18. Appendix

18.1. Appendix 1: Motion controller errors and handling methods

Error classification	Error name(teaching pendant display)	Handling method	Post processing operation
Command point error	Joint command point error	1.Check whether the command point is wrong; 2.Check whether the tool is consistent with the recording of instruction points; 3.Record the instruction points again and modify the teaching program.	Check and confirm. After modifying the program, click the START button again to execute the new program.
	Straight line target point error
	Arc middle point error
	Arc target point error
	The arc command point spacing is too small
	Error in middle point 1 of whole circle/spiral line (including tool discrepancy)
	Error in the middle point 2 of the whole circle/helix (including tool discrepancy)
	Error in middle point 3 of whole circle/spiral line (including tool discrepancy)
	The command point spacing of the whole circle/helix is too small
	TPD command point error
	The TPD command tool does not match the current tool
	TPD The deviation between the current instruction and the starting point of the next instruction is too large	1.Check whether the starting point of TPD track is recorded, and whether there is a motion command (PTP/LIN) moving to the starting point of TPD track before the TPD command in the teaching program; 2.Modify the teaching program.	/
	Internal/external tool switching error	Record the instruction points again and modify the teaching program.	/
	PTP joint command overrun	The movement process command exceeds the soft limit, and the program needs to be modified.	Reverse inching to make the robot leave the soft limit area or switch to the dragging mode to drag the robot out of the soft limit area; After modifying the program, click the START button again to execute the new program.
	TPD joint command overrun
	LIN ARC issued joint command overrun
	JOG joint command overrun
	Command overspeed in Cartesian space	The instruction has problems.	Contact after-sales personnel.
	Torque command overrun in joint space		/
	Command speed in joint space of axis 1-axis 6 exceeds the limit		/
	The joint configuration of the next command changes (there are singular positions in the next command)	Modify the teaching program. When the movement stops, the next program of the current line is modified to PTP command.	/
	The joint configuration of the current command has changed (there is a singular pose in the current command)	1.In the automatic mode, modify the teaching program. When the movement stops, the current program is modified to PTP command; 2.In the manual mode, switch the joint coordinates after power on again and then jog.	/
	Instruction error, only LIN and ARC instructions are allowed between ARCSTART and ARCEND	Check the instruction and modify the teaching program.	/
	Instruction error, only LIN instruction is allowed between WEAVESTART and WEAVEEND		/
	Swing welding parameter error	Check the swing welding parameters and modify the teaching program.	/
	Laser sensor command deviation is too large	Use the laser sensor supporting software to check whether the laser sensor data has jumps.	/
	The laser sensor command is interrupted, and the seam tracking ends in advance	Use the laser sensor supporting software to check whether the laser sensor data is interrupted.	/
	External axis command speed overrun	The instruction has problems.	Contact after-sales personnel.
	Excessive deviation between external axis command and feedback
	Belt tracking - excessive attitude change between starting point and reference point	Recalibrate the position and attitude points of the conveyor belt.	/
	Constant force control - (X, Y, Z, RX, RY, RZ) direction exceeds the maximum adjustment distance	Adjust the constant force control PID value and modify the teaching program.	/
Drive failure	1-6 axis driver fault	If the drive fails, check the drive failure table and check the cause of the drive failure.	Power on again.
Out of soft limit	1-6 axis out of soft limit fault	The movement exceeds the soft limit.	Switch to the dragging mode and drag the robot away from the soft limit area.
Collision fault	1-6 axle collision fault	Collision during movement.	Check the cause of collision, and click the RESUME button on the teaching programming interface when it is necessary to start movement again.
File error	Wrong version of zbt configuration file	The version of the zbt.config configuration file is incorrect.	Contact after-sales personnel.
	The zbt configuration file failed to load	Error loading the zbt.config configuration file.	Power on again, and contact after-sales personnel if the error is still reported.
