected. Prog is 'XXX.prg'! Reason Solution K5 Troubleshooting Guide (en).doc / 08-09-04 igm Robotersysteme AG 5 Robotersysteme AG 43 Error messages K5 Troubleshooting Guide Search sequence only valid in Search Blocks! Found near or at step M.S.T in program 'XXX.prg'! Reason Solution 44 45 46 47 48 49 'Search End' Step M.S.T in program 'XXX.prg' only valid in Search Blocks! Reason There is a ‘Search End’ step without corresponding ‘Search Begin’ Solution Delete the not needed ‘Search End’ step. Referenced search block in step M.S.T in program 'XXX.prg' not found! Reason Target of ‘Search Path Name’ in AUX-step has not been found. Solution Check the AUX-step and the step name of the called search step. Step referenced by ELS jump step M.S.T in program 'XXX.prg' is not an ELS search step! Reason Target of ‘Search Path Name’ in AUX-step ‘ELS Jump’ is not an ELS search step. Solution Check the sensor type in the called search step. Step referenced by CAM jump step M.S.T in program 'XXX.prg' is not a CAM search step! Reason Target of ‘Search Path Name’ in AUX-step ‘Camera Jump’ is not a Camera search step. Solution Check the sensor type in the called search step. Step referenced by jump step M.S.T in program 'XXX.prg' is not a search block ! Reason Target of the jump step is not a search block. Solution Check the jump step and the called search block. Sensor referred by step M.S.T in program 'XXX.prg' not found in current Station (Press Sensor key)! Reason Solution 50 51 52 6 'Shift End' step M.S.T in program 'XXX.prg': Only valid within Shift Blocks! Reason The step extension “Shift End” is only valid within Search blocks Solution Correct the step program accordingly. 'SPS End' step M.S.T in prog 'XXX.prg': Only valid within Shift Block! Reason The step extension "Single Point Shift" is only valid within Single Point Shift blocks. Solution Correct the step program accordingly. It is invalid to change the Substation coords in a Search/Shift block, found 'Name' excpected 'Name'step Nr! Reason The substation has been changed in a search or shift block. Solution Correct the steps in the block accordingly. igm Robotersysteme AG 08-09-04 / K5 Troubleshooting Guide (en).doc K5 Troubleshooting Guide 53 54 Error messages Robotersysteme AG It is invalid to change WRK coords in a Search/Shift block, found 'Name' excpected 'Name'step Nr! Reason The coordinate system has been changed in a search or shift block. Solution Correct the steps in the block accordingly. Step M.S.T is referenced. Unidentified EXTAxis. Prog is 'XXX.prg'! Reason Solution 55 WRK Coord System used with step M.S.T is not identified! Program: 'XXX.prg' Reason Solution 56 Invalid WRK Coord-Nmb used with step M.S.T in program 'XXX.prg'! Reason Solution 57 58 59 'AUX-Subprogram End' step M.S.T in program 'XXX.prg': Only valid in subroutines! Reason The AUX-step Subprogram End is only valid within sub programs. Solution Correct the step program accordingly. Substation is not compatible with current Station M.S.T in program 'XXX.prg'! Reason Substation configuration (number of axes) of the step program does not correspond with parameter file settings Solution Either load the correct parameter file or modify the step program accordingly 'AUX-Loop Exit' step M.S.T is only valid in loops. Prog is 'XXX.prg'! Reason Loops not yet implemented. Solution 60 61 62 'AUX-Subprogram Exit' step M.S.T is only valid in subroutines! Program: 'XXX.prg'! Reason The AUX-step Subprogram Exit is only valid within sub programs. Solution Correct the step program accordingly. Program 'XXX.prg' referenced by step Nr not found in program 'XXX.prg' (Please load)! Reason Called program has not been found. Solution Check the step and the name of the program. Common program error! Reason A non-identifiable error without a specific error cause has occurred Solution Try to define or limit the circumstances which led to this error and report the error code (8 digit HEX code) to igm (in addition, please provide the IOdebug file stored immediately after the event including a short error description) K5 Troubleshooting Guide (en).doc / 08-09-04 igm Robotersysteme AG 7 Robotersysteme AG 63 Error messages K5 Troubleshooting Guide 'Motion' error: Invalid robot type! Reason Solution 64 'Motion error': Invalid global axis type! Reason Solution 65 'Motion' error: Invalid external axis type! Reason Solution 66 'Motion' error: Invalid robot configuration flags! Reason Solution 67 68 69 70 'Motion' error: Unable to reach position! Reason The robot should approach an unreachable position Solution Modify the positions accordingly. If the installation features tracks, move them so the robot's initial position improves 'Motion' error: Elbow streched! Reason With linear robot movements Solution During motion the elbow may not be stretched. Modify the position and/or orientation of involved steps. 'Motion' error: Wrist singularity! Reason With linear robot movements Solution Modify the position and/or orientation of involved steps. Frame Error: Contact igm - Msg No. 1! Reason Solution 71 Frame Error: Contact igm - Msg No. 2! Reason Solution 72 73 Cannot compute center of circle! Reason The circle has been programmed so badly that all points are in line Solution Modify at least one step position of the circle or a segment of the circle Two points are located at the same position! Reason Solution 8 igm Robotersysteme AG 08-09-04 / K5 Troubleshooting Guide (en).doc K5 Troubleshooting Guide 74 Error messages Robotersysteme AG Frame Error: Contact igm - Msg No. 3! Reason Solution 75 No Shift-Information found! Have the Search sequences already been executed? Reason Solution 76 Joint (kinematic) configuration error! Reason Solution 77 78 Can't optimize step! Reason One of the robot axes exceeds maximum speed even after several attempts of the INS control system to optimize the movement (that is, trying to reduce the speed) Solution Check position of start and target step. In particular, observe robot axis #4 and #6 Gas nozzle touched! Reason Solution 79 80 81 'Motion' error Axis 'AxNr' MypSlot 'Nr': Joint limits reached! Reason The joint limits of the axis was reached. The MypSlot number indicates the rack position of the corresponding servo control board Solution Modify the position of the target step. It is also possible to modify axis settings (however, only by igm personnel !) 'Motion' error Axis 'AxNr' MypSlot 'Nr': Accel. limits reached! Reason The maximum axis acceleration of this axis has been reached. The MypSlot number indicates the rack position of the corresponding servo control board Solution Change the type of movement. It may be necessary, for example, to turn axis #4 very quickly to achieve the required movement. In this case, you could consider using non-linear interpolation 'Motion' error Axis 'AxNr' MypSlot 'Nr': Couple tolerance exceeded! Reason Solution 82 'Motion' error Axis 'AxNr' MypSlot 'Nr': Speed limit reached! Reason The maximum axis speed of this axis has been reached. The MypSlot number indicates the rack position of the corresponding servo control board Solution Change the type of movement. It may be necessary, for example, to turn axis #4 very quickly to achieve the required movement. In this case, you could consider using non-linear interpolation K5 Troubleshooting Guide (en).doc / 08-09-04 igm Robotersysteme AG 9 Robotersysteme AG 83 Error messages K5 Troubleshooting Guide Sensor not oriented in target direction Reason Solution 84 85 Emergency button has been pressed! Reason The emergency button has been pressed. Solution Release the emergency button. In Mode 5.70, Manual control in TOOL is not supported Reason Solution 86 87 Servo control error: Axis 'AxNr' Slot 'Nr' Reason The servo control board cannot be accessed Solution Check the hardware. Try replacing the corresponding servo control board. Servo control error! Reason Solution 88 Invalid command Reason Solution 89 CSR-Hold timeout Reason Solution 90 Interrupt timeout Reason Solution 91 Calibration error Reason An error during calibration has occured. Solution 92 Sync error Reason Solution 93 10 Error number 0xNrX Reason A non-identifiable error without a specific error cause has occurred Solution Try to define or limit the circumstances which led to this error and report the error code (8 digit HEX code) to igm (in addition, please provide the IOdebug file stored immediately after the event including a short error description) igm Robotersysteme AG 08-09-04 / K5 Troubleshooting Guide (en).doc K5 Troubleshooting Guide 94 Error messages Robotersysteme AG IO-System error: Opening digital function is invalid! Reason Solution 95 Proceed as described under Errortext 105! IO-System error: Digital function is opened 'exclusivly'! Reason Solution 96 Proceed as described under Errortext 105! Requested IO bit has not been initialized! Reason Solution 97 Proceed as described under Errortext 105! Requested IO bit is already initialized! Reason Solution 98 Proceed as described under Errortext 105! Requested IO bit is not configured! Reason Solution 99 Proceed as described under Errortext 105! Requested IO bit has invalid type! Reason Solution 100 Proceed as described under Errortext 105! Requested IO bit has invalid handle! Reason Solution 101 Proceed as described under Errortext 105! Requested IO bit has invalid argument! Reason Solution 102 Proceed as described under Errortext 105! Requested IO bit is out of range! Reason Solution 103 Proceed as described under Errortext 105! IO-System error: Is any Handler open?! Reason Solution 104 Proceed as described under Errortext 105! Requested IO bit: Allocation error! Reason Solution K5 Troubleshooting Guide (en).doc Proceed as described under Errortext 105! / 08-09-04 igm Robotersysteme AG 11 Robotersysteme AG 105 106 Error messages K5 Troubleshooting Guide Requested IO bit is unknown (not configured?)