Well, in desperation I formatted the memory. Erasing everything in it. Re-mastered the machine, assigning which manipulator is attached, punched in the encoder correction values, 0'ed all the I/O's, disabled and simplified as much as I could. Bare bones basics.
That got rid of the E1001 error. Haven't seen it since. And still don't know what was causing it?
But still no movement.......
I haven't got the key for the Auto/Manual switch, so I unsoldered a wire from the back of it, and disconnected the Safety Plug jumper just to try that combination. Still no movement. Just a blinking green Motor's On button, deadman switch doing nothing but it's beep upon grabbing it.
So I'm about ready to pull the servo amp out and give it a thorough going over..........
At this point my 6yo daughter is with me. "What's that there?" pointing into the controller. It was an add-on terminal connector for just two wires. EMON+ and EMON-. I traced it to the Motor's On button. And into a relay amongst the added on controller wiring behind the door panel. Oh, so that's not external monitoring, it's external motor's on. Hmmmm.
I thought I had bypassed all that beforehand. Seems not enough of it. So I jumpered between them, bypassing that relay. And.............
WOOHOO!!! It works!!
You would not believe how relieved I am.
So I've now set some soft limits so ensure it won't overbalance itself while it's not bolted down. That will be an upcoming project. To make a suitable base frame arrangement for my requirements. Looking forward to it, but I have another major project underway that must be finished first. So it will be some time away. Oh, well. Just knowing it all works now is a huge relief. The prospects of having to purchase a replacement drive unit was almost keeping me up at night!
Thanks to all those that tossed up suggestions. And I hope this topic and my experience has been helpful for others in a similar predicament.
Now I've just got to live with the fact my 6yo daughter help fix it. I'm sure she won't let me forget it either....
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