Service Home Haas Robot - Troubleshooting Guide
Last updated: 04/12/2022

Haas Robot - Troubleshooting Guide

Haas Robot - Troubleshooting Guide

Introduction

This document will show you how to troubleshoot your Haas Robot Package.  If you do not find the alarm or symptom on this document please generate and error report (SHIFT + F3) and contact the service department.

Robot 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 robot that has been power cycled may cause a Version Mismatch. This causes all robot functions to be locked until the alarm is cleared. Release the E-Stop and press RESET to clear the alarm. Then press the E-Stop and press F1 to connect the robot
9160 ROBOT EMERGENCY STOP The Robot Emergency Stop button was pressed either from the robot control box or the remote pendant. Or robot estop chain is broken. Please release the Robot Emergency Stop button(s) and press reset to proceed. Verify all robot estops are released. Verify estop wiring (including external estop inputs) to robot are intact and correctly wired.
The Robot won't Connect to the CNC The wiring from the interface 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 Robot Installation Procedure, Electrical section.
The robot is not unlocked and activated.

The first time connecting a robot 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 robot, and the Machine Generated Code used for Machine Time Extension on the portal.

Note: Go to the Robot MAC Address section to find the MAC address using a laptop.
The CNC software is outdated. Make sure the software is 100.20.000.1200 or higher.  Refer to the Robot Installation Procedure machine requirements section.
The Robot IP address and the CNC are mismatched. If the Robot Software is 1.11 or lower. Upgrade the Robot control to 1.15 or higher. Contact your HFO for more information. See Robot IP Address section for more info.
The arm moved during power off. Connect & Calibrate Haas Robot using the video below.
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. 
  • If all the above check out correct, then unplug the RJ45 from the adaptor and connect it to the RJ45 on a laptop and make sure you are able to connect to the robot via the IPedant.  If you are able to connect to the robot via the laptop then the RJ-45 to USB adapter is defective.

The following errors appear when trying to connect to the iPendant from a PC:

  • "Disconnected From Controller"
  • "iPendant has never been connected"
 The robot may need to be reinitialized.
Do the following steps:
 
  1. Make a backup by following this procedure: How to Make an Image Backup
  2. Reinitialize the robot by following this procedure: How to Reinitialize Robot
E-Stop alarm wont clear. Jumper might be missing from JP1 on the SIO PCB.

Verify the jumper is installed on the SIO PCB at JP1. If it is not installed, reinstall it.

Robot Command Failed Alarms

These alarms are generated when the robot fails to execute a command. A sub-alarm number indicates faults ID and is provided by FANUC robot.

Alarm / Symptom Possible Cause Corrective Action
9156.050 Robot Command Failure SRVO-050 Collision Detect Alarm Jogging the robot in setup mode and the center of rotation of J6 is in line with the center of rotation of J4. Then rotating W or P, will cause J4 axis to attempt to rotate at a very fast speed. This singularity point is called the wrist singularity. Press RESET to clear the alarm. Do not jog the robot through this singularity point.
The robot motion file does not have enough points producing a non-smooth motion. Add more points to the motion file smoothing out the robot motion.
9156.406 SRVO-406 DCS SSO SVOFF input 1,1 The K9 and K10 Relays on I/O PCB are not installed. Make sure you have the K9 and K10 relays installed on the I/O PCB.  Refer to the Robot Installation Procedure, Electrical section.
9156.406 SRVO-406 DCS SSO SVOFF input 1,1 The fence is open in Run Mode. Make sure the interlock is working and that machine is receiving the interlock input signal.
The TB-3B wiring is damaged or miswired. Check the wiring for the TB-3B connector. Compare the wiring of the connector to the wiring diagram.
9156.037 SRVO-037 IMSTP input (Group:1) The TB-3B wiring is damaged or miswired. Check the wiring for the TB-3B connector. Compare the wiring of the connector to the wiring diagram.
9156.062 ROBOT COMMAND FAILED SRVO-062 BZAL alarm The batteries in the robot arm have died. Follow the HRP - Battery Replacement procedure to replace the batteries and follow the HRP - Quick Mastering procedure to remaster the robot.

9156.378 FANUC ROBOT ALARM - SFDI12 Status abnormal

or

9156.378 FANUC ROBOT ALARM - SFDI22 Status abnormal

 The K9 and K10 Relays on I/O PCB are not installed. Make sure you have the K9 and K10 relays installed on the I/O PCB.  Refer to the Robot Installation Procedure, Electrical section.
9156.490 PRIO-490 Modbus TCP Server Error Interference or faulty RJ-45 Ethernet cable. Depending on the Robot build date the cables were not built with ferrite filters installed. Install ferrite filters PN: 64-1252 to both RJ-45 Communication cables at the electrical interface box and to the USB to Ethernet Adapter at the Main Processor PCB. See the Ferrrite Filter section below. If the alarm continues, test the cables refer to Network Cable Tester Tool procedure.

Fanuc Robot Alarms

These alarms are generated when the robot is at fault state.  A sub-alarm number indicates faults ID and is provided by FANUC robot.

