Mobile Industrial Robots MiR Series User manual

Error codes and solutions
Troubleshooting guide (en)
Date: 07/2020
Revision: 1.1
Valid for: All MiR robots

Troubleshooting guide (en) 07/2020 - v.1.1 ©Copyright 2019-2020: Mobile Industrial Robots A/S. 2
This document lists all current error codes that MiR robots can report. The robot error codes are categorized
into the following groups:
•Mission errors are errors that require manual intervention to resolve or the implementation of a
Try/Catch action to provide the robot with an alternative action. Mission errors occur if the robot cannot
complete an action in its current mission. These errors can often be resolved by changing your mission or
modifying the robot's work environment, for example, by moving an obstacle.
•Hardware errors are internal errors that occur when the system detects discrepancies or unexpected
results from the robot components. These issues can sometimes resolve themselves, for example, if a
connection is reestablished.If the issue persists, you have to address the issue by determining the cause of
the issue. Often, the issue is caused by faulty cable connections or broken components. Before inspecting
the robot's internal parts, it is a good idea to see if restarting the robot resolves the issue automatically.
•Environmental errors are errors that continue to occur due to the environment the robot operates in and
cannot be remedied without changing the work environment. These are errors such as localization errors
or stall and slip detection errors. You cannot use Try/Catch actions to provide an alternative approach to
these errors since they indicate that the robot is operating in an unsuitable work environment or with
incorrect settings.
You can see short description of each error code and possible solutions for solving the error. If the suggested
solutions do not remove the error, you can try using the troubleshooting guides on the Distributor site to see if
the issue you are experiencing is described there. Otherwise, contact Technical Support for assistance with
your case.

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Safety
Before beginning this troubleshooting guide, refer to the safety chapter in your MiR product's user guide or
operating guide.
WARNING
To troubleshoot your robot effectively, you may need to investigate the internal or external
parts while the robot is turned on. You will be exposed to electrical and mechanical hazards.
•Only connect the battery in the steps where it is necessary for the robot to be active.
•Disconnect the battery in the steps where it is not necessary for the robot to be active.
•Only qualified personnel may perform the steps in this troubleshooting guide.

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Contacting Technical Support
If you are asked to contact Technical Support in a step or solution in this guide, or if the solution you reach at
the end of the guide does not remedy the issue, you can create a support request through the Distributor site
under Contact Support.
Before creating a support request, it is highly recommended to update to the latest
recommended software, as this may resolve the issue. It will also enable your robot to generate
a more detailed error log, providing Technical Support with more information to troubleshoot
the issue correctly.
In your support request, describe the problem you are experiencing and your observations for each step in the
guide you have completed. To document this, download the troubleshooting documentation sheet with the
same title as this guide from the Distributor site.

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To ensure that Technical Support can diagnose and solve the issue correctly, attach an error log retrieved
from the robot. It is important that the error log is generated as described in the guide How to generate an
error log found on the Distributor site. To assist Technical Support further, include any reported error codes,
images, or videos of the issue.

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How to check cable connections
Most faults in the connectivity across cables occur in the connectors. To determine where the fault is in a
cable, we therefore recommend to start by checking the connectors.
There are two steps in checking the connectors:
•Check that the cable is properly connected to its end connectors.If hey are visible, verify that each wire is
connected to a connector pin by pulling each wire gently (approximately 10N). Avoid pulling harder than
necessary, as this may damage the connection between the wire and connector. When checking a wire, it
should only be able to move 0.5 mm from its original position at most.
•If the cable and connector are securely fixed together, ensure that the connector is correctly plugged into
its socket. The connector is loose if it can be pulled out of the socket easily. To ensure that the connector is
correctly plugged in, gently push the connector into its socket. If a connector has a lock or screws, check
that you cannot unplug it without unlocking or unscrewing it.
Cables are occasionally labeled incorrectly or are missing labels. To locate the correct cable, it
is a good idea to refer to the images shown in the guide or the wiring diagrams found on the
Distributor site.

