If loading a CMOS from an operating robot system into a TED unit, you’ll be greeted by a flurry of alarms when rebooting with newly installed CMOS.
- ALARM 4107 OUT OF RANGE (ABSO DATA)
- ALARM 4740 M-SAF OVERRUN DETECT
- ALARM 89** Vary depending on Moto+ Applications that where on the cloned system
You can often clear many of the alarms by simply pressing the “Reset” button shown on the screen. This will often clear the “one-time start-up” alarms generated by Moto+ applications that likely are not loaded into the TED controller at this point.
Addressing ALARM 4740 Alarm:
If the CMOS you cloned from the production system has external axes or multiple robots you’ll likely get “M-SAF OVERRUN DETECT” alarms on axes other than R1 due to the fact the hardware inputs do not exist on the TED unit. To address the 4740 alarm we’ll need to launch into Maintenance Mode:
Once in Maintenance Mode set your security level to “Management Mode”:
Navigate to “System” --> “Setup” --> “Control Group”
Scroll over to the “OT” (over-travel) column and disable the overtravel for all Robots, Stations, and Bases by choosing the “NO CONNECT” option from the drop-down menu. When completed the “OT” column should look like the right-most image below.
When prompted, choose “YES” to the following to “Modify” and “Initialize” prompts:
You’ll now be notified that you’ll need to perform a “Safety Board FLASH Reset” which can be found under the “File” --> “Initialize” --> “Safety Board FLASH Reset” and choose “YES” when prompted “Reset?”:
Required Parameter Modification from Cloned System:
Fan Alarms:
Once rebooted into regular operation mode you might encounter alarms regarding Fans hardware. These alarms are associated with the fact that on multiple robot systems there is a second robot controller that has it’s own fan hardware and the cloned CMOS is expecting that hardware to exist on the TED which is does not. To clear this alarm be sure to document the following parameter settings BEFORE you change them so you can restore them if placing a CMOS from the TED back into the production hardware.
To clear fan errors on TED, set the following parameters to the values shown:
- S2C786=0 (Document original settings before changing!)
- S2C789=17 (Document original settings before changing!)
- S2C813=1 (Document original settings before changing!)
MotoSim communication:
MotoSim is commonly used with TED to simulate the actual work system that is being worked on. MotoSim can be provide a virtual representation of robots, external axis, positioners, and Base/Station axes. To ensure communication with MotoSim, the following parameters should be verified on the TED unit.
- RS0 = 2
- RS5 = 1
- RS7 = 2
- CMD REMOTE SEL = ON
Simulated Feedback Position:
Since TED is not connected to any actual motors with encoders, specific parameters need to be set to allow the system to operate without receiving actual encoder feedback. Otherwise “Servo Tracking” alarms will occur when trying to run robot jobs on TED. The specific parameters that need to be set to allow this operation can only be obtained from Yaskawa Customer Support. The Serial # for the TED unit must be provided along with a PO# indicating that the you are the purchaser of the TED unit. Yaskawa Customer Support can be reached at: 937-847-3200.