Operation of Machine
1. Overview
If a mechanical fault has occurred then the machine will have to be shut down and inspected for the probable cause (e.g., loose belt or chain, broken component, loss of air pressure, etc.)
2.5 Air Pressure Fault
Air Pressure low alarm shows when incoming air pressure is low.
A Typical Air Pressure Fault is displayed as follows:
SV0401, Air Pressure Low Fault
Air Pressure Fault
Error Code
Type of Faults
Possible Cause
Solutions
501
Air Pressure Low Fault
Air Pressure low alarm shows when incoming air pressure is not equal or greater than the sated value on the pressure switch.
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Check the Incoming air Pressure is not less than 5bar/ low.
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Check the incoming air ON/OFF knob. It will be ON position.
2.3 Miscellaneous Output Faults
All Miscellaneous Output Faults will have an Error Code between 500 and 600.
A Typical Miscellaneous Output Alarm is displayed as follows:
[501] SV2701, MG Vacuum Generator 1 Alarm
Miscellaneous Output Faults
Error Code
Type of Faults
Possible Cause
Solutions
501
Alarm
This is a general Fault for a miscellaneous Output.
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Check the operation of the Device.
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Check for cable damage.
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Check electrical terminations.
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Check PLC input is switching.
510
Manual ON
The Miscellaneous Output Manual ON Function has been enabled. This will override all other control. This can be used to force a signal ON.
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When this is active a hand will flash next to the device on the Mimic Screen. This can be used to track down all Devices that have manual controls enabled.
511
Manual OFF
The Miscellaneous Output Manual OFF Function has been enabled. This will override all other control. This can be used to force a signal OFF.
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When this is active a hand will flash next to the device on the Mimic Screen. This can be used to track down all Devices that have manual controls enabled.
2.2 Miscellaneous Input Faults
All Miscellaneous Input Faults will have an Error Code between 400 and 500.
A Typical Miscellaneous Inputs Alarm is displayed as follows:
[401] PE2301, Rob 1 Rejection Bin Eye Alarm
Miscellaneous Input Faults
Error Code
Type of Faults
Possible Cause
Solutions
401
Alarm
This is a general Fault for a miscellaneous Input. It is generally raised when the input is ON when it is expected to be off.
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Check the operation of the Device. For Example, check that a photocell is switching on and off when objects pass in front of it.
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Check for cable damage.
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Check electrical terminations.
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Check PLC input is switching.
402
Evaluation Error, contact 1 or 2 failed to switch or switched too late
This is a Fault specific to a Safety Device. For example, a Guard Switch. On a dual channel safety device, the two channels have not switched within the specified time period, or one of the channels has not switched at all.
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Check the alignment of the safety switch if it is a guard switch.
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Check the Contacts on the device if it is an E-Stop.
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Check for cable damage.
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Check electrical terminations.
403
Error in the test pulse wiring.
This is a Fault specific to a Safety Device. For example a Guard Switch. The power source at the input terminal is from a different source from that configured in the Safety program.
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Check for cable damage.
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Check electrical terminations.
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Check the contacts on the safety device.
404
Channel 1 Input Test Pulse Error
This is a Fault specific to a Safety Device. For example a Guard Switch. The test pulse on a input is different from that configured in the program or has not been received.
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Check for cable damage.
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Check electrical terminations.
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Check the contacts on the safety device.
405
Channel 2 Input Test Pulse Error
This is a Fault specific to a Safety Device. For example a Guard Switch. The test pulse on a input is different from that configured in the program or has not been received.
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Check for cable damage.
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Check electrical terminations.
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Check the contacts on the safety device.
406
Triggered while machine Running
This is a Fault specific to a Safety Device. The Safety Device has been triggered while the machine was running.
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This is used to log if the machine has been E-Stopped, a guard switch has been opened or a light Curtain has been triggered while the machine was in a running state.
410
Manual ON Enabled
The Miscellaneous Input Manual ON Function has been enabled. This will override all other control. This can be used to force a signal ON.
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When this is active a hand will flash next to the device on the Mimic Screen. This can be used to track down all Devices that have manual controls enabled.
411
Manual OFF Enabled
The Miscellaneous Input Manual OFF Function has been enabled. This will override all other control. This can be used to force a signal OFF.
