8 FAUT FINDING

8.1 General

8.2 Fault indications control system

8.2.1 Error messages (CK 09-1539E)

8.2.2 Status indications
8.2.3 Fuses

8.3 Resident tests

- 8.3.1 Introduction
8.3.2 Main computer
8.3.3 Memory board
8.3.4 Programming unit
8.3.5 Servo system
8.3.6 Floppy disk interface
8.3.7 PO-Bus communication

8.4 Check of robot axis servo performance

CK 09-1500E Aug 1985 8:

 8
FAU-T FINDING

8.1
General Fault finding in the robot control system is simplified con-
siderably by the built-in service aids. These consist partly of
monitoring systems which generate error messages on the pro-
gramming unit in case of a fault, and also indicate statuses with
coloured LEDs on the boards in the control cabinet, and partly of
resident test programs which are run either at system start-up, or
at the operator’s request.
In addition to these built-in tests, there is also an external service
aid, the Test Adapter which can be plugged into the control
system bus and which can then perform specific diagnostic tests
on the control system.

Procedure
The procedure for finding and eliminating faults in the mbot
system is divided into three stages.

0 FAULT INDICATION
E.g. error messages, emergency stop, faulty status, noisy
gearbox, oil leaks, etc.
This stage consists of observing the above indications, and
fmm them deducing which section of the next stage to use in
order to localize the fault.

0 TEST PROCEDURE
E.g. running self-test programs, in difficult cases using the
test adapter. Checking for mechanical play, source of leaks,
short or open circuit, motors, switches, etc.

This stage consists of localizing the fault to a unit or sub-unit

and indicating, in the case the control system which board to
replace, and in the case of the mechanical robot, which
section of the repair chapter to use.
-
0 REPAIR/REPLACEMENT
This stage consists of changing circuit boards or carrying out
the repair instructions in the mechanical repair, Chapter 10.
w-------------------___u______u_________----------------------

FAULT TEST REPAIR/REPLACE

INDICATION PROCEDURE
-----_-_-----------------------------------------------------
e.g. error e.g. diagnostic e.g. replace
message pmgram physical boards charge
noisy gears inspection gearbox
__--------------_-_-----~---------------------------------------------

UK UY-IXJUt Hug lYB>

8.2
Fault ‘indications control system

The fault indications from the central system will be described in

two sections:
Error messages on the programming unit

Status indications on the circuit boards in the cabinet

85.1
Error messages

This section consists of the document CK 09-1539E, “Error

messages”, starting on next paga

After CK U9-1539E section 89.2 will continue an page 8~3.

CK 09- 1500E Aug 1985 ‘8:2

 Error messages for IRB
robots equipped with
SII control system

Contents
1 General
2 Operational errors
3 System faults
4 Error code buffer and
presentation of
control program version

This document is a part of the following documents:

l Programing manuals for all IRB-robots equipped
with SII control system.
l Service manuals for all IRB-robots equipped with
SII control systems.
l “Quick reference”, CK 09-1411 E

CK 09-l 539E Sept 86 ERROR MESSAGES

 1 General

1
General When an error is detected, the ERROR lamp on the control panel illuminates. If a
P-unit is connected to the robot system, an error message is presented at the
same time. in plain language on the upper line of the display. This applies also
when a P-unit is connected after the error has developed and the ERROR lamp
has illuminated.

Errors which can occur are divided into:

l Operational errors; the error messages beginning with a number 001-499.

l System errors; the error messages beginning with a number 501-999.

The appropriate corrective actions for the different errors are described below.

OPERATIONAL ERRORS

1 Check the error type on the upper line of the P-unit display.
2 If further information is necessary, go directly to point 6. Otherwise continue
with point 3.
3 Press the control button SHIFT - the error message is then cleared.
4 Perform the control operation correctly so that the error status is not
repeated.
5 Continue with point 8.
6 Seek the error message displayed in section 10.2.
7 Perform the appropriate actions stipulated in section 10.2.
8 If the same error message returns or persists, despite the incorrect operation
not being repeated, contact service personnel.

SYSTEM FAULTS

1 Seek the error message presented in section 10.3.

2 Perform the appropriate corrective actions as described in section 10.3.
3 If the same error message persists or returns, call service personnel.
1

N.B.

Some error messages described in the sections 2 - 3 can occur for certain types of
-
robots only.

CK 09-l 539E Sept 86 1 ERROR MESSAGES

 2 Operational errors

2
Operational errors
The following tables describe the errors which the operator can cause when
programming or operating the robot system.

These are numbered from 001-499. The table gives.

l Error message
0 Causes
l Recommended corrective action

ERROR MESSAGE CAUSES RECOMMENDED CORREC-

TIVE ACTION

1 .NOT ALLOWED The button concerned is Select another button

PUSHBUTTON temporarily blocked by

2PROG UNIT Attempted :- Place the P-unit in its compartment and

OUT l Synchronization repeat the attempt.
l Program loading from
floppy disk
l Program start from con-
trol panel when the P-
unit is connected and
not in its compartment

3.DATA ERROR 0 Attempted entry of Depress ERASE and enter new

correct numerical numerical value.
value.
0 (For IRB 1000 only)
Attempt to define
OVERLOAD > ZOoA
for a robot which is
not provided with
brakes on all axes.

4.lNSTR NOT After resequencing a Check the program and correct the
FOUND program the system has faulty jump addresses.
detected jumps to non-
existing instructions.

S.PROGRAM Attempt to use a program 0 Program the instruction

MISSING number where instructions under the program number
are missing with: concerned.
0 programming running l Select another program number.
0 editing of complete
program

CK 09-l 539E Sept 86 1 ERROR MESSAGES

2 Operational error5

ERROR MESSAGE CAUSES RECOMMENDED CORREC-

TIVE ACTION

C.MEMORY
FILLED UP
Attempt to: l 1 Clear the program block.
l enter further 2 Erase &perfluous instructions
instructions and programs
l copy program when the 3 Clear program block once again.
robot memory is full l If the system includes a floppy disk
unit, it is possible to:
1. Divide the existing program
and store each section on a
floppy disk under a separate
program number.
2. Utilize the mass memory function for
automatic exchange of the different
program parts in the user memory.

T.PROGRAM END A Attempt to step past A Call the first instruction number in
the RETURN-instruc- the program concerned.
tion

B. Erasure of the B. Enter the RETURN in- struction in the

RETURN-instruction program.

8.PROG NR
OCCUPIED Attempt to copy a pro- Select another program number for
gram under a program the program copy.
number where instruc-
tions are already stored.

9.INSl-R
NUMBER A. Attempt to program in- A Divide the existing program into a
OVERFLOW struction with higher main program and subprograms.
number than 65530. Copy thr program and erase super-
0. Attempt to resequence fluous parts Resequence and insert
a program containing CALL-instructions If available
more than 6553 memory space is too small, use
instructions. floppy disc.
B Avoid resequencing, or split the
program according to point A above.

lO.ADAPTlVITY
ERROR 1 A digital multi-bit l Change one of the min. or max.
sensor or analog -limits (or both) for the signal from
sensor gives a the sensor concerned.
signal outside its 0 Correct current pos- itions in
working area. the program.
lO.ADAPTlVITY
ERROR 2 A digital 2-bit sensor Check the sensor.
gives an illegal
signal.
lO.ADAPTlVITY
ERROR 3 A l-bit sensor is used l Select another sensor - Replace
for direction searching or the sensor.
contour following.

CK 09-l 539E Sept 86 2 ERROR MESSAGES

 2 Operational errors

ERRORMESSAGE CAUSES RECOMMENDEDCORREC-

TIVEACTION

lO.ADAPTlVITY
ERROR 4 A digital sensor with Change the connection according
2-8 bits is completely con- to the installation manual.
nected to the same group section 7.1.
of digital inputs.

lO.ADAPTlVITY
ERROR 6 The correction move- Determine direction and speed
ment has no direction for the correction movement:
or speed. 0 In a new instruction
l By editing an existing instruction.

1 O.ADAPTlVIN
ERROR7 ’ Sensor data for Enter sensor data according
a sensor used to the installation manual
missing. section 10.3.1.

lO.ADAPTlVITY
ERROR 8 The signal level pro- Edit the instruction concerned
grammed for search stop so that the signal level for
is outside the working search stop is within the
range of at least one working range of the sensor.
of the sensor.

11 .OUTSIDE
WORKING The robot axis 1 to 9 has Run the robot in the opposite
AREA 1-9 been run outside its direction with the joystick.
working area with the
joystick.

lI.SELECT
RECTANGULAR Joystick operation must be Select base-coordinate system.
COORD! done with base-coordinate
system for the movement
concerned.

14.KEY LOCK The button concerned is l Unlock the program lock

blocked by the program l Select another button.
lock

15SENSOR NOT
DEFINED No sensor defined for Press ERASE and enter
sensor number entered. new sensor number.

16.SENSOR TYPE
NOT ALLOWED Incorrect sensor type for Press ERASE and enter new
the adaptive function de- sensor number.
fined for the sensor
number entered.

CK 09-l 539E Sept 86 3 ERROR MESSAGES

2 Operational errors

ERROR MESSAGE CAUSES RECOMMENDED CORREC-

TIVE ACTION

17.WRONG
INSTRUCTlON TYPE Attempt to change: l Change the complete
0 Argument instruction.
0 Position l Select another instruction
l Speed number.
for an instruction which
does not contain pos-
itioning.

l8.INSTRUClION
NUMBER OCCUPIED Attempt to program in- 0 Enter another instruction number.
struction with occupied l Renumber the program and then
instruction number. enter an instruction number.

lS.PROGRAM START Attempt to step backwards Erase the message and continue with
and pass-by the first the next action.
instruction in the
program.

21 .TCP NOT
DEFINED Attempt to program e Program another TCP.
activation of an 0 Define the TCP that is to be activated
undefined TCP. via the instruction and try again.

23. ALIGN ERROR (For IRB 1000 only) Turn the tool closer to the required
Attempt to execute ALIGN orientation and try again.
with a too large angle
deviation between the
current tool orientation
and the required one.

24. NOT DEFINED (For IRB 1000 only) l Select another orientation register.
Attempt ot execute l Define the orientation by means
ALIGN-FETCH on an of ALIGN-STORE.
undefined orientation
register.

