Error 20201 limit switch open solution

    Error 20201 limit switch open solution for an IRB6400RM200 controller


    This only took me 6 hours and 5 phone calls to get to the bottom of.. hopefully you have found this before you going throw the same pains and efforts.


    So I know what your thinking. My limit switches are all jumped to each other how can one be open? Well the simple reason is bad documentation you know that part of your manual that says X2 pin 11 not used and X2 pin 12 not used? what it really means is Jumper X2:11 to X2:12 or the robot won't work!


    here is the layout of jumpers you need for your Robot to work



    X1:3 to X1:4
    X1:5 to X1:6
    X1:7 to X1:8
    X1:9 to X1:10
    (X1:11 to X1:12) Inportant just trust me!


    X2: same as X1


    X2:3 to X2:4
    X2:5 to X2:6
    X2:7 to X2:8
    X2:9 to X2:10
    (X2:11 to X2:12) Important just trust me!


    X3:3 to X3:4
    X3:7 to X3:8 and X3:9
    X3:10 to X3:11 and X3:12


    X4: same as X3:
    X4:3 to X4:4
    X4:7 to X4:8 and X4:9
    X4:10 to X4:11 and X4:12


    attached image to prove I'm not a NUT!
    GLHF!

    thanks for such impotant share.
    respectable i m facing error 20202 emergency stop open problem..
    today when i turn on the IRC5 controller, on pendant "instead off guard stop it is emergency stop" and after pressing enabling switch from tech pendant to jog the robot it gives (20202 emergency stop open alarm).
    Led's status on safety board is EPWT led is green rest all are orange or "yellow",
    ES2 led is orange both the emergency switch on the IRC5 Controller and Tech Pendant are connected to ES2,
    ES1 led is complete off
    EN led at the strat is off, when i press enabling switch from pendant it turns orange and holds its state despite i released the switch.
    AS1,AS2,GS1,GS2 all are orange.
    what could be the problem if you kindly guide a little

    No problem friend. so your problem is going to be in X1:9, X1:10. you probably have a relay contact that connects these 2 pins I would wager that your Relays coil is not getting energized or the contact has gone bad.


    if you don't have any external estops jumper X1:9 to X1:10 and X2:9 to X2:10 then your safety chain should turn on.

    Awesome help!! Can you specific where the X3 and X4 connectors are located? I have them on my Contact Board, but no on the Panel board. Newer with ABB and having this same issue!

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