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3.15 Intermittent errors

Description

During operation, errors and malfunctions may occur, in a seemingly random way.

Consequences

Operation is interrupted, and occasionally, event log messages are displayed, that
sometimes do not seem to be related to any actual system malfunction. This sort
of problem sometimes affects the Emergency stop or Enable chains respectively,
and may at times be very hard to pinpoint.

Probable 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.

Recommended actions

In order to remedy the symptom, the following actions are recommended (the
actions are listed in order of probability):

Info/illustration

Action

Check all the cabling, especially the cables in the
Emergency stop and Enable chains. Make sure all
connectors are connected securely.

1

All indication LEDs and their
significance are specified in
section

Troubleshooting LEDs

in the controller on page 63

.

Check if any indication LEDs signal any malfunction
that may give some clue to the problem.

2

The event log messages may
be viewed either on the Flex-
Pendant or using RobotStudio.

Check the messages in the event log. Sometimes
specific error combinations are intermittent.

3

If possible, keep track of the
malfunctions in a log or similar.

Check the robot’s behavior, etc, each time that type
of error occurs.

4

Check whether any condition in the robot working
environment also changes periodically, e.g, interfer-
ence from any electric equipment only operating
periodically.

5

If possible, keep track of the
malfunctions in a log or similar.

Investigate whether the environmental conditions
(such as ambient temperature, humidity, etc) has any
bearing on the malfunction.

6

Operating manual - Troubleshooting IRC5

61

3HAC020738-001 Revision: AA

© Copyright 2005-2018 ABB. All rights reserved.

3 Troubleshooting by fault symptoms

3.15 Intermittent errors

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Summary of Contents for IRC5 Compact

Page 1: ...ROBOTICS Operating manual Troubleshooting IRC5 ...

Page 2: ...Trace back information Workspace R18 2 version a12 Checked in 2018 10 16 Skribenta version 5 3 008 ...

Page 3: ...Operating manual Troubleshooting IRC5 RobotWare 6 08 Document ID 3HAC020738 001 Revision AA Copyright 2005 2018 ABB All rights reserved Specifications subject to change without notice ...

Page 4: ... persons or property fitness for a specific purpose or the like In no event shall ABB be liable for incidental or consequential damages arising from use of this manual and products described herein This manual and parts thereof must not be reproduced or copied without ABB s written permission Keep for future reference Additional copies of this manual may be obtained from ABB Original instructions ...

Page 5: ...m starting the FlexPendant 51 3 7 Problem connecting FlexPendant to the controller 52 3 8 Erratic event messages on FlexPendant 53 3 9 Problem jogging the robot 54 3 10 Reflashing firmware failure 55 3 11 Inconsistent path accuracy 56 3 12 Mechanical noise or dissonance 58 3 13 Manipulator crashes on power down 59 3 14 Problem releasing Robot brakes 61 3 15 Intermittent errors 62 3 16 Force starti...

Page 6: ...5 3 xxxx 212 5 6 4 xxxx 325 5 7 5 xxxx 366 5 8 7 xxxx 405 5 9 9 xxxx 450 5 10 11 xxxx 538 5 11 12 xxxx 541 5 12 13 xxxx 580 5 13 15 xxxx 581 5 14 17 xxxx 583 6 Circuit diagrams 583 6 1 Circuit diagrams 587 Index 6 Operating manual Troubleshooting IRC5 3HAC020738 001 Revision AA Copyright 2005 2018 ABB All rights reserved Table of contents ...

Page 7: ...sive experience in troubleshooting industrial electro mechanical machinery Have in depth knowledge of the robot system function Be familiar with the actual robot installation at hand its surrounding equipment and peripherals References Document ID Reference 3HAC021313 001 Product manual IRC5 IRC5 of design M2004 3HAC047136 001 Product manual IRC5 IRC5 of design 14 3HAC027098 001 Operating manual E...

Page 8: ...e Safety symbols on product labels on page 13 Updated the graphic in the section Live voltage inside Drive Module on page 28 The contents in the following sections were updated Corrections regarding drive system information in chapter Descrip tions and background information Restructured the chapters as per the new document startergy Updated the graphic in the Recommended actions of the section No...

Page 9: ...t log message types See Type of event log messages on page 91 Added a note on the possibility of a slight difference between the English event logs and translated event logs in Type of event log messages on page 91 T Released with RobotWare 6 02 Added Safety tools on page 26 U Released with RobotWare 6 03 Added event logs for functional safety see 9 xxxx on page 405 Added event logs for Connected ...

Page 10: ...This page is intentionally left blank ...

Page 11: ... not followed that can lead to serious injury pos sibly 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 WARNING Warns for electrical hazards which could result in severe personal injury or death ELECTRICAL SHOCK...

Page 12: ...tions NOTE Describes where to find additional information or how to do an operation in an easier way TIP 12 Operating manual Troubleshooting IRC5 3HAC020738 001 Revision AA Copyright 2005 2018 ABB All rights reserved 1 Safety 1 1 Safety signals in the manual Continued ...

Page 13: ...rman and French Symbols on safety labels Description Symbol Warning xx0900000812 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...

Page 14: ... disassemble xx0900000815 Disassembling this part can cause injury Extended rotation xx0900000814 This axis has extended rotation working area compared to standard Brake release xx0900000808 Pressing this button will release the brakes This means that the robot arm can fall down Continues on next page 14 Operating manual Troubleshooting IRC5 3HAC020738 001 Revision AA Copyright 2005 2018 ABB All r...

Page 15: ... if the bolts are not securely fastened xx1500002402 Crush xx0900000817 Risk of crush injuries Continues on next page Operating manual Troubleshooting IRC5 15 3HAC020738 001 Revision AA Copyright 2005 2018 ABB All rights reserved 1 Safety 1 2 Safety symbols on product labels Continued ...

Page 16: ...xx1300001087 Moving robot 1 2 3 4 5 6 xx0900000819 The robot can move unexpectedly xx1000001141 1 2 3 4 xx1500002616 Continues on next page 16 Operating manual Troubleshooting IRC5 3HAC020738 001 Revision AA Copyright 2005 2018 ABB All rights reserved 1 Safety 1 2 Safety symbols on product labels Continued ...

Page 17: ... Lifting of robot xx0900000822 Oil xx0900000823 Can be used in combination with prohibition if oil is not allowed Mechanical stop xx0900000824 Continues on next page Operating manual Troubleshooting IRC5 17 3HAC020738 001 Revision AA Copyright 2005 2018 ABB All rights reserved 1 Safety 1 2 Safety symbols on product labels Continued ...

Page 18: ...is part is pressurized Usually contains additional text with the pressure level Shut off with handle xx0900000827 Use the power switch on the controller Do not step xx1400002648 Warns that stepping on these parts can cause damage to the parts 18 Operating manual Troubleshooting IRC5 3HAC020738 001 Revision AA Copyright 2005 2018 ABB All rights reserved 1 Safety 1 2 Safety symbols on product labels...

Page 19: ...important information about the product The information is useful for all personnel handling the robot for example during installation service or operation The information labels can contain information in text English German and French Symbols on safety labels Description Label Electrical shock xx1400001151 ESD sensitive components inside the controller xx1400001162 Disconnect power supply before...

Page 20: ... for the IRC5 controller xx1400001157 Required installation space xx1400001155 QR code for ABB Basic Care service agreement xx1400001154 Continues on next page 20 Operating manual Troubleshooting IRC5 3HAC020738 001 Revision AA Copyright 2005 2018 ABB All rights reserved 1 Safety 1 3 Safety symbols on controller labels Continued ...

Page 21: ...ernal xx1400001158 Functional test of the robot system internal xx1400001159 Rating label xx1400001163 CE label xx1800000835 Continues on next page Operating manual Troubleshooting IRC5 21 3HAC020738 001 Revision AA Copyright 2005 2018 ABB All rights reserved 1 Safety 1 3 Safety symbols on controller labels Continued ...

Page 22: ...for SafeMove Basic and SafeMove Advanced software xx1700000355 Safety UL label for the Functional Safety solution together with UL mark xx1700000353 22 Operating manual Troubleshooting IRC5 3HAC020738 001 Revision AA Copyright 2005 2018 ABB All rights reserved 1 Safety 1 3 Safety symbols on controller labels Continued ...

Page 23: ...dant by a locally running robot program or by a PLC to which the system may be connected Dangers during troubleshooting This implies that special considerations unconditionally must be taken when troubleshooting 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 normal...

Page 24: ...015i Ergonomics of the thermal environment Part 1 EN ISO 13732 1 2008 EMC Generic emission EN 61000 6 4 2007 A1 2011 IEC 61000 6 4 2006 A1 2010 option 129 1 EMC Generic immunity EN 61000 6 2 2005 IEC 61000 6 2 2005 Arc welding equipment Part 1 Welding power sources EN IEC 60974 1 2012ii Arc welding equipment Part 10 EMC requirements EN IEC 60974 10 2014ii Safety of machinery Electrical equipment o...

Page 25: ... R15 06 Safety standard for robots and robotic equipment ANSI UL 1740 Industrial robots and robot Systems General safety require ments CAN CSA Z 434 14 Operating manual Troubleshooting IRC5 25 3HAC020738 001 Revision AA Copyright 2005 2018 ABB All rights reserved 1 Safety 1 5 Applicable standards Continued ...

Page 26: ...stop and safeguarding mechanisms are supervised so that any failure is detected by the controller and the robot is stopped until the problem is solved Built in stop functions The controller continuously monitor hardware and software functionality If any problems or errors are detected the robot is stopped until the problem has been solved then If the failure is a simple program stop is issued SYSS...

Page 27: ...ing brakes are non operational secure the robot arm system by some other means before working on it 1 How to correctly connect an external voltage supply is detailed in the Product manual of each robot model If you intentionally render the holding brakes non operational by connecting an external voltage supply the utmost care must be taken DANGER NEVER stand inside the robot working area when disa...

Page 28: ... directly behind the rear covers and inside the front cover even when the main switches have been switched off A en1000000049 Continues on next page 28 Operating manual Troubleshooting IRC5 3HAC020738 001 Revision AA Copyright 2005 2018 ABB All rights reserved 1 Safety 1 7 2 Live voltage inside Drive Module ...

Page 29: ... Read this information before opening the rear cover of either module Action Step Make sure the incoming mains power supply has been switched off 1 Use a voltmeter to verify that there is not voltage between any of the terminals 2 Proceed with the service work 3 Operating manual Troubleshooting IRC5 29 3HAC020738 001 Revision AA Copyright 2005 2018 ABB All rights reserved 1 Safety 1 7 2 Live volta...

Page 30: ...r hand at some distance to feel if heat is radiating from the potentially hot component before actually touching it Wait until the potentially hot component has cooled if it is to be removed or handled in any other way The bleeder can be hot up to 80 degrees Do not put anything on hot metal surfaces e g paper or plastic 30 Operating manual Troubleshooting IRC5 3HAC020738 001 Revision AA Copyright ...

Page 31: ...shooting by fault symptoms See Troubleshooting by fault symptoms on page 41 Describes how to troubleshoot if the following does not work cor rectly for example FlexPendant computer unit fieldbus and I O units power supply See Troubleshooting by unit on page 63 Troubleshooting by unit Lists all the available event log messages These may be displayed either on the FlexPendant or using RobotStudio Ha...

Page 32: ...heck the LEDs on the electronic units 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 32 Operating manual Troubleshooting IRC5 3HAC020738 001 Revision AA Copyright 2005 2018 ABB All rights reserved 2 Introduction to troubleshooting 2 1 Overview of troubleshooting Continued ...

Page 33: ...x25 Screw driver Torx Tx25 Ball tipped screw driver Torx 4 mm Screw driver flat blade 8 mm Screw driver flat blade 12 mm Screw driver flat blade Phillips 1 Screw driver 8 mm Box spanner Contents standard toolkit troubleshooting Rem Tool Art no Qty Contents as specified above Normal shop tools Multimeter 1 Oscilloscope 1 Recorder 1 Operating manual Troubleshooting IRC5 33 3HAC020738 001 Revision AA...

Page 34: ...t 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 in the Product manual IRC5 Check any connector between the manipulator and the power supply in the controller Measurement show there are no 12 VDC supply Reference Circuit Diagram in the Product manual IRC5 Chec...

Page 35: ...ice personnel is detailed in section Filing an error report on page 38 Operating manual Troubleshooting IRC5 35 3HAC020738 001 Revision AA Copyright 2005 2018 ABB All rights reserved 2 Introduction to troubleshooting 2 3 1 Troubleshooting strategies Continued ...

Page 36: ... of the units was causing the fault it greatly complicates ordering a new spare part it may introduce new faults to the system Take a look around Often 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 I...

Page 37: ...ilar who was working when the problem first occurred At what stage did the fault occur What to look for during troubleshooting depends greatly of when the fault occurred was the robot just freshly installed Was it recently repaired The table gives specific hints to what to look for in specific situations then If the system has just Check the configuration files connections options and their config...

Page 38: ...es to the error report if not explicitly requested by the support personnel Creating the diagnostics file The diagnostics file is created manually as detailed below Action Tap ABB then Control Panel and then Diagnostics A display is shown en0500002175 1 Specify the name you want for the diagnostics file the save folder of it and tap OK The default save folder is C Temp but any folder may be select...

Page 39: ...nal options A written fault description The more detailed the easier for the ABB support personnel to assist you if available enclose the license key attach the diagnostics file 4 Mail it 5 Operating manual Troubleshooting IRC5 39 3HAC020738 001 Revision AA Copyright 2005 2018 ABB All rights reserved 2 Introduction to troubleshooting 2 4 Filing an error report Continued ...

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Page 41: ... main power supply to the system is present and is within the specified limits 1 How to strap the mains transformer is detailed in the product manual for the controller Make sure that the main transformer is correctly connected to the mains voltage levels at hand 2 Make sure that the main switches are switched on 3 If required troubleshoot the power supply units as explained in section Troubleshoo...

Page 42: ...ith the controller proceed to section Problem connecting FlexPendant to the control ler on page 51 8 42 Operating manual Troubleshooting IRC5 3HAC020738 001 Revision AA Copyright 2005 2018 ABB All rights reserved 3 Troubleshooting by fault symptoms 3 1 Start up failures Continued ...

Page 43: ...the voltage level matches that of the controller re quirement Controller not connected to the mains power supply 1 Ensure that the main transformer is connected cor rectly to the mains voltage level Main transformer is malfunction ing or not connected correctly 2 Ensure that the mains fuse Q1 inside the controller is not tripped Main fuse Q1 might have tripped 3 Operating manual Troubleshooting IR...

Page 44: ...In a WHILE FOR GOTO loop preferably at the end close to the ENDWHILE ENDFOR etc part of the instruction Check whether the program contains logical instructions or other instructions that take no time to execute since such programs may cause the execution to loop if no conditions are fulfilled To avoid such loops you can test by adding one or more WAIT instructions Use only short WAIT times to avoi...

Page 45: ...it uses event driven instructions instead of looped instructions 4 Heavy communication with PLCs or other external computers can cause heavy load in the robot system main computer Operating manual Troubleshooting IRC5 45 3HAC020738 001 Revision AA Copyright 2005 2018 ABB All rights reserved 3 Troubleshooting by fault symptoms 3 3 Low controller performance Continued ...

Page 46: ...m is not supplied with power The main transformer is not connected for the correct mains voltage Circuit breaker F6 if used is malfunctioning or open for any other reason Contactor K41 is malfunctioning or open for any other reason en1000000051 Continues on next page 46 Operating manual Troubleshooting IRC5 3HAC020738 001 Revision AA Copyright 2005 2018 ABB All rights reserved 3 Troubleshooting by...

Page 47: ...sure they match the shop supply voltage Check the main transformer connection 3 The circuit breaker F6 is shown in the circuit diagram in the product manual for the control ler Make sure circuit breaker F6 if used is closed in position 3 4 Operating manual Troubleshooting IRC5 47 3HAC020738 001 Revision AA Copyright 2005 2018 ABB All rights reserved 3 Troubleshooting by fault symptoms 3 4 All LEDs...

Page 48: ...listed in order of probability Tripped circuit breaker F5 Tripped earth fault protection F4 Mains power supply loss Transformers incorrectly connected xx0500001403 Recommended actions Information Action Make sure any equipment connected to the service outlet does not consume too much power causing the circuit breaker to trip Make sure the circuit breaker in the controller has not been tripped 1 Co...

Page 49: ...ke sure the power supply to the robot system is within specifica tions 3 xx0500002028 Make sure the transformer A sup plying the outlet is correctly connec ted i e input and output voltages in accordance with specifications 4 Refer to the plant documentation for voltage val ues Operating manual Troubleshooting IRC5 49 3HAC020738 001 Revision AA Copyright 2005 2018 ABB All rights reserved 3 Trouble...

Page 50: ...power supply from controller is faulty Recommended actions The following actions are recommended listed in order of probability Information Action How to connect the FlexPendant to the controller is detailed in Operating manu al Getting started IRC5 and RobotStu dio Make sure the system is switched on and that the FlexPendant is connected to the controller 1 If faulty replace the FlexPendant Inspe...

Page 51: ...ollowing actions are recommended listed in order of probability Information Action Check all cables from power supply unit to main computer making sure these are correctly con nected 1 Make sure the FlexPendant has been correctly connected to the controller 2 All indication LEDs and their signific ance are specified in section Troubleshooting LEDs in the control ler on page 63 Check all indication...

Page 52: ... causing the cabling to get strained during manipulator movements cable insulation chafed or damaged by rubbing short circuiting signals to earth Recommended actions The following actions are recommended listed in order of probability Information Action Refit any cabling as detailed in the product manual for the robot Inspect all internal manipulator cabling especially all cabling disconnected con...

Page 53: ... in order of probability Information Action How to change operating mode is described in Operating manual IRC5 with FlexPendant Make sure the controller is in manual mode 1 Make sure the FlexPendant is connected cor rectly to the Control Module 2 Press Reset button located on the back of the FlexPendant Note The Reset button resets the FlexPend ant not the system on the Controller Reset the FlexPe...

Page 54: ...o Check the event log for a message specifying which unit failed 1 Was the relevant unit recently replaced 2 If YES make sure the versions of the old and new unit is identical If NO check the software versions Was the RobotWare recently replaced 3 If YES make sure the versions of the old and new unit is identical If NO proceed below Check with your local ABB representative for a firmware version c...

Page 55: ...tailed in Operating manual IRC5 with FlexPendant Make sure the robot tool and work object are correctly defined 1 Update if required Check the revolution counters positions 2 How to calibrate the robot is detailed in Op erating manual IRC5 with FlexPendant If required recalibrate the robot axes 3 Replace faulty bearing as specified in the product manual for the robot Locate the faulty bearing by t...

Page 56: ...ing Recommended actions The following actions are recommended Information Action CAUTION Before approaching the potentially hot robot component observe the safety information in section Hot parts may cause burns on page 30 1 Verify that the service is done according to the maintenance schedule 2 If a bearing is emitting the noise determine which one and make sure that it has suffi cient lubricatio...

Page 57: ...rbox oil may be caused by Incorrect oil quality or level 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 8 Operating manual Troubleshooting IRC5 57 3HAC020738 001 Revision AA Copyright 2005 2018 ABB All rights reserved 3 Troubleshooting by fault symptoms 3 12 Mechanical n...

Page 58: ... to the brake Recommended actions The following actions are recommended Information Action Determine which motor s causes the robot to collapse 1 See the circuit diagram Check the brake power supply to the col lapsing motor during the Motors OFF state 2 If found faulty the motor must be replaced as a complete unit Remove the resolver of the motor to see if there are any signs of oil leaks 3 If fou...

Page 59: ... occur Possible causes The symptom can be caused by the causes are listed in order of probability Brake contactor K44 does not work correctly The system does not go to status Motors ON correctly Faulty brake on the robot axis Supply voltage 24V BRAKE missing en1000000051 Continues on next page Operating manual Troubleshooting IRC5 59 3HAC020738 001 Revision AA Copyright 2005 2018 ABB All rights re...

Page 60: ...t model Please refer to the product manual for the robot Use the push buttons on the robot to test the brakes If just one of the brakes malfunctions the brake at hand is probably faulty and must be replaced 3 If none of the brakes work there is probably no 24V BRAKE power available Check the power supply to make sure 24V BRAKE voltage is OK 4 The event log messages can also be accessed using Robot...

Page 61: ...op and Enable chains Make sure all connectors are connected securely 1 All indication LEDs and their significance are specified in section Troubleshooting LEDs in the controller on page 63 Check if any indication LEDs signal any malfunction that may give some clue to the problem 2 The event log messages may be viewed either on the Flex Pendant or using RobotStudio Check the messages in the event l...

Page 62: ... controller in Boot Application mode has been implemented Consequences The system has startup problems or the FlexPendant cannot connect to the system Recommended action Repeat the following action three times in a row 1 Turn ON the main power switch 2 Wait approximately for 20 seconds 3 Turn OFF the main power switch The currently active system is de selected and a forced start of Boot Applicatio...

Page 63: ...r I O power supply on page 88 Customer I O power supply A Troubleshooting the computer unit on page 68 Computer unit B LED board on page 64 LED board C Troubleshooting the power distribution board on page 81 Power distribution board D Troubleshooting the system power supply on page 76 System power supply E Troubleshooting the contactor interface board on page 86 Contactor interface board F Trouble...

Page 64: ...ld the LED board not be working but the panel board is the problem is the communication between these boards or the LED board itself Check the cabling between them 64 Operating manual Troubleshooting IRC5 3HAC020738 001 Revision AA Copyright 2005 2018 ABB All rights reserved 4 Troubleshooting by unit 4 1 Troubleshooting LEDs in the controller Continued ...

Page 65: ...nt messages on Flex Pendant on page 52 3 Check the cable for connections and integrity 4 Check the 24 V power supply 5 Read the error event log message and follow any instructions of references 6 Restarting a locked FlexPendant In case the FlexPendant is locked by a software error or misuse you can unlock it either using the joystick or using the reset button located on the back on FlexPendant wit...

Page 66: ...ing communication faults follow the outline detailed below Info illustrations Action Faulty cables e g send and receive signals are mixed up 1 Transfer rates baud rates 2 Data widths that are incorrectly set 3 66 Operating manual Troubleshooting IRC5 3HAC020738 001 Revision AA Copyright 2005 2018 ABB All rights reserved 4 Troubleshooting by unit 4 3 Troubleshooting communications ...

Page 67: ...troubleshoot the fieldbuses and I O units can be found in the manual for the respective fieldbus or I O unit Operating manual Troubleshooting IRC5 67 3HAC020738 001 Revision AA Copyright 2005 2018 ABB All rights reserved 4 Troubleshooting by unit 4 4 Troubleshooting fieldbuses and I O units ...

Page 68: ...apter D DSQC 667 PROFIBUS Slave Fieldbus Adapter D DSQC 669 Ethernet IP Slave Fieldbus Adapter D DSQC1004 DeviceNet Slave Fieldbus Adapter D DSQC1006 DeviceNet Master Slave PCIexpress E DSQC1005 PROFIBUS DP Master Slave PCIexpress E Fan with receptacle F For more information and spare part numbers see Product manual IRC5 Continues on next page 68 Operating manual Troubleshooting IRC5 3HAC020738 00...

Page 69: ...ply voltage to the computer unit Replace the computer unit POWER green Disc activity DISC Act Indicates that the computer is writing to the SD card yellow Startup sequence 1 SOLID RED loading bootloader 2 FLASHING RED loading image 3 FLASHING GREEN loading RobotWare 4 SOLID GREEN system ready Fault indication SOLID RED forever check the SD card FLASHING RED forever check the SD card FLASHING GREEN...

