Hi,
I have an IRB 1400 M 94A robot with S4 controller. I have bought all system disks from ABB.
I did a cold-start because there was a lot of errors and now TP ask me for a boot disk 1. When i insert the disc a diskdrive starts for few seconds and TP shows the information: TPU lost contact.
I checked all connections between TP and main board.
The led on Robot computer DSCQ326 is red all the time. Is this broken?
TPU lost contact after insert boot disc (SOLVED)
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case25 -
November 30, 2017 at 1:46 PM -
Thread is marked as Resolved.
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Try disconnecting the batteries for 2 hours and try again.
Does the controller go thru all the cold boot diagnostics without any errors?
The disk could be corrupt - make a copy of the first boot disk and try that.
What software are you trying to load? Is it the same as what you had?
You have the DSQC326 Robot CPU, what EPROMs does it have? What are Main CPU and Extended Memory boards?Try searching the forum for "Hyperterminal", download the "PC as a Service Tool" manual and learn how to hookup to the comm port. This should allow you to follow along the cold boot procedure and then what happens when Boot Disk 1 starts to load.
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If you have tried to load any robotware versions newer than version 3.0 then you've probably caused a memory overflow on the flash memory located on the robot control card.
Unfortunately this is not recoverable and the two chips will have to come off that board and be re flashed.
I know this as I did exactly the same and am waiting for a flash reader to arrive to repair my card!
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Thank You for replies.
- I disconnected batteries right now, so i'll try again later.
- Yes TP is going thru all test without errors and then wait for boot disk. When i insert boot disk, after few seconds it shows TPU loct contact
- I received the software on email, so i copied it on the disks on my own
- the software according to file labels on disks is the arcware 2.0 Here is the text from file disc.id:
Boot disk 1 (1)
Boot unit no 0 Make cmd 4 Mon Oct 30 14:45:38 2017
Program no 3HAB2323-1/05
Serial no 1400-0737
Boot discette label text:ArcWare 2.0
Property of ABB Vasteras/Sweden.All rights reserved.
Reproduction,modification,use or disclosure to third
parties without express authority is strictly forbidden.
(C) Copyright ABB Robotics Products AB 1993.- There are two chips in dsqc326: 4911014--RHJ D62 and 4911014--RHK D63
Main CPU is dsqc325 and memory board is dsqc321. There is also dsqc256A and dsqc315 on the left side of the robot computer- I'll try hyperterminal today, i found Your post earlier, but didn't have rs232 connectors
My questions:
- Is this any special way to prepare diskiettes? Like i said, i've got the software on email
- If i delete image with hyperterminal nothing will go wrong if there's not any software installed? -
Connection to the terminal brought some new information. The errors at the end differ with the boot disk and without the boot disk inside drive.
Connection logs are attached.When i removed batteries for about 3 hours nothing changed.
I cant send to the robot xdelete command or any other command.There is a boot movie:
https://goo.gl/itQL8F -
I think it's the EPROMs. The ones you have are for the old M94A software that was discontinued and upgraded to CommWare 2.0 over 20 years ago. Any of the following sets listed oldest to newest will work with the 2.0 software:
D62 -RND
D63 -RNED62 -RRY
D63 -RRZD62 -SBV
D63 -SDG -
Ok, i have new CPU DSQC326 with eeprom D62 -RND and D63 -RNE.
Still not working, but there's some changes with start. In terminal i have same fault as previous:id = 3 code = 1206 type = 3 arg = tc8569.c 2038 tc8569_recalibrate error after 3 retries!
but there's new line at the end:
id = 3 code = 1203 type = 3 arg =Could not find: flp1:/abb_load.cmd
And this time TPU isn't hang and wait for another disk.
I checked again connections, but it's fine. I checked file names on diskiettes, and i have two versions of software from ABB, Baseware 2.0 and Baseware 2.1, but error is the same with every disk.
I don't know what can i do.
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Disk 1 of either BaseWare software has the 'abb_load.cmd' file. If the system can't find the file then it could be the disks are corrupt or the floppy drive is not reading correctly. Try copying the disks and see if that helps.
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The files are on the disk (i checked what is in abb_load.cmd and file which load next is on the disk too). I copied every system disk1 twice, nothing changed.