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MiR100 and MiR200
Error code Error type Description Solution
101, "CPU load
is too HIGH -
Above 90% for
more than 3
minutes"
Hardware
error.
Can resolve
itself.
An issue has occurred in
the robot software,
requiring unusual
amounts of processing
power.
Reboot the robot. If the problem
persists, and you have not updated to
the latest software, it is recommended
to update your robot. this may solve
the issue.
If the issue occurred after a software
update to the latest version, try to roll
back to a functioning software version
and report the issue to Technical
Support.
201, "Free
Memory is
VERY low"
Hardware
error.
Can resolve
itself.
An issue has occurred in
the robot software.
Reboot the robot. If the problem
persists, and you have not updated to
the latest software, it is recommended
to update your robot. this may solve
the issue.
If the issue occurred after a software
update to the latest version, try to roll
back to a functioning software version
and report the issue to Technical
Support.
301, "No
ethernet
adapter found"
Hardware
error.
Can resolve
itself.
An issue has occurred in
the robot computer.
Reboot the robot. If this does not solve
the issue, contact Technical Support.

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Error code Error type Description Solution
302, "Ethernet
is not
connected"
Hardware
error.
Can resolve
itself.
The connection between
the robot computer and
the router is faulty.
Replace the Ethernet cable from the
robot computer and the router with an
Ethernet cable you are certain is
functional.
If the issue persists, swap the port the
Ethernet cable connects to in the
router. If a new error is shown,
replace the router. If the error
remains the same, contact Technical
Support as described in Contacting
Technical Support on page4.
401, "Very low
free space on
harddrive"
Hardware
error.
Requires
interaction.
The hard drive memory
is almost filled up.
Begin by deleting old backups stored
on the robot.this can be done through
the robot interface under System
>Backups.
If the issue persists, execute a
USBrestore. See the guide How to USB
restore MiR100/MiR200, found on the
Distributor site.
501, "Battery
MIR 100/200:
Battery is TOO
low."
Hardware
error.
Requires
interaction.
The robot has only 5%
power left.
Recharge the robot.
503, "Battery
MIR 100/200:
Missing
charging status
message"
Hardware
error.
Can resolve
itself.
The CAN bus connection
from the battery
management system is
faulty.
Check wire 194 that connects the MiR
board to the battery. If the wire is
correctly connected and the issue
persists, replace the wire or the MiR
board.

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Error code Error type Description Solution
504, "Battery
MIR 100/200:
Unable to
detect
hardware
configuration."
Hardware
error.
Can resolve
itself.
There is an error in the
robot software that
prevents it from
determining the
hardware configuration.
Reboot the robot. If the problem
persists, and you have not updated to
the latest software, it is recommended
to update your robot. this may solve
the issue.
If the issue occurred after a software
update to the latest version, try to roll
back to a functioning software version
and report the issue to Technical
Support.
If the issue persists, execute a
USBrestore. See the guide How to USB
restore MiR100/MiR200, found on the
Distributor site.
601, "Teensy:
Gyroscope data
timed out - Last
Gyroscope
message
received %
(seconds)d
seconds ago"
Hardware
error.
Can resolve
itself.
The MiR board is not
receiving data from the
gyroscope.
Try rebooting the robot.If the issue
persists, check cable 110 that connects
the robot computer to the MiR board
(see Figure 1.1 and Figure 1.2). If the
cable is correctly connected, try to
replace the cable or the MiR board.
602, "Teensy:
Gyroscope data
is jumping
ALOT!"
Hardware
error.
Can resolve
itself.
See error 601, "Teensy:
Gyroscope data timed
out - Last Gyroscope
message received %
(seconds)d seconds ago"
above.
650, "Unable to
find
LightController
MCU"
Hardware
error.
Can resolve
itself.
The connection from the
robot computer to the
MiR board is faulty.
Try rebooting the robot.If the issue
persists, check cable 110 that connects
the robot computer to the MiR board
(see Figure 1.1 and Figure 1.2). If the
cable is correctly connected, try to
replace the cable or the MiR board.

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Error code Error type Description Solution
650, "Unable to
get version of
LightController
MCU"
Hardware
error.
Can resolve
itself.
See the error above.
650,
"Connecting to
Lightcontroller
MCU failed"
Hardware
error.
Can resolve
itself.
See the error above.
650, "No
firmware
available for
this
Lightcontroller
MCU"
Hardware
error.
Can resolve
itself.
The MiR board is
missing its software.
Reboot the robot. If the problem
persists, and you have not updated to
the latest software, it is recommended
to update your robot. this may solve
the issue.
If the issue occurred after a software
update to the latest version, try to roll
back to a functioning software version
and report the issue to Technical
Support.
If the issue persists, execute a
USBrestore. See the guide How to USB
restore MiR100/MiR200, found on the
Distributor site.
650,
"Upgrading
firmware
failed"
Hardware
error.
Can resolve
itself.
This error may occur if
the MiR board failed to
update during a
software update.
Try rebooting the robot.You can also
try upgrading the software again.
If the issue persists, execute a
USBrestore. See the guide How to USB
restore MiR100/MiR200, found on the
Distributor site.

