Hello all. I have an ABB irb6400 with s4c controller that is giving random errors. At first there were
39217 Saturated current contr. on joint irb_6
39214 Low DC-bus voltage
We replaced the rectifier, and all of the dc links (servo amplifiers), we replaced the cable for axis 5 & 6, as well as the middle cable. We replaced the end knuckle (axis 5 & 6) assembly, and still no help. We still get a random 39217 fault on joint 6, but we also get:
50021 Joint position error on irb_6
and sometimes :
50056 Joint collision error on irb_6
We've also changed out the brake contactor (K4 I believe)
The problem seems to fault out in the same place in the program every time, and when I turn axis 1 back toward the home position, I can move all the axis without faults. This leads me to think there is a problem with the cable in the base of the robot. Does this make sense?? or should I try something else?
Thanks in advance.
Random errors - please help
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memiller1 -
March 12, 2018 at 3:53 PM -
Thread is marked as Resolved.
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Also, here is the error log, if that helps
All log messages
Date of saving: 19960104 11:27
3HAB2390-2/80 System Pack S4C 3.0 TP Language Irb 6400 FactoryWare Communication Ethernet Services Advanced FunctCommon log messages
1. 60007 Jogging not permitted! 0104 11:13.13
Jogging cannot be done in this mode.2. 20207 Backplane Enable open 0104 11:13.17
3. 10010 Motors off state 0104 11:13.17
4. 10012 Guard stop state 0104 11:13.25
Runchain opened by any safety guard
except the emergency stop.5. 10010 Motors off state 0104 11:13.25
6. 10011 Motors on state 0104 11:13.25
7. 10012 Guard stop state 0104 11:13.33
Runchain opened by any safety guard
except the emergency stop.8. 10010 Motors off state 0104 11:13.34
9. 10011 Motors on state 0104 11:13.34
10. 39217 Saturated Current Contr. 0104 11:13.37
Drive Unit unable to supply ordered
current, due to low DC-voltage or
broken motor connections. Drive unit,
joint: irb_6.
Measured DC-bus voltage: 383.80 (V)11. 20207 Backplane Enable open 0104 11:13.37
12. 10012 Guard stop state 0104 11:13.37
Runchain opened by any safety guard
except the emergency stop.13. 10010 Motors off state 0104 11:13.38
14. 20072 Not allowed command 0104 11:13.38
Not allowed in Motors Off state.15. 60007 Jogging not permitted! 0104 11:13.38
Jogging cannot be done in this mode.16. 10012 Guard stop state 0104 11:13.49
Runchain opened by any safety guard
except the emergency stop.17. 10010 Motors off state 0104 11:13.49
18. 10011 Motors on state 0104 11:13.50
19. 39217 Saturated Current Contr. 0104 11:13.51
Drive Unit unable to supply ordered
current, due to low DC-voltage or
broken motor connections. Drive unit,
joint: irb_6.
Measured DC-bus voltage: 384.78 (V)20. 39103 Mains missing 0104 11:13.52
Incoming voltage to DC-link too low,
drive system 1.21. 20207 Backplane Enable open 0104 11:13.52
22. 10012 Guard stop state 0104 11:13.52
Runchain opened by any safety guard
except the emergency stop.23. 20207 Backplane Enable open 0104 11:14.20
24. 10010 Motors off state 0104 11:14.20
25. 10012 Guard stop state 0104 11:14.23
Runchain opened by any safety guard
except the emergency stop.26. 10010 Motors off state 0104 11:14.24
27. 10011 Motors on state 0104 11:14.24
28. 39217 Saturated Current Contr. 0104 11:14.28
Drive Unit unable to supply ordered
current, due to low DC-voltage or
broken motor connections. Drive unit,
joint: irb_6.
Measured DC-bus voltage: 384.29 (V)29. 39103 Mains missing 0104 11:14.28
Incoming voltage to DC-link too low,
drive system 1.30. 20207 Backplane Enable open 0104 11:14.28
31. 10012 Guard stop state 0104 11:14.28
Runchain opened by any safety guard
except the emergency stop.32. 20207 Backplane Enable open 0104 11:14.32
33. 10010 Motors off state 0104 11:14.32
34. 10012 Guard stop state 0104 11:14.39
Runchain opened by any safety guard
except the emergency stop.35. 10010 Motors off state 0104 11:14.40
36. 10011 Motors on state 0104 11:14.40
37. 39217 Saturated Current Contr. 0104 11:14.43
Drive Unit unable to supply ordered
current, due to low DC-voltage or
broken motor connections. Drive unit,
joint: irb_6.
