Installation and Commissioning

Fault tracing guide1 Fault tracing guideSometimes errors occur which neither refer to an error message nor can be remediedwith the help of an error message.To make a correct error diagnosis of these particular cases, you must be very experiencedand have an in-depth knowledge of the control system. This section of the ProductManual is intended to provide support and guidance in any diagnostic work.1.1 Starting Troubleshooting WorkAlways start off by consulting a qualified operator and/or check any log books availableto get some idea of what has happened, to note which error messages are displayed,which LEDs are lit, etc. If possible, look at the control system’s error log; if there areany error messages there, it can be accessed from the Service menu. On the basis ofthis error information, you can start your analysis using the various tools, test programs,measuring points, etc., available.Never start off by wildly replacing boards or units since this can result in new errorsbeing introduced into the system.When handling units and other electronic equipment in the controller, the wriststrap in the controller must be used to avoid ESD damage.1.1.1 Intermittent errorsUnfortunately, intermittent errors sometimes occur and these can be difficult to remedy.This problem can occur anywhere in the robot and may be due to externalinterference, internal interference, loose connections, dry joints, heating problems, etc.To identify the unit in which there is a fault, note and/or ask a qualified operator to notethe status of all the LEDs, the messages on the teach pendant, the robot’s behaviour,etc., each time that type of error occurs.It may be necessary to run quite a number of test programs in order to pinpoint theerror; these are run in loops, which should make the error occur more frequently.If an intermittent error occurs periodically, check whether something in the environmentin which the robot is working also changes periodically. For example, it may becaused by electrical interference from a large electric plant which only operatesperiodically. Intermittent errors can also be caused by considerable temperaturechanges in the workshop, which occur for different reasons.Disturbances in the robot environment can affect cabling, if the cable screen connectionsare not intact or have been incorrectly connected.1.1.2 ToolsUsually, the following tools are required when troubleshooting:- Normal shop tools- Multimeter- Oscilloscope- RecorderProduct Manual 3