25. INCOMPAnBLE The required option can . ..V......D......

OPnoN not be activated

- because to that:
A Another parameter
under OPTION is
already activated.
B Required POTION
parametercaan not be
activated for the current
robot type.

CK 09-1539E Sept 86 4 ERROR MESSAGES

 3 System faults

3
System faults The errors which can occur in the robot system itself are described in
the following table. These are numbered fron 501 to 999.
The table gives.
l Error message
0 Causes
l Recommended corrective measures.

ERRORMESSAGE CAUSES RECOMMENDEDCORREC-

TIVEMEASURES
SO1 PARAM
MEMORY FAULT, Attempted start-up or 0 Press the function button PROM so
RELOAD! program-start when the that the normal values of the function
function parameter parameters are entered.
- memory contents are in- l If the system includes a floppy
correct, e.g. when the disk unit:
memory is affected by a 1. Place the floppy disk with alternative
voltage failure. function parameters in the floppy
disk unit and close the hatch.
-- 2. Press the function button DISK so
that the function parameters of the
system (one or more alternative
parameter values) are entered.
502 PROGRAM
MEMORY FAULT The memory contents are l Enter actual robot program from
destroyed. Appears after: floppy disk.
l Start-up procedure l 1 Press the STOP button.
l Change of parameters 2 Enter a program from the
programming unit.
If the error occurs again, despite
these actions, see Service Manual
about checking of memory boards.

SB3 EMERGENCY STOP The robot has been 1~ Correct the cause of the
stopped manually in emergency stop.
an emergency. 2. Press STANDBY or RUN on the
control panel so that the emergency
stop is cancelled. If the emergency
stop cannot be cancelled:
l (For new robots only)
Check the emergency stop relays in
the terminal DSQC 124.
0 Start a common fault tracing, act. to
Chapter 8 in the Service Manual.
SB3 PROGRAM RUN
ERROR 3 Attempt to start program Enter a robot program from floppy
execution when program disk or from programming unit.
is missing.
503 PROGRAM RUN
ERROR 4 Attempt to execute a cor- Call the correct instruction
rection vector for another and try again.
kind of instruction.
504 PROGRAM RUN
ERROR 5 Last instruction was not Insert RETURN-instruction.
RETURN in an executed
program.

CK 09-l 539E Sept 86 1 ERROR MESSAGES

3 System faults
1

ERRORMESSAGE CAUSES RECOMMENDEDCORREC-

TIVEMEASURES

504 PROGRAM RUN

ERROR 6 Attempt to execute a
control instruction
backwards.

504 PROGRAM RUN

ERROR 7 Attempt to execute a 0 Edit the movement path.
movement path outside l Check the TCP location.
the robot’s working area.

504 PROGRAM RUN

ERROR 8 Attempt to call a sub- 0 Edit the program number in
program or robot program the instruction.
without instructions. l Create a subprogram or robot
program with this number.

504 PROGRAM RUN

ERROR 9 Attempt to superimpose a Edit the weaving.
weaving program with a
movement, when the first
instruction in the weaving
subprogram is not a pos-
itioning instruction.

504 PROGRAM RUN

ERROR 10 A Attempt to superimpose A Edit the weaving.
a weaving program with
a movement, when any
instruction in the weaving
subprogram is of a wrong
we.
B Attempt to run an instruc- B Check the program.
tion that is not allowed
for the robot.

504 PROGRAM RUN

ERROR 11 Maximum allowed Check the robot work station
waiting time for a condi- and correct possible faults.
tional WAIT-instruction N.B!
exceeded. The WAIT instruction was programmed
in an older robot system which causes
the robot to stop after time out of the
supervision time. (Compare with section
5.5, “Pause in program running”).

CK 09-l 539E Sept 86 2 ERROR MESSAGES

 3 System faults

ERROR MESSAGE CAUSES RECOMMENDED CORREC-

TIVE MEASURES

504 PROGRAM RUN

ERROR 12 Attempt to execute a l Edit the jump address.
jump to a non-existent l Enter an instruction with this
instruction. number.

504 PROGRAM RUN

ERROR 13 Attempt to execute a Check and change the value
pattern subprogram, when in the register concerned.
the register concerned
contains an incorrect
value.

504 PROGRAM RUN

ERROR 14 Attempt to execute a Edit the robot program.
nested call to a 1 lth
subprogram level (or a
12th level of interrupt
program).

504 PROGRAM RUN

ERROR 16 A Main program A,0 Enter a main program.
(program 0) is missing.
0 The active program re-
placed by the correspon-
ding one on floppy disk
at program loading with
the subfunctional ADDALL
under the GET B-function
C Another mass memory, C Try to perform the corresponding
error GET B-function manually.

504 PROGRAM RUN

ERROR 17 A. A positioning instruc- A. Edit the instruction and repeat
tion after a circle the attempt.
point contains an 0. Run if possible to the end point
illegal argument. of the circle and back from
0. Attempt to back to this point instead.
the start point after
program stop in the
middle of a circular arc.

504 PROGRAM RUN

ERROR 18 The positions of the circle l Remove the circle point and run
points are selected incor- in straight lines instead.
rectly so that either: l Change the position of the
l The radius becomes points concerned so that a
too large. circular arc is obtained.
l Two or several points
in the circular arc
coincide.

CK 09-l 539E Sept 86 3 ERROR MESSAGES

3 Systemfaults

ERRORMESSAGE CAUSES RECOMMENDEDCORREC-

TIVEMEASURES

504 PROGRAM RUN

ERROR 19 The circular inter- 1. Erase the error message with
polation has been inter- the SHIFT key.
rupted so that it cannot 2. Check that there is no obstacle in
continue. the direct path of the robot
forward to the next point.
3. Run instruction by instruction to the
next point.

594 PROGRAM RUN The acknowledgement Check the peripheral

ERROR 20 of transferred data is equipment concerned.
(only for arc welding omitted when executing
robot) the arc welding instruc-
tion EXTPOS.

504 PROGRAM RUN The type of movement l Edit the instruction.

ERROR 21 ordered in a START in- l Change the parameter concerned.
(only for arc welding struction for an external
robot) axis do not correspind
with the similar function
parameter.

504 PROGRAM RUN The START instruction Define the parameter for the
ERROR 22 cannot be performed working area of the current
(only for are welding because the working area external axis.
robot) for the external axis
concerned is not defined.

504 PROGRAM RUN The START instruction Define the parameter for the
ERROR 23 cannot be performed gear ratio of the current
(only for arc welding because the gear ratio external axis.
robot) for the external axis
concerned is not defined.

594 PROGRAM RUN SET, REST, INVERT or Use another digital output.
ERROR 24 PULSE instruction for a
(only for arc welding digital output cannot be
robot) performed because the
output concerned is used
for communication with
arc welding equipment.

504 PROGRAM RUN Attempt to execute a Activate the servo adaptivity

ERROR 25 LOAD instruction when by means of the function parameter
(only for spot welding servo adaptivity is not concerned and try again.
robot with servo activated.
adaptivity)

CK 09-l 539E Sept 86 4 ERROR MESSAGES

 3 System faults

ERROR MESSAGE CAUSES RECOMMENDED CORREC-

TIVE MEASURES

504 PROGRAM RUN A robot axis with a wor- Edit the program in such a way
ERROR 26 king area ~360” has that the movement of the axis
ended up in a socalled can be executed in one way only.
ambigous point, which
means that the succeding
programmed running to
the programmed position
can be executed in
two ways by the robot axis.

504 PROGRAM RUN The value in a number Check the program and edit the
ERROR 27 register is not valid. register handling.

504 PROGRAM RUN The welding board Initiate the board by changing a
ERROR 28 DSQC 114 at position value under the parameter group
(only for spot welding 177 is not initiated. I / 0 TYPE. The value for position
robot equiped 177 isto be 12.
with IWT)

504 PROGRAM RUN The welding board does The board is faulty. (A test no 18
ERROR 29 not send an acknowledge can be performed by the test adapter
(only for spot welding signal before the maxi- for the robot system to define
robot equiped mum time after a WELD the fault).
with IWT) order to the board,
is over-run.

504 PROGRAM RUN

ERROR 50 Automatic definition Select three new positions
of a program displace- and try again.
ment is in progress.
During the process, at
least two positions
approach each other
- too closely:
l When the positions
are selected.
l In the resulting
program displace-
ment.

594 PROGRAM RUN

ERROR 51 Attempt to activate o Activate another TCP.
an undefined TCP l Define required TCP and try again.

CK 09-l 539E Sept 86 5 ERROR MESSAGES

3 System faults

ERROR MESSAGE CAUSES RECOMMENDED CORREC-

TIVE MEASURES

504 PROGRAM RUN

ERROR 53 (For IRB 1000 only)
Attempt to use: A Change the number of grippers
A An undefined gripper in the function parameters.
8 An output which is B Use another gripper/output.
reserved for a gripper.

504 PROGRAM RUN

ERROR 54 (For IRB 1000 only)
Attempt to execute a A Define the pallet
PALLET-instruction with B Use an already defined pallet.
an undefined pallet
-
504 PROGRAM RUN
ERROR 55 (For IRB 1000 only)
Attempt to execute a Change the register values.
PALLET-instruction with
the register values poin-
ting out a position out-
side the pallet.

504 PROGRAM RUN

ERROR 56 (For IRB 1000 only)
Attempt to execute
OVERLOAD >20°/6 for
a robot which is not pro-
vided with brakes on
all axes.

504 PROGRAM RUN

ERROR 57 (For IRB 1000 only)
Attempt to execute a Change the displacements/rotations.
RELTOOL-instruction
with the displacements/
rotations outside the
allowed limits.

504 PROGRAM RUN

ERROR 58 Attempt to execute a Activate the function parameter GLUE
gluing instruction with the under OPTlONk - provided that the
parameter GLUE not robot systen is a gluing system.
activated.

CK 09-l 539E Sept 86 6 ERROR MESSAGES

 3 System faults

ERRORMESSAGE CAUSES RECOMMENDEDCORREC-

TIVEMEASURES

506 SERVO ERROR 2

1101-1102 One or several faults
described below have
developed in the drive
unit rack 1 (1101) or
2 (1102).
A. Overload protection A 1 Waitfora while.
tripped in one or 2 Move the toggle switch RESET
more drive units. on the 15 V regulator to and
(The LED I on the from once.
YYT 102-... servo con-
trol unit concerned is
illuminated).
8. Error in the 15 V B. Measure, and adjust if necessary,
- supply. (The LED 15 V the + 15 V and - 15 V voltages
ERROR on the YYT 102 according to the Service Manual,
servo control unit con- Section 8.22.3
cerned is illuminated).
C. The jumpers on a R/D C. Correct the jumpers according
board DSQC 104/ 123 to the Circuit Diagram.
are wrong. (The LED
F ADR is illuminated).

