irb 6000 m93 error list

ERROR LIST

Error List S31

1General

When an error is detected, the ERROR lamp on the control panel illuminates. If a P-unit isconnected to the robot system, an error message is presented at the same time in plainlanguage on the upper line of the display. This applies also when a P. unit is connectedafter the error has developed and the ERROR lamp has illuminated.

Errors which can occur are divided into:

* Operational errors; the error messages beginning with a number 001-499.

* System errors; the error messages beginning with a number 501-999.

The appropriate corrective actions for the different errors are described below.

OPERATIONAL ERRORS

1 Check the error type on the upper line of the P-unit display.2 If further information is necessary, go directly to point 6. Otherwise continue with point 3.3 Press the control button SHIFI' - the error message is then cleared.4 Perform the control operation correctly so that the error status is not repeated.5 Continue with point 8.6 Seek the error message displayed in section 3, page 6.7 Perform the appropriate actions stipulated in section 3, page 6.8 If the same error message returns or persists, despite the incorrect operation not beingrepeated, contact service personnel.

SYSTEM FAULTS

1 Seek the error message presented in section 4, page 11.2 Perform the appropriate corrective actions as described in section 4, page 11.3 If the same error message persists or returns, call service personnel.

N.B.

Some error messages described in the sections 2- 3 can occur for certain types ofrobots only.

Error List S32

2Error buffer

Means: The system contains an internal error buffer, which can store 9 error messages. In thebuffer the system stores:* All kinds of error messages both system errors and operator errors, occurred at thelatest error occasion.

* Earlier messages about system errors.

The system can, on request, present the contents of the error buffer via:* The programming wilt. Just error messages from the latest error occasion.* A printer, if the optional function Program printout is provided.* A monitor, if this optional function is provided.

Facts: Display on the programming unit of error messagesThe programming unit displays one error message at a time, according to the following:

* When the system stops runnin6 due to an error, the operator will see the first errormessage. An arrow on the display indicates if there are any consequent errors. In thiscase the operator can display these messages also, one by one.

* During manual operation the operator can, on request, display stored messages from thelatest error occasion, one by one. The error messages are chronologically displayed.

* For most error messages, it's possible to get text in plain language by pressing"" on theprogramming unit.

Display on the progrn1ning unit of error messagesThe monitor displays all the messages within the error buffer, according to the following:* When the system stops running due to an error, the operator will see all messages,occurred during that error occasion. The error messages are chronologically displayed.

* During manual operation the operator can, on request, display all stored messages. Theerror messages are in plain language and chronologically displayed.

Printout of error messages* During manual operation the operator can, on request, display stored messages from thelatest error occasion, one by oic.The error messages are chronologically displayed.

Erasure of the contents in the error buffer and show text in plain language* During manual operation the operator can, on request, erase all messages stored inthe error buffer.

* On request, the operathr can get text in plain language for most error messages.

* On request, the operator can load the texts in plain language from disk. See Installationmanual, 83.

Error List S33

1mp1e of a list of error messages

ERROR MESSAGE CODE************************

5t6 SERVO ERROR 2 1405->50' SERVO ERROR 2 1605546 ENABLE CHAIN FAULT 21

506 SERVO ERROR 2 1805506 ENABLE CHAIN FAULT 21

504 PROGRAM RUN ERROR 7

Usedi For fault tracing and for production follow-up.

Ezecute& The system reacts immediately after the procedure is concluded.

Procedures: Display on the programming unit of error messages after production stopRead the error message. Use the SHIFT button to display more error messages, ifrequired.

Ifyou want to read messages about system errors once again, select ERRORS underthe MANUAL menu.

Error List S34

3Operational errors

The following tables describe the errors which the operator can cause when programming oroperating the robot system.

These are numbered from 001-499. The table gives.* Error message* Causes* Recommended corrective action

ERROR MESSAGE CAUSES RECOMMENDED CORRECTIVE ACTION

1.NOTALLOWEDCOMMAND

The button concerned istemporarily blocked bythe system.

Select another button.

LNOTALLOWEDCOMMAND 10

Closed due to that inputPROG STOP is active.

Deactivate input PROG STOP.

3.DATAERROR Attempted entry ofincorrect numericalvalue.

Depress ERASE and enter newnumerical value.

4JNSTh NOTFOUND

After resequencing aprogram the system hasdetected jumps to non-existing instructions.

Check the program and correct thefaultyjump addresses.

5.PROGRAMMISSING

Attempt to use a programnumber where instructionsare missing with:* programming running* editing of completeprogram

* Program the instructionunder the program numberconcerned.

* Select another program number.

&MEMORYFiTTfl Up

Attempt to:* enter further

instructions* copy program when the

robot memory is full

* 1 Clear the program block.2 Erase superiuous instructions

and programs.3 Clear program block once again.

* If the system includes a floppy diskunit, it is possible to:1. Divide the existing program

and store each section on afloppy disk under a separa eprogram number.

2. Utilize the mass memory functionfor automatic exchange .f thedifferent program parts in the usermemory.

Error List S35


7.PROGRAMEND Attempt to step past Call the first instruction number inthe RETURN-instruc- the program concerned.tion

8PROGRAMNUMBER Attempt to copy a pro- Select another program number forOCCUPIED gram under a program the program copy.

number where instructions are already stored.

9. INSTRUCTION A.Atteinpt to program in- A. Divide the existing program into aNUMBER sb,iction with higher main program and subprograms.OVERFLOW number than 65530. Copy the program and erase super

B.Attempt to resequence flues parts. Resequence and inserta program containing CALL-instructions. If availablemore than 6553 memory space is too small, useinstructions, floppy disc.

B.Avoid resequencing, or split theprogram according to point A above.

10. ADAPTiVITY A digital multi-bit * Change one of the mm. or max.ERROR 1 sensors or analog -limits or both for the signal from

sensor gives a the sensor concerned.signal outside its * Correct current positions inworking area. the program.

10. ADAPTIVITY A digital 2-bit sensor Check the sensor.ERROR 2 gives an illegal

signal.

10. ADAPTIVITY A 1-bit sensor is used * Select another sensorERROR 3 for direction searching or * Replace the sensor

contour following.

10. ADAPTIVITY A digital sensor with Change the connection accordingERROR 4 2-8 bits is completely con- to the Installation manual.

nected to the same groupof digital inputs.

10. ADAPTiVITY The correction move- Determine direction and speedERROR 6 ment has no direction for the correction movement:

or speed. * In a new instructionS By editing an existing instruction.

10. ADAPTIViTY Sensor data for En.er sensor data accordingERROR 7 a sensor used to te Programming manual,

missing. uhapter 9.

Error List S36

ERROR MESSAGE CAUSES

10. ADAPTIVITYERROR 8

The signal level programmed for search stopis outside the workingrange of at least oneof the sensor.

RECOMMENDED CORBECTWE ACTION

Edit the instruction concernedso that the signal level forsearch stop is within theworking range of the sensor.

11. OUTSIDEWORKINGAREA 1-12

The robot axis 1 to 12 hasbeen run outside itsworking area with thejoystick.

Bun the robot in the oppositedirection with the joystick.

11. OUTSIDEWORKINGAREA 20

Too large movement withaxis 1,4 or 6 using thejoystick.

Switch-off and start-up therobot system again.


The angle between thelower and upper arms ataxis 3 is too small or toolarge.

Leave this area using the joystick


The main processor is in atemporary fault condition.

Switch - off and start - up therobot system again.

13 ROBOT NOTSYNCHRONIZED

A Some axis is NOTpositioned if it is arobot with absolutemeasurement system.

B Some axis is not synchronized.

A Re-start the system.Remedy possible fault.

B Synchronize the system.

14.AUTO MODElKEYLOCK

A The key-switch is inposition AUTO and/or thekey input on the remotecontrol is activated.

B The parameter SIM C isactive in AUTO mode.

A Choose position TEACH orTEST=100% and/or deactivatethe key input on the remotecontrol.

B Change to TEACH or TEST 100%mode or deactivate SIM C.

15. SENSOR NOTDEFINED

No sensor defined forsensor number entered.

Press ERASE and enternew sensor number.

