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ABB Robot Error 10115 – Resolver Fault: Troubleshooting ABB Robot Motors
⚠️ Quick Fix for ABB Error 10115
If a resolver fault occurs, try these immediate steps:
- Inspect resolver cables and connectors for damage or loose connections
- Verify servo drives are operating normally
- Check DSQC boards handling resolver signals
- Restart the ABB IRC5 Controller using FlexPendant
These steps often restore resolver signal communication quickly and resume safe robot operation.
ABB Robot Error 10115 – Resolver Fault occurs when the ABB IRC5 Controller detects abnormal or missing signals from a motor resolver. Resolvers provide critical position feedback for servo motors, enabling precise motion control. A fault can cause the robot to stop or trigger protective alarms.
Proper troubleshooting minimizes downtime and prevents mechanical damage.
What Does ABB Error 10115 Mean?
Error 10115 indicates that the controller cannot receive accurate feedback from a motor resolver. This may affect one or more robot axes and can trigger safety stops to prevent motion errors.
Affected components may include:
- Motor resolvers
- Servo drives
- DSQC boards
- Resolver cables and connectors
Common Causes of ABB Error 10115
Damaged Resolver Cables
Broken or loose cables disrupt resolver signals to the controller, preventing accurate motor feedback.
Common issues include:
1. Loose or disconnected resolver cables
2. Bending, abrasion, or degradation due to harsh factory environments
Ensure that resolver cables are high-quality, well-routed, and inspected regularly to maintain reliable feedback transmission.
Faulty Resolver
Mechanical wear or electrical failure in the resolver can prevent proper feedback, leading to motion errors.
Common issues include:
1. Worn-out resolver components
2. Electrical malfunctions within the resolver
Regular inspections and timely replacement of resolvers are crucial to avoid recurring feedback errors.
Servo Drive or DSQC Board Faults
Malfunctioning drives or communication boards may prevent resolver signals from being processed.
Electrical Interference
Electromagnetic interference (EMI) can affect resolver signal transmission.
How to Troubleshoot ABB Error 10115
Step 1: Inspect Resolver Cables
- Check all resolver cables for damage or loose connections
- Reconnect or replace as necessary
Step 2: Test Resolver
- Verify that resolvers produce correct signals
- Replace faulty resolvers if needed
Step 3: Inspect Servo Drives and DSQC Boards
- Check drives for proper operation
- Verify DSQC boards handling resolver inputs
- Replace defective modules if necessary
Step 4: Minimize Electrical Interference
- Ensure proper cable routing and shielding
- Avoid running resolver cables alongside high-power lines
Step 5: Reset Controller
After resolving the root cause:
- Reset the alarm using FlexPendant
- Restart the ABB IRC5 Controller
- Test robot motion at reduced speed
- Monitor for recurring resolver faults
Related Components That May Be Affected
- Motor resolvers
- Servo drives
- DSQC boards
- Resolver cables and connectors
When Should You Replace Components?
Replacement is recommended if:
- Resolver signals fail repeatedly despite troubleshooting
- Resolver cables are damaged
- DSQC boards or servo drives show persistent faults
Preventing Resolver Faults
- Regularly inspect resolver cables and connectors
- Maintain servo drives and resolvers according to manufacturer recommendations
- Ensure proper cable shielding and routing
- Use ABB RobotStudio for monitoring resolver signals and diagnostics
Related ABB Robot Error Codes
- ABB Error 10020 – Encoder Signal Lost
- ABB Error 10021 – Encoder Communication Fault
- ABB Error 10112– Axis Calibration Required
- ABB Error 10106 – Axis Not Referenced
- ABB Error 40223 – Motor Overload
-
ABB Error 50056 – Drive System Error
Understanding these related faults can help identify underlying mechanical or electrical issues. For a complete list of ABB robot error codes and troubleshooting solutions, refer to our full ABB error code guide.
Recommended Parts for ABB Error 10115
Conclusion
ABB Robot Error 10115 – Resolver Fault occurs when the controller detects abnormal or missing resolver signals from robot motors. Common causes include damaged resolver cables, faulty resolvers, servo drive or DSQC board faults, and electrical interference.
By inspecting cables, resolvers, drives, and DSQC boards, engineers can restore accurate motion and safe robot operation.
Expert FAQ: Solving ABB Robot Error 10115 (Resolver Fault)
1. What causes ABB Error 10115?
This error is usually caused by damaged resolver cables, faulty resolvers, servo drive or DSQC board faults, or electrical interference.
2. How do I fix Error 10115?
Inspect and repair resolver cables, test and replace faulty resolvers, verify servo drives and DSQC boards, minimize electrical interference, and reset the controller using FlexPendant.
3. Can servo drive faults trigger this error?
Yes, malfunctioning servo drives may prevent resolver signals from reaching the controller and trigger Error 10115.
4. When should I replace resolvers or boards?
Replace if repeated faults occur, or if resolvers, cables, or DSQC boards are damaged or persistently faulty.
Explore the Full Guide: Industrial Robot Fault Codes Library → ABB Robot Error Codes
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