Measured DC-bus voltage: 384.78 (V)38. 39103 Mains missing 0104 11:14.43
Incoming voltage to DC-link too low,
drive system 1.39. 20207 Backplane Enable open 0104 11:14.43
40. 10012 Guard stop state 0104 11:14.43
Runchain opened by any safety guard
except the emergency stop.Operational log messages
1. 10011 Motors on state 0104 11:13.252. 10012 Guard stop state 0104 11:13.33
Runchain opened by any safety guard
except the emergency stop.3. 10010 Motors off state 0104 11:13.34
4. 10011 Motors on state 0104 11:13.34
5. 10012 Guard stop state 0104 11:13.37
Runchain opened by any safety guard
except the emergency stop.6. 10010 Motors off state 0104 11:13.38
7. 10012 Guard stop state 0104 11:13.49
Runchain opened by any safety guard
except the emergency stop.8. 10010 Motors off state 0104 11:13.49
9. 10011 Motors on state 0104 11:13.50
10. 10012 Guard stop state 0104 11:13.52
Runchain opened by any safety guard
except the emergency stop.11. 10010 Motors off state 0104 11:14.20
12. 10012 Guard stop state 0104 11:14.23
Runchain opened by any safety guard
except the emergency stop.13. 10010 Motors off state 0104 11:14.24
14. 10011 Motors on state 0104 11:14.24
15. 10012 Guard stop state 0104 11:14.28
Runchain opened by any safety guard
except the emergency stop.16. 10010 Motors off state 0104 11:14.32
17. 10012 Guard stop state 0104 11:14.39
Runchain opened by any safety guard
except the emergency stop.18. 10010 Motors off state 0104 11:14.40
19. 10011 Motors on state 0104 11:14.40
20. 10012 Guard stop state 0104 11:14.43
Runchain opened by any safety guard
except the emergency stop.System log messages
1. 20072 Not allowed command 0104 11:09.53
Not allowed in Motors Off state.2. 20207 Backplane Enable open 0104 11:10.53
3. 20207 Backplane Enable open 0104 11:10.59
4. 20074 Not allowed command 0104 11:10.59
Not allowed in Guard Stop state.5. 20207 Backplane Enable open 0104 11:10.59
6. 20207 Backplane Enable open 0104 11:11.6
7. 20207 Backplane Enable open 0104 11:11.16
8. 20207 Backplane Enable open 0104 11:11.20
9. 20207 Backplane Enable open 0104 11:12.22
10. 20207 Backplane Enable open 0104 11:13.3
11. 20074 Not allowed command 0104 11:13.13
Not allowed in Guard Stop state.12. 20207 Backplane Enable open 0104 11:13.13
13. 20207 Backplane Enable open 0104 11:13.17
14. 20207 Backplane Enable open 0104 11:13.37
15. 20072 Not allowed command 0104 11:13.38
Not allowed in Motors Off state.16. 20207 Backplane Enable open 0104 11:13.52
17. 20207 Backplane Enable open 0104 11:14.20
18. 20207 Backplane Enable open 0104 11:14.28
19. 20207 Backplane Enable open 0104 11:14.32
20. 20207 Backplane Enable open 0104 11:14.43
Hardware log messages
1. 39103 Mains missing 0104 08:44.23
Incoming voltage to DC-link too low,
drive system 1.2. 39217 Saturated Current Contr. 0104 08:44.45
Drive Unit unable to supply ordered
current, due to low DC-voltage or
broken motor connections. Drive unit,
joint: irb_6.
Measured DC-bus voltage: 383.80 (V)3. 39103 Mains missing 0104 08:44.46
Incoming voltage to DC-link too low,
drive system 1.4. 39217 Saturated Current Contr. 0104 08:44.57
Drive Unit unable to supply ordered
current, due to low DC-voltage or
broken motor connections. Drive unit,
joint: irb_6.
