RX90B-CS7B HIGH POWER FAULT

[spelectron]

Hi
I am trying to diagnose a fault with a Staubli  RX90B-CS7B system whereby when you try to enable high power it enables momentarily and then turns off.  I notice that the MI6 card has all of the Axes fault LEDS lit (1-6), ES - not lit, HPE led flashes on with the High Power.

All the AXES Amplifier modules are showing a "1" on their 7 SEG LEDS

The AWC INTERFACE  LEDS (LHS) appear correct. Down the board to the HPE leds.  These flash on when you try to enable HiPower and immediately go off as goes off.
The AWC CPU board LEDS appear correct.

There does not appear to be any error messages in the V+ Adept Software Monitor. Except for timeout when the HiPower fails...

I and am wondering if the error lights for the 6 AXES on the MI6 board would indicate an error condition that causes the HiPower to immediately turn off, or whether the HiPower is going off before the system starts and extinguishes the AXES fault leds?

Any help would be greatly appreciated.

Best Regards

[Jim C]

On the MI6 you will see all the ES LEDS on whenever arm power is not on. In theory when you have an issue with a single channel you would see that ES LED come on a fraction of a second before the other 5 did.

As you are not getting a specific error message I doubt it is an issue with the MI6, amp, motor, or resolver. Did you see the LED come on for the amp power supply? If not it could be the amp power supply, but before changing it I would check the AP1 and AP2 relays. These relays supply voltage to the power supply. For safety reasons they do not close until you turn on arm power. If either relay is bad, you will not get voltage to the power supply.

[spelectron]

Thanks for you reply Jim
I have checked the power supply and the Top LED on the Amp Power supply does come on.  I have traced the circuit through AP1 and AP2 and they are good. 
I managed to get a schematic of the AWC Interface board and found that the PES relay had 16 ohms resistance across the contacts when closed... I thought I was onto it!! However I replaced the relay and it is not fixed..

As the machine is second hand, it is lacking a most of the information.. If I could get detailed schematics of all the boards I think I could make a bit more progress. 
Is that a possibility?

Regards

[Jim C]

Unfortunately most of boards in the controller are from Adept or other vendors and they do not supply any detailed drawings. Some boards like the interface board were made by Staubli and a detailed drawing was supplied with the electrical drawing set.

It is possible that there is an error message being generated and you are not seeing it. If you have a auto program to launch your application, try disabling it? Auto started applications sometimes would hide error messages. you can either rename the file, go into the config_c utilities and turn off auto start.

[spelectron]

Thanks Jim
A little more playing around and we now have the following

We can abort the running program (CNTR C in the monitor) then enable HI Power manually (EN PO)   The high power button on the cabinet flashes and comes on steady when you press it but as soon as you press the HALT/MAN button on the MCP, the high power drops out...   Before you press the HALT/MANUAL, the HPE LED is lit on the MI-6e and so are all the AXES LEDs on the MI-6. Once pressed the HPE LED extinguishes but the AXES LEDS stay lit.

The L1 LED on the Backplane Power Supply also goes out when the HALT/MAN button is pressed.

NO errors appear on the V+ Monitor.

Regards

[Jim C]

I am puzzled by the lack of an error message. There are many reasons why you might lose power, but they should result in an error message. Applications can some times "hide" the error message (REACTE instruction).

After the Ctrl-C, type in a "STATUS" command and make sure there are no active tasks. If any task is running, abort it ("ABORT 1", "ABORT 7", each task has to be aborted individually). Then try arm power.

You can also watch the LEDs on the AWC Interface board itself. The LEDS show the status of the E-stops and Arm power circuits. For arm power watch the "PES" (system PrESent for AWC card), "LIM SW" (limit switches), "24LSW" (limit switch supply voltage), "HPR" (high power request), "V+ HPE" (high power enable from MI6), "HPE1/2" (high power enable from e-stop circuit), "AP1/2" (Arm Power relays 1 and 2), "V+ BRE" (brake power request), "BRE1/2" (brake power relays 1 and 2) and "24V2" (brake voltage).

I suspect the issue is with the AWC interface board, but it could be the AWC card itself, the MI6, or even an AMP.

[spelectron]

Thanks Jim

Have been away.

I will go through your suggestions and get back.

Regards

[Ztek]

Im not used to Staubli, but work a lot with Adept and have seen simular problems a lot of times.

Do your robot have a PA4 amplifier chassie? If it has, then look behind the filter at the lower part of the front and you will see three (or is it four?) LEDs. If there is some problems in the PA4 chassie, or with the servos, you will get high power for a short time and then go off without any error in the V+, but the error is instead indicated on the leds on the PA4.

[spelectron]

Hi Jim and Ztek
Thanks for your advice.  I ended up taking with Adept in Singapore, they were extremely helpful.  Ended up sending me over the processor and the Mi6 board.  When I put the Mi6 board in BINGO! all fixed... javascript:replaceText('%20:cheer:',%20document.forms.postmodify.message); 

i am able to return the processor board for credit javascript:replaceText('%20:bravo:',%20document.forms.postmodify.message);

Looking at the Opto chips on the old Mi6 I noticed a couple had small raised bubbles and wondered if they had failed... anyway it is working now.

Many thanks to all for your input

Best Regards