Trouble Shooting Manual Robot Controller IRC5 M2004 Document ID: 3HAC020738-001 Revision: - Table of Contents Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 1 Safety 5 1.1 Safety signals, general . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 1.2 Safety during trouble shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 1.3 Applicable safety standards for IRC5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 1.4 Safe Trouble Shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 1.4.1 DANGER - Manipulator without axes' holding brakes are potentially lethal! . . . . . . . . . . . . . . . . 9 1.4.2 DANGER - Live voltage inside covers! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 1.4.3 WARNING - The unit is sensitive to ESD! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 1.4.4 CAUTION - Hot parts may cause burns!. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 2 Reference information 15 2.1 Basic reference material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 2.1.1 Screw joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 2.1.2 Document references . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 2.1.3 Standard toolkit, IRC5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 2.1.4 Standard toolkit, trouble shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 2.2 Descriptions, systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 2.2.1 Measurement System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 2.2.2 Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 2.3 Descriptions, functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 2.3.1 Emergency stop circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 2.3.2 Safeguarded stops. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 2.3.3 Signals RUN (Run chain), EN1 (Enable 1) and EN2 (Enable 2). . . . . . . . . . . . . . . . . . . . . . . . . . 28 2.3.4 Limit switch chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 2.3.5 Breaking the Motors ON chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 2.3.6 Power supply, Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 2.3.7 Power Supply, Drive Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 2.3.8 Communication, Control Module and Drive Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 2.3.9 Reflashing firmware and FlexPendant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 2.4 Working with logs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 2.4.1 What is an event log? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 2.4.2 How events are logged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 2.4.3 Event log file format . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 2.4.4 What are SYS STOP, SYS HALT and SYS FAIL? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 2.4.5 What are informations, warnings and errors? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 2.4.6 Overview, how to read event log messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 2.4.7 Open and close the event log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 2.4.8 How to acknowledge errors and warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 2.4.9 Deleting log entries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 2.4.10 Saving log entries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 2.5 Working with configuration files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 2.5.1 Editing parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 2.6 Indications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 2.6.1 LEDs in the Controller Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 2.6.2 LEDs in the Drive Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 2.6.3 LED indications, digital and combi I/O units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 2.6.4 Safety I/O signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 2.6.5 DeviceNet Bus status LEDs at power-up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 2.6.6 LEDs om Interbus boards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 2.6.7 LEDs on Profibus boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 2 3HAC020738-001 Table of Contents 3 Symptoms 77 3.1 Faults without event log messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 3.1.1 Controller dead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 3.1.2 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 3.1.3 FlexPendant dead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 3.1.4 FlexPendant does not communicate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 3.1.5 Erratic event messages on FlexPendant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 3.1.6 The joystick doesn´t work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 3.1.7 Reflashing firmware failed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 3.1.8 Inconsistent path accuracy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 3.1.9 "Joint error" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 3.1.10 Oil or grease stains on motors and/or gearboxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 3.1.11 Mechanical noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 3.1.12 Manipulator collapses on power-down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 3.2 Event log messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 3.2.1 Overview, event log messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 4 Instructions 271 4.1 Overview, trouble shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272 4.2 Working principles when trouble-shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274 4.3 Instructions per unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278 4.3.1 Trouble Shooting the FlexPendant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278 4.3.2 Trouble Shooting Power Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279 4.3.3 Trouble Shooting I/O units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280 4.4 Instructions per symptom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281 4.4.1 Intermittent errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281 3HAC020738-001 - 3 Overview Overview About This Manual This manual contains instructions for trouble shooting IRC5 based robot systems. Usage This manual should be used whenever robot operation is interrupted by malfunction, regardless of whether an error message is displayed on the Teach Pendant Unit or not. Who Should Read This Manual? This manual is intended for the following personnel: • machine and robot operators qualified to perform very basic trouble shooting and reporting to service personnel. • programmers qualified to write and change RAPID programs. • specialized trouble shooting personnel, usually very experienced service personnel, qualified for methodically isolating, analyzing and correcting malfunctions within the robot system. Prerequisites The reader should... • have extensive experience in trouble shooting industrial electro-mechanical machinery • have indepth knowledge of the robot system function • be familiar with the actual robot installation at hand, it's surrounding equipment and peripherals References A list of document references is given in section Document references. Revisions 4 Revision Description - First release - 3HAC020738-001 1 Safety 1.1. Safety signals, general 1 Safety 1.1. Safety signals, general General This section specifies all dangers that may arise from performing the work detailed in the manual. Each danger is detailed in its own section consisting of: • A caption specifying the danger level (DANGER, WARNING or CAUTION) and the type of danger. • A brief description of what will happen if the operator/service personnel does not eliminate the danger. • An instruction of how to eliminate the danger to facilitate performing the activity at hand. Danger levels The table below defines the captions specifying the danger levels used throughout this manual. Symbol Designation Signification DANGER Warns that an accident will occur if the instructions are not followed, resulting in a serious or fatal injury and/or severe damage to the product. It applies to warnings that apply to danger with, for example, contact with high voltage electrical units, explosion or fire risk, risk of poisonous gases, risk of crushing, impact, fall from height etc. WARNING Warns that an accident may occur if the instructions are not followed, that can lead to serious injury, possibly fatal, and/or great damage to the product. It applies to warnings that apply to danger with, for example, contact with high voltage electrical units, explosion or fire risk, risk of poisonous gases, risk of crushing, impact, fall from height etc. ELECTRICAL SHOCK The electrocution or electrical shock symbol indicates electrical hazards which could result in severe personal injury or death. CAUTION Warns that an accident may occur if the instructions are not followed, that can result in injury and/or damage to the product. It also applies to warnings of risks that include burns, eye injury, skin injury, hearing damage, crushing or slipping, tripping, impact, fall from height etc. Furthermore, it applies to warnings that include function requirements when fitting and removing equipment, where there is a risk of damaging the product or causing a breakdown. danger warning Electrical shock caution 3HAC020738-001 - 5 1 Safety 1.1. Safety signals, general Symbol Designation Signification ELECTROSTATIC The electrostatic discharge (ESD) symbol indicates DISCHARGE (ESD) electrostatic hazards which could result in severe damage to the product. Electrostatic discharge (ESD) NOTE Note symbols alert you to important facts and conditions. TIP Tip symbols direct you to specific instructions, where to find additional information or how to perform a certain operation in an easier way. Note Tip 6 - 3HAC020738-001 1 Safety 1.2. Safety during trouble shooting 1.2. Safety during trouble shooting General All normal service work, installation, maintenance and repair work, is usually performed with all electrical, pneumatical and hydraulic power switched off. All manipulator movements are usually prevented by mechanical stops etc. Trouble shooting work differs from this. While trouble shooting, all power may be switched on, the manipulator movement may be controlled manually from the Teach Pendant Unit or from the robot program. Very important note! This implies that special considerations unconditionally must be taken during trouble shooting work: 3HAC020738-001 • all electrical parts must be considered as live • the manipulator must at all times be expected to perform any movement • since safety circuits may be disconnected or strapped to enable normally prohibited functions, the system must be expected to perform accordingly - 7 1 Safety 1.3. Applicable safety standards for IRC5 1.3. Applicable safety standards for IRC5 Health and safety standards The robot complies fully with the health and safety standards specified in the EEC’s Machinery Directives. The ABB robots controlled by the IRC5 conforms to the following standards: 8 Standard Description EN ISO 12100-1 Safety of machinery, terminology EN ISO 12100-2 Safety of machinery, technical specifications EN 954-1 Safety of machinery, safety related parts of control systems EN 775 Manipulating industrial robots, safety EN 60204 Electrical equipment of industrial machines EN 61000-6-4 (option) EMC, generic emission EN 61000-6-2 EMC, generic immunity Standard Description IEC 204-1 Electrical equipment of industrial machines IEC 529 Degrees of protection provided by enclosures Standard Description ISO 10218 Manipulating industrial robots, safety ISO 9787 Manipulating industrial robots, coordinate systems and motions Standard Description ANSI/RIA 15.06/1999 Safety requirements for industrial robots and robot systems ANSI/UL 1740-1998 (option) Safety standard for robots and robot equipment CAN/CSA Z 434-03 (option) Industrial robots and robot systems - General safety requirements - 3HAC020738-001 1 Safety 1.4.1. DANGER - Manipulator without axes' holding brakes are potentially lethal! 1.4 Safe Trouble Shooting 1.4.1. DANGER - Manipulator without axes' holding brakes are potentially lethal! Description Since the manipulator arm system is quite heavy, especially on larger manipulator models, it is dangerous if the holding brakes are disconnected, faulty, worn or in any way rendered nonoperational. For instance, a collapsing IRB 7600 arm system may kill or seriously injure a person standing beneath it. Procedure Step 3HAC020738-001 Action Info/illustration 1. If you suspect that the holding brakes are nonoperational, secure the manipulator arm system by some other means before working on it. Weight specifications etc. may be found in the Product Manual of each manipulator model. 2. If you intentionally render the holding brakes nonoperational by connecting an external voltage supply, the utmost care must be taken! NEVER stand inside the manipulator working area when disabling the holding brakes unless the arm system is supported by some other means! How to correctly connect an external voltage supply is detailed in the Product Manual of each manipulator model. - 9 1 Safety 1.4.2. DANGER - Live voltage inside covers! 1.4.2. DANGER - Live voltage inside covers! Description The Drive Module has live voltage potentially accessible directly behind the rear covers, even when the main switches have been switched off. xx0400001207 A Live voltage at terminals even if the main power switches have been switched off. Elimination Read this information before opening the rear cover of either module. Step 10 Action Info/illustration 1. Make sure the shop power supply has been switched off. 2. Use a voltmeter to verify that there is not voltage between any of the terminals. 3. Proceed with the service work. - 3HAC020738-001 1 Safety 1.4.3. WARNING - The unit is sensitive to ESD! 1.4.3. WARNING - The unit is sensitive to ESD! Description ESD (electro static discharge) is the transfer of electrical static charge between two bodies at different potentials, either through direct contact or through an induced electrical field. When handling parts or their containers, personnel not connected to ground potential may transfer high static charges. This discharge may destroy sensitive electronics. Elimination Step Action Note/Illustration 1. Use a wrist strap Wrist straps must be tested frequently to ensure that they are not damaged and are operating correctly. 2. Use an ESD protective floor mat. The mat must be grounded through a currentlimiting resistor. 3. Use a dissipative table mat. The mat should provide a controlled discharge of static voltages and must be grounded. Location of wrist strap button The wrist strap button is located on the computer unit in the control module as show in the illustration below. A xx0400001061 A wrist strap button Assemble the wrist strap The picture illustrates how the ESD wrist strap is assembled in the controller cabinet. 3HAC020738-001 - 11 1 Safety 1.4.3. WARNING - The unit is sensitive to ESD! xx0400001055 12 A The strap is fastened to a button on the side of the control cabinet. B When not used, the wrist strap is placed on the power supply unit. C Power supply unit - 3HAC020738-001 1 Safety 1.4.4. CAUTION - Hot parts may cause burns! 1.4.4. CAUTION - Hot parts may cause burns! Description During normal operation, many manipulator parts will become hot, especially the drive motors and gears. Touching these may cause burns of various severity. Elimination The instruction below details how to avoid the dangers specified above: Step 3HAC020738-001 Action Info/illustration 1. Always use your hand, at some distance, to feel if heat radiates from the potentially hot component before actually touching it. 2. Wait until the potentially hot component has cooled if it is to be removed, or handled in any other way, . - 13 1 Safety 1.4.4. CAUTION - Hot parts may cause burns! 14 - 3HAC020738-001 2 Reference information 1.4.4. CAUTION - Hot parts may cause burns! 2 Reference information 3HAC020738-001 - 15 2 Reference information 2.1.1. Screw joints 2.1 Basic reference material 2.1.1. Screw joints General This section details how to tighten the various types of screw joints on the controller. The instructions and torque values are valid for screw joints comprised of metallic materials and do not apply to soft or brittle materials. Tightening torque Before tightening any screw, note the following: • Determine whether a standard tightening torque or special torque is to be applied. The standard torques are specified in the tables below. Any special torques are specified in the Repair, Maintenance or Installation procedure description. Any special torque specified overrides the standard value. • Use the correct tightening torque for each type of screw joint. • Only use correctly calibrated torque keys. • Always tighten the joint by hand, and never use pneumatical tools • Use the correct tightening technique, i.e. do not jerk. Tighten the screw in a slow, flowing motion. • Maximum allowed total deviation from the specified value is 10%! The table below specify the recommended standard tightening torque for oil-lubricated screws with slotted or cross-recess head screws. 16 Dimension Tightening torque (Nm) Class 4.8, oil-lubricated M2.5 0.25 M3 0.5 M4 1.2 M5 2.5 M6 5.0 - 3HAC020738-001 2 Reference information 2.1.2. Document references 2.1.2. Document references General This section specifies all necessary documentation required for service, repair and installation of the industrial robot. If supplemental documentation is required for certain procedures in a manual, this is listed as required equipment in the instruction. The tables below specify the available controller documentation. The first digits of the article numbers are the same for a document in every language. The exception is made in the last digit, represented with an "x" in the tables. Select last digit "x" according to the listing below, depending on desired language: • English, x = 1 • Swedish, x = 2 • German, x = 3 • French, x = 4 • Spanish, x = 5 • Portuguese, x = 6 • Italian, x = 7 • Danish, x = 8 • Dutch, x = 9 References Reference Document ID Product manual, procedures - IRC5 3HAC021313-001 Product manual, reference information - IRC5 3HAC021313-001 Operator's manual - IRC5 with FlexPendant 3HAC16590-1 Operator's manual - RobotStudioOnline 3HAC18236-1 Getting started - IRC5 and RobotStudio 3HAC020738-001 Online 3HAC021564-001 Trouble shooting manual - IRC5 3HAC020738-001 Technical reference manual - System parameters 3HAC17076-1 - 17 2 Reference information 2.1.3. Standard toolkit, IRC5 2.1.3. Standard toolkit, IRC5 General All service (repair, maintenance and installation) instructions contain lists of tools required to perform the specified activity. All special tools, i.e. all tools that are not considered standard as defined below, are listed in their instructions respectively. This way, the tools required are the sum of the Standard Toolkit and any tools listed in the instruction. Contents 18 Tool Remark Screw driver, Torx Tx10 Screw driver, Torx Tx25 Ball tipped screw driver, Torx Tx25 Screw driver, flat blade 4 mm Screw driver, flat blade 8 mm Screw driver, flat blade 12 mm Screw driver Phillips-1 Box spanner 8 mm - 3HAC020738-001 2 Reference information 2.1.4. Standard toolkit, trouble shooting 2.1.4. Standard toolkit, trouble shooting General Listed are tools required to perform the actual trouble shooting work. All tools required to perform any corrective measure, such as replacing parts, are listed in their Product Manual section respectively. Contents 3HAC020738-001 Qty Art. no. Tool Rem. - - Normal shop tools Contents specified in section Standard Toolkit, IRC5. 1 - Multimeter - 1 - Oscilloscope - 1 - Recorder - - 19 2 Reference information 2.2.1. Measurement System 2.2 Descriptions, systems 2.2.1. Measurement System Parts The measurement system consists of the following: • axis computer • one or more serial measurement boards • resolvers Function The measurement system contains information on the position of the axes and this information is continuously updated during operation. Errors Transmission errors are detected by the system’s error control, which alerts and stops program execution if necessary. Common causes of errors in the measurement system are line breakdown, resolver errors, and measurement board interference. The latter type of error relates to the 7th axis, which has its own measurement board. If it is positioned too close to a source of interference, there is a risk of an error. 20 - 3HAC020738-001 2 Reference information 2.2.2. Drive System 2.2.2. Drive System Overview This section describes the basic flow of energy through the drive system, from the three phase mains supply to the pulse width modulated drive current to the robot’s motors. The basic function of the drive system is: • The three phase mains supply is connected to the main contactor (to the left in the figure below) • filtered in the filter • transformed in the transformer • Depending on the state of the system, the Motors ON contactors either connects or disconnects the power to the rectifier unit. This is detailed in section Motors ON, chain and status. • The rectifier converts the AC voltage to a DC voltage • which is stored in the DC link, • and chopped into a pulse width modulated (PWM) pulse train by the drive units • This variable three phase AC current is connected to the motor on each manipulator axis, in which it creates a torque, turning the motor rotor. Function en0300000502 3HAC020738-001 A Shop power supply (three phase 262-600 VAC) B Control signal from the panel board C Control signal from the panel board D Communication with the main computer E RS485 communication between axis computer and contactor interface board F SPI communication between axis computer and main servo drive G RS422 communication between axis computer and serial measurement board (SMB) - 21 2 Reference information 2.2.2. Drive System The remaining components are described below: A (as in the illustration above) A three phase voltage supply (three phases, ground and protective earth) from the shop in which the robot system is installed. The shop power supply is to be dimensioned by the site designer. B (as in the illustration above) Control signal from the panel board. This is activated when the main switch on the Control Module is switched. This way, a single main switch may be used (unless the Drive Module main switch has been switched off) to switch both Control and Drive Modules on. Main contactor The main contactor is the normal way of switching the power to the system on or off. It is activated by the signal from the Panel Board. Filter A low pass filter reduces the amount of harmonics in the input power. Main transformer The main transformer converts the shop voltage supply to a voltage level suitable for supplying the rectifier. It may be connected internally for different voltages. Different capacities are available for different power demands. In some applications, the shop power supply is suited for supplying the rectifier, and in such cases, no transformer is required. A smaller electronics supply transformer will still be required to supply the electronics. This is described in xx. C (as in the illustration above) The safety circuits (detailed in section Motors ON, chain and status) ultimately controls the Motors ON contactors. When these circuits detect any malfunction the safety contactors open, thus disconnecting the mains supply. Reactor Larger robot models use a reactor to reduce the transient load on the contactors during switching on and off. Motors ON contactors Two Motors ON contactors are connected in series with each other. In case of any potentially dangerous malfunctions, the system uses these contactors to disconnect the power from the rectifier. Contactor interface board The contactor interface board, among other things, controls the Motors ON contactors, and opens these through the two RUN-chains in case of any potentially dangerous malfunctions. The illustration shows an overview of the contactor board signal interface. 22 - 3HAC020738-001 2 Reference information 2.2.2. Drive System en0300000545 The contactor interface board communicates on a RS485 line with the axis computer. Rectifier The rectifier converts the filtered, transformed AC voltage to a stabilized DC voltage (DC link voltage). This DC voltage is supplied to the servo drive units. DC link The DC link capacitor is a large capacitor to maintain the DC link voltage during various load situations. The DC link voltage is the rectified voltage supplied to the drive units. Bleeder resistors The bleeder resistors are high power resistors connected in parallel with the DC link. When there is an overvoltage in the DC link (typically caused by one of the axes' motors braking, acting as a generator feeding electrical energy back to the drive unit), a transistor in the rectifier opens and connects the voltage through the bleeder resistors. The DC link voltage drops instantly. D (as in the illustration above) The axis computer receives position references from the main computer. The communication described in greater detail in section Interfaces. Axis computer The axis computer is a single circuit board, controlling the movements of the manipulators axes. Based on the programmed movement requirements, the main computer sends instructions with movement requests to the axis computer which in turn sends instructions to the drive units. The axis computer communicates: 3HAC020738-001 • on a SPI line with the main servo drive • on an Ethernet line with the main computer • on a RS422 line with the serial measurement board (SMB) - 23 2 Reference information 2.2.2. Drive System Main servo drive Based on the current requests from the axis computer, the servo drives generate three phase drive currents to the axes' motors. The technique utilized is called Pulse Width Modulation (PWM) and this creates a voltage pulse train. In the drive unit, the control and power electronics are integrated. Each axis has a drive unit, but for many of the manipulator models, these are assembled into one package, sometimes referred to as a SixPack. Motor The motor is a complete unit housing an AC motor, resolver and brake. The two latter are described below. The voltage pulse train from the drive unit is converted to torque when applied to the inductance in the motors' rotor. R The resolver is a analog generator creating a sinusoidal signal, and the voltage value generated depends on the position of the motor's rotor in relation to the stator. This signal is used by the system to determine the actual position of the rotor. Serial measurement board The serial measurement board (sometimes referred to as SMB), converts the analog resolver signals from all manipulators axes to digital form. It gathers them and sends them to the axis computer for position reference. B The brake fitted to each motor is normally used for holding and emergency stop purposes only. When the Motors OFF signal is active, which results in disconnecting the drive voltage from the motor, the brake is used to hold the manipulator arm in position. It is also used during an emergency stop, when instant stopping is required. Power supply The Drive Unit power supply is a 24 VDC supply for the Drive Unit. Power Supplies Power supplies are described in Supplies for the Drive Module, and Supplies for the Control Module. The complete circuits are also shown in the Circuit Diagram. Communications Communications within the system is described in section Communications for the Drive and Control Modules. The complete circuits are also shown in the Circuit Diagram. 24 - 3HAC020738-001 2 Reference information 2.3.1. Emergency stop circuit 2.3 Descriptions, functions 2.3.1. Emergency stop circuit General The emergency stop circuit is intended to cut the power to the system's drive motors if a potentially dangerous situation should arise. Opening any of the switches connected in series will break the chain, thus opening the Motors ON 1 and 2 contactors. How the emergency stop circuit relates to the Motors ON/OFF circuit is shown in the figure in section The basic circuit . The circuit The illustration shows principle of the emergency stop chain. en0300000522 The controller Circuit Diagram contains detailed information on how to connect the emergency stop buttons. 3HAC020738-001 - 25 2 Reference information 2.3.2. Safeguarded stops 2.3.2. Safeguarded stops General Safeguarded stops are intended to cut the power to the system's drive motors if a potentially dangerous situation should arise, e.g. if a person would enter the manipulator working range during manual or programmed movement. This is achieved by connecting external safety devices, such as light curtains, light beams or pressure sensitive mats. Three stop types are available: General mode safeguarded stop (GS), Automatic mode safeguarded stop (AS) and Superior safeguarded stop (SS). How the safeguarded stop circuit relates to the Motors ON/OFF circuit is shown in the figure in section The basic circuit . Stop type Function Automatic mode safeguarded stop (AS) Used in automatic mode, during normal program execution. General mode safeguarded stop (GS) Used in all operating modes. Superior safeguarded stop (SS) Used in all operating modes. Automatic mode safeguarded stop The AS is bypassed when the operating mode selector is in the MANUAL or MANUAL FULL SPEED position. General mode safeguarded stop When this connection is open the robot changes to the MOTORS OFF mode. To reset to MOTORS ON mode, the device that initiated the safety stop must be interlocked in accordance with applicable safety regulations. This is not normally done by resetting the device itself. Superior safeguarded stop When this connection is open the robot changes to the MOTORS OFF mode. To reset to MOTORS ON mode, the device that initiated the safety stop must be interlocked in accordance with applicable safety regulations. This is not normally done by resetting the device itself. Categories There are two categories of safety stops; category 0 and category 1 (ISO/DIS 11161 Industrial automation systems - safety of integrated manufacturing systems - Basic requirements). 26 - 3HAC020738-001 2 Reference information 2.3.2. Safeguarded stops Definitions: • Category 0: Use when the motor power must be disconnectedimmediately, such as when a light curtain, used to protect against entry into the work cell, is passed. The manipulator motion is likely to be stopped outside the programmed path, which may require special restart routines. • Category 1: Use when the motor power must not be disconnected immediately, such as when gates are used to protect against entry into the work cell. The manipulator motion is stopped within the programmed path, which makes restarting easier. Perform a safety analysis for each potential danger to determine which category to be used. By default, the safety stops are of category 0. Changing stop category is done by setting a parameter. How to do this is detailed in xx. The circuit The illustration shows principle of the safeguarded stop chain. en0300000523 *) The chains are bypassed on delivery, i.e. nothing is connected except a jumper. Any number of switches may be connected in series. The controller Circuit Diagram contains detailed information on how to connect the safeguarded stops. 3HAC020738-001 - 27 2 Reference information 2.3.3. Signals RUN (Run chain), EN1 (Enable 1) and EN2 (Enable 2) 2.3.3. Signals RUN (Run chain), EN1 (Enable 1) and EN2 (Enable 2) General The signals EN1 and EN2 are the controller system's way of checking itself before starting up, i.e. switching the power on. If any computer detects an error, it will affect either one of EN1 and EN2. The RUN signal is the system's start order. How the RUN, EN1 and EN2 circuits relate to the Motors ON/OFF circuit is shown in the figure in section The basic circuit . The controller Circuit Diagram contains detailed information about the signals. RUN The RUN signal is issued by the Panel Board when one of these are activated: • The RUN button is pressed on the FlexPendant, the Control Module or any external control panel unit. • A RUN command is executed in the program. When the signal is issued, the circuit is closed, enabling activation of the Motors ON contactors. EN1 The EN1 signal runs through a number of units checking their status: • Panel unit • Enabling device on FlexPendant • Drive Module When all units are OK, the circuit is closed, enabling activation of the Motors ON contactors. EN2 The EN2 signal runs through a number of units checking their status: • Panel unit • Enabling device on FlexPendant • Axis computer • Drive system rectifier • Contactor Board When all units are OK, the circuit is closed, enabling activation of the Motors ON contactors. 28 - 3HAC020738-001 2 Reference information 2.3.4. Limit switch chain 2.3.4. Limit switch chain General The limit switches are moveable, electro-mechanical switches fitted at the end of a manipulator's axis' working range. They are available for axis 3 for IRB 2400 and IRB 4400 only. This way, the switches can be used to block parts of the manipulators potential working range for safety reasons or other. Usually, the robot program contains a software limit set within the manipulator working range, so that the electro-mechanical limit switch is never hit during normal operation. However, should a limit switch be hit, it must be due to some malfunction, and the Motors ON chain is deactivated, and the robot operation is stopped. The circuit The illustration shows principle of the limit switch circuit. en0300000524 *) The circuits are bypassed on delivery, i.e. nothing is connected except a jumper. Any number of switches may be connected in series. External limit switch Intended for use with external equipment such as track motions etc. The controller Circuit Diagram contains detailed information on how to connect the limit switches. How the limit switch circuit relates to the Motors ON/OFF circuit is shown in the figure in section The basic circuit . 3HAC020738-001 - 29 2 Reference information 2.3.5. Breaking the Motors ON chain 2.3.5. Breaking the Motors ON chain Sequence When any of the conditions specified in section Motors ON, chain and status in not met, the chain is broken as described below: Note that when the manipulator movement is stopped by a limit switch, the manipulator may be run manually using the joystick while pressing the Motors ON button on the FlexPendant. The Motors ON button is supervised and may be depressed for a maximum of 30 seconds! Event results in... Any one of the conditions is no one of the Motors ON chains are broken longer fulfilled 30 a difference in the two Motors ON chains is detected the Motors ON contactors are deactivated open Motors ON contactor power supply is disconnected from the drive motors manipulator stops and is held in position by the holding brakes an interrupt call is sent directly from the panel unit to the main computer to indicate the cause of the interruption - 3HAC020738-001 2 Reference information 2.3.6. Power supply, Control Module 2.3.6. Power supply, Control Module Overview This section describes how the IRC5 Control Module is supplied with electrical power. Supplies The illustration below schematically depicts the main electrical power supply routes. The full IRC5 Circuit Diagram is shown in the Product Manual, IRC5. en0400001051 A21 The Panel Board is supplied with ± 24VDC by the G2 unit. A3 The Main Computer Unit is supplied with ± 24 VDC by the G2 unit. The unit also has internal DC/DC converters for supply to logic circuits, etc. E2 Cooling fan fitted on the rear of the module. It is powered by 24VCOOL from the G2 unit through the Panel Board. E3 Option: Cooling fan fitted on the inside of the module’s door. It is powered by 24VCOOL from the G2 unit through the Panel Board. E22 Cooling fan fitted inside the Computer Unit. It is powered by the G31 power supply unit on the Main Computer Board. E23 Cooling fan fitted inside the Computer Unit. It is powered by the G31 power supply unit on the Main Computer Board. F4 Option: A service outlet earth fault protection protects the 115V/230 VAC service outlet from potentially dangerous earth currents. F5 Option: A circuit breaker protects the Service outlet from overcurrents (2 A). G2 The Control Module Power Supply is the main AC/DC converter (DSQC 604) converting 230 VAC to ±24 VDC for a number of units. G3 The Backup energy bank (capacitor) is used suppling power to the Main Computer Unit. In case of power failure, the unit ensures that a full backup may be taken of the memory contents at the time of the failure. The G3 unit is supplied by the G2 unit. G4, G5 The Customer Power Supplies are optional power supply units (DSQC 608) for supplying Customer Connections. 3HAC020738-001 - 31 2 Reference information 2.3.6. Power supply, Control Module G6 Option: The DeviceNet Power Supply is an optional power supply (DSQC 608) for supplying the DeviceNet units. DNbus Option: The DeviceNet bus board is supplied by the G6 unit. Q2 The main switch on the front of the Control Module. S1 The panel board is supplied by the G2 unit and supplies the Operator’s Panel and FlexPendant. T3 Option: A 230/230 VAC transformer for supplying the Service outlet. X20 A connector connecting the 230 VAC from the main transformer in the Drive Module to the Control Module. X22 Option: A 230 VAC service outlet for supply to external service equipment such as laptop computers, etc. Locations The illustration below shows the physical location of the power supplies in the Control Module. xx0400001059 Voltages Below is a list of the 24V voltages generated in the Control Module, and the power supply unit generating it. 32 Voltage Power Supply unit 24V COOL G2 24V SYS G2 24V PC G2 24 V I/O G4, G5 24V DeviceNet G6 24V PANEL A21 24V TP_POWER A21 - 3HAC020738-001 2 Reference information 2.3.7. Power Supply, Drive Module 2.3.7. Power Supply, Drive Module Overview This section describes how the IRC5 Drive Module is supplied with electrical power. Supplies The illustration below schematically depicts the main electrical power supply routes. The full Circuit Diagram of the IRC5 controller is shown in the Product Manual, IRC5. en0400001052 3HAC020738-001 A41.1 Drive unit providing the drive power to the robot’s motors. It also powers the fan unit. The low voltage electronics in the drive unit are powered by the Drive Module Power Supply. A41.2 The drive equipment rectifier providing a DC voltage to the drive units. A42 The Axis Computer Unit has internal DC/DC converters for supply to logic circuits, etc. A43 The contactor interface board controls a number of contactors in the system, e.g. both RUN contactors. E1 Cooling fans on the rear of the Drive Module.It is powered by the drive unit. F1 A circuit breaker (25 A) protecting the drive equipment from overcurrents. Location not shown; behind cover. F2 A circuit breaker (10 A) protecting the electronics power supply. Location not shown; behind cover. - 33 2 Reference information 2.3.7. Power Supply, Drive Module G1 The Drive Module Power Supply (DSQC 626 for smaller robots and DSQC 627 for IRB 340, IRB 6600 and IRB 7600) in the Drive Module, converting the 230 VAC to 24 VDC. K41 A contactor, controlled by the Control Module Panel Board, supplying the electronics power supply. K42 The first RUN contactor, controlled by the Contactor Board, supplying the drive equipment with power. K43 The second RUN contactor, controlled by the Contactor Board, supplying the drive equipment with power. Q1 The main switch on the front of the Drive Module. T1 The main transformer, converting the mains supply (200-600 VAC) to either 3 x 262 VAC (for smaller robots), 3 x 400 VAC (IRB6600) or 3 x 480 VAC (IRB 7600. X0 The main connector on the connector panel of the Drive Module. Location not shown; behind cover. X25 Connector for supplying two phase power to the Control Module. Location not shown; behind cover. Z1 Option: EMC filter Locations The illustration below shows the physical location of the power supplies in the Drive Module. A41.1.4 A41.1 A41.1.3 A41.2 K43 K44 A41.3 Z1 K42 G1 Q1 H1 A43 F1 K41 F2 XP0 XS25 XS41 XS1 A42 XS2 XS7 xx0400001060 Voltages Below is a list of the 24 V voltages generated in the Drive Module and the power supply unit generating it: 34 Voltage Power Supply unit 24V COOL G1 24V SYS G1 24V BRAKE G1 - 3HAC020738-001 2 Reference information 2.3.8. Communication, Control Module and Drive Module 2.3.8. Communication, Control Module and Drive Module Overview The illustration below schematically depicts the main communication routes. The full IRC5 Circuit Diagram of is shown in the Product Manual, IRC5. Communications This section describes the data communication within and between the IRC5 Control Module and Drive Module. en0400001063 3HAC020738-001 Service port Connector (A7) on the module front for connecting a PC for service purposes, e.g. when installing software etc. Ethernet communication. FlexPendant Connector (A9) on the module front for connecting the FlexPendant. Ethernet communication and safety signals. USB One standard USB port (USB1) on the Control Module front for connecting peripheral equipment and e.g. bulk memory. LAN Local Area Network: connector (LAN1) for communication with other units. - 35 2 Reference information 2.3.8. Communication, Control Module and Drive Module Hard Disk Drive OPTION: Hard disk mass memory. Solid State Drive Solid state disk mass memory. Control Module The complete control module, containing mainly control and safety electronics. Drive Module (X) The complete drive module, containing mainly drive electronics. On systems running the MultiMove option, up to four Drive Modules may be connected to and controlled by one Control Module. Each additional Drive Module must contain all drive hardware. RCC Robot Communication Card: Communication interface between various units as shown in the illustration above and in the Circuit Diagram. Panel Board Communicates through a standard RS485 protocol with the Main Computer (MC) , and works as an interface between the MC and the controls on the Control Module panel. The user may also connect safety equipment to a number of inputs and outputs (as specified in section Safety I/O signals). Main Computer The Main Computer runs the RobotWare application software. EtherNet Board OPTION: Communication interface between the Main Computer and any additional Axis Computers when running the MultiMove option. DeviceNet OPTION: bus for communicating with external equipment. Standard DeviceNet protocol. ProfiBus OPTION: bus for communicating with external equipment. Standard ProfiBus protocol. InterBus OPTION: bus for communicating with external equipment. Standard InterBus protocol. Axis Computer Board (X) The Axis Computer controls the drive units. It also receives position feedback information from the robot’s resolvers through the serial measurement board (SMB). Contactor Interface Board Controls a number of safety related functions within the drive system (signals RUN, SPEED and ENABLE). It also communicates with the axis computer through a RS485 interface. 36 Drive Unit Supplies the drive motors with modulated drive current. Resolver A resolver on each drive motor shaft sends shaft position information to the serial measurement board. PCI Bus A bus on the Main Computer Board itself. All other boards in the Control Module (except the Panel Board) are fitted into PCI slots on the Main Computer Board. Serial Measurement Board The serial measurement board gathers resolver data from all robot axes and sends it to the main computer. - 3HAC020738-001 2 Reference information 2.3.9. Reflashing firmware and FlexPendant 2.3.9. Reflashing firmware and FlexPendant Overview of reflashing After replacing hardware units, such as axis computer, buses, etc., or installing newer versions of RobotWare, the system will automatically attempt reflashing the unit in order to maintain hardware/software compatibility. Reflashing is loading appropriate firmware (hardware specific software) onto a specific unit running this software during operation. If RobotWare is upgraded on the controller, then the FlexPendant will reflash, i.e. update to the new version, when connected. Note that performing any such replacements/updates might require running firmware versions not available! To avoid jeopardizing the function of the system, ABB recommends using the same versions as earlier, unless these are unavailable. Reflashing The automatic reflashing process, described below, must not be disturbed by switching off the controller while running: Step 3HAC020738-001 Event Info 1. When the system is restarted, the system checks the versions of the used firmware. These are checked against the hardware versions used. 2. If the hardware and firmware versions do not match, the system restarts itself automatically while going to a specific Update Mode. During the Update Mode, an attempt is made to download appropriate firmware onto the hardware while a message is very briefly displayed on the FlexPendant. 3. Was an appropriate firmware version found? If YES, the reflash will proceed. If NO, the system will stop. Proceed as detailed in section Reflashing firmware failed in the Trouble Shooting Manual, IRC5. In either case, a message is very briefly displayed on the FlexPendant and stored in the event log. The actual reflashing may take a few seconds up to a few minutes, depending on the hardware to be reflashed. 4. After performing a successful reflash, the system restarts. 5. Another check is made for any additional hardware/firmware mismatches. 6. Was any additional mismatches found? If YES, the process is repeated until none are found. If NO, the process is complete. - 37 2 Reference information 2.4.1. What is an event log? 2.4 Working with logs 2.4.1. What is an event log? Overview Robot systems are often operated without any personnel present. The logging function is a useful way to store information about past events for future reference in order to facilitate fault analysis and tracking. How to access and work with the logs is detailed in section Event log messages in the Trouble Shooting Manual, IRC5 and in section Event log in the Operator's Manual, IRC5. Concept An event log is a written account of events within the robot system. A log has entries, one for each event, tagged with the time of its occurrence. The anatomy of an event log entry The illustrations shows a list of log entries as displayed on the FlexPendant. xx0300000448 A The event type (error, warning, information) B The event code C The event title D The date and time of occurrence Event log message For each entry, a message describing the event is available. The message describes the event in detail and often contains advice on how to solve the problem. All messages are shown in the Trouble Shooting Manual, IRC5. 38 - 3HAC020738-001 2 Reference information 2.4.2. How events are logged 2.4.2. How events are logged Step 1 When an event occurs it becomes available in the all events list (1) as well as in the corresponding category list (2). Placeholder Step 2 When the list of all events fills up and a new event occurs (1) the oldest event (2) will be deleted. The same applies to filled category lists. As long as there is space available in the specific category list (3) an entry will remain in that list even if it has been deleted from the list of all events. In extreme cases the list of all events might cover events from the latest minutes while a certain category list would contain entries from the last year. Placeholder How many events can be logged? The list of all events can hold up to 1000 events. Each category list can hold up to 20 events. 3HAC020738-001 - 39 2 Reference information 2.4.3. Event log file format 2.4.3. Event log file format File structure Logs are saved as plain ASCII text files. The following illustration shows an example of an event log file. B D E F G en0300000478 File elements 40 Item Name A TBD B The date and time when saved C Identity of robot system and installed options D Event code E Event title F The date and time of occurence G The event message H The name of next category - 3HAC020738-001 2 Reference information 2.4.4. What are SYS STOP, SYS HALT and SYS FAIL? 2.4.4. What are SYS STOP, SYS HALT and SYS FAIL? General The robot system may enter specific, predefined error statuses, depending on the fault severity. The error log messages displayed on the FlexPendant often refer to these statuses, and they are described below: SYS STOP SYS STOP is: • All NORMAL tasks will be stopped. The parameter NORMAL is described in the Technical reference manual - System parameters. • The robot motion stops gently. • Jogging is possible. • Program start is possible. SYS HALT SYS HALT is: • All NORMAL tasks will be stopped. The parameter NORMAL is described in the Technical reference manual - System parameters. • The system goes to Guard Stop. • The robot motion stops abruptly, since the holding brakes are applied. • Jogging is possible. • Program start is possible. SYS FAIL SYS FAIL is: 3HAC020738-001 • All NORMAL tasks will be stopped. The parameter NORMAL is described in the Technical reference manual - System parameters. • The system goes to System Failure State. • The robot motion stops abruptly, since the holding brakes are applied. • Jogging is not possible. • Program start is not possible. • Performing a system restart resets the system. How to perform a system restart is detailed in section Restart in the Operator's manual - IRC5 with FlexPendant. - 41 2 Reference information 2.4.5. What are informations, warnings and errors? 2.4.5. What are informations, warnings and errors? What is an information message? An information message is an entry in the log corresponding to normal system events such as: • starting and stopping programs. • change in operational mode. • motors on and off. Information messages never requires any actions from you. They simply display the robot system’s history which is useful for error tracking, statistics collection or monitoring user triggered event routines. What is a warning? A warning is an event that you need to be aware of but is not so severe that the process or RAPID program needs to be stopped. Warnings must sometimes be acknowledged. Warnings often indicate underlying problems that sooner or later need to be solved. What is an error? An error is an event that prevents the robot system from proceeding. The running process or RAPID program cannot continue and is stopped. All errors must be acknowledged. Most errors also require some immediate action from you in order to be solved. 42 - 3HAC020738-001 2 Reference information 2.4.6. Overview, how to read event log messages 2.4.6. Overview, how to read event log messages General This chapter contains information on each individual error event message displayed on the GTPU or the computer screen (Robot Studio Install). For easy navigation, the messages are listed numerically, based on the screen presentation. For some event messages, additional information is given in the Trouble shooting manual in relation to the screen presentation, such as illustrations, diagrams, etc. NOTE that the chapter only deals with events classed as errors! Concepts This section specifies the meaning of a number of concepts used when discussing logs, their use and entries. What is a log? The "log" as a basic concept is described in section What is a log? . What is an event? An event is a specific occurrance which generates an item in the log. For instance, if the manipulator collides with an obstacle, this will cause a message to be sent to the log. A message of the occurrance is displayed along with a time marker, etc. This is the event. What is an event message? An event message is the actual wording, describing what has happened, what consequences this will have on the system, etc. Event messages are divided intop three categories, information, warning and error. These are described below. What is an information message? An information message is an entry in the log corresponding to normal system events such as: • starting and stopping programs. • change in operational mode. • motors on and off. What is a warning? A warning is an event that you need to be aware of but is not so severe that the process or RAPID program needs to be stopped. Warnings must sometimes be acknowledged. Warnings often indicates underlying problems that sooner or later needs to be solved. What is an error? An error is an event that prevents the robot system from proceeding. The running process or RAPID program cannot continue and is stopped. All errors must be acknowledged. Most errors also requires some immediate action from you in order to be solved. What is "acknowledge"? Certain events, mainly errors, require the operator to acknowledge them, before being able to proceed with the program execution. 3HAC020738-001 - 43 2 Reference information 2.4.6. Overview, how to read event log messages This is done by tapping Acknowledge or OK on the FlexPendant. How to read the messages Tapping on a specific event displays the following: en0300000454 44 A Event number. All error events are listed in accordance with this number. B Event title. This very briefly states what has happened. C Event time marker specifies exactly when the event occurred. D Description: A brief description of the event causing the message to be displayed. Intended to assist in understanding the causes and implications of the event. E Consequences: A brief description of any consequences inflicted on the system, transition to other operation mode, emergency stop, caused by the particular event causing the message to be displayed. Intended to assist in understanding the causes and implications of the event. F Probable causes: A list of probable causes, listed in order of probability. G Recommended actions: A list of the recommended correcting actions, based on the “Probable causes” specified above. These may range from “Replace the xx...” to“ Run test program xx...”, i.e. may be actions to isolate the problem as well as correcting it. H Acknowledge or OK button - 3HAC020738-001 2 Reference information 2.4.7. Open and close the event log 2.4.7. Open and close the event log Overview Open the event log to: • view all present entries. • study specific entries in detail. • handle the log entries, such as saving or deleting. Procedure This section details how to open the event log. Step 3HAC020738-001 Action Info/Illustration 1. Tap the status bar. The status window is displayed. 2. Tap Event Log. The event log is displayed. 3. If the log contents do not fit into a single screen, it can How to do this is detailed in be scrolled and/or zoomed. section Scrolling and zooming 4. Tap a log entry to view the event message. 5. Tap the status bar again to close the log. - How to do this is detailed in section View messages. 45 2 Reference information 2.4.8. How to acknowledge errors and warnings 2.4.8. How to acknowledge errors and warnings Overview Errors and sometimes warnings have to be acknowledged as a safety precaution since these normally indicate severe system or process problems. When an error or warning occurs an event dialog is displayed. If more than one error or warning has occurred you only need to acknowledge the latest. Older errors and warnings are listed in the event log. If the robot’s motors where powered before the error or warning condition they will be kept powered. After you have acknowledged, the process or RAPID program will continue. CAUTION! When the error or warning has been acknowledged the robot may move without warning. Make sure all personnel are in a safeguarded space before you proceed. Procedure If you want to... ...then... acknowledge the error or warning and return to operation as fast as possible Tap Acknowledge in the event dialog. acknowledge the error or warning and open the event log Tap Event log... in the event dialog. Removing the confirmation This section details how to remove the confirmation. Step 1. Action Info/Illustration xx xx Setting "the confirmable unit" This section details how to set the "confirmable unit". Step 1. Action Info/Illustration xx xx Exceptions Warnings need to be acknowledged only if your system has been configured for this. The acknowledgement can be overridden in an remotely controlled system. In such cases processes and RAPID programs can be restarted without human intervention. All actions performed under remote control will be logged so that you can analyze these events later. 46 - 3HAC020738-001 2 Reference information 2.4.9. Deleting log entries 2.4.9. Deleting log entries Why should I delete log entries? Logs can be deleted to increase available disk space. Deleting log entries is often a good way to trace faults since you remove old and insignificant log entries not related to the problem you are trying to solve. Delete all log entries Step Action 1. Tap the status bar, then the Event Log tab to open the event log. 2. On the Viewmenu, tap Common. 3. Tap Delete. A confirmation dialog is displayed. 4. Tap OK to delete, Cancel to keep the log intact. Delete log entries of a specific category Step 3HAC020738-001 Action 1. Tap the status bar, then the Event Log tab to open the event log. 2. On the View menu, tap the category of choice. 3. Tap Delete. A confirmation dialog is displayed. 4. Tap OK to delete, Cancel to keep the log intact. - 47 2 Reference information 2.4.10. Saving log entries 2.4.10. Saving log entries Why should I save log entries? You should save log entries when: • you need to clear the log but want to keep the current entries to be viewed later. • you want to send log entries to support to solve a problem. • you want to keep log entries for future reference. NOTE! The log can keep up to 20 entries per category and up to 1000 entries in the all events list. When the buffer is full the oldest entries will be overwritten and lost. There is no way to retrieve these lost log entries. Save all log entries This section details how to save all log entries. Step Action Info/Illustration 1. Tap the status bar, then the Event Log tab to open the event log. 2. On the Viewmenu, tap All. 3. Tap Save As. The file dialog is displayed. 4. If you want to save the log in a different folder, locate and open the folder. 5. In the File name box, type a name for the file. 6. Tap Save. Save log entries of a specific category This section details how to save log entries of a specific category. Step 48 Action Info/Illustration 1. Tap the status bar, then the Event Log tab to open the event log. 2. On the View menu, tap the category of choice. 3. Tap Save As. The file dialog is displayed. 4. If you want to save the entries file in a different folder, locate and open the folder. 5. In the File name box, type a name for the file. 6. Tap Save. - 3HAC020738-001 2 Reference information 2.5.1. Editing parameters 2.5 Working with configuration files 2.5.1. Editing parameters Overview When editing parameters you use the Instance Editor, which is opened from the Configuration Editor. You can either edit the parameters of one single instance, or you can edit several instances at one time. Editing several instances at one time is useful when you want to change the same parameter in several instances, like when moving signals from one IO unit to another. Prerequisite You must have Write access to the controller. See About access rights for details. Edit parameters To edit the parameters of one or several instances: 1. In the Robot View Explorer, expand the Controller and the Configuration node and double-click the topic that contains the parameters to edit. This opens the Configuration Editor. 2. In the Type name list of the Configuration Editor, select the type that the parameter to edit belongs to. The instances of the type is now displayed in the Instance list of the Configuration Editor. 3. In the Instance list, select the instances to edit and press the Enter Key. The Instance Editor is now displayed. 4. In the Parameter list of the Instance Editor, select the parameter to edit and change the value of the parameter in the Value box. When editing several instances at one time, the parameter values you specify will be applied to all instances. For parameters that you don't specify any new value, each instance will keep its existing value for that parameter. 5. Click OK to apply the changes to the configuration database of the controller. For many parameters, the changes will not take affect until the controller is restarted. If your changes require a restart, you will be notified of this. Result You have now updated the controller's system parameters. If the changes require a restart of the controller, the changes will not take affect until you do this. If you are going to make several changes, you can wait with the restart until all changes are done. Related information Configure systems About configurations The configuration editor Layout of the configuration editor Layout of the instance editor 3HAC020738-001 - 49 2 Reference information 2.5.1. Editing parameters How to restart a controller 50 - 3HAC020738-001 2 Reference information 2.6.1. LEDs in the Controller Module 2.6 Indications 2.6.1. LEDs in the Controller Module General The Controller Module features a number of indication LEDs, which provide important information for trouble shooting purposes. All units with LEDs are shown in the illustration below: All LEDs on the respective units, and their significance, are described in the following sections. LEDs dummy A Robot Communication Card (any of the five board slots) B Ethernet board (any of the five board slots) C Control module power supply D Customer I/O power supply (up to three units) E Computer unit F Panel board G LED board Robot Communication Card (RCC) The illustration below shows the LEDs on the Robot Communication Card: 3HAC020738-001 - 51 2 Reference information 2.6.1. LEDs in the Controller Module en0400000918 A Status LED B Service connector LED C TPU connector LED D AXC1 connector LED E-H These are not LEDs and will not be discussed in this context Description Significance Status LED (during startup) The significance of the LEDs are described in the sequence in which they are lit during a normal startup. RED flashing: Main computer self test is running. RED steady: The main computer operating system is loading. GREEN flashing: A system warm start is running. GREEN steady: The system warm start has finished. Status LED (during operation) RED steady: Internal failure. The unit needs to be replaced. RED flashing: Communication failure. The unit does not need to be replaced. GREEN steady: The unit and its function is OK. Service connector LED Shows the status of Ethernet communication between the Service connector and the Robot Communication Card. GREEN OFF:10 Mbps data rate has been selected GREEN ON:100 Mbps data rate has been selected YELLOW flashing: The two units are communicating on the Ethernet channel. YELLOW steady: A LAN link is established. YELLOW OFF: A LAN link is not established. TPU connector LED Shows the status of Ethernet communication between the FlexPendant and the Robot Communication Card. See the description above! AXC1 connector LED Shows the status of Ethernet communication between Axis Computer 1 and the Robot Communication Card. See the description above! 52 - 3HAC020738-001 2 Reference information 2.6.1. LEDs in the Controller Module Ethernet board The illustration below shows the LEDs on the Ethernet board: en0400000919 A AXC2 connector LED B AXC3 connector LED C AXC4 connector LED D-F These are not LEDs and will not be discussed in this context Description Significance AXC2 connector LED Shows the status of Ethernet communication between Axis Computer 2 and the Ethernet board. GREEN OFF:10 Mbps data rate has been selected. GREEN ON:100 Mbps data rate has been selected. YELLOW flashing: The two units are communicating on the Ethernet channel. YELLOW steady: A LAN link is established. YELLOW OFF: A LAN link is not established. AXC3 connector LED Shows the status of Ethernet communication between Axis Computer 3 and the Ethernet board See the description above! AXC4 connector LED Shows the status of Ethernet communication between Axis Computer 4 and the Ethernet board See the description above! Control module power supply The illustration below shows the LEDs on the Control module power supply: 3HAC020738-001 - 53 2 Reference information 2.6.1. LEDs in the Controller Module A dummy A DCOK indicator Description Significance DCOK indicator GREEN: When all DC outputs are above the specified minimum levels. OFF: When one or more DC output/s below the specified minimum level. Customer I/O power supply The illustration below shows the LEDs on the Customer I/O power supply: A dummy A DCOK indicator Description Signficance DCOK indicator GREEN: When all DC outputs are above the specified minimum levels. OFF: When one or more DC output/s below the specified minimum level. Computer unit The illustration below shows the LEDs on the Computer unit: 54 - 3HAC020738-001 2 Reference information 2.6.1. LEDs in the Controller Module C B A dummy A Ethernet LED B Mass memory indication LED C Power ON LED Description Significance Ethernet LED Shows the status of the communication on the main computer Ethernet channel. GREEN OFF:10 Mbps data rate has been selected. GREEN ON:100 Mbps data rate has been selected. YELLOW flashing: The two units are communicating on the Ethernet channel. YELLOW steady: A LAN link is established. YELLOW OFF: A LAN link is not established. Mass memory indication LED YELLOW: A flashing LED indicates communication between hard drive and processor. Power ON LED GREEN steady: The computer unit is supplied with power and working correctly. GREEN OFF: The unit is not powered. Panel board The illustration below shows the LEDs on the Panel board: 3HAC020738-001 - 55 2 Reference information 2.6.1. LEDs in the Controller Module A dummy A Panel board LEDs The panel board LEDs are described from top to bottom below: Description Signficance Status LED GREEN flashing: serial communication error. GREEN steady: no errors found and system is running. RED flashing: system is in power up/selftest mode. RED steady: other error than serial communication error. Indication LED, ES1 YELLOW when Emergency stop chain 1 closed Indication LED, ES2 YELLOW when Emergency stop chain 2 closed Indication LED, GS1 YELLOW when General stop switch chain 1 closed Indication LED, GS2 YELLOW when General stop switch chain 2 closed Indication LED, AS1 YELLOW when Auto stop switch chain 1 closed Indication LED, AS2 YELLOW when Auto stop switch chain 2 closed Indication LED, SS1 YELLOW when Superior stop switch chain 1 closed Indication LED, SS2 YELLOW when Superior stop switch chain 2 closed Indication LED, EN1 YELLOW when ENABLE1=1 and RS-communication is OK LED board The LEDs on the LED board are identical copies of those found on the Panel board as described above. Should the LED board not be working, but the Panel board is, the problem is the communication between these boards. Check the cabling between them. 56 - 3HAC020738-001 2 Reference information 2.6.2. LEDs in the Drive Module 2.6.2. LEDs in the Drive Module General The Drive Module features a number of indication LEDs, which provide important information for trouble shooting purposes. All units with LEDs are shown in the illustration below: All LEDs on the respective units, and their significance, are described in the following sections. LEDs xx0400001084 A Rectifier B Axis Computer C Contactor interface board D Single servo drive E Power supply F Main servo drive Axis computer The illustration below shows the LEDs on the Axis computer: 3HAC020738-001 - 57 2 Reference information 2.6.2. LEDs in the Drive Module xx0300000023 A Status LED B Ethernet LEDs Description Signficance Status LED The significance of the LEDs are described in the sequence the are lit during a normal startup. RED steady: power ON. The axis computer is initializing basic hardware and software RED flashing: contacting host, attempting to download IP address and image file to axis computer. GREEN steady: startup sequence ready. VxWorks is running. RED flashing: an initialization error has occured. The axis computer will notify the main computer if possible. Ethernet LED Shows the status of Ethernet communication between an additional axis computer (2, 3 or 4) and the Ethernet board. GREEN OFF:10 Mbps data rate has been selected. GREEN ON:100 Mbps data rate has been selected. YELLOW flashing: The two units are communicating on the Ethernet channel. YELLOW steady: A LAN link is established. YELLOW OFF: A LAN link is not established. Main servo drive, single servo drive and rectifier unit The illustration below shows the indication LEDs on the Drive Module main servo drive, single servo drive and rectifier unit. NOTE that there are two types of main servo drive units: a six unit drive and a three unit drive which are both used to power a six axes robot. Shown in the illustration is a six unit drive. The three unit drive it half it’s size, but the indication LED is positioned in the same place. 