506 SERVO ERROR 2

1201-1209 (For robot axes without
tacho only).
The current reference sig- Check that the voltages on the text
nal to the servo control outlets I LIM 1 and I LIM 2 respectively
unit YYT 102-... is above are set according to the table in the
the limit set for Service Manual, Section 11.4.
axis 1 (1201)-9(1209). If the fault persists, check YYT 102-...
according to the Service Manual,
Section 7.22.3.
If the fault still persists, check the
corresponding WD board DSQC 104/l 23
according to the Service Manual,
Section 7.19.3.

506 SERVO ERROR 2

1301-1309 Motor for axis 1 (1301) 1 Select run mode SYSTEM OFF.
- 9 (1309) runs at incor- 2 Measure the resistance in the loop
rect speed because of between YETA 250-... and the
0 Short circuit in the motor, step by step according to
motor or its con- the Circuit Diagram.
nections. If no short circuit is detected, check
0 Drive unit fault YETA 250-... according to the points 1
and 2 above.
If a short circuit is still not detected,
check YYT 102-... according to the
Service Manual, Section 7.22.3.

CK 09-l 539E Sept 86 7 ERROR MESSAGES

3 System faults

ERROR MESSAGE CAUSES RECOMMENDED CORREC-

TIVE MEASURES

506 SERVO ERROR 2

1401-1409 Motor for axis 1 ( 140 1) A. 1 Select run mode OPERATION and
- 9 (1409) remains jog the robot away from the
stationary despite ordered obstacle.
operation depending on 2 Remove the obstacle, or edit
A. The robot has en- the program.
countered an obstacle. B. 4 Select run mode STANDBY.
8. The motor receives no 2 Measure the resistance in the
current. loop between YETA 250-... and the
motor, step by step according to
the Circuit Diagram.
If no open circuit is detected, measure
the resistance on YETA 250-... step by
step according to the Circiut Diagram.
If neither an open or a short circuit is
detected on the board YETA 250-...,
check YYT 102-... according to the
Service Manual, Section 7.22.3.

506 SERVO ERROR 2

1501-l 503 Coupling fault in a 1 Select run mode STANDBY.
resolver coupled to R/D 2 Check with one of the robot axes
board 1 (1501)-3(1503). that has a faulty resolver winding
(The LED E on DSQC 104/ by using a dual-trace oscilloscope.
123 is illuminated). Connect it according to the table in
the Service Manual, Section 11.2.1.5.
On channel 2 a pure square wave is to
appear, that does not move.
The square wave for a faulty axis will:
l Change its shape now and then.
a Be missing.
3 Select run mode SYSTEM OFF and
measure the resistance in the loops
for the SIN-, COS- and POSFEEDB-sig-
nals on the robot, step by step.

506 SER\iO ERROR 2

1601-1609 Overspeed protection for Select run mode OPERATION and
axis 1 (1602) - 9 (1609) try again.
when the P-unit is con-
nected and removed from
its compartment.

CK 09-l 539E Sept 86 8 ERROR MESSAGES

 3 System faults

ERROR MESSAGE CAUSES RECOMMENDED CORREC-

TIVE MEASURES

506 SERVO ERROR 2

1700 Voltage level in one of 1 Select run mode STANDBY.
the D/A convertors on the 2 Check the voltage on the test outlet
servo control boards can IREF, situated on all YYT 102-...
not be compensated for The correct value is 0 V. Adjust an in-
because of excessive dis- correct value act. to the following:
placement of the zero- 0 If YYT 102-... is provided with a
level (Offset error). potentiometer ZERO ADJ on the
front, measure IREF during
adjustment of ZERO ADJ.
0 If YYT 1 Ot-.. is not provided with
ZERO ADJ on the front:
1 Pull out YYT 102-... and adjust the
potentiometer R5 in any direction.
2 insert YYT 102-... again and
measure the IREF-voltage.
Repeat the points 1 and 2 above if
necessary.
By using an extension board it is
possible to measure IREF during
adjustment of R5.

506 SERVO ERROR 2

1800 0 (Apply only to spot welding
robots).
Programmed running has 1. Press OPERATION. ’
been commanded after 2. Check that the intended path to
1. The brakes of the the next position is free from
robot on the C-axis obstacles for the robot. Otherwise,
have been applied and run the robot to the next
then released. position with the joystick.
2. The robot has moved 3. Start programmed running
from the position once again.
where it was braked.

l (apply for robots

equipped with brakes).
A robot with the brakes
applied has drifted too
far from its location, be-
cause of heavy load or
bad brakes.

506 SERVO ERROR 2

2101-2109 Axis 1 (1201)-9(2109) Lubricate the robot according to the
lags excessively, possibly Maintenance Manual, or avoid the
due to high friction in the heavy load and try again.
mechanics, or an over-
loaded robot.

CK 09-l 539E Sept 86 9 ERROR MESSAGES

3 System faults

ERROR MESSAGE CAUSES RECOMMENDED CORREC-

TIVE MEASURES

506 SERVO ERROR 2

3100 Open OPERATION con- l (For robots provided with
tactor (secundary fault). EII%control program).
Read the error message that was first
stored and then follow the actions
suggested for this error message.
l (For older robots).
Start a common fault tracing,
according to Chapter 8 in the Service
Manual.

506 SERVO ERROR 2

4104 STALL ALARM. Exchange DSPA 110.
The axis computer
DSPA 110 has stalled
during program execution,
due to an internal pro-
gram or memory fault.

506 SERVO ERROR 2

4102 Memory fault Exchange DSPA 110.
The axis computer DSPA If the fault occurs again, in spite of the
110 is looking for an in- board exchange, trace faults on:
valid address, due to: 0 The WD boards DSQC 1040 23.
l An internal fault. l The data bus at the WD boards.
e A fault on a WD board
DSQC 104/l 23.

506 SERVO ERROR 2

4103 Time-out fault in the axis Exchange DSPA 110.
computer DSPA 110, due If the fault occurs again, despite the
to a missing acknowledge board exchange, start a common
signal from an unit fault tracing, according to Chapter 8
addressed. in the Service Manual.

506 SERVO ERROR 2

4105 Interrupt in axis com- Exchange DSPA 110.
puter activity without If the fault occurs again, despite the
not defined cause (com- board exchange, start a common
mon message). fault tracing, according to Chapter 8 in
the Service Manual.

CK 09-1539E Sept 86 10 ERROR MESSAGES

 3 System faults

ERROR MESSAGE CAUSES RECOMMENDED CORREC-

TIVE MEASURES

506 SERVO ERROR 2

4106 Overflow in COMM buffer. Exchange the control program.
Interrupt in axis com-
puter activity due to that
the COMM buffer to the
main computer is filled up,
possibly due to a control
program fault.

506 SERVO ERROR 2

5110 STALL ALARM. Exchange DSPA 110.
The axis computer DSPA
110 has stalled during pro-
gram execution, due to an
internal program or
memory fault.

506 SERVO ERROR 2

5120 STALL ALARM. Exchange DSPA 110.
The axis computer DSPA
110 has stalled during pro-
gram execution, due to an
internal program or
memory fault.

506 SERVO ERROR 2

5130 The axis computer has re- Exchange the control program.
ceived a faulty internal
parameter, possibly due
to a control program fault.

506 SERVO ERROR 2

7001 Time out. Check the axis computer DSPA 110.
The maximum waiting If it is error-free, exchange the main
times for response to the computer DSPC 150/l 53/l 52.
main computer from the
axis computer has been
exceeded because of
A. Fault in the main
computer.
8. Interrupt in the
activity of the
axis computer.

CK 09-l 539E Sept 86 11 ERROR MESSAGES

3 System faults

ERROR MESSAGE CAUSES RECOMMENDED CORREC-

TIVE MEASURES

506 SERVO ERROR 2

7002 Non-defined channel Exchange the control program.
index.
Communication fault bet-
ween the test adapter
DSQS 108 and the main
computer, possibly due to
a control program fault.

506 SERVO ERROR 2

7003 Hardware fault on the Exchange the axis computer DSPA 110.
axis computer when a
start-up test is performed.

506 SERVO ERROR 2

7004 Incorrect synch position. Exchange the control program.
The sync position of the
robot is not correct
because the values for
the sync position are
not in the robot control
program.

506 SERVO ERROR 2

7005 Fault in the internal Exchange the control program.
calculation routine.

506 SERVO ERROR 2

7006 No answer to Check the axis computer DSPA 110.
TRANSFORM order. If it is error-free, exchange the
A program module in the control program.
main computer begins
running before an
approved acknowledge-
ment for this has been
received.

506 SERVO ERROR 2

7007 STALL ALARM Check the axis computer DSPA 110.
The main computer has If it is error-free, start a commom
detected that the fault tracing, according to Chapter 8
messages from the axis - in the Service Manual.
computer are not sent
sufficiently rapidly.

CM 09-l 539E Sept 86 12 ERROR MESSAGES

 3 System faults

ERRORMESSAGE CAUSES RECOMMENDEDCORREC-

TIVEMEASURES

506 SERVO ERROR 2

7008 No bit in AMW word set. Check the axis computer DSPA 110.
The axis computer has If it is error-free, exchange the main
detected an undefined computer DSPC 150/l 53/l 52.
fault in:
A. Its own program
B. The main computer
program.

506 SERVO ERROR 2

7011 Response not updated. Try again.
The last response from the If the error occurs again, look for
axis computer is not errors in:
updated, according to an 1 The axis computer.
order from the main 2 The communication between
computer. the main computer and the
axis computer.
If the error still is not found,
perform a common fault tracing
according to the Service Manual,
Chapter 8.

506 SERVO ERROR 2

8001 The axis computer has Exchange the main computer
not approved an order DSPC 150/l 53/l 52.
from the main computer
because of a serious
fault in the main com-
puter.

587 JOYSTICK
ERROR Indicates a fault in the If the fault persists, check the
joystick function joystick according to the Service
Manual, Section 8.3.4.