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When this is active a hand will flash next to the device on the Mimic Screen. This can be used to track down all Devices that have manual controls enabled.
2.1 Cylinder Faults
All Cylinder Faults will have an Error Code between 100 and 200.
A Typical Cylinder Alarm is displayed as follows:
[101] CY1801, Minor Flap Folding Cylinder Reed Alarm
Cylinder Faults
Error Code
Type of Faults
Possible Cause
Solutions
101
Reed Alarm
Cylinder has both Reed switches on at the Same time.
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Check the Position of Both Reed Switches on the Cylinder.
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Check the for-cable damage.
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Check electrical terminations.
102
Extend Alarm
The Cylinder Extend Solenoid is ON, and the Extend Reed Switch has been off for a period of time greater than the Extend Fault time.
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Check the Position of the Extend Reed Switch on the Cylinder.
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Check the Cylinder has not been damaged.
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Check for cable damage.
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Check electrical terminations.
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Check the Extend Fault time preset. This can be adjusted from the Cylinder Faceplate screen.
103
Retract Alarm
The Cylinder Retract Solenoid is ON, and the Retract Reed Switch has been off for a period of time greater than the Retract Fault time.
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Check the Position of the Retract Reed Switch on the Cylinder.
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Check the Cylinder has not been damaged.
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Check for cable damage.
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Check electrical terminations.
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Check the Retract Fault time preset. This can be adjusted from the Cylinder Faceplate screen.
110
Manual Extend Enabled
The Cylinder Manual Extend Function has been enabled. This will override all other control.
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When this is active a Hand will flash next to the device on the Mimic Screen. This can be used to track down all Devices that have manual controls enabled.
111
Manual Retract Enabled
The Cylinder Manual Retract Function has been enabled. This will override all other control.
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When this is active a Hand will flash next to the device on the Mimic Screen. This can be used to track down all Devices that have manual controls enabled.
112
Manual OFF Enabled
The Cylinder Manual OFF function has been enabled. This will override all other control.
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When this is active a Hand will flash next to the device on the Mimic Screen. This can be used to track down all Devices that have manual controls enabled.
3. Equipments Alarms Troubleshooting
Should a program or operational fault occur please refer to digital touch screen. In most cases the screen will detail the cause of the fault and its location.
Each alarm starts with a 3- or 4-digit number. This is called an Error Code. The First Part of the Error Code defines the type of device, and the second part defines the type of fault. Each Type of Device will have a range of error Codes. For example, Cylinders have Error Codes ranging from 100 to 200. For most devices we have limited this range to be 100. Below is a list of the Device Types and on the following pages there are tables that can be referenced that specify all the types of alarms associated with a device and actions to solve each fault.
A Typical Alarm would be displayed as shown below:
For example: -
SC6401 Collation Servo 1 Motion servo ON Reset ControlFault
Device Tag
Device Description
Type of Fault
Please find the below Alarms List
2.4 Motor Faults
All Motor Faults will have an Error Code between 600 and 700. Motors Alarms are generally only used for Devices that have DOL Control. They can also be used for VFD Drives if the drive is configured for 2 or 3 Wire Control.
A Typical Motor Alarm is displayed as follows:
[601] MO3102, Outfeed Conveyor 2 Alarm
Motor Faults
Error Code
Type of Faults
Possible Cause
Solutions
601
Forward Feedback OFF Alarm
The Output to Run the Motor is ON and the Run Feedback to the PLC has been OFF for a period of time greater than the Fault time Preset.
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If the motor has DOL control Check that the Motor Starter has not tripped.
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If the motor has VFD control Check that the Drive is not in Fault.
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Check for mechanical blockages.
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Check the Wiring.
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Check the Feedback to the PLC.
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Check that the Fault time preset has been set correctly. This can be adjusted from the Motor Faceplate screen.
602
Reverse Feedback OFF Alarm
The Output to Run the Motor in reverse is ON and the Run Feedback to the PLC has been OFF for a period of time greater than the Fault time Preset.
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If the motor has DOL control Check that the Motor Starter has not tripped.
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If the motor has VFD control Check that the Drive is not in Fault.
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Check for mechanical blockages.
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Check the Wiring.
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Check the Feedback to the PLC.
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Check that the Fault time preset has been set correctly. This can be adjusted from the Motor Faceplate screen.
