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FANUC America Corporation
SYSTEM R-30iB and R-30iB
Mate Controller Software
Error Code Manual
MARRBERCD04121E REV G
© 2014 FANUC America Corporation
All Rights Reserved.
This publication contains proprietary information of FANUC America
Corporation furnished for customer use only. No other uses are
authorized without the express written permission of FANUC America
Corporation.
FANUC America Corporation
3900 W. Hamlin Road
Rochester Hills, Michigan 48309–3253
About This Manual
Copyrights and Trademarks
This new publication contains proprietary information of FANUC America Corporation, furnished for
customer use only. No other uses are authorized without the express written permission of FANUC
America Corporation.
FANUC America Corporation
3900 W. Hamlin Road
Rochester Hills, MI 48309-3253
The descriptions and specifications contained in this manual were in effect at the time this manual
was approved. FANUC America Corporation, hereinafter referred to as FANUC America, reserves
the right to discontinue models at any time or to change specifications or design without notice and
without incurring obligations.
FANUC America’s manuals present descriptions, specifications, drawings, schematics, bills of
material, parts, connections and/or procedures for installing, disassembling, connecting, operating
and programming FANUC America Corporation’s products and/or systems. Such systems consist of
robots, extended axes, robot controllers, application software, the KAREL® programming language,
INSIGHT® vision equipment, and special tools.
FANUC America recommends that only persons who have been trained in one or more approved
FANUC America Training Course(s) be permitted to install, operate, use, perform procedures on,
repair, and/or maintain FANUC America’s products and/or systems and their respective components.
Approved training necessitates that the courses selected be relevant to the type of system installed
and application performed at the customer site.
Warning
This equipment generates, uses, and can radiate radio frequency energy
and if not installed and used in accordance with the instruction manual,
may cause interference to radio communications. As temporarily
permitted by regulation, it has not been tested for compliance with the
limits for Class A computing devices pursuant to subpart J of Part 15 of
FCC Rules, which are designed to provide reasonable protection against
such interference. Operation of the equipment in a residential area is
likely to cause interference, in which case the user, at his own expense,
will be required to take whatever measure may be required to correct the
interference.
FANUC America conducts courses on its systems and products on a regularly scheduled basis at its
headquarters in Rochester Hills, Michigan. For additional information contact
i
About This Manual MARRBERCD04121E REV G
FANUC America Corporation
3900 W. Hamlin Road
Rochester Hills, MI 48309-3253
www.fanucamerica.com
For customer assistance, including Technical Support, Service, Parts & Part Repair, and
Marketing 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:
product.documentation@fanucamerica.com
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 consent
of FANUC America America, Inc.
AccuStat®, ArcTool®, iRVision®, KAREL®, PaintTool®,PalletTool®, SOCKETS®, SpotTool®,
SpotWorks®, and TorchMate® are Registered Trademarks of FANUC America Corporation.
FANUC America reserves all proprietary rights, including but not limited to trademark and trade
name 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™, ARC
Mate 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™, Robo
Spray™, S-420i™, S-430i™, ShapeGen™, SoftFloat™, SOFT PARTS™, SpotTool+™, SR Mate™,
SR ShotTool™, SureWeld™, SYSTEM R-J2 Controller™, SYSTEM R-J3 Controller™, SYSTEM
R-J3iB Controller™, SYSTEM R-J3iC Controller™, SYSTEM R-30iA Controller™, SYSTEM
R-30iA Mate Controller™, SYSTEM R-30iB Controller™, SYSTEM R-30iB Mate 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 America products described
in this manual.
ii
http://www.fanucamerica.com
mailto:product.documentation@fanucamerica.com
MARRBERCD04121E REV G About 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 5,239,739
5,272,805 5,293,107 5,293,911 5,331,264 5,367,944 5,373,221 5,421,218 5,434,489 5,644,898
5,670,202 5,696,687 5,737,218 5,823,389 5,853,027 5,887,800 5,941,679 5,959,425 5,987,726
6,059,092 6,064,168 6,070,109 6,086,294 6,122,062 6,147,323 6,204,620 6,243,621 6,253,799
6,285,920 6,313,595 6,325,302 6,345,818 6,356,807 6,360,143 6,378,190 6,385,508 6,425,177
6,477,913 6,490,369 6,518,980 6,540,104 6,541,757 6,560,513 6,569,258 6,612,449 6,703,079
6,705,361 6,726,773 6,768,078 6,845,295 6,945,483 7,149,606 7,149,606 7,211,978 7,266,422
7,399,363
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 4,894,596
4,899,095 4,920,248 4,931,617 4,934,504 4,956,594 4,967,125 4,969,109 4,970,370 4,970,448
4,979,127 5,004,968 5,006,035 5,008,834 5,063,281 5,066,847 5,066,902 5,093,552 5,107,716
5,111,019 5,130,515 5,136,223 5,151,608 5,170,109 5,189,351 5,267,483 5,274,360 5,292,066
5,300,868 5,304,906 5,313,563 5,319,443 5,325,467 5,327,057 5,329,469 5,333,242 5,337,148
5,371,452 5,375,480 5,418,441 5,432,316 5,440,213 5,442,155 5,444,612 5,449,875 5,451,850
5,461,478 5,463,297 5,467,003 5,471,312 5,479,078 5,485,389 5,485,552 5,486,679 5,489,758
5,493,192 5,504,766 5,511,007 5,520,062 5,528,013 5,532,924 5,548,194 5,552,687 5,558,196
5,561,742 5,570,187 5,570,190 5,572,103 5,581,167 5,582,750 5,587,635 5,600,759 5,608,299
5,608,618 5,624,588 5,630,955 5,637,969 5,639,204 5,641,415 5,650,078 5,658,121 5,668,628
5,687,295 5,691,615 5,698,121 5,708,342 5,715,375 5,719,479 5,727,132 5,742,138 5,742,144
5,748,854 5,749,058 5,760,560 5,773,950 5,783,922 5,799,135 5,812,408 5,841,257 5,845,053
5,872,894 5,887,122 5,911,892 5,912,540 5,920,678 5,937,143 5,980,082 5,983,744 5,987,591
5,988,850 6,023,044 6,032,086 6,040,554 6,059,169 6,088,628 6,097,169 6,114,824 6,124,693
6,140,788 6,141,863 6,157,155 6,160,324 6,163,124 6,177,650 6,180,898 6,181,096 6,188,194
6,208,105 6,212,444 6,219,583 6,226,181 6,236,011 6,236,896 6,250,174 6,278,902 6,279,413
6,285,921 6,298,283 6,321,139 6,324,443 6,328,523 6,330,493 6,340,875 6,356,671 6,377,869
6,382,012 6,384,371 6,396,030 6,414,711 6,424,883 6,431,018 6,434,448 6,445,979 6,459,958
6,463,358 6,484,067 6,486,629 6,507,165 6,654,666 6,665,588 6,680,461 6,696,810 6,728,417
6,763,284 6,772,493 6,845,296 6,853,881 6,888,089 6,898,486 6,917,837 6,928,337 6,965,091
6,970,802 7,038,165 7,069,808 7,084,900 7,092,791 7,133,747 7,143,100 7,149,602 7,131,848
7,161,321 7,171,041 7,174,234 7,173,213 7,177,722 7,177,439 7,181,294 7,181,313 7,280,687
7,283,661 7,291,806 7,299,713 7,315,650 7,324,873 7,328,083 7,330,777 7,333,879 7,355,725
7,359,817 7,373,220 7,376,488 7,386,367 7,464,623 7,447,615 7,445,260 7,474,9397,486,816
7,495,192 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.