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Error code Error type Description Solution
650, "Multiple
teensies found -
this is not
supported!"
Hardware
error.
Requires
interaction.
This error should only
occur if you try to
connect another
controller board to the
robot computer.
Disconnect any devices that have been
connected directly to the robot
computer or router.
651, "Teensy:
Programming
MiR controller
MCU..."
Hardware
error.
Can resolve
itself.
This error may occur
during a software
update when the
software is being
uploaded to the MiR
board.
Wait at least ten minutes to give the
robot time to finish uploading.
Otherwise, if the uploading time
seems excessive, cancel the upload
and try to update the software again.
701,
"MIR100/200
Motor
Controller:
Motor power
usage above
limit!"
Environmental
error.
Requires
interaction.
Hardware
error.
Requires
interaction.
The motors are using
more power than
expected.
This error can occur if the wheels or
axles are blocked, the robot is pulling
too heavy a load, the robot or its load
is colliding with an object that is not
detected by the scanners, or the robot
is traveling up too steep an incline
relative to its load.
If the issue persists, you can also
modify the threshold for stall detection
in the robot interface under System
>Settings>Motor
controller>Advanced settings.

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Error code Error type Description Solution
710,
"MIR100/200
Motor
Controller:
Initialization
failed!"
Hardware
error.
Can resolve
itself.
The connection between
the motor controller and
the robot computer is
faulty.
Verify that power is delivered to the
motor controller. There is a power
LEDlight that will light green if both
the 5V and 24V power is delivered (see
Figure 1.4). If either of these lights is
turned off, you will need to inspect the
cables supplying the power to the
motor controller. For the 24V supply,
wire 041 begins the connection from
the controller to the battery via relays
and fuses. For the 5V power supply,
wire 071 begins the connection. Refer
to the MiR100/MiR200 wiring diagram
found on the Distributor site.
If the motor controller is receiving
power, check the wires 085, 086 and
088 that connect from the motor
controller to the robot computer.
711,
"MIR100/200
Motor
Controller:
Unable to
connect to
motor
controller!"
Hardware
error.
Can resolve
itself.
See error 710,
"MIR100/200 Motor
Controller: Initialization
failed!" above.
712,
"MIR100/200
Motor
Controller: Lost
connection to
motor
controller!"
Hardware
error.
Can resolve
itself.
See error 710,
"MIR100/200 Motor
Controller: Initialization
failed!" above.

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Error code Error type Description Solution
801, "SICK
S300: Lost
connection to
scanner"
Hardware
error.
Can resolve
itself.
See error 10202, "E_
LOCALIZATION_FAILED_
NO_SCANNER_DATA" on
page25.
802, "SICK
S300: No data
for >15 sec"
Hardware
error.
Can resolve
itself.
See error 10202, "E_
LOCALIZATION_FAILED_
NO_SCANNER_DATA" on
page25.
803, "SICK
S300: Got xx
failed
transmissions in
the last xx
seconds"
Hardware
error.
Can resolve
itself.
See error 10202, "E_
LOCALIZATION_FAILED_
NO_SCANNER_DATA" on
page25.
850, "Waiting
for reboot"
Hardware
error.
Can resolve
itself.
This error occurs while
hook software is being
updated.
This error only occurs after you have
uploaded a new software file to an
attached MiRHook. Wait until the
software has completely finished
uploading. This may take a few
minutes.
850, "Uploading
Firmware"
Hardware
error.
Can resolve
itself.
See the error above.

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Error code Error type Description Solution
901, "Camera
(OpenNI):
Waiting for
connection is
taking longer
than expected!"
Hardware
error.
Requires
interaction.
The connection between
at least one of the
cameras and the robot
computer is faulty.
Check the USB cables that connect the
robot computer to the cameras. These
are USB cables 3 and 4 that connect to
the top of the robot computer (see
Figure 1.2). Verify that they are
correctly plugged in and that there are
no obvious signs of damage.
If no faults are found, try hooking up
the camera to your computer via the
USB cable that connects to the robot
computer.
If you are unable to connect to the
camera, try replacing the cable. If you
are still not able to connect to the
camera, replace the camera.
If you were able to connect to the
camera, replace the robot computer.
902, "Camera
(OpenNI): No
Data for xx
seconds"
Hardware
error.
Requires
interaction.
See error 901, "Camera
(OpenNI): Waiting for
connection is taking
longer than expected!"
above.
910, "Camera
(realsense
<R200/D435>):
Lost connection
to camera. No
data for xx
seconds."
Hardware
error.
Can resolve
itself.
See error 5101, "Unable
to connect to camera."
on page17.

