Haas Cobot Package - Troubleshooting Guide

Introduction

This document will show you how to troubleshoot your Haas Cobot. If you do not find the alarm or symptom on this document please perform the following and contact the service department.

Machine Serial Number.
Cobot Serial Number [1].
Error Report at time of alarm or issue. If possible, the cobot needs to be connected to the machine.
If running Robot scheduler jobs, need all the machine programs and robot jobs. Error report only saves the current programs.
Photos or video of issue.

Cobot and Haas Communication Alarms

These alarms and symptoms can happen when the machine and the robot are not communicating.

Alarm / Symptom	Possible Cause	Corrective Action
9147 Robot Protocol Version Mismatch	Connecting to a Cobot that has been power cycled may cause a Version Mismatch. This causes all Cobot functions to be locked until the alarm is cleared.	On the Haas pendant, navigate to Current Commands > Devices > Robot > Setup. Release the [E-STOP] and press RESET to clear the alarm. Then press the [E-STOP] and press F1 to connect the Cobot
9150.10017 Collision stop error	The Cobot's payload is incorrect set.	On the Haas pendant, navigate to Current Commands > Devices > Robot > Setup. Set the correct payload.
9150.10017 Collision stop error	The programmed speed is set higher than the security level's allowable speed. To view the allowable speed on the Cobot teach pendant, Navigate to Config > General Restrictions.	Lower the programmed speed to below the allowable speed displayed in the security setting. OR If the risk assessment allows for a security level increase, then increase the security level until the allowable speed exceeds the programmed speed.
9150.10055 Errors in Payload or RMS in the free drive state.	The Cobot's payload is incorrectly set causing the Cobot to move sporadically when in free drive state.	On the Haas pendant, navigate to Current Commands > Devices > Robot > Setup. Set the correct payload.
9150.40054 Robot in Emergency Stop State	The Cobot's teach pendant [E-STOP] was pressed.	Release the [E-STOP] on the Cobot teach pendant and press [RESET] on the Haas control to clear the alarm.
9155 ROBOT EXCEEDED MAX PAYLOAD	Cobot attempted to clamp a part which would result in exceeding the max payload allowed.	Reduce part weight. See layout drawings for the payload specifications for each Cobot size.
9156 ROBOT COMMAND FAILED, No subcode or other robot alarms.	Cobot software is outdated.	Make sure the Haas Cobot Software Version is 1.16 or higher. To check the Cobot software version, use the teach pendant. On the Setting screen, press System Upgrade to view the current software version.
	Cobot teach pendant [E-STOP] was pressed and the Haas control [RESET] was pressed.	On the Haas pendant, navigate to Current Commands > Devices > Robot > Setup. Press the [E-STOP] and then F1 to reconnect the Cobot to the machine. Release [E-STOP] and press RESET to clear the alarm.
9160 ROBOT EMERGENCY STOP	The Robot Emergency Stop button was pressed from the Cobot teach pendant.	From the Cobot teach pendant, release the E-STOP button and press reset to proceed. Navigate to the Run screen. On the top of the screen, press Open then Enable.
9160 ROBOT EMERGENCY STOP	The robot estop chain is broken.	Verify estop wiring (including external estop inputs) to Cobot are intact and correctly wired.
The Cobot won't connect to the CNC	The wiring from the interface box to the Haas Control is not correct.	Make sure you have connected the terminal connectors on TB-1B in the correct order. Refer to the Electrical Diagram section below.
	The Cobot is not unlocked and activated.	The first time connecting a Cobot to a machine, a Robot Activation window will pop-up. This pop-up shows the Software Version of the machine, the MAC address of the Cobot, and the Generated Code that is used in HBC to receive the unlock code. Once received, enter the Cobot's serial number and unlock code to activate the Cobot.
	The CNC software is outdated.	Make sure the Haas software is 100.23.000.1201 or higher.
	The Cobot IP address and the CNC are mismatched.	Make sure that both Haas and Cobot IP addresses are 10.72.65.82. Check the Haas IP address by searing Parameter 2262. Check the Cobot IP address by using the teach pendant. On the Settings screen, press Network to view the IP address.
	The arm moved during power off.	Reset each Cobot joint's zero position by following the Reset Cobot Zero Position procedure.
The Cobot won't connect to the CNC. Robot Connection Timeout message pops up on the Haas pendant.	The ethernet cable is defective or not connected.	Make sure the ethernet cable works by connecting it to an external device or using the Haas Cable Tester Kit. Connect the ethernet cable directly to the USB adapter on the main processor and then try reconnecting the Cobot to the Haas. If this works, the RJ-45 connector on the interface box is defective.
	The RJ45 to USB adapter is defective.	Make sure the USB cable is connected to the correct USB port on the main processor. Make sure that the user USB port works by plugging a USB device and determine if the USB device gets detected, if it does not get detected follow the USB Troubleshooting Guide and troubleshoot the USB Ports.