iii
About This Manual MARRBERCD04121E REV G
Warning
Information appearing under WARNING concerns the protection of
personnel. 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 ................................................................................................................ 1–1
1.1 OVERVIEW .................................................................................................................... 1–2
1.2 ERROR CODE PROPERTIES ............................................................................................. 1–3
1.2.1 Overview ......................................................................................................................... 1–3
1.2.2 Facility Name and Code ..................................................................................................... 1–7
1.2.3 Severity Descriptions ....................................................................................................... 1–13
1.2.4 Error Message Text .......................................................................................................... 1–15
Chapter 2 ERROR RECOVERY .................................................................................................... 2–1
2.1 GENERAL ERROR RECOVERY PROCEDURES ................................................................. 2–2
2.1.1 Overview ......................................................................................................................... 2–2
2.1.2 Overtravel Release ............................................................................................................ 2–2
2.1.3 Hand Breakage Recovery .................................................................................................... 2–4
2.1.4 Pulse Coder Alarm Recovery ............................................................................................... 2–5
2.1.5 Chain Failure Detection Error Recovery ................................................................................ 2–7
Chapter 3 ERROR CODES ........................................................................................................... 3–1
3.1 A ..................................................................................................................................... 3–4
3.1.1 ACAL Alarm Code ............................................................................................................ 3–4
3.1.2 APSH Alarm Code .......................................................................................................... 3–26
3.1.3 ARC Alarm Code ............................................................................................................ 3–58
3.1.4 ASBN Alarm Code ........................................................................................................... 3–92
3.1.5 ATGP Alarm Code ......................................................................................................... 3–118
3.1.6 ATZN Alarm Code........................................................................................................... 3–119
3.2 B .................................................................................................................................. 3–125
3.2.1 BBOX Alarm Code .......................................................................................................... 3–125
3.2.2 BRCH Alarm Code .......................................................................................................... 3–130
3.3 C .................................................................................................................................. 3–134
3.3.1 CALM Alarm Code ........................................................................................................ 3–134
3.3.2 CD Alarm Code ............................................................................................................. 3–140
3.3.3 CMND Alarm Code ........................................................................................................ 3–146
3.3.4 CNTR Alarm Code ......................................................................................................... 3–150
3.3.5 COND Alarm Code ........................................................................................................ 3–155
3.3.6 COPT Alarm Code ......................................................................................................... 3–156
3.3.7 CPMO Alarm Code ........................................................................................................ 3–161
3.3.8 CVIS Alarm Code .......................................................................................................... 3–202
3.4 D .................................................................................................................................. 3–315
3.4.1 DIAG Alarm Code ........................................................................................................... 3–315
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Contents MARRBERCD04121E REV G
3.4.2 DICT Alarm Code .......................................................................................................... 3–317
3.4.3 DJOG Alarm Code ......................................................................................................... 3–324
3.4.4 DMDR Alarm Code ........................................................................................................ 3–328
3.4.5 DMER Alarm Code ........................................................................................................ 3–330
3.4.6 DNET Alarm Code ......................................................................................................... 3–341
3.4.7 DTBR Alarm Code .......................................................................................................... 3–365
3.4.8 DX Alarm Code ............................................................................................................. 3–366
3.5 E .................................................................................................................................. 3–369
3.5.1 ELOG Alarm Code ......................................................................................................... 3–369
3.6 F................................................................................................................................... 3–370
3.6.1 FILE Alarm Code ........................................................................................................... 3–370
3.6.2 FLPY Alarm Code ......................................................................................................... 3–385
3.6.3 FRCE Alarm Code .......................................................................................................... 3–388
3.6.4 FRSY Alarm Code ......................................................................................................... 3–446
3.6.5 FXTL Alarm Code ......................................................................................................... 3–451
3.7 H ..................................................................................................................................3–473
3.7.1 HOST Alarm Code ......................................................................................................... 3–473
3.7.2 HRTL Alarm Code ......................................................................................................... 3–504
3.8 I ................................................................................................................................... 3–517
3.8.1 IBSS Alarm Code ........................................................................................................... 3–517
3.8.2 ICRZ Alarm Code .......................................................................................................... 3–569
3.8.3 IFPN Alarm Code .......................................................................................................... 3–572
3.8.4 INTP Alarm Code .......................................................................................................... 3–579
3.8.5 IRPK Alarm Code............................................................................................................ 3–655
3.8.6 ISD Alarm Code ............................................................................................................. 3–684
3.8.7 ISDT Alarm Code .......................................................................................................... 3–718
3.9 J ................................................................................................................................... 3–724
3.9.1 JOG Alarm Code ............................................................................................................ 3–724
3.10 K .................................................................................................................................. 3–731
3.10.1 KALM Alarm Code ......................................................................................................... 3–731
3.11 L .................................................................................................................................. 3–732
3.11.1 LANG Alarm Code ........................................................................................................ 3–732
3.11.2 LECO Alarm Code ......................................................................................................... 3–738
3.11.3 LNTK Alarm Code ......................................................................................................... 3–749
3.11.4 LSTP Alarm Code .......................................................................................................... 3–761
3.12 M.................................................................................................................................. 3–764
3.12.1 MACR Alarm Code ........................................................................................................ 3–764
3.12.2 MARL Alarm Code ........................................................................................................ 3–766
3.12.3 MASI Alarm Code ......................................................................................................... 3–771
3.12.4 MCTL Alarm Code ........................................................................................................ 3–778
3.12.5 MEMO Alarm Code ....................................................................................................... 3–781
3.12.6 MHND Alarm Code ....................................................................................................... 3–798
3.12.7 MOTN Alarm Code ........................................................................................................ 3–817
3.12.8 MUPS Alarm Code ......................................................................................................... 3–898
3.13 N .................................................................................................................................. 3–901
3.13.1 NCBN Alarm Code .......................................................................................................... 3–901
3.14 O .................................................................................................................................. 3–904
3.14.1 OPTN Alarm Code ......................................................................................................... 3–904
3.14.2 OS Alarm Code ............................................................................................................. 3–911
3.15 P................................................................................................................................... 3–913
3.15.1 PALL Alarm Code .......................................................................................................... 3–913
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MARRBERCD04121E REV G Contents
3.15.2 PALT Alarm Code .......................................................................................................... 3–956
3.15.3 PICK Alarm Code .......................................................................................................... 3–958
3.15.4 PMON Alarm Code ........................................................................................................ 3–966
3.15.5 PNT1 Alarm Code .......................................................................................................... 3–968