603
Feedback ON Alarm
The Outputs to Run the Motor are OFF and the Run Feedback to the PLC has been ON for a period of time greater than the Fault time Preset.
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If the motor has DOL control Check that the Motor Starter has not tripped.
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If the motor has VFD control Check that the Drive is not in Fault.
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Check for mechanical blockages.
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Check the Wiring.
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Check the Feedback to the PLC.
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Check that the Fault time preset has been set correctly. This can be adjusted from the Motor Faceplate screen.
604
External Feedback Alarm
The External Feedback alarm has been triggered. This can be used for a number of functions, but is normally used to monitor the state of a Local Isolator.
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Check that the Local Isolator has not been switched OFF.
610
Manual ON Enabled
The Motor Manual ON Function has been enabled. This will override all other control.
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When this is active a Hand will flash next to the device on the Mimic Screen. This can be used to track down all Devices that have manual controls enabled.
611
Manual Reverse Enabled
The Motor Manual REVERSE Function has been enabled. This will override all other control
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When this is active a Hand will flash next to the device on the Mimic Screen. This can be used to track down all Devices that have manual controls enabled.
612
Manual OFF Enabled
The Motor Manual OFF Function has been enabled. This will override all other control.
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When this is active a Hand will flash next to the device on the Mimic Screen. This can be used to track down all Devices that have manual controls enabled.
3.1 Camera
Camera Faults
Possible Cause
Solutions
Loose / Shaky Camera
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Loose mounting screws
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Weak or damaged mounting bracket
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Vibration from telescopic lifter
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Misaligned camera holder
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Tighten all camera mounting screws
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Replace or reinforce mounting bracket
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Install vibration pads on mount
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Re-align camera holder/frame
Blurry Image
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Dirty lens
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Lens out of physical focus
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Camera vibration during movement
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Dust on sensor area
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Clean lens with microfiber cloth
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Adjust lens focus ring
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Add vibration isolators
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Clean sensor housing
Mechanical Faults
Camera Misalignment
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Mount plate shifted
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Impact or sudden shock
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Incorrect installation of camera bracket
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Tighten mount plate screws
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Re-align camera orientation
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Reinstall bracket properly
Camera Housing Damage
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Physical impact
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Excessive tightening of screws
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Wear or fatigue of plastic housing
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Replace damaged housing
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Use proper screw torque
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Inspect housing periodically
No Video Output
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Power cable disconnected
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Damaged power wire
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Faulty camera power supply
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Burnt internal component
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Reconnect power cable
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Replace damaged wire
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Test/replace power supply
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Replace camera module
Black Screen / Power Drop
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Loose power pin
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Weak connector contact
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Voltage drop on the power line
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Secure or change power pin
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Replace weak connector
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Stabilize power input
Electrical Faults
Intermittent Output
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Damaged data cable
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Loose pin connection
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Faulty electrical connector
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Replace data cable
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Tighten connector pins
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Replace electrical connector
Camera Overheating
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Overcurrent or incorrect voltage
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Blocked ventilation causing heat buildup
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Internal short or damaged component
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Check and correct voltage supply
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Improve airflow around camera
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Replace camera if internal damage is found
Distorted Image
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EMI interference (motor cables, power lines)
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Poor grounding
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Damaged shielding in camera cable
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Shield or reroute cables
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Ensure proper grounding
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Replace shielded camera cable
5.Assembly-wise Troubleshooting
5.1 Outer Carton Magazine Assembly
Trouble / Symptom
Probable Cause
Check / Corrective Action
Cartons not feeding properly
Carton stack not loaded correctly
Load cartons properly in the magazine and ensure carton orientation is correct.
Carton magazine low level warning
Carton quantity is low or magazine empty
Refill the carton magazine.
Cartons slipping or double feeding
Magazine guide setting incorrect
Adjust magazine side guides as per selected SKU.
Carton not available at plucker
PE sensor not detecting carton
Clean PE sensor, check alignment, and check sensor cable.
Carton jam in magazine
Damaged carton or improper carton quality
Remove damaged carton and use proper carton as per approved specification.
Magazine motor not running
Motor supply issue or MCB/VFD fault
Check MCB, motor wiring, and drive status.
