Alarm Code List - Operator Manual

OPERATOR'S MANUAL

B-83124EN-6/01

R-30*A/R-30*A Mate CONTROLLER

< > !

Alarm Code List(For series 7DA4/7DA5)

Original Instructions

Before using the Robot, be sure to read the "FANUC Robot Safety Manual (B-80687EN)" and

understand the content. No part of this manual may be reproduced in any form. All specifications and designs are subject to change without notice. The products in this manual are controlled based on Japans Foreign Exchange and Foreign Trade Law. The export from Japan may be subject to an export license by the government of Japan. Further, re-export to another country may be subject to the license of the government of the country from where the product is re-exported. Furthermore, the product may also be controlled by re-export regulations of the United States government. Should you wish to export or re-export these products, please contact FANUC for advice. In this manual we have tried as much as possible to describe all the various matters. However, we cannot describe all the matters which must not be done, or which cannot be done, because there are so many possibilities. Therefore, matters which are not especially described as possible in this manual should be regarded as impossible.

SAFETY

B-83124EN-6/01 SAFETY PRECAUTIONS

s - 3

1 SAFETY PRECAUTIONS For the safety of the operator and the system, follow all safety precautions when operating a robot and its peripheral devices installed in a work cell. In addition, refer to the FANUC Robot SAFETY HANDBOOK (B-80687EN).

1.1 WORKING PERSON The personnel can be classified as follows.

Operator: Turns robot controller power ON/OFF Starts robot program from operators panel Programmer or teaching operator: Operates the robot Teaches robot inside the safety fence Maintenance engineer: Operates the robot Teaches robot inside the safety fence Maintenance (adjustment, replacement)

- An operator cannot work inside the safety fence. - A programmer, teaching operator, and maintenance engineer can work inside the safety fence. The

working activities inside the safety fence include lifting, setting, teaching, adjusting, maintenance, etc..

- To work inside the fence, the person must be trained on proper robot operation. During the operation, programming, and maintenance of your robotic system, the programmer, teaching operator, and maintenance engineer should take additional care of their safety by using the following safety precautions. - Use adequate clothing or uniforms during system operation - Wear safety shoes - Use helmet

1.2 WORKING PERSON SAFETY Working person safety is the primary safety consideration. Because it is very dangerous to enter the operating space of the robot during automatic operation, adequate safety precautions must be observed. The following lists the general safety precautions. Careful consideration must be made to ensure working person safety. (1) Have the robot system working persons attend the training courses held by FANUC. FANUC provides various training courses. Contact our sales office for details.

SAFETY PRECAUTIONS B-83124EN-6/01

s - 4

(2) Even when the robot is stationary, it is possible that the robot is still in a ready to move state, and is waiting for a signal. In this state, the robot is regarded as still in motion. To ensure working person safety, provide the system with an alarm to indicate visually or aurally that the robot is in motion.

(3) Install a safety fence with a gate so that no working person can enter the work area without passing through the gate. Install an interlocking device, a safety plug, and so forth in the safety gate so that the robot is stopped as the safety gate is opened.

The controller is designed to receive this interlocking signal of the door switch. When the gate is opened and this signal received, the controller stops the robot as Emergency stop or Control stop (Please refer to "STOP TYPE OF ROBOT" in SAFETY). For connection, see Fig.1.2 (a) and Fig.1.2 (b).

(4) Provide the peripheral devices with appropriate grounding (Class A, Class B, Class C, and Class D). (5) Try to install the peripheral devices outside the work area. (6) Draw an outline on the floor, clearly indicating the range of the robot motion, including the tools such

as a hand. (7) Install a mat switch or photoelectric switch on the floor with an interlock to a visual or aural alarm that

stops the robot when a working person enters the work area. (8) If necessary, install a safety lock so that no one except the working person in charge can turn on the

power of the robot. The circuit breaker installed in the controller is designed to disable anyone from turning it on when it is locked with a padlock.

(9) When adjusting each peripheral device independently, be sure to turn off the power of the robot.

RM1Motor power/brake

RP1PulsecoderRI/RO,XHBK,XROT

EARTH

Safety fence

Interlocking device and safety plug that are activated if thegate is opened.

Fig. 1.2 (a) Safety Fence and Safety Gate


s - 5

Dual chain

Single chainPanel board

FENCE1

FENCE2

Panel board

EAS1

EAS11

EAS2

EAS21

Note

In case of R-30iATerminals EAS1,EAS11,EAS2,EAS21 or FENCE1,FENCE2are provided on the operation box or on the terminal blockof the printed circuit board.

In case of R-30iA MateTerminals EAS1,EAS11,EAS2,EAS21 are providedon the emergency stop board or connector panel.(in case of Open air type)

Termianls FENCE1,FENCE2 are providedon the emergency stop board.

Refer to controller maintenance manual for details.

Fig.1.2 (b) Connection Diagram for Safety Fence

1.2.1 Operator Safety The operator is a person who operates the robot system. In this sense, a worker who operates the teach pendant is also an operator. However, this section does not apply to teach pendant operators. (1) If you do not have to operate the robot, turn off the power of the robot controller or press the

EMERGENCY STOP button, and then proceed with necessary work. (2) Operate the robot system at a location outside of the safety fence (3) Install a safety fence with a safety gate to prevent any worker other than the operator from entering the

work area unexpectedly and to prevent the worker from entering a dangerous area. (4) Install an EMERGENCY STOP button within the operators reach. The robot controller is designed to be connected to an external EMERGENCY STOP button. With this connection, the controller stops the robot operation as Emergency stop or Control stop (Please refer to "STOP TYPE OF ROBOT" in SAFETY) when the external EMERGENCY STOP button is pressed. See the diagram below for connection.

Dual chain

Single chain

NoteConnecto EES1and EES11,EES2 and EES21or EMGIN1and EMGIN2.

In case of R-30iAEES1,EES11,EES2,EES21 or EMGIN1,EMGIN2 are on the panel board.

In case of R-30iA MateEES1,EES11,EES2,EES21are on the emergency stop boardor connector panel (in case of Open air type),.EMGIN1,EMGIN2are on the emergency stop board.

Refer to the maintenance manual of the controller for details.

External stop button

Panel board

EMGIN1

EMGIN2

Panel board

EES1

EES11

EES2

EES21

External stop button

Fig.1.2.1 Connection Diagram for External Emergency Stop Button


s - 6

1.2.2 Safety of the Teach Pendant Operator While teaching the robot, the operator must enter the work area of the robot. The operator must ensure the safety of the teach pendant operator especially. (1) Unless it is specifically necessary to enter the robot work area, carry out all tasks outside the area. (2) Before teaching the robot, check that the robot and its peripheral devices are all in the normal operating

condition. (3) If it is inevitable to enter the robot work area to teach the robot, check the locations, settings, and other

conditions of the safety devices (such as the EMERGENCY STOP button, the DEADMAN switch on the teach pendant) before entering the area.

(4) The programmer must be extremely careful not to let anyone else enter the robot work area. Our operator panel is provided with an emergency stop button and a key switch (mode switch) for selecting the automatic operation mode (AUTO) and the teach modes (T1 and T2). Before entering the inside of the safety fence for the purpose of teaching, set the switch to a teach mode, remove the key from the mode switch to prevent other people from changing the operation mode carelessly, then open the safety gate. If the safety gate is opened with the automatic operation mode set, the robot stops as Emergency stop or Control stop (Please refer to "STOP TYPE OF ROBOT" in SAFETY). After the switch is set to a teach mode, the safety gate is disabled. The programmer should understand that the safety gate is disabled and is responsible for keeping other people from entering the inside of the safety fence. (In case of R-30iA Mate Controller standard specification, there is no mode switch. The automatic operation mode and the teach mode is selected by teach pendant enable switch.)

Our teach pendant is provided with a DEADMAN switch as well as an emergency stop button. These button and switch function as follows: (1) Emergency stop button: Causes an Emergency stop or Control stop (Please refer to "STOP

TYPE OF ROBOT" in SAFETY) when pressed. (2) DEADMAN switch: Functions differently depending on the mode switch setting status.

(a) Automatic operation mode: The DEADMAN switch is disabled. (b) Teach mode: Causes an emergency stop when the operator releases the DEADMAN

switch or when the operator presses the switch strongly. Note)The DEADMAN switch is provided to place the robot in the emergency stop state when the operator releases the teach pendant or presses the pendant strongly in case of emergency. The R-30iA/ R-30iA Mate employs a 3-position DEADMAN switch, which allows the robot to operate when the 3-position DEADMAN switch is pressed to its intermediate point. When the operator releases the DEADMAN switch or presses the switch strongly, the robot enters the emergency stop state.

The operators intention of starting teaching is determined by the controller through the dual operation of setting the teach pendant enable/disable switch to the enable position and pressing the DEADMAN switch. The operator should make sure that the robot could operate in such conditions and be responsible in carrying out tasks safely.