3.15.6 PNT2 Alarm Code ........................................................................................................ 3–1139
3.15.7 PRIO Alarm Code ........................................................................................................ 3–1268
3.15.8 PROC Alarm Code......................................................................................................... 3–1333
3.15.9 PROF Alarm Code ....................................................................................................... 3–1334
3.15.10 PROG Alarm Code ....................................................................................................... 3–1337
3.15.11 PTPG Alarm Code ......................................................................................................... 3–1347
3.15.12 PWD Alarm Code ........................................................................................................ 3–1350
3.16 Q ................................................................................................................................ 3–1360
3.16.1 QMGR Alarm Code ...................................................................................................... 3–1360
3.17 R ................................................................................................................................ 3–1361
3.17.1 RIPE Alarm Code ......................................................................................................... 3–1361
3.17.2 ROUT Alarm Code ....................................................................................................... 3–1365
3.17.3 RPC Alarm Code .......................................................................................................... 3–1370
3.17.4 RPM Alarm Code ......................................................................................................... 3–1372
3.17.5 RRMC Alarm Code........................................................................................................ 3–1374
3.17.6 RTCP Alarm Code ........................................................................................................ 3–1378
3.18 S................................................................................................................................. 3–1381
3.18.1 SCIO Alarm Code ........................................................................................................ 3–1381
3.18.2 SDTL Alarm Code ....................................................................................................... 3–1383
3.18.3 SEAL Alarm Code .......................................................................................................3–1397
3.18.4 SENC Alarm Code......................................................................................................... 3–1457
3.18.5 SENS Alarm Code ....................................................................................................... 3–1459
3.18.6 SHAP Alarm Code ....................................................................................................... 3–1460
3.18.7 SPOT Alarm Code ....................................................................................................... 3–1467
3.18.8 SPRM Alarm Code ....................................................................................................... 3–1503
3.18.9 SRIO Alarm Code ........................................................................................................ 3–1504
3.18.10 SRVO Alarm Code ....................................................................................................... 3–1507
3.18.11 SSPC Alarm Code ........................................................................................................ 3–1603
3.18.12 SVGN Alarm Code ....................................................................................................... 3–1618
3.18.13 SVTL Alarm Code ......................................................................................................... 3–1709
3.18.14 SYST Alarm Code ........................................................................................................ 3–1711
3.19 T ................................................................................................................................ 3–1760
3.19.1 TAST Alarm Code ........................................................................................................ 3–1760
3.19.2 TCPP Alarm Code ........................................................................................................ 3–1763
3.19.3 TG Alarm Code ........................................................................................................... 3–1768
3.19.4 THSR Alarm Code ....................................................................................................... 3–1772
3.19.5 TJOG Alarm Code ....................................................................................................... 3–1782
3.19.6 TMAT Alarm Code ....................................................................................................... 3–1782
3.19.7 TOOL Alarm Code ....................................................................................................... 3–1787
3.19.8 TPIF Alarm Code ......................................................................................................... 3–1792
3.19.9 TRAK Alarm Code ....................................................................................................... 3–1825
3.19.10 TRSV Alarm Code......................................................................................................... 3–1828
3.20 V ................................................................................................................................ 3–1835
3.20.1 VARS Alarm Code ....................................................................................................... 3–1835
3.21 W ............................................................................................................................... 3–1849
3.21.1 WEAV Alarm Code ...................................................................................................... 3–1849
3.21.2 WNDW Alarm Code ..................................................................................................... 3–1853
3.22 X .............................................................................................................................. 3–1859
3.22.1 XMLF Alarm Code ...................................................................................................... 3–1859
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Contents MARRBERCD04121E REV G
Glossary ..................................................................................................................................... GL–1863
Index ............................................................................................................................................. Index–1
viii
List of Tables
Table 1–1. Startup Methods ................................................................................................................ 1–3
Table 1–2. Alarm Log Screen ............................................................................................................. 1–4
Table 1–3. Application Alarm Screen ................................................................................................... 1–4
Table 1–4. Comm Log Screen ............................................................................................................. 1–4
Table 1–5. Fault Recovery Screen ....................................................................................................... 1–4
Table 1–6. Motion Alarm Screen ......................................................................................................... 1–4
Table 1–7. System Alarm Screen ......................................................................................................... 1–5
Table 1–8. ERROR FACILITY CODES ............................................................................................... 1–8
Table 1–9. Severity Descriptions ....................................................................................................... 1–13
Table 1–10. Effects of Error Severity ................................................................................................... 1–15
Table 2–1. MANUAL OT Release Items .............................................................................................. 2–2
Table 3–1. Examples ..................................................................................................................... 3–1393
ix
Safety
FANUC America Corporation 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 safety
system professionals. FANUCAmerica Corporation therefore, recommends that each customer consult
with such professionals in order to provide a workplace that allows for the safe application, use, and
operation of FANUC America Corporation systems.
According to the industry standard ANSI/RIA R15-06, the owner or user is advised to consult the
standards 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 your
responsibility to arrange for the training of the operator of a robot system to recognize and respond to
known hazards associated with your robotic system and to be aware of the recommended operating
procedures 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 America Corporation therefore, recommends that all personnel who intend to operate,
program, repair, or otherwise use the robotics system be trained in an approved FANUC America
Corporation training course and become familiar with the proper operation of the system. Persons
responsible for programming the system-including the design, implementation, and debugging of
application programs-must be familiar with 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 INSTALLATIONSafety 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 MARRBERCD04121E REV G
Keeping People Safe
The safety of people is always of primary importance in any situation. When applying safety measures
to your robotic system, consider the following:
• 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 work
area 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 to
ensure that the workcell is set up safely. These suggestions are intended to supplement and not replace
existing federal, state, and local laws, regulations, and guidelines that pertain to safety.
• Sponsor your personnel for training in approved FANUC America Corporation training course(s)
related to your application. Never permit untrained personnel to operate the robots.
• Install a lockout device that uses an access code to prevent unauthorized persons from operating
the robot.
• Use anti-tie-down logic to prevent the operator from bypassing safety measures.
• Arrange the workcell so the operator faces the workcell and can see what is going on inside the cell.
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MARRBERCD04121E REV G Safety
• Clearly identify the work envelope of each robot in the system with floor markings, signs, and
special barriers. The work envelope is the area defined by the maximum motion range of the
robot, 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 they
comply with applicable current robot safety standards.
• Mount an adequate number of EMERGENCY STOP buttons or switches within easy reach of the
operator 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 shall
exceed the ambient noise level at the end-use application.
• Wherever possible, install safety fences to protect against unauthorized entry by personnel into
the work envelope.
• Install special guarding that prevents the operator from reaching into restricted areas of the work
envelope.
• Use interlocks.
• Use presence or proximity sensing devices such as light curtains, mats, and capacitance and
vision systems to enhance safety.
• Periodically check the safety joints or safety clutches that can be optionally installed between the
robot wrist flange and tooling. If the tooling strikes an object, these devices dislodge, remove
power 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 prevent
hazardous motion due to the effects of electro-magnetic interference (EMI), radio frequency
interference (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 a
moving robot and other equipment.
• Provide enough room inside the workcell to permit personnel to teach the robot and perform
maintenance 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 for
lockout of material flow and pressure.