	User profile version error	Error loading the user.config configuration file	Power on again, and contact after-sales personnel if the error is still reported.
	Incorrect version of exaxis configuration file	The exaxis.config configuration file version is incorrect.	Contact after-sales personnel.
	Failed to load exaxis configuration file	Error loading exaxis.config configuration file.	Power on again, and contact after-sales personnel if the error is still reported.
	The robot model is inconsistent and needs to be reset	/	Contact after-sales personnel.
IO error	Channel error	Check whether the IO command channel in the program is set incorrectly	Check and confirm. After modifying the program, click the START button again to execute the new program.
	Value error	Check whether the IO command value in the program is set incorrectly
	WaitDI wait timeout	Check whether there is effective input signal
	WaitAI waiting timeout
	WaitToolDI wait timeout
	WaitToolAI wait timeout
	Channel configured function error	The function of the current channel has been configured, which cannot be used in teaching and programming. It needs to be replaced with another channel.	The function of the current channel has been configured and cannot be used in teaching programming, so it needs to be replaced with another channel.
	Arc striking timeout	Check the successful arcing signal.	/
	Arc extinguishing timeout	Check the successful arc extinguishing signal.	/
	Location finding timeout	Adjust the locating parameters and modify the teaching program.	/
	IO detection timeout of conveyor belt, resettable	Check IO trigger signal.	/
	Successful arc striking DI not configured	Check the DI configuration	/
Jaw error	Jaw movement timeout error	Waiting for the signal of gripper movement completion timeout.	Contact after-sales personnel.
	485 timeout	/
	Command format error	/
	Movement delay, must be activated before movement	/
	When moving, the active bit must be active	/
	Temperature too high	/
	Voltage too low	/
	Automatically releasing	/
	Internal fault	/
	Activation failed	/
	Overcurrent	/
	Automatic release end	/
Warning	Changes in shoulder joint configuration	Not yet implemented.	/
	Changes in elbow joint configuration		/
	Wrist joint configuration changes		/
	RPY initialization failed	Initialization of RX, RY and RZ fails, and the mobile robot makes RY not equal to ± 90 °.	After moving the robot, power on again.
	After 1 min, switch to the general teaching mode warning	/	/
Wrong number of active slave stations	Wrong number of active slave stations	If the slave station has an error, check whether the EtherCAT cable is normal	Power on again, if not solved, contact after-sales personnel.
Slave error	Drop line from station
	Slave status is inconsistent with the set value
	Slave is not configured
	Slave configuration error
	Slave initialization error
	Slave mailbox communication initialization error
Safety door warning	Safety door triggered	/	/
Motion Warning	LIN command attitude changes too much	Not yet implemented.	/
Interference zone warning	Enter the interference zone	/	/
Parameter error	Tool number overrun error	Export the backup package	Contact after-sales personnel
	Positioning completion threshold error
	Crash level error
	Load weight error
	Load centroid (X, Y, Z) error
	DI filter time error
	AxleDI filter time error
	AI filtering time error
	AxleAI filtering time error
	DI high and low level range error
	DO high and low level range error
	Workpiece number overrun error
	External axis number overrun error
	Conveyor tracking - encoder channel error
	Conveyor tracking - workpiece axis number error
Eight point method	The attitude change of the first group of data is too large	Recalibrate.	/
	Data error, calculation failed		/
External axis out of soft limit fault	External axis 1-4 axis out of soft limit fault	The movement exceeds the soft limit.	Inch the external shaft in reverse direction to leave the soft limit area.
Teaching pendant (raspberry pi) communication	Communication between Webapp and teaching pendant (Raspberry Pie) failed	1.Check whether the teaching pendant (raspberry pie) needs to be enabled. If not, enter the Web page, system settings - general settings - teaching pendant settings, and turn off the teaching pendant to enable; 2.Check whether the teaching pendant (raspberry pie) is connected to the controller network cable normally.	/
Origin error	The origin has changed and needs to be reset	Enter the Web page, assist the application - robot body - operation origin, and reset the operation origin.	/