! Reason Check the IOdebugs (Menu | "Show IOdebugs")! There you will find the exact bitnumber a couple of lines above this errormessage occurred. Solution Search this bitnumber in the parameter file and correct it accordingly. Also it often happens that a buscoupled powersource can not be accessed! Requested IO bit is already used! Reason Solution 107 Requested IO bit: Read/Write error! Reason Solution 108 IO-system/IO-Bit(s) Parameterizing error! Reason Solution 109 Requested IO bit is already defined! Reason Solution 110 Test error! Reason Solution 111 Drives shut off during movement! Reason Solution 112 Internal emergency stop! Reason Solution 113 EMT Calibration FAILED! Reason Solution 114 115 Emergency button has been pressed! Reason The Emergency button has been pressed. Solution Release the emergency button. Servo communication failure! Reason Solution 12 igm Robotersysteme AG 08-09-04 / K5 Troubleshooting Guide (en).doc K5 Troubleshooting Guide 116 Error messages Robotersysteme AG Internal Error! Reason Solution 117 Axis servo control error (KPS)! Reason Solution 118 Limit switch! Reason Solution 119 Axes not ready! Reason Operation can not be executed because the axes are not ready. Solution Wait until the axis are ready. Reason refer to error number 212 Solution refer to error number 212 120 121 122 Servo control error! Reason The servo reported an error. Solution Check the servos. Servo Parameter setup failed! Reason Solution 123 Shot-Pin doesn't open! Reason Solution 124 Tracking error! Reason Solution 125 Action not possible outside of ShiftBlock! Reason Solution 126 Changing Substation is not allowed! Reason Solution K5 Troubleshooting Guide (en).doc / 08-09-04 igm Robotersysteme AG 13 Robotersysteme AG 127 128 129 130 Error messages K5 Troubleshooting Guide Cannot start from this step! Reason The requested step may not be directly approached since it has been programmed with a different torch/welding power source. Solution You must first switch to the correct torch. This can be directly achieved by pressing ADD, provided the robot does not collide with the workpiece if started from the current position Cannot start from outside of ShiftBlock! Reason Attempt to quit a Shift Begin/End block without approaching the Shift End step first Solution If this action is really required (provided no further teaching or correcting within the block is necessary) ALL shift blocks may be deleted by FN+T or GOTO STEP 2.0.0. In addition, if nested blocks are used, the currently active shift may be quit by GOTO STEP to the Shift End step. ELS reference path not yet executed! Reason Program start without having executed the reference sequence required for a laser sensor search sequence Solution Go to the corresponding search sequence and execute it by pressing GOTO STEP. Check by pressing 2nd GOTO STEP if the detected position is valid CAM: Seam not found Reason Solution 131 132 133 134 14 Search tolerance underflow! Reason The gas nozzle touches the workpiece either too shortly after the start or it missed the workpiece Solution Modify the search step position Search tolerance exceeded! Reason The gas nozzle touches the workpiece either too shortly after the start or it missed the workpiece Solution Modify the search step position No Reference Point found in definition! Reason Program and library are not compatible. Either there is a reference point in the main program and no reference point in the library or the other way round Solution A reference point must be programmed in the main program as well as the library, or reference points are not used at all No Reference point found subsequent to WeldingSequenceCall! Reason Program and library are not compatible. Either there is a reference point in the main program and no reference point in the library or the other way round Solution A reference point must be programmed in the main program as well as the library, or reference points are not used at all igm Robotersysteme AG 08-09-04 / K5 Troubleshooting Guide (en).doc K5 Troubleshooting Guide 135 136 Error messages Robotersysteme AG TEX-Label not found! Reason The requested AUX/ToolExchange step does not exist in the tool exchange program Solution Check the tool exchange program (TCHG.PRG) Incomplete multi-layer definition! Reason Solution 137 CoverPass not defined! Reason Solution 138 CoverPass direction invalid! Reason Solution 139 140 141 142 FillGroup reference not found! Reason The fill group step of the library resolved by the Program Check (which number has been programmed with the camera step) is not a fill group definition (internal error) Solution Re- start the Program Check (FN-K) No Cameras start point in the program! Reason The point detected by the camera could not be located (found) in the step program. This is a temporary step prior to the welding seam Solution re-start at the beginning of the seam Shift points too close to each other Reason The distance between at least two of the three points required for a 3D shift is less than 5mm. Solution Teach points ensuring a minimum distance of 5mm. No CameraSeam end point in the program! Reason Solution 143 Input function has not been completed! Reason Solution 144 TCP correction too big Reason Solution K5 Troubleshooting Guide (en).doc / 08-09-04 igm Robotersysteme AG 15 Robotersysteme AG 145 146 Error messages K5 Troubleshooting Guide Current Tool-Id does not correspond with the one in the step program! Tool Exchange required!? Reason The requested step may not be directly approached since it has been programmed with a different torch/welding power source. Solution You must first switch to the correct torch. This can be directly achieved by pressing ADD, provided the robot does not collide with the workpiece if started from the current position Coverpass definition<->Root definition Reason Solution 147 Invalid EndCrater parameter Reason Solution 148 No Weaving Points found Reason Solution 149 There are at least 2 circular points required for circular movements! Reason Solution 150 Dwell time on Weaving Point is too long for this frequency Reason Solution 151 Camera jump step: No Camera search data found in SearchBlock! Reason Solution 152 Invalid Weaving Points Reason Solution 153 No calibration angle or distance defined for this axis! Reason Solution 154 16 'SINGLE STEP -' Not possible due to major step changes! Please use GOTO-STEP instead! Reason ‘SINGLE STEP –‘ not possible (for example because of a substation change). Solution Use ‘STEP –‘ and then ‘GOTO STEP’. igm Robotersysteme AG 08-09-04 / K5 Troubleshooting Guide (en).doc K5 Troubleshooting Guide 155 156 Error messages Robotersysteme AG Invalid Reference Point position! Reason The reference point of a definition or a call was not programmed in such a way that it forms a triangle with the start and the end point Solution Modify the reference point position. Error occured during Program Shift/Corr/Add! Refer to IOdebugs resp. Message history! Reason Solution 157 Step doesn't exist Reason Solution 158 End of program reached Reason At the last step of the step program ’Single Step +’ has been pressed. Solution 159 Insufficient SVW memory capacity! Reason Solution 160 161 162 163 164 165 Arc fault! Reason No arc. Solution Check the position of the torch or the power supply. Gas monitoring alarm! Reason No gas. Solution Check the gas supply. Wire fault! Reason No wire. Solution Check the wire supply. Water fault! Reason No water. Solution Check the water circulation. Program stopped by ISDES! Reason The running program has been stopped by ISDES. Solution See ISDES for detailed information. Can't access IO hardware! Reason Solution K5 Troubleshooting Guide (en).doc / 08-09-04 igm Robotersysteme AG 17 Robotersysteme AG 166 Error messages K5 Troubleshooting Guide Process still active! Reason Solution 167 Can't access power source! Reason Solution 168 Invalid power source parameters Reason Solution 169 