Hello,
We have a Fanuc RJ2 controller hooked to an S420i W arm with Spot weld software. When I was first approached by operator they stated the teach pendant was not responsive or booting up when the controller was powered up. We have 6 of the same identical systems and have swapped pendant and cables already to determine they were not the cause of the problem. Seemed to be the lithium CPU battery had gone dead and from the service records it was a 1 month overdue from the annual service change. We have new batteries in stock so I installed new battery but still same problem. Seems I needed to do an INIT start since there were no backups. I began the INIT process and once I was able to get passed the robot type info and reached the payload information. Shortly after that I got an error screen I’ve not seen before and my picture was not very clear due to dirty pendant screen so I typed out what was said in message. Message read:
Controlled start initialization Error screen
Load group 1 robot library
Opening path: \SMC.COM.
This file cannot be read. Check disk using BMON> DIR and BMON> TEST DISK. If the file is missing, replace the disk. Else replace the drive. Do not continue to load if read errors occur or your system might be corrupted. Consult the installation manual.
Press Enter to continue.
(Loading from disk SLIB2.)
Robot will not let me finish INIT or boot up. I found an old IBM Think pad with the KFloppy program and a cable for transferring data but have not been able to connect to robot thru the RS232 port. I’ve used the same process when getting another one of our robots up and going but this particular system won’t boot passed the Boot screen holding PREV and NEXT buttons. I have an extra controller I can use for parts, and the appropriate SRAM 2mb PCMCIA cards on the way but would it be safe to swap out CPU’s or should I find a way to reinstall the software? We do have an old backup, and not worried about having to re program the parts. Just wondering what the next best step would be for us to take. I’ve checked all the voltages according to the manual under Class 1 fault but I’m assuming since CPU battery died the software has been corrupt and we need to reinstall or change boards? I do have 3 status lights on CPU that are on. Lights 2, 3 and 4 (Green on top row) are on. According to the manual the Axis control printed circuit board need replaced. Any advice is appreciated.