hit counter script
ABB IRC5 Operating Manual
  1. Manuals
  2. Brands
  3. ABB Manuals
  4. Robotics
  5. IRC5 Compact
  6. Operating manual

ABB IRC5 Operating Manual

Troubleshooting
Hide thumbs Also See for IRC5:
1
2
3
4
Table Of Contents
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
101
102
103
104
105
106
107
108
109
110
111
112
113
114
115
116
117
118
119
120
121
122
123
124
125
126
127
128
129
130
131
132
133
134
135
136
137
138
139
140
141
142
143
144
145
146
147
148
149
150
151
152
153
154
155
156
157
158
159
160
161
162
163
164
165
166
167
168
169
170
171
172
173
174
175
176
177
178
179
180
181
182
183
184
185
186
187
188
189
190
191
192
193
194
195
196
197
198
199
200
201
202
203
204
205
206
207
208
209
210
211
212
213
214
215
216
217
218
219
220
221
222
223
224
225
226
227
228
229
230
231
232
233
234
235
236
237
238
239
240
241
242
243
244
245
246
247
248
249
250
251
252
253
254
255
256
257
258
259
260
261
262
263
264
265
266
267
268
269
270
271
272
273
274
275
276
277
278
279
280
281
282
283
284
285
286
287
288
289
290
291
292
293
294
295
296
297
298
299
300
301
302
303
304
305
306
307
308
309
310
311
312
313
314
315
316
317
318
319
320
321
322
323
324
325
326
327
328
329
330
331
332
333
334
335
336
337
338
339
340
341
342
343
344
345
346
347
348
349
350
351
352
353
354
355
356
357
358
359
360
361
362
363
364
365
366
367
368
369
370
371
372
373
374
375
376
377
378
379
380
381
382
383
384
385
386
387
388
389
390
391
392
393
394
395
396
397
398
399
400
401
402
403
404
405
406
407
408
409
410
411
412
413
414
415
416
417
418
419
420
421
422
423
424
425
426
427
428
429
430
431
432
433
434
435
436
437
438
439
440
441
442
443
444
445
446
447
448
449
450
451
452
453
454
455
456
457
458
459
460
461
462
463
464
465
466
467
468
469
470
471
472
473
474
475
476
477
478
479
480
481
482
483
484
485
486
487
488
489
490
491
492
493
494
495
496
497
498
499
500
501
502
503
504
505
506
507
508
509
510
511
512
513
514
515
516
517
518
519
520
521
522
523
524
525
526
527
528
529
530
531
532
533
534
535
536
537
538
539
540
541
542
543
544
545
546
547
548
549
550
551
552
553
554
555
556
557
558
559
560
561
562
563
564
565
566
567
568
569
570
571
572
573
574
575
576
577
578
579
580
581
582
583
584
585
586
587
588
589
590
Table of Contents

Advertisement

Quick Links

See also: Wiring Diagram
ROBOTICS
Operating manual
Troubleshooting IRC5

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the IRC5 and is the answer not in the manual?

Questions and answers

Related Manuals for ABB IRC5

Summary of Contents for ABB IRC5

  • Page 1 ROBOTICS Operating manual Troubleshooting IRC5...
  • Page 2 Trace back information: Workspace R18-2 version a12 Checked in 2018-10-16 Skribenta version 5.3.008...
  • Page 3 Operating manual Troubleshooting IRC5 RobotWare 6.08 Document ID: 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved. Specifications subject to change without notice.
  • Page 4 The information in this manual is subject to change without notice and should not be construed as a commitment by ABB. ABB assumes no responsibility for any errors that may appear in this manual. Except as may be expressly stated anywhere in this manual, nothing herein shall be construed as any kind of guarantee or warranty by ABB for losses, damages to persons or property, fitness for a specific purpose or the like.

  • Page 5: Table Of Contents

    Troubleshooting the system power supply ............. 4.10 Troubleshooting the power distribution board ............4.11 Troubleshooting the contactor interface board ............4.12 Troubleshooting the customer I/O power supply ............. Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 6 5.10 11 xxxx ......................5.11 12 xxxx ......................5.12 13 xxxx ......................5.13 15 xxxx ......................5.14 17 xxxx ......................Circuit diagrams Circuit diagrams ....................Index Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.

  • Page 7: Overview Of This Manual

    Operating manual - General safety information 3HAC031045-001 Operating manual - IRC5 with FlexPendant 3HAC050941-001 Operating manual - RobotStudio 3HAC032104-001 Operating manual - Getting started, IRC5 and RobotStudio 3HAC027097-001 Technical reference manual - System parameters 3HAC050948-001 Application manual - MultiMove 3HAC050961-001 The product documentation is available in several languages.
  • Page 8 Updated Event log messages. Released with RobotWare 5.15. Updated Event log messages. Released with RobotWare 5.15.01. Updated the section Overview of troubleshooting on page Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 9 Released with RobotWare 6.07. • Updated event logs for RobotWare 6.07. • Safety section restructured. Released with RobotWare 6.08. • Updated event logs for RobotWare 6.08. Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 10 This page is intentionally left blank...

  • Page 11: Safety

    ELECTROSTATIC Warns for electrostatic hazards which could result DISCHARGE (ESD) in severe damage to the product. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 12 Symbol Designation Significance NOTE Describes important facts and conditions. Describes where to find additional information or how to do an operation in an easier way. Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.

  • Page 13: Safety Symbols On Product Labels

    Prohibition Used in combinations with other symbols. xx0900000839 Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 14 Brake release Pressing this button will release the brakes. This means that the robot arm can fall down. xx0900000808 Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 15 Tip risk when loosening bolts The robot can tip over if the bolts are not securely fastened. xx0900000810 xx1500002402 Crush Risk of crush injuries. xx0900000817 Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 16 Risk of heat that can cause burns. (Both signs are used) xx0900000818 xx1300001087 Moving robot The robot can move unexpectedly. xx0900000819 xx1000001141 xx1500002616 Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 17 Lifting of robot xx0900000822 Can be used in combination with prohibition if oil is not allowed. xx0900000823 Mechanical stop xx0900000824 Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 18 Shut off with handle Use the power switch on the controller. xx0900000827 Do not step Warns that stepping on these parts can cause damage to the parts. xx1400002648 Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.

  • Page 19: Safety Symbols On Controller Labels

    Disconnect power supply before servicing the controller (only for welding equipment). xx1400001160 Disconnect power supply before servicing the controller (for controllers without UL mains switch). xx1700000354 Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 20 Lifting instruction for the IRC5 controller. xx1400001157 Required installation space. xx1400001155 QR code for ABB Basic Care service agreement. xx1400001154 Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 21 Electrical safety check of the robot system (internal). xx1400001158 Functional test of the robot system (internal). xx1400001159 Rating label xx1400001163 CE label xx1800000835 Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 22 UL certified (robot with controller) xx1400002061 SafeMove label (for SafeMove Basic and SafeMove Advanced software). xx1700000355 Safety UL label (for the Functional Safety solution together with UL mark). xx1700000353 Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.

  • Page 23: Safety During Troubleshooting

    The manipulator must at all times be expected to perform any movement. • Since safety circuits may be disconnected or strapped to enable normally prohibited functions, the system must be expected to perform accordingly. Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.

  • Page 24: Applicable Standards

    Terminology and general principles EN 574:1996 + A1:2008 Safety of machinery - Two-hand control devices - Functional aspects - Principles for design Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 25 Safety requirements for industrial robots and robot systems ANSI/UL 1740 Safety standard for robots and robotic equipment CAN/CSA Z 434-14 Industrial robots and robot Systems - General safety require- ments Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.

  • Page 26: Safety Tools

    IRC5 The IRC5 controller has three separate safeguarding mechanisms, the general mode safeguarded stop (GS), the automatic mode safeguarded stop (AS) and the superior safeguarded stop (SS).

  • Page 27: Safe Troubleshooting

    NEVER stand inside the robot working area when disabling the holding brakes unless the arm system is supported by some other means. DANGER Under no circumstance stand under the manipulator arm. Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.

  • Page 28: Live Voltage Inside Drive Module

    The Drive Module has live voltage potentially accessible directly behind the rear covers and inside the front cover, even when the main switches have been switched off. en1000000049 Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 29 Make sure the incoming mains power supply has been switched off. Use a voltmeter to verify that there is not voltage between any of the terminals. Proceed with the service work. Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.

  • Page 30: Hot Parts May Cause Burns

    The bleeder can be hot, up to 80 degrees. Do not put anything on hot metal surfaces, e.g. paper or plastic. Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.

  • Page 31: Introduction To Troubleshooting

    The error event logs which may be viewed on either the FlexPendant or RobotStudio, contain lots of information about any malfunction detected by the system. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 32 If a fault is thought to be caused by an electronic unit (circuit board in the controller or other), the LEDs on the unit front may give leads. Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.

  • Page 33: Standard Toolkit

    Screw driver Phillips-1 Box spanner 8 mm Contents, standard toolkit, troubleshooting Art. no. Tool Rem. Normal shop tools Contents as specified above. Multimeter Oscilloscope Recorder Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.

  • Page 34: Tips And Tricks While Troubleshooting

    • Check any connector between the manipulator and the power supply in the controller. Measurement show there are no 12 VDC supply. (Reference: Circuit Diagram in the Product manual, IRC5) • Check the power supply unit LED. Check communication parameters and cables! The most common causes of errors in serial communication are: •...
  • Page 35 2 Introduction to troubleshooting 2.3.1 Troubleshooting strategies Continued How to file a complete error report to your local ABB service personnel is detailed in section Filing an error report on page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.

  • Page 36: Work Systematically

    Make sure all such tools are removed when maintenance work is complete! Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.

  • Page 37: Keeping Track Of History

    • options and their configuration been moved from one site Check: to another (an already • connections working robot) • software versions Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.

  • Page 38: Filing An Error Report

    If you require the assistance of ABB support personnel in troubleshooting your system, you may file a formal error report as detailed below. In order for the ABB support personnel to better solve your problem, you may attach a special diagnostics file that the system generates on demand.
  • Page 39 2 Introduction to troubleshooting 2.4 Filing an error report Continued Action Write a regular e-mail addressed to your local ABB support personnel, and make sure to include the following information: • Robot serial number • RobotWare version • External options •...
  • Page 40 This page is intentionally left blank...

  • Page 41: Troubleshooting By Fault Symptoms

    Controller not responding on page If the FlexPendant is not responding, proceed to section Problem starting the FlexPendant on page Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 42 Info/illustration If the FlexPendant starts, but does not commu- nicate with the controller, proceed to section Problem connecting FlexPendant to the control- ler on page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.

  • Page 43: Controller Not Responding

    Main fuse (Q1) might have Ensure that the mains fuse (Q1) inside the controller tripped. is not tripped Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.

  • Page 44: Low Controller Performance

    I/O communication between other external computers can cause PLC and robot system. heavy load in the robot system main computer. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 45 Heavy communication with PLCs or other external computers can cause heavy load in the robot system main computer. Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.

