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  • OPERATOR'S MANUAL (Alarm Code List)

    B-83284EN-1/03

    R-30+B/ R-30+B Mate CONTROLLER

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  • Original Instructions

    Before using the Robot, be sure to read the "FANUC Robot Safety Manual (B-80687EN)" and

    understand the content. No part of this manual may be reproduced in any form. All specifications and designs are subject to change without notice. The products in this manual are controlled based on Japans Foreign Exchange and Foreign Trade Law. The export from Japan may be subject to an export license by the government of Japan. Further, re-export to another country may be subject to the license of the government of the country from where the product is re-exported. Furthermore, the product may also be controlled by re-export regulations of the United States government. Should you wish to export or re-export these products, please contact FANUC for advice. In this manual we have tried as much as possible to describe all the various matters. However, we cannot describe all the matters which must not be done, or which cannot be done, because there are so many possibilities. Therefore, matters which are not especially described as possible in this manual should be regarded as impossible.

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    SAFETY PRECAUTIONS Thank you for purchasing FANUC Robot. This chapter describes the precautions which must be observed to ensure the safe use of the robot. Before attempting to use the robot, be sure to read this chapter thoroughly. Before using the functions related to robot operation, read the relevant operator's manual to become familiar with those functions. If any description in this chapter differs from that in the other part of this manual, the description given in this chapter shall take precedence. For the safety of the operator and the system, follow all safety precautions when operating a robot and its peripheral devices installed in a work cell. In addition, refer to the FANUC Robot SAFETY HANDBOOK (B-80687EN).

    1 WORKING PERSON The personnel can be classified as follows.

    Operator: Turns robot controller power ON/OFF Starts robot program from operators panel Programmer or teaching operator: Operates the robot Teaches robot inside the safety fence Maintenance engineer: Operates the robot Teaches robot inside the safety fence Maintenance (adjustment, replacement)

    - An operator cannot work inside the safety fence. - A programmer, teaching operator, and maintenance engineer can work inside the safety fence. The

    working activities inside the safety fence include lifting, setting, teaching, adjusting, maintenance, etc.

    - To work inside the fence, the person must be trained on proper robot operation. During the operation, programming, and maintenance of your robotic system, the programmer, teaching operator, and maintenance engineer should take additional care of their safety by using the following safety precautions. - Use adequate clothing or uniforms during system operation - Wear safety shoes - Use helmet

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    DEFINITION OF WARNING, CAUTION AND NOTE

    To ensure the safety of users and prevent damage to the machine, this manual indicates each precaution on safety with "Warning" or "Caution" according to its severity. Supplementary information is indicated by "Note". Read the contents of each "Warning", "Caution" and "Note" before attempting to use the oscillator.

    WARNING Applied when there is a danger of the user being injured or when there is a

    danger of both the user being injured and the equipment being damaged if the approved procedure is not observed.

    CAUTION Applied when there is a danger of the equipment being damaged, if the

    approved procedure is not observed.

    NOTE Notes are used to indicate supplementary information other than Warnings and

    Cautions. Read this manual carefully, and store it in a sales place.

    3 WORKING PERSON SAFETY Working person safety is the primary safety consideration. Because it is very dangerous to enter the operating space of the robot during automatic operation, adequate safety precautions must be observed. The following lists the general safety precautions. Careful consideration must be made to ensure working person safety. (1) Have the robot system working persons attend the training courses held by FANUC. FANUC provides various training courses. Contact our sales office for details.

    (2) Even when the robot is stationary, it is possible that the robot is still in a ready to move state, and is

    waiting for a signal. In this state, the robot is regarded as still in motion. To ensure working person safety, provide the system with an alarm to indicate visually or aurally that the robot is in motion.

    (3) Install a safety fence with a gate so that no working person can enter the work area without passing through the gate. Install an interlocking device, a safety plug, and so forth in the safety gate so that the robot is stopped as the safety gate is opened.

    The controller is designed to receive this interlocking signal of the door switch. When the gate is opened and this signal received, the controller stops the robot (Please refer to "STOP TYPE OF ROBOT" in SAFETY PRECAUTIONS for detail of stop type). For connection, see Fig.3 (a) and Fig.3 (b).

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    (4) Provide the peripheral devices with appropriate grounding (Class A, Class B, Class C, and Class D). (5) Try to install the peripheral devices outside the work area. (6) Draw an outline on the floor, clearly indicating the range of the robot motion, including the tools

    such as a hand. (7) Install a mat switch or photoelectric switch on the floor with an interlock to a visual or aural alarm

    that stops the robot when a working person enters the work area. (8) If necessary, install a safety lock so that no one except the working person in charge can turn on the

    power of the robot. The circuit breaker installed in the controller is designed to disable anyone from turning it on when it is locked with a padlock.

    (9) When adjusting each peripheral device independently, be sure to turn off the power of the robot (10) Operators should be ungloved while manipulating the operators panel or teach pendant. Operation

    with gloved fingers could cause an operation error. (11) Programs, system variables, and other information can be saved on memory card or USB memories.

    Be sure to save the data periodically in case the data is lost in an accident. (12) The robot should be transported and installed by accurately following the procedures recommended

    by FANUC. Wrong transportation or installation may cause the robot to fall, resulting in severe injury to workers.

    (13) In the first operation of the robot after installation, the operation should be restricted to low speeds. Then, the speed should be gradually increased to check the operation of the robot.

    (14) Before the robot is started, it should be checked that no one is in the area of the safety fence. At the same time, a check must be made to ensure that there is no risk of hazardous situations. If detected, such a situation should be eliminated before the operation.

    (15) When the robot is used, the following precautions should be taken. Otherwise, the robot and peripheral equipment can be adversely affected, or workers can be severely injured. - Avoid using the robot in a flammable environment. - Avoid using the robot in an explosive environment. - Avoid using the robot in an environment full of radiation. - Avoid using the robot under water or at high humidity. - Avoid using the robot to carry a person or animal. - Avoid using the robot as a stepladder. (Never climb up on or hang from the robot.)

    (16) When connecting the peripheral devices related to stop(safety fence etc.) and each signal (external emergency , fence etc.) of robot. be sure to confirm the stop movement and do not take the wrong connection.

    (17) When preparing trestle, please consider security for installation and maintenance work in high place according to Fig.3 (c). Please consider footstep and safety bolt mounting position.

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    RM1Motor power/brake

    RP1PulsecoderRI/RO,XHBK,XROT

    EARTH

    Safety fence

    Interlocking device and safety plug that are activated if thegate is opened.

