CS8 A Then U / Axis 1 Not Ready — EtherCAT Engage Fault¶

Summary¶

If the CS8 shows A when ready but changes to U when engaging and Flair reports Axis 1 not ready / EtherCAT error, treat it as a robot-controller communication problem until proven otherwise. The field thread checked pendant motion, network cables, E-stops, old jobs, track trip state, Ethernet connector damage, and the internal base connection. The operator eventually got running after using the Staubli pendant to move the axis again.

Symptoms¶

CS8 displays A before engage.
On engage, CS8 changes to U.
Flair reports Axis 1 is not ready or EtherCAT error.
Robot has been moved manually from transport to home.
Track may show a secondary trip, but the main problem is engagement.

Community Guidance¶

[LIKELY] Verify pendant motion to separate robot fault from Flair/network fault¶

2023-06-03 — Michael deAnthony / Chavez.Camera

Confirm CS8 reaches A before booting the computer and Flair.
Try moving the robot with the Staubli pendant.
If pendant motion works, treat the issue as a Flair/network/EtherCAT communication problem.
Replace or reseat network cables, especially any twisted/broken Ethernet connector.
Check the network connection inside the base from the CS8.

confidence_score: 0.78

[CONFIRMED FIELD OUTCOME] Pendant movement restored operation in this case¶

2023-06-03 — Michael deAnthony

The reporter confirmed: "I try using the Pendant again and try moving the axis using it. And somehow this time it works."

This is a field recovery, not a root-cause proof. Preserve it as a recovery step, then inspect cables/base network if it recurs.

confidence_score: 0.72

Image description: CS8 / Flair engage-error screenshots where CS8 shows A before engage, changes to U, and Flair reports Axis 1 not ready or EtherCAT communication fault. Searchable terms: Axis 1 not ready; CS8 A then U; EtherCAT error on engage; pendant works Flair does not; broken ethernet head; connection inside base.

Media Text / Description¶

Image description: CS8 / Flair engage-error screenshots where CS8 shows A before engage, changes to U, and Flair reports Axis 1 not ready or EtherCAT communication fault.

Media 1: Image description: CS8 / Flair engage-error screenshots where CS8 shows A before engage, changes to U, and Flair reports Axis 1 not ready or EtherCAT communication fault. Searchable terms: Axis 1 not ready; CS8 A then U; EtherCAT error on engage; pendant works Flair does not; broken ethernet head; connection inside base.
Media 2: Image description: CS8 / Flair engage-error screenshots where CS8 shows A before engage, changes to U, and Flair reports Axis 1 not ready or EtherCAT communication fault. Searchable terms: Axis 1 not ready; CS8 A then U; EtherCAT error on engage; pendant works Flair does not; broken ethernet head; connection inside base.
Media 3: Image description: CS8 / Flair engage-error screenshots where CS8 shows A before engage, changes to U, and Flair reports Axis 1 not ready or EtherCAT communication fault. Searchable terms: Axis 1 not ready; CS8 A then U; EtherCAT error on engage; pendant works Flair does not; broken ethernet head; connection inside base.

WhatsApp Excerpts¶

[3/6/2023, 12:05:25 pm] ~ Michael deAnthony: Okay now this message appears

[3/6/2023, 12:07:10 pm] ~ Michael deAnthony: Yes ive moved it from transport position to "home" manually. And ive already reseted the the whole system and the pendant, but the its still error

[3/6/2023, 12:11:17 pm] ~ Chavez.Camera: well if the pendant operates it must be a communication error. try replacing the network cables.

[3/6/2023, 12:15:01 pm] ~ Michael deAnthony: Okay I'll try it again

[3/6/2023, 12:30:47 pm] ~ Chavez.Camera: Wait for the A on the CS8 before booting the computer and flair.

[3/6/2023, 1:06:36 pm] ~ Galih Pambudi: Hi this is Galih who work with michael, we have tried to set up all the cable communication and bolt ready to use, the status in CS8 is A. However when I try to engage shows the Ethercat Error? is there any idea to solve this problem?

[3/6/2023, 1:07:55 pm] ~ Chavez.Camera: Did you reset all the emergency stops?

[3/6/2023, 1:10:05 pm] ~ Galih Pambudi: all reset already

[3/6/2023, 1:11:25 pm] ~ Chavez.Camera: try loading an old job, maybe some setting has been changed

[3/6/2023, 1:21:04 pm] ~ Galih Pambudi: i have tried to open the old job but the robot still cannot be engaged

[3/6/2023, 1:23:39 pm] ~ Galih Pambudi:

[3/6/2023, 1:27:42 pm] ~ Chavez.Camera: The track is tripped? Did you home zero?

[3/6/2023, 1:31:17 pm] ~ Galih Pambudi: actually the track is not a main problem, we can fix that, the problem is cannot be engaged

[3/6/2023, 1:38:18 pm] ~ Chavez.Camera: and axis 5 tilt is ok? I really have no idea

[3/6/2023, 1:43:54 pm] ~ .: Happened to me last week. The ethernet cable head (Robot) was broken.

[3/6/2023, 1:45:35 pm] ~ Michael deAnthony: Is it this Ethernet head?

[3/6/2023, 1:47:29 pm] ~ .: Yes. Sorry, not the robot one, the ethernet one. Somehow got twisted and wanst working.

[3/6/2023, 1:48:46 pm] ~ Galih Pambudi: actually we have changed with the new one twice still got a same warning but we will try with other cable again

[3/6/2023, 2:27:22 pm] ~ Chavez.Camera: have you checked the connection inside the base? from the CS8?

[3/6/2023, 2:39:52 pm] ~ Michael deAnthony: Okay, i got it working. I try using the Pendant again and try moving the axis using it. And somehow this time it works.

[3/6/2023, 2:40:23 pm] ~ Michael deAnthony: Thank you @⁨~Chavez.Camera⁩ and everyone for your suggestions.