18. SENSOR TYPENOTALLOWED

Incorrect sensor type forthe adaptive function defined for the sensornumber entered.

Press ERASE and enter newsensor number.

Error List S37

ERROR MESSAGE CAUSES RECOMMENDED CORBECTWE ACTION

17. WRONG Attempt to change: * Change the completeINSTRUCTION TYPE * Argument instruction.

* Position * Select another instruction* Speed number.for an instruction whichdoes not contain positiornng.

18. INSTRUCTION Attempt to program in- * Enter another instruction number.NUMBER OCCUPIED struetion with occupied * Renumber the program and then

instruction number. enter an instruction number.

19.PROGRAM START Attempt to step backwards Erase the message and continue withand pass-by the first the next action.instruction in theprogram.

20 SELECTROBOT Within this area the robot Select the robot coordinate systemCOORDINATES cannot be run in rect.an

gu.lar coordinates.

21. TCP NOT Attempt to program * Program another TCP.DEFINED activation of an * Define the TCP that is to be activated

undefined TCP. via the instruction and try again.

23. ALIGNERROR MH/ASM and GLUEAttempt to execute ALIGN Turn the tool closer to the requiredwith a too large angle de- orientation and try again.viation between the currenttool orientation and the required one.

24.NOT DEFINED MH/ASM and GLUE * Select another orientation register.Attempt to execute ALIGN- * Define the orientation by meansFETCH on an undefined of ALIGN-STORE.orientation register notcontaining a tool orientation.

25. INCOMPATIRLF The required option canOPTION not be activated

- because to that:A Another parameter

under OPTION isalready activated.

B Required POTION parameter can not be activatedfor the current robot type.

Error List S38

ERROR MESSAGE CAUSES RECOMMENDED CORRECTIVE MEASURES

26 NOT ALLOWEDCOMMAND/ROOMFIXEIJ TCP 1-8

1 Can not changecoordinate-system, whenreference point is active.

2 Can not define a frameor pallet in wrist coordinate-system.

3 The function mirror isinterrupted if the position is programmed withfixed TCP. Observethat reflection has beencarried out on earlier positions with ordinary TCP.

4 MODPOS can not be carried out ifa fixed TCPTCP is active and the posinstruction is made with anordinary TCP and withoutexternal axes.

5 The instruction is blockedwhen fixed TCP is active.

6 It is not possible to defineabase point with a roomfixed TCP.

7 Not allowed to define a TCPautomatic when a fixedTCP is active.

8 After programming anearlier pos-instruction a newTCP has been activated, sothat the coordinate-systemhave been changed. Theinstructions are not of thesame size, so it is notallowed to use SAME.

Deactivate reference point

Activate an ordinary TCPO-19

Use the function MODPOSon required positions.

Erase the instruction andprogram it again, to convertto the wrist coordinate-system.

Program in some other way.

Activate an ordinary TCP.

Program in the ordinary way.

27 NO MOREINFORMATION

Required text in plainlanguage not with theloaded texts

28 LOAD TEXT FROM DISK Required text in plainlanguage can not be displayed. The texts have notbeen loaded from thesystem disk.

Load the textsMenu: MANUAL + ERRORS

Error List S39

System faultsThe errors which can occur in the robot system itself are described in the following table.These are numbered from 501 to 999.The table gives.* Error message* Causes* Recommended corrective measures.

ERROR MESSAGE CAUSES RECOMMENDED CORRECTWE MEASURES

501 MEMORYFAULT A The system has discovered 1 Insert the installation diskette, withRECORD a summary check fault in the the right system parameters, into

system parameter memory. the floppy disk unit.Then the system has made 2 Choose the functionsbutton FR DISKa restart with the pare- 3 The system starts-up.meter basic values from 4 Press MAN/PARAM/RESOLV andPROM. check that the system has the

B The system has discovered correct RESOLV data.that the systemparameters Choose the function button PROMloaded has revision and when restarting the system forversion number separated the first time. Then define thefrom the ones in PROM. installation systempararnetersThen the system has re- including RESOLV data.started with the parameterbasic values from PROM.

502 PROGRAM When restarting the Load the program block inMEMORYFAULT system has discovered a question from DISK **

check summary fault inthe robot program memory.

503 EMERGENCYSTOP The robot has been 1. Correct the cause of thestopped in an emergency stop.emergency. 2. Press RESET on the control panel so

that the emergency stop is cancelled.If the emergency stop cannot becancelled:

* Check the safety board.* Start fault tracing, acc. to Chapter 4 inthe Service Manual.

* Causes to the discovery of check summary fault in * Check the robot computer boardsystem parameter memory or program memory: inci. the memory battery back-up*Too low battery voltage, according to the Service Manual.Uncorrected or damaged battery.*Damaged robot computer board.

Error List S310

ERROR MESSAGE CAUSES RECOMMENDED CORRECTiVE MEASURES

503 WORE]NG RANGESTOP 2

One axis has been drivenagainst a limit switch.

* Correct the cause of the stop.* Place the key-switch in positionTEACH.

* Put the sjstem back in operationby pressing the operation buttonand keeping that way and thendepressing the dead man's handle.

* Then drive the axis away fromthe limit switch with the joystick.

If the stop can not be restored:* Check on not used safety circuitsclamps.

* Check the safety board.* Start fault tracing, acc.to Chapter 4

in the Se-iice Manual.

504 PROGRAMRUNERROR 3

Attempt to start programexecution when programis missing.

Enter a robot program from floppydisk or from programming unit.


Attempt to execute a correction vector for anotherkind of instruction.

Call the correct instructionand by again.


Last instruction was notRETURN nor JUMP in anexecuted program.Current program has beenerased by the instructionADD BLOCK.

Insert the correct instruction.


A Attempt to execute amovement path outsidethe robots working area.

B The wrist centre of therobot or the TCP is in20 mm range of thebase Z-axis.

A Edit the iiovement path.Check the TCP location.

B Use robot coordinates ormodify the TCP track.


Attempt to call a subprogram or robot programwithout instructions.

* Edit the program number inthe instruction.

* Create a subprogram or robot programwith this number


MHJASM AND GLUEA Attempt to execute a

weave movement witha weave subprogramwhere the first instruction is not a positioning-instruction.

Edit weaveprogram.

Error List S311


B AW Attempt to execute Edit the program.a weave n' vementwith eithr:* No positioning intruc

tion after weave start.* The distance betweenweave start and nextpositioning instructionis zero. AW.


A Attempt. has been done toexecute an impermissebleinstruction.

B AW Ur efined weiddatanumber.

C notAW Attempt has beenmade to execute a weavemovement when instructionin sub weaving program isfaulty.

A Check the program.

B *Define present weiddata.`Exchange welddata nr.

C Correct the sub weavingprogram.


Attempt to execute ajump to a non-existentinstruction.

* Edit the jump address.* Enter an instruction with thisnumber.


Attempt to execute apattern subprogram, whenthe register concernedcontains a `icorrectvalue.

Check and change the valuein the register concerned.


Attempt to ,xecute anested call to a 11thsubprogram level or a12th level of interruptprogram.

Edit the robot program.

504 PROGRAM RUNERROR 15

The main processor is ina temporary fault condition.

Switch-off and start-upthe robot system once again.Check electrical disturbanceon inputs.


Error List

A Main progr. rnprogram 0 s missing.

B The active p ogram replaced by the corresponding one on flop' diskat program l'ading withthe subfunct onal ADDALLunder the GLT B-function

C Another mass memoryerror

A, B Enter a main program.

C Pry to perform the correspondingGET B-function manually.

S312



A.A positioning instruction after a circlepoint contains anillegal argument

B.Attempt to back tothe start point afterprogram stop in themiddle of a circular arc.

RECOMMENDED CORRECTIVE MEASURES

A. Edit the instruction and repeatthe attempt

B. Run if possible to the end pointof the circle and back fromthis point instead.


The positions of the circlepoints are selected incorrectly so that either:* The radius becomestoo large.

* Two or several pointsin the circuiararccoincide.

* Remove the circle point and runin straight lines instead.

* Change the position of thepoints concerned so that acircular arc is obtained.

504 PROGRAM RUNERROR 19

The circular interpolation has been interrupted so that it cannotcontinue.

