Robot error 20143: Start at main rejected

14.07.2016/JeAP
Rev: 14.07:2016/JeAP

Scope

This memo applies to IRC5 robot controllers w/ DSQC1000 main computer. The behavior described here
was experienced on the 2 first systems shipped with RobotWare 6:

• QCX4036 Sycs - Elazig

Serial no: 2600-105744
RobotWare: 6.02.0106
• QCX1055 Limerick
Serial no: 2600-106160
RobotWare: 6.03.0140

It is our belief that the problem does not occur with the combination DSQC1000 + RW5. It could,
however, be that such systems have not yet been commissioned, for which reason the behavior is simply
not yet reported. To be investigated further.

Problem

Robot program refuses to start due to error 20143 Start at main rejected.

Symptoms

When pressing 'Motors on', the robot system refuses to start program execution, displaying error
message 20143 Start at main rejected

FLSmidth is as standard using cross connections to ensure program execution starts when the operator
presses the 'Motors on' button.

The setup with cross connections (initially recommended by ABB) has been working fine on S4, S4C,
S4Cplus and IRC5 w/ RobotWare 5 for many years, but after migrating our application to RobotWare 6,
we haven't been able to get it to work.

Detailed error information from robot documentation:

The error descrription is somewhat misleading, as neither backup procedure is in progress, nor program
is already running.
Cause

ABB CZ has - basen on an investigation on system 2600-106160 - concluded that the behaviour is caused
by a timing issue in the the robot controller (new DSQC1000 main computer + RW6).

Workaround

ABB has as a workaround suggested to modify the cross connections as follows.

Before modification:
EIO_CROSS:

-Name "CC_Sysi_Startmain" -Res "Sysi_Startmain" -Act1 "Syso_MotOnstate"\

-Oper1 "AND" -Act2 "Allow_Resume" -Act2_invert

-Name "CC_Sysi_Start" -Res "Sysi_Start" -Act1 "Syso_MotOnstate"\

-Oper1 "AND" -Act2 "Allow_Resume"

-Name "CC_Sysi_MotorOff" -Res "Sysi_MotorOff" -Act1 "Syso_CycleOnMem"\

-Oper1 "AND" -Act2 "Syso_CycleOn" -Act2_invert -Oper2 "AND"\

-Act3 "syso_AutoOn"

-Name "CC_Syso_CycleOnMem" -Res "Syso_CycleOnMem" -Act1 "Syso_CycleOn"

After modification:
EIO_CROSS:

-Name "CC_Sysi_Startmain" -Res "Sysi_Startmain" -Act1 "Syso_MotOnstate"\

-Oper1 "AND" -Act2 "Allow_Resume" -Act2_invert -Oper2 "AND" -Act3 "MONPB"\

-Act3_invert

-Name "CC_Sysi_Start" -Res "Sysi_Start" -Act1 "Syso_MotOnstate"\

-Oper1 "AND" -Act2 "Allow_Resume" -Oper2 "AND" -Act3 "MONPB" -Act3_invert

-Name "CC_Sysi_MotorOff" -Res "Sysi_MotorOff" -Act1 "Syso_CycleOnMem"\

-Oper1 "AND" -Act2 "Syso_CycleOn" -Act2_invert -Oper2 "AND"\

-Act3 "syso_AutoOn"

-Name "CC_Syso_CycleOnMem" -Res "Syso_CycleOnMem" -Act1 "Syso_CycleOn"

This will work, but the workaround has a shortcoming: The operator must press and hold the 'Motors on'
button for at least 2 secs to start program execution. If he (by mistake) releases the button before the 2
seconds have elapsed, there will still be permanent light in the 'Motors on' button, but the program
execution will fail to start - i.e. the operator will most likely not understand what is going on.

This workaround can help us throughout the commissioning phase, but we will need to find a more
operator-friendly solution before handing over a project to our end-user.
A temporary version of AddToEIO.cfg with the workaround is available.

Solution

A permanent solution is not yet found. A request for this is forwarded to ABB 14.07.2016.

Background

FLSmidth implements cross connections as described below on all robot systems delivered. The cross
connections ensures that 'Motors on' and program execution always are in sync, when running in Auto
mode:

• Program execution will start when operator presses 'Motors on'.

• Motors will be switched off, when program execution stops.

System inputs (RW5):

-Signal "Sysi_Startmain" -Action "StartMain" -Arg1 "CYCLE"

-Signal "Sysi_Start" -Action "Start" -Arg1 "CYCLE"

-Signal "Sysi_MotorOff" -Action "MotorOff"

System outputs (RW5):

-Status "MotOnState" -Signal "Syso_MotOnstate"

-Status "EmStop" -Signal "Syso_Emstop"

-Status "RunchOk" -Signal "Syso_RunchOk"

-Status "CycleOn" -Signal "Syso_CycleOn"

-Status "AutoOn" -Signal "Syso_AutoOn"

Cross connections: