Wiring Harness/Robot is ghost!

[Robotic Metallizing]

Hi Skooter,

Thanks for the reply. I actually created a post separate from this one to maintain focus on my current non-working boot issue. Prnuk2003 posted there too with the same suspicion. You guys were right! I called ABB and they confirmed that the 3.2 is not compatible...not sure why I was told to load that in the first place. I tried reverting to 3.0 ver. 2.52 from the 2.01. The key disk will not take. At the screen "Insert key disk and press any key to continue" the disk will read and continue to read while the teach pendant flashes blank and come up with "Teach pendant communication lost" Any ideas? I was about to send the board out this afternoon but having gotten a response from ABB I wanted to try this out but to no avail. Prnuk mentioned by going to an incompatible version may require a flash reset completed by ABB. The ABB tech had also said that after so many flashes the chip may need replacing as it can only be completed so many times until problems begin. Let me know what you think and again thanks for your continued help. How can I educate myself as to which versions of software are compatible with which robots? How did you know this was incompatible, just from experience?

Thanks again,

Zack

[prnuk2003]

I used to be a service engineer for ABB back in the day so I was aware that certain revisions could cause issues with certain boards. In some circumstances you had to replace boards with newer versions to be able to jump versions.

If the board does need reflashing because you were given some suspect info then maybe it could be the opportunity to change the board to the DSQC373 that will work with the 3.2 software (and coming to some deal with ABB about the cost) but I suspect you will also need a later main computer board

If you want to stay with that board and revert to RW 3.0 then I have the last release v54 if required.

I have attached an old ABB (SEROP) release document that will be of interest.

[Robotic Metallizing]

Thanks you very much for the info! So regardless if the computer was flashed once or a whole boatload of times once is enough to create and issue with the robot ware installation and the overflow condition. That being said, my only option would be to return the board to OEM and have the computer reset or do as you said and find out my cost to upgrade the controller to the newest 3.2 revision with new hardware. This might be a little bit of a silly question but do you know if that would have to go to Sweden or would Michigan be able to take care of this? Thanks again for the help. I really appreciate this! That is a handy paper to have as well on the different controller components!

[prnuk2003]

It all depends on how ABB want to handle this and the cost for you if you go for the upgrade of the hardware and RW3.2.
I think you may be able to squeeze out a repair to the board from ABB (or they send you a service exchange unit) and try a later revision of RW3.0 to get the robot running again - thus hopefully(??) fixing the problem that you initially tried to solve.
If that initial fault is still there and the software is still suspected as the route cause then work with ABB to look into upgrading to 3.2 with the correct boards. Armed with the information you now have then your local ABB in Michigan should be able to arrange everything required given enough time to schedule the work