Staubli Mode Switch / J113 Bypass — Operating Mode Change or Cannot Engage¶

Summary¶

When a Bolt shuts off the arm lights, reports an operating-mode style warning, or will not engage after a reset, check the Staubli mode selector and the J113 safety/bypass chain. In one resolved case, reseating the Staubli switch cable cleared the issue; in another, the discussion focused on J113 bypass wiring and mode selector state before the root cause moved into EtherCAT cabling.

Symptoms¶

Bolt arm lights switch off unexpectedly.
Flair / CS8 reports an operating mode or safety-chain warning.
Robot will not engage after reset.
Flipping the key switch may work briefly, then the problem returns.
System may have been converted between pedestal and track base.

Community Solutions¶

[CONFIRMED] Reseat / check Staubli mode switch cable¶

2023-01-12 — IanH / David Goldsmith / Timothy Heys Cerchio

Check the Staubli operating mode key/switch has not been bumped.
Reboot and read the CS8 / pendant diagnostic message if available.
Reseat the cable for the Staubli mode switch.
Check the working-mode switch and Staubli E-stop connection at CS8 J113.

The field reporter confirmed that reseating the cable for the Staubli switch restored operation.

confidence_score: 0.84

[LIKELY] Check J113 bypass plug or plug in the real mode selector¶

2023-03-16 — Timothy Heys Cerchio / Riley Morgan / Gordon Eschke

If a bypass jumper is installed:

Inspect for loose wires at the bypass jumper.
Try the actual mode selector rather than the bypass plug if available.
Do not assume J1202/UltiBox pass-through is related; one responder noted J1202 is pass-through to the UltiBox and should not cause this safety message.

confidence_score: 0.72

Screenshot/error description: Staubli / CS8 operating-mode or safety-chain warning; robot will not engage after reset; mode selector or J113 bypass state suspected.

Media Text / Description¶

Screenshot/error description: Staubli / CS8 operating-mode or safety-chain warning; robot will not engage after reset; mode selector or J113 bypass state suspected.

Media 1: Screenshot/error description: Staubli / CS8 operating-mode or safety-chain warning; robot will not engage after reset; mode selector or J113 bypass state suspected.
Media 2: Screenshot/error description: Staubli / CS8 operating-mode or safety-chain warning; robot will not engage after reset; mode selector or J113 bypass state suspected.

WhatsApp Excerpts¶

[12/1/2023, 7:31:36 am] ~ IanH: Hi all, has anyone gotten this error before? I'm on a Bolt Track, robot suddenly shut off and now won't re-engage (it comes up with this error every time). It was working fine up til now. Lights on the track base are still on but the lights on the arm are off

[12/1/2023, 7:33:09 am] ~ David Jeffries: Operating mode change is typically the staubli mode switch I believe. Check that it didn't get switched/bumped?

[12/1/2023, 7:35:04 am] ~ IanH: Yep. We flipped the key back and forth, now it's behaving!

[12/1/2023, 8:13:00 am] ~ IanH: Spoke too soon, same error just occured and changing the staubli mode on the base doesn't seem to be working. Any other suggestions?

[12/1/2023, 8:21:46 am] ~ David Jeffries: Assuming you've tried a reboot on the system?

First I'd see the code on the cs8, any letters or numbers out of place?

My next thought, personally, would be to pull out the pendant and check for error codes there in the staubli logger.

[12/1/2023, 8:36:03 am] ~ IanH: Gave it some time, re-seated the cable for the staubli switch and now it's working again. I'll try checking the pendant if it happens again

[12/1/2023, 9:54:23 am] Timothy Heys Cerchio: @⁨~IanH⁩ If and when you have some downtime it might also be worth opening the back panel on the Bolt Base and checking the Working Mode Switch and Staubli E-Stop connection to CS8 on port J113.

[12/1/2023, 9:59:51 am] ~ IanH: That's the connection I re-seated, if the problem continues I'm going to repeat the process. It's a bolt that was converted from pedestal to track base so that might be a factor

[12/1/2023, 10:01:02 am] Timothy Heys Cerchio: 👍🏼 exactly!

[12/1/2023, 10:44:50 am] ~ Max Pepper: Hi all, just an update on the issue I was having with the strange sound coming from the bolt. If you ever come across a sound similar I would suggest changing the brass pinion gear. If the sound is rhythmic it’s very likely that is the cause. To remove it I suggest using a heat gun while the gear is spinning slowly, we raised it off the tracks and had the brake attached so that we could still rotate the gear while the bolt was not on the track. (NOTE you have to remove a small screw before, there is only one). We had succession with this after heating the gear for roughly 2 minutes, it slipped off itself with no force needed. Do the same with the spare gear, heat it prior to fitting it on as this will expand the metal and make the whole process a lot easier / faster. Be sure to wear heatproof gloves also…

thank you all for your help!

[16/3/2023, 1:58:57 am] ~ João Varela: Hi guys! Can you help me with this issue? Happened the same thing as Monday, the robot disengaged and didn’t engage when told. Reseted the computer, then this message appears when I try to engage

[16/3/2023, 2:02:48 am] Timothy Heys Cerchio: Bolt or JR+?

[16/3/2023, 2:03:30 am] ~ João Varela: Bolt (big one)

[16/3/2023, 2:05:01 am] ~ João Varela: Just restarted the computer and gave me the same message. Probably I’ll switch everything off and on?

[16/3/2023, 2:05:24 am] Timothy Heys Cerchio: Are you using the Staubli E-Stop too or the little bypass plug on CS8?

[16/3/2023, 2:06:33 am] ~ João Varela: What I have on the cs8

[16/3/2023, 2:06:42 am] ~ João Varela: And on the rt