prio

FANUC Robotics SYSTEMR-30iA Controller SoftwareError Code ManualMAROCERCD03061E REV J 2011 FANUC Robotics America Corporation

About This ManualThis manual can be used with controllers labeled R-30iA or R-J3iC. If you have a controller labeledR-J3iC, you should read R-30iA as R-J3iC throughout this manual. You should also read the iRVisionVisual Tracking Start-up Guidance manual for a deeper understanding of PickTool. PickTool is avalue-added application built on top of two key components iRVision Visual Tracking and LineTracking. This manual contains some descriptions that are taken from the iRVision Visual Trackingmanual.

Copyrights and Trademarks

This new publication contains proprietary information of FANUC Robotics America Corporation,furnished for customer use only. No other uses are authorized without the express written permissionof FANUC Robotics America Corporation.

FANUC Robotics America Corporation3900 W. Hamlin RoadRochester Hills, MI 48309-3253

The descriptions and specifications contained in this manual were in effect at the time this manualwas approved. FANUC Robotics America Corporation, hereinafter referred to as FANUC Robotics,reserves the right to discontinue models at any time or to change specifications or design withoutnotice and without incurring obligations.

FANUC Robotics manuals present descriptions, specifications, drawings, schematics, bills ofmaterial, parts, connections and/or procedures for installing, disassembling, connecting, operating andprogramming FANUC Robotics products and/or systems. Such systems consist of robots, extendedaxes, robot controllers, application software, the KAREL programming language, INSIGHTvision equipment, and special tools.

FANUC Robotics recommends that only persons who have been trained in one or more approvedFANUC Robotics Training Course(s) be permitted to install, operate, use, perform procedures on,repair, and/or maintain FANUC Robotics products and/or systems and their respective components.Approved training necessitates that the courses selected be relevant to the type of system installedand application performed at the customer site.

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About This Manual MAROCERCD03061E REV J

Warning

This equipment generates, uses, and can radiate radio frequency energyand if not installed and used in accordance with the instruction manual,may cause interference to radio communications. As temporarilypermitted by regulation, it has not been tested for compliance with thelimits for Class A computing devices pursuant to subpart J of Part 15 ofFCC Rules, which are designed to provide reasonable protection againstsuch interference. Operation of the equipment in a residential area islikely to cause interference, in which case the user, at his own expense,will be required to take whatever measure may be required to correct theinterference.

FANUC Robotics conducts courses on its systems and products on a regularly scheduled basis at itsheadquarters in Rochester Hills, Michigan. For additional information contact

FANUC Robotics America Corporation3900 W. Hamlin RoadRochester Hills, MI 48309-3253

www.fanucrobotics.com

For customer assistance, including Technical Support, Service, Parts & Part Repair, andMarketing Requests, contact the Customer Resource Center, 24 hours a day, at 1-800-47-ROBOT(1-800-477-6268). International customers should call 011-1-248-377-7159.

Send your comments and suggestions about this manual to:[email protected]

The information illustrated or contained herein is not to be reproduced, copied, downloaded,translated into another language, distributed, or published in any physical or electronic format,including Internet, or transmitted in whole or in part in any way without the prior written consentof FANUC Robotics America, Inc.

AccuStat, ArcTool, iRVision, KAREL, PaintTool,PalletTool, SOCKETS, SpotTool,SpotWorks, and TorchMateare Registered Trademarks of FANUC Robotics.

FANUC Robotics reserves all proprietary rights, including but not limited to trademark and tradename rights, in the following names:

AccuAir, AccuCal, AccuChop, AccuFlow, AccuPath, AccuSeal, ARC Mate,ARC Mate Sr., ARC Mate System 1, ARC Mate System 2, ARC Mate System 3, ARCMate System 4, ARC Mate System 5, ARCWorks Pro, AssistTool, AutoNormal,AutoTCP, BellTool, BODYWorks, Cal Mate, Cell Finder, Center Finder, Clean Wall,DualARM, LR Tool, MIG Eye, MotionParts, MultiARM, NoBots, Paint Stick,PaintPro, PaintTool 100, PAINTWorks, PAINTWorks II, PAINTWorks III, PalletMate,PalletMate PC, PalletTool PC, PayloadID, RecipTool, RemovalTool, Robo Chop, RoboSpray, S-420i, S-430i, ShapeGen, SoftFloat, SOFT PARTS, SpotTool+, SR Mate,

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MAROCERCD03061E REV J About This Manual

SR ShotTool, SureWeld, SYSTEM R-J2 Controller, SYSTEM R-J3 Controller, SYSTEMR-J3iB Controller, SYSTEM R-J3iC Controller, SYSTEM R-30iA Controller,TCP Mate,TorchMate, TripleARM, TurboMove, visLOC, visPRO-3D, visTRAC, WebServer,WebTP, and YagTool.

Patents

One or more of the following U.S. patents might be related to the FANUC Robotics productsdescribed in this manual.

FRA Patent List

4,630,567 4,639,878 4,707,647 4,708,175 4,708,580 4,942,539 4,984,745 5,238,029 5,239,7395,272,805 5,293,107 5,293,911 5,331,264 5,367,944 5,373,221 5,421,218 5,434,489 5,644,8985,670,202 5,696,687 5,737,218 5,823,389 5,853,027 5,887,800 5,941,679 5,959,425 5,987,7266,059,092 6,064,168 6,070,109 6,086,294 6,122,062 6,147,323 6,204,620 6,243,621 6,253,7996,285,920 6,313,595 6,325,302 6,345,818 6,356,807 6,360,143 6,378,190 6,385,508 6,425,1776,477,913 6,490,369 6,518,980 6,540,104 6,541,757 6,560,513 6,569,258 6,612,449 6,703,0796,705,361 6,726,773 6,768,078 6,845,295 6,945,483 7,149,606 7,149,606 7,211,978 7,266,4227,399,363

FANUC LTD Patent List

4,571,694 4,626,756 4,700,118 4,706,001 4,728,872 4,732,526 4,742,207 4,835,362 4,894,5964,899,095 4,920,248 4,931,617 4,934,504 4,956,594 4,967,125 4,969,109 4,970,370 4,970,4484,979,127 5,004,968 5,006,035 5,008,834 5,063,281 5,066,847 5,066,902 5,093,552 5,107,7165,111,019 5,130,515 5,136,223 5,151,608 5,170,109 5,189,351 5,267,483 5,274,360 5,292,0665,300,868 5,304,906 5,313,563 5,319,443 5,325,467 5,327,057 5,329,469 5,333,242 5,337,1485,371,452 5,375,480 5,418,441 5,432,316 5,440,213 5,442,155 5,444,612 5,449,875 5,451,8505,461,478 5,463,297 5,467,003 5,471,312 5,479,078 5,485,389 5,485,552 5,486,679 5,489,7585,493,192 5,504,766 5,511,007 5,520,062 5,528,013 5,532,924 5,548,194 5,552,687 5,558,1965,561,742 5,570,187 5,570,190 5,572,103 5,581,167 5,582,750 5,587,635 5,600,759 5,608,2995,608,618 5,624,588 5,630,955 5,637,969 5,639,204 5,641,415 5,650,078 5,658,121 5,668,6285,687,295 5,691,615 5,698,121 5,708,342 5,715,375 5,719,479 5,727,132 5,742,138 5,742,1445,748,854 5,749,058 5,760,560 5,773,950 5,783,922 5,799,135 5,812,408 5,841,257 5,845,0535,872,894 5,887,122 5,911,892 5,912,540 5,920,678 5,937,143 5,980,082 5,983,744 5,987,5915,988,850 6,023,044 6,032,086 6,040,554 6,059,169 6,088,628 6,097,169 6,114,824 6,124,6936,140,788 6,141,863 6,157,155 6,160,324 6,163,124 6,177,650 6,180,898 6,181,096 6,188,1946,208,105 6,212,444 6,219,583 6,226,181 6,236,011 6,236,896 6,250,174 6,278,902 6,279,4136,285,921 6,298,283 6,321,139 6,324,443 6,328,523 6,330,493 6,340,875 6,356,671 6,377,8696,382,012 6,384,371 6,396,030 6,414,711 6,424,883 6,431,018 6,434,448 6,445,979 6,459,9586,463,358 6,484,067 6,486,629 6,507,165 6,654,666 6,665,588 6,680,461 6,696,810 6,728,4176,763,284 6,772,493 6,845,296 6,853,881 6,888,089 6,898,486 6,917,837 6,928,337 6,965,0916,970,802 7,038,165 7,069,808 7,084,900 7,092,791 7,133,747 7,143,100 7,149,602 7,131,8487,161,321 7,171,041 7,174,234 7,173,213 7,177,722 7,177,439 7,181,294 7,181,313 7,280,687