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Safety MARRBERCD04121E REV G
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 the
following rules:
• Never wear watches, rings, neckties, scarves, or loose clothing that could get caught in moving
machinery.
• Know whether or not you are using an intrinsically safe teach pendant if you are working in
a hazardous environment.
• Before teaching, visually inspect the robot and work envelope to make sure that no potentially
hazardous conditions exist. The work envelope is the area defined by the maximum motion range
of 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 unsafe
working conditions to the supervisor or safety department.
• FANUC America Corporation recommends that no one enter the work envelope of a robot that
is on, except for robot teaching operations. However, if you must enter the work envelope, be
sure all safeguards are in place, check the teach pendant DEADMAN switch for proper operation,
and place the robot in teach mode. Take the teach pendant with you, turn it on, and be prepared
to release the DEADMAN 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 as
a limit switch, for any operational convenience. Deactivating a safety
device 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 is
never 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 being
run. 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.
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MARRBERCD04121E REV G Safety
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 the
area 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 automatic
operation.
• 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 the
robot to move.
• Know where the EMERGENCY STOP buttons are located on both the robot control and external
control 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 waiting
for 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 robot
motion immediately is to press an EMERGENCY STOP buttonlocated 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 EMERGENCY
STOP button on the operator panel.
• Never wear watches, rings, neckties, scarves, or loose clothing that could get caught in moving
machinery.
• If power is needed to check the robot motion or electrical circuits, be prepared to press the
EMERGENCY STOP button, in an emergency.
• Be aware that when you remove a servomotor or brake, the associated robot arm will fall if it is
not supported or resting on a hard stop. Support the arm on a solid support before you release
the brake.
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Safety MARRBERCD04121E REV G
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 potentially
hazardous conditions exist.
• Never wear watches, rings, neckties, scarves, or loose clothing that could get caught in moving
machinery.
• Consider all or any overlapping work envelopes of adjoining robots when standing in a work
envelope.
• 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 be
sure that you are in control of the robot. Be sure to take the teach pendant with you, press the
DEADMAN switch, and turn the teach pendant on. Be prepared to release the DEADMAN switch
to turn off servo power to the robot immediately.
• Whenever possible, perform maintenance with the power turned off. Before you open the
controller front panel or enter the work envelope, turn off and lock out the 3-phase power source
at the controller.
• Be aware that an applicator bell cup can continue to spin at a very high speed even if the robot is
idle. Use protective gloves or disable bearing air and turbine air before servicing these items.
• Be aware that when you remove a servomotor or brake, the associated robot arm will fall if it is
not supported or resting on a hard stop. Support the arm on a solid support before you release
the brake.
Warning
Lethal voltage is present in the controller WHENEVER IT IS
CONNECTED to a power source. Be extremely careful to avoid
electrical shock. HIGH VOLTAGE IS PRESENT at the input side
whenever the controller is connected to a power source. Turning the
disconnect or circuit breaker to the OFF position removes power from
the output side of the device only.
• Release or block all stored energy. Before working on the pneumatic system, shut off the system
air supply and purge the air lines.
• Isolate the robot from all remote control signals. If maintenance must be done when the power
is on, make sure the person inside the work envelope has sole control of the robot. The teach
pendant must be held by this person.
• Make sure personnel cannot get trapped between the moving robot and other equipment. Know the
path that can be used to escape from a moving robot. Make sure the escape route is never blocked.
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MARRBERCD04121E REV G Safety
• Use blocks, mechanical stops, and pins to prevent hazardous movement by the robot. Make sure
that such devices do not create pinch points that could trap personnel.
Warning
Do not try to remove any mechanical component from the robot
before thoroughly reading and understanding the procedures in the
appropriate manual. Doing so can result in serious personal injury
and component destruction.
• Be aware that when you remove a servomotor or brake, the associated robot arm will fall if it is
not supported or resting on a hard stop. Support the arm on a solid support before you release
the brake.
• 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 and
all 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 other
external devices safe. Some of these measures are outlined below. Make sure you know all associated
measures for safe use of such devices.
Programming Safety Precautions
Implement the following programming safety measures to prevent damage to machine tools and
other 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 external
device 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.
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Safety MARRBERCD04121E REV G
Mechanical Safety Precautions
Implement the following mechanical safety measures to prevent damage to machine tools and other
external devices.
• Make sure the workcell is clean and free of oil, water, and debris.
• Use DCS (Dual Check Safety), software limits, limit switches, and mechanical hardstops to
prevent undesired movement of the 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 personal
injury or equipment damage.
• In dispensing applications, be aware of all safety guidelines with respect to the dispensing
materials.
Note Any deviation from the methods and safety practices described in this manual must conform
to the approved standards of your company. If you have questions, see your supervisor.
xviii
Chapter 1
OVERVIEW
Contents
Chapter 1 OVERVIEW ............................................................................................ 1–1
1.1 OVERVIEW ................................................................................................ 1–2
1.2 ERROR CODE PROPERTIES ..................................................................... 1–3
1.2.1 Overview ................................................................................................... 1–3
1.2.2 Facility Name and Code ............................................................................ 1–7
1.2.3 Severity Descriptions ............................................................................... 1–13
1.2.4 Error Message Text .................................................................................. 1–15
1–1
1. OVERVIEW MARRBERCD04121E REV G
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 the
recommended error recovery procedure.
Some errors require minimal corrective action to recover from them. Others require more involved
procedures. The first step in the error recovery process is to determine the kind and severity of the
error. After you determine this information, the appropriate error recovery procedure can be used.
Procedure 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 Table
1–1 for the methods of starting the controller. First try a Cold start. If Cold start does not solve
the problem, try a Controlled start and then a Cold start. If the problem still exists, refer to the
Software Installation Manual to reload software if necessary.
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MARRBERCD04121E REV G 1. OVERVIEW
Table 1–1. Startup Methods
Start Method Description Procedure
Cold start (START COLD) Initializes changes to system variables
Initializes changes to I/O setup
Displays the UTILITIES Hints screen
Turn the power disconnect circuit
breaker to ON. When the BMON screen
is displayed on the teach pendant, press
and hold the SHIFT and RESET keys.
After you see files beginning to load on
the teach pendant screen, release all of
the keys.
Controlled start (START CTRL) Allows you to set up application specific
information
Allows you to install options and updates
Allows you to save specific information
Allows you to start KCL
Allows you to print teach pendant screens
and the current robot configuration
Allows you to unsimulate all I/O
Does not allow you to load teach pendant
programs
Press FCTN and select CYCLE START,
select YES, and press ENTER. When
the BMON screen is displayed on
the teach pendant, press and hold
the PREV and NEXT keys. After the
Configuration Menu screen is displayed,
release the keys. Select Controlled start
and press ENTER.
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 display
alarms:
1–3
1. OVERVIEW MARRBERCD04121E REV G
• Automatically using the Active Alarm screen. This screen displays only active errors (with a
severity other than WARN) that have occurred since the last time RESET was pressed.
• Manually using the History Alarm screen. This screen displays up to the last 100 alarms,
regardless of their severity. You can also display detailed information about a specific alarm.