Related alarm / warning:
Carton Magazine Low Level warning is generated when cartons are not available in the magazine. Operator action is to load cartons in the magazine. (Refer Alarm List)
5.2 Outer Carton Plucker Assembly
Trouble / Symptom
Probable Cause
Check / Corrective Action
Carton not picked from magazine
Vacuum not generated
Check vacuum generator, suction cup condition, air supply, and vacuum tubing.
Carton drops during picking
Suction cup leakage or damaged suction cup
Replace suction cup and check vacuum line leakage.
Plucker cylinder not extending/retracting
Reed switch fault, air pressure low, solenoid valve fault
Check cylinder movement, reed switch position, air pressure, and solenoid valve.
Plucker servo not moving
Servo drive fault or MCB tripped
Check SC1501 plucker servo drive and MCB Q1501.
Carton not formed after plucking
Improper carton quality or mechanical setting
Check carton creasing, carton opening path, plucker stroke, and guide settings.
Related alarm / warning:
Carton Magazine Low Level warning is generated when cartons are not available in the magazine. Operator action is to load cartons in the magazine. (Refer Alarm List)
501 PE1501 Outer Carton Present Detect PE @ Plucker Alarm is generated if carton presence is not detected after carton formation. Replace/adjust the carton and check the carton present sensor.
5.3 Inner Carton Magazine Assembly
Trouble / Symptom
Probable Cause
Check / Corrective Action
Inner carton not feeding
Magazine empty or carton stack misaligned
Load inner cartons correctly and adjust guides as per SKU.
Inner carton not detected
PE sensor dirty/misaligned
Clean and align PE sensor. Check cable connection.
Carton jam at magazine outlet
Improper carton quality or guide setting
Remove jammed carton and adjust magazine guide.
Inner carton feed motor not running
Motor supply issue
Check motor supply, MCB, wiring, and control output.
5.4 Inner Carton Plucker Assembly
Trouble / Symptom
Probable Cause
Check / Corrective Action
Inner carton not picked
Vacuum failure or suction leakage
Check vacuum generator, suction cups, air line, and vacuum tubing.
Plucker cylinder not operating
Air pressure low or solenoid valve issue
Check inlet air pressure, solenoid valve, tubing, and cylinder seals.
Cylinder extend/retract feedback not received
Reed switch position fault
Adjust or replace reed switch.
Carton drops before placement
Vacuum loss or damaged carton
Check suction cup condition and carton stiffness.
Plucker movement slow
Flow control/choke setting incorrect
Adjust flow control valve and check for air leakage.
Related alarm / warning:
CY1511, CY1512, CY1513, CY1514, and CY1515 extend/retract reed alarms are generated when cylinder feedback is not received. Check the respective cylinder reed switch, adjust/fix it, acknowledge the alarm, and resume operation.
401 PE1401 – Inner Carton Present Detect PE @ Plucker Alarm is generated when inner carton presence is not detected. Check carton availability, carton formation, and PE sensor setting.
5.5 Gantry Pick & Place Assembly for Inner Carton
Trouble / Symptom
Probable Cause
Check / Corrective Action
Gantry X/Z axis not moving
Servo drive fault or MCB tripped
Check servo drive status and MCB Q3201/Q3202.
Inner carton not picked properly
Gripper/cylinder/vacuum issue
Check gripper alignment, pneumatic cylinder, vacuum, and pick position.
Gantry misses placement position
Home position not completed or position offset
Home the gantry and verify recipe parameters.
Gantry movement abnormal/noisy
Mechanical obstruction or loose mounting
Check rails, actuator, coupling, mounting bolts, and lubrication.
Carton not available for gantry signal
Inner carton PE not detected
Place carton properly and check PE3601 sensor.
Related alarm / warning:
601 SC3201 Gantry Pick & Place X Axis Servo Drive Error and 601 SC3202 Gantry Pick & Place Z Axis Servo Drive Error are generated if MCB Q3201/Q3202 trips. Check MCB, acknowledge alarm, and restart.
401 PE3601 – Carton Rejection Bin Full Alarm / Inner Carton Presence Detect PE_1 requires carton placement on inner main drive for gantry signal.
5.6 Cleated Conveyor Assembly for Inner Cartons
Trouble / Symptom
Probable Cause
Check / Corrective Action
Cartons accumulate on conveyor
Gantry cycle delay, downstream blockage
Check gantry cycle timing, pick sequence, and downstream interlocks.