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About This Manual MAROCERCD03061E REV J

7,283,661 7,291,806 7,299,713 7,315,650 7,324,873 7,328,083 7,330,777 7,333,879 7,355,7257,359,817 7,373,220 7,376,488 7,386,367 7,464,623 7,447,615 7,445,260 7,474,939 7,486,8167,495,192 7,501,778 7,502,504 7,508,155 7,512,459 7,525,273 7,526,121

VersaBell, ServoBell and SpeedDock Patents Pending.

Conventions

This manual includes information essential to the safety of personnel, equipment, software, and data.This information is indicated by headings and boxes in the text.

Warning

Information appearing under WARNING concerns the protection ofpersonnel. It is boxed and in bold type to set it apart from other text.

Caution

Information appearing under CAUTION concerns the protection of equipment,software, and data. It is boxed to set it apart from other text.

Note Information appearing next to NOTE concerns related information or useful hints.

iv

Contents

About This Manual ................................................................................................................................. i

Safety ................................................................................................................................................... xi

Chapter 1 OVERVIEW ................................................................................................................ 111.1 OVERVIEW .................................................................................................................... 121.2 ERROR CODE PROPERTIES ............................................................................................. 131.2.1 Overview ......................................................................................................................... 131.2.2 Facility Name and Code ..................................................................................................... 171.2.3 Severity Descriptions ....................................................................................................... 1111.2.4 Error Message Text .......................................................................................................... 114

Chapter 2 ERROR RECOVERY .................................................................................................... 212.1 GENERAL ERROR RECOVERY PROCEDURES ................................................................. 222.1.1 Overview ......................................................................................................................... 222.1.2 Overtravel Release ............................................................................................................ 222.1.3 Hand Breakage Recovery .................................................................................................... 242.1.4 Pulse Coder Alarm Recovery ............................................................................................... 252.1.5 Chain Failure Detection Error Recovery ................................................................................ 272.2 PAINTTOOL RECOVERY PROCEDURES .......................................................................... 282.2.1 Overview ......................................................................................................................... 282.2.2 Brake Control Release ........................................................................................................ 292.2.3 Purge Fault Recovery ......................................................................................................... 292.2.4 Executing an Exit Cleaner Robot Request Out of Sequence ..................................................... 2102.2.5 Production Mode Recovery ............................................................................................... 212

Chapter 3 ERROR CODES ........................................................................................................... 313.1 A ..................................................................................................................................... 343.1.1 ACAL Alarm Code ............................................................................................................ 343.1.2 APSH Alarm Code .......................................................................................................... 3233.1.3 ARC Alarm Code ............................................................................................................ 3523.1.4 ASBN Alarm Code .......................................................................................................... 3773.1.5 ATGP Alarm Code .......................................................................................................... 3863.1.6 ATZN Alarm Code............................................................................................................ 3873.2 B ................................................................................................................................... 3903.2.1 BBOX Alarm Code ........................................................................................................... 3903.2.2 BRCH Alarm Code ........................................................................................................... 3953.3 C ................................................................................................................................... 3993.3.1 CALM Alarm Code ......................................................................................................... 3993.3.2 CD Alarm Code ............................................................................................................. 31053.3.3 CMND Alarm Code ........................................................................................................ 31113.3.4 CNTR Alarm Code ......................................................................................................... 3115

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Contents MAROCERCD03061E REV J

3.3.5 COND Alarm Code ........................................................................................................ 31173.3.6 COPT Alarm Code ......................................................................................................... 31183.3.7 CPMO Alarm Code ........................................................................................................ 31233.3.8 CVIS Alarm Code .......................................................................................................... 31633.4 D .................................................................................................................................. 32343.4.1 DICT Alarm Code .......................................................................................................... 32343.4.2 DJOG Alarm Code ......................................................................................................... 32423.4.3 DMDR Alarm Code ........................................................................................................ 32453.4.4 DMER Alarm Code ........................................................................................................ 32473.4.5 DNET Alarm Code ......................................................................................................... 32573.4.6 DX Alarm Code ............................................................................................................. 32803.5 E .................................................................................................................................. 32833.5.1 ELOG Alarm Code ......................................................................................................... 32833.6 F................................................................................................................................... 32843.6.1 FILE Alarm Code ........................................................................................................... 32843.6.2 FLPY Alarm Code ......................................................................................................... 32983.6.3 FRCE Alarm Code ......................................................................................................... 33003.6.4 FRSY Alarm Code ......................................................................................................... 33523.6.5 FXTL Alarm Code ......................................................................................................... 33563.7 H .................................................................................................................................. 33773.7.1 HOST Alarm Code ......................................................................................................... 33773.7.2 HRTL Alarm Code ......................................................................................................... 34073.8 I ................................................................................................................................... 34203.8.1 IBSS Alarm Code ........................................................................................................... 34203.8.2 INTP Alarm Code .......................................................................................................... 34723.8.3 ISD Alarm Code ............................................................................................................. 35403.9 J ................................................................................................................................... 35603.9.1 JOG Alarm Code ............................................................................................................ 35603.10 L .................................................................................................................................. 35663.10.1 LANG Alarm Code ........................................................................................................ 35663.10.2 LECO Alarm Code ......................................................................................................... 35713.10.3 LNTK Alarm Code ......................................................................................................... 35733.10.4 LSTP Alarm Code .......................................................................................................... 35823.11 M.................................................................................................................................. 35843.11.1 MACR Alarm Code ........................................................................................................ 35843.11.2 MARL Alarm Code ........................................................................................................ 35873.11.3 MCTL Alarm Code ........................................................................................................ 35923.11.4 MEMO Alarm Code ....................................................................................................... 35953.11.5 MENT Alarm Code ........................................................................................................ 36113.11.6 MHND Alarm Code ....................................................................................................... 36143.11.7 MOTN Alarm Code ........................................................................................................ 36333.11.8 MUPS Alarm Code ......................................................................................................... 37023.12 O .................................................................................................................................. 37043.12.1 OPTN Alarm Code ......................................................................................................... 37043.12.2 OS Alarm Code ............................................................................................................. 37083.13 P................................................................................................................................... 37103.13.1 PALL Alarm Code .......................................................................................................... 37103.13.2 PALT Alarm Code .......................................................................................................... 37473.13.3 PICK Alarm Code .......................................................................................................... 37493.13.4 PMON Alarm Code ........................................................................................................ 37563.13.5 PNT1 Alarm Code .......................................................................................................... 37583.13.6 PNT2 Alarm Code .......................................................................................................... 3927

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MAROCERCD03061E REV J Contents