58 - 3HAC020738-001 2 Reference information 2.6.2. LEDs in the Drive Module xx0400001089 A Single servo drive B Rectifier unit C Main servo drive D Indication LED, single servo drive E Indication LED, rectifier unit F Indication LED, main servo drive unit Description Significance Indication GREEN flashing: Internal function is OK and there is a malfunction in the LEDs D, E and interface to the unit. The unit does not need to be replaced. F GREEN steady: Program loaded successfully, unit function OK and all interfaces to the units is fully functional. RED steady: Permanent internal fault detected. The LED is to have this mode in case of failure at internal self test at start-up, or in case of detected internal failure state in running system. The unit probably needs to be replaced. Drive Module power supply The illustration below shows the LEDs on the Drive Module power supply: 3HAC020738-001 - 59 2 Reference information 2.6.2. LEDs in the Drive Module A xx0400001090 A DCOK indicator Description Significance DCOK indicator GREEN: When all DC outputs are above the specified minimum levels. OFF: When one or more DC output/s below the specified minimum level. Contactor interface board The illustration below shows the LEDs on the Contractor interface board: A xx0400001091 A Status LED Description Status LED 60 GREEN flashing: serial communication error. GREEN steady: no errors found and system is running. RED flashing: system is in power up/selftest mode. RED steady: other error than serial communication error. - 3HAC020738-001 2 Reference information 2.6.3. LED indications, digital and combi I/O units 2.6.3. LED indications, digital and combi I/O units General All digital and combi I/O units have the same LED indications. The figure below shows a digital I/O unit, DSQC 328 and is applicable for the following I/O units: • 120 VAC I/O DSQC 320 • Combi I/O DSQC 327 • Digital I/O DSQC 328 • Relay I/O DSQC 332 xx0100000240 LED description, digital and combi I/O This section describes all the LEDs on the boards. LEDs general The table shows the IN and OUT LEDs. Designation Color Description IN Yellow Lights at high signal on an input. The higher the applied voltage, the brighter the LED will shine. This means that even if the input voltage is just under the voltage level “1”, the LED will glow dimly. OUT Yellow Lights at high signal on an output. The higher the applied voltage, the brighter the LED will shine. MS/NS Green/Red See sections MS LED and NS LED. MS LED 3HAC020738-001 MS LED is... to indicate... ... requiring action: off Not powered Check 24V CAN Green Normal condition - - 61 2 Reference information 2.6.3. LED indications, digital and combi I/O units MS LED is... to indicate... ... requiring action: Flashing green Software configuration missing, standby state Configure device Flashing green/red Device self testing Wait for test to be completed Flashing red Minor fault (recoverable) Restart device Red Unrecoverable fault Replace device NS LED 62 NS LED is... to indicate... ... requiring action: Off Not powered/not on-line - Flashing green On-line, not connected Wait for connection Green On-line, connections established - Red Critical link failure, incapable of communicating (duplicate MAC ID, or bus-off) - Change MAC ID and/or check CAN connection/cables 3HAC020738-001 2 Reference information 2.6.4. Safety I/O signals 2.6.4. Safety I/O signals General In the controller's basic and standard form, certain I/O signals are dedicated to specific safety functions. These are listed below along with a brief description of each. How to access the signals through the FlexPendant is detailed in the Operator's Manual, IRC5 with FlexPendant. Safety I/O signals The list below are the safety I/O signals as used by the standard system. Signal name 3HAC020738-001 Bit value condition Description From - To ES1 Emergency stop, chain 1 = Chain closed 1 From panel board to main computer ES2 Emergency stop, chain 1 = Chain closed 2 From panel board to main computer SOFTESI Soft Emergency stop 1 = Soft stop enabled From panel board to main computer EN1 Enabling device1&2, chain 1 1 = Enabled From panel board to main computer EN2 Enabling device1&2, chain 2 1 = Enabled From panel board to main computer AUTO1 Op mode selector, chain 1 1 = Auto selected From panel board to main computer AUTO2 Op mode selector, chain 2 1 = Auto selected From panel board to main computer MAN1 Op mode selector, chain 1 1 = MAN selected From panel board to main computer MANFS1 Op mode selector, chain 1 1 = Man. full speed selected From panel board to main computer MAN2 Op mode selector, chain 2 1 = MAN selected From panel board to main computer MANFS2 Op mode selector, chain 2 1 = Man. full speed selected From panel board to main computer USERDOOV LD Over load, user DO 1 = Error, 0 = OK From panel board to main computer MONPB Motors-on pushbutton 1 = Pushbutton pressed From panel board to main computer AS1 Auto stop, chain 1 1 = Chain closed From panel board to main computer AS2 Auto stop, chain 2 1 = Chain closed From panel board to main computer SOFTASI Soft Auto stop 1 = Soft stop enabled From panel board to main computer GS1 General stop, chain 1 1 = Chain closed - From panel board to main computer 63 2 Reference information 2.6.4. Safety I/O signals 64 Signal name Description Bit value condition GS2 General stop, chain 2 1 = Chain closed SOFTGSI Soft General stop 1 = Soft stop enabled From panel board to main computer SUPES1 Superior stop, chain1 1 = Chain closed From panel board to main computer SUPES2 Superior stop, chain2 1 = Chain closed From panel board to main computer SOFTSSI Soft Superior stop 1 = Soft stop enabled From panel board to main computer CH1 All switches in run chain 1 closed 1 = Chain closed From panel board to main computer CH2 All switches in run chain 2 closed 1 = Chain closed From panel board to main computer ENABLE1 Enable from MC (read 1 = Enable, 0 = break From panel board to main back) chain 1 computer ENABLE2_1 Enable from AXC1 1 = Enable, 0 = break From panel board to main chain 2 computer ENABLE2_2 Enable from AXC2 1 = Enable, 0 = break From panel board to main chain 2 computer ENABLE2_3 Enable from AXC3 1 = Enable, 0 = break From panel board to main chain 2 computer ENABLE2_4 Enable from AXC4 1 = Enable, 0 = break From panel board to main chain 2 computer PANFAN Superv. of fan in Control module 1 = OK, 0 = Error From panel board to main computer PANEL24OV LD Overload, panel 24V 1 = Error, 0 = OK From panel board to main computer DRVOVLD Overload, drive modules 1 = Error, 0 = OK From panel board to main computer USERDI1 General purpose input 1 = Input level high 1 From panel board to main computer USERDI2 General purpose input 1 = Input level high 2 From panel board to main computer USERDI3 General purpose input 1 = Input level high 3 From panel board to main computer USERDI4 General purpose input 1 = Input level high 4 From panel board to main computer USERDI5 General purpose input 1 = Input level high 5 From panel board to main computer USERDI6 General purpose input 1 = Input level high 6 From panel board to main computer USERDI7 General purpose input 1 = Input level high 7 From panel board to main computer USERDI8 General purpose input 1 = Input level high 8 From panel board to main computer DRV1LIM1 Read back of chain 1 after limit switches From axis computer to main computer - 1 = Chain 1 closed From - To From panel board to main computer 3HAC020738-001 2 Reference information 2.6.4. Safety I/O signals Signal name 3HAC020738-001 Bit value condition Description 1 = Chain 2 closed From - To DRV1LIM2 Read back of chain 2 after limit switches From axis computer to main computer DRV1K1 Read back of contactor 1 = K1 closed K1, chain 1 From axis computer to main computer DRV1K2 Read back of contactor 1 = K2 closed K2, chain 2 From axis computer to main computer DRV1EXTCO External contactors NT closed 1 = Contactors closed From axis computer to main computer DRV1PANCH Drive voltage for 1 contactor-coil 1 1 = Voltage applied From axis computer to main computer DRV1PANCH Drive voltage for 2 contactor-coil 2 1 = Voltage applied From axis computer to main computer DRV1SPEED Read back of op. mode 0 = Man. mode low selected speed From axis computer to main computer DRV1TEST1 A dip in run chain 1 has Toggled been detected From axis computer to main computer DRV1TEST2 A dip in run chain 2 has Toggled been detected From axis computer to main computer SOFTESO Soft Emergency stop 1 = Set soft E-stop From main computer to panel board SOFTASO Soft Auto stop 1 = Set soft Auto stop From main computer to panel board SOFTGSO Soft General stop 1 = Set soft General stop From main computer to panel board SOFTSSO Soft Superior stop 1 = Set soft Sup. Estop From main computer to panel board MOTLMP Motors-on lamp 1 = Lamp on From main computer to panel board ENABLE1 Enable1 from MC 1 = Enable, 0 = break From main computer to chain 1 panel board TESTEN1 Test of Enable1 1 = Start test From main computer to panel board USERDO1 General purpose output 1 1 = Set output level high From main computer to panel board USERDO2 General purpose output 2 1 = Set output level high From main computer to panel board USERDO3 General purpose output 3 1 = Set output level high From main computer to panel board USERDO4 General purpose output 4 1 = Set output level high From main computer to panel board USERDO5 General purpose output 5 1 = Set output level high From main computer to panel board USERDO6 General purpose output 6 1 = Set output level high From main computer to panel board USERDO7 General purpose output 7 1 = Set output level high From main computer to panel board USERDO8 General purpose output 8 1 = Set output level high From main computer to panel board - 65 2 Reference information 2.6.4. Safety I/O signals Signal name Description Bit value condition DRV1CHAIN 1 Signal to interlocking circuit 1 = Close chain 1 From main computer to axis computer 1 DRV1CHAIN 2 Signal to interlocking circuit 1 = Close chain 2 From main computer to axis computer 1 1 = Release brake From main computer to axis computer 1 DRV1BRAKE Signal to brakerelease coil 66 - From - To 3HAC020738-001 2 Reference information 2.6.5. DeviceNet Bus status LEDs at power-up 2.6.5. DeviceNet Bus status LEDs at power-up Process The system performs a test of the MS and NS LEDs during start-up. The purpose of this test is to check that all LEDs are working properly. The test runs as follows: Order LED action 1 NS LED is switched Off. 2 MS LED is switched On green for approx. 0.25 seconds. 3 MS LED is switched On red for approx. 0.25 seconds. 4 MS LED is switched On green. 5 NS LED is switched On green for approx. 0.25 seconds. 6 NS LED is switched On red for approx. 0.25 seconds. 7 NS LED is switched On green. Additional LEDs If a device has other LEDs, each LED is tested in sequence. 3HAC020738-001 - 67 2 Reference information 2.6.6. LEDs om Interbus boards 2.6.6. LEDs om Interbus boards General Interbus communication boards are generally fitted in the Control Module. On the front of the boards, a number of indication LEDs show the status of the unit and it’s communication: Facts, DSQC 351A Below are facts on the DSQC 351A board: Illustration xx0100000225 Board specific LEDs The designations refer to LEDs shown in the figure in section Illustration of DSQC 351A above. 68 Designation Color Description POWER-24 VDC (upper indicator) GREEN Indicates that a supply voltage is present, and has a level above 12 VDC. If there is no light, check that voltage is present on power module. Check also that power is present in power connector. If it is not, check cables and connectors. If power is applied to unit but unit does not work, replace unit. POWER- 5 VDC (lower indicator) GREEN Lit when both 5 VDC supplies are within limits, and no reset is active. If there is no light, check that voltage is present on power module. Check also that power is present in power connector. If it is not, check cables and connectors. If power is applied to unit but unit does not work, replace unit. - 3HAC020738-001 2 Reference information 2.6.6. LEDs om Interbus boards Designation Color Description RBDA RED Lit when this INTERBUS station is last in the INTERBUS network. If it is not (which is required), check parameter setup. BA GREEN Lit when INTERBUS is active. If there is no light, check network, nodes and connections. RC GREEN Lit when INTERBUS communication runs without errors. If there is no light, check system messages in robot and in INTERBUS net. Facts, DSQC 512 Below are facts on the DSQC 512 board Illustration xx0200000288 3HAC020738-001 A LEDs, master B-E, G-L These are not LEDs and will not be discussed in this context F LEDs, slave - 69 2 Reference information 2.6.6. LEDs om Interbus boards LEDs, master en0400001121 70 Designation Color Description PF YELLOW Peripheral fault One or more pieces of peripheral equipment connected to the bus is faulty. HF YELLOW Host failure The unit has lost contact with the host computer. FC GREEN Reserved N.A. BSA YELLOW Bus segment aborted One or more bus segments are disconnected (disabled). FAIL RED Bus failure, an error has occured in the INTERBUS system. SC GREEN flashing Status controller The unit is active, but not configured. SC GREEN Status controller The unit is active, and configured. FO3 YELLOW The fiber optics of channel 3 is OK. Is on during initialisation of the master board or during communication failure. Finns ej med på bild - bör den ändå nämnas?? - 3HAC020738-001 2 Reference information 2.6.6. LEDs om Interbus boards LEDs, slave en0400001122 Designation Color Description UL GREEN Power supply The unit is supplied with external 24 VDC. BA GREEN flashing Bus active The unit is active, but not configured. BA GREEN Bus active The unit is active, and configured. FO1 YELLOW The fiber optics of channel 1 is OK. Is on during initialisation of the slave board or during communication failure. RC GREEN Remote bus check The bus segment beyond the unit is active. RD RED Remote bus disabled The bus segment beyond the unit is disabled. FO2 YELLOW The fiber optics of channel 2 is OK. Is on during initialisation of the slave board or during communication failure. Facts DSQC 529 3HAC020738-001 - 71 2 Reference information 2.6.6. LEDs om Interbus boards Illustration xx0200000287 LEDs, master en0400001121 72 Designation Color Description PF YELLOW Peripheral fault One or more pieces of peripheral equipment connected to the bus is faulty HF YELLOW Host failure The unit has lost contact with the host computer. FC GREEN Reserved N.A. BSA YELLOW Bus segment aborted One or more bus segments are disconnected (disabled). FAIL RED Bus failure, an error has occured in the INTERBUS system. - 3HAC020738-001 2 Reference information 2.6.6. LEDs om Interbus boards 3HAC020738-001 Designation Color Description SC GREEN flashing Status controller The unit is active, but not configured. SC GREEN Status controller The unit is active, and configured. FO3 YELLOW Only for DSQC 512. The fiber optics of channel 3 is OK. Is on during initialisation of the master board or during communication failure. Finns ej med på bild - bör den ändå nämnas?? - 73 2 Reference information 2.6.7. LEDs on Profibus boards 2.6.7. LEDs on Profibus boards General Profibus communication boards are generally fitted in the Control Module. On the front of the boards, a number of indication LEDs show the status of the unit and it’s communication: Facts, DSQC 352 Below are facts on the DSQC 352 board. Illustration xx0100000223 Board specific LEDs The designations refer to LEDs shown in the figure in section Illustration above. Designation Color Description PROFIBUS active Green Lit when the node is communicating with the master. If there is no light, check system messages in robot and in PROFIBUS net. POWER, 24 VDC Green Indicates that a supply voltage is present, and has a level above 12 VDC. If there is no light, check that voltage is present in power unit and in the power connector. If not, check cables and connectors. If power is applied to the unit but it does not work, replace the unit. Facts, DSQC 510 Below are facts on the DSQC 510 board. 74 - 3HAC020738-001 2 Reference information 2.6.7. LEDs on Profibus boards Illustration xx0100000227 A Slave channel. LED marked S, see section LEDs. See section Connections, slave connector for connection tables! B Master channel. LED marked M, see section LEDs. See section Connections, master connector for connection tables! LEDs Designation Description 3HAC020738-001 0 Indicates the status of the slave channel. Lit when the slave is in data exchange mode. 1 Indicates the status of the master channel. Lit when the master has the Profibus token. - 75 2 Reference information 2.6.7. LEDs on Profibus boards 76 - 3HAC020738-001 3 Symptoms 2.6.7. LEDs on Profibus boards 3 Symptoms 3HAC020738-001 - 77 3 Symptoms 3.1.1. Controller dead 3.1 Faults without event log messages 3.1.1. Controller dead Description The robot controller is completely or intermittently "dead”. No indication are lit and no operation what so ever is possible. Consequences The system may not be operated using the FlexPendant. Possible causes The symptom may be caused by (the causes are listed in order of probability): • The controller is not connected to the mains power supply. • The main transformer is malfunctioning or not connected correctly • The main fuse (Q1) may have tripped • Recommended actions In order to remedy the symptom, the following actions are recommended (the actions are listed in order of probability): Step Action Info/illustration 1. Make sure the mains power supply in the shop is working and that the voltage level matches that of the controller requirement. 2. Make sure the main transformer has been correctly connected for the mains voltage level at hand. 3. Make sure the mains fuse (Q1) inside the Drive Module has not tripped. If it has, reset it. Approval critera A fully functional controller. 78 - 3HAC020738-001 3 Symptoms 3.1.2. Fuses 3.1.2. Fuses General The supply to the robot system is protected by several fuses: Automatic fuses • One three-phase, 20 A, fuse on the transformer supplying the DC-link in the MOTORS ON state. • One single-phase, 10 A, fuse supplying the power supply unit. • Two fuses, one 3.15 A and one 6.3 A, for customer AC supplies. Fuses in base connector unit The base connector unit has six PTC resistance fuses for: • Serial measurement system channel 1 • Serial measurement system channel 2 • CAN 1.1 • CAN 1.2 • CAN 1.3 • CAN 2 The fuses protect against 24 V short-circuits and return to the normal state when there is no longer a risk of short-circuiting. Fuse in panel unit The panel unit has one PTC fuse to protect the MOTORS ON chains. An open fuse is indicated on the FlexPendant (see section xx, 24V panel). Fuse protecting the 24 V customer supply cabling The cabling from the customer 24 V supply is protected by a 2A fuse on terminal XT31 in the upper compartment of the controller. Protection for process power supply unit The process power supply unit is provided with a short circuit energy limitation, individual for each supply voltage, making fuses obsolete. 3HAC020738-001 - 79 3 Symptoms 3.1.3. FlexPendant dead 3.1.3. FlexPendant dead Description The robot FlexPendant is completely or intermittently "dead". No entries are possible, and no functions are available. If the FlexPendant starts up, but does not display any screen, proceed as detailed in section FlexPendant does not communicate. Consequences The system may not be operated using the FlexPendant. Possible causes The symptom may be caused by (the causes are listed in order of probability): • The FlexPendant is not connected to the controller. • The cable from the controller is damaged. • The cable connector is damaged. • The FlexPendant is faulty. • FlexPendant power supply from controller is faulty. Recommended actions In order to remedy the symptom, the following actions are recommended (the actions are listed in order of probability): Step Action Info/Illustration 1. Make sure the FlexPendant is connected to the controller. How to connect the FlexPendant to the controller section Connecting a FlexPendant. 2. Inspect the FlexPendant cable for any visible If faulty, replace the damage. If possible, connect a different FlexPendant FlexPendant. to eliminate the FlexPendant and cable as error sources. 3. Check the 24 VDC power supply from the controller. Also see the Circuit Diagram in the controller Repair manual. Approval criteria A fully functional FlexPendant with all screen keys working. 80 - 3HAC020738-001 3 Symptoms 3.1.4. FlexPendant does not communicate 3.1.4. FlexPendant does not communicate Description The FlexPendant starts up, but does not display any screen. No entries are possible, and no functions are available. The FlexPendant is not completely “dead”. If it is “dead”, proceed as detailed in section FlexPendant dead. Consequences The system may not be operated using the FlexPendant. Possible causes The symptom may be caused by (the causes are listed in order of probability): • The main computer has lost its power supply, and not communication is possible between FlexPendant and main computer. Recommended actions In order to remedy the symptom, the following actions are recommended (the actions are listed in order of probability): Step 3HAC020738-001 Action Info/Illustration 1. Make sure the main computer unit power supply is OK. 2. If the power supply is OK, check all cables from power supply unit to main computer, making sure these are correctly connected. 3. Make sure the FlexPendant has been correctly connected to the Control Module. 4. If all cables and power supplies are OK, replace the main computer board. 5. Perform a restart and resume normal operation. 6. Check all indication LEDs on all units in the Control and Drive Modules. 7. Make sure the ribbon cable from the main computer to the hard disk drive in the main computer unit is correctly connected at both ends. - How to replace the main computer board is detailed in the Product Manual, IRC5. All indication LEDs and their significance are specified in section Indications. 81 3 Symptoms 3.1.5. Erratic event messages on FlexPendant 3.1.5. Erratic event messages on FlexPendant Description The event messages displayed on the FlexPendant are erratic and do not seem to correspond to any actual malfunctions on the robot. Several types of messages may be displayed, all seemingly erroneous. This type of fault often appears after major manipulator disassembly or overhaul. Consequences Major operational disturbances due to the constantly appearing messages. Possible causes The symptom may be caused by (the causes are listed in order of probability): • Internal manipulator cabling not correctly performed. Causes may be: faulty connection of connectors, cable loops too tight causing the cabling to get strained during manipulator movements, cable insulationchafed or damaged by rubbing shortcircuiting signals to earth. Recommended actions In order to remedy the symptom, the following actions are recommended (the actions are listed in order of probability): Step Action Info/Illustration 1. Inspect all internal manipulator cabling, especially all cabling disconnected, connected re-routed or bundled during recent repair work. Refit any cabling as detailed in the manipulator Product Manual. 2. Inspect all cable connectors to amke sure these are correctly connected and tightened. 3. Inspect all cable insulation for damage. Replace any faulty cabling as detailed in the manipulator Product Manual. Approval criteria Correctly performed internal manipulator cabling should eliminate all erratic event messages on FlexPendant. 82 - 3HAC020738-001 3 Symptoms 3.1.6. The joystick doesn´t work 3.1.6. The joystick doesn´t work Description The system can be started but the joystick on the FlexPendant doesn´t seem to work. Consequences The robot can not be jogged manually. Possible causes The symptom may be caused by (the causes are listed in order of probability): • The Flexpandant may not have been connected correctly or the cable may be damaged. • The power supply to the FlexPendant does not work correctly. • The FlexPendant is malfunctioning. Recommended actions In order to remedy the symptom, the following actions are recommended (the actions are listed in order of probability): Step 3HAC020738-001 Action Info/illustration 1. Make sure the FlexPendant is connected correctly to Detailed in section the Control Module and Panel Board. Connecting a FlexPendant. 2. Make sure the FlexPendant cable has not been damaged. 3. Make sure the Control Module Power Supply and Panel Board are working correctly. 4. If nothing else works, replace the faulty FlexPendant.. - How to check the power supply is detailed in section Trouble Shooting Power Supplies. 83 3 Symptoms 3.1.7. Reflashing firmware failed 3.1.7. Reflashing firmware failed Description When reflashing firmware, the automatic process may fail . The reflashing process is described in section Reflashing firmware in the Operator's Manual, IRC5 with FlexPendant. Consequences The automatic reflashing process is interrupted and the system stops. Possible causes This fault most often occur due to a lack of campatibility between hardware and software. Consequences In order to remedy the symptom, the following actions are recommended (the actions are listed in order of probability): Step 84 Action Info/illustration 1. Check the FlexPendant event log for a message specifying which unit failed. How to access the FlexPendant event log is detailed in section Event log. 2. Was the relevant unit recently replaced? If YES; make sure the versions of the old and new unit is identical. If NO; check the software versions. How to check the versions is detailed in section xx. 3. Was the RobotWare recently replaced? If YES; make sure the versions of the old and new unit is identical. If NO; proceed below! How to check the versions is detailed in section xx. 4. Check with your local ABB representative for a firmware version compatible with your hardware/ software combination. 5. Install the new firmware version, and retry flashing the unit in question. - 3HAC020738-001 3 Symptoms 3.1.8. Inconsistent path accuracy 3.1.8. Inconsistent path accuracy Description The path of the robot TCP is not consistent. It varies from time to time, and this may sometimes be accompanied by noise emerging from bearings, gearboxes or other locations. Consequences Production is not possible. Possible causes The symptom may be caused by (the causes are listed in order of probability): • Robot not calibrated correctly • Robot TCP not correctly defined • Parallel bar damaged(applies to robots fitted with parallel bars only) • Mechanical joint between motor and gearbox damaged. This often causes noise to be emitted from the faulty motor. • Bearings damaged or worn (especially if the path inconsistency is coupled with clicking or grinding noises from one or more bearings). Recommended actions In order to remedy the symptom, the following actions are recommended (the actions are listed in order of probability): Step Action Info/Illustration 1. Check the trueness of the parallel bar (applies to robots fitted with parallel bars only). Replace faulty parallel bar as specified in the robot Product Manual. 2. Locate the faulty motor by tracking the noise. Study the path of the robot TCP to establish which axis, and thus which motor, may be faulty. Replace faulty motor/gearbox as specified in the robot Product Manual. 3. Locate the faulty bearing by tracking the noise. Replace faulty bearing as specified in the robot Product Manual. 4. Make sure the robot Tool and Work Object are correctly defined. How to define these are detailed in section Jogging in the Operator's Manual, IRC5 with FlexPendant. 5. Check the revolution counters' position. Updated if required as detailed in section Calibration. 6. If required, recalibrate the robot axes. Make sure the robot is calibrated as detailed in section Calibration in the Operator's Manual, IRC5 with FlexPendant. Approval criteria - 3HAC020738-001 - 85 3 Symptoms 3.1.9. "Joint error" 3.1.9. "Joint error" Description The FlexPendant displays "Joint error", especially after long stand-stills. Consequences The motors are overloaded, and the current to the motors are restricted. Occasional motor overcurrents are detected. Possible causes The symptom may be caused by (the causes are listed in order of probability): • Too cold oil in the gearboxes has too high viscosity Recommended actions In order to remedy the symptom, the following actions are recommended (the actions are listed in order of probability): Step Action Info/Illustration 1. Raise the temperature in the shop. 2. Write a simple robot program to jog each axis prior to starting production. Repeat running this program before each production start-up. Approval criteria When the robot runs without causing the "Joint error" to be displayed, the gearboxes are sufficiently warmed. 86 - 3HAC020738-001 3 Symptoms 3.1.10. Oil or grease stains on motors and/or gearboxes 3.1.10. Oil or grease stains on motors and/or gearboxes Description The area surrounding the motor or gearbox shows signs of oil leaks. This may be at the base, closest to the mating surface, or at the furthest end of the motor at the resolver. Consequences Besides the dirty appearance, in some cases there are no serious consequences. However, in some cases the leaking oil lubricates the motor brake, causing the manipulator to collaps at power-down. Possible causes The symptom may be caused by (the causes are listed in order of probability): • Leaking seal between gearbox and motor. • Gearbox overfilled with oil • Gearbox oil too hot Recommended actions In order to remedy the symptom, the following actions are recommended (the actions are listed in order of probability): Step Action Info/Illustration 1. xx Caution! Before approaching the potentially hot manipulator component, observe the safety information in section CAUTION - Hot parts may cause burns!. 3HAC020738-001 2. Inspect all seals and gaskets between motor and gearbox. The different manipulator models use different types of seals. Replace seals and gaskets as specified in the robot Product Manual. 3. Check the gearbox oil level. Correct oil level is specified in the robot Product Manual. 4. Too hot gearbox oil may be caused by: • Oil quality or level used is incorrect • The robot work cycle runs a specific axis too hard. Investigate whether it is possible to program small "cooling periods" into the application. • Overpressure created inside gearbox. Check the recommended oil level and type as specified in the robot Product Manual. Manipulators performing certain, extremely heavy duty work cycles may be fitted with vented oil plugs. These are not fitted to normal duty manipulators, but may be purchased from your local ABB representative. - 87 3 Symptoms 3.1.10. Oil or grease stains on motors and/or gearboxes Approval criteria No oil seepage is acceptable. 88 - 3HAC020738-001 3 Symptoms 3.1.11. Mechanical noise 3.1.11. Mechanical noise Description During operation, no mechanical noise should be emitted from motors, gearboxes, bearings or similar. A faulty bearing often emits scraping, grinding or clicking noises shortly before failing. Consequences Failing bearings cause the path accuracy to become inconsistent, and in severe cases the joint may seize completely. Possible causes The symptom may be caused by (the causes are listed in order of probability): • Worn bearings • Contaminations have entered the bearing races • Loss of lubrication in bearings If the noise is emitted from a gearbox, the following may also apply: • Overheating Recommended actions In order to remedy the symptom, the following actions are recommended (the actions are listed in order of probability): Step Action Info/Illustration 1. xx Caution! Before approaching the potentially hot manipulator component, observe the safety information in section CAUTION Hot parts may cause burns!. 3HAC020738-001 2. Determine which bearing is emitting the noise. 3. Make sure the bearing has sufficient lubrication. As specified in the robot Product Manual. 4. If possible, disassemble the joint and measure the clearance. As specified in the robot Product Manual. 5. Bearings inside motors are not to be replaced individually, but the complete motor is replaced. Replace faulty motors as specified in the robot Product Manual. - 89 3 Symptoms 3.1.11. Mechanical noise Step Action Info/Illustration 6. Make sure the bearings are fitted correctly. Also see section Mounting instructions for bearings in the robot Product Manual for general instruction on how to handle bearings. 7. Too hot gearbox oil may be caused by: • Oil quality or level used is incorrect • The robot work cycle runs a specific axis too hard. Investigate whether it is possible to program small "cooling periods" into the application. • Overpressure created inside gearbox. Check the recommended oil level and type as specified in the robot Product Manual. Manipulators performing certain, extremely heavy duty work cycles may be fitted with vented oil plugs. These are not fitted to normal duty manipulators, but may be purchased from your local ABB representative. Approval criteria All bearing clearances should be within the specifications and all bearings should have sufficient lubrication. 90 - 3HAC020738-001 3 Symptoms 3.1.12. Manipulator collapses on power-down 3.1.12. Manipulator collapses on power-down Description The manipulator is able to work correctly while MOTORS ON is active, but when MOTORS OFF is active, it collapses under its own weight. The holding brakes integral to each motor is not able to hold the weight of the manipulator arm. Consequences It may cause severe injuries or death to personnel working in the area or severe damage to the manipulator and/or surrounding equipment. Possible causes The symptom may be caused by (the causes are listed in order of probability): • faulty brake • faulty power supply to the brake Recommended actions In order to remedy the symptom, the following actions are recommended (the actions are listed in order of probability): Step Action Info/Illustration 1. Determine which motor(s) is causing the collapse. 2. Check the brake power supply to the collapsing motor Also see the Circuit Diagram during the MOTORS OFF state. in the robot Product Manual. 3. Remove the resolver of the motor to see if there are any signs of oil leaks. 4. Remove the motor from the gearbox to inspect it from If found faulty, the motor the drive side. must be replaced as a complete unit as detailed in the Product Manual. If found faulty, the motor must be replaced as a complete unit as detailed in the Product Manual. Approval criteria All holding brakes of all axes must be able to hold the manipulator arm including max. allowed load for at least 500 cycles. 3HAC020738-001 - 91 3 Symptoms 3.2.1. Overview, event log messages 3.2 Event log messages 3.2.1. Overview, event log messages Version This chapter contains all standard error log messages included in the RobotWare version 5.04.0054. Since the event log contents is constantly being updated, this chapter is a mix of older and newer messages, but it is always the latest information available. Arguments In many of the event log messages, you will find the marker arg. This is a variable which may have a number of significances, mainly depending on the context in which it appears. This is not a desired function, but a slight short-coming of the automated system generating the event log messages. Argument example In the example below, arg signifies the name of the mechanical unit to causing the error. en0400001021 92 - 3HAC020738-001 3 Symptoms Recommended actions 10002, Program pointer has been reset 1. Check which safety device caused the stop. Description 2. Close the device. The program pointer of task arg has been reset. 3. To resume operation, switch the system back to state Motors ON. Consequences 10013, Emergency stop state When started, program execution will start on the first instruction of the task's entry routine. NOTE that the manipulator may move to unexpected position when restarted! Description The system is in the Emergency stop state, since the Motors ON circuit has been opened by an Emergency Stop device. Probable causes The operator has probably requested this action manually. Consequences All program execution and thus robot actions are immediately halted. The robot axes are meanwhile held in position by mechanical holding brakes. 10009, Work memory full Description Probable causes The task arg has no memory left for new RAPID instructions or data. Any emergency stop device connected to the emergency stop input have been opened. These may be internal (on the controller or on the FlexPendant) or external (devices connected by the system builder). The internal devices are shown in the Circuit Diagram. Recommended actions Save the program and then restart the system. 10010, Motors OFF state Recommended actions Description 1) Check which emergency stop device caused the stop. The system is in the Motors OFF state. It enters this state either after switching from Manual mode to Automatic, or after the Motors ON circuit has been opened during program execution. 2) Close/reset the device. 3) To resume operation, switch the system back to state Motors ON by pressing this button on the Control Module. Consequences 10014, System failure state No operation will be possible until after closing the Motors ON circuit. The manipulator's axes are meanwhile held in position by mechanical holding brakes. Description Execution of all tasks has been stopped due to malfunction. 10011, Motors ON state Consequences Description No program execution or manual manipulator jogging will be possible until after the system has been restarted. The system is in the Motors ON state. Probable causes Consequences A large number of malfunctions may cause this condition. Please use the FlexPendant or RobotStudioOnline to check other event log messages for events occurring at this time! The Motors ON circuit has been closed., enabling power supply to the manipulator's motors. Normal operation may be resumed. Recommended actions 10012, Safety guard stop state 1. Determine what caused the stop by studying the event log. 2. Remedy the fault. Description 3. Restart the system as detailed in the Operator's Manual. The system is in the Guard stop state. It enters this state either after switching from Automatic mode to Manual, or after the Motors ON circuit has been opened by an Emergency Stop, General Stop, Automatic Stop or Superior Stop. 10015, Manual mode selected Description Consequences The system is in the Manual mode. No operation will be possible until after closing the Motors ON circuit. The manipulator's axes are meanwhile held in position by mechanical holding brakes. Consequences Programmed operation is possible, but only with a max. speed of 250 mm/s. The manipulator may also be jogged manually after pressing the enabling device on the FlexPendant. Probable causes Any safety device connected to the system's stop inputs have been opened. These are shown in the Circuit Diagram. 3HAC020738-001 - 93 3 Symptoms 10016, Automatic mode requested 10021, Execution error reset Description Description The system has been ordered to go to the Automatic mode. The program execution has left a spontaneous error state. Consequences Recommended actions The system will go to the Automatic mode. 10023, Hold to run timeout 10017, Automatic mode confirmed Description Description The system is in the Automatic mode. The hold to run button on the programming unit must be pressed within timeout limit. Consequences Recommended actions Programmed operation is possible. The manipulator may also be jogged manually after pressing the enabling device on the FlexPendant. 10024, Collision triggered Description 10018, Manual mode full speed requested Some mechanical part of the manipulator has collided with a piece of fixed equipment in the cell. Description Consequences The system has been ordered to go to the Manual mode without any speed restraints. Manipulator movement is interrupted and program execution is stopped. Consequences The system will go to the Manual mode full speed. 10025, Collision confirmed 10019, Manual mode full speed confirmed Description The collision detection has been confirmed. Description Recommended actions The system is in the Manual mode without any speed restraints. Consequences 10026, Collision retraction Programmed operation is possible while pressing the hold-to-run button on the FlexPendant. The manipulator may also be jogged manually after pressing the enabling device on the FlexPendant. Description The manipulator has attempted to back away from the obstacle, into which it collided, and succeeded. 10020, Execution error state Consequences The system is ready to go back to normal operation. Description Execution of all tasks has been stopped due to a spontaneous error. 10027, Collision retraction fail Consequences No program execution or manual manipulator jogging will be possible until after the system has been restarted. Description The manipulator has attempted to back away from the obstacle, into which it collided, and failed. Probable causes A large number of malfunctions may cause this condition. Please use the FlexPendant or RobotStudioOnline to check other event log messages for events occurring at this time! Consequences The system is NOT ready to go back to normal operation. Probable causes Recommended actions This may be caused by the robot being stuck to the object into which it collided. 1. Determine what caused the stop by studying the event log. 2. Remedy the fault. Recommended actions 3. Restart the system as detailed in the Operator's Manual. 1) Go to Manual Mode. 2) Manually run the robot away from the object. 94 - 3HAC020738-001 3 Symptoms 3) Resume operation by restarting the program. 10035, Axis not calibrated 10030, All axes commutated Description Description After checking, the system has found that one or more manipulator axes are not calibrated. After checking, the system has found all manipulator axes to be commutated. Consequences To enable operation, all manipulator axes must be calibrated. Consequences Probable causes Normal operation is possible. The manipulator drive motor and related units may have been altered, e.g. after replacing a faulty unit. 10031, All axes calibrated Recommended actions Description Calibrate the manipulator axes as detailed in the manipulator Product Manual. After checking, the system has found all manipulator axes to be calibrated. 10036, Revolution counter not updated Consequences Normal operation is possible. Description 10032, All revolution counters updated After checking, the system has found that the revolution counters of one or more manipulator axes are not updated. Description Consequences After checking, the system has found all revolution counters for all manipulator axes to be updated. To enable operation, the revolution counters of all manipulator axes must be updated. Consequences Probable causes Normal operation is possible. The manipulator drive motor and related units may have been altered, e.g. after replacing a faulty unit. 10033, All axes synchronized Recommended actions Description Update the revolution counters of all manipulator axes as detailed in the manipulator Product Manual. After checking, the system has found all manipulator axes to be synchronized. 10037, Axis not synchronized Consequences Description Normal operation is possible. After checking, the system has found that one or more manipulator axes are not synchronized. 10034, Axis not commutated Consequences Description To enable operation, all manipulator axes must be synchronized. After checking, the system has found that one or more manipulator axes are not commutated. Probable causes The manipulator drive motor and related units may have been altered, e.g. after replacing a faulty unit. Consequences To enable operation, all manipulator axes must be commutated. Recommended actions Probable causes Synchronize the manipulator axes as detailed in the manipulator Product Manual. The manipulator drive motor and related units may have been altered, e.g. after replacing a faulty unit. Recommended actions 10038, SMB memory is OK Commutate the manipulator axes as detailed in the manipulator Product Manual. Description During startup, the system has found that all data on the Serial Measurement Board (SMB) is OK. 3HAC020738-001 - 95 3 Symptoms Consequences Recommended actions Operation is possible. 10045, System restarted 10039, SMB memory is not OK Description Description An already installed system was restarted. During startup, the system has found that data in the Serial Measurement Board (SMB) memory is not OK. Recommended actions Consequences 10046, System restarted in cold mode All data must be OK before automatic operation is possible. Manually jogging the robot is possible. Description Probable causes First start after installation. There are differences between the data stored on the SMB and the data stored in the controller. This may be due to replacement of SMB, controller or both. Recommended actions 10048, Background task did stop Recommended actions Description 1) Update the Serial Measurement Board data as detailed in Operator's Manual, IRC5. The task arg stopped without reason. Recommended actions 10040, Program loaded Description 10051, Event routine error A program or program module has been loaded into task arg. After loading, arg bytes memory remain. The size of the loaded program is arg. Description 10041, Program deleted Recommended actions The task arg could not start the specified system event routine arg. The routine is either unknown to the system or the program is unlinkable. Insert the routine in a system module or correct the program. Description A program or program module was deleted from task arg. 10052, Regain start Consequences Description If the deleted program contained the task entry routine, the program will no longer be executable. A regain movement has started. Recommended actions Probable causes The program may have been removed manually. Recommended actions 10053, Regain ready 1) Define an entry routine in one of the task's remaining programs, or: Description 2) Load a program containing an entry routine. The regain movement is ready. Recommended actions 10043, Restart failed Description 10054, Regain rejected The task arg can't restart. Description Regain on path not possible, as one client has already ordered it. 10044, Program Pointer updated Recommended actions Description A new regain movement is ordered during an already started regain movement. Reduce the number of start orders from e.g system I/O The task arg could have changed the Program Pointer position. 96 - 3HAC020738-001 3 Symptoms Consequences 10055, Path process restarted If the server arg is defined as TRUSTED, robot program execution will be stopped. If the server is defined as NON-TRUSTED, execution will proceed. These definitions are specified in the Application manual Robot communication and I/O control. Description The path process has been restarted. Recommended actions Probable causes If this message is displayed at first start-up, the server configuration may be incorrect. If displayed during operation, the previously working communication has been lost due to a broken connection. Also see the I/O event log! 10060, Test of enable chain Description The enable chain is always tested at startup. If the test failed an error message concerning enable will follow. Recommended actions 1. Check the FTP server configuration. Recommended actions 2. Check all communication hardware, cables and such. If enable chain test at startup failed the related error message will be "Enable chain timeout" 3. Check the FTP client configuration on the controller. 10080, An updated RAPID file is found 10074, NFS server up Description Description The control system communicates correctly with the NFS server arg. The SEMISTATIC task arg has an older version of a module installed than the source arg 10075, NFS server down Recommended actions Restart the system with a P-START to install the newer version. Description The control system is not able to communicate correctly with the NFS server arg. 10081, Background task arg Consequences Description If the server arg is defined as TRUSTED, robot program execution will be stopped. If the server is defined as NON-TRUSTED, execution will proceed. These definitions are specified in the Application manual Robot communication and I/O control. failed to load a newer version of a module. The source of the module is arg. Recommended actions See previous messages for the cause or restart the system with a PSTART to load the newer version. Probable causes If this message is displayed at first start-up, the server configuration may be incorrect. If displayed during operation, the previously working communication has been lost due to a broken connection. Also see the I/O event log! 10082, RAPID Task supervision Recommended actions Task arg is not running. The system will be set in SysFail state. It's now impossible to change to motors on arg. Description 1. Check the NFS server configuration. 2. Check all communication hardware, cables and such. Recommended actions 3. Check NFS client configuration on the controller. See previous messages for the cause. Restart the system to reset the error state. 10076, FTP server up 10083, RAPID Task supervision Description Description The control system communicates correctly with the FTP server arg. Task arg is not running. The system will be set in motors off state. arg 10077, FTP server down Recommended actions See previous messages for the cause. Description The control system is not able to communicate correctly with the FTP server arg. 3HAC020738-001 - 97 3 Symptoms Recommended actions 10084, RAPID Task supervision Description 10092, (Re)start not possible Task arg is not running. The main task will also stop arg. Description Recommended actions (Re)start is not possible due to lost contact with IO module arg configured with trustlevel 3. See previous messages for the cause. 10085, RAPID Task supervision Recommended actions Description 10093, (Re)start not possible Task arg can't be stopped. The trustLevel is set to a safety level. Description Recommended actions (Re)start of task arg is not possible before a warm start is done. If the task should be possible to stop change the trustLevel or task type in the system parameters menu. Recommended actions The background task is configured with Trustlevel set to SysHalt 10086, Robot is purged OK 10095, At least one task is unchecked in the task selection panel Description Purging pressure regained after a purge fault. Description Recommended actions One or more of the NORMAL tasks are unchecked in the task selection panel when performing a (re)start. 10087, Purge state: arg. Recommended actions Description State changed. 10096, arg not active! Recommended actions Description 10088, Restart not possible The workobject arg contains a coordinated mechanical unit which is not activated. Description Recommended actions Restart is not possible from the current program position. The system has been in system failure state and the program may, for that reason, be in an unsafe condition. Activate the mechanical unit and perform the operation again. 10097, Restart not possible Recommended actions Description The Program Pointer must be moved before restart. The task arg is set in blocked state and the program is for that reason not possible to restart from the current program position. 10090, P-Start done Recommended actions Description The Program Pointer must be moved before restart. An ordered P-Start is done. All tasks are reset and all user programs are lost. 10098, Restart not possible Recommended actions Description 10091, Restart not possible The task arg has been in system failure state and the program is for that reason not possible to restart from the current program position. Description Recommended actions A restart after collision detection is not possible before acknowledge the error dialogue. The Program Pointer must be moved before restart. 98 - 3HAC020738-001 3 Symptoms 10106, Service Message 10120, Program stopped Description Description It's time for service for robot arg because it is arg days since the last service. The task arg has stopped. The reason is that an external or internal stop after current instruction has occurred. Recommended actions Recommended actions 10107, Service Message 10121, Program stopped Description Description It remains arg days for robot arg until it's time for service. The task arg has stopped. The reason is that the task has reached an exit instruction. Recommended actions Recommended actions 10108, Service Message 10122, Program stopped Description It's time for service for robot arg cause it's arg hours of production since last service. Description Recommended actions Recommended actions 10109, Service Message 10123, Program stopped Description Description It remains arg hours of production for robot arg to next service. The task arg has stopped. The reason is that the task is ready with this step. The task arg has stopped. The reason is that the task is ready. Recommended actions Recommended actions 10110, Service Message 10124, Program stopped Description The gearbox at arg of robot arg needs service. Description Recommended actions The task arg has stopped. The reason is that the task has reached a break instruction. Recommended actions 10111, Service Message Description 10125, Program stopped The gearbox at arg of robot arg has reached arg of its service interval. Description Recommended actions The task arg has stopped. The reason is that an external or internal stop has occurred. 10112, Service Message Recommended actions Description 10126, Program stopped The system date and time has changed. This could cause problems with the SIS calender notification. Description Recommended actions The task arg has stopped. The reason is that an error has occurred. The SIS parameters Calender Limit and Calender Warning might need to be changed 3HAC020738-001 - 99 3 Symptoms Recommended actions 10150, Program started Description 10127, Program stopped Execution of task arg has been started from the first instruction of the task's entry routine. The originator could not be determined. Description The task arg has stopped. The reason is that Cannot execute backward past beginning of instruction list. Recommended actions Recommended actions 10151, Program started Description 10128, Program stopped Execution of task arg has been started from the first instruction of the task's entry routine. The originator is an external client. Description The task arg has stopped. The reason is that Cannot execute backward past this instruction. Recommended actions Recommended actions 10152, Program started Description 10129, Program stopped Execution of task arg has been started from the first instruction of the task's entry routine. The start order was initiated by an action causing the UNDO handler to execute. Description The task arg has stopped. The reason is that the event routine for RESET or POWER_ON is ready. 10155, Program restarted Recommended actions Description 10130, Program stopped Execution of task arg has been restarted from where it was previously stopped. The originator could not be determined. Description Recommended actions The task arg has stopped. The reason is that the task is ready with this move step. 10156, Program restarted Recommended actions Description 10131, Program stopped Execution of task arg has been restarted from where it was previously stopped. The originator is an external client. Description Recommended actions The task arg has stopped. The reason is that the routine called from system IO interrupt is ready. 10157, Program restarted Recommended actions Description 10132, Program stopped Execution of task arg has been restarted from where it was previously stopped. The restart order was initiated by an action causing the UNDO handler to execute. Description The task arg has stopped. The reason could not be determined. 10170, Background task arg Recommended actions Description 10133, Program stopped refuse to start. Task is empty. Description The task arg has stopped. The reason is that the task is ready with the execution of the UNDO handlers. 100 - 3HAC020738-001 3 Symptoms Recommended actions 2. Perform an I-start. 10171, Background task arg 10190, Protected area not done Description Description refuse to start. Wrong state. A power fail did occur in the middle of a protected area for the task arg. The system is trying to selfheal. Recommended actions Recommended actions 10172, Background task arg 10191, Protected area not done Description Description refuse to start. Can't set PP to the main routine. A power fail did occur in the middle of a protected area for the task arg. A pending error is removed from the queue. Probable causes The module that contains the main routine was not loaded since the module file is missing in the target directory. Recommended actions The module that contains the main routine was not loaded since the configuration file has no entry for automatic loading of the module. 10192, Protected area not done The main routine is missing. Description The main entry is corrupted. A power fail did occur in the middle of a protected area for the task arg. A pending exit is removed from the queue. Recommended actions Load the module by hand or perform an I-start when the cause of the problem is removed. Recommended actions 10193, Protected area not done 10173, Background task arg Description Description A power fail did occur in the middle of a protected area for the task arg. This may result in an extra program cycle. refuse to start. Can't set the execution mode. Recommended actions Recommended actions 10174, Background task arg 10194, Protected area not done Description Description refuse to start. The start order failed. A power fail did occur in the middle of a protected area for the task arg. The task will be restarted from the main routine. Recommended actions Recommended actions 10175, Background task arg Description 10195, Protected area not done refuse to start due to a syntax error. Description Recommended actions A power fail did occur in the middle of a protected area for the task arg. All tasks are reset and all user programs are lost. 10176, Background task arg Recommended actions Try to save the user program and do a warm start of the system Description refuse to start. Can't load module. 10196, Protected area not done Probable causes Description The module file is missing in the target directory. A power fail did occur in the middle of a protected area for the task arg. Recommended actions 1. Copy the module file to the target directory. 3HAC020738-001 - 101 3 Symptoms Recommended actions Recommended actions 10210, Execution cancelled 10217, Execution cancelled Description Description The restart will clear the execution in task arg of a POWER ON system event routine. The restart will clear the execution in task arg of a USER routine. Recommended actions Recommended actions 10218, Execution cancelled 10211, Execution cancelled Description Description The restart will clear the execution in task arg. The restart will clear the execution in task arg of a STOP system event routine. Recommended actions Recommended actions 10230, Backup step ready Description 10212, Execution cancelled The backup step Prepare is ready. Description Recommended actions The restart will clear the execution in task arg of an EMERGENCY STOP system event routine. 10231, Backup step ready Recommended actions Description 10213, Execution cancelled The backup step Configuration is ready. Description Recommended actions The restart will clear the execution in task arg of a START system event routine. 10232, Backup step ready Recommended actions Description The backup of Task is ready. 10214, Execution cancelled Recommended actions Description The restart will clear the execution in task arg of a RESTART system event routine. 10250, Restore step ready Description Recommended actions The restore step Prepare is ready. Recommended actions 10215, Execution cancelled Description 10251, Restore step ready The restart will clear the execution in task arg of a RESET system event routine. Description The restore step Configuration is ready. Recommended actions Recommended actions 10216, Execution cancelled 10252, Restore step ready Description The restart will clear the execution in task arg of an INTERNAL system event routine. 102 Description The restore of Task is ready. - 3HAC020738-001 3 Symptoms Recommended actions Recommended actions 10253, Restore step ready 10354, Restore aborted due to lost system data. Description Description The restore of User Task is ready. Recommended actions The system is using a backup of the system data, since the system data was not properly saved at last shutdown. Due to this, a previously ordered Restore from directory arg was attempted again, but was aborted. 10300, A P-Start is ordered Consequences Description No RAPID programs or modules will be loaded. The P-Start has been ordered from the system. Probable causes Recommended actions The system data was not properly saved at last shutdown. Recommended actions 10301, A P-Start is ordered After recovering from the system data loss by a (B)ackup-Restart or system re-installation, please verify that the backup directory arg is OK, and perform the Restore again. Description The P-Start has been ordered manually or automatically during a configuration. 10400, arg logged on Recommended actions Description User using application arg at location arg has logged on. 10304, An update has been ordered 10401, arg logged off Description An update of program configuration is done. Description Recommended actions User using application arg at location arg has logged off. 10350, Update of task failed 10420, New unsafe robot path Description Description The system could not update task arg to the new configuration. The robot path has been cleared after a modpos operation on task arg. The robot will for that reason move towards the position pointed out by the move instruction at the program pointer. Move instructions between the modposed robtarget and the program pointer will be skipped. Recommended actions 10351, A task is removed Consequences Description The programmed speed is used for this movement. The task arg was removed because of configuration changes. The new untested path may contain obstacles that might cause a collision. Recommended actions Recommended actions 10352, A task is added Check your program pointer and move it if necessary. Reduce the speed. Description The task arg was installed because of configuration changes. 11020, Backup error Recommended actions Description Error during the backup step Prepare. Unknown error. 10353, A task is reinstalled Recommended actions Description arg The task arg was reinstalled because of configuration changes. 3HAC020738-001 - 103 3 Symptoms Recommended actions 11021, Backup error arg Description Error during the backup step Prepare. General error. 11028, Backup error Recommended actions Description arg Error during the backup step Prepare. Error writing configuration parameters. 11022, Backup error Recommended actions Description arg Error during the backup step Prepare. The directory contains items that are to be created. 11029, Backup error Recommended actions Description arg Error during the backup step Prepare. The structure is too deep. Recommended actions 11023, Backup error arg Description Error during the backup step Prepare. The directory lacks at least one neccessary item. 11030, Backup error Description Recommended actions Error during the backup step Prepare. No more objects. arg Recommended actions 11024, Backup error arg Description 11031, Backup error Error during the backup step Prepare. The directory does not exist. Description Recommended actions arg Error during the backup step Prepare. The directory lacks at least one neccessary item. 11025, Backup error Recommended actions arg Description Error during the backup step Prepare. Directory cannot be created. 11032, Backup error Recommended actions Description arg Error during the backup step Prepare. The system version doesn't match the backup. 11026, Backup error Recommended actions Description arg Error during the backup step Prepare. Error whilst writing the backup. Recommended actions 11033, Backup error arg Description 11027, Backup error Error during the backup step Prepare. Error restoring configuration parameters. Description Recommended actions Error during the backup step Prepare. Error reading configuration parameters. arg 104 - 3HAC020738-001 3 Symptoms Recommended actions 11034, Backup error arg Description Error during the backup step Prepare. Error restoring configuration parameters. 11120, Backup error Description Recommended actions Error during the backup step Configuration. Unknown error. arg Recommended actions 11035, Backup error 11121, Backup error Description Error during the backup step Prepare. Mismatch between current system and the backup. Description Error during the backup step Configuration. General error. Recommended actions Recommended actions arg 11122, Backup error 11036, Backup error Description Description Error during the backup step Prepare. Write error. Error during the backup step Configuration. The directory contains items that are to be created. Recommended actions Recommended actions arg 11123, Backup error 11037, Backup error Description Description Error during the backup step Configuration. The directory lacks at least one neccessary item. Error during the backup step Prepare. At least one modname is too long. Recommended actions Recommended actions arg 11124, Backup error 11038, Backup error Description Description Error during the backup step Configuration. The directory does not exist. Error during the backup step Prepare. Unknown task. Recommended actions Recommended actions arg 11125, Backup error 11039, Backup error Description Description Error during the backup step Configuration. Directory cannot be created. Error during the backup step Prepare. Storage media full. Recommended actions Recommended actions arg 11126, Backup error 11040, Backup error Description Description Error during the backup step Configuration. Error whilst writing the backup. Error during the backup step Prepare. Item not possible to delete. 3HAC020738-001 - 105 3 Symptoms Recommended actions Recommended actions 11127, Backup error 11134, Backup error Description Description Error during the backup step Configuration. Error reading configuration parameters. Error during the backup step Configuration. Error restoring configuration parameters. Recommended actions Recommended actions 11128, Backup error 11135, Backup error Description Description Error during the backup step Configuration. Error writing configuration parameters. Error during the backup step Configuration. Mismatch between current system and the backup. Recommended actions Recommended actions 11129, Backup error 11136, Backup error Description Description Error during the backup step Configuration. The structure is too deep. Error during the backup step Configuration. Write error. Recommended actions Recommended actions 11130, Backup error 11137, Backup error Description Description Error during the backup step Configuration. No more objects. Error during the backup step Configuration. At least one modname is too long. Recommended actions Recommended actions 11131, Backup error 11138, Backup error Description Error during the backup step Configuration. The directory lacks at least one neccessary item. Description Recommended actions Recommended actions 11132, Backup error 11139, Backup error Description Description Error during the backup step Configuration. The system version doesn't match the backup. Error during the backup step Configuration. Storage media full. Error during the backup step Configuration. Unknown task. Recommended actions Recommended actions 11140, Backup error 11133, Backup error Description Description Error during the backup step Configuration. Item not possible to delete. Error during the backup step Configuration. Error restoring configuration parameters. 106 - 3HAC020738-001 3 Symptoms Recommended actions Recommended actions 11220, Backup error 11227, Backup error Description Description Error during the backup of Task. Unknown error. Error during the backup of Task. Error reading configuration parameters. Recommended actions Recommended actions 11221, Backup error 11228, Backup error Description Error during the backup of Task. General error. Description Recommended actions Error during the backup of Task. Error writing configuration parameters. Recommended actions 11222, Backup error Description 11229, Backup error Error during the backup of Task. The directory contains items that are to be created. Description Error during the backup of Task. The structure is too deep. Recommended actions Recommended actions 11223, Backup error 11230, Backup error Description Error during the backup of Task. The directory lacks at least one neccessary item. Description Recommended actions Recommended actions 11224, Backup error 11231, Backup error Description Description Error during the backup of Task. The directory does not exist. Error during the backup of Task. The directory lacks at least one neccessary item. Error during the backup of Task. No more objects. Recommended actions Recommended actions 11225, Backup error 11232, Backup error Description Error during the backup of Task. Directory cannot be created. Description Recommended actions Error during the backup of Task. The system version doesn't match the backup. Recommended actions 11226, Backup error Description 11233, Backup error Error during the backup of Task. Error whilst writing the backup. Description Error during the backup of Task. Error restoring configuration parameters. 