Introduction

This article is to help the user on how to troubleshoot Alarm 4197 [137] or Error 4241 [137]. Reading this article will help the user troubleshoot other subcodes on Alarm 4197 or Error 4241.

Overview

Alarm 4197 & Error 4241 are essentially the same and the controller software lets the user know that there is an error in the Safety Logic Circuit. Typically Alarm 4197 or Error 4241 occurs when the user is trying to use a safety signal in the Safety Logic Circuit that has not been allocated. It can also be that the safety signal used in the Safety Logic Circuit has been deallocated accidentally by the user in Maintenance Mode, by disabling the Functional Safety Board. Figure 1 & Figure 2 illustrate Error 4241 & Alarm 4197, that occurred on an HC30PL YRC1000, after the user disabled the Functional Safety Board (F-Safe Board), which will be explain in detail later this article.

Figure 1: Error 4241 [137] displaying after the user disabled the F-Safe Board, and trying to READBACK → WRITE, in the Safety Logic Circuit.

Figure 2: Alarm 4197 [137] occurred at bootup, after the user disabled the F-Safe Board in Maintenance Mode.

Subcode on Alarm 4197 & Error 4241

The subcode on both Alarm 4197 & Error 4241 indicate the rung number in the Safety Logic Circuit that is causing the issue, or that the safety signal is not allocated. The Safety Logic Circuit has a total 128 rungs available on the USER side, and 128 rungs on the SYSTEM side. The 128 rungs on the SYSTEM side of the Safety Logic Circuit are not available to the user, but the user can see them from the Safety Logic Circuit Screen.

Figure 3: The USER side of the Safety Logic Circuit, with the cursor down to rung 128.

Figure 4: The SYSTEM side of the Safety Logic Circuit, for an HC30PL YRC1000. The user cannot modify the SYSTEM side of the Safety Logic Circuit but can navigate to it by pressing the [PAGE] key on the pendant, inside the Safety Logic Circuit screen.

In essence the controller software lists the rungs in following order:

Table 1: A table on how the Controller Software list the rungs on the USER side & SYSTEM side.

Referencing Table 1, subcode 137 from Figure 1, Figure 2, and referencing Figure 4, tells the user that line 009 in the SYSTEM side of the Safety Logic Circuit is causing Error 4241 or Alarm 4197 to occur. Knowing that the SYSTEM side of the Safety Logic Circuit cannot be modified by the user indicates that either FS-OUT51 or PFLIN19 has been deallocated by the user.

Figure 5:  Screenshot of the SYSTEM side of the Safety Logic Circuit but relabeled to indicate the rung numbers as described in Table 1.  Subcode 137 is referencing line 009 in the SYSTEM side of the Safety Logic Circuit.

Re-enabling the F-Safe Board

In the example above, the user deallocated safety signal FS-OUT51, by disabling the F-Safe Board, under the Functional Safety – Option Function, in Maintenance Mode. Doing so, caused Alarm 4197 [137] to occur at start up and the user could not modify the USER side of the Safey Logic Circuit. In the case of FS-OUT51, this signal is a necessary safety signal that is used in the Power Force Limiting of the HC30PL YRC1000.

Figure 6: Functional Safety – Connection Setting of the F-Safe Board in Maintenance Mode. Once it was set to USED, Alarm 4197 [137] & Error 4241 [137] stopped occurring.

The F-Safe Board can be disabled by the user with Safety Mode Security Level. Once the F-Safe Board is set back to “USED”, press “ENTER” on the Pendant key. A confirmation screen will appear, asking the user to confirm the modification, select “YES”. Then it will ask to initialize Functional Safety Related Files and select “NO”.

Figure 7: How to re-enable the F-Safe Board in Maintenance Mode.

Disabling Safety Signals Individually

As mentioned in the Overview section, individual safety signals can be deallocated in Normal Mode, under {SAFETY FUNC.} → {F-SAFETY SIGNAL ALLOC} or {SLC EXT. SIGNAL ALLOC} screen. Doing so can cause Alarm 4197 or Error 4241 to occur, with the subcode indicating which rung is being affected in the Safety Logic Circuit.

Figure 8: Safety Signal FS-OUT51 can be deallocated individually, through the {SLC EXT. SIGNAL ALLOC}. Doing so will cause Error 4241 [137] to occur, since FS-OUT51 is used in the SYSTEM side of the Safety Logic Circuit.

Conclusion

Understanding that the subcode for Alarm 4197 or Error 4241, indicates the rung number in the Safety Logic Circuit that is causing the issue. Even though the rungs on the SYSTEM side of the Safety Logic Circuit cannot be modified by the user, the signals referenced by the SYSTEM side can still be deallocated, causing the alarm or error to occur. On HC robots, the SYSTEM side of the Safety Logic Circuit contains the Safety Logic for Power & Force Limiting to work correctly. For additional information on the Default Settings of the Safety General Purpose I/O Signals or Functional Safety Condition files reference the YRC1000/YRC1000micro Collaborative Operation Instructions (181437-1CD), Section 11 & 12 for additional information.