  • Page 46: All Leds Are Off At Controller

    Circuit breaker F6 (if used) is malfunctioning or open for any other reason. • Contactor K41 is malfunctioning or open for any other reason. en1000000051 Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 47 Make sure circuit breaker F6 (if used) The circuit breaker F6 is shown in the circuit is closed in position 3. diagram in the product manual for the control- ler. Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.

  • Page 48: No Voltage In Service Outlet

    Make sure any equipment connected to the service controller has not been tripped. outlet does not consume too much power, causing the circuit breaker to trip. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 49 Refer to the plant documentation for voltage val- ues. Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.

  • Page 50: Problem Starting The Flexpendant

    How to connect the FlexPendant to the that the FlexPendant is connected to the controller is detailed in Operating manu- controller. al - Getting started, IRC5 and RobotStu- dio. Inspect the FlexPendant cable for any visible If faulty, replace the FlexPendant.

  • Page 51: Problem Connecting Flexpendant To The Controller

    All indication LEDs and their signific- troller. ance are specified in section Troubleshooting LEDs in the control- ler on page Check all status signals on the main computer. Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.

  • Page 52: Erratic Event Messages On Flexpendant

    Inspect all cable insulation for damage. Replace any faulty cabling as de- tailed in the product manual for the robot. Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.

  • Page 53: Problem Jogging The Robot

    The following actions are recommended (listed in order of probability): Action Information Make sure the controller is in manual mode. How to change operating mode is described in Operating manual - IRC5 with FlexPendant. Make sure the FlexPendant is connected cor- rectly to the Control Module. Reset the FlexPendant.

  • Page 54: Reflashing Firmware Failure

    Was the RobotWare recently replaced? If YES; make sure the versions of the old and new unit is identical. If NO; proceed below! Check with your local ABB representative for a firmware version compatible with your hard- ware/software combination. Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA ©...

  • Page 55: Inconsistent Path Accuracy

    Check the revolution counters’ positions. Update if required. If required, recalibrate the robot axes. How to calibrate the robot is detailed in Op- erating manual - IRC5 with FlexPendant. Locate the faulty bearing by tracking the Replace faulty bearing as specified in the noise.

  • Page 56: Mechanical Noise Or Dissonance

    Make sure the bearings are fitted correctly. Tighten the screws if a heat sink, fan, or metal sheet is loose. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 57 Investigate whether it chased from your local ABB representat- is possible to program small "cooling ive. periods" into the application. • Overpressure created inside gearbox. Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.

  • Page 58: Manipulator Crashes On Power Down

    Remove the motor from the gearbox to in- If found faulty, the motor must be replaced spect it from the drive side. as a complete unit. Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.

  • Page 59: Problem Releasing Robot Brakes

    The system does not go to status Motors ON correctly. • Faulty brake on the robot axis. • Supply voltage 24V BRAKE missing. en1000000051 Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 60 The event log messages can also cause the brakes to remain activated. In such be accessed using RobotStudio. cases, event log messages will provide additional information. Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.

  • Page 61: Intermittent Errors

    Investigate whether the environmental conditions If possible, keep track of the (such as ambient temperature, humidity, etc) has any malfunctions in a log or similar. bearing on the malfunction. Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.

  • Page 62: Force Starting Of Boot Application

    This action shall not affect any of the files in the directories belonging to the de-selected system and this action has no effect if the controller is already in the Boot Application mode. Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.

  • Page 63: Troubleshooting By Unit

    Troubleshooting the drive system on page 72 Panel board Troubleshooting the panel board on page 70 Axis computer Troubleshooting the axis computer on page 74 Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 64 Should the LED board not be working, but the panel board is, the problem is the communication between these boards or the LED board itself. Check the cabling between them. Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.

  • Page 65: Troubleshooting The Flexpendant

    Move the joystick to the left once, with full deflec- tion. Move the joystick down once, with full deflection. A dialog is displayed. Tap Reset. The FlexPendant is restarted. Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.

  • Page 66: Troubleshooting Communications

    When troubleshooting communication faults, follow the outline detailed below: Action Info/illustrations Faulty cables (e.g. send and receive signals are mixed up). Transfer rates (baud rates). Data widths that are incorrectly set. Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.

  • Page 67: Troubleshooting Fieldbuses And I/O Units

    Further information Information about how to troubleshoot the fieldbuses and I/O units can be found in the manual for the respective fieldbus or I/O unit. Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.

  • Page 68: Troubleshooting The Computer Unit

    DeviceNet Master/Slave PCIexpress DSQC1006 PROFIBUS-DP Master/Slave PCIexpress DSQC1005 Fan with receptacle For more information and spare part numbers, see Product manual - IRC5. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 69 (red/green) Not used. For information about the LEDs on the AnybusCC slave fieldbus adapter and the PCIExpress master/slave fieldbus board, see the corresponding fieldbus manual. Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.

  • Page 70: Troubleshooting The Panel Board

    The panel board unit, DSQC 643, is located as shown in the illustration below. xx1300000679 Operator’s panel Computer unit Drive system Axis computer Panel board unit Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 71 YELLOW when Superior stop (SS) switch chain 1 closed Indication LED, SS2 YELLOW when Superior stop (SS) switch chain 2 closed Indication LED, EN1 YELLOW when ENABLE1=1 and RS-communication is OK Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.

  • Page 72: Troubleshooting The Drive System

    Additional Rectifier Unit (only used for additional axes in combination with small robots) Main Drive Unit for small robots Main Drive Unit for large robots Additional Drive Units (for additional axes) Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 73 YELLOW flashing: The two units are communicating on the Ethernet channel. • YELLOW steady: A LAN link is established. • YELLOW OFF: A LAN link is not established. Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.

  • Page 74: Troubleshooting The Axis Computer

    4.8 Troubleshooting the axis computer Location The illustration below shows the location of the axis computer, DSQC 668, in the controller. xx1300000809 Axis computer Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 75 YELLOW flashing: The two units are communicating on the Ether- net channel. • YELLOW steady: A LAN link is established. • YELLOW OFF: A LAN link is not established. Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.

  • Page 76: Troubleshooting The System Power Supply

    The illustration below shows the location of the system power supply, DSQC 661, in the controller. xx1300000813 Customer I/O power supply Power distribution board System power supply Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 77 Check the FlexPendant for errors and warnings. Make sure that the control system power supply is in run-time mode. Do this by waiting 30 seconds after power-on. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 78 The DC output connector X2 is shown in the Circuit Dia- gram in Product manu- al - IRC5. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 79 How to replace the unit is be faulty, replace it detailed in Product manu- and verify that the al - IRC5. fault has been fixed. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 80 Adjust AC input DSQC 661 cabling Faulty Cabling OK cabling The power supply Probable cause of unit works dysfunction: Fix cabling transformer T1 or properly filter xx1200001313 Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.

  • Page 81: Troubleshooting The Power Distribution Board

    Risk of burns. Be careful when removing the unit. Do not route or place cables on top of the power distribution board. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 82 This may take a long time and is completely normal. It does not mean that there is something wrong with the 662. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 83 If no or the wrong voltage is detec- in the Circuit Diagram in ted, proceed with step 5. Product manual - IRC5. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 84 How to replace the unit is be faulty, replace it detailed in Product manu- and verify that the al - IRC5. fault has been fixed. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 85 24V_DC input and 3.Fix connection AC ok 24v ok Problem with USB 6. Replace DSQC 662 Troubleshoot DSQC 661 The power supply unit works properly xx1200001314 Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.

  • Page 86: Troubleshooting The Contactor Interface Board

    Brake contactor Jumpers (3pcs) Contactor interface board LEDs The illustration below shows the LEDs on the Contractor interface board: xx0400001091 Status LED Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 87 GREEN flashing: serial communication error. GREEN steady: no errors found and system is running. RED flashing: system is in power-up/self-test mode. RED steady: other error than serial communication error. Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.

  • Page 88: Troubleshooting The Customer I/O Power Supply

    To avoid damaging the Customer I/O power supply units, the units must be separated with 3 pcs of exterior support. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 89 DCOK indicator GREEN: When all DC outputs are above the specified minimum levels. OFF: When one or more DC output/s below the specified minimum level. Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 90 This page is intentionally left blank...

  • Page 91: Troubleshooting By Event Log

    5.1 Event log messages 5 Troubleshooting by event log 5.1 Event log messages Type of event log messages The IRC5 supports three types of event log messages: Type Description Information These messages are used to log information into the event log, but that do not require specific actions on the part of the user.

  • Page 92: How To Read Rapid Event Log Messages

    2400 - 2449 AristoMig 2500 - 2599 Weld Data Monitor 2600 - 2649 GSI 2700 - 2702 Integrated Vision 4800 - 4814 Miscellaneous Process Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 93 13 xxxx Paint 15 xxxx RAPID 17 xxxx Connected Service Embedded event logs which are generated during starting, registering, unregistering, losing connectivity, and so on. Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.

  • Page 94: Xxxx

    Motors ON circuit has been opened by an Emergency Stop, General Stop, Automatic Stop or Superior Stop, or in manual mode if enabling device was released. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 95 The system is in the Manual mode without any speed restraints. Description The manipulator has attempted to back away from the obstacle, into which it collided, and succeeded. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 96 Product Manual. Description After checking, the system has found all manipulator axes to be synchronized. Consequences Normal operation is possible. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 97 After loading, arg bytes memory remain. The size of the loaded The task arg stopped without reason. program is arg bytes. Recommended actions Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 98 Unable to reset the program pointer for task arg. Recommended actions Consequences The program will not start. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 99 The control system communicates correctly with the FTP server the system with a "Reset RAPID" to load the newer version. arg. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 100 10090, Reset RAPID done Description The workobject arg contains a coordinated mechanical unit Description which is not activated. Reset RAPID is done. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 101 It remains arg days for robot arg until it's time for service. Description Serial memory data are moved from controller memory to robot Recommended actions memory by arg. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 102 The task arg has stopped. The reason is that the task has from system IO interrupt or a service routine is ready. reached a break instruction. Recommended actions Recommended actions Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 103 10145, Task selection panel is set reached a stop instruction. Description Recommended actions Task arg has been added in Task Selection Panel by arg. Recommended actions Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 104 The start order was initiated by an action causing the UNDO handler to execute. 10170, Background task arg Description refuse to start. Task is empty. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 105 10176, Background task arg Recommended actions Description refuse to start. Can't load module. Probable causes The module file is missing in the target directory. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 106 EMERGENCY STOP system event routine. 10200, Event logs are cleared Recommended actions Description User arg has cleared all event logs. Recommended actions Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 107 The restart will clear the execution in task argof a STEP system Description event routine. The restore of User Task is ready. Recommended actions Recommended actions Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 108 Please check that the device has enough space left. Description Recommended actions The arg shows that the mechanical brake for axis arg for If you are experiencing a problem with the system contact ABB mechanical unit arg is fully functional. support. 10280, The coordinate system has been changed...
  • Page 109 The Sensitivity for task arg for Jog Supervision is set to arg% Description by user: arg. The tool has been changed to arg in task arg by arg. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 110 Due to Check your program pointer and move it if necessary. Reduce the speed. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 111 RobotWare system. Use disk recovery The system remains unchanged. functionality. Recommended actions Contact the update Deployment Package provider or ABB 10456, Insufficient disk space to perform request support. Description Available disk space on the controller was insufficient to perform 10452, Update of RobotWare System done the requested action.
  • Page 112 Write error. Verify that the backup drive isn't write protected If it is a network drive, verify that controller hasn't lost contact Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 113 Consequences Recommended actions The backup request is aborted. Reset the system. No backup was created. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 114 Consequences Error during the backup of Task. The backup request is aborted. The directory does not exist. No backup was created. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 115 The given backup path has exceeded the maximum allowed Low on program memory. arg characters. Consequences The backup request is aborted. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 116 12031, Restore error the UAS issues. Description Error during the restore step Prepare. The directory lacks at least one necessary item. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 117 Error during the restore of Task. 12123, Restore error Unknown error. Description Error during the restore step Configuration. The directory lacks at least one necessary item. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 118 The subnet mask arg for network interface arg is illegal. The LAN connection is not working -The DHCP server is not activated. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 119 12610, Available RAM memory low for your location. Description The available amount of RAM memory is low. Total RAM memory size: arg bytes. Free: arg bytes. Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.