3HAC020738-001 - 107 3 Symptoms Recommended actions Recommended actions 11234, Backup error 12020, Restore error Description Description Error during the backup of Task. Error restoring configuration parameters. Error during the restore step Prepare. Unknown error. Recommended actions arg 11235, Backup error 12021, Restore error Description Description Error during the backup of Task. Mismatch between current system and the backup. Error during the restore step Prepare. General error. Recommended actions Recommended actions Recommended actions arg 11236, Backup error 12022, Restore error Description Description Error during the backup of Task. Write error. Error during the restore step Prepare. The directory contains items that are to be created. Recommended actions Recommended actions Check: No space left on device. Corrupt device. arg 11237, Backup error 12023, Restore error Description Error during the backup of Task. At least one modname is too long. Description Recommended actions Error during the restore step Prepare. The directory lacks at least one neccessary item. Recommended actions 11238, Backup error arg Description Error during the backup of Task. Unknown task. 12024, Restore error Recommended actions Description Error during the restore step Prepare. The directory does not exist. 11239, Backup error Recommended actions Description arg Error during the backup of Task. Storage media full. 12025, Restore error Recommended actions Description 11240, Backup error Error during the restore step Prepare. Directory cannot be created. Description Recommended actions Error during the backup of Task. Item not possible to delete. arg 12026, Restore error Description Error during the restore step Prepare. Error whilst writing the backup. 108 - 3HAC020738-001 3 Symptoms Recommended actions 12033, Restore error arg Description Error during the restore step Prepare. Error restoring configuration parameters. 12027, Restore error Description Recommended actions Error during the restore step Prepare. Error reading configuration parameters. arg Recommended actions 12034, Restore error arg Description Error during the restore step Prepare. Error restoring configuration parameters. 12028, Restore error Description Recommended actions Error during the restore step Prepare. Error writing configuration parameters. arg Recommended actions 12035, Restore error arg Description Error during the restore step Prepare. Mismatch between current system and the backup. 12029, Restore error Description Recommended actions Error during the restore step Prepare. The structure is too deep. arg Recommended actions 12036, Restore error arg Description 12030, Restore error Error during the restore step Prepare. Write error. Description Recommended actions Error during the restore step Prepare. No more objects. arg Recommended actions 12037, Restore error arg Description 12031, Restore error Error during the restore step Prepare. At least one modname is too long. Description Error during the restore step Prepare. The directory lacks at least one neccessary item. Recommended actions arg Recommended actions 12038, Restore error arg Description 12032, Restore error Error during the restore step Prepare. Unknown task. Description Recommended actions Error during the restore step Prepare. The system version doesn't match the backup. arg Recommended actions 12039, Restore error arg Description Error during the restore step Prepare. Storage media full. 3HAC020738-001 - 109 3 Symptoms Recommended actions Recommended actions arg 12126, Restore error 12040, Restore error Description Description Error during the restore step Prepare. Item not possible to delete. Error during the restore step Configuration. Error whilst writing the backup. Recommended actions Recommended actions arg 12127, Restore error 12120, Restore error Description Description Error during the restore step Configuration. Unknown error. Error during the restore step Configuration. Error reading configuration parameters. Recommended actions Recommended actions 12121, Restore error 12128, Restore error Description Description Error during the restore step Configuration. General error. Error during the restore step Configuration. Error writing configuration parameters. Recommended actions Recommended actions 12122, Restore error 12129, Restore error Description Description Error during the restore step Configuration. The directory contains items that are to be created. Error during the restore step Configuration. The structure is too deep. Recommended actions Recommended actions 12123, Restore error 12130, Restore error Description Description Error during the restore step Configuration. The directory lacks at least one neccessary item. Error during the restore step Configuration. No more objects. Recommended actions Recommended actions 12131, Restore error 12124, Restore error Description Description Error during the restore step Configuration. The directory lacks at least one neccessary item. Error during the restore step Configuration. The directory does not exist. Recommended actions Recommended actions 12132, Restore error 12125, Restore error Description Description Error during the restore step Configuration. The system version doesn't match the backup. Error during the restore step Configuration. Directory cannot be created. 110 - 3HAC020738-001 3 Symptoms Recommended actions Recommended actions 12133, Restore error 12140, Restore error Description Description Error during the restore step Configuration. Error restoring configuration parameters. Error during the restore step Configuration. Item not possible to delete. Recommended actions Recommended actions 12220, Restore error 12134, Restore error Description Description Error during the restore of Task. Unknown error. Error during the restore step Configuration. Error restoring configuration parameters. Recommended actions Recommended actions 12221, Restore error Description 12135, Restore error Error during the restore of Task. General error. Description Recommended actions Error during the restore step Configuration. Mismatch between current system and the backup. 12222, Restore error Recommended actions Description 12136, Restore error Error during the restore of Task. The directory contains items that are to be created. Description Recommended actions Error during the restore step Configuration. Write error. Recommended actions 12223, Restore error 12137, Restore error Description Description Error during the restore of Task. The directory lacks at least one neccessary item. Error during the restore step Configuration. At least one modname is too long. Recommended actions Recommended actions 12224, Restore error Description 12138, Restore error Error during the restore of Task. The directory does not exist Description Recommended actions Error during the restore step Configuration. Unknown task. Recommended actions 12225, Restore error Description 12139, Restore error Error during the restore of Task. Directory cannot be created Description Error during the restore step Configuration. Storage media full 3HAC020738-001 - 111 3 Symptoms Recommended actions Recommended actions 12226, Restore error 12233, Restore error Description Description Error during the restore of Task. Error whilst writing the backup Error during the restore of Task. Error restoring configuration parameters. Recommended actions Recommended actions 12227, Restore error 12234, Restore error Description Description Error during the restore of Task. Error reading configuration parameters Error during the restore of Task. Error restoring configuration parameters. Recommended actions Recommended actions 12228, Restore error 12235, Restore error Description Description Error during the restore of Task. Error writing configuration parameters Error during the restore of Task. Mismatch between current system and the backup. Recommended actions Recommended actions 12229, Restore error 12236, Restore error Description Description Error during the restore of Task. The structure is too deep Error during the restore of Task. Write error. Recommended actions Recommended actions 12230, Restore error 12237, Restore error Description Description Error during the restore of Task. No more objects Error during the restore of Task. At least one modname is too long. Recommended actions Recommended actions 12231, Restore error 12238, Restore error Description Error during the restore of Task. The directory lacks at least one neccessary item. Description Recommended actions Recommended actions 12232, Restore error 12239, Restore error Description Description Error during the restore of Task. The system version doesn't match the backup. Error during the restore of Task. Storage media full. 112 Error during the restore of Task. Unknown task. - 3HAC020738-001 3 Symptoms Recommended actions Recommended actions 12240, Restore error 12326, Restore error Description Description Error during the restore of Task. Item not possible to delete. Error during the restore of User Task. Error whilst writing the backup Recommended actions Recommended actions 12320, Restore error 12327, Restore error Description Description Error during the restore of User Task. Unknown error. Error during the restore of User Task. Error reading configuration parameters Recommended actions Recommended actions 12321, Restore error 12328, Restore error Description Error during the restore of User Task. General error. Description Recommended actions Error during the restore of User Task. Error writing configuration parameters Recommended actions 12322, Restore error Description 12329, Restore error Error during the restore of User Task. The directory contains items that are to be created. Description Error during the restore of User Task. The structure is too deep Recommended actions Recommended actions 12323, Restore error 12330, Restore error Description Error during the restore of User Task. The directory lacks at least one neccessary item. Description Recommended actions Recommended actions 12324, Restore error 12331, Restore error Description Description Error during the restore of User Task. The directory does not exist Error during the restore of User Task. The directory lacks at least one neccessary item. Error during the restore of User Task. No more objects Recommended actions Recommended actions 12325, Restore error 12332, Restore error Description Description Error during the restore of User Task. Directory cannot be created Error during the restore of User Task. The system version doesn't match the backup. 3HAC020738-001 - 113 3 Symptoms Recommended actions Recommended actions 12333, Restore error 12340, Restore error Description Description Error during the restore of User Task. Error restoring configuration parameters. Error during the restore of User Task. Item not possible to delete. Recommended actions Recommended actions 20010, Emergency stop state 12334, Restore error Description Description The emergency stop circuit has previously been broken, and while broken, an attempt was made to operate the robot. Error during the restore of User Task. Error restoring configuration parameters. Consequences Recommended actions The system remains in state "Waiting for Motors ON after emergency stop". 12335, Restore error Probable causes Description An attempt has been made to maneuvre a control, before switching the system back to status Motors ON. Error during the restore of User Task. Mismatch between current system and the backup. Recommended actions 1) To resume operation, switch the system back to state Motors ON by pressing the Motors ON button on the Control Module. Recommended actions 12336, Restore error 20011, Emergency stop state. Description Description Error during the restore of User Task. Write error. Emergency stop reset is required. Recommended actions Recommended actions First release the Em stop button 12337, Restore error and then press the panel button. Description 20012, Sys failure state active Error during the restore of User Task. At least one modname is too long. Description Recommended actions Fatal non-recoverable system error. Warm start is required. 12338, Restore error Recommended actions Turn the mains switch off and on Description again if the soft restart command is Error during the restore of User Task. Unknown task. ignored or not possible to reach. Recommended actions 20025, Stop order timeout 12339, Restore error Description Description The stop order was carried out Error during the restore of User Task. Storage media full. as a forced guard stop when no acknowledgement was received within the expected time 114 - 3HAC020738-001 3 Symptoms Recommended actions Recommended actions 1) Update the Serial Measurement Board data as detailed in Operator's Manual, IRC5. 20030, Axis not commutated Description 20051, Not allowed command One or several internal drive unit axes are not commutated. Description Recommended actions The command is only allowed when the client is in control of the resource (program/motion). Consequences 20031, Axis not calibrated. The system remains in the same status, and the requested action will not be performed. Description One or several absolute/relative Recommended actions measurement axes are not calibrated. 1) Check if the client is in control, by checking "Write Access" in RobotStudioOnline. Recommended actions 2) Check if the client who ought to be in control really is. Check what axis that are not calibrated and calibrate them. 20054, Not allowed command 20032, Rev. counter not updated Description The command is only allowed when the program is NOT executing. Description Revolution counter is not updated. Consequences One or several absolute measurement axes are not synchronized. The system remains in the same status, and the requested action will not be performed. Recommended actions Recommended actions Move the robot to the sync position 1) Make sure the program is not executing. and update the revolution counters. 20060, Not allowed command 20033, Axis not synchronized. Description Description The command is not allowed in Auto mode. One or several relative measurement Consequences axes are not synchronized. The system remains in the same status, and the requested action will not be performed. Recommended actions Order Motors On and synchronize all Recommended actions mechanical units in the list. 1) Make sure the system is NOT in Auto Mode. 20034, SMB memory is not OK 20061, Not allowed command Description Description This action is not allowed since data in the Serial Measurement Board (SMB) memory is not OK. The command is not allowed when changing to Auto mode. Consequences Consequences The system remains in the same status, and the requested action will not be performed. All data must be OK before automatic operation is possible. Manually jogging the robot is possible. Recommended actions Probable causes 1) Make sure the system is NOT changing to Auto Mode. There are differences between the data stored on the SMB and the data stored in the controller. This may be due to replacement of SMB, controller or both. 3HAC020738-001 - 115 3 Symptoms Recommended actions 20062, Not allowed command 1) Investigate by whom and why the action was requested, and, if required, correct the reason. Description The command is not allowed in Manual mode. Consequences 20072, Not allowed command The system remains in the same status, and the requested action will not be performed. Description The command is not allowed in Motors OFF state. Recommended actions Consequences 1) Make sure the system is NOT is Manual Mode. The system remains in the same status, and the requested action will not be performed. 20063, Not allowed command Recommended actions Description 1) Make sure the system is in Motors ON state. The command is not allowed in Manual full speed mode. Consequences 20073, Not allowed command The system remains in the same status, and the requested action will not be performed. Description The command is not allowed while changing to Motors OFF state. Recommended actions Consequences 1) Make sure the system is NOT in Manual full speed Mode. The system remains in the same status, and the requested action will not be performed. 20064, Not allowed command Recommended actions Description 1) Investigate by whom and why the action was requested, and, if required, correct the reason. The command is not allowed when changing to Manual full speed mode. Consequences 20074, Not allowed command The system remains in the same status, and the requested action will not be performed. Description The command is not allowed in Guard Stop state. Recommended actions Consequences 1) Make sure the system is NOT changing to Manual full speed Mode. The system remains in the same status, and the requested action will not be performed. 20070, Not allowed command Recommended actions Description 1) Make sure the system is NOT is Guard Stop state. The command is not allowed in Motors ON state. Consequences 20075, Not allowed command The system remains in the same status, and the requested action will not be performed. Description The command is not allowed in Emergency Stop state. Recommended actions Consequences 1) Make sure the system is in Motors OFF state. Emergency stop reset is required. Recommended actions 20071, Not allowed command 1) Make sure the system is NOT in Emergency Stop state. Description The command is not allowed while changing to Motors ON state. 20076, Not allowed command Consequences Description The system remains in the same status, and the requested action will not be performed. 116 The command is not allowed in System Failure state. - 3HAC020738-001 3 Symptoms Consequences Consequences A non-recoverable system error has resulted, and a warm start is required. The system remains in the same status, and the requested action will not be performed. Recommended actions Recommended actions 1) Make sure the system is NOT in Emergency Stop state. 1) Synchronize the axis as detailed in the Calibration Pendulum Instruction or the Instructions for Levelmeter calibration, depending on which equipment to be used. 2) Perform a restart as detailed in the Operator's Manual, IRC5. 3) If restarting is not possible, switch the main power OFF and then back ON. 20084, Not allowed command 20080, Not allowed command Description This command is not allowed since data in the Serial Measurement Board (SMB) memory is not OK. Description The command is not allowed when axis has not been commutated. Consequences Consequences The system remains in the same status, and the requested action will not be performed. All data must be OK before automatic operation is possible. Manually jogging the robot is possible. Recommended actions Recommended actions 1) Commutate the axis as detailed in the Additional Axes Manual. 1) Update the Serial Measurement Board data as detailed in Operator's Manual, IRC5. 2) Investigate by whom and why the action was requested, and, if required, correct the reason. 20081, Not allowed command 20089, The call chain does not originate from main when switching to auto. Description Description The command is not allowed when axis is not calibrated. The call chain has been altered to begin at a routine other than main. Consequences Consequences The system remains in the same status, and the requested action will not be performed. When coming to the end of the cycle, the next cycle will not start at main, but at the beginng of the routine set as "temporary main". Recommended actions Probable causes 1) Calibrate the axis as detailed in the Calibration Pendulum Instruction or the Instructions for Levelmeter calibration, depending on which equipment to be used. Someone has used "Move PP to routine" to debug the program. Recommended actions Move PP to main if not the intension is to have the call chain to start at routine set as "temporary main". 20082, Not allowed command If the program allways shall start at the new routine, change System Parameter "Main entry" (Domain Controller, Type Task) to the new routine name. Description The command is not allowed when axis revolution counter is not updated. 20092, Not allowed command Consequences Description The system remains in the same status, and the requested action will not be performed. Not allowed in state System IO Start Blocked. Recommended actions Recommended actions 1) Update the revolution counter as detailed in Operator's Manual, IRC5. 20083, Not allowed command 20093, At least one task is unchecked in the task selection panel Description Description The command is not allowed when axis is not synchronized. One or more of the NORMAL tasks are unchecked in the task selection panel when requesting automatic operating mode. 3HAC020738-001 - 117 3 Symptoms Recommended actions 20098, Not allowed to jog with LOCAL PERS Tool 20094, Load name could not be found Description Description The object arg is of type LOCAL PERS and is not posible to jog. Load name arg could not be found. Recommended actions Consequences Change Tool. It is not possible to jog without a correct defined load. The module with the load definition is probably deleted. 20099, Not allowed to jog with LOCAL PERS Work Object Recommended actions Description Load module with load definition. The object arg is of type LOCAL PERS and is not posible to jog. Probable causes Choose other load. Recommended actions Change Work Object. 20095, Tool name could not be found 20101, TP (program) in control. Description Tool name arg could not be found. Description Consequences The teachpendant programming It is not possible to jog without a correct defined tool. window has focus and is in control of the program server. Probable causes Recommended actions The module with the tool definition is probably deleted. Change to the production window Recommended actions and perform the command again. Load module with tool definition. Choose other tool. 20111, TP (program) in control 20096, WorkObject name could not be found Description The teachpendant programming Description window has focus and is in control WorkObject name arg could not be found. of the program server. Consequences Recommended actions It is not possible to jog without a correct defined workobject. Change to the production window Probable causes and perform the command again. The module with the workobject definition is probably deleted. Recommended actions Load module with workobject definition. Choose other workobject. 20097, Not allowed to jog with LOCAL PERS Load Description The object arg is of type LOCAL PERS and is not posible to jog. Recommended actions Change Load. 118 - 3HAC020738-001 3 Symptoms Recommended actions 20120, System IO in control Re-edit the configuration file, and change the version of the cfg domain. Description Recommended actions 20135, Line too long 20130, Out of memory in cfg Description Line arg contains arg characters, which is more than the allowed arg. Description Consequences Recommended actions The configuration in file will not be installed. Probable causes 20131, Unable to read file - Description Recommended actions Re-edit the configuration file and reduce the number of characters, e.g. by splitting the instance into several lines. End each line, except the last one, with a trailing backslash "\" to achieve this. Recommended actions 20132, Parameters not saved 20136, Attribute value out of the allowed range Description Parameters cannot be saved. Description Probably, because disk is write Attribute arg on line arg in file arg is out of the allowed range. The allowed range is < arg> - < arg>. protected or no space available. Recommended actions Consequences Check if disk is write-protected or The configuration in file will not be installed. if space on disk is enough. Probable causes - 20133, Instance can not be saved Recommended actions Description Re-edit the configuration file and change the value on the attribute to fit inside the allowed range. Not allowed to overwrite instance in line arg of file arg. Consequences 20137, Instance name occupied The instance may be write protected and the configuration in file will not be installed. Description Probable causes Instance in line arg in file arg is already occupied. Consequences Recommended actions The configuration in file will not be installed. You are not allowed to change the instance. Probable causes - 20134, Wrong domain version or incorrect file Recommended actions Description 1) Re-edit the configuration file and change the instance name to add it to the file OR The cfg domain version of file arg is wrong. The software is made for version arg. 2) Use the "Replace" mode to overwrite the instance previously using the name. This may be selected when loading the configuration file using RobotStudioOnline, and the procedure is detailed in the RobotStudioOnline Manual. Consequences The configuration in file will not be installed. Probable causes - 3HAC020738-001 - 119 3 Symptoms Recommended actions 20138, Unknown type or attribute in cfg file Description 20143, Start main rejected. Type/attribute in position arg on line arg of file arg is not recognized. Description Consequences Start of main program via System IO The configuration in file will not be installed. not allowed. Probable causes Recommended actions The configuration type may not be installed, illegal/mistyped attribute, or the name is too long. 20144, Stop rejected. Recommended actions Description 1) Re-edit the configuration file. Stop of program via System IO 20139, Mandatory attribute is missing in cfg file not allowed. Description Recommended actions Missing mandatory attribute arg on line arg in file arg. 20145, Stop cycle rejected. Consequences The configuration in file will not be installed. Description Probable causes Stop of program cycle via System IO not allowed. Missing/mistyped mandatory attribute. Recommended actions Recommended actions 1) Re-edit the configuration file. 20146, Man. interrupt rejected. 20140, Motors On rejected. Description Description Manual interrupt of program via Motors On via System IO System IO not allowed. not allowed. Recommended actions Recommended actions 20147, Load and start rejected. 20141, Motors Off rejected. Description Description Load and start of program via Motors Off via System IO System IO not allowed. not allowed. Recommended actions Recommended actions Program file name (including mass memory unit) to be loaded must be defined. 20142, Start rejected. Description 20148, Confirm rejected. Start/restart of program via System Description IO not allowed. Emergency Stop reset confirm via The reason could be that the robot System IO not allowed. is outside of regain distance. 120 - 3HAC020738-001 3 Symptoms Recommended actions Recommended actions 20149, Error reset rejected. 20159, No System Output signal Description Description Program execution error reset via A System Output has been configured to System IO not allowed. an I/O-signal that doesn't exist. System Output: arg Recommended actions Signal Name: arg 20153, Mot. On, Start rejected. 20161, Path not find Description Description Motors On, Start/restart of program The system module arg in task via System IO not allowed. arg has a corresponding The reason could be that the robot specification in the configuration is outside of regain distance. for "Task modules" that point out Recommended actions a non existing file path Recommended actions 20154, Stop instruction rejected View "Task modules" in the "System Parameter" menu and change the path Description in the item for this system module Stop of program instruction via System IO not allowed. 20162, Write error Recommended actions Description A write error occur when the system try 20156, Undefined Argument to save the system module arg Description at arg Interrupt routine name in task arg. Or the file is not defined system was full Recommended actions Recommended actions Declarate the interrupt routine name View "Task modules" in the "System or use already declared interrupt Parameter" menu and change the path routine name. in the item for this system module 20157, Undefined Argument 20164, Reconfig failed Description Description LoadStart program name There are still some unsaved system is not defined module Recommended actions Recommended actions Read error descriptions in earlier messages. 20158, No System Input signal Try another system start Description A System Input has been configured to 20165, Program Pointer lost. an I/O-signal that doesn't exist. System Input: arg Description Signal Name: arg Restart is no longer possible from current position. 3HAC020738-001 - 121 3 Symptoms Recommended actions 2) Fix the cause of the fault. The program has to be 3) Restart the program. started from the beginning. 20172, The system has failed 20166, Refuse to save module Description Description An error was detected, which caused the system to fail. The module arg Consequences is older than the source in task arg. The system goes to status SYS FAIL. The program and robot motion is stopped and the motors are switched OFF. The full meaning of this status is described in the Trouble Shooting Manual, IRC5. Recommended actions Probable causes at arg A number of errors may cause this status transition. 20167, Unsaved module Recommended actions Description 1) Check other event log messages occuring at the same time to determine the actual cause. The module arg 2) Fix the cause of the fault. is changed but not saved 3) Perform a system restart as detailed in the Operator's Manual, IRC5. in task arg. Recommended actions 20178, Wrong task name configured Description 20170, The system was stopped Wrong task name arg configured for System Input arg. Description Consequences An error was detected, which stopped the system. The digital input signal with not be connected to the specified event. Consequences Recommended actions The system goes to status SYS STOP and the robot is stopped along the path. The full meaning of this status is described in the Trouble Shooting Manual, IRC5. Change the configuration and restart the system. 20179, Disk memory critically low Probable causes Description A number of errors may cause this status transition. The amount of free storage capacity on the disk has reached a critical level. It is now less than 10 Mb. Execution of RAPID programs is stopped. Recommended actions 1) Check other event log messages occuring at the same time to determine the actual cause. Consequences 2) Fix the cause of the fault. The disk memory is very close to be completely full. When this happens the system will not be able to function. 20171, The system was halted Probable causes Description Too much data on the disk An error was detected, which halted the system. Recommended actions Consequences 1) Save the files on some other disk connected to the network. The system goes to status SYS HALT, the program and robot motion is stopped and the motors are switched OFF. The full meaning of this status is described in the Trouble Shooting Manual, IRC5. 2) Erase data from disk. 3) After removing files from the drive, restart the program. Probable causes 20181, System Reset rejected. A number of errors may cause this status transition. Description Recommended actions System Reset via System IO 1) Check other event log messages occuring at the same time to determine the actual cause. 122 not allowed. - 3HAC020738-001 3 Symptoms Recommended actions 20189, Robot data not valid Description 20184, Incorrect argument for System Inputs Could not load the system independent Description robot data from file arg. An undefined Start Mode has been The file exists but the content is not declared for System IO. valid. Internal code: arg Recommended actions Recommended actions Check other logged messages for needed actions. 20185, Incorrect Name Make sure there is free memory Description left on the device. An undefined Name has been declared in current runchn_bool configuration. 20192, Disk memory low Recommended actions Description 20187, Diagnostics record file created The amount of free storage capacity on the disk is less than 25 MB. When reaching 10 MB, execution of RAPID programs will be stopped. Description Consequences Due to any of a number of faults, a system diagnostics file was created at arg. This file contains internal debug info and is intended for trouble shooting and debugging purposes. The disk memory is close to being completely full. When this happens the system will not be able to function. Consequences Too much data on the disk The system will react to the error causing the stop as specified in its own event log text. Recommended actions Probable causes 1) Save the files on some other disk connected to the network. Probable causes 2) Erase data from disk. A number of errors may cause this. Faults causing the system to go to status SYS FAIL will generally also create a diagnostics record file. 20193, Robot data update warning Recommended actions Description If required, the file may be appended to an error report sent to your local ABB representative. Axis sync values and service information data (SIS) was restored from backup. The system independent robot data was 20188, System data is not valid not saved during system shutdown. The Description data was restored from latest backup. The contents of the file, arg, containing system persistent data is invalid. Internal error code: arg. The system has been started using last good system data saved earlier at arg. Recommended actions Make sure there is free memory left on the device. Consequences The backup battery may be drained. Check Any changes made in the system configuration or RAPID programs since arg will NOT be available after restart. Any such changes will have to be re-implemented. the hardware log. 20194, System data not backuped Recommended actions 1) Check other event log messages occuring at the same time to determine the actual cause. Description 2) If acceptable, perform a B-restart to accept starting with the loaded last good system data. but a backup of the current system data The system was restored successfully could not be created. 3) Reinstall the system. Recommended actions 4) Check the available disk storage capacity. If required, erase data to increase free storage capacity. 3HAC020738-001 Make sure there is free memory left on - 123 3 Symptoms the device arg. 2) If acceptable, perform a B-restart to accept starting with the loaded last good system data. 20195, System data was lost during the last shutdown of this system 3) Reinstall the system. 20198, System data from last shutdown is lost Description Description Normally, all system data is saved on shutdown. During the last shutdown saving data has failed. The system has been started using last good system data saved earlier at arg. Normally, all system data is saved on shutdown. This time, the saved data was corrupt and the system has been started using system data saved earlier at arg. Consequences Consequences argAny changes made in system configuration or RAPID programs since arg will NOT be available after restart. Any such changes will have to be re-implemented. Any changes made in system configuration or RAPID programs since arg will NOT be available after restart. Any such changes will have to be re-implemented. Probable causes Recommended actions The backup energy bank may have been been drained at the time of the shut down. The storage disk may be full. 1) Check the hardware log for faults occurring in conjunction. Recommended actions 2) If acceptable, perform a B-restart to accept starting with the loaded system data. 1) Check other event log messages occuring at the same time to determine the actual cause. 3) Reinstall the system. 2) If acceptable, perform a B-restart to accept starting with the loaded system data. 20199, System SoftStop Rejected 3) Reinstall the system. Description 4) Check the available disk storage capacity. If required, erase data to increase free storage capacity. The System Input SoftStop is not allowed Recommended actions 20196, Module saved 20201, Limit Switch open Description During reconfiguration of the system a changed and not saved module was found. Description The limit switch on the robot has opened. The module was saved to Consequences arg. The system goes to the Motors OFF status. Recommended actions Probable causes The robot has been run outside the working range defined by the limit switches fitted to the robot. 20197, System data from the previous run can not be found Recommended actions Description 1) Press the "Override Limit" button on the Drive Module and manually jog the robot back into it's normal working range. Normally, all system data is saved on shutdown. The file containing system persistent data can not be found. The system has been started using last good system data saved earlier at arg. 2) Resume operation. 20202, Emergency Stop open Consequences argAny changes made in system configuration or RAPID programs since arg will NOT be available after restart. Any such changes will have to be re-implemented. Description The emergency stop circuit has previously been broken, and while broken, an attempt was made to operate the robot. Probable causes Consequences The file containing the saved system data may have been manually moved or deleted. The system remains in the Emergency Stop status. Recommended actions Probable causes 1) Check the location and availability of the saved system data file. An attempt has been made to maneuvre a control, e.g. the enabling device. 124 - 3HAC020738-001 3 Symptoms Recommended actions Probable causes 1) To resume operation, first reset the emergency stop button triggering the stop. One or more of the switch connected in series with the General Mode Safeguarded Stop circuit have been opened, which may be causes by a large number of faults. This is possible in any operational mode. The General Mode Safeguarded Stop circuit is described in the Trouble Shooting Manual. 2) Then switch the system back to state Motors ON by pressing the Motors ON button on the Control Module. 20203, Enabling Device open Recommended actions 1) Locate the switch, reset it and restart the system. Description 2) Check cables and connections. Only one of the two Enabling Device chains was opened. Consequences 20208, Chain switches open The system goes to status SYS HALT. Description Probable causes A safety chain, other than Auto Stop and General Stop, has been broken. The FlexPendant Enabling Device may be faulty or incorrectly connected. The FlexPendant and its Enabling Device is described in the Trouble Shooting Manual, IRC5. Consequences The system goes to the Guard Stop status. Recommended actions 1) Check the FlexPendant cable and its connection. Probable causes 2) If required, replace the faulty FlexPendant or its cable. 20204, Operation Key open One or more of the switch connected in series with the RUN Chain Top circuit have been opened, which may be causes by a large number of faults. The RUN Chain Top is described in the Trouble Shooting Manual and Circuit Diagram. Description Recommended actions 1) Locate the switch, reset it and restart the system. Recommended actions 2) Check cables and connections. 20205, Auto Stop open 20209, External Contactor open Description Description The Automatic Mode Safeguarded Stop circuit has been broken. An external contactor has been opened. Consequences Consequences The system goes to the Auto Stop status. The system goes from the Motors OFF status to SYS HALT when attempting to start. Probable causes One or more of the switch connected in series with the Automatic Mode Safeguarded Stop circuit have been opened, which may be causes by a large number of faults. This is only possible while in the Auto operational mode. The Automatic Mode Safeguarded Stop circuit is described in the Trouble Shooting Manual. Probable causes The RUN chain of external equipment has been broken, which may be caused by the external contactor auxiliary contacts or, if used, any PLC, controlling it. The external contactor supplies power to a piece of external equipment, equivalently to how the RUN contactor supplies a robot. This fault may occur when attempting to go to the Motors ON mode only. The RUN chain is described in the Trouble Shooting Manual and Circuit Diagram. Recommended actions 1) Locate the switch, reset it and restart the system. 2) Check cables and connections. Recommended actions 1) Locate the switch, reset it and restart the system. 20206, General Stop open 2) Check cables and connections. Description 3) Check the external contactor auxiliary contacts. The General Mode Safeguarded Stop circuit has been broken. 4) If used, check any PLC equipment controlling the external contactor. Consequences The system goes to the General Stop status. 3HAC020738-001 - 125 3 Symptoms 20211, Two channel fault, ENABLE chain 2) Check other event log messages occuring at the same time to determine the cause of the fault. Description 3) To assist in returning the chains to a defined status, first pressing, then resetting the Emergency Stop may work. A switch in only one of the two ENABLE chains was briefly affected, opening the chain and then reclosing it, without the other chain being affected. 20215, Superior Stop open Consequences Description The system goes to status SYS HALT. The Superior Mode Safeguarded Stop circuit has been opened. Probable causes Consequences There may be a loose signal connection on either the axis computer or the panel board. The ENABLE chain is described in the Trouble Shooting Manual and Circuit Diagram. The system goes to the Superior Stop status. Probable causes One or more of the switch connected in series with the Superior Mode Safeguarded Stop circuit have been opened, which may be causes by a large number of faults. This is possible in any operational mode. The Superior Mode Safeguarded Stop circuit is described in the Trouble Shooting Manual. Recommended actions 1) Check cables and connections. 2) Make sure all signal connectors on the axis computer board and panel board are securely connected. 3) If there is no loose connection, replace the faulty board. Recommended actions 1) Locate the switch, reset it and restart the system. 20212, Two channel fault, RUN CHAIN 20216, Enabling device active in Auto mode Description Only one of the two RUN chains was closed. Description Consequences The system goes to status SYS HALT. The system has detected that the Enabling device has been pressed for more than 3 seconds in Automatic operating mode. Probable causes Consequences Any of the switches connected to the RUN chain may be faulty or not correctly connected, causing only one channel to close. The RUN chain is described in the Trouble Shooting Manual, IRC5. The system goes to status Guard Stop. Recommended actions 1. Release the Enabling device Recommended actions 2. Switch to Manual mode 1) Check cables and connections. 2) Check other event log messages occuring at the same time to determine which switch caused the fault. 20220, Superior stop conflict 3) Make sure all switches are working correctly. Description 4) To assist in returning the chains to a defined status, first pressing, then resetting the Emergency Stop Only one of the two Superior Mode Safeguarded Stop chains was opened. 5) If there is no loose connection, replace the faulty switch. Consequences The system goes to status SYS HALT. 20213, Two channel fault Probable causes Description Any of the switches connected to the Superior Stop chain may be faulty or not correctly connected, causing only one channel to close. The Superior Stop chain is described in the Trouble Shooting Manual, IRC5. A brief status change in any of the RUN or ENABLE chains has been detected. Consequences The system goes to status SYS HALT. Recommended actions 1) Check cables and connections. Probable causes 2) Check other event log messages occuring at the same time to determine which switch caused the fault. This may be caused by a number of faults. The ENABLE and RUN chains are described in the Trouble Shooting Manual, IRC5. 3) Make sure all switches are working correctly. Recommended actions 4) If there is no loose connection, replace the faulty switch. 1) Check cables and connections. 126 - 3HAC020738-001 3 Symptoms 20221, Run chain conflict Probable causes Description Status conflict The FlexPendant Enabling Device may be faulty or incorrectly connected. The FlexPendant and its Enabling Device is described in the Trouble Shooting Manual, IRC5. for Run chain. Recommended actions Recommended actions 1) Check the FlexPendant cable and its connection. Please check the Run chain cables. 2) If required, replace the faulty FlexPendant or its cable. 20222, Limit switch conflict 20225, Auto Stop conflict Description Description Only one of the two Limit switch chains was opened. Only one of the two Automatic Mode Safeguarded Stop chains was opened. Consequences Consequences The system goes to status SYS HALT. The system goes to status SYS HALT. Probable causes Probable causes Any of the switches connected to the Limit switch chain may be faulty or not correctly connected, causing only one channel to close. The Limit switch chain is described in the Trouble Shooting Manual, IRC5. Any of the switches connected to the Auto Stop chain may be faulty or not correctly connected, causing only one channel to close. The Auto Stop chain is described in the Trouble Shooting Manual, IRC5. Recommended actions Recommended actions 1) Check cables and connections. 1) Check cables and connections. 2) Check other event log messages occuring at the same time to determine which switch caused the fault. 2) Check other event log messages occuring at the same time to determine which switch caused the fault. 3) Make sure all switches are working correctly. 3) Make sure all switches are working correctly. 4) If there is no loose connection, replace the faulty switch. 4) If there is no loose connection, replace the faulty switch. 20223, Emergency Stop conflict 20226, General Stop conflict Description Description Only one of the two Emergency Stop chains was opened. Only one of the two General Mode Safeguarded Stop chains was opened. Consequences The system goes to status SYS HALT. Consequences Probable causes The system goes to status SYS HALT. Any of the switches connected to the Emergency Stop chain may be faulty or not correctly connected, causing only one channel to close. The Emergency Stop chain is described in the Trouble Shooting Manual, IRC5. Probable causes Any of the switches connected to the General Stop chain may be faulty or not correctly connected, causing only one channel to close. The General Stop chain is described in the Trouble Shooting Manual, IRC5. Recommended actions 1) Check cables and connections. Recommended actions 2) Check other event log messages occuring at the same time to determine which switch caused the fault. 1) Check cables and connections. 2) Check other event log messages occuring at the same time to determine which switch caused the fault. 3) Make sure all switches are working correctly. 4) If there is no loose connection, replace the faulty switch. 3) Make sure all switches are working correctly. 4) If there is no loose connection, replace the faulty switch. 20224, Enabling Device conflict 20227, Motor Contactor conflict, DRV1 Description Only one of the two Enabling Device chains was opened. Description Consequences Only one of the two Motor Contactors for drive system 1 has acknowledged the activation order. The system goes to status SYS HALT. 3HAC020738-001 - 127 3 Symptoms Consequences 20233, Delayed General Stop due to circuit imbalance The system goes to status SYS HALT. Probable causes Description A failure of the motor contactor auxiliary contacts or the supply to these. The system has detected an imbalance in the two parallel General Stop circuits. Recommended actions Consequences 1) Check cables and connections. The system goes to status Guard Stop after approximately 1 sec. 2) Check the function of the auxiliary contacts. Probable causes The contact pair in any of the safety devices connected to the General Stop circuit are not working correctly. 20231, Delayed Emergency Stop due to circuit imbalance Recommended actions Description 1. Isolate the safety device causing the conflict. The system has detected an imbalance in the two parallel Emergency Stop circuits. 2. Make sure the device used is a two-channel device. Consequences 4. Make sure all connections are tight. The system goes to status Emergency Stop after approximately 1 sec. 5. Replace the device if required. 3. Check the contact pair. Probable causes The contact pair in any of the Emergency Stop buttons are not working correctly. 20234, Immediate Emergency Stop due to circuit imbalance Recommended actions Description 1. Isolate the Emergency Stop button causing the conflict. The system has detected an imbalance in the two parallel Emergency Stop circuits. 2. Check the contact pair. 3. Make sure all connections are tight. Consequences 4. Replace the button if required. The system goes directly to status Emergency Stop. Probable causes 20232, Delayed Auto Stop due to circuit imbalance The contact pair in any of the Emergency Stop buttons are not working correctly. Description Recommended actions The system has detected an imbalance in the two parallel Auto Stop circuits. 1. Isolate the Emergency Stop button causing the conflict. Consequences 3. Make sure all connections are tight. The system goes to status Guard Stop after approximately 1 sec. 4. Replace the button if required. 2.Check the contact pair. Probable causes The contact pair in any of the safety devices connected to the Auto Stop circuit are not working correctly. 20235, Immediate Auto Stop due to circuit imbalance Recommended actions Description 1. Isolate the safety device causing the conflict. The system has detected an imbalance in the two parallel Auto Stop circuits. 2. Make sure the device used is a two-channel device. 3. Check the contact pair. Consequences 4. Make sure all connections are tight. The system goes directly to status Guard Stop. 5. Replace the device if required. Probable causes The contact pair in any of the safety devices connected to the Auto Stop circuit are not working correctly. Recommended actions 1. Isolate the safety device causing the conflict. 128 - 3HAC020738-001 3 Symptoms 2. Make sure the device used is a two-channel device. Probable causes 3. Check the contact pair. The contact pair in any of the safety devices connected to the Superior Stop circuit are not working correctly. 4. Make sure all connections are tight. 5. Replace the device if required. Recommended actions 1. Isolate the safety device causing the conflict. 20236, Immediate General Stop due to circuit imbalance 2. Make sure the device used is a two-channel device. 3. Check the contact pair. 4. Make sure all connections are tight. Description 5. Replace the device if required. The system has detected an imbalance in the two parallel General Stop circuits. 20240, Conflict between ENABLE signals Consequences The system goes directly to status Guard Stop. Description Probable causes A switch in only one of the two ENABLE chains was affected, without the other chain being affected. The contact pair in any of the safety devices connected to the General Stop circuit are not working correctly. Consequences The system goes to status SYS HALT. Recommended actions 1. Isolate the safety device causing the conflict. Probable causes 2. Make sure the device used is a two-channel device. 4. Make sure all connections are tight. There may be a loose signal connection on either the contactor board or the panel board. The ENABLE chain is described in the Trouble Shooting Manual and Circuit Diagram. 5. Replace the device if required. Recommended actions 3. Check the contact pair. 1) Check cables and connections. 20237, Immediate Superior Stop due to circuit imbalance 2) Make sure all signal connectors on the contactor board and panel board are securely connected. 3) If there is no loose connection, replace the faulty board. Description The system has detected an imbalance in the two parallel Superior Stop circuits. 20241, Operating mode conflict Description Consequences There is a conflict between the operating mode selected on the operating mode selector on the controller cabinet front and the actual operating mode as detected by the axis computer. The system goes directly to status Guard Stop. Probable causes The contact pair in any of the safety devices connected to the Superior Stop circuit are not working correctly. Consequences The system goes to status SYS HALT. Recommended actions Probable causes 1. Isolate the safety device causing the conflict. There may be a hardware fault in the operating mode selector, its cabling or panel board. There may also be a software fault. 2. Make sure the device used is a two-channel device. 3. Check the contact pair. 4. Make sure all connections are tight. Recommended actions 5. Replace the device if required. 1. Press Motors ON or the enabling device to restart. 2. Check the operating mode selector function. 3. Check its cabling and panel board. 20238, Delayed Superior Stop due to circuit imbalance 4. Make sure all connections are tight. 5. Replace the faulty unit. Description The system has detected an imbalance in the two parallel Superior Stop circuits. 20248, Motor Contactor conflict, DRV2 Description Consequences Only one of the two Motor Contactors for drive system 2 has acknowledged the activation order. The system goes to status Guard Stop after approximately 1 sec. 3HAC020738-001 - 129 3 Symptoms Consequences 20270, Access error The system goes to status SYS HALT. Description Probable causes Panel Module access error. A failure of the motor contactor auxiliary contacts or the supply to these. Recommended actions Examine your I/O configuration files. Recommended actions 1) Check cables and connections. 20280, Symbol conflict 2) Check the function of the auxiliary contacts. Description 20249, Motor Contactor conflict, DRV3 The signal arg defined in the IO configuration conflict with another Description program symbol with the same name. Only one of the two Motor Contactors for drive system 3 has acknowledged the activation order. Due on that fact the signal will not be mapped to a program variable. Consequences Recommended actions The system goes to status SYS HALT. Rename the signal in Probable causes the IO configuration. A failure of the motor contactor auxiliary contacts or the supply to these. 20281, IO configuration error Recommended actions Description 1) Check cables and connections. argarg with signal 2) Check the function of the auxiliary contacts. name arg has wrong signal type. Found arg expected arg. 20250, Motor Contactor conflict, DRV4 Recommended actions Description Change your configuration Only one of the two Motor Contactors for drive system 4 has acknowledged the activation order. and restart the system. Consequences 20282, Resource and index exist The system goes to status SYS HALT. Description Probable causes Resource arg A failure of the motor contactor auxiliary contacts or the supply to these. Index arg. Recommended actions Recommended actions 1) Check cables and connections. 20283, Text database is full. 2) Check the function of the auxiliary contacts. Description 20261, Strings to long Resource arg Index arg Description Recommended actions Description\Reason: - Elog message number arg: Total String length arg > 20284, Wrong Signal Type For System Input arg characters Description Recommended actions The System Input arg is configured with an I/O-signal of Check list: wrong type. 1. Reduce the total string length. The I/O-signal arg is of type arg and this System Input requires an I/O-signal of type arg. 130 - 3HAC020738-001 3 Symptoms Recommended actions Change the configuration for the specified System Input. 20290, Unknown Mechanical Unit Name For System Output 20285, Wrong Signal Type For System Output Description Description A System Output is configured with a mechanical unit name which is unknown by the system. The System Output arg is configured with an I/O-signal of System Output: arg wrong type. Mechanical unit name: arg The I/O-signal arg is of type arg and this System Output Recommended actions requires an I/O-signal of type arg. Recommended actions The specified mechanical unit must be configured in order to be used by System Outputs Change the configuration for the specified System Output. Verify that the mechanical unit name is correctly spelled. 20286, Not Unique I/O-Signal For System Output 20291, Unknown System Input Restriction Type Description The configured System Input Restriction Type is unknown by the system. Description Each System Output must have an unique I/O-signal configured. Unknown System Input Restriction: arg It is not possible to configure same I/O-signal to several System Outputs. Recommended actions System Output: arg Verify that the System Input Restriction name is correctly spelled. Signal Name: arg 20292, Unknown System Input Restriction Recommended actions Description 20287, Not Unique I/O-signal For System Input The configured System Input Restriction is unknown by the system. Description System Input Restriction Type: arg Each System Input must have an unique I/O-signal configured. Unknown System Input Restriction: arg It is not possible to configure same I/O-signal to several System Inputs. Recommended actions System Input: arg Verify that the System Input Restriction name is correctly spelled. Signal Name: arg 20293, System Input is Restricted Recommended actions Description 20288, Unknown System Output Type The system input arg is restricted by the system input arg set by I/O signal arg. Description The configured System Output type is unknown by the system. Consequences Unknown System Output: arg The action called for by system input arg will not take place, and the operation will NOT be affected. Recommended actions Probable causes Verify that the System Output name is correctly spelled. System input arg may be set by external equipment, such as PLCs, etc, for a number of reasons. 20289, Unknown System Input Type Recommended actions Description 1) Investigate why the system input was set, and, if required, correct the reason. The configured System Input type is unknown by the system. Unknown System Input: arg Recommended actions Verify that the System Input name is correctly spelled. 3HAC020738-001 - 131 3 Symptoms Recommended actions 20294, The requested action arg can not be fulfilled since the IO unit is disabled. 1) Check the fan cable is correctly inserted. 2) Check that the fan is rotating and that the air flow is not obstructed. Description 3) Check the output voltage from the main fan power supply unit. The requested action can not be fulfilled since the IO unit is not responding. 4) Check the input voltage to the main fan power supply unit. Replace any faulty unit. Consequences It is not possible to decide if there are any restrictions set to the action. 20309, Motor Fan 3 Malfunction Probable causes Description The requested action will not be fulfilled until the I/O unit is enabled again. The Motor fan unit 3 in drive module arg has malfunctioned. Consequences Recommended actions - Never disable a unit with System Inputs/Outputs. Probable causes The fan or the main fan power supply unit may be faulty or a fan power cable may be badly connected. 20295, Signal is set to category safety and can not be used as System Output Recommended actions Description 1) Check the fan cable is correctly inserted. The System Output arg is configured with an I/O-signal with wrong category. The I/O-signal arg has category Safety and can not be used as System Output. 2) Check that the fan is rotating and that the air flow is not obstructed. 3) Check the output voltage from the main fan power supply unit. 4) Check the input voltage to the main fan power supply unit. Replace any faulty unit. Recommended actions Choose another signal or set to another category. 20311, Enable 1 open 20307, Motor Fan 1 Malfunction Description Description The ENABLE 1 circuit monitoring the Panel Board has been opened. The Motor fan unit 1 in drive module arg has malfunctioned. Consequences Consequences The system goes to status SYS HALT. - Probable causes Probable causes There may be an internal fault in the Panel Board or the internal supervision has detected a fault. The fan or the main fan power supply unit may be faulty or a fan power cable may be badly connected. Recommended actions Recommended actions 1) Check all connections to the panel board 1) Check the fan cable is correctly inserted. 2) If faulty, replace the panel board. 2) Check that the fan is rotating and that the air flow is not obstructed. 3) Check the output voltage from the main fan power supply unit. 20312, Enable 2 open 4) Check the input voltage to the main fan power supply unit. Replace any faulty unit. Description The ENABLE 2 circuit monitoring the Axis Computer has been opened. 20308, Motor Fan 2 Malfunction Consequences Description The system goes to status SYS HALT. The Motor fan unit 2 in drive module arg has malfunctioned. Probable causes Consequences There may be an internal fault in the Axis Computer. Recommended actions Probable causes 1) Check all connections to the axis computer. The fan or the main fan power supply unit may be faulty or a fan power cable may be badly connected. 2) If faulty, replace the axis computer. 132 - 3HAC020738-001 3 Symptoms Recommended actions 20313, Enable1 supervision fault 1) Attempt restarting by pressing the Motors ON button. If restarting is IMPOSSIBLE it indicates a hardware fault in either Panel board, Axis computer or Contactor board. If restarting is POSSIBLE, it indicates a software fault. In such case, contact your local ABB representative. Description The ENABLE1 circuit has been broken. This circuit monitors the function of the panel board and the main computer. Consequences 2) Determine which unit is faulty by checking its indication LEDs. The LEDs are described in the Trouble Shooting Manual. Replace the faulty unit. The system goes to status SYS HALT. Probable causes A fault, probably a software fault, has been detected by any of the units supervised by the ENABLE1 circuit. 20316, Enable2 Supervision fault Recommended actions Description 1) Attempt restarting by pressing the Motors ON button. If restarting is IMPOSSIBLE it indicates a hardware fault in either Panel board, Axis computer or Contactor board. If restarting is POSSIBLE, it indicates a software fault. In such case, contact your local ABB representative. The ENABLE2 circuit to drive module 3 has been broken. This circuit monitors e.g. the function of the panel board and the axis computer. 2) Determine which unit is faulty by checking its indication LEDs. The LEDs are described in the Trouble Shooting Manual. Replace the faulty unit. Probable causes 20314, Enable2 supervision fault Recommended actions Consequences The system goes to status SYS HALT. A fault, probably a software fault, has been detected by any of the units supervised by the ENABLE2 circuit. 1) Attempt restarting by pressing the Motors ON button. If restarting is IMPOSSIBLE it indicates a hardware fault in either Panel board, Axis computer or Contactor board. If restarting is POSSIBLE, it indicates a software fault. In such case, contact your local ABB representative. Description The ENABLE2 circuit to drive module 1 has been broken. This circuit monitors e.g. the function of the panel board and the axis computer. Consequences 2) Determine which unit is faulty by checking its indication LEDs. The LEDs are described in the Trouble Shooting Manual. Replace the faulty unit. The system goes to status SYS HALT. Probable causes A fault, probably a software fault, has been detected by any of the units supervised by the ENABLE2 circuit. 20317, Enable2 Supervision fault Recommended actions Description 1) Attempt restarting by pressing the Motors ON button. If restarting is IMPOSSIBLE it indicates a hardware fault in either Panel board, Axis computer or Contactor board. If restarting is POSSIBLE, it indicates a software fault. In such case, contact your local ABB representative. The ENABLE2 circuit to drive module 4 has been broken. This circuit monitors e.g. the function of the panel board and the axis computer. 2) Determine which unit is faulty by checking its indication LEDs. The LEDs are described in the Trouble Shooting Manual. Replace the faulty unit. Probable causes 20315, Enable2 Supervision fault Recommended actions Consequences The system goes to status SYS HALT. A fault, probably a software fault, has been detected by any of the units supervised by the ENABLE2 circuit. 1) Attempt restarting by pressing the Motors ON button. If restarting is IMPOSSIBLE it indicates a hardware fault in either Panel board, Axis computer or Contactor board. If restarting is POSSIBLE, it indicates a software fault. In such case, contact your local ABB representative. Description The ENABLE2 circuit to drive module 2 has been broken. This circuit monitors e.g. the function of the panel board and the axis computer. Consequences 2) Determine which unit is faulty by checking its indication LEDs. The LEDs are described in the Trouble Shooting Manual. Replace the faulty unit. The system goes to status SYS HALT. Probable causes A fault, probably a software fault, has been detected by any of the units supervised by the ENABLE2 circuit. 3HAC020738-001 - 133 3 Symptoms 20350, Not a valid task name 20354, The argument is undefined Description Description The task name arg can not be used as a name of a task. It is either already used as an installed symbol or a reserved word in the system. The configured argument arg for task arg is not a valid type. Consequences Consequences The behaviour of the task will be undefined. The task will not be installed in the system. Recommended actions Recommended actions Change the configuration and restart the controller. Change the configuration of the task name and restart the controller. 20355, Mechanical unit group name not correct 20351, Max number of tasks exceeded Description Description The configured name of arg in task arg is not correct. The maximum number of tasks, arg, of the configuration type arg is exceeded. The reason could be: Consequences 2. The configured name is not a member of the mechanical unit group All configured tasks will not be installed. 3. The configured name is already used by another task. Recommended actions Consequences Change the configuration and restart the system. The task will not be installed or it will not be possible to execute RAPID motion instructions. 20352, Not a valid motion planner name Recommended actions 1. The argument is not used in the configuration Change the configuration and restart the controller. Description The motion planner name for mechanical unit group arg in arg is not correct. 20356, Maximum number of motion tasks exceeded The reason can be one of: 1. empty name Description 2. not present in the motion configuration 3. already in use by another mechanical unit group Only arg tasks are allowed to control mechanical units i.e. execute RAPID move instructions. Consequences Recommended actions The system will not be able to use. Change the configuration and restart the controller. Recommended actions 20357, No configured motion task Change the configuration and restart the controller. Description 20353, Mechanical unit not found No task is configured to control mechanical units i.e. execute RAPID move instructions. Description The mechanical unit arg in arg can not be found in the list of configured mechanichal units. Consequences Consequences Recommended actions It is not possible to execute any RAPID instructions that use the configured mechanical units. Change the configuration to include a task controlling mechanical units. Probable causes Restart the controller. It is not possible to execute any RAPID move instructions. The unit is probably not present in the motion configuration. 20358, No members of arg configured Recommended actions Description Change the configuration and restart the controller. The configuration type is required in a multi robot system. 134 - 3HAC020738-001 3 Symptoms Consequences Consequences It is not possible to execute any RAPID move instructions. Exceeded instances are ignored. Recommended actions Recommended actions Change the configuration and restart the controller. Change the configuration and restart the controller. 20359, Cfg type arg is configured 20365, Update of configuration is done Description Description The type was found but not expected in a system with current options. All tasks are reset to its main routine due to configuration changes. Recommended actions Recommended actions Check if the right configuration file is loaded or remove all instances of the type. 20366, Type error in task configuration Restart the controller. Description The task arg is configured with wrong type. Task configured to control mechanical units i.e. execute RAPID move instructions must be of type arg. 20360, Unknown event in cfg type arg Description The event arg is not a system event. Consequences Recommended actions The task will not be installed. Change the configuration and restart the system. Recommended actions Change the configuration and restart the controller. 