3.13.7 PRIO Alarm Code ........................................................................................................ 310553.13.8 PROF Alarm Code ....................................................................................................... 310983.13.9 PROG Alarm Code ....................................................................................................... 311023.13.10 PTPG Alarm Code ......................................................................................................... 311123.13.11 PWD Alarm Code ........................................................................................................ 311143.14 Q ................................................................................................................................ 311243.14.1 QMGR Alarm Code ...................................................................................................... 311243.15 R ................................................................................................................................ 311253.15.1 RIPE Alarm Code ......................................................................................................... 311253.15.2 ROUT Alarm Code ....................................................................................................... 311293.15.3 RPC Alarm Code .......................................................................................................... 311343.15.4 RPM Alarm Code ......................................................................................................... 311363.15.5 RTCP Alarm Code ........................................................................................................ 311383.16 S................................................................................................................................. 311413.16.1 SCIO Alarm Code ........................................................................................................ 311413.16.2 SEAL Alarm Code ....................................................................................................... 311433.16.3 SENC Alarm Code......................................................................................................... 311913.16.4 SENS Alarm Code ....................................................................................................... 311933.16.5 SHAP Alarm Code ....................................................................................................... 311943.16.6 SPOT Alarm Code ....................................................................................................... 312013.16.7 SPRM Alarm Code ....................................................................................................... 312363.16.8 SRIO Alarm Code ........................................................................................................ 312383.16.9 SRVO Alarm Code ....................................................................................................... 312413.16.10 SSPC Alarm Code ........................................................................................................ 313283.16.11 SVGN Alarm Code ....................................................................................................... 313433.16.12 SVTL Alarm Code ......................................................................................................... 314063.16.13 SYST Alarm Code ........................................................................................................ 314083.17 T ................................................................................................................................ 314543.17.1 TAST Alarm Code ........................................................................................................ 314543.17.2 TCPP Alarm Code ........................................................................................................ 314573.17.3 TG Alarm Code ........................................................................................................... 314623.17.4 THSR Alarm Code ....................................................................................................... 314663.17.5 TJOG Alarm Code ....................................................................................................... 314763.17.6 TMAT Alarm Code ....................................................................................................... 314763.17.7 TOOL Alarm Code ....................................................................................................... 314803.17.8 TPIF Alarm Code ......................................................................................................... 314863.17.9 TRAK Alarm Code ....................................................................................................... 315143.17.10 TRSV Alarm Code......................................................................................................... 315173.18 V ................................................................................................................................ 315233.18.1 VARS Alarm Code ....................................................................................................... 315233.19 W ............................................................................................................................... 315363.19.1 WEAV Alarm Code ...................................................................................................... 315363.19.2 WNDW Alarm Code ..................................................................................................... 315413.20 X .............................................................................................................................. 315473.20.1 XMLF Alarm Code ...................................................................................................... 31547

Glossary ..................................................................................................................................... GL1551

Index ............................................................................................................................................. Index1

vii

List of Tables

Table 11. Startup Methods ................................................................................................................ 13Table 12. Alarm Log Screen ............................................................................................................. 14Table 13. Application Alarm Screen ................................................................................................... 14Table 14. Comm Log Screen ............................................................................................................. 14Table 15. Fault Recovery Screen ....................................................................................................... 14Table 16. Motion Alarm Screen ......................................................................................................... 14Table 17. System Alarm Screen ......................................................................................................... 15Table 18. Error Facility Codes ........................................................................................................... 18Table 19. Severity Descriptions ....................................................................................................... 112Table 110. Effects of Error Severity ................................................................................................... 114Table 111. Hexadecimal Error Message Display ................................................................................... 115Table 112. Hexadecimal Notation and Axis in Error Examples ................................................................ 116Table 21. MANUAL OT Release Items .............................................................................................. 22Table 22. Cancel/Continue Recovery Conditions and their Effect on the Current Operating Mode ................ 213

ix

SafetyFANUC Robotics is not and does not represent itself as an expert in safety systems, safety equipment,or the specific safety aspects of your company and/or its work force. It is the responsibility of the owner,employer, or user to take all necessary steps to guarantee the safety of all personnel in the workplace.

The appropriate level of safety for your application and installation can best be determined by safetysystem professionals. FANUC Robotics therefore, recommends that each customer consult with suchprofessionals in order to provide a workplace that allows for the safe application, use, and operation ofFANUC Robotic systems.

According to the industry standard ANSI/RIA R15-06, the owner or user is advised to consult thestandards to ensure compliance with its requests for Robotics System design, usability, operation,maintenance, and service. Additionally, as the owner, employer, or user of a robotic system, it is yourresponsibility to arrange for the training of the operator of a robot system to recognize and respond toknown hazards associated with your robotic system and to be aware of the recommended operatingprocedures for your particular application and robot installation.

Ensure that the robot being used is appropriate for the application. Robots used in classified (hazardous)locations must be certified for this use.

FANUC Robotics therefore, recommends that all personnel who intend to operate, program, repair,or otherwise use the robotics system be trained in an approved FANUC Robotics training course andbecome familiar with the proper operation of the system. Persons responsible for programming thesystem-including the design, implementation, and debugging of application programs-must be familiarwith the recommended programming procedures for your application and robot installation.

The following guidelines are provided to emphasize the importance of safety in the workplace.

CONSIDERING SAFETY FOR YOUR ROBOT INSTALLATION

Safety is essential whenever robots are used. Keep in mind the following factors with regard to safety:

The safety of people and equipment Use of safety enhancing devices Techniques for safe teaching and manual operation of the robot(s) Techniques for safe automatic operation of the robot(s) Regular scheduled inspection of the robot and workcell Proper maintenance of the robot

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Safety MAROCERCD03061E REV J

Keeping People and Equipment Safe

The safety of people is always of primary importance in any situation. However, equipment must bekept safe, too. When prioritizing how to apply safety to your robotic system, consider the following:

People External devices Robot(s) Tooling Workpiece

Using Safety Enhancing Devices

Always give appropriate attention to the work area that surrounds the robot. The safety of the workarea can be enhanced by the installation of some or all of the following devices:

Safety fences, barriers, or chains Light curtains Interlocks Pressure mats Floor markings Warning lights Mechanical stops EMERGENCY STOP buttons DEADMAN switches

Setting Up a Safe Workcell

A safe workcell is essential to protect people and equipment. Observe the following guidelines toensure that the workcell is set up safely. These suggestions are intended to supplement and not replaceexisting federal, state, and local laws, regulations, and guidelines that pertain to safety.

Sponsor your personnel for training in approved FANUC Robotics training course(s) related toyour application. Never permit untrained personnel to operate the robots.

Install a lockout device that uses an access code to prevent unauthorized persons from operatingthe robot.

Use anti-tie-down logic to prevent the operator from bypassing safety measures.

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MAROCERCD03061E REV J Safety

Arrange the workcell so the operator faces the workcell and can see what is going on inside the cell. Clearly identify the work envelope of each robot in the system with floor markings, signs, andspecial barriers. The work envelope is the area defined by the maximum motion range of therobot, including any tooling attached to the wrist flange that extend this range.

Position all controllers outside the robot work envelope. Never rely on software or firmware based controllers as the primary safety element unless theycomply with applicable current robot safety standards.

Mount an adequate number of EMERGENCY STOP buttons or switches within easy reach of theoperator and at critical points inside and around the outside of the workcell.

Install flashing lights and/or audible warning devices that activate whenever the robot is operating,that is, whenever power is applied to the servo drive system. Audible warning devices shallexceed the ambient noise level at the end-use application.

Wherever possible, install safety fences to protect against unauthorized entry by personnel intothe work envelope.

Install special guarding that prevents the operator from reaching into restricted areas of the workenvelope.

Use interlocks. Use presence or proximity sensing devices such as light curtains, mats, and capacitance andvision systems to enhance safety.

Periodically check the safety joints or safety clutches that can be optionally installed between therobot wrist flange and tooling. If the tooling strikes an object, these devices dislodge, removepower from the system, and help to minimize damage to the tooling and robot.

Make sure all external devices are properly filtered, grounded, shielded, and suppressed to preventhazardous motion due to the effects of electro-magnetic interference (EMI), radio frequencyinterference (RFI), and electro-static discharge (ESD).

Make provisions for power lockout/tagout at the controller. Eliminate pinch points . Pinch points are areas where personnel could get trapped between amoving robot and other equipment.

Provide enough room inside the workcell to permit personnel to teach the robot and performmaintenance safely.

