Troubleshooting hardware problems

About this topic

This topic lists the following commonly encountered hardware problems, the causes of the problems, and ways to resolve the problems:

•	Communication or power problems

•	Gripper, labware, or teachpoint problems

•	Homing problems

If you are still experiencing problems with the Direct Drive Robot after trying the solutions, contact Automation Solutions Technical Support.

Communication or power problems

 

Problem	Cause	Solution
The robot does not turn on.	The system electrical requirements are not met.	Make sure the system electrical requirements are met. See Electrical requirements.
	The Direct Drive Robot is not connected to the power source.	Connect the Direct Drive Robot to the power source. See Power supply.
	One or more of the robot fuses are blown.	Check the Logic and Motor Power lights on the front of the power supply to see which fuse(s) are blown, then replace the blown fuse(s). See Replacing fuses in power supply G5411-60010 or Replacing fuses in power supply G5411-60005. If the fuses are blown immediately after replacement, stop using the robot and contact Automation Solutions Technical Support.
The Logic light on the front of the power supply does not turn on.	The robot power is not turned on.	Turn on the robot. See Turning on and turning off the robot.
	The robot power cable is not connected to the power supply or the power source.	Connect the power cable to the power supply and the power source. See Installing the robot.
	One or more of the following fuses might be blown: AC main fuse, switch fuse, or cable fuse.	Replace the fuse(s). See Replacing fuses in power supply G5411-60010 or Replacing fuses in power supply G5411-60010. If the fuses are blown immediately after replacement, stop using the robot and contact Automation Solutions Technical Support.
	If you turn on the robot, the Logic light does not turn on but you can still hear the fan in the power supply, then the indicator light bulb is blown.	Replace the light bulb. Contact Automation Solutions Technical Support for assistance.
The Motor Power light on the front of the power supply does not turn on.	The robot profile is not initialized.	Initialize the profile.
	The Logic light is also off.	Troubleshoot the Logic light problems.
	The emergency stop button is pressed down.	Recover from the emergency stop. See Recovering from an emergency stop.
	The robot communications cable is not connected to the power supply or the robot.	Connect the communications cable to the power supply and the robot. See Installing the robot.
	The Robot fuse is blown.	Replace the Robot fuse. See Replacing fuses in power supply G5411-60010 or Replacing fuses in power supply G5411-60010. If the fuse is blown immediately after replacement, stop using the robot and contact Automation Solutions Technical Support.
	If you turn on the robot, the Logic light turns on, the Motor Power light remains off, but you can still jog the robot, then the indicator light bulb is blown.	Replace the light bulb. Contact Automation Solutions Technical Support for assistance.
The blue light on the robot hand continues to blink after the robot has finished its startup routine.	The robot configuration file might be corrupt.	Reload the backup copy of the robot and gripper firmware and try again. See Restoring existing firmware for instructions.
The blue light on the robot hand remains on after the robot has finished its startup routine.	The gripper firmware (ASB code) might be corrupt.	Reload the backup copy of the robot and gripper firmware and try again. See Restoring existing firmware for instructions.

Gripper, labware, or teachpoint problems

 

Problem	Cause	Solution
Labware drops or is held loosely by the robot.	The labware definition for the microplate type might contain incorrect information.	Check the labware definition for errors.
	The Grip torque parameter value is incorrect for the labware.	In Labware Editor, change the Grip torque value for the labware.
	The Gripper offset range is incorrect.	In the Labware Editor and the Direct Drive Robot Diagnostics, change the Gripper Offset Range values.
	The robot gripper pads are dirty or worn.	Clean or replace the robot gripper pads. See Cleaning the robot gripper pads or Replacing robot gripper pads.
	The gripper pads are loose.	Tighten the screws that are holding the pads to the grippers.
	Shim washers are missing or installed incorrectly beneath the screws at the back end of the grippers.	Check and make sure the shim washers are in place. See “About the shim washers” on page 183.
	The grippers are damaged.	See Replacing robot gripper pads
Labware bends when held by the robot.	The Grip torque parameter value is incorrect for the labware.	In Labware Editor, change the Grip torque value for the labware.
The robot is not moving to and from the teachpoints accurately.	The robot axes need to be recalibrated.	Home the robot. See Homing the robot and grippers.
	The teachpoint coordinates or orientations are inaccurate. The approach height value might be incorrect.	Verify and edit the teachpoint. See Verifying teachpoints.
The robot is unable to place labware at the target location accurately.	The target location teachpoint is incorrect.	Verify and edit the teachpoints. See Verifying teachpoints.
	The teachpoint of the previously scheduled device is incorrect.	Verify and edit the teachpoints. See Verifying teachpoints.
	The target device was moved or reconfigured and the teachpoint was not updated.	Verify and edit the teachpoints. See Verifying teachpoints.
	Approach height setting is incorrect.	Check the approach height setting.
	The labware might be damaged or deformed.	Replace the damaged or deformed labware.
	The robot gripper pads are dirty or worn.	Clean or replace the robot gripper pads. See Cleaning the robot gripper pads or Replacing robot gripper pads.
	The robot grippers are damaged.	Contact Automation Solutions Technical Support to replace the robot grippers.
	Incorrect gripper offset range is specified.	Check and correct the gripper offset ranges for the labware, the pick location, and the place location. See Setting the gripper offset parameters.
The robot placed the labware such that the A1 well is in the wrong orientation.	The incorrect A1-well orientation is specified for the teachpoint.	In the teachpoint file, verify the A1-well orientation specification. Change the specification if necessary. See Specifying the A1-well orientation.
The robot collides with devices or obstacles when moving from teachpoint to teachpoint.	The incorrect robot-arm orientation, approach height, or approach distance values are used.	In the teachpoint file, check and correct the robot-arm orientation, approach height value, and approach distance value. See Setting teachpoints.

Homing problems

 

Problem	Cause	Solution
The robot does not home.	The robot is in a position where it cannot home.	Disable the motors, manually move the robot into the safe zone, enable the motors, and home the robot.
	The homing offsets are incorrect.	Contact Automation Solutions Technical Support.
	The circular encoders are dirty or damaged.	Contact Automation Solutions Technical Support.
The robot crashes into the base during the homing process.	The robot moved beyond its Z-axis index.	Jog the robot upward, a few centimeters above the base, and try again.
	The Base clearance value is incorrect.	Adjust the Base clearance value in the Setup tab. See Replacing robot grippers for instructions.
	The homing sensor needs adjustment.	Contact Automation Solutions Technical Support.

Related information

 

For information about...	See...
Direct Drive Robot component names	Hardware components
Software error messages	Troubleshooting error messages
Diagnosing problems	Using DDR Diagnostics
Reporting problems	Reporting problems