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Error code Error type Description Solution
911, "Camera
(realsense
<R200/D435>):
Unable to
connect to
camera,
however it
seems to be
available. "
Hardware
error.
Can resolve
itself.
This error may occur
after a new camera or
robot computer has
been installed.
If the error occurred after a software
update, or you have replaced either
one of the cameras or the robot
computer, try rebooting the robot.
Otherwise, verify that you are using
the latest firmware (5.10.6) on the
camera . If the latest firmware is
being used and the issue persists, refer
to the solution in error 901, "Camera
(OpenNI): Waiting for connection is
taking longer than expected!" on the
previous page..
911, "Camera
(realsense
<R200/D435>):
Unable to
detect camera
with serial:
'xxxx,yyyy,zzzz,
(etc)', however
xx other
cameras are
connected with
serial:
xxxx,yyyy,zzzz,
(etc)"
Hardware
error.
Requires
interaction.
Both cameras have
another serial number
than those the robot
computer is searching
for.
In the robot interface, go to System >
Settings > 3D cameras. Change the
serial number of the cameras to the
last two serial numbers reported in the
error.
Select Save changes.If the error does
not disappear within a minute, try
rebooting the robot.
If the robot does not operate correctly,
especially during docking, you may
have swapped the serial numbers
between the right and left side
camera. Go back to the 3D camera
setttings, and swap the two serial
numbers.

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Error code Error type Description Solution
911, "Camera
(realsense
<R200/D435>):
Unable to
detect camera
with serial:
'xxxx,yyyy,zzzz,
(etc)', however
1 other camera
are connected
with serial:
xxxx"
Hardware
error.
Requires
interaction.
One of the cameras has
another serial number
than the number the
robot computer is
searching for.
In the robot interface, go to System >
Settings > 3D cameras. Change the
serial number of the undetected
cameras to the last serial number
reported in the error.
Select Save changes.If the error does
not disappear within a minute, try
rebooting the robot.
911, "Camera
(realsense
<R200/D435>):
Unable to
detect camera
with serial:
'xxxx,yyyy,zzzz,
(etc)' and no
other cameras
available"
Hardware
error.
Requires
interaction.
See error 5101, "Unable
to connect to camera."
on the next page.
912, "Camera
(realsense
<R200/D435>):
The serial
number is not
configured for
this camera!"
Hardware
error.
Requires
interaction.
The robot computer
does not have any serial
number to search for.
In the robot interface, go to System >
Settings > 3D cameras. Insert the
correct serial number for the cameras
that do not display any serial numbers.

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Error code Error type Description Solution
1001, "SICK PLC
(MIR100/200):
Receiving SICK
Safety PLC data
timed out."
Hardware
error.
Can resolve
itself.
The communication
between the safety
PLCand the robot
computer is faulty.
Replace the Ethernet cable from the
safety PLC and the router with an
Ethernet cable you are certain is
functional (see Figure 1.3).
If the issue persists, swap the port the
Ethernet cable connects to in the
router. If a new error is shown,
replace the router. If the error
remains the same, try the same steps
but with the Ethernet cable that
connects the robot computer to the
router.
1004:
"Unsupported
SICK program
version"
Hardware
error.
Requires
interaction.
You have modified the
SICKprogram on the
safety PLC. If you are
experiencing errors in
the safety system, we
cannot troubleshoot
programs with custom
modifications.
Download a new standard
configuration file from the robot
interface and upload it to the safety
PLC.Refer to the how-to guide How to
apply the default configuration of the
SICK safety system on MiR100/MiR200
found on the Distributor site.
1005: "Gear
ratio
configuration
mismatch! Sick
is configured
with: xxx and
Robot software
is configured
with: yyy"
Hardware
error.
Requires
interaction.
Either the safety PLC or
the robot computer is
using the wrong gear
ratio configuration.
Refer to the solution in error Safety on
page3.
If the robot does not drive correctly
after this, contact Technical Support
for assistance with correcting the gear
ratio.
5101, "Unable
to connect to
camera."
Hardware
error.
Can resolve
itself.
The robot computer is
not able to
communicate to one of
the 3D cameras.
See the solution in error 901, "Camera
(OpenNI): Waiting for connection is
taking longer than expected!" on
page14.

