Here’s a list of some common ABB robot errors and solutions:
### 1. **Error 20204: Overload Fault**
- **Cause:** This fault occurs when the robot experiences a mechanical overload, typically due to excessive load or obstruction in its movement.
- **Solution:**
- Check the payload and ensure it’s within the robot’s rated capacity.
- Remove any obstructions in the robot’s path.
- Recalibrate or reconfigure if necessary.
### 2. **Error 20002: Joint Collision**
- **Cause:** This error is triggered when a joint collides with another object or part of the robot.
- **Solution:**
- Check for physical obstructions in the work area.
- Reprogram the robot’s path to avoid risky moves.
- Inspect for worn-out parts that could be causing improper movements.
### 3. **Error 20311: Resolver Fault**
- **Cause:** This error occurs due to an issue with the resolver, which provides feedback on the motor’s position and speed.
- **Solution:**
- Check connections for any loose or damaged cables.
- Replace the resolver or motor if the issue persists.
- Perform calibration on the affected motor.
### 4. **Error 20216: Drive Overtemperature**
- **Cause:** Excessive temperature in one of the drive units.
- **Solution:**
- Ensure adequate cooling and ventilation around the robot.
- Check for dust accumulation in cooling fans or vents and clean them.
- Avoid overloading the robot, as it can increase heat generation.
### 5. **Error 38008: System Software Fault**
- **Cause:** This can be due to a software issue or corruption in the controller.
- **Solution:**
- Restart the robot controller.
- If the error persists, reinstall or update the software.
- Contact ABB support if the issue cannot be resolved with software updates.
### 6. **Error 20208: Battery Backup Fault**
- **Cause:** This error indicates a failure or low charge in the backup battery.
- **Solution:**
- Replace the backup battery as per ABB’s recommendations.
- Ensure that the robot is powered down when replacing the battery to avoid loss of data.
### 7. **Error 20254: Encoder Communication Fault**
- **Cause:** The encoder, which tracks the position of the robot’s arm, has an issue communicating with the controller.
- **Solution:**
- Check encoder cable connections for any signs of wear or damage.
- Reset the encoder and controller to clear temporary communication glitches.
- Replace the encoder if the issue is persistent.
### 8. **Error 20223: Brake Release Failure**
- **Cause:** This error means the brake on one of the robot joints failed to release properly.
- **Solution:**
- Inspect the brake for wear or damage.
- Test the brake function and, if necessary, replace the brake or the associated components.
- Re-calibrate the joint position if required.
### 9. **Error 38911: Safety Controller Failure**
- **Cause:** Indicates an issue with the safety controller, which may cause the robot to shut down for safety reasons.
- **Solution:**
- Inspect the safety circuits, including emergency stops, protective doors, and safety relays.
- Restart the robot controller.
- If unresolved, consult ABB support for further diagnostics.
### 10. **Error 37020: Position Deviation Fault**
- **Cause:** The robot’s actual position deviates significantly from the commanded position.
- **Solution:**
- Check for obstructions or interference in the robot’s path.
- Verify payload setup and make sure it’s balanced and securely mounted.
- Adjust the robot’s speed and acceleration settings if needed to prevent overshooting.
ABB robots come with robust diagnostics, but always refer to the specific documentation for the robot model in use, as exact error codes and solutions can vary between models.
