Problem loading software IRB6400 S4 M96 ( Urgent )

    Hello


    I have issues loading the software. IRB6400 M96 ( all siemens motors) 2.8 -1.2 S4

    The problem is if i select that i have all siemens motors ( Option M96) after that it asks for boot disk 2.

    I insert the boot disk 2 of 2 and press. Ok. It answers me incorrect boot disk. Insert boot disk2 and press ok. I sure that i have selected correct disk from emulator and press OK again.

    Then it will say Startup error config-1 and goes on.

    But nothing works after that.


    If i select siemens ( 1-4 siemens motors and 5,6 elmo), then the installation will finish as it should be, no errors at all.

    But if i try to arm the motors it will says :

    Low current fault on drive unit 1, 2, 3, 4,5,6.


    I assume that i should choose the M96 ( all siemens motors), but it wont install it.

    What to check or do ?


    Tried to make new disks to emulator. No results.

    Tried to install software again and again about 5 times. All same issues if i choose M96.

    Tried to swap the drive unit boards with new ones, still same errors. ( With Simenes option and M96 option ).

    When you select Siemens, it is for an M94A robot with Siemens motors at 4, 5, & 6. For M94A, I would look at axis 4 motor, if it was Elmo, I loaded Elmo. If it was Siemens, I loaded Siemens. Not sure why it gives an incorrect disk the first time but seems to load the second time.

    If it is an M96 robot, then I suspect corrupt file(s).


    Regarding the low current faults on all 6 axes - it seems like a separate issue. Is the fault code 39008 on each axis? Make sure the motor cable is securely seated at the robot and controller when enabling motors.

    Hello


    Thank you for answers :)

    The robot has 1-4 siemens motors ( 5th i assume it is siemens,cannot see),6axis is siemens. So i assume it is M96. Also it is written in control cabinet.

    Here are all my config files. What config should i look from there ?

    Fault code 39008 comes to all axes when arming the motors.

    Edited once, last by kri5too ().

    Installation script, see install.cmd on boot Disk (3)

    Thank you for the files. Install with M96 settings went great.But unfortunately i get same errors while enabling the motors.

    Low current fault on drive unit 1 to 6(all axes). Error code 39008


    I have replaced contactors KM1,KM2,KM3. Problem still exists.

    Also I have one spare 266G so i have tried it to 4,5,6 axes but still no results, same faults.


    Any ideas what to control ? What would be faulty ?

    Edited 2 times, last by kri5too ().

    Yes I have. I get the same errors on drive unit 1-6.I am 100% sure that 1,2,3,4 and 6 are siemens.(cause i can see the labels )


    Can it be bad rectifier ?

    I have tried to troubleshoot it but i am not sure that i did it correctly.

    Thats how i did it.

    I soldered measuring points to rectifier capacitors and measured the dc voltage on capacitor. It was 340v if i armed(ofcourse it started to drop because i got the drive unit faults). Is there any other way to test it ?


    One other thing, maybe this can cause this.I get the error 33106 Drive unit exceeded maximum on channel 4 on every startup.

    I have tried to swap the servo drives(with new one and existing one from 5 and 6 axis)but still i get the error on startup.Nevertheless it allows me to arm and get the drive unit fault to all drives.

    Edited 5 times, last by kri5too ().

    This is from memory but 340V seems just a little low but that could be from dealing with incoming AC voltages that tended to be on the high side of the transformer taps. The bus caps are a good place to measure the DC-bus. I do remember regen FET usually turns on around 400V.


    The 33106 Drive Unit Offset Error was typically a bad drive or cable harness issue - don't remember ever having a motor cause this. Usually the offset error will follow the drive if swapped in to axis 5 or 6 though. Double check the +15V and -15V out of the DSQC258 Power Supply and make sure the AC component (ripple) measures below 30mV. The +15/-15 are used by the current offset circuits in the drive units.


    Check axis 2/3 motor part #. If 3HAB4040-1 & axes 4, 5, & 6 are Siemens, it is an M94A - select Siemens.

    If axis 2/3 motors part # are 3HAB5760-1, select M96.

    Have to make sure you're using the correct motor parameters and gear ratios.

    Quote

    Check axis 2/3 motor part #. If 3HAB4040-1 & axes 4, 5, & 6 are Siemens, it is an M94A - select Siemens.

    If axis 2/3 motors part # are 3HAB5760-1, select M96.

    Have to make sure you're using the correct motor parameters and gear ratios.

    Yep they are 3HAB5760-1, so it should be M96. So installed the M96 settings.

    Still the drive units faults while arming.

    Everyone who has some thoughts what to control just write here. I am out of ideas :( Any clue will help me .


    Ordered new (used) system board, used (robot computer). They will arrive after 2 weeks, i assume that they are not faulty, but just in case for the future.

    Do you bought this robot second hand or was this robot ever in Production in your company?


    Quote from Skooter

    This is from memory but 340V seems just a little low but that could be from dealing with incoming AC voltages

    340 VDC are ok.



    What's about the LED on the rectifier?





    Do you have measured the coil from the motors directly on the backplane (dismount drive units) ?

    The resistance should be about .5 to 2.0 ohms. To ground greather 10Megaohms.


    Faulty capacitors in the rectifier can destroy the MOS-FET Transistors on the drive units. Have you checked the Transistors with the diode-Function from a measuring device?

    i bought the robot second hand.


    I have measured motors from motor to back of the robot , but not back to the backplane.(will do that ) .


    Checked the rectifier diods and they were good.


    Should the contactors km1,km2 stay switched on while i get the errors ?

    SJX brings up very good points about the contactors. You should double-check the wiring to the contactors to verify they are correct and they are operating properly. Sheet 9 in the prints. Have seen abnormal or no faults showing where contactors were replaced but wired incorrectly.

    Make sure KM1 & KM2 pull all the way down when energized. You may want to pull each of the contactors and test their operation with a 24V supply so you can accurately measure resistance of each contacts. Should be less than 1 ohm every time. I usually test the coils by operating at 18-20VDC just to see if they are getting weak.


    Were you able to check the +15V & -15V? They are common to current measurement in all 6 drive units.

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