18.2. Appendix 2: Servo driver fault code table

Fault code	Fault name	Processing method
1	Software overcurrent fault	1. Check whether the joint load or resistance becomes larger or abnormal; 2. If the fault is still not eliminated, repair or replace the drive board.
2	Overvoltage fault	Reduce the speed or acceleration of the robot.
3	Under voltage fault	1. Check whether the 48V power supply voltage output of the control box is abnormal; 2. Check the drive plate and joint housing for short circuit; 3. If the fault is still not eliminated, repair or replace the drive board.
4	Overheating fault	Reduce the load or speed of the robot.
5	Overload fault	Reduce the load or speed of the robot.
6	Overspeed fault	1. Check whether the magnetic braiding assembly and the motor shaft fixing jackscrew are loose; 2. Re-perform encoder zero calibration; 3. If the fault is still not eliminated, repair or replace the magnetic editor assembly.
7	Parameter abnormal fault	Repair or replace the drive plate.
8	Runaway fault	1. Check whether the magnetic braiding assembly and the motor shaft fixing jackscrew are loose; 2. Re-perform encoder zero calibration; 3. If the fault is still not eliminated, repair or replace the magnetic editor assembly.
9	Position error fault	1. Check whether the joint load or resistance becomes larger or abnormal; 2. If the fault is still not eliminated, repair or replace the drive board.
10	Position overflow fault	1. Check whether the hard limit is loose; 2. Re-perform robot zero calibration.
11	Hardware overcurrent fault	Repair or replace the drive plate.
12	Drive inhibit fault	The robot is NOT enabled.
13	Motor locked rotor fault	1. Check whether the brake electromagnet is engaged; 2. Check whether the hard limit is hit; 3. If the fault is still not eliminated, repair or replace the drive board.
14	Power supply failure	The robot is NOT enabled.
15	STO fault	The robot is NOT enabled.
16	Phase current AD zero setting fault	Repair or replace the drive plate.
17	EEPROM fault	Repair or replace the drive plate.
18	Hall fault	1. Check whether the hall harness is inserted firmly and whether there is short circuit or open circuit; 2. If the fault is still not eliminated, repair or replace the joint.
19	Encoder failed	Repair or replace the magnetic braid assembly.
20	Encoder zero setting fault	1. Re-perform encoder zero calibration; 2. If the fault is still not eliminated, repair or replace the magnetic editor assembly.
21	Encoder Z-phase signal loss fault	The robot is NOT enabled.
22	Encoder count fault	The robot is NOT enabled.
23	Encoder multi turn data overflow fault	The robot is NOT enabled.
24	External clock fault	Repair or replace the drive plate.
25	UVW phase sequence fault	The robot is NOT enabled.
26	FPGA fault	The robot is NOT enabled.
27	Zero return fault	The robot is NOT enabled.
28	Magnetic encoder fault	1. Check whether the magnetic braiding assembly and the motor shaft fixing jackscrew are loose; 2. If the fault is still not eliminated, repair or replace the magnetic editor assembly.
29	Motor power line disconnection fault	1. Check whether the power line of the motor is firmly inserted, and whether there is short circuit or open circuit; 2. If the fault is still not eliminated, repair or replace the drive board.
30	EtherCAT fault	1. Check whether the network cable is firmly plugged, and whether there is short circuit or open circuit; 2. If the fault is still not eliminated, repair or replace the drive board
31	EtherCAT_SM_DOG fault	1. Check whether the network cable is firmly plugged, and whether there is short circuit or open circuit; 2. If the fault is still not eliminated, repair or replace the drive board.
32	EtherCAT_FATALSYNC failure	1. Check whether the network cable is firmly plugged, and whether there is short circuit or open circuit; 2. If the fault is still not eliminated, repair or replace the drive board.
33	EtherCAT_SYNC fault	1. Check whether the network cable is firmly plugged, and whether there is short circuit or open circuit; 2. If the fault is still not eliminated, repair or replace the drive board.
34	EtherCAT_RFT failure	1. Check whether the network cable is firmly plugged, and whether there is short circuit or open circuit; 2. If the fault is still not eliminated, repair or replace the drive board.
35	Drive shaft address fault	1. Re-configure the drive axis address; 2. If the fault is still not eliminated, repair or replace the drive board.
36	Robot zero calibration fault	1. Re-perform robot zero calibration; 2. First use JLINK to erase FLASH, then download the program again and zero; 3. If the fault is still not eliminated, repair or replace the drive board.
37	Encoder communication failure	1. Check whether the encoder harness is inserted firmly and whether there is short circuit or open circuit; 2. If the fault is still not eliminated, repair or replace the magnetic editor assembly.
40	Magnetic encoder module failure - zero calibration failure	1. Re-zero the magnetic braiding assembly; 2. If the fault is still not eliminated, repair or replace the magnetic editor assembly.
41	Magnetic encoder module fault - multi turn fault	1. Check whether the magnetic braiding assembly and the motor shaft fixing jackscrew are loose; 2. If the fault is still not eliminated, repair or replace the magnetic editor assembly.
42	Magnetic encoder module failure - multi turn small magnetic encoder failure	1. Check whether the multi turn small magnetic braiding chip is abnormal; 2. If the fault is still not eliminated, repair or replace the magnetic editor assembly.
43	Magnetic encoder module failure - multi turn large magnetic encoder failure	1. Check whether the multi turn magnetic braiding chip is abnorma; 2. If the fault is still not eliminated, repair or replace the magnetic editor assembly.
44	Magnetic braiding module fault - single turn magnetic braiding fault	1. Check whether the single turn magnetic braiding chip is abnormal; 2. If the fault is still not eliminated, repair or replace the magnetic editor assembly.
45	Magnetic encoder module failure - optical encoder failure	1. Check whether the optical coding disc is polluted or not stuck; 2. If the fault is still not eliminated, repair or replace the magnetic editor assembly.

