Some base cables in the IRB6400 were known to come apart when they aged. Take a peek inside the base of the robot around the base cable track and see if there is any pieces of cable sheathing laying in the bottom. If so, that may point to current issues due to insulation breakdown once motor power is applied. Also make sure the track itself is not broken.
Problem loading software IRB6400 S4 M96 ( Urgent )
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kri5too -
November 22, 2020 at 4:43 PM -
Thread is Unresolved
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Which exactly softwareversion do you have installed and which version of Main / RobotComputer do you have ?
Early Versions from 2.0 has a problem with a risk of "high CPU load for axis computer" during startup and can be the reason for error 33106.
Also M96 Version of IRB6400 was fully introduced in 2.0 Ver.08.
Also attached docu with some infos about troubleshooting / fault tracing from this S4 system.
It has also some information about communication beetween driveunits and Axis-computer on Robotcomputer-Board.
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That screen is of the teach pendant firmware.
You can find software revision level by looking at the Info screen in the Service Menu, it will have a part # with a "/xx" at the end. The xx is the revision level.
You can also find it by looking at the disc.id file on one of the boot disc. Open it in a text editor and look at the program part # - once again, the numbers after the "/" is the revision level of the software.
Posting the software part # might be helpful.
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I am away from factory i can check from the Service menu tomorrow.
But from the disc.id i can see :
Bootdisk 1 of 3, 2 of 3 and 3 of 3
Program no 3HAB2316-1/13
Serial no IRB6400-2562
On IRB disk 1 of 2 and 2 of 2 i can see :
Program no 3HAB2319-1/08
Serial no IRB6400-2562
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According to my notes, those are the highest rev levels for both the Basic 2.0 software and the IRB6400 Elmo/Siemens 2.0 disk set.
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According to my notes, those are the highest rev levels for both the Basic 2.0 software and the IRB6400 Elmo/Siemens 2.0 disk set.
That's right. So software version shouldn't be the problem. Good to know.
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Thank you guys for the effort.
I am two days away then will go to troubleshoot again.
Measure the -15 ,+15
Look the base cables, etc what was mentioned before.
I will get back with the results
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Hi again
Had a bit time to visit the robot.
I found something strange if i looked the motor parameters.
In system parameters ---manipulator---Motor i can see that all motors fit with reality exept 6th axis motor.
There is 3HAB5762 but from the motor i read 3HAC3579
Can this cause this error ? How to fix it ? I cannot find my motor from the list.
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Think, 3HAC3579-1 should be compatible to 3HAB5762-1.
Normally, when ABB makes some improvements on a part, they used it also as spare part for older models.
Original in the IRB6400M96 documentation:
From the documentation IRB6400S (Shelf) , 120kg Version M2000:
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Hi
So this should be not a issue ?
DSQC 314B
Tested again looked the rectifier diodes. They seem good for me.
But soldered again measuring leads to capacitor.
When i arm i can measure 340-360 VDC. Should be ok
but if I measure AC from the capacitors i get some 270V ( for 1-2 seconds, after that the relays deactivate). Is this normal ?
I can be sure that the wires are good. Measured two times from the motor leads to the back of the cabinet. Demounted the arm to look 5th axis also and it was good .
From where i can measure -+15V ? I cannot find measuring points from manual ...
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Listed in the Troubleshooting Tools section of the Product Manual:
Backplane connector X4:
0V @ A24, C24, A25, C25
+15V @ A26, C26, A27, C27
-15V @ A28, C28, A29, C29
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Thanks:)
Controlled the +-15 and all good.
Also checked the ribbon cable, also all good.
I assume it is not faulty robot computer ? Then i should get some errors... They only error that pops up sometimes is the
33106 Drive Unit Offset Error on channel 4 Maybe the answer is somewhere there ?
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but if I measure AC from the capacitors i get some 270V ( for 1-2 seconds, after that the relays deactivate). Is this normal ?
On the DC-side of the rectifier ?
Do you have also checked contacts on KM3 and the 2 10 ohm resistor?
What's about the LED's on the DSQC 314A? Is it green after gives power to the rectifier or red?
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?
Are all transistors on the drive units ok?
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On the DC-side of the rectifier ?
Do you have also checked contacts on KM3 and the 2 10 ohm resistor?
What's about the LED's on the DSQC 314A? Is it green after gives power to the rectifier or red?
Are all transistors on the drive units ok?
2x10 ohm resitors - Ok
Controlled drive unit transistors. Result ok.
Also swapped boards to new one, one by one, also still the same errors.
Yes i measured the AC voltage from the capasitors (dc side).
Here you can see the lights and also AC voltage on caps.
External Content www.youtube.comContent embedded from external sources will not be displayed without your consent.Through the activation of external content, you agree that personal data may be transferred to third party platforms. We have provided more information on this in our privacy policy.Here can be seen DC voltage.
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Yes i measured the AC voltage from the capasitors (dc side).
It's always difficult to say, what your multi-measuring-device do, when you try to measure the AC- component from a DC-voltage.
Normaly, the AC-part should be not so high. It's normally only about +- 2Volts.
Contacts from the Backplane are also ok?
Bridge C16 -C12 (PowerOK from external driveunit) on XT3 is also installed?
Possible exchange Rectifier or Robot Computer Board?
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It's always difficult to say, what your multi-measuring-device do, when you try to measure the AC- component from a DC-voltage.
Normaly, the AC-part should be not so high. It's normally only about +- 2Volts.
Contacts from the Backplane are also ok?
Bridge C16 -C12 (PowerOK from external driveunit) on XT3 is also installed?
Possible exchange Rectifier or Robot Computer Board?
Hi
About the rectifier. I desoldered the diodes and rectifier to control them on the ground. They are ok . Also the transistor on rectifier board.
Controlled contacts from Backplane and they were ok .
Bridge on C16-C12 also ok .
On next week should arrive me a used (ausbruch like germans say) Robot computer, then i can test with that.
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They only error that pops up sometimes is the 33106 Drive Unit Offset Error on channel 4 Maybe the answer is somewhere there ?
I had a problem with an S4 base cable and another with an S4C robot-to-controller motor cable where there was leakage to ground that only showed on the 500V scale of the insulation tester (megger). The S4 base cable was the sheathing coming off the cable with the shielding wires breaking and wearing into the wire insulation. The S4C motor cable ended up being the wires inside the robot side connector were pulled too tight inside and an axis 4 motor wire was cutting into the shell, leaking only under motor power. It actually tested good at 250V to ground but bad at 500V.
My experiences would have me triple checking for a leakage with axis 4 motor leads to somewhere.
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The S4 base cable was the sheathing coming off the cable with the shielding wires breaking and wearing into the wire insulation.
Broken base cable chain is typical for this mechanical unit.
Typical with this trouble are defect cables.
I'm agree with scooter, that's not easy to found this kind of errors.
You can visually check the chain, if you remove the cover on axis 1.It helps, when you turn also axis 1 with the brake release Button.
Also a good idea measuring cables on this unit, when turning axis 1.
Maybe, the error occured, when you turn axis one in another position?
Other ideas for fault tracing:
All 6 drive units have a fault at the moment.
What happens, when we unpluged some motor cables? (with bridge on PTC)
Maybe, we found a combination, that only one have a fault ?
Startup fault from axis 4 comes also with disconnected motor cable?
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