*ADC dead* Jt (n)

Defective boards

Replace boards in the following
sequence, checking if problem
priests after each replacement

1 Digital servo board for
indicated joint
2 "B" interface board
3 "A" interface board

Replace faulty board

*ARM POWER off*

a ARM POWER is not
turned on

b System malfunction

a Turn on ARM POWER and
reenter last command

b See Symptom in Table 5-2
(ARM POWER does not come on)

*BAD POT Jt n*

a Faulty calibration

b Dirty or dry
potentiometer

c Faulty potentiometer 
in indicated joint

d Faulty PC boards

a Run DIA POTCAL.  Create
overlay as required

b Clean and lubricate potentiometer

c Replace entire motor assembly
on indicated joint

d Check seating.  Replace
boards in the following
sequence and check problem
after each step:

1 Servo Interface board
3 Parellel interface board
3 Digital servo board
Exchange boards to isolate fault
4 LSI-11 processor board

Replace faulty board

*Brake release
enabled

a Top panel switch
enabled

b Faulty toggle
switch


c Faulty PC
boards

a Move switch to OFF 
position

b Check switch for continuity;
replace switch tray is faulty

c Check seating.  Replace
boards in the following
sequence and recheck problem
after each step:

1 Power amplifier control
board
2 High power function 
assembly (Call RP Automation)
3 Servo interface board
4 Parallel interface board

Replace faulty board

*Calibration 
will move our 
of range*
Jt n 

Arm to close to
end of range

Reposition arm using teach pendant 
in JONT mode and repeat CALIBRATE command

*CHECKSUM Error*

a diskette is use is 
defective

b Defective or loose floppy
drive connector



c Board(s) not securely seated


d Defective
board(s)

a Attempt same procedure
using known good diskette

b Check connection floppy drive
if connection good
check continuity of cable
Replace cable id necessary

c Check boards in card cage
for proper seating

d Replace boards in the following 
sequence, checking if problem persists 
after each replacement

1 Quad serial interface
(DLV11-J)
2 LSI_11 microprocessor
3 Clock/terminator board
4 EPROM

Replace faulty board

*CLOCK OVERRUN*

a Defective clock
board

b Defectgive LSI-11
board

c LSI-11 affected 
by electrical
noise

a Replace defective board


b Replace defective board


c Ensure all covers correctly
installed

*Directory Error*

a Incorrect disk,
not properly 
installed, or
not formatted

b Damaged disk

a Make sure correct diskette 
is used, it is properly 
installed in drive, and it is
properly formatted

b Replace disk

*[FATAL]
ADC DEAD*
JT n

Defective 
board(s)

Replace boards in the following 
sequence, checking if problem persists 
after each replacement

1 Digital servo board
for affect joint
2 servo interface board
3 Clock/terminator board

Replace faulty board

*[FATAL] CPU
ERROR*
TRAP TO nn
FROM nnnnnn

a Electrical noise
on lines








b Defective 
board(s)

a isolate all high power or
high frequency lines as 
far from robot as practical
In some rare instances 
such lines may require
additional shielding 



b Replace boards in the following 
sequence, checking if problem persists 
after each replacement

1 LSI-11 microprocessor
board
2 EPROM board
3 CMOS board

Replace faulty board

*[FATAL]
Envelope error*
Jt (n) 

a Minor joint degeneracy 
occurs when Jt5 
is near o degrees,
therefore aligning 
axes of Jt4 and Jt6
Error occurs as VAL 
a temps to reposition Jt4 and 6
simultaneously for
tool orientation


b Major joint usable to 
maintain position
along path of motion













c Major joint
runaway



















d Minor joint 
runaway

















e Joint stalled

f Major joint 
drop

a Reprogram arm;  include offset 
in Joint 5








b Ensure That payload (including 
tooling) is within 
specified limits.  Place affected joint 
in FREE mode; ensure that brake is 
not dragging, and thatthere is no binding 
of gears or bearings.  Replace
power amplifier board and 
retry move