1. Erase the error message withthe SHiFT key.

2. Check that there is no obstacle inthe direct path of the robotforward to the next point

3. Run instruction by instruction to thenext point.

504 PROGRAMRUNERROR 20only for arc weldingrobot

The acknowledgmentoftransferred data isomitted when executingthe arc welding instruction EXTPOS.

Check the peripheralequipment concerned.

504 PROGRAMRUNERROR 24only for arc weldingrobot

A SE'I', RESET, INVERT orPULSE instruction for adigital output cannot beperformed because theoutput concerned is usedfor communication witharc welding equipment

A Use another digital output

B An incorrect attempt hasbeen made to affect a digital output used for activation/deactivation of astation.

B When activating/deactivating a station, only SET andRESET of a digital outputare used.

Error List S313

ERROR MESSAGE CAUSES RECOMMENDED COBRECTWE MEASURES


A Arobotaxiswithaworking area>360has ended up in a socalled ambiguous point,which means that thesucceeding programmedrunning to the programmed position can be executed in two ways by therobot axis. The resultingpositions differs from theprogrammed one.

* Edit the program in such a way thatthe movement of the axis c n beexecuted in one way only

* Check that this will not cause anyproblems later. Remove the check.See programming manual Section 8.5,MODIFYIHANDCHK.

B The wrist axes are rotated more than aspecified limit valueaxis 4, 45, axis 6, 900.

C The time, programmedfor the time positioning,is to short.

D Program running inrectangular coordinatesis not possible.

E Weaving: the crosatime isto short compared to theamplitude.

* Edittheprograminsucl iwaythis movement will not occur.

* Check that this will not cause anyproblems later. Remove the check.See Programming manual Section 8.5,MODIFYIHANDCHK.

C Increase the programmed time.

D Change to program running in robotor modrect coordinates, or move themotion a little away from the singularpoint.

E Increase crosstime or dec seamplitude.


The value in a numberregister is not valid.

Check the program and edit theregister handling.


Automatic definitionof a program displacement is in progress.During the process, atleast two positionsapproach each othertoo closely:* When the positionsare selected.* In the resultingprogram displacement.

Select three new positionsand try again.


Attempt to activatean undefined TCP

* Activate another TCP.* Define required TCP and try

again.

Error List S314


504 PROGRAMRUN MBJASM and GLUEERROR5 Attempt to use: A Change the number of grippers

A An undefined gripper, in the function parameters.B An output which is re- B Use another gripper/output

served for a gripper.

504 PROGRAMRUN MHJASM and GLUEERROR 54 Attempt to execute a A Define the pallet

PALLET-instruction with B Use an already defined pallet.an undefined pallet

504 PROGRAMRUN MHJASM and GLUEERROR 55 Attempt to execute Change the register values.

a PALLET-instructionwith the register valuespointing out a positionoutside the pallet

504 PROGRAM RUN Attempt to execute a Activate the GLUE function parameterERROR 58 gluing instruction with GLUE under OPTION - provided that

the parameter GLUE not the robot system is a gluing system.activated.

504 PROGRAMRUN AWERROR 62 Weaving data not de- * Select another weaving data

fined for the current wea- field.ving data field. * Define weaving data.

504 PROGRAMRUN AWERROR 63 CROSSTIM isO. Define CROSSTIM.

504 PROGRAMRUN AWERROR 64 BASEPoint not defined. Define BASEPo1nt and try again.

504 PROGRAMRUN AWERROR 65 Sensor data undefined for * Select another sensor data field.

current sensor data field * Define sensor data.

504 PROGRAMRUN AWER'OR 66 Internal error in calculation Edit the start position for AUTO-

of end position for AUTO- SEARCH and try again. If the errorSEARCH. persists after several trials, check the

computer board.

504 PROGRAMRUN AWERROR 67 The robot velocity is to high Edit the program. Reduce the zero

at connection or dis- zone or the velocity.connection of SPS.

504 PROGRAMRUN No position stored in the * Select another position register.ERROR 68 current position register. * Store a position.

Error List S315


504 PROGRAMRUN Internal system fault. Switch off and start-up the systemERROR 69 once again.

504 PROGRAMRUN The soft-servo number or Active another set of softness, orERROR 70 softness vector is undefined, define the relevant softness set under

the manual menu.

504 PROGRAMRUN The wrist centre point or Use robot coordinatesERROR 71 the TCP has entered with- or modify the robot pass.

in2Omm ofthebaseZ-axis. This is not allowedin rect. or modrect.coordinates.

504 PROGRAM RUN Incorrect TCP may be Check that the correct TCP is activeERROR 72 active, at the programiningunit. Continue

program execution by pressinginstruction start or program startonce more.

504 PROGRAMRUN The weaving amplitude * Change TCPERROR 73 cannot be reached because * Reduce the amplitude.

the TCP is too close to thex-axis weaving axis ofthe wrist.

504 PROGRAMRUN The robot moved when Stop the robot and repeatERROR 74 the activation/deactivation the attempt

of a station was requested.

504 PROGRAMRUN Timeout in supervision of a Check welding controller.ERROR 75 spot weld. WELD READY

not received Within 5 s afterSTART 12.

504 PROGRAMRUN Output used in SW! function Define the function parameterERROR 76 not defined, for GRIPPER 3.

504 PROGRAMRUN Execution of an SW! function Define the SW! parameter orERROR 77 without activated SW! change the instruction.

parameter.

504 PROGRAM RUN The program number in the Change the program numberERROR 78 instruction is not permitted. in the instruction.

504 PROGRAMRUN Attempt to reach a posi- Check the program and activeERROR 80 tion with a wrong TCP TCP.

active have been made.Poe-instructions and storedpositions can not be usedbetween fixed TCP andordinary TCP.

Error List S316


504 PROGRAMRUN Attempt to switch coordi- The reference point has to be deERROR 81 nate-system with a TCP- activated before change of

nstruCton have been coordinate-system is possible.made, when the referenc*'point is active.

504 PROGRAM RUN Attempt to execute an The instruction in question canERROR 82 instruction have been only be executed with a ordinary

made,who don't function TCP active.together with a fixedTCP.

504 PROGRAMRUN Attempt to activate an Un- Activate another LOAD. DefineERROR 84 defined LOAD. required LOAD and try again.

504 PROGRAMRUN Incorrect LOAD may be Check on the prog.unit, that theERROR 85 activated, correct LOAD is active. Continue

program execution by pressinginstruction start or programstart once more.

504 WRONGLYPLACED No digital I/O-board defined Check the function parametersI/O BOARD in place stated by the para- for the I/O and SWI.

meter BOARD POSITION.

505 SERVO The servo computer does Check the computer board.ERROR1 notacceptanorderfrotn

the main computer, becauseof a serious system fault

505 SERVO ERROR The axes computer has Be-initiate the system. If the fault8001 not accepted an order persists,replace the main processor

from the main computer, board.due to a serious error inthe main computer.

506 SERVO ERROR 2 Resolver fault, channel x. A Check for any fault by measuring1101-1124 Fine resolver, resistance in wiring and resolver.

axis 11101- 121112 resolver-20ohmCoarse resolver, B Replace the serial measurementaxes 71119- 121124 board or the axis board.

506 SERVO ERROR 2 Resoiver error, channel y. See error type 1101 - 11241201.1224 Fine resolver,

axis 11201- 121212Coarse resolver,axis 71219- 121224

Error List S317


506 SERVO ERROR 21301 - 1312

Speed error.The motor for axis 1 1301-121312 runs considerablyfaster than is commandedfrom the control system.Cause, internal axes:A Considerable interference

between the axes athigh speeds results inincorrect speed at certainpoints in the user'sprogram.

B Incorrectly commutatedmotor

C Axis stops the motorreceives no current

D Incorrect acceleration ofthe motor.

Cause, external axes:E See point A above.F Incorrect acceleration of the

motor.

A Lower the programmed speed locallyin the program where the error occursand/or change the positioning patternso that the axis which trips becauseof the incorrect speed is not so activein this part of the program.

B Check that the correct commutatoroffset is entered for the axis. If theaxis has been repaired, remeasuredand enter a new offset

C 1. Check all fuses.2. Check the motor current using the

test outlets. Check the wiring, thedrive unit and the robot computerboard.

