Fault code 10125 randomly stoping program execution

    Hi guys

    I have a IRC5 Multi-Move system running RW 5.16 with 2 IRB1600 robots here that occasionally runs into the fault code 10125.

    This started to happen at the end of last year without any change to the running system and so far we could figure out why or
    even a way to trigger the behavior. It just happens at random.

    There is nothing in the logs, just the 10125 fault for each robot at the same time, nothing before and nothing after... on the PLC
    side nothing appears in the logs.


    Mayby someone already ran into a similar situation and could guide me to the cause of the fault. ABB Support didn´t had a good
    idea what causes the problem and just recommended a reset with an I-Start or check the PLC side.

    My next step is to have our PLC guy sniffing the Profibus connection and trying match up when the fault happens next time as I
    don´t see anything I could check on the robot side.

    Thanks in advance :winking_face:

    Regarding 'random':

    Does this happen at the same place in the program at random times or random places in the program?

    I've had glitches that would drop the safety circuit but too quick to register internal inputs that determine fault codes. Not easy to find. Some were traced to noise on inputs, others to vibrations affecting loose connections, dirty contacts, weak contactors.

    Lemster68

    With nothing else in the logs I mean exactly that. Neither me nor ABB remoting into the system could find any other log entry around the time of the stop under any filter.


    Skooter

    It happens at different places in the same program but also in different programs. So far we could only observer that it happens more often in an area where the arm is streched out and less often in the
    other areas where the arm is mostly retracted.

    The point with loose connection or weak contactors sounds interesting, as the system ist running more then 11 years without much in major parts changes. So contactors getting weak doesn´t sound far fetched.

    Switches, connections, contactors are mechanical and are subject to movement & vibration.

    Noise induced glitches can be related to shielding, grounding, cable routing, sensors that still switch but become noisy, light curtains that become sensitive to other light or vibration, scratched or dirty area scanner lenses, safety mats :frowning_face: , etc.

    I've used a portable oscilloscope to monitor signals too many times to count.

    Thanks for the info, we will keep that in mind. At first we are running now a log on the PLC side with
    per cycle logging for the Profibus.

    If we can´t find anything we will go towards the classis i/o and log that (no oscilloscope at hand, but
    dedicated logging hardware with logging digital i/o with fast analog inputs)

    I will update when we find anything

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