Cobot does jog but the grippers (and configured outputs if any) do not work.	The fuse on the Cobot control box is blown due to the terminal blocks installed incorrectly on the Haas I/O PCB.	Measure the continuity across the resistor on the fuse in the Cobot control box. Verify that there is no continuity. Replace the fuse with the spare or order 93-4053.Check inside the Haas control cabinet and make sure TB-1B and TB-3B are installed correctly. Refer to the Electrical Diagram section below.
Cobot does jog but the Cobot LED ring is not illuminate.	The End I/O Module on the Cobot is defective.	Measure the voltage across the Cobot's I/O port M12 connector pins 11 and 12. Verify that there is no voltage. Replace the End I/O Module on the Cobot.
Cobot does not jog. The Cobot LED ring is not illuminated but the robot icon on the Haas screen is green.	Cobot is blackout.	On the Cobot teach pendant, go to the Run screen. On the top of the screen, press Open then Enable.
Cobot does not jog in a straight line, It makes an arcing motion when moving in Cartesian along a single axis.	The Cobot joints were not lined up to the correct location.	Move all joints to zero and check to see if the hash lines on both sides of the joint are lined up. Reset each Cobot joint's zero position by following the Reset Cobot Zero Position procedure.
Cobot control box powered on. But when pressing "open" on the teach pendant the cobot fails to initialize and gives a message "robot is already in an unitialized state." The end I/O Module LED ring also doesn't illuminate	The cable connecting the cobot to the control box is damaged or defective	Check both ends of the cables. Check for damage to the connector pins. Make sure when connecting to the robot base that the cable is oriented correctly. The pins are labeled. Order a replacement cable if there is severe damage. See the Control Box Cable section for how to test the cable.
Cobot does not jog. When trying to jog, a yellow warning message appears saying "Please activate Light Curtain or Cell Safe".	The safety parameters has not been applied.	Re-upload the configuration files from HBC to recieve the safety parameter.
E-Stop alarm wont clear.	Jumper might be missing from JP1 on the SIO PCB.	Verify the jumper is installed on the Haas I/O PCB at JP1. If it is not installed, reinstall it.
Machine needs to be Manually Recovered or goes into Robot APL Recovery.	The Cobot cycle was interrupted or the machine/Cobot was in a unsafe condition and needs to be recovered.	See the Haas Robot - APL Recovery section in HRP Operation for more information.
Machine goes into Robot APL Recovery between two scheduled jobs.	Machine motion was active when next job was started.	Add a machine dwell to the Post Run sequence in the first job. The dwell needs to be long enough to give the Cobot enough time to finish dropping off the part and moving to ready position. Start at around 15-20 seconds and adjusting up or down from there. The dwell is long enough if the second job is able to start and the machine does not go into Robot APL Recovery.
The Cobot dual air solenoid assembly leaks air out of the regulator knob when trying to decrease the air pressure.	The Cobot dual air solenoid assembly was incorrectly configured.	Correctly configure the Cobot dual air solenoid assembly. Refer to the Cobot Dual Air Solenoid section below.
When signing into the teach pendant with username and password admin, an error message prevents logging in. The error message reads: Login Fail: TypeError: Cannot read property 'data' of undefined.	The teach pendant and cobot control box lost power unexpectedly, causing a loss of data.	Follow the instructions in AD0765 - TypeError Recovery for how to reinstall the system software package.
When moving from the ready position to the part pickup/dropoff position, the cobot unclamps without completing the motion and then doesn't move to the next part before clamping the grippers.	The user frame may not be set correctly.	Reset the user frame by going through the three point method. Then, redo the motion files for loading and unloading parts using the new user frame.
The teach pendant is in a permanent E-stop state. The window with the E-stop message can't be reset.	The 24VDC power supply is not connected the PSUP board, or isn't receiving an input voltage.	Verify that the power supply is connected to the PSUP board and that the voltage on the lines going to the 24VDC power supply is 110VAC.
When trying to activate the Cobot through HBC you get a warning saying, RobotDetails "macAddress" field cannot be empty.	The MAC Address needs to be updated in the system.	Take a photo of the label on the cobot packaging that includes the robot serial number, and MAC Address. Attach the photo to the work order and contact Haas Service to have the system updated. See Cobot Label section below.
After the cobot alarmed out from a crash event, the LED ring on the cobot does not stay green when trying to enable the cobot. The cobot will alarm out again when trying to enable so that the cobot can be jogged.	The cobot is obstructed and needs to be manually moved away from all objects to open space.	Refer to the Cobot - Crash Recovery section below for details on how to manually move the cobot to a free position where it can be enabled without generating any alarms.