D Replace the robot computer or driveunit.

F 1. Check external controller, drivestage and external wiring.

2. Replace robot computer or externalaxis board.

506 SERVO ERROR 21401-1412

Jam error, internal axes

The motor for axis 1 1401 -71407 remains stationary despite the robotcomputer commandingcurrent to the motor.Cause.A. The robot has run

against an obstacle.B. Overload.C.The motor receives

current but is incorrectly commutated.

D.The motor does notreceive current

E.Resolver fault.F.Motor fault.G.Mechanical fault

A 1. Select operation mode RUN andrun away from the obstacle.

2. Remove the obstacle or edit theprogram.

B. Check that the load and its leverarm do not exceed the specifiedmaximum limits.

C. Check that the correct comniutator offset is entered for theaxis. If the axis has been repairedmeasure and enter the correctoffset

D 1. Check all fuses.2. Check the wiring, the drive unitand the robot computer board.

E. Turn the axis with the system inthe STAND BY mode and check ifresolver fault is indicated.

F. Measure motor data.G. Check, with the system in theSTANDBY mode that axis movementis free in its complete working range.

Error List S318


Jam error, external axes.

The motor for external axis7 1407 - 12 1412 runs slowerthan2%despitethrobot Bcomputer commanding ahigher speed.Cause:A The axis has run

against an obstacle.B The axis receives no

torque.C Axis not correctly adjusted.

RECOMMENDED CORBEC.TWE MEASURES

A 1. Select operation mode RUN andrun the axes away from theobstacle.

2. Remove the obstacle or edit theprogram.

1. Check that any brake is released.

2. Check that a speed referenceis received from the axis board.If unrepairable, replace the axisboard.

3. Check the external controller,driver, wiring and motor.

C. Increase the KP-value for the axis.The KP-values are defined in thesystem parameters.

506 SERVO ERROR 21500

Resolver fault, supply 1. Check for any fault by measuringresistance in. wiring and resolver.resolver-20ohm

2. Replace the serial measurementboard or the axis board.

506 SERVO ERROR 21601-1612

Too high speed in TEST-position for axis 1 1601 -axis 12 1612.The speed protection istripped when the program.ming unit is connected andout and the key switch notin position 100 %.Cause:A Chain fault related to

an emergency atop.B External interference on

the robot or the externalaxes.

C Low motor torque.D Incorrectly adjusted

external axes 7-12.

A Correct the primary fault.

B Reduce the effect of external forces

C See w506, SERVO ERROR 21401-140?, item C and D.

D Check that the adjustment of the external axes does not cause any heavyspeed overshoots.

506 SERVO ERROR 21701-1707Concerns only robotswith tachometer.

Resolver/tacho signaldiffers for axis 1 1701-axis 71707.Cause:Tachometer signal indicatesanother speed than thatcalculated from the resolversignal.

1. If new tachometer has beeninstalled, check that positivevoltage is obtained if the axis isturned in a positive direction.

2. Check that the voltage reachesthe axis board.

3. Replace the axis board.

Error List S319


506 SERVO ERROR 21801-1812

Position error with brakeactivated for axis 11801- 121812.One of axes 1-12 movedthough the system hasordered the brakes to beapplied.Cause:A Manual release of the

brakes and movementofthe axis.

B Abrupt braking, withthe brake, from highspeed, by the DeadMan's Handle ora switch-over to STANDBY

C Poor brake.

A,B Check that all axes are in safepositions f .r program start orsynchrorzing. If not, run the robot toa safe position using the programming unit.

C Change the brake.

506 SERVO ERROR 22001-2024

Resolver error channel x or yaxes 12001- 122012Coarse resolver,axes 72013- 122024

A Check for fault by measuringresistance in wiring and resolverresolver-20 ohm

B Replace the serial measurementboard or the axis board.

506 SERVO ERROR 22101-2107

Racing protection at start-up.

The racing protection for axis12101- axis 72107 hastripped as the axis has notremained stationary when theRUN status was activated the Bfirst time after initialization.Cause:A Incorrect commutation

offsetB Faulting tachometerB concerns only robotswith tachometer.

C Faulty resolverD Low motor torque

A 1. Check that the correct commutator offset is entered.

2. If the commutation has beenchanged because of repairs,make new measurements.See In ``llation manual.

1. If the tachometer is newly installed, check that positivevoltag... is obtained when theaxis is turned in a positivedirection.

2. Check that the voltage isreceived at the axis board.

C If the resolver is newly installed,check turning the axis very slowlyin a positive direction and readingwith the help of the programming unitthat the resolver value increaseswhen reaching 8191, the valuerestarts frot' 0.

D 1. Check the drive unit.2. Check the re'istances of the

motor windings.

Error List S320


Servo lag error for axes 12101 - 12 2112 when runningintheTESTmode.Cause:Major positioning errorbecause the axis has notrotated in accordance withthe received position references.

RECOMMENDED CORRECTiVE MEASURES

See "error code 1401-1421"See "error code 1301-1312"

506 SERVO ERROR2201-2224

Resolver error, channels xandy. Fine resolveraxes 12201 - 122212Coarse resolver,axes 72213 - 122224

A Cheek for fault by measuring theresistance of the wiring and theresolver resolver-20 ohm.

B Replace the serial or the serialmeasurement board or the axis board.

506 SERVO ERROR 223XX

Error in the revolution Check the measurement system,counter of axis XX.. Axes 1-6 especially all resolver and measurementare supervised by measure- board connections. Recalibrate the robotment board 1 and axis 7 by revolution counter. Check the robotboard 2. All revolution calibration position. If the problem per.counters on the measurement sists, replace the serialmeasurementboards are uncalibrated.


Incorrect input data.Cause:Parameters entered are outside specified limits.

Check that all parametersentered are within thelimits specified.

506 SERVO ERROR 25105-51115120-51235130-5136

* External electricalequipment hasjammedthe robot computer.

* Erroneous computerboard.

Re-initiate the system and start-upagain. If the error persists,replace the computer board.

506 SERVO ERROR 25137-5138

A External electricalequipment has jammedthe robot computer orserial measurementboard.

B Faulty computer boardor serial measurementboard.

C Faulty wiring betweenthe robot computerboard and the serialmeasurement board.

Re-initiate the system and start-upagain. If the error persists, checkthe wiring or replace the computer boardand/or the serial measurement board.

Error List21

S3



The maximum permissiblewaiting time for answer tothe main computer from theaxis computer has expired,depending on:* An earlier error has caused

the servo computer to halt.* Fault in the robot computer.

Find and correct the earlier errorthen re-initialize the system.If the error persists, change therobot computer board.


Non-valid channel index.Communication fault between the diagnostic software and the main computer, caused by a fault inthe control program.

Exchange the control program.


Erroneous sync position.The sync position of therobot is not correct,because there are no valuesfor the sync position in therobot control program.



Fault in internalcalculation routinein the control program.



Execution of a programmodule in the maincomputer starts, before avalid acknowledge signalhas occurred.

Check the computer board.Ifno error is found, changethe control program.


STALL ALARM.The main computer has detected that messages fromthe axis computer are nottransmitted fast enough.

Check the computer board.If no error is found, perform acommon error tracing, accordingto Chapter 4 in the ServiceManual.


The servo computer hasdetected an undefinederror in:* It's own program.* The main computerprogram.

Check the computer board.


Maximal waiting time foranswer to the main computerfrom the servo computer, forrespond on a movementsegment, has been exceeded.

Re-initialize the system.

Error List S322


506 SERVO ERROR 2 The servo computer has given Re-initialize the system.7010 an unalkwable error code to the

main computer.

506 SERVO ERROR 2 The servo computer has not Re-initiate the system.8001 approved an order from the If the fault remains, replace

main computer due to a the control program.serious error in the maincomputer.

508 SERVO ERROR 2 Transmission fault A Check the installation9000 between the serial B Check and measure the wiring

measurement board C Change the serial measurementand the r.oot board or the robot computercomputer board. board.Causes:A External disturbancesB Wiring faultC Electronic fault

507 JOYSTICK 1 Indicates a fault in the If the fault persists, check theERROR joystick function. joystick according to the Service Manual.