GNS: Common sensor error! Reason Solution 170 ArcSS: Common sensor error! Reason Solution 171 ELS: Common sensor error! Reason Solution 172 CAM: Common sensor error! Reason Solution 173 174 175 176 18 ArcSeamSensing error: Watchdog error Reason Seam sensing does not work. Solution Check the weaving settings or reboot the machine. ArcSeamSensing: Arc Fault Reason The seam sensing board detects longer than 4 weaving points no arc. Solution Reboot the machine. ArcSS: Board IO error Reason Communication error to the arc seam sensing board. Solution Press the RESET button on the seam sensing board or reboot the machine. Can't initialize ArcSeamSensing board! Reason Seam sensing board does not work Solution If the error re-occurs after repeated START attempts, press the RESET button on the seam sensing board. igm Robotersysteme AG 08-09-04 / K5 Troubleshooting Guide (en).doc K5 Troubleshooting Guide 177 178 Error messages Robotersysteme AG Invalid Seamsensing starttriangle (geomertry)! Reason Weaving with seam sensing has been incorrectly programmed Solution The weaving points must form a triangle with the starting points and may not be in line. Modify the weaving points accordingly (it is recommended to use Weaving Width/Height) ELS CRC error during serial transmission Reason Solution 179 ELS timeout error during serial transmission Reason Solution 180 Invalid message telegram received from ELS Reason Solution 181 No serial communication with ELS Reason Solution 182 ELS: Invalid checksum Reason Solution 183 ELS: Internal buffer overflow Reason Solution 184 ELS: Cannot compute result Reason Solution 185 ELS: Too many invalid measurements Reason Solution 186 ELS: General error Reason Solution 187 ELS: Invalid command Reason Solution K5 Troubleshooting Guide (en).doc / 08-09-04 igm Robotersysteme AG 19 Robotersysteme AG 188 Error messages K5 Troubleshooting Guide ELS: Buffer overflow Reason Solution 189 ELS: Restart SearchStep! Reason Solution 190 CAM: I/O data error! Reason Solution 191 CAM: Joint setup failed! Reason Solution 192 CAM: No communication! Reason Solution 193 CAM: Unknown Camera type Reason Solution 194 CAM: Camera alarm! Reason Solution 195 CAM: External Camera alarm! Reason Solution 196 CAM: Max. temperature exceeded Reason Solution 197 198 20 Action locked (incorrect state 1), press STOP to continue! Reason Operation is not possible. Solution Press the STOP button to continue. Action locked (incorrect state 2), press STOP to continue! Reason Operation is not possible. Solution Press the STOP button to continue. igm Robotersysteme AG 08-09-04 / K5 Troubleshooting Guide (en).doc K5 Troubleshooting Guide 199 200 201 Error messages Robotersysteme AG FATAL: ALF Command not implemented?!? Reason Connection to ALF broken. Solution Reboot the machine. FATAL: ALF closed?!? Reason Connection to ALF broken. Solution Reboot the machine. FATAL: Too many keys pressed simultaneously! Reason Solution 202 203 Console disconnected or communication lost! Reason Communication between controller and console is lost. Solution Check the connection between controller and console. FATAL: Connection to SYNC/KNINET Station lost! Reason Solution 204 FATAL: Key on the teachpendant stuck (is permanently pressed)! Reason Solution 205 Keyboard locked! Reason Solution 206 Air Fault! Reason Solution 207 External Stop! Reason Solution 208 UPS Active! Reason UPS was activated. Solution 209 ALF Par Invalid?!? Reason Connection to ALF broken. Solution Reboot the machine. K5 Troubleshooting Guide (en).doc / 08-09-04 igm Robotersysteme AG 21 Robotersysteme AG 210 211 Error messages K5 Troubleshooting Guide External STOP active! Reason External STOP is active. Solution Check the connected devices. Alf Myp Info!?! Reason Solution 212 213 214 Power supply failed! Reason The power supply failed. Solution Check the power supply. Drives are shut off! Reason The drives are shut off. Solution Switch on the drives. Alf Req Zero Input!?! Reason Solution 215 FATAL: ULF Command not implemented?!? Reason Solution 216 FATAL: ULF connection lost?!? Reason Solution 217 FATAL: ULF Command out of range?!? Reason Solution 218 FATAL: ULF send discrepancy?!? Reason Solution 219 FATAL: Parameter Block size error!? INSVX.O and K5VX.EXE are not compatible?! Reason Solution 220 22 Failed to Get Step 'Nr'! Reason The entered step is not valid. Solution Enter a valid step number. igm Robotersysteme AG 08-09-04 / K5 Troubleshooting Guide (en).doc K5 Troubleshooting Guide 221 Error messages Robotersysteme AG Failed to Add Step! Reason Solution 222 Failed to Insert Step 'Nr'! Reason Solution 223 Failed to Delete Step 'Nr'! Reason Solution 224 225 Can't delete steps with a StepNumber smaller than 3.0.0! Reason Steps with a step number smaller than 3.0.0 must not be deleted. Solution Check your input. Failed to Modify Step 'Nr'! Reason Solution 226 Failed to read last step of program!?! Reason Solution 227 Failed to store Step 'Nr'! Reason Solution 228 Failed to read step before step : Nr!?! Reason Solution 229 Failed to read step subsequent to step: Nr!?! Reason Solution 230 Tool-Id mismatch! Current Id is 'Name' but 'Name' is required! Tool Exchange required?! Reason The requested step may not be directly approached since it has been programmed with a different torch/welding power source. Solution You must first switch to the correct torch. This can be directly achieved by pressing ADD, provided the robot does not collide with the workpiece if started from the current position K5 Troubleshooting Guide (en).doc / 08-09-04 igm Robotersysteme AG 23 Robotersysteme AG 231 Error messages K5 Troubleshooting Guide FN-CORR invalid, because Substation has been changed! Use CORR instead of FNCORR! Reason Solution 232 233 234 235 236 Invalid to change WRK number, use CORR instead of FN-CORR! Reason There was an attempt to change the workpiece coordinate system of a teached step without changing its position. Due to the coordinate position change this is not possible. Solution Approach step, change workpiece coordinate system, use CORR instead of FN-CORR. Step 2.0.0 must be a non-linear JOG step (for '.PRG' files)! Reason Step 2.0.0 is not a non-linear JOG-step. Solution Correct step 2.0.0 accordingly or insert a new step with ALT+INS. Correction to this step type is not allowed! Use ADD or INS instead! Reason A mainstep was corrected to a substep or vice versa. Solution Delete the mainstep and create a new substep with ADD or INS. Cannot correct a Mainstep to a Substep and vice versa! Use ADD or INS instead! Reason A mainstep was corrected to a substep or vice versa. Solution Delete the mainstep and create a new substep with ADD or INS. FATAL: Failed to get position data?!? Reason Solution 237 238 239 240 24 No Name defined! Reason No name is defined. Solution Enter a name. No Jump target defined! Reason No jump target is defined. Solution Enter a jump target. No Search path Reference name defined! Reason No search path reference name is defined. Solution Enter a search path reference name. FillGroup Name missing! Reason No fill group name is defined. Solution Enter a fill group name. igm Robotersysteme AG 08-09-04 / K5 Troubleshooting Guide (en).doc K5 Troubleshooting Guide 241 Error messages Robotersysteme AG Welding Sequence Definition name missing! Reason No welding sequence definition is defined. Solution Enter a welding sequence definition. Reason refer to error number 240 Solution refer to error number 240 Reason refer to error number 241 Solution refer to error number 241 242 243 244 Root reference name missing while Start Coverpass is unequal to zero! Reason Solution 245 End Coverpass number must not be smaller than the Start Coverpass number! Reason Solution 248 Parameter file 'Name' not found! Reason Solution 249 Failed to load Parameter file! Reason Solution 250 Failed to save Parameter file! Reason Solution 253 Failed to load parameters for Substation NR! Reason Solution 255 Failed to save changes!?! Reason Solution 256 FATAL: Failed to save Pre-defined function(s) in PAR!?! Reason Solution K5 Troubleshooting Guide (en).doc / 08-09-04 igm Robotersysteme AG 25 Robotersysteme AG 257 Error messages K5 Troubleshooting Guide FATAL: Failed to save Ext. Start Assignments in PAR!?! Reason Solution 258 FATAL: Failed to delete External start assignment!?! Reason Solution 259 Failed to add Ext. start 'Nr : Name'! Start Number already assigned! Reason Solution 260 Invalid function name! Reason Solution 261 Input Error: Neither inputs nor outputs defined! Reason Solution 262 263 264 Input Error: Nr is not a valid Output bit number! Inputs: X000-X099, Outputs: X100-X199 Reason The entered bit number is invalid. Solution Enter a valid bit number. Input Error: Nr is not a valid Input bit number! Inputs: X000-X099, Outputs: X100-X199 Reason The entered bit number is invalid. Solution Enter a valid bit number. FATAL: Failed to save Robot