SYST-002

Display alarm detail on teach pendant

Press MENU > ALARM > F1 [TYPE] > *All* to view the SYST-002 alarm. Press ENTER on the alarm to view additional details including the program name and line number where HOLD was executed.

The alarm detail screen shows the exact line number - note this before resetting to quickly locate the HOLD instruction.

Locate HOLD instruction in program

Press SELECT, choose the program listed in alarm detail, press ENTER. Use FIND function (FCTN > Find) or scroll to the line number shown in alarm. Examine preceding comment lines (often above HOLD statements) explaining what operator action is required.

Programmers typically add comments like '! Wait for part load' or '! Check fixture' immediately before HOLD instructions.

Complete required operator action

Perform the action indicated by program comments or operation documentation (load part, verify position, acknowledge inspection, wait for external equipment, etc.). Verify all safety conditions before proceeding.

Never bypass intentional HOLD points without completing the required action - these exist for quality control, safety, or process synchronization.

Clear HOLD and resume operation

Press RESET button to clear the HOLD alarm. Press and hold enable switch, then press START to resume program execution from the next line. Monitor first motion after resume for correct operation.

If HOLD recurs immediately, an unconditional HOLD may be in a loop or the triggering condition hasn't cleared.

Identify conditional HOLD statement

Navigate to program line shown in alarm (MENU > ALARM for line number, then SELECT > [Program]). Look for logic statements before HOLD: IF DI[x]=ON THEN, IF R[x]>value THEN, or JMP LBL[x] (SKIP,condition) patterns. Note the condition variables (DI, DO, R, PR, flags).

Conditional HOLDs often use format: 'IF condition THEN' on one line followed by 'HOLD' on the next line, or combined as 'HOLD (condition)'.

Check I/O and register states

Press MENU > I/O > Digital to view DI/DO states referenced in condition. For registers, press MENU > DATA > REGISTERS (R[], PR[], SR[]). Compare actual values against the conditional logic. Document which condition triggered the HOLD.

Use MENU > I/O > I/O Diagnos to see signal names and real-time states. Toggle simulation mode (MENU > I/O > Simulated I/O) to test if I/O is the issue.

Determine why condition is active

Investigate the root cause of the triggering condition: check external devices if DI-based, verify PLC/cell controller signals, inspect workpiece sensors, or check if register was set by previous program logic. Review I/O wiring and device functionality.

Do not force signals or manually change registers without understanding why the condition exists - it may indicate a real process fault or safety issue.

Resolve condition and resume

Correct the upstream issue (reset external device, clear obstruction, adjust fixture, etc.) and verify the condition clears on I/O or register display. Press RESET to clear alarm, then START to continue. If condition persists, force I/O temporarily (MENU > I/O > Force) only for troubleshooting, then restore automatic control.

Check System Variables $FAST_SOCKET, $WAITTMOUT, or custom SR[] registers if HOLD is part of error recovery logic.

Identify active Karel programs

Press MENU > STATUS > Program Status to view all running tasks. Note any Karel programs (.PC files) running in background or called from TP. Check alarm detail for program context - Karel HOLDs may show calling TP program name.

Karel programs typically run on tasks 2-8. Look for programs with names like *KCL* or custom names ending in .PC in the task list.

Review Karel HOLD commands

Access Karel source if available (USB/MD: drive or teach pendant file listing). Search for HOLD, PAUSE_TASK, or SET_VAR calls that modify $INOVRP or $MCR system variables. Check for error handlers that issue HOLD on exception conditions.

Common Karel patterns: 'SET_VAR(entry_inovrp, FALSE, status)' or 'PAUSE_TASK(current_task, status)' both create HOLD conditions.

Check system variable states

Press MENU > DATA > System Variables. Check $INOVRP (must be TRUE to run), $MCR.$GENOVERRIDE (>0 to move), and $TP_PRIORITY (task priority). If Karel set these FALSE or 0, it creates a HOLD condition. Note which variable is affected.

Filter system vars by typing '$IN' or '$MCR' in search field. Use F2 [DETAIL] to see variable attributes and which task last modified them.

Reset Karel conditions and restart

If Karel HOLD is erroneous, abort Karel task: MENU > STATUS > Program Status > [Select Karel program] > F5 [ABORT]. Press RESET to clear SYST-002. Restart TP program. If Karel is required, investigate why it issued HOLD and correct source code or triggering inputs.

Aborting Karel programs may interrupt critical background processes like vision tracking, conveyor tracking, or safety monitoring. Verify Karel function before aborting.