Author Topic: Fanuc M6i robot Rj2 controller  (Read 16106 times)

Offline trevpossy

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Fanuc M6i robot Rj2 controller
« on: April 19, 2009, 12:01:19 AM »
Can any one help  i have problems in start up cannot calibrate,  master,or jog robot the whilest the robot is in error status mctl003 i have no other  active alarms the books remedy is clear the error and try again When i press the shift reset i can see the main contactors pull in for a short time then release if i press a jog key at the same time that the contactor is in mctl 014 waiting for servo ready appears on top of screen only for the short time that the contactor is in thensrvo 21 srdy off (group 1 axis 6 ) appears Obviously i wont be able to move robot unless i can get the contactor to stay energised   my other problem is that i only have copy of manuel for a Rj series controller not an Rj2 controller and there may be some wiring issues that are causing me trouble also they seem to be very similar in many areas any help would be appreciated for a very frustrated aussie

Offline Mtech

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Re: Fanuc M6i robot Rj2 controller
« Reply #1 on: April 19, 2009, 06:47:23 AM »
Hello,
Does your full alarm message read SRVO-21 SRDY OFF/Door open (Group 1 Axis 6). If so you will have to close your controller door to continue. Sound like you have started the system,pressed shift & reset to clear all for alarms in preperation to start jogging the axis to mastering position, but have a open circuit at the controller door to run your servos. Close door and or check circuit/switch. If this is ok then you have some other issues with your servo interface module.  Also can have a bad connection or cable between axis control PCB and your servo amp. I do not have a PDF handy. however I seen one in the Fanuc Robot forum section I think under the message (On the Scrounge again). It was a operations manual which should have all this info in it. Best of luck to you.
« Last Edit: April 19, 2009, 06:49:04 AM by Mtech »

Offline trevpossy

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Re: Fanuc M6i robot Rj2 controller
« Reply #2 on: April 19, 2009, 12:09:21 PM »
Thanks for the reply the full message srvo-21 SRDY off the other message that keeps coming up is (MCTL 003 system in error status ) not allowing me to proceed with setting up robot i have the door shut however not sure if all the conections in the small controll cabinet are correct unit was decomissioned out of factory and all the wires going to these terminals were cut off for example   emg in 1 2  fence  1 2 svon  1 2 estop 1 2 emg out 2 C 1  I have put a LOOP BETWEEN TERMINALS 1 AND  2 on the first three pairs of terminals Wondering also if the main MCC contactor for the servos should stay energised after pressing shift then reset leaving power at servos ready to jog so i can master and calibrate The teach pendant has the top led light on error  there is a dash on the numeric display on the servo pcb also there are no green or red led lights showing at all on the process I/O PCB not sure if they are not lit because it is turned off in the program someware thanks again for your imput

Offline Mtech

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Re: Fanuc M6i robot Rj2 controller
« Reply #3 on: April 20, 2009, 04:49:21 AM »
Ok bare with me as its been a long long time on a J2. Here we go,You get MCTL003 and SRVO-21 because your amplifer is shut down because you mentioned you have a (-) dash on the display. I do believe that this is a indication that your MCC contactor is unarm(off). It will read (0) when armed and ready.Just as you have noted it is not armed. Just for process of elemination sake from your menu and status key go to safety signal/status. This will tell you if you have a signal missing like fence, Ext. e-stop,SOP e-stop, handbroken, and so on.Have you gone through each of these to ensure that they are made if needed or bypassed if not? If ok then you have repaired your wiring properly if not check terminal connections and V supply for them. Check the wiring at door switch,wiring between servo amp and Axis control PCB. Also check fuse on your I/O PCB you should have I do think a green status indicator and if not this then it should be one of the red ones because its faulted. I think there is one fuse on this but do not quote me on this as it might be two. On this Srvo - 21 alarm have you noticed if it the same axis number each time its reset. Your first message said G1 Axis 6. Is that still the same or do you keep getting various Axis numbers? If it alarms on more than 2 axis check wiring between EMG board term. 5 and 6 on servo amp. If just one axis faulted then go to that servo amp board and lift the signal wire inspect/clean connection and reseat. If alarm SRVO 21 goes away good but if still on then go to one good axis swap the signal wire with that amplifer cable that is not in alarm and try to reset. If you still get the alarm the axis control board or amplifier might be bad. But if the axis faulted number changes (ex. G1 Axis 2) to that one you change it to then the cable is bad/faulty. Did you get a chance to download the manual that I refered to in my last message?
« Last Edit: April 20, 2009, 04:55:23 AM by Mtech »

Offline trevpossy

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Re: Fanuc M6i robot Rj2 controller
« Reply #4 on: April 21, 2009, 12:28:44 AM »
Thanks for your reply i have managed to remove the (MCTL system is in error status) when i turned on  the robot  lock the faut goes out on the teach pendant and the remote consol. I went into status then  safty signal seems to be ok all are on false and change to true when e stops are pressed on remote,TP and if i remove bridges Checked the fuse in i/o board seems to be ok Still have no lights on the I/O board do I need to turn it on in software The manual that you reffered to is for a rj controller not rj2 wiring is similar but not the same  i have checked plugs all the plugs labled are in the correct sockets there are thee plugs not conected labels on leads dont match any other sockets .The error i have now is Servo 075 pulse not established  and jog 002 Robot not calibrated looked in book and was wondering what rotate axis motor manually by at least 1 revolution meant do I take cover off and turn by hand to get a pulse established then i can calibrate robot and master also when trying to master now i get the message waiting for servo ready Thanks again for your much appreciated imput