Optionally, you can set up your system to store additional alarms in an alarm log called
MD:errext.ls. If you have the Extended Alarm Log option installed and set up, then this file,
stored on the MD: device, will display up to the last 1000 alarms. In this case, the alarms are
numbered and contain the date, time, error message, cause code, and severity. Programming
events will be displayed the same as error messages but will not have cause codes or severities.
For information on setting up the Extended Alarm Log, refer to the Software Installation Manual.
Table 1–2 through Table 1–7 describe each kind of alarm that can be displayed.
Table 1–2. Alarm Log Screen
ITEM DESCRIPTION
Alarm Status This item allows you to monitor the entire list of active alarms. Press F3, HIST, to
display the history of alarms.
Table 1–3. Application Alarm Screen
ITEM DESCRIPTION
Application Alarm Status This item allows you to monitor application alarms. Application alarms include
anything that is related to the given application-specific tool that is loaded.
Table 1–4. Comm Log Screen
ITEM DESCRIPTION
Comm Log Status This item allows you to monitor any communication alarms when a communication
option is loaded.
Table 1–5. Fault Recovery Screen
ITEM DESCRIPTION
Fault Recovery Status This item allows you to monitor fault recovery status.
Table 1–6. Motion Alarm Screen
ITEM DESCRIPTION
Motion Alarm Status This item allows you to monitor the Motion Alarm screen status such as, SRVO
alarms or any other alarms related to robot movement.
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MARRBERCD04121E REV G 1. OVERVIEW
Table 1–7. 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 than
WARN, that have occurred since the last controller RESET. The most recent error is number 1.
SRVO-007 External emergency stop
TEST1 LINE 15 ABORTED
Alarm: ACTIVE
1 SRVO-007 External emergency stop
2. To toggle between the Active Alarm screen and Hist Alarm screen, press F3 (ACTIVE or HIST).
3. If you are using an iPendant and are in Single Display Mode, you can toggle between wide
screen and normal screen. Press F2, [ VIEW ] and select Wide or Normal.
4. To disable the automatic display of all errors with a certain severity type, modify the value of
the system variable $ER_SEV_NOAUTO[1-5]. These errors will still be logged in the Active
Alarm screen, but they will no longer force the screen to immediately become visible. Refer to
the Software Reference Manual for more detailed information about how to set these variables.
5. To disable the automatic display of a specific error code, modify the $ER_NOAUTO.$noalm_num
and $ER_NOAUTO.$er_code system variables. These errors will still be logged in the Active
Alarm screen, but they will no longer force the screen to immediately become visible. Refer to
the Software Reference Manual for more detailed information about how to set these variables.
6. To display the screen that occurred immediately before the alarm, press RESET. If you have
toggled between HIST and ACTIVE, the previous screen might not be available.
1–5
1. OVERVIEW MARRBERCD04121E REV G
When there are no active alarms (the system is not in error status), the following message will be
displayed on the Active Alarm screen.
There are no active alarms.
Press F3(HIST) to enter alarm history screen.
Note When you reset the system by pressing the RESET key, the alarms displayed on this
screen are cleared.
Procedure 1-3 Displaying the Alarm Log Manually
Steps
1. Press MENU.
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 following
screen for an example.
SRVO-007 External emergency stop
TEST1 LINE 15 ABORTED
Alarm: HIST
1 SRVO-007 External emergency stop
2 SRVO-001 Operator panel emergency st
3 R E S E T
4 SRVO-029 Robot calibrated (Group:1)
5 SRVO-001 Operator panel emergency st
6 SRVO-012 Power fail recovery
7 INTP-127 Power fail detected
8 SRVO-047 LVAL alarm (Group:1 Axis:5)
9 SRVO-047 LVAL alarm (Group:1 Axis:4)
10 SRVO-002 Teach pendant emergency stop
Note The most recent error is number 1.
• To display the complete error message that does not fit on the screen, press F5, DETAIL,and the right arrow key on the teach pendant.
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MARRBERCD04121E REV G 1. OVERVIEW
• To display the cause code for an error message, press F5, DETAIL. Cause codes provide
further information about the cause of the error. If the specified error has a cause code, the
cause code message is displayed immediately below the error line, on the status line. When
you press RESET, the error and cause code disappears and the status line is redisplayed.
6. To display the motion log, which lists only motion-related errors, press F1, [TYPE], and
select Motion Log.
7. To display the system log, which displays only system errors, press F1, [TYPE], and select
System Log.
8. To display the application log, which displays only application-specific errors, press F1,
[TYPE], and select Appl Log.
9. The Fault and Incident Reporting option displays the reporting log. The reporting log
displays the top five alarms that occurred while the robot 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, press
F1, [TYPE], and select Comm Log.
11. To display the password log, which displays only password-specific errors, press F1, [TYPE],
and select Password Log.
12. To display more information about an error, move the cursor to the error and press F5,
DETAIL. The error detail screen displays information specific to the error you selected,
including the severity. If the error has a cause code, the cause code message will be displayed.
When you are finished viewing the information, press PREV.
13. To display cause and remedy information specific to an error, move the cursor to the error
and press SHIFT and the Help/Diag button on the iPendant.
14. To remove all of the error messages displayed on the screen, press and hold SHIFT and
press F4, CLEAR.
15. To change the view displayed on the screen, press F2, [ VIEW ]. To show or hide the cause
codes for each alarm, select Show Cause or Hide Cause. If an alarm has no cause code, the time
the alarm occurred will be shown instead. If you are using an iPendant and are in Single Display
Mode, you can also toggle between wide screen and normal screen by selecting Wide or Normal.
1.2.2 Facility Name and Code
The facility name and code identify the type of error that occurred. Facility information is displayed at
the beginning of the error code:
1–7
1. OVERVIEW MARRBERCD04121E REV G
PROG-048 PAUSE Shift released while running
In the example, the facility name PROG corresponds to facility code 3. The error code number
is 048. Facility codes are used in error handling from a KAREL program. The facility codes are
listed in Table 1–8 .