Measured DC-bus voltage: 381.85 (V)5. 39103 Mains missing 0104 08:44.57
Incoming voltage to DC-link too low,
drive system 1.6. 39217 Saturated Current Contr. 0104 11:10.53
Drive Unit unable to supply ordered
current, due to low DC-voltage or
broken motor connections. Drive unit,
joint: irb_6.
Measured DC-bus voltage: 384.29 (V)7. 39217 Saturated Current Contr. 0104 11:10.59
Drive Unit unable to supply ordered
current, due to low DC-voltage or
broken motor connections. Drive unit,
joint: irb_6.
Measured DC-bus voltage: 384.29 (V)8. 39103 Mains missing 0104 11:10.59
Incoming voltage to DC-link too low,
drive system 1.9. 39217 Saturated Current Contr. 0104 11:11.15
Drive Unit unable to supply ordered
current, due to low DC-voltage or
broken motor connections. Drive unit,
joint: irb_6.
Measured DC-bus voltage: 383.80 (V)10. 39103 Mains missing 0104 11:11.15
Incoming voltage to DC-link too low,
drive system 1.11. 39217 Saturated Current Contr. 0104 11:12.22
Drive Unit unable to supply ordered
current, due to low DC-voltage or
broken motor connections. Drive unit,
joint: irb_6.
Measured DC-bus voltage: 383.31 (V)12. 39217 Saturated Current Contr. 0104 11:13.3
Drive Unit unable to supply ordered
current, due to low DC-voltage or
broken motor connections. Drive unit,
joint: irb_6.
Measured DC-bus voltage: 382.34 (V)13. 39103 Mains missing 0104 11:13.3
Incoming voltage to DC-link too low,
drive system 1.14. 39217 Saturated Current Contr. 0104 11:13.37
Drive Unit unable to supply ordered
current, due to low DC-voltage or
broken motor connections. Drive unit,
joint: irb_6.
Measured DC-bus voltage: 383.80 (V)15. 39217 Saturated Current Contr. 0104 11:13.51
Drive Unit unable to supply ordered
current, due to low DC-voltage or
broken motor connections. Drive unit,
joint: irb_6.
Measured DC-bus voltage: 384.78 (V)16. 39103 Mains missing 0104 11:13.52
Incoming voltage to DC-link too low,
drive system 1.17. 39217 Saturated Current Contr. 0104 11:14.28
Drive Unit unable to supply ordered
current, due to low DC-voltage or
broken motor connections. Drive unit,
joint: irb_6.
Measured DC-bus voltage: 384.29 (V)18. 39103 Mains missing 0104 11:14.28
Incoming voltage to DC-link too low,
drive system 1.19. 39217 Saturated Current Contr. 0104 11:14.43
Drive Unit unable to supply ordered
current, due to low DC-voltage or
broken motor connections. Drive unit,
joint: irb_6.
Measured DC-bus voltage: 384.78 (V)20. 39103 Mains missing 0104 11:14.43
Incoming voltage to DC-link too low,
drive system 1.Motion log messages
1. 50021 Joint position error 0104 08:21.43
Actual position of joint irb_6
is too far away from the ordered
position2. 50056 Joint collision error 0104 08:32.44
Actual torque on joint irb_6 is
higher than ordered while at low
or zero speed.3. 50056 Joint collision error 0104 08:32.59
Actual torque on joint irb_6 is
higher than ordered while at low
or zero speed.4. 50056 Joint collision error 0104 08:33.11
Actual torque on joint irb_6 is
higher than ordered while at low
or zero speed.5. 50056 Joint collision error 0104 08:33.23
Actual torque on joint irb_6 is
higher than ordered while at low
or zero speed.6. 50056 Joint collision error 0104 08:33.39
Actual torque on joint irb_6 is
higher than ordered while at low
or zero speed.7. 50056 Joint collision error 0104 08:34.40
Actual torque on joint irb_6 is
higher than ordered while at low
or zero speed.8. 50056 Joint collision error 0104 08:36.41
Actual torque on joint irb_6 is
higher than ordered while at low
or zero speed.9. 50037 MOTORS ON order ignored 0104 08:36.42
MOTORS ON order ignored since the
previous stop was not yet acknowledged.10. 50056 Joint collision error 0104 08:36.49
Actual torque on joint irb_6 is