Program the robot to load and unload material safely. If high voltage electrostatics are present, be sure to provide appropriate interlocks, warning,and beacons.

If materials are being applied at dangerously high pressure, provide electrical interlocks forlockout of material flow and pressure.

xiii


Staying Safe While Teaching or Manually Operating the Robot

Advise all personnel who must teach the robot or otherwise manually operate the robot to observe thefollowing rules:

Never wear watches, rings, neckties, scarves, or loose clothing that could get caught in movingmachinery.

Know whether or not you are using an intrinsically safe teach pendant if you are working ina hazardous environment.

Before teaching, visually inspect the robot and work envelope to make sure that no potentiallyhazardous conditions exist. The work envelope is the area defined by the maximum motion rangeof the robot. These include tooling attached to the wrist flange that extends this range.

The area near the robot must be clean and free of oil, water, or debris. Immediately report unsafeworking conditions to the supervisor or safety department.

FANUC Robotics recommends that no one enter the work envelope of a robot that is on, except forrobot teaching operations. However, if you must enter the work envelope, be sure all safeguardsare in place, check the teach pendant DEADMAN switch for proper operation, and place therobot in teach mode. Take the teach pendant with you, turn it on, and be prepared to release theDEADMAN switch. Only the person with the teach pendant should be in the work envelope.

Warning

Never bypass, strap, or otherwise deactivate a safety device, such asa limit switch, for any operational convenience. Deactivating a safetydevice is known to have resulted in serious injury and death.

Know the path that can be used to escape from a moving robot; make sure the escape path isnever blocked.

Isolate the robot from all remote control signals that can cause motion while data is being taught. Test any program being run for the first time in the following manner:

Warning

Stay outside the robot work envelope whenever a program is beingrun. Failure to do so can result in injury.

Using a low motion speed, single step the program for at least one full cycle.

Using a low motion speed, test run the program continuously for at least one full cycle.

Using the programmed speed, test run the program continuously for at least one full cycle.

Make sure all personnel are outside the work envelope before running production.

xiv


Staying Safe During Automatic Operation

Advise all personnel who operate the robot during production to observe the following rules:

Make sure all safety provisions are present and active. Know the entire workcell area. The workcell includes the robot and its work envelope, plus thearea occupied by all external devices and other equipment with which the robot interacts.

Understand the complete task the robot is programmed to perform before initiating automaticoperation.

Make sure all personnel are outside the work envelope before operating the robot. Never enter or allow others to enter the work envelope during automatic operation of the robot. Know the location and status of all switches, sensors, and control signals that could cause therobot to move.

Know where the EMERGENCY STOP buttons are located on both the robot control and externalcontrol devices. Be prepared to press these buttons in an emergency.

Never assume that a program is complete if the robot is not moving. The robot could be waitingfor an input signal that will permit it to continue activity.

If the robot is running in a pattern, do not assume it will continue to run in the same pattern. Never try to stop the robot, or break its motion, with your body. The only way to stop robotmotion immediately is to press an EMERGENCY STOP button located on the controller panel,teach pendant, or emergency stop stations around the workcell.

Staying Safe During Inspection

When inspecting the robot, be sure to

Turn off power at the controller. Lock out and tag out the power source at the controller according to the policies of your plant. Turn off the compressed air source and relieve the air pressure. If robot motion is not needed for inspecting the electrical circuits, press the EMERGENCYSTOP button on the operator panel.


If power is needed to check the robot motion or electrical circuits, be prepared to press theEMERGENCY STOP button, in an emergency.

Be aware that when you remove a servomotor or brake, the associated robot arm will fall if it isnot supported or resting on a hard stop. Support the arm on a solid support before you releasethe brake.

xv


Staying Safe During Maintenance

When performing maintenance on your robot system, observe the following rules:

Never enter the work envelope while the robot or a program is in operation. Before entering the work envelope, visually inspect the workcell to make sure no potentiallyhazardous conditions exist.


Consider all or any overlapping work envelopes of adjoining robots when standing in a workenvelope.

Test the teach pendant for proper operation before entering the work envelope. If it is necessary for you to enter the robot work envelope while power is turned on, you must besure that you are in control of the robot. Be sure to take the teach pendant with you, press theDEADMAN switch, and turn the teach pendant on. Be prepared to release the DEADMAN switchto turn off servo power to the robot immediately.

Whenever possible, perform maintenance with the power turned off. Before you open thecontroller front panel or enter the work envelope, turn off and lock out the 3-phase power sourceat the controller.

Be aware that an applicator bell cup can continue to spin at a very high speed even if the robot isidle. Use protective gloves or disable bearing air and turbine air before servicing these items.


Warning

Lethal voltage is present in the controller WHENEVER IT ISCONNECTED to a power source. Be extremely careful to avoidelectrical shock. HIGH VOLTAGE IS PRESENT at the input sidewhenever the controller is connected to a power source. Turning thedisconnect or circuit breaker to the OFF position removes power fromthe output side of the device only.

Release or block all stored energy. Before working on the pneumatic system, shut off the systemair supply and purge the air lines.

Isolate the robot from all remote control signals. If maintenance must be done when the poweris on, make sure the person inside the work envelope has sole control of the robot. The teachpendant must be held by this person.

Make sure personnel cannot get trapped between the moving robot and other equipment. Know thepath that can be used to escape from a moving robot. Make sure the escape route is never blocked.

xvi


Use blocks, mechanical stops, and pins to prevent hazardous movement by the robot. Make surethat such devices do not create pinch points that could trap personnel.

Warning

Do not try to remove any mechanical component from the robotbefore thoroughly reading and understanding the procedures in theappropriate manual. Doing so can result in serious personal injuryand component destruction.


When replacing or installing components, make sure dirt and debris do not enter the system. Use only specified parts for replacement. To avoid fires and damage to parts in the controller,never use nonspecified fuses.

Before restarting a robot, make sure no one is inside the work envelope; be sure that the robot andall external devices are operating normally.

KEEPING MACHINE TOOLS AND EXTERNAL DEVICES SAFE

Certain programming and mechanical measures are useful in keeping the machine tools and otherexternal devices safe. Some of these measures are outlined below. Make sure you know all associatedmeasures for safe use of such devices.

Programming Safety Precautions

Implement the following programming safety measures to prevent damage to machine tools andother external devices.

Back-check limit switches in the workcell to make sure they do not fail. Implement failure routines in programs that will provide appropriate robot actions if an externaldevice or another robot in the workcell fails.

Use handshaking protocol to synchronize robot and external device operations. Program the robot to check the condition of all external devices during an operating cycle.

xvii


Mechanical Safety Precautions

Implement the following mechanical safety measures to prevent damage to machine tools and otherexternal devices.

Make sure the workcell is clean and free of oil, water, and debris. Use software limits, limit switches, and mechanical hardstops to prevent undesired movement ofthe robot into the work area of machine tools and external devices.

KEEPING THE ROBOT SAFE

Observe the following operating and programming guidelines to prevent damage to the robot.

Operating Safety Precautions

The following measures are designed to prevent damage to the robot during operation.

Use a low override speed to increase your control over the robot when jogging the robot. Visualize the movement the robot will make before you press the jog keys on the teach pendant. Make sure the work envelope is clean and free of oil, water, or debris. Use circuit breakers to guard against electrical overload.

Programming Safety Precautions

The following safety measures are designed to prevent damage to the robot during programming:

Establish interference zones to prevent collisions when two or more robots share a work area. Make sure that the program ends with the robot near or at the home position. Be aware of signals or other operations that could trigger operation of tooling resulting in personalinjury or equipment damage.

In dispensing applications, be aware of all safety guidelines with respect to the dispensingmaterials.

Note Any deviation from the methods and safety practices described in this manual must conformto the approved standards of your company. If you have questions, see your supervisor.

xviii


ADDITIONAL SAFETY CONSIDERATIONS FOR PAINT ROBOTINSTALLATIONS

Process technicians are sometimes required to enter the paint booth, for example, during daily orroutine calibration or while teaching new paths to a robot. Maintenance personal also must workinside the paint booth periodically.