20361, Only shared modules in the shared task Description 20367, No configured mechanical units The module arg is not configured shared and can not be loaded into the shared task. Description The instance arg of configuration type arg has no mechanical unit argument. Recommended actions Change the configuration and restart the system. Consequences 20362, Not defined task name It will not be possible to performe any actions against the motion system, i.e. execute RAPID move instructions. Description Recommended actions The task arg in cfg type arg is not configured in the system. Change the configuration and restart the controller. Recommended actions 20368, Not connected mechanical unit group Change the configuration and restart the system. Description 20363, Module not a system module There are no RAPID motion task connected with the mechanical unit group arg. Description The module arg loaded from the file arg is not a system module. Consequences Recommended actions It will not be possible to use the mechanical units that belongs to this group. Change the file suffix or add a module attribute to the module. Probable causes Load the module again or restart the system. The cause of this error can be a missing RAPID task instance in the controller domain of the configuration or a task that has not been configured as a motion task. 20364, Max number of mechanical unit groups exceeded Recommended actions Description 1. Add a motion task instance that are connected to the mechanicl unit group. The maximum number of mechanical unit groups, arg, of the configuration type arg is exceeded. 3HAC020738-001 2. Change an existing non motion task to a motion task. - 135 3 Symptoms 3. Remove the mechanical unit group. 20505, Delayed stop open 4. Check for misspelled names. Description 20380, No motion planner connected to mechanical unit Recommended actions Description 20506, Test Stop open The mechanical unit arg has no motion planner connected. Description Consequences Recommended actions It is not possible to use this mechanical unit in any operations such as calibration or activation. 20511, Soft-start relay open Probable causes The cause of this error is probably an error in the configuration. Description Recommended actions The Soft-start relay (KM3) should be closed when the motor relays (KM1/KM2) Check the motion and/or controller configuration. are closed. 20501, ES panel open Recommended actions Check relay KM3. Description 20521, Test Stop conflict Recommended actions Description 20502, ES pendant open Status conflict for the Test Stop chain. Description Recommended actions Recommended actions Please check the two channel safety guard that caused the status conflict. 20503, ES ext.cat.0 open Description 20522, Purge relay conflict Recommended actions Description Status conflict 20504, Purge relay open for the purge relay. Description Recommended actions Status active Please check the two channel safety when system not purged OK: guard that caused the status conflict. 1. Pressure too low. 20523, HwMotorOn relay conflict 2. Pressure too high. 3. High flow on. Description Recommended actions Status conflict 1. Check other error messages for for the HW motor on relay. primary fault reason. Recommended actions 2. If no other error messages, check Please check the two channel safety purge unit and air supply, and search guard that caused the status conflict. for leaks in the purge system. 136 - 3HAC020738-001 3 Symptoms Recommended actions 20524, SwMotorOn relay conflict Please check the two channel safety Description guard that caused the status conflict. Status conflict for the SW motor on relay. 20530, ES relay conflict Recommended actions Description Please check the two channel safety Status conflict guard that caused the status conflict. for the Emergercy Stop relay feedback. Recommended actions 20525, ES panel conflict Please check the two channel safety Description guard that caused the status conflict. Status conflict for the Emergency Stop panel chain. 20531, Delayed Stop conflict Recommended actions Description Please check the two channel safety Status conflict guard that caused the status conflict. for the delayed stop circuit. Recommended actions 20526, ES pendant conflict Please check the two channel safety Description guard that caused the status conflict. Status conflict for the Emergency Stop pendant chain. 20532, Run chain cur. conflict Recommended actions Description Please check the two channel safety Status conflict guard that caused the status conflict. for the run chain current balance monitoring. 20527, ES ext.cat.0 conflict Recommended actions Description Please check the two channel safety Status conflict guard that caused the status conflict. for the Emergency Stop ext.cat.0 chain. 20533, ES chain cur. conflict Recommended actions Please check the two channel safety Description guard that caused the status conflict. Status conflict for the Emergency Stop current balance. 20528, Safety Switch conflict monitoring. Description Recommended actions Status conflict Please check the two channel safety for the paint safety switch. guard that caused the status conflict. Recommended actions 20551, Run Chain circuit fault Please check the two channel safety guard that caused the status conflict. Description Status active 20529, Cabin Interlock conflict when Current Balance Monitoring on run Description chain detects fault. Status conflict Recommended actions for the cabin interlock circuit. Check run chain. 3HAC020738-001 - 137 3 Symptoms please check line voltage for 20552, ES circuit fault one phase missing. Description Status active 20557, Enable 2 AXC 2 open when Current Balance Monitoring on Description emergency stop chain detects fault. Status active when Recommended actions enable from Axis Computer 2 open. Check emergency stop. Recommended actions 1. Check other error messages for 20553, AEXB board not OK primary fault reason. Description 2. If no other error messages, Status active please check line voltage for when serial communication towards AEXB one phase missing. is down. Recommended actions 20558, Manipulator fault 1. Check cables towards AEXB board. Description 2. Replace AEXB board. Status active 3. Replace ACCB board. when power to manipulator is lost, or manipulator's enable chain conditions 20554, Collision sensor active is not OK. Description Recommended actions Status active 1. Check the power to the manipulator. when digital collision sensor on ACCB is 2. Check that the enable chain on MCOB active. is OK. Recommended actions Check the collision sensors connected to 20559, Collision sensor active ACCB. Description Status active 20555, ACA SW module not OK when digital collision sensor on MCOB is active. Description Status active Recommended actions when ACA software module is not OK, or Check the collision sensors connected to communication with AMA is down. MCOB. Recommended actions 1. Check that the ACA SW is running. 20560, Axis limit on MCOB 2. Check the communication towards AMA. Description 3. Check that the AMA SW is running. Status active when limit sensor on MCOB is active. 20556, Enable 2 AXC 1 open Recommended actions Description Check the limit sensors connected to Status active when MCOB. enable from Axis Computer 1 open. Recommended actions 20561, AMA SW not OK 1. Check other error messages for Description primary fault reason. Status active 2. If no other error messages, 138 - 3HAC020738-001 3 Symptoms when AMA software has opened the enable 20580, Missing instance name in cfg file chain on MCOB. Description Recommended actions Missing instance name on line arg in file arg. Check the AMA SW. Consequences 20562, Reset ES fault The configuration in file will not be installed. Description Probable causes Status active - when Reset Emergency Stop input is Recommended actions blocked for more than 3 seconds. 1) Re-edit the configuration file. Recommended actions 20581, Configuration attribute value out of the allowed range Check the connection of external reset of Emergency Stop. Description 20571, Safety Switch open Configuration attribute arg on line arg in file arg is out of the allowed range. The max. allowed length is arg characters. Description Paint System Safety Switch has opened Consequences the Cabin Interlock chain. The configuration in file will not be installed. Recommended actions Probable causes Check manual switch for disconnecting - of the paint control system. Recommended actions 1) Re-edit the configuration file and change the value on the attribute to fit inside the allowed range. 20572, Cabin Interlock open Description Cabin Interlock chain. 31810, DeviceNet master/slave board is missing Recommended actions Description Check cabin ventilation and other cabin The DeviceNet master/slave board does not work. Cabin Interlock Signal has opened the safety functions. Consequences No communication on the Devicenet is possible. 20573, Controller ID is Missing Probable causes Description The DeviceNet master/slave board is either malfunctioning or missing. Controller ID is the controller's unique identity. It is by default equal to the serial number of the controller's cabinet. The software configuration of the controller is missing this identity information. Recommended actions 1. Make sure a DeviceNet master/slave board is installed. 2. Replace the board if faulty. Probable causes This may happen if the storage media of the controller has been replaced or reformated. 31910, Profibus-DP master/slave board is missing Recommended actions Description Read the serial number of the controller from the controller cabinet to find out what the controller ID should be. Use RobotStudio tools to set this value for the controller. The Profibus-DP master/slave board does not work. Consequences No communication on the Profibus is possible. 3HAC020738-001 - 139 3 Symptoms Probable causes 2. Replace the Profibus-DP master/slave board if faulty. The Profibus-DP master/slave board is either malfunctioning or missing. 31914, Profibus startup error Recommended actions Description 1. Make sure a Profibus-DP master/slave board is installed. - Profibus master bus error Error code arg. Check cabling, terminators and modules then restart. 2. Replace the board if faulty. Recommended actions 31911, Profibus board update error Description 31915, Profibus bus error The RobotWare software was not able to download new driver software to the Profibus-DP master/slave board. The arg channel (ch arg) of the Profibus board could not be programmed. Internal error code:arg. - Profibus master bus error Error code arg. Check cabling, terminators and modules. Consequences Recommended actions Description No communication on the Profibus is possible. Probable causes 31916, Profibus bus OK The RobotWare software may be corrupt or the board hardware may be malfunctioning. Description - Profibus regained contact on the master bus. Recommended actions Recommended actions 1. Restart the system to reattempt downloading the software. 2. Reinstall the present system files. 31917, Profibus-DP master/slave board exception 3. Create and run a new system to download the driver software. 4. Replace the board if faulty. Description 31912, Profibus-DP master/slave board failure A fatal error has occured on the Profibus-DP master/slave board. Arg1 channel in task arg. Parameters arg Description Consequences The Profibus-DP master/slave board did not start up correctly. No communication on the Profibus is possible. Consequences Probable causes No communication on the Profibus is possible. The Profibus-DP master/slave board hardware may be malfunctioning. Probable causes Recommended actions The Profibus-DP master/slave board hardware may be malfunctioning. 1. Restart the system. Recommended actions 2. Replace the Profibus-DP master/slave board if faulty. 1. Restart the system. 2. Replace the Profibus-DP master/slave board if faulty. 32500, Robot Communication Card is missing 31913, Profibus-DP master/slave board internal error Description Description Consequences The Profibus-DP master/slave board reported internal error arg. No communication with the Panel board is possible. The system goes to status SYS FAIL. The system cannot contact the Robot Communication Card FPGA. Consequences Probable causes No communication on the Profibus is possible. The Robot Communication Card is either malfunctioning or missing. Probable causes Recommended actions The Profibus-DP master/slave board hardware may be malfunctioning. 1. Make sure a Robot Communication Card is installed. Recommended actions 2. Replace the board if faulty. 1. Restart the system. 140 - 3HAC020738-001 3 Symptoms 32501, Incorrect RCC firmware 32550, Firmware reflash started Description Description The FPGAR11-Firmware on the RCC (DSQC602) is of an incompatible version. Current version: arg.arg Requested version: arg.arg A required update of the arg firmware has started. File used: [arg]. Recommended actions Wait for the reflash to complete Recommended actions 1. Replace the DSQC602 board 32551, Firmware reflash completed 2. Restart the system Description 32502, Can't find file The update of arg firmware has sucessfully completed. Description Recommended actions The system cannot find the file: [arg] 32552, Firmware reflash failed Recommended actions Reinstall the system Description The update of arg firmware failed. 32503, Requested info not in file Internal errorcode:arg Description Recommended actions The system cannot find information about what software to download to HardWare ID="arg", Version="arg", Revision="arg" in file [arg]. 1. Check other errormessages for detailed explanation 2. Restart the system 3. Reinstall the system Consequences 4. Replace the arg xx Probable causes 32553, Firmware file is corrupt The file has either been damaged, or the actual hardware version of the unit is not supported. Description The firmware file [arg] is corrupt. Internal errorcode:arg Recommended actions 1. Reinstall the system Recommended actions 2. Replace the unit to a version which is supported by this SW-release. Reinstall the system 32530, No panel board communication 32554, Firmware file not found Description Description There is no serial communication between the panel board and the robot communication card. The firmware file [arg] is not found. Recommended actions Consequences Reinstall the system The system goes to status SYS FAIL. 32570, Firmware reflash started Probable causes Probably hardware fault in cable between panel board and robot communication card. The panel board, or it's power supply, may also be faulty. Description A required update of the arg firmware has started. Replacing old firmware version: [arg]. Recommended actions Recommended actions 1) Restart the system to resume operation. Wait for the reflash to complete 2) Make sure the cable between robot communication card and panel unit is working and correctly connected. 3) Check the panel unit power supply. 4) Replace the panel board if faulty. 3HAC020738-001 - 141 3 Symptoms 32571, Firmware reflash completed 32581, Firmware reflash completed Description Description The update of arg firmware has sucessfully completed. New version: [arg]. Internal code:[arg] The update of arg firmware has sucessfully completed. Internal code:[arg] Recommended actions Recommended actions No action required 32572, Firmware reflash failed 32582, Firmware reflash failed Description The update of arg firmware failed. Description Current version:arg. Internal errorcode:arg The update of arg firmware failed. Internal errorcode:arg Recommended actions 1. Check other errormessages for detailed explanation. Recommended actions 2. Reinstall the system. 1. Check other errormessages for detailed explanation. 2. Reinstall the system. 32573, Unable to download firmware file 32583, Firmware file corrupt Description Description The firmware file [arg] is not found. Internal errorcode:arg. The update of arg firmware failed. Recommended actions The firmware file [arg] is corrupt. Reinstall the system Internal errorcode:arg. Recommended actions 32574, Corrupt axis computer hardware Reinstall the system Description The [arg] flash memory has a corrupt content. Internal errorcode:arg 32584, Firmware file not found Recommended actions Description 1. Check other errormessages for detailed explanation The update of arg firmware failed. 2. Restart the system The firmware file [arg] is not found. 3. If failure occour again, replace the board Internal errorcode:arg. Recommended actions 32575, Found no axis computer board Reinstall the system Description System failed to detect any connected axis computer 32585, Found no contactor board Recommended actions Description 1. Check system for axis computer board System failed to detect one or more contactor boards 2. Check ethernet cables between the main computer and the axis computer Recommended actions 3. Restart the system 1. Check system for missing contactor boards 32580, Firmware reflash started 2. Check ethernet cables between the axis computers and the contactor boards 3. Restart the system Description A required update of the arg firmware has started. Internal code: [arg]. 32590, Firmware reflash started File: [arg]. Description Recommended actions A required update of the arg firmware in drive module arg has started. Wait for the reflash to complete 142 File: [arg]. - 3HAC020738-001 3 Symptoms Recommended actions 33504, Revolution counter update failure Wait for the reflash to complete, this will take approximately 3.5 minutes. Description Update of the revolution counter for joint arg failed. 32591, Firmware reflash completed Consequences Description Joint not synchronised The update of arg firmware in drive module arg has sucessfully completed. Probable causes Recommended actions 2. Measurment system error No action required Recommended actions 1. Joint missing or not active 1. Check if joint active 32592, Firmware reflash failed 2. Check configuration files 3. Check measurement system Description The update of arg firmware in drive module arg has failed. 37001, Motors ON contactor activation error Recommended actions 1. Check other errormessages for detailed explanation. Description 2. Reinstall the system. Motors ON contactor for mechanical unit arg failed to close when ordered. 32593, Firmware file corrupt Consequences The mechanical unit can not be run manually or automatically. Description The update of arg firmware in drive module arg has failed. Probable causes The firmware file [arg] is corrupt. The FlexPendant enabling device may have been toggled too quickly, or the system may not be configured correctly. On rare occasions, this fault may occur in combination with other faults, in which case this may be found in the error log. Recommended actions Reinstall the system Recommended actions 32594, Firmware file not found 1) To resume normal operation, first acknowledge the error, then release the enabling device and press it again after approx. one second. Description 2) Check any other error log messages coinciding in time with this one for clues. The update of arg firmware in drive module arg has failed. The firmware file [arg] is not found. 3) Check the system motion configuration regarding Motors ON relay. How to check the configuration file is detailed in the Trouble Shooting Manual. Recommended actions Reinstall the system 37043, Overload on Panel Board signals 32601, Interbus master/slave board is missing Description Description The AC_ON or SPEED signals draw too much current. The Interbus master/slave board does not work. Consequences Consequences Probable causes The Panel Board shuts down the signals, causing the system to go to either status SYS FAIL (for AC_ON) or status SYS HALT (for SPEED). The Interbus master/slave board is either malfunctioning or missing. Probable causes Recommended actions A load connected to the circuit may be too high, or the Panel Board may be malfunctioning. See the Circuit Diagram! No communication on the Interbus is possible. 1) Make sure a Interbus master/slave board is installed. 2) Replace the board if faulty. Recommended actions 1) Check all loads connected to the AC_ON and SPEED circuits 3HAC020738-001 - 143 3 Symptoms 2) Check the Panel Board cabling and connectors, and replace any faulty unit if required. Consequences The mechanical unit can not be run manually or automatically. Probable causes 37044, Overload on Panel Board digital output signals The activation relay configured within the system may be faulty, or the system may not be configured correctly. Description Recommended actions The Panel Board User Digital outputs draw too much current. 1) Check the contactor and make sure its connections are connected correctly. Consequences 2) Check the system motion configuration regarding the activation relay. How to check the configuration file is detailed in the Trouble Shooting Manual. The Panel Board shuts down the signals, causing the system to go to status SYS HALT. Probable causes A load connected to the circuit may be too high, or the Panel Board may be malfunctioning. See the Circuit Diagram! 37050, Overtemperature in main computer processor Recommended actions Description 1) Check all loads connected to the User Digital outputs The temperature in the main computer processor is too high. 2) Check the Panel Board cabling and connectors, and replace any faulty unit if required. Consequences The system goes to status SYS HALT. 37045, Faulty External Computer fan Probable causes The External Computer fan in the Control Module spins too slowly. The unit may be overloaded, its fan may be malfunctioning or air flow may be restricted. Consequences Recommended actions No system consequence. The Control Module temperature will rise. 1) Make sure the fan is operating. Description 2) Check that air flow to the power supply unit fan is not restricted. Probable causes Faulty fan, cabling or power supply. See the Circuit Diagram! 37053, Low CMOS battery voltage level Recommended actions Description 1) Check the cabling to the External Computer fan. The CMOS battery on the computer board is empty. 2) Check the fan, and replace any faulty unit if required. Consequences On restart, the system will use an erroneous setup or no restart will be possible. 37046, Overload on Panel Board signals Description Probable causes The 24 V PANEL supply draws too much current. Faulty battery. Consequences Recommended actions The Panel Board shuts down the signal, causing the system to go to status SYS HALT. 1. Replace the CMOS battery Probable causes 37054, Faulty Computer Unit fan A load connected to the circuit may be too high, or the Panel Board may be malfunctioning. See the Circuit Diagram! Description Recommended actions The fans in the Computer Unit spin too slowly. 1) Check all loads connected to the 24V PANEL circuit. Consequences 2) Check Panel Board cabling, and replace any faulty unit if required. No system consequence. The Computer Unit temperature will rise. Probable causes 37049, Activation contactor activation error Faulty fan, cabling or power supply. See the Circuit Diagram! Description The activation relay for mechanical unit arg failed to close. 144 - 3HAC020738-001 3 Symptoms Recommended actions Probable causes 1. Check the cabling to the Computer Unit fan. 2. Check the fan. This may be caused by a faulty fan, cabling or power supply. See the Circuit Diagram! 3. Check the fan power supply. Recommended actions 4. Replace the faulty component if required. 1. Check the cabling to the Computer Unit Power Supply fan. 2. Check the fan. 37056, Cooling fan error 3. Check the fan power supply. 4. Replace the faulty component if required. Description Cooling unit fan has stopped or is rotating very slowly (Less than arg rpm). 37068, Faulty Battery Unit connector Recommended actions Description 1. Check the fan cables. The backup battery connector is faulty. 2. Replace the fan. Consequences No system consequence. 37059, POWER Supply error Recommended actions Description 1. Make sure the connector is fully inserted. The Control Module Power Supply reports an error. 2. Check the connector and cables for faulty connection. Probable causes 3. Replace the battery unit if required. The incoming AC voltage is out of range. 37069, Faulty backup Power Supply Recommended actions 1) Restart the system. Description 2) Check incoming AC voltage. The backup energy bank in the Control Module supplying the backup voltage is faulty. 3) Check the Computer Module Power Supply, and replace any faulty unit if required. Consequences 37062, Computer Module power supply warning After switching the power off, a B type restart must be performed. No system data changes will be saved at power off. Description Probable causes The arg V voltage of the Computer Module power supply is arg V, which is out of the allowed range. This may be caused by a faulty backup energy bank, cabling or charger. Consequences Do not turn the main power off until battery has been charged, or the system may perform a cold start! Recommended actions - 1) Check the backup energy bank cabling and connectors. Probable causes 2) Check the backup energy bank. The power supply unit, cabling, input voltage to the power supply or the output load may cause the faulty voltage level. See the Trouble Shooting Manual and Circuit Diagram! 3) Check the power supply. 4) Replace the faulty unit if required. Recommended actions 37070, Overtemp in Control Module Power Supply 1) Check all cabling to the power supply unit. 2) Measure the output and input voltage levels. 3) Replace the faulty unit if required. Description The temperature in the control module power supply is too high. 37067, Faulty Computer Unit Power Supply fan Consequences Description The system is shut down immediately. The fan in the Computer Unit Power Supply spins too slowly. Probable causes This may be caused by poor cooling, too high a load on the power supply or by a faulty power supply. Consequences No system consequence. The Computer Unit Power Unit temperature will rise. 3HAC020738-001 - 145 3 Symptoms Recommended actions 37074, Purge pressure too low 1) Check the cooling fan. 2) Check the output power. Description 3) Replace any faulty unit if required. Purge system number: arg Recommended actions 37071, Low backup battery voltage level Check the purge air supply and search for leaks in: 1. The purge unit. Description 2. The flexible hose conduit. The voltage in the computer unit backup battery unit is too low to be functional. 3. The manipulator itself. Consequences 37075, Purge pressure too high No system consequence. No backup will be made at power loss. Description Probable causes Purge system number: arg This may be caused by a faulty battery unit, cabling or charger. Recommended actions Recommended actions Check the purge unit and the air supply. Do not turn the main power off until battery has been charged, or the system may perform a cold start! 37076, Unexpected low purge flow 1. Check the battery unit cabling and connectors. 2. Check the battery unit. Description 3. Check the power supply. Purge system number: arg 4. Replace the faulty unit if required. Recommended actions Check the purge unit and the air supply. Search for leaks in the purge system. 37072, Backup battery has expired Description The backup battery has reached the end of its life, as calculated by the system. 37077, Unexpected high purge flow Description Consequences Purge system number: arg No system consequence. No backup will be made at power loss. Recommended actions Probable causes Check the purge unit and the air supply. Faulty battery. Recommended actions 37078, Purge timers differ 1. Replace the backup battery unit. Description 37073, Backup battery status Unacceptable divergence between software and firmware count down timers. Description Recommended actions The backup battery has a remaning capacity of at least arg number of parameter saves. Change AEXB board. Consequences 37079, Purge timer restarted Description Probable causes Purge hardware has restarted the count down timer. Recommended actions Recommended actions 1. Check other error messages for primary fault reason. Charge the battery by leaving the system switched on for more than 24 hours. 146 2. If no other error messages, the system will try to purge once again. - 3HAC020738-001 3 Symptoms Recommended actions 37080, Signal on purge system 2 Description 37092, Drivesystem fuse burned Sensor number: arg overriden. Description Recommended actions Status active when fuse on drive system is burned. Check the dummy plug for purge system Recommended actions 2. No sensor signals shall be connected if dummy plug is inserted. 1. Check fuse. 2. Check for other electrical fault. 37081, Purge timers differ Description 37093, ES circuit - supply fault Unacceptable divergence between firmware and hardware count down timers. Description Status active when 24V supply on emergency stop chain is low or missing. Recommended actions Change AEXB board. Recommended actions Check 24V supply. 37084, Purge init timer fault Description 37094, Activate connection error More or less than one selector are set for the init timer on the configuration connector at AEXB. Default time (300s) is used. Description Could not activate arg. Connection relay input arg indicates no connection. Recommended actions Check the init timer selectors on the configuration connector at AEXB board. Recommended actions 1. Check that if mechanical unit is connected. 37085, Low purge flow expected 2. Check the connection relay input signal setup. Description 37097, Brake short circuit fault Purge system number: arg Recommended actions Description Check the purge unit and the air supply. The supervision of brakes on MCOB has detected a short circuit on axis arg and turned ON all brakes. 37086, High purge flow expected Recommended actions 1. Check for short circuit on brakes. Description Purge system number: arg 37098, Brake open circuit fault Recommended actions Description Check the purge unit and the air supply. Search for leaks in the purge system. The supervision of brakes on MCOB has detected an open circuit on axis arg and turned ON all brakes. Recommended actions 37090, Temp. too high, sensor arg 1. Check for open circuit on brakes. Description System overheat detected. Sensors 1-7: motor 1-7, sensor 8: Serial measurement board. Run chain has been opened. 37099, Temp. too high, sensor arg Description System overheat detected on motors, SMU or process equipment. Run chain has been opened. Recommended actions Sensors 1-8: Robot motors 1-8 3HAC020738-001 - 147 3 Symptoms Sensor 9: Serial measurement unit (SMU) 37103, Power supply warning, faulty 24V SYS level Sensors 10-14: Process 1-5 Please refer to current robot config. for more details. Description 37100, I/O node flash disk error The 24V SYS output of the Control Module Power Supply is out of range. Description Consequences Flash name: arg No system consequence. Flash disk function: arg Error description: arg Probable causes The Control Module Power Supply unit, cabling or the output load may cause the faulty voltage level. The power supplies are shown in the Trouble Shooting Manual and the Circuit Diagram! Recommended actions Report error. Recommended actions 37101, Auxiliary Brake Release Failure 1) Check all cabling to the Control Module Power Supply unit. Description 2) Check the output voltage level, and replace any faulty unit if required. The brakes for mechanical unit arg fail to disengage. Consequences 37104, There is no backup voltage available! The robot can not be operated. Description Probable causes The backup energy bank maintaining the backup voltage is not functional. The configuration of brake relay may be incorrect, or the brake relay may be faulty If an external brake relay is being used, the relay must be correctly defined in the motion configuration file. Consequences After switching the power off, a B type restart must be performed. No system data changes will be saved at power off. Recommended actions 1) Check that the external brake relay (if used) is correctly defined in the configuration file. Probable causes 2) Check that the corresponding I/O signal is correctly defined in the I/O configuration file. How to check the configuration files is detailed in the Trouble Shooting Manual. This may be caused by a faulty backup energy bank, cabling or charger. Recommended actions Before working on the system, perform a controlled shutdown to ensure all system data is correctly saved. 37102, Power supply warning, faulty 24V COOL level 1) Check the cables and connectors of the backup energy bank. 2) Check the backup energy bank. Description 3) Check the power supply. The 24V COOL output of the Control Module Power Supply is out of range. 4) Replace the faulty unit if required. Consequences No system consequence. 37105, Regained communication: Power Supply and Computer Unit Probable causes Description The Control Module Power Supply unit cabling or the output load may cause the faulty voltage level. The power supplies are shown in the Trouble Shooting Manual and the Circuit Diagram! The main computer has regained communication with the Control Module Power Supply. Recommended actions 37106, Low backup energy bank voltage level 1) Check all cabling to the Control Module Power Supply unit. Description 2) Check the output voltage level, and replace any faulty unit if required. The voltage in the computer unit backup energy bank is too low to be functional. Consequences No system consequence. No system data changes will be saved at power off. 148 - 3HAC020738-001 3 Symptoms Probable causes 38100, Configuration failure This may be caused by a faulty backup energy bank, cabling or charger. Description Recommended actions Drive Module has detected configuration failure at measurement link. Before working on the system, perform a controlled shutdown to ensure all system data is correctly saved. Drive module: arg Measurement link: arg 1) Check the cables and connectors of the backup energy bank. Board node: arg 2) Check the backup energy bank. 3) Check the power supply. Recommended actions 4) Replace the faulty unit if required. - Check configuration for measurement link. - Check configuration for measurement board. - Check configuration for measurement nodes. 37107, Faulty backup energy bank Description 38101, Transmission failure between axis computer and SMB The backup energy bank in the Control Module maintaining the backup voltage is not functional. Consequences Description If switching the power off, a B type restart must be performed. No backup will be made at power off. A transmission failure has been detected between the axis computer and the serial measurement board on measurement link arg in Drive Module arg 1. Probable causes Consequences This may be caused by a faulty backup energy bank, cabling or charger. The system goes to status SYS HALT and loses its calibration information. Recommended actions Before working on the system, perform a controlled shutdown to ensure all system data is correctly saved. Probable causes This may be caused by bad connections or cables (screening), especially if non-ABB cables are used for external axes. Possible causes are also faulty serial measurement board or axis computer. 1) Check the backup energy bank cable and connector. 2) Check the backup energy bank. 3) Replace the faulty unit if required. Recommended actions 1) Reset the robot's revolution counters as detailed in the robot Product Manual. 37108, Lost communication: Power Supply and Computer Unit 2) Make sure the cable between serial measurement board and axis computer is connected correctly, and that it meets the specification set by ABB. Description The main computer has lost communication with the Control Module Power Supply. 3) Make sure the cable screen is correctly connected at both ends. Consequences 4) Make sure no extreme levels of electromagnetic interference are emitted close to the robot cabling. The main computer cannot retrieve status info or switch the power supply off. No system data changes will be saved at power off. 5) Make sure the serial measurement board and axis computer are fully functional. Replace any faulty unit. Probable causes 38102, Internal failure The USB cable from the main computer to the Control Module Power Supply may be faulty or disconnected, or the power supply may be faulty. Description The measurement system has detected a hardware or software fault on measurement link arg in Drive Module arg. Recommended actions Before working on the system, perform a controlled shutdown to ensure all system data is correctly saved. Consequences The system goes to status SYS HALT and loses its calibration information. 1) Check the cabling and connectors to the Control Module Power Supply. 2) Check the power supply unit, and replace any faulty unit if required. Probable causes This may be caused by some temporary disturbance in the robot cell or by a faulty axis computer. 3HAC020738-001 - 149 3 Symptoms 3) Perform a re-commutation of the motor at hand. How to do this is specified in the Additional Axes Manual. Recommended actions 1) Restart the system. 2) Reset the robot's revolution counters as detailed in the robot Product Manual. 38105, Data not found. 3) Make sure no extreme levels of electromagnetic interference are emitted close to the robot cabling. Description Configuration data for measurement board not found. 4) Make sure the axis computer is fully functional. Replace any faulty unit. System will use default data. Drive module: arg Measurement link: arg 38103, Transmission timeout between axis computer and SMB Board node: arg Recommended actions Description Check configuration. The communication has been lost between the axis computer and the serial measurement board on measurement link arg in Drive Module arg 1. 38200, Battery backup lost Consequences Description The system goes to status SYS HALT and loses its calibration information. Battery backup on Serial Measurement Board lost since last power down or restart. Probable causes Battery normally disconnected at delivery. Drive module: arg This may be caused by bad connections or cables (screening), especially if non-ABB cables are used for external axes. Possible causes are also faulty serial measurement board or axis computer. Measurement link: arg Measurement board: arg Recommended actions Recommended actions 1) Reset the robot's revolution counters as detailed in the robot Product Manual. - Ignore error and connect battery at first installation. - For rechargable battery: After 18 hours recharging with power on, check battery voltage during power off. 2) Make sure the cable between serial measurement board and axis computer is connected correctly, and that it meets the specification set by ABB. - Check battery connection to Serial Measurement Board. - Replace battery. 3) Make sure the cable screen is correctly connected at both ends. 4) Make sure no extreme levels of electromagnetic interference are emitted close to the robot cabling. 38201, Serial Board not found 5) Make sure the serial measurement board and axis computer are fully functional. Replace any faulty unit. Description Serial Measurement Board not found on measurement link. Drive module: arg 38104, Overspeed During Teach Mode Measurement link: arg Measurement board: arg Description One or more axes of the robot connected to drive module arg has exceeded the maximum speed for teach mode operation. Recommended actions Consequences - Check connections and cables to Serial Measurement Board. The system goes to status SYS HALT. - Replace Serial Measurement Board. - Check system configuration parameters. Probable causes 38203, SMB offset X error The robot may have been moved manually while in state Motors OFF. The error may also be caused by a misadjustment in the relation, commutation, between motor shaft and resolver on an external axis, primarily during installation. Description Offset error for X signal at Serial Measurement Board. Drive module: arg Recommended actions Measurement link: arg 1) Press the Enabling Device to attempt resuming operation. Measurement board: arg 2) Check other event log messages occuring at the same time to determine the actual cause. Recommended actions - Replace Serial Measurement Board. 150 - 3HAC020738-001 3 Symptoms Measurement board: arg 38204, SMB offset Y error Board node: arg Description Recommended actions Offset error for Y signal at Serial Measurement Board. - Check resolver and resolver connections. Drive module: arg - Replace Serial Measurement Board. Measurement link: arg - Replace resolver. Measurement board: arg Recommended actions 38209, Resolver error - Replace Serial Measurement Board Description Too low voltage from X or Y resolver signals. 38205, SMB Linearity Error Sum of squared X and Y too low. Description Joint: arg Linearity error for X-Y signal difference at Serial Measurement Board. Drive module: arg System may still operate with warning. Measurement link: arg System will not function with error. Measurement board: arg Drive module: arg Board node: arg Measurement link: arg Recommended actions Measurement board: arg - Check resolver and resolver connections. Recommended actions - Replace Serial Measurement Board. - Replace Serial Measurement Board. - Replace resolver. 38206, SMB Linearity X Error 38210, Transmission fault. Description Description Linearity error for X signal on Serial Measurement Board. Serial Measurement Board SMS communication failed. Drive module: arg Status: arg Measurement link: arg Drive module: arg Measurement board: arg Measurement link: arg Measurement board: arg Recommended actions Board node: arg - Replace Serial Measurement Board. Recommended actions - Restart system. 38207, SMB Linearity Y Error - Check cable and connectors for SMB communication. Description - Replace the Serial Measurement Board. Linearity error for Y signal at Serial Measurement Board. Drive module: arg 38211, Functionality error. Measurement link: arg Description Measurement board: arg The Serial Measurement Board does not support 7 axes. Recommended actions Drive module: arg - Replace Serial Measurement Board. Measurement link: arg Measurement board: arg 38208, Resolver error Recommended actions Description - Check configurations of the 7th axis. Too high voltage from X or Y resolver signals. - Replace Serial Measurement Board to a board with 7 axes functionality. Sum of squared X and Y exceeds max. Joint: arg Drive module: arg Measurement link: arg 3HAC020738-001 - 151 3 Symptoms Consequences 38212, Data not found. Description Probable causes Configuration data for Serial Measurement Board not found. System will use default data. The resolver feedback may be poor or the speed loop gain may be badly adjusted. Drive module: arg Measurement link: arg Recommended actions Measurement board: arg 1) Check the resolver cable and the resolver grounding for this joint. If this joint is an external axis, then check that the motor data in the configuration file is correct. How to check the configuration file is detailed in the Trouble Shooting Manual. Recommended actions - Check configuration. 2) Reduce the gain of the speed loop. 38213, Battery charge low. 39402, Motor Angle Reference Error Description Less than 2 months until battery on Serial Measurement Board is discharged. Counting from first time this message was displayed. Description The motor angle reference is increasing too quickly for joint arg, connected to drive module arg. Drive module: arg Measurement link: arg Consequences Measurement board: arg Recommended actions Probable causes - Replace battery on serial measurement. The resolver feedback may be poor or the speed loop gain may be badly adjusted. 38214, Battery failure. Recommended actions Description Drive module: arg 1) Check the resolver cable and the resolver grounding for this joint. If this joint is an external axis, then check that the motor data in the configuration file is correct. How to check the configuration file is detailed in the Trouble Shooting Manual. Measurement link: arg 2) Reduce the gain of the speed loop. Transportation shut down of battery failed. The battery will still be in normal mode. Measurement board: arg 39403, Torque Loop Regulation Error Recommended actions - Retry shut down. Description - Replace serial measurement board. The torque-current controller cannot produce enough current for joint arg, connected to drive module arg. 38215, Battery flag failure. Consequences Description - Reset of battery flag not possible. Probable causes Drive module: arg The motor data in the configuration files may be wrong or the DC bus voltage may be too low. Measurement link: arg Measurement board: arg Recommended actions Recommended actions 1) Check that the motor data in the configuration file is correct for this joint. How to check the configuration file is detailed in the Trouble Shooting Manual. - Replace serial measurement board. 2) Check that no DC bus errors are present in the event log. 39401, Torque Current Reference Error 3) Check that the incoming mains voltage is within the specification. Description 4) Check that the motor cables are not damaged or badly connected. The torque-current reference is increasing too quickly for joint arg, connected to drive module arg. 152 - 3HAC020738-001 3 Symptoms 39404, Field Loop Regulation Error 39407, Drive Unit has the wrong type code Description Description The field-current controller cannot produce enough current for joint arg, connected to drive module arg. The type code for drive unit arg in drive module arg is different from the one specified in the configuration file. Installed drive unit type is arg, and the configured type is arg. Consequences - Consequences Probable causes No operation will be possible until after correcting the fault. The system goes to status SYS HALT. The motor data in the configuration files may be wrong or the DC bus voltage may be too low. Probable causes The configuration file may contain incorrect values, the configuration key may be incorrect or the hardware may be of the wrong type. If the drive unit was recently replaced, a drive unit with the wrong type code may have been fitted or the key was not replaced with one for the correct hardware/software combination. Recommended actions 1) Check that the motor data in the configuration file is correct for this joint. How to check the configuration file is detailed in the Trouble Shooting Manual. 2) Check that no DC bus errors are present in the event log. Recommended actions 3) Check that the incoming mains voltage is within the specification. 1) Make sure the values in the configuration file match the installed hardware. 4) Check that the motor cables are not damaged or badly connected. 39405, Maximum PWM Reached in Torque Controller 2) Make sure the configuration key match the installed hardware/ software combination. How to check the configuration file is detailed in the Trouble Shooting Manual. Description 3) If the drive unit was recently replaced, make sure a unit of the correct type code is used. The torque-current control loop has been saturated for joint arg, connected to drive module arg. 39408, Rectifier Unit has the wrong type code Consequences Description - The type code for rectifier unit arg in drive module arg is different from the one specified in the configuration file. Installed rectifier unit type is arg, and the configured type is arg. Probable causes The mains voltage may be too low or the motor windings or motor cables may be broken. Consequences 1) Check that no DC bus errors are present in the event log. No operation will be possible until after correcting the fault. The system goes to status SYS HALT. 2) Check that the incoming mains voltage is within specified limits. Probable causes 3) Check the motor cables and motor windings for open circuits. The configuration file may contain incorrect values, the configuration key may be incorrect or the hardware may be of the wrong type. If the rectifier unit was recently replaced, a rectifier unit with the wrong type code may have been fitted or the key was not replaced with one for the correct hardware/software combination. Recommended actions 39406, Maximum PWM Reached in Field Controller Description Recommended actions The field-current control loop has been saturated for joint arg, connected to drive module arg. 1) Make sure the values in the configuration file match the installed hardware. Consequences 2) Make sure the configuration key match the installed hardware/ software combination. How to check the configuration file is detailed in the Trouble Shooting Manual. Probable causes 3) If the rectifier unit was recently replaced, make sure a unit of the correct type code is used. The DC bus voltage may be too low or the motor windings or motor cables may be broken. Recommended actions 1) Check that no DC bus errors are present in the event log. 2) Check that the incoming mains is within specified limits. 3) Check the motor cables and motor windings for open circuits. 3HAC020738-001 - 153 3 Symptoms Probable causes 39409, Capacitor Unit has the wrong type code There may be a break in the communication link cable between the axis computer and the main drive unit, the drive module may be incorrectly grounded or excessive noise may interfere with the communication signals. Description The type code for capacitor unit arg in drive module arg is different from the one specified in the configuration file. Installed capacitor unit type is arg, and the configured type is arg. Recommended actions Consequences 1) Check the communication link cable between the axis computer and the main drive unit is correctly connected. No operation will be possible until after correcting the fault. The system goes to status SYS HALT. 2) Check that the module is properly grounded. Probable causes 3) Check for external electromagnetic noise sources close to the drive module.. The configuration file may contain incorrect values, the configuration key may be incorrect or the hardware may be of the wrong type. If the capacitor unit was recently replaced, a capacitor unit with the wrong type code may have been fitted or the key was not replaced with one for the correct hardware/software combination. 39412, Too Many Missed Reference Updates Recommended actions Too many missed communication packets have been detected for joint arg, in drive module arg. 1) Make sure the values in the configuration file match the installed hardware. Consequences Description No operation will be possible until after correcting the fault. The system goes to status SYS HALT. 2) Make sure the configuration key match the installed hardware/ software combination. How to check the configuration file is detailed in the Trouble Shooting Manual. Probable causes 3) If the capacitor unit was recently replaced, make sure a unit of the correct type code is used. 39410, Drive Unit Communication Warning There may be a break in the communication link cable between the axis computer and the main drive unit, the drive module may be incorrectly grounded or excessive noise may interfere with the communication signals. Description Recommended actions A large number of communication errors are being detected between the axis computer and drive unit number arg in drive module arg. 1) Check the communication link cable between the axis computer and the main drive unit is correctly connected. 2) Check that the module is properly grounded. Consequences 3) Check for external electromagnetic noise sources close to the drive module.. Probable causes External noise may interfere with the communication signals. 39413, Drive Software Not Synchronised Recommended actions Description 1) Check the communication link cable between the axis computer and the main drive unit is correctly connected. The axis computer software in drive module arg has become unsynchronised with the drive software for joint arg. This is an unstable software state. 2) Check that the module is properly grounded. 3) Check for external electromagnetic noise sources close to the drive module. Consequences No operation will be possible until after correcting the fault. The system goes to status SYS HALT. 39411, Too Many Communication Errors Probable causes Description There may be glitches in the system timing. Three or more consequtive communication packets have been lost between the axis computer and drive unit arg in drive module arg. Recommended actions 1) Restart the controller. Consequences 2) If the problem persists, contact your local ABB representative.. No operation will be possible until after correcting the fault. The system goes to status SYS HALT. 154 - 3HAC020738-001 3 Symptoms 2) Restart the controller. 39414, Unknown Capacitor Type Code 3) If the problem persists, contact your local ABB representative. Description The type code for the capacitor unit arg in drive module arg is not recognised by the system. 39417, Cannot find Drive Software Version File Description Consequences The system cannot locate a valid drive version file on the disk. No operation will be possible until after correcting the fault. The system goes to status SYS HALT. The file may have been erased my mistake. Without this file it is not possible to check if the drive units software needs updating. Probable causes Recommended actions The wrong type of capacitor unit may have been fitted or the capacitor version used is not supported by the software. Contact your local ABB representative. Recommended actions 39418, Unknown Drive Unit type code 1) Check the type of capacitor unit fitted. Replace if it is the wrong type. Description 2) If the problem persists, contact your local ABB representative. The type code for the drive unit arg in drive module arg is not recognised by the system. Installed drive unit type is arg, and the configured type is arg. 39415, Communication with the Drive Unit Lost Consequences Description No operation will be possible until after correcting the fault. The system goes to status SYS HALT. Communication with drive unit number arg in drive module arg has been lost. Probable causes Consequences The connection to the drive unit may be bad or the hardware may be faulty. No operation will be possible until after correcting the fault. The system goes to status SYS HALT. Recommended actions Probable causes 1) Make sure the cable connections on the drive unit are correct. There may be a break in the communication link cable between the axis computer and the main drive unit, the drive module may be incorrectly grounded or excessive noise may interfere with the communication signals. 2) Make sure the drive unit is one supported by this controller. 3) If the drive unit was recently replaced, make sure a unit of the correct type code is used. Recommended actions 39419, Unknown Rectifier type code 1) Check the communication link cable between the axis computer and the main drive unit is correctly connected. Description 2) Check that the module is properly grounded. The type code for the rectifier unit arg in drive module arg is not recognised by the system. Installed rectifier unit type is arg, and the configured type is arg. 3) Check for external electromagnetic noise sources close to the drive module.. Consequences 39416, Drive Unit Not Responding No operation will be possible until after correcting the fault. The system goes to status SYS HALT. Description The main drive unit in drive module arg is not responding. Probable causes Consequences The connection to the drive unit may be bad or the hardware may be faulty. No operation will be possible until after correcting the fault. The system goes to status SYS HALT. Recommended actions 1) Make sure the cable connections on the rectifier unit unit are correct. Probable causes 2) Make sure the rectifier unit is one supported by this controller. There may be a break in the communication link cable between the axis computer and the main drive unit, or there may be a lock-up in the software. 3) If the rectifier unit was recently replaced, make sure a unit of the correct type code is used. Recommended actions 1) Check the communication link cable between the axis computer and the main drive unit is correctly connected. 3HAC020738-001 - 155 3 Symptoms 39420, Drive Unit built in test failure 39423, Drive Unit Internal Warning Description Description Drive unit number arg in drive module arg has detected an internal hardware failure. Internal measurement warning for drive unit number arg in drive module arg. Consequences Consequences No operation will be possible until after correcting the fault. The system goes to status SYS HALT. No operation will be possible until after correcting the fault. The system goes to status SYS HALT. Probable causes Probable causes The test software is not working correctly, or the actual hardware is faulty. There may be problems with the control cable, the DC link connection (bus bar or cable) or internal hardware. Recommended actions Recommended actions 1) Perform a shutdown and then restart the system. 1) Check the control cables and DC link connection (bus bar or cable) are correctly inserted for this unit. 2) If the problem persists, isolate the faulty drive unit and replace it. 2) Restart the system. 39421, Drive Unit configuration test failure 39424, Drive Unit internal error Description Description Drive unit number arg in drive module arg has detected an internal error. Internal measurement warning for drive unit number arg in drive module arg. Consequences Consequences No operation will be possible until after correcting the fault. The system goes to status SYS HALT. No operation will be possible until after correcting the fault. The system goes to status SYS HALT. Probable causes Probable causes The connection to the drive unit may be bad or incorrect hardware may have been fitted. The connection to the drive unit may be bad or incorrect hardware may have been fitted. It may also be caused by faulty control cable, DC link connection (bus bar or cable) or internal hardware. Recommended actions 1) Perform a shutdown and then restart the system. Recommended actions 2) If the problem persists, isolate the faulty drive unit and replace it. 1) Make sure the control cables and DC link connection (bus bar or cable) are correctly connected for this unit. 39422, Drive Unit watchdog timeout 2) Perform a shutdown and then restart the system. Description 3) If the problem persists, isolate the faulty unit and replace it. The time limit for watchdog timer for drive unit number arg in drive module arg has expired. 39425, Drive Unit measurement failure Consequences Description No operation will be possible until after correcting the fault. The system goes to status SYS HALT. A current measurement circuit in drive unit number arg, drive module arg, attached to joint arg has failed. Probable causes Consequences The connection to the drive unit may be bad or incorrect hardware may have been fitted. It may also be caused by an internal error in the drive unit. No operation will be possible until after correcting the fault. The system goes to status SYS HALT. Probable causes Recommended actions This may be caused by a faulty or lacking DC link connection between the rectifier and drive units. 1) Perform a shutdown and then restart the system. 2) If the problem persists, isolate the faulty drive unit and replace it. Recommended actions 1) Make sure the DC link connection (bus bar or cable) is correctly connected between the rectifier and drive unit. 2) Check the indication LEDs on the rectifier and drive units. The significance of the LEDs is described in the Trouble Shooting Manual. 156 - 3HAC020738-001 3 Symptoms 39426, Rectifier internal failure 39431, Update of Drive Unit Software in Progress Description The rectifier on communication link arg attached to drive module arghas detected an internal failure. Description Consequences Please wait for the upgrade to be completed. This will take approximately 3.5 minutes. The drive unit software in drive module arg is being updated. No operation will be possible until after correcting the fault. The system goes to status SYS HALT. NOTE: Please do not turn off the power or restart the controller until the download is complete. Probable causes Recommended actions This may be caused by a faulty or lacking signal connection between the rectifier and drive units. Please wait... Recommended actions 39432, Incompatible boot version in drive unit 1) Make sure the signal cable is correctly connected between the rectifier and drive unit. Description 2) Check the indication LEDs on the rectifier and drive units. The significance of the LEDs is described in the Trouble Shooting Manual. The boot version in drive module arg is version arg, which is not allowed. The latest allowed boot version is arg. Consequences 39427, Rectifier communication missing No operation will be possible until after correcting the fault. The system goes to status SYS HALT. Description The communication with the rectifier on drive comm link arg, drive module arg has been lost. Probable causes The boot version is not compatible with the hardware version. Consequences Recommended actions No operation will be possible until after correcting the fault. The system goes to status SYS HALT. 1) Replace the drive unit with one using a boot version equal to or greater than the latest allowed one. Probable causes 39434, Drive Unit Start Failure This may be caused by a faulty or lacking signal connection between the rectifier and drive units. Description Recommended actions The drive unit in drive module arg failed to start. drive boot status = arg. drive dsp1 status = arg 1) Make sure the signal cable is correctly connected between the rectifier and drive unit. 2) Perform a shutdown and then restart the system. Consequences 3) If the problem persists, isolate the faulty rectifier unit and replace it. The robot can not be operated. Probable causes 39428, Rectifier startup error A number of errors may cause this. Description Recommended actions The rectifier on drive comm link arg, drive module arg has detected a startup error. 1) Switch the main power off to the module and then switch it back on. Note that a normal restart will NOT suffice! 2) If the problem persists, replace the drive unit. Consequences No operation will be possible until after correcting the fault. The system goes to status SYS HALT. 39440, Open circuit in bleeder resistor circuit Probable causes Description This may be caused by an internal error in the rectifier unit. The bleeder resistor connected to the rectifier on drive link arg, drive module arg, is an open circuit. Recommended actions Consequences 1) Make sure the signal cable is correctly connected between the rectifier and drive unit. No operation will be possible until after correcting the fault. The system goes to status SYS HALT. 2) Perform a shutdown and then restart the system. 3) If the problem persists, isolate the faulty rectifier unit and replace it. 3HAC020738-001 - 157 3 Symptoms Probable causes Consequences This may be caused by a faulty bleeder resistor cable or bleeder resistor. No operation will be possible until after correcting the fault. The system goes to status SYS HALT. Recommended actions Probable causes 1) Make sure the bleeder resistor cable is correctly connected to the rectifier unit. The user program may contain too much hard braking of the manipulators, which is more likely if the system contains external axes. 2) Make sure the cable and resistor is working correctly by measuring their resistance respectively. Disconnect before measuring. Recommended actions 3) Replace any faulty component. 1) Rewrite the user program to reduce the amount of hard braking. 39441, Short circuit in bleeder resistor circuit 39444, Bleeder Resistor Overload at Critical Description Description The bleeder resistor connected to the rectifier on drive link arg, drive module arg, is a short circuit. The bleeder resistors have been overloaded for the rectifier on drive communication link arg, drive module arg. Consequences Consequences No operation will be possible until after correcting the fault. The system goes to status SYS HALT. No operation will be possible until after correcting the fault. The system goes to status SYS HALT. Probable causes Probable causes This may be caused by a faulty bleeder resistor cable or bleeder resistor. The user program may contain too much hard braking of the manipulators, which is more likely if the system contains external axes. Recommended actions 1) Make sure the bleeder resistor cable is correctly connected to the rectifier unit. Recommended actions 1) Rewrite the user program to reduce the amount of hard braking.. 2) Make sure the cable and resistor is working correctly by measuring their resistance respectively. Disconnect before measuring. 39450, Faulty Fan Unit Power Supply 3) Replace any faulty component. Description 39442, Bleeder Resistance Too Low The power supply for the fan unit in drive module arg is not within its allowed voltage limits. Description The bleeder resistance is too low for the rectifier on drive comm link arg, drive module arg. Consequences Consequences Probable causes No operation will be possible until after correcting the fault. The system goes to status SYS HALT. The main fan power supply unit may be faulty or the supply to this power supply unit may not be within its allowed voltage limits. Probable causes Recommended actions The bleeders may have the wrong resistance value or one of the bleeders may have failed, causing a short circuit. 1) Check the fan cable is correctly inserted. - 2) Check that all fans are working. 3) Check the input voltage to the main fan power supply unit. Replace any faulty unit. Recommended actions 1) Check the bleeder resistors to see that they are the correct resistance value for this drive module configuration. 39451, Fan Unit Malfunction 2) Check that none of the resistors have failed. How to check the configuration file is detailed in the Trouble Shooting Manual. Description The fan unit in drive module arg has malfunctioned. 39443, Bleeder Resistor Overload Warning Consequences - Description Probable causes The power consumed by the bleeder resistors is approaching overload for the rectifier on drive communication link arg, drive module arg. 158 The fan unit may be faulty, a loss of power supply or the fan power cable may not be connected correctly. - 3HAC020738-001 3 Symptoms Recommended actions 39461, DC Link Voltage Too High 1) Make sure the fan cable is correctly connected. 2) Make sure all fans are working and that air flow is not obstructed. Description 3) Measure the output voltage from the drive unit supplying the fan. Replace any faulty unit. The DC link voltage is too high for the rectifier on drive communication link arg, drive module arg. Consequences 39452, Axis Computer Cooling Fan Malfunction No operation will be possible until after correcting the fault. The system goes to status SYS HALT. Description Probable causes The cooling fan above the axis computer in drive module arg has malfunctioned. This can occur if the fan has failed or if the cable between the fan and the contactor board is not inserted correctly. The user program may contain too much hard braking of the manipulators, which is more likely if the system contains external axes. The brake resistors may also be faulty. Recommended actions Recommended actions Check that the fan cable is correctly inserted. If this does not help and the fan is not turning then replace the fan. 1) Check the bleeder resistors to see that they are the correct resistance value for this drive module configuration. 2) Check that none of the resistors have failed. 3) If possible, rewrite the user program to reduce the amount of hard braking. 39453, Transformer Cooling Fan Malfunction Description 39462, DC Link Voltage at Critical The cooling fan for the transformer supplying drive module arg has malfunctioned. Description Recommended actions The DC link voltage is critically high for the rectifier on drive communication link arg, drive module arg. Check to see that the transformer fan cable is correctly inserted in the contactor board. Consequences If the cable is ok and the fan has stopped then replace the fan unit. No operation will be possible until after correcting the fault. The system goes to status SYS HALT. 39460, DC Link Voltage Too Low Probable causes Description The DC link voltage is too low for the rectifier on drive communication link arg, drive module arg. The user program may contain too much hard braking of the manipulators, which is more likely if the system contains external axes. The brake resistors may also be faulty. Consequences Recommended actions No operation will be possible until after correcting the fault. The system goes to status SYS HALT. 1) Check the bleeder resistors to see that they are the correct resistance value for this drive module configuration. Probable causes 2) Check that none of the resistors have failed. The DC link bus bar may be incorrectly connected or the three-phase mains power may be interrupted while the robot is in the Motors ON state. The mains contactor may also have been opened whilst the robot is in Motors ON state (breaking the safety chain). The incoming main power supply may also be too low. 3) Rewrite the user program to reduce the amount of hard braking. Recommended actions A brief short circuit was detected in the motor/motor cable for the motor attached to joint arg in drive module arg. 39463, Motor Phase Short Circuit Warning Description 1) Make sure the DC link bus bar is correctly connected. 2) Make sure the mains supply has not been interrupted. Consequences 3) Make sure the safety chain has not been broken. - 4) Make sure the Drive Module Power Supply output voltage is within acceptable limits as specified in the Product Manual. Probable causes This may be due to dust or metal fragments contaminating the contacts or motor windings. Recommended actions No action is required if the problem does not persist. 3HAC020738-001 - 159 3 Symptoms 3) If the axis is an external axis, check that the motor load is not too high for the drive unit. 39464, Short circuit in Motor phase circuit Description 39467, Drive Unit Temperature Warning The motor or motor cable for joint arg in drive module arg, drive unit number arg, is a short circuit. Description Consequences No operation will be possible until after correcting the fault. The system goes to status SYS HALT. The temperature has risen above the warning level in drive unit number arg, drive module arg, which is the lowest abnormal level of three. Probable causes Consequences This may be caused by a faulty motor or motor cable. It may also be caused by contamination in the contactors for the cables or a failure of the motor windings. Probable causes 1) Make sure the motor cable is correctly connected to the drive unit. The ambient temperature may be too high, the cooling fans may have failed or the user program may consume more current than the drive system can supply. 