2 Erroneous coordinatesystem button.

508 DISK MEMORY Error in the floppy * Repeat attemptFAULT 1 disk memory. * Change disk

508 DISK MEMORY Data stored has dis- * Repeat attemptFAULT 2 appeared. * Change disk

508 DISK MEMORY Data stored incorrect * Repeat attemptFAULT 3 * Change disk

508 DISK MEMORY A. Floppy disk faulty Repeat attemptFAULT 4 B. Floppy disk not B. Change disk

formatted.

508 DISK MEMORY Floppy disk with storage * Remove storage protectionFAULT 8 protection. * Change disk

508 DISK MEMORY Floppy disk unit not Insert disk correctlyFAULT 7 ready. * Close hatch

Change disk

508 DISK MEMORY Erroneous data it * Try againFAULTS attempt of storing * Change disk

data on floppy disk.

508 DISK MEMORY Internal Winchester Re-initiate the systemFAULT 10 fault

Error List S323

ERROR MESSAGE CAUSES RECOMMENDED CORREC`FIVE MEASURES

508 ERROR iNPROGRAM 18

Not possible to load the blockinto the reserved memoryarea. The block containsother instructions thancomment instructions or iscorrupt.

Load the block into the user memory andcheck the contents. Edit the block orselect a block from the system disk andtry again.

508TPROGRAMTOO BIG 18 into the reserved memory

area. More than 25% of theblock is used.

check the contents. Edit the block orselect a block from the system disk andtry again.

508 DISK MEMORYFAULT 20

Attempted loading offunction parameters fromwrong disk.

* Change disk


Attempt to programstorage when thewhole floppy diskis occupied.

* Change disk


Attempt to load program from an emptyfloppy disk.

* Replace disk


Attempt to load a program block not availableon the floppy disk.

* Select another program blocknumber.

* Change disk.


Attempt to add a programblock that is larger thanthe user memory.

1. Erase all programs in the usermemory program numbers 0- 9999.

2. Load required program block, with thefunction ADDALL under theMANUAL menu.

If this does not work, split the programblock into two parts at the robot, wherethe block was originally programmed.

5d DISK MEMORYFAULT 28

An attempt has been madeto add a program blockas the space availablein the user memory isinsufficient

1. Erase any superfluous programsin the user memory.

2. Store the remaining part of theprogram block as block X.

3. Load the program block containing therequired program.

4. Erase all unwanted programs.5. Add block X with the functionADDALL.

If this is not successful, use theinstruction GET B in the program foralternate running of program blocks XandN.

Error List S3

Not possible to load the block Load the block into the user memory and

24



Error in the storedprogram block.

* Select another block number.* Change disk.

508 DISK MEMORYFAULT28

Fault when formattingfloppy disk.

* Change disk* Tryagain


Attempt to load a non-existing subprogram fromfloppy disk.

* Select another block number.* Select another program number.


Floppy disk function isfaulty.

Re-initiate the system.

508 DISK MEMORYFAULT 31for arc weldingrobots only

Weld data missing forthe program blockconcerned.

* Select another block numr* Change disc.

508 DISK MEMORYFAULT 32for arc weldingrobots only

Incorrect version ofweld data.

Select disc with right weld dataversion.

509 SYNC ERROR Error when the robotsystem is to besynchronized.

* Press twice on SYNC on the controlpaneL

* If repeated attempts are notsuccessful, perform a commonerror tracing, according toChapter 4 in the Service Manual.

509 SYNCHRONIZATION ERROR 1OXX

Robot axis OC is outside itsoutside the working rangeError has occurred in thecontrol system, axis

Move the axis into the working rangeand switch the system off. Try again.If the problem persists, it might becaused by DSQC 234, see the ServiceManuaLCheck the robot calibration position before returning the robot to prodwition!

509 SYNCHRONIZATION ERROR 11XX

Working range defined forexternal axis no. O is toogreat with the gear ratioin use.

Redefine the working range underPARAM or check that the correctresolver configuration has beenselected.

509 SYNCBRONIZATION ERROR 14XX

Resolver on axis no. CCnot calibrated.

509SYNCURONIZATION ERROR 1SXX

Error List

Resolver error.Axis no. has obtained animpermissible resolvervalue with absolute measurement.

Check the measurement system.

S325

ERROR MESSAGE CAUSES RECOMMENDED CORBEClIVE MEASURES

509 SYNCHRONIZATION ERROR 16

System fault in absolutemeasurement system.

See instructions in ServiceManual for checking therobot system.

509 SYNCHRONIZATION ERROR 17

The robot is too faraway to restart.The robot program runningcan not be restarted directly.

Start-up the system the conventionalway. Check the robot calibrationposition before returning the robot toproduction!

509 SYNCHRONIZATION ERROR 2Oxxconcerns only robots inthe 8000-eerie.

Robot axis xx is outsidethe working area.

Manoeuvre the axis into theworkingarea and switch offthe system. Try once more.

509 SYNCHRONIZATION ERROR 2IXX

The revolution counterfor axis not calibrated.

Calibrate the revolutioncounter and start-up again.

509 SYNCHRONIZATION ERROR 22XX

Error on the revolutioncounter on axis OL Therevolution counter has lost.

Check the measurementsystem. The robot remainsunsynchronized. Operationmode is blocked until theerror is remedied.

509 SYNCHRONIZATION ERROR23

Error on the revolutioncounter on axis XX. Theexpected revolution countervalue does NOT correspondto that of the serialmeasurementboard revolution.counter.

Check the measurement system,especially all resolver and measurementboard connections. Recalibrate the robotrevolution counter. Check the robotcalibration position. If the problempersists, replace the serialmeasurementboard.

510 SYSTEMFAULT 3

Internal fault in thecontrol program modulein programmed robotrunning.

Switch-off and start-upthe robot system once again.If the fault persists exchangethe control program.

510 SYSTEMFAULT 4

A. The internal restartwas interruptedundefined.

B. Power failure in aninstruction that can'tbe restarted.

A,BSwitch off the system and startin the conventional way.

510 SYSTEMFAULT 5

Restart data inmemory is wrong.

Switch off the system and start in theconventional way.

510 SYSTEMFAULT 6

An error has occurred in theerror buffer. All old messageshave been erased.

Error List S326


513 WRONGLYPLACED A Board missing on A Place a board on position X or110 BOARD X position X. change the system parameterX=subcode which B The board on posi- for subcode 1-6.defines the board tion X does not corresposition concerned pond to the board- B Place the correct type ofboard or

type specified in the change the system parameter forsystem parameters subcode 1-6.specified manuallyfor subcode 1-6. C Check the board.

C The board on positionX erroneous.

The board positions in questionare coded for the board type,that is specified in the systemparameters manual specifications for the 6 1/0 positions.The board positions are codedin accordance with the following:

Subcode Type acc to param0 Safety board1 1/0 board, position 12 1/0 board, position 23 1/0 board, position 34 1/0 board, position 45 110 board, position 56 1/0 board, position 6

514 COMMUNICATION Insufficient space in the Restart the robot system.ERROR 1 robot buffer memory forapply only to robots data from superior corn-equipped with computer puter.link

514 COMMUNICATION Data fault in message Check superior computer.ERROR 2 received from superiorapply only to robots computer.equipped withcomputer link

514 COMMUNICATION Transmission error on Repeat the attempt.ERROR 3 the data link.apply only to robots equippedwith computer link

514 COMMUNICATION Insufficient space in Erase any superfluous programERROR 4 the robot memory when in the robot memory.apply only to robots attempting to load aequipped with program from a superiorcomputer link computer

Error List S327


514 COMMUNICATION Program with program Select a program withERROR S number selected not in another program number.apply only to robots equipped the robot memory.with computer link

514 COMMIJNICATION Maximum waiting time Check superior computer.ERROR 6 before acknowledgmentapply only to robots from superior computerequipped with exceeded.computer link

514 COMMUNICATION Computer link not Check that function parameterERROR 8 implemented. C LINK is set See Inst. manual.For robots withcomputer link only

514 COMMUNICATION Fault in vision system. Restart the vision system. If the faultERROR 9 persists, check the connection orFor robots with contact service personnel.computer link only

514 COMMUNICATION Vision timeout. Restart the vision system. If the errorERROR 10 persists, check the connection orFor robots with contact service personnel.computer link only

514 COMMUNICATION Incorrect robot mode. Set robot in STANDBY MODE.ERROR 11For robots withcomputer link only

514 COMMUNICATION Insufficient space in robot Check that the block to be loaded isERROR 12 memory when an attempt is intended for the robot in question.For robots with made to load configurationcomputer link only data.

