Need help with IRB 6000 with m93 controller synch error. I keep getting an error code 509 Synch error 2201 along with 506 Servo error 2 (2004)(7001). I tried replacing the SMB board along with replacing the cables to the resolvers on axis 1-3 because the cables did not look healthy.. I also tried replacing the main measurement cable from the robot to the cabinet. Is there anything that I could be missing?. Please help.
509 Synch error 2201
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s3 fanatic -
October 4, 2017 at 2:45 PM -
Thread is marked as Resolved.
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506 servo error 2 (2004) is Axis 4 resolver, you need to measure the resistance, probably best to start at the base connection/plug and compare the readings with another axis resolver. Drawings should be in the manuals section on here.
The 7001 message can be discounted for now as it's just a time-out (the arm has been commanded to move but nothing happened)
509 Sync error 2201 is Axis 1 rev counter missing, so again you need to check the wiring, start at the base connections and if it's OK work your way back to the cards in the cabinet. Did you update the rev counters with the arm in the sync/calibration position?.
Remember to remove mains power from the cabinet before disconnecting any plugs for testing
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Thanks Roboweld
I will try that. After looking at the schematic , there are three legs on the resolver and assuming that I should be getting 20 ohms on each leg of the resolver. Axis 1 seems to be a hit or miss sometimes but I need to check the resolver on that also. As far as trying to sync it in the calibration position it will never let me get that far. It will either do one or two things, its not very consistent at all. It will either boot up and find nothing wrong and able to move axis 4- 6 with no issues until I start moving axis 2 or 3. Or it will boot up and give the 2201 error right away preventing any movement until the problem is resolved. -
I'm not sure what readings you will get across the resolver as it's probably been 15 years since I "played" with one!. The resolver has 3 windings (6 wires total), 2 are fixed and the 3rd is turned by the shaft so you may get a different reading on that one?.
It sounds like the main issue to sort first is the axis 1 rev counter problem, once all the wiring has be proved OK, you may need to substitute a known good one.
Please excuse me if I over simplify things, but I don't know your skill level.
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It has been a long time but I found some notes on the resolver connector:
Round, 8-pin Trim-Trio # UTG012-8P
Pins A - B = Cos @ 74 ohms
Pins C - D = Sin @ 74 ohms
Pins E - F = Ref @ 25 ohms
Pin G = Shield
Pin H = no connectionVin is 10VPP, Vout is 5VPP, frequency is 3 KHz
I prefer to use a scope with possible resolver issues because a shorted winding may not give a significant resistance change but will give a significant drop in output voltage.
Intermittent or low resolver output can cause the rev counter to be lost and many times the S3 does not give a reason why. -
Thats pretty much what I got when I measured on the resolver in each leg. I dont have a scope to test those but will keep that in mind for future reference. But as far as that it seems ok.
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Update: So far I have a narrowed down to couple of things
1. Found that the pins were recessed back in the connector on the motor side for the resolver for axis 4 when I started tracing. So I replaced the pins on the connector because the tabs that lock the pin into place had collapsed no longer holding them into place.2. After I found the pin problem it came down to a servo error on axis 4 for the resolver when moving axis 2 or 3. Only found this due to only making a small program to do one movement at a time and for each axis to see if I would get an error. It seems to be any movement up,down, backwards or forwards it would error. So I came to conclusion the cable that runs in the chest is causing my error. So to make along story short I replaced the cable that runs from the axis 4 resolver to the SMB boards and so far i have no errors and works fine. I am confident that this has fix my issue but that not confident that there is some other problem lingering once I put the robot back into production. I'll keep you posted on what happens next.
Thank you Skooter and Roboweld for all your help -
That's good news, thanks for letting us know