Table 1–8. ERROR FACILITY CODES
FACILITY NAME FACILITY CODE (DECIMAL) FACILITY CODE
(HEXADECIMAL)
DESCRIPTION
ACAL 112 0X70 ACCUCAL II ERROR CODE
APSH 38 0X26 APPLICATION SHELL
ARC 53 0X35 ARC WELDING
APPLICATION
ASBN 22 0X16 MNEMONIC EDITOR
ATGP 102 0X66 ATTACH GRO LEAD
THROUGH AND FORCE
CONTROL
ATZN 138 0X8A AUTOZONE
BBOX 118 0X76 POSITION BUMPBOX
BRCH 144 0X90 BRAKE CHECK
CALM 106 0X6A CALMATE
CD 82 0X52 COORDINATED MOTION
SOFTPART
CMND 42 0X2A COMMAND PROCESSOR
CNTR 73 0X49 CONTINUOUS TURN
SOFTPART
COND 4 0X4 CONDITION HANDLER
COPT 37 0X25 COMMON OPTIONS
CPMO 114 0X72 CONSTANT PATH ERROR
CODE
CUST 97 0X61 CUSTOMER SPECIFIC
ERRORS
CVIS 117 0X75 INTEGRATED VISION
(CONTROLLER VISION)
1–8
MARRBERCD04121E REV G 1. OVERVIEW
Table 1–8. ERROR FACILITY CODES (Cont’d)
FACILITY NAME FACILITY CODE (DECIMAL) FACILITY CODE
(HEXADECIMAL)
DESCRIPTION
DIAG 148 0X94 IRDIAGNOSTICS
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
DTBR 149 0X95 DATA TRANSFER BETWEEN
ROBOTS
DX 72 0X48 DELTA TOOL/FRAME
SOFTPART
ELOG 5 0X5 ERROR LOGGER
FILE 2 0X2 FILE SYSTEM
FLPY 10 0XA SERIAL FLOPPY DISK
SYSTEM
FRCE 91 0X5B IMPEDANCE CONTROL
(FORCE CONTROL)
FRSY 85 0X55 FLASH FILE SYSTEM
FXTL 136 0X88 C-FLEX TOOL
HOST 67 0X43 HOST COMMUNICATIONS
GENERAL
HRTL 66 0X42 HOST COMMUNICATIONS
RUN TIME LIBRARY
IBSS 88 0X58 INTERBUS-S
ICRZ 124 0X7C IC RAILZONE
IFPN 153 0X99 INTERFACE PANEL
INTP 12 0XC INTERPRETER INTERNAL
ERRORS
IRPK 127 0X7F IRPICKTOOL
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1. OVERVIEW MARRBERCD04121E REV G
Table 1–8. ERROR FACILITY CODES (Cont’d)
FACILITY NAME FACILITY CODE (DECIMAL) FACILITY CODE
(HEXADECIMAL)
DESCRIPTION
ISD 39 0X27 ISD (INTEGRAL SERVO
DISPENSER)
ISDT 95 0X5F INTEGRAL SERVO DRIVEN
TOOL
JOG 19 0X13
MANUAL JOG TASK
KALM 122 0X7A KAREL ALARM
LANG 21
0X15 LANGUAGE UTILITY
LECO 109 0X6D ARC ERRORS FROM
LINCOLN ELECTRIC
LNTK 44 0X2C LINE TRACKING
LSTP 108 0X6C LOCAL STOP ERROR
CODES
MACR 57 0X39 MACRO OPTION
MARL 83 0X53 MATERIAL REMOVAL
MASI 147 0X93 MULTI-ARM SYNC
INSTRUCTIONS
MCTL 6 0X6 MOTION CONTROL
MANAGER
MEMO 7 0X7 MEMORY MANAGER
MHND 41 0X29 MATERIAL HANDLING
SHELL AND MENUS
MOTN 15 0XF MOTION SUBSYSTEM
MUPS 48
0X30
MULTI-PASS MOTION
NCBN 150 0X96 NC TO BIN CONVERSION
OPTN 65 0X41 OPTION INSTALLATION
OS 0 0X0 OPERATING SYSTEM
PALL 115 0X73 PALLETTOOL
1–10
MARRBERCD04121E REV G 1. OVERVIEW
Table 1–8. ERROR FACILITY CODES (Cont’d)
FACILITY NAME FACILITY CODE (DECIMAL) FACILITY CODE
(HEXADECIMAL)
DESCRIPTION
PALT 26 0X1A PALLETIZING APPLICATION
PICK 132 0X84 PICKTOOL
PMON 28 0X1C PC MONITOR
PNT1 86 0X56 PAINT APPLICATION
ERRORS POST V6.31
PNT2 137 0X89 PAINTTOOL APPLICATION
ERRORS #2
PRIO 13 0XD DIGITAL I/O SUBSYSTEM
PROC 146 0X92 PROCESS LOGGER
PROF 92 0X5C PROFIBUS DP
PROG 3 0X3 INTERPRETER
PTPG 140 0X8C PAINT PLUG-IN
PWD 31 0X1F PASSWORD LOGGING
QMGR 61 0X3D KAREL QUEUE MANAGER
RIPE 130 0X82 ROS IP ERRORS
ROUT 17 0X11 SOFTPART BUILT-IN
ROUTINE FOR
INTERPRETER
RPC 93 0X5D RPC
RPM 43 0X2B ROOT PASS
MEMORIZATION
RRMC 126 0X7E REDUNDANT ROBOT
MOTION CONTROL
RTCP 89 0X59 REMOTE TCP
SCIO 25 0X19 SYNTAX CHECKING
FOR TEACH PENDANT
PROGRAMS
SDTL 123 0X7B SYSTEM DESIGN TOOL
SEAL 51 0X33 SEALING APPLICATION
1–11
1. OVERVIEW MARRBERCD04121E REV G
Table 1–8. ERROR FACILITY CODES (Cont’d)
FACILITY NAME FACILITY CODE (DECIMAL) FACILITY CODE
(HEXADECIMAL)
DESCRIPTION
SENC 143 0X8F SECONDARY ENCODER
SENS 58 0X3A SENSOR INTERFACE
SHAP 79 0X4F SHAPE GENERATION
SPOT 23 0X17 SPOT WELDING
APPLICATION
SPRM 131 0X83 RAMP MOTION SOFTPART
SRIO 1 0X1 SERIAL DRIVER
SRVO 11 0XB FLTR AND SERVO IN
MOTION SUB-SYSTEM
SSPC 69 0X45 SPECIAL SPACE CHECKING
FUNCTION
SVGN 30 0X1E SERVO WELD GUN
APPLICATION
SVTL 135 0X87 SERVO TOOL
SYST 24 0X18 FACILITY CODE OF
SYSTEM
TAST 47 0X2F THROUGH-ARC SEAM
TRACKING
TCPP 46 0X2E TCP SPEED PREDICTION
TG 90 0X5A TRIGGERING ACCURACY
THSR 60 0X3C TOUCH SENSING
SOFTPART
TJOG 116 0X74 TRACKING JOG
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 0X86 TRAY SERVER TASK
ERROR TEXT
VARS 16 0X10 VARIABLE MANAGER
SUBSYSTEM
1–12
MARRBERCD04121E REV G 1. OVERVIEW
Table 1–8. ERROR FACILITY CODES (Cont’d)
FACILITY NAME FACILITY CODE (DECIMAL) FACILITY CODE
(HEXADECIMAL)
DESCRIPTION
WEAV 45 0X2D WEAVING
WNDW 18 0X12 WINDOW I/O MANAGER
SUB-SYSTEM
XMLF 129 0X81 XML ERRORS
1.2.3 Severity Descriptions
The severity of the error indicates how serious the error is. The severity is displayed after the error
number. For example:
PROG-048 PAUSE Shift released while running
Note You can display the severity of the error code on the ALARM screen. Refer to Procedure 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 error
codes with a particular severity. This is used in conjunction with the $ER_AUTO_ENB system
variable.
