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
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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
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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.
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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
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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
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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
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3HAC020738-001
2 Reference information
1.4.4. CAUTION - Hot parts may cause burns!
2 Reference information
3HAC020738-001
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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
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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
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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
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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.
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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)
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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
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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)
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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.
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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
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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.
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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.
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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.
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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.
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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.
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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
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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.
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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.
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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.
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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
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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.
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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.
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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.
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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.
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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
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2.5.1. Editing parameters
How to restart a controller
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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:
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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!
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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:
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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:
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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:
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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.
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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:
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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.
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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:
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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.
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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
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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
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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
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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
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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.
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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.
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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.
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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
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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.
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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.
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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.
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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.
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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.
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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.
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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
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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.
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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.
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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
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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
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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
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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
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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.
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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
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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.
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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
-
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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.
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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.
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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.
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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
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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
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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.
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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.
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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.
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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.
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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
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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,
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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.
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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.
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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.
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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].
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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
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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.
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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.
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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.
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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
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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.
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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.
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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.
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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
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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.
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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
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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.
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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
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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
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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
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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
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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.
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-
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
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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
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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
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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
-
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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
-
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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
-
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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
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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
-
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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
-
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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
-
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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
-
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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
-
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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
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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
-
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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.
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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
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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
-
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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.
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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
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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
-
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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.
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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
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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
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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
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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.
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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.
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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
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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.
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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>
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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.
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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.
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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
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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.
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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.
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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.
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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.
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3 Symptoms
2) If the InterBus option is NOT required: configure a new system
WITHOUT this option, and install the system.
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4 Instructions
4 Instructions
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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
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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.
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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.
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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
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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.
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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.
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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.
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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.
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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
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4 Instructions
4.4.1. Intermittent errors
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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
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