Troubleshooting

SafeMove not calibrated: This error indicates that no SafeMove Configuration is available yet.

• Consequence: No possibility to use the robot in automatic mode. You can just jog the robot manually.
• Possible causes: no SafeMove Configuration is available
• How to avoid & solve:
• Load: user defined SafeMove Configuration + Synchronize SafeMove
• Load: the default
  

Safety controller not ready: An attempt to go to Motors on was rejected by the Safety Controller.

• 
• Consequence: The system goes to Guard stop state. Actions Check other elogs for more details. 
• Possible causes: Check if the robot with its tool center is in a safety zone (in the SafeMove window, see fig. below). 
• How to avoid & solve:
• Switch to manual mode and move the robot axis wise out of the zone.

Safety controller not synchronized: This error indicates that no SafeMove Configuration is available yet.

• Consequence:
• The supervision functions can only be active while SafeMove is synchronized. When unsynchronized, only manual mode operation with reduced speed is possible until synchronization is executed successfully.
• If SafeMove becomes unsynchronized, the robot will stop, and the Stand Still Supervision function will be deactivated. A movement with reduced speed is possible.
• Possible causes: no synchronization of SafeMove.
• How to avoid & solve:
  After setting or loading a SafeMove configuration, please synchronize the SafeMove: e.g. use “MoveAbsJ” to move the robot in the synchronization position. This position is identified in RobotStudio under the tab “Synchronization”. The default values of these angles are zero, but the user can customize them.

After using MoveAbsJ, from the FlexPendant, access with admin user:

Settings -> Safety Controller -> Synchronization.

Safety Controller Wrong Synchronization Position: The axis argument position does not match its synchronization position, as defined in the safety configuration for the safety controller on drive module argument available yet.

• Consequence: Synchronization will not be performed, and the safety controller will go to the unsynchronized state. If SafeMove becomes unsynchronized, the robot will stop, and the Stand Still Supervision function will be deactivated. A movement with reduced speed is possible.
• Possible causes: One or more axes are not in the correct synchronization position. The revolution counters or calibration values of the robot controller are not correct.
• How to avoid & solve:
• Check that the synchronization positions in the safety configuration are correct, and that all axes are in their synchronization position. Followed by a new synchronization of the safety controller. Check that the synchronization switch is working properly.
• Sometimes it is necessary to Reset the SafeMove Configuration. Two options:
  log in as Admin, than from RobotStudio -> Reset to Factory Settings.
  OR
  from the FlexPendant -> Settings -> Backup and Recovery -> reset user data -> reset safety settings
  

Safety Controller Automatic Mode Warning: This error indicates that no SafeMove Configuration is available yet or it has not been locked.

• Consequence: No possibility to use the robot in automatic mode. You can just jog the robot manually.
• Possible causes: The active safety controller configuration has not been locked OR Safe Configuration is missing.
• How to avoid & solve:
  or
  Please lock the configuration: log in as Admin -> settings -> Safety controller: tick on “Locked"

SafeMove violated -> Safety guard stop state: The system is in the Guard stop state. It enters this state either after switching from Automatic- to Manual mode, or after the Motors ON circuit has been opened by an Emergency Stop or Automatic Stop, or in Manual mode if Enabling device was released.

• Consequence: No operation will be possible until after closing the Motors ON circuit. The manipulator's axes are meanwhile held in position by mechanical holding brakes.
• Possible causes: Any safety device connected to the system's stop inputs have been opened. These are shown in the Circuit Diagram.
• How to avoid & solve:
  - Check which safety device caused the stop
  - Close the circuit.
  - To resume operation, switch the system back to state Motors ON.
  

Safety controller Servo-Lag Limit exceeded: Possible collision has occurred, than SafeMove will detect this and initiate a stop.

• Consequence: No operation will be possible until after closing the Motors ON circuit. The manipulator's axes are meanwhile held in position by mechanical holding brakes.
• Possible causes: possible collision has occurred.
• How to avoid & solve:
  - Please jog in manual mode the robot from the collision area

Motion supervision: Possible collision has occurred or the robot has entered a Safe Area.