2) Check the cable and motor by measuring their resistance respectively. Disconnect before measuring. Recommended actions 3) Replace any faulty component. 1) Check that the fans are running and that the air flow is not obstructed. 39465, Motor Current Warning 2) Check that the ambient temperature does not exceed the cabinet rating. Description 3) If the system contains external axes then check that motors are not too large for the drive units. Recommended actions The motor current is too high for joint arg in drive module arg, drive unit number arg. 4) If possible, rewrite the user program to reduce the amount of hard acceleration. Consequences - 39468, Drive Unit Temperature Alarm Probable causes Description The motor load may be too high or the motor may have stalled (maybe due to a collision). The temperature has risen above the alarm level in drive unit number arg, drive module arg, which is the second abnormal level of three. Recommended actions Consequences 1) Check that the robot has not collided with anything. 2) If possible, reduce the speed of the user program. No operation will be possible until after correcting the fault. The system goes to status SYS HALT. 3) If the axis is an external axis, check that the motor load is not too high for the drive unit. Probable causes The ambient temperature may be too high, the cooling fans may have failed or the user program may consume more current than the drive system can supply. 39466, Motor Current Overload Description Recommended actions The motor current is too high for joint arg in drive module arg, drive unit number arg. 1) Check that the fans are running and that the air flow is not obstructed. Consequences 2) Check that the ambient temperature does not exceed the cabinet rating. No operation will be possible until after correcting the fault. The system goes to status SYS HALT. 3) If the system contains external axes then check that motors are not too large for the drive units. Probable causes 4) If possible, rewrite the user program to reduce the amount of hard acceleration. The motor load may be too high or the motor may have stalled (maybe due to a collision). 39469, Drive Unit Temperature Critical Recommended actions 1) Check that the robot has not collided. Description 2) If possible, reduce the speed of the user program. 160 The temperature has risen above the critical level in drive unit number arg, drive module arg, which is the top abnormal level of three. - 3HAC020738-001 3 Symptoms Consequences Recommended actions No operation will be possible until after correcting the fault. The system goes to status SYS HALT. 1) Check that the robot has not collided. 2) Check that the fans are running and that the air flow is not obstructed. Probable causes 3) Check that the ambient temperature does not exceed the cabinet rating. The ambient temperature may be too high, the cooling fans may have failed or the user program may consume more current than the drive system can supply. 4) If the system contains external axes then check that motors are not too large for the drive units. Recommended actions 5) If possible, rewrite the user program to reduce the amount of hard acceleration. 1) Check that the fans are running and that the air flow is not obstructed. 2) Check that the ambient temperature does not exceed the cabinet rating. 39472, Incoming mains phase missing 3) If the system contains external axes then check that motors are not too large for the drive units. Description The rectifier connected to communication link arg in drive module arg detects a power loss in one phase. 4) If possible, rewrite the user program to reduce the amount of hard acceleration. Consequences 39470, Power Semiconductor Warning No operation will be possible until after correcting the fault. The system goes to status SYS HALT. Description Probable causes The power seminconductor is approaching overload for joint arg, in drive unit number arg, drive module arg . This may be caused by an actual mains power loss, some malfunction in the Motors ON contactors or its cabling. On rare occasions, this fault may occur in combination with other faults, in which case this may be found in the error log. Consequences - Recommended actions Probable causes 1) Measure the incoming three-phase voltage on the main contactor in the drive module. No voltage means the fault may be in the factory power supply. The motor load may be too high, the motor may have stalled (maybe due to a collision), the motor load may be too high or there may not be enough cooling. 2) If the voltage is OK, measure the three-phase voltage on the rectifier input. No voltage means the fault may be in the wiring to the rectifier. Recommended actions 3) Check the indication LEDs on the rectifier unit. The significance of these is described in the Tropuble Shooting Manual. 1) Check that the robot has not collided. 2) Check that the fans are running and that the air flow is not obstructed. 4) If the voltage is OK, check any other error log messages coinciding in time with this one for clues. 3) Check that the ambient temperature does not exceed the cabinet rating. 39473, All incoming mains phases missing 4) If the system contains external axes then check that motors are not too large for the drive units. Description 5) If possible, rewrite the user program to reduce the amount of hard acceleration. The rectifier connected to communication link arg in drive module arg detects a power loss in one or more phases. 39471, Power Semiconductor Overload Error Consequences Description No operation will be possible until after correcting the fault. The system goes to status SYS HALT. The power seminconductor has been overloaded for joint arg, in drive unit number arg, drive module arg . Probable causes No operation will be possible until after correcting the fault. The system goes to status SYS HALT. This may be caused by an actual mains power loss, some malfunction in the Motors ON contactors or its cabling. On rare occasions, this fault may occur in combination with other faults, in which case this may be found in the error log. Probable causes Recommended actions The motor load may be too high, the motor may have stalled (maybe due to a collision), the motor load may be too high or there may not be enough cooling. 1) Measure the incoming three-phase voltage on the main contactor in the drive module. No voltage means the fault may be in the factory power supply. Consequences 3HAC020738-001 - 161 3 Symptoms 2) If the voltage is OK, measure the three-phase voltage on the rectifier input. No voltage means the fault may be in the wiring to the rectifier. Recommended actions 1) Check that the fans are running and that the air flow is not obstructed. 3) Check the rectifier LEDs. The significance of these is described in the Tropuble Shooting Manual. 2) Check that the ambient temperature does not exceed the cabinet rating. 4) If the voltage is OK, check any other error log messages coinciding in time with this one for clues. 3) If the system contains external axes then check that motors are not too large for the drive units. 39474, Rectifier Current Warning 4) If possible, rewrite the user program to reduce the amount of hard acceleration. Description The rectifier connected to drive communication link arg in drive module arg is approaching overload. 39477, Rectifier Temperature Error Description Consequences The temperature in the rectifier unit connected to drive communication link arg in drive module arg has reached a too high a level. No operation will be possible until after correcting the fault. The system goes to status SYS HALT. Consequences Probable causes The total motor current may be greater than that which the rectifier can supply. No operation will be possible until after correcting the fault. The system goes to status SYS HALT. Recommended actions Probable causes 1) If possible, rewrite the user program to reduce the amount of hard acceleration. The cooling fans may be faulty or the air flow may be obstructed. The ambient temperature may be too high or the system may be running with a too high load for extended periods. 39475, Rectifier Current Error Recommended actions Description 1) Check that the fans are running and that the air flow is not obstructed. The rectifier connected to drive communication link arg in drive module arg has reached overload. 2) Check that the ambient temperature does not exceed the cabinet rating. Consequences 3) If the system contains external axes then check that motors are not too large for the drive units. No operation will be possible until after correcting the fault. The system goes to status SYS HALT. 4) If possible, rewrite the user program to reduce the amount of hard acceleration. Probable causes The total motor current may be greater than that which the rectifier can supply. 39478, Internal Motor PTC Temperature Error Description Recommended actions The temperature in one or more robot motors connected to drive module arg is has reached a too high a level. 1) If possible, rewrite the user program to reduce the amount of hard acceleration. Consequences No operation will be possible until after correcting the fault. The system goes to status SYS HALT. 39476, Rectifier Temperature Warning Description Probable causes The temperature in the rectifier unit connected to drive communication link arg in drive module arg is approaching a too high a level. The motor may have stalled (possibly due to a collision), the motor may be overloaded or the ambient temperature may be higher than the rated level for the robot. Consequences No operation will be possible until after correcting the fault. The system goes to status SYS HALT. Recommended actions Probable causes 2) Check that the ambient temperature does not excced the robot rating. 1) Check that the robot has not collided. The cooling fans may be faulty or the air flow may be obstructed. The ambient temperature may be too high or the system may be running with a too high load for extended periods. 3) Allow the robot to cool down, and then run the system again. Replace any motors damaged by the excessive heat. 4) If possible, rewrite the user program to reduce the amount of hard acceleration. 162 - 3HAC020738-001 3 Symptoms 39479, External Motor PTC Temperature Error 39500, Logic Voltage to Drive Unit Warning Description Description One or more external axis motors connected to drive module arg is has reached a too high a level. The 24V supply from the Drive Module Power Supply to the main drive unit in drive module arg is out of range. Consequences Consequences No operation will be possible until after correcting the fault. The system goes to status SYS HALT. - Probable causes The 24V supply from the Drive Module Power Supply may be out of range. Probable causes The motor may have stalled (possibly due to a collision), the motor may be overloaded or the ambient temperature may be higher than the rated level for the robot. Recommended actions 1) Make sure the power cable from the Drive Module Power Supply to the main drive unit is connected correctly. Recommended actions 1) Check that the external axis has not collided. 2) Check if the power supply unit LED is red. The full meaning of all LED indications are described in the Trouble Shooting Manual, IRC5. 2) Check that the ambient temperature does not exceed the rating. 3) Allow the motor to cool down, and then run the system again. Replace any motors damaged by the excessive heat. 39501, Logic Voltage to Drive Unit Error 4) If possible, rewrite the user program to reduce the amount of hard acceleration. Description 39482, Mains Voltage Too High The 24V supply to the main drive unit in drive module arg is out of range. Consequences Description No operation will be possible until after correcting the fault. The system goes to status SYS HALT. The mains voltage detected in drive module arg is too high. Consequences Probable causes The robot can not be operated. The 24V supply from the power supply unit may be out of range. Probable causes Recommended actions The mains transformer may be incorrectly wired or the external supply voltage may be too high. 1) Make sure the power cable from the power supply unit to the main drive unit is connected correctly. Recommended actions 2) Check if the power supply unit LED is red. The full meaning of all LED indications are described in the Trouble Shooting Manual, IRC5. 1) Measure the incoming mains voltage at the main contactor in the drive module. Make sure it is within the range specified for this module. 39502, Logic Voltage to Rectifier Error 2) Check the wiring of the mains transformer as detailed in the robot Product Manual. Description The 24V to the rectifier in drive module arg is out of range. 39483, DC Link Short Circuit Consequences Description - A short circuit has been detected on the DC link of drive module arg. Probable causes Consequences The cable between the drive unit and the rectifier may be badly connected, or the power supply voltage to the drive unit may be out of range. The robot can not be operated. Probable causes Recommended actions The DC bus bar may be badly connected or its contact surfaces may be contaminated causing a short circuit. 1) Check that the power cable between the power supply unit and the rectifier unit has been connected correctly. Recommended actions 2) Check the 24 V voltage in the power cable to the drive unit.. 1) Check that all DC link bus bars have been correctly connected. 2) Check that all contacts are free from contamination. 3HAC020738-001 - 163 3 Symptoms Consequences 39503, Power Supply Overtemperature No operation will be possible until after correcting the fault. The system goes to status SYS FAIL. Description The temperature in the Drive Module Power Supply of drive module arg has reached a critical level. Probable causes The main power switch on the Drive Module may be turned off. The incoming mains cable may be faulty (break), or the circuit breaker for the power supply may have tripped. The fault may also occur if the connector from the power supply unit is not correctly connected to the axis computer. Consequences No operation will be possible until after correcting the fault. The system goes to status SYS HALT. Probable causes Recommended actions The fan unit may be faulty, the cooling air flow may be obstructed or the ambient temperature may be too high. 1) Check that the main power switch in turned on for the Drive Module and restart the system. Recommended actions 2) Check that the connector from the power supply unit is correctly connected to the axis computer. 1) NOTE! Do not try to restart the controller for approx. ten minutes to let it cool down. 3) Measure the voltage at the mains contactor to ensure that the mains is present. 2) Make sure the fans are running and that the air flow is not obstructed. 4) Check that the power supply fuses/circuit breakers in the drive module have not tripped. 3) Make sure the ambient temperature does not exceed the drive module rating. 4) Make sure the power supply connectors are correctly connected to the axis computer. 39520, Communication lost with Drive Module Description 39504, Power Supply to Brakes Overload The main computer has lost contact with drive module arg. Description Consequences The brake power circuit in drive module arg draws too much current. The system goes to status SYS HALT No operation will be possible until the fault has been corrected. Consequences Probable causes No operation will be possible until after correcting the fault. The system goes to status SYS HALT. This may be due to a cable break, badly connected connector or high levels of interference in the cable. Probable causes Recommended actions The brake power cable may be faulty (short circuit), or external axis motors with brakes consuming too much power may be used. The fault may also occur if the cable from the power supply unit is not correctly connected to the drive module. 1) Make sure the cable between Control Module and Drive Module is not damaged and that both connectors are correctly connected. 2) Make sure no extreme levels of electromagnetic interference are emitted close to the robot cabling. Recommended actions 1) Make sure the power supply cable is correctly connected to the drive module. 39521, Drive Module Communication Warning 2) Check the brake supply cable for short circuits. Description 3) Make sure the total current consumed by external axes' motors does not exceed the specification for the drive module. There are a large number of communication errors being detected on the ethernet link to drive module arg. 4) Make sure the power supply connectors are correctly connected to the axis computer. This can be due to external noise sources interfering with the cable. Recommended actions 5) Make sure the 24 V BRAKE voltage is within specified limits. See the Circuit Diagram in the Product Manual, IRC5. Check that there are no electromagnetic interference sources running near the cable or the drive or computer modules. 39505, Mains Voltage to Power Supply Lost 39522, Axis computer not found Description Description The mains power supply to the power supply unit in Drive Module arg is missing. 164 The axis computer in drive module arg is not connected to the main computer. - 3HAC020738-001 3 Symptoms Consequences Probable causes The system goes to status SYS FAIL. No operation will be possible until the fault has been corrected. Probable causes This may be due to faulty communication cable between axis computer and contactor interface board or it's connectors. It may also be due to severe interference or if the contactor interface board has lost it's power supply. This may be due to a cable break, badly connected connectors or loss of power supply. Recommended actions Recommended actions 1) Make sure the cable between the axis computer and the contactor interface board is intact and correctly connected. 1) Make sure the main power switch on Drive Module arg has been switched ON. 2) Make sure the Drive Module Power Supply is supplying the contactor interface board correctly. 2) Make sure the cable between Control Module and Drive Module is not damaged and that both connectors are correctly connected. 3) Make sure no extreme levels of electromagnetic interference are emitted close to the robot cabling. 3) Make sure the cable is connected to the correct AXC connector on the Main Computer Unit Robot Communication Card or EtherNet Board (if the MultiMove option has been installed). 4) If the system went to status SYS FAIL, it will require being restarted after the fault has been fixed. 4) Restart the system. 40001, Argument error 5) Make sure the Power Supply Unit in Drive Module arg is working correctly. Description 39523, Unused Axis computer connected The optional argument arg has been used more than once in the same routine call. Description Recommended actions Axis computer in the drive module arg is connected to the main computer but not in use. 1) Make sure the optional parameter is not used more than once in the same routine call. Probable causes 40002, Argument error This can be due to configuration problem. Description Recommended actions The argument arg has been specified for more than one parameter. 1. Disconnect the unused axis computer or setup the system to use the axis computer. Recommended actions 2. Restart the system. The parameter list, from which the parameter is selected, contains parameters mutually exclusive. 39524, Drive Module Command timeout 1) Make sure the argument is used for one parameter only. Description 40003, Argument error Drive Module arg does not respond to command arg. The system has stopped the program for safety reasons. Description An argument for the required parameter arg was expected, but the optional argument arg was found. Recommended actions 1. Check that drive module is powered on. 2. Check the cable between the main computer and axis computer. Recommended actions 3. Restart the system. 1) Make sure all arguments are specified in the same order as the parameters for the routine called. 39530, Communication with Contactor Interface Board Lost 40004, Argument error Description Description Communication has been lost between axis computer and contactor interface board in drive module arg. The argument for REF parameter arg is not a data reference. Consequences 1) Make sure the argument is a data or a parameter reference. Recommended actions If the problem is detected at startup, the system goes to status SYS FAIL. If it is detected during operation, the system goes to SYS HALT. 3HAC020738-001 - 165 3 Symptoms 40005, Argument error 40010, Argument error Description Description The argument for INOUT parameter arg is not a variable or persistent reference, or it is read-only. A reference to the required parameter arg in an optional argument is missing. Recommended actions Recommended actions 1) Make sure the argument is a variable or a persistent variable parameter or a persistent parameter reference and that it is NOT readonly. Each required parameter must have a reference argument, specified with a leading backslash character (\). 1) Change the optional argument into a required argument. 2) Also make sure the argument is NOT written within brackets (). 40011, Argument error 40006, Argument error Description Description Parameter arg is missing an optional argument value. The required argument arg is not found in its correct position in the argument list. Recommended actions Recommended actions The only parameters which may be specified by a name only are "switch" parameters. All others must be assigned a value. Make sure all arguments are specified in the same order as the parameters for the routine called. 1) Make sure parameter has a value. 40012, Argument error 40007, Argument error Description Description The "switch" argument arg has a value. The optional argument arg is not found in its correct position in the argument list. Probable causes An argument corresponding to a "switch" parameter may not be assigned a value. Recommended actions 1) Make sure all arguments are specified in the same order as the parameters for the routine called. Recommended actions 1) Remove the value. 40008, Argument error 40013, Argument error Description Description A reference to the optional parameter arg is missing. The call to routine arg has too few arguments. Recommended actions Recommended actions Each optional parameter must have a reference argument, specified with a leading backslash character (\). A routine call must supply values for all required parameters of the routine being called. The argument list must have as many arguments, as the parameter list has parameters. 1) Change the required argument into an optional argument. 1) Add more arguments to fit the parameter list. 40009, Argument error Description 40014, Argument error A reference to the required parameter arg in a conditional argument is missing. Description The call to routine arg has too many arguments. Recommended actions Recommended actions Each conditional value for an optional parameter must refer to an optional parameter in the calling routine. No arguments, more than those defined by the called routine parameter list, must be supplied. The argument list must have as many arguments, as the parameter list has parameters. 1) Change the conditional value. 1) Remove excessive arguments from the argument list. 166 - 3HAC020738-001 3 Symptoms Recommended actions 40015, Data declaration error Any expression contained within a data declaration must be a constant expression. Description The number of array dimensions is arg, but may be 1, 2 or 3 only. 1) Make sure no expression contains variables or persistent references, or function calls. Recommended actions 1) Change the dimension expression. 40021, Instruction error 40016, Data declaration error Description Missing expression in RETURN instruction. Description Too many Probable causes dimensions in array definition A RETURN instruction within a function must specify a value to be returned. Recommended actions Recommended actions An array may have at most 3 dimensions. 1) Add a value expression. Rewrite the program so that no more than 3 dimensions are needed. 40022, Type error 40017, Type error Description Description Illegal combination of operand types arg and arg for the '*' operator. Indexed data argarg is not of array type. Recommended actions Recommended actions Allowed operand type combinations are: "num"*"num", "num"*"pos", "pos"*"num", "pos"*"pos" and "orient"*"orient". Only data that have been declared to be arrays may be indexed. 1) Check the operand types. 1) Remove the index or indices. 2) Declare the data to be an array. 40023, Instruction error 40018, Type error Description Cannot transfer control into another instruction list. Description Recommended actions Data argarg is not of record type. It is not possible to jump into a program flow instruction. Recommended actions 1) Make sure that the label is located in the same instruction list as the GOTO instruction, at the same or an outer level. Components are only available for data of record type. 1) Check the type and name of the referenced data. 40024, Type error 40019, Limit error Description Description Illegal type arg for left operand of binary '+' or '-' operator. Error when creating the persistent variable arg (internal error code arg). Recommended actions Recommended actions Allowed operand types for the binary "+" operator are "num", "pos" and "string", and for the binary "-" operator "num" and "pos". An error occurred when the persistent variable was to be inserted into the shared database. Probably the database is full. 1) Check the operand types. 1) Increase the value for the System Parameter: AveragePers. 40025, Type error 40020, Data declaration error Description Illegal type arg for operand of unary '+' or '-' operator. Description Recommended actions Expression arg is not a constant expression. Allowed operand types for the unary "+" and "-" operators are "num" and "pos". 3HAC020738-001 - 167 3 Symptoms 1) Check the operand types. Recommended actions 40026, Type error Allowed operand types for the "*" operator are "num", "pos" or "orient". 1) Check the operand types. Description Illegal type arg for right operand of binary '+' or '-' operator. 40032, Type error Recommended actions Description Allowed operand types for the binary "+" operator are "num", "pos" and "string", and for the binary "-" operator "num" and "pos". Illegal type arg for right operand of '*' operator. 1) Check the operand types. Recommended actions 40027, Type error Allowed operand types for the "*" operator are "num", "pos" or "orient". 1) Check the operand types. Description Illegal type arg for left operand of '/', 'DIV' or 'MOD' operator. 40033, Type error Recommended actions Description Allowed operand type for the "/", "DIV" or "MOD" operators is "num". Illegal type arg for operand of 'NOT' operator. 1) Check the operand types. Recommended actions Allowed operand type for the "NOT" operator is "bool". 40028, Type error 1) Check the operand types. Description 40034, Type error Illegal type arg for right operand of '/', 'DIV' or 'MOD' operator. Description Recommended actions Illegal type arg for left operand of 'OR', 'XOR' or 'AND' operator. Allowed operand type for the "/", "DIV" or "MOD" operators is "num". Recommended actions 1) Check the operand types. Allowed operand type for the "OR", "XOR" or "AND" operators is "bool". 40029, Type error 1) Check the operand types. Description 40035, Type error Illegal type arg for left operand of '<', '<=', '>' or '>=' operator. Description Recommended actions Illegal type arg for right operand of 'OR', 'XOR' or 'AND' operator. Allowed operand type for the "<", "<=", ">" or ">=" operators is "num". Recommended actions 1) Check the operand types. Allowed operand type for the "OR", "XOR" or "AND" operators is "bool". 40030, Type error 1) Check the operand types. Description 40036, Type error Illegal type arg for right operand of '<', '<=', '>' or '>=' operator. Description Recommended actions Incorrect number of indices in index list for array arg with arg dimension(s). Allowed operand type for the "<", "<=", ">" or ">=" operators is "num". 1) Check the operand types. Recommended actions 40031, Type error 1) Make sure that the number of indices in the index list corresponds to the number of dimensions of the indexed data array. Description Illegal type arg for left operand of '*' operator. 168 - 3HAC020738-001 3 Symptoms name arg ambiguous 40037, Data declaration error Recommended actions Description Global data must have names that are LOCAL illegal in unique among all the global types, data, routine constant declaration global routines and modules in the Recommended actions entire program. Rename the data Only program data declarations may have or change the conflicting name. the LOCAL attribute. Remove the LOCAL attribute or move the declaration 40042, Name error outside of the routine. Description Global routine 40038, Data declaration error name arg ambiguous Description Recommended actions LOCAL illegal in Global routines must have names that are routine variable declaration unique among all the global types, data, Recommended actions global routines and modules in the Only program data declarations may have entire program. Rename the routine the LOCAL attribute. Remove the LOCAL or change the conflicting name. attribute or move the declaration outside of the routine. 40043, Name error Description 40039, Name error Global variable Description name arg ambiguous Constant name Recommended actions arg ambiguous Global data must have names that are Recommended actions unique among all the global types, data, Routine data must have names that are global routines and modules in the unique within the routine. Program data entire program. Rename the data must have names that are unique within or change the conflicting name. the module. Rename the data or change the conflicting name. 40044, Name error Description 40040, Name error Label name Description arg ambiguous Global constant Recommended actions name arg ambiguous Labels must have names that are unique Recommended actions within the routine. Rename the label or Global data must have names that are change the conflicting name. unique among all the global types, data, global routines and modules in the 40045, Name error entire program. Rename the data Description or change the conflicting name. Module name arg ambiguous 40041, Name error Recommended actions Description Modules must have names that are unique Global persistent 3HAC020738-001 among all the global types, global data, - 169 3 Symptoms global routines and modules in the 40050, Type error entire program. Rename the module Description or change the conflicting name. Operand types arg and 40046, Name error arg for binary '+' or '-' Description operator not equal Parameter name Recommended actions arg ambiguous The two operands of the '+' and '-' Recommended actions operators must have equal type. Check Parameters must have names that are the operand types. unique within the routine. Rename the parameter or change the conflicting 40051, Type error name. Description Operand types 40047, Name error arg and Description arg for '=' or '<>' Persistent name operator not equal arg ambiguous Recommended actions Recommended actions The two operands of the '=' and '<>' Program data must have names that are operators must have equal type. Check unique within the module. Rename the the operand types. data or change the conflicting name. 40052, Instruction error 40048, Name error Description Description RETURN with Routine name expression only allowed in function arg ambiguous Recommended actions Recommended actions In a procedure or trap the RETURN Routines must have names that are unique instruction must not specify a return within the module. Rename the routine or value expression. Remove the expression. change the conflicting name. 40054, Type error 40049, Name error Description Description Different Variable name dimension of array type ( arg ) and arg ambiguous aggregate ( arg ) Recommended actions Recommended actions Routine data must have names that are Make sure that the number of expressions unique within the routine. Program data in the aggregate is the same as the must have names that are unique within dimension of the data array. the module. Rename the data or change the conflicting name. 40055, Type error Description Assignment target type arg is not value or 170 - 3HAC020738-001 3 Symptoms semi-value type 40059, Data declaration error Recommended actions Description The type, of the data to be assigned a Place holder for value, must be a value or semi-value value expression not allowed in type. Data of non-value types may only definition of named constant be set by special type specific Recommended actions predefined instructions or functions. Complete the data declaration or change the data name to a place holder. 40056, Type error Description 40060, Data declaration error Type arg for left operand of Description '=' or '<>' operator not value or Place holder for semi-value type array dimension not allowed in definition of named constant or variable Recommended actions The '=' and '<>' operators may only be Recommended actions applied to expressions of value or semi- Complete the data declaration or change value type. If comparisons are to be the data name to a place holder. made, special type specific predefined functions are needed. 40061, Routine declaration error Description 40057, Type error Place holder for Description parameter array dimensions not allowed Type in definition of named routine arg for right operand of Recommended actions '=' or '<>' operator not value or Complete the parameter declaration or semi-value type change the routine name to a place Recommended actions holder. The '=' and '<>' operators may only be applied to expressions of value or semi- 40062, Name error value type. If comparisons are to be made, special type specific predefined Description functions are needed. Place holder for parameter name not allowed in definition of named routine 40058, Type error Recommended actions Description Complete the routine declaration or TEST expression change the routine name to a place type arg not value or holder. semi-value type Recommended actions 40063, Data declaration error The TEST instruction may only be applied to an expression of value or semi-value Description type. If comparisons are to be made, Place holder for special type specific predefined initial value expression not allowed in functions are needed. definition of named persistent Recommended actions Complete the data declaration or change 3HAC020738-001 - 171 3 Symptoms the data name to a place holder. arg Recommended actions 40064, Routine declaration error Make sure that the number of expressions Description in the aggregate is the same as the Place holder for number of components in the record type. parameter not allowed in definition of named routine 40069, Reference error Recommended actions Description Complete the parameter declaration, Data reference remove the place holder or change the arg is ambiguous routine name to a place holder. Recommended actions At least one other object sharing the 40065, Reference error same name as the referred data is Description visible from this program position. Make Place holder for sure that all object names fulfill the type not allowed in definition of named naming rules regarding uniqueness. data, record component or routine 40070, Reference error Recommended actions Complete the data or routine declaration Description or change the data or routine name to a Function place holder. reference arg is ambiguous Recommended actions 40066, Data declaration error At least one other object sharing the Description same name as the referred function is Place holder for visible from this program position. Make initial value expression not allowed in sure that all object names fulfill the definition of named variable naming rules regarding uniqueness. Recommended actions 40071, Reference error Complete the data declaration or change the data name to a place holder. Description 40067, Type error arg is ambiguous Description Recommended actions Too few At least one other object sharing the components in record aggregate of type same name as the referred label is arg visible from this program position. Make Label reference sure that all object names fulfill the Recommended actions naming rules regarding uniqueness. Make sure that the number of expressions in the aggregate is the same as the 40072, Reference error number of components in the record type. Description Procedure 40068, Type error reference arg is ambiguous Description Recommended actions Too many At least one other object sharing the components in record aggregate of type same name as the referred procedure is 172 - 3HAC020738-001 3 Symptoms visible from this program position. Make 40077, Reference error sure that all object names fulfill the Description naming rules regarding uniqueness. arg not optional parameter reference in 40073, Reference error conditional argument value Description Recommended actions Trap reference The specified name identifies an object arg is ambiguous other than an optional parameter. Change Recommended actions the name to refer to an optional At least one other object sharing the parameter. same name as the referred trap is visible from this program position. Make 40078, Reference error sure that all object names fulfill the Description naming rules regarding uniqueness. arg 40074, Reference error not optional parameter reference Description Recommended actions arg The specified name identifies an object other than an optional parameter. Change not entire data reference the name to refer to an optional Recommended actions parameter. The specified name identifies an object other than data. Check if the desired 40079, Reference error data is hidden by some other object with Description the same name. Task arg: arg is not a procedure reference 40075, Reference error Recommended actions Description The specified name identifies an object other than a procedure. Check if the arg desired procedure is hidden by some not function reference other object with the same name. Recommended actions The specified name identifies an object 40080, Reference error other than a function. Check if the desired function is hidden by some other Description object with the same name. arg not required parameter reference 40076, Reference error Recommended actions Description The specified name identifies an object other than a required parameter. Change arg the name to refer to a required not label reference parameter. Recommended actions The specified name identifies an object 40081, Reference error other than a label. Check if the desired label is hidden by some other object Description with the same name. arg not trap reference 3HAC020738-001 - 173 3 Symptoms Recommended actions 40089, Reference error The specified name identifies an object other than a trap. Check if the desired Description trap is hidden by some other object with Reference to unknown record component the same name. arg 40082, Reference error Recommended actions The record type contains no record Description component with the specified name. arg not type name 40090, Reference error Recommended actions The specified name identifies an object Description other than a type. Check if the desired Reference to type is hidden by some other object with unknown required parameter the same name. arg Recommended actions 40083, Type error The called routine contains no required parameter (or other object) with the Description specified name. arg not value type 40092, Reference error Recommended actions Description Only variables which lack initial value, and 'VAR' mode parameters may be of Unknown type name semi-value or non-value type. arg Recommended actions 40086, Reference error No data type (or other object) with the specified name is visible from this Description program position. Reference to unknown label arg 40093, Instruction error Recommended actions The routine contains no label (or other Description object) with the specified name. Assignment target is read only 40087, Reference error Recommended actions The data to be assigned a value may not Description be a constant, read only variable or Reference to read only persistent. unknown optional parameter arg 40094, Data declaration error Recommended actions The called routine contains no optional Description parameter (or other object) with the Persistent specified name. declaration not allowed in routine Recommended actions Persistents may only be declared at module level. Move the persistent declaration from the routine. 174 - 3HAC020738-001 3 Symptoms 40095, Instruction error 40100, Parameter error Description Description RAISE without 'switch' only expression only allowed in error handler allowed for optional parameter Recommended actions Recommended actions Add an error number expression to the Change the parameter into an optional RAISE instruction. parameter, or change the data type of the parameter. If the object is not a parameter, change the data type. 40096, Instruction error Description 40101, Type error RETRY only Description allowed in error handler Type mismatch of Recommended actions expected type arg and The RETRY instruction may only be used found type arg in error handlers. Remove it. Recommended actions The expression is not of the expected 40097, Instruction error data type. Description TRYNEXT only 40102, Type error allowed in error handler Description Recommended actions Type mismatch of The TRYNEXT instruction may only be used aggregate, expected type in error handlers. Remove it. arg Recommended actions 40098, Parameter error The aggregate does not match the Description expected data type. 'switch' parameter must have transfer mode IN 40103, Type error Recommended actions Description Remove the parameter transfer mode Persistent specifier. If IN transfer mode is not argarg type sufficient, change the data type of the mismatch parameter. Recommended actions There is already a persistent data with 40099, Parameter error the same name but with another data Description type. Rename the persistent, or change 'switch' its data type. parameter cannot be dimensioned 40104, Data declaration error Recommended actions Remove the array dimension Description specification, or change the data type Cannot determine of the parameter. array dimensions (circular constant references ?) 3HAC020738-001 - 175 3 Symptoms Recommended actions type. Declare data with the desired data Check that any referred constants are type and aggregate value. Use the name correctly defined. If so, the program is of the data instead of the aggregate. too complex. Try to rewrite the 40109, Type definition error declarations. Description 40105, Data declaration error Cannot determine Description type of record component Cannot determine arg type of constant value (circular (circular type definitions?) constant references ?) Recommended actions Recommended actions Check that the type of the component is Check that any referred constants are correctly defined. If so, it could be correctly defined. If so, the program is a circular definition, the type of a too complex. Try to rewrite the component could not refer to the its declarations. own record type. 40106, Data declaration error 40110, Reference error Description Description Cannot evaluate Record name constant value expression (circular arg is ambiguous constant references ?) Recommended actions Recommended actions At least one other object sharing the Check that any referred constants are same name as the referred record name is correctly defined. If so, the program is visible from this program position. Make too complex. Try to rewrite the sure that all object names fulfill the declarations. naming rules regarding uniqueness. 40107, Data declaration error 40111, Name error Description Description Cannot determine Global record type of variable value (circular name arg ambiguous constant references?) Recommended actions Recommended actions Global type must have names that are Check that any referred constants are unique among all the global types, data, correctly defined. If so, the program is global routines and modules in the too complex. Try to rewrite the entire program. Rename the record declarations. or change the conflicting name. 40108, Type error 40112, Reference error Description Description Unknown aggregate Alias name type arg is ambiguous Recommended actions Recommended actions An aggregate may not be used in this At least one other object sharing the position since there is no expected data same name as the referred alias name is 176 - 3HAC020738-001 3 Symptoms visible from this program position. Make visible from this program position. Make sure that all object names fulfill the sure that all object names fulfill the naming rules regarding uniqueness. naming rules regarding uniqueness. 40113, Name error 40117, Type definition error Description Description Global alias Place holder for name arg ambiguous record component not allowed in definition of named record Recommended actions Global type must have names that are Recommended actions unique among all the global types, data, Complete the definition or change global routines and modules in the the data name to a place holder. entire program. Rename the alias or change the conflicting name. 40119, Reference error Description 40114, Type definition error Cannot use the semi-value type Description arg for record components Type reference Recommended actions of alias name arg is an alias type 40120, Reference error Recommended actions Check that the type of the component is Description correctly defined. If so, it could be Illegal reference a circular definition. The type of a to installed task object component could not refer to its arg from shared object own record type. Recommended actions Install the referred object shared, or 40115, Type definition error install the referring ReaL object/ archive or RAPID module in each task Description (not shared). Cannot determine type of alias arg (circular type definitions?) 40121, Reference error Recommended actions Description Check that the type of the alias is Cannot use semi-value type for arrays correctly defined. If so, it could be Recommended actions a circular definition, the type of an alias could not refer to a record that 40122, Reference error use this alias as a component. Description 40116, Reference error arg not procedure reference Description Recommended actions Record component name The specified name identifies an object other than a procedure. arg is ambiguous Check if the desired procedure is hidden by some other object with the same name. Recommended actions At least one other object sharing the same name as the referred component is 3HAC020738-001 - 177 3 Symptoms Recommended actions 40123, Argument error No data (or other object) with the specified name is visible from this Description program position. Argument for 'PERS' parameter arg is not a persistent reference or is read only 40129, Reference error Recommended actions Description Make sure the argument is just a persistent or persistent parameter reference and that it is writeable. Reference to unknown function arg Do not use () around the argument. Recommended actions 40124, Argument error No function (or other object) with the specified name is visible from this program position. Description 40130, Reference error Argument for 'VAR' parameter arg is not variable reference or is read only Description Recommended actions Reference to unknown procedure arg Make sure the argument is just a variable or variable parameter reference and and that it is writeable. Recommended actions Do not use () around the argument. No procedure (or other object) with the specified name is visible from this program position. 40125, Instruction error 40131, Reference error Description Description The Interrupt number is not static variable reference, or it is shared, or it is read only Reference to unknown trap arg Recommended actions Recommended actions No trap (or other object) with the specified name is visible from this program position. Make sure the interrupt number is just a variable or variable parameter reference. The variable must be static and not shared. The variable may not be read only. 40135, Syntax error. 40126, Value error Description Expected arg Description Recommended actions Integer value arg is too large Recommended actions 40136, Syntax error The value of the expression must be an integer value. The current value is outside the integer range. Description Unexpected arg 40127, Value error Recommended actions Description arg is not an integer value 40137, Syntax error Recommended actions Description The value of the expression must be an exact integer value. The current value has a fraction part. Expected arg but found arg Recommended actions 40128, Reference error 40138, Syntax error Description Reference to unknown entire data arg Description Syntax error, stack backed up 178 - 3HAC020738-001 3 Symptoms Recommended actions 40146, Not enough heap space. Description 40139, Syntax error There is not enough heap space to fulfil the action arg Description Recommended actions Syntax error, parsing terminated Rewrite your program Recommended actions 40147, Identifier is reserved word in current language 40140, Numerical value for symbol arg is out of range. Description Description The identifier arg is a reserved word in current language. Recommended actions Recommended actions Make the value smaller Change the name of the identifier 40141, String too long 40148, Identifier too long Description Description The string arg is too long. The name of the identifier arg is too long. Recommended actions Recommended actions Make the string shorter. Rename the identifier with a shorter name. 40142, TxId is out of range 40149, Placeholder too long Description Description The Text identifier arg is out of range. The placeholder arg is too long. Recommended actions Recommended actions Rename the placeholder with a shorter name. 40143, Aggregate is out of range 40150, Unexpected "unknown token Description Description The aggregate arg is out of range. Unexpected "unknown token. Recommended actions Recommended actions Make the aggregate smaller Remove the unknown token. 40144, Integer out of range 40155, Argument error Description Description The integer arg is out of range. Task arg : Argument for Recommended actions 'PERS' parameter arg is not Make the integer smaller. persistent reference or is read only Recommended actions 40145, Parser stack is full Make sure the argument Description is just a persistent or persistent The parser stack is full arg. parameter reference and and that it is writeable. Recommended actions Do not use () around the argument. Make smaller modules 3HAC020738-001 - 179 3 Symptoms Recommended actions 40156, Argument error Check for RAPID errors and correct the program. Description Task arg : Argument for 40161, Option is missing. 'VAR' parameter arg is not Description variable reference or is read only The instruction arg requires the option arg. Recommended actions Make sure the argument Consequences is just a variable or variable The program will not execute properly. parameter reference and and that Probable causes it is writeable. The system image doesn't include the required option. Do not use () around the argument. Recommended actions 40157, Instruction error Update the system image with the required option. Description 40165, Reference error Task arg : Interrupt number is not a static variable reference, Description is shared, or is read only. Task arg : Reference to Recommended actions unknown entire data arg Make sure the interrupt number is just a variable or variable parameter Recommended actions reference. The variable must be No data (or other object) with the static and not shared. The variable may specified name is visible from this not be read only. program position. 40158, Value error 40166, Reference error Description Description Task arg : Integer value Task arg : Reference to unknown function arg arg too large Recommended actions Recommended actions No function (or other object) with the The value of the expression must be an specified name is visible from this integer value. The current value is program position. outside the integer range. 40168, Reference error 40159, Value error Description Description Task arg : Reference to unknown procedure arg Task arg : arg not Recommended actions integer value No procedure (or other object) with the Recommended actions specified name is visible from this The value of the expression must be an program position. exact integer value. The current value 40170, Reference error has a fraction part. Description 40160, Task arg : Errors in RAPID program. Task arg : Reference to unknown trap arg Description Recommended actions There are errors in the RAPID program. No trap (or other object) with the specified name is visible from this 180 - 3HAC020738-001 3 Symptoms program position. 40191, Instruction error 40171, Reference error Description Task arg : Variable and trap Description routine already connected Task arg: Recommended actions Reference to unknown data (or other object) found during execution of module arg. It is not legal to connect a specific variable with a specific trap routine Recommended actions more than once. Check the program for unresolved references. 40192, Argument error 40172, Reference error Description Description Task arg : arg Task arg: is second present conditional argument Reference to unknown module arg. for excluding parameters Recommended actions Recommended actions No module (or other object) with the specified name is visible from this program position. Check the program for incorrect module reference or if the module is missing. Arguments may not be present for more than one parameter from a list of parameters that exclude each other. 40173, Reference error 40193, Execution error Description Description Task arg: Task arg : Late binding Reference to object arg that is not a module. procedure call error arg Recommended actions Recommended actions The specified name identifies an object other than a module. There is an error in the procedure call Check the program for incorrect module reference. instruction. See previous message for the actual cause. 40174, Reference error Description 40194, Value error Task arg: Description Reference to module arg is ambiguous. Task arg : Division by zero Recommended actions Recommended actions At least one other object sharing the same name as the referred module is visible from this program position. Make sure that all object names fulfill the naming rules regarding uniqueness. Cannot divide by 0. Rewrite the program so that the divide operation is not executed when the divisor is 0. 40175, Reference error 40195, Limit error Description Task arg: Description Reference to procedure arg is ambiguous. Task arg : The configured maximum Recommended actions number of RETRYs ( arg retries) At least one other object sharing the same name as the referred procedure is visible from this program position. Make sure that all object names fulfill the naming rules regarding uniqueness. is exceeded. Recommended actions The error correction performed before the RETRY instruction is executed, is 3HAC020738-001 - 181 3 Symptoms probably not enough to cure the error. numbers available. Rewrite the program Check the error handler. to use fewer interrupt numbers. This message may also occur as a consequence of a system error. 40196, Instruction error Description 40202, Type error Task arg : Attempt to Description execute place holder Task arg : Dimensions arg Recommended actions and arg of conformant array Remove the place holder or the dimension number arg are incompatible instruction containing it, or make the instruction complete. Then continue Recommended actions execution. The array is not of the expected size. Array assignment may only be performed on arrays of identical size. 40197, Execution error Description 40203, Reference error Task arg : Function does not Description return any value Task arg : Optional Recommended actions parameter arg not present The end of the function has been reached without a RETURN instruction being Recommended actions executed. Add a RETURN instruction The value of a non present optional specifying a function return value. parameter may not be referred. Use the predefined function 'Present' to check the presence of the parameter before 40198, Value error using its value. Description Task arg : Illegal 40204, Value error orientation value Description arg Task arg : Array index arg Recommended actions for dimension number arg out of bounds Attempt to use illegal orientation (1- arg ) (quaternion) value Recommended actions The array index value is non-positive or 40199, Value error violates the declared size of the array. Description Task arg : Illegal error number arg in arg. 40205, Value error Recommended actions Description Use error numbers in the range 1-90 or book error numbers with the instruction BookErrNo. Task arg : String too long Recommended actions 40200, Limit error String value exceeds the maximum allowed length. Rewrite the program to use Description strings of less length. Task arg : No more interrupt number available Recommended actions There is a limited number of interrupt 182 - 3HAC020738-001 3 Symptoms 40206, Interrupt queue full 40222, Limit error Description Description Task arg : Task arg : Execution stack To many interrupts occured while overflow executing a trap routine. Probably Recommended actions cause, too slow Trap routine or/and too The program is too complex to execute. many subsequently interrupts. Probably the program contains recursive Recommended actions routines. Proposal: - Minimize execution time in the Trap 40223, Execution error routine. 2. Disable interrupts while executing Description a Trap routine (ISleep\IWatch). The execution of task arg has been stopped by a runtime error. Consequences 40207, Value error The program execution is immediately halted. Description Probable causes Task arg : Illegal error number arg in arg The program error is considered UNRECOVERABLE so no error recovery attempt by an error handler routine (if used) was allowed. The actual cause of the error may vary, and is likely to be specified in an event log message logged simultaneously as this one. Recommended actions Error numbers used in an ERROR handler must be positive. Recommended actions 40208, Error event queue full 1) Check other event log messages logged simultaneously to determine the actual cause. Description Task arg: The program was already executing an error event when a new event occurred. 40224, Execution error Recommended actions Description Attend the cause of the error event and restart the program. Task arg : Illegal return code arg from ReaL routine This is always caused by an internal 40209, Error context already consumed error in the ReaL routine. Description Recommended actions An error event in task arg has occurred. The context of the RAPID instruction that has generated this event is however already consumed. No error handeling is therefore possible to execute. 40225, Execution error Recommended actions Description Attend the cause of the error event and restart the program. Task arg : Execution could not be restarted 40221, Execution error Execution of the program could not be continued after power failure. Description Task arg : Execution aborted Recommended actions Restart the program. Recommended actions Execution was aborted due to a fatal 40226, Name error error. Description Task arg : Procedure name arg is not a RAPID identifier excluding 3HAC020738-001 - 183 3 Symptoms reserved words clause. Recommended actions The procedure name, must be a legal 40241, Value error RAPID identifier not equal to any of Description the reserved words of the RAPID Task arg : Array dimension language. Change the name expression. number arg out of range (1- arg ) Recommended actions 40227, Limit error The value of the 'DimNo' parameter of Description the 'Dim' function must be an integer Task arg : Runtime stack value in the specified range. overflow The program is too complex to execute. 40242, Type error Probably the program contains recursive Description routines. Task arg : Data is not an Recommended actions array Recommended actions 40228, Execution error The 'DatObj' parameter of the 'Dim' function must be an array. Description The execution of task arg has been stopped by a runtime error arg. Consequences 40243, Value error The program execution is immediately halted. Description Probable causes Task arg : Unknown interrupt The program error is considered RECOVERABLE but the error was not recovered. The actual cause of the error may vary, and is likely to be specified in an event log message logged simultaneously as this one. number Recommended actions Check that the specified interrupt Recommended actions variable has been initialized by 1) Check other event log messages logged simultaneously to determine the actual cause. CONNECT, and that the interrupt has been defined using the ISignalDI or other interrupt definition instruction. 40229, Execution error Description 40244, Value error Task arg : Unhandled raise Description error arg Task arg : Recommended actions Object arg is of An error was raised by a RAISE non-value type instruction but was not handled by any Recommended actions ERROR clause. Use expression or data object of value or semivalue type. 40230, Execution error Description 40245, Parameter error Task arg : Unhandled Description non-fatal runtime error Parameters in arg Recommended actions and arg is not A non-fatal runtime error has occurred matching (late binding) but was not handled by any ERROR 184 - 3HAC020738-001 3 Symptoms Recommended actions 40255, Symbol definition error Make sure that all procedures that are called from the same late binding node Description have matching parameters. I.e they Task arg : 'ANYTYPE#' only should be matching concerning base type, allowed for parameter (not for mode and required/optional parameters. arg ) Recommended actions 40251, Name error Use another type. Description Task arg : Ambiguous symbol 40256, Parameter error name arg Description Recommended actions Task arg : 'alt' must not be Installed objects must have names that set for first optional parameter are unique. Rename the object or change arg in alternatives list the conflicting name. Recommended actions Make sure that only the second and 40252, Limit error following in each list of excluding optional parameters are marked as Description alternatives. Task arg : Error arg when creating sdb entry for arg 40257, Parameter error Recommended actions Description An error occurred when the persistent was to be inserted into the shared Task arg : REF mode database. Probably the database is full. parameter arg cannot be dimensioned 40253, Type definition error Recommended actions Remove the array dimension Description specification, or change the mode of the Task arg : Alias parameter. arg of alias arg not allowed 40258, Parameter error Recommended actions Description It is not possible to define an alias type equal to another alias type. Task arg : 'switch' Instead, define two alias types equal to parameter arg can not be the same atomic or record type. dimensioned Recommended actions 40254, Symbol definition error Remove the array dimension specification, or change the data type Description of the parameter. Task arg : 'ANYTYPE#' parameter arg cannot be dimensioned 40259, Parameter error Recommended actions Description Remove the dimension specification. Task arg : 'switch' 'ANYTYPE#' includes array types. parameter arg must have transfer mode IN (specified value arg ) 3HAC020738-001 - 185 3 Symptoms Recommended actions 40264, Symbol definition error Remove the parameter transfer mode specifier. If IN transfer mode is not Description sufficient, change the data type of the Task arg : Missing C parameter. function for arg Recommended actions 40260, Symbol definition error A C-function that executes the ReaL function being defined, must be Description specified. Task arg : 'switch' only allowed for optional parameter (not for arg ) 40265, Symbol definition error Recommended actions Description Change the parameter into an optional Task arg : Missing value parameter, or change the data type of initialization function for the parameter. If the object is not a arg parameter, change the data type. Recommended actions A value initialization function must be 40261, Type definition error specified. Description Task arg : Value type class 40266, Reference error for arg must be one of Description REAL_SYMVALTYP_VAL, _SEMIVAL, _NONVAL or Task arg : arg _NONE (specified value arg ) is not a data type name (object Recommended actions arg ) Change the value type class. The specified name identifies an object other than a type. 40262, Data declaration error Recommended actions Description 40267, Reference error Task arg : Too many array dimensions for arg Description (specified value arg ) Task arg : arg Recommended actions is not a value data type (object An array may have at most 3 dimensions. arg ) Only record components, alias types, variables and 'VAR' mode parameters may 40263, Name error be of semi-value or non-value type. Description Recommended actions Task arg : Symbol name arg 40268, Symbol definition error is not a RAPID identifier excluding reserved words Description Recommended actions Task arg : Missing value The names of installed objects, conversion function for arg including parameters and components, Recommended actions must be legal RAPID identifiers not A value conversion function must be equal to any of the reserved words of specified for a semi-value type. the RAPID language. Change the name. 186 - 3HAC020738-001 3 Symptoms 40269, Symbol definition error 40274, Parameter error Description Description Task arg : Not enough Task arg : Unknown parameter memory for value of data transfer mode arg for arg arg Recommended actions Recommended actions More memory required. The specified parameter transfer mode is not one of IN, 'VAR', 'PERS', 'INOUT' or REF. Use corresponding REAL_SYMPARMOD_x. 40270, Type definition error Description 40275, Symbol definition error Task arg : Private type Description arg can only be semi-value or non-value type (specified value Task arg : Unknown symbol arg ) definition type arg The symbol definition type tag does not Recommended actions specify one of the allowed symbol Change the value type class. types (REAL_SYMDEF_x). Recommended actions 40271, Type definition error Description 40277, Undo Aborted Task arg : Private type arg size must be multiple Description of 4 (specified value arg ) Task arg Recommended actions The program execution was stopped while processing the UNDO statements. All RAPID types must have a size that is UNDO was not fully executed. a multiple of four. Change the specified The undo-processing was executing routine arg when it was aborted. type size. Recommended actions 40272, Type error If the processing of UNDO takes too long, try to remove timeconsuming Description instructions such as TPWrite from the UNDO-clause. Task arg : Persistent type If the undo processing never seems to finish, make sure any loops in the undo-statements are correct. mismatch for arg Recommended actions 40278, Undo Aborted There is already a persistent data with the same name but with another data Description type. Rename the persistent, or change Task arg its data type. The processing of UNDO was aborted due to an EXIT-statement in the routine arg. 40273, Reference error UNDO was not fully executed. Description Recommended actions Task arg : Unknown data type 40279, Undo Aborted name arg for arg Description Recommended actions Task arg There is no data type (or other object) The processing of UNDO was aborted due to a run-time error in routine arg. with the specified name. 3HAC020738-001 - 187 3 Symptoms device (file name UNDO was not fully executed. arg ) Recommended actions Investigate the cause of the error. Recommended actions 40280, Undo Aborted 40304, I/O error Description Description Task arg Task arg : I/O error The instructions BREAK, RAISE, RETURN and STOP are not allowed to use in an arg ) (file name undo-clause or any routine that is called from an undo-clause. Recommended actions The instruction arg was found in UNDO context when One of: executing the routine arg. Permission denied (write protected) Recommended actions No such file or directory Avoid executing the instruction when in undo-context. No space left on device 40281, Undo Aborted 40322, Load error Description Description Task arg Task arg : RAPID syntax The program execution of UNDO statements was aborted due to edit operation. error(s) in file arg Recommended actions 40301, I/O error The source file to be loaded contains Description RAPID syntax errors. Correct the source Task arg : Permission denied file. The syntax errors are logged in a (file name separate file. arg ) 40323, Load error Recommended actions Description 40302, I/O error Task arg : Syntax error(s) in header in file Description arg Task arg : No such file or directory (file name Recommended actions arg ) The source file to be loaded contains syntax error in the file header. Correct Consequences the source file. The syntax errors are If the missing file is a module then automatic loading of the module to a task will fail. logged in a separate file. Probable causes 40324, Load error The file was not properly copied to the target directory. Description Recommended actions Task arg : Keywords not Check if the file was saved to the target directory with an incorrect name. defined in specified language (file arg ) 40303, I/O error Recommended actions Cannot load RAPID source code in the Description national language specified in the file Task arg : No space left on 188 header. - 3HAC020738-001 3 Symptoms one 40325, Load error Recommended actions Description Task arg : Not enough heap space 40353, Mechanical Unit arg Missing! Recommended actions Description There is not enough free memory left. The mechanical unit component of the workobject arg is faulty. Probable causes 40326, Load error - No mechanical unit is defined. - The mechanical unit defined can not be found. Description - The robot can not move the workobject by itself. Task arg : Parser stack full (file Recommended actions arg ) Check the mechanical unit component of the workobject. Recommended actions 40502, Digital Input Break The program is too complex to load. Description 40327, Load error Task: arg A digital input interrupted the execution of arg. Description Program Ref. arg Task arg : Not current RAPID version (file Recommended actions arg ) Recovery: arg Recommended actions Cannot load RAPID source code of the 40504, Parameter error version specified in the file header. Description 40328, Load error arg Task: arg arg Description arg Task: arg Program memory is full. Recommended actions arg Recovery: arg Recommended actions 40506, System Access Error The module arg could not be loaded because the program memory is full. Description Recovery: arg Task: arg arg 40351, Memory allocation error arg Description arg Task arg : Failed to Recommended actions allocate hash table, use linear list Recovery: arg Recommended actions 40507, Limit Error 40352, Memory allocation error Description Description Task: arg Can not step further back on path arg. Task arg : Failed to Program Ref. arg update persistent expression, keep old 3HAC020738-001 - 189 3 Symptoms Recommended actions Illegal data type of argument for parameter arg. Recovery: arg Recommended actions 40508, Orientation Value Error Change the parameter to a legal type. Make sure the value type is value or semivalue. Description 40517, Search Error Task: arg Wrong orientation value in arg. Description Program Ref. arg Task: arg Recommended actions No search hit or more than 1 search hit during stepwise forward execution. All used orientations must be normalized, i.e. the sum of the quaternion elements squares must equal 1. The number of hits during search was arg. The search instruction is ready and the next instruction can be executed. Program Ref. arg 40511, Parameter Error Consequences Description No position has been returned from the search instruction. Task: arg Recommended actions The parameter arg in arg is specified with a negative value. Program Ref. arg 40518, Type Error Recommended actions Description The parameter must be set to a positive value. Task: arg 40512, Missing External Axis Value Expected type differs from read type in arg. Program Ref. arg Description Recommended actions Some active external axis have incorrect or no order value. Check the type in the argument. Recommended actions Reprogram the position. 