I/O Communication problem wiith PLC

errors appeared when disconnecting the cables behind the robot.....

Then your 1HW is probably faulty then as it is not being detected.....Very surprised in 12 years this is a first time I hear about.

Possible backplane has issue (KX board) but would be surprised.

You are getting strange faults to me.....Is this robot being re-purposed from a different application?

Are all connections secure to KX board?

Has any reloading of software taken place?

Have you a file save to provide?

Have you an error log to provide?

Quote from kwakisaki

Then your 1HW is probably faulty then as it is not being detected.

as I said above, I tried with another 1 HW board ... the same error.

Place both 1HW boards in Slot 1 and Slot 2 and set Aux 0611 to 64 input and 64 output and test again.

(If forgot to add, make sure each 1HW is addressed correctly 1-32 and 33-64)

Is this being re-purposed?

Has you done any file loads over original?

Have you an error log?

Have you checked all connections to KX board?

Quote from kwakisaki

Very surprised in 12 years this is a first time I hear about.

all things / issues have a beginning at a time ...

Quote from kwakisaki

Place both 1HW boards in Slot 1 and Slot 2 and set Aux 0611 to 64 input and 64 output and test again.

(If forgot to add, make sure each 1HW is addressed correctly 1-32 and 33-64)

I will try this option as well...

Testing the CL buttons:

With umbilicals connected AND disconnected, can you test CL1 and CL2 functionality again and check:

- Signal monitor screen and retest CL1 and CL2 again and see if signal 9,10 (CL1 toggles) and 13,14 (CL2 toggles).

- Report back results.

Quote from kwakisaki

Have you an error log?

No, I haven't but I will download tomorrow...

Quote from kwakisaki

Have you checked all connections to KX board?

I don't know what other connections I can check on this board (Kx)....

You managed to take a look over the AS file?

KX is the backplane for the rack the 1HW and other boards are mounted to.

- This has many connections on the side to interface with the rest of the controller and arm.

- Check these connections are terminated correctly and no bent pins etc.

Is this robot being re-puposed?

What is the robots history prior to these issues?

Have you 1RB board spare at all?

The backup looks ok, testing KROSET and all signals appear to be working as expected (CL buttons etc) and no errors.

- But this is only software.

If you can fit both 1HW boards without umbilicals and confirm IO board error is cleared and signal CL1 and CL2 toggles, then it does suggest electrical problem.

Quote from kwakisaki

Place both 1HW boards in Slot 1 and Slot 2 and set Aux 0611 to 64 input and 64 output and test again.

(If forgot to add, make sure each 1HW is addressed correctly 1-32 and 33-64)

Another question regarding your verification proposal:

the settings in Aux 0611 are made with the 1HW cards removed from the slots, ie I make the settings in Aux0611, stop the power supply, insert the cards set on 1-32 and 33-64 and then start the power supply again? There is a rule?

Quote from kwakisaki

Is this robot being re-puposed?

What is the robots history prior to these issues?

Have you 1RB board spare at all?

These robots worked on palletizing applications..the robot works very well (from a mechanical point of view, positioning, etc.) except this two problems ...

No, I haven't a spare for a 1RB board..

No rule required, but in your case I would try longwinded method:

- Change Aux 0611 to 0 input and 0 output.

- Power off.

- add 1x 1Hw (set at 1-32) and power up.

- Change Aux 0611 to 32 input and 32 output and power off.

- Power up - No error should be displayed.

- Power off and remove board.

- Power back on - No.1 IO board installed error should be displayed.

- Power off.

- Insert 1HW back in and power back on.

- Should be error free.

- Then repeat above for 2nd Board (set to 33-64 and Aux 0611 to 64)

I would do this for when umbilicals are connected AND disconnected and see if results differ.

So this robot WAS working correctly then?

- So at what point did these stop working and these problems occur.

- What measures have been done in order to try and rectify this situation before coming here.

Ok, I will try your sugetions...

I think I told you before, the CN2 & CN4 plugs are disconnected, therefore I do not have an external power supply of 24 VDC per 1HW. I don't think that's a problem ...I think the Kx board should see it on the master BUS...

When you get chance can you provide a file save - directly from the controller as it is......The file you provided is not.

KX board is just a backplane, there is no intelligence on it.

VME Bus is just 'circuit traces' on board connecting up 1RA - 1RB - 1KP - 1HW and any other board installed.

CN2 and CN4 connections should never interfere with communication side of 1HW and VME Bus.

Your issues appear closely related in my opinion and a 'result' of a single problem.

- Electrical between Controller and Arm (umbilical, internal arm harness, external arm harness).

ok I understand. Thank you. I will do the suggested checks and I will come back with conclusions ...

I assume the robot arm moves no problems and no random stoppages in certain positions with errors?

No, I tested it. I programmed him to make 3 layers on a pallet, after which I repeated the program to see if it is positioned in exactly the same place and he executed it without problems...and no errors ... except for the VMEbus error, which occurred when I connected the plug to the solenoid valve island.

Prior to all that.......

- Was the arm IO ever working previously with the same solenoid island and harness - or has this been an addition?

OK....If it was that 'clear cut':

- Disconnect just the solenoid island when testing the 1HW's again (leave the main umbilicals attached, so you wont have the other errors).

- This will make it a little clearer.