    Fig. 3 (a) Safety fence and safety gate

    Dual chain

    Single chainPanel board

    FENCE1

    FENCE2

    Panel board

    EAS1

    EAS11

    EAS2

    EAS21

    Note

    In case of R-30iATerminals EAS1,EAS11,EAS2,EAS21 or FENCE1,FENCE2are provided on the operation box or on the terminal blockof the printed circuit board.

    In case of R-30iA MateTerminals EAS1,EAS11,EAS2,EAS21 are providedon the emergency stop board or connector panel.(in case of Open air type)

    Termianls FENCE1,FENCE2 are providedon the emergency stop board.

    Refer to controller maintenance manual for details.

    Emergency stop boardor Panel board (Note)

    In case of R-30iB, R-30iB Mate Terminals EAS1,EAS11,EAS2,EAS21 are provided on the emergency stop board. Refer to the ELECTRICAL CONNCETIONS Chapter of CONNECTION of R-30iB controller maintenance manual (B-83195EN) or R-30iB Mate controller maintenance manual (B-83525EN) for details.

    Fig. 3 (b) Limit switch circuit diagram of the safety fence

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    Steps

    Hook for safety belt

    Fence

    Trestle

    Footstepfor maintenance

    Fig.3 (c) Footstep for maintenance

    3.1 OPERATOR SAFETY The operator is a person who operates the robot system. In this sense, a worker who operates the teach pendant is also an operator. However, this section does not apply to teach pendant operators. (1) If you do not have to operate the robot, turn off the power of the robot controller or press the

    EMERGENCY STOP button, and then proceed with necessary work. (2) Operate the robot system at a location outside of the safety fence (3) Install a safety fence with a safety gate to prevent any worker other than the operator from entering

    the work area unexpectedly and to prevent the worker from entering a dangerous area. (4) Install an EMERGENCY STOP button within the operators reach. The robot controller is designed to be connected to an external EMERGENCY STOP button. With this connection, the controller stops the robot operation (Please refer to "STOP TYPE OF ROBOT" in SAFETY PRECAUTIONS for detail of stop type), when the external EMERGENCY STOP button is pressed. See the diagram below for connection.

    Dual chain

    Single chain

    NoteConnect EES1and EES11,EES2 and EES21or EMGIN1and EMGIN2.

    In case of R-30iAEES1,EES11,EES2,EES21 or EMGIN1,EMGIN2 are on the panel board.

    In case of R-30iA MateEES1,EES11,EES2,EES21are on the emergency stop boardor connector panel (in case of Open air type).EMGIN1,EMGIN2are on the emergency stop board.

    Refer to the maintenance manual of the controller for details.

    External stop button

    Panel board

    EMGIN1

    EMGIN2

    Panel board

    EES1

    EES11

    EES2

    EES21

    External stop button

    (Note) Connect EES1 and EES11, EES2 and EES21 In case R-30iB, R-30iB Mate EES1,EES11,EES2,EES21 are on the emergency stop board Refer to the ELECTRICAL CONNCETIONS Chapter of CONNECTION of R-30iB controller maintenance manual (B-83195EN) or R-30iB Mate controller maintenance manual (B-83525EN) for details.

    Emergency stop boa rd

    or Pane l boa rd

    Fig.3.1 Connection diagram for external emergency stop button

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    3.2 SAFETY OF THE PROGRAMMER While teaching the robot, the operator must enter the work area of the robot. The operator must ensure the safety of the teach pendant operator especially. (1) Unless it is specifically necessary to enter the robot work area, carry out all tasks outside the area. (2) Before teaching the robot, check that the robot and its peripheral devices are all in the normal

    operating condition. (3) If it is inevitable to enter the robot work area to teach the robot, check the locations, settings, and

    other conditions of the safety devices (such as the EMERGENCY STOP button, the DEADMAN switch on the teach pendant) before entering the area.

    (4) The programmer must be extremely careful not to let anyone else enter the robot work area. (5) Programming should be done outside the area of the safety fence as far as possible. If programming

    needs to be done in the area of the safety fence, the programmer should take the following precautions: Before entering the area of the safety fence, ensure that there is no risk of dangerous situations

    in the area. Be prepared to press the emergency stop button whenever necessary. Robot motions should be made at low speeds. Before starting programming, check the entire system status to ensure that no remote instruction

    to the peripheral equipment or motion would be dangerous to the user. Our operator panel is provided with an emergency stop button and a key switch (mode switch) for selecting the automatic operation mode (AUTO) and the teach modes (T1 and T2). Before entering the inside of the safety fence for the purpose of teaching, set the switch to a teach mode, remove the key from the mode switch to prevent other people from changing the operation mode carelessly, then open the safety gate. If the safety gate is opened with the automatic operation mode set, the robot stops (Please refer to "STOP TYPE OF ROBOT" in SAFETY PRECAUTIONS for detail of stop type). After the switch is set to a teach mode, the safety gate is disabled. The programmer should understand that the safety gate is disabled and is responsible for keeping other people from entering the inside of the safety fence.

    Our teach pendant is provided with a DEADMAN switch as well as an emergency stop button. These button and switch function as follows: (1) Emergency stop button: Causes an emergency stop (Please refer to "STOP TYPE OF ROBOT" in SAFETY

    PRECAUTIONS for detail of stop type) when pressed. (2) DEADMAN switch: Functions differently depending on the teach pendant enable/disable switch setting

    status. (a) Disable: The DEADMAN switch is disabled. (b) Enable: Servo power is turned off when the operator releases the DEADMAN switch or when the

    operator presses the switch strongly. Note) The DEADMAN switch is provided to stop the robot when the operator releases the teach pendant or

    presses the pendant strongly in case of emergency. The R-30iB/R-30iB Mate employs a 3-position DEADMAN switch, which allows the robot to operate when the 3-position DEADMAN switch is pressed to its intermediate point. When the operator releases the DEADMAN switch or presses the switch strongly, the robot stops immediately.

    The operators intention of starting teaching is determined by the controller through the dual operation of setting the teach pendant enable/disable switch to the enable position and pressing the DEADMAN switch. The operator should make sure that the robot could operate in such conditions and be responsible in carrying out tasks safely.

    Based on the risk assessment by FANUC, number of operation of DEADMAN SW should not exceed about 10000 times per year.

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    The teach pendant, operator panel, and peripheral device interface send each robot start signal. However the validity of each signal changes as follows depending on the mode switch and the DEADMAN switch of the operator panel, the teach pendant enable switch and the remote condition on the software.

