Motoman K6SB ERC -95, Errors in start up diagnostics

[Vezku-]

Hello,

I have Motoman K6SB ERC MY95, I dont know the history of this machine and what it has been doing previosly.
The problems is when starting up...

The diagnostics starts to count down from 13 - > 0

Then comes the
MAKE ABS DATA <FAILED>

Error is with
SV1, line 2 ; error 03
SV2, line 1 & 2 ; error 05


What does these errors stands for? I swapped the cables between the servopack units, but still the same.
Looks like the errors comes from servomotors or wiring?

Could you help me on this one?

[Pcarbines]

Hello Vesku, I'm getting into brain cell cobwebs here so I'm attaching the ERC  instructions for re-recording the encoder absolute data. Please remember to replace the encoder battery in the Base of the robot as well as one in Door mounted control section, instructions show this also.
I've included "Soft Key tree" which is a great aid with these earlier controllers.
You will need to get security code to gain access to this "OP1" operation, because we cann't place these codes on the forum you will need to e-mail myself or another member .
Please remember that the system data battery could also need replacement , replace this systems battery with power "On" the ERC controller, If data gone you will need to initalize system , if not then with the power on you willn't lose whats still there.
Your other error codes should wait till your get Absolute data re-recorded.

[Vezku-]

Hello Vesku, I'm getting into brain cell cobwebs here so I'm attaching the ERC  instructions for re-recording the encoder absolute data. Please remember to replace the encoder battery in the Base of the robot as well as one in Door mounted control section, instructions show this also.
I've included "Soft Key tree" which is a great aid with these earlier controllers.
You will need to get security code to gain access to this "OP1" operation, because we cann't place these codes on the forum you will need to e-mail myself or another member .
Please remember that the system data battery could also need replacement , replace this systems battery with power "On" the ERC controller, If data gone you will need to initalize system , if not then with the power on you willn't lose whats still there.
Your other error codes should wait till your get Absolute data re-recorded.

Thanks Pcarbines,

that helped a bit. I changed the battery (3.6volts) from the manipulator and did the "drain" operation by short-circuiting the OBT - RST wires for the servos that had those OBT - RST wires marked. I only find two servos that had those markings.

After these procedures one of the error is gone. Two more to go...
Do anyone have that specific wiring information for the other servos to that "drain" operation?

I´ll have to check tomorrow the battery from the control cabinet.

[Vezku-]

I have achieved little more process in this project.
The battery in the control cabinet was fine, I did the RST - OBT "drain" process for the two servos.
Finally the ERC Yasnac screen opened, it gave error #1290 for the wrong position of the four axes.

At the moment I only have a plug in the teach pendant input to "cheat" that the pendant is in place. (looking for erc teach pendant!!!)

I push the "servo -on" button, but then error #0210 comes of "external servo off signal is on"
Is there a input that I have to short-circuit to get the servo power on?

From the I/O setting I noticed that Extrenal servo off is named in #RIN004, where this connection is located?

with best regards and many thanks,
Vezku

[Pcarbines]

Page 13 of ERC maintanence manual I sent you is only external control that I can picture from here.
CN01 - 41 & 49 , 1 TB -1 & 2 .
I'm not aware of any connection in ERC called Rin 004 it might be internal in which case you could be hog tied. Prior owners could have changed Systems program as well.
 Din 4 is external  (Hold or Servo , however its been selected) and thats 5TB-7 & 8. Page 17  of maintanence Manual.
To try and get this machine running without a Teach Pendant is next to impossible.

[JG]

Here's some documentation I found helpful while kicking my old ERC.  Whatever you do, DO NOT reinitialize the concurrent IO data (otherwise an expensive service call will be required).

[Vezku-]

Thank you Pcarbines and JG of your shared files.
I got rid of that #RIN04 (ext.hold), by straight connection to +24.

Also the red light is gone (stop-button).

The only input that is bugging right now is #SIN006 (servo -off) -see the attachment

When I press the SERVO ON -button the ERR 0210 lights on.(extrenal servo off is on)
Also the "SAFETY MODE" is on all time time. My Motoman knows finnish, so all the data in the screencapture is finnish.
Thats why someone my error translations can be different of the offical.