18.3. Appendix 3: End plate 485 upgrade

During field use, it is possible to update the firmware to meet the new requirements. A new upgrade file (XX_XX_MAIN. bin) will be provided to upgrade the terminal board through the 485 interface (USB to 485 module is required). The upgrade steps are as follows:

Step1: 485 wiring. There is a 5Pin communication aviation connector at the end of the robot. The pin pin distribution and pin pin description of the aviation connector are shown in Fig. 1.Connect the 485 - A and 485 - B at the end of the robot with A and B of the USB to 485 tool using twisted pair cables.

Figure 18.3-1 Pin Pin Distribution of Aviation Connector

Step2: hardware connection. connect the USB end of the USB to 485 tool to the PC, and in the PC device manager, if the USB&485 tool is identified, the following interface will appear.

Figure 18.3-2 USB&485 Port Identification Description

Step3:Upgrade the tool. After the wiring is completed, open the “Fair Serial Port Debugging Assistant”, click the “Terminal Board” button, and select the above identified serial port in the “Serial Port Parameter Setting” function. The baud rate is 115200, the data bit is 8, the check bit is none, and the stop bit is 1. Then open the serial port. After success, the prompt “Serial port opened successfully” will appear.

Figure 18.3-3 Serial Port Parameter Settings

Step4:Firmware upgrade. Select “End plate” and click “Firmware upgrade”, as shown in the fig.

Figure 18.3-4 End Plate Firmware Upgrade

• First, click “Flash Erase”. After the erasure is successful, you will be prompted in the receiving data area that the erasure is successful.

• Open the file (the file to be upgraded), select the path to store it, as shown below. After the selection, the file name to be upgraded will appear in the file name display box.

Figure 18.3-5 Select Upgrade File

• Click “Send File”, and when the progress bar displays 100%, it means that the upgrade file has been sent.

Step5:Upgrade verification. The system is restarted and powered on. In the “Maintenance Information” column, select “Query terminal board firmware version information”, and the firmware version information will be displayed in the “Receive Data Area”. If it is consistent with the upgraded file version information, the upgrade is successful, otherwise the upgrade fails.

Figure 18.3-6 Querying Firmware Version Information

18.4. Appendix 4: Control Box 485 Upgrade

There is a “power communication” interface on the robot control box board, and USB&485 tools A and B are respectively connected to the “485-A” and “485-B” of its interface.

The upgrade process is the same as that of the terminal board, and the software can be selected accordingly, which will not be repeated here.

Figure 18.4-1 Power Communication Interface

18.5. Appendix 5: List of Spare Parts and Vulnerable Parts

Spare Part Name	Part No.	Quantity/piece(s)
M8 * 30 screw	4.0.08.2006185	4
Straight pin A type 8 * 20	4.5.00.2013076	2
Fuse 5x20 6A	/	1