    In case of R-30iB Controller

    Mode Teach pendant enable switch

    Software remote

    condition Teach pendant Operator panel Peripheral device

    Local Not allowed Not allowed Not allowed On Remote Not allowed Not allowed Not allowed

    Local Not allowed Allowed to start Not allowed AUTO mode

    Off Remote Not allowed Not allowed Allowed to start

    Local Allowed to start Not allowed Not allowed On

    Remote Allowed to start Not allowed Not allowed Local Not allowed Not allowed Not allowed

    T1, T2 mode

    Off Remote Not allowed Not allowed Not allowed

    T1,T2 mode:DEADMAN switch is effective. (6) To start the system using the operators panel, make certain that nobody is the robot work area and

    that there are no abnormal conditions in the robot work area. (7) When a program is completed, be sure to carry out a test operation according to the procedure

    below. (a) Run the program for at least one operation cycle in the single step mode at low speed. (b) Run the program for at least one operation cycle in the continuous operation mode at low

    speed. (c) Run the program for one operation cycle in the continuous operation mode at the intermediate

    speed and check that no abnormalities occur due to a delay in timing. (d) Run the program for one operation cycle in the continuous operation mode at the normal

    operating speed and check that the system operates automatically without trouble. (e) After checking the completeness of the program through the test operation above, execute it in

    the automatic operation mode. (8) While operating the system in the automatic operation mode, the teach pendant operator should

    leave the robot work area.

    3.3 SAFETY OF THE MAINTENANCE ENGINEER For the safety of maintenance engineer personnel, pay utmost attention to the following. (1) During operation, never enter the robot work area. (2) A hazardous situation may arise when the robot or the system, are kept with their power-on during

    maintenance operations. Therefore, for any maintenance operation, the robot and the system should be put into the power-off state. If necessary, a lock should be in place in order to prevent any other person from turning on the robot and/or the system. In case maintenance needs to be executed in the power-on state, the emergency stop button must be pressed.

    (3) If it becomes necessary to enter the robot operation range while the power is on, press the emergency stop button on the operator panel, or the teach pendant before entering the range. The maintenance personnel must indicate that maintenance work is in progress and be careful not to allow other people to operate the robot carelessly.

    (4) When entering the area enclosed by the safety fence, the maintenance worker must check the entire system in order to make sure no dangerous situations exist. In case the worker needs to enter the safety area whilst a dangerous situation exists, extreme care must be taken, and entire system status must be carefully monitored.

    (5) Before the maintenance of the pneumatic system is started, the supply pressure should be shut off and the pressure in the piping should be reduced to zero.

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    (6) Before the start of teaching, check that the robot and its peripheral devices are all in the normal operating condition.

    (7) Do not operate the robot in the automatic mode while anybody is in the robot work area. (8) When you maintain the robot alongside a wall or instrument, or when multiple workers are working

    nearby, make certain that their escape path is not obstructed. (9) When a tool is mounted on the robot, or when any moving device other than the robot is installed,

    such as belt conveyor, pay careful attention to its motion. (10) If necessary, have a worker who is familiar with the robot system stand beside the operator panel

    and observe the work being performed. If any danger arises, the worker should be ready to press the EMERGENCY STOP button at any time.

    (11) When replacing a part, please contact FANUC service center. If a wrong procedure is followed, an accident may occur, causing damage to the robot and injury to the worker.

    (12) When replacing or reinstalling components, take care to prevent foreign material from entering the system.

    (13) When handling each unit or printed circuit board in the controller during inspection, turn off the circuit breaker to protect against electric shock.

    If there are two cabinets, turn off the both circuit breaker. (14) A part should be replaced with a part recommended by FANUC. If other parts are used, malfunction

    or damage would occur. Especially, a fuse that is not recommended by FANUC should not be used. Such a fuse may cause a fire.

    (15) When restarting the robot system after completing maintenance work, make sure in advance that there is no person in the work area and that the robot and the peripheral devices are not abnormal.

    (16) When a motor or brake is removed, the robot arm should be supported with a crane or other equipment beforehand so that the arm would not fall during the removal.

    (17) Whenever grease is spilled on the floor, it should be removed as quickly as possible to prevent dangerous falls.

    (18) The following parts are heated. If a maintenance worker needs to touch such a part in the heated state, the worker should wear heat-resistant gloves or use other protective tools. Servo motor Inside the controller Reducer Gearbox Wrist unit

    (19) Maintenance should be done under suitable light. Care must be taken that the light would not cause any danger.

    (20) When a motor, reducer, or other heavy load is handled, a crane or other equipment should be used to protect maintenance workers from excessive load. Otherwise, the maintenance workers would be severely injured.

    (21) The robot should not be stepped on or climbed up during maintenance. If it is attempted, the robot would be adversely affected. In addition, a misstep can cause injury to the worker.

    (22) When performing maintenance work in high place, secure a footstep and wear safety belt. (23) After the maintenance is completed, spilled oil or water and metal chips should be removed from the

    floor around the robot and within the safety fence. (24) When a part is replaced, all bolts and other related components should put back into their original

    places. A careful check must be given to ensure that no components are missing or left not mounted. (25) In case robot motion is required during maintenance, the following precautions should be taken :

    - Foresee an escape route. And during the maintenance motion itself, monitor continuously the whole system so that your escape route will not become blocked by the robot, or by peripheral equipment. - Always pay attention to potentially dangerous situations, and be prepared to press the emergency stop button whenever necessary.

    (26) The robot should be periodically inspected. (Refer to the robot mechanical manual and controller maintenance manual.) A failure to do the periodical inspection can adversely affect the performance or service life of the robot and may cause an accident

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    (27) After a part is replaced, a test operation should be given for the robot according to a predetermined method. (See TESTING section of Controller operators manual.) During the test operation, the maintenance staff should work outside the safety fence.

    4 SAFETY OF THE TOOLS AND PERIPHERAL DEVICES

    4.1 PRECAUTIONS IN PROGRAMMING (1) Use a limit switch or other sensor to detect a dangerous condition and, if necessary, design the

    program to stop the robot when the sensor signal is received. (2) Design the program to stop the robot when an abnormal condition occurs in any other robots or

    peripheral devices, even though the robot itself is normal. (3) For a system in which the robot and its peripheral devices are in synchronous motion, particular care

    must be taken in programming so that they do not interfere with each other. (4) Provide a suitable interface between the robot and its peripheral devices so that the robot can detect

    the states of all devices in the system and can be stopped according to the states.

    4.2 PRECAUTIONS FOR MECHANISM (1) Keep the component cells of the robot system clean, and operate the robot in an environment free of

    grease, water, and dust. (2) Dont use unconfirmed liquid for cutting fluid and cleaning fluid. (3) Employ a limit switch or mechanical stopper to limit the robot motion so that the robot or cable does

    not strike against its peripheral devices or tools. (4) Observe the following precautions about the mechanical unit cables. When theses attentions are not

    kept, unexpected troubles might occur. Use mechanical unit cable that have required user interface. Dont add user cable or hose to inside of mechanical unit. Please do not obstruct the movement of the mechanical unit cable when cables are added to

    outside of mechanical unit. In the case of the model that a cable is exposed, Please do not perform remodeling (Adding a

    protective cover and fix an outside cable more) obstructing the behavior of the outcrop of the cable.