data in PAR!?! Reason Solution 265 FATAL: Failed to save Station data in PAR!?! Reason Solution 268 Couldn't create Weaving Points! Reason Solution 269 26 Invalid step configuration for Width/Height programming! Reason Start and target step must be of a certain type Solution Check the start step and the end step of the path. The target step must be a WORK step including weaving. In addition, the workpiece coordinate system may not be switched. igm Robotersysteme AG 08-09-04 / K5 Troubleshooting Guide (en).doc K5 Troubleshooting Guide 270 271 Robotersysteme AG Provided input data insufficient! Reason The provided input data is insufficient. Solution Check your input data. Can't compute new Weaving Points! Reason Solution 272 Error messages The position or the type of start or target point do not allow computation of weaving points. Check the start step and the end step of the path. The target step must be a WORK step including weaving. In addition, the workpiece coordinate system may not be switched. Coordinates for Starting Step of Weaving path not found! Reason Solution 273 274 Only 0, 2 or 3 WeavingPoints for Width/Height programming are valid! Reason Invalid number of weaving points found. Solution Correct the step program accordingly. Can't compute coordinate frame. Check Positions! Reason Solution 276 Saved WRK with step. Don't forget to save Parameters, too! Reason Solution 277 Unknown axis type Reason Solution 279 Input error: P1, P2 or P3 position missing! Reason Solution 280 Interpreter Locked! Reason Solution 281 FATAL Error: Couldn't activate Params (with ALF)!? Reason Connection to ALF broken. Solution Reboot the machine. K5 Troubleshooting Guide (en).doc / 08-09-04 igm Robotersysteme AG 27 Robotersysteme AG 282 283 284 Error messages K5 Troubleshooting Guide FATAL Error: Failed to copy Params to ALF!?! Reason Connection to ALF broken. Solution Reboot the machine. FATAL Error: Failed to send current context settings to ALF!?! Reason Connection to ALF broken. Solution Reboot the machine. Error: Step must be a JOG or WORK step! Reason The selected step must be a JOG or WORK step. Solution 285 Error: Substation or Working Coordinate system mismatch!? Reason Solution 286 Step range end is smaller/equal than step range starting number! Reason Solution 287 Insertion of steps into the selected step range is not valid! Reason Solution 288 Manipulation within a step area smaller '2.0.0' is not possible! Reason Solution 293 295 296 297 28 Axis configurations of source Station and target Station are different! Reason Station shift not possible, because source substation and target substation have different axis configuration. Solution Check the axis configuration of the sub stations. Begin or End Step Number is missing! Reason Begin and/or end step number is missing. Solution Check your input. Target Step Number is missing! Reason Target step number is missing. Solution Check your input. Value 'Number of Insertions' is missing or not valid! Reason The number of insertions is not valid or missing. Solution Check your input at ‘Amount’. igm Robotersysteme AG 08-09-04 / K5 Troubleshooting Guide (en).doc K5 Troubleshooting Guide 298 299 Error messages Robotersysteme AG Inputs missing: For a 1D shift ONE Source and Target point, for a 3D shift all points are required! Reason For a 1D shift one source AND target point are required. For a 3D shift three source AND target points are required. Solution Check the points. Position is in Wrk Coord System Nr, but 1 (World) is required! Reason Solution 300 Incorrect Source SubStat - Nr at Shift Begin (M.S.T), but Nr (or 0,1,2) is required! Reason Solution 301 Incorrect Source SubStat - Nr at Shift Begin (M.S.T), but Nr or 1 (Rob) is required! Reason Solution 302 Incorrct Wrk Coord System - Nr at Shift Begin (M.S.T), Nr or 1 (World) expected! Reason Solution 303 Step (M.S.T): INCORRECT Source SubStat - NUMB, NUMB (or 0,1,2) expected! Reason Solution 304 Step (M.S.T): WrkNmb NUMB => NUMB - NOT ALLOWED! Reason Solution 305 Step (M.S.T): WrkNmb NUMB => NUMB - NOT ALLOWED! Reason Solution 306 Step (M.S.T): SubStat NUMB => NUMB - NOT ALLOWED! Reason Solution 307 ShiftCoor of ELS or CAM RefPos on SN (M.S.T) failed! Reason Solution 308 ShiftCoor of SN (M.S.T) failed! Reason Solution K5 Troubleshooting Guide (en).doc / 08-09-04 igm Robotersysteme AG 29 Robotersysteme AG 309 Error messages K5 Troubleshooting Guide Failed to modify SN (M.S.T)! Reason Solution 310 LIB: Definition 'NAME' not found! Reason Solution 311 LIB: Target step of definition 'NAME' not found! Reason Solution 312 LIB: Ref point of definition 'NAME' not found! Reason Solution 314 Username not found Reason Solution 315 316 Incorrect Password entered! Reason A wrong password was entered. Solution Enter the right password. This user-entry cannot be deleted! Reason Solution 317 318 Current User is not authorized for this action Reason The current user is not authorized for this operation. Solution Check your input or switch to another user account. Action not allowed! Key-Lock in AUTOMATIC mode is active! Reason Solution 319 Failed to create New user! Already existing? Reason Solution 320 30 No more AUX steps found in program! Reason There is no more AUX step in the remaining step program. Solution Check your input. igm Robotersysteme AG 08-09-04 / K5 Troubleshooting Guide (en).doc K5 Troubleshooting Guide 323 324 331 332 333 Error messages Robotersysteme AG Program 'XXX.prg' must be deactivated first! Reason For this operation the program must be deactivated. Solution Deactivate the program. Cannot activate a new program while another program is still running! Reason There was an attempt to activate a program while another program is running. Solution Stop the running program and then activate the other program. Failed to delete file 'Name'! Reason File cannot be deleted. Solution Check the write protection. Failed to load program 'XXX.prg'! Reason The program cannot be loaded. Solution The file is corrupted. Failed to open program 'XXX.prg'! Reason Solution 334 Failed to activate program 'XXX.prg'! Reason Solution 335 Failed to reset Programm Call stack!?! Reason Solution 336 Failed to deactivate program 'XXX.prg'! Reason Solution 337 Failed to save program 'XXX.prg'! Reason Solution 338 Program 'XXX.prg' not in Memory, please load first! Reason Solution 339 Cannot activate the Library Program because it is not referred to by the current program 'XXX.prg'! (refer to step 1.0.0) Reason Solution K5 Troubleshooting Guide (en).doc / 08-09-04 igm Robotersysteme AG 31 Robotersysteme AG 340 341 342 343 344 345 346 347 348 Error messages K5 Troubleshooting Guide Cannot rename multiple files (Please select one file only!) Reason Only one file can be renamed at the same time. Solution Select only one file. Couldn't create new step program 'XXX.prg'! Reason There is already a step program with this name. Solution Choose another name for the step program. No Program Active! Reason For this operation the program must be activated. Solution Activate the program. Disk drive not ready! Floppy inserted and formatted? Reason There is no floppy in the drive or the inserted floppy is not formatted or defect. Solution Insert a formatted floppy. Host-PC not accessible! Check Host-PC or Network connection! Reason The Host PC is not accessible. Solution Check the host pc or the network connection. Directory Name not found! Reason The directory was not found. Solution Check your input. Insufficient space available on target device 'Name'! Reason There is not enough free memory on the target device. Solution Check the free memory on the target device. Use another target device. Max. number of step programs in Memory reached (Nr)! Please delete programs currently not required. Reason The maximum number of step programs in the memory is reached. Solution Delete currently not required step programs. Failed to start Program 'XXX.prg'! Reason Solution 349 Failed to Stop program!?!?! Reason Solution 350 FATAL Error: Failed to initialize SVW!?! Reason Solution 32 igm Robotersysteme AG 08-09-04 / K5 Troubleshooting Guide (en).doc K5 Troubleshooting Guide 351 352 353 354 355 356 357 358 359 Error messages Robotersysteme AG Invalid File Extension! Only '.prg' or '.lib' is allowed! Reason Invalid file extension. Solution File can be saved only with .prg or .lib. Invalid File Extension! Only '.prg' is allowed! Reason Invalid file extension. Solution Program can be saved only with the extension .prg. Invalid File Extension! Only '.lib' is allowed! Reason Invalid file extension. Solution Library can be saved only with the extension .lib. Failed to create directory 'XXX'! Reason Directory cannot be created. Solution Check if the volume is write protected. Input Error. 