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Error code Error type Description Solution
5102, "Missing
data from
camera: Time
since last frame
[s] "
Hardware
error.
Can resolve
itself.
See error 5101, "Unable
to connect to camera."
on the previous page.
5103, "Lost
connection to
camera: Time
since last frame
[s] "
Hardware
error.
Can resolve
itself.
See error 5101, "Unable
to connect to camera."
on the previous page.
5001, "Robot
and hook is out
of time sync!"
Hardware
error.
Can resolve
itself.
The hook computer is
still syncing with the
robot computer.
Wait approximately ten minutes to see
if the computers begin to sync. If not,
reboot the robot. If the issue still
persists, you can manually sync the
robot and hook under System >
Settings > Time and date.
5210, "Hook
controller:
Initialization
failed!"
Hardware
error.
Can resolve
itself.
The connection between
the hook's motor
controllers and the hook
computer is faulty.
Remove the cover from MiRHook, and
check the connections from the top
interface to the motor controllers. (see
Figure 1.5)
If the motor controllers are receiving
power, check the connections from the
hook computer to the motor
controllers.
5211, "Hook
controller:
Unable to
connect to
motor
controller!"
Hardware
error.
Can resolve
itself.
See error 5210, "Hook
controller: Initialization
failed!" above.

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Error code Error type Description Solution
5212, "Hook
controller: "Lost
connection to
motor
controller!""
Hardware
error.
Can resolve
itself.
See error 5210, "Hook
controller: Initialization
failed!" on the previous
page.
5302, "Hook
brake failed:
Moved too far!"
Hardware
error.
Requires
interaction.
The brake was expected
to reach a current limit
for successful activation,
but the motor moved
too many encoder ticks
before the current limit
was reached.
There is likely a mechanical error in
the hook. Check the various parts of
the hook as described in the
maintenance chapter in the MiR Hook
100 and MiR Hook 200 Operating
guide. You can also test the brake by
signing into the robot and going to
Hook > Manual control and selecting
Activate and Deactivate brake.
5302, "Hook
brake failed:
Timeout!"
Hardware
error.
Requires
interaction.
The brake was expected
to reach a current limit
for successful activation
of the brake, but the
limit was not reached
before timeout (5
seconds).
See the solution description above.
5302, "Hook
brake failed:
Fault flag
active!"
Hardware
error.
Requires
interaction.
The brake was expected
to reach a current limit
for successful activation
of the brake, but a fault
flag was raised by the
motor controller before
activation.
Sign into the robot interface and go to
Monitoring > Hardware health and
locate the error. Errors such as
Undervoltage or Short circuit
indicate issues due to the wiring of the
hook brake.Otherwise, follow the
solution description in error Safety on
page3

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Error code Error type Description Solution
5302, "Hook
brake release
failed: Above
ampere limit!"
Hardware
error.
Requires
interaction.
The brake was expected
to move a certain
number of encoder ticks
for successful release of
the brake, but the motor
was drawing too much
current.
See the solution description in error
Safety on page3.
5302, "Hook
brake release
failed:
Timeout!"
Hardware
error.
Requires
interaction.
The brake was expected
to move a certain
number of encoder ticks
for successful release of
the brake, but this was
not achieved before
timeout (5 seconds).
See the solution description in error
Safety on page3.
5302, "Hook
brake release
failed: Fault
flag active!"
Hardware
error.
Requires
interaction.
The brake was expected
to move a certain
number of encoder ticks
for successful release of
the brake, but a fault
flag was raised by the
motor controller before
release.
See the solution description in error
Safety on page3.
5302, "Hook
brake error:
Missing
encoder signal"
Hardware
error.
Can resolve
itself.
Detection of missing
encoder signals from
the brake motor. No
encoder ticks have been
detected while motor
power has been applied.
Remove the cover from MiRHook, and
check the wiring from the encoders to
the motor controllers. Refer to Figure
1.5.
5302, "Hook
brake error:
Stall detected"
Hardware
error.
Can resolve
itself.
Detection of stall from
the brake motor. No
encoder ticks have been
detected while a large
amount of motor power
has been applied.
See the solution description in error
Safety on page3.