CK 09-l 539E Sept 86 ERROR MESSAGES

3 System faults

ERROR MESSAGE CAUSES RECOMMENDED CORREC-

TIVE MEASURES

508 DISK MEMORY

FAULT 1 Error in the floppy First, press STOP.
disk memory. 0 Repeat attempt
l Change disk

508 DISK MEMORY

FAULT 2 Data stored has dis- First, press STOP.
appeared. 0 Repeat attempt
e Change disk

508 DISK MEMORY

FAULT 3 Data stored incorrect First, press STOP.
0 Repeat attempt
l Change disk

508 DISK MEMORY

FAULT 4 A. Floppy disk missing First, press STOP.
B. Floppy disk faulty A. Insert required disk
C. Floppy disk not B. Change disk
formatted. C. Format the disk

508 DISK MEMORY

FAULT6 Floppy disk with storage First, press STOP.
protection- 0 Remove storage protection
l Change disk

508 DISK MEMORY

FAULT 7 Floppy disk unit not First, press STOP.
ready l Insert disk correctly
l Close hatch
l Change disk

588 DISK MEMORY

FAULT 8 Errounous data at First, press STOP.
attempt of storing l Try again
data on floppy disk. o Change disk

588 DISK MEMORY

FAULT 20 Attempted loading of First, press STOP.
function parameters from l Change disk
wrong disk.

CK 09-l 539E Sept 86 14 ERROR MESSAGES

 3 System faults

ERROR MESSAGE CAUSES RECOMMENDED CORREC-

TIVE MEASURES

508 DISK MEMORY

FAULT 21 Attempt to program First, press STOP.
storage when the l Change disk
whole floppy disk
is occupied.

508 DISK MEMORY

FAULT 22 Attempt to load pro- First, press STOP.
gram from an empty l Replace disk
floppy disk.

-. 508 DISK MEMORY

FAULT 23 Attempt to load a pro- First, press STOP.
gram block via the l Replace the floppy disk.
control panel from an
empty floppy disk.

508 DISK MEMORY

FAULT 24 Attempt to load a pro- First, press STOP.
gram block not available l Select another program block
on the floppy disk. number.
l Change disk.

508 DISK MEMORY

FAULT 25 Attempt to add a program 1. Press STOP.
block that is larger than 2. Erase all programs in the user
the user memory. memory (program numbers O-9999).
3. Load required program block, with
the function ADDALL under the
MANUAL menu.

If this does not work, split the program

block into two parts at the robot, where
the block was originally programmed.

CK 09-l 539E Sept 86 15 ERROR MESSAGES

3 System faults

ERROR MESSAGE CAUSES RECOMMENDED CORREC-

TIVE MEASURES

508DISK MEMORY
FAULT 26 An attempt has been made 1~ Press STOP.
to add a program block 2. Erase any superfluous programs
as the space availibte in the user memory.
in the user memory is 3. Store the remaining part of the
insufficient- program block as block X.
4. Load the program block containing
the required program.
5. Erase all unwanted programs.
6. Add block X with the function
ADDALL.

If this is not succesful, use the

instruction GET 8 in the program for
alternate running of program blocks X
and N.

508 DISK MEMORY

FAULT 27 Error in the stored First, press STOP.
program block. l Select another block number.
l Change disk.

508 DISK MEMORY

FAULT 28 Fault when formatting First, press STOP.
floppy disk. e Change disk
l Try again

508 DISK MEMORY

FAULT 29 Attempt to load a non- First, press STOP.
existing subprogram from l Select another block number.
floppy disk. l Select another program number.

508 DISK MEMORY

FAULT 30 Floppy disk function is First, press STOP.
faulty. Call service personnel.

508 DISK MEMORY

FAULT 31 Weld data missing for First, press STOP.
(apply only for the program block l Select another block number.
arc welding and concerned. l Change disc.
spot welding robots)

CK 09-l 539E Sept 86 ERROR MESSAGES

..-
 3 System faults

ERROR MESSAGE CAUSES RECOMMENDED CORREC-

TIVE MEASURES

509 SYNC ERROR Error when the robot 0 Press twice on SYNC on the control
system is to be panel.
synchronized. l If repeated attempts are not
successful, see Service Manual.
l (apply only for spot welding robots
equipped with IWT).
Check if the contact units are open
(inputs Pl and P2 on DSQC 114) or if
the welding gun is open (output Vl).
See also error message S26.
l (apply only for arc welding robots
equipped with IWT).
Check the contact units PSl and PS2.
See also error message 526.

510 SYSTEM
FAULT 1 Fault in the check sum Check the memory boards.
with an internal test of
the PROM memory.

510 SYSTEM
FAULT 2 Fault in RWM Check the memory boards.

510 SYSTEM
FAULT 3 Internal fault in the Start-up the robot system once again.
control program If the error message returns,
module for programmed exchange the control program.
running

510 SYSTEM
FAULT4
6. An error has occured in
the error buffer and all
old error messages have
been erased.

511 DATA ERROR 0 Memory fault Correct the cause of the error.
MEMORY SIZE l Memory board Then reload the function parameters
DSMB 125 is missing. from PROM or DISK.

512 DATA ERROR A Wrong address code A Set the right address code.
I / O-BOARD on jumpers Sl. 8 l Put the board into the right place.
8 l/O-board in the wrong l Change a faulty parameter value
place in the under l I/O . .
electronic rack. C Check all I/O boards.
C i/O-board faulty.

CK 09-l 539E Sept 86 17 ERROR MESSAGES

3 System faults

ERRORMESSAGE CAUSES RECOMMENDEDCORREC-

TIVEMEASURES

514 COMMUNICATION
FAULT 1 Insufficient space in the Restart the robot system.
(apply only to robots robot buffer memory for
equipped with data from superior com-
computer link) puter.

514 COMMUNlCATlON
FAULT 2 Data fault in message Check superior computer.
(apply only to robots received from superior
equipped with computer.
computer link)

514 COMMUNICATION
FAULT 3 Transmission error on Repeat the attempt.
(apply only to robots the data link.
equipped with
computer link)

514 COMMUNlCATlON
FAULT 4 Insufficient space in Erase any superfluous program
(apply only to robots the robot memory when in the robot memory.
equipped with attempting to load a
computer link) program from a superior
computer

514 COMMUNICATION
FAULT 5 Program with program Select a program with
(apply only to robots number selected not in another program number.
equipped with the robot memory.
computer link)

514 COMMUNlCATlON
FAULT 6 Maximum waiting time Check superior computer.
(apply only to robots before acknowledgement
equipped with from superior computer
computer link) . exceeded.

515 TlMEOUT FAULT

(apply only to arc When programming the Check the external equipment.
welding robots) arc welding instruction
EXTPOS, the response
from the external equip-
ment is not received before
the maximum permissible
waiting time has been
exceeded.

CK 09-l 539E Sept 86 18 ERROR MESSAGES

 3 System faults

ERRORMESSAGE CAUSES RECOMMENDEDCORREC-

TIVEMEASURES

516 OVERRIDE ERROR 1

(apply only to arc Override has been de- A. Wait until welding is performed.
welding robots) fined as: B. Try again.
A. Welding is not per-
formed.
B. The welding data
number has been
changed.

516 OVERRIDE ERROR 2

(apply only to arc The limit values for Store the values and keep
welding robots) override definition has defining override values.
ben exceeded.

516 OVERRIDE ERROR 3

(apply only to arc The safety pad is not Press the safety pad.
welding robots) depressed.

517 WELD ERROR 1010

(apply only to arc The current supervision Check the thread feeder and
welding robots) has detected that current current supply.
has disappeared for longer
then 150 ms.

517 WELD ERROR 1020

(apply only to arc The gas/coolant super- Check the gas flow and
welding robots) vision has detected that coolant flow.
gas/coolant is missing.

517 WELD ERROR 2010

(apply only to arc The welding arc has not Check thread feeder and
welding robots) been lighted before 2 current supply.
seconds from welding
start order.

517 WELD ERROR 2020

(apply only to arc Gas and coolant flow Check gas flow and coolant flow.
welding robots) received has not been
started before 2 seconds
after the robot has moved
to the position for wel-
ding start.

CK 09-l 539E Sept 86 19 ERROR MESSAGES

3 System faults

ERRORMESSAGE CAUSES RECOMMENDEDCORREC-

TIVEMEASURES

518 WELD OVERTEMP

(only for spot welding The therm0 switch on Check water flow circuit to
robot equipped with IWT) the thyristor block in the the power unit.
power unit is indicating
too high temperature.
Input sifnal TEMPOK.

919 NO WATER FLOW

(only for spot welding The flow detector on the Check if the water is switched on
robot equipped with IWT) outgoing water detects and with necessary flow level
too low water flow (more (10 I / min). Check the water distri-
than 5 seconds). input bution circuits for leakages.
signal FLOW.
.
520 CONTACT UNIT FAULT
(only for spot welding At least one of the con- Control valves (V3 and V4) for
robot equipped with IWT) tact units is not closed the contact units.
(input signals Pl and P2)
after being acti vated
(output signals V3 and V4)
in the welding cycle.

521 IMPROPER DATA

(only for spot welding Attempt to entry incorrect See Programming Manual
robot equipped with IWT) numerical value. for proper values.

522 POWER FAULT

(only for spot welding l Loss of the input signal Power supply to the power unit?
robot equipped with IWT) SYNC from the power Check earth fault tripping or if
unit. main fuses are blown.
l The thyristor in the Replace power unit.
power unit are not
switched on (input
CURRENT) when being
ordered (output HEAT).
l The thyristors are’on
without order.

523 ERROR COMMON DRIVE UNIT 1

(apply only to arc At power-on the activation Try again. If repeated attempts
welding robots) of manipulator 1 failed are not successful, see
(max. allowed waiting time Service Manual.
for acknowledgement sig-
nal from manipulator
3 seconds exceeded).

CK 09-l 539E Sept 86 20 ERROR MESSAGES

 3 System faults

ERROR MESSAGE CAUSES RECOMMENDED CORREC-

TIVE MEASURES

523 ERROR COMMON DRIVE UNIT 2

(apply only to arc At request of activation of Stop program running and
welding robots) a manipulator the robot try again.
was moving.

524 OUTSIDE DEFINED LIMIT 6 - 9

(apply only to arc The working area limit for Edit the program in a way that the
welding robots) external axis 6 - 9 has been corresponding STOP instruction
exceeded when the current will be executed before the current
axis was moving by means axis exceeds its working area.
of a START instruction.

