Uploaded by sega

Ошибки

advertisement
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
Download