    Please do not interfere with the other parts of mechanical unit when install equipments in the robot.

    (5) The frequent power-off stop for the robot during operation causes the trouble of the robot. Please avoid the system construction that power-off stop would be operated routinely. (Refer to bad case example.) Please execute power-off stop after reducing the speed of the robot and stopping it by hold stop or cycle stop when it is not urgent. (Please refer to "STOP TYPE OF ROBOT" in SAFETY PRECAUTIONS for detail of stop type.) (Bad case example) Whenever poor product is generated, a line stops by emergency stop. When alteration was necessary, safety switch is operated by opening safety fence and

    power-off stop is executed for the robot during operation. An operator pushes the emergency stop button frequently, and a line stops. An area sensor or a mat switch connected to safety signal operate routinely and power-off stop

    is executed for the robot. (6) Robot stops urgently when collision detection alarm (SRVO-050) etc. occurs. The frequent urgent

    stop by alarm causes the trouble of the robot, too. So remove the causes of the alarm.

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    SAFETY OF THE ROBOT MECHANISM 5.1 PRECAUTIONS IN OPERATION

    (1) When operating the robot in the jog mode, set it at an appropriate speed so that the operator can manage the robot in any eventuality.

    (2) Before pressing the jog key, be sure you know in advance what motion the robot will perform in the jog mode.

    5.2 PRECAUTIONS IN PROGRAMMING (1) When the work areas of robots overlap, make certain that the motions of the robots do not interfere

    with each other. (2) Be sure to specify the predetermined work origin in a motion program for the robot and program the

    motion so that it starts from the origin and terminates at the origin. Make it possible for the operator to easily distinguish at a glance that the robot motion has

    terminated.

    5.3 PRECAUTIONS FOR MECHANISMS (1) Keep the work areas of the robot clean, and operate the robot in an environment free of grease, water,

    and dust.

    5.4 PROCEDURE TO MOVE ARM WITHOUT DRIVE POWER IN EMERGENCY OR ABNORMAL SITUATIONS

    For emergency or abnormal situations (e.g. persons trapped in or by the robot), brake release unit can be used to move the robot axes without drive power.

    Please refer to controller maintenance manual and mechanical unit operators manual for using method of brake release unit and method of supporting robot.

    6 SAFETY OF THE END EFFECTOR 6.1 PRECAUTIONS IN PROGRAMMING

    (1) To control the pneumatic, hydraulic and electric actuators, carefully consider the necessary time delay after issuing each control command up to actual motion and ensure safe control.

    (2) Provide the end effector with a limit switch, and control the robot system by monitoring the state of the end effector.

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    7 STOP TYPE OF ROBOT The following three robot stop types exist:

    Power-Off Stop (Category 0 following IEC 60204-1) Servo power is turned off and the robot stops immediately. Servo power is turned off when the robot is moving, and the motion path of the deceleration is uncontrolled. The following processing is performed at Power-Off stop. - An alarm is generated and servo power is turned off. - The robot operation is stopped immediately. Execution of the program is paused.

    Controlled stop (Category 1 following IEC 60204-1) The robot is decelerated until it stops, and servo power is turned off. The following processing is performed at Controlled stop. - The alarm "SRVO-199 Controlled stop" occurs along with a decelerated stop. Execution of the

    program is paused. - An alarm is generated and servo power is turned off.

    Hold (Category 2 following IEC 60204-1) The robot is decelerated until it stops, and servo power remains on. The following processing is performed at Hold. - The robot operation is decelerated until it stops. Execution of the program is paused.

    WARNING The stopping distance and stopping time of Controlled stop are longer than the

    stopping distance and stopping time of Power-Off stop. A risk assessment for the whole robot system, which takes into consideration the increased stopping distance and stopping time, is necessary when Controlled stop is used.

    When the emergency stop button is pressed or the FENCE is open, the stop type of robot is Power-Off stop or Controlled stop. The configuration of stop type for each situation is called stop pattern. The stop pattern is different according to the controller type or option configuration. There are the following 3 Stop patterns.

    Stop pattern Mode

    Emergency stop

    button

    External Emergency

    stop FENCE open SVOFF input Servo disconnect

    AUTO P-Stop P-Stop C-Stop C-Stop P-Stop A T1 P-Stop P-Stop - C-Stop P-Stop T2 P-Stop P-Stop - C-Stop P-Stop AUTO P-Stop P-Stop P-Stop P-Stop P-Stop

    B T1 P-Stop P-Stop - P-Stop P-Stop T2 P-Stop P-Stop - P-Stop P-Stop AUTO C-Stop C-Stop C-Stop C-Stop C-Stop

    C T1 P-Stop P-Stop - C-Stop P-Stop T2 P-Stop P-Stop - C-Stop P-Stop

    P-Stop: Power-Off stop C-Stop: Controlled stop -: Disable

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    The following table indicates the Stop pattern according to the controller type or option configuration. Option R-30iB/ R-30iB Mate

    Standard A (*) Controlled stop by E-Stop (A05B-2600-J570) C (*)

    (*) R-30iB / R-30iB Mate does not have servo disconnect. / R-30iB Mate does not have SVOFF input. The stop pattern of the controller is displayed in "Stop pattern" line in software version screen. Please refer to "Software version" in operator's manual of controller for the detail of software version screen.

    "Controlled stop by E-Stop" option When "Controlled stop by E-Stop" (A05B-2600-J570) option is specified, the stop type of the following alarms becomes Controlled stop but only in AUTO mode. In T1 or T2 mode, the stop type is Power-Off stop which is the normal operation of the system.

    Alarm Condition SRVO-001 Operator panel E-stop Operator panel emergency stop is pressed. SRVO-002 Teach pendant E-stop Teach pendant emergency stop is pressed. SRVO-007 External emergency stops External emergency stop input (EES1-EES11, EES2-EES21) is

    open. SRVO-408 DCS SSO Ext Emergency Stop In DCS Safe I/O connect function, SSO[3] is OFF. SRVO-409 DCS SSO Servo Disconnect In DCS Safe I/O connect function, SSO[4] is OFF.

    Controlled stop is different from Power-Off stop as follows: - In Controlled stop, the robot is stopped on the program path. This function is effective for a system

    where the robot can interfere with other devices if it deviates from the program path. - In Controlled stop, physical impact is less than Power-Off stop. This function is effective for

    systems where the physical impact to the mechanical unit or EOAT (End Of Arm Tool) should be minimized.