The teach pendant, operator panel, and peripheral device interface send each robot start signal. However the validity of each signal changes as follows depending on the mode switch and the DEADMAN switch of the operator panel, the teach pendant enable switch and the remote condition on the software.


s - 7

In case of R-30iA Controller or CE or RIA specification of R-30iA Mate Controller

Mode Teach pendant enable switch

Software remote

condition Teach pendant Operator panel Peripheral device

Local Not allowed Not allowed Not allowed On Remote Not allowed Not allowed Not allowed

Local Not allowed Allowed to start Not allowed AUTO mode

Off Remote Not allowed Not allowed Allowed to start

Local Allowed to start Not allowed Not allowed On

Remote Allowed to start Not allowed Not allowed Local Not allowed Not allowed Not allowed

T1, T2 mode

Off Remote Not allowed Not allowed Not allowed

In case of standard specification of R-30iA Mate Controller

Teach pendant enable switch Software remote condition Teach pendant Peripheral device On Ignored Allowed to start Not allowed

Local Not allowed Not allowed Off Remote Not allowed Allowed to start

(5) (Only when R-30iA Controller or CE or RIA specification of R-30iA Mate controller is selected.) To

start the system using the operators panel, make certain that nobody is the robot work area and that there are no abnormal conditions in the robot work area.

(6) When a program is completed, be sure to carry out a test run according to the procedure below. (a) Run the program for at least one operation cycle in the single step mode at low speed. (b) Run the program for at least one operation cycle in the continuous operation mode at low speed. (c) Run the program for one operation cycle in the continuous operation mode at the intermediate

speed and check that no abnormalities occur due to a delay in timing. (d) Run the program for one operation cycle in the continuous operation mode at the normal

operating speed and check that the system operates automatically without trouble. (e) After checking the completeness of the program through the test run above, execute it in the

automatic operation mode. (7) While operating the system in the automatic operation mode, the teach pendant operator should leave

the robot work area.

1.2.3 Safety of the Maintenance Engineer For the safety of maintenance engineer personnel, pay utmost attention to the following. (1) During operation, never enter the robot work area. (2) Except when specifically necessary, turn off the power of the controller while carrying out

maintenance. Lock the power switch, if necessary, so that no other person can turn it on. (3) If it becomes necessary to enter the robot operation range while the power is on, press the emergency

stop button on the operator panel, or the teach pendant before entering the range. The maintenance personnel must indicate that maintenance work is in progress and be careful not to allow other people to operate the robot carelessly.

(4) When disconnecting the pneumatic system, be sure to reduce the supply pressure. (5) Before the start of teaching, check that the robot and its peripheral devices are all in the normal

operating condition. (6) Do not operate the robot in the automatic mode while anybody is in the robot work area. (7) When you maintain the robot alongside a wall or instrument, or when multiple workers are working

nearby, make certain that their escape path is not obstructed. (8) When a tool is mounted on the robot, or when any moving device other than the robot is installed, such

as belt conveyor, pay careful attention to its motion.


s - 8

(9) If necessary, have a worker who is familiar with the robot system stand beside the operator panel and observe the work being performed. If any danger arises, the worker should be ready to press the EMERGENCY STOP button at any time.

(10) When replacing or reinstalling components, take care to prevent foreign matter from entering the system.

(11) When handling each unit or printed circuit board in the controller during inspection, turn off the circuit breaker to protect against electric shock.

If there are two cabinets, turn off the both circuit breaker. (12) When replacing parts, be sure to use those specified by FANUC. In particular, never use fuses or other parts of non-specified ratings. They may cause a fire or result in

damage to the components in the controller. (13) When restarting the robot system after completing maintenance work, make sure in advance that there

is no person in the work area and that the robot and the peripheral devices are not abnormal.

1.3 SAFETY OF THE TOOLS AND PERIPHERAL DEVICES 1.3.1 Precautions in Programming

(1) Use a limit switch or other sensor to detect a dangerous condition and, if necessary, design the program to stop the robot when the sensor signal is received.

(2) Design the program to stop the robot when an abnormal condition occurs in any other robots or peripheral devices, even though the robot itself is normal.

(3) For a system in which the robot and its peripheral devices are in synchronous motion, particular care must be taken in programming so that they do not interfere with each other.

(4) Provide a suitable interface between the robot and its peripheral devices so that the robot can detect the states of all devices in the system and can be stopped according to the states.

1.3.2 Precautions for Mechanism (1) Keep the component cells of the robot system clean, and operate the robot in an environment free of

grease, water, and dust. (2) Employ a limit switch or mechanical stopper to limit the robot motion so that the robot or cable does

not strike against its peripheral devices or tools. (3) Observe the following precautions about the mechanical unit cables. When theses attentions are not

kept, unexpected troubles might occur. Use mechanical unit cable that have required user interface. Dont add user cable or hose to inside of mechanical unit. Please do not obstruct the movement of the mechanical unit cable when cables are added to

outside of mechanical unit. In the case of the model that a cable is exposed, Please do not perform remodeling (Adding a

protective cover and fix an outside cable more) obstructing the behavior of the outcrop of the cable.

Please do not interfere with the other parts of mechanical unit when install equipments in the robot.

(4) Emergency stop is method of urgently stop. Please avoid the system construction that emergency stop would be operated routinely. (Refer to bad case example.) The frequent emergency stop causes the trouble of the robot. Please push the emergency stop button after reducing the speed of the robot and stopping it by hold stop or cycle stop when it is not urgent. (Bad case example) Whenever poor product is paid, a line stops by emergency stop. When alteration was necessary, the robot during operation is urgently stopped by opening a door

of the safety enclosure/fence and operating safe switch. An operator pushes the emergency stop button frequently, and a line stops.


s - 9

An area sensor and a mat switch, a fence open switch connected to an emergency stop circuit operate routinely

(5) Robot stops urgently when collision detection alarm (SV050) etc. occurs. The frequent urgent stop by alarm causes the trouble of the robot, too. So remove the causes of the alarm.

1.4 SAFETY OF THE ROBOT MECHANISM 1.4.1 Precautions in Operation

(1) When operating the robot in the jog mode, set it at an appropriate speed so that the operator can manage the robot in any eventuality.

(2) Before pressing the jog key, be sure you know in advance what motion the robot will perform in the jog mode.

1.4.2 Precautions in Programming (1) When the work areas of robots overlap, make certain that the motions of the robots do not interfere

with each other. (2) Be sure to specify the predetermined work origin in a motion program for the robot and program the

motion so that it starts from the origin and terminates at the origin. Make it possible for the operator to easily distinguish at a glance that the robot motion has terminated.

1.4.3 Precautions for Mechanisms (1) Keep the work areas of the robot clean, and operate the robot in an environment free of grease, water,

and dust.

1.4.4 Procedure to move arm without drive power in emergency or abnormal situations

For emergency or abnormal situations (e.g. persons trapped in or by the robot), brake release unit can be used to move the robot axes without drive power. Please refer to controller maintenance manual and mechanical unit operators manual for using method of brake release unit and method of supporting robot.

1.5 SAFETY OF THE END EFFECTOR 1.5.1 Precautions in Programming

(1) To control the pneumatic, hydraulic and electric actuators, carefully consider the necessary time delay after issuing each control command up to actual motion and ensure safe control.

(2) Provide the end effector with a limit switch, and control the robot system by monitoring the state of the end effector.

1.6 STOP TYPE OF ROBOT There are the following 3 stop types of robot.

Emergency stop Robot stops immediately and servo power is turned off.


s - 10

The following processing is performed at Emergency stop. - The robot operation is stopped immediately. Execution of the program is paused. - An alarm is generated and the servo power is turned off.

Control stop Robot is slowly decelerated until it stops then servo power is turned off. The following processing is performed at Control stop. - The alarm "SRVO-199 Control stop" occurs along with a decelerated stop. Execution of the program

is paused. - Then, an alarm is generated and the servo power is turned off.

Hold Robot is slowly decelerated until it stops, servo power keeps on. The following processing is performed at Hold. - The robot operation is decelerated until it stops. Execution of the program is paused. When E-Stop button is pressed or FENCE is open, the stop type of robot is Emergency stop or Control stop. The configuration of stop type for each situation is called "Stop pattern". The Stop pattern is different according to the controller type or option configuration. There are the following 3 Stop patterns.