I thought this is drive too, but green led is blinking when cpu read disk.
That's mean the disk drive may be broken? -
Is there any terminal commands that may help? I think to ask cpu about floppy disk drive status or other settings.
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I thought this is drive too, but green led is blinking when cpu read disk.
That's mean the disk drive may be broken?
The green LED indicates it is attempting to read but it doesn't guaranty the data is being read error free or read at all. If it can't find the file, then there must be a reason.Sorry I missed this the first time but I believe the DSQC321 4MB memory board is not compatible with 2.1 or the extended CommWare 2.0 RAP. You may need to try a DSQC317 6MB memory board. The larger DSQC323 and 324 will also work.
You can also quit trying to delete an image that does not exist in this S4 hardware setup. That is for the 4.0 software in the S4C+ where the memory is imaged to the flashdrive during shutdown.
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So cpu can't find the files, because of memory? Or there's other possible reason, a problem with DSQC 325 for example?
I have option to buy dsqc 317 so i will try.
I hope it does not turn out that after replacing all the drivers will still not work. -
So cpu can't find the files, because of memory? Or there's other possible reason, a problem with DSQC 325 for example?
I would try another disk drive first or test the current one in an old PC.Regarding the software/hardware compatibility, at our facility the DSQC321 would NOT test in the controller running BaseWare 2.1, it had to test in the older unit with the only the Basic CommWare 2.0 and it also did not work with the larger CommWare 2.0 RAP software.
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Ok, i will check the drive today, dsqc's will arrive in next week, so i'll let You know about progress.
Many thanks you for your help so far.edit:
It worked!
I installed the system baseware 2.0 and arcware 2.0 with english language (before it was sweden).
Disk drive was broken, simple as that.Next week i'll connect the robot and see what happen, because now i have connection error, and robot stands in the other hall.
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I connected the robot and there are few problems. There are 3 which are important i think. On the beginning i had over 20 faults.
20030 and 10034 Axis not commutated
33201 Axis cpu read error
38001 Battery backup lost (i charged the battery for 18 hours yesterday and now it has 7V)How to commutate axes? I cannot find documentation about this robot. I found one on scribd and download it tommorow, because site need registration creditcard.
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The resolvers on the IRB1400 motors are set to a commutation value of 1.5708 and must not be moved. Verify this value in the parameters. The 38001 is a standard msg that shows up whenever the rev. counters are lost. The 33201 Axis CPU read error is the one to worry about.
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Yes, there are information about commutation value in instruction and how to set it, so i will do it, thank You.
But i see i don't have the board DSQC 233 which is axis cpu accordind to instruction IRB1400 M94A.
I was told the robot fully worked 2 years ago and nobody touch it since then, but i stop believing it.. -
The DSQC233 is an external axis board. You only need it if you have external axes.
DO NOT attempt to set the commutation, the resolvers are set to the motors from the factory. When you reloaded software, it would have set the commutation values in the manipulator parameters to the factory default of 1.5708.
The "33201 Axis cpu read error" needs to be addressed. You should make sure the CPU boards are seated to the backplane. You may want to try reloading software again. -
I connected the robot and there are few problems. There are 3 which are important i think. On the beginning i had over 20 faults.20030 and 10034 Axis not commutated
33201 Axis cpu read error
38001 Battery backup lost (i charged the battery for 18 hours yesterday and now it has 7V)How to commutate axes? I cannot find documentation about this robot. I found one on scribd and download it tommorow, because site need registration creditcard.
Hi All,
I am new here and this is the my first post.
I think, if the reinstall dosen't help for you, the problem is with the hardware. "CPU read error" - communication fail between main computer and robot computer across the back plain. -> Commutation error -> Battery backup lost (or old battery)
Take out the two computer card and memory, clean the connectors and take in. Important! If you take out either card, the software will be lost. You will make reinstall!
If it dosen't work, can you change the computer cards from the other robot? First the robot computer.
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I'll check the connections again. The DSQC326 is bought brand new. So maybe i will change the main cpu dsqc 325, but i must order it first.
When i try to do something with the axes (for example jog) or run a calibration program from disc there's an error:
servots.c 746 not allowes if servo task not initialized OK
So i can't do nothing with the the arm.
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