[Vezku-]

Update on this case:
The "SAFETY MODE" was on because the teach pendant wasn´t at place. I overrided the two switches.
Safety mode is gone, but now on the same line is "2" and on the upper right corner says "STOP".
I belive that still some safety switch is still activated.

From the TB1 connector I jump wired the points for "HOLD" and the "2" -> "4".

Does these numbers tell what stop is activated?

Now I can get the servos on, and from the ABS reading page seems like every servo is working just fine. I dont have the teach pendant so I cant move them...
Many of the functions related to program editing is forbidden along with error 1010, what does this mean?

Thanks!

[novatop]

In the Alarm list , the 1010 error is
Arithmetic Processing Error

Operation was disabled on the HA 0 CPU

Reset the alarm and try again.
Turn OFF the power and then turn it ON again.
if The error can be confirmed by reproducing it, replace arithmetic HA 02 board.

In the operation manual i found error 1010 Edit-lock mode . Perhaps the edit-lock key on the sub-panel is set.

[Vezku-]

In the Alarm list , the 1010 error is
Arithmetic Processing Error

Operation was disabled on the HA 0 CPU

Reset the alarm and try again.
Turn OFF the power and then turn it ON again.
if The error can be confirmed by reproducing it, replace arithmetic HA 02 board.

In the operation manual i found error 1010 Edit-lock mode . Perhaps the edit-lock key on the sub-panel is set.

The alarm dont go away and I cant get into "EDIT" mode.
I checked that the edit key works fine. (measured the wires between the key-switch)

Could it really be a broken HA 02 board...?

I can reset the program that is selected at the moment in OP2 mode.
When I change to OP1 and push start, the program is activated and the robot starts to move. Right now the calibration isn´t done so it moves a bit and gives an error.
But still the robot is working as it should be...
I´ve been trying to search used teach pendant, but no luck.

[novatop]

Where are you from?

[Vezku-]

Where are you from?

Finland

[Electric Delight]

If the system was initialized, when you turn on the robot you have standard PLC and not safety PLC. ( for test leave ERC in AUTO and robot is working, in step is not working ) The problem is that you need safety plc and program for install It.
If you need boards, motors,servo or Teaching Pendant let me know, I have many of that.
Electric Delight

[Vezku-]

If the system was initialized, when you turn on the robot you have standard PLC and not safety PLC. ( for test leave ERC in AUTO and robot is working, in step is not working ) The problem is that you need safety plc and program for install It.
If you need boards, motors,servo or Teaching Pendant let me know, I have many of that.
Electric Delight

Do you mean that Jokab-safety box? I´ve been wondering are the ports really open. I have jump-wired three of the boxes to get them "open". There is biggest box in the middle and there is only the "ON" -light green. The A and B lights are off.
If you have ERC teach pendant with the thin spikes, email me!
Also if you have the schematics for Jokabs, email them also for me!
Thanks!

[Vezku-]

If the system was initialized, when you turn on the robot you have standard PLC and not safety PLC. ( for test leave ERC in AUTO and robot is working, in step is not working ) The problem is that you need safety plc and program for install It.
If you need boards, motors,servo or Teaching Pendant let me know, I have many of that.
Electric Delight

Do you mean that Jokab-safety box? I´ve been wondering are the ports really open. I have jump-wired three of the boxes to get them "open". There is biggest box in the middle and there is only the "ON" -light green. The A and B lights are off.
If you have ERC teach pendant with the thin spikes, email me!
Also if you have the schematics for Jokabs, email them also for me!
Thanks!

For information this robot has been used in a painting job and for unknown 
reason the company has sold this robot with all the wires (relays etc.) attached to it. This was back in 2003.
Then the new owner has never even unwrapped this robot from package and it has been waiting for a job in a warehouse. Our company bought it and here we are...

Thats why I´m wondering about those safety relays... Could there be somekind of connection that has been removed straight from the Jokabs connectors...?

The Jokab models are:  3x JSBT4 and one bigger relay.

Looks like that these are only safety relays, not PLC? The Jokabs PLC is called Pluto.

Any ideas?