SYST-005

Verify Current Master Device Status

Press MENU on teach pendant > STATUS > Device > Check 'Master Device' field. It will display 'UOP' if this alarm is active. Note which operations you're attempting that are being blocked.

Take a screenshot or note the exact status display - this helps identify if the mode is switching unexpectedly or locked in UOP mode.

Check UOP Control Source Configuration

Navigate to MENU > SYSTEM > Config > I/O UOP. Review settings $UOPCNTRL.$UOP_MODE and $UOPCNTRL.$UOP_MASTER. Verify if UOP master is enabled (=1) and if this is intentional for your application.

In integrated cells, UOP master is often required during AUTO mode. The configuration may be correct for production but needs temporary override for maintenance.

Examine UOP Input Signals

Go to MENU > I/O > UOP Signals. Check UI[17] through UI[32] for active UOP panel signals. Specifically verify *SFSPD (UI[29]), *RMT (UI[30]), and cycle start/stop signals are in expected states.

Do not force UOP signals while robot is in motion or during automated cycles. Coordinate with PLC/cell control personnel first.

Switch to Teach Pendant Master Control

If teach pendant control is needed: Set T1/T2 mode switch to T1 or T2 position on teach pendant. This should automatically override UOP master unless locked by system configuration. Verify MENU > STATUS > Device now shows 'TP' as master.

If mode switch doesn't override UOP, check system variable $MCR.$GEN_OVR[1] - if set to 0, it prevents TP override. May require config modification with proper access level.

Verify Safety Chain and Remote Conditions

Check that remote mode is not forced active. Navigate to MENU > SYSTEM > Master/Cal > Check 'Remote Condition' setting. If set to 'Process', UOP will remain master regardless of mode switch position during cycle execution.

In R-30iB controllers with DCS (Dual Check Safety), the safety configuration may lock UOP master during certain operational states. Review safety configuration file if persistent.

Check Master Override System Variables

From teach pendant: MENU > DATA > Host Comm > Karel Vars. Search for $MCR.$GEN_OVR - this controls master device override permissions. Value of 0 locks UOP control; 1 allows teach pendant override in T1/T2.

Modifying system variables requires proper access level and understanding of cell safety requirements. Document original values before changes.

Review UOP Panel Configuration Parameters

Navigate to MENU > SYSTEM > Config > I/O UOP Pnl. Check parameters: $UOPCNTRL.$RMT_MSTR (Remote master enable), $UOPCNTRL.$PANEL_TYPE (Panel type configuration). If $RMT_MSTR = TRUE, UOP will maintain master control during remote operations.

Parameter $UOPCNTRL.$LOCKOUT can prevent mode changes. If set to TRUE, only UOP device can release master control - requires PLC signal change.

Inspect Production Macro or Background Logic

Check for running background logic that forces UOP mode. Go to MENU > SETUP > Host Comm > Protocols. Review any active KAREL programs or macros listed. Check Program Select for any *MASTER_CTL type programs in execution.

Some integrators use KAREL background tasks to enforce UOP control during specific production states. Review program AUT_STAT.KL or similar system programs if present.

Verify Application Configuration Files

Access MENU > FILE > Config Files. Check for custom .SV (system variable) or .VR (vision resource) files that may contain master device locks. Look for files named *MASTER*, *UOP*, or *CELL_CTRL* that may enforce control hierarchy.

Configuration files loaded at startup can override teach pendant settings. Check FROM (File Recovery On-site Maintenance) directory for MCR or UOP config backups that show original settings.

Monitor Real-Time UOP Signal States

Navigate to MENU > I/O > UOP Signals > Force screen. Monitor UI[30] (*RMT - Remote mode signal) and UI[29] (*SFSPD - Speed override). If *RMT is continuously ON, PLC is holding remote/UOP control. Note signal timestamps to identify if stuck.

Never force UOP signals without proper lockout/tagout procedures and coordination with automation team. May cause unexpected robot motion.

Check PLC Interlock Logic and Handshaking

Examine robot outputs going to PLC: MENU > I/O > Digital > Output. Check DO[11] (SFSPD_EN - Speed enable), DO[12] (RMT_EN - Remote enable). If these are ON, robot is acknowledging UOP control. Verify PLC logic permits mode change requests.

Most integrated cells require specific PLC handshake sequences to release UOP control. Contact controls engineer for 'LOCAL MODE' or 'MAINTENANCE MODE' switch on HMI.