Major Alarm: 1322 - Regernative Trouble (Converter) - XRC Robot Welder

[Ryanrpm]

Hello all,

I've ran this welding program hundreds of times.  Upon the change out of welded parts to fresh parts, I press the "Servo On" button and I receive this alarm.  1322 - Regenerative Trouble (Converter) and then this binary code:
0000-0000-0000-0010.

I'm about ready to call Yaskawa service but wanted to see if any of you also had some advice or trouble shooting tips.
Thanks, Ryan

[jax.]

Ryanrpm

I have had this problem before and it turned out to be corroded pins in the back of the cabinet (where the transformer is). Hope this may put you on the right track.

[Ryanrpm]

Would you be able to take a picture of what pins you are referring to?

[jax.]

Its the only cable that you have to disconnect if you are to remove the back panel completely away from the controller. 6 pin plastic connector normally cable tied to the back panel.

[Ryanrpm]

Please guide me to the location you are talking about.  There are a billion wires in this thing.

[Ryanrpm]

Our maintanance guy and I have gone over all connections and have found no corroded wire terminals or pins.  We've tested all the fuses.  We've isolated the issue to the controller, not the manipulator.  We are almost certain it is the converter that went bad.

This unit was refurbished when we bought it and an entire work cell from Robotworx, and it has only been in our facility for about 8 months, so it is still under warranty.

It's a major drag having to hand weld alot of our parts....I hope the turn around is quick. 

Jax, thanks for your help.

[Robo Guru]

Did you look at the regenerative resistor yet?  You can measure it out with your ohm meter to make sure that it is not shorted.  Typically they are very low ohm values.... maybe less than 12 ohms.

I would consider replacing this resistor or your servo pack.

RoboGuru

[Ryanrpm]

Yes, we tested the resistor and it was 12.6 ohms.   

[Ryanrpm]

An update...

We replaced the converter and this did not fix the problem.  We will replace the servo pack now.

[Ryanrpm]

Jax, if you're still up for it, I would appreciate more info regarding this 6 pin connector you mentioned.  Do you have a picture of what you are referring to?

[Ryanrpm]

An update....
We replaced the servo pack and upgraded the software.  This did not fix the alarm error.  RobotWorx is sending out more parts.  They are not sure what is causing this problem. 

If any of you have more advice or troubleshooting tips, please chime in!!
(Going on 3 weeks now that we are down.) 

[Robodoc]

In your original message you said the data from the alarm is 0000_0000_0000_0010.  Does this robot have an  external axis?  Have you been looking at the robot 6 axis and have a problem with the external axis?

[Ryanrpm]

Yes, this robot has an external axis in the form of a tilt/rotate table.  The robot is axis 1-6 and the tilt rotate table is axis 7&8. 

Could the table be the problem?  How should I proceed in trouble shooting the external axis?

[Robodoc]

First check the resistance of the external axis servo pack.  Depending on the size of the tilt and rotate you may have one converter with two amplifiers or two converters and one amp on each.  The re-gen resistor plugs into the converter.  Same as before, unplug the resistor from the converter and check the resistance.  If that is OK, replace the converter.

[Ryanrpm]

An update......

This will give final closure to this thread.  Robotdoc was correct: We had a faulty converter on the external axis.  Once that was replaced everything was working fine.  I believe it went faulty in the first place because it overheated  .  To prevent this from happening again we will place dust filters over the fans to prevent dirt from clogging the fan openings and sticking to components on the inside of the cabinet.

Thanks to all who contributed to this thread, your help was greatly appreciated!

Ryanrpm from Nevada.