• Consequence: No operation will be possible until after closing the Motors ON circuit. The manipulator's axes are meanwhile held in position by mechanical holding brakes.
• Possible causes: possible collision has occurred or robot has entered a Safe Area.
• How to avoid & solve:
  - Please jog in manual mode the robot from the collision/Safe area.

Safety controller Standstill violation: If the robot tries to move due to an error during active Stand Still Supervision, SafeMove will detect this and initiate a stop. Since there is a certain reaction time involved a slight jerk may occur.

• Consequence: No operation will be possible until after closing the Motors ON circuit. The manipulator's axes are meanwhile held in position by mechanical holding brakes.
• Possible causes: Someone forced the robot to move from the program causing possible collision.
• How to avoid & solve:
  - Please jog in manual mode the robot from the collision area.

Safety Controller Tool Force violation: Tool Force Supervision was violated in the safety controller for the drive module.

• Consequence: If configured with a stop action, the safety controller will stop all robot movements, and no operation will be allowed until the violation has ceased or manual mode has been selected.
   
  If “NoStop” is selected than you will get this event as a warning.
• Possible causes: The force acting on the tool exceeded the configured maximum value.
• How to avoid & solve:
  Switch to manual mode, and jog the robot out of the violation area.
   

Safety Controller Tool Speed Violation: Tool Speed supervision was violated.

• 
• Consequence: If configured with a stop action, the safety controller will stop all robot movements, and no operation will be allowed until the violation has ceased or manual mode has been selected.
• 
• Possible causes: The speed of the tool exceeded the configured maximum value.
• How to avoid this:
  - Switch to manual mode, and jog the robot out of the violation area.

Lead-Through doesn't work in Auto using ASI: Pressing the predefined ASI button the Lead-Through is not activating.

• Consequence: Not possible to activate the Lead-Through from the ASI buttons. 
• Possible causes: "Use buttons in auto mode" option not selected. 
• How to avoid & solve: 
• Click on the "ASI Setting" widget on the home screen (see first picture), then scroll all the way down until the checkbox "Use buttons in auto mode" appears (see second picture). This must be activated so that the ASI buttons, e.g. for lead-through, also work in auto mode.
• 
•  
OR
• Another procedure/option, different than the Lead-Through one, is selected.
OR
• Please switch off Robot and start it again
OR
• Safemove configuration + Synchronization is missing → ABB recommend to bring Robot in synchronization posItion.

Overspeed During teach mode: the robot will stop since some or all the joints exceeded the maxium speed allowed.

• 


• Consequence: No operation will be possible until after closing the Motors ON circuit. The manipulator's axes are meanwhile held in position by mechanical holding brakes.
• Possible causes: using the LT, the robot has been moved too fast.
• How to avoid & solve:
• Please jog in manual mode the robot from the collision/Safe area more smoothly.

• Consequence: Not possible to run the program.
• Possible causes: syntax errors in the RAPID program.
• How to avoid & solve: 
• Either go to the code window on FlexPendant and click on "check program" (see second figure, step 1). Then the detailed error message will be shown (see second figure, step 2).
• It is also possible to connect your Controller to RobotStudio and evaluate the RAPID code there.
• 

• Consequence: Not possible to use the FlexPendant.
• Possible causes: Errors in the starting of the FlexPendant OR different users try to log in, e.g. one user on the FlexPendant and another one on RobotStudio
• How to avoid & solve:
• Please select the 3 dots in the upper right part of the FP and press “Restart the application”.
  
OR 

• ❖ Shut down the robot
OR 

• ❖ Remove the main power plug from the controller
OR 

• ❖ Reconnect and restart
OR 

• ❖ Resetting the FlexPendant: there is a small reset button net to the USB slot, you might need a pen to press it.
OR 

• ❖ Reset the security communication certificates via robot studio.
OR 

• ❖ The FlexPendant should have fix IP: 192.168.125.250 but some have DHCP active  Please change the TPU's IP address to fixed in Windows on the TPU.