'xyz' has been defined, but valid value range is: 'abc' Reason The entered value is outside of the valid range. Solution Enter a valid value. Text too long (Nr), text was truncated Only Nr characters allowed! Reason The text is too long. The text was truncated. Solution Use a shorter name. Invalid value input. Format is 'Bitnumber State' e.g. '1002 1' or '1103 0' or '1109:1' Reason The entered values have the wrong format. Solution Check your input. Invalid value input. Format is 'Min-Value Max-Value' e.g. '-100.1 200.5' or '100 300' Reason The entered values have the wrong format. Solution Check your input. Program 'XXX.prg' stopped with error! Reason Solution 360 361 Searched Text not found! Reason The searched text has not been found. Solution Check your input. Failed to analyze step! Check valid combinations! Reason Solution K5 Troubleshooting Guide (en).doc / 08-09-04 igm Robotersysteme AG 33 Robotersysteme AG 362 Error messages K5 Troubleshooting Guide Incompatible Substation configuration (prog-AxId:AxNr, required-AxId:AxNr)! Reason Solution 363 364 External/Workpiece Coordinate-System with step '1.Nr.0' not compatible, overwrite using values assumed from Parameter file? Reason Parameter file and step program are not identical regarding the workpiece coordinate systems. Possibly, an external axis have be re-identified after the step program generation. Solution If ADD is answered, the identification data of the current parameter file are copied into the step program overwriting stored information. In order to avoid future system messages the program must be saved again. It is recommended to check whether the program can be still executed using the new identification data before it is saved. Displayed step is not identical with step in step program! Reason Solution 365 FATAL ERROR EXCEPTION!! Please forward this Error to igm! "xyz" Reason Solution 366 FATAL MATH ERROR EXCEPTION!! Please forward this Error to igm! "xyz" Reason Solution 368 369 Action not allowed outside of active ShiftBlock: 'x-y' [Nr]! Reason Attempt to quit the currently active shift block Solution If this action is really required (provided no further teaching or correcting within the block is necessary) ALL shift blocks may be deleted by FN+T or GOTO STEP 2.0.0. In addition, if nested blocks are used, the currently active shift may be quit by GOTO STEP to the Shift End step. Unauthorized action, since you are neither user 'Admin' nor 'igm_Service'! Reason Solution 370 371 Message History saving error! Floppy not inserted or full? Reason There is no floppy in the drive or the inserted floppy is full. Solution Insert an empty, formatted floppy. Error while saving IODebugs! Reason Solution 34 igm Robotersysteme AG 08-09-04 / K5 Troubleshooting Guide (en).doc K5 Troubleshooting Guide 372 373 374 375 376 Error messages Robotersysteme AG All Robots must be stopped before SYNC mode may be changed! Reason The SYNC mode may only be changed when the robots are stopped. Solution Stop the robots. Cannot calibrate more than one axis simultanously! Reason Only one axis can be calibrated at the same time. Solution Calibrate only one axis at the same time. Only programs in memory may be merged! Reason Only programs in the memory may be merged. Solution Load the desired programs in the memory. More than 1 program must be selected! Reason More than one step program must be selected for merging. Solution Select all the step programs you want to merge. Failed to turn on Drives!!?? Reason Solution 377 378 Working limits may not exceed Hard Limits. Valid value range is x..y! Reason Working limits must be smaller than hard limits. Solution Check the limits. Min/Max Limit values exchanged and/or Working-Limits adjusted to be inside the HardLimits! Reason Solution 379 380 External Start ignored, since the Operating mode is not AUTO, the DRIVES are off, not EOP or wrong sync-range! Reason The external start is ignored because of one of the above reasons. Solution Check the conditions for the external start. External Start ignored! Max. number of pre-selections reached! Reason Solution 381 382 One or more used axes are not calibrated! (cal:0xAxNr, mask:0xAxNr) Reason One or more used axes are not calibrated. Solution Calibrate the indicated axes. Failed to send Gasnozzle Search voltage ON/OFF command! Reason Solution K5 Troubleshooting Guide (en).doc / 08-09-04 igm Robotersysteme AG 35 Robotersysteme AG 383 384 385 386 387 388 Error messages K5 Troubleshooting Guide Failed to format Floppy! Floppy inserted? Floppy defect? Reason There is no floppy in the drive or the inserted floppy is defect. Solution Insert a new floppy. Action is not possible! Drives are off! Reason Operation can not be executed because the drives are shut off. Solution Switch on the drives. Can't turn on drives, since the operation mode is not AUTO! Please use the permissionswitch instead! Reason The drives cannot be turned on because the operation mode is not AUTO. Solution Press the permission switch when you turn on the drives. External emergency button has been pressed! Reason The external emergency button has been pressed. Solution Release the external emergency button. Safety gate! Reason The safety gate has been activated. Solution Check the safety gate. Activation during manual movement! Reason Solution 389 Internal speed limit! Reason Speedlimit inside the controllersoftware to high. This boundary cannot be adjusted directly, is set to 10% above the nominal rpm-value of the axis and is used for internal safety purposes. Normally this error must not occur. Solution 390 Internal tracking error! Reason Speedlimit inside the controllersoftware to high. This boundary cannot be adjusted directly, is set to 2 motor revolutions and is used for internal safety purposes. Normally this error must not occur. Solution 391 392 Torchsafety switched! Reason The torch has been collided with an object. Solution Move the robot manually or deactivate the Torch switch-off and move the robot from the object. Servoerror Reason Solution 36 igm Robotersysteme AG 08-09-04 / K5 Troubleshooting Guide (en).doc K5 Troubleshooting Guide 393 Error messages Robotersysteme AG Testerror Reason Solution 394 Motor Overtemperature Reason Solution 395 HEDA: Bus Error Reason Solution 396 HEDA: Bus Warning Reason Solution 397 HEDA: Bus Sync Vers Reason Solution 398 HEDA: Bus Comm Error Reason Solution 399 HEDA: Bus not synchronized Reason Solution 400 HEDA: Bus negative response Reason Solution 401 HEDA: Tracking error Reason Tracking error of a COMPAX servo drive. The limit is set with servo parameter P79. Solution 402 HEDA: Bus Watchdog error Reason Solution 403 HEDA: Bus Offline Reason Solution K5 Troubleshooting Guide (en).doc / 08-09-04 igm Robotersysteme AG 37 Robotersysteme AG 404 Error messages K5 Troubleshooting Guide HEDA E00: No error Reason Solution 405 HEDA E01: Not configured Reason Solution 406 HEDA E05: Machine zeropos - Initiator not found Reason Solution 407 HEDA E07: Calculation error Reason Solution 408 HEDA E08: Synchronous - STOP is pending Reason Solution 409 HEDA E09: Drive is not moving Reason Solution 410 HEDA E10: Tracking error too big Reason COMPAX Tracking error limit crossed. Adjustable with servo-parameter P13. Solution 411 HEDA E11: Programmed position not reached Reason Solution 412 HEDA E15: Error in 2. position-measurementsystem Reason Solution 413 HEDA E16: Selected setnumber does not exist Reason Solution 414 HEDA E17: Selected setnumber too big Reason Solution 38 igm Robotersysteme AG 08-09-04 / K5 Troubleshooting Guide (en).doc K5 Troubleshooting Guide 415 Error messages Robotersysteme AG HEDA E18: The topmost set 250 is already in use Reason Solution 416 HEDA E19: No more space in setmemory available Reason Solution 417 HEDA E20: Target position above positive limit Reason Solution 418 HEDA E21: Target position below negative limit Reason Solution 419 HEDA E22: Not moved to machine zerosition Reason Solution 420 HEDA E23: The pending command is not allowed Reason Solution 421 HEDA E24: Selected speed invalid Reason Solution 422 HEDA E25: Selected position invalid Reason Solution 423 HEDA E26: REPEAT without END or GOSUB without RETURN Reason Solution 424 HEDA E27: Parameter must not be overwritten Reason Solution 425 HEDA E29: Motorparameters are missing Reason Solution K5 Troubleshooting Guide (en).doc / 08-09-04 igm Robotersysteme AG 39 Robotersysteme AG 426 Error messages K5 Troubleshooting Guide HEDA E30: Hardware - Malfunction Reason Solution 427 HEDA E31: Error in parameters Reason Solution 428 HEDA E32: Error in parameters Reason Solution 429 HEDA E33: Error in program - memory Reason Solution 430 HEDA E34: Error in program - memory Reason Solution 431 HEDA E35: Hardware - Malfunction Reason Solution 432 HEDA E36: Hardware - Malfunction Reason Solution 433 HEDA E37: Auxiliary voltage +15 V missing Reason Solution 434 HEDA E38: Link Voltage too high Reason Solution 435 HEDA E39: Temperature too high (>85 Deg) Reason Solution 436 HEDA E40: Input Enable of output stage