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E-Stop / Work-Cell / Key-Switch Chain Warning

Summary

Several image-defined messages were not robot motion errors at all. They indicated that the E-stop chain, work-cell chain, mode key, or HHB/bypass chain was open or not being read correctly.

Symptoms

  • Robot will not engage.
  • Message appears to reference work cell, key, E-stop, bypass, or operating mode.
  • E-stop LEDs are not both powered/healthy.
  • Pendant may show a clearer safety-chain message than Flair.

Evidence

Timestamp User Media Evidence
2022-11-17 23:20 Cvitan Bolt Jr+ safety chain / E-stop warning screenshot cleared by resetting all E-stops. Image description: Bolt Jr+ safety-chain / E-stop style warning; cleared after resetting all E-stops.
2022-12-23 09:49 Marcin Biegunajtys Flair E-stop or work-cell chain warning screenshot. Image description: Message identified in chat as E-stop / work-cell chain warning.
2023-12-13 06:44 IanH Bolt Pedestal boot warning, cannot engage, suspected E-stop chain or safety chain open. Image description: Bolt Pedestal booted with safety-chain style message and could not engage; E-stop chain suspected.
2024-01-13 01:48 AMC Flair key switch or operating mode warning screenshot., Related key switch warning / operating mode message screenshot. Image description: Message was about the key / operating mode. If key is correct, suspect loose connector or key-switch wiring.
2022-11-17 23:20 - Cvitan: Image description: Bolt Jr+ safety-chain / E-stop style warning; cleared after resetting all E-stops. 2022-12-23 09:49 - Marcin Biegunajtys: Image description: Message identified in chat as E-stop / work-cell chain warning. 2023-12-13 06:44 - IanH: Image description: Bolt Pedestal booted with safety-chain style message and could not engage; E-stop chain suspected. 2024-01-13 01:48 - AMC: Image description: Message was about the key / operating mode. If key is correct, suspect loose connector or key-switch wiring. 2024-01-13 01:48 - AMC: Image description: Message was about the key / operating mode. If key is correct, suspect loose connector or key-switch wiring. [18/11/2022, 2:12:42 am] ~ Felix Roth [18/11/2022, 2:12:43 am] ~ Felix Roth: We want to connect this 12v stepper motor to the trigger box. We managed to get the motor to a hold Status but what ever we wire it‘s not spinning forward. Any suggestions? [18/11/2022, 2:13:29 am] ~ Felix Roth

Media Text / Description

  • Media 1: 2022-11-17 23:20 - Cvitan: Image description: Bolt Jr+ safety-chain / E-stop style warning; cleared after resetting all E-stops.
  • Media 2: 2022-12-23 09:49 - Marcin Biegunajtys: Image description: Message identified in chat as E-stop / work-cell chain warning.
  • Media 3: 2023-12-13 06:44 - IanH: Image description: Bolt Pedestal booted with safety-chain style message and could not engage; E-stop chain suspected.
  • Media 4: 2024-01-13 01:48 - AMC: Image description: Message was about the key / operating mode. If key is correct, suspect loose connector or key-switch wiring.
  • Media 5: 2024-01-13 01:48 - AMC: Image description: Message was about the key / operating mode. If key is correct, suspect loose connector or key-switch wiring.
  • Media 6: [18/11/2022, 2:12:42 am] ~ Felix Roth
  • Media 7: [18/11/2022, 2:12:43 am] ~ Felix Roth: We want to connect this 12v stepper motor to the trigger box. We managed to get the motor to a hold Status but what ever we wire it‘s not spinning forward. Any suggestions?
  • Media 8: [18/11/2022, 2:13:29 am] ~ Felix Roth

WhatsApp Excerpts

Media Text / Description

  • E-stop
  • work-cell chain
  • safety chain
  • key switch
  • operating mode
  • HHB bypass
  • Image description: Flair or robot-side safety warning where the robot cannot engage because the E-stop, work-cell, key-switch, operating-mode, or HHB/bypass chain is open.

[17/11/2022, 11:20:10 pm] ~ Cvitan: Hello everyone, we are new Bolt jnr + users so this maybe some newbie mistake, but we dont know what to to with this error. We suppose we connected everything alright. Obviusly we checked all estops. :)

[17/11/2022, 11:25:59 pm] ~ Peter Constan-Tatos: Do you have the E stop with the key switch and small red button?

[17/11/2022, 11:26:29 pm] ~ Peter Constan-Tatos: Do both led’s light up ?

[17/11/2022, 11:31:57 pm] ~ Cvitan: Thank you, I just reseted all estops and it powered both leds.

[17/11/2022, 11:32:00 pm] ~ Cvitan: Thank you!

[17/11/2022, 11:32:30 pm] ~ Peter Constan-Tatos: 😀👍

[18/11/2022, 2:12:42 am] ~ Felix Roth:

[18/11/2022, 2:12:43 am] ~ Felix Roth: We want to connect this 12v stepper motor to the trigger box. We managed to get the motor to a hold Status but what ever we wire it‘s not spinning forward. Any suggestions?

[18/11/2022, 2:13:29 am] ~ Felix Roth:

[18/11/2022, 2:14:49 am] ~ Der Mo: You need a stepper driver

[18/11/2022, 2:16:39 am] ~ Dan Gottesman: yeah, the triggers box doesn’t work with motors; it just handles “on/off” sorts of signals.

you’d need something like a quad/octo box, or the stepper breakout cable for the ulti box i order to work with a motor.

[18/11/2022, 2:16:55 am] ~ Der Mo: TopDirect Verbessert TB6600 Stepper Driver 4A 9-42V Schrittmotor Treiber Controller 2/4 Phasen Hybrid Schrittmotor Treiber Fahrer für 3D Printer Drucker / CNC https://amzn.eu/d/caSetse https://amzn.eu/d/caSetse

Community Solutions

[CONFIRMED] Reset Every E-Stop And Close The Safety Chain

Check the main E-stop, desktop E-stop box, HHB/deadman/bypass, and any external safety chain plugs. Reset all E-stops before re-engaging.

Confidence: 0.9

[LIKELY] Check Key Switch / Operating Mode Wiring

If the key position is correct but the warning persists, suspect the key-switch wiring or an internal connector.

Confidence: 0.78

[LIKELY] Use The Pendant For Clearer Robot-Side Messages

When Flair only shows a generic warning, the robot pendant/logger may identify the exact safety chain or mode input that is open.

Confidence: 0.78

Official Documentation

Flair Classic Manual — Ch.1 Introduction: High Speed Robot Safety — p.16

Flair Classic Manual — Ch.5 Setups: Axis Safety — p.123

Flair 7 Manual — Ch.1 Introduction: High Speed Robot Safety — p.2

Flair 7 Manual — Ch.5 Setups: Limits and Safety — p.80