Offline Mtech

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Re: Fanuc M6i robot Rj2 controller
« Reply #5 on: April 21, 2009, 05:50:54 AM »
Glad to here you’re making progress. That’s good. First Servo 075, to clear
this turn TP and console key switch on. Press reset or shift reset to clear alarms.
Then in the upper right corner of your screen you will see the robot % speed and
something that  looks like TOOL, JOINT, or WORLD and ect… This will need
to say JOINT. Simply press COORD key until this appears. Now with that done
press and hold anyone of the two shift keys, pull deadman, and press ( J1,J2,J3 ect.)
key to move 1 axis at a time at least 1 motor revolution. This will resolve that
problem. If the alarm is just on one axis(G1,Axis 2) just do that one if not do the
ones required (all). Press reset again to clear alarms if any. This alarm has to be
cleared for mastering. Once done then lets work on Jog 002. Press menu,system
master/cal if  once system is selected you might have to press F1 type to see the
master/cal. Select this Master/cal. and I think #6 is calibrate, highlight and press
enter. F4 for yes. If you don’t see master/cal set system variable $Master_Enb to 1.
Once this is done you are ready to master. If for some reason mastering was already
done you can set system variable $DMR_GRP[].$master_done to TRUE and skip
the rest but I don’t think this applies to your situation. But for a future note you might
want to write that down. I will try to find you a PDF manual. Sorry I thought it was
a RJ2. I will have to look into the I/O board as I haven’t seen one in many years.
Any ways I hope this helps you.

Offline trevpossy

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Re: Fanuc M6i robot Rj2 controller
« Reply #6 on: April 21, 2009, 12:22:54 PM »
Thanks so much for further imput I understand what you are refering to in your last note However i have been unable to move any axis at all srvo 075 pulse not established G;1A:FBD       Zero joint     Pause 4/5

Offline WB

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Re: Fanuc M6i robot Rj2 controller
« Reply #7 on: April 21, 2009, 08:16:37 PM »
Hello trevpossy,

When you have enabled the mastering menu ($MASTER_ENB=1):
Go to MENU > SYSTEM  > TYPE > MASTER/CAL. There you will find a RES_PCA "Reset Pulse Coder Alarm" at one of the function keys (F2 or F3). Press this first to reset the alarm.

When this is done, you should be able to jog the robot.
Jog the axis with the fault for more then one motor-revolution, master and then calibrate the robot.

Succes!

Offline Mtech

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Re: Fanuc M6i robot Rj2 controller
« Reply #8 on: April 21, 2009, 08:31:42 PM »
Sorry about that. I was in a hurry when I typed that and left a very important detail. Follow WB's instruction. Once this is done then you should be able to start jogging the robot. Thank you WB for catching this.

Offline trevpossy

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Re: Fanuc M6i robot Rj2 controller
« Reply #9 on: April 22, 2009, 02:36:57 AM »
Thanks also for this suggestion have reset pulse But stil wont allow me to jog I am learning heaps whilst fiddling around though i guess patience is the key!

Offline Mtech

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Re: Fanuc M6i robot Rj2 controller
« Reply #10 on: April 22, 2009, 07:38:38 PM »
Once you reset the encoder does the alarm clear and the controller hold free of all alarms or is there another alarm present at the time of jogging?

Offline Lerak

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Re: Fanuc M6i robot Rj2 controller
« Reply #11 on: April 23, 2009, 03:01:04 PM »
First, be sure to have the Coord in Joint mode.

Then, follow the WB instruction.

If it starts well the first time, you haven't checked all !

Offline trevpossy

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Re: Fanuc M6i robot Rj2 controller
« Reply #12 on: April 24, 2009, 12:06:39 AM »
Thank you i have tried pressing cord still cant jog I can get rid of my fault red light  on pendant when turning robot lock on however when i do this the mcc contactor wont energise at all taking me back to system is in error status When i try to jog however when i turn robot lock off the red error light comes back on and the fault that comes up is waiting for servo ready when i try to jog Really do appreciate everyones help. Is trouble shooting usually this complicated ?Trev

Offline Mtech

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Re: Fanuc M6i robot Rj2 controller
« Reply #13 on: April 24, 2009, 04:11:35 AM »
Hello,Sometimes frustration makes these things worse. However it is also hard to describe problems and solve problems over the internet. But the good news is that it sounds like you are all most there. Lets do this as a step by step process. This way everyone knows what step you have or have not taken and what problems you experience at which process step. I know this will help me.
Question 1. What are the alarm messages from power up and tp key off  and  tp on/off switch turned to off?

Step 1. Turn controller key switch to T1 or T2
Step 2. Turn teach pendant on/off switch to ON
Step 3. Press and hold a deadman switch
Step 4. Press reset to clear alarms

Question 2. Are all alarms acknowleged, and controller fault light go out?

Step 5. Press COORD to where JOINT appears in the upper right hand corner next to your speed %
Step 6. Adjust Speed % to say 25 or 30. ( a speed of fine or Vfine will appear that the robot may not be moving)
Step 7. Press and hold one of the blue shift keys and press one of the blue J1 (X) jog keys.

Question 3. Does the axis J1 axis move?
Question 4. What are the alarms if it doesn't?

Step 7. If controller faulted clear all alarms and Press and hold the **other** blue shift key.
Step 8. While holding the shift key press any of the blue axis jog keys?

Question 4. Does the robot move or if faulted what are the alarm messages?

This may sound childish but I have a tendency to forget steps and just leave things out. Sorry. Best of luck.


Offline trevpossy

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Re: Fanuc M6i robot Rj2 controller
« Reply #14 on: April 25, 2009, 04:34:46 PM »
Thank you I will have  another look on the weekend and will get back to you with my results.Still havnt got any lights on on the I/O pcb  Can you tell me where the power comes from Or socket  number .I Am  still good for a challenge Really appreciate your effort and Patience