UP6, XRC ctrl, '24V DC SUPPLY FAILURE' - have done the basics, still problems

Hello, I am new to motoman robots. I have two UP6 robots both with XRC control boxes. The robots have an external playback panel that is fed by a very big mil-spec amphenol connector. The teach pendant attaches to that box instead of the a panel on the control front.

The power supply unit inside the xrc controls is making 24V none of the red error lights are on.

The i/o contactor unit is setup for internal 24v supply to power the i/o.

I measure 23.2V on the 24VU to 024VU rail on the i/o contactor unit.

the fuses f03, f04 are NOT blown.

there is a yellow box on the same DIN rail as f03, f04 that is wired in, but it's power lamp does not illuminate.

none of the I/O outside the control (i.e. at the spade connectors) has any voltage on them at all.

the robots won't continue / won't be able to move because of this issue.

both robots have this same issue, so i pretty certain it is some kind of configuration problem that isn't documented in the main up6 manipulator, or xrc control manuals, which i do have and have been digging through big time. any sugguestions would be very much so appreciated. overall the story is that i am working on getting these to do some machine tending; they used to be welding robots.

some more detail is that the playback panels on these machines are remote over that big amphenol cable (like 80 pin?) and there are no playback panels on the xrc control cabinet because of this.

none of the lamps light up on the remote playback panels. it is another indication of the 24V problem being for real - its just that i measure 24V on the i/o contactor unit CN27 / wago connector. I saw in the manual that the fuses F03, F04 are actually located on the side of the i/o contactor board. it appears that the fuses were broken out onto a DIN rail in the bottom of my crtl cabinets. I'll be next to the robots here in an hour, will check it then about whether there are fuses on the side of that PCB or not.

I found out that there needs to be 24V external input supplied to the JZRCR-CO02 unit. I did this over the cable external to the machine which is N1 and P1. This got rid of the 24V failure alarm.

Now the remote playback panel has lights on it, and seems to be functioning OK.

Now my problem is the safety alarms. I am getting alarm 4222 [0000_0010] and 4222 [0000_0011]. for the time being, i just need to verify that the robot can move. I will sort out all the safety I/O when I install the robot in its application.

There is the 'force' terminal that can be shorted. I could try that but it seems unsafe / not clear whether the e-stop would stop the motion anymore. This i could do just to verify the robots move. I have some terminal blocks that I am using to short out the safety signals right now such as external estop, external hold, and so on. There is a cable labeled 00112 that is hooked up to a relay. there is no mate for it though, it is unclear whether it should have gnd, or 24V applied to it. also there are the ESR105, ESR104, ESR204, ESR205 pins which i don't know what they do and don't see it in the manual about what they're for. I don't know which combination to short together to set the saftey switch as made.

got it figured out. it was CN06 on the i/o board, it was setup i think for multi robot control. i shorted 1 to 3, 2 to 4, 5 to 7, 6 to 8 - this cleared the I/O error and i can move my robot.

now i get a servo tracking error on the Z axis (big axis at the base of the robot). this is the only axis that gets the error. the other axis move just fine.