40519, End Of File Description 40513, Mechanical Unit Error Task: arg Description End of file was found before all bytes were read in arg. Task: arg Program Ref. arg Not possible to activate or deactivate mechanical unit. Recommended actions Program Ref. arg Recovery: arg 40514, Execution Error 40521, Parameter Error Description Task: arg Description The robot is too far from path to perform StartMove of the interrupted movement. Task: arg Program Ref. arg Program Ref. arg Recommended actions Recommended actions Position the robot to the interrupted position in the program. Specify a file or a directory. Can not open arg . There is only a device specified. Recovery: arg 40522, Limit Error 40515, Type Error Description Stop watch overflow. Description Task: arg 190 - 3HAC020738-001 3 Symptoms Recommended actions 40528, File Access Error Recovery: arg Description Task: arg 40523, Mechanical Unit Conflict File or serial channel is not open. Description ProgramRef. arg Not possible to deactivate mechanical unit argdue to the configuration. Probable causes Recommended actions - The path or filename is wrong. Check the configuration. - The I/O device reference is already in use. - The maximum number of simultaneously opened files is exceeded. 40524, Conveyor Access Error Recommended actions Description - Check the path or filename. Task: arg - If the I/O device reference is already in use, close it or use another. The conveyor is not activated. Recovery: arg Program Ref. arg 40529, File Access Error Recommended actions Recovery: arg Description Task: arg 40525, Conveyor Access Error Could not access the file arg. Program Ref. arg Description Task: arg Probable causes No single number defined. - The path or filename is wrong. Program Ref. arg - The I/O device reference is already in use. - The maximum number of simultaneously opened files is exceeded. 40526, Conveyor Access Error Recommended actions - Check the path or filename. Description - If the I/O device reference is already in use, close it or use another. Task: arg Recovery: arg The mechanical unit arg is not a single. Program Ref. arg 40530, Parameter Error 40527, File Access Error Description Task: arg Description Can not open arg. The number of characters, parameter arg in WriteBin, you want to write to the serial channel is greater than the size of the array containing the characters to be written. Program Ref. arg Program Ref. arg Probable causes Recommended actions - The path or filename is wrong. Make the array bigger or decrease the parameter. Task: arg - The I/O device reference is already in use. - The maximum number of simultaneously opened files is exceeded. 40531, Parameter Error Recommended actions Description - Check the path or filename. Task: arg - If the I/O device reference is already in use, close it or use another. The array arg in WriteBin is smaller than 0 or greater than 255. Recovery: arg Program Ref. arg Recommended actions Change the size of the array to be 0 - 255. 3HAC020738-001 - 191 3 Symptoms 40534, Timeout Program Ref. arg Description 40540, File Access Error Task: arg A timeout interrupted the execution of arg. Description Program Ref. arg Task: arg arg is not a directory. Recommended actions ProgramRef. arg Recovery: arg Recommended actions 40535, Type Error Check that the path is the correct path to the directory you want to open. Description Recovery: arg Task: arg 40541, File Access Error The data you was trying to read in the file was not a numeric type. Program Ref. arg Description Recommended actions Task: arg Recovery: arg Directory arg is not accessible. Program Ref. arg 40536, System Access Error Recommended actions Description Check the directory you are trying to open. Task: arg Recovery: arg Too many pending read requests. 40542, File Access Error Program Ref. arg Description 40537, File Access Error Task: arg Description Could not access the file system arg. Task: arg Program Ref. arg The serial channel is not open, or you are trying to use the instruction on a file. Recommended actions - Check the path and filename. Program Ref. arg Recovery: arg Recommended actions - Open the serial channel. 40543, File Access Error - Check that the instruction is used on a serial channel. Description Recovery: arg Task: arg You can not open arg. 40538, Max Time Expired Program Ref. arg Description Probable causes Task: arg There are too many directories already open. The programmed waiting time has expired. Recommended actions Program Ref. arg Close one of the already open directories. Recommended actions Recovery: arg Recovery: arg 40544, File Access Error 40539, System Access Error Description Description Task: arg Task: arg Could not create the directory arg. Not allowed option in this task. 192 - 3HAC020738-001 3 Symptoms Program Ref. arg Recommended actions Recommended actions - Check the path. - Check the path. - Check write and execute permission for the directory under which the file you want to copy is located. - Check write and execute permission for the directory under which the new directory should be created. Recovery: arg Recovery: arg 40549, System Access Error 40545, File Access Error Description Description Task: arg Unknown mechanical unit arg. Task: arg Program Ref. arg Could not remove the directory arg. Program Ref. arg Recommended actions Recommended actions Recovery: arg - Check the path. 40555, I/O Error - Check write and execute permission for the directory under which the directory you want to remove is located. Description Recovery: arg Task: arg Unable to read I/O signal. 40546, File Access Error Program Ref. arg Description 40556, I/O Error Task: arg Could not remove the file arg. Description Program Ref. arg Task: arg Recommended actions Unable to write I/O signal. - Check the path. Program Ref. arg - Check if you have write permission for the file. - Check write and execute permission for the directory under which the file you want to remove is located. 40557, I/O Error Recovery: arg Description Task: arg 40547, File Access Error Configuration error for I/O signal. Program Ref. arg Description Task: arg Recommended actions Could not rename the file arg. Check the IO signal configuration or alias definition. Program Ref. arg 40558, I/O Error Recommended actions - Check the path. Description - Check write permission for the file you want to rename. Task: arg - Check write and execute permission for the directory under which the file you want to remove is located. Unable to read the I/O signal arg in unit arg. Program Ref. arg Recovery: arg 40559, I/O Error 40548, File Access Error Description Description Task: arg Task: arg Unable to write to the I/O signal arg in unit arg. Could not copy the file arg. Program Ref. arg Program Ref. arg 3HAC020738-001 - 193 3 Symptoms Recommended actions Recommended actions Check the orientation. All used orientations must be normalized i.e. the sum of the quaternion elements squares must equal 1. 40560, System Access Error Description 40565, Parameter Error Task: arg Can't save program module arg. Description Program Ref. arg Task: arg Both arguments must be >= 0. Program Ref. arg 40561, System Access Error Recommended actions Description Check the value of the arguments. Task: arg arg is not a module name. 40566, Parameter Error Program Ref. arg Consequences Description You can not unload, save or erase this module. Task: arg Both arguments must be > 0 and <= 100. Recommended actions Program Ref. arg Check the name of the module. Recommended actions 40562, Parameter Error Check the value of the arguments. Description 40567, Parameter Error Task: arg Unknown axis number for the mechanical unit arg. Description Program Ref. arg Task: arg Quaternion error. Recommended actions Program Ref. arg Check the value for argument AxisNo. Recommended actions Recovery: arg Check the aom component of loaddata. 40563, System Access Error 40568, Parameter Error Description Task: arg Description Mechanical unit arg is not active. Task: arg Program Ref. arg Axis may not have a value less than 0. Program Ref. arg Recommended actions Activate the mechanical unit. Recommended actions Recovery: arg Change to a positive value. 40564, Argument Error 40569, Argument Error Description Description Task: arg Task: arg Orientation definition error. The argument AccMax must be set if the argument AccLim is set to TRUE. GripLoads attach frame in tool or work object (user + object) is unnormalized. Program Ref. arg Program Ref. arg Recommended actions Set a value to argument AccMax. 194 - 3HAC020738-001 3 Symptoms Consequences 40570, Argument Error If no repositioning is done, before restart of circular search, movement that can cause damage might occur. Description Task: arg Recommended actions The argument DecelMax must be set if argument DecelLim is set to TRUE. Recovery: arg Program Ref. arg 40576, ParId Error Recommended actions Description Set a value to argument DecelMax. Task: arg The array size of argument AxValid is not equal to number of axes. 40571, Argument Error Program Ref. arg Description Recommended actions Task: arg Check the size of the array. The value of parameter AccMax is too low. Program Ref. arg 40577, ParId Error Recommended actions Increase the value of parameter AccMax. Description Recovery: arg Task: arg This parameter identification can not be done in this robot type. 40572, Argument Error Program Ref. arg Description 40578, ParId Error Task: arg The value of parameter DecelMax is too low. Description Program Ref. arg Task: arg Recommended actions The optional argument PayLoad is missing. For PayLoad identification the argument must be given. Increase the value of parameter DecelMax. Program Ref. arg Recovery: arg Recommended actions 40573, Argument Error Give a value to the argument PayLoad. Description 40579, ParId Error Task: arg The value of argument On is too low. Description Program Ref. arg Task: arg Recommended actions The optional argument PayLoad may only be used for PayLoad identification. Increase the value of argument On. Program Ref. arg Recovery: arg Recommended actions Remove the argument PayLoad. 40574, Search Warning 40580, ParId Error Description Task: arg Description Number of hits during search was arg. Task: arg Before performing next search, make sure that TCP is moved back to the start position of the search path. Faulty state for LoadIdInit. Program Ref. arg Program Ref. arg Recommended actions Check the whole ParId sequence. 3HAC020738-001 - 195 3 Symptoms Recommended actions 40581, ParId Error Remove argument WObj. Description Task: arg 40587, ParId error Faulty state for ParIdMoveSeq. Description Program Ref. arg Task: arg Recommended actions ParIdMoveSeq / Parameter MoveData: Check the whole ParId sequence. Faulty array size. Program Ref. arg 40582, ParId Error Recommended actions Description Check the size of the array. Task: arg Faulty state for LoadIdInit. 40588, ParId Error Program Ref. arg Description Recommended actions Task: arg Check the whole ParId sequence. ParIdMove / Parameter StartIndex: Faulty StartIndex. 40583, ParId Error Program Ref. arg Description Recommended actions Task: arg Check the StartIndex. Backward execution not allowed. Program Ref. arg 40589, ParId Error 40584, ParId Error Description Task: arg Description ParIdMove / Parameter StartIndex: Task: arg Point at negative movetype. ParIdMoveSeq / Parameter NextMove: Program Ref. arg Faulty array size. Program Ref. arg 40590, ParId error Recommended actions Description Check the size of the array. arg arg 40585, ParId Error Recommended actions Description arg Task: arg Missed argument WObj in LoadId for PayLoad with roomfix TCP. 40591, Argument Error Program Ref. arg Description Recommended actions Task: arg Add argument WObj. Unknown type of parameter identification. Program Ref. arg 40586, ParId Error Recommended actions Description Check the argument ParIdType. Task: arg Not allowed argument WObj. The argument is only to be used for PayLoad with roomfix TCP. Program Ref. arg 196 - 3HAC020738-001 3 Symptoms 40592, Program Stop During Load Identification 40597, Speed Override Description Description No type of program stop during load identification is not allowed. Task: arg Speed override is not 100 percent. Recommended actions Program Ref. arg Start the identification procedure from the beginning again. Recommended actions 40593, Power Fail During Load Identification - Change the speed override to 100. Description - Restart the program execution again for load identification from beginning. Task: arg A Power Fail during load identification results in faulty load result. 40603, Argument Error Program Ref. arg Description Recommended actions Argument arg may not have a negative value. Restart the program execution again with the same run mode (without PCP move) for load identification from the beginning. Recommended actions Recovery: arg Set argument arg to a positive value. 40594, User Error During Load Identification 40604, Argument Error Description Description Task: arg Argument Tool has undefined load of the tool. Error resulting in raise of PCP to the beginning of the parameter identification procedure. Recommended actions Program Ref. arg Define the actual load of the tool before use of the tool for jogging or program movement. Recommended actions Start the identification procedure from the beginning again. 40605, Argument Error Recovery: arg Description Argument Tool has negative load of the tool. 40595, Argument Error Recommended actions Description Define the correct load of the tool before use of the tool for jogging or program movement. Task: arg Unknown type of load identification. Program Ref. arg 40606, Argument Error Recommended actions Description Check the argument LoadIdType. Argument Tool has at least one inertia data component with negative value. 40596, Program Stop During Load Identification Recommended actions Description Define all inertia data components (ix, iy or iz) to actual positive values. Task: arg Any type of program stop during load identification is not allowed. Program Ref. arg 40607, Execution Error Recommended actions Description Restart the program execution again for load identification from beginning. Task: arg Not allowed to change run mode from forward to backward or vice versa when running a circular movement. Program Ref. arg 3HAC020738-001 - 197 3 Symptoms Optional argument arg can only be combined with output signal argument arg. Recommended actions If possible, select the original run mode and press start to continue the Program Ref. arg stopped circular movement. If this is not possible, move robot and program pointer for a new start. Recommended actions Check and change the arguments. 40608, Argument Error Description 40614, Argument Error Task: arg Description Orientation definition error in arg. Task: arg Program Ref. arg Argument arg is not 0 or 1. Recommended actions Program Ref. arg All used orientations must be normalized i.e. the sum of the quaternion elements squares must equal 1. Recommended actions Digital signals can only be set or checked to 0 or 1. 40609, Argument Error 40615, Argument Error Description Description Task: arg Task: arg Argument \WObj specifies a mechanical unit with too long name. Argument arg is not an integer value. Program Ref. arg Program Ref. arg Recommended actions Recommended actions Use max. 16 characters to specify the name of a mechanical coordinated unit. Digital group of in/out signals, process identity or process selector can only have an integer value. 40611, Execution Error 40616, Argument Error Description Description Task: arg Task: arg Not allowed to step backwards with this move instruction. Argument arg is outside allowed limits. Program Ref. arg Program Ref. arg Consequences Recommended actions Step backwards to a position defined with another tool or work object could result in faulty path. Used group of digital in/out signals can only be set or checked within 0 to arg according to configuration in system parameters. Recommended actions Check tool and work object. 40617, Argument Error Description 40612, Argument Error Task arg : Description Task: arg Argument SetValue, ScaleValue or CheckValue is outside allowed limits. No argument programmed for the name of the output signal. Program Ref. arg Program Ref. arg Recommended actions Recommended actions Used analog in/out signals can only be set/checked within arg to arg according configuration in the system parameters. Possible to set one position fix IO such as digital, group of digitals or analog output signal during the robot movement. Recovery: arg 40613, Argument Error 40620, Argument Error Description Description Task: arg Argument arg have too large negative value. 198 - 3HAC020738-001 3 Symptoms Too many move instructions in sequence with concurrent RAPID program execution. Recommended actions Set argument arg to arg or more. Program Ref. arg 40622, Argument Error Recommended actions Description Edit the program to max. 5 MoveX \Conc in sequence on the basic execution level of the program. Task: arg The value of argument Time is too low for cyclic interrupts. 40632, Instruction Error Program Ref. arg Description Recommended actions Task: arg Change the value for Time, to a value greater than 0.25 s. No move instructions with concurrent RAPID program execution are allowed within the StorePath-RestoPath part of the program. 40623, Argument Error Program Ref. arg Description Recommended actions Task: arg Edit the program so it does not contain any MoveX \Conc instructions within the StorePath-RestoPath part of the program. The value of argument Time is too low for single interrupts. Program Ref. arg Recommended actions 40634, Reference Error Change the value for Time to a value greater than 0.05 s. Description Task: arg 40624, Argument Error The signal arg is unknown in the system. Program Ref. arg Description Task: arg Recommended actions Argument arg is not between 0 and 2. All signals (except AliasIO signals) must be defined in the system parameters and can not be defined in the RAPID program. Program Ref. arg Recommended actions 40636, Sensor Error Specify the flank to generate the interrupt. 0 = Negative flank (high -> low). Description 1 = Positive flank (low -> high). Task: arg 2 = Both negative and positive flank. No measurement from sensor. Program Ref. arg 40625, Limit Error Recommended actions Description Requested data is not available. Task: arg Recovery: arg The robot is outside its limits. Program Ref. arg 40637, Sensor Error Probable causes Description - Axis outside working area. Task: arg - Limits exceeded for at least one coupled joint. Not ready yet. Program Ref. arg Recommended actions Recovery: arg Recommended actions Requested function is not ready yet. 40631, Instruction Error Recovery: arg Description Task: arg 3HAC020738-001 - 199 3 Symptoms 40638, Sensor Error Recovery: arg Description 40643, Sensor Error Task: arg General error. Description Program Ref. arg Task: arg Camera alarm. Recommended actions Program Ref. arg General error has occurred which is not specifically connected to the requested action. Read the block "Error log" if the function is available. Recommended actions Some error has been detected in the camera. Run Camcheck to test if the Recovery: arg camera is OK. 40639, Sensor Error Recovery: arg Description 40644, Sensor Error Task: arg Sensor busy, try later. Description Program Ref. arg Task: arg Temperature alarm. Recommended actions Program Ref. arg The sensor is busy with an other function. Recommended actions Recovery: arg The camera is overheated it needs more cooling air or water. 40640, Sensor Error Recovery: arg Description 40645, Sensor Error Task: arg Unknown command. Description Program Ref. arg Task: arg Value out of range. Recommended actions Program Ref. arg The function requested from the sensor is unknown. Recommended actions Recovery: arg The value of the data sent to the sensor is out of range. 40641, Sensor Error Recovery: arg Description 40646, Sensor Error Task: arg Illegal variable or block number. Description Program Ref. arg Task: arg Camera check failed. Recommended actions Program Ref. arg Requested variable or block is not defined in the sensor. Recommended actions Recovery: arg The CAMCHECK function failed. The camera is broken. Send it for repair. 40642, Sensor Error Recovery: arg Description Task: arg 40647, Sensor Error External alarm. Description Program Ref. arg Task: arg Recommended actions Communication time out. Alarm from external equipment. 200 Program Ref. arg - 3HAC020738-001 3 Symptoms Recommended actions 40652, Axis Is Moving Increase the time out time and check the connections to the sensor. Description Recovery: arg Task: arg A Robot axis, an external axis or an independent axis is moving. 40648, Search Error Program Ref. arg Description Recommended actions Task: arg All Robot axes, external axes and independent axes have to stand still. Not possible to do StorePath while searching on basic path level. Use MoveL with Fine argument for the Robot and external axes. Program Ref. arg Use IndRMove for the independent axes. Recommended actions Recovery: arg If using program with robot movements in TRAP, then such interrupt must be 40654, Axis Is Not Active deactivated during any search. Description E.g. ISleep - SearchL - IWatch Task: arg The axis is not active or it is not defined. 40649, Path Limitation Program Ref. arg Description Recommended actions Task: arg The mechanical unit has to be activated and the axis has to be defined, before this instruction is executed and before a robtarget is saved. arg is already done. Instruction arg must first be executed, before a new arg can be done. Recovery: arg Program Ref. arg Recommended actions 40655, Axis Is Not Independent Check the RAPID program. Description Task: arg 40650, Wrong Combination Of Parameters The axis is not in independent mode. Description Program Ref. arg Task: arg Consequences Optional parameters and switches are not used in a correct combination. It is only possible to get the status from an axis in independent mode. Program Ref. arg Recommended actions Recommended actions Set the axis to independent. - No optional parameters and no switch keeps the old coordinate system. Recovery: arg - The switch Old has the same function. 40658, Parameter Error - RefPos or RefNum has to be defined with Short, Fwd or Bwd. Description Task: arg 40651, Use Numeric Input Parameter arg can only be used, if parameter arg is greater than zero. Description Program Ref. arg Task: arg Recommended actions Use numeric input for the position instead of a robtarget. Parameter arg has effect only in the first TriggX instruction, in a sequence of several TriggX instructions, that controls the speed proportional AO signal. Program Ref. arg Recommended actions The position can not be defined with a robtarget for robot axes. 40661, Search Error Use the optional parameter for numeric input of the position. Description Task: arg 3HAC020738-001 - 201 3 Symptoms The signal arg for the SearchX instruction is already high at the start of searching. Worldzone ' arg ' is defined locally in current routine. Program Ref. arg Program Ref. arg Recommended actions Recommended actions Define the world zone as global or local in module. Recovery: arg 40667, Illegal World Zones 40662, Invalid Worldzone Type Description Description Task: arg Task: arg WorldZone arg is not entire data reference. The switch \ arg must be associated with a arg worldzone. Program Ref. arg Program Ref. arg Recommended actions Recommended actions Check the value of argument WorldZone. If use of switch \Temp, the datatype must be wztemporary in WorldZone. 40668, Shapedata Not In Use If use of switch \Stat, the datatype must be wzstationary in WorldZone. Description 40663, World Zone Not In Use Task: arg Description The ' arg ' argument of the instruction arg must refer to a defined shapedata. Task: arg Program Ref. arg The argument arg of the instruction arg refers to a not used worldzone. Recommended actions Program Ref. arg Recommended actions A shapedata is used to store a volume definition. It must have been defined The worldzone must have been defined and activated by a WZLimSup or WZDOSet instruction. by WZBoxDef, WZSphDef or WZCylDef before it can be used by WZLimSup or WZDOSet. 40664, World Zone Already In Use 40669, World Zone Too Small Description Description Task: arg Task: arg The ' arg ' worldzone has already been defined and activated. A world zone can only be defined once. At least one side or radius is less than the minimal allowed in instruction arg . Program Ref. arg Program Ref. arg Recommended actions Recommended actions Use a worldzone with another name. Check previous volume definition instruction. 40665, Too Many World Zones 40670, Invalid World Zone Description Description Task: arg Task: arg It is not possible to add the world zone arg . The world zone table is full. The index of the world zone argument arg in arg is not a valid index defined by WZLimSup or WZDOSet. Program Ref. arg Program Ref. arg Recommended actions Recommended actions Check the RAPID program to see if any word zone might be removed. Check the RAPID program. 40666, Illegal World Zones 40671, Illegal Use Of World Zone Description Description Task: arg Task: arg 202 - 3HAC020738-001 3 Symptoms The argument ' arg ' for arg must be a temporary world zone. Recommended actions Program Ref. arg Check the value for DeltaJointVal. The DeltaJointVal for all axes to supervise must be > 0 mm or degrees. Recommended actions Check the argument.. 40677, Parameter Error 40672, World Zone Already In Use Description Task: arg Description The DeltaJointVal for external axis arg is <= 0. Task: arg Program Ref. arg It is not possible to add the world zone arg . Another world zone with the same name is already defined in the system. Recommended actions Program Ref. arg Check the value for DeltaJointVal. The DeltaJointVal for all axes to supervise must be > 0 mm or degrees. Recommended actions Check the name of the world zone. 40678, Parameter Error 40673, I/O Access Error Description Task: arg Description LowJointVal is higher than or equal to HighJointVal for robot axis arg. Task: arg Program Ref. arg The signal given in parameter arg is write protected for RAPID access. Recommended actions Program Ref. arg Select other user signal or change the access mode for the signal. Check the values for HighJointVal and LowJointVal. The HighJointVal must be higher than the LowJointVal for all axes with defined high or/ and low limits. 40674, I/O Access Error 40679, Parameter Error Description Description Task: arg Task: arg The signal given in parameter arg is not write protected for user access from Flex Pendant or RAPID. LowJointVal is higher than or equal to HighJointVal for external axis arg. Program Ref. arg Program Ref. arg Recommended actions Recommended actions Change the access mode to system type for the signal in the I/O configuration. Check the values for HighJointVal and LowJointVal. The HighJointVal must be higher than the LowJointVal for all axes with defined high or/ and low limits. Recommended actions 40675, Execution Error 40680, Parameter Error Description Not allowed to change the run mode from forward to backward or vice versa when running an invisible trap routine. Description Recommended actions Error in used WZHomeJointDef. It is not allowed to specify supervision of not active axis arg Task: arg If possible, select the original run mode and press start to continue. Program Ref. arg Recommended actions 40676, Parameter Error Set the argument MiddleJointVal to 9E9 for the actual axis. Description Task: arg 40681, Parameter Error The DeltaJointVal for robot axis arg is <= 0. Program Ref. arg Description Task: arg 3HAC020738-001 - 203 3 Symptoms Error in used WZLimJointDef. It is not allowed to specify limitation of not active axis arg. Probable causes - Module not loaded with Load instr. Program Ref. arg - Not same file path as used for Load Recommended actions Recommended actions Set the argument LowJointVal and HighJointVal to 9E9 for the actual axis. - Check if the program module has been loaded with the instruction Load. - Check if the file path and name are the same in the UnLoad and Load instruction. 40700, Syntax Error Recovery: arg Description Task: arg 40705, Syntax Error Syntax error. arg Description Task: arg 40701, Program Memory Full Syntax error arg Description Recommended actions The task arg , has only arg free bytes in its user space. More syntax errors will follow this. Recommended actions Remove some other module and try again. 40706, Load Error 40702, File Not Found Description Task: arg Description The program module is already loaded. Task: arg Program Ref. arg The file arg was not found. Program Ref. arg Probable causes Recommended actions The module name in the head of the file arg already exists in the program memory. - Check the file path and the file name. Recommended actions - Check if the file exists. Recovery: arg Recovery: arg 40707, I/O Unit Name Invalid 40703, Unload Error Description Description Task: arg Task: arg The unit name arg does not exist. The program module could not be unloaded. Program Ref. arg The reason is that the module is changed but not saved. Program Ref. arg Recommended actions Recommended actions - Check if the unit name is misspelled. The instruction UnLoad: - Check if the unit is defined. Use the optional switch ErrIfChanged, without recover from this situation, in an Error handler. Recovery: arg Recovery: arg 40708, I/O Unit Is Not Enabled Description 40704, UnLoad Error Task: arg Description I/O unit arg was not enabled. arg Program Ref. arg The program module couldn't be unloaded. Probable causes The maximum period of waiting time was too short. 204 - 3HAC020738-001 3 Symptoms The signal in argument FromSignal must be defined in the IO configuration, while the signal in argument ToSignal must be declared in the RAPID program and not defined in the IO configuration. Recommended actions Increase the waiting time or make a retry. Recovery: arg Program Ref. arg Recommended actions 40709, I/O Unit Is Not Disabled Check the IO configuration and the RAPID program. Description Task: arg 40714, Argument Error I/O unit arg was not disabled. Description Program Ref. arg Task: arg Probable causes Orientation definition error in arg . The maximum period of waiting time was too short. Program Ref. arg Recommended actions Recommended actions Increase the waiting time or make a retry. This is probably an off-line generated "dummy" position (undefined orienta- Recovery: arg tion), that needs to be modified with modpos. 40710, Argument Error 40720, Alias IO Installation Description Task: arg Description The argument arg is an expression value, is not present or is of the type switch. The system could not refresh all IO signals as RAPID symbols. Program Ref. arg Consequences No IO signals can be used in a RAPID program. Recommended actions Change the parameter arg to a valid one. Probable causes Recovery: arg - Incorrect IO configuration - Incorrect task configuration 40711, Alias Type Error Recommended actions Description Restart the controller. Task: arg 40721, IO Installation The data types for the arguments FromSignal and ToSignal must be the same and must be of signalxx type. Description Program Ref. arg Task arg: Recommended actions The system could not refresh all IO signals as RAPID symbols. Change the type to a valid one (signalai/ao, signaldi/do, signalgi/go). Consequences No IO signals can be used in a RAPID program. 40712, Event Routine Error Probable causes Description - Incorrect IO configuration Task: arg - Incorrect task configuration Too many event routines, the routine arg will not be executed. Recommended actions Recommended actions Restart the controller. Encapsulate the routine in one of the others that are specified for the same event. 40722, Mechanical Units 40713, Alias Define Error Description The system could not refresh all mechanical units as RAPID symbols. Description Task: arg 3HAC020738-001 - 205 3 Symptoms Consequences Recommended actions No mechanichal units can be used in a RAPID program. Check if the positions are too close or not specified with enough accuracy. Probable causes Recovery: arg - Incorrect motion configuration - Incorrect task configuration 40731, Value Error Recommended actions Description Restart the controller. Task: arg 40724, Save or Erase Error The value of the argument arg for signal arg is above its maximum logical value. Description Program Ref. arg Task: arg Recommended actions The program module arg could not be saved or could not be erased. Change the argument or change the maximum logical value parameter Program Ref. arg for the signal. Recommended actions 40732, Value Error - Check the spelling of the module name - Check if the module is loaded. Description Recovery: arg Task: arg The value of the argument arg for signal arg is below its minimum logical value. 40726, Reference Error Program Ref. arg Description Task: arg Recommended actions The reference to the load session is not valid. Change the argument or change the min logical value parameter for the signal. Program Ref. arg Recommended actions 40733, Value Error Check if the specified reference is the same as in StartLoad Recovery: arg Description Task: arg 40727, Save Error The value of the argument arg for signal arg is below the value for argument arg. Description Program Ref. arg Task: arg Missing file source arg. Recommended actions Program Ref. arg Change the values of the arguments. Recommended actions 40734, Symbol Definition Error Use FilePath argument to specify the file destination. Description Recovery: arg Task: arg 40728, Frame Error The string in text table arg at index arg is too long. Program Ref. arg Description Task: arg Recommended actions Unable to calculate new frame. Change the file for the text table and perform a cold start. Program Ref. arg 40735, Argument Error Probable causes The positions have not the required relations or are not specified with enough accuracy. 206 Description The axis is not defined. - 3HAC020738-001 3 Symptoms Recommended actions Probable causes The axis has to be defined, before this instruction is executed. The program module with the PERS variable is probably removed from the 40736, Mechanical Unit Error program memory. Recommended actions Description Check if the module with the PERS variable is removed, if so put it back. Task: arg It is not possible to define a payload on the robot with this instruction. Program Ref. arg 40741, Context Error Recommended actions Description Use the instruction GripLoad instead of MechUnitLoad. Task: arg Instruction arg may only be used in an event routine. 40737, Symbol Definition Error Program Ref. arg Description Recommended actions Task: arg Remove the instruction. The requested text or text package does not exist. Text table arg, Index arg. Program Ref. arg 40742, Parameter Error Recommended actions Description Check the arguments. Task: arg The timing parameter DipLag is larger than the system parameter Event preset time. 40738, I/O Error Program Ref. arg Description Recommended actions Unable to access the I/O signal arg on unit arg . Impossible to restart. Increase the system parameter Event preset time or check the equipment dip lag (delay) compensation. Probable causes Recovery: arg The connection with the I/O module is broken. 40743, Parameter Error Recommended actions Reestablish the connection with the I/O unit. To make it possible Description to restart the program move PCP to a safe restart position. Task: arg 40739, Parameter Error Program Ref. arg Description Recommended actions Task: arg Check the argument. None of the option arguments DO1, GO1, GO2, GO3 or GO4 are specified. 40744, Parameter Error Not a valid subtype in argument arg. Program Ref. arg Description Recommended actions Task: arg Specify at least one of the arguments. Invalid value in arg in argument arg. Program Ref. arg 40740, Execution Error Recommended actions Check the argument. Description The PERS variable specified in the instruction TriggStopProc can not be updated, because it does not exist any more. 3HAC020738-001 - 207 3 Symptoms 40745, Parameter Error 40752, Argument Error Description Description Task: arg Task: arg arg is less than arg in argument arg. Some load session with StartLoad - WaitLoad has not been finished. Program Ref. arg Program Ref. arg Recommended actions Recommended actions Check the argument. Finish the load session with WaitLoad, cancel it with CancelLoad or set PCP to main. 40746, Parameter Error Recovery: arg Description 40753, Memory Fault Task: arg Description arg TRUE in parameter arg in combination with conveyor coordination. Because of power fail in executed Load or StartLoad ... WaitLoad instruction, the RAPID program memory is inconsistent. Program Ref. arg *** TO REPAIR DO P-START *** Recommended actions arg Cannot use fine points when leaving conveyors after coordinated stoppoint. Recommended actions Use a zone instead. Important to do P-start, because the RAPID program memory is destroyed: 40747, Access Error - Faulty init value of PERS variables - Reduction of the available program memory size Description Task: arg 40754, Argument Error Can not read or write to the system parameter arg. The parameter is internal and protected from reading and writing. Description Program Ref. arg Task: arg There are no arguments given. Recommended actions Program Ref. arg Recovery: arg Recommended actions If you want a limitation set the optional argument On with a value, otherwise set to Off. 40748, Value Error Description Task: arg 40755, Context Error The data to write from parameter CfgData to the system parameter, is outside valid limits. Description Program Ref. arg Task: arg Instruction arg may only be used in a trap routine. Recommended actions Program Ref. arg Recovery: arg Recommended actions Remove the instruction. 40749, Execution Error Description 40756, Context Error Task: arg It is not possible to execute StartMove when the robot is moving. Description Program Ref. arg Task: arg Recommended actions Instruction arg may only be used in a trap routine ordered through instruction arg. Recovery: arg 208 Program Ref. arg - 3HAC020738-001 3 Symptoms Recommended actions 40763, Execution Error Check that INTNO has the interrupt number used by arg. Description Task: arg 40757, Argument Error Description The instruction arg can not be executed while the system is in a stop state. Task: arg Program Ref. arg The load session you are trying to cancel is not in use. Program Ref. arg 40764, Switch Argument Error Recommended actions Description Recovery: arg Task: arg The instruction arg must be used with one switch argument. 40758, I/O Error Program Ref. arg Description Recommended actions Unable to access the I/O signal arg unit arg . Use one of the switch Total or Free. Probable causes 40765, Argument Error The connection with the I/O module is broken. Recommended actions Description Reestablish the connection with the I/O unit. Task: arg In the instruction arg the argument arg is not an open directory. Program Ref. arg 40759, Parameter Error Recommended actions Description Open the directory before trying to read it. Task: arg Recovery: arg The argument Data in arg has improper data type. Program Ref. arg 40766, Parameter Error Recommended actions Description Check the data type.Non-value and semi-value types may not be used. Task: arg 40761, Parameter Error In the instruction arg the argument arg can't be used without the argument arg. Description Program Ref. arg Task: arg Recommended actions The argument arg has a negative value. Check the RAPID program. Program Ref. arg 40767, Search Error Recommended actions Set the value positive or to zero. Description Task: arg 40762, Value Error Object of the type arg could not be searched for. Description Program Ref. arg Task: arg Recommended actions The value of argument arg forces the robot out of workspace. Check the RAPID program. Program Ref. arg 40768, Symbol Access Error Recommended actions Decrease the value. Description Task: arg No system symbol arg is accessable in the system. 3HAC020738-001 - 209 3 Symptoms Program Ref. arg Probable causes Recommended actions Start window passed or Checkpoint not satisfied. Recovery: arg Recommended actions 40769, Symbol Read Access Error If Checkpoint not used, Checkpoint Distance and Checkpoint Window Width must be set to zero. Rerun the instruction Description Recovery: arg Task: arg The symbol arg is not a readable object. 40775, Conveyor Error Program Ref. arg Description Recommended actions Task: arg Recovery: arg Another arg instruction is waiting for a distance to the object. Program Ref. arg 40770, Symbol Type Error 40776, Conveyor Error Description Task: arg Description The symbol arg is of type arg and not the expected type arg . Task: arg Program Ref. arg Another arg instruction is waiting for the object. Recommended actions Program Ref. arg Check the RAPID program. 40777, Conveyor Error 40771, Symbol Access Error Description Description Task: arg Task: arg The arg instruction is already connected. The symbol arg is not accessable in this scope. Program Ref. arg Program Ref. arg Recommended actions Recommended actions Recovery: arg Recovery: arg 40778, Value Error 40772, I\O Error Description Description Task: arg Task: arg The arg instruction has lost contact with the conveyor. Booking of the new error number arg failed. The init value must be -1 or the old number. Program Ref. arg Program Ref. arg Recommended actions 40773, Instruction Interrupted Check the init value of the new errnum variable. Description 40779, Error Number Local Task: arg The instruction arg was interrupted, reason unknown. Description Program Ref. arg Task: arg The RAPID user error number arg must not be declared as local in routine. 40774, Object Dropped Program Ref. arg Description Task: arg Recommended actions The object that the instruction arg was waiting for has been dropped. Check the errnum declaration. Program Ref. arg 210 - 3HAC020738-001 3 Symptoms File or serial channel is not opened for reading. 40780, Data Object Error Program Ref. arg Description Recommended actions Task: arg Check how the file or serial channel was opened. There is no valid data object for the argument arg of the instruction arg. Program Ref. arg 40786, Read Error Recommended actions Description Check if there is a right data object. Task: arg One or more bytes is not read properly. The value of the read data might be 40781, File Error inconsistent. Description Program Ref. arg Task: arg Recommended actions The parameter arg does not correspond to any loaded text file. Recovery: arg Program Ref. arg Recommended actions 40787, User Frame Error Check if the text file is (correct) installed. Description Task: arg 40782, Mode Error Not possible to get the coordinated user frame. Description Program Ref. arg Task: arg File or serial channel is not opened for writing. 40788, Axis Error Program Ref. arg Description Recommended actions Task: arg Check how the file or serial channel was opened.. The single axis is not init correctly. Program Ref. arg 40783, Mode Error Description 40789, Limitation Error Task: arg Description File or serial channel is not opened in a character-based mode. Task: arg Program Ref. arg The string length of the argument for the file path is too long. Recommended actions Program Ref. arg Check how the file or serial channel was opened. Probable causes 40784, Mode Error The maximum allowed string length is 200 characters for the full system file path. Description Recommended actions Task: arg Shorten the length of the path. File or serial channel is not opened in a binary mode. Program Ref. arg 40790, Value Error Recommended actions Description Check how the file or serial channel was opened. Task: arg The RAPID string is too long. 40785, Mode Error Program Ref. arg Description Probable causes Task: arg String value exceeds the maximum allowed length. 3HAC020738-001 - 211 3 Symptoms Recommended actions 40795, Error Installing Text Table Rewrite the program to use strings of less length. Description Recovery: arg Task: arg System memory for text tables is full. 40791, I/O Error Program Ref. arg Description Recommended actions Task: arg Reduce the amount of user defined text string installed from RAPID. Cold start the system and try again. No space left on device (file name arg). Program Ref. arg Recommended actions 40796, Overload Error Recovery: arg Description Task: arg 40792, I/O Error The system is overloaded so the actual order can not be ready in time. Program Ref. arg Description Task: arg Recommended actions File open/access error for path arg. Reduce the main computer load, for example by: Program Ref. arg - Add WaitTime in RAPID loops Recommended actions - Increase filter time for I/O signals - Check permission, is the file write protected? - Avoid cyclic interrupts - Check if the file or directory exists. 40797, I/O Error - Check if there is any space left on device. Recovery: arg Description Unable to access the I/O signal arg on unit arg. 40793, Error Installing Text Table Probable causes Description The connection with the I/O module is broken. Task: arg No or faulty text resource name or index number in the text file. Recommended actions Program Ref. arg Reestablish the connection with the I/O unit. Consequences 40798, System Access Error The contents of some of the text tables may have been destroyed. Description Recommended actions arg Correct the error, cold start the system and try again. 40799, Execution Error 40794, Error Installing Text Table Description Description Task: arg Task: arg The time between TestSignDefine and TestSignRead is too short. The specified index within the text resource already exists in the system. Program Ref. arg Program Ref. arg Recommended actions Probable causes Put a WaitTime (0.1s) after TestSignDefine. - Error in the index numbering. - The file has been installed twice. 40800, Tool Error Recommended actions Description If error in the index, correct it, cold start the system and try again. Task: arg The component robhold in the tool has not got the correct value. 212 - 3HAC020738-001 3 Symptoms Program Ref. arg 40805, Motion Error Recommended actions Description Change the value of robhold. Task: arg If the robot is holding the tool the value should be TRUE. If the robot is not holding the tool, i.e. a stationary tool, the value should be FALSE. Error from MocGenInstr. Ref to former message for reason. Program Ref. arg 40801, Calculation error 40806, IOF Error Description Task: arg Description Can not calculate the tool frame. Task: arg Program Ref. arg Error from IofGenInstr. Ref to former message for reason. Probable causes Program Ref. arg It is not possible to calculate the tool frame with the selected approach points. 40807, File Error Recommended actions Description Select new approach points as accurate as possible. Task: arg The file arg already exists. 40802, Execution Error Program Ref. arg Description Recommended actions Task: arg To be able to rename or copy: Not possible to do subscribe. Change the file name or remove the existing file. Program Ref. arg Recovery: arg Probable causes There is no memory left to make another subscription on this variable. 40812, Execution Error Recommended actions Description To continue, PCP must be moved to main! Task: arg Not allowed to run this program in non_motion_execution_mode. 40803, Error msg too long Recommended actions Description Change mode. The length of the following error message was too long and has been cut. 40813, Execution Error This means you will not be able to read the whole message. Description Task: arg 40804, Argument Error The task is not allowed to execute the instruction arg. Description Program Ref. arg Task: arg Probable causes The argument "type" in stoppointdata may not be followtime in the instructions MoveJ, MoveAbsJ and MoveExtJ. The task is not configured to control mechanical units. Program Ref. arg Recommended actions Recommended actions Change the configuration or remove the instruction. Change "type" to inpos or stoptime. 40814, Execution Error Description Task: arg 3HAC020738-001 - 213 3 Symptoms StartMove could not get the regain distance. 41008, Conveyor I/O init error Program Ref. arg Description Probable causes Application error. Error in the initialization of the I/O signal for item source arg, for conveyor Recommended actions arg. I/O signal name arg. Please restart the path. 41009, Conveyor does not exist Recovery: arg Description 41000, Item source exists Error for item source arg. The conveyor arg does not exist. Description 41010, No conveyor name given Item source arg already exists. Two item sources may not have the same name. Description 41001, Not a valid name Error for item source arg. No conveyor name specified. Description 41011, Conveyor limits error Choose arg or arg Description Error for item source arg, conveyor arg. The limits are incorrectly specified. 41002, Buffer size exceeded Description 41012, Conveyor data are defined late Fatal internal error for item source arg. Try warm start or cold start. Please report this error. Description Error for item source arg, conveyor arg. The ItmSrcCnvDat instruction must be called before the ItmSrcFlush instruction. 41003, Item source not defined Description 41100, Too Many Corrections The item source object has not been defined. Description 41004, Itmsrc internal error Task: arg Description Max 5 correction descriptors are allowed to be connected. Internal error for item source arg. Program Ref. arg Error type: arg. Recommended actions Check number of connected descriptors. 41005, Flush item source first Recovery: arg Description 41101, Correction Not Connected Item source arg must be flushed before it is used. Description 41006, Ack item target first Task: arg Can not write to correction descriptor. Description Program Ref. arg Item target must be acknowledged before executing the GetItmTgt(s) instruction again. Recommended actions Error occured for item source arg. Check that the current correction descriptor is connected. Recovery: arg 41007, Item target buffer full Description Item target buffer full for item source arg . 214 - 3HAC020738-001 3 Symptoms Recommended actions 41102, No Corrections Connected. Check mechanical unit name. Description Recovery:arg Task: arg Correction unable to be read. 41204, Servo Tool error. Program Ref. arg Description Probable causes Task: arg No correction descriptor connected. Emergency stop when executing instruction in background task. Recommended actions Program Ref. arg Check if any correction generator is connected. Recommended actions Recovery: arg Retry after emergency stop reset. Recovery:arg 41200, Servo Tool Open Error. 41205, Servo Tool Error. Description Task: arg Description Not possible to open servo gun in motors off state. Task: arg Program Ref. arg Not possible to close servo gun. The gun is not open. Recommended actions Program Ref. arg Retry after setting motors on. Recommended actions Recovery: arg Retry after opening the gun. Recovery: arg 41201, Servo Tool Close Error. 41206, Servo Tool Parameter Error. Description Task: arg Description Not possible to close servo gun in motors off state. Task: arg Program Ref. arg The parameter PrePos must be a positive value. Recommended actions Program Ref. arg Retry after setting motors on. Recommended actions Recovery: arg Change the parameter value. Recovery: arg 41202, Servo Tool Calibration Error. 41207, Servo Tool Init Error. Description Task: arg Description Not possible to calibrate servo gun in motors off state. Task: arg Program Ref. arg The position for servo tool arg is not initialized. Recommended actions Program Ref. arg Retry after setting motors on. Recommended actions Recovery: arg Change the parameter value or perform a tip change calib. Recovery: arg 41203, Servo Tool Error. 41208, Servo Tool Synchronization Error. Description Task: arg Description Servo tool arg does not exist. Task: arg Program Ref. arg The tips for servo tool arg are not synchronized. Program Ref. arg 3HAC020738-001 - 215 3 Symptoms Recommended actions 41302, Argument Error Synchronize via ManServiceCalib or perform a tool change calibration. Description Recovery: arg The argument Type does not correspond to a service value. 41209, Servo Tool Activation Error. 41303, Argument Error Description Description Task: arg The argument Robot must be between 1 and arg. Servo tool arg is not activated. Recommended actions Program Ref. arg Check and change the value. Recommended actions Use ActUnit to activate. 41304, Argument Error Recovery: arg Description 41210, Servo Tool Error. The argument Level doesn't correspond to a service level. Description 41400, Parameter Error Task: arg Description Not possible to execute instruction in motors off state for servo tool arg. Task: arg Faulty AxisNo. Program Ref. arg Program Ref. arg Recommended actions Retry after setting motors on. Recommended actions Recovery: arg Check and change the value. 41211, Servo Tool Error. 41401, I/O Error Description Description Task: arg Unable to access the I/O signal. Not possible to perform a recalibration of the gun arg. Signal and unit unknown. Program Ref. arg Probable causes Recommended actions The connection with the I/O module is broken. Retry after checking values. Recommended actions Recovery: arg Reestablish the connection with the I/O unit. 41300, Argument Error 41402, Value Error Description Description The argument Joint must be between 1 and arg. Task: arg Recommended actions Illegal value of argument for parameter Axis or Strength. Check and change the value. Program Ref. arg Recommended actions 41301, Argument Error Check and change the value. Description 41403, Value Error The argument Type doesn't correspond to a service value. Description Task: arg Illegal value of argument for parameter Speed Priority Type. 216 - 3HAC020738-001 3 Symptoms Program Ref. arg 41409, Parameter Error 41404, Parameter Error Description Task: arg Description Ambiguous symbol arg. Task: arg Program Ref. arg Argument On or Off missing. Recommended actions Program Ref. arg Check and change the RAPID program. Recommended actions Check the RAPID program. One of the switch On or Off must be given. 41410, Parameter Error Description 41405, Parameter Error Task: arg Search error for symbol arg. Description Program Ref. arg Task: arg Argument TuneValue not allowed together with argument Off. Recommended actions Program Ref. arg Recovery: arg Recommended actions 41411, Parameter Error Check and change the RAPID program. Description 41406, Parameter Error Task: arg Unknown module name arg. Description Program Ref. arg Task: arg This TuneType is only valid for option Advanced Shape Tuning. Probable causes Program Ref.arg The module does not exist. Recommended actions Recommended actions Change TuneType or install option. Check and change the RAPID program. 41407, Parameter Error 41412, Parameter Error Description Description Task: arg Task: arg Symbol arg is read-only. Ambiguous module arg. Program Ref. arg Program Ref. arg Recommended actions Recommended actions Recovery: arg Check and change the RAPID program. 41408, Parameter Error 41413, Parameter Error Description Description Task: arg Task: arg The symbol arg was not found. Ambiguous routine name arg. Program Ref. arg Program Ref. arg Recommended actions Recommended actions Recovery: arg Check and change the RAPID program. 3HAC020738-001 - 217 3 Symptoms 41414, Parameter Error 41420, Parameter Error Description Description Task: arg Task: arg Unknown routine name arg. The argument type of arg is not compatible with cfg type. Expected arg. Program Ref. arg Program Ref. arg Probable causes Recommended actions The routine does not exist. Recovery: arg Recommended actions Check and change the RAPID program. 41421, Parameter Error 41415, Parameter Error Description Task: arg Description Unknown cfg domain in argument arg. Task: arg Program Ref. arg The module name arg does not exist. Recommended actions Program Ref. arg Check and change the RAPID program. Recommended actions Recovery: arg Check and change the RAPID program. 41422, Parameter error 41416, Parameter Error Description Description Task: arg Task: arg Unknown cfg type in argument arg. The symbol arg is not a module. Program Ref. arg Program Ref. arg Recommended actions Recommended actions Check and change the RAPID program. Check and change the RAPID program. Recovery: arg 41417, System Access Error 41423, Parameter Error Description Description Task: arg Task: arg Can not convert date. Unknown cfg instance in argument arg. Program Ref. arg Program Ref. arg Recommended actions Recommended actions Warm start and retry. Check and change the RAPID program. Recovery: arg 41419, Parameter Error 41424, Parameter Error Description Task: arg Description arg must be num, bool or string. Task: arg Program Ref. arg Unknown cfg attribute in argument arg. Program Ref. arg Recommended actions Check and change the RAPID program. Recommended actions Check and change the RAPID program. Recovery: arg 218 - 3HAC020738-001 3 Symptoms Orientation definition error in arg . 41425, Parameter Error Program Ref. arg Description Recommended actions Task: arg Check orientation. Incorrect path in argument arg. All used orientations must be normalized i.e. the sum of the quaternion elements squares must equal 1. Program Ref. arg Recommended actions 41431, System Access Error Check and change the path. Recovery: arg Description Task: arg 41426, I/O Error Unknown LOGSRV instance. Description Program Ref. arg Unable to access the I/O signal. Signal and unit unknown. Recommended actions Consequences Warm start and retry. Impossible to restart. 41432, System Access Error Probable causes The connection with the I/O module is broken. Description Recommended actions Task: arg Can not set test signals. Reestablish the connection with the I/O unit. To make it possible to restart the program move PCP to a safe restart position. Program Ref. arg Recommended actions 41427, Argument Error Warm start and retry. Description Task arg : 41433, Parameter Error The delaytime has to be positive. Description Program Ref. arg Task: arg Recommended actions Unknown mechanical unit. Change the value of delaytime. Program Ref. arg Recommended actions 41428, Axis Error Check if the mechanical unit exists in the system. Recovery: arg Description Task: arg The single axis is not init correctly. The sensor is not activated. 41434, Parameter Error Program Ref. arg Description Task: arg 41429, Axis Error Argument Axis is out of range. Program Ref. arg Description Task: arg Recommended actions The single axis is not init correctly. Check and change the value of the argument axis. The sensor process is not init correctly. Recovery: arg Program Ref. arg 41435, Parameter Error 41430, Argument Error Description Description Task: arg Task: arg Argument Channel is out of range. 3HAC020738-001 - 219 3 Symptoms Program Ref. arg Consequences Recommended actions The called RAPID routine could not be executed. Check and change the value of argument Channel. Recommended actions An argument of the data type switch must be specified. 41437, System Access Error 41441, Load Error Description Task: arg Description Can not reset all test signals. Task: arg Program Ref. arg Module loaded with path arg is active and therefore can not be erased. Recommended actions Program Ref. arg Warm start and retry. Probable causes 41438, Undefined Load If there is a CONNECT to a trap routine in the module, an IDelete on the trap has to be done before the module can be unloaded. Description Recommended actions Task: arg Check that the module does not contain routines or data that are still active, for example CONNECT. WARNING! Argument arg has undefined load (mass=0). Program Ref. arg 41442, Reference Error Consequences Description IMPORTANT TO DEFINE CORRECT LOAD to avoid mechanical damages of the robot. Task: arg The reference in argument arg is not an entire persistent variable. Program Ref. arg Recommended actions Define the actual load for the tool or the grip load before program movement or jogging. A good motion performance requires a correctly defined load. Recommended actions 41439, Undefined Load in any motion instruction. It is not possible to use record component or array element in arg. arg . It is only possible to use entire persistent variables for Tool, WObj or Load Description 41443, Argument Error Task: arg WARNING! Description Argument arg has undefined load centre of gravity. Task: arg Program Ref. arg Argument Tool has negative load of the tool. Consequences Program Ref. arg IMPORTANT TO DEFINE CORRECT LOAD to avoid mechanical damage of the robot. Recommended actions Define the correct load of the tool before use of the tool for jogging or program movement. Recommended actions Define the actual centre of gravity for the tool load or the grip load before program movement or jogging (cog.x, cog.y and cog.z can not be 0 mm at the same time). 41444, Argument Error Description Task: arg 41440, Argument Is Missing Description Argument Tool has at least one inertia data component with negative value. Task: arg Program Ref. arg One of the switch parameters arg or arg has to be defined. Recommended actions Program Ref. arg 220 Define all inertia data components (ix, iy or iz) to actual positive values. - 3HAC020738-001 3 Symptoms 41445, Argument Error 41450, Argument Error Description Description Task: arg Task: arg No \WObj specified for movement with stationary TCP. Argument \WObj specifies a mechanical unit name, which is not activated Program Ref. arg or is unknown in the system. Recommended actions Program Ref. arg Add argument \WObj for actual work object. Recommended actions If not movement with stationary TCP, change the component "robhold" in argument Tool to TRUE (robot holds the tool). The mechanical unit name defined in \WObj must correspond to the name earlier defined in the system parameters and must be activated. 41446, Argument Error 41451, Argument Error Description Task: arg Description Undefined if robot holds the tool or the work object. Task: arg Program Ref. arg Argument arg contains an illegal interrupt number. Program Ref. arg Recommended actions Check if mismatch between argument Tool and argument \WObj for data component robhold. Probable causes 41447, Argument Error Recommended actions Description Use the instrucion CONNECT to allocate and connect an interrupt number to a trap routine. Input interrupt number is illegal because it has not been allocated by the instruction CONNECT. Task: arg Argument arg has at least one data component with negative value. 41452, Argument Error Program Ref. arg Description Recommended actions Task: arg Set all data components in argument arg to positive values. Argument arg contains an interrupt number, which is already in use for other purposes. 41448, Argument Error Program Ref. arg Description Recommended actions Task: arg Before reuse of an interrupt variable in the program, it must have been canceled with the instruction IDelete. Argument arg may not have a negative value. Program Ref. arg 41453, Type Error Recommended actions Set argument arg to a positive value. Description Task: arg 41449, Value Error Illegal data type of argument arg. Program Ref. arg Description Task: arg Recommended actions Illegal value in argument arg. Check the RAPID program. Program Ref. arg 41454, Reference Error Recommended actions Check the RAPID program. Description Task: arg Trigg parameter number arg, reference to undefined trigg data. Program Ref. arg 3HAC020738-001 - 221 3 Symptoms Recommended actions 41460, Argument Error Define trigg data by executing instruction TriggIO, TriggInt, TriggEquip, TriggSpeed or TriggCheckIO before execution of instruction TriggL, TriggC, TriggJ, CapL or CapC. Description 41455, System Access Error Program Ref. arg Description Recommended actions Task: arg Check and change the argument. Task: arg Argument arg or arg or arg not within range. Operative system get time failed. Program Ref. arg 41461, Value Error Recommended actions Description Warm start and retry. Task: arg Illegal value of argument arg. 41456, Argument Error Program Ref. arg Description Recommended actions Task: arg The index must be an integer and in range 1 to 1024. Argument arg not within range. Program Ref. arg 41462, Value Error Recommended actions Description Value must be in range arg Task: arg Illegal value of argument for parameter arg. 41457, Argument Error Program Ref. arg Description Recommended actions Task: arg The value must be an integer and in the correct range. Missing optional argument. Program Ref. arg 41463, Argument Switch Is Missing. Recommended actions Description Add one of the optional arguments '\X', '\Y' or '\Z'. Task: arg There is an argument missing. 41458, Argument Error Program Ref. arg Description Recommended actions Task: arg One of the switch parameters \Hex1, \Long4, \Float4 or \ASCII has to be defined. Argument arg or arg not within range. Program Ref. arg 41464, Index To High. Recommended actions Description Check and change the value of the argument. Task: arg Illegal value in argument arg. 41459, Argument Error Program Ref. arg Description Recommended actions Task: arg Check the RAPID program. Argument arg not within range. Program Ref. arg 41465, The String Is Empty. Recommended actions Description Check and change the value of the argument. Task: arg 222 - 3HAC020738-001 3 Symptoms Illegal value in argument arg. Recommended actions Program Ref. arg Check and change the value of the argument. Recommended actions 41471, Instruction Error Check the argument, and use a non-empty string. Description 41466, The Variables Are Equal. Task: arg Description You are not allowed to disable unit arg. Task: arg Program Ref. arg The argument FromRawData and ToRawData are equal. Recommended actions Program Ref. arg Recovery: arg Recommended actions 41472, Instruction Error Check and change the RAPID program. Description 41467, Value Error Task: arg Description There is no client e.g. a Flex Pendant taking care of TP-instructions. Program Ref. arg Task: arg Illegal value in argument arg. Recommended actions Program Ref. arg If no client should be available, remove the TP-instructions. Recommended actions 41473, System Access Error Check and change the value. It must be an integer and in range 0 to 255. Description It was not possible to send data using SCWrite to external computer. 