WARNING
Before proceeding to item b
ensure that arm is properly 
supported prier to releasing 
joint brakes in FREE mode.  
Failure to mechanically support 
the arm will result in arm collapsing

c Check electrical connections of 
affected joint Check cables for 
connections of affected hone Check 
cables for continuity replace if faulty
Replace components in the 
following sequence and recheck
problem after each step:

1 Digital servo board 
Exchange boards to 
isolate fault
2 Servomotor
3 Power amplifier
4 Low power interconnect cable
5 Arm harness 
call RP Automation
6 Arm cable board
call RP Automation

Replace faulty component

d Check electrical connections
of affected joint
Check cables for continuity; 
replace if faulty  Replace 
components in the following 
sequence and recheck problem 
after each step:

1 Digital servo board
2 Servomotor
3 Power amplifier
4 Low power interconnect cable
5 arm harness
call RP Automation
6 Arm cable board
call RP Automaton

Replace faulty component

e Free joint of restraint

f Check electrical connection 
of affected joint
Check cables for continuity; 
replace if faulty Replace 
components in the following 
sequence and recheck problem 
after each step

1 Power amplifier
2 Low power interconnect cable
3 Arm harness 
call RP Automation
4 Digital servo board
exchange boards to isolate fault

Replace faulty component

[FATAL]

NOTE
When [FATAL]  appears on screen
it indicates that a sufficiently
serious problem had
developed to cause
the operation system to 
shut down.  For possible
system look up message
alphabetically
following word [FATAL]

*Function timeout*
Jt n 

a Robot is blocked
and cannot reach
its destination

b Arm has run into a 
software/hardware stop


c Current overload 
circuit tripped




d Motor potenti-
ometer not prop-
erly zeroed 
(possible loosed 
potentiometer cap).


e Joint stalled,
 arm unable to 
move to program-
med location.



f Faulty electric
al interconnec-
tion.




g Faulty PC 
board(s).

a Turn on ARMPOWER and try
motion again


b Change program steps or 
locations as necessary to 
avoid hardware stops

c Shut system down and allow 
a few moments for cooling.
If problem persists, look 
for shorts using standard 
short isolation routines.

d Check potentiometer voltage
using procedure found in 
Appendix A.  If necessary, 
zero potentiometer.



e Inspect operating envelope
for physical barriers.
Inspect drive train for 
mechanical problems. 
Inspect servomotor brake 
systems.

f Check seating of ribbon
cable interconnecting parallel
interface board and servo 
interface board. 
Replace ribbon cable if 
faulty.

g.Check seating.  Replace
boards in the following
sequence and recheck prob-
lem after each step.

(1) Digital servo board.
      Exchange boards to
      isolate fault.
(2) Servo interface board.
(3) Parallel interface board.

Replace faulty board.

*Initialization error*

a. Current overload
    circuit tripped.




b. Board(s) not
    securely seated.

c. Defective 
    board(s).








d. Blown fuse in 
low voltage 
power supply

a. Shut system down and allow
a few moments for cooling. 
If problem persists, look
for shorts using standard
short isolation routines.

b. Check boards in card cage
for proper seating.

c. Replace boards in the fol-
lowing sequence, checking 
if problem persists after 
each replacement.

(1) Clock/terminator board.
(2) EPROM board.
(3) Quad serial interface
board.

d. Check connector P23 at
CRT/TTY for following 
voltage levels:

(1) Pins 3 & 5 = +12 vdc.

(2) Pins 1 & 5 = -12 vdc.

(3) Pins 4 & 5 = +5 vdc.

NOTE

Lack of voltage readings 
are indicative of a blown 
low voltage power supply 
fuse.  Replace fuse if 
necessary.

*[FATAL] Lost 
encoder sync*
Jt (n)  

a. Defective 
encoder light
source.

b. Faulty encoder 
disk.

c. Faulty digital 
servo board.


d. Faulty arm cable 
assembly.



e. Electrical 
noise.

a. Replace motor on affected 
joint.


b. Replace motor on affected 
joint. 

c. Check seating.  Exchange 
boards to isolate fault. 
Replace faulty board.

d. Check seating; replace
assembly (call RP Automation 
Field Service for assis-
tance).

e. Install shield from inter-
connecting cable.