525 I / O-INlTlATlON FAULT

(only for spot welding l Attempt to initiate a Check the Installation Manual
robot equipped with IWT) normal I /O-board with for the right parameter code
the n/VT-board para- ( IWT-board = 12).
meter code. Initiate the IWT-board
l Attempt to activate
GRIP l/2 when the IWT-
board is not intiated.

526 MOTION PROTECTION

(only for spot welding The movement of the Control the status of the relevant
robot equipped with IVVT) robot axis is inhibited signals (Pl, P2 and Vl).
because: Check if the valves for the contact
l At least one of the units are closed or not. Note that
contact units is the valves for the contact units
closed (indicated by can be activated manually.
the input signals
Pl and P2).
. GUN STROKE (out-
put signal Vl) is
activated.
-
527 NOT ALLOWED BOARD ADDRESS
(only for spot welding Attempt to initiate the Valid address for the IWT-board
robot equipped with IWT) IWT-board on wrong is 177.
position.

528 IWT NOT IMPLEMENTED

(only for spot welding Attempt to initiate the
robot equipped with IWT) IWT function for a stan-
dard control system.

529 I IO-BOARD ERROR

(only for spot welding Internal fault on the Replace the circuit board.
robot equipped with IWT) IWT board.

530 USE D5QC 117 WHEN SA

Attempt to activate servo Replace the current resolver supply
adaptivity when DSQC 117 board DSQC 103 with the board
is not present at position DSQC 117 and try again.
137.

CK 09-l 539E Sept 86 21 ERROR MESSAGES

 3 System faults

ERROR MESSAGE CAUSES RECOMMENDED CORREC-

TIVE MEASURES

531 GLUE HARDWARE MISSING

The hardware for gluing Check the gluing hardware
is:
l Not connected.
l Not connected correctly.
l Damaged

602 VISION SYSTEM ERROR

The hardware for . . ..-..........
VISION is missing.
Otherwise - see separate
documentation for VISION.

CK 09-l 539E Sept 86 22 ERROR MESSAGES

 4 Error buffer

4
Error buffer and presentation of control program version

Means: The system contains an internal error buffer, which can store 12 error messages.
In the buffer the system stores:
l All kinds of error messages, occured at the latest error occasion.
l Earlier messages about system errors.

The system can, on request, present the contents of the error buffer via:
l The programming unit.
0 A printer, if the optional function Program printout is provided.
l A monitor, if this optional function is provided.

Facts Display on the programming unit of error messages

The programming unit displays one error message at a time, according to the
following:
l When the system stops running due to an error, the operator will see the
first error message about the main error. An arrow on the display indicates
further messages about consequent errors. In this case the operator can
display these messages also, one by one.
l During manual operation the operator can, on request, display stored
messages from the latest error occasion, one by one. The main error is
displayed first of all.

Display on the monitor of error messages

The monitor displays all the messages within the error buffer, according to the
following:
l When the system stops running due to an error, the operator will see all
messages, occured during that error occasion. The main error is displayed on
the top of the list.
l During manual operation the operator can, on request, display all stored
messages. The oldest message is displayed on the top of the list.

Printout of error messages

l During manual operation the operator can, on request, display. stored
messages from the latest error occasion, one by one.
The oldest message is displayed first of all.

Erasure of the contens in the error buffer

l During manual operation the operator can, on request, erase all messages
stored in the error buffer.

used: For fault tracing and for production follow-up.

Executed: The system reacts immediately after the procedure is concluded.

CK 09- 1539E Sept 86 ERROR MESSAGES

4 Error buffer

Procedures: Display on the programming unit of ermr messages after production stop.
Menu: MANUAL Function: ERROR5
Read the error message. Use the SHIFT button to display more error messages, if
required.
If you want to read messages about system errors once again, select ERROR5
under the MANUAL menu as below.

Display on the programming unit of error messages from the latest error
occasion :
Menu: MANUAL Function: ERROR5
1 5elect ERROR5 under the MANUAL menu and read the error message.
2 Use SHIFT button to display more error messages, if required.

Display of error messages on the monitor after production stop

Read the error messages displyed on the monitor.

Display of all error messages in the buffer on the monitor

Menu: MANUAL Function: ERROR5
Select ERROR5 under the MANUAL menu and read the error messages that are
displayed on the monitor.

Printout of all error messages in the buffer

krenu: MANUAL Function: LIST
I Select LIST under the MANUAL menu.
2 Select ERRORS.
The system responds by printing out a list of the messages in the buffer. The
version of the control program is also printed out.

CK 09-l 539E Sept 86 2 ERROR MESSAGES

 4 Error buffer

Display on the programming unit of control program version

Menu: MANUAL Function: ERROR5
Display error messages with the SHIFT button until the display shows the
following information:

The control program version is also displayed on the monitor.

Erasure of all messages in the error buffer

Menu: MANUAL Function: ERROR5
1 Select ERROR5 under the MANUAL menu.
2 Select ERASE.
3 Answer with YES. (If the answer is NO the system will not erase any message).

CK 09-l 539E Sept 86 3 ERROR MESSAGES

85.2
Status indications
Status indication is by means of coloured LEDs situated on the
front panel of the circuit boards in the control cabinet, and the
terminal unit.

In the following table of status indications the colours of the

LEDs are indicated as (G) green, (Y) yellow and (R) red, where:

Green indicates normal status.

Yellow indicates the presence of a signal.

Red indicates a fault.

The symbols on the board fronts in the following illustrations have

the following meanings:

0 LED status

% Measurement point (output)

.2 Trim potentiometer for adjustment

4 Toggle switch

General

BUS-init is generated either at system power-on or when oper-

ating toggle switch ACTIV on DSPC 150/152/15X

CK 09- P500E Aug 1985 8:3

 Terminal Unit (D14.153.X90)
Different
Terminal Unit (D14.153.X90) emergency stop
relays on DSQC
124

ROBOT
PB ALL
IN-f GREEN
EXT
RACK

The green LEDs on the terminal unit indicate, when extinguished,

where the emergency stop loop has been interrupted, starting at
the RACK:

RACK lights if STAL is out on DSPC 150/152/153 while DCDK

is tit on DSSR 115 (UO>/DSQC 116 and ENABLE is lit on
YYE 109A.

EXT lights if the external emergency stop loop is not inter-

rupted.
INT lights if the rectifier does not indicate earth fault
(option) or over-voltage,

!z!i lights as long as the emergency stop buttons on the

operators panel and programming unit are not activated.

ROBOT lights as long as the robot limit switches are not

activated. The function can be by-passed by OPER-
ATION or STANDBY buttons.

Na6I
For DSQC 124:
If an emergency stop has occured, even though all LEDzs still are
illuminated, iook for maIfunctia3 in the emergency stop days
(safety function).

CK 09-PSOOE Aug 1985 84

.
 5 V requlator DSSR 115 (llO)/DSQC 116

24 V/A Not used, should not light.

24V/A (G)
(Only DSSR 110)
24V/B G1 Not used, should not light.
24 V/B
DCOK IG) (Only DSSR 110)

DCOK Lights if 24 V in > 16 V

and
5V (Adj) 5 V out > 4.6 V

Trim-potentiometer for
adjusting +5 V.

24 V/A Test outlet for 24 V/A.

Not used. (Only DSSR 110)

24 V/B Test outlet for 24 V/A.

24V/A Not used. (Only DSSR 110)

Test outlet for 24 V in.

Test outlet for +5 V.

0 V-outlet,

CK 09- 1500E Aug 1985 8:5

 Main computer DSPC 150/152/153

-.HLT Lights when the processor is

.nll (RI mu ,pj halted:
ERAIN SIAL(RI More than one unit replies,
no unit replies, or two un-
successful bus-access
attempts consecutively.

DMA Lights when the bus is

released to a DMA unit.
A-AUTO
0410
C=NoRMAl ERR Lights if no or more than
RESTART
one unit replies, time-out,
IIT or bus signal BUS ERROR.

STAL Stall alarm - not updated.

PO-A ENABLE Toggle switch
PD-8
up: hot start (auto)
Centre: console (s/b)
v24 IV) Down: cold start
(normal)

ACTIV Toggle switch

UP DSPC 15.. -
init (restart>
Centre: Normal (0)
Down: System-init (init)
DSPC
15.” (in) Data in on V24-channel

(out) Data out on V24-

channel

W-A (Only DSPC 150)

Data input/output channel A

PO-B (Only DSPC 150)

Data input/output channel B
not used.

CK 09-1500E Aug 1985 8~6

 Axis computer DSPA 110

HLT The processor is halted.

HLT (R) STAL (R)
Two consequtive, unsuccess-
COMM h’) BERR(R) ful bus access attempts.
v24 1 WI Q-a- V24 0 (Y)
- STAL Stall alarm - not updated.

- COMM The slave computer has

- control of the bus.
-
-
- BERR Lights at time-out or bus
-- signal BUS ERROR.
--
-
V24 I Data in on V24-channel.

V24 0 Data out on V24-channel.

-
.-

-
-
-

l--
L-m
-
--

110

CK 09-1500E Aug 1985 8:7

Floppy disk interface DSMC 110 PO-Bus communication unit DSCA 121

F (RI 0;V R (y, FO(R)

00 (Y) Q-e 01 (Y) cl-lo

A-- A(Y) 3-e 0 (Y)
4 O(Y)
-
1- 1-
- -
- -
- -
-
r -
r
L --
- -_
-- -
- -

-
T -
P-
- -
-
-
--
-
c
.-
i :-
_---
- -
- T
-
-
-
- -
ZEI Dl%
110 r-l

F,
Lights at bus-init. Lights when channe 810 is not
Extinguished by main pro- initiated,
cessor after a positive Lights at bus-init.
diagnostic result. Extinguished by processor 0
on the board if resident test
Ready from corresponding is successfully completed,
IL
drive. and when the main pro-
cessor has written an inter-
00 Drive 00 selected. rupt vector to the board.

01 Drive 01 selected. Data input on channel A.

Data input on channel B not

used

!2 Data output on channel A

(or 8).

CK 09- 1500E Aug 1985 8:8

Digital input board, Digital input board,
32 channel OS01 110 16 channel DSDI 130

9 (Y)
10
11
12
14 13
15 14
18 15
18
17 25
18 28
19 27
20 28
27
22 ii
23 31
24 32

z Lights at bus-init or internal c Lights at bus-init or internal

f auk fault.
Extinguished by the processor Extinguished by the pro-
on the board if the resident cessor on the board if the
test is successfully completed. resident test is successfully
completed
p-32 Reflects the actual status at
the respective inputs, 1-16 Reflects the actual status
at the respective inputs.