41468, Value Error Failed to send variable arg Description 41474, Value Error Task: arg Illegal value in argument arg. Description Program Ref. arg Task: arg Recommended actions Illegal value in argument arg. Check and change the value. NoOfBytes must be an integer and in range 1 to 1024, and not higher than RawData length. Program Ref. arg Recommended actions 41469, Value Error Check the value. TimeOut must be a positive integer. Description 41475, Wrong size of tasklist Task: arg Illegal value in argument arg. Description Program Ref. arg Task: arg Recommended actions The tasklist (PERS tasks ...) has wrong number of elements. It must not have less than 1 or more than arg. Check the value. NoOfBytes must not be higher than RawData length. Program Ref. arg Recommended actions 41470, Argument Error Check and change the number of arguments in the tasklist. Description 41476, Non-consistent task list Task: arg Argument arg or arg not within range. Description Program Ref. arg Task: arg 3HAC020738-001 - 223 3 Symptoms arg in the tasklist (PERS tasks ...) is not one of the tasks that are configured in the system (max arg tasks can be configured). Program Ref. arg Recommended actions Program Ref. arg Activate the TCP-robot in the task. Recommended actions Add the task to the system (in sys.cfg) or remove it from the tasklist. 41488, Value Error 41477, TimeOut Description Task: arg Description Task: arg There is no TCP-robot defined in the program task. One or several robot axis value input is not equal to 9E9. The time set in argument arg in instruction WaitSyncTask has expired. Program Ref. arg Program Ref. arg Recommended actions Recommended actions Change the robot axis value to 9E9. Recovery: arg 41489, Value error 41483, Argument Error Description Description Task: arg Task: arg The value of the ID is negative or is not an integer. The robot axis arg is not moveable and therefore must not be supervised. Program Ref. arg Program Ref. arg Recommended actions Recommended actions Check the value of the optional argument ID. The value must be a nonnegative integer. Change the value of axis arg to 9E9. 41490, TimeOut 41484, TimeOut Description Description Task: arg Task: arg The time set in argument arg in instruction SyncMoveOff has expired. The time set in argument arg in instruction SyncMoveOn has expired. Program Ref. arg Program Ref. arg Recommended actions Recommended actions Recovery: arg Recovery: arg 41491, Instruction Error 41486, Instruction Error Description Description Task: arg Task: arg The instruction arg is not available if there is a TCP-robot defined in the program task. The instruction arg is only available if there is a TCP-robot defined in the program task. Program Ref. arg Program Ref. arg Recommended actions Recommended actions - Check the configuration. - Check the configuration. - The instruction must be removed, if the task is supposed to have a TCP-robot. - The instruction must be removed, if the task is not supposed to have a TCP-robot. 41492, Instruction Error 41487, Instruction Error Description Description Task: arg Task: arg The instruction arg only works if the mechanical unit is active. The instruction arg only works if the TCP-robot is active. Program Ref. arg 224 - 3HAC020738-001 3 Symptoms Recommended actions Consequences Activate the mechanical unit in the task. Restart of current instruction is blocked. Recommended actions 41493, Execution Error Move PP again to suitable position in this program task. In same cases, the PP must also be moved to suitable position in other cooperated program task(s). Description Task: arg Then try to restart the program. There is no TCP-robot available in the task. Program Ref. arg 41498, No Defined UserFrame In Mechanical Unit arg! Recommended actions To be able to run the instruction a TCP-robot must be available in the task. Description 41494, Instruction error The workobject arg contains a coordinated mechanical unit which has no defined userframe. Recommended actions Description Check the mechanical unit component of the workobject. Task: arg The task does not control mechanical unit: arg. Program Ref. arg 41499, Synchronized Mode Recommended actions Description Check the configuration. Task: arg System is in synchronized mode. Instruction must have an ID. Program Ref. arg 41495, Move PP Error Recommended actions Description Add switch \ID with an identification number to the instruction. Task: arg Not ready with the switch from independent to synchronized mode. Program Ref. arg 41500, Independant Mode Consequences Description Restart of current instruction is blocked. Task: arg System is in independant mode. Instruction must not have an ID. Recommended actions Program Ref. arg Move PP to start the program again. Recommended actions 41496, Move PP Error Remove switch \ID from the instruction. Description 41501, Illegal Id Task: arg Not ready with the switch from synchronized to independent mode. Description Program Ref. arg Task: arg ErrorId has wrong value. It must be an integer in interval arg - arg. Consequences Program Ref. arg Restart of current instruction is blocked. Recommended actions Recommended actions Change the value. Move PP to start the program again. 41502, Illegal Domain 41497, Move PP Error Description Description Task: arg Task: arg COMMON_ERR domain can not be used. Not allowed to move PP when waiting in instruction WaitSyncTask. Program Ref. arg Program Ref. arg 3HAC020738-001 - 225 3 Symptoms Recommended actions 41508, LoadId Error Choose another Elog Domain. Description Task: arg 41503, Illegal Error Type Load Identification is not available for this robot type. Description Program Ref. arg Task: arg Error type TYPE_ALL can not be used. 41509, LoadId Error Program Ref. arg Description Recommended actions Task: arg Use another Error Type. Not valid load identification position. Program Ref. arg 41504, No Mechanical Unit Stated Recommended actions Description Change the position for the robot. Task: arg No TCP in the system and no Mechanical Unit added to the instruction. 41510, LoadId Error Program Ref. arg Description Recommended actions Task: arg Add a Mechanical Unit, that exists in the task, to the instruction . Not allowed to identify (or use) tool0. Program Ref. arg 41505, Mechanical Unit Not In Task Recommended actions Description Set the tool that should be identified, active in the jogging window. Task: arg The Mechanical Unit stated does not exist in the task. 41511, LoadId Error Program Ref. arg Description Recommended actions Task: arg Add another Mechanical Unit to the instruction. Not allowed to identify load0. Program Ref. arg 41506, Task Does Not Read a TCP Robot Recommended actions Description Use another load for identification. Task: arg The read task does not read a tcp robot. 41512, Internal Error Program Ref. arg Description Recommended actions Task: arg Change the configuration or add a Mechanical Unit, that exists in the task, to the instruction. Measurement axes > 2 at the same time. Program Ref. arg 41507, Task Reads Other Mechanical Unit 41513, LoadId Error Description Description Task: arg Task: arg Task reads another Mechanical Unit than the one stated in the instruction. Selection of PayLoad out of limits. Program Ref. arg Program Ref. arg Recommended actions Recommended actions Change Mechanical Unit in the instruction. Select a PayLoad in the system. 226 - 3HAC020738-001 3 Symptoms Recommended actions 41514, LoadId Error Select one of the Mechanical Units displayed. Description Task: arg 41519, LoadId Error Wobj0 can not be active for roomfix TCP. Description Program Ref. arg Task: arg Recommended actions Mass must be > 0 kg. Select another Work Object. Program Ref. arg Recommended actions 41515, LoadId Error Specify the mass to something greater than 0. Description Task: arg 41520, Error Recovery Constant Not Booked Selection of method out of limits. Description Program Ref. arg Task: arg Recommended actions Error recovery constant arg is not booked. Select one of the identification methods given. Program Ref. arg 41516, LoadId Error Recommended actions Description Use instruction BookErrNo to book the constant or use an error recovery constant booked by the system (can not be used with ErrRaise). Task: arg The configuration angle is not adequate. Program Ref. arg 41521, Task Status Error Consequences Description It is not possible to run the identification. Task: arg Probable causes None of the tasks in the tasklist is a NORMAL, activated task. Program Ref. arg The selected value of the configuration angle is less than 30, or has another value that is not possible to use for identification. Recommended actions Check in the Task Selection Panel that at least one of the tasks in the tasklist are selected = activated. Recommended actions Select a configuration angle between +/- 30 and +/- 90 degrees. Check in the .cfg-file that at least one of the tasks selected is NORMAL. 41517, LoadId Error 41522, Wrong Error Recovery Constant Used Description Task: arg Description PP at beginning of Load Identification. Task: arg Program ready for new Start. Program Ref. arg Error recovery constant arg has been booked by the system. The constant can not be used with instruction ErrRaise. Probable causes Program Ref. arg Check former elog message for reason. Recommended actions Book a new error recovery constant with instruction BookErrNo. 41518, LoadId Error 41523, Argument Error Description Task: arg Description Selection of MechUnit out of limits. Task: arg Program Ref. arg Argument arg is not an integer or is negative. Program Ref. arg 3HAC020738-001 - 227 3 Symptoms Recommended actions 41529, Instruction Error Change the value of the argument Description Task: arg 41524, Instruction Error Description The switch \Inpos is only allowed when the task is in control of a mechanical unit. Task: arg Program Ref. arg The program is executing in an UNDO handler. It is not allowed to execute the instruction arg in an UNDO handler. Recommended actions Remove the switch \Inpos from the instruction Program Ref. arg Recommended actions 41530, Instruction error Remove the instruction. Description 41525, Instruction Error Task: arg Description It is not possible to execute the instruction arg, while the coordinated workobject has a reference to the mechanical unit arg, located in another task. Task: arg Program Ref. arg The program is executing in an EVENT routine. It is not allowed to execute the instruction arg in an EVENT routine. Recommended actions Program Ref. arg Change to a workobject with reference to a mechanical unit located in the same task as the tcp robot. Recommended actions Remove the instruction. 41531, Task Not In TaskList 41526, Instruction Error Description Description Task: arg Task: arg arg is not one of the tasks in the TaskList, or there is a mismatch between the tasklists in the different tasks. Instruction arg may only be used in an ERROR handler. Program Ref. arg Program Ref. arg Recommended actions Recommended actions - Add current task to the TaskList. Remove the instruction or move it to an ERROR handler. - Check that the tasklists in the different tasks are similar. 41527, Argument Switch Is Missing. 41532, Mismatch of task list Description Description Task: arg Task: arg There is an argument missing. The task list, arg, does not match with the task lists in the other tasks. Program Ref. arg Program Ref. arg Recommended actions Probable causes One of the switch parameters \Continue or \BreakOff in arg has to be defined. It can depend on different content in the lists or different names of the task lists. Recommended actions 41528, Instruction Error Change the content or the name of the task lists. Description PP must be moved to main in all tasks before you can continue. Task: arg Instruction arg may only be used in a no stepin routine. 41533, Mismatch Of SyncID Recommended actions Description Remove the instruction or move it to a no stepin routine. Task: arg SyncID arg does not match with SyncID in the other task/tasks. 228 - 3HAC020738-001 3 Symptoms Program Ref. arg 41538, Wrong TaskList Recommended actions Description Change SyncID. Task: arg PP must be moved to main in all tasks before you can continue. The task, arg, in the TaskList is a read task and can not be synchronized. 41534, Inconsistent Synch Data Program Ref. arg Description Recommended actions Task: arg Change the TaskList or the configuration. Inconsistent synchdata in TaskList arg. Program Ref. arg 41539, Speed Too High Recommended actions Description Change content of the TaskList. Task: arg PP must be moved to main in all tasks before you can continue. Speed is over 100 mm/s. This is too fast when Stiff Stop (switch \Stop) is used. 41535, Unexpected SyncMoveOn Program Ref. arg Description Recommended actions Task: arg Change the speed. Unexpected SyncMoveOn (SyncID arg). The system is already in synchronized mode. 41540, Wrong Mechanical Unit Program Ref. arg Description Recommended actions Task: arg Remove the SyncMoveOn instruction. Every SyncMoveOn must be followed by a SyncMoveOff instruction. The task reads the control task, arg, which does not control the mechanical unit arg. Program Ref. arg 41536, Unexpected SyncMoveOn Recommended actions Description Change \MechUnit or the configuration. Task: arg Unexpected SyncMoveOn (SyncID arg). The system is waiting for a SyncMoveOff. 41541, Not Allowed From a Read Task Program Ref. arg Description Task: arg Recommended actions The instruction is not allowed to execute in a read task. Remove the SyncMoveOn instruction. Every SyncMoveOn must be followed by a SyncMoveOff instruction. Program Ref. arg Recommended actions 41537, Unexpected SyncMoveOff Remove the instruction. Description 41542, Program Stop Task: arg Unexpected SyncMoveOff (SyncID arg). The system is waiting for a SyncMoveOn. Description Task: arg Program Ref. arg Not possible to regain to path because of program stop in the system. Recommended actions Program Ref. arg Remove the SyncMoveOff instruction. Every SyncMoveOn must be followed by a SyncMoveOff instruction. Recommended actions 3HAC020738-001 Recovery: arg - 229 3 Symptoms 41543, Argument Error 41548, Module Error Description Description Task: arg Task: arg A loaddata has been defined, but is no longer available in the system. The module you are trying to erase, arg, is active and thus can not be removed. Program Ref. arg Program Ref. arg Probable causes Recommended actions The instruction GripLoad might have been run in a module that is no longer available in the system. Check that the module you want to erase is not active. Recommended actions 41549, Unexpected SyncMoveOn Be sure to run GripLoad Load0, to reset loaddata. Description 41544, Obsolete Instruction Task: arg Description Wrong path level. It is not possible to use SyncMoveOn and SyncMoveOff on StorePath level. Task: arg Program Ref. arg The procedure arg is obsolete and will not have the expected behaviour. PFIOResto will do nothing at all. Recommended actions PFDOVal and PFGOVal will act as the functions DOutput and GOutput respectively Check the RAPID program. arg. 41550, PathRecorder Start/Stop Error 41545, Argument Error Description Task: arg Description Unable to execute arg. Task: arg Recommended actions The argument arg may not be of type LOCAL PERS. Program Ref. arg Ensure that a backward motion has not been initiated with PathRecMoveBwd Recommended actions without being terminated with PathRecMoveFwd. Remove the directive LOCAL from the data declaration. 41551, PathRecorder Move Error 41546, Argument Error Description Description Task: arg Task: arg Unable to execute arg. The given identifier can not be reached. The object arg does not exist in the system or is of type LOCAL PERS. Recommended actions Program Ref. arg Ensure that the PathRecorder has been started. Recommended actions Ensure that the program pointer not is being moved manually. - Declare the object Ensure that the limit of arg recorded move instructions is not exceeded. - Remove the directive LOCAL from the data declaration 41552, PathRecorder Path Level Error 41547, Argument Error Description Description Task: arg Task:arg Can not execute arg on current path level. The \Corr switch can not be used without the option Path Offset. Recommended actions Program Ref. arg - Switch to trap-level. Recommended actions - Execute StorePath to switch path level. Remove the argument or install the option. 230 - 3HAC020738-001 3 Symptoms Program Ref. arg 41553, Destroyed Data Recommended actions Description Wait a short while and try again. System data arg in one of the tasks has been changed. It is NOT allowed to change this data. 41558, Argument Switch Missing Recommended actions Description The system has restored the data when it was started, but the program has to be checked. Remove where arg has been assigned a value. Task: arg An argument is missing to instruction arg. 41554, Synchronized Mode Program Ref. arg Description Recommended actions Task: arg Add switch SyncOrgMoveInst or SyncLastMoveInst to the instruction. It is not possible to use the optional parameter \Conc when the system is in synchronized mode. 41559, Not PERS variable Program Ref. arg Description Recommended actions Task: arg Remove the optional parameter \Conc from any move instruction used in synchronized mode. The task list, arg, is either LOCAL or TASK persistent. It is not allowed. It has to be global. Program ref. arg 41555, No Contact With Unit Recommended actions Change the task list to PERS. Description Task: arg 41560, No Start of Movement There is no contact with the unit arg. Program Ref. arg Description Probable causes Task: arg The unit may have been disabled (IODisable "UNIT1", 1;) It was not possible to start the movement. No power to the unit. Program Ref. arg Recommended actions Probable causes Recovery: arg 1. There has been an emergency stop. 2. There was another error in the system. 41556, No Contact With Unit Recommended actions Description 1. Reset the emergensy stop, if there has been one. Task: arg 2. Check former error messages for reason. There is no contact with unit. Program Ref. arg 41561, No Text in Function Key Probable causes Description The unit may have been disabled (IODisable "UNIT1", 1;) Task: arg No power to the unit. The instruction TPReadFK has no text in either of the function keys. Recommended actions Program Ref. arg Recovery: arg Consequences 41557, Execution Error When the instruction is executing there will be no button available to press. With no button to press the program will execute forever, unless one of the arguments \MaxTime or \DIBreak is used. Description Recommended actions Task: arg Put a text in one of the function keys TPFK1 .. TPFK5 Not allowed to change run mode when the motion planner is still working. 3HAC020738-001 - 231 3 Symptoms Recommended actions 41562, Risk for faulty circular movement Remove the instruction. Description Task: arg 50021, Joint position error Risk for faulty circular movement because of: Description 1) An asychron process error has occured and was not handled in any error handler Actual position of joint arg is too far away from the ordered position. 2) Program Pointer at circular instruction in combination with done MODPOS of any previous move instruction Recommended actions Program Ref. arg Check trim parameters, external forces or hardware. Consequences 50022, Too low DC-link voltage The Program may not be started from the current position, beceause there is a risk that the robot might perform an unexpected movement. Description The drive units cannot detect the dc link voltage, or the voltage is too low. Probable causes One of following: This can occur if the DC link bus bar is not correctly inserted or if the mains contactors do not close properly. 1) The RAPID program is missing an error handler or the error handler does not handle this specific error Recommended actions 2) MODPOS operation done when not running in step or move step mode Check the DC bus bar is correctly inserted between the drive unit and the rectifier. Recommended actions Check that the motors on contactors are closed and that there is voltage on the side connected to the rectifier. One of following: 1) Edit the program 2) Move the program pointer to be able to start the porgram. 50024, Corner path failure 41563, Argument Error Description Description Corner path executed as stop point due to some of the following reasons: Task: arg - Time delay. The Mechanical Unit arg specified in the WObj for this MOVE - Closely programmed points. instruction is the same Mechanical Unit arg as the robot - System requires high CPU-load. for this program task. Recommended actions arg Consequences - Reduce the number of instructions between consecutive move instructions. It is not possible that the robot moves the work object itself. - Reduce speed, use wider spaced points, use /CONC option. - Increase ipol_prefetch_time. Recommended actions Edit the used wobjdata. 50025, Restart interrupted 41564, Not allowed to run from a Motion Task Description Current position is too far from path. Description Task: arg Recommended actions The instructions StopMove or StartMove with the option parameter Make a new restart with regain. \AllMotionTasks are not allowed to run from a motion program task. Program Ref. : arg 50026, Close to singularity Probable causes Description It is only allowed to do stop and restart of all movements in the system from Robot too close to singularity. Recommended actions a supervision program task running as a read (or background) program task. 232 Modify path away from the singularity or change to joint interpolation. - 3HAC020738-001 3 Symptoms Recommended actions 50027, Joint Out of Range Change to MOTORS OFF. Description Position for arg joint arg is out of working range. 50035, Command not allowed Recommended actions Description Use the joystick to move the joint into its working range. An attempt was made to synchronize in MOTORS ON state. Recommended actions 50028, Jog in wrong direction Change to MOTORS OFF. Description Position for arg joint arg is out of working range. 50036, Correct regain impossible Recommended actions Description Use the joystick to move the joint in opposite direction. A stop occurred with too many close points with corner zones. At restart the robot will move to a point farther forward in the program. 50029, Robot outside its limits Recommended actions Description Reduce the number of close points, increase the distance between them or reduce the speed. The robot arg has reached the configuration limit for the parallelogram transmission. Recommended actions 50037, MOTORS ON order ignored Use the joystick to move the involved joint into the working range again. Description MOTORS ON order ignored since the previous stop was not yet acknowledged. 50030, Robot outside its limits Recommended actions Description Order MOTORS ON again. Jogging was made in wrong direction when parallelogram was out of working range for robot arg. 50041, Robot in a singularity Recommended actions Description Use the joystick to move the joint in opposite direction. The robot is too close to a singularity. Recommended actions 50031, Command not allowed Description During program execution, use SingArea instruction or joint interpolation. System parameters cannot be changed in MOTORS ON state. During jogging, use axis by axis. Recommended actions 50042, Could not create path Change to MOTORS OFF. Description 50032, Command not allowed Recommended actions Description Increase the distance between close points and/or decrease speed and/ or change acceleration value. An attempt was made to calibrate while in MOTORS ON state. Recommended actions 50050, Position outside reach Change to MOTORS OFF. Description 50033, Command not allowed Position for arg joint arg is outside working area. The reason may be that ConfL_Off is used and a movement is too large, more than 90 degrees for an axis. Description An attempt was made to commutate the motors in MOTORS ON state. Recommended actions - Check work object or working range. 3HAC020738-001 - 233 3 Symptoms - Move the joint in joint coordinates. 50057, Joint not synchronized - Check motion configuration parameters. Description - Insert intermediate points on large movements. The position of joint arg after power down/failure is too far away from the position before the power down/failure. 50052, Joint speed too high Recommended actions Description Make a new update of the revolution counter. The speed of joint arg is too high relative the ordered speed. Recommended actions 50058, Tool coord. system error - Check the tune parameters, external forces on the joint and hardware. Description - Reduce programmed speed. The z-direction of the tool coordinate system is almost parallel with the path direction. 50053, Too large revolution counter difference Recommended actions Description Change the tool coordinate system to achieve at least 3 degrees deviation between z-direction and path direction. The system has detected too large a difference between the actual revolution counter value on the serial measurement board and the value anticipated by the system. 50060, Incorrect tool Consequences The robot is not calibrated and may be jogged manually, but no automatic operation is possible. Description Probable causes Recommended actions The position of the robot arm may have been changed manually while the power supply was switched off. The serial measurement board, resolver or cables may also be faulty. Check the tool and object data. The definition of stationary tool is not valid. 50063, Circle uncertain Recommended actions Description 1) Update the revolution counter. The points are misplaced for robot arg, reason arg: 2) Check resolver and cables. 1 End point too close to start. 3) Check the serial measurement board to determine whether it is faulty. Replace the unit if faulty. 2 Circle point too close to start. 3 Circle point too close to end. 4 Uncertain reorientation. 50055, Joint load too high Recommended actions Description Verify the points in the circle. Actual torque on joint arg too high. Might be caused by incorrect load data, too high acceleration, high external process forces, low temperature or hardware error. 50065, Kinematics error Recommended actions Description -Check load data. The destination of the movement is outside the reach of the robot or too close to a singularity. Robot arg. -Reduce acceleration or speed. -Check hardware. Recommended actions Change the destination position. 50056, Joint collision Description 50066, Robot not active Actual torque on joint arg is higher than ordered while at low or zero speed. Might be caused by jam error (the arm has got stuck) or hardware error. Description Attempt to coordinate motion or calculate position of deactivated robot arg. Recommended actions Check that arm is not stuck. Check hardware. 234 - 3HAC020738-001 3 Symptoms Reduce speed, use fine point, increase AccSet, increase Queue time, avoid singularity (SingArea\Wrist), inc. dynamic resol. Recommended actions Activate robot via the Motion Unit key, then Jogging window, or program. Check work object and program. 50083, Speed lowered by system. 50067, Unit not active Description Description The speed has been lowered by the system due to dynamic limitations. Attempt to coordinate motion or calculate position of deactivated single unit arg. Recommended actions Recommended actions Decrease speed and/or do not use close positions at high speed and/or increase acceleration (if below 100%). Activate unit via Motion Unit key, then Jogging window, or program. Check work object and program. 50085, Too many user frames. Description 50076, Orientation not correct For mechanical unit arg more than one user frame has been defined. Description Recommended actions Orientation is incorrectly defined. Take away one user frame or define one more mechanical unit. Recommended actions Make an accurate normalization of the quaternion elements. 50086, Singularity problem Description 50078, Too many close positions Description Too close to wrist singularity with respect to numerical resolution for joint 4 of arg. Too many consecutive closely spaced positions. Recommended actions Recommended actions Change destination position a few increments. Increase the distance between consecutive close positions. 50087, Singularity problem 50079, Cannot use wrist weaving Description Too close to wrist singularity with respect to numerical resolution for joint 6 of arg. Description Wrist weaving not possible. Recommended actions Recommended actions Change destination position a few increments. Use smaller weaving amplitude or a larger TCP. 50088, Restart not possible 50080, Position not compatible Description Description It is not possible to restart the path due to a previous error. The desired position cannot be reached with the given robot configuration. Robot arg. Recommended actions Move the program pointer to clear the path and start a new movement. Recommended actions Modify the robot position in the program. 50089, Weaving changed 50082, Deceleration limit Description Description The ordered weaving is not achieved due to: Calculation of joint deceleration time exceeds internal limits for this motion. - high weaving frequency You cannot proceed without removing the cause(s) of this error. - that SingArea/Wrist is used with wrist weave. Recommended actions Recommended actions Increase path resolution (sys param or by PathResol for critical movements). Increase weave length or period time. 3HAC020738-001 - not allowed shift of weave method or - 235 3 Symptoms Don't shift between arm and wrist weave. 50101, Manipulator configuration Use SingArea/Off with wrist weave. Description 'arg' is not free for the param. 50091, Restart not possible. 'arg' in type 'arg' named 'arg'. Description Recommended actions Restart no longer possible. Change of unit state made restart of program impossible. Use another one. For internal names, see moc_chk.log. Recommended actions 50102, Manipulator configuration Move the program pointer and start a new movement. Description 50092, Axis computer response 'arg' used in the parameter 'arg' in type 'arg' named 'arg' is not defined. Description Recommended actions Incorrect response from axis computer. Use another one that is defined or define the used one. For internal names, see moc_chk.log. Recommended actions Check motion configuration parameters. 50103, Manipulator configuration Check axis computer hardware. Description 50094, TuneServo not possible The orientation defined by quaternions including 'arg' in the type 'arg' named Description 'arg' is not normalized.(SQRSUM =1) Tuning is not implemented for the specified joint. Recommended actions Recommended actions Check the quaternions and/or recalculate them. For internal names, see moc_chk.log. Verify that a parameter and/or joint that can be used with TuneServo is chosen. 50104, Manipulator configuration 50095, Cannot access joint. Description Description The parameter 'arg' in type 'arg' named 'arg' is not 'arg'. Cannot access external joint. Recommended actions Recommended actions Check the value. For internal names, see moc_chk.log. Check configuration and activation of external Joints. 50128, Manipulator configuration 50096, TuneServo not allowed Description Description Terminating the topic check for manipulator due to earlier errors. Tuning is not allowed for the specified joint. Recommended actions Recommended actions Correct the reported errors and run topic check again. Verify that a parameter and/or joint that can be used with TuneServo is chosen. 50132, Commutation failed Description 50100, Manipulator configuration Commutation failed for joint arg. Description Recommended actions There are more configurations or numerical errors in motion domain. - Make a new commutation. Recommended actions - Restart the system. Correct previous ones and try again. 236 - 3HAC020738-001 3 Symptoms 50133, Test signal error. 50141, Jog or Speed error Description Description No test signals are available for robot arg. One of the following problems occured: -Jogging error Recommended actions -High speed error Verify that correct test signals are defined. -Robot too close to singularity Recommended actions 50134, Corr. vector warning -Jog with incremental movement Description -Reduce the programmed speed Sensor correction vector calculations failed due to previous error. 50142, Manipulator configuration Recommended actions Description 50135, SoftAct not possible. Configuration of the manipulator failed. Description arg Soft servo is not possible to activate. arg Recommended actions Recommended actions Verify that a joint that can be used with SoftAct is chosen. Check the parameter values under System parameters:Manipulator. If mismatch between int/ext parameters i.e. wrong MOC.cfg loaded cold start the system with correct parameters. 50137, No finepoint 50143, Robot axes configuration Description Continous mode without any finepoint in the program. Description Recommended actions Actual configuration is not the same as ordered and/or movement of any robot axis is larger than 90 degrees. Robot arg, axis arg. Change at least one corner zone in the program to a fine point. Recommended actions 50138, Arm check point limit Use SingArea_Wrist, ConfL_Off, modify position or insert intermediary point. Description The robot arg has reached the limit for arm check point. 50144, Displ frame uncertain Recommended actions Description Use the joystick to move the involved joint into the working range again. Calibration of displacement frame uncertain for robot arg, due to one or several of: - Wrong TCP. 50139, Arm check point limit - Reference points inaccurate. Description - Reference points badly spaced. Jogging was made in wrong direction when arm check point was out of working range for robot arg. Recommended actions Recommended actions - Verify that correct TCP is used. Use the joystick to move the joint in opposite direction. - Try more than 3 reference points. If estimated error is unacceptable: - Be careful when positioning robot to reference points. 50140, Payload too large 50145, Kinematic limitation Description Description Heavy payload caused static torque limit to be exceeded on joint arg. Kinematic limitation for robot arg, no solution found. Recommended actions - Long segment. Check and reduce payload for arm and/or wrist. Reduce joint working range to decrease static torque due to gravity. 3HAC020738-001 - Position close to singularity. - 237 3 Symptoms - Joint 1, 2 or 3 out of range. 50156, Not an independent joint - Position outside reach. Description Recommended actions Joint arg is not configured as an independent joint. - Insert an intermediary point to reduce the length of the segment. - Use MoveAbsJ. Recommended actions - Check working range. Modify the program or configure the joint as an independent joint. 50146, Restart limitation 50157, Corr. vector warning Description Description Corner path executed as a stop point. Power fail restart not possible near the stop point. Sensor correction vector X calculations failed due to previous error. Recommended actions Recommended actions Use finepoint in the Move-instr before RestoPath, ActUnit, Wait or Stop-instr to make power fail restart possible. 50158, Sensor process missing Description 50147, Power fail restart failed Sensor process missing during initialization. Named sensor process arg could not be found or initialized. Description Recommended actions Re-creation of the path failed. Check process name in motion and process configuration files. Recommended actions Move the program pointer and start a new movement. 50159, No external process 50153, Command not allowed Description Description Attempt to coordinate motion or calculate position of single arg without an external process. The given instruction, or command, was not allowed since the robot program was executing in a hold state. (argargarg) Recommended actions Check process name in motion and process configuration files. Recommended actions Modify program or stop program execution before issuing command. 50160, Cannot reach position 50154, Command not allowed Description Description Programmed position of independent joint arg is outside working range and thus cannot be reached. SingArea\Wrist mode interpolation is not supported for the arg robot. Recommended actions Recommended actions - Change the position. Replace SINGAREA\WRIST instruction with SINGAREA\OFF. - Check the joint working area limits. - Check the used work object. 50155, Power fail restart failed 50161, Singularity area Description Description Not possible to restart the Move-instruction before RestoPath, ActUnit, Wait or Stop-instruction. Robot arg is close to a singularity. Work area with kinematic limitations. Recommended actions Recommended actions Remove MOTION WARNING 50146 Restart limitation, by changing the Move-instruction to finepoint. Move the program pointer and start a new movement. 238 During jogging, use axis by axis. During program execution, use MoveAbsJ. - 3HAC020738-001 3 Symptoms 50162, Internal position error Recommended actions Description Split segments with long interpolation time (path_resolution * 4 minutes) or change to joint interpolation or move position away from singularity. Error caused by internal numerical limitation. Recommended actions 50172, MoveJ not allowed - Reset independent joint. - Reduce work area if extended. Description - Remove or separate close points. MoveJ not allowed with work object coordinated with external position mechanical unit. 50163, Position adjustment Recommended actions Description Change interpolation mode or work object. External position adjustment too large. TCP speed, orientation speed, or external position speed exceed allowed robot performance. 50173, Fine point necessary Recommended actions Description - Reduce programmed TCP- and orientation speeds. Use fine point when changing tool or work object coordination when work object is coordinated with external position mechanical unit. - Modify the path. - WaitWObj closer to sync. Recommended actions - Run in AUTO. Create a fine point and then change the tool. 50164, Deactivation not possible 50174, WObj not connected Description Description Deactivation of mechanical unit may not be done while in independent mode. The WObj is not connected to the conveyor arg. Robot TCP cannot be coordinated to work object. Object can be dropped because of time synchronization fault on conveyor node. Recommended actions Make sure that independent mode is not used and try to deactivate again. Recommended actions Check for missing WaitWObj. Check for DropWObj occuring before end of coordination. 50167, Warning: new sync Check for time synchronization fault, see status on conveyor node. Description Warning: a new object sync signal has arrived while conveyor is active and program is running. 50175, Conveyor moving Recommended actions Conveyor arg moving while attempt to coordinate robot TCP to conveyor work object while in prohibited mode. 50168, New sync on arg Recommended actions Description It is not possible to coordinate to conveyor while in Manual Reduced Speed, or stepping in Auto, and the conveyor is moving. Description New object sync arrived while conveyor was tracking the previous object. Cannot track two objects simultaneously. 50176, Conveyor not active Recommended actions Description Reduce speed of conveyor. Increase programmed speed. Conveyor arg was not active when attempt to coordinate robot TCP to conveyor work object. 50171, Speed too low Recommended actions Description Make sure conveyor mechanical unit is active. Check for fine point for last coordinated motion before DeactUnit. Numerical problem when interpolation of long segments with low speed and heavy external axes or when interpolation close to singularity. 3HAC020738-001 - 239 3 Symptoms Recommended actions 50177, Unable to restart Description 50186, Missing function Conveyor arg moving while attempting to restart or before pressing Stop or stepping through program. Description Not possible to run robot arg with coordinated base frame. Function not installed in this system. Recommended actions Make sure conveyor is standing still. Move the program pointer and start a new movement. Recommended actions Install the option Multiple Axis Positioner. 50178, Non optimal movement 50187, Missing function Description Required torque too high. Manual adjustment of acceleration or speed is needed. Description Not possible to coordinate user frame with robot arg Function not installed in this system. Recommended actions Reduce acceleration (AccSet 50 100) in this movement, restore it afterwards (AccSet 100 100). Optimize performance by search for max acceleration 50-99. Alternatively, reduce speed. Recommended actions Install the option Multiple Axis Positioner. 50188, Non optimal movement 50181, Out of coupled range Description Description Required torque too high. Manual adjustment of weave frequency or amplitude is needed. Joint arg and arg are out of coupled working range. Recommended actions Recommended actions Use the joystick to move joints into their coupled working range. Reduce weave frequency or weave amplitude in this movement. Alternatively, reduce speed. 50182, Jog in wrong direction 50189, Relay signal not found Description Joint arg and arg are out of coupled working range. Description Recommended actions The signal arg for relay arg is not found in the I/O configuration. The mechanical unit using this relay is ignored. Use the joystick to move joints into their coupled working range. Recommended actions Check I/O signal definitions and System Parameters definition of Manipulator, Types: Relay. 50183, Robot outside work area. Description The robot has reached the World Zone arg, arg 50190, Permanent interpolator lock error Recommended actions Description Check the reason of the World Zone. Use the joystick to move the robot out of the World Zone if needed. Scanned number of active joints not equal to expected number of joints. Recommended actions 50184, Corr. vector warning Check configuration of the unit that is using general kinematics. Description Sensor correction vector calculations failed due to previous error. 50191, Too many TCP speed's Recommended actions Description The number of TCP speed's in one segment is too large. Maximum number of TCP speed's is arg. 50185, Corr. vector warning Description Sensor correction vector calculations failed due to previous error. 240 - 3HAC020738-001 3 Symptoms Recommended actions 50198, Calibration failed Check if one segment has too many TCP speed's set or if a sequence of segments have increasing DipLag. Description Internal error during calibration due to unknown origin switch. 50192, Jogging error Recommended actions Description - Report the occurance to ABB. - Make a new calibration. Jogging is started too soon after program stop. Recommended actions 50200, Torque error Try to jog the robot again. Description Torque calculation error due to high speed. 50193, Joint not synchronized Recommended actions Description - Check load data. The speed of joint arg before power down/failure was too high. - Reduce speed. Recommended actions Make a new update of the revolution counter. 50201, Orientation outside reach 50194, Internal position error Description The error of the programmed orientation exceeds the acceptance limit. Description Recommended actions Error caused by internal numerical limitation. Joint number arg. Calculated reference position = arg. - Adjust robtarget orientation. - Adjust/check orientations of currently used frames: tool frame, base frame, user frame, object frame... Recommended actions - Adjust the system parameters in Uncal ctrl master 0. - If TuneServo is used, adjust parameter Tune_df. 50203, Measurement node used 50195, Cannot move independent Description The measurement node for joint arg is already used. Description Recommended actions Joint arg cannot be moved in independent mode. Select another node. Recommended actions Make sure that independent mode is not used when trying to move joint. 50204, Motion supervision Description 50196, Calibration failed Motion supervision triggered for axis arg on mechanical unit arg. Description Consequences Points 0 and 1 too close. The movement of mechanical unit arg is halted immediately. It then returns to a position on the path on which it was running. There, it will remain in status Motors ON, awaiting a start request. Recommended actions Make a new calibration with larger distance between points 0 and 1. Probable causes 50197, Calibration failed Triggering of the motion supervision may be caused by a collision, incorrect load definition or forces in external process. Description Recommended actions Points 0, 1, 2 on a line or point 2 too close to points 0 or 1. 1) If possible, acknowledge the fault, and resume operation by pressing the Start button on the FlexPendant. Recommended actions 2) Make sure any loads are defined and identified correctly. Make a new calibration with points moved so that 0, 1 and 2 are not on a line or with larger distance between point 2 and points 0 and 1. 3HAC020738-001 3) If the mechanical unit is exposed to forces from the external processes, use RAPID command or system parameters to raise the supervision level. - 241 3 Symptoms 50205, Data logger error: 50212, Missing option Description Description arg General kinematics can not be used without the option 'GKIN'. Recommended actions Recommended actions Solution: Install the option 'GKIN'. arg 50214, Work area config failed 50206, Probe warning Description Description Probe buffer is full. Possibly the defined work area is larger than max allowed area for robot arg. Recommended actions Recommended actions Adjust the work area parameters in Robot system parameters and try again. 50207, Add intermediate point Description 50215, Load identification fail Intermediate point not coordinated to external pos mechanical unit is necessary when changing conveyor. Description Axis arg will move outside working range. Recommended actions Recommended actions Create an intermediate point then change the conveyor. Move the axis to a position further from the working range limit. 50208, Missing function 50218, Path not finished Description Description Friction compensation can not be activated for joint arg. Previous motion path was not finished before new motion was sent. Recommended actions Recommended actions Install the option Advanced Shape Tuning. Use StorePath when in Trap routines. Move the program pointer and start a new movement. 50209, Kinematic limitation Description 50220, No input signal No acceptable solution found. Residual: %ld deg in orientation, %ld mm in x, Description %ld mm in y, %ld mm in z. No input signal to contactor relay for mechanical unit arg Recommended actions Recommended actions Insert an intermediary point. Check singularity. Increase position and orient. tolerance. Use MoveAbsJ. Check working range. Ensure that an input signal is connected and configured. 50221, Object outside limit 50210, Load identification fail Description Object on conveyor arg is outside max dist or min dist limits. Object Dropped. Description Cannot perform load identification because configuration angle is too small. Recommended actions Recommended actions Check limits or reduce conveyor speed. - Increase configuration angle. 50222, Mismatch type - MechUnit Description Mismatch between selected manipulator type and selected mechanical unit. 242 - 3HAC020738-001 3 Symptoms Recommended actions 50230, Test signal error Make sure that selected manipulator corresponds to selected mechanical unit and try again. Description Invalid axis number arg for mechanical unit arg. 50224, Cannot define load Recommended actions Description Check mechanical unit and axis number. It is not allowed to define a load on axis arg for mechanical unit arg. 50231, Test signal error Recommended actions Description Change axis number or mechanical unit. Mechanical unit arg not active. 50225, Old boot safe area lost Recommended actions Description Activate mechanical unit before defining test signals. Error in boot safe memory area. 50234, Overflow during logging - Area updated with new data. - System unsynchronized. Description Recommended actions An overflow occured when logging test signals or data log signals. Update all revolution counters. Recommended actions - Define fewer signals. 50226, Motor reference error - Reduce load on main computer. Description - Reduce network load. Calculation time for motor references exceeds internal limits. 50235, No interrupts received Recommended actions - Reduce load on main computer. Description - Restart controller. No interrupts received from the robot communication card within timeout. 50227, Test signal error Consequences The system goes to status SYS FAIL. Description Probable causes Invalid channel number arg. The robot communication card may be faulty. Recommended actions Recommended actions Allowed channel numbers are 1 - 12 for test signals and 1 - 6 for data log signals. 1) Restart the system to resume operation. 2) Replace the robot communication card if faulty. 50228, Test signal error 3) Check any other error log messages coinciding in time with this one for clues. Description Unknown test signal number arg. 50236, Reference underrun Recommended actions Description Make sure that a valid test signal number is defined. Reference underrun in Main computer interrupt routine for Axis computer connected to connector board arg. 50229, Test signal error Recommended actions Description - Reduce load on main computer. Unknown mechanical unit arg. - Restart controller. - Replace Axis computer board. Recommended actions Check spelling or configuration. 3HAC020738-001 - 243 3 Symptoms 50237, Reference task error 50244, AbsAcc calibration failed Description Description Reference task queue full (Slot id = arg) Could not perform an AbsAcc calibration. Recommended actions Recommended actions - Reduce load on main computer. - Restart controller. - Restart controller. - Check that the harddrive isn't full. - Replace Axis computer board(s). - Install more memory. 50239, Optimal Em. Stop change 50245, Command not allowed Description Description Optimal Emergency Stop changed to Electrical brake mode because of acceleration limitation. Cannot set non motion execution mode when in MOTORS ON state. Recommended actions Change to MOTORS OFF. Recommended actions Limit acceleration in the program. 50246, Linked motor error 50240, Optimal Em. Stop change Description Description Large position offset between follower axis and master axis. Optimal Emergency Stop changed to Electrical brake mode because of torque limitation. Recommended actions Start linked motor service program. Recommended actions Check load data. 50247, Clear of Path failed Description 50241, Missing function The movement has to be stopped when the path is to be cleared. Description Absolute Accuracy not purchased. Recommended actions Recommended actions Use StopMove before the ClearPath instruction. Move the program pointer and start a new movement. Change Robot system parameter use_robot_calib to uncalib. 50248, Internal Servo Tool error 50242, Unsync due to CFG data Description Description Internal error for tool arg in state arg - Mismatch between controller and cfg data for joint arg (calibration offset or calibration position), or arg arg - Valid flags for calibration offset or commutation offset not true in cfg. arg Recommended actions Recommended actions Update measurement system: Contact ABB. - Update revolution counter. - Recalibrate joint. 50249, Programmed force reduced - Change cfg data. Description 50243, No acceleration limit Programmed tip force too high for tool arg. Requested motor torque (Nm)= arg. Force was reduced to max motor torque. Description Recommended actions Acceleration limitation is not implemented for robot arg. 1) Reduce programmed tip force. 2) Check force vs torque calibration in system parameters. 3) Check max motor torque in system parameters. 244 - 3HAC020738-001 3 Symptoms 50250, Calibration force reduced 50256, Sync pos warning Description Description Requested calibration force too high for tool arg. Requested motor torque (Nm)= arg. Force was reduced to max motor torque Sensor movement outside limits. The sensor start pos should be arg than arg and found arg. Recommended actions Recommended actions 1) Check calib forces in sys par. Check programmed sensor position in robtarget. Start sync earlier or change robtarget. 2) Check force vs torque calibration in system parameters. 3) Check max motor torque in system parameters. 50257, Sync speed warning 50251, Tool opening failed Description Programmed speed outside limits. The speed should be arg than arg and found arg. Description An ordered tool axis movement of arg was detected during tool opening. Recommended actions Recommended actions - Check programmed robot speed Make sure the tool opening is ready before executing next tool axis movement. Decrease the system parameter 'post sync time'. - Check sensor teach pos 50252, Tool opening failed 50258, Sensor direction error Description Description An ordered tool axis movement of arg was detected during tool opening in calibration. Programmed sensor pos speed arg and found sensor speed arg in opposite direction. Recommended actions Recommended actions Make sure no movements of the tool axis are ordered during calibration. - Check programmed sensor positions in robtarget. 50253, Cannot deactivate unit 50259, Sensor max dist error Description Description Deactivation of mechanical unit may not be done while in process mode. Distance between sensor position and programmed position too large. arg Recommended actions Recommended actions Make sure to leave process mode before deactivating mechanical unit. - Check programmed sensor positions in robtarget. - Check sensor nominal speed. - Start sync earlier or reduce waitsensor dist . - Check sensor speed. 50254, Linked motor error. - Start sync earlier or reduce waitsensor dist. Description 50260, Sensor Check dist error Too large speed for follower axis when follower axis is in jog mode. Description Recommended actions Distance sensor pos to programmed pos arg too large arg. Start linked motor service program. Reset jog mode. Recommended actions 50255, Missing function - Check programmed sensor positions in robtarget. - Check sensor speed Description - Increase max deviation. Linked motors can't be used without installing appropriate option. Recommended actions Install the option 'Electronically linked motors'. 3HAC020738-001 - 245 3 Symptoms 50261, WZone outside work area - Adjust programmed thickness Description 50267, Open request failed The definition of minimum limit for the World Zone arg is outside work area for: argargarg... Description Not allowed to open Servo Tool:arg in reverse direction Recommended actions Recommended actions Change the definition of the World Zone so the limit will be inside work area or insert 9E9 to remove an axis from test by the WZone. Check that programmed robtarget positions of the Servo Tool are larger than programmed thickness. 50262, WZone outside work area 50268, Calibration failed Description The definition of maximum limit for the World Zone arg is outside work area for: argargarg... Description Recommended actions Recommended actions Change the definition of the World Zone so the limit will be inside work area or insert 9E9 to remove an axis from test by the WZone. Adjust Servo Tool position before calibration Not allowed to calibrate Servo Tool:arg from negative position 50269, Tune value out of limit 50263, Duty factor warning Description Description Tune value for Servo Tool: arg is out of limit. Parameter: arg The duty factor for gear box at arg is too high. Recommended actions Recommended actions Adjust tune value Reduce the speed or increase the wait time. 50270, Pre position ignored 50264, Saved parameters used Description Description Pre position was ignored during calibration of Servo Tool arg. The pre position arg mm is out of range or is larger than current pos. Valid calibration data was found after system update and will be used unless a calib.cfg file is added with RobInstall or in syspar directory. Recommended actions Recommended actions - Skip pre position. If calibration data from file should be used, add a calib.cfg file with RobInstall or in syspar directory and make a new installation of system. - Adjust pre position. 50271, Poor event accuracy 50265, Thickness out of reach Description Description The system is presently configured with time event supervision, and now an event could not be accurately activated. Servo Tool: arg Programmed thickness arg mm is out of reach Recommended actions Recommended actions - Check working range (min. stroke) Decrease the programmed speed or increase the distance between the programmed positions. Turn off this check by changing the system parameters. 50266, Close request failed 50272, Manipulator configuration Description Description Not allowed to close Servo Tool:arg in reverse direction Failed to read arg data for arg , from the configuration file. - Adjust programmed thickness Pre close position: arg mm Recommended actions Programmed thickness: arg mm Check the configuration file - cold start the system with correct parameters. Recommended actions - Adjust pre close position 246 - 3HAC020738-001 3 Symptoms Check both configuration data for the current instance and any instances below (children). 50278, Manipulator configuration Description 50273, Manipulator configuration Failed to configure servo gun (arg). Description Recommended actions Incorrect configuration parameter arg for arg. The configuration parameter could for instance be an unknown type or a numerical value that is out of range. Check the servo gun data in the configuration file. Cold start the system with correct parameters. Recommended actions 50279, Manipulator configuration Check the configuration file - cold start the system with correct parameters. Description Servo tool change requires option Servo Tool Change. Without this option, installation of this mechanical unit is not allowed. 50274, Manipulator configuration Recommended actions Description Check the configuration file - cold start the system with correct parameters. Failed to read or create arg with the name: arg. If the current instance exists it is read, else it is created. In other words, the instance could not be read or created. 50280, System configuration Recommended actions Description Check the configuration file - cold start the system with correct parameters. Mechanical Unit arg is defined in more than one Rapid program. Recommended actions 50275, Manipulator configuration Check the configuration file - cold start the system with correct parameters. Description Failed to read next arg name, previous name is arg. The previous instance is ok, but the next instance cannot be read. 50281, Another process failed Recommended actions Description Check the configuration file - cold start the system with correct parameters. Task: arg This is a failure caused by another process. When using a multirobot controller system this failure occurs when a process fails and stops the motion planner. When this happens all other processes bound to the same motion planner are also stopped. 50276, Manipulator configuration Description arg Standard servo queue length (arg) out of range (min=1, max=arg). Recommended actions Recommended actions Check other messages from same time for reason. Check std_servo_queue_length in the configuration file - cold start the system with correct parameters. Recovery: arg 50282, Record not ready 50277, Manipulator configuration Description Description Record not ready to activate Number of joints (arg) in dynamic group override. Allowed number is arg. Recommended actions Make sure that record is finished before activating. Recommended actions Check sensor_start_signal Check the configuration file - cold start the system with correct parameters. 50283, Unknown record file name Description Record file name: arg is unknown. 3HAC020738-001 - 247 3 Symptoms Recommended actions 50289, Point type mismatch at sync Check file name or existence with file manager. Description Record a new file The move instructions with syncId = arg, have a mix between finepoints and zonepoints. 50284, Cannot activate Mechanical Unit Recommended actions Description Make sure that the move instruction in all cooperating program tasks specifies the same kind of point type, either finepoints or zonepoints. The Mechanical Unit arg cannot be activated because it is not connected to a Rapid task. Recommended actions 50290, Service unavailable Check that the connection between Mechanical Unit and Rapid task is done correctly in the SYS.cfg. Description Unable to obtain correct license. 50285, DitherAct not possible Recommended actions Please check the license settings. Description Dithering is not possible to activate. 50291, Deactivation not allowed Recommended actions Description Verify that a joint that can be used with DitherAct is chosen. Deactivation of mechanical unit arg is not allowed when task is in synchronized motion mode. 50286, Chain of coordinated frames Probable causes Description Instruction DeactUnit is used in a synchronized part of the program. It is not allowed to have a chain of coordinated frames. Recommended actions You have at least three units, where one unit is following another unit, which is following the third unit. - Make sure no DeactUnit instruction is used in a synchronized part of the program. Recommended actions - Move the program pointer to main. Rearrange the units so that all units, which perform coordinated movements, are following the same unit. 50292, Activation not allowed 50287, Unit not stopped Description Description Activation of mechanical unit arg is not allowed when task is in synchronized motion mode. The robot arg is semi coordinated to Unit arg and the Unit must stand still when the Robot is moving in the user_frame. Probable causes Instruction ActUnit is used in a synchronized part of the program. Recommended actions Use WaitSyncTask for the involved programs and check that the Unit is stopped in a fine point before the WaitSyncTask. Recommended actions 50288, Sync ID mismatch - Move the program pointer to main. - Make sure no ActUnit instruction is used in a synchronized part of the program. Description 50293, Configuration error The specified id number for the move instruction has to be equal for all cooperating program tasks. Description Current id number mismatch arg, arg. The configuration file is erroneous concerning SMB memory storage. Recommended actions Probable causes Verify that the specified id numbers are equal and that all PP are synchronized before program start. Wrong parameter set up in configuration file. Wrong type of SMBboard. Recommended actions - Make sure that parameter memory_index is defined. 248 - 3HAC020738-001 3 Symptoms - Use SMB-board with memory functionality. Probable causes Recommended actions 50294, Transmission error of data Description 50299, Speed control warning Transmission of data between cabinet and SMB-memory has faild. Description Probable causes Speed for Unit arg is reduced due to limiting Unit arg. Cable, or transmission electronics failed. Electrical interference high. Task: arg Intruction line: arg Recommended actions Probable causes - Restart try once more. Programmed speed too high on this Unit or movement too long on limiting Unit - Check cables. - Check SMB-board. Recommended actions - Check drive module. Change path or programmed speed . Set speed control off 50295, Manipulator data missing 50300, Sensor memory missing Description Data in SMB- and cabinet memory missing. Description Probable causes No sensor memory is defined for this mechanical unit. Configuration file missing. New SMB-board together with new cabinet. Probable causes Recommended actions Sensor memory is not defined in configuration for this mechanical unit. - Load new configuration files. Recommended actions Add memory index in configuration file for all joints for this mechanical unit. 50296, SMB memory data difference Description Data in SMB-memory is not same as in cabinet. 50301, All sensor data missing Probable causes Description Wrong cfg used, manipulator/SMB or cabinet exchanged. All data is missing in SMB-memory at board arg, link arg, drive module arg. Recommended actions Probable causes - Select manually the data to be used via teach pendent. An error in SMB-memory or communication has occurd. The data has been cleared. 50297, Memory updated in SMB Recommended actions Description If proper data exists in cabinet - transfer the data to SMB-memory. If still problem - check communication cable to SMB-board. Replace SMB-board. Data for mechanical unit arg is moved from cabinet to SMB-memory. Probable causes Recommended actions 50302, Sensor data missing Description 50298, Memory updated in cabinet No serial number is defined for mechanical unit arg in SMB-memory. Description Probable causes Data for mechanical unit arg is moved from SMB-memory to cabinet. The sensor memory has been cleared or new SMB-board has been installed. Recommended actions If proper data exists in cabinet - transfer the data to SMB-memory. 3HAC020738-001 - 249 3 Symptoms 50303, Cabinet data missing 61005, Invalid filter time Description Description No serial number is defined for mechanical unit arg in cabinet. The I/O configuration for signal <arg> is invalid. Probable causes The passive filter time should either be 0 ms or in the range [arg, arg] ms. The cabinet memory has been cleared or new cabinet has been installed.. This signal has been rejected. Recommended actions Recommended actions 1. Correct the passive filter time for the signal. If proper data exists in SMB-memory - transfer the data to cabinet memory. 61006, Invalid filter time 61001, Duplicated address Description Description The I/O configuration for signal <arg> is invalid. The I/O configuration is invalid. The active filter time should either be 0 ms or in the range [arg, arg] ms. The same addresses have been given for unit <arg> and unit <arg>. This signal has been rejected. Units connected to the same bus must have unique addresses. Recommended actions This unit has been rejected. 1. Correct the active filter time for the signal. Recommended actions 1.Check that addresses are correct. 61007, Logical values out of range 2.Check that the units are connected to the correct bus. Description 61002, Unit type undefined The I/O configuration for signal <arg> is invalid. Description The logical minimum value must be less than the logical maximum value. The I/O configuration for unit arg is invalid. This signal has been rejected. Consequences Recommended actions This unit type has been rejected, and no functions depending on this unit type will work. 1. Correct the logical values for the signal so that the minimum value becomes less than the maximum value. Probable causes 61008, Physical values out of range The unit type named arg is unknown. All units must refer to an existing, defined unit type. Description Recommended actions The I/O configuration for signal <arg> is invalid. 1) Make sure the unit type is defined. The physical minimum value must be less than the physical maximum value. 2) Make sure the unit type is correctly spelt. This signal has been rejected. 61003, Unit undefined Recommended actions 1. Correct the physical values for the signal so that the minimum value becomes less than the maximum value. Description The I/O configuration for signal arg is invalid. Consequences 61017, Cross-connection without actor signal This signal has been rejected, and no functions depending on it will work. Description Probable causes The I/O configuration is invalid. The unit arg is unknown. All signals must refer to an existing/defined unit. The parameter <Actor signal arg> of one of the cross-connections have been omitted. Rules: Recommended actions 1. All cross-connections must specify at least one actor signal, i.e. parameter <Actor signal 1> must always be specified. 1) Make sure the unit is defined. 2) Make sure the unit name is correctly spelt. 250 - 3HAC020738-001 3 Symptoms 2. For each operator specified an actor signal must follow, e.g. if parameter <Operator 2> is specified then parameter <Actor 3> must also be specified. 61037, Closed chain in cross-connection Description This cross-connection has been rejected. The I/O configuration is invalid. The signal <arg> is part of a cross-connection chain that is closed (i.e. forms a circular dependence that cannot be evaluated). Recommended actions 1. Correct the cross-connection so the required actor signals are specified. The complete cross-connection configuration has been rejected. Recommended actions 61019, Signal undefined 1. Correct the configuration for the cross-connections where the signal above is part. Description The I/O configuration of a cross-connection is invalid. 61038, Cross-connection max depth exceeded Consequences Description The cross connection has been rejected, and no functions depending on it will work. The I/O configuration is invalid. The signal <arg> is part of a cross-connection chain that is too deep. Probable causes The maximum depth of a cross-connection chain is <arg>. The parameter <Actor signal arg> of one of the cross-connections contains a reference to an undefined signal named arg. The complete cross-connection configuration has been rejected. Recommended actions Recommended actions 1. Make the cross connection less deep. 1) Make sure the signal is defined. 