not active Reason Solution 40 igm Robotersysteme AG 08-09-04 / K5 Troubleshooting Guide (en).doc K5 Troubleshooting Guide 437 Error messages Robotersysteme AG HEDA E41: Output stage reports an error Reason Solution 438 HEDA E42: Resolver- / Encodererror Reason Solution 439 HEDA E43: Output overloaded Reason Solution 440 HEDA E44: Pos. Auxiliary voltage out of tolerance Reason Solution 441 HEDA E45: Neg. Auxiliary voltage out of tolerance Reason Solution 442 HEDA E46: Powersupply +24V too high Reason Solution 443 HEDA E47: Powersupply +24V too low Reason Solution 444 HEDA E48: Motor thermoswitch reports an error Reason Solution 445 HEDA E49: Motor or Drive reports blocking Reason Solution 446 HEDA E50: Endswitch 1 activated Reason Solution 447 HEDA E51: Endswitch 2 activated Reason Solution K5 Troubleshooting Guide (en).doc / 08-09-04 igm Robotersysteme AG 41 Robotersysteme AG 448 Error messages K5 Troubleshooting Guide HEDA E52: Error in Emergency-Stop - circuitry Reason Solution 449 HEDA E53: Motor overloaded Reason Solution 450 HEDA E54: Speed is higher than max. motorspeed Reason Solution 451 HEDA E55: External Emergency-Stop Reason Solution 452 HEDA E56: Emergency-Stop directly to COMPAX-M Reason Solution 453 HEDA E57: Link Voltage too low (<70V) Reason Solution 454 HEDA E58: Temperature is getting too high or SinCos - Temp-error Reason Solution 455 HEDA E65: Encodererror Reason Solution 456 HEDA E72: Block - Check - Character - Error Reason Solution 457 HEDA E90: Syntaxerror Reason Solution 458 HEDA E91: Command is not executeable in this COMPAX-operationmode Reason Solution 42 igm Robotersysteme AG 08-09-04 / K5 Troubleshooting Guide (en).doc K5 Troubleshooting Guide 459 Error messages Robotersysteme AG HEDA E92: Function is running, can't execute command Reason Solution 460 HEDA E93: Setmemory is active, can't execute command Reason Solution 461 HEDA E94: Password is missing Reason Solution 462 KPS: IBS_ERROR Reason Solution 463 KPS: IBS_ERROR_KPS Reason Solution 464 KPS: IBS_ERROR_DSE Reason Solution 465 KPS: IBS_UNKOWN_PARTICIPANT Reason Solution 466 KPS: DSE_RDW Reason Solution 467 KPS: DSE_CHECKSUM Reason Solution 468 KPS: BRAKE_CHANNEL1 Reason Solution 469 KPS: BRAKE_CHANNEL2 Reason Solution K5 Troubleshooting Guide (en).doc / 08-09-04 igm Robotersysteme AG 43 Robotersysteme AG 470 Error messages K5 Troubleshooting Guide KPS: HEAT_SINK_TEMP Reason Solution 471 KPS: OVER_VOLTAGE Reason Solution 472 KPS: OVER_VOLTAGE_CHARGING Reason Solution 473 KPS: UNDER_VOLTAGE_CHARGING Reason Solution 474 KPS: UNDER_VOLTAGE Reason Solution 475 KPS: WATCHDOG_KPS Reason Solution 476 KPS: BALLASTRESISTOR_TEMP Reason Either the temperature of the ballast resistor is too high or the cabinet fan is switched off. Usually the fuse for the fan has been turned off. Solution 477 KPS: PUFFERBATTERYVOLTAGE_LOW Reason Solution 478 KPS: CABINETT_TEMPERATURE Reason Solution 479 KPS: BALLASTSWITCH_TO_LONG_ON Reason Solution 480 KPS: BALLASTSWITCH_TO_LONG_ON_CHARGING Reason Solution 44 igm Robotersysteme AG 08-09-04 / K5 Troubleshooting Guide (en).doc K5 Troubleshooting Guide 481 Error messages Robotersysteme AG KPS: CHARGING_UNIT Reason Solution 482 KPS: K1_CONTACT_FAULT Reason Solution 483 KPS: SYSTEM_FAULT_KPS Reason Solution 484 KPS: FAULT_PARASET_KPS Reason Solution 485 KPS: INT_FAULT_KPS Reason Solution 486 KPS: COMMUNICATION_ERROR_EEPROM_CONTROL Reason Solution 487 KPS: UNKNOWN Reason Solution 488 DSE: LENZE_TRIP Reason Solution 489 DSE: RESOLVER Reason Solution 490 DSE: FOLLOWING_ERROR Reason Solution 491 DSE: MOTOR_BLOCKED Reason Solution K5 Troubleshooting Guide (en).doc / 08-09-04 igm Robotersysteme AG 45 Robotersysteme AG 492 Error messages K5 Troubleshooting Guide DSE: COLLISION_DETECTION Reason Solution 493 DSE: NO_COMMAND_VALUE Reason Solution 494 DSE: OVER_CURRENT Reason Solution 495 DSE: BRAKE Reason Solution 496 DSE: SYNC_INPUT Reason Solution 497 DSE: SYNCRONIZATION_SERVO_BUS Reason Solution 498 DSE: DURING_QUICKSTOP Reason Solution 499 DSE: SERVOBUS Reason Solution 500 DSE: SHORT_CIRCUIT Reason Solution 501 DSE: EARTH_FAULT Reason Solution 502 DSE: IXT_OVERLOAD Reason Solution 46 igm Robotersysteme AG 08-09-04 / K5 Troubleshooting Guide (en).doc K5 Troubleshooting Guide 503 Error messages Robotersysteme AG DSE: MOTORPHASE_FAILURE_DETECTION Reason Solution 504 DSE: HEAT_SINK_TEMP Reason Solution 505 DSE: SYSTEM_FAULT_DRIVE Reason Solution 506 DSE: FAULT_PARASET Reason Solution 507 DSE: COMMUNICATION_ERROR_EEPROM_CONTROL Reason Solution 508 DSE: COMMUNICATION_ERROR_EEPROM_POWER Reason Solution 509 DSE: EXT_FAULT_DRIVE Reason Solution 510 DSE: INT_FAULT_DRIVE Reason Solution 511 DSE: CHECKSUMFAULT_DRIVE Reason Solution 512 DSE: NO_POWER Reason Solution 513 DSE: WRONG_OPERATION_MODE Reason Solution K5 Troubleshooting Guide (en).doc / 08-09-04 igm Robotersysteme AG 47 Robotersysteme AG 514 Error messages K5 Troubleshooting Guide DSE: UNKNOWN Reason Solution 515 TCP Correction cannot be called from inside TCP correction program! Deactivate the active program first! Reason Solution 516 Tool Exchange cannot be called from inside Toolexchange program! Deactivate the active program first! Reason Solution 517 Error: This shift requires equal Coordinate length for Source and Target!? Reason Solution 518 Error: This shift requires equal substation for World and Work!? Reason Solution 519 Error: The count is zero! Reason Solution 520 Failed to create file 'Name'! Is the media write protected? Reason Solution 521 Failed to save file 'Name'! Is enough space available on the media? Reason Solution 522 Failed to open file 'Name'!? Reason Solution 523 Warning: No printer (driver) installed on this system! Only file print is available. Reason Solution 524 Error: Failed to update the Sync-information! Reason Solution 48 igm Robotersysteme AG 08-09-04 / K5 Troubleshooting Guide (en).doc K5 Troubleshooting Guide 525 Error messages Robotersysteme AG Targetprogramname or Shiftdata are missing! Reason Solution 526 Template Filename is missing! Reason Solution 527 530 531 532 Invalid Stationname on step 1.0.0 in program 'XXX.prg', Stationname: xyz! Reason Called program is not compatible with the current parameter file settings Solution Check the start step of the called program. The station name must correspond with current parameter file settings. Maybe you are required to transfer the program from another control system using StationShift. K5VxSim.exe is not running, aborting the application! K5VxSim has to run, before you can use K5Vx3ds.exe. Reason K5VxSim is not running when K5 Offline is started. Solution Start K5VxSim first. Failed to connect to 3D Studio Max! Is the Hardlock dongle installed and the plugin registered? Reason Failed to connect K5 Offline and 3dsmax. Solution Check if the dongle is connected or the plugins in 3dsmax are registered. Failed to connect to RealTimeValue Position Server!?! Reason Solution 533 534 535 Program stopped by 3DS collision detection! Reason Program stopped by a collision in 3dsmax. Solution Check the program or the setting of the collision mode. Bad Stepprogram Version number entered (Nr)! Also the number cannot be higher than the current supported version 'Nr'! Reason The entered stepprogram version number is not valid. Solution Enter a valid version number. Missing ignition rewind steps after Step M.S.T in program 'XXX.prg'! Reason Solution 536 Different number of SyncSteps, Start not possible! Station XYZ: Nr Station XYZ: Nr Reason Solution K5 Troubleshooting Guide (en).doc / 08-09-04 igm Robotersysteme AG 49 Robotersysteme AG 537 Error messages K5 Troubleshooting Guide Different end of program state, Start not possible! Station XYZ: Nr Station XYZ: Nr Reason Solution 538 For KNINET/SYNC another K5VxSim.exe must also run in Slave-Mode! Continuing in SINGLE mode! Reason Solution 539 KNINET/SYNC mode is requested, but entry 'SyncNeighbours' is missing in the parameterfile! Starting in SINGLE mode! Reason Solution 540 KNINET unknown error! Reason Solution 541 KNINET offline! Reason Solution 542 KNINET SyncType mismatch! Reason Solution 543 KNINET SyncID mismatch! Reason Solution 544 KNINET number of Sync-Steps mismatch! Reason Solution 545 Could'nt add TCP-Correction steps, Nest working coordinate system not defined! Reason Solution 546 Could'nt create nest coordinate system, Actual tools is not refence tool! Reason Solution 547 50 Could not open Conversionfile for K4 program! Filename: Name Reason Cannot open the conversionfile for K4 programs. Solution Check the filename or the entry in the K5-Ini-file. igm Robotersysteme AG 08-09-04 / K5 Troubleshooting Guide (en).doc K5 Troubleshooting Guide 548 549 550 551 Error messages Robotersysteme AG Could not convert K4-function Nr at step xyz! Reason K4 function cannot be converted to K5 function. Solution Check the conversionfile. Could not convert K4-program Name! Reason The K4-program cannot be