ELEC-10138 Industrial
Robotics
ERROR & FAULT RECOVERY
2
OBJECTIVES
• Recover from Errors & Faults
• Robot Singularity
• Software Axis Limits
• Recover from DCS faults
• Chain Failure Detection error
ALARM & ERROR RECOVERY
3
Errors can occur because of:
• Hardware – a broken cable or tooling
• Software – incorrect program or data
• External – an E-Stop or an overtravel has
occurred
Most Errors can be cleared by correcting the
problem and using the RESET key
DISPLAYING THE ALARM LOG
4
1. To display the Active Alarm Screen:
• Press MENU
• Press ALARM
2. To view Alarm History:
• Press F3, HIST
3. To view Motion errors, Application-specific errors,
Communication error and Password errors:
• Press F1 [TYPE]
4. To display more information about an error:
• Move the cursor to the error and press F5 [DETAIL], when you are
finished, press PREV
5. To remove all of the error messages displays on the screen:
• Press and hold SHIFT and press F4 [CLEAR]
DISPLAYING THE ALARM LOG
5
• If troubleshooting, it is usually best
to view the Active alarms in the
Alarm Log. This should sort out what
is presently a problem.
• If you want to see earlier alarms,
you can view the History of the last
100.
F3
• If line 1 had an alarm …
• the first 4 lines (up to the first
RESET) would be the active
alarms.
• Note: You can view a fault
definition by pressing SHIFT & DIAG
keys
6
ENABLING DEVICE SWITCH ERROR
DEADMAN Switch Error
To clear a DEADMAN switch error, Press the
DEADMAN switch to the centre or middle
position and press the RESET button.
** by default when you release the
DEADMAN and then press it again, you must
then press the RESET key to reset the fault.
Most faults can be cleared by first correcting
the problem, then press the RESET button.
DEADMAN SWITCH
7
DEADMAN Switch
Error
To clear the error
Press the DEADMAN
switch in the center
R-30iA and later teach Position and press
pendants have three RESET
positions
DCS ERROR 8
• DCS position/speed check features check the
speed and position of motors with two
independent CPUs in the robot controller. These
functions can detect position and speed errors
immediately and shut down the motor.
• When this option has been installed and setup
on R-30iA and newer controllers, the following
example is showing a DCS position error when
the robot moves outside the DCS boundaries.
Recovery
• When a Cartesian/Joint DCS error, press and
hold the SHIFT key then press RESET key and
while continuing to hold the SHIFT key, jog the
robot back into the safe zone
DCS ERROR RECOVERY 9
• When a Cartesian/Joint DCS error occurs, press
and hold the SHIFT key then press RESET key and
while continuing to hold the SHIFT key, jog the
robot back into the safe zone.
To clear the error
SHIFT RESET
Safe Position Unsafe Position
ABORT ALL
10
• If a previous program was tested and the
END of the program was not executed, you
may need to abort the program in order to
execute a different program.
• You cannot delete a program if it is
paused, assigned to a macro, or write
protected. If the program is paused, you
must abort it.
• Press FCTN and select ABORT (ALL)
ABORT ALL 11
Already locked by other task
Fctn 1 ABORT (ALL)
Conditions that cause this
error:
•When deleting a program that
is currently used.
•A different program needs to
be selected or current one
needs to be Aborted.
SINGULARITY
12
Singularity occurs when an infinite number of joint
angles generate the same set of Cartesian data (J4,
J5 and J6 on a 6 axis robot).
Joint jogging is not effected by Singularity errors.
To recover from singularity:
1. Press the COORD key and select JOINT
2. Move Joint 5, “+” or “-” 10 degrees
3. You can now return to your prior Cartesian
coordinate motion and continue jogging the
robot
13
SINGULARITY: DEFINITION
J4 and J6
are aligned when
J5 is at or near Zero Degrees
NOTE: Only occurs in Cartesian.
When running programs the system
can read a few lines ahead to see if
Singularity may occur
Wrist Singularity
MOTION GROUP
14
• Maximum of 40 axes on R-30iA and newer
controllers
• Motion group
o Defines different groups of axes that can be used for
independent pieces of equipment, positioning tables and
other devices
o Maximum of 9 axes in a single group
o Maximum of 8 motion groups on R-30iA series and newer
controller
• With multiple groups, the axes that jog depend on
which group you have selected. Select groups
using the FCTN menu or by pressing the SHIFT and
COORD keys.
15
MOTION GROUP: EXTENDED AXES
If your system contains more than nine axes,
there is more than one group that controls
motion. The robot is ALWAYS in group1.
• Axes beyond standard number of robot axes
• Maximum of 3 extended axes in a motion
group
• Controller can control a maximum of 40
axes, however, only 9 axes can belong to a
single group
• Axes 1 through 6 are always assigned to
group 1
3rd Digit 16
2nd Digit
• (G:1 A:1 Hex) = (G:1 A: 001 Hex)
1st Digit
• Answer: Axis 1
MOTN–017 limit error (G:1 A:(3) (2) (1) HEX)
Hexadecimal Digit Third Digit (3) Second Digit (2) First Digit (1)
• (G:1 A:10 Hex) = (G:1 A:010 Hex) 0 none none none
• Answer: Axis 5 1 axis 9 axis 5 axis 1
2 n/a axis 6 axis 2
3 n/a axes 5 & 6 axes 1 & 2
• (G:1 A:11 Hex) = (G:1 A:011 Hex) 4 n/a axis 7 axis 3
• Answer: Axis 1 & 5
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
• (G:2 A:1 Hex) 8 n/a axis 8 axis 4
9 n/a axes 5 & 8 axes 1 & 4
• Servo Gun or Aux. Axis
A n/a axes 6 & 8 axes 2 & 4
B n/a axes 5, 6, & 8 axes 1, 2, & 4
• (G:1 A:52 Hex) = (G:1 A:052 Hex) C n/a axes 7 & 8 axes 3 & 4
• Answer: Axis 2, 5, & 7 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).
17
CHAIN FAILURE DETECTION ERROR RECOVERY
• The system detected either a
SRVO-230 Chain1 (+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.
• Typically a Chain Fault Error can
occur from dual pole contacts
not opening or closing at the
same time.
For instance a cell gate safety
switch malfunction.
18
CHAIN FAILURE DETECTION ERROR RECOVERY
ROBOT F NUMBER 19
FANUC America
Corporation provides and
F number which is a
unique number for the
robot’s identification. The F
number provides
information such as
controller type, robot
model, installed options
and sale information. The
number is located at the
base of the robot and on
the controller cabinet.
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STATUS VERSION IDENTIFICATION
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