We are having a problem running programs in auto mode. Sometimes in the middle of program execution, the robot will simply stop. Message on the TPU says that it has lost communication with the control. No amount of fiddling with the TPU gets any action from the control.
After turning the control off and then on again, the message I get on the TPU is; "The system data was not saved during shut down. All modifications of programs and parameters since FEB 24 are lost. Select action:" Options are Restart, I-start or X-start. After the restart, an error message reads that the Rev Counters are not synced.
Just to be safe, I have been starting from a restored back up made recently. I should mention that this shut down has also occurred while the robot was in auto mode and waiting for the next program load. I have noticed that when the shut down occurs, there is an audible click from the control, as if an electrical contactor was dropping out. I'm still able to run in manual mode after start up without any of this happening, so I believe it is only an auto mode issue.
Can anyone give me some direction on a fix; is there a parameter that needs to be adjusted, or is it likely related to a failing part?
ABB 6400R M2000 S4C+ control. System is used as a 6 axis CNC to mill wood parts.
Thanks for any help on this.
Marv