Page 70: ...on below D C E B A xx1300000679 Operator s panel A Computer unit B Drive system C Axis computer D Panel board unit E Continues on next page 70 Operating manual Troubleshooting IRC5 3HAC020738 001 Revision AA Copyright 2005 2018 ABB All rights reserved 4 Troubleshooting by unit 4 6 Troubleshooting the panel board ...

Page 71: ... 2 closed Indication LED ES2 YELLOW when General stop GS switch chain 1 closed Indication LED GS1 YELLOW when General stop GS switch chain 2 closed Indication LED GS2 YELLOW when Auto stop AS switch chain 1 closed Indication LED AS1 YELLOW when Auto stop AS switch chain 2 closed Indication LED AS2 YELLOW when Superior stop SS switch chain 1 closed Indication LED SS1 YELLOW when Superior stop SS sw...

Page 72: ...ed for additional axes in combination with small robots A Main Drive Unit for small robots B Main Drive Unit for large robots C Additional Drive Units for additional axes D Continues on next page 72 Operating manual Troubleshooting IRC5 3HAC020738 001 Revision AA Copyright 2005 2018 ABB All rights reserved 4 Troubleshooting by unit 4 7 Troubleshooting the drive system ...

Page 73: ... 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 Ethernet LEDs B and D Operating manual Troubleshooting IRC5 73 3HAC020738 001 Revision AA Copyrig...

Page 74: ...cation of the axis computer DSQC 668 in the controller A xx1300000809 Axis computer A Continues on next page 74 Operating manual Troubleshooting IRC5 3HAC020738 001 Revision AA Copyright 2005 2018 ABB All rights reserved 4 Troubleshooting by unit 4 8 Troubleshooting the axis computer ...

Page 75: ...hardware RED flashing forever Missing connection to main computer main computer start up problem or RobotWare installation problem GREEN flashing forever Missing connections to peripheral units or RobotWare start up problem Status 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...

Page 76: ...QC 661 in the controller C A B xx1300000813 Customer I O power supply A Power distribution board B System power supply C Continues on next page 76 Operating manual Troubleshooting IRC5 3HAC020738 001 Revision AA Copyright 2005 2018 ABB All rights reserved 4 Troubleshooting by unit 4 9 Troubleshooting the system power supply ...

Page 77: ...ooting Ohmmeter Resistive load e g main computer on 24V_PC Voltmeter Preparations Action Check the FlexPendant for errors and warnings 1 Make sure that the control system power supply is in run time mode 2 Do this by waiting 30 seconds after power on Continues on next page Operating manual Troubleshooting IRC5 77 3HAC020738 001 Revision AA Copyright 2005 2018 ABB All rights reserved 4 Troubleshoot...

Page 78: ...ult has been fixed and restart this guide if necessary A minimum load of 2A is re quired on the DC output connector X2 for the DSQC 661 to work properly If no short circuit is found pro ceed with step 4 Check both the DC output connector X2 on DSQC 661 and the input connector X1 on DSQC 662 Check for short circuit on DC output 3 If a short circuit is found on DSQC 661 proceed with step 10 Measure ...

Page 79: ...uide if necessary Their physical location is shown in the Circuit Diagram in Product manual IRC5 If the fuses are open proceed with step 8 Make sure that they are open Check main fuse F2 and optional fuse F6 if used 7 If the fuses are closed open them Verify that the fault has been fixed and restart this guide if necessary Their physical location is shown in the Circuit Diagram in Product manual I...

Page 80: ...Q1 2 5 Measure AC input Switches closed Wrong AC level Open fuses 8 Measure AC to cabinet Close switches Q1 2 Switches open Fuses open Fuses closed 9 Check cabling Adjust AC input AC ok AC not ok Fix cabling Probable cause of dysfunction transformer T1 or filter Faulty cabling Cabling OK 10 Replace DSQC 661 The power supply unit works properly Wrong DC level xx1200001313 80 Operating manual Troubl...

Page 81: ...ion board B System power supply C CAUTION Hot surface on top of the power distribution board unit Risk of burns Be careful when removing the unit Do not route or place cables on top of the power distribution board Continues on next page Operating manual Troubleshooting IRC5 81 3HAC020738 001 Revision AA Copyright 2005 2018 ABB All rights reserved 4 Troubleshooting by unit 4 10 Troubleshooting the ...

Page 82: ...rnings 1 Note When the AC power has been cut off the indicator LED Status LED on DSQC 662 will turn red and stay red until UltraCAP is empty This may take a long time and is completely normal It does not mean that there is something wrong with the 662 Make sure that the power distribution board is in run time mode Do this by waiting 1 minute after power on 2 Continues on next page 82 Operating man...

Page 83: ...omes back up verify that the fault has been fixed and restart this guide if ne cessary Make sure that the USB cable is properly connected on both ends Try to fix the commu nication between the power supply and the computer by recon necting the cable 3 If unable to fix the communication proceed with step 6 If the correct voltage is detected on all outputs and the Status LED is green the power suppl...

Page 84: ...tors X1 and X2 are connected properly on both ends The DC input connector X1 and ACOK_N connector X2 are shown in the Circuit Dia gram in Product manu al IRC5 How to replace the unit is detailed in Product manu al IRC5 The DSQC 662 may be faulty replace it and verify that the fault has been fixed 6 Continues on next page 84 Operating manual Troubleshooting IRC5 3HAC020738 001 Revision AA Copyright...

Page 85: ... DC level Low DC input output Outputs low 3 Fix connection Connected Problem with USB Not connected USB Communication error Connection OK Firmware upgrade error 24v ok 24v not ok Wrong DC level 5 Measure 24V_DC input and AC ok xx1200001314 Operating manual Troubleshooting IRC5 85 3HAC020738 001 Revision AA Copyright 2005 2018 ABB All rights reserved 4 Troubleshooting by unit 4 10 Troubleshooting t...

Page 86: ...42 A MOTOR ON contactor K43 B Brake contactor C Jumpers 3pcs D Contactor interface board E LEDs The illustration below shows the LEDs on the Contractor interface board A xx0400001091 Status LED A Continues on next page 86 Operating manual Troubleshooting IRC5 3HAC020738 001 Revision AA Copyright 2005 2018 ABB All rights reserved 4 Troubleshooting by unit 4 11 Troubleshooting the contactor interfac...

Page 87: ...unning RED flashing system is in power up self test mode RED steady other error than serial communication error Operating manual Troubleshooting IRC5 87 3HAC020738 001 Revision AA Copyright 2005 2018 ABB All rights reserved 4 Troubleshooting by unit 4 11 Troubleshooting the contactor interface board Continued ...

Page 88: ...ore Customer I O power supply units mounted in a row and too close to each other there will be a heating problem and the units can be damaged To avoid damaging the Customer I O power supply units the units must be separated with 3 pcs of exterior support Continues on next page 88 Operating manual Troubleshooting IRC5 3HAC020738 001 Revision AA Copyright 2005 2018 ABB All rights reserved 4 Troubles...

Page 89: ...N When all DC outputs are above the specified minimum levels DCOK indicator OFF When one or more DC output s below the specified minimum level Operating manual Troubleshooting IRC5 89 3HAC020738 001 Revision AA Copyright 2005 2018 ABB All rights reserved 4 Troubleshooting by unit 4 12 Troubleshooting the customer I O power supply Continued ...

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Page 91: ... take focus on a display device Warning These messages indicate something is seriously wrong with the system and that operation has stopped They are used when an immediate action should be taken by the user Error Note The message type is not contained in the actual message text but in the code itself when the message is generated Messages can only appear as one type and the message should be writt...

Page 92: ...s and positioning 5 xxxx I O events events dealing with inputs and outputs data buses and so on 7 xxxx User events events defined by the user 8 xxxx Functional safety events events related to functional safety 9 xxxx Process events application specific events arc welding spot welding and so on 11 xxxx 0001 0199 Continous Application Platform 0200 0399 Discrete Application Platform 0400 0599 Arc 06...

Page 93: ...xxx Connected Service Embedded event logs which are generated during starting registering unregistering losing connectivity and so on 17 xxxx Operating manual Troubleshooting IRC5 93 3HAC020738 001 Revision AA Copyright 2005 2018 ABB All rights reserved 5 Troubleshooting by event log 5 2 How to read RAPID event log messages Continued ...

Page 94: ...eased Consequences 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 Probable causes Any safety device connected to the system s stop inputs have been opened These are shown in the Circuit Diagram Recommended actions Check which safety device caused the stop Close the device To resume operation...

Page 95: ...d 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 10020 Execution error state Description The program execution in task arg has been stopped due to a spontaneous error Consequences No program execution will be possible until the error has been removed Probable causes A l...

Page 96: ...e or more manipulator axes are not commutated Consequences To enable operation all manipulator axes must be commutated Probable causes The manipulator drive motor and related units may have been altered e g after replacing a faulty unit Recommended actions Commutate the manipulator axes as detailed in the manipulator Product Manual 10035 Axis not calibrated Description After checking the system ha...

Page 97: ... 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 bytes 10041 Program deleted Description A program or program module was deleted from task arg Consequences If the deleted program contained the task entry routine the program will no longer be executable Probable causes The program may have been removed manually Re...

Page 98: ... enable chain Description The enable chain is always tested at startup If the test failed an error message concerning enable will follow Recommended actions If enable chain test at startup failed the related error message will be Enable chain timeout 10061 A target has been modified Description A target in module arg in task arg has been modified or tuned Start line arg column arg end line arg 100...

Page 99: ...wn Description The control system is not able to communicate correctly with the FTP server arg Consequences 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 Probable causes If this message is displayed at first s...

Page 100: ...static tasks are restarted from the beginning not from the state they had when the system was stopped Modules will be installed and loaded in accordance with the set configuration System parameters will not be affected Probable causes Reset RAPID was ordered by the user The system forced Reset RAPID due to inconsistent data malfunction or unrecoverable task state 10091 Restart not possible Descrip...

Page 101: ...escription It remains arg days for robot arg until it s time for service Recommended actions 10108 Time for service Description It s time for service for robot arg cause it s arg hours of production since last service Recommended actions 10109 Close to service Description It remains arg hours of production for robot arg to next service Recommended actions 10110 Gearbox needs service Description Th...

Page 102: ...The task arg has stopped The reason is that an external or internal stop has occurred Recommended actions 10126 Program stopped Description The task arg has stopped The reason is that an error has occurred Recommended actions 10127 Backward execution not possible Description The task arg has stopped The reason is that it is not possible to execute backward past beginning of instruction list Recomm...

Page 103: ... stopped Description The task arg has stopped The reason is that the task has reached a stop instruction Recommended actions 10137 Program stopped Description The task arg has stopped The reason is that the task has reached a stop AllMoveTask instruction Recommended actions 10138 Program stopped Description The task arg has stopped The reason is that an stop from system input has occurred Recommen...

Page 104: ...ute 10153 Run mode is changed Description Run mode has been changed to single cycle by arg 10154 Run mode is changed Description Run mode has been changed to continuous mode by arg 10155 Program restarted Description Execution of task arg has been restarted from where it was previously stopped The originator could not be determined Recommended actions 10156 Program restarted Description Execution ...

Page 105: ...directory Reset the system 10177 Task refuses to start Description Task arg There is not sufficient program memory or the program memory is fragmented Modules could be missing or data may not have been installed Recommended actions Unload reload modules and restart the system Split large data structures Do Reset RAPID Increase stack size for task 10178 A static semistatic task can t be stepped Des...

Page 106: ... protected area for the task arg Recommended actions 10200 Event logs are cleared Description User arg has cleared all event logs Recommended actions 10201 Event logs for one domain is cleared Description User arg has cleared domain argX XXX Recommended actions 10202 Date and or time is changed Description Date and or time is changed to arg by arg Recommended actions 10205 Configuration parameter ...

Page 107: ...ription The restart will clear the execution in task argof a STEP system event routine Recommended actions 10230 Backup step ready Description The backup step Prepare is ready Recommended actions 10231 Backup step ready Description The backup step Configuration is ready Recommended actions 10232 Backup step ready Description The backup of Task is ready Recommended actions 10233 Backup step ready D...

Page 108: ...and attach it to your error report if reported to ABB support 10270 Cyclic Brake Check Done Description The Cyclic Brake Check has been done for all brakes supervised by Safety Controllers 10271 Cyclic Brake Check Started Description The Cyclic Brake Check has been started 10272 Brake Check Done Description The Brake Check has been done for all brakes 10273 Brake Check Started Description The Brak...

Page 109: ...o arg in task arg by arg 10290 The robot has been calibrated Description The mechanical unit arg axis arg has been calibrated by arg 10291 Goto position Description The functionality Goto position has been used by arg 10292 Revolution Counter updated Description The revolution counter for robot arg axis arg has been updated by arg 10293 Path Supervision is set to On Description The Path supervisio...

Page 110: ...uses The system data was not properly saved at last shutdown Recommended actions 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 10355 Restore error Description Error during the restore of Task Trying to load to unknown task arg Consequences Loading has been aborted for arg Pro...

Page 111: ...te package 10453 Update package deleted Description Update package with the following ID arg was deleted from the controller Consequences Update package is no longer available Disk space used by the package has been reclaimed 10454 Incomplete update package deleted Description Incomplete update package with the following ID arg was deleted from the controller Consequences Disk space used by the up...

Page 112: ...ite protected If it is a network drive verify that controller hasn t lost contact 11026 Backup error Description An error occurred while preparing to create a backup Error while creating the backinfo txt file Consequences The backup request is aborted No backup was created Probable causes You may not have write access to the backup drive The drive might be full If it is a network drive you might h...

Page 113: ...e system 11042 Backup error Description An error occurred while preparing to create a backup Error while verifying the system system xml isn t present in the SYSTEM directory Consequences The backup request is aborted No backup was created Probable causes system xml isn t present in the SYSTEM directory Recommended actions Reset the system 11044 Backup error Description Error while verifying the b...

Page 114: ...s The backup request is aborted No backup was created 11136 Backup error Description Error during the backup step Configuration Write error Consequences The backup request is aborted No backup was created Probable causes The destination is write protected The controller has lost contact with a mounted device e g NFS FTP USB Recommended actions Verify that the destination isn t write protected Veri...

Page 115: ...nces The backup request is aborted No backup was created Probable causes The given backup path has exceeded the maximum allowed arg characters Recommended actions Use a shorter path to create the backup 11230 Backup error Description Error during the backup of Task No more objects Consequences The backup request is aborted No backup was created 11231 Backup error Description Error during the backu...

Page 116: ... grant or add the grant to the existing user If shown after a System Diagnostics file generation please regenerate it after solving the UAS issues 12020 Restore error Description Error during the restore step Prepare Unknown error Recommended actions arg 12023 Restore error Description Error during the restore step Prepare The directory lacks at least one necessary item Recommended actions arg 120...

Page 117: ...re The path is too long Probable causes The maximum allowed arg characters has been exceeded Recommended actions Make sure no files with deep structures or long names have been added to the backup used to restore from 12130 Restore error Description Error during the restore step Configuration No more objects 12131 Restore error Description Error during the restore step Configuration The directory ...

Page 118: ...t 12511 Network interface IP address illegal Description The network IP address arg for interface arg is illegal missing Consequences The interface will not be configured and may not be used Probable causes The network IP address may be mistyped or it already exists on the network Recommended actions Make sure the interface IP address is correct and not a duplicate 12512 Network gateway IP address...

Page 119: ...ct 12610 Available RAM memory low Description The available amount of RAM memory is low Total RAM memory size arg bytes Free arg bytes Consequences The system may run out of memory Recommended actions It is recommended to restart the system 12611 Available RAM memory very low Description The available amount of RAM memory is very low Total RAM memory size arg bytes Free arg bytes Consequences The ...

Page 120: ...drive unit axes are not commutated Recommended actions 20031 Axis not calibrated Description One or several absolute relative measurement axes are not calibrated Recommended actions Check what axis that are not calibrated and calibrate them 20032 Rev counter not updated Description Revolution counter is not updated One or several absolute measurement axes are not synchronized Recommended actions M...

Page 121: ...tion will not be performed Recommended actions Make sure the system is NOT in Auto Mode 20061 Not allowed command Description The command is not allowed when changing to Auto mode Consequences The system remains in the same status and the requested action will not be performed Recommended actions Make sure the system is NOT changing to Auto Mode 20062 Not allowed command Description The command is...

Page 122: ...and the requested action will not be performed Probable causes The system is manually jogged 20070 Not allowed command Description The command is not allowed in Motors ON state Consequences The system remains in the same status and the requested action will not be performed Recommended actions Make sure the system is in Motors OFF state 20071 Not allowed command Description The command is not allo...

Page 123: ... allowed when axis is not calibrated Consequences The system remains in the same status and the requested action will not be performed Recommended actions Calibrate the axis as detailed in the Calibration Pendulum Instruction or the Instructions for Level meter calibration depending on which equipment to be used 20082 Not allowed command Description The command is not allowed when axis revolution ...

Page 124: ...ejected Description One or more of the NORMAL tasks were disabled and could not be enabled when automatic mode was requested Consequences The system cannot enter automatic mode Probable causes It is not possible to reset Task Selection Panel in synchronized block Recommended actions Switch back to manual mode 2a Set PP to main 2b or step out of synchronized block 2c or set System Parameter Control...

Page 125: ...again 20104 The system path is too long Description The system path is too long It is not possible for the system to act in a safe way Consequences The system will enter system failure state Recommended actions Move the system to a location with a shorter file path 20105 Backup already in progress Description A backup is already in progress Consequences The command Backup from System Input Signal ...

Page 126: ...ion may have been deleted Recommended actions If you require the old definition locate the program or module of the original work object data and load it 20130 Active Task Menu is restored Description During a controller restart the Active Task Menu is restored in Auto mode Consequences If one or several tasks were unchecked they are now checked again after the restart in Auto mode Probable causes...

Page 127: ...stem will not be in full production mode in auto Recommended actions For full production mode Switch back to manual mode Set system parameter Controller Auto Condition Reset AllDebugSettings Reset to YES Switch back to automatic mode and confirm For more info see the Technical Reference Manual System Parameters 20136 Reduced Speed Description The system was running at reduced speed during startup ...

Page 128: ... be that the robot is outside of regain distance The program was executing An ongoing Backup operation Recommended actions Jog robot into regain zone or move the program pointer Stop program before activating System Input Start 20143 Start at main rejected Description Start of program at main via System IO was rejected Consequences Program will not be possible to start Probable causes The program ...

Page 129: ...a System IO was rejected Consequences Program will not be possible to start Probable causes The reason could be that the robot is outside of regain distance The program was executing An ongoing Backup operation Recommended actions Jog robot into regain zone or move the program pointer Stop program before activating System Input Motors On and Start 20154 Stop instruction rejected Description Stop o...

Page 130: ...S STOP and the robot is stopped along the path The full meaning of this status is described in the Trouble Shooting Manual IRC5 Probable causes A number of errors may cause this status transition Recommended actions Check other event messages occurring at the same time to determine the actual cause Fix the cause of the fault 20171 The system was halted Description An error was detected which halte...

Page 131: ...specified event Recommended actions Change the configuration and restart the controller 20179 Disk memory critically low Description 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 Consequences The disk memory is very close to being completely full When this happens the system will not be able to function...

Page 132: ...d actions Save the files on some other disk connected to the network Erase data from disk 20193 Robot data update warning Description Axis sync values and service information data SIS was restored from backup The system independent robot data was not saved during system shutdown The data was restored from latest backup Recommended actions Make sure there is free memory left on the device The backu...

Page 133: ...nded actions Rename the signal in the IO configuration 20281 IO configuration error Description arg arg with signal name arg has wrong signal type Found arg expected arg Recommended actions Change your configuration and restart the controller 20282 Resource and index exist Description Resource arg Index arg Recommended actions 20283 Text database is full Description Resource arg Index arg Recommen...

Page 134: ... Unknown System Input Restriction arg Recommended actions Verify that the System Input Restriction name is correctly spelled 20292 Unknown System Input Restriction Description The configured System Input Restriction is unknown by the system System Input Restriction Type arg Unknown System Input Restriction arg Recommended actions Verify that the System Input Restriction name is correctly spelled 2...

Page 135: ...ndefined number Consequences The undefined number was replaced with arg 20322 Positive infinity Description Positive infinity was found in task arg A symbol of type arg was found holding positive infinity Consequences The positive infinity was replaced with arg 20323 Negative infinity Description Negative infinity was found in task arg A symbol of type arg was found holding negative infinity Conse...

Page 136: ...escription The mechanical unit arg in arg cannot be found in the list of configured mechanical units Consequences It is not possible to execute any RAPID instructions that use the configured mechanical units Probable causes The unit is probably not present in the Motion configuration Recommended actions Change the configuration and restart the controller 20354 The argument is undefined Description...

Page 137: ...ons Change the configuration and restart the controller 20363 Module not a system module Description The module arg loaded from the file arg is not a system module Recommended actions Change the file suffix or add a module attribute to the module Load the module again or restart the controller 20364 Max number of Mechanical Unit Groups exceeded Description The maximum number of Mechanical Unit Gro...

Page 138: ...d Probable causes The sys cfg file loaded into the system does not contain any regain distance information No sys cfg file has been loaded due to file errors Recommended actions Load a new sys cfg file and restart the controller 20371 A default Mechanical Unit Group is used Description The configuration of task arg has no connection to arg The attribute arg is required in a MultiMove system and is...

Page 139: ...cription Start of program at main via System IO was rejected The reason is that write access is held by arg using arg Recommended actions 20392 Manual interrupt rejected Description Manual interrupt of program via System IO was rejected The reason is that write access is held by arg using arg Recommended actions 20393 Load and start rejected Description Load and start of program via System IO was ...

Page 140: ...ll not be started System will not be in full production mode in auto Recommended actions For full production mode Switch back to manual mode Set system parameter Controller Auto Condition Reset AllDebugSettings Reset to Yes Switch back to automatic mode and confirm For more info see the Technical Reference Manual System Parameters 20401 Too many CFG instances Description There are too many instanc...

Page 141: ...r caused by a power fail 20411 Energy saving activated Description The robot system has entered an energy saving state Consequences The robot system will not be able to perform any normal tasks 20412 Energy saving deactivated Description The robot system has resumed from an energy saving state Consequences The robot system will now be able to perform any normal tasks 20413 Motors On failed Descrip...

Page 142: ...ctions Make sure that no other client e g RobotStudio holds write access and that the system is in Auto mode 20426 Write Access rejected Description Requesting Write Access via System IO was rejected The reason is that write access is held by arg using arg 20440 Failed to initialize FW upgrade framework Description The firmware upgrade framework for hardware boards could not be initialized Consequ...

Page 143: ...er SC on mechanical unit arg Either CBC test interval has expired or a previous brake check failed Recommended actions Decrease speed and execute Brake check 20451 SC arg Not synchronized Description Safety Controller SC arg is not synchronized with supervised mechanical units Recommended actions Move all mechanical units supervised by Safety Controller arg to the synchronization positions defined...

Page 144: ...n has been downloaded If no new safety configuration has been downloaded and this event message comes after a restart download a new safety configuration to the Safety Controller Create and download a new safety configuration if this event message comes after every restart and there is a request for new pin code again 20458 SC arg Internal Failure Description Internal Failure in Safety Controller ...

Page 145: ...nical unit arg Tool arg was active Cause arg Probable causes Exceeded speed Wrong tool position Wrong tool orientation Wrong elbow position Wrong tool point 1 position Wrong tool point 2 position Wrong tool point 3 position Wrong tool point 4 position Wrong tool point 5 position Wrong tool point 6 position Wrong tool point 7 position Wrong tool point 8 position Recommended actions Reduce speed Mov...

Page 146: ... is disabled Consequences All safety supervision has been disabled in the Safety Controller Risk for safety hazards Recommended actions Download a safety configuration to the Safety Controller 20477 SC arg SMB Communication Failure Description Safety Controller SC arg failed to communicate with serial measurement board SMB Recommended actions Make sure that the cabling from SMB to Safety Controlle...