Table 1–9. Severity Descriptions
SEVERITY $ER_SEV_NOAUTO[1-5]PAUSE [1]
STOP [2]
SERVO [3]
ABORT [4]
SYSTEM [5]
WARN
WARN errors only warn of potential problems or unexpected circumstances. They do not directly
affect any operations that might be in progress. If a WARN error occurs, you should determine what
caused the error and what, if any, actions should be taken.
1–13
1. OVERVIEW MARRBERCD04121E REV G
For example, the WARN error Singularity position indicates a singularity position was encountered
during a move. No action is required. However, if you do not want the motion to encounter a
singularity position, you can reteach the program positions.
PAUSE
PAUSE errors pause program execution but allow the robot to complete its current motion segment, if
any are in progress. This error typically indicates that some action must be taken before program
execution can be resumed. PAUSE errors cause the operator panel FAULT light to go on and the
teach pendant FAULT LED to go on.
Depending on the action that is required, you might be able to resume a paused program at the point
where the PAUSE error occurred after you have corrected the error condition. If the program can
be resumed, you can either select the RESUME function key or press the operator CYCLE START
button, or press the UOP CYCLE START button if the setting of the REMOTE/LOCAL setup item on
the System Configuration menu is set to LOCAL.
STOP
STOP errors pause program execution and stop robot motion. When a motion is stopped, the robot
decelerates to a stop and any remaining part of the current motion segment is saved, meaning the
motion can be resumed. STOP errors usually indicate that some action must be taken before the
motion and program execution can be resumed.
Depending on the action that is required, you might be able to resume the motion and program
execution after correcting the error condition. If the motion and program can be resumed, you can
either select the RESUME function key or press the operator CYCLE START button if the setting of
the REMOTE/LOCAL setup item on the System Configuration menu is set to LOCAL. If the robot is
in production mode, you must choose the appropriate recovery option.
SERVO
SERVO errors shut off the drive power to the servo system and pause program execution. SERVO
errors cause the operator panel FAULT light to go on and the teach pendant FAULT LED to go on.
SERVO errors are usually caused by hardware problems and could require trained service personnel.
However, some SERVO errors require you to reset the servo system by pressing the operator panel
FAULT RESET button or the teach pendant RESET key. Others require a Cold start of the controller.
ABORT
ABORT errors abort program execution and STOP robot motion. When an ABORT error occurs, the
robot decelerates to a STOP and the remainder of the motion is canceled. An ABORT error indicates
that the program has a problem that is severe enough to prevent it from continuing to run.
You will need to correct the problem and then restart the program. Depending on the error, correcting
the problem might mean editing the program or modifying the data.
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MARRBERCD04121E REV G 1. OVERVIEW
SYSTEM
SYSTEM errors usually indicate a system problem exists that is severe enough to prevent any further
operation. The problem could be hardware or software related.
You will need the assistance of trained service personnel to correct SYSTEM errors. After the error
has been corrected, you will need to reset the system by turning off the robot, waiting a few seconds,
and turning on the robot.
If a program was executing when the error occurred, you will need to restart the program.
NONE
NONE errors can be returned as status from some KAREL built-in routines and can also be used
to trigger KAREL condition handlers. NONE errors are not displayed on the teach pendant or
CRT/KB. They also are not displayed on the alarm log screen. NONE errors do not have any effect
on programs, robot motion, or servo motors.
Table 1–10 summarizes the effects of error severities.
Table 1–10. Effects of Error Severity
Severity Program Robot Motion Servo Motors
WARN No effect No effect No effect
PAUSE Paused The current move is completed
then the robot stops.
No effect
STOP Paused Decelerated STOP, motion
retained
No effect
SERVO Paused Decelerated STOP, motion
retained
Power shutdown
ABORT Aborted EMERGENCY STOP, motion
canceled
No effect
SYSTEM Aborted EMERGENCY STOP, motion
canceled
Power shut down Requires a
FCTN:CYCLE POWER
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 the
error code. For example:
PROG-048 PAUSE Shift released while running
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1. OVERVIEW MARRBERCD04121E REV G
Some error messages might contain cause codes, or percent (%) notation. For more information on
displaying cause codes, refer to Procedure 1-2 .
Percent Notation (%)
A percent sign followed by the letter s (%s) indicates that a string, representing a program name, file
name, or variable name, actually appears in the error message when the error occurs.
A percent sign followed by the letter d (%d) indicates that an integer, representing a program line
number or other numeric value, actually appears in the error message when the error occurs.
For example:
INTP-327 ABORT (%^s, %d^5) Open file failed
When this error occurs, the actual name of the file that could not be opened will appear on the teach
pendant error line instead of %s. The actual program line number on which that error occurred will
appear on the teach pendant error line instead of %d.
1–16
Chapter 2
ERROR RECOVERY
Contents
Chapter 2 ERROR RECOVERY ................................................................................ 2–1
2.1 GENERAL ERROR RECOVERY PROCEDURES ........................................ 2–2
2.1.1 Overview ................................................................................................... 2–2
2.1.2 Overtravel Release .................................................................................... 2–2
2.1.3 Hand Breakage Recovery ......................................................................... 2–4
2.1.4 Pulse Coder Alarm Recovery .................................................................... 2–5
2.1.5 Chain Failure Detection Error Recovery ................................................... 2–7
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2. ERROR RECOVERY MARRBERCD04121E REV G
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 motion
limits. When this happens one of the overtravel limit switches is tripped and the system does the
following:
• Shuts off drive power to the servo system and applies robot brakes
• Displays an overtravel alarm error message
• Lights the operator panel FAULT light
• Turns on the teach pendant FAULT status indicator
• Limits motion for the axes involved in the overtravel
If you are jogging in JOINT, the axis number indicating the axis (or axes) in an overtravel will be
displayed in the error log. You can manually release overtravel on your system from the MANUAL OT
Release screen. The axis that is in overtravel will display TRUE in either OT_MINUS or OT_PLUS.
Refer to Table 2–1 for information on the MANUAL OT Release items.
Use Procedure 2-1 to recover from an overtravel error.
Table 2–1. 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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MARRBERCD04121E REV G 2. ERROR RECOVERY
Procedure 2-1 Recovering from an Overtravel Error
Conditions
• An axis (or axes) are inovertravel and the overtravel alarm has occurred. If you are jogging in
JOINT the axis number indicating the axis (or axes) in an overtravel will be displayed in the
error log.
Steps
1. Press MENU.
2. Select SYSTEM.
3. Press F1, [TYPE].
4. Select OT Release. You will see a screen similar to the following. The axis that is overtraveled
will display TRUE in either OT_MINUS or OT_PLUS.
MANUAL OT Release
AXIS OT MINUS OT PLUS
1 FALSE TRUE
2 FALSE FALSE
3 FALSE FALSE
4 FALSE FALSE
5 FALSE FALSE
6 FALSE FALSE
7 FALSE FALSE
8 FALSE FALSE
9 FALSE FALSE
5. Move the cursor to the OT PLUS or OT MINUS value of the axis in overtravel.
6. Press F2, RELEASE. The value of the overtraveled axis should change back to FALSE.
7. If the robot is calibrated, you will see the message Can’t Release OT. Press HELP for detail.
a. If you press F5, DETAIL, you will see a screen similar to the following.