  • Page 120: Xxxx

    Update the robot memory as detailed in Operator's Manual, IRC5. Description One or several internal drive unit axes are not commutated. Recommended actions Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 121 The command is only allowed in Manual mode (reduced or full Make sure the system is NOT in Auto Mode. speed). Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 122 Investigate by whom and why the action was requested, and, The system remains in the same status, and the requested if required, correct the reason. action will not be performed. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 123 Make sure the system is NOT in Emergency Stop state. Perform Recommended actions a restart as detailed in the Operator's Manual, IRC5. If restarting Synchronize the axis as detailed in the Calibration Pendulum is not possible, switch the main power OFF and then back ON.
  • Page 124 Recommended actions Description WorkObject name arg could not be found. Consequences It is not possible to jog without a correct defined workobject. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 125 The Task Selection Panel is having an update. It is not possible to do the requested command. Recommended actions Change to the production window and perform the command again. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 126 The work object data was removed. The module containing the System parameter AllDebugSettings is set to Yes. original tool definition may have been deleted. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 127 Program pointer will not be set to main. System will not be in Consequences full production mode in auto. All disabled normal tasks will be enabled. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 128 The arguments for the System Input Load and Start are wrong. The program was executing. An ongoing Backup operation. The module was loaded, but the system failed to set the Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 129 System Output: arg. Signal Name: arg. rejected. Consequences Consequences The system goes to system failure state. Program will not be possible to start. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 130 Check other event messages occurring at the same time to determine the actual cause. Fix the cause of the fault. Perform Description a controller restart as detailed in the Operator's Manual, IRC5. The module arg is changed but not saved in task arg. Recommended actions...
  • Page 131 Due to any of a number of faults, a system diagnostics file was created at arg. This file contains internal debug info and is intended for trouble shooting and debugging purposes. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 132 During reconfiguration of the system a changed and not saved Probable causes module was found. Too much data on the disk. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 133 Rename the signal in the IO configuration. It is not possible to configure same I/O-signal to several System Outputs. System Output: arg. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 134 Never disable a unit with System Inputs/Outputs. Description The configured System Input Restriction Type is unknown by the system. Unknown System Input Restriction: arg. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 135 A symbol of type 'arg' was found holding an undefined number. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 136 RAPID move instructions. Recommended actions Recommended actions Change the configuration and restart the controller. Change the configuration and restart the controller. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 137 It will not be possible to perform any actions against the motion The task arg in cfg type arg is not configured in the system. system, i.e. execute RAPID move instructions. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 138 No task is given for module arg in cfg type arg. Consequences Recommended actions Default value for the regain distance will be used. Change the configuration and restart the controller. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 139 (PROC) that takes The reason is that write access is held by arg using arg. zero (0) parameters. Recommended actions Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 140 Switch back to manual mode. Set system System will not be in full production mode in auto. parameter Controller / Auto Condition Reset / AllDebugSettings Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 141 The system has been restarted, intentional or caused by a Probable causes power fail. The system is in Emergency Stop state. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 142 The reason could be that another client already holds write The board's firmware or hardware may be corrupt. access or that the system isn't in Auto mode. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 143 Safety Controller (SC) arg is not synchronized with supervised mechanical units. Recommended actions Perform a restart as detailed in the Operator's Manual, IRC5. Recommended actions Move all mechanical units supervised by Safety Controller arg 20445, The USB to Serial adapter was removed to the synchronization positions defined in the safety configuration.
  • Page 144 Controller (SC) arg. configuration if this event message comes after every restart and there is a request for new pin code again. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 145 PIN-Code for the Safety Controller in the Control Panel. Description Safe Tool Zone (STZ) arg is violated on mechanical unit arg. Tool arg was active. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 146 Verify RAPID program. Verify process equipment. Check that movement is not ongoing when SST is active. Check previous Description event messages. Safety Controller (SC) arg is disabled. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 147 Check that the failing axis is activated. If failing axis is activated Probable causes replace brake(s) as soon as possible. If Override (OVR) is active, then OVR speed limitations will be active. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 148 Consequences The system goes to status SYS HALT. Consequences The system remains in the Emergency Stop status. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 149 Recommended actions Status conflict for the Emergency Stop panel chain. Check cables and connections. Consequences The system goes to status emergency stop. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 150 The system goes to status SYS HALT. Status active when digital collision sensor on Manipulator Controller Board (MCOB) arg is active. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 151 Status active when Servo disconnect switch on system arg is Recommended actions off. Check power on MCOB. Consequences The system goes to status SYS HALT. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 152 20577, HV ON open Check cabin ventilation and other cabin safety functions. Description High Voltage (HV) switch on operating panel is opened. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 153 Manipulator Interface Board (MIB). Probable causes Consequences Broken Ethernet cable between PIB and MC. High network load. The system goes to status SYS HALT. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 154 Status active when external process enable connection on test and validation purposes. Manipulator Controller Board (MCB) arg is open. Consequences ABB will not provide long-term support on unofficial releases. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA...
  • Page 155 Some files in the package have a path that is Description too long and could not be handled by the controller software. A feature to perform ABB Robotics internal tests has been During the installation process the controller software was enabled in arg.
  • Page 156 User" to select camera login credentials to be used by the Inspection Tool to the job. Follow the instruction in the controller. RobotStudio context menu and save the job. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 157 Recommended actions Description DryRun will be executed in fully at next program start. Error while reading the DryRun configuration file arg. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 158 The program pointer's original position could not be reached Description while restarting execution in DryRun mode from the beginning DryRun was rejected due to unfinished movement. of the routine. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 159 An update of camera information has been ordered by an The camera arg is of type arg. The instruction arg is not external client. available on a camera arg. Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.

  • Page 160: Xxxx

    Reinstall the present system files. Create and run a new system Faulty PROFIBUS cabling, terminators and/or module(s). to download the driver software. Replace the board if faulty. Duplicated PROFIBUS addresses. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 161 Probably hardware fault in cable between safety system and performed. Robot Communication Card. The safety system, or its power supply, may also be faulty. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 162 Probable causes Recommended actions The RobotWare installation is faulty. Change the affected hardware to a compatible version. Recommended actions Reinstall the system. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 163 Reinstall the system. goes to system failure state. Probable causes The RobotWare version is too old to support the axis computer unit. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 164 32573, Unable to download firmware file Description The firmware file arg is not found. Internal error code:arg. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 165 Reinstall the system. The update of arg firmware in drive module arg has failed. The firmware file [arg] is not found. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 166 No operation will be possible until the fault is corrected. The The Anybus module is missing. system goes to Motors Off state with zero torque. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 167 Check that the motor configuration is correct. Check that the The system goes to Motors Off state. robot has not collided. If possible, reduce the speed of the user Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 168 DISCHARGED WHEN THE SYSTEM IS POWERED OFF. Probable causes This may be caused by a faulty bleeder resistor cable or a faulty bleeder resistor. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 169 (optional). Consequences The system goes to Motors Off state to protect the hardware. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 170 How to check the configuration file is detailed in the Trouble Shooting Manual. Verify that the motor cables are not Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 171 Disconnect before measuring. temperature does not exceed the cabinet's temperature rating. If possible, rewrite the user program to reduce the amount of Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 172 How to check the configuration file is detailed in the position arg is different from the one specified in the Trouble Shooting Manual. Verify that the motor cables are not Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 173 Check for other hardware event log unit communication link. Disconnect unused drive unit(s). messages. Check incoming mains voltage to the rectifier unit. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 174 Motors Off state. Consequences No operation will be possible until the fault is corrected. The system goes to Motors Off state. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 175 In drive module arg, the drive unit at unit position arg has DISCHARGED VERY SLOWLY (APPROXIMATELY 1 HOUR) corrupt information stored on the unit. WHEN THE SYSTEM IS POWERED OFF. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 176 Check any other error log messages coinciding in time with this one for clues. Check the system motion configuration regarding Motors ON relay. How to check the configuration file Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 177 Make sure the fans are operating. Check that air flow to the unit Faulty fan, cabling or power supply. See the circuit diagram! fans is not restricted. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 178 Description V, which is out of the allowed range. Purge system number arg associated with manipulator interface Consequences board (MIB) arg. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 179 (MCOB) arg. Sensors 1-7: motor 1-7. Sensor 8: Serial Default time (300s) is used. measurement board. Run chain has been opened. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 180 The supervision of brakes on manipulator controller board (MCOB/MCB) arg has detected an open circuit on axis arg and turned ON all brakes. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 181 Check the backup This may be caused by a faulty backup energy bank, cabling or charger. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 182 (MIB) arg. Leak detection is enabled, but no signal is configured for the Consequences supervision. The system goes to status SYS HALT. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 183 A fault is observed on motor contactor KM101. Description Consequences The temperature in the transformer is too high. The system goes to status SYS HALT. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 184 Check cables and connections. Replace SIB if faulty. Replace MIB if faulty. Recommended actions Check cables and connections. Replace SIB if faulty. Replace MIB if faulty. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 185 Recommended actions opened. Reported from safety interface board (SIB). Check cables and connections. Replace SIB if faulty. Consequences Paint enable chain opens. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 186 The Brake Check has found that the mechanical brake for the mechanical unit arg axis no arg should be tested. The actual Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 187 Replace MIB if faulty. Description Only one of the two high voltage (HV) chains is opened. Reported from manipulator interface board (MIB) arg. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 188 Check cables and connections on the safety system for Check cables and connections on the safety system. Check for ES_INPUT. other error messages for external connections (interlocks). Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 189 The power distribution board (PDB) temperature will rise. Paint equipments are maybe switched off. Probable causes Faulty fan, cabling or power supply. See the circuit diagram! Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 190 The file(s) on the mass storage Recommended actions device will not be accessible. None, the previous shutdown time could be longer than usual. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 191 Reset the robot's revolution counters as detailed in the robot and that it meets the specification set by ABB. Make sure the Product Manual. Make sure the cable between serial cable screen is correctly connected at both ends. Make sure...
  • Page 192 Linearity error for X-Y signal difference at serial measurement supplied through a jumper in the robot signal cable (refer to the board. IRC5 circuit diagram), and disconnecting the cable interrupts System may still operate with warning. the battery power supply. Some earlier robot versions used System will not function with error.
  • Page 193 Serial measurement board SMS communication failed. Drive module: arg. Status: arg. Measurement link: arg. Drive module: arg. Measurement board: arg. Measurement link: arg. Measurement board: arg. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 194 DSQC633D functionality. The PMC card that is configured in the motion configuration is not set up correctly and cannot be started. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 195 The force sensor detected signals with noise level higher than sensor. expected. Task: arg. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 196 Description The motor angle reference is increasing too quickly for joint arg, connected to drive module arg. Consequences Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 197 If the capacitor unit was recently replaced, a capacitor unit with the wrong type code may have been fitted Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 198 Check for external electromagnetic noise sources close to the drive module. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 199 The file may have been erased my mistake. Without this file it Check the type of capacitor unit fitted. Replace if it is the wrong is not possible to check if the drive unit software needs type. If the problem persists, contact your local ABB updating. representative.
  • Page 200 LEDs on the rectifier and drive units. The significance module arg. of the LEDs is described in the Trouble Shooting Manual. Supervision code = arg. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 201 Note that a normal restart will NOT suffice! If the problem Probable causes persists, replace the drive unit. This may be caused by an internal error in the rectifier unit. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 202 No operation will be possible until after correcting the fault. The drive communication link arg, drive module arg. system goes to status SYS HALT. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 203 The user program may contain too much hard braking of the manipulators, which is more likely if the system contains additional axes. The brake resistors may also be faulty. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 204 The temperature has risen above the warning level in drive unit number arg, drive module arg, which is the lowest abnormal level of three. Consequences Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 205 Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 206 No volts means the problem is in mains cable too high a level. connector or the factory power supply. If the voltage is OK, Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 207 Check the wiring of the mains transformer as system goes to status SYS HALT. detailed in the robot Product Manual. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 208 39485, Run chain close in motor off state supply unit LED is red. The full meaning of all LED indications are described in the Trouble Shooting Manual, IRC5. Description Run chain arg is open when system is in motor on state. The 39501, Logic Voltage to Drive Unit Error problem occurred in drive system arg.
  • Page 209 LED is red. The full meaning of all LED indications are used. The fault may also occur if the cable from the power described in the Trouble Shooting Manual, IRC5. supply unit is not correctly connected to the drive module.
  • Page 210 Make sure that the power supply to the missing axis computer switch, or loss of power supply. axis computer is working correctly. Restart the controller. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 211 Restart the Consequences controller. System goes to status SYS HALT. Probable causes This may be due internal errors. Recommended actions Contact your local ABB support office. Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.

