SYST-003

Verify Enable Switch Position

Check the three-position enable switch on the back of the teach pendant. The switch should be fully released (not pressed) for automatic operation. The middle position enables manual operation, and fully pressed or released disables the pendant.

Never bypass or defeat the teach pendant enable switch. This is a critical safety device per ANSI/RIA R15.06 standards.

Check TP Enable Status on Screen

On the teach pendant screen, verify the status indicator in the top-right corner. Look for 'TP ENABLED' message. Press MENUS → SYSTEM → F1 [TYPE] → Variables to view system variable $TP_ENABLE. A value of TRUE indicates the TP is enabled.

You can also check the I/O signal 'TPENBL' (TP Enable signal) under MENUS → I/O → Digital → Input to verify the hardware switch state.

Release Enable Switch Properly

Fully release the enable switch and verify the 'TP ENABLED' indicator disappears from the teach pendant screen. The switch must be completely released, not in the middle position.

If the enable switch feels stuck or doesn't return to the released position, the teach pendant may require maintenance or switch replacement.

Reset and Verify Alarm Clears

Press the RESET button on the teach pendant or operator panel to clear the SYST-003 alarm. Verify the alarm clears and does not immediately return. If it returns, proceed to check the operating mode selection.

Check Mode Selector Switch Position

Locate the mode selector keyswitch on the operator panel (typically on the controller cabinet door). Verify it is rotated to the AUTO position. T1 mode allows 250mm/sec maximum speed with TP enabled, T2 allows 100% speed with TP enabled, and AUTO mode requires TP disabled for external control.

Changing from T1/T2 to AUTO mode requires a risk assessment. Ensure all personnel are clear of the robot work envelope before switching to AUTO mode.

Verify Mode Display on Teach Pendant

Check the top-left corner of the teach pendant screen for the current operating mode display. It should show 'AUTO' for automatic operation. If it shows 'T1' or 'T2', the mode switch must be changed to AUTO.

The system variable $MCR.$GENOVERRIDE shows the mode: 1=T1, 2=T2, 3=AUTO. Check via MENUS → SYSTEM → Variables.

Check Remote/Local Switch Position

If equipped, verify the REMOTE/LOCAL switch on the operator panel is in the REMOTE position. Some configurations require this switch to be in REMOTE for automatic operation even when in AUTO mode.

The REMOTE/LOCAL functionality can be customized via PMC ladder logic. Check system configuration parameter $MCR_GRP.$MASTER_CFG bits if behavior seems unusual.

Verify AUTO Mode Requirements Met

Navigate to MENUS → SYSTEM → F1 [TYPE] → Master/Cal and check that all calibration and mastering is complete. AUTO mode may be restricted if the robot is not fully mastered. Also verify safety circuit is closed (no safety stops or E-stops active).

Check system variable $AUTOENBL. If FALSE, automatic operation is disabled. This can be set via PMC ladder or Karel programs for application-specific lockouts.

Check Safety Circuit Configuration

Navigate to MENUS → I/O → Digital → Input and check signals IMSTP (Immediate Stop) and SFSPD (Safe Speed). Verify no safety-related inputs are detecting TP enable as a fault condition. Also check signals *SFGRD (Safeguard) and *PPABN (Peripheral Panel Abnormal).

Do not modify safety circuit signals without proper safety certification and lockout/tagout procedures. Violations can result in serious injury or death.

Review PMC Ladder Logic

Access the PMC ladder program via MENUS → SYSTEM → F1 [TYPE] → PMC. Review ladder logic for references to R632 (TP Enable input signal). Look for custom interlocks that check TP enable state before setting CSTOPI (Cycle Start Permit) or SFSPD signals.

Use PMC signal trace function (F3 [TRACE]) on signal R632 to identify all ladder rungs that reference the TP enable condition. This reveals custom interlocks.

Check Dual Check Safety (DCS) Configuration

If the system has Dual Check Safety option, navigate to MENUS → SYSTEM → F1 [TYPE] → DCS Setup. Verify DCS is not configured to prevent operation when TP is enabled. Check DCS configuration parameters in $DCS_CFG for TP_ENABLE monitoring.

R-30iB controllers with DCS may have parameter $SCR.$TPENBL_CHK that enforces TP disable checking. Verify this parameter matches your safety requirements.