Page 147: ... arg CBC interrupted or incorrect Description Safety Controller SC has detected that the last Cyclic Brake Check CBC on mechanical unit arg was interrupted or incorrect Recommended actions Check previous event messages Perform a new brake check only if needed typically if event message 20485 also has been displayed 20487 SC arg Unsynchronized speed exceeded Description Exceeded axis speed when Saf...

Page 148: ...n attempt has been made to maneuver a control e g the enabling device Recommended actions To resume operation first reset the emergency stop panel button Then switch the system back to state Motors ON by pressing the Motors ON button on the Control Module 20502 ES pendant open Description The emergency stop pendant has previously been broken and while broken an attempt was made to operate the robo...

Page 149: ...onflict for the Emergency Stop panel chain Consequences The system goes to status emergency stop Recommended actions Please check the two channel safety guard that caused the status conflict 20526 ES pendant conflict Description Status conflict for the Emergency Stop pendant chain Consequences The system goes to status emergency stop Recommended actions Please check the two channel safety guard th...

Page 150: ...tion Status active when enable from Axis Computer 1 open Consequences The system goes to status SYS HALT Recommended actions Check other error messages for primary fault reason If no other error messages please check line voltage for one phase missing 20557 Enable 2 AXC 2 open Description Status active when enable from Axis Computer 2 open Consequences The system goes to status SYS HALT Recommende...

Page 151: ...sequences The system goes to status SYS HALT Recommended actions If Servo disconnect switch is not installed check the disable link on Manipulator Interface Board MIB 20564 Brake rel on axes 1 7 Description Status active when manual brake release on axes 1 and 7 enabled Consequences The system goes to status SYS HALT Recommended actions Check switch for manual brake release of axes 1 and 7 20565 E...

Page 152: ...r 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 Probable causes This may happen if the storage media of the controller has been replaced or reformatted Recommended actions Read the serial number of the controller from the controller cabinet to find out what the controller I...

Page 153: ...nipulator Interface Board MIB Consequences The system goes to status SYS HALT Probable causes Serial Peripheral Interface SPI communication is down on SPI 1 Recommended actions Check cables between PIB SIB and MIB 20585 Enable chain opened from IPS Description Status active when enable chain is opened from signal Safety PibSw Enable Consequences The system goes to status SYS HALT Recommended actio...

Page 154: ... on Manipulator Controller Board MCB arg is open Consequences The system goes to status SYS HALT Recommended actions Check connection on MCB X2 20593 IO power low on MCB Description Status active when IO power below 16V on Manipulator Controller Board MCB arg Consequences The system goes to status SYS HALT Recommended actions Check power on MCB 20594 Communication fault between PIB and MC Descript...

Page 155: ...or connectors between the phases or to ground Short circuit in motor between the phases or to ground Recommended actions Check replace cables and connectors Check replace motor 20620 The system has entered an internal test mode Description A feature to perform ABB Robotics internal tests has been enabled in arg Consequences The system may not behave as expected Recommended actions Restart the cont...

Page 156: ...art Inspection Tool to the job Follow the instruction in the RobotStudio context menu and save the job 20635 Too many cameras connected Description Number of cameras connected to the robot controller is arg Max number of cameras for a robot controller is arg Consequences The robot controller will not communicate with all the cameras Probable causes Maximum number of cameras for a robot controller ...

Page 157: ...yRun configuration Probable causes The file does not follow the recommended XML format The signal arg is missing in the I O configuration Recommended actions Review the DryRun configuration file arg and make sure that the entry for signal arg is correct See the recommended XML format in user documentation 20644 DryRun configuration error Description Error while reading the DryRun configuration fil...

Page 158: ...for camera arg has timed out Consequences If the camera is still processing the image then new commands towards the camera may not respond and also timeout If when the current processing image completes it will insert the results into the database Probable causes The timeout set in configuration for the maximum time for image requests may be set too low The camera may be in an error state The comm...

Page 159: ... update of camera information has been ordered by an external client Consequences If a camera is busy doing any time consuming operation such as loading a job or processing an image the camera refresh service for that specific camera will be postponed until the ongoing operation is finished 20657 Camera IP address changed Description The IP address of camera arg with MAC address arg has changed Ol...

Page 160: ...install the present system files Create and run a new system to download the driver software Replace the board if faulty 31912 PROFIBUS master board failure Description The PROFIBUS master board did not start up correctly Consequences No communication on the Profibus is possible Probable causes The PROFIBUS master board hardware may be malfunctioning Recommended actions Restart the controller Repl...

Page 161: ...y system is working and correctly connected Check the safety system power supply Replace the unit if faulty 32540 Drive unit firmware re flash started Description In drive module arg a required upgrade of the firmware in the drive unit at unit position arg has started The old firmware revision arg is replaced with revision arg Recommended actions Wait for the firmware upgrade process to complete D...

Page 162: ...re installation is faulty Recommended actions Reinstall the system 32550 Firmware re flash started Description A required update of the arg firmware has started File used arg Recommended actions Wait for the re flash to complete 32551 Firmware re flash completed Description The update of arg firmware has completed successfully 32552 Firmware re flash failed Description The update of arg firmware f...

Page 163: ...rdware revision arg is not supported Consequences The system is unable to use the axis computer The system goes to system failure state Probable causes The RobotWare version is too old to support the axis computer unit Recommended actions Replace the axis computer to one with compatible revision Upgrade the system to a RobotWare version supporting the axis computer revision 32564 Axis computer fir...

Page 164: ...e arg Recommended actions Reinstall the system 32574 Corrupt axis computer hardware Description The arg flash memory has a corrupt content Internal error code arg Recommended actions Check other hardware event log messages for detailed explanation of the error condition Restart the controller If failure occurs again replace the axis computer 32575 Found no axis computer board Description System fa...

Page 165: ...puter failed to detect the safety system Recommended actions Check communication cables between the axis computer and the safety system Check power supply to the safety system Restart the controller 32590 Firmware re flash started Description A required update of the arg firmware in drive module arg has started File arg Recommended actions Wait for the re flash to complete this will take approxima...

Page 166: ...robable causes The Anybus module is either malfunctioning or missing Recommended actions Make sure a Anybus module is installed Replace the module if faulty 34100 Drive system not supported Description The configured drive system in drive module arg is not of type Drive System 04 Consequences The system goes to system failure state Probable causes Wrong drive module key used i e the configuration ...

Page 167: ...is correct Check that the robot has not collided If possible reduce the speed of the user program Check that the axis load is not too high for the motor Verify that the maximum motor current is not too small compared to the maximum current of the drive unit Check the motor cable and motor by measuring their resistance respectively Disconnect before measuring 34251 Incoming mains phase missing Desc...

Page 168: ...VOLTAGE THE DC LINK WILL NOT BE DISCHARGED WHEN THE SYSTEM IS POWERED OFF Probable causes This may be caused by a faulty bleeder resistor cable or a faulty bleeder resistor Recommended actions WARNING HIGH VOLTAGE CAN BE PRESENT Make sure the bleeder resistor cable is properly connected to the rectifier unit Disconnect the bleeder and check the cable and measure the bleeder resistance The expected...

Page 169: ...obable causes This error occur when the DC link voltage becomes too low and all mains phases are missing Recommended actions Check the hardware event log for other errors Check incoming mains voltage Check that the correct voltage is selected with jumpers on the transformer optional Check all internal 3 phase components main switch mains filter fuse contactors and cabling in the drive module 34265...

Page 170: ... detected a too large torque current deviation for the motor The joint is connected to drive module arg in the drive unit at unit position arg and node arg Consequences Operation will be possible but system is close to a stopping error Probable causes The motor data in the configuration files may be wrong The motor cables are not correctly connected or damaged Short circuit in motor cable between ...

Page 171: ...t s temperature rating If possible rewrite the user program to reduce the amount of hard acceleration and hard deceleration Reduce the static torque due to gravity or external forces 34308 Drive unit critical temperature error Description The drive unit for joint arg has reached a critical high temperature level The joint is connected to drive module arg with the drive unit at unit position arg an...

Page 172: ...e one specified in the configuration Installed drive unit hardware identity is arg and the configured identity is arg Consequences No operation will be possible until the fault is corrected The system goes to system failure state Probable causes The drive unit type does not match the one specified in the installation key Recommended actions Verify that the drive unit position is correct i e the Et...

Page 173: ...ssages Check incoming mains voltage to the rectifier unit Check the motor cable and motor by measuring their resistance respectively Disconnect before measuring 34319 Drive unit critical error Description The drive unit for joint arg gives an unspecified error but is likely due to over temperature or short circuit The joint is connected to drive module arg with the drive unit at unit position arg ...

Page 174: ...d The system goes to Motors Off state WARNING HIGH VOLTAGE THE DC LINK MAY BE DISCHARGED VERY SLOWLY APPROXIMATELY 1 HOUR WHEN THE SYSTEM IS POWERED OFF Probable causes The bleeder resistor is not connected or faulty The user program may contain too much deceleration of the manipulator s axes This fault is more likely if the system contains additional axes Recommended actions WARNING HIGH VOLTAGE ...

Page 175: ...ING HIGH VOLTAGE THE DC LINK MAY BE DISCHARGED VERY SLOWLY APPROXIMATELY 1 HOUR WHEN THE SYSTEM IS POWERED OFF Probable causes The bleeder resistor is not connected or faulty The user program may contain too much deceleration of the manipulator s axes This fault is more likely if the system contains additional axes Recommended actions WARNING HIGH VOLTAGE CAN BE PRESENT Make sure the bleeder resis...

Page 176: ...it on a DC bus It can be both inside the drive unit and in the cables Recommended actions Check incoming mains Check DC cabling Check if there are any short circuit Replace the drive unit s 34423 Incompatible drive unit types Description The configured drive system in drive module arg contains incompatible drive unit types Consequences The system goes to system failure state Probable causes Drive ...

Page 177: ...k the cabling to the external computer fan Check the fan and replace any faulty unit if required 37046 Safety signals overloaded Description The 24 V PANEL supply draws too much current Consequences The safety system shuts down the signal causing the system to go to status SYS HALT Probable causes A load connected to the circuit may be too high or the safety system unit may be malfunctioning See t...

Page 178: ... the output load may cause the faulty voltage level See the Trouble Shooting Manual and circuit diagram Recommended actions Check all cabling to the power supply unit Measure the output and input voltage levels Replace the faulty unit if required 37069 Faulty backup Power Supply Description The backup energy bank in the control module supplying the backup voltage is faulty Consequences After switc...

Page 179: ...e time key is correctly mounted Replace purge time key 37081 Purge timers differ Description Unacceptable divergence between CPLD and FPGA firmware on manipulator interface board MIB arg purge timers Consequences The purge timer will be restarted Recommended actions Replace MIB if faulty 37082 Divergence between PIB and MIB outputs Description Process interface board PIB and manipulator interface ...

Page 180: ...oller board MCOB MCB arg has detected an open circuit on axis arg and turned ON all brakes Recommended actions Check for open circuit on brakes 37099 Temp too high sensor arg Description System overheat detected on manipulator controller board MCOB MCB arg Sensors supervised on motors Serial measurement unit SMU or process equipment Run chain has been opened Sensors 1 8 Robot motors 1 8 Sensor 9 S...

Page 181: ...he system perform a controlled shutdown to ensure all system data is correctly saved Check the cables and connectors of the backup energy bank Check the backup energy bank Check the power supply Replace the faulty unit if required 37105 Regained communication with Power Supply Description The main computer has regained communication with the control module power supply 37106 Low backup energy bank...

Page 182: ... How to check the configuration files is detailed in the Trouble Shooting Manual Check I O signals are correctly connected 37110 Missing signal for Leak Detection Description Leak detection is enabled but no signal is configured for the supervision Recommended actions Configure the signal under Configuration Process Foundry Prime Leak Detection 37111 Leak Detected Description To high leak detected...

Page 183: ...ature in the transformer is too high Consequences The system goes to status SYS HALT Probable causes The unit may be overloaded its fans may be malfunctioning or the air flow may be restricted Recommended actions Make sure the fans are operating Check that air flow to the unit fans is not restricted 37209 Overtemperature in cabinet Description The temperature in the cabinet is too high Consequence...

Page 184: ...ety interface board SIB and manipulator interface board MIB arg reports divergence on brake chain 2 feedback signals Consequences The system goes to status SYS HALT Recommended actions Check cables and connections Replace SIB if faulty Replace MIB if faulty 37218 Cabin Interlock chain 1 feedback conflict Description Safety interface board SIB and manipulator interface board MIB arg reports diverge...

Page 185: ...lace SIB if faulty 37225 Cabin Interlock chain 2 conflict Description Divergence on cabin interlock chain 2 between input and output signals on safety interface board SIB Consequences Paint enable chain opens Recommended actions Check cables and connections Replace SIB if faulty 37226 HV Interlock chain 1 conflict Description Divergence on high voltage HV interlock chain 1 between input and output...

Page 186: ...ate Cyclic Brake Check for axis topic Motion type Arm 37233 Cyclic Brake Check Configuration Error Description The cyclic brake check has found that the mechanical brake for the mechanical unit arg axis no arg should be tested according to the configuration But the actual mechanical unit cannot be included in the Safety Controller because activation deactivation at runtime is allowed Consequences ...

Page 187: ...s opened Reported from manipulator interface board MIB arg Consequences Paint enable chain opens Recommended actions Replace MIB if faulty 37241 HV Interlock chain conflict from MIB Description Only one of the two high voltage HV chains is opened Reported from manipulator interface board MIB arg Consequences Paint enable chain opens Recommended actions Replace MIB if faulty 37242 Run chain conflic...

Page 188: ...p circuit Description Two or several status changes detected on signal within few milliseconds This message is most likely caused by bad connections in MODE_STOP circuits Consequences Motors are maybe switched off Recommended actions Check cables and connections on the safety system for Auto_Mode_Stop or Test_Mode_Stop Enabling Device 37251 Glitch in Delayed Stop circuit Description Two or several...

Page 189: ...equences Paint equipments are maybe switched off Recommended actions Check cables and connections on the safety system for system 2 interlock 37258 Glitch in Process Interlock circuit Description Two or several status changes detected on signal within few milliseconds This message is most likely caused by bad connections in process interlock circuits Consequences Paint equipments are maybe switche...

Page 190: ...oved or there was a malfunction of the mass storage device Recommended actions Check that the mass storage device firmly is in place If the problem persists try with another device 37503 Mass storage file system error Description Mass storage file system error Consequences An error was detected in the filesystem The error was corrected The correction could lead to missing file s Probable causes Th...

Page 191: ...rt the controller Reset the robot s revolution counters as detailed in the robot Product Manual Make sure no extreme levels of electromagnetic interference are emitted close to the robot cabling Make sure the axis computer is fully functional Replace any faulty unit 38103 Lost communication with the SMB Description The communication has been lost between the axis computer and the serial measuremen...

Page 192: ...ery power supply triggering the battery warning to be logged Reset the battery power warning by updating the revolution counters as detailed in the Calibration or Product Manual Replace the battery if discharged 38201 Serial Board not found Description Serial measurement board not found on measurement link Drive module arg Measurement link arg Measurement board arg Recommended actions Check system...

Page 193: ...troller Check cable and connectors for SMB communication Replace the serial measurement board 38211 Measurement functionality error Description The serial measurement board does not support 7 axes Drive module arg Measurement link arg Measurement board arg Recommended actions Check configurations of the 7th axis Replace serial measurement board to a board with 7 axes functionality 38212 Data not f...

Page 194: ... temperature Description The temperature of the motor encoder is too high Joint arg Drive module arg Measurement link arg Measurement board arg Board node arg Consequences The life time of the encoder can be reduced Recommended actions Stop robot and wait for motor encoder to cool down Reduce ambient temperature Change robot program to avoid high speeds and torques 38230 PMC card not connected cor...

Page 195: ...onment have applied too high force or torque to the sensor 38235 Saturation warning of force sensor input Description The analog input values of the measurement board connected to the force sensor have saturated and the time in saturation has reached the warning level The measurement board is connected to the axis computer in drive module arg Recommended actions Check the load that was applied to ...

Page 196: ...Reference Warning Description The motor angle reference is increasing too quickly for joint arg connected to drive module arg Consequences Probable causes The resolver feedback may be poor or the speed loop gain may be badly adjusted Recommended actions Check the resolver cable and the resolver grounding for this joint If this joint is an additional axis then check that the motor data in the confi...

Page 197: ...detailed in the Trouble Shooting Manual If the drive unit was recently replaced make sure a unit of the correct type code is used 39408 Rectifier Unit has the wrong type code 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 Consequences No operation ...

Page 198: ...rectly connected Check that the module is properly grounded Check for external electromagnetic noise sources close to the drive module 39412 Too Many Missed Reference Updates Description Too many missed communication packets have been detected for joint arg in drive module arg Consequences No operation will be possible until after correcting the fault The system goes to status SYS HALT Probable ca...

Page 199: ...e may have been erased my mistake Without this file it is not possible to check if the drive unit software needs updating Recommended actions Contact your local ABB representative 39418 Unknown Drive Unit type code Description The type code for the drive unit arg in drive module arg is not recognized by the system Installed drive unit type is arg and the configured type is arg Consequences No oper...

Page 200: ... to status SYS HALT Probable causes There may be problems with the control cable the DC link connection bus bar or cable or internal hardware Recommended actions Check the control cables and DC link connection bus bar or cable are correctly inserted for this unit Restart the controller 39424 Drive Unit internal error Description Internal measurement warning for drive unit number arg in drive modul...

Page 201: ...sed by an internal error in the rectifier unit Recommended actions Make sure the signal cable is correctly connected between the rectifier and drive unit Perform a shutdown and then restart the controller If the problem persists isolate the faulty rectifier unit and replace it 39431 Update of Drive Unit Software in Progress Description The drive unit software in drive module arg is being updated P...

Page 202: ... until after correcting the fault The system goes to status SYS HALT Probable causes This may be caused by a faulty bleeder resistor cable or bleeder resistor Recommended actions Make sure the bleeder resistor cable is correctly connected to the rectifier unit Make sure the cable and resistor is working correctly by measuring their resistance respectively Disconnect before measuring Replace any fa...

Page 203: ...453 Transformer Cooling Fan Malfunction Description The cooling fan for the transformer supplying drive module arg has malfunctioned Recommended actions Check if fan cable is correctly inserted Replace the faulty fan unit 39460 DC Link Voltage Too Low Description The DC link voltage is too low for the rectifier on drive communication link arg drive module arg Consequences No operation will be poss...

Page 204: ...causes 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 Recommended actions Make sure the motor cable is correctly connected to the drive unit Check the cable and motor by measuring their resistance respectively Disconnect before measuring Replace any faulty component 39465 Motor current w...

Page 205: ...ans are running and that the air flow is not obstructed Check that the ambient temperature does not exceed the cabinet rating If the system contains additional axes then check that motors are not too large for the drive units If possible rewrite the user program to reduce the amount of hard acceleration 39470 Power Semiconductor Warning Description The power semiconductor is approaching overload f...

Page 206: ... which case this may be found in the error log Recommended actions Make sure the mains switch is closed and that there is mains voltage present No volts means the problem is in mains cable connector or the factory power supply If the voltage is OK disconnect the input mains cable and measure the resistance of all three phases across all the components in the 3 phase supply chain Start from the con...

Page 207: ...SYS HALT 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 Check that the robot has not collided Check that the ambient temperature does not exceed the robot rating Allow the robot to cool down and then run the system again Replace any motors damaged by t...

Page 208: ...wn the system and replace the contactor If the contactor has been pulled down manually take this message as a warning only 39486 DC Link Not Connected Description The DC Link connection to the drive serving joint arg in drive module arg drive unit number arg is missing or is not properly connected Consequences The system goes to SYS_HALT Probable causes The DC bus bar is either missing or is not p...

Page 209: ... 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 Recommended actions Make sure the power supply cable is correctly connected to the drive module Check the brake supply cable for short circuits Make sure the total current consumed by additional axes motors does not exceed the specification for the drive modul...

Page 210: ...that both connectors are correctly connected Make sure that the power supply to the axis computer is working correctly Restart the controller 39523 Unused Axis computer connected Description Axis computer in the drive module arg is connected to the main computer but not in use Probable causes This can be due to configuration problem Recommended actions Disconnect the unused axis computer or setup ...

Page 211: ...r is working correctly Restart the controller 39530 Axis Computer Lost Communication With Safety System Description Communication has been lost between axis computer and the safety system in drive module arg Consequences System goes to system failure state Probable causes This may be due to a faulty communication cable or connection between the axis computer and the safety system It may also be du...

Page 212: ...t is NOT read only Also make sure the argument is NOT written within brackets 40006 Argument error Description Parameter arg is missing an optional argument value Recommended actions The only parameters that may be specified by a name only are switch parameters All others must be assigned a value Make sure parameter has a value 40007 Argument error Description The optional argument arg is not foun...

Page 213: ...n error Description The number of array dimensions is arg but may be 1 2 or 3 only Recommended actions Change the dimension expression 40016 Data declaration error Description Too many dimensions in array definition Recommended actions An array may have at most 3 dimensions Rewrite the program so that no more than 3 dimensions are needed 40017 Type error Description Indexed data arg arg is not of ...

Page 214: ... Illegal type arg for operand of unary or operator Recommended actions Allowed operand types for the unary and operators are num and pos Check the operand types 40026 Type error Description Illegal type arg for right operand of binary or operator Recommended actions Allowed operand types for the binary operator are num pos and string and for the binary operator num and pos Check the operand types ...

Page 215: ...ns Only program data declarations may have the LOCAL attribute Remove the LOCAL attribute or move the declaration outside of the routine 40038 Data declaration error Description LOCAL illegal in routine variable declaration Recommended actions Only program data declarations may have the LOCAL attribute Remove the LOCAL attribute or move the declaration outside of the routine 40039 Name error Descr...

Page 216: ...nge the conflicting name 40048 Name error Description Routine name arg ambiguous Recommended actions Routines must have names that are unique within the module Rename the routine or change the conflicting name 40049 Name error Description Variable name arg ambiguous Recommended actions Routine data must have names that are unique within the routine Program data must have names that are unique with...

Page 217: ...definition of named constant Recommended actions Complete the data declaration or change the data name to a place holder 40060 Data declaration error Description Place holder for array dimension not allowed in definition of named constant or variable Recommended actions Complete the data declaration or change the data name to a place holder 40061 Routine declaration error Description Place holder ...

Page 218: ... program position Make sure that all object names fulfill the naming rules regarding uniqueness 40071 Reference error Description Label reference arg is ambiguous Recommended actions At least one other object sharing the same name as the referred label is visible from this program position Make sure that all object names fulfill the naming rules regarding uniqueness 40072 Reference error Descripti...

Page 219: ... a required parameter 40081 Reference error Description arg not trap reference Recommended actions The specified name identifies an object other than a trap Check if the desired trap is hidden by some other object with the same name 40082 Reference error Description arg not type name Recommended actions The specified name identifies an object other than a type Check if the desired type is hidden b...

Page 220: ... Instruction error Description TRYNEXT only allowed in error handler Recommended actions The TRYNEXT instruction may only be used in error handlers Remove it 40098 Parameter error Description switch parameter must have transfer mode IN Recommended actions Remove the parameter transfer mode specifier If IN transfer mode is not sufficient change the data type of the parameter 40099 Parameter error D...

Page 221: ... in this position since there is no expected data type Declare data with the desired data type and aggregate value Use the name of the data instead of the aggregate 40109 Type definition error Description Cannot determine type of record component arg circular type definitions Recommended actions Check that the type of the component is correctly defined If so it could be a circular definition the t...

