Which locations should be checked when an ABB robot repeatedly alarms but recovers after a restart?
Even if an ABB robot's intermittent alarm temporarily recovers after a restart, the event log, control power supply, internal communication, feedback cables, cooling, and specific posture correlations should be checked.
An ABB robot experiencing sporadic alarms that can continue running after a power-off restart does not mean the fault has disappeared. Intermittent issues are often related to power fluctuations, connector contact, cooling, moving cables, or internal communication. It is necessary to save on-site information before clearing the alarm.
- Save the event log
Record the complete alarm code, occurrence time, program line, robot posture, operating speed, and load. Comparing whether multiple faults are concentrated on the same axis, the same action, or after the equipment has been running for a period of time can help distinguish random electrical problems from cable faults caused by fixed motion positions.
- Check the power supply and cooling
Measure the control power supply and 24V circuit. Check contactors, terminals, power modules, cabinet fans, and filter screens. If the alarm occurs when the machine warms up but not when cold, focus on observing air duct blockages, fan speed, and drive module temperature.
- Check communication and feedback links
Check the connections between the main computer, axis computer, drive unit, and I/O modules. For single-axis encoder or position feedback alarms, also check the feedback plug, shield grounding, internal harness within the robot body, and the connecting cables between the control cabinet and the robot.
- Reproduce and verify
Repeat the original action at low speed under controlled conditions and compare by changing posture, speed, or load. After locating the fault point, complete continuous automatic cycle and warm-up operation tests. Do not use a single successful restart as the standard for repair completion.
The focus of handling intermittent alarms on ABB robots is to preserve logs and search for repeating conditions, gradually narrowing down the scope through time, posture, temperature, and associated axes.
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