CK 09- 1500E
- - -_ ----- Am
---=I
1985
-- --
Sk9
-- s
Digital input/output- Analog input board,
board DSDX 110 32 channel DSAI 120

F (W 8.9 CC (G)
-
-
-
-
-
-
-
-
-
-
-_
-
-
--.
-

OUTPUT 1 (VI 0uTPu1 9 (Y,

5 :i’
4
:3
ii
::
: 16

L
INPUT 1 (VI
‘NPUT
11(y) -
5
4 :: 13
ii
11: -
: 16
DSAl
120

E Lights at bus-inlt or internal Lights at bus-init.

fault. Extinguished by the Extinguished by the main
processor on the board if the processor after a positive
resident test is successfully diagnostic result.
completed.
(Conversion c ornple ted)
OUT PUTS Reflects the actual status Lights for 100 ms after
* at the respective outputs. completion of an A/D cm-
versioh
INPUTS Reflects the actual status
1-16 at the respective inputs,

CK 09-15OOE Aug 1985 8:lO

Digital output board, Digital output board,
32 channel DSDO 110 16 channel DSDO 130/131

F (RI F (RI
1 Q (Y) 1 9(Y)
2 10
3 11 2 10
3 11
12
13 A 12
14 5 13
6 14
15
15
0-e
.. . .
16
.l 16
17
18
04s 25
26 -- l
19 --I
20
21
a9
ao.
9:
29 --.
22
23
09.
0.0.
30
31
---
_.--
24 00 32

il.'- -
-
+
.- ._-
.i- -.
.-
.-.
LL -
: -’
--
I+-* -
-- -.
-
--
- _-
-_

DGO
130
cl

Lights at bus-init. !f. Lights at bus-init.

z
Extinguished by main pro- Extinguished by main pro-
cessor after a positive cessor after a positive diag-
diagnostic result. nostic result.

z Reflects the actual status 1-16 Reflects the actual status

of the respective outputs. - of the respective outputs.

CK 09-1500E Aug 1985 8:ll

 Resolver exciter DSQC 103
Part I (lower part) of DSQC 117/115

xp1 floating input gives normal

operation.
0 V in disconnects the
internal reference signal
and connects input X12.

Input for external reference

signal.
Test output of internal
reference signal.

RREF Test output for selected

reference signal (external or
in temal).

x11 SIN Test output of resolver

x12 SINUS supply signal.
Xl3 Test output of resolver
RREF COSINUS supply signal.
SIN
0 v output.
cos
ov Part II (upper part) of DSQC 117

E
Lights at bus-init.
Extinguished by the main
processor after a positive
diagnosis result.

Analoq output
Test outlet of analog
output.
FO
blw.o6 Part II (upper part) of DSQC 115
OUTPUT
0 !z Lights at bus-init.
Extinguished by the main
processor after a positive
diagnosis result.

CH 1,CH 2
Test outlets of analog
outputs.

+I5 V EXT, -15 V EXT, 0 V EXT

Inputs for external 215 V
supply.

CK 09-1500E Aug 1985 8:12

 R/D-converter DSQC 104/123

E Indicates resolver connec-

tion failure.
E (RI R 6)
FADR(RI E Indicates normal operation.
ILIM(Y) SYNC(Y) FADR Indicates that the axis com-
ILIM tY, SYNC(Y) puter is not running.
ILIM(Y) SYNC(Y)
ILIM l-3 Indicates current limit for
respective axis. The indi-
Pl cation originates on the
drive units.
P2
P3 SYNC l-3 Lights when the respective
sync switch on the robot is
not activated (= 0).

P l-3 Output of resolver feedback

signal after zero detection.

FE1 FB l-3 Output of resolver feedback

FB2
signal.
FE3 REF l-3 Output of analog reference
REFl signal to axis servo.
REF2 0 v output,
RER
ov

CK 09-1500E Aug 1985 8:13

 15 V-requlator YYE 109A
ENABLE Lights if:
input signal ENABLE = 1
=+i5 V iswithin limits
ENABLE(G)
WV ERROR(R)
-15 V is within limits
+24 V is available
switch RESET is not acti-
RESET
vated

15 V ERROR
Lights if +15 V or -15 V are
outside limits.
RESET Toggle switch for resetting
* 15 V Adj.
ENABLE and 15 V ERROR.
_ 15 V Adj.
Simultaneously activates
bus signal RESET.

+lS V ADJ Trimpot. for adjusting +lS V

-15 V ADJ Trimpot. for adjusting -15 V

-24 V -24 V Test outlet for -24 V input

+lS v Test outlet for +lS V output

-15 v Test outlet for -15 V output

0 V outlet.

CK 09- 1500E Aug 1985 8:14

Servo control unit YYT 102-A....
ZERO ADJTrimpot. for adjustment of
offset deviation of speed
reference.

RUN OK (G1 h>n, Not used led, only m pre-

vious versima)
I)> (RI

ZERO Ad, (n+fR)) + PSER VO Potentiometer for ‘soft

- servo” (only on previous
versions and m
PSERVO O-100 4 YYT 120-H).

REF AD3 Trlmpot. for adjustment of

REF Adj apeed reference. Should be
I LlMl set to maximum value =
maximum clodcw ise.
I LlM2

ILIM 1 Trimpot. for adjustment of

current limit 1.
REF
rip- ILIM 2 Trimpot. for adjustment of
TACHO T current limit 2.
?-
I REF
Test outlet for speed ref-
I ereme.
CONTR
TACHO Test outlet for tacho feed-
lLlM1 back,
I UM2
IREF Test outlet for current ref-
I SIM +- erence.
-8% Test outlet for current
102-.. I
fee&a&

CONTR Test outletfor cmtrol vol-

tage to power stage.

ILIM 1 Test outlet for current

RUNOK Lights if: BLOCK = 0 limit 1.
I >isout
ENARE = 1 ILIM 2 Test outlet for current
RUN = 1 limit 2.

I > Lights if the overload pro- ISIM Input for current simulation.
tection has tripped.
Can be extinguished by COM 0 V outlet.
reset m the 15 V-regulator
after some delay allowing the
motor to load.

CK 09-15ooE Aug 1985 &15

 Servo power staqe YTEA 250-8 /I5

DC OK (G)
bights if voltages U+ and U-
are present.

CK 09-1500E Aug 1985 8:16

 Asynchronous communication unit
DSCA 114

I = INPUT (VlOO - V103)

0 = OUTPUT (VllO - Vll3>
E”O
I 0
C
C = Carrier detect (VU0 - V123)
S
Clil
I 0
S = Clear to send (v130 - V133)
C
CH2 S

I
C
CH3 r 01135) Lights at bus-init or internal
fault. Extinguished by the
processor on the board after
a successful start-up.

OSCA
114

CK 09-1500E Aug 1985 8:17

 Analoq output board DSAO 110

ERR Lights at bus-init. E Lights at bus-init.

Extinguished by the Extinguished by the main
main computer after computer after a positive
a positive diagnos- diagnistics result.
tics result.
ADJUST l-4 Adjustment of zem offset
for output channels l-4.

CK 09-1SOOE Aug 1985 8~18

 Weldinq timer board DSQC 114

BOARD FAULT .f WEI 0 FAjJJ

T_EST POINT SYNC I

TEST POINT HEAT . I

WELD CYCLE ACTIYE

a
G
1

3
v1
WELD REQUBT WELD INHIBITEQ
-
WELD POWER P HEAT
W STRWX GUN RETRACT STROKE
EROM?JWIUT,WITS -v REAR CONTACT JJ?jIT

II
c
1
2
u
WELD ALLOUED -4 YELD EN=
CURRENT c SYNC
PRESSURE 1 i PRESSURE 2
FLOW TEMPOJ

CK 09- 1500E Aug 1985 8:19

8.23
Fuses The control cabinet is fitted with fuses in the following units:

Regulator unit
Power unit
Rectifier unit
Terminal unit

Pn the first three eases, the positioning and rating of the fuses are
evident from the accompanying diagrams. In the case of the
connection units and terminal unit, the position and rating vary
from type to type and are therefore given in tabular form.
Rectifier unit (can also be provided according to British or
American standard)

Fll to 19 - fuse insert 10 A (quick blow)

Art. No. SK 161 0007
Power unit (can also be provided according to British or American
Y

0OoO
0o”o
c
Fl Fuse insert 10 A (quick blow) Art. No. SK 161 0007

F2-4 Fuse insert 6 A (quick blow) Art. No. SK 1610005

F5-6 Fuse insert 2 A (quick blow) Art. No. SK 161 0001

F7-9 Fuse insert 6 A (quick blow) Art. No. SK 1610005

FM-12 Fuse insert 16 A (slow blow) Art. No. SK 1610041

F13-14 Fuse insert 16 A (quick blow) Art. No. SK 1610009

AU IRB except IRB 98/Z

Fl5-17 Fuse insert 16 A (slow blow) Art. No. SK 161 0041

IRB 90/Z
Fl5-17 Fuse insert 20 A (slow blow) Art. No. SK 161 0043

CK 09-1500E Aug 1905 8:20

 5 V-requla tor

. I=101

’ F102

FlOl Cartridge fuse 6.3 A Art. No. 5672 2011-22

(DSSR 110 / 115)
FlO2 Cartridge fuse 8 A A&No.5672 2011-23
(DSSR 110)
F102 Cartridge fuse 10 A Art.No. 5672 2011-24
(DSSR 115)
F201 Cartridge fuse 10 A Art. No. 5672 2011-24
(DSQC 116)
F202 Cartridge fuse 3,15 A Art. No.5672 2011-19
(DSQC116)

CK UY-1XlU~ Aug 1785 8:21

Type of terminal unit Fuse position Fuse rating
and fuse number (terminal number) ~,“‘2”oid!grntjwe
_-------------------_______________o____-----------------------------------~--------

(DSDX 110)

DSQC 1012) Fl 192 2A

F2 3,4 2A

DSQC 124 Fl 2 2A
F2 4 2A
F3 40 2A

DSTD 16019
2
F3
1, 2
697
24,25
2A
2A
2A
F4 29, 30 2A

(DSDI 1109
DSTD 15019 Fl 192 %A
F2 6, 7 1A
F3 24,25 1A
F4 29930 1A

(DSDO 1109

DSTD l%Ol) Fl. 192 2A

F2 69 7 2A
F3 24,25 2A
F4 29, 30 2A

(DSDf 1309

DSTD 140 F% 1A
F2 23 1A
F3 l&l7 1A
F4 2P922 1A

1) Replaced by DSQC 122.