Page 222: ...cription Cannot use the semi value type arg for record components Recommended actions 40120 Reference error Description Illegal reference to installed task object arg from shared object Recommended actions Install the referred object shared or install the referring ReaL object archive or RAPID module in each task not shared 40121 Reference error Description Cannot use semi value type for arrays Re...

Page 223: ...rence to unknown procedure arg Recommended actions No procedure or other object with the specified name is visible from this program position 40131 Reference error Description Reference to unknown trap arg Recommended actions No trap or other object with the specified name is visible from this program position 40135 Syntax error Description Expected arg Recommended actions 40136 Syntax error Descr...

Page 224: ...r with a shorter name 40150 Unexpected unknown token Description Unexpected unknown token Recommended actions Remove the unknown token 40152 Data declaration error Description TASK illegal in routine variable declaration Recommended actions Only program data declarations may have the TASK attribute Remove the TASK attribute or move the declaration outside of the routine 40155 Argument error Descri...

Page 225: ...e controller Check for RAPID errors and correct the program 40163 Module error Description The module arg has too many lines to be loaded Maximum number of lines allowed in a module is arg Consequences Module or program if the module was part of a program cannot be loaded Probable causes The module has too many lines Recommended actions Split the module in two or several smaller modules 40165 Refe...

Page 226: ...truction error Description Task arg Variable and trap routine already connected Recommended actions It is not legal to connect a specific variable with a trap routine more than once 40192 Argument error Description Task arg arg is second present conditional argument for excluding parameters Recommended actions Arguments may not be present for more than one parameter from a list of parameters that ...

Page 227: ...nt optional parameter may not be referred Use the predefined function Present to check the presence of the parameter before using its value 40204 Value error Description Task arg Array index arg for dimension number arg out of bounds 1 arg Recommended actions The array index value is non positive or violates the declared size of the array 40205 Value error Description Task arg RAPID String arg too...

Page 228: ...f task arg has been stopped by a runtime error Consequences The program execution is immediately halted Probable causes 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 Check othe...

Page 229: ...ter of the Dim function must be an array 40243 Value error Description Task arg Unknown interrupt number Recommended actions Check that the specified interrupt variable has been initialized by CONNECT and that the interrupt has been defined using the ISignalDI or other interrupt definition instruction 40244 Value error Description Task arg Object arg is of non value type Recommended actions Use ex...

Page 230: ...de parameter arg cannot be dimensioned Recommended actions Remove the array dimension specification or change the mode of the parameter 40258 Parameter error Description Task arg switch parameter arg cannot be dimensioned Recommended actions Remove the array dimension specification or change the data type of the parameter 40259 Parameter error Description Task arg switch parameter arg must have tr...

Page 231: ... must be specified for a semi value type 40269 Symbol definition error Description Task arg Not enough memory for value of data arg Recommended actions More memory required 40270 Type definition error Description Task arg Private type arg can only be semi value or non value type specified value arg Recommended actions Change the value type class 40271 Type definition error Description Task arg Pri...

Page 232: ...xt when executing the routine arg Recommended actions Avoid executing the instruction when in undo context 40281 Undo Aborted Description Task arg The program execution of UNDO statements was aborted due to edit operation 40301 File access error Description Task arg is trying to access file arg but failing Consequences No data in the file may be accessed Probable causes File may be write protected...

Page 233: ...d actions Check if large data structures could be split into smaller blocks Use of installed modules can save program memory 40326 Load error Description Task arg Parser stack full file arg Recommended actions The program is too complex to load 40327 Load error Description Task arg Not current RAPID version file arg Recommended actions Cannot load RAPID source code of the version specified in the ...

Page 234: ...et to main The dynamic loaded module is removed A copy of the changed module is saved Recommended actions If the changes shall be saved replace the original file with the copy 40355 A Stop QStop event routine has been stopped Description Task arg A arg event routine has been stopped by an external stop command Any running Stop QStop event routines will be stopped after arg ms when controller recei...

Page 235: ... path arg Program ref arg Recommended actions Recovery arg 40508 Orientation Value Error Description Task arg Wrong orientation value in arg Program ref arg Recommended actions All used orientations must be normalized i e the sum of the quaternion elements squares must equal 1 40511 Parameter Error Description Task arg The parameter arg in arg is specified with a negative value Program ref arg Rec...

Page 236: ...eck the Motion Configuration Active mechanical units cannot have the same arg Physical Axis Logical Axis Drive Unit Configuration 40524 Conveyor Access Error Description Task arg The conveyor is not activated Program ref arg Recommended actions Recovery arg 40525 Conveyor Access Error Description Task arg No single number defined Program ref arg 40526 Conveyor Access Error Description Task arg The...

Page 237: ...y to be 0 255 40534 Timeout Description Task arg A timeout interrupted the execution Program ref arg Recommended actions Recovery arg 40535 Type Error Description Task arg The data you was trying to read in the file was not a numeric type Program ref arg Recommended actions Recovery arg 40536 System Access Error Description Task arg Too many pending read requests Program ref arg 40537 File Access ...

Page 238: ...actions Check the path Check write and execute permission for the directory under which the directory you want to remove is located Recovery arg 40546 File Access Error Description Task arg Could not remove the file arg Program ref arg Recommended actions Check the path Check if you have write permission for the file Check write and execute permission for the directory under which the file you wan...

Page 239: ...escription Task arg Can t save program module arg Program ref arg 40561 System Access Error Description Task arg arg is not a module name Program ref arg Consequences You cannot unload save or erase this module Recommended actions Check the name of the module 40562 Parameter Error Description Task arg Unknown axis number for the mechanical unit arg Program ref arg Recommended actions Check the val...

Page 240: ...t be set if argument DecelLim is set to TRUE Program ref arg Recommended actions Set a value to argument DecelMax 40571 Argument Error Description Task arg The value of parameter AccMax is too low Program ref arg Recommended actions Increase the value of parameter AccMax Recovery arg 40572 Argument Error Description Task arg The value of parameter DecelMax is too low Program ref arg Recommended ac...

Page 241: ...argument PayLoad 40579 ParId Error Description Task arg The optional argument PayLoad may only be used for PayLoad identification Program ref arg Recommended actions Remove the argument PayLoad 40580 ParId Error Description Task arg Faulty state for LoadIdInit Program ref arg Recommended actions Check the whole ParId sequence 40581 ParId Error Description Task arg Faulty state for ParIdMoveSeq Pro...

Page 242: ...ameter identification Program ref arg Recommended actions Check the argument ParIdType 40592 Program Stop During Load Identification Description Task arg No type of program stop is allowed during load identification Program ref arg Recommended actions Start the identification procedure from the beginning again Recovery arg 40593 Power Fail During Load Identification Description Task arg A Power Fa...

Page 243: ...ription No type of Program Stop is allowed during the Load Identification movements Consequences It is not possible to complete the Load Identification sequence Note that some axes for the actual mechanical unit are now in independent mode Probable causes A program stop caused errors in the measurements and this was detected when restarting the Load Identification movements Recommended actions Res...

Page 244: ...s identity or process selector can only have an integer value 40616 Argument Error Description Task arg Argument arg is outside allowed limits Program ref arg Recommended actions Used group of digital in out signals can only be set or checked within 0 to arg according to configuration in system parameters Recovery arg 40617 Argument Error Description Task arg One of the arguments SetValue SetDvalu...

Page 245: ...cription Task arg No move instructions with concurrent RAPID program execution are allowed within the StorePath RestoPath part of the program Program ref arg Recommended actions Edit the program so it does not contain any MoveX Conc instructions within the StorePath RestoPath part of the program 40634 Reference Error Description Task arg The signal arg is unknown in the system Program ref arg Prob...

Page 246: ...ernal alarm Program ref arg Recommended actions Alarm from external equipment Recovery arg 40643 Sensor Error Description Task arg Camera alarm Program ref arg Recommended actions Some error has been detected in the camera Run Camcheck to test if the camera is OK Recovery arg 40644 Sensor Error Description Task arg Temperature alarm Program ref arg Recommended actions The camera is overheated it n...

Page 247: ...or RefNum has to be defined with Short Fwd or Bwd 40651 Use Numeric Input Description Task arg Use numeric input for the position instead of a robtarget Program ref arg Recommended actions The position cannot be defined with a robtarget for robot axes Use the optional parameter for numeric input of the position 40652 Axis Is Moving Description Task arg A Robot axis an external axis or an independe...

Page 248: ...f switch Temp the datatype must be wztemporary in WorldZone If use of switch Stat the datatype must be wzstationary in WorldZone 40663 World Zone Not In Use Description Task arg The argument arg of the instruction arg refers to a not used worldzone Program ref arg Recommended actions The worldzone must have been defined and activated by a WZLimSup or WZDOSet instruction 40664 World Zone Already In...

Page 249: ...rogram ref arg Recommended actions Check the name of the world zone 40673 I O Access Error Description Task arg The signal given in parameter arg is write protected for RAPID access Program ref arg Recommended actions Select other user signal or change the access mode for the signal 40674 I O Access Error Description Task arg The I O signal arg is not write protected for user access from FlexPenda...

Page 250: ...ed actions Set the argument LowJointVal and HighJointVal to 9E9 for the actual axis 40698 Read error Description Task arg is trying to read file arg but is failing Consequences It was not possible to read load arg Probable causes If trying to access file on FTP mounted disc make sure that the size of arg isn t larger than the maximum file size configured in the FTP protocol settings 40699 Program ...

Page 251: ...ule name in the head of the file arg already exists in the program memory Recommended actions Recovery arg 40707 I O Device Name Invalid Description Task arg The I O device name arg does not exist Program ref arg Recommended actions Check if the I O device name is misspelled Check if the I O device is defined Recovery arg 40708 I O Device Is Not Enabled Description Task arg I O device arg was not ...

Page 252: ...tion The system could not refresh all I O signals as RAPID symbols Consequences No I O signals can be used in a RAPID program Probable causes Incorrect I O configuration Incorrect task configuration Recommended actions Restart the controller 40721 I O Installation Description Task arg The system could not refresh all I O signals as RAPID symbols Consequences No I O signals can be used in a RAPID p...

Page 253: ...ent arg for signal arg is above its maximum logical value Program ref arg Recommended actions Change the argument or change the maximum logical value parameter for the signal Recovery arg 40732 Value Error Description Task arg The value of the argument arg for signal arg is below its minimum logical value Program ref arg Recommended actions Change the argument or change the min logical value param...

Page 254: ...d in the instruction TriggStopProc cannot be updated because it does not exist anymore Probable causes The program module with the PERS variable is probably removed from the program memory Recommended actions Check if the module with the PERS variable is removed if so put it back 40741 Context Error Description Task arg Instruction arg may only be used in an event routine Program ref arg Recommend...

Page 255: ...ome load session with StartLoad WaitLoad has not been finished Program ref arg Recommended actions Finish the load session with WaitLoad cancel it with CancelLoad or set PP to main Recovery arg 40753 Memory Fault Description Task arg Because of power fail in executed Load or StartLoad WaitLoad instruction the RAPID program memory is inconsistent TO REPAIR DO ADVANCED RESTART Reset RAPID Program re...

Page 256: ...ument arg forces the robot out of workspace Program ref arg Recommended actions Decrease the value 40763 Execution Error Description Task arg The instruction arg cannot be executed while the system is in a stop state Program ref arg 40764 Switch Argument Error Description Task arg The instruction arg must be used with one switch argument Program ref arg Recommended actions Use one of the switch To...

Page 257: ...cription Task arg The object that the instruction arg was waiting for has been dropped Program ref arg Probable causes Start window passed or Checkpoint not satisfied Recommended actions If Checkpoint not used Checkpoint Distance and Checkpoint Window Width must be set to zero Rerun the instruction Recovery arg 40775 Conveyor Error Description Task arg Another arg instruction is waiting for a dist...

Page 258: ...s not opened in a binary mode Program ref arg Recommended actions Check how the file or serial channel was opened 40785 Mode Error Description Task arg File or serial channel is not opened for reading Program ref arg Recommended actions Check how the file or serial channel was opened 40786 Read Error Description Task arg One or more bytes is not read properly The value of the read data might be in...

Page 259: ...ces The contents of some of the text tables may have been destroyed Recommended actions Correct the error reset the system and try again 40794 Error Installing Text Table Description Task arg The specified index within the text resource already exists in the system Program ref arg Probable causes Error in the index numbering The file has been installed twice Recommended actions If error in the ind...

Page 260: ...ot possible to do subscribe Program ref arg Probable causes There is no memory left to make another subscription on this variable Recommended actions To continue PP must be moved to main 40803 Error message too long Description The length of the following error message was too long and has been cut This means you will not be able to read the whole message 40804 Argument Error Description Task arg ...

Page 261: ...or the argument Axis 40816 RolGenInstr Error Description Task arg Error from instruction RolGenInstr Ref to former user or internal error message for reason Program ref arg Recovery arg 41000 Item source exists Description Item source arg already exists Two item sources may not have the same name 41001 Not a valid name Description Choose arg or arg 41002 Buffer size exceeded Description Fatal inte...

Page 262: ...store Consequences Nothing stored Probable causes Try to store a recorded profile not existing or not activated Recommended actions Instruction ActivateProfile must be called before StoreProfile 41052 Can t use this profile data file Description File not found or data not valid Consequences Profile not used Probable causes File not found or data not valid Recommended actions Check file directory a...

Page 263: ...y arg 41205 Servo Tool Error Description Task arg Not possible to close servo gun The gun is not open Program ref arg Recommended actions Retry after opening the gun Recovery arg 41206 Servo Tool Parameter Error Description Task arg The parameter PrePos must be a positive value Program ref arg Recommended actions Change the parameter value Recovery arg 41207 Servo Tool Init Error Description Task ...

Page 264: ...oes not correspond to a service value 41303 Argument Error Description The argument Robot must be between 1 and arg Recommended actions Check and change the value 41304 Argument Error Description The argument Level doesn t correspond to a service level 41400 Parameter Error Description Task arg Faulty AxisNo Program ref arg Recommended actions Check and change the value Press Start to continue 414...

Page 265: ...ror Description Task arg Unknown module name arg Program ref arg Probable causes The module does not exist Recommended actions Check and change the RAPID program 41412 Parameter Error Description Task arg Ambiguous module arg Program ref arg Recommended actions Check and change the RAPID program 41413 Parameter Error Description Task arg Ambiguous routine name arg Program ref arg Recommended actio...

Page 266: ...r Description Task arg Unknown cfg type in argument arg Program ref arg Recommended actions Check and change the RAPID program Recovery arg 41423 Parameter Error Description Task arg Unknown cfg instance in argument arg Program ref arg Recommended actions Check and change the RAPID program Recovery arg 41424 Parameter Error Description Task arg Unknown cfg attribute in argument arg Program ref arg...

Page 267: ...Recommended actions Check if the mechanical unit exists in the system Recovery arg 41434 Parameter Error Description Task arg Argument Axis is out of range Program ref arg Recommended actions Check and change the value of the argument axis Recovery arg 41435 Parameter Error Description Task arg Argument Channel is out of range Program ref arg Recommended actions Check and change the value of argum...

Page 268: ...example CONNECT Recovery arg 41442 Reference Error Description Task arg The reference in argument arg is not an entire persistent variable Program ref arg Recommended actions 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 in any motion instruction 41443 Argument Error Description Task arg Argument ...

Page 269: ...t Error Description Task arg Argument arg contains an illegal interrupt number Program ref arg Probable causes Input interrupt number is illegal because it has not been allocated by the instruction CONNECT Recommended actions Use the instruction CONNECT to allocate and connect an interrupt number to a trap routine 41452 Argument Error Description Task arg Argument arg contains an interrupt number ...

Page 270: ...e argument 41461 Value Error Description Task arg Illegal value of argument arg Program ref arg Recommended actions The index must be an integer and in range 1 to 1024 41462 Value Error Description Task arg Illegal value of argument for parameter arg Program ref arg Recommended actions The value must be an integer and in the correct range 41463 Argument Switch Is Missing Description Task arg There...

Page 271: ... arg You are not allowed to deactivate I O device arg Program ref arg Recommended actions Recovery arg 41472 Instruction Error Description Task arg There is no client e g a FlexPendant taking care of instruction Program ref arg Recommended actions Recovery arg 41473 System Access Error Description It was not possible to send data using SCWrite to external computer Failed to send variable arg 41474...

Page 272: ...xpired Program ref arg Recommended actions Recovery arg 41486 Instruction Error Description Task arg The instruction arg is only available if there is a TCP robot defined in the program task Program ref arg Recommended actions Check the configuration The instruction must be removed if the task is not supposed to have a TCP robot 41487 Instruction Error Description Task arg The instruction arg only...

Page 273: ...rogram when having an active instruction Then a PP movement within program has been done Recommended actions Move PP to start the program again PP must be moved in all program tasks To have a well defined state of the system you should move PP to main 41496 Move PP Error Description Task arg Not ready with the switch from synchronized to independent mode Program ref arg Consequences Restart of cur...

Page 274: ...Illegal Error Type Description Task arg Error type TYPE_ALL cannot be used Program ref arg Recommended actions Use another Error Type 41504 No Mechanical Unit Stated Description Task arg No TCP in the system and no mechanical unit added to the instruction Program ref arg Recommended actions Add a mechanical unit that exists in the task to the instruction 41505 Mechanical Unit Not In Task Descripti...

Page 275: ...next user action to do 41513 LoadId Error Description Task arg Selection of PayLoad out of limits Program ref arg Recommended actions Select a PayLoad in the system Press Start to continue 41514 LoadId Error Description Task arg wobj0 cannot be active for roomfix TCP Program ref arg Recommended actions Select another Work Object Check next Event Log message for the next user action to do 41515 Loa...

Page 276: ...or Description Task arg None of the tasks in the task list is a NORMAL activated task Program ref arg Recommended actions Check in the Task Selection Panel that at least one of the tasks in the task list are selected activated Check in the cfg file that at least one of the tasks selected is NORMAL 41522 Wrong Error Recovery Constant Used Description Task arg Error recovery constant arg has been bo...

Page 277: ...ismatch between the task lists in the different tasks Program ref arg Recommended actions Add current task to the TaskList Check that the task lists in the different tasks are similar When using PERS variables it might be necessary to unload the modules containing the task lists and then reload them again 41532 Mismatch of task list Description Task arg Failed to synchronize because of The task li...

Page 278: ...wed by a SyncMoveOff instruction 41537 Unexpected SyncMoveOff Description Task arg Unexpected SyncMoveOff SyncID arg The system is waiting for a SyncMoveOn Program ref arg Recommended actions Remove the SyncMoveOff instruction Every SyncMoveOn must be followed by a SyncMoveOff instruction 41538 Wrong TaskList Description Task arg The task arg in the TaskList is a read task and cannot be synchroniz...

Page 279: ...be of type LOCAL PERS Program ref arg Recommended actions Remove the directive LOCAL from the data declaration 41546 Argument Error Description Task arg The object arg does not exist in the system or is of type LOCAL PERS Program ref arg Recommended actions Declare the object Remove the directive LOCAL from the data declaration 41547 Argument Error Description Task arg The Corr switch cannot be us...

Page 280: ...gned a value 41554 Synchronized Mode Description Task arg It is not possible to use the optional parameter Conc when the system is in synchronized mode Program ref arg Recommended actions Remove the optional parameter Conc from any move instruction used in synchronized mode 41555 No Contact With I O Device Description Task arg There is no contact with the I O device arg Program ref arg Probable ca...

Page 281: ...use there is a risk that the robot might perform an unexpected movement Probable causes One of following The RAPID program is missing an error handler or the error handler does not handle this specific error MODPOS operation done when not running in step or move step mode Recommended actions One of following Edit the program Move the program pointer to be able to start the program 41563 Argument E...

Page 282: ...s 41570 Socket error Description Task arg The socket cannot accept incoming connection requests since it is not set to listen state Program ref arg Probable causes SocketAccept is used before SocketListen Recommended actions Set socket to listen for incoming connections before trying to accept 41571 Socket error Description Task arg The address and port is already in use and cannot be used by this...

Page 283: ... Unexpected error when connecting socket Check event log for other messages for possible cause Program ref arg Recommended actions Move program pointer to Main and restart program 41579 Socket error Description Task arg The connection was refused by the remote host Program ref arg 41580 Socket error Description Task arg The socket is already connected and cannot be connected again Program ref arg ...

Page 284: ...nreachable A socket operation was attempted to an unreachable network This usually means the local software knows no route to reach the remote host Program ref arg Consequences The operation was aborted Recommended actions Check your connection and network settings Recovery arg 41590 Socket error Description Task arg The byte array is invalid A byte array can only contain integers between 0 and 25...

Page 285: ...socket and recreate before trying to bind socket to a new address 41598 Socket error Description Task arg Unexpected error trying to listen for connections Program ref arg Recommended actions Move program pointer to Main and restart program 41599 Socket error Description Task arg The socket has not been bound to an address Program ref arg Recommended actions Use SocketBind to specify which address...

Page 286: ... When moving PP to main the socketdev variable keeps it value but is not valid anymore Recommended actions Use socket instructions when handling data types of arg Do not declare and use socketdev variables in a shared module 41606 Socket error Description Task arg The socket type is of the type datagram protocol UDP IP Current instruction arg is only supported for stream type protocol TCP IP Progr...

Page 287: ...datapos arg is undefined Program ref arg Recommended actions All datapos is retrieved with the function GetNextSym 41616 Reference Error Description Task arg The taskid arg is unknown in the system Program ref arg Recommended actions Program tasks must be defined in the system parameter and not in the RAPID program Taskid can be used as a parameter when declaring a routine 41617 Too intense freque...

Page 288: ...ed Probable causes Error in the RAPID program Recommended actions Check and change the RAPID program PP must be moved in all tasks before you can continue 41623 Faulty use of arg Description Task arg Instruction arg is used multiple times or the instruction is used when already in synchronized motion mode arg suspends synchronized coordinated movements arg resumes synchronized coordinated movement...

Page 289: ... actions Remove the instruction 41632 Argument does not exist Description Task arg Only TP_LATEST is supported in TPShow instruction Program ref arg Consequences Using other argument than TP_LATEST nothing will happen Recommended actions Remove the instruction 41633 Can only be used in an UNDO handler Description Task arg The instruction arg can only be used in an UNDO handler Program ref arg Cons...

Page 290: ... The program execution is stopped immediately Probable causes The task arg was not active when start from main was done Deactivation of task arg with service routine arg but not deactivating the task in the task selection panel Activation of task arg that earlier was deactivated in task selection panel and deactivated with service routine arg Recommended actions Move PP to main to reset tasks used...

Page 291: ...rcular movement before restarting the program Recommended actions Find out why the program has been blocked maybe in other logs correct the problem and move program pointer in all Motion tasks before restarting the program 41647 Program Halted from RAPID Description Task arg Program and movement are halted with System Halt from RAPID Program ref arg Consequences Due to a programmed System Halt in ...

Page 292: ...struction has been executed in synchronized mode and the StartMove in independent mode 41653 Argument error CalcJointT Description Task arg It is not possible to execute the function CalcJointT with argument UseCurWObjPos if the coordinated workobject moved by some mechanical unit is located in the same task as the TCP robot or if the workobject is not moved by any mechanical unit at all Program r...

Page 293: ...o space left for the new view Description Task arg Maximum number of views has been exceeded There is no space left on the FlexPendant for the new view Program ref arg Consequences The view will not be launched Probable causes Too many open views Recommended actions Close one view and try again Recovery arg 41661 Assembly could not be found Description Task arg The assembly could not be found or d...

Page 294: ...n used with switch arg and without optional argument arg Program ref arg Consequences The program execution is stopped immediately Probable causes An illegal combination of optional arguments and switches was used Recommended actions Correct the RAPID program 41670 Entire Array Not Allowed As Argument Description Task arg The argument arg is of data type any type and can for that reason only be ch...