Stop pattern Mode

E-Stop button

External E-Stop FENCE open SVOFF input

Servo disconnect

AUTO E-Stop E-Stop C-Stop C-Stop E-Stop A T1 E-Stop E-Stop - C-Stop E-Stop T2 E-Stop E-Stop - C-Stop E-Stop AUTO E-Stop E-Stop E-Stop E-Stop E-Stop

B T1 E-Stop E-Stop - E-Stop E-Stop T2 E-Stop E-Stop - E-Stop E-Stop AUTO C-Stop C-Stop C-Stop C-Stop C-Stop

C T1 E-Stop E-Stop - C-Stop E-Stop T2 E-Stop E-Stop - C-Stop E-Stop

E-Stop: Emergency stop C-Stop: Control stop -: Not stop The following is the Stop pattern according to the controller type or option configuration.

R-30iA R-30iA Mate Option Standard

(Single) Standard

(Dual) RIA type CE type Standard RIA type CE type

Standard B(*) A A A B(**) A A Stop pattern C (A05B-2500-J570)

N/A N/A C C N/A C C

(*) R-30iA standard (single) does not have servo disconnect. (**) R-30iA Mate Standard does not have servo disconnect, and stop type of FENCE open is control stop.


s - 11

"Stop pattern C" option "Stop pattern C"(A05B-2500-J570) is an optional function. When this option is loaded, the stop type of the following alarms becomes Control stop but only in AUTO mode. In T1 or T2 mode, the stop type is Emergency stop which is the normal operation of the system.

Alarm Condition SRVO-001 Operator panel E-stop Operator panel E-stop is pressed. SRVO-002 Teach pendant E-stop Teach pendant E-stop is pressed. SRVO-007 External emergency stops External emergency stop input (EES1-EES11, EES2-EES21) is

open. (R-30iA controller) SRVO-194 Servo disconnect Servo disconnect input (SD4-SD41, SD5-SD51) is open.

(R-30iA controller) SRVO-218 Ext.E-stop/ServoDisconnect External emergency stop input (EES1-EES11, EES2-EES21) is

open. (R-30iA Mate controller) SRVO-408 DCS SSO Ext Emergency Stop In DCS Safe I/O connect function, SSO[3] is OFF. SRVO-409 DCS SSO Servo Disconnect In DCS Safe I/O connect function, SSO[4] is OFF.

Control stop is different from Emergency stop as follows: - In Control stop, the robot is stopped on the program path. This function is effective for a system where

the robot can interfere with other devices if it deviates from the program path. - In Control stop, physical impact is less than Emergency stop. This function is effective for systems

where the physical impact to the mechanical unit should be minimized. - The stopping distance and stopping time of Control stop is longer than the stopping distance and

stopping time of Emergency stop, depending on the robot model and axis. Please refer the operator's manual of a particular robot model for the data of stopping distance and stopping time.

This function is available only in CE or RIA type hardware. When this option is loaded, this function can not be disabled. The stop type of DCS Position and Speed Check functions is not affected by the loading of this option

WARNING The stopping distance and stopping time of Control stop is longer than the

stopping distance and stopping time of Emergency stop. A risk assessment for the whole robot system, which takes into consideration the increased stopping distance and stopping time, is necessary when this option is loaded.

B-83124EN-6/01 TABLE OF CONTENTS

c - 1

TABLE OF CONTENTS

SAFETY PRECAUTIONS............................................................................s-1 1 INTRODUCTION .....................................................................................1

1.1 MANUAL PLAN ............................................................................................. 1

2 OVERVIEW .............................................................................................3 2.1 OVERVIEW ................................................................................................... 3 2.2 ERROR CODE PROPERTIES ...................................................................... 4

2.2.1 Overview ..................................................................................................................4 2.2.2 Facility Name and Code ...........................................................................................7 2.2.3 Severity Descriptions ...............................................................................................9 2.2.4 Error Message Text ................................................................................................11

3 ERROR RECOVERY.............................................................................13 3.1 GENERAL ERROR RECOVERY PROCEDURES ...................................... 13

3.1.1 Overview ................................................................................................................13 3.1.2 Overtravel Release..................................................................................................13 3.1.3 Hand Breakage Recovery .......................................................................................15 3.1.4 Pulse Coder Alarm Recovery .................................................................................15 3.1.5 Chain Failure Detection Error Recovery ................................................................16

3.2 PAINTTOOL RECOVERY PROCEDURES ................................................. 17 3.2.1 Overview ................................................................................................................17 3.2.2 Brake Control Release............................................................................................17 3.2.3 Purge Fault Recovery .............................................................................................18 3.2.4 Executing an Exit Cleaner Robot Request out of Sequence...................................18 3.2.5 Production Mode Recovery....................................................................................19

4 ERROR CODES ....................................................................................21 4.1 A .................................................................................................................. 21

4.1.1 ACAL Alarm Code.................................................................................................21 4.1.2 APSH Alarm Code .................................................................................................29 4.1.3 ARC Alarm Code ...................................................................................................41 4.1.4 ASBN Alarm Code.................................................................................................52 4.1.5 ATGP Alarm Code.................................................................................................56 4.1.6 ATZN Alarm Code.................................................................................................56

4.2 B .................................................................................................................. 58 4.2.1 BBOX Alarm Code ................................................................................................58

4.3 C.................................................................................................................. 60 4.3.1 CALM Alarm Code................................................................................................60 4.3.2 CD Alarm Code......................................................................................................63 4.3.3 CMND Alarm Code ...............................................................................................65 4.3.4 CNTR Alarm Code.................................................................................................67 4.3.5 COND Alarm Code ................................................................................................68 4.3.6 COPT Alarm Code .................................................................................................68 4.3.7 CPMO Alarm Code ................................................................................................70 4.3.8 CVIS Alarm Code ..................................................................................................90

4.4 D................................................................................................................ 116 4.4.1 DICT Alarm Code ................................................................................................116 4.4.2 DJOG Alarm Code ...............................................................................................119 4.4.3 DMDR Alarm Code .............................................................................................120

TABLE OF CONTENTS B-83124EN-6/01

c - 2

4.4.4 DMER Alarm Code..............................................................................................121 4.4.5 DNET Alarm Code...............................................................................................125 4.4.6 DX Alarm Code....................................................................................................135

4.5 E ................................................................................................................ 137 4.5.1 ELOG Alarm Code...............................................................................................137

4.6 F ................................................................................................................ 137 4.6.1 FILE Alarm Code.................................................................................................137 4.6.2 FLPY Alarm Code................................................................................................143 4.6.3 FRCE Alarm Code ...............................................................................................144 4.6.4 FRSY Alarm Code ...............................................................................................166 4.6.5 FXTL Alarm Code ...............................................................................................168

4.7 H................................................................................................................ 177 4.7.1 HOST Alarm Code...............................................................................................177 4.7.2 HRTL Alarm Code...............................................................................................190

4.8 I.................................................................................................................. 195 4.8.1 IBSS Alarm Code.................................................................................................195 4.8.2 INTP Alarm Code ................................................................................................216 4.8.3 ISD Alarm Code...................................................................................................245

4.9 J................................................................................................................. 254 4.9.1 JOG Alarm Code ..................................................................................................254

4.10 L................................................................................................................. 256 4.10.1 LANG Alarm Code ..............................................................................................256 4.10.2 LECO Alarm Code...............................................................................................259 4.10.3 LNTK Alarm Code...............................................................................................259 4.10.4 LSTP Alarm Code ................................................................................................263

4.11 M................................................................................................................ 264 4.11.1 MACR Alarm Code..............................................................................................264 4.11.2 MARL Alarm Code..............................................................................................265 4.11.3 MCTL Alarm Code ..............................................................................................268 4.11.4 MEMO Alarm Code.............................................................................................269 4.11.5 MENT Alarm Code ..............................................................................................276 4.11.6 MHND Alarm Code .............................................................................................278 4.11.7 MOTN Alarm Code..............................................................................................285 4.11.8 MUPS Alarm Code ..............................................................................................315

4.12 O................................................................................................................ 316 4.12.1 OPTN Alarm Code...............................................................................................316 4.12.2 OS Alarm Code ....................................................................................................317

4.13 P ................................................................................................................ 318 4.13.1 PALL Alarm Code ...............................................................................................318 4.13.2 PALT Alarm Code ...............................................................................................335 4.13.3 PICK Alarm Code ................................................................................................336 4.13.4 PMON Alarm Code..............................................................................................339 4.13.5 PNT1 Alarm Code................................................................................................340 4.13.6 PNT2 Alarm Code................................................................................................411 4.13.7 PRIO Alarm Code ................................................................................................468 4.13.8 PROF Alarm Code ...............................................................................................488 4.13.9 PROG Alarm Code...............................................................................................489 4.13.10 PTPG Alarm Code................................................................................................494 4.13.11 PWD Alarm Code ................................................................................................495

4.14 Q................................................................................................................ 499 4.14.1 QMGR Alarm Code .............................................................................................499

4.15 R................................................................................................................ 499 4.15.1 RIPE Alarm Code.................................................................................................499