    - The stopping distance and stopping time of Controlled stop is longer than the stopping distance and stopping time of Power-Off stop, depending on the robot model and axis. Please refer to the operator's manual of a particular robot model for the data of stopping distance and stopping time.

    When this option is loaded, this function cannot be disabled. The stop type of DCS Position and Speed Check functions is not affected by the loading of this option.

    WARNING The stopping distance and stopping time of Controlled stop are longer than the

    stopping distance and stopping time of Power-Off stop. A risk assessment for the whole robot system, which takes into consideration the increased stopping distance and stopping time, is necessary when this option is loaded.

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    TABLE OF CONTENTS

    SAFETY PRECAUTIONS............................................................................s-1 1 INTRODUCTION .....................................................................................1

    1.1 MANUAL PLAN ............................................................................................. 1

    2 OVERVIEW .............................................................................................3 2.1 OVERVIEW ................................................................................................... 3 2.2 ERROR CODE PROPERTIES ...................................................................... 4

    2.2.1 Overview ..................................................................................................................4 2.2.2 Facility Name and Code ...........................................................................................8 2.2.3 Severity Descriptions .............................................................................................10 2.2.4 Error Message Text ................................................................................................12

    3 ERROR RECOVERY.............................................................................15 3.1 GENERAL ERROR RECOVERY PROCEDURES ...................................... 15

    3.1.1 Overview ................................................................................................................15 3.1.2 Overtravel Release..................................................................................................15 3.1.3 Hand Breakage Recovery .......................................................................................17 3.1.4 Pulsecoder Alarm Recovery ...................................................................................17 3.1.5 Chain Failure Detection Error Recovery ................................................................19

    4 ERROR CODES ....................................................................................20 4.1 A .................................................................................................................. 20

    4.1.1 ACAL Alarm Code.................................................................................................20 4.1.2 APSH Alarm Code .................................................................................................28 4.1.3 ARC Alarm Code ...................................................................................................40 4.1.4 ASBN Alarm Code.................................................................................................54 4.1.5 ATGP Alarm Code.................................................................................................61 4.1.6 ATZN Alarm Code.................................................................................................61

    4.2 B .................................................................................................................. 63 4.2.1 BBOX Alarm Code ................................................................................................63 4.2.2 BRCH Alarm Code.................................................................................................65

    4.3 C.................................................................................................................. 68 4.3.1 CALM Alarm Code................................................................................................68 4.3.2 CD Alarm Code......................................................................................................70 4.3.3 CMND Alarm Code ...............................................................................................72 4.3.4 CNTR Alarm Code.................................................................................................74 4.3.5 COND Alarm Code ................................................................................................75 4.3.6 COPT Alarm Code .................................................................................................75 4.3.7 CPMO Alarm Code ................................................................................................78 4.3.8 CVIS Alarm Code ..................................................................................................84

    4.4 D................................................................................................................ 118 4.4.1 DIAG Alarm Code ...............................................................................................118 4.4.2 DICT Alarm Code ................................................................................................119 4.4.3 DJOG Alarm Code ...............................................................................................122 4.4.4 DMDR Alarm Code .............................................................................................123 4.4.5 DMER Alarm Code..............................................................................................125 4.4.6 DNET Alarm Code...............................................................................................129 4.4.7 DTBR Alarm Code...............................................................................................139 4.4.8 DX Alarm Code....................................................................................................139

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    4.5 E ................................................................................................................ 141 4.5.1 ELOG Alarm Code...............................................................................................141

    4.6 F ................................................................................................................ 141 4.6.1 FILE Alarm Code.................................................................................................141 4.6.2 FLPY Alarm Code................................................................................................148 4.6.3 FORC Alarm Code...............................................................................................149 4.6.4 FRSY Alarm Code ...............................................................................................169 4.6.5 FXTL Alarm Code ...............................................................................................171

    4.7 H................................................................................................................ 180 4.7.1 HOST Alarm Code...............................................................................................180 4.7.2 HRTL Alarm Code...............................................................................................193

    4.8 I.................................................................................................................. 198 4.8.1 IB-S Alarm Code..................................................................................................198 4.8.2 ICRZ Alarm Code ................................................................................................220 4.8.3 INTP Alarm Code ................................................................................................221 4.8.4 ISD Alarm Code...................................................................................................253 4.8.5 ISDT Alarm Code ................................................................................................262

    4.9 J................................................................................................................. 262 4.9.1 JOG Alarm Code ..................................................................................................262

    4.10 K ................................................................................................................ 265 4.10.1 KALM Alarm Code..............................................................................................265

    4.11 L................................................................................................................. 265 4.11.1 LANG Alarm Code ..............................................................................................265 4.11.2 LECO Alarm Code...............................................................................................267 4.11.3 LNTK Alarm Code...............................................................................................273 4.11.4 LSTP Alarm Code ................................................................................................278

    4.12 M................................................................................................................ 280 4.12.1 MACR Alarm Code..............................................................................................280 4.12.2 MARL Alarm Code..............................................................................................281 4.12.3 MASI Alarm Code ...............................................................................................283 4.12.4 MCTL Alarm Code ..............................................................................................284 4.12.5 MEMO Alarm Code.............................................................................................286 4.12.6 MENT Alarm Code ..............................................................................................293 4.12.7 MHND Alarm Code .............................................................................................294 4.12.8 MOTN Alarm Code..............................................................................................302 4.12.9 MUPS Alarm Code ..............................................................................................333

    4.13 O................................................................................................................ 334 4.13.1 OPTN Alarm Code...............................................................................................334 4.13.2 OS Alarm Code ....................................................................................................337

    4.14 P ................................................................................................................ 337 4.14.1 PALL Alarm Code ...............................................................................................337 4.14.2 PALT Alarm Code ...............................................................................................354 4.14.3 PICK Alarm Code ................................................................................................355 4.14.4 PMON Alarm Code..............................................................................................358 4.14.5 PNT1 Alarm Code................................................................................................359 4.14.6 PNT2 Alarm Code................................................................................................430 4.14.7 PRIO Alarm Code ................................................................................................487 4.14.8 PROF Alarm Code ...............................................................................................512 4.14.9 PROG Alarm Code...............................................................................................513 4.14.10 PTPG Alarm Code................................................................................................518 4.14.11 PWD Alarm Code ................................................................................................519

    4.15 Q................................................................................................................ 523 4.15.1 QMGR Alarm Code .............................................................................................523