Alarm / Symptom Possible Cause Corrective Action
9150.378 FANUC ROBOT ALARM - SFDI12 Status abnormal

or 

9150.378 FANUC ROBOT ALARM - SFDI22 Status abnormal		 The K9 and K10 Relays on I/O PCB are not installed. Make sure you have the K9 and K10 relays installed on the I/O PCB.  Refer to the Robot Installation Procedure, Electrical section.
9150.403 FANUC ROBOT ALARM - SRVO-403 DCS Cart. speed limit The DCS Zone was not setup or not setup correctly.  Check the DCS setup and make sure it is setup or setup correctly.
The motion exceeds the speed limit set by the Cartesian Speed Check. Decrease the robot speed.
9150.488 FANUC ROBOT ALARM - SRVO-488 DCS CPC Speed Limit This alarm is generated when the robot has a DCS Cartesian Position Check Zone setup with a speed limit and the robot is jogged outside the work zone above the speed limit. Lower the feed rate and jog back into the DCS Cartesian Position Check Zone. Verify the work zone is setup correctly by checking the 4D DCS Display.
9152.x Robot Hit Joint Limit or robot does not jog Jogging the robot in setup mode and the center of rotation of J6 is in line with the center of rotation of J4. Then rotating W or P, will cause J4 axis to attempt to rotate at a very fast speed, traveling past the travel limit. This singularity point is called the wrist singularity. The Joint Position will be greater than the Robot Joint Travel Limit. The Sub-Code of the alarm represents the joint number. Connect to the robot using the Remote Pendant through the web interface. Clear the alarm and jog the robot joint away from the travel limit. Reconnect to the Haas control.

Haas Robot - Active Alarms

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

 

Connect & Jog Haas Robot

If alarm 9152.x Robot Hit Joint Limit is generated follow the video below. Connect to the robot using the Remote Pendant through the web interface. Clear the alarm and jog the robot joint away from the travel limit. Reconnect to the Haas control.

Connect & Calibrate Haas Robot

Robot Control Wiring

1

Robot Control Box
  • Open the Robot Controller door by using a straight head screwdriver to turn the latch counter-clockwise,  then turn the breaker counter-clockwise past its off position.
  • Remove the cable cover [1] from the robot control box
  • Remove the top cover [2].  This will make the installation of the power cable easier.
  • Feed the 230VAC Power cable P/N 33-5830 [3] as shown. 
  • Feed the Robot Control Signal cables P/N 33-8590 [4] as shown.
      Note:     Make sure the Robot Control signal cables P/N 33-8590 are as far away from the power cable as possible. 

  • Pull enough slack on the cable with ferrules [5] to reach the TB0P20 PCB,  you will add connector to these wires in step 7.
  • Route the RJ45 cable and the cable with the large connector from cable P/N 33-8590 together [6] as shown.

2

To connect the power cable, remove the plastic cover from above the Breaker.  To remove cover, insert a straight-head screwdriver into the opening, and push the tab to the left allowing the cover to slide forward.

Connect the cables to L to 1 and N to 3.  Connect the ground to the plate to the right of the Breaker.

After the power cable is connected, reinsert the plastic cover.

Robot Joint Travel Limits

Robot Joint Travel Limits

J1 (+/-170°)

J2 (+/-122.5°)

J3 (+/-215°)

J4 (+/-190°)

J5 (+/-125°)

J6 (+/-360°)

 

Robot IP Address

Depending on the Robot build date. The IP address of the robot control may be different then the IP address in the Haas control. If the Robot Software is 1.11 or lower. Update the Robot Software to 1.15 or higher and verify the following parameters values are set correctly:

2262 Robot IP Address to 10.72.65.82
2263 Aux IP Address to 10.72.65.77

Recheck the connection.

Robot MAC Address

1

Follow this video to connect a laptop to the robot.

2

Once connected to the robot on the laptop, select Current Robot Status [1] from the menu on the left. 

Then click Summary Configuration/Status [2].

3

At this point the F number [1], if needed, can be found on this page.

Click the Ethernet Config Info link [2] and the MAC address can be found on this page at [3].

Fanuc Memory Device (MD) Backup

1

To create a Memory Device (MD) backup of the robot. Connect to the Fanuc Control with a laptop and iPendant. See Connect & Jog Robot video above.

Navigate to the Navigate pendant.

2

Set the default device to the device you want. The two options are UT1: for the Fanuc Teach Pendant or UD1: for the USB port on the front of the Fanuc Control Box.

  • Press MENU and then File.
  • Press F1, [TYPE]. Select File.
  • Press F5, [UTIL]. Select Set Device.
  • Navigate to the Device you want to save the backup to, UT1: or UD1:.
  • Press F4, [BACKUP]. If you do not see [BACKUP], press FCTN and select RESTORE/BACKUP.
  • Select All of Above and press ENTER.
  • It will prompt you select the backup operation you want to perform. Press F4 and then YES to back up the current file.
  • The backup process will take a few minutes to complete.

Robot With Light Curtain

Robot Electrical Box to Robot Control
  • Connect the E-STOP cable [1] P/N 33-8550 from Robot Electrical Interface Box  to the Robot External E-stop Box (see diagram).
  • Connect the Robot Control Signal Cables [2] P/N 33-8590A to the Robot Electrical Interface Box.

Robot Power

  • Connect the 230VAC Power Cable [3] P/N 33-8530 to the Robot Electrical Interface Box.

Light Curtain

  • Connect the Light Curtain cables [4] to the Receiver/ Emitter connections at the Robot Electrical Interface box.
Robot Arm
  • Connect the Robot Control Cable [5] to the Robot Arm.

Ground Wire

  • Connect the Ground Wire [6] from the Chassis of the Robot Control to the Robot mount.

Ferrite Filter Installation

Depending on the Robot build date the cables were not built with ferrite filters installed. Install ferrite filters PN: 64-1252 to both RJ-45 Communication cables at the electrical interface box and to the USB to Ethernet Adapter at the Main Processor PCB. 

Electrical Diagrams

HRP-1 Wiring Diagram

   

HRP-2/3 Wiring Diagram

Feedback

Cookie Notice

We use cookies to improve your user experience. Our Cookie Notice describes which cookies we use, why we use them, and how you can find more information about them. Please confirm you consent to us using analytics cookies. If you do not consent, you may still use our website with a reduced user experience.