B-83124EN-6/01 TABLE OF CONTENTS

c - 3

4.15.2 ROUT Alarm Code...............................................................................................501 4.15.3 RPC Alarm Code..................................................................................................503 4.15.4 RTCP Alarm Code ...............................................................................................505

4.16 S ................................................................................................................ 506 4.16.1 SCIO Alarm Code ................................................................................................506 4.16.2 SEAL Alarm Code ...............................................................................................507 4.16.3 SENS Alarm Code................................................................................................528 4.16.4 SHAP Alarm Code ...............................................................................................529 4.16.5 SPOT Alarm Code................................................................................................532 4.16.6 SPRM Alarm Code...............................................................................................547 4.16.7 SRIO Alarm Code ................................................................................................548 4.16.8 SRVO Alarm Code...............................................................................................549 4.16.9 SSPC Alarm Code ................................................................................................585 4.16.10 SVGN Alarm Code...............................................................................................591 4.16.11 SYST Alarm Code................................................................................................609

4.17 T ................................................................................................................ 629 4.17.1 TAST Alarm Code ...............................................................................................629 4.17.2 TCPP Alarm Code................................................................................................630 4.17.3 TG Alarm Code ....................................................................................................632 4.17.4 THSR Alarm Code ...............................................................................................634 4.17.5 TJOG Alarm Code................................................................................................639 4.17.6 TMAT Alarm Code ..............................................................................................639 4.17.7 TOOL Alarm Code...............................................................................................641 4.17.8 TPIF Alarm Code .................................................................................................643 4.17.9 TRAK Alarm Code...............................................................................................656

4.18 V ................................................................................................................ 657 4.18.1 VARS Alarm Code...............................................................................................657

4.19 W ............................................................................................................... 663 4.19.1 WEAV Alarm Code .............................................................................................663 4.19.2 WNDW Alarm Code ............................................................................................664

4.20 X ................................................................................................................ 667 4.20.1 XMLF Alarm Code ..............................................................................................667

B-83124EN-6/01 1.INTRODUCTION

- 1 -

1 INTRODUCTION This chapter explains the manual plan and the safety precautions that must be observed in working with the FANUC Robot. Contents of this chapter 1.1 MANUAL PLAN

1.1 MANUAL PLAN About this manual

FANUC Robot series (R-30i A CONTROLLER) Operators Manual. This manual describes how to operate the FANUC Robot, an all-purpose compact robot. It is controlled by the FANUC R-30iA controller (called the robot controller hereinafter) containing the FANUC Robot software. This manual describes the error code listings, causes, and remedies.

Related manuals The following manuals are available:

OPERATORS MANUAL (Manuals for Handling, Spot+, Arc, Dispense, etc application are prepared.)

Intended readers: Operators responsible for designing, introducing, operating, and adjusting the robot system at the work site. Topics: Functions, operations and the procedure for operating the robot. Programming procedure, interface. Use: Guide to teaching, introducing, and adjusting the robot at the work site, and application designing.

OPERATOR'S MANUAL (This manual)

Topics: Error code listings, causes, and remedies. Use: Installing and activating the system, connecting the mechanical unit to the peripheral device and maintenance the robot.

Robot controller

MAINTENANCE MANUAL Topics: Installing and activating the system, connecting the mechanical unit to the peripheral device and maintenance the robot.

Mechanical unit OPERATORS MANUAL or MAINTENANCE MANUAL

Topics: Installing and activating the robot, connecting the mechanical unit to the controller, maintaining the robot. Use: Guide to installation, activation, connection, and maintenance.

1.INTRODUCTION B-83124EN-6/01

- 2 -

Notation This manual contains safety precautions against injury and property damage. Those precautions are labeled Warning or Caution, according to the degree of importance. Supplementary explanation is given under Note. Before starting to use a robot, carefully read the Warning, Caution, and Note.

WARNING Failure to follow the instruction given under Warning can cause fatal or serious

injury to the user. This information is indicated in bold type in a box so that it can be easily distinguished from the main body of this manual.

CAUTION

Failure to follow the instruction given under Caution can cause injury to the user or property damage. This information is indicated in a box so that it can be easily distinguished from the main body of this manual.

NOTE The information given under Note is a supplementary explanation, which is

neither a warning nor a caution. Carefully read and save this manual.

B-83124EN-6/01 2.OVERVIEW

- 3 -

2 OVERVIEW 2.1 OVERVIEW

Errors occur because of Hardware problems - a broken cable or tooling Software problems - incorrect program or data External problems - an open safety door or an overtravel has occurred Depending on the severity of the error, you must take certain steps to recover from it. A complete listing of error codes is provided in this manual. Use Procedure 2-1 as the recommended error recovery procedure. Some errors require minimal corrective action to recover from them. Others require procedures that are more involved. The first step in the error recovery process is to determine the kind and severity of the error. After you determine this information, the appropriate error recovery procedure can be used.

Procedure 2-1 Error Recovery Recommendation

Conditions An error has occurred.

Steps 1 Determine the cause of the error. 2 Correct the problem which caused the error. 3 Release the error. 4 Restart the program or robot. If the basic recovery procedures do not clear the error, try restarting the controller. Refer to Table

2.1 for the methods of starting the controller. First try a Cold start. If Cold start does not solve the problem, try a Controlled start and then a Cold start.

Table 2.1 Startup Methods

Start Method Description Procedure Cold start (START COLD) Initializes changes to system variables

Initializes changes to I/O setup Displays the UTILITIES Hints screen

Turn the power disconnect circuit breaker to ON. When the BMON screen is displayed on the teach pendant, press and hold the SHIFT and RESET keys. After you see files beginning to load on the teach pendant screen, release all of the keys.

Controlled start (START CTRL) Allows you to set up application specific information Allows you to install options and updates Allows you to save specific information Allows you to start KCL Allows you to print teach pendant screens and the current robot configuration Allows you to unsimulate all I/O Does not allow you to load teach pendant programs

Press FCTN and select CYCLE START, select YES, and press ENTER. When the BMON screen is displayed on the teach pendant, press and hold the PREV and NEXT keys. After the Configuration Menu screen is displayed, release the keys. Select Controlled start and press ENTER.

2.OVERVIEW B-83124EN-6/01

- 4 -

2.2 ERROR CODE PROPERTIES 2.2.1 Overview

An error code consists of: The facility name and error code number The severity of the error The message text of the error Refer to Section 2.2.2, Section 2.2.3, and Section 2.2.4. The error code will be displayed as follows: FACILITY_NAME - ERROR_CODE_NUMBER Error message text The Alarm Log screen displays a list of errors that have occurred. There are two ways to display alarms: Automatically using the Active Alarm screen. This screen displays only active errors (with a

severity other than WARN) that have occurred since the last time RESET was pressed. Manually using the History Alarm screen. This screen displays up to the last 100 alarms, regardless

of their severity. You can also display detailed information about a specific alarm. Optionally, you can set up your system to store additional alarms in an alarm log called MD:errext.ls. If you have the Extended Alarm Log option installed and set up, then this file, stored on the MD: device, will display up to the last 1000 alarms. In this case, the alarms are numbered and contain the date, time, error message, cause code, and severity. Programming events will be displayed the same as error messages but will not have cause codes or severities.

For information on setting up the Extended Alarm Log, refer to the Software Installation Manual. Table 2.2.1(a) through Table 2.2.1(f) describe each kind of alarm that can be displayed.

Table 2.2.1(a) Alarm Log Screen ITEM DESCRIPTION

Alarm Status This item allows you to monitor the entire list of active alarms. Press F3, HIST, to display the history of alarms.

Table 2.2.1(b) Application Alarm Screen

ITEM DESCRIPTION Application Alarm Status This item allows you to monitor application alarms. Application alarms include

anything that is related to the given application-specific tool that is loaded.

Table 2.2.1(c) Comm Log Screen ITEM DESCRIPTION

Comm Log Status This item allows you to monitor any communication alarms when a communication option is loaded.

Table 2.2.1(d) Fault Recovery Screen

ITEM DESCRIPTION Fault Recovery Status This item allows you to monitor fault recovery status.

Table 2.2.1(e) Motion Alarm Screen

ITEM DESCRIPTION Motion Alarm Status This item allows you to monitor the Motion Alarm screen status such as, SRVO

alarms or any other alarms related to robot movement.


- 5 -

Table 2.2.1(f) System Alarm Screen ITEM DESCRIPTION

System Alarm Status This item allows you to monitor system alarm messages such as SYST alarms. Use Procedure 2-2 to display the Alarm Log screen.

Procedure 2-2 Displaying the Alarm Log Automatically

Conditions To display the Active Alarm screen automatically,

Set the system variable $ER_AUTO_ENB to TRUE either on the SYSTEM Variables menu or by setting Auto display of alarm menu to TRUE on the SYSTEM Configuration menu. Then perform a Cold start.

An error, whose severity is either PAUSE or ABORT must have occurred.