Whenever personnel are working inside the paint booth, ventilation equipment must be used.Instruction on the proper use of ventilating equipment usually is provided by the paint shop supervisor.

Although paint booth hazards have been minimized, potential dangers still exist. Therefore, todayshighly automated paint booth requires that process and maintenance personnel have full awareness ofthe system and its capabilities. They must understand the interaction that occurs between the vehiclemoving along the conveyor and the robot(s), hood/deck and door opening devices, and high-voltageelectrostatic tools.

Caution

Ensure that all ground cables remain connected. Never operate the paint robotwith ground provisions disconnected. Otherwise, you could injure personnelor damage equipment.

Paint robots are operated in three modes:

Teach or manual mode Automatic mode, including automatic and exercise operation Diagnostic mode

During both teach and automatic modes, the robots in the paint booth will follow a predeterminedpattern of movements. In teach mode, the process technician teaches (programs) paint paths usingthe teach pendant.

In automatic mode, robot operation is initiated at the System Operator Console (SOC) or ManualControl Panel (MCP), if available, and can be monitored from outside the paint booth. All personnelmust remain outside of the booth or in a designated safe area within the booth whenever automaticmode is initiated at the SOC or MCP.

In automatic mode, the robots will execute the path movements they were taught during teach mode,but generally at production speeds.

When process and maintenance personnel run diagnostic routines that require them to remain in thepaint booth, they must stay in a designated safe area.

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Paint System Safety Features

Process technicians and maintenance personnel must become totally familiar with the equipment andits capabilities. To minimize the risk of injury when working near robots and related equipment,personnel must comply strictly with the procedures in the manuals.

This section provides information about the safety features that are included in the paint system andalso explains the way the robot interacts with other equipment in the system.

The paint system includes the following safety features:

Most paint booths have red warning beacons that illuminate when the robots are armed and readyto paint. Your booth might have other kinds of indicators. Learn what these are.

Some paint booths have a blue beacon that, when illuminated, indicates that the electrostaticdevices are enabled. Your booth might have other kinds of indicators. Learn what these are.

EMERGENCY STOP buttons are located on the robot controller and teach pendant. Becomefamiliar with the locations of all E-STOP buttons.

An intrinsically safe teach pendant is used when teaching in hazardous paint atmospheres. A DEADMAN switch is located on each teach pendant. When this switch is held in, and the teachpendant is on, power is applied to the robot servo system. If the engaged DEADMAN switchis released during robot operation, power is removed from the servo system, all axis brakes areapplied, and the robot comes to an EMERGENCY STOP. Safety interlocks within the systemmight also E-STOP other robots.

Warning

An EMERGENCY STOP will occur if the DEADMAN switch is releasedon a bypassed robot.

Overtravel by robot axes is prevented by software limits. All of the major and minor axes aregoverned by software limits. Limit switches and hardstops also limit travel by the major axes.

EMERGENCY STOP limit switches and photoelectric eyes might be part of your system. Limitswitches, located on the entrance/exit doors of each booth, will EMERGENCY STOP allequipment in the booth if a door is opened while the system is operating in automatic or manualmode. For some systems, signals to these switches are inactive when the switch on the SOC isin teach mode.When present, photoelectric eyes are sometimes used to monitor unauthorizedintrusion through the entrance/exit silhouette openings.

System status is monitored by computer. Severe conditions result in automatic system shutdown.

xx


Staying Safe While Operating the Paint Robot

When you work in or near the paint booth, observe the following rules, in addition to all rules forsafe operation that apply to all robot systems.

Warning

Observe all safety rules and guidelines to avoid injury.

Warning

Never bypass, strap, or otherwise deactivate a safety device, such as alimit switch, for any operational convenience. Deactivating a safety deviceis known to have resulted in serious injury and death.

Warning

Enclosures shall not be opened unless the area is known to benonhazardous or all power has been removed from devices within theenclosure. Power shall not be restored after the enclosure has beenopened until all combustible dusts have been removed from the interiorof the enclosure and the enclosure purged. Refer to the Purge chapterfor the required purge time.

Know the work area of the entire paint station (workcell). Know the work envelope of the robot and hood/deck and door opening devices. Be aware of overlapping work envelopes of adjacent robots. Know where all red, mushroom-shaped EMERGENCY STOP buttons are located. Know the location and status of all switches, sensors, and/or control signals that might cause therobot, conveyor, and opening devices to move.

Make sure that the work area near the robot is clean and free of water, oil, and debris. Reportunsafe conditions to your supervisor.

Become familiar with the complete task the robot will perform BEFORE starting automatic mode. Make sure all personnel are outside the paint booth before you turn on power to the robot servosystem.

Never enter the work envelope or paint booth before you turn off power to the robot servo system. Never enter the work envelope during automatic operation unless a safe area has been designated. Never wear watches, rings, neckties, scarves, or loose clothing that could get caught in movingmachinery.

xxi


Remove all metallic objects, such as rings, watches, and belts, before entering a booth whenthe electrostatic devices are enabled.

Stay out of areas where you might get trapped between a moving robot, conveyor, or openingdevice and another object.

Be aware of signals and/or operations that could result in the triggering of guns or bells. Be aware of all safety precautions when dispensing of paint is required. Follow the procedures described in this manual.

Special Precautions for Combustible Dusts (powder paint)

When the robot is used in a location where combustible dusts are found, such as the application ofpowder paint, the following special precautions are required to insure that there are no combustibledusts inside the robot.

Purge maintenance air should be maintained at all times, even when the robot power is off. Thiswill insure that dust can not enter the robot.

A purge cycle will not remove accumulated dusts. Therefore, if the robot is exposed to dustwhen maintenance air is not present, it will be necessary to remove the covers and clean out anyaccumulated dust. Do not energize the robot until you have performed the following steps.

1. Before covers are removed, the exterior of the robot should be cleaned to remove accumulateddust.

2. When cleaning and removing accumulated dust, either on the outside or inside of the robot, besure to use methods appropriate for the type of dust that exists. Usually lint free rags dampenedwith water are acceptable. Do not use a vacuum cleaner to remove dust as it can generate staticelectricity and cause an explosion unless special precautions are taken.

3. Thoroughly clean the interior of the robot with a lint free rag to remove any accumulated dust.

4. When the dust has been removed, the covers must be replaced immediately.

5. Immediately after the covers are replaced, run a complete purge cycle. The robot can now beenergized.

Staying Safe While Operating Paint Application Equipment

When you work with paint application equipment, observe the following rules, in addition to all rulesfor safe operation that apply to all robot systems.

xxii


Warning

When working with electrostatic paint equipment, follow all national andlocal codes as well as all safety guidelines within your organization.Also reference the following standards: NFPA 33 Standards for SprayApplication Using Flammable or Combustible Materials , and NFPA 70National Electrical Code .

Grounding: All electrically conductive objects in the spray area must be grounded. This includesthe spray booth, robots, conveyors, workstations, part carriers, hooks, paint pressure pots, as wellas solvent containers. Grounding is defined as the object or objects shall be electrically connectedto ground with a resistance of not more than 1 megohms.

High Voltage: High voltage should only be on during actual spray operations. Voltage should beoff when the painting process is completed. Never leave high voltage on during a cap cleaningprocess.

Avoid any accumulation of combustible vapors or coating matter. Follow all manufacturer recommended cleaning procedures. Make sure all interlocks are operational. No smoking. Post all warning signs regarding the electrostatic equipment and operation of electrostaticequipment according to NFPA 33 Standard for Spray Application Using Flammable orCombustible Material.

Disable all air and paint pressure to bell. Verify that the lines are not under pressure.

Staying Safe During Maintenance

When you perform maintenance on the painter system, observe the following rules, and all othermaintenance safety rules that apply to all robot installations. Only qualified, trained service ormaintenance personnel should perform repair work on a robot.

Paint robots operate in a potentially explosive environment. Use caution when working withelectric tools.

