Hey,
I have an IRC5 2600ID arc welding robot that is about a year old, it has weld guide 3 installed. I have never used the weld guide because it gives errors about 1 out of 8 to 10 seams. It has always been a nuisance constantly faulting. Although when it is not giving errors it does track the weld correctly. I can put bent coupons in the weld fixture and it will track beautifully most of the time. Bought the robot new from ABB and I went to Auburn Hills for the run off it did function correctly there (we only ran 1 piece to check it while I was there so it likely was the same issue). This week I have been trying to get it to work. I think it is a communication problem, I get the errors if welding is blocked or not so I feel like it is not an issue with weave width or frequency or weld parameters, the errors normally say current sensor is not working, but there is no current when not welding. I have checked all the connections that go to the weld guide module in the cabinet, the voltage and current sensor are separate (not a dual sensor like the manual shows in its pictures) The wires for each of these appear good outside of the cabinet. the arrows on the current sensor are pointing toward the power supply on the positive cable ( I thought the arrows should point in the direction of current flow but this is how it came from ABB and weld guide works more than not so I guess it is correct) any help would be greatly appreciated. Pictures of errors are attached.