Steps 1 The following screen will automatically be displayed. It lists all errors with a severity other than

WARN, that have occurred since the last controller RESET. The most recent error is number 1.

SRVO-007 External emergency stop TEST1 LINE 15 ABORTEDAlarm: ACTIVE 1 SRVO-007 External emergency stop

2 To toggle between the Active Alarm screen and Hist Alarm screen, press F3 (ACTIVE or HIST). 3 If you are using an iPendant and are in Single Display Mode, you can toggle between wide screen

and normal screen. Press F2, [ VIEW ] and select Wide or Normal. 4 To disable the automatic display of all errors with a certain severity type, modify the value of the

system variable $ER_SEV_NOAUTO[1-5]. These errors will still be logged in the Active Alarm screen, but they will no longer force the screen to immediately become visible. Refer to the Software Reference Manual for more detailed information about how to set these variables.

5 To disable the automatic display of a specific error code, modify the $ER_NOAUTO.$noalm_num and $ER_NOAUTO.$er_code system variables. These errors will still be logged in the Active Alarm screen, but they will no longer force the screen to immediately become visible. Refer to the Software Reference Manual for more detailed information about how to set these variables.

6 To display the screen that occurred immediately before the alarm, press RESET. If you have toggled between HIST and ACTIVE, the previous screen might not be available.

When there are no active alarms (the system is not in error status), the following message will be displayed on the Active Alarm screen.

There are no active alarms. Press F3(HIST) to enter alarm history screen.

NOTE When you reset the system by pressing the RESET key, the alarms displayed on

this screen are cleared.

Procedure 2-3 Displaying the Alarm Log Manually

Steps 1 Press MENUS. 2 Press ALARM. 3 Press F3, HIST. 4 Press F1, [TYPE].


- 6 -

5 Select Alarm Log. The alarm log will be displayed. This lists all errors. See the following screen for an example.

SRVO-007 External emergency stop TEST1 LINE 15 ABORTED Alarm: HIST 1 SRVO-007 External emergency stop 2 SRVO-001 Operator panel emergency st3 R E S E T 4 SRVO-029 Robot calibrated (Group:1)5 SRVO-001 Operator panel emergency st6 SRVO-012 Power fail recovery 7 INTP-127 Power fail detected 8 SRVO-047 LVAL alarm (Group:1 Axis:5)9 SRVO-047 LVAL alarm (Group:1 Axis:4)10 SRVO-002 Teach pendant emergency stop

NOTE The most recent error is number 1.

To display the complete error message that does not fit on the screen, press F5, DETAIL, and

the right arrow key on the teach pendant. To display the cause code for an error message, press F5, DETAIL. Cause codes provide

further information about the cause of the error. If the specified error has a cause code, the cause code message is displayed immediately below the error line, on the status line. When you press RESET, the error and cause code disappears and the status line is redisplayed.

6 To display the motion log, which lists only motion-related errors, press F1, [TYPE], and select Motion Log.

7 To display the system log, which displays only system errors, press F1, [TYPE], and select System Log.

8 To display the application log, which displays only application-specific errors, press F1, [TYPE], and select Appl Log.

9 To display the reporting log which displays the top five alarms that occurred while the robot was in Auto mode, press F1, [TYPE], and select Reporting. a To view the top five faults by incident, press F2, INCIDENT. b To view the top five faults by total asserted time, press F3, T_TIME. c To view the top five faults by longest asserted time for any given fault, press F4, L_TIME.

10 To display the communication log, which displays only communication-specific errors, press F1, [TYPE], and select Comm Log.

11 To display the password log, which displays only password-specific errors, press F1, [TYPE], and select Password Log.

12 To display more information about an error, move the cursor to the error and press F5, DETAIL. The error detail screen displays information specific to the error you selected, including the severity. If the error has a cause code, the cause code message will be displayed. When you are finished viewing the information, press PREV.

13 To display cause and remedy information specific to an error, move the cursor to the error and press SHIFT and the Help/Diag button on the iPendant.

14 To remove all of the error messages displayed on the screen, press and hold SHIFT and press F4, CLEAR.

15 To change the view displayed on the screen, press F2, [ VIEW ]. To show or hide the cause codes for each alarm, select Show Cause or Hide Cause. If an alarm has no cause code, the time the alarm occurred will be shown instead. If you are using an iPendant and are in Single Display Mode, you can also toggle between wide screen and normal screen by selecting Wide or Normal.


- 7 -

2.2.2 Facility Name and Code The facility name and code identify the type of error that occurred. Facility information is displayed at the beginning of the error code: PROG-048 PAUSE Shift released while running In the example, the facility name PROG corresponds to facility code 3. The error code number is 048. Facility codes are used in error handling from a KAREL program. The facility codes are listed in Table 2.2.2.

Table 2.2.2 Error Facility Codes

Facility Name Facility Code (Decimal) Facility Code (Hexadecimal) Description

ACAL 112 0x70 AccuCal II error code APSH 38 0x26 Application shell ARC 53 0x35 Arc welding application ASBN 22 0x16 Mnemonic editor ATGP 102 0x66 Attach gro lead through

and force control CALM 106 0x6a CalMate CD 82 0x52 Coordinated motion

softpart CMND 42 0x2a Command processor CNTR 73 0x4g Continuous turn softpart COND 4 0x4 Condition handler COPT 37 0x25 Common options CPMO 114 0x72 Constant Path error code CUST 97 0x61 Customer specific errors CVIS 117 0x75 Integrated Vision

(Controller Vision) DICT 33 0x21 Dictionary processor DJOG 64 0x40 Detached jog DMDR 84 0x54 Dual Motion Drive DMER 40 0x28 Data monitor DNET 76 0x4c DeviceNet DX 72 0x48 Delta Tool/Frame softpart ELOG 5 0x5 Error logger FILE 2 0x2 File system FLPY 10 0xa Serial floppy disk system FRCE 91 0x5b Impedance control (force

control) FRSY 85 0x55 Flash file system FXTL 136 C-flex tool HOST 67 0x43 Host communications

general HRTL 66 0x42 Host communications run

time library IBSS 88 0x58 Interbus-S INTP 12 0xc Interpreter internal errors ISD 39 0x27 ISD (Integral Servo

Dispenser) JOG 19 0x13 Manual jog task LANG 21 0x15 Language utility


- 8 -


LECO 109 0x6D Arc errors from Lincoln Electric

LNTK 44 0x2c Line tracking LSTP 108 0x6C Local Stop error codes MACR 57 0x39 MACRO option MARL 83 0x53 Material removal MCTL 6 0x6 Motion control manager MEMO 7 0x7 Memory manager MENT 68 0x44 ME-NET MHND 41 0x29 Material Handling shell and

menus MOTN 15 0xf Motion subsystem MUPS 48 0x30 Multi-pass motion NOM 133 Nominal Position OPTN 65 0x41 Option installation OS 0 0x0 Operating system PALL 115 0x73 PalletTool PALT 26 0x1a Palletizing application PMON 28 0x1c PC monitor PNT1 86 0x56 Paint Application Errors

POST V6.31 PRIO 13 0xd Digital I/O subsystem PROF 92 0x5c Profibus DP PROG 3 0x3 Interpreter PWD 31 0x1f Password logging QMGR 61 0x3d KAREL queue manager RIPE 130 Ros IP errors ROUT 17 0x11 Softpart built-in routine for

interpreter RPC 93 0x5d RPC RPM 43 0x2b Root Pass Memorization RTCP 89 0x59 Remote TCP SCIO 25 0x19 Syntax checking for teach

pendant programs SEAL 51 0x33 Sealing application SENS 58 0x3a Sensor interface SHAP 79 0x4f Shape generation SPOT 23 0x17 Spot welding application SPRM 131 Ramp motion softpart SRIO 1 0x1 Serial driver SRVO 11 0xb FLTR & SERVO in motion

sub-system SSPC 69 0x45 Special space checking

function SVGN 30 0x1e Servo weld gun application SYST 24 0x18 Facility code of system TAST 47 0x2f Through-Arc Seam

Tracking TCPP 46 0x2e TCP speed prediction TG 90 0x5a Triggering accuracy THSR 60 0x3c Touch Sensing softpart TJOG 116 0x74 Tracking Jog


- 9 -


TMAT 119 0x77 Torch Mate TOOL 29 0x1d Servo tool change TPIF 9 0x9 Teach pendant user

interface TRAK 54 0x36 Tracking softpart TRSV 134 Tray server task error text VARS 16 0x10 Variable Manager

Subsystem WEAV 45 0x2d Weaving WMAP 103 0x67 All wafer handling robot

related Errors WNDW 18 0x12 Window I/O manager

sub-system XMLF 129 XML errors

2.2.3 Severity Descriptions The severity of the error indicates how serious the error is. The severity is displayed after the error number. For example: PROG-048 PAUSE Shift released while running

NOTE You can display the severity of the error code on the ALARM screen. Refer to

Procedure 2-2.

