A stopped robot with the line waiting is one of the most stressful situations. Before calling the service team, there's a set of quick, safe checks that floor staff can do and that often solve the stoppage in minutes —or at least speed up the later diagnosis.
Important: any check must follow the cell's safety procedures. When in doubt, do not re-arm.
Step 1 — Read the alarm
Look at the teach pendant (FlexPendant on ABB, smartPAD on KUKA, iPendant on FANUC) and note the exact code. The alarm is clue number one: it tells you which subsystem is affected. Don't clear it without writing it down.
Step 2 — Check safety
Many 'no apparent cause' stoppages are safety conditions:
- Is any emergency stop pressed (on the pendant or in the cell)?
- Are doors or fences open or a scanner/light curtain triggered?
- Is the mode selector where it should be (auto/manual)?
Step 3 — Check the power
Confirm the controller is receiving power: check the main switch, breakers and RCDs in the cabinet, and whether anything has tripped. A voltage drop or a tripped RCD leaves the robot out of service.
Step 4 — Air and peripherals
If the cell uses compressed air, check the pressure: a gripper or tool without air can stop the cycle. Also check presence sensors, limit switches and the end-of-arm tool.
Step 5 — Resettable or not?
If, after fixing the cause, the alarm is resettable, re-arm following the procedure. If the alarm comes back, affects axes or you don't understand the reason, don't insist: call a technician to avoid worsening the fault.
What to note before calling
For a fast repair, have ready: make and model, controller type, exact alarm code, what the robot was doing when it stopped and whether it's recurring. We work with ABB, KUKA and FANUC, and with that data we solve it sooner.
Frequently asked questions
It stopped with no alarm, what do I check?
Safety (e-stops, doors), power (RCDs) and air pressure. Many no-alarm stoppages are safety or auxiliary services.
Is it safe to re-arm?
Only if you identify and fix the cause and the alarm is resettable. When in doubt, don't re-arm.
What data do I have ready when calling?
Make, model, controller, exact alarm code, what was happening and whether it repeats.