When a maintenance technician is repairing or adjusting a robot, the work area is under the controlof that technician. All personnel not participating in the maintenance must stay out of the area.

For some maintenance procedures, station a second person at the control panel within reach of theEMERGENCY STOP button. This person must understand the robot and associated potentialhazards.

Be sure all covers and inspection plates are in good repair and in place. Always return the robot to the home position before you disarm it.

xxiii


Never use machine power to aid in removing any component from the robot. During robot operations, be aware of the robots movements. Excess vibration, unusual sounds,and so forth, can alert you to potential problems.

Whenever possible, turn off the main electrical disconnect before you clean the robot. When using vinyl resin observe the following: Wear eye protection and protective gloves during application and removal

Adequate ventilation is required. Overexposure could cause drowsiness or skin and eyeirritation.

If there is contact with the skin, wash with water.

Follow the Original Equipment Manufacturers Material Safety Data Sheets.

When using paint remover observe the following: Eye protection, protective rubber gloves, boots, and apron are required during booth cleaning.

Adequate ventilation is required. Overexposure could cause drowsiness.

If there is contact with the skin or eyes, rinse with water for at least 15 minutes. Then, seekmedical attention as soon as possible.

Follow the Original Equipment Manufacturers Material Safety Data Sheets.

xxiv

Chapter 1

OVERVIEW

Contents

Chapter 1 OVERVIEW ............................................................................................ 111.1 OVERVIEW ................................................................................................ 121.2 ERROR CODE PROPERTIES ..................................................................... 13

1.2.1 Overview ................................................................................................... 131.2.2 Facility Name and Code ............................................................................ 171.2.3 Severity Descriptions ............................................................................... 1111.2.4 Error Message Text .................................................................................. 114

11

1. OVERVIEW MAROCERCD03061E REV J

1.1 OVERVIEW

Note Refer to the Error Code Manual for error code listings, causes, and remedies.

Errors occur because of

Hardware problems - a broken cable or tooling Software problems - incorrect program or data External problems - an open safety door or an overtravel has occurred

Depending on the severity of the error, you must take certain steps to recover from it.

A complete listing of error codes is provided in the Error Code Manual. Use Procedure 1-1 as therecommended error recovery procedure.

Some errors require minimal corrective action to recover from them. Others require more involvedprocedures. The first step in the error recovery process is to determine the kind and severity of theerror. After you determine this information, the appropriate error recovery procedure can be used.

Procedure 1-1 Error Recovery Recommendation

Conditions

An error has occurred.

Steps

1. Determine the cause of the error.

2. Correct the problem which caused the error.

3. Release the error.

4. Restart the program or robot.

If the basic recovery procedures do not clear the error, try restarting the controller. Refer to Table11 for the methods of starting the controller. First try a Cold start. If Cold start does not solvethe problem, try a Controlled start and then a Cold start. If the problem still exists, refer to theSoftware Installation Manual to reload software if necessary.

12

MAROCERCD03061E REV J 1. OVERVIEW

Table 11. Startup Methods

Start Method Description Procedure

Cold start (START COLD) Initializes changes to system variablesInitializes changes to I/O setupDisplays the UTILITIES Hints screen

Turn the power disconnect circuitbreaker to ON. When the BMON screenis displayed on the teach pendant, pressand hold the SHIFT and RESET keys.After you see files beginning to load onthe teach pendant screen, release all ofthe keys.

Controlled start (START CTRL) Allows you to set up application specificinformationAllows you to install options and updatesAllows you to save specific informationAllows you to start KCLAllows you to print teach pendant screensand the current robot configurationAllows you to unsimulate all I/ODoes not allow you to load teach pendantprograms

Press FCTN and select CYCLE START,select YES, and press ENTER. Whenthe BMON screen is displayed onthe teach pendant, press and holdthe PREV and NEXT keys. After theConfiguration Menu screen is displayed,release the keys. Select Controlled startand press ENTER.

1.2 ERROR CODE PROPERTIES

1.2.1 Overview

An error code consists of:

The facility name and error code number The severity of the error The message text of the error

Refer to Section 1.2.2 , Section 1.2.3 , and Section 1.2.4 .

The error code will be displayed as follows:

FACILITY_NAME - ERROR_CODE_NUMBER Error message text

The Alarm Log screen displays a list of errors that have occurred. There are two ways to displayalarms:

13


Automatically using the Active Alarm screen. This screen displays only active errors (with aseverity other than WARN) that have occurred since the last time RESET was pressed.

Manually using the History Alarm screen. This screen displays up to the last 100 alarms,regardless of their severity. You can also display detailed information about a specific alarm.Optionally, you can set up your system to store additional alarms in an alarm log calledMD:errext.ls. If you have the Extended Alarm Log option installed and set up, then this file,stored on the MD: device, will display up to the last 1000 alarms. In this case, the alarms arenumbered and contain the date, time, error message, cause code, and severity. Programmingevents will be displayed the same as error messages but will not have cause codes or severities.

For information on setting up the Extended Alarm Log, refer to the Software Installation Manual.

Table 12 through Table 17 describe each kind of alarm that can be displayed.

Table 12. Alarm Log Screen

ITEM DESCRIPTION

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

Table 13. Application Alarm Screen

ITEM DESCRIPTION

Application Alarm Status This item allows you to monitor application alarms. Application alarms includeanything that is related to the given application-specific tool that is loaded.

Table 14. Comm Log Screen

ITEM DESCRIPTION

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

Table 15. Fault Recovery Screen

ITEM DESCRIPTION

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

Table 16. Motion Alarm Screen

ITEM DESCRIPTION

Motion Alarm Status This item allows you to monitor the Motion Alarm screen status such as, SRVOalarms or any other alarms related to robot movement.

14


Table 17. System Alarm Screen

ITEM DESCRIPTION

System Alarm Status This item allows you to monitor system alarm messages such as SYST alarms.

Use Procedure 1-2 to display the Alarm Log screen.

Procedure 1-2 Displaying the Alarm Log Automatically

Conditions

To display the Active Alarm screen automatically, Set the system variable $ER_AUTO_ENB to TRUE either on the SYSTEM Variables menu

or by setting Auto display of alarm menu to TRUE on the SYSTEM Configuration menu.Then perform a Cold start.

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

Steps

1. The following screen will automatically be displayed. It lists all errors with a severity other thanWARN, that have occurred since the last controller RESET. The most recent error is number 1.

SRVO-007 External emergency stopTEST1 LINE 15 ABORTEDAlarm: ACTIVE1 SRVO-007 External emergency stop

2. To toggle between the Active Alarm screen and Hist Alarm screen, press F3 (ACTIVE or HIST).

3. If you are using an iPendant and are in Single Display Mode, you can toggle between widescreen and normal screen. Press F2, [ VIEW ] and select Wide or Normal.

4. To disable the automatic display of all errors with a certain severity type, modify the value ofthe system variable $ER_SEV_NOAUTO[1-5]. These errors will still be logged in the ActiveAlarm screen, but they will no longer force the screen to immediately become visible. Refer tothe Software Reference Manual for more detailed information about how to set these variables.

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

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

15


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

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

Note When you reset the system by pressing the RESET key, the alarms displayed on thisscreen are cleared.

Procedure 1-3 Displaying the Alarm Log Manually

Steps

1. Press MENUS.

2. Press ALARM.

3. Press F3, HIST.

4. Press F1, [TYPE].

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

SRVO-007 External emergency stopTEST1 LINE 15 ABORTEDAlarm: HIST1 SRVO-007 External emergency stop2 SRVO-001 Operator panel emergency st3 R E S E T4 SRVO-029 Robot calibrated (Group:1)5 SRVO-001 Operator panel emergency st6 SRVO-012 Power fail recovery7 INTP-127 Power fail detected8 SRVO-047 LVAL alarm (Group:1 Axis:5)9 SRVO-047 LVAL alarm (Group:1 Axis:4)10 SRVO-002 Teach pendant emergency stop

Note The most recent error is number 1.

