Something like ABB's Robot Studio would indeed be nice. To be able to plug into a robot and see everything it is doing, control it from the software, pull backups, and write and revise programs is a powerful tool. Not to mention that the limited free version has no time limit.
On my RJ3iB (w/ color tp) it's Menu > File > File > F5[Util] > Set Device and select MC. Then you can copy your .LS to the MC. Alternatively, selecting PRINT will save a .TP as an .LS on the MC.
My experience with this has been that certain pieces of equipment will sometimes generate enough vibration to cause a momentary misalignment with the light curtains or cause a connector to lose connection. If I see it happening only when certain programs are run that's the path I follow.
How far does the offset in PR move it? Will it move ok from P to P without the offset in P? Does it pass through singularity in the motion? Have you tried an intermediate point between P and P?
I saw something similar to this once when a robot tried to move to a point programmed in user frame 0 while another user frame was still active.
For the SRVO-051 my R-J3 book says:
1. Replace the servo amplifier.
2. If this does not clear the alarm, verify that all connectors are securely connected.
You may want to take another look at those cables and connectors.
You can change the sensitivity of collision guard programatically. In the collision guard setup you have to set a register to use for sensitivity. Use it to decrease sensitivity when interacting with the chuck and then increase sensitivity when done.
1: R[13:Col Guard Sensitivity]=75
2: Col Guard Adjust
6: R[13:Col Guard Sensitivity]=100
7: Col Guard Adjust
I know this is not exactly what you're looking for, but it will give you more control over when the robot stops due to collision detections.
I don't know if you can find those pre-assembled but, if you google something like Wire Harness Assembly you should be able to find a company to make those for you.
I also have several RJ3s with various versions of HandlingTool. None of them have the IF(...) statement.
Alternatively you could use a program call
1: IF R<>1 OR R<>1, CALL PRG001
Depending on what you are doing with your process, you can add other lines in PRG001 to do whatever else happens along with the output turning on. Then you can potentially call this in other programs as well.
[shadow=red,left]3. There may be a way (i am not sure) to have a pop-up occur on the TP which will prompt the user to select a program.[/shadow]
There is a way to do this. I think you have to have the Menu Utility option. An Operator Entry menu and/or List menu will do this. The Operator Entry menu can be configured to accept various types of data such as boolean, numeric, etc. The List menu can be configured to list up to 8 items or so that can be selected.
Does your eoat turn with axis 6? I sometimes see this when a bearing fails in my gripper and there is too much friction at low jog speeds.
The other thing that comes to mind is that your brake may be sticking after the momentary power loss when you turn the pendant on.
I often see this on my RJ3 robots. Push the e-stop on the teach pendant, then reset it and your SRVO-237 should go away. Sometimes it takes multiple attempts. Afterwards you should be able to clear the SRVO-230.