  • Page 212: Xxxx

    NOT read-only. Also make sure the argument is NOT written within brackets (). Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 213 Expression arg is not a constant expression. The number of array dimensions is arg, but may be 1, 2 or 3 only. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 214 Illegal type arg for operand of unary '+' or '-' operator. Description Illegal type arg for left operand of '*' operator. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 215 Rename the data or change the conflicting name. corresponds to the number of dimensions of the indexed data 40042, Name error array. Description Global routine name arg ambiguous. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 216 Rename the data or change the conflicting name. Make sure that the number of expressions in the aggregate is the same as the dimension of the data array. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 217 Complete the data declaration or change the data name to a place holder. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 218 The specified name identifies an object other than a function. Check if the desired function is hidden by some other object with the same name. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 219 Recommended actions 40081, Reference error The record type contains no record component with the specified name. Description arg not trap reference. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 220 The RETRY instruction may only be used in error handlers. Recommended actions Remove it. The aggregate does not match the expected data type. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 221 Try to rewrite the declarations. 40113, Name error 40108, Type error Description Description Global alias name arg ambiguous. Unknown aggregate type. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 222 Cannot use the semi-value type arg for record components. The Interrupt number is not static variable reference, or it is Recommended actions shared, or it is read only. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 223 The string arg is too long. 40131, Reference error Recommended actions Description Make the string shorter. Reference to unknown trap arg. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 224 Task arg: Interrupt number is not a static variable reference, is Recommended actions shared, or is read only. Rename the identifier with a shorter name. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 225 Change the type of the task to NORMAL. Restart the controller. Check for RAPID errors and correct the program. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 226 Remove the place holder or the instruction containing it, or Description make the instruction complete. Then continue execution. Task arg: Variable and trap routine already connected. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 227 40203, Reference error Error numbers used in an ERROR handler must be positive. Description Task arg: Optional parameter arg not present. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 228 Task arg: Runtime stack overflow. The program is too complex contains recursive routines. to execute. Probably the program contains recursive routines. Recommended actions Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 229 Task arg: Data is not an array. Description Task arg: Ambiguous symbol name arg. Recommended actions The 'DatObj' parameter of the 'Dim' function must be an array. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 230 40257, Parameter error Recommended actions An array may have at most 3 dimensions. Description Task arg: REF mode parameter arg cannot be dimensioned. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 231 The specified parameter transfer mode is not one of IN, 'VAR', A value conversion function must be specified for a semi-value 'PERS', 'INOUT' or REF. Use corresponding type. REAL_SYMPARMOD_x. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 232 Avoid executing the instruction when in undo-context. 40304, File access error Description Task arg is trying to access file arg, but failing. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 233 Check if large data structures could be split into smaller blocks. symbol: arg. Use of installed modules can save program memory. Consequences The module will not be installed. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 234 No interrupt is lost when PP is set to main. A copy of the changed module is saved on arg. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 235 Recommended actions Description Recovery: arg. Task: arg. The robot is too far from path to perform StartMove of the interrupted movement. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 236 Program ref: arg. unit arg is already active. Probable causes The I/O device reference is not open, or has already been closed. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 237 Program ref: arg. 40540, File Access Error Recommended actions Description Recovery: arg. Task: arg. arg is not a directory. Program ref: arg. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 238 Check the path. Check write and execute permission for the directory under which the new directory should be created. 40549, System Access Error Recovery: arg. Description Task: arg. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 239 Recommended actions Check the orientation. All used orientations must be normalized i.e. the sum of the quaternion elements squares must equal 1. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 240 Set a value to argument AccMax. search, make sure that TCP is moved back to the start position of the search path. Program ref: arg. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 241 Task: arg. Check the size of the array. The optional argument PayLoad may only be used for PayLoad identification. Program ref: arg. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 242 ParIdMove / Parameter StartIndex: Point at negative move type. Recommended actions Program ref: arg. Start the identification procedure from the beginning again. Recovery: arg. 40590, ParId error Description Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 243 Also possible to cancel the Service Use max. 16 characters to specify the name of a mechanical Routine to completely skip the Load Identification. coordinated unit. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 244 Change the value for Time, to a value greater than or equal to Argument arg is not an integer value. 0.1 s. Program ref: arg. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 245 Edit the program to max. 5 MoveX \Conc in sequence on the Recommended actions basic execution level of the program. Requested function is not ready yet. Recovery: arg. Recovery: arg. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 246 The CAMCHECK function failed. The camera is broken. Send it for repair. Description Recovery: arg. Task: arg. External alarm. Program ref: arg. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 247 Optional parameters and switches are not used in a correct combination. 40655, Axis Is Not Independent Program ref: arg. Description Task: arg. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 248 WorldZone. If use of switch \Stat, the datatype must be Recommended actions wzstationary in WorldZone. Check the value of argument WorldZone. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 249 Description Program ref: arg. Task: arg. The DeltaJointVal for external axis arg is <= 0. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 250 40702, File Not Found limitation of not active axis arg. Program ref: arg. Description Task: arg. The file arg was not found. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 251 Change the parameter arg to a valid one. The module name in the head of the file arg already exists in Recovery: arg. the program memory. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 252 Recommended actions modpos. Restart the controller. 40720, Alias I/O Installation Description The system could not refresh all I/O signals as RAPID symbols. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 253 Recommended actions Recovery: arg. The axis has to be defined, before this instruction is executed. 40731, Value Error Description Task: arg. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 254 Check the argument. Description The PERS variable specified in the instruction TriggStopProc cannot be updated, because it does not exist anymore. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 255 It is not possible to execute StartMove when the robot is moving. Program ref: arg. 40756, Context Error Recommended actions Description Recovery: arg. Task: arg. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 256 Program ref: arg. Description Recommended actions Task: arg. The value of argument arg forces the robot out of Check the RAPID program. workspace. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 257 Description Recommended actions Task: arg. Check the init value of the new errnum variable. The instruction arg was interrupted, reason unknown. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 258 Check how the file or serial channel was opened. Description Task: arg. The single axis is not init correctly. Program ref: arg. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 259 40797, I/O Error 40793, Error Installing Text Table Description Unable to access the I/O signal arg on I/O device arg. Description Task: arg. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 260 To be able to rename or copy: Change the file name or remove Description the existing file. Task: arg. Recovery: arg. Not possible to do subscribe. Program ref: arg. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 261 Task: arg. GetItmTgt(s) instruction again. Error occurred for item source Unknown axis number for the mechanical unit arg. arg. Program ref: arg. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 262 No correction descriptor connected. No valid profile data to store. Recommended actions Consequences Check if any correction generator is connected. Nothing stored. Recovery: arg. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 263 Program ref: arg. Task: arg. Servo tool arg is not activated. Recommended actions Program ref: arg. Retry after emergency stop reset. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 264 41405, Parameter Error The argument Type doesn't correspond to a service value. Description Task: arg. Argument arg not allowed together with argument Off. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 265 The module name arg does not exist. Program ref: arg. Program ref: arg. Recommended actions Recommended actions Recovery: arg. Check and change the RAPID program. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 266 Impossible to restart. Recommended actions Probable causes Check and change the RAPID program. The connection with the I/O module is broken. Recovery: arg. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 267 Define the actual load for the tool or the grip load before 41433, Parameter Error program movement or jogging. A good motion performance requires a correctly defined load. Description Task: arg. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 268 It is undefined if the robot holds the tool or the work object. 41442, Reference Error Program ref: arg. Description Task: arg. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 269 Description be activated. Task: arg. Operative system get time failed. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 270 Argument arg or arg or arg not within range. Check the argument, and use a non-empty string. Program ref: arg. Recommended actions Check and change the argument. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 271 (max arg tasks can be configured). Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 272 The time set in argument arg in instruction SyncMoveOn has Task: arg. expired. The time set in argument arg in instruction SyncMoveOff has Program ref: arg. expired. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 273 PP movement within RAPID program when having active arg Task: arg. instruction. Not ready with the switch from independent to synchronized mode. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 274 Domain arg cannot be used. Recommended actions Program ref: arg. Change mechanical unit in the instruction. Recommended actions Choose another Elog Domain. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 275 Program ref: arg. 41517, LoadId Error Recommended actions Description Check next Event Log message, for the next user action to do. Task: arg. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 276 (cannot be used with Program ref: arg. ErrRaise). Recommended actions Remove the instruction. 41521, Task Status Error Description Task: arg. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 277 Use of task lists that are non-global can cause this error. can be used even when the coordinated workobject is located Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 278 41537, Unexpected SyncMoveOff Recommended actions Description Remove the instruction. Task: arg. Unexpected SyncMoveOff (SyncID arg). The system is waiting for a SyncMoveOn. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 279 Program ref: arg. Task: arg. Recommended actions Unable to execute arg. Remove the directive LOCAL from the data declaration. Program ref: arg. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 280 It is not possible to use the optional parameter \Conc when the Add switch SyncOrgMoveInst or SyncLastMoveInst to the system is in synchronized mode. instruction. Program ref: arg. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 281 MODPOS of any previous move instruction. Program Description ref: arg. Task: arg. Illegal value in argument arg. Program ref: arg. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 282 Use another socket to listen for incoming connections. Task: arg. The socket must be created before it can be used in any socket instruction. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 283 Unexpected error when connecting socket. Check event log for Task: arg. other messages for possible cause. The specified data is too big. Program ref: arg. Program ref: arg. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 284 The data received is too long to be stored in a string. The Task: arg. maximum length of data that can be stored in a string is 80 Network is unreachable. characters. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 285 The socket has already been bound to an address and cannot be bound again. Recommended actions Program ref: arg. Move program pointer to Main and restart program. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 286 The variable has been used when creating a new socket. When moving PP to main, the socketdev variable keeps it value, but is not valid anymore. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 287 Recommended actions Change the argument \InitValue to an integer. Edit the program. Recovery: arg. 41619, Argument error icondata Description Task: arg. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 288 Instruction arg \arg is used in independent motion mode. Program ref: arg. Program ref: arg. Consequences Consequences The program execution is immediately halted. The program execution is immediately halted. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 289 Recommended actions Program ref: arg. Remove the instruction. Probable causes Use of task lists that are non-global can cause this error. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 290 It is not allowed to add tasks in the task selection panel after start from main. 41642, Argument Error Program ref: arg. Description Task: arg. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 291 This is described in the manual. Due to a programmed System Stop RAPID Block in RAPID both program execution and movements are stopped. The problem Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 292 \AllMotionTasks active in the StopMove instruction but not in Recovery: arg. the StartMove instruction. The StopMove instruction has been executed in synchronized mode and the StartMove in independent mode. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 293 41660, No space left for the new view Task: arg. Description The assembly exist but no new instance could be created. Task: arg. Status arg. Program ref: arg. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 294 The program execution is stopped immediately. Description Recommended actions Task: arg. Report this to ABB Robotics. Invalid combination of parameters in Trigg. Program ref: arg. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 295 The number of simultaneous subscriptions on signal events has been exceeded. 41677, Device access error Program ref: arg. Description Task: arg. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 296 41687, File Open Error A non-valid name is used. Description Recommended actions Task: arg. Change name to search for. Unable to open arg. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 297 No RMQ is configured for task arg. Program ref: arg. Consequences No data can be fetched. Consequences The program execution is stopped immediately. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 298 RMQ configured for task arg. Program ref: arg. Program ref: arg. Consequences Consequences The program execution is stopped immediately. No message has been received. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 299 Check the client program. Increase the waiting time for 41711, Value is not percent instruction arg. Description Recovery: arg. Task: arg. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 300 PP to Main in all tasks to reset the Program ref: arg. process error. 41720, Path Not In Stop Point 41715, Invalid Direction Description Description Task: arg. Task: arg. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 301 Cartesian Soft Servo Activation is not allowed with a moving work object. Only a programmed user frame is allowed. Description Program ref: arg. Task: arg. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 302 Execute instructions in right order. Description Recovery: arg. Task: arg. The calculation result is not within the range 0 - 4294967295. Program ref: arg. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 303 ERROR handler. Program ref: arg. Program ref: arg. Recommended actions Recommended actions Check the RAPID program. Remove the instruction. Recovery: arg. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 304 The value for parameter arg is out of limit. Description Program ref: arg. Task: arg. Recommended actions Mechanical unit arg not found. Recovery: arg. Program ref: arg. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 305 The integer value arg cannot be copied to a arg datatype. The value is out of limit for the data type arg. Program ref: arg. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 306 Motion task that task arg is connected to does not control a Data of type cameradev has been declared in the program. TCP-robot. Program ref: arg. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 307 Recommended actions matching the used arg. Use a higher timeout value or use an error handler to retry instruction. Recovery: arg. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 308 The operation failed because the camera does not support data used is of wrong data type. current action (used switch arg). Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 309 External. The camera has to be set to Run Mode. The camera has no job loaded. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 310 Task: arg. Report this problem to ABB Robotics if this happens. The current load data that is used when CSSAct is called has a mass of arg Kg. SoftMove need to have an accurate load 41794, Search error definition.
  • Page 311 Load identification of the load can be Recovery: arg. done with the service routine LoadIdentify. 41800, Manual action needed Description Task: arg. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 312 Task: arg. Recovery: ERR_ARRAY_SIZE. The logical output value calculated by the argument ScaleValue in TriggSpeed instruction and the programmed speed in current Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 313 Recovery: arg. Recommended actions 41813, File or directory access error Use smaller sizes of the matrix used in the instruction. If this is not possible, report the problem to ABB Robotics. Description Task: arg. 41810, Only allowed for 6 axis robot Unable to open file arg for writing, or directory specified does not exist.
  • Page 314 The EGM identity arg is not valid. Program ref: arg. Consequences The program execution is stopped immediately. Consequences The program execution is stopped immediately. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 315 The program execution is stopped immediately. Correct the used frame type. Recommended actions Use EGM in RAPID tasks with TCP robot only. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 316 TriggEquip, TriggSpeed or TriggCheckIO before current make sure that TCP is moved back to the start position of the instruction. ContactL path. Program ref: arg. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 317 Check the I/O configuration for I/O signals and device transfer. back to the start position of the search path. Change signal used in RAPID program. Program ref: arg. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 318 (see earlier error logs). The I/O signal that is updated with the cyclic bool value has been lost. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 319 Recommended actions A value change on a persistent boolean variable interrupted Use arg with TCP robot only. the execution. Program ref: arg. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 320 41887, BrakeCheck Error The program execution is stopped immediately. Description Probable causes Task: arg. Using CyclicBrakeCheck without required options. BrakeCheck is already active. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 321 A num variable is used to store the read integer value, and that Program ref: arg value is above the maximum integer value for a num. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 322 Cannot calculate a line because the two points are too close. 41901, Text Table Name not valid Program ref: arg Description Task: arg Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 323 2) One or several tasks is deactivated in the task selection No action needed. panel, and then the paths cannot be finished for all mechanical units. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 324 2) Cancel call routine to end arg. One or several mechanical units connected to task arg is too far from the path to perform a regain movement. Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.