Carton reaches end but gantry does not pick
Carton present sensor not detecting, gantry interlock not complete
Check PE sensor, sensor cable, gantry home position, and PLC signal.
Cartons getting tilted or jammed
Side guide misalignment, damaged cleat, improper carton formation
Adjust guides, replace damaged cleat, and verify carton dimensions.
Conveyor vibration during running
Loose mounting bolts, gearbox misalignment
Tighten mounting bolts and check motor-gearbox alignment.
5.7 Infeed Conveyor Assembly
Trouble / Symptom
Probable Cause
Check / Corrective Action
Sachets not moving smoothly
Conveyor belt misalignment or obstruction
Remove obstruction and adjust belt tracking.
Sachet overflow
Downstream robot not picking or bin full
Check robot operation and empty overflow bin.
Conveyor motor not running
Motor/gearbox/VFD issue
Check motor supply, gearbox, VFD, and wiring.
Encoder feedback issue
Encoder cable loose or damaged
Check encoder coupling, wiring, and feedback status.
Sachets rejected at infeed
Improper orientation or vision rejection
Check sachet orientation, camera setting, and rejection bin.
Related alarm / warning:
401 PE2301 Infeed Rejected Sachet Detect PE, 401 PE2304 Infeed Overflow Bin Full Alarm, and Sachet Overflow Bin warning require removal of sachets from the rejection/overflow bin, then acknowledge alarm and restart.
5.8 Camera / Vision Assembly
Trouble / Symptom
Probable Cause
Check / Corrective Action
Sachet position not detected
Camera lens dirty or incorrect trigger
Clean lens and check trigger signal.
Wrong pick position to robot
Calibration issue
Verify camera calibration and robot-camera coordinates.
Frequent sachet rejection
Lighting or image setting issue
Check camera light, exposure, focus, and product teaching.
No image/communication error
Camera cable or network issue
Check Ethernet cable, camera power, and IP settings.
5.9 Robot Assembly
Trouble / Symptom
Probable Cause
Check / Corrective Action
Robot not picking sachets
Robot not powered, not in auto, or vision signal missing
Enable robot power, check auto mode, and verify camera/PLC signal.
Robot drops sachets
Vacuum/gripper issue at pick head
Check vacuum, suction cups, pick head cylinder, and tubing.
Robot rejection bin full
Rejection bin not emptied
Remove sachets from rejection bin.
Robot not ready
Safety reset not done or robot fault active
Press safety reset, clear robot fault, and restart.
Robot picks wrong quantity
Recipe mismatch or robot sequence issue
Verify selected SKU recipe and robot program selection.
Related alarm / warning:
Robot rejection bin full alarms PE2302 and PE2303 require removing sachets from the rejection bin, acknowledging the alarm, and restarting.
Robot High Power Not Enabled warning requires pressing Safety Reset from SCADA.
5.10 Robot Pick Head Assembly
Trouble / Symptom
Probable Cause
Check / Corrective Action
Sachet not picked
Vacuum not available
Check vacuum generator, solenoid valve, suction cups, and tubing.
Sachet falls during travel
Suction cup leakage or low vacuum
Replace suction cup and check vacuum pressure.
Pick head cylinder not operating
Pneumatic cylinder/solenoid issue
Check solenoid output, air pressure, and cylinder movement.
Pick confirmation not received
PE sensor not detecting sachet
Clean and align pick head PE sensor.
Multiple sachets not picked equally
Pick head alignment mismatch
Adjust pick head position and suction cup height.
5.11 Main Drive Assembly
Trouble / Symptom
Probable Cause
Check / Corrective Action
Main drive not indexing
Servo drive fault or MCB tripped
Check SC1701/SC1702 servo drive and MCB Q1701/Q1702.
Carton not detected on main drive
PE1701 sensor not sensing carton
Place carton properly and check PE sensor.
Indexing position incorrect
Encoder/home position issue
Check encoder feedback, servo home, and mechanical reference.
Abnormal noise/vibration
Gearbox/coupling/mounting issue
Check gearbox oil, coupling alignment, and mounting bolts.
Carton jam during indexing
Guide setting or carton deformation
Remove jammed carton and adjust guide plates.
