SL8500 - Robot Failure, Unable to Move Robot to Service Area

Asset ID:	1-72-1554779.1
Update Date:	2017-09-21
Keywords:

Solution Type Problem Resolution Sure

Solution 1554779.1 : SL8500 - Robot Failure, Unable to Move Robot to Service Area

Applies to:

Sun StorageTek SL8500 Modular Library System - Version All Versions and later
Information in this document applies to any platform.
SL8500 with 8 robots, one expansion module.
Taking the library offline and rebooting it failed to resolve the problem.
How do I get the failed robot moved into the service area so that I can recover the tape which is still in the hand and then replace the robot?
Note that this is a 'black site' so the above messages had to be re-typed - no electronic log transfer is possible.

Symptoms

robot 1,4,0,2,0 failed
reboot of robot and diags fail

Error log shows:

Result Code: 3955, RC3955
Error code from device Code: 506 - Robot reach not safe
...
Result Code: 1302, RC1302
Failure from robot Code: 506 - Robot reach not safe
...
Result Code: 3955, RC3955
Error code from device Code: 512 - Robot cannot go operational
...
Result Code: 1302, RC1302
Failure from robot Code: 512 - Robot cannot go operational
...
Result Code: 3215, RC3215
Robot initialization error - Derived rail length doesn't match configuration
Parameters : Configured=15 Derived=6
...
Result Code: 3215
Robot initialization error - Can't calculate expansion modules
Parameters : knownSingleBot init, the number of frames reported by robot, 1,4,0,1,0 was 10
...

The robot is sitting in front of drive 1,4,-2,1,2
Robot 1,4,0,1,0 cannot complete its reboot as it get to the failed robot and returns and then fails to complete diagnostics.
There were two messages about an hour before the robot failure messages, logged as:

Device Address: : 1.4.-2.1.2
Result Code: 3955
Error from device Code: 602 - Drive is empty

Cause

Cartridge stuck in tape drive. The robotic hand grabbed the cartridge and became non-funtional.

Solution

The robot may have hold of the cartridge in the drive. Try removing the drive where the robot is stopped at. (In this case, the robot is sitting in front of drive 1,4,-2,1,2)
This "may" release the cartridge from the hand.

Otherwise..
You will need to go in and drag the robot back. The robot will not move if it declares reach unsafe.
The robot may have hold of the cartridge in the drive which is why the other robot cannot push it.

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There was a stuck tape, and removing the drive brought the tape with it and now all bots are good.

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