Applicable Systems
AC500
AC590
ACS580
ACS880
Symptoms
The ABB IRC5 robot controller displays alarm 10034, indicating an encoder calibration error. The robot axis encoder data is invalid or the encoder has lost its calibration reference.
Possible Causes
- Robot has not been zero-point calibrated after maintenance
- Encoder battery depleted causing loss of absolute position data
- Encoder cable loose or damaged causing signal errors
- Encoder resolver internal fault requiring motor service
Troubleshooting Steps
- Step 1: Verify if the robot has been zero-point calibrated
After motor replacement or battery change, the robot must be re-calibrated using the teach pendant - Step 2: Check encoder cable connections at motor and controller
Cables must be fully seated with no bent pins; check for cable damage from flexing - Step 3: If not calibrated, perform zero-point calibration procedure
Follow the ABB calibration procedure using the teach pendant and calibration pins - Step 4: If calibration fails, check encoder battery voltage
Encoder batteries must be replaced before calibration if voltage is low
How to Reset
To reset: 1) Perform the zero-point calibration. 2) Power cycle the controller. 3) If the alarm persists after calibration, check encoder cable and battery. Caution: Operating a robot with uncalibrated encoders can cause unpredictable motion and collision with fixtures.
Frequently Asked Questions
- Q: When should encoder calibration be performed?
Encoder calibration must be performed after motor replacement, encoder battery replacement, or if the robot has lost its absolute position reference. ABB recommends periodic verification as part of preventive maintenance.
- Q: How long do ABB IRC5 encoder batteries last?
Encoder batteries typically last 2-3 years depending on operating conditions. ABB recommends proactive replacement before the low battery warning appears to prevent loss of calibration data.
Source: ABB IRC5 Operating Manual - Trouble Shooting, Document 3HAC020738-001, Alarm Code 10034
Category: Robot