Page 295: ...ask arg Unable to write to file arg the disc is full Program ref arg Recommended actions Make sure there are enough free space on the disc Recovery arg 41678 Device access error Description Task arg Unable to write to file arg the file is write protected Program ref arg Recommended actions Remove the write protection of the file or select a different filename Recovery arg 41679 Device access error...

Page 296: ...le Probable causes If the file was located on an USB disk check that the disk is not removed or has too many files in root folder Check that the given file is not a directory Recommended actions Do a check of Probable Causes Recovery arg 41688 Invalid Argument Description Task arg Inparameter arg is declared as a PERS Program ref arg Consequences The program execution is stopped immediately Probab...

Page 297: ...pe used in argument Data is of type arg If the data types has equal names the structure of the data can be different Recommended actions Use data type arg in argument Data Check that the data types are equal defined in both sender and receiver code Recovery arg 41695 RMQ Error Not equal dimensions on data Description Task arg The data types are equal but the dimensions differs between the data in ...

Page 298: ...type is used in two arg instructions with two different interrupt identities Recommended actions A unique interrupt identity is needed for each data type when order and enable interrupts for a specific data type 41701 RMQ Error No message to collect Description Task arg Instruction arg failed There was no message to collect Program ref arg Consequences No message was collected Probable causes This...

Page 299: ... in arg of instruction arg The client has received the message The answer is delayed so the time out time for instruction arg expired Recommended actions Check the client program Increase the waiting time for instruction arg Recovery arg 41706 RMQ Error Max Time Expired Description Task arg The programmed waiting time has expired Program ref arg Consequences No message has been received Probable c...

Page 300: ... error If a restart is needed first move PP to Main in all tasks to reset the process error 41715 Invalid Direction Description Task arg The argument arg must be either CSS_X CSS_Y CSS_Z CSS_XY CSS_XZ CSS_YZ CSS_XYZ CSS_XYRZ Program ref arg Recommended actions Check the value of arg 41716 Invalid Offset Direction Description Task arg The argument arg must be either CSS_POSX CSS_NEGX CSS_POSY CSS_N...

Page 301: ... Soft Servo are invalid The current combination can lead to unstable behavior Program ref arg Recommended actions Change the configuration for Cartesian Soft Servo 41726 Ignored StopMoveReset actions for task Description Task arg The StopMoveReset instruction had no impact on the system Program ref arg Consequences The StopMove was not reset Probable causes The Motion task has not been stopped The...

Page 302: ...ction arg is used with a switch that requires option Wrist Interpolation Program ref arg Consequences The program execution is immediately stopped Probable causes Missing a RobotWare option Recommended actions Do not use any of the following switches arg 41739 StorePath required Description Task arg Instruction arg is executing in an error handler or a trap routine Use arg before using a movement ...

Page 303: ...allowed to execute the instruction arg in a BACKWARD handler Program ref arg Recommended actions Remove the instruction 41746 Instruction Error Description Task arg The program is executing at USER level i e in an event routine or a service routine It is not allowed to execute the instruction arg at USER level Program ref arg Recommended actions Remove the instruction 41747 Process signal off Desc...

Page 304: ... parameter arg is out of limit Program ref arg Recommended actions Recovery arg 41753 Invalid path level Description Task arg Program ref arg arg requires the robot to run at the first path level Consequences The program execution is stopped immediately Probable causes Executing arg on wrong path level Recommended actions Check the RAPID program 41754 Path Recorder cleared Description Task arg WAR...

Page 305: ...ediately Recommended actions Use a variable of the type arg instead of a variable of type arg 41762 The argument string value is invalid Description Task arg The argument string arg is invalid and cannot be converted Program ref arg Consequences The program execution is stopped immediately Probable causes The only valid letter characters is a f and A F and only for HexToDec The and characters is n...

Page 306: ...tion task that task arg is connected to does not control a TCP robot Program ref arg Consequences The program execution is stopped immediately Probable causes arg is used in a non Motion task that is connected to a Motion task that does not control a TCP robot Recommended actions Check the configuration The instruction must be removed The non Motion task arg is connected to a Motion task that does...

Page 307: ...an error handler to retry instruction Recovery arg 41774 Type error Description Task arg It is not possible to set value arg into a variable of current type arg Check the used optional argument and use an argument with proper type Program ref arg Probable causes Wrong argument type used Recommended actions Check the RAPID program and use other type of variable to store the data in Recovery arg 417...

Page 308: ... with instruction arg cannot be modified the parameter is not recognized or RAPID data used is of wrong data type Program ref arg Consequences Parameter not modified Probable causes The reasons are Wrong optional RAPID argument used Value is out of range A cell with specified name does not exist The cells needs to be of type EditInt EditFloat or EditString Trying to set wrong type to the cell e g ...

Page 309: ... has no job loaded Recommended actions Go to RobotStudio Integrated Vision tab Setup Image and change the Trigger property to External and save the job Run the instruction CamSetRunMode Load a job into the camera Recovery arg 41786 Parameter out of range Description Task arg The value used for the parameter arg for camera arg is out of range Program ref arg Consequences The program execution is st...

Page 310: ... Current tool when the instruction CSSAct was run is tool0 or another tool with too small mass The current tool is set by a move instruction or by jogging prior to the CSSAct instruction Recommended actions Use as accurate tool definition as possible Use the load identification If simple tests of SoftMove is done with only the mounting flange as tool then a tool definition similar to tool0 needs t...

Page 311: ...g Recommended actions Define the correct load of the load before use of it for jogging or program movement Load identification of the load can be done with the service routine LoadIdentify 41797 Signal not accessible Description Task arg The I O signal arg is not accessible Program ref arg Probable causes The reason for this error is one of the following The real input or output on the I O device ...

Page 312: ... current instruction exceeds the maximum physical output value for the analog signal used in AOp argument in TriggSpeed instruction Program ref arg Probable causes Logical analog output exceeds physical output value Logical output value Scale value programmed TCP speed in mm s Physical output value for analog signal According definition in configuration for actual analog output signal The analog s...

Page 313: ...cution is stopped immediately Probable causes The signal named arg is configured in the I O configuration and cannot be reset Recommended actions Check the RAPID program and the argument used in instruction arg 41812 Domain not valid or not in use Description Task arg The domain arg used in instruction arg is not valid or is not in use Program ref arg Probable causes A domain that is not valid or ...

Page 314: ...f the signal is defined in the RAPID program it must be connected to the configured signal with instruction AliasIO Recommended actions Re establish the connection with the I O device Re connect the RAPID program defined signal using AliasIO 41818 SDB Error in Cyclic bool Description Failure while evaluating a logical expression setup with RAPID instruction SetupCyclicBool The persistent variable ...

Page 315: ...D instruction arg Consequences The program execution is stopped immediately Recommended actions Check if The device name is spelled correctly The device is connected The device is up and running 41825 EGM not connected Description The state of the EGM instance with EGM identity arg is not connected Consequences The program execution is stopped immediately Recommended actions Use the instructions E...

Page 316: ...nsequences If no repositioning is done before restart of ContactL movement that can cause damage might occur Recommended actions Recovery arg 41832 EGM UdpUc inbound message contains invalid data Description The UdpUc server application on the external device arg that is feeding EGM with position data sent invalid data Consequences The program execution is stopped immediately Recommended actions C...

Page 317: ...Consequences If no repositioning is done before restart of circular search movement that can cause damage might occur Recommended actions Recovery arg 41845 Outside reach Error Description Task arg The position robtarget is outside the robot s working area Program ref arg Probable causes The robtarget used is outside reach Recommended actions Use a robtarget that is within the robot s working area...

Page 318: ...se three base types Program ref arg Consequences The program execution is stopped immediately Probable causes Wrong value type used Recommended actions Change type used in optional argument arg 41852 Wrong signal value for signal arg Description It is not possible to set the I O signal arg to value arg Consequences The program execution is stopped immediately Probable causes The I O signal arg is ...

Page 319: ...can only be used if the mechanical unit is a TCP robot Program ref arg Consequences The program execution is stopped immediately Recommended actions Use arg with TCP robot only 41864 Argument error Description Task arg Bad combination of switches The switch arg can only be combined with switch arg Program ref arg Consequences The program execution is stopped immediately Recommended actions Correct...

Page 320: ...ny SafeMove option or EPS option 41885 BrakeCheck Error Description Task arg When having a SafeMove option or the EPS option CyclicBrakeCheck should be used to test brakes Program ref arg Consequences The program execution is stopped immediately Probable causes Use of BrakeCheck routine when CyclicBrakeCheck should be used Recommended actions Use CyclicBrakeCheck to test brakes 41886 CyclicBrakeCh...

Page 321: ...imum integer value for num 8388608 Value read arg Program ref arg Consequences The program execution is stopped immediately Probable causes A num variable is used to store the read integer value and that value is above the maximum integer value for a num Recommended actions Change datatype used in arg to a dnum variable 41890 Parameter error Description Task arg The value used in argument NumPoint...

Page 322: ... two points are too close Program ref arg Consequences The program execution is stopped immediately Recommended actions Correct the RAPID program 41898 Argument error Description Task arg The point distribution is not a plane Program ref arg arg arg arg Consequences The program execution is stopped immediately Recommended actions Correct the RAPID program 41899 Argument error Description Task arg ...

Page 323: ...heck program has detected that motion task arg is deactivated in the task selection panel Program ref arg Consequences The program execution is stopped immediately Probable causes Task has been deactivated in the task selection panel Recommended actions Activate the task arg in the task selection panel and execute the brake check program again 41905 Argument error Description Task arg Cannot calcu...

Page 324: ...oo far from the path to perform a regain movement Program ref arg Consequences The execution of the routine arg has been stopped Probable causes The mechanical unit has been jogged from the path Recommended actions 1 Start execution again and choose if regain or remove path 2 Cancel call routine to end arg 324 Operating manual Troubleshooting IRC5 3HAC020738 001 Revision AA Copyright 2005 2018 ABB...

Page 325: ...away from the singularity or change the jogging mode for the robot to joint axis jogging In the case when the robot position is dependent on an additional axis being jogged then that dependency may also need to be relaxed that is by changing the jogging coordinate system for the robot from world to base 50027 Joint Out of Range Description Position for arg joint arg is out of working range Recomme...

Page 326: ...unter difference for joint arg 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 Consequences The robot is not calibrated and may be jogged manually but no automatic operation is possible Probable causes The position of the robot arm may have been changed manually while the power supply...

Page 327: ...m 50076 Orientation not correct Description Orientation is incorrectly defined Recommended actions Make an accurate normalization of the quaternion elements 50078 Too many close positions Description Too many consecutive closely spaced positions Recommended actions Increase the distance between consecutive close positions 50079 Cannot use wrist weaving Description Wrist weaving not possible Recomm...

Page 328: ...2 Axis computer response Description Incorrect response from the axis computer Recommended actions Check Motion system parameters Check the axis computer hardware 50094 TuneServo not possible Description Tuning is not implemented for the specified joint Recommended actions Verify that a parameter and or joint that can be used with TuneServo is chosen 50096 TuneServo not allowed Description Tuning ...

Page 329: ...system parameters in topic Motion Use correct parameters and reset the system 50143 Robot axes configuration Description Actual configuration is not the same as ordered and or movement of any robot axis is larger than 90 degrees Robot arg axis arg Recommended actions Use SingArea_Wrist ConfL_Off modify position or insert intermediary point Proceeding in automatic mode will not be possible without ...

Page 330: ...ption Programmed position of independent joint arg is outside working range and thus cannot be reached Recommended actions Change the position Check the joint working area limits Check the used work object 50163 Position adjustment Description External position adjustment too large TCP speed orientation speed or external position speed exceed allowed robot performance Recommended actions Reduce pr...

Page 331: ... Description Joint arg and arg are out of coupled working range Recommended actions Use the joystick to move joints into their coupled working range 50182 Jog in wrong direction Description Joint arg and arg are out of coupled working range Recommended actions Use the joystick to move joints into their coupled working range 50183 Robot outside work area Description The robot has reached the World ...

Page 332: ...e reach Description The error of the programmed orientation exceeds the acceptance limit Recommended actions Adjust robtarget orientation Adjust check orientations of currently used frames tool frame base frame user frame object frame It is possible but not recommendable to switch off the orientation supervision using the corresponding system parameter Please see system parameters documentation fo...

Page 333: ...0215 Load identification fail Description Axis arg will move outside working range Recommended actions Move the axis to a position further from the working range limit 50218 Path not finished Description Task arg Previous motion path was not finished before new motion was sent Program ref arg Recommended actions Use StorePath when in Trap routines Move the program pointer and start a new movement ...

Page 334: ...rg not active Consequences Logged signals for deactivated units may be invalid Recommended actions Activate mechanical unit to avoid this event message 50234 Overflow during logging Description An overflow occurred when logging signals Recommended actions Define fewer signals Reduce load on the main computer Reduce network load 50235 No Motion interrupts received Description The system has not gen...

Page 335: ...ster axis 50247 Clear of Path failed Description The movement has to be stopped when the path is to be cleared Recommended actions Use StopMove before the ClearPath instruction Move the program pointer and start a new movement 50248 Servo Tool error Description Error for tool arg in state arg arg arg arg 50249 Programmed force reduced Description Programmed tip force too high for tool arg Requeste...

Page 336: ...tsensor distance 50259 Sensor max distance error Description Distance between sensor position and programmed position too large arg Recommended actions Check programmed sensor positions in robtarget Check sensor speed Start sync earlier or reduce waitsensor distance 50260 Sensor Check dist error Description Distance sensor pos to programmed pos arg too large arg Recommended actions Check programme...

Page 337: ...se the distance between the programmed positions Turn off this check by changing the system parameters 50272 Motion configuration Description Failed to read arg data for arg Recommended actions Check the configuration file Use correct parameters and reset the system Check both system parameters for the current instance and any instances below in the structure 50273 Motion configuration Description...

Page 338: ...meters and reset the system 50281 Process failed Description Task arg A process in the task arg has failed This is caused by a failure of a process in this task or a synchronized task if MultiMove is used arg Recommended actions Check other messages occurring at the same time for the reason Recovery arg 50282 Record not ready Description Record not ready to activate Recommended actions Make sure t...

Page 339: ...id number mismatch arg arg Recommended actions Verify that the specified id numbers are equal and that all program pointers are synchronized before program start 50289 Point type mismatch at sync Description The move instructions with syncId arg have a mix between finepoints and zonepoints Recommended actions Make sure that the move instruction in all cooperating program tasks specifies the same k...

Page 340: ...s been cleared Recommended actions If proper data exists in controller transfer the data to robot memory If still problem check communication cable to the SMB board Replace the SMB board 50302 Sensor data missing Description No serial number is defined for mechanical unit arg in robot memory Probable causes The robot memory has been cleared or new SMB board has been installed Recommended actions I...

Page 341: ...Independent reset movement failed for arg a synchronized movement MoveL MoveJ of the servo tool occurred during the independent reset movement Recommended actions Make sure the synchronized speed of the servo tool is zero during execution of independent reset movements 50314 Independent move outside reach Description Programmed independent move position for arg is outside reach Programmed position...

Page 342: ...s not connected to any motion task Recommended actions Check the connection between mechanical unit and RAPID task in the configuration topic Controller 50323 Failed to read force sensor Description Failed to return calibrated force sensor reading Probable causes Force control system not calibrated Recommended actions Use the instruction FCCalib before using this instruction 50324 Force control ca...

Page 343: ...larger than zero Recommended actions Change the parameters above according to the manual 50335 Parameter error in FCRefSpiral Description Not allowed parameter value used in function FCRefSpiral Probable causes Error in parameter values of function FCRefSpiral Recommended actions Modify the parameter values in function FCRefSpiral 50336 Parameter error in FCGetProcessData Description Failed to ret...

Page 344: ...the supervision or the program 50346 Motor temperature error Description Motor temperature for joint arg is too high Consequences It is not possible to continue until the motor has cooled down 50348 Log signal definition failed Description Definition of a signal failed for arg axis arg on channel arg Probable causes The signal number does not correspond to an actual log signal 50349 Same synchroni...

Page 345: ...orce the system parameters need to be updated Note that there is an absolute limit of force reference size that depends on the robot type 50355 Ordered torque reference is too large Description The ordered torque reference is larger than the configured maximum value Consequences The ordered torque has been reduced to the configured maximum value Recommended actions To allow a larger reference torq...

Page 346: ...and type Drive System to No for normal operation 50366 Reference Error Description An error has occurred in the reference calculation in motion planner arg Internal status arg Consequences The controller goes to Motors Off Recommended actions Check the error logs for previous errors that could be causing this problem Try to restart the program possibly after moving the program pointer Restart the ...

Page 347: ...ram 50375 Dynamic load too high Description Required torque for robot arg axis arg too high Recommended actions If weaving one of these actions may help Reduce weave frequency or weave amplitude for this movement Reduce process speed Check load data Increase zone size if small zones are used Increase distance between programmed points if they are close If Conveyor Tracking Reduce conveyor speed 50...

Page 348: ...ons Verify that any modified parameter are within allowed limits 50384 Cartesian Soft Servo quaternions invalid Description The quaternions of the tool workobject or the argument RefOrient in the CSSAct instruction are invalid Consequences Cartesian Soft Servo will not activate Recommended actions Check the quaternions of the tool workobject or the argument RefOrient in the CSSAct instruction 5038...

Page 349: ...gging or a programmed movement has been detected Consequences The ordered movement is ignored Recommended actions Movement during Cartesian Soft Servo is only allowed if the switch AllowMove has been used in the CSSAct instruction 50392 SafeMove communication error Description Communication with the SafeMove controller on drive module arg has failed Consequences Brake tests cannot be done Recommen...

Page 350: ...her mechanical unit must use the same tool and work object as the previous move instruction Consequences The robot will stop Recommended actions Change the move instruction before arg so that they both use the same frames Alternatively add a redundant MoveL to the start point of the circle arc using the same frames as the MoveC instruction 50399 Absolute Accuracy circle is first movement instructi...

Page 351: ...The task execution will stop Recommended actions Remove movement coordination while doing the wrist interpolation 50406 Wrist Interpolation point not on circle plane Description Task arg Program ref arg The target arg is not on the circle plane The deviation is arg mm p1 starting point p2 circle point p3 end point Consequences For a cutting process the cut hole will not be circular Recommended act...

Page 352: ...ctly 50413 Bleeder resistor overload error Description In drive module arg the bleeder resistor connected to the rectifier unit at drive unit position arg was overloaded Consequences No operation will be possible until the bleeder resistor has cooled down The system goes to Motors Off Probable causes The user program may contain too much deceleration of the manipulator s axes This fault is more li...

Page 353: ... and node arg Consequences No operation will be possible until the drive has cooled down The system goes to Motors Off Probable causes The joint may be running with a too high torque for extended periods of time Short circuit in the manipulator using long motor cables Recommended actions If possible rewrite the user program to reduce the amount of high acceleration and high deceleration Reduce the...

Page 354: ...iption The time between trig signal and start of indexing movement is configured too low Consequences The program execution is stopped Recommended actions Increase system parameter Time before indexing move in topic Motion and type Single Type to at least arg ms Remove or decrease robot acceleration limitations if possible Please consult the Conveyor Tracking application manual for further actions...

Page 355: ...t to collide Recommended actions Jog the robot in another direction if the problem occurred during jogging Change the robot program to increase the clearance between the involved objects Decrease the safety distance for the involved objects in the Collision Avoidance configuration file If you are sure that the involved objects are not about to collide then try the following Check that the Collisio...

Page 356: ...eJ 50437 Follower axis is connected to wrong Motion Planner Description The follower axis arg is connected to a motion planner with a lower number than its corresponding master axis arg Consequences The performance of the Electronically Linked Motors will be decreased compared to the normal setup Recommended actions Change the Motion configuration in such a way that the follower axis arg is in the...

Page 357: ...y increasing the system parameters Number of Internal Event Objects in topic Motion and type Motion Planner and restart the controller 50444 Manipulator supervision Description Loose arm detection triggered for axis arg on mechanical unit arg Consequences 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...

Page 358: ...ns that are used by External Motion Interface are not properly normalized Other illegal numerical values used as input to External Motion Interface Recommended actions Make sure that the External Motion Interface input data is correct and restart the program 50449 Mechanical unit close to joint bound Description The movement created by the External Motion Interface correction arg is causing mechan...

Page 359: ...anical unit arg joint arg Consequences The program execution is stopped and the system goes to Motors Off state Probable causes The deviation of the position from the path or the latest finepoint exceeded the maximum allowed value Recommended actions Check the application that is utilizing the External Motion Interface functionality to increase the maximum allowed position value or modify the prog...

Page 360: ...escription External Motion Interface correction arg cannot be deactivated while mechanical units are moving Consequences The program execution is stopped and the system goes to Motors Off state Probable causes An attempt is made to deactivate a correction while one or more mechanical units are moving Recommended actions Make sure all movements and other External Motion Interface corrections have f...

Page 361: ...nfiguration can cause unexpected movement of the axis at program start due to brakes being released while the axis is not being controlled Recommended actions Check the configuration file Use correct parameters and reset the system 50468 Cartesian speed limits changed Description Cartesian speed limits have been changed for robot arg The current Global Speed Limit is arg m s and Arm Check Point Sp...

Page 362: ...reference direction 50476 AxisCal error Description Data moved from robot to controller memory AxisCal data not valid in robot memory AxisCal cleared in controller for mechanical unit arg Recommended actions Load new AxisCal data if data available 50477 Axis Calibration data missing Description Mechanical unit arg is calibrated with axis calibration but system parameters are missing from controlle...

Page 363: ...he control to the position control In this case the starting position for the force movement is more closed than current position is and that will lead to closing movement before position control can take over The situation indicate that there was a collision with the plate during the closing movement that the plate thickness is not correct or that the calibration is not correct Recommended action...

Page 364: ...tween the two arms will not work Collision prediction will not work Probable causes The base frame data are different for the two units Recommended actions Give both units the same base frame system parameters 50492 Error during jogging Description An attempt was made to jog in some mode other than axis by axis while one or more revolution counters were not updated Recommended actions Use axis by ...

Page 365: ...unctionality has currently beta status and shall only be used for testing and evaluation Recommended actions Unless you are doing tests in cooperation with ABB we recommend that you change the value back to the previous value 50501 Short movements Description One or more consecutive move instructions resulted in movements close to zero length Task arg Program ref arg Consequences Programming with ...

Page 366: ...e for the I O signal 71007 Logical values out of range Description The I O configuration for I O signal arg is invalid The logical minimum value must be less than the logical maximum value This I O signal has been rejected Recommended actions Correct the logical values for the I O signal so that the minimum value becomes less than the maximum value 71008 Physical values out of range Description Th...

Page 367: ...oss connection Description The I O configuration is invalid The I O signal arg is part of a cross connection chain that is closed i e forms a circular dependence that cannot be evaluated The complete cross connection configuration has been rejected Recommended actions Correct the configuration for the cross connections where the I O signal above is part 71038 Cross connection max depth exceeded De...

Page 368: ... Make sure that the network cable is connected to the controller Make sure the I O device is correctly powered Make sure the cabling to the I O device is correctly connected 71076 Communication error from rtp1 Description No response from the serial line Recommended actions Check the device or connection 71077 Communication error from rtp1 Description Not possible to deliver the received message R...

Page 369: ...evices so that the maximum limit is not exceeded 71098 NFS server lost Description The contact with the NFS server arg is lost Recommended actions The NFS server The network connection The NFS client 71099 Trusted NFS server lost Description The contact with the trusted NFS server arg is lost Recommended actions The NFS server The network connection The NFS client 71100 Max number of Industrial Ne...

Page 370: ... Export the directory on the server computer 71128 Ethernet not installed Description The Ethernet Services option has to be installed when using remote mounted disk Recommended actions Restart the controller and install the Ethernet Services option 71129 Too many remote disks Description The maximum number of remote mounted disks have been exceeded The maximum number is arg Recommended actions Re...