To display the complete error message that does not fit on the screen, press F5, DETAIL,and the right arrow key on the teach pendant.

16


To display the cause code for an error message, press F5, DETAIL. Cause codes providefurther information about the cause of the error. If the specified error has a cause code, thecause code message is displayed immediately below the error line, on the status line. Whenyou press RESET, the error and cause code disappears and the status line is redisplayed.

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

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

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

9. To display the reporting log which displays the top five alarms that occurred while therobot was in Auto mode , press F1, [TYPE], and select Reporting.

1. To view the top five faults by incident, press F2, INCIDENT.

2. To view the top five faults by total asserted time, press F3, T_TIME.

3. To view the top five faults by longest asserted time for any given fault, press F4,L_TIME.

10. To display the communication log, which displays only communication-specific errors, pressF1, [TYPE], and select Comm Log.

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

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

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

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

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

1.2.2 Facility Name and Code

The facility name and code identify the type of error that occurred. Facility information is displayed atthe beginning of the error code:

17


PROG-048 PAUSE Shift released while running

In the example, the facility name PROG corresponds to facility code 3. The error code numberis 048. Facility codes are used in error handling from a KAREL program. The facility codes arelisted in Table 18 .

Table 18. Error Facility Codes

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

Description

ACAL 112 0x70 AccuCal II error code

APSH 38 0x26 Application shell

ARC 53 0x35 Arc welding application

ASBN 22 0x16 Mnemonic editor

ATGP 102 0x66 Attach gro lead through andforce control

CALM 106 0x6a CalMate

CD 82 0x52 Coordinated motion softpart

CMND 42 0x2a Command processor

CNTR 73 0x4g Continuous turn softpart

COND 4 0x4 Condition handler

COPT 37 0x25 Common options

CPMO 114 0x72 Constant Path error code

CUST 97 0x61 Customer specific errors

CVIS 117 0x75 Integrated Vision (ControllerVision)

DICT 33 0x21 Dictionary processor

DJOG 64 0x40 Detached jog

DMDR 84 0x54 Dual Motion Drive

DMER 40 0x28 Data monitor

DNET 76 0x4c DeviceNet

DX 72 0x48 Delta Tool/Frame softpart

ELOG 5 0x5 Error logger

FILE 2 0x2 File system

FLPY 10 0xa Serial floppy disk system

FRCE 91 0x5b Impedance control (forcecontrol)

18


Table 18. Error Facility Codes (Contd)


Description

FRSY 85 0x55 Flash file system

FXTL 136 C-flex tool

HOST 67 0x43 Host communications general

HRTL 66 0x42 Host communications runtime library

IBSS 88 0x58 Interbus-S

INTP 12 0xc Interpreter internal errors

ISD 39 0x27 ISD (Integral ServoDispenser)

JOG 19 0x13 Manual jog task

LANG 21 0x15 Language utility

LECO 109 0x6D Arc errors from LincolnElectric

LNTK 44 0x2c Line tracking

LSTP 108 0x6C Local Stop error codes

MACR 57 0x39 MACRO option

MARL 83 0x53 Material removal

MCTL 6 0x6 Motion control manager

MEMO 7 0x7 Memory manager

MENT 68 0x44 ME-NET

MHND 41 0x29 Material Handling shell andmenus

MOTN 15 0xf Motion subsystem

MUPS 48 0x30 Multi-pass motion

NOM 133 Nominal Position

19




Description

OPTN 65 0x41 Option installation

OS 0 0x0 Operating system

PALL 115 0x73 PalletTool

PALT 26 0x1a Palletizing application

PMON 28 0x1c PC monitor

PNT1 86 0x56 Paint Application Errors POSTV6.31

PRIO 13 0xd Digital I/O subsystem

PROF 92 0x5c Profibus DP

PROG 3 0x3 Interpreter

PWD 31 0x1f Password logging

QMGR 61 0x3d KAREL queue manager

RIPE 130 Ros IP errors

ROUT 17 0x11 Softpart built-in routine forinterpreter

RPC 93 0x5d RPC

RPM 43 0x2b Root Pass Memorization

RTCP 89 0x59 Remote TCP

SCIO 25 0x19 Syntax checking for teachpendant programs

SEAL 51 0x33 Sealing application

SENS 58 0x3a Sensor interface

SHAP 79 0x4f Shape generation

SPOT 23 0x17 Spot welding application

SPRM 131 Ramp motion softpart

SRIO 1 0x1 Serial driver

SRVO 11 0xb FLTR & SERVO in motionsub-system

SSPC 69 0x45 Special space checkingfunction

SVGN 30 0x1e Servo weld gun application

SYST 24 0x18 Facility code of system

110




Description

TAST 47 0x2f Through-Arc Seam Tracking

TCPP 46 0x2e TCP speed prediction

TG 90 0x5a Triggering accuracy

THSR 60 0x3c Touch Sensing softpart

TJOG 116 0x74 Tracking Jog

TMAT 119 0x77 Torch Mate

TOOL 29 0x1d Servo tool change

TPIF 9 0x9 Teach pendant user interface

TRAK 54 0x36 Tracking softpart

TRSV 134 Tray server task error text

VARS 16 0x10 Variable Manager Subsystem

WEAV 45 0x2d Weaving

WMAP 103 0x67 All wafer handling robotretated Errors

WNDW 18 0x12 Window I/O managersub-system

XMLF 129 XML errors

1.2.3 Severity Descriptions

The severity of the error indicates how serious the error is. The severity is displayed after the errornumber. For example:


Note You can display the severity of the error code on the ALARM screen. Refer to Procedure 1-2 .

$ER_SEV_NOAUTO[1-5] System Variable

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

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Table 19. Severity Descriptions

SEVERITY $ER_SEV_NOAUTO[1-5]

PAUSE [1]

STOP [2]

SERVO [3]

ABORT [4]

SYSTEM [5]

WARN

WARN errors only warn of potential problems or unexpected circumstances. They do not directlyaffect any operations that might be in progress. If a WARN error occurs, you should determine whatcaused the error and what, if any, actions should be taken.

For example, the WARN error Singularity position indicates a singularity position was encounteredduring a move. No action is required. However, if you do not want the motion to encounter asingularity position, you can reteach the program positions.

PAUSE

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

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

STOP

STOP errors pause program execution and stop robot motion. When a motion is stopped, the robotdecelerates to a stop and any remaining part of the current motion segment is saved, meaning themotion can be resumed. STOP errors usually indicate that some action must be taken before themotion and program execution can be resumed.

Depending on the action that is required, you might be able to resume the motion and programexecution after correcting the error condition. If the motion and program can be resumed, you caneither select the RESUME function key or press the operator CYCLE START button if the setting ofthe REMOTE/LOCAL setup item on the System Configuration menu is set to LOCAL. If the robot isin production mode, you must choose the appropriate recovery option.

112


SERVO

SERVO errors shut off the drive power to the servo system and pause program execution. SERVOerrors cause the operator panel FAULT light to go on and the teach pendant FAULT LED to go on.

SERVO errors are usually caused by hardware problems and could require trained service personnel.However, some SERVO errors require you to reset the servo system by pressing the operator panelFAULT RESET button or the teach pendant RESET key. Others require a Cold start of the controller.

ABORT

ABORT errors abort program execution and STOP robot motion. When an ABORT error occurs, therobot decelerates to a STOP and the remainder of the motion is canceled. An ABORT error indicatesthat the program has a problem that is severe enough to prevent it from continuing to run.

You will need to correct the problem and then restart the program. Depending on the error, correctingthe problem might mean editing the program or modifying the data.

SYSTEM

SYSTEM errors usually indicate a system problem exists that is severe enough to prevent any furtheroperation. The problem could be hardware or software related.

You will need the assistance of trained service personnel to correct SYSTEM errors. After the errorhas been corrected, you will need to reset the system by turning off the robot, waiting a few seconds,and turning on the robot.

