ABB IRB 4400 - Battery 2 Low Voltage

[Robotic Metallizing]

Good morning guys,

 
I've got a little bit of a problem here, hopefully someone has a little advice/solution. I've got an IRB 4400 and when running production it will randomly fault out and come up with a revolution counter not updated error, mind you that it's running perfectly fine when this error will just pop up. I will proceed to update the rev counters, sometimes axis 1, other time axis 3, or both 5 and 6, I believe I have never had to update axis 4. Then I will run the program, sometimes all of the points will be off by a few inches, other times only part of the program will off and other points will be fine. When checking the points the robot will fault out again, usually in the same location relative to the part i'm working with and display a manual speed too high warning error. I will then have to warm start the robot to get it to run again and when booting I get the following error...

03:01502
Battery 2 low voltage.

I have replaced the battery inside of the base of the robot with what i thought was a good battery, which battery is in fact "battery 2?" When the other errors occur again I'll post more info on the other errors.

I should also note when the trunk of the robot is vertical and the arm is extended out to create a 90 degree angle it makes an awful almost grinding type noise as if the servo is constantly twitching back and forth and I think its becoming worse. Any ideas as to what could be happening? Thanks guys! 

[SkyeFire]

Yow... I would call up ABB tech support immediately.  It's hard to say what your actual issue is, but that grouping of errors can't possibly be good.  My guess is either a bad SMB cable, or possibly an SMB unit that's starting to go bad in a very gradual fashion.

[Robotic Metallizing]

Thanks for the reply, I did get in touch with ABB and the tech had the same idea that it may be the SMB. In the meantime i swapped out the battery that was giving the low voltage error, the two "D" size batteries inside of the controller and rebooted to find I need to reinstall the baseware for the robot.

Now, let me ask a very odd question. I have the original key disk and had some trouble installing baseware. I talked with ABB and they sent me the baseware 3.2 rev. 56 to try installing, reason being when i kept getting to disk 4 with the baseware version that came with the robot the teach pendant would display "teach pendant communication has been lost" and wouldn't restart or do anything for that matter. I had back up copies of the disks and tried using fresh floppies without any kind of luck.

Now, with the new baseware things seem to install pretty smoothly.... that is until i get to disk 4. I insert the disk, it installing accordingly and reboots the controller. When the start up is complete I then get a prompt asking to choose an install mode, as per ABB recommendation i choose silent. Next thing i know the teach pendant displays IRB 6400 and continues loading rapid, system config so on and so forth. Why is my IRB 4400 loading 6400 configuration files??? ABB doesn't know at this point and I'm in a real pinch to get this robot back up and running as temporary as it may be until the SMB can get replaced.

Has anyone ever encountered this problem?

[Rainman]

Dear Robotic Metallizing

When you are going to install software from silent mode the installation follows the information on the key disk.
In my idea is better you chose Query mode that ii this mode we have Question  about changing language, robot type (within the same family),gain access to service mode, parameters etc, makes it possible to exclude options but not add more than included in the key disk.