Page 371: ... actions Check cable and FTP server settings 71166 FTP server went down Description The connection to a trusted FTP server has been lost IP address arg Recommended actions Check cable and FTP server settings 71167 Wrong transmission protocol Description No matching transmission protocol was found in the communication configuration Recommended actions Change the transmission protocol 71169 Ethernet...

Page 372: ...m has been configured with the desired network Make sure the network option at hand is installed Check the I O configuration for network 71205 Could not mount directory Description Mounting directory arg on the computer arg failed Protocol arg Recommended actions Check the FTP server setup Check the FTP client configuration Check communication hardware cabling 71220 No PROFIBUS option has been ins...

Page 373: ...maining fields in the binary file match the I O configuration 71231 Wrong PROFIBUS device is connected Description PROFIBUS device arg at address arg has the wrong identity number Reported identity number is arg Expected identity number is arg Consequences The robot controller will not be able to activate the device Probable causes The I O device at address arg may be the wrong type of device The ...

Page 374: ...ion is too big Description The memory partition for communication purposes cannot be allocated The requested partition arg kB System partition will be used Recommended actions Decrease commPartSize 71290 Could not add FTP device Description Adding the FTP device arg to the operating system failed Application protocol arg Recommended actions Change the local path of the configuration of the FTP dev...

Page 375: ...ommended actions Make sure any terminating resistors are correctly connected Make sure all communication cables and connectors are working correctly and of the recommended type Check network topology and cable length Make sure the DeviceNet Power Supply unit is working correctly Replace any faulty unit 71301 Bus off DeviceNet network communication failure Description A major number of communicatio...

Page 376: ...code arg Recommended actions Restart the controller Report the problem to ABB 71307 DeviceNet generic connection 1 Description On DeviceNet I O device arg connection 1 configuration is generic Real values Connection 1 type arg Connection 1 input size arg Connection 1 output size arg Recommended actions Update your current I O device configuration 71308 DeviceNet generic connection 2 Description On...

Page 377: ...nfiguration is invalid The maximum number arg of I O access levels in the I O system has been exceeded Recommended actions Modify the configuration of the I O system by reducing the number of I O access levels so that the maximum limit is not exceeded 71321 Invalid I O access level Description The I O configuration is invalid The I O signal arg has a reference to an invalid undefined I O access le...

Page 378: ...d connection for the network 71331 Invalid network Description The I O configuration for network arg is invalid The name of the network is not valid Installed valid networks are arg Consequences This network has been rejected and no functions depending on it will work Recommended actions Correct the name for the network 71332 Invalid recovery time Description The I O configuration for the I O devi...

Page 379: ... device map arg is invalid since bit arg is out of range All bits in the device map must be in the range 0 arg This I O signal has been rejected Recommended actions Correct the device map 71347 Device map with overlapping segments Description The I O configuration for I O signal arg is invalid The device map arg contains segments e g bit arg that overlap each other This I O signal has been rejecte...

Page 380: ... O configuration is invalid I O device arg has an invalid unknown Device Trust Level arg Installed valid Device Trust Levels are arg Consequences This I O device has been rejected and no functions depending on it will work Recommended actions Correct the Device Trust Level for the I O device 71356 Bus type mismatch Description The I O configuration is invalid Device arg refers to a network and a u...

Page 381: ...re it is not abnormal and change if required If an extremely heavy I O load is normal and required investigate whether programming delays in the RAPID application may solve the problem 71365 Safety I O queue overload Description The safety I O queue handling safety I O signals has been overloaded Consequences The system will go to status SYS HALT Probable causes This is caused by too frequent sign...

Page 382: ...The connector and the physical channel using the connector will not be available for use Probable causes The configuration files may have been faulty A configuration file with improperly configured Physical Channels may have been loaded Recommended actions Make sure physical connector configuration is valid Reinstall the system to make sure the system configuration files are OK 71381 Communication...

Page 383: ...ut size Description On DeviceNet I O device arg the connection output size arg does not match the I O device When using strobe connection the only valid output sizes are 1 or 1 Recommended actions Change size in configuration Check module Use DN_Generic device template 71393 Error when allocating generic size Description Failed to allocate generic arg size 1 on DeviceNet I O device arg Probable ca...

Page 384: ...n found but no option has been installed Consequences No communication on arg Anybus module is possible There may be consequential errors from configuring when no such option has been installed Probable causes An attempt may have been made to add the arg Anybus module functionality without installing the option correctly Recommended actions If the arg Anybus module option is required configure a n...

Page 385: ...ns Change port number 71409 Not able to add a port to arg Description Not able to define port arg of route arg due to lack of resources Consequences The route is not available Messages to I O devices connected to port arg are not forwarded Probable causes The network arg doesn t support this many ports Recommended actions When possible reduce the number of ports or report the problem to ABB 71410 ...

Page 386: ...ined as a PROFINET internal device while another PROFINET internal device has already been configured Recommended actions Remove I O device arg from the configuration 71446 PROFINET configuration mismatch Description Configuration mismatch between the Anybus adapter and the connecting PROFINET controller in slot arg Consequences The Anybus adapter will indicate a diagnostic error and no communicat...

Page 387: ...Recommended actions Specify a valid IP address in the network configuration Restart the controller 71455 EtherNet IP connection type unknown Description The I O configuration is invalid The unit type arg has an invalid unknown connection type arg The connection type must be one of the following MULTICAST POINT2POINT Consequences This unit type has been rejected Recommended actions Correct the conn...

Page 388: ...for EtherNet IP Description The subnet mask arg for the EtherNet IP network is illegal Consequences No communication on the EtherNet IP network is possible Recommended actions Correct the subnet mask in the EtherNet IP network configuration Restart the controller 71463 Illegal address for EtherNet IP network Description The EtherNet IP address arg is reserved Consequences No communication on the E...

Page 389: ...ctions Correct the configuration assembly for the adapter in the I O configuration 71480 Adapter occupied by another scanner Description It is not possible to connect to the adapter arg because it already has an active connection Consequences No communication with the adapter arg is possible as long as the adapter is occupied by another scanner Recommended actions Release the connection from the o...

Page 390: ... configuration 71489 PROFINET internal device configuration warning Description A PROFINET controller has established a connection with the PROFINET internal device on the arg network The connecting PROFINET controller and the internal PROFINET device slot configuration differs The internal PROFINET device is currently configured with the following modules Slot 1 DI arg bytes Slot 2 DO arg bytes C...

Page 391: ...ded actions Configure a new system with the PROFINET controller device option or remove the I O device arg from the I O configuration 71498 PROFINET network configuration changed Description I O configuration for the network arg have been changed by an external configuration tool or a connecting controller The following values have been changed Station name arg 71499 I O signals in cross connectio...

Page 392: ...ller 71505 Device command syntax error Description Could not send device command to I O device arg because there is a syntax error in the command path string Device command name arg The syntax error Missing comma Consequences The device command was not sent Recommended actions Correct the device command path string 71506 Device command syntax error Description Could not send device command to I O ...

Page 393: ...g Consequences The device command was not sent Recommended actions Check the device command syntax Make sure that the network cable is connected to the controller Make sure the I O device has is correctly powered Make sure the cabling to the I O device is correctly connected 71514 Device command connection error Description Could not send device command arg to the I O device arg because no active ...

Page 394: ...nown alarm Description The I O device arg has reported an unknown alarm in slot arg Use I O device specific documentation for explanation on the alarm code Alarm code arg 71525 PROFINET I O device diagnostics Description The I O device arg has reported diagnostic data in slot arg Use I O device specific documentation for more explanation on the diagnostic data arg 71526 PROFINET I O device unknown...

Page 395: ...32 The gateway address is missing Description The destination address arg on arg is defined but no gateway address is defined Consequences The destination address will not be used since the gateway address is missing Recommended actions Specify a gateway address to be used in conjunction with the destination address Or Remove destination address definition 71533 Invalid configuration size for Ethe...

Page 396: ...al Safe Level arg This I O signal has been rejected Recommended actions Correct the Signal Safe Level for the I O signal 71541 Network auto configuration scan successful Description The network auto configuration operation scan on network arg was successful Recommended actions View the information in the Event log 71542 Network auto configuration scan not successful Description The network auto co...

Page 397: ...vel arg I O signals with overlapping device mapping must have the same value on the Signal Safe Level parameter ActionAtSysRestart Consequences The I O signal arg has been rejected and no functions depending on it will work Recommended actions Correct the Signal Safe Level definitions for the overlapping I O signals in the I O configuration 71550 Overlapping I O signals with differing default valu...

Page 398: ...figuration has been rejected Recommended actions Change the signal type or transfer another signal 71557 Signal transfer was defined but no internal device was found Description The signal arg is being transferred but no internal device was found Recommended actions Make sure the device is defined configured before restarting the controller 71558 Transfer signals overlap Description The signal arg...

Page 399: ...ption The signal arg has both the TransferFromDevice and TransferToDevice attribute Consequences The configuration has been rejected Recommended actions Correct the configuration 71567 Signal transfer without offset Description The signal arg is being transferred to from a device but is missing the offset attribute Consequences The configuration has been rejected Recommended actions Correct the co...

Page 400: ...rg is of wrong type Consequences Some I O signals might not be possible to use Probable causes The module type used in slot arg may be of wrong type or of a different version compared to the actual hardware on the I O device Recommended actions Update the PROFINET configuration file to match the hardware Check the I O device 71574 PROFINET configuration mismatch Description The I O device arg repo...

Page 401: ...Consequences Some I O signals might not be possible to use Probable causes The submodule in subslot arg in slot arg on device arg demands maintenance Recommended actions Check the device diagnostic data for additional diagnostic information Consult the device vendor for additional information 71580 Submodule has diagnostic information available Description The submodule in subslot arg in slot arg ...

Page 402: ... in subslot arg in slot arg on device arg is of wrong type Consequences Some I O signals might not be possible to use Probable causes The submodule in subslot arg in slot arg on device arg is of wrong type Recommended actions Update the PROFINET configuration file to match the hardware Check the I O device 71586 Submodule is missing Description The submodule in subslot arg in slot arg on device ar...

Page 403: ...device arg that does not fulfill the requirements for the action Consequences The configuration has been rejected Probable causes Transfer to from a safety slot Transfer from a slot with input size 0 and Transfer to a slot with output size 0 Recommended actions Make sure that neither of the probable causes are true When using RobotStudio only internal devices that fulfill the requirements are show...

Page 404: ...arg Recommended actions Check the configuration 71599 Mount permission denied Description Permission was denied to mount device on remote host arg Protocol arg Recommended actions Check the username and password 71600 Authentication not supported by remote host Description User and password authentication is currently required when mounting a device on a remote host using SFTP Remote host arg Prot...

Page 405: ...s ON button on the control module 90203 Enabling Device open Description Only one of the two enabling device chains was opened Consequences The system goes to status SYS HALT Probable causes The FlexPendant enabling device may be faulty or incorrectly connected The FlexPendant and its enabling device is described in the Trouble Shooting Manual IRC5 Recommended actions Check the FlexPendant cable a...

Page 406: ...otors ON mode only The run chain is described in the Trouble Shooting Manual and Circuit Diagram Recommended actions Locate the switch reset it and restart the controller Check cables and connections Check the external contactor auxiliary contacts If used check any PLC equipment controlling the external contactor 90211 Two channel fault Enable Chain Description A switch in only one of the two enab...

Page 407: ...commended actions Locate the switch reset it and restart the controller 90216 Enabling device active in Auto mode Description The system has detected that the enabling device has been pressed for more than 3 seconds in Automatic operating mode Consequences The system goes to status Guard Stop Recommended actions Release the enabling device Switch to Manual mode 90217 Limit Switch open DRV2 Descrip...

Page 408: ...onflict Description Only one of the two Emergency Stop chains was opened Consequences The system goes to status SYS HALT Probable causes 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 Recommended actions Check cables and connections Check o...

Page 409: ...t working correctly Recommended actions Isolate the Emergency Stop button causing the conflict Check the contact pair Make sure all connections are tight Replace the button if required 90232 Delayed Auto Stop due to circuit imbalance Description The system has detected an imbalance in the two parallel Auto Stop circuits Consequences The system goes to status Guard Stop after approximately 1 sec Pr...

Page 410: ...quences The system goes to status Guard Stop after approximately 1 sec Probable causes The contact pair in any of the safety devices connected to the Superior Stop circuit is not working correctly Recommended actions Isolate the safety device causing the conflict Make sure the device used is a two channel device Check the contact pair Make sure all connections are tight Replace the device if requi...

Page 411: ...ble causes A failure of the motor contactor auxiliary contacts or the supply to these Recommended actions Check cables and connections Check the function of the auxiliary contacts 90249 Motor Contactor conflict DRV3 Description Only one of the two motor contactors for drive system 3 has acknowledged the activation order Consequences The system goes to status SYS HALT Probable causes A failure of t...

Page 412: ... actions Wait until the overheated motor has cooled down before ordering Motors On again 90258 Motor temperature high DRV4 Description Over temperature in manipulator motor Make sure to let the motor cool down before ordering Motors On again Recommended actions Wait until the overheated motor has cooled down before ordering Motors On again If optional air filter is used check if it is clogged and ...

Page 413: ...ns Check drive module software options Install a system with correct Safety Controller option Install a Safety Controller of the correct type 90269 SC arg Motor Calibration Data Error Description No calibration data has been downloaded to Safety Controller SC on drive module arg or erroneous data Recommended actions Download motor calibration data to Safety Controller SC 90270 System failure durin...

Page 414: ... contactor unit The fan or the drive module power supply may be faulty Recommended actions Make sure the fan cable is correctly connected Make sure the fan is free to rotate and that the air flow is not obstructed Make sure the drive module power supply output and input voltages are within specified limits as detailed in the Trouble shooting manual Replace any faulty unit 90308 Motor cooling fan m...

Page 415: ... Probable causes A fault probably a software fault has been detected by any of the units supervised by the Enable 1 circuit Recommended actions Attempt restarting by pressing the Motors ON button If restarting is IMPOSSIBLE it indicates a possible hardware fault If restarting is POSSIBLE it indicates a software fault In such case contact your local ABB representative Determine which unit is faulty...

Page 416: ...bably a software fault has been detected by any of the units supervised by the Enable 2 circuit Recommended actions Attempt restarting by pressing the Motors ON button If restarting is IMPOSSIBLE it indicates a hardware fault in safety system axis computer If restarting is POSSIBLE it indicates a software fault In such case contact your local ABB representative Determine which unit is faulty by ch...

Page 417: ... safety configuration is correct Check for configuration error Download motor calibration values Check if axis 4 or 6 is configured as independent if YES check that the EPS configuration is configured likewise 90454 SC arg Servo Lag Limit exceeded Description Safety Controller SC arg detected a too big difference between the ordered and actual position for mechanical unit arg on axis arg Recommend...

Page 418: ...ion for Safety Controller SC arg Recommended actions Restart robot controller Reinstall system 90462 SC arg Calibration Offset not found Description Failed to retrieve motor calibration offsets for Safety Controller SC arg Recommended actions Download new calibration offsets to the SC 90463 SC arg safety configuration downloaded Description Download of safety configuration was successful for Safet...

Page 419: ... synchronization 90472 SC arg New safety configuration Description Safety Controller SC arg has received a new safety configuration A new PIN code is needed to activate Recommended actions Log in as a user with safety configuration grants Enter new PIN Code for the Safety Controller in the Control Panel 90473 SC arg Dual Computer mismatch Description Safety Controller SC arg have had conflicting v...

Page 420: ...sed additional axis or download a safety configuration without supervision of the additional axis 90480 SC arg SST violation Description Safe Stand Still SST arg in Safety Controller SC is violated on mechanical unit arg axis arg Recommended actions Verify RAPID program Verify process equipment Check that movement is not ongoing when SST is active Check previous event messages 90481 SC arg OVR act...

Page 421: ...her a system reset has been performed or it s the first startup of SC Recommended actions Download a configuration to SC arg 90490 SC arg OVR Speed exceeded Description Override OVR Speed limit exceeded on mechanical unit arg Probable causes If Override OVR is active then OVR speed limitations will be active Recommended actions Decrease speed Deactivate OVR 90491 SC arg Override active during star...

Page 422: ...by the safety controller for drive module arg The cause was arg Consequences The safety controller will stop all robot movements Probable causes The square sum of the measured positions exceeded the configured max The square sum of the measured positions was below the configured minimum value Too high acceleration was detected in the resolver input Recommended actions Check the configured square s...

Page 423: ...oo slow deceleration was detected during a Category 1 stop in the safety controller for drive module arg Consequences The Category 1 stop is automatically changed to a Category 0 stop Recommended actions Usually no actions are necessary If this happens frequently check the Application manual for mechanical units configuration For external axes change the parameter value for Brake ramp in the safet...

Page 424: ... the safety controller will stop all robot movements Probable causes TCP speed too high Elbow speed too high Tool speed at point 1 too high Tool speed at point 2 too high Tool speed at point 3 too high Tool speed at point 4 too high Tool speed at point 5 too high Tool speed at point 6 too high Tool speed at point 7 too high Tool speed at point 8 too high Robot wrist speed too high TCP speed too lo...

Page 425: ...troller will stop all robot movements No full speed operation is possible until the mismatch has ceased Probable causes One or more axes points or volumes are close to a zone or range border Recommended actions In manual mode jog away from the zone or range border 90521 Safety Controller Brake Test violation Description Movement detected during Brake test for drive module arg axis arg Probable cau...

Page 426: ...l robot movements Probable causes The orientation of the tool was outside the configured bounds while Tool Orientation supervision was active Recommended actions Switch to manual mode and jog the robot so that the tool orientation does not violate the configured bounds 90529 Safety Controller axis Position violation Description Axis position supervision arg in the safety controller for drive modul...

Page 427: ...om the external power supply contactors was incorrect Consequences The external supply output will remain in its old state Recommended actions Check the connections to the external power supply 90537 Missing Sync request Description The synchronization switch is pressed without a synchronization request being sent to the Safety Controller Consequences No synchronization will be done Recommended ac...

Page 428: ...r more mechanical units were temporarily disabled during an upgrade a new restart with all mechanical units enabled should be sufficient 90600 Invalid SiosCfg tag Description The SiosCfg tag on line arg is invalid Consequences The system will stop all robot movements Probable causes The safety configuration has not been created using RobotStudio Recommended actions Update the safety configuration ...

Page 429: ...robable causes The safety configuration has not been created using RobotStudio Recommended actions Update the safety configuration 90608 Could not create network instance Description Could not create network arg instance It already exists Consequences The system will stop all robot movements Probable causes The safety configuration has not been created using RobotStudio Recommended actions Update ...

Page 430: ...tions Update the safety configuration 90615 Could not attach device to net Description Attaching device arg to net arg failed Consequences The system will stop all robot movements Probable causes The safety configuration has not been created using RobotStudio Recommended actions Update the safety configuration 90616 Could not find device Description Could not find device arg Consequences The syste...

Page 431: ... The safety configuration has not been created using RobotStudio Recommended actions Update the safety configuration 90623 Signal direction invalid in device mapping Description Device arg signal arg direction is invalid Consequences The system will stop all robot movements Probable causes The safety configuration has not been created using RobotStudio Recommended actions Update the safety configu...

Page 432: ...onfiguration 90630 Signal default value empty or out of range Description Signal arg default value is empty or out of range to the signal type Consequences The system will stop all robot movements Probable causes The safety configuration has not been created using RobotStudio Recommended actions Update the safety configuration 90631 Signal type is invalid Description Signal arg type is invalid Con...

Page 433: ...g failed Device I O size is arg Consequences The system will stop all robot movements Probable causes The safety configuration has not been created using RobotStudio Recommended actions Update the safety configuration 90638 Signal overlaps other signal Description Signal arg arg mapping to device arg failed Bits already mapped Consequences The system will stop all robot movements Probable causes T...

Page 434: ... all robot movements Probable causes The safety configuration has not been created using RobotStudio Recommended actions Update the safety configuration 90646 FuncIOMapping attribute missing Description FuncIOMapping arg attribute arg is missing on line arg Consequences The system will stop all robot movements Probable causes The safety configuration has not been created using RobotStudio Recommen...

Page 435: ...l robot movements Probable causes Restore from an unsupported safety configuration Recommended actions Update the safety configuration 90655 Invalid value of the encoding attribute Description Device arg signal arg map encoding is invalid Consequences The system will stop all robot movements Probable causes RobotStudio version is too old to handle the expected version Recommended actions Update Ro...

Page 436: ...cIO must also be specified Consequences The system will stop all robot movements Probable causes The safety configuration has not been created using RobotStudio Recommended actions Update the safety configuration 90665 New safety configuration accepted Description The safety configuration was successfully updated 90666 Safety Controller configuration version not supported Description The safety co...

Page 437: ...tion The TPU has been reattached to the robot controller The functionality of the emergency stop button must be verified by the operator 90673 Repeating detach of TPU request detected Description Repeating detach of TPU request detected Consequences The system will stop all robot movements Probable causes The operator has requested to detach the TPU within 5 seconds of the end of the previous deta...

Page 438: ...e safety configuration Consequences The system will stop all robot movements Probable causes The safety configuration has not been created using RobotStudio Recommended actions Update the safety configuration 90687 Safety configuration item attribute missing Description Configuration item arg missing on line arg Consequences The system will stop all robot movements Probable causes The safety confi...

Page 439: ... all robot movements Probable causes The safety configuration has not been created using RobotStudio Recommended actions Update the safety configuration 90694 Signal types differ Description The operation signal type arg differs from the operator signal type arg on line arg Consequences The system will stop all robot movements Probable causes The safety configuration has not been created using Rob...

Page 440: ...The system will stop all robot movements Probable causes Internal error Recommended actions Check for other event messages Restart the robot controller 90701 arg stop failed Description The Safety Network Controller arg was unable to stop Consequences The system will stop all robot movements Communication with the network is not possible Probable causes Internal error Recommended actions Check for...

Page 441: ...ns Remove or rename the extra device configuration 90721 Module already configured Description Network arg device arg module arg is already configured on device arg Consequences The system will stop all robot movements Probable causes User has used the same module name twice Recommended actions Remove or rename the extra module configuration 90722 Slot occupied by other module Description Network ...

Page 442: ...scription An external CIP Safety Scanner is attempting to connect to the CIP Safety Adapter of this robot controller with an unsupported electronic key Consequences Communication with the external CIP Safety Scanner will not be possible Probable causes The external CIP Safety Scanner has an invalid value for parameter arg Recommended actions Check the electronic key configuration of the external C...

Page 443: ...Adapter and disable it in the external Scanner as well 90777 CIP Safety Configuration Mismatch Size Mismatch Description The configuration of EterNet IP Device arg or its EterNet IP IO connections in I O System Configuration does not match the corresponding configuration in Visual SafeMove Consequences CIP Safety Communication with arg may not work properly The CIP Safety Configuration Signature S...

Page 444: ...oller Verify that the indicated signal to the Safety Controller is stable 90790 arg setup failed Description The arg was unable to setup properly Consequences arg is not running Probable causes No communication with the PROFIsafe host Bad parameter values Recommended actions Check parameters and connection to the PROFIsafe host Try again 90791 arg start failed Description The arg was unable to sta...

Page 445: ... restart the system 90802 Lock Information Error Description The lock information in the safety configuration file arg does not match the lock information stored in the Safety Controller cause arg Checksum safety configuration file arg Checksum Safety Controller arg Consequences No full speed operation is possible Probable causes The safety configuration file contains LockInfo but has not been loc...

Page 446: ... robot type that is supported by the Safety Controller 90809 Safety Controller set to default configuration Description The safety controller configuration failed validation checks Consequences The safety controller is running with the default configuration Probable causes User misconfiguration Recommended actions Correct the safety controller configuration 90810 Safety Controller hardware diagnos...