If a program was executing when the error occurred, you will need to restart the program.

ERROR

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

NONE

NONE errors can be returned as status from some KAREL built-in routines and can also be usedto trigger KAREL condition handlers. NONE errors are not displayed on the teach pendant orCRT/KB. They also are not displayed on the alarm log screen. NONE errors do not have any effecton programs, robot motion, or servo motors.

Table 110 summarizes the effects of error severities.

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Table 110. Effects of Error Severity

Severity Program Robot Motion Servo Motors

WARN No effect No effect No effect

PAUSE Paused The current move is completedthen the robot stops.

No effect

STOP Paused Decelerated STOP, motionretained

No effect

SERVO Paused Decelerated STOP, motionretained

Power shutdown

ABORT Aborted EMERGENCY STOP, motioncanceled

No effect

SYSTEM Aborted EMERGENCY STOP, motioncanceled

Power shut down Requires aFCTN:CYCLE POWER

ERROR No effect No effect No effect

NONE No effect No effect No effect

1.2.4 Error Message Text

The message text describes the error that has occurred. Message text is displayed at the end of theerror code. For example:


Some error messages might contain cause codes, percent (%) notation, or hexadecimal notation. Formore information on displaying cause codes, refer to Procedure 1-2 .

Percent Notation (%)

A percent sign followed by the letter s (%s) indicates that a string, representing a program name, filename, or variable name, actually appears in the error message when the error occurs.

A percent sign followed by the letter d (%d) indicates that an integer, representing a program linenumber or other numeric value, actually appears in the error message when the error occurs.

For example:

INTP-327 ABORT (%^s, %d^5) Open file failed

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When this error occurs, the actual name of the file that could not be opened will appear on the teachpendant error line instead of %s. The actual program line number on which that error occurred willappear on the teach pendant error line instead of %d.

Hexadecimal Notation

Hexadecimal notation is used to indicate the specific axes in error, when one or more axes are inerror at the same time.

Most robots have interaction limits, in addition to normal joint limits. Even when all axes arewithin their respective limits an error might occur. This could possibly be caused by the interactionbetween multiple axes. In this case, hexadecimal notation can help you to find the specific axisin error. For example:

MOTN-017 STOP limit error (G:1 A:6 Hex)

The number after the A is the hexadecimal digit that shows which axes are out of limit. The Hexindicates that the axis numbers are in hexadecimal format. Table 111 lists the sixteen hexadecimaldigits and the corresponding axes that are in error.

Note Hexadecimal digits for the decimal values of 10 through 15 are represented by the letters Athrough F respectively. Refer to Table 111 .

To determine which axes are in error, you must evaluate each digit in the error message separately.Refer to Table 111 .

Note If only one number appears in the error message after the A:, you must read it as the first digit.

Table 111. Hexadecimal Error Message Display

MOTN-017 limit error (G:1 A:(3)(2) (1) HEX)

Hexadecimal Digit Third Digit (3) Second Digit (2) First Digit (1)

0 none none none

1 axis 9 axis 5 axis 1

2 n/a axis 6 axis 2

3 n/a axes 5 & 6 axes 1 & 2

4 n/a axis 7 axis 3

5 n/a axes 5 & 7 axes 1 & 3

6 n/a axes 6 & 7 axes 2 & 3

7 n/a axes 5, 6, & 7 axes 1, 2, & 3

8 n/a axis 8 axis 4

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Table 111. Hexadecimal Error Message Display (Contd)

MOTN-017 limit error (G:1 A:(3)(2) (1) HEX)

Hexadecimal Digit Third Digit (3) Second Digit (2) First Digit (1)

9 n/a axes 5 & 8 axes 1 & 4

A n/a axes 6 & 8 axes 2 & 4

B n/a axes 5, 6, & 8 axes 1, 2, & 4

C n/a axes 7 & 8 axes 3 & 4

D n/a axes 5, 7, & 8 axes 1, 3, & 4

E n/a axes 6, 7, & 8 axes 2, 3, & 4

F n/a axes 5, 6, 7, & 8 axes 1, 2, 3, & 4

Note: If only one number appears in the error message after the A:, you must read it as the first digit (1).

Table 112 contains some examples of how to interpret Hexadecimal notation in an error message.

Table 112. Hexadecimal Notation and Axis in Error Examples

Error Explanation

MOTN-017 (G:1 A:6 Hex) Axes 2 and 3 are out of their interaction limit.

MJOG-013 (G:1 A:20 Hex) Axis 6 jogged to limit.

MOTN-017 (G:1 A:100 Hex) Axis 9 limit error.

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Chapter 2

ERROR RECOVERY

Contents

Chapter 2 ERROR RECOVERY ................................................................................ 212.1 GENERAL ERROR RECOVERY PROCEDURES ........................................ 22

2.1.1 Overview ................................................................................................... 222.1.2 Overtravel Release .................................................................................... 222.1.3 Hand Breakage Recovery ......................................................................... 242.1.4 Pulse Coder Alarm Recovery .................................................................... 252.1.5 Chain Failure Detection Error Recovery ................................................... 272.2 PAINTTOOL RECOVERY PROCEDURES ................................................... 28

2.2.1 Overview ................................................................................................... 282.2.2 Brake Control Release .............................................................................. 292.2.3 Purge Fault Recovery ............................................................................... 292.2.4 Executing an Exit Cleaner Robot Request Out of Sequence .................... 2102.2.5 Production Mode Recovery ..................................................................... 212

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2.1 GENERAL ERROR RECOVERY PROCEDURES

2.1.1 Overview

This section contains procedures for recovery from certain errors. These errors are:

Overtravel release Hand breakage recovery Pulse coder alarm Chain failure detection recovery

2.1.2 Overtravel Release

An overtravel error occurs when one or more of the robot axes moves beyond the software motionlimits. When this happens one of the overtravel limit switches is tripped and the system does thefollowing:

Shuts off drive power to the servo system and applies robot brakes Displays an overtravel alarm error message Lights the operator panel FAULT light Turns on the teach pendant FAULT status indicator Limits motion for the axes involved in the overtravel

If you are jogging in JOINT, the axis number indicating the axis (or axes) in an overtravel will bedisplayed in the error log. You can manually release overtravel on your system from the MANUAL OTRelease screen. The axis that is in overtravel will display TRUE in either OT_MINUS or OT_PLUS.

Refer to Table 21 for information on the MANUAL OT Release items.

Use Procedure 2-1 to recover from an overtravel error.

Table 21. MANUAL OT Release Items

ITEM DESCRIPTION

AXIS This item displays the number for each axis.

OT MINUS This item displays whether a particular axis is in an overtravel condition.

OT PLUS This item displays whether a particular axis is in an overtravel condition.

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Procedure 2-1 Recovering from an Overtravel Error

Conditions

An axis (or axes) are in overtravel and the overtravel alarm has occurred. If you are jogging inJOINT the axis number indicating the axis (or axes) in an overtravel will be displayed in theerror log.

Steps

1. Press MENUS.

2. Select SYSTEM.

3. Press F1, [TYPE].

4. Select OT Release. You will see a screen similar to the following. The axis that is overtraveledwill display TRUE in either OT_MINUS or OT_PLUS.

MANUAL OT ReleaseAXIS OT MINUS OT PLUS

1 FALSE TRUE2 FALSE FALSE3 FALSE FALSE4 FALSE FALSE5 FALSE FALSE6 FALSE FALSE7 FALSE FALSE8 FALSE FALSE9 FALSE FALSE

5. Move the cursor to the OT PLUS or OT MINUS value of the axis in overtravel.

6. Press F2, RELEASE. The value of the overtraveled axis should change back to FALSE.

7. If the robot is calibrated, you will see the message Cant Release OT. Press HELP for detail.

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

MANUAL OT ReleaseWhen robot is calibrated, overtravelcannot be released. Press SHIFT &RESET to clear the error, and jog outof the overtravel condition.

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2. ERROR RECOVERY MAROCERCD03061E REV J

Note

prio

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