$ER_SEV_NOAUTO[1-5] System Variable The $ER_SEV_NOAUTO[1-5] system variable enables or disables the automatic display of all error codes with a particular severity. This is used in conjunction with the $ER_AUTO_ENB system variable.

Table 2.2.3(a) Severity Descriptions SEVERITY $ER_SEV_NOAUTO[1-5]

PAUSE [1] STOP [2] SERVO [3] ABORT [4] SYSTEM [5]

WARN

WARN errors only warn of potential problems or unexpected circumstances. They do not directly affect any operations that might be in progress. If a WARN error occurs, you should determine what caused the error and what, if any, actions should be taken. For example, the WARN error Singularity position indicates a singularity position was encountered during a move. No action is required. However, if you do not want the motion to encounter a singularity position, you can reteach the program positions.

PAUSE PAUSE errors pause program execution but allow the robot to complete its current motion segment, if any are in progress. This error typically indicates that some action must be taken before program execution can be resumed. PAUSE errors cause the operator panel FAULT light to go on and the teach pendant FAULT LED to go on.


- 10 -

Depending on the action that is required, you might be able to resume a paused program at the point where the PAUSE error occurred after you have corrected the error condition. If the program can be resumed, you can either select the RESUME function key or press the operator CYCLE START button, or press the UOP CYCLE START button if the setting of the REMOTE/LOCAL setup item on the System Configuration menu is set to LOCAL.

STOP STOP errors pause program execution and stop robot motion. When a motion is stopped, the robot decelerates to a stop and any remaining part of the current motion segment is saved, meaning the motion can be resumed. STOP errors usually indicate that some action must be taken before the motion and program execution can be resumed. Depending on the action that is required, you might be able to resume the motion and program execution after correcting the error condition. If the motion and program can be resumed, you can either select the RESUME function key or press the operator CYCLE START button if the setting of the REMOTE/LOCAL setup item on the System Configuration menu is set to LOCAL. If the robot is in production mode, you must choose the appropriate recovery option.

SERVO SERVO errors shut off the drive power to the servo system and pause program execution. SERVO errors cause the operator panel FAULT light to go on and the teach pendant FAULT LED to go on. SERVO errors are usually caused by hardware problems and could require trained service personnel. However, some SERVO errors require you to reset the servo system by pressing the operator panel FAULT RESET button or the teach pendant RESET key. Others require a Cold start of the controller.

ABORT ABORT errors abort program execution and STOP robot motion. When an ABORT error occurs, the robot decelerates to a STOP and the remainder of the motion is canceled. An ABORT error indicates that the program has a problem that is severe enough to prevent it from continuing to run. You will need to correct the problem and then restart the program. Depending on the error, correcting the problem might mean editing the program or modifying the data.

SYSTEM SYSTEM errors usually indicate a system problem exists that is severe enough to prevent any further operation. The problem could be hardware or software related. You will need the assistance of trained service personnel to correct SYSTEM errors. After the error has been corrected, you will need to reset the system by turning off the robot, waiting a few seconds, and turning on the robot. If a program was executing when the error occurred, you will need to restart the program.

ERROR ERROR errors occur during the translation of a KAREL program. When an ERROR error occurs, translation is stopped and a .PC file is not generated. Fix the error in the program and retranslate it. When you translate a program and no ERROR errors occur, translation is successful and a .PC file is generated.

NONE NONE errors can be returned as status from some KAREL built-in routines and can also be used to trigger KAREL condition handlers. NONE errors are not displayed on the teach pendant or CRT/KB. They also are not displayed on the alarm log screen. NONE errors do not have any effect on programs, robot motion, or servo motors. Table 2.2.3(b) summarizes the effects of error severities.


- 11 -

Table 2.2.3(b) Effects of Error Severity Severity Program Robot Motion Servo Motors

WARN No effect No effect No effect PAUSE Paused The current move is

completed then the robot stops.

No effect

STOP Paused Decelerated STOP, motion retained

No effect

SERVO Paused Decelerated STOP, motion retained

Power shutdown

ABORT Aborted EMERGENCY STOP, motion canceled

No effect

SYSTEM Aborted EMERGENCY STOP, motion canceled

Power shut down Requires a FCTN: CYCLE POWER

ERROR No effect No effect No effect NONE No effect No effect No effect

2.2.4 Error Message Text The message text describes the error that has occurred. Message text is displayed at the end of the error code. For example: PROG-048 PAUSE Shift released while running Some error messages might contain cause codes, percent (%) notation, or hexadecimal notation. For more information on displaying cause codes, refer to Procedure 1-2.

Percent Notation (%) A percent sign followed by the letter s (%s) indicates that a string, representing a program name, file name, or variable name, actually appears in the error message when the error occurs. A percent sign followed by the letter d (%d) indicates that an integer, representing a program line number or other numeric value, actually appears in the error message when the error occurs. For example: INTP-327 ABORT (%^s, %d^5) Open file failed When this error occurs, the actual name of the file that could not be opened will appear on the teach pendant error line instead of %s. The actual program line number on which that error occurred will appear on the teach pendant error line instead of %d.

Hexadecimal Notation Hexadecimal notation is used to indicate the specific axes in error, when one or more axes are in error at the same time. Most robots have interaction limits, in addition to normal joint limits. Even when all axes are within their respective limits an error might occur. This could possibly be caused by the interaction between multiple axes. In this case, hexadecimal notation can help you to find the specific axis in error. For example: MOTN-017 STOP limit error (G:1 A:6 Hex) The number after the A is the hexadecimal digit that shows which axes are out of limit. The Hex indicates that the axis numbers are in hexadecimal format. Table 2.2.4(a) lists the sixteen hexadecimal digits and the corresponding axes that are in error.


- 12 -

NOTE Hexadecimal digits for the decimal values of 10 through 15 are represented by

the letters A through F respectively. Refer to Table 2.2.4(a). To determine which axes are in error, you must evaluate each digit in the error message separately. Refer to Table 2.2.4(a).

NOTE If only one number appears in the error message after the A:, you must read it

as the first digit.

Table 2.2.4(a) Hexadecimal Error Message Display MOTN-017 limit error (G:1 A:(3)(2) (1) HEX)

Hexadecimal Digit Third Digit (3) Second Digit (2) First Digit (1) 0 none none none 1 axis 9 axis 5 axis 1 2 n/a axis 6 axis 2 3 n/a axes 5 & 6 axes 1 & 2 4 n/a axis 7 axis 3 5 n/a axes 5 & 7 axes 1 & 3 6 n/a axes 6 & 7 axes 2 & 3 7 n/a axes 5, 6, & 7 axes 1, 2, & 3 8 n/a axis 8 axis 4 9 n/a axes 5 & 8 axes 1 & 4 A n/a axes 6 & 8 axes 2 & 4 B n/a axes 5, 6, & 8 axes 1, 2, & 4 C n/a axes 7 & 8 axes 3 & 4 D n/a axes 5, 7, & 8 axes 1, 3, & 4 E n/a axes 6, 7, & 8 axes 2, 3, & 4 F n/a axes 5, 6, 7, & 8 axes 1, 2, 3, & 4 Note: If only one number appears in the error message after the A:, you must read it as the first digit (1).

Table 2.2.4(b) contains some examples of how to interpret Hexadecimal notation in an error message.

Table 2.2.4(b) Hexadecimal Notation and Axis in Error Examples Error Explanation

MOTN-017 (G:1 A:6 Hex) Axes 2 and 3 are out of their interaction limit. MJOG-013 (G:1 A:20 Hex) Axis 6 jogged to limit. MOTN-017 (G:1 A:100 Hex)

Axis 9 limit error.

B-83124EN-6/01 3.ERROR RECOVERY

- 13 -

3 ERROR RECOVERY 3.1 GENERAL ERROR RECOVERY PROCEDURES 3.1.1 Overview

This section contains procedures for recovery from certain errors. These errors are: Overtravel release Hand breakage recovery Pulse coder alarm Chain failure detection recovery

3.1.2 Overtravel Release An overtravel error occurs when one or more of the robot axes moves beyond the software motion limits. When this happens one of the overtravel limit switches is tripped and the system does the following: Shuts off drive power to the servo system and applies robot brakes Displays an overtravel alarm error message Lights the operator panel FAULT light Turns on the teach pendant FAULT status indicator Limits motion for the axes involved in the overtravel If you are jogging in JOINT, the axis number indicating the axis (or axes) in an overtravel will be displayed in the error log. You can manually release overtravel on your system from the MANUAL OT Release screen. The axis that is in overtravel will display TRUE in either OT_MINUS or OT_PLUS. Refer to Table 3.1.2 for information on the MANUAL OT Release items. Use Procedure 3-1 to recover from an overtravel error.