  • Page 325: Xxxx

    Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 326 Check the tune parameters, external forces on the joint and Make a new update of the revolution counter. hardware. Reduce programmed speed. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 327 'Interpolation Buffer Startup Adjust' in topic Motion and type Activate robot from the Jogging window, or program. Check Motion Planner. work object and program. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 328 Description Restart no longer possible. Change of mechanical unit state Description made restart of program impossible. Commutation failed for joint arg. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 329 Check and reduce payload for arm and/or wrist. Reduce joint Re-creation of the path failed. working range to decrease static torque due to gravity. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 330 Check process name in topic Motion and type Process Description configuration files. MoveJ not allowed with work object coordinated with external position mechanical unit. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 331 Joint arg and arg are out of coupled working range. Recommended actions Use the joystick to move joints into their coupled working range. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 332 Recommended actions operation by pressing the Start button on the FlexPendant. Report the occurrence to ABB. Make a new calibration. Make sure any loads are defined and identified correctly. If the mechanical unit is exposed to forces from the external...
  • Page 333 It is not allowed to define a load on axis arg for mechanical unit system parameters and try again. arg or the interpolation is not stopped in a finepoint. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 334 Invalid axis number arg for mechanical unit arg. limitation. Recommended actions Recommended actions Check mechanical unit and axis number. Check load data. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 335 Start linked motor service routine. Jog the follower axis to same axis movement. Decrease the system parameter position as the master axis. 'Post-synchronization Time'. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 336 The duty factor for the gearbox of joint arg of robot arg is too 50258, Sensor direction error high. Continued running without adjustment may cause damage Description to motor and gearbox. Contact your local ABB service support Programmed sensor pos speed arg and found sensor speed center. arg in opposite direction.
  • Page 337 The system is presently configured with time event supervision, and now an event could not be accurately activated. Program ref. arg. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 338 Verify that a joint that can be used with DitherAct is chosen. Use correct parameters and reset the system. 50286, Mix of coordinated frames Description Task: arg. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 339 Check status via the FlexPendant and check if right system finepoints and zonepoints. parameters (serial number) loaded in controller. Check that Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 340 An error in robot memory or communication has occurred. The 50307, Extended working range data has been cleared. Description The option Extended working range has been installed. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 341 RAPID task. Recommended actions Make sure that the system is in Motors Off state before disconnecting the drive module. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 342 Failed to return to position control. operated. Probable causes Cannot set position control if the robot is moving due to external forces or ordered references. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 343 An error in the parameter 'Box' in either FCCondPos or Recommended actions FCSupvPos. Change the parameters above according to the manual. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 344 Force. Torque. Teach TCP speed. Teach Reorientation It is not possible to execute an Independent Move when speed. Software Equalizing is active. Consequences The robot will stop. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 345 To allow a larger reference force the system parameters need to be updated. Note that there is an absolute limit of force reference size that depends on the robot type. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 346 Run service routine to activate the current vector. Set system parameter 'Current Vector On' in topic Motion and type Drive System to No, for normal operation. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 347 Recommended actions Recommended actions Change the parameter value. Move program pointer, jog robot away from current position and restart the program. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 348 Some system parameters has been set to a value that is not Probable causes allowed. The system damping is too low. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 349 Recommended actions Consequences Increase the allowed speed error in the configuration or modify Program run or restart will be interrupted. the program. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 350 The last move instruction with correction specified has to be a instruction. finepoint. Consequences Program ref. arg. The robot will stop. Recommended actions Change the zone parameter to fine. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 351 Choose another robot configuration or another wrist axis combination. Recommended actions Remove movement coordination while doing the wrist 50409, Wrist Interpolation not possible interpolation. Description Task: arg. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 352 Rewrite the user program to reduce the amount of high The robot will stop. decelerations. Disconnect the bleeder and check the cable and Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 353 The common Base Frame can only be solved in synchronized unit at unit position arg and node arg. move. Program ref. arg. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 354 After fine calibration of joint arg witch is using alternative calibration position, the joint has not been moved to normal synchronize position for updating the revolution counter. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 355 IndReset executed or PP to Main is done. Description Increase the normal working area. Predicted a collision between objects 'arg' and 'arg'. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 356 The movement can also be changed by use of SingArea\Wrist, ConfL\Off or be replaced by MoveJ. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 357 SyncMoveOn and SyncMoveOff are not allowed to be executed while External Motion Interface is active. Check the application Consequences The movement of all mechanical units was halted immediately. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 358 Motors Off state. by External Motion Interface are not properly normalized. Other illegal numerical values used as input to External Motion Interface. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 359 Avoid moving too close to the singularity. Description The position is outside the allowed range for External Motion Interface correction arg, mechanical unit arg joint arg. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 360 Make sure the input is inside the bounds, and restart the 50463, Log server communication error program. Description Sending logged signals over the network failed. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 361 Mechanical unit arg shares brake relay with mechanical unit The I/O signal arg is low. arg, but 'Activate at Start Up' and 'Deactivation Forbidden' is missing. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 362 Recommended actions mode. During program execution, use MoveAbsJ or use a different Consequences reference direction. Joints in independent mode cannot be jogged. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 363 The load on the mechanical unit is bigger than expected. Consequences Recommended actions The opening sequence will start with a closing movement. Make sure all loads are defined correctly. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 364 System parameter 'Start ramp' and/or 'Stop have different base frame data. ramp' in topic Process and type Conveyor systems. Increase Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 365 'Max tracking error at pick pos'. evaluation. Recommended actions 50497, Maximum number of axes in drive module Unless you are doing tests in cooperation with ABB we reached recommend that you change the value back to the previous value.