2) Replaced by DSQC 124

CK 09-1500E Aug 1985 8:22

Type of terminal unit Fuse position Fuse rating
and fuse number (terminal number) :,;t&Wrn~,a
_---------------------------------------------------------------------------------

(~~01 110,
DSDO 110,
DSDX 1109

DSQC 122 Fl 192 2A

F2 4, 5 2A
F3 24,25 2A
F4 27,28 2A

(DSDO 130)

DSTD 130 NO FUSES

(DSAI 1209

DSTA 121 Fl 45,46 100 mA

(DSAO 110)

DSTA 160 NO FUSES

CK 09-1500E Aug 1985 8~23

I

CK Cl9-150UE Aug 1985 8: 24

8.3
Resident tests

83.1
Introduction
Most of the functional sub units in the robot control system are
equipped with a built-in resident test program which consists of
two functions. Firstly an initialization check, which is performed
immediately after power-on, and secondly a continuous monitor-
ing function which occurs during operation.
If a fault occurs part, or all, of the system(s) will stop depending
upon where the fault occur

The normal effect is an emergency stop and an ermr message (on

the programming unit). Some faults only light an LED cn the
board, and some indications can only be cleared by restarting the
system. Resident test programs are described here for the fol-
lowing units:

Main computer

Control program PROM.

Memory board

Function parameter memory, memory test and content test,

R/W memory test, program memory content test.
Proqramminq unit

Joystick and program test, selectable self-test.

Servo system
R/D convertor value check, communication main com-
puter - axis computer.

Servo and measuring system, communication with R/D-

convertor.
Floppy disk interface

Formatting, reading and writing parameters, reading and

writing robot program, communication RAM - floppy disk.

PD-bus communication
bocal PROM and RWM, PD-bus communication.

CK 09-P50OE Aug 1985 8~25

8.3.2
Main computer
Test of cmtrol proqram memory PROM)

The check sum is calculated by the control program PROMS of the

main computer. In the basic version, 8 PROMS are located on the
main computer board - DSPC 150/152/153, 10 - 12 cn the memory
board - DSMB X24. Control program with several functions con-
sists of more than 20 PROMS. The PROMS beyond 20 are then
placed on the memory board - DSMB 125.
The check sum is calculated at power-on and ccntinuously &ring
operation. There ls a check sum for each kbyte in the control
program. The check sLlm ccnsists of a 16 bit word, of which the
low byte ls the sum of all 512 low bytes and the high byte is the
sum of all 512 high bytes.
An error in the check sum calculator stops system operation and
an ermr message 1s presented on the programming unit.

510 SYSTEM ERROR 1

Operation of the robot is prevented and communication between

cmtml program and programming unit ceases.
All of the PROMS on DSPC 150/152/153 and DSMB 124 (and DSMB
12% must be replaced before the system can be operated again.

Test of Read/Write memory

The complete RWM of the main computer is tested at power-on

and continuously &ring operation.

The mepnory is tested by data being loaded into the memory and
then dumped and checked.
If an error is detected, the system ls stopped and an ermr
message 18 presented m the programming unit. -

510 SYSTEM ERROR 2

Further operation of the robot is prevented and communication

between the control progmm and the progmmming unit ceases

CK 09.15oOE Aug 1985 8~26

.
 8.33
Memory board
Test of function parameter memory
I
The contents of the function parameter memory are tested at
power-on and cmtinuously during operation.

The check sum for the function parameters is calculated and

compared with the check sum stored in the memory.
If an ermr is detected, the system goes to STANDBY and an error
message is presented m the programming unit.

501 PARAMETER MEMORY FAULT, RELOAD!

To “RELOAD” means that new parameters must be loaded into

the memory. Two operations are then available at the program-
ming unit.

1. DISK The function parameters have been previously stored

---- on disk and can now be reentered into the memory.

2. PROM Standard values of the function parameters are

entered. These values are stored in PROMS.

Test of pmqram memory

The contents of the pmgmm memory are tested at power-on and

continuously during operation.
The check sum is checked and when an ermr is detected, the
system goes to STANDBY and an ermr message is presented on
the programming unit.

502 PROGRAM MEMORY ERROR

The lamp “FROM DISK” m the operators panel of the cmtml

cabinet begins flashing. A program previously stored m disk can
then be loaded. When the pushbutton “FROM DISK” is depressed
the system reads the flrst pmgram stored from the disk and stores
this ln the progmm memory.
If the pmgram ls not to be mad from the disk, the STOP button is
depressed. The lamp “FROM DISK” extinguishes and the system
returns to its normal operation.

I CK 09015OOE Aug 1985 8:27 I

8.3.4
Programming unit
Prerequisite

Turn SYSTEM DFF (at least 5 seconds).

Connect programming unit if not already connected.
Hold the safety pad on the programming unit depressed while
switching system to STANDBY.

Note! The programming unit should not be disconnected while the

srn is powered up.
Self-test of pmqramminq unit

The programming unit is now in test mode and the messages

KEYBOARD TEST and NK are displayed on the screen.

If the messages are not displayed, switch off the programming

unit again and wait at least 5 seconds before switching on again
with the safety pad depressed. If the messages are still not
displayed the display board or the programming board is faulty.

Bispl ay -Joystick

#Safety pad
Keyboard

Keyboard test

NK stands for No Key, that is, no key is depressed. When any key
is depressed NK will be replaced by a code for that key (see figure
below). For example, Bl stands for the leftmost key in the top
mwe

CK 0901500E Aug 1985 8~28

 Test all keys and check that the correct code is displayed. Note
that the blank squares in the figure above are not marked on the
keyboard but they must also be tested. If any fault is found, check
connection of keyboard to contact X3.
Replace keyboard.
Replace programming unit.

LED test

Check that the LEDs of the key provided with come m when any
other key is depressed. In case of trouble replace display board or
programming board. Check the colours of the LEDs against the
following list:

A3: green
red
g yellow
Fh yellow
G2: yellow
Gk yellow

Multlple key test

Depress two or more keys at once and check that the code MK,
Multiple Key, is displayed. If not, change the programming board.

Screen test

Depress the safety pad and note the two vertical lines drifting
from left to right across the screen. The lines consist of 7 dots
arranged as shown in the figure below.

Each character position consists of 5 such mws of dots. There are

40 characters on each line and altogether 200 mws of dots are
scanned, Check whether all the dots in each mw light up and that
no points outside the illuminated mw are alight.
When all the vertical rows have been scanned a horizontal row of
bright dots will drift from the top to the bottom of the screen.
Carry out a similar check; whether all the dots in the row light
up, and all the other dots are dark.

CK 0901500E Aug 1985 8:29

 slmulraneousr ys srarrlng room me ANTL.

I::::
11-1:
1::::
1::::
z I
Check that all underscores light up and that not more than one
underscore lights up at a time in the same line. This will occur in
the presence of a short-circuit between two or more underscores.

If any fault is detected or suspected while testing the display dot

matrix, during horizontal or vertical line advance, the Vrift” can
be arrested by pressing the red key at the bottom left of the
programming unit. The row or rows in question can be stepped
forward by means of the green key (above the red me) to the
position where a fault was noticed during rapid advance.
I Rapid advancing will start automatically after about three
! seconds if neither the red nor the green key is down. It will stop
completely for as long as the red key is held down.
I
The above does not apply to the underscores, which cannot be
controlled manually.
/
If the bright mw or mws of dots are stepped past an end position,
single stepping will continue fmm the beginning (top> or the same
line (column). If a fault is noticed near the beginning of a line or
column during rapid advance, the advance can be interrupted near
the end of the line or column and stepped forward until it returns
to the beginning.
e
I
If any fault is detected, change display board or programming
board.
I

! The screen test will then start again from the beginning as
/
explained previously, and continues repeating until the safety pad
is held down during the last phase (underscore) of the screen test.

CK 090 1500E Aug 1985 8:fO

L
 Joystick test

To go over to the joystick test, hold the safety pad down during
the underscore phase of the screen test.
During the joystick test the characters +X/-X, +Y/-Y or +2/-Z
will be displayed on the bottom line of the screen depending on
the setting of the two switches above the joystick. Two groups of
four underscores are also displayed on the top line of the screen.

LH. Switch -

Set the left-hand switch to EXT position and the right-hand

switch to position 1 (towards the operator). Check that +X/-X is
displayed on the bottom line.
Test the joystick function by moving the joystick left and right.
As the stick is moved to the right an analog indication will appear
on the screen m the right, or the +X-side. The response on the
screen is proportional to the deflection of the stick, i.e. the bar
grows longer in pmportion to the deflection. Make sure the
maximum response is within the underscored marks. The response
must not flicker amund but should accurately follow the move-
ments of the stick. When the stick is in zero position there is no
indication m the screen. Allowed tolerance is 2 2 bars.

-Limit 1 bar ftimit

I
... . .. .. If ..... ..... .....
:: :::::I::.:: . . . ::
. . . . .. . .. 1tii.i Ii
.. . . .. . .. . . ..

CK 090 1500E Aug 1985 8:31

 Go over to the Y axis test by setting the right-hand switch to 2.
The screen response is now tested by moving the stick forward or
back. forward gives a positive respmse, back (towards the oper-
ator) a negative response.
Check that the maximum response is within the marks.

The Z axis test is obtained by setting the left-hand switch to INT

(internal) position (towards the operator).
The corresponding test is performed by turning the top of the
stick. Clockwise gives a positive response and counter-clockwise a
negative respmse m the screen.

In case of trouble check the cmnections of the switches, and the

connections and settings of the potentiometers in the joystick
unit.
Ad&sting
oo- 0~0.0 0ioystick:
0 o-o-
The X and Y axes potentiometers of the joystick can be adjusted
orre the joystick panel has been unscrewed fmm the programming
unit,
Slacker the screws just enough to allow the potentiometers to be
c turned, Adjust to give best tern setting for respective axis. If no
satisfactory setting can be achieved, chaqe the whole joystick
unit,

CK 09015OCE Aug 1985 832

 Fault messaqes

In the course of the joystick test, fault messages El to E6 may be

displayed on the bottom line of the screen. If the fault is of a
temporary nature the fault message is erased when the stick is
passed through zero.
The meaning of the fault messages are as follows:

El: Calibration error

A calibration error has been detected during the calibration

of the joystick function by the program.