Table 3.1.2 MANUAL OT Release Items ITEM DESCRIPTION

AXIS This item displays the number for each axis. OT MINUS This item displays whether a particular axis is in an overtravel condition. OT PLUS This item displays whether a particular axis is in an overtravel condition.

Procedure 3-1 Recovering from an Overtravel Error

Conditions An axis (or axes) are in overtravel and the overtravel alarm has occurred. If you are jogging in

JOINT the axis number indicating the axis (or axes) in an overtravel will be displayed in the error log.

Steps

1 Press MENUS. 2 Select SYSTEM. 3 Press F1, [TYPE]. 4 Select OT Release. You will see a screen similar to the following. The axis that is overtraveled will

display TRUE in either OT_MINUS or OT_PLUS.

3.ERROR RECOVERY B-83124EN-6/01

- 14 -

MANUAL OT Release AXIS OT MINUS OT PLUS 1 FALSE TRUE 2 FALSE FALSE 3 FALSE FALSE 4 FALSE FALSE 5 FALSE FALSE 6 FALSE FALSE 7 FALSE FALSE 8 FALSE FALSE 9 FALSE FALSE

5 Move the cursor to the OT PLUS or OT MINUS value of the axis in overtravel. 6 Press F2, RELEASE. The value of the overtraveled axis should change back to FALSE. 7 If the robot is calibrated, you will see the message Can't Release OT. Press HELP for detail.

a If you press F5, DETAIL, you will see a screen similar to the following.

MANUAL OT Release When robot is calibrated, overtravel cannot be released. Press SHIFT & RESET to clear the error, and jog outof the overtravel condition.

NOTE For the following steps, press and hold down the SHIFT key until you have

completed Step 7.b through Step 7.d.

b Press and continue pressing SHIFT and press F2, RESET. Wait for servo power. c Continuously press and hold the DEADMAN switch and turn the teach pendant ON/OFF

switch to ON. d Jog the overtraveled axis off the overtravel switch. When you have finished jogging, you can

release the SHIFT key.

NOTE If you accidentally release the shift key during Step 7.b through Step 7.d, you will

have to repeat them. 8 If the robot is not calibrated, perform the following steps:

NOTE For the following steps, press and hold down the SHIFT key until you have

completed Step 8.a through Step 8.d.

a Press and continue pressing SHIFT and press F2, RESET. Wait for servo power. b Press COORD until you select the JOINT coordinate system. c Continuously press and hold the DEADMAN switch and turn the teach pendant ON/OFF

switch to ON. d Jog the overtraveled axis off the overtravel switch. When you have finished jogging, you can

release the SHIFT key.


- 15 -

NOTE If you accidentally release the shift key during this step, you will need to repeat

it.

9 Turn the teach pendant ON/OFF switch to OFF and release the DEADMAN switch. 10 Check CRM68 & CRF7 connection on the amplifier PCB if the robot is not in an actual overtravel

condition.

3.1.3 Hand Breakage Recovery A hand breakage error occurs when the hand breakage detection switch is tripped on robots equipped with hand breakage hardware. The switch is tripped when the robot tool strikes an obstacle, which could possibly cause the tool to break. The system Shuts off drive power to the servo system and applies robot brakes Displays an error message indicating that the hand is broken Lights the operator panel FAULT light Lights the teach pendant FAULT LED The status of the hand breakage detection switch is displayed on the STATUS Safety Signals screen. Use Procedure 3-2 to recover from a hand breakage.

Procedure 3-2 Recovering from a Hand Breakage

Conditions The hand breakage error message is displayed.

Steps

1 If you have not already done so, continuously press and hold the DEADMAN switch and turn the teach pendant ON/OFF switch to ON.

2 Hold down the SHIFT key and press RESET. The robot can now be moved. 3 Jog the robot to a safe position. 4 Press the EMERGENCY STOP button. 5 Request a trained service person to inspect and, if necessary, repair the tool. 6 Determine what caused the tool to strike an object, causing the hand to break. 7 If the hand breakage occurred while a program was being executed, you might need to reteach

positions, modify the program, or move the object that was struck. 8 Test run the program if it has been modified, if new positions have been recorded, or if objects in the

work envelope have been moved.

3.1.4 Pulse Coder Alarm Recovery If the pulse counts at power up do not match the pulse counts at power down, a pulse mismatch error occurs for each motion group and each axis. Use Procedure 3-3 to reset a pulse coder alarm.

Procedure 3-3 Resetting a Pulse Coder SRVO-062 Alarm

Steps 1 Press MENUS. 2 Select SYSTEM. 3 Press F1, [TYPE]. 4 Select Master/Cal. If Master/Cal is not listed on the [TYPE] menu, do the following; otherwise, continue to Step 5.

a Select VARIABLE from the [TYPE] menu.


- 16 -

b Move the cursor to $MASTER_ENB. c Press the numeric key 1 and then press ENTER on the teach pendant. d Press F1, [TYPE]. e Select Master/Cal. You will see a screen similar to the following.

SYSTEM Master/Cal 1 FIXTURE POSITION MASTER 2 ZERO POSITION MASTER 3 QUICK MASTER 4 SINGLE AXIS MASTER 5 SET QUICK MASTER REF 6 CALIBRATE Press ENTER or number key to select.

5 Press F3, RES_PCA. You will see a screen similar to the following.

SYSTEM Master/Cal 1 FIXTURE POSITION MASTER 2 ZERO POSITION MASTER 3 QUICK MASTER 4 SINGLE AXIS MASTER 5 SET QUICK MASTER REF 6 CALIBRATE Press ENTER or number key to select.

Reset pulse coder alarm? [NO] 6 Press F4, YES. You will see a screen similar to the following.

SYSTEM Master/Cal 1 FIXTURE POSITION MASTER 2 ZERO POSITION MASTER 3 QUICK MASTER 4 SINGLE AXIS MASTER 5 SET QUICK MASTER REF 6 CALIBRATE

Pulse coder alarm reset!

3.1.5 Chain Failure Detection Error Recovery A Single Chain Failure Detection fault will be set if one safety chain is in an Emergency Stop condition, and the other is not in an Emergency Stop condition. When a Single Chain Failure Detection fault occurs, the system does the following: Shuts off drive power to the servo system and applies robot brakes Displays an error message indicating that a single chain failure has occurred. Lights the operator panel FAULT light Lights the teach pendant FAULT LED

Chain Failure Detection Errors Refer to the Maintenance Manual for more information on chain failure detection errors, SRVO-230 and 231, SRVO-266 through 275 (external checking -customer), and SRVO-370 through 385 (internal checking)


- 17 -

Procedure 3-4 Chain Failure Detection Error Recovery

Conditions The system detected either a SRVO-230 Chain 1 (+24V abnormal) or a SRVO-231 Chain 2 (0V

abnormal) error. You cannot reset the chain failure errors, even after turning the controller OFF and then ON again.

Steps 1 Correct the cause of the alarm. 2 Press MENUS. 3 Select ALARMS. You will see a screen similar to the following.

ALARM: Active SRVO-230 Chain 1(+24V) abnormal

4 Press F4, RES_CH1. You will see a screen similar to the following

ALARM: Active SRVO-230 Chain 1(+24V) abnormal Reset Single Channel Fault [NO]

5 Press F4, YES to reset the fault. 6 Press the RESET button on the teach pendant or operator panel.

WARNING If you reset the chain failure fault without fixing the cause of it, the same alarm

will occur, but the robot can move until the alarm occurs again. Be sure to fix the cause of the chain failure before you continue. Otherwise, you could injure personnel or damage equipment.

3.2 PAINTTOOL RECOVERY PROCEDURES 3.2.1 Overview

There are special recovery procedures for the following PaintTool situations: Brake control release Purge fault Executing an in cleaner robot action without executing an exit cleaner robot action Cancel/Continue a cycle during production I/O write error Use Procedure 3-5 to release or engage the brakes. Use Procedure 3-6 to recover from a purge fault. Use Procedure 3-7 to execute an exit cleaner robot request out of sequence. Use Procedure 3-8 to cancel or continue a cycle during production.

3.2.2 Brake Control Release To recover from some error codes, you might have to release the brakes. You can release and engage the brakes using the teach pendant or using a keyswitch on the operator panel. This section describes how to release and engage the brakes using both methods. Use Procedure 3-5 to release or engage the brakes using the operator panel.


- 18 -

Procedure 3-5 Releasing or Engaging the Brakes Using the Operator Panel

NOTE When you release the brakes using the operator panel, the robot will be put into

an EMERGENCY STOP and the brakes will be released. You cannot restart the robot until you engage the brakes.