2) Make sure the signal name is correctly spelt. 61045, Invalid filter specification 61020, Cross-connection without resultant signal Description The I/O configuration for signal <arg> is invalid. No filter times can be specified for this type of signal. Description This signal has been rejected. The I/O configuration is invalid. Recommended actions The parameter <Resultant signal> of one of the cross-connections have been omitted. 1. Set filter time to 0 or remove the statement. All cross-connections must specify a resultant signal. This cross-connection has been rejected. 61049, Analog signal inverted Recommended actions Description 1. Correct the cross-connection so that there are one result signal per cross-connection. The I/O configuration for signal <arg> is invalid. Analog signals must not be inverted. Only digital and group signals can be inverted. 61021, Duplicated cross-connection resultants This signal has been rejected. Description Recommended actions The I/O configuration is invalid. 1. Remove the invert for the signal (or change the signal type). Multiple cross-connections have the same resultant signal <arg>. Having more than one cross-connection that result in the setting of the same signal may cause unpredictable behaviors, as you cannot control their order of evaluation. 61050, Cross-connection with non digital actor signal The complete cross-connection configuration has been rejected. Description Recommended actions The I/O configuration is invalid. 1. Make sure that the signal is not specified as the resultant of several cross-connections. The parameter <Actor signal arg> of one of the cross-connections refer to a signal named <arg>, that is not digital. Only digital signals can be cross-connected. This cross-connection has been rejected. 3HAC020738-001 - 251 3 Symptoms Recommended actions Probable causes 1. Remove the non-digital signal from the cross-connection. The unit may have been disconnected from the system. Recommended actions 61052, Max number of cross-connections exceeded 1) Make sure the unit has been correctly installed. 2) Make sure the cabling to the unit is correctly connected. Description The I/O configuration is invalid. 61061, Communication failure on I/O bus The maximum number of cross-connections <arg> in the I/O system has been exceeded. Description A communication failure on bus arg has been detected. Not all the cross-connections have been accepted. Recommended actions Recommended actions 1. Check other messages for fieldbus specific error. Modify the configuration of the I/O system (by reducing the number of cross-connections) so that the maximum limit is not exceeded. 2. If no units are configured to bus, configure units or remove bus configuration. 61054, Invalid signal type 61072, Cannot read stored signal value Description Description The I/O configuration for signal <arg> is invalid. Cannot read the stored signal value for signal <arg> as it is not stored. The specified signal type <arg> is invalid/unknown. Valid signal types are: Recommended actions - DI (Digital input) 1. Change the configuration of the signal by setting the store attribute. - DO (Digital output) - AI (Analog input) 61076, Communication error from rtp1 - AO (Analog output) - GI (Group input) Description - GO (Group output) No response from the serial line. This signal has been rejected. Recommended actions Recommended actions 1. Check the device or connection. 1. Correct the signal type of the signal. 61077, Communication error from rtp1 61056, Power fail restore full Description Description Not possible to deliver the received message. Signal <arg> could not be setup for power failure restore. Recommended actions The table for power fail is full. 1. Check the communication flow. Recommended actions 61078, Communication error from rtp1 1. Remove some other signals from the restore list. Description 61058, Lost communication with I/O unit The response from the device has a invalid frame sequence. Description Recommended actions The previously working communication with unit arg on bus arg has been lost. 1. Check for noise on the serial line Consequences 61080, Max number of unit types exceeded It is not possible to access the unit itself or signals on the unit since it is currently not communicating with the controller. The system will go to state SYS FAIL, if the unit has been assigned trustlevel 0 in the configuration. 252 Description The I/O configuration is invalid. The maximum number <arg> of unit types in the I/O system has been exceeded. - 3HAC020738-001 3 Symptoms Recommended actions Recommended actions Modify the configuration of the I/O system (by reducing the number of unit types) so that the maximum limit is not exceeded. Modify the configuration of the I/O system (by reducing the number of subscribtions) so that the maximum limit is not exceeded. 61081, Max number of physical signals exceeded 61085, Max number of units exceeded Description The I/O configuration is invalid. The I/O configuration is invalid. The maximum number <arg> of units in the I/O system has been exceeded. Description The maximum number <arg> of physical signals (bit-mappings) in the I/O system has been exceeded. Recommended actions Modify the configuration of the I/O system (by reducing the number of units) so that the maximum limit is not exceeded. Recommended actions Modify the configuration of the I/O system (by reducing the number of physical signals) so that the maximum limit is not exceeded. 61097, Input signal stored 61082, Max number of signals exceeded Description Description The I/O configuration for signal <arg> is invalid. The I/O configuration is invalid. Input signals must not be stored. The maximum number <arg> of user-defined signals (including panel signals) in the I/O system has been exceeded. Only output signals can be stored. Recommended actions Recommended actions Modify the configuration of the I/O system (by reducing the number of signals) so that the maximum limit is not exceeded. 1. Remove the store for the signal (or change the signal type). This signal has been rejected. 61098, NFS server lost 61083, Max number of symbols exceeded Description Description The contact with the NFS server <arg> is lost. The I/O configuration is invalid. Recommended actions The maximum number <arg> of symbols in the I/O system has been exceeded. 1. The NFS server. 2. The network connection. The number of symbols is the sum of all named configuration instances: 3. The controller configuration. - Buses - Unit types 61099, Trusted NFS server lost - Units - Signals Description - Command types The contact with the trusted NFS server <arg> is lost. - Access levels Recommended actions - Trust levels 1. The NFS server. Recommended actions 2. The network connection. Modify the configuration of the I/O system (by reducing the number of symbols) so that the maximum limit is not exceeded. 3. The controller configuration. 61100, Max number of buses exceeded 61084, Max number of subscribed signals exceeded Description The I/O configuration is invalid. The maximum number <arg> of buses in the I/O system has been exceeded. Description The I/O configuration is invalid. The maximum number <arg> of subcribed signals in the I/O system has been exceeded. 3HAC020738-001 Recommended actions Modify the configuration of the I/O system (by reducing the number of buses) so that the maximum limit is not exceeded. - 253 3 Symptoms 61101, Bus undefined 61110, Interbus bus failure Description Description The I/O configuration for unit arg is invalid. The control system has lost communication with the unit at address arg.arg. Interbus specific error code: arg. Consequences Consequences This unit has been rejected, and no functions depending on it will work. Parts of the Interbus network will not be accessible, depending on the network topology and the nature of the fault. Probable causes The bus named arg is unknown. All units must refer to a defined bus. Probable causes Recommended actions A number of errors may cause this. Further information may be found in the standard Interbus documentation. 1) Make sure the bus is defined. Recommended actions 2) Make sure the bus name is correctly spelt. 1) Make sure the unit at the above address is functioning correctly. 2) Check the Interbus specific error code as specified in the Interbus Manuals: Firmware Service and Error Messages. 61108, Interbus unit failure Description 61111, ID code mismatch Unit arg at address arg reported peripheral fault. Interbus specific error code: arg. Description Consequences The ID code arg read from Interbus unit arg doesn't match the expected value arg from the unit type configuration. The unit can not be contacted by the control system. Parts of the Interbus network will not be accessible, depending on the network topology and the nature of the fault. Consequences The unit has not been configured, and can not be used by the system. Probable causes Probable causes A number of errors may cause this. Further information may be found in the standard Interbus documentation. Wrong ID code value may have been introduced to the system parameter configuration file. The Interbus network may have been configured with a unit with the wrong ID code. Recommended actions 1) Make sure the unit at the above address is functioning correctly. Recommended actions 2) Check the Interbus specific error code as specified in the Interbus Manuals: Firmware Service and Error Messages. 1) Check the ID code of the unit's unit type in the system parameter configuration file. How to check the configuration file is detailed in the Trouble Shooting Manual. 61109, Interbus bus failure 2) Replace the unit with a unit of the correct ID code in the Interbus configuration as specified in the supplier's documentation. Description 3) Specify a generic unit type in the system parameter configuration file: ibsGeneric and ibsSlave. The control system has lost communication with the Interbus network. There is no error message from any Interbus board. Consequences 61114, Invalid IP address Parts of the Interbus network will not be accessible, depending on the network topology and the nature of the fault. Description The IP address <arg> is not valid. Probable causes A number of errors may cause this. Further information may be found in the standard Interbus documentation. Recommended actions 1. Check the communication configuration. Recommended actions 61115, Invalid subnet mask 1) Make sure the Customer Power Supply unit, supplying the Interbus network with power, is working correctly. Replace any faulty unit. Description 2) Make sure any fuses are correctly connected. The subnet mask <arg> is not valid. 3) Make sure all communication cables and connectors are working correctly and of the recommended type. Recommended actions 4) Check network topology and cable length. 1. Check the communication configuration. 5) Restart system. 254 - 3HAC020738-001 3 Symptoms 61116, Disabled unit with trustlevel 0 61129, Too many remote disks Description Description The I/O configuration of unit <arg> is invalid. The maximum number of remote mounted disks have been exceeded. Units with trustlevel 0 (Required) is not allowed to be disabled. The maximum number is <arg>. This unit has been rejected. Recommended actions Recommended actions 1. Reduce the number of remote mounted disks. 1. Correct the configuration of the unit by either enabling it or changing the trustlevel. 61130, Too many remote servers Description 61122, Incorrect IP address Description The maximum number of servers for remote mounted disks have been exceeded. The address <arg> in protocol <arg> is not a correct IP address. The maximum number is <arg>. Recommended actions Recommended actions 1. Correct the address. 1. Reduce the number of servers. 61123, No transmission protocol 61131, Could not mount directory Description Description The transmission protocol <arg> given for application protocol <arg> could not be found. Protocol: <arg>. Recommended actions Recommended actions 1. Change the transmission protocol. 1. Check the server setup. 61125, Mount Permission denied 61139, Access error from IO Description Description Permission was denied to mount the directory <arg> on the server <arg>. Cannot read or write signal <arg> due to communication down. Mounting directory <arg> on the computer <arg> failed. Recommended actions Recommended actions 1. Check 'No contact with I/O unit' report for reason. 1. Change the User or Group ID. 61141, Default signal value out of range 61126, Directory not exported Description Description The I/O configuration for signal <arg> is invalid. Mounting directory <arg> as <arg> failed since it is not exported on the server computer <arg>. The default value is out of range. This signal has been rejected. Protocol: <arg>. Recommended actions Recommended actions 1.Change the default value for the signal. 1. Export the directory on the server computer. 61145, Interbus bus has been deactivated 61128, Ethernet not installed Description Description The Interbus bus has switched to a none running mode. The Ethernet Services option has to be installed when using remote mounted disk. Recommended actions 1) Restart the system Recommended actions 2) Check that correct Interbus boot project is selected. 1. Reboot and install the Ethernet Services option. 3HAC020738-001 - 255 3 Symptoms 61147, No response from the Interbus network 61164, Internal signal in cross-connection Description Description Access to the Interbus network is denied. The I/O configuration contains an invalid cross-connection. Recommended actions The actor arg signal <arg> is an user-defined signal whereas the resultant signal <arg> is an internal signal. 1) Check the Interbus board It is not allowed to set up cross-connections where user-defined signals affects internal signals. 2) Check the internal Interbus configuration 3) Reduce the cycle time on the slave unit. Recommended actions Correct the cross-connection so that there are no internal signals in the resultant expression. 61148, No access to the Interbus network Description 61165, FTP server went down Access to the Interbus service interface is denied during arg, error code is 0xarg. Description Recommended actions The connection to a non-trusted FTP server has been lost. 1) Check the internal Interbus configuration IP address: <arg>. 2) The Interbus may be faulty. Replace any faulty unit if required. Recommended actions 1. Check cable and FTP server settings. 61156, IPC queue full Description 61166, FTP server went down The interprocess communication (IPC) queue <arg> was full, when sending to trap routine. Description The connection to a trusted FTP server has been lost. Recommended actions IP address: <arg>. 1. Restart the system Recommended actions 61158, Address out of range 1. Check cable and FTP server settings. Description 61167, Wrong transmission protocol The I/O configuration is invalid. The address of unit <arg> is invalid (out of range). Description This unit has been rejected. No matching transmission protocol was found in the configuration. Recommended actions Recommended actions 1. Change the address 1. Change the transmission protocol. 2. Check the address syntax 61169, Ethernet not installed 61163, Signal on internal unit Description Description The option Ethernet Services with FTP is not installed on this system. The I/O configuration is invalid. Recommended actions The user-defined signal <arg> must not be connected to the internal unit named <arg> 1. Reboot and install the Ethernet Services with FTP option. User defined signals are not allowed to be connected to internal units. 61182, Signal undefined This signal has been rejected. Recommended actions Description 1. Connect the signal to another unit. The I/O configuration is invalid. The parameter <Resultant signal> of one of the cross-connections contains a reference to an undefined signal named <arg>. This cross-connection has been rejected. 256 - 3HAC020738-001 3 Symptoms Recommended actions This signal has been rejected. 1. Correct the cross-connection so that the resultant signal refers to an existing signal. Recommended actions 1. Correct the encoding type for the signal. 61183, Cross-connection with invalid operator 61201, Unknown bus Description Description The I/O configuration is invalid. The I/O configuration is invalid. The parameter <Operator arg> of one of the cross-connections contains an invalid/unknown operator: <arg>. Consequences Valid values for the logical operator are: This bus has been rejected, and no functions depending on it will work. - AND Probable causes - OR The bus named arg cannot be found in the system. This cross-connection has been rejected. Recommended actions Recommended actions 1) Make sure the system has been configured with the desired bus. 1. Correct the operator. 2) Make sure the bus option at hand is installed. 3) Check the bus configuration. How to check the configuration file is detailed in the Trouble Shooting Manual. 61185, Duplicated name Description The I/O configuration is invalid. 61205, Could not mount directory The identifier <arg> has already been used as the name of another configuration instance. Description Mounting directory <arg> on the computer <arg> failed. The following configuration instances must have unique names: Protocol: <arg>. - Access level - Bus Recommended actions - Unit type 1. Check the FTP server setup - Unit 2. Check the FTP client configuration - Signal 3. Check communication hardware, cabling - Command type This configuration instance has been rejected. 61220, No Profibus option has been installed Recommended actions Description 1. Rename one of the configuration instances in the I/O-configuration file. A Profibus-DP master/slave board has been fitted, but no Profibus option has been installed. 2. Restart the system. Consequences Description No communication on the Profibus is possible. There may be consequential errors from configuring Profibus when no such option has been installed. IO Mapping error on unit <arg>. Probable causes Recommended actions An attempt may have been made to add the Profibus functionality, without installing the option correctly. 61193, Invalid physical IO mapping 1. Check configuration for physical signal mapping Recommended actions 61196, Invalid encoding type 1. If the Profibus option is required: configure a new system WITH this option, and install the system. Description 2. If the Profibus option is NOT required: configure a new system WITHOUT this option, and install the system. The I/O configuration for signal <arg> is invalid. The encoding type <arg> is not valid for signal type <arg>. Valid encoding types are: - UNSIGNED - TWO_COMP 3HAC020738-001 - 257 3 Symptoms Recommended actions 61221, Profibus firmware file not found Description 61227, Initialization of Profibus slave failed The Profibus <arg> firmware file not found or not readable. The board firmware may be out of date. Description Recommended actions The slave channel on the Profibus-DP master/slave board did not start up correctly. 1. Reinstall the system Consequences No communication on the Profibus slave channel is possible. 61222, Profibus file not found Probable causes Description The board hardware may be malfunctioning. The binary Profibus configuration was not found. - File: <arg> Recommended actions - Path: <arg> 1. Restart the system. 2. Replace the Profibus slave board if faulty. Recommended actions 1. Make sure the file exists. 61228, Profibus binary cfg fault 2. Change the path in the I/O-configuration. Description 61223, Profibus file parse error The configuration data in the binary file is not accepted by the slave at address arg. Description The binary Profibus configuration file is corrupt. (Internal error: arg) Recommended actions - File: <arg> 1. Make the configuration data in the binary file match the configuration for the slave and reboot the system - Path: <arg> Recommended actions 61229, Profibus binary prm fault 1. Recreate and download the binary configuration file using the external Profibus configuration tool. Description 61224, Profibus channel has been reflashed The parameter data in the binary file is not accepted by the slave at address arg. Description Recommended actions The arg channel firmware of the Profibus board has been updated from <arg> to <arg>. 1. Make the parameter data in the binary file match the parameters for the slave and reboot the system. 61225, Profibus cfg error 61230, Unit configuration error Description Description Unit arg is configured in system parameters but is missing or incorrect in profibus binary file. The local slave channel has more DI/DO than the configuration in its master. Recommended actions Recommended actions 1. Check/change system parameters. 1. Make the number of DI/DO of the external Profibus master more or equal than the local slave. 2. Check/change profibus binary file. 61226, Profibus configuration ok 61241, Too many boards on bus Description Description The number of DI/DO of the external Profibus master is now more or equal than for the unit of DP_SLAVE type. The I/O configuration for unit <arg> is invalid. The number of units on bus <arg> must not exceed <arg>. This unit has been rejected. Recommended actions 1. Reduce the number of defined boards and reboot the system. 258 - 3HAC020738-001 3 Symptoms 61244, Incorrect Interbus unit type Probable causes Description Unit arg at address arg has a unit type not supported by the system. The Interbus unit address in the Interbus configuration file differs from that in the system parameters configuration file, or the unit may not have been configured at all in the Interbus configuration file. Consequences Recommended actions The unit has not been configured, and can not be used by the system. 1) Make sure the configuration file EIO.cfg is correct. How to check the configuration file is detailed in the Trouble Shooting Manual. Probable causes 2) Reconfigure the Interbus network. One or more of the units connected to the network is of a hardware version not supported by the system. 61249, Interbus unit configuration mismatch Recommended actions Description 1) Replace the unsupported unit with one of the correct version. The Interbus unit with address arg.arg is configured in the Interbus configuration file, but not in the system parameters configuration file. 2) Make sure the system parameter configuration file is correct. How to check the configuration file is detailed in the Trouble Shooting Manual. Consequences 3) Reconfigure the Interbus network. The unit has not been configured, and can not be used by the system. Probable causes 61245, Unit not defined in Interbus The Interbus unit address in the Interbus configuration file differs from that in the system parameters configuration file, or the unit may not have been configured at all in the system parameters configuration file. Description Unit arg.arg is not assigned to any address in the Interbus configuration. Recommended actions 1) Make sure the configuration file EIO.cfg is correct. How to check the configuration file is detailed in the Trouble Shooting Manual. Consequences The unit has not been configured, and can not be used by the system. 2) Reconfigure the Interbus network. Probable causes Data for defining the unit is missing in the Interbus configuration file. 61250, Can not configure Interbus board Recommended actions Description 1) Change the Interbus configuration file using the CMD tool under the Process Data menu. Add an address for the unit. The CMD tool is available from your local ABB representative. An error has occurred when downloading Interbus configuraion files to the Interbus board. Interbus specific error code: arg. Consequences 61246, No access to Interbus data The bus has not been configured, and can not be used by the system. Description Probable causes Access to the Interbus board data interface is denied. arg not performed, error code arg. In RobotStudioOnline, the path specifying the configuration files points out the wrong files or that configuration file is incorrect. Recommended actions Recommended actions 1) The Interbus board may be faulty. Replace any faulty boards if required. 1) Use RobotStudioOnline to check the path to the configuration files. 2) Check the Interbus internal configuration. 3) Check the Interbus specific error code as specified in the Interbus Manuals: Firmware Service and Error Messages. 2) Make sure the configuration files are correct. 61248, Interbus unit configuration mismatch 61258, Interbus file not found Description Description The Interbus unit with address arg is configured in the system parameters configuration file, but not in the Interbus configuration file. The Interbus configuration file arg, configured in the system parameters, was not found. Consequences Consequences The unit has not been configured, and can not be used by the system. The bus has not been configured, and can not be used by the system. 3HAC020738-001 - 259 3 Symptoms Probable causes Probable causes The Interbus configuration file does not exist or the path specified in the system parameters was incorrect. 1. The address of the unit in the system parameters is not the same as in the bus specific configuration file. Recommended actions 2. The unit has not been configured at all in the bus specific configuration file. 1) Make sure the Interbus configuration files are correctly located. Recommended actions 2) Use RobotStudioOnline to check the path to the configuration files. 1. Check unit configuration in system parameters 2. Check bus specific configuration file 61259, Can not read the Interbus configuration file 61274, Interbus bus failure Description Description An error occurred when attempting to read the Interbus board configuration file arg. The control system was unable to determine the bus operating mode of the Interbus board. Consequences Recommended actions The bus has not been configured, and can not be used by the system. 1) Restart the system. Recommended actions 1) Reload the Interbus configuration file to the robot controller. 61276, Regained contact with unit 2) Restart the system. Description 61260, Interbus bus failure Regained contact with unit <arg>. Description Recommended actions The control system has lost communication with the Interbus network. Interbus specific error code: arg. 61278, Mount Permission denied Consequences Description Parts of the Interbus network will not be accessible, depending on the network topology and the nature of the fault. Permission was denied to mount the directory <arg> on the server <arg>. Probable causes Recommended actions A number of errors may cause this. Further information may be found in the standard Interbus documentation. 1. Check the username and password. Recommended actions 61288, Mount Path is too large 1) Make sure all communication cables and connectors are working correctly and of the recommended type Description 2) Check the Interbus specific error code as specified in the Interbus Manuals: Firmware Service and Error Messages. Mount path is too large. Mount path consists of FTP server mount point and server path. - Max length: <arg> - Protocol used: <arg> 61261, Transport layer failure Recommended actions Description Change FTP server mount point or server path. The physical channel for transport layer arg is invalid. Recommended actions 61289, Memory Partition is too big 1. Verify that the physical channel is valid, see manual. Description The memory partition for communication purposes can not be allocated. The requested partition arg kB. System partition will be used. 61273, Unit configuration mismatch Description Unit arg is configured in the system parameters, but it cannot be found in the bus specific configuration file. 260 Recommended actions Decrease commPartSize - 3HAC020738-001 3 Symptoms Recommended actions 61290, Could not add FTP Device 1. Change size in configuration. Description 2. Check module. Adding the FTP device <arg> to the operating system failed. Application protocol <arg>. 61297, Invalid connection type Recommended actions Description Change the local path of the configuration of the FTP device. The DeviceNet unit <arg> does not support the connections configured. 61291, Invalid Local Path Recommended actions Description 1. Change connection 1 type and/or connection 2 type in configuration. Local path of the FTP device <arg> is invalid. 2. Use DN_GENERIC unit type. Recommended actions 61298, Duplicated address Local path must end with : Description 61293, Invalid input size The address arg for the DeviceNet master on bus arg is occupied by another IO module on the network. Description Recommended actions On DeviceNet unit <arg> the connection 1 input size does not match the unit. 1. Change master address in configuration. 2. Disconnect IO module occupying the address from the network. Recommended actions 3. Restart system. 1. Change size in configuration. 2. Check module. 61299, No bus power 3. Use DN_GENERIC unit type Description 61294, Invalid output size The 24 V power supply from the DeviceNet Power Supply is missing. Description Consequences On DeviceNet unit <arg> the connection 1 output size does not match the unit. No communication on the DeviceNet bus arg is possible. Recommended actions 2. Check module. The power supply unit, cabling, input voltage to the power supply or the output load may cause the power loss. See the Trouble Shooting Manual and Circuit Diagram! 3. Use DN_GENERIC unit type Recommended actions Probable causes 1. Change size in configuration. 1) Check all cabling to the power supply unit. 61295, Invalid input size 2) Measure the output and input voltage levels. 3) Replace the faulty unit if required. Description On DeviceNet unit <arg> the connection 2 input size does not match the unit. 61300, DeviceNet Bus communication warning Recommended actions Description 1. Change size in configuration. A minor number of communiction errors occured on DeviceNet bus arg. 2. Check module. Consequences 61296, Invalid output size Normal operation will be maintained, even on the DeviceNet. Description Probable causes On DeviceNet unit <arg> the connection 2 output size does not match the unit. The fault may be caused by interference, power supply units and cables, or communication cables. 3HAC020738-001 - 261 3 Symptoms Recommended actions - Actual: <arg> 1) Make sure any terminating resistors are correctly connected. Recommended actions 2) Make sure all communication cables and connectors are working correctly and of the recommended type. 1. Change vendor id in configuration. 2. Check that the type of unit is correct. 3) Check network topology and cable length. 4) Make sure the DeviceNet Power Supply unit is working correctly. Replace any faulty unit. 61304, Invalid DeviceNet device type Description 61301, Bus Off, DeviceNet Bus comm. failure The device type read from DeviceNet unit arg doesn't match value in unit type configuration. Description - Configuration: <arg> A major number of communiction errors occured on DeviceNet bus arg. - Actual: <arg> Recommended actions Consequences 1. Change device type in configuration. All communication on the DeviceNet Bus has stopped. 2. Check that the type of unit is correct. Probable causes The fault may be caused by interference, power supply units and cables, or communication cables. 61305, Invalid DeviceNet product code Description Recommended actions The product code read from DeviceNet unit arg doesn't match value in unit type configuration. 1) Make sure the DeviceNet Power Supply unit is working correctly. Replace any faulty unit. - Configuration: <arg> 2) Make sure any terminating resistors are correctly connected. - Actual: <arg> 3) Make sure all communication cables and connectors are working correctly and of the recommended type. Recommended actions 4) Check network topology and cable length. 1. Change product code in configuration 5) Restart system. 2. Check that the type of unit is correct. 61302, No DeviceNet option has been installed 61306, DeviceNet Unknown error Description Description A DeviceNet master/slave board has been fitted, but no DeviceNet option has been installed. An unknown error is reported from unit arg error code arg. Recommended actions Consequences 1. Restart system. No communication on the DeviceNet is possible. There may be consequential errors from configuring DeviceNet when no such option has been installed. 2. Report problem to ABB. 61307, DeviceNet generic connection 1 Probable causes An attempt may have been made to add the DeviceNet functionality, without installing the option correctly. Description Recommended actions Real values: On DeviceNet unit arg connection 1 configuration are generic. - Connection 1 type: <arg> 1. If the DeviceNet option is required: configure a new system WITH this option, and install the system. - Connection 1 input size: <arg> - Connection 1 output size: <arg> 2. If the DeviceNet option is NOT required: configure a new system WITHOUT this option, and install the system. Recommended actions 1. Create a new unit type with correct values. 61303, Invalid DeviceNet Vendor id 2. Update your current unit type configuration. Description The vendor id read from DeviceNet unit arg doesn't match value in unit type configuration. - Configuration: <arg> 262 - 3HAC020738-001 3 Symptoms Recommended actions 61308, DeviceNet generic connection 2 1. Change configuration. Description On DeviceNet unit arg connection 2 configuration are generic. 61313, Fieldbus command type order number not unique. Real values: - Connection 2 type: <arg> - Connection 2 input size: <arg> Description - Connection 2 output size: <arg> The I/O configuration is invalid. Recommended actions Fieldbus command <arg> and <arg> are connected to the same unit type <arg> and have the same order number <arg>. 1. Create a new unit type with correct values. The order number of commands connected to the same unit must be unique. 2. Update your current unit type configuration. This command has been rejected. 61309, DeviceNet generic unit identification Recommended actions Description 1. Correct the configuration. On DeviceNet unit arg Identity configuration are generic. 61314, Invalid fieldbus command type Real values: - Vendor Id: <arg> Description - Product code: <arg> The I/O configuration is invalid. - Device type: <arg> Recommended actions One of the fieldbus commands has a reference to an invalid/unknown command type named < arg>. 1. Create a new unit type with correct values. All fieldbus commands must refer to an existing command type. 2. Update your current unit type configuration. This fieldbus command has been rejected. Recommended actions 61310, DeviceNet Unit connection error 1. Correct the fieldbus command type for the command. Description 61315, Max number of fieldbus commands exceeded DeviceNet IO Unit <arg> are occupied by another master. Recommended actions 1. Check configuration. Description 2. Cycle power on IO unit. The I/O configuration is invalid. 61311, Nothing connected to DeviceNet bus The maximum number <arg> of fieldbus commands in the I/O system has been exceeded. Description Recommended actions Unable to communicate on DeviceNet bus <arg> because no units are physically connected. Modify the configuration of the I/O system (by reducing the number of fieldbus commands) so that the maximum limit is not exceeded. Recommended actions 61316, Max number of fieldbus command types exceeded 1. Check cables and connectors. 2. Connect DeviceNet units to bus. 3. Restart system. Description 4. Remove DeviceNet option The I/O configuration is invalid. The maximum number <arg> of fieldbus command types in the I/O system has been exceeded. 61312, DeviceNet Unit explicit connection not enabled Recommended actions Modify the configuration of the I/O system (by reducing the number of fieldbus command types) so that the maximum limit is not exceeded. Description DeviceNet IO Unit <arg> does not have the explicit message connection enabled. 3HAC020738-001 - 263 3 Symptoms 61317, DeviceNet Unit reset 61323, Invalid bit values Description Description DeviceNet IO Unit arg have been restarted through fieldbus command arg, The I/O configuration for signal <arg> is invalid. The minimum bit value <arg> must not be less than <arg>. to make sure fieldbus command values are activated. The maximum bit value <arg> must not exceed <arg>. This will cause the unit to loose contact while the unit is restarted and then automatically be reconnected. The minimum bit value must be less than the maximum bit value. This signal has been rejected. Recommended actions Recommended actions 1. Do nothing. 1. Check that the signal is configured with the correct encoding type. 2. If restart not necessary remove fieldbus command configuration on unit type. 2. Check that the min and max bit values are correct. 61324, Physical limitation values out of range 61318, Failed to send fieldbus command Description Description The I/O configuration for signal <arg> is invalid. Fieldbus command <arg> to unit <arg> was not successfully sent. Recommended actions The physical limitation minimum value must be less than the physical limitation maximum value. 1. Check fieldbus command configuration. This signal has been rejected. Recommended actions 61320, Max number of access levels exceeded 1. Correct the physical limitation values for the signal so that the minimum value becomes less than the maximum value. Description The I/O configuration is invalid. 61325, Invalid bus configuration The maximum number <arg> of access levels in the I/O system has been exceeded. Description Recommended actions The I/O configuration for bus <arg> is invalid. Modify the configuration of the I/O system (by reducing the number of access levels) so that the maximum limit is not exceeded. User-defined (externally loaded) buses must no be specified as local. This bus has been rejected. Recommended actions 61321, Invalid access level 1. Change the bus type of the bus. Description The I/O configuration is invalid. 61326, Invalid unit type configuration The signal <arg> has a reference to an invalid/undefined access level <arg>. Description The I/O configuration for unit type < arg> is invalid. All signals must either omit the access level or refer to an existing access level. User-defined (externally loaded) unit types must no be specified as local. This signal has been rejected. This bus has been rejected. Recommended actions Recommended actions 1. Change access level to one that exist or define a new access level. 1. Change the bus type of the unit type. 61322, FCI option not installed Description 61327, Logical cross-connections option not installed The FCI (Fieldbus Command Interface) option has not been correctly installed in the system. Description The I/O configuration is invalid. Recommended actions Cross-connections containing logical operators is prohibited since the option for logical cross-connections is not installed. Reinstall the system using a proper key containing the FCI option. This cross-connection instance has been rejected. 264 - 3HAC020738-001 3 Symptoms Recommended actions Valid bustypes are: 1. Install the option for use of logical cross-connections. - DNET (DeviceNet) 2. Do not use inversion or logical operators (OR / AND) in the crossconnection expressions. - IBUS (Interbus) - PBUS (Profibus) - SIM (Simulated) - LOC (Local) 61328, Invalid name This bus has been rejected. Description Recommended actions The I/O configuration is invalid. The configuration instance named <arg> does not comply with the rules of RAPID identifiers. 1. Correct the bus type for the bus. This configuration instance has been rejected. 61332, Invalid recovery time Recommended actions Description Correct the name of the configuration instance so that it comply with the following rules: The I/O configuration for bus <arg> is invalid. Rules of RAPID identifiers: 1, The length must not exceed 16 characters. The recovery time (how often to try regain contact with lost units) must not be less than 5 seconds. 2, The first character must be a letter (a-z or A-Z). This bus has been rejected. 3, Subsequent characters must be letters (a-z or A-Z), digits (0-9) or underscores (_). Recommended actions The value of the recovery time parameter <arg> is incorrect. 1. Correct the recovery time for the bus. 61329, Invalid board number 61333, Invalid DeviceNet baudrate Description The I/O configuration for bus <arg> is invalid. Description Board number <arg> is not valid for <arg> buses. The I/O configuration for bus <arg> is invalid. Valid board numbers: The value of the DeviceNet baudrate parameter <arg> is incorrect. - Devicenet {1, 2} Valid DeviceNet baudrates are: - Profibus {1} - 125 - Interbus {1} - 250 - Local {1} - 500 - Simulated {1, 2} This bus has been rejected. This bus has been rejected. Recommended actions Recommended actions 1. Correct the DeviceNet baudrate for the bus 1. Correct the board number for the bus. 61330, Conflicting bus types 61334, Command type without reference to unit type Description Description The I/O configuration for bus <arg> is invalid. The I/O configuration is invalid. There are duplicated <arg> buses with same board number <arg>. No reference to a unit type is defined for the command type named <arg>. Buses of the same type must have unique board numbers. All command types must have a reference to an existing unit type. This bus has been rejected. This command type has been rejected. Recommended actions Recommended actions 1. Correct the board number for the bus. 1. Define a unit type reference for the command type. 61331, Invalid bus type 61335, Invalid unit type Description Description The I/O configuration for bus <arg> is invalid. The I/O configuration for command type < arg> is invalid. The bus type <arg> is invalid or unknown 3HAC020738-001 - 265 3 Symptoms The unit type named <arg> is invalid/unknown. 61340, Invalid unit All command types must refer to an existing/defined unit type. Description This command type has been rejected. The I/O configuration is invalid. Recommended actions One of the fieldbus commands has a reference to an invalid/unknown unit name <arg>. 1. Correct the unit type for the command type. All fieldbus commands must have a reference to an existing unit. 61336, Command type without DeviceNet path This fieldbus command has been rejected. Description Recommended actions The I/O configuration is invalid. 1. Correct the unit for the fieldbus command. No DeviceNet path is defined for the command type named <arg>. This command type has been rejected. 61341, Fieldbus command without reference to command type Recommended actions 1. Define a DeviceNet path for the command type. Description The I/O configuration is invalid. 61337, Command type without DeviceNet service identifier One of the fieldbus commands has no reference to a command type. All fieldbus commands must have a reference to an existing command type. Description This fieldbus command has been rejected. The I/O configuration is invalid. Recommended actions No DeviceNet service identifier is defined for the command type named <arg>. 1. Define a command type reference for the fieldbus command. This command type has been rejected. Recommended actions 61342, Unit type mismatch 1. Define a DeviceNet service identifier for the command type. Description The I/O configuration is invalid. 61338, Invalid DeviceNet service identifier One of the fieldbus commands refers to an unit named <arg> and a command-type named <arg> that refer to different unit types. Description The I/O configuration is invalid. The unit and command type refered to by a fieldbus command must refer to the same unit type. DeviceNet service identifier <arg> is not valid for command type <arg>. This fieldbus command has been rejected. Valid DeviceNet service identifiers are: Recommended actions - Reset (5) 1. Correct the configuration. - Apply (13) 61344, Unitmap undefined - Set (16) This command type has been rejected. Description Recommended actions The I/O configuration for signal <arg> is invalid. 1. Correct the DeviceNet service identifier for the command type. Unitmap is undefined or empty. An unitmap must be specified for all physical signals (i.e. signals connected to an unit). 61339, Fieldbus command without reference to unit This signal has been rejected. Description Recommended actions The I/O configuration is invalid. 1. Define an unitmap for the signal. One of the fieldbus commands has no reference to a unit. 61346, Unitmap out of range All fieldbus commands must have a reference to an existing unit. This fieldbus command has been rejected. Description Recommended actions The I/O configuration for signal <arg> is invalid. 1. Define a unit reference for the fieldbus command. The unitmap <arg> is invalid since bit <arg> is out of range. 266 - 3HAC020738-001 3 Symptoms All bits in the unitmap must be in the range [0, arg]. Valid bustypes are: This signal has been rejected. - DNET (DeviceNet) - IBUS (Interbus) Recommended actions - PBUS (Profibus) 1. Correct the unitmap. - SIM (Simulated) - LOC (Local) 61347, Unitmap with overlapping segments This signal has been rejected. Description Recommended actions The I/O configuration for signal <arg> is invalid. 1. Correct the bus type for the unit type. The unitmap <arg> contains segments (e.g bit arg) that overlap each other. 61351, Invalid connection 1 type This signal has been rejected. Description Recommended actions The I/O configuration is invalid. 1. Correct the unitmap. The unit type <arg> has an invalid/unknown type for connection 1 <arg>. 61348, Unitmap with unexpected character The type for connection 1 must be one of the following: Description - POLLED The I/O configuration for signal <arg> is invalid. - STROBE Found unexpected end or character at position <arg> in the unitmap: <arg>. - COS This signal has been rejected. - COS_ACKSUP - CYCLIC - CYCLIC_ACKSUP Recommended actions This unit type has been rejected. Correct the unitmap so that is comply with the following syntax: - {bit} = ([0-9]+) Recommended actions - {range} = ([0-9]+[-][0-9]+) Correct the connection 1 type of the unit type. - {segment} = ({bit} | {range}) 61352, Invalid connection 2 type - {unitmap} = ({segment}[,])*{segment} Examples of valid unitmaps: Description - "1" The I/O configuration is invalid. - "0-7, 15-8" - "1,4-3,7" The unit type <arg> has an invalid/unknown type for connection 2 <arg>. 61349, Invalid signal size The type for connection 2 must either be ommitted or one of the following: - POLLED Description - STROBE The I/O configuration for signal <arg> is invalid. - COS There is a mismatch between the signal type and the size of the signal. - CYCLIC The signal size <arg> is given by the unitmap: <arg>. - COS_ACKSUP This signal has been rejected. - CYCLIC_ACKSUP Recommended actions This unit type has been rejected. Correct either the signal type or the unitmap so that the following rules are fulfilled: Recommended actions - The size of digital signals must be exactly one bit. Correct the connection 2 type of the unit type. - The size of analog and group signals must be between 2 and 32 bits. 61353, Unit without reference to unit type 61350, Invalid bus type Description Description The I/O configuration is invalid. The I/O configuration is invalid. No reference to a unit type is defined for the unit named <arg>. The unit type <arg> has an invalid/unknown bus type <arg>. This signal has been rejected. 3HAC020738-001 - 267 3 Symptoms Recommended actions 61358, Power fail restore full 1. Define a unit type reference for the unit. Description Unit <arg> could not be setup for power failure restore. 61354, Unit without reference to bus The table for power fail is full. Description Recommended actions The I/O configuration is invalid. 1. Remove some other units from the restore list. No reference to a bus is defined for the unit named <arg>. This unit has been rejected. 61359, SIO option not installed Recommended actions Description 1. Define a bus reference for the unit. The serial channel COM2 could not be used because the SIO option is not installed. 61355, Invalid trustlevel Recommended actions Description 1. Install option. The I/O configuration is invalid. Unit type <arg> has an invalid/unknown trustlevel <arg>. 61361, Cross-connection with non digital resultant signal Valid trustlevel values are: - 0 (Required) - 1 (Error when lost) Description - 2 (Loss accepted) The I/O configuration is invalid. - 3 (Stop when lost) The parameter <Resultant signal> of one of the cross-connections refer to a signal named <arg>, that is not digital. This command type has been rejected. Only digital signals can be cross-connected. Recommended actions This cross-conection has been rejected. 1. Correct the trustlevel for the unit type. Recommended actions 61356, Bus type mismatch 1. Remove the non-digital signal from the cross-connection. Description 61362, Cannot set physical state of signal to valid The I/O configuration is invalid. Unit <arg> refers to a bus and a unit type with different bus types. This unit has been rejected. Description Recommended actions Cannot change physical state of signal <arg> to VALID. The reason is that the signal is mapped to bit(s) that lies outside the data area of the unit it is assigned to. 1. Check that the unit is connected to the correct bus and that the bus type of that bus is correct. Signal assigned to unit: <arg> 2. Check that the unit refers to the correct unit type and that the bus type of that unit type is correct. Signal mapped to bit(s): <arg> Data area of unit: <0 - arg> The physical state of this signal remains NOT VALID. 61357, Duplicated units on local bus Recommended actions Description 1. Check that the unit mapping of the signal is correct. The I/O configuration for unit <arg> is invalid. 2. Check that the signal is assigned to the correct unit. There is already another user-defined unit connected to the local bus. Only one user-defined unit may be connected to the local bus. This unit has been rejected. 61363, Slave configuration invalid Recommended actions Description 1. Correct the configuration. The unit arg configured on the master address is not valid as an internal slave. Recommended actions 1. Change the address on the unit. 268 - 3HAC020738-001 3 Symptoms 2. Change the unit type on the unit to DN_SLAVE. Probable causes 61364, I/O queue overload This is caused by too frequent signal changes or too large bursts of signal changes, generated by input or output signals being actors in cross connections. Description Recommended actions The I/O queue handling input and output signals to and from the system has been overloaded. 1) Check the cross connections. How to check the configuration file is detailed in the Trouble Shooting Manual. Consequences 2) Check the frequency of input and output signals being actors in cross connections. The system will go to status SYS STOP. 3) If an extremely heavy I/O load is normal and required, investigate whether programming delays in the RAPID application may solve the problem. Probable causes This is caused by too frequent signal changes or too large bursts of signal changes, generated by input signals or cross connections between signals. 61367, No communication with I/O unit Recommended actions Description 1) Check the cross connections. How to check the configuration file is detailed in the Trouble Shooting Manual. During startup, no communication was established with unit arg on bus arg. 2) Check the frequency of input signals from any external equipment connected to the system. Make sure it is not abnormal, and change if required. Consequences It is not possible to access the unit or signals on the unit, since it is currently not communicating with the controller. The system will go to state SYS FAIL, if the unit has been assigned trustlevel 0 in the configuration. 3) If an extremely heavy I/O load is normal and required, investigate whether programming delays in the RAPID application may solve the problem. Probable causes 61365, Safety I/O queue overload The unit is either not connected to the system, or it is connected, but has been assigned the wrong address. Description The safety I/O queue handling safety input and output signals has been overloaded. Recommended actions 1) Make sure all unit addresses match the configuration. Consequences 2) Make sure all addresses are unique, and not used by more than one unit. The system will go to status SYS HALT. 3) Change the address and/or connect the missing unit. Probable causes 4) If you changed the address, the power supply to the unit must be cycled (switched OFF and then back ON), to make sure the address has been changed. This is caused by too frequent signal changes of safety signals. Sometimes this may be due to erratic ground connection in signals from external equipment. Recommended actions 61368, No InterBus option has been installed 1) Repeated safety input signals will cause the system to halt. See the error log for other faults that may cause the condition. Description 2) Check the grounding of each signal from any external equipment affecting the safety signals. A Interbus master/slave board has been fitted, but no InterBus option has been installed. 3) Check the frequency of input signals from any external equipment connected to the system. Make sure it is not abnormal, and change is required. Consequences No communication on the InterBus is possible. There may be consequential errors from configuring InterBus when no such option has been installed. 61366, Cross connection I/O queue overload Probable causes Description An attempt may have been made to add the InterBus functionality, without installing the option correctly. The cross connection I/O queue handling input and output signals to and from the system has been overloaded. Recommended actions Consequences 1) If the InterBus option is required: configure a new system WITH this option, and install the system. The system will go to status SYS STOP. 3HAC020738-001 - 269 3 Symptoms 2) If the InterBus option is NOT required: configure a new system WITHOUT this option, and install the system. 270 - 3HAC020738-001 4 Instructions 4 Instructions 3HAC020738-001 - 271 4 Instructions 4.1. Overview, trouble shooting 4.1. Overview, trouble shooting How to use this manual when trouble shooting The illustration and description detail how to put the information in this manual to best use during trouble shooting the robot system. en0400001200 272 - 3HAC020738-001 4 Instructions 4.1. Overview, trouble shooting Instruction for Trouble Shooting Symptoms • Each fault or error is first detected as a symptom. It could be an event log message on the FlexPendant, an observation that the gearbox on axis 6 is getting hot or that I’m not able to start the controller. These symptoms are listed in chapter Symptoms and in Appendix xx for faults represented by an event log message. References may be made to sections Instructions per unit or Instructions per symptom. Instructions per unit • Trouble shooting information gathered for a specific unit, e.g. the FlexPendant. An easy to follow list with recommended tests and actions, most often with references to more detailed information in sections Instructions per symptom and Indications. Instructions per symptom • Trouble shooting information based on a specific symptom, e.g. the the FlexPendant does not communicate. An easy to follow list with recommended tests and actions, most often with references to more detailed information in sections ref-format = "Heading on Page">Instructions per unit and Indications. Indications • All indication LEDs and other indications (as found on the Control and Drive Modules as well as separate circuit boards, etc) are described in this section along with information about their indication modes and significances respectively. Recommended actions are often specified or references to instructions containing such. Reference information for Trouble Shooting Description • Sections Descriptions, systems and Descriptions, functions contain descriptions of the various systems and functions of the controller. This information is intended for reference use when the system seems to faulty or acting in strange ways. Working with logs • Section Working with logs contains information on how to access and handle (save, delete, etc) the event log information specifying malfunctions. Working with configuration files • Section Working with configuration files contains information on how to check the configuration files, since many potential malfunctions may be due to incorrect data in them. Further information on how to create and handle the configuration files are given in the Operating Manual, RobotStudioOnline. Circuit Diagram • 3HAC020738-001 All electrical circuits and wiring for the controller are shown in the Circuit Diagram, which is a part of the Controller Product Manual. - 273 4 Instructions 4.2. Working principles when trouble-shooting 4.2. Working principles when trouble-shooting General Trouble shooting complex technical systems such as robot systems requires a systematic approach. The personnel must be trained and qualified to perform the task, and will be helped by using the correct tools and methods. This section specifies some of these methods. Any special tools are specified in the section Standard toolkit, trouble shooting IRC5. Read the documentation! A great deal of effort was put into writing the event log messages as well as the technical manuals. Though imperfect, they may give vital clues. They are also constantly being upgraded. Do not wait until nothing else works to read the manual! References to document numbers are specified in the chapter Reference Information in the Product manual. Remember that the product documentation is available in several languages electronically as .pdf-files as well as in binder format! Order the format best suited for your needs! Read the Circuit Diagram! The complete electrical circuitry of the system is documented in the Product Manual. It contains a lot of information useful, or even essential, to a trained trouble shooter. References to document numbers are specified in the chapter Reference Information in the Product manual. Isolate the fault! Any fault may give rise to a number of symptoms, event log messages on the FlexPendant or other. In order to effectively eliminate the fault, it is vital to distinguish the original symptom from the consequential ones. A help in isolating the fault may be creating a historical fault log as specified in section Make a historical fault log! Do not replace units randomly! Before replacing any part at all, it is important to establish a probable cause for the fault, thus determining which unit to replace. Randomly replacing units may sometimes solve the acute problem, but also leaves the trouble shooter with a number of units that may/may not be perfectly functional. Replace one thing at a time! When replacing a presumably faulty unit that has been isolated, it is important that only one unit be replaced at a time. Test the system after replacing to see if the problem has been solved. 274 - 3HAC020738-001 4 Instructions 4.2. Working principles when trouble-shooting If replacing several units at once: • it is impossible to determine which of the units was causing the fault. • it greatly complicates ordering a new spare part. • it may introduce new faults to the system. Make a historical fault log! In some cases, a particular installation may give rise to faults not encountered in others. Therefore, charting each installation may give tremendous assistance to the trouble shooter. To facilitate trouble shooting, a log of the circumstances surrounding the fault gives the following advantages: • it enables the trouble shooter to see patterns in causes and consequences not apparant at each individual fault occurrance. • it may point out a specific event always taking place just before the fault, for example a certain part of the work cycle being run. Check up the history! Make sure you always consult the historical log if it is used. Also remember to consult the operator, or similar, who was working when the problem first occurred. Read the logs! The event logs available on the FlexPendant contain lots of information about any malfunction detected by the system. How to access the logs is detailed in section Event log messages. A number of logs are available by either viewing all logs (as detailed in section Viewing all log entries) or selecting the log of your choice. en0300000547 3HAC020738-001 - 275 4 Instructions 4.2. Working principles when trouble-shooting Fault sequence Any malfunction detected by the system may result in a number of sequential errors. These are also displayed in the logs on the FlexPendant, and may cause confusion when trying to understand what acutally happened. The basic rule is to view the event log messages in order of time: one of the early detected faults is more likely to be the original fault. However, this is not always true: when a number of faults are detected within a small space of time, even small delays in processing may cause the original fault to be displayed further down the log. Check the electronical unit's LEDs! If a fault is thought to be caused by an electronic unit (circuit board in the controller or other), the LEDs on the unit front may give leads. These are described in section Indications. Split the fault chain in two! When trouble shooting any system, a good practice is to split the fault chain in two. This means: • identify the complete chain. • decide and measure the expected value at the middle of the chain. • use this to determine in which half the fault is caused. • split this half into two new halves, etc. • finally, a single component may be isolated. The fault one. Example A specific IRB 7600 installation has a 12 VDC power supply to a tool at the manipulator wrist. This tool does not work, and when checked, there is no 12 VDC supply to it. • Check at the manipulator base to see if there is 12 VDC supply. Measurement show there are no 12 VDC supply. (Reference: Circuit Diagram) • Check any connector between the manipulator and the power supply in the controller. Measurement show there are no 12 VDC supply. (Reference: Circuit Diagram) • Check the power supply unit LED. (Reference: Indications) Take a look around! In some cases, the cause may be evident once you see it. In the area of the unit acting erroneously, be sure to check: • Are the attachment screws secured? • Are all connectors secured? • Are all cabling free from damage? • Are the units clean (especially for electronic units)? • Is the correct unit fitted? Check for tools left behind! Some repair and maintenance work require using special tool to be fitted to the robot equipment. If these are left behind (e.g. balancing cylinder locking device or signal cable to a computer unit used for measuring purposes), they may cause erratic robot behaviour. 276 - 3HAC020738-001 4 Instructions 4.2. Working principles when trouble-shooting Make sure all such tools are removed when maintenance work is complete! Check the software versions! Make sure the RobotWare and other software run by the system are the correct version. Certain versions are not compatible with certain hardware combinations. Also, make a note of all software versions run, since this will be useful information to the ABB support people. Check communication parameters and cables! The most common causes of errors in serial communication are: • Faulty cables (e.g. send and receive signals are mixed up) • Transfer rates (baud rates) • Data widths that are incorrectly set. Use the internal test program to pinpoint these problems, as detailed in section xx. 3HAC020738-001 - 277 4 Instructions 4.3.1. Trouble Shooting the FlexPendant 4.3 Instructions per unit 4.3.1. Trouble Shooting the FlexPendant General The FlexPendant communicates, via the Panel Board, with the Control Module Main Computer. The FlexPendant is physically connected to the Panel Board through a cable in which the +24 V supply and two Enabling Device chains runs. Procedure The procedure below details what to do if the FlexPendant does not work correctly. Step 278 Action Info/illustration 1. If the FlexPendant is completely “dead”, proceed as detailed in section FlexPendant dead. 2. If the FlexPendant starts, but does not operate correctly, proceed as detailed in section FlexPendant does not communicate. 3. If the FlexPendant starts, seems to operate, but displays erratic event messages, proceed as detailed in section Erratic event messages on FlexPendant. 4. If none of the above type cases apply, please proceed below! 5. Read the event log message on the FlexPendant and follow any instructions of references. 6. If the display is not illuminated, try adjusting the contrast. 7. Check the cable for connections and integrity. 8. Check the 24 V power supply. - Communication errors between the FlexPendant and the main computer are displayed as event log messages on the FlexPendant. 3HAC020738-001 4 Instructions 4.3.2. Trouble Shooting Power Supplies 4.3.2. Trouble Shooting Power Supplies Overview This section details how to trouble shoot electrical power supplies in the Control and Drive Modules. Trouble Shooting Procedure When trouble shooting power supply faults, follow the outline detailed below. Step 3HAC020738-001 Action Info/illustration 1. Check the indication LED on the power supply unit. The significance of all indication LEDs are specified in section Indications. 2. Disconnect the output connector of the power supply unit. 3. Measure the output voltage of the unit. If no or the wrong voltage is detected, proceed below. Most nominal voltage values are specified in the Circuit Diagram in the Product Manual, IRC5. 4. Measure the input voltage. If the input voltage is correct, the power supply unit may be faulty. Most nominal voltage values are specified in the Circuit Diagram in the Product Manual, IRC5. 5. If required, disconnect the loads from the power supply unit, one by one, to eliminate any overloads. 6. If the power supply unit is found How to replace the unit is detailed in the faulty, replace it, and verify that the Product Manual, IRC5. fault has been fixed. - 279 4 Instructions 4.3.3. Trouble Shooting I/O units 4.3.3. Trouble Shooting I/O units Checking function The procedure detailed below is to be used when a certain I/O unit does not communicate through it's in- and outputs as expected. Step Action Info/illustration 1. Check that the current I/O signal has the desired status using the I/O menu on the FlexPendant display. 2. Check the I/O unit’s LED for the current input or output. If the output LED is not lit, check that the 24 V I/O power supply is OK. 3. Check on all connectors and cabling from the I/O unit to the process connection. 4. Make sure the process bus, to which the I/O unit is connected, is working. If a bus has stopped running, an event log message is usually stored in the FlexPendant event log. Also check the indication LEDs on the bus boards. Checking channel communication The I/O channels can be read and activated from the I/O menu on the FlexPendant. In the event of an error in the I/O communication to and from the robot, check as follows: Step Action Info/illustration 1. Is I/O communication programmed in the current program? 2. On the unit in question, the MS (Module Status) and NS (Network Status) LEDs must be lit with a steady green light. See the tables below regarding other conditions. LED indications All LEDs, and their significance, are described in section Indications. 280 - 3HAC020738-001 4 Instructions 4.4.1. Intermittent errors 4.4 Instructions per symptom 4.4.1. Intermittent errors General Occasionally, intermittent errors occur and may be difficult to remedy. Description This section overviews possible causes and suggests actions to be taken to fix intermittent errors. Possible causes Such errors may occur anywhere in the robot system and may be due to: • external interference • internal interference • loose connections or dry joints, e.g. incorrectly connected cable screen connections. • thermal phenomena , e.g. major temperature changes within the workshop area. Suggested actions First, the unit individual causing the problem must be identified. Take note of the following each time the robot behaviour is erratic: 3HAC020738-001 • the status of all the LEDs. • the messages on the FlexPendant. Sometimes specific error combinations are intermittent, and these are described in chapter Error combinations. • the robot’s behaviour, etc, each time that type of error occurs. • whether any condition in the robot working environment also changes periodically, e.g , interference from large electric equipment only operating periodically. • Run test programs to pinpoint the fault. How to use these is described in xx . Several of these are run in loops, which should make the error occur more frequently - 281 4 Instructions 4.4.1. Intermittent errors 282 - 3HAC020738-001 Index C cold gearbox oil 86 collapsing manipulator 87, 91 Configuration, Edit Parameter 49 D damaged bearings 85, 89 Damaged cable 80 damaged cable insulation 82 Damaged connector 80 damaged parallel bar 85 E erratic event messages 82 F faulty brake 91 faulty calibration 85 faulty connections 82 faulty power supply 91 faulty TCP definition 85 FlexPendant, dead 80 FlexPendant, faulty 80 H hot gearbox oil 87, 89 I Instance, Edit 49 L leaking seals 87 N noise 85, 89 O oil leaks 87 overfilled gearbox 87 overloaded motors 86 P Parameter, Edit 49 path accuracy 85 Power supply, faulty 80 S strained cables 82 System Parameters, Edit 49 3HAC020738-001 283