SRVO-006

Emergency reset and tool clearance

Hold SHIFT + RESET on the teach pendant to perform a fault reset while maintaining the alarm state. Then hold SHIFT while jogging the robot in JOINT or TOOL mode to move the end-effector away from the collision point. This allows movement despite the active HBK alarm.

Use low override speed (5-10%) when jogging with SHIFT held. This is the only way to move the robot with an active HBK alarm.

Ensure the collision area is clear and the robot path is safe before jogging. Movement is possible but the alarm will persist until the HBK signal is restored.

Visual inspection of safety joint

Inspect the safety hand or collision detection joint at the tool interface. Look for visible deflection, misalignment, or mechanical damage. Safety joints typically use spring-loaded pins or plates that separate during impact to break an electrical contact.

Most safety joints have visual indicators (alignment marks or red warning zones) that show when they've been triggered. Check the joint from multiple angles.

Reset safety joint mechanism

Manually reset the safety joint according to the tooling manufacturer's specifications. This typically involves pushing or twisting the joint mechanism until it clicks back into place and the electrical contacts re-engage. Verify the HBK signal is restored before releasing SHIFT.

Do not force the safety joint if it does not reset easily. Damage may prevent proper engagement and compromise safety.

Verify HBK signal restoration

Navigate to MENU > I/O > Digital Input and monitor the HBK signal status (typically *HBK or HBK input). The signal should read ON when the safety joint is properly seated. Press RESET to clear the alarm once the signal is restored.

The HBK input number varies by system config but is typically DI[17] to DI[20] on standard wrist connections. Check the I/O assignment list for your specific configuration.

Inspect wrist connector and cable

Check the robot wrist connector (typically a multi-pin circular connector at J6 or tool flange) for loose connections, bent pins, or contamination. Disconnect and reconnect the cable while observing proper orientation. Inspect the cable routing through the J5-J6 wrist area for pinch points or wear.

Wrist cables on high-cycle applications often fail at the J5/J6 twist area. Flex the cable while monitoring the HBK signal on the I/O screen to detect intermittent faults.

Disconnect robot servo power before disconnecting/reconnecting wrist connectors to prevent inadvertent signal changes. Tag out and lockout as per facility safety procedures.

Measure HBK circuit continuity

Using a multimeter, measure voltage at the HBK input on the wrist connector. With tooling connected and safety joint seated, you should read approximately 24VDC. Disconnect the tool cable and measure resistance across the HBK circuit through the safety joint (typically <10 ohms when closed).

If measuring at the connector is difficult, check the HBK signal at the robot base connection panel. Consult your robot's connection diagram for the specific terminal location.

Check robot cable integrity

Navigate to MENU > SYSTEM > Variables and check system variable $SCR_GRP[1].$HAND_BRK (value should be TRUE when HBK is safe). If the signal reads FALSE with the cable connected and joint reset, the cable may have internal wire breakage requiring replacement.

The HBK circuit typically runs through the robot's standard connection cable package. Cable replacement usually requires service documentation and may need factory-trained personnel for proper routing.

Bypass test with jumper (diagnostic only)

For diagnostic purposes only, temporarily jumper the HBK signal circuit at the wrist connector to close the circuit. If the alarm clears, the fault is in the tooling wiring. If it persists, the fault is in the robot cable or control system. Remove jumper and restore proper wiring before resuming production.

Jumper testing bypasses a critical safety circuit. Only perform this test during troubleshooting with proper lockout/tagout. Never operate the robot in production mode with HBK bypassed.

Verify tooling configuration requirements

Determine if your application requires hand broken monitoring. If the end-of-arm tooling does not include a safety joint or collision detection device, and your risk assessment allows, the HBK function can be disabled. Document the decision per your facility's safety change management process.

Disabling HBK removes a safety layer. Ensure adequate risk assessment and alternative collision protection measures (force limiting, area scanners, etc.) are in place per ISO 10218 or applicable safety standards.

Access hand broken configuration

Navigate to MENU > SYSTEM > Config. Press F1 [TYPE] and select 'Hand Broken Config' or search for HAND_BRK. The current setting shows whether HBK monitoring is enabled. You will need appropriate access level to modify (typically MANUAL SETUPS level or higher).

On R-30iA/B controllers, the setting may be under Config > I/O Config > Hand Broken. Path varies slightly by controller software version.