Related alarm / warning:
601 SC1701 Main Drive Servo Drive_1 Error and 601 SC1702 Main Drive Servo Drive_2 Error are generated if MCB Q1701/Q1702 trips. Check MCB, acknowledge alarm, and restart.
501 PE1701 Main Drive Box Present PE is generated when carton is not detected; place carton and restart.
5.12 Flap Folding / Tucking Assembly
Trouble / Symptom
Probable Cause
Check / Corrective Action
Minor flap not closing
Flap guide/cylinder setting incorrect
Adjust minor flap guide and check cylinder movement.
Major flap not closing
Major flap folding cylinder not operating
Check CY1803/CY1804/CY1805 cylinder, reed switch, and air pressure.
Carton top not tucked properly
Tucking cylinder stroke issue
Check CY1806 stroke, reed switch, and mechanical alignment.
Consecutive carton rejection due to flap open
Flap sensor setting or tucking assembly issue
Correct tucking assembly setting or flap sensor setting.
Flap open PE alarm
Flap not closed or sensor misaligned
Close flap, adjust sensor, acknowledge alarm, and restart.
Related alarm / warning:
CY1801 to CY1806 extend/retract reed alarms are related to flap folding and tucking cylinders. Check respective cylinder reed switch, pneumatic movement, and acknowledge the alarm after correction.
501 PE1702, 501 PE1703, and 501 PE1704 are flap open detection alarms. Correct flap closing condition, check sensor setting, and restart.
Consecutive Carton Rejection Alarm Due to Flap Open requires correction of the tucking assembly or minor flap sensor setting.
5.13 Carton Barcode Scanner Assembly
Trouble / Symptom
Probable Cause
Check / Corrective Action
Barcode not scanned
Barcode scanner not reading code
Clean scanner lens and check barcode position.
Wrong barcode rejection
Wrong SKU or wrong carton loaded
Verify selected recipe and carton barcode.
Consecutive rejection due to barcode
Barcode scanner setting issue
Check scanner teach setting, trigger signal, and communication.
No scanner communication
Cable/network issue
Check scanner cable, power, and communication status.
5.14 Outfeed Conveyor and Rejection Assembly
Trouble / Symptom
Probable Cause
Check / Corrective Action
Carton not moving out
Conveyor motor/gearbox issue
Check motor, gearbox, belt, and wiring.
Carton rejected continuously
Barcode fail or flap open fail
Check barcode scanner and flap folding assembly.
Rejection cylinder not operating
Cylinder reed/solenoid/air issue
Check CY3101 cylinder, reed switch, solenoid valve, and air supply.
Rejection bin full
Rejected cartons accumulated
Empty rejection bin and acknowledge alarm/warning.
Carton not rejected when faulty
Rejection cylinder or PLC output issue
Check reject cylinder output, sensor, and pneumatic connection.
Related alarm / warning:
108/112 CY3101 Carton Rejection Cylinder Extend/Retract Reed Alarm requires checking extend/retract reed switch and cylinder operation.
6.Alarm Troubleshooting Reference
During machine operation, if any alarm, warning, fault, safety trip, communication error, sensor fault, servo fault, or pneumatic fault is generated, the operator shall refer to the detailed Alarm Troubleshooting Document for alarm description, probable causes, machine condition, and corrective actions.
The complete alarm troubleshooting reference includes:
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Sensor alarms
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Cylinder reed switch alarms
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Servo drive alarms
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Motor faults
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Safety interlock alarms
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Guard door alarms
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Robot alarms
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Barcode verification alarms
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Communication alarms
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Pneumatic pressure alarms
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Bin full and rejection alarms , etc..
Click below to view the complete alarm troubleshooting list:
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7.Operations Troubleshooting
4.1 Once the machine is installed, the machine's critical parameters cannot be changed by the operator; the BRML team is to be involved to make changes to these parameters.
In case the admin provides these authorities to the operator or any other user, the following might be the circumstance.
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The robots/cobots are not homing.
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Camera & scanner might be inaccurate rejection or acceptance.
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The machine is not able to home & run smoothly.
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Robot collision with the surrounding area might result in permanent damage to the robot.
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Servo functionality might be affected.
And communicate with the BRML team and explain the problems. The BRML team solves the problem & runs the machine.
4.2 If the software is corrupted. The BRML team has to be involved in making a solution to the problem.