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    4.16 R................................................................................................................ 524 4.16.1 RIPE Alarm Code.................................................................................................524 4.16.2 ROUT Alarm Code...............................................................................................525 4.16.3 RPC Alarm Code..................................................................................................527 4.16.4 RPM Alarm Code.................................................................................................528 4.16.5 RTCP Alarm Code ...............................................................................................529

    4.17 S ................................................................................................................ 530 4.17.1 SCIO Alarm Code ................................................................................................530 4.17.2 SDTL Alarm Code ...............................................................................................531 4.17.3 SEAL Alarm Code ...............................................................................................537 4.17.4 SENS Alarm Code................................................................................................559 4.17.5 SHAP Alarm Code ...............................................................................................560 4.17.6 SPOT Alarm Code................................................................................................563 4.17.7 SPRM Alarm Code...............................................................................................584 4.17.8 SRIO Alarm Code ................................................................................................585 4.17.9 SRVO Alarm Code...............................................................................................586 4.17.10 SSPC Alarm Code ................................................................................................627 4.17.11 SVGN Alarm Code...............................................................................................634 4.17.12 SYST Alarm Code................................................................................................666

    4.18 T ................................................................................................................ 687 4.18.1 TAST Alarm Code ...............................................................................................687 4.18.2 TCPP Alarm Code................................................................................................689 4.18.3 TG Alarm Code ....................................................................................................691 4.18.4 THSR Alarm Code ...............................................................................................693 4.18.5 TJOG Alarm Code................................................................................................697 4.18.6 TMAT Alarm Code ..............................................................................................697 4.18.7 TOOL Alarm Code...............................................................................................699 4.18.8 TPIF Alarm Code .................................................................................................702 4.18.9 TRAK Alarm Code...............................................................................................716

    4.19 V ................................................................................................................ 717 4.19.1 VARS Alarm Code...............................................................................................717

    4.20 W ............................................................................................................... 723 4.20.1 WEAV Alarm Code .............................................................................................723 4.20.2 WNDW Alarm Code ............................................................................................725

    4.21 X ................................................................................................................ 727 4.21.1 XMLF Alarm Code ..............................................................................................727

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    1 INTRODUCTION This chapter explains the manual plan and the safety precautions that must be observed in working with the FANUC Robot. Contents of this chapter 1.1 MANUAL PLAN

    1.1 MANUAL PLAN About this manual

    FANUC Robot series (R-30iB/R-30iB Mate CONTROLLER) Operators Manual. This manual describes how to operate the FANUC Robot, an all-purpose compact robot. It is controlled by the FANUC R-30iB and R-30iB Mate controller (called the robot controller hereinafter) containing the FANUC Robot software. This manual describes the error code listings, causes, and remedies.

    Related manuals The following manuals are available:

    OPERATOR'S MANUAL (Alarm Code List) B-83284EN-1 (This manual)

    Topics: Error code listings, causes, and remedies. Use: Installing and activating the system, connecting the mechanical unit to the peripheral device and maintenance the robot.

    OPERATORS MANUAL (Basic Operation) B-83284EN

    Intended readers: Operators responsible for designing, introducing, operating, and adjusting the robot system at the work site. Topics: Functions, operations and the procedure for operating the robot. Programming procedure, interface and alarm. Use: Guide to teaching, introducing, and adjusting the robot at the work site, and application designing.

    Optional Function OPERATORS MANUAL B-83284EN-2

    Intended readers: Operators responsible for designing, introducing, operating, and adjusting the robot system at the work site. Topics: Description of the software optional functions. Use: Guide to teaching, introducing, and adjusting the robot at the work site, and application designing.

    Robot controller

    Arc Welding Function OPERATORS MANUAL B-83284EN-3

    Intended readers: Operators responsible for designing, introducing, operating, and adjusting the robot system at the work site. Topics: Description of the setting and operation for arc welding application software. Use: Guide to teaching, introducing, and adjusting the robot at the work site, and application designing.

  • 1.INTRODUCTION B-83284EN-1/03

    - 2 -

    Spot Welding Function OPERATORS MANUAL B-83284EN-1

    Intended readers: Operators responsible for designing, introducing, operating, and adjusting the robot system at the work site. Topics: Description of the setting and operation for spot welding application software. Use: Guide to teaching, introducing, and adjusting the robot at the work site, and application designing.

    Dispense Function OPERATORS MANUAL B-83284EN-1

    Intended readers: Operators responsible for designing, introducing, operating, and adjusting the robot system at the work site. Topics: Description of the setting and operation for dispense application software. Use: Guide to teaching, introducing, and adjusting the robot at the work site, and application designing.

    Robot controller

    MAINTENANCE MANUALB-83195EN (for R-30iB), B-83525EN (for R-30iB Mate)

    Topics: Installing and activating the system, connecting the mechanical unit to the peripheral device and maintenance the robot.

    Mechanical unit OPERATORS MANUAL Topics: Installing and activating the robot, connecting the mechanical unit to the controller, maintaining the robot. Use: Guide to installation, activation, connection, and maintenance.

  • B-83284EN-1/03 2.OVERVIEW

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    2 OVERVIEW 2.1 OVERVIEW

    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 this manual. Use Procedure 2-1 as the recommended error recovery procedure. Some errors require minimal corrective action to recover from them. Others require procedures that are more involved. 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 2-1 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

    2.1 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.

    Table 2.1 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.

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    2.2 ERROR CODE PROPERTIES 2.2.1 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 2.2.2, Section 2.2.3, and Section 2.2.4. 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: 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. Table 2.2.1(a) through Table 2.2.1(e) describe each kind of alarm that can be displayed.

    Table 2.2.1(a) 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 2.2.1(b) 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 2.2.1(c) Comm log screen ITEM DESCRIPTION

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

    Table 2.2.1(d) 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.

    Table 2.2.1(e) System alarm screen ITEM DESCRIPTION

    System Alarm Status This item allows you to monitor system alarm messages such as SYST alarms. Use Procedure 2-2 to display the Alarm Log screen.

    Procedure 2-2 Displaying the Alarm Log Automatically

    Conditions To display the Active Alarm screen automatically,

  • B-83284EN-1/03 2.OVERVIEW

    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.

    Alarm : Active 1/1 1 SRVO-007 External emergency stop

    SRVO-007 External emergency stop TEST1 LINE 15 AUTO ABORTED JOINT 30%

    2 To toggle between the Active Alarm screen and Hist Alarm screen, press F3 (ACTIVE or HIST). 3 If you 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.