514 COMMUNICATION Incorrect check sum in con- Make another attempt to load theERROR 13 figuration data loaded, configuration data.For robots with Robot system initializedcomputer link only with configuration data

from PROM.

514 COMMUNICATION Incorrect weld data version. Configurate to right weld dataERROR 14 version on superior computer.For robots withcomputer link only

515 TIMEOUT ERROR When programming the arc- Check the external equipment.only arc welding robots welding instruction EPOS,

the response from the external equipment is not received before the maximumpermissible waiting time hasbeen exceeded.

Error List S328

ERROR MESSAGE CAUSES RECOMMENDED CORRECTWE ACTION

516 OVERRIDE ERROR 1only arc weldingrobots

Override has been defined as:A. Welding is not performed.B.The welding datanumber has been changed.

A.Wait until welding is performed.B.Try again.

516 OVERRIDE ERROR 2only arc weldingrobots

The limit values foroverride definition hasbeen exceeded.

Store the values and keepdefining override values.

517 WELD ERROR 1010only arc weldingrobots

The current supervisionhas detected that currenthas disappeared for longerthen 500 ma.

Check the thread feeder andcurrent supply.


The gas/coolant supervision Check the gas flow andhas detected that gas/coolant coolant flow.is missing.


The welding arc has notbeen lighted before theindicated time fromwelding start order.

Check thread feeder andcurrent supply.Change the maximum timein the start data.


Gas and coolant flow receivedhas not been started before2 seconds after the robothas moved to the positionfor welding start.

Check gas flow and coolant flow.

523 ERROR STATIONDRiVE UNIT 1only arc weldingrobots

At power-on the activationofmanipulator 1 failedm allowed waiting timefor acknowledgment signal from manipulator3 seconds exceeded.

1'ry again. If repeated attemptsare not successful, seeService Manual.

52$ ERROR STATIONDRIVE UNiT 2only arc welding robots

The robot moved whenactivation/deactivationof a station was requested.

Stop the robot and repeatthe attempt


An input indicates that thedrive units of a station havebeen activated, in spite of thefact that no such order hasbeen given on the output.

Check that the station connectionis in accordance with the functionparameter STATION. In that casecheck the external equipment


Error List

An input indicates that thedrive units of a station havebeen deactivated, in spite ofthe fact that no such orderhas been given on the output

Check the cables and thatthe station connection is inaccordance with the function parameter STATION. Inthat case check the externalequipment.

S329

ERROR MESSAGE CAUSES RECOMMENDED CORREC.TWE ACTION

523 ERROR STATIONDRIVE UNITSonly arc weldingrobots

An output for activating aSTATION is set, but noanswer from correspondinginput has been given within5 sec.

Check the the connections fromORBiT to the robot controlsystem.

523 ERROR STATIONDRIVE UNIT 6only arc weldingrobots

Signals for activation toSTATIONS have been resetat an earlier stop. Thesesignals have automaticallybeen set high again.

Check that the connected stationsare relevant.Ifthat is the case,restart the program again,otherwise connect the STATIONSin question.

524 OUTSIDE WORKINGAREA 7. 12

External axis is outsideworking area.

Modify the program.

536 DMH FAULT A The dead man's handlehas been held in anintermediate position

B A fault in the contacts ofthe dead man's handle.

Press the dead man's handleagain. If the fault remains,check the contacts under thedead man's handle.

536 SPtw SUPERVISION FAULT 5

The key switches positionand reported status of theservo computer's SPEEDsignal do not coincide.

Y*?nine the SPEED signal statuson the back panel between thesafety board and the robotcomputer board.

536 RUN RELAY FAULT13

Control signal and checksignal to/from the operationcontactor do not coincide.

Cheek the operation contactorand the cabling.

336 ENABLE CHAINFAULT 21

The ENABLE chain hasbeen broken as a result ofone ofthe following fault:A Drive unit/fatal fault

B Rectifier/fatal fault

C Measurement system/fatal or nonfatal fault

Check the LED on the frontof the safety board.A The LED is lit.nonfatal fault

The occurred fault is automaticly reset. The enablechain is closed after afewseconds. The system can bein operation mode again.

B The LED is put out:fatal faultThe occurred fault has to bemanually reset The enablecan only be reset by ansystem initiation.Search forthe cause to the fault andremedy it Do a system initiation.

53 SAFHAZARD Fault in the safety boardindicated via the super.vision for the ENABLE loop.

Replace the safety board.

36 SAFE'lY HAZARD34

An attempt has been madeto start-up the system withundefined commutatingoffset.

Define the commutating offset

1 rror List S330

ERROR MESSAGE CAUSES RECOM?VIENDED CORREC.TWE ACTION

536 RUN BUTTON The run button has been Check and if needed remedyFAULT 35 pressed for 30 seconds. the run butt3n or the cabling.

536 KEY STATUS The position/status of the Change the position of the keyFAULT 36 key is incorrect updated e.i. or swich the off and on the system.

because of two key turnsin a raw, when the systemwas in operation or the runchain was broken.

536 MOTOR OVER- Overload in motor 1.7. Re-start the system.LOAD FAULT 101.107

538 WORK STOP 1 One or severai work stop * Check for the cause to theswitchers connected to the stop and remedy any possiblesystem have been activated, problem in the system.

* Then reset the activatedswitchers.

538 SAFETY STOP 2 One or several safety stop * Check for the cause to theswitchers connected to the stop and remedy any possiblesystem have been activated, problem in the system.

* Then reset the activated switchers.If the stop can not be reset:* Check the clamps that arenot used by the safety circuits.

* Check the safety board.* Perform a common error tracing

according to the Service manual.

539 INTERNAL EEC- No power from the internal Check if possible clamps onTI.PIR POWER FAULT rectifier. not used internal rectifier.1 Check and if needed remedy

rectifier and cabling.

539 `1'ERNAL EEC- No power from the external Check if possible clamps onTIF'JJK POWER FAULT rectifier. not used external rectifier.2 Check and if needed remedy

rectifier and cabling.

539 WARNING! EEC- At least one phase in the Check and if needed remedyT1FJiU PEASE MISSING 3 power supply to the rectifier. fuses and cabling.

540 BRAKES RELAY System error which means Examine the connections to theFAULT that the brakes are not robot brakes an I locate the break

released normally, in the connection.

542 MOTORTYPE Attempt has been made to Define motortype according to theNOT DEFINED take the system in operation Installation manuai S3.

without that the motortypehas been defined.

Error List S331


544 WARNING NEW The system has discovered Choose if the system is to be startedRESOLVERDATA a difference etween the new on the new or old resolver data.

LOADED new resolv': values, and Remaining system parametersthe resolver values already in according to earlier executedthe parameter mernoly. operation. Check that the robot

has the right system parametersafter re-start.

547 HYDRAULIC Faulty pressure in the Z axis Check the pressure unit.PRESSURE ERROR 1 pressure unit

ROBOTS IN THE8000 SERIES

550 WELD ERROR 1 WELD RE' DY not reset Check the welding controller.when START 1 or START 2is activated.

550 WELDERROR 2 WELD READY not received Check the welding controller.within lOs after START 1 orSTART 2 has been activated.

551 WELD ERROR TIMER Signal TIMER OK is missing. Check the welding controller.

552 WELD ERROR Signal CURRENT OK is Check the welding controller.CURRENT missing.

553 WELD ERROR FLOW Signal FLOW OK is missing Check the cooling waterfor more than 5 sec. supply.

554 WELD ERRORTEMP SignalTEOK is missing. Check the welding controller.

555 WELD ERROR The system has been waiting Check the welding gun andENABLE MOVE for signal ENABLE MOVE sensors

more than 5 sec. upon gunopening.

