Robots — troubleshooting procedures

Step-by-step procedures, calibration guides, and troubleshooting for industrial robots.

18 published procedures.

• Universal Robots e-Series — Protective Stop Recovery

  A UR e-Series Protective Stop shows a red PolyScope popup naming the safety function that tripped. Read the reason, remove the cause, then unlock and restart — and use Recovery mode if a joint is out of limits.

• Yaskawa Motoman Alarm 4107 — Out of Range (ABSO Data)

  Motoman alarm 4107 OUT OF RANGE (ABSO DATA) means the controller's stored absolute position no longer matches the encoder — usually an encoder battery, cable, or a robot moved with power off. Recover the absolute data carefully.

• ABB IRC5 — Revolution Counter & SMB Battery

  An ABB IRC5 robot that comes up with error 20032 'Revolution counter not updated' has lost its axis position memory — usually a flat SMB battery or an unclean power-down. Learn to read the event log, replace the SMB battery, and re-update the revolution counters.

• Kawasaki E Controller — Motor Power Won't Turn On

  On a Kawasaki E-series controller, Motor Power that won't energize is usually an emergency stop, an overtravel switch, or a Cubic S safety fault — not a dead drive. Work the safety chain, then read the error code.

• Denso RC8 — Reading the Error Log & Encoder Reset

  The Denso RC8 controller logs up to 1000 timestamped errors with a level and detail. Read the code and level first — and know the encoder-reset + CALSET path when a dead battery or motor swap erases position data.

• Stäubli CS8C/CS9 — ESB1-2 Safety Chain Open

  A Stäubli ESB1-2 error means part of the external safety chain is still open, or the two redundant safety channels disagree. Find the open input in the cell wiring before you can re-enable the arm.

• Epson RC700 — E-Stop / Safeguard Recovery & Dynamic Brake

  When an Epson RC700 drops to servo-free with dynamic braking, it's an emergency stop, a safeguard input, or one of a defined list of servo faults. Read the EPSON RC+ status code, clear the cause, then cancel the stop.

• Doosan Cobot — Collision Stop & Safety Recovery

  When a Doosan cobot detects a collision it does a Floating Reaction then a Safe Operating Stop. Clear the obstruction, recover, and if it keeps tripping, review the collision sensitivity and stop mode.

• Nachi FD/CFD Controller — Errors, Alarms & Reset

  A Nachi FD/CFD controller separates faults into Errors (E) that stop the robot and turn the servo off, and Alarms (A) that stop it temporarily. Learn to read the code on the pendant, clear it, and recover from the common "step number not designated" alarm.

• Hyundai Hi5/Hi6 Robot — Reading & Clearing Alarms

  A Hyundai Hi5 or Hi6 robot reports every fault on the teach-pendant taskbar with an error code, a message and a timestamp. Learn to capture that information, find the real cause, and clear the alarm the right way instead of just acknowledging it.

• Omron Adept Cobra/Viper — Faults & ACE Diagnostics

  Omron's Adept-derived Cobra and Viper robots are configured and diagnosed in ACE, with faults logged by the V+ operating system. Learn to read the V+ log, recover from an E-stop / high-power lockout, and work the common amplifier, encoder and tool-config faults.

• KUKA KRC4 Safety Stop Acknowledge & Recovery

  Recover a KUKA KRC4 robot from a Safety Stop (SS1/SS2) message: find the open safety input, physically restore the circuit, then acknowledge on the smartPAD and re-enable drives.

• Comau C5G — DRIVE OFF on DRIVE ON & Alarm Codes

  When a Comau C5G robot drops to DRIVE OFF the moment you try to power it up, the controller is reporting a motor/encoder problem. Learn to read the C5G message format, find the real first-cause alarm, reset the state and re-issue DRIVE ON.

• Dobot Magician — Alarms & Studio Connection

  A Dobot Magician turns its indicator red when an alarm is active — out-of-workspace, joint overspeed, a sensor read fault or an MCU/FPGA init failure. Learn what each means, how to Clear Alarms in Dobot Studio, and how to fix a Studio connection that won't open.

• Mitsubishi MELFA CR750 — Error Levels & Reset Recovery

  MELFA robot errors carry a level prefix (H, L, C) that tells you how to recover. Learn which errors clear with the ERROR RESET button and which require a controller power cycle.

• Techman TM Cobot — E-Stop & Encoder Standstill Recovery

  A Techman TM cobot signals its state through the mode-indicator light ring. Release the E-stop and watch it change from red to blue; recover an Encoder Standstill (Cat. 0 stop) by power-cycling from the robot stick.

• FANUC SRVO-021 SRDY Off Alarm Recovery

  Diagnose and clear the FANUC SRVO-021 "SRDY off" servo alarm — from checking the 3-phase amplifier supply to correcting the FSSB amplifier configuration after a controller reload.

• Robot Synchronization in Safety Mode — ABB SafeMove Procedure

  Step-by-step procedure to synchronize an ABB robot in SafeMove safety mode using the FlexPendant. Covers PPE, manual mode selection, SYNCRO routine execution, axis verification, and return to automatic mode.