converted to K5. Solution Check the entries in the conversionfile. CAM reference path not yet executed! Reason The camera reference path is not yet executed. Solution Execute the camera reference path. Bad insert position! Please choose another target step. Reason Solution 552 Bad selection range! Reason Solution 553 Bad selection range end! Reason Solution 554 555 556 557 558 ISDES Database Name could not be created !! Reason The database for embedded ISDES could not be created. Solution Check if there is already a corrupted file with this name in the parameter directory. ISDES Database Name could not be opened !! Reason The database for embedded ISDES could not be opened. Solution Check if the database can be opened. Supervised Parameters for ISDES not defined !! Reason In the parameterfile no parameters are defined for supervision by embedded ISDES. Solution Correct the parameter file accordingly. ISDES Database Name has invalid format !! Reason The database for embedded ISDES has an invalid format. Solution The database is corrupted. Program stopped by ISDES! Name errorlimit minimum reached! Reason The running program has been stopped by embedded ISDES. Solution K5 Troubleshooting Guide (en).doc / 08-09-04 igm Robotersysteme AG 51 Robotersysteme AG 559 Error messages K5 Troubleshooting Guide Program stopped by ISDES! Name errorlimit maximum reached! Reason The running program has been stopped by embedded ISDES. Solution 560 Name errorlimit minimum reached! Reason Embedded ISDES has detected that a supervised parameter had reached its minimum errorlimit. Solution 561 Name errorlimit maximum reached! Reason Embedded ISDES has detected that a supervised parameter had reached its maximum errorlimit. Solution 562 Name warninglimit minimum reached! Reason Embedded ISDES has detected that a supervised parameter had reached its minimum warninglimit. Solution 563 Name warninglimit maximum reached! Reason Embedded ISDES has detected that a supervised parameter had reached its maximum warninglimit. Solution 564 565 570 571 Failed to save ISDES parameters! Reason The embedded ISDES parameters cannot be saved to floppy. Solution Insert an empty, formatted floppy. Failed to load ISDES parameters! Reason The embedded ISDES parameters cannot be loaded from floppy. Solution Check if the ISDES database on the floppy can be opened. ISDES parameters 'Name' not found! Reason The ISDES parameters cannot be found on the floppy. Solution Check if the ISDES database is saved on the floppy. Different Sync-range, Start not possible! Station XYZ before Sync-Step Nr Station XYZ before Sync-Step Nr Reason Solution 572 Position difference external axis watch to big. Set zero position on axis! Reason Solution 52 igm Robotersysteme AG 08-09-04 / K5 Troubleshooting Guide (en).doc K5 Troubleshooting Guide 573 Error messages Robotersysteme AG The Slave controller was turned off in KNINET Mode - continuing not possible! You now have to shutdown the Master controller also! Reason Solution 574 System Locked! The Master controller is waiting to be powered off! Reason Solution 575 576 External Start NUMB ignored due to missing programname assignment! Reason No programname is assigned to this external start. Solution Assign a program to this external start. Failed to copy external start assignment to the Slave controller! Reason Solution 577 Stopped from KNINET! Reason Solution 578 Sync ignition timeout! Reason Solution 579 RT280 Inverse check error (V5.70 not supported on RT280)! Reason Solution 580 The Begin-stepnumber must be a nonlinar JOG step! Reason Solution 581 'Shift Begin' step M.S.T without a searchblock ahead? Program: 'XXX.prg'! Reason Solution 582 No motion possible because brake activated! Reason Solution 583 FailSafe activated - check IOdebugs! Reason Solution K5 Troubleshooting Guide (en).doc / 08-09-04 igm Robotersysteme AG 53 Robotersysteme AG 584 585 586 587 588 Error messages K5 Troubleshooting Guide Programmed speed can't be reached! Reason The programmed speed cannot be reached. Solution Correct the step program accordingly. Refer also to K5 Releasenotes – search for the string "ChkWrkSpd". Could not convert K5-function Nr at step Nr! Reason K5 function cannot be converted to K4 function. Solution Check the conversionfile. Could not convert K5-program Name! Reason The K5-program cannot be converted to K4. Solution Check the entries in the conversionfile. Conversionfile for K4 program not defined in K5-Inifile Name Reason The conversionfile for K4 programs is not defined in the K5-Ini-file. Solution Check the filename and correct the K5-Ini-file accordingly. Dedicated root not found! Reason Solution 589 Error at seam coordinate system of root! Reason Solution 590 SYNC action only allowed if both stations in main program! Reason Solution 591 Program stopped by MotionCheck!$$Check IOdebugs! Reason Solution 592 DSE: COMMUNICATION_CAN_RDW Reason Solution 593 DSE: OVER_VOLTAGE Reason Solution 594 DSE: HEAT_SINK_SENSOR Reason Solution 54 igm Robotersysteme AG 08-09-04 / K5 Troubleshooting Guide (en).doc K5 Troubleshooting Guide 595 Error messages Robotersysteme AG DSE: TEMP_SENSOR Reason Solution 596 DSE: IIT_WARNING Reason Solution 597 DSE: SLAVE_WRONG_AMPLIFIER Reason Solution 598 DSE: SLAVE_DEVIATION_WARNING Reason Solution 599 DSE: SLAVE_DEVIATION_ALARM Reason Solution 600 DSE: SLAVE_DEVIATION_CRITICAL Reason Solution 601 DSE: SLAVE_SPEED_DEVIATION Reason Solution 602 DSE: ASR_ERROR Reason Solution 603 DSE: COMMUTATION_FAULT Reason Solution 604 DSE: INVALID_PARAMETER Reason Solution 605 DSE: COMMUT_MASTERING_SERVO Reason Solution K5 Troubleshooting Guide (en).doc / 08-09-04 igm Robotersysteme AG 55 Robotersysteme AG 606 Error messages K5 Troubleshooting Guide DSE: COMMUT_MASTERING_NO_POWER Reason Solution 607 DSE: WITHIN_QUARTER_TURN Reason Solution 608 DSE: ENCODER_BATTERY Reason Solution 609 DSE: SEC_AXIS_OFF_ACTIVE Reason Solution 610 DSE: FAN_ERROR Reason Solution 611 DSE: ABSPOS_DEVIATION Reason Solution 612 DSE: EXT_ENCODER_ERR Reason Solution 613 DSE: FORCE_CONTROLLER_ERR Reason Solution 614 DSE: BRAKE_CHANNEL_CLOSED Reason Solution 615 DSE: M_S_MAX_POSITION_LIMIT Reason Solution 616 KPS: PUFFERBATTERYVOLTAGE_LOWER_19V Reason Solution 56 igm Robotersysteme AG 08-09-04 / K5 Troubleshooting Guide (en).doc K5 Troubleshooting Guide 617 Error messages Robotersysteme AG KPS: PUFFERBATTERYVOLTAGE_LOWER_22V Reason Solution 618 KPS: FAN_TEMPERARTUR Reason Solution 619 KPS: STARTUP_SEQUENCE_FAULT Reason Solution 620 KPS: PARAMETER_CHECKSUM_FAULT Reason Solution 621 KPS: ENCODE_FPGA_LOOPBACK_FAULT Reason Solution 622 KPS: POWER_INTERFACE_FAULT Reason Solution 623 KPS: A2D_FAULT Reason Solution 624 KPS: A2D_OFFSET_FAULT Reason Solution 625 KPS: INVALID_PARAMETER Reason Solution 626 KPS: FATAL_SYSTEM_ERROR Reason Solution 627 KPS: A2D_TIMEOUT_FAULT Reason Solution K5 Troubleshooting Guide (en).doc / 08-09-04 igm Robotersysteme AG 57 Robotersysteme AG 628 Error messages K5 Troubleshooting Guide KPS: COMMAND_TIMEOUT Reason Solution 629 KPS: SOFTWARE_VERSION_MISMATCH Reason Solution 630 KPS: INVALID_COMMAND Reason Solution 631 KPS: WRONG_MOTOR_RATING Reason Solution 632 KPS: TEMP_WARNING Reason Solution 633 KPS: FPGA_FAULT Reason Solution 634 KPS: OUTPUT_FAULT Reason Solution 635 KPS: MODEL_NUMBER Reason Solution 636 KPS: DC_CURR_TOO_HIGH Reason Solution 637 KPS: DC_CURR_PEAK Reason Solution 638 KPS: DC_CURR_RMS Reason Solution 58 igm Robotersysteme AG 08-09-04 / K5 Troubleshooting Guide (en).doc K5 Troubleshooting Guide 639 Error messages Robotersysteme AG KPS: PHASE_LOSS Reason Solution 640 KPS: DRIVE_DISABLED Reason Solution 641 PC-Fan failed - Please shut down system immediately! Reason Solution 642 Cabinet Top-Fan failed - Please shut down system immediately! Reason Solution 643 Could not open iLS template definition file! Filename: 'Name' Reason Solution 644 System startup error - please check IOdebugs! Reason Solution 645 Searchpoints not created! Displayed step must be a JOG (not a SearchBegin) or WORK step! Reason Solution 646 Refer to K5 Offline documentation / SeamCreator. Welding steps not created! Displayed step must be a WORK step - but does not to be added to the stepprogram! Reason Solution 647 Refer to K5 Offline documentation / SeamCreator. iLS Searchdrive not created! Reason Solution 648 649 Refer to K5 Offline documentation / SeamCreator. Unable not load igmilsfitter.dll! Reason The required component igmilsfitter.dll could not be located or loaded. Solution Try a re-installation of the K5 Software. A template with name 'NAME' already exists! Reason Occurs with iLS resp. iCAM Solution Choose a template name which is not already existing K5 Troubleshooting Guide (en).doc / 08-09-04 igm Robotersysteme AG 59 Robotersysteme AG 650 651 652 653 Error messages K5 Troubleshooting Guide Maximum number of templates reached! Reason Occurs with iLS resp. iCAM Solution Delete not