580 ERROR/ROBOT A robot computer board corn- See subcode in chapter 5.COMPUTERBOARD ponent is malfunctioning. See

chapter 5 for further information.

582 ERROR/ROBOT Erroneous signals from drive See subcode in chapter 5.DRIVE UNIT unit after start-up. See

chapter 5 for further information.

583 ERROR/DRiVE Drive unit exc eds limit Check the drive unit connection.UNIT OFF8 x values when c tnnensating If all connections are correct, replace

for offset. See chapter 5 for the drive unit.further informatic 1. If this doesn't work, change the

robot computer board.

Subcode x Jnit1 Driveunitl2 Driveunit23 Driveunit3

Error List S332


4 Driveunit45 Driveunit56 Driveuxut67 Driveunit7

587 ERROR/SAFETY Data from the safety board See subcode in chapter 5.BOARD is incorrect. See chapter 5 for

further information.

570 ERROR/MEASURE The measurement system See subcode in chapter 5.SYSTEM, AXES 16 diagnostics has discovered

an error. See chapter 5 forfurther information.

571 ERROR/MEASURE The measurement system See subcode in chapter 5.SYSTEM, AXES 7 diagnostics has discovered


572 ERROR/MEASURE The measurement system See subcode in chapter 5.SYSTEM, AXES 8.12 diagnostics has discovered


573 ERROR/MEASURE The measurement system See subcode in chapter 5.SYSTEM, AXES 7.12 diagnostics has discovered


580 WARNING DISK Error when starting disk. See subcode in chapter 5.See chapter 5 for furtherinformation.

581 WARNING COMPT.n Error when starting com- See subcode in chapter 5.L4K puter link. See chapter 5

for further information.

582 WARNING PIWTER Error when starting printer. See subcode in chapter 5.See chapter 5 for furtherinformation.

583 WARNING SENSOR Error when testing the main See subcode in chapter 5.computer serial links. Seechapter 5 for furtherinformation.

585 WARNING PROG Error when starting the See subcode in chapter 5.UNITxm programming unit. See

chapter 5 for furtherinformation.

586 WARNING MONITOR Error when starting monitor. See subcode in chapter 5.See chapter 5 for furtherinformation.

Error List S333


588 WARNINGWINCHESTER

Error when starting theWinchester memory. Seechapter 5 for furtherinformation.

See subcode in chapter 5.

589RCnatMISSING

The configuration check ofthe rectifier indicates typecode 0, that means no rectifierconnected.

Check that:* rectifier is connected correctly

590 REninaWRONGTYPE

Wrong type of rectifier. Check the rectifier with re Pectto robot type and change to theright type.

591 DRiVE SYSTEMERROR

The drive system hasindicated error, but noerror status is placed ineither rectifier or drive unit..

Re-initiate the system.

592 RECTuutt OUTPUTVOLTAGE HIGH

The voltage from the rectifieris too high.

Change rectifier.

593 REC-IiFiIaL TEMP.HIGH

The rectifier unit is isoverloaded.

Check if the surroundingtemperature is too high.Reduce the intermittenceduring the run mode.

594 SHUNT RESISTANCETEMP. HIGH

The return supply powerfrom the robot motors istoo high. Too high surroundings temperature and toohigh input voltage to therectifier can also causetoo high temperature.

Check the input voltageto the rectifier.Check the surroundingstemperature around thecontrol cabinet.Reduce the intermittenceduring run mode.

595 DRiVE tjrrMISSING 1-7

The configuration checkof the drive unit for the axisin question, indicates type0, that means no diveunit connected.

Check if t he drive unit onthe axis in question is in theright position. Check the flatcable between drive `mit andcomputer.

596 DRiVE UNiT WRONGTYPEX

The drive units on the axis Check the type of drive units onX in question are of the wrong the axis in question, and changetype. to the right type.

597 DRiVE urrCURRENTHIGH X

The drive unit for the axisX in question has gone intothe over current limit.

Check that the cabling out ofthe drive units or the motorwinding is short-circuit.Check that the out-put onthe drive unit isn't shortcircuit.

Error List S3-e

34


598 DRIVE urrCURRENTERRORX

The current out fromthe drive unit for the axisX in question do not correspond to the ordered value.

Check that the cables out fromthe drive unit in question areunbroken. Probable error causeis interruption in one of the cablesor the motor winding.

599 DRIVE urr TEMP.HIGH X

The temperature on theout-put level on the drive-unit in question for the axisx in question has exceeded.

Check:* iftherobotaxisfortheaxisin

question do not work slowly* the commutation offset* that the surroundings temp.around the control cabinetis below the max. allowed

Reduce the intermittenceduring run mode.

602 VISIONSYSTEMERROR

5

The hardware for VISIONis not available.

Otherwise see separatedocumentation for VISION.

Diagnostic messages

Diagnostic error concerns the fault- and warning message the system discovers when testingthe hard ware during the start-up sequence.Depending on the type of malfunction, two types of message may be displayed: error messageor warning message.

Error message:When this type ofmessage is displayed on the programming unit, the system is alwaysinterrupted and put in an error mode. If the malfunction occurs during start-up, this isinterrupted.

Warning message:The printout is given after a malfunction has been detected in any of the units, but themalfunction is not serious enough to interrupt the system.

Normally, all message printouts are displayed on the programming unit display, but duringthe diagnostic test at start-up, no text can be displayed during certain periods of time. Theerror codes may then be displayed by the error LED on the computer board front. See chapter6 for a detailed description.

Error and warning messages using a subeode:

ERROR/ROBOT COMPUTER BOARDERROR/DRIVE UNIT xxERROR/SAFETY BOARD xxERROR/MEASUREMENTSYSTEM, AXES 1-6 xxERROR/MEASUREMENT SYSTEM, AXIS 7 xxxxERROR/MEASUREMENT SYSTEM, AXES 8-12 xxxxERROR/MEASUREMENT SYSTEM, AXES 7-12 xxxxWARNiNG DISKxmWARNING COMPUTER LINKxm

560562567570571572573580581

S3Errcr List35

Error at main computerinstruction test

PROM checksum error

Error when testing theenable chain

RECOMMENDED CORRECTWEACTION

Replace the robot computer board

a Replace the robot computer boardb Replace voltage supply unit DSQC 241c Replace the computer rack rear plane



582 WARNING PRINTER xxu583 WARNING SENSOR xxxx585 WARNING PROGRAMMING UNIT xm586 WARNING MONITORxm588 WARNINGWINCHESTERmxfor which xxxx represents one of the following subcodes, more thoroughly describing the causeof the message.The following is the list of the subcodes which may be displayed along with an error orwarning message.

SUBCODE CAUSE

RWM error

Code downloading error

Main computer error whenhandling not allowed command

Error in test 1 of communicationbetween I/O and main computers

Error in test 2 of communicationbetween 1/0 and main computers

Error at ending of 1/0 computer first test sections

Error when testing the maincomputer sensors, serial channels

a Replace the EPROMb Replace the robot computer board








0001

0002

0003

0004

0008

0009

0010

0011

0013

0014

0017

0018

0019

0039

0040

Error when starting the 1/0computer later test sections

Error in test 1 of communicationbetween servo and main computers

Error in test 2 of commu- Replace the robot computer boardnication between servo andmain computers

Servo computer communication error Replace the robot computer board

Error when starting the servo Replace the robot computer boardcomputer later test sections

Error List S336

SIJBCODE

0070

0071

0072

0075

0076

0080

0081

0101

0102

0105

0106

0107

0108

0109

0112

0114

0116

CAUSE

Error when testing the main computer serial channel. Out = low,In = high

Error when testing the main computer serial channel. Out = low,In = high

Error when testing the main computer serial channel A

Error when testing the 110 computer serial channel A, computerlink

Error when testing the 1/0 computer serial channel B, printer

Error when testing the I/O bus

Erroneous data from the 1/0 bus

Error at 1/0 computerinstruction test

PROM checksum error, I/O computer

Erroneous 1/0 computer `safl timer"

Erroneous 1/0 computer" time outtimer"

Erroneous 110 computer" intervaltime?