Steps

1 To release the brakes, set the BRAKE ENABLE switch to ON. 2 To engage the brakes, set the BRAKE ENABLE switch to OFF.

3.2.3 Purge Fault Recovery Use Procedure 3-6 to recover from a purge fault.

Procedure 3-6 Recovering from a Purge Fault

Conditions The controller is on. A purge fault condition exists and the purge fault LED on the controller is lit.

Steps 1 Check to see if one of the following conditions exists:

Any robot covers have been removed. Plant air pressure has failed. Robot air line has been removed. Purge solenoids have failed. If any of these conditions exist, you must correct the condition before you can continue.

2 Press the PURGE ENABLE button on the controller operator panel to initiate the purge cycle. 3 Wait for the PURGE COMPLETE LED to light. This process takes approximately five minutes from

the time you press PURGE ENABLE.

3.2.4 Executing an Exit Cleaner Robot Request out of Sequence Use Procedure 3-7 to execute an exit cleaner robot request out of sequence.

Procedure 3-7 Executing an Exit Cleaner Robot Request Out of Sequence

Conditions The Color Change option is running on your controller. A fault exists following an in cleaner robot action request but before an exit cleaner robot action

request is executed.

Steps 1 Press RESET to clear the fault.

WARNING The next step causes the robot to move. Make sure all personnel and

unnecessary equipment are out of the workcell and that all safeguards are in place; otherwise, the robot could injure personnel or damage equipment.


- 19 -

2 Jog the robot out of the cleaner box. 3 Press MENUS. 4 Select MOVE MENU.

1 HOME PR [home program ] 2 CLNIN PR [cleanin program ] 3 CLNOUT PR [cleanout program] 4 BYPASS PR [bypass program ] 5 PURGE PR [purge program ] 6 SPECIAL1 PR [Special Pos 1 ] 7 SPECIAL2 PR [Special Pos 2 ]Press SHIFT and F4 to move.

5 Position the cursor on the predefined position you want to test. 6 Make sure that STEP mode is disabled. If the STEP status indicator is on, press the STEP key. 7 Continuously press and hold the DEADMAN switch. 8 Turn the teach pendant ON/OFF switch to the ON position.

WARNING The next step causes the robot to move. Make sure all personnel and

unnecessary equipment are out of the workcell and that all safeguards are in place; otherwise, personnel could be injured and equipment damaged. In the next step of this procedure, if you want to stop the program before it has finished executing, release the SHIFT key or press the EMERGENCY STOP button.

9 Hold down the SHIFT key and press F4, MOVE_TO. The F4 key can be released, but the SHIFT

key must be held continuously until the program has completed executing. 10 When the robot has completed moving through the selected program, an @ sign will be displayed on

the screen indicating that the robot is at the position. See the following screen for an example when the robot has finished the CLNOUT program.

1 HOME PR [home program ] 2 CLNIN PR [cleanin program ] 3 CLNOUT @ PR [cleanout program] 4 BYPASS PR [bypass program ] 5 PURGE PR [purge program ] 6 SPECIAL1 PR [Special Pos 1 ] 7 SPECIAL2 PR [Special Pos 2 ] Press SHIFT and F4 to move.

3.2.5 Production Mode Recovery Use Procedure 3-8 to perform production mode recovery.

Procedure 3-8 Production Mode Recovery

Conditions The robot is in production mode. The program running in production is paused. An error has occurred and has been reset. The ALARMS Recovery screen is posted automatically.


- 20 -

Steps 1 Press the HOLD button on the teach pendant. 2 Fix the problem that caused you to press HOLD. 3 Press the RESET button on the teach pendant or operator panel to reset the fault. 4 If cancel/continue is enabled and a job is playing back in production when the HOLD key is pressed,

select either CANCEL or CONTINUE from the Alarm/Recovery screen. See the following screen for an example.

This screen is displayed if you can recover from the error.

Recoverable error condition. Press F2 (CONT) to continue or F3(CANC) to cancel the current job.

This screen is displayed if you cannot recover from the error.

Nonrecoverable error condition. Press F3 (CANC) to cancel the current job.

5 If the previous screen is not displayed, you can display it automatically by doing the following:

a Press MENUS. b Select ALARMS. c Press F1, [TYPE]. d Select Recovery.

NOTE Hold is released when program execution begins.

Refer to Table 3.2.5.

Table 3.2.5 Cancel/Continue Recovery Conditions and their Effect on the Current Operating Mode Operating Mode Continue Result Cancel Result

Current Job Active Cycle The current cycle is continued and the job queue is unchanged.

The current cycle is continued and the job queue is unchanged.

Cancel/Continue is Disabled

N/A The current cycle is continued and the job queue is unchanged.

Special Move Active The special move is continued if currently in progress.

The special move is cancelled if currently in progress.

Color Change Option The color queue is unchanged. The color queue is unchanged. Tracking Option The tracking queue is unchanged. The tracking queue is unchanged. Current Cycle The current cycle is continued and the job

queue is unchanged. The current cycle is cancelled and the current job is removed from the job queue.

Special Move The special move is continued if currently in progress.

The special move is cancelled if currently in progress.

Color Change Option The color change option is restarted if in progress and the color queue is unchanged.

The color change option is cancelled if in progress and the current color is removed from the color queue.

Tracking Option The tracking queue is unchanged. The current tracking detect is removed from the tracking queue.

B-83124EN-6/01 4.ERROR CODES

- 21 -

4 ERROR CODES 4.1 A 4.1.1 ACAL Alarm Code

ACAL-000 Fail to run DETECT Motn Cause: The AccuCal2 Motn failed to run. The AccuCal2 motion cannot be started. Remedy: Clear all the errors before executing AccuCal2.

ACAL-001 Robot is not ready. Cause: The robot is not ready. The system cannot issue motion because it is in an error state. Remedy: Clear all faults, then retry the operation.

ACAL-002 Fail to fit circle. Cause: AccuCal2 cannot converge within the set threshold. Remedy: Perform the following:

z Increase the number of iterations allowed. z Increase the convergence threshold setting. z Make sure the TCP has not been changed.

ACAL-003 Contact before search. Cause: The robot is in contact with the part before starting a search motion. Remedy: Reteach the starting position.

ACAL-004 No contact detected. Cause: No contact was made during the AccuCal2 motion. Remedy: Make sure the sensor and software are installed correctly.

ACAL-005 Undefined program name. Cause: The AccuCal2 program name was not defined. Remedy: Select an AccuCal2 teach pendant program before pressing the EXEC key.

ACAL-006 TPE operation error. Cause: This is an internal teach pendant editor program error. Remedy: Abort the program and run again. If this doesn't resolve the problem, cycle power and try again. If this doesn't resolve

the problem, reinstall the controller software.

ACAL-007 Calibration internal error. Cause: This is an AccuCal2 internal error. Remedy: Turn off the controller, and turn it on again to recover. If the problem persists, reinstall the controller software.

ACAL-008 File open error. Cause: The output file cannot be opened. Remedy: Check the path, and file name to be sure they are correct.

ACAL-009 No matching Start inst. Cause: You are trying to execute a CALIB END instruction without a matching CALIB START instruction. Remedy: Add a CALIB START instruction before the CALIB END.

ACAL-010 Invalid schedule number. Cause: The schedule number in CALIB, UTOOL, or UFRAME START is invalid. Remedy: Provide a correct schedule number in CALIB (or UTOOL or UFRAME) START[] teach pendant instruction.

4.ERROR CODES B-83124EN-6/01

- 22 -

ACAL-011 Cannot access $MNUFRAME. Cause: The current $MNUFRAMENUM[] is incorrect and cannot be accessed. Remedy: Go to the USER FRAME menu to select a valid user frame.

ACAL-012 Cannot access $MNUTOOL. Cause: Cannot access $MNUTOOL. The current $MNUTOOLNUM[] is incorrect. Remedy: Display the FRAME menu to select a valid tool frame.

ACAL-013 Backward execution ignored. Cause: Backward execution was ignored. The AccuCal2 instructions can not be executed backward. Remedy: The backward execution of the AccuCal2 instructions is ignored. Rewrite the instructions if you do not want this to

happen.

ACAL-014 System loading error. Cause: System loading error. The AccuCal2 is loaded incorrectly. Remedy: Reload the controller.

ACAL-015 Not enough data. Cause: Not enough data exists to compute the frame offset. Remedy: Add more Detect instructions in the AccuCal2 program.

ACAL-016 No Preplan motion for Detect Cause: The Detect instruction does not allow pre-plan motion. Remedy: None.

ACAL-017 Wrong number of searches. Cause: An incorrect number of searches was performed. Remedy: Re-teach the AccuCal2 program with an appropriate number of searches. Refer to the application-specific Operator's

Manual for information on the number of searches required for each calibration type.

ACAL-018 Nonorthogonal search ve

Alarm Code List - Operator Manual

Documents

Transcript of Alarm Code List - Operator Manual