Page 447: ...o the safety controller are properly attached Restart the system and check if the error remains If the error remains replace the Safety Controller board 90816 Invalid Mode Selector input Description The Mode Selector has an invalid number of set inputs arg Consequences No operation will be possible until the fault has been corrected and the system have been restarted Probable causes This may be ca...

Page 448: ...er to see if the error remains If the error remains consider replacing the Safety Controller hardware 90832 File arg not found Description The XML file arg which is used by the safety controller was not found Consequences No operation will be possible until the fault has been corrected and the system has been restarted Probable causes Restore of a backup from a system with a different configuratio...

Page 449: ...that are not supported by the installed system options Recommended actions Remove the instance arg in the safety configuration and download it to the controller or install the required option arg 90852 Empty Safety Configuration Description The safety configuration is empty Consequences No supervision of the robot will be performed Recommended actions Use the configurator to add safety supervision...

Page 450: ...rg Recommended actions Check the signal s that failed arg arg Recovery You might want to handle errno arg in your error handler 110005 Process Supervision Phase END_MAIN Description Task arg Supervision failed for process phase END_MAIN arg Recommended actions Check the signal s that failed arg arg Recovery You might want to handle errno arg in your error handler 110006 Process Supervision Phase P...

Page 451: ...not performed Recommended actions Remove the logical instructions that cause the delay or check that the last application movement instruction indicates that it is the last one 110014 Option Optical Tracking or Weldguide is missing Description Task arg The optional argument Track may not be used without the option Optical Tracking or Weldguide or Sensor Interface arg Recommended actions Remove the...

Page 452: ... or end 3 Increase the length of the process movements 110019 Option Optical Tracking is missing Description Task arg The optional argument FillTrBuff may not be used without the option Optical Tracking or Weldguide or Sensor Interface arg Recommended actions Remove the optional argument Track or order a RobotWare license that depending on your equipment contains the option Optical Tracking or Wel...

Page 453: ...ine for CAP_STOP in your RAPID code 110034 Skip without process finished Description The robot has reached the end of the distance it was requested to move without active application process Recommended actions Recovery You might want to handle errno arg in your error handler 110035 Process start position reached Description Task arg The look ahead buffer for tracking is filled and the robot TCP h...

Page 454: ...ctions Correct the component length 110103 Invalid weave cycle time Description Task arg The weave cycle time used is invalid 0 100 s Recommended actions Correct the component cycle_time 110104 Invalid weave width Description Task arg The weave width used is invalid 0 1 m Recommended actions Correct the component width 110105 Invalid weave height Description Task arg The weave height used is inval...

Page 455: ...weave sync left value is invalid 0 100 Recommended actions Correct the component ptrn_sync_left in capweavedata 110116 Invalid weave sync right Description Task arg The weave sync right value is invalid 0 100 Recommended actions Correct the component ptrn_sync_right in capweavedata 110117 Weave bias not allowed Description Task arg It is not allowed to use bias for shapes other than Zig zag 1 Reco...

Page 456: ... error occurred Description Task arg arg Recommended actions Check the Internal Log 110133 Wrong path level Description Task arg arg This instruction is not allowed on this path level arg Recommended actions Use RestoPath to change to path level 0 110134 Change from fine to z0 Description Task arg arg A fine point is not allowed in the middle of a Process sequence The zone data was changed from fi...

Page 457: ...f admitted subscriptions arg Consequences The subscription was not set up Recommended actions Reduce the number of sensor variable subscriptions IVarValue 110160 Track error Description Task arg Track error arg Recommended actions Check joint definition Recovery arg 110161 Track start error Description Task arg Track start error arg Recommended actions Check joint definition in captrackdata Recove...

Page 458: ...alarm from sensor Description Task arg The sensor temperature is out of admitted bounds arg 110174 Value to sensor out of range Description Task arg The value sent to the sensor is out of bounds arg 110175 Camera check failed Description Task arg It was not possible to perform a sensor camera check arg 110176 Sensor communication time out Description Task arg Timeout occured in communication with ...

Page 459: ...ssibly switch between the right and left lap joint definitions 110180 Sensor Calibration Data updated Description The sensor calibration data for arg arg and arg are updated Task arg Recommended actions If you use CAP without RW Arc you have to rerun the RAPID instruction CapLATRSetup arg arg arg SensorFreq xxx to make CAP use the updated sensor calibration data 110181 Track max incremental corr e...

Page 460: ...llowed Recommended actions Check the program sequence 110206 Application error Description Task arg Missing I O signal arg Recommended actions Check the I O configuration 110207 Application error Description Task arg Process number arg of application arg was already installed Recommended actions 110208 Application error Description Task arg Number arg is not a valid start number Recommended action...

Page 461: ...number of processes are limited to 4 110220 Application error Description Task arg The user data variable choice does not exist arg arg 110221 Application error Description Task arg The user data variable has incorrect type arg arg 110222 Application error Description Task arg The internal process data type lacks daintdata as first element arg arg Recommended actions Check the program 110223 Appli...

Page 462: ...nal reference is not valid no AliasIO has been done or the signal is write protected in the EIO configuration Recommended actions Check the EIO configuration 110303 Parameter error Description Task arg The optional signals arg and arg must be used together See specification in arg arg Recommended actions Check the program 110304 Parameter error Description Task arg The parameter arg of the instruc...

Page 463: ... activate deactivate Description Task arg Error in arg This daproc is not possible to activate deactivate arg Recommended actions Check index in the daproc descriptor 110401 Gas supervision Description Task arg arg Gas supervision signal not set at start of welding Recommended actions Check the gas equipment Recovery You might want to handle errno arg in your error handler 110402 Water supervision...

Page 464: ...dle errno arg in your error handler 110409 Schedule strobe undefined Description Task arg arg Schedule strobe undefined Recommended actions Define a weld schedule strobe input Recovery You might want to handle errno arg in your error handler 110410 Schedule transfer error Description Task arg arg It was not possible to transfer the schedule Probable causes The schedule port was busy with previous ...

Page 465: ...ption Task arg arg Gas supervision signal went low during welding Seam name arg Time from weld start arg min Recommended actions Check the gas equipment Recovery You might want to handle errno arg in your error handler 110422 Water supervision Description Task arg arg Water supervision signal went low during welding Seam name arg Time from weld start arg Recommended actions Check the cooling water...

Page 466: ...tart arg Recommended actions Check the welding equipment Recovery You might want to handle errno arg in your error handler 110429 Arc ignition failed Description Task arg arg Seam name arg Time from weld start arg Recommended actions Check the welding equipment Recovery You might want to handle errno arg in your error handler 110430 Arc fill ignition failed Description Task arg arg Arc ignition fa...

Page 467: ...ing Seam name arg Time from weld start arg Recommended actions Recovery You might want to handle errno arg in your error handler 110438 User defined signal supervision Description Task arg arg User defined signal defined by USERIO4 went low during welding Seam name arg Time from weld start arg Recommended actions Recovery You might want to handle errno arg in your error handler 110439 User defined...

Page 468: ...rt arg 110449 Current supervision Description Task arg arg Current supervision signal went low during welding Seam name arg Time from weld start arg 110450 Wirefeed supervision Description Task arg arg Wirefeed supervision signal went low during welding Seam name arg Time from weld start arg 110451 Torch supervision Description Task arg arg Torch supervision signal went low during welding Seam nam...

Page 469: ...71 Undefined Signal Error Description arg Failing signal during weld phase arg could not be determined 110472 Configuration Parameter Error Description Task arg PROC Configuration Parameter argarg is a required parameter Recommended actions Check the installation of PROC domain parameters 110473 Weld Equipment Error Description Task arg arg Error arg format ErrorCode ErrorText Recommended actions ...

Page 470: ...ed actions See Weld Data Monitor elog for more information 110480 Arc Welding Task Busy Description Task arg arg Serious File System problem encountered Recommended actions The Controller must be restarted to solve the problem 110481 System Retry limit Description Task arg arg Max number of retries has been reached on system level System Misc NoOfRetry arg Recommended actions Increase parameter va...

Page 471: ...k buffer size b la v 0 5 s internal delay Recommended actions Check sensor mounting sensor setup travel speed and trackdata Recovery You might want to handle errno arg in your error handler 110501 Track start error Description Task arg arg Not any valid correction data from the sensor while executing the current ArcX instruction Recommended actions Check sensor setup and trackdata Recovery You mig...

Page 472: ...r signal arg to avoid this message 110508 Wirestick supervision Description Task arg arg Wirestick supervision signal set at end of welding Recommended actions Check if the wire got stuck at the object Recovery You might want to handle errno arg in your errorhandler 110509 Weld Repair notification Description Welding was interrupted in task arg at seam arg An attempt to re weld the interrupted sea...

Page 473: ...tion Task arg Fronius Tracking Equipment is activated Version arg Last modified arg Consequences Seamtracking will be possible 110518 Fronius Tracking Equipment Description Task arg Fronius Tracking Equipment is deactivated Version arg Last modified arg Consequences Seamtracking will not be possible Probable causes Controller option 1553 Tracking Interface is missing Recommended actions Install th...

Page 474: ... than zero 0 110606 Gun not activated Description Task arg The servo gun arg is not activated Consequences It will not be possible to run any spot instructions until the servo gun is activated Probable causes The servo gun has not been activated before trying to run this instruction Recommended actions Activate the servo gun arg Use the instruction ActUnit to activate the servo gun or set the Acti...

Page 475: ...nfiguration parameters for the servo gun 2 Run the service routine ManualGunSearch to search the system for servo guns and to update the gun name parameter in gundata 110611 Invalid data value Description Task arg Invalid value of data arg Allowed values are arg to arg Current value is arg Consequences It will not be possible to run this instruction until this data is changed Probable causes An in...

Page 476: ...is changed Recommended actions Change the value of the pre closing time parameter in gundata arg 110619 Invalid gun pre equalizing time Description Task arg Invalid value of the pre equalizing time in gundata arg Allowed interval 0 to max arg s Current value arg s Current gun arg Consequences It will not be possible to run any spot instructions until this value is changed Recommended actions Chang...

Page 477: ... program number parameter in spotdata or check that the correct value is used as targetid or spotid 110625 Invalid simulation type Description Task arg Invalid value of the simulation type parameter in simdata Allowed values are 0 to arg Current value arg Consequences It will not be possible to run any spot instructions until this value is changed Recommended actions Change the value of the simula...

Page 478: ...ontroller reported an error and stopped the weld sequence Recommended actions 1 Check the event log for additional weld timer error logs if Bosch 2 Check the weld controller for any errors 110632 Tip wear ratio not allowed Description Task arg Tip wear ratio only allowed when using the ReCalcTcp method Consequences It will not be possible to run this instruction Recommended actions Check that the ...

Page 479: ...time Current robtarget arg Current weld program arg Consequences The weld will not start until the valid weld program signal is set by the weld controller Recommended actions 1 Check that the weld program valid signal is set in the weld controlller 2 Check that the configured program valid timeout time is big enough 110639 Configuration error Description Task arg Process configuration data can not...

Page 480: ...d Recommended actions If a new reference has to be done because the reference position has been moved the RefChange switch should be used instead 110645 Instruction error Description Task arg Software equalizing error The instructions SpotML and SpotMJ can not be used with the software equalizing functionality activated Consequences It is not possible to run this instruction with software equalizi...

Page 481: ...ed in the correct position Recommended actions 1 Check that the correct tips are mounted on the gun 2 Check that the reference plate is in the correct position or check that sensor is working properly 3 Increase the MeasureWearL movein distance parameter Configuration Process Spot SoftWare Equalizing 110651 Unexpected tip size after change Description Task arg New tips with unexpected size the siz...

Page 482: ... wear out of range the tip wear exceeds the configured tip wear supervision value Actual tip wear moveable tip arg mm Tip wear tolerance arg to arg mm Current gun arg Probable causes The current tip wear exceeds the maximum allowed value defined in the tip wear supervision configuration data Configuration Process Spot Gun Equipment Tip wear supervision value Recommended actions Check that the maxi...

Page 483: ... latest version supplied in this RobotWare release 2 Load the correct ed module s and Reset RAPID 110661 Signal label error Description Task arg The SignalLabel name arg is not defined in the I O configuration Probable causes The SignalLabel name is not defined in the I O configuration Recommended actions 1 Check that the SignalLabel is defined in the I O configuration 2 Add the missing SignalLabe...

Page 484: ...ption Task arg arg The current plate thickness error was ignored Current gun arg argarg Probable causes The operator probably ignored the thickness error Recommended actions Check that it was OK to ignore the thickness error 110669 Gun index number out of range Description Task arg The gun number arg is not a valid gun number the gun index is out of range Allowed values are arg to max arg Conseque...

Page 485: ... the tool is less than min configured value and or the center of gravity is not defined correctly arg arg arg Consequences It will not be possible run this instruction until a correctly defined tool is used Probable causes LoadIdentify for this tool has not been done Recommended actions Check that the tool is correctly defined before running this routine Run the LoadIdentify routine 110674 Gun typ...

Page 486: ...t the correct name is used in the setup routine or in the I O configuration 110680 Max gun force exceeded Description Task arg The externally ordered gun force is too high and will be ignored Ordered force arg N Current force arg N Maximum force arg N Consequences Execution is stopped Probable causes The ordered gun force is too high and exceeds the maximum allowed force for this gun Recommended a...

Page 487: ...gun equipment configuration and restart the system Configuration Process Spot Gun Equipment 110686 Invalid deflection force Description Task arg Invalid value of the deflection force parameter in gundata arg Allowed interval 0 to max arg arg Current value arg arg Current gun arg Consequences It will not be possible to run any spot instructions until this value is changed Probable causes 1 Used def...

Page 488: ...e program check program selection select proper program 110703 No valid weld program no schedule programmed Description Task arg arg wrong program selected invalid spot selection invalid parameters in started program Recommended actions Check program selection check spot selection check value range of the following parameters power unit number electrode stepper number program number 110704 The bat...

Page 489: ...s measured in KUR mode Recommended actions Check connectors and cables 110713 No current weld 1 to 3 Description Task arg arg Electrodes not closed no electrical contact at the point to be welded contamination of sheets use of sealant Recommended actions Check closing mechanisms robot machine check position and pressure of electrodes clean sheets check conductivity 110714 Current is too low weld 1...

Page 490: ...mmended actions Check setting at Operation Modify Programming Welding parameters Time monitoring 110719 Bosch IO signal error Description Task arg It is not possible to read the timer status signal the Bosch timer I O unit is lost Consequences It will not possible to get the timer status Probable causes The power to the Bosch IO unit is lost or the cable is damaged Recommended actions 1 Check the ...

Page 491: ...e inside the process cabinet or check process cabinet cooling 110728 IO bus fault Description Task arg arg The serial IO module has signalled a bus fault to the timer module Recommended actions Replace IO module or timer 110729 Electrode life has expired end of stepper Description Task arg arg The specified electrode has reached the Electrode life Expired End of stepper condition Recommended actio...

Page 492: ...be possible to access the timer from the FlexPendant Probable causes Faulty configuration or disconnected hardware Recommended actions Check configuration and that the communication cable are connected 110791 Faulty configuration Description Number of configured weld timers are arg The configuration file s for Bosch weld timer interface does not contain all expected data Consequences It will not b...

Page 493: ...or fl2_delay in equipdata is out of limits arg 110809 Dispense Error Description Task arg arg Value for ref_speed in equipdata is out of limits arg 110810 Dispense Error Description Task arg arg Value for equip_no in beaddata is out of limits arg 110811 Dispense Error Description Task arg arg Unexpected Stop Stopped while dispensing was active arg arg 110812 Dispense Error Description Task arg arg...

Page 494: ... is out of limits arg 110822 Dispense Error Description Task arg arg Value for z_offset in beaddata is out of limits arg 110823 Dispense Error Description Task arg arg Size of triggdata array exceeds upper limit 10 arg 111000 Itemsource exists Description Itemsource arg already exists Two itemsources may not have the same name Recommended actions Check itemsource name at arg Recovery arg 111001 No...

Page 495: ...11008 Too many item targets Description Too many item targets pushed to itemsource arg arg arg Recommended actions Instruction arg Recovery arg 111009 Conveyor eio init error Description Error in the initialisation of the I O signals for itemsource arg for conveyor arg Recommended actions Instruction arg Recovery arg 111010 Conveyor does not exist Description Error for itemsource arg The conveyor ...

Page 496: ... system may not run as expected Recommended actions Check network connection Check state of remote system Check robot program for infinite loops 111100 Work object buffer full Description Too many conveyor strobes stored in buffer for itemsource arg In queue index arg Out queue index arg 111101 Item target buffer full Description Item target buffer full for itemsource arg Item tag arg Scene number...

Page 497: ...commended actions Check the position generation frequency and the network connections 111109 Failed to open signal Description An error occured when opening Position Generator signal arg for itemsource arg Status arg Recommended actions Check the Position Generator signal name 111110 Failed to open signal Description An error occured when opening Trig signal arg for itemsource arg Status arg Recom...

Page 498: ... connection Check state of remote system Check robot program for infinite loops 111118 Conveyor moving with negative speed Description Conveyor arg is moving with negative speed Measured speed arg mm s Consequences Item detection may fail Probable causes 1 Conveyor is moving in reversed direction 2 Encoder is not connected properly Recommended actions 1 Check the conveyor control 2 Check the encod...

Page 499: ...rg does not match tasklist in partdata arg in task arg Recommended actions Check and change the tasklists so they match 111413 Invalid task name Description Taskname arg in partdata is invalid 111414 GAP Execution Error Description The tasklist must include this task arg 111415 GAP Execution Error Description Task arg Tasks could not be cross checked Station arg 111416 GAP Execution Error Descript...

Page 500: ... arg Probable causes The configured signal run_part_signal_in or run_menu_signal_in wasn t set to 0 within configured timeout arg seconds after the configured signal run_ack_out was set to 1 Recommended actions Make sure to reset configured signal run_part_signal_in or run_menu_signal_in after configured signal run_ack_out is set to 1 111432 Not valid plc code in task Description Not valid plc cod...

Page 501: ... program pointer to the main routine and restart program execution 111510 BullsEye Error Description An error occured while reading data from the stored reference data module 111511 BullsEye Data Saved Description The reference data has been saved successfully 111512 BullsEye Error Description An error occured while saving the reference data 111513 BullsEye Tool Initialized Description The tool ar...

Page 502: ...1 BullsEye RangeCheck Failed Description No solution could be found within acceptable Joint Limits and Singularity checks A Twist of arg and a Tilt of arg was specified Task arg Consequences BullsEye will not be able to evaluate this tool Recommended actions Try a different start position or relocate the BullsEye device If no acceptable position can be found try reducing the requested Tilt and Twi...

Page 503: ...ll not be able to evaluate this tool Recommended actions Execute the BESetupToolJ setup instruction to define the beam position 111529 BullsEye Updated TCP Description The TCP for Tool arg has been updated by BEUpdateTool Task arg New TCP arg Change arg Elapsed Time arg 111530 BullsEye Error Description Beam location could not be determined Tool arg Task arg Consequences BullsEye will not be able ...

Page 504: ...on The TCP for Tool arg has been updated by BECheckTcp Task arg New TCP arg Change arg Elapsed Time arg 111538 BullsEye Debug On Description Debug mode has been turned on Task arg 111539 BullsEye Debug Off Description Debug mode has been turned off Task arg 111540 BullsEye Error Description An error has occurred The cause has not been identified Task arg Recommended actions If problems persists tr...

Page 505: ...et arg The preset limit arg 111558 SmarTac Search Override Description Default search result selected after failed search Manual override selected Search Type Search 1D Search Name arg 111559 SmarTac Result Description Part detected Search Type Part Search 111560 SmarTac Search Override Description Default search result selected No part found during part search Manual override TRUE selected Search...

Page 506: ... to access arg in the PROC configuration Recommended actions Check the PROC configuration file for errors 111606 Production Monitor Error Description Text Resource Error Production Monitor could not access text Index arg File arg Recommended actions Report to ABB 111607 Production Monitor DB Description Creating the tblCycRes table in the WebWare database 111608 DB Table Creation Failed Descriptio...

Page 507: ...620 Production Monitor Mismatch Description The part information for arg has changed in task arg Consequences The reference data stored for this part can no longer be linked to the part program Recommended actions Please delete the reference file to store new data 111621 Production Monitor Error Description The reference data module for part arg is already loaded An attempt will be made to unload ...

Page 508: ...are server 111630 DB Table Created Description The table tblSmtc1D was successfully added to the WebWare database 111631 DB Table Creation Failed Description Failed to create WebWare table tblSmtcPart Consequences Production Monitor will be unable to log data to the database Recommended actions Check the WebWare server 111632 DB Table Created Description The table tblSmtcPart was successfully adde...

Page 509: ...T found 111702 Torch Services Error Description Torch services MechClean configuration error Check PROC cfg domain 111703 Torch Services Error Description Torch services MechClean configuration error Torch Services was unable to find arg arg in PROC configuration 111704 Torch Services Error Description Torch services MechClean configuration error Torch Services tried to access an illegal type arg ...

Page 510: ...O 111718 Torch Services Error Description Torch services MechClean Spray Liquid empty Recommended actions Refill Spray or check sensor 111751 Navigator Configuration Error Description Navigator configuration error IO arg NOT found 111752 Navigator Configuration Error Description Navigator configuration error Navigator was unable to find arg arg in PROC configuration 111753 Navigator Configuration ...

Page 511: ...ription The Prepared for PickMaster option has not been correctly installed in the system Recommended actions Reinstall the system using a proper key containing the Prepared for PickMaster option 111914 Uplink message failed Description The system failed to send an uplink message Status arg Recommended actions Check network connection Check state of remote system 111915 Failed to open Work Object ...

Page 512: ...target in the operation was finished Since the program context cannot be secured next operation will be executed Recommended actions Make sure the tool is empty and cleared since the whole cycle will be executed from beginning An unfinished operation may be finished manually Restart in reduced speed to avoid unexpected behavior 111923 Targets lost after LOST acknowledge Description arg targets wit...

Page 513: ... defined in the I O configuration of the controller Recommended actions Check the controller I O configuration of the signal 111928 Restart job failed Description A job failed to restart on work area arg Consequences The work area has entered a response error state Probable causes Start layer count arg and start product count arg is more than the total number of layers for the job arg Recommended ...

Page 514: ...ruction Recommended actions Use an error handler and do a RETRY on instruction If a arg is used an this error occur often increase the arg Recovery arg 111954 Can not retrieve targets Description Task arg Instruction arg failed Program Ref arg Probable causes There is no target ready when executing instruction No arg or a low value is used on arg in this instruction Recommended actions Use an erro...

Page 515: ...ution is immediately halted Probable causes An instruction function is executed without a valid descriptor The Work Area descriptor has not been fetched correctly or it is a restart after power fail Recommended actions Check manual about how to get valid descriptors for Work Areas 111962 Invalid target handle Description Task arg Instruction arg failed The target handle that is used refer to an ob...

Page 516: ...rmat Description The flow arg failed to request a format with index arg The reply came from Work Area arg Consequences The flow is stopped immediately Probable causes The setup file is corrupted or incomplete Wrong response from IO signals Recommended actions Verify the project setup using PickMaster PC application Look for internal errors 112003 Uplink message failed Description The system failed...

Page 517: ...The program execution is immediately halted Probable causes The project name has not been initiated Recommended actions Check the project name used when starting project 112058 Stop of project ordered during start Description A stop order has been received during startup of project arg Consequences Project arg is not started Probable causes Stop during start of project The stop can be from another...

Page 518: ...ble causes The trigged operation set arg is not configured in the project The trigged combination of product I O value arg and format I O value arg is not configured in the project Status arg Recommended actions Review the project setup Check the product and format selection groups signal values 112151 Incorrect target set Description The target set sent to the pump process arg is not the requeste...