higher than ordered while at low
or zero speed.11. 50056 Joint collision error 0104 08:42.48
Actual torque on joint irb_6 is
higher than ordered while at low
or zero speed.12. 50056 Joint collision error 0104 08:43.34
Actual torque on joint irb_6 is
higher than ordered while at low
or zero speed.13. 50056 Joint collision error 0104 08:44.2
Actual torque on joint irb_6 is
higher than ordered while at low
or zero speed.14. 50056 Joint collision error 0104 08:44.18
Actual torque on joint irb_6 is
higher than ordered while at low
or zero speed.15. 50056 Joint collision error 0104 08:45.9
Actual torque on joint irb_6 is
higher than ordered while at low
or zero speed.16. 50021 Joint position error 0104 11:08.33
Actual position of joint irb_6
is too far away from the ordered
position17. 50056 Joint collision error 0104 11:08.58
Actual torque on joint irb_6 is
higher than ordered while at low
or zero speed.18. 50056 Joint collision error 0104 11:09.16
Actual torque on joint irb_6 is
higher than ordered while at low
or zero speed.19. 50056 Joint collision error 0104 11:09.29
Actual torque on joint irb_6 is
higher than ordered while at low
or zero speed.20. 50021 Joint position error 0104 11:09.48
Actual position of joint irb_6
is too far away from the ordered
positionProgram log messages
No message to show!Operator log messages
1. 60007 Jogging not permitted! 0101 11:05.5
Jogging cannot be done in this mode.2. 60007 Jogging not permitted! 0101 11:06.19
Jogging cannot be done in this mode.3. 60007 Jogging not permitted! 0101 16:30.47
Jogging cannot be done in this mode.4. 60007 Jogging not permitted! 0104 08:34.31
Jogging cannot be done in this mode.5. 60007 Jogging not permitted! 0104 08:34.41
Jogging cannot be done in this mode.6. 60007 Jogging not permitted! 0104 08:34.48
Jogging cannot be done in this mode.7. 60007 Jogging not permitted! 0104 08:35.14
Jogging cannot be done in this mode.8. 60007 Jogging not permitted! 0104 08:35.29
Jogging cannot be done in this mode.9. 60007 Jogging not permitted! 0104 08:36.2
Jogging cannot be done in this mode.10. 60007 Jogging not permitted! 0104 08:36.20
Jogging cannot be done in this mode.11. 60007 Jogging not permitted! 0104 08:44.2
Jogging cannot be done in this mode.12. 60007 Jogging not permitted! 0104 08:44.23
Jogging cannot be done in this mode.13. 60007 Jogging not permitted! 0104 08:44.47
Jogging cannot be done in this mode.14. 60007 Jogging not permitted! 0104 11:08.39
Jogging cannot be done in this mode.15. 60007 Jogging not permitted! 0104 11:09.17
Jogging cannot be done in this mode.16. 60007 Jogging not permitted! 0104 11:09.34
Jogging cannot be done in this mode.17. 60007 Jogging not permitted! 0104 11:09.53
Jogging cannot be done in this mode.18. 60007 Jogging not permitted! 0104 11:10.59
Jogging cannot be done in this mode.19. 60007 Jogging not permitted! 0104 11:13.13
Jogging cannot be done in this mode.20. 60007 Jogging not permitted! 0104 11:13.38
Jogging cannot be done in this mode.IO & Communication log messages
No message to show!User log messages
1. 80002 Major Fault 163-1 0101 10:51.45
IRB not at Home2. 80002 Major Fault 163-1 0101 10:55.3
IRB not at HomeSpotweld log messages
No message to show!Internal log messages
No message to show! -
It sounds like a problem with low current on one of the 3 phases going to axis 6 motor. I had the saturation error with a burnt axis 6 motor connector pin about a year ago. Before replacing the base cable, double-check the pins at R1.MP at the robot base - I've seen these pushed in and making poor contact in the past. Try moving axis 1 around near its position where the error occurs to see if you can associate the fault with axis motion (base cable).