    Table 2.2.1(f) Setting of $ER_SEV_NOAUTO[]

    SEVERITY $ER_SEV_NOAUTO[1-5] PAUSE $ER_SEV_NOAUTO[1] STOP $ER_SEV_NOAUTO[2] SERVO $ER_SEV_NOAUTO[3] ABORT $ER_SEV_NOAUTO[4] SYSTEM $ER_SEV_NOAUTO[5]

    FALSE: Automatic alarm screen display is disabled. TRUE: Automatic alarm screen display is enabled.

    NOTE If a PAUSE alarm is detected, followed by an ABORT alarm, when the automatic

    display of a PAUSE alarm is disabled, automatic display is not performed during FAULT output.

    5 To disable the automatic display of a specific error code, modify the following system variables. The

    errors designated in the following system variables will still be logged in the Active Alarm screen, but they will no longer force the screen to immediately become visible.

    Table 2.2.1(g) System variables to disable the automatic display of a specific alarm

    System variables Description $ER_NOAUTO. $NOAUTO_ENB

    Enables or disables the function to suppress automatic alarm screen display for an alarm specified in $ER_NOAUTO.$NOAUTO_CODE[] while the automatic alarm screen display is enabled. FALSE : The function to suppress automatic alarm screen display is disabled. TRUE : The function to suppress automatic alarm screen display is enabled.

    $ER_NOAUTO. $NOAUTO_NUM

    Sets the number of alarms set in $ER_NOAUTO.$NOAUTO_CODE[].

    $ER_NOAUTO. $NOAUTO_CODE [1 to 20]

    Error number consisting of facility code and alarm number. Example 11 002 (SRVO-002 alarm) Facility code : 11, Alarm number : 002 About facility code, refer to 2.2.2 Facility Name and Code.

    - 5 -

  • 2.OVERVIEW B-83284EN-1/03

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    For the alarms listed below, which are caused by a user operation and which cause the system to stop, $ER_NOAUTO.$NOAUTO_ENB is set to TRUE by default. When the setting is changed to FALSE, the corresponding alarm screen is automatically displayed.

    SRVO-001 Operator panel E-stop SRVO-002 Teach pendant E-stop SRVO-003 Deadman switch released SRVO-004 Fence open SRVO-005 Robot overtravel SRVO-012 Power failure recovery

    When an alarm set in $ER_NOAUTO.$NOAUTO_CODE[] and another alarm are detected in that

    order while $ER_NOAUTO.$NOAUTO_ENB is set to TRUE, automatic display is not performed. While FAULT is output, automatic display is not performed even if an alarm is detected.

    NOTE 1. When a PAUSE, STOP, ABORT alarm is detected, the FAULT signal is output

    with the servo system started. Each time an alarm reset signal is input, the FAULT signal is reset. If continuous monitoring is performed to raise an alarm, automatic alarm display may be performed at each RESET input.

    2. When a SERVO or SYSTEM alarm is detected, the FAULT signal is reset after the servo system starts.

    Automatic return function The automatic return function displays the screen which was displayed until automatic screen

    display when an alarm reset signal is input. This function is used together with the automatic display function. The automatic return function is executed as describe below. When the automatic alarm screen display function is enabled, the alarm screen is automatically

    displayed if an alarm occurs. When the alarm is eliminated by the input of an alarm reset signal, the previous screen is automatically displayed.

    If the alarm screen is not displayed automatically because of an alarm but displayed by means of menu selection, the previous screen is not displayed even if an alarm reset signal is input.

    If another screen is displayed before an alarm reset signal is input, the automatic return function is not executed.

    The automatic return function is executed when the FAULT signal is turned off. If the power is turned off and on after the alarm screen is displayed by automatic alarm display

    function, the automatic return function does not work after the start-up. This is not affected by the start mode (cold start, hot start, etc.)

    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. 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.

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    NOTE When you reset the system by pressing the RESET key, the alarms displayed on

    this screen are cleared.

    Procedure 2-3 Displaying the Alarm Log Manually

    Steps 1 Press MENU. 2 Select 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.

    Alarm : Hist 1/25 1 SRVO-007 External emergency stop 2 R E S E T 3 SRVO-001 Operator panel E-stop 4 R E S E T 5 SRVO-001 Operator panel E-stop 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 E-stop 11 R E S E T

    [ TYPE ] [ VIEW ] ACTIVE CLEAR DETAIL

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

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

    11 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.

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

    13 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

  • 2.OVERVIEW B-83284EN-1/03

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    occurred will be shown instead. If you are in Single Display Mode, you can also toggle between wide screen and normal screen by selecting Wide or Normal.

    2.2.2 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: 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 2.2.2.

    Table 2.2.2 Error facility codes

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

    ACAL 112 0x70 AccuCal APSH 38 0x26 Application shell ARC 53 0x35 Arc welding application ASBN 22 0x16 Mnemonic editor ATGP 102 0x66 Attach group ATZN 138 0x8a Auto zone BBOX 118 0x76 Bump box CALM 106 0x6a Calibration Mate CD 82 0x52 Coordinated motion CMND 42 0x2a Command processor CNTR 73 0x49 Continuous turn COND 4 0x4 Condition handler COPT 37 0x25 Common options CPMO 114 0x72 Constant Path CUST 97 0x61 Customer specific errors CVIS 117 0x75 Vision 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 ELOG 5 0x5 Error logger FILE 2 0x2 File system FLPY 10 0xa Serial floppy disk system FORC 91 0x5b force control (force sensor) 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 IB-S 88 0x58 Interbus-S INTP 12 0xc Interpreter internal errors ISD 39 0x27 ISD (Integral Servo Dispenser) JOG 19 0x13 Manual jog KALM 122 0x7a KAREL alarm LANG 21 0x15 Language utility LECO 109 0x6d Arc errors from Lincoln Electric

  • B-83284EN-1/03 2.OVERVIEW

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

    LNTK 44 0x2c Line tracking LSTP 108 0x6c Local Stop error MACR 57 0x39 MACRO MARL 83 0x53 Material removal MCTL 6 0x6 Motion control MEMO 7 0x7 Memory MENT 68 0x44 ME-NET MHND 41 0x29 Material Handling shell and menus MOTN 15 0xf Motion MUPS 48 0x30 Multi-pass motion NOM 133 0x85 Nominal Position OPTN 65 0x41 Option installation OS 0 0x0 Operating system PALL 115 0x73 PalletTool PALT 26 0x1a Palletizing application PICK 132 0x84 Pick tool PMON 28 0x1c PC monitor PNT1 86 0x56 Paint application PNT2 137 0x89 Paint application PRIO 13 0xd Digital I/O 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 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 SENS 58 0x3a Sensor interface SHAP 79 0x4f Shape generation SPOT 23 0x17 Spot welding application SPRM 131 0X83 Ramp motion SRIO 1 0x1 Serial driver SRVO 11 0xb FLTR & SERVO SSPC 69 0x45 Special space checking SVGN 30 0x1e Servo weld gun application SYST 24 0x18 System TAST 47 0x2f Through-Arc Seam Tracking TCPP 46 0x2e TCP speed prediction TG 90 0x5a Triggering accuracy THSR 60 0x3c Touch Sensing 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

  • 2.OVERVIEW B-83284EN-1/03

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

    TRSV 134 0x86 Tray server VARS 16 0x10 Variable WEAV 45 0x2d Weaving WMAP 103 0x67 All wafer handling robot WNDW 18 0x12 Window I/O XMLF 129 0x81 XML errors

    2.2.3 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 2-2.