E2: Read error

Time-out has occurred when testing pulse times.

E3: The right-hand switch (arm/wrist) is short-circuited.

E& The left-hand switch (internal/external) is short-circuited.

E5: The right-hand switch (arm/wrist) is open.

E6: The left-hand switch (internal/external) is open.

In case of fault messages El and E2, check the connections and

settings of the potentiometers (dark display at tern deflection).
Change potentiometer, change programming board.
In case of fault messages E3 - E6, check the connections of the
micro-switches and the functioning of the switches.

Note: If fault messages E3 - E6 are displayed m the screen

aionally when operating the switches, but the fault condition
can be cancelled by passing the stick through zero, this state of
affairs is normal.

Repeat test

The test can be repeated, starting from the keyboard test, by

depressing the green key while the ]oystick test is in pmgress,

The test can be terminated by depressing the red key. The

program will go over to normal mode and the screen should go
dark.

CK 0901500E Aug 1985 Es55

I

83.5
Servo system
Following resident tests of the servo system are performed

1. Measured value reading on R/D convertor.

During operation, the connection of the resolver signals is
supervised in the hardware and by the axis control program to
ensure that the values read assume expected values.

2. The servo system is supervised by the axis control program

during operation.
I The following are monitored:
0
that the main switch for the drive unit is on.
that the drive units are at standby (no tripping),

that the axes do not stall. This is indicated by the axis

remaining still with maximum current reference. The
tripping delay is appmx. 0.2 seconds.
e that the speed does not depart from the speed com-
Fended.
0 that the speed is limited to 25 % when the programming
unit is connected and removed from its compartment.

In the case of an error detected above:

0 standby mode is established, which means that the main
contactor for the drive units is switched off.

an error message is generated to the main computer,

which presents it on the programming unit.

CK 0901500E Aug 1985 8:34

85.6
Floppy disk interface
Floppy disk handling can be divided into six operations:

1. Storage of function parameters

2. Reading of function parameters
3. Storage of robot programs
4. Reading of robot programs
5. Supplementing with subprogram or complete mbot programs
6. Formatting of floppy disk

A brief description follows of the tests of memory size etc.,

programmed with each of these operations.
Certain tests of the communication RAM - Floppy disk are also
performed. When an error is detected, the text DISK MEM FAULT
is presented on the programming unit, followed by an error code
indicating the nature of the error and the communication with the
disk ceases.
Communication RAM - Floppy disk
With each transmission, the status register of the control unit for
the floppy disk is read. The bits S2 - S4 and S6 - S7 are reflected
in the error code. When a disk is loaded from the RAM and a
COMPARE is performed detecting an error, the error code “NOT
EQUAL BYTE” is presented.
The error code is stored internally as bioriented data after each
data transmission. A conversion to binary data is then performed
and the error code is given as the number of the lowest bit set.
Storaqe of function parameters

No special tests.

Readinq of function parameters

A check sum is calculated and compared with the last sum stored
in the function parameters.
Storaqe of robot proqram

A test is performed first to check if the first word in the heading

of the disk contains the number 24077. This indicates that the disk
has been used previously. If this is not the case, the disk is
cleared. If the disk has been used previously, a test is performed
to check if sufficient vacant accommodation remains.
If a CRC error, i.e. a voltage failure, is detected when the disk
heading is stored, this is cleared and an error code is generated.
The storage operation must then be repeated.

CK 09.1500E Aug 1985 8:35

 Readinq of robot proqram
The first word in the disk heading is checked to see if it contains
the number 24077, i.e. if it has been used before. If such is not the
case there is no program to read and an error code is generated. If
reading is commanded from the system, a search is first made for
the program. If no program is found, an error code is generated. If
reading is commanded from the programming unit, the program
number is sought first. If this is not found, an error code is
generated. The length of the program is compared with the length
of the robot program currently in the RAM memory. If it is too
large, an error code is generated. A check sum test is performed
after the reading.
Supolementinq of robot proqram

The heading of the disk is first checked to see if it contains the

number 24077, which indicates that it has been used previously. If
this is not the case, there is no program to read and an error code
is generated.

A search is made for the required program number. If this is not

found, an error code is generated. A test is made to see if the
space available in the mbot program in the RAM, is at least 256
bytes, i.e. one sector. If such is not the case, an error code is
generated. e
After the heading of the mbot program is read into the vacant
area, a check is made to see if the required robot program, when
packed in the RAM, is accommodated in the vacant area. If the
vacant area is not sufficient, an error code is generated. The
program pointer is updated after the entry of the robot program.
If a subprogram is to be supplemented, and cannot be found, an
error code is generated. A new check sum is calculated and this is
stored in the program heading. If any error is detected during the
supplementing of a program, the heading of the vacant area is
written back to its original state.
Formattinq a floppy disk

After each formatted track, a check is made to see if the write

buffer is empty. If this is not the case, an error signal is
generated.

CK 09.1500E Aug 1985 8~36

8.3.7
PD-BWB canmunication

The following tests are performed at power-on.

The PD-master starts its test program which includes the follow-
ing:
0
test of local PROM (check sum)
0 test of local RWM

When the test results are approved, LED F@ extinguishes.

The PD-handler che&s the result of the PD-master’s test program

by reading in the W-master’s memory. A check is made at the
same time that the PD-master ls located correctly and has the
correct address. If the result of the check is negative, the LEDs
under Cl-l@ remain extinguished.

If the result of the test is positive, the PD-handler continues its

testing of the communication between master and handler. (A
message ls sent from the handler to the master and is acknow-
ledged by the master.) The PD-master’s Poll Table is then
initialized. (Time gaps between polling, unit address and similar
are transmitted to the PD-master.) All of the LEDs under
CH@will then flash. If there ls any malfunction, the LEDs will
extinguish, otherwise the PROM polling of the programming unit
will begin.
If the polling is successful, the LEDs Cl-@/A and Cl-@/6 will
flash at high frequency, this appearing as a steady illumination. If
the polling is not successful, the cmtact with the programming
unit is lnterr@ed for other reasms than those given above, ag.
the pmgmmming unit is not cmnected. All of the LEDs under
Cl-i@ will then flash with a frequency of appmx. 1.5 s. The PD-
handler will make repeated attempts to restart the system.
While the polling Femains unsuccessful, the programming unit will
present “PROG UMT COMMUNICATION FAULT”, if it is cm-
netted and functioning correctly. If it is not so, the pmgmmming
unit resident test program &ould be run.

CK 09015ooE Aug 1985 B37

 8.4
Check of robot axis servo performance
I
I General
Before testing axis servo performance prefer to do a tachometer
I

control in the following order:

Make a program in robot coordinates with the speed

V = 500 mm/s9 MAX 1000 mm/s.
The program shall be performed in such a way that each axis
can be operated, one at a time, in forward and return motion.
0 The operation speed shall be 100 %.
0 The tachometer signal is measured with an oscilloscope
connected to test output marked TACHO on the drive unit
frame.

The tachometer signal is checked on one axis at the time

with start on axis 1.
0 The signals shall be the following

IRB model Level Ripple, max

IRB 612, axes l-5 4.5 V a.25 V 350 mVpp

IRB L6/2, axes l-5 4.5 V 9.25 V 350 mVpp
IRB G6/2, axes l-5 4.5 V LO.25 V 350 mVpp
Third wrist motion 4.1 V 9.25 V 10% of tacho voltage

IRB 60/2, 5 axes 4.5 V 9.25 V 400 mVpp

IRB 60/2, 6 axes 4.5 V 9.25 V 400 mVpp

IRB 90/2, axis P 4.0 v LO.15 v 200 mVpp

IRB 9012, axes 2-f 4.5 V LO.15 V 350 mVpp
IRB 90/2, axes 4-6 4.5 V LO.15 V 200 mVpp

IRB 1000 4.5 v 2.0 % 5% of tacho voltage

-
The axis control is described in Chapter 5.
The speed control for the robot axes are implemented in hardware
with tachometer feed-back.
The performance can be checked by making test runs, recording
the result and comparing it with typical diagrams.

Required equipment:
0 Test adapter
Chart recorder, 25 - 125 mm/s, e.g. Brush 220

I
I CK 0901500E Aug 1985 8~38
 Preparations

For making the test runs, test program 8 on the test adapter is
used. Read the running instructions for this thorougly in
Chapter 9.
Fit the test adapter to rack position 014.181 and connect (at
X100) 2 15 V power supply.
Connect the chart recorder as follows:
Axis Channel 1 Channel 2
Velocity signal Current signal
-- --------------I---------------
022.113 TACHO 022.113 I
2’ 022.125 TACHO 022.125 I
3 022.137 TACHO 022.137 I
4 022.149 TACHO* 022.149 I
5 022.161 TACHO* 022.161 I
6 022.173 TACHO* 022.173 I
4 014.181 U2** 022.149 I
S 014.181 U2** 022.161 I
6 014.181 U2** 022.173 I
-------u--u------------------------

*Axes 4-6 on all IRB models, except for IRB 90/2.

**Axes 4-6 for IRB 90/2.
All signals are referenced to COM (0 V) on corresponding servo
board.

CK 09-1500E Aug 1985 8:39

 Trouble shootinq
The axis does not start at all
---------u-------------------
Use test program 8.5 to look up .error messages. Look for the
primary fault by looking back in the table. Note that CON-
TACTOR almost always is a secondary “fault”.

JAM can have several causes. It is indicated if the motor does not
start, even if the regulator tries with maximum current.

Look for:
m drive unit control board fault
power stage fault
B open motor connection
short-circuited motor connection
m short-circuit in the motor
w mechanical fault
brake fault including brake supply, connection and the brake
itself

The axis runs awg-

-w--------------
Look forz
0
drive unit control board fault
0 power stage fault

Abnormally w-h2h ------------------------m

e--w---w--- current at constant speed

Look for” a mechanical problem. The current level corresponds to

the friction.

Signs
-w of instability
--------------
Look for.
drive unit control board fault
a mechanical problem such as back-lash

CK 09-1500E Aug 1985 8:40