Brooks Automation 6. Service Procedures
Part Number: 603988 Rev. A Troubleshooting
Symptom Recommended Action
“Encoder Data,
Accel/decel Limit
Error”
The encoder cable may be damaged and the encoder may be getting intermittent
communication, causing apparent jumps in position. Check the encoder connectors. Replace
the cable. Replace the motor.
“Encoder
Communication
Error”
Check the encoder connectors on flat ribbon cable. Replace the encoder cable or
motor/encoder.
"Encoder
quadrature error"
Replace the slip ring. Replace the motor/encoder (only the Gripper motor ).
"Missing zero
index"
See "Encoder Operation Error" on page 84.
“Motor duty cycle
exceeded”
Reduce the speed or acceleration of the robot. Check for instability.
“Amplifier under
voltage”
The motor power supply has reached current limit and shutdown. Slow down the robot. Check
the Energy Dump PCA. Replace the 48V supply.
“Amplifier Fault” Check the harness and motor for shorts.
“Amplifier Over
Voltage”
Check that energy dump resistor is connected.
“Soft Envelope
Error”
Make sure that the robot is not pressing against the surface. If this occurs on the gripper
repeatedly, replace the slip ring.
“Hard Envelope
Error”
This symptom typically means that the robot has crashed into something.
Pneumatic
Gripper Sensor
not working
Check the continuity of the cable through the wrist. Check the green lights on te sensor to see if
the sensor is triggering.
“Time Out Nulling
Error”
Check that joint is free to move with the brake off. Check that the joint is not vibrating or
unstable. If unstable check the belt tension. If Gripper, replace the slip ring after checking that
the brake releases.
“Joint Out of
Range”
The joint actual or commanded position may be beyond the software limit stop. Move the joint
back into range while monitoring the virtual pendant or check the program for commanded
position.
“PAC Files
Corrupted”
See "Recovering from Corrupted PAC Files" on page 74.
Physical or audible problem
Brown streaks on
linear bearing
Clean with alcohol and add grease to the bearing blocks. This should not be required sooner
than 20,000 hours of run time. Grease is Alvania Grease EP2 from Shell.
Mechanical noise
from any joint
Check the joint bearings for failure. Re-tension the belt.
Loud buzzing or
vibration from
any joint
Re-tension the timing belts.
Copyright © 2023 Brooks Automation, Inc.
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