    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. 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, press the operator 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, 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.

  • B-83284EN-1/03 2.OVERVIEW

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    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.

    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.

    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 retranslate it. When you translate a program and no ERROR errors occur, translation is successful and a .PC file is generated.

    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 2.2.3(a) summarizes the effects of error severities.

    Table 2.2.3(a) Effects of error severity Severity Program Robot Motion Servo Motors Range

    WARN No effect No effect No effect -- PAUSE Paused The current move is

    completed then the robot stops.

    No effect LOCAL (PAUSE.L) GLOBAL (PAUSE.G)

    STOP Paused Decelerated STOP, motion retained

    No effect LOCAL (STOP.L) GLOBAL (STOP.G)

    SERVO Paused Immediate STOP, motion retained

    Power shutdown GLOBAL

    SREVO2 Aborted Immediate STOP, motion canceled

    Power shutdown GLOBAL

    ABORT Aborted Decelerated STOP, motion canceled

    No effect LOCAL (ABORT.L) GLOBAL (ABORT.G)

    SYSTEM Aborted Immediate STOP, motion canceled

    Power shut down Requires a FCTN: CYCLE POWER

    GLOBAL

    ERROR No effect No effect No effect -- NONE No effect No effect No effect --

    Range in which the alarm is applied when multiple programs run simultaneously (multitask function)LOCAL The alarm is applied only to a program which has caused the alarm.

    Range

    GLOBAL The alarm is applied to all programs.

  • 2.OVERVIEW B-83284EN-1/03

    Color Display According to the Alarm Severity On the alarm history screen, each message is displayed in the color specified according to its alarm severity.

    The color assigned to each alarm severity is listed below:

    Table 2.2.3(b) Alarm Severity and the color of alarm message Alarm severity Color

    NONE WARN

    White

    PAUSE.L PAUSE.G

    Yellow

    STOP.L STOP.G

    Yellow

    SERVO SERVO2

    Red

    ABORT.L ABORT.G

    Red

    SYSTEM Red RESET(*) Blue SYST-026 System normal power up(*) Blue

    NOTE Messages "RESET" and "SYST-026 System normal power up" are displayed in

    blue.

    2.2.4 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 Some error messages might contain cause codes, percent (%) notation, or hexadecimal notation. For more information on displaying cause codes, refer to Procedure 2-3.

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    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.

    Hexadecimal Notation Hexadecimal notation is used to indicate the specific axes in error, when one or more axes are in error at the same time. Most robots have interaction limits, in addition to normal joint limits. Even when all axes are within their respective limits an error might occur. This could possibly be caused by the interaction between multiple axes. In this case, hexadecimal notation can help you to find the specific axis in 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 Hex indicates that the axis numbers are in hexadecimal format. Table 2.2.4(a) lists the sixteen hexadecimal digits and the corresponding axes that are in error.

    NOTE Hexadecimal digits for the decimal values of 10 through 15 are represented by

    the letters A through F respectively. Refer to Table 2.2.4(a). To determine which axes are in error, you must evaluate each digit in the error message separately. Refer to Table 2.2.4(a).

    NOTE If only one number appears in the error message after the A:, you must read it

    as the first digit.

  • 2.OVERVIEW B-83284EN-1/03

    - 14 -

    Table 2.2.4(a) 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 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 2.2.4(b) contains some examples of how to interpret Hexadecimal notation in an error message.

    Table 2.2.4(b) 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.

  • B-83284EN-1/03 3.ERROR RECOVERY

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    3 ERROR RECOVERY 3.1 GENERAL ERROR RECOVERY PROCEDURES 3.1.1 Overview

    This section contains procedures for recovery from certain errors. These errors are: Overtravel release Hand breakage recovery Pulsecoder alarm Chain failure detection recovery

    3.1.2 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 3.1.2 for information on the MANUAL OT Release items. Use Procedure 3-1 to recover from an overtravel error.

    Table 3.1.2 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.

    Procedure 3-1 Recovering from an Overtravel Error

    Conditions An axis (or axes) are in overtravel 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.

  • 3.ERROR RECOVERY B-83284EN-1/03

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    MANUAL OT Release 1/9 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

    [ TYPE ] RELEASE 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.

    NOTE For the following steps, press and hold down the SHIFT key until you have

    completed Step 7.b through Step 7.d.

    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 7.b through Step 7.d, 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 8.a through Step 8.d.

    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.

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    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 & CRF8 connection on the amplifier PCB if the robot is not in an actual overtravel

    condition.

    3.1.3 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. Lights the teach pendant FAULT LED. The status of the hand breakage detection switch is displayed on the STATUS Stop Signals screen. Use Procedure 3-2 to recover from a hand breakage.

    Procedure 3-2 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.

    3.1.4 Pulsecoder 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 3-3 to reset a Pulsecoder alarm.

    Procedure 3-3 Resetting a Pulsecoder SRVO-062 Alarm

    Steps 1 Press MENU. 2 Select SYSTEM. 3 Press F1, [TYPE]. 4 Select Master/Cal. If Master/Cal is not listed on the [TYPE] menu, do the following; otherwise, continue to Step 5.

    a Select Variables from the [TYPE] menu.

  • 3.ERROR RECOVERY B-83284EN-1/03

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    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 TORQUE = [ON ] 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.

    [ TYPE ] LOAD RES_PCA DONE 5 Press F3, RES_PCA. You will see a screen similar to the following.

    SYSTEM Master/Cal TORQUE = [ON ] 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 Pulsecoder alarm? [NO]

    [ TYPE ] YES NO 6 Press F4, YES. You will see a screen similar to the following.

    SYSTEM Master/Cal TORQUE = [ON ] 1 FIXTURE POSITION MASTER 2 ZERO POSITION MASTER 3 QUICK MASTER 4 SINGLE AXIS MASTER 5 SET QUICK MASTER REF 6 CALIBRATE Pulsecoder alarm reset!

    [ TYPE ] LOAD RES_PCA DONE

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    3.1.5 Chain Failure Detection E


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