Haas Cobot - Active Alarms

More than one alarm may be present if the machine generates an alarm. Navigate to the Active Alarms tab to view all active alarms.

Alarm 9150.40054 Robot in Emergency Stop State is triggered when the Cobot teach pendant [E-STOP] was pushed. To clear this alarm, reset the [E-STOP] button on the Cobot teach pendant and press [RESET] on the Haas control to clear the alarm.

Teach pendant login error

When signing into the teach pendant with username and password 'admin', an error message prevents logging in.

The error message reads[1]: Login Fail: TypeError: Cannot read property 'data' of undefined.

Refer to AD0765 - TypeError Recovery for how to clear this alarm.

Cobot Label

If you try to activate the Cobot and get a MAC Address warning, you need to do the following.

Find the original packaging for either the robot arm or the control box.

Compare the label on the packaging to the Cobot ID plate on the physical arm.

Verify that the serial number on the Cobot ID plate [1] matches the serial number on the packaging label [2].

After verifying that they match, take a clear photo of both the label on the Cobot packaging and the Cobot ID plate [1]. Attach both photos to the work order.

Contact Haas Service and provide the work order number so that the system can be updated with the Cobot's information.

Note: Make sure that the photo clearly shows the Cobot's Serial number [2] and the Cobot's MAC Address [3].

Once the system is updated you can continue with the activation process through HBC.

Cobot Dual Air Solenoid

Make sure that the Cobot dual air solenoid assembly is incorrectly configured by verifiying that the solenoid [1] is installed into the regulator input [2].

NOTE: The regulator [2] will have an arrow marking the port indicating which port is the input.

Remove the pressure gauge [3] from the regulator.

Remove the regulator knob from the regulator in order to remove the entire solenoid assembly from the dual air solenoid enclosure.

Remove the input airline fitting [4] from the regulator.

Remove the solenoid [1] from the regulator.

Remove the plug in the regulator.

Rotate the regulator 90 degrees.

IMPORTANT: Install the input airline fitting [1] into the regulator input [2].

Install the solenoid [3] into the regulator.

Install the plug into the regulator.

Secure the regulator onto the dual air solenoid enclosure.

Install the pressure gauge [4] into the regulator.

Cobot - Crash Recovery

After a crash that causes the cobot to alarm out, you might not be able to enable the cobot through the teach pendant right away.

If you enable the cobot and the LED ring around joint 6 doesn't go bright green, you will have to physically free the cobot from any obstructions.

Make sure that the cobot is in a disabled state. It will have a "disabled" message [1] shown. You can put the cobot in a disabled state by pressing the [Close] button [2].

Navigate to the Brake Operation [2] window by pressing Config [1] on the top window.

You can then disable the brake on any joint motor in order to manually move the robot.

Warning: When the brake is disabled the joint will rotate based on the weight of the cobot that the joint supports.

Important: Only disable the brake on 1 joint at a time if possible. Start with the joints that are highest on the arm, for example joint 5 [2] or joint 6 [1].

When you press on the green brake button for an axis, the button will go red and be unlocked [1] as shown in the image.

When the joint is unlocked, pull/push on the joint to rotate it by hand so that the arm is free of any obstructions.

If you need to unlock a second joint, lock the first joint by pressing on the red unlocked joint button [1]. Once it is locked you can safely unlock a different joint.

When the cobot arm is free, lock all the joint brakes and go back to the run window [2] and enable the cobot.

Cobot to Control Box Cable

Inspect the pins on both ends of the cable for damage. Check the connector at the base of the robot. If the pins are bent [2], straighten them out as best as possible.

Check the pins on the control box side as well.

Plug the cable into the control box connector and continue to the next step.

Note: The pins in all the connectors are labeled as shown in the image.

Use a volt meter to check the following voltages on the end of the cable:

Measure 48V between pin 4 [1] and pin 10 [2].
Measure 48V between pin 8 [3] and pin 12 [4].

Warning: Be careful not short out any pins with a lead of the volt meter.

The pin out for the cable is given below:

Pin	Function
1	Transmit +
4	48 Vin+
5	Transmit -
6	Shield
8	48 Vin+
9	Receive +
10	Gnd
11	Receive -
12	Gnd

Cobot Log Record

Plug a USB drive into the Cobot control box USB port [1].

NOTE: Either USB port will work. [1]

On the robot teach pendant, navigate to the Monitor tab [2].

Navigate to the Log tab [3].

Press Export [4]. When the popup appears, select the USB drive. The log record will be saved to the USB drive.

Electrical Diagrams

Robot Safety Device Interface Box Connections:

Cobot Control Box Connections: