SYST-004

Verify current operation mode on teach pendant

Press MENU on teach pendant, select 6: SYSTEM > 1: Master/Cal > F1 [TYPE]. Check if 'SOP Enable' shows 'TRUE'. This indicates SOP is currently the active input device and blocking automatic operations.

On R-30iA controllers, you can also see SOP status directly on the TP status bar at the top of the screen - look for 'SOP' indicator lit.

Disable SOP and select proper operator panel

From MENU > SYSTEM > Master/Cal screen, toggle F4 [SOP] to set 'SOP Enable' to 'FALSE'. Then select the appropriate input device: UOP (User Operator Panel) for production AUTO mode, or TP (Teach Pendant) for teaching/manual operations.

Changing from SOP to UOP or TP may alter enabled motion speeds and override limits. Verify safe operation conditions before proceeding.

Check system configuration variable $OP_PANEL_ENABLE

Navigate to MENU > NEXT > SYSTEM > Variables, search for $OP_PANEL_ENABLE. This system variable shows current operator panel: 1=CRT, 2=Teach Pendant, 3=UOP, 4=SOP. Verify it matches your operational requirements.

You can monitor this variable in background logic or TP programs using IF $OP_PANEL_ENABLE=4 THEN statements to prevent SOP-incompatible operations.

Verify no hardware SOP enable signal present

Check physical SOP connection at controller. If an external SOP device is connected via the operator panel connector, ensure its enable switch is in the correct position. Disconnect SOP cable if not in use to prevent inadvertent enabling.

On systems with multiple operator panels, the last panel to assert control typically becomes active. Check all connected panels for enable switches or buttons.

Check operator panel selection parameter

Navigate to MENU > NEXT > SYSTEM > Variables and check $OP_PANEL variable. Also review $SHELL_CFG.$SHOW_SOP_SEL which controls whether SOP selection is available on the teach pendant interface. If set incorrectly, it may force SOP mode.

Parameter $SHELL_CFG.$SHOW_SOP_SEL requires controlled start ($CSTR) if modified. Plan for a controller restart if changes are needed.

Review PMC ladder logic for forced SOP enable

Access MENU > NEXT > PMC > PMCDGN, check ladder logic for signals forcing SOP enable (typically F signals or G signals mapped to operator panel control). Search for 'SOP' or check addresses related to UI_OPSEL or operator panel selection flags.

Modifying PMC ladder logic requires proper backup and understanding of machine safety circuits. Never alter safety-related PMC logic without complete documentation and authorization.

Examine custom KAREL or TP programs

Check for custom KAREL programs or TP background logic that may be setting $OP_PANEL or $OP_PANEL_ENABLE variables. Search loaded programs for SET_VAR or assignment statements affecting operator panel selection.

Use STATUS > Program Select > KAREL Progs to see all running KAREL programs. Any program with 'OP_PANEL' in variable assignments should be reviewed.

Verify dual check safety (DCS) configuration

On systems with DCS or advanced safety options, check MENU > SYSTEM > Safety Config to ensure safety configuration isn't locking operator panel selection. Some safety configurations restrict panel switching during certain operational states.

If DCS safety is enabled, operator panel changes may require specific conditions like T1 mode and motor off. Check safety manual for your specific safety option version.

Identify the blocked operation or command

Review the operation or program that triggered SYST-004. Check alarm history (MENU > ALARM > F5 [HIST]) to see what command or action preceded the alarm. Common blocked operations include PLC start signals, RUN commands from HMI, or high-speed motion instructions.

The alarm log timestamp correlation with PLC or HMI logs often reveals exact trigger - look for remote I/O start signals arriving while SOP was active.

Review application-specific SOP restrictions

Check your application documentation or custom system configuration for SOP-restricted operations. Navigate to MENU > SETUP > Host Comm to verify if remote operation settings conflict with SOP mode (remote start typically requires UOP).

Many integrators disable certain features in SOP mode via PMC logic for safety. If this is a recurring issue, request documentation on SOP mode limitations from system integrator.

Switch to appropriate control mode for operation

For production/AUTO operations: disable SOP and enable UOP. For teaching/manual: disable SOP and enable TP. For remote/HMI control: ensure UOP is enabled and mode switch is in AUTO position. Each operation type has a specific compatible operator panel configuration.

When switching from SOP to AUTO/UOP mode, ensure all personnel are clear of robot work envelope and all safety interlocks are properly functioning before initiating motion.

Configure operator panel change procedures

If panel switching is frequent, consider implementing TP macro programs or PMC ladder sequences to automate safe panel transitions. Document proper procedures in your work instructions specifying when each panel mode should be used.

You can create a simple TP program with JMP LBL[] logic that checks $OP_PANEL_ENABLE and prompts operator to switch modes if incorrect for the desired operation, preventing this alarm proactively.