anymore necessary templates A template with number NUMB already exists! Reason Occurs with iLS resp. iCAM Solution Choose a template number which is not already existing CAM: Joint geometry alarm - COMMON! Reason Occuss with Laser Cameras. With the programmed step a valid seam geometry cannot be calculated. Solution Change the positions of the affected steps. Also the weaving geometry could cause such an errer message! CAM: Joint geometry alarm - GAP! Reason Occuss with Laser Cameras. Solution 654 CAM: Joint geometry alarm - AREA! Reason Occuss with Laser Cameras. Solution 655 CAM: Joint geometry alarm - WELDED AREA! Reason Occuss with Laser Cameras. Solution 656 CAM: Joint geometry alarm - EDGE! Reason Occuss with Laser Cameras. Solution 657 658 659 Version mismatch in igmilsfitter.dll. Can not proceed. Please install right version! Reason The DLL does not fit to the K5 Version Solution Reinstall the entire K5 Version WSD name of coverpass NAME does not match WSD name NAME of referenced root! Program 'XXX.prg'! Reason Happens with splitted multilayers, when the names do not match. Solution Check the programmed steps and the reference names used there. Step M.S.T referenced by GNS jump in 'XXX.prg' is not GNS search step with jump function! Reason Solution 60 igm Robotersysteme AG 08-09-04 / K5 Troubleshooting Guide (en).doc K5 Troubleshooting Guide 660 661 662 663 Error messages Robotersysteme AG Axis- resp. Objectname 'NAME' not found in 3ds scene! Reason K5 Offline: The required objectname could not be found in 3ds. Solution Check all objects in the scene and compare the names with the parameterfile. Parent Axis/Object 'NAME' not found in 3ds scene! Reason K5 Offline: The required objectname could not be found in 3ds. Solution Check all objects in the scene and compare the names with the parameterfile. Empty Axis- resp. Objectname!? Reason K5 Offline: The required objectname could not be found in 3ds. Solution Check all objects in the scene and compare the names with the parameterfile. Load iLS-history from 'NAME' failed! Reason There is no history or it cannot be found in the given directory. Solution 664 HEDA E76: Heda synchronization error Reason Solution 665 HEDA E77: Heda transmission error Reason Solution 666 HEDA E78: Heda multiple transmission error Reason Solution 667 HEDA E79: Heda coupling error Reason Solution 668 669 670 ISDES-Authorization failed! Reason An invalid ISDES authorization code was entered Solution Check the code or request a new on from igm Failed to rename Program XXX.prg to XXX.prg Reason The attempt to rename a certain file failed. Solution Does the K5 software have write access to the selected file? There were no shift settings saved yet! Reason Solution K5 Troubleshooting Guide (en).doc / 08-09-04 igm Robotersysteme AG 61 Robotersysteme AG 671 Error messages K5 Troubleshooting Guide Data not accepted! The Shift-setting substation (NUMB) does not match the current substation (NUMB)! Reason Solution 672 673 674 675 Power source not ready! Reason The powersource is either not turned on or the contraller cannot establish a communication. Solution Check the wiring and the settings in the parameterfile. No step range selected! Please mark a begin and an end step. Reason It was tried to launch a steparea action without selecting something before Solution Select the desired step range before. CAM: Camera setup failed! Does the programmed Joint-Type (template) exist on the camera? Reason It was tried to select a template which does not exist on the camera Solution Create this corresponding template with the corresponding number on the camera or you select one template, which exists. Encoder reference path not yet executed! Reason Solution 676 Failed to get position from external encoder! Reason Solution 677 678 679 Actual program can't be called! Reason It was tried to call the same programme recursively. Solution Remove the AUX call step which causes this. The call on the same programm is not possible! Power source NUMB in fault state! Reason A fault has appeared on the current source. Solution Reset the powersource or try to load the parameters newly. External encoder not defined in actual substation! Reason Solution 680 Address of external encoder not defined! Reason Solution 62 igm Robotersysteme AG 08-09-04 / K5 Troubleshooting Guide (en).doc K5 Troubleshooting Guide 681 Error messages Robotersysteme AG Can not save invalid camera calibration result! Reason iCAM: Solution 682 Invalid Mount-Index! Valid range: 1..Nr Reason Solution 683 684 HASP Dongle could be sucessfully located, but probably there are too many concurrent systems running?! Reason K5 Offline: It was tried to start several authorities of the programm. This is not possible! Solution If the Dongle is installed on a network server, there is only a limited number of clients which can connect to. Close other clients first. DeviceNet offline! For details see IOdebugs! Reason Solution 685 Invalid change of work-coordinates in weld sequence on step M.S.T! Reason Solution 686 Step referenced by shift begin step M.S.T in program 'XXX.prg' is not a search block! Reason Solution 687 688 689 Creation of TCP correction program with torch 8 not allowed! Reason With the Torch number 8 no TCP correction can be generated! Solution Choose another pistol number. Circular SINGLESTEP not possible! Use GoTo-Step instead! Reason Appears with Single-Step +/- in a circle resp. arcsgement. Solution Certain step transitions cannot be carried out with SingleStep in the circle. Use GOTOSTEP instead of this one. Invalid digital function! Reason Solution 690 Weaving with camera not allowed at step M.S.T in XXX.prg! Reason Solution K5 Troubleshooting Guide (en).doc / 08-09-04 igm Robotersysteme AG 63 Robotersysteme AG 691 692 Error messages K5 Troubleshooting Guide ESC Error, see ESC Monitor for details. Reason A fault has happened at the Esc bus Solution Open the ESC monitor and eliminate the pending error. Could not calculate camera calibration! Reason Solution 693 Check the programmed points according to the Laser Camera Calibration documentation. Camera offset out of range! Reason Solution 694 695 696 697 Please refer to Laser Camera Calibration documentation. Invalid iLS Calibration result! Reason iLS: The calibration cannot be calculated. Either the individual search movements are programmed wrongly or too many invalid readings are availably. Solution Check the search drives and the measurement results. iLS calibration differs to much from actual parameters! Reason iLS: A renewed calibration yielded a too big deviation of the current settings. Solution Check the iLS-calibrating programm resp. the current used settings. Camera reached end of seam before seam even started! Reason Laser Camera: The end-point of the path lies behind the starting point found by the camera. Solution Change the position of the end-point Failed to open called program! Reason Solution 698 Opening torch change program failed! Reason Solution 699 Not all points defined! Reason Not all required points have been provided at a Laser TCP correction. Solution 700 Function not used for Laser TCP correction! Reason Solution 64 igm Robotersysteme AG 08-09-04 / K5 Troubleshooting Guide (en).doc K5 Troubleshooting Guide 701 Error messages Robotersysteme AG Error calculating 2D shift! Reason Solution 702 Reason Solution 703 Reason Solution 704 Reason Solution 705 Reason Solution 706 Reason Solution 707 Reason Solution 708 Reason Solution 709 Reason Solution 710 Reason Solution 711 Reason Solution K5 Troubleshooting Guide (en).doc / 08-09-04 igm Robotersysteme AG 65 Robotersysteme AG Error messages K5 Troubleshooting Guide 712 Reason Solution 713 Reason Solution 714 Reason Solution 715 Reason Solution 716 Reason Solution 717 Reason Solution 718 Reason Solution 719 Reason Solution 720 Reason Solution 721 Reason Solution 722 Reason Solution 66 igm Robotersysteme AG 08-09-04 / K5 Troubleshooting Guide (en).doc K5 Troubleshooting Guide Error messages Robotersysteme AG 723 Reason Solution 724 Reason Solution 725 Reason Solution 726 Reason Solution 727 Reason Solution 728 Reason Solution 729 Reason Solution 730 Reason Solution 731 Reason Solution 732 Reason Solution 733 Reason Solution K5 Troubleshooting Guide (en).doc / 08-09-04 igm Robotersysteme AG 67 Robotersysteme AG Error messages K5 Troubleshooting Guide 734 Reason Solution 735 Reason Solution 736 Reason Solution 737 Reason Solution 738 Reason Solution 739 Reason Solution 740 Reason Solution 741 Reason Solution 742 Reason Solution 743 Reason Solution 744 Reason Solution 68 igm Robotersysteme AG 08-09-04 / K5 Troubleshooting Guide (en).doc K5 Troubleshooting Guide Error messages Robotersysteme AG 745 Reason Solution 746 Reason Solution 747 Reason Solution 748 Reason Solution 749 Reason Solution 750 Reason Solution K5 Troubleshooting Guide (en).doc / 08-09-04 igm Robotersysteme AG 69