  • Page 366: Xxxx

    The active filter time should either be 0 ms or in the range [arg, arg] ms. This I/O signal has been rejected. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 367 The I/O configuration of cross connection arg is invalid. The parameter Actor arg refer to an I/O signal arg that is not digital. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 368 Make sure the I/O device is correctly powered. Make sure the The I/O configuration is invalid. cabling to the I/O device is correctly connected. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 369 71098, NFS server lost Description The subnet mask arg is not valid. Description The contact with the NFS server arg is lost. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 370 Recommended actions The inter-process communication (IPC) queue arg was full, Export the directory on the server computer. when sending to trap routine. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 371 Consequences Check cable and FTP server settings. The cross connection has been rejected, and no functions depending on it will work. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 372 This network has been rejected, and no functions depending Recommended actions on it will work. Make sure the file exists. Change the path in the I/O configuration. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 373 I/O configuration. 71263, CAN communication failure Description CAN communication failed due to arg. Code: arg. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 374 On DeviceNet I/O device arg the connection 2 input size does not match the I/O device. Recommended actions Change size in I/O configuration. Check module. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 375 If the DeviceNet option is required: configure a new system DeviceNet network. with this option, and install the system. If the DeviceNet option Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 376 5.8 7 xxxx Continued is not required: configure a new system without this option, and Recommended actions install the system. Restart the controller. Report the problem to ABB. 71303, Invalid DeviceNet vendor id 71307, DeviceNet generic connection 1 Description Description...
  • Page 377 I/O system. Correct the physical limitation values for the I/O signal so that the minimum value becomes less than the maximum value. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 378 The service identifier <arg> is not valid for the device command Select a valid connection for the network. <arg>. Valid service identifiers are: Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 379 The size of analog and group I/O signals Define a device map for the I/O signal. must be between 1 and 32 bits. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 380 Define a network reference for the I/O device. Consequences The cross connection has been rejected, and no functions depending on it will work. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 381 Trouble Shooting Manual. Check the frequency of input I/O signals from any external equipment connected to the system. Make sure it is not abnormal, and Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 382 The full meaning of this status is Make sure the connector defined in the physical channel described in the Trouble Shooting Manual, IRC5. configuration is referring to an available connector. Make sure the option Multiple Serial Ports is installed if required by the Probable causes used configuration.
  • Page 383 The option holding the transport protocol arg is not installed or the protocol name is faulty. Recommended actions Install missing option. Change the transport protocol name. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 384 The I/O device arg has an invalid value (zero) for the input or Check for noise on the serial line. output size. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 385 The number arg is outside its range. The DeviceNet network has regained the 24 V bus power. Recommended actions Change port number. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 386 I/O device will be possible. An EtherNet/IP network is configured, but the EtherNet/IP Scanner/Adapter option has not been installed. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 387 Recommended actions Consequences Correct the gateway in the EtherNet/IP network configuration. No communication on the arg network is possible. Restart the controller. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 388 The maximum number, arg, of internal I/O signals in the I/O The subnet mask arg for the EtherNet/IP network is illegal. system has been exceeded. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 389 A PROFINET identification request has been received from an external configuration tool. Description The MAC address on the arg network is arg. The adapter arg has invalid configuration assembly. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 390 The gateway address is not changed. Add the I/O device arg to the PROFINET configuration file or remove the I/O device from the I/O configuration. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 391 The PROFINET configuration file may be corrupt or have been internal PROFINET device. created with an incompatible file format. Recommended actions Generate a new PROFINET configuration file. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 392 The syntax error: Bad data type. controller. Consequences The device command was not sent. Recommended actions Correct the device command path string. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 393 Correct the service identifier. Set the parameter Quick Connect to "Not used" for the adapter in the I/O configuration. Restart the controller. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 394 Probable causes A MultiMove system is installed and occupies the specified Description Ethernet port. Not able to connect to the adapter arg. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 395 Recommended actions Recommended actions Correct the input size for the adapter in the I/O configuration. Provide a valid destination address. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 396 Probable causes This I/O signal has been rejected. Internal info: Recommended actions Correct the Signal Safe Level for the I/O signal. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 397 ActionAtSysRestart exceeded. Description The I/O signal arg has overlapping bit(s) in the device map with the I/O signal arg. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 398 The configuration has been rejected. not allowed. Recommended actions Consequences Change the signal type or transfer another signal. The configuration has been rejected. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 399 Correct the configuration. The signal arg has a transfer defined but uses the wrong offset. Consequences The configuration has been rejected. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 400 Module in slot arg is of wrong type. Consequences Consequences Some I/O signals might not be possible to use. Some I/O signals might not be possible to use. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 401 I/O controller. Consequences Consequences Some I/O signals might not be possible to use. Some I/O signals might not be possible to use. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 402 The submodule in subslot arg in slot arg on device arg is of Correct the device command path string. wrong type. Consequences Some I/O signals might not be possible to use. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 403 Using the default fingerprint configuration, no secure verification of remote host has been done. Consequences Fingerprint received: arg. The configuration has been rejected. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 404 Mounting device on remote host arg failed. Remove the usage of fingerprint in the configuration or replace Protocol: arg. the SFTP server. Recommended actions Check the configuration. Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.

  • Page 405: Xxxx

    The Safety Controller has opened the limit switch because of connected. The FlexPendant and its enabling device is a safety violation. described in the Trouble Shooting Manual, IRC5. Recommended actions Recommended actions Check for reason found in other event messages. Check the Check the FlexPendant cable and its connection.
  • Page 406 RUN contactor supplies a robot. This fault may occur when Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 407 Recommended actions This may be caused by a number of faults. The enable and run Release the enabling device. Switch to Manual mode. chains are described in the Trouble Shooting Manual, IRC5. 90217, Limit Switch open, DRV2 Recommended actions Check cables and connections. Check other event messages Description occurring at the same time to determine the cause of the fault.
  • Page 408 The FlexPendant enabling device may be faulty or incorrectly Description connected. The FlexPendant and its enabling device is Status conflict for run chain. described in the Trouble Shooting Manual, IRC5. Recommended actions Recommended actions Please check the run chain cables.
  • Page 409 The contact pair in any of the Emergency Stop buttons is not The system goes directly to status Emergency Stop. working correctly. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 410 There may be a hardware fault in the operating mode selector Isolate the safety device that was opened. Reset the device or its cabling to the safety system. switch. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 411 Only one of the two motor contactors for drive system 2 has it is clogged and has to be exchanged. acknowledged the activation order. Consequences The system goes to status SYS HALT. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 412 Description Wait until the overheated motor has cooled down before Communication error with Safety Controller (SC) arg. ordering Motors On again. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 413 Remote change of operating mode from a PLC is not allowed. Found arg Safety Controller (SC) on drive module arg, expected arg. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 414 The fan or the drive module module arg does not work correctly. power supply may be faulty. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 415 The Enable 2 circuit monitoring the axis computer has been system, axis computer. If restarting is POSSIBLE, it indicates opened. a software fault. In such case, contact your local ABB representative. Determine which unit is faulty by checking its Consequences indication LEDs.
  • Page 416 If restarting is POSSIBLE, it indicates A fault, probably a software fault, has been detected by any of a software fault. In such case, contact your local ABB the units supervised by the Enable 2 circuit. representative. Determine which unit is faulty by checking its indication LEDs.
  • Page 417 Check that the case. The configuration doesn't fit with the used hardware. synchronization switch is working properly. Check that motor Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 418 Recommended actions Recommended actions Restart robot controller. Reinstall system. Check SC cabling. Check SC health. Restart robot controller, after performing recommended actions. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 419 90471, SC arg Synchronization Timeout Safety Controller (SC) arg is not correctly configured for synchronization. Description Synchronization time limit expired for Safety Controller (SC) arg. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 420 Perform a brake check. Recommended actions Reinstall the supervised additional axis, or download a safety configuration without supervision of the additional axis. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 421 Incorrect tool change with Tool arg on mechanical unit arg. Probable causes Either a system reset has been performed or it's the first startup of SC. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 422 Recommended actions Make sure that the speed during synchronization is within limits, and perform a new synchronization of the safety controller. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 423 Check that exactly one tool selection input is active. while inside Safety Area arg. Consequences The safety controller will stop all robot movements. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 424 Tool Speed supervision arg was violated in the safety controller Consequences for drive module arg. The safety controller will stop all robot movements. The cause was arg. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 425 The Safety Controller failed to load the safety configuration file The safety controller will stop all robot movements. No full arg. speed operation is possible until the mismatch has ceased. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 426 Tool arg was active. Consequences If configured with a stop action, the safety controller will stop all robot movements. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 427 The external power supply was activated while the feedback The safety controller will stop all robot movements. from the external power supply contactors was incorrect. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 428 The safety configuration has not been created using 90600, Invalid SiosCfg tag RobotStudio. Description Recommended actions The SiosCfg tag on line arg is invalid. Update the safety configuration. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 429 The net arg, specified on line arg has already been specified. 90611, Device create failed Consequences The system will stop all robot movements. Description Device arg failed. The device already exists. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 430 The system will stop all robot movements. RobotStudio. Probable causes Recommended actions The safety configuration has not been created using Update the safety configuration. RobotStudio. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 431 90626, Signal name is missing Consequences The system will stop all robot movements. Description Signal name is missing on line arg. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 432 The system will stop all robot movements. Recommended actions Probable causes Update the safety configuration. The safety configuration has not been created using RobotStudio. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 433 RobotStudio. Description Recommended actions Signal arg arg mapping to device arg failed. Device I/O size is Update the safety configuration. arg. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 434 Mapping of FuncIO arg to signal arg failed because a mapping RobotStudio. has already been specified. Recommended actions Consequences Update the safety configuration. The system will stop all robot movements. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 435 The version of the sc_cfg file is not supported. Description Consequences Could not set signal value for FuncIO arg. The system will stop all robot movements. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 436 Reset the safety controller to factory settings and create a new 90664, FuncIOMappings dependency failed safety configuration. Description FuncIOMappings for FuncIO arg has dependency to FuncIO arg. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 437 Probable causes Description The safety configuration has not been created using The TPU has been reattached to the robot controller. RobotStudio. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 438 90686, Safety configuration item missing RobotStudio. Description Recommended actions Configuration item "arg" is missing in the safety configuration. Update the safety configuration. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 439 The signal type "arg", specified on line arg, is unknown. Recommended actions Consequences Update the safety configuration. The system will stop all robot movements. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 440 Check cables. Check for other event messages. Restart the robot controller. Description The Safety Network Controller arg failed to initialize. Consequences The system will stop all robot movements. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 441 Re-assign the erroneous module to the correct F-Destination Consequences address. The system will stop all robot movements. Probable causes User has used the same device name twice. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 442 Description The CIP Safety Adapter of this robot controller has rejected a safety Forward Close from an external CIP Safety Scanner. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 443 The arg device does not exist in CIP Safety Scanner The external Safety Scanner has a signature configured but configuration in Visual SafeMove. it did not match the value in the ABB Safety Configuration Recommended actions Report of the CIP Safety Adapter or the Adapter configured the Verify that the device arg is added in Visual SafeMove signature to "Not Used".
  • Page 444 The arg was unable to setup properly. Description Consequences The arg F-Parameters do not match F-Parameters from the arg is not running. PROFIsafe host. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 445 Make sure to use the configurator when creating the safety possible until the fault has been corrected and the system have configuration file. been restarted. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 446 Remove the Safety Controller board and the Safety Controller ID: arg. option from the system. Change to a robot type that is supported by the Safety Controller. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 447 Restart the system and check if the error remains. Probable causes If the error remains replace the Safety Controller board. This may be caused by faulty hardware. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 448 Safety Controller hardware. If the work load is increased, the safety controller will stop the robot. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 449 Restart the system and check if the error remains. Probable causes The safety configuration file contains elements that are not supported by the installed system options. Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.

