KR150L150 with KRC1 can not turn drives on no errors

Hello all, I recently purchased a KR150L150 robot from eBay. It has a KRC1 controller and came from a GM plant. I have dealt with GM robots in the past and trying to run them without issue. This one I am having a weird issue with though. When the robot came in someone had taken the RAM module from the motherboard. I grabbed one from a parts robot I have here and reloaded the KSS software as it was corrupt to an extent and would not do anything once the controller was booted and software loaded. Once I was done with that I checked the Auto-EXT I/O but did not need to change anything to 1025 as they already were. No errors, only the status message of drive contactor off. When I put it in jog mode and pull in a dead man wait a couple of second and hit an axis jog key it does not turn servo power on and only give me the message of :1376 Active Commands Inhibited. Of coarse the most common of status messages giving me no where to really start looking of problems. I had an issue before similar but that was chased down to a dirty contactor on the safety board. These contactors seem to be working perfectly fine. (I could see the dirty one on the other robot flickering when pulling in the dead man) Anyone ever run into this before and can point me in a direction?

Quote from kr16_2

GM used to have "servo disconnect" boxes.
These were running intermediate voltage through separte switch box outside KRC1.
Once KRC1 was moved box was disconnected and voltage never goes through (no errors)

On PM6-600 you need to have a jumper (very short jumper for high voltage - thick cables, square plug)
It was on a left or right side of PM6-600
Check if you have it. If there is some wires tunning out if there -> you are a lucky one with servo disconnect option
You can jumper it out on terminal block where the wires are going to.

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Hi there KR16, yes this has a servo disconnect but I have that jumped out. Even went back and ohm-ed the terminals to make sure I had good contacts on my jumpers.

Quote from SkyeFire

When you squeeze the deadman, does the power icon on the KCP turn green?

You're using an X11 jumper plug to satisfy the hardware safeties, yes? I once had a similar problem years ago, but with a KRC2 -- there were two X11 wires for enabling Teach mode, but it turned out only one of them generated an error if it was mis-wired -- the other just prevented the motors from coming on. Never ran into it on a KRC1, but it might be worth checking for.

The GM KRC1s used two safety boards, if I recall correctly -- there wasn't enough space on the regular board for all the relays GM demanded. I would suggest tracing through the relays, using their readout LEDs on the board. That should narrow down which (if any) relay is the culprit.

Hey Skyfire, this will sound dumb but where is the power icon on the KCP? This being a GM bot the X11 is not the same, this has a CC1 bypass plug to satisfy the hardware safeties. I will take another look at the relays, I'll have to find my print out of what they all are again, been awhile sense I had to do that.

Hello all, just wanted to update this in the case that anyone comes across this issue. I traced the problem to four DIP switches on the FE207 card. X1, X3, X4, X5 were open and needed to be closed. Closed when 1x PM0 or PM6 and Open when 2x PM0 or PM6. This was a "parts" robot but it appears someone was playing with the switches not knowing much about it. I do not believe that this robot ever had an extra PM6 as there is no other evidence of one.