MANUAL OT Release
When robot is calibrated, overtravel
cannot be released. Press SHIFT &
RESET to clear the error, and jog out
of the overtravel condition.
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2. ERROR RECOVERY MARRBERCD04121E REV G
Note For the following steps, press and hold down the SHIFT key until you have
completed Step 7b through Step 7d .
b. Press and continue pressing SHIFT and press F2, RESET. Wait for servo power.
c. Continuously press and hold the DEADMAN switch and turn the teach pendant ON/OFF
switch to ON.
d. Jog the overtraveled axis off the overtravel switch. When you have finished jogging,
you can release the SHIFT key .
Note If you accidentally release the shift key during Step 7b through Step 7d , you will
have to repeat them.
8. If the robot is not calibrated, perform the following steps:
Note For the following steps, press and hold down the SHIFT key until you have completed
Step 8a through Step 8d .
a. Press and continue pressing SHIFT and press F2, RESET. Wait for servo power.
b. Press COORD until you select the JOINT coordinate system.
c. Continuously press and hold the DEADMAN switch and turn the teach pendant ON/OFF
switch to ON.
d. Jog the overtraveled axis off the overtravel switch. When you have finished jogging,
you can release the SHIFT key .
Note If you accidentally release the shift key during this step, you will need to repeat it.
9. Turn the teach pendant ON/OFF switch to OFF and release the DEADMAN switch.
10. Check CRM68 & CRF7 connection on the amplifier PCB if the robot is not in an actual
overtravel condition.
2.1.3 Hand Breakage Recovery
A hand breakage error occurs when the hand breakage detection switch is tripped on robots equipped
with hand breakage hardware. The switch is tripped when the robot tool strikes an obstacle, which
could possibly cause the tool to break. The system
• Shuts off drive power to the servo system and applies robot brakes
• Displays an error message indicating that the hand is broken
• Lights the operator panel FAULT light
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MARRBERCD04121E REV G 2. ERROR RECOVERY
• Lights the teach pendant FAULT LED
The status of the hand breakage detection switch is displayed on the STATUS Safety Signals screen.
Use Procedure 2-2 to recover from a hand breakage.
Procedure 2-2 Recovering from a Hand Breakage
Conditions
• The hand breakage error message is displayed.
Steps
1. If you have not already done so, continuously press and hold the DEADMAN switch and
turn the teach pendant ON/OFF switch to ON.
2. Hold down the SHIFT key and press RESET. The robot can now be moved.
3. Jog the robot to a safe position.
4. Press the EMERGENCY STOP button.
5. Request a trained service person to inspect and, if necessary, repair the tool.
6. Determine what caused the tool to strike an object, causing the hand to break.
7. If the hand breakage occurred while a program was being executed, you might need to reteach
positions, modify the program, or move the object that was struck.
8. Test run the program if it has been modified, if new positions have been recorded, or if objects
in the work envelope have been moved.
2.1.4 Pulse Coder Alarm Recovery
If the pulse counts at power up do not match the pulse counts at power down, a pulse mismatch error
occurs for each motion group and each axis. Use Procedure 2-3 to reset a pulse coder alarm.
Procedure 2-3 Resetting a Pulse Coder SRVO-062 Alarm
Steps
1. Press MENU.
2. Select SYSTEM.
3. Press F1, [TYPE].
4. Select Master/Cal.
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2. ERROR RECOVERY MARRBERCD04121E REV G
If Master/Cal is not listed on the [TYPE] menu, do the following; otherwise, continue
to Step 5 .
a. Select VARIABLE from the [TYPE] menu.
b. Move the cursor to $MASTER_ENB.
c. Press the numeric key 1 and then press ENTER on the teach pendant.
d. Press F1, [TYPE].
e. Select Master/Cal. You will see a screen similar to the following.
SYSTEM Master/Cal
1 FIXTURE POSITION MASTER
2 ZERO POSITION MASTER
3 QUICK MASTER
4 SINGLE AXIS MASTER
5 SET QUICK MASTER REF
6 CALIBRATE
Press ’ENTER’ or number key to select.
5. Press F3, RES_PCA. You will see a screen similar to the following.
SYSTEM Master/Cal
1 FIXTURE POSITION MASTER
2 ZERO POSITION MASTER
3 QUICK MASTER
4 SINGLE AXIS MASTER
5 SET QUICK MASTER REF
6 CALIBRATE
Press ’ENTER’ or number key to select.
Reset pulse coder alarm? [NO]
6. Press F4, YES. You will see a screen similar to the following.
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MARRBERCD04121E REV G 2. ERROR RECOVERY
SYSTEM Master/Cal
1 FIXTURE POSITION MASTER
2 ZERO POSITION MASTER
3 QUICK MASTER
4 SINGLE AXIS MASTER
5 SET QUICK MASTER REF
6 CALIBRATE
Pulse coder alarm reset!
2.1.5 Chain Failure Detection Error Recovery
A Single Chain Failure Detection fault will be set if one safety chain is in an Emergency Stop
condition, and the other is not in an Emergency Stop condition.
When a Single Chain Failure Detection fault occurs, the system does the following:
• Shuts off drive power to the servo system and applies robot brakes
• Displays an error message indicating that a single chain failure has occurred.
• Lights the operator panel FAULT light
• Lights the teach pendant FAULT LED
Chain Failure Detection Errors
Refer to the Maintenance Manual for more information on chain failure detection errors, SRVO-230
and 231, SRVO-266 through 275 (external checking -customer), and SRVO-370 through 385 (internal
checking)
Procedure 2-4 Chain Failure Detection Error Recovery
Conditions
• The system detected either a SRVO-230 Chain 1 (+24V abnormal) or a SRVO-231 Chain 2
(0V abnormal) error.
• You cannot reset the chain failure errors, even after turning the controller OFF and then ON again.
Steps
1. Correct the cause of the alarm.
2. Press MENU.
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2. ERROR RECOVERY MARRBERCD04121E REV G
3. Select ALARMS. You will see a screen similar to the following.
ALARM: Active
SRVO-230 Chain 1(+24V) abnormal
4. Press F4, RES_CH1. You will see a screen similar to the following
ALARM: Active
SRVO-230 Chain 1(+24V) abnormal
Reset Single Channel Fault [NO]
5. Press F4, YES to reset the fault.
6. Press the RESET button on the teach pendant or operator panel.
Warning
If you reset the chain failure fault without fixing the cause of it, the
same alarm will occur, but the robot can move until the alarm occurs
again. Be sure to fix the cause of the chain failure before you continue.
Otherwise, you could injure personnel or damage equipment.
2–8
Chapter 3
ERROR CODES
Contents
Chapter 3 ERROR CODES ....................................................................................... 3–1
3.1 A ................................................................................................................. 3–4
3.1.1 ACAL Alarm Code ..................................................................................... 3–4
3.1.2 APSH Alarm Code .................................................................................... 3–26
3.1.3 ARC Alarm Code ...................................................................................... 3–58
3.1.4 ASBN Alarm Code .................................................................................... 3–92
3.1.5 ATGP Alarm Code ..................................................................................