  • Page 450: Xxxx

    Description Task: arg Supervision failed for process phase MAIN. Recovery: You might want to handle errno arg in your error handler Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 451 2. The last instruction in the sequence of application movement instruction do not fit together. instructions, that does not indicate the sequence end. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 452 110019, Option 'Optical Tracking' is missing It is not possible to start the process on the current instruction Description Task: arg. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 453 Recommended actions Recommended actions Check the signal(s) that failed: Add a TRAP routine for CAP_STOP in your RAPID code. Recovery: Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 454 Correct the component length. Task: arg The weave dwell_right used is invalid: 110103, Invalid weave cycle time (0 - 1) [m] Description Task: arg Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 455 The horizontal weave offset is invalid: Correct the components 'dwell_right/center/left' and/or 'length' in capweavedata. 110114, Invalid vertical weave offset Description Task: arg Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 456 It is not allowed to use the optional argument \ReportAtTool Recommended actions with other sensors than Look Ahead Trackers (e.g. Laser Specify a DI signal Trackers). Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 457 Reduce the number of sensor variable subscriptions (IVarValue). Recommended actions Move PP to main, or step through the rest of the CAP sequence. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 458 The average calibration precisions obtained in the x-, y-, z- directions of the sensor tool are: arg. The desired ones are: arg. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 459 110185, Value larger than sensordatatype allows The sensor calibration data for arg (arg and arg) are updated. Task: arg Description Task: arg. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 460 Forward sequence jumping is not allowed. 110211, Application error Recommended actions Check the program sequence. Description Task: arg The instruction arg reported a fatal error. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 461 Description An automatic restart of the processes will not be possible. Task: arg The user data variable choice does not exist. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 462 The signal reference is not valid, no AliasIO has been done or the signal is write protected in the EIO configuration.. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 463 Number of daprocs must be in the interval 1 - arg. Description Task: arg Recommended actions Voltage supervision signal not set at start of welding. Check the configuration. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 464 Check the welding equipment. 110413, Torch supervision Recovery: You might want to handle errno arg in your error Description handler. Task: arg Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 465 110421, Gas supervision Check the welding equipment. Recovery: You might want to handle errno arg in your error Description handler. Task: arg Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 466 Torch supervision signal went low during welding. Seam name: arg. Description Time from weld start: arg. Task: arg Seam name: arg. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 467 110442, User defined signal supervision User defined signal defined by USERIO3 went low during Description welding. Task: arg Seam name: arg. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 468 110463, Weld Error Recovery Failed Task: arg Description Voltage supervision signal went low during welding. Incorrect Weld Error Recovery Usage. Seam name: arg Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 469 110476, Calibration variable error Recommended actions Description Check the installation of PROC domain parameters. Task: arg Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 470 See Weld Data Monitor elog for more information. Escape option is not available. Request has been changed to 110480, Arc Welding Task Busy MoveOut. Description Task: arg Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 471 2. the relationship between sensor look-ahead (la), sensor frequency (f) and travel speed (v) is bad. It has to fulfill Flying arg is not possible with finepoint. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 472 Change the value or change the min logical parameter for signal arg to avoid this message. This robot is welding synchronized with a non-welding external axis or robot in task arg. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 473 Description Probable causes Task: arg. No equipments are defined in the 'Spot Equipments' Fronius Tracking Equipment is activated. configuration. Version: arg. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 474 The gun position is not synchronized for the servo gun arg. A gun synchronization calibration is needed to find the contact position of the gun. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 475 It is not possible to close or open the servo gun arg in motors off or emergency stop state. Description Task: arg Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 476 It will not be possible to run any spot instructions until this value input (GI). is changed. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 477 Change the value of the program number parameter in spotdata or check that the correct value is used as targetid or spotid. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 478 The data value is outside the limit. Current robtarget: arg Recommended actions Current gun: arg Change the value. Consequences The weld was not completed. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 479 The index number is too high. Recommended actions Recommended actions Add the missing signal arg. Change the index number. 110641, Invalid simulation time Description Task: arg Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 480 Current value: arg mm. A reference measurement has already been done. Current gun: arg Instruction: arg deflection = spotdata.tip_force * gundata{arg}.deflection_dist / gundata{arg}.deflection_force Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 481 Task: arg Touchup force. Touch up error, no surface, or sensor signal was found during the search sequence. Current gun: arg Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 482 Tip wear out of range, the tip wear exceeds the configured tip wear supervision value. Actual tip wear (moveable tip): arg mm. Tip wear tolerance: arg to arg mm. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 483 It is not possible to run synchronized Spot instructions when supplied in this RobotWare release. the software equalizing mode is activated. 2. Load the correct(ed) module(s) and Reset RAPID. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 484 There is a risk that improvements and/or corrections added Check the values and try to do a force calibration again. since previous RobotWare releases are unavailable. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 485 The current used tool seems to have undefined load data. Recommended actions Rebuild the system with the 'Multiple Gun Support' selected. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 486 This signal is not defined in the I/O configuration. Minimum force: arg N. Signal: arg Maximum force: arg N. Current robtarget: arg Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 487 Add the missing signal to the gun equipment configuration, and Task: arg. restart the system. Configuration - Process - Spot Gun Equipment Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 488 (P)/Start-Inhibit (P) for one program - check program selection, select proper program. 110707, External temperature too high. Description Task:arg Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 489 Squeezed sensor cable - incorrect connector assignment - conditions - variant resistances (impedance) in secondary defective sensor. circuit, e.g. shunt resistor - mains voltage fluctuations. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 490 It is not possible to read the timer status signal, the Bosch timer 2. Check duty cycle, load. I/O unit is lost. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 491 3. Check temperature inside the process cabinet or check The mains voltage is too low or inexistent. The mains voltage process cabinet cooling. was below limits. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 492 110802, Dispense Error 110760, Tool Change Error Description Description Task: arg Task:arg Value for DPUSER data dp_fl1_corr is out of limits. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 493 Description Task: arg Value for flow1 in beaddata is out of limits. Value for fl2_delay in equipdata is out of limits. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 494 The calculated flow value is out of limits. Description Fatal internal error for itemsource arg. Recommended actions Try system restart or system reset. Please report this error. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 495 The limits are incorrect specified. Item target buffer full for itemsource arg. Recommended actions Recommended actions Instruction: arg Instruction: arg Recovery: arg Recovery: arg Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 496 Probable causes Recommended actions Network interrupt. Check the position generation frequency. CPU overload in controller system. CPU overload in remote system. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 497 Recommended actions Status arg. Check the Queue Idle signal name. Recommended actions Check the position generation frequency and the network connections. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 498 Task: arg, failed to advance to station arg Check robot program for infinite loops. 111404, GAP Error Description Task: arg , Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 499 111423, GAP proc error Recommended actions Description Check and change the tasklists so they match. GAP_EE_EVT Unknown proc arg Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 500 Create the procedure arg or change the procedure in the menu to an existing procedure. 111501, BullsEye Text Error Description BullsEye could not access text. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 501 BullsEye will be unable to generate proper message dialogs. 111510, BullsEye Error Recommended actions Description Please report this error to your ABB support representative. An error occured while reading data from the stored reference data module. 111502, BullsEye Obsolete Message...
  • Page 502 Singularity Check failed for a Twist of arg and a Tilt of arg protections implemented. Please ensure that the baseframe Task: arg definition is accessible. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 503 Task: arg Beam has moved or calibration changed. Tool: arg Consequences Task: arg BullsEye will not be able to evaluate this tool. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 504 If problems persists, try: 1. Execute the BESetupToolJ setup instruction to reinitialize 111535, BullsEye Day1 TCP Updated the tool. 2. Please contact your ABB support representative if problem Description cannot be corrected. The operator has permitted the Day1 TCP to be updated.
  • Page 505 Description The magnitude of the offset = arg SmarTac could not access text. The preset limit = arg Index given: arg Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 506 Production Monitor will be unable to log data to the database. Configuration Error. Recommended actions Production Monitor experienced an unknown error trying to Check the WebWare server. access: Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 507 Recommended actions The reference data for part, arg, could not be read from the Check the WebWare server. stored data file. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 508 Production Monitor will be unable to log data to the database. Recommended actions Recommended actions Check the WebWare server. Check the WebWare server. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 509 Switch to Automatic Mode and try again. Torch services Wirecut configuration error. Torch Services experienced an unknown error trying to access: arg/arg in PROC configuration. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 510 111717, Torch Services Warning Target buffer full for Work Area arg. Description Target number: arg. Torch services MechClean has unconfigured IO. Scene number arg. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 511 There was no action list name for target in Work Area: arg. Min: arg Status arg. Given: arg. Recommended actions Check the tool name for target. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 512 "arg" are lost because to occur if the operation is a multidrop. the operation was interrupted. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 513 = arg. Number of products in top layer = arg. The signal has to few bits defined in the I/O configuration of the controller. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 514 Program Ref. arg Consequences Probable causes The program execution is immediately halted. There is no operation to retrieve when executing instruction. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 515 Restart the project or rewrite the RAPID program. The Work Area descriptor that is used refers to an object that does not exist. Program Ref.arg Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 516 The flow arg failed to request a format with index arg. The reply came from Work Area arg. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 517 Consequences Recommended actions Project not started. The program execution is Try to start project again. immediately halted Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 518 The format selection I/O values for position request and target The target pump process "arg" failed to request new target set generation is not the same. from project. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 519 The robot is not able to move to the target position. The signal name is not configured in the IO configuration. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 520 The event can't be set. The intermediate part value is not valid. The InterMidPart argument must be between 0 and 1. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 521 Program Ref: arg Stack search detected empty stack. Consequences Task: arg Stack search can not be completed. Instruction arg failed. Program Ref. arg Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 522 The requested flow arg could not be found in the loaded project. The flow can be identified both with its name and its selection value. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 523 The project has been stopped or is not yet started. Consequences Recommended actions The robot cannot perform the movement. Recovery: arg Probable causes Work space restrictions of the intermediate position. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 524 It will not be possible to start the Flow arg if it is set in error position state. Description Probable causes Task: arg The recover action is not one of PM_RECOVER_CONTINUE_OPERATION, Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 525 112393, Flow recover with redo last pick 112384, Invalid default height Description Description The Flow arg will redo last unfinished operation at next flow Task: arg start. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 526 112402, SID file is not compatible - Following WorkAreas are empty: Description Task:arg Context: arg The SID file version is not compatible. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 527 Description The power supply voltage is too low in unit arg. Fault code: arg Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 528 The load on the system's CAN-bus is temporarily too high in Internal unit: arg unit arg. Consequences Fault code: arg The power unit is stopped and cannot be started. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 529 Fault code: arg Fault code: arg Internal unit: arg Internal unit: arg Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 530 Program execution does not work in unit arg. Weld Data Monitor will be inoperable. Fault code: arg Recommended actions Internal unit: arg Please review PROC settings to correct. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 531 PROC could not be found. Default values have been applied. Consequences Task: arg Weld Data Monitor is unable to evaluate this weld seam. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 532 The file may have been left open by another application. Data read from the binary file did not match the expected size. Seam Name: arg Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 533 Measured value: arg Consequences Maximum limit: arg Weld Data Monitor will be unable to evaluate the data from this Minimum limit: arg seam. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 534 WDM will reduce sampling rate to a fraction of the requested Description frequency. Weave frequency is too fast for arg in task arg. Consequences No monitoring will occur. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 535 Recommended actions Check that the HOME/GSI folder exists and that the configuration and settings files can be found there. Restart communciation. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 536 112700, Integrated Vision not installed Recommended actions 1. Set the camera in program mode. Description 2. Load a valid ABB job into the camera or use Robot Studio to The option Integrated Vision is not installed on this system. create a new job. Consequences No communication with the camera is possible.
  • Page 537 114812, arg Description Description Recommended actions Recommended actions 114808, arg 114813, arg Description Description Recommended actions Recommended actions 114809, arg 114814, arg Description Description Recommended actions Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.

