Stäubli RX90 with CS7M not working

[eriked]

Hi,

I'm trying to get a RX90 with a CS7M controller back in action :)

Teach Pendant display:
"Lost communication with the controller_
No programmed primed
a.cal util running
No programmed primed"
Error messages:
SIO: Estop: red
MI-6: ES: red
Fault: red
On the safety board diods: D1, D14 and D54 are red.
On the Basicio: D40 diod is red.

The previous lab reseacher tried to fix the problem but he didn't have enough time to figure everything out.

What he did was to short-circuit the door cell emergency stop (on J11 pin 49&50) and the External Emergency Stop (on J11 pin 43&44). But he couldn't figure out how to short-circuit the Limit Switch, Local Front Panel EStop and the Remote Front Panel EStop. And neither can I.

Any suggestions?

[Jim C]

Since you mention LEDs on the Safety board, I am assuming it is a -06 or later safety board. Earlier versions has test points instead of LEDs.

D1 shows you have 24 VDC to the e-stop circuit. If D2 is not on, the the front panel e-stop is open. Normally you should have a plug on J1 of the safety board to the front panel, with the E-stop switch on pins 11 to 12, and a jumper on J1B pins 11 to 12. J1B is the remote front panel. The limit switches are on J2, pins 16 to 17 of the safety board to the arm interconnect cable. The limit switches are inside the arm on joints 1,2 and 3 for a RX90.

J11 on the controller should be a 37 pin sub D connector. You need to jumper pins 32 to 33 or connect them to an external e-stop.

The ES LED on the SIO and MI6 are normal. They will not go out until you get arm power on. The red fault light indicates the open e-stop.

[eriked]

Thank you for your answer.

The electrical diagram says safety board 231 249 08 1/15. If you refer to the part '08' when you mean later than 06 then, yes.

The J11 I have here is a 50 pin d-sub connector.  The J11 you can access from outside of the controller (section 1.5.3 of the Controller - CS7 M manual connector (7)). Is there another J11 or what did you mean?

[Jim C]

On Staubli part numbers the last two digits normally indicate the revision, so 08 is the revision of the safety board. The most common version of J11 had 37 pin. There were versions with 50 pins. On the 50 pin J11 besides the pins you have already jumpered you will also should jumper pins 41 and 42 AUMANU+ and - (AU is e-stop). This are only used in manual mode and are provide for additional deadman switches in case you need extra people in the cell.

J11 in on the back of the controller next to the interconnect cable.

What does it say on the ID plate? Please give me all values, machine number, model, and so on. We made small changes in the controllers over time and for different customers.

Did you check the e-stops and leds on the safety board again?

[eriked]

The ID Plate on the controller says:
Type: CS7 M RX90
Mass: 80kg
Machine nr: 599132-01
Fabrication: F-03-1999

We jumpered pins 41 and 42 on J11 (besides the beforementioned jumpers on pins 49&50 and 43-44). Also we put a jumper on J12, remote front panel on pins 8 and 9

Now the LEDs are red on D1-D8 and D14 and D54. The red fault light is still on.

If I press the front panel ES now D1, D14 and D54 are red

[Jim C]

D8 being on, D9 being off, and D54 on shows the brake select switch on the base of arm is out of position 0. Turn it back the position 0 (past the Joint 1 position).

[eriked]

Okey
Now D1-9 and D14 are red. Fault indicator is not on and neither is ES on SIO. ES on MI6 is still red though.

Is D10 supposed to be lit or not? The manual was a bit unclear to us which one of them meant that it was an internal controller error. If there is an internal controller error, how do we proceed?

[Jim C]

D10 not being on can be one of three things.

1. J1-13 to 14 and j1B 13 to 14. These are for a arm power off on the front panel and remote front panel. The standard front panel does not have this button so they are usually jumpered.

2. J10 pin 5 to 6 jumper. J10 was a connector for an OEM to installed one of their control boards. On standard systems it is a jumper plug.

3. System Power Enable (syspes) from SIO on J3 pins 23 to 24.

D11 indicates HPE signal from MI6 on J6 pins 13 to 14.

D12 is relay R4 controlled by the arm power button on the front panel

D13 is power to AP 1 and 2 which energizes the high power module from the amplifiers

At that point arm power should be on.

[eriked]

I've now jumpered J1b 13 to 14 by putting a jumper on the connection J12 19 to 20.

Now arm power goes on for perhaps 2 seconds. Then it loses its power again.

Any thoughts? I haven't tried the other two things that you mentioned yet because I haven't figured out how to place the jumper. I can't do it for the I/O connections (J11 and J12), right?

[Jim C]

Do you get an error message when arm power goes out?

J10 on the safety board does need to have jumpers from 2 to 3 (brake release) and 5 to 6 (arm power).

the SYSPES is a signal from the SIO to the safety board. It is not a jumper.

Typing EN PO (enable power) on the terminal or the comp/pwr button on the pendant should cause the green arm power button on the front panel to start flashing. Pressing the flashing green arm power button should case arm power to come and the green light should be on steady. Pressing it a second time will turn arm power off (you can also type in DIS PO or disable power, or press the dis po button on the pendant).

[eriked]

I checked and J10 already had jumpers on 2-3 and 5-6.

If I press comp/pwr on the pendant the green arm power botton starts to flash. When I press it arm power goes on and the green light goes on for approx 1 sec.

I checked the LEDs on the safety board and during this one second D10, D11, D12, D13, D14, D15, D53, D16 and D20 are lit. Also D1-D9 are lit as before. On the front panel on MI-6 instead of ES being lit all the yellow leds were lit (during this 1 sec). After this 1 sec everything goes back the way it they were before.

We don't have a terminal connected yet but we are working on it. If we use the manual mode and try to power the arm the pendant gives the error message *arm power off* when the arm powers down after 1 second.

[Jim C]

It looks like everything is OK for arm power. Hopefully the terminal will tell us what is shutting it down. D20 on the safety board is for the arm power button. It should only be on while the green arm power button is pressed. Continuing to hold down the button will turn power off.

[eriked]

Now we have connected the RX90 to a terminal emulator on a PC (HyperTerminal).

The output reads ".*Robot power off*"

During the start-up one potential error occurs:
CS7(M) Controller
Waitung for communication start ...
*** Watchdog: Comunication error

I've attached a text file, Molly.txt, of the complete terminal output during the start-up procedure and the typing of the command .enable power

Do you have any ideas? Are there any commands that we should try?

[Jim C]

OK this is a robot from a DASY system which was used for testing EM radiation from cell phones. I suspect the application itself is shutting power down due a communications error between the controller and external controller like a PC.

The application is autostarting. The easiest thing to do is to turn dip switch 1 on the front of the SIO card to off. This will disable the autostart. Let the controller boot up then at the prompt on the terminal type EN PO which is short for enable power.

Assuming you are not trying to run an actual DASY system you use FDEL to delete the auto.v2 program or FREN to rename it.

If this is a DASY system you are trying to use, you need to contact SPEAG, Schmid and Partners who built and support the DASY system.

[eriked]

Thank you very much for all your help. It seems to work fine now.