Page 519: ...g the PickMaster PC application 112203 Wrong PickMaster Error Source Value Description The value that was read arg after an event was trigged does not match one or several configured bits in the IO signal arg Consequences The system goes to SYS STOP state Recommended actions Verify the configuration using the PickMaster PC application Verify external equipment generating the signal value 112204 Wr...

Page 520: ...rt value Description Task arg The intermediate part value is not valid The InterMidPart argument must be between 0 and 1 Program Ref arg Consequences The intermediate position is not possible to calculate Probable causes Wrong InterMidPart value Recommended actions Review the InterMidPart for the instruction 112354 Unknown event signal name Description Task arg The event signal name arg is unknown...

Page 521: ...obable causes 1 Stack is empty or 2 Tool center point for Search Tool data Tool configuration is not correctly defined 3 The expected location of the stack is not correct 4 The search stop signal was not triggered correctly Recommended actions If the stack not is empty Check definition of tool center point for Search Tool data Check definition of work object tune frame work area frame and displace...

Page 522: ... is not possible to recover from this error until the faulty signal is corrected Probable causes 1 The signal is unknown in the system If the signal is defined in the RAPID program it must be connected to the configured signal with instruction AliasIO 2 Signal argument is outside allowed limits 3 There is no contact with the IO unit The unit may have been disabled IODisable UNIT1 1 No power to the...

Page 523: ...s and flows are missing Program Ref arg Consequences It is not possible to start or stop flows from the IO interface Project status signal might also be incorrect Probable causes The signals are not and or wrong configured in the IO configuration One reason can be that an old backup is used Recommended actions This message can be ignored if the IO interface is not used 112373 The Requested Work Ar...

Page 524: ...equences It will not be possible to start the Flow arg if it is set in error state Probable causes The recover action is not one of PM_RECOVER_CONTINUE_OPERATION PM_RECOVER_REDO_LAYER PM_RECOVER_NEXT_PALLET or PM_RECOVER_REDO_LAST_PICK Recommended actions Recover arg 112378 Flow is already starting up Description Task arg The flow arg is already starting up Only one call to PmFlowStart is allowed ...

Page 525: ...ry arg 112384 Invalid default height Description Task arg The I O value of signal arg does not correspond to a valid default height Program Ref arg Consequences It was not possible to set the default height Probable causes The I O value of arg does not correspond to a valid default height selection Recommended actions Make sure that arg is set to a proper value before arg is pulsed 112385 Too many...

Page 526: ...g WorkAreas are empty arg arg arg 112397 Flow recover with redo last pick Description The Flow arg will redo last unfinished operation at next flow start Recommended actions Verify that The tool is empty New products can be supplied on arg The reason for the stop is solved 112398 arg Description arg 112399 PickMaster Flow Stopped Immediately Description The Flow arg is stopped immediately Conseque...

Page 527: ...2407 Schedule does not exist Description The schedule arg does not exist in the power source arg in arg Consequences The welding results will not be as expected Recommended actions Make sure that the schedule has been created before using it in a weld instruction 112410 Program memory error EPROM Description The program memory is damaged in unit arg Fault code arg Internal unit arg Recommended act...

Page 528: ... from the DC voltage that supplies it Fault code arg Internal unit arg Consequences The power unit is stopped and cannot be started Recommended actions Turn off the mains power supply to reset the unit If the fault persists send for a service technician 112417 Low battery voltage or power supply Description Unit arg See description corresponding to the internal unit arg WDU Low battery voltage 3 V...

Page 529: ...nsequences The current welding process stops Recommended actions Check the cables If the fault persists send for a service technician 112428 Memory error in battery supplied data memory RAM Description The battery has lost voltage in unit arg Fault code arg Internal unit arg Recommended actions Turn off the mains power supply to reset the unit The welding data unit is reset 112429 Non permitted se...

Page 530: ...cription Program execution does not work in unit arg Fault code arg Internal unit arg Recommended actions Turn off the mains power supply to reset the unit If the fault persists send for a service technician 112438 No water flow Description I O unit arg Error code arg Internal unit arg 112439 Lost contact with TIG card Description I O unit arg Error code arg Internal unit arg 112441 No gas flow De...

Page 531: ...508 WDM Failed to Read WDM_SIGNATURE Description The WDM_SIGNATURE or WDM_SIGNATURE_DATA section of the PROC could not be read Task arg Consequences Weld Data Monitor may be inoperable Recommended actions Please review PROC settings to correct 112509 WDM Failed to Read WDM_TOLERANCE Description The WDM_TOLERANCE section of the PROC could not be read Task arg Consequences Weld Data Monitor may be i...

Page 532: ...and relearn 112516 WDM Data Checksum Error Description Data read from the binary file did not match the expected size Seam Name arg Task arg Consequences Weld Data Monitor is unable to evaluate this weld seam Recommended actions Delete the stored WDM files and relearn 112517 WDM Unknown Error Description An unexpected error occurred in WriteSigData Seam Name arg Task arg Consequences Weld Data Mon...

Page 533: ...g Task arg Measured samples arg Signature samples arg Consequences Weld Data Monitor will be unable to evaluate the data from this seam 112524 WDM Weld End Error Description An unspecified error occurred at the end of the seam Task arg Consequences Weld Data Monitor may be inoperable Recommended actions Please contact your ABB representative 112525 WDM Weld Start Error Description An unspecified e...

Page 534: ...weave frequency to enable Weld Data Monitoring 112536 WDM Weave Change Error Description The weave parameters have changed since learning of seam arg in task arg Consequences No monitoring will occur Recommended actions Please remove the stored signature and relearn with new parameters Or reinstate old parameters 112537 WDM Speed Change Error Description The weld travel speed has changed since lea...

Page 535: ... since learning was finished for seam arg in task arg Consequences No monitoring will occur Recommended actions Please remove the stored signature and relearn with new parameters Or reinstate old parameters 112600 Init of communication interface failed Description Task arg Communication interface could not be initialized Program Ref arg Recommended actions Check communication settings and paramete...

Page 536: ...Normally only the service port is supported Recommended actions Recommended Actions 1 Check cabling between robot controller and camera 2 Check that the LED power and link indicators on the camera are active 3 Use RobotStudio to check that the IP address has been configured correctly 112702 Camera job is not valid Description The camera arg is in running mode but the loaded job is not a valid ABB ...

Page 537: ...arg arg Recommended actions 114810 arg Description arg arg arg arg Recommended actions 114811 arg Description arg arg arg arg Recommended actions 114812 arg Description arg arg arg arg Recommended actions 114813 arg Description arg arg arg arg Recommended actions 114814 arg Description arg arg arg arg Recommended actions Operating manual Troubleshooting IRC5 537 3HAC020738 001 Revision AA Copyrigh...

Page 538: ...uration 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 120005 Attribute value out of allowed range Description Attribute arg on line arg in file arg is out of the allowed range The allowed range is arg arg Consequences The configuration in file will not be installed Probable cause...

Page 539: ... Re edit the configuration file and change the version string according to this layout domain CFG_1 0 version revision 120012 Illegal domain name Description The domain name arg in configuration file arg is illegal Consequences The configuration in file will not be installed Probable causes The domain name may be mistyped or the domain is not installed in the system Recommended actions Re edit the...

Page 540: ...ile 120017 Invalid Rapid Identifier Description The value arg of parameter arg for configuration instance arg is invalid Consequences The configuration in file will not be installed Probable causes The value might be mistyped Recommended actions Correct the value of the parameter so that it complies with the following rules Rules of RAPID identifiers The length must not exceed 16 characters The fi...

Page 541: ... an existing signal 131015 Too many trig events Description The maximum number of trig events 10 between two PaintL instructions is exceeded Task arg Instruction arg Context arg Recommended actions Reduce the number of trig events 131016 Illegal value for signal arg Description An attempt was made to set an illegal value arg for signal arg Consequences Signal will not be set Recommended actions Ch...

Page 542: ...dex file 131052 Failed to get index file data Description Cannot find column number arg Row arg File arg Task arg Context arg Recommended actions Check if column number exists at row in index file 131400 Invalid program mapping index Description Line arg in file arg is invalid Consequences The index will be ignored Recommended actions Check line in file for errors 131401 Program mapping missing co...

Page 543: ...tion The system was unable to communicate with external material change engine on PIB Consequences Material change information will not be updated Recommended actions Check that material change has been installed correctly on PIB Check communcation between main computer and PIB 131700 Maximum negative lag of conveyor reached Description The conveyor is running too fast compared to configured nomin...

Page 544: ...nd main computer Restart the controller 132604 Regained contact with PIB Description Controller has regained contact with the Process Interface Board PIB after watchdog fault 132999 Process error context Description arg arg arg arg arg Probable causes This message is associated with an IPS error and is used to map the problem to TCP position for visualization purposes 133000 IPS Cfg Error Descript...

Page 545: ...found File name must be option lic Could not obtain option arg Reference arg Recommended actions 1 Check that license file exist on license server 133009 IPS License Error Description License code in license file is not correct Could not obtain option arg Reference arg Recommended actions 1 Check that the license file on license server is identical to the original license file 133010 IPS License E...

Page 546: ...en a device is disabled it is not possible to operate it Recommended actions 1 Enable named device and set a new command to it 2 Check if IPS config is set up to disable the named device 133203 arg Disconn Description The resource s for named device is disconnected and named device is not operational The connect signal for the device is set to 0 Recommended actions 1 Set the connect signal for the...

Page 547: ...133210 arg Act val lo Description Actual value for named device has exceeded minimum limit IPS has discovered too low actual value compared to the setpoint value Recommended actions 1 Check for IPS configured DEVIATION alarms and verify that parameter limits are OK 2 Check if the sensor used by named device is noisy or sending values 133211 arg Comp hi Description Regulator for named device has co...

Page 548: ...namic Delay Compensation function for named device measured a transition at a time when none was expected Recommended actions 1 Check relay and electrical connections for the sensor 2 Check if the sensor signal is noisy 133218 arg Timeout On Description IPS has discovered a trig timeout for an on transition The Dynamic Delay Compensation function has timed out for an on transition Recommended acti...

Page 549: ... device and retry 133225 DMC error Description Following Digital Motor Controller DMC error message was sent to IPS arg IPS has lost communication or discovered an error sent from the named DMC driver Recommended actions 1 Check cables to the DMC 2 Check power supply to the DMC 3 For more info see the Unit Description Paint manual 133226 arg Description Setpoint error IPS has discovered an error t...

Page 550: ...nded actions 1 Check if an already saved curve on the IPS node has an incompatible number format than expected 2 Delete the saved curve on the IPS board 133257 SDI error Description SDI board have issued following error arg with error code arg Recommended actions 1 Check SDI board for errors 133258 VCD error MacID arg Description IPS has discovered an error on a VCD board with following details ar...

Page 551: ... selected brush number exists in loaded brush table 3 Check global brush table if brush number larger than 900 133270 Failed to update IPS parameters Description IPS failed to update IPS parameter values after reconnect of IPS agent connections The update was initiated after the IPS agents have been lost for any reason typically caused by a purge fault The system must be restarted to ensure all pa...

Page 552: ...ck replace SDI board 3 Contact customer support 133287 Servo coeff set error Description SDI board has discovered a problem to assign a specified set of coeffisients Recommended actions 1 Check FILTERASSIGN section in SDI configuration file for errors 2 Check replace SDI board 3 Contact customer support 133288 Servo illegal hardware Description SDI board has discovered an error while loading confi...

Page 553: ...ription SDI board has discovered an short circuit in the Drive unit used by arg Recommended actions 1 Check for short circuit in cabling 2 Check for short circuit in servo motor 3 Replace Drive unit 133307 Servo temp warning Description SDI board has discovered a high temperature warning in the Drive unit used by arg ALLOW SYSTEM TO COOL DOWN Recommended actions 1 Check cooling fans and filters fo...

Page 554: ...e on DC bus detected in the Drive unit used by arg Recommended actions 1 Check incoming mains 2 Check replace bleeder resistors and cabling 3 Check replace DC link 4 Replace Drive Unit 133314 Servo torque command err Description SDI board has discovered a servo torque command error with too big difference in 3 consecutive torque references This error is received from the Drive unit used by arg Rec...

Page 555: ...actions 1 Check SDI configuration 2 Check servomotor cables 3 Check resolver and resolver cabling 4 Replace SDI board 133321 Servo max current error Description SDI board has discovered a maximum current error received from the Drive unit used by arg Recommended actions 1 Check SDI configuration 2 Check DC bus voltage 3 Check servomotor cables 133322 Servo unknown error code Description SDI board ...

Page 556: ...rameter Description SDI board has discovered an attempt to write parameter values to locked parameters on a Drive unit This is an internal error received from the Drive unit used by arg Recommended actions 1 Check SDI configuration 2 Check replace Drive unit 3 Check replace SDI board 4 Contact customer support 133329 Servo diagnosis no par Description SDI board has asked for a non existing paramet...

Page 557: ...ecommended actions 1 Check resolver cabling 2 Contact customer support 133336 Servo speed flt overflow Description SDI board has discovered a servo speed filter overflow error for arg Recommended actions 1 Change SDI board 2 Contact customer support 133337 Servo res angle overflow Description SDI board has discovered a resolver angle calculation overflow error for arg Recommended actions 1 Check r...

Page 558: ...ard has discovered an ordered position step length larger than the maximum specified step length configured for arg Recommended actions 1 Check the MaxStepSize parameter in the configuration for named servo 2 Check acc speed for superior interpolator 3 Check resolver and resolver cabling 133345 Speed error Description SDI board has discovered a speed error for arg Recommended actions 1 Check acc s...

Page 559: ...e rectifier unit 2 Perform a shutdown and then restart the system 3 If the problem persists isolate the faulty rectifier unit and replace it 133501 Handler is not calibrated Description Could not enable the handler because the handler was not calibrated Recommended actions Calibrate the handler 133502 Belt on the handler is not calibrated Description Could not enable the handler because the belt o...

Page 560: ...mand toggle error Description A command toggle was sent to the SDI board while the acknowledge signal was high Recommended actions 1 Assure that the command toggle signal is low before toggling a new command 133550 Joint speed error Description The speed of joint arg deviates too much relative to the ordered speed Recommended actions 1 Check the parameters 2 Check for external forces 3 Reduce prog...

Page 561: ...rror during init of subscribers 134017 Buffer full Description Buffer1 arg Buffer2 arg 134018 Log semaphore timeout Description Log arg Message arg 134019 Master required Description arg must be master to execute the command arg 134020 File not found Description arg could not be found Recommended actions Make sure that the file exists 134021 Syntax Error Description The file arg contains syntax er...

Page 562: ...cision may not be reliable Recommended actions Procedures subscribed to the decide event should be checked for delays 134035 Invalid material index Description Material index arg is not mapped to any system Consequences Material change cannot be performed Recommended actions Correctly assign the material index in the index files 134036 Material Change Error Description Timeout while waiting for se...

Page 563: ...cription Command arg not allowed when the controller is in e stop state Recommended actions Remove emergency stop conditions and reset emergency stop state 134055 Configuration error Description Could not add arg xml into the configuration settings There are too many configuration files Consequences The option arg will be set to zero Recommended actions Merge the configuration into another file or...

Page 564: ...ded actions Change the row number to a positive integer 134066 CSV parser error Description There were too many columns on a row in the file arg Consequences The remaining columns on the row line in the file will be skipped Recommended actions Reduce the amount of columns or increase the buffer size 134067 CSV parser error Description Could not open the file arg for reading Recommended actions Mak...

Page 565: ... stations 134107 Storage station is not an IFS Description The returned cartridge was not stored in an IFS Consequences The post processing of the cartridge will be skipped 134108 Possible CBS collision Description Robot execution has been stopped in order to avoid a collision with the CBS handler arg Recommended actions Manually move CBS handler away from robot and resume execution 134110 Safe Mo...

Page 566: ...eleration failed Description Timeout while waiting for servo controller to complete previous command Recommended actions Check that servo controller and communication interface is ok 134124 Set servo acceleration failed Description Timeout while waiting for acknowledge from servo controller Recommended actions Check that servo controller and communication interface is ok 134125 Set servo speed fai...

Page 567: ...cate missing cartridge and verify the integrity of the system 134139 Gripper sense failed Description Unknown gripper specified arg 134140 Gripper access check failed Description Unknown gripper specified arg 134145 Vacuum check error Description Timeout while waiting for sensor feedback 134146 DCU check error Description Timeout while waiting for DCU to become ready Recommended actions Check if D...

Page 568: ...es will not be detected and cannot avoid damage to the system 134164 Left cartridge sensor bypassed Description Left cartridge sensor bypassed Consequences Some integrity failures will not be detected and cannot avoid damage to the system 134165 Release sensor bypassed Description Release sensor bypassed 134166 Vacuum sensor bypassed Description Vacuum sensor bypassed Consequences Failure to produ...

Page 569: ...on error Description Too many IFS stations have been defined Consequences Some IFS stations will be skipped 134180 Could not set baseplate data Description Address arg Content arg 134181 Could not get baseplate data Description Content arg 134182 Could not get baseplate data Description Type arg 134183 Could not get baseplate data Description Access arg 134184 Could not get baseplate data Descript...

Page 570: ...oblem causing the failure and resume the operation 134202 Exchange cartridge step one failed Description Exchange cartridge failed in state arg Recommended actions Fix the problem causing the failure and resume the operation 134203 Exchange cartridge step two failed Description Exchange cartridge failed in state arg Recommended actions Fix the problem causing the failure and resume the operation 1...

Page 571: ...ended actions Reconfigure baseplate access 134219 Unexpected cartridge in applicator Description An unexpected cartridge was found while probing applicator Recommended actions Remove the offending cartridge and resume the operation 134220 Unexpected cartridge presence Description An unexpected cartridge was found during start check Recommended actions Remove the offending cartridge and verify the ...

Page 572: ...ocess operation specified arg 134242 Maintenance operation error Description Not possible to move a cartridge from or to a hole 134243 Maintenance operation error Description Unknown cartridge specified arg 134244 Maintenance operation error Description No IFS solution for the cartridge specified arg 134245 Maintenance operation failure Description Integrity check failed Recommended actions Fix th...

Page 573: ...4313 Cartridge 2 home sensor bypassed Description Cartridge 2 home sensor bypassed Consequences System will run slower and integrity failures will not be detected 134314 Cartridge 1 DSD sensor bypassed Description Cartridge 1 DSD sensor bypassed Consequences System will run slower and integrity failures will not be detected 134315 Cartridge 2 DSD sensor bypassed Description Cartridge 2 DSD sensor ...

Page 574: ...will run completely empty before swapping occurs Recommended actions Add the missing value into the VB configuration file 134342 VB configuration error Description Enough catridge volume not specified Consequences System will not behave optimally Filling will always occur even if cartridges have enough volume Recommended actions Add the missing value into the VB configuration file 134343 VB config...

Page 575: ...ct 134411 Unknown cartridge specified Description Unknown cartridge ID arg Recommended actions Check that paint command paramters are correct 134412 Unknown position specified Description Unknown position ID arg Recommended actions Check that paint command paramters are correct 134420 Bypass cartridge error Description Not allowed to run system with two or more sensors disabled for cartridge arg R...

Page 576: ...ning unit up Parking unit is not in a valid position 134513 Cleaning unit move error Description Unable to move cleaning unit up Timeout while waiting for sensor feedback 134514 Cleaning unit move error Description Unable to move cleaning unit down Timeout while waiting for semaphore 134515 Cleaning unit move error Description Unable to move cleaning unit down Timeout while waiting for sensor feed...

Page 577: ...Unable to rotate color changer while it is docked Recommended actions Undock color changer 134611 RCC movement error Description Timeout while waiting for motor feedback Recommended actions Check motor configuration 134612 RCC movement error Description Unable to enable motor Recommended actions Check motor configuration 134613 RCC movement error Description Unable to disable motor Recommended act...

Page 578: ...n the file 135021 Material change index file error Description Unable to open index file arg Recommended actions Check that the file exists 135022 Material change index file error Description The file arg contains an invalid index arg Recommended actions Fix the problem in the file 135031 Material change system index error Description Material index arg is missing an action specifier Recommended a...

Page 579: ...nal number arg on device arg Recommended actions Check IPS configuration or signals used in material change sequences 135064 Material change signal error Description Failed to write signal number arg on device arg Recommended actions Check IPS configuration or signals used in material change sequences 135071 Material change alarm monitor error Description Invalid signal name in configuration file ...

Page 580: ...dule Description Task arg Module line column arg There is an error with symbol arg 580 Operating manual Troubleshooting IRC5 3HAC020738 001 Revision AA Copyright 2005 2018 ABB All rights reserved 5 Troubleshooting by event log 5 13 15 xxxx ...

Page 581: ... to the ABB Connected Services Center server has failed Consequences No communication to the ABB Connected Services center shall be possible Probable causes Validation of the server certificate was unsuccessfull Recommended actions 1 Check if this controller date and time is accurate 2 Contact ABB support for assistance 170032 Connected Services no server connection Description This controller is ...

Page 582: ...ontact ABB support for assistance 170037 Connected Services credentials renewal error Description Connected Services Agent has failed to automatically renew login credentials at ABB Connected Services Center Probable causes Possible connectivity problem with the server Recommended actions 1 Verify connectivity 2 Repeat manually the registration process 3 Contact ABB support for assistance 170038 C...

Page 583: ...pe C 3HAC025611 001 Circuit diagram IRB 260 3HAC028647 009 Circuit diagram IRB 360 3HAC036446 005 Circuit diagram IRB 460 3HAC025691 001 Circuit diagram IRB 660 3HAC025691 001 Circuit diagram IRB 760 3HAC046307 003 Circuit diagram IRB 1200 3HAC2800 3 Circuit diagram IRB 1410 3HAC021351 003 Circuit diagram IRB 1600 1660 3HAC039498 007 Circuit diagram IRB 1520 3HAC6670 3 Circuit diagram IRB 2400 3HA...

Page 584: ...Valid for motor Type A Positioners Article numbers for circuit diagrams Product 3HAC035753 001 Circuit diagram Service diagram IRBP C 3HAC035753 002 Circuit diagram Service diagram IRBP L 3HAC035753 003 Circuit diagram Service diagram IRBP K R 3HAC035753 004 Circuit diagram Service diagram IRBP A 3HAC035753 005 Circuit diagram Service diagram IRBP B D 3HAC035754 001 Circuit diagram Service diagram...

Page 585: ... diagram SpotPack SWC IRC5 M2004 3HAC044736 001 Circuit diagram SpotPack SWC IRC5 Design 2014 PROFINET Use the correct circuit diagram IRB 6600 IRB 6650 and IRB 6650S The cable harness of the robot is available in two different designs Either the cabling is divided between the upper and lower arm or not Accordingly there are also two different versions of the circuit diagram Decide which circuit d...

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Page 587: ...hot gearbox oil 56 I Incompatibility hardware software 54 Interference 61 L labels controller 19 robot 13 LED Board LEDs 64 LEDs indication 46 Live voltage Drive Module 28 M Main Drive Unit 73 Additional Drive Unit 73 Main transformer 46 Manual how to use 31 N noise 55 56 P Panel Board LEDs 71 panel board unit 70 DSQC 643 70 path accuracy 55 power distribution board LED 82 test equipment 82 troubl...

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Page 590: ...elephone 47 22 87 2000 ABB Engineering Shanghai Ltd Robotics and Motion No 4528 Kangxin Highway PuDong District SHANGHAI 201319 China Telephone 86 21 6105 6666 ABB Inc Robotics and Motion 1250 Brown Road Auburn Hills MI 48326 USA Telephone 1 248 391 9000 abb com robotics 3HAC020738 001 Rev AA en Copyright 2005 2018 ABB All rights reserved Specifications subject to change without notice ...

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