  • Page 538: Xxxx

    The configuration file contains invalid input. Consequences Recommended actions The configuration in file will not be installed. Re-edit the configuration file. Probable causes Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 539 The version string in the configuration file is mistyped/missing. Description The configuration file is corrupted. The arg 'arg' is invalid. Parameter 'arg' is invalid here. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 540 The first character must be a letter (a-z or A-Z). Probable causes Subsequent characters must be letters (a-z or A-Z), digits (0-9) The value might be mistyped. or underscores (_). Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.

  • Page 541: Xxxx

    Consequences Brush factor is not set. Description Recommended actions The following signal did not exist: Check channel number and factor. 'arg' Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 542 IPS parameter not set Recommended actions Check if column number exists at row in index file. Recommended actions Check IPS and RobotWare compatibility or contact ABB support 131400, Invalid program mapping index. 131020, Unknown IPS command sent from RAPID Description Line arg in file arg is invalid.
  • Page 543 Check for other process related error messages. Description 132500, Unable to open symbol. Description Output for symbol arg not found. NOTE: No paint-related outputs available Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 544 1. Broken cable 2. High network load. 133003, IPS Cfg Error Recommended actions Description If problem persists: Assertion error: arg. Check main computer Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 545 2. Check if correct license file loaded. 3. Check in IPS config file for errors. Description License file is not found. File name must be 'option.lic'. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 546 2. Fix the actual alarm state. 133202, arg:Disabled Description Impossible to set a command value to Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 547 OK. cure! Paint equipment may be destroyed! 2. Check if the sensor, used by named Start to flush system at once! Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 548 133221, arg:Max output 133217, arg:Unexp. trans. Description Description The closed loop regulator for named IPS has discovered an unexpected Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 549 Recommended actions device and retry. 133252, arg:Calc. curve Description IPS has recalculated a dynamic or calibrated curve, number arg, for named Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 550 1. Check if an already saved curve on 1. Check that named file has the correct format for its use. the IPS node has an incompatible number Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 551 133281, Servo meas. system error Recommended actions Description 1. Check other error messages for detailed explanation. SDI board has discovered an error on the Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 552 Description Recommended actions SDI board has discovered an error while 1. Restart robot controller. loading configuration. 2. Replace Drive unit. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 553 2. Check for short circuit in servo temperature error in the Drive unit motor. used by: arg. 2. Replace Drive unit. ALLOW SYSTEM TO COOL DOWN! Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 554 DC-voltage or broken motor connections, received from the Drive unit used by: arg. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 555 Drive unit regulator (d-part) illegal node address error. This is an used by: arg. internal error, received from Drive unit used by: arg Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 556 3. Check/replace SDI board. Recommended actions 4. Contact customer support. 1. Check SDI configuration. 2. Check/replace Drive unit. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 557 This error is 4. Check if configuration is correct typical if the resolver feedback for used setup. is noisy. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 558 1. Check bleeder connections. 3. Replace serial measurement board. 2. Too much deceleration. 3. Check AC voltage to DC-link. 4. Replace DC-link unit. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 559 The bleeder resistor connected to the rectifier is a short circuit, Description detected by: arg. SDI board has discovered that a servo did not request for a new step from the Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 560 134003, Invalid token 133512, Command toggle error. Description Token arg is out of bounds. Description A command toggle was sent to the Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 561 134011, Subscriber unknown error Recommended actions Wait for the current directly loaded program to finish executing. Description Unknown error during init. of subscribers. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 562 Description The signal arg could not be found. Material change decision timed out. Could be due to a material change cancel. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 563 Description Description Command arg not allowed when the controller is in e-stop state. First dimension passed to XML-parser was to big. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 564 Encountered a row number that was not a positive integer in the file: arg Consequences The CBS is in an unreliable state. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 565 Description Description The returned cartridge was not stored in an IFS. Timeout while waiting for servo controller to complete previous command. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 566 Timeout while waiting for sensor feedback. Timeout while waiting for servo controller to complete previous Recommended actions command. Check that arm sensors are working. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 567 134138, No cartridge present. Description Description Unable to set primary CC selector to address: arg Expected a cartridge in gripper: arg Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 568 Home address is not specified. Some integrity failures will not be detected, and cannot avoid Consequences damage to the system. System will not work correctly. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 569 134178, CBS configuration error. Description Description Index: arg Data: arg Too many IFS stations have been defined. Consequences Some IFS stations will be skipped. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 570 Fix the problem causing the failure and resume the operation. An impossible to reach 'From' address was specified: arg Consequences Cannot continue the operation. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 571 Cannot continue with the operation. Recommended actions 134218, Exchange cartridge error. Disable the CBS servos. Description An impossible to reach 'From' address was specified: arg Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 572 Description Description Unknown cartridge process operation specified: arg A timeout occured while waiting for another task to resume the exchange process. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 573 System will run slower, and integrity failures will not be detected. 134321, Move DSF failed. Description Timeout while waiting for sensor feedback. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 574 Swap cartridge volume not specified. Description Unknown maintenance operation specified: arg Consequences System will not behave optimally. Cartridges will run completely empty before swapping occurs. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 575 134431, Cartridge move error. 134411, Unknown cartridge specified. Description Description Could not move cartridge arg to home position. Unknown cartridge ID: arg. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 576 Unable to move cleaning unit up. Parking unit is not in a valid Description position. Manipulator is not in material change position. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 577 Timeout while waiting for sensor: arg. Recommended actions Description Check dock and undock sensors. Internal error in calibration routine. Recommended actions Check process configuration. Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 578 135052, Material change sequence error. Fix the problem in the file. Description The file 'arg' contains invalid data on line: arg Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 579 Communcation against IPS has been re-established. 135100, Material change user error. 135063, Material change signal error. Description Description Failed to read signal number arg on device: arg Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.

  • Page 580: Xxxx

    5 Troubleshooting by event log 5.13 15 xxxx 5.13 15 xxxx 150330, RAPID error in module Module (line/column): arg There is an error with symbol: arg Description Task:arg Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.

  • Page 581: Xxxx

    170032, Connected Services no server 170003, Connected to ABB Connected Services connection Center Description Description This controller is unable to to reach ABB Connected Services Robot controller is successfully connected to ABB Connected center. Services Center. Consequences 170004, Connected Services reset by server Connected Services functionality is unavailable for this robot system.
  • Page 582 2. Repeat manually the registration process. error 3. Contact ABB support for assistance. Description 170038, Connected Services credentials renewed Connected Services Agent has failed to register at ABB Connected Services Center. Description Connected Services Agent has automatically renewed login Probable causes credentials at ABB Connected Services Center.

  • Page 583: Circuit Diagrams

    Controllers Product Article numbers for circuit diagrams Circuit diagram - IRC5 3HAC024480-011 Circuit diagram - IRC5 Compact 3HAC049406-003 Circuit diagram - IRC5 Panel Mounted Con- 3HAC026871-020 troller Circuit diagram - Euromap 3HAC024120-004 Circuit diagram - Spot welding cabinet 3HAC057185-001 Robots...
  • Page 584 Circuit diagram - Service diagram IRBP IF 3HAC035754-005 Circuit diagram - Service diagram Safety 3HEA800730-001 Options A/L/S Circuit diagram - Service diagram Safety In- 3HEA802301-001 terface A/L/S Continues on next page Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 585 6650S, IRB 7600 Circuit diagram - DressPack 6660 3HAC029940-001 Circuit diagram - DressPack 6700 3HAC044246-002 Circuit diagram - SpotPack SWC IRC5 M2004 3HAC026208-001 Circuit diagram - SpotPack SWC IRC5 Design 3HAC044736-001 2014 PROFINET Use the correct circuit diagram (IRB 6600, IRB 6650 and IRB 6650S) The cable harness of the robot is available in two different designs.
  • Page 586 This page is intentionally left blank...

  • Page 587: Index

    Incompatibility, hardware/software, 54 safety, 11 Interference, 61 system power supply test equipment, 77 troubleshooting, flowchart, 80 labels system power supply, LEDs, 77 controller, 19 Operating manual - Troubleshooting IRC5 3HAC020738-001 Revision: AA © Copyright 2005-2018 ABB. All rights reserved.
  • Page 590 PuDong District SHANGHAI 201319, China Telephone: +86 21 6105 6666 ABB Inc. Robotics and Motion 1250 Brown Road Auburn Hills, MI 48326 Telephone: +1 248 391 9000 abb.com/robotics © Copyright 2005-2018 ABB. All rights reserved. Specifications subject to change without notice.

Table of Contents

Save PDF