1/0 computer error whenhandling not allowed command

Error in communication betweenI/O and main computers

Internal diagnostics error in1/0 computer

Error when testing theenable chain

Error when initiating the1/0 computer

RECOMMENDED CORRECTIVEACTION

Is used at manufacturing check ofrobot computer board








a Replace the EPROMb Replace the robot computer board







a Replace the robot computer boardb Replace voltage supply unit DSQC 241c Replace the computer rack rear plane


Error List S337

SUBCODE CAUSE RECOMMENDED CORRECTIVEACTION

0120 Error when testing printer output Replace the robot computer board ifprinter is to be used

0121 Error when testing computer link Replace the robot computer board ifcomputer link is to be used

Error when testing disk a Check main cablingb Replace mass memoryc Replace the robot computer board

0124 Error when testing the a Check that 24 V I/O is there.safety board b Replace the safety board DSQC 228

Error when testing the a Check main cablingWinchester memory b Check that the massmemory gets

12V.c Replace the massmemory.d Replace the robot computer board

0130 Robot computer board pd bus error Replace the robot computer board

0131 Error when testing the programming a Perform a restartunit b Check main cabling especially

the 24 V supply.c Replace the programming unit

0133 Error when testing the monitor a Check main cablingb Replace monitorc Check system parameters

Non standard programming unit a Perform a restartb Check main cablingc Replace the programming unit

Not allowed I/O computer inter. Replace the robot computer boardruption

0139 1/0 computer not responding Replace the robot computer board

0140 Computer bus error, I/O computer Replace the robot computer board

0201 Error at servo computer Replace the robot computer boardinstruction tea t

0202 PROM checksum error, servo corn- a Replace the EPROMputer b Replace the robot computer board

0205 Erroneous servo computer stall Replace the robot computer boardtime?

0206 Erroneous servo computer time out Replace the robot computer boardtime?

Error List S338

SUBCODE

0207

0208

0209

0210

0211

0218

0239

0240

0302

0315

0358,

0701

0702

0722

0723

0724

CAUSE

Erroneous I/O computer" intervaltimer"

I/O computer error whenhandling not allowed command

Error in communication betweenservo and main computers

Error at ending of servo computer first test sections

Error at ending of servo computer last test sections

Servo computer initiation error

Servo computer not responding

Data bus error, servo computer

Checksum error, axis computersin-arctan table

Error when loading test programto the axis computer

Start-up error, axis computer

Status bit error, FAULTRES-N,of the drive system

Address bit error, SAO-SA5,of the drive system

Status POWER UP-N erroneousfrom drive system after reset.

Signal RUNNING erroneousfrom drive system after reset

Status AC-N erroneousfrom drive system after reset

RECOMMENDED CORRECTiVEACTION


Replace the robot computer boarc.












a Replace rectifierb Check flat cable between robotcomputer board and drive system.c Replace the robot computer.d Replace drive unit rack

a Replace rectifierb Check flat cable between robotcomputer board and drive system.c Replace the robot computerd Replace drive unit rack

a Replace rectifierb Check flat cable between robotcomputer board and drive system.c Replace the robot computer.d Replace drive unit rack

Enor List S339

SUBCODE

0731

CAUSE

Signal FAULT-N erroneous

RECOMMENDED CORRECTWEACTION

Is used at manufacturing check ofrobo' computer board

0732

0733

0734

0741

0742

0744

0902

0903

0907

0920

Error List

Signal RUNNING erroneous

Read data error, R3 SDO

Read data error, R3 SD1

Axis computer does not respond atdrive unit test

Too large AD converter offset error

Too large AD converter offset error

Too large offset error on any driveunit channel

The axis computer does respond atoffset compensation, drive units

Communication error tomeasurement system.

Not allowed offset error on the Xchannel ofmeasurement system.

Not allowed offset error on the Xchannel ofmeasurement system.

Too large difference between X andY channels ofmeasurement system.

Disruption in cabling, the loop isclosed without passing measureirentboard no 2.Linearity error on the X channelof measurement system.X ramp does not increase

Linearity error on the Y channelof measurement system.Y ramp does not increase

Communication error tomeasurement system DSQC 233



Is used at manufacturing check ofrcot computer board


a Replace the robot computer board

a Replace the robot computer board

a Replace the robot computer boardb Replace the drive unit


a Replace serialmeasurement board.b Replace the robot computer board

Replace serialmeasurement board.



A Do a restartB Install missing equipmentC Check the cabling between

the measurement board andthe robot computer.

D Exchange the identifiedser ilmeasurement board.

E Exc. iange robotcomputer board.

Replace serialmeasuretnent board.

a Replace measurement board DSQC 233b Replace the robot computer board

S340

SUBCODE

0921

0922

0923

0924

0925

0926

0927

0928

0929

0930

0960

0961

0962

Error List

CAUSE

Offset error on AD converter tomeasurement system DSQC 233

Offset error on DA converter, ch. 1to measurement system DSQC 233






Linearity error, cli. 1 ofmeasurement system DSQC 233

Linearity error, cli. 2,4, 6 ofmeasurement system DSQC 233

Linearity error, ch. 3 and 5 ofmeasurement system DSQC 233

Error at local ring controllerloopback'

Error at wring controllerloopbackw

Error at ring controllerloopback

RECOMMENDED CORRECTIVEACTION

Replace measurement board DSQC 233













S341

6Test mode errors

To enable performing tests in the test mode, the key switch must be set in either positionTEACH or position TEST V=100% when the robot is in its normal initiated mode.

Then, the robot is to be initiated in the test mode by pressing both push buttons on thecomputer board front, and then letting the initiation button up a couple of seconds beforeletting up the test button.

If an error is discovered during start-up diagnostics in the test mode, the subcode of the errormessage will not only be displayed on the programming unit but also on the robot computerboard error lamp.

This enables obtaining an error code in cases where the error message is not displayed on theprogramming unit. The displayed subcode is one ofthe subcodes explained in section 5.

To obtain an subcode from a faulty system, the operator must perform an initiation to enterthe test mode which. This is described above. During this restart, the diagnostic system willperform the same tests once more, and the error will be rediscovered.

The error lamp on the robot computer board front will blink repeatedly to indicate the errorsubcode in accordance with the following description. The blinking of the error lamp will berepeated until the system is reinitiated.

E.g. error code560 ERROR/ROBOTCOMPUTERBOARD

302

FAULV lamp

IS LIT

IS NOT LIT

Robotcomputerboard frontDSOC23O

3

10 If11112i I 111itime, saconds

Error List42

S3

Test of board DSQC 233, axis board:

The error printouts available are the same as for a normal start-up according to sections 4 and5.

I.e.570 ERROR/MEASUREMENT SYSTEM AXES 1-6 xm571 ERROR/MEASUREMENT SYSTEM AXIS 7572 ERROR/MEASUREMENT SYSTEM AXES 8-12 xxxx573 ERROR/MEASUREMENT SYSTEM AXES 7-12 mxxm = sub codes

Test of board DSQC 236, drive unit:

The error code parameter XX indicates outputlinput in accordance with the table below:

XX Function XX Function

01 Enable loop error 02 Type code error03 Test sequence error 04 Axis computer does not respond05 Drive unit missing

Test of board DSQC 209, analog in/output board:

The error printout parameter XX indicates the output/input in accordance to the table below:


0 Boardabsent 1 CH12 CH2 3 CR34 CH4

Test of board DSQC 223 , digital in/output board:

The error printout parameter XX indicates the output/input in accordance to the table below:


0 Boardabsent 1 CR12 CR2 3 CR34 CR4 5 CR56 CH6 7 CR78 CR8 9 CH910 CH1O 11 CR1112 CH12 13 CH1314 CH14 15 CR1516 CH16

Error List S343

Test of board DSQC 224, combined digital and analog in/output board:

The error printout parameter XX indicates the outputiinput in accordance to the table below:


0 Boardabsent 1 CH12 CH2 3 CH34 CH4 5 CH56 CH6 7 CH78 CH8 9 CH910 CH1O 11 CH1112 CH12 13 CHI314 CH14 15 CH1516 CH16

21 Analog CH 1 22 Analog CH 2

Error List S344

irb 6000 m93 error list

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