*Memory error*
loc nnnnnn

a. Operator error.




b. Weak CMOS 
batteries.



c. CMOS board 
defective or not 
seated securely. 

a. Check that no attempt has 
been made to store data 
beyond the capacity of the 
CMOS memory.

b. Check CMOS battery charge. 
Replace batteries if nec-
essary.

c. Check to ensure secure 
seating of CMOS board. 
Replace defective CMOS 
board.

*HARDWARE
DEFECT*

a Temperature
fault


b Faulty power
amplifier



c Faulty power
amplifier
control board

a Turn system off and allow
time for cooling; then
reinitialize

b inspect controller top
panel and power amplifier
If power amplifier assembly
is faulty, replace

c Check seating; replace 
board if faulty

*[FATAL] MOTOR
STALLED* Jt (n)

Robot arm 
restrained from
moving to pro-
grammed position.

Free arm of restraint.

*No zero index*
Jt (n)  

a. Defective digi-
tal servo board.


b. Defective
encoder. 

a. Replace defective digital 
servo board of affected joint.

b. Replace motor of affected 
joint. 

*Out of range*
Jt (n)

a. Arm outside of 
or adjacent to 
robot arm oper-
ating envelope.

b. Faulty poten-
tiometer.




c. Faulty electri-
cal interconnec-
tion 



d. Faulty PC
 board(s).

a. Reposition arm.




b. Exchange harness connec-
tions to isolate servo-
motor.  Clean and lubricate 
potentiometer.  Replace 
servomotor if faulty.

c. Check cables for contin-
uity; replace if faulty.
If arm harness is faulty, 
Call RP Automation Field Ser-
vice.

d. Check seating.  Replace 
boards in the following 
sequence and recheck prob-
lem after each step:

  (1) Servo interface board.
  (2) Parallel interface board.
  (3) Digital servo board
   Exchange boards to 
isolate fault.  
  (4) LSI-11 processor board.

*40V POWER
DEFECTIVE*

a. Blown fuse on
high-power func-
tion assembly.

b. Faulty PC 
board(s).

a. Replace fuse.



b. Check seating.  Replace 
faulty boards in the fol-
lowing sequence and re-
check problem after each 
step:

(1) Power amplifier 
assembly.
(2) Power amplifier con-
trol board. 
(3) High-power function 
board (call RP Automation 
Field Service for 
assistance).

Replace faulty board. 

*[FATAL] SERVO
DEAD* JT n

a. Current overload 
circuit tripped. 




b. Overheated 
amplifier.








c. Defective motor.



d. Defective
encoder.

e. Faulty elec-
trical connec-
tion.




f. Faulty PC 
board(s). 

a. Shut system down and allow 
a few moments for cooling. 
If problem persists, look 
for shorts using standard 
short isolation routines.

b. Shut system down and allow 
a few moments for cooling. 
If problem returns after a 
short running period, the 
ambient temperature may be 
at fault and it may be nec-
essary to consider non-
standard cooling procedures 
for the robot. 

c. Replace motor on affected
joint.

d. Replace motor on affected
joint.


e. Check seating of ribbon 
cable connecting Servo 
interface board and Parallel 
interface board.  Replace 
ribbon cable if faulty. 


f. Check seating.  Replace 
boards in the following 
sequence and recheck pro-
blem after each step. 

(1) Digital servo board.
(2) Parallel interface board.
(3) Servo interface board.

*[FATAL] SEVO
RAM ERROR*
Jt (n)

Faulty digital 
servo board.

Check seating.  Exchange 
boards to isolate fault.  
Replace faulty board.

*PROM ERROR*
BANK n

a Faulty EPROM
chip





b Defective EPROM 
board

a Remove EPROM board and 
inspect ships for broken
or bent pins.  Ensure all 
ships are securely seated
Replace affected ship if
necessary

b Replace defective EPROM 
board